Aprilia Atlantic Classic 500 EN PDF

1073 1
ATLANTIC 500
10/2002-00
8140632
workshopmanual
LIST OF SECTIONS
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 intentionally 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 knowledge of vehicle repairing techniques.
Repairing or checking the vehicle without such knowledge 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 accompanying 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 unchanged, 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 constitutes no engagement.
aprilia assumes no responsibility about the performance 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
General Information
Periodic Maintenance
Operations
Engine
Fuel System
Cooling System
Electrical Equipment
Cycle Parts
1
2
3
4
5
6
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Atlantic 500
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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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!
WARNING
Indicates a potential hazard which may result in serious injury or even death.
CAUTION
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 recommendations.
WARNING
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 procedures 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.
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REPLACING COMPONENTS
CAUTION
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.
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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

1
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
WARNING
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.).
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ENGINE OIL
WARNING
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 performance complying with or exceeding the A.P.I. SJ specifications.
TRANSMISSION OIL
WARNING
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
WARNING
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
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CAUTION
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
WARNING
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.
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COOLANT
WARNING
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.
WARNING
Be careful not to spill the coolant on the red- hot parts of the engine: it may catch fire and send out invisible 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.
CAUTION
Only use nitrite-free antifreeze and anticorrosive providing protection to temperatures of at least -35 C
(31 F).
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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.
WARNING
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

WARNING
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
WARNING
After the first 1,000 km (625 mi), carry out the checking operations indicated in the column After runningin 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.
1-8
Release 00
2002-09
chap. 1
General Information
Atlantic 500
PRECAUTIONS AND GENERAL INFORMATION

When repairing, disassembling and reassembling the vehicle, scrupulously observe the following recommendations.
WARNING
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 procedures 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.
CAUTION
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.
CAUTION
Using NON-genuine aprilia spares may result in damage and poor performance.
chap. 1
Release 00
2002-09
1-9
General Information
Atlantic 500
TECHNICAL DATA
DIMENSIONS
Max. length
Max. width
Max. height (front part of the fairing included)
Seat height
Distance between centres
Min. ground clearance
Weight ready for starting
2270 mm (89.4 in)

720 mm (28.3 in)
1450 mm (57.0 in)
780 mm (30.7 in)
1575 mm (62.0 in)
150 mm (5.9 in)
200 Kg (440.9 lbs)
ENGINE
4-stroke single-cylinder, 4 valves, single camshaft in cylinder
head controlled by chain system on the flywheel side
4
1
460 cm3 (28.0 cu.in)
92 mm / 69 mm (3.6 in / 2.7 in)
10.5 : 1
electric
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
liquid cooling, forced circulation with centrifugal pump
Type
Number of valves
Number of cylinders
Total displacement
Bore / stroke
Compression ratio
Starting
Engine idling rpm
Clutch
Change
Lubrication system
Cooling
TRANSMISSION
Speed change gear
Primary
Secondary
automatic stepless
V-belt
gears
short 1/11.988
long 1/4.86
Total engine/wheel ratio
CAPACITIES
Fuel (reserve included)
Fuel reserve
Engine oil
- engine oil change and engine oil filter replacement only
- change for engine overhaul
Transmission oil
Coolant
(50% water + 50% antifreeze with ethylene glycol)
Front fork oil
Seats
Vehicle max. load
(driver + luggage)
Vehicle max. load
(driver + passenger + luggage)
17 l (4.48 gal)
4 l (1.05 gal)
1500 cm3 (91.5 cu.in)
1700 cm3 (103.7 cu.in)
~ 250 cm3 (15.25 cu.in)
1.5 l (0.39 gal)
220 cm3 (13.42 cu.in) (for each rod)
2
105 Kg (231.4 lbs)
180 Kg (396.8 lbs)
THROTTLE BODY
Model
Choke tube
1-10
38 mm (1.5 in) and single injector

diameter 39 mm (1.53 in)
Release 00
2002-09
chap. 1
General Information
FUEL SUPPLY
Type
Fuel
Atlantic 500
Electronic injection by electric fuel pump

Lead free petrol (4 Stars
) with minimum octane number 95
(N.O.R.M.) and 85 (N.O.M.M.)
FRAME
Type
Steering inclination angle
Fore stroke
SUSPENSIONS
Front
Stroke
high resistance steel tubes

28, 50
118 mm (4.6 in)
hydraulically operated telescopic fork

100 mm (3.93 in) rear
Two double-acting hydraulic shock absorbers with preload
adjustment to five positions
100 mm (3.93 in)
Rear
Wheel stroke
BRAKES
Front
disc brake - 260 mm (10.23 in) - with hydraulic transmission

disc brake - front 260 mm (10.23 in) combined with the rear
brake 220 mm (8.66 in)
Rear, combined
WHEEL RIMS
Type
Front
Rear
in light alloy
15 x 3.00
14 x 3.75
TYRES
Type
Front
Rear
STANDARD INFLATION PRESSURE
Front
Rear
INFLATION PRESSURE WITH PASSENGER
Front
Rear
tubeless
120 / 70 - 15 M/C 56R
140 / 60 - 14 M/C REINF. 64R
210 kPa (2.1 bar/30.4 psi)
230 kPa (2.3 bar/33.3 psi)
220 kPa (2.2 bar/31.9 psi)
260 kPa (2.6 bar/37.7 psi)
IGNITION
Type
Spark advance
C.D.I. / Inductive
Variable spark advance controlled by the injection power unit
SPARK PLUG
Standard
- Alternatively
Spark plug gap
CHAMPION RG6YC
NGK - CR7EKB
0.7 - 0.8 mm (0.027 - 0.031 in)
CONTINUED
chap. 1
Release 00
2002-09
1-11
General Information
Atlantic 500
ELECTRIC SYSTEM
Battery
Fuses
Generator (with permanent magnet)
12 V - 14 Ah
30 - 20 - 15 - 3 A
14 V - 330 W
BULBS
Low / high beam
Front parking lights
Direction indicators
Rear parking light / stoplight
Helmet compartment light
Number plate
Dashboard light
Third stoplight
12 V - 55 W / 12 V - 35 W
12 V - 5 W
rear 16 W - front 10 W
12 V - 5 / 21 W
12 V - 3 W
12 V - 5 W
LED
12 V - 2.3 W
WARNING LIGHTS
Direction indicators
Engine oil pressure
Low beam
High beam
Low fuel
Brake pads wear
Coolant high temperature indicator
LED
LED
LED
LED
LED
LED
LED
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
If you wish to have an intermediate performance between the products offered,
F.A.5 W and
FORK 5W and
FORK 20W, these can be mixed as indicated below:
SAE 10W =
SAE 15W =
FORK 20W.
F.A.20W or
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.
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.
WARNING
Brake fluid (recommended):
Use new brake fluid only.

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.
WARNING
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.
1-12
Release 00
2002-09
chap. 1
General Information
Atlantic 500
TIGHTENING TORQUES TABLE

DESCRIPTION
ftlb
Nm
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 fixing screw
7.23
10
Windscreen support stop nut
7.23
10
Damper to frame fixing screw
7.23
10
Nut
7.23
10
Damper fixing screw, fork side
7.23
10
14.75
20
FRAME ASSEMBLY
Footrest fixing screw
WINDSCREEN SUPPORT ASSEMBLY
STEERING DAMPER ASSEMBLY
FOOTBOARDS ASSEMBLY
Footboard fixing screw
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 screw
33.19
45
Lower nut
22.12
30
Side stand screw
7.23
10
STAND ASSEMBLY
FRONT SUSPENSION ASSEMBLY

Nut
11.06
15
Steering series self-locking nut
79.59
110
Flanged screw
18.44
25
Screw
36.88
50
Screw
18.44
25
19.91
27
19.91
27
Screw
29.50
40
Right and left switch
1.47
U bolts fixing screws
7.23
10
Hexagonal-head screw
7.23
10
Vibration-damping weights fixing screws
7.23
10
18.44
25
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
REAR SUSPENSIONS ASSEMBLY
FRONT BRAKE ASSEMBLY

REAR BRAKE ASSEMBLY
HANDLEBAR AND CONTROLS ASSEMBLY
ENGINE ASSEMBLY
Shock absorber support fixing screw
EXHAUST ASSEMBLY
chap. 1
Release 00
2002-09
1-13
General Information
Atlantic 500
DESCRIPTION
ftlb
Nm
Wheel pin
36.88
50
Speedometer sensor screw
0.66
0.9
Hub screw
7.23
10
110.64
150
14.75
20
7.23
10
7.23
10
7.23
10
18.44
25
7.23
10
Coil fixing screw
1.47
Nut
1.47
Rotary switch screw
7.23
10
Rotary switch screw
7.23
10
Harness to relay clamp
3.68
Reflector nut
1.10
1.5
M5 self-locking nuts fuel pump flange
2.21
2.21
2.21
5.90
5.16
FRONT WHEEL ASSEMBLY
REAR WHEEL ASSEMBLY

Nut
PASSENGER HANDLE SUPPORTS ASSEMBLY
Passenger handles support fixing screw
PASSENGER SEAT BACK SUPPORT ASSEMBLY
Seat back support fixing screw
HEADLIGHT CARRIER BOW LOWER SUPPORT ASSEMBLY
Seat back support fixing screw
WINDSCREEN SUPPORT ASSEMBLY
Windscreen support self-locking nut
PASSENGER HANDLES ASSEMBLY
Passenger handle fixing screw
BUMPER TUBES ASSEMBLY
STAINLESS STEEL flanged screw
ELECTRICAL COMPONENTS ASSEMBLY
COOLING SYSTEM ASSEMBLY

Sleeve clamps
FILTER BOX ASSEMBLY
Sleeve clamps
SEAT ASSEMBLY
Seat hinge nut
FUEL TANK ASSEMBLY
Nut
1-14
Release 00
2002-09
chap. 1
Periodic Maintenance Operations
Atlantic 500
Periodic Maintenance
Operations
chap. 2
Release 00
2002-09
2-1
Atlantic 500
This section describes the operations to be performed

periodically when servicing the main vehicle components.
CAUTION
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 maintenance intervals for the various components.
CAUTION
ENGINE CODE
2-2
BELT REPLACEMENT
8106810
6,000 Km (3,750 mi)
8106983
12,000 Km (7,500 mi)
Release 00
2002-09
chap. 2
Atlantic 500
PERIODIC MAINTENANCE SCHEDULE

TO BE PERFORMED BY aprilia authorized dealer
End of running-in
1,000 km (625 mi)
COMPONENTS
Accelerator cable (adjustment)
Variator belt
Steering bearings and steering
Wheel bearings
Engine oil filter
Clutch shoes - clutch housing
Valve clearance
Braking systems
Cooling system
Stop light switches
Brake fluid
Coolant
Engine oil
Fork oil
Transmission oil
Variator rollers and variator plastic guides
Wheels/ tyres and inflation pressure
Nut, bolt, screw tightening
Brakes fluid bleeding
Fuel pipes
Fuel filter
Battery/ electrolyte level
Spark plug
Carburation - slow running
Air cleaner
Accelerator operation
Brake locking operation
Light system
Light direction - operation
Suspensions
Engine oil pressure warning light
Front and rear brake pad wear
C
C
Every 6,000 km
Every 12,000 km
(3,750 mi) or 8 months (7,500 mi) or 16 months
C
S (code 8106810)
C
C
S (code 8106983)
every 6,000 km (3,750 mi): S

C
C
R
every 18,000 Km (11,250 mi)
C
C
C
C
C
every 6,000 km (3,750 mi): C / every 2 years: S
every 2,000 km (1,250 mi): C / every 2 years: S
every 3,000 km (1,875 mi): C / every 6,000 km (3,750 mi): S
every 30,000 km (18,750 mi) or 4 years: S
S
C
every 24,000 km (15,000 mi): S
C
every 16,000 km (10,000 mi): C
C
C
C
C
C
every 4 years: S
every 24,000 km (15,000 mi): C every 48,000 km (30,000 mi):S
C
C
S
C
P
C
C
C
C
C
every 18,000 km (11,250 mi):S
C
C
C
C
C
C
on every start: C (*)

every 2,000 km (1,250 mi): C
(*) to check, see TABLE OF INSTRUMENTS AND INDICATORS

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.
chap. 2
Release 00
2002-09
2-3
Atlantic 500
LUBRICATING POINTS
KEY TO LUBRICATION CHART
A proper lubrication is important to ensure the correct

operation and duration of the vehicle components.
1)
2)
3)
4)
5)
6)
7)
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 LUBRICANTS.
Brake lever pin

Steering bearings
Sidestand pivot
Central stand pivot
Throttle control
Throttle cable
Rear axle
= Grease
= Oil
The points to lubricate are shown in the LUBRICATION CHART.
LUBRICATION CHART
1
2
2-4
Release 00
2002-09
chap. 2
Atlantic 500
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).
WARNING
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.
WARNING
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.
chap. 2
Release 00
2002-09
2-5
Atlantic 500
REMOVING THE BATTERY COVER

3
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)
CHECKING AND CLEANING THE TERMINALS
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.
WARNING
Tighten the clamp screws.
2-6
Release 00
2002-09
chap. 2
Atlantic 500
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.
WARNING
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).
CAUTION
Handle with care to prevent the electrolyte leakage.
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 recharge.
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.
chap. 2
Release 00
2002-09
2-7
Atlantic 500
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.
CAUTION
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 (CHECKING 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 electrolyte level again and if necessary top up with
distilled water.
Put back the element plugs.
CAUTION
Reassemble the battery only 5-10 minutes after

disconnecting the recharger, since the battery
continues to produce gas for a short lapse of time.
2-8
Release 00
2002-09
chap. 2
Atlantic 500
INSTALLING THE BATTERY

BATTERY COVER).
Put the battery in its container.
CAUTION
Always connect the battery breather pipe, to

prevent the sulphuric acid vapours from corroding
the electric system, painted parts, rubber elements 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).
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 (REMOVING THE RIGHT AND LEFT INSPECTION COVERS).
To remove and clean the spark plug:
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.
chap. 2
Release 00
2002-09
2-9
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 deposits, 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).
0.7
0.8mm
mm
0,7-0,8
(0.027
0.031
in)
(0.027-0.031 in)
CAUTION
The spark plug must be well tightened, otherwise

the engine may overheat and be seriously damaged. Use the recommended type of spark plug
only, see TECHNICAL DATA, in order not to compromise 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).
Standard
Spark plug
CHAMPION RG6YC
- Alternatively
NGK - CR7EKB
Spark plug gap
0.7 - 0.8 mm
(0.027 - 0.031 in)
ADJUSTING
THE THROTTLE CONTROL
4
3

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.
WARNING
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.
2-10
Release 00
2002-09
chap. 2
Atlantic 500
AIR FILTER
1

The air cleaner should be inspected and cleaned
every 6,000 km (3,750 mi), depending on the conditions 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 / UNLOCKING).
Remove the safety clamp (1).
Pull out the pin (2) fixing the piston to the air filter
cover, as shown in the figure.
CAUTION
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.
CAUTION
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).
5
4
CLEANING
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.
CAUTION
DO NOT OIL THE FILTERING ELEMENT in order

not to compromise the filter and engine correct
operation.
CAUTION
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.
chap. 2
Release 00
2002-09
2-11
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 (TABLE OF LUBRICANTS).
CAUTION
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.

WARNING
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 described above may result in the incorrect measurement of the engine oil level.
Unscrew and extract the plug/ dipstick (1).
Clean the part in contact with the oil with a clean
cloth.
Tighten the plug/ dipstick (1) completely, screwing
it into the filling hole (2).
Withdraw the plug/ dipstick (1) again and read the
oil level on the dipstick itself:
MAX
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.
2-12
Release 00
2002-09
chap. 2
MIN
Atlantic 500
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).
WARNING
Do not use the vehicle with insufficient lubrication

or with contaminated or unsuitable lubricants,
since this would accelerate the wear of the moving 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 (TABLE 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.

WARNING

down.
chap. 2
Release 00
2002-09
2-13
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).
WARNING
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.
WARNING
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 lubricated the relative O rings.
Screw and tighten the engine oil drain plug (4).
Pour in about 1700 cm3 (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.
CHECKING THE TRANSMISSION OIL LEVEL AND

TOPPING UP
Read through the paragraphs LUBRICANTS, MAINTENANCE AND TABLE OF LUBRICANTS.

WARNING

2-14
Release 00
2002-09
chap. 2
Atlantic 500
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
MIN
MAX = maximum level

MIN = minimum level
The oil level is correct when it reaches the MAX

mark on the dipstick.
CAUTION
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 crankcase.
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 SPECIFICATIONS.
WARNING

chap. 2
Release 00
2002-09
2-15
Atlantic 500
RENEWING THE TRANSMISSION OIL

Read through the paragraph LUBRICANTS, MAINTENANCE and TABLE OF LUBRICANTS.
NOTE Put the vehicle on a solid and flat surface.

CAUTION

CAUTION
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.
CAUTION

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 cm3 (18.3 cu.in).
Screw and tighten the drain nut (2).
Top up as described under paragraph (CHECKING THE TRANSMISSION OIL LEVEL AND
TOPPING UP).
DISC BRAKES
NOTE This vehicle is provided with front and rear
disc brakes, with separate hydraulic circuits.
CAUTION
The following information refers to a single braking system, but is valid for both.
Any sudden play variations or elastic resistance
of the brake lever is due to the hydraulic system
failure.
CAUTION
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 ENVIRONMENT.
2-16
Release 00
2002-09
chap. 2
Atlantic 500
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).
WARNING
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).
MIN = minimum level.

if the fluid does not reach at least the MIN mark:
CAUTION
The level of the fluid gradually decreases with pad

wear.
Check the brake pads (CHECKING THE PADS

WEAR) and the disc wear.
CAUTION
Check the braking efficiency.

If the brake lever stroke is excessive or if the
braking efficiency becomes poor, it may be necessary to bleed the system.
chap. 2
Release 00
2002-09
2-17
Atlantic 500
RESTORING THE BRAKE FLUID LEVEL

Read through the paragraph DISC BRAKES.
Remove the four screws (2) from brake fluid reservoir
(3).
Remove cover (4).
4
2
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.
CAUTION
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).
WARNING
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).
2-18
Release 00
2002-09
chap. 2
Atlantic 500
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.
CAUTION
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 operating 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).
CAUTION
Take care not to soil the pads or the disc with

brake fluid.
Place the free end of the transparent pipe in a container (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.
CAUTION
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.
CAUTION
After refitting the parts, repeatedly operate the

brake lever and ensure that the braking system is
working properly.
chap. 2
Release 00
2002-09
2-19
Atlantic 500
BLEEDING THE INTEGRAL BRAKING SYSTEM

The air present in the hydraulic circuit acts as a cushion, absorbing much of the pressure applied by the brake
pump and reducing the effectiveness of the caliper during the braking.
The presence of air can be noticed by a spongy feel of
the brake lever and poor braking action.
WARNING
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 operating conditions.
NOTE The lever of the l.h. pump acts either on the

rear caliper and on the right front caliper.
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.
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.
2-20
Release 00
2002-09
chap. 2
Atlantic 500
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.
8
9
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.
10
Add oil in the brake fluid reservoir (2) for about 2-3
times.
CAUTION
Never allow the fluid reservoir (2) to empty completely, to prevent air from entering the circuit.
8
6
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.
11
12
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.
chap. 2
Release 00
2002-09
2-21
Atlantic 500
CHECKING AND RESTORING THE COOLANT

LEVEL
Read through the paragraphs COOLANT and

PRECAUTIONS AND GENERAL INFORMATION.
MAX
CAUTION
Do not use the vehicle if the coolant is below the

minimum prescribed level MIN.
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 ENVIRONMENT
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).
WARNING
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.
CAUTION
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.
CAUTION
Only use antifreeze and anticorrosive fluid free

from nitrite, ensuring protection at a temperature
of at least 35C (31F).
2-22
Release 00
2002-09
chap. 2
Atlantic 500
RENEWING THE COOLANT

Read through the paragraphs COOLANT and
PRECAUTIONS AND GENERAL INFORMATION.
1
CAUTION

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.
CAUTION
Switch off the engine and allow the engine and the
exhaust system to cool down.
DO NOT DISPOSE OF THE COOLANT IN THE ENVIRONMENT
FRONT HOOD).
Remove the splash guard, see (REMOVING THE
SPLASH GUARD).
MAX
MIN
CAUTION
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 cm3
(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 cm3 (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).
CAUTION
Exhaust gases are harmful.

Avoid running the engine in closed or poorly
ventilated places.
chap. 2
Release 00
2002-09
2-23
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).
CAUTION
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
To refit the plastic parts follow the reverse procedure.
CAUTION
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
CAUTION
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).
2-24
Release 00
2002-09
chap. 2
Atlantic 500
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).
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.
CHECKING AND ADJUSTING THE STEERING

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.
chap. 2
Release 00
2002-09
2-25
Atlantic 500
ADJUSTING THE BEARINGS PLAY

Remove the legshield, see (REMOVING THE
LEGSHIELD).
Unloose the check nut (1).
CAUTION
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.
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.
CAUTION
Tighten the ring nut to increase the damper adjusting brake, thus increasing the effort required
for turning the handlebar, which becomes less
easy to handle.
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 fasteners are securely tightened (see REMOVING THE
ENGINE LINKAGE).
2-26
Release 00
2002-09
chap. 2
Atlantic 500
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 SUSPENSION).
CAUTION
Check that both shock absorbers are adjusted to

the same position. See (ADJUSTMENT).
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 silentblock.
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).
CAUTION
Adjust both shock absorbers to the same position
chap. 2
Release 00
2002-09
2-27
Atlantic 500
ADJUSTMENT OF THE REAR

SUSPENSION SPRING PRELOAD
Adjusting
ring
Function
Attitude
Rotation
(arrow A)
Spring
preload
increase
The vehicle
is more rigid
RecomSmooth or
mended
normal roads
kind of road
Notes
Drive with
passenger
Rotation
(arrow B)
Spring
preload
decrease
The vehicle
is less rigid
Roads with
uneven
surface
Drive
without
passenger
WHEELS AND TYRES

WHEELS INSPECTION
Check that the wheel rims are not cracked or distorted. 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).
TYRES
This vehicle is provided with tubeless tyres.
WARNING
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.
2-28
Release 00
2002-09
chap. 2
Atlantic 500
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 become 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 tubeless 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 operations 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.
chap. 2
Release 00
2002-09
2-29
Atlantic 500
MINIMUM TREAD DEPTH LIMIT (2)

front:............2 mm [0.078 in] (
rear:.........2 mm [0.078 in] (
3 mm) [0.118 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)
TYRES PRESSURE
FRONT
RIDER ONLY
REAR
2.1 bar (30.4 psi) 2.3 bar (33.3 psi)
FULL LOAD
2.2 bar (31.9 psi) 2.6 bar (37.7 psi)
(passenger + driver)
According to the tests carried out by aprilia, only the

tyres listed below have been approved for this model:
MANUFACTURER
SIZE
MODEL
FONT
MICHELIN
REAR
FONT
REAR
2-30
CHENG SHIN
MAXXIS
120/70-15 56S
140/60-14 64S
GOLD STANDARD
GOLD STANDARD
120/70-1556R
140/60-14 64R
M-6002
M-6002
Release 00
2002-09
chap. 2
Engine
Atlantic 500
Engine
chap. 3
Release 00
2002-09
3-1
Engine
Atlantic 500
COMPONENTS THAT CAN BE REMOVED

WITHOUT REMOVING THE ENGINE
The following parts can be removed and refitted without 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)
10
RIGHT SIDE
- Oil pressure sensor (9)
- Engine oil filter (10)
- Exhaust silencer (11) see (REMOVING THE EXHAUST SILENCER)
- Water pump (12)
- Ignition casing (13)
- Flywheel
- Stator coil
- Pulse generator (pick-up)
11
12
13
LEFT SIDE
- Driving belt box air filter
- Transmission crankcase cover (14)
- Speed variator assembly
- Clutch assembly
- Drive belt
Unless otherwise specified, for information on removing procedures refer to the ENGINE WORKSHOP
MANUAL n1063 , n1064 , n1065 , n1066
, n1067
and n1068 .
14
6
3-2
Release 00
2002-09
chap. 3
Engine
Atlantic 500
REMOVING THE ENGINE FROM THE FRAME
Read through the paragraph (PRECAUTIONS AND

GENERAL INFORMATION).
5
2
6
CAUTION
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).
CAUTION
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 handlebar, brake pump, instruments and indicators,
silencer exhaust, document holder, ignition
switch/steering lock.
Clean the engine and the related components.
CAUTION
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 temperature sensor of the throttle body.
chap. 3
Release 00
2002-09
3-3
Engine
Atlantic 500
Detach the water inlet pipe (8) to the pump by

unloosing screw (9) on hose clamp (10).
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.
13
15
12
11
Detach the electrical connection (14) of the coolant

temperature sensor (15).
14
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.
17
18
16
Detach the electrical connection (19) from the phase

sensor (20) and release the wires from the clamps
fixing them to the frame.
20
19
3-4
Release 00
2002-09
chap. 3
Engine
Atlantic 500
Remove rubber protection (21) and detach the

engine oil pressure sensor wire connector (22).
21
22
3
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.
23
26
24
25
WARNING
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 operator 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
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.
chap. 3
Release 00
2002-09
3-5
Engine
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.
28
CAUTION
Since the engine is heavy, proceed with caution. In

particular, mind the hands.
27
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.
29
B unscrew and remove the right pin (30) fixing the

engine to the frame. Keep the washer.
CAUTION
Proceed with caution.

In particular, mind the limbs and fingers.
Proceed with caution when lifting and moving the
engine.
30
A and B Lean the engine assembly on the work

bench.
CAUTION
Close the engine intake manifold in order to

prevent dirt and foreign bodies from getting in.
3-6
Release 00
2002-09
chap. 3
Fuel System
Atlantic 500
Fuel System
chap. 4
Release 00
2002-09
4-1
Fuel System
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
4-2
Release 00
2002-09
chap. 4
Fuel System
Atlantic 500
FUEL SUPPLY SYSTEM
5
3
10
4
8
1
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
chap. 4
Release 00
2002-09
4-3
Fuel System
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).
CAUTION
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.
CAUTION
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:
CAUTION
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
n1067
and n1068 .
4-4
Release 00
2002-09
, n1064
, n1065
chap. 4
, n1066
Fuel System
Atlantic 500
FUEL PUMP REMOVAL/DISMANTLING
CAUTION
Read through the paragraphs (PRECAUTIONS AND

GENERAL INFORMATION) and (FUEL).
Work with caution during removal of the fuel

pump (5) to avoid damage to the fuel pre-filter (6).
PUMP ASSEMBLY REMOVAL
Remove the fuel pump (5) from the tank (7).
CAUTION
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).
2
3
4
1
chap. 4
Release 00
2002-09
4-5
Fuel System
Atlantic 500
FUEL PUMP AND FUEL LEVEL FEELER DISASSEMBLY AND CHECKING

For dismantling of the components refer to WORKSHOP MANUALS n1063 , n1064 , n1065 ,
n1066 , n1067
and n1068 .
THROTTLE BODY
1)
2)
3)
4)
5)
6)
Stepper motor
Valve position sensor
Air temperature sensor
Valve
Valve opening control cables support plate
Valve opening/closure wiring control guide
4-6
Release 00
2002-09
chap. 4
Fuel System
Atlantic 500
THROTTLE BODY REMOVAL

Read through the paragraphs (PRECAUTIONS AND
GENERAL INFORMATION) and (FUEL).
Remove the air filter box, see (AIR FILTER).
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.
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.
4
6
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.
9
8
chap. 4
Release 00
2002-09
4-7
Fuel System
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).
10
10
12
11

throttle body (12) to the intake manifold (11).
Separate the throttle body (12) from the intake manifold (11).
Remove the screw (14) fixing the injector (15) to the
Intake manifold.
Remove the injector (15) from the intake manifold
(11).
4-8
Release 00
2002-09
15
14
11
12
13
chap. 4
Cooling System
Atlantic 500
Cooling System
chap. 5
Release 00
2002-09
5-1
Cooling System
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 working.
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 .
10
3
1
4
9
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
5
5-2
Release 00
2002-09
chap. 5
Cooling System
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 REMOVAL ).

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.
CAUTION
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.
ELECTRICAL COOLING FAN REMOVAL
1
3

Remove the radiator, see (RADIATOR REMOVAL).
Disconnect the electrical fan connection (1).
electrical fan to the support (3).
Remove the electrical fan (4).
chap. 5
Release 00
2002-09
5-3
Cooling System
Atlantic 500
EXPANSION TANK REMOVAL

Read through paragraphs (COOLANT) and (PRECAUTIONS AND GENERAL INFORMATION).
Place the vehicle on its central stand.
Remove the front hood, see (FRONT HOOD REMOVAL).
Remove the legshields, see (LEGSHIELDS REMOVAL).
Remove the dash board, see (DASHBOARD REMOVAL).
CAUTION
DO NOT DISPOSE OF COOLANT IN THE ENVIRONMENT.

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
3
2
6
5
1
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 attachment.
Remove the clamp (5). Replace with a new one during
reassembly.
Pull out the hose (1) from the expansion tank attachment.
Quickly place the container under the expansion tank
to collect the coolant.
CAUTION
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.
5-4
Release 00
2002-09
chap. 5
Cooling System
Atlantic 500
THERMOSTAT VALVE
For information concerning the thermostat valve, see
WORKSHOP MANUALS n1063 , n1064 ,
and n1068 .
n1065 , n1066 , n1067
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 .
chap. 5
Release 00
2002-09
5-5
Cooling System
5-6
Atlantic 500
Release 00
2002-09
chap. 5
Atlantic 500
chap. 6
Release 00
2002-09
6-1
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 NOLOAD OPERATION) and (CHECKING THE
ALTERNATOR CONTINUITY) and the voltage
regulator (VOLTAGE REGULATOR).
17
24
37
19
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.
6-2
Release 00
2002-09
chap. 6
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:

1
Multimeter negative (-) terminal on:
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
chap. 6
Release 00
2002-09
1 3
2
6-3
Atlantic 500
FUEL INJECTION SYSTEM

INJECTION SUPPLY WIRE DIAGRAM
37
R/Gr
R/N
35
1
V/N
R/Bi
R/Gr
R/Gr
Ar/N
Ar/V
24
B 15A V/N
C 15A
E 3A V/R
A 15A V/R
D 15A
F
STAND
SPIA
CAVALLETTO
SWITCH
R/Bi
1
2
3
4
R/B
5
6
7
8
9
10
11
12
13
14
15
16
Ar/N
17
18
19
20
21
22
23
24
25 Gr/N
26
V/R
52
E.C.U.
CONTROL
UNIT
CENTRALINA
E.C.U.
R/N
B
M/N
M/V
Gr/N
R/B
R/M
Ar/V
1
2
5
3
N
V
M
INIETTORE POMPA
FUEL
FUEL
BENZINA
BENZINA
INJECTOR PUMP
10
19
11
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
Release 00
2002-09
R
R
85
86
87
30
R/M
R/M
R/M
M/N
R/N
Gr/N
Ar/V
BOBINA
COIL
6-4
R 30A V/R
R 20A R/Bi
chap. 6
22
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
Lowered
Raised
chap. 6
Release 00
2002-09
6-5
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 (8730).
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.
CAUTION
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.
6-6
Release 00
2002-09
chap. 6
Atlantic 500
IGNITION/INJECTION SYSTEM
E.C.U. CONNECTIONS
43
x1000r/min
mp/h
Km/h
EFI
ABS
SET
TRIP
FAN
RELE VENTOLA
RELAY
36
M/Bi
3
4
5
6
7
Az/R
Ar
R/B
Vi
B
9
10
11
12
13
14
15
16
M
R
M/G
B/N
Gr/R
Az
Az/V
Ro/G
6
R
M
54
POMPA
FUEL
BENZINA
PUMP
Gr
Ar
Ar/R
Bi/N
Gr
Ro/N
Gr
M/Bi
M/G
R/M
R/M
Gr/R
Ar/Bi
R/M
Az
Ro
G
Vi
Gr/N
R/B
R/M
18 Ro/N
Vi/N
19
Ar/Bi
20
G
21
Gr
22
23 N
24 Ro
25 Gr/N
26
52
E.C.U.
CONTROL
UNIT
CENTRALINA
E.C.U.
Ro/G
Gr
Bi/N
N
Bi/N
Az/V
Az/R
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Ar/R
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
RELE
INJECTOR
INIEZIONE
SECONDARIO
RELAY
13
14
15
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
chap. 6
Release 00
2002-09
6-7
Atlantic 500
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
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).
6-8
Release 00
2002-09
chap. 6
Atlantic 500
CONNECTIONS TO THE E.C.U. CONTROL UNIT
COMPONENT
TERMINALS
NOMINAL
VALUE
CABLE COLOUR
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
* With drop sensor in upright position.
chap. 6
Release 00
2002-09
6-9
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).
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
B
A
Also verify the resistance between the high

voltage terminal and the casing of the coil.
Standard value: 7.4 k

CAUTION
Before measuring, remove the H.V. cable complete

with the spark plug cap.
6-10
Release 00
2002-09
chap. 6
Atlantic 500
DROP SENSOR CHECK

2
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).
CAUTION
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).
15%
Standard value: resistance 62 k
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.
chap. 6
Release 00
2002-09
6-11
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.
6-12
Release 00
2002-09
chap. 6
Atlantic 500
THROTTLE VALVE POTENTIOMETER

(ACCELERATOR SENSOR) CHECK
With motor off:
Disconnect the three-way connector (black) (1).
CAUTION

Set the ignition switch to .

With a multimeter (scale k), measure the
resistance between the potentiometer terminals.
MEASUREMENT (A)
A
Resistance between the two terminals A and B, in any

position of the throttle valves:
10%
Standard value: 5 k
B
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:
to 6 k
10%
Standard value: from 1 k
NOTE To unscrew the two screws more easily, block

with LOCTITE243, 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.
chap. 6
Release 00
2002-09
6-13
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.
1
2
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 temperature 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
B1
B2
A2
6-14
Release 00
2002-09
chap. 6
Atlantic 500
FUEL PUMP CHECK
(direct current)
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).
CAUTION
Observe the pump polarity.
AIR THERMISTOR FUNCTION CHECK

CAUTION
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 temperature as indicated.

Temperature C
Resistance
9750
10
5970
20
3740
30
2410
NOTE If the values do not change as the temperature changes, or change too much from those given in
the table, replace the thermistor (2).
chap. 6
Release 00
2002-09
6-15
Atlantic 500
STARTING AND STOP LIGHTS SYSTEM

37
34
35
R/Gr
R/N
V/G
G/R
V/G
R/N
Gr/N
V/G
33
R/N
B/G
B
V/G
30
85
86
87
V/N
R/Bi
55
R/Gr
Gr/N
R/N
B/G
G/R
B/G
Gr/N
56
1
V/G
B
V/G
B
V/G
B
V/G
B
V/G
B
24
B 15A V/N
C 15A
E 3A
A 15A V/R
D 15A
F
V/R
Ar/V
V/G
B
V/R
R/Bi
R/Gr
V/G
B
G/R
B
R
R
N
N
R
R
22
R/Bi
B/Bi
B
M/N
N
V
M
85
86
87
30
M/N
R/N
Gr/N
Ar/V
R 30A V/R
R 20A R/Bi
M
21
9
19
11
20
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
6-16
Release 00
2002-09
chap. 6
54
58
31
31
58
54
31
31
Atlantic 500
STARTING RELAY CHECK
Disconnect the two-way connector (1)(white).

CAUTION

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).
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 (8730).

chap. 6
Release 00
2002-09
6-17
7) ENGINE OFF BUTTON (

Cable
Rs
R/N
Atlantic 500
R/Gr
8) START BUTTON ( )
Cable
Rs
V/G
G/R
9) IGNITION BUTTON
G/Gr
V/N
R/Bi
ZADI
Cable
Rs
PUSH
10) FRONT BRAKE LIGHT SWITCH

Cable
Rs
Gr/N
V/G
ON
11) REAR BRAKE LIGHT SWITCH

Cable
Rs
V/G
R/N
ON
10 11
12) SIDE STAND SWITCH
Cable
Rs
N( )
OPEN
CLOSED
12
6-18
Release 00
2002-09
chap. 6
Atlantic 500
ELECTRIC COOLING FAN

WIRING DIAGRAM
35
38
G/N
R/Bi
Vi/N
V
V/N
R/Bi
30
87
85
86
24
V
B 15A
V/N
C 15A
E 3A
A 15A
D 15A
F
6
R/Bi
Vi/N
B
G/N
22
Gr
Ar
R 30A R/Bi
E.C.U. CONTROLE.C.U.
UNIT
CENTRALINA
52
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
16
B
G/N
19
15
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
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.
chap. 6
2
1
Release 00
2002-09
6-19
Atlantic 500
WATER THERMISTOR CHECK

See (COOLANT THERMISTOR FUNCTION CHECK)
on page 6-14.
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 (8730).

6-20
Release 00
2002-09
chap. 6
Atlantic 500
COOLANT TEMPERATURE AND FUEL LEVEL INDICATORS

WIRING DIAGRAM
43
x1000r/min
mp/h
Km/h
EFI
ABS
SET
TRIP
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Ar/R
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Bi/N
35
V/N
R/Bi
24
B 15A
V/N
C 15A
E 3A
A 15A
D 15A
F
R/Bi
Ar/N
G/V
Ar/R
Bi/N
R 20A R/Bi
1
22
8
19
15

8) Fuel level sensor
15) Water thermistor
19) Battery
22) Main fuses
24) Secondary fuses
35) Key switch
43) Dashboard
chap. 6
Release 00
2002-09
6-21
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
resistance 80
resistance >1090
bottom scale indication

start of red zone indication 5
start of scale indication
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
VIEWED FROM A
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
6-22
Release 00
2002-09
chap. 6
Atlantic 500
LIGHTS AND ACOUSTIC SIGNALS SYSTEM

WIRING DIAGRAM
39
SCROLL
37
PASSING
STOP
G
V/N
G/N
40
B
Gr
G/N
N
Bi
V/N
35
48
G/Gr
G
V/N
R/Bi
G/Gr
V
G/N
B
Gr
G/N
N
Bi
V
V
Gr
N
B
N
B
Bi
G
B
Bi
49
N
B
Bi
G
B
Bi
G
B
G
B
G
B
B
G
B
G
B
R/Bi
50
54
58
31
31
58
54
31
31
26
G/Gr
B
G
B
B
Ar/N
27
24
B
G
B 15A
V/N
C 15A
E 3A V/R
A 15A V/R
D 15A R/Bi
F
V/R
R/Bi
25
V/R
22
R
R
R 30A V/R
R 20A R/Bi
19

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
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)
chap. 6
Release 00
2002-09
6-23
Atlantic 500
DIRECTION INDICATORS AND DISPLAY DATA

WIRING DIAGRAM
43
39
SCROLL
x1000r/min
EFI
mp/h
Km/h
PASSING
STOP
ABS
SET
46
B/Bi
M
B/Bi
Bi/G
R
B/N
Az
15 16
R/Bi
B/N
Az/Bi
TRIP
12
R
Az
B/N
R/Bi
Az/Bi
Bi/G
5 6 7 8
B/Bi
29
Az
30
R
R
Az
Az
47
Az

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.
6-24
Az
Release 00
2002-09
chap. 6
Atlantic 500
MULTIFUNCTION LCD DISPLAY

Turning the ignition key (1) to position , all the
segments on the Multifuncion LCD display are activated 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.
10
11
AVG VBATT Km/h ml/G Vmax
mph
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).
"
SERVICE
"
LAP
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).
C
F
12
CEV
13
ZADI
CAUTION
PU
SH
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
Battery tension (Vbatt)

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

MODE
Chronometer (LAP)
MODE
Km to next maintenance programmed (SERVICE)

MODE
chap. 6
Release 00
2002-09
6-25
Atlantic 500
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.
ABS
/RESET
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.
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).
ZADI
1
PU
SH
2
5
ODO TRIP 1 TRIP 2
By pressing the TRIP/RESET button in sequence the

following functions are activated:
Odometer (ODO)
TRIP/RESET
First trip (TRIP 1)

TRIP/RESET
Second trip (TRIP 2)
ABS
TRIP/RESET
/ RESET
6-26
Release 00
2002-09
chap. 6
Atlantic 500
DIRECTION INDICATOR AND SPEEDOMETER

WIRING DIAGRAM
43
x1000r/min
mp/h
Km/h
EFI
ABS
44
SET
TRIP
Ro
Gr/B
Gr/Bi
B/Ar
Ro
M
Gr/B
Gr/Bi
Vi
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
B/Ar
Vi
B/Ar
Gr/Bi
V
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
42
45

42)
43)
44)
45)
Air temperature thermistor

Dashboard
Speed sensor
Pressure oil sensor
chap. 6
Release 00
2002-09
6-27
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).
ENGINE
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.
6-28
Release 00
2002-09
chap. 6
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.
2
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 .
-
1.5 mm
If the 1st test results in an incorrect value, disconnect the sensor (3) and repeat the 1st test; if the
incorrect value persists, the dashboard is defective and must be replaced with one that is known
to work.
If the 1st test results in a correct value and the 2nd
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 dashboard, the dasboard is defective and must be
replaced with one that is known to work.
chap. 6
Release 00
2002-09
6-29
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).
- 12.700 k
Correct value: 12.200 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).
6-30
Release 00
2002-09
chap. 6
Atlantic 500
SWITCHES
Using a pocket multimeter, check the continuity of the
switches by referring to the tables below.
Replace any faulty components.
PASSING
1) HORN BUTTON ( )
Cable
Rs
Gr
MODE
B
1
2) TURN INDICATOR SWITCH (

Cable
Rs
B/Bi
Az
)
B/N
STOP
3) LIGHTS SWITCH (
BEAM BUTTON
(PASSING )
Cable
Rs
G/N
) / FLASHING FULL
Bi
V/N
PASSING
4) MODE BUTTON (MODE)

Cable
Rs
Ro
SCROLL
5) HAZARD BUTTON (
Cable
Rs
B/Bi
7
6
6) LIGHTS SWITCH (
Cable
Rs
V/N
- )
G/N
chap. 6
Release 00
2002-09
6-31
Atlantic 500
BULB REPLACEMENT
WARNING
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 breakage. If you touch the bulb with bare hands, remove 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
CAUTION
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).
6-32
Release 00
2002-09
chap. 6
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 RECHARGE).
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
Release 00
2002-09
6-33
Atlantic 500
FULL BEAM BULBS
Turn the bulb socket/bulb (8) anticlockwise and

extract it from the parabolic setting.
CAUTION
10
To remove the bulb socket/bulb from its connection, 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.
PARKING LIGHT BULBS
12
CAUTION
11
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.
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.
6-34
Release 00
2002-09
chap. 6
Atlantic 500
CAUTION
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.
5
3
CAUTION
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).
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 protective screen in its housing.
CAUTION
Carefully and gently tighten the pommel (3) in

order to avoid damage to the protective screen.
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).
2
1
CAUTION
Proceed with care.

Do not damage the tangs and/or their seatsstro.
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.
chap. 6
Release 00
2002-09
6-35
Atlantic 500
NUMBER PLATE LIGHT REPLACEMENT


CAUTION
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.
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.
3
1
4
CAUTION
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.
THIRD STOP LIGHTS REPLACEMENT

Lift the saddle, see (UNBLOCKING/BLOCKING
THE SADDLE).
Loosen and remove the two fixing screws (1) of
the backrest.
CAUTION
When removing the backrest, proceed with caution in order to avoid breaking the coupling
prongs.
Remove the backrest (2) by pulling upwards.
6-36
Release 00
2002-09
chap. 6
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.
NOTE During reassembly, correctly set the
protective screen in its housing.
CAUTION
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.
chap. 6
Release 00
2002-09
6-37
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).
CAUTION
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.
6
9
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).
6-38
Release 00
2002-09
chap. 6
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)
10
11
12
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.
chap. 6
Release 00
2002-09
6-39
Atlantic 500
ELECTRICAL COMPONENTS LAYOUT

43
33
39
25
13
47
56
24
31
28
30
51
53
49
27
50
55
23
40
16
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
6-40
Release 00
11
14
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
2002-09
chap. 6
15
Atlantic 500
ELECTRICAL COMPONENTS LAYOUT
20
22
35
34
37
19
38
36
32
31
29
10
17
48
26
42
45
46
21
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
chap. 6
54
52
44

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
Release 00
2002-09
6-41
51
50
47
G
B
B
Az
G
B
R
N
B
Bi
G
Az
SECONDARY FUSES:
B
Bi
B
Bi
N
B
R
B
52
R
N
B
Bi
G
Az
A - INJECTION, STARTING.
B - ENGINE KILL, STOPLIGHT.
C - LIGHT, CLAXON, DASHBOARD, FAN RELAY.
D - POWER SOCKET.
E - E.C.U. SYSTEM.
F - FREE.
49
48
46
M/Bi
1
V/G
2
Az/R
3
Ar
4
R/B
5
Vi
6
B
7
Ro/G
8
M
9
R
10
11 M/G
B/N
12
Gr/R
13
Az
14
Az/V
15
Ro/G
16
Ar/N
17
18 Ro/N
Vi/N
19
Ar/Bi
20
G
21
Gr
22
23 N
24 Ro
25 Gr/N
26
N
Az
Ro
G
Vi
Az/V
TRIP
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Gr/Bi
R/M
Gr/R
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Gr/B
Ar/R
M
B
B
R/M
Ar/N
G/V
SET
54
R
M
44
B
Ar/N
B
G/V
B/N
R/Bi
Az/Bi
Bi/G
R/Bi
R/Bi
Az/R
B/Bi
Vi
M/V
R
Az
Ar/Bi
R/M
ABS
G/B
57
10
42
11
R/M
Ro/G
V/G
12
40
STOP
39
13
14
15
33
V/G
R/N
B/G
Gr/N
PASSING
V
Gr
Vi
E.C.U. CONTROL UNIT
B/Ar
Gr/Bi
V
Gr/B
Gr/Bi
B/Ar
38
16
37
V/G
G/R
45
V
B/Ar
Ar
Bi/N
Ro
G/Gr
Bi
N
M/N
R/N
Gr/N
Ar/V
85
86
87
30
Gr/N
R/B
R/M
Ar/V
1
2
5
3
G
V/N
R/N
G/N
B/G
G/R
SCROLL
Gr
M/Bi
M/G
R
B/N
Az
B
Gr
G/N
N
Bi
V/N
R/Bi
B/N
Az/Bi
B
Gr
G/N
N
Bi
V
Gr
Ro/N
B/Bi
M
Ro
V
B/Bi
Bi/G
Ar
V
Gr
Ar
Ar/R
Bi/N
17
34
Gr/N
V/G
R/Gr
R/Gr
Gr/N
EFI
B
M/N
M/V
N
V
M
36
18
28
R/Gr
V
Ar/N
Ar/V
Ar
24
B 15A
C 15A
E 3A
A 15A
D 15A
F
23
30
87
85
86
G/N
R/Bi
Vi/N
V
B
G/N
B
G/N
Bi/N
N
Ro/G
Gr
G
G
G
G/Gr
V
R/N
N
N
V/R
V/R
V
V
R/Bi
R/Bi
G/N
G
G
G
G
G
G
V/N
V/N
V/R
V/R
R/Bi
V/R
19
35
22
R/Bi
B
Ar/N
mp/h
Km/h
30
85
86
87
25
26
55
20
R
R
x1000r/min
N
N
G/Gr
G
V/N
R/Bi
V/R
R/Bi
R 30A V/R
R 20A R/Bi
R
R
2002-09
B
G
R/N
B/G
B
V/G
G/R
B
Release 00
R/Bi
B/Bi
21
G
B
G
V/G
B
Az
G
V/G
B
Az
G/Gr
B
R
V/G
G
B
R
V/G
G
B
V/G
B
37
27
B
Az
G
V/G
B
31
54
58
31
58
54
56
V/G
G
B
R
B
Gr/N
V/G
34
30
29
MODIFICATION FOR ASD VERSION
R/Gr
6-42
V/G
G/R
V/N
V/N
V/N
R/N
43
31
31
53
32
Atlantic 500
WIRING DIAGRAM 500 C.C. ATLANTIC SCOOTER
chap. 6
Ro
M
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)
chap. 6
Atlantic 500
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
Release 00
2002-09
6-43
6-44
Atlantic 500
Release 00
2002-09
chap. 6
Cycle parts
Atlantic 500
Cycle parts
chap. 7
Release 00
2002-09
7-1
Cycle parts
Atlantic 500
BODYWORK
PASSENGER FOOTREST REMOVAL
1
1
Place the vehicle on the central stand.

CAUTION
Work with care.

Unscrew and remove the three screws (1).
Remove the passenger footrest (2).
2
LOWER PROTECTION COVER REMOVAL

3
CAUTION
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.
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.
UNLOCKING/LOCKING THE SEAT

2
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-clockwise 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.
ZADI
3
PU
SH
WARNING
Before riding again, make sure that the seat is

correctly locked.
7-2
Release 00
2002-09
chap. 7
Cycle parts
Atlantic 500
SEAT REMOVAL

Lift up the seat (4) (see UNLOCKING/LOCKING THE
SEAT).
CAUTION
Work with care.

Utilising a suitable pincer, unclip the clip (5).
CAUTION
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).
7
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).
CAUTION

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).
2
chap. 7
Release 00
2002-09
7-3
Cycle parts
Atlantic 500
LEFT AND RIGHT HAND INSPECTION COVER

REMOVAL

Remove the left and right hand rubber mats (1) by lifting them up with the hands.
Unscrew and remove the screw (2).
CAUTION
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.
CAUTION
When reassembling, correctly insert the tabs into

their relative seats
LEGSHIELD REMOVAL
1
Place the vehicle in the central stand.

CAUTION
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).
CAUTION
Work with care.

Do not damage the plastic finish.
2
7-4
Release 00
2002-09
chap. 7
Cycle parts
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).
7
CAUTION

3
Utilising a flat-bladed screwdriver (3), lever up the
edge of the legshield in such a way that it frees itself
from its seat.
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 document compartment.
6
chap. 7
Release 00
2002-09
7-5
Cycle parts
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 closure.
Remove the legshield (10).
7
8
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 direction.
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.).
CAUTION
The prolonged use of the electrical socket without

the engine switched on can cause a partial discharge of the battery.
FRONT MUDGUARD REMOVAL

CAUTION

5

Remove the front mudguard (6) by releasing it from
the front part of the vehicle.
7-6
Release 00
2002-09
chap. 7
Cycle parts
Atlantic 500
PASSENGER HANDLE-GRIP REMOVAL

8
Place the machine on the central stand.

CAUTION

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.
10
10
COMPLETE SIDE PANEL REMOVAL

4
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).
7
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.
A
7
chap. 7
Release 00
2002-09
7-7
Cycle parts
Atlantic 500
REMOVAL OF THE CHROMED STRIP FROM THE

SIDE PANELS
Remove the complete side panel (see COMPLETE
SIDE PANEL REMOVAL).
CAUTION

Unscrew and remove the screw (1) situated inside the
side panel.
Remove the chromed strip by slightly arcing it in the
central part.
SIDE PANEL SEPARATION

3
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).
CAUTION

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.
7-8
Release 00
2002-09
chap. 7
Cycle parts
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

Unscrew and remove the seven screws (2).

Remove the foot platform (3).
2
3
2
7
SPRAY GUARD REMOVAL
CAUTION

6
4
Remove the front mudguard (see FRONT MUDGUARD REMOVAL).

Remove the front wheel (see FRONT WHEEL REMOVAL).
Unscrew and remove the three screws (4) (on the
right and left side of the vehicle).
Remove the spray guard (6) by sliding it out from
underneath.
chap. 7
Release 00
2002-09
7-9
Cycle parts
Atlantic 500
FRONT SHIELD REMOVAL

Remove the spray guard (see SPRAY GUARD REMOVAL).
CAUTION

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 screwdriver.
Remove the front shield (2), sliding it out from the front
part of the vehicle.
PASSENGER BACKREST REMOVAL
Lift up the seat (see UNLOCKING/LOCKING OF THE

SEAT).
Slacken and remove the two fixing screws (1) of the
backrest.
CAUTION
During the backrest removal, proceed with care so

as not to break the engagement teeth.
1
Remove the backrest (2) by pulling it upwards.
PLASTIC BACKREST REMOVAL

Remove the passenger backrest (see PASSENGER
BACKREST REMOVAL).
Remove the cover (2) of the seat closure.
7-10
Release 00
2002-09
chap. 7
Cycle parts
Atlantic 500
Unscrew and remove the seven screws (3).

Disconnect the electrical connection (4).
Remove the support arc (5).
7
3
4
3
3
Disconnec the electrical connection from the bulbs (6)

and the third stoplight.
Lift up and remove the plastic part (7) of the backrest.
7
6
7
REAR MUDGUARD REMOVAL

CAUTION


Remove the number plate light cover.
Remove the plastic cover by pulling it (2).
Unscrew and remove the four screws (3).

Support and slightly remove the rear mudguard (4).
4
3
chap. 7
Release 00
2002-09
7-11
Cycle parts
Atlantic 500
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
TAIL UNIT REMOVAL

1
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).
2
LOWER COVER REMOVAL

4
CAUTION

5

Remove the lower cover (5).
7-12
Release 00
2002-09
chap. 7
Cycle parts
Atlantic 500
FOOTREST SUPPORT AND LOWER SPRAY

GUARD REMOVAL
Remove the central tunnel (see CENTRAL TUNNEL
REMOVAL).
Remove the chromed protection tube (2).
2
1
Unscrew and remove the five screws (3).

Remove the footrest support. (4).
7
Support the lower spray guard (5).
Disconnect the overflow tube (6) of the coolant tank.
Remove the lower spray guard (5).
chap. 7
Release 00
2002-09
7-13
Cycle parts
Atlantic 500
FRONT PANEL REMOVAL

CAUTION

ABS
CAUTION
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.
3
2
CAUTION
When reassembling, correctly insert the engagement tabs into their appropriate seats with their
relative clips.
UPPER HANDLEBAR COVER REMOVAL

2
Lift up and remove the cover (2).
Unscrew and remove the five screws (3).

3
7-14
Release 00
2002-09
chap. 7
Cycle parts
Atlantic 500
Unscrew and remove the two screws (4) on the right

and left side of the vehicle.
Remove the upper handlebar cover (5).
4
LOWER HANDLEBAR COVER REMOVAL
Remove the upper handlebar cover (see UPPER

HANDLEBAR REMOVAL).
Separate the plastic parts (2) by pulling them outwards.
7
COMPLETE INSTRUMENT PANEL REMOVAL
CAUTION

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).
chap. 7
Release 00
2002-09
7-15
Cycle parts
Atlantic 500
Remove the front panel (see FRONT PANEL REMOVAL).

Remove the windshield (see WINDSHIELD REMOVAL).
Lift up the complete instrument panel (5) and disconnect the electrical connections (6) directly from the
instrument panel.
Remove the complete instrument panel (5).
WINDSHIELD REMOVAL

Slacken and remove the six fixing screws (1) of the
front panel.
Remove the front panel (2).
INSTRUMENT PANEL REMOVAL
Remove the complete instrument panel (see INSTRUMENT PANEL REMOVAL).

Unscrew and remove the four screws (1).
Remove the instrument panel (2).
7-16
Release 00
2002-09
chap. 7
Cycle parts
Atlantic 500
COMPLETE LIGHTING ASSEMBLY REMOVAL

Remove the hood, (see WINDSHIELD REMOVAL).
Remove the front spray guard (see FRONT SPRAY
GUARD REMOVAL).
Remove the complete instrument panel (see INSTRUMENT PANEL REMOVAL).
6
4
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).
7
Disconnect the electrical connection (5).
Remove the complete lighting assembly (6).
chap. 7
Release 00
2002-09
7-17
Cycle parts
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.

4
Remove the battery cover (see BATTERY COVER

REMOVAL).
Disconnect the electrical connections (5) of the
battery.
Remove the battery (see BATTERY REMOVAL).
7-18
Release 00
2002-09
chap. 7
Cycle parts
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
12
11
7
Disconnect the battery breather tube (13) from the clip
(14).
13
14
Remove the clip (15) and slide out the pin (16).
Remove the seat hinge (17).
17
16
15
chap. 7
Release 00
2002-09
7-19
Cycle parts
Atlantic 500

18
Unscrew and remove the four screws (19) of the

carburettor cover (20).
Remove the carburettor cover (20).
19
20
Slacken the bands (22) via the screw (21) and slide
out the fuel breather tube (23) by pulling it outwards.
23
21
22
Unscrew and remove the six screws (24) from the

filter box (25).
24
25
24
7-20
Release 00
2002-09
chap. 7
Cycle parts
Atlantic 500
NOTE Make sure that you have a new band before

substituting the old one.
26
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 forwards.
27
29
28
chap. 7
Release 00
2002-09
7-21
Cycle parts
Atlantic 500
FRONT WHEEL
4
5
11
7
3
10
8
9
12
1
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
7-22
Release 00
2002-09
chap. 7
Cycle parts
Atlantic 500
REMOVING THE FRONT WHEEL

5
CAUTION
When removing/refitting the parts, take care not to

damage the brake line, the disc and the pads.

1
WARNING
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.
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).
3
NOTE To ensure proper refitting, carefully check the

positions of the parts, the washers and the spacer.
4
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.
WARNING
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 REFITTING).
chap. 7
Release 00
2002-09
7-23
Cycle parts
Atlantic 500
REPLACING THE BEARINGS

CAUTION
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:
CAUTION
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.
CAUTION
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).
WARNING
Check the bearings centering to the wheel hub.
7-24
Release 00
2002-09
chap. 7
Cycle parts
Atlantic 500
CHECK
CAUTION
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.
CAUTION
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)
CAUTION
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 damaged 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).
chap. 7
Release 00
2002-09
7-25
Cycle parts
Atlantic 500
REFITTING THE FRONT WHEEL

CAUTION
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).
1
3
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).
CAUTION
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).
7-26
Release 00
2002-09
chap. 7
Cycle parts
Atlantic 500
REAR WHEEL
5
4
1
3
7
KEY
1)
2)
3)
4)
5)
Wheel assembly
Spacer
Oil seal
Brake caliper and silencer supporting plate
Nut
chap. 7
Release 00
2002-09
7-27
Cycle parts
Atlantic 500
REMOVING THE REAR WHEEL

WARNING
Allow the engine and the exhaust terminal to cool

down completely.
6
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).
11
9
8
10
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.
13
12
14
7-28
Release 00
2002-09
chap. 7
Cycle parts
Atlantic 500
REMOVING THE EXHAUST TERMINAL

WARNING
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).
3
2
4
2
chap. 7
Release 00
2002-09
7-29
Cycle parts
Atlantic 500
CHECK
CAUTION
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.
CAUTION
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 damaged 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).
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).
7-30
Release 00
2002-09
chap. 7
Cycle parts
Atlantic 500
5
3
6
8
5
3
7
9
KEY
1)
2)
3)
4)
5)
6)
7)
8)
9)
Brake control lever

Brake fluid pump/tank
Brake fluid pipe
Braking retarder
Brake caliper breather valve
Pipe fitting screw
Brake caliper
Brake pads
Brake disc
chap. 7
Release 00
2002-09
7-31
Cycle parts
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.
2
CAUTION
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.
CAUTION
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).
7-32
Release 00
2002-09
chap. 7
Cycle parts
Atlantic 500
CHECKING THE BRAKE DISC

CAUTION
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 necessary.
Brake disc oscillation tolerance: 0.1 mm (0.004 in)
7
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.
CAUTION
When refitting, apply LOCTITE 270 over the

threads of the brake disc screws.
Remove the brake disc.
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).
chap. 7
Release 00
2002-09
7-33
Cycle parts
Atlantic 500
11
7
2
8
10
5
9
10
4
3
6
12
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
7-34
Release 00
2002-09
chap. 7
Cycle parts
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).
CAUTION
The vibration-damping plates are removed together with the pads.
Remove the pads (4) (complete with the vibrationdamping plates (5)) by withdrawing them one by one.
5
CAUTION
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.
WARNING
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 rotation 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).
chap. 7
Release 00
2002-09
7-35
Cycle parts
Atlantic 500
CHECKING THE BRAKE DISC

CAUTION
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 necessary.
Brake disc oscillation tolerance: 0.1 mm (0.004 in)
REMOVING THE BRAKE DISC

Take down the front wheel (REMOVING THE FRONT
WHEEL).
Remove the five brake disc screws (7).
CAUTION
When refitting, apply LOCTITE 270 over the

threads of the brake disc screws.
Remove the brake disc.
7-36
Release 00
2002-09
chap. 7
Cycle parts
Atlantic 500
STEERING
For information on how to check and adjust the

steering, refer to the paragraph (CHECKING AND
ADJUSTING THE STEERING).
4
1
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.
5
3
CAUTION
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).
7
8
CAUTION
Arrange for a suitable support to hold the handlebar 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.
Unloose and remove screw (9) and release the

odometer sensor (10).
10
chap. 7
Release 00
2002-09
7-37
Cycle parts
Atlantic 500

11
vehicle l.h.side.
Release the brake caliper (12) from the fork.
12
CAUTION
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.
11
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.
13
14
15
Remove counternut (15).
16
CAUTION
17
Support the fork to prevent it from falling.
20
19
21
NOTE When removing the fork, pay attention to the

balls coming out of the lower bearing.
23
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.
25
22
NOTE For the grease type to be used with the
24
bearings, refer to the (LUBRICANT CHART).

Grease and proceed with the reassembly.
18
7-38
Release 00
2002-09
chap. 7
Cycle parts
Atlantic 500
CHECKING THE BEARINGS

CAUTION
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.
CAUTION
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.
CAUTION
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.
7
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.
chap. 7
Release 00
2002-09
7-39
Cycle parts
Atlantic 500
1
21
4
3
4
13
3
11
14
15
2
12
16
17
11
13
24
14
22
15
24
16
17
23
19
18
10
20
19
20
KEY
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) 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
7-40
Release 00
2002-09
chap. 7
Cycle parts
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).
2
1
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.
2
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).
3
4
CAUTION
The spring is immersed in oil.

Avoid dripping the oil when removing the spring.
7
85 mm (3.34 in)
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.
REMOVING THE FORK ASSEMBLY

To remove the fork assembly (in case it is to be replaced), follow the instructions described in paragraph
(DISASSEMBLY).
chap. 7
Release 00
2002-09
7-41
Cycle parts
Atlantic 500
REMOVING THE ROD-WHEEL CARRIER ASSEMBLY (with installed fork)

Put the vehicle on the stand.
CAUTION
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.
1
2
CAUTION
Do not pull the front brake lever after removing the

brake caliper as the caliper piston may come out of
5
1

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 complete with the wheel carrier.
Repeat the last three operations also for the second
rod.
6
3
7
4
7-42
Release 00
2002-09
chap. 7
Cycle parts
Atlantic 500
WHEEL CARRIER ROD DISASSEMBLY
CAUTION
Check the oil quantity.

If less than 225 cm3 (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 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.
CAUTION
Pay attention to possible oil leakages as the rodwheel carrier assembly is full with oil.
Do not overturn or incline the unit excessively
when removing it.
CAUTION
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 rod-wheel carrier assembly, see (REMOVING THE ROD-WHEEL CARRIER ASSEMBLY) (with
installed fork).
Prepare a container with capacity of at least 200 cm3
(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.
Remove the seal gasket (15).

Remove the cup (16).
Remove the bush (17).
7
3
16
17
8
10
1
2
11
9
13
14
15
7
6
12
chap. 7
Release 00
2002-09
7-43
Cycle parts
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).
WARNING
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.
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 silentblock.
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.
7-44
Release 00
2002-09
chap. 7
Cycle parts
Atlantic 500
ADJUSTMENT OF THE REAR SUSPENSION

SPRING PRELOAD
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
Recommended Smooth or normal

roads
kind of road
Notes
Drive with passenger
Roads with uneven

surface
Drive without
passenger
REMOVING THE SHOCK ABSORBER

3
2
WARNING
Wait for the engine and the exhaust terminal to

cool down completely.
6
CAUTION
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).
chap. 7
Release 00
2002-09
7-45
Cycle parts
7-46
Atlantic 500
Release 00
2002-09
chap. 7
aprilia s.p.a.
via G.Galilei, 1
30033 Noale (VE) Italy
tel. +39 041.5829111
fax +39 041.441054
LIST OF SECTIONS
Introduction
This manual provides basic information on standard servicing 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 information 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 aftersales mechanics.
Before performing any operation, ensure that the information 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 inadequate 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 necessary 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
General Information
General Specifications
General information and maintenance
Automatic transmission
Final reduction
Flywheel cover
Flywheel and starting system
Thermal unit and timing system
Crankcase and driving shaft
Fuel injection
Lubrication
Cooling system
Starting
1
2
3
4
5
6
7
8
9
10
11
12
13
General Information
500-4T
General Information
chap. 1
Release 00
2001-12
General Information
500-4T
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 H2O 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
1-4
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chap. 1
General Information
500-4T
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
chap. 1
Release 00
2001-12
1-5
General Information
500-4T
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
1-6
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500-4T
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
chap. 1
Release 00
2001-12
1-7
General Information
500-4T
SAFETY PRECAUTIONS
The following symbols are used in the manual to stress the importance of certain pieces of information:
CAUTION
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.
WARNING
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 components.
WARNING
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.
CAUTION
Do not hold mechanical parts or engine components in the mouth, as some of them are made of toxic
materials.
CAUTION
Avoid starting the engine in closed or poorly ventilated rooms.

CAUTION
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. tightening 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.
CAUTION
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 workbench.
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.
1-8
Release 00
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chap. 1
General Information
500-4T
CAUTION
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.
WARNING
Failure to observe the above prescription may result in seizure or early breakage of the parts.
WARNING
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 assembly.
WARNING
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 components. 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.
CAUTION
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 operations 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 knowledge 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.
chap. 1
Release 00
2001-12
1-9
General Information
500-4T
CAUTION
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.
CAUTION
Fuel is highly flammable, and in certain conditions can even become explosive. Always handle it with great
care.
CAUTION
Avoid inhaling fuel fumes as they are toxic. Fuel should be handled in a closed environment only if an
adequate air change is ensured.
CAUTION
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.
WARNING
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.
WARNING

TRANSMISSION OIL
Use TUTELA ZC 90 oil. Alternatively, use brand name oil complying with or exceeding the API GL-4 specifications.
WARNING
Insufficient lubrication or the use of unsuitable lubricants may result in irreparable damage due to increased wear and tear of the moving parts.
WARNING
Do not overtighten the oil drain plug. Excessive tightening may damage the crankcase.
WARNING
Used oil contains substances that are harmful to the environment. Even small quantities must be disposed
of in compliance with the regulations in force.
WARNING
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.
WARNING
Used oil contains substances that are harmful to the environment. Even small quantities must be disposed
of in compliance with the regulations in force.
1-10
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chap. 1
500-4T
chap. 2
Release 00
2001-12
2-1
500-4T
TABLE OF LUBRICANTS
USE
CHARACTERISTICS
Rear hub oil

Grease (joints, pins, bearings)
PRODUCTS
Oil SAE 80W/90 superior to the API

GL3 specifications
TUTELA ZC 90
Complex calcium soap grease

NLGI 1-2
SYSTEM TW 249 AREXONS
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
SELENIA HI Scooter 4Tech
Grease for driven pulley shaft

compensating ring and movable
driven pulley slip seat
Molybdenum bisulphide grease
MONTBLANC
MOLYBDENUM
GREASE (Dis.498345)
Grease for steering bearings, pin

seats and swinging arm
Grease with lithium soap and zinc

oxide NLG12 of the swinging arm
Engine oil
Brake fluid
Coolant
TUTELA TOP 4
Paraflu 11fe (Diluted)
TUTELA ZETA 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.
REGULAR SERVICE INTERVALS CHART

OPERATIONS TO BE CARRIED OUT BY THE aprilia Official Dealer (WHICH CAN BE CARRIED OUT EVEN BY THE USER)
After running-in
[1,000 km (625 mi)]
Components
Every 6,000 km
(3,750 mi) or 8 months
Variator belt
Engine oil filter
Clutch shoes
Valve clearance
After 12,000 km
(7,500 mi) or 16 months
S
every 6,000 km(3,750 mi): S
C
C
then every 18,000 Km (11,250 mi)
R
Engine oil
Transmission oil
Variator rollers and variator plastic guides
Fuel filter
Spark plug
Carburettor - idling
Air cleaner
Engine oil
Engine oil pressure warning light
every 3,000 km (1,875 mi): C/every 6,000 km (3,750 mi): S

every 24,000 km (15,000 mi): S
C
C
every 24,000 km (15,000 mi): C every 48,000 km (30,000 mi): S
C
S
C
P
every 18,000 km (11,250 mi): S
every 1,000 km (625 mi): C
on every start: C (*)
C = check and clean, adjust, lubricate or replace if necessary. P = clean; S = replace; R = adjust.
Carry on the maintenance operations more frequently if you use the vehicle in rainy and dusty areas or on even ground.
(*) To check these components see pages 15-16: TABLE OF INSTRUMENTS AND INDICATORS.
2-2
Release 00
2001-12
chap. 2
500-4T
Tools
46-55 mm (1.81-2.16 in)

wrench
8140300
Flywheel extractor
8140301
Clutch bell retainer
Flywheel retainer
8140304
8140303
Countershaft lock
wrench
Driving shaft lock

wrench
8140307
8140305
Countershaft timing pin
Engine support
connector
8140609
8140309
15 mm (0.59 in) guide

for water pump gasket
Oil filter wrench
8140610
8140611
Fuel pressure manometer
Fuel pressure manometer fitting

8140181
8140612
chap. 2
Release 00
2001-12
2-3
500-4T
NOTES
2-4
Release 00
2001-12
chap. 2
500-4T
General information and

maintenance
chap. 3
Release 00
2001-12
3-1
500-4T
SAFETY PRESCRIPTIONS
MAINTENANCE REGULATIONS
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.
Use only genuine APRILIA spare parts and recommended lubricants. The use of non-original or nonconforming spare parts can cause damage to the
vehicle.
Battery electrolyte contains sulphuric acid. Protect the

eyes, clothes and skin. Sulphuric acid is highly corrosive, if it comes into contact with eyes or skin, wash
the affected area abundantly with water and seek
immediate medical assistance.
The only specific tools that can be used are those

expressly designed for this vehicle.
The battery produces hydrogen gas which is potentially explosive. Do not smoke near the battery and
keep naked flames and sparks well clear, especially
when the battery is on charge.
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.
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.
After reassembling, check that all the components are

correctly installed and that they work perfectly.
Clean brake shoes, drums and pads in a well ventilated 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.
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 electrical components are correctly installed, paying particular attention to ground and battery connections.
3-2
Release 00
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chap. 3
500-4T
SPECIFICATIONS (500 CC 4-STROKE, 4-VALVES H20 ENGINE)

ENGINE
Type
Bore
Stroke
Displacement
Compression ratio
Timing
Valves play
Valves play adjustment
Idle speed
CO% value
Starting system
Lubrication
Lubrication pressure
Minimum allowed
Fuel system
Max power (at crankshaft)
Max torque (at crankshaft)
single-cylinder, 4-stroke
92 mm (3.62 in)
69 mm (2.71 in)
460 cm3 (28.06 cu.in)
10.5 : 1
chain-operated overhead single-shaft flywheel side, integrated phonic wheel, 4-valves and automatic starting valve
lifter
Intake: 0.20 mm (0.007 in) Exhaust: 0.20 mm (0.007 in)
threaded register on equalizers
1450 50 rpm
1 1.5 %
electric starter
trochoid pump (inside the crankcase), oil filter and pressure
adjustment by-pass
4 bar (58 Psi)
0.4 - 0.6 bar (5.8 - 8.7 Psi)
electronic injection with electric fuel pump, throttle body 38
mm (1.49 in) and single injector
29 kW (39CV) bei 7250 rpm
40 Nm (4 Kgm) bei 5500 rpm
liquid, by means of motorized pump, 3-way thermostat and
electric fan.
automatic speed variator by means of expanding pulleys, Vbelt, automatic clutch, reduction gear, and transmission
compartment cooling by air forced-circulation.
high efficiency inductive type integrated with injection,
variable spark advance and separated high voltage coil
Cooling system
Transmission
Ignition type
Spark advance (before T.D.C.)
Spark plug
Engine-wheel ratio
Engine oil
Quantity
variable controlled by injection power unit

CHAMPION RG 6 YC NGK CR7 EKB
Short: 1/11.988 Long: 1/4.86
SAE 5W/40 exceeding API SJ specifications
~ 1,7 l (0.4488 Gal)
TUTELA ZC 90
Hub oil
Quantity
250 cc (15.25 cu.in)

~ 1.8 l (0.4752 Gal)
Cooling system capacity
chap. 3
Release 00
2001-12
3-3
500-4T
SPARK PLUG
Check and replacement
Remove the spark plug when the engine cold. Replace 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 levering 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 recommended 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.
AIR CLEANER
The air cleaner should be cleaned and checked every
6,000 km (3,750 miles), depending on the use conditions. If you use the vehicle on wet or dusty roads, the
cleaning or replacement operations must be carried
on more frequently. To clean the filtering element, it is
necessary to remove it from the vehicle.
REMOVAL
Raise the saddle (UNLOCKING / LOCKING THE
SADDLE)
Remove the safety clip (1).
Remove the pin (2) fastening the piston to the air
cleaner cover.
CAUTION
While removing the pin, hold the saddle to avoid its

fall.
Holding the saddle, remove the six screws (3) fastening the air cleaner cover to the plastic material under
the saddle.
CAUTION
While lifting the air cleaner cover, avoid removing

the suction sleeve from the filter box.
Carefully lift the air cleaner cover (4)

Remove the air cleaner (5)
3-4
Release 00
2001-12
chap. 3
500-4T
CLEANING
5
DANGER
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 pressurised air jet.
CAUTION
DO NOT OIL THE FILTERING ELEMENT to avoid

damaging the filter and the engine.
4
CAUTION
While reassembling the filter (1), insert it into the

filter cover (2) (the gasket must adhere perfectly to
its seat) and then screw the cover on the filter box.
4
5
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.
3
DANGER
The engine and the system components get very hot

and remain hot for some time even after the engine
has been stopped. Before touching such components, wear insulating gloves or wait until the engine
and the exhaust system have cooled down.
Stop the engine and let it cool down so as to allow the

oil to flow into the oil pan and to cool down.
chap. 3
Release 00
2001-12
3-5
500-4T
IMPORTANT The non-performance of the operations described above may lead to an incorrect measurement of the engine oil level.
Unscrew and extract the plug/dipstick (1)

Clean the part in contact with the oil with a clean cloth.
Tighten the plug/dipstick (1) completely screwing it
into the filling hole (2)
Extract the plug/dipstick (1) again and read the oil
level on the dipstick:
MAX =
MIN =
MAX
maximum level;
minimum 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,
CAUTION
Do not exceed the MAX mark and do not leave the oil
below the MIN mark to avoid serious damages to the
engine.
If necessary, carry on the topping up.
TOPPING UP
Pour a small quantity of oil into the filling hole (2) and
wait about one minute until the oil flows uniformly
inside the oil pan.
Carry on the oil level check and, if necessary, the
topping up.
Top up with small quantities of oil, until the prescribed
level is reached.
At the end of the operation screw and tighten the plug/
dipstick (1).
DANGER
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.
3-6
Release 00
2001-12
chap. 3
MIN
500-4T
REPLACING THE OIL AND THE ENGINE OIL

FILTER

ground.
DANGER

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).
DANGER

DANGER
Used oil contains substances that are very dangerous for the environment: to change it, contact an
aprilia Official Dealer, who will provide for the
disposal of used oils in accordance with the laws in
force.
Unscrew and remove the oil drain plug (4) and then
empty the reservoir completely.
Install a new oil cartridge filter (3) and lubricate the Orings 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 characteristics superior to the API ST specification.
Oil filter wrench
8140611
chap. 3
Release 00
2001-12
3-7
500-4T
CHECKING THE TRANSMISSION OIL LEVEL AND

TOPPING UP
2
1

ground.
Position the vehicle on the central stand
DANGER


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,
CAUTION
Do not exceed the MAX mark and do not leave the oil
below the MIN mark to avoid serious damages to the
engine.
If necessary, carry on the topping up.
TOPPING UP
Pour a small quantity of oil into the filling hole (2) and
wait about one minute until the oil flows uniformly
inside the oil pan.
Carry on the oil level check and, if necessary, the
topping up.
Top up with small quantities of oil, until the prescribed
level is reached.
At the end of the operation, screw and tighten the
plug/dipstick (1).
USE SAE 80W/90 OIL, SUPERIOR TO API GL3
SPECIFICATIONS.
DANGER

3-8
Release 00
2001-12
chap. 3
500-4T
REPLACING THE TRANSMISSION OIL

IMPORTANTE Position the vehicle on firm and flat

ground.
DANGER

To replace the oil, contact an aprilia Official Dealer.
DANGER
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.
chap. 3
Release 00
2001-12
3-9
500-4T
COOLANT
CAUTION

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.
DANGER
The coolant is noxious: do not swallow it; any contact 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 ENVIRONMENT
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% antifreeze.

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.
1
DANGER
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.
3-10
Release 00
2001-12
chap. 3
500-4T
CHECKING AND TOPPING UP

DANGER
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 expansion tank (2) is included between MIN and MAX
marks.
MIN =
minimum level.
MAX =
maximum level.
Otherwise:
Remove the front cover, see (REMOVING THE
FRONT COVER).
Loosen the filler cap (1) anticlockwise without removing it.
Wait a few seconds in order to release any residual
pressure.
MAX
MIN
3
1
2
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).
DANGER
The coolant is noxious: do not swallow it; any contact 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.
CAUTION
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).
CAUTION
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).
chap. 3
Release 00
2001-12
3-11
500-4T
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 Chapter 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 footrest by following the instructions given in the corresponding 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.
CAUTION
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 corresponding 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 relative chapter.
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.
3-12
Release 00
2001-12
chap. 3
500-4T
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 manometer becomes constant. If the pressure is included between 8-11 bar (116-159.5 Psi), remove the tool and reassemble 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
chap. 3
8140612
Release 00
2001-12
3-13
500-4T
NOTES
3-14
Release 00
2001-12
chap. 3
500-4T
chap. 4
Release 00
2001-12
4-1
500-4T
B
C
D
A
LUBRICATE WITH OIL
APPLY PRODUCT
WARNING: HANDLE WITH CARE
LUBRICATE WITH GREASE
CLEAN WITH CARE
ALWAYS REPLACE
REFERENCE
QUANTITY
TORQUE Nm 9092 2326

Ft-lbs
66.367.8 1719.1
4-2
1720 160175 6575 1113

12.514.7 118129 4855.3 8.19.5
Release 00
2001-12
chap. 4
500-4T
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, therefore allowing for the specific tool fitting.
Driving pulley lock wrench tool
chap. 4
8140305
Release 00
2001-12
4-3
500-4T
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 uncover one of the holes in the driven pulley axle support.
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.
4-4
Release 00
2001-12
chap. 4
500-4T
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.
chap. 4
Release 00
2001-12
4-5
500-4T
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.
CAUTION
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.
4-6
Release 00
2001-12
chap. 4
500-4T
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 support 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)
chap. 4
Release 00
2001-12
4-7
500-4T
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 completely 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.
4-8
Release 00
2001-12
chap. 4
500-4T
Check the pins and collar condition, and then reassemble 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 necessary, 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)
chap. 4
Release 00
2001-12
4-9
500-4T
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)
CAUTION
Do not lubricate or clean the bushes.

Measure the O.D. of the pulley sliding bush shown in
the figure.
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.
4-10
Release 00
2001-12
chap. 4
500-4T
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.
chap. 4
Release 00
2001-12
4-11
500-4T
DRIVEN PULLEY UNIT ASSEMBLY

Fit the driven pulley unit and relevant belt.
HOUSING ASSEMBLY
Fit the housing and the spacer.
DRIVEN PULLEY AXLE SUPPORT ASSEMBLY

Make sure the 2 centering dowels are properly fitted in
the crankcase.
DRIVEN PULLEY AXLE SUPPORT BEARINGS DISASSEMBLY

Check that the bearing turns freely. Replace the
bearing if necessary.
Remove the snap ring.
4-12
Release 00
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chap. 4
500-4T
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 BEARING ASSEMBLY
Heat the driven pulley axle support with the thermal

gun.
Fit the bearing on the specific tool. Grease it to prevent 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.
chap. 4
Release 00
2001-12
4-13
500-4T
Fit the washer and the nut.
Insert the specific tool tooth in the hole on the housing.

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)
4-14
Release 00
2001-12
chap. 4
500-4T
FIXED DRIVING HALF PULLEY ASSEMBLY

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).
chap. 4
Release 00
2001-12
4-15
500-4T
Turn the pulley central nut aligning its holes horizontally 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 Ftlbs)
BELT ANTIFLAPPING ROLLER ASSEMBLY

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)
4-16
Release 00
2001-12
chap. 4
500-4T
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.
chap. 4
Release 00
2001-12
4-17
500-4T
NOTES
4-18
Release 00
2001-12
chap. 4
Final reduction
500-4T
Final reduction
chap. 5
Release 00
2001-12
5-1
Final reduction
500-4T
LUBRICATE WITH OIL
APPLY PRODUCT
CLEAN WITH CARE
ALWAYS REPLACE
REFERENCE
QUANTITY
TORQUE Nm
Ft-lbs
5-2
2427 1517
17.720 11.112.5
Release 00
2001-12
chap. 5
Final reduction
500-4T
REDUCTION UNIT COVER

Drain the rear hub oil through the oil drain plug situated 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.
chap. 5
Release 00
2001-12
5-3
Final reduction
500-4T
DISASSEMBLY OF WHEEL AXLE BEARING 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.
5-4
Release 00
2001-12
chap. 5
Final reduction
500-4T
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 Automatic 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 ASSEMBLY

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) .
chap. 5
Release 00
2001-12
5-5
Final reduction
500-4T
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.
5-6
Release 00
2001-12
chap. 5
Final reduction
500-4T
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
chap. 5
Release 00
2001-12
5-7
Final reduction
500-4T
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.
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
0.0003
0.01
in)
diameter:
A = 20 -- 0.02
mm (0.78 -- 0.0007
Wheel axle bearing
- 0.0003
diameter:
B = 30 -- 0.010
0.023 mm (1.18 - 0.0009 in)
0.0003
0.01
in)
mm (0.6 -- 0.0007
C = 15 -- 0.02
Driven pulley shaft
0.0003
0.01
in)
bearing diameter:
D = 17 -- 0.02
mm (0.67 -- 0.0007
- 0.0003
- 0.01
(0.78
E = 20 - 0.02 mm
- 0.0007 in)
- 0.0003
F = 25 -- 0.01
0.02 mm (0.98 - 0.0007 in)
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.
5-8
Release 00
2001-12
chap. 5
Final reduction
500-4T
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 General 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)
chap. 5
Release 00
2001-12
5-9
Final reduction
500-4T
NOTES
5-10
Release 00
2001-12
chap. 5
Flywheel cover
500-4T
Flywheel cover
chap. 6
Release 00
2001-12
6-1
Flywheel cover
500-4T
F
B
LUBRICATE WITH OIL
APPLY PRODUCT
CLEAN WITH CARE
ALWAYS REPLACE
REFERENCE
QUANTITY
14
TORQUE Nm
Ft-lbs
6-2
34 1113 45 2430 34
810 1.52.5 1216 1.52 34 3.54.5
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
Release 00
2001-12
chap. 6
Flywheel cover
500-4T
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. Remove 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 thermostat cover.
Remove the thermostat.
chap. 6
Release 00
2001-12
6-3
Flywheel cover
500-4T
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.
6-4
Release 00
2001-12
chap. 6
Flywheel cover
500-4T

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.
CAUTION
Avoid any interferences between the stator and

rotor while removing the cover.
CAUTION
Do not drop the bypass valve and relevant spring.
FLYWHEEL COVER COMPONENTS DISASSEMBLY

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.
chap. 6
Release 00
2001-12
6-5
Flywheel cover
500-4T
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. direction. Prevent the shaft from turning by inserting a 12
mm wrench in the drive.
6-6
Release 00
2001-12
chap. 6
Flywheel cover
500-4T
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.
chap. 6
Release 00
2001-12
6-7
Flywheel cover
500-4T
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 COMPONENTS - 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.
6-8
Release 00
2001-12
chap. 6
Flywheel cover
500-4T
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)
chap. 6
Release 00
2001-12
6-9
Flywheel cover
500-4T
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.
6-10
Release 00
2001-12
chap. 6
Flywheel cover
500-4T
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.
chap. 6
Release 00
2001-12
6-11
Flywheel cover
500-4T
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 Ftlbs)
15 mm (0.59 in) guide for water pump gasket 8140610
6-12
Release 00
2001-12
chap. 6
Flywheel cover
500-4T
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)
chap. 6
Release 00
2001-12
6-13
Flywheel cover
500-4T
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 Ftlbs)
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.
6-14
Release 00
2001-12
chap. 6
Flywheel cover
500-4T
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 interferences between the stator and the rotor.
CAUTION
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 prescribed 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)
WATER PUMP COVER ASSEMBLY

Carefully fit a new O ring preventing it from coming
into contact with grease or oil.
CAUTION
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 Ftlbs)
chap. 6
Release 00
2001-12
6-15
Flywheel cover
500-4T
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)
6-16
Release 00
2001-12
chap. 6
Flywheel cover
500-4T
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
chap. 6
Release 00
2001-12
6-17
Flywheel cover
500-4T
NOTES
6-18
Release 00
2001-12
chap. 6
500-4T
7
chap. 7
Release 00
2001-12
7-1
500-4T
LUBRICATE WITH OIL
APPLY PRODUCT
CLEAN WITH CARE
ALWAYS REPLACE
REFERENCE
QUANTITY
TORQUE Nm
Ft-lbs
7-2
1315
9.511
34
1113 115125
2.22.9 8.19.5 84.892.2
Release 00
2001-12
chap. 7
500-4T
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.
7
MAGNETO FLYWHEEL DISASSEMBLY
IMPORTANT To disassemble the magneto flywheel, 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.
chap. 7
Release 00
2001-12
7-3
500-4T
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.
7-4
Release 00
2001-12
chap. 7
500-4T
Refit the nut as to slightly uncover the shaft and to

free the space where the washer was.
CAUTION
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.
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
Remove the extractor.

Remove the nut and the magneto flywheel complete
with the starting ring gear.
Remove the key from the driving shaft.
Withdraw the starting ring gear from the free wheel by

turning it clockwise.
chap. 7
Release 00
2001-12
7-5
500-4T
Remove the freewheel from the magneto flywheel by

unloosing the 6 fixing screws.
IMPORTANT To be able to disassemble the freewheel, 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.
7-6
Release 00
2001-12
chap. 7
500-4T
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.
0.0003
0.008
Hub outside diameter: 45.665 ++ 0.005
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.
0.020
0.0007
Brass I.D.: 27 ++ 0.041
mm (1.06 ++ 0.0016
in)
IDLER GEAR WITH TORQUE LIMITER

Check the toothing out for signs of wear.
Check the diameter of the two bearings.
0
Gear bearing diameter: 12 -- 00.011 mm (0.47 -- 0.0004
in)
Also check the bearings diameter on the flywheel

cover and engine crankcase.
12 +- 0.034
0.016 mm
0.0013
(0.47 -- 0.0006
in)
+ 0.034
Engine crankcase bearing diameter: 12 - 0.016 mm
(0.47 -- 0.0013
0.0006 in)
Flywheel cover bearing diameter:
chap. 7
Release 00
2001-12
7-7
500-4T
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 Ftlbs)
Oil the freewheel rollers.
7-8
Release 00
2001-12
chap. 7
500-4T
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.
7
IDLER GEAR WITH TORQUE LIMITER
ASSEMBLY
Grease the gear housing on the engine crankcase.
Fit the idler gear with the torque limiter.
chap. 7
Release 00
2001-12
7-9
500-4T
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 procedure 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.
7-10
Release 00
2001-12
chap. 7
500-4T
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)
chap. 7
Release 00
2001-12
7-11
500-4T
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 Flywheel cover.
7-12
Release 00
2001-12
chap. 7
500-4T
chap. 8
Release 00
2001-12
8-1
500-4T
D
P
C
N
F
O
M
G
A
LUBRICATE WITH OIL
APPLY PRODUCT
CLEAN WITH CARE
ALWAYS REPLACE
REFERENCE
QUANTITY
TORQUE Nm 46 3035 1113 56 3842 4446 1113 68 1014 78.5 34 1113 1113 34
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
8-2
Release 00
2001-12
chap. 8
500-4T
Remove the external transmission cover and the

transmission cover complete with net filter, as described 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 previously removed.
Remove the intake manifold assembly.
TAPPET COVER DISASSEMBLY

Unloose the 4 fixing screws and remove the tappet
cover with relevant gasket.
chap. 8
Release 00
2001-12
8-3
500-4T
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 compartment.
Align the reference marks on the phonic wheel and on

the head.
8-4
Release 00
2001-12
chap. 8
500-4T
Unloose the tightener central screw.

Unloose the 2 fixing screws and remove the tightener
and relevant gasket.
Remove the internal hexagonal-head screw and the

counterweight, as shown in the figure.
Remove the timing chain gear from the camshaft

Remove the timing chain gear.
Remove the phonic wheel.
chap. 8
Release 00
2001-12
8-5
500-4T
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 DISASSEMBLY

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 threading.
Remove the camshaft.
Remove the pins and equalizers by acting through the

holes, transmission side.
8-6
Release 00
2001-12
chap. 8
500-4T
HEAD DISASSEMBLY
Remove the spark plug.
Remove the cooling system outlet union and relevant O ring by unloosing the 2 screws.
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 2 fixing nuts on the head, exhaust and

intake side.
Remove the 3 side fixings shown in the figure.
chap. 8
Release 00
2001-12
8-7
500-4T
IMPORTANT If necessary, the head can be removed 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.
CAUTION
Collect the thermal unit coolant in a suitable

container when the head is disassembled.
VALVES DISASSEMBLY
Disassemble the cotters, caps, springs and valves by
means of the specific tool provided with an adapter.
Valves disassembly tool

Adapter
CAUTION
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.
Remove the spring supports.
IMPORTANT Blow compressed air in the housings

to facilitate the spring supports removal.
8-8
Release 00
2001-12
chap. 8
500-4T
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.
CAUTION
To avoid damaging the piston, hold it while disassembling the cylinder.
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.
CAUTION
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.
chap. 8
Release 00
2001-12
8-9
500-4T
CHECKING CONNECTING ROD SMALL

END
Measure the connecting rod small end diameter by
means of a reamer.
0.025
Standard diameter: 22 ++ 0.015
mm (0.86 ++ 0.0009
0.0006 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.
GUDGEON PIN DIAMETER

Check the gudgeon pin outside diameter by means of
a micrometer.
Standard diameter: 22
0
- 0.004
mm (0.86 -00.0001 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)
0.0003
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.
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)
8-10
Release 00
2001-12
chap. 8
500-4T
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)
0.0003
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).
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.
A=0.9 --0.005
mm (0.035 --0.0002
in)
0.030
0.0011
C=0.9 ++ 0.03
mm (0.035 ++0.001
in)
0.0003
0.01
0.0002
B=1.5 -- 0.005
mm (0.8 -- 0.0011
in)
0.03
0.002
D=2 + -0,05
mm (1.5 +- 0.0007
in)
0.02
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)
1st compression ring
GAS RINGS
Insert alternately the 3 gas rings in the cylinder, in the
area of its original diameter. Insert the rings orthogonally 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.
chap. 8
Release 00
2001-12
8-11
500-4T
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)
IMPORTANT Before replacing the rings, make sure that the instructions regarding the ring-slot and pistoncylinder allowances have been followed. However, the bedding of new rings on secondhand cylinders may differ
from the standard bedding conditions.
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.
8-12
Release 00
2001-12
chap. 8
500-4T
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.
CAUTION
Using a hammer may damage the locks housing.
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 maintain 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 measurement 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)

+ 0.10 + 0.185 mm (+ 0.003 + 0.007 in)
0.6 0.05 mm (0.023 0.002 in)

0.8 0.05 mm (0.031 0.002 in)
chap. 8
Release 00
2001-12
8-13
500-4T
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.
8-14
Release 00
2001-12
chap. 8
500-4T
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.
Standard diameter mm (in)
A
13 + 0,018 (0.51 + 00.0007)
20 + 0,021 (0.78 + 00.0008)
42 + 0,025 (1.65 + 00.0009)
If worn, also check the corresponding component

when the head is replaced.
CHECKING THE VALVE SEALING SURFACES
Visually check the valves sealing surfaces.
CAUTION
Do not change the valves assembly position (RHLH).

If the valve sealing surface is discontinued in one or
more points, or if it is bent, replace the valve.
chap. 8
Release 00
2001-12
8-15
500-4T
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.
8-16
Release 00
2001-12
chap. 8
500-4T
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)
chap. 8
Release 00
2001-12
8-17
500-4T
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 compound. 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).
CAUTION
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.
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.
8-18
Release 00
2001-12
chap. 8
500-4T
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).
chap. 8
Release 00
2001-12
8-19
500-4T
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
- 0.002
Support A : 42 -- 0.060
0.085 mm (1.65 - 0.003 in)
- 0.0007
mm
(0.78
Support B : 20 -- 0.020
- 0.0016 in)
0.041
Minimum allowed diameter
Support A : 41.910 mm (1.65 in)
Support B : 19.940 mm (0.78 in)
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.
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 that the equalizer pins show no signs of scoring

or wear.
- 0.0003
Standard diameter: 13 -- 0.010
0.018 mm (0.51 - 0.0007 in)
Check the inside diameter of each equalizer.
- 0.0003
0.015 mm (0.51 + 0.0005 in)
Check that the cam sliding shoe and the registers
articulated plate show no signs of wear.
Replace the component if necessary.
8-20
Release 00
2001-12
chap. 8
500-4T
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 mechanism shows no signs of wear.
Check the tightener spring condition.
If necessary, replace the whole assembly.
HEAD AND TIMING SYSTEM PARTS ASSEMBLY
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.
chap. 8
Release 00
2001-12
8-21
500-4T
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)
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.
CAUTION
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)
8-22
Release 00
2001-12
chap. 8
500-4T
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 prescribed 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 respecting 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)
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 opposite to the equalizers.
chap. 8
Release 00
2001-12
8-23
500-4T
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 prescribed 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.
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)
8-24
Release 00
2001-12
chap. 8
500-4T
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.
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.
chap. 8
Release 00
2001-12
8-25
500-4T
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 compartment side.
Assemble the counterweight

Center it by means of the bell fixing screws.
Tighten the counterweight fixing screw to the prescribed torque. Apply LOCTITE 242.
Tightening torque:
Counterweight fixing screw: 7 - 8.5 Nm (5.1 - 6.2
Ft-lbs)
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.
8-26
Release 00
2001-12
chap. 8
500-4T
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)
Position the engine with the valve play adjustment

timing reference marks aligned with the head.
Check the valve-equalizer play by means of a thickness 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.
CHECKING THE REVS-TIMING SENSOR

AIR GAP
Align one tooth of the phonic wheel with the revstiming 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.
chap. 8
Release 00
2001-12
8-27
500-4T
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 Ftlbs)
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)
8-28
Release 00
2001-12
chap. 8
500-4T
Assemble the transmission cover complete with net

filter, and the external transmission cover according to
the procedure described in Chapter Automatic Transmission.
Assemble the cooling system sleeves using new

clamps. Follow the procedure described in Chapter
Flywheel cover.
INTAKE MANIFOLD PARTS DISASSEMBLY
Injector disassembly
IMPORTANT Remove the injector from the manifold 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.
chap. 8
Release 00
2001-12
8-29
500-4T
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.
CAUTION
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 manifoldhead.
CAUTION
The penetration of air may compromise the injection system correct operation, in particular with
engine running at idle speed.
8-30
Release 00
2001-12
chap. 8
500-4T
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 MANIFOLD

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 ENGINE
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)
chap. 8
Release 00
2001-12
8-31
500-4T
NOTES
8-32
Release 00
2001-12
chap. 8
500-4T
chap. 9
Release 00
2001-12
9-1
500-4T
LUBRICATE WITH OIL
APPLY PRODUCT
CLEAN WITH CARE
ALWAYS REPLACE
REFERENCE
QUANTITY
14
TORQUE Nm 2529 56
Ft-lbs
18.421.4 3.74.4
9-2
810 1113 1012

5.97.4 8.19.5 7.48.8
Release 00
2001-12
chap. 9
500-4T
Remove the external transmission cover, the transmission 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 System.
9
Remove the thermal assembly (cylinder, head, piston)
as described in Chapter Thermal Assembly.
chap. 9
Release 00
2001-12
9-3
500-4T
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 crankcase and the driving shaft.
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.
9-4
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2001-12
chap. 9
500-4T
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.
CAUTION
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.
9
REMOVING THE COUNTERSHAFT CONTROL 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.
chap. 9
Release 00
2001-12
9-5
500-4T
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 unscrewing the 2 fixing screws and relevant washers.
9-6
Release 00
2001-12
chap. 9
500-4T
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.
chap. 9
Release 00
2001-12
9-7
500-4T
Remove the bearing from the half crankcase transmission 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 crankcase inner side.
Assemble the snap ring.
9-8
Release 00
2001-12
chap. 9
500-4T
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 crankcase inner side.
CHECKING DRIVING SHAFT COMPONENTS

Check the connecting rod end play.
chap. 9
Release 00
2001-12
9-9
500-4T
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)
CAUTION
The driving shaft can be reused when the width

conforms to the standard values and the surfaces show no signs of scoring.
Shim
Check the total dimension of the driving shaftshoulder-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.
9-10
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2001-12
chap. 9
500-4T
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
40.010 - 40.016 (1.5751 - 1.5754)
Class 2
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.
chap. 9
Release 00
2001-12
9-11
500-4T
CAUTION
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 crankcase) with the same class.
Check the driving shaft gear according to the procedure 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.
9-12
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2001-12
chap. 9
500-4T
For the half crankcase flywheel side, pay special

attention to the lubrication ducts to the main bearing
brasses, oil pump compartment and channels, and bypass duct situated on the flywheel cover.
IMPORTANT As already described in Chapter

Lubrication, it is very important that the by-pass housing on the flywheel cover shows no signs of wear that
would compromise the sealing of the lubrication pressure 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 openings for the lubrication.
The full half bearing supports the thrusts produced by the combustion, therefore it is positioned opposite to the cylinder.
To avoid the oil supply ducts choking, the coupling 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.
chap. 9
Release 00
2001-12
9-13
500-4T
Check the brasses diameter in the 3 directions

Repeat the measuring on the other half of the
brass. See figure.
Coupling
surface
IMPORTANT Do not measure the mating of the 2

half bearings as the ends are splined to allow deformation 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 depending on the thickness, see table below:
TYPE
IDENTIFICATION
THICKNESS mm (in)
Red
1.982 - 1.987 (0.0780 - 0.0782)
Blue
1.987 - 1.992 (0.0782 - 0.0784)
Yellow
1.992 - 1.997 (0.0784 - 0.0786)
Half shafts coupling with half crankcase and brass

Half shaft
Class
Half shaft
Class
Brass
class
Spare crankcase
preparation
1
2
B
C
FC1
Drg. CM1033015001
1
2
A
B
FC2
Drg. CM1033015002
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.
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 transmission, and the hub cover with relevant gears and
bearings, as described in Chapter Final Reduction.
9-14
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chap. 9
500-4T
OIL PUMP
Overhaul the oil pump as described in Chapter Lubrication.
COUNTERSHAFT
Measure the 2 countershaft supports by means of a
micrometer, as shown in the figure.
0.01
0.0003
mm (0.67 -- 0.0007
in)
Standard diameter: 17 -- 0.02
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.
9
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)
chap. 9
Release 00
2001-12
9-15
500-4T
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 Ftlbs)
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, carefully 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 hexagon.
Tightening torque:
Driving shaft gear fixing screws: 10 - 12 Nm (7.4 8.8 Ft-lbs)
9-16
Release 00
2001-12
chap. 9
500-4T
Lubricate the main bearing brass on the half crankcase 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 transmission side by means of a screwdriver.
chap. 9
Release 00
2001-12
9-17
500-4T
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.
CAUTION
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 crankcase 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)
9-18
Release 00
2001-12
chap. 9
500-4T
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 system.
Assemble the flywheel cover with the cooling system

sleeves as described in Chapter Flywheel cover.
9
Assemble the driving pulley assembly, transmission
cover complete with net filter and the external transmission cover as described in Chapter Automatic
transmission.
chap. 9
Release 00
2001-12
9-19
500-4T
NOTES
9-20
Release 00
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Fuel injection
500-4T
10
Fuel injection
chap. 10
Release 00
2001-12
10-1
Fuel injection
500-4T
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
10-2
Release 00
2001-12
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Fuel injection
500-4T
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
10
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
chap. 10
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Fuel injection
500-4T
The control unit has its own auto-diagnosis system

connected to an indicator on the instrument panel.
ABS
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 revolution 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.
10-4
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Fuel injection
500-4T
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.
10
chap. 10
Release 00
2001-12
10-5
Fuel injection
500-4T
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%.
10-6
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2001-12
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Fuel injection
500-4T
COMPONENTS LAYOUT
37
36
40
52
42
14
16
43
44
54
10
ABS
13
55
15
22
20
24
45
11
38
10
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
chap. 10
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
Release 00
40
42
43
44
45
52
54
55
CLAXON
DASHBOARD AIR T THERMISTOR
DASHBOARD
SPEED SENSOR
OIL PRESSURE SENSOR
E.C.U. CENTRAL UNIT
DIAGNOSTICS OUTLET
STOPLIGHT RELAY
2001-12
10-7
Fuel injection
500-4T
LAYOUT OF THE EMS CONTROL UNIT TERMINALS AND IMMOBILIZER

Representation of the control unit connector and the connector system side.
CONTROL UNIT SIDE
SYSTEM SIDE
EMS CONTROL UNIT

N
FUNCTION
FUNCTION
THROTTLE POTENTIOMETER FEED (+5V)
14
STEPPER MOTOR
15
DIGITAL INSTRUMENT (FUEL INJECTION INDICATOR - NEGATIVE)
DIGITAL INSTRUMENT (REVOLUTIONS COUNTER CONTROL) 16
DECODER (SERIAL)
ENGINE TEMPERATURE (+)
17
BASE FEED (POSITIVE)
86 ELECTRICAL FAN ELECTROMAGNETIC SWITCH
18
AIR TEMPERATURE SENSOR (+)
ENGINE REVOLUTIONS SENSOR
19
85 ELECTROMAGNETIC SWITCH (PUMP-INJECTOR-H.V. COIL) (-)
EMS DIAGNOSIS CONNECTOR
20
H.V. COIL (NEGATIVE CONTROL)
21
STEPPER MOTOR
22
SENSORS FEED (-)
10
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)
10-8
Release 00
2001-12
chap. 10
Fuel injection
500-4T
EMS SYSTEM DIAGRAM
43
x1000r/min
37
mp/h
Km/h
EFI
ABS
38
TRIP
30
87
85
86
R/Gr
36
STOP
INTERRUTTORE
SWITCH
STOP
Bi/N
N
V
R/N
G/N
R/Bi
Vi/N
V
Bi/N
R/N
CLAXON
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Az/V
M/V
R/Bi
R/Bi
Az/R
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
LEFT
DEVIOLUCI
DIMMER
SINISTRO
R/Gr
SET
Ar/R
RELE
STOPLIGHTS
LUCI STOP
RELAY
R/N
Ro/G
Gr
COMMUTATORE
KEY SWITCH
A CHIAVE
STOP
R/Bi
R/Bi
COMMUTATORE
KEY SWITCH
A CHIAVE
R/Gr
V
Ar/N
Ar/V
P
5
12
6
7
10
13
11
14
R 30A V/R
R 30A R/Bi
B
G/N
Gr
Ar
Ar/R
Bi/N
Gr
Ro/N
R/M
Ro/G
V/G
15
22
R
B
M/N
M/V
Gr
M/Bi
M/G
N
V
M
B
G/N
1
2
5
3
M/N
R/N
Gr/N
Ar/V
85
86
87
30
B
R/M
R/M
Gr/R
Ar/Bi
R/M
Gr/N
R/B
R/M
Ar/V
AL REGOLATORE
TO VOLTAGE
DIREGULATOR
TENSIONE
1
1
RELE
STARTING
AVVIAMENTO
RELAY
19
16
A
B
C
D
F
1)
2)
3)
4)
5)
6)
7)
9)
10)
11)
12)
13)
14)
15)
16)
19)
22)
24)
36)
37)
38)
43)
52)
54)
24
B 15A V/N
V/N
C 15A
E 3A V/R
A 15A V/R
D 15A
F
V/R
R/Bi
54
R
M
LUCE
VANO
TOP CASE
BAULETTO
LIGHT
Az
Ro
G
Vi
ECU
CONTROLE.C.U.
UNIT
CENTRALINA
M/Bi
1
V/G
2
Az/R
3
Ar
4
R/B
5
Vi
6
B
7
Ro/G
8
M
9
R
10
11 M/G
B/N
12
Gr/R
13
Az
14
Az/V
15
Ro/G
16
Ar/N
17
18 Ro/N
Vi/N
19
Ar/Bi
20
G
21
Gr
22
23 N
24 Ro
25 Gr/N
26
N
52
INTERRUTTORI
SWITCH
STOP
SECONDARY
FUSES:
FUSIBILI SECONDARI:
A - INIEZIONE,
AVVIAMENTO.
-STARTING
INJECTION
B - ENGINE KILL, LUCI STOP.
-ENGINE CKILL,
STOPLIGHTS
- LUCI, CLAXON,
CRUSCOTTO, RELE' VENTOLA.
D - PRESA DI CORRENTE.
-LIGHTS, EELECTRIC
HORN,
DASHBOARD,
FAN RELAY
- ALIMENTAZIONE PERMANENTE E.C.U.
F - LIBERO.
-ECU PERMANENT
FEED.
-FREE
Multiple connectors
Revolution sensor
Stepper motor
Coil
Spark plug
Fuel injector
Fuel pump
Primary injection relay (with diode)
Secondary injection relay
Side stand switch
Lambda sensor (not available)
Accelerator sensor
Engine air thermistor
Engine water thermistor/dashboard
Fan
Battery
Primary fuses
Secondary fuses
Fall sensor
Right dimmer
Fan relay
Dashboard
ECU control unit
Diagnostics connector
chap. 10
10
Release 00
2001-12
10-9
Fuel injection
500-4T
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
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)
Fuel supply
Spark plug
Shielded cap
H.V. coil (secondary isolation)
Spark plug feed
Compression end pressure
Coolant temperature
Valve gear timing-ignition injection
Air intake temperature
Parameter reliability
10-10
Release 00
2001-12
chap. 10
Fuel injection
500-4T
2) DIFFICULT COLD START OR WARM START OF THE ENGINE


self-diagnosis
Starting

Air temperature
Coolant temperature
Atmospheric pressure
Starter and electromagnetic switch

Battery
Earth connections
Compression end pressure
Spark plug feed
Fuel supply
Parameter correctness
chap. 10
Spark plug
Shielded cap
H.V. coil
Phase revolutions sensor
Spark lead
Petrol pressure (low)

Injector capacity (low)
Injector stability (poor)
10
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
Release 00
2001-12
10-11
Fuel injection
500-4T
3) THE ENGINE DOES NOT MAINTAIN IDLING SPEED

IDLING SPEED IS UNSTABLE
IDLING SPEED IS TOO LOW
Air temperature
Coolant temperature
Presence of anomalies revealed through fuel

injection self-diagnosis
Spark plug
Ignition timing
Ignition efficiency
Throttle valve position sensor

Stepper
Coolant temperature sensor
Air intake temperature sensor
Air filter
Choke tube and throttle valve
Supplementary air duct and stepper
Air intake system cleanliness
head-intake manifold
Throttle body-manifold
Air intake hose
Filter box
Intake system seal (infiltrations)
Fuel pump
Pressure regulator
Fuel filter
Injector capacity
Fuel supply (low pressure)
Analysis of exhaust gas prior to the catalytic converter
10-12
Release 00
Trimmer value adjustment (CO% adjustment)
2001-12
chap. 10
Fuel injection
500-4T
4) THE ENGINE DOES NOT TURN OVER ON IDLING SPEED

IDLING SPEED TOO HIGH
self-diagnosis

Air temperature
Coolant temperature
Ignition timing
Ignition efficiency

Stepper
Head-intake manifold
Air intake hose
Filter box
Fuel pump
Pressure regulator
Fuel filter
Injector capacity
Fuel supply (pressure low)
5) BACKFIRING IN DECELERATION

self-diagnosis
chap. 10

Air temperature
Coolant temperature
Stepper
Release 00
2001-12
10-13
10
Fuel injection
500-4T
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
6) IRREGULAR RUNNING OF THE ENGINE WITH THROTTLE VALVE SLIGHTLY OPEN

Air temperature
Coolant temperature

self-diagnosis
Air filter
Choke and throttle valve
Supplementary air duct and stepper
Air intake system cleanliness
Air intake hose

Filter box
Intake system seal
Check spark plug wear
Ignition system
Throttle valve position signal

Coolant temperature signal
Air intake temperature signal
Spark lead
TPS reset carried out correctly
Analysis of exhaust gas taken prior to the catalytic

converter
10-14
Release 00
2001-12
chap. 10
Fuel injection
500-4T
7) POOR ENGINE RUNNING ON FULL POWER

IRREGULAR RUNNING OF THE ENGINE DURING ACCELERATION STAGE
self-diagnosis
Spark plug feed
Air intake system
Fuel supply

Air temperature
Coolant temperature
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
8) PRESENCE OF DETONATION (COMBUSTION SHOCK)

self-diagnosis
Ignition efficiency

Air temperature
Coolant temperature
Spark plug
Throttle valve position

Coolant temperature
Air temperature intake
Spark lead
Intake system seal
Filter box
Air intake hose
10
Reset TPS carried out correctly
Fuel supply
Fuel pressure
Fuel filter
Injector capacity
Fuel quality
Thickness selection of the cylinder base gasket
chap. 10
Release 00
2001-12
10-15
Fuel injection
500-4T
DIAGNOSIS TESTER LINK CIRCUIT
VEHICLE
SYSTEM
DIAGNOSIS
TESTER
CONNECTOR
FUEL INJECTION
SYSTEM
3
2
1
23
10
FUEL INJECTION
CONTROL UNIT
CIRCUIT DIAGRAM
Connect the diagnosis tester n 8140595.

If the diagnosis tester gives the information "THE CONTROL UNIT DOES NOT RESPOND", remove the underpanel 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
YES
The circuit works correctly
Check the control unit
10-16
Release 00
2001-12
chap. 10
Fuel injection
500-4T
FUEL INJECTION INDICATOR CIRCUIT

CIRCUIT DIAGRAM
5
5
12
7
12
9
12
1
16
15
23
4
1
DIGITAL INSTRUMENT
30A FUSE
7.5A FUSE
CONTROL UNIT
7.5A FUSE
TERMINAL
15 - 23
CONDITIONS
- commutator set to
"ON"
- side stand raised
- switch set to "RUN"
STANDARD VALUES
during checks
OV
after checks
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.
10
chap. 10
Release 00
2001-12
10-17
Fuel injection
500-4T
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.
- 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 displayed (see figure).
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
10-18
Release 00
- 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.
2001-12
chap. 10
Fuel injection
500-4T
- 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
RETURN
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.
NJECTOR TRING
RUNNING
DIRECTION
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.
DELIVERY
The pipes are crossed and fastened to the suction

manifold to avoid the wear of the quick-connections
connecting the injector T-ring.
10
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.
CAUTION
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
chap. 10
Release 00
2001-12
10-19
Fuel injection
500-4T
CIRCUIT DIAGRAM
43
35
37
!
x1000r/min
mp/h
Km/h
V/N
R/Bi
EFI
M/V
B
Ar/N
B
G/V
R/N
R/Gr
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1
2
3
4
R/B
5
6
7
8
9
10
11
12
Gr/R
13
14
15
16
Ar/N
17
18
19
Ar/Bi
20
21
22
23 N
24
25 Gr/N
26
STOP
INTERRUTTORI
SWITCH STOP
R/Gr
Ar/N
Ar/V
24
B 15A V/N
C 15A
E 3A V/R
A 15A V/R
D 15A
F
V/R
R/Bi
CENTRALINA
E.C.U.
ECU CONTROL
UNIT
52
TRIP
R/Gr
SET
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
R/N
ABS
R 30A V/R
R 30A R/Bi
B
M/N
M/V
Gr/N
R/B
R/M
Ar/V
P
5
22
N
V
M
1
2
5
3
M/N
R/N
Gr/N
Ar/V
85
86
87
30
B
R/M
Ar/N
G/V
Ar/Bi
R/M
R/M
Gr/R
6
7
10
11
MULTIPLE CONNECTORS
11
SIDE STAND SWITCH
COIL
19
BATTERY
SPARK PLUG
22
PRIMARY FUSES
FUEL INJECTOR
24
SECONDARY FUSES
FUEL PUMP
35
KEY SELECTOR
FUEL LEVEL SENSOR
37
RIGHT DIMMER
PRIMARY INJECTION RELAY (WITH DIODE)
43
DASHBOARD
10
SECONDARY INJECTION RELAY
52
ECU CONTROL UNIT
19
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.
10-20
Release 00
2001-12
chap. 10
Fuel injection
500-4T
Circuit control
Proceed as follows:
Set to "ON" with the emergency switch set to "RUN" and the side stand raised.
There is pump revolution for 2 seconds.
YES
NO
The pump does not turn or turns

continuously.
Attempt ignition.
Check that the engine revolution matches that of
the pump.
YES
The electrical feed of the pump is

conformant.
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.
NO
YES
Malfunctioning of:
- injector
- HV coil
- signals panel
YES
10
Malfunctioning of the
pump command relay circuit.
chap. 10
Release 00
2001-12
10-21
Fuel injection
500-4T
The control unit has revealed an anomaly on the line of the secondary
injection relay of pin 5.
YES
YES
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.
YES
Check and reset the

earthing insulation of line
5-2 (of the relay). Check
the two sections separately: vehicle system/
injection system
Check the connector and the

harness on injection side
Cancel the code and

check from the beginning.
Check the efficiency of the 15A fuse (see

figure).
NO
10-22
YES
Release 00
2001-12
chap. 10
Fuel injection
500-4T
YES
Check the efficiency of the pump control electromagnetic switch. Check the continuity of the harness between the electromagnetic switch and the pump (see the
relative wiring diagram).
NO
Reset and repeat the check from the beginning.
YES
Check the earthing insulation of HV coil

and injector coil primary circuit. See the
relative wiring diagram.
NO
YES
Reset the harness insulation and

replace the fuse.
10
chap. 10
Release 00
2001-12
10-23
Fuel injection
500-4T
Check resistance of the windings in the pump.

Resistance 1.5
NO
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.
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 functioning control
Check the pump support connector.

YES
10-24
Release 00
NO
Replace the pump. See

the relative paragraph
of the VEHICLE SHOP
HANDBOOK .
Reset
2001-12
chap. 10
Fuel injection
500-4T
Pump electrical controls
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 excessively 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
10
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.
chap. 10
Release 00
2001-12
10-25
Fuel injection
500-4T
Hydraulic control and system maintenance

Before any check of the system pressure, it is important 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.
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.
CAUTION
Disconnect the pipe end with the utmost care. Avoid

sprays in the eyes.
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.
CAUTION
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.
CAUTION
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.
10-26
Release 00
2001-12
chap. 10
Fuel injection
500-4T
The system pressure must be checked by connecting

with the pump side in order to make the operation
easier.
FORWARD
SPEED
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.
8140612
Checking the pressure regulator
Connect the diagnosis tester No. 8140595. Select

the function OPERATING DIAGNOSIS from the
menu. Select the function PUMP DIAGNOSIS.
10
Operate the function with the under panel feed on and the engine off. The control unit operates the pump for
30 seconds.
chap. 10
Release 00
2001-12
10-27
Fuel injection
500-4T
Let the system bleed for a few seconds. Make sure that there is no external blow-by. Check the regulation pressure with a pump supply voltage higher than 12 V. Regulation pressure = 300 320 KPa
(3 3,2 bar)
NO
YES
The pressure regulator works correctly
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.
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).
YES
10-28
Release 00
NO
2001-12
chap. 10
Fuel injection
500-4T
YES
NO
Replace the pressure regulator
Replace the fuel pump
Refer to the check of the pump support.
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.
Let the system bleed for a few seconds. Make sure

that there is no external blow-by. By means of longflat-nose pliers, throttle the return pipeline momentarily 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)
10
YES
chap. 10
NO
Release 00
2001-12
10-29
Fuel injection
500-4T
Check the system seal
The pressure is lower
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)
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).
NO
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 belonging to the specific tool. This operation makes the fuel
pressure increase.
YES
The system seal is good.
Check if the pressure decreases with the same tendency as the system without throttling.
The pressure decreases much more slowly

Replace the pressure regulator (refer to the check
of the pump support). Check the system seal again.
10-30
Release 00
2001-12
chap. 10
Fuel injection
500-4T
No tendency variations
Repeat the test by throttling the pipe of the
specific tool No. 8140181 in the area between by-pass and injector. Check if the
pressure decreases with the same tendency
as the system without throttling.
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 between by-pass and injector. Check if the
pressure decreases much more slowly.
YES
The single-acting valve of the pump is faulty.

Replace the pump (refer to the check of the
pump support).
10
NO
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.
chap. 10
Release 00
2001-12
10-31
Fuel injection
500-4T
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)
YES
NO
The fuel filter is not obstructed. It is possible to keep on using it for no more than
48000 km (30,000 miles).
10-32
Release 00
The delivery is lower than 250 cc (15.25 cu.in)

The fuel filter is dirty. Replace the pump support.
2001-12
chap. 10
Fuel injection
500-4T
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
13-23
Conditions
During timing of the pump
with the engine stopped
Standard
Battery tension
CIRCUIT DIAGRAM
INTERRUTTORI STOP
24
RELE
LUCI
STOP
Ar/V
B 15A
C 15A
E 3A
A 15A V/R
D 15A
F
Gr/N
R/B
R/M
Ar/V
1
2
5
3
M/N
R/N
Gr/N
Ar/V
85
86
87
30
B
R/M
R/M
Gr/R
INTERRUTTORE
CAVALLETTO
LATERALE
Ar/Bi
R/M
CENTRALINA E.C.U.
N
52
1
2
3
4
R/B
5
6
7
8
9
10
11
12
Gr/R
13
14
15
16
17
18
19
Ar/Bi
20
21
22
23 N
24
25 Gr/N
26
10
P
5
6
9
10
COIL
SPARK PLUG
10
SECONDARY INJECTION RELAY
FUEL INJECTOR
24
SECONDARY FUSES (15A)
FUEL PUMP
52
ECU CONTROL UNIT
chap. 10
Release 00
2001-12
10-33
Fuel injection
500-4T
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".
The injector control circuit is

efficient. Proceed with injector
hydraulics control.
No injector openings are

revealed.
The fuel injection tester responds
"test completed successfully".
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
10-34
YES
Release 00
2001-12
NO
chap. 10
Fuel injection
500-4T
Check the pump relay control circuit (see the

pump supply wiring diagram)
HV coil failure is indicated.
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%
10
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.
Replace the injector.
Reset the continuity or replace the harness.
chap. 10
Release 00
2001-12
10-35
Fuel injection
500-4T
REVOLUTIONS SENSOR
Terminals
7-12
Conditions
Starting speed
Standard
0,8 - 4.5 V~
CIRCUIT DIAGRAM
52
CENTRALINA
E.C.U.
ECU CONTROL
UNIT
N
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
B
B/N
1
2
MULTIPLE CONNECTORS
52
ECU CONTROL UNIT
ENGINE REVOLUTION SENSOR
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:
INDICATOR ON
10-36
Release 00
10
2001-12
SEC
INDICATOR OFF
chap. 10
Fuel injection
500-4T
To control the sensor and related circuit proceed as follows:

Connect the diagnosis tester No. 8140595. See the relative paragraph. Start the engine.
YES
NO
The engine starts normally

Select the errors function from the menu. Check for
the presence of anomalies concerning the
"signals panel".
The engine does not start

Select the errors function from the menu.
NO
No anomaly is
revealed.
YES
Proceed according
to the indication
revealed
NO
IThe value increases

progressively with time,
insisting with engine
ignition.
Check the circuit and
the sensor.
10
YES
chap. 10
Release 00
2001-12
10-37
Fuel injection
500-4T
YES
Disconnect the connection between the phaserevolutions 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
Check the earthing isolation between one pole and

the shielding.
+ = infinity (>1M)
S -
YES
Replace the revolutions

sensor.
NO
Check the harness and, if necessary, take the

measurement from the control unit PIN.
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.
10-38
Release 00
2001-12
chap. 10
Fuel injection
500-4T
HV COIL
Terminals
20-23
Conditions
During pump timing
with engine stopped
Standard
Battery tension
CIRCUIT DIAGRAM
RELAY
RELE
LUCI
LIGTHS
STOP
STOP
COIL
SPARK PLUG
FUEL INJECTOR
FUEL PUMP
24
Ar/V
B 15A
C 15A
E 3A
A 15A V/R
D 15A
F
Gr/N
R/B
R/M
Ar/V
10 SECONDARY INJECTION RELAY
1
2
5
3
85
86
87
30
B
R/M
M/N
R/N
Gr/N
Ar/V
INTERRUTTORE
SIDE
STAND
CAVALLETTO
LATERALE
SWITCH
R/M
Gr/R
4
SWITCH
INTERRUTTORI
STOP STOP
Ar/Bi
R/M
ECU CONTROLE.C.U.
UNIT
CENTRALINA
N
52
1
2
3
4
R/B
5
6
7
8
9
10
11
12
Gr/R
13
14
15
16
17
18
19
Ar/Bi
20
21
22
23 N
24
25 Gr/N
26
24 SECONDARY FUSES (15A)
P
5
6
7
52 ECU CONTROL UNIT
10
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:
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.
10
Test completed successfully
Test failed
Select the errors function

from the menu.
Check for the presence of
current or memorized errors
with respect to the HV coil
Repeat the test
NO
chap. 10
Test failed
YES
Check the continuity of the HV coil on LV and HV sides
Release 00
2001-12
10-39
Fuel injection
500-4T
NO
The coil circuit control is

efficient.
Proceed with secondary

control of the della HV coil,
cable and shield cover
YES
Check continuity of the HV coil primary

See diagram
Resistance of the primary = 0,5 8%
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)
YES
10-40
Release 00
2001-12
NO
NO
chap. 10
Fuel injection
500-4T
YES
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%
YES
The coil conforms.

NO
NO
NO
Replace the coil.
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.
10
For full information concerning the spark plug, see the

chapter "Maintenance" Chapter. GENERAL INFORMATION 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.
chap. 10
Release 00
2001-12
10-41
Fuel injection
500-4T
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.
10-42
Release 00
2001-12
chap. 10
Fuel injection
500-4T
- 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 traditional 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

Terminals
4-22
Conditions
coolant temperature
Standard
With sensor connected:
20 = 2500 100
80 = 308 6
CIRCUIT DIAGRAM
43
TO TEMPERATURE
INDICATOR
36
x1000r/min
mp/h
Km/h
EFI
Bi/N
N
ABS
42
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1
Ro
M
Ar/R
M
B
TRIP
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Ro/G
Gr
SET
Bi/N
Ro
M/Bi
10
Ar
M/G
Ro/G
Ar/N
Ro/N
24
Ar/N
Gr
N
B 15A
C 15A
E 3A V/R
A 15A
D 15A
F
Gr
Ar
Ar/R
Bi/N
Gr
Ro/N
Gr
M/Bi
M/G
CENTRALINA
ECU
CONTROLE.C.U.
UNIT
N
52
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
13
14
15
36
FALL SENSOR
42
43
DASHBOARD
24 SECONDARY FUSES
52
ECU CONTROL UNIT
chap. 10
Release 00
2001-12
10-43
Fuel injection
500-4T
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.
YES
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.
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
10-44
Release 00
2001-12
chap. 10
Fuel injection
500-4T
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.
RESISTANCE
9.6 k
5.975 k
3.81 k
2.5 k
1.68 k
0.3 k
TEMPERATURE
-10 C (14 F)
0 C (32 F)
+10 C (50 F)
+20 C (68 F)
+30 C (86 F)
+80 C (176 F)
NO
YES
Replace the sensor.

Check harness and/or control unit.
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 temperature and resistance values. Check by following the
table.
AIR INTAKE TEMPERATURE SENSOR

Terminals
Conditions
Standard
18-22
air intake temperature 20C (68F) With sensor connected: 3750 200
CIRCUIT DIAGRAM
43
36
x1000r/min
mp/h
Km/h
EFI
Bi/N
N
ABS
42
M/Bi
Ar
M/G
Ro/G
Ar/N
Ro/N
24
Ar/N
Gr
N
B 15A
C 15A
E 3A V/R
A 15A
D 15A
F
Gr
Ar
Ar/R
Bi/N
Gr
Ro/N
Gr
M/Bi
M/G
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
52
CENTRALINA
E.C.U.
ECU
CONTROL
UNIT
Ro
M
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Ar/R
M
B
10
TRIP
Ro/G
Gr
SET
Bi/N
Ro
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
13
14
15
36
FALL SENSOR
42
43
DASHBOARD
24 SECONDARY FUSES
52
ECU CONTROL UNIT
chap. 10
Release 00
2001-12
10-45
Fuel injection
500-4T
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.
NO
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
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)
YES
The air intake temperature sensor is probably

giving a correct indication.
NO
Do not connect the control unit connector
10-46
Release 00
2001-12
chap. 10
Fuel injection
500-4T
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.
RESISTANCE
9.6 k
5.975 k
3.81 k
2.5 k
1.68 k
TEMPERATURE
-10 C (14 F)
0 C (32 F)
+10 C (50 F)
+20 C (68 F)
+30 C (86 F)
NO
Proceed with sensor replacement.

YES
Check the harness and/or the control unit.
10
chap. 10
Release 00
2001-12
10-47
Fuel injection
500-4T
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
Proceed with replacement of the fuel injection control unit.

NO
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
YES
The ambient pressure

signal is correct.
10-48
Release 00
NO
Replace the fuel injection

control unit.
2001-12
chap. 10
Fuel injection
500-4T
T.P.S.=THROTTLE POSITION SENSOR

Terminals
1-22
11-22
Conditions
Ignition set to "ON"
Opening the throttle gradually
progressive
Standard
5V
Volt=
progressive increase
CIRCUIT DIAGRAM
43
36
x1000r/min
mp/h
Km/h
EFI
Bi/N
N
ABS
42
1
Ro
M
Ar/R
M
B
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
TRIP
Ro/G
Gr
SET
Bi/N
Ro
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
M/G
Ro/G
Ar/N
Ro/N
24
Ar/N
Gr
N
B 15A
C 15A
E 3A V/R
A 15A
D 15A
F
Gr
Ar
Ar/R
Bi/N
Gr
Ro/N
Gr
M/Bi
M/G
CENTRALINA
E.C.U.
ECU
CONTROL
UNIT
Ar
52
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
M/Bi
13
14
15
MULTIPLE CONNECTORS
36
FALL SENSOR
ACCELERATOR SENSOR
42
14
ENGINE AIR THERMISTOR
43
DASHBOARD
15
DASHBOARD/ENGINE WATER THERMISTOR
52
ECU CONTROL UNIT
24
SECONDARY FUSES
1
13
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.
10
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
chap. 10
Release 00
YES
2001-12
10-49
Fuel injection
500-4T
NO
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
Gradually open the throttle valve,

check that mV indication
Increases gradually in proportion to opening variations.
YES
The TPS conforms.

NO
YES
YES
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.
10-50
Release 00
2001-12
chap. 10
Fuel injection
500-4T
STEPPER MOTOR
CIRCUIT DIAGRAM
Vi
24
Az
Ar/N
Ar/N
B 15A
C 15A
E 3A V/R
A 15A
D 15A
F
N
Ro
Az
Ro
G
Vi
ECU CONTROLE.C.U.
UNIT
CENTRALINA
52
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
MULTIPLE CONNECTORS
24
SECONDARY FUSES
STEPPER MOTOR
52
ECU CONTROL UNIT
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.
10
chap. 10
Release 00
2001-12
10-51
Fuel injection
500-4T
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.
YES
NO
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
YES
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".
YES
10-52
NO
Release 00
2001-12
NO
chap. 10
Fuel injection
500-4T
NO
NO
Check the coolant temperature sensor signal. See the

relative paragraph.
If necessary check the control unit.
YES
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.
NO
YES
Test failed
No revolutions variation

Revolutions variations perceived.
Stepper and related circuit are efficient.

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.
10
NO
If the valve does not move, replace the throttle body.

See Chapter. THERMAL UNIT AND TIMING SYSTEM.
chap. 10
Release 00
2001-12
10-53
Fuel injection
500-4T
YES
Proceed with control of the stepper circuit.
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
NO
Check the continuity of the four stepper supply lines and the earthing insulation of the four stepper
supply lines.
YES
Check the earthing isolation of the 4

wires of the stepper.
14-23 = >1M (infinity)
NO
YES
NO
10-54
Release 00
2001-12
chap. 10
Fuel injection
500-4T
NO
NO
Repair or replace the harness.

YES
Connect the stepper connector.

Repeat continuity control of the tool pins.
14-24 = ~ 51
6-21 = ~ 51
If necessary, replace the control unit.
YES
The stepper circuit is efficient.
NO
Check the control unit connection

If necessary replace
la control unit.
10
chap. 10
Release 00
2001-12
10-55
Fuel injection
500-4T
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:

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
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.
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.
10-56
Release 00
Repair according to the

indications given.
2001-12
chap. 10
Fuel injection
500-4T
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)
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 increase/decrease the value set on the display and
check the value on the exhaust analyser display.
YES
Regulation is correct.
NO
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.
10
The display shows the words "TRIMMER VALUE".

The numeric indication may be positive or negative.
chap. 10
Release 00
2001-12
10-57
Fuel injection
500-4T
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:
TRIMMER
VALUE
+100
FUEL INJECTION TIMING
CO
HIGH
INCREASES
+ 50
+ 10
0
MEDIUM
- 10
- 50
-100
LOW
DECREASES
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.
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 CO2 value does not fall within the preset values, LAMBDA
value will also be false.
In this case check accurately the exhaust system seal.
10-58
Release 00
2001-12
chap. 10
Fuel injection
500-4T
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.
10
chap. 10
Release 00
2001-12
10-59
Fuel injection
500-4T
ELECTRICAL FAN CONTROL CIRCUIT
Terminals
Conditions
5-23
Standard
Set ignition to position "ON"

Switch on "RUN"
Side stand raised
Electrical fan stopped
Battery
tension
CIRCUIT DIAGRAM
38
35
24
Ar/N
Vi/N
V
Ar/N
B 15A
V/N
C 15A
E 3A V/R
A 15A
D 15A
F
R/Bi
ECU CONTROLE.C.U.
UNIT
CENTRALINA
52
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
G/N
R/Bi
Vi/N
V
V/N
R/Bi
30
87
85
86
B
G/N
++
B
G/N
16
MULTIPLE CONNECTORS
35
KEY SELECTOR
16
FAN
38
FAN RELAY
24
SECONDARY FUSES
52
ECU CONTROL UNIT
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.
10-60
Release 00
2001-12
chap. 10
Fuel injection
500-4T
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.
YES
NO
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.
YES
NO
NO
Test failed.
The fan does not rotate.
Test completed successfully.

The fan rotates.
The electrical ventilation system conforms.
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.
10
chap. 10
Release 00
2001-12
10-61
Fuel injection
500-4T
Disconnect the electrical fan control

electromagnetic switch
Check continuity of the excitation coil.
85 - 86 = 15050
NO
YES
Replace the electromagnetic switch.
Reset or replace the harness.
10-62
Release 00
2001-12
chap. 10
Fuel injection
500-4T
REVOLUTIONS COUNTER CONTROL CIRCUIT
Terminals
Conditions
Standard
Ignition set to "ON"

Switch set to "RUN"
Side stand raised
Engine stopped
3 - 23
9 - 10 Volt
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:
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.
NO
YES
The control circuit of the revolutions counter is

working.
Repair or replace the harness.
10
chap. 10
Release 00
2001-12
10-63
Fuel injection
500-4T
NOTES
10-64
Release 00
2001-12
chap. 10
Lubrication
500-4T
11
Lubrication
chap. 11
Release 00
2001-12
11-1
Lubrication
500-4T
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

5W/40
specification API SJ
Oil pump
Type
Trochoidal
Rotor thicknesses
8 mm (0.31 in)
Assembly clearances
lobe ends 0.05 - 0.008 mm

(0.002 - 0.0003 in)
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)
Type
piston
Piston diameter
-0.039
-0.0015
13.9 -0.057
mm (0.54 -0.0022
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

signal switch
Calibration
0.3 - 0.6 bar (0.01 - 0.02 Psi)
Head ubrication control

jet
Diameter
1 0.05 mm
(0.039 0.002 in)
Piston cooling nozzle
Diameter
0.8 0.05 mm
(0.031 0.002 in)
Crankcase ventilation
control
Device
metal reed valve

and decanting chamber
11-2
Release 00
By-pass
2001-12
chap. 11
5 - 7 Nm
(3.7 - 5.1 Nm)
Lubrication
500-4T
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 provides 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.
chap. 11
Release 00
2001-12
11-3
11
Lubrication
500-4T
DIAGNOSTICS GUIDE
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.
YES
NO
Check and reset the electrical

system.
Control the actual oil pressure.
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
IMPORTANT
Measure the pressure with a cold idling engine.

Standard values: 20C (176F) Temperature
~ 4.5 bar (65.25 Psi)
1400 rpm.
The revolutions may be revealed by either the exhaust gas analyser or diagnosis
tester.
NO
YES
Allow the engine to warm up and repeat the control with warm oil.
Standard values: 80C (176F) Temperature
~ 1.5 bar
1400 rpm.
(21.75 Psi)
YES
Pressures of less than 4 bar

revealed.
11-4
Release 00
Replace the minimum

oil pressure switch.
2001-12
NO
Pressures of less than

1.3 - 1.5 bar (18.85 - 21.75 Psi)
revealed.
chap. 11
Lubrication
500-4T
Replace the oil filter and repeat the pressure control with oil at 80C.
YES
The anomaly is resolved.

Recommend respect for the advised
miles covered.
NO
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.
NO
Replace damaged components

(chapter FLYWHEEL COVER).
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
YES
Proceed with engine overhaul (chapter

CRANKCASE AND DRIVING SHAFT MOTOR).
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).
chap. 11
Release 00
2001-12
11-5
11
Lubrication
500-4T
CHECKING THE OIL PUMP

Remove the two screws and the oil pump cover.
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.
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.
11-6
Release 00
2001-12
chap. 11
Lubrication
500-4T
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.
11
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)
chap. 11
Release 00
2001-12
11-7
Lubrication
500-4T
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)
YES
NO
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.
YES
Proceed with efficiency checks of the

unidirectional reed valve and the drainage hole of
the decanting chamber.
NO
Reset efficiency of the valve

or the drainage hole.
YES
NO
Proceed with seal checks of the thermal unit

(elastic clamps, valve guides and oil seals),
see chapter THERMAL UNIT AND TIMING SYSTEM.
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).
11-8
Release 00
2001-12
chap. 11
Cooling system
500-4T
12
Cooling system
chap. 12
Release 00
2001-12
12-1
Cooling system
500-4T
Expansion tank
Radiator
Drainage 2
Cylinder
3-way thermostat
integrated into the
pump cover
Head
Drainage 1
12-2
Release 00
2001-12
chap. 12
Cooling system
500-4T
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)
Type
injection operated
Initial electroventilation
106 C (222.8 F)
End electroventilation
98 C (208.4 F)
Type
centrifuge
Command
coaxial to the counter shaft
RADIATOR
Type
in aluminium with horizontal circulation
EXPANSION TANK
Type
self-discharging, parallel to the

radiator
ELECTROVENTILATION
WATER PUMP
12
chap. 12
Release 00
2001-12
12-3
Cooling system
500-4T
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 working.
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.
MAX
MIN
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.
12-4
Release 00
2001-12
chap. 12
Cooling system
500-4T
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.
CAUTION
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.
THERMOSTAT CONTROL
12
Before dismantling it is advisable to carry out certain

checks:
Connect the diagnosis tester and select the PARAMETERS function (see Chapter FUEL INJECTION);
Start the engine from cold and allow it to warm.
Check manually the moment in which heating commences 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 thermostat temperature is referred to the pump inlet.
chap. 12
Release 00
2001-12
12-5
Cooling system
500-4T
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 thermostat.
THERMOSTAT
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.

CAUTION
For correct trial testing, avoid direct contact

between the thermostat and the container.
On revealing incorrect values, replace the thermostat;

Reassemble the thermostat and its cover as described in Chapter FLYWHEEL COVER;
Repeat the procedure from filling to discharge.
12-6
Release 00
2001-12
chap. 12
Cooling system
500-4T
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 electrical 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.
12
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 instrument 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.
chap. 12
Release 00
2001-12
12-7
Cooling system
500-4T
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 regulation 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.
YES
NO
Check gasket seal of the head (see Chapter

THERMAL UNIT AND TIMING SYSTEM)
Replace the plug.
Coolant consumption
Check external seals of the system as described previously.

YES
NO
Check gasket seal of the head (see Chapter

THERMAL UNIT AND TIMING SYSTEM)
Proceed to repair of the damaged seals.
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)
12-8
Release 00
2001-12
chap. 12
Starting
500-4T
13
Starting
chap. 13
Release 00
2001-12
13-1
Starting
500-4T
SPECIFICATIONS
STARTING MOTOR
BATTERY
SOLENOID
STARTER
STARTING
TRANSMISSION
Type
MITSUBA SM13D
Power
0.9 kW
Capacity
14Ah
Starting current
125 A
Type
HERMETIC
Capacity
150A continuous
Crown and free wheel coaxial to the flywheel.

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.
13-2
Release 00
2001-12
chap. 13
Starting
500-4T
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/m3 (2.11 - 2.12 lb/cu yd)
NO
Recharge and if necessary replace the battery

YES
Check correct connection of the negative terminals

(battery negative and starting motor
negative) between themselves and the chassis.
NO
13
Reset the connections.

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.
chap. 13
Release 00
2001-12
13-3
Starting
500-4T
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.
YES
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
NO
The motor is efficient
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.
YES
NO
Replace definitively the solenoid starter.
Repeat the battery controls

and if necessary replace
the starting motor.
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.
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).
13-4
Release 00
2001-12
chap. 13
ATLANTIC 500
I
Aggiornamento 2004 - UK Update 2004
Mise jour 2004 - D Aktualisierung 2004 - E Actualizacin 2004
Presa cuffia per radio interfono

Presente sul codone e sullo scudo interno a fianco del vano porta documenti.
I
UK Headset intercom outlet

On the tail guard and on the inner shield, close to the glove compartment.
Prise couteurs pour radio-interphone

F
Existant sur le corps de selle et sur le bouclier interne, ct du dgagement porte-documents.
Kopfhreranschluss fr Radio-/Sprechanlage
Sie ist der Heckverkleidung und an der inneren Abdeckung seitlich des Dokumentenfachs
vorhanden.
D
E
Toma auricular para la radio-interfono
Presente en el cuerpo asiento y en el escudo interno a la par del portadocumentos.
I
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 radiofrequenza 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.
UK 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 system 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 ignition 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
F
Tmoin antivol (systme antidmarrage lectronique immobiliseur) (
sive contre le vol. Il confirme que le systme antivol est actif.
). Lorsque la moto est teinte, il clignote de manire dissua-
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.
pag. 1
ATLANTIC 500
I
Immobilizer- Wegfahrsperre
Kontrollleuchte - Diebstahlsicherung (Immobilizer) (
zeigt gleichzeitig an, dass die Wegfahrsperre aktiv ist.
D
). Bei abgestelltem Motor blinkt die Kontrollleuchte zur Abschreckung auf und
WICHTIG Es kommt oft vor, dass ein gestohlenes Fahrzeug aufgrund der Daten, die in der Betriebs- und Wartungsanleitung eingetragen 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 Kopie 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 Signal stellt das Password dar, anhand dessen das entsprechende Steuergert den eingesteckten Schlssel erkennt und nur in diesem
Fall einen Anlass des Motors ermglicht.
E
Antirrobo Immobilizer
Testigo antirrobo (immobilizer) (
antirrobo est activado.
IMPORTANTE
). Con la moto detenida mantiene un destello disuasivo contra robos. Confirma que el sistema de
En muchos casos, los vehculos robados son identificados a travs de los datos anotados en el manual de uso y
mantenimiento.
IMPORTANTE
tor
by
Para aumentar la proteccin contra robos, el vehculo est dotado de un sistema electrnico de bloqueo mo, 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.
I
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.
UK 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

F
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
D
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.
E
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
I
Power outlet
The 12V power outlet is on only when ignition switch is turned
UK
Prise de courant
F
La prise de courant 12V n'est alimente qu'aprs dplacement sur
du contacteur d'allumage cl.
Stromanschluss
D
Der 12V-Stromanschluss ist erst nach dem Umstellen des Zndschlsselschalters auf die Postion
funktionstchtig.
E
Toma de corriente
La toma de corriente de 12V funciona solamente despus de haber girado el interruptor de encendido a llave en posicin
pag. 2
I
ATLANTIC 500
43
!!
39
SCROLL
25
x1000r/min
mp/h
Km/h
EFI
EFI
PASSING
37
STOP
B
G
ABS
30
85
86
87
1
V/Bi
V/R
V/N
R/Bi
G/Vi
R/Gr
G/N
V/G
G/R
55
Gr/N
G/Vi
N
N
R/Gr
V/G
G/R
V/N
V/N
V/N
R/N
30
87
85
86
G/N
R/Bi
Vi/N
V
G/M
G/N
B/Bi
Bi/G
Ar
V
Bi
V
V/Bi
N
R/B
B/N
Az/Bi
B
V
Gr
1
R/N
B/Bi
M
Ro
V
R/N
V/G
G/N
N
Gr
1
Gr
Ro
M
Bi
V/N
R
B/N
Az
B
Bi/N
N
40
1
Ro/G
Gr
R/Bi
V
B
M/Ro
35
57
28
1 2
N
N
V
B/Ar
Ar
Bi/N
Ro
G
Bi
N
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Gr/B
Gr/Bi
B/Ar
B
Ar/N
B
G/V
B/N
R/B
Az/Bi
Bi/G
R/Bi
R/Bi
Az/R
B/Bi
Vi
M/V
R
Az
42
Gr/N
B/G
B
V/G
TRIP
Gr/Bi
G/B
B
Az/V
Ro/G
Gr/B
Ar/R
M
B
B/Ar
Gr/Bi
V
Ar/N
SET
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Vi
56
R/Bi
R
B
46
34
38
26
33
36
44
45
V/G
B
R
B
48
51
N
B
49
R
N
B
Bi
G
Az
R
N
B
Bi
G
Az
B
Bi
B
Bi
G
B
G
B
R
V/G
G
B
R
V/G
G
B
G
V/G
B
Az
G
V/G
B
Az
50
R
M
54
UK
R/Gr
V
Ar/N
Ar/V
Ar
G/N
58
31
54
31
53
30
27
V/N
V/N
R/Bi
R/Bi
V/Bi
V/N
5 N
4 N
3 N
2
6
N
1
59
B
G/R
B
R/Bi
B/Bi
30A V/R
20A R/Bi
1
B
G/N
R
R
N
N
V/R
V/R
G
G
G
Gr
Ar
Ar/R
Bi/N
22
G
G
G
Gr
M/Bi
M/G
V
V
R/Bi
R/Bi
B
G/N
P
2
R/M
Ro/G
V/G
N
V
M
FUSE F
Gr
Ro/N
G/B
M/N
M/V
B
R/M
V
V/Bi
1
2
3
5
Gr/N
R/B
R/M
Ar/V
1
2
5
3
85
86
87
30
B
R/M
Ar/N
G/V
Ar/Bi
R/M
R/M
Gr/R
Az
Ro
G
Vi
FUSE E
M/N
R/N
Gr/N
Ar/V
FUSE D
R
R
V/R
R/Bi
24
FUSE C
N
B 15A
C 15A
E 3A
A 15A
D 15A
F7.5A
23
31
58
31
G/M
G/Vi
B/G
M/Ro
G/N
B
B
1 3 2
FUSE B
32
54
Gr/Bi
FUSE A
SPARE I SPARE H SPARE G
41
G
B
G
B
G
G
G
52
E.C.U.
47
FUSE A 15A
FUSE B 15A
FUSE C 15A
FUSE D 15A
FUSE E 3A
FUSE F 7.5A
SPARE G 15A
SPARE H 3A
SPARE I 7.5A
B
Az
1
M/Bi
1
V/G
2
Az/R
3
Ar
4
R/B
5
Vi
6
B
7
Ro/G
8
M
9
10 R
11 M/G
12 B/N
Gr/R
13
14 Az
Az/V
15
16 Ro/G
Ar/N
17
18 Ro/N
Vi/N
19
Ar/Bi
20
G
21
Gr
22
N
23
Ro
24
25
Gr/N
26
N
B
Az
29
V/G
G
B
G
V/G
B
10
58
11
12
13
14
15
16
17
18
19
20
21
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 H2O 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-abbaglianti

59) Ponticello
1) Multiple connectors
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 H2O 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
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
pag. 3
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
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
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
ATLANTIC 500
43
!!
39
SCROLL
25
x1000r/min
mp/h
Km/h
EFI
EFI
PASSING
37
STOP
B
G
ABS
55
Gr/N
G/Vi
N
N
30
85
86
87
V/Bi
V/R
V/N
R/Bi
G/Vi
R/Gr
G/N
Gr/N
B/G
B
V/G
R/Gr
V/G
G/R
V/N
V/N
V/N
R/N
V/G
G/R
G/N
R/Bi
Vi/N
V
30
87
85
86
1
R/N
B/Bi
M
Ro
V
G/N
N
Gr
R/N
V/G
G/M
G/N
B/Bi
Bi/G
Ar
V
Bi
V
V/Bi
N
V
Gr
R/B
B/N
Az/Bi
B
Ro
M
Bi
V/N
R
B/N
Az
B
Gr
40
Ro/G
Gr
R/Bi
V
B
Bi/N
N
28
1 2
N
N
M/Ro
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
35
57
42
V
B/Ar
Ar
Bi/N
Ro
G
Bi
N
B
Ar/N
B
G/V
B/N
R/B
Az/Bi
Bi/G
R/Bi
R/Bi
Az/R
B/Bi
Vi
M/V
R
Az
Gr/Bi
G/B
B
Az/V
Ro/G
Gr/B
Ar/R
M
B
B/Ar
Gr/Bi
V
TRIP
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Vi
56
R/Bi
R
B
46
SET
Gr/B
Gr/Bi
B/Ar
Ar/N
26
34
38
45
33
36
44
V/G
B
R
B
48
51
N
B
49
R
N
B
Bi
G
Az
R
N
B
Bi
G
Az
B
Bi
B
Bi
G
B
G
B
R
V/G
G
B
R
V/G
G
B
G
V/G
B
Az
G
V/G
B
Az
50
R
M
54
B 15A
C 15A
E 3A
A 15A
D 15A
F7.5A
V/N
V/N
R/Bi
R/Bi
V/Bi
V/N
58
31
54
31
53
30
27
5 N
4 N
3 N
2
6
N
1
59
B
G/R
B
R/Bi
B/Bi
N
N
V/R
V/R
30A V/R
20A R/Bi
G
G
G
B
G/N
1
V
V
R/Bi
R/Bi
22
G
G
G
Gr
Ar
Ar/R
Bi/N
Gr
Ro/N
Gr
M/Bi
M/G
R/M
Ro/G
V/G
B
G/N
P
2
1
N
V
M
FUSE F
G/B
M/N
M/V
B
R/M
V
V/Bi
Gr/N
R/B
R/M
Ar/V
1
2
3
5
1
2
5
3
FUSE E
85
86
87
30
B
R/M
Ar/N
G/V
Ar/Bi
R/M
R/M
Gr/R
Az
Ro
G
Vi
FUSE D
M/N
R/N
Gr/N
Ar/V
R
R
V/R
R/Bi
24
FUSE C
N
31
23
R/Gr
V
Ar/N
Ar/V
Ar
G/N
R
R
FUSE B
31
58
G/M
G/Vi
B/G
M/Ro
G/N
B
FUSE A
SPARE I SPARE H SPARE G
41
FUSE A 15A
FUSE B 15A
FUSE C 15A
FUSE D 15A
FUSE E 3A
FUSE F 7.5A
SPARE G 15A
SPARE H 3A
SPARE I 7.5A
32
54
Gr/Bi
B
1 3 2
G
G
G
52
E.C.U.
47
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
Gr/N
26
N
B
Az
G
B
G
B
G
V/G
B
B
Az
1
M/Bi
V/G
Az/R
Ar
R/B
Vi
B
Ro/G
M
R
M/G
B/N
Gr/R
Az
Az/V
Ro/G
Ar/N
Ro/N
Vi/N
Ar/Bi
G
Gr
N
Ro
29
V/G
G
B
10
58
11
12
13
14
15
16
17
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) H2O-Thermistor Motor/Instrumentenbrett
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 Sicherungen
42) Thermistor Lufttemperatur / Instrumentenbrett
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)
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 fusibles
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 versin USA)
57) Antena immobilizer
58) Rel encendido faros luces de crucede carretera
59) Puente
pag. 4
19
18
20
21
57) Immobilizer-Antenne
58) Relais fr Einschaltung der Abblend-/
Fernlichter
59) berbrckung
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APRum_INTERFONO#02_CAP01e01.FM Page 20 Friday, March 14, 2003 10:15 AM
NOTE
ASK FOR GENUINE SPARE PARTS ONLY

20
use and maintenance Radio MOB Control
APRum_INTERFONO#02_CAP01s01.FM Page 1 Saturday, March 8, 2003 10:40 AM
DISPOSITIVO DE COMUNICACIN INTEGRADA
2003 aprilia s.p.a. - Noale (VE)
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.
Primera edicin: Febrero 2003
PELIGRO
Indica un riesgo potencial de graves
lesiones o muerte.
ATENCIN
Indica un riesgo potencial de lesiones
leves o daos al vehculo.
Reimpresin:
Redactado e impreso por:
DECA s.n.c.
Via Risorgimento, 23/1 - Lugo (RA) - Italia
Tel. +39 - 0545 35235
Fax +39 - 0545 32844
E-mail: deca@decaweb.it
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
uso y mantenimiento Radio MOB Control
IMPORTANTE
el
trmino
"IMPORTANTE" en el presente manual
precede importantes informaciones 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-PRECAUCIONESAVISOS GENERALES
IMPORTANTE
Este manual debe

ser considerado parte integrante del kit
radio interfono y siempre debe
acompaarlo, incluso en caso de reventa.
aprilia ha realizado este manual prestando
la mxima atencin a la seriedad y
actualidad de las informaciones
suministradas.
Sin embargo, en consideracin del hecho
que los productos aprilia estn sujetos a
continuas mejoras de proyectacin,
podran existir ligeras diferencias entre las
caractersticas del vehculo en su posesin
y las descritas en el manual. Para
cualquier aclaracin relativa a las
informaciones contenidas en el manual,
contactar a su Concesionario Oficial
aprilia.
Les agradecemos por haber elegido
aprilia.
Los derechos de memorizacin
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:
OPT
opcional
INDICE GENERAL
INTRODUCCIN
El sistema de comunicacin integrado
APRILIA RADIO MOB CONTROL,
especficamente desarrollado 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
activacin independiente del ruido
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
central
detecta
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 las teclas permite 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 dispositivo en un centro de
asistencia aprilia.
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
PERSONALIZACIN DEL DISPOSITIVO EN EL

VEHCULO
HERRAMIENTAS EN DOTACIN
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:

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:
Confirma el logo elegido y enciende el

OK/Men dispositivo
El logo queda memorizado tambin en caso de desactivacin de

la batera.
4
LEYENDA
1) Conector a jack
2) Clip para fijacin al casco
3) Altoparlante casco
4) Micrfono
INSTRUMENTOS E INDICADORES
5
1
3
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
)
)
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
Desplazamiento del men hacia el final (hacia la

derecha)
- Presin breve: bsqueda automtica

- Presin larga: desplazamiento manual
Bsqueda memorias hacia abajo en modalidad SS
Bsqueda frecuencia hacia abajo en modalidad MS
Desplazamiento del men hacia el inicio (hacia la

izquierda)
- Presin breve: bsqueda automtica

- Presin larga: desplazamiento manual
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
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

Permanece en espera la llamada y permite al
(Funcin activa solo si hay una llamada telefnica en conductor hablar libremente con el pasajero
independientemente del estado del interfono.
curso)
El display visualiza las modalidades posibles para
retomar la llamada en entrada
Una presin breve
Retoma la lnea comunicando slo al conductor
Funcin activa slo si haba precedentemente en espera
una llamada telefnica
Una presin breve
Retoma la linea comunicando slo al pasajero
Funcin activa slo si haba precedentemente en espera
+
Presin
contempornea de
las teclas
y-
Una presin breve

Retoma la lnea comunicando al conductor y al
Funcin activa slo si haba precedentemente en espera pasajero.
Presin contempornea breve
Conmuta de modalidad MS a SS o viceversa
Funcin activa slo si se est escuchando la radio, con
modalidad seek o scan
DOTACIONES AUXILIARES
CABLES DE INTERCONEXIN OPT
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 OPT

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.
OPERACIONES PRELIMINARES
INSTALACIN DEL AURICULAR EN

EL CASCO
Fijar el clip elstico (1) en el borde inferior
del casco, del lado izquierdo. En la
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 tense o se desconecte, 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
la altura de la oreja, por medio 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 punto blanco en la barra del
micrfono debe estar dirigido hacia la
boca.
ATENCIN
Para
garantizar
un
buen
funcionamiento de los auriculares:
no quitar la parte de goma-espuma
colocada como proteccin del
altoparlante (5);
evitar lo ms posible que el
micrfono y el altoparlante entren en
contacto con el agua.
no est presente. Los smbolos

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 DE LOS AURICULARES

AL VEHCULO
La toma de auricular de tipo a jack (1)
permite un rpido acople tambin 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
para
evitar
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
10
CONEXIN DEL CELULAR AL

VEHCULO
El sistema de comunicacin integrado est
dotado de un especfico conector de 8
vas, colocado en una zona fcilmente
alcanzable
del
vehculo
(ver
PERSONALIZACIN DEL DISPOSITIVO
EN EL VEHCULO).
El cable de interfas entre el telfono (con
conector compatible) y el vehculo se
puede localizar en la 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
telfono celular para establecer
correctamente las funciones antes
descritas.
Los telfonos Motorola 8700, Startac 130,
CD920, CD930 y BOSCH M-com 506
deben estar apagados antes de ser
conectados al cable del vehculo. La
activacin del telfono se realiza
automticamente.
CONEXIN DE UNA FUENTE

MUSICAL EXTERNA
La central del sistema integrado 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
compartimiento bajo asiento 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.
Para permitir al cliente la mxima
personalizacin y flexibilidad 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.
ENCENDIDO/APAGADO
El encendido es posible slo con la llave
en posicin de marcha.
Presionar la tecla 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 funcionamiento retomar
regularmente cuando la llave se coloque
en posicin de marcha, manteniendo en lo
posible las condiciones establecidas
precedentes.
Es posible mantener encendido el
dispositivo (por un tiempo predeterminado,
para evitar olvidos) tambin con la llave en
posicin de parada. Ver la 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 los altoparlantes operando en los
pulsadores + y -.
La regulacin del volumen opera en la
funcin activa en ese momento. De esta
manera es posible adaptar 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 posible regular de manera
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.
11
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
(seleccin
disponibles, utilizar las teclas
hacia atrs) y
(seleccin hacia
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 confirmar el tem seleccionado,
presionar OK/ON Men.
Algunas funciones del men principal
necesitan otro men secundario (desde
ahora llamado "sub-men"). Para una
explic ac in ms completa, 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 principal) simplemente
presionando la tecla C/OFF.
12
Los tems del men y de los relativos submen se indican a continuacin:
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
Las descripciones que se indican a

continuacin, explican detalladamente las
funciones del sistema que se pueden ver
en el men.
USO DE LA RADIO
OK/ON Entra en el men
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 desactivan todas las otras
potencias del sistema RDS (frecuencia
alternativa, informaciones del trfico, PTY)
AF (alternative Frequencies) permite al
receptor enganchar de manera
automtica una frecuencia alternativa de
la misma emisora, para asegurarse una
mejor escucha.
TA (Traffic Announcement identification) Si
la emisor a sintoniz ada transmite
informaciones sobre el trfico, 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
3 veces
Desplaza la eleccin al cuarto

tem del men (RDS)
OK/ON Confirma (si entra en el submen RDS)
OK/ON Confirma el primer tem del

sub-men (off)
O:
O:
2 veces
O:
3 veces
Para
finalizar:
OK/ON
Desplaza la eleccin al
segundo tem del sub-men
(AF)
Desplaza la eleccin al tercer
tem del sub-men (TA)
La funcin AF permanece
activa.
tem del sub-men (PTY)
Las funciones AF y TA
permanecen activas
Confirma
el
tem
seleccionado
y aparece
la inscripcin AF o TA o PTY
en el display
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
emisora preferida, que se pueden
seleccionar desde el men TUNING. Las
modalidades de bsqueda se indican a
continuacin:
Seek: las teclas
realizan la
bsqueda completa de la 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 presin larga.
Manteniendo 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
13
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 la zona, que permanecen
automticamente memorizadas en las
memorias desde el 11 hasta el 20. Segn
la cantidad de emisoras presentes en la
zona y del tipo/nivel de seales
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.
Durante la sintona (sea manual,
automtica 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
14

OK/ON Co nfirma la eleccin d el
primer tem del men
(TUNING)

sub-men (Seek)
aparece la inscripcin MS en
el display
O:
OK/ON
O:
2 veces
OK/ON
OK/ON
OK/ON
Desplaza la eleccin al segundo

tem del sub-men (Scan)
Confirma
el
tem
seleccionado,
aparece la
inscripcin SS en el display
tem del sub-men (Zapping)
Confirma
el
tem
seleccionado
, aparece
el smbolo
en el
display
Activa
la
bsqueda
automtica. Durante la
bsqueda y la escucha en
secuencia de los programas,
la inscripcin ZP destella
Bloquea la bsqueda de la
emisora sintonizada
aparece nuevamente el
smbolo
en el display
Con este procedimiento se
abandona la modalidad
Zapping
O:
3 veces

tem del sub-men (Autostore)
OK/ON C o n f i r m a
el
tem
seleccionado,
aparece
una barra de progresin y
comienza el procedimiento
de memorizacin.
Al finalizar el procedimiento el
sistema se coloca siempre
automticamente en la
modalidad SS (Scan)
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 -.
Memorizacin de una emisora

Las memorias del 1 al 10 estn a
disposicin del usuario.
Se
recomienda
efectuar
la
memorizacin de las emisoras con el
vehculo parado en un lugar seguro.
La memorizacin de una emisora en
cualquiera de las primeras diez memorias
disponibles puede realizarse en cualquier
momento, si el dispositivo operativo est
en la modalidad RADIO y la funcin
TUNING est operativa en la modalidad
Seek (inscripcin MS en el display)
o
Bsqueda de la frecuencia en
modalidad
manual
o
automtica hasta que se
encuentre la emisora deseada
Presin Entra en el procedimiento de

larga de memorizacin. Abajo a la
OK/ON izquierda en el display aparece
un nmero de memoria (que
puede ser cambiado a gusto
del 1 a 10 con las teclas
) y la frecuencia de la
emisora
actualmente
memorizada. De esta manera
es posible elegir la posicin
deseada
y
evitar
superposiciones no deseadas
Para elegir el nmero de la

memoria que se desea
utilizar para la emisora que
se preseleccion.
OK/ON Confirma la memorizacin.
USO DEL INTERFONO

La funcin de interfono 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.
Sin embargo, estn previstas dos
modalidades de activacin automtica
(High y Low) para evitar que el ruido de
fondo pueda, en situaciones especiales,
activar el interfono tambin 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.
segundo tem del men
(INTERC)
OK/ON Confirma (entra en el submen)

sub-men (Off)
apaga
eventuales inscripc iones
relativas al interfono en el
display
O:
(On)
el
tem
seleccionado,
aparece la
inscripcin IC en el display.
O:
2 veces

tem del sub-men (VLOW)
el
tem
seleccionado,
aparece la
inscripcin ICL en el display.
O:
3 veces

tem del sub-men (VHIGH)
el
tem
seleccionado,
aparece la
inscripcin ICH en el display.
15
Selecciones abreviadas para 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.
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.
2 veces

tem del men (AUDIO)
OK/ON Confirma (entra en el sub-
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.
men)
2 presiones
breves en
secuencia de
OK/ON
Enciende el interfono en
modalidad Vox Low
aparece la inscripcin ICL
en el display
La desactivacin es posible repitiendo el

mando rpido o por medio del men
principal.
sub-men (Bass)
aparece el grfico de la
regulacin
O:
(Treble)
men)

sub-men (Radio)
O:
(Aux)
O:
2 veces

tem del sub-men (Off)
aparece el grfico de la
regulacin
notas agudas
para Vuelve al men principal

finalizar
C/Off
Desplaza la eleccin al quinto

tem del men (Source)
OK/ON Confirma (entra en el sub-
notas bajas
+ o - Aumenta o disminuye las
4 veces
+ o - Aumenta o disminuye las
OK/ON
16
Confirma
Para
finalizar: seleccionado
OK/ON
el
tem
USO DEL ALTAVOZ PARA

CELULAR
El men principal del dispositivo de
comunicacin integrado permite preestablecer el destino de las llamadas de
telfono en entrada.
Se recomienda efectuar el establecimiento
del men en condiciones de total
seguridad, con el vehculo parado.
5 veces
Desplaza la eleccin al sexto

tem del men (TELEPH)

sub-men (Driver)
aparece la inscripcin D en
el display.
O:
Cuando entra una llamada telefnica, la

central enva un tono especial a ambos
auriculares. Al finalizar el tono, la
comunicacin es enviada slo al piloto o al
piloto y al pasajero segn la seleccin
efectuada en el men principal.
Selecciones abreviadas para la

administracin de las llamadas
telefnicas en entrada
Durante el transcurso de una conversacin
telefnica puede ser necesario
comunicarse con el pasajero manteniendo
en espera la llamada. Es posible realizar la
comunicacin como se indica a
continuacin:
C/Off M a n t i e n e e n e s p e r a l a
llamada y permite al piloto
conversar con el pasajero
IMPORTANTE
Si est en curso una

comunicacin telefnica y el conmutador
de llave se coloca en la posicin de
parada, el dispositivo se apagar
automticamente al finalizar la
comunicacin.
(Driver+Pass)
el
tem
seleccionado,
aparece la
inscripcin DP en el display.
Todas las llamadas telefnicas
en entrada sern enviadas a
ambos, piloto y pasajero.
17
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
modalidad preferida de uso de los
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.
18

6 veces
sptimo tem del men
(SPEAKS)
OK/ON Confirma (entra en el submen SPEAKS)
APAGADO RETARDADO
Es posible mantener encendido el
dispositivo por 15 minutos ms, desde el
momento en que la llave se coloca en
posicin de parada. Esta funcin puede
ser til para mantener encendido el
dispositivo evitando que otros dispositivos
de la moto utilicen corriente de la batera.

sub-men (off)
el
smbolo de los autoparlantes
aparece con barras.
O:
(Auto)
Confirma
tem
el smbolo
de los altoparlantes est
dentro de un cuadro
rectangular
OK/ON seleccionado,
el

O:
tem del sub-men (On)
2 veces
el
tem
seleccionado

7 veces
Desplaza la eleccin al octavo

tem del men (Power)

(delay)
aparece la
inscripcin AD
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.
Si la funcin AD ha sido activada por error,

se puede desactivar desde el men:
7 veces
Desplaza la eleccin al octavo

tem del men (Power)
OK/ON C o n f i r m a e l p r i m e r t e m
seleccionado (key)
desaparece - si est presentela inscripcin AD
Nota: Para no comprometer el
encendido de la moto se recomienda no
activar ms de una vez la funcin delay
con el motor apagado.
ESPECIFICACIONES TCNICAS
Alimentacin
Absorcin con vehculo apagado
Absorcin mx. slo con auriculares
Absorcin mx. con auriculares y altoparlantes
Absorcin del circuito de la llave
Respuesta en frecuencia con altoparlantes
Respuesta en frecuencia interfono
Regulacin tonos
Micrfonos
Altoparlantes auriculares
Potencia mx. de salida en los altoparlantes exteriores
Tipo de altoparlante
10,5 16V
0 mA
500 mA
1,5 A
1,5 mA
20020000 Hz 3dB
2005000 Hz 3dB
12dB
-69 dB 3dB unidireccional
8 ohm - 0,5 W
2x7W
bi-cono
19
APRum_INTERFONO#02_CAP01s01.FM Page 20 Friday, March 14, 2003 10:28 AM
NOTAS
PIDA SOLO RECAMBIOS ORIGINALES

20
aprilia
genuine accessories
I
F
D
E
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
GB INSTRUCTIONS FOR FITTING AND USING THE TUNNEL BAG ON THE ATLANTIC SCOOTER
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.
F 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.
D 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.
E 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.
GB 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.
F 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.
D POSITIONIERUNG UND BEFESTIGUNG DER TASCHE AM

SCOOTER
Die zwei elastischen Bnder 2 (entsprechend der Abbildung) in die
Schnallen 3 der Tasche einfhren.
E 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.
GB PLACING AND SECURING THE BAG ON THE SCOOTER
2
Release 00 del 07_2002
Thread (see the drawing) the two elastic tapes 2 through the bag
buckles 3.
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.
Die Tasche auf den Scooter setzen und die beiden

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.
GB 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.
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.
Cod. 8702129

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1073 1

DASHBOARD CHECK ......................................................................................................................... 6-22

COMPLETE INSTRUMENT PANEL REMOVAL .................................................................................. 7-15

The use of open flames is forbidden under all circumstances.

BEFORE REMOVING COMPONENTS

USING THE MANUAL

NOTE Tampering with serial numbers is subject to

severe penalties. In particular, tampering with the

NOTES ON FUEL, LUBRICANTS, COOLANT AND OTHER ITEMS

DO NOT DISPOSE OF FUEL IN THE ENVIRONMENT.

HIGH TEMPERATURE COMPONENTS

PRECAUTIONS AND GENERAL INFORMATION

The use of open flames is forbidden under all circumstances.

Never reuse circlips.

2270 mm (89.4 in)

Total engine/wheel ratio

38 mm (1.5 in) and single injector

Electronic injection by electric fuel pump

high resistance steel tubes

hydraulically operated telescopic fork

disc brake - 260 mm (10.23 in) - with hydraulic transmission

F. A. 5W 67% of the volume +

Bearings and other lubrication points (recommended):

BIMOL GREASE 481 -

Brake fluid (recommended):

Use new brake fluid only.

BRAKE 5.1 DOT 5 (DOT 4 compatible).

TIGHTENING TORQUES TABLE

Steering stop plate screw

Key switch break-off screw

Key switch fixing screw

Windscreen support fixing screw

Windscreen support stop nut

Damper to frame fixing screw

Damper fixing screw, fork side

WINDSCREEN SUPPORT ASSEMBLY

STEERING DAMPER ASSEMBLY

Frame connecting rod pin

Engine connecting rod pin

Side stand screw

FRONT SUSPENSION ASSEMBLY

Steering series self-locking nut

Right and left switch

U bolts fixing screws

Vibration-damping weights fixing screws

Plate to engine fixing screw

Silencer fixing screw

Heat guard protections fixing screw

REAR SUSPENSIONS ASSEMBLY

FRONT BRAKE ASSEMBLY

Speedometer sensor screw

Coil fixing screw

Rotary switch screw

Rotary switch screw

Harness to relay clamp

M5 self-locking nuts fuel pump flange

FRONT WHEEL ASSEMBLY

REAR WHEEL ASSEMBLY

COOLING SYSTEM ASSEMBLY

Periodic Maintenance Operations

Periodic Maintenance Operations

This section describes the operations to be performed

Before performing any servicing or checks, switch