Aprilia ATLANTIC 500 User Manual 02-2002 Part5

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 PRELIMINAR Y 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 Wheels/tyres
Steering Side stand and cen-
tral stand Fastening elements
Fuel tank
Coolant
Engine stop switch
- )
( Lights, warning lights,
injection warning light, horn and electric devices
Injection pump
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. Check the tyre surface, the inflation pressure, wear and
any damage. Make sure that it rotates smoothly, without any clear-
ance or slackening. Make sure that they work smoothly and that the spring
tension brings them back to their normal position. If nec­essary, lubricate joints and articulations.
Make sure that the fastening elements are not loose. If necessary, adjust or tighten them.
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.
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.
Check
Page
26, 48
24, 65
28, 29
57 - 64
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30 51 49
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33
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S A P
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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 posi-
” (in the countries where required).
tion “
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6
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 dash-
“ board, 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.
7
IMPORTANT After a long period of in-
activity 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 be-
cause you may damage the starter.
5
9
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.
ABS
8
Press the start push-button “ ” (8) with-
out accelerating and release it as soon as the engine starts.
CAUTION
After the engine starting, the engine oil pressure warning light “ 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.
” (5) must go
Keep at least one brake lever pulled and
do not accelerate until you start.
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.
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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
IMPORT ANT 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).
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 DIFFER­ENT 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.
9
8
10
To leave:
Release the accelerator grip (9) (Pos. A),
operate the rear brake and move the vehi­cle 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 rear-
view 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.
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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.
Do not accelerate or decelerate repeat-
WARNING
edly 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.
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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 SERV­ICE INTERVAL CHART”, see pages 41-42, in order to avoid personal injuries and/or damages to the vehicle.
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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 com-
pletely 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) progres-
sively 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).
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2
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5
6
4
5
7
Move the engine stop switch (1) to posi-
tion “
”.
CAUTION
With the engine off and the ignition switch in position “ down.
Turn the key (2) and move the ignition
switch (3) to position “
Position the vehicle on the stand, see be-
side (POSITIONING THE VEHICLE ON THE STAND).
”, the battery may run
”.
CAUTION
Do not leave the key in the ignition switch.
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).
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.
WARNING
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SUGGESTIONS TO A VOID THEFT
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 “Body­Guard” 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: ................................................
...................................................................
PHONE NUMBER: ....................................
IMPORTANT In most cases, stolen vehi-
cles are identified through the data written on the use and maintenance book.
MAINTENANCE
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.
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)
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REGULAR SERVICE INTERVALS CHART
OPERATIONS TO BE CARRIED OUT BY THE aprilia Official Dealer
Components
Accelerator cable (adjustment) C C Variator belt S Steering bearings and steering C C Wheel bearings C Engine oil filter every 6000 km: S Clutch shoes CC Valve clearance R in seguito ogni 18000 Km Braking systems C C
Cooling system C C
Stoplight switches C Brake fluid every 6000 km (3750 mi): C/ every 2 years: S Coolant every 2000 km (1250 mi): C/ every 2 years: S Engine oil a every 3000 km: C/every 6000 km (3750 mi): S
Fork oil every 30000 km (18750 mi) or every 4 years: S Transmission oil S C every 24000 km: S Variator rollers and variator plastic guides C
Wheels/tyres and inflation pressure C Bolt tightening C C
Brake fluid bleeding C Fuel pipes C C every 4 years: S
Fuel filter
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.
After running-in
[1000 km (625 mi)]
Every 6000 km
(3750 mi) or 8 months
every 24000 km (15000 mi): C every 48000 km (30000 mi): S
After 12000 km
(7500 mi) or 16 months
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OPERATIONS TO BE CARRIED OUT BY THE aprilia Official Dealer (WHICH CAN BE CARRIED OUT EVEN BY THE USER)
Components
Battery - Electrolyte level C C Spark plug CS Carburettor - idling C C Air cleaner P every 18000 km: S Accelerator working C C
Brake locking working C C Light system C C Brake fluid C C Coolant C every 2000 km (1250 mi): C Engine oil every 1000 km (625 mi): C
Light direction - working C Wheels/tyres and inflation pressure every month: C Suspensions C C
Engine oil pressure warning light on every start: C (*)
Front and rear brake pad wear C every 2000 km (1250 mi): 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.
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After running-in
[1000 km (625 mi)]
Every 6000 km
(3750 mi) or 8 months
After 12000 km
(7500 mi) or 16 months
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 num-
bers 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).
Frame no. __________________________
ENGINE NUMBER
The engine number is stamped near the lower support of the rear shock absorber.
Engine no. __________________________
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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.
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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 neces-
sary, the topping up.
T op 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
Carefully read page 26 (LUBRICANTS), page 40 (MAINTENANCE) and page 74 (TABLE OF LUBRICANTS).
IMPORT ANT 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.
IMPORT ANT
operations described above may lead to an incorrect measurement of the engine oil level. To change the oil, contact an aprilia Offi­cial Dealer.
Unscrew and extract the plug/dipstick (1).Unscrew and remove the oil cartridge fil-
ter from the engine (3).
The non-performance of the
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.
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 lu-
bricate 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
Carefully read page 26 (LUBRICANTS), page 40 (MAINTENANCE) and page 74 (TABLE OF LUBRICANTS).
IMPORT ANT 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.
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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 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 neces-
sary, the topping up.
T op 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
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 TRANSMISSION OIL
Carefully read page 26 (LUBRICANTS), page 40 (MAINTENANCE) and page 74 (TABLE OF LUBRICANTS).
IMPORT ANT 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.
IMPORT ANT
operations described above may lead to an in­correct measurement of the engine oil level.
The non-performance of the
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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 extract the plug/dipstick (1).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 TA­BLE OF LUBRICANTS.
1
2
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.
T o clean the filtering element, it is necessary to remove it from the vehicle.
3
3
4
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).
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4
5
4
4
CHECKING THE WEAR OF THE BRAKE PADS
Carefully read page 27 (BRAKE FLUID ­recommendations), (DISK BRAKES) and page 40 (MAINTENANCE).
IMPORTANT The following information
5
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.
refers to one single braking system, but it is valid for both.
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
DO NOT OIL THE FIL TERING ELEMENT to avoid damaging the filter and the engine.
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While reassembling the filter (1), insert it
CAUTION
into the filter cover (2) (the gasket must adhere perfectly to its seat) and then screw the cover on the filter case.
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