Aprilia Atlantic Classic 500 en

ATLANTIC 500
10/2002-00
1073 1
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Foreword
This manual provides basic information about ordinary
vehicle servicing procedures.
The data and illustrations that make up the manual
were up to date at the time of publication.
The manual is intended for aprilia dealers and their
qualified mechanics. Many concepts have been inten-
tionally omitted as they were considered superfluous.
Since this publication cannot provide exhaustive
mechanical knowledge, it is assumed that people who
make use of this manual have received a basic
training in mechanics and possess a working knowl-
edge of vehicle repairing techniques.
Repairing or checking the vehicle without such knowl-
edge would be ineffective and even dangerous.
As the repairing and checking procedures are not
described in full detail, special care should be taken to
avoid damage to property and personal injury.
With a view to providing its customers with the best
possible riding experience, aprilia is committed to
continually improving its products and the accompany-
ing documentation.
aprilia dealers and world branches are informed about
all major technical modifications and changes in
repairing procedures. Such modifications will be
covered in later editions of this manual.
Should any need or doubt arise about repairing and
checking procedures, do not hesitate to contact aprilias
Consumer Service (A.C.S.): they will be pleased to
provide any information you may require and let you
know of any technical modifications and updates.
For further information, please refer to:
SPARE PARTS CATALOGUE 6801;
ROTAX ENGINE WORKSHOP MANUAL 10631-I
10641-E
10651-F
10661-D
10671-UK
10681-USA
The main features described herein remaining un-
changed, aprilia reserves the right to change its
models at any time.
The right to store this document in electronic form and
to adapt or reproduce it in whole or in part is reserved
worldwide.
The mention of third parties products and services is
made for the sole purpose of information and consti-
tutes no engagement.
aprilia assumes no responsibility about the perfor-
mance and use of such products or services.
First edition: september 2002
Produced and printed by:
CLD s.r.l. Editing division
Via D. Alighieri, 37/A - 56012 Fornacette (PI)
Tel. +39 (0)587 - 42 28 00
Fax +39 (0)587 - 42 28 01
www.cld.it
E-mail: cld@cld.it
On behalf of:
aprilia S.p.A.
Via G. Galilei, 1 - 30033 Noale (VE) - Italia
Tel. +39 (0)41 - 58 29 111
Fax +39 (0)41 - 44 10 54
www.aprilia.com
www.serviceaprilia.com
LIST OF SECTIONS
6
Electrical Equipment
4
Fuel System
3
Engine
1
General Information
7
Cycle Parts
5
Cooling System
2
Periodic Maintenance
Operations
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TABLE OF CONTENTS
Chapter 1
SAFETY WARNINGS............................................................................................................................. 1-2
PRECAUTIONS AND GENERAL INFORMATION................................................................................. 1-2
REPLACING COMPONENTS................................................................................................................ 1-3
USING THE MANUAL............................................................................................................................ 1-3
IDENTIFICATION DATA......................................................................................................................... 1-4
NOTES ON FUEL, LUBRICANTS, COOLANT AND OTHER ITEMS .................................................... 1-4
FUEL ...................................................................................................................................................... 1-4
RUNNING-IN RULES............................................................................................................................. 1-8
PRECAUTIONS AND GENERAL INFORMATION................................................................................. 1-9
SPARE PARTS....................................................................................................................................... 1-9
TECHNICAL DATA............................................................................................................................... 1-10
LUBRICANT CHART............................................................................................................................ 1-12
TIGHTENING TORQUES TABLE ........................................................................................................ 1-13
Chapter 2
PERIODIC MAINTENANCE PROGRAMME.......................................................................................... 2-2
PERIODIC MAINTENANCE SCHEDULE .............................................................................................. 2-3
LUBRICATING POINTS......................................................................................................................... 2-4
BATTERY ............................................................................................................................................... 2-5
REMOVING THE BATTERY COVER .................................................................................................... 2-6
CHECKING AND CLEANING THE TERMINALS................................................................................... 2-6
REMOVING THE BATTERY .................................................................................................................. 2-7
LONG INACTIVATY OF THE BATTERY ................................................................................................ 2-7
CHECKING THE ELECTROLYTE LEVEL ............................................................................................. 2-8
RECHARCING THE BATTERY.............................................................................................................. 2-8
INSTALLING THE BATTERY ................................................................................................................. 2-9
SPARK PLUG ........................................................................................................................................ 2-9
ADJUSTING THE THROTTLE CONTROL .......................................................................................... 2-10
AIR FILTER .......................................................................................................................................... 2-11
ENGINE OIL......................................................................................................................................... 2-12
CHECKING AND RESTORING THE ENGINE OIL LEVEL.................................................................. 2-12
RENEWING THE ENGINE OIL AND ................................................................................................... 2-13
THE ENGINE OIL FILTER ................................................................................................................... 2-13
CHECKING THE TRANSMISSION OIL LEVEL AND TOPPING UP.................................................... 2-14
TOPPING UP ....................................................................................................................................... 2-15
RENEWING THE TRANSMISSION OIL .............................................................................................. 2-16
DISC BRAKES ..................................................................................................................................... 2-16
CHECK................................................................................................................................................. 2-17
RESTORING THE BRAKE FLUID LEVEL ........................................................................................... 2-18
CHECKING BRAKE PAD WEAR ......................................................................................................... 2-18
BLEEDING THE BRAKING SYSTEM (FRONT SIDE ONLY) .............................................................. 2-19
BLEEDING THE INTEGRAL BRAKING SYSTEM............................................................................... 2-20
CHECKING AND RESTORING THE COOLANT LEVEL .................................................................... 2-22
RENEWING THE COOLANT ............................................................................................................... 2-23
CIRCUIT BLEEDING ........................................................................................................................... 2-25
CHECKING AND ADJUSTING THE STEERING ................................................................................. 2-25
ADJUSTING THE BEARINGS PLAY ................................................................................................... 2-26
STEERING DAMPER .......................................................................................................................... 2-26
CHECK ENGINE PIN BUSHINGS ....................................................................................................... 2-26
CHECKING THE FRONT SUSPENSION ............................................................................................ 2-27
CHECKING THE REAR SUSPENSION .............................................................................................. 2-27
ADJUSTING THE REAR SUSPENSION ............................................................................................. 2-27
ADJUSTMENT OF THE REAR SUSPENSION SPRING PRELOAD .................................................. 2-28
WHEELS AND TYRES......................................................................................................................... 2-28
WHEELS INSPECTION ....................................................................................................................... 2-28
TYRES ................................................................................................................................................. 2-28
PRESSURE TYRES ............................................................................................................................ 2-30
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Chapter 3
COMPONENTS THAT CAN BE REMOVED WITHOUT REMOVING THE ENGINE............................. 3-2
REMOVING THE ENGINE FROM THE FRAME ................................................................................... 3-3
Chapter 4
FUEL TANK AND PUMP ........................................................................................................................ 4-2
EMS FUEL INJECTION SYSTEM.......................................................................................................... 4-2
FUEL SUPPLY SYSTEM ....................................................................................................................... 4-3
FUEL SUPPLY CHECK.......................................................................................................................... 4-4
FUEL PUMP REMOVAL/DISMANTLING............................................................................................... 4-5
FUEL PUMP AND FUEL LEVEL FEELER DISASSEMBLY AND CHECKING....................................... 4-6
THROTTLE BODY ................................................................................................................................. 4-6
THROTTLE BODY REMOVAL............................................................................................................... 4-7
Chapter 5
SYSTEM DESCRIPTION....................................................................................................................... 5-2
COOLANT.............................................................................................................................................. 5-2
RADIATOR REMOVAL........................................................................................................................... 5-3
ELECTRICAL COOLING FAN REMOVAL ............................................................................................. 5-3
EXPANSION TANK REMOVAL .............................................................................................................. 5-4
THERMOSTAT VALVE ........................................................................................................................... 5-5
COOLANT PUMP .................................................................................................................................. 5-5
COOLANT THERMISTOR ..................................................................................................................... 5-5
Chapter 6
CHECKING THE RECHARGING SYSTEM........................................................................................... 6-2
CHECKING THE RECHARGING VOLTAGE ......................................................................................... 6-2
CHECKING THE ALTERNATOR NO-LOAD .......................................................................................... 6-2
CHECKING THE ALTERNATOR CONTINUITY..................................................................................... 6-3
VOLTAGE REGULATOR........................................................................................................................ 6-3
FUEL INJECTION SYSTEM .................................................................................................................. 6-4
INJECTION SUPPLY WIRE DIAGRAM ................................................................................................. 6-4
STAND SWITCH CONTROL ................................................................................................................. 6-5
INJECTION RELAY CONTROLS........................................................................................................... 6-5
IGNITION/INJECTION SYSTEM ........................................................................................................... 6-7
E.C.U. CONNECTIONS ......................................................................................................................... 6-7
CONNECTIONS TO THE E.C.U. CONTROL UNIT ............................................................................... 6-9
CHECKING THE HV COIL................................................................................................................... 6-10
DROP SENSOR CHECK ..................................................................................................................... 6-11
RPM SENSOR CHECK ....................................................................................................................... 6-12
THROTTLE VALVE POTENTIOMETER (ACCELERATOR SENSOR) CHECK .................................. 6-13
INJECTOR CHECK.............................................................................................................................. 6-14
COOLANT THERMISTOR FUNCTION CHECK .................................................................................. 6-14
FUEL PUMP CHECK ........................................................................................................................... 6-15
AIR THERMISTOR FUNCTION CHECK ............................................................................................. 6-15
STARTING AND STOP LIGHTS SYSTEM .......................................................................................... 6-16
STARTING RELAY CHECK ................................................................................................................. 6-17
STOP LIGHTS RELAY CHECK ........................................................................................................... 6-17
ELECTRIC COOLING FAN.................................................................................................................. 6-19
CHECKING THE ELECTRIC FAN ....................................................................................................... 6-19
WATER THERMISTOR CHECK .......................................................................................................... 6-20
FAN RELAY CHECK ............................................................................................................................ 6-20
COOLANT TEMPERATURE AND FUEL LEVEL INDICATORS........................................................... 6-21
WIRING DIAGRAM .............................................................................................................................. 6-21
WATER TEMPERATURE..................................................................................................................... 6-22
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DASHBOARD CHECK......................................................................................................................... 6-22
FUEL LEVEL ........................................................................................................................................ 6-22
DASHBOARD CHECK......................................................................................................................... 6-22
FUEL LEVEL SENSOR CHECK .......................................................................................................... 6-22
LIGHTS AND ACOUSTIC SIGNALS SYSTEM.................................................................................... 6-23
WIRING DIAGRAM .............................................................................................................................. 6-23
HORN CHECK ..................................................................................................................................... 6-23
TOP CASE SWITCH CHECK .............................................................................................................. 6-23
DIRECTION INDICATORS AND DISPLAY DATA ................................................................................ 6-24
WIRING DIAGRAM .............................................................................................................................. 6-24
CONTROLS ON THE LEFT SIDE OF THE HANDLEBAR .................................................................. 6-24
DIRECTION INDICATOR AND SPEEDOMETER................................................................................ 6-27
WIRING DIAGRAM .............................................................................................................................. 6-27
DASHBOARD CHECK......................................................................................................................... 6-28
SENSOR CHECK ................................................................................................................................ 6-28
SPEEDOMETER.................................................................................................................................. 6-29
AIR TEMPERATURE SENSOR ........................................................................................................... 6-30
SWITCHES .......................................................................................................................................... 6-31
BULB REPLACEMENT........................................................................................................................ 6-32
BATTERY............................................................................................................................................. 6-33
NUMBER PLATE LIGHT REPLACEMENT .......................................................................................... 6-36
HELMET COMPARTMENT LIGHT REPLACEMENT .......................................................................... 6-36
THIRD STOP LIGHTS REPLACEMENT.............................................................................................. 6-36
VERTICAL BEAM ADJUSTMENT........................................................................................................ 6-37
HORIZONTAL BEAM ADJUSTMENT .................................................................................................. 6-38
REPLACING THE FUSES ................................................................................................................... 6-38
ELECTRICAL COMPONENTS LAYOUT ............................................................................................. 6-40
ELECTRICAL COMPONENTS LAYOUT ............................................................................................. 6-41
WIRING DIAGRAM 500 C.C. ATLANTIC SCOOTER .......................................................................... 6-42
Chapter 7
BODYWORK.......................................................................................................................................... 7-2
PASSENGER FOOTREST REMOVAL .................................................................................................. 7-2
LOWER PROTECTION COVER REMOVAL ......................................................................................... 7-2
UNLOCKING/LOCKING THE SEAT ...................................................................................................... 7-2
SEAT REMOVAL .................................................................................................................................... 7-3
CENTRAL TUNNEL REMOVAL ............................................................................................................. 7-3
LEFT AND RIGHT HAND INSPECTION COVER REMOVAL................................................................ 7-4
LEGSHIELD REMOVAL......................................................................................................................... 7-4
DOCUMENT COMPARTMENT.............................................................................................................. 7-6
FRONT MUDGUARD REMOVAL .......................................................................................................... 7-6
PASSENGER HANDLE-GRIP REMOVAL ............................................................................................. 7-7
COMPLETE SIDE PANEL REMOVAL ................................................................................................... 7-7
REMOVAL OF THE CHROMED STRIP FROM THE SIDE PANELS..................................................... 7-8
SIDE PANEL SEPARATION................................................................................................................... 7-8
FOOT PLATFORM REMOVAL............................................................................................................... 7-9
SPRAY GUARD REMOVAL ................................................................................................................... 7-9
FRONT SHIELD REMOVAL................................................................................................................. 7-10
PASSENGER BACKREST REMOVAL ................................................................................................ 7-10
PLASTIC BACKREST REMOVAL........................................................................................................ 7-10
REAR MUDGUARD REMOVAL........................................................................................................... 7-11
LOWER COVER REMOVAL ................................................................................................................ 7-12
TAIL UNIT REMOVAL .......................................................................................................................... 7-12
FOOTREST SUPPORT AND LOWER SPRAY GUARD REMOVAL.................................................... 7-13
FRONT PANEL REMOVAL .................................................................................................................. 7-14
UPPER HANDLEBAR COVER REMOVAL.......................................................................................... 7-14
LOWER HANDLEBAR COVER REMOVAL ......................................................................................... 7-15
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COMPLETE INSTRUMENT PANEL REMOVAL .................................................................................. 7-15
WINDSHIELD REMOVAL .................................................................................................................... 7-16
INSTRUMENT PANEL REMOVAL ....................................................................................................... 7-16
COMPLETE LIGHTING ASSEMBLY REMOVAL ................................................................................. 7-17
CRASH HELMET COMPARTMENT REMOVAL .................................................................................. 7-18
FRONT WHEEL ................................................................................................................................... 7-22
KEY ...................................................................................................................................................... 7-22
REMOVING THE FRONT WHEEL ...................................................................................................... 7-23
REPLACING THE BEARINGS............................................................................................................. 7-24
CHECK................................................................................................................................................. 7-25
REFITTING THE FRONT WHEEL ....................................................................................................... 7-26
REAR WHEEL ..................................................................................................................................... 7-27
KEY ...................................................................................................................................................... 7-27
REMOVING THE REAR WHEEL......................................................................................................... 7-28
REMOVING THE EXHAUST TERMINAL ............................................................................................ 7-29
CHECK................................................................................................................................................. 7-30
FRONT BRAKE.................................................................................................................................... 7-30
KEY ...................................................................................................................................................... 7-31
REPLACING THE BRAKE PADS......................................................................................................... 7-32
CHECKING THE BRAKE DISC ........................................................................................................... 7-33
REMOVING THE BRAKE DISC........................................................................................................... 7-33
REAR BRAKE ...................................................................................................................................... 7-33
KEY ...................................................................................................................................................... 7-34
REPLACING THE BRAKE PADS......................................................................................................... 7-35
CHECKING THE BRAKE DISC ........................................................................................................... 7-36
REMOVING THE BRAKE DISC........................................................................................................... 7-36
STEERING........................................................................................................................................... 7-37
CHECKING THE BEARINGS .............................................................................................................. 7-39
KEY ...................................................................................................................................................... 7-40
CHECKING THE OIL LEVEL ............................................................................................................... 7-41
REMOVING THE FORK ASSEMBLY................................................................................................... 7-41
REMOVING THE ROD-WHEEL CARRIER ASSEMBLY ..................................................................... 7-42
WHEEL CARRIER ROD DISASSEMBLY ............................................................................................ 7-43
CHECKING THE COMPONENTS ....................................................................................................... 7-44
ADJUSTING THE REAR SUSPENSION ............................................................................................. 7-44
ADJUSTMENT OF THE REAR SUSPENSION SPRING PRELOAD .................................................. 7-45
REMOVING THE SHOCK ABSORBER............................................................................................... 7-45
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General Information
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General Information
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General Information
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Atlantic 500
SAFETY WARNINGS
The following precautionary warnings are used throughout this manual in order to convey the following messages:
Safety warning. When you find this symbol on the vehicle or in the manual, be careful to the potential
risk of personal injury. Non-compliance wit the indications given in the message preceded by this
symbol may result in grave risks for your and other peoplesafety and for the vehicle!
Indicates a potential hazard which may result in serious injury or even death.
Indicates a potential hazard which may result in minor personal injury or damage to the vehicle.
NOTE The word NOTE in this manual precedes important information or instructions.
PRECAUTIONS AND GENERAL INFORMATION
When repairing, disassembling and reassembling the vehicle, scrupulously observe the following recommenda-
tions.
The use of open flames is forbidden under all circumstances.
Before performing any servicing or checks, switch off the engine, remove the ignition key, allow the engine
and the exhaust system to cool down, and if possible lift the vehicle on solid level flooring using specific
equipment.
To avoid burns, pay special attention to hot engine and exhaust parts.
The vehicle is made up of inedible parts. On no account must any parts be bitten, sucked, chewed or
swallowed.
Unless otherwise specified, the reassembly of parts is carried out by following the disassembling proce-
dures in reverse order.
Any overlapping operations in cross-references to other chapters should be interpreted logically so as to
avoid unnecessary removal of components.
Never use fuel as a solvent to clean the vehicle.
Disconnect the battery negative (-) cable, control unit and spark plug lug, before performing any electric
welding.
When two or more people are working at the same time, pay attention to the safety of each of them.
BEFORE REMOVING COMPONENTS
Remove any dirt, mud, dust and foreign bodies from the vehicle before removing any components.
Use the tools specially designed for this vehicle whenever necessary.
REMOVING COMPONENTS
Never loosen screws and nuts using tools other than the specific spanners.
Mark the positions on all connecting joints (pipes, cables, etc.) before separating them, and identify them with
different marks.
Clearly mark each part so it can be easily identified during reinstallation.
Clean and wash the removed components with a low-flash detergent.
Keep mating parts together, as they have adapted to one another through wear and tear. Some components must
be used in combination or replaced as a set.
Keep away from heat sources.
WARNING
CAUTION
WARNING
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REPLACING COMPONENTS
Never reuse circlips. Always replace removed circlips with new ones.
When fitting a new circlip, take care not to part its ends more than is required to fit it on the shaft.
After fitting a circlip, ensure that it is fully and firmly inserted in its seat.
Never use compressed air to clean the bearings.
NOTE Bearings should always rotate freely, smoothly and silently, otherwise they must be replaced.
Only use GENUINE aprilia spares.
Always use the recommended lubricants and consumables.
If possible, lubricate parts before refitting them.
When tightening screws and nuts, start with the larger or the inner ones, and then proceed diagonally.
Carry out the tightening in successive steps before applying the full tightening torque.
Always replace self-locking nuts, seal rings, circlips, O-rings, cotter pins and screws (if the threads are damaged)
with new ones.
Clean all mating surfaces, oil seal rims and gaskets before refitting.
Apply a film of lithium grease to the oil seal rims.
Replace the oil seals and the bearings so that the marks or serial numbers face outwards (side in view).
Generously lubricate the bearings before fitting them.
Check that every component has been fitted properly.
After repairing or servicing any parts, carry out preliminary checks and test the vehicle on private ground or in a
low-traffic area.
USING THE MANUAL
HOW TO CONSULT THE MANUAL
The manual is divided into chapters, each corresponding to a major type of components.
For easy reference, refer to the TABLE OF CONTENTS.
Unless otherwise specified, parts are reassembled by following the disassembling procedures in reverse order.
The terms left and right refer to the rider sitting on the vehicle in a normal riding position.
Refer to the OPERATION AND MAINTENANCE MANUAL for information on how to operate and maintain the
vehicle.
CAUTION
General Information
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IDENTIFICATION DATA
The frame number may be used to order the spare
parts.
NOTE Tampering with serial numbers is subject to
severe penalties. In particular, tampering with the
frame number immediately voids the warranty.
FRAME NUMBER
The frame number is stamped on the frame central
tube. To read it, open the central glove compartment
door and remove the cover (1).
ENGINE NUMBER
The engine number is stamped near the lower support
of the rear shock absorber.
NOTES ON FUEL, LUBRICANTS, COOLANT AND OTHER ITEMS
FUEL
The fuel used in internal combustion engines is highly flammable and can be explosive under certain
conditions.
Refuelling and servicing should be carried out in a well ventilated place after switching off the engine.
Do not smoke while refuelling or in the presence of fuel fumes. Avoid contact with open flames, sparks and
any other potential source of ignition or explosion.
Avoid spilling fuel from the tank filler as it may catch fire on contact with the hot engine surfaces.
Should any fuel be inadvertently spilled, be sure to dry up the area before starting the engine.
Since fuel expands when exposed to heat and direct sunlight, avoid filling the tank to the brim.
Carefully close the tank cap after refuelling.
Do not allow fuel to come into contact with the skin and avoid ingesting it or inhaling its fumes. Do not
transfer fuel from one vessel into another using a length of tube.
DO NOT DISPOSE OF FUEL IN THE ENVIRONMENT.
KEEP OUT OF REACH OF CHILDREN.
Use only leaded (4 Stars ) or unleaded premium grade petrol, min. O. N. 95 (N. O. R. M.) and 85 (N. O. M. M.).
WARNING
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ENGINE OIL
Engine oil can cause serious damage to the skin if handled every day and for long periods.
Wash your hands carefully after using the oil.
Do not dispose of the oil in the environment.
Put it in a sealed container and take it to the filling station where you usually buy it or to an oil salvage
center.
In case any maintenance operation has to be carried out, it is advisable to use latex gloves.
Check the engine oil after the first 1,000 km (625 mi) and then every 3,000 km (1,875 mi). Change the oil every
6,000 km (3,750 mi), see CHANGING THE ENGINE OIL AND THE ENGINE OIL FILTER.
Engine oil (recommended):
Synthetic oil SAE 5W/40 of the SELENIA HI Scooter 4Tech type. Alternatively, use brand-name oils with perform-
ance complying with or exceeding the A.P.I. SJ specifications.
TRANSMISSION OIL
Transmission oil can cause serious damage to the skin if handled every day and for long periods.
center.
Renew the transmission oil after the first 1,000 km (625 mi) and then every 12,000 km (7,500 mi). Refer to
the engine workshop manual.
Transmission oil (recommended):
SAE 80W/90 oil of the TUTELA ZC90 type.
Alternatively, use brand-name oils with performance complying with or exceeding the A.P.I. GL-3 specifications.
BRAKE FLUID
Brake fluid can cause irritation if it comes into contact with the skin or the eyes.
Carefully wash any parts of the body that should happen to come into contact with the fluid. Contact an
ophthalmologist or a physician if the fluid comes into contact with the eyes.
DO NOT DISPOSE OF THE FLUID IN THE ENVIRONMENT.
When handling brake fluid, take care not to spill it on plastic and painted parts as they would be damaged.
Check the brake fluid level every 6,000 km (3,750 mi) (CHECKING AND RESTORING THE FRONT BRAKE
FLUID LEVEL). Renew the fluid every 2 years (RENEWING THE FRONT BRAKE FLUID).
Brake fluid (recommended):
TUTELA TOP 4.
Alternatively, use brand-name brake fluids with performance complying with or exceeding the specifications.
Synthetic fluid SAE J1703, NHTSA 116 DOT 4, ISO 4925
WARNING
WARNING
WARNING
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Do not use brake fluids other than those prescribed. To avoid damaging the braking system, never mix
different types of fluids when topping up.
Never use brake fluid taken from an old container, or from a container that has been open for a long time.
Sudden changes in brake play or a spongy feel of the brake levers are due to problems in the hydraulic
circuits.
Take special care in ensuring that the brake discs and the brake linings are not oily or greasy, especially
after checking or servicing the brakes.
Ensure that the brake lines are not twisted or worn.
Take care not to let any water or dust into the brake circuit.
Latex gloves are recommended for all maintenance operations involving the hydraulic circuit.
FORK OIL
Fork oil can cause serious damage to the skin if handled every day and for long periods.
center.
The response of the suspension can be partly altered by changing the adjustment of the shock absorbers
and/or the viscosity of the oil they contain.
Viscosity grades can be chosen according to the desired vehicle geometry.
WARNING
CAUTION
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COOLANT
The coolant is harmful if ingested. Contact with the skin or the eyes may cause irritation. Should the liquid
come into contact with the skin or the eyes, generously rinse with water and seek medical attention.
If the fluid is ingested, cause vomiting, generously rinse the mouth and throat with water and immediately
seek medical attention.
DO NOT DISPOSE OF THE COOLANT IN THE ENVIRONMENT.
Be careful not to spill the coolant on the red- hot parts of the engine: it may catch fire and send out invis-
ible flames.
In case maintenance operations are to be performed, it is advisable to use latex gloves.
Do not use the vehicle if the coolant is below the minimum prescribed levelMIN.
Check the coolant level before starting off and every 2,000 km (1,250 mi) (CHECKING AND RESTORING THE
COOLANT LEVEL). Renew the coolant every two years (RENEWING THE COOLANT).
The coolant is made up of 50% water and 50% antifreeze.This mixture is ideal for most running temperatures and
ensures good protection against corrosion.
It is advisable to keep the same mixture also in the hot season, since in this way losses due to evaporation are
reduced and it is not necessary to top up very frequently.
The mineral salt deposits left in the radiator by evaporated water are thus reduced and the efficiency of the cooling
system remains unchanged.
If the outdoor temperature is below 0, check the cooling circuit frequently and if necessary increase the antifreeze
concentration (up to maximum 60%).
For the cooling solution use distilled water, in order not todamage the engine.
Engine coolant (recommended):
PARAFLU 11 FE (diluted).
Alternatively, use brand-name coolants with performance complying with or exceeding the specifications.
Antifreeze fluid based on monoethylene glycol, CUNA NC 958-16.
NOTE Different antifreezes have different characteristics. The degree of protection provided by each product is
specified on its label.
Only use nitrite-free antifreeze and anticorrosive providing protection to temperatures of at least -35 C
(31 F).
CAUTION
WARNING
WARNING
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CARBON MONOXIDE
Whenever the engine needs to be run in order to carry out some operation, ensure that this is done in the open air
or in a well-ventilated room.
Never run the engine in a closed environment unless the place is equipped with an exhaust system.
Exhaust gases contain carbon monoxide, a poisonous gas that may cause fainting or even death.
Run the engine in an open space or in a closed space equipped with an exhaust system.
HIGH TEMPERATURE COMPONENTS
The engine and the exhaust components reach high temperatures during use and remain hot for some time
even after the engine has been switched off.
Before handling these components, put on insulating gloves or wait for the engine and the exhaust system
to cool down.
RUNNING-IN RULES
After the first 1,000 km (625 mi), carry out the checking operations indicated in the column After running-
in of the Regular Service Intervals Chart, see REGULAR SERVICE INTERVALS CHART, in order to avoid
hurting your-self or other people and/ or damaging the vehicle.
The running- in of the engine is primary to ensure its working life and its 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.
NOTE Only after the first 1,000 km (625 mi) of running-in it is possible to obtain the best speed and acceleration
performance from the vehicle.
Keep to the following indications:
Do not open the throttle completely if the speed is low, both during and after the running-in.
0-100 km (0-62 mi)
During the first 100 km (62 mi) put on the brakes with caution, avoiding sharp and prolonged brakings.
This ensures a correct bedding-in of the pads on the brake disc.
0-500 km (0-312 mi)
During the first 500 km (312 mi), do not exceed the 80% of the maximum allowed speed.
Avoid driving at constant speed for long distances.
After the first 1,000 km (625 mi), progressively increase the speed until reaching the highest performance levels.
WARNING
WARNING
WARNING
General Information
chap. 1
1-9
1
Release 00 2002-09
Atlantic 500
PRECAUTIONS AND GENERAL INFORMATION
When repairing, disassembling and reassembling the vehicle, scrupulously observe the following recommenda-
tions.
The use of open flames is forbidden under all circumstances.
Before performing any servicing or checks, switch off the engine, remove the ignition key, allow the engine
and the exhaust system to cool down, and if possible lift the vehicle on solid level flooring using specific
equipment.
To avoid burns, pay special attention to hot engine and exhaust parts.
The vehicle is made up of inedible parts.
Non mordere, succhiare, masticare o ingerire nessuna parte dello stesso per nessun motivo.
Unless otherwise specified, the reassembly of parts is carried out by following the disassembling proce-
dures in reverse order.
Avoid running the engine in closed or poorly ventilated places.
Petrol is highly flammable and explosive. Handle with the utmost care.
Never use fuel as a solvent to clean the vehicle.
When two or more people are working at the same time, pay attention to the safety of each of them.
Only use the recommended lubricants.
Where provided, use the special tools designed for this type of vehicle.
Start tightening the screws and nuts with a greater diameter or the inner ones, in a crosswise manner.
Carefully clean the disassembled components using a detergent with a low degree of flammability.
Lubricate the parts (when possible) before reassembling.
Check that every component has been fitted properly.
Always replace the gaskets, gas rings, piston rings, O rings and split pins with new ones.
Mark the position on all the junction points (tubes, cables, etc.) before separating them.
Use different and clear identification marks as each part must be easily recognisable during the assembling
operations.
Never reuse circlips.
Always replace removed circlips with new ones.
When fitting a new circlip, take care not to part its ends more than is required to fit it on the shaft.
After fitting a circlip, ensure that it is fully and firmly inserted in its seat.
SPARE PARTS
Only use Genuine aprilia Spares.
All Genuine aprilia Spares are high-quality parts specially designed and manufactured for aprilia vehicles.
Using NON-genuine aprilia spares may result in damage and poor performance.
WARNING
CAUTION
CAUTION
General Information
chap. 1
1-10
Release 00 2002-09
Atlantic 500
DIMENSIONS
Max. length
Max. width
Seat height
Distance between centres
Min. ground clearance
Weight ready for starting
2270 mm (89.4 in)
720 mm (28.3 in)
780 mm (30.7 in)
1575 mm (62.0 in)
150 mm (5.9 in)
200 Kg (440.9 lbs)
Max. height (front part of the fairing included) 1450 mm (57.0 in)
ENGINE
Number of cylinders
Total displacement
Engine idling rpm
Clutch
Change
Lubrication system
1
460 cm
3
(28.0 cu.in)
10.5 : 1
1450 50 rpm(rpm)
automatic, dry centrifugal clutch
gear automatic
forced-circulation by means of a trochoidal pump (inside the
crankcase), oil filter and bypass for pressure adjustment
Type
4-stroke single-cylinder, 4 valves, single camshaft in cylinder
head controlled by chain system on the flywheel side
Cooling liquid cooling, forced circulation with centrifugal pump
Number of valves 4
Bore / stroke 92 mm / 69 mm (3.6 in / 2.7 in)
Starting electric
CAPACITIES
Fuel (reserve included)
Seats
Vehicle max. load
(driver + luggage)
4 l (1.05 gal)
2
105 Kg (231.4 lbs)
Fuel reserve
Engine oil
17 l (4.48 gal)
Front fork oil 220 cm
3
(13.42 cu.in) (for each rod)
- engine oil change and engine oil filter replacement only 1500 cm
3
(91.5 cu.in)
- change for engine overhaul 1700 cm
3
(103.7 cu.in)
Transmission oil ~ 250 cm
3
(15.25 cu.in)
Coolant
(50% water + 50% antifreeze with ethylene glycol)
1.5 l (0.39 gal)
TECHNICAL DATA
Compression ratio
Speed change gear
Primary
Secondary
Total engine/wheel ratio
V-belt
gears
TRANSMISSION
automatic stepless
short 1/11.988
long 1/4.86
Vehicle max. load
(driver + passenger + luggage)
180 Kg (396.8 lbs)
Model
Choke tube diameter 39 mm (1.53 in)
THROTTLE BODY
38 mm (1.5 in) and single injector
General Information
chap. 1
1-11
1
Release 00 2002-09
Atlantic 500
CONTINUED
Type Electronic injection by electric fuel pump
FUEL SUPPLY
Fuel Lead free petrol (4 Stars ) with minimum octane number 95
(N.O.R.M.) and 85 (N.O.M.M.)
Type high resistance steel tubes
28, 50
FRAME
Fore stroke 118 mm (4.6 in)
TYRES
Front 120 / 70 - 15 M/C 56R
Rear 140 / 60 - 14 M/C REINF. 64R
STANDARD INFLATION PRESSURE
Front 210 kPa (2.1 bar/30.4 psi)
Rear 230 kPa (2.3 bar/33.3 psi)
INFLATION PRESSURE WITH PASSENGER
Front 220 kPa (2.2 bar/31.9 psi)
Rear 260 kPa (2.6 bar/37.7 psi)
Type in light alloy
WHEEL RIMS
Front 15 x 3.00
Rear 14 x 3.75
Type tubeless
Type C.D.I. / Inductive
IGNITION
Spark advance Variable spark advance controlled by the injection power unit
Steering inclination angle
Front
Stroke
Rear
Wheel stroke
100 mm (3.93 in) rear
Two double-acting hydraulic shock absorbers with preload
adjustment to five positions
SUSPENSIONS
hydraulically operated telescopic fork
100 mm (3.93 in)
Front disc brake - 260 mm (10.23 in) - with hydraulic transmission
BRAKES
Rear, combined
disc brake - front 260 mm (10.23 in) combined with the rear
brake 220 mm (8.66 in)
Standard CHAMPION RG6YC
SPARK PLUG
- Alternatively NGK - CR7EKB
Spark plug gap 0.7 - 0.8 mm (0.027 - 0.031 in)
General Information
chap. 1
1-12
Release 00 2002-09
Atlantic 500
LUBRICANT CHART
Engine oil (recommended): SUPERBIKE 4, SAE 5W - 40 or 4T FORMULA RACING, SAE 5W - 40.
As an alternative to the recommended oil, it is possible to use high- quality oils with characteristics in compliance
with or superior to the A.P.I. SJ specifications.
Transmission oil (recommended): F.C., SAE 75W - 90 or GEAR SYNTH, SAE 75W - 90.
As an alternative to the recommended oil, it is possible to use high- quality oils with characteristics in compliance
with or superior to the A.P.I. GL3 specifications.
Fork oil (recommended): F.A. 5W or F.A. 20W; an alternative FORK 5W or FORK 20W.
If you wish to have an intermediate performance between the products offered, F.A.5 W and F.A.20W or
FORK 5W and FORK 20W, these can be mixed as indicated below:
SAE 10W = F. A. 5W 67% of the volume + F. A. 20W 33% of the volume, or
FORK 5W 67% of the volume + FORK 20W 33% of the volume.
SAE 15W = F. A. 5W 33% of the volume + F. A. 20W 67% of the volume, or
FORK 5W 33% of the volume + FORK 20W 67% of the volume.
Bearings and other lubrication points (recommended): BIMOL GREASE 481 - GREASE SM2.
As an alternative to the recommended product, use high- quality grease for rolling bearings, working temperature
range -30 C +140 C (-22 F....+284 F), dripping point 150 C 230 C (302 F.....446 F), high protection
against corrosion, good resistance to water and oxidation.
Protection of the battery poles: neutral grease or Vaseline.
Use new brake fluid only.
Brake fluid (recommended): F.F. DOT 5 (DOT 4 compatible) - BRAKE 5.1 DOT 5 (DOT 4 compatible).
Alternatively, use brand-name fluids with performance complying with or exceeding the specifications.
Synthetic fluido SAE J1703, NHTSA 116 DOT 4, ISO 4925.
Use only antifreeze and anticorrosive without nitrite, ensuring protection at -35 C (-31 F) at least.
Engine coolant (recommended): ECOBLU - 40 C - COOL.
Alternatively, use brand-name coolants with performance complying with or exceeding the specifications.
Antifreeze fluid based on monoethylene glycol, CUNA NC 956-16.
Battery
Fuses
Generator (with permanent magnet)
30 - 20 - 15 - 3 A
14 V - 330 W
ELECTRIC SYSTEM
12 V - 14 Ah
Low / high beam
Front parking lights
Direction indicators
12 V - 5 W
rear 16 W - front 10 W
BULBS
12 V - 55 W / 12 V - 35 W
Rear parking light / stoplight
Helmet compartment light 12 V - 3 W
12 V - 5 / 21 W
Number plate 12 V - 5 W
WARNING
WARNING
Dashboard light LED
Third stoplight 12 V - 2.3 W
Direction indicators
Engine oil pressure
Low beam
LED
LED
WARNING LIGHTS
LED
High beam
Low fuel LED
LED
Brake pads wear LED
Coolant high temperature indicator LED
General Information
chap. 1
1-13
1
Release 00 2002-09
Atlantic 500
TIGHTENING TORQUES TABLE
DESCRIPTION ftlb Nm
FRAME ASSEMBLY
Footrest fixing screw 14.75 20
Steering stop plate screw 8.68 12
Locking ring 36.88 50
Key switch break-off screw 7.23 10
Threaded bushing 0.22 0.3
Key switch fixing screw 7.23 10
WINDSCREEN SUPPORT ASSEMBLY
Windscreen support fixing screw 7.23 10
Windscreen support stop nut 7.23 10
STEERING DAMPER ASSEMBLY
Damper to frame fixing screw 7.23 10
Nut 7.23 10
Damper fixing screw, fork side 7.23 10
FOOTBOARDS ASSEMBLY
Footboard fixing screw 14.75 20
ENGINE MOUNT CONNECTING RODS ASSEMBLY
Socket hexagonal-head screw 59 80
Frame connecting rod pin 44.25 60
Engine connecting rod pin 44.25 60
STAND ASSEMBLY
Stand screw 33.19 45
Lower nut 22.12 30
Side stand screw 7.23 10
FRONT SUSPENSION ASSEMBLY
Nut 11.06 15
Steering series self-locking nut 79.59 110
Flanged screw 18.44 25
REAR SUSPENSIONS ASSEMBLY
Screw 36.88 50
Screw 18.44 25
FRONT BRAKE ASSEMBLY
Socket hexagonal-head screw 19.91 27
REAR BRAKE ASSEMBLY
Socket hexagonal-head screw 19.91 27
HANDLEBAR AND CONTROLS ASSEMBLY
Screw 29.50 40
Right and left switch 1.47 2
U bolts fixing screws 7.23 10
Hexagonal-head screw 7.23 10
Vibration-damping weights fixing screws 7.23 10
ENGINE ASSEMBLY
Shock absorber support fixing screw 18.44 25
EXHAUST ASSEMBLY
Plate to engine fixing screw 36.88 50
Silencer fixing screw 36.88 50
Manifold clamp 7.23 10
Serpress Nut 18.44 25
Heat guard protections fixing screw 0.59 0.8
General Information
chap. 1
1-14
Release 00 2002-09
Atlantic 500
DESCRIPTION ftlb Nm
FRONT WHEEL ASSEMBLY
Wheel pin 36.88 50
Speedometer sensor screw 0.66 0.9
Hub screw 7.23 10
REAR WHEEL ASSEMBLY
Nut 110.64 150
PASSENGER HANDLE SUPPORTS ASSEMBLY
Passenger handles support fixing screw 14.75 20
PASSENGER SEAT BACK SUPPORT ASSEMBLY
Seat back support fixing screw 7.23 10
HEADLIGHT CARRIER BOW LOWER SUPPORT ASSEMBLY
Seat back support fixing screw 7.23 10
WINDSCREEN SUPPORT ASSEMBLY
Windscreen support self-locking nut 7.23 10
PASSENGER HANDLES ASSEMBLY
Passenger handle fixing screw 18.44 25
BUMPER TUBES ASSEMBLY
STAINLESS STEEL flanged screw 7.23 10
ELECTRICAL COMPONENTS ASSEMBLY
Coil fixing screw 1.47 2
Nut 1.47 2
Rotary switch screw 7.23 10
Rotary switch screw 7.23 10
Harness to relay clamp 3.68 5
Reflector nut 1.10 1.5
M5 self-locking nuts fuel pump flange 2.21 3
COOLING SYSTEM ASSEMBLY
Sleeve clamps 2.21 3
FILTER BOX ASSEMBLY
Sleeve clamps 2.21 3
SEAT ASSEMBLY
Seat hinge nut 5.90 8
FUEL TANK ASSEMBLY
Nut 5.16 7
Periodic Maintenance Operations
2-1
Atlantic 500
2
Periodic Maintenance
Operations
Release 00 2002-09 chap. 2
2-2
Atlantic 500
This section describes the operations to be performed
periodically when servicing the main vehicle compo-
nents.
Before performing any servicing or checks, switch
off the engine, remove the key, allow the engine
and the exhaust system to cool down, and if
possible lift the vehicle on solid level flooring
using specific equipment.
To avoid burns, be sure to keep away from hot
engine and exhaust parts.
NOTE to refit the components follow the reverse
procedure, unless otherwise specified.
PERIODIC MAINTENANCE PROGRAMME
To maintain the vehicle in perfect running order,
aprilia recommends observing the scheduled main-
tenance intervals for the various components.
CAUTION
CAUTION
ENGINE CODE BELT REPLACEMENT
8106810 6,000 Km (3,750 mi)
8106983 12,000 Km (7,500 mi)
2-3
Atlantic 500
2
PERIODIC MAINTENANCE SCHEDULE
TO BE PERFORMED BY aprilia authorized dealer
Accelerator cable (adjustment) C C
Variator belt S (code 8106810) S (code 8106983)
Steering bearings and steering C C
COMPONENTS Every 12,000 km
(7,500 mi) or 16 months
End of running-in
1,000 km (625 mi)
Every 6,000 km
Clutch shoes - clutch housing C C
Valve clearance R every 18,000 Km (11,250 mi)
Cooling system C C
Stop light switches C
Transmission oil S C every 24,000 km (15,000 mi): S
Wheels/ tyres and inflation pressure every 16,000 km (10,000 mi): C
Nut, bolt, screw tightening C C
Fuel pipes C C every 4 years: S
Fuel filter every 24,000 km (15,000 mi): C every 48,000 km (30,000 mi):S
Wheel bearings C
Braking systems C C
C = check and clean, adjust, lubricate or replace as necessary; P = clean; S = renew; R = adjust.
The above operations must be performed at shorter intervals if the vehicle is used in rainy or dusty areas, or on rough
roads.
Brakes fluid bleeding C
Spark plug C S
Accelerator operation C C
Brake locking operation C C
Suspensions C C
Carburation - slow running C C
Air cleaner P every 18,000 km (11,250 mi):S
Light direction - operation C
Battery/ electrolyte level C C
Light system C C
Engine oil filter every 6,000 km (3,750 mi): S
Brake fluid every 6,000 km (3,750 mi): C / every 2 years: S
Coolant every 2,000 km (1,250 mi): C / every 2 years: S
Fork oil every 30,000 km (18,750 mi) or 4 years: S
Variator rollers and variator plastic guides C
Front and rear brake pad wear C every 2,000 km (1,250 mi): C
Engine oil pressure warning light on every start: C (*)
(*) to check, see TABLE OF INSTRUMENTS AND INDICATORS
Engine oil every 3,000 km (1,875 mi): C / every 6,000 km (3,750 mi): S
2-4
Atlantic 500
LUBRICATING POINTS
A proper lubrication is important to ensure the correct
operation and duration of the vehicle components.
NOTE Before proceeding with lubrication, thoroughly
clean all the components to remove any traces of
oxidation, grease, dirt and dust. All exposed parts that
are subject to rust must be lubricated with engine oil
or grease. Please refer to the TABLE OF LUBRI-
CANTS.
The points to lubricate are shown in the LUBRICA-
TION CHART.
LUBRICATION CHART
KEY TO LUBRICATION CHART
1) Brake lever pin
2) Steering bearings
3) Sidestand pivot
4) Central stand pivot
5) Throttle control
6) Throttle cable
7) Rear axle
I = Grease
L = Oil
1
2
3 4
1 5
6
7
2-5
Atlantic 500
2
BATTERY
Carefully read (PRECAUTIONS AND GENERAL
INFORMATION).
Check the electrolyte level and the tightening of the
terminals after the first 1,000 km (625 mi) and then
every 6,000 km (3,750 mi).
The electrolyte in the battery is toxic and caustic
and if it gets in contact with the skin it can cause
burns, since it contains sulphuric acid. Wear
protection clothes, a face mask and/ or goggles
during maintenance operations.
In case of contact with the skin, rinse with plenty
of water.
In case of contact with the eyes, rinse with plenty
of water for fifteen minutes, then consult an
doctor without delay.
If the electrolyte is accidentally swallowed, drink a
lot of water or milk, then continue drinking milk of
magnesia or vegetable oil and consult a doctor
without delay.
The battery gives off explosive gases; keep it
away from flames, sparks, cigarettes and any
other source of heat.
During the recharging or the use, make sure that
the room is properly ventilated and avoid inhaling
the gases released during the recharging.
Never invert the connection of the battery cables.
Do not incline the vehicle too much, in order to
avoid dangerous leaks of the battery fluid.
KEEP AWAY FROM CHILDREN.
Connect and disconnect the battery with the
ignition switch in position .
Connect first the positive cable (+) and then the
negative cable (-).
Disconnect following the reverse order.
The electrolyte is corrosive.
Do not pour or spill it, especially on the plastic
parts.
WARNING
WARNING
2-6
Atlantic 500
REMOVING THE BATTERY COVER
Read through paragraph BATTERY.
NOTE Put the vehicle on a solid and flat surface
Make sure the ignition lock switch is turned to .
Lift the saddle, see (UNLOCKING/ LOCKING THE
SEAT).
Remove the mat from the helmet compartment.
Unloose and remove the two screws (1).
Remove the battery cover from the bottom (2)
paying attention to the upper tangs (3).
Disconnect the electrical connector (4) of the
helmet compartment light.
Remove the battery cover (2)
1
2
4 3
5 6
CHECKING AND CLEANING THE TERMI-
NALS
Remove the battery cover, see (REMOVING 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.
If necessary:
Disconnect first the negative () and then the
positive cable (+).
Brush with a wire brush to eliminate any sign of
corrosion.
Reconnect first the positive (+) and then the
negative cable ().
Cover the terminals of the cables and of the
battery with neutral grease or Vaseline.
Tighten the clamp screws.
WARNING
2-7
Atlantic 500
2
7 8
REMOVING THE BATTERY
BATTERY COVER).
Remove the battery breather pipe (7).
Remove the battery (8) from its seat by slightly
turning it to the right, as shown by the arrow.
Disconnect first the negative () and then the
positive cable (+).
Remove the battery (8) from its compartment and
put it on a flat surface, in a cool and dry place.
Once it has been removed, the battery must be
stored in a safe place and kept away from children.
Refit the battery cover, see (REMOVING THE
BATTERY COVER).
Handle with care to prevent the electrolyte leak-
age.
WARNING
CAUTION
LONG INACTIVATY OF THE BATTERY
Read through the paragraphs BATTERY.
When the vehicle is to remain inactive for a long
period, remove the battery and place it in a cool and
dry place. Fully charge the battery with a slow re-
charge.
If the battery is left on the vehicle, disconnect the
cables from the terminals.
Check the charge periodically (about once a month)
during the winter or when the vehicle is left inactive, to
prevent the battery from deteriorating.
2-8
Atlantic 500
CAUTION
CHECKING THE ELECTROLYTE LEVEL
To check the electrolyte level, proceed as follows:
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 electrolyte level increases
during the recharge.
Top up by adding distilled water.
RECHARCING THE BATTERY
Remove the battery, see (REMOVING THE
BATTERY). Remove the element plugs.
Remove the element plugs.
Check the electrolyte level, see beside (CHECK-
ING THE ELECTROLYTE LEVEL).
Connect the battery with a battery charger.
A recharge with an amperage equal to 1/10th of
the battery capacity is recommended.
After the recharging operation, check the electro-
lyte level again and if necessary top up with
distilled water.
Put back the element plugs.
Reassemble the battery only 5-10 minutes after
disconnecting the recharger, since the battery
continues to produce gas for a short lapse of time.
CAUTION
2-9
Atlantic 500
2
CAUTION
INSTALLING THE BATTERY
BATTERY COVER).
Put the battery in its container.
Always connect the battery breather pipe, to
prevent the sulphuric acid vapours from corroding
the electric system, painted parts, rubber ele-
ments or gaskets when they exit the breather pipe
itself.
Connect, in order, the positive (+) and negative ()
cable.
Cover the terminals of the cables and of the
battery with neutral grease or Vaseline.
Connect the battery breather pipe (1).
Refit the battery cover, see (REMOVING THE
BATTERY COVER).
1
SPARK PLUG
Read through the paragraphs MAINTENANCE.
Check the spark plug every 6,000 km (3,750 mi) and
replace every 12,000 Km (7,500 mi).
Periodically remove the spark plug, eliminate any
carbon deposits and change it if necessary.
To reach the spark plug:
Remove the left inspection cover, see (REMOV-
ING THE RIGHT AND LEFT INSPECTION COV-
ERS).
To remove and clean the spark plug:
1
2
WARNING
Before carrying out the following operations, let
the engine and the exhaust silencer cool down
until they reach room temperature, in order to
avoid burns.
Move the coolant pipe (1) to gain access to the
spark plug.
Disconnect the cap (2) from the spark plug high
voltage cable.
Remove all the dirt from the base of the spark
plug, then unscrew it with the spanner you will find
in the tool kit and extract it from its seat, taking
care that neither dust nor other substances enter
the cylinder.
Make sure that there are neither carbon deposits,
nor corrosion marks on the electrode 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.
2-10
Atlantic 500
Energetically blow some air, in order to prevent
the removed residues from getting into the engine.
If the spark plug has crackings on the insulating
material, corroded electrodes or excessive depos-
its, it must be changed.
Check the spark plug gap with a thickness gauge.
The gap must be 0.7 0.8 mm (0.027 - 0.031 in);
if necessary adjust it, carefully bending the earth
electrode.
Make sure that the washer is in good conditions.
With the washer on, screw the spark plug by hand
in order not to damage the thread.
Tighten the spark plug by 1/2 turn as to compress
the washer, using the spanner found in the tool kit.
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 dam-
aged. Use the recommended type of spark plug
only, see TECHNICAL DATA, in order not to com-
promise the life and performance of the engine.
Correctly fit the spark plug to prevent it from
disconnecting due to the engine vibrations.
Refit the left inspection cover, see (REMOVING
THE RIGHT AND LEFT INSPECTION COVERS).
CAUTION
0,7-0,8 mm
(0.027-0.031 in)
Standard CHAMPION RG6YC
Spark plug
- Alternatively NGK - CR7EKB
Spark plug gap
1
2
3
4
5
ADJUSTING
THE THROTTLE CONTROL
The idle stroke of the throttle grip must be 2 - 3 mm
(0.078 - 0.118 in), measured on the edge of the grip
itself.
If this is not the case, proceed as follows:
Position the vehicle on the centre stand.
Withdraw the protection element (1).
Loosen the lock nut (2).
Rotate the adjuster (3) in such a way as to restore
the prescribed value.
After the adjustment, tighten the lock nut (2) and
check the idle stroke again.
Put back the protection element (1).
Cable (4) opens the throttle
Cable (5) closes the throttle.
After the adjustment, make sure that the rotation
of the handlebar does not modify the engine idling
rpm and that the throttle grip returns smoothly
and automatically to its original position after
being released.
WARNING
0.7 - 0.8 mm
(0.027 - 0.031 in)
0.7 0.8 mm
(0.027 - 0.031 in)
2-11
Atlantic 500
2
1
2
AIR FILTER
The air cleaner should be inspected and cleaned
every 6,000 km (3,750 mi), depending on the condi-
tions of use.
If the vehicle is used on dusty or wet roads, the
cleaning operations should be carried out more
frequently.
To clean the filtering element it is necessary to remove
it from the vehicle.
REMOVAL
Lift the saddle (SADDLE LOCKING / UNLOCK-
ING).
Remove the safety clamp (1).
Pull out the pin (2) fixing the piston to the air filter
cover, as shown in the figure.
When removing the pin, hold the saddle to prevent
it from falling.
Hold the saddle, unloose and remove the six
screws (3) fixing the air filter cover to the plastic
under the saddle.
When lifting the air filter cover, take care not to
detach the intake sleeve from the filter box.
Carefully lift the air filter cover (4).
Remove the air filter (5).
CLEANING
3
3
4
CAUTION
CAUTION
5
4
4
4
5
CAUTION
CAUTION
WARNING
Do not use petrol or inflammable solvents to wash
the filtering element, in order to avoid fires or
explosions.
Do not use any additives or liquids for cleaning as
to prevent the forming of moisture inside the filter
box. Only use compressed air.
Clean the filtering element (5) with a jet of air.
DO NOT OIL THE FILTERING ELEMENT in order
not to compromise the filter and engine correct
operation.
Refit the filter (5) in the filter cover (4) (make sure
the gasket adheres perfectly to its seat), tighten
the cover to the filter box.
2-12
Atlantic 500
ENGINE OIL
Check the engine oil after the first 1,000 km (625 mi)
or at the end of the running in period, and then every
3,000 km (1,875 mi). Change the oil every 6000 km
(3,750 mi), see RENEWING THE ENGINE OIL AND
ENGINE OIL FILTER.
NOTE Use oil with specifications 5/W 40, see (TA-
BLE OF LUBRICANTS).
When topping up the engine oil, never exceed the
MAX mark.
CHECKING AND RESTORING THE ENGINE OIL
LEVEL
Carefully read LUBRICANTS, MAINTENANCE and
LUBRICANT CHART.
CHECK
NOTE Position the vehicle on firm and flat ground.
The engine and the components of the exhaust
system become very hot and remain hot for some
time after the engine has been stopped. Before
handling these components, wear insulating
gloves or wait until the engine and the exhaust
system have cooled down.
Switch off the engine, let the oil flow into the
crankcase and allow the engine and the oil to cool
down.
NOTE The non-performance of the operations de-
scribed above may result in the incorrect measure-
ment 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).
Withdraw the plug/ dipstick (1) again and read the
oil level on the dipstick itself:
MAX= maximum level;
MIN = minimum level.
The difference between MAX and MIN is about:
400 cc (24.4 cu.in)
The level is correct if the oil reaches approx. the
MAX mark on the dipstick.
CAUTION
WARNING
MIN
MAX
2
3
1
1
2-13
Atlantic 500
2
WARNING
Never exceed the MAX mark, nor leave the oil
below the MIN mark, in order to avoid serious
damage to the engine.
If necessary, provide for topping up.
TOPPING UP
Pour a small quantity of oil in the filling hole (2)
and wait about one minute, so that the oil flows
uniformly into the oil pan.
Check the oil level and top up if necessary.
Top up by adding small quantities of oil, until
reaching the prescribed level.
At the end of the operation, screw and tighten the
plug/ dipstick (1).
Do not use the vehicle with insufficient lubrication
or with contaminated or unsuitable lubricants,
since this would accelerate the wear of the mov-
ing parts and may also cause irreparable failures.
RENEWING THE ENGINE OIL AND
THE ENGINE OIL FILTER
Check the engine oil level every 3,000 km (1,875 mi),
see (CHECKING THE ENGINE OIL LEVEL AND
TOPPING UP).
NOTE Use oil with specifications 5/W 40, see (TA-
BLE OF LUBRICANTS).
When topping up the engine oil, never exceed the
MAX mark.
Check the engine oil after the first 1,000 km (625 mi)
and then:
every 6,000 km (3,750 mi), renew
every 3,000 km (1,875 mi), check level/top up.
Put the vehicle on the central stand.
down.
WARNING
4
2-14
Atlantic 500
NOTE Make sure the above procedures are carried
before the engine oil level is checked
Unscrew and remove cap/dipstick (1).
Unloose and remove the engine oil cartridge filter
(3).
Do not use the vehicle if lubrication is insufficient.
Never use unsuitable or contaminated lubricants
as they accelerate the wear and tear of moving
parts and can cause irreparable damage.
The used oil contains substances that are to the
detrimental of the environment. Dispose of the
used oils in compliance with the regulations in
force.
Unloose and remove the oil drain plug (4) to allow
the engine oil to flow out completely.
Fit a new oil cartridge filter (3) after having lubri-
cated the relative O rings.
Screw and tighten the engine oil drain plug (4).
Pour in about 1700 cm
3
(103.7 cu.in) of engine oil
through the filling hole (2).
Screw and tighten the oil dipstick (1).
Start the vehicle and let the engine run for a few
minutes. Switch it off and allow it cool down.
Check the engine oil level again with dipstick (1). If
necessary, top up without exceeding the MAX
mark.
Top up and change the oil using SAE synthetic oil
5/W 40 exceeding the API ST specifications.
WARNING
WARNING
CHECKING THE TRANSMISSION OIL LEVEL AND
TOPPING UP
Read through the paragraphs LUBRICANTS, MAIN-
TENANCE AND TABLE OF LUBRICANTS.
1
WARNING
3
1
2
4
2-15
Atlantic 500
2
Unscrew and remove cap/dipstick (1).
Clean dipstick with a clean cloth.
Completely screw the cap-dipstick (1) into the
filling hole (2).
Remove the cap-dipstick (1) again and check the
oil level:
MAX= maximum level
MIN = minimum level
The oil level is correct when it reaches the MAX
mark on the dipstick.
The oil level should never exceed the MAX mark
or go below the MIN mark in order to prevent
serious damages to the engine.
Top up if necessary.
TOPPING UP
Pour a small amount of oil in the filling hole (2)
and wait until the oil starts flowing into the crank-
case.
Check the oil level, top up if necessary.
Add small quantities of oil until the prescribed level
is reached.
Afterwards, screw and tighten the cap-dipstick (1).
SAE80W/90 OIL EXCEEDING THE API GL3 SPECI-
FICATIONS.
CAUTION
WARNING
MIN
MAX
1
2-16
Atlantic 500
RENEWING THE TRANSMISSION OIL
Read through the paragraph LUBRICANTS, MAINTE-
NANCE and TABLE OF LUBRICANTS.
NOTE Put the vehicle on a solid and flat surface.
The used oil contains substances that are to the
detrimental of the environment. Dispose of the
used oils in compliance with the regulations in
force.
down.
Unscrew and remove the cap-dipstick (1).
Unscrew and remove the drain nut (2).
Let the oil flow into a container with capacity of at
least 300 cm
3
(18.3 cu.in).
Screw and tighten the drain nut (2).
Top up as described under paragraph (CHECK-
ING THE TRANSMISSION OIL LEVEL AND
TOPPING UP).
CAUTION
CAUTION
CAUTION
1
DISC BRAKES
NOTE This vehicle is provided with front and rear
disc brakes, with separate hydraulic circuits.
CAUTION
CAUTION
2
The following information refers to a single brak-
ing system, but is valid for both.
Any sudden play variations or elastic resistance
of the brake lever is due to the hydraulic system
failure.
Check that the brake disck and the frictional
gaskets are not greasy, in particular after having
performed maintenance or check operations.
Check that the brake tube is not twisted or worn.
DO NOT DISPOSE OF THE LIQUID IN THE ENVI-
RONMENT.
2-17
Atlantic 500
2
CAUTION
The brakes are the parts that most ensure your
safety and for this reason they must always be
perfectly working; check them before every trip.
A dirty disc soils the pads, with consequent
reduction of the braking efficiency. Dirty pads
must be replaced, while dirty discs must be
cleaned with a high-quality degreaser.
Renew the brake fluid every two years.
NOTE This vehicle is provided with front and rear
disc brakes, with separate hydraulic circuits.
The following information refers to a single braking
system, but is valid for both.
When the disc pads wear out, the brake fluid level in
the reservoir decreases to automatically compensate
for their wear.
The brake fluid reservoirs are located under the
handlebar cover, next to the brake lever connections.
Periodically check the brake fluid level in
the reservoirs, see beside (CHECK) and the wear of
the pads, see (CHECKING THE PADS WEAR).
Do not use the vehicle if the braking system leaks
fluid.
CHECK
To check the level:
NOTE Put the vehicle on a solid and flat surface.
Turn the handlebar so that the fluid in the brake
fluid reservoir is at the same level as the MIN
mark shown on the glass (1).
Check that the fluid in the resevoir exceeds the
MIN mark shown on the glass (1).
if the fluid does not reach at least the MIN mark:
The level of the fluid gradually decreases with pad
wear.
Check the brake pads (CHECKING THE PADS
WEAR) and the disc wear.
Check the braking efficiency.
If the brake lever stroke is excessive or if the
braking efficiency becomes poor, it may be neces-
sary to bleed the system.
CAUTION
CAUTION
WARNING
1
2-18
Atlantic 500
CAUTION
RESTORING THE BRAKE FLUID LEVEL
Read through the paragraph DISC BRAKES.
Remove the four screws (2) from brake fluid reservoir
(3).
Remove cover (4).
NOTE To avoid spilling the brake fluid when topping
up, ensure that the fluid in the reservoir is parallel with
the reservoir rim (in a horizontal position).
Remove the gasket under the cover.
NOTE To fill the reservoir to the MAX level, ensure
that the rim of the brake fluid reservoir is parallel with
the ground and add fluid until sight (5) is completely
covered.
Top up to the MAX level only if the brake pads are
new.
The level of the fluid gradually decreases with pad
wear.
Topping up to the MAX level when the pads are
worn will cause the brake fluid to overflow when
the pads are replaced.
Fill reservoir (3) with brake fluid (see LUBRICANT
CHART) until sight (1) is completely covered.
To refit the components, follow the reverse procedure
to the removal.
CHECKING BRAKE PAD WEAR
The following information are referred to one
braking system only, but are valid for both.
Check the brake pad wear after the first 1,000 km (625
mi) and successively every 2,000 km (1,250 mi).
The wear of the brake pads depends on the use, on
the kind of drive and on the road.
The wear is heavier when driving on dirty or wet
roads.
FRONT BRAKE CALIPER
Front side from the bottom for both calipers.
REAR BRAKE CALIPER
Rear side from the bottom for both pads (C).
The excessive wear of the friction material would
cause the contact of the pad metal support with
the disc, with consequent metallic noise and
production of sparks from the caliper; braking
efficiency, safety and soundness of the disc would
thus be negatively affected.
If the thickness of the frictional material (also of
one pad only) becomes 1.5 mm (0.059 in), replace
both pads (both front and rear pad).
WARNING
2
3
4
2
1
2-19
Atlantic 500
2
CAUTION
CAUTION
BLEEDING THE BRAKING SYSTEM
(FRONT SIDE ONLY)
Any air present in the brake circuit acts as a cushion,
absorbing much of the pressure applied by the brake
pump and reducing the effectiveness of the brake
caliper. The presence of air is indicated by a spongy
feel of the brake lever and a reduction in the braking
action.
In view of the danger for both the rider and the
vehicle, it is essential that the hydraulic circuit
should be bled after reinstalling the brakes and
restoring the braking system to its normal operat-
ing conditions.
Loosen the four screws (2) on brake fluid reservoir (3).
Remove the cap (4).
up, be sure to keep the fluid in the reservoir parallel
with the ground.
Remove the gasket above the cover.
Check if the brake fluid completely covers sight (6), and
if necessary top up.
Remove the cap from breather valve (7).
Connect a transparent pipe (9) to breather valve (8).
Take care not to soil the pads or the disc with
brake fluid.
Place the free end of the transparent pipe in a con-
tainer (10).
Slowly pull the brake lever 2-3 times to the end of its
travel and then keep it pulled.
Loosen breather valve (8), press the lever and check
if any air bubbles come out of the transparent pipe
with the brake fluid.
Before releasing the brake lever, retighten
breather valve (8) so as to prevent air from getting
into the brake circuit.
When the brake fluid comes out with no air bubbles,
tighten breather valve (8) and then release the brake
lever.
Tightening torque for breather valve (8):
14 Nm (1.4 kgm).
NOTE Repeat the last three operations until all the
air has been purged.
After refitting the parts, repeatedly operate the
brake lever and ensure that the braking system is
working properly.
CAUTION
CAUTION
2
3
4
2
6
2-20
Atlantic 500
WARNING
BLEEDING THE INTEGRAL BRAKING SYSTEM
The air present in the hydraulic circuit acts as a cush-
ion, absorbing much of the pressure applied by the brake
pump and reducing the effectiveness of the caliper dur-
ing the braking.
The presence of air can be noticed by a spongy feel of
the brake lever and poor braking action.
In view of the danger for both the rider and the
vehicle, it is essential that the hydraulic circuit
should be bled after reinstalling the brakes and
restoring the braking system to its normal operat-
ing conditions.
NOTE The lever of the l.h. pump acts either on the
rear caliper and on the right front caliper.
2
3
1
1
6
4 5
With the specific tool (6), suck the oil through the
breather pipe (4) of the right front caliper (5) by
unscrewing the breather pipe (4) nut by half turn.
Add oil in the brake fluid reservoir (2) for about 2-3
times.
Loosen the four screws (1) on brake fluid reservoir (2).
Remove the cap (3).
up, be sure to keep the fluid in the reservoir parallel
with the ground.
2-21
Atlantic 500
2
Unloose and remove the three screws (7).
Remove the rear brake caliper (8) of the plate (9) and
the relevant cable lead.
Fit the rear brake caliper (8) so that the breather valve
(10) is in the highest position.
With the specific tool, suck the oil through the breather
valve (10) of the rear brake caliper (8) by unscrewing
the breather valve (10) nut by half turn.
Add oil in the brake fluid reservoir (2) for about 2-3
times.
Never allow the fluid reservoir (2) to empty com-
pletely, to prevent air from entering the circuit.
7
8
7
9
6
8
10
CAUTION
Refit the rear brake caliper. Remove the front hood,
see (REMOVING THE FRONT HOOD).
With the specific tool, suck the oil through the retarder
(12) breather (11), by unscrewing the breather (11) nut
by half turn.
12
11
Operate the brake lever until the reservoir is
completely free from air bubbles.
Refit the cover (3) of the brake fluid reservoir (2).
Refit the front hood, see (REMOVING THE FRONT
HOOD).
NOTE Perform the bleeding again if the braking
action is poor.
2-22
Atlantic 500
WARNING
CAUTION
CHECKING AND RESTORING THE COOLANT
LEVEL
Read through the paragraphs COOLANT and
PRECAUTIONS AND GENERAL INFORMATION.
Do not use the vehicle if the coolant is below the
minimum prescribed level MIN.
Check the coolant level every 2,000 km (1,250 mi)
and after long trips; have the coolant changed every
16 months.
DO NOT DISPOSE OF THE FLUID IN THE ENVI-
RONMENT
Remove the front hood, see (REMOVING THE
FRONT HOOD).
Check that the coolant level in the expansion tank (2)
is between the MIN and MAX mark (see figure).
Do not remove the expansion tank plug (1) when
the engine is hot, since the coolant is under
pressure and its temperature is high.
If it gets in contact with the skin or with clothes it
may cause severe burns and/or damage.
Contrariwise, unscrew and the remove the filler cap
found under the front hood. Add coolant until it roughly
reaches the MAX level.
Do not exceed the maximum level as this would cause
the coolant to overflow during the engine operation.
Replace the filler cap.
Replace the front hood.
In case of excessive consumption of coolant and
in case the tank remains empty, make sure that
there are no leaks in the circuit.
The coolant is harmful: DO NOT INGEST.
Only use antifreeze and anticorrosive fluid free
from nitrite, ensuring protection at a temperature
of at least 35C (31F).
CAUTION
CAUTION
MIN
MAX
2
2-23
Atlantic 500
2
1
MIN
MAX
2
RENEWING THE COOLANT
Read through the paragraphs COOLANT and
PRECAUTIONS AND GENERAL INFORMATION.
minimum level.
Check the level of the coolant every 2,000 km (1,250
mi) and after long journeys. Renew the coolant every
16 months.
Switch off the engine and allow the engine and the
exhaust system to cool down.
DO NOT DISPOSE OF THE COOLANT IN THE ENVI-
RONMENT
FRONT HOOD).
Remove the splash guard, see (REMOVING THE
SPLASH GUARD).
Do not remove the expansion tank cap when the
engine is hot. The coolant is under pressure at
high temperatures and can cause burns and/or
damage clothes.
Remove filler cap (1) from expansion tank (2).
Place a container with a capacity of at least 1500 cm
3
(91.5 cu.in) under the crankcase, below drain screw.
Unloose and remove the screw clamp (3), disconnect
the union.
Drain all the coolant into the container and then pour it
into another container for liquid recovery.
Replace the union and fix with clamp (3).
Pour 1200 cm
3
(73.2 cu.in) of coolant in the expansion
tank (2).
Add coolant until it roughly reaches the MAX level
Do not exceed the maximum level as this would cause
the coolant to overflow during engine operation.
Replace filler cap (1).
Remove the right inspection cover, see (REMOVING
THE RIGHT AND LEFT INSPECTION COVER).
Exhaust gases are harmful.
Avoid running the engine in closed or poorly
ventilated places.
CAUTION
CAUTION
CAUTION
CAUTION
3
4
2-24
Atlantic 500
Start the engine and let it idle.
Place a container under the engine to gather any
coolant coming out of breather screw (5).
The coolant in the circuit is under pressure. To
avoid dangerous spurts, loosen breather screw (5)
slowly and moderately.
Loosen breather screw (5) on thermostatic valve
(6); allow a moderate quantity of coolant to flow
out together with any air bubbles and then tighten
breather screw (5).
Check the level of the fluid in expansion tank (2)
and then top up to the MAX level (see page 2-25
CIRCUIT BLEEDING for the bleeding).
Ride a few kilometres until the engine reaches the
normal operating temperature.
CAUTION
CAUTION
CAUTION
CAUTION
To refit the plastic parts follow the reverse procedure.
If coolant consumption is excessive, or if the
coolant runs out in the tank, check for possible
leakage from the circuit.
The coolant is harmful: DO NOT INGEST
KEEP OUT OF REACH OF CHILDREN
Only use nitrite-free anticorrosive and antifreeze
agents providing a protection at temperatures of
-35 C (-31 F) or lower
For more information on the cooling system, see
(COOLING SYSTEM).
5
6
2-25
Atlantic 500
2
CHECKING AND ADJUSTING THE STEER-
ING
CHECKING THE BEARINGS PLAY
Read through the paragraph PRECAUTIONS AND
GENERAL INFORMATION.
Periodically check the play existing on the steering.
To carry out this operation, proceed as follows:
Shake the fork in the riding direction (see figure).
If any play is found, adjust.
Switch on the engine.
The air bubbles will start coming out of the circuit
through the transparent pipe (2).
Check that the pipe between the expansion tank
and the radiator starts spraying liquid into the
expansion tank (visible from the front side). In this
case, it means that the thermostatic valve is open
and the circuit is completely full.
Close the bleeder valve.
NOTE If the heater fan turns on it is unimportant as
the sensor that activates the fan is located on the
cylinder head and not on the radiator.
CIRCUIT BLEEDING:
FRONT HOOD).
Remove the filter box, see (REMOVING THE
FILTER BOX).
Open the expansion tank cap.
Remove the breather cap located on the cylinder
head T union (1).
Connect a transparent rubber pipe (2) between
the breather pipe and the expansion tank.
Screw breather nut (3) by
1
/
2
turn.
Add coolant in the expansion tank (4) up to the
max level (check level through the glass in the
front compartment).
2
2
1
4
3
2-26
Atlantic 500
CAUTION
CHECK ENGINE PIN BUSHINGS
Periodically check the slack existing between the
engine pin bushings.
Shake the wheel transversally with respect to the
riding direction.
If any play is found, check that all fulcrum axis fasten-
ers are securely tightened (see REMOVING THE
ENGINE LINKAGE).
ADJUSTING THE BEARINGS PLAY
Remove the legshield, see (REMOVING THE
LEGSHIELD).
Unloose the check nut (1).
To avoid damaging the steering bearings, take
care not to tighten adjusting nut (2) forcefully.
Turn in adjusting nut (2) until the play of the bearings
is eliminated.
Check the play by shaking the fork in the direction of
motion and ensuring that the steering can rotate freely
and smoothly.
While holding adjusting nut (2) in position, tighten
counternut (1) with a spanner
Tightening torque for counternut (1):
110 Nm (11 kgm).
Repeat the last but one step.
1
2
1
CAUTION
STEERING DAMPER
It is possible to adjust the steering damper when
riding the vehicle at full load (driver + passenger +
luggage).
Turn the ring nut (1) clockwise to increase the damper
brake.
Tighten the ring nut to increase the damper ad-
justing brake, thus increasing the effort required
for turning the handlebar, which becomes less
easy to handle.
2-27
Atlantic 500
2
CHECKING THE FRONT SUSPENSION
Inspect the front suspension after the first 1,000 km
(625 mi) and then every 6,000 km (3,750 mi) or 8
months.
Renew the oil in the front suspension every 12,000 km
(7,500 mi), see FRONT SUSPENSION.
Check that no oil is leaking from the fork, and that the
outside surface of the fork rods is not scratched or
grooved. Replace any damaged parts.
Also perform the following checks:
While pulling the front brake lever, repeatedly stroke
the fork by pushing down on the handlebar. The fork
should move smoothly, and there should be no traces
of oil on the fork rods.
Check the tightening of all parts and the function of the
front suspension joints (see FRONT SUSPENSION).
CHECKING THE REAR SUSPENSION
Inspect the rear suspension after the first 1,000 km
(625 mi) and subsequently every 6,000 km (3,750 mi)
or 8 months.
Check that no oil is leaking from the shock absorbers.
Check the tightening of all parts and the function of
the rear suspension joints (see REAR SUSPEN-
SION).
Check that both shock absorbers are adjusted to
the same position. See (ADJUSTMENT).
CAUTION
1
ADJUSTING THE REAR SUSPENSION
The rear suspension consists of a doubleeffect shock
absorber (braking with compressed/extended shock
absorber) fixed to the engine by means of a silent-
block.
The standard adjustment, set by the manufacturer, is
suitable for a driver weighing about 70 kg (154.3 lbs).
If your weight and needs are different, adjust the ring
nut (1) with the appropriate spanner provided in the
tool kit, thus setting the ideal travelling conditions (see
table).
Adjust both shock absorbers to the same position
CAUTION
2-28
Atlantic 500
WHEELS AND TYRES
WHEELS INSPECTION
Check that the wheel rims are not cracked or dis-
torted. If necessary replace them.
Check the radial runout of the wheel.
If the wheel is distorted beyond the acceptable limit,
check the condition of the rim and the bearings.
If necessary replace the wheel.
Runout limits:
Vertical runout: 2 mm (0.078 in)
Lateral runout: 2 mm (0.078 in)
Check the wheel trim.
Slowly turn the wheel several times and observe the
point at which it stops.
If the wheel is not statically balanced, it will always
stop at the same point. Fit a balancing weight at the
lightest point (top).
Adjusting
ring
Rotation
(arrow A)
Rotation
(arrow B)
Function Spring
preload
increase
Spring
preload
decrease
Attitude The vehicle
is more rigid
The vehicle
is less rigid
Recom-
mended
kind of road
Smooth or
normal roads
Roads with
uneven
surface
Notes Drive with
passenger
Drive
without
passenger
ADJUSTMENT OF THE REAR
SUSPENSION SPRING PRELOAD
TYRES
This vehicle is provided with tubeless tyres.
Periodically check the tyre inflation pressure at
room temperature, see (TECHNICAL DATA).
If the tyres are hot, the measurement is not correct.
Carry out the measurement especially before and
after long rides.
If the inflation pressure is too high, the ground
unevenness cannot be dampened and is therefore
transmitted to the handlebar, thus compromising
the driving comfort and reducing road holding
during turns.
WARNING
2-29
Atlantic 500
2
If, on the contrary, the inflation pressure is too
low, the tyre sides (1) are under greater stress and
the tyre itself may slip on the rim or it may be-
come loose, with consequent loss of control of
the vehicle.
In case of sudden braking the tyres could even get
out of the rims.
Further, the vehicle could skid while turning.
Check the surface and the wear of the tyres, since
tyres in bad conditions can impair both the grip
and the controllability of the vehicle.
Some types of tyres homologated for this vehicle
are provided with wear indicators.
There are several kinds of wear indicators.
Visually check if the tyres are worn and in this
case have them changed.
If the tyres are old, even if not completely worn
out, they may become hard and may not ensure
good road holding.In this case, have the tyres
changed.
Change the tyre when it is worn out or in case of
puncture on the tread side, if the puncture is
larger than 5 mm (0.196 in).
After repairing a tyre, have the wheels balanced.
Use only tyres in the size suggested by aprilia,
see TECHNICAL DATA.
Do not install tyres with air tube on rims for tube-
less tyres and viceversa.
Make sure that the tyres always have their valve
sealing caps on, to prevent them from suddenly
going flat.
Change, repair, maintenance and balancing opera-
tions are very important and should be carried out
by qualified technicians with appropriate tools.
If the tyres are new, they may still be covered with
a slippery film: drive carefully for the first miles.
Do not oil the tyres with unsuitable fluids.
1
2-30
Atlantic 500
2
TYRES PRESSURE
MINIMUM TREAD DEPTH LIMIT (2)
front:............2 mm [0.078 in] ( 3 mm) [0.118 in]
rear:.........2 mm [0.078 in] ( 3 mm) [0.118 in]
Do not exceed the max transportable weight as this
would compromise the vehicles stability, handiness
and may cause damages to the tyres.
MAX LOAD 180 Kg (396.8 lbs)
FRONT REAR
RIDER ONLY
FULL LOAD
(passenger + driver)
2.1 bar (30.4 psi) 2.3 bar (33.3 psi)
2.2 bar (31.9 psi) 2.6 bar (37.7 psi)
According to the tests carried out by aprilia, only the
tyres listed below have been approved for this model:
MANUFACTURER SIZE MODEL
FONT
FONT
REAR
REAR
MICHELIN
CHENG SHIN
MAXXIS
120/70-15 56S
140/60-14 64S
120/70-1556R
140/60-14 64R
GOLD STANDARD
GOLD STANDARD
M-6002
M-6002
Engine
chap. 3
3-1
Release 00 2002-09
3
Engine
Atlantic 500
Engine
chap. 3
3-2
Release 00 2002-09
Atlantic 500
COMPONENTS THAT CAN BE REMOVED
WITHOUT REMOVING THE ENGINE
The following parts can be removed and refitted with-
out removing the engine from the frame.
UPPER SIDE
- Throttle body (1) see (THROTTLE BODY)
- Intake manifold sleeve (2)
- Starter motor (3)
- Coolant temperature thermistor (4) (on cylinder head)
- Injector (5)
FRONT SIDE
- Tappet cover (6)
- Head (7)
- Cylinder (8)
RIGHT SIDE
- Oil pressure sensor (9)
- Engine oil filter (10)
- Exhaust silencer (11) see (REMOVING THE EX-
HAUST SILENCER)
- Water pump (12)
- Ignition casing (13)
- Flywheel
- Stator coil
- Pulse generator (pick-up)
LEFT SIDE
- Driving belt box air filter
- Transmission crankcase cover (14)
- Speed variator assembly
- Clutch assembly
- Drive belt
4
6
7
Unless otherwise specified, for information on remov-
ing procedures refer to the ENGINE WORKSHOP
MANUAL n1063 , n1064 , n1065 , n1066
, n1067 and n1068 .
8
2
1
5
11
13
9
10
12
14
3
Engine
chap. 3
3-3
3
Release 00 2002-09
Atlantic 500
REMOVING THE ENGINE FROM THE FRAME
Read through the paragraph (PRECAUTIONS AND
GENERAL INFORMATION).
Disconnect the battery.
Completely empty out the coolant circuit (RENEWING
THE COOLANT).
Remove the right and left inspection covers, see
(REMOVING THE RIGHT AND LEFT INSPECTION
COVER).
Clean the outside of the engine with a brush, rags
and a degreasing detergent.
Take care not to damage rubber and plastic parts
with corrosive or penetrating detergents and
solvents.
If a steam cleaner is required, take care not to
direct any high-pressure water or air jet, or any
steam jet towards the following parts: wheel hubs,
controls on the left and right sides of the handle-
bar, brake pump, instruments and indicators,
silencer exhaust, document holder, ignition
switch/steering lock.
Clean the engine and the related components.
To ensure proper refitting of the parts, suitably
mark the wires, sleeves, pipes, etc.
On reassembly, make sure that all the parts are
correctly fitted.
Unloose and remove screw (1) fixing the injector
supply pipes support (2).
Detach the two connections (3) supplying fuel to the
injector.
Detach the injector electrical connection (4).
Detach the automatic starter electrical connection (5).
Detach the electrical connection (6) from the sensor
detecting the position of the throttle body throttle.
Remove the spark plug (7) and release the relative
cable.
Disconnect the electrical connection from the air tem-
perature sensor of the throttle body.
CAUTION
CAUTION
CAUTION
4
3
1
2
7
5
6
Engine
chap. 3
3-4
Release 00 2002-09
Atlantic 500
Detach the water inlet pipe (8) to the pump by
unloosing screw (9) on hose clamp (10).
Unloose the two nuts (16) fixing the cable guides to
the throttle body support.
Remove the cable guide and relevant control delivery
barrel (17) on the throttle body.
Remove the cable guide and the relevant control
return barrel (18) on the throttle body.
8
10
Detach the water outlet pipe (11) from the cylinder by
unloosing screw (12) on hose clamp (13) found on the
union above the cylinder.
Detach the electrical connection (14) of the coolant
temperature sensor (15).
Detach the electrical connection (19) from the phase
sensor (20) and release the wires from the clamps
fixing them to the frame.
17
11
15
14
12
13
9
18
16
20
19
Engine
chap. 3
3-5
3
Release 00 2002-09
Atlantic 500
Remove rubber protection (21) and detach the
engine oil pressure sensor wire connector (22).
Unloose and remove the nut fixing the starter relay
cable (23) and remove the cable (24).
Unloose and remove the two screws (25) fixing the
starter to the crankcase, and release the cables for
the ground.
Detach connector (26) of the injection positive cable.
Owing to the weight and bulk of the components
and the vehicle, the following operations are to be
performed in cooperation with a second operator.
Before starting work, the two operators should
agree on their respective roles in the operations to
be performed (in the following instructions A
operations are to be carried out by the 1st opera-
tor and B operations by the 2nd operator), on
the procedures to be followed and on any warning
signs to be placed.
EXERCISE EXTREME CAUTION.
WARNING
21
22
26
23
WARNING
The weight and bulk of the vehicle can cause
dangerous unbalancing and tipping of the vehicle
during the hoisting phase.
PROCEED WITH CAUTION AND MAKE SURE YOU
CAN BEAR THE WEIGHT OF THE VEHICLE.
Remove the rear wheel, see (REMOVING THE REAR
WHEEL).
A Lift the vehicle from its rear side, fasten up the
wheel with belts if necessary.
25
24
Engine
chap. 3
3-6
Release 00 2002-09
Atlantic 500
A arrange for suitable supports to be placed under
the engine for the next positioning, after the frame
removal.
B unscrew and remove pin (27) fixing the left rear
suspension (28).
Keep the nut and the washer.
Since the engine is heavy, proceed with caution. In
particular, mind the hands.
A carefully lean the engine on the floor.
B unscrew and remove the left pin (29) fixing the
engine to the frame. Keep the washer.
A hold the left side of the engine.
CAUTION
B unscrew and remove the right pin (30) fixing the
engine to the frame. Keep the washer.
Proceed with caution.
In particular, mind the limbs and fingers.
Proceed with caution when lifting and moving the
engine.
CAUTION
A and B Lean the engine assembly on the work
bench.
Close the engine intake manifold in order to
prevent dirt and foreign bodies from getting in.
CAUTION
27
29
30
28
Fuel System
chap. 4
4-1
Release 00 2002-09
4
Fuel System
Atlantic 500
Fuel System
chap. 4
4-2
Release 00 2002-09
Atlantic 500
FUEL TANK AND PUMP
EMS FUEL INJECTION SYSTEM
The fuel injection system used is of the integrated fuel injection and ignition type.
Fuel is injected indirectly into the manifold by means of the electroinjector.
Fuel injection and ignition are timed on a 4-stroke cycle via a phonic wheel keyed to the cam shaft control and a
reluctance variation sensor.
Fuel supply and ignition are controlled in relation to the engine revolutions and the opening of the throttle control.
Further corrections are carried out on the basis of the following parameters:
- Coolant temperature
- Air intake temperature
- Environmental pressure
The system carries out a idling supply correction on a cold engine via a stepper motor inserted on to a by-pass
circuit of the throttle valve. The control unit controls the stepper motor and the timing of the injector opening, thus
guaranteeing idling stability and correct fuel supply.
Under all working conditions, fuel supply is controlled by modifying the injector opening time.
Petrol supply pressure is kept constant on the basis of environmental pressure.
The supply circuit is composed of:
- Fuel pump
- Fuel filter
- Injector
- Pressure regulator
The pump, filter and regulator are inserted into the fuel tank via a single support.
The injector is connected by means of two snap-connector tubes. This allows continuous circulation and avoids the
risk of fuel overheating. The pressure regulator is situated at the end of the circuit. The fuel pump is controlled by
the EMS control unit; thus guaranteeing vehicle safety.
The ignition circuit is composed of:
- H.V. coil
- H.V. cable
- Shielded cap
- EMS control unit
- Spark plug
The EMS control unit controls ignition with optimum advance, at the same time guaranteeing 4-stroke cycle timing
(ignition only during compression phase).
The EMS fuel injection-ignition system controls the working of the engine by means of a preset programme.
Should certain entry signals fail, an acceptable working of the engine is still guaranteed in order that the user may
reach a repairs centre.
Obviously, this will not happen if the revolutions signal fails, nor if there is an anomaly in the control circuit:
- Fuel pump
- H.V. Coil
- Injector
Fuel System
chap. 4
4-3
4
Release 00 2002-09
Atlantic 500
FUEL SUPPLY SYSTEM
KEY TO FUEL SUPPLY SYSTEM
1) Fuel pump
2) Fuel tank
3) Intake manifold
4) Fuel supply pipe (DELIVERY)
5) Fuel supply pipe (RETURN)
6) Excess fuel drain pipe
7) Injector
8) Fuel level float
9) Fuel pump filter
10) Fuel supply cap
5
3
8
9
6
1
10
2
4
7
Fuel System
chap. 4
4-4
Release 00 2002-09
Atlantic 500
MAINTENANCE
Check the condition of the fuel feed pipes every 6,000 km (3,750 mi) or 8 months.
Any pipes showing signs of desiccation, cracks or cuts must be replaced.
Ensure that the pipes are not twisted or choked.
FUEL SUPPLY CHECK
Read through paragraphs (PRECAUTIONS AND GENERAL INFORMATION) and (FUEL).
Fuel fumes are a health hazard.
Before proceeding, ensure that the working area is suitably aerated. Do not inhale fuel fumes.
Avoid contact of fuel with the skin.
Do not smoke or use open flames.
Do not dispose of fuel in the environment.
Ensure that the tank contains fuel.
Remove the central tunnel, see (REMOVAL OF CENTRAL TUNNEL).
To one side of the vehicle, place a container with an approx. 1 l capacity (0.264 gal) to collect the fuel.
Work with caution. Be ready to collect the fuel that exits from the fuel supply pipe (RETURN) .
Disconnect the fuel supply pipe (RETURN) from the fuel pump (5) (see SUPPLY SYSTEM diagram).
Place the free end of the pipe in the container.
Set the ignition switch to .
Without throttle, allow the starter motor to work for a few seconds and at the same time check that the fuel flows out
of the pipe (4).
If the flow is discontinuous or inexistent, verify the integrity and efficiency of the following components:
DO NOT INVERT THE PIPES DURING REASSEMBLY.
Mark the pipes and their attachments in order to reassemble them correctly.
Check that the pipes ARE NOT twisted and are not choked or obstructed.
To carry out checks follow instructions in WORKSHOP MANUALS n1063 , n1064 , n1065 , n1066 ,
n1067 and n1068 .
CAUTION
CAUTION
CAUTION
Fuel System
chap. 4
4-5
4
Release 00 2002-09
Atlantic 500
FUEL PUMP REMOVAL/DISMANTLING
Read through the paragraphs (PRECAUTIONS AND
GENERAL INFORMATION) and (FUEL).
PUMP ASSEMBLY REMOVAL
Fuel fumes are a health hazard.
Before proceeding, ensure that the working area
is suitably aerated. Do not inhale fuel fumes.
Avoid contact of fuel with the skin.
Do not smoke or use open flames.
Remove the central tunnel, see (REMOVAL OF
CENTRAL TUNNEL).
Disconnect the electrical control connection (1) from
the fuel pump.
Disconnect the fuel supply pipes (2) from the pump
casing.
Unscrew and remove the six nuts (3).
Remove the fuel pump fixing clamp (4).
CAUTION
CAUTION
Work with caution during removal of the fuel
pump (5) to avoid damage to the fuel pre-filter (6).
Remove the fuel pump (5) from the tank (7).
2
3
1
2
6
7
5
3
4
Fuel System
chap. 4
4-6
Release 00 2002-09
Atlantic 500
FUEL PUMP AND FUEL LEVEL FEELER DISAS-
SEMBLY AND CHECKING
For dismantling of the components refer to WORK-
SHOP MANUALS n1063 , n1064 , n1065 ,
n1066 , n1067 and n1068 .
THROTTLE BODY
1) Stepper motor
2) Valve position sensor
3) Air temperature sensor
4) Valve
5) Valve opening control cables support plate
6) Valve opening/closure wiring control guide
4
1
2
5 3
6
Fuel System
chap. 4
4-7
4
Release 00 2002-09
Atlantic 500
THROTTLE BODY REMOVAL
Read through the paragraphs (PRECAUTIONS AND
GENERAL INFORMATION) and (FUEL).
Remove the air filter box, see (AIR FILTER).
Loosen the two nuts (7) that fix the cable runners to
the fuel supply support.
Pull out the cable runner and its related delivery barrel
(8) of the carburettor control.
Pull out the cable runner and its related return barrel
(9) of the carburettor control.
Disconnect the electrical connection (4) of the air
temperature sensor.
Disconnect the electrical connection (5) of the stepper
motor.
Disconnect the electrical connection (6) of the valve
position sensor.
Disconnect the delivery and return fuel supply pipes
(1) to the injector.
Unscrew and remove the fixing screw (2) of the fuel
pipe clamps.
Disconnect the electrical connection (3) of the injector
control.
5
6
8
9
7
4
3
1
2
Fuel System
chap. 4
4-8
Release 00 2002-09
Atlantic 500
Unscrew and remove the three screws (10) fixing the
intake manifold (11) to the head.
Remove the intake manifold (11) including the throttle
body (12).
12
12
11
15 14
13
throttle body (12) to the intake manifold (11).
Separate the throttle body (12) from the intake mani-
fold (11).
Remove the screw (14) fixing the injector (15) to the
Intake manifold.
Remove the injector (15) from the intake manifold
(11).
10
11
10
Cooling System
chap. 5
5-1
Release 00 2002-09
5
Cooling System
Atlantic 500
Cooling System
chap. 5
5-2
Release 00 2002-09
Atlantic 500
SYSTEM DESCRIPTION
The cooling system is constructed with a centrifugal pump coaxial to the countershaft and as such completes a
number of revolutions identical to that of the driving shaft.
The pump has two ducts, one for entry and one for exit.
The exit duct supplies the cylinder and consequently the cylinder head; the entry duct leads from the cylinder head
and its entrance to the pump is controlled by the thermostat plate.
The main stabilizer of the thermostat acts instead on the main pump entry duct leading from the radiator.
The radiator is fed from the cylinder head exit; the expansion tank is inserted parallel to the radiator with the ducts
on two levels: the delivery high up (in the air) and the fluid return low down (in the fluid).
The system thus composed is 2-way.
The first way is the internal engine circulation and involves the pump, cylinder and cylinder head; this circulation is
fully active when the thermostat is fully closed.
The second way is active with the thermostat fully open and is the main circulation which involves the pump,
cylinder, cylinder head, radiator and expansion tank; for medium openings of the thermostat, however, the two
circuits are both partially inserted, therefore the two ways are superimposed.
This kind of circuit is defined as the type with inlet thermostat. The thermostat is crossed by an inverted flow, that is
with cold water which tends to lower the temperature of the wax cell.
This system allows optimization of the engine heating phases.
The expansion tank, parallel to the radiator and inserted on the main circuit, guarantees autodraining when work-
ing.
For the filling stages of the system there is a drain exiting from the cylinder head (see filling rules).
The electrical fan is controlled by the fuel injection system with temperature measured on the cylinder head of the
engine.
COOLANT
For information concerning the coolant see (COOLANT); (CHECKING AND TOPPING UP OF THE COOLANT) and
(REPLACING COOLANT) in the related WORKSHOP MANUALS n1063 , n1064 , n1065 , n1066 ,
n1067 and n1068 .
1
7
6
8
5
9
2
3
4
10
Key
1) Radiator/pump pipe
2) Thermostat valve
3) Pump/head cylinder pipe
4) Cylinder head/pump pipe
5) Radiator
6) Cylinder head/radiator pipe
7) Expansion tank
8) Expansion tank/radiator
pipe
9) Electrical fan
10) Water pump casing
Cooling System
chap. 5
5-3
5
Release 00 2002-09
Atlantic 500
RADIATOR REMOVAL
Read through the paragraphs (COOLANT) and
(PRECAUTIONS AND GENERAL INFORMATION).
Drain the coolant completely, see (REPLACING
COOLANT), in the WORKSHOP MANUALS n1063
, n1064 , n1065 , n1066 , n1067 and
n1068 .
Remove the legshields, see (LEG SHIELDS RE-
MOVAL ).
Remove the front splash guard, see (SPLASH
GUARDS REMOVAL).
Remove the thermo-reflecting material.
Disconnect the three pipes (1) on the radiator.
Unscrew and remove the two fixing screws (2) of the
radiator.
Work with caution. Do not damage the radiator
cooling fins.
Remove the radiator (3) lightly turning it clockwise,
and pull towards the left side of the vehicle.
CAUTION
1
1
1
3
2
ELECTRICAL COOLING FAN REMOVAL
Remove the radiator, see (RADIATOR REMOVAL).
Disconnect the electrical fan connection (1).
electrical fan to the support (3).
Remove the electrical fan (4).
1
3
4
2
Cooling System
chap. 5
5-4
Release 00 2002-09
Atlantic 500
EXPANSION TANK REMOVAL
Read through paragraphs (COOLANT) and (PRECAU-
TIONS AND GENERAL INFORMATION).
Place the vehicle on its central stand.
Remove the front hood, see (FRONT HOOD RE-
MOVAL).
Remove the legshields, see (LEGSHIELDS RE-
MOVAL).
Remove the dash board, see (DASHBOARD RE-
MOVAL).
DO NOT DISPOSE OF COOLANT IN THE ENVIRON-
MENT.
On removing the hose (1) any coolant present will
exit from the expansion tank (2).
Be ready with a container with capacity of approx.
1 litre to collect the liquid on exit.
Place an absorbent cloth under the expansion tank
to collect any coolant that may be dispersed.
NOTE Keep a supply of hose clamps to replace the
originals (of a special kind without screws).
Remove the clamp (3). Replace with a new one during
reassembly.
Pull the hose (4) out from the expansion tank attach-
ment.
Remove the clamp (5). Replace with a new one during
reassembly.
Pull out the hose (1) from the expansion tank attach-
ment.
Quickly place the container under the expansion tank
to collect the coolant.
Coolant is hazardous to health.
Keep the container in a safe place.
DO NOT LEAVE WITHIN REACH OF CHILDRENI
Unscrew and remove the two screws (6) and screw
(7).
Remove the expansion tank.
CAUTION
CAUTION
2
3
4
5
1
6
7
Cooling System
chap. 5
5-5
5
Release 00 2002-09
Atlantic 500
THERMOSTAT VALVE
For information concerning the thermostat valve, see
WORKSHOP MANUALS n1063 , n1064 ,
n1065 , n1066 , n1067 and n1068 .
COOLANT PUMP
For information concerning the coolant pump, see
n1065 , n1066 , n1067 and n1068 .
COOLANT THERMISTOR
For information concerning the coolant thermistor, see
n1065 , n1066 , n1067 and n1068 .
Cooling System
chap. 5
5-6
Release 00 2002-09
Atlantic 500
chap. 6
6-1
Release 00 2002-09
6
Atlantic 500
chap. 6
6-2
Release 00 2002-09
Atlantic 500
CHECKING THE RECHARGING SYSTEM
The following key will help the reader to consult this
section.
CABLE COLOURS
Ar orange
Az light blue
B blue
Bi white
G yellow
Gr gray
M brown
N black
R red
V green
Vi violet
Ro pink
CHECKING THE RECHARGING VOLTAGE
Check the electrolyte level (CHECKING THE
ELECTROLYTE LEVEL).
Check the battery voltage (RECHARGING THE
BATTERY).
Start the engine and rev it up to 5000 rpm (throttle
twist grip rotated by approximately 1/4 of its
travel).
Set the lights switch in the position and the
lights selector switch in the position.
Using a pocket multimeter, measure the direct
voltage between the positive (+) and negative (-)
terminals of the battery.
If the multimeter reads voltages of less than 13 V
or more than 15 V:
check the no-load operation and continuity of the
alternator (CHECKING THE ALTERNATOR NO-
LOAD OPERATION) and (CHECKING THE
ALTERNATOR CONTINUITY) and the voltage
regulator (VOLTAGE REGULATOR).
Key to second figure
17) Voltage regulator
19) Battery
37) Ignition switch (right switch)
24) Main fuse
Standard charging voltage: 13 - 15 V (c.c.) at 5000
rpm.
CHECKING THE ALTERNATOR NO-LOAD
OPERATION
Remove the right side panel, see (REMOVAL OF
THE SIDE PANELS).
Detach regulator wiring connector (1).
Start the engine and rev it up to 5000 rpm
(throttle twist grip rotated by approximately 1/4 of
its travel).
Using a pocket multimeter, alternately measure
the a.c. voltage between the three yellow wires
(G). If the multimeter readings are less than 50 V,
the alternator is faulty.
Standard no-load voltage: more than 50 V (a.c.)
at 5000 rpm.
17
24
19
37
1
1
chap. 6
6-3
6
Release 00 2002-09
Atlantic 500
CHECKING THE ALTERNATOR CONTINUITY
With motor off:
Remove the right side panel, see (SIDE PANELS
REMOVAL).
Detach regulator wiring connector (1).
Using a pocket multimeter, check continuity
between stator yellow wires (G).
Also check the insulation of the stator support.
Standard resistance: 0.1 - 1
Standard resistance between stator support and
wiring: (infinite resistance)
VOLTAGE REGULATOR
Remove the tail panel, see (TAIL PANEL
REMOVAL).
Remove the right side panel, see (SIDE PANELS
REMOVAL).
Disconnect the connectors (1) and (2).
Using a pocket multimeter (1 k scale) on the
regulator side, measure the resistance between
the wires shown in the table below.
If the measured resistance is not as specified,
replace the regulator.
Multimeter positive (+) terminal on:
M
u
l
t
i
m
e
t
e
r

n
e
g
a
t
i
v
e

(
-
)

t
e
r
m
i
n
a
l

o
n
:
1 2 3 4 5 6 7
1
2
3
4 0
5 0
6 0
7 0
CAUTION
This is a rough measuring method. If possible,
verify the recharging process by using another
regulator which has been checked to be in
working order
1 1
1
2
4
5
6 7
1
2
3
chap. 6
6-4
Release 00 2002-09
Atlantic 500
FUEL INJECTION SYSTEM
INJECTION SUPPLY WIRE DIAGRAM
1
R
/M
19
R
V
/R
1
N
R
/B
i
24
22
R
2
0
A
3
0
A
R
/B
i
R
11
1
M V N
BM
/N
BOBINA
R
/M
18
C
E
N
T
R
A
L
I
N
A

E
.
C
.
U
.
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
1
25
26
23
24
19
20
21
22
G
r
/N
A
r
/V
M
/N
R
/N
9
3
0
8
7
8
6
8
5
Ar/V V/R
Ar/N V/R
52
R
/M
Ar/N
V/N
R
/M
A
r
/V
R
/B
10
G
r
/N
3 5 2 1
C
E
A
D
F
B
R/Gr
1 1
15A
15A
3A
15A
15A
M
/V
R/B
Gr/N
N
R
V
/R
R
INIETTORE
BENZINA
POMPA
BENZINA
SPIA
CAVALLETTO
R
/N
R
/G
r
V
/N
R
/B
i
R
/G
r
R
/N
35
37
Key to wire diagram
9) Main injection relay
10) Secondary injection relay
11) Side stand switch
19) Battery
35) Key switch
37) Right switch
52) E.C.U. Control unit
E
.
C
.
U
.

C
O
N
T
R
O
L

U
N
I
T
COIL
FUEL
PUMP
FUEL
INJECTOR
STAND
SWITCH
chap. 6
6-5
6
Release 00 2002-09
Atlantic 500
STAND SWITCH CONTROL
Rotation of the side stand (1) must be free from
obstruction.
Carry out the following checks:
The springs (2) must not be damaged, worn, rusty
or weakened.
The stand must turn freely, by greasing the joint if
necessary, see (TABLE OF LUBRICANTS).
On the side stand (1) there is a safety switch (3) with
the role of preventing or interrupting engine running
with the side stand (1) lowered.
To check that the safety switch is working (3):
Sit on the saddle in driving position.
Raise the side stand (1).
Start the engine.
With the throttle twistgrip released and the motor
idling, lower the side stand (1) which should
activate the safety switch (3).
At this point:
- the engine should stop;
- on the dashboard the side stand lowered indicator
should light up.
If this does not happen, replace the switch (3).
STAND SWITCH
Cables
Position
N
Lowered
Raised
V N
chap. 6
6-6
Release 00 2002-09
Atlantic 500
INJECTION RELAY CONTROLS
To verify that the relay is working:
Remove the seat, see (REMOVING THE SEAT).
Supply a 12 V tension to the two male terminals
(85-86).
With a multimeter (in ohm meter mode) verify the
continuity between the other two terminals (87-
30).
Correct value with supply to the relay: 0
Correct value without supply to the relay:
If the resulting values do not correspond to those
prescribed, replace the relay concerned.
For the main injection relay only:
Observe the polarity supplying terminal (86) with
the + and terminal (85) with the -, as in the
interior there is a diode.
CAUTION
chap. 6
6-7
6
Release 00 2002-09
Atlantic 500
IGNITION/INJECTION SYSTEM
E.C.U. CONNECTIONS
1 3 2 4 6 5 7 8 9 10 1112 13 14 15 17 16 18 19 20 1 5 4 3 2 8 7 6 16 12 11 10 9 13 14 15
EFI
TRIP SET W
mp/h x1000r/min
Km/h
!
POMPA
BENZINA
4
R
/M
A
r
/B
i
36
15
14
6 13
18
C
E
N
T
R
A
L
I
N
A

E
.
C
.
U
.
3
4
5
6
7
9
10
11
12
13
14
15
16
1
25
26
23
24
19
20
21
22
1
3
A
z
R
o
V
i
G
G
r
R
o
/G
52
R
/M
Ro
Ar/Bi
G
Gr
Vi/N
Ro/N
Gr/R
B
Vi
M/Bi
G
r
/R
N
G
r
R
o
/N
A
r
G
r
M
/B
i
M
/G
G
r
2
1
54
R
/M
R
/B
RELE
INIEZIONE
SECONDARIO
G
r
/N
43
B
i/N
A
r
/R
RM
B
Az/R
R/B
Ar
M
R
M/G
B/N
Az/V
Az
N
Gr/N
A
z
/R
A
z
/V
A
r/R
Ro/G
N B
i/N
ABS ABS ABS ABS
EFI EFI EFI
!! !!! !!! !! !!! !!
B
i/N
N NNN
RELE VENTOLA
R
/M
Key to wire diagram
2) Revolutions sensor
3) Stepper motor
4) Coil
6) Fuel injector
13) Accelerator sensor
14) Engine air thermistor
15) Dashboard/engine water thermistor
36) Drop sensor
43) Dashboard
52) E.C.U.Control unit
E
.
C
.
U
.

C
O
N
T
R
O
L

U
N
I
T
FUEL
PUMP
INJECTOR
RELAY
FAN
RELAY
chap. 6
6-8
Release 00 2002-09
Atlantic 500
CAUTION
Since inside the C.D.I. control unit there are diodes, condensers and other electrical components, the
measuring method described is approximate.
Further checking is recommended by replacing the control unit with another pre-checked to ensure it is in
working order, or carry out the checks described in the chapter (ELECTRICAL SYSTEM CONTROL USING A
C.D.I. CONTROL UNIT CONNECTOR).
1 2 3 4 5 6 7
8 9 10 11 12 13
14 15 16 17 18 19
20 21 22 23 24 25 26
chap. 6
6-9
6
Release 00 2002-09
Atlantic 500
CONNECTIONS TO THE E.C.U. CONTROL UNIT
COMPONENT
RPM sensor 7 - 12 680 B - B/N
Stepper Motor 14 - 24 52 Az - Ro
Stepper Motor 6 - 21 52 Vi - G
Accelerator sensor 1 - 22 5 k M/Bi - Gr
Accelerator sensor 1 - 11 1 - 6 k M/Bi - M/G
Air injection terminals 18 - 22 see tab. Ro/N - Gr
Water injection terminals 4 - 22 see tab. Ar - Gr
Drop sensor 16 -22 62 k * Ro/G - Gr
Coil 20 0.6 Ar/Bi - R/M
Injector 13 14.5 Gr/R - R/M
TERMINALS
NOMINAL
VALUE
CABLE COLOUR
* With drop sensor in upright position.
chap. 6
6-10
Release 00 2002-09
Atlantic 500
CHECKING THE HV COIL
Remove the left inspection cover, see
(REMOVING THE RIGHT AND LEFT
INSPECTION COVERS).
Disconnect terminal (1).
Unscrew and remove the two screws (2).
Disconnect the spark plug (3).
Remove the coil (4).
4
1
2
With a pocket multimeter (scale 200 ), measure
the resistance (from the coil side) between the
terminals (A e B) indicated in the diagram.
If the resistance measured is not correct, replace
the coil.
Standard value: 0.6 0.1
Also verify the resistance between the high
voltage terminal and the casing of the coil.
Standard value: 7.4 k
Before measuring, remove the H.V. cable complete
with the spark plug cap.
A
B
CAUTION
3
chap. 6
6-11
6
Release 00 2002-09
Atlantic 500
DROP SENSOR CHECK
With motor off:
FRONT HOOD).
Check that the sensor (1) is mounted correctly (with
the arrow imprinted on the rubber pointing upwards).
Partially remove the fuse carriers (2).
Disconnect the two-way connector (3)(white/grey)
and take measurements (on terminals sensor
side).
During reassembly ensure correct coupling of the
electrical connector (3).
With a multimeter (scale x 100 k), measure the
resistance between the black and white/black
cable terminals (N -Bi/N).
Standard value: resistance 62 k 15%
Remove the sensor (1) with the rubber washer in
its housing, and lean it sideways to an angle of
more than 45 (simulating the parking position).
Standard value: 0 - 1
If the resistance is different from that prescribed,
the sensor (1) must be replaced.
Repeat the operations leaning the sensor towards
the opposite side.
CAUTION
3
1
2
chap. 6
6-12
Release 00 2002-09
Atlantic 500
RPM SENSOR CHECK
With motor off:
Disconnect the three-way connector (1) and take
measurements.
With a multimeter (scale x 100 ) measure the
resistance between the sensor terminals,
observing polarity (see diagram).
Standard value: 680 10%
If the resistance is infinite or different from the
prescribed value, the sensor must be replaced.
- +
+
1
chap. 6
6-13
6
Release 00 2002-09
Atlantic 500
THROTTLE VALVE POTENTIOMETER
(ACCELERATOR SENSOR) CHECK
With motor off:
Disconnect the three-way connector (black) (1).
Set the ignition switch to .
With a multimeter (scale k), measure the
resistance between the potentiometer terminals.
MEASUREMENT (A)
Resistance between the two terminals A and B, in any
position of the throttle valves:
Standard value: 5 k 10%
MEASUREMENT (B)
Resistance between the terminals A and C:
From the value of the throttle completely closed,
accelerating progressively up to completely open, the
resistance will vary as follows:
Standard value: from 1 k to 6 k 10%
NOTE To unscrew the two screws more easily, block
with LOCTITE
243, preheat with a blow of hot air.

Unscrew and remove the screws.
Remove the potentiometer.
If the resistance values are different from those
prescribed, replace the potentiometer.
CAUTION
A
B
C
1
chap. 6
6-14
Release 00 2002-09
Atlantic 500
INJECTOR CHECK
With motor off:
Disconnect the two-way connector (1) (black) and
take measurements (on the terminals on the
injector side).
With a multimeter (scale x 100 ), measure the
resistance between the injector terminals.
Standard value: 14.5 10% to 25C
If the resistance is infinite () or less than the
prescribed value, the injector (2) must be
replaced.
COOLANT THERMISTOR FUNCTION CHECK
Remove the thermistor (1), see (COOLANT
THERMISTOR REMOVAL).
Connect a multimeter (2) (set in ohm metre mode)
as illustrated in the diagram, to the thermistor (1).
Immerse the thermistor (1) in a container (3)
containing coolant.
In the same container immerse a thermometer (4)
with 0 -150 C gauge (32 -302 F).
Place the container on a hotplate (5) and slowly
heat the liquid.
Check the temperature indicated on the
thermometer (4) and the value of the thermistor
(1) indicated on the multimeter.
Verify that the values vary in relation to the temperatu-
re as indicated.
NOTE If the standard values do not change as the
temperature changes, or change too much from those
given in the table, replace the thermistor (1).
Repeat these operations also for the other
thermistor.
Temperature C A1 - A2 () B1 - B2 ()
60 557 10% 576 10%
90 196 10% 231 10%
120 80.6 10% 105 10%
A1
B2
B1
A2
1
1
2
chap. 6
6-15
6
Release 00 2002-09
Atlantic 500
FUEL PUMP CHECK
Supply terminals 1 and 4 of the pump connector
with a 12V tension (c.c.).
Verify that the pump works, emitting the
characteristic hum, and check on the manometer
that the supply pressure reaches at least i 150
KPa (1.5 bar).
Observe the pump polarity.
CAUTION
AIR THERMISTOR FUNCTION CHECK
During reassembly ensure the correct coupling of
the electrical connector (1).
Remove the thermistor (2).
Connect a multimeter (3) (set to ohm meter mode)
al thermistor (2), as illustrated in the diagram.
Immerse the thermistor in a container (4)
containing water.
In the same container immerse a thermometer (5)
with 0 -150 C gauge (32 -302 F).
Place the container on a hotplate (6) and slowly
heat the liquid.
Check the temperature indicated on the
thermometer (5)and the value of the thermistor
indicated on the multimeter.
Verify that the values vary in relation to the temperatu-
re as indicated.
CAUTION
Temperature C
0 9750
10 5970
20 3740
30 2410
Resistance
NOTE If the values do not change as the temperatu-
re changes, or change too much from those given in
the table, replace the thermistor (2).
1
2
(direct current)
chap. 6
6-16
Release 00 2002-09
Atlantic 500
STARTING AND STOP LIGHTS SYSTEM
Key to wire diagram
9) Main injection relay
19) Battery
20) Starting relay
21) Starting motor
24) Secondary fuses
33) Rear stop light switch
34) Front stop light switch
35) Key switch
37) Right switch
55) Stop lights relay
56) Third stop light bulbs
19
21
20
V
/R
R
V
/R
1
N
R
/B
i
G
/R
B
R
24
22
R
2
0
A
3
0
A
R
/B
i
RR
M
11
M V N
BM
/
N
G
r
/
N
A
r
/
V
M
/
N
R
/
N
9
3
0
8
7
8
6
8
5
Ar/V
V/R
V/N
C
E
A
D
F
1
B
R/Gr
1
55
8
7
8
5
3
0
8
6
B B
/G
R
/N
V
/G
1
15A
15A
3A
15A
15A
B
/B
i
R
/B
i
NR
V
/R
R
54
58
B
R
/N
G
/R
V
/G
R
/G
r
V
/N
R
/B
i
V/G
B
V/G
B
/G
G
/R
R
/G
r
R
/N
B B
V/G
31
V/G
B
31
B
58
54
V/G V/G
B
V/G
R
/N
V
/G
B
/G
G
r/N
V
/G
G
r
/N
G
r/N
35
31
56
37
1
33
31
34
chap. 6
6-17
6
Release 00 2002-09
Atlantic 500
STARTING RELAY CHECK
Disconnect the two-way connector (1)(white).
Pull the relay out from the special hooks (2).
Pull out the two rubber protectors (3-4).
Disconnect the cables from their respective
terminals on the relay (2).
Supply the two internal terminals to the connector
(1) with a 12V tension from the relay side.
With a multimeter (set to Ohm meter mode) verify
the continuity between the two screw contacts on
the relay (2).
prescribed, replace the relay (2).
CAUTION
STOP LIGHTS RELAY CHECK
To access the relay raise the saddle and remove
the left tail lamp, see (TAIL LAMP BULBS
REPLACEMENT).
Supply the two male terminals (85-86) with a 12V
tension;
With a multimeter (set to ohm meter mode) verify
the continuity between the other two terminals (87-
30).
1
3
2
4
chap. 6
6-18
Release 00 2002-09
Atlantic 500
PUSH
Z
A
D
I
9
10 11
12
7) ENGINE OFF BUTTON ( - )
8) START BUTTON ( )
9) IGNITION BUTTON
10) FRONT BRAKE LIGHT SWITCH
11) REAR BRAKE LIGHT SWITCH
12) SIDE STAND SWITCH
Cable
Rs
R/N R/Gr
Cable
Rs
V/G G/R
Cable
Rs
G/Gr G
V/N R/Bi
Cable
Rs
Gr/N V/G
ON
Cable
Rs
V/G R/N
ON
Cable
Rs
N ( ) V
OPEN
CLOSED
M
chap. 6
6-19
6
Release 00 2002-09
Atlantic 500
ELECTRIC COOLING FAN
WIRING DIAGRAM
CHECKING THE ELECTRIC FAN
To check the operation of electric fan (1):
Remove the leg shields,see (LEG SHIELDS
REMOVAL).
Disconnect the electrical connection (2) operating
the electrical fan (1).
Directly supply the electrical fan with a 12 volt
direct current.
2
1
12
C
E
N
T
R
A
L
I
N
A

E
.
C
.
U
.
22
N
24
23
26
25
52
Vi/N
21
20
19
17
16
15
14
13
18
2
11
10
9
8
7
6
5
4
3
1
G
/
N
16
1
BG
/
N
B
3
0
A
22
R
R
19
N
R
/
B
i
R
/
B
i
D
F
V/N
15A
15A
3A
15A
15A B
A
E
C
V
24
1
1
8
6
38
8
7
3
0
8
5
15
A
r
G
r
35
R
/
B
i
V
/
N
G
/
N
R
/
B
i
V
i/
N
V
Key to wiring diagram
15) Water thermistor
16) Fan
19) Battery
24) Secondary fuses
35) Key switch
38) Fan relay
52) E.C.U. control unit
E
.
C
.
U
.

C
O
N
T
R
O
L

U
N
I
T
chap. 6
6-20
Release 00 2002-09
Atlantic 500
FAN RELAY CHECK
Remove the seat, see (SEAT REMOVAL).
Supply the two male terminals (85-86) with a 12V
tension.
With a multimeter (set to ohm meter mode) verify
the continuity between the other two terminals (87-
30).
WATER THERMISTOR CHECK
See (COOLANT THERMISTOR FUNCTION CHECK)
on page 6-14.
chap. 6
6-21
6
Release 00 2002-09
Atlantic 500
COOLANT TEMPERATURE AND FUEL LEVEL INDICATORS
WIRING DIAGRAM
A
r
/
R
B
i
/
N
15
1
2
0
A
22
R
R
19
N
R
/
B
i
R
/
B
i
D
F
V/N
15A
15A
3A
15A
15A B
A
E
C
V
24
1
1
13
B B
W
SET
9 10 1112 6 7 8 2 3 4 5 1
A
r
/
R
1
B
15 14 16 9 8 7 5 6 4 2 3 1
B VB
i/
N
TRIP
20 19 18 16 17 15 14 13 12 11 10
x1000r/min
EFI EFI EFI
ABS ABS ABS ABS
EFI
43
! !! ! !! !!! !! ! !! ! !
Km/h
mp/h
8
A
r
/
N
G
/
V
35
R
/
B
i
V
/
N
8) Fuel level sensor
15) Water thermistor
19) Battery
22) Main fuses
24) Secondary fuses
35) Key switch
43) Dashboard
chap. 6
6-22
Release 00 2002-09
Atlantic 500
WATER TEMPERATURE
DASHBOARD CHECK
Disconnect the water thermistor connector and
connect an electrical resistance (from the connector
side) between the orange/red and white/black cables.
Turn the key to ON and verify the indication on the
dashboard.
Connector values:
resistance <60 bottom scaleindication
resistance 80 start of red zone indication 5
resistance >1090 start of scaleindication
WATER THERMISTOR CHECK
See (COOLANT THERMISTOR FUNCTION CHECK)
pages 6-14.
FUEL LEVEL
DASHBOARD CHECK
Disconnect the pump assembly connector and
connect an electrical resistance (from the connector
side) between the yellow-green and orange-black
cables.
Turn the key to ON and verify the indication on the
dashboard.
Connector values:
resistance 250 1/2 scale indication 5
resistance 3 full indication
resistance 820 empty indication and indicator lit
FUEL LEVEL SENSOR CHECK
Disconnect the pump assembly/sensor connector.
Connect an ohm meter to terminals 2 and 3 and
verify the indication at different fuel levels.
Correct value with full tank - less than 16
Correct value with 8 litres of fuel - 300-400
Correct value with litres - more than 800
VIEWED FROM A
R
chap. 6
6-23
6
Release 00 2002-09
Atlantic 500
LIGHTS AND ACOUSTIC SIGNALS SYSTEM
WIRING DIAGRAM
HORN CHECK
Directly supply the horn with 12 V to the two terminal
endings.
If it does not work, activate the special adjuster.
If necessary replace it with a new one.
TOP CASE SWITCH CHECK
With a multimeter in ohm meter mode, verify the
continuity between the two terminals.
Value with the switch free (saddle raised)
Value with the switch pressed (saddle closed)
PASSING
STOP
SCROLL
19
V
/R
R
V
/R
1
N
R
/B
i
24
22
R
2
0
A
3
0
A
R
/B
i
R
V/R
V/R
R/Bi
V
C
E
A
D
F
B
26
A
r/N
B
1
25
1
15A
15A
3A
15A
15A
V/N
R/Bi
BG
R
V
/R
R
54
58
G
/N
G
B
GV
/N
VG
r
N G
/N
BG
r
B
i
V
/N
V
/N
R
/B
i
G
/G
r
G V B
i
N G
/N
G
r
BG
/N
G
/G
r
V
G/Gr
B
G
B
G
31
G
B
31
B
58
G
54
G
B
B
G
B
B
G
B
G
B
Bi
N
B
Bi
N
B
B
Bi
N
B
Bi
G G
35
1
27
40
31
37
39
31
50
48
49
19) Battery
22) Main fuses
24) Secondary fuses
25) Top case light
26) Top case switch
27) Number plate light
31) Parking/stop lights bulbs
35) Key switch
37) Right switch
39) Left switch
40) Horn
48) Dipped beam bulbs
49) Full beam bulbs
50) Parking lights bulb
chap. 6
6-24
Release 00 2002-09
Atlantic 500
DIRECTION INDICATORS AND DISPLAY DATA
WIRING DIAGRAM
PASSING
5 8 7 6 16 12 15
EFI
TRIP SET
W
mp/h x1000r/min
Km/h
!
STOP
SCROLL
43
1
1
B
/N
R
/B
i
B
/B
i
B
i/G
A
z
/B
i
RA
z
ABS ABS ABS ABS
EFI EFI EFI
!! !!! !!! !! !!! !!
1
Az
R
R R
Az
47
46
B
/N
RA
z
B
/B
i
M
A
z
/B
i
B
/N
R
/B
i
B
/B
i
B
i/G
Az
R
R R
Az Az
39
30
29
1
29) Rear right indicator
30) Rear left indicator
39) Left lights switch
43) Dashboard
46) Front right indicator
47) Front left indicator
CONTROLS ON THE LEFT SIDE OF THE
HANDLEBAR
NOTE The electrical components work only with the
ignition switch in position .
MODE BUTTON (MODE)
Press repeatedly to select the various data visualized
on the Multifuncion LCD display.
HAZARD BUTTON ( )
ACTIVATION
Press to activate the four indicators, at this point it is
possible to turn the ignition switch to position and
remove the key.
DEACTIVATION
Insert the key in the ignition lock switch and turn to
position , press the HAZARD button again to
deactivate the system.
NOTE The flashing frequency of the hazard remains
unvaried even with a burnt out bulb.
chap. 6
6-25
6
Release 00 2002-09
Atlantic 500
LAP
SERVICE
mph AVG VBATT Km/h ml/G Vmax
C
F
CEV
3
4
5
6
7 8
9 10
11
12
13
" "
.
MULTIFUNCTION LCD DISPLAY
Turning the ignition key (1) to position , all the
segments on the Multifuncion LCD display are acti-
vated for a few seconds (in this way working checks
are carried out on the components) and the last
function imposed after the vehicle was stopped is
visualized.
After the first 1,000 Km (625 mi) and then every
6,000 Km (3,750 mi), SERVICE will appear on the
display.
In this case carry out the operations prescribed in
the periodical maintenance programme, see pages
2-3 (PERIODICAL MAINTENANCE PROGRAMME).
CAUTION
PUSH
Z A
D
I
1
2
The various functions are selected then visualized on
the display by pressing the MODE button (2) on the
controls to the left side of the handlebars.
The segments forming the multifunction LCD display
are as follows:
Chronometer indicator (3), programmed maintenance
due icon (4), average speed icon expressed in mph
(5), average speed (6), battery tension icon (7),
average speed icon expressed in Km/h (8).
(The same icon is used for the consumption function
expressed with the symbol Km//l, consumption
expressed in ml/G (used only for versions) (9),
maximum speed icon (10), external temperature icon
expressed in degrees Celsius (C)(11), external
temperature icon expressed in degrees Fahrenheit
(F) (12), six-figure displays of the values relating to
the functions set and identified by the respective icons
(13).
By pressing the MODE button, the functions are
obtained in the following sequence:
External temperature in C
MODE
Maximum speed (Vmax)+km/h or mph
MODE
Average speed AVG (Km/h or mph)

MODE
MODE
Battery tension (Vbatt)

MODE
Fuel consumption (km/L or ML/G)

MODE
Chronometer (LAP)
MODE
Km to next maintenance programmed (SERVICE)
chap. 6
6-26
Release 00 2002-09
Atlantic 500
1
/RESET
ABS
RESETTING OF AVERAGE SPEED, MAXIMUM
SPEED, FUEL CONSUMPTION AND
CHRONOMETER VALUES
NOTE Cancellation of this information is only
possible if the odometer is visualized to the right of
the digital display.
Keep the TRIP/RESET button (1) pressed for more
than three seconds.
NOTE The function visualized will be cancelled.
START/STOP AND CHRONOMETER RESETTING
NOTE Cancellation of this information is only
possible if the odometer is visualized to the right of
the digital display.
START/STOP:
Keep the MODE button (2) pressed for more than
three seconds.
RESETTING:
Keep the TRIP/RESET button (1) pressed for more
than three seconds, only when the chronometer is
stopped.
1
PUSH
Z A
D
I
ODO TRIP 1 TRIP 2
2 3
4
5
DIGITAL ODOMETER
NOTE The LCD displays only work with the ignition
switch in position .
Turning the ignition key (1) to position , all the
segments are activated on the LCD display for a few
seconds and in this way working checks of the
components can be carried out, after the odometer is
always visible.
The segments forming the LCD display are as follows:
Odometer visualized icon (2), first trip visualized icon
(3), second trip visualized icon (4), 5-figure
visualization of values relating to the selected
functions (5).
/ RESET
ABS
1
By pressing the TRIP/RESET button in sequence the
following functions are activated:
TRIP/RESET
TRIP/RESET
TRIP/RESET
Odometer (ODO)
First trip (TRIP 1)
Second trip (TRIP 2)
chap. 6
6-27
6
Release 00 2002-09
Atlantic 500
DIRECTION INDICATOR AND SPEEDOMETER
WIRING DIAGRAM
1 3 2 4 6 5 7 8 9 10 1112 13 14 15 17 16 18 19 20 1 5 4 3 2 8 7 6 16 12 11 10 9 13 14 15
EFI
TRIP SET
W
mp/h x1000r/min
Km/h
!
B
42
R
o
M
43
1
1
1
44 45
V
i
G
r
/
B
G
r
/
B
i
MR
o
G
r
/
B
V
i
G
r
/
B
i
B
/
A
r
G
r
/
B
i
ABS ABS ABS ABS
EFI EFI EFI
!! !!! !!! !! !!! !!
V
B
/
A
r
B
/
A
r
42) Air temperature thermistor
43) Dashboard
44) Speed sensor
45) Pressure oil sensor
chap. 6
6-28
Release 00 2002-09
Atlantic 500
DASHBOSRD CHECK
If the dashboard is in good working order, the red
LED of the oil pressure should go on with the
ignition switch to the position.
SENSOR CHECK
With the ignition switch in position the red LED
indicator , relating to engine oil pressure, must
light up.
If the red LED indicator , does not regularly
light up, verify that the sensor is working.
With a multimeter (scale 100 ) verify the
continuity between the pin terminal (1) and the
sensor casing (2)(see diagram).
Correct value with engine off: 0
Correct value with engine running:
prescribed, check that the engine oil level is correct,
see (ENGINE OIL LEVEL CHECK AND TOPPING UP)
and if necessary replace the sensor.
1
2
ENGINE
chap. 6
6-29
6
Release 00 2002-09
Atlantic 500
SPEEDOMETER
Check the correct coupling of the speed sensor
connector (1).
Check the correct coupling of the dashboard
connectors (2).
Check the distance between the speed sensor (3)
and the front brake disc fixing screws (4).
Distance between sensor (3) and screws (4): 1.5
1 mm.
Check that all the screws (4) are present.
With engine off and the ignition switch in position
carry out the following tests:
1st Test
Without disconnecting the speed sensor connector
(1) connect a multimeter and measure the tension
between the grey/blue (Gr/B) and blue/orange (B/
Ar) cables.
Correct value: > 9 V (c.c.).
2nd Test
Without disconnecting the speed sensor connector
(1), connect a multimeter and measure the tension
between the grey/white (Gr/Bi) and blue/orange
(B/Ar) cables.
Correct value: > 6 V (c.c.).
3rd Test
Place the vehicle on the special rear stand
Carry out the 2nd test.
Manually turn the front wheel bringing one of the
screws (4) in line with the sensors (3). The
multimeter indication will give zero V for approx.
two seconds, then return to >6 V .
- If the 1st test results in an incorrect value, discon-
nect the sensor (3) and repeat the 1st test; if the
incorrect value persists, the dashboard is defec-
tive and must be replaced with one that is known
to work.
- If the 1st test results in a correct value and the 2
nd
with an incorrect value, the sensor (3) is defective
and must be replaced.
- If the 1st and 2nd tests result in a correct value
and the 3rd test with an incorrect value, the sensor
(3) is defective and must be replaced.
- If all three tests result in a correct value but the
speed does not appear to the left of the dash-
board, the dasboard is defective and must be
replaced with one that is known to work.
1
2 2
1.5 mm
chap. 6
6-30
Release 00 2002-09
Atlantic 500
AIR TEMPERATURE SENSOR
To verify that the air temperature sensor works:
Disconnect the two-way connector (1).
Carry out the sensor check in an environment with
controlled temperature of 20 C (68 F).
Measure the electrical resistance with an ohm
meter (scale 0-20 k) between the connector
terminals (1).
Correct value: 12.200 k - 12.700 k
If the air temperature sensor works correctly check the
dashboard:
Apply a resistance equal to 12.4 k between the
sensor terminals (cabling side).
If the dashboard works correctly it should indicate
a temperature of 20 1 C (68 3 F).
1
1
+ -
chap. 6
6-31
6
Release 00 2002-09
Atlantic 500
SWITCHES
Using a pocket multimeter, check the continuity of the
switches by referring to the tables below.
Replace any faulty components.
1) HORN BUTTON ( )
2) TURN INDICATOR SWITCH ( )
3) LIGHTS SWITCH ( - ) / FLASHING FULL
BEAM BUTTON
(PASSING )
4) MODE BUTTON (MODE)
5) HAZARD BUTTON ( )
6) LIGHTS SWITCH ( - - )
Cable
Rs
Gr B
Cable
Rs
B/Bi Az R B/N
STOP
Cable
Rs
G/N N Bi V/N
PASSING
Cable
Rs
Ro V
SCROLL
Cable
Rs
B/Bi M
7
6
8
MODE
PASSING
3
1
4
2
5
Cable
Rs
V/N G G/N
chap. 6
6-32
Release 00 2002-09
Atlantic 500
BULB REPLACEMENT
Before changing a bulb, move the ignition switch
to position and wait a few minutes, so that
the bulb cools down. Change the bulb wearing
clean gloves or using a clean and dry cloth.
Do not leave fingerprints on the bulb, since these
may cause its overheating and consequent break-
age. If you touch the bulb with bare hands, re-
move any fingerprint with alcohol, in order to
avoid any damage.
DO NOT FORCE THE ELECTRIC CABLES.
HEADLIGHT BULB REPLACEMENT
Carefully read BULBS.
The headlight contains:
Two bulbs for full beam (1).
One bulb for dipped beam (2).
One parking light bulb (3).
To change the bulbs, proceed as follows:
Remove the front hood, see (REMOVAL OF THE
FRONT HOOD).
LOW/HIGH BEAM BULB
To extract the bulb electric connector, do not pull
its electric wires.
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 reflector.
Extract the bulb (5).
For the reassembly:
NOTE Insert the bulb (5) in the reflector, ensuring
that the three pins on the bulb coincide with the
respective slots in the bulb casing.
Position the bulb socket (6) in the reflector and
rotate it clockwise.
Connect the bulb electric connector (4).
WARNING
CAUTION
1
2
3
5
6
4
chap. 6
6-33
6
Release 00 2002-09
Atlantic 500
BATTERY
For safety regulations and general information
concerning the battery, see (BATTERY).
For other information, see (ELECTROLYTE LEVEL
CHECK),(BATTERY RECHARGE) and (BATTERY
PROLONGED INACTIVITY).
ACTIVATING THE BATTERY
Read through paragraph (BATTERY).
Remove the battery cover, see (BATTERY
COVER REMOVAL).
Remove the battery, see (BATTERY REMOVAL).
Check the battery electrolyte level, see (BATTERY
ELECTROLYTE LEVEL CHECK).
Recharge the battery, see (BATTERY RE-
CHARGE).
RETURN UNDER GUARANTEE
Read through paragraph (BATTERY).
The guarantee is considered no longer valid if the
battery shows signs of:
Damage (casing dented, poles bent, etc.).
Diffuse formation of sulphate (incorrect activation
and/or use of the battery).
Insufficient level of electrolytic liquid (to avoid
leakage during transportation it is sufficient to
close the vent with the special cap).
Missing elements (caps, etc.).
chap. 6
6-34
Release 00 2002-09
Atlantic 500
FULL BEAM BULBS
Turn the bulb socket/bulb (8) anticlockwise and
extract it from the parabolic setting.
To remove the bulb socket/bulb from its connec-
tion, take special care not to damage the two
housings (9).
Remove the bulb (10).
Correctly fit a bulb of the same kind.
For reassembly, repeat the operations in reverse
order.
CAUTION
PARKING LIGHT BULBS
To extract the bulb socket, do not pull its electric
wires.
Working from the front of the vehicle, grasp the
bulb socket (11), pull it and take it out of its seat.
Extract the parking light bulb (12) and replace it
with a new one of the same type.
CAUTION
REPLACING THE REAR LIGHT BULBS
The rear light contains:
Two bulbs for parking/stop lights (1).
Two bulbs for rear indicator lights (2).
To change them:
Raise the saddle,see (SADDLE UNBLOCKING
AND BLOCKING).
NOTE The following information is only for one
indicator but is valid for both operations.
Remove the fixing pommel (3) of the rear lights
assembly of the vehicle.
8
10
9
11
12
1
1
2
2
chap. 6
6-35
6
Release 00 2002-09
Atlantic 500
During the following operations do not pull or
force the electrical cables.
Pull out the rear lights assembly (4) first pulling out
the upper part and then distancing it from its
housing.
Work with caution.
Do not damage the pins and/or their housings.
Holding the rear lights assembly by hand, turn it
anticlockwise and remove the bulb socket (5) with
the bulb (6) from the parabolic housing (4).
CAUTION
CAUTION
Remove the bulb from the housing.
NOTE Set the bulb in the bulb socket, ensuring that
the two guiding pins are in line with their respective
slots on the bulb socket.
NOTE During reassembly, correctly place the protec-
tive screen in its housing.
Carefully and gently tighten the pommel (3) in
order to avoid damage to the protective screen.
CAUTION
FRONT INDICATOR LIGHTS BULB
REPLACEMENT
To change the bulbs:
Remove the front hood, see (FRONT HOOD
REMOVAL). As an alternative, it is also possible to
remove the box covers to gain access to the bulbs
(see DASHBOARD REMOVAL).
Proceed with care.
Do not damage the tangs and/or their seatsstro.
CAUTION
For the LEFT indicator:
Working from the front of the vehicle, turn the
support (1) clockwise with the bulb (2) and remove
both from the housing.
Gently press the bulb (2) and turn it anticlockwise.
Extract the bulb from its seat.
NOTE Insert the bulb in the bulb socket, making the
two bulb pins coincide with the relevant guides on the
socket.
For reassembly repeat the operations in reverse
order.
For the RIGHT indicator:
Pull the secondary fuse box (3) from its housing in
order to have sufficient space for dismantling
operations.
Continue as described for the LEFT indicator.
3
4
5
6
1
2
3
chap. 6
6-36
Release 00 2002-09
Atlantic 500
NUMBER PLATE LIGHT REPLACEMENT
Do not pull the electrical cables when removing
the bulb socket.
Grasp the bulb socket (1), pull and remove it from
its housing.
Pull out and replace the bulb (2) with one of the
same kind.
CAUTION
HELMET COMPARTMENT LIGHT REPLACEMENT
Lift the saddle, see (SADDLE UNBLOCKING/
BLOCKING).
Loosen and remove the screw (1) fixing the glass
to the battery cover.
Remove the glass (2) by pulling downwards.
Do not pull the electrical cables when removing
the bulb socket.
Grasp the bulb socket (3), pull and remove it from
its housing.
Pull out and replace the bulb (4) with one of the
same kind.
CAUTION
THIRD STOP LIGHTS REPLACEMENT
Lift the saddle, see (UNBLOCKING/BLOCKING
THE SADDLE).
Loosen and remove the two fixing screws (1) of
the backrest.
When removing the backrest, proceed with cau-
tion in order to avoid breaking the coupling
prongs.
Remove the backrest (2) by pulling upwards.
CAUTION
1
2
2
1
3
4
2
1
chap. 6
6-37
6
Release 00 2002-09
Atlantic 500
Loosen and remove the two fixing screws (3) of
the protective screen (4) of the third stop light.
Pull out the all-glass bulbs (5) from their housing.
CAUTION
NOTE During reassembly, correctly set the
protective screen in its housing.
Carefully and gently tighten the screw (3) in order
to avoid damaging the protective screen.
VERTICAL BEAM ADJUSTMENT
To quickly check the alignment of the headlight
beam, place the vehicle on level ground, 10
metres from a vertical wall.
Turn on the low beam, sit on the vehicle and
check that the top of the lighted area on the wall is
slightly lower than the projection of the headlight
axis (approximately 9/10 of the overall height).
To adjust the headlight beam:
Use the special handle (1) from the front of the
vehicle.
Turning it CLOCKWISE, the beam is raised.
Turning it ANTICLOCKWISE, the beam is
lowered.
3
5
4
1
chap. 6
6-38
Release 00 2002-09
Atlantic 500
HORIZONTAL BEAM ADJUSTMENT
Remove the internal front shield, see (INTERNAL
FRONT SHIELD REMOVAL).
To carry out the beam adjustment:
Use the special handle (as indicated on the
diagram) from the front of the vehicle.
Turn CLOCKWISE and the beam will move to the
RIGHT (with respect to the direction faced).
Turn ANTICLOCKWISE and the beam will move
to the LEFT (with respect to the direction faced).
REPLACING THE FUSES
Carefully read (MAINTENANCE).
Do not repair faulty fuses.
Never use fuses different from the recommended
ones.
The use of unsuitable fuses may damage the
electric system or, in case of short circuit, may
even cause a fire.
NOTE If a fuse blows frequently, there probably is a
short circuit or an overload in the electric system.
If an electric component does not work or works
irregularly, or if the engine fails to start, it is
necessary to check the fuses.
Check the 3 A and the 15 A fuses first and then
the 20-30 A fuse.
To carry out the checking:
Remove the battery cover, see (BATTERY
COVER REMOVAL) or remove the front hood, see
(FRONT HOOD REMOVAL).
Extract the fuses one by one and check if the
filament (1) is broken.
Before replacing a fuse, try to find out the cause of
the trouble, if possible.
Then replace the damaged fuse with a new one
having the same amperage.
NOTE If you use one of the spare fuses, put a new
fuse in the appropriate seat.
Replace the battery cover, see (BATTERY
COVER REMOVAL) or replace the front hood, see
(FRONT HOOD REMOVAL).
CAUTION
1
5
4
3 2
6
7
9
8
chap. 6
6-39
6
Release 00 2002-09
Atlantic 500
SECONDARY FUSE LAYOUT
(FRONT HOOD)
15 A (2) fuse
From voltage regulator to: injection, stop/starting
lights logistics (Housing A on the wire diagram).
15 A (3) fuse
From the ignition switch to: engine kill logistics,
stop lights (Housing B on the wire diagram).
15 A (4) fuse
From the ignition switch to: lights, horn,
dashboard, fan relay, radio power supply
(Housing C on the wire diagram).
15 A (5) fuse
From the main fuse to the power socket in the
glove compartment .
3 A (6) fuse
From the voltage regulator to permanent supply
of the ECU control unit (Housing E on the wire
diagram).
15 A (7) fuse
Spare.
3 A (8) fuse
Spare.
Free (9)
MAIN FUSE LAYOUT
(BATTERY COMPARTMENT)
20 A (10) fuse
From the battery to: ignition switch, fuse (2),
helmet compartment light, cooling fan, permanent
supply to the dashboard.
30 A (11) fuse
From the battery to: voltage regulator, fuse (3),
fuse (5).
30 A (12) fuse
Spare.
10 11
12
chap. 6
6-40
Release 00 2002-09
Atlantic 500
ELECTRICAL COMPONENTS LAYOUT
43 33 39 6 13 3 25
56
31
30
53
27
55
15 14 5
11
4
16 40
23
50
49
51
24
28
47
KEY
3) Stepper motor
4) Coil
5) Spark plug
6) Fuel injector
15) Dashboard / engine water thermistor
16) Fan
23) Power socket
24) Secondary fuses
25) Top case light
28) Radio power supply
31) Parking/stop lights
39) Left indicator lights
40) Horn
43) Dashboard
49) Full beam bulbs
51) Headlight
53) Left tail lamp
56) 3 stop light bulbs
chap. 6
6-41
6
Release 00 2002-09
Atlantic 500
ELECTRICAL COMPONENTS LAYOUT
20 22 2 35 37 34 38
36
9
46
10
48
42
44 52 8 54 7 21 45
26
17
29
31
19
32
18
KEY
7) Fuel pump
8) Fuel level feeler
9) Main injection relay (with diode)
18) Flywheel
19) Battery
20) Starting relay
21) Starting motor
22) Main fuses
26) Compartment switch
32) Right tail lamp
35) Key switch
36) Drop sensor
37) Right switch
38) Fan relay
42) Dashboard air temperature thermistor
44) Speed sensor
45) Oil pressure sensor
48) Dipped beam bulb
54) Diagnostics socket
chap. 6
6-42
Release 00 2002-09
Atlantic 500
WIRING DIAGRAM 500 C.C. ATLANTIC SCOOTER
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chap. 6
6-43
6
Release 00 2002-09
Atlantic 500
WIRING DIAGRAM KEY
1) Multiple connectors
3) Stepper motor
4) Coil
5) Spark plug
6) Fuel injector
7) Fuel pump
8) Fuel level feeler
9) Main injection relay (with diode)
12) Lambda feeler (optional)
15) Dashboard/engine water thermistor
16) Fan
18) Flywheel
19) Battery
20) Starting relay
21) Starting motor
22) Main fuses
23) Power socket
24) Secondary fuses
25) Top case light
26) Compartment light switch
32) Right tail lamp
35) Key switch
36) Drop sensor
37) Right switch
38) Fan relay
39) Left switch
40) Horn
42) Dashboard air T thermistor
43) Dashboard
44) Speed sensor
48) Dipped beam bulb
49) Full beam bulbs
51) Headlight
53) Left tail lamp
54) Diagnostics power socket
56) Third stop light bulbs
57) Handbrake switch (optional)
CABLE COLOURS
Ar orange
Az light blue
B blue
Bi white
G yellow
Gr gray
M brown
N black
R red
V green
Vi violet
Ro pink
chap. 6
6-44
Release 00 2002-09
Atlantic 500
Cycle parts
chap. 7
7-1
Release 00 2002-09
7
Cycle parts
Atlantic 500
Cycle parts
chap. 7
7-2
Release 00 2002-09
Atlantic 500
BODYWORK
PASSENGER FOOTREST REMOVAL
Place the vehicle on the central stand.
Work with care.
Unscrew and remove the three screws (1).
Remove the passenger footrest (2).
LOWER PROTECTION COVER REMOVAL
Work with care. Do not damage the tongue and/or
the relative seats. Handle the painted components
with care. Do not drag them or ruin them.
Unscrew and remove the four screws (3) on the r.h.
side, and the four screws on the l.h. side.
Remove the breather pipe from the expansion tank.
1
1
2
CAUTION
CAUTION
UNLOCKING/LOCKING THE SEAT
Position the vehicle on the central stand.
Insert the key (1) into the ignition switch (2).
Press and rotate the ignition key (1) in an anti-clock-
wise direction.
Via the pneumatic piston, the seat (3) remains in a
raised position and the under-seat compartment is
illuminated.
To lock the seat, lower it and press it (without forcing
it), making the lock click.
Before riding again, make sure that the seat is
correctly locked.
WARNING
PUSH
Z A
D
I
3
5
5
4
3
1
2
Unscrew and remove the screw (4) placed on the
leading edge, behind the front wheel.
Remove the lower protection cover (5), supporting it to
prevent it from dropping.
Cycle parts
chap. 7
7-3
7
Release 00 2002-09
Atlantic 500
SEAT REMOVAL
Lift up the seat (4) (see UNLOCKING/LOCKING THE
SEAT).
Work with care.
Utilising a suitable pincer, unclip the clip (5).
Prop up the seat do make sure it does not fall
unexpectedly.
Remove the pin (6).
Unscrew and remove the four nuts (7).
Remove the seat (4).
CENTRAL TUNNEL REMOVAL
Remove the seat (see SEAT REMOVAL).
Remove the right and left inspection covers (see
RIGHT AND LEFT INSPECTION COVER REMOVAL).
Remove the legshield (see LEGSHIELD REMOVAL).
Unscrew and remove the two screws (1) on the right
and left side.
Unscrew and remove the screw (2) on the right and
left side.
Remove the central tunnel (3).
CAUTION
CAUTION
CAUTION
4
5
6
7
3
1
3
2
Cycle parts
chap. 7
7-4
Release 00 2002-09
Atlantic 500
LEFT AND RIGHT HAND INSPECTION COVER
REMOVAL
Remove the left and right hand rubber mats (1) by lift-
ing them up with the hands.
Unscrew and remove the screw (2).
Work with care.
Do not damage the tabs (3) and/or the relative
seats. Handle the painted and plastic components
Utilising a screwdriver, pull up the lower part of the
inspection cover (4) until it slips out from its seat.
When reassembling, correctly insert the tabs into
their relative seats
CAUTION
CAUTION
LEGSHIELD REMOVAL
Place the vehicle in the central stand.
Work with care.
Do not damage the tongue and/or the relative
seats. Handle the painted components with care.
Do not drag them or ruin them.
Remove the rubber foot mat by lifting it with the
hands.
Open the door of the document compartment (see
DOCUMENT COMPARTMENT).
Work with care.
Do not damage the plastic finish.
CAUTION
CAUTION
2
1
3
3
4
1
2
Cycle parts
chap. 7
7-5
7
Release 00 2002-09
Atlantic 500
Utilising a flat-bladed screwdriver (3), lever up the
speaker cover (4) to free it from its seat, as indicated
in the figure.
Remove the speaker cover (4).
Utilising a flat-bladed screwdriver (3), lever up the
edge of the legshield in such a way that it frees itself
from its seat.
CAUTION
Once the legshield is freed from its seat, remove it
slightly to disconnect the electrical connection (6) from
the 180W electrical socket situated inside the docu-
ment compartment.
3
4
5
3
6
Cycle parts
chap. 7
7-6
Release 00 2002-09
Atlantic 500
Pull the tabs (7) towards the cable (9), in such a way
that the cable head (8) is freed by lifting it up. Pull the
cable (9) in the direction indicated by the arrow to free
the legshield from the document compartment clo-
sure.
Remove the legshield (10).
DOCUMENT COMPARTMENT
Thanks to the utilisation of the document compartment
it is not necessary to carry cumbersome objects
around with you every time you park the vehicle.
Insert the key (1) into the ignition switch (2).
Press and rotate the key in an anti-clockwise direc-
tion.
The door of the document compartment (3) opens
automatically.
Inside the document compartment there is a 12V
socket (4).
The socket can be utilised for as an electrical feed for
items with an output of not more than 180W (mobile
phones, inspection lamp, etc.).
The prolonged use of the electrical socket without
the engine switched on can cause a partial dis-
charge of the battery.
CAUTION
FRONT MUDGUARD REMOVAL
Remove the front mudguard (6) by releasing it from
the front part of the vehicle.
CAUTION
1
2
4
3
6
5
9
8
10
7
7
Cycle parts
chap. 7
7-7
7
Release 00 2002-09
Atlantic 500
PASSENGER HANDLE-GRIP REMOVAL
Place the machine on the central stand.
Lift up the seat (see UNLOCKING/LOCKING THE
SEAT).
Utilising a small flat head screwdriver, lever up the two
rubber plugs (8).
Remove the passenger handle-grip (10) by rotating it
towards the vehicle.
CAUTION
COMPLETE SIDE PANEL REMOVAL
Remove the inspection covers (see RIGHT AND LEFT
HAND INSPECTION COVER REMOVAL).
Remove the passenger footrests (see PASSENGER
FOOTREST REMOVAL).
Lift up the seat (see UNLOCKING/LOCKING OF THE
SEAT).
From inside the crash helmet compartment, slacken
and remove the fixing knob (3) of the light assembly
(4).
Slightly lift up the rear light assembly (4) from the side
panel and disconnect the electrical connection (5).
Remove the rear light assembly (4).
Lower the side stand (only for the left side).
Remove screw (A) from the number plate holder .
Rotating away from the vehicle, remove the cover (7)
complete with the chromed strip.
10
10
1
4
7
2
3
5
6
7
8
9
L
L
A
Cycle parts
chap. 7
7-8
Release 00 2002-09
Atlantic 500
REMOVAL OF THE CHROMED STRIP FROM THE
SIDE PANELS
Remove the complete side panel (see COMPLETE
SIDE PANEL REMOVAL).
Unscrew and remove the screw (1) situated inside the
side panel.
Remove the chromed strip by slightly arcing it in the
central part.
CAUTION
SIDE PANEL SEPARATION
Remove the complete side panels (see COMPLETE
Remove the chromed strip on the side panels (see
REMOVAL OF THE CHROMED STRIP FROM THE
SIDE PANELS).
Unscrew and remove the screw (2) situated under the
chromed strip.
Separate the two screws of the side panels (3) and
(4), sliding them against one another but also paying
attention to not damage the tabs.
CAUTION
3
2
4
1
Cycle parts
chap. 7
7-9
7
Release 00 2002-09
Atlantic 500
FOOT PLATFORM REMOVAL
Remove the rubber mats (1) by lifting them by hand.
Remove the cover to gain access to the spark plug
(A).
CAUTION
SPRAY GUARD REMOVAL
CAUTION
6
4
5
6
Unscrew and remove the seven screws (2).
Remove the foot platform (3).
Remove the spray guard (6) by sliding it out from
underneath.
2
3
2
A
1
Remove the front mudguard (see FRONT MUD-
GUARD REMOVAL).
Remove the front wheel (see FRONT WHEEL RE-
MOVAL).
Unscrew and remove the three screws (4) (on the
right and left side of the vehicle).
Cycle parts
chap. 7
7-10
Release 00 2002-09
Atlantic 500
FRONT SHIELD REMOVAL
Remove the spray guard (see SPRAY GUARD RE-
MOVAL).
Unscrew and remove the three screws (1) (three on
the right and three on the left).
Free the front shield (2) from its supports by acting on
the tabs (3) via the utilisation of a flat head screw-
driver.
Remove the front shield (2), sliding it out from the front
part of the vehicle.
CAUTION
PASSENGER BACKREST REMOVAL
Lift up the seat (see UNLOCKING/LOCKING OF THE
SEAT).
Slacken and remove the two fixing screws (1) of the
backrest.
During the backrest removal, proceed with care so
as not to break the engagement teeth.
Remove the backrest (2) by pulling it upwards.
CAUTION
PLASTIC BACKREST REMOVAL
Remove the passenger backrest (see PASSENGER
BACKREST REMOVAL).
Remove the cover (2) of the seat closure.
2
1
2
1
1
2
3
1
Cycle parts
chap. 7
7-11
7
Release 00 2002-09
Atlantic 500
Unscrew and remove the seven screws (3).
Disconnect the electrical connection (4).
Remove the support arc (5).
Disconnec the electrical connection from the bulbs (6)
and the third stoplight.
Lift up and remove the plastic part (7) of the backrest.
REAR MUDGUARD REMOVAL
Remove the number plate light cover.
Remove the plastic cover by pulling it (2).
CAUTION
3
7
4
3 3
5
3
6
7
1
2
3
4
3 3
Unscrew and remove the four screws (3).
Support and slightly remove the rear mudguard (4).
Cycle parts
chap. 7
7-12
Release 00 2002-09
Atlantic 500
TAIL UNIT REMOVAL
Remove the plastic backrest (see PLASTIC
BACKREST REMOVAL).
Remove the rear mudguard (see REAR MUDGUARD
REMOVAL).
Remove the rear light assembly (see COMPLETE
Unscrew and remove the three screws (2), taking care
to recover the washers and ferrules.
Remove the tail unit by sliding out from the rear of the
vehicle (3).
LOWER COVER REMOVAL
Remove the lower cover (5).
CAUTION
Holding the rear mudguard in the hand, disconnect
the number plate light bulb (5), slide out the battery
overflow tube (6) from the guide clip (7).
Remove the rear mudguard (4).
5
4
7
6
1
3
2
3
5
4
Cycle parts
chap. 7
7-13
7
Release 00 2002-09
Atlantic 500
FOOTREST SUPPORT AND LOWER SPRAY
GUARD REMOVAL
Remove the central tunnel (see CENTRAL TUNNEL
REMOVAL).
Remove the chromed protection tube (2).
Unscrew and remove the five screws (3).
Remove the footrest support. (4).
2
1
4
3
5
6
Support the lower spray guard (5).
Disconnect the overflow tube (6) of the coolant tank.
Remove the lower spray guard (5).
Cycle parts
chap. 7
7-14
Release 00 2002-09
Atlantic 500
FRONT PANEL REMOVAL
During the removal, take care to not drop the clips
attached to the engagement tabs.
Slightly widen the tabs of the front panel as indicated
by the arrow A in such a way that the engagement
tabs are freed from the windshield.
Slightly lift up the lower part of the front panel, as
indicated by arrow B.
Remove the front panel (3) by pulling it with caution.
When reassembling, correctly insert the engage-
ment tabs into their appropriate seats with their
relative clips.
CAUTION
CAUTION
UPPER HANDLEBAR COVER REMOVAL
Lift up and remove the cover (2).
Unscrew and remove the five screws (3).
ABS
1 1
2
3
2
1
5
3
CAUTION
Cycle parts
chap. 7
7-15
7
Release 00 2002-09
Atlantic 500
Unscrew and remove the two screws (4) on the right
and left side of the vehicle.
Remove the upper handlebar cover (5).
LOWER HANDLEBAR COVER REMOVAL
Remove the upper handlebar cover (see UPPER
HANDLEBAR REMOVAL).
Separate the plastic parts (2) by pulling them out-
wards.
COMPLETE INSTRUMENT PANEL REMOVAL
Utilising a flat head screwdriver (1), lever up the
speaker cover (2) to free it from its seat (as indicated
in the figure).
Remove the speaker cover (2).
CAUTION
4
4
1
1
2 2
1
2
3
Cycle parts
chap. 7
7-16
Release 00 2002-09
Atlantic 500
Remove the front panel (see FRONT PANEL RE-
MOVAL).
Remove the windshield (see WINDSHIELD RE-
MOVAL).
4
Lift up the complete instrument panel (5) and discon-
nect the electrical connections (6) directly from the
instrument panel.
Remove the complete instrument panel (5).
WINDSHIELD REMOVAL
MOVAL).
Slacken and remove the six fixing screws (1) of the
front panel.
Remove the front panel (2).
5
6
1
2
1
INSTRUMENT PANEL REMOVAL
Remove the complete instrument panel (see INSTRU-
MENT PANEL REMOVAL).
Unscrew and remove the four screws (1).
Remove the instrument panel (2).
2
1 1
1
Cycle parts
chap. 7
7-17
7
Release 00 2002-09
Atlantic 500
COMPLETE LIGHTING ASSEMBLY REMOVAL
Remove the hood, (see WINDSHIELD REMOVAL).
Remove the front spray guard (see FRONT SPRAY
GUARD REMOVAL).
MOVAL).
Remove the complete instrument panel (see INSTRU-
MENT PANEL REMOVAL).
Unscrew and remove the two screws (2) and recover
the relative self-locking nut.
Unscrew the cap of the coolant tank (4).
Unloose the two screws of the lower bow (above the
fork).
4
2
1
6
3
6 2
Disconnect the electrical connection (5).
Remove the complete lighting assembly (6).
5
Cycle parts
chap. 7
7-18
Release 00 2002-09
Atlantic 500
CRASH HELMET COMPARTMENT REMOVAL
Remove the seat (see SEAT REMOVAL).
Remove the central tunnel (see CENTRAL TUNNEL
REMOVAL).
Remove the left and right hand side panels (see
COMPLETE SIDE PANEL REMOVAL).
Unscrew and remove the two screws (1) and recover
the relative washers.
(Carry out this operation also on the right hand side)
Unscrew and remove the two fixing screws (2) of the
seat lock (3) from the crash helmet compartment and
free the lock from the crash helmet compartment.
Slide out the relay (4) by pulling it upwards.
2
4
1
3
Remove the battery cover (see BATTERY COVER
REMOVAL).
Disconnect the electrical connections (5) of the
battery.
Remove the battery (see BATTERY REMOVAL).
5
5
5
Cycle parts
chap. 7
7-19
7
Release 00 2002-09
Atlantic 500
Slide the starter relay (6) out of its seat inside the
battery compartment.
Support it by hand and slide off the rubber protection
cover (7).
Unscrew and remove the nut (8).
Slide out from the rear, the wiring that comes out of
the crash helmet compartment.
Slide out the starter relay lead (9).
Slide out the battery lead (10).
Slide out the earth lead (11).
Slide out the fuse lead (12).
10
Disconnect the battery breather tube (13) from the clip
(14).
Remove the clip (15) and slide out the pin (16).
Remove the seat hinge (17).
8
7
6
12
11
13
14
15
16
17
9
Cycle parts
chap. 7
7-20
Release 00 2002-09
Atlantic 500
18
Unscrew and remove the four screws (19) of the
carburettor cover (20).
Remove the carburettor cover (20).
Slacken the bands (22) via the screw (21) and slide
out the fuel breather tube (23) by pulling it outwards.
Unscrew and remove the six screws (24) from the
filter box (25).
19
20
21
22
23
24
25
24
Cycle parts
chap. 7
7-21
7
Release 00 2002-09
Atlantic 500
NOTE Make sure that you have a new band before
substituting the old one.
Remove the plastic band (26) and slide out the tube
(27).
Remove the engine cover (25) by lifting it upwards.
Disconnect the electrical connections (28) of the crash
helmet compartment light switch.
Remove the crash helmet compartment (29) by lifting
up the front part and moving the complete unit for-
wards.
26 27
28
29
Cycle parts
chap. 7
7-22
Release 00 2002-09
Atlantic 500
FRONT WHEEL
KEY
1) Axle
2) Odometer sensor
3) r.h. outer spacer
4) r.h. oil seal
5) r.h. bearing
6) Wheel
7) Inner spacer
8) l.h. bearing
9) l.h. oil seal
10) l.h. brake disc
11) r.h. brake disc
12) l.h. outer spacer
2
4
1
11
5
3
6
7
8
9
10
12
Cycle parts
chap. 7
7-23
7
Release 00 2002-09
Atlantic 500
REMOVING THE FRONT WHEEL
When removing/refitting the parts, take care not to
damage the brake line, the disc and the pads.
Place a suitable support under the vehicle so that
there is room for the front wheel to move and the
vehicle does not topple over.
CAUTION
WARNING
4
3
1
2
1
5
NOTE Perform the following operation also on the
r.h. side of the vehicle.
Remove the two screws (1).
Carefully release the brake caliper (2).
Unloose screw (3).
NOTE To ensure proper refitting, carefully check the
positions of the parts, the washers and the spacer.
Unscrew the wheel pin (4).
Support the front wheel (5) and manually pull out axle
(4).
Remove wheel (5).
Keep the right and left spacers.
Do not pull the front brake lever after removing
the wheel as the caliper piston may come out of
its seat and cause a leakage of brake fluid.
For instructions on how to refit the wheel, (see REFIT-
TING).
WARNING
Cycle parts
chap. 7
7-24
Release 00 2002-09
Atlantic 500
REPLACING THE BEARINGS
The bearings must be checked and if necessary
replaced every time they are removed.
Clean both sides of the hub with a rag.
Removal
Working on the left side of the vehicle:
Insert a drift (with no point) into the wheel hub and act
on the inner race of right-hand bearing (1), taking care
to shift the strike points (by 90) so as not to offset the
bearing.
Extract right-hand bearing (1).
Extract spacer (2).
Working on the right side of the vehicle:
Maintain the drift perpendicular to the bearing (on
the same axis as the axle) to avoid offsetting and
damaging the latter.
Insert a bumper with diameter of 15 mm (0.59 in) into
the wheel hub and lean it against the ring inside the
left bearing (3).
Drive out the bearing by repeatedly hitting the drift
with moderate force with a plastic mallet.
Refitting
Working on the right side of the vehicle:
Rest the bearing on the wheel hub.
Maintain the drift perpendicular to the bearing (on
the same axis as the axle) to avoid offsetting and
damaging the bearing.
Lean a bumper with diameter of 31 mm (1.22 in)
against the bearing outer diameter.
Fully insert right-hand bearing (1) by repeatedly hitting
the drift with moderate force with a plastic mallet.
Fit spacer (2).
Working on the left side of the vehicle:
Repeat the first three steps for left-hand bearing (3).
Check the bearings centering to the wheel hub.
CAUTION
1
3
2
CAUTION
CAUTION
WARNING
Cycle parts
chap. 7
7-25
7
Release 00 2002-09
Atlantic 500
CHECK
Check the condition of all components, and in
particular of those listed below.
Bearings
Manually rotate inner race (1), making sure it turns
smoothly without any sticking and/or noise.
Also check that there is no axial play.
Replace any bearings showing the above defects.
Grease the balls (or rollers) at the sides of each
bearing (see LUBRICANT CHART).
The operation is unnecessary if the bearings are
of the self-lubricating type.
Axle
Check the pin runout using a dial gauge.
If the runout exceeds the maximum allowed limit,
replace the pin.
Maximum runout: 0.25 mm (0.0098 in)
Lubricate the pin (only the area in contact with the
bearings) see (TABLE OF LUBRICANTS).
Wheel rim
Using a dial gauge, check that the radial and axial
runout of the wheel rim does not exceed the specified
limit.
Excessive runout is usually caused by worn or dam-
aged bearings. If, after replacing the bearings, the
runout still exceeds the prescribed limit, replace the
wheel rim.
Maximum radial and axial runout: 2 mm (0.078 in)
Speedometer drive
Check that it shows no signs of damage and/or
excessive wear.
Tyre
Check the condition of the tyre (TYRES).
CAUTION
1
CAUTION
CAUTION
Cycle parts
chap. 7
7-26
Release 00 2002-09
Atlantic 500
REFITTING THE FRONT WHEEL
When refitting the front wheel, take care not to
damage the brake line, the disc and the pads.
Position the wheel between the fork rods.
Insert axle (1) from the right side of the vehicle.
Insert the spacer (2) between the hub and the left fork
rod.
Insert the spacer between the hub and the left fork
rod.
Screw and tighten the wheel pin (1).
NOTE Perform these operations also on the vehicle
r.h. side.
Carefully refit the brake caliper to brake disc (4).
Tighten the two screws (5).
While pulling the front brake lever, repeatedly stroke
the fork by pressing down on the handlebar.
This will allow the fork rods (1) to settle appropriately .
Tighten axle clamp screw (3).
After refitting the parts, repeatedly pull the front
brake lever and check the operation of the braking
system
Check the wheel centering and balancing, see
(WHEELS/TYRES).
CAUTION
1 2
3
4
5
5
CAUTION
Cycle parts
chap. 7
7-27
7
Release 00 2002-09
Atlantic 500
REAR WHEEL
KEY
1) Wheel assembly
2) Spacer
3) Oil seal
4) Brake caliper and silencer supporting plate
5) Nut
3
2
4
5
1
Cycle parts
chap. 7
7-28
Release 00 2002-09
Atlantic 500
REMOVING THE REAR WHEEL
Allow the engine and the exhaust terminal to cool
down completely.
Remove the exhaust terminal, see (REMOVING THE
EXHAUST TERMINAL).
Unloose and remove screw (5) fixing the pipe guide
clamp.
Unloose and remove the two screws (6) fixing the rear
brake caliper (7).
Release the rear brake caliper (7) from the support
(3).
Unscrew and remove pin (8) fixing the suspension
(11).
WARNING
7
6
5
3
11
8
10
9
Keep nut (9) and washer (10).
Release the right suspension (11) of support (3).
Unscrew and remove the wheel pin nut (12) using a
pneumatic gun.
Unloose and remove the two screws (13) fixing the
support (3) to the engine. Keep the washers.
Remove support (3) by pulling it outwards.
Remove wheel (14) by pulling it outwards, including
the rear brake disc.
3
12
13
14
Cycle parts
chap. 7
7-29
7
Release 00 2002-09
Atlantic 500
REMOVING THE EXHAUST TERMINAL
Allow the engine and the exhaust terminal to cool
down completely.
Unloose clamp (1) by unscrewing the nut fixing the
exhaust terminal to the manifold.
Unscrew and remove the three bolts (2) fixing the
terminal to support (3), keep the relevant nuts.
Remove the exhaust terminal (4).
WARNING
2
4
2
3
1
Cycle parts
chap. 7
7-30
Release 00 2002-09
Atlantic 500
CHECK
Check the condition of all components and in
particular of those listed below.
Bearings
Manually rotate inner race (1), making sure it turns
smoothly without any sticking and/or noise.
Check that there is no axial play.
Replace any bearings showing the above defects.
Lubricate the balls (or rollers) on the side of each
bearing, see (TABLE OF LUBRICANTS).
Lubrication is not necessary if the bearing is of
the self-lubricating type.
Axle
Refer to the ENGINE WORKSHOP MANUAL no.1063
, no.1064 , no.1065 , no.1066 , no.1067
and no.1068 .
Wheel rim
Using a dial gauge, check that the radial and axial
runout of the wheel rim does not exceed the specified
limit.
Excessive runout is usually caused by worn or dam-
aged bearings. If, after replacing the bearings, the
runout still exceeds the prescribed limit, replace the
wheel rim.
Maximum radial and axial runout: 2 mm (0.078 in)
Tyre
Check the condition of the tyre (TYRES).
CAUTION
1
CAUTION
FRONT BRAKE
For general information, refer to the paragraph
(BRAKES FLUID).
For more information on:
Braking system parts, see (BRAKING SYSTEM).
Pads wear checking, see (CHECKING PADS WEAR).
Braking system bleeding, see (BRAKING SYSTEM
BLEEDING).
Cycle parts
chap. 7
7-31
7
Release 00 2002-09
Atlantic 500
KEY
1) Brake control lever
2) Brake fluid pump/tank
3) Brake fluid pipe
4) Braking retarder
5) Brake caliper breather valve
6) Pipe fitting screw
7) Brake caliper
8) Brake pads
9) Brake disc
8
1
2
4
3
6
8
7
5
9
7
5
3
9
Cycle parts
chap. 7
7-32
Release 00 2002-09
Atlantic 500
REPLACING THE BRAKE PADS
NOTE Perform the following operations on both
sides.
Unloose and remove screw (1).
Unloose and remove the two screws (2) and release
the brake caliper (3).
Hold the brake caliper in one hand and remove plate
(4).
Remove the two pins (5).
Remove the two pads.
Do not pull the brake lever after removing the
brake pads as the caliper pistons may come out of
their seats and cause a leakage of brake fluid.
Always replace both pads and make sure to
properly position them inside the caliper.
Fit two new pads.
Insert the two pins (5).
Correctly position plate (4).
Screw on screw (1), without tightening it.
Correctly position the brake calipers.
Screw and tighten the two screws (2).
Screw and tighten screw (1).
2
CAUTION
CAUTION
4
1
3
2
5
Cycle parts
chap. 7
7-33
7
Release 00 2002-09
Atlantic 500
CHECKING THE BRAKE DISC
The following operations must be performed when
the brake disc is installed on the wheel.
Visually check the surface of the brake disc. If it
shows any signs of scoring or damage, replace the
disc (REMOVING THE BRAKE DISC).
Check the wear of the brake disc by measuring its
minimum thickness with a micrometer at several
points.
If the minimum thickness of the disc, even at one
point, is less than the prescribed limit, replace the
disc.
Minimum thickness of the brake disc: 3.5 mm (0.137
in)
With a dial gauge, check that the disc oscillation does
not exceed the allowed tolerance. Replace if neces-
sary.
Brake disc oscillation tolerance: 0.1 mm (0.004 in)
CAUTION
REMOVING THE BRAKE DISC
Take down the front wheel (REMOVING THE FRONT
WHEEL).
Remove the five brake disc screws (7).
NOTE Turn in all screws manually, and then tighten
them diagonally in the following order: A-B-C-D-E.
Check the disc direction of rotation.
When refitting, apply LOCTITE 270 over the
threads of the brake disc screws.
Remove the brake disc.
CAUTION
REAR BRAKE
For general information, refer to the paragraph
(BRAKES FLUID).
For more information on:
Braking system parts, see (BRAKING SYSTEM).
Pads wear checking, see (CHECKING PADS WEAR).
Braking system bleeding, see (BRAKING SYSTEM
BLEEDING).
Cycle parts
chap. 7
7-34
Release 00 2002-09
Atlantic 500
KEY
1) Brake control lever
2) Brake fluid pump/tank
3) Brake fluid pipe
4) Valve
5) Pipe fitting screw
6) Brake caliper
7) Pad pin
8) Stop ring
9) Brake pads
10) Antivibration plates
11) Pad spring
12) Brake disc
3
5
9
10
8
2
11
10
7
4
6
1
12
Cycle parts
chap. 7
7-35
7
Release 00 2002-09
Atlantic 500
REPLACING THE BRAKE PADS
Remove the rear brake caliper, see (REMOVING THE
REAR BRAKE CALIPER).
Remove stop ring (1).
Remove pin (2).
Remove spring (3).
The vibration-damping plates are removed to-
gether with the pads.
Remove the pads (4) (complete with the vibration-
damping plates (5)) by withdrawing them one by one.
Do not pull the brake lever after removing the
brake pads as the caliper piston may come out of
Replace the pads (4).
Replace the vibration-damping plates (5) if they show
signs of wear.
Always replace both pads and make sure to
properly position them inside the caliper.
Fit two new pads and vibration-damping plates paying
attention to the assembly direction (direction of rota-
tion of the wheel).
Correctly install the spring (3), see Turn Indicator.
Fit the pin (2).
Fit the stop ring (1).
Check the brake fluid level, see (CHECKING THE
BRAKE FLUID LEVEL).
4
1
5
CAUTION
CAUTION
WARNING
3
2
Cycle parts
chap. 7
7-36
Release 00 2002-09
Atlantic 500
CHECKING THE BRAKE DISC
The following operations must be performed when
the brake disc is installed on the wheel.
Visually check the surface of the brake disc. If it
shows any signs of scoring or damage, replace the
disc (REMOVING THE BRAKE DISC).
Check the wear of the brake disc by measuring its
minimum thickness with a micrometer at several
points.
If the minimum thickness of the disc, even at one
point, is less than the prescribed limit, replace the
disc.
Minimum thickness of the brake disc: 3.5 mm (0.137
in)
With a dial gauge, check that the disc oscillation does
not exceed the allowed tolerance. Replace if neces-
sary.
Brake disc oscillation tolerance: 0.1 mm (0.004 in)
CAUTION
REMOVING THE BRAKE DISC
Take down the front wheel (REMOVING THE FRONT
WHEEL).
Remove the five brake disc screws (7).
When refitting, apply LOCTITE 270 over the
threads of the brake disc screws.
Remove the brake disc.
CAUTION
Cycle parts
chap. 7
7-37
7
Release 00 2002-09
Atlantic 500
STEERING
For information on how to check and adjust the
steering, refer to the paragraph (CHECKING AND
ADJUSTING THE STEERING).
Disassembly
Remove the handlebar cover, see (REMOVING THE
UPPER HANDLEBAR COVER) and (REMOVING
THE LOWER HANDLEBAR COVER).
Put the vehicle onto an elevator, leaving the front
wheel out, and lower central stand.
Place a suitable support under the vehicle so as to
prevent it from falling.
The vehicle should rest on the frame and not, on
any account, on the fuel tank.
Ensure that the vehicle is stable.
Keep nut (2) and the washers.
Keep nut (4) and the washers.
Remove the front mudguard, see (REMOVING THE
FRONT MUDGUARD).
CAUTION
CAUTION
2
1
4
5
3
8
7
6
Unloose and remove screw (9) and release the
odometer sensor (10).
10
9
Arrange for a suitable support to hold the handle-
bar that remains connected to the vehicle by
means of the electrical cables and the brake pipes.
Proceed with care. Do not force the electrical
cables.
Completely pull upwards the handlebar (5) (complete
with switches).
Release the plate (7) of the steering trapezoid (8) of
the steering suspension.
Cycle parts
chap. 7
7-38
Release 00 2002-09
Atlantic 500
11
11
12
vehicle l.h.side.
Release the brake caliper (12) from the fork.
Do not pull the front brake lever after removing
the brake caliper as the caliper piston may come
out of its seat and cause a leakage of brake fluid.
CAUTION
Unloose and remove the two screws (13)
Remove the brake oil pipes stop plate (14).
Release the pipes and the brake caliper from the fork.
14
13
Remove counternut (15).
Support the fork to prevent it from falling.
NOTE When removing the fork, pay attention to the
balls coming out of the lower bearing.
Remove adjusting nut (16).
Remove the plastic gasket (17).
Remove the fork (18) from the steering tube (19).
Remove revolving ring (20) and upper bearing balls
(21).
Remove lower bearing balls (22).
Remove the grease from all bearing components,
fixed rings (23) and (24) included.
Remove the dust cover gasket (25).
Check the components for any signs of wear and
replace as necessary.
NOTE For the grease type to be used with the
bearings, refer to the (LUBRICANT CHART).
Grease and proceed with the reassembly.
CAUTION
16
15
17
20
21
23
19
18
22
24
25
Cycle parts
chap. 7
7-39
7
Release 00 2002-09
Atlantic 500
CHECKING THE BEARINGS
Check the condition of all components.
Check that the areas that come into contact with balls
(1) on both revolving ring (2) and fixed ring (3) are not
damaged or worn out. If they are, replace the bearing
assembly.
Grease the two rings (2) and (3) in the areas where
they are in contact with the balls (see LUBRICANT
CHART).
Reassembly
To reassemble, follow the disassembling procedure in
reverse order, taking care to interpose the steps given
below.
Ensure that the pipes and the cables are not
twisted
NOTE The hole for the fixing to the handlebar clamp
must be aligned with the slot on the fork pin.
4
5
CAUTION
CAUTION
CAUTION
To avoid damaging the steering bearings, take
care not to screw adjusting nut (4) tight.
Screw in adjusting nut (4) until the play of the bearings
is eliminated.
Check the play by stroking the fork in the direction of
motion and checking that the steering can rotate
smoothly and freely.
Lock adjusting nut (4) in position and tighten
counternut (5) with a spanner.
Repeat the second operation.
CAUTION
Cycle parts
chap. 7
7-40
Release 00 2002-09
Atlantic 500
KEY
1) Fork base
2) Fork clamp screws
3) Spring stop ring
4) Rubber cap
5) Seal cap
6) Brake pipe cable lead
7) GACO ring OR type
8) Spring
9) Pumping element
10) Return spring
11) Bottom bumper
12) Left rod
13) Dust cover gasket
14) Lock spring ring
15) Seal gasket
16) Cup
17) Bush
18) Left wheel carrier
19) Seal washer
20) Lower screw
21) Right rod
22) Right wheel carrier
23) Locking screw
24) Bush
1
21
17
16
15
14
13
11
22
23
19
20
19
20
18
24
24
10
9
8
5
7
3
4
4
7
3
6
6
2
2
17
16
15
14
13
11
12
Cycle parts
chap. 7
7-41
7
Release 00 2002-09
Atlantic 500
CHECKING THE OIL LEVEL
If bottom strokes are noticed in the fork, check the
oil level in the rods.
Remove the front shield, see (REMOVING THE
INNER SHIELD).
NOTE To facilitate the removal of the two seal caps
(3), it is necessary to remove them both at the same
time.
Remove the spring stop ring (1).
Remove the plastic cap (2).
Slowly pump the fork until the two seal caps (3)
complete with O rings (4) have come out.
NOTE Check the O rings conditions. Replace if
necessary.
NOTE Check the spring position (5) (the turns with a
smaller diameter and closer to each other must be
facing upwards).
The spring is immersed in oil.
Avoid dripping the oil when removing the spring.
Pull out the spring (5).
Move the fork to its full bump position, insert a gauged
rod (meter) in one of the two rods and check that
there is a distance of 85 mm (3.34 in) between the rod
upper edge and the oil level.
Top up the fork oil if necessary. See (TABLE OF
LUBRICANTS).
Repeat these two operations also for the second rod.
CAUTION
8
5

m
m

(
3
.
3
4

i
n
)
2
1
5
3
4
2
1
REMOVING THE FORK ASSEMBLY
To remove the fork assembly (in case it is to be re-
placed), follow the instructions described in paragraph
(DISASSEMBLY).
Cycle parts
chap. 7
7-42
Release 00 2002-09
Atlantic 500
REMOVING THE ROD-WHEEL CARRIER ASSEM-
BLY (with installed fork)
Put the vehicle on the stand.
Place a suitable stand under the vehicle to prevent
it from falling.
Remove the front mudguard, see (REMOVING THE
FRONT MUDGUARD).
Remove the front wheel, see (REMOVING THE
FRONT WHEEL).
Remove the front shield, see (REMOVING THE INNER
SHIELD).
vehicle left side.
Release the brake caliper (2) from the fork.
Do not pull the front brake lever after removing the
brake caliper as the caliper piston may come out of
CAUTION
CAUTION
Remove the brake oil pipes stop plate (4) and the lock
(6).
Release the pipes and the brake caliper from the fork.
Remove the odometer sensor (6) from the fork rod (7).
Completely remove, by lowering it, the fork rod com-
plete with the wheel carrier.
Repeat the last three operations also for the second
rod.
1
1
2
6
5
6
3
4
7
Cycle parts
chap. 7
7-43
7
Release 00 2002-09
Atlantic 500
WHEEL CARRIER ROD DISASSEMBLY
To disassemble the rubber cap (1), lock spring ring
(snap ring) (2), seal cap (3) complete with O ring (4),
and spring (5), perform the (CHECKING THE OIL
LEVEL) operations on the wheel carrier rod that is to
be disassembled, leaving out the last two oil check
operations.
Pay attention to possible oil leakages as the rod-
wheel carrier assembly is full with oil.
Do not overturn or incline the unit excessively
when removing it.
Remove the rod-wheel carrier assembly, see (REMOV-
ING THE ROD-WHEEL CARRIER ASSEMBLY) (with
installed fork).
Prepare a container with capacity of at least 200 cm
3
(12.2 cu.in).
Let the rod retract completely in the wheel carrier, turn
the rod wheel carrier assembly and drain the oil into
the container.
CAUTION
CAUTION
Check the oil quantity.
If less than 225 cm
3
(13.72 cu.in), top up or renew.
Unloose and remove screw (6) (wheel carrier bottom)
and keep the copper washer (7).
Remove the rod (8) complete with pumping element
(9).
Turn the wheel carrier (10) to take out the bottom
bumper (11) and the counter spring (12).
Remove the dust cover gasket (13).
Remove the lock spring ring (snap ring) (14).
To reassemble, make sure the sharp edge of the
lock spring ring (snap ring) (14) is in the same
position as shown in the figure.
Remove the seal gasket (15).
Remove the cup (16).
Remove the bush (17).
CAUTION
1
2
4
5
3
12
9
8
15
14
13
11
17
16
10
6
7
Cycle parts
chap. 7
7-44
Release 00 2002-09
Atlantic 500
CHECKING THE COMPONENTS
Rod
The sliding surface must show no signs of scoring and/
or damage.
If the rod is damaged, replace it.
With a dial gauge, check that the rod bending is lower
than the limit value.
If necessary, replace the rod.
Bending limit: 0.2 mm (0.007 in).
A bent rod must NEVER be straightened as its
structure would become weak, thus compromising
the vehicle safety.
Wheel carrier
Check that it shows no signs of damage and/or flaws.
Replace if necessary.
Spring
Check the spring condition.
Pumping element
Check the pumping element condition.
Replace if it shows signs of damage.
WARNING
ADJUSTING THE REAR SUSPENSION
The rear suspension consists of a doubleeffect shock
absorber (braking with compressed/extended shock
absorber) fixed to the engine by means of a silent-
block.
The standard adjustment, set by the manufacturer, is
suitable for a driver weighing about 70 kg (154.3 lbs).
If your weight and needs are different, adjust the ring
nut (1) with the appropriate spanner provided in the
tool kit, thus setting the ideal travelling conditions (see
table).
Adjust both shock absorbers to the same posi-
tion.
1
Cycle parts
chap. 7
7-45
7
Release 00 2002-09
Atlantic 500
ADJUSTMENT OF THE REAR SUSPENSION
SPRING PRELOAD
REMOVING THE SHOCK ABSORBER
Wait for the engine and the exhaust terminal to
cool down completely.
Remove one shock absorber per time.
To maintain the vehicle in the upright position,
always leave one shock absorber assembled to
the vehicle.
NOTE Perform the following operations for both
shock absorbers.
Unloose and remove the lower screw (4) and keep nut
(5).
Unloose and remove screw (2) and keep the nut (3).
Remove the shock absorber (6).
CAUTION
WARNING
2
3
6
5
6
4
Adjusting
ring
Rotation
(arrow A)
Rotation
(arrow B)
Function
Attitude
Recommended
kind of road
Notes
Spring preload
increase
The vehicle is more
rigid
Smooth or normal
roads
Drive with passenger
Spring preload
decrease
The vehicle is less
rigid
Roads with uneven
surface
Drive without
passenger
Cycle parts
chap. 7
7-46
Release 00 2002-09
Atlantic 500
aprilia s.p.a.
via G.Galilei, 1
30033 Noale (VE) Italy
tel. +39 041.5829111
fax +39 041.441054
Introduction
This manual provides basic information on standard servic-
ing procedures. The data and illustrations contained in the
manual were up to date at the moment of publication.
Owing to aprilias constant commitment to improving the
quality and performance of its products, vehicles are subject
to change without notice. Users of this publication should
consequently be aware that, for some models, the informa-
tion provided may not be entirely up to date.
Updates of specifications and servicing procedures resulting
from changes made to vehicles will be notified to all aprilia
distributors, who will in turn make them available to after-
sales mechanics.
Before performing any operation, ensure that the informa-
tion contained in this manual is applicable to the vehicle to
be serviced.
This publication is meant for aprilia dealers and their
trained and qualified mechanics.
The description of many service and repair operations has
been deliberately omitted in that it is assumed that users of
this manual have received a basic training in mechanics,
that they are aware of vehicle repairing techniques, and that
they have at their disposal all the information published by
aprilia on the vehicle. Should any of these three conditions
not be fulfilled, repairs and/or servicing may prove inad-
equate and thereby result in danger or injury.
This manual does not provide a detailed description of all
the procedures required to perform repairs and servicing
operations. It is therefore essential to exercise extreme
caution in order to prevent damage to the vehicle and its
components as well as personal injury to mechanics and the
user.
In case of doubt as to the repairing or servicing procedures,
please contact aprilias AFTER-SALES DEPARTMENT:
aprilias technicians will be pleased to provide all neces-
sary support.
For further information, please refer to:
- THE CYCLE PARTS WORKSHOP MANUAL
- THE ENGINE SPARE PARTS CATALOGUE
- THE CHASSIS SPARE PARTS CATALOGUE
aprilia reserves the right to make any changes at any moment to
all its models.
This manual is copyright worldwide. Any reproduction thereof in
printed or electronic form is forbidden.
The mention of third parties products is only made for information
purposes, and constitutes no engagement.
aprilia assumes no responsibility for the use of products it has not
expressly recommended or approved.
First release: December 2001
Designed and printed by:
CLD s.r.l. Technical Manuals Department
Via D. Alighieri, 37/A - 56012 Fornacette (PI)
Tel. +39 (0)587 - 42 28 00
Fax +39 (0)587 - 42 28 01
www.cld.it
E-mail: cld@cld.it
for:
aprilia S.p.A.
Via G. Galilei, 1 - 30033 Noale (VE) - Italia
Tel. +39 (0)41 - 58 29 111
Fax +39 (0)41 - 44 10 54
www.aprilia.com
LIST OF SECTIONS
6
Flywheel cover
4
Automatic transmission
3
General information and mainte-
nance
2
General Specifications
1
General Information
7
Flywheel and starting system
8
Thermal unit and timing system
5
Final reduction
9
Crankcase and driving shaft
Fuel injection
Lubrication
Cooling system
13
Starting
12
11
10
General Information
500-4T
chap. 1
3
Release 00 2001-12
1
General Information
General Information
500-4T
1-4
TABLE OF CONTENTS
Chapter 1
Introduction ............................................................................................................................................ 1-1
Table of contents .................................................................................................................................... 1-4
Safety precautions ................................................................................................................................. 1-8
Recommendations on maintenance....................................................................................................... 1-8
General safety rules ............................................................................................................................... 1-9
Carbon monoxide ................................................................................................................................... 1-9
Fuel ...................................................................................................................................................... 1-10
Transmission oil ................................................................................................................................... 1-10
Engine oil ............................................................................................................................................. 1-10
Chapter 2
Table of lubricants .................................................................................................................................. 2-2
Tools ....................................................................................................................................................... 2-3
Chapter 3
Safety rules ............................................................................................................................................ 3-2
Maintenance rules .................................................................................................................................. 3-2
Technical data of the 500 cc 4T 4V H
2
O engine..................................................................................... 3-3
Spark plug .............................................................................................................................................. 3-4
Air cleaner .............................................................................................................................................. 3-4
Cleaning ................................................................................................................................................. 3-5
Checking the engine oil level and topping up......................................................................................... 3-5
Changing the oil and the engine oil filter ................................................................................................ 3-7
Checking the transmission oil level and topping up ............................................................................... 3-8
Changing the transmission oil ................................................................................................................ 3-9
Coolant ................................................................................................................................................. 3-10
Checking and topping up ..................................................................................................................... 3-11
Water pump.......................................................................................................................................... 3-12
Checking the timing.............................................................................................................................. 3-12
Checking/adjusting the valve clearance............................................................................................... 3-13
Checking the compression end pressure............................................................................................. 3-13
Chapter 4
External transmission cover ................................................................................................................... 4-3
Transmission cover ................................................................................................................................ 4-3
Belt anti-flapping roller ........................................................................................................................... 4-3
Driving pulley.......................................................................................................................................... 4-3
Driven pulley axis support ...................................................................................................................... 4-4
Clutch housing ....................................................................................................................................... 4-5
Driven pulley assembly .......................................................................................................................... 4-5
Clutch disassembly ................................................................................................................................ 4-6
Pins stop collar ....................................................................................................................................... 4-6
Fixed driven half pulley bearings............................................................................................................ 4-7
Fixed driven half pulley .......................................................................................................................... 4-7
Mobile driven half pulley......................................................................................................................... 4-8
Fixed driven half pulley bearings assembly ........................................................................................... 4-8
Driven pulley assembly .......................................................................................................................... 4-8
Spring..................................................................................................................................................... 4-9
Driving belt ............................................................................................................................................. 4-9
Clutch reassembly................................................................................................................................ 4-10
Mobile driving half pulley ...................................................................................................................... 4-10
Rollers housing assembly .................................................................................................................... 4-11
Driven pulley unit assembly ................................................................................................................. 4-12
General Information
500-4T
1-5
1
Housing assembly ................................................................................................................................ 4-12
Driven pulley axle support assembly.................................................................................................... 4-12
Driven pulley axle support bearings disassembly ................................................................................ 4-12
Driven pulley axle support bearing assembly....................................................................................... 4-13
Fixed driving half pulley assembly ....................................................................................................... 4-15
Belt antiflapping roller assembly .......................................................................................................... 4-16
Transmission cover .............................................................................................................................. 4-16
External transmission cover ................................................................................................................. 4-17
Chapter 5
Reduction unit cover .............................................................................................................................. 5-3
Wheel axle and intermediate shaft disassembly .................................................................................... 5-3
Hub housing bearings ............................................................................................................................ 5-3
Disassembly of wheel axle bearing from cover ...................................................................................... 5-4
Disassembly of intermediate shaft bearing from cover .......................................................................... 5-4
Driven pulley shaft disassembly ............................................................................................................. 5-5
Driven pulley shaft bearing assembly .................................................................................................... 5-5
Hub cover check .................................................................................................................................... 5-7
Bearings assembly on hub cover ........................................................................................................... 5-7
Checking hub shafts............................................................................................................................... 5-8
Hub gears assembly .............................................................................................................................. 5-8
Hub cover assembly............................................................................................................................... 5-9
Chapter 6
Thermostat cover disassembly .............................................................................................................. 6-3
Water pump cover disassembly ............................................................................................................. 6-4
Flywheel cover disassembly .................................................................................................................. 6-4
Flywheel cover components disassembly .............................................................................................. 6-5
Stator ...................................................................................................................................................... 6-5
Checking the cover case components - Cover case.............................................................................. 6-8
Stator ...................................................................................................................................................... 6-8
Bypass piston and spring ....................................................................................................................... 6-9
Water pump shaft ................................................................................................................................. 6-10
Water pump rotor ................................................................................................................................. 6-10
Checking the water pump cover ........................................................................................................... 6-10
Reed valve ........................................................................................................................................... 6-11
Assembling the flywheel cover components ........................................................................................ 6-11
Stator assembly ................................................................................................................................... 6-13
Flywheel cover assembly on the engine .............................................................................................. 6-14
Water pump cover assembly................................................................................................................ 6-15
Thermostat cover assembly ................................................................................................................. 6-16
Chapter 7
Flywheel cover disassembly .................................................................................................................. 7-3
Starting motor disassembly .................................................................................................................... 7-3
Magneto flywheel disassembly .............................................................................................................. 7-3
Checking the magneto flywheel components......................................................................................... 7-6
Starting ring gear and freewheel ............................................................................................................ 7-7
Idler gear with torque limiter ................................................................................................................... 7-7
Freewheel assembly on magneto flywheel ............................................................................................ 7-8
Starting ring gear assembly on magneto flywheel ................................................................................. 7-9
Idler gear with torque limiter assembly................................................................................................... 7-9
Magneto flywheel assembly on engine ................................................................................................ 7-10
Starting motor assembly ...................................................................................................................... 7-11
Flywheel cover assembly ..................................................................................................................... 7-12
General Information
500-4T
1-6
Chapter 8
Intake manifold disassembly .................................................................................................................. 8-3
Tappet cover disassembly ...................................................................................................................... 8-3
Valve gear disassembly ......................................................................................................................... 8-4
Camshaft and equalizers disassembly................................................................................................... 8-6
Head disassembly .................................................................................................................................. 8-7
Valves disassembly ................................................................................................................................ 8-8
Cylinder and piston disassembly............................................................................................................ 8-9
Checking connecting rod small end ..................................................................................................... 8-10
Gudgeon pin diameter .......................................................................................................................... 8-10
Piston ................................................................................................................................................... 8-11
Gas rings .............................................................................................................................................. 8-11
Piston assembly ................................................................................................................................... 8-12
Cylinder gasket selection ..................................................................................................................... 8-13
Compression rings assembly ............................................................................................................... 8-14
Cylinder assembly ................................................................................................................................ 8-14
Head check .......................................................................................................................................... 8-15
Checking the valve sealing surfaces .................................................................................................... 8-15
Checking valve seat wear .................................................................................................................... 8-16
Valves check ........................................................................................................................................ 8-16
Valve-guide play check ........................................................................................................................ 8-17
Valves tightness test ............................................................................................................................ 8-18
Springs, caps, cotters check ................................................................................................................ 8-18
Valves assembly .................................................................................................................................. 8-19
Camshaft check ................................................................................................................................... 8-20
Checking timing system parts .............................................................................................................. 8-21
Head and timing system parts assembly ............................................................................................. 8-21
Checking the revs-timing sensor air gap.............................................................................................. 8-27
Tappets cover assembly....................................................................................................................... 8-28
Intake manifold parts disassembly ....................................................................................................... 8-29
Injector assembly ................................................................................................................................. 8-30
Disassembly of throttle body from manifold ......................................................................................... 8-30
Throttle body assembly to manifold ..................................................................................................... 8-31
Intake manifold assembly to engine..................................................................................................... 8-31
Chapter 9
Engine crankcase opening..................................................................................................................... 9-4
Driving shaft disassembly ...................................................................................................................... 9-5
Removing the countershaft control gear and the oil pump..................................................................... 9-5
Countershaft disassembly ...................................................................................................................... 9-6
Oil pump disassembly ............................................................................................................................ 9-6
Replacing the countershaft bearings...................................................................................................... 9-7
Checking driving shaft components ....................................................................................................... 9-9
Driving shaft alignment check .............................................................................................................. 9-11
Engine half crankcase check ............................................................................................................... 9-12
Main bearing brass check .................................................................................................................... 9-13
Oil pump ............................................................................................................................................... 9-15
Countershaft ......................................................................................................................................... 9-15
Oil pump assembly............................................................................................................................... 9-15
Driving shaft assembly ......................................................................................................................... 9-16
Crankcase coupling.............................................................................................................................. 9-17
Chapter 10
Introduction .......................................................................................................................................... 10-3
Safety measures .................................................................................................................................. 10-5
Troubleshooting.................................................................................................................................... 10-6
General Information
500-4T
1-7
1
Layout of the components .................................................................................................................... 10-7
Layout of the EMS control unit terminals and immobiliser ................................................................... 10-8
EMS system diagram........................................................................................................................... 10-9
Troubleshooting.................................................................................................................................. 10-10
Diagnosis tester link circuit ................................................................................................................. 10-16
Fuel injection indicator circuit ............................................................................................................. 10-17
Self-diagnosis system ........................................................................................................................ 10-18
Fuel supply system ............................................................................................................................ 10-19
General details ................................................................................................................................... 10-19
Pump feeding circuit ........................................................................................................................... 10-20
Circuit control ..................................................................................................................................... 10-21
Hydraulic control and system maintenance ....................................................................................... 10-26
Pressure regulator control .................................................................................................................. 10-27
Pump and fuel filter control ................................................................................................................ 10-29
Fuel filter control ................................................................................................................................. 10-33
Injector circuit control ......................................................................................................................... 10-33
Revolution sensor .............................................................................................................................. 10-36
AT coil ................................................................................................................................................. 10-39
Shielded cap control ........................................................................................................................... 10-41
Ignition timing ..................................................................................................................................... 10-41
Coolant temperature sensor ............................................................................................................... 10-43
Air intake temperature sensor ............................................................................................................ 10-45
Pressure sensor ................................................................................................................................. 10-48
Throttle position sensor ...................................................................................................................... 10-49
Stepper motor .................................................................................................................................... 10-51
Adjusting the minimum carburation.................................................................................................... 10-56
Electric fan control circuit ................................................................................................................... 10-60
Revolution counter control circuit ....................................................................................................... 10-63
Chapter 11
Specifications ....................................................................................................................................... 11-2
General characteristics of the lubrication system................................................................................. 11-3
Diagnostics guide................................................................................................................................. 11-4
Checking the oil pump.......................................................................................................................... 11-6
Oil pump assembly............................................................................................................................... 11-7
Chapter 12
Specifications ....................................................................................................................................... 12-3
System description............................................................................................................................... 12-4
System filling rule ................................................................................................................................. 12-4
Thermostat control ............................................................................................................................... 12-5
Electroventilation control ...................................................................................................................... 12-7
System seal control .............................................................................................................................. 12-8
Chapter 13
Specifications ....................................................................................................................................... 13-2
Controls and diagnostics guide ............................................................................................................ 13-3
General Information
500-4T
1-8
SAFETY PRECAUTIONS
The following symbols are used in the manual to stress the importance of certain pieces of information:
This symbol is used when special precautions are needed in dangerous situations that can cause death or
serious injury to the operator and other exposed people, or result in serious and permanent damage to the
vehicle.
This symbol denotes a potentially hazardous situation that may result in minor personal injury or damage
to the vehicle.
IMPORTANT This term precedes important information or instructions that deserve special attention.
RECOMMENDATIONS ON MAINTENANCE
IMPORTANT Always observe the following precautions when repairing, fitting or removing engine com-
ponents.
All engine inspections and maintenance operations must be carried out while the engine is switched off.
Also ensure that no parts (such as the silencer, the brakes and other components that are subject to
heating) are hot after removing the engine from the vehicle. If necessary, wait for all parts to cool down.
Use suitable equipment to support the engine, taking care to place it on a level and solid working surface.
Do not hold mechanical parts or engine components in the mouth, as some of them are made of toxic
materials.
Avoid starting the engine in closed or poorly ventilated rooms.
Keep away from heat sources. Do not use bright flames.
IMPORTANT Operators servicing or repairing the engine must have all operating instructions to hand
and follow them scrupulously while observing the safety precautions prescribed for each part (e.g. tighten-
ing torques). When two or more operators are required to work on the same engine at the same time, all of
them must observe the rules that ensure their own safety and that of others.
Avoid using lubricants other than those shown in the table.
Always use the special tools that are prescribed in this manual. Never attempt to perform operations that require
the use of special equipment with tools other than those specified in this manual.
Failure to comply with the above instructions can result in serious personal injury, as is the case when an
unsuitable spanner slips off a fastening device, causing the operators hand to strike against the work-
bench.
When clamping fastening devices, always begin with the largest ones. Apply sufficient torque to tighten
each of the large-diameter fasteners, starting with the innermost device, and then proceeding diagonally.
Following the same order, clamp the fastening devices with the prescribed torques, and then check the
torque value for each of the fasteners.
CAUTION
WARNING
WARNING
CAUTION
CAUTION
CAUTION
CAUTION
General Information
500-4T
1-9
1
Never use flammable solvents to clean the parts. Only use antifire detergents and solvents. Failure to
observe this precaution may result in a fire breaking out and in serious or even fatal personal injury.
Before fitting or assembling any components, always lubricate the metallic parts and the gaskets.
Failure to observe the above prescription may result in seizure or early breakage of the parts.
When fitting or assembling parts, be sure to perform the operation properly. Some of the parts can be fitted
upside down or in the opposite direction, and the error will become evident only at the end of the assem-
bly.
Incorrect fitting or assembly can result in irreparable engine damage, seizure or malfunction.
Never reuse gaskets, seeger rings, snap rings, O-rings and cotter pins.
When fitting a new snap ring on a shaft, be sure not to part its ends more than necessary. Once it is in
place, ensure that it is firmly seated in its groove. Remember that snap rings do have a fitting direction, as
the rounded rim of the ring is designed to bear the thrust load (sharp edge on the outside).
Generously lubricate the bearings before fitting them.
IMPORTANT Bearings must rotate freely, smoothly and noiselessly, otherwise they need to be replaced.
Apply distinctive marks to the positions of all connections (pipes, wires, etc.) before removing the compo-
nents. Each part must be clearly identifiable to allow it to be properly reinstalled.
Before fitting new gaskets, thoroughly clean all their surfaces. Take care to remove any fragments of the
old gaskets and any residues of the gasket adhesive.
IMPORTANT Failure to observe this prescription will result in leakage from the engine.
Never reuse oil seals and gaskets. Before fitting oil seals and gaskets, apply a film of grease to the rims of
the oil seals, and a film of grease or adhesive to the gaskets. Unless otherwise directed in this manual,
install the oil seals and the bearings so that their marks or identification numbers are clearly visible when
the parts have been fitted.
IMPORTANT Unless otherwise directed, reassembling operations are to be performed in reverse order to
the disassembly.
Failure to observe the above directions may result in serious and dangerous engine malfunctions such as
seizure and breakage. Should such breakdowns occur during driving, the vehicle may overturn and cause
serious or even fatal personal injury. If you are unsure about your ability to properly perform the opera-
tions described in this manual, please contact your local Aprilia dealer, or Aprilias Customer Care. Never
attempt to perform any of the operations described in this manual if you do not have the specific knowl-
edge and special equipment required, as well as a clean, well-lit and well-ventilated working area.
GENERAL SAFETY RULES
CARBON MONOXIDE
If any operations are to be performed while the engine is running, it is essential that they should be carried out in
the open air or in a well-ventilated room.
CAUTION
WARNING
WARNING
WARNING
CAUTION
General Information
500-4T
1-10
Avoid operating in indoor spaces that are not provided with an exhaust-gas venting system. Exhaust gases
contain carbon monoxide, a toxic gas that may cause fainting or even death.
FUEL
For information on the type of fuel to be used, please refer to the operation and maintenance manual provided with
the vehicle.
Fuel is highly flammable, and in certain conditions can even become explosive. Always handle it with great
care.
Avoid inhaling fuel fumes as they are toxic. Fuel should be handled in a closed environment only if an
adequate air change is ensured.
Never smoke near fuel stores or where fuel fumes may be present. Also avoid sparks, open flames and
whatever may cause the ignition or explosion of the fumes.
Avoid spilling fuel on the skin. Wear protective gloves when pouring it. To avoid ingesting fuel or inhaling
its fumes, use a length of tube without sucking with the mouth.
TRANSMISSION OIL
Use TUTELA ZC 90 oil. Alternatively, use brand name oil complying with or exceeding the API GL-4 specifications.
Insufficient lubrication or the use of unsuitable lubricants may result in irreparable damage due to in-
creased wear and tear of the moving parts.
Do not overtighten the oil drain plug. Excessive tightening may damage the crankcase.
Used oil contains substances that are harmful to the environment. Even small quantities must be disposed
of in compliance with the regulations in force.
To avoid serious skin damage due to prolonged contact with oil, accurately wash the hands after handling
the lubricant.
ENGINE OIL
Use Selenia HI Scooter 4 Tech oil.
Used oil contains substances that are harmful to the environment. Even small quantities must be disposed
of in compliance with the regulations in force.
CAUTION
CAUTION
CAUTION
CAUTION
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
500-4T
chap. 2
2-1
Release 00 2001-12
2
500-4T
2-2
* As an alternative to the recommended oil, it is possible to use high-quality oils with characteristics in compliance with or
superior to the specifications indicated in the table.
** As an alternative to the recommended product, use high-quality grease for rolling bearings, working temperature range 30
C + 140 C (-22F ... +284F), dripping point 150 C 230 C (302F ... 446F), high protection against corrosion, good
resistance to water and oxidation.
TABLE OF LUBRICANTS
USE CHARACTERISTICS PRODUCTS
Rear hub oil
Grease (joints, pins, bearings)
Engine oil
Brake fluid
Coolant
Grease for driven pulley shaft
compensating ring and movable
driven pulley slip seat
Grease for steering bearings, pin
seats and swinging arm
Oil SAE 80W/90 superior to the API
GL3 specifications
Complex calcium soap grease
NLGI 1-2
Synthetic oil SAE 5W/40 superior to
the API SJ specification
Synthetic fluid SEA J1703, NHTSA 116
DOT 4, ISO 4925
Antifreeze with ethylene glycol, CUNA
NC 956-16
Molybdenum bisulphide grease
Grease with lithium soap and zinc
oxide NLG12 of the swinging arm
TUTELA ZC 90
SYSTEM TW 249 AREXONS
SELENIA HI Scooter 4Tech
TUTELA TOP 4
Paraflu 11fe (Diluted)
MONTBLANC
MOLYBDENUM
GREASE (Dis.498345)
TUTELA ZETA 2
Components
After running-in
[1,000 km (625 mi)]
Every 6,000 km
After 12,000 km
Variator belt S
Engine oil filter every 6,000 km(3,750 mi): S
Clutch shoes C C
Valve clearance R then every 18,000 Km (11,250 mi)
Engine oil every 3,000 km (1,875 mi): C/every 6,000 km (3,750 mi): S
Transmission oil S C every 24,000 km (15,000 mi): S
Variator rollers and variator plastic guides 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.
REGULAR SERVICE INTERVALS CHART
OPERATIONS TO BE CARRIED OUT BY THE aprilia Official Dealer (WHICH CAN BE CARRIED OUT EVEN BY THE USER)
Fuel filter every 24,000 km (15,000 mi): C every 48,000 km (30,000 mi): S
Spark plug C S
Carburettor - idling C C
Air cleaner P every 18,000 km (11,250 mi): S
Engine oil every 1,000 km (625 mi): C
Engine oil pressure warning light on every start: C (*)
(*) To check these components see pages 15-16: TABLE OF INSTRUMENTS AND INDICATORS.
500-4T
2-3
2
Tools
46-55 mm (1.81-2.16 in)
wrench
8140300
Flywheel extractor
8140301
Flywheel retainer
8140303
Clutch bell retainer
8140304
Driving shaft lock
wrench
8140305
Countershaft lock
wrench
8140307
Engine support
connector
8140309
Countershaft timing pin
8140609
Oil filter wrench
8140611
15 mm (0.59 in) guide
for water pump gasket
8140610
Fuel pressure manom-
eter fitting
8140612
Fuel pressure manom-
eter
8140181
500-4T
2-4
NOTES
500-4T
chap. 3
3-1
Release 00 2001-12
General information and maintenance
3
General information and
maintenance
500-4T
chap. 3
3-2
Release 00 2001-12
SAFETY PRESCRIPTIONS
If the work to be carried out requires the vehicle
engine to be running, make sure the workshop is well
ventilated and use proper exhausters. Do not run the
engine in closed places. Exhaust fumes are toxic.
Battery electrolyte contains sulphuric acid. Protect the
eyes, clothes and skin. Sulphuric acid is highly corro-
sive, if it comes into contact with eyes or skin, wash
the affected area abundantly with water and seek
immediate medical assistance.
The battery produces hydrogen gas which is poten-
tially explosive. Do not smoke near the battery and
keep naked flames and sparks well clear, especially
when the battery is on charge.
Petrol is highly flammable and can be explosive in
certain conditions. Do not smoke in the work area and
do not introduce naked flames or sparks.
Clean brake shoes, drums and pads in a well venti-
lated place. When using compressed air direct the jet
away from you to avoid inhaling the dust. Although the
brake linings are asbetos-free, inhalation of the
resulting dust is harmful.
MAINTENANCE REGULATIONS
Use only genuine APRILIA spare parts and recom-
mended lubricants. The use of non-original or non-
conforming spare parts can cause damage to the
vehicle.
The only specific tools that can be used are those
expressly designed for this vehicle.
Always fit new gaskets, seal rings and split pins when
reassembling parts.
After disassembly, clean parts with non-flammable
solvent or a solvent with a high flash point. Lubricate
all surfaces before reassembly with the exception of
conical couplings.
After reassembling, check that all the components are
correctly installed and that they work perfectly.
Use only metric tools for disassembly, assembly and
maintenance work. Metric screws, nuts and bolts
cannot be interchanged with BS components. The
vehicle may be damaged if unsuitable tools or nuts,
bolts or screws are used.
When working on the electrical system, ensure electri-
cal components are correctly installed, paying particu-
lar attention to ground and battery connections.
500-4T
chap. 3
3-3
Release 00 2001-12
3
ENGINE
Compression ratio
Bore
10.5 : 1
Type single-cylinder, 4-stroke
Displacement 460 cm
3
(28.06 cu.in)
SPECIFICATIONS (500 CC 4-STROKE, 4-VALVES H
2
0 ENGINE)
92 mm (3.62 in)
Stroke 69 mm (2.71 in)
Timing chain-operated overhead single-shaft flywheel side, inte-
grated phonic wheel, 4-valves and automatic starting valve
lifter
Valves play Intake: 0.20 mm (0.007 in) Exhaust: 0.20 mm (0.007 in)
Valves play adjustment threaded register on equalizers
Idle speed 1450 50 rpm
CO% value 1 1.5 %
Starting system electric starter
Lubrication trochoid pump (inside the crankcase), oil filter and pressure
adjustment by-pass
Lubrication pressure 4 bar (58 Psi)
Minimum allowed
0.4 - 0.6 bar (5.8 - 8.7 Psi)
Fuel system electronic injection with electric fuel pump, throttle body 38
mm (1.49 in) and single injector
Max power (at crankshaft)
Max torque (at crankshaft)
40 Nm (4 Kgm) bei 5500 rpm
Cooling system
Transmission automatic speed variator by means of expanding pulleys, V-
belt, automatic clutch, reduction gear, and transmission
compartment cooling by air forced-circulation.
Ignition type
high efficiency inductive type integrated with injection,
variable spark advance and separated high voltage coil
Spark advance (before T.D.C.) variable controlled by injection power unit
29 kW (39CV) bei 7250 rpm
liquid, by means of motorized pump, 3-way thermostat and
electric fan.
Spark plug CHAMPION RG 6 YC NGK CR7 EKB
Engine-wheel ratio Short: 1/11.988 Long: 1/4.86
Engine oil SAE 5W/40 exceeding API SJ specifications
Quantity ~ 1,7 l (0.4488 Gal)
Hub oil TUTELA ZC 90
Quantity 250 cc (15.25 cu.in)
Cooling system capacity
~ 1.8 l (0.4752 Gal)
500-4T
chap. 3
3-4
Release 00 2001-12
AIR CLEANER
The air cleaner should be cleaned and checked every
6,000 km (3,750 miles), depending on the use condi-
tions. 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
Raise the saddle (UNLOCKING / LOCKING THE
SADDLE)
Remove the safety clip (1).
Remove the pin (2) fastening the piston to the air
cleaner cover.
While removing the pin, hold the saddle to avoid its
fall.
Holding the saddle, remove the six screws (3) fasten-
ing the air cleaner cover to the plastic material under
the saddle.
While lifting the air cleaner cover, avoid removing
the suction sleeve from the filter box.
Carefully lift the air cleaner cover (4)
Remove the air cleaner (5)
CAUTION
CAUTION
SPARK PLUG
Check and replacement
Remove the spark plug when the engine cold. Re-
place the spark plug every 12,000 Km (7,500 miles).
The use of unsuitable control units or spark plugs other
than those specified can seriously damage the engine.
Recommended spark plug: CHAMPION RG 6 YC
NGK CR 7 EKB
Put the vehicle on its central stand.
Open the door on the left side of the vehicle by lever-
ing in the recess in the lower part of the door after
removing the screw.
Disconnect the spark plug high voltage cable cap;
Unscrew the spark plug with the spanner provided;
check the spark plug to see if the insulator is cracked,
the electrodes are worn out or excessively sooty. Also
check the condition of the sealing washer and measure
the electrodes gap with a suitable thickness gauge.
Electrode gap: 0.7 - 0.8 mm (0.027 - 0.031 in)
If necessary adjust the gap by carefully bending the
side electrode. If the spark plug has any of the defects
mentioned above replace it with a plug of the recom-
mended type;
Insert the plug into the hole with the proper inclination,
screw it in fully by hand and then tighten it with the
specially designed spanner.
Tightening torque: 10 Nm (1 Kgm)
Push the spark plug cap all the way down onto the
spark plug and then proceed to the reassembly.
1
2
3
3
4
500-4T
chap. 3
3-5
Release 00 2001-12
3
CLEANING
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 box. Use
compressed air only.
Clean the filtering element (5) by means of a pressu-
rised air jet.
DO NOT OIL THE FILTERING ELEMENT to avoid
damaging the filter and the engine.
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 box.
CAUTION
CAUTION
DANGER
CHECKING THE ENGINE OIL LEVEL AND
TOPPING UP
Carefully read (LUBRICANTS), (MAINTENANCE) and
(TABLE OF LUBRICANTS).
CHECKING
IMPORTANT Position the vehicle on firm and flat
ground.
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 compo-
nents, 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.
DANGER
5
4
4
4
5
1
2
3
4
500-4T
chap. 3
3-6
Release 00 2001-12
IMPORTANT The non-performance of the opera-
tions described above may lead to an incorrect meas-
urement 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;
The difference between MAX and MIN is about:
400 cc (24.4 cu.in)
The level is correct if the oil reaches about the MAX,
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).
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.
CAUTION
DANGER
1
MAX MIN
500-4T
chap. 3
3-7
Release 00 2001-12
3
REPLACING THE OIL AND THE ENGINE OIL
FILTER
ground.
To change the oil, contact an aprilia Official Dealer.
Unscrew and extract the plug/dipstick (1).
Unscrew and remove the oil cartridge filter from the
engine (3).
Used oil contains substances that are very danger-
ous 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 (103.7 cu.in) 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 character-
istics superior to the API ST specification.
Oil filter wrench 8140611
DANGER
DANGER
DANGER
500-4T
chap. 3
3-8
Release 00 2001-12
CHECKING THE TRANSMISSION OIL LEVEL AND
TOPPING UP
ground.
Position the vehicle on the central stand
DANGER
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.
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,
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.
CAUTION
DANGER
1
1
2
500-4T
chap. 3
3-9
Release 00 2001-12
3
REPLACING THE TRANSMISSION OIL
IMPORTANTE Position the vehicle on firm and flat
ground.
DANGER
To replace the oil, contact an aprilia Official Dealer.
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 (15.25
cu.in) 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.
DANGER
3
500-4T
chap. 3
3-10
Release 00 2001-12
COOLANT
MIN level.
Check the coolant level every 2,000 km (1,250 miles)
and after long trips: have the coolant replaced by an
aprilia Official Dealer every two years.
The coolant is noxious: do not swallow it; any con-
tact with the skin or the eyes can cause irritations.
Should the coolant get in contact with your skin or
eyes, rinse with plenty of water and call a doctor. If
it is swallowed, induce vomit, rinse mouth and throat
with plenty of water and call a doctor immediately.
DO NOT DISPOSE OF THE COOLANT IN THE ENVI-
RONMENT
Avoid spilling the coolant on the red-hot parts of the
engine; it may catch fire and produce invisible flames.
In case of maintenance operations, it is advisable to
use latex gloves.
For the coolant change, contact an aprilia Official
Dealer.
The coolant consists of 50% water and 50% anti-
freeze.
Such mixture is ideal for most working temperatures
and ensures a good protection against corrosion.
It is advisable to use the same mixture in the hot
season as well, since losses due to evaporation are
reduced and frequent topping up operations are no
more necessary.
Consequently, mineral salt deposits left in the radiator
by evaporated water are reduced and it is possible to
keep the cooling system in good conditions.
Should the outside temperature be below 0 C (32 F),
check the cooling circuit frequently by increasing the
antifreeze concentration (up to max. 60%), if needed.
Use distilled water for the coolant solution so as to
avoid damaging the engine.
Do not remove the expansion tank plug (1) when the
engine is hot, since the coolant is under pressure
and very hot.
If coming in contact with skin or clothes, it may
cause serious damages and/or burns.
CAUTION
DANGER
DANGER
1
500-4T
chap. 3
3-11
Release 00 2001-12
3
CHECKING AND TOPPING UP
Check the coolant and carry on the topping up
operations only with cold engine.
Stop the engine and wait until it has cooled down.
IMPORTANTE Position the vehicle on a firm and
flat ground.
Open the crash helmet compartment, see (CRASH
HELMET COMPARTMENT).
Make sure that the level of the coolant in the expan-
sion tank (2) is included between MIN and MAX
marks.
MAX = maximum level.
Otherwise:
Remove the front cover, see (REMOVING THE
FRONT COVER).
Loosen the filler cap (1) anticlockwise without remov-
ing it.
Wait a few seconds in order to release any residual
pressure.
IMPORTANT A breather pipe (3) is connected to
the filler cap (1). Neither force, nor disconnect the
breather pipe (3).
Unscrew and remove the filler cap (1).
The coolant is noxious: do not swallow it; any con-
tact with the skin or the eyes can cause irritations.
Do not use your fingers or any other object to check
if there is enough coolant.
When topping up, never exceed the MAX level so
as to prevent the coolant from flowing out of the tank
during the engine working.
Top up with coolant, see (TABLE OF LUBRICANTS),
until reaching approx. the MAX mark.
Put back the filler cap (1).
In case of excessive consumption of coolant and if
the tank remains empty, make sure there are no
leaks in the circuit. To repair it, contact an aprilia
Official Dealer.
Put back the front cover, see (REMOVING THE
FRONT COVER).
DANGER
DANGER
CAUTION
CAUTION
MIN
MAX
2
3
2
1
500-4T
chap. 3
3-12
Release 00 2001-12
CHECKING THE TIMING
Remove the timing check plug, positioned on the
flywheel cover, by means of a TORX wrench.
Remove the transmission cover and the relative
soundproofing material by following the instructions
given in the corresponding chapter.
Remove the head cover by following the instructions
given in the corresponding chapter;
Rotate the driving shaft by means of the driving pulley,
until the mark on the magneto support coincides with
that on the flywheel cover (TDC).
Make sure that the mark on the phonic wheel is
aligned with that on the head.
If the mark is on the opposite side of the head index,
rotate the driving shaft again.
WATER PUMP
If you hear noises or notice that some water is flowing
out of the draining hole of the water pump, this means
that it is necessary to check it, as described in Chap-
ter Flywheel cover. Carry on some preliminary
operations:
Position the vehicle on the central stand on flat ground;
Remove the lower right body side and the right foot-
rest by following the instructions given in the corre-
sponding chapter;
Remove the exhaust silencer, in order to reach the
flywheel cover, by following the instructions given in
the corresponding chapter;
Empty the cooling system, by removing the sleeves
positioned on the water pump cover and the filling
plug positioned on the expansion tank.
Carry on this operation with cold engine.
Open the water pump cover by loosening the six
fastening screws (see figure).
Cooling system capacity: about 1.8 litres (0.47 Gal).
Drain the cooling system partially and check the pump
by following the instructions given in the correspond-
ing manual;
After removing the failure and reassembling all the
components, it is possible to fill and bleed the cooling
system.
IMPORTANT To change the coolant, see the rela-
tive chapter.
CAUTION
500-4T
chap. 3
3-13
Release 00 2001-12
3
CHECKING/ADJUSTING THE VALVE SLACK
To check the valve slack, it is necessary to make the
timing marks coincide as described in the previous
paragraph.
By means of a thickness gauge, make sure the slack
between the valve and the register corresponds to the
shown values. If the values of the valve slack, suction
and exhaust respectively, are different from those
indicated, adjust them by loosening the lock nut and
acting on the register with a screwdriver, as shown in
the figure.
Suction: 0.20 mm (0.007 in) with cold engine
Exhaust: 0.20 mm (0.007 in) with cold engine
CHECKING THE COMPRESSION END PRESSURE
Remove the spark plug cap with cold engine.
Remove the ignition spark plug.
Fit a compression test manometer in the spark plug seat by mounting a 10 mm (0.39 in) spark plug fitting on the
proper tightening torque.
Run the engine by means of the starter and with the throttle body completely open, until the value on the manom-
eter becomes constant. If the pressure is included between 8-11 bar (116-159.5 Psi), remove the tool and reassem-
ble the spark plug.
If the pressure should be lower than the shown value, check the number of revolutions of the engine with which the
test is carried on: if it is lower than 450 rpm, check the starting system; if the number of revolutions is optimal or a
little bit higher, check the timing; if there are no irregularities, proceed as follows:
Make sure that the cylinder base gasket has been correctly selected;
Check the seal of the heating section (piston rings valves)
Tightening torque:
Compression test fitting: 10 Nm
Fuel pressure manometer fitting 8140612
500-4T
chap. 3
3-14
Release 00 2001-12
NOTES
500-4T
chap. 4
4-1
4
Release 00 2001-12
500-4T
chap. 4
4-2
Release 00 2001-12
LUBRICATE WITH OIL APPLY PRODUCT
LUBRICATE WITH GREASE CLEAN WITH CARE ALWAYS REPLACE
WARNING: HANDLE WITH CARE
REFERENCE A B C D E F G H I L M N O P Q
QUANTITY 1 4 1 1 1 7
TORQUE Nm 9092 2326 1720 160175 6575 1113
E
B
A
D
C
F
Ft-lbs 66.367.8 1719.1 12.514.7 118129 4855.3 8.19.5
500-4T
chap. 4
4-3
4
Release 00 2001-12
EXTERNAL TRANSMISSION COVER
Unloose the 5 fixing screws.
Remove the external plastic cover.
TRANSMISSION COVER
Remove the cover and net filter.
IMPORTANT Disassemble the net filter only if it is
to be replaced.
BELT ANTIFLAPPING ROLLER
Check that the roller is in good condition and that it
turns freely.
Unloose the fixing screw with a 13 mm (0.51 in)
wrench
Remove the roller and relevant bearing.
IMPORTANT If the roller does not turn freely,
replace it.
DRIVING PULLEY
Turn the pulley central nut with a 27 mm (1.06 in)
wrench to align the internal holes horizontally, there-
fore allowing for the specific tool fitting.
Driving pulley lock wrench tool 8140305
500-4T
chap. 4
4-4
Release 00 2001-12
First fit the specific tool stop ring on the pulley until the
groove is fully in contact.
Afterwards, insert the tool so that the studs on the ring
fit the holes in the tool.
Tighten, also manually, the two fixing nuts of the tool
Unloose the central nut.
Remove the cup washer and the plain washer.
Remove the fixed driving half pulley.
Remove the washer to bush connection.
Move the belt downwards.
Hold the roller stop plate, remove the mobile driving
half pulley with its bush and rear washer, taking care
not to let the rollers come out.
DRIVEN PULLEY AXLE SUPPORT
To be able to fit the specific tool for removal of the
driven pulley shaft nut, unloose the 2 upper screws of
the driven pulley axle support.
Manually turn the clutch housing as to partially un-
cover one of the holes in the driven pulley axle sup-
port.
Insert the specific tool on the driven pulley axle
support, checking that the tooth fits the hole in the
housing previously uncovered, and that it is resting on
the support.
Tighten the 2 fixing screws.
Unloose the driven pulley shaft nut.
500-4T
chap. 4
4-5
4
Release 00 2001-12
Remove the specific tool
Unloose the 2 remaining fixing screws of the driven
pulley axle support.
Remove the driven pulley axle support and the
washer.
Remove the spacer below.
CLUTCH HOUSING
Remove the clutch housing.
Check that the clutch housing shows no signs of wear
or damage.
Measure the clutch housing I.D.
Standard value: 160.2 mm (6.30 in)
Max value: 160.5 mm (6.32 in)
IMPORTANT Check that the measured eccentricity
is max 0.2 mm
DRIVEN PULLEY ASSEMBLY
Remove the driven pulley assembly and relevant belt.
500-4T
chap. 4
4-6
Release 00 2001-12
CLUTCH DISASSEMBLY
Remove the clutch and driven pulley by means of the
specific tool;
Prepare the tool with the pins screwed in the E
position on the internal side;
Assemble the driven pulley assembly on the tool and
insert the pins in the ventilation holes;
Bring the rear stop screw in contact with the fixed
driven pulley, as shown in the figure.
Put the tool in a vice firmly. Do not overtighten the
rear screw to avoid buckling the tool.
Remove the fixing ring nut with the specific spanner of
55 mm (2.16 in).
Unloose the tool screw and dismount the driven
pulley, clutch, spring with sheath assembly.
Ring tool 55 mm (2.16 in) 8140300
PINS STOP COLLAR
Remove the collar by means of 2 screwdrivers.
Remove the 4 guide pins.
Remove the mobile driven half pulley.
CAUTION
500-4T
chap. 4
4-7
4
Release 00 2001-12
FIXED DRIVEN HALF PULLEY BEARINGS
Check that the bush shows no signs of wear or
damage; if necessary, replace the fixed driven half
pulley.
Remove the stop ring with the pliers.
Remove the ball bearing by inserting the specific tool
in the roller bearing.
IMPORTANT Hold the pulley to avoid damaging the
thread.
IMPORTANT If the bearings are overhauled with
the driven pulley unit assembled, make sure to sup-
port the unit with bell.
Remove the roller bearing by means of the specific
tool, supporting the fixed half pulley with the bell.
FIXED DRIVEN HALF PULLEY
Check the belt contact surface out for signs of wear.
Measure the pulley bush O.D.
Minimum allowed diameter: 49.96 mm (1.966 in)
Standard diameter: 49.965 mm (1.967 in)
500-4T
chap. 4
4-8
Release 00 2001-12
MOBILE DRIVEN HALF PULLEY
Check the belt contact surface out for signs of wear.
Remove the 2 internal and external O rings.
Measure the mobile half pulley bush I.D.
Maximum allowed diameter: 50.08 mm (1.971 in)
FIXED DRIVEN HALF PULLEY BEARINGS
ASSEMBLY
Fit a new roller bearing using the specific tool.
IMPORTANT Put the bearing and the incorporated
oil seal on the outside.
Hold the half pulley to avoid damaging the thread.
Operate with tool, with the driven pulley unit com-
pletely assembled.
Fit a new ball bearing by means of the specific tool.
Fit the stop snap ring.
DRIVEN PULLEY ASSEMBLY
Fit the new oil seals
Fit the new O rings
IMPORTANT The O rings come supplied in 2 sizes.
The larger one is installed on the work end radius, half
pulley base.
Fit the half pulley on the bush taking care not to
damage the upper O ring.
500-4T
chap. 4
4-9
4
Release 00 2001-12
Check the pins and collar condition, and then reas-
semble them.
Lubricate the driven pulley assembly with a hook-bill
greaser. Apply 10 gr. of TUTELA MRM2 grease
through one of the holes inside the bush until grease
comes out of the opposite hole.
SPRING
Measure the free length of the mobile driven half
pulley spring.
Standard length: 125.5 mm (4.94 in)
Limit allowed after use: 120 mm (4.72 in)
Check the thickness of the clutch weights friction
material.
Minimum allowed thickness: 1 mm (0.04 in)
The weights must show no traces of grease. If neces-
sary, check the seals of the driven pulley assembly.
IMPORTANT During the running in phase the
weights must have a central contact surface and must
not be different one from the other to avoid the clutch
jerking
Do not open the weights with the tools to avoid the
return springs load variation.
DRIVING BELT
Check that the driving belt is not damaged.
Check the belt width.
Minimum width: 25 mm (0.98 in)
Standard width: 26.2 mm (1.03 in)
500-4T
chap. 4
4-10
Release 00 2001-12
CLUTCH REASSEMBLY
Prepare the specific tool as already done during the
disassembly phase;
Preassemble the driven pulley unit with the driving
belt according to its direction of rotation.
Insert the driven pulley unit, spring with sheath and
clutch in the tool.
Compress the spring and insert the clutch on the
driven pulley bush.
IMPORTANT Take care not to damage the sheath
or the bush threaded end.
Screw the ring nut manually and then tighten it with
the specific wrench to the prescribed torque.
Tightening torque:
Clutch ring nut: 65 - 75 Nm (48 - 55.3 Ft-lbs)
55 mm wrench tool (2.16 in) 020444Y009
To facilitate the reassembly operation, turn the mobile
driven pulley and fit the belt on the smaller diameter.
MOBILE DRIVING HALF PULLEY
Check that the internal bushes shown in the figure
show no signs of anomalous wear. Measure the I.D.
Maximum allowed diameter: 30.12 mm (1.185 in)
Do not lubricate or clean the bushes.
Measure the O.D. of the pulley sliding bush shown in
the figure.
CAUTION
Check that the rollers are not damaged or worn.
Check that the shoes of the roller stop plate are not
worn.
Check the rollers housing and belt contact surfaces
condition on both half pulleys.
500-4T
chap. 4
4-11
4
Release 00 2001-12
ROLLERS HOUSING ASSEMBLY
Fit the spacer with the internal beveling facing the
insertion side.
Put the rollers in the half pulley as shown in the figure.
The covered side must rest on the internal thrust side
of the roller housing.
Assemble the half pulley with the rollers stop plate and
the sliding shoes.
Fit the half pulley on the driving shaft.
Fit the spacer bush.
500-4T
chap. 4
4-12
Release 00 2001-12
DRIVEN PULLEY UNIT ASSEMBLY
Fit the driven pulley unit and relevant belt.
HOUSING ASSEMBLY
Fit the housing and the spacer.
DRIVEN PULLEY AXLE SUPPORT AS-
SEMBLY
Make sure the 2 centering dowels are properly fitted in
the crankcase.
DRIVEN PULLEY AXLE SUPPORT BEAR-
INGS DISASSEMBLY
Check that the bearing turns freely. Replace the
bearing if necessary.
Remove the snap ring.
500-4T
chap. 4
4-13
4
Release 00 2001-12
Hold the driven pulley axle support by means of the
specific tool.
Remove the bearing by means of the specific tool.
IMPORTANT If the bearing decay has caused the
external race to lose strength, replace the driven
pulley axle support.
DRIVEN PULLEY AXLE SUPPORT BEAR-
ING ASSEMBLY
Heat the driven pulley axle support with the thermal
gun.
Fit the bearing on the specific tool. Grease it to pre-
vent it from coming out.
Refit the new bearing by means of the specific tool.
Refit the snap ring.
Fit the driven pulley axle support and tighten the two
lower screws.
500-4T
chap. 4
4-14
Release 00 2001-12
Fit the washer and the nut.
Insert the specific tool tooth in the hole on the hous-
ing.
Tighten the 2 screws making sure that the catch is in
contact with the driven pulley axle support.
Tighten the housing fixing nut to the prescribed
torque.
Tightening torque:
Driven pulley shaft nut: 90 - 92 Nm
(66.3 - 67.8 Ft-lbs)
Remove the specific tool
Insert the 2 remaining fixing screws of the driven
pulley axle support and cross-tighten the 4 screws to
the prescribed torque.
Tightening torque:
Driven pulley axle support fixing
screws: 23 - 26 Nm (17 - 19.1 Ft-lbs)
500-4T
chap. 4
4-15
4
Release 00 2001-12
FIXED DRIVING HALF PULLEY ASSEM-
BLY
Fit the spacer.
Fit the fixed driving half pulley making sure it is in
contact with the spacer and with the sliding bush of
the mobile driving pulley.
Fit the plain washer and the cup washer as shown in
the figure.
Insert the nut in its previous position (nut side in
contact with the cup washer).
500-4T
chap. 4
4-16
Release 00 2001-12
Turn the pulley central nut aligning its holes horizon-
tally to be able to install the specific tool.
IMPORTANT Make sure that the lock wrench fits
easily in the pulley and engine crankcase.
Fully insert the stop ring from the rear side.
Fit the tool by drawing the nuts near manually and
making sure it is on a flat surface.
Tighten the driving pulley fixing nut to the prescribed
torque.
Remove the specific tool.
Tightening torque:
Driving pulley nut: 157 - 172 Nm (115.8 - 126.8 Ft-
lbs)
BELT ANTIFLAPPING ROLLER ASSEM-
BLY
Fit the belt antiflapping roller with the belt containment
edge to the engine crankcase side.
Tighten the central screw to the prescribed torque.
IMPORTANT Turn the driven pulley and/or the
driving pulley until the belt is properly tensioned.
Tightening torque:
Antiflapping roller screw: 16.7 - 19.6 Nm (12.3 -
14.4 Ft-lbs)
TRANSMISSION COVER
IMPORTANT Check the transmission air filter metal
net condition. If damaged, replace it. If necessary,
clean it by blowing compressed air.
Fit the transmission cover.
Fully tighten the 7 fixing screws to the prescribed
torque.
Tightening torque:
Transmission cover screws: 10.8 - 12.8 Nm (7.9 -
9.4 Ft-lbs)
500-4T
chap. 4
4-17
4
Release 00 2001-12
EXTERNAL TRANSMISSION COVER
IMPORTANT Make sure that the air intake and the
three air outlets are completely free.
Fit the plastic external transmission cover;
Tighten the 5 fixing screws to the prescribed torque.
500-4T
chap. 4
4-18
Release 00 2001-12
NOTES
Final reduction
500-4T
chap. 5
5-1
5
Release 00 2001-12
Final reduction
500-4T
chap. 5
5-2
Release 00 2001-12
Final reduction
QUANTITY 6 1
TORQUE Nm 2427 1517
A
B
Ft-lbs 17.720 11.112.5
500-4T
chap. 5
5-3
5
Release 00 2001-12
Final reduction
REDUCTION UNIT COVER
Drain the rear hub oil through the oil drain plug situ-
ated under the engine.
Remove the 7 fixing screws.
Remove the hub cover and relevant gasket.
WHEEL AXLE AND INTERMEDIATE
SHAFT DISASSEMBLY
Remove the intermediate shaft.
Remove the wheel axle and relevant gear.
HUB HOUSING BEARINGS
Check the bearings condition (wear, clearance and
noise).
In case of fault, proceed as described below.
Use the following parts to disassemble the wheel axle
bearing situated on the engine crankcase.
Remove the bearing on the intermediate shaft engine
crankcase by means of the provided extractor.
Final reduction
500-4T
chap. 5
5-4
Release 00 2001-12
DISASSEMBLY OF WHEEL AXLE BEAR-
ING FROM COVER
Remove the snap ring on the hub cover external side.
Support the hub cover using the studs kit.
Remove the oil seal by means of a screwdriver.
DISASSEMBLY OF INTERMEDIATE
SHAFT BEARING FROM COVER
Support the hub cover using the studs kit.
500-4T
chap. 5
5-5
5
Release 00 2001-12
Final reduction
DRIVEN PULLEY SHAFT DISASSEMBLY
To disassemble the driven pulley shaft and relevant
bearing and oil seal, remove the transmission cover
and clutch assembly, as described in Chapter Auto-
matic transmission.
Remove the driven pulley shaft from the bearing.
Remove the oil seal by acting with a screwdriver from
the hub gears box inside.
Remove the snap ring shown in the figure.
Remove the driven pulley shaft bearing from the
engine crankcase by means of the specific tool.
DRIVEN PULLEY SHAFT BEARING AS-
SEMBLY
Heat the crankcase with the thermal gun.
Fully insert the driven pulley shaft bearing by means
of the specific tool.
IMPORTANT Position the bearing with balls facing
the hub side (valid for bearings with a plastic cage) .
Final reduction
500-4T
chap. 5
5-6
Release 00 2001-12
Heat the idler gear bearing housing.
Fit the intermediate shaft bearing by means of the
specific tool.
the hub side (valid for bearings with a plastic cage).
Heat the wheel axle bearing housing located on the
crankcase.
Fit the wheel axle bearing in the crankcase lower
housing by means of the specific tool.
15 mm (0.59 in) guide for water pump gasket 8140610
Fit the driven pulley shaft bearing snap ring.
IMPORTANT Respect the position shown in the
figure.
Fit the pulley shaft oil seal, transmission side.
500-4T
chap. 5
5-7
5
Release 00 2001-12
Final reduction
HUB COVER CHECK
Check that the coupling
Check the bearings I.D.
If necessary, replace the hub cover.
BEARINGS ASSEMBLY ON HUB COVER
Heat the bearing housings on the cover by means of
the thermal gun.
Support the hub cover with the studs kit.
Fit the intermediate shaft bearing on the cover by
means of the specific tool.
Heat the wheel axle bearing housing from the cover
outside.
Fully insert the wheel axle bearing on the cover by
Final reduction
500-4T
chap. 5
5-8
Release 00 2001-12
Refit the ring.
Support the hub cover with the studs kit.
Fit the wheel axle oil seal with the seal lip facing the
cover inside.
Position the oil seal aligned with the crankcase.
HUB GEARS ASSEMBLY
Position the 3 shafts as shown in the figure.
IMPORTANT Pay attention to the spacer between
the wheel axle support on the crankcase and the gear.
CHECKING HUB SHAFTS
Check that the 3 shafts show no signs of wear or
deformation on the toothed surfaces, bearing and oil
seal I.D.
If necessary, replace the damaged parts.
Intermediate shaft bearing
diameter: A = 20
- 0.01
mm
Wheel axle bearing
diameter: B = 30
- 0.010
mm
C = 15
- 0.01
mm
Driven pulley shaft
bearing diameter: D = 17
- 0.01
mm
E = 20
- 0.01
mm
F = 25
- 0.01
mm
- 0.02
- 0.023
- 0.02
- 0.02
- 0.02
- 0.02
(0.78
- 0.0003
in)
(1.18
- 0.0003
in)
(0.6
- 0.0003
in)
- 0.0007
- 0.0007
- 0.0009
(0.67
- 0.0003
in)
(0.78
- 0.0003
in)
(0.98
- 0.0003
in)
- 0.0007
- 0.0007
- 0.0007
500-4T
chap. 5
5-9
5
Release 00 2001-12
Final reduction
HUB COVER ASSEMBLY
Check the centering dowels correct position.
Fit a new gasket.
Fit the cover taking care to correctly position the
breather pipe.
Insert the 7 fixing screws and tighten them to the
prescribed torque, paying attention to the position of
the breather pipe hose clamp and to the shorter screw
shown in the figure.
Refill with oil up to the Max level (see Chapter Gen-
eral information and maintenance).
Tightening torque:
Hub cover screws: 24 - 27 Nm (17.7 - 20 Ft-lbs)
Recommended oil: TUTELA ZC 90
Amount: ~ 250 cc (15.25 cu.in)
500-4T
chap. 5
5-10
Release 00 2001-12
Final reduction
NOTES
Flywheel cover
500-4T
chap. 6
6-1
6
Release 00 2001-12
Flywheel cover
500-4T
chap. 6
6-2
Release 00 2001-12
Flywheel cover
QUANTITY 6 14 1 1 6 3 1 1 2 2 1
TORQUE Nm 34 1113 45 2430 34 810 1.52.5 1216 1.52 34 3.54.5
B
D
E
M
H
I
G
L
F
C
Ft-lbs 2.22.9 8.19.5 2.93.7 17.722.1 2.22.9 5.97.4 0.81.8 8.811.8 0.81.5 2.22.9 2.63.3
500-4T
chap. 6
6-3
6
Release 00 2001-12
Flywheel cover
Disassemble the flywheel cover by removing the 2
cooling system sleeves.
Remove the 4 clamps shown in the figure.
IMPORTANT The clamps must be replaced. Re-
move the clamps by opening them with a screwdriver
or by cutting them. Take care not to damage the
plastic unions.
Remove the cooling tube bracket from the manifold
fixing.
THERMOSTAT COVER DISASSEMBLY
Unloose the 3 fixing screws and remove the thermo-
stat cover.
Remove the thermostat.
Flywheel cover
500-4T
chap. 6
6-4
Release 00 2001-12
WATER PUMP COVER DISASSEMBLY
Unloose the 6 fixing screws and remove the water
pump cover and relevant O ring.
IMPORTANT If necessary, disassemble the pump
cover complete with thermostat and sleeves.
FLYWHEEL COVER DISASSEMBLY
Drain the engine oil by removing the drain plug.
Collect the oil in a suitable container.
Remove the prefilter.
Remove the oil filter by means of a suitable wrench.
500-4T
chap. 6
6-5
6
Release 00 2001-12
Flywheel cover
Remove the flywheel cover and relevant gasket, and
the stand stop bracket.
IMPORTANT Screws come supplied in 3 different
lengths plus 2 for the stand stop. Take note of their
positions.
Avoid any interferences between the stator and
rotor while removing the cover.
Do not drop the bypass valve and relevant spring.
CAUTION
CAUTION
FLYWHEEL COVER COMPONENTS DIS-
ASSEMBLY
Remove the bypass and relevant spring.
Remove the seal gasket.
STATOR
Remove the 2 fixing screws and the harness guide
bracket.
Unloose the 3 fixing screws and remove the stator
complete with the harness.
Flywheel cover
500-4T
chap. 6
6-6
Release 00 2001-12
Unloose the 2 fixing screws and remove the support
of the reed valve with gate.
Remove the blow-by reed valve and relevant seal
gasket.
Unloose the fixing screw and remove the gas outlet
pipe and relevant O-ring.
Remove the water pump rotor by unscrewing it from
its shaft.
IMPORTANT The threading goes in the r.h. direc-
tion. Prevent the shaft from turning by inserting a 12
mm wrench in the drive.
500-4T
chap. 6
6-7
6
Release 00 2001-12
Flywheel cover
Remove the shaft and relevant stop washer.
Remove the O-ring.
Remove the ceramic ring and relevant gasket.
Remove the O ring for the pump shaft lubrication by
means of a properly shaped tool.
Flywheel cover
500-4T
chap. 6
6-8
Release 00 2001-12
Remove the engine oil dipstick and the plug of the
valve gear timing reference hole
Remove the oil minimum pressure sensor.
CHECKING THE COVER CASE COMPO-
NENTS - COVER CASE
Check that the case coupling surface shows no signs of
wear or deformation.
Check that the bypass valve seat, torque limiter support
and water pump shaft support show no signs of wear.
Bypass housing hole diameter: 13.9 mm (0.54 in)
Diameter of starting gear shaft support: 12 mm (0.47 in)
Diameter of pump shaft support: 8 mm (0.31 in)
Check that the coupling surface and the oil filter pipe
show no signs of wear or deformation.
STATOR
Check the stator and relevant harness condition.
500-4T
chap. 6
6-9
6
Release 00 2001-12
Flywheel cover
Check the 3 phases continuity.
IMPORTANT The indicated values have been
measured at ambient temperature. Higher values will
be measured with stator at operative temperative.
Approximate resistance of each phase: 0.2 - 1
Check the earth insulation of each phase.
If troubles are noticed, remember to carefully check
the harness as this is realized with 2 types of cables:
stiff cables near the stator, and soft cables near the
connector.
Check that the winding does not interfere with the
fixing screw heads.
BYPASS PISTON AND SPRING
Check that the bypass outside diameter shows no
signs of damage or scoring.
Outside diameter: 10.5 mm (0.41 in)
Check the spring free length.
Limit length after use: 64.0 mm (2.51 in)
Flywheel cover
500-4T
chap. 6
6-10
Release 00 2001-12
WATER PUMP SHAFT
Check that the water pump shaft shows no signs of
wear on the part in contact with the case, in the oil
seal working area, and on the drive.
Check that the ceramic seal working areas are not
scored or worn.
WATER PUMP ROTOR
Check that the rotor is not deformed or cracked.
Check that the plastic rotor is perfectly integral with
the metal part.
CHECKING THE WATER PUMP COVER
Check that the water pump cover is not deformed or
cracked.
Check the O ring condition.
Check that the coupling surfaces of the thermostat
cover and the cooling bypass lock slot are not worn or
cracked.
500-4T
chap. 6
6-11
6
Release 00 2001-12
Flywheel cover
REED VALVE
Check that the blow-by circuit reed closes correctly.
ASSEMBLING THE FLYWHEEL COVER
COMPONENTS
Make sure that all the components are well clean
before reassembling them.
Carefully check all the cover case lubrication ducts, in
particular:
The 3 bypass channels.
Oil supply duct to water pump shaft support.
Pump draining duct.
Flywheel cover
500-4T
chap. 6
6-12
Release 00 2001-12
Oil pressure sensor supply duct.
Oil vapors decantation chamber exhaust.
Refit the blowby reed valve with a new seal gasket.
Refit the support with gate and tighten the screws to
Tightening torque:
Support screws: 0.3 - 0.4 Nm (0.22 - 0.40 Ft-lbs)
Fit a new pump shaft O ring by means of the specific
tool.
Fit the oil minimum pressure sensor and tighten it to
the presrcibed torque.
Tightening torque:
Oil minimum pressure sensor: 4 - 5 Nm (2.9 - 3.7 Ft-
lbs)
15 mm (0.59 in) guide for water pump gasket 8140610
500-4T
chap. 6
6-13
6
Release 00 2001-12
Flywheel cover
Preassemble the ceramic seal and relevant gasket.
IMPORTANT The bevel must face the gasket. Take
care not to dirty the ceramic ring with oil or grease in
order not to compromise the seal.
Fit the ceramic seal on the flywheel cover.
IMPORTANT Assemble the seal by hand to avoid
damaging it.
Fit the water pump shaft after lubricating the seat on
the flywheel cover.
Fit the mechanical seal on the shaft aligning it with the
rotor stop surface.
IMPORTANT The depth of the final fitting depends
on the rotor.
Screw the rotor and lock it to the prescribed torque.
Tightening torque:
Water pump rotor: 4 - 5 Nm (2.9 - 3.7 Ft-lbs)
STATOR ASSEMBLY
Fit the stator and relevant harness. Tighten the 3
screws to the prescribed torque.
IMPORTANT Fit the harness rubber seal in the
relevant seat on the crankcase.
Tightening torque:
Stator fixing screws: 8 - 10 Nm (5.9 - 7.4 Ft-lbs)
Flywheel cover
500-4T
chap. 6
6-14
Release 00 2001-12
Fit the harness guide and tighten the 2 screws to the
prescribed torque.
Tightening torque:
Harness guide fixing screws: 3 - 4 Nm (2.2 - 2.9 Ft-
lbs)
Temporarily fit the valve timing control hole plug and
the engine oil dipstick.
Fit the blow-by recovery duct with a new O ring.
Tighten the screw to the prescribed torque.
Tightening torque:
Blow-by recovery duct fixing screws: 3 - 4 Nm (2.2
- 2.9 Ft-lbs)
Fit the spring and the bypass piston on the flywheel
cover.
IMPORTANT Lubricate the bypass valve.
FLYWHEEL COVER ASSEMBLY ON THE
ENGINE
Fit a new gasket on the engine crankcase
Make sure the 3 centering dowels are there.
500-4T
chap. 6
6-15
6
Release 00 2001-12
Flywheel cover
Turn the driving shaft as to align the countershaft drive
with a reference mark on the crankcase (see figure).
Align the water pump shaft with the same reference
on the cover.
IMPORTANT This is useful especially in case of
interventions with the water pump cover assembled.
Fit the flywheel cover on the engine. Avoid any interfer-
ences between the stator and the rotor.
Failure to observe the above procedure may cause
the ceramic magnetos breaking.
Refit the stand stop.
Tighten the 14 fixing screws of the cover to the pre-
scribed torque.
IMPORTANT The screws come supplied in three
different lengths: the 5 shorter screws are located in the
position shown in the figure, and the longer screw is
situated under the engine oil filler plug.
Tightening torque:
Flywheel cover fixing screws: 11 - 13 Nm (8.1 - 9.5 Ft-lbs)
CAUTION
WATER PUMP COVER ASSEMBLY
Carefully fit a new O ring preventing it from coming
into contact with grease or oil.
Failure to observe this procedure may cause the O
ring buckling.
Refit the water pump cover. Tighten the 6 fixing
Tightening torque:
Flywheel cover fixing screws: 3 - 4 Nm (2.2 - 2.9 Ft-
lbs)
CAUTION
Flywheel cover
500-4T
chap. 6
6-16
Release 00 2001-12
THERMOSTAT COVER ASSEMBLY
Refit the thermostat.
IMPORTANT Check the thermostat as described in
Chapter Cooling. The thermostat seal provides for the
sealing to the outside and for the internal sealing with
the thermostat closed.
Assemble the thermostat cover. Tighten the 3 fixing
Tightening torque:
Thermostat cover fixing screws: 1.5 - 2 Nm (0.8 - 1.5
Ft-lbs)
Fit a new oil filter, lubricate the seal, tighten to the
prescribed torque.
Tightening torque:
Oil filter: 12 - 16 Nm (8.8 - 11.8 Ft-lbs)
Guide for water pump gasket 8140611
Assemble the two cooling system sleeves using 4 new
clamps.
Fit the supporting bracket. Tighten the intake manifold
fixing screw to the prescribed torque.
IMPORTANT Lock the clamps by means of suitable
pliers. Take care not to dent the tubes. Arrange for
proper tightening making sure it is not insufficient.
Tightening torque:
Intake manifold screws: 11 - 13 Nm (8.1 - 9.5 Ft-lbs)
500-4T
chap. 6
6-17
6
Release 00 2001-12
Flywheel cover
Reassemble the prefilter and the engine oil drain plug.
Tighten it to the prescribed torque.
Refill the engine with oil of the recommended type.
Tightening torque:
Oil drain plug: 24 - 30 Nm (17.7 - 22.1 Ft-lbs)
Recommended oil: Selenia HI Scooter 4 Tech 5W/40
500-4T
chap. 6
6-18
Release 00 2001-12
Flywheel cover
NOTES
500-4T
chap. 7
7-1
7
Release 00 2001-12
500-4T
chap. 7
7-2
Release 00 2001-12
QUANTITY 6 3 2 1
TORQUE Nm 1315 34 1113 115125
C
B
D
A
Ft-lbs 9.511 2.22.9 8.19.5 84.892.2
500-4T
chap. 7
7-3
7
Release 00 2001-12
FLYWHEEL COVER DISASSEMBLY
Remove the cooling system sleeves and the flywheel
cover as described in Chapter Flywheel Cover.
STARTING MOTOR DISASSEMBLY
IMPORTANT This operation can also be performed
with the flywheel cover assembled.
Unloose the two fixing screws and remove the engine
earth cable.
Remove the starting motor assembly.
MAGNETO FLYWHEEL DISASSEMBLY
IMPORTANT To disassemble the magneto fly-
wheel, first remove the chain guide shoe stop plate
Unloose the 3 fixing screws, remove the chain guide
shoe stop plate and the starting ring gear.
Align the two holes on the flywheel with the housing
on the crankcase to be able to fit the specific tool.
500-4T
chap. 7
7-4
Release 00 2001-12
Screw the flywheel lock tool bush on the threading
intended for the extractor.
Fully insert the specific tool as shown in the figure
making sure that the pins perfectly fit in the holes
previously aligned, and that it is almost in contact with
the flywheel.
Unloose the magneto flywheel fixing nut.
Remove the specific tool and the fixing nut.
Remove the washer.
500-4T
chap. 7
7-5
7
Release 00 2001-12
Remove the extractor.
Remove the nut and the magneto flywheel complete
with the starting ring gear.
Remove the key from the driving shaft.
Refit the nut as to slightly uncover the shaft and to
free the space where the washer was.
This operation is necessary as the flywheel is
firmly locked, hence the cone detachment could
cause the rotor to fall with consequent breaking
of the magnetos.
Withdraw the starting ring gear from the free wheel by
turning it clockwise.
CAUTION
Fit the extractor.
Use a 27 mm (1.06 in) wrench and a 19 mm (0.74 in)
bush to unlock the magneto flywheel.
Flywheel extractor tool 8140301
500-4T
chap. 7
7-6
Release 00 2001-12
Remove the freewheel from the magneto flywheel by
unloosing the 6 fixing screws.
IMPORTANT To be able to disassemble the free-
wheel, it is recommendable to first unloose the 6 fixing
screws with the flywheel still assembled on the driving
shaft.
The freewheel is precisely coupled with the flywheel; if
disassembly becomes difficult, use 2 screws as
holding points and as extractors.
Remove the idler gear provided with a torque limiter.
CHECKING THE MAGNETO FLYWHEEL
COMPONENTS
Check the magnetos condition.
Check that the magneto supporting cage shows no
signs of deformation or breaking.
Check that the flywheel riveting is not loose.
500-4T
chap. 7
7-7
7
Release 00 2001-12
STARTING RING GEAR AND FREEWHEEL
Check that the freewheel rollers and the starting ring
gear hub surface show no signs of anomalous wear or
dents.
Check the hub outside diameter.
Hub outside diameter: 45.665
+ 0.008
mm (1.8
+ 0.0002
in)
Check the starting ring gear brass I.D.
Check that the toothing shows no signs of wear.
IMPORTANT If the hub is damaged, replace the
starting ring gear and the free wheel. If only the brass
is damaged, it is sufficient to replace the starting ring
gear assembly. In this case also check the diameter
and surface of the driving shaft support. Replace the
driving shaft if necessary.
Brass I.D.: 27
+ 0.020
mm (1.06
+ 0.0007
in)
IDLER GEAR WITH TORQUE LIMITER
Check the toothing out for signs of wear.
Check the diameter of the two bearings.
Gear bearing diameter: 12
- 0
mm (0.47
- 0
in)
Also check the bearings diameter on the flywheel
cover and engine crankcase.
Flywheel cover bearing diameter: 12
+ 0.034
mm
(0.47
- 0.0013
in)
Engine crankcase bearing diameter: 12
+ 0.034
mm
(0.47
- 0.0013
in)
+ 0.005
+ 0.041
- 0.011
- 0.016
- 0.016
+ 0.0003
+ 0.0016
- 0.0004
- 0.0006
- 0.0006
500-4T
chap. 7
7-8
Release 00 2001-12
IMPORTANT The torque limiter is provided with 4
gears that function as clutch driving plates. The driven
plates are made with 4 Belleville washers with a
splined shape; this assembly allows to transmit
torques below 10 kgm.
In case of wrong starting operations, any
counterstrokes likely to damage the engine structure
are avoided by the limiter, with consequent reversal of
rotation of the driving shaft.The limiter assembly
cannot be overhauled. If defects are found on the
toothed disks, it is recommendable to replace the
assembly.
FREEWHEEL ASSEMBLY ON MAGNETO
FLYWHEEL
Check the freewheel contact surfaces condition.
Carefully clean the freewheel to remove any trace of
LOCTITE.
Degrease the freewheel holes threading and the fixing
screws.
Apply LOCTITE 242 to the screw ends.
Assemble the freewheel on the magneto flywheel
making sure that the ground part is in contact with the
flywheel, that is the wheel snap ring must be visible.
Cross-tighten the 6 fixing screws to the prescribed
torque.
Tightening torque:
Free wheel fixing screws: 13 - 15 Nm (9.5 - 11 Ft-
lbs)
Oil the freewheel rollers.
500-4T
chap. 7
7-9
7
Release 00 2001-12
STARTING RING GEAR ASSEMBLY ON
MAGNETO FLYWHEEL
Oil the inner brass and the starting ring gear hub
surface.
Fit the starting ring gear on the flywheel and turn it
clockwise at the same time.
IDLER GEAR WITH TORQUE LIMITER
ASSEMBLY
Grease the gear housing on the engine crankcase.
Fit the idler gear with the torque limiter.
500-4T
chap. 7
7-10
Release 00 2001-12
MAGNETO FLYWHEEL ASSEMBLY ON
ENGINE
Insert the key on the driving shaft
Assemble the magneto flywheel making sure to
correctly insert the key. At the same time, mesh the
torque limiter gear with the starting ring gear.
Insert the washer and the nut on the driving shaft.
Fully screw the flywheel lock tool guide bush, and
unscrew it by 1/4 of a turn.
IMPORTANT Failure to observe the above proce-
dure will cause the guide locking on the flywheel.
Flywheel lock tool 8140303
Align the 2 magneto flywheel holes with the housing
on the crankcase intended for the specific tool.
500-4T
chap. 7
7-11
7
Release 00 2001-12
Insert the specific tool making sure to perfectly fit the
pins.
Flywheel lock tool 8140303
Tighten the flywheel lock nut to the prescribed torque.
Tightening torque:
Flywheel lock nut: 115 - 120 Nm (84.8 - 88.5 Ft-lbs)
Assemble the chain guide shoe stop plate and tighten
the 3 screws to the prescribed torque.
Tightening torque:
Chain guide shoe plate fixing screws: 3 - 4 Nm
(2.2 - 2.9 Ft-lbs)
STARTING MOTOR ASSEMBLY
Check the O ring condition and oil it.
Fit the starting motor.
Fix the earth cable.
Tightening torque:
Starting motor fixing screws: 11 - 13 Nm (8.1 - 9.5
Ft-lbs)
500-4T
chap. 7
7-12
Release 00 2001-12
FLYWHEEL COVER ASSEMBLY
Grease the housing of the idler gear with torque
limiter, located on the flywheel cover.
Align the water pump drive with a reference mark and
fit the flywheel cover as described in Chapter Fly-
wheel cover.
500-4T
chap. 8
8-1
8
Release 00 2001-12
500-4T
chap. 8
8-2
Release 00 2001-12
REFERENCE A B C D E F G H I L M N O P
QUANTITY 3 1 2 1 4 4 4 4 1 1 2 3 3 1
TORQUE Nm 46 3035 1113 56 3842 4446 1113 68 1014 78.5 34 1113 1113 34
O
P
N
I
D
C
G
E
M
B
L
H
F
A
Ft-lbs 2.94.4 22.125.8 8.19.5 3.74.4 2830.9 32.433.9 8.19.5 4.45.9 7.410.3 5.16.2 2.22.9 8.19.5 8.19.5 2.22.9
500-4T
chap. 8
8-3
8
Release 00 2001-12
Remove the external transmission cover and the
transmission cover complete with net filter, as de-
scribed in Chapter Automatic Transmission.
Remove the flywheel cover, the flywheel and the idler
gear with torque limiter as described in Chapter
Flywheel Cover, and in Chapter Flywheel and Starting
system.
INTAKE MANIFOLD DISASSEMBLY
Unloose the 3 fixing screws, one of which locks the
supporting bracket of the cooling bypass tube previ-
ously removed.
Remove the intake manifold assembly.
TAPPET COVER DISASSEMBLY
Unloose the 4 fixing screws and remove the tappet
cover with relevant gasket.
500-4T
chap. 8
8-4
Release 00 2001-12
VALVE GEAR DISASSEMBLY
Turn the engine until the intake valves close, that is
the reference mark on the phonic wheel must be
moved upwards as shown in the figure.
Remove the central screw and the valve lifter weight
stop bell by means of the specific tool.
Remove the return spring and the valve lifter weight
with the relevant stop washer.
IMPORTANT Make sure the spring and the washer
do not drop in the engine through the chain compart-
ment.
Align the reference marks on the phonic wheel and on
the head.
500-4T
chap. 8
8-5
8
Release 00 2001-12
Remove the internal hexagonal-head screw and the
counterweight, as shown in the figure.
Unloose the tightener central screw.
Unloose the 2 fixing screws and remove the tightener
and relevant gasket.
Remove the timing chain gear from the camshaft
Remove the timing chain gear.
Remove the phonic wheel.
500-4T
chap. 8
8-6
Release 00 2001-12
Remove the engine revs-stroke sensor and relevant O
ring by unloosing the two fixing screws.
IMPORTANT Check this component as described
in Chapter Injection.
CAMSHAFT AND EQUALIZERS DISAS-
SEMBLY
Unloose the 3 fixing screws and remove the camshaft
stop bracket.
IMPORTANT Removing the fixing screws may turn
out to be difficult. Make sure not to damage the
internal hexagon. If necessary, first unglue the thread-
ing.
Remove the camshaft.
Remove the pins and equalizers by acting through the
holes, transmission side.
500-4T
chap. 8
8-7
8
Release 00 2001-12
HEAD DISASSEMBLY
Remove the spark plug.
Remove the cooling system outlet union and rel-
evant O ring by unloosing the 2 screws.
Remove the 2 fixing nuts on the head, exhaust and
intake side.
Remove the coolant temperature sensor.
IMPORTANT The sensor controls both the injection
and the analogue instrument on the dashboard.
Check this component according to the procedure
described in Chapter Injection.
Remove the 3 side fixings shown in the figure.
500-4T
chap. 8
8-8
Release 00 2001-12
IMPORTANT If necessary, the head can be re-
moved together with the camshaft, equalizer pins and
fixing bracket.
Unloose the 4 head to cylinder fixing nuts in 2-3 times
in a crossed sequence.
Remove the head, the 2 centering dowels, the gasket
and the lower chain guide shoe.
IMPORTANT Avoid removing the dowels if they are
forced in a housing.
Collect the thermal unit coolant in a suitable
container when the head is disassembled.
Put the valves away in such a way as to easily
recognize their original position on the head
(flywheel side and transmission side).
Remove the oil seals by means of the specific tool.
VALVES DISASSEMBLY
Disassemble the cotters, caps, springs and valves by
means of the specific tool provided with an adapter.
Valves disassembly tool
Adapter
CAUTION
Remove the spring supports.
IMPORTANT Blow compressed air in the housings
to facilitate the spring supports removal.
CAUTION
500-4T
chap. 8
8-9
8
Release 00 2001-12
CYLINDER AND PISTON DISASSEMBLY
Remove the timing chain.
Unloose the fixing screw and remove the spacer and
the tightener pad.
IMPORTANT It is recommendable to mark the
chain in order to refit it in the original direction of
rotation.
Remove the cylinder and relevant gasket, and the
centering dowel.
IMPORTANT The second centering is made
possible thanks to a pin fitted in the cylinder.
To avoid damaging the piston, hold it while disas-
sembling the cylinder.
CAUTION
Remove the 2 stop rings of the piston gudgeon pin
through the specific openings.
Remove the gudgeon pin and the piston.
IMPORTANT Close the cylinder housing opening
on the crankcase with paper or a cloth, to prevent one
of the two stop rings from falling inside.
Remove the compression rings and the scraper ring.
Mark the compression rings assembly position to
avoid inverting them if they are re-used.
IMPORTANT Take care not to damage the rings
during the disassembly procedure.
CAUTION
500-4T
chap. 8
8-10
Release 00 2001-12
CHECKING CONNECTING ROD SMALL
END
Measure the connecting rod small end diameter by
means of a reamer.
Standard diameter: 22
+ 0.025
mm (0.86
+ 0.0009
in)
IMPORTANT If the connecting rod small end
diameter exceeds the standard value, if it shows signs
of wear or overheating, replace the driving shaft as
described in Chapter Crankcase and Driving Shaft.
+ 0.015
GUDGEON PIN DIAMETER
Check the gudgeon pin outside diameter by means of
a micrometer.
0
mm (0.86
0
in)
Calculate the connecting rod small end - gudgeon pin
allowance.
Standard clearance: 0.015 - 0.029 mm (0.0006 -
0.0011 in)
Measure the piston support diameter.
+ 0.006
mm (0.86
+ 0.0002
in)
Calculate the gudgeon pin - piston allowance.
Standard clearance: 0.001 - 0.010 mm (0.00003 -
0.0003 in)
IMPORTANT The gudgeon pin housings are
provided with 2 lubrication ducts. Therefore the
diameter must be measured according to the piston
axis.
- 0.004
+ 0.001
Measure the piston outside diameter orthogonally to
the gudgeon pin axis.
Perform the measurement as shown in the figure:
A = 43.2 mm (1.7 in)
Piston diameter: 92 mm (3.6 in)
+ 0.0006
- 0.0001
+ 0.0003
500-4T
chap. 8
8-11
8
Release 00 2001-12
Measure the cylinder inside diameter by means of a
reamer in the directions shown in the figure and at
three different heights.
+ 0.018
mm (3.62
+ 0.0007
in)
Make sure that the lining is not exfoliated.
Check that the head coupling surface shows no signs
of wear or deformation.
Maximum allowed runout: 0.05 mm (0.002 in)
The pistons and cylinders are classified according to
their diameter. The coupling is made under the same
conditions (A-A, B-B, C-C, D-D).
+ 0.010
PISTON
Carefully clean the gas ring slots.
With suitable feelers, measure the allowance between
the gas rings and piston slots as shown in the figure.
If values higher than those indicated in the table are
measured, replace the piston.
IMPORTANT Measure the play by inserting the
feeler gauge blade on the 2nd gas ring side.
GAS RINGS
Insert alternately the 3 gas rings in the cylinder, in the
area of its original diameter. Insert the rings orthogo-
nally to the cylinder axis using the piston to such
purpose.
Measure the gas rings opening (see figure) by means
of a feeler gauge.
If values higher than those prescribed are measured,
replace the rings.
C
D
A
B
+ 0.0003
1st compression ring A=0.9
- 0.005
mm (0.035
- 0.0002
in) C=0.9
+ 0.03
mm (0.035
+ 0.001
in)
B=1.5
- 0.005
mm (0.8
- 0.0002
in) D=2
+ 0,05
mm (1.5
+ 0.002
in)
2nd compression ring 12
- 0.005
mm (8.8
- 0.0002
in) 1.25
+ 0.03
mm (0.05
+ 0.0011
in)
Scraper ring 2.5
- 0.005
mm (1.8
- 0.0002
in) 2.5
+ 0.03
mm (1.8
+ 0.0011
in)
- 0.030
- 0.03
+ 0.01
- 0.02
- 0.0011 + 0.0003
- 0.0011 - 0.0007
500-4T
chap. 8
8-12
Release 00 2001-12
IMPORTANT Before replacing the rings, make sure that the instructions regarding the ring-slot and piston-
cylinder allowances have been followed. However, the bedding of new rings on secondhand cylinders may differ
from the standard bedding conditions.
Standard opening Max value
Compression ring 0.15 - 0.35 mm (0.006 - 0.013 in) 0.5 mm

(0.019 in)
Scraper ring 0.25 - 0.50 mm (0.009 - 0.019 in) 0.65 mm (0.025 in)
Scraper ring 0.25 - 0.50 mm (0.009 - 0.019 in) 0.65 mm (0.025 in)
PISTON ASSEMBLY
Assemble the piston and the gudgeon pin on the
connecting rod. Position the piston with the arrow
facing the exhaust.
Insert the gudgeon pin stop ring in the specific tool,
with the opening in the position marked on the tool.
S = left
D = right
Fit the stop ring by means of the punch.
500-4T
chap. 8
8-13
8
Release 00 2001-12
Assemble the gudgeon pin lock using the pin, as
Tool for gudgeon pin lock assembly
IMPORTANT The stop rings assembly tool must be
used by hand.
Using a hammer may damage the locks housing.
CAUTION
CYLINDER GASKET SELECTION
Temporarily assemble the cylinder on the piston
without its gasket.
Fit a dial gauge on the specific tool using the short
connection, as shown in the figure.
Set the dial gauge to zero with a preload of a few
millimeters by means of a surface plate,
Fix the dial gauge.
Check that the feeler pin is sliding perfectly.
Assemble the tool on the cylinder without changing
the dial gauge position.
Lock the tool using the head fixing original nuts.
Move the driving shaft up to the TDC (dial gauge
reversal of rotation point).
Measure the deviation from the zero setting value.
Consult the table below to find the thickness of the
cylinder gasket to be used for reassembly. Identifying
the right cylinder gasket thickness will allow to main-
tain the right compression ratio.
Remove the specific tool and the cylinder.
IMPORTANT If the deviation (projection or recess)
is near to the change of class, repeat the measure-
ment on the opposite side. Reassemble the tool by
inverting its position.
Measured recess / projection Gasket thickness
- 0.185 - 0.10 mm (- 0.007 - 0.003 in) 0.4 0.05 mm (0.015 0.002 in)
- 0.10 + 0.10 mm (- 0.003 + 0.003 in) 0.6 0.05 mm (0.023 0.002 in)
+ 0.10 + 0.185 mm (+ 0.003 + 0.007 in) 0.8 0.05 mm (0.031 0.002 in)
500-4T
chap. 8
8-14
Release 00 2001-12
COMPRESSION RINGS ASSEMBLY
Put the scraper ring spring on the piston.
Assemble the scraper ring by keeping the opening
opposite to the spring joint and with the top writing
facing the piston crown. The chamfer must always be
positioned towards the piston crown.
Assemble the second ring with the identification letter
or the top writing facing the piston crown. The step
must always face the opposite side of the piston
crown.
Assemble the first compression ring respecting the
direction of its housing.
We suggest a suitable tool be used to fit the rings.
IMPORTANT The point of contact of the 2 sealing
rings with the cylinder has a conical shape allowing for
a better bedding.
Offset the ring openings by 120 as shown in the
figure.
Lubricate the parts with engine oil.
The engine requires the 1st compression ring with L
section.
CYLINDER ASSEMBLY
Fit the cylinder gasket having the selected thickness.
Assemble the cylinder by means of the fork and the
ring clamp, as shown in the figure.
IMPORTANT Before assembling the cylinder,
carefully clean the lubrication duct by blowing in air,
and oil the cylinder liner. Make sure that the two
dowels are there.
500-4T
chap. 8
8-15
8
Release 00 2001-12
HEAD CHECK
Check that the head surface shows no signs of wear
or deformations by means of a ground bar and a
feeler gauge.
Maximum allowed runout: 0.1 mm (0.003 in)
In case of troubles, replace the head.
Check the sealing surface of the intake and exhaust
manifold.
Check that the camshaft and equalizer pin supports
show no signs of wear.
Check that the head cover surface shows no signs of
wear.
Check that the coolant sealing pad shows no signs of
oxidation.
If worn, also check the corresponding component
when the head is replaced.
Standard diameter mm (in)
A 13
+ 0,018
(0.51
+ 0.0007
)
B 20
+ 0,021
(0.78
+ 0.0008
)
C 42
+ 0,025
(1.65
+ 0.0009
)
0
0
0
CHECKING THE VALVE SEALING SUR-
FACES
Visually check the valves sealing surfaces.
Do not change the valves assembly position (RH-
LH).
If the valve sealing surface is discontinued in one or
more points, or if it is bent, replace the valve.
CAUTION
500-4T
chap. 8
8-16
Release 00 2001-12
CHECKING VALVE SEAT WEAR
Remove any carbon deposits from the valve seat.
Check the width of the imprint on the valve seat V by
means of Prussian blue.
Measure the inside diameter of each valve guide.
Perform the measurement according to the thrust
direction of the equalizer at three different heights.
Standard value: 1

- 1.3 mm (0.03

- 0.05 in)
Limit allowed: 1.6 mm (0.06 in)
If the imprint width on the valve seat exceeds the
recommended limits, regrind the seats with the 45
cutter and then recondition them.
In case of excessive wear or damages, replace the
head.
VALVES CHECK
Check the valve stem diameter in the three points
Standard diameter
Intake: 4.987 - 4.972 mm (0.196 - 0.195 in)
Exhaust: 4.975 - 4.960 mm (0.1958 - 0.1952 in)
Minimum allowed diameter
Intake: 4.96 mm (0.195 in)
Exhaust: 4.945 mm (0.194 in)
Calculate the valve - valve guide clearance.
Check the valve stem deviation by putting it on a V
surface. Measure the deformation by means of a dial
gauge.
500-4T
chap. 8
8-17
8
Release 00 2001-12
Check the valve head concentricity by placing a dial
gauge at right angle to the valve head and turning the
valve head on a V surface.
VALVE-GUIDE PLAY CHECK
After measuring the valve guide and valve stem
diameters, check the guide-and-stem play.
Intake:
Standard play: 0.013 - 0.04 mm (0.0005 - 0.001 in)
Exhaust:
Check that the surface in contact with the register
articulated terminal shows no signs of wear.
Valve standard length
Intake: 95.0 0.3 mm (3.74 0.01 in)
Exhaust: 94.2 0.3 mm (3.70 0.01 in)
500-4T
chap. 8
8-18
Release 00 2001-12
If no troubles have been found after performing the
above check, it is possible to use the same valves. To
obtain a perfect sealing, it is recommendable to grind
the valve seats by using a fine grain lapping com-
pound. While grinding the valve seats, keep the head
with the valve axis horizontally to prevent the lapping
compound residuals from entering the valve guide
stem coupling. (see figure).
To avoid scoring the contact surface do not insist
on turning the valve when the lapping compound
is finished. Carefully wash the head and the
valves with a product suitable for the type of
lapping compound used.
IMPORTANT Do not change the valves assembly
position.
CAUTION
VALVES TIGHTNESS TEST
Fit the valves in the head.
Test alternately the intake and the exhaust valves.
The test must be performed after filling the manifold
with petrol. Check that the head is well in contact with
the screw caps by keeping them pressed with the
fingers.
SPRINGS, CAPS, COTTERS CHECK
Check that the upper spring caps and the cotters
show no signs of anomalous wear.
500-4T
chap. 8
8-19
8
Release 00 2001-12
Measure the spring free length.
Limit allowed after use: 43.7 mm (1.72 in)
VALVES ASSEMBLY
Put the valve spring caps on the head.
Assemble, alternately, the 4 oil seals by means of the
specific tool.
Lubricate the oil seals and the valve guides.
Assemble the valves, springs, and caps. Compress
the springs and insert the cotters in their seats by
means of the specific tool provided with adapter.
IMPORTANT Do not change the valves assembly
position. Assemble the valve springs according to the
reference colour, cotters side (large coil spring).
500-4T
chap. 8
8-20
Release 00 2001-12
Check that the automatic valve lifter cam, the stop
roller and the rubber stop on the containment bell
show no signs of wear.
Check that the valve lifter spring is not overstressed.
Replace any worn parts.
Check the cams heights by means of a gauge.
Standard height
Intake: 33.988 mm (1.33 in)
Exhaust: 33.417 mm (1.31 in)
Limits allowed
Intake: 33.740 mm (1.32 in)
Exhaust: 33.170 mm (1.30 in)
Standard end play: 0 - 0.22 mm (0 - 0.008 in)
Maximum allowed end play: 0.3 mm (0.011 in)
Replace the defective parts in case of anomalous
wear or values different from those prescribed.
Check that the groove shown in the figure, seat of the
stop plate, shows no signs of wear.
CAMSHAFT CHECK
Check that the camshaft supports show no signs of
anomalous wear or scoring.
Measure the camshaft supports by means of a
micrometer.
Standard diameter
Support A : 42
- 0.060
mm (1.65
- 0.002
in)
Support B : 20
- 0.020
mm (0.78
- 0.0007
in)
Minimum allowed diameter
Support A : 41.910 mm (1.65 in)
Support B : 19.940 mm (0.78 in)
- 0.085
- 0.041
Check that the equalizer pins show no signs of scoring
or wear.
- 0.010
mm (0.51
- 0.0003
in)
Check the inside diameter of each equalizer.
+ 0.026
mm (0.51
- 0.0003
in)
Check that the cam sliding shoe and the registers
articulated plate show no signs of wear.
Replace the component if necessary.
- 0.018
+ 0.015
- 0.003
- 0.0016
- 0.0007
+ 0.0005
500-4T
chap. 8
8-21
8
Release 00 2001-12
CHECKING TIMING SYSTEM PARTS
Check that the guide shoe and the tension pad are not
excessively worn.
Check that the camshaft control timing gear and
driving shaft pinion assembly show no signs of wear.
Replace the pads, or the whole assembly if the chain,
or ring gear, are worn.
IMPORTANT If the chain has damaged the pinion,
replace the driving shaft as described in Chapter
Crankcase and Driving Shaft.
Remove the central screw with the washer and the
tightener spring. Make sure the unidirectional mecha-
nism shows no signs of wear.
Check the tightener spring condition.
If necessary, replace the whole assembly.
HEAD AND TIMING SYSTEM PARTS AS-
SEMBLY
Fit the chain guide shoe
Fit the two centering dowels between the head and
the cylinder.
Assemble the head gasket.
IMPORTANT The figure shows the assembly
position of the two centering dowels between the head
and the cylinder. The gasket assembly position is
forced by the dowels.
The head gasket is made of steel and has a standard
thickness.
500-4T
chap. 8
8-22
Release 00 2001-12
Lock the 3 side fixings shown in the figure to the
prescribed torque.
Tightening torque:
Head fixing screws: 10 - 12 Nm (7.4 - 8.8 Ft-lbs)
Assemble the coolant temperature sensor with the
washer and tighten to the prescribed torque.
Failure to observe the recommended tightening
torques may cause damage to the sensor.
Tightening torque:
Coolant temperature sensor: 10 - 12 Nm (7.4 - 8.8
Ft-lbs)
Make sure the head lubrication duct is well clean. If
necessary, clean with a jet of compressed air.
Assemble the head.
Oil the studs and the 4 fixing nuts.
Screw the 4 fixing nuts in a crossed manner to the
pre-torque value of 20 Nm (0.78 Ft-lbs).
Afterwards, cross-tighten them to the prescribed
torque.
Tightening torque:
Head fixing nuts: 42 - 45 Nm (30.9 - 33.2 Ft-lbs)
Lock the fixing nuts, exhaust and intake side, to the
prescribed torque.
Tightening torque:
Head fixing nuts, exhaust/intake: 10 - 12 Nm (7.4 -
8.8 Ft-lbs)
CAUTION
500-4T
chap. 8
8-23
8
Release 00 2001-12
Assemble the pins and equalizers from the flywheel
side.
Lubricate the 2 equalizers through the upper holes.
Clean the camshaft by means of compressed air, in
particular the groove, seat of the stop plate.
Lubricate the 2 supports.
Assemble the camshaft in the head, with cams oppo-
site to the equalizers.
Clean the cooling system outlet union with jets of
compressed air.
Check the O ring sealing.
Assemble the union with the larger diameter facing
the transmission side. Tighten the 2 fixing screws to
Assemble the spark plug and tighten it to the pre-
scribed torque.
Tightening torque:
Cooling system outlet union fixing screws: 3 - 4 Nm
(2.2 - 2.9 Ft-lbs)
Spark plug: 12 - 14 Nm (8.8 - 10.3 Ft-lbs)
Fit the timing control chain on the driving shaft re-
specting the original direction of rotation.
Assemble the tension pad and relevant spacer, tighten
the fixing screw to the prescribed torque. Smear
thread locking compound LOCTITE medium type 242.
Tightening torque:
Tension pad fixing screw: 10 - 14 Nm (7.4 - 10.3
Ft-lbs)
500-4T
chap. 8
8-24
Release 00 2001-12
Assemble the phonic wheel on the camshaft, keeping
the timing reference mark visible.
Assemble the engine revs-timing sensor with a new O
ring as shown in the figure. Tighten the 2 fixing screws
to the prescribed torque.
IMPORTANT Check this component as described
in Chapter Injection.
Tightening torque:
Timing revs sensor fixing screws: 3 - 4 Nm (2.2 -
2.9 Ft-lbs)
Remove any LOCTITE residuals from the camshaft
stop bracket fixing screws by means of a brush.
Apply LOCTITE 242 to the fixing screws after cleaning
them from any residual of thread locking compound.
Assemble the camshaft stop bracket with countersinks
well visible. Tighten the 3 fixing screws to the pre-
scribed torque taking care not to damage the internal
hexagon.
Tightening torque:
Camshaft stop bracket fixing screws: 4 - 6 Nm
(2.9 - 4.4 Ft-lbs)
Check that the phonic wheel timing pin opening and
toothing show no signs of deformation or dents.
500-4T
chap. 8
8-25
8
Release 00 2001-12
Align the phonic wheel and head reference marks as
Keep the chain slightly tensioned, turn the driving
shaft by means of the driving pulley until the reference
mark on the magneto support and the one on the
flywheel cover are aligned.
Assemble the idler gear with torque limiter, flywheel
and flywheel cover as described in Chapter Flywheel
and Starting System and in Chapter Flywheel Cover.
IMPORTANT To facilitate the assembly operation,
assemble the flywheel cover without the cooling
system sleeves.
Remove the timing control plug by means of a TORX
wrench.
500-4T
chap. 8
8-26
Release 00 2001-12
Remove the central screw
Install the valve lifter counterweight paying attention to
correctly position the stop ring.
Oil the decompressor counterweight control pin.
Assemble the return spring. Load it by about 3/4 of a
turn.
Fit the chain on the camshaft timing gear
Fit the timing gear on the camshaft, aligning the
reference marks.
IMPORTANT During the timing check, keep the
chain tensioned by pressing from the tightener com-
partment side.
Assemble the counterweight
Center it by means of the bell fixing screws.
Tighten the counterweight fixing screw to the pre-
scribed torque. Apply LOCTITE 242.
Tightening torque:
Counterweight fixing screw: 7 - 8.5 Nm (5.1 - 6.2
Ft-lbs)
500-4T
chap. 8
8-27
8
Release 00 2001-12
Position the engine with the valve play adjustment
timing reference marks aligned with the head.
Check the valve-equalizer play by means of a thick-
ness gauge.
Prescribed play: intake 0.20 mm (0.007 in)
(cold engine)
exhaust 0.20 mm (0.007 in)
(cold engine)
If different values are measured, adjust by unloosing
the check nut and by acting on the register with a tool
as shown in the figure.
Turn the engine. Move the reference marks to the
upper position as shown in the figure (intake end).
Fit the valve lifter counterweight stop bell.
Tighten the fixing screw to the prescribed torque,
using LOCTITE 242.
IMPORTANT The bell timing is given by the head
of the counterweight fixing screw
Check that the decompression counterweight is free
and the returning action of the spring.
Tightening torque:
Valve lifter counterweight stop bell
fixing screws: 30 - 35 Nm (22.1 - 25.8 Ft-lbs)
CHECKING THE REVS-TIMING SENSOR
AIR GAP
Align one tooth of the phonic wheel with the revs-
timing sensor.
Check the air gap by means of a feeler.
Standard air gap: from 0.20 mm (0.007 in) to 0.70 mm
(0.027 in)
Perform the check in 3-4 points.
500-4T
chap. 8
8-28
Release 00 2001-12
Set the tightener cursor in the rest position by keeping
pressed the stop dog.
Assemble the tightener on the cylinder with a new
gasket.
Tighten the two fixing screw to the prescribed torque.
Tightening torque:
Tightener fixing screws: 11 - 13 Nm (8.1 - 9.5 Ft-
lbs)
Fit the spring with the central screw and washer.
Tighten the central screw to the prescribed torque.
Tightening torque:
Tightener screw: 5 - 6 Nm (3.7 - 4.4 Ft-lbs)
TAPPETS COVER ASSEMBLY
Check the gasket condition.
Assemble the tappets cover and tighten the 4 screws
to the prescribed torque.
IMPORTANT Make sure the gasket is in the right
position.
Tightening torque:
Tappets cover fixing screws: 11 - 13 Nm (8.1 - 9.5
Ft-lbs)
500-4T
chap. 8
8-29
8
Release 00 2001-12
Assemble the transmission cover complete with net
filter, and the external transmission cover according to
the procedure described in Chapter Automatic Trans-
mission.
Assemble the cooling system sleeves using new
clamps. Follow the procedure described in Chapter
Flywheel cover.
INTAKE MANIFOLD PARTS DISASSEM-
BLY
Injector disassembly
IMPORTANT Remove the injector from the mani-
fold only if it is faulty. Check the injector operation with
the injector assembled on the manifold (see Chapter
Injection)
To remove the injector, first remove the T joint central
fixing screw supporting the injector.
Remove the manifold injector.
IMPORTANT The abovementioned procedure is
necessary to be able to wash or replace the manifold.
500-4T
chap. 8
8-30
Release 00 2001-12
INJECTOR ASSEMBLY
Check that the components are well clean
Assemble new O rings and lubricate them with
grease.
Apply thread locking compound LOCTITE 242 to the
fixing screw and tighten it to the prescribed torque.
Tightening torque:
Injector support fixing screw: 3 - 4 Nm (2.2 - 2.9
Ft-lbs)
DISASSEMBLY OF THROTTLE BODY
FROM MANIFOLD
IMPORTANT The throttle body assembly includes
various components that come supplied all together.
Check the components as described in Chapter
Injection.
The throttle body is supplied already calibrated.
Absolutely avoid tampering with the valve beat
register as the register has been suitably sealed.
For any troubles related with the slow running,
see Chapter Injection.
IMPORTANT The throttle body can be removed
with the manifold disassembled or assembled.
Remove the 3 fixing screws shown in the figure.
Check the condition of the sealing lips on the coupling
surfaces between manifold-throttle body and manifold-
head.
The penetration of air may compromise the injec-
tion system correct operation, in particular with
engine running at idle speed.
CAUTION
CAUTION
500-4T
chap. 8
8-31
8
Release 00 2001-12
Check that the throttle valve and relevant duct are well
clean.
Also check that the additional air duct operated by the
Stepper-motor is well clean.
THROTTLE BODY ASSEMBLY TO MANI-
FOLD
Perform the disassembly operations in the reverse
order. Tighten the 3 fixing screws to the prescribed
torque.
Tightening torque:
Throttle body fixing screws: 11 - 13 Nm (8.1 - 9.5
Ft-lbs)
INTAKE MANIFOLD ASSEMBLY TO EN-
GINE
Assemble the intake manifold on the engine
Insert the 3 fixing screws and tighten them to the
prescribed torque. One of the screws is provided with
a clamp supporting the cooling system sleeve.
Tightening torque:
Intake manifold fixing screws: 11 - 13 Nm (8.1 - 9.5
Ft-lbs)
500-4T
chap. 8
8-32
Release 00 2001-12
NOTES
500-4T
chap. 9
9-1
9
Release 00 2001-12
500-4T
chap. 9
9-2
Release 00 2001-12
QUANTITY 1 2 2 14 4
TORQUE Nm 2529 56 810 1113 1012
D
B C
A
E
Ft-lbs 18.421.4 3.74.4 5.97.4 8.19.5 7.48.8
500-4T
chap. 9
9-3
9
Release 00 2001-12
Remove the external transmission cover, the trans-
mission cover complete with net filter and the driving
pulley assembly as described in Chapter Automatic
transmission.
Remove the flywheel cover with the cooling system
sleeves as described in chapter Flywheel cover.
Remove the magneto flywheel with the starting control
as described in Chapter Flywheel and Starting Sys-
tem.
Remove the thermal assembly (cylinder, head, piston)
as described in Chapter Thermal Assembly.
500-4T
chap. 9
9-4
Release 00 2001-12
ENGINE CRANKCASE OPENING
Remove the engine mount setscrew on the half
crankcase, flywheel side.
Remove the crankcase 14 coupling screws.
IMPORTANT The fixing screws come in 3 different
lengths. Take note of their right position.
Check the driving shaft end play before you open the
engine crankcase.
Use for this procedure a plate (e.g. specific tool) and a
stand with dial gauge, specific tool.
Crankcase separating plate tool
Dial gauge and stand tool
Limit allowed after use: 0.60 mm (0.023 in)
If the play exceeds the indicated values, it means that
the supporting surfaces of the crankcase driving shaft
are worn.
To correctly measure the play, completely restore the
play in both directions by acting between the crank-
case and the driving shaft.
500-4T
chap. 9
9-5
9
Release 00 2001-12
Separate the crankcase by keeping assembled the
driving shaft on the half crankcase, flywheel side.
Remove the coupling gasket.
IMPORTANT The support bush can be maintained
in the half crankcase, flywheel side.
DRIVING SHAFT DISASSEMBLY
Before disassembling the driving shaft, check the
timing with the countershaft. Perform this check by
turning the driving shaft until the two holes on the
driving shaft are aligned with the hole on the
countershaft control gear.
This position also allows for the driving shaft removal.
Remove the driving shaft with the shim washer,
flywheel side.
While separating the crankcase and removing the
driving shaft, take care that the shaft threaded
ends do not interfere with the main bearing brass.
Failure to observe this recommendation may
cause damage to the main bearing brass.
REMOVING THE COUNTERSHAFT CON-
TROL GEAR AND THE OIL PUMP
Remove the control gear by acting on the 4 fixing
screws.
IMPORTANT The head screws are blocked with
LOCTITE thread locking compound. Take care not to
damage the control hexagon. To achieve the best
results, it is recommendable to use a hexagonal
socket wrench.
Remove the gear only when necessary.
CAUTION
500-4T
chap. 9
9-6
Release 00 2001-12
COUNTERSHAFT DISASSEMBLY
Position the specific tool as shown in the figure.
Countershaft lock wrench tool 8140307
Remove the fixing nut and relevant washer.
Remove the specific tool and withdraw the
countershaft complete with control gear.
OIL PUMP DISASSEMBLY
Remove the oil pump compartment gate by unscrew-
ing the 2 fixing screws and relevant washers.
500-4T
chap. 9
9-7
9
Release 00 2001-12
Remove the oil pump complete with gear by unloosing
the 2 fixing screws through the slots situated on the
gear itself.
Remove the gasket.
REPLACING THE COUNTERSHAFT
BEARINGS
Check the bearings out for anomalous noise or play.
Replace if necessary.
Half crankcase flywheel side
Remove the snap ring situated on the inner side.
Overturn the half crankcase.
Remove the bearing from the half crankcase flywheel
side by means of the specific tool and a hammer.
500-4T
chap. 9
9-8
Release 00 2001-12
Remove the bearing from the half crankcase transmis-
sion side by means of the specific tool.
Before assembling a new bearing, heat the half
crankcase flywheel side by means of the specific tool.
Put the half crankcase on a wooden base.
Fit a new bearing on the specific tool after having
greased the fitting slot.
Assemble the new bearing on the half crankcase by
IMPORTANT If a bearing with a plastic cage is
used, position the balls so that they face the crank-
case inner side.
Assemble the snap ring.
500-4T
chap. 9
9-9
9
Release 00 2001-12
Before assembling the new bearing on the crankcase
transmission side, heat the housing by means of the
specific tool.
Fit a new bearing on the specific tool after having
greased the fitting slot.
Assemble a new bearing on the engine crankcase by
IMPORTANT If a bearing with a plastic cage is
used, position the balls so that they face the crank-
case inner side.
CHECKING DRIVING SHAFT COMPO-
NENTS
Check the connecting rod end play.
500-4T
chap. 9
9-10
Release 00 2001-12
Check the connecting rod diametral play.
Standard play: 0.046 - 0.076 mm(0.001 - 0.002 in)
Check that the end play containment surfaces show
no signs of scoring. Measure the driving shaft width
by means of a gauge, as shown in the figure.
IMPORTANT Check that the measuring is not
distorted by the driving shaft support radius.
Standard dimensions: 63.6 - 63.45 mm (2.503 -
2.498 in)
The driving shaft can be reused when the width
conforms to the standard values and the sur-
faces show no signs of scoring.
Shim
Check the total dimension of the driving shaft-
shoulder-gear assembly.
Standard thickness: 71.804 - 72.000 mm (2.826 -
2.834 in)
Make sure that the shim is not scored.
IMPORTANT If reused, maintain the original
assembly position.
Support for driving shaft control tool
If the driving shaft-crankcase end play exceeds the
standard values but the driving shaft is not damaged,
the trouble is certainly due to the wear or wrong
machining of the engine crankcase.
CAUTION
500-4T
chap. 9
9-11
9
Release 00 2001-12
Check the diameter of both the driving shaft supports
according to the axis and planes shown in the figure.
The half shafts are subdivided in Class 1 and Class 2,
as shown in the table below.
Standard
diameter mm (in)
Class 1
Class 2
40.010 - 40.016 (1.5751 - 1.5754)
40.016 - 40.022 (1.5754 - 1.5756)
DRIVING SHAFT ALIGNMENT CHECK
Assemble the driving shaft on the support. Measure
the disalignment in the 4 points shown in the figure.
Support for driving shaft control tool
Max. out-of-line allowed: A = 0.15 mm (0.006 in)
B = 0.01 mm (0.0004 in)
C = 0.01 mm (0.0004 in)
D = 0.10 mm (0.004 in)
Check the condition of the driving shaft cone, tange
seat, oil seal housing, and the threading.
If necessary, replace the driving shaft.
IMPORTANT The main bearings cannot be ground.
The connecting rod cannot be replaced. To check the
connecting rod small end, see Chapter Thermal Unit
and Timing System.
While cleannig the driving shaft, make sure that no
dirt enters the shaft lubrication hole.
500-4T
chap. 9
9-12
Release 00 2001-12
If the driving shaft made up of two half shafts of
different classes is to be replaced, it is also
necessary to replace the two half crankcases and
to match the two components (shaft and crank-
case) with the same class.
Check the driving shaft gear according to the proce-
dure described in Chapter Thermal Unit and Timing
System.
ENGINE HALF CRANKCASE CHECK
Before checking the crankcases, carefully clean all
the surfaces and lubrication ducts.
For the half crankcase transmission side, act on the
main bearing brass, cooling jet transmission side
(see figure) and lubrication duct.
IMPORTANT The jet is fed through the main
bearing brass. Correct operation of this component
improves the piston crown cooling. Its clogging will
cause troubles that are difficult to notice (piston
temperature increase). Failure of this component may
drastically reduce the lubrication pressure to the main
bearing brass and connecting rod.
CAUTION
500-4T
chap. 9
9-13
9
Release 00 2001-12
For the half crankcase flywheel side, pay special
attention to the lubrication ducts to the main bearing
brasses, oil pump compartment and channels, and by-
pass duct situated on the flywheel cover.
IMPORTANT As already described in Chapter
Lubrication, it is very important that the by-pass hous-
ing on the flywheel cover shows no signs of wear that
would compromise the sealing of the lubrication pres-
sure adjusting piston. The head lubrication duct is
provided with a choking jet, that provides for a head
lubrication of the low pressure type. This is to reduce
the oil temperature in the pan.
The jet clogging will prejudice the lubrication to the
head and timing system mechanism.
The jet failure will reduce the lubrication pressure to the
main bearing brasses and connecting rod.
Check that the surfaces show no signs of dents or
deformation, especially on the cylinder-crankcase
surface and crankcase coupling area.
A defective gasket and crankcase coupling surface (see
flywheel cover coupling) may cause leaks of the oil under
pressure, thus compromising the lubrication pressure to
the main bearing brasses and connecting rod.
Check that the driving shaft end play containment
surfaces show no signs of wear. Check the dimensions
according to the procedures described for the end play
check and driving shaft dimensions.
MAIN BEARING BRASS CHECK
- A good lubrication of the bearing brasses is
achieved with a good lubrication pressure (4 bar)
and good oil flow rate. To this purpose, the
bearing brasses must be positioned correctly to
avoid the oil supply ducts choking.
- The main bearing brasses are obtained with 2
half bearings, 1 full and 1 with holes and open-
ings for the lubrication.
- The full half bearing supports the thrusts pro-
duced by the combustion, therefore it is posi-
tioned opposite to the cylinder.
- To avoid the oil supply ducts choking, the cou-
pling surface of the two half bearings must be
perfectly orthogonal with the cylinder axis, as
- The oil supply channels square measure is also
affected by the brass driving depth respect to the
driving shaft end play containment surface.
IMPORTANT To maintain the brass position on the
crankcase, the driving is forced on cast iron rings that
are fitted in the casting of both half crankcases.
500-4T
chap. 9
9-14
Release 00 2001-12
Coupling
surface
- Check the brasses diameter in the 3 directions
- Repeat the measuring on the other half of the
brass. See figure.
IMPORTANT Do not measure the mating of the 2
half bearings as the ends are splined to allow defor-
mation while being fitted.
- The brasses standard diameter after the driving
changes according to the coupling selected.
- The brasses housing in the crankcases are
subdivided in 2 classes, as for the driving shaft
Class 1 and Class 2.
- The brasses are subdvided in 3 classes depend-
ing on the thickness, see table below:
IMPORTANT When assembling the spare parts, use the shaft with two shoulders class 1 with crankcase FC1
(or class 2 with crankcase FC2).
A spare crankcase cannot be used with a mixed class driving shaft. The shaft for the spare parts is provided
with half shafts of the same class.
TYPE IDENTIFICATION THICKNESS mm (in)
A Red 1.982 - 1.987 (0.0780 - 0.0782)
B Blue 1.987 - 1.992 (0.0782 - 0.0784)
C Yellow 1.992 - 1.997 (0.0784 - 0.0786)
Half shafts coupling with half crankcase and brass
Half shaft Half shaft Brass Spare crankcase
Class Class class preparation
1 B FC1
2 C Drg. CM1033015001
1 A FC2
2 B Drg. CM1033015002
1
2
IMPORTANT To replace the half crankcases,
remove the countershaft bearings as described
above. Remove from the half crankcase, transmission
side, the antiflapping roller and the driven pulley
assembly, as described in Chapter Automatic trans-
mission, and the hub cover with relevant gears and
bearings, as described in Chapter Final Reduction.
500-4T
chap. 9
9-15
9
Release 00 2001-12
OIL PUMP
Overhaul the oil pump as described in Chapter Lubri-
cation.
COUNTERSHAFT
Measure the 2 countershaft supports by means of a
micrometer, as shown in the figure.
- 0.01
mm (0.67
- 0.0003
in)
Check that the water pump drive shows no signs of
wear.
OIL PUMP ASSEMBLY
Check the gasket correct position.
IMPORTANT The gasket tooth must be positioned
in the relevant seat.
Assemble the oil pump complete with the gear.
Fit the 2 fixing screws through the slots on the gear
and then tighten them to the prescribed torque.
IMPORTANT The pump assembly position is
determined by the screws. Failure to observe the
tightening torque may change the rotors to pump
casing allowance.
Tightening torque:
Oil pump fixing screws: 5 - 6 Nm (3.7 - 4.4 Ft-lbs)
- 0.02 - 0.0007
500-4T
chap. 9
9-16
Release 00 2001-12
Assemble the countershaft with the gear on the half
crankcase flywheel side.
Fit the specific tool in the position shown in the figure.
Countershaft lock wrench tool 8140307
Hold the countershaft and fit the washer with nut
Tighten the nut to the prescribed torque, apply
LOCTITE 242
Remove the specific tool.
Tightening torque:
Countershaft fixing nut: 25 - 29 Nm (18.4 - 21.4 Ft-
lbs)
DRIVING SHAFT ASSEMBLY
Check that the countershaft control gear and the oil
pump show no signs of dents or deformation. Replace if
necessary.
IMPORTANT If the countershaft control gear and the
oil pump are to be replaced, also replace the
countershaft gear.
Before assembling the gear on the driving shaft, care-
fully clean the two coupling surfaces by removing any
residuals of LOCTITE from the holes by means of a
brush.
Blow compressed air and degrease the fixing holes on
both surfaces to improve the new LOCTITE setting.
Apply LOCTITE 242 again.
Repeat the same procedure for the 4 fixing screws.
Fit the control gear on the driving shaft with the holes
countersink well visible.
IMPORTANT In order not to damage the screws
control hexagon, use a socket wrench with inner hexa-
gon.
Tightening torque:
Driving shaft gear fixing screws: 10 - 12 Nm (7.4 -
8.8 Ft-lbs)
500-4T
chap. 9
9-17
9
Release 00 2001-12
Lubricate the main bearing brass on the half crank-
case flywheel side.
Grease the shim washer.
Fit the shim washer on the driving shaft, in its original
position.
Insert the specific tool for the timing in the hole on the
countershaft.
Countershaft timing pin tool 8140609
Assemble the driving shaft on the pin. Further insert it
in the brass very carefully.
Before completing the assembly, fit the oil pump gear
with the control gear.
Complete the assembly and remove the specific tool.
IMPORTANT While assembling the shaft on the
half crankcase, take care not to damage the main
bearing brass with the threaded tang of the driving
shaft and with the timing control toothed pinion.
Assemble the oil pump compartment gate.
Tighten the 2 flanged fixing screws to the prescribed
torque.
Tightening torque
Gate fixing screws: 8 - 10 Nm (5.9 - 7.4 Ft-lbs)
CRANKCASE COUPLING
Remove the oil seal on the half crankcase transmis-
sion side by means of a screwdriver.
500-4T
chap. 9
9-18
Release 00 2001-12
Grease and assemble a new oil seal by means of the
specific tool. Put it at 0.5 mm (0.02 in) from the
crankcase surface.
The oil seal wrong position will compromise the
lubrication oil circulation.
Assemble the gasket on the half crankcase flywheel
side.
Lubricate the main bearing brass on the half crank-
case transmission side.
Mate the 2 half crankcases taking care not to
damage the half crankcase brass transmission
side, with the driving shaft threaded tang.
Insert, without locking it, the engine mount setscrew
on the half crankcase flywheel side.
Fit the 14 fixing screws, using the shorter screw A
and the longer screws B, as shown in the figure.
Fully screw the screws and then tighten them to the
prescribed torque.
Check that the driving shaft turns freely.
IMPORTANT Remove any part in excess from the
crankcase coupling gasket on the cylinder surface in
order to improve the sealing.
Tightening torque:
Crankcase coupling screws: 11 - 13 Nm (8.1 - 9.5
Ft-lbs)
CAUTION
500-4T
chap. 9
9-19
9
Release 00 2001-12
Assemble the thermal unit (cylinder, head, piston) as
described in Chapter Thermal unit and Timing system.
Assemble the magneto flywheel with starting control
as described in Chapter Flywheel and Starting sys-
tem.
Assemble the flywheel cover with the cooling system
sleeves as described in Chapter Flywheel cover.
Assemble the driving pulley assembly, transmission
cover complete with net filter and the external trans-
mission cover as described in Chapter Automatic
transmission.
500-4T
chap. 9
9-20
Release 00 2001-12
NOTES
500-4T
Fuel injection
Fuel injection
10
10-1
500-4T
Fuel injection
10-2
INDEX
INTRODUCTION............................................................................................................................................... 10-3
PRECAUTIONS ................................................................................................................................................ 10-5
TROUBLESHOOTING...................................................................................................................................... 10-6
COMPONENTS LAYOUT ................................................................................................................................ 10-7
LAYOUT OF THE EMS CONTROL UNIT TERMINALS AND IMMOBILISER................................................... 10-8
EMS SYSTEM DIAGRAM................................................................................................................................ 10-9
TROUBLESHOOTING.................................................................................................................................... 10-10
DIAGNOSIS TESTER LINK CIRCUIT ........................................................................................................... 10-16
FUEL INJECTION INDICATOR CIRCUIT ....................................................................................................... 10-17
SELF-DIAGNOSIS SYSTEM ......................................................................................................................... 10-18
FUEL SUPPLY SYSTEM ................................................................................................................................ 10-19
GENERAL DETAILS ....................................................................................................................................... 10-19
PUMP FEEDING CIRCUIT ............................................................................................................................. 10-20
CIRCUIT CONTROL ....................................................................................................................................... 10-21
HYDRAULIC CONTROL AND SYSTEM MAINTENANCE ............................................................................. 10-26
CHECKING THE PRESSURE REGULATOR ................................................................................................. 10-27
CHECKING THE PUMP AND THE FUEL FILTER .......................................................................................... 10-29
CHECKING THE FUEL FILTER...................................................................................................................... 10-33
CHECKING THE INJECTOR CIRCUIT ......................................................................................................... 10-33
REVOLUTION SENSOR................................................................................................................................ 10-36
HV COIL.......................................................................................................................................................... 10-39
SHIELDED CAP CONTROL ........................................................................................................................... 10-41
IGNITION TIMING........................................................................................................................................... 10-41
COOLANT TEMPERATURE SENSOR........................................................................................................... 10-43
AIR INTAKE TEMPERATURE SENSOR ........................................................................................................ 10-45
PRESSURE SENSOR .................................................................................................................................... 10-48
THROTTLE POSITION SENSOR.................................................................................................................. 10-49
STEPPER MOTOR ......................................................................................................................................... 10-51
MINIMUM CARBURATION REGULATION.................................................................................................... 10-56
ELECTRIC FAN CONTROL CIRCUIT ........................................................................................................... 10-60
REVOLUTION COUNTER CONTROL CIRCUIT ........................................................................................... 10-63
500-4T
Fuel injection
10
10-3
INTRODUCTION
EMS fuel injection system
The fuel injection system used is of the integrated fuel injection and ignition type.
Fuel is injected indirectly into the manifold by means of the electroinjector.
Fuel injection and ignition are timed on a 4-stroke cycle via a phonic wheel splined to the cam shaft control and a
reluctance variance sensor.
Carburation and ignition are managed in relation to the engine revolutions and the opening of the throttle valve. Further
corrections are carried out on the basis of the following parameters:
- Coolant temperature
- Air intake temperature
- Ambient pressure
The system carries out the idling supply correction on a cold engine via a stepper motor inserted on to a by-pass circuit
of the throttle valve. The control unit manages the stepper motor and the timing of the injector opening, thus guaranteeing
idling stability and correct carburation.
Under all working conditions, carburation is managed by modifying the injector opening time.
Fuel supply pressure is kept constant on the basis of ambient pressure.
The feed circuit is composed of:
- Fuel pump
- Fuel filter
- Injector
- Pressure regulator
The pump, filter and regulator are inserted into the fuel tank via a single support.
The injector is connected by means of two quick-connection tubes. This allows continuous circulation and avoids the
risk of petrol overheating. The pressure regulator is situated at the end of the circuit. The fuel pump is commanded
by the EMS control unit; thus guaranteeing vehicle safety.
The ignition circuit is composed of:
- H.V. coil
- H.V. cable
- Shielded cap
- EMS control unit
- Spark plug
The EMS control unit manages ignition with optimum advance, at the same time guaranteeing 4-stroke cycle timing
(ignition only during compression stage).
The EMS igntion-injection system manages the working of the engine by means of a preset programme.
Should certain entry signals fail, an acceptable working of the engine is still guaranteed in order that the user may reach
a repairs centre.
Obviously, this will not happen if the revolutions signal fails, nor if there is an anomaly in the control circuit:
- Fuel pump
- A.T.Coil
- Injector
Fuel injection
500-4T
chap. 10
10-4
Release 00 2001-12
The control unit has its own auto-diagnosis system
connected to an indicator on the instrument panel.
Anomalies may be discovered and cancelled with a
8140595 diagnosis tester.
In any event, when the anomaly is no longer present, its
memorization is automatically cancelled after 16 usage
cycles (cold start, warm running, stopping).
The diagnosis tester is also indispensible for idling
carburation regulation.
The EMS ignition-injection system controls the revolu-
tion counter and the electric fan for the radiator
cooling.
The EMS control unit supply is further controlled by
the emergency switch and the side stand switch in
order to make the vehicle safer.
ABS
500-4T
Fuel injection
10
10-5
PRECAUTIONS
1 - Before proceeding with any repairs concerning the fuel injection system, check for the presence of registered
anomalies.
Do not disconnect the battery prior to checking the anomaly.
2 - The supply system is pressurized at 300 Kpa (3 BAR). Before disconnecting the quick-connection of a supply
system tube, check that no open flames are present and do not smoke. Act with caution to avoid spraying into the
eyes.
3 - During repairs on electrical components, the battery should remain connected only in cases of necessity.
4 - When carrying out functional controls, ensure that the battery tension is more than 12V.
5 - Before attempting to restart the engine, ensure that the tank holds at least two litres of petrol. Failure to respect
this regulation could damage the fuel pump.
6 - If a long period of inactivity is foreseen for the vehicle, fill the fuel tank to more than half-full. This guarantees that
the pump will remain immersed in the petrol.
7 - When washing the vehicle do not place pressure on the electrical components and cables.
8 - When ignition irregularities are revealed, begin controls by checking the battery and fuel injection system.
9 - Before disconnecting the EMS control unit connector, carry out the following operations in the order given:
- Set the ignition switch to OFF
- Disconnect the battery
Failure to respect this regulation may damage the control unit.
10 - When mounting the battery take care to not invert the polarity.
11 - So as not to cause damage, disconnect and reconnect the EMS system connectors only if it proves necessary.
Before reconnecting, verify that the connections are not wet.
12 - During electrical controls do not forcefully insert the tester prods into the connectors. Do not take measurements
which are not foreseen by the manual.
13 - At the end of each control carried out with the diagnosis tester, remember to protect the system connector with
the appropriate cap.
Failure to respect this regulation could damage the EMS control unit.
14 - Before reconnecting the supply system quick-connections, verify that the terminals are perfectly clean.
500-4T
Fuel injection
10-6
TROUBLESHOOTING
Suggestions for troubleshooting
1 Damage to the EMS system could derive most probably from the connections and not from the components.
Before carrying out a search on the EMS system, carry out the following controls:
1 Electrical feed
- Battery tension
- Burnt out fuse
- Electromagnetic switches
- Connectors
2 Frame earthed
3 Fuel supply
- Fuel pump broken
- Fuel filter dirty
4 Ignition system
- Spark plug faulty
- Coil broken
- Shielded cap broken
5 Air intake circuit
- Air filter dirty
- By-pass circuit dirty
- Stepper motor broken
6 Others
- Incorrect valve gear timing
- Idling carburation incorrect
- T.P.S reset sensor incorrect
2 Anomalies in the EMS system may derive from loose connectors. Ensure therefore that all connections are carried
out correctly.
Check the connectors, paying attention to the following points:
1 check that the terminals are not bent.
2 check that the connectors are properly engaged.
3 check that poor functioning is modified by provoking a slight vibration of the connector.
3 Before replacing the EMS control unit check the entire system accurately.
If the anomaly disappears by replacing the EMS control unit, install the original control unit again to see if the anomaly
returns.
4 For the fault search use a multimeter with an internal resistance of more than 10K/V.
Unsuitable instruments could damage the EMS control unit.
The recommended instruments are those with a definition superior to 0.1V and 0.5; precision must be superior to 2%.
500-4T
Fuel injection
10
10-7
COMPONENTS LAYOUT
2 REVOLUTION SENSOR
4 COIL
5 SPARK PLUG
6 FUEL INJECTOR
7 FUEL PUMP
9 INJECTION PRIMARY RELAY (with diode)
10 INJECTION SECONDARY RELAY
11 SIDE STAND SWITCH
13 ACCELERATOR SENSOR
ABS
43
9
10
13
15
55
20
45
5
11
7
38
24
22
40
52
44
42
16
54
14
2
6
37
36
4
14 ENGINE AIR THERMISTOR
15 DASHBOARD/ENGINE WATER THERMISTOR
16 FAN
20 START RELAY
22 PRIMARY FUSES
24 SECONDARY FUSES
36 FALL SENSOR
37 RIGHT DIMMER
38 FAN RELAY
40 CLAXON
42 DASHBOARD AIR T THERMISTOR
43 DASHBOARD
44 SPEED SENSOR
45 OIL PRESSURE SENSOR
52 E.C.U. CENTRAL UNIT
54 DIAGNOSTICS OUTLET
55 STOPLIGHT RELAY
500-4T
Fuel injection
10-8
LAYOUT OF THE EMS CONTROL UNIT TERMINALS AND IMMOBILIZER
Representation of the control unit connector and the connector system side.
EMS CONTROL UNIT
N FUNCTION N FUNCTION
1 THROTTLE POTENTIOMETER FEED (+5V) 14 STEPPER MOTOR
2 - 15 DIGITAL INSTRUMENT (FUEL INJECTION INDICATOR - NEGATIVE)
3 DIGITAL INSTRUMENT (REVOLUTIONS COUNTER CONTROL) 16 DECODER (SERIAL)
4 ENGINE TEMPERATURE (+) 17 BASE FEED (POSITIVE)
5 86 ELECTRICAL FAN ELECTROMAGNETIC SWITCH 18 AIR TEMPERATURE SENSOR (+)
6 ENGINE REVOLUTIONS SENSOR 19 85 ELECTROMAGNETIC SWITCH (PUMP-INJECTOR-H.V. COIL) (-)
7 EMS DIAGNOSIS CONNECTOR 20 H.V. COIL (NEGATIVE CONTROL)
8 - 21 STEPPER MOTOR
9 EMS DIAGNOSIS CONNECTOR 22 SENSORS FEED (-)
10 EMS DIAGNOSIS CONNECTOR 23 CONTROL UNIT NEGATIVE
11 THROTTLE POTENTIOMETER SIGNAL 24 STEPPER MOTOR
12 ENGINE REVOLUTIONS SENSOR 25 -
13 INJECTOR CONTROL (NEGATIVE) 26 UNDER PANEL FEED (POSITIVE)
CONTROL UNIT SIDE SYSTEM SIDE
500-4T
Fuel injection
10
10-9
EMS SYSTEM DIAGRAM
2) Revolution sensor
3) Stepper motor
4) Coil
5) Spark plug
6) Fuel injector
7) Fuel pump
9) Primary injection relay (with diode)
12) Lambda sensor (not available)
15) Engine water thermistor/dashboard
16) Fan
19) Battery
22) Primary fuses
24) Secondary fuses
36) Fall sensor
37) Right dimmer
38) Fan relay
43) Dashboard
52) ECU control unit
54) Diagnostics connector
B - ENGINE KILL, LUCI STOP.
C - LUCI, CLAXON, CRUSCOTTO, RELE' VENTOLA.
E - ALIMENTAZIONE PERMANENTE E.C.U.
A - INIEZIONE, AVVIAMENTO.
D - PRESA DI CORRENTE.
F - LIBERO.
FUSIBILI SECONDARI:
M
/V
A
r/R
B
i/N
G
r/N
R
/B
A
r/V
R
/M
R
/M
R
o
/G
V
/G
M
/G
M
/B
i
R
o
/N
R
/N
M
/N
A
r/V
G
r/N
M
/N
3
0
A
3
0
A
22
G
/N
R
/M
R
R
12 3
2 6
5
7
A
r/B
i GV
i
R
o
A
z
1 G
r/R
R
/M
R
/M
4
B
P
10 9
11
2 1
8
5
8
6
8
7
3
0
1 1 53 1
B
NVM
13
14
16
15
1
G
r
G
r
1 1
G
r
A
r
BG
/N
B
19
N
R
12
C
E
N
T
R
A
L
I
N
A

E
.
C
.
U
.
22
N
N
Gr/N
N
1
N
Ro
24
23
26
25
52
Ro/G
Az
Az/V
Gr/R
Ar/N
Ro/N
Vi/N
Gr
G
Ar/Bi
21
20
19
17
16
15
14
13
18
V/G
2
B/N
M/G
R
M
Ar
R/B
Az/R
Vi
B
Ro/G
11
10
9
8
7
6
5
4
3
M/Bi
1
R
/B
i
R
/B
i
M R
54
B
D
F
V
/R
V
/R
V/N
15A
15A
3A
15A
15A R/Gr
B
A
E
C
V/N
V
V/R Ar/N
V/R Ar/V
24
13
R
/B
i
R
/B
i
A
z
/R
B B
W SET
9 10 1112 6 7 8 2 3 4 5 1
A
r/R
A
z
/V
M
/V
1
B
15 14 16 9 8 7 5 6 4 2 3 1
B VB
i/N
TRIP
20 19 18 16 17 15 14 13 12 11 10
x1000r/min
EFI EFI EFI
ABS ABS ABS ABS
EFI
43
! !! ! !! !!! !! ! !! ! !
Km/h
mp/h
8
6
38
8
7
3
0
8
5
B
i/N
N
R
o
/G
G
r
1
1
36
1
R/Bi
AL REGOLATORE
DI TENSIONE
RELE
AVVIAMENTO
R
LUCE VANO
BAULETTO
COMMUTATORE
A CHIAVE
INTERRUTTORE
STOP
RELE
LUCI STOP
COMMUTATORE
A CHIAVE
CLAXON
DEVIOLUCI
SINISTRO
INTERRUTTORI
STOP
37
R
/B
i
G
/N
R
/B
i
V
i/N
VR
/N
R
/G
r
V
V
R
/G
r
R
/N
R
/N
E
C
U

C
O
N
T
R
O
L

U
N
I
T
STOP
SWITCH
STOP
SWITCH
STOPLIGHTS
RELAY
KEY SWITCH
LEFT
DIMMER
TOP CASE
LIGHT
STARTING
RELAY
TO VOLTAGE
REGULATOR
SECONDARY FUSES:
A -STARTING INJECTION
B -ENGINE KILL, STOPLIGHTS
C -LIGHTS, ELECTRIC HORN, DASHBOARD, FAN RELAY
D -ECU PERMANENT FEED.
F -FREE
KEY SWITCH
500-4T
Fuel injection
10-10
TROUBLESHOOTING
1) THE ENGINE DOES NOT START EVEN WITH NORMAL MOTORING OVER
Proceed with the following controls:
Presence of anomalies revealed through injection
self-diagnosis
Fuel supply
Spark plug feed
Compression end pressure
Parameter reliability
Pump relay (see the relative paragraph)
H.V. coil (see the relative paragraph)
Injector (see the relative paragraph)
Phase revolutions sensor (see the relative paragraph)
Presence of fuel in the tank
Fuel pump starting
Petrol pressure (low)
Injector capacity (low)
Spark plug
Shielded cap
H.V. coil (secondary isolation)
Coolant temperature
Valve gear timing-ignition injection
Air intake temperature
500-4T
Fuel injection
10
10-11
2) DIFFICULT COLD START OR WARM START OF THE ENGINE
Starting
Compression end pressure
Spark plug feed
Starter and electromagnetic switch
Battery
Earth connections
Spark plug
Shielded cap
H.V. coil
Phase revolutions sensor
Spark lead
Petrol pressure (low)
Injector capacity (low)
Injector stability (poor)
self-diagnosis
Air temperature
Coolant temperature
Atmospheric pressure
Fuel supply
Parameter correctness
Coolant temperature
Air intake temperature
Throttle valve position
Stepper (steps and actual opening)
Cleanliness of auxiliary air duct of the throttle
valve
air filter efficiency
500-4T
Fuel injection
10-12
3) THE ENGINE DOES NOT MAINTAIN IDLING SPEED
IDLING SPEED IS UNSTABLE
IDLING SPEED IS TOO LOW
Ignition efficiency
Air intake system cleanliness
Intake system seal (infiltrations)
Fuel supply (low pressure)
Analysis of exhaust gas prior to the catalytic converter
Spark plug
Ignition timing
Throttle valve position sensor
Stepper
Coolant temperature sensor
Air intake temperature sensor
Air filter
Choke tube and throttle valve
Supplementary air duct and stepper
head-intake manifold
Throttle body-manifold
Air intake hose
Filter box
Fuel pump
Pressure regulator
Fuel filter
Injector capacity
Trimmer value adjustment (CO% adjustment)
Presence of anomalies revealed through fuel
injection self-diagnosis
Air temperature
Coolant temperature
500-4T
Fuel injection
10
10-13
4) THE ENGINE DOES NOT TURN OVER ON IDLING SPEED
IDLING SPEED TOO HIGH
Ignition efficiency
Fuel supply (pressure low)
Ignition timing
Stepper
Head-intake manifold
Air intake hose
Filter box
Fuel pump
Pressure regulator
Fuel filter
Injector capacity
self-diagnosis
Air temperature
Coolant temperature
5) BACKFIRING IN DECELERATION
Stepper
self-diagnosis
Air temperature
Coolant temperature
500-4T
Fuel injection
10-14
6) IRREGULAR RUNNING OF THE ENGINE WITH THROTTLE VALVE SLIGHTLY OPEN
Air intake system cleanliness
Intake system seal
Ignition system
TPS reset carried out correctly
Analysis of exhaust gas taken prior to the catalytic
converter
Air filter
Choke and throttle valve
Supplementary air duct and stepper
Air intake hose
Filter box
Check spark plug wear
Throttle valve position signal
Coolant temperature signal
Air intake temperature signal
Spark lead
Intake manifold-head
Air intake hose
Filter box
Fuel supply (pressure low)
Fuel pump
Pressure regulator
Fuel filter
Injector capacity
Exhaust system seal (infiltrations)
Manifold-head
Manifold-silencer
Analyser socket
Silencer soldering
self-diagnosis
Air temperature
Coolant temperature
500-4T
Fuel injection
10
10-15
8) PRESENCE OF DETONATION (COMBUSTION SHOCK)
Intake system seal
Reset TPS carried out correctly
Fuel supply
Throttle valve position
Coolant temperature
Air temperature intake
Spark lead
Filter box
Air intake hose
Fuel pressure
Fuel filter
Injector capacity
Fuel quality
Thickness selection of the cylinder base gasket
7) POOR ENGINE RUNNING ON FULL POWER
IRREGULAR RUNNING OF THE ENGINE DURING ACCELERATION STAGE
Spark plug feed
Air intake system
Fuel supply
Spark plug
Shielded cap
H.V. cable
H.V. coil
Air filter
Box filter (seal)
Air intake hose (seal)
Throttle valve position signal
Coolant temperature signal
Air intake temperature signal
Spark lead
Fuel level in the tank
Fuel pressure
Fuel filter
Injector capacity
self-diagnosis
Air temperature
Coolant temperature
self-diagnosis
Air temperature
Coolant temperature
Ignition efficiency
Spark plug
500-4T
Fuel injection
10-16
DIAGNOSIS TESTER LINK CIRCUIT
Connect the diagnosis tester n 8140595.
If the diagnosis tester gives the information "THE CONTROL UNIT DOES NOT RESPOND", remove the under-
panel feed for 10 seconds and reset to "ON"; if the same information is repeated proceed as follows:
Check the diagnosis tester connections
YES
NO
Check the basic and under-panel feeds
of the control unit.
Reset
CIRCUIT DIAGRAM
DIAGNOSIS
TESTER
CONNECTOR
VEHICLE
SYSTEM
FUEL INJECTION
SYSTEM
F
U
E
L

I
N
J
E
C
T
I
O
N
C
O
N
T
R
O
L

U
N
I
T
9
2
3
1
23
10
The circuit works correctly
YES
Check the control unit
500-4T
Fuel injection
10
10-17
FUEL INJECTION INDICATOR CIRCUIT
CIRCUIT DIAGRAM
TERMINAL CONDITIONS STANDARD VALUES
15 - 23
- commutator set to
"ON"
- side stand raised
- switch set to "RUN"
during checks
after checks
O V
battery tension
The fuel injection indicator is commanded whenever the setting is "ON" with a timing of 3 seconds generated by
the digital instrument. This phase is normally superimposed by fuel injection control unit control. This timing
lasts 5 seconds.
1 DIGITAL INSTRUMENT 4 30A FUSE
2 7.5A FUSE 5 CONTROL UNIT
3 7.5A FUSE
2
1
23
15
5
12
7
12
9
12
1
16
3
4
5
500-4T
Fuel injection
10-18
- Control of memorized anomalies
Connect the diagnosis tester No. 8140595 with the
vehicle system (see the relative page).
IMPORTANT
The link with AXONE may be lost upon ignition of the
vehicle, because of a voltage drop due to the current
absorption from the starter.
Select the ERROR function on the menu and press
the + or push-buttons until the symbol is dis-
played (see figure).
SISTEMA DI AUTODIAGNOSI
The fuel injection control unit has a self-diagnosis function.
When an anomaly is revealed, the control unit proceeds to:
- lighting of the fuel injection indicator (only when current).
- activation of engine management controls on basic data entered in the control unit (where possible).
- memorization of the anomaly (always).
If an anomaly revealed is not always present, the indicator follows the state of the anomaly and memorization remains
active. Memorization of the event is cancelled automatically if the anomaly does not occur again for more than 16
usage cycles (warm up - usage - cooling). Disconnection of the battery does not cancel the memorization.
The tester pages show the list of the anomalies
revealed by the self-diagnosis.
The anomalies revealed by the self-diagnosis are
signalled by a beep and shown on the line of the
display.
Such anomalies are placed on three lines:
ATT = current anomalies (beep)
MEM = memorised anomalies and cancelled error
(beep)
STO = anomalies visible until the instrument is
disconnected.
The anomalies revealed by the self-diagnosis can
refer to the following system circuits or control unit
sectors:
- throttle valve position signal
- room pressure signal
- coolant temperature signal
- air intake temperature signal
- incorrect battery voltage
- injector and relative circuit
- HV coil and relative circuit
- stepper and relative circuit
- pump relay circuit
- electric fan relay circuit
- RAM memory
- ROM memory
- EPROM
- Microprocessor
- Signal panel (revolution - phase - unstable cycle)
The underlined anomalies lead to the engine stop.
In the other cases, the engine works and is managed by
the basic data.
500-4T
Fuel injection
10
10-19
- Cancellation of memorized anomalies
After any repair, connect the diagnosis tester No.
8140595 (see the relative page). Select the function
CANCELLATION OF ANOMALIES from the menu
ACTUATORS.
Press OK and follow the instructions.
Or press the push-button from the error video
page.
Carry on a running test and see if the anomaly
returns.
Consult the relative sections of the chapter in order
to remove any anomaly.
FUEL SUPPLY SYSTEM
General details
The fuel supply to the injector is controlled by a
pump, a filter and a pressure regulator integrated
with the fuel level indicator inside the tank.
The pump group is connected with the injector by
means of:
2 semirigid pipes
4 quick-connections
1 T-ring with O-Ring and lock bracket for the injector.
The pipes are crossed and fastened to the suction
manifold to avoid the wear of the quick-connections
connecting the injector T-ring.
IMPORTANT before carrying out work on the supply system, all parts should be cleaned accurately to avoid
damaging the stability of the quick-connections or allowing the infiltration of impurities into the ducts.
The system is pressurized.
Do not smoke while working on parts.
Sprays of fuel can be expected.
PRECAUTIONS:
- Before starting the engine, ensure there is fuel in the tank.
- Do not run the vehicle on the reserve tank, so as to avoid the risk of running dry.
- If a long period of disuse is expected, fill the tank to at least half.
FAILURE TO RESPECT THESE REGULATIONS MAY DAMAGE THE PUMP
NJECTOR T-
RING
RETURN
DELIVERY
RUNNING
DIRECTION
CAUTION
500-4T
Fuel injection
10-20
Pump feed circuit
The control unit intervenes by activating the pump under the following conditions:
- setting to "ON" with emergency switch set to "RUN" and side stand raised.
Pump feed for 2 seconds.
- when the phase revolutions signal is present.
Continuous feed
The initial timing is useful to drain the system, especially after leaving the vehicle parked with the engine
warm. In these conditions, fuel altered by overheating will be mixed with that in the tank.
During use, the pump function will be subordinated by the engine revolutions.
CIRCUIT DIAGRAM
1 MULTIPLE CONNECTORS 11 SIDE STAND SWITCH
4 COIL 19 BATTERY
5 SPARK PLUG 22 PRIMARY FUSES
6 FUEL INJECTOR 24 SECONDARY FUSES
7 FUEL PUMP 35 KEY SELECTOR
8 FUEL LEVEL SENSOR 37 RIGHT DIMMER
9 PRIMARY INJECTION RELAY (WITH DIODE) 43 DASHBOARD
10 SECONDARY INJECTION RELAY 52 ECU CONTROL UNIT
M
/
V
G
r
/
N
R
/
B
A
r
/
V
R
/
M
G
/
V
R
/
N
M
/
N
A
r
/
V
G
r
/
N
M
/
N
R
/
M
A
r
/
N
6
5
7
A
r
/B
i
G
r
/
R
R
/
M
R
/M
4
B
P
10 9
11
2 1
8
5
8
6
8
7
3
0
1
8
1 53
B
NVM
12
C
E
N
T
R
A
L
I
N
A

E
.
C
.
U
.
22
N
N
N
24
23
26
25
52
Gr/R
Ar/N
Ar/Bi
21
20
19
17
16
15
14
13
18
2
R/B
11
10
9
8
7
6
5
4
3
1
13
B B
W
SET
9 10 1112 6 7 8 2 3 4 5 1
M
/V
1
B
15 14 16 9 8 7 5 6 4 2 3 1
B
TRIP
20 19 18 16 17 15 14 13 12 11 10
x1000r/min
EFI EFI EFI
ABS ABS ABS ABS
EFI
43
! !! ! !! !!! !! ! !! ! !
Km/h
mp/h
G
/V
A
r
/N
3
0
A
3
0
A
22
R
R
19
N
R
R
/B
i
R
/B
i
D
F
V
/R
V
/R
15A
15A
3A
15A
15A
R/Gr
B
A
E
C
V/N
V/R Ar/N
V/R Ar/V
24
1
1
1
Gr/N
INTERRUTTORI STOP
35
37
R
/B
i
V
/N
R
/N
R
/G
r
R
/G
r
R
/N
STOP
SWITCH
E
C
U

C
O
N
T
R
O
L

U
N
I
T
500-4T
Fuel injection
10
10-21
Set to "ON" with the emergency switch set to "RUN" and the side stand raised.
There is pump revolution for 2 seconds.
Circuit control
Proceed as follows:
YES
NO
Attempt ignition.
Check that the engine revolution matches that of
the pump.
The pump does not turn or turns
continuously.
The electrical feed of the pump is
conformant.
YES
NO
Connect the diagnosis tester No. 8140595 with
the vehicle system (see the relative paragraph)
with engine off.
Attempt ignition.
Select the "ERRORS" function menu.
Check for the presence of anomalies.
Malfunctioning of:
- injector
- HV coil
- signals panel
YES
Malfunctioning of the
pump command relay circuit.
YES
NO
500-4T
Fuel injection
10-22
The control unit has revealed an anomaly on the line of the secondary
injection relay of pin 5.
Earthed line
In this case, the pump
always turns, when the
under panel feed is
present.
Line disconnected
The relay cannot control the
pump feeding.
Check and reset the
earthing insulation of line
5-2 (of the relay). Check
the two sections sepa-
rately: vehicle system/
injection system
Cancel the code and
check from the beginning.
YES
YES
Check the efficiency of the 15A fuse (see
figure).
YES NO
YES
Check the connector and the
harness on injection side
500-4T
Fuel injection
10
10-23
Check the efficiency of the pump control electromag-
netic switch. Check the continuity of the harness be-
tween the electromagnetic switch and the pump (see the
relative wiring diagram).
Reset and repeat the check from the beginning.
NO
YES
Reset the harness insulation and
replace the fuse.
Check the earthing insulation of HV coil
and injector coil primary circuit. See the
relative wiring diagram.
NO
YES
YES
500-4T
Fuel injection
10-24
Check resistance of the windings in the pump.
Resistance 1.5
Replace the fuse and proceed
with pump control.
Proceed with control of absorbed
current.
Select the function menu "ACTIVE DIAGNOSIS" of
the diagnosis tester 8140595.
Select the fuel pump simulation function.
Activate the function with under-panel feed inserted
and engine stopped.
NO
The tester asks the control unit to activate the pump for 30 seconds
Check acoustically the following conditions:
- relay closure
- pump revolution
- relay opening
YES NO
The pump receives feed.
Proceed with the pump function-
ing control
Check the pump support connector.
NO
Replace the pump. See
the relative paragraph
of the VEHICLE SHOP
HANDBOOK .
Reset
YES
500-4T
Fuel injection
10
10-25
Resistive check
Disconnect the pump support connector. Using a tester
measure the resistance of the pump windings.
Connect the tester prods to the pump support pins as
Resistance = ~1.5
On meeting with infinite resistance replace the pump.
With infinite resistance, the pump will not turn.
With resistance close to 0 W the pump absorbs exces-
sively with the possibility that the 10 A fuse n 2 will burn
out. Proceed with controls as below.
Pump absorption control
Pump absorption may vary depending on:
- feed tension
- running-in of the pump
- adjusting pressure
- cleanliness of the delivery filter
To carry out a control of the current absorbed, proceed
as follows:
- disconnect the pump command electromagnetic
switch connector
- with the ignition key set to "OFF", jump 30-87 to the
connector using the tester prods in amperometer
function (see figure).
- check the pump revolution and its absorption
Current absorbed = ~ 3.5 - 4.2 A
NOTE: this absorption refers when:
- feed tension = ~ 12 V
- pump run-in
- system pressure = 300 KPa (3 BAR)
- clean fuel filter
A dirty filter causes absorption increase.
If the overpressure valve is opened the pump absorbs
~ 6-7 A
If excessive absorptions are revealed (> 5A) proceed
with replacement of the filter.
If the anomaly is still present, replace the pump as
described in the VEHICLE SHOP HANDBOOK.
Pump electrical controls
500-4T
Fuel injection
10-26
Hydraulic control and system maintenance
Before any check of the system pressure, it is impor-
tant to clean the components of the feeding system
very accurately.
To carry on the checking operations, it is necessary to
use the specific tool for the fuel pressure check,
included in the tool kit.
The specific tool is provided with quick-connections of
the same kind as the system.
To disconnect the female pipe ends (injector side), it is
necessary to press the two tongues and extract the
pipe end.
Do not force the pipe end if it does not go out; try to
turn it. The system is arranged in such a way that, by
increasing the traction, the pipe end is further locked.
To disconnect the male pipe ends (pump side) it is
necessary to press the rings coaxial to the pipe and
extract the pipe ends.
Do not force the pipe end if it does not go out; try to
turn it. The system is arranged in such a way that, by
increasing the traction, the pipe end is further locked.
Before disconnecting any quick-connection, reduce
the system pressure.
Disconnect the electric connector from the pump
support while the engine is running and wait until it
stops. The engine stops at about 1,5 bar.
Disconnect the pipe end with the utmost care. Avoid
sprays in the eyes.
CAUTION
CAUTION
CAUTION
500-4T
Fuel injection
10
10-27
The system pressure must be checked by connecting
with the pump side in order to make the operation
easier.
Connect the manometer with the delivery pipeline (right
side) and the extension pipe with the return pipeline (left
side).
IMPORTANT Before the mounting, make sure that
the tool ducts are cleaned.
Fuel pressure manometer fitting 8140612
Checking the pressure regulator
Connect the diagnosis tester No. 8140595. Select
the function OPERATING DIAGNOSIS from the
menu. Select the function PUMP DIAGNOSIS.
Operate the function with the under panel feed on and the engine off. The control unit operates the pump for
30 seconds.
FORWARD
SPEED
500-4T
Fuel injection
10-28
YES
The pressure regulator works correctly
Regulation pressure too low
Operate the pump rotation again.
By means of long-flat-nose pliers, throttle the return pipeline momentarily
by acting
only on the extension belonging to the specific tool (the pipe delivered
along with the vehicle does not allow this operation).
Fuel pressure = higher than 300 KPa (3 bar).
Pressure too high
Make sure that the return pipeline is
neither obstructed nor squashed.
NO
Replace the pressure regulator
See the check of the pump support.
NO
NO YES
Let the system bleed for a few seconds. Make sure that there is no external blow-by. Check the regula-
tion pressure with a pump supply voltage higher than 12 V. Regulation pressure = 300 320 KPa
(3 3,2 bar)
500-4T
Fuel injection
10
10-29
Replace the pressure regulator
Refer to the check of the pump support.
Replace the fuel pump
Refer to the check of the pump support.
Checking the pump and the fuel filter
This operation is useful during maintenance to check the working of the delivery filter.
Connect the diagnosis tester No. 8140595.
Connect the fuel pressure control kit.
Select the function OPERATING DIAGNOSIS from
the diagnosis tester menu
Select the function PUMP DIAGNOSIS.
The pump is operated for 30 seconds.
NO YES
Let the system bleed for a few seconds. Make sure
that there is no external blow-by. By means of long-
flat-nose pliers, throttle the return pipeline momen-
tarily by acting only on the extension belonging to
the specific tool No. 8140181, with a pump supply
voltage higher than 12 V. Check the maximum
system pressure.
Maximum pressure = > 600 KPa (6 bar)
YES NO
500-4T
Fuel injection
10-30
Check if the pressure decreases with the same tendency as the system without throttling.
Check the system seal
Operate the pump for 30 seconds by
means of the diagnosis tester No.
8140595. After the pump stop,
wait 3 minutes.
Check the system pressure.
Fuel pressure = higher than 200 KPa (2
bar)
The pressure is lower
Carefully check the voltage with pump
under stress. If the voltage is higher
than 12 V, replace the pump (see the
check of the pump support).
The system seal is good.
Repeat the test. When the pump stops, by means of
long-flat-nose pliers, throttle the return pipeline
momentarily by acting only on the extension belong-
ing to the specific tool. This operation makes the fuel
pressure increase.
NO
YES
The pressure decreases much more slowly
Replace the pressure regulator (refer to the check
of the pump support). Check the system seal again.
500-4T
Fuel injection
10
10-31
The pressure decreases much more slowly
Check and, if necessary, replace the injector due to
an insufficient seal (see Chap. HEATING GROUP
AND TIMING SYSTEM).
No tendency variations
Repeat the test by throttling the pipe of the
specific tool No. 8140181 in the area be-
tween by-pass and injector. Check if the
pressure decreases much more slowly.
NO YES
No tendency variations
Repeat the test by throttling the pipe of the
specific tool No. 8140181 in the area be-
tween by-pass and injector. Check if the
pressure decreases with the same tendency
as the system without throttling.
The single-acting valve of the pump is faulty.
Replace the pump (refer to the check of the
pump support).
Carefully check the seals of the pipes and of
the injector fitting. If necessary, repeat the seal
checks of the components.
IMPORTANT The weak seal of the system only makes the starting less immediate.
500-4T
Fuel injection
10-32
Check the free delivery
Disconnect the pump connector, start the engine,
wait until it stops, connect the pump connector
again. Disconnect the fuel return pipe from the
pump support (left pipe).
Insert the return pipe into a graduated receptacle.
Operate the fuel pump for 10 seconds by means of
the diagnosis tester No. 8140595. Make sure that
the supply voltage is higher than 12V.
Measure the quantity of fuel delivered.
Pump free delivery: 300 - 320 cc (18.3 - 19.52 cu.in)
The fuel filter is not obstructed. It is possi-
ble to keep on using it for no more than
48000 km (30,000 miles).
The delivery is lower than 250 cc (15.25 cu.in)
The fuel filter is dirty. Replace the pump support.
NO
YES
500-4T
Fuel injection
10
10-33
Checking the fuel filter
It is necessary to check:
- the current absorbed by the pump (see the
relative paragraph).
The obstructed filter leads to:
- reduction of the performance, especially with full
power.
- pump absorption increase
IMPORTANT Do not blow in compressed air. An
obstructed filter may cause the injector obstruction.
Injector circuit control
Terminals Conditions Standard
13-23 During timing of the pump Battery tension
with the engine stopped
CIRCUIT DIAGRAM
COIL
SPARK PLUG
FUEL INJECTOR
FUEL PUMP
PRIMARY INJECTION RELAY (WITH DIODE)
SECONDARY INJECTION RELAY
SECONDARY FUSES (15A)
ECU CONTROL UNIT
9
10
24
52
4
5
6
7
G
r
/
N
R
/
B
A
r
/
V
R
/
M
R
/
N
M
/
N
A
r
/
V
G
r
/
N
R
/
M
6
5
7
A
r
/B
i
G
r
/
R
R
/
M
R
/M
4
B
P
10 9
2 1
8
5
8
6
8
7
3
0
1 1 53
D
F
15A
15A
3A
15A
15A B
A
E
C
V/R Ar/V
24
INTERRUTTORI STOP
+
INTERRUTTORE
CAVALLETTO
LATERALE
RELE
LUCI
STOP
12
C
E
N
T
R
A
L
I
N
A

E
.
C
.
U
.
22
N
N
N
24
23
26
25
52
Gr/R
Ar/Bi
21
20
19
17
16
15
14
13
18
2
R/B
11
10
9
8
7
6
5
4
3
1
Gr/N
500-4T
Fuel injection
10-34
Connect the diagnosis tester 8140595.
(see the relative paragraph)
Select the "active diagnosis" function on the menu
Select the "injector diagnosis" function.
Activate the function with under-panel feed inserted and the engine stopped.
The control unit commands the fuel pump constantly and at the same time activates opening
of the injector. The injector openings are repeated for a few seconds.
Acoustically check the injector openings and await the tester result.
4 injector openings
are revealed.
The fuel injection tester responds
test completed successfully".
No injector openings are
revealed.
The fuel injection tester
responds "test failed".
No injector openings are
revealed.
The fuel injection tester responds
"test completed successfully".
The injector control circuit is
efficient. Proceed with injector
hydraulics control.
The injector control circuit works correctly.
Repeat the acoustic check and carry on the
hydraulic control of the injector (see the relative
VEHICLE SHOP HANDBOOK)
Select the ERRORS function from the menu.
Check if only the injector damage is present.
NO
YES NO
500-4T
Fuel injection
10
10-35
HV coil failure is indicated. Check the pump relay control circuit (see the
pump supply wiring diagram)
Check the supply circuit with the 15A fuse
and the electromagnetic switch. Common
supply to the fuel pump.
(see the pump supply wiring diagram)
YES
No continuity
Disconnect the connector and repeat the resistive
control directly on the injector terminals.
Resistance =14,5 2%
YES
NO
Check the continuity between:
- red-yellow supply connector of the injector and
pin 13
- injector supply connector and black-green cable
terminal on the connector between the vehicle
system and the injection system.
Reset the continuity or replace the harness.
Replace the injector.
500-4T
Fuel injection
10-36
REVOLUTIONS SENSOR
7-12 Starting speed 0,8 - 4.5 V~
The sensor allows recognition of the revolutions and the angular position of the driving shaft with reference to the
TDC. As the phonic wheel is keyed on the camshaft it is also possible to recognize the 4-stroke cycle. This solution
allows command of the injector and spark plug every 2 revolutions of the driving shaft.
The sensor is of the reluctance variation kind, and can therefore be assimilated to a alternate tension generator which
feeds the control unit.
The signal frequency is interrupted by the vacuum generated by two cogs lacking on the phonic wheel.
The sensor signal is fundamental in order to achieve engine ignition.
The engine may however function even with an unstable signal, due to corrective action on the control unit.
The total absence of revolutions signals does not cause the fuel injection indicator to light up.
When the signal anomaly (open circuit) occurs during use on the road, the indicator signals the start of the anomaly,
blinking as follows:
CIRCUIT DIAGRAM
MULTIPLE CONNECTORS
ECU CONTROL UNIT
ENGINE REVOLUTION SENSOR 2 1
52
INDICATOR ON
INDICATOR OFF
2
1
2
CENTRALINA E.C.U.
2
2
N
NN
1
N
2
4
2
3
2
6
2
5
52
2
1
2
0
1
9
1
7
1
6
1
5
1
4
1
3
1
8
2
B
/
N
B
1
1
1
0
98765431
5 5 10
SEC
ECU CONTROL UNIT
500-4T
Fuel injection
10
10-37
Connect the diagnosis tester No. 8140595. See the relative paragraph. Start the engine.
The engine starts normally
Select the errors function from the menu. Check for
the presence of anomalies concerning the
"signals panel".
To control the sensor and related circuit proceed as follows:
YES NO
NO
The engine does not start
Select the errors function from the menu.
NO YES
No anomaly is
revealed.
Proceed according
to the indication
revealed
IThe value increases
progressively with time,
insisting with engine
ignition.
Check the circuit and
the sensor.
YES
500-4T
Fuel injection
10-38
Disconnect the connection between the phase-
revolutions sensor and the fuel injection system.
Measure the resistance of the sensor
connecting the multimeter between
the terminals marked and .
Phase-revolution sensor resistance =680 15%
YES NO
Replace the revolutions
sensor.
Check the earthing isolation between one pole and
the shielding.
+ k k-
kS + k - = infinity (>1M)
YES
NO
YES
IMPORTANT
- During repairs install the sensor cable correctly .
- Do not force the cable.
- A poor shielding of the cable may prejudice the functioning of the engine at high speed.
Check the harness and, if necessary, take the
measurement from the control unit PIN.
500-4T
Fuel injection
10
10-39
Connect the diagnosis tester 8140595 (see the
relative paragraph)
Select the function operating diagnosis from the
menu.
Activate the HV coil control with the commutator set
to "ON", switch on "RUN" and side stand raised.
Await the response of the tester.
HV COIL
20-23 During pump timing Battery tension
with engine stopped
The ignition system integrated with the fuel injection is of the high-efficiency induction type.
The control unit controls two important parameters:
- Spark advance
This is optimized on the spot on the basis of engine revolutions, engine load, temperature and environmental
pressure.
With the engine idling, it is optimized to achieve speed stability at 1450 50 rpm.
- Magnetization time
The magnetization time of the coil is controlled via the control unit.
The ignition power is increased during the engine starting phase
The fuel injection system recognizes the 4-stroke cycle, and so ignition is commanded only during the compression
phase.
To control the ignition circuit proceed as follows:
Test completed successfully
Test failed
Repeat the test
Test failed
Select the errors function
from the menu.
Check for the presence of
current or memorized errors
with respect to the HV coil
NO YES
CIRCUIT DIAGRAM
COIL
SPARK PLUG
FUEL INJECTOR
FUEL PUMP
PRIMARY INJECTION RELAY (WITH DIODE)
SECONDARY INJECTION RELAY
SECONDARY FUSES (15A)
ECU CONTROL UNIT
4
5
6
7
9
10
24
52
G
r/N
R
/B
A
r/V
R
/M
R
/N
M
/N
A
r/V
G
r/N
R
/M
6 5
7
A
r/B
i
G
r/R
R
/M
R
/M
4
B
P
10 9
2 1 8
5
8
6
8
7
3
0
1 1 53
D
F
15A
15A
3A
15A
15A B
A
E
C
V/R Ar/V
24
INTERRUTTORI STOP
+
INTERRUTTORE
CAVALLETTO
LATERALE
RELE
LUCI
STOP
12
C
E
N
T
R
A
L
I
N
A

E
.
C
.
U
.
22
N
N
N
24
23
26
25
52
Gr/R
Ar/Bi
21
20
19
17
16
15
14
13
18
2
R/B
11
10
9
8
7
6
5
4
3
1
Gr/N
Check the continuity of the HV coil on LV and HV sides
E
C
U

C
O
N
T
R
O
L

U
N
I
T
SWITCH
STOP
RELAY
LIGTHS
STOP
SIDE STAND
SWITCH
500-4T
Fuel injection
10-40
The coil circuit control is
efficient.
Proceed with secondary
control of the della HV coil,
cable and shield cover
NO
Check continuity of the HV coil primary
See diagram
Resistance of the primary = 0,5 8%
NO
YES
YES
Check the earthing isolation of the primary circuit
Measure between one of the two terminals of the
primary and the earth.
Primary-earth = infinity (>1M)
NO
YES
500-4T
Fuel injection
10
10-41
Check the resistance of the secondary
Measure the resistance between one of the two
terminals of the primary and the spark plug cable outlet.
Primary-HV cable outlet = 3.1K 9%
NO NO
NO
Replace the coil.
YES
The coil conforms.
Shielded cap control
Measure the resistance of the shielded cap
Resistance = 5 K
If substantially different values are obtained (<1; >20K),
proceed with replacement.
NOTE
The lack of shielding on the cap or spark plug may lead
to problems in the fuel injection system.
For full information concerning the spark plug, see the
chapter "Maintenance" Chapter. GENERAL INFOR-
MATION AND MAINTENANCE.
IGNITION TIMING
The spark advance is determined electronically on the
basis of known parameters from the control unit.
For this reason it is not possible to state reference
values based on the number of engine revolutions.
YES
Fuel injection
500-4T
chap. 10
10-42
Release 00 2001-12
The spark advance value can be obtained at any time
by means of the diagnosis tester 8140595.
Using stroboscopic lamp it is possible to check if the
spark advance, determined by the fuel
injection system, corresponds to that truly activated on
the engine.
Proceed as follows:
- Remove the transmission box cover. See chapter
AUTOMATIC TRANSMISSION
- Remove the plug for inspection of the TDC reference
made between the flywheel and the cover crankcase.
See chapter FLYWHEEL HOUSING.
- Using the driving pulley, rotate the engine until the
reference alignment to identify the TDC is found.
- Reproduce the reference between the driving pulley
and the engine crankcase See figure.
500-4T
Fuel injection
10
10-43
- Reassemble the flywheel side inspection plug.
- Connect the diagnosis tester 8140595. See the
relative paragraph.
- Start the engine.
- Select the function from the menu "parameters".
- Select the stroboscopic lamp command in the tradi-
tional 4-stroke engine position (1 spark 2 revolutions).
- Check correspondence between the revolutions
values and actual spark advance and those stated by
the diagnosis tester.
- If the values do not correspond check:
- valve gear timing
- phase-revolutions sensor
- fuel injection control unit
COOLANT TEMPERATURE SENSOR
4-22 coolant temperature With sensor connected:
20 = 2500 100
80 = 308 6
CIRCUIT DIAGRAM
ACCELERATOR SENSOR
ENGINE AIR THERMISTOR
DASHBOARD/ENGINE WATER THERMISTOR
SECONDARY FUSES
FALL SENSOR
DASHBOARD AIR T THERMISTOR
DASHBOARD
ECU CONTROL UNIT
36
42
43
52
13
14
15
24
TO TEMPERATURE
INDICATOR
12
C
E
N
T
R
A
L
I
N
A

E
.
C
.
U
.
22
N
N
N
24
23
26
25
52
Ro/G
Ar/N
Ro/N
Gr
21
20
19
17
16
15
14
13
18
2
M/G
Ar
11
10
9
8
7
6
5
4
3
M/Bi
1
A
r/R
B
i/N
M
/G
M
/B
i
R
o
/N
13
14
15
1
G
r
G
r
1
G
r
A
r
D
F
15A
15A
3A
15A
15A B
A
E
C
V/R Ar/N
24
B
i/N
N
R
o
/G
G
r
1
36
+
13
B B
W SET
9 10 1112 6 7 8 2 3 4 5 1
M A
r/R
1
B
15 14 16 9 8 7 5 6 4 2 3 1
M R
o
B R
o
B
i/N
TRIP
20 19 18 16 17 15 14 13 12 11 10
1
42
x1000r/min
EFI EFI EFI
ABS ABS ABS ABS
EFI
43
! !! ! !! !!! !! ! !! ! !
Km/h
mp/h
E
C
U

C
O
N
T
R
O
L

U
N
I
T
500-4T
Fuel injection
10-44
The coolant temperature sensor mounted on the engine head, supplies indications to the digital instrument and fuel
injection.
It is constructed with two electrically distinct sections.
The fuel injection section has a NTC sensor connected with a 5V feed circuit. The resistance variation causes a circuit
tension variation. This tension is linked to a temperature value.
With this information, the control unit can manage the engine functioning, optimizing it for all temperatures.
Damage to this circuit causes the fuel injection indicator to light up and protective action (amongst which continuous
running of the electrical fan). Under these conditions, the engine can still function even if not at optimum standard,
but always safeguarding the integrity of the catalyctic converter.
The most difficult anomaly to manage is an unreal temperature indication, but one which is comprised in the possible
temperatures field. This may lead to a lack of protective action and incorrect carburation management. Such an
anomaly can be highlighted more easily at ignition stage.
To check the sensor and related circuit proceed as follows.
Connect the diagnosis tester 8140595. See the relative paragraph.
Check if anomalies concerning the coolant temperature sensor have been registered.
NO
The EMS system has not received temperature indications that are not included in the field of
possible temperature.
If it is suspected that a temperature indication is incorrect, proceed in any
event as indicated below.
IMPORTANT an incorrect temperature indication may be perceived by matching it with the analog
instrument indication on activation of the electrical fan.
In all cases, before proceeding with the sensor control, check the filling and drainage of the
cooling system. See Chapter. GENERAL INFORMATION AND MAINTENANCE.
Before proceeding with control of the sensor and related circuit, it is advisable to wait until the engine has
cooled completely so that the vehicle is adjusted to the working environment temperature.
YES
Set ignition to "ON" with switch on "RUN" and side stand raised.
Select the "parameters" menu.
Do not start the engine.
Check indications for:
coolant temperature
air intake temperature
ambient temperature indicated by the digital instrument
The three indications are equal or differ by little (for example 1C).
YES
The temperature sensor is probably giving a correct indication.
Proceed with control at ~80 C (176 F).
NO
500-4T
Fuel injection
10
10-45
Disconnect the coolant temperature sensor
connection.
Measure the sensor resistance between the
terminals indicated on the diagram.
Check that the resistance corresponds with the
values stated on the basis of temperature.
NO
YES
Replace the sensor.
RESISTANCE TEMPERATURE
9.6 k -10 C (14 F)
5.975 k 0 C (32 F)
3.81 k +10 C (50 F)
2.5 k +20 C (68 F)
1.68 k +30 C (86 F)
0.3 k +80 C (176 F)
IMPORTANT
To check the sensor more accurately, it is necessary to
remove it from the engine and check its resistance at
controlled temperature.
By using a proper receptacle, dip the metallic part of the
sensor in water, heat progressively and read the tem-
perature and resistance values. Check by following the
table.
AIR INTAKE TEMPERATURE SENSOR
18-22 air intake temperature 20C (68F) With sensor connected: 3750 200
CIRCUIT DIAGRAM
Check harness and/or control unit.
12
C
E
N
T
R
A
L
I
N
A

E
.
C
.
U
.
22
N
N
N
24
23
26
25
52
Ro/G
Ar/N
Ro/N
Gr
21
20
19
17
16
15
14
13
18
2
M/G
Ar
11
10
9
8
7
6
5
4
3
M/Bi
1
A
r/R
B
i/N
M
/G
M
/B
i
R
o
/N
13
14
15
1
G
r
G
r
1
G
r
A
r
D
F
15A
15A
3A
15A
15A B
A
E
C
V/R Ar/N
24
B
i/N
N
R
o
/G
G
r
1
36
+
13
B B
W SET
9 10 1112 6 7 8 2 3 4 5 1
M A
r/R
1
B
15 14 16 9 8 7 5 6 4 2 3 1
M R
o
B R
o
B
i/N
TRIP
20 19 18 16 17 15 14 13 12 11 10
1
42
x1000r/min EFI EFI EFI
ABS ABS ABS ABS
EFI
43
! !! ! !! !!! !! ! !! ! !
Km/h
mp/h
ACCELERATOR SENSOR
SECONDARY FUSES
FALL SENSOR
DASHBOARD
ECU CONTROL UNIT
36
42
43
52
13
14
15
24
E
C
U

C
O
N
T
R
O
L

U
N
I
T
500-4T
Fuel injection
10-46
Do not connect the control unit connector
The air intake temperature sensor is inserted in the lower part of the throttle body from the filter box side.
The sensor is an NTC and has the same function layout as the coolant temperature sensor.
This signal is used to optimize the engine functioning. It is, however, a less influential signal than that of the coolant
temperature.
In case of circuit damage, the control unit commands the lighting up of the fuel injection indicator and activates
protection control, thus guaranteeing engine function.
To control the sensor and related circuit, proceed as follows.
Connect the diagnosis tester 8140595. See the
relative paragraph.
Select the ERRORS function from the menu.
Check if any anomalies concerning the air intake
temperature sensor have been registered.
The EMS system has not received temperature indications not included in
the field of those possible.
If it is suspected that a temperature indication is incorrect, proceed with
controls as indicated below.
YES
NO
Before proceeding with control of the sensor and related circuit, it is advisable to wait until the engine has
cooled completely so that the vehicle is adjusted to the working ambient temperature.
Set ignition to "ON" with switch on "RUN" and side stand raised.
On the diagnosis tester, select the parameters menu
Do not start the engine.
Check indications for:
coolant temperature
air intake temperature
ambient temperature indicated by the digital instrument.
The three indications are equal or differ by little (for example, 1C)
The air intake temperature sensor is probably
giving a correct indication.
NO
YES
500-4T
Fuel injection
10
10-47
Disconnect the air intake temperature
sensor connector.
Measure the resistance between the
sensor terminals.
Check that the resistance corresponds to the values
stated on the basis of temperature.
NO
YES
RESISTANCE TEMPERATURE
9.6 k -10 C (14 F)
5.975 k 0 C (32 F)
3.81 k +10 C (50 F)
2.5 k +20 C (68 F)
1.68 k +30 C (86 F)
Proceed with sensor replacement.
Check the harness and/or the control unit.
500-4T
Fuel injection
10-48
PRESSURE SENSOR
This sensor does not have an installation, in that it is inserted directly into the control unit.
The sensor allows the control unit to optimize engine performance based on altimeter variations.
To control the sensor proceed as follows.
relative paragraph.
Check if anomalies concerning the pressure sensor
have been registered.
YES
NO
Proceed with replacement of the fuel injection control unit.
Select the parameters function from the menu.
Check that the mm/Hg pressure indication
corresponds to that of another vehicle or to an
external barometer.
Max error: 20 mmHg
NO YES
The ambient pressure
signal is correct.
Replace the fuel injection
control unit.
500-4T
Fuel injection
10
10-49
T.P.S.=THROTTLE POSITION SENSOR
1-22 Ignition set to "ON" 5V
11-22 Opening the throttle gradually Volt=
progressive progressive increase
The TPS is set on the throttle body and is of the fixed type.
This sensor receives a 5V feed from the control unit and sends it a gradually increasing tension as the throttle opening
increases. The control unit converts this tension into an angular position of the throttle.
The number of engine revolutions and the TPS are the two basic signals for management of the engine.
Damage to this circuit causes the fuel injection indicator to light up and activation of protection. Under these
conditions the engine can function even if not on optimum, always safeguarding the integrity of catalyctic converter.
The TPS is particularly important in correspondence with the small openings in the throttle. These are also the areas
where the sensor works most often and therefore to be controlled more often.
To control the sensor and related circuit proceed as follows.
relative paragraph.
Ignition set to "ON" with switch on "RUN"
and side stand raised.
Select the "ERRORS" function from the tester menu
Check if the control unit has revealed anomalies
Concerning the TPS.
NO
CIRCUIT DIAGRAM
YES
MULTIPLE CONNECTORS
ACCELERATOR SENSOR
SECONDARY FUSES
FALL SENSOR
DASHBOARD
ECU CONTROL UNIT
36
42
43
52
1
13
14
15
24
12
C
E
N
T
R
A
L
I
N
A

E
.
C
.
U
.
22
N
N
N
24
23
26
25
52
Ro/G
Ar/N
Ro/N
Gr
21
20
19
17
16
15
14
13
18
2
M/G
Ar
11
10
9
8
7
6
5
4
3
M/Bi 1
A
r/R
B
i/N
M
/G
M
/B
i
R
o
/N
13
14
15
1
G
r
G
r
1
G
r
A
r
D
F
15A
15A
3A
15A
15A B
A
E
C
V/R Ar/N
24
B
i/N
N
R
o/G
G
r
1
36
+
13
B B
W SET
9 10 1112 6 7 8 2 3 4 5 1
M A
r/R
1
B
15 14 16 9 8 7 5 6 4 2 3 1
M R
o
B R
o
B
i/N
TRIP
20 19 18 16 17 15 14 13 12 11 10
1
42
x1000r/min EFI EFI EFI
ABS ABS ABS ABS
EFI
43
! !! ! !! !!! !! ! !! ! !
Km/h
mp/h
E
C
U

C
O
N
T
R
O
L

U
N
I
T
500-4T
Fuel injection
10-50
YES
Select the "parameters" function from the
diagnosis tester menu.
Check if the control unit recognizes the
extreme positions:
throttle valve to minimum
throttle valve to maximum
NO
Check regulation of the throttle command flexible
transmissions.
NO
Reset or replace.
YES
YES
Gradually open the throttle valve,
check that mV indication
Increases gradually in proportion to opening variations.
YES
The TPS conforms.
NO
NO
Check the TPS sensor harness continuity and the earthing
insulation of the three circuit lines.
Check the control units: (check + SV on the sensor) between
pins 1-22 of the control unit.
500-4T
Fuel injection
10
10-51
STEPPER MOTOR
The throttle body is supplied with an auxiliary air circuit. This is activated more or less by a piston valve controlled
by a stepper.
The stepper is fed by the control unit only when necessary to vary the opening.
Revolution is subdivided in rev fractions called steps.
By varying the opening steps, it is possible to adequately feed the engine to facilitate the ignition procedure and
correct the cold engine air feed.
When the engine reaches normal running temperature, the stepper is partly closed.
To avoid anomalous wear on the adjusting piston, the speed functioning is achieved with a minimum opening of
around 20 steps.
To recover any adjustments, when ignition is set to OFF, the piston closes completely and reopens by the number
of steps pre-established (autoreset).
When the control unit modifies the opening steps of the stepper, it also modifies the fuel injection timing to guarantee
that correct carburation is maintained.
Idling speed is practically stable 1450-50 rpm. After a warm starting phase the first revolutions increase is perceivable
with the subsequent closure of the stepper to stabilize the speed.
On revealing speed irregularities, before proceeding with electrical controls, check accurately the cleanliness of the
throttle and the auxiliary air circuit.
MULTIPLE CONNECTORS
STEPPER MOTOR
SECONDARY FUSES
ECU CONTROL UNIT
24
52
1
3
CIRCUIT DIAGRAM
3
GV
i
R
o
A
z
1
12
C
E
N
T
R
A
L
I
N
A

E
.
C
.
U
.
22
N
N
N
Ro
24
23
26
25
52
Az
Ar/N
G
21
20
19
17
16
15
14
13
18
2
Vi
11
10
9
8
7
6
5
4
3
1
D
F
15A
15A
3A
15A
15A B
A
E
C
V/R Ar/N
24
+
E
C
U

C
O
N
T
R
O
L

U
N
I
T
500-4T
Fuel injection
10-52
Start the engine and allow it to warm up.
With a coolant temperature greater than 70C (158 F),
the control unit should command the stepper
with around 20 "steps".
To control the stepper and related circuit, proceed as follows.
Connect the diagnosis tester 8140595. See the relative paragraph.
Set ignition to "ON" with switch in position "RUN" and side stand raised.
Lift the vehicle with the central stand.
Select the errors function from the menu
Check if the control unit has registered anomalies
concerning the stepper circuit.
Select the parameters function from the menu
Check the number of "steps" programmed by
the control unit to achieve ignition.
This arrangement is a function of the engine
temperature.
20 C (68 F) = ~ 80-90 steps
NO
YES
NO
YES
YES
NO
500-4T
Fuel injection
10
10-53
Check the coolant temperature sensor signal. See the
relative paragraph.
If necessary check the control unit.
YES
NO
Select the active diagnosis function from the
menu
Select "stepper" diagnosis
Activate the diagnosis with the engine
warm and idling.
Check if the stepper commands any revolutions variation
and await the response of the diagnosis tester.
Revolutions variations perceived.
YES
Stepper and related circuit are efficient.
Test failed
No revolutions variation
NO
No revolutions variation.
Remove the throttle body (see
Chapter. THERMAL UNIT AND
TIMING SYSTEM).
Check cleanliness of the auxiliary
air circuit.
Set ignition from "ON" to "OFF" and
again to "ON" and check if
the piston valve moves.
If the valve does not move, replace the throttle body.
See Chapter. THERMAL UNIT AND TIMING SYSTEM.
NO
NO
500-4T
Fuel injection
10-54
Proceed with control of the stepper circuit.
YES
Disconnect the stepper connection.
Check the resistance of the stepper circuits
connecting the tester as shown in the diagram.
The two measurements must have the same value.
Resistance = ~ 51
NO
Proceed with replacement of the throttle body.
See Chapter. THERMAL UNIT AND TIMING SYSTEM. YES
Check the continuity of the four stepper supply lines and the earthing insulation of the four stepper
supply lines.
Check the earthing isolation of the 4
wires of the stepper.
14-23 = >1M (infinity)
NO
YES NO
NO
YES
500-4T
Fuel injection
10
10-55
Repair or replace the harness.
NO
NO
YES
Connect the stepper connector.
Repeat continuity control of the tool pins.
14-24 = ~ 51
6-21 = ~ 51
If necessary, replace the control unit.
The stepper circuit is efficient.
Check the control unit connection
If necessary replace
la control unit.
NO YES
500-4T
Fuel injection
10-56
MINIMUM CARBURATION REGULATION
The fuel injection system control unit is programmed to guarantee optimum carburation during use on the road.
Minimum carburation necessitates a refinement destined to compensate for the productive tollerances and
adjustments of the engine.
This regulation is carried out by modifying the opening time of the injector when the engine is idling.
To carry out the regulation, proceed as follows:
Preheat and check reset of the exhaust gas analyzer
494929.
Remove the plug of the exhaust manifold and connect
the extension with the intake for the analyser tube.
Minimum carburation regulation must be carried out on an engine in good working condition.
Preventive checks:
- spark plug
- air filter
- good air intake system seal
- good exhaust system seal
- valves play
- fuel filter
- fuel pressure
Connect the diagnosis tester 8140595 see the relative paragraph.
Select the ERRORS function from the menu
Check the presence of any anomalies.
YES
NO
Select the PARAMETERS function
from the menu.
Repair according to the
indications given.
500-4T
Fuel injection
10
10-57
Activate the exhaust gas analyser and check
the following conditions:
- CO = 1.250.25%
- CO2 = 14.501%
Press the keys of the AXONE 2000 to in-
crease/decrease the value set on the display and
check the value on the exhaust analyser display.
Start the engine and allow it to warm up until the following conditions are reached:
- coolant temperature = more than 70C (158 F)
- air intake temperature = 25 - 30C (77 - 86 F)
On revealing non-conformant CO values adjust fuel injection timing to minimum.
Select the CO PRECALIBRATION function from the diagnosis tester menu
Activate the adjusting function.
NO
YES
Regulation is correct.
The display shows the words "TRIMMER VALUE".
The numeric indication may be positive or negative.
500-4T
Fuel injection
10-58
To increase CO it is necessary to increase fuel injection timing.
To decrease CO it is necessary to decrease fuel injection timing.
Regulate the trimmer value according to indications given in the table:
After changing the trimmer value, wait until the CO value becomes constant. When the regulation is
correct, press OK to memorise the value in the control unit.
IMPORTANT When the CO percentage is correct and the CO
2
value does not fall within the preset values, LAMBDA
value will also be false.
In this case check accurately the exhaust system seal.
IMPORTANT A trimmer value of 0 corresponds to medium fuel injection.
After regulation, engines may find carburation with either positive or negative trimmer values. This is due to normal
production tolerance.
TRIMMER
VALUE
+100
+ 50
+ 10
0
- 10
- 50
-100
FUEL INJECTION TIMING C O
HIGH
LOW
INCREASES
DECREASES
MEDIUM
500-4T
Fuel injection
10
10-59
When the CO percentage is correct and the HC (PPM) value is greater than the maximum allowed limit, check:
- spark plug
- valves play
- timing phase
- exhaust valve seal
If it proves necessary to replace the control unit it is important to carry out TPS reset and preventively preset the
trimmer value of the original control unit (if available).
In all cases check the CO value again.
500-4T
Fuel injection
10-60
CIRCUIT DIAGRAM
The electrical ventilation system is fed by an electromagnetic switch connected under the panel and controlled by
the fuel injection control unit.
The fuel injection control unit manages control of the electrical fan on the basis of temperatures revealed by the
engine.
If a prolonged rotation of the electrical fan should occur, before proceeding with electrical system controls, check
accurately:
- level of the expansion tank
- drain from the tube leading to the engine
- drain on outlet from the cylinder head
- thermostat efficiency
- pump efficiency.
For these controls, see chapter COOLING.
ELECTRICAL FAN CONTROL CIRCUIT
5-23 Set ignition to position "ON"
Switch on "RUN" Battery
Side stand raised tension
Electrical fan stopped
1
16
24
MULTIPLE CONNECTORS
FAN
SECONDARY FUSES
KEY SELECTOR
FAN RELAY
ECU CONTROL UNIT
35
38
52
12
C
E
N
T
R
A
L
I
N
A

E
.
C
.
U
.
22
N
N
N
24
23
26
25
52
Vi/N
21
20
19
17
16
15
14
13
18
2
11
10
9
8
7
6
5
4
3
1
Ar/N
G
/N
16
1
BG
/N
B
R
/B
i
D
F
V/N
15A
15A
3A
15A
15A B
A
E
C
V
V/R Ar/N
24
++
8
6
38
8
7
3
0
8
51
35
V
R
/B
i
G
/N
R
/B
i
V
i/N
VV
/N
V
E
C
U

C
O
N
T
R
O
L

U
N
I
T
500-4T
Fuel injection
10
10-61
To control the circuit, proceed as follows:
Connect the diagnosis tester 8140595 see the relative paragraph.
Select the ERRORS function from the menu
Check if the control unit has registered anomalies concerning the electrical ventilation control circuit.
NO
YES
Select the ACTIVE DIAGNOSIS
function from the menu
Activate the electrical fan
diagnosis function
Check acoustically the electrical
fan rotation.
Await the results from the
diagnosis tester.
Test completed successfully.
The fan rotates.
NO YES
The electrical ventilation system conforms.
Test failed.
The fan does not rotate.
NO
Test completed successfully.
The fan has not worked.
The electromagnetic switch control circuit is efficient.
Check the electrical fan connection, electromagnetic switch contact efficiency,
positive wires, negative wire and the electrical fan motor.
500-4T
Fuel injection
10-62
Disconnect the electrical fan control
electromagnetic switch
Check continuity of the excitation coil.
85 - 86 = 15050
Replace the electromagnetic switch.
NO YES
Reset or replace the harness.
500-4T
Fuel injection
10
10-63
The analog revolutions counter receives commands from the digital instrument panel which in turn receives signals
from the fuel injection control unit.
To control the revolutions counter and related circuit, proceed as follows:
REVOLUTIONS COUNTER CONTROL CIRCUIT
Ignition set to "ON"
Switch set to "RUN"
Side stand raised
Engine stopped
3 - 23 9 - 10 Volt
Select Active diagnosis on the menu
Activate diagnosis of the revolutions counter.
Check that revolutions counter instrument rises
from zero to 3500 revolutions before
returning to zero.
The control circuit of the revolutions counter is
working.
NO YES
Repair or replace the harness.
500-4T
Fuel injection
10-64
NOTES
Lubrication
Lubrication
500-4T
chap. 11
11-1
11
Release 00 2001-12
Lubrication
500-4T
chap. 11
11-2
Release 00 2001-12
SPECIFICATIONS
Sump capacity Overhaul 1.7 litres (0.44 Gal)
Oil and filter change 1.5 litres (0.39 Gal)
Recommended engine oil Selenia HI Scooter - 4Tech specification API SJ
5W/40
Assembly clearances
lobe ends 0.05 - 0.008 mm
Radial play of the external rotor 0.05 - 0.12 mm (0.002 - 0.004 in)
End play of the rotors 0.025 - 0.065 mm (0.0009 0.002 in)
By-pass Type piston
Piston diameter 13.9
-0.039
mm (0.54
-0.0015
in)
Free length of spring 62.5 mm (2.46 in)
Calibration pressure 4 bar (58 Psi)
Pre-filter Type plastic mesh
Oil filter Type paper with overpressure by-pass
and antidraining
Minimum oil pressure Calibration 0.3 - 0.6 bar (0.01 - 0.02 Psi)
signal switch
Head ubrication control Diameter 1
0.05
mm
jet (0.039
0.002
in)
Piston cooling nozzle Diameter 0.8
0.05
mm
(0.031
0.002
in)
Crankcase ventilation Device metal reed valve
control and decanting chamber
-0.057
Oil pump Type Trochoidal
Rotor thicknesses 8 mm (0.31 in)
(0.002 - 0.0003 in)
-0.0022
5 - 7 Nm
(3.7 - 5.1 Nm)
Lubrication
500-4T
chap. 11
11-3
11
Release 00 2001-12
GENERAL CHARACTERISTICS OF THE LUBRICATION SYSTEM
The lubrication system is divided into two sections:
- high pressure
- low pressure
All the components forming part of the high pressure section are situated on the engine crankcase; whilst the low
pressure section exclusively concerns the thermal unit.
The trochoidal pump is installed in the sump and is controlled by means of a pair of drive wheels.
To guarantee pump integrity a pre-filter is used.
The pre-filter is of a pull-out type and the related plug also acts as engine oil drain.
The pump delivery is controlled by a piston by-pass calibrated to 4 bar. This is positioned prior to the cartridge filter
and both are installed on the flywheel cover, and as such its gasket is subject to system pressure.
The by-pass positioned prior to the cartridge filter improves the working conditions of the filter itself, especially with
cool oil.
The filter is supplied with a antidraining valve and a overpressure valve; the latter intervenes when the filter mass
causes a pressure drop greater than 1 0.2 bar (0.039 0.007 Psi).
Of course, these conditions are met only by cool oil and a high engine running speed or by a dirty filter.
The filtered oil is used to lubricate the water pump spindle and, on reaching the engine crankcase, to lubricate the
main bearings, the housing of the big end of the connecting rod and of the cooling piston nozzle, set in the housing
on the transmission side.
The main bearing, transmission side, is provided with a oil seal and related exhaust tube.
Leading from the housing on the flywheel side is the timing feed tube; the delivery at the head is controlled by the
special jet screwed into the engine crankcase.
The timing components work with low pressure lubrication.
The camshaft housings are set directly in the aluminium of the head; the camshaft end play is recovered in part
from the oil sent to the smallest diameter housing.
The camshaft provides for lubrication of the equalizers by means of special holes; these are set in such a position
as to guarantee lubrication after vehicle parking. This result is achieved by the position most probably assumed by
the camshaft during the engine stop phase.
The oil used for lubrication of the head, returns to the sump via the chain housing channel and as such also pro-
vides lubrication to the chain itself.
To avoid fumes recovered from the crankcase transporting quantities of oil, a unidirectional valve and a decanting
chamber are used. The unidirectional valve is of the metal reed valve type; the decanting chamber is supplied with
a drainage hole. Any inefficiency in these may lead to the presence of oil in the air feed tube to the engine.
An excess of oil fumes may cause occlusions in the channels set in the throttle body.
For indicating minimum oil pressure of the system a pressure switch situated immediately after the filter outlet is
used.
The lubrication circuit does not concern the countershaft, which is lubricated by the oil transported by the drive
wheels or by that centrifuged from the engine driving shaft.
The same thing occurs for the piston and the gudgeon pin, although in this case the cooling nozzle is particularly
relevant.
Lubrication
500-4T
chap. 11
11-4
Release 00 2001-12
DIAGNOSTICS GUIDE
Remove the switch and install the special tool and
related gasket.
Manometer tool
Manometer union tool
Remove the dipstick with the oil loading plug and
insert a plug prepared with a temperature probe as
part of the specific tool.
Insert the probe until it comes into contact with the
bottom of the crankcase then pull it back a few
millimetres.
Multimeter with temperature probe
Lighting up of the minimum oil pressure indicator with a
warm engine.
Remove the electrical connector of the minimum pressure switch.
Check that the indicator lamp turns off.
Control the actual oil pressure.
Check and reset the electrical
system.
NO YES
Measure the pressure with a cold idling engine.
Standard values: 20C (176F) Temperature
1400 rpm.
IMPORTANT The revolutions may be revealed by either the exhaust gas analyser or diagnosis
tester.
~ 4.5 bar (65.25 Psi)
YES NO
Allow the engine to warm up and repeat the control with warm oil.
Standard values: 80C (176F) Temperature
1400 rpm.
~ 1.5 bar
(21.75 Psi)
NO YES
Replace the minimum
oil pressure switch.
Pressures of less than
1.3 - 1.5 bar (18.85 - 21.75 Psi)
revealed.
Pressures of less than 4 bar
revealed.
Lubrication
500-4T
chap. 11
11-5
11
Release 00 2001-12
Replace the oil filter and repeat the pressure control with oil at 80C.
The anomaly is resolved.
Recommend respect for the advised
miles covered.
NO
YES
Check the presence of anomalous clearances on the driving shaft:
- end play (see chapter CRANKCASE AND DRIVING SHAFT)
- radial play especially in the cylinder axis direction
- play according the the rotational direction of the connecting rod in quadrature
Remove the flywheel cover and proceed with efficiency checks of the by-pass and seal of the
cover towards the crankcase inner side, as described in chapter FLYWHEEL COVER.
YES
NO
Replace damaged components
(chapter FLYWHEEL COVER).
Proceed with engine overhaul (chapter
CRANKCASE AND DRIVING SHAFT MOTOR).
YES NO
Open the engine crankcase and proceedwith with
removal of the oil pump, as described in chapter
CRANKCASE AND DRIVING SHAFT.
Proceed with oil pump control as described
in the following pages.
Check correct assembly of the cooling
nozzle and the timing feed jet.
Visually check the dimensions of the
couplings concerning the driving shaft
(chapter CRANKCASE AND DRIVING SHAFT).
IMPORTANT Any anomalies discovered in the couplings and timing components are not revealable through
lubrication pressure control. These may occur with a noise increase.
IMPORTANT Revealing pressure anomalies on the crankcase it is always advisable to proceed with visual and
dimensional controls of the timing components (see chapter THERMAL UNIT AND TIMING SYSTEM).
Lubrication
500-4T
chap. 11
11-6
Release 00 2001-12
CHECKING THE OIL PUMP
Remove the two screws and the oil pump cover.
Reassemble the rotors on the pump casing keeping
the 2 references in sight.
Insert the shaft and drive wheel and assemble the
retaining ring and rotate it with the opening on the
opposite side of the shaft facing.
Check any anomalous plays between the shaft and
pump casing.
Remove the internal rotor retaining ring turning it so
that the opening is in correspondence with the shaft
facing.
Remove the rotors and clean them accurately with
petrol and compressed air.
Pull out the shaft complete with drive wheel to check
its condition and any signs of wear the shaft itself.
Lubrication
500-4T
chap. 11
11-7
11
Release 00 2001-12
Using a thickness gauge check the distance between
the rotors in the position shown in the figure.
Clearance limit allowed: 0.012 mm (0.0004 in)
Check the distance between the external rotor and the
pump casing, see figure.
Clearance limit allowed: 0.25 mm (0.009 in)
Check the rotors end play using a ground bar as a
reference plane as shown in the figure.
Value limit allowed: 0.1 mm (0.003 in)
OIL PUMP ASSEMBLY
Lubricate the internal rotors.
Check that the pump cover does not show signs of
wear or scratching.
On revealing non-conformant values or scratches,
Assemble the pump cover in the position giving
alignment of the holes for the fixing screws to the
crankcase.
Block the two fixing screws to the torque prescribed.
Tightening torque:
Oil pump coupling screws 0.7 - 0.9 Nm (0.51 - 0.66
Ft-lbs)
Lubrication
500-4T
chap. 11
11-8
Release 00 2001-12
DIAGNOSTICS GUIDE
On discovering an oil leak from the coupling gasket of the flywheel cover or from the oil filter,
proceed with lubrication pressure control.
Install the specific tool 8140181.
Check the system pressure with cold engine and medium-high running speed.
Standard pressure < 6 bar (87 Psi)
NO YES
Proceed with replacement of the damaged
components.
Check the adjusting by-pass efficiency
(see chapter FLYWHEEL COVER)
and reset the correct flow.
IMPORTANT The standard pressures are obtained using oil of the recommended viscosity. A greater viscosity
leads to an increase in system pressure.
On discovering oil consumption greater than 250 gr/1000 km in a run in engine
proceed as described below.
Check the presence of oil in the recovery duct on the filter box.
NO
YES
Proceed with efficiency checks of the
unidirectional reed valve and the drainage hole of
the decanting chamber.
Proceed with seal checks of the thermal unit
(elastic clamps, valve guides and oil seals),
see chapter THERMAL UNIT AND TIMING SYSTEM.
YES
NO
Reset efficiency of the valve
or the drainage hole.
IMPORTANT Such an anomaly may occur also if the oil level is too high.
In this case the anomaly could be linked also to a malfunctioning of the fuel injection system due to
occlusion of the throttle body ducts (see chapter FUEL INJECTION).
Cooling system
Cooling system
500-4T
chap. 12
12-1
12
Release 00 2001-12
Cooling system
500-4T
chap. 12
12-2
Release 00 2001-12
Expansion tank
Radiator
Drainage 2
3-way thermostat
integrated into the
pump cover
Cylinder
Head
Drainage 1
Cooling system
500-4T
chap. 12
12-3
12
Release 00 2001-12
SPECIFICATIONS
Cooling system capacity 1.8 l (0.4752 Gal)
Recommended fluid 50% mixture of water and sealed circuit fluid (PARAFLU 11 FE)
Seal pressure Plug calibrated to 0.9 bar (13.05 Psi)
THERMOSTAT Type wax, with switch
Initial opening 75 2 C (167 35.6 F)
Opening stroke at 90 C (194F) 4 mm (0.15 in)
ELECTROVENTILATION Type injection operated
Initial electroventilation 106 C (222.8 F)
End electroventilation 98 C (208.4 F)
WATER PUMP Type centrifuge
Command coaxial to the counter shaft
RADIATOR Type in aluminium with horizontal circulation
EXPANSION TANK Type self-discharging, parallel to the
radiator
Cooling system
500-4T
chap. 12
12-4
Release 00 2001-12
SYSTEM DESCRIPTION
The cooling system is made with a centrifuge pump coaxial to the counter shaft and as such completes a number
of revolutions identical to that of the driving shaft.
The pump has two ducts, one for inlet and one for outlet.
The outlet duct feeds the cylinder and consequently the head; the inlet duct leads from the head and its entrance to
the pump is controlled by the thermostat plate.
The main seal of the thermostat acts instead on the main pump inlet duct leading from the radiator.
The radiator is fed from the head outlet; the expansion tank is inserted parallel to the radiator with the ducts on two
levels: the delivery high up (in the air) and the fluid backflow low down (in the fluid).
The system composed in this way is a 2-way type.
The first way is the internal engine circulation and involves the pump, cylinder and head; this circulation is fully
active when the thermostat is fully closed.
The second way is active with the thermostat fully open and is the main circulation which involves the pump,
cylinder, head, radiator and expansion tank; for medium openings of the thermostat, however, the two circuits are
both partially inserted, therefore the two ways are superimposed.
This kind of circuit is defined as the type with inlet thermostat. The thermostat is crossed by an inverted flow, that is
with cold water which tends to lower the temperature of the wax cell.
This system allows optimization of the engine heating phases.
The expansion tank, parallel to the radiator and inserted on the main circuit, guarantees self-drainage when work-
ing.
For the filling stages of the system there are two drains: one on entry to the pump and one exiting from the head
(see filling rules).
The electrical fan is operated by the fuel injection system with temperature measured on the engine head.
SYSTEM FILLING RULE
Prepare the 50-50 mixture of water and coolant;
Fill the system up to the level between MIN and MAX
shown on the filling hole of the expansion tank;
Do not close the expansion tank with the plug.
Loosen the drain screw situated on the pump intake
sleeve controlled by the thermostat;
Keep it open until the air discharge has stopped
completely;
Retighten the drain screw.
MAX
MIN
Cooling system
500-4T
chap. 12
12-5
12
Release 00 2001-12
Loosen the drain situated on the joint exiting from the
head;
Keep it open until the air discharge has stopped
completely;
Retighten the drain screw;
Start the engine for a few seconds;
Repeat the drain operation at the head exit;
Repeat these operations several times until only fluid
is discharged;
Reset the level in the expansion tank and screw on
the plug;
Start the engine and allow it to warm up until the
electroventilation temperature is reached;
Stop the engine;
Reset the level with a cold engine.
The electroventilation is controlled through the
temperature measured at the head.
Activation of the fan cannot be considered an
indication of completed discharge.
The discharge can be considered complete when
a temperature increase is noted in the expansion
tank.
CAUTION
THERMOSTAT CONTROL
Before dismantling it is advisable to carry out certain
checks:
Connect the diagnosis tester and select the PARAM-
ETERS function (see Chapter FUEL INJECTION);
Start the engine from cold and allow it to warm.
Check manually the moment in which heating com-
mences in the left box of the radiator;
Check the temperature indicated on the diagnosis
tester.
Initial thermostat opening: ~ 75 C (167F)
IMPORTANT The temperature measured by the
tester is that of the head outlet, whilst the true thermo-
stat temperature is referred to the pump inlet.
Cooling system
500-4T
chap. 12
12-6
Release 00 2001-12
On revealing values or gradual heating considerably
different to that of the engine, proceed with thermostat
control;
Remove the thermostat cover and the thermostat
itself as described in Chapter FLYWHEEL COVER.
Visually check that the thermostat has no mechanical
damage;
Prepare a metal container with ~ 1 litre of water;
Immerse the thermostat keeping it to the centre of the
container;
Immerse the thermometer probe of the multimeter
near to the thermostat;
Heat the container with a heat gun;
Check the temperature at initial opening of the ther-
mostat.
Initial opening temperature: ~ 75 C (167F)
Multimeter tool
Heater tool
Continue to heat until the thermostat is fully opened:
Opening length: 4 mm (0.15 in) a 90 2 C (194 35.6
F)
IMPORTANT Heating must be seen as gradual.
For correct trial testing, avoid direct contact
between the thermostat and the container.
CAUTION
On revealing incorrect values, replace the thermostat;
Reassemble the thermostat and its cover as de-
scribed in Chapter FLYWHEEL COVER;
Repeat the procedure from filling to discharge.
THERMOSTAT
Cooling system
500-4T
chap. 12
12-7
12
Release 00 2001-12
ELECTROVENTILATION CONTROL
Connect the fuel injection diagnosis tester and select
the ERRORS function from the menu.
Check the presence of anomalies in the electrical fan
control circuit (See Chapter FUEL INJECTION).
Select the ACTIVE DIAGNOSIS function from the
menu and command working simulation of the electri-
cal fan (see Chapter FUEL INJECTION);
With a certainly efficient electrical fan, check the initial
temperature after ventilation.
Select the PARAMETERS function from the menu,
visualizing the coolant temperature.
Electrical fan activation: 106 C (222.8 F)
Electrical fan disactivation: 98 C (208.4 F)
On revealing non-conformant values proceed with
replacement of the fuel injection control box (see
Chapter FUEL INJECTION);
If the temperature indication on the analogic instru-
ment is close to the red area, but the indication in
degrees on the diagnosis tester is less than the
electrical fan temperature, proceed with a check on
the head temperature sensor and related fuel injection
circuit (see Chapter FUEL INJECTION);
IMPORTANT The electroventilation temperature of
106 C (222.8 F) is manageable only with a system
filled with a 50-50 mixture and pressurized to 0.9 bar
(13.05 Psi).
Avoid engine functioning without pressurization so as
not to risk overheating the engine without having first
inserted the electrical fan.
If the electroventilation times increase, check the
initial opening temperature of the thermostat and the
correctness of coolant density.
Optimum density is obtained with a 50-50 mixture of
water and circuit coolant.
Cooling system
500-4T
chap. 12
12-8
Release 00 2001-12
SYSTEM SEAL CONTROL
Check adequate seal of the circuit when it is under pressure and heated;
For a more complete control wait until the system has cooled because small leaks, invisible due to evaporation
phenomena, may occur;
The water pump has a drainage hole for any leaks resulting from mechanical seal of the cooling system or of
the oil seal from the spindle seal;
On discovery of coolant or oil leaks, proceed with overhaul of the pump (see Chapter FLYWHEEL COVER).
IMPORTANT During repairs on the cooling system, do not use grease or oils. Failure to respect this regula-
tion causes permanent deformation of the gasket seals.
DIAGNOSTICS GUIDE
Eccessive system pressure
Check condition of the expansion tank plug.
IMPORTANT The plug has an overpressure valve calibrated to 0.9 bar (13.05 Psi).
There is also the valve which must allow entry of air during the cooling phase.
Check gasket seal of the head (see Chapter
THERMAL UNIT AND TIMING SYSTEM)
Replace the plug.
NO YES
Coolant consumption
Check external seals of the system as described previously.
Check gasket seal of the head (see Chapter
THERMAL UNIT AND TIMING SYSTEM)
Proceed to repair of the damaged seals.
NO YES
On discovering water leaking into
the engine oil, check
the head cooling circuit pad.
Presence of oil in the coolant.
Check of the head gasket seal (see Chapter THERMAL UNIT AND TIMING SYSTEM)
Starting
Starting
500-4T
chap. 13
13-1
13
Release 00 2001-12
Starting
500-4T
chap. 13
13-2
Release 00 2001-12
SPECIFICATIONS
STARTING MOTOR Type MITSUBA SM13D
Power 0.9 kW
BATTERY Capacity 14Ah
Starting current 125 A
SOLENOID Type HERMETIC
STARTER
Capacity 150A continuous
STARTING Crown and free wheel coaxial to the flywheel.
TRANSMISSION Idler gear integrated with torque limiter.
Starting system description
The starting system transmission is between the rotor of the motor and driving shaft with free wheel coaxial to the
flywheel and torque limiter on the intermediate shaft.
The limiter is calibrated to 10 Kgm (100 Nm); the function of this component is to safeguard engine structure and
engine ignition kinematism in case of incorrect engine ignition manoevre with subsequent voltage build-up of
inverse revolution.
The free wheel allows a suitably silent starting.
Command of the starting (excitation of the solenoid starter) is slaved by consensus of the side stand and the OFF/
RUN emergency switch, thus not allowing ignition in dangerous conditions.
The engine ignition command circuit is not controlled by the immobilizer system, so before activating the engine
ignition system in an anomalous manner, check the consensus of the immobilzer.
With regard to checking the consensus circuit, see Chapter ELECTRICAL EQUIPMENT; whilst for controls of the
driving shaft command transmission, take action as described in Chapter FLYWHEEL AND ENGINE IGNITION
SYSTEM.
Starting
500-4T
chap. 13
13-3
13
Release 00 2001-12
Controls and diagnostics guide
The starting motor is marketed as complete.
Before deciding to replace it, it is necessary to proceed with the following checks:
Battery
Check repose tension (several hours).
Tension > 12,5 V.
Check the electrolyte density of each element.
B = 30 - 32
Specific weight: 1.25 - 1.26 Kg/m
3
(2.11 - 2.12 lb/cu yd)
Recharge and if necessary replace the battery
NO
YES
Check correct connection of the negative terminals
(battery negative and starting motor
negative) between themselves and the chassis.
Reset the connections.
NO
YES
Connect the diagnosis tester
(see Chapter FUEL INJECTION).
Connect the induction pliers of an amperometer to
the positive feed cable of the starting motor.
Remove the 10A fuse N 2
(see Chapter FUEL INJECTION).
Set to "ON" with the switch on "RUN"
and side stand raised.
Select the "PARAMETERS" function.
Starting
500-4T
chap. 13
13-4
Release 00 2001-12
Activate engine ignition (with vehicle movement blocked) for sufficient time to note the revolutions and
absorption of the starting motor.
Absorption in running speed: from 80 to 120A
Running speed: from 300 to 400 rpm
IMPORTANT The stated revolutions value is that indicated by the diagnosis tester. The revolutions reading
does not correspond to the actual revolutions, however it is valid for the diagnosis.
The values are correct
For final confirmation, carry out a blank
absorption control.
Remove the starting motor (see Chapter
FLYWHEEL AND STARTING SYSTEM).
Reconnect the earth and positive and
carry out the control.
Blank absorption of current: < 40A
YES
The motor is efficient
YES
Check rotor rotation
NO
Low running speed
High electrical absorption
Check the engine revolution
(e.g.: possible fusion of the brasses)
and if no anomalies are revealed, replace the starting motor.
NO
Low running speed
Low electrical absorption
Repeat the test connecting the solenoid starter power terminals or
Check the new values.
Replace definitively the solenoid starter.
YES
Repeat the battery controls
and if necessary replace
the starting motor.
NO
NO
High running speed
Low electrical absorption
The engine turns too easily; check the compression end pressure
(see Chapter GENERAL INFORMATION AND MAINTENANCE).
On revealing incorrect values, proceed as indicated.
NO
IMPORTANT If the running speed of the driving shaft proves to be low and is coupled with anomalous noise,
proceed with checks of the free wheel and the torque limiter (see Chapter MAGNETO FLYWHEEL AND STARTING
SYSTEM).
pag. 1
Aggiornamento 2004 - Update 2004
Mise jour 2004 - Aktualisierung 2004 - Actualizacin 2004
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Presa cuffia per radio interfono
Presente sul codone e sullo scudo interno a fianco del vano porta documenti.
Headset ! intercom outlet
On the tail guard and on the inner shield, close to the glove compartment.
Prise couteurs pour radio-interphone
Existant sur le corps de selle et sur le bouclier interne, ct du dgagement porte-docu-
ments.
Kopfhreranschluss fr Radio-/Sprechanlage
Sie ist der Heckverkleidung und an der inneren Abdeckung seitlich des Dokumentenfachs
vorhanden.
Toma auricular para la radio-interfono
Presente en el cuerpo asiento y en el escudo interno a la par del portadocumentos.
Antifurto Immobilizer
Spia antifurto (immobilizer) ( ). A moto spenta lampeggia come deterrente contro i furti. Conferma che il sistema antifurto attivo.
IMPORTANTE In molti casi, i veicoli rubati vengono identificati attraverso i dati riportati sul libretto di uso / manutenzione.
IMPORTANTE Per aumentare la protezione contro il furto, il veicolo dotato di sistema elettronico di blocco motore
by che si attiva automaticamente estraendo la chiave di accensione.
Conservare la seconda chiave in luogo sicuro perch una volta smarrita anche la seconda non pi possibile farne una copia. Questo
comporta la sostituzione di numerosi componenti del veicolo (oltre alle serrature).
Ogni chiave racchiude infatti nell' impugnatura un dispositivo elettronico - transponder - che ha la funzione di modulare il segnale di ra-
diofrequenza emesso all'atto dell'avviamento da una speciale antenna incorporata nel commutatore. Il segnale modulato costituisce la
!parola d'ordine" con cui l'apposita centralina riconosce la chiave e solo a questa condizione consente l'avviamento del motore.
Immobilizer antitheft system
Anti-theft device (immobilizer) light ( ). Blinks when the engine is off as a deterrent to prevent theft. Indicates that the anti-theft sy-
stem is operating.
NOTE In most cases, stolen vehicles are identified through the data written on the Use and Maintenance Book.
NOTE The vehicle is fitted with an immobilizer anti-theft system by an electronic system that prevents en-
gine starting unless an authorised key is used - for added security. The immobilizer system is automatically activated each time the igni-
tion key is removed from the switch.
Keep the second key in a safe place, as you cannot make any copy once lost.
If this should be the case, many parts of the vehicle, locks included, will have to be changed.
Embedded in the key grip is a transponder, an electronic device that modulates the radiofrequency signal emitted by a special antenna
built into the switch when the key is turned to on. The modulated signal acts as a !password" that tells the system control unit whether an
authorised key is being used to start the engine.
Antidmarrage lectronique cl code
Tmoin antivol (systme antidmarrage lectronique # immobiliseur) ( ). Lorsque la moto est teinte, il clignote de manire dissua-
sive contre le vol. Il confirme que le systme antivol est actif.
IMPORTANT Dans de nombreux cas, les vhicules vols sont identifis grce aux informations du manuel d'utilisation/entretien.
IMPORTANT Pour augmenter la protection contre les vols, le vhicule est dot d'un systme anti-dmarrage lectronique
by et qui se met en marche automatiquement en retirant la cl de contact.
Gardez la deuxime cl dans un lieu sr car si vous perdez aussi la deuxime cl, il ne sera plus possible d'en faire un double. Il en
dcoulerait le remplacement de nombreux composants du vhicule (en plus des serrures).
En effet, chaque cl renferme un dispositif lectronique - transponder - qui sert moduler le signal de radiofrquence mis au moment
du dmarrage par une antenne spciale incorpore dans le commutateur. Le signal modul constitue le !mot de passe" grce auquel le
botier lectronique spcial reconnat la cl et permet le dmarrage du moteur seulement cette condition.
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"Immobilizer#- Wegfahrsperre
Kontrollleuchte - Diebstahlsicherung (Immobilizer) ( ). Bei abgestelltem Motor blinkt die Kontrollleuchte zur Abschreckung auf und
zeigt gleichzeitig an, dass die Wegfahrsperre aktiv ist.
WICHTIG Es kommt oft vor, dass ein gestohlenes Fahrzeug aufgrund der Daten, die in der Betriebs- und Wartungsanleitung einge-
tragen sind, identifiziert werden kann.
WICHTIG Im Hinblick auf einen hheren Diebstahlschutz wurde das Fahrzeug mit einem elektronischen Motorsperrsy-
stem by ausgestattet, das sich nach dem Abziehen des automatisch einschaltet.
Den zweiten Schlssel an einem sicheren Ort aufbewahren. Falls auch dieser verloren gehen sollte, kann von den Schlsseln keine Ko-
pie mehr gefertigt werden. Dies wrde (ber die Schlsser hinaus) den Austausch einer Reihe an Fahrzeugkomponenten erforderlich
machen.
In jedem Schlssel ist eine elektronische Vorrichtung (Transponder) im Schlsselkopfschutz enthalten, die das auf Radiofrequenz beim
Anlassen von einer speziellen Antenne abgegebene Signal moduliert. Diese Antenne befindet sich im Umschalter. Das umgeformte Si-
gnal stellt das !Password" dar, anhand dessen das entsprechende Steuergert den eingesteckten Schlssel erkennt und nur in diesem
Fall einen Anlass des Motors ermglicht.
Antirrobo Immobilizer
Testigo antirrobo (immobilizer) ( ). Con la moto detenida mantiene un destello disuasivo contra robos. Confirma que el sistema de
antirrobo est activado.
IMPORTANTE En muchos casos, los vehculos robados son identificados a travs de los datos anotados en el manual de uso y
mantenimiento.
IMPORTANTE Para aumentar la proteccin contra robos, el vehculo est dotado de un sistema electrnico de bloqueo mo-
tor by , que se activa automticamente al extraer la llave de encendido.
Conservar la segunda llave en un lugar seguro, porque una vez perdida tambin la segunda llave, no es posible hacer una copia.
Esto implica la sustitucin de numerosos componentes del vehculo (adems de las cerraduras).
Cada llave posee un dispositivo electrnico -transponder- que cumple la funcin de modular la seal de radio frecuencia, emitida en el
momento del encendido, por medio de una antena especial incorporada en el conmutador. La seal modulada constituye la ! palabra
clave ! con la que la central reconoce la llave y slo bajo esta condicin permite el encendido del motor.
Logica di funzionamento luci anabbaglianti
Girando la chiave di accensione in !ON", si accendono automaticamente le luci anabbaglianti. Se non viene avviato il motore entro tre
secondi le luci anabbaglianti si spengono per preservare la batteria, lasciando accese le luci di posizione.
Low beam operation logics
Turn the key to !ON" and the low beam is automatically switched on. If the engine is not started within 3 seconds, low beam will turn off
to keep battery charge. Only parking lights will stay on.
Logique de fonctionnement feu de croisement
Si l'on dplace la cl de contact sur !ON", le feu de croisement s'claire automatiquement. Si l'on ne met pas le moteur en marche dans
les trois secondes, les feux de croisement s'teignent pour prserver la batterie, en laissant les feux de position allums.
Abblendlichter-Funktionslogik
Durch das Umstellen des Zndschlsselschalters auf !ON" schalten sich automatisch die Abblendlichter ein. Sollte der Motor innerhalb
der folgenden 3 Sekunden nicht angelassen werden, werden die Abblendlichter automatisch aus- und die Standlichter eingeschaltet, um
so einem Verbrauch der Batterieladung vorzubeugen.
Lgica de funcionamiento luces de cruce
Girando la llave de encendido en !ON", se activan automticamente las luces de cruce. Si no se enciende el motor dentro de los tres
segundos, las luces de cruce se apagan para preservar la batera, dejando encendidas las luces de posicin.
Presa di corrente
La presa di corrente a 12V funziona solo dopo aver girato linterruttore di accensione a chiave in posizione ! !.
Power outlet
The 12V power outlet is on only when ignition switch is turned ! !.
Prise de courant
La prise de courant 12V n'est alimente qu'aprs dplacement sur ! ! du contacteur d'allumage cl.
Stromanschluss
Der 12V-Stromanschluss ist erst nach dem Umstellen des Zndschlsselschalters auf die Postion ! ! funktionstchtig.
Toma de corriente
La toma de corriente de 12V funciona solamente despus de haber girado el interruptor de encendido a llave en posicin ! !.
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ATLANTIC 500
30
29
32
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SCROLL
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1
25
26
23
24
19
20
21
22
1
3
A
z
R
o
V
i
GG
r/N
A
r/V
M
/N
R
/N
9
3
0
8
7
8
6
8
5
Ar/V
Ar
R/Bi
Ar/N R/Bi
V/Bi
G
/V
42
G
r
R
o
/G
23
52
B
R
/M
Ro
Ar/Bi
G
Gr
Vi/N
Ro/N
Ar/N
Gr/R
Ro/G
B
Vi
M/Bi
R
o
M
G
r/R
N
G
r
R
o
/N
A
r
G
r
M
/B
i
M
/G
G
r
V
V/N
12
V
/G
R
o
/G
R
/M
1 1
2
1
54
R
/M
A
r/V
R
/B
10
G
r/N
3 5 2 1
16
C
E
A
D
F
1
B
R/Gr
BBB
43
1 1 1
1
1
1 1
1
45
55
8
7
8
5
3
0
8
6
B B
/G
G
r/N
V
/G
1
1
15A
15A
3A
15A
15A
V/N
B
i/N
A
r/R
M
/V
B
/B
i
R
/B
i
RM
B
Az/R
R/B
Ar
V/G
M
R
M/G
B/N
Az/V
Az
N
Gr/N
N
N
A
r/N
G
/V
B
/N
R
/B
B
/B
i
A
z/R
R
/B
i
B
i/G
R
/B
i
A
z/B
i
V
i
M
/V
RA
z
A
z/V
G
r/B
i
A
r/R
MB
i/N
A
r
VR
o
GB
i
NM
/R
o
G
r/B
V
i
Ro/G
N B
i/N
G
r/B
i
B
/A
r
ABS ABS ABS ABS
EFI EFI EFI
!! !!! !!! !! !!! !!
N
R
o
/G
B G
/B
2 1
NN
NN
N
N
25
26
G B
A
r/N
B
V/N 7.5A
B
G/N
R
/B
i
58
1235
BR
/M
V
/B
i
V
1
B
/A
r
G
r/B
R
B
/A
r
G
r/B
i
V
44
1
1
1
22
1
R
5
4
3
2
6
1
N
59
1 3 2
FUSE C 15A
FUSE F 7.5A
FUSE A 15A
FUSE E 3A
SPARE G 15A
SPARE H 3A
SPARE I 7.5A
FUSE D 15A
FUSE B 15A
41
FUSE A
FUSE B
FUSE C
FUSE D
FUSE E
FUSE F
S
P
A
R
E
S
P
A
R
E
I
S
P
A
R
E

G
H
1) Connettori multipli
2) Sensore giri
3) Stepper motor
4) Bobina
5) Candela
6) Iniettore benzina
7) Pompa benzina
8) Sonda livello benzina
9) Rel iniezione principale (con diodo)
10) Rel iniezione secondario
11) Interruttore cavalletto laterale
12) Sonda lambda (non di serie)
13) Sensore acceleratore
14) Termistore aria motore
15) Termistore H
2
O motore/cruscotto
16) Ventola
17) Regolatore di tensione
18) Volano
19) Batteria
20) Rel avviamento
21) Motorino avviamento
22) Fusibili principali
23) Presa di corrente
24) Fusibili secondari
25) Luce vano bauletto
26) Interruttore luce vano
27) Luce targa
28) Alimentazione per autoradio
29) Indicatore di direzione posteriore dx
30) Indicatore di direzione posteriore sx
31) Lampade posizione/stop
32) Fanale posteriore dx
33) Interruttore stop posteriore
34) Interruttore stop anteriore
35) Commutatore a chiave
36) Sensore di caduta
37) Devioluci destro
38) Rel ventola
39) Devioluci sinistro
40) Claxon
41) Etichetta e descrizioni dei fusibili
42) Termistore T aria cruscotto
43) Cruscotto
44) Sensore di velocit
45) Sensore pressione olio
46) Indicatore di direzione ant. dx
47) Indicatore di direzione ant. sx
48) Lampada luce anabbagliante
49) Lampade luci abbaglianti
50) Lampada luce di posizione
51) Fanale anteriore
52) Centralina E.C.U.
53) Fanale posteriore sx
54) Presa diagnostica E.C.U.
55) Rel luci stop
56) Lampade 3 stop (no su versione USA)
57) Antenna immobilizer
58) Rel accensione fari anabbaglianti-ab-
baglianti
59) Ponticello
COLORE CAVI
Ar arancio
Az azzurro
B blu
Bi bianco
G giallo
Gr grigio
M marrone
N nero
R rosso
V verde
Vi viola
Ro rosa
2) RPM sensor
3) Stepper motor
4) Coil
5) Spark plug
6) Fuel injector
7) Fuel pump
8) Fuel level sensor
9) Injection main relay (with diode)
10) Injection auxiliary relay
12) Oxygen sensor (not standard)
13) Throttle sensor
15) Dashboard/engine H
2
O thermistor
16) Fan
18) Flywheel
19) Battery
20) Starter relay
21) Starter motor
22) Main fuses
23) Power socket
24) Auxiliary fuses
25) Compartment light
26) Compartment light switch
29) Rear right direction indicator
30) Rear left direction indicator
31) Brake light/parking light bulbs
32) RH tail light
33) Rear brake light switch
34) Front brake light switch
35) Key-operated switch
36) Bank angle sensor
37) Right dimmer switch
38) Fan relay
39) Left dimmer switch
40) Horn
41) Fuse label and descriptions
42) Dashboard air T thermistor
43) Dashboard
44) Speed sensor
46) Front right direction indicator
47) Front left direction indicator
48) Low beam bulb
49) High beam bulb
50) Parking light bulb
51) Headlight
52) E.C.U.
53) LH tail light
54) E.C.U. diagnosis outlet
55) Stop light relay
56) Third stop lights (not on USA version)
57) Immobilizer antenna
58) Low beam/hi-beam connection relay
59) Jumper
CABLE COLORS
Ar Orange
Az Light blue
B Blue
Bi White
G yellow
Gr Grey
M Brown
N Black
R Red
V Green
Vi Violet
Ro Pink
1) Connecteurs multiples
2) Capteur de tours
3) Moteur pas pas
4) Bobine
5) Bougie
6) Injecteur carburant
7) Pompe carburant
8) Sonde niveau de carburant
9) Relais d'injection principal (avec diode)
10) Relais d'injection secondaire
11) Contacteur bquille latrale
12) Sonde lambda (non de srie)
13) Capteur acclrateur
14) Thermistance d'air moteur
15) Thermistance d'eau moteur/tableau de
bord
16) Ventilateur
17) Rgulateur de tension
18) Volant
19) Batterie
20) Relais de dmarrage
21) Dmarreur lectrique
22) Fusibles principaux
23) Prise de courant
24) Fusibles secondaires
25) Eclairage compartiment top-case
26) Contacteur clairage compartiment
27) Eclairage de plaque
28) Alimentation autoradio
29) Clignotant de direction arrire droit
30) Clignotant de direction arrire gauche
31) Lampes feu de position/stop
32) Feu arrire droit
33) Contacteur feu de stop arrire
34) Contacteur feu de stop avant
35) Commutateur cl
36) Capteur de chute
37) Inverseur route-croisement droit
38) Relais du ventilateur
39) Inverseur route-croisement gauche
40) Avertisseur sonore
41) Etiquette et descriptions des
42) Thermistance T d'air tableau de bord
43) Tableau de bord
44) Transmetteur de vitesse
45) Capteur pression d'huile
46) Clignotant de direction avant droit
47) Clignotant de direction avant gauche
48) Lampe feu de croisement
49) Lampe feu de route
50) Lampe feu de position
51) Phare avant
52) Botier lectronique E.C.U.
53) Feu arrire gauche
54) Prise de diagnostic E.C.U.
55) Relais feux de stop
56) Lampes troisime feu de stop (pas pour
version USA)
57) Antenne systme antidmarrage
lectronique (immobiliseur)
58) Relais d'allumage feux de croisement -
route
59) Cavalier
COLORIS DES CABLES
Ar orange
Az bleu ciel
B bleu
Bi blanc
G jaune
Gr gris
M marron
N noir
R rouge
V vert
Vi violet
Ro rose
I
UK
F
pag. 4
I UK
F D E
ATLANTIC 500
30
29
32
35
34
1
27
40
47
50
46
31
48
49
51
56
28
39
1
37
33
31
53
57
Az
54
58
G
/V
i
G
r/N
R
B
G
B
R
B
VG
r
N G
/N
BG
r
B
/N
RA
z
B
i
V
/N
Az
B
B
G
R
B
B
G
B
Bi
N
Az
R
B
/B
i
MR
o
V
/N
R
/B
i
V/G
B
V/G
V B
i
N V
/B
i
G
r
B A
z/B
i
B
/N
R
/B
B
/B
i
B
i/G
A
r
V V
i/N
R
/B
i
G
/N
V
/G
G
/R
R
/G
r
R
/N
G
B
R
G
B
V/G
G
B
Bi
N
B
B
Bi
V
/G
R
/N
G
/R
V
/N
V
/N
R
/G
r
V
/N
31
G
V/G
B 31 B
58 G
54 V/G
Az
G
V/G
Az
B
V/G
G
/M
G
/N
B
G
B
V
V
R
N
B
Bi
Az
G G
G
/N
B V R
/B
i
G
/V
i
V
/G
R
/N
Gr/Bi
G/M
G/Vi
B/G
M/Ro
G/N
B
N
N
N
N
V
/R
V
/B
i
1 3 2 4 6 5
PASSING
7 8 9 10 11 12 13 14 15 17 16 18 19 20 1 5 4 3 2 8 7 6 16 12 11 10 9 13 14 15
EFI
TRIP SET W
mp/h x1000r/min
Km/h
!
STOP
SCROLL
1
7
P 8
A
r/N
R
/M
B
17
BG
/N
G
/N
BG R
/B
i
R
/B
i
V V
NNV
/R
V
/R
G
19
18
21 20
V
/R
R
V
/R
1
1
G G G
G G
GG
R
/B
i
G
/R
B
R
24
R
2
0
A
3
0
A
R
/B
i
RR
M
5
11
B
1
M V N
G
/B
M
/N
4
R
/M
A
r/B
i
1
36
15 14
8
5
3
0
8
7
8
6
38
6
13
18

E
.
C
.
U
.
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
1
25
26
23
24
19
20
21
22
1
3
A
z
R
o
V
i
GG
r/N
A
r/V
M
/N
R
/N
9
3
0
8
7
8
6
8
5
Ar/V
Ar
R/Bi
Ar/N R/Bi
V/Bi
G
/V
42
G
r
R
o
/G
23
52
B
R
/M
Ro
Ar/Bi
G
Gr
Vi/N
Ro/N
Ar/N
Gr/R
Ro/G
B
Vi
M/Bi
R
o
M
G
r/R
N
G
r
R
o
/N
A
r
G
r
M
/B
i
M
/G
G
r
V
V/N
12
V
/G
R
o
/G
R
/M
1 1
2
1
54
R
/M
A
r/V
R
/B
10
G
r/N
3 5 2 1
16
C
E
A
D
F
1
B
R/Gr
BBB
43
1 1 1
1
1
1 1
1
45
55
8
7
8
5
3
0
8
6
B B
/G
G
r/N
V
/G
1
1
15A
15A
3A
15A
15A
V/N
B
i/N
A
r/R
M
/V
B
/B
i
R
/B
i
RM
B
Az/R
R/B
Ar
V/G
M
R
M/G
B/N
Az/V
Az
N
Gr/N
N
N
A
r/N
G
/V
B
/N
R
/B
B
/B
i
A
z/R
R
/B
i
B
i/G
R
/B
i
A
z/B
i
V
i
M
/V
RA
z
A
z/V
G
r/B
i
A
r/R
MB
i/N
A
r
VR
o
GB
i
NM
/R
o
G
r/B
V
i
Ro/G
N B
i/N
G
r/B
i
B
/A
r
ABS ABS ABS ABS
EFI EFI EFI
!! !!! !!! !! !!! !!
N
R
o
/G
B G
/B
2 1
NN
NN
N
N
25
26
G B
A
r/N
B
V/N 7.5A
B
G/N
R
/B
i
58
1235
BR
/M
V
/B
i
V
1
B
/A
r
G
r/B
R
B
/A
r
G
r/B
i
V
44
1
1
1
22
1
R
5
4
3
2
6
1
N
59
1 3 2
FUSE C 15A
FUSE F 7.5A
FUSE A 15A
FUSE E 3A
SPARE G 15A
SPARE H 3A
SPARE I 7.5A
FUSE D 15A
FUSE B 15A
41
FUSE A
FUSE B
FUSE C
FUSE D
FUSE E
FUSE F
S
P
A
R
E
S
P
A
R
E
I
S
P
A
R
E

G
H
1) Merfachstecker
2) Drehzahlsensor
3) Schrittmotor
4) Spule
5) Zndkerze
6) Einspritzdse
7) Kraftstoffpumpe
8) Sonde Kraftstoffpegel
9) Haupteinspritzrelais (mit Diode)
10) Sekundres Einspritzrelais
11) Seitenstnderschalter
12) Lambda-Sonde (nicht serienmig)
13) Gassensor
14) Thermistor fr Motorluft
15) H
2
O-Thermistor Motor/Instrumenten-
brett
16) Lfterrad
17) Spannungsregler
18) Schwungrad
19) Batterie
20) Anlasserrelais
21) Anlassmotor
22) Hauptsicherungen
23) Stromanschluss
24) Zusatzsicherungen
25) Fachbeleuchtung
26) Fachbeleuchtungsschalter
27) Kennzeichenbeleuchtung
28) Versorgung fr Radio
29) Hinterer Blinker - rechts
30) Hinterer Blinker - links
31) Stand-/Bremslichter
32) Rechtes Rcklicht
33) Hinterer Bremslichtschalter
34) Vorderer Bremslichtschalter
35) Zndschlsselschalter
36) Sturzsensor
37) Rechter Lichtumschalter
38) Lfterradrelais
39) Linker Lichtumschalter
40) Hupe
41) Etikette und Beschreibung der Siche-
rungen
42) Thermistor Lufttemperatur / Instru-
mentenbrett
43) Instrumentenbrett
44) Tachometersensor
45) ldrucksensor
46) Vorderer Blinker, rechts
47) Vorderer Blinker, links
48) Glhbirne fr Abblendlicht
49) Glhbirne fr Fernlicht
50) Glhbirne fr Standlicht
51) Scheinwerfer
52) E.C.U.-Steuergert
53) Linkes Rcklicht
54) E.C.U.-Diagnosestecker
55) Bremslichterrelais
56) Glhbirnen 3. Bremslicht (nicht bei
Version USA)
57) Immobilizer-Antenne
58) Relais fr Einschaltung der Abblend-/
Fernlichter
59) berbrckung
KABELFARBEN
Ar Orange
Az Hellblau
B Blau
Bi Wei
G Gelb
Gr Grau
M Braun
N Schwarz
R Rot
V Grn
Vi Lila
Ro Rosarot
1) Conectores mltiples
2) Sensor revoluciones
3) Stepper motor
4) Bobina
5) Buja
6) Inyector combustible
7) Bomba combustible
8) Sonda nivel combustible
9) Rel inyeccin principal (con diodo)
10) Rel inyeccin secundario
11) Interruptor caballete lateral
12) )Sonda lambda (no de serie)
13) Sensor acelerador
14) Termistor aire motor
15) Termistor H2O motor/salpicadero
16) Ventilador
17) Regulador de tensin
18) Volante
19) Batera
20) Rel de encendido
21) Motor de encendido
22) Fusibles principales
23) Toma de corriente
24) Fusibles secundarios
25) Luz maletero
26) Interruptor luz compartimiento
27) Luz matrcula
28) Alimentacin para autorradio
29) Indicador de direccin trasero der
30) Indicador de direccin trasero izq
31) Lmparas posicin/stop
32) Faro trasero der
33) Interruptor stop trasero
34) Interruptor stop delantero
35) Conmutador de llave
36) Sensor de cada
37) Conmutador de luces derecho
38) Rel ventilador
39) Conmutador de luces izquierdo
40) Claxon
41) Etiqueta y descripciones de los fusi-
bles
42) Termistor T aire salpicadero
43) Salpicadero
44) Sensor de velocidad
45) Sensor presin aceite
46) Indicador de direccin del. der
47) Indicador de direccin del. izq
48) Lmpara luz de cruce
49) Lmpara luz de carretera
50) Lmpara luz de posicin
51) Faro delantero
52) Central E.C.U.
53) Faro trasero izq.
54) Toma de diagnosis E.C.U.
55) Rel luces stop
56) Lmparas tercer stop (no en la ver-
sin USA)
57) Antena immobilizer
58) Rel encendido faros luces de cruce-
de carretera
59) Puente
.
COLORES CABLES
Ar anaranjado
Az azul claro
B azul
Bi blanco
G amarillo
Gr gris
M marrn
N negro
R rojo
V verde
Vi violeta
Ro rosa
D
E
INTEGRAAL COMMUNICATIESYSTEEM
APRumINTERFONO#02CAP01nl01.FM Page 1 Tuesday, March 11, 2003 2:07 PM
gebruik en onderhoud Radio MOB Control
2
2003 apriIia s.p.a. - Noale (VE)
Eerste uitgave: Februari 2003
Herdruk:
Opgesteld en gedrukt door:
DECA s.n.c.
Via Risorgimento, 23/1 - Lugo (RA) - ltalia
Tel. +39 - 0545 35235
Fax +39 - 0545 32844
E-mail: deca@decaweb.it
www.decaweb.it
in opdracht van :
aprilia s.p.a.
via G. Galilei, 1 - 30033 Noale (VE) - ltaly
Tel. +39 - (0)41 58 29 111
Fax +39 - (0)41 44 10 54
www.aprilia.com
WAARSCHUWI NGEN VOOR UW
VEILIGHEID
De hierna opgesomde waarschuwingen
worden in de hele handleiding gebruikt:
Dit symbooI wijst op gevaar voor
uw veiIigheid. Dit symbooI, dat op
het voertuig of in de handIeiding staat,
wijst op gevaarIijke situaties die IetseI
kunnen ver oor zaken. AI s u het
voorschrift dat bij het symbooI hoort
niet naIeeft, kunt u uw eigen veiIigheid,
die van anderen en die van het voertuig
in gevaar brengen! tijdens het rijden!
GEVAAR
Dit symbooI wijst op zeer gevaarIijke
situaties met mogeIijke ernstige IetseIs
of de dood aIs gevoIg.
OPGELET
Dit symbooI waarschuwt voor gevaar
voor Iichte verwondingen of schade aan
het voertuig.
BELANGRI JK Het woor d
"BELANGRlJK" staat in deze handleiding bij
belangrijke informatie of instructies.
TECHNISCHE INFORMATIE
lndien niet expliciet vermeld, dienen de
demontagehandelingen in de omgekeerde
volgorde te worden uitgevoerd om het
geheel opnieuw te monteren.
De woorden "rechts" en "links " gaan altijd
uit van de bestuurder die in een normale
rijhouding op het voertuig zit.
WAARSCHUWI NGEN-
VOORZORGEN- ALGEMENE
AANBEVELINGEN
BELANGRIJK De onderhavi ge
gebruiksaanwijzingen (handleiding) maken
i nt egr aal deel ui t van het
communicatiesysteem en dienen dit altijd
te vergezellen, ook als het systeem aan
derden wordt verkocht.
apriIia heeft bij het opstellen van deze
gebruiksaanwijzingen zo veel mogelijk
ernaar gestreefd correcte en actuel e
informatie te verstrekken.
Omdat de producten van apriIia echter
voortdurend worden verbeterd, kan het
toch gebeuren dat u kleine verschillen
aantreft tussen de kenmerken van het
voertuig dat u bezit en het voertuig dat in
deze gebr ui ksaanwi j zi ngen wor dt
beschreven. Cont acteer uw erkende
apriIia deal er al s u uitleg nodig hebt
omtrent de informatie in deze handleiding.
Wij zijn van mening dat u met apriIia een
goede keuze hebt gemaakt.
De rechten om de onderhavige documentatie
elektronisch op te slaan, te verveelvoudigen en
geheel of gedeeltelijk aan te passen, zijn
voorbehouden voor alle landen.
l n deze handl ei di ng wor den de
ver schi l l ende ui t voer i ngen met de
volgende symbolen aangeduid:
optie OPT
3
ALGEMENE INHOUDSOPGAVE
WAARSCHUWINGEN VOOR UW VEILIGHEID2
TECHNISCHE INFORMATIE ........................ 2
WAARSCHUWINGEN-VOORZORGEN-
ALGEMENE AANBEVELINGEN..................... 2
INLEIDING EN PRESENTATIE...................... 3
ALGEMENE lNHOUDSOPGAVE .......................... 3
HET SYSTEEM AAN UW EIGEN VOERTUIG
AANPASSEN................................................. 4
BIJBEHORENDE UITRUSTINGEN................ 4
INSTRUMENTEN EN CONTROLELAMPJES . 5
TABEL VAN DE lNSTRUMENTEN
EN CONTROLELAMPJES...................................... 6
EXTRA UITRUSTINGEN ............................... 8
AANSLUlTKABELS ................................................ 8
KEELMlCROFOON ............................................... 8
VOORBEREIDINGEN .................................... 9
DE HEADSET lN DE HELM MONTEREN.............. 9
DE HEADSET AANSLUlTEN OP HET VOERTUlG 10
EEN GSM AANSLUlTEN ..................................... 10
EEN MUZlEKBRON AANSLUlTEN ..................... 10
HET SYSTEEM AAN/UlT ZETTEN ...................... 11
HET VOLUME REGELEN .................................... 11
MUTE.................................................................... 11
HET INTEGRALE COMMUNICATIESYSTEEM
GEBRUIKEN ............................................... 12
HET MENU GEBRUlKEN..................................... 12
DE RADlO GEBRUlKEN ...................................... 13
DE lNTERCOM GEBRUlKEN............................... 15
DE HOGE EN DE LAGE TONEN REGELEN....... 16
DE MUZlEKBRON KlEZEN.................................. 16
DE GSM HANDSFREE GEBRUlKEN .................. 17
LUlSTEREN MET LUlDSPREKERS OP HET
VOERTUlG (lNDlEN AANWEZlG) ........................... 18
UlTGESTELD UlTSCHAKELEN........................... 18
TECHNISCHE GEGEVENS.......................... 19
INLEIDING EN PRESENTATIE
Het i nt egral e communi cat i esyst eem
APRlLlA RADlO MOB CONTROL dat
speciaal is ontworpen om op voertuigen
van aprilia te worden gemonteerd is een
alles in n- systeem met de volgende
mogelijkheden:
FM radio ontvanger met RDS.
traditionele intercom met inschakelsysteem
dat ook bij windlast werkt.
handsfree telefoneren (aansluiting van
GSM van de klant met een optioneel
kabel t j e) met de mogel i j khei d de
i nkomende oproep al l een naar de
bestuurder over te schakelen, alleen
naar de passagier of naar beide. De
besturing merkt automatisch dat de
telefoon wordt opgebeld en waarschuwt
de bestuurder met een toon en een
lampje.
mogelijkheid om een muziekbron aan te
sluiten (walkman, CD, MP3) met een
optioneel kabeltje.
stereoversterker en luidsprekers (naar
gelang van het model) voor hifikwaliteit
als het voertuig niet of traag rijdt.
De satelliet op het stuur heeft een groot
di spl ay en een dr aai baar
bedieningenpaneel voor ergonomisch
verantwoord gebruik. Bedienen en lezen
van informatie wordt vergemakkelijkt door
de verl i cht i ng van het di spl ay en de
toetsen.
Een handig bladermenu om alle functies
snel en optimaal te kiezen
OPGELET
Het verdi ent aanbeveI i ng om het
communi cat i esyst eem t e I at en
monteren door een technisch centrum
van aprilia.
4
HET SYSTEEM AAN UW EIGEN VOERTUIG AANPASSEN
ln het geheugen van het communicatiesysteem zitten de namen
van enkele voertuigen uit het gamma van Aprilia en Guzzi.
Het l ogo van het voer t ui g ver schi j nt zodr a het
communicatiesysteem wordt aangezet en in enkele bijzondere
gevallen (zoals bijvoorbeeld als het systeem aan staat en geen
muziekbron is aangesloten)
Kies het logo op de volgende manier:
Het logo blijft in het geheugen opgeslagen ook zonder de accu.
De sleutel in het contact in de startstand draaien
Het communicatiesysteem moet uit staan (eventueel uitzetten door de
toets C/off lang genoeg in te drukken.)
Lang indrukken:
(20 seconden)
Het communicatiesysteem gaat aan staan en
het logo verschijnt.
2SPHUNLQJ Bij deze handeling wordt het
display niet verlicht
I Het logo kiezen
Na afIoop:
OK/Menu
Bevesti gt het gekozen l ogo en zet het
communicatiesysteem aan
BIJBEHORENDE UITRUSTINGEN
LEGENDA
1) Jackaansluiting
2) Clip voor bevestiging op de helm
3) Luidspreker in helm
4) Microfoon
4
1 2 3
5
INSTRUMENTEN EN CONTROLELAMPJES
LEGENDA
1) Volumeregeltoets (-)
2) Volumeregeltoets (+)
3) Keuzetoets geheugens en frequentie ( )
4) Keuzetoets geheugens en frequentie ( )
5) Toets MUTE/OFF
6) Toets OK/ON
7) Display
3
1
5
6 2 4 7
6
TABEL VAN DE INSTRUMENTEN EN CONTROLELAMPJES
Toets DefauItfunctie Functie in het menu
Geheugens kiezen in opgaande richting in SS mode
Frequentie kiezen in opgaande richting in MS mode
Kort indrukken: automatisch zoeken
Lang indrukken: manueel verplaatsen
in menu bladeren naar einde toe (naar rechts)
Geheugens kiezen (naar onder) in SS mode
Frequentie kiezen (naar onder) in MS mode
Kort indrukken: automatisch zoeken
Lang indrukken: manueel verplaatsen
in menu bladeren naar begin (naar links)
+ Hoger volume
- Lager volume
OK/ON
Menu
Als het systeem uit staat: om het systeem aan te zetten
Als het systeem aan staat:
Kort indrukken: Menu openen
Lang indrukken: Schakelt opslagen in geheugen in
Bevestigt de keuze
ln de opslagfunctie: slaat op in geheugen
C/OFF
Mute
Als het systeem aan staat:
Kort indrukken: mute (ogenblikkelijk geluidsdemping -20
dB)
Lang indrukken: zet systeem uit
Keert terug naar vorig niveau zonder bevestigen
C/OFF
Mute
Kort indrukken (als Mute werd ingeschakeld): keert
geleidelijk aan terug naar vorig volume
7
SneI kiezen
Toets SneI kiezen inschakeIen Functie
OK/ON
Mute
Twee keer kort achtereenvolgens indrukken ln/Uit schakelen van intercom in VOX LOW (lCL)
mode.
C/OFF
Mute
Een keer kort indrukken
(Functie alleen vrijgegeven als een telefoongesprek
bezig is)
Zet het gesprek in stand by zodat de bestuurder vrij
met de passagier kan praten, onafhankelijk van de
staat van de intercom.
Op het display verschijnen alle mogelijkheden om het
telefoongesprek weer te activeren.
Kort indrukken
Deze functie is alleen actief als u een telefoongesprek in
stand by hebt gezet
Herneemt de communicatie, alleen met de bestuurder
Kort indrukken
stand by hebt gezet
Herneemt de communicatie, alleen met de passagier
+
Kort indrukken
stand by hebt gezet en herneemt de communicatie met
passagier en bestuurder
Tegelijkertijd de toetsen indrukken
Tegelijkertijd de
toetsen indrukken
en -
Kort tegelijkertijd indrukken
Alleen actief als de radio aan staat in de zoek- of
kiesfunctie
Schakelt over van MS naar SS of vice versa
8
EXTRA UITRUSTINGEN
AANSLUITKABELS
ln onze verkooppunten en technische
servicecentra vindt u de kabel om de
telefoon op uw voertuig en het systeem
aan te sluiten. Er zijn kabeltjes voor de
meest e op di t ogenbl i k i n de handel
verkrijgbare GSM's.
ln onze verkooppunten en technische
servicecentra vindt u de kabel om een
autonome muziekbron (bijvoorbeeld een
draagbare MPS-lezer) aan te sluiten op het
syst eem. De aansl ui t i ng van de
geluidsbron kan afhankelijk van het model
in de kuip worden gemonteerd, of bij
voorkeur in de ruimte onder het zadel
(ruimer en beter beschermd) of in het
koffertje.
Laat de aansluiting door een technische
service van apriIia monteren.
KEELMICROFOON
ln onze verkooppunten kunt u een speciale
headset met keelmicrofoon vinden die
gemakkel i j k i n de hel m kan worden
gemonteerd en windgeruis vermindert.
OPT OPT
9
VOORBEREIDINGEN
DE HEADSET IN DE HELM
MONTEREN
De veerclip (1) links op de onderkant van de
helm vastmaken. ln de meeste helmen is er
ruimte tussen de bekleding en de buitenkant
waarin u de clip kunt vastmaken zonder iets
aan de helm te wijzigen.
OPGELET
Steek de kabeI tussen de metaIen cIip
en de rand van de heIm zoaIs op de
afbeeIding zodat deze niet te strak kan
gaan zitten en er niet aan kan worden
gerukt.
Maak de luidspreker aan de binnenkant van
de helm vast met het speciale klittenband
(2). Als u de luidspreker niet goed ter hoogte
van uw oor vastmaakt, hoort u het geluid
onvoldoende of helemaal niet.
BELANGRIJK
In integraaIheImen dient u de beugel (3)
van de microfoon in de vorm van de helm
te buigen en ervoor te zorgen dat er geen
luchtstroom tegen het dopje (4) komt.
In open heImen buigt u de beugel (3) van
de microfoon zo dat het dopje (4) zo dicht
mogelijk bij uw mond zit.
De wi tte stip op de beugeI van de
microfoon dient in de richting van uw
mond te zitten.
OPGELET
Voor een correct werkende headset:
de schuimrubberen dop op de
Iuidspreker (5) Iaten zitten;
zo veeI mogeIijk vermijden dat er
wat er aan de mi cr of oon of de
Iuidspreker komt.
1
2
4 3
5
10
DE HEADSET AANSLUITEN OP
HET VOERTUIG
De jackaansluiting (1) van de headset kan
gemakkelijk worden aangesloten, ook als
het zicht beperkt is.
Steek de connector/connectoren in hun
respectievelijke aansluitingspunten.
OPGELET
Op eIke aansIuiting zit een rubberen
beveiIigingsdopje (2) dat goed gesIoten
moet worden aIs de aansIuiting niet
wordt gebruikt omdat een onbedekt
contact storingen in het systeem kan
veroorzaken.
Het systeem merkt automatisch of er een
of twee headsets zijn aangesloten. Als een
headset wordt i n- of ui t geschakel d,
verschijnen onderaan links op het display
de symbolen van de helmen.
Als geen headset wordt gesignaleerd,
staat er een schuin streepje over het
symbool . De symbol en ver dwi j nen
automatisch bij de eerste reset van het
display.
Al l e f unct i es van het syst eem, met
uitzondering van de intercom, werken ook
als alleen de headset van de passagier is
ingeschakeld.
EEN GSM AANSLUITEN
Het communi cati esysteem bevat een
connector met 8 pinnen die op een goed
bereikbare pl ek van het voertui g kan
worden geplaatst (zie HET SYSTEEM
AAN UW El GEN VOERTUl G
AANPASSEN).
De aansluitkabel voor de telefoon (met
compatibele connector) is beschikbaar in
onze ver kooppunt en en t echni sche
servicecentra.
De GSM dient op automatisch antwoorden
te worden gezet; op deze manier hoeft u
geen t oet sen i n t e dr ukken om de
verbinding tot stand te brengen.
Lees aandachtig de gebruiksaanwijzingen
van de GSM om de hierboven beschreven
functies in te stellen.
De mobi el e tel efoons Motorol a 8700,
Startac 130, CD920, CD930 en BOSCH M-
com 506 moeten uit worden gezet voordat
ze met de voer t ui gkabel wor den
aangesl ot en. De t el ef oon schakel t
automatisch in.
EEN MUZIEKBRON AANSLUITEN
Het integrale communicatiesysteem van
aprilia heeft een extra ingang waarop een
muziekbron kan worden aangesloten. U
kunt er dus een CD-lezer op aansluiten
(mi t s shockproof voor probl eeml oos
afspelen op het voertuig), een MP3-lezer
of een walkman.
De muziekbron kan naar believen in de
kuipbinnenkant worden geplaatst, in de
ruimte onder het zadel of in het koffertje,
afhankelijk van het type voertuig. De bron
dient een eigen stroomvoeding te hebben
of aangesloten te worden op de aansteker
van het voertuig (indien aanwezig) met een
ni et met het syst eem meegel everde
adaptor. ln elk geval kan de muziekbron
niet op afstand worden bediend door de
satelliet.
Om de i nst al l at i e van de br on zo
persoonlijk en flexibel mogelijk te maken
wordt de aansluitkabel afzonderlijk in de
verkooppunten en technische centra van
apriIia verkocht. Wend u voor een correcte
montage van de aansluitkabel op de plaats
die u wenst tot een technische service van
apriIia.
2
1
11
HET SYSTEEM AAN / UIT ZETTEN
U kunt het systeem alleen aanzetten als de
sleutel in de startstand staat.
Druk 2 seconden lang de toets OK/ON in
om het systeem aan te zetten.
Druk minstens 2 seconden op de toets
C/OFF om het systeem uit te zetten.
Als u de sleutel in de stopstand zet, wordt
ook het communicatiesysteem uitgezet. ln
dit geval zal het systeem automatisch aan
gaan zodra de sleutel weer in de startstand
wordt gezet en worden de voordi en
i ngest el de f unct i es zoveel mogel i j k
behouden .
U kunt het systeem ook aan laten staan
(voor een bepaalde geprogrammeerde tijd
zodat u het niet vergeet uit te zetten)als de
sleutel in de stopstand staat. Zie pag. 18
(UlTGESTELD UlTSCHAKELEN) voor
meer details.
HET VOLUME REGELEN
U kunt op elk ogenblik het volume van de
headset of de luidsprekers met de toetsen
+ en - regelen.
Alleen het volume van de bron die op dat
ogenblik wordt gebruikt, wordt geregeld.
Dit betekent dat elk apparaat (telefoon,
radio, muziekbron, intercom) afzonderlijk
aan de wensen van de gebruiker kan
worden aangepast.
Op het display wordt de geluidsregeling
duidelijk en onmiddellijk weergegeven.
U kunt het volume niet afzonderlijk voor de
berijder en de passagier regelen.
MUTE
Als u een muziekbron beluistert, (radio of
aux), en u drukt heel even op de toets
C/Off, wordt het vol ume onmi ddel l i j k
gedempt met ongeveer 20 dB(A).
Als u de toets C/Off opnieuw indrukt, keert
het volume geleidelijk aan terug naar
vorige niveau.
Al s u, nadat u de f unct i e Mut e hebt
ingeschakeld, de toetsen + of - gebruikt,
zal het syst eem weer normaal gaan
functioneren, maar met het gedempte
volume.
12
HET INTEGRALE COMMUNICATIESYSTEEM GEBRUIKEN
HET MENU GEBRUIKEN
Om al l e f unct i es van het
communicatiesysteem snel en eenvoudig
te bedienen is een menu ingebouwd dat
horizontaal over het display beweegt.
Om dit menu weer te geven, drukt u op de
toets OK/ON Menu
Om door de verschi llende functi es te
bladeren, gebruikt u de bladertoetsen
(achteruit) en (vooruit).
De gekozen maar nog niet bevestigde
functie verschijnt met een negatieve letter.
Een of twee kleine pijltjes bovenaan op het
display duiden de positie van de functie die
u hebt gekozen aan t.o.v. de rest van het
menu.
Om de gekozen functie te bevestigen,
drukt u op OK/ON Menu.
Sommige functies van het hoofdmenu
verwijzen naar een "secundair" menu.
Lees verderop i n de tekst voor een
volledig uitleg van alle menuonderdelen.
U kunt op elk ogenblik terugkeren naar het
vorige menu (of het hoofdmenu verlaten)
met de toets C/OFF.
De onderdel en van het menu en de
bijbehorende secundaire menu's zijn de
volgende:
Hi erna worden al l e f unct i es van het
systeem die kunnen worden bediend in het
menu in detail uitgelegd.
1. TUNING
seek
scan
zapping
store
5. SOURCE
radio
aux
off
2. INTERC
off
on
vIow
vhigh
6. TELEPH
driver
driver + Pass
3. AUDIO
Bass
TrebIe
7. SPEAKS
Off
Auto
On
4. RDS
off
af
ta
pty
8. POWER
key
deIay
13
DE RADIO
GEVAAR
Een kIeine afIeiding of verstrooidheid
kan fataaI zijn. Wij raden dus aan aIIe
handeIingen waarvoor moeite dient te
worden gedaan (stations en functies
kiezen enzovoort), uit te voeren terwijI
het voertuig veiIig stiI staat zodat u niet
afgeIeid wordt tijdens het rijden.
RDS-diensten
De f unct i es en di enst en di e worden
aangeboden door het RDS-systeem
(Radio Data System) zijn sterk afhankelijk
van de manier waarop de verschillende
stations werken en van de kwaliteit van het
signaal dat wordt ontvangen.
Als de kwaliteit van het signaal voldoende
is, kunt u gebruik maken van de volgende
services:
Off De naam van het zendstation wordt
weergegeven, maar alle andere functies
van het RDS-syst eem (al t ernat i ve
frequencies, verkeersinformatie, PTY)
zijn uitgeschakeld
met de AF (Alternative Frequencies) kan
de ontvanger automatisch afstemmen op
een alternatieve frequentie van dezelfde
zender met een betere luisterkwaliteit
TA (Traffic Announcement identification) Als
de zender waarop men heeft afgestemd
verkeersinformatie uitzendt, wordt de
muziekbron automatisch onderbroken om
de informatie te ontvangen
PTY (Program Type) met deze functie
kiest u elk aangeboden programma
(News, Sport, enz) met de toetsen ..
Werking van de functie PTY
Al s u t e wer k gaat zoal s hi er boven
beschreven, kunt u de PTY mode
activeren. Het laatst gekozen programma
blijft in het geheugen opgeslagen, maar u
kunt dit wijzigen met de toetsen .
Al s de PTY mode act i ef i s zal het
automatisch zoeken, zappen en autostore
(zie de volgende paragraaf "afstemmen")
beperkt worden tot alle zenders die het
gekozen programma uitzenden.
Vergeet niet dat de PTY alleen goed werkt
als het signaal goed is en als de zenders
de identificatiecode van het programma
vrijgeven
Afstemmen
Voor een gemakkel i j k gebrui k op het
voertuig, met zo weinig toetsen die moeten
bediend worden, zijn er verschillende
mogel i j kheden i ngebouwd om af t e
stemmen op uw voorkeurprogramma's die
in het menu van de TUNlNG kunnen
worden gekozen. Dit zijn de verschillende
zoekmogelijkheden:
Seek: met de toetsen overloopt u
het hele frequentiegamma. U zoekt
automati sch al s u de toets l i chtj es
indrukt (op het display verschijnt de
melding SEARCH en het zoeken stopt
zodr a een st at i on met een goede
ontvangstkwaliteit wordt gevonden) of
manueel al s u de toets i ets l anger
indrukt. Als u de toets ingedrukt houdt,
gaat het zoeken geleidelijker aan sneller
verlopen. U kunt het automatisch zoeken
SEARCH stoppen met de toets C/Off.
Scan: Met de bladertoetsen
(achteruit) e (vooruit) bladert u door
de 20 beschikbare geheugens.
Zapping: De FM-band wordt continu en
automatisch afgezocht. Als een station
OK/ON Menu openen
3 X drukken Ki est het vi er de
menuonderdeel (RDS)
OK/ON Bevestigt (opent het secundaire
menu van de RDS)
OK/ON Bevest i gt het eer st e
onderdeel van het secundaire
menu (off)
Of:
Of:
2 X
indrukken
Of:
3 X drukken
Ki est het t weede
menuonder deel van het
secundaire menu (AF)
Kiest het derde onderdeel
van het secundai re menu
(TA)
De AF-functie blijft actief.
Kiest het vierde onderdeel
(PTY)
De functies AF en TA blijven
actief
Na afIoop:
OK/ON
Bevest i gt het gekozen
onder deel en de
meldingen AF, TA of PTY
verschijnen op het display
14
met een goede ontvangstkwaliteit wordt
gevonden, stopt het zoeken en wordt het
si gnaal naar de headset of de
luidsprekers gestuurd. Het systeem blijft
ongeveer 10 seconden l ang op di t
st at i on af gest emd, waar na het
aut omat i sch een ander st at i on zal
zoeken. Al s de best uur der het
automatisch zoeken wenst te stoppen,
dient hij de toets OK/ON in te drukken.
Om opnieuw automatisch te zoeken,
hoeft u slechts de toets in te drukken.
Store (Autostore): De 10 beste stations
wor den gezocht en aut omat i sch
opgeslagen in de geheugens van 11 tot
20. Afhankelijk van het aantal in het
gebied aanwezige zendstations en van
het type/niveau van de beschikbare
si gnal en kan di t proces een ti ental
seconden in beslag nemen. Als er in het
gebied minder dan 10 zendstations
beschikbaar zijn die voldoen aan de
geprogrammeerde kwaliteitsvereisten,
kunnen enkele geheugens vrij blijven of
bezet worden door stations die niet
voldoen aan de kwaliteitsvereisten.
Tijdens het afstemmen (zowel manueel,
automatisch als zoeken in een opgeslagen
geheugen) verschijnt op het display de
volgende informatie:
naam van de zender (indien uitgezonden)
frequentie van de zender
nummer van het geheugen waarin het
st at i on i s opgesl agen al s di t al i s
opgeslagen in een van de 20 beschikbare
geheugens
SneI overschakeIen van Seek naar Scan
en vice versa
Al s de r adi o aan st aat kunt u snel
overschakelen van de Seek mode (MS)
naar de Scan mode (SS) of vice versa als u
de toetsen en - tegelijkertijd indrukt.
OK/ON Menu openen
OK/ON Bevestigt de keuze van het
eer st e menuonder deel
(TUNlNG)
menu ( Seek) de
afkorting MS verschijnt op het
display
Of:
OK/ON
Kiest het tweede onderdeel van
het secundaire menu (Scan)
onderdeel de afkorting
SS verschijnt op het display
Of:
2 X
drukken
OK/ON
RI
OK/ON
OK/ON
(Zapping)
onder deel het
symbool verschijnt op
het display
Start het automatisch zoeken
Ti j dens het zoeken en
achtereenvolgens beluisteren
van de programma's knippert
de afkorting ZP
Stopt het zoekproces op de
afgestemde zender het
symbool verschijnt op
het display
Verlaat de functie Zapping
Of:
3 X
drukken
OK/ON
Kiest het vierde onderdeel van
het secundai r e menu
(Autostore)
onderdeel er verschijnt
een schuifbalk op het display
en de opsl agpr ocedur e
begint.
Aan het ei nde van de
procedure gaat het systeem
automatisch in de SS (Scan)
mode staan
15
Een station in het geheugen opsIaan
De geheugens van 1 t ot 10 zi j n t er
beschikking van de klant.
Wij raden aan stations in het geheugen
op te sIaan terwijI de motor stiI staat, in
veiIige omstandigheden.
U kunt op elk ogenblik een station opslaan
in een van de 10 beschikbare geheugens,
mits het apparaat in de RADlO mode staat
en de TUNlNG-functie op Seek staat (MS
op het display)
DE INTERCOM GEBRUIKEN
De intercom voor de communicatie tussen
twee helmen kan worden gekozen op 4
manieren (in het menu):
Off: Geen enkele communicatie tussen
de helmen, beide berijders kunnen naar
de radio en de muziekbron luisteren.
On: de verbinding tussen de helmen is
altijd actief
VLOW (Vox Low): zoals boven, maar
met een laag stemvolume.
VHlGH (Vox High): de intercom staat uit
maar schakelt in zodra de bestuurder of
de passagier iets zegt in de microfoon.
Zowel de stem van de passagier als die
van de bestuurder moet luid genoeg zijn
om de i nt ercom aut omat i sch i n t e
schakelen
De elektronische besturing is uitgerust met
een mechanisme dat achtergrondgeluid
waarneemt(windgeruis) en dit zo veel
mogelijk te beperken of te elimineren.
Toch zi j n er t wee ver schi l l ende
automatische inschakelwijzen voorzien
(High en Low) om te voorkomen dat het
achtergrondgeluid in bepaalde situaties de
intercom kan inschakelen zonder dat de
gebruiker hierom gevraagd heeft.
Het inschakelen van de intercom dempt
aut omat i sch het vol ume van de
muziekbron (radio of aux) met ongeveer 20
dB.
RI Manueel of automatisch de
frequentie zoeken totdat u
de gewenste zender vindt
De toets
OK/ON Iang
indrukken
Start de opslagfunctie. Links
onder aan op het di spl ay
ver schi j nt een
geheugennummer (dat u naar
believen kunt wijzigen van 1
tot 10 met de toetsen
en de frequentie van de in dit
het geheugen opgeslagen
zender . U kunt op deze
mani er zel f de
geheugenpositie kiezen en
voorkomen dat een zender de
vorige wist
RI Om het geheugennummer te
ki ezen dat u wenst t e
gebruiken voor de gekozen
zender.
OK/ON Bevestigt het opslaan in het
geheugen.
OK/ON Menu openen
Ki est het t weede
menuonderdeel (lNTERC)
OK/ON Bevest i gt ( en opent het
secundaire menu)
menu ( Of f ) en wi st
event uel e mel di ngen met
betrekking tot de intercom op
het display
Of:
OK/ON
Kiest het tweede onderdeel
(On)
onder deel en de
afkorting IC verschijnt op het
display.
Of:
2 keer
OK/ON
(VLOW)
onderdeel De afkorting
ICL verschijnt op het display
Of:
3 keer
OK/ON
Kiest het vierde onderdeel
(VHlGH)
onderdeel De afkorting
ICH verschijnt op het display
16
SneIIe keuzemogeIijkheden om de
intercom aan te zetten en in te steIIen
Tijdens het rijden kan het gebeuren dat u
de intercom nodig hebt voor een dringende
communicatie.
Daarom is een snelle manier voorzien om
de intercom in de VLOW (Vox Low) mode
aan te zetten. Deze snelle bedieningswijze
werkt niet als de intercom al aan staat.
U kunt de intercom uit zetten met dezelfde
snelle bediening of in het hoofdmenu.
DE HOGE EN DE LAGE TONEN
REGELEN
Met de versterker in de elektronische
besturing kunt u de hoge en de lage tonen
van het weergegeven geluid regelen.
DE MUZIEKBRON KIEZEN
U kunt tussen twee muziekbronnen kiezen:
Radio en Aux. U kunt natuurlijk ook de
muziekbron volledig uitschakelen met Off
en het apparaat aan laten staan met alleen
het logo op het display.
Wij raden aan de muziekbron te kiezen
terwijI de motor stiI staat, in veiIige
omstandigheden.
2 keer kort
achtereen-
volgens
indrukken:
OK/ON
Zet de intercom aan in de
Vox Low mode De melding
,&/ verschijnt op het display
.
OK/ON Menu openen
2 X
indrukken
Ki est het der de
menuonderdeel (AUDlO)
OK/ON Bevest i gt ( opent het
secundaire menu)
menu ( Bass) en de
regelgrafiek verschijnt
+ of - Voor meer of minder sterke
lage noten
of
OK/ON
Bevest i gt het t weede
menu ( Tr ebl e) De
regelgrafiek verschijnt
+ of - Voor meer of minder sterke
hoge tonen
na afIoop
C/Off
Keer t t er ug naar het
hoofdmenu
OK/ON Menu openen
4 X
indrukken
Ki est het vi j f de
menuonderdeel (Source)
secundaire menu)
menu (Radio)
Of:
Of:
2 X
indrukken
Ki est het t weede
menuonder deel van het
secundaire menu (Aux)
Kiest het derde onderdeel van
het secundaire menu (Off)
Na afIoop:
OK/ON
onderdeel
17
DE GSM HANDSFREE GEBRUIKEN
Met het menu van het i nt egr al e
communi cat i esyst eem kunt u de
best emmi ng van i nkomende
telefoonoproepen programmeren.
Wij raden aan dit te doen terwijI de
mot or st i I st aat , i n vei I i ge
omstandigheden.
Zodr a een t el ef oonopr oep wor dt
gesignaleerd, wordt een speciale toon naar
bei de headsets gestuurd Al s de toon
ophoudt, wordt de communicatie naar de
bestuurder gestuurd, of naar de bestuurder
en de passagier, naar gelang van de keuze
die in het hoofdmenu is gemaakt.
SneIIe keuzemogeIijkheden voor het
beheer van i nkomende
teIefoonoproepen
Ti j dens een tel efoongesprek kan het
gebeuren dat u met de passagier wenst te
communiceren en het telefoongesprek in
stand by wenst te zetten. Dit doet u op
twee manieren:
BELANGRI JK Al s t i j dens het
telefoongesprek de sleutel in het contact in
de stopstand wordt gezet, zal het systeem
pas worden ui tgezet op het ogenbl i k
waarop de verbinding wordt verbroken.
OK/ON Menu openen
5 X
indrukken
Ki est het zesde
menuonderdeel (TELEPH)
secundaire menu)
menu ( Dr i ver ) ; de
afkorting D verschijnt op het
display
Of:
OK/ON
(Driver+Pass)
onder deel en de
afkorting DP verschijnt op het
di spl ay Al l e i nkomende
t el ef oonoproepen worden
zowel naar de bestuurder als
naar de passagier gestuurd.
C/Off Het gesprek wordt in stand by
gezet en de bestuurder kan
met de passagier praten
18
LUISTEREN MET LUIDSPREKERS OP
HET VOERTUIG (INDIEN AANWEZIG)
Op enkel e voer t ui gen zi t t en t wee
luidsprekers voor de bestuurder die een
goede luisterkwaliteit waarborgen als het
voertuig stil staat of langzaam rijdt. ln het
hoofdmenu kunt u het gebruik van deze
externe luidsprekers programmeren. Dit
doet u op de volgende manier:
Auto: de voertuigluidsprekers zijn alleen
i ngeschakel d al s bei de headset s
ui t geschakel d zi j n en de
jackaansluitingen niet zijn aangesloten
On: de voertuigluidsprekers zijn altijd
ingeschakeld en zenden de gekozen
muzi ekbron ui t (Radi o of Aux). De
luidsprekers zullen nooit het geluid van
de intercomcommunicaties of van de
GSM weergeven.
Off: de voertuigluidsprekers staan altijd uit.
OPGELET
AI s bei de headset s wor den
uitgeschakeId, zaI de gebruiker niet
gemakkeIijk merken dat er een oproep
voor de mobieIe teIefoon is. Om de
opr oep t e beant woor den zaI de
gebruiker sneI de headset moeten
aansIuiten of de teIefoonkabeI van het
voertuig moeten haIen.
UITGESTELD UITSCHAKELEN
U kunt het systeem zo programmeren dat
het nog 15 minuten aan blijft staan nadat u
de sleutel in de stopstand hebt gezet. Dit
kan handig zijn als u het systeem aan
wenst laten te staan zonder dat andere
motoronderdelen accustroom verbruiken.
Als u de functie "Delay" kiest blijven alle
functies van het communicatiesysteem
actief.
U kunt het syst eem op el k gewenst
ogenblik uitzetten met de toets C/OFF
Als de sleutel van de stopstand in de
startstand wordt gezet voordat 15 minuten
zi j n verstreken, wordt de AD f uncti e
automatisch uitgeschakeld.
OK/ON Menu openen
6 X drukken Ki est het zevende
menuonderdeel (SPEAKS)
secundai r e menu van de
SPEAKS)
menu (off) en over het
symbool van de luidsprekers
staat een schuin streepje.
Of:
OK/ON
(Auto)
onder deel en het
symbool van de luidsprekers
st aat i n een r echt hoeki g
kadertje
Of:
2 X
drukken
OK/ON
Kiest het derde onderdeel van
het secundaire menu (On)
onderdeel
OK/ON Menu openen
7 X
drukken
Ki est het acht st e
menuonderdeel (Power)
OK/ON OK/ONBevestigt (opent het
secundaire menu)
(delay)
OK/ON bevestigt De afkorting
AD verschijnt
19
Als de AD-functie per ongeluk is
ingeschakeld, kunt u deze uitschakelen in
het menu:
Opmerking: Om geen Iast te krijgen met
het starten van het voertuig, raden wij
aan de deIay-functie niet meer dan 1
keer aan te zetten terwijI de motor uit
staat.
OK/ON Menu openen
7 voIte Kiest het achtste onderdeel
van het menu (Power)
OK/ON Bevest i gt ( en opent het
secundaire menu)
OK/ON Bevestigt het eerste gekozen
onder deel ( key)
Verdwijnt als de melding AD
verschijnt.
TECHNISCHE GEGEVENS
Stroomvoeding 10,5 16V
Stroomafname met stiIstaand voertuig 0 mA
Max. stroomafname aIIeen met kopteIe-
foons
500 mA
Max. stroomafname met kopteIefoons
en Iuidsprekers
1,5 A
Stroomafname van het sIeuteIcircuit 1,5 mA
Luidsprekerfrequentie 20020000 Hz 3dB
Intercomfrequentie 2005000 Hz 3dB
ToonregeIing 12dB
Microfoons -69 dB 3dB n richting
HeadsetIuidsprekers 8 ohm - 0,5 W
Max. vermogen uitgang voertuigIuid-
sprekers
2 x 7 W
TweetoonIuidsprekers
APRumINTERFONO#02CAP01e01.FM Page 1 Saturday, March 8, 2003 9:41 AM
use and maintenance Radio MOB Control
2
2003 apriIia s.p.a. - Noale (VE)
First edition: February 2003
Reprinted on:
Produced and printed by:
DECA s.n.c.
Via Risorgimento, 23/1 - Lugo (RA) - ltalia
Tel. +39 - 0545 35235
Fax +39 - 0545 32844
www.decaweb.it
for:
aprilia s.p.a.
via G. Galilei, 1 - 30033 Noale (VE) - ltaly
Tel. +39 - (0)41 58 29 111
Fax +39 - (0)41 44 10 54
www.aprilia.com
SAFETY INFORMATION
The following conventions are used to identify
safety information throughout the manual:
This symboI identifies safety-
reIated information. Whenever
you see this symboI in the manuaI or
attached to the vehicIe, take utmost
care to avoid the risk of injury. FaiIure
to compIy with the instructions given
after this symboI may put your safety,
as weII as that of other persons or the
motorcycIe at risk!
WARNING
FaiIure to compIy with given indications
may Iead to severe injury or death.
CAUTION
FaiIure to compIy with given indications
may Iead to injuries or damages to the
motorcycIe.
I MPORTANT The t er m
"l MPORTANT! " pr ecedes i mpor t ant
information or instructions.
TECHNICAL INFORMATION
Unless expressly specified otherwise,
i nst al l / r eassembl e by f ol l owi ng
removal/disassembly procedure in the
reverse order.
The terms "left" and "right" are referred to
the motorcycle when viewed from the
riding position.
GENERAL PRECAUTI ONS AND
INFORMATION
IMPORTANT This manual is part of
the radio intercom and should always be
attached to it, even if resold.
apriIia has paid their utmost care to give
correct and up-to-date information.
However, as apriIia products are ever
i mproved i n t hei r desi gn, t he owned
vehicle might be slightly different from the
one described in this manual. Please
contact your Official apriIia Dealer for
further information.
Thank you for buying apriIia!
Al l ri ghts of storage usi ng el ectroni c
means, reproduction and total or partial
adaptation, whatever the means adopted,
are reserved in all countries.
ln this manual any variants are identified
with the following symbols:
option OPT
3
CONTENTS
SAFETY INFORMATION ............................... 2
TECHNICAL INFORMATION......................... 2
GENERAL PRECAUTIONS AND
INFORMATION ............................................. 2
FOREWORD .................................................. 3
CONTENTS............................................................ 3
CUSTOMIZATION OF THE COMMUNICATION
SYSTEM........................................................ 4
OUTFIT......................................................... 4
INSTRUMENTS AND INDICATORS............... 5
TABLE - lNSTRUMENTS AND lNDlCATORS........ 6
AUXILIARY EQUIPMENT.............................. 8
lNTERCONNECTlON CABLES.............................. 8
THROAT MlCROPHONE HEADSET ..................... 8
PRELIMINARY OPERATIONS....................... 9
lNSTALLATlON OF HEADSET lNTO THE HELMET 9
CONNECTlNG THE HEADSET TO THE VEHlCLE10
CONNECTlNG THE MOBlLE TELEPHONE TO THE
VEHlCLE............................................................... 10
CONNECTlON WlTH AN EXTERNAL MUSlC
DEVlCE................................................................. 10
SYSTEM SWlTCHlNG-ON/SWlTCHlNG-OFF..... 11
TURNlNG UP/DOWN THE VOLUME................... 11
MUTE.................................................................... 11
HOW TO USE THE INTEGRATED
COMMUNICATION SYSTEM....................... 12
MENU ................................................................... 12
RADlO................................................................... 13
lNTERCOM........................................................... 15
TONE CONTROL ................................................. 16
SELECT AUDlO SOURCE................................... 16
HAND-FREE SPEAKERPHONE FOR MOBlLE
PHONE................................................................. 17
EXTERNAL SPEAKERS (lF FlTTED) .................. 18
DELAYED SYSTEM SWlTCH-OFF...................... 18
SPECIFICATIONS ....................................... 19
FOREWORD
APRl Ll A RADl O MOB CONTROL
communi cat i on syst em, especi al l y
designed for apriIia vehicles, features the
following functions all in a single device:
FM radio receiver with RDS;
classic intercom with activation not
conditioned by surrounding noise;
hand-free speakerphone for mobile
phones ( vi a opt i onal connect or ) .
lncoming calls can be switched only to
the rider, pillion passenger or both; The
cont rol uni t aut omat i cal l y det ect s
incoming calls alerting the rider through
a beep and a control light;
connection to external device (tape, CD
or MP3 player) via optional connector;
stereo amplifier and pair of loudspeakers
(depending on models) for top-quality
sound when not riding or riding at low
speed.
The satellite onto the handlebar has a
large matrix display and adjustable control
unit for improved ergonomic features.
Lighted display and keys for easy detection
of controls and reading.
Quick and easy function selection through
scroll menu.
CAUTION
I t i s war mI y r ecommended t he
communication system be instaIIed by
an authorized aprilia service center.
4
CUSTOMIZATION OF THE COMMUNICATION SYSTEM
The control unit memory includes some vehicle names belonging
to Aprilia and Guzzi range.
Vehicle logo is displayed just after switching on the
communication system and under some particular conditions (for
example when it is on with no audio source enabled).
Select vehicle logo as follows:
Logo is saved even if batteries are removed.
Position the key-operated switch to ON
Ensure that the communication system is off (if not, press C/off for about
20 seconds)
Press for a Iong
time (approx. 20
seconds):
The communication system will power on and
logo is displayed.
1RWH Display is not lighted at this time.
I Select logo
When finished:
dddPdd OK/Menu
To confirm the selected logo and power on
the communication system
OUTFIT
LEGEND
1) Jack plug
2) Crash helmet clip
3) Crash helmet speaker
4) Microphone
4
1 2 3
5
INSTRUMENTS AND INDICATORS
LEGEND
1) Volume down (-)
2) Volume up (+)
3) Scan memories and frequency ( )
4) Scan memories and frequency ( )
5) MUTE/OFF
6) OK/ON
7) Display
3
1
5
6 2 4 7
6
TABLE - INSTRUMENTS AND INDICATORS
Key DefauIt function Function into the menu
Scan memories up in SS mode
Scan frequencies up in MS mode
- Press shortly: automatic search
- Press for a long time: manual shifting
Scroll menu to the end (to the right)
Scan memories down in SS mode
Scan frequencies down in MS mode
- Press shortly: automatic search
- Press for 20 seconds: manual shifting
Scroll menu to the start (to the left)
+ Volume up
- Volume down
OK/ON
Menu
when communication system is off: switch on the
communication system
When the communication system is on:
- Press shortly: call menu
- Press for a long time: enable saving mode.
Confirm selection
ln saving mode: save
C/OFF
Mute
when communication system is on:
- Press shortly: mute (- 20 dB with immediate effect)
- Press for a long time: the communication system
switches off.
Return to upper level without confirmation
C/OFF
Mute
Press shortly (only if in Mute mode) set to original volume
in stages
7
Abbreviated seIections
Key Key to enabIe abbreviated seIection Function
OK/ON
Menu
Press twice shortly Enable/disable intercom in VOX LOW (lCL)
C/OFF
Mute
Press once shortly
(This function is enabled onl y i n case of ongoing
telephone call)
Put telephone call on hold: the rider can freely talk to
the pillion passenger regardless of intercom status.
Selectable options to resume incoming calls are
displayed
Press once shortly
This function is enabled only if a telephone call is on hold
Telephone call is resumed only to the rider
Press once shortly
Tel ephone cal l i s resumed onl y t o t he pi l l i on
passenger
+
Press once shortly
Telephone call is resumed both to rider and pillion
passenger.
Press
and - at the
same time
Press once at the same time shortly
This function is enabled only if listening to the radio in
seek or scan mode
To switch from MS to SS mode or vice versa.
8
AUXILIARY EQUIPMENT
INTERCONNECTION CABLES
lnterface cable for motorcycle telephone
outlet and customer's telephone will be
available at our Sales and After-sales
Service. Cabl es for the most popul ar
mobile telephones will be available.
lnterconnection cables for control unit and
external self-powered audio devices (for
example a portable MP3 player) will be
available at our Sales and After-sales
Service. Depending on the supplied model,
audio outlet can be in the front shield or
under-seat compartment (larger and safer)
or glove compartment.
l t i s war ml y r ecommended t he
interconnection cable be installed and
connected by an authorized apriIia center.
THROAT MICROPHONE
HEADSET
A special throat microphone headset for
easier installation into the helmet and
lower air rustle will be available at our
Sales center.
OPT
OPT
9
PRELIMINARY OPERATIONS
INSTALLATION OF HEADSET INTO
THE HELMET
Fit the clip (1) onto helmet lower left edge.
ln most cases, the helmet features an air
space between helmet lining and outer
shell. Fit the metal clip in there so that no
changes to the helmet are needed.
CAUTION
Route the cabIe between metaI cIip and
heImet rim as shown in the picture so
not to put headset connector under
tension or puIIs.
Strap the speaker (2) into the helmet at ear
level. lf not correctly positioned, speaker
volume will be too low.
IMPORTANT
In fuII-face crash hel mets bend the
mi crophone stem (3) and adj ust i t to
hel met shape. Ensure that ai r i s not
blowing on the crown (4).
I n ot her cr ash hel met s, bend t he
microphone stem (3) so to have the crown
(4) as close as possible to your mouth.
The white area onto microphone stem
shouId be aiming at your mouth.
CAUTION
For proper headset operation:
do not remove foam-rubber
protecting the speaker (5);
microphone and speaker shouId
never get wet.
1
2
4 3
5
10
CONNECTING THE HEADSET TO
THE VEHICLE
Headset j ack pl ug (1) can be easi l y
connected even in the dark.
Connect the connector(s) into its(their)
outlet(s).
CAUTION
Each outIet has a rubber safety cap (2).
Recap the outIet after use to ensure
troubIe-free operation of the system.
The system automatically detects one or
two headset when connected. When a
headset is connected or disconnected,
hel met symbol s are di spl ayed at the
bottom left.
Symbols are crossed if the headset is not
connected. Symbols will automatically
disappear after first display refreshing.
Apart f rom t he i nt ercom, al l syst em
functions are enabled even though only the
pillion passenger's headset is connected.
CONNECTING THE MOBILE
TELEPHONE TO THE VEHICLE
The integrated communication system has
a special 8-way connector which can be
easily reached (see CUSTOMlZATlON OF
THE COMMUNlCATlON SYSTEM).
Vehicle-telephone interface cable and its
compatible connector are available at our
Sales and After-sales centers.
Set the mobile telephone to automatic
answer mode so that no keys need to be
pressed to pick up the incoming calls.
Read mobi l e t el ephone i nst ruct i ons
carefully to set as specified above.
Motorol a 8700, Startac 130, CD920,
CD930 and Bosch M-com 506 should be
powered off before being connected with
the vehicle cable. The mobile telephone is
automatically activated.
CONNECTION WITH AN
EXTERNAL MUSIC DEVICE
The control uni t of apriIia i ntegrated
communication system has an auxiliary
outlet for connection with an external
music device. External devices such as CD
players -provided that they are shockproof
for trouble-free operation when riding- MP3
players or magnetic tape players.
The external device can be housed into the
front shield, under-seat compartment or
glove compartment, depending on rider's
will and motorcycle model. The external
device can be fed by its own power supply
or connect ed t o t he ci gar - l i ght er
connect i on -i f avai l abl e- t hrough an
adapt er whi ch i s not i ncl uded i n t he
standard outfit. However, the external
musi c devi ce cannot be r emot el y
controlled by the satellite.
The connection cable between control unit
and external music device is available at
our Sales and After-sales centers and not
included in the standard outfit so that the
Customer can customize the installation
according to his/her wishes. lt is warmly
recommended the connection cable be
installed and connected by an apriIia
authorized center.
2
1
11
SYSTEM SWITCHING-
ON/SWITCHING-OFF
The system can be switched on only if the
ignition key is positioned to ON.
Press OK/ON for 2 seconds to switch the
system on.
Press C/OFF for at least 2 seconds to
switch the system off.
l f t he key i s t ur ned t o OFF, t he
communication system will also switch off.
lt wi l l swi tch on agai n and keep l ast
selected settings -as far as possible- once
the key is positioned to ON once again.
The communication system can be kept on
for a set time even if the ignition key is
posi t i oned t o OFF. See page 18
(DELAYED SYSTEM SWlTCH-OFF) for
further details.
TURNING UP/DOWN THE VOLUME
The headset/speaker vol ume can be
turned up (+) or down (-) at any time.
Only the selected operating mode will be
affected. ln this way, all operating modes
(telephone, radio, external music device
and intercom) can be set as required.
Volume level is clearly displayed.
The volume level is set for both rider and
pillion passenger.
MUTE
Press C/OFF shortly when listening to an
external source, such as radio or auxiliary
devi ce, to i mmedi atel y turn down the
volume by about 20 dB (A).
Press C/OFF once again to turn up the
volume to the original level.
lf + or - are pressed after selecting Mute,
the system returns to standard operating
mode but the volume is set to Mute level.
12
HOW TO USE THE INTEGRATED COMMUNICATION SYSTEM
MENU
A horizontally scrollable menu ensures
quick and easy access to all available
functions.
Press OK/ON Menu to display the menu.
Press "next" or "previous" to scroll all
available functions.
The selected function -to be confirmed yet-
is displayed in negative characters.
One or two direction arrows at the top help
understanding the position of the selected
option within the whole menu.
Press OK/ON Menu to confirm selection.
Some functions in the main menu are
linked to a submenu. See descriptions
below on all menu options.
Press C/OFF at any time to return to
previous menu or exit if in the main menu.
Menu and submenu options are the
following:

Pages below give a detailed description of
system functions which can be selected on
the menu.
1. TUNING
seek
scan
zapping
store
5. SOURCE
radio
aux
off
2. INTERC
off
on
vIow
vhigh
6. TELEPH
driver
driver + Pass
3. AUDIO
Bass
TrebIe
7. SPEAKS
Off
Auto
On
4. RDS
off
af
ta
pty
8. POWER
key
deIay
13
RADIO
WARNING
CareIessness may be the cause of fataI
accidents. AII operations requiring
rider's concentration, such as radio
tuning or seIection of operating mode,
must be carried out under fuII safety
conditions when not riding.
RDS mode
Functi ons and opti ons of Radi o Data
System mode are strongly affected by the
transmission mode of radio stations and
signal quality in the receiving area.
ln case of good signal quality available
services are the following:
Off Radio station name is displayed but
all other RDS functions are disabled
(such as alternative frequency, road
traffic information, PTY)
AF (Alternative Frequencies): the
recei ver t unes aut omat i cal l y t o an
alternative frequency for the same radio
station for improved signal quality.
TA (Traffic Announcement
identification): if the tuned radio station
transmits road traffic information, aux
source is temporarily disconnected to
enable road traffic information reception.
PTY (Program Type): identification of the
program (News, Sport and so on) by
pressing the keys ..

PTY mode
Enable PTY mode as described above.
The control unit saves the last selected
pr ogram, whi ch can be modi f i ed by
pressing the keys .
When PTY mode is active, automati c
search, zapping and autostore (see next
paragraph "Tuning") is enabled only for
those radi o stati ons t ransmi tti ng the
selected program.
lt should be remembered that PTY mode
works properly provided that the signal
quality is good and program identification
number is transmitted by the radio station.
Tuning
For easier use when riding and limit the
number of available keys, different modes
for searching the required radio stations
are included in the TUNlNG menu. Search
modes are the following:
Seek: press the keys for complete
scanning of the frequency range. Press
shortly for automatic search (SEARCH is
displayed and scanning stops once a
radio station transmitting a good signal is
detected) or for a long time for manual
sear ch. Keep t he key pr essed t o
increase scanning speed. Press C/OFF
to stop automatic SEARCH.
Scan: Press scroll up or down to
scroll all 20 available memories.
Zapping: FM band is steadily and
automatically scanned.
Once a radio station transmitting a good
signal is detected, scanning stops and
signal is sent to headset or speakers.
The system stays tuned to the detected
radio station for about 10 seconds, then
it automatically starts searching for the
next radio station. Press OK/ON to stop
automatic search. Press once again
to restart searching.
OK/ON Enter menu
3 times Select fourth menu option
(RDS)
OK/ON Conf i r m ( ent er RDS
submenu)
OK/ON Confirm first submenu option
(off)
Or:
Or:
twice
Or:
3 times
Se|ect seccnd submenu cpticn
(AF)
Se|ect third submenu cpticn (TA)
AF is active.
Se|ect fcurth submenu cpticn
(PTY)
AF and TA are active
When
finished:
OK/ON
Confirm selection. AF
or TA or PTY ar e
displayed
14
Store (Autostore): The 10 local radio
stations having the clearer signal are
searched and automatically saved from
position 11 to 20. lt may take some
seconds, depending on the number of
t he l ocal radi o stat i ons and si gnal
levels/type. lf less than 10 radio stations
meeting default settings are available,
some positions may not be taken or
taken by stations featuring poor quality
signal.
While tuning to some station -either in
manual or automatic mode or recalling a
position- the following is displayed:
name of the radio station, if transmitted
frequency of the radio station
position number if stored in one of the 20
available positions
Short-cut from Seek to Scan and vice
versa
When listening to the radio, press and - to
quickly switch from Seek (MS) to Scan (SS)
mode and vice versa.

OK/ON Enter menu
OK/ON Confirm selection of the first
menu option (TUNlNG)
(Seek) . MS is displayed.
Or:
OK/ON
Sel ect second submenu
option (Scan)
Confirm selection. SS is
displayed.
Or:
Twice
OK/ON
RU
OK/ON
OK/ON
Select third submenu option
(Zapping)
Conf i r m sel ect i on.
Symbol is displayed .
St ar t aut omat i c sear ch.
Dur i ng sear ch and
progressive program tuning,
ZP is flashing
St op search when t uned:
symbol i s di spl ayed
again
Quit Zapping
Or:
3 times
OK/ON
Select fourth submenu option
(Autostore)
Conf i r m sel ect i on. A
control bar is displayed and
saving procedure is started.
When finished, the system
will automatically switch to SS
mode (Scan mode).
15
Saving a radio station
Available positions are from 1 to 10.
Save radio stations under fuII safety
Any radio stations can be saved from 1 to
10 at any time, provided that the system is
in RADlO mode and TUNlNG is enabled in
Seek mode (MS to be displayed)
INTERCOM
Four menu options are available to select
intercom mode.
Off: No communications between rider
and pillion passenger but both can listen
to the radio or external music device.
On: rider and passenger are connected.
VLOW (Vox Low): ditto but in a low
voice.
VHlGH (Vox High): intercom is in stand-
by mode and turns to On as soon as
rider or pillion passenger speak into the
microphone. Pillion passenger or rider
need to speak to the microphone in a
loud voice to turn it on.
The electronic unit has a device for the
detection of background noise (rustle) and
reduce it as low as possible.
This is why two different activation modes
are available, i.e. High and Low: to avoid
that the background noise can turn the
intercom on under certain conditions when
not required by the user.
When the intercom is activated, audio
source vol ume l evel (radio or aux) i s
automatically lowered by approx. 20 dB.
RU scan frequencies in manual
or automatic mode until the
r equi r ed r adi o st at i on i s
detected.
Press
OK/ON for a
Iong time
Enter Saving procedure. The
position number is displayed
at the left bottom along with
the frequency of the saved
station. Press keys to scroll
from 1 to 10 . ln this
way, the required position can
be selected so not to save the
same radio station twice.
RU sel ect t he number of t he
position to save the selected
radio station.
OK/ON Confirm saving.
OK/ON Enter menu
Select second menu option
(lNTERC)
OK/ON Confirm (submenu is entered)
( Of f ) ; i nt er com t ext
displayed is turned off.
Or:
OK/ON
option (On)
Confirm selection. ,& is
displayed.
Or:
twice
OK/ON
(VLOW)
Confirm selection. ICL is
displayed.
Or:
3 times

OK/ON
Select fourth submenu option
(VHlGH)
Confirm selection. ICH is
displayed.
16
Shortcuts to power on and set the
intercom
When riding there might be the need to use
the intercom for an urgent communication.
To this aim, a shortcut is available to
activate the intercom in VLOW mode (vox
Low). The shortcut has not effect if the
intercom is already enabled.
Pr ess OK/ ON t wi ce once agai n t o
deactivate the intercom or deactivate on
the main menu.
TONE CONTROL
The control unit amplifier allows tone
control.
SELECT AUDIO SOURCE
Three different options are available: Radio
and Aux. Audio source can be completely
switched off through Off still keeping the
system on to display the logo.
SeIect the audio source under fuII
safety conditions when not riding.
Press OK/ON
twice for a
short time:
the intercom will activate in
Vox Low mode. lCL will
also be displayed.
OK/ON Enter menu
Twice Sel ect t hi rd menu opt i on
(AUDlO)
(Bass) setting graph is
displayed
+ or - Adjust bass
Or:
OK/ON
option (Treble); setting
graph is displayed
+ or - Adjust trebles
When
finished
press C/Off
to return to the main menu
OK/ON Enter menu
4 times Sel ect f i f t h menu opt i on
(Source)
(Radio)
Or:
Or:
Twice
option (Aux)
(Off)
When
finished:
OK/ON
Confirm selected option
17
HAND-FREE SPEAKERPHONE FOR
MOBILE PHONE
The mai n menu of t he i nt egr at ed
communication system allows destination
setting of incoming calls
SeIect menu options under fuII safety
The control unit sends a beep to both rider
and pillion passenger in case of incoming
calls. After the beep, the call is sent either
to the rider or the pillion passenger or both
depending on main menu setting.
Shortcuts for incoming caIIs
During a telephone conversation, the rider
mi ght need t o t al k wi t h t he pi l l i on
passenger and put the telephone call on
hold. Communication can be managed as
follows:
IMPORTANT lf the key-operated
switch is positioned to off while speaking
on the phone, the communication system
will switch off only after hanging-up.
OK/ON Enter menu
5 times Sel ect si xt h menu opt i on
(TELEPH)
(Driver) . D is displayed.
Or:
OK/ON
option (Driver+Pass)
Confirm selection. DP is
displayed. All incoming calls
will be sent to both rider and
pillion passenger.
C/Off Put telephone call on hold so
that the rider can speak with
the pillion passenger
18
EXTERNAL SPEAKERS (IF FITTED)
Some vehicles include a pair of speakers
fitted before the rider for good- quality
stereo sound when the vehicle is stopped
or ri di ng at l ow speed. Set speaker
operating mode on the main menu. As
follows:
Auto: external speakers are on only if
both headsets are disconnected.
On: external speakers are always on
and play the music from the radio or aux.
They never play intercom or mobile
telephone sound.
Off: external speakers are off.
CAUTION
If both headset are disconnected, an
incoming caII cannot be picked-up. In
this case, re-connect the headset or
disconnect the teIephone from vehicIe
connection cabIe.
DELAYED SYSTEM SWITCH-OFF
The system can be switched off after 15
mi nut es t he i gni t i on key has been
positioned to OFF. This function ensures
system power supply but disconnects all
other devices so to save the battery.
When in Delay mode all system functions
are enabled.
Press C/OFF to switch if off at any time.
lf the ignition key is positioned to ON
before 15 mi nutes have el apsed, AD
function is automatically disabled.
OK/ON Enter menu
6 times Select seventh menu option
(SPEAKS)
OK/ON Conf i r m ( ent er SPEAKS
submenu)
( of f ) ; speaker symbol i s
crossed.
Or:
OK/ON
option (Auto)
Conf i r m sel ect i on;
speaker symbol i s i nt o a
frame
Or:
twice
OK/ON
(On)
Confirm selected option
OK/ON Enter menu
7 times Sel ect ei ght h menu opt i on
(Power)
Select second submenu option
(Delay)
OK/ON Confirm AD is displayed
19
lf AD function is accidentally activated, it
can be disable on the menu:
Note: EnabIe DeIay mode onIy once
when the engine is off for troubIe-free
engine ignition.
OK/ON Enter menu
7 times Sel ect ei ghth menu opti on
(Power)
OK/ON Confirm first selected option
(key), AD disappears (if
displayed).
SPECIFICATIONS
Power suppIy 10.5 16V
Current absorption when the engine is off 0 mA
Max. absorption onIy with headset 500 mA
Max. absorption with headset and speakers 1.5 A
Key circuit absorption 1.5 mA
Speakers frequency response 20020000 Hz 3dB
Intercom frequency response 2005000 Hz 3dB
Tone controI 12dB 12dB
Microphones -69 dB 3dB - unidirectionaI -69 dB 3dB unidirectional
Headset speakers 8 ohm - 0.5 W
Max. output power to externaI speakers 2 x 7 W 2 x 7 W
Speaker type biconical
20
NOTE
ASK FOR GENUINE SPARE PARTS ONLY
APRum_INTERFONO#02_CAP01e01.FM Page 20 Friday, March 14, 2003 10:15 AM
DISPOSITIVO DE COMUNICACIN INTEGRADA
APRum_INTERFONO#02_CAP01s01.FM Page 1 Saturday, March 8, 2003 10:40 AM
uso y mantenimiento Radio MOB Control
2
2003 aprilia s.p.a. - Noale (VE)
Primera edicin: Febrero 2003
Reimpresin:
Redactado e impreso por:
DECA s.n.c.
Via Risorgimento, 23/1 - Lugo (RA) - Italia
Tel. +39 - 0545 35235
Fax +39 - 0545 32844
www.decaweb.it
por cuenta de:
aprilia s.p.a.
via G. Galilei, 1 - 30033 Noale (VE) - Italia
Tel. +39 - (0)41 58 29 111
Fax +39 - (0)41 44 10 54
www.aprilia.com
MENSAJES DE SEGURIDAD
Los siguientes mensajes de sealizacin se
utilizan en todo el manual para indicar lo
siguiente:
Smbolo de aviso relativo a la
seguridad. Cuando este smbolo se
encuentra presente en el vehculo o en el
manual, prestar atencin a los potenciales
riesgos de lesiones. La inobservancia a lo
indicado en los avisos precedidos por
este smbolo puede comprometer la
seguridad: de usted, de terceros y del
vehculo.
PELIGRO
Indica un riesgo potencial de graves
lesiones o muerte.
ATENCIN
Indica un riesgo potencial de lesiones
leves o daos al vehculo.
I MPORTANTE el t rmi no
"IMPORTANTE" en el presente manual
precede importantes i nformaci ones o
instrucciones.
INFORMACIONES TCNICAS
Si no est expresamente descripto, el
montaje de los grupos se realiza en sentido
inverso a las operaciones de desmontaje.
Los trminos "derecha" e "izquierda" se
refieren al piloto sentado en el vehculo en la
normal posicin de conduccin.
ADVERTENCIAS-PRECAUCIONES-
AVISOS GENERALES
IMPORTANTE Este manual debe
ser considerado parte integrante del kit
r adi o i nt er f ono y si empr e debe
acompaarlo, incluso en caso de reventa.
aprilia ha realizado este manual prestando
l a mxi ma at enci n a l a seri edad y
act ual i dad de l as i nf or maci ones
suministradas.
Sin embargo, en consideracin del hecho
que los productos aprilia estn sujetos a
cont i nuas mej oras de proyect aci n,
podran existir ligeras diferencias entre las
caractersticas del vehculo en su posesin
y l as descr i t as en el manual . Par a
cual qui er acl ar aci n r el at i va a l as
informaciones contenidas en el manual,
contactar a su Concesi onari o Ofi ci al
aprilia.
Les agradecemos por haber el egi do
aprilia.
Los der echos de memor i zaci n
electrnica, reproduccin y adaptacin
total o parcial, por cualquier medio, estn
reservados en todos los pases.
En este manual las variantes se indican
con los siguientes smbolos:
opcional
OPT
3
INDICE GENERAL
MENSAJES DE SEGURIDAD......................... 2
INFORMACIONES TCNICAS....................... 2
ADVERTENCIAS-PRECAUCIONES-AVISOS
GENERALES ................................................. 2
INTRODUCCIN........................................... 3
INDICE GENERAL.................................................. 3
PERSONALIZACIN DEL DISPOSITIVO EN
EL VEHCULO............................................... 4
HERRAMIENTAS EN DOTACIN.................. 4
INSTRUMENTOS E INDICADORES............... 5
TABLA INSTRUMENTOS E INDICADORES.......... 6
DOTACIONES AUXILIARES.......................... 8
CABLES DE INTERCONEXIN............................. 8
AURICULAR A LARINGFONO............................ 8
OPERACIONES PRELIMINARES................... 9
INSTALACIN DEL AURICULAR EN EL CASCO. 9
CONEXIN DE LOS AURICULARES AL
VEHCULO............................................................ 10
CONEXIN DEL CELULAR AL VEHCULO........ 10
CONEXIN DE UNA FUENTE MUSICAL
EXTERNA............................................................. 10
ENCENDIDO/APAGADO...................................... 11
REGULACIN DEL VOLUMEN ........................... 11
MUTE.................................................................... 11
CMO USAR EL DISPOSITIVO DE
COMUNICACIN INTEGRADA.................... 12
USO DE LA RADIO.............................................. 13
USO DEL INTERFONO........................................ 15
REGULACIN DE LOS TONOS ALTOS Y BAJOS 16
SELECCIN DE LA FUENTE DE AUDIO ........... 16
USO DEL ALTAVOZ PARA CELULAR ................. 17
ESCUCHA CON ALTOPARLANTES EXTERNOS
(SI ESTN PREVISTOS) .......................................... 18
APAGADO RETARDADO .................................... 18
ESPECIFICACIONES TCNICAS ................ 19
INTRODUCCIN
El sistema de comunicacin integrado
APRI LI A RADI O MOB CONTROL,
especficamente desarrol lado para el
montaje en los vehculos aprilia, agrupa
en un nico dispositivo las siguientes
funciones:
Receptor de radio FM con RDS.
Interfono tradicional con sistema de
acti vaci n i ndependi ente del rui do
ambiental.
Altavoz para telfono celular (conexin a
un telefno celular del cliente por medio
de cable opcional) con posibilidad de
cambiar la llamada telefnica slo para
el piloto, slo para el pasajero o para
ambos. La cent r al det ect a
automticamente la presencia de una
llamada telefnica en entrada y avisa al
piloto con una seal sonora y visual.
Posibilidad de conectar una fuente de
audio externa (lector cintas, CD, MP3)
por medio de cable opcional.
Amplificador de potencia estreo y par
de altoparlantes (segn el modelo) para
una mejor calidad de sonido cuando el
vehculo est parado o a baja velocidad.
El satlite colocado en el manillar est
dotado de un amplio display a matriz y de
un grupo mandos orientables para mejorar
la ergonoma. La iluminacin del display y
de l as t ecl as per mi t e una mayor
individualizacin de los mandos y de la
lectura de las informaciones.
Un prctico men de seleccin rpida
facilita la ptima y rpida seleccin de
todas las funciones previstas.
ATENCIN
Se recomienda realizar la instalacin
del di sposi t i vo en un cent r o de
asistencia aprilia.
4
PERSONALIZACIN DEL DISPOSITIVO EN EL
VEHCULO
La central contiene en su memoria los nombres de algunos
vehculos de la gama aprilia y Guzzi.
El logo del vehculo se visualiza con el encendido y en algunos
casos particulares (por ejemplo, cuando el dispositivo est
encendido pero sin ninguna fuente de audio)
Para elegir el logo, operar como se indica a continuacin:
El logo queda memorizado tambin en caso de desactivacin de
la batera.
Colocar el conmutador de llave en la posicin de marcha Asegurarse
que el dispositivo est apagado (eventualmente apagarlo con presin
larga de C/off.)
Presin larga:
(20 segundos)
el dispositivo se enciende y se visualiza el
logo.
Nota: Durante esta operacin el display no
se ilumina
Elegir el logo
Para finalizar:
OK/Men
Confirma el logo el egido y enciende el
dispositivo
HERRAMIENTAS EN DOTACIN
LEYENDA
1) Conector a jack
2) Clip para fijacin al casco
3) Altoparlante casco
4) Micrfono
4
1 2 3
5
INSTRUMENTOS E INDICADORES
LEYENDA
1) Tecla regulacin volumen (-)
2) Tecla regulacin volumen (+)
3) Tecla bsqueda memorias y frecuencia ( )
4) Tecla bsqueda memorias y frecuencia ( )
5) Tecla MUTE/OFF
6) Tecla OK/ON
7) Display
3
1
5
6 2 4 7
6
TABLA INSTRUMENTOS E INDICADORES
Tecla Funcin default Funcin dentro del men
Bsqueda memorias hacia arriba en modalidad SS
Bsqueda frecuencia hacia arriba en modalidad MS
- Presin breve: bsqueda automtica
- Presin larga: desplazamiento manual
Desplazamiento del men hacia el final (hacia la
derecha)
Bsqueda memorias hacia abajo en modalidad SS
Bsqueda frecuencia hacia abajo en modalidad MS
- Presin breve: bsqueda automtica
- Presin larga: desplazamiento manual
Desplazamiento del men hacia el inicio (hacia la
izquierda)
+ Volumen aumenta
- Volumen disminuye
OK/ON
Men
Con dispositivo apagado: encendido dispositivo
Con dispositivo encendido:
- Presin breve: Llama men
- Presin larga: Activa modalidad memorizacin
Confirma la eleccin
En la memorizacin: memoriza
C/OFF
Mute
Con dispositivo encendido:
- Presin breve: mute (disminucin inmediata -20 dB)
- Presin larga: apagado dispositivo
Vuelve al nivel superior sin confirmar
C/OFF
Mute
Presin breve (slo si anteriormente se entr en la
disminucin Mute): restablece gradualmente el volumen
al nivel precedente
7
Selecciones abreviadas
Tecla Modalidad de activacin de la seleccin rpida Funcin
OK/ON
Men
Dos presiones breves en secuencia Activa/Desactiva interfono en modalidad VOX LOW
(ICL).
C/OFF
Mute
Una presin breve
(Funcin activa solo si hay una llamada telefnica en
curso)
Permanece en espera l a l l amada y permi te al
conduct or habl ar l i brement e con el pasaj ero
independientemente del estado del interfono.
El display visualiza las modalidades posibles para
retomar la llamada en entrada
Una presin breve
Funcin activa slo si haba precedentemente en espera
una llamada telefnica
Retoma la lnea comunicando slo al conductor
Una presin breve
Retoma la linea comunicando slo al pasajero
+
Una presin breve
Retoma la lnea comunicando al conductor y al
pasajero.
Presin
contempornea de
las teclas
y -
Presin contempornea breve
Funcin activa slo si se est escuchando la radio, con
modalidad seek o scan
Conmuta de modalidad MS a SS o viceversa
8
DOTACIONES AUXILIARES
CABLES DE INTERCONEXIN
En la red de venta y asistencia estar
disponible el cable de interfaz entre la
toma del telfono de la moto y el telfono
del cliente. Estarn disponibles los cables
para la mayor parte de telfonos celulares
que actualmente se encuentran en el
mercado.
En la red de venta y asistencia estar
disponible el cable de interconexin entre
la central y la fuente de audio externa
autoalimentada (por ejemplo, un lector
MP3 portatil). La toma para la fuente de
audio podr estar colocada (segn los
modelos) en la proteccin delantera o,
preferiblemente, en el compartimiento bajo
asiento (con mucha ms capacidad y
proteccin) o en el maletero.
Para realizar el correcto montaje del cable
de interconexin se recomienda dirigirse a
la red de asistencia aprilia.
AURICULAR A LARINGFONO
En la red de venta estar disponible un
auricular especial a laringfono que facilita
el montaje en el casco y reduce el ruido
debido a ruidos aerodinmicos.
OPT OPT
9
OPERACIONES PRELIMINARES
INSTALACIN DEL AURICULAR EN
EL CASCO
Fijar el clip elstico (1) en el borde inferior
del casco, del l ado i zqui erdo. En l a
mayora de los cascos hay un espacio
intermedio entre el acolchado y la carcasa
externa en la cual introducir el clip metlico
sin necesidad de modificar el casco.
ATENCIN
Para evitar que el conector del auricular
se t ense o se desconect e, se
recomienda pasar el cable entre el clip
metlico y el borde del casco como
ilustra la figura.
Colocar el altoparlante dentro del casco, a
l a al t ura de l a orej a, por medi o del
especfico velcro (2). Si el altoparlante se
coloca de manera incorrecta respecto a la
oreja, baja notablemente el nivel sonoro,
volvindose insuficiente.
IMPORTANTE
En los cascos integrales doblar la barra (3)
del micrfono para adaptarlo a la forma del
casco y para que la cpsula (4) no sea
golpeada por el aire.
En los cascos abiertos doblar la barra (3)
del micrfono para que la cpsula (4) se
encuentre lo ms cerca posible de la boca.
El punt o bl anco en l a bar r a del
micrfono debe estar dirigido hacia la
boca.
ATENCIN
Par a gar ant i zar un buen
funcionamiento de los auriculares:
no quitar la parte de goma-espuma
col ocada como pr ot ecci n del
altoparlante (5);
evitar lo ms posible que el
micrfono y el altoparlante entren en
contacto con el agua.
1
2
4 3
5
10
CONEXIN DE LOS AURICULARES
AL VEHCULO
La toma de auricular de tipo a jack (1)
permi te un rpi do acopl e tambi n en
condiciones de escasa visibilidad.
Introducir el conector / los conectores en
las especficas tomas previstas.
ATENCIN
Cada toma est dotada de un capuchn
protector (2) de goma, para cerrar
cuidadosamente cuando la toma misma
no es usada par a evi t ar
malfuncionamientos del sistema.
El sistema puede detectar de manera
automtica la presencia de uno o dos
auriculares. Cuando se introduce o extrae
el auricular, en la parte inferior izquierda
del display se visualizan los smbolos de
los cascos.
Los smbolos tienen barras si el auricular
no est pr esent e. Los s mbol os
desaparecen automticamente con la
primera actualizacin del display.
Todas las funciones del sistema - con
excepcin del interfono - funcionan slo
con el auricular del pasajero conectado.
CONEXIN DEL CELULAR AL
VEHCULO
El sistema de comunicacin integrado est
dotado de un especfico conector de 8
vas, colocado en una zona fcilmente
al canzabl e del veh cul o ( ver
PERSONALIZACIN DEL DISPOSITIVO
EN EL VEHCULO).
El cable de interfas entre el telfono (con
conector compatible) y el vehculo se
puede l ocal i zar en l a red de venta y
asistencia.
El telfono celular se establece en la
modalidad de respuesta automtica; de
esta manera se evita presionar las teclas
para tomar la comunicacin.
Leer atentamente las instrucciones del
t el f ono cel ul ar par a est abl ecer
cor r ect ament e l as f unci ones ant es
descritas.
Los telfonos Motorola 8700, Startac 130,
CD920, CD930 y BOSCH M-com 506
deben est ar apagados ant es de ser
conectados al cable del vehcul o. La
act i vaci n del t el f ono se r eal i za
automticamente.
CONEXIN DE UNA FUENTE
MUSICAL EXTERNA
La cent ral del si st ema i nt egrado de
comunicacin aprilia prev un ingreso
auxiliar en el cual es posible conectar una
fuente musical externa. Luego pueden ser
conectados los lectores de CD (si estn
dotados de la funcin shockproof para
poder funcionar correctamente a bordo del
vehculo), los lectores MP3, los lectores de
cintas magnticas.
El dispositivo de fuente externo puede ser
colocado en la proteccin delantera, en el
compart i mi ent o baj o asi ento o en el
maletero, a eleccin del cliente y del tipo
de vehculo. Dicho dispositivo deber estar
dotado de una alimentacin autnoma o
conectado a la toma del encendedor de
cigarrillos del vehculo (si est prevista) por
medio de un adaptador no suministrado.
En cada caso no ser posible el control
remoto del satlite de la fuente musical
externa.
Par a per mi t i r al cl i ent e l a mxi ma
per sonal i zaci n y f l exi bi l i dad de
instalacin, el cable de conexin entre la
central y la fuente musical externa se
vende separadamente en nuestra red de
Venta y Asistencia aprilia. Para el correcto
montaje del cable en la posicin deseada
por el cliente, se recomienda dirigirse a la
red de Asistencia aprilia.
2
1
11
ENCENDIDO/APAGADO
El encendido es posible slo con la llave
en posicin de marcha.
Pr esi onar l a t ecl a OK/ ON por dos
segundos para encender el dispositivo.
Presionar la tecla C/OFF por lo menos
durante dos segundos para apagar el
dispositivo.
Colocando la llave en posicin de parada,
se apaga tambin el dispositivo. En este
caso su f unci onami ent o r et omar
regularmente cuando la llave se coloque
en posicin de marcha, manteniendo en lo
posi bl e l as condi ci ones establ eci das
precedentes.
Es posi bl e mant ener encendi do el
dispositivo (por un tiempo predeterminado,
para evitar olvidos) tambin con la llave en
posi ci n de parada. Ver l a pg. 18
(APAGADO RETARDADO) para ulteriores
detalles.
REGULACIN DEL VOLUMEN
En cualquier momento es posible regular
el volumen de escucha en el auricular y/o
en l os al toparl antes operando en l os
pulsadores + y -.
La regulacin del volumen opera en la
funcin activa en ese momento. De esta
maner a es posi bl e adapt ar cada
dispositivo (telfono, radio, fuente externa,
interfono) a las exigencias del usuario.
El display indicar de manera clara e
inmediatamente el nivel de regulacin del
volumen.
No es posi bl e r egul ar de maner a
independiente el nivel del pasajero con el
del piloto.
MUTE
Durante la escucha de una fuente externa
(radio o aux), una presin breve en la tecla
C/Off provoca una inmediata disminucin
del nivel sonoro en aprox. 20 dB(A).
Presionando nuevamente la tecla C/Off el
volumen se restablece gradualmente al
nivel precedente.
Si luego de haber activado la funcin Mute
se presionan las teclas + o -, el dispositivo
retorna al funcionamiento normal pero el
volumen actual cambia al atenuado con la
activacin del Mute.
12
CMO USAR EL DISPOSITIVO DE COMUNICACIN INTEGRADA
USO DEL MEN
Para permitir un rpido y fcil acceso a
todas las funciones del dispositivo, ha sido
predispuesto un men de seleccin rpida
horizontal.
Para visualizar el men, presionar la tecla
OK/ON Men
Para seleccionar las distintas funciones
disponibles, utilizar las teclas (seleccin
haci a at r s) y ( sel ecci n haci a
adelante).
La funcin seleccionada, pero an no
confirmada, se visualiza con carcter
negativo.
Una o dos pequeas flechas en la parte
alta del display ayudan a descubrir la
posicin del tem seleccionado respecto a
la extensin completa del men.
Para confi rmar el tem sel ecci onado,
presionar OK/ON Men.
Algunas funciones del men principal
necesitan otro men secundario (desde
ahora llamado "sub-men"). Para una
expl i caci n ms compl et a, ver ms
adelante todas los tems de los men.
En cualquier momento es posible retornar
al men precedente (o salir si se encuentra
en el men pr i nci pal ) si mpl ement e
presionando la tecla C/OFF.
Los tems del men y de los relativos sub-
men se indican a continuacin:
Las descri pci ones que se i ndi can a
continuacin, explican detalladamente las
funciones del sistema que se pueden ver
en el men.
1. TUNING
seek
scan
zapping
store
5. SOURCE
radio
aux
off
2. INTERC
off
on
vlow
vhigh
6. TELEPH
driver
driver + Pass
3. AUDIO
Bass
Treble
7. SPEAKS
Off
Auto
On
4. RDS
off
af
ta
pty
8. POWER
key
delay
13
USO DE LA RADIO
PELIGRO
Una distraccin puede ser fatal. Se
recomienda realizar todas las operaciones
ms significativas (eleccin de las
estaciones, modalidad de funciones, etc.)
en condiciones de seguridad y con el
vehculo parado, para evitar distracciones
durante la conduccin.
Modalidad de funcionamiento RDS
Las funciones y los servicios ofrecidos por
el sistema RDS (Radio Data System) estn
muy influenciados por las modalidades de
transmisin de las estaciones emisoras y
de la calidad de la seal en la zona de
recepcin.
Si la calidad de la seal lo permite, los
servicios que se pueden utilizar son:
Off Se visualiza el nombre de la emisora
pero se desacti van todas l as otras
potencias del sistema RDS (frecuencia
alternativa, informaciones del trfico, PTY)
AF (alternative Frequencies) permite al
r ecept or enganchar de maner a
automtica una frecuencia alternativa de
la misma emisora, para asegurarse una
mejor escucha.
TA (Traffic Announcement identification) Si
l a emi sor a si nt oni zada t ransmi t e
i nf ormaci ones sobre el t rf i co, se
interrumpe la escucha de la fuente aux y se
activa la recepcin de las informaciones.
PTY (Program Type) permite identificar
el tipo de programa (News, Sport, etc),
seleccionable con las teclas .
Funcionamiento de la modalidad PTY
Operando como se indica en el punto
precedente es posible activar la modalidad
PTY. La central memoriza el ltimo tipo de
programa seleccionado, pero es posible
cambiarlo utilizando las teclas .
Cuando la modalidad PTY est activada,
las funciones de bsqueda automtica,
zapping y autostore (ver prrafo siguiente
"sintona") limitan el campo de bsqueda
slo a las emisoras que transmiten el tipo
de programa seleccionado.
Se recuerda que la modalidad PTY funciona
de manera satisfactoria slo si la calidad de la
seal es buena y si las emisoras transmiten
con el cdigo de identificacin del programa
Sintona
Para facilitar el uso en la moto y limitar el
nmero de teclas, han sido introducidas
distintas modalidades de bsqueda de la
emi sor a pr ef er i da, que se pueden
seleccionar desde el men TUNING. Las
modalidades de bsqueda se indican a
continuacin:
Seek: las teclas realizan la
bsqueda compl eta de l a gama de
frecuencia. La bsqueda es automtica
con una presin breve (el display visualiza
SEARCH y la bsqueda se detiene en la
primera emisora de buena calidad) o
manual con una pr esi n l ar ga.
Manteni endo la tecla presionada la
bsqueda aumenta progresivamente de
velocidad para facilitar el desplazamiento
rpido. Es posible detener la bsqueda
automtica SEARCH presionando C/Off.
Scan: las teclas (seleccin hacia
atrs) y (seleccin hacia adelante)
realizan la bsqueda completa de las
veinte memorias disponibles.
Zapping: La banda FM se busca
continuamente de manera automtica.
Cuando se individualiza una emisora
OK/ON Entra en el men
3 veces Desplaza la eleccin al cuarto
tem del men (RDS)
OK/ON Confirma (si entra en el sub-
men RDS)
OK/ON Confirma el primer tem del
sub-men (off)
O:
O:
2 veces
O:
3 veces
Despl aza l a el ecci n al
segundo tem del sub-men
(AF)
Desplaza la eleccin al tercer
tem del sub-men (TA)
La funci n AF permanece
activa.
Desplaza la eleccin al cuarto
tem del sub-men (PTY)
Las f unci ones AF y TA
permanecen activas
Para
finalizar:
OK/ON
Conf i r ma el t em
seleccionado y aparece
la inscripcin AF o TA o PTY
en el display
14
cuya seal es de buena calidad, la
bsqueda se detiene y la relativa seal
es enviada al auricular y/o altoparlantes.
La sintona permanece bloqueada en
esta emisora por aprox. diez segundos,
luego de los cuales el sistema procede
de manera automtica a la bsqueda de
otra emisora. Si el piloto desea impedir
el avance automtico, debe presionar
OK/ON. Para continuar la bsqueda
automtica es suficiente presionar la
tecla .
Store (Autostore): Se realiza una
bsqueda de las diez mejores emisoras
de l a zona, que per manecen
automticamente memorizadas en las
memorias desde el 11 hasta el 20. Segn
la cantidad de emisoras presentes en la
zona y del t i po/ ni vel de seal es
disponibles, la operacin se realizar en
unos cuantos segundos. Si en la zona no
se encuentran diez emisoras que cumplan
los requisitos de calidad pre-establecidos,
algunas memorias podran quedar libres u
ocupadas por emisoras de menor calidad.
Dur ant e l a si nt on a ( sea manual ,
aut omt i ca o de bsqueda de una
memoria pre-establecida), en el display
aparecen las siguientes informaciones:
nombre de la emisora (si es transmitido)
frecuencia de la emisora
nmero de la memoria ocupada por la
emi sor a y si l a emi sor a ya est
memor i zada en una de l as vei nt e
memorias disponibles
Seleccin rpida entre las modalidades
Seek y Scan, y viceversa
Durante el funcionamiento de la radio es posible
pasar rpidamente del funcionamiento Seek (MS)
al funcionamiento Scan (SS) o viceversa, con la
presin contempornea de las teclas y -.
OK/ON Conf i rma l a el ecci n del
pr i mer t em del men
(TUNING)
sub- men ( Seek)
aparece la inscripcin MS en
el display
O:
OK/ON
Desplaza la eleccin al segundo
tem del sub-men (Scan)
Conf i r ma el t em
seleccionado, aparece la
inscripcin SS en el display
O:
2 veces
OK/ON
o
OK/ON
OK/ON
tem del sub-men (Zapping)
Conf i r ma el t em
seleccionado , aparece
el s mbol o en el
display
Act i va l a bsqueda
aut omt i ca. Dur ant e l a
bsqueda y la escucha en
secuencia de los programas,
la inscripcin ZP destella
Bloquea la bsqueda de la
emi sora si ntoni zada
apar ece nuevament e el
smbolo en el display
Con este procedimiento se
abandona l a modal i dad
Zapping
O:
3 veces
OK/ON
tem del sub-men (Autostore)
Conf i r ma el t em
seleccionado, aparece
una barra de progresin y
comienza el procedimiento
de memorizacin.
Al finalizar el procedimiento el
sistema se coloca siempre
aut omt i cament e en l a
modalidad SS (Scan)
15
Memorizacin de una emisora
Las memor i as del 1 al 10 est n a
disposicin del usuario.
Se r ecomi enda ef ect uar l a
memorizacin de las emisoras con el
vehculo parado en un lugar seguro.
La memori zaci n de una emi sora en
cualquiera de las primeras diez memorias
disponibles puede realizarse en cualquier
momento, si el dispositivo operativo est
en l a modal i dad RADIO y l a funci n
TUNING est operativa en la modalidad
Seek (inscripcin MS en el display)
USO DEL INTERFONO
La funci n de i nterfono entre cascos
puede ser seleccionada (por medio del
men) en 4 modalidades:
Off: No hay ninguna comunicacin entre
los cascos, ambos pasajeros pueden
escuchar la radio y la fuente musical
externa.
On: la conexin entre los cascos est
siempre activa
VLOW (Vox Low): como se indica arriba,
pero la activacin se produce con un
tono de voz modesto.
VHIGH (Vox High): el interfono est
normalmente apagado pero se activa en
cuanto el piloto o el pasajero conversan
en el micrfono. El umbral de activacin
es alto (o bien la activacin necesita que
el piloto o el pasajero conversen con un
tono de voz bastante elevado)
La central electrnica est dotada de un
dispositivo que puede detectar el ruido de
fondo (ruidos aerodinmicos) y, en lo
posible, reducirlo o eliminarlo.
Si n embar go, est n pr evi st as dos
modalidades de activacin automtica
(High y Low) para evitar que el ruido de
fondo pueda, en situaciones especiales,
acti var el i nterfono tambi n si no es
solicitado por el usuario.
La activacin del interfono provoca la
disminucin automtica del nivel de la
fuente de audio (radio o aux) en aprox. 20
dB.
o Bsqueda de la frecuencia en
modal i dad manual o
aut omt i ca hast a que se
encuentre la emisora deseada
Presin
larga de
OK/ON
Entra en el procedimiento de
memori zaci n. Abaj o a l a
izquierda en el display aparece
un nmero de memoria (que
puede ser cambiado a gusto
del 1 a 10 con las teclas
) y l a frecuenci a de l a
emi sor a act ual ment e
memorizada. De esta manera
es posible elegir la posicin
deseada y evi t ar
superposiciones no deseadas
o Para elegir el nmero de la
memor i a que se desea
utilizar para la emisora que
se preseleccion.
OK/ON Confirma la memorizacin.
segundo t em del men
(INTERC)
OK/ON Confirma (entra en el sub-
men)
sub-men (Off) apaga
event ual es i nscri pci ones
relativas al interfono en el
display
O:
OK/ON
(On)
Conf i r ma el t em
inscripcin IC en el display.
O:
2 veces
OK/ON
tem del sub-men (VLOW)
Conf i r ma el t em
inscripcin ICL en el display.
O:
3 veces
OK/ON
tem del sub-men (VHIGH)
Conf i r ma el t em
inscripcin ICH en el display.
16
Sel ecci ones abr evi adas par a el
encendido y el establecimiento del
interfono
Durante el uso del vehculo puede ser
necesario utilizar el interfono para una
comunicacin urgente.
Por tal motivo ha sido previsto un mando
abreviado que permite activar el interfono
en modalidad VLOW (Vox Low). El mando
abreviado no tiene efecto si el interfono ya
est operativo.
La desactivacin es posible repitiendo el
mando rpi do o por medi o del men
principal.
REGULACIN DE LOS TONOS
ALTOS Y BAJOS
El amplificador que se encuentra en la
central permite regular los tonos altos y
bajos de la reproduccin sonora.
SELECCIN DE LA FUENTE DE
AUDIO
Es posible seleccionar entre dos fuentes
de audio: Radio y Aux. En alternativa, es
posible apagar completamente la fuente
de audio con la funcin Off manteniendo
encendido el dispositivo que visualizar el
logo.
Se recomienda elegir la fuente de audio
preferida con el vehculo parado en un
lugar seguro.
2 presiones
breves en
secuencia de
OK/ON
Enciende el interfono en
modalidad Vox Low
aparece la inscripcin ICL
en el display
2 veces Desplaza la eleccin al tercer
tem del men (AUDIO)
men)
sub- men ( Bass)
apar ece el gr f i co de l a
regulacin
+ o - Aumenta o di smi nuye l as
notas bajas
O:
OK/ON
(Treble)
aparece el grfico de la
regulacin
+ o - Aumenta o di smi nuye l as
notas agudas
para
finalizar
C/Off
Vuelve al men principal
4 veces Desplaza la eleccin al quinto
tem del men (Source)
men)
sub-men (Radio)
O:
O:
2 veces
(Aux)
tem del sub-men (Off)
Para
finalizar:
OK/ON
Conf i r ma el t em
seleccionado
17
USO DEL ALTAVOZ PARA
CELULAR
El men pri nci pal del di sposi t i vo de
comuni caci n i ntegrado permi te pre-
establecer el destino de las llamadas de
telfono en entrada.
Se recomienda efectuar el establecimiento
del men en condi ci ones de total
seguridad, con el vehculo parado.
Cuando entra una llamada telefnica, la
central enva un tono especial a ambos
aur i cul ar es. Al f i nal i zar el t ono, l a
comunicacin es enviada slo al piloto o al
piloto y al pasajero segn la seleccin
efectuada en el men principal.
Sel ecci ones abr evi adas par a l a
admi ni st r aci n de l as l l amadas
telefnicas en entrada
Durante el transcurso de una conversacin
t el ef ni ca puede ser necesar i o
comunicarse con el pasajero manteniendo
en espera la llamada. Es posible realizar la
comuni caci n como se i ndi ca a
continuacin:
IMPORTANTE Si est en curso una
comunicacin telefnica y el conmutador
de l l ave se col oca en l a posi ci n de
par ada, el di sposi t i vo se apagar
aut omt i cament e al f i nal i zar l a
comunicacin.
5 veces Desplaza la eleccin al sexto
tem del men (TELEPH)
men)
sub- men ( Dr i ver )
aparece la inscripcin D en
el display.
O:
OK/ON
(Driver+Pass)
Conf i r ma el t em
inscripcin DP en el display.
Todas las llamadas telefnicas
en entrada sern enviadas a
ambos, piloto y pasajero.
C/Off Mant i ene en esper a l a
llamada y permite al piloto
conversar con el pasajero
18
ESCUCHA CON ALTOPARLANTES
EXTERNOS (SI ESTN PREVISTOS)
Algunos vehculos incluyen un par de
altoparlantes colocados frente al piloto,
suministrando un nivel de escucha estreo
de buena calidad con el vehculo parado o
en marcha a baja velocidad. Desde el
men principal es posible establecer la
modal i dad pr ef er i da de uso de l os
altoparlantes externos. Por lo tanto:
Auto: los altoparlantes externos se
activan slo cuando ambos auriculares
estn desactivados de las tomas a jack
del vehculo
On: los altoparlantes externos estn
siempre activos y reproducen la fuente
musical seleccionada (Radio o Aux). No
reproducen las comunicaciones del
interfono ni las del celular.
Off: los altoparlantes externos estn
siempre apagados.
ATENCIN
Si se desactivan ambos auriculares la
entrada de una llamada en el celular no es
muy fcil de detectar por el usuario. Para
tomar la comunicacin es necesario
apresurarse en conectar el auricular del
piloto o desactivar el telfono del cable
de conexin del vehculo.
APAGADO RETARDADO
Es posi bl e mant ener encendi do el
dispositivo por 15 minutos ms, desde el
momento en que la llave se coloca en
posicin de parada. Esta funcin puede
ser t i l para mant ener encendi do el
dispositivo evitando que otros dispositivos
de la moto utilicen corriente de la batera.
La activacin de la funcin Delay mantiene
operativas todas las funciones del dispositivo.
Se puede apagar en cualquier momento
presionando la tecla C/OFF
Si se pasa la llave de posicin en parada a
llave en posicin de marcha antes de los
15 minutos, la funcin AD se desactiva
automticamente.
6 veces Despl aza l a el ecci n al
spt i mo t em del men
(SPEAKS)
men SPEAKS)
sub- men ( of f ) el
smbolo de los autoparlantes
aparece con barras.
O:
OK/ON
(Auto)
Conf i r ma el t em
seleccionado, el smbolo
de l os al toparl antes est
dent r o de un cuadr o
rectangular
O:
2 veces
OK/ON
tem del sub-men (On)
Conf i r ma el t em
seleccionado
7 veces Desplaza la eleccin al octavo
tem del men (Power)
OK/ON Conf i rma (ent ra en el sub-
men)
(delay)
OK/ON Conf i r ma apar ece l a
inscripcin AD
19
Si la funcin AD ha sido activada por error,
se puede desactivar desde el men:
Not a: Par a no compr omet er el
encendido de la moto se recomienda no
activar ms de una vez la funcin delay
con el motor apagado.
7 veces Desplaza la eleccin al octavo
tem del men (Power)
OK/ON Confi rma (entra en el sub-
men)
OK/ON Conf i r ma el pr i mer t em
sel ecci onado ( key)
desaparece - si est presente-
la inscripcin AD
ESPECIFICACIONES TCNICAS
Alimentacin 10,5 16V
Absorcin con vehculo apagado 0 mA
Absorcin mx. slo con auriculares 500 mA
Absorcin mx. con auriculares y altoparlantes 1,5 A
Absorcin del circuito de la llave 1,5 mA
Respuesta en frecuencia con altoparlantes 20020000 Hz 3dB
Respuesta en frecuencia interfono 2005000 Hz 3dB
Regulacin tonos 12dB
Micrfonos -69 dB 3dB unidireccional
Altoparlantes auriculares 8 ohm - 0,5 W
Potencia mx. de salida en los altoparlantes exteriores 2 x 7 W
Tipo de altoparlante bi-cono
20
NOTAS
PIDA SOLO RECAMBIOS ORIGINALES
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Release 00 del 07_2002
ISTRUZIONI PER IL FISSAGGIO E LUTILIZZO DELLA BORSA TUNNEL SU SCOOTER ATLANTIC
INSTRUCTIONS POUR LA FIXATION ET LUTILISATION DU SAC TUNNEL SUR LE SCOOTER ATLANTIC
ANLEITUNG ZUR BEFESTIGUNG UND VERWENDUNG DER TASCHE TUNNEL AM SCOOTER ATLANTIC
INSTRUCCIONES PARA LA FIJACIN DE LA BOLSA-TNEL SOBRE LA SCOOTER ATLANTIC
INSTRUCTIONS FOR FITTING AND USING THE TUNNEL BAG ON THE ATLANTIC SCOOTER
A
FISSAGGIO PUNTI DI AGGANCIO BORSA
Sollevare parzialmente lestremit anteriore dei due tappetini poggia
piedi e svitare la vite A.
Tramite la stessa vite A, posizionare e fissare (come da disegno)
laggancio con anello 1 sul pianale dello scooter.
Coppia di serraggio vite 1: 4Nm (0.4 Kgm)
Riposizionare e fissare i tappetini nella loro apposita sede del pianale
dello scooter.
FIXATION POINTS DACCROCHAGE DU SAC
Soulever en partie lextrmit avant des deux petits tapis dappui pour
les pieds et dvisser les vis A.
A laide de la mme vis A, positionner et fixer (comme sur le dessin)
lattelage avec anneau 1 sur la plate-forme du scooter.
Couple de serrage vis 1: 4Nm (0.4 Kgm)
Remettre en place et fixer les petits tapis lendroit adquat sur la
plate-forme du scooter.
ANBRINGUNG DER BEFESTIGUNGSSTELLEN FR DIE TASCHE
Den vorderen Teil der zwei Fumatten anheben und die Schraube A
abschrauben.
Mittels derselben Schraube A entsprechend der Abbildung die
Befestigung mit Ring 1 am Trittbrett des Scooters positionieren und
fixieren.
Anzugsmoment Schrauben: 1: 4Nm (0.4 Kgm)
Die Matten wieder ausrichten und an der vorgesehenen Stelle des
Trittbretts des Scooters befestigen.
FIJACIN PUNTOS DE ENGANCHE BOLSA
Levantar parcialmente los extremos anteriores de los dos tapetes
apoya-pies y aflojar el tornillo A.
A travs del mismo tornillo A, posicionar y fijar (como en el dibujo) el
enganche de anillo 1 sobre la plataforma de la scooter.
Par de fijacin tornillo 1: 4Nm (0.4 Kgm)
Volver a posicionar y fijar los tapetes en su sitio sobre la plataforma
de la scooter.
SECURING THE BAG HOOK-UPS
Partially raise the front of the two mats covering the floor panel and
remove the screw A.
Using the screw A, place and secure (see the drawing) the hook-up
with ring 1 on the scooter floor panel.
Tightening torque for screw 1: 4Nm (0.4 Kgm)
Replace the mats on the floor panel.
POSIZIONAMENTO E FISSAGGIO BORSA SULLO SCOOTER
Inserire (come da disegno) le due fettuccine elastiche 2 nelle fibbie 3
della borsa.
POSITIONNEMENT ET FIXATION DU SAC SUR LE SCOOTER
Introduire (comme le montre le dessin) les deux brides lastiques 2
dans les boucles 3 du sac.
POSITIONIERUNG UND BEFESTIGUNG DER TASCHE AM
SCOOTER
Die zwei elastischen Bnder 2 (entsprechend der Abbildung) in die
Schnallen 3 der Tasche einfhren.
POSICIONAMIENTO Y FIJACIN BOLSA SOBRE LA SCOOTER
Introducir (como se indica en el dibujo), las dos cintas elsticas 2 en
las hebillas 3 de la bolsa.
PLACING AND SECURING THE BAG ON THE SCOOTER
Thread (see the drawing) the two elastic tapes 2 through the bag
buckles 3.
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A
1
3
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2
Posizionare la borsa sullo scooter e agganciare i due
moschettoni nellapposito aggancio ad anello 1 fissato sul
pianale dello scooter.
Regolare la lunghezza dellelastico in modo da ottenere un
fissaggio stabile della borsa sullo scooter.
In caso di pioggia, coprire la borsa con lapposita cuffia di
protezione.
Positionner le sac sur le scooter et accrocher les deux
mousquetons dans la boucle anneau 1 approprie fixe sur
la plate-forme du scooter.
Rgler la longueur de llastique de faon obtenir une fixation
stable du sac sur le scooter.
En cas de pluie, couvrir le sac laide du capuchon de protection
ad hoc.
Di e Tasche auf den Scooter setzen und di e bei den
Karabinerhaken an dem entsprechenden, am Trittbrett des
Scooters befestigten Ringhaken 1 einhaken.
Die Lnge des Gummis so einstellen, dass eine stabile
Befestigung der Tasche am Scooter gewhrleistet ist.
Bei Regen ist die Tasche mit der entsprechenden Schutzhlle
zu bedecken.
Posicionar la bolsa sobre la scooter, y enganchar los dos
mosquetones en el enganche especial en forma de anillo 1
fijado a la plataforma de la scooter.
Graduar la longitud del elstico, en manera de obtener una
fijacin estable de la bolsa a la scooter.
En caso de lluvia, cubrir la bolsa con el forro especial de
proteccin.
Place the bag on the scooter and hook up the two catches to
the ring hook 1 on the floor panel.
Adjust the length of the elastic so the bag is secure and stable.
During rain, cover the bag with the protecting hood.
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Cod. 8702129
- Carico max consentito KG 3
- Prima della partenza, assicurarsi dellesatto aggancio della borsa sullo scooter.
- Considerare che quando si viaggia con la borsa tunnel, la guida diventa meno maneggevole.
- Per la pulizia della borsa, utilizzare detergenti neutri con acqua fredda.
- Chargement max autoris KG 3
- Avant le dpart, sassurer que le sac est bien accroch au scooter.
- Tenir compte du fait que lorsquon voyage avec le sac tunnel, la conduite est moins aise.
- Pour nettoyer le sac, utiliser des dtergents neutres dans de leau froide.
- Maximal zulssige Belastung 3 kg
- Vor der Fahrt sicherstellen, dass die Tasche ordnungsgem am Scooter befestigt ist.
- Bercksichtigen, dass bei der Fahrt mit der Tunnel-Tasche das Lenken weniger handlich wird.
- Zur Suberung der Tasche neutrale Reinigungsmittel und kaltes Wasser verwenden.
- Carga mx. permitida: 3 Kg
- Antes de arrancar, asegurarse que la bolsa est debidamente enganchada a la scooter.
- Tener en cuenta que cuando se viaja con la bolsa-tnel, la maniobrabilidad disminuye.
- Para la limpieza de la bolsa, utilizar detergentes neutros con agua fra.
- Max load 3 kg
- Before starting out, makes sure the bag is properly fitted to the scooter.
- Remember that handling is affected by the bag.
- Clean the bag with cold water and neutral detergents.
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ATLANTIC 500

243, preheat with a blow of hot air.

Average speed AVG (Km/h or mph)

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