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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...
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Aprilia Atlantic Sprint 500 2005-08 Workshop Service Repair Manual
🏷️ 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 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.
Potential Problems:
Fuel injector clogging (use quality fuel), thermostat sticking, occasional electrical connector issues.
Maintenance Parts
Oil Filter Part Number:
e.g., AP8102220, HF183 (K&N), KN-183 (K&N)
Air Filter Part Number:
e.g., AP257862
Spark Plug Part Number:
e.g., NGK CR9EB
📚 Vehicle History
Brand Heritage
Brand Origin:
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.
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