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Fuel system

chap. 4

4-5

4

Release 00

2002-09

Atlantic 500

REMOVING/DISASSEMBLING THE FUEL
PUMP

Read carefully (PRECAUTIONS AND GENERAL
INFORMATION) and (FUEL).

REMOVING THE PUMP ASSEMBLY

Fuel vapors are dangerous to health.
Before proceeding, make sure that the place of
work is sufficiently ventilated.
Do not inhale fuel vapors.
Avoid fuel contact with skin.
Do not smoke or use naked flames.
Dispose of fuel correctly.

Remove the central tunnel, see (REMOVING THE
CENTRAL TUNNEL).
Disconnect the electric connection (1) that controls the
fuel pump.
Disconnect the fuel supply pipes (2) from the body of
the fuel pump.
Unscrew and remove the six nuts (3).
Remove the fuel pump fastening bracket (4).

CAUTION

CAUTION

Work with caution when removing the fuel pump
(5), taking care not to damage the fuel pre-filter
(6).

Remove the fuel pump (5) from the tank (7).

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3

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7

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Summary of Contents for ATLANTIC 500

Page 1: ...ATLANTIC 500 11 2002 00 1074 2 workshopmanual 8140633 ...

Page 2: ...s manual If you have any questions regarding the applicability of any service procedure given in this manual contact aprilia consumer ser vices A C S A C S Technical Counselors will be able to assist you with any problems you might face as well as providing you with information on any updates and technical changes to the vehicle you are servicing For further information refer to SPARE PARTS CATALO...

Page 3: ...RY ELECTROLYTE 2 8 BATTERY RECHARGING 2 8 BATTERY INSTALLATION 2 9 SPARK PLUG 2 9 ADJUSTING THE THROTTLE CONTROL 2 10 AIR FILTER 2 11 ENGINE OIL 2 12 ENGINE OIL CHANGE AND OIL FILTER 2 13 CHECKING AND TOPPING UP THE TRANSMISSION OIL LEVEL 2 14 CHANGING THE TRANSMISSION OIL 2 16 DISC BRAKES 2 16 CHECKING 2 17 TOPPING UP BRAKE FLUID 2 18 CHECKING WEAR OF THE BRAKE PADS 2 18 BLEEDING THE BRAKING SYST...

Page 4: ... WITHOUT LOAD 6 2 CHECKING THE ALTERNATOR CONTINUITY 6 3 VOLTAGE REGULATOR 6 3 IGNITION SYSTEM 6 4 FUEL INJECTION SUPPLY WIRING DIAGRAM 6 4 CHECKING THE STAND SWITCH 6 5 IGNITION FUEL INJECTION SYSTEM 6 7 CONNECTIONS TO THE ELECTRONIC CONTROL UNIT 6 7 CONNECTIONS TO THE E C U CONTROL UNIT 6 9 CHECKING THE HT COIL 6 10 CHECKING THE DROP SENSOR 6 11 CHECKING THE RPM SENSOR 6 12 CHECKING THE THROTTLE...

Page 5: ... POSITIONS 6 40 ELECTRIC COMPONENTRY POSITIONS 6 41 WIRING DIAGRAM SCOOTER ATLANTIC 500 CC 6 42 Chapter 7 BODYWORK 7 2 REMOVING THE PASSENGER FOOTBOARDS 7 2 REMOVING THE BOTTOM GUARD 7 2 LOCKING RELEASING THE SADDLE 7 2 REMOVING THE SADDLE 7 3 REMOVING THE CENTRAL TUNNEL 7 3 REMOVING THE RIGHT AND LEFT INSPECTION COVERS 7 4 REMOVING THE LEG SHIELD 7 4 STORAGE COMPARTMENT 7 6 REMOVING THE FRONT MUD...

Page 6: ...T MUFFLER 7 29 INSPECTION 7 30 FRONT BRAKE 7 30 KEY 7 31 CHANGING THE BRAKE PADS 7 32 CHECKING THE BRAKE DISC 7 33 REMOVING THE BRAKE DISC 7 33 REAR BRAKE 7 33 KEY 7 34 CHANGING THE BRAKE PADS 7 35 CHECKING THE BRAKE DISC 7 36 REMOVING THE BRAKE DISC 7 36 STEERING 7 37 INSPECTION OF THE BEARINGS 7 39 KEY 7 40 CHECKING THE OIL LEVEL 7 41 REMOVING THE WHOLE FORK 7 41 REMOVING THE ROD WHEEL SUPPORT A...

Page 7: ...Atlantic 500 6 Release 00 2002 09 ...

Page 8: ...General information chap 1 Release 00 2002 09 1 1 Atlantic 500 General information 1 ...

Page 9: ...nd exhaust that are still hot to avoid burns Motorcycle parts are not edible do not bite suck chew or swallow any of the motorcycle parts for any reason whatsoever Unless expressly stated otherwise follow the disassembly steps in reverse order when reassembling units The overlapping of operations in references to other chapters must be interpreted in a logical way to avoid the unnecessary removal ...

Page 10: ...gs O rings split pins and screws if there is any sign of thread damage Thoroughly clean all mating surfaces oil seal rims and gaskets before reassembly Apply a thin film of lithium based grease to oil seal rims Refit the oil seal and bearings with the identification mark or serial number facing outwards visible Lubricate bearings thoroughly when fitting Check to make sure that each component has b...

Page 11: ...ber V I N stamped on the steering head of the frame A and on the identification plate B under the right carpet DIGIT MEANING 1 Manufacturer s identification alphanumeric code 2 Vehicle type 3 Model 4 Country for which the vehicle is intended 5 Check digit number 6 Model year 7 Assembling factory designation N NOALE VE S SCORZÉ VE 0 NOT SPECIFIED 8 Sequential serial number VEHICLE IDENTIFICATION NU...

Page 12: ...lose the filler cap properly after refueling Do not allow fuel to come into contact with the skin Do not swallow fuel or inhale the vapors Do not transfer fuel from one container to another with a tube DO NOT DISPOSE OF FUELIN DRAINS WATER COURSES OR THE SOIL KEEP OUT OF REACH OF CHILDREN Use only leaded 4 star or unleaded petrol with minimum octane rating 95 N O R M and 85 N O M M ENGINE OIL Engi...

Page 13: ...very two years CHANGING THE FRONT BRAKE FLUID WARNING WARNING Do not use fluids other than those specified and do not top up with different fluids as this will damage the braking system Do not use fluids that have been stored in old containers or that have been open for a long time Sudden variations in the play or looseness of the brake levers are caused by problems in the hydraulic circuits Check...

Page 14: ...olant every two years CHANGING THE COOLANT The coolant solution is made up of 50 water and 50 antifreeze This is the ideal mixture for most running temperatures and ensures good protection against corrosion You are advised to keep the same mixture in the warmer season as well to reduce loss by evaporation and avoid frequent topping up This will also reduce the quantity of mineral salt deposits lef...

Page 15: ...ng operation shown in the column After running in of the REGULAR SERVICE INTERVALS CHART The internal parts of the engine and transmission must be properly run in to ensure their long life and dependable operation If possible while breaking in your motorcycle ride on hilly roads and or roads with many curves so that the engine and transmission undergo lots of speed changes NOTE The best vehicle sp...

Page 16: ...genuine aprilia SPARE PARTS Only use the recommended lubricants Use when necessary the special tools designed for this vehicle When tightening screws nuts and bolts start with the largest diameter or innermost fasteners and tighten diago nally across their layout Carefully clean all disassembled parts with a nonflammable detergent Lubricate the parts naturally where possible before refitting Make ...

Page 17: ...General information chap 1 1 10 Release 00 2002 09 Atlantic 500 POSITION OF THE WARNING ADHESIVE LABELS A 12 B C D E 15 16 2a 6 14 3 19 11 17 5 13 8 10 1 4 9 18 7 ...

Page 18: ...2002 09 Atlantic 500 Ref Description 1 2 2a 3 4 5 6 7 8 9 Ref Description 10 11 12 13 14 15 16 17 18 19 WARNING ADHESIVE LABELS CHART NOT PROVIDED FOR 49 STATES FOR STATE OF CALIFORNIA ONLY MAXIMUM WEIGHT LOAD ALLOWED lbs 20 kg 5 Muffler stamping ...

Page 19: ...General information chap 1 1 12 Release 00 2002 09 Atlantic 500 CALIFORNIA EVAPORATIVE EMISSION SYSTEM ...

Page 20: ...e 5 Roll over valve 6 Roll over valve purge valve connection tube 7 Purge valve 8 Purge valve carbon canister connection tube 9 Carbon canister 10 Intake coupling hose 11 Throttle 12 Air box 13 Warm air inlet from air box 14 Carbon canister washing hose 15 One way valve 16 Purge valve throttle connection tube 17 Tee 18 Narrow passage 19 Security valve 20 Tee ...

Page 21: ...five 5 years or 11 185 miles 18 000 km whichever first occurs Class III motorcycles 280 cm3 and larger for a period of use of five 5 years or 18 641 miles 30 000 km which ever first occurs If an emission related part on your motorcycle is defective the part will be repaired or replaced by aprilia This is your emission control system DEFECTS WARRANTY OWNER S WARRANTY RESPONSIBILITIES As the motorcy...

Page 22: ...nal parts intake manifold fuel tank fuel injection system spark advance mechanism crank case breather air cutoff valves fuel tank cap for evaporative emission controlled motorcycles oil filter cap pressure control valve fuel vapor separator canister igniters breaker governors ignition coils ignition wires ignition points condensers and spark plugs if failure occurs prior to the first scheduled rep...

Page 23: ... WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE IS LIMITED TO THE EXPRESS EMISSION CONTROL SYSTEM WARRANTY TERMS STATED IN THIS WARRANTY THE FOREGOING STATEMENTS OF WARRANTY ARE EXCLUSIVE AND IN LIEU OF ALL OTHER REMEDIES SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU C No dealer is authorized to modify this...

Page 24: ... chain on the flywheel side Cooling Fluid with forced circulation by centrifugal pump Number of valves 4 Bore stroke 3 6 in 2 7 in 92 mm 69 mm Starting Electric CAPACITY Fuel including reserve Seats Vehicle max load rider luggage 1 05 gal 4 l 2 231 4 lbs 105 Kg Fuel reserve Engine oil 4 48 gal 17 l Front fork oil 13 42 cu in 220 cm3 for tube engine oil and oil filter change 91 5 cu in 1500 cm3 cha...

Page 25: ...9 psi Rear 260 kPa 2 6 bar 37 7 psi Type light alloy WHEEL RIMS Front 15 x 3 00 Rear 14 x 3 75 Type Without inner tube tubeless Type C D I inductive IGNITION Ignition advance Variable advance managed by the injection control unit Steering angle Front Stroke Rear Wheel stroke 3 93 in 100 mm rear Two dual effect hydraulic shock absorbers with pre load with five settings SUSPENSIONS Hydraulically ope...

Page 26: ...F 30 C 140 C dripping point 302 F 446 F 150 C 230 C high protection against corrosion good resistance to water and oxidation Protection of battery poles Neutral grease or Vaseline Use only fresh brake fluid Brake fluid recommended F F DOT 5 DOT 4 compatible BRAKE 5 1 DOT 5 DOT 4 compatible As an alternative to the fluid recommended you may use high quality fluids with performance levels that meet ...

Page 27: ...ENGINE FORK ASSEMBLY TCEI screw 59 80 Frame fork pin 44 25 60 Engine fork pin 44 25 60 STAND ASSEMBLY Stand screw 33 19 45 Low nut 22 12 30 Side stand screw 7 23 10 FRONT SUSPENSION ASSEMBLY Nut 11 06 15 Steering series self locking nut 79 59 110 Flanged screw 18 44 25 REAR SUSPENSION ASSEMBLY Screw 36 88 50 Screw 18 44 25 FRONT BRAKE ASSEMBLY TCEI screw 19 91 27 REAR BRAKE ASSEMBLY TCEI screw 19 ...

Page 28: ...pport fastening screw 7 23 10 WINDSHIELD SUPPORT ASSEMBLY Windshield support fastening self locking nut 7 23 10 PASSENGER HANDLES ASSEMBLY Passenger handles fastening TCEI screw 18 44 25 BUMPER PIPES ASSEMBLY Stainless steel flanged TBEI screw 7 23 10 ELECTRICAL COMPONENTS ASSEMBLY Coil fastening screw 1 47 2 Nut 1 47 2 Rotary switch screw 7 23 10 Rotary switch screw 7 23 10 Relay cable fastener 3...

Page 29: ...General information chap 1 1 22 Release 00 2002 09 Atlantic 500 ...

Page 30: ...Routine maintenance operations chap 2 Release 00 2002 09 2 1 Atlantic 500 2 Routine maintenance operations ...

Page 31: ...cle on a workstand which is solidly attached to the floor Raise the motorcycle up to the point where it may conveniently be worked on Use extreme caution when working aroun parts of the engine and exhaust which may remain hot for a long time NOTE Unless expressly stated otherwise reas semble the motorcycle in the reverse order from the disassembly steps given in this manual ROUTINE MAINTENANCE PLA...

Page 32: ...ission oil 3 1 every 15 000 mi 24 000 km 3 Variator rollers and plastic variator guides 1 Wheels tires and inflation pressure 1 Tighten nuts and bolts 1 1 Fuel lines 1 1 every 4 years 3 Fuel filter every 15 000 mi 24 000 km 1 every 30 000 mi 48 000 km 3 Spark plug 1 3 Wheel bearings 1 Brake system 1 1 Bleed brake fluid 1 Battery Electrolyte level 1 1 Throttle operation 1 1 Air filter 2 every 11 25...

Page 33: ...ating completely clean the oxidation from all parts and remove all grease dirt and dust Any exposed parts subject to rusting must be lubricated with engine oil or grease see LUBRICANT CHART The LUBRICATION DIAGRAM shows the lubrica tion points LUBRICATION DIAGRAM KEY TO LUBRICATION DIAGRAM 1 Brake lever pivot 2 Steering bearings 3 Side stand pivot 4 Center stand pivot 5 Throttle control 6 Throttle...

Page 34: ... large amounts of milk or water then continue with milk of magnesia or vegetable oil See a physician immediately Since the battery gives off explosive hydrogen gas keep away from open flames sparks or cigarettes or any other source of heat Make sure the area is adequately ventilated during recharging or while running the engine avoid inhaling the fumes emitted while recharging the battery KEEP OUT...

Page 35: ...onnect the electrical connector 4 for the helmet compartment lighting Remove the battery cover 2 1 2 4 3 5 6 CHECKING AND CLEANING TERMINALS Remove the battery cover see alongside RE MOVING THE BATTERY COVER Make sure that the battery cable terminals 5 6 are in good condition not corroded or encrusted with deposits covered with neutral grease or Vaseline If necessary Disconnect the negative and po...

Page 36: ...red in a safe place and out of the reach of children Replace the battery cover see alongside RE MOVING THE BATTERY COVER Handle with extreme care since without bleeding it may leak electrolyte WARNING LEAVING THE BATTERY IDLE FOR LONG PERIODS Read the BATTERY section carefully If the vehicle is not in use for a long period of time remove the battery and place it in a cool dry place Recharge the ba...

Page 37: ...creases during recharging Restore the fluid level by adding distilled water BATTERY RECHARGING Remove the battery see REMOVING THE BATTERY Remove the plugs from the elements Check the level of battery electrolyte see along side CHECKING THE LEVEL OF BATTERY ELECTROLYTE Connect the battery to a battery charger We recommend recharging using un amperage 1 10 of the battery capacity Once recharging is...

Page 38: ... Periodically remove the spark plug clean to remove carbon deposits and replace if necessary To access the spark plug Remove the left inspection cover see REMOV ING THE RIGHT AND LEFT INSPECTION COV ERS To remove and clean Before proceeding to the next steps let the engine and muffler cool to ambient temperature to avoid burns Move the coolant hose 1 for better access Disconnect the cap 2 of the s...

Page 39: ...IONS otherwise you may compromise the performance and life span of the engine Insert the spark plug cap correctly so that it does not vibrate off Remount the left inspection cover see REMOV ING THE RIGHT AND LEFT INSPECTION COV ERS CAUTION 0 7 0 8 mm 0 027 0 031 in Standard CHAMPION RG6YC SPARK Alternatively NGK CR7EKB PLUG Spark plug gap 1 2 3 4 5 ADJUSTING THE THROTTLE CONTROL Carefully read MAI...

Page 40: ... up the saddle unscrew and remove the six screws 3 fastening the air filter cover to the saddle support lower molded cover While lifting the air filter cover make sure not to disconnect the intake coupling of the filter case Carefully lift the air filter cover 4 Remove the air filter 5 CLEANING Do not use fuel or flammable solvents to wash the filter element to avoid the risk of fire or explosion ...

Page 41: ...components become very hot and remain hot for some time even after the engine has been shut off Before handling these components wear insulating gloves or wait until the engine and exhaust sys tem have cooled down Stop the engine and let it cool to allow the oil to drain into the half case and cool NOTE If you do not carry out the previous opera tions you risk taking an incorrect measurement of th...

Page 42: ...gine oil every 1 875 miles 3 000 km see CHECKING THE ENGINE OIL LEVEL AND TOPPING UP NOTE Use oil with 5 W 40 specifications see LU BRICANT CHART When topping up engine oil we recommend that you never exceed the MAX level It is necessary to check the engine oil after the first 625 miles 1 000 km and then every 3 750 miles 6 000 km replace oil every 1 875 miles 3 000 km check level top up NOTE Plac...

Page 43: ...n the engine oil drain plug 4 Fill through the filling hole 2 with approximately 103 7 cu in 1700 cc of engine oil Tighten the oil level dipstick 1 Start the vehicle and let it run for a few minutes Shut it off and let it cool Check the engine oil level again using the dipstick 1 and top up if neces sary without ever exceeding the MAX level When topping up and changing oil use new oil of the type ...

Page 44: ...e MAX marking or below the MIN marking as this could seriously damage the engine Top up if necessary TOPPING UP Add a small amount of oil through the filling hole 2 and wait about a minute for the oil to flow evenly within the half case Check the oil level and top up if necessary Top up with small amounts of oil until the pre scribed level is reached When you have finished tighten the cap dipstick...

Page 45: ... tighten the transmission oil drain screw 2 Top up the transmission with approximately 18 3 cu in 300 cc of oil of the type prescribed in the lubricant chart Tighten the cap dipstick 1 Check the transmission fluid level again using the dipstick 1 and top up if necessary without ever exceeding the MAX level When topping up and changing oil use new oil of the type indicated in the LUBRICANT CHART WA...

Page 46: ...are located beneath the handle bar cover close to the brake lever couplings Check the level of brake fluid in the tanks on a regular basis see CHECKING as well as the wear of the pads see CHECKING WEAR OF THE BRAKE PADS Do not use the vehicle if any liquid is leaking from the brake system CHECKING To check the level NOTE Place the vehicle on a firm flat surface Place the vehicle on the center stan...

Page 47: ...efully read DISC BRAKES The following information refers to a single brake system but is valid for both systems Check the wear of the brake pads after the first 625 mi 1 000 km and every 1 250 mi 2 000 km thereafter The wear of the disc brake pads depends on use riding style and road conditions Wear is increased during use on dirty or wet roads It is especially important to check the wear of the b...

Page 48: ...to the ground Remove the gasket above the cover Make sure that the level of the fluid completely covers the glass gauge 6 and top up if necessary Remove the protection cap 7 from the bleeder nip ple Connect a transparent tube 9 to the bleeder nip ple 8 Do not contaminate the pads or the disc with brake fluid Place the free end of the transparent tube into a con tainer 10 Slowly pull the brake leve...

Page 49: ...y dan gerous for the vehicle and the rider it is abso lutely necessary to bleed the hydraulic circuit after the brakes have been refitted and normal conditions of brake system use have been re stored NOTE The left hand pump lever acts on the rear caliper and on the front right hand caliper 2 3 1 1 6 4 5 Suck out the oil from the bleeder nipple 4 of the front right hand caliper 5 using the specific...

Page 50: ...uid tank 2 approx 2 3 times Never completely empty the oil from the fluid tank 2 in order to prevent air from entering the sys tem 7 8 7 9 6 8 10 CAUTION Proceed to refit the rear brake caliper Remove the front outer shield see REMOVING THE FRONT OUTER SHIELD Suck out the oil from the bleeder nipple 11 of the delaying device 12 using the specific equipment and unscrewing the bleeder nut 11 by half...

Page 51: ...remove the plug of the expansion tank while the engine is warm because the coolant is under pressure and at a high temperature May cause serious burns and or damage in con tact with skin or clothes If this is not the case unscrew and remove the filling cap below the front outer shield Top up until the coolant level approximately reaches the MAX level Do not exceed this level otherwise the coolant ...

Page 52: ...use serious burns and or damage in con tact with skin or clothes Unscrew and remove the cap 1 of the expansion tank 2 Place a container with a capacity of more than 91 5 cu inches 1500 cc under the base beneath the out let coupling Unscrew and remove the hose clamp 3 and discon nect the coupling Let the coolant flow out completely into the container then pour it into a collection container for liq...

Page 53: ... 5 on the thermostatic valve 6 let a small quantity of fluid flow out together with any air bubbles then tighten the bleeder screw 5 Check the level of the coolant in the expansion tank 2 and top up to the MAX level to bleed it see page 2 24 BLEEDING THE CIRCUIT Run the engine for a few kilometers until it reaches normal working temperature Switch off the engine and wait until both the engine and ...

Page 54: ...ront side This means that the thermostatic valve is open and the circuit is filled up Close the bleeder nipple NOTE The fact that the electric cooling fan switches on is not indicative since the sensor which triggers the fan is fitted to the cylinder head and not to the radiator 2 Connect a transparent rubber pipe 2 between the bleeder and the expansion tank Open the bleeder nut 3 by half a turn F...

Page 55: ...2 in order not to damage the steering bearings Tighten the register nut 2 until the bearing play has been recovered Check the play by shaking the fork in the direction of travel and making sure that steering turns both freely and fluidly Hold the register nut 2 firmly in position and tighten the counter nut 1 with a wrench Counter nut 1 tightening torque 110 Nm 11 kgm Repeat the penultimate operat...

Page 56: ...n of the front suspension joints see FRONT SUSPENSION CHECKING THE REAR SUSPENSION Carefully read PRECAUTIONS AND GENERAL INFORMATION Check the rear suspension after the first 625 miles 1 000 km and then every 3 750 miles 6 000 km or every 8 months Check that the shock absorbers show no sign of oil leakage Check that all parts are correctly tightened and check the operation of the rear suspension ...

Page 57: ...D ADJUSTMENT FOR REAR SUSPENSION SPRING TIRES This vehicle is equipped with tubeless tires no inner tube Periodically check the inflation pressure of the tires at ambient temperature see TECHNICAL SPECIFICATIONS If the tires are warm the measurement will not be correct Always measure before and after any long trips If the inflation pressure is too high the shocks of rough terrain are not absorbed ...

Page 58: ...they are not completely worn out they may harden and be unable to ensure good adherence In this case have the tires replaced Have the tire replaced if worn or if the tread area contains any puncture larger than 0 196 in 5 mm across After repairing a tire have the wheels balanced Use only tires of the size indicated by the manu facturer see TECHNICAL SPECIFICATIONS Never install tires with inner tu...

Page 59: ...ts stability and handling and may damage the tires MAX LOAD 396 8 lbs 180 Kg FRONT REAR ONLY RIDER FULL LOAD passenger driver 30 4 psi 2 1 bar 33 3 psi 2 3 bar 31 9 psi 2 2 bar 37 7 psi 2 6 bar After thorough testing aprilia has approved only the following makes of tire for this model MANUFACTURER DIMENSIONS MODEL FRONT FRONT REAR REAR MICHELIN CHENG SHIN MAXXIS 120 70 15 56S 140 60 14 64S 120 70 ...

Page 60: ...Engine chap 3 3 1 Release 00 2002 09 3 Engine Atlantic 500 ...

Page 61: ...4 above head Injector 5 FRONT Tappet cover 6 Head 7 Cylinder 8 RIGHT SIDE Oil pressure sensor 9 Engine oil filter 10 Exhaust muffler 11 see REMOVING THE EX HAUST MUFFLER Water pump 12 Ignition casing 13 Flywheel Stator coil Pulse generator pick up LEFT SIDE Transmission belt box air filter Transmission cover carter 14 Speed variator unit Clutch unit Drive belt 4 6 7 For removals of parts not descr...

Page 62: ...eel hubs the right and left handlebar controls brake pump the instruments and gauges the exhaust outlet glove compartment or the ignition switch steering lock Clean the engine and connected components Mark all cables hoses pipes etc to avoid getting them mixed up when refitting During reassembly be sure to insert the parts correctly Unscrew and remove the screw 1 that fastens the fuel injector sup...

Page 63: ...hrottle unit control Slide out the cable duct and relevant return barrel 18 on the throttle unit control 8 10 Disconnect the water outlet hose 11 from the cylin der by loosening the screw 12 of the hose clamp 13 on the coupling above the cylinder Disconnect the electric connection 14 of the coolant temperature sensor 15 Disconnect the electric connection 19 of the stroke sensor 20 and free the cab...

Page 64: ...mponents and motorcycle Agree beforehand on how to divide up the tasks the tasks are marked as follows those marked A are to be done by the first operator and those marked B by the second operator the proce dure to follow This procedure is designed to ensure the safety of both mechanics PROCEED WITH GREAT CARE WARNING 21 22 26 23 WARNING The size and weight of the motorcycle may cause it to tilt d...

Page 65: ...ting on the ground B Unscrew and remove the left pin 29 that fixes the engine to the frame and retrieve the washer A Support the left hand side of the engine CAUTION B Unscrew and remove the right pin 30 that fixes the engine to the frame and retrieve the washer Proceed with care Beware of finger and limb injuries Take care when lifting and moving the motorcycle CAUTION A and B Lower the complete ...

Page 66: ...Fuel system chap 4 4 1 Release 00 2002 09 4 Fuel system Atlantic 500 ...

Page 67: ...pt constant according to ambient pressure The supply circuit is comprised of Fuel pump Fuel filter Fuel Injector Pressure regulator The pump filter and regulator are inserted into the fuel tank on a single support The fuel injector is connected by two pipes with snap on couplings This forms a continual circuit that prevents the risk of fuel boiling The pressure regulator is located at the end of t...

Page 68: ... FUEL SUPPLY SYSTEM FUEL SUPPLY SYSTEM KEY 1 Fuel pump 2 Fuel tank 3 Intake manifold 4 Fuel supply pipe DELIVERY 5 Fuel supply pipe RETURN 6 Excess gasoline bleeder pipe 7 Fuel injector 8 Fuel level float 9 Fuel pump filter 10 Filler cap 5 3 8 9 6 1 10 2 4 7 ...

Page 69: ... REMOVING THE CENTRAL TUNNEL Place a container with a capacity of approx 0 264 gallons 1 l alongside the vehicle This is to recover fuel Work with caution Collect the fuel that comes out of the fuel supply pipe RETURN Disconnect the fuel supply pipe RETURN from the fuel pump 5 see FUEL SUPPLY SYSTEM drawing Place the free end of the pipe into the container Set the ignition switch to Without accele...

Page 70: ... Avoid fuel contact with skin Do not smoke or use naked flames Dispose of fuel correctly Remove the central tunnel see REMOVING THE CENTRAL TUNNEL Disconnect the electric connection 1 that controls the fuel pump Disconnect the fuel supply pipes 2 from the body of the fuel pump Unscrew and remove the six nuts 3 Remove the fuel pump fastening bracket 4 CAUTION CAUTION Work with caution when removing...

Page 71: ... LEVEL PROBE To disassemble these parts see the ENGINE WORK SHOP MANUALS n 1063 n 1064 n 1065 n 1066 n 1067 and n 1068 THROTTLE UNIT 1 Stepper motor 2 Throttle position sensor 3 Air temperature sensor 4 Valve 5 Valve opening cable support plate 6 Valve opening closing wiring control guide 4 1 2 5 3 6 ...

Page 72: ...rburetor control Slide out the cable guide and relevant return barrel 9 on the carburetor control Disconnect the electric connection 4 of the air temperature sensor Disconnect the electric connection 5 of the stepper motor Disconnect the electric connection 6 of the throttle position sensor Disconnect the delivery and return fuel supply pipes 1 of the fuel injector Unscrew and remove the screw 2 t...

Page 73: ... manifold 11 and throttle unit 12 12 12 11 15 14 13 Unscrew and remove the three screws 13 that fasten the throttle unit 12 to the intake manifold 11 Remove the throttle unit 12 from the intake manifold 11 Unscrew and remove the screw 14 that fastens the fuel injector 15 to the intake manifold Remove the fuel injector 15 from the intake manifold 11 10 11 10 ...

Page 74: ...Cooling system chap 5 5 1 Release 00 2002 09 5 Cooling system Atlantic 500 ...

Page 75: ... is the main circulation involving pump cylinder head radiator and expansion tank For medium thermostat openings both circuits are partially enabled and therefore the two paths overlap This type of circuit is defined as having an intake thermostat The thermostat is crossed by an inverse flow that is with cold water which tends to lower the temperature of the wax cell This system allows optimizatio...

Page 76: ...lecting material Disconnect the three hoses 1 on the radiator Unscrew and remove two radiator fastening screws 2 Proceed with care Do not damage the radiator fins Remove the radiator 3 turning it slightly clockwise and pulling towards the left side of the vehicle CAUTION 1 1 1 3 2 REMOVING THE ELECTRIC COOLING FAN Read carefully PRECAUTIONS AND GENERAL INFORMATION Remove the radiator see REMOVING ...

Page 77: ...ter in position to catch the fluid as it comes out Place an absorbent cloth under the expansion tank to catch any coolant that spills out NOTE Prepare screwdriver type worm clamps to replace the original clamps special type without screws Remove the clamp 3 Replace with a new clamp when reassembling Slide the sleeve 4 out from the expansion tank coupling Remove the clamp 5 Replace with a new clamp...

Page 78: ...E WORKSHOP MANUAL n 1063 n 1064 n 1065 n 1066 n 1067 and n 1068 COOLANT PUMP For information on the coolant pump see ENGINE WORKSHOP MANUAL n 1063 n 1064 n 1065 n 1066 n 1067 and n 1068 COOLANT THERMISTOR For more information about the coolant thermistor see ENGINE WORKSHOP MANUALS n 1063 n 1064 n 1065 n 1066 n 1067 and n 1068 ...

Page 79: ...Cooling system chap 5 5 6 Release 00 2002 09 Atlantic 500 ...

Page 80: ...Electrical system chap 6 6 1 Release 00 2002 09 6 Electrical system Atlantic 500 ...

Page 81: ... reading is less than 13 V or greater than 15 V Check the function and continuity of the alternator without load see CHECKING THE ALTERNATOR WITHOUT LOAD and CHECKING THE ALTER NATOR CONTINUITY and the voltage regulator see VOLTAGE REGULATOR Key to second figure 17 Voltage regulator 19 Battery 37 Ignition switch right hand dimmer 24 Main fuse Standard charge voltage 13 to 15 V d c at 5 000 rpm CHE...

Page 82: ...nity VOLTAGE REGULATOR Remove the rear part of the fairing see REMOV ING THE REAR PART OF THE FAIRING Remove the right side panel see REMOVING THE SIDE PANELS Disconnect the connectors 1 and 2 Using a portable tester scale x 1 kΩ test from the regulator side the resistance between the wires indicated in the table below If the resistance reading is incorrect change the regulator Tester positive ter...

Page 83: ...20 21 22 Gr N Ar V M N R N 9 30 87 86 85 Ar V V R Ar N V R 52 R M Ar N V N R M Ar V R B 10 Gr N 3 5 2 1 C E A D F B R Gr 1 1 15A 15A 3A 15A 15A M V R B Gr N N R V R R INIETTORE BENZINA POMPA BENZINA SPIA CAVALLETTO R N R Gr V N R Bi R Gr R N 35 37 Key 9 Main fuel injection relay 10 Secondary fuel injection relay 11 Side stand switch 19 Battery 35 Key commutator 37 Right hand dimmer 52 E C U contro...

Page 84: ...to the side stand 1 to prevent or interrupt engine operation when the side stand 1 is lowered To check the working state of the safety switch 3 proceed as follows Sit on the vehicle in the riding position Bring up the side stand 1 Start the engine Release the accelerator handle and idling the engine lower the side stand 1 which will trigger the safety switch 3 At this point the engine must stop th...

Page 85: ...male terminals 85 86 Use a tester as an ohmmeter to check the continuity between the other two terminals 87 30 Correct value with relay energized 0 Ω Ω Ω Ω Ω Correct value with relay not energized Ω Ω Ω Ω Ω If the values do not correspond to those given above replace the relevant relay switch For main fuel injection relay only Respect polarity energizing the terminal 86 with and the terminal 85 wi...

Page 86: ...3 24 19 20 21 22 1 3 Az Ro Vi G Gr Ro G 52 R M Ro Ar Bi G Gr Vi N Ro N Gr R B Vi M Bi Gr R N Gr Ro N Ar Gr M Bi M G Gr 2 1 54 R M R B RELE INIEZIONE SECONDARIO Gr N 43 Bi N Ar R R M B Az R R B Ar M R M G B N Az V Az N Gr N Az R Az V Ar R Ro G N Bi N ABS ABS ABS ABS EFI EFI EFI Bi N N N N N RELE VENTOLA R M Key 2 Rev sensor 3 Stepper motor 4 Coil 6 Fuel injector 13 Accelerator sensor 14 Engine air ...

Page 87: ...ontrol unit the measuring method indicated is approximate We recommend carrying out another check by replacing the control unit with another perfectly operating unit or by carrying out the checks listed in the chapter CHECKING THE ELECTRICAL SYSTEM FROM THE C D I CONTROL UNIT CONNECTOR 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 ...

Page 88: ...Ω Az Ro Stepper Motor 6 21 52 Ω Vi G Accelerator Sensor 1 22 5 kΩ M Bi Gr Accelerator Sensor 1 11 1 6 kΩ M Bi M G Fuel Inj Air Terminal 18 22 see tab Ro N Gr Fuel Inj H2 O Terminal 4 22 see tab Ar Gr Drop Sensor 16 22 62 kΩ Ro G Gr Coil 20 0 6 Ω Ar Bi R M Fuel Injector 13 14 5 Ω Gr R R M TERMINAL RATED VALUE CABLE COLOURS With drop sensor in the upright position ...

Page 89: ...spark plug cap 3 Remove the coil 4 4 1 2 Use a pocket tester scale 200 Ω to measure the resistance coil side between the terminals shown in the figure A and B If the resistance is incorrect replace the coil Standard value 0 6 Ω Ω Ω Ω Ω 0 1 Ω Ω Ω Ω Ω Also check the resistance between the high voltage terminal and the coil casing Standard value 7 4 kΩ Ω Ω Ω Ω Before measuring remove the HT cable com...

Page 90: ...als On reassembly make sure that the electrical connector 3 is correctly coupled Use a tester scale x 100 kΩ to measure the resistance between the terminals of the black and black white cables N Bi N Standard value resistance 62 kΩ Ω Ω Ω Ω 15 Remove the sensor 1 and rubber element from its seat and incline it sideways by an angle greater than 45 simulating a situation where the vehicle is lying on...

Page 91: ... three way connector 1 and carry out the relevant measurements Use a tester scale x 100 Ω to measure the resistance between the sensor terminals respect ing the relevant polarity see figure Standard value 680 Ω Ω Ω Ω Ω 10 If the resistance is infinite or different from the prescribed value the sensor must be replaced Ω 1 ...

Page 92: ... the two terminals A and B whatever the position of the throttle Standard value 5 kΩ Ω Ω Ω Ω 10 READING B Resistance between the terminals A and C From the reading with the throttle completely closed progressively accelerating until it is fully open resis tance will vary as follows Standard value from 1 kΩ Ω Ω Ω Ω 6 kΩ Ω Ω Ω Ω 10 NOTE To make unscrewing the two screws easier lock with LOCTITE 243 ...

Page 93: ...t a tester 2 set as an ohmmeter to the thermistor 1 as shown in the figure Immerse the thermistor 1 in a container 3 filled with coolant Immerse a thermometer 4 with a range of 32 302 F 0 150 C in the same container Place the container on a burner 5 and heat the coolant slowly Check the temperature shown by the thermometer 4 and the value of the thermistor 1 as shown on the tester Make sure that t...

Page 94: ...er 3 set as an ohmmeter to the thermistor 2 as shown in the figure Immerse the thermistor in a container 4 filled with water Immerse a thermometer 5 with a range of 32 302 F 0 150 C in the same container Place the container on a burner 6 and heat the water slowly Check the temperature shown by the thermometer 5 and the value of the thermistor 1 as shown on the tester Make sure that the value varie...

Page 95: ...tch 35 Key commutator 37 Right hand dimmer 55 Stop lights relay 56 Third stop bulbs 19 21 20 V R R V R 1 N R Bi G R B R 24 22 R 20A 30A R Bi R R M 11 M V N B M N Gr N Ar V M N R N 9 30 87 86 85 Ar V V R V N C E A D F 1 B R Gr 1 55 87 85 30 86 B B G R N V G 1 15A 15A 3A 15A 15A B Bi R Bi N R V R R 54 58 B R N G R V G R Gr V N R Bi V G B V G B G G R R Gr R N B B V G 31 V G B 31 B 58 54 V G V G B V G...

Page 96: ...he relay 2 Correct value with relay energized 0 Ω Ω Ω Ω Ω Correct value with relay not energized Ω Ω Ω Ω Ω If the resulting values do not correspond to those given replace the relay 2 CAUTION CHECKING THE STOP LIGHTS RELAY To check the working state of the relay proceed as follows To access the relay lift the saddle and remove the left rear light see REPLACING THE REAR LIGHT BULBS Energize 12 V th...

Page 97: ... G G R G Gr G V N R Bi Wires Pos Gr N V G ON Wires Pos V G R N ON Wires Pos N V OPEN CLOSED M PUSH ZADI 9 10 11 12 7 ENGINE STOP SWITCH 8 STARTER BUTTON 9 IGNITION SWITCH 10 FRONT STOP LIGHT SWITCH 11 REAR STOP LIGHT SWITCH 12 SIDE STAND SWITCH Wires Pos Wires Pos Wires Pos ...

Page 98: ...of the electric cooling fan 1 control Directly energize the electric cooling fan with 12 V DC power 2 1 12 CENTRALINA E C U 22 N 24 23 26 25 52 Vi N 21 20 19 17 16 15 14 13 18 2 11 10 9 8 7 6 5 4 3 1 G N 16 1 B G N B 30A 22 R R 19 N R Bi R Bi D F V N 15A 15A 3A 15A 15A B A E C V 24 1 1 86 38 87 30 85 15 Ar Gr 35 R Bi V N G N R Bi Vi N V Key 15 Water thermistor 16 Fan 19 Battery 24 Secondary fuses ...

Page 99: ...nergize 12 V the two male terminals 85 86 Use a tester as an ohmmeter to check the continuity between the other two terminals 87 30 Correct value with relay energized 0 Ω Ω Ω Ω Ω Correct value with relay not energized Ω Ω Ω Ω Ω If the values do not correspond to those given replace the relevant relay switch CHECKING THE WATER THERMISTOR See CHECKING THE CONDITION OF THE COOL ANT THERMISTOR on page...

Page 100: ...D F V N 15A 15A 3A 15A 15A B A E C V 24 1 1 13 B B W SET 9 10 11 12 6 7 8 2 3 4 5 1 Ar R 1 B 15 14 16 9 8 7 5 6 4 2 3 1 B V Bi N TRIP 20 19 18 16 17 15 14 13 12 11 10 x1000r min EFI EFI EFI ABS ABS ABS ABS EFI 43 Km h mp h 8 Ar N G V 35 R Bi V N Key 8 Fuel level probe 15 Water thermistor 19 Battery 22 Main fuses 24 Secondary fuses 35 Key commutator 43 Dashboard ...

Page 101: ...ANT THERMISTOR on page 6 14 FUEL LEVEL CHECKING THE DASHBOARD Disconnect the connector of the pump assembly and connect from the connector side an electrical resistor between the yellow green and orange black cables Turn the key to ON and check the signal on the dashboard Connector values resistance 250 Ω indication 1 2 scale 5 resistance 3 Ω indication full resistance 820 Ω indication empty and i...

Page 102: ... pressed saddle down value PASSING STOP SCROLL 19 V R R V R 1 N R Bi 24 22 R 20A 30A R Bi R V R V R R Bi V C E A D F B 26 Ar N B 1 25 1 15A 15A 3A 15A 15A V N R Bi B G R V R R 54 58 G N G B G V N V Gr N G N B Gr Bi V N V N R Bi G Gr G V Bi N G N Gr B G N G Gr V G Gr B G B G 31 G B 31 B 58 G 54 G B B G B B G B G B Bi N B Bi N B B Bi N B Bi G G 35 1 27 40 31 37 39 31 50 48 49 Key 19 Battery 22 Main ...

Page 103: ...ght direction indicator 47 Front left direction indicator HANDLEBAR LEFT SIDE CONTROLS NOTE The electrical components only work when the ignition switch is in the position MODE BUTTON MODE Press repeatedly to select the different data shown on the multifunction LCD HAZARD BUTTON ENABLING Press to enable the four indicators At this point it is possible to turn the ignition switch to the position an...

Page 104: ...atch function indicator 3 scheduled mainte nance due icon 4 average speed icon in miles per hour mph 5 average speed 6 battery voltage icon 7 average speed expressed in kilometers per hour icon Km h 8 The same icon is used for the consumption levels function expressed with the symbol Km l consumption levels espresso in ml G used only for the versions 9 maximum speed icon 10 external temperature ic...

Page 105: ...RESET Hold the key 1 TRIP RESET down for longer than three seconds only when the stopwatch is stopped 1 PU SH ZADI ODO TRIP 1 TRIP 2 2 3 4 5 DIGITAL ODOMETER NOTE The LCDs operate only with the ignition switch set to When the ignition key 1 is turned to position all segments are activated on the LCD to perform a functional test of components and the odometer will always be displayed The following ...

Page 106: ... 5 7 8 9 10 11 12 13 14 15 17 16 18 19 20 1 5 4 3 2 8 7 6 16 12 11 10 9 13 14 15 EFI TRIP SET W mp h x1000r min Km h B 42 Ro M 43 1 1 1 44 45 Vi Gr B Gr Bi M Ro Gr B Vi Gr Bi B Ar Gr Bi ABS ABS ABS ABS EFI EFI EFI V B Ar B Ar Key 42 Dashboard air temperature thermistor 43 Dashboard 44 Speed sensor 45 Oil pressure sensor ...

Page 107: ...f the engine oil pressure should light up If the red LED does not light up check the working state of the sensor Use a tester scale 100 Ω to check the continuity between the tab terminal 1 and the body of the sensor 2 see figure Correct value engine off 0 Ω Ω Ω Ω Ω Correct value engine on Ω Ω Ω Ω Ω If the values do not correspond to those given check to see that the engine oil level is correct see...

Page 108: ... gray white Gr Bi and blue orange B Ar cables Correct value 6 V c c 3rd Test Place the vehicle on the rear support stand Carry out the 2nd test Turn the front wheel by hand so that one of the screws 4 is level with the sensor 3 The tester reading will move to zero V for approximately 2 seconds before returning to 6 V If the 1st test shows an incorrect value disconnect the sensor 3 and repeat the t...

Page 109: ...ith a con trolled temperature of 68 F 20 C Use an ohmmeter scale 0 20 kΩ to measure electrical resistance between the terminals of the connector 1 Correct value 12 200 kΩ Ω Ω Ω Ω 12 700 kΩ Ω Ω Ω Ω If the air temperature sensor is operating correctly check the dashboard Apply a resistance of 12 4 kΩ between the sensor terminals cabling side If the dashboard is operating correctly it should show a t...

Page 110: ...e for each switch Replace the switch if it is faulty 1 HORN BUTTON 2 DIRECTION INDICATOR SWITCH 3 HIGH LOW BEAM SELECTOR HIGH BEAM BLINK BUTTON PASSING 4 MODE BUTTON MODE 5 HAZARD BUTTON 6 LIGHTS SWITCH Wires Pos Gr B Wires Pos B Bi Az R B N STOP Wires Pos G N N Bi V N PASSING Wires Pos Ro V SCROLL Wires Pos B Bi M Wires Pos V N G G N 7 6 8 MODE PASSING 3 1 4 2 5 ...

Page 111: ... HEADLIGHT BULBS Read carefully BULBS The headlight contains two high beam bulbs 1 one low beam bulb 2 one parking light bulb 3 To replace Removing the front hood see REMOVING THE FRONT HOOD LOW BEAM BULBS To extract the bulb electric connector do not pull its electric wires Grasp the bulb electric connector 4 pull it and disconnect it from the bulb 5 Rotate the bulb socket 6 counterclockwise and ...

Page 112: ...COVER Remove the battery see REMOVING THE BATTERY Check the electrolyte level in the battery see CHECKING THE ELECTROLYTE LEVEL Recharge the battery see RECHARGING THE BATTERY RETURN UNDER WARRANTY Carefully read BATTERY The warranty will be considered null and void if the battery shows signs of the following Damage dented container bent poles etc Diffuse sulphation incorrect activation and or use...

Page 113: ...the bulb socket do not pull the electri cal cables Working from the front of the vehicle grasp the bulb socket 11 turn it and extract it from the seat Remove the parking light bulb 12 and replace it with another of the same type CAUTION CHANGING TAILLIGHT BULBS Read carefully BULBS The taillight houses Two parking light brake light bulbs 1 Two rear direction indicator lamps 2 To replace Lift the s...

Page 114: ...void damaging the lens CAUTION CHANGING THE FRONT DIRECTION INDICATOR LAMPS Carefully read alongside BULBS To replace Removing the front hood see REMOVING THE FRONT HOOD Alternatively it is possible to remove the case covers to reach the bulbs see REMOVING THE DASHBOARD Work very carefully Do not damage the tabs and or slots into which they are fitted CAUTION For the LEFT direction indicator Worki...

Page 115: ... remove the screw 1 fastening the transparent part to the battery cover Remove the transparent part 2 by pulling it downward Do not pull on the wires to remove the bulb socket Grasp the socket 3 pull it and remove it from its seat Remove the bulb 4 and replace it with another of the same type CAUTION CHANGING THE THIRD STOP LIGHT BULBS Carefully read BULBS To replace Lift the saddle see LOCKING RE...

Page 116: ...avoid damaging the protective shield VERTICAL ADJUSTMENT HEADLIGHT BEAM To quickly check the correct adjustment of the beam place the vehicle on flat ground 32 81 ft 10 m away from a wall Switch on the headlight sit on the vehicle and make sure that the headlight beam projected onto the wall is just below the horizontal line of the projector approximately 9 10 of the total height To adjust the hea...

Page 117: ...t NOTE If a fuse blows frequently there is probably a short circuit or overload in the electrical system In this case see an aprilia dealer Check the fuses whenever an electric component does not work or works irregularly or if the vehicle fails to start First check the 3 A and 15 A fuses and then the 20 30 A fuses To check Remove the battery cover see REMOVING THE BATTERY COVER or remove the fron...

Page 118: ...n dashboard fan relay radio power supply Seat C on the wiring dia gram 15A Fuse 5 From the main fuse to the power socket in the stor age compartment 3A Fuse 6 From the voltage regulator to the permanent power supply of the ECU Control unit Slot E on the wiring diagram 15A Fuse 7 Spare 3A Fuse 8 Spare Free 9 MAIN FUSE LAYOUT BATTERY COMPARTMENT 20A Fuse 10 From battery to ignition switch fuse 2 hel...

Page 119: ...rottle sensor 14 Engine air thermistor 15 Engine dashboard H2O thermistor 16 Fan 23 Current socket 24 Secondary fuses 25 Storage compartment light 27 License plate lamp 28 Radio power supply 30 Left rear direction indicator 31 Parking brake lamps 33 Rear stop switch 39 Left dimmer switch 40 Horn 43 Dashboard 47 Left front direction indicator 49 Highbeam bulbs 50 Parking light bulb 51 Headlight 53 ...

Page 120: ...relay 17 Voltage regulator 18 Flywheel 19 Battery 20 Starter relay 21 Starter motor 22 Main fuses 26 Storage compartment light switch 29 Right rear direction indicator 31 Parking brake lamps 32 Right taillight 34 Front stop switch 35 Key selector switch 36 Overturn sensor 37 Right dimmer switch 38 Fan relay 42 Dashboard air thermistor T 44 Speed sensor 45 Oil pressure sensor 46 Right front directi...

Page 121: ...1 1 1 44 45 26 Ar N B 55 87 85 30 86 B B G R N V G 1 25 1 57 15A 15A 3A 15A 15A V N Bi N Ar R M V B Bi R Bi R M B Az R R B Ar V G M R M G B N Az V Az N Gr N N N Ar N G V B N R Bi B Bi Az R R Bi Bi G R Bi Az Bi Vi M V R Az Gr B Az V Gr Bi Ar R M Bi N Ar B Ar V Ro G Gr Bi N B G B Gr B Vi R Bi Ro G N Bi N V Gr Bi B Ar Gr Bi B Ar 1 B B G ABS ABS ABS ABS EFI EFI EFI D POWER SOCKET A FUEL INJECTION STAR...

Page 122: ...ght switch 27 License plate lamp 28 Radio power supply 29 Right rear direction indicator 30 Left rear direction indicator 31 Parking brake lamps 32 Right taillight 33 Rear stop switch 34 Front stop switch 35 Key selector switch 36 Overturn sensor 37 Right dimmer switch 38 Fan relay 39 Left dimmer switch 40 Horn 42 Dashboard air thermistor T 43 Dashboard 44 Speed sensor 45 Oil pressure sensor 46 Ri...

Page 123: ...Electrical system chap 6 6 44 Release 00 2002 09 Atlantic 500 ...

Page 124: ...Cycle parts chap 7 7 1 Release 00 2002 09 7 Cycle parts Atlantic 500 ...

Page 125: ...he four screws 3 on the right and the four screws on the left Remove the breather pipe from the expansion tank 1 1 2 CAUTION CAUTION LOCKING RELEASING THE SADDLE Insert the key 1 in the ignition switch 2 Press and turn the ignition key 1 counter clockwise The pneumatic piston keeps the saddle 3 raised and lights the saddle compartment To lock the saddle lower and press without forcing until the lo...

Page 126: ...CENTRAL TUNNEL Place the motorcycle on the center stand Remove the saddle see UNLOCKING LOCKING THE SADDLE Remove the left and right inspection covers see REMOVING THE LEFT AND RIGHT INSPECTION COVERS Remove the leg shield see REMOVING THE LEG SHIELD Proceed with care Do not damage the tabs and or corresponding tab slots Handle painted parts carefully without scraping or damaging them Unscrew and ...

Page 127: ...ver to force up the bottom of the inspection cover 4 until it leaves its seat When reassembling insert the tabs correctly in their slots CAUTION CAUTION REMOVING THE LEG SHIELD Place the motorcycle on the center stand Proceed with care Do not damage the tabs and or corresponding tab slots Handle painted parts carefully without scraping or damaging them Remove the rubber footrest cover by lifting i...

Page 128: ...d with care Do not damage the tabs and or corresponding tab slots Handle painted parts carefully without scraping or damaging them Using a flathead screwdriver 3 along the perimeter of the leg shield prize it away from its slots CAUTION Once the leg shield is free of all slots pull it away gently in order to be able to disconnect the electric connection 6 from the 180 W power socket inside the sto...

Page 129: ... The glove compartment door opens automatically Inside the storage compartment is a 12V power socket 3 The power socket may be used to power appliances requiring no more than 180 W cellular phone flash light etc Extended use of the socket with the vehicle stopped and engine off may partly drain the battery CAUTION REMOVING THE FRONT MUDGUARD Place the motorcycle on the center stand Proceed with ca...

Page 130: ...vers see REMOVING THE LEFT AND RIGHT INSPECTION COVERS Remove the passenger footboards see REMOVING THE PASSENGER FOOTBOARDS Lift the saddle see UNLOCKING LOCKING THE SADDLE Place the vehicle on the center stand Unscrew and remove the 3 screws 1 Unscrew and remove the screw 2 From the inside of the helmet compartment loosen and remove the fastening knob 3 of the light assem bly 4 Gently lift the r...

Page 131: ...rome plated strip by gently bending it in the center CAUTION SEPARATING THE SIDE PANELS Remove the whole side panels see REMOVING THE WHOLE SIDE PANELS Remove the chrome plated strip on the sides see REMOVING THE CHROME PLATED SIDE PANEL STRIP Proceed with care Do not damage the tabs and or corresponding tab slots Handle painted parts carefully without scraping or damaging them Unscrew and remove ...

Page 132: ...ON REMOVING THE SPLASH GUARD Place the motorcycle on the center stand Proceed with care Do not damage the tabs and or corresponding tab slots Handle painted parts carefully without scraping or damaging them Remove the front mudguard see REMOVING THE FRONT MUDGUARD Remove the front wheel see REMOVING THE FRONT WHEEL Unscrew and remove the three screws 4 on the left and right sides of the vehicle CA...

Page 133: ...s supports by prizing out its tabs 3 with a flathead screwdriver Remove the front shield 2 sliding it away from the front of the vehicle CAUTION REMOVING THE PASSENGER BACKREST Lift the saddle see UNLOCKING LOCKING THE SADDLE Loosen and remove the two screws 1 that fasten the backrest to the vehicle Proceed with care when removing the backrest in order not to break the insertion tabs Remove the ba...

Page 134: ... REAR MUDGUARD Place the motorcycle on the center stand Proceed with care Do not damage the tabs and or corresponding tab slots Handle painted parts carefully without scraping or damaging them Unscrew and remove the two screws 1 Remove the license plate light cover Pull off the plastic cover 2 Unscrew and remove the 4 screws 3 CAUTION 3 6 4 3 3 5 3 1 2 3 4 3 3 Gently pull away the rear mudguard 4 ...

Page 135: ... 2 making sure to keep the relevant washers and bushings Remove the rear part of the fairing by sliding it back wards 3 REMOVING THE BOTTOM COVERS Place the motorcycle on the center stand Proceed with care Do not damage the tabs and or corresponding tab slots Handle painted parts carefully without scraping or damaging them Unscrew and remove the two screws 4 Remove the bottom cover 5 CAUTION Still...

Page 136: ... THE LEG SHIELD Remove the central tunnel see REMOVING THE CENTRAL TUNNEL Unscrew and remove the two screws 1 Remove the chrome plated protection pipe 2 Unscrew and remove the 5 screws 3 Remove the footrest support 4 2 1 4 3 5 6 Support the bottom splash guard 5 Disconnect the bleeder pipe 6 from the coolant tank Remove the bottom splash guard 5 ...

Page 137: ...the clips installed on the tabs from falling out Slightly spread the fins of the front hood as shown by the arrows A to release the tabs from the front fairing Lift the bottom of the hood slightly as shown by the arrow B Pull the front hood 3 carefully to remove When reassembling insert the tabs correctly in their slots with the corresponding clips CAUTION CAUTION CAUTION REMOVING THE TOP HANDLEBA...

Page 138: ...nd remove the 3 screws 1 Separate the plastic parts 2 by pulling them out wards REMOVING THE COMPLETE DASHBOARD Place the motorcycle on the center stand Proceed with care Do not damage the tabs and or corresponding tab slots Handle painted parts carefully without scraping or damaging them Use a flathead screwdriver 1 to prize the speaker cover 2 away from its seat as shown in the figure Remove the...

Page 139: ...m the dashboard Remove the complete dashboard 5 REMOVING THE FRONT FAIRING Carefully read MAINTENANCE Place the motorcycle on the center stand Removing the front hood see REMOVING THE FRONT HOOD Loosen and remove the six screws 1 fastening the front fairing to the vehicle Remove the front fairing 2 5 6 1 2 1 REMOVING THE DASHBOARD PANEL Remove the complete dashboard see REMOVING THE COMPLETE DASHB...

Page 140: ... REMOVING THE FRONT SHIELD Remove the complete dashboard see REMOVING THE COMPLETE DASHBOARD Unscrew and remove the screw 1 Unscrew and remove the two screws 2 being sure to keep the relevant self locking nut Unscrew and remove the screw 3 Unscrew the coolant filler cap 4 Unscrew the two screws of the bottom arch above the fork 4 2 1 6 3 6 2 5 Disconnect the electric connection 5 Remove the comple...

Page 141: ...DE PANELS Unscrew and remove the two screws 1 making sure to keep the relevant washers Repeat this operation on the right side also Unscrew and remove the two screws 2 that fasten the saddle lock 3 to the helmet compartment and free the lock from the compartment Slide out the relay 4 by pulling it upwards 2 4 1 3 Remove the battery cover see REMOVING THE BATTERY Remove the battery see REMOVING THE...

Page 142: ...rotection cap 7 Unscrew and remove the nut 8 Slide the cables from the helmet compartment out to the rear Slide out the starter relay cable 9 Slide out the battery cable 10 Slide out the ground cable 11 Slide out the fuse wire 12 10 Disconnect the battery bleeder pipe 13 from its clip 14 Remove the clip 15 and slide out the pin 16 Remove the saddle hinge 17 8 7 6 12 11 13 14 15 16 17 9 ...

Page 143: ...ws 18 18 Unscrew and remove the four screws 19 of the carburetor cover 20 Remove the carburetor cover 20 Use the screw 21 to loosen the clamp 22 and slide out the fuel suction hose 23 by pulling it outwards Unscrew and remove the six screws 24 of the filter case 25 19 20 21 22 23 24 25 24 ...

Page 144: ...ce the old one Remove the hose clamp 26 and slide out the pipe 27 Remove the engine cover 25 by lifting it upwards Disconnect the electric connection 28 of the helmet compartment light switch Remove the helmet compartment 29 by lifting the front section upwards and moving the whole block forwards 26 27 28 29 ...

Page 145: ...00 FRONT WHEEL KEY 1 Wheel pin 2 Km counter sensor 3 Right external spacer 4 Right oil seal 5 Right bearing 6 Wheel 7 Internal spacer 8 Left bearing 9 Left oil seal 10 Left brake disc 11 Right brake disc 12 Left external spacer 2 4 1 11 5 3 6 7 8 9 10 12 ...

Page 146: ...AUTION WARNING 4 3 1 2 1 5 NOTE Perform the following operations on the right side of the vehicle also Unscrew and remove the two screws 1 Remove the brake calliper 2 by withdrawing it carefully Loosen the screw 3 NOTE Observe the assembly order of the parts washers and spacers in order to be able to reas semble them correctly Remove the axle wheel 4 Hold the front wheel 5 and take out the axle 4 ...

Page 147: ...s in order not to misalign or ruin the bearing Insert a pad diameter 0 59 in or 15 mm into the wheel hub and rest it against the left bearing inner ring 3 Hit the pad gently several times with a rubber hammer and remove the bearing Refitting Work from the right side of the vehicle Rest the bearing against the wheel hub Keep the pad perpendicular to the bearing aligned with the wheel axis in order ...

Page 148: ...ng a dial indicator check the radial runout of the pin If it exceeds limit values replace the pin Max radial runout 0 0098 in 0 25 mm Apply grease to the pin bearing contact point only see LUBRICANT CHART Rim Using a dial indicator determine that the radial and axial runout of the rim are within specification Excessive runout is usually caused by worn or dam aged bearings or a bent axle If after c...

Page 149: ... 1 NOTE Perform this operation from the right side of the vehicle also Refit the brake caliper 4 by sliding it carefully onto the brake disc Screw in and tighten the two screws 5 Apply the front brake lever and press on the handle bar repeatedly to move the fork downwards In this way the fork rods will settle correctly Screw in and tighten the wheel pin clamp screw 1 Screw in and tighten the screw...

Page 150: ...Cycle parts chap 7 7 27 7 Release 00 2002 09 Atlantic 500 REAR WHEEL KEY 1 Complete wheel 2 Spacer 3 Oil retainer 4 Brake caliper exhaust support plate 5 Nut 3 2 4 5 1 ...

Page 151: ...wo screws 6 fastening the rear brake caliper 7 Free the rear brake caliper 7 from its support 3 Unscrew and remove the pin 8 fastening the suspen sion 11 WARNING 7 6 5 3 11 8 10 9 Be sure to keep the nut 9 and washer 10 Free the right suspension 11 from its support 3 Using a pneumatic gun unscrew and remove the wheel pin nut 12 Unscrew and remove the two screws 13 that fasten the support 3 to the ...

Page 152: ... the motorcycle on the center stand Wait until the engine and exhaust muffler cool down completely Loosen the clamp 1 using the relevant lock nut that fastens the exhaust muffler to the manifold Unscrew and remove the three bolts 2 fastening the muffler to the support 3 being sure to keep the nuts Remove the exhaust muffler 4 WARNING 2 4 2 3 1 ...

Page 153: ...ANUAL n 1063 n 1064 n 1065 n 1066 n 1067 and n 1068 Rim Using a dial indicator determine that the radial and axial runout of the rim are within specification Excessive runout is usually caused by worn or dam aged bearings or a bent axle If after checking these components you determine the rim still does not meet specification the rim must be replaced Max radial and axial runout 0 078 in 2 mm Tires...

Page 154: ...e 00 2002 09 Atlantic 500 KEY 1 Brake lever 2 Brake fluid pump tank 3 Brake fluid tube 4 Braking delaying device 5 Brake caliper breather valve 6 Tube union screw 7 Brake calliper 8 Brake pads 9 Brake disc 8 1 2 4 3 6 8 7 5 9 7 5 3 9 ...

Page 155: ...ke caliper remove the plate 4 Slide out the two pins 5 Remove the two pads Do not engage the front brake lever after removing the pads this may cause the caliper piston to leave its seat allowing brake fluid to leak Always replace both pads together in order to ensure they are correctly placed inside the caliper Insert two new pads Insert the two pins 5 Position the plate 4 correctly Install the s...

Page 156: ...on does not exceed tolerance levels and if it does replace the disc Brake disc oscillation tolerance 0 004 in 0 1 mm CAUTION REMOVING THE BRAKE DISC Read carefully PRECAUTIONS AND GENERAL INFORMATION Remove the front wheel see REMOVING THE FRONT WHEEL Unscrew and remove the five brake disc screws 7 NOTE Screw in the screws manually and tighten them up in diagonal order in the following sequence A ...

Page 157: ...2 09 Atlantic 500 KEY 1 Brake lever 2 Brake fluid pump tank 3 Brake fluid tube 4 Valve 5 Tube union screw 6 Brake calliper 7 Pad pin 8 Collar 9 Brake pads 10 Anti vibration springs 11 Pad springs 12 Brake disc 3 5 9 10 8 2 11 10 7 4 6 1 12 ...

Page 158: ...age the brake lever after removing the pads this may cause the caliper piston to leave its seat allowing brake fluid to leak Replace the pads 4 Replace the vibration damping plates 5 if they are worn Always replace both pads together in order to ensure they are correctly placed inside the caliper Insert two new pads together with the vibration damping plates taking care to respect the fitting dire...

Page 159: ...f the minimum thickness is less than the limit value even in a single point replace the disc Minimum brake disc thickness value 0 137 in 3 5 mm Use a dial indicator to check that disc oscillation does not exceed tolerance levels and if it does replace the disc Brake disc oscillation tolerance 0 004 in 0 1 mm CAUTION REMOVING THE BRAKE DISC Read carefully PRECAUTIONS AND GENERAL INFORMATION Remove ...

Page 160: ...st rest on the frame and never on the fuel tank for any reason Ensure that the vehicle is stable Unscrew and remove the screw 1 Be sure to keep the nut 2 and relevant washers Unscrew and remove the screw 3 Be sure to keep the nut 4 and relevant washers Remove the front mudguard REMOVING THE FRONT MUDGUARD Prepare a suitable support for the handlebars which remain connected to the vehicle by the el...

Page 161: ...e fork 14 13 Unscrew and remove the locknut 15 Hold on to the fork to stop the motorcycle falling over accidentally NOTE Take care that the inner ball bearings do not come out when sliding off the fork Unscrew and remove the register nut 16 Slide off the plastic gasket 17 Slide off the fork 18 from the steering shell 19 Remove the rotating seat 20 and balls 21 from the top bearing Remove the balls...

Page 162: ...low the disassembly instructions in reverse order including the following steps Make sure that no pipes or cables are twisted NOTE The hole for fastening to the handlebar clamp must be aligned with the cable on the fork pin 4 5 CAUTION CAUTION CAUTION Do not forcefully screw or tighten the register nut 4 in order not to damage the steering bearings Tighten the register nut 4 until bearing play is ...

Page 163: ...g 8 Spring 9 Pumping element 10 Return spring 11 Bottom pad 12 Left rod 13 Dust guard gasket 14 Retaining ring 15 Gasket seal 16 Retainer cap 17 Bushing 18 Left wheel support 19 Washer 20 Bottom screw 21 Right rod 22 Right wheel support 23 Lock screw 24 Bushing 1 21 17 16 15 14 13 11 22 23 19 20 19 20 18 24 24 10 9 8 5 7 3 4 4 7 3 6 6 2 2 17 16 15 14 13 11 12 ...

Page 164: ...n proper working order and if not replace NOTE Check the position of the spring 5 coils with smaller diameter closer together at the top The spring is immersed in oil Avoid drips when removing Slide out the spring 5 Bring the fork to the end of its travel insert a cali brated rod measuring rule into one of the two rods and make sure that there are 3 34 in 85 mm of air between the top rim of the ro...

Page 165: ... the left side of the vehicle also Unscrew and remove the two screws 1 Free the brake caliper 2 from the fork Do not engage the front brake lever after removing the brake caliper this may cause the caliper piston to leave its seat allowing brake fluid to leak CAUTION CAUTION Unscrew and remove the two screws 3 Remove the brake oil pipe retaining plate 4 and retainer 6 Free the piping and brake cal...

Page 166: ...epare a measuring container with a capacity of no less than 12 2 cu in 200 cm3 Retract the rod fully into the wheel support rotate the rod wheel support assembly and bleed the oil into the container CAUTION CAUTION Check the oil quantity If less than 13 72 cu in 225 cm3 top up or replace Unscrew and remove the screw 6 bottom of wheel support and be sure to keep the copper washer 7 Slide out the ro...

Page 167: ...damage and or cracking and replace if necessary Spring Make sure that the spring is in perfect working order Pumping element Make sure it is in perfect working order and replace if there are any signs of damage WARNING ADJUSTING THE REAR SUSPENSION The rear suspension is comprised of a pair of dual effect shock absorbers braking in compression extension fixed to the engine by means of a silent blo...

Page 168: ...ays leave one shock absorber fitted NOTE Perform the following operations on both shock absorbers Unscrew and remove the bottom screws 4 and be sure to keep the nut 5 Unscrew and remove the screw 2 and be sure to keep the nut 3 Remove the shock absorber 6 CAUTION WARNING 2 3 6 5 6 4 Function Attitude Recommended kind of road Notes Spring preload increase The vehicle is more rigid Smooth or normal ...

Page 169: ...Cycle parts chap 7 7 46 Release 00 2002 09 Atlantic 500 ...

Page 170: ...aprilia s p a via G Galilei 1 30033 Noale VE Italy tel 39 041 5829111 fax 39 041 5829190 www serviceaprilia com ...

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