APRILIA ATLANTIC 300 - Service Station Manual Download Page 148

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Refitting

- Always use a new oil guard when refitting

- Prepare the new oil guard by lubricating its seal-

ing lip.

- Preassemble the oil guard with the appropriate

tool, positioning the screws.

- Place the sheath over the crankshaft

- Insert the tool with the oil seal on the crankshaft

until it comes into contact with the crankcase

- Insert the adaptor bushing of the tool in the hole

on the crankcase.

- Position the oil guard by inserting the bracket

which is part of the appropriate tool

- Tighten the threaded bar onto the crankshaft up

to the end of travel

- Use the nut to move the base of the tool until you

can feel the end of the stroke of the oil seal driving

- Remove all of the tool components following the

procedure in reverse order.

CAUTION

DO NOT LUBRICATE THE KEYING SURFACE ON THE EN-
GINE CRANKCASE

CAUTION

ORIENT THE OIL GUARD BY POSITIONING THE CHAIN
HOUSING CHANNEL FACING DOWNWARDS. ONCE THE
POSITION IS REACHED, DO NOT RETRACT THE OIL
GUARD. FAILURE TO COMPLY WITH THIS RULE CAN
CAUSE A WRONG POSITIONING OF THE OIL GUARD
COUPLING SHEATH.

CAUTION

FAILURE TO COMPLY WITH THIS ASSEMBLY PROCE-
DURE CAN SERIOUSLY DAMAGE THE ENGINE DUE TO
THE WRONG TENSIONING OF THE OIL PUMP DRIVING
CHAIN

Engine

ATLANTIC 300 i.e.

ENG - 148

Summary of Contents for ATLANTIC 300 -

Page 1: ...SERVICE STATION MANUAL 895759 ATLANTIC 300 i e ...

Page 2: ...d and tested together with the actual vehicle itself All Aprilia Original Spare Parts undergo quality control procedures to guarantee reliability and durability The descriptions and illustrations given in this publication are not binding While the basic characteristics as described and illustrated in this booklet remain unchanged Aprilia reserves the right at any time and without being required to...

Page 3: ... and changes in repair procedures are communicated to all aprilia Sales Outlets and its International Subsidiaries These changes will be introduced in the subsequent editions of the manual In case of need or further queries on repair and check procedures consult aprilia CUSTOMER DEPARTMENT which will be prepared to provide any information on the subject and any further communications on updates an...

Page 4: ......

Page 5: ...CTERISTICS CHAR TOOLING TOOL MAINTENANCE MAIN ELECTRICAL SYSTEM ELE SYS ENGINE FROM VEHICLE ENG VE ENGINE ENG INJECTION INJEC SUSPENSIONS SUSP BRAKING SYSTEM BRAK SYS COOLING SYSTEM COOL SYS CHASSIS CHAS PRE DELIVERY PRE DE ...

Page 6: ...INDEX OF TOPICS CHARACTERISTICS CHAR ...

Page 7: ... TO FUEL VAPOURS AVOID CONTACT WITH NAKED FLAMES SPARKS OR ANY OTHER SOURCE THAT MAY CAUSE FUEL TO CATCH FIRE OR EXPLODE CAUTION DO NOT DISPOSE OF FUEL INTO THE ENVIRONMENT CAUTION KEEP OUT OF THE REACH OF CHILDREN HIGH TEMPERATURE COMPONENTS The engine and the components of the exhaust system can get very hot and remain hot for some time even after the engine has been switched off Before handling...

Page 8: ...ylene glycol which under certain conditions can become flammable When it burns ethylene glycol produces invisible flames which however can cause burns CAUTION MAKE SURE NOT TO POUR THE COOLANT ON HOT ENGINE OR EXHAUST SYSTEM COMPO NENTS IT MAY CATCH FIRE PRODUCING INVISIBLE FLAMES WHEN CARRYING OUT MAIN TENANCE OPERATIONS IT IS ADVISABLE TO WEAR LATEX GLOVES EVEN IF IT IS TOXIC THE COOLANT HAS A S...

Page 9: ...and reassembling the vehicle follow the recommendations reported below carefully CAUTION THE USE OF NAKED FLAMES IS FORBIDDEN FOR ANY KIND OF OPERATION BEFORE START ING ANY MAINTENANCE OPERATION OR INSPECTION ON THE VEHICLE SWITCH OFF THE ENGINE AND REMOVE THE KEY WAIT UNTIL THE ENGINE AND THE EXHAUST SYSTEM ARE COLD IF POSSIBLE RAISE THE VEHICLE USING A SUITABLE TOOL ON FIRM AND LEVEL GROUND TO A...

Page 10: ...en nuts and screws in suc cessive steps before applying the tightening torque Always replace self locking nuts washers sealing rings circlips O rings OR cotter pins and screws with new parts if the thread is damaged When assembling the bearings make sure to lubricate them well Check that each component is assembled correctly After a repair or routine maintenance carry out pre ride checks and test ...

Page 11: ...G TORQUES OF FASTENING PARTS ON A REGULAR BASIS AND ALWAYS USE A TORQUE WRENCH TO REFIT THESE COMPONENTS IF THESE RECOMMENDATIONS ARE NOT COMPLIED WITH ONE OF THE COMPONENTS MAY BECOME LOOSE AND EVEN DE TACHED THUS BLOCKING A WHEEL OR OTHERWISE COMPROMISING THE VEHICLE S MA NOEUVRABILITY THIS CAN LEAD TO FALLS WITH THE RISK OF SERIOUS INJURY OR DEATH Vehicle identification These numbers are necess...

Page 12: ...que limitator Clutch Automatic centrifugal dry with buffer stopper Gearbox Automatic variator CVT with torque server range 2 82 2 3 1 0 81 1 Fuel system Electronic injection P I α N type with closed loop system through lambda probe on the exhaust and 3 way catalytic con verter Fuel Unleaded petrol N O R min 95 Ignition Electronic inductive discharge of high efficiency and variable advance with tri...

Page 13: ...12V 12 Ah fuses 20 15 7 5 A Alternator permanent magnet type 12V 235W BULBS AND WARNING LIGHTS Specification Desc Quantity High beam bulb 12V 55W Low beam bulb 12V 55W Tail light bulb 12V 16W Turn indicator bulb 12V 10W Rear light stop light bulb 12 V 5 W 21 W Low fuel warning light 12V 1 2W Low beam warning light 12V 1 2W High beam warning light 12V 1 2W Instrument panel lighting warning light 12...

Page 14: ...2 5 ftlb Oil filter fitting on crankcase 27 33 19 9 24 4 ftlb engine oil drainage plug mesh filter 24 30 17 7 22 1 ftlb Oil filter 4 6 3 4 4 ftlb Oil pump cover screws 7 9 5 2 6 6 ftlb Screws fixing oil pump to crankcase 5 6 3 7 4 4 ftlb oil pump driving crown gear screw 10 14 7 4 10 3 ftlb Oil pump cover plate screws 4 6 3 4 4 ftlb Oil sump screws 10 14 7 4 10 3 ftlb Minimum oil pressure sensor 1...

Page 15: ...r pump rotor driving joint 3 4 2 2 3 ftlb Thermostat cover screws 3 4 2 2 3 ftlb Bleed screw 3 2 2 ftlb FRAME ASSEMBLY Name Torque in Nm Screw fixing support to chassis 10 20 7 4 ftlb Screw fixing the brakeforce distribution mechanism to curved support 12 20 8 9 ftlb Screw fixing passenger handgrip to chassis M8x60 25 20 18 5 ftlb Screw fixing passenger handgrip to chassis M6x45 10 20 7 4 ftlb Scr...

Page 16: ...e Torque in Nm Nut fixing manifold to engine 15 20 11 1 ftlb Clamp fixing muffler to manifold 17 20 12 5 ftlb Muffler plate fixing screw 25 20 18 5 ftlb Screw fixing protection to muffler 7 20 5 2 ftlb COOLING UNIT Name Torque in Nm Thermal switch retainer 20 20 14 8 ftlb Clamp fixing radiator head return pipe qty 1 3 20 2 2 ftlb Pre fitted radiator fixing screw 10 20 7 4 ftlb Clamp fixing radiato...

Page 17: ... ftlb Screw fixing helmet compartment to chassis 4 3 ftlb Screw fixing fuel lid to footrest 1 0 7 ftlb Nut fixing lock to fuel lid 4 3 ftlb Screw fixing lever to fuel lid lock block 1 0 7 ftlb Screw fixing footrest to under footrest Self tap 3 9x14 plastic 1 0 7 ftlb Screw fixing footrest to under footrest Self tap 5 5x22 3 2 2 ftlb Screw fixing footrest to chassis 3 2 2 ftlb Screw fixing side lid...

Page 18: ...s to relay 4 20 3 ftlb Screw fixing battery red cable to main cable harness cable 10 20 7 4 ftlb INSTRUMENT PANEL UNIT Name Torque in Nm Screw fixing instrument panel on panel 1 0 7 ftlb Front and rear panel fixing screw 0 5 0 4 ftlb Screw fixing panel to internal shield 1 20 0 7 ftlb Screw fixing panel to curved support 1 0 7 ftlb TANK UNIT Name Torque in Nm Screw fixing fuel tank to chassis 5 20...

Page 19: ...0 064 NOTE THE PISTON MUST BE FITTED WITH THE ARROW FACING TOWARDS THE EXHAUST SIDE THE PISTON RINGS MUST BE FITTED WITH THE REFERENCE TOP OR THE STAMPED MARK FACING UPWARDS Check the pin outside diameter Characteristic Pin outside diameter 16 0 0 004 mm Measure the diameter of the bearings on the pis ton Characteristic Standard diameter 16 0 006 0 001 mm Calculate the pin piston coupling clearanc...

Page 20: ...06 mm 1st compression ring maximum clearance allowed after use 0 07 mm 2nd compression ring standard coupling clearance 0 015 0 06 mm 2nd compression ring maximum clearance allowed after use 0 07 mm oil scraper standard coupling clearance 0 015 0 06 mm oil scraper maximum clearance al lowed after use 0 07 mm Check that the coupling surface with the head is not worn or misshapen Pistons and cylinde...

Page 21: ...ansmissionside half shaft 16 6 0 0 05 A D 0 20 to 0 50 Flywheel side halfshaft 16 6 0 0 05 B D 0 20 to 0 50 Connecting rod 18 0 10 0 15 C D 0 20 0 50 Spacer tool 51 4 0 05 E D 0 20 0 50 Crankshaft bearing diameter Measure the bearings on both x y axes ATLANTIC 300 i e Characteristics CHAR 21 ...

Page 22: ...CRANKSHAFT Specification Desc Quantity Camshaft bearings Standard diameter Cat 1 28 998 29 004 mm Crankshaft bearings Standard diameter Cat 2 29 004 29 010 mm Characteristics ATLANTIC 300 i e CHAR 22 ...

Page 23: ...MAXIMUM OFF LINE ALLOWED Specification Desc Quantity A 0 15 mm B 0 010 mm C 0 010 mm D 0 10 mm ATLANTIC 300 i e Characteristics CHAR 23 ...

Page 24: ... channels the coupling surface of the two half bearings must be perpendicular to the cylinder axis as shown in the figure The oil supplying channel section is also influenced by the depth to which the bushings are driven compared with the crankshaft axial clearance of the limiting surface Measure the bushings diameter at the 3 positions indicated in the figure Repeat the measurements for the other...

Page 25: ...ITH CRANK CASE HALVES OF THE SAME CATEGORY AND ARE FIT TED WITH CATEGORY C YELLOW BUSHINGS Characteristic Crankshaft bushing maximum clearance al lowed 0 08 mm Crankcase diameter without bushing CAT 1 32 959 32 965 mm CAT 2 32 953 32 959 mm Cylinder head Clean all the coupling surfaces thoroughly before servicing the head Pay attention to the position of the springs and valves so as not to change ...

Page 26: ...use 38 2 mm Remove any carbon deposits from the valve seats Check the width of the mark on the valve seat V with Prussian blue Characteristic Standard value 1 1 3 mm Limit allowed 1 6 mm If the width of the mark on the valve seat is larger than the prescribed limits true the seats with a 45 milling cutter and then grind Replace the head in case of excessive wear or damage STANDARD LENGTH OF VALVE ...

Page 27: ... 4 960 mm MINIMUM DIAMETER ALLOWED Specification Desc Quantity Inlet 4 96 mm Outlet 4 945 mm Calculate the clearance between the valve and its guide Check the deviation of the valve stem by resting it on a V shaped support and measuring the ex tent of the deformation using a dial gauge Characteristic Limit value allowed 0 1 mm ATLANTIC 300 i e Characteristics CHAR 27 ...

Page 28: ... mm After measuring the valve guide diameter and the valve stem diameter check the clearance be tween guide and stem INTAKE Specification Desc Quantity Standard clearance 0 013 0 04 mm Limit allowed 0 08 mm EXHAUST Specification Desc Quantity Standard clearance 0 025 0 052 mm Limit allowed 0 09 mm Check that there are no signs of wear on the faying surface with the set screw articulated terminal C...

Page 29: ...FT CAREFULLY WASH THE CYLINDER HEAD AND THE VALVES WITH A SUITABLE PRODUCT FOR THE TYPE OF LAPPING COMPOUND BEING USED CAUTION DO NOT CHANGE THE VALVE FITTING POSITION RH LH Check the camshaft bearings for signs of abnormal wear or scores Using a micrometer measure the camshaft bearings STANDARD DIAMETER Specification Desc Quantity Camshaft check Standard diameter Bearing A Ø 36 95 36 975 mm Camsh...

Page 30: ... Maximum axial clearance admitted 0 42 mm Check the outside diameter of the rocker pins Check there are no signs of wear or scoring on the rocker pins Check the internal diameter of each rocker arm Check there are no signs of wear on the contact pads with the cam and on the jointed adjustment plate DIAMETER OF PINS AND ROCKING LEVERS Specification Desc Quantity Rocking levers inside diameter Stand...

Page 31: ...ane formed by the cylinder crown The further the piston enters into the cylinder the thinner the base gasket to be used should be to compensate the compression ratio and vice versa NOTE DISTANCE A SHOULD BE MEASURED WITH NO GASKET FITTED BETWEEN THE CRANK CASE AND THE CYLINDER AND AFTER RESETTING THE DIAL GAUGE WITH SUPPORT ON A GROUND PLANE ATLANTIC 300 i e Characteristics CHAR 31 ...

Page 32: ... SYNTH SAE 75W 90 Gearbox oil API GL4 GL5 AGIP FORK 7 5W Fork oil AGIP GREASE SM2 Lithium grease with molybdenum for bearings and other points needing lubri cation NLGI 2 AGIP BRAKE 4 Brake fluid FMVSS DOT4 AGIP PERMANENT SPECIAL Coolant Ready mixed biodegradable coolant with long life technology and characteristics red Freezing protection up to 40 C Compliant with CUNA 956 16 standard AGIP FILTER...

Page 33: ...INDEX OF TOPICS TOOLING TOOL ...

Page 34: ...versal tool for clutch assemblies AP8140665 Adapter for clutch assembly removal AP8140535 Front pulley fitting removal AP8140181 Fuel pressure checking tool AP8140266 Comparator door AP8140729 Chain cover fitting removal Tooling ATLANTIC 300 i e TOOL 34 ...

Page 35: ...ractor AP8140659 Valve oil seal punch AP8140662 Punch for roller casing 020425Y Shaft oil seal punch 020376Y Adapter handle 020455Y 10 mm guide for oil seal on water pump shaft 020412Y Clutch oil seal punch D 15 mm ATLANTIC 300 i e Tooling TOOL 35 ...

Page 36: ... 020439Y Shaft 2 oil seal punch 17 mm 020359Y 42 x 47 mm punch 020363Y Crankshaft oil seal punch D 20 mm 020456Y Ø 24 mm punch 020364Y 25 mm Adaptor 020414Y 28 mm punch 020357Y 32x35 mm punch Tooling ATLANTIC 300 i e TOOL 36 ...

Page 37: ... mm punch 020360Y 52x55 mm punch AP8140917 Tool for valve pressure plate AP8140661 Lock wrench for clutch bell AP8140300 55 mm wrench 020627Y Flywheel lock wrench AP8140179 Support for valve fitting removal ATLANTIC 300 i e Tooling TOOL 37 ...

Page 38: ...ption AP8140660 Piston fitting ring AP8140664 Guide to mount the movable driven pulley 020483Y 30 mm guide 020477Y 37 mm Adaptor 002095Y Engine support AP8140919 Valve oil seal extractor Tooling ATLANTIC 300 i e TOOL 38 ...

Page 39: ...tion AP8140920 Tool for pin rings AP8140922 Crankcase splitting strip AP8140921 Oil seal punch 001467Y035 Bell for OD 47 mm bearings 020481Y Adaptor cable harness AP8140915 Crankcase check ATLANTIC 300 i e Tooling TOOL 39 ...

Page 40: ...Stores code Description AP8140916 Hub cover support AP8140252 Multipurpose wrench 020331Y Digital multimeter 020680Y TXB Navigator Tooling ATLANTIC 300 i e TOOL 40 ...

Page 41: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Page 42: ...cks after a maintenance operation MAINTENANCE SCHEDULE Adequate maintenance is fundamental to ensuring long lasting optimum operation and performance of your vehicle For this purpose Aprilia offers a set of checks and maintenance services at the owner s expense which are included in the summary table shown on the following page Any minor faults should be reported without delay to any Official Apri...

Page 43: ... age cable from the spark plug Clean off any trace of dirt from the spark plug base Then unscrew it using the spanner supplied in the toolkit and remove it from its fitting being careful not to let dust or any other substance come into the cylinder Check that the spark plug electrode and centre porcelain are free of carbon deposits or signs of corrosion If nec essary clean using suitable spark plu...

Page 44: ...UG OTHERWISE THE ENGINE DURATION AND PERFORMANCE COULD BE COMPROMISED Characteristic Spark plug electrode gap 0 7 0 8 mm Locking torques N m Spark plug 12 14 8 9 10 3 ftlb Insert the spark plug tube correctly so that it does not get detached due to engine vibrations Refit the right inspection cover Hub oil Check NOTE USE RECOMMENDED OIL ONLY REFER TO THE RECOMMENDED PRODUCTS TABLE Ride a few kilom...

Page 45: ...E TOP UP Pour a small quantity of oil through the tube and wait about one minute so that the oil flows evenly into the crankcase Check the oil level and top up if required Top up with small quantities of oil until the recommended level is reached At the end of the operation screw and tighten the tap dipstick 1 CAUTION DO NOT RIDE THE MOTORCYCLE WITH INSUFFICIENT LUBRICATION OR WITH CONTAMINA TED O...

Page 46: ...let it run for sev eral minutes Stop the engine and let it cool down Check the transmission oil level again Air filter Clean the air filter following the instructions on the scheduled maintenance table Carry out the main tenance procedures more frequently if the vehicle is used in rainy or dusty areas or off road In this case the air filter can be partially cleaned after travelling along these kin...

Page 47: ...FOR PEOPLE AND THE VEHICLE ITSELF CAUTION WHEN CLEANING THE FILTERING ELEMENT CHECK THAT IT IS NOT TORN IF IT IS REPLACE THE FILTERING ELEMENT NOTE THE FILTERING ELEMENT SHOULD BE WELL IMPREGNATED BUT SHOULD NOT DRIP To replace Replace the air filter with a new one of the same type CAUTION NEVER REUSE AN OLD FILTER Engine oil Replacement CAUTION PARK THE MOTORCYCLE ON SAFE AND LEVEL GROUND Park th...

Page 48: ...l ing O rings with oil Screw and tighten the engine oil drain age plug 3 When refilling add approx 1300 cm of engine oil through the fill opening Screw and tighten the measuring cap dipstick 1 Start the engine and let it run for several minutes Stop the engine and let it cool down Check the engine oil level again using the cap dipstick 1 and top up if necessary without exceeding the MAX level NOTE...

Page 49: ... on the measuring dipstick CAUTION IN ORDER TO AVOID DAMAGING THE ENGINE OIL LEVEL MUST NEVER EXCEED THE MAX MARK OR FALL BELOW THE MIN MARK Top up if required TOP UP Do not exceed the MAX level mark when topping up with engine oil Pour a small quantity of oil through the tube 2 and wait approximately five minutes so that the oil flows evenly into the crankshaft Check the oil level and top up if r...

Page 50: ...Synthetic oil that exceeds the requirements of API SL ACEA A3 JASO MA specifications Oil pressure warning light The vehicle is equipped with a warning light on the instrument panel that comes on when the key is turned to ON This light should however turn off once the engine is started If the light turns on when braking at idle speed or on a bend check the oil level and the lubri cation system Tran...

Page 51: ...r as shown in the figure TDC Make sure that the reference 4V on the camshaft control pulley is aligned with the reference point on the head as shown in the second figure If the refer ence mark is opposite the mark on the head make the crankshaft turn once more To use this reference mark remove the spark plug and make the engine spin opposite its normal di rection of rotation applying a calliper sp...

Page 52: ...t until it cools off Lift the saddle Unscrew and remove the two screws 1 Remove the protection Keep the vehicle upright with the two wheels on the ground Make sure that the coolant level inside the expansion tank is between the MIN and MAX reference marks see figure Otherwise top up CAUTION WAIT FOR THE ENGINE TO COOL DOWN BEFORE CHECKING OR TOPPING UP THE COOLANT LEVEL NOTE PARK THE MOTORCYCLE ON...

Page 53: ...o not exceed this level Otherwise the coolant will spill out when the en gine is running Refit the filler cap 2 CAUTION IF THERE IS AN EXCESSIVE CONSUMPTION OF COOL ANT OR WHEN THE EXPANSION TANK REMAINS EMPTY CHECK THAT THERE ARE NO LEAKS IN THE CIRCUIT Braking system Check the brake fluid following the instructions on the scheduled maintenance table CAUTION PURGE THE AIR IN THE SYSTEM IN CASE OF...

Page 54: ...OSURE OF THE BRAKE FLUID BRAKE FLUID IS HYGROSCOPIC AND ABSORBS MOISTURE WHEN IN CONTACT WITH AIR LEAVE THE BRAKE FLUID RESERVOIR OPEN ONLY FOR THE TIME NEEDED TO COMPLETE THE TOPPING UP PROCEDURE Lift and remove the cover 2 Remove the gasket 3 Top up the reservoir with brake fluid up to the correct level Follow the reverse order for refitting the components CAUTION DO NOT SHAKE THE VEHICLE TO AVO...

Page 55: ...for the rear brake calliper 2 Replace both brake pads when the fric tion material even if in one brake pad only is worn to about 1 5 mm 0 05 in Front pad 3 Rear pad 4 NOTE THE FOLLOWING INFORMATION REFERS TO ONE BRAK ING CIRCUIT BUT APPLIES TO BOTH CAUTION CHECK BRAKE PADS FOR WEAR MAINLY BEFORE EACH RIDE CAUTION EXCESSIVE WEAR OF THE FRICTION MATERIAL MAKES THE PAD METAL SUPPORT GET INTO CONTACT ...

Page 56: ...the light beam to the left in relation to the riding direction LIGHT BEAM VERTICAL ADJUSTMENT For a quick check of the correct direction of the front light beams place the scooter ten metres from a vertical wall and make sure the ground is level Turn on the low beam light sit on the vehicle and check that the light beam projected to the wall is a little below the headlight horizontal straight line...

Page 57: ...crewdriver to operate on the lower set screws 2 on both head lights TIGHTEN the screw clockwise to lower the light beam UNDO the screw anticlockwise to raise the light beam ATLANTIC 300 i e Maintenance MAIN 57 ...

Page 58: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 59: ...Components arrangement ATLANTIC 300 i e Electrical system ELE SYS 59 ...

Page 60: ...t position 5 V Voltage with the vehicle inclined 0 V 3 Main fuses MAIN FUSES LAYOUT BATTERY COMPARTMENT Specification Desc Quantity 1 20A fuse From the battery to ignition switch fan relay control unit 2 15A fuse From the battery to plug socket helmet compartment light 4 Battery 12V 12 Ah Electrical system ATLANTIC 300 i e ELE SYS 60 ...

Page 61: ...t Right tail light stop light bulb 12V 5W 21W Left tail light stop light bulb 12V 5W 21W License plate light bulb 12V 5W Turn indicator bulbs 12V 10W 8 STARTER MOTOR Supply battery voltage Resistance 0 5 Ohm ATLANTIC 300 i e Electrical system ELE SYS 61 ...

Page 62: ...oad voltage at terminals 45 V 11 Start up relay Relay voltage powered 0 Ohm Relay voltage not powered endless 12 Water Temperature Sensor COOLANT TEMPERATURE C F RESISTANCE VALUE OHM Specification Desc Quantity 10 14 9 6 kOhm 0 32 5 975 kOhm 10 50 3 81 kOhm 20 68 2 5 kOhm 30 86 1 68 kOhm Electrical system ATLANTIC 300 i e ELE SYS 62 ...

Page 63: ...Low fuel warning light on 14 Injection relay Relay voltage powered 0 Ohm Relay voltage not powered endless 15 Auxiliary fuses SECONDARY FUSES LAYOUT FRONT CASE Specification Desc Quantity 1 15A fuse From the ignition switch to instrument panel warning lights lights horn stop lights 2 15A fuse From the ignition switch to ignition safety logic injection relay instrument panel warning lights ATLANTIC...

Page 64: ...icator bulbs 12V 10W 17 Fan Fan relay powered battery supply Fan relay not powered not powered 18 Fan relay Relay voltage powered 0 Ohm Relay voltage not powered endless 19 Spark plug Characteristic Spark plug NGK CR8EKB Spark plug electrode gap 0 7 0 8 mm Electrical system ATLANTIC 300 i e ELE SYS 64 ...

Page 65: ... Make sure that all the connectors are correctly connected Check switches for correct fastening and operation Check air sensors and speedometer sensor for correct fastening and operation CAUTION THE SENSING AREA OF THE SENSORS MUST BE ALWAYS CLEAN POSSIBLE DEPOSITS OF MUD DIRT ETC ALTER THE DETECTION AND THE FOLLOWING DATA SENDING The following indications will be useful for browsing this section ...

Page 66: ...he two connectors and disconnect them by pulling them in opposite directions If there are signs of dirt rust humidity etc clean the connector internal parts carefully by using a pressurised air jet Make sure that the cables are correctly linked to the connector internal terminal ends NOTE THE TWO CONNECTORS CONNECT ONLY FROM ONE SIDE CONNECT THEM THE RIGHT WAY ROUND Then fit the two connectors mak...

Page 67: ...Conceptual diagrams key 1 Multiple connectors 2 Fuel level transmitter 3 Fall sensor 4 Fan 5 Engine temperature gauge ATLANTIC 300 i e Electrical system ELE SYS 67 ...

Page 68: ...Left light switch 21 Horn button 22 Turn indicator control 23 Horn 24 Ignition key 25 Front stop switch 26 Starter button 27 Engine stop 28 Rear twin light stop light bulb 29 CDI control unit 30 License plate bulb 31 Left rear turn indicator 32 Right rear turn indicator 33 Glove box light switch 34 Glove box light 35 Stop lights relay 36 Start up relay 37 Starter motor 38 Auxiliary fuses 39 Main f...

Page 69: ... R red Ro pink V green Vi purple Checks and inspections Ignition circuit Ignition coil check Use a pocket tester to check the coil In every case the continuity of the primary and secondary wind ings must be checked The Ohm reading need not be exact but if the windings are not damaged their continuity must be detected getting the following Ohm resistance values CAUTION DISCONNECT THE SPARK PLUG CAP...

Page 70: ...g checks The springs 2 should not be damaged worn rusty or slacken The stand should turn freely grease the joint if required A safety switch 3 is installed on the side stand 1 to inhibit or stop engine operation when the side stand 1 is lowered To check the safety switch 3 correct operation Sit on the vehicle in riding position Fold up the side stand again 1 Start the engine With the throttle grip...

Page 71: ...CDI control unit TROUBLESHOOTING Check that the 20A fuse and the 15A fuse are not damaged Check the spark plug and replace it if necessary Check the condition of the high voltage cable and the spark plug cap Check the coil Check the pick up Earth the green brown cable If the ignition works check the stand logic system ATLANTIC 300 i e Electrical system ELE SYS 71 ...

Page 72: ...ery voltage Start the engine and take it to 5000 rpm throttle grip twisted approximately 1 4 of its travel With a pocket tester check the continuous voltage between the battery positive and negative terminals If the tester indicates voltage values below 13V or above 15V check the off load operation and the alternator and voltage regulator continuity Electric characteristic Standard load voltage 13...

Page 73: ...oltage regulator con nector 1 With a pocket tester check the con tinuity between the yellow cables com ing from the stator Also check the stator support insula tion Electric characteristic Standard resistance value 0 1 1 Ohm Standard resistance value between the cables and the stator support endless Voltage regulator check Remove the tail fairing Disconnect the voltage regulator con nector 1 Undo ...

Page 74: ...er in Ohm meter function measure the continuity between the power terminals Exact value infinite resistance Power the control contacts connector with a 12V battery With a tester in Ohm meter function measure the continuity between the power terminals Exact value resistance 0 Ohm START BUTTON CHECK Disconnect the button connector With a tester in ohmmeter function check the continuity between the c...

Page 75: ...es not work operate on the cor responding set screw Replace it with a new component if necessary Horn button check Disconnect the button connector With a tester in ohmmeter function check the continuity between the contacts in the press ed and released positions according to the connections Replace it with a new component if necessary ATLANTIC 300 i e Electrical system ELE SYS 75 ...

Page 76: ...indicators do not work Check the bulbs Check the turn indicators cable connections Check the turn indicator switch The indicators do not flash but remain steadily on Check the bulb technical data Check the blinkers TURN INDICATOR SWITCH CHECK Disconnect the switch connector With a tester in ohmmeter function check the continuity between the various cables at different po sitions according to the c...

Page 77: ...smitter 6 Fuel level indicator 24 Key switch 38 Auxiliary fuses 39 Main fuses 41 Battery 48 Fuel Level Sensor INDICATOR CHECK Disconnect the transmitter connector and connect on the connector side an electrical re sistance between the grey green and blue cables Turn the key to ON and check the indication on the instrument panel ATLANTIC 300 i e Electrical system ELE SYS 77 ...

Page 78: ...nnect an ohmmeter to the transmitter terminals that are the grey green and blue cable ends Check the indications at different fuel levels FUEL LEVEL VALUE ON TESTER OHM Specification Desc Quantity 1 Full tank 10 Ohm 2 Tank with 8 litres of fuel 38 Ohm 10 3 Empty tank 90 Ohm COOLANT TEMPERATURE GAUGE KEY 5 Coolant temperature gauge 24 Key switch 38 Auxiliary fuses 39 Main fuses Electrical system AT...

Page 79: ...ance to the white blue terminal Turn the key to ON and check the gauge indications displayed on the panel RESISTANCE VALUE OHM GAUGE INDICATION Specification Desc Quantity 1 75 Ohm End of scale 2 105 Ohm Red area starts 5 3 1000 Ohm Scale start ELECTRIC FAN SYSTEM KEY 4 Fan 24 Key switch 38 Auxiliary fuses 39 Main fuses 41 Battery 54 Fan relay ATLANTIC 300 i e Electrical system ELE SYS 79 ...

Page 80: ... the table NOTE REPLACE THE THERMISTOR 1 IF STAND ARD VALUES DO NOT VARY OR DIFFER WIDELY FROM THE ONES INDICATED ON THE TABLE TEMPERATURE RESISTANCE Specification Desc Quantity 100 C 212 F 144 Ohm 80 C 176 F 262 Ohm 60 C 140 F 512 Ohm 40 C 104 F 1090 Ohm Lights list TROUBLESHOOTING Possible Cause Operation One bulb does not work Check the bulb Check if there is voltage in the bulb holder terminal...

Page 81: ...and then the 20A fuses Set the ignition switch to OFF to avoid an accidental short circuit For main fuses Carry out the first four operations described in the Battery electrolyte level check section For auxiliary fuses Remove the front cover Check Take out one fuse at a time and check if the filament is broken Before replacing the fuse find and whenever possible solve the problem that cause it to ...

Page 82: ...1 15A fuse From the ignition switch to instrument panel warning lights lights horn stop lights 2 15A fuse From the ignition switch to ignition safety logic injection relay instrument panel warning lights Dry charge battery BATTERY REMOVAL Remove the battery cover Disconnect first the negative lead and then the positive one Slide off the breather pipe from the bat tery Remove the battery Characteri...

Page 83: ...e negative one Cover the leads and terminals with neutral grease or petroleum jelly CHECK In case of malfunction check first that the recharge system works properly To check the battery Remove the battery from the vehicle as follows Visually check that there are no signs of sulphation signalled by white colouring of one or more cells the electrolyte level is between the two MIN and MAX reference n...

Page 84: ...RT UP RELAY WHEN THE STARTER BUTTON IS PRESSED THE BATTERY IS COMPLETELY DISCHARGED Remove the battery Remove the cell caps Check the battery electrolyte level Connect the battery to a battery charger It is advisable to recharge at a current of 1 10 of the battery rated capacity Once the battery is recharged control the electrolyte level and top up with distilled water if required Refit the caps t...

Page 85: ...vel and the tightening of terminals CAUTION THE BATTERY ELECTROLYTE IS TOXIC CORROSIVE AND AS IT CONTAINS SULPHURIC ACID IT CAN CAUSE BURNS WHEN IN CONTACT WITH THE SKIN WEAR PROTECTION CLOTHES A FACE MASK AND OR SAFETY GOGGLES WHEN CARRYING OUT MAINTENANCE OPERATIONS IF THE ELECTROLYTIC FLUID GETS INTO CONTACT WITH THE SKIN WASH WITH ABUNDANT COOL WATER IF IT COMES INTO CONTACT WITH THE EYES RINS...

Page 86: ...the leads and the breather pipe If the motorcycle is not used for a long period it is necessary to recharge it periodically at least once a month for at least 10 hours for instance during the long winter break Periodically once a month restore the electrolytic fluid level only with distilled water Connectors ECU key Injection warning light LED Pin 1 Rpm indicator on the instrument panel Pin 2 CAN ...

Page 87: ...on sensor negative Pin 15 Diagnosis Pin 16 Immobiliser LED Pin 17 Side stand Pin 18 Not used Pin 19 Injection load relay Pin 20 Not used Pin 21 HV coil Pin 22 Speed sensor Pin 23 Start up enabling Pin 24 Rollover protection switch Pin 25 Ground Pin 26 ATLANTIC 300 i e Electrical system ELE SYS 87 ...

Page 88: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 89: ...AND EXHAUST SILENCER TO COOL OFF COMPLETELY Locking torques N m Nut fixing manifold to engine 15 20 11 1 ftlb Disconnect the lambda probe Undo and remove the three fixing screws 2 Remove the exhaust system Locking torques N m Muffler plate fixing screw 25 20 18 5 ftlb ATLANTIC 300 i e Engine from vehicle ENG VE 89 ...

Page 90: ...ng screw 25 20 18 5 ftlb CAUTION EACH TIME THE EXHAUST SYSTEM IS REMOVED RE PLACE THE CONNECTING INTERNAL GRAPHITE SLEEVE OF THE SILENCER TO THE EXHAUST PIPE Removal of the engine from the vehicle Before removing the engine from the chassis disconnect the battery wash it with a steam cleaner and cut off coolant supply CAUTION BEFORE CARRYING OUT THE OPERATIONS BELOW BEAR IN MIND THAT THE ENGINE MU...

Page 91: ...round connection from the starter motor Remove the rubber protection then unscrew and remove the nut 2 and disconnect the cable from the starter motor Disconnect the connector 3 from the water temperature sensor NOTE THE POSSIBLE OVERLAPPING OF OPERATIONS REFER RED TO IN OTHER CHAPTERS MUST BE INTERPRETED LOGICALLY AVOIDING ANY UNNECESSARY REMOVAL OF COMPONENTS Disconnect the pick up 4 ATLANTIC 30...

Page 92: ... from the thermo static valve Slide off the pipe 6 from the coolant pump Undo and remove the lower screw 7 Disconnect the spark plug tube NOTE GET A HOIST AND BELTS FOR LIFTING Engine from vehicle ATLANTIC 300 i e ENG VE 92 ...

Page 93: ...er and the spacer Remove the engine together with the centre stand and the rear wheel INSTALLING THE ENGINE ON THE CHASSIS Move the chassis with small alternating movements until it is perfectly aligned with the fixing holes From the left side insert the pin 1 and place the washer and the spacer CAUTION WORK WITH CARE PAYING ATTENTION TO YOUR FIN GERS AND LIMBS ATLANTIC 300 i e Engine from vehicle...

Page 94: ...lamp Locking torques N m Nut fixing connecting rod to engine 40 20 29 5 ftlb Tighten the shock absorber lower screw 4 Locking torques N m Screw fixing shock absorber to engine 40 20 29 5 ftlb Insert the pipe 5 in the thermostatic valve Connect the spark plug tube Engine from vehicle ATLANTIC 300 i e ENG VE 94 ...

Page 95: ...t the helmet compartment Top up with coolant NOTE CARRY OUT AN OVERALL CHECK ON ALL THE COMPO NENTS THAT HAVE UNDERGONE ANY OPERATION ES PECIALLY THAT the electrical cables are correctly fastened with suitable clamps the electrical connectors are correctly coupled the pipes and sleeves are correctly fitted and secured with suitable clamps the throttle cable must slide freely and must not cause the...

Page 96: ...Locking torques N m Starter motor screws 11 13 8 1 9 6 ftlb Locking torques N m Starter motor cable fixing nut 5 20 3 7 ftlb Engine from vehicle ATLANTIC 300 i e ENG VE 96 ...

Page 97: ...INDEX OF TOPICS ENGINE ENG ...

Page 98: ...nserting a screwdriver in the slotted holes Using the clutch bell lock wrench shown in the figure remove the driven pulley shaft nut and washer Specific tooling AP8140661 Lock wrench for clutch bell Pull out the cap dipstick from the engine oil filling tube Remove the 10 screws Now remove the transmission cover NOTE WHEN REMOVING THE TRANSMISSION COVER BE CAREFUL NOT TO DROP THE CLUTCH BELL Engine...

Page 99: ...e two different levels as well as the small casing Removing the driven pulley shaft bearing Remove the seeger ring from the inside of the cover Remove the bearing from the crankcase Specific tooling 020376Y Adapter handle 020375Y 28x30 mm punch 020412Y Clutch oil seal punch D 15 mm ATLANTIC 300 i e Engine ENG 99 ...

Page 100: ...020357Y 32x35 mm punch 020412Y Clutch oil seal punch D 15 mm Baffle roller Plastic roller Check that the roller shows no signs of abnormal wear and that it rotates freely Remove the special fixing screws as indicated in the photograph Check the roller outside diameter does not have defects that could jeopardise belt functioning For refitting place the roller with the belt contain ment edge on the ...

Page 101: ...4 134 2 mm Checking the bell working surface eccentricity Fit the bell on a driven pulley shaft with 2 bearings inside diameter 15 and 17 mm Lock with the original spacer and nut Place the bell shaft assembly on the support to check the crankshaft alignment Using a feeler pin gauge and the magnetic base measure the bell eccentricity Repeat the measurement at 3 positions Central internal external I...

Page 102: ...riven pulley spring compressor tool Fit the driven pulley assembly on the tool by inserting the 3 pins in the ventilation holes on the mass holder support Make sure that the clutch is perfectly inserted into the adapter ring before proceeding to tighten the clutch nut Use the special multipurpose wrench to remove the nut fixing the clutch Disassemble the driven pulley into its components Clutch an...

Page 103: ...s and pull the half pulleys apart Removing the driven half pulley bearing Check there are no signs of wear and or noise otherwise replace it Remove the snap ring using two flat blade screw drivers Place pulley bushing on the threaded side ade quately on a wood support Using a hammer and pin knock the ball bearing out as shown in the figure Support the pulley properly Specific tooling 001467Y035 Be...

Page 104: ...ide diameter of the pulley bushing Check the surface in contact with the belt to make sure there are no signs of abnormal wear Check the riveted joints work properly Check the evenness of the surface in contact with the belt Characteristic Half pulley minimum diameter Minimum diameter allowed Ø 40 96 mm Half pulley standard diameter Standard diameter Ø 40 985 mm wear limit 0 3 mm Engine ATLANTIC 3...

Page 105: ...OVABLE DRIVEN HALF PULLEY DIMENSIONS Specification Desc Quantity wear limit 0 3 mm standard diameter Ø 41 000 41 035 Maximum diameter admitted Ø 41 08 mm Refitting the driven half pulley bearing Place pulley bushing on the threaded side ade quately on a wood support Assemble a new roller casing as shown in the figure To fit the new ball bearing follow the example in the picture using a specific pu...

Page 106: ...sing a curved spout grease gun lubricate the driven pulley assembly with approximately 6 grams of grease Apply the grease through one of the holes in the bushing until grease comes out through the hole on the opposite side This proce dure is necessary to prevent the presence of grease beyond the O rings NOTE THE TORQUE SERVER CAN BE GREASED WITH BEAR INGS FITTED OR WHEN THEY ARE BEING REPLACED IT ...

Page 107: ... the lever pin in the hole of the adaptor ring Tighten the fixing nut to the prescribed torque NOTE WHEN PRELOADING THE SPRING BE CAREFUL NOT TO DAMAGE THE PLASTIC STOP OF THE SPRING AND THE BUSHING THREADING NOTE FOR DESIGN REASONS THE NUT IS SLIGHTLY ASYMMETRIC THE FLATTEST SURFACE SHOULD BE MOUNTED CONTACTING THE CLUTCH Specific tooling AP8140259 Universal tool for clutch assemblies AP8140665 A...

Page 108: ...g belt standard width 21 3 0 2 mm Driving belt minimum width 19 5 mm During the wear checks foreseen in the scheduled maintenance services check that the rim bottom of the toothing does not show signs of incisions or cracking see figure the rim bottom of the tooth must not have incisions or cracking if it does change the belt Engine ATLANTIC 300 i e ENG 108 ...

Page 109: ...easure the outside diameter of the pulley sliding bushing shown in the figure Check that the rollers are not damaged or worn Check the guide shoes for the variator roller con trast plate are not worn Check that there is no wear in the roller housings or the surfaces in contact with the belt on both half pulleys Check that stationary driving pulley does not show signs of abnormal wear on the groove...

Page 110: ...Refitting the driving pulley Preassemble the movable half pulley with the roller contrast plate by placing the rollers in their housings with the larger support surface touching the pulley according to the direction of rotation Check that the roller contact plate does not show flaws or is damaged on the grooved edge Fit the entire bushing assembly on the crank shaft Fit the driven pulley Clutch be...

Page 111: ...ut 75 83 55 4 61 3 ftlb Refitting the transmission cover Check there are 2 centring dowels and that the sealing gasket for the oil sump has been ade quately fitted on the transmission cover Replace the cover by tightening the 10 screws to the prescribed torque Refit the oil filling cap dipstick Refit the steel washer and the driven pulley nut Tighten the nut to the specified torque using the lock ...

Page 112: ...lley shaft nut 54 60 39 9 44 3 ftlb End gear Removing the hub cover Empty the rear hub through the oil drainage plug Remove the 7 flanged screws indicated in the figure Remove the hub cover and the relevant gasket Removing the wheel axle Remove the wheel axle with gear Remove the intermediate gear Engine ATLANTIC 300 i e ENG 112 ...

Page 113: ...le bearings Remove the seeger ring from the outside of the hub cover Support the hub cover and expel the bearing Remove the oil seal as shown in the figure using the specific tool Specific tooling 020376Y Adapter handle 020477Y 37 mm Adaptor 020483Y 30 mm guide AP8140916 Hub cover support ATLANTIC 300 i e Engine ENG 113 ...

Page 114: ...transmission side Remove the seeger ring indicated in the figure Remove the driven pulley shaft bearing Specific tooling 020376Y Adapter handle 020375Y 28x30 mm punch 020363Y Crankshaft oil seal punch D 20 mm Inspecting the hub shaft Check the three shafts for wear or distortions on the toothed surfaces on the bearing housings and the oil seal positions In faults are found replace the damaged part...

Page 115: ...ng with a modular punch as shown in the figure Fit the seeger ring Fit the oil guard with its sealing lip facing the hub internal side and place it flush with the internal surface using the specific tool used on the 52 mm side The 52 mm side of the adaptor should face the bearing Specific tooling 020376Y Adapter handle 020360Y 52 x 55 mm adaptor 020483Y 30 mm guide ATLANTIC 300 i e Engine ENG 115 ...

Page 116: ...be fitted using the appropriate tools The 42 mm side of the adaptor should face the bearing Specific tooling 020150Y Air heater support 020151Y Air heater 020376Y Adapter handle 020359Y 42 x 47 mm adaptor 020412Y Clutch oil seal punch D 15 mm NOTE Use the stud bolt kit to support the cover adequately when fitting the bearing on the cover Engine ATLANTIC 300 i e ENG 116 ...

Page 117: ...tor 020363Y Crankshaft oil seal punch D 20 mm NOTE WHEN FITTING THE BEARINGS ON THE ENGINE CRANKCASE THE CRANKCASE SHOULD AS FAR AS POSSIBLE BE SUPPORTED ON A SURFACE TO ALLOW THE BEARINGS TO BE DRIV EN VERTICALLY Refit the seeger ring with the opening facing the bearing opposite and fit the new oil guard levelled with the crankcase on the pulley side Refitting the hub bearings Assemble the 3 shaf...

Page 118: ...rew easily recognisable by its different colour as shown in the figure Fasten the bleeding pipe support bracket with the lower screw Fit the remaining screws and tighten the 7 screws to the prescribed torque Locking torques N m Rear hub cover screws 24 27 17 7 19 9 ftlb Flywheel cover Removing the hub cover Remove the clamp fixing the hose to the cylinder Remove the 10 clamps Remove the flywheel c...

Page 119: ...e harness Locking torques N m Screws fixing freewheel to flywheel 13 15 9 6 11 1 ftlb Refitting the stator Refit the stator and the flywheel carrying out the removal steps but in reverse order tightening the retainers to the prescribed torque Locking torques N m Stator unit screws 3 4 2 2 3 ftlb Apply LOCTITE 242 medium strength threadlock ATLANTIC 300 i e Engine ENG 119 ...

Page 120: ...he engine and tighten the screws to the prescribed torque Follow the removal procedure but in reverse order CAUTION TAKE CARE TO CORRECTLY POSITION THE FLYWHEEL CONNECTOR MAKE SURE THE CEN TRING DOWELS ARE FITTED Locking torques N m Flywheel cover screw 11 13 8 1 9 6 ftlb Flywheel and starting Removing the starter motor Remove the two screws indicated in the figure Take out the starter motor from ...

Page 121: ... up the flywheel fixing nut by 3 or 4 threads so that the flywheel does not fall accidentally upon extraction Screw the extractor onto the flywheel and extract it as shown in the photograph Remove the tongue on the crankshaft Remove the starter motor gear Undo the screw and remove the crown gear bracket Remove the flywheel crown gear Specific tooling AP8140252 Multipurpose wrench AP8140301 Flywhee...

Page 122: ...heel holes and the fixing screws Apply the recommended product to the end of the screws Recommended products Loctite 243 Medium strength threadlock Fit the freewheel on the magneto flywheel mak ing sure that the ground side is in contact with the flywheel that is the wheel seeger ring should be visible Tighten the 6 fixing screws in a criss cross se quence to the prescribed torque Locking torques ...

Page 123: ...ear Tighten the flywheel fixing nut to the prescribed torque with a multipurpose wrench Refit the retention plate Specific tooling AP8140252 Multipurpose wrench Locking torques N m Flywheel nut 94 102 69 4 75 3 ftlb Refitting the starter motor Fit and lubricate a new O ring on the starter mo tor Fit the starter motor on the crankcase and lock the 2 screws to the prescribed torque Locking torques N...

Page 124: ...indicated in the figure Removing the timing system drive First remove the parts listed below transmission cover driving pulley with belt oil sump with spring and by pass piston oil pump pulley cover O ring on the crankshaft and the sprocket wheel separa tion washer Remove the tappet cover Remove the central screw fastener and the au tomatic valve lifter retaining cover indicated in the figure Engi...

Page 125: ...its end of stroke washer Loosen the central screw on the tensioner first Remove the 2 clamps indicated in the figure Remove the tensioner and its gasket Remove the internal hex screw and the counter weight shown in the figure Remove the camshaft control pulley and its washer ATLANTIC 300 i e Engine ENG 125 ...

Page 126: ...E CHAIN IN ORDER TO EN SURE THAT THE INITIAL DIRECTION OF ROTATION IS MAINTAINED Removing the cam shaft Remove the 2 screws and the camshaft mounting bracket indicated in the figure Remove the camshaft Remove the pins and the rocking levers from the flywheel side holes NOTE IF NECESSARY THE HEAD MAY BE REMOVED TOGETH ER WITH THE CAMSHAFT ROCKING LEVER PINS AND MOUNTING BRACKET THE HEAD CAN ALSO BE...

Page 127: ...ACKET THE HEAD CAN ALSO BE RE MOVED WITHOUT TAKING OUT THE CHAIN AND THE CHAIN TIGHTENER OF THE CRANKSHAFT Removing the valves Using the appropriate tool fitted with an adapter remove the cotter pins plates springs and valves Remove the oil seals with the specific tool Remove the spring lower supports CAUTION Arrange the valves so as to recognise their original position on the head Specific toolin...

Page 128: ...VING THE CYLINDER NOTE BE CAREFUL NOT TO DAMAGE THE SEALING RINGS DURING REMOVAL Inspecting the small end NOTE TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES SEE THE SPECIFICATIONS CHAP TER See also Crankcase crankshaft connecting rod Inspecting the wrist pin NOTE TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES SEE THE SPECIFICATIONS CHAP TER See also Cylinder piston assy Cylinder piston assy Inspe...

Page 129: ... piston Install piston and pin onto the connecting rod with the piston arrow aligned facing the exhaust Fit the pin snap ring onto the appropriate tool With the opening in the position indicated on the tool S left D right Set the snap ring into its position with the punch Fit the pin stop ring using the plug as shown in the figure piston fitting Install piston and pin onto the connecting rod with ...

Page 130: ...k the perfect sliding of the feeler pin Fit the tool on the cylinder without changing the dial gauge position Lock the tool with the original head fixing nuts Rotate the crankshaft up to TDC the reversal point of the dial gauge rotation Measure the deviation from the reset value By means of the table see the Specifications chapter identify the cylinder base gasket thickness to be used upon refitti...

Page 131: ...the word top or the reference mark facing the piston crown Offset the piston ring ports on the three rings by 120º as shown in the figure Lubricate the components with engine oil Engines are fitted with top ring with an L section NOTE THE 2 PISTON RINGS ARE MADE WITH A TAPERED CY LINDRICAL CONTACT SECTION THIS IS TO OBTAIN A BETTER BEDDING Refitting the cylinder Fit the cylinder base gasket of the...

Page 132: ...ings of wear are found replace the parts if the chain pinion or pulley are worn replace the whole assembly Remove the central screw with the washer and the tensioner spring Check that the one way mechanism is not worn Check the condition of the tensioner spring If signs of wear are found replace the whole as sembly Inspecting the valve sealings Fit the valves into the cylinder head Alternatively t...

Page 133: ...aps and the cotters show no signs of abnormal wear Refitting the valves Lubricate the valve guides with engine oil Place the valve spring supports on the head Using the specified punch fit the 4 sealing rings Fit the valves the springs and the plates Using the specified tool with the appropriate adaptor compress the springs and insert the cotters in their seats NOTE DO NOT CHANGE THE VALVE FITTING...

Page 134: ...timing chain sprocket wheel on the crank shaft with the chamfer facing the insertion side Loop the timing chain around the sprocket on the crankshaft Fit the chain tensioner pad from the cylinder head side Fit the spacer and the fixing screw Tighten the screw to the prescribed torque Fit the pins and rocker levers Lubricate the 2 rocking levers through the holes at the top Lubricate the 2 bearings...

Page 135: ... the automatic valve lifter cam to the camshaft Fit the automatic valve lifter return spring During this operation the spring must be loaded approximately 180 Fit the automatic valve lifter retaining dish using the counterweight fixing screw as reference Tighten the central fixing screw to the prescribed torque Set the tensioner slider to its home position Fit the chain tensioner on the cylinder u...

Page 136: ... 11 1 ftlb Timing chain tensioner central screw 5 6 3 7 4 4 ftlb Camshaft retention plate screw 4 6 3 4 4 ftlb Fit the timing chain guide pad Insert the centring dowels between the cylinder head and the cylinder fit the cylinder head gasket and the cylinder head Lubricate the stud bolt threading Tighten up the nuts to an initial pre torque of 7 1 Nm Tighten up the nuts to a second pre torque of 10...

Page 137: ...NG THE HEAD MAKE SURE THAT THE LUBRICATION CHANNEL IS GENERALLY CLEAN AND USE A JET OF COMPRESSED AIR FOR CLEANING Locking torques N m Timing chain tensioner support screw 11 13 8 1 9 6 ftlb Refitting the rocker arms cover Refit the head cover by tightening the 5 screws to the prescribed torque Take care to correctly position the gasket Locking torques N m Cylinder head cover screws 6 7 4 4 5 2 ft...

Page 138: ...shaft on the crank case Remove the ten crankshaft coupling screws Separate the crankcase while keeping the crank shaft in one of the two crankcase half Remove the crankshaft Remove the crankshaft halves coupling gasket Remove the two screws and the internal cover shown in the figure Remove the flywheel side oil seal Remove the oil filter fitting shown in the figure Check the connecting rod axial c...

Page 139: ...RANKSHAFT CHECK THAT THE THREADED SHAFT ENDS DO NOT INTERFERE WITH THE MAIN BUSH INGS FAILURE TO OBSERVE THIS PRECAUTION CAN DAMAGE THE MAIN BUSHINGS CAUTION WHEN SEPARATING THE CRANKCASE KEEP THE CRANKSHAFT IN ONE OF THE CRANKCASE HALF THE CRANKSHAFT MIGHT ACCIDENTALLY FALL IF THIS RULE IS NOT OBSERVED NOTE WHEN MEASURING THE CRANKSHAFT WIDTH MAKE SURE THAT THE MEASUREMENTS ARE NOT MODIFIED BY TH...

Page 140: ...s or de formation paying special attention to the cylinder crankcase surfaces and the crankcase halves coupling surfaces Defects in the crankcase coupling gasket or the surfaces indicated in the figure can cause a drop in oil pressure and thus affect the lubricating pres sure for the main bushings and the connecting rod Check that the surfaces limiting the crankshaft axial clearance show no signs ...

Page 141: ...pling surface of the two half bearings must be perpendicular to the cylinder axis as shown in the figure The oil supplying channel section is also influ enced by the depth to which the bushings are driven compared with the crankshaft axial clear ance of the limiting surface Measure the bushings diameter at the 3 positions indicated in the figure Repeat the measurements for the other half of the bu...

Page 142: ...torque Position the oil pre filter element as shown in the photograph Place a new gasket on one of the crankcase half preferably on the transmission side together with the centring dowels Lubricate the main bushings and insert the crank shaft in the transmission side crankcase half Couple the 2 crankcase halves Fit the 10 screws and tighten them to the pre scribed torque Fit and lubricate a new O ...

Page 143: ... indicated in the photograph If it driving depth varies significantly from that indicated it means that the stud bolt has yielded Should this occur replace it By working on two cylinder head fixing nuts fitted nut and lock nut remove the stud bolt from its seat as shown in the photograph Thoroughly clean the threaded seat on the crank case Refit a new stud bolt and apply the special product on the...

Page 144: ...Lubrication Conceptual diagrams LUBRICATION CIRCUIT Engine ATLANTIC 300 i e ENG 144 ...

Page 145: ...ATLANTIC 300 i e Engine ENG 145 ...

Page 146: ...ific tools on the engine once the measurement is complete Refit the oil pressure switch and washer tightening it to the prescribed torque and fit the flywheel cover If oil pressure reading are not within the specified limits check in the following order the oil filter the oil by pass valve the oil pump and the crankshaft seals NOTE THIS CHECK MUST BE CARRIED OUT WITH OIL AT THE CORRECT LEVEL AND W...

Page 147: ...base of the appropriate tool on the oil guard using the screws supplied Specific tooling AP8140729 Chain cover fitting removal Screw the threaded bar onto the base of the tool and extract the oil guard Specific tooling AP8140729 Chain cover fitting removal ATLANTIC 300 i e Engine ENG 147 ...

Page 148: ...the crankshaft up to the end of travel Use the nut to move the base of the tool until you can feel the end of the stroke of the oil seal driving Remove all of the tool components following the procedure in reverse order CAUTION DO NOT LUBRICATE THE KEYING SURFACE ON THE EN GINE CRANKCASE CAUTION ORIENT THE OIL GUARD BY POSITIONING THE CHAIN HOUSING CHANNEL FACING DOWNWARDS ONCE THE POSITION IS REA...

Page 149: ...screwdriver through one of its holes Remove the central screw with Belleville washer indicated in the figure Remove the chain and the crown gear Remove the control sprocket wheel and its O ring Remove the oil pump by unscrewing the 2 screws indicated in the figure Remove the sealing gasket NOTE IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN SURE THAT THE INITIAL DIRECTION OF ROTATION IS MAINTAIN...

Page 150: ...ure distance between rotors with a thick ness gauge at the position shown in the picture Measure the distance between the outer rotor and the pump body see figure Check the axial clearance of the rotors using a trued bar as shown in the figure Characteristic Rotor axial clearance Limit value allowed 0 09 mm Distance between outer rotor and pump body limit clearance allowed 0 20 mm Distance between...

Page 151: ... for the crankcase fixing screws are aligned Make sure the gasket is the correct position and refit the pump on the engine crankcase The pump can only be fitted in one position Tighten the screws to the prescribed torque Fit a new O ring on the pinion Assemble the chain Fit the pulley the central screw and the belleville washer Tighten to the specified torque Assemble the oil pump cover by tighten...

Page 152: ...l as described in the Transmission chapter Drain the oil from the sump as described above Remove the 7 screws shown in the figure and the 2 brackets fixing the rear brake fluid pipe Remove the spring the by pass piston the gas ket and the centring dowels shown in the figure Inspecting the by pass valve Check the free length of the spring Check that the plunger is not scored Make sure that it slide...

Page 153: ...ting brackets of the rear brake pipes in the reverse order followed for removal Tighten the screws to the prescribed torque Refit the driving pulley assembly the belt the pinion and the transmission cover as described in the Transmissions chapter When testing the lubrication system refer to the Crankcase and Crankshaft chapter re garding lubrication of the crankshaft and con necting rod Locking to...

Page 154: ...INDEX OF TOPICS INJECTION INJEC ...

Page 155: ...based on the ambient pressure The fuel supply circuit consists of Fuel pump Fuel filter Injector Pressure regulator Pump filter and regulator are placed into the fuel tank using a single support The injector is connected by two pipes provided with fast release fittings This results in a continuous circulation thereby avoiding the risk of fuel boiling The pressure regulator is at the end of the cir...

Page 156: ...s further controlled by the emergency switch to further enhance vehicle safety Precautions 1 Before fixing any part of the injection system check to see whether there are any faults Check for faults before disconnecting the battery 2 The fuel supply system is pressurised at 250 kPa 2 5 BAR Before disconnecting the fast release fitting of a fuel supply pipe check that there are no naked flames Do n...

Page 157: ...fectly dry 12 When carrying out electric inspections do not force the tester probes into the connectors Do not take measurements not specifically required by the manual 13 At the end of every check carried out with the diagnostic tester protect the system connector with the specific cap Failure to observe this rule can damage the MIU electronic control unit 14 Before reconnecting the fast release ...

Page 158: ...tire system carefully before replacing the MIU control unit If the fault is still present after the MIU control unit is replaced install the original control unit again and check whether the fault occurs again 4 Use a multimeter with an internal resistance over 10 K W V when troubleshooting Instruments that are not suitable may damage the MIU control unit Instruments must be used with definitions ...

Page 159: ...ive Pin 13 Injector 14 Engine revolution sensor negative Pin 15 Diagnosis Pin 16 Immobiliser LED Pin 17 Side stand Pin 18 Not used Pin 19 Injection load relay Pin 20 Not used Pin 21 HV coil Pin 22 Speed sensor Pin 23 Start up enabling Pin 24 Rollover protection switch Pin 25 Ground Pin 26 EMS circuit diagram ATLANTIC 300 i e Injection INJEC 159 ...

Page 160: ...art ENGINE DOES NOT START EVEN IF PULLED Possible Cause Operation Faults detected by self diagnosis Pump relay HV coil Injector Engine speed timing sensor Fuel system Fuel present in the tank Fuel pump activation Fuel pressure low Injector flow low Power to the spark plug Spark plug Shielded cap HV Coil secondary insulation Parameter reliability Coolant temperature Distribution timing adjustment i...

Page 161: ...t temperature sensor Intake air temperature sensor Intake system cleaning Air filter Diffuser and throttle valve Supplementary air pipe and Stepper Intake system seal seepage Intake manifold head Throttle body manifold Intake sleeve Filter housing Fuel system low pressure Fuel pump Pressure regulator Fuel filter Injector flow Engine does not rev down ENGINE DOES NOT RETURN TO IDLING IDLING TOO HIG...

Page 162: ...cer Silencer welding Engine revs irregularly REGULAR ENGINE PROGRESS WITH VALVE SLIGHTLY OPEN Possible Cause Operation Intake system cleaning Air filter Diffuser and throttle valve Supplementary air pipe and Stepper Intake system seal Intake sleeve Filter housing Ignition system Spark plug wear check Parameter reliability Throttle valve position signal Coolant temperature signal Intake air tempera...

Page 163: ...e Lambda Probe Ignition efficiency Spark plug Parameter reliability Throttle valve position signal Coolant temperature signal Intake air temperature signal Ignition advance Intake system seal Intake sleeve Filter housing TPS reset successful TPS reset successful Fuel system Fuel pressure Fuel filter Injector flow Fuel quality Selecting the thickness for the cylinder base gasket Selecting the thick...

Page 164: ...Removing the butterfly valve Remove the fuel piping fixing screw indicated in the figure Remove the fast release fittings from the injector support Injection ATLANTIC 300 i e INJEC 164 ...

Page 165: ...ree screws fixing the manifold to the cylinder head and the clip fixing the throttle body to the manifold Remove the MIU control unit connector Remove the clip fixing the throttle body to the pu rifier bellows ATLANTIC 300 i e Injection INJEC 165 ...

Page 166: ...itting the butterfly valve To refit follow the removal steps but in reverse or der being careful to position the clip fixing the throttle body to the air filter bellows at 45 as shown in the photograph Injection ATLANTIC 300 i e INJEC 166 ...

Page 167: ...p supply circuit COMPONENTS Specification Desc Quantity 1 Battery 12V 12 Ah 2 Fuse 20 A 3 Ignition key contacts 4 Fuse 15 A 5 Side stand 6 Injection load remote control ATLANTIC 300 i e Injection INJEC 167 ...

Page 168: ...y between pins 30 and 87 of the remote control Check the power supply line of the injection load remote control energising coil upon switching to ON make sure there is battery voltage for 2 sec onds between the green red cable and the blue red cable of the remote control base If there is none check the continuity of the Green Red cable between the fuse box under the saddle hinge and the remote con...

Page 169: ...e interface wiring is insulated from the earth connection Specific tooling Digital multimeter Circuit leak test Fit the specific tool for fuel pressure control with the pipe fitted with the pressure gauge on the de livery pipe Checking under regular functioning by placing the specific tool between the pump and the injector With 12V battery voltage check that the fuel pressure is 2 5 BAR and that t...

Page 170: ... Specific tooling AP8140181 Fuel pressure checking tool Fuel filter check Disconnect the terminals of the electrical pump Remove the screw indicated in the photograph Remove the clamp fixing the piping to the filter shown in the photograph Injection ATLANTIC 300 i e INJEC 170 ...

Page 171: ...Separate the lower part of the pump support as shown in the photograph Remove the filter from the pump support ATLANTIC 300 i e Injection INJEC 171 ...

Page 172: ...g the injector circuit COMPONENTS Specification Desc Quantity 1 Battery 12V 12 Ah 2 Fuse 20 A 3 Ignition key contacts 4 Fuse 15 A 5 Side stand 6 Injection load remote control Injection ATLANTIC 300 i e INJEC 172 ...

Page 173: ... the remote control Check the power supply line of the injection load remote control energising coil upon switching to ON make sure there is battery voltage for 2 sec onds between the green red cable and the blue red cable of the remote control base If there is none check the continuity of the Green Red cable between the fuse box under the saddle hinge and the remote control base and check the con...

Page 174: ...earth connection If there is none check the continuity of the Green Red cable between the fuse box No 4 15A and the remote control base NOTE CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED BATTERY REMOTE CONTROLS CONTROL UNIT FUSES ETC Injection ATLANTIC 300 i e INJEC 174 ...

Page 175: ... ON and check there is voltage with in jector disconnected and control unit connected between the Red Brown cable of the injector con nector and the earth connection With injector disconnected and the injector load remote control disconnected check the continuity of the Red Brown cable between the injector con nector and remote control base ATLANTIC 300 i e Injection INJEC 175 ...

Page 176: ...lied for the injection tester Connect the cable terminals to an auxiliary battery Activate the fuel pump with the active diagnosis Check that within 15 seconds approximately 40 cm of fuel is delivered with a regulation pressure of about 2 5 BAR Specific tooling AP8140181 Fuel pressure checking tool Carry out the injector sealing test Dry the injector outlet with a blast of compressed air Activate ...

Page 177: ...Components location ATLANTIC 300 i e Injection INJEC 177 ...

Page 178: ...coil 8 Flywheel revolution timing sensor 9 Lambda probe 10 Injection load remote control 11 Battery 12V 12 Ah 12 Electric fan remote control 13 fall sensor Tachometer With interface wiring disconnected from the control unit and connected to the system check that the sensor resistance between pins 13 15 is between 100 and 150 Ohm at an engine temperature of about 20 Injection ATLANTIC 300 i e INJEC...

Page 179: ...rol unit check the continuity of the rpm sensor connector red cable between pin 13 and pin 1 and the rpm sensor connector white cable between pin 15 and pin 2 With the interface wiring disconnected from the control unit and the rpm sensor connector also disconnected check that the red and brown cables pin 13 15 are insulated from each other and in sulated from the earth connection Specific tooling...

Page 180: ...HT coil COMPONENTS Specification Desc Quantity 1 Battery 12V 12 Ah 2 Fuse 20 A 3 Ignition key contacts 4 Fuse 15 A 5 Side stand 6 Injection load remote control Injection ATLANTIC 300 i e INJEC 180 ...

Page 181: ... control unit The power of the ignition is increased during the engine start up phase The injection system recognises the 4 stroke cycle so ignition is only commanded in the compression phase Specific tooling Digital multimeter Check that the 20A main fuse No 2 and the injection load 15A No 4 fuse are in good conditions Check there is voltage between pins 22 and 26 of the interface wiring for arou...

Page 182: ...r switching the line ON make sure there is battery voltage for two seconds between the Green Red cable and the Black Purple cable of the remote control base If there is none check the continuity of the Green Red cable between the fuse box in the battery compartment and the remote control base and of the Black Purple cable between pin 8 of the control unit and the remote control base NOTE CONTINUIT...

Page 183: ...earth connection If there is none check the continuity of the Green Red cable between the fuse box No 4 15A and the remote control base NOTE CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED BATTERY REMOTE CONTROLS CONTROL UNIT FUSES ETC ATLANTIC 300 i e Injection INJEC 183 ...

Page 184: ...Injection ATLANTIC 300 i e INJEC 184 ...

Page 185: ...th the control unit side connector disconnected and the coolant tempera ture sensor connector connected check the re sistance values between pins 9 and 26 in relation to the engine temperature 20 2500 100 Ω 80 308 6 Ω With the control unit side connector disconnected and the coolant temperature connector also dis ATLANTIC 300 i e Injection INJEC 185 ...

Page 186: ...trol of the idle speed This regulation must not be tampered with in any way whatsoever The injection system will complete the management of the idling through the Stepper and the variation of the ignition advance After the pre calibration the throttle body has an open valve with a variable angle depending on the tolerances of the machining of the pipe and the valve itself The valve position sensor...

Page 187: ...he TPS reset is also carried out when the control unit is replaced place the control unit filter box bellows fixing clip at 45 upon refitting as shown in the photograph Lambda probe The lambda probe or oxygen sensor is a sensor which provides information about the oxygen content in the exhaust fumes The signal generated is not of the proportional but of the ON OFF type i e whether there is oxygen ...

Page 188: ...e the multimeter probes between pins 4 and 11 With the engine running at idle speed check that the voltage oscillates between 0V and 1V With the throttle valve fully open the voltage is 1V During the closing phase the voltage is 0V If the voltage remains constant the sensor may be damaged Remove the sensor and check that there are no oil or carbon deposits in it Injection ATLANTIC 300 i e INJEC 18...

Page 189: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 190: ... spacer 4 Ring 5 Front brake disc 6 Front wheel pin 7 Front wheel spacer 8 Washer 9 TBEI screw M6x20 10 Tubeless valve 11 Odometer gear 12 Cover 110 90 13 13 Speedometer cable 14 Black clamp NOTE GREASE THE WHEEL PIN 6 Suspensions ATLANTIC 300 i e SUSP 190 ...

Page 191: ... the bearings If the wheel oscillates during rotation check the affected components If the wheel stops always at the same point after turning it several times pro ceed with balancing Removing the front wheel Park the vehicle on its centre stand Place a support under the chassis Remove the brake calliper Loosen the locking screw 1 CAUTION UPON REMOVING REFITTING PAY ATTENTION NOT TO DAMAGE THE BRAK...

Page 192: ...ID LEAKAGE Collect the spacer from the wheel left side Front wheel hub overhaul CAUTION CHECK THAT ALL THE PARTS ARE IN GOOD CONDITIONS SPECIALLY THE ONES BELOW BEARINGS Manually rotate the internal ring 1 which must turn smoothly without obstacles and or noise There must be no axial clearance The bearings presenting these problems must be replaced GASKETS Suspensions ATLANTIC 300 i e SUSP 192 ...

Page 193: ... ditions Check tyre pressure mainly before and after a long trip Check tyre inflation pressure every month at ambient temperature This vehicle is fit ted with tyres without inner tubes Tubeless CAUTION CHECK TYRE TREAD FOR WEAR BADLY WORN TYRES COMPROMISE TRACTION AND HANDLING REPLACE TYRES WHEN WORN OR IF THERE IS A PUNC TURE BIGGER THAN 5 MM IN THE TREAD SOME TYRE TYPES HOMOLOGATED FOR THIS SCOO...

Page 194: ...des of the hub with a cloth Remove the right bearing 1 with a suitable extractor Remove the left oil seal 2 Remove the left bearing 3 with a suitable extractor Collect the internal spacer 4 Clean the inside of the hub thoroughly Wash all the parts with clean deter gent CAUTION UPON REFITTING USE A BUFFER WITH A DIAMETER EQUAL TO THE EXTERNAL RING OF THE BEARINGS TO INSERT THE BEARINGS DO NOT HIT T...

Page 195: ...eel Spread a thin layer of lubricating grease all along the wheel pin Tighten the wheel pin from the right side Locking torques N m Wheel pin fixing screw 40 20 29 5 ftlb Tighten the locking screw 1 Locking torques N m Safety screw fixing screw 10 20 7 4 ftlb ATLANTIC 300 i e Suspensions SUSP 195 ...

Page 196: ...r rotation whereas a very loose steering involves poor sta bility CHECKING THE BEARINGS CLEARANCE Rest the vehicle on its centre stand Place a support under the chassis Shake the fork in the riding direction Adjust if clearance is detected ADJUSTING THE BEARING CLEARANCE Remove the legshield Loosen the lock nut 1 CAUTION NEVER TIGHTEN THE ADJUSTING NUT 2 WITH FORCE SO AS NOT TO DAMAGE THE STEERING...

Page 197: ...t Removal Remove the handlebar cover Remove the throttle grip Remove the rear brake pump Remove the left hand grip Release the clamps from the handle bar Loosen the terminal locking screw 1 Locking torques N m Screw fixing handlebar to fork 42 20 31 ftlb Undo and remove the safety screw 2 Remove the handlebar Locking torques N m Safety screw fixing screw 20 20 14 8 ftlb ATLANTIC 300 i e Suspension...

Page 198: ... cap 5 Sealing cap 6 O Ring 7 Spring 8 Pumping member 9 Counter spring 10 End stop buffer 11 Left stem 12 Dust guard gasket 13 Safety circlip 14 Sealing gasket 15 Cap 16 Bushing 17 Left wheel holder 18 Sealing washer 19 Lower screw Suspensions ATLANTIC 300 i e SUSP 198 ...

Page 199: ...the front brake lever press the handlebar repeatedly to send the fork to the fully down The stroke should be soft and there should be no oil marks on the stems If marks are found or reported at the fork end of stroke replace the oil Check that the fork does not leak oil and that the stem external surfaces have neither grooves nor scratches In this case replace all the damaged components which can ...

Page 200: ...S REFER TO REMOVING ONLY ONE WHEEL HOLDER STEM SLEEVE BUT THEY APPLY TO BOTH Remove the upper seeger ring 2 Remove the wheel holder stem sleeve WHEEL HOLDER STEMS SLEEVES REMOVAL Drain off the oil Place the stem in a vice fitted with pro tection jaws aluminium Undo and remove the lower screw 1 Suspensions ATLANTIC 300 i e SUSP 200 ...

Page 201: ...ng NOTE BE CAREFUL NOT TO DAMAGE THE SLEEVE INTERIOR WHEN REMOVING THE DIFFERENT COMPONENTS Remove the pumping member 2 and the spring 3 from the stem Remove the dust guard from the sleeve Remove the Seeger ring ATLANTIC 300 i e Suspensions SUSP 201 ...

Page 202: ...G Place the sleeve in a vice fitted with protection jaws aluminium NOTE GET A COLLECTING CONTAINER BEFORE CARRYING OUT THESE OPERATIONS CAUTION THE WHEEL HOLDER STEM SLEEVE UNIT CONTAINS OIL DO NOT TURN IT OVER OR TILT IT TOO MUCH WHEN REMOVING IT Suspensions ATLANTIC 300 i e SUSP 202 ...

Page 203: ...r the pumping element until the Seeger ring 1 can be removed Remove the Seeger ring 1 Remove the cap and the O ring Remove the spring and wait some mi nutes so that the oil deposited on it drips off ATLANTIC 300 i e Suspensions SUSP 203 ...

Page 204: ... bending is below the limit value If over the value replace the stem CAUTION A BENT STEM SHOULD NEVER BE STRAIGHTENED BECAUSE ITS STRUCTURE WOULD BE WEAKENED AND USING THE VEHICLE MAY BECOME DANGEROUS Characteristic Bending limit 0 2 mm SLEEVE Check that there are no damages and or cracks otherwise replace it If there are signs of excessive wear or damage replace the affected component Replace the...

Page 205: ...n jaws aluminium Fit the spacer 1 CAUTION BE EXTREMELY CAREFUL SO THAT NO FOREIGN BOD IES GET INTO THE SLEEVE OR THE WHEEL HOLDER STEM Insert the washer NOTE SPREAD A THIN LAYER OF FORK OIL ON GASKETS AND BUSHINGS BEFORE REFITTING THEM Insert the oil seal ATLANTIC 300 i e Suspensions SUSP 205 ...

Page 206: ...r ring Fit the dust guard Insert the pumping member and the spring in the stem Fit the components below on the sleeve in the following order the cen tring bushing 2 and the stem Suspensions ATLANTIC 300 i e SUSP 206 ...

Page 207: ...ith oil OIL FILLING Place the wheel holder stem sleeve unit in a vice fitted with protection jaws aluminium Fit the spring Pour fork oil into the wheel holder stem sleeve unit CAUTION NEVER REUSE OIL ATLANTIC 300 i e Suspensions SUSP 207 ...

Page 208: ...e cap with the O ring Fit the pumping member 1 Lower the pumping element until the Seeger ring 2 can be fitted Fit the Seeger ring 2 Fit the upper closing cap Steering column Suspensions ATLANTIC 300 i e SUSP 208 ...

Page 209: ...t 2 Locking torques N m Lock nut fixing screw 110 20 81 2 ftlb Set nut fixing screw 15 20 11 1 ftlb Slide off the fork with the front wheel from the headstock NOTE BE CAREFUL THE LOWER BEARING BALLS DO NOT COME OUT WHEN SLIDING OFF THE FORK Slide off and remove the plastic gasket 3 Remove the rotating seat 4 and the balls 5 of the upper bearing Remove the rotating seat 6 and the balls of the lower...

Page 210: ...TYPE OF GREASE INDICATED IN THE RECOMMENDED PRODUCTS TABLE Steering bearing Check that the ball contact area 1 on the rotat ing seat 2 and on the fixed seat 3 is not damaged or too worn Replace the whole bearing if necessary CAUTION CHECK THAT THE COMPONENTS ARE IN GOOD CONDI TIONS CAUTION APPLY GREASE ON BALL CONTACT AREAS ON BOTH SEATS 2 AND 3 Rear KEY Suspensions ATLANTIC 300 i e SUSP 210 ...

Page 211: ...ut obstacles and or noise other wise replace the bearings If the wheel oscillates during rotation check the affected components If the wheel stops at the same point ev ery time after rotating it several times proceed with balancing Removing the rear wheel Remove the exhaust Remove the rear mudguard Slide off the rear brake calliper keep ing it linked to the oil pipe Undo and remove the screw 1 Loc...

Page 212: ...the nut cover Unscrew and remove the wheel pin nut Remove the muffler supporting plate Locking torques N m Rear wheel fixing nut 120 20 88 6 ftlb Remove the shim washer 2 located on the wheel pin Remove the rear wheel Suspensions ATLANTIC 300 i e SUSP 212 ...

Page 213: ...t all the components that fix the fulcrum axis are firmly tightened Removal Remove the lower protection Remove both undertails Disconnect the spring 1 Fasten the belts to the passenger handgrip Tension the belts while lifting the hoist arm CAUTION FOR SAFETY REASONS IT IS NECESSARY THE INTER VENTION OF A SECOND OPERATOR Working on the right side unscrew and remove the nut 2 Locking torques N m ATL...

Page 214: ...ock fixing screw 5 Locking torques N m Screw fixing shock absorber to engine 40 20 29 5 ftlb Locking torques N m Nut fixing silent block to chassis 50 20 36 9 ftlb Collect in order the internal nut 6 the screw 5 with the relevant wash er Working from the right side unscrew and remove the nut 7 From the left side slide off the screw and collect the washer Remove the connecting rod assem blies Suspe...

Page 215: ...both with re duced and full vehicle load It is at any rate possi ble to insert personal settings depending on vehicle utilisation operate on the ring nut to define the ideal running settings see table REAR SUSPENSION ADJUSTMENT Specification Desc Quantity Riding without passenger Spring preloading decrease unscrewing Riding with passenger Spring preloading increase tightening Removal Remove the ta...

Page 216: ...te side Remove the centre stand CAUTION GREASE SLIP BANDS AND BE CAREFUL NOT TO DAM AGE THE SEALING RINGS DURING REFITTING TIGHTEN THE NUT AND CHECK THE CORRECT STAND RETURN Locking torques N m Nut fixing centre stand to engine 28 20 20 7 ftlb Side stand Remove the central tunnel Disconnect the connector from the side stand Suspensions ATLANTIC 300 i e SUSP 216 ...

Page 217: ...from the stand Unscrew and remove the nut 1 Locking torques N m Screw fixing side stand to chassis 10 20 7 4 ftlb From the opposite side remove in or der screw washer stand switch and stand ATLANTIC 300 i e Suspensions SUSP 217 ...

Page 218: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 219: ...lliper 6 Front brake pads 7 Brakeforce distribution mechanism front calliper pipe 8 Brakeforce distribution mechanism rear calliper pipe 9 Rear brake calliper 10 Rear brake pads 11 Rear brake lever Brakeforce distribution mechanism pipe 12 Rear brake lever control 13 Rear brake pump fluid reservoir Rear brake disc ATLANTIC 300 i e Braking system BRAK SYS 219 ...

Page 220: ...BE CARRIED OUT WITH BRAKE DISC FITTED ON THE WHEEL Check the brake disc for wear by measuring the minimum thickness with a micrometer at different points Replace the disc if the minimum thickness even at a single point of the disc is less than the minimum value Characteristic Disc thickness minimum value 3 5 mm Using a dial gauge check that disc os cillation does not exceed the tolerance otherwise...

Page 221: ... BE CARRIED OUT WITH BRAKE DISC FITTED ON THE WHEEL Check the brake disc for wear by measuring the minimum thickness with a micrometer at different points Replace the disc if the minimum thickness even at a single point of the disc is less than the minimum value Characteristic Disc thickness minimum value 4 mm Using a dial gauge check that disc os cillation does not exceed the tolerance otherwise ...

Page 222: ...ng calliper to fork 25 20 18 5 ftlb Unscrew and remove the pin 3 Slide off the brake pads CAUTION AFTER REMOVING THE PADS DO NOT OPERATE THE BRAKE LEVER OTHERWISE THE CAL LIPER PLUNGER COULD GO OUT OF ITS SEAT RESULTING IN BRAKE FLUID LEAKAGE Insert the two new brake pads Tighten the pin 3 Tighten the dowel 2 Place the brake calliper on the brake disc properly Tighten the two screws 1 CAUTION ALWA...

Page 223: ...em off one at a time CAUTION AFTER REMOVING THE PADS DO NOT OPERATE THE BRAKE LEVER OTHERWISE THE CAL LIPER PLUNGER COULD GO OUT OF ITS SEAT RESULTING IN BRAKE FLUID LEAKAGE Replace the pads 5 Insert the two new brake pads Insert the spring 4 correctly Insert the pin 3 Fit the seeger ring 2 Check the brake fluid CAUTION ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED IN SIDE T...

Page 224: ...ly pressed Loosen the bleeding valve 1 4 of a turn so that the brake fluid flows into the container This will release tension on the brake lever and will make it go to the end of stroke Repeat the operation until the fluid draining into the container is air bubble free Screw the bleed valve and remove the pipe Top up the reservoir until the right brake fluid level is obtained Refit the rubber prot...

Page 225: ...en the bleed valve 1 2 approx imately half a turn again Check the fluid coming from the pipe and when the fluid changes colour from dark to light tighten the bleed valve 1 2 and remove the pipe Refit the rubber protection cover Top up the oil in the reservoir up to the correct level NOTE THE FOLLOWING INFORMATION REFERS TO ONE BRAK ING CIRCUIT BUT APPLIES TO BOTH CAUTION HANDLE THE FLUID CAREFULLY...

Page 226: ...and on the rear brake calliper CAUTION BE CAREFUL WHEN HANDLING BRAKE FLUID IT AL TERS THE CHEMICAL COMPOSITION OF PAINTING AND PLASTIC AND RUBBER PARTS ETC IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN CAR RYING OUT SERVICE WORK WHEN YOU USE THE BRAKE FLUID MAKE SURE NOT TO SPILL IT ONTO PLASTIC OR PAINTED COMPONENTS AS IT WILL DAMAGE THEM CAUTION CONSIDERING THE DANGER FOR VEHICLE AND RIDER IT IS ST...

Page 227: ...t fully pressed Loosen the bleed valve 1 4 of a turn so that the brake fluid flows into the con tainer This will release tension on the brake lever and will make it go to the end of stroke Repeat the operation until the fluid draining into the container is air bubble free Screw the bleed valve and remove the pipe Top up the reservoir until the right brake fluid level is obtained Refit the rubber p...

Page 228: ... into the con tainer This will release tension on the brake lever and will make it go to the end of stroke Repeat the operation until the fluid draining into the container is air bubble free Screw the bleed valve and remove the pipe Top up the reservoir until the right brake fluid level is obtained Refit the rubber protection cover NOTE UPON BLEEDING THE HYDRAULIC SYSTEM FILL THE RESERVOIR WITH TH...

Page 229: ...OTE UPON REFITTING PURGE THE AIR OF THE BRAKING SYS TEM Locking torques N m Screw fixing the brakeforce distribution mechanism to curved support 12 20 8 9 ftlb REAR BRAKE PUMP REMOVAL Remove the left switch Undo and remove the two screws 1 Remove the brake pump U bolt Remove the brake pump keep it con nected to the brake pipe Remove the brake pump completely if necessary Disconnect the two rear st...

Page 230: ...Braking system ATLANTIC 300 i e BRAK SYS 230 ...

Page 231: ...INDEX OF TOPICS COOLING SYSTEM COOL SYS ...

Page 232: ...ctrical connection 1 of the electric fan control Power the electric fan directly with a 12V direct current voltage according to polarity Check if the electric fan is operating correctly ELECTRIC FAN RELAY CHECK Disconnect all the relay cables With a tester in Ohm meter function measure the continuity between the power terminals Exact value infinite resistance Power the control contacts connector w...

Page 233: ...ront side and collect the screws Undo and remove the two nuts 2 on the rear side and collect the screws Remove the air deflector housing Unscrew and remove the two screws 3 Remove the electric fan ATLANTIC 300 i e Cooling system COOL SYS 233 ...

Page 234: ...c fan connector Disconnect the two thermal switch con nectors Operating from both sides cut the clamp 1 Slide off both air deflectors from the ra diator Operating from both sides undo and remove the two screws 2 Undo and remove the central screw 3 Remove the clamps Cooling system ATLANTIC 300 i e COOL SYS 234 ...

Page 235: ...low into a collecting con tainer of suitable capacity FILLING Place the sleeve 1 and fix it with the clamp 2 Top up the expansion tank with cool ant Start up the engine and let it run until the cooling fan is activated let it cool down and check the fluid level in the expansion tank again Top up if necessary Thermostat ATLANTIC 300 i e Cooling system COOL SYS 235 ...

Page 236: ...saddle Unscrew and remove the two screws 1 Remove the protection Disconnect the connector from the wa ter temperature sensor Unscrew and remove the water tem perature sensor Cooling system ATLANTIC 300 i e COOL SYS 236 ...

Page 237: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 238: ...e ignition key anti clockwise Lift the saddle Undo and remove the four screws and the hook Remove the saddle UNDERTAIL REMOVAL NOTE THE FOLLOWING OPERATIONS REFER TO REMOVING ONLY ONE UNDERTAIL BUT APPLY TO BOTH Lift the saddle Undo and remove the two screws 1 Chassis ATLANTIC 300 i e CHAS 238 ...

Page 239: ... screws 1 NOTE THE OPERATIONS DESCRIBED ABOVE REFER TO RE MOVING ONLY ONE MIRROR BUT APPLY TO BOTH MIR RORS Remove the external protection Undo and remove the two screws 2 Remove the mirror Locking torques N m Screw fixing mirrors to curved support 10 7 4 ftlb ATLANTIC 300 i e Chassis CHAS 239 ...

Page 240: ...e the two screws 1 Remove the upper cover Operating from both sides unscrew and remove the front screw 2 Operating from both sides unscrew and remove the lower screw 3 Unscrew and remove the three screws 4 Chassis ATLANTIC 300 i e CHAS 240 ...

Page 241: ...et type bulb from its fitting and replace the bulb Insert the bulb holder in its fitting and lock it by turning it clockwise CLOCK BATTERY REPLACEMENT Remove the instrument panel to have access to the rear part Release the snap on lid Replace the button cell battery Reposition the snap on lid INSTRUMENT PANEL Remove the top fairing glass Working from both sides undo and re move the instrument pane...

Page 242: ... Lift the instrument panel Disconnect the odometer cable Disconnect the three instrument panel connectors 2 3 4 being careful not to jerk the flexible printed circuit Chassis ATLANTIC 300 i e CHAS 242 ...

Page 243: ... SWITCH REMOVAL Undo and remove the three lower screws 6 Undo and remove the screw 7 Remove the switch lower cover Disconnect the engine stop connector Disconnect the engine start up con nector Remove the switch upper cover ATLANTIC 300 i e Chassis CHAS 243 ...

Page 244: ... HIGH BEAM AND LOW BEAM BULB RE PLACEMENT Open the glove box 3 and release the end of stroke side rods by pressing them down moder ately Hold the bulb connector 4 pull and disconnect it from the bulb Turn the bulb holder 5 anticlockwise and take it out from the parabole fitting Take out the bulb When refitting the bulb NOTE INSERT THE BULB IN THE PARABOLE FITTING SO THAT THE THREE BULB TABS COINCI...

Page 245: ...bulb 7 clockwise and extract them from their fitting Press the bulb 7 slightly and turn it anticlockwise Take out the bulb from its fitting NOTE INSERT THE BULB IN THE BULB HOLDER SO THAT THE TWO GUIDING PINS COINCIDE WITH THEIR GUIDES ON THE BULB HOLDER Install a bulb of the same type ade quately TURN INDICATOR REMOVAL Remove both fairings Disconnect the two connectors from the turn indicator ATL...

Page 246: ... CLEAN OFF PRINTS WITH ALCOHOL TO AVOID DAMAG ING THE BULB DO NOT FORCE ELECTRICAL CABLES NOTE BEFORE REPLACING A BULB CHECK THE FUSES TAIL LIGHT BULB REPLACEMENT Place the vehicle on the service stand Remove the front closing CAUTION PROCEED WITH CAUTION DO NOT DAMAGE THE TAB AND OR ITS SLOTS Working from the rear part of the bulb holder turn and extract the entire bulb holder Extract the bulb fr...

Page 247: ... Operating from both sides disconnect the two connectors from the turn indi cator Disconnect the front light connector Remove the front light Frame central cover Remove the saddle Remove the tail fairing Remove the legshield CAUTION PROCEED WITH CAUTION DO NOT DAMAGE THE TAB AND OR ITS SLOTS ATLANTIC 300 i e Chassis CHAS 247 ...

Page 248: ...h the hands Operating from both sides unscrew the four screws 1 Operating from both sides undo and remove the five screws 2 and the three screws 3 Operating from both sides undo and remove the two screws 4 and the four screws 5 Chassis ATLANTIC 300 i e CHAS 248 ...

Page 249: ...nk cap Remove the cover under the fuel tank cap Remove the two screws 6 WARNING PUT A CLEAN CLOTH IN THE TANK OPENING Operating from both sides remove the screw 7 and the screw 8 Undo and remove the internal screw of the glove box Operating from both sides undo the screw 9 Remove the locking gasket ATLANTIC 300 i e Chassis CHAS 249 ...

Page 250: ... Remove the central tunnel by pulling it backwards CAUTION PROCEED WITH CAUTION DO NOT DAMAGE THE TAB AND OR ITS SLOTS Chassis ATLANTIC 300 i e CHAS 250 ...

Page 251: ...ect the ignition lock connector 3 Unscrew and remove the two screws 4 Remove the fuel tank Remove the side stand Remove the radiator Remove the helmet compartment Remove the connecting rods Remove the shock absorber Disconnect the throttle grip cable from the throttle body 5 Slide off the rear calliper from the disc Unscrew and remove the screw 6 Remove the coil 10 NOTE RELEASE ALL THE CABLES AND ...

Page 252: ...connect the two connectors 8 from the start up relay Unscrew and remove the two screws 9 Remove the control unit holding frame Remove the chassis by lifting it Knee guard Park the vehicle on its centre stand Unscrew and remove the eight side screws 1 Chassis ATLANTIC 300 i e CHAS 252 ...

Page 253: ...erating from both sides unscrew and remove the two screws 3 CAUTION PROCEED WITH CAUTION DO NOT DAMAGE THE TAB AND OR ITS SLOTS Remove the legshield Front wheel housing MUDFLAP REMOVAL Remove the complete steering Remove the central tunnel Operating from both sides cut the clamp 1 Slide off both air deflectors from the ra diator ATLANTIC 300 i e Chassis CHAS 253 ...

Page 254: ...REPLACEMENT In the rear headlamps there are Two tail light stop light bulbs 6 Two rear turn indicator bulbs 5 NOTE THE FOLLOWING INFORMATION REFERS TO ONLY ONE INDICATOR BUT IT APPLIES TO BOTH Replacement Undo the two fixing screws 8 and re move the glass 7 CAUTION PROCEED WITH CAUTION DO NOT DAMAGE THE TAB AND OR ITS SLOTS Chassis ATLANTIC 300 i e CHAS 254 ...

Page 255: ...N DO NOT DAMAGE THE TAB AND OR ITS SLOTS Tighten the screws 8 carefully and slightly to avoid damaging the glass 7 REMOVAL Remove the tail section RIGHT Disconnect the connector 1 Slide off the license plate lamp bulb 2 Undo and remove the three screws 3 Remove the right headlight assembly LEFT Disconnect the connector 1 Undo and remove the three screws 4 Remove the left headlight assembly ATLANTI...

Page 256: ...e same type Side fairings Remove the front closing Remove the legshield Operating from both sides undo and remove the upper screw 1 NOTE THE OPERATIONS DESCRIBED BELOW REFER TO RE MOVING ONLY ONE FAIRING BUT APPLY TO BOTH Operating from both sides undo and remove the screw 2 Unscrew and remove the four screws 3 Remove the fairing Chassis ATLANTIC 300 i e CHAS 256 ...

Page 257: ...e plate holder Air filter AIR FILTER CASE REMOVAL Unscrew and remove the two screws 1 Unscrew and remove the screw 2 Remove the protection 3 from the engine breather pipe Unscrew and remove the two screws 4 Locking torques N m Screw fixing filter case to engine 8 20 5 9 ftlb Locking torques N m Screw fixing filter case to bulkhead 8 20 5 9 ftlb ATLANTIC 300 i e Chassis CHAS 257 ...

Page 258: ...dy Move the filter case Slide off the engine breather pipe 6 from the filter case Remove the air filter case AIR FILTER REMOVAL Remove the air filter case Undo and remove the nine screws 1 Open the air filter case Remove the air filter 2 Chassis ATLANTIC 300 i e CHAS 258 ...

Page 259: ...and remove the three upper screws 1 Operating from both sides undo and remove the lower screw 2 Move the tail section and disconnect the rear lighting connector Disconnect the saddle unlocking ca ble Remove complete the tail section ATLANTIC 300 i e Chassis CHAS 259 ...

Page 260: ...nd collect the washers Locking torques N m Screw fixing passenger handgrip to chassis M6x45 10 20 7 4 ftlb Unscrew and remove the two screws 2 Locking torques N m Screw fixing passenger handgrip to chassis M8x60 25 20 18 5 ftlb Remove the luggage rack Chassis ATLANTIC 300 i e CHAS 260 ...

Page 261: ... and remove the three fixing screws 2 and collect the cable guide Remove the rear mudguard Locking torques N m Screw fixing rear mudguard to engine 10 20 7 4 ftlb Helmet bay Remove the tail section Remove the saddle Remove the battery and slide off the main fuse boxes Unscrew and remove the two front screws 1 ATLANTIC 300 i e Chassis CHAS 261 ...

Page 262: ...and remove the two screws 3 fixing the expansion tank Move the expansion tank and keep it connected to the cooling system pipes Disconnect the two plug socket con nectors 4 and the helmet compart ment light connector Remove the helmet compartment Chassis ATLANTIC 300 i e CHAS 262 ...

Page 263: ...rews 1 Remove the front mudguard Locking torques N m Front mudguard fixing screw 7 5 2 ftlb Fuel tank FUEL PROBE REMOVAL Remove the central tunnel Disconnect the delivery pipe and the fuel return pipe 1 Disconnect the fuel probe connector 2 Undo and remove the ring nut 3 ATLANTIC 300 i e Chassis CHAS 263 ...

Page 264: ...ted to the coolant delivery and reverse pipes Disconnect the delivery pipes and the fuel return pipe 1 Disconnect the fuel probe connector 2 Undo and remove the two rear screws 3 and collect the relevant washers and the front screw 4 Lower and remove the fuel tank Chassis ATLANTIC 300 i e CHAS 264 ...

Page 265: ...ompartment Remove the cooling system pipe Remove the expansion tank Front central cover Operating from both sides undo and remove the rear screw 1 Unscrew and remove the two front screws 2 Unscrew and remove the two lower screws 3 Remove the front locking ATLANTIC 300 i e Chassis CHAS 265 ...

Page 266: ...the top fairing INSTRUMENT PANEL SUPPORT REMOVAL TOP FAIRING Remove the front light Remove the instrument panel Release the instrument panel support top fairing from the clamps Disconnect the right switch connector Disconnect the left switch connector Disconnect the ignition lock connector 1 Chassis ATLANTIC 300 i e CHAS 266 ...

Page 267: ...g Unscrew and remove the two screws 2 fixing the brakeforce distribution mechanism Locking torques N m Screw fixing the brakeforce distribution mechanism to curved support 12 20 8 9 ftlb Unscrew and remove the three screws 3 fixing the light upper support ATLANTIC 300 i e Chassis CHAS 267 ...

Page 268: ... to the chassis Remove the instrument panel top fair ing support Locking torques N m Screw fixing support to chassis 10 20 7 4 ftlb Lower cover Park the vehicle on its centre stand Operating from both sides remove the rear mat by lifting it with the hands Operating from both sides unscrew and remove the seven screws 1 Chassis ATLANTIC 300 i e CHAS 268 ...

Page 269: ... Operating from both sides unscrew and remove the rear screw 2 Undo and remove the three front screws 3 Lower the side stand Remove the lower protection ATLANTIC 300 i e Chassis CHAS 269 ...

Page 270: ...INDEX OF TOPICS PRE DELIVERY PRE DE ...

Page 271: ...arts fixing screws Electrical system Main switch Headlamps high beam lights low beam lights tail lights front and rear and their warning lights Headlight adjustment according to regulations in force Front and rear stop light switches and their bulbs Turn indicators and their warning lights Instrument panel lights Instrument panel fuel and temperature indicator if present Instrument panel warning l...

Page 272: ...CASE OF CONTACT WITH YOUR EYES OR SKIN WASH WITH ABUNDANT WATER FOR AP PROX 15 MIN AND SEEK MEDICAL ATTENTION IMMEDIATELY IF ACCIDENTALLY SWALLOWED IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL SEEK IMMEDIATE MEDICAL ATTENTION BATTERIES PRODUCE EXPLOSIVE GASES KEEP CLEAR OF NAKED FLAMES SPARKS OR CIGARETTES VENTILATE THE AREA WHEN RECHARGING INDOORS ALWAYS WEAR EYE PROTECTION WHEN W...

Page 273: ...tion Hydraulic braking system Brake levers stroke Clutch Check for correct operation Engine Check for correct general operation and absence of abnormal noise Other Documentation check Chassis and engine numbers check Supplied tools check License plate fitting Locks checking Tyre pressure check Installation of mirrors and any possible accessories NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES AS ...

Page 274: ...4 Crankcase 20 128 138 141 Crankshaft 20 128 138 139 141 146 Cylinder 18 25 124 127 129 131 134 E ECU 86 Electric fan 232 Electrical system 13 59 271 Engine oil 47 Exhaust 89 162 F Fairings 256 Fork 198 Front wheel 191 192 195 253 Fuel 163 170 263 Fuses 81 H Handlebar 196 240 243 Headlight 56 244 Horn 75 Hub oil 44 I Identification 11 Instrument panel 241 L Lambda probe 187 License plate holder 25...

Page 275: ...l filter 50 Oil sump 152 153 R Rear wheel 211 Recommended products S Saddle Shock absorbers 215 Side fairings 256 Side stand 216 Spark plug 43 Stand 216 Start up Starter motor 120 123 T Tank 263 265 Transmission 13 98 111 Tyres 14 V Voltage regulator 73 W Warning lights ...

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