APRILIA ATLANTIC 500 - 02-2002 PART6 User manual

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use and maintenance Atlantic 500
WARNING
REAR BRAKE CALLIPER
– Ontherearpart,from below, forbothpads
(C).
The excessive wear of the friction mate-
rial would cause the contacts of the pad
metal support with the disk, with conse-
quent metallic noise and production of
sparks from the calliper; braking effi-
ciency, safety and soundness of the disk
would be compromised.
C
Check the wear of the brake pads espe-
cially before every trip.
To carry on a quick check of the brake pad
wear:
♦Position the vehicle on the central stand.
♦Carryonavisualcheckbetweenthebrake
disk and the pads, proceeding:
FRONT BRAKE CALLIPER
– On the front, part from below, for both cal-
lipers.
WARNING ♦Ifthe thicknessof thefrictionmaterial(even
if of one pad only) has reduced to about
1.5 mm, have both pads replaced.
– Front pads (2).
– Rear pads (3).
Have the pads replaced by your aprilia
Official Dealer.
WARNING
3
2
1,5mm
1,5mm
1,5mm
1,5mm

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use and maintenance Atlantic 500
CHECKING THE STAND
Carefully read page 40 (MAINTENANCE).
FOR THE SIDE STAND ONLY
Danger of fall or overturning
When straightening the vehicle, from the
parking position to the driving position,
the stand goes automatically up.
IMPORTANT The following information
refers to one stand only, but it is valid for
both.
Thestand (4)must rotatewithout hindrances.
Carry on the following checks:
♦The springs (5) must not be damaged,
worn, rusty or weakened.
♦The stand must rotate without hindrances;
if necessary, grease the joint (see page 74
TABLE OF LUBRICANTS).
CHECKING THE SWITCHES
The vehicle is provided with two switches:
- Stoplight switch on the rear brake control
lever (combined)
- Stoplight switch on the front brake control
lever.
If you need assistance or technical advice,
contactyour aprilia OfficialDealer, who can
ensure you an accurate and prompt service.
WARNING
4
54
CHECKING THE FRONT AND REAR
SUSPENSIONS
Carefully read page 39 (MAINTENANCE).
To replace the front suspension oil con-
tact your aprilia Official Dealer, who can
ensure you an accurate and prompt serv-
ice.
Havethe front suspension oilchanged every
30000 km (18750 miles) or every 4 years.
Carry on the following checks after the first
1000 km (625 miles) and successively after
6000 km (3750 miles):
♦With pulled front brake lever, push the fork
repeatedlydownwards.The strokemust be
smooth and there must not be any trace of
oil on the rods.
♦Make sure that all components are fas-
tened and that the front and rear suspen-
sion joints work correctly.
Should you notice irregularities in the
operation or if the help of skilled person-
nel should be necessary, contact your
aprilia Official Dealer.
CAUTION
CAUTION

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use and maintenance Atlantic 500
CHECKING THE STEERING
Carefully read page 40 (MAINTENANCE).
It is necessary to check the steering slack
occasionally.
To carry on the check:
♦Position the vehicle on the central stand.
IMPORTANT Provide for a support with
height and rest surface suitable to support
the vehicle safely.
♦Place the support under the vehicle and a
spongy cloth between them, so that the
front wheel can move freely and the vehi-
cle cannot fall down.
ADJUSTMENT OF THE REAR SUSPEN-
SION SPRING PRELOAD
ADJUSTING THE REAR SUSPEN-
SION
The rear suspension consists of a pair of
double-actionshock absorbers (braking with
compressed/extended shock absorber) fas-
tened to the engine by means of silent-
blocks.
The standard adjustment, set by the manu-
facturer, is suitable for a driver weighing
about 70 kg. In case of different weights or
needs, adjust the ring nut (1) by means of
the appropriate spanner provided in the tool
kit,thus settingthe idealdrive conditions(see
table).
Set both shock absorbers on the same
position.
CAUTION
Adjusting
ring nut Rotation
(arrow A) Rotation
(arrow B)
Function Spring
preload
increase
Spring
preload
decrease
Attitude The vehicle
is more rigid The vehicle
is less rigid
Suggested
kind of
road
Smooth or
normal roads Uneven roads
Notes Drive with
passenger Drive without
passenger
1

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use and maintenance Atlantic 500
CHECKING THE ENGINE FULCRUM
AXIS
Carefully read page 40 (MAINTENANCE).
Periodically check the slack between the
engine pin bushes.
To carry on the check:
♦Position the vehicle on the central stand.
♦Shakethe wheel transversally with respect
to the riding direction.
♦If you notice some slack, contact your
aprilia OfficialDealer, who will restore the
optimal operating conditions.
Make sure that the vehicle is stable.
♦Shake the fork in the riding direction.
If you shake the fork excessively, the
stand will move, thus producing an incor-
rect slack. Repeat the previous operation
more than once.
♦If the slack is considerable, contact your
aprilia OfficialDealer, who willrestore the
optimal operating conditions.
CAUTION
CAUTION
1
STEERING SHOCK ABSORBER
Carefully read page 40 (MAINTENANCE).
In case of full load trips (driver + passenger
+ luggage), it is possible to adjust the steer-
ing shock absorber.
To adjust the steering shock absorber:
♦If you rotate the ring nut (1) clockwise, the
shock absorber becomes more rigid.
If you tighten the ring nut, the shock ab-
sorber becomes more rigid and conse-
quently the effort to be made to rotate the
handlebar increases, thus reducing the
manoeuvrability.
CAUTION

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use and maintenance Atlantic 500
REMOVING THE RIGHT AND LEFT
INSPECTION COVERS
Carefully read page 40 (MAINTENANCE).
♦Position the vehicle on the central stand.
♦Remove the right or left mat (1), by lifting it
with your hands.
♦Unscrew and remove the screw (2).
Proceed with the utmost care.
Do not damage the tangs (3) and/or the
corresponding seats.
Handle the plastic and painted compo-
nents with care; do not scrape or dam-
age them.
♦By means of a screwdriver, lift the lower
part of the inspection cover (4) with force,
until it comes out of its seat.
Upon reassembly, fit the tangs correctly
in their seats.
REMOVING THE FAIRING
Carefully read page 40 (MAINTENANCE).
♦Position the vehicle on the central stand.
♦Remove the front cover, see page 54 (RE-
MOVING THE FRONT COVER).
♦Loosen and remove the six screws (1) fas-
tening the fairing to the vehicle.
♦Remove the fairing (2).
CAUTION
CAUTION
2
1
4
3
3
1
1
2

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use and maintenance Atlantic 500
Handle the plastic and painted compo-
nents with care; do not scrape or dam-
age them.
♦Remove the rear-view mirror (2) by pulling
it upwards.
♦Take the cover (1).
REMOVING THE REAR-VIEW
MIRRORS
Carefully read page 40 (MAINTENANCE).
The following information refers to one rear-
view mirror only, but it is valid for both.
♦Position the vehicle on the central stand.
IMPORTANT Group the components of
theleft andright rear-viewmirrors separately.
♦Remove the cover (1).
Hold the rear-view mirror (2) in order to
prevent it from falling down accidentally.
REMOVING THE FRONT COVER
Carefully read page 40 (MAINTENANCE).
♦Position the vehicle on the central stand.
♦Unscrew and remove the two screws (1).
Proceed with care.
Do not damage the tangs and/or the cor-
responding seats.
Handle the plastic and painted compo-
nents with care; do not scrape or dam-
age them.
♦Unscrew and remove the two screws (2).
Upon disassembly, prevent the tang clips
from falling down.
CAUTION
CAUTION
CAUTION
CAUTION
2
1
11
ABS

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use and maintenance Atlantic 500
♦Slightly open the front cover wings (see
arrow A) in order to disengage the tangs
from the fairing.
♦Slightly lift the lower part of the cover, see
arrow B.
♦Removethe frontcover(3) by pullingit with
care.
Upon reassembly, fit the tangs correctly
in their seats by means of their clips.
CAUTION
If this is not the case, proceed as follows:
♦Position the vehicle on the central stand.
♦Remove the protection element (1).
♦Loosen the lock nut (2).
♦Turnthe adjuster (3) so as to reset thepre-
scribed value.
♦After the adjustment, tighten the lock nut
(2) and check the idle stroke again.
♦Mount the protection element (1) again.
♦The cable (4) acts on the gas opening.
♦The cable (5) acts on the gas closing.
After the adjustment, make sure that the
handlebar rotation does not change the
engine idling rpm and that the accelera-
tor grip, after being released, comes back
smoothly and automatically to its origi-
nal position.
WARNING
ADJUSTING THE ACCELERATOR
CONTROL
Carefully read page 40 (MAINTENANCE).
The idle stroke of the accelerator grip must
be 2 – 3 mm, measured on the edge of the
grip itself.
3
2
1
2
3
4
5

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use and maintenance Atlantic 500
♦Energeticallyblow some air inorder to pre-
ventthe removedresidues fromgetting into
the engine. If the spark plug has crackings
on the insulating material, corroded elec-
trodes or excessive deposits, it must be
replaced.
♦Checkthe gapbetween the electrodeswith
a thickness gauge. The gap must be 0.7 –
0.8 mm; if necessary, adjust it, carefully
bending the earth electrode.
♦Make sure that the washer is in good con-
ditions. With mounted washer, screw the
spark plug manually so as to avoid dam-
aging the thread.
♦Tightenthe sparkplug withthe spanneryou
will find in the tool kit, giving it half a turn to
compress the washer.
Spark plug driving torque:
12 ÷ 14 Nm (1.2 ÷ 1.4 kgm)
The spark plug must be well tightened,
otherwise the engine may overheat and
be seriously damaged.
Use the recommended types of spark
plug only, see page 70 (TECHNICAL
DATA)in order to avoidcompromising the
engine performance and life.
♦Positionthe sparkplugcap suitably,so that
it does not come off due to the engine vi-
brations.
♦Mount the left inspection cover again, see
page 53 (REMOVING THE LEFT AND
RIGHT INSPECTION COVERS).
SPARK PLUG
Carefully read page 40 (MAINTENANCE).
Check the spark plug every 6000 km (3750
miles) and replace it every 12000 km (7500
miles).
Periodicallyremove thespark plugandclean
it, removing carbon deposits; if necessary,
change it.
To reach the spark plug:
♦Removethe leftinspection cover, see page
53 (REMOVING THE LEFT AND RIGHT
INSPECTION COVERS).
To remove and clean it:
Before carrying on the following opera-
tions, let the engine and the exhaust si-
lencer cool down until they reach room
temperature, in order to avoid burns.
♦Move the coolant pipe (1) in order to reach
the spark plug more easily.
♦Removethehigh voltagecable cap(2) from
the spark plug.
♦ Remove the dirt from the base of the spark
plug, then unscrew it with the spanner you
find in the tool kit and extract it from its seat,
taking care that neither dust nor other sub-
stances enter the cylinder.
♦Makesure that there arenocarbon depos-
itsor corrosion marks on theelectrode and
on the central porcelain part; if necessary,
clean them with the special cleaners for
spark plugs, with an iron wire and/or a
metal brush.
WARNING
CAUTION
12
0,7-0,8 mm0,7-0,8 mm

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use and maintenance Atlantic 500
LONG INACTIVITY OF THE
BATTERY
Should the vehicle remain unused for more
than fifteen days, it would be necessary to
recharge the battery, in order to avoid its
sulphation, see page 59 (RECHARGING
THE BATTERY):
♦Remove the battery, see page 58 (RE-
MOVING THE BATTERY) and keep it in a
cool and dry place.
Checkthe charge periodically (about once a
month), during the winter or when the vehi-
cle remains unused, in order to prevent the
deterioration of the battery.
♦Recharge it completely with a normal
charge,see page 59 (RECHARGINGTHE
BATTERY).
Ifthe battery remains on the vehicle, discon-
nect the cables from the terminals.
BATTERY
Carefully read page 40 (MAINTENANCE).
Check the electrolyte level and the tighten-
ing of the terminals after the first 1000 km
(625 miles) and then every 6000 km (3750
miles).
Danger of fire.
Keep fuel and other flammable sub-
stances away from the electric compo-
nents.
The battery electrolyte is toxic and caus-
tic and if it gets in contact with the skin,
it can cause burns, since it contains sul-
phuric acid. Wear protection clothes, a
facemask and/or goggles in case of main-
tenance operations.
In case of contact with the skin, rinse with
plenty of water.
Incase of contact with the eyes, rinse with
plenty of water for fifteen minutes, then
consult an oculist immediately.
If the electrolyte is accidentally swal-
lowed, drink a lot of water or milk, then
continue drinking milk of magnesia or
vegetable oil and consult a doctor imme-
diately.
The battery produces explosive gases;
keep it away from flames, sparks, ciga-
rettes and any other heat source.
During the recharging or the use, make
sure that the room is properly ventilated
and avoid inhaling the gases released
during the recharging.
KEEP OUT OF REACH OF CHILDREN
Do not incline the vehicle too much, in
order to avoid dangerous leaks of the
battery fluid.
Never invert the connection of the bat-
tery cables.
Connect and disconnect the battery with
the ignition switch in position “ ” oth-
erwise some components may be dam-
aged.
Connect first the positive cable (+) and
then the negative cable (-).
Disconnect following the reverse order.
The battery fluid is corrosive.
Do not pour o spill it, especially on the
plastic parts.
In case of installation of a “MAINTE-
NANCE-FREE” battery, to recharge it use
a specific battery charger (with constant
voltage/amperage or constant voltage).
The use of a conventional battery charger
may damage the battery.
PUSH
ZADI
CAUTION
WARNING

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use and maintenance Atlantic 500
REMOVING THE BATTERY
COVER
Carefully read page 57 (BATTERY).
IMPORTANTPositionthe vehicle onfirm
and flat ground.
♦Make sure that the ignition switch is in po-
sition “ ”.
♦Raise the saddle, see page 23 (UNLOCK-
ING/LOCKING THE SADDLE).
♦Takethe fittedcarpetoutofthe helmetcom-
partment.
♦Unscrew and remove the two screws (1).
♦Remove the battery cover from below (2),
paying attention to the upper tangs (3).
♦Disconnectthe electric connector(4) of the
crash helmet compartment lighting.
♦Remove the battery cover (2).
CHECKING AND CLEANING
THE TERMINALS
♦Removethe batterycover,seebeside (RE-
MOVING THE BATTERY COVER).
♦Make sure that the cable terminals (5) and
the battery terminals (6) are:
- in good conditions (and not corroded or
covered with deposits);
-covered with neutral grease or Vaseline oil.
If necessary:
♦Disconnect first the negative cable (-) and
then the positive (+) cable.
♦Brushwith a wirebrushto remove anysign
of corrosion.
♦Reconnect first the positive cable (+) and
then the negative cable (-).
♦Cover the terminals with neutral grease or
Vaseline oil.
REMOVING THE BATTERY
♦Removethe batterycover,seebeside (RE-
MOVING THE BATTERY COVER).
♦Remove the battery breather pipe (7).
♦Remove the battery (8) from its seat,
slightly rotating it rightwards (see the ar-
row).
♦Disconnect first the negative cable (-) and
then the positive (+) cable.
♦ Definitelyremove thebattery fromits seatand
putit on aflat surface, in acool and dryplace.
Once the battery has been removed, it
must be stored in a safe place and kept
away from children.
♦ Mount the battery cover again, see beside
(REMOVING THE BATTERY COVER).
Handle with care because the electrolyte
may flow out of the battery after removing
the breather pipe.
WARNING
1
2
4
3
56
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CAUTION

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use and maintenance Atlantic 500
CHECKING THE ELECTROLYTE
LEVEL
To check the electrolyte level:
♦Remove the battery cover, see page 58
(REMOVING THE BATTERY COVER).
♦Make sure that the fluid level is included
between the two MIN and MAX notches
stamped on the battery side.
Otherwise:
♦Remove the element plugs.
Top up with distilled water only. Do not
exceed the MAX mark, since the electro-
lyte level increases during the recharge.
♦Top up by adding distilled water.
RECHARGING THE BATTERY
♦Removethebattery,seepage58(REMOV-
ING THE BATTERY).
♦Remove the element plugs.
♦Check the electrolyte level, see beside
(CHECKING THE ELECTROLYTE
LEVEL).
♦Connectthe battery with a battery charger.
♦A recharge with an amperage equal to 1/
10th of the battery capacity is recom-
mended.
♦After the recharge operation, check the
electrolytelevel again and if necessary top
up with distilled water.
♦Mount the element plugs again.
Reassemblethe battery only 5-10 minutes
after disconnecting the battery charger,
since the battery continues to produce
gas for a short lapse of time.
INSTALLING THE BATTERY
♦Remove the battery cover, see page 58
(REMOVING THE BATTERY COVER).
♦Fit the battery in its seat.
Always connect the battery breather pipe,
to prevent the sulphuric acid vapours
from corroding the electric installation,
painted parts, rubber elements or gaskets
when they exit the breather pipe.
♦Connectfirst thepositive cable (+)and then
the negative cable (-).
♦Cover the terminals with neutral grease or
Vaseline oil.
♦Connect the battery breather pipe (1).
♦Mount the battery cover again, see page
58 (REMOVING THE BATTERY COVER).
CAUTION
CAUTION
CAUTION
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use and maintenance Atlantic 500
ARRANGEMENT OF THE SECOND-
ARY FUSES (FRONT COVER)
–15A fuse (2)
From the voltage regulator to: injection,
stoplight/starting logic (seatAin the wiring
diagram).
–15 A fuse (3)
From the ignition switch to: engine kill logic,
stoplights (seat B in the wiring diagram)
–15 A fuse (4)
From the ignition switch to: lights, horn,
dashboard, fan relay, power supply for car
radio set (seat C in the wiring diagram).
–15A fuse (5)
From the primary fuse to the outlet in the
crash helmet compartment.
–3A fuse (6)
From the voltage regulator to the perma-
nent power supply of the ECU central unit
(seat E in the wiring diagram).
–15A fuse (7)
Spare fuse.
–3A fuse (8)
Spare fuse.
–Free fuse (9)
REPLACING THE FUSES
Carefully read page 40 (MAINTENANCE).
Do not repair defective fuses.
Never use fuses different from the pre-
scribed ones: the electric system may be
damaged or a fire may be produced, in
case of short circuit.
IMPORTANT When a fuse is frequently
damaged, there may be a short circuit or an
overload. In this case, contact your aprilia
Official Dealer.
If an electric component does not work or
works irregularly or if the engine does not
start, it is necessary to check the fuses.
Check 3A and 15A fuses first and then 30 A
fuses.
To carry on the check:
♦Remove the battery cover, see page 58
(REMOVING THE BATTERY COVER), or
the front cover, see page 54 (REMOVING
THE FRONT COVER).
♦Extract the fuses one by one and make
sure that the filament (1) is not broken.
♦Before replacing the fuse, try to find out
the cause of the problem, if possible.
♦Replace the fuse, if it is damaged, with a
new one having the same amperage.
IMPORTANT If you use a spare fuse, fit
an identical one in the suitable seat.
♦Mount the battery cover again, see page
58 (REMOVING THE BATTERY COVER)
or put back the front cover, see page 54
(REMOVING THE FRONT COVER).
CAUTION
1
5
4
3
26
7
9
8

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use and maintenance Atlantic 500
VERTICAL ADJUSTMENT OF
THE HEADLIGHT BEAM
To quickly check the correct direction of the
headlight beam, place the vehicle at ten
metres from a vertical wall, making sure that
the ground is flat.
Turn on the low beam, sit on the vehicle and
make sure that the beam projected on the
wallis slightly under the horizontal lineof the
headlight (about 9/10th of the total height).
To adjust the headlight beam:
♦Act on the suitable knob (1) positioned on
the front of the vehicle. By turning it
CLOCKWISE, the headlight beam is set
upwards. By turning itANTICLOCKWISE,
the headlight beam is set downwards.
ARRANGEMENT OF THE PRIMARY
FUSES (BATTERY COMPARTMENT)
–30A fuse (10)
From the battery to: ignition switch, fuse
(2),helmet compartment light, cooling fan,
dashboard permanent power supply.
–30A fuse (11)
Fromthe battery to: voltageregulator,fuse
(3), fuse (5).
–30A fuse (12)
Spare fuse.
10 11
12
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HORIZONTAL ADJUSTMENT OF
THE HEADLIGHT BEAM
♦Remove the front inner shield, see page
54 (REMOVING THE FRONT INNER
SHIELD).
To adjust the headlight beam:
♦Act on the appropriate knob (as shown
above) positioned on the front of the vehi-
cle. By turning it CLOCKWISE, the head-
light beam moves rightwards (with respect
to the riding direction). By turning it ANTI-
CLOCKWISE, the headlight beam moves
leftwards (with respect to the riding direc-
tion).
BULBS
Carefully read page 40 (MAINTENANCE).
Danger of fire.
The electric components must be kept
away from fuel and other flammable sub-
stances.
Before replacing a bulb, move the igni-
tion switch to position “ ” and wait a
few minutes until the bulb cools down.
When changing the bulb, wear clean
gloves or use a clean and dry cloth.
Do not leave fingerprints on the bulb,
since they may cause overheating and
breakage.
If you touch the bulb with bare hands,
remove any fingerprint with alcohol to
avoid its damaging.
DONOT FORCE THE ELECTRIC CABLES.
IMPORTANT Before replacing a bulb,
check the fuses, see page 60 (REPLACING
THE FUSES).
WARNING
CAUTION
REPLACING THE BULBS OF THE
FRONT DIRECTION INDICATORS
Carefully read beside (BULBS).
To replace the bulbs:
♦Remove the front cover, see page 54 (RE-
MOVING THE FRONT COVER).
Proceed with care.
Do not damage the tangs and/or their
seats.
CAUTION
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2

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use and maintenance Atlantic 500
To replace the bulb of the LEFT direction in-
dicator:
♦Acting on the front of the vehicle, rotate
the support (1) with the bulb (2) clockwise
and extract both from their seat.
♦Slightly press the bulb (2) and rotate it an-
ticlockwise.
♦Extract the bulb from its seat.
IMPORTANTIntroduce the bulb into the
bulb socket by making the two elements co-
incide with the respective guides on the bulb
socket.
♦Correctly mount a bulb of the same kind.
♦ Upon reassembly, carry on the same opera-
tions in reverse order.
To replace the bulb of the RIGHT direction
indicator:
♦Extract the secondary fuse box (3) from its
seat in order to have more space to carry
on the dismounting operations.
♦Then carry on the same operations de-
scribed for the left direction indicator.
REPLACING THE HEADLIGHT
BULBS
Carefully read page 61 (BULBS).
The headlight houses the following bulbs:
- Two high beam bulbs (1).
- One low beam bulb (2).
- One parking light bulb (3).
To replace the bulb:
♦Remove the front cover, see page 54 (RE-
MOVING THE FRONT COVER).
LOW BEAM BULBS
While extracting the bulb electric connec-
tor, do not pull the electric cables.
♦Grasp the bulb electric connector (4), pull
it and disconnect it from the bulb (5).
♦Rotate the bulb socket (6) anticlockwise
and extract it from the parabola seat.
♦Remove the bulb (5).
Upon reassembly:
IMPORTANT Fit the bulb (5) in the pa-
rabola seat by making the three elements
on the bulb coincide with the respective
guides (7) on the parabola seat.
♦Place the bulb socket (6) into the parabola
seat and turn it clockwise.
♦Connect the bulb electric connector (4).
CAUTION
3
1
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use and maintenance Atlantic 500
HIGH BEAM BULBS
♦Rotate the bulb socket/bulb (8) anticlock-
wise and extract it from the parabola seat.
To extract the bulb socket/bulb from the
seat, try to avoid damaging the two tangs
(9).
♦Remove the bulb (9).
♦Replaceit withanew oneofthe samekind.
Upon reassembly, carry on the same op-
erations in reverse order.
PARKING LIGHTS
While extracting the bulb socket, do not
pull the electric cables.
♦Actingon the front of thevehicle,grasp the
bulb socket (1), pull it and extract it from
its seat.
♦Extract the parking light bulb (2) and re-
place it with a new one of the same kind.
REPLACING THE REAR LIGHT
BULBS
Carefully read page 61 (BULBS).
The rear light houses the following bulbs:
- Two parking light/stoplight bulbs (3).
- Two rear direction indicator bulbs (4).
To change them:
♦Raise the saddle, see page 23 (UNLOCK-
ING/LOCKING THE SADDLE).
IMPORTANT The following information
refers to one indicator only, but it is valid for
both.
♦Remove the knob (5) fastening the rear
lighting group to the vehicle.
CAUTION
CAUTION
9
8
1
2
3
3
4
4