2002 Aprilia Atlantic 500 Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: Aprilia Model: Atlantic 500 Year: 2002 Codes Engine Code: M357-M (Piaggio Quasar 500) 👋 Introduction Market Position Vehicle Segment: Maxi-scooter, Sport-scooter Competitive Analysis Key Competitors: Yamaha TMAX 500, Suzuki Burgman 650, Honda Silver Wing 600, Kymco Xciting 500. Key Features Vehicle Features: Powerful 500cc engine, comfortable ride, large underseat storage, sporty handling for its class. Manual Utility Target Audience: DIY mechanics, independent repair shops, and Aprilia Atlantic 500 owners seeking to perform maintenance and repairs. 📋 Manual Details Coverage Areas Covered Models: Aprilia Atlantic 500 (2002 model year) Page Count Page Count: 400 Manual Type Manual Type: Factory Service Repair Workshop Manual Content Focus: Diagnostic, Repair, Maintenance, and Overhaul Procedures. Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine Overhaul: Complete engine disassembly, inspection, repair, and reassembly procedures for the Piaggio Quasar 500 engine. Fuel System: Fuel injection system diagnosis and repair, fuel pump, injectors, fuel pressure regulator, throttle body, EFI control unit. Cooling System: Radiator, coolant pump, thermostat, fan, coolant hoses, and bleeding procedures. Transmission Clutch: Automatic CVT transmission (CVT), clutch unit, belt inspection and replacement, variator, and torque converter. Electrical System: Wiring diagrams, battery, charging system (stator, regulator/rectifier), starter motor, ignition system, lighting, indicators, and instrument panel. Braking System: Hydraulic brake system diagnosis and repair, front and rear brake calipers, master cylinders, brake lines, brake pads, and rotors. Suspension Steering: Front fork assembly, rear shock absorbers, swingarm, steering head bearings, and steering column. Chassis Bodywork: Frame inspection, body panel removal and installation, seat, fairings, luggage compartment, and general chassis components. Diagnostics Troubleshooting: Step-by-step troubleshooting guides for common and uncommon problems, fault codes, and diagnostic procedures. Exhaust System: Exhaust pipe, muffler, lambda sensor (if applicable) inspection and replacement. Cooling System Capacities: Specific coolant capacity for the Aprilia Atlantic 500. Ignition Timing: Information on ignition timing checks and related components. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug checks, air filter cleaning/replacement, brake fluid changes, coolant checks. Component Rebuild: Detailed procedures for rebuilding engine components (e.g., cylinder head, piston, crankshaft), brake calipers, and suspension units. Wiring Repair: Guidance on tracing electrical faults, repairing damaged wiring, and replacing electrical components. Suspension Adjustment: Information on suspension adjustments, fork oil changes, and seal replacement. Torque Specifications: Comprehensive list of all critical torque specifications for engine, chassis, and bolt-on components. Engine Tuning: Information on carburetor/fuel injection adjustments and basic engine tuning for optimal performance. Tire Replacement: Information on tire removal, mounting, and balancing. Valve Adjustment: Procedures for checking and adjusting valve clearances. Technical Depth Diagnostic Tools: Information on required tools and potential diagnostic equipment (though specific ECU readers are generally not detailed in this type of manual). Rebuild Level: Full workshop-level detail, suitable for complete engine rebuilds and complex repairs. Diagnostic Charts: Extensive diagnostic flowcharts and symptom-to-cause tables. Wiring Diagrams: Detailed, full-color wiring diagrams for all electrical systems. 📊 Manual Specifications File Format File Format: PDF Print Quality Image Resolution: High-resolution, clear diagrams and schematics. Binding Type Binding Type: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format) Searchability Searchable Text: Yes, with OCR for easy keyword searching. ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, liquid-cooled, single-cylinder, DOHC, 4 valves. Displacement: 460 cc (28.07 cubic inches) Bore X Stroke: 92 mm x 69 mm (3.62 in x 2.72 in) Compression Ratio: 10.5:1 Valve Actuation: DOHC (Double Overhead Camshaft), 4 valves per cylinder. Performance Horsepower: Approximately 33.5 HP (25 kW) at 7,000 RPM Torque: Approximately 37 Nm (27.3 lb-ft) at 5,500 RPM Top Speed: Approximately 150-160 km/h (93-99 mph) depending on conditions. Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline, 95 RON (Octane rating) Engine Oil Oil Type: SAE 5W-40 Synthetic or Semi-Synthetic Motorcycle Oil (API SG or higher, JASO MA) Oil Capacity With Filter: 1.5 Liters (1.6 US quarts) 🔧 Transmission Standard Transmission Type: Automatic Continuously Variable Transmission (CVT) Features Clutch Type: Automatic centrifugal clutch Final Drive: Belt drive Fluid Specs Cv Fluid Type: Specific CVT oil (refer to manual for exact specification and capacity) 📐 Dimensions Exterior Length: Approximately 2,180 mm (85.8 in) Width: Approximately 800 mm (31.5 in) Height: Approximately 1,420 mm (55.9 in) (seat height may vary) Weights Dry Weight: Approximately 205 kg (452 lbs) Gross Vehicle Weight Rating Gvwr: Refer to vehicle placard Cargo Underseat Storage: Spacious underseat storage compartment, capable of holding two full-face helmets. 🛡️ Safety Features Ratings Crash Test Ratings: Not applicable to motorcycles/scooters in the same manner as automobiles. Active Features Braking System: Front: Dual 260mm discs with 2-piston calipers. Rear: 240mm disc with 2-piston caliper. (Optional ABS might be available on some markets/later models, check specific vehicle VIN). Lighting: Halogen headlight, LED taillight and brake light, front and rear turn signals. Passive Features Body Structure: Steel tube frame chassis. 💡 Technology Features Infotainment Instrument Cluster: Analog speedometer and...
Specific CVT oil (refer to manual for exact specification and capacity)
📐 Dimensions
Exterior
Length:
Approximately 2,180 mm (85.8 in)
Width:
Approximately 800 mm (31.5 in)
Height:
Approximately 1,420 mm (55.9 in) (seat height may vary)
Weights
Dry Weight:
Approximately 205 kg (452 lbs)
Gross Vehicle Weight Rating Gvwr:
Refer to vehicle placard
Cargo
Underseat Storage:
Spacious underseat storage compartment, capable of holding two full-face helmets.
🛡️ Safety Features
Ratings
Crash Test Ratings:
Not applicable to motorcycles/scooters in the same manner as automobiles.
Active Features
Braking System:
Front: Dual 260mm discs with 2-piston calipers. Rear: 240mm disc with 2-piston caliper. (Optional ABS might be available on some markets/later models, check specific vehicle VIN).
Lighting:
Halogen headlight, LED taillight and brake light, front and rear turn signals.
Passive Features
Body Structure:
Steel tube frame chassis.
💡 Technology Features
Infotainment
Instrument Cluster:
Analog speedometer and tachometer, digital odometer, trip meter, fuel gauge, coolant temperature gauge, clock, and indicator lights.
Driver Assistance
ABS:
Anti-lock Braking System (ABS) may have been an option on some models or markets. This manual would cover its components and diagnostics if equipped.
Connectivity
Ignition System:
Electronic ignition system with CDI.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 6,000 km (3,700 miles) or annually.
Air Filter Cleaning:
Every 6,000 km (3,700 miles).
Spark Plug Replacement:
Every 12,000 km (7,500 miles) or as needed based on condition.
Cv Belt Inspection:
Every 12,000 km (7,500 miles).
Brake Fluid Change:
Every 2 years or as per manual recommendations.
Fluid Specifications
Coolant Type:
Ethylene glycol based antifreeze coolant, 50% mixture with distilled water.
Brake Fluid Type:
DOT 4 Hydraulic Brake Fluid.
Known Issues
Common Wear Items:
CV belt wear, variator roller wear, potential voltage regulator issues (common on many scooters of this era), fork seal leaks.
Electrical Gremlins:
Some owners report minor electrical issues over time, which are typically addressable with proper diagnostic and repair procedures detailed in the manual.
📚 Vehicle History
Brand Heritage
Aprilia Heritage:
Aprilia is an Italian manufacturer renowned for its sporting motorcycles and scooters, often incorporating innovative engineering.
Model Evolution
Atlantic Lineage:
The Atlantic line was Aprilia's entry into the maxi-scooter market, designed for comfort, touring, and urban commuting with significant power.
Production
Manufacturing Location:
Italy
Production Years:
The Atlantic 500 was produced from the early 2000s onwards, with the 2002 model being one of the initial iterations.
🏆 Awards & Recognition
Recognitions
Vehicle Awards:
While the Atlantic 500 was well-received for its performance and comfort, specific industry awards for this model year are not widely documented in general consumer publications.
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