APRILIA Atlantic 500 Workshop Manual
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APRILIA Atlantic 500 Workshop Manual

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ATLANTIC 500
1073 1
10/2002-00
workshopmanual

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Summary of Contents for APRILIA Atlantic 500

  • Page 1 ATLANTIC 500 1073 1 10/2002-00 workshopmanual...

  • Page 2: General Information

    The data and illustrations that make up the manual were up to date at the time of publication. The manual is intended for aprilia dealers and their Periodic Maintenance qualified mechanics. Many concepts have been inten- Operations tionally omitted as they were considered superfluous.

  • Page 3: Table Of Contents

    Atlantic 500 TABLE OF CONTENTS Chapter 1 SAFETY WARNINGS ..........................1-2 PRECAUTIONS AND GENERAL INFORMATION ................. 1-2 REPLACING COMPONENTS ........................ 1-3 USING THE MANUAL ..........................1-3 IDENTIFICATION DATA ......................... 1-4 NOTES ON FUEL, LUBRICANTS, COOLANT AND OTHER ITEMS ............ 1-4 FUEL ..............................
  • Page 4 Atlantic 500 Chapter 3 COMPONENTS THAT CAN BE REMOVED WITHOUT REMOVING THE ENGINE......3-2 REMOVING THE ENGINE FROM THE FRAME ................... 3-3 Chapter 4 FUEL TANK AND PUMP ........................4-2 EMS FUEL INJECTION SYSTEM......................4-2 FUEL SUPPLY SYSTEM ........................4-3 FUEL SUPPLY CHECK ..........................
  • Page 5 Atlantic 500 DASHBOARD CHECK ......................... 6-22 FUEL LEVEL ............................6-22 DASHBOARD CHECK ......................... 6-22 FUEL LEVEL SENSOR CHECK ......................6-22 LIGHTS AND ACOUSTIC SIGNALS SYSTEM ..................6-23 WIRING DIAGRAM ..........................6-23 HORN CHECK ............................. 6-23 TOP CASE SWITCH CHECK ......................6-23 DIRECTION INDICATORS AND DISPLAY DATA ................
  • Page 6 Atlantic 500 COMPLETE INSTRUMENT PANEL REMOVAL .................. 7-15 WINDSHIELD REMOVAL ........................7-16 INSTRUMENT PANEL REMOVAL ....................... 7-16 COMPLETE LIGHTING ASSEMBLY REMOVAL ................. 7-17 CRASH HELMET COMPARTMENT REMOVAL .................. 7-18 FRONT WHEEL ........................... 7-22 KEY ..............................7-22 REMOVING THE FRONT WHEEL ...................... 7-23 REPLACING THE BEARINGS ......................
  • Page 7 Atlantic 500 Release 00 2002-09...
  • Page 8 General Information Atlantic 500 General Information chap. 1 Release 00 2002-09...

  • Page 9: Chapter 1 Safety Warnings

    General Information Atlantic 500 SAFETY WARNINGS The following precautionary warnings are used throughout this manual in order to convey the following messages: Safety warning. When you find this symbol on the vehicle or in the manual, be careful to the potential risk of personal injury.

  • Page 10: Replacing Components

    Never use compressed air to clean the bearings. NOTE Bearings should always rotate freely, smoothly and silently, otherwise they must be replaced. Only use GENUINE aprilia spares. Always use the recommended lubricants and consumables. If possible, lubricate parts before refitting them.

  • Page 11: Identification Data

    General Information Atlantic 500 IDENTIFICATION DATA The frame number may be used to order the spare parts. NOTE Tampering with serial numbers is subject to severe penalties. In particular, tampering with the frame number immediately voids the warranty. FRAME NUMBER The frame number is stamped on the frame central tube.
  • Page 12 General Information Atlantic 500 ENGINE OIL WARNING Engine oil can cause serious damage to the skin if handled every day and for long periods. Wash your hands carefully after using the oil. Do not dispose of the oil in the environment.
  • Page 13 General Information Atlantic 500 CAUTION Do not use brake fluids other than those prescribed. To avoid damaging the braking system, never mix different types of fluids when topping up. Never use brake fluid taken from an old container, or from a container that has been open for a long time.
  • Page 14 General Information Atlantic 500 COOLANT WARNING The coolant is harmful if ingested. Contact with the skin or the eyes may cause irritation. Should the liquid come into contact with the skin or the eyes, generously rinse with water and seek medical attention.

  • Page 15: Running-In Rules

    General Information Atlantic 500 CARBON MONOXIDE Whenever the engine needs to be run in order to carry out some operation, ensure that this is done in the open air or in a well-ventilated room. Never run the engine in a closed environment unless the place is equipped with an exhaust system.

  • Page 16: Precautions And General Information

    After fitting a circlip, ensure that it is fully and firmly inserted in its seat. SPARE PARTS Only use Genuine aprilia Spares. All Genuine aprilia Spares are high-quality parts specially designed and manufactured for aprilia vehicles. CAUTION Using NON-genuine aprilia spares may result in damage and poor performance.

  • Page 17: Technical Data

    General Information Atlantic 500 TECHNICAL DATA DIMENSIONS Max. length 2270 mm (89.4 in) Max. width 720 mm (28.3 in) Max. height (front part of the fairing included) 1450 mm (57.0 in) Seat height 780 mm (30.7 in) Distance between centres 1575 mm (62.0 in)
  • Page 18 General Information Atlantic 500 FUEL SUPPLY Type Electronic injection by electric fuel pump Fuel Lead free petrol (4 Stars ) with minimum octane number 95 (N.O.R.M.) and 85 (N.O.M.M.) FRAME Type high resistance steel tubes Steering inclination angle 28°, 50’...

  • Page 19: Lubricant Chart

    General Information Atlantic 500 ELECTRIC SYSTEM Battery 12 V - 14 Ah Fuses 30 - 20 - 15 - 3 A Generator (with permanent magnet) 14 V - 330 W BULBS Low / high beam 12 V - 55 W / 12 V - 35 W...

  • Page 20: Tightening Torques Table

    General Information Atlantic 500 TIGHTENING TORQUES TABLE DESCRIPTION ftlb FRAME ASSEMBLY Footrest fixing screw 14.75 Steering stop plate screw 8.68 Locking ring 36.88 Key switch break-off screw 7.23 Threaded bushing 0.22 Key switch fixing screw 7.23 WINDSCREEN SUPPORT ASSEMBLY Windscreen support fixing screw 7.23...
  • Page 21 General Information Atlantic 500 DESCRIPTION ftlb FRONT WHEEL ASSEMBLY Wheel pin 36.88 Speedometer sensor screw 0.66 Hub screw 7.23 REAR WHEEL ASSEMBLY 110.64 PASSENGER HANDLE SUPPORTS ASSEMBLY Passenger handles support fixing screw 14.75 PASSENGER SEAT BACK SUPPORT ASSEMBLY Seat back support fixing screw 7.23...
  • Page 22 Periodic Maintenance Operations Atlantic 500 Periodic Maintenance Operations chap. 2 Release 00 2002-09...

  • Page 23: Periodic Maintenance Programme

    NOTE to refit the components follow the reverse procedure, unless otherwise specified. PERIODIC MAINTENANCE PROGRAMME To maintain the vehicle in perfect running order, aprilia recommends observing the scheduled main- tenance intervals for the various components. CAUTION ENGINE CODE BELT REPLACEMENT...

  • Page 24: Periodic Maintenance Schedule

    Periodic Maintenance Operations Atlantic 500 PERIODIC MAINTENANCE SCHEDULE TO BE PERFORMED BY aprilia authorized dealer End of running-in Every 6,000 km Every 12,000 km COMPONENTS 1,000 km (625 mi) (3,750 mi) or 8 months (7,500 mi) or 16 months Accelerator cable (adjustment)

  • Page 25: Lubricating Points

    Periodic Maintenance Operations Atlantic 500 LUBRICATING POINTS KEY TO LUBRICATION CHART 1) Brake lever pin A proper lubrication is important to ensure the correct 2) Steering bearings operation and duration of the vehicle components. 3) Sidestand pivot 4) Central stand pivot...

  • Page 26: Battery

    Periodic Maintenance Operations Atlantic 500 BATTERY Carefully read (PRECAUTIONS AND GENERAL INFORMATION). Check the electrolyte level and the tightening of the terminals after the first 1,000 km (625 mi) and then every 6,000 km (3,750 mi). WARNING The electrolyte in the battery is toxic and caustic and if it gets in contact with the skin it can cause burns, since it contains sulphuric acid.

  • Page 27: Removing The Battery Cover

    Periodic Maintenance Operations Atlantic 500 REMOVING THE BATTERY COVER Read through paragraph BATTERY. NOTE Put the vehicle on a solid and flat surface • Make sure the ignition lock switch is turned to “ ”. • Lift the saddle, see (UNLOCKING/ LOCKING THE SEAT).

  • Page 28: Removing The Battery

    Periodic Maintenance Operations Atlantic 500 REMOVING THE BATTERY • Remove the battery cover, see (REMOVING THE BATTERY COVER). • Remove the battery breather pipe (7). • Remove the battery (8) from its seat by slightly turning it to the right, as shown by the arrow.

  • Page 29: Checking The Electrolyte Level

    Periodic Maintenance Operations Atlantic 500 CHECKING THE ELECTROLYTE LEVEL To check the electrolyte level, proceed as follows: • Remove the battery cover, see (REMOVING THE BATTERY COVER). • Make sure that the fluid level is included between the two “MIN” and “MAX” notches stamped on the battery side.

  • Page 30: Installing The Battery

    Periodic Maintenance Operations Atlantic 500 INSTALLING THE BATTERY • Remove the battery cover, see (REMOVING THE BATTERY COVER). • Put the battery in its container. CAUTION Always connect the battery breather pipe, to prevent the sulphuric acid vapours from corroding...

  • Page 31: Adjusting The Throttle Control

    Periodic Maintenance Operations Atlantic 500 • Energetically blow some air, in order to prevent the removed residues from getting into the engine. If the spark plug has crackings on the insulating 0.7 – 0.8 mm material, corroded electrodes or excessive depos- 0,7-0,8 mm its, it must be changed.

  • Page 32: Air Filter

    Periodic Maintenance Operations Atlantic 500 AIR FILTER Read through the paragraphs MAINTENANCE. The air cleaner should be inspected and cleaned every 6,000 km (3,750 mi), depending on the condi- tions of use. If the vehicle is used on dusty or wet roads, the cleaning operations should be carried out more frequently.

  • Page 33: Engine Oil

    Periodic Maintenance Operations Atlantic 500 ENGINE OIL Check the engine oil after the first 1,000 km (625 mi) or at the end of the running in period, and then every 3,000 km (1,875 mi). Change the oil every 6000 km (3,750 mi), see RENEWING THE ENGINE OIL AND ENGINE OIL FILTER.

  • Page 34: Renewing The Engine Oil And

    Periodic Maintenance Operations Atlantic 500 Never exceed the “MAX” mark, nor leave the oil below the “MIN” mark, in order to avoid serious damage to the engine. • If necessary, provide for topping up. TOPPING UP • Pour a small quantity of oil in the filling hole (2) and wait about one minute, so that the oil flows uniformly into the oil pan.

  • Page 35: Checking The Transmission Oil Level And Topping Up

    Periodic Maintenance Operations Atlantic 500 NOTE Make sure the above procedures are carried before the engine oil level is checked • Unscrew and remove cap/dipstick (1). • Unloose and remove the engine oil cartridge filter (3). WARNING Do not use the vehicle if lubrication is insufficient.
  • Page 36 Periodic Maintenance Operations Atlantic 500 • Unscrew and remove cap/dipstick (1). • Clean dipstick with a clean cloth. • Completely screw the cap-dipstick (1) into the filling hole (2). • Remove the cap-dipstick (1) again and check the oil level:...

  • Page 37: Topping Up

    Periodic Maintenance Operations Atlantic 500 RENEWING THE TRANSMISSION OIL Read through the paragraph LUBRICANTS, MAINTE- NANCE and TABLE OF LUBRICANTS. NOTE Put the vehicle on a solid and flat surface. • Put the vehicle on the central stand. CAUTION Do not use the vehicle if lubrication is insufficient.

  • Page 38: Check

    Periodic Maintenance Operations Atlantic 500 CAUTION The brakes are the parts that most ensure your safety and for this reason they must always be perfectly working; check them before every trip. A dirty disc soils the pads, with consequent reduction of the braking efficiency. Dirty pads must be replaced, while dirty discs must be cleaned with a high-quality degreaser.

  • Page 39: Restoring The Brake Fluid Level

    Periodic Maintenance Operations Atlantic 500 RESTORING THE BRAKE FLUID LEVEL Read through the paragraph DISC BRAKES. Remove the four screws (2) from brake fluid reservoir (3). Remove cover (4). NOTE To avoid spilling the brake fluid when topping up, ensure that the fluid in the reservoir is parallel with the reservoir rim (in a horizontal position).

  • Page 40: Bleeding The Braking System (Front Side Only)

    Periodic Maintenance Operations Atlantic 500 BLEEDING THE BRAKING SYSTEM (FRONT SIDE ONLY) Read through the paragraph DISC BRAKES. Any air present in the brake circuit acts as a cushion, absorbing much of the pressure applied by the brake pump and reducing the effectiveness of the brake caliper.

  • Page 41: Bleeding The Integral Braking System

    Periodic Maintenance Operations Atlantic 500 BLEEDING THE INTEGRAL BRAKING SYSTEM Read through the paragraph DISC BRAKES. The air present in the hydraulic circuit acts as a cush- ion, absorbing much of the pressure applied by the brake pump and reducing the effectiveness of the caliper dur- ing the braking.
  • Page 42 Periodic Maintenance Operations Atlantic 500 Unloose and remove the three screws (7). Remove the rear brake caliper (8) of the plate (9) and the relevant cable lead. Fit the rear brake caliper (8) so that the breather valve (10) is in the highest position.

  • Page 43: Checking And Restoring The Coolant Level

    Periodic Maintenance Operations Atlantic 500 CHECKING AND RESTORING THE COOLANT LEVEL Read through the paragraphs COOLANT and PRECAUTIONS AND GENERAL INFORMATION. CAUTION Do not use the vehicle if the coolant is below the minimum prescribed level “MIN”. Check the coolant level every 2,000 km (1,250 mi) and after long trips;...

  • Page 44: Renewing The Coolant

    Periodic Maintenance Operations Atlantic 500 RENEWING THE COOLANT Read through the paragraphs COOLANT and PRECAUTIONS AND GENERAL INFORMATION. CAUTION Do not use the vehicle if the coolant is below the minimum level. Check the level of the coolant every 2,000 km (1,250 mi) and after long journeys.
  • Page 45 Periodic Maintenance Operations Atlantic 500 • Start the engine and let it idle. • Place a container under the engine to gather any coolant coming out of breather screw (5). CAUTION The coolant in the circuit is under pressure. To avoid dangerous spurts, loosen breather screw (5) slowly and moderately.

  • Page 46: Circuit Bleeding

    Periodic Maintenance Operations Atlantic 500 CIRCUIT BLEEDING: • Remove the front hood, see (REMOVING THE FRONT HOOD). • Remove the filter box, see (REMOVING THE FILTER BOX). • Open the expansion tank cap. • Remove the breather cap located on the cylinder head “T”...

  • Page 47: Adjusting The Bearings Play

    Periodic Maintenance Operations Atlantic 500 ADJUSTING THE BEARINGS PLAY Remove the legshield, see (REMOVING THE LEGSHIELD). Unloose the check nut (1). CAUTION To avoid damaging the steering bearings, take care not to tighten adjusting nut (2) forcefully. Turn in adjusting nut (2) until the play of the bearings is eliminated.

  • Page 48: Checking The Front Suspension

    Periodic Maintenance Operations Atlantic 500 CHECKING THE FRONT SUSPENSION Read through the paragraph PRECAUTIONS AND GENERAL INFORMATION. Inspect the front suspension after the first 1,000 km (625 mi) and then every 6,000 km (3,750 mi) or 8 months. Renew the oil in the front suspension every 12,000 km (7,500 mi), see FRONT SUSPENSION.

  • Page 49: Adjustment Of The Rear Suspension Spring Preload

    Periodic Maintenance Operations Atlantic 500 ADJUSTMENT OF THE REAR SUSPENSION SPRING PRELOAD Rotation Adjusting Rotation (arrow B) ring (arrow A) Spring Spring Function preload preload increase decrease Attitude The vehicle The vehicle is more rigid is less rigid Recom- Smooth or...
  • Page 50 5 mm (0.196 in). After repairing a tyre, have the wheels balanced. Use only tyres in the size suggested by aprilia, see TECHNICAL DATA. Do not install tyres with air tube on rims for tube- less tyres and viceversa.
  • Page 51 2.1 bar (30.4 psi) 2.3 bar (33.3 psi) FULL LOAD 2.2 bar (31.9 psi) 2.6 bar (37.7 psi) (passenger + driver) According to the tests carried out by aprilia, only the tyres listed below have been approved for this model: MANUFACTURER SIZE...
  • Page 52 Engine Atlantic 500 Engine chap. 3 Release 00 2002-09...

  • Page 53: Components That Can Be Removed Without Removing The Engine

    Engine Atlantic 500 COMPONENTS THAT CAN BE REMOVED WITHOUT REMOVING THE ENGINE The following parts can be removed and refitted with- out removing the engine from the frame. UPPER SIDE - Throttle body (1) see (THROTTLE BODY) - Intake manifold sleeve (2)
  • Page 54 Engine Atlantic 500 REMOVING THE ENGINE FROM THE FRAME Read through the paragraph (PRECAUTIONS AND GENERAL INFORMATION). CAUTION Switch off the engine and allow the engine and the exhaust system to cool down. Disconnect the battery. Completely empty out the coolant circuit (RENEWING THE COOLANT).
  • Page 55 Engine Atlantic 500 Detach the water inlet pipe (8) to the pump by unloosing screw (9) on hose clamp (10). Detach the water outlet pipe (11) from the cylinder by unloosing screw (12) on hose clamp (13) found on the union above the cylinder.
  • Page 56 Engine Atlantic 500 Remove rubber protection (21) and detach the engine oil pressure sensor wire connector (22). Unloose and remove the nut fixing the starter relay cable (23) and remove the cable (24). Unloose and remove the two screws (25) fixing the starter to the crankcase, and release the cables for the ground.
  • Page 57 Engine Atlantic 500 “A” arrange for suitable supports to be placed under the engine for the next positioning, after the frame removal. “B” unscrew and remove pin (27) fixing the left rear suspension (28). Keep the nut and the washer.
  • Page 58 Fuel System Atlantic 500 Fuel System chap. 4 Release 00 2002-09...

  • Page 59: Chapter 4 Fuel Tank And Pump

    Fuel System Atlantic 500 FUEL TANK AND PUMP EMS FUEL INJECTION SYSTEM The fuel injection system used is of the integrated fuel injection and ignition type. Fuel is injected indirectly into the manifold by means of the electroinjector. Fuel injection and ignition are timed on a 4-stroke cycle via a phonic wheel keyed to the cam shaft control and a reluctance variation sensor.

  • Page 60: Fuel Supply System

    Fuel System Atlantic 500 FUEL SUPPLY SYSTEM KEY TO FUEL SUPPLY SYSTEM 1) Fuel pump 2) Fuel tank 3) Intake manifold 4) Fuel supply pipe (DELIVERY) 5) Fuel supply pipe (RETURN) 6) Excess fuel drain pipe 7) Injector 8) Fuel level float...

  • Page 61: Fuel Supply Check

    Fuel System Atlantic 500 MAINTENANCE Check the condition of the fuel feed pipes every 6,000 km (3,750 mi) or 8 months. Any pipes showing signs of desiccation, cracks or cuts must be replaced. Ensure that the pipes are not twisted or choked.

  • Page 62: Fuel Pump Removal/Dismantling

    Fuel System Atlantic 500 FUEL PUMP REMOVAL/DISMANTLING CAUTION Read through the paragraphs (PRECAUTIONS AND Work with caution during removal of the fuel GENERAL INFORMATION) and (FUEL). pump (5) to avoid damage to the fuel pre-filter (6). PUMP ASSEMBLY REMOVAL Remove the fuel pump (5) from the tank (7).

  • Page 63: Fuel Pump And Fuel Level Feeler Disassembly And Checking

    Fuel System Atlantic 500 FUEL PUMP AND FUEL LEVEL FEELER DISAS- SEMBLY AND CHECKING For dismantling of the components refer to WORK- SHOP MANUALS n°1063 , n°1064 , n°1065 n°1066 , n°1067 and n°1068 THROTTLE BODY 1) Stepper motor 2) Valve position sensor...

  • Page 64: Throttle Body Removal

    Fuel System Atlantic 500 THROTTLE BODY REMOVAL Read through the paragraphs (PRECAUTIONS AND GENERAL INFORMATION) and (FUEL). Remove the air filter box, see (AIR FILTER). Disconnect the delivery and return fuel supply pipes (1) to the injector. Unscrew and remove the fixing screw (2) of the fuel pipe clamps.
  • Page 65 Fuel System Atlantic 500 Unscrew and remove the three screws (10) fixing the intake manifold (11) to the head. Remove the intake manifold (11) including the throttle body (12). Unscrew and remove the three screws (13) fixing the throttle body (12) to the intake manifold (11).
  • Page 66 Cooling System Atlantic 500 Cooling System chap. 5 Release 00 2002-09...

  • Page 67: Chapter 5 System Description

    Cooling System Atlantic 500 SYSTEM DESCRIPTION The cooling system is constructed with a centrifugal pump coaxial to the countershaft and as such completes a number of revolutions identical to that of the driving shaft. The pump has two ducts, one for entry and one for exit.

  • Page 68: Radiator Removal

    Cooling System Atlantic 500 RADIATOR REMOVAL Read through the paragraphs (COOLANT) and (PRECAUTIONS AND GENERAL INFORMATION). Drain the coolant completely, see (REPLACING COOLANT), in the WORKSHOP MANUALS n°1063 , n°1064 , n°1065 , n°1066 , n°1067 n°1068 Remove the legshields, see (LEG SHIELDS RE- MOVAL ).

  • Page 69: Expansion Tank Removal

    Cooling System Atlantic 500 EXPANSION TANK REMOVAL Read through paragraphs (COOLANT) and (PRECAU- TIONS AND GENERAL INFORMATION). Place the vehicle on its central stand. Remove the front hood, see (FRONT HOOD RE- MOVAL). Remove the legshields, see (LEGSHIELDS RE- MOVAL).

  • Page 70: Thermostat Valve

    Cooling System Atlantic 500 THERMOSTAT VALVE For information concerning the thermostat valve, see WORKSHOP MANUALS n°1063 , n°1064 n°1065 , n°1066 , n°1067 and n°1068 COOLANT PUMP For information concerning the coolant pump, see WORKSHOP MANUALS n°1063 , n°1064 n°1065 , n°1066...
  • Page 71 Cooling System Atlantic 500 chap. 5 Release 00 2002-09...
  • Page 72 Electrical Equipment Atlantic 500 Electrical Equipment chap. 6 Release 00 2002-09...

  • Page 73: Checking The Recharging System

    Electrical Equipment Atlantic 500 CHECKING THE RECHARGING SYSTEM The following key will help the reader to consult this section. CABLE COLOURS orange light blue blue white yellow gray brown black green violet pink CHECKING THE RECHARGING VOLTAGE • Check the electrolyte level (CHECKING THE ELECTROLYTE LEVEL).

  • Page 74: Checking The Alternator Continuity

    Electrical Equipment Atlantic 500 CHECKING THE ALTERNATOR CONTINUITY With motor off: • Remove the right side panel, see (SIDE PANELS REMOVAL). • Detach regulator wiring connector (1). • Using a pocket multimeter, check continuity between stator yellow wires (G). •...

  • Page 75: Fuel Injection System

    Electrical Equipment Atlantic 500 FUEL INJECTION SYSTEM INJECTION SUPPLY WIRE DIAGRAM Ar/N R/Gr Ar/N Ar/V STAND SPIA Gr/N CAVALLETTO SWITCH POMPA INIETTORE BOBINA FUEL FUEL COIL BENZINA BENZINA INJECTOR PUMP Key to wire diagram Main injection relay 10) Secondary injection relay...

  • Page 76: Stand Switch Control

    Electrical Equipment Atlantic 500 STAND SWITCH CONTROL Rotation of the side stand (1) must be free from obstruction. Carry out the following checks: • The springs (2) must not be damaged, worn, rusty or weakened. • The stand must turn freely, by greasing the joint if necessary, see (TABLE OF LUBRICANTS).

  • Page 77: Injection Relay Controls

    Electrical Equipment Atlantic 500 INJECTION RELAY CONTROLS To verify that the relay is working: • Remove the seat, see (REMOVING THE SEAT). • Supply a 12 V tension to the two male terminals (85-86). • With a multimeter (in ohm meter mode) verify the continuity between the other two terminals (87- 30).

  • Page 78: Ignition/Injection System

    Electrical Equipment Atlantic 500 IGNITION/INJECTION SYSTEM E.C.U. CONNECTIONS ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! x1000r/min mp/h Km/h TRIP 13 14 15 7 8 9 10 11 12 13 14 15 18 19 20...
  • Page 79 Electrical Equipment Atlantic 500 CAUTION Since inside the C.D.I. control unit there are diodes, condensers and other electrical components, the measuring method described is approximate. Further checking is recommended by replacing the control unit with another pre-checked to ensure it is in working order, or carry out the checks described in the chapter (ELECTRICAL SYSTEM CONTROL USING A C.D.I.

  • Page 80: Connections To The E.c.u. Control Unit

    Electrical Equipment Atlantic 500 CONNECTIONS TO THE E.C.U. CONTROL UNIT NOMINAL TERMINALS CABLE COLOUR COMPONENT VALUE 680 Ω RPM sensor 7 - 12 B - B/N 52 Ω Stepper Motor 14 - 24 Az - Ro 52 Ω Stepper Motor...

  • Page 81: Checking The Hv Coil

    Electrical Equipment Atlantic 500 CHECKING THE HV COIL • Remove the left inspection cover, see (REMOVING THE RIGHT AND LEFT INSPECTION COVERS). • Disconnect terminal (1). • Unscrew and remove the two screws (2). • Disconnect the spark plug (3).

  • Page 82: Drop Sensor Check

    Electrical Equipment Atlantic 500 DROP SENSOR CHECK With motor off: • Remove the front hood, see (REMOVING THE FRONT HOOD). Check that the sensor (1) is mounted correctly (with the arrow imprinted on the rubber pointing upwards). • Partially remove the fuse carriers (2).

  • Page 83: Rpm Sensor Check

    Electrical Equipment Atlantic 500 RPM SENSOR CHECK With motor off: • Disconnect the three-way connector (1) and take measurements. With a multimeter (scale x 100 Ω) measure the • resistance between the sensor terminals, observing polarity (see diagram). Standard value: 680 Ω Ω Ω Ω Ω ± 10% •...

  • Page 84: Throttle Valve Potentiometer (Accelerator Sensor) Check

    Electrical Equipment Atlantic 500 THROTTLE VALVE POTENTIOMETER (ACCELERATOR SENSOR) CHECK With motor off: • Disconnect the three-way connector (black) (1). CAUTION During reassembly ensure correct coupling of the electrical connector (1). • Set the ignition switch to “ ”. •...

  • Page 85: Injector Check

    Electrical Equipment Atlantic 500 INJECTOR CHECK With motor off: • Disconnect the two-way connector (1) (black) and take measurements (on the terminals on the injector side). With a multimeter (scale x 100 Ω), measure the • resistance between the injector terminals.

  • Page 86: Fuel Pump Check

    Electrical Equipment Atlantic 500 FUEL PUMP CHECK (direct current) • Supply terminals 1 and 4 of the pump connector with a 12V tension (c.c.). • Verify that the pump works, emitting the characteristic hum, and check on the manometer that the supply pressure reaches at least i 150 KPa (1.5 bar).

  • Page 87: Starting And Stop Lights System

    Electrical Equipment Atlantic 500 STARTING AND STOP LIGHTS SYSTEM R/Gr Ar/V Key to wire diagram Main injection relay 11) Side stand switch 19) Battery 20) Starting relay 21) Starting motor 24) Secondary fuses 33) Rear stop light switch 34) Front stop light switch...

  • Page 88: Starting Relay Check

    Electrical Equipment Atlantic 500 STARTING RELAY CHECK • Disconnect the two-way connector (1)(white). CAUTION During reassembly ensure correct coupling of the electrical connector (1). • Pull the relay out from the special hooks (2). • Pull out the two rubber protectors (3-4).
  • Page 89 Electrical Equipment Atlantic 500 7) ENGINE OFF BUTTON ( Cable R/Gr 8) START BUTTON ( ) Cable 9) IGNITION BUTTON Cable G/Gr R/Bi PUSH 10) FRONT BRAKE LIGHT SWITCH Cable Gr/N 11) REAR BRAKE LIGHT SWITCH Cable 10 11 12) SIDE STAND SWITCH...

  • Page 90: Electric Cooling Fan

    Electrical Equipment Atlantic 500 ELECTRIC COOLING FAN WIRING DIAGRAM Vi/N Key to wiring diagram 15) Water thermistor 16) Fan 19) Battery 24) Secondary fuses 35) Key switch 38) Fan relay 52) E.C.U. control unit CHECKING THE ELECTRIC FAN • To check the operation of electric fan (1): •...

  • Page 91: Water Thermistor Check

    Electrical Equipment Atlantic 500 WATER THERMISTOR CHECK See (COOLANT THERMISTOR FUNCTION CHECK) on page 6-14. FAN RELAY CHECK To verify that the relay is working: • Remove the seat, see (SEAT REMOVAL). • Supply the two male terminals (85-86) with a 12V tension.

  • Page 92: Coolant Temperature And Fuel Level Indicators

    Electrical Equipment Atlantic 500 COOLANT TEMPERATURE AND FUEL LEVEL INDICATORS WIRING DIAGRAM ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! x1000r/min mp/h Km/h TRIP 2 3 4 5 6 7 8 9 10 11 12...

  • Page 93: Water Temperature

    Electrical Equipment Atlantic 500 WATER TEMPERATURE DASHBOARD CHECK • Disconnect the water thermistor connector and connect an electrical resistance (from the connector side) between the orange/red and white/black cables. • Turn the key to ON and verify the indication on the dashboard.

  • Page 94: Lights And Acoustic Signals System

    Electrical Equipment Atlantic 500 LIGHTS AND ACOUSTIC SIGNALS SYSTEM WIRING DIAGRAM SCROLL PASSING STOP R/Bi G/Gr R/Bi Key to wiring diagram 19) Battery 22) Main fuses 24) Secondary fuses 25) Top case light 26) Top case switch 27) Number plate light...

  • Page 95: Direction Indicators And Display Data

    Electrical Equipment Atlantic 500 DIRECTION INDICATORS AND DISPLAY DATA WIRING DIAGRAM ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! SCROLL x1000r/min mp/h Km/h PASSING STOP TRIP Key to wiring diagram 29) Rear right indicator...
  • Page 96 Electrical Equipment Atlantic 500 MULTIFUNCTION LCD DISPLAY Turning the ignition key (1) to position “ ”, all the segments on the Multifuncion LCD display are acti- vated for a few seconds (in this way working checks are carried out on the components) and the last function imposed after the vehicle was stopped is visualized.
  • Page 97 Electrical Equipment Atlantic 500 RESETTING OF AVERAGE SPEED, MAXIMUM SPEED, FUEL CONSUMPTION AND CHRONOMETER VALUES NOTE Cancellation of this information is only possible if the odometer is visualized to the right of the digital display. /RESET Keep the TRIP/RESET button (1) pressed for more than three seconds.

  • Page 98: Direction Indicator And Speedometer

    Electrical Equipment Atlantic 500 DIRECTION INDICATOR AND SPEEDOMETER WIRING DIAGRAM ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! x1000r/min mp/h Km/h TRIP 13 14 15 7 8 9 10 11 12 13 14 15...

  • Page 99: Dashboard Check

    Electrical Equipment Atlantic 500 DASHBOSRD CHECK • If the dashboard is in good working order, the red LED “ ” of the oil pressure should go on with the ignition switch to the “ ” position. SENSOR CHECK • With the ignition switch in position “ ” the red LED indicator “...

  • Page 100: Speedometer

    Electrical Equipment Atlantic 500 SPEEDOMETER • Check the correct coupling of the speed sensor connector (1). • Check the correct coupling of the dashboard connectors (2). • Check the distance between the speed sensor (3) and the front brake disc fixing screws (4).

  • Page 101: Air Temperature Sensor

    Electrical Equipment Atlantic 500 AIR TEMPERATURE SENSOR To verify that the air temperature sensor works: • Disconnect the two-way connector (1). • Carry out the sensor check in an environment with controlled temperature of 20 °C (68 °F). • Measure the electrical resistance with an ohm meter (scale 0-20 kΩ) between the connector...

  • Page 102: Switches

    Electrical Equipment Atlantic 500 SWITCHES Using a pocket multimeter, check the continuity of the switches by referring to the tables below. Replace any faulty components. 1) HORN BUTTON ( ) MODE Cable 2) TURN INDICATOR SWITCH ( Cable B/Bi STOP...

  • Page 103: Bulb Replacement

    Electrical Equipment Atlantic 500 BULB REPLACEMENT WARNING Before changing a bulb, move the ignition switch to position “ ” and wait a few minutes, so that the bulb cools down. Change the bulb wearing clean gloves or using a clean and dry cloth.

  • Page 104: Battery

    Electrical Equipment Atlantic 500 BATTERY For safety regulations and general information concerning the battery, see (BATTERY). For other information, see (ELECTROLYTE LEVEL CHECK),(BATTERY RECHARGE) and (BATTERY PROLONGED INACTIVITY). ACTIVATING THE BATTERY Read through paragraph (BATTERY). • Remove the battery cover, see (BATTERY COVER REMOVAL).
  • Page 105 Electrical Equipment Atlantic 500 FULL BEAM BULBS • Turn the bulb socket/bulb (8) anticlockwise and extract it from the parabolic setting. CAUTION To remove the bulb socket/bulb from its connec- tion, take special care not to damage the two housings (9).
  • Page 106 Electrical Equipment Atlantic 500 CAUTION During the following operations do not pull or force the electrical cables. • Pull out the rear lights assembly (4) first pulling out the upper part and then distancing it from its housing. CAUTION Work with caution.

  • Page 107: Number Plate Light Replacement

    Electrical Equipment Atlantic 500 NUMBER PLATE LIGHT REPLACEMENT Carefully read BULBS. To change the bulbs: CAUTION Do not pull the electrical cables when removing the bulb socket. • Grasp the bulb socket (1), pull and remove it from its housing.

  • Page 108: Vertical Beam Adjustment

    Electrical Equipment Atlantic 500 • Loosen and remove the two fixing screws (3) of the protective screen (4) of the third stop light. • Pull out the all-glass bulbs (5) from their housing. • Correctly fit a bulb of the same kind.

  • Page 109: Horizontal Beam Adjustment

    Electrical Equipment Atlantic 500 HORIZONTAL BEAM ADJUSTMENT • Remove the internal front shield, see (INTERNAL FRONT SHIELD REMOVAL). To carry out the beam adjustment: • Use the special handle (as indicated on the diagram) from the front of the vehicle.
  • Page 110 Electrical Equipment Atlantic 500 SECONDARY FUSE LAYOUT (FRONT HOOD) – 15 A (2) fuse From voltage regulator to: injection, stop/starting lights logistics (Housing A on the wire diagram). – 15 A (3) fuse From the ignition switch to: engine kill logistics, stop lights (Housing B on the wire diagram).

  • Page 111: Electrical Components Layout

    Electrical Equipment Atlantic 500 ELECTRICAL COMPONENTS LAYOUT 28) Radio power supply 3) Stepper motor 30) Rear left indicator 4) Coil 31) Parking/stop lights 5) Spark plug 33) Rear stop light switch 6) Fuel injector 39) Left indicator lights 11) Side stand switch...
  • Page 112 Electrical Equipment Atlantic 500 ELECTRICAL COMPONENTS LAYOUT 31) Parking/stop lights 2) Revolutions sensor 32) Right tail lamp 7) Fuel pump 34) Front stop light switch 8) Fuel level feeler 35) Key switch 9) Main injection relay (with diode) 36) Drop sensor...

  • Page 113: Wiring Diagram 500 C.c. Atlantic Scooter

    Electrical Equipment Atlantic 500 WIRING DIAGRAM 500 C.C. ATLANTIC SCOOTER 6-42 chap. 6 Release 00 2002-09...
  • Page 114 Electrical Equipment Atlantic 500 WIRING DIAGRAM KEY CABLE COLOURS 1) Multiple connectors orange 2) Revolutions sensor light blue 3) Stepper motor blue 4) Coil white 5) Spark plug yellow 6) Fuel injector gray 7) Fuel pump brown 8) Fuel level feeler...
  • Page 115 Electrical Equipment Atlantic 500 6-44 chap. 6 Release 00 2002-09...
  • Page 116 Cycle parts Atlantic 500 Cycle parts chap. 7 Release 00 2002-09...

  • Page 117: Chapter 7 Bodywork

    Cycle parts Atlantic 500 BODYWORK PASSENGER FOOTREST REMOVAL Place the vehicle on the central stand. CAUTION Work with care. Unscrew and remove the three screws (1). Remove the passenger footrest (2). LOWER PROTECTION COVER REMOVAL Place the vehicle on the central stand.

  • Page 118: Seat Removal

    Cycle parts Atlantic 500 SEAT REMOVAL Place the vehicle on the central stand. Lift up the seat (4) (see UNLOCKING/LOCKING THE SEAT). CAUTION Work with care. Utilising a suitable pincer, unclip the clip (5). CAUTION Prop up the seat do make sure it does not fall unexpectedly.

  • Page 119: Left And Right Hand Inspection Cover Removal

    Cycle parts Atlantic 500 LEFT AND RIGHT HAND INSPECTION COVER REMOVAL Place the vehicle on the central stand. Remove the left and right hand rubber mats (1) by lift- ing them up with the hands. Unscrew and remove the screw (2).
  • Page 120 Cycle parts Atlantic 500 Utilising a flat-bladed screwdriver (3), lever up the speaker cover (4) to free it from its seat, as indicated in the figure. Remove the speaker cover (4). Unscrew and remove the two screws (5). CAUTION Work with care. Do not damage the tongue and/or the relative seats.

  • Page 121: Document Compartment

    Cycle parts Atlantic 500 Pull the tabs (7) towards the cable (9), in such a way that the cable head (8) is freed by lifting it up. Pull the cable (9) in the direction indicated by the arrow to free the legshield from the document compartment clo- sure.

  • Page 122: Passenger Handle-Grip Removal

    Cycle parts Atlantic 500 PASSENGER HANDLE-GRIP REMOVAL Place the machine on the central stand. CAUTION Work with care. Do not damage the tongue and/or the relative seats. Handle the painted components with care. Do not drag them or ruin them.

  • Page 123: Removal Of The Chromed Strip From The Side Panels

    Cycle parts Atlantic 500 REMOVAL OF THE CHROMED STRIP FROM THE SIDE PANELS Remove the complete side panel (see COMPLETE SIDE PANEL REMOVAL). CAUTION Work with care. Do not damage the tongue and/or the relative seats. Handle the painted components with care.

  • Page 124: Foot Platform Removal

    Cycle parts Atlantic 500 FOOT PLATFORM REMOVAL Place the vehicle on the central stand. Remove the rubber mats (1) by lifting them by hand. Remove the cover to gain access to the spark plug (A). CAUTION Work with care. Do not damage the tongue and/or the relative seats.

  • Page 125: Front Shield Removal

    Cycle parts Atlantic 500 FRONT SHIELD REMOVAL Remove the spray guard (see SPRAY GUARD RE- MOVAL). Remove the legshield (see LEGSHIELD REMOVAL). CAUTION Work with care. Do not damage the tongue and/or the relative seats. Handle the painted components with care. Do not drag them or ruin them.

  • Page 126: Rear Mudguard Removal

    Cycle parts Atlantic 500 Unscrew and remove the seven screws (3). Disconnect the electrical connection (4). Remove the support arc (5). Disconnec the electrical connection from the bulbs (6) and the third stoplight. Lift up and remove the plastic part (7) of the backrest.

  • Page 127: Lower Cover Removal

    Cycle parts Atlantic 500 Holding the rear mudguard in the hand, disconnect the number plate light bulb (5), slide out the battery overflow tube (6) from the guide clip (7). Remove the rear mudguard (4). TAIL UNIT REMOVAL Remove the plastic backrest (see PLASTIC BACKREST REMOVAL).

  • Page 128: Footrest Support And Lower Spray Guard Removal

    Cycle parts Atlantic 500 FOOTREST SUPPORT AND LOWER SPRAY GUARD REMOVAL Remove the legshield (see LEGSHIELD REMOVAL). Remove the central tunnel (see CENTRAL TUNNEL REMOVAL). Unscrew and remove the two screws (1). Remove the chromed protection tube (2). Unscrew and remove the five screws (3).

  • Page 129: Front Panel Removal

    Cycle parts Atlantic 500 FRONT PANEL REMOVAL Place the vehicle on the central stand. Unscrew and remove the two screws (1). CAUTION Work with care. Do not damage the tongue and/or the relative seats. Handle the painted components with care. Do not drag them or ruin them.

  • Page 130: Lower Handlebar Cover Removal

    Cycle parts Atlantic 500 Unscrew and remove the two screws (4) on the right and left side of the vehicle. Remove the upper handlebar cover (5). LOWER HANDLEBAR COVER REMOVAL Remove the upper handlebar cover (see UPPER HANDLEBAR REMOVAL). Unscrew and remove the three screws (1).

  • Page 131: Windshield Removal

    Cycle parts Atlantic 500 Remove the front panel (see FRONT PANEL RE- MOVAL). Remove the windshield (see WINDSHIELD RE- MOVAL). Unscrew and remove the screw (4). Lift up the complete instrument panel (5) and discon- nect the electrical connections (6) directly from the instrument panel.

  • Page 132: Complete Lighting Assembly Removal

    Cycle parts Atlantic 500 COMPLETE LIGHTING ASSEMBLY REMOVAL Remove the hood, (see WINDSHIELD REMOVAL). Remove the front spray guard (see FRONT SPRAY GUARD REMOVAL). Remove the front panel (see FRONT PANEL RE- MOVAL). Remove the complete instrument panel (see INSTRU- MENT PANEL REMOVAL).

  • Page 133: Crash Helmet Compartment Removal

    Cycle parts Atlantic 500 CRASH HELMET COMPARTMENT REMOVAL Remove the seat (see SEAT REMOVAL). Remove the central tunnel (see CENTRAL TUNNEL REMOVAL). Remove the left and right hand side panels (see COMPLETE SIDE PANEL REMOVAL). Unscrew and remove the two screws (1) and recover the relative washers.
  • Page 134 Cycle parts Atlantic 500 Slide the starter relay (6) out of its seat inside the battery compartment. Support it by hand and slide off the rubber protection cover (7). Unscrew and remove the nut (8). Slide out from the rear, the wiring that comes out of the crash helmet compartment.
  • Page 135 Cycle parts Atlantic 500 Unscrew and remove the two screws (18). Unscrew and remove the four screws (19) of the carburettor cover (20). Remove the carburettor cover (20). Slacken the bands (22) via the screw (21) and slide out the fuel breather tube (23) by pulling it outwards.
  • Page 136 Cycle parts Atlantic 500 NOTE Make sure that you have a new band before substituting the old one. Remove the plastic band (26) and slide out the tube (27). Remove the engine cover (25) by lifting it upwards. Disconnect the electrical connections (28) of the crash helmet compartment light switch.

  • Page 137: Front Wheel

    Cycle parts Atlantic 500 FRONT WHEEL 1) Axle 2) Odometer sensor 3) r.h. outer spacer 4) r.h. oil seal 5) r.h. bearing 6) Wheel 7) Inner spacer 8) l.h. bearing 9) l.h. oil seal 10) l.h. brake disc 11) r.h. brake disc 12) l.h.

  • Page 138: Removing The Front Wheel

    Cycle parts Atlantic 500 REMOVING THE FRONT WHEEL Read through the paragraph (PRECAUTIONS AND GENERAL INFORMATION). CAUTION When removing/refitting the parts, take care not to damage the brake line, the disc and the pads. Put the vehicle on the central stand.

  • Page 139: Replacing The Bearings

    Cycle parts Atlantic 500 REPLACING THE BEARINGS Read through the paragraph (PRECAUTIONS AND GENERAL INFORMATION). CAUTION The bearings must be checked and if necessary replaced every time they are removed. Clean both sides of the hub with a rag. Removal...

  • Page 140: Check

    Cycle parts Atlantic 500 CHECK CAUTION Check the condition of all components, and in particular of those listed below. Bearings Manually rotate inner race (1), making sure it turns smoothly without any sticking and/or noise. Also check that there is no axial play.

  • Page 141: Refitting The Front Wheel

    Cycle parts Atlantic 500 REFITTING THE FRONT WHEEL CAUTION When refitting the front wheel, take care not to damage the brake line, the disc and the pads. Position the wheel between the fork rods. Insert axle (1) from the right side of the vehicle.

  • Page 142: Rear Wheel

    Cycle parts Atlantic 500 REAR WHEEL 1) Wheel assembly 2) Spacer 3) Oil seal 4) Brake caliper and silencer supporting plate 5) Nut 7-27 chap. 7 Release 00 2002-09...

  • Page 143: Removing The Rear Wheel

    Cycle parts Atlantic 500 REMOVING THE REAR WHEEL Read through the paragraph (PRECAUTIONS AND GENERAL INFORMATION). Put the vehicle on the central stand. WARNING Allow the engine and the exhaust terminal to cool down completely. Remove the exhaust terminal, see (REMOVING THE EXHAUST TERMINAL).

  • Page 144: Removing The Exhaust Terminal

    Cycle parts Atlantic 500 REMOVING THE EXHAUST TERMINAL Read through the paragraph (PRECAUTIONS AND GENERAL INFORMATION). Put the vehicle on the central stand. WARNING Allow the engine and the exhaust terminal to cool down completely. Unloose clamp (1) by unscrewing the nut fixing the exhaust terminal to the manifold.

  • Page 145: Check

    Cycle parts Atlantic 500 CHECK CAUTION Check the condition of all components and in particular of those listed below. Bearings Manually rotate inner race (1), making sure it turns smoothly without any sticking and/or noise. Check that there is no axial play.

  • Page 146: Key

    Cycle parts Atlantic 500 1) Brake control lever 2) Brake fluid pump/tank 3) Brake fluid pipe 4) Braking retarder 5) Brake caliper breather valve 6) Pipe fitting screw 7) Brake caliper 8) Brake pads 9) Brake disc 7-31 chap. 7...

  • Page 147: Replacing The Brake Pads

    Cycle parts Atlantic 500 REPLACING THE BRAKE PADS Read through the paragraph (PRECAUTIONS AND GENERAL INFORMATION). Put the vehicle on the central stand. NOTE Perform the following operations on both sides. Unloose and remove screw (1). Unloose and remove the two screws (2) and release the brake caliper (3).

  • Page 148: Checking The Brake Disc

    Cycle parts Atlantic 500 CHECKING THE BRAKE DISC CAUTION The following operations must be performed when the brake disc is installed on the wheel. Visually check the surface of the brake disc. If it shows any signs of scoring or damage, replace the disc (REMOVING THE BRAKE DISC).

  • Page 149: Key

    Cycle parts Atlantic 500 1) Brake control lever 2) Brake fluid pump/tank 3) Brake fluid pipe 4) Valve 5) Pipe fitting screw 6) Brake caliper 7) Pad pin 8) Stop ring 9) Brake pads 10) Antivibration plates 11) Pad spring...

  • Page 150: Replacing The Brake Pads

    Cycle parts Atlantic 500 REPLACING THE BRAKE PADS Read through the paragraph (PRECAUTIONS AND GENERAL INFORMATION). Remove the rear brake caliper, see (REMOVING THE REAR BRAKE CALIPER). Remove stop ring (1). Remove pin (2). Remove spring (3). CAUTION The vibration-damping plates are removed to- gether with the pads.

  • Page 151: Checking The Brake Disc

    Cycle parts Atlantic 500 CHECKING THE BRAKE DISC CAUTION The following operations must be performed when the brake disc is installed on the wheel. Visually check the surface of the brake disc. If it shows any signs of scoring or damage, replace the disc (REMOVING THE BRAKE DISC).

  • Page 152: Steering

    Cycle parts Atlantic 500 STEERING For information on how to check and adjust the steering, refer to the paragraph (CHECKING AND ADJUSTING THE STEERING). Disassembly Read through the paragraph (PRECAUTIONS AND GENERAL INFORMATION). Remove the handlebar cover, see (REMOVING THE UPPER HANDLEBAR COVER) and (REMOVING THE LOWER HANDLEBAR COVER).
  • Page 153 Cycle parts Atlantic 500 NOTE Perform the following operation also on the vehicle l.h.side. Unloose and remove the two screws (11). Release the brake caliper (12) from the fork. CAUTION Do not pull the front brake lever after removing the brake caliper as the caliper piston may come out of its seat and cause a leakage of brake fluid.

  • Page 154: Checking The Bearings

    Cycle parts Atlantic 500 CHECKING THE BEARINGS CAUTION Check the condition of all components. Check that the areas that come into contact with balls (1) on both revolving ring (2) and fixed ring (3) are not damaged or worn out. If they are, replace the bearing assembly.

  • Page 155: Key

    Cycle parts Atlantic 500 13) Dust cover gasket 1) Fork base 14) Lock spring ring 2) Fork clamp screws 15) Seal gasket 3) Spring stop ring 16) Cup 4) Rubber cap 17) Bush 5) Seal cap 18) Left wheel carrier...

  • Page 156: Checking The Oil Level

    Cycle parts Atlantic 500 CHECKING THE OIL LEVEL If “ bottom strokes” are noticed in the fork, check the oil level in the rods. Remove the front shield, see (REMOVING THE INNER SHIELD). NOTE To facilitate the removal of the two seal caps (3), it is necessary to remove them both at the same time.

  • Page 157: Removing The Rod-Wheel Carrier Assembly

    Cycle parts Atlantic 500 REMOVING THE ROD-WHEEL CARRIER ASSEM- BLY (with installed fork) Put the vehicle on the stand. CAUTION Place a suitable stand under the vehicle to prevent it from falling. Remove the front mudguard, see (REMOVING THE FRONT MUDGUARD).

  • Page 158: Wheel Carrier Rod Disassembly

    Cycle parts Atlantic 500 WHEEL CARRIER ROD DISASSEMBLY CAUTION Check the oil quantity. Read through the paragraph (PRECAUTIONS AND If less than 225 cm (13.72 cu.in), top up or renew. GENERAL INFORMATION). Unloose and remove screw (6) (wheel carrier bottom) To disassemble the rubber cap (1), lock spring ring and keep the copper washer (7).

  • Page 159: Checking The Components

    Cycle parts Atlantic 500 CHECKING THE COMPONENTS The sliding surface must show no signs of scoring and/ or damage. If the rod is damaged, replace it. With a dial gauge, check that the rod bending is lower than the limit value.

  • Page 160: Adjustment Of The Rear Suspension Spring Preload

    Cycle parts Atlantic 500 ADJUSTMENT OF THE REAR SUSPENSION SPRING PRELOAD Adjusting Rotation Rotation ring (arrow A) (arrow B) Spring preload Function Spring preload increase decrease The vehicle is less The vehicle is more Attitude rigid rigid Recommended Smooth or normal...
  • Page 161 Cycle parts Atlantic 500 7-46 chap. 7 Release 00 2002-09...
  • Page 162 G.Galilei, 1 30033 Noale (VE) Italy tel. +39 041.5829111 fax +39 041.441054 www.serviceaprilia.com...

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