Aprilia Atlantic Sprint 500 2005-08 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Aprilia Model: Atlantic Sprint 500 Model Code: AP02 Generation Generation Code: First Generation Codes Chassis Codes: AP02 Engine Codes: M268 (Piaggio Quasar) 👋 Introduction Market Position Market Segment: Premium Sport Scooter / Maxi-Scooter Target Audience: Commuters seeking performance and comfort, touring riders, enthusiasts who perform their own maintenance. Competitive Analysis Key Competitors: Yamaha TMAX, Suzuki Burgman 400/650, Honda Silver Wing, Gilera GP800 (later models). Key Features Performance Focus: The Atlantic Sprint 500 was known for its powerful engine and sporty handling, bridging the gap between traditional scooters and motorcycles. Design Philosophy: Sporty ergonomics, aerodynamic bodywork, and a focus on rider comfort for longer distances. 📋 Manual Details Coverage Areas Model Years Covered: 2005, 2006, 2007, 2008 Regions Covered: Global (primarily European market focus evident in documentation) Page Count Estimated Page Count: 400-600 (typical for a comprehensive workshop manual of this era) Manual Type Manual Type: Workshop Service Repair Manual Language Language: English (primary), likely with translations available in other languages Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine disassembly, assembly, inspection, and repair of all internal components (pistons, rings, connecting rods, crankshaft, cylinder head, valves, camshafts, timing system). Fuel System: Fuel injection system (EFI), fuel pump, injectors, fuel pressure regulator, throttle body, fuel lines, fuel tank, evaporative emission control system. Ignition System: Ignition coil, spark plug, crankshaft position sensor, CDI unit, wiring diagrams for ignition. Cooling System: Radiator, water pump, thermostat, coolant hoses, fan operation, coolant type and capacity. Exhaust System: Exhaust manifold, catalytic converter, muffler, oxygen sensors, lambda sensors. Transmission: CVT (Continuously Variable Transmission) system: variator, torque driver, drive belt, driven pulley, clutch, gears, lubrication, and overhaul procedures. Brakes: Front and rear hydraulic brake systems, brake calipers, master cylinders, brake fluid type, bleeding procedures, brake pad replacement, rotor inspection and replacement. Suspension: Front telescopic fork: oil type, level, seal replacement, fork leg disassembly. Rear shock absorber and swingarm: lubrication, adjustment, replacement. Steering: Handlebar assembly, steering stem, bearings, lubrication, adjustment, and replacement. Electrical System: Battery, starter motor, alternator, lighting system (headlight, taillight, indicators), horn, fuses, relays, wiring harnesses, fault finding with wiring diagrams. Chassis And Bodywork: Frame inspection, fairing removal and installation, seat, storage compartments, footrests, body panel torque specifications. Diagnostic Troubleshooting: Detailed diagnostic flowcharts and procedures for identifying and resolving common and uncommon issues across all systems. Procedures Included Routine Maintenance: Oil changes, filter replacements (oil, air), spark plug replacement, coolant checks and changes, brake fluid flushes, chain/belt inspection and adjustment (if applicable, though likely shaft/CVT). Detailed service intervals. Component Disassembly Reassembly: Step-by-step instructions for removing, disassembling, inspecting, repairing, and reassembling major and minor components. Troubleshooting Guides: System-specific troubleshooting charts to diagnose problems efficiently, including symptom-based diagnosis. Torque Specifications: Precise torque values for all critical fasteners throughout the vehicle, ensuring proper assembly and preventing damage. Electrical Diagnostics: In-depth electrical troubleshooting, including use of multimeters, interpretation of wiring diagrams, and testing of sensors and actuators. Rebuild Procedures: Detailed instructions for complete engine rebuilds, transmission overhauls, and suspension component overhauls. Technical Depth Depth Level: Comprehensive: Covers everything from basic owner maintenance to full professional-level repair and diagnostics. Diagnostic Capability: Advanced: Includes information on ECU (Engine Control Unit) diagnostics and potential fault codes (OBD if applicable). 📊 Manual Specifications File Format File Format: PDF Searchable: Likely searchable text within the PDF, allowing quick access to specific topics. Print Quality Print Quality: High-resolution scans suitable for clear printing of diagrams and text. Binding Type Binding Type: N/A (Digital PDF format) Paper Type Paper Type: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, single-cylinder, liquid-cooled, SOHC Displacement: 492.6 cc Bore X Stroke: 94 mm x 71 mm Compression Ratio: 10.5:1 Valve Train: SOHC, 4 valves Performance Horsepower Ps: ~39 PS (28.6 kW) @ 7,500 rpm Torque Nm: ~43 Nm (31.7 lb-ft) @ 6,000 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline (95 RON recommended) Ignition System: Electronic CDI with variable spark advance Cooling System Cooling Method: Liquid-cooled Coolant Capacity: ~1.3 Liters Lubrication Oil Type: SAE 5W-40 Synthetic Motorcycle Oil (API SG or higher, JASO MA approved) Oil Capacity With Filter: ~1.6 Liters 🔧 Transmission Standard Transmission Type: Automatic, Continuously Variable Transmission (CVT) Features Transmission Fluid: Refer to manual for specific CVT fluid type and change intervals (typically specific CVT fluid, not standard ATF or gear oil). Final Drive: Automatic centrifugal clutch and V-belt drive 📐 Dimensions Exterior Length: ~2240 mm Width: ~780 mm Height: ~1430 mm Wheelbase: ~1570 mm Weights Dry Weight: ~204 kg Wet Weight: ~221 kg Maximum Load Capacity: ~150 kg (rider + passenger + luggage) Fuel Capacity Fuel Tank Capacity: 15 Liters (including ~3.5 Liters reserve) 🛡️ Safety Features Ratings Safety Ratings: No specific crash test ratings typical for motorcycles/scooters. Safety reliant on rider and vehicle design integrity. Active Features Braking System: Dual...
Front and rear hydraulic brake systems, brake calipers, master cylinders, brake fluid type, bleeding procedures, brake pad replacement, rotor inspection and replacement.
Suspension:
Front telescopic fork: oil type, level, seal replacement, fork leg disassembly. Rear shock absorber and swingarm: lubrication, adjustment, replacement.
Steering:
Handlebar assembly, steering stem, bearings, lubrication, adjustment, and replacement.
Electrical System:
Battery, starter motor, alternator, lighting system (headlight, taillight, indicators), horn, fuses, relays, wiring harnesses, fault finding with wiring diagrams.
Chassis And Bodywork:
Frame inspection, fairing removal and installation, seat, storage compartments, footrests, body panel torque specifications.
Diagnostic Troubleshooting:
Detailed diagnostic flowcharts and procedures for identifying and resolving common and uncommon issues across all systems.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements (oil, air), spark plug replacement, coolant checks and changes, brake fluid flushes, chain/belt inspection and adjustment (if applicable, though likely shaft/CVT). Detailed service intervals.
Component Disassembly Reassembly:
Step-by-step instructions for removing, disassembling, inspecting, repairing, and reassembling major and minor components.
Troubleshooting Guides:
System-specific troubleshooting charts to diagnose problems efficiently, including symptom-based diagnosis.
Torque Specifications:
Precise torque values for all critical fasteners throughout the vehicle, ensuring proper assembly and preventing damage.
Electrical Diagnostics:
In-depth electrical troubleshooting, including use of multimeters, interpretation of wiring diagrams, and testing of sensors and actuators.
Rebuild Procedures:
Detailed instructions for complete engine rebuilds, transmission overhauls, and suspension component overhauls.
Technical Depth
Depth Level:
Comprehensive: Covers everything from basic owner maintenance to full professional-level repair and diagnostics.
Diagnostic Capability:
Advanced: Includes information on ECU (Engine Control Unit) diagnostics and potential fault codes (OBD if applicable).
📊 Manual Specifications
File Format
File Format:
PDF
Searchable:
Likely searchable text within the PDF, allowing quick access to specific topics.
Print Quality
Print Quality:
High-resolution scans suitable for clear printing of diagrams and text.
Binding Type
Binding Type:
N/A (Digital PDF format)
Paper Type
Paper Type:
N/A (Digital PDF format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-stroke, single-cylinder, liquid-cooled, SOHC
Displacement:
492.6 cc
Bore X Stroke:
94 mm x 71 mm
Compression Ratio:
10.5:1
Valve Train:
SOHC, 4 valves
Performance
Horsepower Ps:
~39 PS (28.6 kW) @ 7,500 rpm
Torque Nm:
~43 Nm (31.7 lb-ft) @ 6,000 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline (95 RON recommended)
Ignition System:
Electronic CDI with variable spark advance
Cooling System
Cooling Method:
Liquid-cooled
Coolant Capacity:
~1.3 Liters
Lubrication
Oil Type:
SAE 5W-40 Synthetic Motorcycle Oil (API SG or higher, JASO MA approved)
Refer to manual for specific CVT fluid type and change intervals (typically specific CVT fluid, not standard ATF or gear oil).
Final Drive:
Automatic centrifugal clutch and V-belt drive
📐 Dimensions
Exterior
Length:
~2240 mm
Width:
~780 mm
Height:
~1430 mm
Wheelbase:
~1570 mm
Weights
Dry Weight:
~204 kg
Wet Weight:
~221 kg
Maximum Load Capacity:
~150 kg (rider + passenger + luggage)
Fuel Capacity
Fuel Tank Capacity:
15 Liters (including ~3.5 Liters reserve)
🛡️ Safety Features
Ratings
Safety Ratings:
No specific crash test ratings typical for motorcycles/scooters. Safety reliant on rider and vehicle design integrity.
Active Features
Braking System:
Dual Hydraulic Disc Brakes (Front), Single Hydraulic Disc Brake (Rear). ABS was an optional feature on some variants.
Lighting:
Halogen Headlight, LED Taillight/Brake Light, LED Indicators, providing good visibility.
Passive Features
Frame Construction:
Steel backbone frame designed for rigidity and stability.
Tyres Front:
120/70-15
Tyres Rear:
160/60-15
💡 Technology Features
Infotainment
Instrument Cluster:
Digital and analog instrument cluster displaying speedometer, tachometer, fuel gauge, odometer, trip meters, coolant temperature, and indicator lights.
Driver Assistance
ABS:
Optional Anti-lock Braking System (ABS) available on some models, enhancing braking safety.
Connectivity
Diagnostic Ports:
Likely includes a diagnostic connector for electronic diagnostics and fault code retrieval.
🔧 Maintenance
Service Intervals
First Service:
1,000 km or 6 months
Subsequent Service Intervals:
Every 6,000 km or 12 months (includes engine oil and filter change)
Major Service Intervals:
Includes CVT belt check/replacement, valve clearance check, spark plug replacement at prescribed intervals (e.g., 12,000 km or 24,000 km).
Fluid Specifications
Engine Oil Grade:
SAE 5W-40 Synthetic (API SG/SH/SJ/SL, JASO MA)
Brake Fluid Type:
DOT 4
Coolant Type:
Ethylene glycol based antifreeze with corrosion inhibitors (e.g., Aprilia Coolant or equivalent).
Known Issues
Common Wear Items:
CVT belt wear, variator rollers, starter motor brushes, voltage regulator, rear shock absorber seals.
Aprilia is an Italian manufacturer with a rich heritage in motorcycle racing and sportbike development.
Model Evolution
Predecessors:
Successor to earlier Aprilia Scarabeo and Leonardo models, introducing a more powerful engine and advanced features.
Platform Sharing:
Shares the Piaggio Quasar 500 engine with other Piaggio Group products of the era.
Production
Production Period:
Produced from roughly 2002-2008, with the 500cc engine variant prominent from 2004 onwards.
🏆 Awards & Recognition
Recognitions
Awards And Recognition:
While specific awards for this model year might not be widely publicized, the Atlantic Sprint 500 was generally well-regarded for its performance and comfort in the maxi-scooter segment during its production run.
Ratings
Owner Satisfaction:
Owner satisfaction often cited strong engine performance and comfortable riding position, though some users reported higher than average maintenance costs compared to Japanese competitors.
Certifications
Emissions Standards:
Compliant with Euro 3 emissions standards applicable for the production years.