APRILIA ATLANTIC 500 Instructions For Use Manual

INSTRUCTIONS FOR USE

WARNING

Before departure, always carry on a preliminary check of the vehicle to make sure that it works safely and correctly, see the following table (TABLE OF PRELIMINARY

CHECKS). The non-performance of such operations can cause serious injuries to people or damages to the vehicle.

Do not hesitate to contact your aprilia

Official Dealer if you do not understand the working of the controls or if you suspect or discover some irregularities.

It does not take long to carry on a checking operation and the resulting safety is considerable.

TABLE OF PRELIMINARY CHECKS

Component

Front and rear disk brakes

Brake levers

Accelerator

Engine oil

Check

Check the working, the idle stroke of the control levers, the fluid level and make sure that there are no leaks. Check the wear of the pads. If necessary, carry on the topping up of the brake reservoir.

Make sure that they work smoothly.

If necessary, lubricate the articulations.

Make sure that it works smoothly and that it can be opened and closed completely, in all steering positions.

Adjust and/or lubricate it, if necessary.

If necessary, check it and/or top up the oil reservoir.

Wheels/tyres

Steering

Check the tyre surface, the inflation pressure, wear and any damage.

Make sure that it rotates smoothly, without any clearance or slackening.

Side stand and central stand

Make sure that they work smoothly and that the spring tension brings them back to their normal position. If necessary, lubricate joints and articulations.

Fastening elements Make sure that the fastening elements are not loose. If necessary, adjust or tighten them.

Fuel tank

Coolant

Engine stop switch

( - )

Check the fuel level and top up, if necessary. Make sure that there are no leaks or occlusions in the circuit. Make sure that the fuel filler cap is correctly tightened.

The coolant level in the expansion tank must be included between the MIN and MAX marks.

Check the correct working.

Lights, warning lights, injection warning light, horn and electric devices

Injection pump

Make sure that the acoustic and visual devices work correctly. Replace the bulbs or carry out the necessary repairs in case of failure.

Make sure it works correctly.

Page

26, 48

–

–

24, 65

28, 29

19

57 - 64

–

55

26

30

51

49 use and maintenance Atlantic 500 33

3

1 2

PUS

H

PASSING

MODE

5

8

6 7

STARTING

WARNING

Exhaust gases contain carbon monoxide, a substance that is extremely noxious if inhaled. Avoid starting the engine in badly-ventilated or closed rooms. The non-observance of this warning may cause loss of consciousness and even death by asphyxia.

Do not get on the vehicle for the starting.

Do not start the engine if the vehicle is positioned on the side stand.

♦ Position the vehicle on the central stand

♦ to start the engine.

Make sure that the light switch (1) is in

♦ position “•”.

Make sure that the dimmer switch (2) is in position “ ”.

♦ Move the engine stop switch (3) to position “ ” (in the countries where required).

♦ Turn the key (4) and move the ignition switch to position “ ”.

CAUTION

At this point:

– the engine oil pressure warning light

“ ” (5), positioned on the dashboard, comes on and remains on until the engine starts. The Engine Fuel Injection (EFI) warning light (6) remains on for about three seconds, after all the other warning lights have gone out. If it does not come on or if both warning lights should not go out after three seconds, contact your aprilia Official

Dealer.

♦ Lock one wheel at least by means of a brake lever (6). If this operation is not carried on, the start relay receives no current and the engine does not start.

IMPORTANT

After a long period of inactivity of the vehicle, carry on the operations described on page 36 (STARTING

AFTER A LONG PERIOD OF INACTIVITY).

IMPORTANT

To avoid the excessive wear of the battery, do not keep the start push-button “ ” pressed for more than five seconds (ten in case of starting after a long period of inactivity). If the engine does not start within this lapse of time, wait ten seconds and press the start push-button again

“ ”.

CAUTION

Avoid pressing the start push-button

“ ” (8) while the engine is running because you may damage the starter.

34 use and maintenance Atlantic 500

9

5

ABS

8

♦ Press the start push-button “ ” (8) without accelerating and release it as soon as the engine starts.

♦ Keep at least one brake lever pulled and do not accelerate until you start.

CAUTION

After the engine starting, the engine oil pressure warning light “ ” (5) must go out. If the warning light remains on, or if it comes on during the normal working of the engine, it means that the oil pressure in the circuit is not sufficient. In this case, stop the engine immediately and contact your aprilia Official Dealer. Do not use the vehicle if the engine oil quantity is insufficient so as to avoid damaging the engine components.

CAUTION

Do not leave abruptly with cold engine.

To reduce the emission of polluting substances and the fuel consumption, it is advisable to warm the engine up by driving at slow speed for the first kilometres.

DIFFICULT STARTING

The feeding system of the vehicle is able to control the starting according to both engine conditions (warm/cold) and room temperature and pressure.

use and maintenance Atlantic 500 35

STARTING AFTER A LONG PERIOD OF

INACTIVITY

After a long period of inactivity, if the starting is not immediate, the fuel feeding circuit may be partially empty.

DEPARTURE AND DRIVE

IMPORTANT

Before departure, carefully read the “Safe drive” chapter, see page 5

(SAFE GUIDE).

CAUTION

If, while driving, the low fuel warning light

“ ” (10), positioned on the dashboard comes on, this means that the electric reserve is operating and there are still 4 litres of fuel available. Refuel as soon as possible, see page 25 (FUEL).

10

8

9

WARNING

If you drive without passenger, make sure that the passenger footrests are folded.

While driving, keep your hands on the grips and your feet on the footrests.

NEVER DRIVE IN ANY POSITION DIFFER-

ENT FROM THOSE INDICATED.

If you drive with a passenger, instruct him/ her so as to avoid problems during the manoeuvres.

Before leaving, make sure that the stand/ stands is/are completely up.

To leave:

♦ Release the accelerator grip (9) (Pos. A), operate the rear brake and move the vehi-

♦ cle down the stand.

Get on the vehicle and keep one foot at least on the ground so as to avoid losing balance.

♦ Correctly adjust the inclination of the rearview mirrors.

WARNING

With the vehicle at rest, try to get acquainted with the use of the rear-view mirrors. The reflecting surface is convex, therefore the objects seem to be farther than they really are. These mirrors offer a “wide-angle” view and only experience allows you to evaluate the distance of the following vehicles.


♦ Release the brake lever and accelerate, by turning the accelerator grip slightly; the vehicle will start moving.

CAUTION

Do not leave abruptly with cold engine.

To reduce the emission of polluting substances and the fuel consumption, it is advisable to warm the engine up by driving at slow speed for the first kilometres.

WARNING

Do not accelerate or decelerate repeatedly or continuously since you could accidentally lose control of the vehicle.

In case of braking, decelerate and operate both brakes in order to obtain uniform deceleration, suitably exerting pressure on the braking parts.

By operating only the front brake or only the rear brake, you reduce the braking force notably, thus locking one wheel and consequently losing grip.

If you stop uphill, decelerate completely and use only the brakes to keep the vehicle steady.

The use of the engine to keep the vehicle steady may cause the speed variator overheating.

WARNING

Before beginning to turn, slow down or brake driving at moderate and constant speed or accelerating slightly; do not brake at the last moment: you could easily skid.

If the brakes are operated continuously on downhill stretches, the friction material may overheat, thus reducing the braking efficiency. Exploit the engine compression by using both brakes intermittently.

Never drive downhill with the engine off.

In case of wet road or scarce wheel grip

(snow, ice, mud, etc.)drive at moderate speed, avoiding abrupt braking or manoeuvres that could cause grip loss and fall.

Pay attention to any obstacle or variation of the roadbed.

Uneven roads, rails, manhole covers, indications painted on the road surface, building site metal plates become slippery with rain, therefore it is necessary to avoid all these obstacles with the utmost care, driving slowly and bending the vehicle as little as possible.


7

WARNING

Always use the direction indicators in time when you change lane or direction, avoiding abrupt and dangerous manoeuvres.

Switch off the direction indicators immediately after changing direction. Be very careful overtaking other vehicles or when you are overtaken. In case of rain, the water cloud produced by big vehicles reduces visibility; air shift may make you lose control of the vehicle.

RUNNING-IN

WARNING

After the first 1000 km (625 miles), carry on the checks indicated in the “after running-in” column of the “REGULAR SERV-

ICE INTERVAL CHART”, see pages 41-42, in order to avoid personal injuries and/or damages to the vehicle.


The engine running-in is very important in order to ensure its working life and its correct functioning.

If possible, drive on roads with many hills and/ or bends, so that the engine, the suspensions and the brakes undergo to a more effective running-in.

IMPORTANT

Only after the first 1000 running-in kilometres (625 miles) it is possible to obtain the best acceleration and speed performance from the vehicle.

Keep to the following indications:

♦

Do not rotate the accelerator grip completely at low speed, both during and after the running-in.

♦

0-100 km (0-62 mi)

During the first 100 km (62 miles) use the brakes smoothly and avoid abrupt and long braking. This is necessary to ensure a correct bedding-in of the pads on the brake disk.

♦

0-500 km (0-312 mi)

During the first 500 kilometres (312 miles) do not exceed 80% of the maximum allowed speed.

♦

Avoid keeping a constant speed for long distances.

♦

After the first 1000 km (625 miles) progressively increase the speed until you reach the highest performance levels.

STOP

WARNING

If possible, avoid stopping abruptly, slowing down suddenly and braking at the last moment.

♦ Release the accelerator grip (pos. A) and gradually operate the brakes to stop the vehicle.

♦ During a short stop, keep at least one brake on.

WARNING

Park the vehicle on a firm and flat ground to avoid its fall. Do not lean the vehicle against walls and do not lay it down on the ground. Make sure that the vehicle, and in particular its red-hot parts, are not dangerous for people and children. Do not leave the vehicle unattended with the engine on or with the key inserted into the ignition switch. Do not sit on the vehicle when the stand is down.

♦ Stop the engine, see above (STOP).

1

2

3

PUS

H

4 5 6

4 5

7

♦ Move the engine stop switch (1) to position “ ”.

CAUTION

With the engine off and the ignition switch in position “ ”, the battery may run down.

♦ Turn the key (2) and move the ignition

♦ switch (3) to position “ ”.

Position the vehicle on the stand, see beside (POSITIONING THE VEHICLE ON

THE STAND).

♦ Lock the steering, see page 19 (STEER-

ING LOCK) and extract the key.

POSITIONING THE VEHICLE ON

THE STAND

Carefully read page 37 (PARKING).

CENTRAL STAND

♦ Grasp the left grip (4) and the passenger grab rail (5).

♦ Push down the stand lever (6).

SIDE STAND

♦ Grasp the left grip (4) and the passenger grab rail (5).

WARNING

Danger of fall or overturning.

When straightening the vehicle, from the parking position to the driving position, the stand goes up automatically.

♦ Push the side stand (7) with your right foot and extend it completely.

♦ Incline the vehicle until the stand rests on the ground.

♦ Steer the handlebar completely leftwards.

WARNING

Make sure that the vehicle is stable.

CAUTION

Do not leave the key in the ignition switch.


SUGGESTIONS TO AVOID THEFT

MAINTENANCE

NEVER leave the ignition key inserted and always use the steering lock.

Park the vehicle in a safe place, possibly in a garage or a protected place.

If possible, use the suitable aprilia “Body-

Guard” armored cable or an additional antitheft device.

Make sure that all the documents and the road taxes are in order.

Write down your personal data and telephone number in this page so as to facilitate the identification of the owner in case of finding after theft.

SURNAME: ...............................................

NAME: .......................................................

ADDRESS: ................................................

WARNING

Danger of fire

Keep fuel and other inflammable substances away from electric components.

Before starting any maintenance or inspection operation of the vehicle, stop the engine and extract the key, wait until the engine and the exhaust system have cooled down, lift the vehicle by means of the suitable equipment, on a firm and flat ground.

Before proceeding, make sure that the room is properly ventilated.

Pay particular attention to the red-hot parts of the engine and of the exhaust system so as to avoid burns.

The vehicle is made up of not edible parts: some of them are noxious or even toxic.

Never bite any part of the vehicle.

...................................................................

PHONE NUMBER: ....................................

IMPORTANT

In most cases, stolen vehicles are identified through the data written on the use and maintenance book.

CAUTION

To carry on the reassembly of the groups it is necessary to repeat the disassembly operations in reverse order, if not expressly indicated otherwise.

In case of maintenance operations, it is advisable to use latex gloves.


Normally, routine maintenance operations can be carried on by the user; however, in some cases, it may be necessary to use specific tools and technical expertise.

If you need assistance or technical advice, contact your aprilia Official Dealer, who can ensure you an accurate and prompt service.

It is advisable to ask the aprilia Official

Dealer to test the vehicle on the road after a repair or a periodic maintenance operation.

Personally perform the “Preliminary checks” after any maintenance operation, see page

33 (TABLE OF PRELIMINARY CHECKS)

REGULAR SERVICE INTERVALS CHART

OPERATIONS TO BE CARRIED OUT BY THE aprilia Official Dealer

Components

Accelerator cable (adjustment)

Variator belt

Steering bearings and steering

Wheel bearings

Engine oil filter

Clutch shoes

Valve clearance

Braking systems

Cooling system

Stoplight switches

Brake fluid

Coolant

Engine oil

Fork oil

After running-in

[1000 km (625 mi)]

C

C

Every 6000 km

(3750 mi) or 8 months

C

S

C

C

C

R

C

After 12000 km

(7500 mi) or 16 months every 6000 km: S

C in seguito ogni 18000 Km

Transmission oil

Variator rollers and variator plastic guides

Wheels/tyres and inflation pressure

C

C a

S

C

C every 6000 km (3750 mi): C/ every 2 years: S every 2000 km (1250 mi): C/ every 2 years: S every 3000 km: C/every 6000 km (3750 mi): S every 30000 km (18750 mi) or every 4 years: S

C every 24000 km: S

C

C

Bolt tightening

Brake fluid bleeding

Fuel pipes

Fuel filter

C

C

C

C

C every 4 years: S every 24000 km (15000 mi): C every 48000 km (30000 mi): S

C = check and clean, adjust, lubricate or replace if necessary. P = clean; S = replace; R = adjust.

Carry on the maintenance operations more frequently if you use the vehicle in rainy and dusty areas or on even ground.


OPERATIONS TO BE CARRIED OUT BY THE aprilia Official Dealer (WHICH CAN BE CARRIED OUT EVEN BY THE USER)

Components

After running-in

[1000 km (625 mi)]

Every 6000 km

(3750 mi) or 8 months

After 12000 km

(7500 mi) or 16 months

Battery - Electrolyte level

Spark plug

Carburettor - idling

Air cleaner

Accelerator working

Brake locking working

Light system

Brake fluid

Coolant

Engine oil

Light direction - working

Wheels/tyres and inflation pressure

Suspensions

Engine oil pressure warning light

Front and rear brake pad wear

C

C

C

C

C

C

C

C

C

C S

C every 18000 km: S P

C

C

C

C every 2000 km (1250 mi): C every 1000 km (625 mi): C

C every month: C

C

on every start: C (*) every 2000 km (1250 mi): C C

C = check and clean, adjust, lubricate or replace if necessary. P = clean; S = replace; R = adjust.

Carry on the maintenance operations more frequently if you use the vehicle in rainy and dusty areas or on even ground.

(*) To check these components see pages 15-16: TABLE OF INSTRUMENTS AND INDICATORS.


1

IDENTIFICATION DATA

It is a good rule to write down the frame and engine numbers in the space provided in this manual.

The frame number can be used for the purchase of spare parts.

NOTE Do not alter the identification numbers if you do not want to incur severe penal and administrative sanctions. In particular, the alteration of the frame number results in the immediate invalidity of the guarantee.

FRAME NUMBER

The frame number is stamped on the central tube of the frame. To be able to read it, remove the cover (1).

ENGINE NUMBER

The engine number is stamped near the lower support of the rear shock absorber.

Frame no. __________________________ Engine no. __________________________ use and maintenance Atlantic 500 43

1

2 4

1

MAX MIN

3

CHECKING THE OIL LEVEL AND

TOPPING UP

Carefully read page 26 (LUBRICANTS), page 40 (MAINTENANCE) and page 74

(TABLE OF LUBRICANTS).

CHECKING

IMPORTANT

Position the vehicle on firm and flat ground.

♦ Position the vehicle on the central stand.

WARNING

The engine and the system components get very hot and remain hot for some time even after the engine has been stopped. Before touching such components, wear insulating gloves or wait until the engine and the exhaust system have cooled down.

♦ Stop the engine and let it cool down so as to allow the oil to flow into the oil pan and to cool down.

IMPORTANT

The non-performance of the operations described above may lead to an incorrect measurement of the engine oil level.

♦

♦

Unscrew and extract the plug/dipstick (1).

Clean the part in contact with the oil with a clean cloth.

♦ Tighten the plug/dipstick (1) completely screwing it into the filling hole (2).

♦ Extract the plug/dipstick (1) again and read the oil level on the dipstick:

MAX = maximum level;

MIN = minimum level.

The difference between MAX and MIN is about:

– 400 cc

♦ The level is correct if the oil reaches about the MAX mark on the dipstick.

CAUTION

Do not exceed the MAX mark and do not leave the oil below the MIN mark to avoid serious damages to the engine.

♦ If necessary, carry on the topping up.

TOPPING UP

♦ Pour a small quantity of oil into the filling

♦

♦

♦ hole (2) and wait about one minute until the oil flows uniformly inside the oil pan.

Carry on the oil level check and, if necessary, the topping up.

Top up with small quantities of oil, until the prescribed level is reached.

At the end of the operation screw and tighten the plug/dipstick (1).

WARNING

Do not use the vehicle with insufficient lubrication or with improper and contaminated lubricants since they may accelerate the wear of the moving parts and cause irreversible damages.


REPLACING THE OIL AND THE

ENGINE OIL FILTER



IMPORTANT



WARNING

The engine and the system components get very hot and remain hot for some time even after the engine has been stopped.

Before touching such components, wear insulating gloves or wait until the engine and the exhaust system have cooled down.


IMPORTANT


To change the oil, contact an aprilia Official Dealer.

♦

♦


Unscrew and remove the oil cartridge filter from the engine (3).

WARNING


WARNING

Used oil contains substances that are very dangerous for the environment: to change it, contact an aprilia Official

Dealer, who will provide for the disposal of used oils in accordance with the laws in force.

♦ Unscrew and remove the oil drain plug (4) and then empty the reservoir completely.

♦ Install a new oil cartridge filter (3) and lubricate the O-rings of the filter.

♦ Screw and tighten the engine oil drain plug

♦

(4).

Pour about 1700 cc oil into the filling hole

(2).

♦

♦

Screw and tighten the oil dipstick (1).

Start the vehicle and let it run for a few minutes. Stop it and let it cool down. Check the engine oil level again by means of the dipstick (1) and, if necessary, top up without exceeding the MAX mark.

For topping up and replacement operations, use new synthetic oil (SAE 5/W 40 type) with characteristics superior to the

API ST specification.

1

CHECKING THE TRANSMISSION

OIL LEVEL AND TOPPING UP



IMPORTANT Position the vehicle on firm and flat ground.


WARNING



♦

♦


Clean the part in contact with the oil with a clean cloth.

♦ Tighten the plug/dipstick (1) completely screwing it into the filling hole (2).

♦ Extract the plug/dipstick (1) again and read the oil level on the dipstick:

MAX = maximum level

MIN = minimum level

♦ The level is correct if the oil reaches about the MAX mark on the dipstick.

CAUTION

Do not exceed the MAX mark and do not leave the oil below the MIN mark to avoid serious damages to the engine.

♦ If necessary, carry on the topping up.

TOPPING UP

♦ Pour a small quantity of oil into the filling hole (2) and wait about one minute until the oil flows uniformly inside the oil pan.

♦ Carry on the oil level check and, if necessary, the topping up.

♦ Top up with small quantities of oil, until the prescribed level is reached.

♦ At the end of the operation, screw and tighten the plug/dipstick (1).

USE SAE 80W/90 OIL, SUPERIOR TO API

GL3 SPECIFICATIONS.

WARNING


REPLACING THE TRANSMISSION OIL



IMPORTANT



WARNING



IMPORTANT



To replace the oil, contact an aprilia Official Dealer.

WARNING

While changing the transmission oil, prevent it from coming in contact with the rear brake disk.

♦

♦


Unscrew and remove the transmission oil

♦ drain screw (3).

Let the transmission oil flow out completely and collect it into a container with suitable capacity.

♦ Screw and tighten the transmission oil drain

♦ screw (3).

Lubricate the transmission with about 250 cc oil in accordance with the Table of Lubricants.

♦

♦

Screw and tighten the plug/dipstick (1).

Check the transmission oil level again by means of the dipstick (1) and, if necessary, top up without exceeding the MAX mark.

For topping up and replacement operations, use the new oils given in the TA-

BLE OF LUBRICANTS.

2

1

3

4

3

AIR CLEANER

Carefully read page 40 (MAINTENANCE).

The air cleaner should be cleaned and checked every 6000 km (3750 miles), depending on the use conditions.

If you use the vehicle on wet or dusty roads, the cleaning or replacement operations must be carried on more frequently.

To clean the filtering element, it is necessary to remove it from the vehicle.

REMOVAL

♦

♦

Position the vehicle on the central stand.

Raise the saddle (UNLOCKING / LOCK-

♦

♦

ING THE SADDLE).

Remove the safety clip (1).

Remove the pin (2) fastening the piston to the air cleaner cover.

CAUTION

While removing the pin, hold the saddle to avoid its fall.

♦ Holding the saddle, remove the six screws

(3) fastening the air cleaner cover to the plastic material under the saddle.

CAUTION

While lifting the air cleaner cover, avoid removing the suction sleeve from the filter case.

♦ Carefully lift the air cleaner cover (4).

♦ Remove the air cleaner (5).


4

5


5

4

4

CLEANING

WARNING

Do not use petrol or flammable solvents to wash the filtering element so as to avoid the risk of fires or explosions. Do not use any additive or liquid to clean it in order to avoid moisture inside the filter case. Use compressed air only.

♦ Clean the filtering element (5) by means of a pressurised air jet.

CAUTION

DO NOT OIL THE FILTERING ELEMENT to avoid damaging the filter and the engine.

Check the wear of the brake pads after the first 1000 km (625 miles), then every 2000 km (1250 miles). The brake pad wear depends on the use, on the kind of drive and on the road.

CAUTION

While reassembling the filter (1), insert it into the filter cover (2) (the gasket must adhere perfectly to its seat) and then screw the cover on the filter case.

CHECKING THE WEAR OF THE

BRAKE PADS

Carefully read page 27 (BRAKE FLUID recommendations), (DISK BRAKES) and page 40 (MAINTENANCE).

IMPORTANT

The following information refers to one single braking system, but it is valid for both.

APRILIA ATLANTIC 500 Instructions For Use Manual

TABLE OF PRELIMINARY CHECKS

SUGGESTIONS TO AVOID THEFT

REGULAR SERVICE INTERVALS CHART

IDENTIFICATION DATA

CHECKING THE OIL LEVEL AND

TOPPING UP

AIR CLEANER

CHECKING THE WEAR OF THE

BRAKE PADS

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