073 1 ATLANTIC 500 10/2002-00 8140632 workshopmanual
LIST OF SECTIONS Foreword This manual provides basic information about ordinary vehicle servicing procedures. The data and illustrations that make up the manual were up to date at the time of publication. The manual is intended for aprilia dealers and their qualified mechanics. Many concepts have been intentionally omitted as they were considered superfluous.
Atlantic 500 TABLE OF CONTENTS Chapter 1 SAFETY WARNINGS ............................................................................................................................. 1-2 PRECAUTIONS AND GENERAL INFORMATION ................................................................................. 1-2 REPLACING COMPONENTS ................................................................................................................ 1-3 USING THE MANUAL ...............................................
Atlantic 500 Chapter 3 COMPONENTS THAT CAN BE REMOVED WITHOUT REMOVING THE ENGINE............................. 3-2 REMOVING THE ENGINE FROM THE FRAME ................................................................................... 3-3 Chapter 4 FUEL TANK AND PUMP ........................................................................................................................ 4-2 EMS FUEL INJECTION SYSTEM.............................................................................................
Atlantic 500 DASHBOARD CHECK ......................................................................................................................... 6-22 FUEL LEVEL ........................................................................................................................................ 6-22 DASHBOARD CHECK ......................................................................................................................... 6-22 FUEL LEVEL SENSOR CHECK ...................................
Atlantic 500 COMPLETE INSTRUMENT PANEL REMOVAL .................................................................................. 7-15 WINDSHIELD REMOVAL .................................................................................................................... 7-16 INSTRUMENT PANEL REMOVAL ....................................................................................................... 7-16 COMPLETE LIGHTING ASSEMBLY REMOVAL ..................................................................
Atlantic 500 6 Release 00 2002-09
General Information Atlantic 500 1 General Information chap.
General Information Atlantic 500 SAFETY WARNINGS The following precautionary warnings are used throughout this manual in order to convey the following messages: Safety warning. When you find this symbol on the vehicle or in the manual, be careful to the potential risk of personal injury.
General Information Atlantic 500 REPLACING COMPONENTS CAUTION 1 Never reuse circlips. Always replace removed circlips with new ones. When fitting a new circlip, take care not to part its ends more than is required to fit it on the shaft. After fitting a circlip, ensure that it is fully and firmly inserted in its seat. Never use compressed air to clean the bearings. NOTE Bearings should always rotate freely, smoothly and silently, otherwise they must be replaced. Only use GENUINE aprilia spares.
General Information Atlantic 500 IDENTIFICATION DATA The frame number may be used to order the spare parts. NOTE Tampering with serial numbers is subject to 1 severe penalties. In particular, tampering with the frame number immediately voids the warranty. FRAME NUMBER The frame number is stamped on the frame central tube. To read it, open the central glove compartment door and remove the cover (1). ENGINE NUMBER The engine number is stamped near the lower support of the rear shock absorber.
General Information Atlantic 500 ENGINE OIL WARNING 1 Engine oil can cause serious damage to the skin if handled every day and for long periods. Wash your hands carefully after using the oil. Do not dispose of the oil in the environment. Put it in a sealed container and take it to the filling station where you usually buy it or to an oil salvage center. In case any maintenance operation has to be carried out, it is advisable to use latex gloves.
General Information Atlantic 500 CAUTION Do not use brake fluids other than those prescribed. To avoid damaging the braking system, never mix different types of fluids when topping up. Never use brake fluid taken from an old container, or from a container that has been open for a long time. Sudden changes in brake play or a spongy feel of the brake levers are due to problems in the hydraulic circuits.
General Information Atlantic 500 COOLANT WARNING The coolant is harmful if ingested. Contact with the skin or the eyes may cause irritation. Should the liquid come into contact with the skin or the eyes, generously rinse with water and seek medical attention. If the fluid is ingested, cause vomiting, generously rinse the mouth and throat with water and immediately seek medical attention. DO NOT DISPOSE OF THE COOLANT IN THE ENVIRONMENT. KEEP OUT OF REACH OF CHILDREN.
General Information Atlantic 500 CARBON MONOXIDE Whenever the engine needs to be run in order to carry out some operation, ensure that this is done in the open air or in a well-ventilated room. Never run the engine in a closed environment unless the place is equipped with an exhaust system. WARNING Exhaust gases contain carbon monoxide, a poisonous gas that may cause fainting or even death. Run the engine in an open space or in a closed space equipped with an exhaust system.
General Information Atlantic 500 PRECAUTIONS AND GENERAL INFORMATION When repairing, disassembling and reassembling the vehicle, scrupulously observe the following recommendations. WARNING The use of open flames is forbidden under all circumstances. Before performing any servicing or checks, switch off the engine, remove the ignition key, allow the engine and the exhaust system to cool down, and if possible lift the vehicle on solid level flooring using specific equipment.
General Information Atlantic 500 TECHNICAL DATA DIMENSIONS Max. length Max. width Max. height (front part of the fairing included) Seat height Distance between centres Min. ground clearance Weight ready for starting 2270 mm (89.4 in) 720 mm (28.3 in) 1450 mm (57.0 in) 780 mm (30.7 in) 1575 mm (62.0 in) 150 mm (5.9 in) 200 Kg (440.9 lbs) ENGINE 4-stroke single-cylinder, 4 valves, single camshaft in cylinder head controlled by chain system on the flywheel side 4 1 460 cm3 (28.0 cu.in) 92 mm / 69 mm (3.
General Information FUEL SUPPLY Type Fuel Atlantic 500 Electronic injection by electric fuel pump Lead free petrol (4 Stars ) with minimum octane number 95 (N.O.R.M.) and 85 (N.O.M.M.) FRAME Type Steering inclination angle Fore stroke SUSPENSIONS Front Stroke high resistance steel tubes 28°, 50’ 118 mm (4.6 in) hydraulically operated telescopic fork 100 mm (3.93 in) rear Two double-acting hydraulic shock absorbers with preload adjustment to five positions 100 mm (3.
General Information Atlantic 500 ELECTRIC SYSTEM Battery Fuses Generator (with permanent magnet) 12 V - 14 Ah 30 - 20 - 15 - 3 A 14 V - 330 W BULBS Low / high beam Front parking lights Direction indicators Rear parking light / stoplight Helmet compartment light Number plate Dashboard light Third stoplight 12 V - 55 W / 12 V - 35 W 12 V - 5 W rear 16 W - front 10 W 12 V - 5 / 21 W 12 V - 3 W 12 V - 5 W LED 12 V - 2.
General Information Atlantic 500 TIGHTENING TORQUES TABLE DESCRIPTION ftlb Nm 14.75 20 Steering stop plate screw 8.68 12 Locking ring 36.88 50 Key switch break-off screw 7.23 10 Threaded bushing 0.22 0.3 Key switch fixing screw 7.23 10 Windscreen support fixing screw 7.23 10 Windscreen support stop nut 7.23 10 Damper to frame fixing screw 7.23 10 Nut 7.23 10 Damper fixing screw, fork side 7.23 10 14.
General Information Atlantic 500 DESCRIPTION ftlb Nm Wheel pin 36.88 50 Speedometer sensor screw 0.66 0.9 Hub screw 7.23 10 110.64 150 14.75 20 7.23 10 7.23 10 7.23 10 18.44 25 7.23 10 Coil fixing screw 1.47 2 Nut 1.47 2 Rotary switch screw 7.23 10 Rotary switch screw 7.23 10 Harness to relay clamp 3.68 5 Reflector nut 1.10 1.5 M5 self-locking nuts fuel pump flange 2.21 3 2.21 3 2.21 3 5.90 8 5.
Periodic Maintenance Operations Atlantic 500 2 Periodic Maintenance Operations chap.
Periodic Maintenance Operations Atlantic 500 This section describes the operations to be performed periodically when servicing the main vehicle components. CAUTION Before performing any servicing or checks, switch off the engine, remove the key, allow the engine and the exhaust system to cool down, and if possible lift the vehicle on solid level flooring using specific equipment. To avoid burns, be sure to keep away from hot engine and exhaust parts.
Periodic Maintenance Operations Atlantic 500 PERIODIC MAINTENANCE SCHEDULE TO BE PERFORMED BY aprilia authorized dealer End of running-in 1,000 km (625 mi) COMPONENTS Accelerator cable (adjustment) Variator belt Steering bearings and steering Wheel bearings Engine oil filter Clutch shoes - clutch housing Valve clearance Braking systems Cooling system Stop light switches Brake fluid Coolant Engine oil Fork oil Transmission oil Variator rollers and variator plastic guides Wheels/ tyres and inflation pressu
Periodic Maintenance Operations Atlantic 500 LUBRICATING POINTS KEY TO LUBRICATION CHART A proper lubrication is important to ensure the correct operation and duration of the vehicle components. 1) 2) 3) 4) 5) 6) 7) NOTE Before proceeding with lubrication, thoroughly clean all the components to remove any traces of oxidation, grease, dirt and dust. All exposed parts that are subject to rust must be lubricated with engine oil or grease. Please refer to the TABLE OF LUBRICANTS.
Periodic Maintenance Operations Atlantic 500 BATTERY Carefully read (PRECAUTIONS AND GENERAL INFORMATION). Check the electrolyte level and the tightening of the terminals after the first 1,000 km (625 mi) and then every 6,000 km (3,750 mi). 2 WARNING The electrolyte in the battery is toxic and caustic and if it gets in contact with the skin it can cause burns, since it contains sulphuric acid. Wear protection clothes, a face mask and/ or goggles during maintenance operations.
Periodic Maintenance Operations Atlantic 500 REMOVING THE BATTERY COVER 3 Read through paragraph BATTERY. 4 NOTE Put the vehicle on a solid and flat surface • • • • • • • Make sure the ignition lock switch is turned to “ ”. Lift the saddle, see (UNLOCKING/ LOCKING THE SEAT). Remove the mat from the helmet compartment. Unloose and remove the two screws (1). Remove the battery cover from the bottom (2) paying attention to the upper tangs (3).
Periodic Maintenance Operations Atlantic 500 REMOVING THE BATTERY • • • • • Remove the battery cover, see (REMOVING THE BATTERY COVER). Remove the battery breather pipe (7). Remove the battery (8) from its seat by slightly turning it to the right, as shown by the arrow. Disconnect first the negative (–) and then the positive cable (+). Remove the battery (8) from its compartment and put it on a flat surface, in a cool and dry place.
Periodic Maintenance Operations Atlantic 500 CHECKING THE ELECTROLYTE LEVEL To check the electrolyte level, proceed as follows: • Remove the battery cover, see (REMOVING THE BATTERY COVER). • Make sure that the fluid level is included between the two “MIN” and “MAX” notches stamped on the battery side. Otherwise: • Remove the element plugs. CAUTION Top up with distilled water only. Do not exceed the “MAX” mark, since the electrolyte level increases during the recharge.
Periodic Maintenance Operations Atlantic 500 INSTALLING THE BATTERY • • Remove the battery cover, see (REMOVING THE BATTERY COVER). Put the battery in its container. 1 CAUTION Always connect the battery breather pipe, to prevent the sulphuric acid vapours from corroding the electric system, painted parts, rubber elements or gaskets when they exit the breather pipe itself. • • • • 2 Connect, in order, the positive (+) and negative (–) cable.
Periodic Maintenance Operations Atlantic 500 • Energetically blow some air, in order to prevent the removed residues from getting into the engine. If the spark plug has crackings on the insulating material, corroded electrodes or excessive deposits, it must be changed. • Check the spark plug gap with a thickness gauge. The gap must be 0.7 – 0.8 mm (0.027 - 0.031 in); if necessary adjust it, carefully bending the earth electrode. • Make sure that the washer is in good conditions.
Periodic Maintenance Operations Atlantic 500 AIR FILTER 1 Read through the paragraphs MAINTENANCE. The air cleaner should be inspected and cleaned every 6,000 km (3,750 mi), depending on the conditions of use. If the vehicle is used on dusty or wet roads, the cleaning operations should be carried out more frequently. 2 2 To clean the filtering element it is necessary to remove it from the vehicle. REMOVAL • Position the vehicle on the centre stand. • Lift the saddle (SADDLE LOCKING / UNLOCKING).
Periodic Maintenance Operations Atlantic 500 ENGINE OIL Check the engine oil after the first 1,000 km (625 mi) or at the end of the running in period, and then every 3,000 km (1,875 mi). Change the oil every 6000 km (3,750 mi), see RENEWING THE ENGINE OIL AND ENGINE OIL FILTER. NOTE Use oil with specifications 5/W 40, see (TABLE OF LUBRICANTS). CAUTION When topping up the engine oil, never exceed the “MAX” mark.
Periodic Maintenance Operations Atlantic 500 Never exceed the “MAX” mark, nor leave the oil below the “MIN” mark, in order to avoid serious damage to the engine. • If necessary, provide for topping up. 4 TOPPING UP • Pour a small quantity of oil in the filling hole (2) and wait about one minute, so that the oil flows uniformly into the oil pan. • Check the oil level and top up if necessary. • Top up by adding small quantities of oil, until reaching the prescribed level.
Periodic Maintenance Operations Atlantic 500 NOTE Make sure the above procedures are carried 1 before the engine oil level is checked • • 2 Unscrew and remove cap/dipstick (1). Unloose and remove the engine oil cartridge filter (3). WARNING Do not use the vehicle if lubrication is insufficient. Never use unsuitable or contaminated lubricants as they accelerate the wear and tear of moving parts and can cause irreparable damage.
Periodic Maintenance Operations • • • • Atlantic 500 Unscrew and remove cap/dipstick (1). Clean dipstick with a clean cloth. Completely screw the cap-dipstick (1) into the filling hole (2). Remove the cap-dipstick (1) again and check the oil level: 1 MAX MIN MAX = maximum level MIN = minimum level • 2 The oil level is correct when it reaches the “MAX” mark on the dipstick.
Periodic Maintenance Operations Atlantic 500 RENEWING THE TRANSMISSION OIL Read through the paragraph LUBRICANTS, MAINTENANCE and TABLE OF LUBRICANTS. 1 NOTE Put the vehicle on a solid and flat surface. • Put the vehicle on the central stand. CAUTION Do not use the vehicle if lubrication is insufficient. Never use unsuitable or contaminated lubricants as they accelerate the wear and tear of moving parts and can cause irreparable damage.
Periodic Maintenance Operations Atlantic 500 CAUTION The brakes are the parts that most ensure your safety and for this reason they must always be perfectly working; check them before every trip. A dirty disc soils the pads, with consequent reduction of the braking efficiency. Dirty pads must be replaced, while dirty discs must be cleaned with a high-quality degreaser. 2 Renew the brake fluid every two years.
Periodic Maintenance Operations Atlantic 500 RESTORING THE BRAKE FLUID LEVEL Read through the paragraph DISC BRAKES. Remove the four screws (2) from brake fluid reservoir (3). Remove cover (4). 4 2 2 NOTE To avoid spilling the brake fluid when topping up, ensure that the fluid in the reservoir is parallel with the reservoir rim (in a horizontal position). Remove the gasket under the cover.
Periodic Maintenance Operations Atlantic 500 BLEEDING THE BRAKING SYSTEM (FRONT SIDE ONLY) Read through the paragraph DISC BRAKES. Any air present in the brake circuit acts as a cushion, absorbing much of the pressure applied by the brake pump and reducing the effectiveness of the brake caliper. The presence of air is indicated by a spongy feel of the brake lever and a reduction in the braking action.
Periodic Maintenance Operations Atlantic 500 BLEEDING THE INTEGRAL BRAKING SYSTEM Read through the paragraph DISC BRAKES. The air present in the hydraulic circuit acts as a cushion, absorbing much of the pressure applied by the brake pump and reducing the effectiveness of the caliper during the braking. The presence of air can be noticed by a spongy feel of the brake lever and poor braking action.
Periodic Maintenance Operations Atlantic 500 Unloose and remove the three screws (7). Remove the rear brake caliper (8) of the plate (9) and the relevant cable lead. Fit the rear brake caliper (8) so that the breather valve (10) is in the highest position. 8 9 7 2 7 With the specific tool, suck the oil through the breather valve (10) of the rear brake caliper (8) by unscrewing the breather valve (10) nut by half turn. 10 Add oil in the brake fluid reservoir (2) for about 2-3 times.
Periodic Maintenance Operations Atlantic 500 CHECKING AND RESTORING THE COOLANT LEVEL 2 Read through the paragraphs COOLANT and PRECAUTIONS AND GENERAL INFORMATION. MAX CAUTION Do not use the vehicle if the coolant is below the minimum prescribed level “MIN”. MIN Check the coolant level every 2,000 km (1,250 mi) and after long trips; have the coolant changed every 16 months. DO NOT DISPOSE OF THE FLUID IN THE ENVIRONMENT Put the vehicle on the central stand.
Periodic Maintenance Operations Atlantic 500 RENEWING THE COOLANT Read through the paragraphs COOLANT and PRECAUTIONS AND GENERAL INFORMATION. 1 CAUTION Do not use the vehicle if the coolant is below the minimum level. Check the level of the coolant every 2,000 km (1,250 mi) and after long journeys. Renew the coolant every 16 months. 2 CAUTION Switch off the engine and allow the engine and the exhaust system to cool down.
Periodic Maintenance Operations • • Atlantic 500 Start the engine and let it idle. Place a container under the engine to gather any coolant coming out of breather screw (5). 5 6 CAUTION The coolant in the circuit is under pressure. To avoid dangerous spurts, loosen breather screw (5) slowly and moderately. • Loosen breather screw (5) on thermostatic valve (6); allow a moderate quantity of coolant to flow out together with any air bubbles and then tighten breather screw (5).
Periodic Maintenance Operations Atlantic 500 CIRCUIT BLEEDING: • Remove the front hood, see (REMOVING THE FRONT HOOD). • Remove the filter box, see (REMOVING THE FILTER BOX). • Open the expansion tank cap. • Remove the breather cap located on the cylinder head “T” union (1). • • • 2 3 2 1 Connect a transparent rubber pipe (2) between the breather pipe and the expansion tank. Screw breather nut (3) by 1/2 turn.
Periodic Maintenance Operations Atlantic 500 ADJUSTING THE BEARINGS PLAY Remove the legshield, see (REMOVING THE LEGSHIELD). Unloose the check nut (1). CAUTION To avoid damaging the steering bearings, take care not to tighten adjusting nut (2) forcefully. 1 Turn in adjusting nut (2) until the play of the bearings is eliminated. Check the play by shaking the fork in the direction of motion and ensuring that the steering can rotate freely and smoothly.
Periodic Maintenance Operations Atlantic 500 CHECKING THE FRONT SUSPENSION Read through the paragraph PRECAUTIONS AND GENERAL INFORMATION. Inspect the front suspension after the first 1,000 km (625 mi) and then every 6,000 km (3,750 mi) or 8 months. Renew the oil in the front suspension every 12,000 km (7,500 mi), see FRONT SUSPENSION. Check that no oil is leaking from the fork, and that the outside surface of the fork rods is not scratched or grooved. Replace any damaged parts.
Periodic Maintenance Operations Atlantic 500 ADJUSTMENT OF THE REAR SUSPENSION SPRING PRELOAD Adjusting ring Function Attitude Rotation (arrow A) Spring preload increase The vehicle is more rigid RecomSmooth or mended normal roads kind of road Notes Drive with passenger Rotation (arrow B) Spring preload decrease The vehicle is less rigid Roads with uneven surface Drive without passenger WHEELS AND TYRES Read through the paragraph PRECAUTIONS AND GENERAL INFORMATION.
Periodic Maintenance Operations Atlantic 500 If, on the contrary, the inflation pressure is too low, the tyre sides (1) are under greater stress and the tyre itself may slip on the rim or it may become loose, with consequent loss of control of the vehicle. In case of sudden braking the tyres could even get out of the rims. Further, the vehicle could skid while turning.
Periodic Maintenance Operations Atlantic 500 MINIMUM TREAD DEPTH LIMIT (2) front:............2 mm [0.078 in] ( rear:.........2 mm [0.078 in] ( 3 mm) [0.118 in] 3 mm) [0.118 in] 2 Do not exceed the max transportable weight as this would compromise the vehicle’s stability, handiness and may cause damages to the tyres. MAX LOAD 180 Kg (396.8 lbs) TYRES PRESSURE FRONT RIDER ONLY REAR 2.1 bar (30.4 psi) 2.3 bar (33.3 psi) FULL LOAD 2.2 bar (31.9 psi) 2.6 bar (37.
Engine Atlantic 500 3 Engine chap.
Engine Atlantic 500 COMPONENTS THAT CAN BE REMOVED WITHOUT REMOVING THE ENGINE 5 The following parts can be removed and refitted without removing the engine from the frame.
Engine Atlantic 500 REMOVING THE ENGINE FROM THE FRAME 1 3 Read through the paragraph (PRECAUTIONS AND GENERAL INFORMATION). 5 2 6 CAUTION Switch off the engine and allow the engine and the exhaust system to cool down. Disconnect the battery. Completely empty out the coolant circuit (RENEWING THE COOLANT). Remove the right and left inspection covers, see (REMOVING THE RIGHT AND LEFT INSPECTION COVER). 4 7 3 CAUTION Clean the outside of the engine with a brush, rags and a degreasing detergent.
Engine Atlantic 500 Detach the water inlet pipe (8) to the pump by unloosing screw (9) on hose clamp (10). 8 10 9 Detach the water outlet pipe (11) from the cylinder by unloosing screw (12) on hose clamp (13) found on the union above the cylinder. 13 15 12 11 Detach the electrical connection (14) of the coolant temperature sensor (15). 14 Unloose the two nuts (16) fixing the cable guides to the throttle body support.
Engine Atlantic 500 Remove rubber protection (21) and detach the engine oil pressure sensor wire connector (22). 21 22 3 Unloose and remove the nut fixing the starter relay cable (23) and remove the cable (24). Unloose and remove the two screws (25) fixing the starter to the crankcase, and release the cables for the ground. Detach connector (26) of the injection positive cable.
Engine Atlantic 500 “A” arrange for suitable supports to be placed under the engine for the next positioning, after the frame removal. “B” unscrew and remove pin (27) fixing the left rear suspension (28). Keep the nut and the washer. 28 CAUTION Since the engine is heavy, proceed with caution. In particular, mind the hands. 27 “A” carefully lean the engine on the floor. “B” unscrew and remove the left pin (29) fixing the engine to the frame. Keep the washer. “A” hold the left side of the engine.
Fuel System Atlantic 500 4 Fuel System chap.
Fuel System Atlantic 500 FUEL TANK AND PUMP EMS FUEL INJECTION SYSTEM The fuel injection system used is of the integrated fuel injection and ignition type. Fuel is injected indirectly into the manifold by means of the electroinjector. Fuel injection and ignition are timed on a 4-stroke cycle via a phonic wheel keyed to the cam shaft control and a reluctance variation sensor. Fuel supply and ignition are controlled in relation to the engine revolutions and the opening of the throttle control.
Fuel System Atlantic 500 FUEL SUPPLY SYSTEM 5 3 10 4 7 6 4 8 1 9 2 KEY TO FUEL SUPPLY SYSTEM 1) Fuel pump 2) Fuel tank 3) Intake manifold 4) Fuel supply pipe (DELIVERY) 5) Fuel supply pipe (RETURN) 6) Excess fuel drain pipe 7) Injector 8) Fuel level float 9) Fuel pump filter 10) Fuel supply cap chap.
Fuel System Atlantic 500 MAINTENANCE Check the condition of the fuel feed pipes every 6,000 km (3,750 mi) or 8 months. Any pipes showing signs of desiccation, cracks or cuts must be replaced. Ensure that the pipes are not twisted or choked. FUEL SUPPLY CHECK Read through paragraphs (PRECAUTIONS AND GENERAL INFORMATION) and (FUEL). CAUTION Fuel fumes are a health hazard. Before proceeding, ensure that the working area is suitably aerated. Do not inhale fuel fumes. Avoid contact of fuel with the skin.
Fuel System Atlantic 500 FUEL PUMP REMOVAL/DISMANTLING CAUTION Read through the paragraphs (PRECAUTIONS AND GENERAL INFORMATION) and (FUEL). Work with caution during removal of the fuel pump (5) to avoid damage to the fuel pre-filter (6). PUMP ASSEMBLY REMOVAL Remove the fuel pump (5) from the tank (7). CAUTION Fuel fumes are a health hazard. Before proceeding, ensure that the working area is suitably aerated. Do not inhale fuel fumes. Avoid contact of fuel with the skin.
Fuel System Atlantic 500 FUEL PUMP AND FUEL LEVEL FEELER DISASSEMBLY AND CHECKING For dismantling of the components refer to WORKSHOP MANUALS n°1063 , n°1064 , n°1065 , n°1066 , n°1067 and n°1068 . THROTTLE BODY 1) 2) 3) 4) 5) 6) Stepper motor Valve position sensor Air temperature sensor Valve Valve opening control cables support plate Valve opening/closure wiring control guide 6 2 5 4-6 1 4 Release 00 2002-09 3 chap.
Fuel System Atlantic 500 THROTTLE BODY REMOVAL Read through the paragraphs (PRECAUTIONS AND GENERAL INFORMATION) and (FUEL). Remove the air filter box, see (AIR FILTER). Disconnect the delivery and return fuel supply pipes (1) to the injector. Unscrew and remove the fixing screw (2) of the fuel pipe clamps. Disconnect the electrical connection (3) of the injector control. 1 4 2 3 Disconnect the electrical connection (4) of the air temperature sensor.
Fuel System Atlantic 500 Unscrew and remove the three screws (10) fixing the intake manifold (11) to the head. Remove the intake manifold (11) including the throttle body (12). 10 10 12 11 Unscrew and remove the three screws (13) fixing the throttle body (12) to the intake manifold (11). Separate the throttle body (12) from the intake manifold (11). Remove the screw (14) fixing the injector (15) to the Intake manifold. Remove the injector (15) from the intake manifold (11).
Cooling System Atlantic 500 5 Cooling System chap.
Cooling System Atlantic 500 SYSTEM DESCRIPTION The cooling system is constructed with a centrifugal pump coaxial to the countershaft and as such completes a number of revolutions identical to that of the driving shaft. The pump has two ducts, one for entry and one for exit. The exit duct supplies the cylinder and consequently the cylinder head; the entry duct leads from the cylinder head and its entrance to the pump is controlled by the thermostat plate.
Cooling System Atlantic 500 RADIATOR REMOVAL Read through the paragraphs (COOLANT) and (PRECAUTIONS AND GENERAL INFORMATION). 1 Drain the coolant completely, see (REPLACING COOLANT), in the WORKSHOP MANUALS n°1063 , n°1064 , n°1065 , n°1066 , n°1067 and n°1068 . 1 Remove the legshields, see (LEG SHIELDS REMOVAL ). Remove the front splash guard, see (SPLASH GUARDS REMOVAL). Remove the thermo-reflecting material. Disconnect the three pipes (1) on the radiator.
Cooling System Atlantic 500 EXPANSION TANK REMOVAL Read through paragraphs (COOLANT) and (PRECAUTIONS AND GENERAL INFORMATION). Place the vehicle on its central stand. Remove the front hood, see (FRONT HOOD REMOVAL). Remove the legshields, see (LEGSHIELDS REMOVAL). Remove the dash board, see (DASHBOARD REMOVAL). CAUTION DO NOT DISPOSE OF COOLANT IN THE ENVIRONMENT. On removing the hose (1) any coolant present will exit from the expansion tank (2). Be ready with a container with capacity of approx.
Cooling System Atlantic 500 THERMOSTAT VALVE For information concerning the thermostat valve, see WORKSHOP MANUALS n°1063 , n°1064 , and n°1068 . n°1065 , n°1066 , n°1067 COOLANT PUMP 5 For information concerning the coolant pump, see WORKSHOP MANUALS n°1063 , n°1064 , n°1065 , n°1066 , n°1067 and n°1068 . COOLANT THERMISTOR For information concerning the coolant thermistor, see WORKSHOP MANUALS n°1063 , n°1064 , n°1065 , n°1066 , n°1067 and n°1068 . chap.
Cooling System 5-6 Atlantic 500 Release 00 2002-09 chap.
Electrical Equipment Atlantic 500 6 Electrical Equipment chap.
Electrical Equipment Atlantic 500 CHECKING THE RECHARGING SYSTEM The following key will help the reader to consult this section. CABLE COLOURS Ar orange Az light blue B blue Bi white G yellow Gr gray M brown N black R red V green Vi violet Ro pink CHECKING THE RECHARGING VOLTAGE • Check the electrolyte level (CHECKING THE ELECTROLYTE LEVEL). • Check the battery voltage (RECHARGING THE BATTERY). • Start the engine and rev it up to 5000 rpm (throttle twist grip rotated by approximately 1/4 of its travel).
Electrical Equipment Atlantic 500 CHECKING THE ALTERNATOR CONTINUITY With motor off: • Remove the right side panel, see (SIDE PANELS REMOVAL). • Detach regulator wiring connector (1). • Using a pocket multimeter, check continuity between stator yellow wires (G). • Also check the insulation of the stator support. 1 1 Standard resistance: 0.1 - 1 Ω Standard resistance between stator support and wiring: ∞ (infinite resistance) VOLTAGE REGULATOR • Remove the tail panel, see (TAIL PANEL REMOVAL).
Electrical Equipment Atlantic 500 FUEL INJECTION SYSTEM INJECTION SUPPLY WIRE DIAGRAM 37 R/Gr R/N 35 1 V/N R/Bi R/Gr R/Gr Ar/N Ar/V 24 B 15A V/N C 15A E 3A V/R A 15A V/R D 15A F STAND SPIA CAVALLETTO SWITCH R/Bi 1 2 3 4 R/B 5 6 7 8 9 10 11 12 13 14 15 16 Ar/N 17 18 19 20 21 22 23 24 25 Gr/N 26 V/R 52 E.C.U. CONTROL UNIT CENTRALINA E.C.U.
Electrical Equipment Atlantic 500 STAND SWITCH CONTROL Rotation of the side stand (1) must be free from obstruction. Carry out the following checks: • • The springs (2) must not be damaged, worn, rusty or weakened. The stand must turn freely, by greasing the joint if necessary, see (TABLE OF LUBRICANTS). On the side stand (1) there is a safety switch (3) with the role of preventing or interrupting engine running with the side stand (1) lowered.
Electrical Equipment Atlantic 500 INJECTION RELAY CONTROLS To verify that the relay is working: • • • Remove the seat, see (REMOVING THE SEAT). Supply a 12 V tension to the two male terminals (85-86). With a multimeter (in ohm meter mode) verify the continuity between the other two terminals (8730). Correct value with supply to the relay: 0 Ω Correct value without supply to the relay: ∞ Ω If the resulting values do not correspond to those prescribed, replace the relay concerned.
Electrical Equipment Atlantic 500 IGNITION/INJECTION SYSTEM E.C.U. CONNECTIONS 43 ! x1000r/min mp/h Km/h EFI ABS SET TRIP FAN RELE VENTOLA RELAY 36 M/Bi 3 4 5 6 7 Az/R Ar R/B Vi B 9 10 11 12 13 14 15 16 M R M/G B/N Gr/R Az Az/V Ro/G 6 R M 1 B 54 4 2 3 POMPA FUEL BENZINA PUMP Gr Ar Ar/R Bi/N Gr Ro/N Gr M/Bi M/G R/M R/M Gr/R 1 Ar/Bi R/M Az Ro G Vi 1 Gr/N R/B R/M 18 Ro/N Vi/N 19 Ar/Bi 20 G 21 Gr 22 23 N 24 Ro 25 Gr/N 26 N 52 E.C.U. CONTROL UNIT CENTRALINA E.C.U.
Electrical Equipment Atlantic 500 1 2 3 4 6 5 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 CAUTION Since inside the C.D.I. control unit there are diodes, condensers and other electrical components, the measuring method described is approximate. Further checking is recommended by replacing the control unit with another pre-checked to ensure it is in working order, or carry out the checks described in the chapter (ELECTRICAL SYSTEM CONTROL USING A C.D.I.
Electrical Equipment Atlantic 500 CONNECTIONS TO THE E.C.U. CONTROL UNIT COMPONENT TERMINALS NOMINAL VALUE CABLE COLOUR RPM sensor 7 - 12 680 Ω B - B/N Stepper Motor 14 - 24 52 Ω Az - Ro Stepper Motor 6 - 21 52 Ω Vi - G Accelerator sensor 1 - 22 5 kΩ M/Bi - Gr Accelerator sensor 1 - 11 1 - 6 kΩ M/Bi - M/G Air injection terminals 18 - 22 see tab. Ro/N - Gr Water injection terminals 4 - 22 see tab. Ar - Gr Drop sensor 16 -22 62 kΩ * Ro/G - Gr Coil 20 0.
Electrical Equipment Atlantic 500 CHECKING THE HV COIL • Remove the left inspection cover, see (REMOVING THE RIGHT AND LEFT INSPECTION COVERS). • Disconnect terminal (1). • Unscrew and remove the two screws (2). • Disconnect the spark plug (3). • Remove the coil (4). 4 3 2 1 • • With a pocket multimeter (scale 200 Ω), measure the resistance (from the coil side) between the terminals (A e B) indicated in the diagram. If the resistance measured is not correct, replace the coil. Standard value: 0.
Electrical Equipment Atlantic 500 DROP SENSOR CHECK 2 With motor off: • 1 Remove the front hood, see (REMOVING THE FRONT HOOD). Check that the sensor (1) is mounted correctly (with the arrow imprinted on the rubber pointing upwards). • • 3 Partially remove the fuse carriers (2). Disconnect the two-way connector (3)(white/grey) and take measurements (on terminals sensor side). CAUTION 6 During reassembly ensure correct coupling of the electrical connector (3).
Electrical Equipment Atlantic 500 RPM SENSOR CHECK With motor off: • Disconnect the three-way connector (1) and take measurements. • With a multimeter (scale x 100 Ω) measure the resistance between the sensor terminals, observing polarity (see diagram). 1 Standard value: 680 Ω ± 10% • If the resistance is infinite or different from the prescribed value, the sensor must be replaced. + 6-12 Release 00 2002-09 chap.
Electrical Equipment Atlantic 500 THROTTLE VALVE POTENTIOMETER (ACCELERATOR SENSOR) CHECK With motor off: • Disconnect the three-way connector (black) (1). 1 CAUTION During reassembly ensure correct coupling of the electrical connector (1). • • Set the ignition switch to “ ”. With a multimeter (scale kΩ), measure the resistance between the potentiometer terminals.
Electrical Equipment Atlantic 500 INJECTOR CHECK With motor off: • Disconnect the two-way connector (1) (black) and take measurements (on the terminals on the injector side). • With a multimeter (scale x 100 Ω), measure the resistance between the injector terminals. 1 2 Standard value: 14.5 ± 10% Ω to 25°C If the resistance is infinite (∞) or less than the prescribed value, the injector (2) must be replaced.
Electrical Equipment Atlantic 500 FUEL PUMP CHECK • • (direct current) Supply terminals 1 and 4 of the pump connector with a 12V tension (c.c.). Verify that the pump works, emitting the characteristic hum, and check on the manometer that the supply pressure reaches at least i 150 KPa (1.5 bar). CAUTION Observe the pump polarity. AIR THERMISTOR FUNCTION CHECK CAUTION 6 2 During reassembly ensure the correct coupling of the electrical connector (1). • • • • • • Remove the thermistor (2).
Electrical Equipment Atlantic 500 STARTING AND STOP LIGHTS SYSTEM 37 34 35 R/Gr R/N V/G G/R V/G R/N Gr/N V/G 33 1 R/N B/G B V/G 30 85 86 87 V/N R/Bi 55 R/Gr Gr/N R/N B/G G/R B/G Gr/N 1 56 1 V/G B V/G B V/G B V/G B V/G B 24 B 15A V/N C 15A E 3A A 15A V/R D 15A F V/R Ar/V V/G B V/R R/Bi R/Gr V/G B G/R B 1 R R N N R R 22 R/Bi B/Bi B M/N N V M 85 86 87 30 M/N R/N Gr/N Ar/V R R 30A V/R R 20A R/Bi 1 M 21 9 19 11 20 Key to wire diagram 9) Main injection relay 11) Si
Electrical Equipment Atlantic 500 STARTING RELAY CHECK • Disconnect the two-way connector (1)(white). CAUTION During reassembly ensure correct coupling of the electrical connector (1). • • • • • 1 Pull the relay out from the special hooks (2). Pull out the two rubber protectors (3-4). Disconnect the cables from their respective terminals on the relay (2). Supply the two internal terminals to the connector (1) with a 12V tension from the relay side.
Electrical Equipment 7) ENGINE OFF BUTTON ( Cable Rs R/N - Atlantic 500 ) R/Gr 8) START BUTTON ( ) Cable Rs V/G G/R 9) IGNITION BUTTON G/Gr G V/N R/Bi ZADI Cable Rs 9 PUSH 10) FRONT BRAKE LIGHT SWITCH Cable Rs Gr/N V/G ON 11) REAR BRAKE LIGHT SWITCH Cable Rs V/G R/N ON 10 11 12) SIDE STAND SWITCH Cable Rs N( ) V M OPEN CLOSED 12 6-18 Release 00 2002-09 chap.
Electrical Equipment Atlantic 500 ELECTRIC COOLING FAN WIRING DIAGRAM 35 38 G/N R/Bi Vi/N V V/N R/Bi 30 87 85 86 1 24 V B 15A V/N C 15A E 3A A 15A D 15A F 6 R/Bi Vi/N B G/N 22 Gr Ar R 30A R/Bi 1 N E.C.U. CONTROLE.C.U. UNIT CENTRALINA 52 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 16 R N B G/N 1 19 15 Key to wiring diagram 15) Water thermistor 16) Fan 19) Battery 24) Secondary fuses 35) Key switch 38) Fan relay 52) E.C.U.
Electrical Equipment Atlantic 500 WATER THERMISTOR CHECK See (COOLANT THERMISTOR FUNCTION CHECK) on page 6-14. FAN RELAY CHECK To verify that the relay is working: • • • Remove the seat, see (SEAT REMOVAL). Supply the two male terminals (85-86) with a 12V tension. With a multimeter (set to ohm meter mode) verify the continuity between the other two terminals (8730).
Electrical Equipment Atlantic 500 COOLANT TEMPERATURE AND FUEL LEVEL INDICATORS WIRING DIAGRAM 43 ! x1000r/min mp/h Km/h EFI ABS SET TRIP 6 B V B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Ar/R B B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 Bi/N W 35 V/N R/Bi 1 24 B 15A V/N C 15A E 3A A 15A D 15A F R/Bi V Ar/N G/V Ar/R Bi/N R 20A R/Bi 1 22 R N 1 8 19 15 Key to wiring diagram 8) Fuel level sensor 15) Water thermistor 19) Battery 22) Main fuses 24) Secondary fuses 35
Electrical Equipment Atlantic 500 WATER TEMPERATURE DASHBOARD CHECK • • Disconnect the water thermistor connector and connect an electrical resistance (from the connector side) between the orange/red and white/black cables. Turn the key to ON and verify the indication on the dashboard.
Electrical Equipment Atlantic 500 LIGHTS AND ACOUSTIC SIGNALS SYSTEM WIRING DIAGRAM 39 SCROLL 37 PASSING STOP G V/N G/N 40 B Gr G/N N Bi V/N 35 48 G/Gr G V/N R/Bi G/Gr V G/N B Gr G/N N Bi V V Gr 1 N B N B Bi G B Bi 49 N B Bi G B Bi G B G B G B G G G B B G B G B B R/Bi 50 54 58 31 31 58 54 31 31 1 26 G/Gr B 6 G B B Ar/N 27 1 24 B G B 15A V/N C 15A E 3A V/R A 15A V/R D 15A R/Bi F V/R R/Bi 25 V/R V N 22 R R R R 30A V/R R 20A R/Bi 1 19 Key to wiring d
Electrical Equipment Atlantic 500 DIRECTION INDICATORS AND DISPLAY DATA WIRING DIAGRAM 43 ! 39 SCROLL x1000r/min EFI mp/h Km/h PASSING STOP ABS SET 46 B/Bi M B/Bi Bi/G 1 R B/N Az 15 16 R/Bi B/N Az/Bi TRIP 12 R Az B/N R/Bi Az/Bi Bi/G 5 6 7 8 B/Bi W 1 R R 29 Az 30 R R R R Az Az 47 Az Key to wiring diagram 29) Rear right indicator 30) Rear left indicator 39) Left lights switch 43) Dashboard 46) Front right indicator 47) Front left indicator CONTROLS ON THE LEFT SIDE OF THE
Electrical Equipment Atlantic 500 MULTIFUNCTION LCD DISPLAY Turning the ignition key (1) to position “ ”, all the segments on the Multifuncion LCD display are activated for a few seconds (in this way working checks are carried out on the components) and the last function imposed after the vehicle was stopped is visualized. 6 7 9 8 10 5 11 AVG VBATT Km/h ml/G Vmax mph 4 After the first 1,000 Km (625 mi) and then every 6,000 Km (3,750 mi), SERVICE will appear on the display.
Electrical Equipment Atlantic 500 RESETTING OF AVERAGE SPEED, MAXIMUM SPEED, FUEL CONSUMPTION AND CHRONOMETER VALUES NOTE Cancellation of this information is only possible if the odometer is visualized to the right of the digital display. ABS /RESET Keep the TRIP/RESET button (1) pressed for more than three seconds. NOTE The function visualized will be cancelled.
Electrical Equipment Atlantic 500 DIRECTION INDICATOR AND SPEEDOMETER WIRING DIAGRAM 43 ! x1000r/min mp/h Km/h EFI ABS 44 W SET TRIP Ro M 1 Gr/B Gr/Bi B/Ar Ro M 1 Gr/B Gr/Bi Vi 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 B/Ar Vi B/Ar Gr/Bi V 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 6 42 B 45 Key to wiring diagram 42) 43) 44) 45) Air temperature thermistor Dashboard Speed sensor Pressure oil sensor chap.
Electrical Equipment Atlantic 500 DASHBOSRD CHECK • If the dashboard is in good working order, the red LED “ ” of the oil pressure should go on with the ignition switch to the “ ” position. SENSOR CHECK • • • 1 2 With the ignition switch in position “ ” the red LED indicator “ ”, relating to engine oil pressure, must light up. If the red LED indicator “ ”, does not regularly light up, verify that the sensor is working.
Electrical Equipment Atlantic 500 SPEEDOMETER • • • Check the correct coupling of the speed sensor connector (1). Check the correct coupling of the dashboard connectors (2). Check the distance between the speed sensor (3) and the front brake disc fixing screws (4). 1 Distance between sensor (3) and screws (4): 1.5 ± 1 mm. • Check that all the screws (4) are present.
Electrical Equipment Atlantic 500 AIR TEMPERATURE SENSOR To verify that the air temperature sensor works: • • • Disconnect the two-way connector (1). Carry out the sensor check in an environment with controlled temperature of 20 °C (68 °F). 1 Measure the electrical resistance with an ohm meter (scale 0-20 kΩ) between the connector terminals (1). Ω - 12.700 kΩ Ω Correct value: 12.200 kΩ 1 If the air temperature sensor works correctly check the dashboard: + • • Ω Apply a resistance equal to 12.
Electrical Equipment Atlantic 500 SWITCHES Using a pocket multimeter, check the continuity of the switches by referring to the tables below. Replace any faulty components.
Electrical Equipment Atlantic 500 BULB REPLACEMENT WARNING Before changing a bulb, move the ignition switch to position “ ” and wait a few minutes, so that the bulb cools down. Change the bulb wearing clean gloves or using a clean and dry cloth. Do not leave fingerprints on the bulb, since these may cause its overheating and consequent breakage. If you touch the bulb with bare hands, remove any fingerprint with alcohol, in order to avoid any damage. DO NOT FORCE THE ELECTRIC CABLES.
Electrical Equipment Atlantic 500 BATTERY For safety regulations and general information concerning the battery, see (BATTERY). For other information, see (ELECTROLYTE LEVEL CHECK),(BATTERY RECHARGE) and (BATTERY PROLONGED INACTIVITY). ACTIVATING THE BATTERY 6 Read through paragraph (BATTERY). • • • • Remove the battery cover, see (BATTERY COVER REMOVAL). Remove the battery, see (BATTERY REMOVAL). Check the battery electrolyte level, see (BATTERY ELECTROLYTE LEVEL CHECK).
Electrical Equipment Atlantic 500 FULL BEAM BULBS • Turn the bulb socket/bulb (8) anticlockwise and extract it from the parabolic setting. 9 CAUTION 10 To remove the bulb socket/bulb from its connection, take special care not to damage the two housings (9). • • • Remove the bulb (10). Correctly fit a bulb of the same kind. For reassembly, repeat the operations in reverse order. 8 PARKING LIGHT BULBS 12 CAUTION 11 To extract the bulb socket, do not pull its electric wires.
Electrical Equipment Atlantic 500 CAUTION During the following operations do not pull or force the electrical cables. • 4 Pull out the rear lights assembly (4) first pulling out the upper part and then distancing it from its housing. 5 3 CAUTION Work with caution. Do not damage the pins and/or their housings. • Holding the rear lights assembly by hand, turn it anticlockwise and remove the bulb socket (5) with the bulb (6) from the parabolic housing (4). • Remove the bulb from the housing.
Electrical Equipment Atlantic 500 NUMBER PLATE LIGHT REPLACEMENT Carefully read BULBS. 2 To change the bulbs: CAUTION Do not pull the electrical cables when removing the bulb socket. • • Grasp the bulb socket (1), pull and remove it from its housing. Pull out and replace the bulb (2) with one of the same kind. 1 HELMET COMPARTMENT LIGHT REPLACEMENT Carefully read BULBS. 2 To change the bulbs: • Lift the saddle, see (SADDLE UNBLOCKING/ BLOCKING).
Electrical Equipment • • • Atlantic 500 Loosen and remove the two fixing screws (3) of the protective screen (4) of the third stop light. Pull out the all-glass bulbs (5) from their housing. Correctly fit a bulb of the same kind. 3 NOTE During reassembly, correctly set the 5 protective screen in its housing. 6 CAUTION Carefully and gently tighten the screw (3) in order to avoid damaging the protective screen.
Electrical Equipment Atlantic 500 HORIZONTAL BEAM ADJUSTMENT • Remove the internal front shield, see (INTERNAL FRONT SHIELD REMOVAL). To carry out the beam adjustment: • Use the special handle (as indicated on the diagram) from the front of the vehicle. • Turn CLOCKWISE and the beam will move to the RIGHT (with respect to the direction faced). • Turn ANTICLOCKWISE and the beam will move to the LEFT (with respect to the direction faced). REPLACING THE FUSES Carefully read (MAINTENANCE).
Electrical Equipment Atlantic 500 SECONDARY FUSE LAYOUT (FRONT HOOD) – 15 A (2) fuse From voltage regulator to: injection, stop/starting lights logistics (Housing A on the wire diagram). – 15 A (3) fuse From the ignition switch to: engine kill logistics, stop lights (Housing B on the wire diagram). – 15 A (4) fuse From the ignition switch to: lights, horn, dashboard, fan relay, radio power supply (Housing C on the wire diagram).
Electrical Equipment Atlantic 500 ELECTRICAL COMPONENTS LAYOUT 43 33 39 25 3 13 47 56 24 31 28 30 51 53 49 27 50 55 23 40 16 KEY 3) Stepper motor 4) Coil 5) Spark plug 6) Fuel injector 11) Side stand switch 13) Accelerator sensor 14) Engine air thermistor 15) Dashboard / engine water thermistor 16) Fan 23) Power socket 24) Secondary fuses 25) Top case light 27) Number plate light 6-40 6 Release 00 11 4 5 14 28) Radio power supply 30) Rear left indicator 31) Parking/stop lights
Electrical Equipment Atlantic 500 ELECTRICAL COMPONENTS LAYOUT 20 2 22 35 34 37 19 38 36 32 9 31 29 10 17 48 26 42 45 6 46 21 18 KEY 2) Revolutions sensor 7) Fuel pump 8) Fuel level feeler 9) Main injection relay (with diode) 10) Secondary injection relay 17) Voltage regulator 18) Flywheel 19) Battery 20) Starting relay 21) Starting motor 22) Main fuses 26) Compartment switch 29) Rear right indicator chap.
51 50 47 G B B Az G B R N B Bi G Az SECONDARY FUSES: B Bi B Bi N B R B 1 52 R N B Bi G Az A - INJECTION, STARTING. B - ENGINE KILL, STOPLIGHT. C - LIGHT, CLAXON, DASHBOARD, FAN RELAY. D - POWER SOCKET. E - E.C.U. SYSTEM. F - FREE.
Electrical Equipment WIRING DIAGRAM KEY 1) Multiple connectors 2) Revolutions sensor 3) Stepper motor 4) Coil 5) Spark plug 6) Fuel injector 7) Fuel pump 8) Fuel level feeler 9) Main injection relay (with diode) 10) Secondary injection relay 11) Side stand switch 12) Lambda feeler (optional) 13) Accelerator sensor 14) Engine air thermistor 15) Dashboard/engine water thermistor 16) Fan 17) Voltage regulator 18) Flywheel 19) Battery 20) Starting relay 21) Starting motor 22) Main fuses 23) Power socket 24) Se
Electrical Equipment 6-44 Atlantic 500 Release 00 2002-09 chap.
Cycle parts Atlantic 500 7 Cycle parts chap.
Cycle parts Atlantic 500 BODYWORK PASSENGER FOOTREST REMOVAL 1 1 Place the vehicle on the central stand. CAUTION Work with care. Unscrew and remove the three screws (1). Remove the passenger footrest (2). 2 LOWER PROTECTION COVER REMOVAL 3 Place the vehicle on the central stand. CAUTION Work with care. Do not damage the tongue and/or the relative seats. Handle the painted components with care. Do not drag them or ruin them. Unscrew and remove the four screws (3) on the r.h.
Cycle parts Atlantic 500 SEAT REMOVAL 4 Place the vehicle on the central stand. Lift up the seat (4) (see UNLOCKING/LOCKING THE SEAT). CAUTION Work with care. Utilising a suitable pincer, unclip the clip (5). 6 5 7 CAUTION Prop up the seat do make sure it does not fall unexpectedly. Remove the pin (6). Unscrew and remove the four nuts (7). Remove the seat (4). 7 CENTRAL TUNNEL REMOVAL Place the vehicle on the central stand. Remove the seat (see SEAT REMOVAL).
Cycle parts Atlantic 500 LEFT AND RIGHT HAND INSPECTION COVER REMOVAL 1 2 Place the vehicle on the central stand. Remove the left and right hand rubber mats (1) by lifting them up with the hands. Unscrew and remove the screw (2). CAUTION Work with care. Do not damage the tabs (3) and/or the relative seats. Handle the painted and plastic components with care. Do not drag them or ruin them. Utilising a screwdriver, pull up the lower part of the inspection cover (4) until it slips out from its seat.
Cycle parts Atlantic 500 Utilising a flat-bladed screwdriver (3), lever up the speaker cover (4) to free it from its seat, as indicated in the figure. Remove the speaker cover (4). 3 4 Unscrew and remove the two screws (5). 5 7 CAUTION Work with care. Do not damage the tongue and/or the relative seats. Handle the painted components with care. Do not drag them or ruin them. 3 Utilising a flat-bladed screwdriver (3), lever up the edge of the legshield in such a way that it frees itself from its seat.
Cycle parts Atlantic 500 Pull the tabs (7) towards the cable (9), in such a way that the cable head (8) is freed by lifting it up. Pull the cable (9) in the direction indicated by the arrow to free the legshield from the document compartment closure. Remove the legshield (10). 7 8 9 10 DOCUMENT COMPARTMENT 1 Thanks to the utilisation of the document compartment it is not necessary to carry cumbersome objects around with you every time you park the vehicle.
Cycle parts Atlantic 500 PASSENGER HANDLE-GRIP REMOVAL 8 Place the machine on the central stand. CAUTION 9 Work with care. Do not damage the tongue and/or the relative seats. Handle the painted components with care. Do not drag them or ruin them. Lift up the seat (see UNLOCKING/LOCKING THE SEAT). Utilising a small flat head screwdriver, lever up the two rubber plugs (8). Unscrew and remove the two screws (9). Remove the passenger handle-grip (10) by rotating it towards the vehicle.
Cycle parts Atlantic 500 REMOVAL OF THE CHROMED STRIP FROM THE SIDE PANELS Remove the complete side panel (see COMPLETE SIDE PANEL REMOVAL). 1 CAUTION Work with care. Do not damage the tongue and/or the relative seats. Handle the painted components with care. Do not drag them or ruin them. Unscrew and remove the screw (1) situated inside the side panel. Remove the chromed strip by slightly arcing it in the central part.
Cycle parts Atlantic 500 1 FOOT PLATFORM REMOVAL Place the vehicle on the central stand. Remove the rubber mats (1) by lifting them by hand. Remove the cover to gain access to the spark plug (A). A CAUTION Work with care. Do not damage the tongue and/or the relative seats. Handle the painted components with care. Do not drag them or ruin them. Unscrew and remove the seven screws (2). Remove the foot platform (3). 2 3 2 7 SPRAY GUARD REMOVAL Place the vehicle on the central stand.
Cycle parts Atlantic 500 FRONT SHIELD REMOVAL Remove the spray guard (see SPRAY GUARD REMOVAL). Remove the legshield (see LEGSHIELD REMOVAL). 3 CAUTION 1 Work with care. Do not damage the tongue and/or the relative seats. Handle the painted components with care. Do not drag them or ruin them. 1 2 Unscrew and remove the three screws (1) (three on the right and three on the left). Free the front shield (2) from its supports by acting on the tabs (3) via the utilisation of a flat head screwdriver.
Cycle parts Atlantic 500 Unscrew and remove the seven screws (3). Disconnect the electrical connection (4). Remove the support arc (5). 7 3 4 5 3 3 3 Disconnec the electrical connection from the bulbs (6) and the third stoplight. Lift up and remove the plastic part (7) of the backrest. 7 6 7 REAR MUDGUARD REMOVAL 2 Place the vehicle on the central stand. CAUTION Work with care. Do not damage the tongue and/or the relative seats. Handle the painted components with care.
Cycle parts Atlantic 500 Holding the rear mudguard in the hand, disconnect the number plate light bulb (5), slide out the battery overflow tube (6) from the guide clip (7). Remove the rear mudguard (4). 5 4 6 7 TAIL UNIT REMOVAL 1 Remove the plastic backrest (see PLASTIC BACKREST REMOVAL). Remove the rear mudguard (see REAR MUDGUARD REMOVAL). Remove the rear light assembly (see COMPLETE SIDE PANEL REMOVAL). Unscrew and remove the three screws (1).
Cycle parts Atlantic 500 FOOTREST SUPPORT AND LOWER SPRAY GUARD REMOVAL Remove the legshield (see LEGSHIELD REMOVAL). Remove the central tunnel (see CENTRAL TUNNEL REMOVAL). Unscrew and remove the two screws (1). Remove the chromed protection tube (2). 2 1 Unscrew and remove the five screws (3). Remove the footrest support. (4). 4 3 7 Support the lower spray guard (5). Disconnect the overflow tube (6) of the coolant tank. Remove the lower spray guard (5). 6 5 chap.
Cycle parts Atlantic 500 FRONT PANEL REMOVAL 1 1 Place the vehicle on the central stand. Unscrew and remove the two screws (1). CAUTION Work with care. Do not damage the tongue and/or the relative seats. Handle the painted components with care. Do not drag them or ruin them. ABS Unscrew and remove the two screws (2). CAUTION During the removal, take care to not drop the clips attached to the engagement tabs.
Cycle parts Atlantic 500 Unscrew and remove the two screws (4) on the right and left side of the vehicle. Remove the upper handlebar cover (5). 4 4 LOWER HANDLEBAR COVER REMOVAL 2 2 Remove the upper handlebar cover (see UPPER HANDLEBAR REMOVAL). Unscrew and remove the three screws (1). Separate the plastic parts (2) by pulling them outwards. 1 1 7 COMPLETE INSTRUMENT PANEL REMOVAL Place the vehicle on the central stand. CAUTION 2 Work with care.
Cycle parts Atlantic 500 Remove the front panel (see FRONT PANEL REMOVAL). Remove the windshield (see WINDSHIELD REMOVAL). Unscrew and remove the screw (4). 4 Lift up the complete instrument panel (5) and disconnect the electrical connections (6) directly from the instrument panel. Remove the complete instrument panel (5). 5 6 WINDSHIELD REMOVAL 2 Carefully read (MAINTENANCE). Place the vehicle on the central stand. Remove the front panel (see FRONT PANEL REMOVAL).
Cycle parts Atlantic 500 COMPLETE LIGHTING ASSEMBLY REMOVAL Remove the hood, (see WINDSHIELD REMOVAL). Remove the front spray guard (see FRONT SPRAY GUARD REMOVAL). Remove the front panel (see FRONT PANEL REMOVAL). Remove the complete instrument panel (see INSTRUMENT PANEL REMOVAL). Unscrew and remove the screw (1). 1 6 4 Unscrew and remove the two screws (2) and recover the relative self-locking nut. Unscrew and remove the screw (3). Unscrew the cap of the coolant tank (4).
Cycle parts Atlantic 500 CRASH HELMET COMPARTMENT REMOVAL Remove the seat (see SEAT REMOVAL). Remove the central tunnel (see CENTRAL TUNNEL REMOVAL). Remove the left and right hand side panels (see COMPLETE SIDE PANEL REMOVAL). Unscrew and remove the two screws (1) and recover the relative washers.
Cycle parts Atlantic 500 Slide the starter relay (6) out of its seat inside the battery compartment. Support it by hand and slide off the rubber protection cover (7). Unscrew and remove the nut (8). 7 8 6 Slide out from the rear, the wiring that comes out of the crash helmet compartment. Slide out the starter relay lead (9). Slide out the battery lead (10). Slide out the earth lead (11). Slide out the fuse lead (12). 10 12 11 9 7 Disconnect the battery breather tube (13) from the clip (14).
Cycle parts Atlantic 500 Unscrew and remove the two screws (18). 18 Unscrew and remove the four screws (19) of the carburettor cover (20). Remove the carburettor cover (20). 19 20 Slacken the bands (22) via the screw (21) and slide out the fuel breather tube (23) by pulling it outwards. 23 21 22 Unscrew and remove the six screws (24) from the filter box (25). 24 25 24 7-20 Release 00 2002-09 chap.
Cycle parts Atlantic 500 NOTE Make sure that you have a new band before substituting the old one. 26 Remove the plastic band (26) and slide out the tube (27). Remove the engine cover (25) by lifting it upwards. Disconnect the electrical connections (28) of the crash helmet compartment light switch. Remove the crash helmet compartment (29) by lifting up the front part and moving the complete unit forwards. 27 29 28 7 chap.
Cycle parts Atlantic 500 FRONT WHEEL 6 2 4 5 11 7 3 10 8 9 12 1 KEY 1) Axle 2) Odometer sensor 3) r.h. outer spacer 4) r.h. oil seal 5) r.h. bearing 6) Wheel 7) Inner spacer 8) l.h. bearing 9) l.h. oil seal 10) l.h. brake disc 11) r.h. brake disc 12) l.h. outer spacer 7-22 Release 00 2002-09 chap.
Cycle parts Atlantic 500 REMOVING THE FRONT WHEEL 5 Read through the paragraph (PRECAUTIONS AND GENERAL INFORMATION). 1 CAUTION When removing/refitting the parts, take care not to damage the brake line, the disc and the pads. 2 Put the vehicle on the central stand. 1 WARNING Place a suitable support under the vehicle so that there is room for the front wheel to move and the vehicle does not topple over. NOTE Perform the following operation also on the r.h. side of the vehicle.
Cycle parts Atlantic 500 REPLACING THE BEARINGS Read through the paragraph (PRECAUTIONS AND GENERAL INFORMATION). 1 CAUTION 2 The bearings must be checked and if necessary replaced every time they are removed. Clean both sides of the hub with a rag. Removal 3 Working on the left side of the vehicle: Insert a drift (with no point) into the wheel hub and act on the inner race of right-hand bearing (1), taking care to shift the strike points (by 90°) so as not to offset the bearing.
Cycle parts Atlantic 500 CHECK CAUTION Check the condition of all components, and in particular of those listed below. 1 Bearings Manually rotate inner race (1), making sure it turns smoothly without any sticking and/or noise. Also check that there is no axial play. Replace any bearings showing the above defects. CAUTION Grease the balls (or rollers) at the sides of each bearing (see LUBRICANT CHART). The operation is unnecessary if the bearings are of the self-lubricating type.
Cycle parts Atlantic 500 REFITTING THE FRONT WHEEL CAUTION When refitting the front wheel, take care not to damage the brake line, the disc and the pads. Position the wheel between the fork rods. Insert axle (1) from the right side of the vehicle. Insert the spacer (2) between the hub and the left fork rod. Insert the spacer between the hub and the left fork rod. Screw and tighten the wheel pin (1). 2 1 3 NOTE Perform these operations also on the vehicle r.h. side.
Cycle parts Atlantic 500 REAR WHEEL 5 4 1 3 2 7 KEY 1) 2) 3) 4) 5) Wheel assembly Spacer Oil seal Brake caliper and silencer supporting plate Nut chap.
Cycle parts Atlantic 500 REMOVING THE REAR WHEEL Read through the paragraph (PRECAUTIONS AND GENERAL INFORMATION). 7 Put the vehicle on the central stand. 5 WARNING Allow the engine and the exhaust terminal to cool down completely. 3 6 Remove the exhaust terminal, see (REMOVING THE EXHAUST TERMINAL). Unloose and remove screw (5) fixing the pipe guide clamp. Unloose and remove the two screws (6) fixing the rear brake caliper (7). Release the rear brake caliper (7) from the support (3).
Cycle parts Atlantic 500 REMOVING THE EXHAUST TERMINAL Read through the paragraph (PRECAUTIONS AND GENERAL INFORMATION). Put the vehicle on the central stand. WARNING Allow the engine and the exhaust terminal to cool down completely. 1 Unloose clamp (1) by unscrewing the nut fixing the exhaust terminal to the manifold. Unscrew and remove the three bolts (2) fixing the terminal to support (3), keep the relevant nuts. Remove the exhaust terminal (4). 3 2 4 2 chap.
Cycle parts Atlantic 500 CHECK CAUTION Check the condition of all components and in particular of those listed below. 1 Bearings Manually rotate inner race (1), making sure it turns smoothly without any sticking and/or noise. Check that there is no axial play. Replace any bearings showing the above defects. CAUTION Lubricate the balls (or rollers) on the side of each bearing, see (TABLE OF LUBRICANTS). Lubrication is not necessary if the bearing is of the self-lubricating type.
Cycle parts Atlantic 500 1 8 2 4 5 3 6 8 7 5 3 7 9 9 KEY 1) 2) 3) 4) 5) 6) 7) 8) 9) Brake control lever Brake fluid pump/tank Brake fluid pipe Braking retarder Brake caliper breather valve Pipe fitting screw Brake caliper Brake pads Brake disc chap.
Cycle parts Atlantic 500 REPLACING THE BRAKE PADS Read through the paragraph (PRECAUTIONS AND GENERAL INFORMATION). 4 Put the vehicle on the central stand. NOTE Perform the following operations on both 1 sides. Unloose and remove screw (1). Unloose and remove the two screws (2) and release the brake caliper (3). Hold the brake caliper in one hand and remove plate (4). Remove the two pins (5). Remove the two pads.
Cycle parts Atlantic 500 CHECKING THE BRAKE DISC CAUTION The following operations must be performed when the brake disc is installed on the wheel. Visually check the surface of the brake disc. If it shows any signs of scoring or damage, replace the disc (REMOVING THE BRAKE DISC). Check the wear of the brake disc by measuring its minimum thickness with a micrometer at several points. If the minimum thickness of the disc, even at one point, is less than the prescribed limit, replace the disc.
Cycle parts Atlantic 500 11 7 2 8 10 5 1 9 10 4 3 6 12 KEY 1) Brake control lever 2) Brake fluid pump/tank 3) Brake fluid pipe 4) Valve 5) Pipe fitting screw 6) Brake caliper 7) Pad pin 8) Stop ring 9) Brake pads 10) Antivibration plates 11) Pad spring 12) Brake disc 7-34 Release 00 2002-09 chap.
Cycle parts Atlantic 500 REPLACING THE BRAKE PADS Read through the paragraph (PRECAUTIONS AND GENERAL INFORMATION). 1 Remove the rear brake caliper, see (REMOVING THE REAR BRAKE CALIPER). Remove stop ring (1). Remove pin (2). Remove spring (3). CAUTION The vibration-damping plates are removed together with the pads. Remove the pads (4) (complete with the vibrationdamping plates (5)) by withdrawing them one by one.
Cycle parts Atlantic 500 CHECKING THE BRAKE DISC CAUTION The following operations must be performed when the brake disc is installed on the wheel. Visually check the surface of the brake disc. If it shows any signs of scoring or damage, replace the disc (REMOVING THE BRAKE DISC). Check the wear of the brake disc by measuring its minimum thickness with a micrometer at several points. If the minimum thickness of the disc, even at one point, is less than the prescribed limit, replace the disc.
Cycle parts Atlantic 500 STEERING 2 For information on how to check and adjust the steering, refer to the paragraph (CHECKING AND ADJUSTING THE STEERING). 4 1 Disassembly Read through the paragraph (PRECAUTIONS AND GENERAL INFORMATION). Remove the handlebar cover, see (REMOVING THE UPPER HANDLEBAR COVER) and (REMOVING THE LOWER HANDLEBAR COVER). Put the vehicle onto an elevator, leaving the front wheel out, and lower central stand.
Cycle parts Atlantic 500 NOTE Perform the following operation also on the 11 vehicle l.h.side. Unloose and remove the two screws (11). Release the brake caliper (12) from the fork. 12 CAUTION Do not pull the front brake lever after removing the brake caliper as the caliper piston may come out of its seat and cause a leakage of brake fluid. 11 Unloose and remove the two screws (13) Remove the brake oil pipes stop plate (14). Release the pipes and the brake caliper from the fork.
Cycle parts Atlantic 500 CHECKING THE BEARINGS CAUTION Check the condition of all components. Check that the areas that come into contact with balls (1) on both revolving ring (2) and fixed ring (3) are not damaged or worn out. If they are, replace the bearing assembly. CAUTION Grease the two rings (2) and (3) in the areas where they are in contact with the balls (see LUBRICANT CHART).
Cycle parts Atlantic 500 1 21 2 6 4 3 4 7 6 13 3 11 14 7 15 2 12 5 16 17 8 11 13 24 14 22 15 24 9 16 17 23 19 18 10 20 19 20 KEY 13) Dust cover gasket 14) Lock spring ring 15) Seal gasket 16) Cup 17) Bush 18) Left wheel carrier 19) Seal washer 20) Lower screw 21) Right rod 22) Right wheel carrier 23) Locking screw 24) Bush 1) Fork base 2) Fork clamp screws 3) Spring stop ring 4) Rubber cap 5) Seal cap 6) Brake pipe cable lead 7) “GACO” ring OR type 8) Spring 9) Pumping element 10
Cycle parts Atlantic 500 CHECKING THE OIL LEVEL If “ bottom strokes” are noticed in the fork, check the oil level in the rods. Remove the front shield, see (REMOVING THE INNER SHIELD). 2 1 NOTE To facilitate the removal of the two seal caps (3), it is necessary to remove them both at the same time. Remove the spring stop ring (1). Remove the plastic cap (2). Slowly pump the fork until the two seal caps (3) complete with O rings (4) have come out. 2 NOTE Check the O rings conditions.
Cycle parts Atlantic 500 REMOVING THE ROD-WHEEL CARRIER ASSEMBLY (with installed fork) Put the vehicle on the stand. CAUTION Place a suitable stand under the vehicle to prevent it from falling. Remove the front mudguard, see (REMOVING THE FRONT MUDGUARD). Remove the front wheel, see (REMOVING THE FRONT WHEEL). Remove the front shield, see (REMOVING THE INNER SHIELD). NOTE Perform the following operation also on the vehicle left side. Unloose and remove the two screws (1).
Cycle parts Atlantic 500 WHEEL CARRIER ROD DISASSEMBLY CAUTION Check the oil quantity. If less than 225 cm3 (13.72 cu.in), top up or renew. Read through the paragraph (PRECAUTIONS AND GENERAL INFORMATION). Unloose and remove screw (6) (wheel carrier bottom) and keep the copper washer (7). Remove the rod (8) complete with pumping element (9). Turn the wheel carrier (10) to take out the bottom bumper (11) and the counter spring (12). Remove the dust cover gasket (13).
Cycle parts Atlantic 500 CHECKING THE COMPONENTS Rod The sliding surface must show no signs of scoring and/ or damage. If the rod is damaged, replace it. With a dial gauge, check that the rod bending is lower than the limit value. If necessary, replace the rod. Bending limit: 0.2 mm (0.007 in). WARNING A bent rod must NEVER be straightened as its structure would become weak, thus compromising the vehicle safety. Wheel carrier Check that it shows no signs of damage and/or flaws. Replace if necessary.
Cycle parts Atlantic 500 ADJUSTMENT OF THE REAR SUSPENSION SPRING PRELOAD Adjusting ring Rotation (arrow A) Rotation (arrow B) Function Spring preload increase Spring preload decrease Attitude The vehicle is more rigid The vehicle is less rigid Recommended Smooth or normal roads kind of road Notes Drive with passenger Roads with uneven surface Drive without passenger REMOVING THE SHOCK ABSORBER Read through the paragraph (PRECAUTIONS AND GENERAL INFORMATION).
Cycle parts 7-46 Atlantic 500 Release 00 2002-09 chap.
aprilia s.p.a. via G.Galilei, 1 30033 Noale (VE) Italy tel. +39 041.5829111 fax +39 041.441054 www.serviceaprilia.
