APRILIA ATLANTIC 300

SERVICE STATION MANUAL

895759

ATLANTIC 300 i.e.

SERVICE STATION

MANUAL

ATLANTIC 300 i.e.

THE VALUE OF SERVICE

Due to the continuous technical updates and specific mechanic training programs for Aprilia products,

only Aprilia Official Network mechanics know this vehicle fully and have the special tools necessary to

carry out maintenance and repair operations correctly.

The reliability of the vehicle also depends on its mechanical state. Checking the vehicle before riding, its

regular maintenance and using only Original Aprilia Spare Parts are essential!

For information about the nearest Official Dealer and/or Service Centre, consult the Yellow Pages or

search directly from the map on our Official Website:

www.aprilia.com

Only by requesting aprilia Original Spare Parts can you be sure of purchasing products that were

developed and tested together with the actual vehicle itself. All Aprilia Original Spare Parts undergo

quality control procedures to guarantee reliability and durability.

The descriptions and illustrations given in this publication are not binding; While the basic characteristics

as described and illustrated in this booklet remain unchanged, Aprilia reserves the right, at any time and

without being required to update this publication beforehand, to make any changes to components, parts

or accessories, which it considers necessary to improve the product or which are required for

manufacturing or construction reasons.

Not all versions/models shown in this publication are available in all Countries. The availability of

individual versions/models should be confirmed with the official Aprilia sales network.

prohibited. Aprilia - After-sales service.

Aprilia trademark is property of Piaggio & C. S.p.A.

SERVICE STATION MANUAL

ATLANTIC 300 i.e.

-Thismanualprovidesthemaininformationtocarryoutregularmaintenanceoperationsonyourvehicle.

- This manual is intended to aprilia Dealers and their qualified mechanics; several concepts have been

deliberately omitted as they are considered unnecessary. As it is not possible to include complete

mechanical notions in this manual, users should have basic mechanical knowledge or minimum

knowledge about the procedures involved when repairing scooters. Without this knowledge, repairing or

checking the vehicle may be inefficient or even dangerous. As the vehicle repair and check procedures

are not described in detail, be extremely cautious so as not to damage components or injure individuals.

In order to optimise customer satisfaction when using our vehicles, aprilia s.p.a. commits itself to

continually improve its products and the relative documentation. The main technical modifications and

changes in repair procedures are communicated to all aprilia Sales Outlets and its International

Subsidiaries. These changes will be introduced in the subsequent editions of the manual. In case of

need or further queries on repair and check procedures, consult aprilia CUSTOMER DEPARTMENT,

which will be prepared to provide any information on the subject and any further communications on

updates and technical changes related to the vehicle.

NOTE Provides key information to make the procedure easier to understand and carry out.

CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.

WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.

Personal safety Failure to completely observe these instructions will result in serious risk of personal

injury.

Safeguarding the environment Sectionsmarkedwiththissymbolindicatethecorrectuseofthevehicle

to prevent damaging the environment.

Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious

damage to the vehicle and sometimes even the invalidity of the guarantee.

INDEX OF TOPICS

CHARACTERISTICS CHAR

TOOLING TOOL

MAINTENANCE MAIN

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

ENGINE ENG

INJECTION INJEC

SUSPENSIONS SUSP

BRAKING SYSTEM BRAK SYS

COOLING SYSTEM COOL SYS

CHASSIS CHAS

PRE-DELIVERY PRE DE

INDEX OF TOPICS

CHARACTERISTICS CHAR

Rules

Safety rules

CARBON MONOXIDE

If you need to keep the engine running in order to carry out any procedure, please ensure that you do

so in an open or very well ventilated area.

Never let the engine run in an enclosed area.

If you do work in an enclosed area, make sure to use a smoke-extraction system.

CAUTION

EXHAUSTEMISSIONSCONTAINCARBONMONOXIDE,APOISONOUSGASWHICHCANCAUSE

LOSS OF CONSCIOUSNESS AND EVEN DEATH.

FUEL

FUEL USED TO POWER INTERNAL COMBUSTION ENGINES IS HIGHLY FLAMMABLE AND CAN

BECOME EXPLOSIVE UNDER SPECIFIC CONDITIONS. IT IS THEREFORE RECOMMENDED TO

CARRY OUT REFUELLING AND MAINTENANCE OPERATIONS IN A WELL VENTILATED AREA

WITH THE ENGINE OFF. DO NOT SMOKE WHILE REFUELLING OR WHEN CLOSE TO FUEL

VAPOURS, AVOID CONTACT WITH NAKED FLAMES, SPARKS OR ANY OTHER SOURCE THAT

MAY CAUSE FUEL TO CATCH FIRE OR EXPLODE.

CAUTION

DO NOT DISPOSE OF FUEL INTO THE ENVIRONMENT.

CAUTION

KEEP OUT OF THE REACH OF CHILDREN

HIGH-TEMPERATURE COMPONENTS

The engine and the components of the exhaust system can get very hot and remain hot for some time

even after the engine has been switched off.

Before handling these components, make sure that you are wearing insulating gloves or wait until the

engine and the exhaust system have cooled down.

TRANSMISSION OIL AND USED FORK OIL

CAUTION

IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN CARRYING OUT SERVICE WORK.

THE TRANSMISSION OIL MAY CAUSE SKIN DAMAGE IF HANDLED FREQUENTLY AND FOR

LONG PERIODS.

WASH YOUR HANDS CAREFULLY AFTER HANDLING OIL.

HAND THE OIL OVER TO OR HAVE IT COLLECTED BY THE NEAREST USED OIL RECYCLING

COMPANY OR THE SUPPLIER.

ATLANTIC 300 i.e. Characteristics

CHAR - 7

IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN CARRYING OUT SERVICE WORK.

CAUTION

DO NOT DISPOSE OF OIL INTO THE ENVIRONMENT.

CAUTION

KEEP OUT OF THE REACH OF CHILDREN

BRAKE FLUID

CAUTION

THE BRAKE FLUID MAY DAMAGE PAINTED, PVC OR RUBBER SURFACES. WHEN SERVICING

THE BRAKE SYSTEM, PROTECT THESE COMPONENTS WITH A CLEAN CLOTH.

ALWAYS WEAR PROTECTIVE GOGGLES WHEN SERVICING THE BRAKE SYSTEM.

THE BRAKE FLUID IS EXTREMELY DANGEROUS TO THE EYES.

IN THE EVENT OF ACCIDENTAL CONTACT WITH THE EYES, RINSE THEM IMMEDIATELY WITH

ABUNDANT COLD, CLEAN WATER AND SEEK MEDICAL ADVICE.

CAUTION

KEEP OUT OF THE REACH OF CHILDREN

COOLANT

The coolant contains ethylene glycol which, under certain conditions, can become flammable. When it

burns, ethylene glycol produces invisible flames which, however, can cause burns.

CAUTION

MAKE SURE NOT TO POUR THE COOLANT ON HOT ENGINE OR EXHAUST SYSTEM COMPO-

NENTS; IT MAY CATCH FIRE PRODUCING INVISIBLE FLAMES. WHEN CARRYING OUT MAIN-

TENANCE OPERATIONS, IT IS ADVISABLE TO WEAR LATEX GLOVES. EVEN IF IT IS TOXIC,

THE COOLANT HAS A SWEET FLAVOUR WHICH MAKES IT VERY ATTRACTIVE TO ANIMALS.

NEVER LEAVE THE COOLANT IN OPEN CONTAINERS IN AREAS ACCESSIBLE TO ANIMALS

AS THEY MAY DRINK IT.

CAUTION

KEEP OUT OF THE REACH OF CHILDREN

CAUTION

DO NOT REMOVE THE RADIATOR CAP WHEN THE ENGINE IS STILL HOT. THE COOLANT IS

UNDER PRESSURE AND MAY CAUSE BURNS.

HYDROGEN GAS AND BATTERY ELECTROLYTE

CAUTION

HYDROGEN GAS AND BATTERY ELECTROLYTE

Characteristics ATLANTIC 300 i.e.

CHAR - 8

THE BATTERY ELECTROLYTE IS TOXIC, CORROSIVE AND AS IT CONTAINS SULPHURIC ACID,

IT CAN CAUSE BURNS WHEN IN CONTACT WITH THE SKIN.

WHEN HANDLING THE BATTERY ELECTROLYTE, WEAR TIGHT-FITTING GLOVES AND PRO-

TECTIVE APPAREL.

IF THE ELECTROLYTIC FLUID GETS INTO CONTACT WITH THE SKIN, WASH WITH ABUNDANT

COOL WATER.

IT IS PARTICULARLY IMPORTANT TO PROTECT THE EYES BECAUSE EVEN TINY AMOUNTS

OF BATTERY ACID MAY CAUSE BLINDNESS. IF IT COMES INTO CONTACT WITH THE EYES,

RINSE THEM CAREFULLY WITH WATER FOR FIFTEEN MINUTES, THEN SEE AN EYE SPECIAL-

IST AS SOON AS POSSIBLE.

IF IT IS ACCIDENTALLY SWALLOWED, DRINK LARGE QUANTITIES OF WATER OR MILK, FOL-

LOWED BY MILK OF MAGNESIA OR VEGETAL OIL, AND SEEK MEDICAL ADVICE IMMEDIATE-

LY.

THE BATTERY RELEASES EXPLOSIVE GASES. KEEP IT AWAY OF FLAMES, SPARKS, CIGA-

RETTES OR ANY OTHER HEAT SOURCE.

ENSURE ADEQUATE VENTILATION WHEN SERVICING OR RECHARGING THE BATTERY.

CAUTION

KEEP OUT OF THE REACH OF CHILDREN

CAUTION

THE BATTERY LIQUID IS CORROSIVE.

DO NOT POUR OR SPILL IT, PARTICULARLY ON PLASTIC COMPONENTS.

ENSURE THAT THE ELECTROLYTIC ACID IS COMPATIBLE WITH THE BATTERY TO BE ACTI-

VATED.

GENERAL PRECAUTIONS AND INFORMATION

When repairing, dismantling and reassembling the vehicle follow the recommendations reported below

carefully.

CAUTION

THE USE OF NAKED FLAMES IS FORBIDDEN FOR ANY KIND OF OPERATION. BEFORE START-

ING ANY MAINTENANCE OPERATION OR INSPECTION ON THE VEHICLE, SWITCH OFF THE

ENGINE AND REMOVE THE KEY. WAIT UNTIL THE ENGINE AND THE EXHAUST SYSTEM ARE

COLD, IF POSSIBLE, RAISE THE VEHICLE USING A SUITABLE TOOL ON FIRM AND LEVEL

GROUND. TO AVOID BURNS PAY SPECIAL CARE WITH HOT ENGINE AND EXHAUST SYSTEM

PARTS. DO NOT HOLD ANY MECHANICAL OR ANY OTHER SCOOTER PARTS WITH YOUR

MOUTH: SCOOTER COMPONENTS ARE NOT EDIBLE, ON THE CONTRARY SOME OF THEM

ARE HARMFUL AND EVEN TOXIC. UNLESS OTHERWISE INDICATED, REFIT THE UNITS FOL-

LOWING REMOVAL OPERATIONS BUT IN REVERSE ORDER. THE POSSIBLE OVERLAPPING

OF OPERATIONS REFERRED TO IN THE OTHER CHAPTERS MUST BE CARRIED OUT LOGI-

CALLY, AVOIDING ANY UNNECESSARY REMOVAL OF COMPONENTS. DO NOT POLISH MATT-

PAINTED SURFACES WITH POLISHING PASTE. NEVER USE FUEL AS SOLVENT FOR

CLEANING THE SCOOTER. DO NOT USE ALCOHOL, PETROL OR SOLVENTS TO CLEAN RUB-

BER AND PLASTIC PARTS AND THE SADDLE. USE ONLY WATER AND NEUTRAL SOAP

INSTEAD. DISCONNECT THE BATTERY NEGATIVE LEAD (-) IF YOU INTEND TO CARRY OUT

ELECTRICAL WELDING WORK. WHEN TWO OR MORE PEOPLE WORK AT THE SAME TIME,

MAKE SURE ALL SAFETY MEASURES ARE OBSERVED EACH OF THEM.

BEFORE REMOVING COMPONENTS

ATLANTIC 300 i.e. Characteristics

CHAR - 9

•Before disassembling components, remove dirt, mud, dust and foreign bodies from the ve-

hicle.

•Use the special tools designed for this vehicle, as required.

REASSEMBLING COMPONENTS

CAUTION

NEVER REUSE A CIRCLIP; IF A CIRCLIP HAS BEEN REMOVED, IT MUST BE REPLACED WITH

A NEW ONE. WHEN INSTALLING A CIRCLIP, ENSURE THAT ITS ENDS ARE NOT STRETCHED

MORE THAN IS NECESSARY TO FIT IT ONTO THE SHAFT.

AFTER INSTALLING THE CIRCLIP, CHECK THAT IT IS FULLY AND CLEANLY INSTALLED IN ITS

SEAT.

DO NOT USED COMPRESSED AIR TO CLEAN BEARINGS.

NOTE

BEARINGS MUST ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTHERWISE, THEY

NEED TO BE REPLACED.

•Use only ORIGINAL Aprilia SPARE PARTS.

•Comply with lubricant and consumables usage guidelines.

•Lubricate parts (whenever possible) before reassembling them.

•Whentightening nutsandscrews, starteitherfrom thecomponentswith thelargest diameter

or from the innermost components, proceeding diagonally. Tighten nuts and screws in suc-

cessive steps before applying the tightening torque.

•Always replace self-locking nuts, washers, sealing rings, circlips, O-rings (OR), cotter pins

and screws with new parts if the thread is damaged.

•When assembling the bearings, make sure to lubricate them well.

•Check that each component is assembled correctly.

•After a repair or routine maintenance, carry out pre-ride checks and test the vehicle on

private grounds or in an area with low traffic.

•Clean all mating surfaces, oil seal rims and gaskets before refitting. Smear a thin layer of

lithium-based grease on the oil seal rims. Reassemble the oil seal and the bearings with the

brand or lot number facing outward (visible side).

ELECTRIC CONNECTORS

Electric connectors must be disconnected as described below as non-compliance with the procedure

so described causes irreparable damage to both the connector and the cable harness: Press the rele-

vant safety hooks, if any.

CAUTION

DO NOT DISCONNECT CONNECTORS BY PULLING THE CABLES.

•Grip the two connectors and disconnect them by pulling them in opposite directions.

Characteristics ATLANTIC 300 i.e.

CHAR - 10

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