APRILIA 500 Sprint Use & Maintenance Book Download

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use and maintenance

Atlantic 125/250/500 Sprint

Suspensions - check

Steering - check

Injection system tubes sealing - visual check

Crankcase breather - drain

At 20000 km, 40000 km, 60000 km and at 80000 km

Operation

Safety fastening points - check

Driven pulley bush

Spark plug - change

Belt - change

Throttle control - adjust

Air filter - check

Belt comp.air filter - check

Engine oil filter - change

Valve clearance - check

Electric system and battery - check

Coolant level - check

Brake fluid level - check

Engine oil - change

Brake pads - check for wear

Converter rollers/ sliders - change

Tire pressure and wear - check

Vehicle and braking system test - road test

Hub oil - check

Idling speed - adjust

Stand striker roller - change

Crankcase breather - drain

Suspensions - check

Steering - check

Injection system tubes sealing - visual check

Fuel filter - check

APRum_ATLANT125#02_##uk.book Page 45 Tuesday, March 14, 2006 5:15 PM

Summary of Contents for 500 Sprint

Page 1: ...8181011 500 SPRINT APRum_ATLANT125 02_ uk book Page 1 Tuesday March 14 2006 5 15 PM ...

Page 2: ...may result in serious injury or even death CAUTION Indicates a potential hazard which may result in minor personal injury or damage to the vehicle NOTE The word NOTE in this manual identifies important information or instructions TECHNICAL INFORMATION The operations preceded by this symbol must be repeated on the opposite side of the vehicle Unless expressly indicated otherwise reassembly is a rev...

Page 3: ... vehicles undergo periodical inspections Users in these countries must contact an aprilia Authorised dealer to have the non homologated components replaced with others homologated for use in the country in question have their vehicles inspected at the required intervals NOTE Soon after purchasing the vehicle write down the identification data indicated on the SPARE PARTS IDENTIFICATION LABEL in th...

Page 4: ...AND TOPPING UP TRANSMISSION FLUID LEVEL 50 CHANGING TRANSMISSION OIL 51 AIR FILTER 52 CHECKING THE BRAKE PADS FOR WEAR 53 CHECKING THE STAND 54 CHECKING THE SWITCHES 54 INSPECTING THE FRONT AND REAR SUSPENSIONS 55 ADJUSTING THE REAR SUSPENSION 55 ADJUSTING THE REAR SUSPENSION 55 CHECKING THE STEERING 56 CHECKING THE ENGINE PIVOT 56 REMOVING THE RIGHT AND LEFT INSPECTION COVERS 57 REMOVING THE REAR...

Page 5: ...safe riding APRum_ATLANT125 02_ uk book Page 5 Tuesday March 14 2006 5 15 PM ...

Page 6: ...used by inexperienced riders NEVER lend your vehicle to a beginner and make sure any person borrowing your vehicle fills the legal requirements for driving Strictly observe all posted signs and national and local road regulations Avoid any sudden or risky manoeuvres that may endanger your and other people s safety for example wheelies speeding etc and adjust your riding style to road surface condi...

Page 7: ...Remember to report any malfunction to the technicians and or mechanics to facilitate their work Never use the vehicle when the amount of damage it has suffered makes it unsafe to ride Never change the position inclination or colour of number plate direction indicators lights and horns Any modification made to the vehicle will invalidate the warranty Making any modifications to the vehicle and or r...

Page 8: ...ith moving parts or with the handlebars Do not ride with sharp or pointed objects in your pockets as they might cause injury in the event of a fall this includes keys pens glass vials etc note that the same applies to your passenger ACCESSORIES The owner of the vehicle is responsible for the choice installation and use of any accessory Any accessories installed must not cover the horns or lights o...

Page 9: ... sides of the vehicle to keep it stable Make sure that the luggage is firmly secured to the vehicle especially before long trips Avoid fixing bulky heavy and or dangerous objects to the handlebars mudguards and forks this could slow down the vehicle s response in turns and would inevitably affect handling Do not secure bulky bags to the vehicle sides as they could hit people or obstacles when ridi...

Page 10: ...lmet compartment 4 Seat lock 5 Air filter 6 Engine oil level filler plug 7 Centre stand 8 Converter air scoop 9 Left passenger footpeg 10 Side stand 11 Left inspection cover 12 Expansion tank 13 Coolant expansion tank plug 1 2 12 13 3 4 5 6 7 8 9 10 11 125 250 500 500 APRum_ATLANT125 02_ uk book Page 10 Tuesday March 14 2006 5 15 PM ...

Page 11: ...p 7 Front brake fluid reservoir 8 Ignition switch steering lock 9 Auxiliary fuse carrier 10 Warning horn 11 Fuel tank filler plug 12 Fuel tank 13 Right inspection cover 14 Spark plug 15 Right passenger footpeg 16 Engine oil level filler plug 10 1 2 3 4 5 7 8 9 11 12 13 14 15 16 6 500 125 250 125 250 125 250 500 APRum_ATLANT125 02_ uk book Page 11 Tuesday March 14 2006 5 15 PM ...

Page 12: ...uments and indicators 3 Right rear view mirror 4 Throttle grip 5 Front brake lever 6 Electrical controls on the right side of the handlebar 7 Ignition switch steering lock 8 Electrical controls on the left side of the handlebar 9 Combined brake lever front and rear ITI 4 5 6 8 9 1 3 2 7 APRum_ATLANT125 02_ uk book Page 12 Tuesday March 14 2006 5 15 PM ...

Page 13: ... direction indicator light 6 Green right direction indicator light 7 Red EFI light 8 Green low beam light 9 Blue high beam warning light 10 Amber low fuel warning light 11 Fuel level indicator 12 Coolant temperature indicator 13 Digital clock function and setting push buttons 14 Digital clock 15 Total kilometres odometer 16 Trip meter 17 Speedometer 18 Trip meter reset knob ITI ABS 1 2 3 4 5 6 7 8...

Page 14: ...that oil pressure in the circuit is too low Stop the engine immediately and contact an aprilia Authorised dealer Side stand light Comes on when the side stand is down When the side stand is down the warning light comes on and engine starting is inhibited Electronic fuel injection check light EFI It comes on for about three seconds whenever the ignition switch is set to with the engine stopped as a...

Page 15: ... temperature is sufficient for driving the vehicle If the pointer reaches the red area or the light comes on stop the engine and check the coolant level see page 27 COOLANT Exceeding the maximum coolant temperature allowed red max area may lead to severe engine damage Digital clock Hour and date display see page 19 DIGITAL CLOCK DATE DISPLAY Total kilometres odometer It indicates the total number ...

Page 16: ...the switch to the left to indicate the turn to the right move the switch to the right Press the switch to cancel the signal 3 DIMMER SWITCH HIGH BEAM FLASHER PUSH BUTTON PASSING If the dimmer switch is in position the low beam comes on while if it is in position the high beam comes on The high beam flasher is operated by pressing the dimmer switch to position PASSING NOTE Release the dimmer switch...

Page 17: ... in position it is possible to start the engine the engine can be stopped by pressing the switch to position CAUTION With the engine stopped and the ignition switch in position the battery may run flat When the vehicle has come to a standstill and you have stopped the engine set the ignition switch to position 2 STARTER BUTTON When the starter button is pressed the starter motor will crank the eng...

Page 18: ...K WARNING Never turn the key to position when riding or you will lose control of the vehicle OPERATION To lock the steering u Turn the handlebar fully to the left u Push in the key 2 and turn it to position P U SH 1 ZA DI 2 Position Function Key removal Steering lock The steering is locked It is not possible to start the engine or switch on the lights It is possible to remove the key Neither the e...

Page 19: ...n and the day will be displayed on the right Press the push button 1 to set the desired day Hour press the push button 2 again and the time will be displayed on the left with letter A or P A AM P PM Press the push button 1 to set the desired time u Minutes press the push button 2 again and the minutes will be displayed on the right Press the push button 1 to set the desired minutes Now the clock i...

Page 20: ...on wrench 8x120 mm rod The tool kit includes double ended crosshead flat blade screwdriver handle for screwdriver 8 mm combination wrench 16x70 mm socket wrench with hexagon 13 mm combination wrench pin wrench with square pin tool case UNLOCKING LOCKING THE SEAT u Insert the key 2 into the seat lock u Press and turn the key counter clockwise u To lock the seat lower and press it without exerting t...

Page 21: ...arge small appliances rated up to 180 W mobile phone inspection lamp etc CAUTION Prolonged use of the power socket with the engine stopped may compromise the battery charge PRESETTING THE INTERPHONE KIT Only for preset vehicles u Inside the front shield is a power socket for the interphone system control unit u On the right and left sides of the central tunnel are two standard jacks 2 for the inte...

Page 22: ...t 2 on the instrument panel will flash the motion sensors and the under seat compartment sensors will activate after 30 seconds After 50 seconds from vehicle switch off or from alarm disable the system automatically disables engine ignition in order to ensure a minimum safety level in case you forget to enable the alarm system manually In this case the siren connected to the motion and under seat ...

Page 23: ...ed before starting the engine Never fill the tank to the rim as fuel expands from heat and when left under direct sunlight Tighten the filler plug securely after refuelling Avoid contact with skin do not inhale fuel vapours do not swallow fuel or transfer it between different receptacles using a hose DO NOT RELEASE FUEL IN THE ENVIRONMENT KEEP AWAY FROM CHILDREN Use only premium grade unleaded pet...

Page 24: ...alfunctions contact an aprilia Authorised dealer Transmission fluid For instructions on transmission oil check and change see page 40 SCHEDULED MAINTENANCE CHART To check the fluid level and to change the fluid contact an aprilia Authorised Dealer ENGINE OIL Periodically check the engine oil level see page 48 CHECKING AND TOPPING UP ENGINE OIL LEVEL NOTE Use oil with specifications 5 W 40 see page...

Page 25: ...er WARNING Pay special attention to the brake disc and friction material making sure that they are neither dirty nor oily especially after maintenance operations or inspections Make sure the brake hose is not twisted or worn KEEP AWAY FROM CHILDREN DO NOT RELEASE INTO THE ENVIRONMENT DISC BRAKES WARNING The brakes are critical to your safety and must always be kept in sleek running order Check the...

Page 26: ...icle on the centre stand u Rotate the handlebar so that the fluid contained in the brake reservoir is parallel to the MIN mark stamped on the glass gauge 1 u Make sure that the fluid contained in the reservoir exceeds the MIN mark stamped on the glass gauge 1 MIN minimum level CAUTION Do not use the vehicle if the fluid is below the MIN mark CAUTION Brake fluid level decreases as the brake pads we...

Page 27: ...hanged at an aprilia Authorised Dealer Coolant mixture is a 50 solution of water and antifreeze This is the ideal solution for most operating temperatures and provides good corrosion protection This solution is also suited to the warm season as the mixture is less prone to evaporative loss and will reduce the need for top ups In addition less water evaporation means fewer mineral salts depositing ...

Page 28: ...ing it anticlockwise without removing it u Wait a few seconds in order to release any residual pressure u Unscrew and remove the cap 4 WARNING Coolant is toxic when ingested Contact with eyes or skin may cause irritation Do not put your fingers or any other object into the filler opening in order to ensure that there is coolant CAUTION Never top up beyond the MAX level mark or coolant will leak ou...

Page 29: ...uipped with wear indicators There are several kinds of wear indicators For more information on how to check the tyres for wear contact your Dealer Visually inspect the tyres for wear and have them changed if worn Old tyres even if not completely worn down may become hard and provide poor grip If so have them replaced Have a tyre changed when worn or punctured if the puncture in the tread is larger...

Page 30: ...ts sale or delivery to the final purchaser or while it is in use except if carried out for maintenance repair or replacement purposes and The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person Check the exhaust muffler silencer and the silencer pipes making sure that they show no traces of rust or holes and that the exhaust system is op...

Page 31: ...l positions of the steering Adjust and or lubricate as required 60 Engine oil Check and or top up as required 24 Wheels tyres Check tyre surface inflation pressure Check for wear or damage 29 Steering Steering should rotate smoothly and evenly There should be no play or looseness 56 Side stand and centre stand Make sure that they work smoothly and that the spring tension brings them back to their ...

Page 32: ... instrument panel should come on The light should go out as soon as you start the engine If the light does not come on or fails to go out after three seconds contact an aprilia Authorised Dealer u Lock at least one wheel by pulling a brake lever 5 If this operation is not carried out the start relay receives no current and therefore the engine does not start NOTE After a long period of inactivity ...

Page 33: ...t is too low Stop the engine immediately and contact an aprilia Authorised dealer Do not use the vehicle with insufficient engine oil in order to avoid damaging the engine components u Keep at least one brake operated and do not accelerate until you are ready to move off DIFFICULT STARTING The fuel system manages starting according to engine temperature ambient temperature and pressure STARTING AF...

Page 34: ...If you are riding with a passenger give your passenger proper instructions to avoid problems when manoeuvring Before leaving make sure that the stand stands is are completely up To move off u Release the throttle grip 2 Pos A engage the rear brake then move the vehicle down the stand u Get on the vehicle keeping at least one foot on the ground in order not to lose balance u Adjust the rear view mi...

Page 35: ...e engine braking or the clutch may overheat WARNING When approaching a turn slow down or brake and take the turn at moderate constant speed or accelerate slightly braking in a turn will greatly increase your chances of skidding Continued application of the brakes on long downhill grades may cause the brakes to overheat thereby reducing braking efficiency Shift down to use engine braking and apply ...

Page 36: ...ect engine running is essential to ensuring proper performance and durability Twisty hilly roads are ideal for an effective running in of engine suspension and brakes NOTE Only after the first 1000 km 625 mi of running in it is possible to obtain the best speed and acceleration performance from the vehicle Follow these recommendations u Do not open the throttle completely if the speed is low both ...

Page 37: ... u Set the engine stop switch 1 to position CAUTION With the engine stopped and the ignition switch in position the battery may run flat u Turn the key 2 and set the ignition switch 3 to position u Place the vehicle on the stand see on the side PLACING THE VEHICLE ON THE STAND CAUTION Never leave the key in the ignition switch u Lock the steering see page 18 STEERING LOCK and remove the key PUTTIN...

Page 38: ...or at a guarded parking place If possible use the appropriate aprilia Body Guard shielded cable or an additional antitheft device Make sure you have all the necessary documents with you and that the road tax has been paid Write your personal data and telephone number in this page to help trace the vehicle back to you in the event it is stolen and subsequently recovered SURNAME NAME ADDRESS TELEPHO...

Page 39: ...id burns Do not put any vehicle parts into your mouth vehicle components are not edible and some of them are harmful or even toxic CAUTION Unless expressly indicated otherwise reassembly is a reversal of the disassembly procedure Wear latex gloves during servicing Normally the owner can take care of routine maintenance However some maintenance operations require specific tools and are best left to...

Page 40: ... lubricate and change if necessary Rear shock absorbers check Battery terminals check Spark plug check Carburettor idling adjustment Accelerator operation check Brake operation check Coolant check Engine oil change Tire inflating pressure every month Battery terminals tightening check 125 Front suspension check Brake pads wear check Every 6000 km 3750 mi or 8 months Check clean adjust lubricate an...

Page 41: ... filter cleaning Converter cover air filter cleaning Valve clearance check Brake fluid check Front suspension fluid check Transmission oil every 6000 km 3750 mi check Transmission oil change every 24000 km 14913 mi Engine oil filter screen and magnetic screw check Converter rollers and converter plastic guides check Wheels tires check Nut bolt screw tightening check Carburetion at idle speed adjus...

Page 42: ...n Coolant change Brake fluid change At 1000 km Operation Safety fastening points check Throttle control adjust Oil filter change Electric system and battery check Coolant level check Brake fluid level check Engine oil change Brake pads check for wear Tire pressure and wear check Vehicle and braking system test road test 250 Hub oil change Steering check At 5000 km 25000 km 35000 km 55000 km 65000 ...

Page 43: ...p air filter check Engine oil filter change Electric system and battery check Coolant level check Brake fluid level check Engine oil change Brake pads check for wear Converter rollers sliders change Tire pressure and wear check Vehicle and braking system test road test Hub oil check Suspensions check Steering check At 60000 km Operation Spark plug change Belt change Throttle control adjust Air fil...

Page 44: ...Throttle control adjust Engine oil filter change Electric system and battery check Coolant level check Brake fluid level check Engine oil change Brake pads check for wear Tire pressure and wear check Vehicle and braking system test road test Hub oil change 500 Idling speed adjust Crankcase breather drain Steering check Injection system tubes sealing visual check Every 5000 km Operation Engine oil ...

Page 45: ...p air filter check Engine oil filter change Valve clearance check Electric system and battery check Coolant level check Brake fluid level check Engine oil change Brake pads check for wear Converter rollers sliders change Tire pressure and wear check Vehicle and braking system test road test Hub oil check Idling speed adjust Stand striker roller change Crankcase breather drain Suspensions check Ste...

Page 46: ...aw with fines and imprisonment In addition altering the frame number invalidates the warranty FRAME NUMBER The frame number is stamped on the frame central tube To expose the frame number open the glove compartment page 21 GLOVE TOOL KIT COMPARTMENT and remove the snap on guard Frame no ________________________ ENGINE NUMBER The engine number is stamped near the lower support of the rear shock abs...

Page 47: ... 1 u Fit the case mounting plate 2 and tighten the four screws 3 u Locate the front end A of the case to the support on the mounting plate Press down the rear end B of the case moderately until locking it in place CAUTION Ensure that the case is securely in place 1 3 2 B A APRum_ATLANT125 02_ uk book Page 47 Tuesday March 14 2006 5 15 PM ...

Page 48: ...ely screwing it into the filling hole 2 u Withdraw the plug dipstick 1 again and read the oil level on the dipstick itself MAX maximum level MIN minimum level The difference between MAX and MIN amounts to approximately 200 cu cm 400 cc u The level is correct if the oil reaches approx the MAX mark on the dipstick CAUTION Never exceed the MAX mark or let oil level drop below the MIN mark as this may...

Page 49: ...nated or unsuitable lubricants since this would cause early wear of the moving parts and may also cause irreparable failures u Unscrew and remove the oil drain plug 4 and then drain all engine oil u Install a new oil cartridge filter 3 Lubricate the filter O rings before installation u Screw and tighten the engine oil drain plug 4 u Pour engine oil into the filler opening 2 see page 75 TECHNICAL D...

Page 50: ...elf MAX maximum level MIN minimum level u The level is correct if the oil reaches approx the MAX mark on the dipstick CAUTION Never exceed the MAX mark or let oil level drop below the MIN mark as this may lead to severe engine damage u If necessary provide for topping up TOPPING UP u Pour a small quantity of oil in the filling hole and wait about one minute so that the oil flows into the oil pan u...

Page 51: ...it cool down in order to allow the oil to flow into the oil pan and to cool down WARNING Make sure not to spill oil on the rear brake disc while changing oil u Unscrew and extract the plug dipstick 1 u Release and remove the transmission fluid drain screw 2 u Let all transmission oil drain out Collect it in a container with adequate capacity u Fit and tighten the transmission fluid drain screw 2 u...

Page 52: ...ine screws 1 u Remove the filter casing cover 2 together with the filter 3 u Check the filtering element 3 and change it if required CLEANING WARNING Do not use petrol or inflammable solvents to wash the filtering element in order to avoid fires or explosions Do not use additives or fluid detergents as this would lead to moisture build up inside the filter casing Use compressed air only u Blow the...

Page 53: ...ct the brake pads before each ride Outlined below is a quick brake pad inspection procedure u Position the vehicle on the centre stand u Visually check in between brake disc and pads as follows FRONT BRAKE CALLIPERS Check the pads of both callipers looking from the bottom up at the front end REAR BRAKE CALLIPER Check both pads C looking from the bottom up at the rear end WARNING If brake pads were...

Page 54: ...s interfere with stand 1 rotation Check for the following u The springs 2 must not be damaged worn rusty or weakened u The side stand must rotate freely if necessary grease the joint see p page 79 LUBRICANT CHART CHECKING THE SWITCHES The vehicle is fitted with two switches Brake light switch on the rear brake lever integral braking system Brake light switch on the front brake lever Side stand dow...

Page 55: ...N The rear suspension consists of a double effect shock absorber compression rebound damping fixed to the engine by means of a silentblock The standard adjustment set by the manufacturer is suitable for a rider weighing about 70 kg If your weight and needs are different adjust the ring nut 1 thus setting the ideal travelling conditions see table ADJUSTMENT OF THE REAR SUSPENSION SPRING PRELOAD ADJ...

Page 56: ... the fork excessively otherwise you may take in consideration the movement of the stand thus observing an incorrect slack Repeat the previous operation more than once u If you find that there is considerable slack contact your aprilia Authorised Dealer to restore the optimal steering conditions CHECKING THE ENGINE PIVOT Carefully read page 39 MAINTENANCE Periodically check the slack existing betwe...

Page 57: ...VING THE REAR VIEW MIRRORS Carefully read page 39 MAINTENANCE The following information applies to both rear view mirrors u Position the vehicle on the centre stand NOTE Collect the left mirror components separately from the right mirror components u Slip off the rubber gaiter 1 and unscrew the two retaining screws 2 u Remove the protective cover 3 CAUTION Hold the rear view mirror 4 to prevent it...

Page 58: ...attention to the fixing tab clips They might come loose during removal u Pull the front cover 9 gently to remove CAUTION Ensure that the tabs with the clips locate correctly into their seats on refitting REMOVING THE HEADLIGHT FAIRING Carefully read page 39 MAINTENANCE u Position the vehicle on the centre stand u Remove the rear view mirrors see page 57 REMOVING THE REAR VIEW MIRRORS u Remove the ...

Page 59: ... Start the engine Correct engine rpm reading is about 1600 100 rpm Note that the rear wheel will be at standstill If necessary u Open the helmet compartment under the seat u Unscrew the screw 1 and remove the protective cover 2 u Turn the adjuster screw 3 on the carburettor u By SCREWING IT clockwise you increase the engine rpm u By UNSCREWING IT anticlockwise you decrease the engine rpm u Turn th...

Page 60: ...hed turn the handlebar to make sure its movement does not affect the engine idle rpm and check that the throttle grip when opened and then released returns smoothly to the closed position SPARK PLUG Carefully read page 39 MAINTENANCE Check the spark plug every time a scheduled maintenance service is performed At regular intervals remove the spark plug and clean off any carbon deposits or replace a...

Page 61: ...rroded electrodes or excessive deposits u Check the electrode gap with a feeler gauge The gap must be 0 7 0 8 mm if necessary adjust it carefully bending the earth electrode u Make sure that the washer is in good condition Fit the washer and screw the spark plug finger tight to avoid damaging the thread u Tighten using the spanner supplied with the tool kit Screw in each spark plug by one half tur...

Page 62: ...e charging process KEEP AWAY FROM CHILDREN Avoid leaning the vehicle at steep angles or you might spill battery fluid WARNING Never invert the battery cables Ensure that the ignition switch is in position before connecting or disconnecting the battery otherwise some components might damage Connect the positive cable first and then the negative cable Disconnect in the reverse order Battery fluid is...

Page 63: ...onnect first the negative and then the positive cable u Brush with a wire brush to eliminate any sign of corrosion u Connect first the positive and then the negative cable u Coat the terminals of cables and battery with neutral grease or Vaseline REMOVING THE BATTERY u Remove the battery cover see REMOVING THE BATTERY COVER at the side u Remove the battery breather pipe 5 only u Disconnect first t...

Page 64: ...r charging the battery check battery fluid level again and top up with distilled water if needed only u Refit the battery caps only WARNING When you disconnect the battery charger allow 5 10 minutes before refitting the battery as it will keep producing gas for a few minutes INSTALLING THE BATTERY u Remove the battery cover see page 63 REMOVING THE BATTERY COVER u Refit the battery 1 into its moun...

Page 65: ...battery cover see page 63 REMOVING THE BATTERY COVER or only remove the front cover see page 58 REMOVING THE FRONT COVER u Extract all fuses one by one and check for blown fuses A blown fuse is identified by the filament 1 in the centre being broken u Before replacing a fuse identify the cause of the failure if possible u Replace the blown fuse with a new one with equal current rating NOTE When yo...

Page 66: ...agram 15A fuse C From ignition switch to lights horn instrument panel fan relay radio power supply Housing C on the wiring diagram 15A fuse D From main fuse to power socket inside glove compartment 3A fuse E From voltage regulator to ECU permanent power supply Housing E on the wiring diagram 15A fuse F Spare 3A fuse G Spare Spare H 30A fuse I From battery to ignition switch fuse A helmet compartme...

Page 67: ...urn the lower adjuster screws 2 of both headlamp bulbs with a screwdriver or an 8mm wrench to adjust as follows turn CLOCKWISE to lower the beam Turn ANTICLOCKWISE to raise the beam HORIZONTAL ADJUSTMENT OF THE HEADLIGHT BEAM u Open the glove compartment 1 and release the side stop rods moderately pressing down u Remove the right and left protective covers by pressing on the upper locking tab To a...

Page 68: ... Before changing a bulb check the fuses see page 65 CHANGING THE FUSES REPLACING THE FRONT DIRECTION INDICATOR BULBS Read paragraph BULBS at the side carefully To change the bulbs u Remove the front cover see page 58 REMOVING THE FRONT COVER CAUTION Proceed with care Do not damage the tabs and or their seats u Working from the front of the vehicle twist the bulb holder 3 with the bulb 4 clockwise ...

Page 69: ...ckwise and extract it from its seat Upon reassembly NOTE Insert the bulb in the holder making the three bulb pins match with the relevant guides on the reflector seat u Position the bulb 4 in the reflector and rotate it clockwise u Connect the bulb electric connector 3 REPLACING THE PARKING LIGHT BULB Carefully read page 68 BULBS NOTE The parking light bulb may be replaced without removing the hea...

Page 70: ... LIGHT BULBS Carefully read page 68 BULBS The tail light accommodates the following bulbs Two parking light brake light bulbs 1 Two rear direction indicator bulbs 2 NOTE The following information applies to both direction indicators To change the bulbs u Unscrew the two retaining screws 3 and remove lens 4 CAUTION Proceed with care Do not damage the tabs and or their seats 2 1 2 1 4 3 APRum_ATLANT...

Page 71: ... holder 1 and pull to extract u Remove the bulb and fit a new bulb of equal rating REPLACING THE HELMET COMPARTMENT LIGHT BULB Carefully read page 68 BULBS To change the bulbs u Raise the seat see page 20 UNLOCKING LOCKING THE SEAT u Release and remove the screw 2 securing the transparent cover to the battery cover u Remove the transparent cover 3 by pulling it downwards CAUTION Do not pull on the...

Page 72: ...ly Fuel vapours are harmful to human health Ensure the area is well ventilated before proceeding Do not inhale fuel vapours Do not smoke nor use naked flames DO NOT RELEASE FUEL IN THE ENVIRONMENT u Place the vehicle on the centre stand on firm and level ground u Stop the engine and wait until it has cooled down u Prepare a container large enough to hold the fuel in the tank and place it on the fl...

Page 73: ...egreaser small brushes and cloth CAUTION Before washing the vehicle 1 Empty the front and under seat compartments Remove the matting inside the under seat compartment 2 Make sure the compartments are properly closed 3 Use only mild detergent to wash the vehicle rinse with water but do not use a water cleaner see page 73 CAUTION Wash the vehicle thoroughly before applying silicone wax Do not polish...

Page 74: ... see page 62 LONG INACTIVITY OF THE BATTERY and page 63 REMOVING THE BATTERY u Wash and dry the vehicle see page 73 CLEANING u Polish painted surfaces with wax u Inflate the tyres see page 75 TECHNICAL DATA u By means of a suitable support position the vehicle so that both tyres are raised from the ground u Store the vehicle in an unheated dry place away from sunlight where temperature is reasonab...

Page 75: ...6M Type One cylinder 4 stroke engine with 4 valves forced lubrication with wet sump one overhead camshaft Number of cylinders 1 Total displacement 124 cu cm Total displacement 244 cu cm Total displacement 459 cm3 Bore stroke 57 x 48 6mm Bore stroke 72 x 60mm Bore stroke 92 x 69mm Compression ratio 12 0 0 5 1 Compression ratio 11 0 0 5 1 Compression ratio 10 5 0 5 1 Starting electric Engine idling ...

Page 76: ...Transmission fluid Transmission fluid 150 cu cm 250 cu cm Cooling system Cooling system 1 200 cu cm 1 500 cu cm Seats 2 Max carrying load rider passenger luggage Max carrying load rider passenger luggage 210 kg 200 kg Transmission Converter automatic stepless Primary V belt Final gears Total engine wheel ratio minimum maximum 1 29 26 1 8 78 Total engine wheel ratio minimum maximum 1 19 30 1 6 80 T...

Page 77: ...less Front 110 90 13 56P Front 120 70 14 55R Rear 130 70 13 63P Rear 140 60 14 64R STANDARD INFLATION PRESSURE Front 200 kpa Front 230 kpa Rear 220 kpa Rear 240 kpa INFLATION PRESSURE WITH PASSENGER Front 220 kpa Front 230 kpa Rear 240 kpa Rear 260 kpa Ignition Type Capacity discharge ignition with variable advance Spark advance Variable controlled by the ECU 5 minimum 24 4000 rpm Spark advance Va...

Page 78: ...or with permanent magnet 12 V 180 W Generator with permanent magnet 12 V 235 W Generator with permanent magnet 12 V 380 W Bulbs Low beam 12 V 55 W High beam 12 V 55 W Parking light 12 V 16 W Direction indicator light 12 V 10 W Tail light brake light 12V 5W 21W Warning lights Instrument panel lighting 12 V 1 2 W Direction indicators 12 V 1 2 W Engine oil pressure 12 V 1 2 W Low beam 12 V 1 2 W High...

Page 79: ... grease use top brand rolling bearing grease that will resist a temperature range of 30 C 140 C with dropping point 150 C 230 C high corrosion protection good resistance to water and oxidisation Battery lead protection Neutral grease or Vaseline WARNING Use new brake fluid only Do not mix different brands or types of oil unless you are sure that the different oil bases are compatible Recommended b...

Page 80: ...the Authorised Dealer and or Service Centre nearest you please consult the Yellow Pages or the map provided at our web site www aprilia com When you demand aprilia Original Parts you are purchasing products that have been developed and tested as early as the vehicle design stage aprilia Original Parts systematically undergo strict quality control procedures to ensure total reliability and long ser...

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APRILIA 500 Sprint, Use & Maintenance Book

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