APRILIA Atlantic 300 Service Station Manual
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APRILIA Atlantic 300 Service Station Manual

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SERVICE STATION MANUAL
895759
ATLANTIC 300 i.e.

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Summary of Contents for APRILIA Atlantic 300

  • Page 1 SERVICE STATION MANUAL 895759 ATLANTIC 300 i.e.
  • Page 2 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 update this publication beforehand, to make any changes to components, parts or accessories, which it considers necessary to improve the product or which are required for manufacturing or construction reasons.
  • Page 3 - This manual provides the main information to carry out regular maintenance operations on your vehicle. - This manual is intended to aprilia Dealers and their qualified mechanics; several concepts have been deliberately omitted as they are considered unnecessary. As it is not possible to include complete mechanical notions in this manual, users should have basic mechanical knowledge or minimum knowledge about the procedures involved when repairing scooters.
  • Page 5 INDEX OF TOPICS CHAR HARACTERISTICS TOOL OOLING MAIN AINTENANCE ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE INJEC NJECTION SUSP USPENSIONS BRAK SYS RAKING SYSTEM COOL SYS OOLING SYSTEM CHAS HASSIS PRE DE DELIVERY...
  • Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...

  • Page 7: Safety Rules

    ATLANTIC 300 i.e. Characteristics Rules Safety rules CARBON MONOXIDE If you need to keep the engine running in order to carry out any procedure, please ensure that you do so in an open or very well ventilated area. Never let the engine run in an enclosed area.
  • Page 8 ATLANTIC 300 i.e. Characteristics IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN CARRYING OUT SERVICE WORK. CAUTION DO NOT DISPOSE OF OIL INTO THE ENVIRONMENT. CAUTION KEEP OUT OF THE REACH OF CHILDREN BRAKE FLUID CAUTION THE BRAKE FLUID MAY DAMAGE PAINTED, PVC OR RUBBER SURFACES. WHEN SERVICING THE BRAKE SYSTEM, PROTECT THESE COMPONENTS WITH A CLEAN CLOTH.
  • Page 9 ATLANTIC 300 i.e. Characteristics THE BATTERY ELECTROLYTE IS TOXIC, CORROSIVE AND AS IT CONTAINS SULPHURIC ACID, IT CAN CAUSE BURNS WHEN IN CONTACT WITH THE SKIN. WHEN HANDLING THE BATTERY ELECTROLYTE, WEAR TIGHT-FITTING GLOVES AND PRO- TECTIVE APPAREL. IF THE ELECTROLYTIC FLUID GETS INTO CONTACT WITH THE SKIN, WASH WITH ABUNDANT COOL WATER.
  • Page 10 DO NOT USED COMPRESSED AIR TO CLEAN BEARINGS. NOTE BEARINGS MUST ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTHERWISE, THEY NEED TO BE REPLACED. • Use only ORIGINAL Aprilia SPARE PARTS. • Comply with lubricant and consumables usage guidelines. • Lubricate parts (whenever possible) before reassembling them.

  • Page 11: Vehicle Identification

    ATLANTIC 300 i.e. Characteristics • In presence of dirt, rust, humidity etc., clean the connector's internal parts carefully, using a pressurised air jet. • Ensure that the cables are correctly fastened to the internal connector terminals. NOTE THE TWO CONNECTORS CONNECT ONLY FROM ONE SIDE; CONNECT THEM THE RIGHT WAY ROUND.
  • Page 12 ATLANTIC 300 i.e. Characteristics MANUFACTURER IDENTIFICATION PLATE • Remove the right rubber mat. • Lift the base «1». Dimensions and mass WEIGHT AND DIMENSIONS Specification Desc./Quantity Max. length 2085 mm (82.086 in) Max. width 785 mm (30.905 in) Max. height (to windshield) 1370 mm (53.937 in)
  • Page 13 ATLANTIC 300 i.e. Characteristics Transmission TRANSMISSION Specification Desc./Quantity Variator Continuous, automatic Primary drive V-belt Secondary With gears Engine/wheel total ratio short 1:17.21 long 1:6.06 Capacities CAPACITY Specification Desc./Quantity Fuel (reserve included) 9.5 l (2.509 gal) Fuel reserve 1.5 l (0.396 gal) Engine oil change 1000 cm³...
  • Page 14 ATLANTIC 300 i.e. Characteristics Specification Desc./Quantity Rear suspensions 1 hydraulic shock absorber Rear suspensions - travel 105 mm (4.134 in) Brakes BRAKES Specification Desc./Quantity Front brake Stainless steel disc - Ø 240 x 4.5 mm (9.45 x 0.177 in) - with hydraulic transmission and 3-pistons floating calliper.

  • Page 15: Crankcase And Crankshaft

    ATLANTIC 300 i.e. Characteristics TRANSMISSION Name Torque in Nm Belt support roller screw 11÷13 (8.1÷9.6 ftlb) Clutch assembly nut on driven pulley 45÷50 (33.2÷36.9 ftlb) Driving pulley nut 75÷83 (55.4÷61.3 ftlb) Transmission cover screws 11÷13 (8.1÷9.6 ftlb) Driven pulley shaft nut 54÷60 (39.9÷44.3 ftlb)
  • Page 16 ATLANTIC 300 i.e. Characteristics Name Torque in Nm Screw fixing rotating switch to stand 10 ± 20% (7.4 ftlb) REAR SUSPENSION UNIT Name Torque in Nm Screw fixing shock absorber to chassis 40 ± 20% (29.5 ftlb) Screw fixing shock absorber to engine 40 ±...
  • Page 17 ATLANTIC 300 i.e. Characteristics Name Torque in Nm Screw fixing left and right shells (M 5x25) 1 ± 20% (0.7 ftlb) Anti-vibration weight fixing screw 10 ± 20% (7.4 ftlb) Screw fixing brake pumps to handlebar 10 ± 20% (7.4 ftlb)

  • Page 18: Assembly Clearances

    ATLANTIC 300 i.e. Characteristics ELECTRICAL SYSTEM UNIT Name Torque in Nm Screw fixing voltage regulator to electrical component support- 6 ± 20% (4.4 ftlb) ing plate Screw fixing control unit to electrical component supporting 6 ± 20% (4.4 ftlb) plate Screw fixing coil to chassis 5 ±...
  • Page 19 ATLANTIC 300 i.e. Characteristics CYLINDER - PISTON Specification Desc./Quantity Piston diameter 74.967 +0.014 -0.014 mm Cylinder diameter 75 +0.038 +0.01 mm COUPLING CATEGORIES Name Initials Cylinder Piston Play on fitting cylinder - piston 75.01 ÷ 75.017 74.953 ÷ 74.960 0.050 ÷ 0.064 cylinder - piston 75.017 ÷...
  • Page 20 ATLANTIC 300 i.e. Characteristics - Carefully clean the sealing rings housings. - Measure the sealing rings - pistons coupling clearance using suitable sensors, as shown in the diagram - If clearances measured exceed the limits speci- fied in the table below, the piston should be re- placed by a new one.
  • Page 21 ATLANTIC 300 i.e. Characteristics CRANKSHAFT / CONNECTING ROD AXIAL CLEARANCE Name Description Dimensions Initials Quantity Transmissionside half- 16.6 +0-0.05 D = 0.20 to 0.50 shaft Flywheel-side halfshaft 16.6 +0-0.05 D = 0.20 to 0.50 Connecting rod 18 -0.10 -0.15 D = 0.20 ÷ 0.50 Spacer tool 51.4 +0.05...
  • Page 22 ATLANTIC 300 i.e. Characteristics 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 CHAR - 22...
  • Page 23 ATLANTIC 300 i.e. Characteristics MAXIMUM OFF-LINE ALLOWED Specification Desc./Quantity 0.15 mm 0.010 mm 0.010 mm 0.10 mm CHAR - 23...
  • Page 24 ATLANTIC 300 i.e. Characteristics Characteristic Crankshaft-crankcase axial clearance (H) 0.15 ÷ 0.40 mm - Measure the inside diameter of the connecting rod small end using a bore meter. NOTE IF THE CONNECTING ROD SMALL END DIAMETER EX- CEEDS THE STANDARD DIAMETER, SHOWS SIGNS OF WEAR OR OVERHEATING, REPLACE THE CRANKSHAFT AS DESCRIBED IN THE «CRANKCASE AND CRANK-...
  • Page 25 ATLANTIC 300 i.e. Characteristics BUSHING CATEGORY CRANKCASE BUSHING INSIDE DIAMETER AFTER FITTING HALVES CATEGORY 29.024 ÷ 29.054 29.018 ÷ 29.048 29.018 ÷ 29.048 Combine the crankshaft with two crankwebs category 1 with a crankcase category 1 (or cat. 2 with cat.
  • Page 26 ATLANTIC 300 i.e. Characteristics - Check that the coolant sealing buffer is not rusted. Measure the camshaft seat bearings and rocking lever support pins with a bore meter HEAD BEARINGS Specification Desc./Quantity bearing «A» Ø 12.000 ÷ 12.018 bearing «B»...
  • Page 27 ATLANTIC 300 i.e. Characteristics - Measure the diameter of the valve stem at the three positions indicated in the diagram. STANDARD DIAMETER Specification Desc./Quantity Inlet: 4.987 ÷ 4.972 mm Outlet: 4.975 ÷ 4.960 mm MINIMUM DIAMETER ALLOWED Specification Desc./Quantity Inlet: 4.96 mm...
  • Page 28 ATLANTIC 300 i.e. Characteristics - Check the concentricity of the valve head by placing a dial gauge at right angles to the valve head and rotating it on the «V» shaped support. Characteristic Limit allowed: 0.03 mm Measure the valve guides.
  • Page 29 ATLANTIC 300 i.e. Characteristics - If no faults are found during the above checks, the same valves can be reused. For better sealing results, we recommend grinding the valve seats. Grind the valves gently with fine-grained lapping compound. Upon grinding, keep the cylinder head in horizontal position.
  • Page 30 ATLANTIC 300 i.e. Characteristics - Using a gauge, measure the height of the cams. TANDARD HEIGHT Specification Desc./Quantity Camshaft check: Standard height Inlet: 30.285 mm Camshaft check: Standard height Outlet: 29.209 mm - Check camshaft axial clearance AMSHAFT AXIAL CLEARANCE Specification Desc./Quantity...
  • Page 31 ATLANTIC 300 i.e. Characteristics Slot packing system Characteristic Compression ratio 10.5 ÷ 11.5 : 1 Distance "A" to be measured is a value of piston recess, it indicates by how much the piston crown descends below the plane 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.
  • Page 32 ATLANTIC 300 i.e. Characteristics ENGINE SHIMMING Name Measure A Thickness Shimming 3.70 - 3.60 0.4 ± 0.05 Shimming 3.60 - 3.40 0.6 ± 0.05 Shimming 3.40 - 3.30 0.8 ± 0.05 Products RECOMMENDED PRODUCTS TABLE Product Description Specifications AGIP CITY HI TEC 4T...
  • Page 33 INDEX OF TOPICS TOOL OOLING...
  • Page 34 ATLANTIC 300 i.e. Tooling PECIAL TOOLS Stores code Description AP8140259 Universal 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 TOOL - 34...
  • Page 35 ATLANTIC 300 i.e. Tooling Stores code Description AP8140301 Flywheel extractor 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...
  • Page 36 ATLANTIC 300 i.e. Tooling Stores code Description 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...
  • Page 37 ATLANTIC 300 i.e. Tooling Stores code Description 020375Y 28x30 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...
  • Page 38 ATLANTIC 300 i.e. Tooling Stores code Description 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 TOOL - 38...
  • Page 39 ATLANTIC 300 i.e. Tooling Stores code Description 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 TOOL - 39...
  • Page 40 ATLANTIC 300 i.e. Tooling Stores code Description AP8140916 Hub cover support AP8140252 Multipurpose wrench 020331Y Digital multimeter 020680Y TXB Navigator TOOL - 40...
  • Page 41 INDEX OF TOPICS MAIN AINTENANCE...

  • Page 42: Maintenance Chart

    For servicing or technical advice, consult an Official Aprilia Dealer for prompt and accurate service. Ask your Official Aprilia Dealer to test the vehicle on the road after a repair but nonetheless, personally carry out the Pre-ride Checks after a maintenance operation.

  • Page 43: Spark Plug

    ATLANTIC 300 i.e. Maintenance km x 1,000 Wheels / tyres Suspension Steering Break pad wear Spark plug Check the spark plug at each scheduled maintenance operation. Remove the spark plug regularly, clean off carbon scales, and replace it if necessary.
  • Page 44 ATLANTIC 300 i.e. Maintenance • Make sure the washer is in good con- ditions. Once the washer is fitted, man- ually screw the spark plug to avoid damaging the thread. • Tighten using the spanner supplied in the tool kit, make the spark plug com- plete 1/2 a turn to press the washer.
  • Page 45 ATLANTIC 300 i.e. Maintenance • Unscrew and pull out the measuring cap-dipstick «1». • Clean the area in contact with oil with a clean cloth. • Screw the cap-dipstick «1» fully into its tube. • Remove the cap-dipstick «1» again...
  • Page 46 ATLANTIC 300 i.e. Maintenance WAIT SOME MINUTES UNTIL THE ENGINE AND THE EXHAUST SYSTEM ARE COLD. • Unscrew and take out the measuring cap-dipstick «1». • Remove the rear brake calliper. • Remove the rear wheel. • Remove the rear brake disc and collect the spacer.

  • Page 47: Engine Oil

    ATLANTIC 300 i.e. Maintenance • Clean the inside of the air filter case with a clean cloth. • Clean the intake ducts. CAUTION PARTIAL AIR FILTER CLEANING DOES NOT EXCLUDE NOR POSTPONE AIR FILTER REPLACE- MENT. DO NOT START THE ENGINE WITHOUT THE AIR FILTER.
  • Page 48 ATLANTIC 300 i.e. Maintenance • Stop the engine and let it cool off so that the oil in the crankcase flows down and cools as well. • Unscrew and pull out the measuring cap-dipstick «1». • Place a collecting container with + 1300 cm³...
  • Page 49 ATLANTIC 300 i.e. Maintenance • Stop the engine and let it cool off so that the oil in the crankcase flows down and cools as well. NOTE FAILURE TO FOLLOW THESE OPERATIONS MAY RE- SULT IN AN INCORRECT READING OF THE ENGINE OIL LEVEL.

  • Page 50: Engine Oil Filter

    ATLANTIC 300 i.e. Maintenance Engine oil filter Change the cartridge filter each time you change the oil. Use only the recommended type of oil to top- up and change. Make sure the O-rings of the pre-filter and the drainage plug are in good conditions. Lubricate them and refit the mesh filter and the oil drainage plug.

  • Page 51: Checking The Ignition Timing

    ATLANTIC 300 i.e. Maintenance • Undo and remove the counterweight fixing screw. • Remove the counterweight. • Remove the throttle grip. Checking the ignition timing - Remove the plastic cap on the flywheel cover - Turn the flywheel until the reference mark «T» on the rotor matches the reference mark on the fly- wheel cover as shown in the figure (TDC).

  • Page 52: Cooling System

    ATLANTIC 300 i.e. Maintenance Cooling system • Wash the air intakes behind the front wheel with a pressure water jet; be careful not to bend the radiator fins • From the bottom with compressed air. CAUTION IT IS NOT NECESSARY TO REMOVE THE RADIATOR.

  • Page 53: Braking System

    ATLANTIC 300 i.e. Maintenance DO NOT ADD ADDITIVES OR ANY OTHER SUBSTANCE TO THE COOLANT. WHEN USING A FUNNEL OR ANY OTHER ELEMENT, MAKE SURE IT IS PERFECTLY CLEAN. Top-up Topping up: • Unscrew and remove the filler cap «2».
  • Page 54 ATLANTIC 300 i.e. Maintenance CAUTION BRAKE LEVEL DECREASES GRADUALLY AS BRAKE PADS WEAR DOWN. Level check NOTE THESE OPERATIONS APPLY TO BOTH BRAKES. • Park the vehicle on its centre stand. • Check that the fluid in the reservoir is above the "MIN" reference mark.
  • Page 55 ATLANTIC 300 i.e. Maintenance System check Check brake pads for wear following the instruc- tions on the scheduled maintenance table. Disc brake pad wear depends on the use, the riding style and the roads. To carry out a quick pad check: •...

  • Page 56: Headlight Adjustment

    ATLANTIC 300 i.e. Maintenance Headlight adjustment LIGHT BEAM HORIZONTAL ADJUSTMENT To adjust the light beam: • Open the glove-box «1» and release the end of stroke side rods by pressing them down moderately. • Use a screwdriver to operate on the upper set screws «3»...
  • Page 57 ATLANTIC 300 i.e. Maintenance • Use a screwdriver 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. MAIN - 57...
  • Page 58 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 59 ATLANTIC 300 i.e. Electrical system Components arrangement ELE SYS - 59...
  • Page 60 ATLANTIC 300 i.e. Electrical system 1. Stop light relay - Relay voltage, powered: 0 Ohm - Relay voltage, not powered: endless 2. fall sensor - Voltage with the vehicle in the correct position: 5 - Voltage with the vehicle inclined: 0 V 3.
  • Page 61 ATLANTIC 300 i.e. Electrical system 5. CDI control unit 6. Diagnostics socket 7. Rear light - 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.
  • Page 62 ATLANTIC 300 i.e. Electrical system 9. HV coil - Coil primary resistance: 0.5 Ohm ± 8% - Coil secondary resistance: 3.1 Ohm ± 9% 10. Voltage regulator - Recharging voltage: 13-15 V - No-load voltage at terminals: 45 V 11. Start-up relay...
  • Page 63 ATLANTIC 300 i.e. Electrical system Specification Desc./Quantity 80°(176°) 0.3 kOhm 13. Fuel Level Sensor RESISTANCE BETWEEN THE CABLES (COLOUR - OHM) - CORRECT INDICATION Specification Desc./Quantity Grey/Blue - Blue (1 -16Ohm) [4/4] Grey/Blue - Blue (790-827 Ohm) Grey/Blue - Blue (557 - 627 Ohm) [Low fuel warning light on] 14.
  • Page 64 ATLANTIC 300 i.e. Electrical system 16. Headlamp - High beam light bulb 12V - 55W - Low beam light bulb 12V - 55W - Tail light bulb 12V - 16W - Turn indicator bulbs: 12V - 10W 17. Fan Fan relay, powered: battery supply Fan relay, not powered: not powered 18.
  • Page 65 ATLANTIC 300 i.e. Electrical system 20. Lambda probe 21. Alternator Permanent magnet type. - Supply: battery voltage 12 V - 180 W at 6000 rpm - Resistance: 0.1-1 Ohm - Resistance between the cables and the stator support: endless ELECTRICAL COMPONENT CHECK •...
  • Page 66 ATLANTIC 300 i.e. Electrical system Ro pink V green Vi purple NOTE NUMBERS DISPLAYED ON THE SPECIFIED ELECTRICAL CIRCUIT DIAGRAMS CORRESPOND TO THE GENERAL ELECTRIC CIRCUIT DIAGRAM. ELECTRIC CONNECTORS Disconnect the two electrical connectors strictly observing the following procedure: •...
  • Page 67 ATLANTIC 300 i.e. Electrical system Conceptual diagrams key: 1 Multiple connectors 2 Fuel level transmitter 3 Fall sensor 4 Fan 5 Engine temperature gauge ELE SYS - 67...
  • Page 68 ATLANTIC 300 i.e. Electrical system 6 Fuel gauge 7 Radio pre-installation 8 Antitheft device (Not used) 9 Complete front headlamp 10 Instrument panel lighting bulb 11 Left front turn indicator 12 Tail light bulb 13 Low beam bulb 14 High beam bulb...
  • Page 69 ATLANTIC 300 i.e. Electrical system 44 Pick-Up 45 Oil pressure sensor 46 Injection relay 47 Lambda probe 48 Fuel level sensor 49 Fuel pump 50 Side stand switch 51 Injector 52 Spark plug 53 Coil 54 Fan control relay CABLE COLOUR...
  • Page 70 ATLANTIC 300 i.e. Electrical system Electric characteristic Secondary coil winding resistance 2.9 kOhm ± 10% Primary coil winding resistance 0.2 Ohm ± 10% Pick-up check • Disconnect the pick-up connector. • With a pocket tester (1000 Ohm scale) measure the resistance between the terminals of the red and white cables.
  • Page 71 ATLANTIC 300 i.e. Electrical system 24. Key switch 27. Engine stop switch 38. Auxiliary fuses 39. Main fuses 41. Battery 44. Pick-up 46. Injection relay 50. Side stand switch 52. Spark plug 53. HV coil 56. CDI control unit TROUBLESHOOTING •...
  • Page 72 ATLANTIC 300 i.e. Electrical system • Replace the CDI control unit with another one in proper operating conditions. Battery recharge circuit 39. Main fuses 41. Battery 42. Voltage regulator 43. Alternator RECHARGE VOLTAGE CHECK • Park the vehicle on its centre stand.
  • Page 73 ATLANTIC 300 i.e. Electrical system ALTERNATOR NO-LOAD OPERATION CHECK • Disconnect the voltage regulator con- nector «1». • Start the engine and take it to 5000 rpm (throttle grip twisted approximately 1/4 of its travel). • With the pocket tester measure voltage (alternating current) alternately among the three yellow cables.
  • Page 74 ATLANTIC 300 i.e. Electrical system Standard load voltage: 13-15 V (dc) at 5000 rpm Locking torques (N*m) Screw fixing voltage regulator to electrical component supporting plate 6 ± 20% (4.4 ftlb) Start up system check TROUBLESHOOTING • Check the battery condition.
  • Page 75 ATLANTIC 300 i.e. Electrical system Horn control 21. horn button 23. Horn 24. Key switch 38. Auxiliary fuses 39. Main fuses 41. Battery Horn check • Power the horn directly with 12V at the ends of both terminals. • If it does not work, operate on the cor- responding set screw.
  • Page 76 ATLANTIC 300 i.e. Electrical system Turn signals system check 11. Front left turn indicator bulb 15. Front right turn indicator bulb 18. Turn indicators 22. Turn indicator switch 31. Rear left turn indicator bulb 32. Rear right turn indicator bulb 38.
  • Page 77 ATLANTIC 300 i.e. Electrical system With a tester in voltmeter function, check for intermittent battery voltage between the two component cables (Green - Blue/Black). level indicators FUEL GAUGE 2. Fuel level transmitter 6. Fuel level indicator 24. Key switch 38. Auxiliary fuses 39.
  • Page 78 ATLANTIC 300 i.e. Electrical system RESISTANCE VALUE (OHM) - GAUGE INDICATION Specification Desc./Quantity 10 Ohm Full tank 38 Ohm Half the scale ± 5° 90 Ohm Empty tank and low fuel warning light on FUEL LEVEL SENSOR CHECK • Disconnect the transmitter connector.
  • Page 79 ATLANTIC 300 i.e. Electrical system 41. Battery 55. Coolant temperature sensor 56. CDI control unit COOLANT TEMPERATURE GAUGE CHECK • Disconnect the water thermistor connector and connect (on the connector side) an electrical resistance to the white/blue terminal. • Turn the key to «ON» and check the gauge indications displayed on the panel.
  • Page 80 ATLANTIC 300 i.e. Electrical system 56. CDI control unit COOLANT THERMISTOR OPERATION CHECK • Remove the thermistor «1». • Connect a tester «2» (ohmmeter func- tion) to the thermistor «1» as shown in the figure. • Immerse the thermistor «1» in a con- tainer with coolant «3».
  • Page 81 ATLANTIC 300 i.e. Electrical system Fuses CAUTION NEVER ATTEMPT TO REPAIR FAULTY FUSES. NEVER USE FUSES OTHER THAN THE ONES SPECIFIED. A SHORT CIRCUIT MAY DAMAGE THE ELECTRICAL SYSTEM OR EVEN CAUSE A FIRE. NOTE IF A FUSE BLOWS OUT FREQUENTLY, IT MAY BE DUE TO A SHORT CIRCUIT OR OVERLOAD.
  • Page 82 ATLANTIC 300 i.e. Electrical system MAIN FUSES LAYOUT ( BATTERY COMPARTMENT) Specification Desc./Quantity 20A fuse From the battery to: ignition switch, fan relay, control unit. 15A fuse From the battery to: plug socket, helmet compartment light. SECONDARY FUSES LAYOUT (FRONT CASE) Specification Desc./Quantity...

  • Page 83: Battery Installation

    ATLANTIC 300 i.e. Electrical system Battery installation CHECKING AND CLEANING TERMINALS AND LEADS • Make sure the ignition switch is set to «OFF». • Lift the saddle. • Unscrew and remove the two screws «1». • Remove the battery protection.
  • Page 84 ATLANTIC 300 i.e. Electrical system BATTERY ELECTROLYTE LEVEL CHECK To check electrolyte level: • Rest the vehicle on its centre stand. • Lift the saddle. • Unscrew and remove the two screws «1». • Remove the battery protection. • Check that the electrolyte level is be- tween the two «MIN»...
  • Page 85 ATLANTIC 300 i.e. Electrical system • If the vehicle is inactive longer than fifteen days, it is necessary to recharge the battery to avoid sulphation, • Remove the battery and put it away in a cool and dry place. •...
  • Page 86 ATLANTIC 300 i.e. Electrical system ACTIVATION AND MAINTENANCE • Remove the battery from the vehicle. • Remove the cell caps and the breather cap. • Fill the cells with electrolyte fluid with 1.3 specific weight. • Charge the battery with a slow charge (current rating equal to 1/10 of the battery capacity) for at least 10 hours: Refit battery to the motorcycle upon delivery to customer, that is to say, when a mileage is set.
  • Page 87 ATLANTIC 300 i.e. Electrical system - Engine stop switch (Pin 12) - Engine revolution sensor positive (Pin 13) - Injector (14) - Engine revolution sensor negative (Pin 15) - Diagnosis (Pin 16) - Immobiliser LED (Pin 17) - Side stand (Pin 18)
  • Page 88 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 89 ATLANTIC 300 i.e. Engine from vehicle Exhaust assy. Removal • Rest the vehicle on its centre stand. • Unscrew and remove the two nuts «1». CAUTION ALLOW ENGINE AND EXHAUST SILENCER TO COOL OFF COMPLETELY. Locking torques (N*m) Nut fixing manifold to engine 15 ± 20% (11.1 ftlb) •...
  • Page 90 ATLANTIC 300 i.e. Engine from vehicle EXHAUST SILENCER REMOVAL • Rest the vehicle on its centre stand. CAUTION ALLOW ENGINE AND EXHAUST SILENCER TO COOL OFF COMPLETELY. • Loosen the clamp «1» fixing the exhaust silencer to the manifold. •...
  • Page 91 ATLANTIC 300 i.e. Engine from vehicle The procedure to remove the engine from the chassis is described below sequentially: • Remove the helmet compartment. • Remove the exhaust system. • Remove the calliper from the rear brake disc. • Undo and remove the screw «1» and disconnect the ground connection from the starter motor.
  • Page 92 ATLANTIC 300 i.e. Engine from vehicle • Slide off the pipe «5» 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.
  • Page 93 ATLANTIC 300 i.e. Engine from vehicle • Fasten the belts to the chassis rear section. • Lift the hoist arm until the belts are taut. • Working on the right side, unscrew and remove the nut «8». • From the opposite side, slide off the pin «9»...
  • Page 94 ATLANTIC 300 i.e. Engine from vehicle • From the opposite side, tighten the nut «2». • Insert the pipe «3» in the coolant pump. • Fasten the pipe «3» with the clamp. Locking torques (N*m) Nut fixing connecting rod to engine 40 ± 20% (29.5 ftlb) •...
  • Page 95 ATLANTIC 300 i.e. Engine from vehicle • Connect the following electric connec- tors in order: - Pick UP «6». - Water temperature sensor «7». • Place the starter motor earth cable. • Tighten the screw «8». • Place the starter motor power supply cable.
  • Page 96 ATLANTIC 300 i.e. Engine from vehicle 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) ENG VE - 96...
  • Page 97 INDEX OF TOPICS NGINE...

  • Page 98: Automatic Transmission

    ATLANTIC 300 i.e. Engine This section describes the operations to be carried out on the engine and the tools required. Automatic transmission Transmission cover - To remove the transmission cover, it is necessary to remove the plastic cover first by inserting a screwdriver in the slotted holes.
  • Page 99 ATLANTIC 300 i.e. Engine Air duct - Remove the transmission compartment air intake cover shown in the photograph. - Remove the 5 screws on the 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.
  • Page 100 ATLANTIC 300 i.e. Engine Refitting the driven pulley shaft bearing - Slightly heat the crankcase internal side so as not to damage the coated surface. - Insert the bearing in its housing. - Refit the seeger ring. CAUTION REST THE COVER ON A SUITABLE SURFACE TO AVOID DAMAGING THE COVER COAT.

  • Page 101: Removing The Driven Pulley

    ATLANTIC 300 i.e. Engine Removing the driven pulley - Remove the clutch bell and the entire driven pul- ley assembly. NOTE THE ASSEMBLY CAN ALSO BE REMOVED EVEN IF THE DRIVING PULLEY IS MOUNTED. Inspecting the clutch drum - Make sure that the clutch bell is not worn or dam- aged.

  • Page 102: Removing The Clutch

    ATLANTIC 300 i.e. Engine AP8140915 Crankcase check Inspecting the clutch - Check the thickness of the clutch mass friction material. - The masses must not show traces of lubricants; otherwise, check the driven pulley unit seals. NOTE UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CEN- TRAL FAYING SURFACE AND MUST NOT BE DIFFERENT FROM ONE ANOTHER.
  • Page 103 ATLANTIC 300 i.e. Engine Pin retaining collar - Simultaneously turn and pull the collar manually to remove it. NOTE USE 2 SCREWDRIVERS IN CASE OF ANY DIFFICULTY. NOTE BE CAREFUL NOT TO PUSH THE SCREW DRIVERS IN TOO FAR TO AVOID DAMAGING THE O-RING SEAL.
  • Page 104 ATLANTIC 300 i.e. Engine - Remove the roller bearing using the specific punch. Specific tooling 020376Y Adapter handle 020456Y Ø 24 mm punch 020363Y Crankshaft oil seal punch D 20 mm Inspecting the driven fixed half-pulley • Measure the outside diameter of the pulley bushing.
  • Page 105 ATLANTIC 300 i.e. Engine Inspecting the driven sliding half-pulley - Remove the 2 inner sealing rings and the 2 O- rings; - Measure the inside diameter of the movable half- pulley bushing. - Check the contact surface with the belt to make sure there are no signs of abnormal wear.
  • Page 106 ATLANTIC 300 i.e. Engine Specific tooling 020376Y Adapter handle 020375Y 28x30 mm punch AP8140662 Punch for roller casing Refitting the driven pulley - Insert the new oil seals and O-rings on the mov- able half-pulley. - Lightly grease the O-rings (A) shown in the figure.
  • Page 107 ATLANTIC 300 i.e. Engine Specific tooling AP8140664 Guide to mount the movable driven pulley Inspecting the clutch spring - Measure the length of the movable driven half- pulley spring, when unloaded. Characteristic Standard length 123 mm limit after use 118 mm Refitting the clutch - Assemble the spring, clutch and driven pulley.
  • Page 108 ATLANTIC 300 i.e. Engine Refitting the driven pulley - Refit the clutch bell. Drive-belt • Make sure that the driving belt is not damaged. • Check belt for correct width. Characteristic Driving belt - standard width 21.3 ± 0.2 mm Driving belt - minimum width 19.5 mm...

  • Page 109: Removing The Driving Pulley

    ATLANTIC 300 i.e. Engine Removing the driving pulley - Turn the crankshaft until the slots of the pulley are on a horizontal axis - With the specific tool remove the fixing nut, the Belleville spring and its washer - Remove the stationary driving half-pulley and the steel washer in contact with it...
  • Page 110 ATLANTIC 300 i.e. Engine movable driving half-pulley bushing: Max. di- ameter admitted Ø 26.12 mm sliding bushing: Standard Diameter Ø 25.959 ÷ 25.98 mm sliding bushing: Minimum diameter admitted Ø 25.95 mm roller: Standard Diameter Ø 20.5 ÷ 20.7 mm roller: Minimum diameter admitted Ø...
  • Page 111 ATLANTIC 300 i.e. Engine - Fit the steel shim contacting the bushing and the stationary driving half-pulley. - Install the appropriate tool as described in the removal phase. - Tighten the nut and washer to the prescribed torque. Specific tooling...
  • Page 112 ATLANTIC 300 i.e. Engine Specific tooling AP8140661 Lock wrench for clutch bell Locking torques (N*m) Transmission cover screws 11÷13 (8.1÷9.6 ftlb) Driven pulley shaft nut 54÷60 (39.9÷44.3 ftlb) End gear Removing the hub cover - Empty the rear hub through the oil drainage plug.
  • Page 113 ATLANTIC 300 i.e. Engine Removing the hub bearings - Check the status of the bearings being examined (wear, clearance and noise). Removing the wheel axle bearings - Remove the seeger ring from the outside of the hub cover. - Support the hub cover and expel the bearing.
  • Page 114 ATLANTIC 300 i.e. Engine Removing the driven pulley shaft bearing - Should the driven pulley shaft, its bearing and oil guard be removed, take out the transmission cover and the clutch assembly as described above. - Extract the driven pulley shaft from its bearing.
  • Page 115 ATLANTIC 300 i.e. Engine - In case of faults, replace the damaged parts. Refitting the wheel axle bearing - Support the hub cover on a wooden surface. - warm the cover crankcase with the specific heat gun. - Fit the wheel shaft bearing with a modular punch as shown in the figure.
  • Page 116 ATLANTIC 300 i.e. Engine Refitting the hub cover bearings To fit the hub box bearings, the engine crankcase and the cover should be heated with the specific heat gun. - The three 15-mm bearings must be fitted using the appropriate tools: The 42-mm side of the adaptor should face the bearing.
  • Page 117 ATLANTIC 300 i.e. Engine Refit the driven pulley shaft bearing with a modular punch as shown in the figure. NOTE IF A BEARING WITH AN ASYMMETRICAL BALL RETEN- TION CAGE IS USED, PLACE IT SO THAT THE BALLS ARE VISIBLE FROM THE HUB INTERNAL SIDE.
  • Page 118 ATLANTIC 300 i.e. Engine Refitting the ub cover - Fit a new gasket together with the centring dow- els. - Seal the gasket of the bleeding pipe using black silicone sealant. - Fit the cover making sure the bleeding pipe is in the correct position.

  • Page 119: Removing The Stator

    ATLANTIC 300 i.e. Engine Removing the stator - Remove the 2 Pick-Up screws and the one for the wiring bracket as well as the 3 stator fixing screws shown in the figure. - Remove the stator and its cable harness.
  • Page 120 ATLANTIC 300 i.e. Engine Refitting the flywheel cover - Position the keying clip on the crankshaft and orient the end as shown in the figure. - Orient the water pump shaft taking as reference the transmission gear seat as shown in the pho- tograph.
  • Page 121 ATLANTIC 300 i.e. Engine Removing the flywheel magneto - Remove the keying clip of the water pump shaft and crankshaft - Refit the driving half-pulley (if removed) - Lock the crankshaft rotation with a multipurpose wrench - Unscrew and remove the flywheel nut and its...
  • Page 122 ATLANTIC 300 i.e. Engine Inspecting the flywheel components - Check that the internal plastic parts of the flywheel and the Pick-Up control plate are in good conditions. Refitting the free wheel - Make sure the freewheel faying surfaces are in good condition.
  • Page 123 ATLANTIC 300 i.e. Engine Refitting the flywheel magneto - Remove the freewheel retention plate indicated in the photograph - Remove the transmission gear and the freewheel - Insert the freewheel on the flywheel as shown in the photo - Then refit the flywheel together with the free-...
  • Page 124 ATLANTIC 300 i.e. Engine Cylinder assy. and timing system Removing the intake manifold Loosen the 3 screws and remove the air intake manifold. When refitting, tighten the screws to the prescribed torque. Removing the rocker-arms cover Remove the 5 screws indicated in the figure...
  • Page 125 ATLANTIC 300 i.e. Engine - Remove the return spring of the automatic valve- lifter assembly, the automatic valve-lifter assembly and its end of stroke washer. - Loosen the central screw on the tensioner first. - Remove the 2 clamps indicated in the figure.
  • Page 126 ATLANTIC 300 i.e. Engine - Remove the command sprocket wheel and the timing chain. - Remove the screw indicated in the figure, the spacer and the tensioner pad. The tensioner pad must be removed operating from the transmission side. The lower chain guide pad can only be removed after the head has been removed.

  • Page 127: Removing The Cylinder Head

    ATLANTIC 300 i.e. Engine Removing the cylinder head - Remove the spark plug. - Remove the 2 side retainers indicated in the fig- ure. - Loosen the 4 head-cylinder fixing nuts in two or three stages and in a criss-cross sequence.

  • Page 128: Inspecting The Small End

    ATLANTIC 300 i.e. Engine Removing the cylinder - piston assy. Cylinder and piston removal - Remove the chain guide pad. - Remove the 4 sealing O-rings on the stud bolts - Slide off the cylinder. - Remove the gasket on the cylinder base.

  • Page 129: Removing The Piston

    ATLANTIC 300 i.e. Engine Cylinder - piston assy. Cylinder - piston assy. Inspecting the cylinder NOTE TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- TER. See also Cylinder - piston assy. Cylinder - piston assy. Inspecting the piston rings...
  • Page 130 ATLANTIC 300 i.e. Engine 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. NOTE THE TOOL FOR INSTALLING THE RETAINER RINGS MUST BE USED MANUALLY.
  • Page 131 ATLANTIC 300 i.e. Engine Refitting the piston rings • Place the oil scraper spring on the pis- ton. • Fit the oil scraper ring keeping the port opposite to the spring union and the word "top" facing the piston crown. In any case, the chamfered side of the must be facing the piston crown.

  • Page 132: Inspecting The Cylinder Head

    ATLANTIC 300 i.e. Engine AP8140921 Oil seal punch AP8140660 Piston fitting ring Inspecting the cylinder head NOTE TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- TER. See also Cylinder head Inspecting the timing system components - Check that the guide slider and the tensioner pad are not excessively worn.
  • Page 133 ATLANTIC 300 i.e. Engine Inspecting the valve housings NOTE TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- TER. See also Cylinder head Inspecting the valves NOTE TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- TER.
  • Page 134 ATLANTIC 300 i.e. Engine Specific tooling AP8140179 Support for valve fitting/removal AP8140659 Valve oil seal punch AP8140917 Tool for valve pressure plate Inspecting the cam shaft NOTE TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- TER. See also...
  • Page 135 ATLANTIC 300 i.e. Engine - Insert the retention plate and tighten the two screws shown in the picture to the prescribed tor- que. - Refit the spacer on the camshaft. - Rotate the engine so that the piston is at top dead centre, using the reference marks on the flywheel and the crankcase.
  • Page 136 ATLANTIC 300 i.e. Engine Locking torques (N*m) Timing chain tensioner support screw 11÷13 (8.1÷9.6 ftlb) Spark plug 12÷14 (8.9÷10.3 ftlb) Starter ground screw 7÷8.5 (5.2÷6.3 ftlb) Timing chain tensioner pad screw 10÷14 (7.4÷10.3 ftlb) Starter ground bell screw 11÷15 (8.1÷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)
  • Page 137 ATLANTIC 300 i.e. Engine - Rotate by an angle of 270° - To carry out the operations described above, fol- low the tightening sequence indicated in the figure. - Fit the two screws on the timing chain side and tighten them to the prescribed torque.
  • Page 138 ATLANTIC 300 i.e. Engine Refitting the intake manifold - Assemble the inlet manifold and tighten the 3 screws. Locking torques (N*m) Inlet manifold screws 11÷13 (8.1÷9.6 ftlb) Crankcase - crankshaft Splitting the crankcase halves - Before opening the crankcase, it is advisable to check the axial clearance of the crankshaft.
  • Page 139 ATLANTIC 300 i.e. Engine - If the crankshaft-crankcase axial clearance ex- ceeds what specified and the crankshaft does not show any defect, the problem must be due to ei- ther excessive wear or wrong machining on the crankcase. - Check the diameters of both crankshaft bearings according to the axes and surfaces shown in the figure.
  • Page 140 ATLANTIC 300 i.e. Engine Inspecting the crankcase halves - Before checking the crankcase halves, thorough- ly clean all the surfaces and oil pipes. - For the crankcase half on the transmission side, take particular care cleaning the housing and oil...
  • Page 141 ATLANTIC 300 i.e. Engine DUCE OIL TEMPERATURE. JET CLOGGING IMPAIRS HEAD LUBRICATION AND THE TIMING MECHANISMS. A JET FAILURE CAUSES A DROP IN LUBRICATION PRES- SURE FOR THE MAIN BUSHINGS AND CONNECTING ROD. Inspecting the crankshaft plain bearings - In order to obtain proper bushing lubrication, it is necessary to have both an outstanding lubricating pressure (3.2 bar) and a good oil flow rate.
  • Page 142 ATLANTIC 300 i.e. Engine A spare crankcase cannot be combined with a crankshaft with mixed categories. Spare shafts have half-shafts of the same category. NOTE SPARE CRANKCASES ARE CHOSEN WITH HALF-SHAFTS OF THE SAME CATEGORY. - Fit the internal bulkhead by locking the 2 screws to the prescribed torque.
  • Page 143 ATLANTIC 300 i.e. Engine Locking torques (N*m) Screws for engine crankcase internal bulkhead (transmission-side half shaft) 4÷6 (3÷4.4 ftlb) Engine crankcase coupling screws 11÷13 (8.1÷9.6 ftlb) engine oil drainage plug/mesh filter 24÷30 (17.7÷22.1 ftlb) Oil filter fitting on crankcase 27÷33 (19.9÷24.4 ftlb)
  • Page 144 ATLANTIC 300 i.e. Engine Lubrication Conceptual diagrams LUBRICATION CIRCUIT ENG - 144...
  • Page 145 ATLANTIC 300 i.e. Engine ENG - 145...

  • Page 146: Oil Pressure Check

    ATLANTIC 300 i.e. Engine Oil pressure check - Disconnect the electrical connection of the mini- mum oil pressure switch and then remove the switch. - Check that the oil pressure reading is between 0.5 ÷ 1.2 atm with engine idling at 1650 rpm and oil at the required temperature (wait for at least one electric ventilation).
  • Page 147 ATLANTIC 300 i.e. Engine Removal - First remove the transmission cover and the en- tire driving pulley - Install the 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...
  • Page 148 ATLANTIC 300 i.e. Engine 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...

  • Page 149: Oil Pump

    ATLANTIC 300 i.e. Engine Specific tooling AP8140729 Chain cover fitting/removal Oil pump Removal - Undo the 2 clamping screws in the figure and re- move the cover over the pump control crown gear. - Block the rotation of the oil pump driving pulley by inserting a screwdriver through one of its holes.
  • Page 150 ATLANTIC 300 i.e. Engine Inspection - Remove the two screws and the oil pump cover. - Remove the circlip fixing the inner rotor. - Remove and wash the rotors thoroughly with pet- rol and compressed air. - Reassemble the rotors in the pump body, keep- ing the 2 reference marks visible.
  • Page 151 ATLANTIC 300 i.e. Engine Refitting - Check there are no signs of wear on the oil pump shaft or body. - Check there are no signs of wear or scoring on the oil pump cover. - If non-conforming values or signs of wear are found, replace the faulty parts or the assembly.
  • Page 152 ATLANTIC 300 i.e. Engine FIT THE BELLEVILLE WASHER SO THAT ITS OUTER RIM TOUCHES THE PULLEY. MAKE SURE THAT THE PUMP TURNS FREELY. Locking torques (N*m) 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 screws 7÷9 (5.2÷6.6 ftlb)
  • Page 153 ATLANTIC 300 i.e. Engine Refitting the oil sump - Refit the by-pass valve plunger in its housing. - Insert the pressure-regulating spring. - Fit a new sump seal. - Refit the two centring dowels. - Refit the sump, taking care to locate the spring in the appropriate piece found in the sump.
  • Page 154 INDEX OF TOPICS INJEC NJECTION...
  • Page 155 ATLANTIC 300 i.e. Injection MIU injection system This is an integrated ignition and injection system. Injection is indirect in the manifold through an electro-injector. Injection and ignition are timed on the 4-stroke cycle using a tone wheel keyed onto the crankshaft (24-2 teeth) and a reluctant variation (pick-up) sensor.
  • Page 156 ATLANTIC 300 i.e. Injection - HV coil - Injector The control unit is fitted with a self-diagnosis sys- tem connected to a warning light on the instrument panel. Failures are detected and restored by the diagnostic tester. In any case, when the fault is no longer present, data storage is automatically wiped clean after 16 cycles of use (cold starting, running at regular engine temperature, stop).
  • Page 157 ATLANTIC 300 i.e. Injection 6. If the vehicle is not going to be used for a long time, refill the tank up to a little over half its capacity. This ensures that the pump will be covered by fuel. 7. When washing the vehicle, do not press the electric components and wirings.
  • Page 158 ATLANTIC 300 i.e. Injection c. Faulty stepper motor F: Others a. Not correctly adjusted timing system b. Not correct idle carburetion c. Not correctly reset throttle valve position sensor 2 MIU system failure may be caused by loose connectors. Make sure that all connections are properly implemented.
  • Page 159 ATLANTIC 300 i.e. Injection - Fan relay (Pin 8) - Water temperature sensor (Pin 9) - CAN line "H" (Pin 10) - Lambda probe "S+" (Pin 11) - Engine stop switch (Pin 12) - Engine revolution sensor positive (Pin 13)
  • Page 160 ATLANTIC 300 i.e. Injection CIRCUIT DIAGRAM Specification Desc./Quantity Battery Lambda probe Spark plug Fuse 15 A Fuel injector HV coil Front/ rear stop switches Fuse 15 A Key switch contacts Fuel pump Injection load remote control Starter button Start-up remote control...
  • Page 161 ATLANTIC 300 i.e. Injection Possible Cause Operation Shielded cap HV coil Engine speed timing sensor Ignition advance Fuel system Fuel pressure (low) Injector flow (low) Injector seal (poor) Correctness of the parameters Coolant temperature Intake air temperature Stepper throttle valve position (steps...
  • Page 162 ATLANTIC 300 i.e. Injection Possible Cause Operation Injector flow Exhaust backfires in deceleration EXHAUST BACKFIRING WHEN DECELERATING Possible Cause Operation Faults detected by self-diagnosis Pump relay HV coil Injector Engine speed timing sensor Air temperature Coolant temperature Lambda Probe Correctness of the parameters...
  • Page 163 ATLANTIC 300 i.e. Injection Possible Cause Operation Injector Engine speed timing sensor Air temperature Coolant temperature Lambda Probe Power to spark plug Spark plug Shielded cap HV Cable HV Coil Intake system Air filter Filter housing (seal) Intake sleeve (seal)
  • Page 164 ATLANTIC 300 i.e. Injection Removing the butterfly valve Remove the fuel piping fixing screw indicated in the figure. • Remove the fast-release fittings from the injector support. INJEC - 164...
  • Page 165 ATLANTIC 300 i.e. Injection • Remove the injector connector. Remove the three 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-...
  • Page 166 ATLANTIC 300 i.e. Injection • Remove throttle control retainer. Refitting 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.
  • Page 167 ATLANTIC 300 i.e. Injection Pump supply circuit COMPONENTS Specification Desc./Quantity Battery 12V - 12 Ah Fuse 20 A Ignition key contacts Fuse 15 A Side stand Injection load remote control INJEC - 167...
  • Page 168 ATLANTIC 300 i.e. Injection Specification Desc./Quantity Fuel pump HV coil Fuel injector Electric fan remote control When switched to "ON", the fuel pump starts to rotate for 2 seconds and then stops. With engine on and when a revolution timing signal is displayed, the pump is continuously supplied.
  • Page 169 ATLANTIC 300 i.e. Injection Upon switching to "ON", check that there is battery voltage for about two seconds between the Red- Brown cable of the pump connector and earth connection, with pump connector disconnected. Other- wise, check the continuity of the Red-Brown cable between the pump connector and the injection relay.
  • Page 170 ATLANTIC 300 i.e. Injection BAR. Check that within 15 seconds the pump has a flow rate of approx. 110 cm³. Specific tooling AP8140181 Fuel pressure checking tool Fuel filter check Disconnect the terminals of the electrical pump Remove the screw indicated in the photograph...
  • Page 171 ATLANTIC 300 i.e. Injection Separate the lower part of the pump support as shown in the photograph. Remove the filter from the pump support INJEC - 171...
  • Page 172 ATLANTIC 300 i.e. Injection Inspecting the injector circuit COMPONENTS Specification Desc./Quantity Battery 12V - 12 Ah Fuse 20 A Ignition key contacts Fuse 15 A Side stand Injection load remote control INJEC - 172...
  • Page 173 ATLANTIC 300 i.e. Injection Specification Desc./Quantity Fuel pump HV coil Fuel injector Electric fan remote control Checking the resistance at the injector ends: 14.5 ± 5% Ohm Check the efficiency of 15A fuse No.4 of the injection load. Check the efficiency of the injection load remote control: Check the resistance of the energising coil between pins 86 and 85: 80 ÷...
  • Page 174 ATLANTIC 300 i.e. Injection Check there is fixed voltage between the Green- Red cable of the remote control base and the 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.
  • Page 175 ATLANTIC 300 i.e. Injection With both the control unit and the injector discon- nected, check the continuity of the Grey-Red cable between pin 14 of the interface wiring and the in- jector connector Switch to "ON" and check there is voltage, with in-...
  • Page 176 ATLANTIC 300 i.e. Injection Inspecting the injector hydraulics To check the injector, remove the intake manifold by removing the three fixing screws at the head and the clip connecting the control unit to the mani- fold Fit the appropriate tool to check fuel pressure check and position the manifold over a scaled con- tainer at least 100 cm³.
  • Page 177 ATLANTIC 300 i.e. Injection Components location INJEC - 177...
  • Page 178 ATLANTIC 300 i.e. Injection COMPONENTS LAYOUT Specification Desc./Quantity Instrument panel Throttle body and injection electronic control unit (MIU) Diagnosis socket Fuel pump Water Temperature Sensor Fuel injector HV coil Flywheel - revolution timing sensor Lambda probe Injection load remote control...
  • Page 179 ATLANTIC 300 i.e. Injection Disconnect the fuel pump connector. Start the en- gine and wait for it to stop. With the wiring con- nected to the control unit and the system, try to start-up the engine and check that the alternating voltage between pins 13 and 15 is over 2.5 V ~...
  • Page 180 ATLANTIC 300 i.e. Injection HT coil COMPONENTS Specification Desc./Quantity Battery 12V - 12 Ah Fuse 20 A Ignition key contacts Fuse 15 A Side stand Injection load remote control INJEC - 180...
  • Page 181 ATLANTIC 300 i.e. Injection Specification Desc./Quantity Fuel pump HV coil Fuel injector Electric fan remote control The combined ignition/injection system is a high-efficiency induction system. The control unit manages two significant parameters: - Ignition advance This is optimised at once according to the engine revs, engine load, temperature and ambient pressure.
  • Page 182 ATLANTIC 300 i.e. Injection Check the efficiency of the injection load remote control: Check the resistance of the energising coil between pins 86 and 85: 80 ÷ 120 Ohm. Apply a voltage of 12V to pins 86 and 85; make sure that there is continuity between pins 30 and 87 of the remote control.
  • Page 183 ATLANTIC 300 i.e. Injection Check there is fixed voltage between the Green- Red cable of the remote control base and the 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.
  • Page 184 ATLANTIC 300 i.e. Injection INJEC - 184...
  • Page 185 ATLANTIC 300 i.e. Injection Coolant temperature sensor TEMPERATURE SENSOR Specification Desc./Quantity Water Temperature Sensor Engine stop switch On the interface wiring with 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.
  • Page 186 ATLANTIC 300 i.e. Injection connected, check the insulation between the two Orange and Blue-Green cables With the control unit side connector disconnected and the coolant temperature sensor connector dis- connected, check the continuity of the Orange cable between pin 9 of the interface wiring and the...
  • Page 187 ATLANTIC 300 i.e. Injection Shift to «ON». Press the + and - keys go to the "adjustment" screen page and select «TPS RESET» parameter. Specific tooling 020680Y TXB Navigator Make sure that the throttle valve control is in con- tact with the stop screw.
  • Page 188 ATLANTIC 300 i.e. Injection Install the electronic control unit interface wiring. Start the engine and warm it up until the electric fan switches on. Use an analogue multimeter with a direct voltage scale measuring down to 2V. Place the multimeter probes between pins 4 (-)
  • Page 189 INDEX OF TOPICS SUSP USPENSIONS...
  • Page 190 ATLANTIC 300 i.e. Suspensions Front Key: 1. Front wheel rim 2. Bearing 3. Wheel internal 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.

  • Page 191: Removing The Front Wheel

    ATLANTIC 300 i.e. Suspensions CHECKS Check according to the instructions on the sched- uled maintenance table. • Rest the vehicle on its centre stand. • Place a support under the chassis. • Turn the wheel manually towards on direction and another.
  • Page 192 ATLANTIC 300 i.e. Suspensions • Collect the odometer gear. • Remove the wheel. CAUTION DO NOT OPERATE THE FRONT BRAKE LEVER AFTER REMOVING THE WHEEL: IF YOU DO THE CALLIPER PLUNGER COULD SLIP OUT OF ITS SEAT RESULTING IN BRAKE FLUID LEAKAGE.
  • Page 193 ATLANTIC 300 i.e. Suspensions Check that the gaskets are in good conditions; replace them if they show signs of damage or excessive wear. WHEEL AXLE Using a dial gauge, check the wheel pin «2» ec- centricity. Replace the pin «2» if the eccentricity exceeds the limit value.
  • Page 194 ATLANTIC 300 i.e. Suspensions NEW TYRES CAN BE COVERED BY A SLIPPERY COAT: RIDE WITH CAUTION DURING THE FIRST KILOMETRES. DO NOT APPLY UNSUITABLE LIQUIDS ON TYRES. TYRE SIZE IS INDICATED ON THE VEHICLE REGISTRA- TION DOCUMENT AND ANY DIFFERENCE IS LEGALLY PUNISHABLE.
  • Page 195 ATLANTIC 300 i.e. Suspensions Refitting the front wheel • Fit the wheel between the fork stems. • Place the odometer gear on the wheel. • Spread a thin layer of lubricating grease all along the wheel pin. • Tighten the wheel pin from the right side.
  • Page 196 ATLANTIC 300 i.e. Suspensions • Place the brake calliper on the disc. • Tighten the two screws «2». Locking torques (N*m) Screw fixing calliper to fork 25 ± 20% (18.5 ftlb) Handlebar Check according to the instructions on the sched- uled maintenance table.
  • Page 197 ATLANTIC 300 i.e. Suspensions • Check clearance shaking the fork in the riding direction and check for smooth and free steering rotation. • Hold still the adjusting nut «2» and tighten the lock nut with a wrench «1». • Repeat the operation before last.

  • Page 198: Front Fork

    ATLANTIC 300 i.e. Suspensions Front fork KEY: 1. Fork base 2. Fork clamp screws 3. Snap ring 4. Rubber cap 5. Sealing cap 6. O-Ring 7. Spring 8. Pumping member 9. Counter spring 10. End stop buffer 11. Left stem 12.
  • Page 199 ATLANTIC 300 i.e. Suspensions 20. Right stem 21. Right wheel holder 22. Locking screw The front suspension consists of a hydraulic fork connected to the steering headstock by means of one plate. Inspect the front suspension following the instruc- tions on the scheduled maintenance table.
  • Page 200 ATLANTIC 300 i.e. Suspensions Removal STEM REMOVAL • Remove the front wheel. • Remove the front mudguard. • Undo and remove the two screws «1». NOTE THE FOLLOWING OPERATIONS REFER TO REMOVING ONLY ONE WHEEL HOLDER STEM - SLEEVE, BUT THEY APPLY TO BOTH.
  • Page 201 ATLANTIC 300 i.e. Suspensions • Remove the stem and collect the cen- tring bushing. 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.
  • Page 202 ATLANTIC 300 i.e. Suspensions • Remove the oil seal. • Remove the washer. • If necessary, remove the spacer «4». OIL EMPTYING Place the sleeve in a vice fitted with protection jaws (aluminium). NOTE GET A COLLECTING CONTAINER BEFORE CARRYING OUT THESE OPERATIONS.
  • Page 203 ATLANTIC 300 i.e. Suspensions • Remove the upper closing cap. • Lower 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.
  • Page 204 ATLANTIC 300 i.e. Suspensions • Drain off the oil into the collecting con- tainer by pumping it out with the stem. Overhaul WHEEL HOLDER STEM • Check the sliding surface for scorings and/or scratches. These scorings can be eliminated by rubbing them with wet sandpaper (grain 1).
  • Page 205 ATLANTIC 300 i.e. Suspensions Refitting WHEEL HOLDER STEM - SLEEVE REFIT • Place the sleeve in the vice fitted with protection 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.
  • Page 206 ATLANTIC 300 i.e. Suspensions • Fit the Seeger 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.
  • Page 207 ATLANTIC 300 i.e. Suspensions • Tighten the lower screw «3». • Refill with 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.

  • Page 208: Steering Column

    ATLANTIC 300 i.e. Suspensions • Remove the 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.
  • Page 209 ATLANTIC 300 i.e. Suspensions Removal • Position the vehicle on lifting platform, rest it on its centre stand with the front wheel jutting out of the platform. • Place a support under the chassis. • Remove the handlebar. • Remove the instrument panel.
  • Page 210 ATLANTIC 300 i.e. Suspensions • Remove the dust guard gasket «10». • Check the components for wear; re- place if required. • After refitting all the components pro- ceed with the bearing clearance ad- justment. NOTE FOR BEARINGS, USE THE TYPE OF GREASE INDICATED IN THE RECOMMENDED PRODUCTS TABLE.

  • Page 211: Removing The Rear Wheel

    ATLANTIC 300 i.e. Suspensions 1. Complete wheel 2. Seeger 3. Bearing 4. Brake calliper and muffler supporting plate 5. Nut CHECKS Check according to the instructions on the sched- uled maintenance table. • Rest the vehicle on its centre stand.
  • Page 212 ATLANTIC 300 i.e. Suspensions • Remove the split pin located on the wheel pin. • Remove 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) •...
  • Page 213 ATLANTIC 300 i.e. Suspensions Swing-arm Check frequently the existing clearance among the engine pin bushings and the engine pin. To check: • Rest the vehicle on its centre stand. • Shake the wheel perpendicularly to the riding direction. • If there is clearance, check that all the components that fix the fulcrum axis are firmly tightened.
  • Page 214 ATLANTIC 300 i.e. Suspensions Nut fixing connecting rod to engine 40 ± 20% (29.5 ftlb) • From the left side, slide off the engine screw «3» and collect the washer. • Unscrew and remove the shock ab- sorber lower screw «4».

  • Page 215: Shock Absorbers

    ATLANTIC 300 i.e. Suspensions Shock absorbers REAR SUSPENSION INSPECTION Inspect the rear suspension following the instruc- tions on the scheduled maintenance table. Check that the shock absorbers do not leak. Check the tightening of all the elements and the correct operation of the rear suspension joints.

  • Page 216: Side Stand

    ATLANTIC 300 i.e. Suspensions Centre-stand CENTRE STAND REMOVAL • Place the vehicle on its side stand. • Disconnect the two springs. • Unscrew and remove the nut «1». • Slide off the screw from the opposite side. • Remove the centre stand.
  • Page 217 ATLANTIC 300 i.e. Suspensions • Release the two springs 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.
  • Page 218 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
  • Page 219 ATLANTIC 300 i.e. Braking system KEY: 1. Front brake lever control 2. Front brake pump /fluid reservoir 3. Front brake lever-front calliper pipe 4. Brakeforce distribution mechanism 5. Front brake calliper 6. Front brake pads 7. Brakeforce distribution mechanism-front calliper pipe 8.

  • Page 220: Front Brake Disc

    ATLANTIC 300 i.e. Braking system Removal • Remove the rear wheel. • Undo and remove the three brake disc screws «1». • Remove the brake disc. NOTE WHILE REFITTING, SCREW ALL THE SCREWS «1» MAN- UALLY AND TIGHTEN THEM OPERATING DIAGONALLY.

  • Page 221: Front Brake Pads

    ATLANTIC 300 i.e. Braking system Removal • Remove the front wheel. • Undo and remove the five brake disc screws «1». • Remove the brake disc. NOTE WHILE REFITTING, SCREW ALL THE SCREWS «1» MAN- UALLY AND TIGHTEN THEM OPERATING DIAGONALLY.
  • Page 222 ATLANTIC 300 i.e. Braking system Removal • Park the vehicle on its centre stand. • Undo and remove the two screws «1». • Slide off the brake calliper from the disc by opening the plungers to the maxi- mum and bending them with an out-...
  • Page 223 ATLANTIC 300 i.e. Braking system Removal • Undo and remove the two screws «1». • Slide off the brake calliper from the disc. Locking torques (N*m) Screw fixing calliper to muffler plate 25 ± 20% (18.5 ftlb) • Remove the seeger ring «2».
  • Page 224 ATLANTIC 300 i.e. Braking system Fill - Bleeding the braking system RETARDING VALVE • Remove the instrument panel. PERFORM THE BLEEDING, REMOVE THE BRAKE PIPE CLAMP NEXT TO THE FRONT HEADLAMP. THEN CHECK THAT THE BRAKE PIPE IS LOWER THAN THE RETARDING VALVE.
  • Page 225 ATLANTIC 300 i.e. Braking system BRAKE FLUID CHANGE • Change the brake fluid following the in- structions on the scheduled mainte- nance table. • Remove the rubber protection cover. • Insert a transparent plastic pipe in the bleed valve «1-2» of the calliper and insert the other end of this pipe into a container to collect the fluid.
  • Page 226 ATLANTIC 300 i.e. Braking system BRAKING SYSTEM AIR BLEEDING If there is air in the hydraulic system, it acts as a bearing, absorbing a large part of the pressure from the brake pump and minimising calliper effi- ciency during braking. The presence of air is sig- nalled by the "sponginess"...
  • Page 227 ATLANTIC 300 i.e. Braking system Rear - combined • Remove rear calliper, keep it connec- ted to the pipes. • Place the rear calliper in a lifted posi- tion, to facilitate the air drainage. • Remove the rubber protection cover of the bleeding valve «4».
  • Page 228 ATLANTIC 300 i.e. Braking system Front • Remove the rubber protection cover of the bleed valve «3». • Insert a transparent plastic pipe in the bleed valve «3» of the front brake cal- liper and insert the other end of this pipe into a container to collect the fluid.
  • Page 229 ATLANTIC 300 i.e. Braking system Removal BRAKEFORCE DISTRIBUTION MECHANISM REMOVAL • Remove the instrument panel. • Drain off the braking system. • Undo and remove the two screws «1» and the bleed valve, and collect the rel- evant gaskets. •...
  • Page 230 ATLANTIC 300 i.e. Braking system BRAK SYS - 230...
  • Page 231 INDEX OF TOPICS COOL SYS OOLING SYSTEM...

  • Page 232: Circuit Diagram

    ATLANTIC 300 i.e. Cooling system Circuit diagram The centrifugal pump (inside the engine, activated by the engine) sucks in the coolant from the radiator and sends it through the ducts in the cylinder and the cylinder head to cool down the internal parts of the engine.
  • Page 233 ATLANTIC 300 i.e. Cooling system • Undo and remove the two nuts «1» on the front 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.

  • Page 234: Coolant Replacement

    ATLANTIC 300 i.e. Cooling system Coolant replacement RADIATOR REMOVAL • Drain off the system. • Remove the lower protection. • Disconnect the electric fan connector. • Disconnect the two thermal switch con- nectors. • Operating from both sides, cut the clamp «1».
  • Page 235 ATLANTIC 300 i.e. Cooling system • Slide off the sleeves «4» from the ra- diator. • Remove the radiator. EMPTYING • Remove the expansion tank cap. • Loosen the clamp 2» and slide off the sleeve «1». • Let the fluid flow into a collecting con- tainer of suitable capacity..
  • Page 236 ATLANTIC 300 i.e. Cooling system Removal • Lift the 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.
  • Page 237 INDEX OF TOPICS CHAS HASSIS...
  • Page 238 ATLANTIC 300 i.e. Chassis Seat • Park the vehicle on its centre stand. • Insert the key in the saddle lock. • Push and turn the ignition key anti- clockwise. • Lift the saddle. • Undo and remove the four screws and the hook.
  • Page 239 ATLANTIC 300 i.e. Chassis • Remove the helmet compartment. Driving mirrors • Lift the union rubber. • Undo and remove the two screws «1». NOTE THE OPERATIONS DESCRIBED ABOVE REFER TO RE- MOVING ONLY ONE MIRROR BUT APPLY TO BOTH MIR- RORS.
  • Page 240 ATLANTIC 300 i.e. Chassis Rear handlebar cover • Unscrew and remove 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».

  • Page 241: Instrument Panel

    ATLANTIC 300 i.e. Chassis • Remove the upper handlebar cover. • Unscrew and remove the two screws «5». • Remove the lower handlebar cover. Instrument panel INSTRUMENT PANEL BULBS REPLACEMENT • Remove the instrument panel. • Turn the bulb holder clockwise and slide it off.
  • Page 242 ATLANTIC 300 i.e. Chassis • 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. CHAS - 242...
  • Page 243 ATLANTIC 300 i.e. Chassis • Remove the instrument panel. Front handlebar cover RIGHT 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.
  • Page 244 ATLANTIC 300 i.e. Chassis LEFT SWITCH REMOVAL • Undo and remove the three lower screws «1». • Undo and remove the screw «2». • Remove the switch lower cover. • Disconnect the light connector «3». • Disconnect the turn indicator connec- tor «4».
  • Page 245 ATLANTIC 300 i.e. Chassis • Place the bulb holder «5» in its para- bole fitting and turn it clockwise. • Connect the bulb connector «4». TURN INDICATOR BULB REPLACEMENT • Remove the front locking. • Working from the front part of the vehicle, turn the holder «8» with the bulb «7» clockwise and extract them from their fitting.
  • Page 246 ATLANTIC 300 i.e. Chassis • Unscrew and remove the two screws «6». NOTE THE OPERATIONS INDICATED ABOVE REFER TO RE- MOVING ONLY ONE FRONT TURN INDICATOR, BUT AP- PLY TO BOTH INDICATORS. CAUTION BEFORE REPLACING A BULB, TURNTHE IGNITION SWITCH TO"OFF". TO REPLACE THE BULB, WEAR CLEAN GLOVES OR USE A CLEAN DRY CLOTH.
  • Page 247 ATLANTIC 300 i.e. Chassis Front headlamp removal • Remove both fairings. • Undo and remove the two upper screws «1». • Unscrew and remove the two lower screws "2". • Operating from both sides, disconnect the two connectors from the turn indi- cator.
  • Page 248 ATLANTIC 300 i.e. Chassis • Operating from both sides, remove the mat by lifting it with 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».
  • Page 249 ATLANTIC 300 i.e. Chassis • Insert the key in the tank lock. • Push and turn the ignition key anticlockwise. • Lift the fuel tank lid. • Unscrew and remove the fuel tank cap. • Remove the cover under the fuel tank cap.
  • Page 250 ATLANTIC 300 i.e. Chassis • Remove the central tunnel by pulling it backwards. CAUTION PROCEED WITH CAUTION. DO NOT DAMAGE THE TAB AND/OR ITS SLOTS. CHAS - 250...
  • Page 251 ATLANTIC 300 i.e. Chassis CHASSIS REMOVAL • Remove the mudflap. • Remove the front light. • Disconnect the two horn connectors «1». • Unscrew and remove the screw «2». NOTE THE POSSIBLE OVERLAPPING OF OPERATIONS REFER- RED TO IN THE OTHER CHAPTERS MUST BE CARRIED OUT LOGICALLY, AVOIDING ANY UNNECESSARY RE- MOVAL OF COMPONENTS.
  • Page 252 ATLANTIC 300 i.e. Chassis • Disconnect the following connectors: - voltage regulator «11»; - start-up connector «7»; - disconnect the two connectors «8» from the start- up relay. • Unscrew and remove the two screws "9". • Remove the control unit holding frame.
  • Page 253 ATLANTIC 300 i.e. Chassis • Insert the key in the tank lock. • Push and turn the ignition key anti- clockwise. • Lift the fuel tank lid. • Unscrew and remove the two screws «2». • Lift the front closing.
  • Page 254 ATLANTIC 300 i.e. Chassis • Operating from both sides, unscrew and remove the four side screws «2». • Undo and remove the central screw «3». • Remove the mudflap. Taillight assy. REAR HEADLAMP BULB REPLACEMENT In the rear headlamps there are: •...
  • Page 255 ATLANTIC 300 i.e. Chassis • Turn anticlockwise and extract the (tail light/stop light ) bulb «6» or the (turn indicator) bulb «5». • Install a bulb of the same type ade- quately. NOTE UPON REFITTING, PLACE THE GLASS «7» CORRECTLY INTO PLACE.

  • Page 256: License Plate Light

    ATLANTIC 300 i.e. Chassis License plate light LICENSE PLATE LIGHT BULB REPLACEMENT • Grip the bulb holder «10», pull and take it out from its fitting. • Slide off and replace the bulb with one of the same type. Side fairings •...
  • Page 257 ATLANTIC 300 i.e. Chassis License plate holder • Operating from both sides, undo and remove the four screws «1». • Move the license plate holder. • Undo and remove the two bulb sup- porting screws «2». • Remove the license plate holder.
  • Page 258 ATLANTIC 300 i.e. Chassis • Loosen the clamp «5» and slide off the intake pipe from the throttle body. • Move the filter case. • Slide off the engine breather pipe «6» from the filter case. • Remove the air filter case.
  • Page 259 ATLANTIC 300 i.e. Chassis Tail guard • Remove both undertails. • Operating from both sides, undo 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.
  • Page 260 ATLANTIC 300 i.e. Chassis • Lift the saddle. • Remove the luggage rack locking. • Undo and remove the two screws «1» and collect the washers. Locking torques (N*m) Screw fixing passenger handgrip to chassis (M6x45) 10 ± 20% (7.4 ftlb) •...

  • Page 261: Rear Mudguard

    ATLANTIC 300 i.e. Chassis Rear mudguard • Undo and remove the two screws fixing the filter case «1». Locking torques (N*m) Screw fixing filter case to engine 8 ± 20% (5.9 ftlb) • Undo and remove the three fixing screws «2» and collect the cable guide.
  • Page 262 ATLANTIC 300 i.e. Chassis • Unscrew and remove the two rear screws «2». • Lift the helmet compartment. • Unscrew and remove the two screws «3» fixing the expansion tank. • Move the expansion tank and keep it connected to the cooling system pipes.

  • Page 263: Front Mudguard

    ATLANTIC 300 i.e. Chassis Front mudguard • Park the vehicle on its centre stand. • Operating from both sides, undo and remove the two screws «1». • Remove the front mudguard. Locking torques (N*m) Front mudguard fixing screw 7 (5.2 ftlb)
  • Page 264 ATLANTIC 300 i.e. Chassis • Turn the fuel probe and lift it to remove FUEL TANK REMOVAL • Lower the radiator, keep it connected to the coolant delivery and reverse pipes. • Disconnect the delivery pipes and the fuel return pipe «1».
  • Page 265 ATLANTIC 300 i.e. Chassis Expansion tank • Drain off the cooling system. • Release the expansion tank from the helmet compartment. • Remove the cooling system pipe. • Remove the expansion tank. Front central cover • Operating from both sides, undo and remove the rear screw «1».
  • Page 266 ATLANTIC 300 i.e. Chassis Flyscreen TOP FAIRING REMOVAL • Remove the front locking. • Remove both mirrors. • Unscrew and remove the two front screws «1». • Remove the top fairing. INSTRUMENT PANEL SUPPORT REMOVAL - TOP FAIRING • Remove the front light.
  • Page 267 ATLANTIC 300 i.e. Chassis • Remove the secondary fuse box from its fitting. • Remove the safety relay from its hous- ing. • 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) •...

  • Page 268: Lower Cover

    ATLANTIC 300 i.e. Chassis • Unscrew and remove the two screws «4» fixing the light lower support • Unscrew and remove the four screws «5» fixing the instrument panel - top fairing support to the chassis. • Remove the instrument panel - top fair-...
  • Page 269 ATLANTIC 300 i.e. Chassis • 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. CHAS - 269...
  • Page 270 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 271 ATLANTIC 300 i.e. Pre-delivery Carry out the listed checks before delivering the motorcycle. WARNING HANDLE FUEL WITH CARE. Aesthetic inspection - Paintwork - Fitting of Plastic Parts - Scratches - Dirt Tightening torques inspection - Safety fasteners: front and rear suspension unit...
  • Page 272 ATLANTIC 300 i.e. Pre-delivery - Through the diagnosis tool, check that the last mapping version is present in the control unit/s and, if required, program the control unit/s again: consult the technical service website to know about available upgrades and details regarding the operation.
  • Page 273 ATLANTIC 300 i.e. Pre-delivery - Front and rear brake efficiency - Front and rear suspension efficiency - Abnormal noise Static test Static check after test drive: - Restarting when warmed up - Starter operation (if present) - Minimum holding (turning the handlebar)
  • Page 274 Air filter: 46, 257 Battery: 72, 82, 83 Brake: 219–222, 228 Brake disc: 219, 220 Brake pads: 221, 222 Brake pump: 228 Bulbs: Bushings: Clutch: 101, 102, 107 Coil: 180 Connectors: 86 coolant: 185, 234 Coolant: 185, 234 Crankcase: 20, 128, 138–141 Crankshaft: 20, 128, 138, 139, 141, 146 Cylinder: 18, 25, 124, 127–129, 131–134 ECU: 86...
  • Page 275 Maintenance: 42 Maintenance Table: Mirrors: 239 Mudguard: 261, 263 Oil filter: 50 Oil sump: 152, 153 Rear wheel: 211 Recommended products: Saddle: Shock absorbers: 215 Side fairings: 256 Side stand: 216 Spark plug: 43 Stand: 216 Start-up: Starter motor: 120, 123 Tank: 263, 265 Transmission: 13, 98, 111 Tyres: 14...

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