APRILIA ATLANTIC 125 Workshop Manual
  1. Manuals
  2. Brands
  3. APRILIA Manuals
  4. Scooter
  5. ATLANTIC 125 -
  6. Workshop manual

APRILIA ATLANTIC 125 Workshop Manual

Hide thumbs Also See for ATLANTIC 125:
Table of Contents

Advertisement

Quick Links

Download this manual See also: Use and Maintenance Book, Manual
ATLANTIC 125 - 200
1101 2
00/2002-12
workshopmanual

Advertisement

Table of Contents
loading

Related Manuals for APRILIA ATLANTIC 125

Summary of Contents for APRILIA ATLANTIC 125

  • Page 1 ATLANTIC 125 - 200 1101 2 00/2002-12 workshopmanual...
  • Page 2 FOREWORD ATLANTIC 125 - 200 FOREWORD GENERAL INFORMATION ROUTINE MAINTENANCE LUBRICATION FUEL SYSTEM COOLING SYSTEM ENGINE CHASSIS ELECTRICAL SYSTEM 0 - 1...
  • Page 3 FOREWORD ATLANTIC 125 - 200 SUMMARY 0.1. FOREWORD ............................ 3 0.1.1. FOREWORD ........................... 3 0.1.2. REFERENCE MANUALS ......................4 0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS..............5 0 - 2...
  • Page 4 manual.
  • Page 5 FOREWORD ATLANTIC 125 - 200 0.1.2. REFERENCE MANUALS ENGINE WORKSHOP MANUALS aprilia part # (description) 8140680 8140681 8140682 8140683 8140684 PARTS CATALOGUES aprilia part # (description) 6642 SPECIAL TOOLS CATALOGUES aprilia part # (description) 001M OWNER’S MANUALS aprilia part # (description)
  • Page 6 FOREWORD ATLANTIC 125 - 200 0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS = number < = is less than > = is more than < = is less than or equal to > = is more than or equal to = approximately ∞ = infinite °C...
  • Page 7 FOREWORD ATLANTIC 125 - 200 RIGHT SIDE = right side = Society of Automotive Engineers T.B.E.I. = crowned-head Allen screw T.C.E.I. = cheese-headed Allen screw T.E. =hexagonal head TEST = diagnostic check T.P. =flat head screw = Twin Spark Ignition...

  • Page 8: General Information

    GENERAL INFORMATION ATLANTIC 125 - 200 GENERAL INFORMATION 1 - 1...

  • Page 9: Table Of Contents

    GENERAL INFORMATION ATLANTIC 125 - 200 SUMMARY 1.1. MANUAL LAYOUT ......................3 1.1.1. CONVENTIONS USED IN THE MANUAL................3 1.1.2. SAFETY INFORMATION .....................4 1.2. GENERAL RULES.......................5 1.2.1. BASIC SAFETY RULES ......................5 1.3. DANGEROUS ELEMENTS....................8 1.3.1. WARNINGS CONCERNING FUEL, LUBRICANTS, COOLANT AND OTHER COMPONENT PARTS ..........................8...

  • Page 10: Manual Layout

    GENERAL INFORMATION ATLANTIC 125 - 200 1.1. MANUAL LAYOUT 1.1.1. CONVENTIONS USED IN THE MANUAL • This manual is divided in sections and subsections, each covering a set of the most significant components. For quick reference, see the sections index.

  • Page 11: Safety Information

    GENERAL INFORMATION ATLANTIC 125 - 200 1.1.2. SAFETY INFORMATION The following conventions are used to identify safety information throughout the manual: This symbol identifies safety-related information. Whenever you see this symbol in the manual or attached to the motorcycle, use utmost care to avoid the risk of injury. Disregarding the instructions...

  • Page 12: General Rules

    GENERAL INFORMATION ATLANTIC 125 - 200 1.2. GENERAL RULES 1.2.1. BASIC SAFETY RULES CARBON MONOXIDE Should it be necessary to perform some operations with the vehicle running, make sure to work outdoors or in a well- ventilated room. Avoid starting the engine in closed or badly-ventilated rooms.
  • Page 13 GENERAL INFORMATION ATLANTIC 125 - 200 DANGER Be careful not to spill the coolant on the red-hot parts of the engine and the exhaust system: it may catch fire and send out invisible flames. In case any maintenance operation should be required, it is advisable to use latex gloves.
  • Page 14 Never clean a bearing with compressed air. NOTE All bearings must rotate freely with no hardness or noise. Replace any bearings that do not meet these requirements. Use aprilia ORIGINAL SPARE PARTS only. Use the specified lubricants and consumables. Where possible, lubricate a part before assembly.

  • Page 15: Dangerous Elements

    GENERAL INFORMATION ATLANTIC 125 - 200 1.3. DANGEROUS ELEMENTS 1.3.1. WARNINGS CONCERNING FUEL, LUBRICANTS, COOLANT AND OTHER COMPONENT PARTS DANGER The fuel used to operate engines is highly flammable and becomes explosive under particular conditions. Refueling and engine service should take place in a well-ventilated area with the engine stopped. Do not smoke when refueling or in the proximity of sources of fuel vapors.
  • Page 16 GENERAL INFORMATION ATLANTIC 125 - 200 BRAKE FLUID NOTE This vehicle is fitted with front and rear disc brakes. Each braking system is operated by an independent hydraulic circuit. The information provided below applies to both braking systems. DANGER Do not use the vehicle in case brakes are worn out or do not work properly! The brakes are the parts that most ensure your safety and for this reason they must always be perfectly working.
  • Page 17 GENERAL INFORMATION ATLANTIC 125 - 200 DISC BRAKES DANGER 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.
  • Page 18 GENERAL INFORMATION ATLANTIC 125 - 200 TYRES WARNING If tyres are excessively inflated, the vehicle will be hard and uneasy to ride, thus making you feel not at your ease. In addition the roadworthiness, mainly on wet surfaces and during cornering, will be impaired.

  • Page 19: Running-In

    GENERAL INFORMATION ATLANTIC 125 - 200 1.4. RUNNING-IN 1.4.1. RUNNING-IN RECOMMENDATIONS The running-in of the engine is essential to ensure its duration and correct functioning. If possible, drive on hilly roads and/or roads with many bends, so that the engine, the suspensions and the brakes undergo a more effective running-in.

  • Page 20: Vehicle Identification Data

    GENERAL INFORMATION ATLANTIC 125 - 200 1.5. VEHICLE IDENTIFICATION DATA 1.5.1. SERIAL NUMBERS LOCATION The vehicle serial numbers are used for its homologation. NOTE Do not alter the identification numbers if you do not want to incur severe penal and administrative sanctions. In...

  • Page 21: Using Tools And Spare Parts

    Should some parts be replaced, use aprilia Original Spare Parts only. aprilia high-quality Original Spare Parts have been expressly designed and manufactured for aprilia vehicles. WARNING The use of aprilia non-original spare parts can impair the vehicle performance or cause serious damage to the vehicle itself. 1 - 14...

  • Page 22: Technical Data

    GENERAL INFORMATION ATLANTIC 125 - 200 1.7. TECHNICAL DATA 1.7.1. TECHNICAL DATA DIMENSIONS Max. length 2100 mm Max. width (rear-view mirrors included) 900 mm Seat height 790 mm Max. height (front part of the fairing included) 1400 mm Min. ground clearance...
  • Page 23 GENERAL INFORMATION ATLANTIC 125 - 200 SUSPENSIONS Front telescopic fork with hydraulic operation Stroke 110 mm Rear n. 1 Hydraulic monoshock Stroke 105 mm BRAKES Front Hydraulic disc brake - ∅ 240 mm Hydraulic disc brake - ∅ 190 mm (combined with front...

  • Page 24: Decals Instructions

    GENERAL INFORMATION ATLANTIC 125 - 200 1.7.2. DECALS INSTRUCTIONS Should some frame parts be removed: NOTE Plastic and painted parts shall be handled with care. Do not score or damage them. Operate with care. Do not damage keys and/or keyways.
  • Page 25 GENERAL INFORMATION ATLANTIC 125 - 200 NOTE If present, remove the application tape (5) 20 to 30 minutes after applying the decal. • Remove the application tape (5) from the decal surface. • To ensure a good adhesion, use the spatule again by taking special care to the corners and edges.

  • Page 26: Products

    GENERAL INFORMATION ATLANTIC 125 - 200 1.8. PRODUCTS 1.8.1. LUBRICANT CHART LUBRICANT PRODUCT Engine oil RECOMMENDED: SUPERBIKE – 4T FORMULA RACING, SAE 5W - 40. As an alternative to the recommended oils, it is possible to use select oils having properties in compliance with or even above A.P.I. SJ specifications.

  • Page 27: Use Of Products

    GENERAL INFORMATION ATLANTIC 125 - 200 1.8.2. USE OF PRODUCTS For all maintenance operations, use the product listed below only. The listed materials have been tested for many years and are suitable for all the applications specified by the manufacturer.

  • Page 28: Tightening

    GENERAL INFORMATION ATLANTIC 125 - 200 1.9. TIGHTENING 1.9.1. GENERAL TIGHTENING TORQUE SETTINGS The table shows the tightening toque settings for 8.8 class screws made of steel/aluminum or other similar materials. Screw or bolt Wrench Tightening torque thread M 10...
  • Page 29 ROUTINE MAINTENANCE ATLANTIC 125 - 200 ROUTINE MAINTENANCE 2 - 1...
  • Page 30 ROUTINE MAINTENANCE ATLANTIC 125 - 200 SUMMARY 2.1. ROUTINE MAINTENANCE ......................3 2.1.1. INTRODUCTION ........................3 2.1.2. ROUTINE MAINTENANCE TABLE..................4 2.2. POINTS TO BE LUBRICATED ......................5 2.2.1. POINTS TO BE LUBRICATED....................5 2.3. TIGHTENING ........................... 6 2.3.1. NUT, BOLT, SCREW TIGHTENING ..................6 2.3.2.

  • Page 31: Routine Maintenance

    2.1. ROUTINE MAINTENANCE 2.1.1. INTRODUCTION To keep your vehicle in top performance conditions, aprilia strongly recommends to respect the routine maintenance schedule for the different parts of the vehicle. This section describes the routine maintenance operations for vehicle main components.

  • Page 32: Routine Maintenance Table

    ROUTINE MAINTENANCE ATLANTIC 125 - 200 2.1.2. ROUTINE MAINTENANCE TABLE After running-in Every 6000 km Every 12000 km Parts [1000 km (3728 mi) or (7456 mi) or (621 mi)] 8 months 16 months Rear shock absorbers Battery –Electrolyte level Spark plug Carburetor –...

  • Page 33: Points To Be Lubricated

    ROUTINE MAINTENANCE ATLANTIC 125 - 200 LUBRICATING CHART 2.2. POINTS TO BE LUBRICATED Steering bearings Rear wheel shaft and bearing 2.2.1. POINTS TO BE LUBRICATED Center stand spindle A good lubrication ensures vehicle smooth operation and Side stand spindle durability.

  • Page 34: Tightening

    ROUTINE MAINTENANCE ATLANTIC 125 - 200 2.3. TIGHTENING 2.3.1. NUT, BOLT, SCREW TIGHTENING Check all fastening parts with accuracy. Mainly check all safety-related components and, in particular: Handlebar-to-upper plate fastener; Front brake control lever; Clutch control lever; Fuel delivery line;...

  • Page 35: Fastening Elements

    ROUTINE MAINTENANCE ATLANTIC 125 - 200 2.3.2. FASTENING ELEMENTS Check and, if necessary, tighten after the first 1000 km (621 mi) and after every 6000 km (3728 mi) or 8 months. WARNING The fastening elements specified in the table must be tightened to the specified torque value using a ®...
  • Page 36 ROUTINE MAINTENANCE ATLANTIC 125 - 200 FRONT AND REAR BRAKES Description Q.ty Screw/Nut Notes Front calliper fixing M8x40 Front calliper fixing M8x45 Rear calliper fixing M8x40 Rear brake cable retainer M6x20 Front calliper fixing M6x35 HANDLEBARS AND CONTROLS Description Q.ty...

  • Page 37: Battery

    ROUTINE MAINTENANCE ATLANTIC 125 - 200 2.4. BATTERY 2.4.1. BATTERY Carefully read 1.2.1. Two different types of battery are available on the market: battery needing to be maintained with plugs; maintenance-free battery without plugs needing no electrolyte level check and topping up.

  • Page 38: Checking And Cleaning The Terminals

    ROUTINE MAINTENANCE ATLANTIC 125 - 200 2.4.2. CHECKING AND CLEANING THE TERMINALS Carefully read 2.4.1. • Make sure that the ignition switch is in position " ". • Raise the seat. • Undo and remove the two screws (1). •...

  • Page 39: Checking The Battery Electrolyte Level

    ROUTINE MAINTENANCE ATLANTIC 125 - 200 2.4.3. CHECKING THE BATTERY ELECTROLYTE LEVEL Carefully read 2.4.1. To check battery electrolyte level, proceed as follows: • Raise the vehicle on center stand. • Raise the seat. • Undo and remove the two screws (1).

  • Page 40: Recharging The Battery

    ROUTINE MAINTENANCE ATLANTIC 125 - 200 2.4.4. RECHARGING THE BATTERY Carefully read 2.4.1. NOTE If the battery is almost fully flat, when the starting button " " is pressed, the starting relay will issue a vibrating noise. Do not remove the battery plugs: without plugs the battery may be damaged.

  • Page 41: Long Inactivity Of The Battery

    ROUTINE MAINTENANCE ATLANTIC 125 - 200 2.4.5. LONG INACTIVITY OF THE BATTERY Carefully read 2.4.1. WARNING If the vehicle remains unused for more than twenty days, disconnect the 20A fuses. The removal of the 20A fuses requires the setting to zero of the following functions: digital clock and red line setting.

  • Page 42: Electrical Parts

    ROUTINE MAINTENANCE ATLANTIC 125 - 200 2.5. ELECTRICAL PARTS 2.5.1. ELECTRICAL PARTS Carefully read 1.2.1. • Position the vehicle on the stand. • Make sure that all lighting devices are working properly. • Make sure that headlamp is properly adjusted, 8.13.1.

  • Page 43: Spark Plugs

    ROUTINE MAINTENANCE ATLANTIC 125 - 200 2.6. SPARK PLUGS 2.6.1. SPARK PLUGS TIGHTENING TORQUE SETTINGS Spark plug: 20 Nm (2.0 kgm). Check the spark plug after the first 1000 km (621 mi) and then every 6000 km (3728 mi), change it every 12000 km (7456 mi).
  • Page 44 ROUTINE MAINTENANCE ATLANTIC 125 - 200 WARNING The spark plug must be well tightened, otherwise the engine may overheat and be seriously damaged. Use the recommended type of spark plugs only, in order not to compromise the life and performance of the engine.

  • Page 45: Air Cleaner

    ROUTINE MAINTENANCE ATLANTIC 125 - 200 2.7. AIR CLEANER 2.7.1. AIR CLEANER Clean the air cleaner every 6000 km (3728 mi) or 8 months. • It is possible to clean the air cleaner partially after riding the vehicle on this kind of roads.

  • Page 46: Tubes

    ROUTINE MAINTENANCE ATLANTIC 125 - 200 2.8. TUBES 2.8.1. TUBES Carefully read 1.2.1. FUEL Check fuel lines every 6000 km (3728 mi) or 8 months. Change them every two years. WARNING In case of wear, cracking or other damage, change the fuel lines.

  • Page 47: Coolant

    ROUTINE MAINTENANCE ATLANTIC 125 - 200 2.9. COOLANT 2.9.1. CHECKING AND TOPPING UP THE COOLANT LEVEL Carefully read 1.2.1. 1.3.1. • Check the coolant level before starting and change it every two years. WARNING Check the coolant level and top up the expansion reservoir with cold engine.

  • Page 48: Cleaning The Radiator

    ROUTINE MAINTENANCE ATLANTIC 125 - 200 2.9.2. CLEANING THE RADIATOR NOTE The radiator can be cleaned without being removed from vehicle. • Wash with a pressurized water jet aimed from behind the rear wheel air inlets. • Blow from below with compressed air.

  • Page 49: Brake Fluid

    ROUTINE MAINTENANCE ATLANTIC 125 - 200 2.10. BRAKE FLUID 2.10.1. CHECKING AND TOPPING UP THE BRAKE FLUID Carefully read 1.2.1. 1.3.1.. Check the brake fluid after the first 1000 km (621 mi) and then every 6000 km (3728 mi) or 8 months, change it every two years.
  • Page 50 ROUTINE MAINTENANCE ATLANTIC 125 - 200 • Raise and remove cover (2). • Remove gasket (3). NOTE In order not to spill the brake fluid while topping up, do not shake the vehicle. • Top up tank with brake fluid, see 1.8.1., to...

  • Page 51: Changing The Brake Fluid

    ROUTINE MAINTENANCE ATLANTIC 125 - 200 2.10.2. CHANGING THE BRAKE FLUID Carefully read 1.2.1. 1.3.1. • Brake fluid must be changed every two years. NOTE These operations apply to both front and rear brakes. WARNING When using the fluid, take care not to spill it on the plastic and painted parts, since it damages them.

  • Page 52: Checking The Brake Pad Wear

    ROUTINE MAINTENANCE ATLANTIC 125 - 200 2.10.3. CHECKING THE BRAKE PAD WEAR Carefully read 1.2.1. 1.3.1. 2.1.2. NOTE The following instructions apply to both brakes. Check the brake pad wear after the first 1000 km (621 mi) and successively every 2000 km (1242 mi).

  • Page 53: Bleeding The Braking Systems

    ROUTINE MAINTENANCE ATLANTIC 125 - 200 2.10.4. BLEEDING THE BRAKING SYSTEMS Carefully read 1.2.1. 1.3.1.. For maintenance operations schedule, see 2.1.2. The air, if any, present inside the hydraulic circuit will serve as “pad” by absorbing most of the pressure coming from the brake master cylinder and thus reducing the callipers efficiency during braking.
  • Page 54 ROUTINE MAINTENANCE ATLANTIC 125 - 200 DELAY VALVE • Remove the instrument panel, 7.2.6. • Remove the rubber cap (1) from the bleed valve (2). • Insert one end of a transparent plastic tubing inside the bleed valve (2) of the delay valve, and the other end in a container for collection.
  • Page 55 ROUTINE MAINTENANCE ATLANTIC 125 - 200 REAR BRAKE • Remove the rear brake calliper, but leave it connected to the tubes, 7.7.5. • Position the rear brake calliper as high as possible, to make air bleeding easier. • Remove the rubber cap from the bleed valve (4).

  • Page 56: Engine Oil

    ROUTINE MAINTENANCE ATLANTIC 125 - 200 2.11. ENGINE OIL 2.11.1. CHECKING THE ENGINE OIL LEVEL AND TOPPING UP Carefully read 1.2.1. 1.3.1. Change engine oil after the first 1000 km (621 mi), namely after running-in, and then check it every 3000 km (1864 mi).

  • Page 57: Changing The Engine Oil And The Oil Filter

    ROUTINE MAINTENANCE ATLANTIC 125 - 200 2.11.2. CHANGING THE ENGINE OIL AND THE OIL FILTER Carefully read 1.2.1. 1.3.1. Change the engine oil filter after the first 1000 km (621 mi), namely after running-in, and the every 6000 km (3728 mi).

  • Page 58: Transmission Oil

    ROUTINE MAINTENANCE ATLANTIC 125 - 200 2.12. TRANSMISSION OIL 2.12.1. CHECKING AND TOPPING UP THE TRANSMISSION OIL Carefully read 1.2.1. 1.3.1. Change transmission oil after the first 1000 km (621 mi), namely after running-in, and then check it every 6000 km (3728 mi) or 8 months.

  • Page 59: Changing The Transmission Oil

    ROUTINE MAINTENANCE ATLANTIC 125 - 200 2.12.2. CHANGING THE TRANSMISSION OIL Carefully read 1.2.1. 1.3.1. Change transmission oil after the first 1000 km (621 mi), namely after running-in, and then check it every 6000 km (3728 mi) or 8 months. Change oil every 24000 km (14913 mi).

  • Page 60: Throttle

    ROUTINE MAINTENANCE ATLANTIC 125 - 200 2.13. THROTTLE 2.13.1. THROTTLE Inspect after the first 1000 km (621 mi) and then every 6000 km (3728 mi) or 8 months. CHECKING FOR THROTTLE PROPER OPERATION DANGER Throttle operation may be impaired when the throttle cables are damaged, bent in tight turns or twisted.
  • Page 61 ROUTINE MAINTENANCE ATLANTIC 125 - 200 WARNING Turn the handlebars and ensure that idling speed is unaffected by handlebar movement. Open the throttle and ensure that the twistgrip springs back to the closed position smoothly when released. If twistgrip adjuster is fully tightened, loose or in case correct free play is not reached, proceed as follows: •...

  • Page 62: Idling Adjustment

    ROUTINE MAINTENANCE ATLANTIC 125 - 200 2.13.2. IDLING ADJUSTMENT Adjust as follows whenever idling speed seems erratic. Proceed as follows: • Ride a few kilometers until warming engine up to regular operating temperature. • Raise the seat. • Undo and remove the screw (1).

  • Page 63: Front End

    ROUTINE MAINTENANCE ATLANTIC 125 - 200 2.14. FRONT END 2.14.1. STEERING Inspect after the first 1000 km (621 mi) and then every 6000 km (3728 mi) or 8 months. The steering is fitted with rolling bearings to ensure smooth handling.

  • Page 64: Front Suspension

    ROUTINE MAINTENANCE ATLANTIC 125 - 200 2.14.2. FRONT SUSPENSION The front suspension is managed by a hydraulic fork, which is held to the steering stem by two yokes. NOTE Vehicle set-up may not be modified. Inspect front suspension after the first 1000km (621 mi), and then every 6000 km (3728 mi) or 8 months.

  • Page 65: Rear Axle

    ROUTINE MAINTENANCE ATLANTIC 125 - 200 2.15. REAR AXLE 2.15.1. CHECKING THE ENGINE AXLE Check the clearance between the engine shaft bushes and the engine shaft. To check, proceed as follows: • Position the vehicle on the center stand. •...

  • Page 66: Rear Suspension Inspection

    ROUTINE MAINTENANCE ATLANTIC 125 - 200 2.15.2. REAR SUSPENSION INSPECTION Inspect the rear suspension after the first 1000 km (621 mi), and then every 6000 km (3728 mi) or 8 months. Check that no oil leaks out of shock absorbers.

  • Page 67: Wheels

    ROUTINE MAINTENANCE ATLANTIC 125 - 200 2.16. WHEELS 2.16.1. WHEELS Carefully read 1.2.1. FRONT WHEEL Check every 6000 km (3728 mi). • Place the vehicle on the center stand. • Place a mount under frame. • Rotate the wheel manually in both directions.
  • Page 68 ROUTINE MAINTENANCE ATLANTIC 125 - 200 2.17. TYRES 2.17.1. TYRES Check tyre condition every month. It is a good rule to measure tyre inflation pressures before and after a long trip. Tyre inflation pressures should be checked monthly with the tyres at ambient temperature.

  • Page 69: Exhaust System

    ROUTINE MAINTENANCE ATLANTIC 125 - 200 2.18. EXHAUST SYSTEM 2.18.1. EXHAUST MANIFOLD NUTS Tighten the exhaust manifold nuts after the first 1000 km (621 mi) and every 6000 km (3728 mi) or 8 months. DANGER Allow the engine to cool down to ambient temperature.
  • Page 70 LUBRICATION ATLANTIC 125 - 200 LUBRICATION 3 - 1...
  • Page 71 LUBRICATION ATLANTIC 125 - 200 SUMMARY 3.1. LUBRICATION ..........................3 3.1.1. LUBRICATION......................... 3 3 - 2...
  • Page 72 LUBRICATION ATLANTIC 125 - 200 3.1. LUBRICATION 3.1.1. LUBRICATION The lubrication system is described in the engine workshop manual, 0.1.2. 3 - 3...
  • Page 73 FUEL SYSTEM ATLANTIC 125 - 200 FUEL SYSTEM 4 - 1...
  • Page 74 FUEL SYSTEM ATLANTIC 125 - 200 SUMMARY 4.1. FUEL SUPPLY ..............................3 4.1.1. FUEL SUPPLY DIAGRAM .......................... 3 4.1.2. CHANGING THE FUEL FILTER ......................... 4 4.1.3. REMOVING THE FUEL TANK........................5 4.1.4. REMOVING THE FUEL SENSOR ......................6 4.2. AIR FILTER ..............................7 4.2.1.

  • Page 75: Fuel Supply

    FUEL SYSTEM ATLANTIC 125 - 200 4.1. FUEL SUPPLY 4.1.1. FUEL SUPPLY DIAGRAM Key: Vacuum ports. SAI valve. Fuel tank connection. Pump delivery. Fuel filter. Anti-flow valve . Vacuum fuel pump. 4 - 3...

  • Page 76: Changing The Fuel Filter

    FUEL SYSTEM ATLANTIC 125 - 200 4.1.2. CHANGING THE FUEL FILTER Carefully read 1.2.1. 1.3.1. • Put a cloth under the fuel filter. • Release the two clips (1). • Remove the fuel filter (2). NOTE Install a new filter of the same type fitted originally.

  • Page 77: Removing The Fuel Tank

    FUEL SYSTEM ATLANTIC 125 - 200 4.1.3. REMOVING THE FUEL TANK • Lower the cooler, but leave it connected to the coolant delivery and return pipes, 5.3.1. • Disconnect the fuel delivery pipe (1). • Disconnect the fuel sensor connector (2).

  • Page 78: Removing The Fuel Sensor

    FUEL SYSTEM ATLANTIC 125 - 200 4.1.4. REMOVING THE FUEL SENSOR • Remove the central tunnel, 7.1.7. • Disconnect the fuel delivery pipe (1). • Disconnect the fuel sensor connector (2). • Undo and remove ring nut (3). • To remove fuel sensor, turn and lift it.

  • Page 79: Air Filter

    FUEL SYSTEM ATLANTIC 125 - 200 4.2. AIR FILTER 4.2.1. REMOVING THE AIR BOX TIGHTENING TORQUE SETTINGS Screws (4) 8 Nm (0.8 Kgm). • Undo and remove the two screws (1). • Undo and remove screw (2). • Remove the engine breather pipe protection (3).

  • Page 80: Removing The Air Cleaner

    FUEL SYSTEM ATLANTIC 125 - 200 4.2.2. REMOVING THE AIR CLEANER • Remove the air box, 4.2.1. • Undo and remove the nine screws (1). • Open the air box. • Remove the air cleaner (2). 4 - 8...

  • Page 81: Carburetor

    FUEL SYSTEM ATLANTIC 125 - 200 4.3. CARBURETOR 4.3.1. REMOVING THE CARBURETOR • Remove the air filter box, 4.2.1. • Raise the seat, 7.1.2. • Undo and remove screw (1). • Remove protection. • Loosen check nut (2). • Remove throttle cable from carburetor.
  • Page 82 FUEL SYSTEM ATLANTIC 125 - 200 • Loosen clamp and disconnect fuel line. • Loosen intake manifold clamp (4). • Remove carburetor. 4 - 10...

  • Page 83: Carburetor Disassembly

    FUEL SYSTEM ATLANTIC 125 - 200 4.3.2. CARBURETOR DISASSEMBLY • Turning the two screws (1), remove protection, bracket and starter. • Remove fastening screw (2) and pick-up pump rocker arm and spring. • Remove the two retaining screws, the vacuum chamber cover and the spring.
  • Page 84 FUEL SYSTEM ATLANTIC 125 - 200 • Remove pick-up pump piston with ring nut, guard, OR- seal and spring from float chamber. • Use a suitable pin and hammer to support the carburetor and, working from the throttle control side, remove the float pin.
  • Page 85 FUEL SYSTEM ATLANTIC 125 - 200 • Remove the idle flow screw with OR-seal, washer and spring. WARNING Do not remove the parts driven into the carburetor body, such as fuel delivery duct, needle location, starter jet, progression recess cap and full-power jet, throttle control shaft. Do not remove the throttle-to-shaft jointing screws.

  • Page 86: Assembling The Carburetor

    FUEL SYSTEM ATLANTIC 125 - 200 4.3.3. ASSEMBLING THE CARBURETOR • Before reassembling the carburetor, thoroughly clean carburetor body with fuel and compressed air. • Take special care to the fuel delivery line and to the metering rod location. •...
  • Page 87 FUEL SYSTEM ATLANTIC 125 - 200 • Thoroughly wash and blow spray nozzle full-power circuit, diffuser and jet. • Install the spray nozzle into the carburetor body. Make sure that the cylindrical side, which is shorter, is facing the diffuser.
  • Page 88 FUEL SYSTEM ATLANTIC 125 - 200 • Remove the float chamber exhaust screw (3), thoroughly wash and blow the float chamber. Make sure to perfectly clean the pick-up pump intake and delivery valve. • As these are one-way valves, gently blow with...
  • Page 89 FUEL SYSTEM ATLANTIC 125 - 200 • Check that the pick-up pump control rocker arm is not excessively worn. • Check that the rocker arm set screw juts of: - 125 cc engine: 3.7 mm - 200 cc engine: 3.2 mm.
  • Page 90 FUEL SYSTEM ATLANTIC 125 - 200 • Make sure that the membrane is not broken or hardened. If this is the case, change it. • Refit the tapered metering rod on the vacuum valve. • Make sure that the spring is correctly positioned on the metering rod and that coupling is perfectly seated.

  • Page 91: Checking The Automatic Starter

    FUEL SYSTEM ATLANTIC 125 - 200 4.3.4. CHECKING THE AUTOMATIC STARTER • Check that the automatic starter piston is not scored or oxidized. • Check that the piston can run smoothly into its mount. • Check that the piston seal is not out of shape.

  • Page 92: Adjusting The Idling Mixture

    FUEL SYSTEM ATLANTIC 125 - 200 4.3.5. ADJUSTING THE IDLING MIXTURE • The idling mixture does not need to be often adjusted. This adjustment shall be made in full compliance with some dispositions. • Before proceeding to carburetor adjustment, make...
  • Page 93 FUEL SYSTEM ATLANTIC 125 - 200 • Using the tester rev counter or a separate rev counter, adjust the idling screw until reaching a rpm value of 1700 ÷ 1800 g/min. NOTE The ignition system produces a big power. In case unsuitable rev counters are used, some reading errors may arise.
  • Page 94 COOLING SYSTEM ATLANTIC 125 - 200 COOLING SYSTEM 5 - 1...
  • Page 95 COOLING SYSTEM ATLANTIC 125 - 200 SUMMARY 5.1. COOLING SYSTEM DIAGRAM ....................... 3 5.1.1. COOLING SYSTEM DIAGRAM ....................3 5.2. COOLANT ............................4 5.2.1. CHANGING COOLANT ......................4 5.3. RADIATOR ............................5 5.3.1. REMOVING THE RADIATOR ....................5 5.3.2. REMOVING THE ELECTRIC FAN..................7 5.4.

  • Page 96: Cooling System Diagram

    COOLING SYSTEM ATLANTIC 125 - 200 5.1. COOLING SYSTEM DIAGRAM 5.1.1. COOLING SYSTEM DIAGRAM The centrifugal pump, which is located inside and driven by engine, sucks coolant from radiator and sends it to the cylinder and head ducts to cool engine inner parts.

  • Page 97: Coolant

    COOLING SYSTEM ATLANTIC 125 - 200 5.2. COOLANT 5.2.1. CHANGING COOLANT DRAINING THE CIRCUIT • Remove the expansion reservoir cap, 5.5.1. • Loosen clamp (2) and slide out hose (1). • Let the fluid flow into a suitable container for collection.

  • Page 98: Radiator

    COOLING SYSTEM ATLANTIC 125 - 200 5.3. RADIATOR 5.3.1. REMOVING THE RADIATOR • Drain the circuit, 2.12.2. • Remove lower protection, 7.1.8. • Disconnect electric fan connector. • Disconnect the two connectors on temperature switch. • Working from both sides, cut clamp (1).
  • Page 99 COOLING SYSTEM ATLANTIC 125 - 200 • Slide hoses (4) out of radiator. • Remove radiator. 5 - 6...

  • Page 100: Removing The Electric Fan

    COOLING SYSTEM ATLANTIC 125 - 200 5.3.2. REMOVING THE ELECTRIC FAN • Lower the radiator, but leave it connected to hoses, 5.3.1. WARNING Proceed with extreme care not to damage radiator fins. • Undo and remove the two nuts (1) on the front side.
  • Page 101 COOLING SYSTEM ATLANTIC 125 - 200 • Undo and remove the two screws (3). • Remove the electric fan. 5 - 8...

  • Page 102: Water Temperature Sensor

    COOLING SYSTEM ATLANTIC 125 - 200 5.4. WATER TEMPERATURE SENSOR 5.4.1. REMOVING THE WATER TEMPERATURE SENSOR • Raise the seat, 7.1.2. • Undo and remove screw (1). • Remove protection. • Disconnect the water temperature sensor. • Undo and remove the water temperature sensor.

  • Page 103: Removing The Expansion Reservoir

    COOLING SYSTEM ATLANTIC 125 - 200 5.5. REMOVING THE EXPANSION RESERVOIR 5.5.1. REMOVING THE EXPANSION RESERVOIR • Drain the cooling system, 5.2.1. • Release the expansion reservoir from the support 7.1.16. • Remove the two cooling system tubes. • Remove the expansion reservoir.
  • Page 104 ENGINE ATLANTIC 125 - 200 ENGINE 6 - 1...
  • Page 105 ENGINE ATLANTIC 125 - 200 SUMMARY 6.1. EXHAUST SYSTEM......................... 3 6.1.1. EXHAUST SILENCER REMOVAL ..................3 6.1.2. EXHAUST SYSTEM REMOVAL ..................... 4 6.1.3. ENGINE COMPONENTS THAT CAN BE REMOVED LEAVING THE ENGINE IN THE FRAME ............................ 5 6.2. ENGINE............................6 6.2.1.

  • Page 106: Exhaust System

    ENGINE ATLANTIC 125 - 200 6.1. EXHAUST SYSTEM 6.1.1. EXHAUST SILENCER REMOVAL TORQUE WRENCH SETTINGS Clamp (1) 20 Nm (2.0 kgm) Screws (2) 25 Nm (2.5 kgm) • Place the vehicle on the centre stand. DANGER Allow some time for the engine and the exhaust silencer to cool down completely.

  • Page 107: Exhaust System Removal

    ENGINE ATLANTIC 125 - 200 6.1.2. EXHAUST SYSTEM REMOVAL TORQUE WRENCH SETTINGS Nuts (1) 18 Nm (1.8 kgm) Screws (2) 25 Nm (2.5 kgm) DANGER Allow some time for the engine and the exhaust silencer to cool down completely. •...

  • Page 108: Engine Components That Can Be Removed Leaving The Engine In The Frame

    ENGINE ATLANTIC 125 - 200 6.1.3. ENGINE COMPONENTS THAT CAN BE REMOVED LEAVING THE ENGINE IN THE FRAME The components listed below can be removed and refitted with no need to take the engine out of the frame. LEFT SIDE OF ENGINE •...

  • Page 109: Engine

    ENGINE ATLANTIC 125 - 200 6.2. ENGINE 6.2.1. ENGINE REMOVAL Read 1.2.1. carefully. TORQUE WRENCH SETTINGS Lower bolt (9) 50 Nm (5.0 kgm) WARNING The engine is removed by lowering it from the frame. Make sure to have all necessary equipment ready at hand and in place before proceeding.
  • Page 110 ENGINE ATLANTIC 125 - 200 • Disconnect the pick-up (4). • Disconnect the vacuum hose (5) from the intake manifold. • Withdraw the drain hose (6) from the head. • Disconnect the hose (7) from the thermal expansion valve. •...
  • Page 111 ENGINE ATLANTIC 125 - 200 • Disconnect the spark plug cap. NOTE You will need a hoist and suitable slings to lift the engine. • Fix the slings to the rear end of the frame. • Lift the hoist arm until stretching the slings taut.

  • Page 112: Installing The Engine Into The Frame

    ENGINE ATLANTIC 125 - 200 6.2.2. INSTALLING THE ENGINE INTO THE FRAME Read 1.2.1. carefully. TORQUE WRENCH SETTINGS Lower mounting bolt (4) 50 Nm (5.0 kgm) DANGER Handle the engine with care and be careful of your finger and limbs.
  • Page 113 ENGINE ATLANTIC 125 - 200 • Connect the spark plug cap correctly. • Connect the following electric connectors in the order: Pick-up (8). • Coolant temperature sensor (9). • Position the grounding cable of the starter motor. • Tighten the screw (10).
  • Page 114 ENGINE ATLANTIC 125 - 200 NOTE Inspect any components you have disturbed and check that: electric leads are secured correctly with the suitable ties; WARNING The leads should not be twisted or trapped under any components. electric connectors are connected to the matching connectors;...

  • Page 115: Chassis

    CHASSIS ATLANTIC 125 - 200 CHASSIS 7 - 1...
  • Page 116 CHASSIS ATLANTIC 125 - 200 SUMMARY 7.1. BODYWORK ..........................4 7.1.1. BODYWORK ........................4 7.1.2. SADDLE REMOVAL......................6 7.1.3. REMOVING THE REAR SIDE PANELS................7 7.1.4. LUGGAGE RACK REMOVAL ....................8 7.1.5. TAIL REMOVAL........................9 7.1.6. REMOVING THE NUMBER PLATE HOLDER..............10 7.1.7. REMOVING THE CENTRAL TUNNEL................11 7.1.8.
  • Page 117 CHASSIS ATLANTIC 125 - 200 7.8.2. REMOVING THE STANCHION TUBES AND SLIDERS ............ 67 7.8.3. DISASSEMBLING THE STANCHION TUBES AND SLIDERS........... 68 7.8.4. DRAINING THE FRONT FORK..................71 7.8.5. FILLING THE FORK ......................73 7.8.6. COMPONENT INSPECTION .................... 75 7.8.7.

  • Page 118: Bodywork

    CHASSIS ATLANTIC 125-200 7.1. BODYWORK 7.1.1. BODYWORK Light unit Front cover Left mirror Rear brake lever Rear brake master cylinder Left switch Glove compartment Legshield Central tunnel 10. Saddle lock 11. Luggage rack 12. Tail 13. Tail light 14. Number plate holder 15.
  • Page 119 CHASSIS ATLANTIC 125-200 29. Saddle 30. Rear side panel 31. Battery 32. Throttle control 33. Right switch 34. Front brake lever 35. Right mirror 36. Windshield screen 37. Auxiliary fuses 38. Proportioning valve 39. Right side fairing 40. Front wheel 41.

  • Page 120: Saddle Removal

    CHASSIS ATLANTIC 125 - 200 7.1.2. SADDLE REMOVAL • Place the vehicle on the centre stand. • Insert the ignition key into the saddle lock. • Press and turn the key anticlockwise. • Raise the saddle. • Release and remove the four screws.

  • Page 121: Removing The Rear Side Panels

    CHASSIS ATLANTIC 125 - 200 7.1.3. REMOVING THE REAR SIDE PANELS NOTE The procedures described below apply to both side panels. • Raise the saddle, 7.1.2. • Release and remove the two screws (1). • Remove the side panel. 7 - 7...

  • Page 122: Luggage Rack Removal

    CHASSIS ATLANTIC 125 - 200 7.1.4. LUGGAGE RACK REMOVAL TORQUE WRENCH SETTINGS Screws (1) 10 Nm (1.0 kgm) Screws (2) 24 Nm (2.4 kgm) • Raise the saddle, 7.1.2. • Remove the luggage rack cover. • Release and remove the two screws (1) and collect the two washers.

  • Page 123: Tail Removal

    CHASSIS ATLANTIC 125 - 200 7.1.5. TAIL REMOVAL • Remove the luggage rack, 7.1.4. • Remove both rear side panels, 7.1.3. • Release and remove the three upper screws (1) on both sides. • Release and remove the lower screw (2) on both sides.

  • Page 124: Removing The Number Plate Holder

    CHASSIS ATLANTIC 125 - 200 7.1.6. REMOVING THE NUMBER PLATE HOLDER • Release and remove the four screws (1) on both sides. • Shift the number plate holder. • Release and remove the two screws of the bulb holder (2).

  • Page 125: Removing The Central Tunnel

    CHASSIS ATLANTIC 125 - 200 7.1.7. REMOVING THE CENTRAL TUNNEL • Remove the saddle, 7.1.2. • Remove the tail, 7.1.5. • Remove the legshield, 7.1.9. WARNING Proceed carefully. Do not damage the tab and/or its recesses. • Lift and remove the mat on both sides with your hands.
  • Page 126 CHASSIS ATLANTIC 125 - 200 • Remove the rubber gaiter placed underneath the fuel filler cap. NOTE Place a clean cloth into the filler cap opening. WARNING Proceed carefully. Do not damage the tab and/or its recesses. • Remove the central tunnel pulling in a rearward motion.

  • Page 127: Air Dam Removal

    CHASSIS ATLANTIC 125 - 200 7.1.8. AIR DAM REMOVAL • Place the vehicle on the centre stand. • Lift and remove the front mat with your hands on both sides. • Lift and remove the rear mat with your hands on both sides.
  • Page 128 CHASSIS ATLANTIC 125 - 200 • Release and remove the three screws (3) at the front end. • Lower the side stand. • Remove the air dam. 7 - 14...

  • Page 129: Legshield Removal

    CHASSIS ATLANTIC 125 - 200 7.1.9. LEGSHIELD REMOVAL • Place the vehicle on the centre stand. • Release and remove the eight screws (1) at the sides. • Insert the ignition key into the fuel tank lock. • Press and turn the key anticlockwise.

  • Page 130: Front Cover Removal

    CHASSIS ATLANTIC 125 - 200 7.1.10. FRONT COVER REMOVAL • Release and remove the screw (1) at the rear end on both sides. • Release and remove the two screws (2) at the front end. • Release and remove the two screws (3) at the lower end.

  • Page 131: Screen Removal

    CHASSIS ATLANTIC 125 - 200 7.1.11. SCREEN REMOVAL • Remove the front cover, 7.1.10. • Remove both mirrors, 7.1.12. • Release and remove the two front screws (1). • Remove the windshield screen. 7 - 17...

  • Page 132: Rear-View Mirror Removal

    CHASSIS ATLANTIC 125 - 200 7.1.12. REAR-VIEW MIRROR REMOVAL TORQUE WRENCH SETTINGS Screws (2) 10 Nm (1.0 kgm) NOTE The procedures described below apply to both mirrors. • Slip off the rubber gaiter. • Release and remove the two screws (1).

  • Page 133: Removing The Side Fairings

    CHASSIS ATLANTIC 125 - 200 7.1.13. REMOVING THE SIDE FAIRINGS NOTE The procedures described below apply to both fairings. • Remove the front cover, 7.1.10. • Remove the legshield, 7.1.9. • Release and remove the upper screw (1) on both sides.

  • Page 134: Front Mudguard Removal

    CHASSIS ATLANTIC 125 - 200 7.1.14. FRONT MUDGUARD REMOVAL TORQUE WRENCH SETTINGS Screws (1) 7 Nm (0.7 kgm) • Place the vehicle on the centre stand. • Release and remove the two screws (1) at both sides. • Remove the front mudguard.

  • Page 135: Rear Mudguard Removal

    CHASSIS ATLANTIC 125 - 200 7.1.15. REAR MUDGUARD REMOVAL TORQUE WRENCH SETTINGS Airbox screws (1) 8 Nm (0.8 kgm) Screws (2) 12 Nm (1.2 kgm) • Unscrew the two retaining screws (1) of the airbox. • Unscrew the three retaining screws (2) and collect the cable retainer.

  • Page 136: Helmet Compartment Removal

    CHASSIS ATLANTIC 125 - 200 7.1.16. HELMET COMPARTMENT REMOVAL • Remove the tail, 7.1.5. • Remove the saddle, 7.1.2. • Remove the battery and extract the main fuse carrier, 7.2.1. • Release and remove the two screws (1) at the front end.

  • Page 137: Handlebar Cover Removal

    CHASSIS ATLANTIC 125 - 200 7.1.17. HANDLEBAR COVER REMOVAL • Release and remove the two screws (1). • Remove the upper cover. • Release and remove the screw (2) at the front end on both sides. • Release and remove the screw (3) at the lower end on both sides.
  • Page 138 CHASSIS ATLANTIC 125 - 200 • Remove the upper handlebar cover. • Release and remove the two screws (5). • Remove the lower handlebar cover. 7 - 24...

  • Page 139: Splashguard Removal

    CHASSIS ATLANTIC 125 - 200 7.1.18. SPLASHGUARD REMOVAL • Remove the complete headstock, 7.8.1. • Remove the central tunnel, 7.1.7. • Shear the tie (1) on both sides. • Withdraw both air scoops from the radiator. • Release and remove the four screws (2) at both sides.

  • Page 140: Battery Removal

    CHASSIS ATLANTIC 125 - 200 7.1.19. BATTERY REMOVAL • Perform the first four operations described at paragraph 2.4.2. • Disconnect the negative (-) cable first and then the positive (+) cable. • Disconnect the breather hose from the battery. •...

  • Page 141: Engine Control Unit Removal

    CHASSIS ATLANTIC 125 - 200 7.1.20. ENGINE CONTROL UNIT REMOVAL • Remove the tail, 7.1.5. • Disconnect the ECU connector (1). • Release and remove the two screws (2). • Remove the ECU. 7 - 27...

  • Page 142: Voltage Regulator Removal

    CHASSIS ATLANTIC 125 - 200 7.1.21. VOLTAGE REGULATOR REMOVAL • Remove the tail, 7.1.5. • Disconnect the voltage regulator connector (1). • Release and remove the two screws (2). • Remove the voltage regulator. 7 - 28...

  • Page 143: Removing The Right Switch

    CHASSIS ATLANTIC 125 - 200 7.1.22. REMOVING THE RIGHT SWITCH • Release and remove the three screws (1) at the lower end. • Release and remove the screw (2). • Remove the switch lower cover. • Disconnect the engine kill switch connector.

  • Page 144: Removing The Left Switch

    CHASSIS ATLANTIC 125 - 200 7.1.23. REMOVING THE LEFT SWITCH • Release and remove the three screws (1) at the lower end. • Release and remove the screw (2). • Remove the switch lower cover. • Disconnect the light connector (3).

  • Page 145: Dashboard Removal

    CHASSIS ATLANTIC 125 - 200 7.1.24. DASHBOARD REMOVAL • Remove the windshield, 7.1.11. • Release and remove the dashboard retaining screw (1) on both sides. • Lift the dashboard. • Disconnect the speedometer cable. • Disconnect the three dashboard connectors (2-3-4).
  • Page 146 CHASSIS ATLANTIC 125 - 200 • Remove the dashboard. 7 - 32...

  • Page 147: Headlight Removal

    CHASSIS ATLANTIC 125 - 200 7.1.25. HEADLIGHT REMOVAL • Remove both side fairings, 7.1.13. • Release and remove the two upper screws (1). • Release and remove the two lower screws (2). • Disconnect the two direction indicator connectors on both sides.

  • Page 148: Removing The Front Direction Indicators

    CHASSIS ATLANTIC 125 - 200 7.1.26. REMOVING THE FRONT DIRECTION INDICATORS NOTE The procedures described below apply to both direction indicators. • Remove both side fairings, 7.1.13. • Disconnect the two direction indicator connectors. • Release and remove the two screws (1).

  • Page 149: Removing The Tail Light Unit

    CHASSIS ATLANTIC 125 - 200 7.1.27. REMOVING THE TAIL LIGHT UNIT • Remove the tail, 7.1.5. RIGHT • Disconnect the connector (1). • Extract the tail light bulb (2). • Release and remove the three screws (3). • Remove the right light unit.

  • Page 150: Coil Removal

    CHASSIS ATLANTIC 125 - 200 7.1.28. COIL REMOVAL • Remove the air dam, 7.1.8. • Disconnect the spark plug cap. • Disconnect the two coil connectors (1). • Release and remove the bolt (2) and collect the nut. 7 - 36...

  • Page 151: Controls

    CHASSIS ATLANTIC 125 - 200 7.2. CONTROLS 7.2.1. THROTTLE CONTROL REMOVAL • Remove the right switch, 7.2.5. • Release and remove the two screws (1). • Lower the brake master cylinder clamp. • Disconnect both throttle cables (2). • Remove the brake master cylinder clamp.

  • Page 152: Removing The Rear Brake Master Cylinder

    CHASSIS ATLANTIC 125 - 200 7.2.2. REMOVING THE REAR BRAKE MASTER CYLINDER • Remove the left switch, 7.2.5. • Release and remove the two screws (1). • Remove the brake master cylinder clamp. • Remove the brake master cylinder but leave it connected to the brake hose.

  • Page 153: Frame

    CHASSIS ATLANTIC 125 - 200 7.3. FRAME 7.3.1. HANDLEBAR REMOVAL TORQUE WRENCH SETTINGS Clamp bolt (1) 45 Nm (4.5 kgm) Safety screw (2) 20 Nm (2.0 kgm) • Remove the handlebar cover, 7.1.17. • Remove the throttle control, 7.3.1. •...

  • Page 154: Removing The Dashboard/Windshield Mounting Bracket

    CHASSIS ATLANTIC 125 - 200 7.3.2. REMOVING THE DASHBOARD/WINDSHIELD MOUNTING BRACKET TORQUE WRENCH SETTINGS Screws (2) 12 Nm (1.2 kgm) Screws (5) 10 Nm (1.0 kgm) • Remove the headlight, 7.2.7. • Remove the dashboard, 7.2.6. • Release all ties fitted to the dashboard/windshield mounting bracket.
  • Page 155 CHASSIS ATLANTIC 125 - 200 • Take the safety relay out of its mount. • Release and remove the two retaining screws (2) of the braking system proportioning valve. • Release and remove the three retaining screws (3) of the headlight upper mount.
  • Page 156 CHASSIS ATLANTIC 125 - 200 • Release and remove the four screws (5) securing the dashboard/windshield mounting bracket to the frame. • Remove the dashboard/windshield mounting bracket. 7 - 42...

  • Page 157: Side Stand Removal

    CHASSIS ATLANTIC 125 - 200 7.3.3. SIDE STAND REMOVAL TORQUE WRENCH SETTINGS Screws (1) 20 Nm (2.0 kgm) • Remove the central tunnel, 7.1.7. • Disconnect the side stand switch connector. • Unhook the two springs from the stand. •...

  • Page 158: Centre Stand Removal

    CHASSIS ATLANTIC 125 - 200 7.3.4. CENTRE STAND REMOVAL TORQUE WRENCH SETTINGS Nut (1) 27 Nm (2.7 kgm) • Place the vehicle on the side stand. • Unhook the two springs. • Release and remove the nut (1). • Withdraw the bolt from the opposite end.

  • Page 159: Frame Removal

    CHASSIS ATLANTIC 125 - 200 7.3.5. FRAME REMOVAL TORQUE WRENCH SETTINGS Screw (6) 12 Nm (1.2 kgm) NOTE Certain procedures include cross-references to relevant sections of the manual. Some of the operations described there may not be strictly required for the job at hand.
  • Page 160 CHASSIS ATLANTIC 125 - 200 • Disconnect the following connectors: voltage regulator; Engine Control Unit; starter motor connector (7); disconnect the two connectors (8) at the starter relay end. • Release and remove the two screws (9). • Remove the ECU bracket.

  • Page 161: Front Wheel

    CHASSIS ATLANTIC 125 - 200 7.4. FRONT WHEEL 7.4.1. FRONT WHEEL DIAGRAM Key: Wheel spindle Speedometer drive Right oil seal Right bearing Wheel Inner spacer Left bearing Left oil seal Brake disc Spacer NOTE Grease the wheel spindle (1). 7 - 47...

  • Page 162: Front Wheel Removal

    CHASSIS ATLANTIC 125 - 200 7.4.2. FRONT WHEEL REMOVAL TORQUE WRENCH SETTINGS Pinch bolt (1) 12 Nm (1.2 kgm) Wheel spindle 40 Nm (4.0 kgm) WARNING Use great care when removing and refitting the wheel to avoid damaging the brake hoses, brake discs and brake pads.
  • Page 163 CHASSIS ATLANTIC 125 - 200 • Collect the spacer fitted to the left side of wheel. 7 - 49...

  • Page 164: Front Wheel Disassembly

    CHASSIS ATLANTIC 125 - 200 7.4.3. FRONT WHEEL DISASSEMBLY Read 1.2.1. carefully. • Remove the front wheel, see 7.5.2. • Clean both ends of the hub with a cloth. • Remove the right oil seal (1). • Remove the right bearing (2) using a suitable extractor.

  • Page 165: Inspecting The Front Wheel Components

    CHASSIS ATLANTIC 125 - 200 7.4.4. INSPECTING THE FRONT WHEEL COMPONENTS WARNING Check that all components are in perfect condition. Pay special attention to the components listed below. BEARINGS Rotate the inner ring (1) manually. The ring should turn smoothly, with no hardness or noise.

  • Page 166: Refitting The Front Wheel

    CHASSIS ATLANTIC 125 - 200 7.4.5. REFITTING THE FRONT WHEEL TORQUE WRENCH SETTINGS Pinch bolt (1) 12 Nm (1.2 kgm) Wheel spindle 40 Nm (4.0 kgm) Screws (2) 25 Nm (2.5 kgm) • Position the wheel between the fork legs.

  • Page 167: Rear Wheel

    CHASSIS ATLANTIC 125 - 200 7.5. REAR WHEEL 7.5.1. REAR WHEEL DIAGRAM Key: Complete wheel Circlip Bearing Brake calliper and silencer carrier 7 - 53...

  • Page 168: Rear Wheel Removal

    CHASSIS ATLANTIC 125 - 200 7.5.2. REAR WHEEL REMOVAL TORQUE WRENCH SETTINGS Screw (1) 25 Nm (2.5 kgm) Wheel spindle nut 110 Nm (11.0 kgm) • Remove the exhaust, 1.8.1. • Remove the rear mudguard, 7.1.15. • Remove the rear brake calliper but leave it connected to the hose, 7.7.5.
  • Page 169 CHASSIS ATLANTIC 125 - 200 • Remove the shim (2) fitted to the wheel spindle. • Remove the rear wheel. 7 - 55...

  • Page 170: Brakes

    CHASSIS ATLANTIC 125 - 200 7.6. BRAKES 7.6.1. BRAKES DIAGRAM Key: Front brake lever Front brake master cylinder/fluid reservoir Front brake lever to calliper hose Proportioning valve Front brake calliper Front brake pads Proportioning valve to front brake calliper hose...

  • Page 171: Replacing The Front Brake Pads

    CHASSIS ATLANTIC 125 - 200 7.6.2. REPLACING THE FRONT BRAKE PADS TORQUE WRENCH SETTINGS Bolts (1) 25 Nm (2.5 kgm) • Place the vehicle on the centre stand. • Release and remove the two bolts (1). • Push the brake calliper pistons fully open, tilt the calliper outwards and ease it off the brake disc.

  • Page 172: Front Brake Disc Inspection

    CHASSIS ATLANTIC 125 - 200 7.6.3. FRONT BRAKE DISC INSPECTION NOTE These procedures must be performed with the brake disc installed to the wheel. • Check for wear measuring disc thickness with a micrometer gauge at different positions around the disc.

  • Page 173: Front Brake Disc Removal

    CHASSIS ATLANTIC 125 - 200 7.6.4. FRONT BRAKE DISC REMOVAL • Remove the front wheel, 7.5.2. • Release and remove the five brake disc screws (1). NOTE To refit, start all screws (1) manually in their holes and tighten in a cross pattern.

  • Page 174: Replacing The Rear Brake Pads

    CHASSIS ATLANTIC 125 - 200 7.6.5. REPLACING THE REAR BRAKE PADS TORQUE WRENCH SETTINGS Bolts (1) 25 Nm (2.5 kgm) • Release and remove the two bolts (1). • Remove the brake calliper from the disc. • Remove the retaining ring (2).

  • Page 175: Rear Brake Disc Inspection

    CHASSIS ATLANTIC 125 - 200 7.6.6. REAR BRAKE DISC INSPECTION NOTE These procedures must be performed with the brake disc installed to the wheel. • Check for wear measuring disc thickness with a micrometer gauge at different positions around the disc.

  • Page 176: Rear Brake Disc Removal

    CHASSIS ATLANTIC 125 - 200 7.6.7. REAR BRAKE DISC REMOVAL • Remove the rear wheel, 7.5.2. • Release and remove the three brake disc screws (1). NOTE To refit, start all screws (1) manually in their holes and tighten in a cross pattern.

  • Page 177: Proportioning Valve Removal

    CHASSIS ATLANTIC 125 - 200 7.6.8. PROPORTIONING VALVE REMOVAL TORQUE WRENCH SETTINGS Screws (2) 10 Nm (1.0 kgm) • Remove the dashboard, 7.2.6. • Drain the brake circuit, 2.10.2. • Release and remove the two screws (1) and the drain valve.

  • Page 178: Headstock

    CHASSIS ATLANTIC 125 - 200 7.7. HEADSTOCK 7.7.1. HEADSTOCK REMOVAL TORQUE WRENCH SETTINGS Locknut (1) 110 Nm (11.0 kgm) • Place the vehicle on a lift with the front wheel protruding over the lift edge. Put the vehicle on the centre stand.

  • Page 179: Component Inspection

    CHASSIS ATLANTIC 125 - 200 7.7.2. COMPONENT INSPECTION WARNING Ensure that all components are in good condition. Check the contact areas of the balls (1) on the rotary (2) and fixed (3) races for damage or wear. Replace the complete bearing if any component is damaged or worn.

  • Page 180: Front Fork

    CHASSIS ATLANTIC 125 - 200 7.8. FRONT FORK 7.8.1. FRONT FORK DIAGRAM Key: Steering stem and bottom yoke Fork clamp bolts Retaining ring Rubber cap Sealing cap O-ring Spring Damping cylinder Counter spring 10. Centring bush 11. Left slider 12. Dust seal 13.

  • Page 181: Removing The Stanchion Tubes And Sliders

    CHASSIS ATLANTIC 125 - 200 7.8.2. REMOVING THE STANCHION TUBES AND SLIDERS NOTE The procedures described below apply to both fork legs. • Remove the front wheel, 7.5.2. • Remove the front mudguard, 7.1.14. • Release and remove the two bolts (1).

  • Page 182: Disassembling The Stanchion Tubes And Sliders

    CHASSIS ATLANTIC 125 - 200 7.8.3. DISASSEMBLING THE STANCHION TUBES AND SLIDERS • Drain all oil, 7.8.4. • Place the fork leg in a vice with soft (aluminium) jaws. • Release and remove the capscrew (1). • Remove the slider and collect the centring bush.
  • Page 183 CHASSIS ATLANTIC 125 - 200 • Prise the dust seal off the stanchion. • Prise out the retaining ring. • Remove the oil seal. • Remove the washer. 7 - 69...
  • Page 184 CHASSIS ATLANTIC 125 - 200 • Remove the shim (4) if needed. 7 - 70...

  • Page 185: Draining The Front Fork

    CHASSIS ATLANTIC 125 - 200 7.8.4. DRAINING THE FRONT FORK NOTE Make sure to have a container having a capacity greater than, 1.7.1., ready at hand before proceeding. • Place the slider in a vice with soft (aluminium) jaws. WARNING The stanchion-and-slider assembly contains oil.
  • Page 186 CHASSIS ATLANTIC 125 - 200 • Raise the spring and allow some time before extracting it to let oil drip back into the slider. • Drain oil into the container. Pump the slider back and forth to facilitate draining. 7 - 72...

  • Page 187: Filling The Fork

    CHASSIS ATLANTIC 125 - 200 7.8.5. FILLING THE FORK • Place the stanchion-and-slider assembly in a vice with soft (aluminium) jaws. • Insert the spring. • Pour oil into the fork. WARNING Never reuse have drained previously. • Insert the top cap complete with O-ring.
  • Page 188 CHASSIS ATLANTIC 125 - 200 • Insert the damping cylinder (1). • Push down the damping cylinder until exposing the retaining ring (2) groove. • Insert the retaining ring (2). • Fit the top cap. 7 - 74...

  • Page 189: Component Inspection

    CHASSIS ATLANTIC 125 - 200 7.8.6. COMPONENT INSPECTION Read 1.2.1. carefully. STANCHION TUBE • Inspect the sliding surface for scoring and/or scratching. Eliminate minor scoring with wet sand paper (grain size 1). • Replace the stanchion if badly scored. •...

  • Page 190: Refitting The Stanchion Tubes And Sliders

    CHASSIS ATLANTIC 125 - 200 7.8.7. REFITTING THE STANCHION TUBES AND SLIDERS • Place the slider in a vice with soft (aluminium) jaws. • Position the shim (1). WARNING Make sure no dirt or objects fall into the slider or the stanchion.
  • Page 191 CHASSIS ATLANTIC 125 - 200 • Insert the dust seal. • Insert the damping cylinder and the spring into the slider. • Insert the centring bush (2) first and then the slider into the stanchion. • Tighten the capscrew (3).

  • Page 192: Rear Suspension

    CHASSIS ATLANTIC 125 - 200 7.9. REAR SUSPENSION 7.9.1. SHOCK ABSORBER REMOVAL TORQUE WRENCH SETTINGS Top nut (1) 50 Nm (5.0 kgm) Lower bolt (2) 50 Nm (5.0 kgm) • Remove the tail, 7.1.5. • Release and remove the top nut (1).
  • Page 193 CHASSIS ATLANTIC 125 - 200 7.9.2. REMOVING THE LINKAGES TORQUE WRENCH SETTINGS Nut (2) 40 Nm (4.0 kgm) Shock absorber bolt (4) 50 Nm (5.0 kgm) Nut (9) 60 Nm (6.0 kgm) • Remove the air dam, 7.1.8. • Remove both rear side panels, 7.1.3.
  • Page 194 CHASSIS ATLANTIC 125 - 200 • Collect in the order: inner nut (6), bolt (5) and washer. • Release and remove the nut (7) working form the right side. • Withdraw the bolt from the left side and collect the washer.

  • Page 195: Electrical System

    ELECTRICAL SYSTEM ATLANTIC 125 - 200 ELECTRICAL SYSTEM 8 - 1...
  • Page 196 ELECTRICAL SYSTEM ATLANTIC 125 - 200 SUMMARY 8.1. LAYOUT OF COMPONENTS.......................3 8.1.1. LAYOUT OF ELECTRICAL COMPONENTS................3 8.2. FOREWORD ..........................4 8.2.1. FOREWORD ........................4 8.3. BATTERY ............................5 8.3.1. BATTERY..........................5 8.4. IGNITION SYSTEM AND STAND LOGIC..................7 8.4.1. IGNITION SYSTEM AND STAND LOGIC ................7 8.5.

  • Page 197: Layout Of Components

    ELECTRICAL SYSTEM ATLANTIC 125 - 200 8.1. LAYOUT OF COMPONENTS 8.1.1. LAYOUT OF ELECTRICAL COMPONENTS Key: 15. Engine Control Unit Headlight 16. Coolant thermistor Battery 17. ECU relay Spark plug 18. Front brake light switch Main fuses 19. Dashboard Coil 20.

  • Page 198: Foreword

    ELECTRICAL SYSTEM ATLANTIC 125 - 200 8.2. FOREWORD 8.2.1. FOREWORD Please read the following information before reading this section. Note For ease of reference, the same numbering is used in the specific wiring diagrams and in the general schematics. WIRING COLOUR CODES...

  • Page 199: Battery

    ELECTRICAL SYSTEM ATLANTIC 125 - 200 8.3. BATTERY 8.3.1. BATTERY Battery rating: 12 V - 9 Ah ACTIVATION AND MAINTENANCE • Remove the battery from the vehicle, see 7.2.1. • Remove the cell caps and the breather cap. • Fill the cells with electrolyte fluid with 1.3 specific weight.
  • Page 200 ELECTRICAL SYSTEM ATLANTIC 125 - 200 SAFETY RULES WARNING Battery fluid contains sulphuric acid. Avoid contact with skin and do not spill on your clothing. Keep the battery away from sources of heat or ignition (such as sparks). This is...

  • Page 201: Ignition System And Stand Logic

    ELECTRICAL SYSTEM ATLANTIC 125 - 200 8.4. IGNITION SYSTEM AND STAND LOGIC 8.4.1. IGNITION SYSTEM AND STAND LOGIC Key: Key-operated switch Engine kill switch Main fuses Battery Auxiliary fuses HT coil Spark plug Automatic starter CDI control unit Side stand switch...
  • Page 202 ELECTRICAL SYSTEM ATLANTIC 125 - 200 TEST READINGS Ignition coil test Test the coil using a portable multimeter. Check for continuity of the primary and secondary windings. The resistance readings found need not match standard values exactly. If the windings are in good working order, resistance readings should approximate the standard values.
  • Page 203 ELECTRICAL SYSTEM ATLANTIC 125 - 200 SIDE STAND SWITCH TEST Ensure that there is no obstruction to side stand (1) rotation. Check for the following: • Inspect the springs (2) for any sign of damage, wear, rust or weakening. •...

  • Page 204: Charge System

    ELECTRICAL SYSTEM ATLANTIC 125 - 200 8.5. CHARGE SYSTEM 8.5.1. CHARGE SYSTEM AND POWER SUPPLY Key: Main fuses Power socket Battery Generator Voltage regulator CHECKING CHARGE VOLTAGE • Check battery fluid level, 2.4.3. • Check battery voltage, 2.4.1. • Start the engine and rev it up to 5000 rpm (rotate throttle twistgrip up to 1/4th of travel).
  • Page 205 ELECTRICAL SYSTEM ATLANTIC 125 - 200 ALTERNATOR LOADLESS OPERATION TEST • Disconnect the voltage regulator connector (1). • Start the engine and rev it up to 5000 rpm (rotate throttle twistgrip up to 1/4th of travel). • Measure AC voltage across the three yellow (G) wires using multimeter.

  • Page 206: Starter Circuit

    ELECTRICAL SYSTEM ATLANTIC 125 - 200 8.6. STARTER CIRCUIT 8.6.1. STARTER CIRCUIT Key: Key-operated switch Starter button Parking/left brake light bulb Parking/right brake light bulb Front brake light switch Rear brake light switch Brake light /starting interlock relay Starter relay...

  • Page 207: Atlantic 125

    ELECTRICAL SYSTEM ATLANTIC 125 - 200 STARTER RELAY TEST • Disconnect the two-way connector (1) (coloured white). • Release the relay (2) from its mount. • Slip off the two rubber gaiters (3-4). • Disconnect the wires from their respective terminals on the relay (2).
  • Page 208 ELECTRICAL SYSTEM ATLANTIC 125 - 200 SWITCH TEST Check switch continuity using a multimeter. Change any switch that operates other than as specified in the relevant diagram. Wires Starter button Start command Wires Front brake light switch Bi/n Lever pulled...

  • Page 209: Sensors

    ELECTRICAL SYSTEM ATLANTIC 125 - 200 8.7. SENSORS 8.7.1. SENSOR CIRCUIT Key: Fuel level indicator Complete dashboard Coolant thermistor Oil pressure sensor Fuel level sensor NOTE Terminal 2 of the 7-way connector is fed a positive voltage which is controlled by the switch.
  • Page 210 ELECTRICAL SYSTEM ATLANTIC 125 - 200 Coolant thermistor test • Remove the thermistor (1), 5.4.1. • Set a multimeter (2) to the Ohm range and attach the multimeter leads to the thermistor (3) as shown in the figure. • Suspend the thermistor (1) in a container (3) filled with coolant.
  • Page 211 ELECTRICAL SYSTEM ATLANTIC 125 - 200 Low fuel light test • Disconnect the sensor connector, 4.1.3. • Connect an ohmmeter to the orange-black and blue wire terminals. • Check for continuity across the terminals when fuel inside the tank is less than 1.5 litres. With any other quantity of fuel resistance should be infinite (open circuit).

  • Page 212: Fan And Rear Top Box Light

    ELECTRICAL SYSTEM ATLANTIC 125 - 200 8.8. FAN AND REAR TOP BOX LIGHT 8.8.1. FAN AND REAR TOP BOX LIGHT SYSTEM Key: Main fuses Battery Thermal switch Rear top box light switch Rear top box light FAN SYSTEM CHECK Cooling fan test To check for proper fan operation: •...
  • Page 213 ELECTRICAL SYSTEM ATLANTIC 125 - 200 Thermal switch test • Remove the air dam, 7.1.8. • Disconnect the two connectors. • Release and remove the thermal switch (2). • Set a multimeter (3) to the Ohm range to the thermal switch (2) as shown in the figure.

  • Page 214: Light Circuit

    ELECTRICAL SYSTEM ATLANTIC 125 - 200 8.9. LIGHT CIRCUIT 8.9.1. LIGHT CIRCUIT Key: High beam light Parking lamp light Dashboard backlighting bulbs Complete dashboard Left switch Key-operated switch Parking light/left brake light Parking light /right brake light Number plate light...
  • Page 215 ELECTRICAL SYSTEM ATLANTIC 125 - 200 SWITCH TEST • Check switch continuity using a multimeter. • Change any switch that operates other than as specified in the relevant diagram. Wires Light switch 8 - 21...

  • Page 216: Visual And Acoustic Signals

    ELECTRICAL SYSTEM ATLANTIC 125 - 200 8.10. VISUAL AND ACOUSTIC SIGNALS 8.10.1. VISUAL AND ACOUSTIC SIGNALLING SYSTEM Key: Right indicator light Left indicator light Complete dashboard Warning horn Horn button Key-operated switch Direction indicator switch Rear left direction indicator Rear right direction indicator...
  • Page 217 ELECTRICAL SYSTEM ATLANTIC 125 - 200 WARNING HORN TEST • Feed 12 Volts to the two connectors of the waning horn. • If the horn does not operate, adjust through the adjuster. • Replace the horn if necessary. SWITCH TEST •...

  • Page 218: Bulb Replacement

    ELECTRICAL SYSTEM ATLANTIC 125 - 200 8.11. BULB REPLACEMENT 8.11.1. BULB REPLACEMENT Read 1.2.1., 1.7.1. carefully. WARNING Before proceeding to change a bulb, rotate the ignition switch to “ ”.Wear clean gloves or use a clean, dry cloth to handle bulbs. Do not put your fingerprints on a bulb, as this may cause overheating leading to failure.
  • Page 219 ELECTRICAL SYSTEM ATLANTIC 125 - 200 • Grasp the bulb connector (2) and pull to disconnect. • Twist the bulb holder (3) anticlockwise and extract from the reflector seat. • Extract the bulb. On refitting: Insert the bulb into the reflector seat and ensure that...
  • Page 220 ELECTRICAL SYSTEM ATLANTIC 125 - 200 FRONT DIRECTION INDICATOR BULBS • Remove the front cover, 7.1.10. • Working from the front end of the vehicle, rotate the holder (8) with the bulb (9) clockwise and extract both. • Press the bulb (9) moderately and twist anticlockwise.

  • Page 221: Replacing The Fuses

    ELECTRICAL SYSTEM ATLANTIC 125 - 200 8.12. REPLACING THE FUSES 8.12.1. REPLACING THE FUSES WARNING Never attempt to repair a defective fuse. Never use a fuse of a rating other than specified. This could damage the electrical system or cause a short circuit, with the risk of fire.

  • Page 222: Beam Setting

    ELECTRICAL SYSTEM ATLANTIC 125 - 200 8.13. BEAM SETTING 8.13.1. BEAM HEIGHT SETTING 10 m This is a quick beam inspection procedure. Place the vehicle ten metres away from a vertical wall. It is important that the motorcycle be on level ground.

  • Page 223: Beam Horizontal Setting

    ELECTRICAL SYSTEM ATLANTIC 125 - 200 8.13.2. BEAM HORIZONTAL SETTING To adjust the horizontal position of the beam: • Open the glove compartment (1) and unhook the side guides by pressing moderately downwards. • Use a screwdriver and rotate the upper adjuster...

  • Page 224: Wiring Diagram

    ELECTRICAL SYSTEM ATLANTIC 125 - 200 8.14. WIRING DIAGRAM 8.14.1. WIRING DIAGRAM 8 - 30...
  • Page 225 ELECTRICAL SYSTEM ATLANTIC 125 - 200 Key: WIRE COLOUR CODING Multi-pin connectors Orange High beam warning light Light blue Low fuel light Blue Parking light warning light White Dashboard backlighting bulbs Yellow Check light (not in use) Grey Right direction indicator repeater light...
  • Page 226 G.Galilei, 1 30033 Noale (VE) Italy tel. +39 041.5829111 fax +39 041.5829190 www.aprilia.com www.serviceaprilia.com...

This manual is also suitable for:

Atlantic 200Atlantic 250Atlantic 500 sprint

Table of Contents