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INTRODUCTION 0
0-1
INTRODUCTION
ATLANTIC 125 - 200
SUMMARY
0.1. FOREWORD ...............................................................................................................................3
0.1.1. FOREWORD .......................................................................................................................3
0.1.2. REFERENCE MANUALS.....................................................................................................4
0.1.3. ABBREVIATIONS / SYMBOLS / CONVENTIONS................................................................5
0-2
INTRODUCTION
ATLANTIC 125 - 200
0.1. FOREWORD
0.1.1. FOREWORD
- This manual provides the information required for normal servicing.
- This manual is intended for use by aprilia Dealers and their qualified mechanics. Certain information has been
omitted intentionally, as this manual does not purport to provide a comprehensive treatise on mechanics. The
persons who will use this manual must be fully conversant with the basics of mechanics and with the basic
procedures of motorcycle repair. Repairing or inspecting a motorcycle when one does not possess such basic
knowledge or training could result in improper servicing and make the motorcycle unsafe to ride. For the same
reason, certain basic precautions have been omitted in the descriptions of repair and inspection procedures; you
are therefore invited to take special care to avoid damage to motorcycle components or injury to persons. Take
special care to avoid damage to motorcycle components or injury to persons. aprilia s.p.a.'s mission is to
constantly enhance the riding pleasure of final users through the on-going improvement of its products as well as of
the relevant technical literature. All aprilia Points of Sale and Subsidiaries worldwide are kept updated on major
engineering changes and modifications to repair procedures. Such changes and modifications are then reflected in
the next release of the relevant manual. In case of need or doubt regarding repair and inspection procedures,
contact the aprilia SERVICE DEPARTMENT, which will be pleased to help, as well as providing you with updates
and technical modifications regarding the vehicle.
aprilia s.p.a. reserves the right to make changes to its products at any time, barring any such changes as may alter the
essential features of a product as specified in the relevant manual.
All rights of storage using electronic means, reproduction and total or partial adaptation, whatever the means adopted,
are reserved in all countries.
The mention of third parties’ products is only made for information purposes, and constitutes no engagement.
aprilia s.p.a. is not liable in any way for the performance or use of its products.
DECA srl.
via Risorgimento, 23/1 - 48022 Lugo (RA) - Italy
Tel. +39 - 0545 35235
Fax +39 - 0545 32844
E-mail: deca@decaweb.it
www.decaweb.it
On behalf of:
aprilia s.p.a.
Via G. Galilei, 1 – 30033 Noale (VE) – Italy
Tel. +39 – (0)41 58 29 111
Fax +39 – (0)41 58 29 190
www.aprilia.com
www.serviceaprilia.com
0-3
INTRODUCTION
ATLANTIC 125 - 200
PARTS CATALOGS
aprilia part# (description)
6642
0-4
INTRODUCTION
ATLANTIC 125 - 200
0-5
INTRODUCTION
ATLANTIC 125 - 200
RIGHT
SIDE = right-hand side
SAE = Society of Automotive Engineers
TEST = diagnostic check
T.B.E.I. = crowned-head Allen screw
T.C.E.I. = cheese-headed Allen screw
T.E. = hexagonal head
T.P. = flat head screw
TSI = Twin Spark Ignition
UPSIDE-
DOWN = inverted fork legs
V = Volt
W = Watt
Ø = Diameter
0-6
GENERAL INFORMATION
ATLANTIC 125 - 200
GENERAL INFORMATION 1
1-1
GENERAL INFORMATION
ATLANTIC 125 - 200
SUMMARY
1.1. STRUCTURE OF THE MANUAL..................................................................................................3
1.1.1. CONVENTIONS USED IN THE MANUAL............................................................................3
1.1.2. SAFETY WARNINGS ..........................................................................................................4
1.2. GENERAL WARNINGS ...............................................................................................................5
1.2.1. GENERAL SAFETY RULES ................................................................................................5
1.3. HAZARDOUS SUBSTANCES......................................................................................................8
1.3.1. WARNINGS CONCERNING FUEL, LUBRICANTS, COOLANT AND OTHER COMPONENT
PARTS ................................................................................................................................8
1.4. RUNNING-IN .............................................................................................................................12
1.4.1. RUNNING-IN INSTRUCTIONS..........................................................................................12
1.5. VEHICLE IDENTIFICATION.......................................................................................................13
1.5.1. LOCATION OF SERIAL NUMBERS...................................................................................13
1.6. USING TOOLS AND SPARE PARTS.........................................................................................14
1.6.1. SPARE PARTS .................................................................................................................14
1.7. SPECIFICATIONS .....................................................................................................................15
1.7.1. SPECIFICATIONS.............................................................................................................15
1.7.2. HOW TO APPLY THE DECALS.........................................................................................17
1.8. PRODUCTS...............................................................................................................................19
1.8.1. LUBRICANT CHART .........................................................................................................19
1.8.2. PRODUCT APPLICATIONS ..............................................................................................20
1.9. TIGHTENING.............................................................................................................................21
1.9.1. TORQUE FIGURES...........................................................................................................21
1.10. POSITION OF THE WARNING ADHESIVE LABELS .............................................................22
1.10.1. POSITION OF THE WARNING ADHESIVE LABELS .........................................................22
1.10.2. CALIFORNIA EVAPORATIVE EMISSION SYSTEM .........................................................28
1-2
GENERAL INFORMATION
ATLANTIC 125 - 200
VERSION:
Italy Greece Malaysia
United Holland Chile
Kingdom
Austria Switzerland Croatia
Portugal Denmark Australia
Finland Japan United
States of
America
Belgium Singapore Brazil
Germany Slovenia Republic of
South Africa
France Israel New
Zealand
Spain South Canada
Korea
1-3
GENERAL INFORMATION
ATLANTIC 125 - 200
Safety warning. When you find this symbol on the vehicle or in the manual, be careful to the potential
risk of personal injury. Disregarding the instructions identified by this symbol may compromise the
safety of the user, the motorcycle and third parties.
DANGER
Indicates a potential hazard which may result in serious injury or even death.
WARNING
Indicates a potential hazard which may result in minor personal injury or damage to the vehicle.
IMPORTANT: The word "IMPORTANT" in this manual precedes important information or instructions.
1-4
GENERAL INFORMATION
ATLANTIC 125 - 200
DANGER
Exhaust emissions contain carbon monoxide, a poisonous gas that may cause loss of consciousness
or even death.
FUEL
DANGER
The fuel used to operate engines is highly flammable and becomes explosive under particular
conditions.
It is important to carry out the refueling and the maintenance operations in a well-ventilated area, with
the engine off.
Do not smoke when refueling or in the proximity of sources of fuel vapors. Avoid contact with bare
flames, sources of sparks or any other source which may ignite the fuel or lead to explosion.
DANGER
Wear latex gloves during servicing.
Prolonged or repeated contact with engine oil may cause severe skin damage.
Wash your hands thoroughly after handling engine oil.
Dispose of engine oil through the nearest waste oil reclamation firm or through the supplier.
Wear latex gloves during servicing.
BRAKE FLUID
WARNING
Brake fluid can damage painted, plastic and rubber parts. When servicing the brake circuit, protect all
such parts with a clean cloth.
Always wear safety glasses when servicing the brake system.
Brake fluid is extremely dangerous in contact with the eyes.
In case of contact with the eyes, rinse abundantly with cool, clean water and immediately seek
medical attention.
COOLANT
The coolant contains ethyl glycol which is flammable under certain conditions. Ethyl glycol burns with an invisible flame.
Burn hazard.
1-5
GENERAL INFORMATION
ATLANTIC 125 - 200
DANGER
Take care not to spill coolant onto hot engine or exhaust system parts. It may ignite and produce
invisible flames.
Wear latex gloves when servicing.
Coolant is sweet and very attractive to animals; it is nonetheless a toxic product. Never leave the
coolant in open containers and accessible to animals as they may be tempted to drink it.
Do not remove the radiator cap when the engine is still warm. The coolant is pressurized and can
cause burns.
DANGER
The battery electrolyte is a toxic, caustic substance containing sulphuric acid and thus able to cause
severe burns in case of contact.
Wear close-fitting gloves and protective clothing when handling the battery electrolyte.
If any battery fluid gets on your skin, rinse the affected area with abundant fresh water.
Take especial care to protect the eyes; even a small amount of battery fluid can cause blindness. If
battery fluid is spilled into your eyes, flush with abundant water for fifteen minutes and contact an eye
specialist immediately.
If battery fluid is swallowed accidentally, drink abundant water or milk. Seek medical attention
immediately and keep drinking milk of magnesia or vegetable oil in the meantime.
The battery gives off explosive gases. Keep the battery well away from any sources of ignition, such
as flames, sparks, or any heat sources.
Make sure the area is well-ventilated when servicing or refilling the battery.
DANGER
Using bare flames is strictly forbidden when working on the motorcycle. Before servicing or
inspecting the motorcycle: stop the engine and remove the key from the ignition switch; allow the
engine and exhaust system to cool down; where possible, lift the motorcycle using adequate
equipment placed on firm and level ground. Pay particular attention to any parts of the engine or
exhaust system that may still be hot to the touch to avoid burns.
Never put any mechanical parts or other vehicle components in your mouth when you have both
hands busy. None of the motorcycle components is edible. Some components are harmful to the
human body or toxic.
If not expressly indicated otherwise, for the reassembly of the units repeat the disassembly
operations in reverse order. Where a procedure is cross-referred to relevant sections in the manual,
proceed sensibly to avoid disturbing any parts unless strictly necessary. Do not use polishing pastes
on matt paints.
Never use fuel instead of solvent to clean the motorcycle.
Do not use alcohol, petrol or solvents to clean the rubber and plastic parts and the saddle: use only
water and mild soap.
Always disconnect the battery negative (–) lead before soldering any electrical components.
When two or more persons service the same motorcycle together, special care must be taken to avoid
personal injury.
Read 1.3.1. carefully.
1-6
GENERAL INFORMATION
ATLANTIC 125 - 200
DANGER
Never reuse circlips or snap rings. These parts must always be renewed once they have been
disassembled.
When fitting a new circlip or snap ring, open the ends just sufficiently to allow fitment to the shaft.
Make a rule to check that a newly-fitted circlip or snap ring has located fully into its groove.
Never use compressed air to clean bearings.
IMPORTANT: All bearings must run freely with no hardness or noise. Replace any bearings that do not meet these
requirements.
- Only use GENUINE aprilia spares.
- Use the specified lubricants and consumables.
- Where possible, lubricate a part before assembly.
- When tightening nuts and bolts, start with the largest or innermost nut/bolt and observe a cross pattern. Tighten
evenly in subsequent steps until achieving the specified torque.
- Replace any self-locking nuts, gaskets, seals, circlips or snap rings, O-rings, split pins, bolts and screws which
have a damaged thread.
- Lubricate bearings abundantly before assembly.
- Make a rule to check that all components you have fitted are correctly in place.
- After repairing the motorcycle and after each service inspection, perform the preliminary checks, and then operate
the motorcycle in a private estate area or in a safe area away from traffic.
- Clean all mating surfaces, oil seal edges and gaskets before assembly. Apply a light coat of lithium grease along
the edges of oil seals. Fit oil seals and bearings with the brand or serial number facing outwards (in view).
ELECTRICAL CONNECTORS
Disconnect electrical connectors as follows: failure to follow the instructions can seriously damage the connectors and
the wiring:
Press down on the locking tab, where fitted.
WARNING
Never separate two connectors by pulling on the wiring.
• Grasp both connectors and pull them in opposite directions until they become separated.
• Remove any dirt, rust, moisture, etc. from inside the connector with compressed air.
• Ensure that the wires are securely crimped to the terminals inside each connector.
IMPORTANT: A connector will only locate properly into the matching connector when it is inserted in the correct
mounting position.
• Reconnect the two connectors and ensure that they are fully engaged (if fitted with the special locking tabs, it
should click audibly into place).
TIGHTENING TORQUES
DANGER
Do not forget that the tightening torques of all fastenings on wheels, brakes, wheel spindles and other
suspension components are essential to ensuring safe operation of the motorcycle and must be set to
the indicated values.
Regularly check the tightening torques on all fastenings, and always use a torque wrench when fitting
them.
Failure to observe these instructions can result in parts loosening or coming away, thus jamming a
wheel or creating other problems which could affect the handling of the motorcycle, potentially
resulting in serious injury or death.
1-7
GENERAL INFORMATION
ATLANTIC 125 - 200
DANGER
The fuel used to operate engines is highly flammable and becomes explosive under particular
conditions.
It is important to carry out the refueling and the maintenance operations in a well-ventilated area, with
the engine off.
Do not smoke when refueling or in the proximity of sources of fuel vapors. Avoid contact with bare
flames, sources of sparks or any other source which may ignite the fuel or lead to explosion.
Take care not to spill fuel out of the filler, or it may ignite when in contact with hot engine parts.
In the event of accidental fuel spillage, make sure the affected area is fully dry before starting the
engine. Fuel expands from heat and when left under direct sunlight.
Never fill the fuel tank up to the rim. Tighten the filler cap securely after each refueling.
Avoid any contact of the fuel with the skin and the inhalation of vapors; do not swallow fuel or pour it
from a receptacle into another by means of a tube.
DO NOT RELEASE FUEL INTO THE ENVIRONMENT.
KEEP AWAY FROM CHILDREN.
Use only premium-grade unleaded fuel with a minimum octane rating of 95 (N.O.R.M.) and 85 (N.O.M.M.).
LUBRICANTS
DANGER
Correct lubrication is essential to the safety of the motorcycle.
Failure to maintain the lubricant level or the use of incorrect, old or dirty lubricant can cause the
engine or transmission to seize, resulting in accidents, serious injury or death.
Prolonged or repeated contact with engine oil may cause severe skin damage.
Wash your hands thoroughly after handling engine oil.
Do not release oil into the environment.
Dispose of engine oil through the nearest waste oil reclamation firm or through the supplier.
WARNING
When charging the vehicle with oil, take care to prevent spillages. Immediately clean up any spilt oil,
which can damage painted parts.
Oil on the tires can make them very slippy and dangerous to use.
In case of oil leaks, do not use the motorcycle. Identify the cause of the leak and repair it.
ENGINE OIL
DANGER
Prolonged or repeated contact with engine oil may cause severe skin damage.
Wash your hands thoroughly after handling engine oil.
Do not release oil into the environment.
Dispose of engine oil through the nearest waste oil reclamation firm or through the supplier.
Wear latex gloves during servicing.
Change engine oil after the first 621 mi (1000 km) and successively every 3728 mi (6000 km), 2.11.2.
DANGER
Front suspension response can be modified to a certain extent by changing damping settings and/or
selecting a particular grade of oil. Standard oil grade is SAE 20 W. Different oil grades can be selected
to obtain a particular suspension response. (Choose SAE 5W for a softer suspension, 20W for a stiffer
suspension).
The two grades can also be mixed in varying solutions to obtain the desired response.
F.A. or Fork have special properties, which enable them to retain virtually the same
viscosity regardless of temperature to give constant damping response.
(Recommended) front forks oil, see 1.8.1.
1-8
GENERAL INFORMATION
ATLANTIC 125 - 200
BRAKE FLUID
IMPORTANT This motorcycle is fitted with two (front and rear) disk brakes with independent hydraulic circuits. The
information provided below applies to both braking systems.
DANGER
Do not drive the vehicle if the brakes are worn or not operating correctly! The brakes are the vehicle’s
most important safety component and using the vehicle with the brakes in less than perfect operating
condition comprises a high probability of traffic accident, which can result in serious injury or death.
The brakes are significantly less effective on a wet road surface.
DANGER
If the road surface is wet with rain, maintain a double braking distance, inasmuch as both the brakes
themselves and the grip of the tires are significantly less effective in such conditions.
Water on the brakes, whether due to a recent wash or picked up from the wet road surface, puddles or
drains, can result in significantly reduced brake effectiveness.
Failure to observe these instructions can result in serious accidents, with the risk of serious personal
injury or death.
The brakes are essential to your safety. Do not drive the vehicle if the brakes are not perfectly
operational.
Always check the brakes before riding the motorcycle.
Brake fluid is an irritant. Avoid contact with eyes or skin.
In the event of accidental contact, wash affected body parts thoroughly. In the event of accidental
contact with eyes, contact an eye specialist or seek medical advice.
DO NOT DISPOSE OF THE FLUID INTO THE ENVIRONMENT.
KEEP AWAY FROM CHILDREN.
When handling brake fluid, take care not to spill it onto plastic or paint-finished parts or they will
damage.
Check the brake fluid level after the first 621mi (1000 km) and every 3728 mi (6000 km) thereafter, see
2.10.1., and 2.10.4.; replace the brake fluid every two years and see 2.10.2..
DANGER
Do not use any brake fluids other than the specified type. Never mix different types of fluids to top up
level, as this will damage the braking system.
Do not use brake fluid from containers which have been kept open or in storage for long periods.
Any sudden changes in slack or hardness in the brake levers are warning signs of problems with the
hydraulic circuits.
Ensure that the brake discs and friction material have not become contaminated with oil or grease.
This is particularly important after servicing or inspections.
Make sure the brake lines are not twisted or worn.
Avoid accidental ingress of water or dust into the circuit.
Wear latex gloves when servicing the hydraulic circuit.
1-9
GENERAL INFORMATION
ATLANTIC 125 - 200
DISK BRAKES
DANGER
The brakes are the vehicle’s most important safety component.
To ensure your personal safety, they must be in perfect working order and should be checked before
every ride.
Oil or other liquids on the disks will contaminate the brake pads.
Dirty brake pads must be replaced. Dirty or oily brake disks must be cleaned with a high quality
degreasing product.
If the vehicle is often used on wet road surfaces or on dusty or rough tracks, or in case of use in
competition, reduce the service intervals by half, see 2.1.2..
Check the wear of the brake pads, see 2.10.3..
When the pads are worn, the fluid level in the tank lowers to compensate for the wear.
The front brake fluid reservoir is on the RH side of the handlebar, next to the front brake lever.
The rear brake fluid reservoir is under the RH side fairing.
Do not use the vehicle if the brake system is leaking in any position.
COOLANT
DANGER
Coolant is toxic when ingested and is an irritant, contact with eyes or skin may cause irritation.
In the event of contact with eyes, rinse repeatedly with abundant water and seek medical advice. In the
event of ingestion, induce vomiting, rinse mouth and throat with abundant water and seek medical
advice immediately.
DO NOT DISPOSE OF THE FLUID INTO THE ENVIRONMENT.
KEEP AWAY FROM CHILDREN.
DANGER
Take care not to spill coolant onto hot engine parts. It may ignite and produce invisible flames. Wear
latex gloves when servicing.
Do not ride when coolant is below the minimum level.
Check the coolant level before departure and every 621 mi (1000 km), see 2.9.1.; replace every 16 months, see
5.2.1..
Coolant mixture is a 50% solution of water and anti-freeze. This is the ideal solution for most operating temperatures and
provides good corrosion protection. This solution is also suited to the warm season, as it is less prone to evaporative loss
and will reduce the need for top-ups. In addition, less water evaporation means fewer minerals salts depositing in the
radiator, which helps preserve the efficiency of the cooling system.
When the outside temperature drops below freezing, check the coolant circuit frequently and add more anti-freeze (up to
60% maximum) to the solution.
Use distilled water in the coolant mixture. Tap water will damage the engine.
(Recommended) coolant, see 1.8.1..
Refer to the chart given below and add water with the quantity of anti-freeze to obtain a solution with the desired freezing
point:
IMPORTANT The different brands of anti-freeze available on the market have varying specifications. Always read
product label to determine the degree of protection afforded.
WARNING
Use only nitrite-free anti-freeze and corrosion inhibitors with a freezing point of -35°C as a minimum.
1 - 10
GENERAL INFORMATION
ATLANTIC 125 - 200
TIRES
WARNING
An overinflated tire results in a hard, uncomfortable and less secure ride.
Overinflation also affects grip, especially on curves and in the wet.
An underinflated tire (insufficient pressure) can slip on the wheel rim, resulting in loss of control.
Underinflation also affects grip and handling, as well as braking efficiency.
Tire replacement and repair, and wheel servicing and balancing are delicate operations. They should
be carried out using adequate tools and are best left to experienced mechanics.
New tires may be covered with a thin layer of protective coating which is slippery. Drive carefully for
the first few kilometers (miles).
Never use any kind of rubber treatment product on the tires.
In particular, take care not to allow the tire to come into contact with liquid fuel, which rapidly
deteriorates the tire rubber.
A tire which has come into contact with oil or fuel cannot be cleaned and must be replaced.
DANGER
Certain OEM tires are equipped with wear indicators.
There are various types of wear indicators.
Contact your Dealership for tire checking information.
Check tire wear visually and have the tires replaced when they are worn.
If a tire deflates during a ride, do not attempt to continue the trip.
Avoid sudden braking or steering maneuvers, and do not decelerate rapidly.
Slowly decelerate and move to the edge of the road braking with the engine until you come to a
standstill.
Failure to observe these instructions can result in serious accidents, with the risk of serious personal
injury or death.
Never use tube tires on tubeless tire rims, or vice versa.
1 - 11
GENERAL INFORMATION
ATLANTIC 125 - 200
1.4. RUNNING-IN
1.4.1. RUNNING-IN INSTRUCTIONS
Proper engine running-in is essential to preserving engine life and performance over time.
Twisty roads and gradients are ideal to break in engine, suspension and brakes effectively.
Varying speed frequently is also recommended.
This will vary the amount of stress placed on vehicle components continuously, allowing engine parts to cool down when
less stressed.
While it is important to put a certain amount of stress to engine components during the running-in period, it is equally
important to spare the engine at this stage in vehicle's life.
WARNING
Top acceleration performance is only obtained after covering the first 932 mi (1500 km).
WARNING
After covering the first 621 mi (1000 km), perform the checks listed in the "post running-in" column,
see 2.1.2.. Failure to perform these checks may lead to personal injury to yourself or third
persons, or vehicle damage.
• After the first 621 mi (1000 km), gradually increase the speed to maximum performance.
1 - 12
GENERAL INFORMATION
ATLANTIC 125 - 200
ENGINE NUMBER
The engine number is etched at the rear end of engine, near
to the suspension.
DIGIT MEANING
1. Manufacturer’s identification alphanumeric code
2. Error Type
3. Model
4. Country for which the vehicle is intended
5. # = Check digit number
6. Model year
7. Assembling factory designation (N = NOALE-VE-, S =
SCORZÉ-VE- 0 = NOT SPECIFIED)
8. Sequential serial number
1 - 13
GENERAL INFORMATION
ATLANTIC 125 - 200
WARNING
Using any parts other than original aprilia parts may lead to loss of performance and damage.
1 - 14
GENERAL INFORMATION
ATLANTIC 125 - 200
1.7. SPECIFICATIONS
1.7.1. SPECIFICATIONS
DIMENSIONS
Max. length 82.7 in (2100 mm)
Max. width (on the rear view mirrors) 35.4 in (900 mm)
Seat height 31.1 in (790 mm)
Maximum height (at front windscreen) 55.1 in (1400 mm)
Min. ground clearance 7.8 in (190 mm)
Empty weight (ready to start) 6.3 in (160 kg)
Wheelbase 57.9 in (1470 mm)
ENGINE
Make Piaggio Leader 125 4T 4V Water
Make (200) Piaggio Leader 200 4T 4V Water
Type 4-stroke single-cylinder with 4 valves, forced lubrication
with wet sump, overhead camshaft.
Number of cylinders 1
Total displacement 7.6 in³ (124 cm³)
Total displacement (200) 12.1 in³ (197.75 cm³)
Bore/stroke 2.2 in / 1.9 in (57 mm /48.6 mm)
Bore/stroke (200) 2.8 in / 1.9 in (72 mm /48.6 mm)
Intake valve play 0.10
Exhaust valve play 0.15
Compression ratio 12.5 ± 0.5: 1
Compression ratio (200) 11.5 ± 0.5: 1
Starting Electric
Engine idling rpm 1750 ± 100 rpm
Clutch Centrifugal
Transmission Automatic
Cooling Fluid (50% water + 50% coolant) with forced circulation
CAPACITY
Fuel (reserve included) 10.5 liters
Fuel reserve 1.5 liters
Engine oil
- only engine oil change 61.0 in³ (1000 cm³)
- engine oil and filter change 67.1 in³ (1100 cm³)
- replacement (engine overhaul) 70.1 in³ (1150 cm³)
Transmission oil 15.3 in³ (250 cm³)
Coolant 1.2 liters
Seats 2
Max vehicle load (driver + passenger + luggage) (210 kg)
TRANSMISSION
Variator automatic continuous
Primary V-belt
End Gear train
Total engine/wheel ratio (125)
- short 1:28.03
- long 1:8.41
Total engine/wheel ratio (200)
- short 1:21.05
- long 1:7.37
CARBURETOR
Model (125) WVF 7C* Ø29 WALBRO
Model (200) CVK 7C* 30 KEIHIN
Model (200) WVF 7D* Ø 29 WALBRO
FUEL SUPPLY
Type Vacuum pump
Fuel Premium grade unleaded petrol, min. O.N. 95 (N.O.R.M.)
and 85 (N.O.M.M.).
FRAME
Type Single-beam with overlying duplex cradle
Steering inclination angle 27°
Trail 4.1 in (104 mm)
1 - 15
GENERAL INFORMATION
ATLANTIC 125 - 200
SUSPENSIONS
Front telescopic hydraulic fork
Stroke 4.3 in (110 mm)
Rear n. 1 hydraulic shock absorber
Stroke 4.1 in (105 mm)
BRAKES
Front Disk – Ø 9.4 in (Ø 240 mm) – with hydraulic transmission
Rear Disk – Ø 7.5 in (Ø 190 mm) – with hydraulic transmission
(combined with front brake)
WHEELS
Wheel rims
Front E – 13 x 3.00 DOT - D
Rear E – 13 x 3.50 DOT - D
TIRES
Front 110/90 – 13" 56P
Rear 130/70 – 13" 63P
STANDARD INFLATION PRESSURES
Front 30.5 PSI (210 kPa)
Rear 31.9 PSI (220 kPa)
INFLATION PRESSURE WITH PASSENGER
Front 31.9 PSI (220 kPa)
Rear 34.8 PSI (240 kPa)
IGNITION
Type Magneti Marelli, capacitive discharge with variable
advance
Spark advance 15° ± 1 – 2000 rpm 10° ± 1 – 2000 rpm
Spark advance (200) 34° ± 1 – 6000 rpm. 32° ± 1 – 6500 rpm
Standard sparkplug NGKCR8EB
Spark plug gap 0.02-0.03 in (0.7 – 0.8 mm)
ELECTRICAL SYSTEM
Battery 12 V – 12 Ah
Fuses 20 – 15 – 7.5 A
Alternator (with permanent magnet) 12 V – 180 W
BULBS
Low beam 12 V – 55 W
High beam (F) 12 V – 55 W
Parking lights 12 V – 16 W
Direction indicators 12 V – 10 W
Tail/brake lights 12 V – 5 W / 21 W
WARNING LIGHTS
Dashboard lights 12 V – 1.2 W
Direction indicators 12 V – 1.2 W
Engine oil pressure 12 V – 1.2 W
Low beam 12 V – 1.2 W
High beam 12 V – 1.2 W
Fuel reserve 12 V – 1.2 W
1 - 16
GENERAL INFORMATION
ATLANTIC 125 - 200
We recommend using:
- - a medium spatula (1);
1 - 17
GENERAL INFORMATION
ATLANTIC 125 - 200
1 - 18
GENERAL INFORMATION
ATLANTIC 125 - 200
1.8. PRODUCTS
1.8.1. LUBRICANT CHART
LUBRICANT PRODUCT
Engine oil RECOMMENDED: SUPERBIKE 4, SAE 5W – 40 or
4T FORMULA RACING, SAE 5W - 40.
As an alternative to the recommended oils, it is possible to use select oils
having properties in compliance with or even above 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, use select oils having properties
in compliance with or even above A.P.I. GL3 specifications
Fork oil RECOMMENDED: F.A. 5W or F.A. 20W, as an alternative
FORK 5W or FORK 20W.
Should you wish to reach an average behavior between those offered by
F.A. 5W and by F.A. 20W or FORK 5W and by
FORK 20W, mix the products as follows:
SAE 10W = F.A. 5W 67% of the volume, + F.A. 20W 33% of the
volume.
FORK 5W 67% of the volume + FORK 20W
33% of the volume.
SAE 15W = F.A. 5W 33% of the volume, + F.A. 20W 67% of the
volume.
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 select oil for rolling
bearings, useful temperature range -30°C…+140°C, dripping point
150°C…230°C, highly anticorrosive, water and oxidization resistant.
Battery terminals Neutral grease or vaseline.
Brake fluid The braking system is filled with Autofluid FR. DOT 4 (DOT 5 can be
used as well) + BRAKE 5.1 DOT 4 (DOT 5 compatible).
NOTE Before mixing different makes or types of oil, check their
compatibility.
As an alternative to the recommended fluid, use fluids having properties in
compliance with or even above SAE J1703, NHTSA 116 DOT 4, ISO 4925
specifications.
Engine coolant RECOMMENDED: ECOBLU – 40° C + COOL.
As an alternative to the recommended fluid, use fluids having properties in
compliance or even above basic ethylene glicol CUNA NC 956-16
specifications.
1 - 19
GENERAL INFORMATION
ATLANTIC 125 - 200
Description Use
Molykote 111 / N. ROTAX 897 161 - Space between the two water pump oil seals.
- Starter transmission gears.
LOCTITE ANTI-SEIZE 76710 N. ROTAX 297 431 - Engine shaft ball bearing seats.
- Engine countershaft ball bearing seats.
- Gearshaft ball bearing seats.
LOCTITE 648 / N. ROTAX 899 788 - Hex nut for locking the flywheel to the engine shaft.
- Casing water hose.
- Casing electric starter hole cover (RX only)
1 - 20
GENERAL INFORMATION
ATLANTIC 125 - 200
1.9. TIGHTENING
1.9.1. TORQUE FIGURES
Tightening torque table for class 8.8 screws, in
steel/aluminum or similar strength material.
1 - 21
GENERAL INFORMATION
ATLANTIC 125 - 200
1 - 22
GENERAL INFORMATION
ATLANTIC 125 - 200
1 - 23
GENERAL INFORMATION
ATLANTIC 125 - 200
1 - 24
GENERAL INFORMATION
ATLANTIC 125 - 200
10
11
12
13
1 - 25
GENERAL INFORMATION
ATLANTIC 125 - 200
14
15
16
17
1 - 26
GENERAL INFORMATION
ATLANTIC 125 - 200
18
19 Muffler stamping.
20
21
1 - 27
GENERAL INFORMATION
ATLANTIC 125 - 200
1. Fuel tank
2. Tank fumes breather tube
3. Drain tube
4. Carbon canister – to carburetor
5. To filter housing sleeve
6. Carbon canister
7. Multifunction valve
8. Filter housing sleeve
9. Carburetor
1 - 28
PERIODIC MAINTENANCE
ATLANTIC 125 - 200
PERIODIC MAINTENANCE 2
2-1
PERIODIC MAINTENANCE
ATLANTIC 125 - 200
SUMMARY
2.1. PERIODIC MAINTENANCE .........................................................................................................3
2.1.1. INTRODUCTION .................................................................................................................3
2.1.2. PERIODIC MAINTENANCE CHART....................................................................................4
2.2. LUBRICATION POINTS...............................................................................................................5
2.2.1. LUBRICATION POINTS.......................................................................................................5
2.3. TIGHTENING...............................................................................................................................6
2.3.1. TORQUE OF NUTS AND BOLTS ........................................................................................6
2.3.2. FASTENERS.......................................................................................................................7
2.4. BATTERY ....................................................................................................................................9
2.4.1. BATTERY............................................................................................................................9
2.4.2. CHECKING AND CLEANING THE TERMINALS AND CLAMPS ........................................10
2.4.3. CHECKING THE ELECTROLYTE LEVEL..........................................................................11
2.4.4. RECHARGING THE BATTERY .........................................................................................12
2.4.5. LONG INACTIVITY OF THE BATTERY .............................................................................13
2.5. ELECTRIC COMPONENTS .......................................................................................................14
2.5.1. ELECTRIC COMPONENTS...............................................................................................14
2.6. SPARK PLUG ............................................................................................................................15
2.6.1. SPARK PLUG....................................................................................................................15
2.7. AIR CLEANER...........................................................................................................................17
2.7.1. AIR CLEANER...................................................................................................................17
2.8. TUBES.......................................................................................................................................18
2.8.1. TUBES ..............................................................................................................................18
2.9. COOLANT .................................................................................................................................19
2.9.1. CHECKING AND TOPPING UP COOLANT LEVEL ...........................................................19
2.9.2. CLEANING THE RADIATOR .............................................................................................20
2.10. BRAKE FLUID .......................................................................................................................21
2.10.1. CHECKING AND TOPPING UP BRAKE FLUID LEVEL .....................................................21
2.10.2. CHANGING THE BRAKE FLUID .......................................................................................23
2.10.3. CHECKING BRAKE PADS FOR WEAR.............................................................................24
2.10.4. BLEEDING THE BRAKE CIRCUITS ..................................................................................25
2.1.1...................................................................................................................................................25
2.11. ENGINE OIL ..........................................................................................................................28
2.11.1. CHECKING AND TOPPING UP THE ENGINE OIL ............................................................28
2.11.2. ENGINE OIL AND FILTER CHANGE.................................................................................29
2.12. TRANSMISSION OIL.............................................................................................................30
2.12.1. CHECKING AND TOPPING UP THE TRANSMISSION OIL...............................................30
2.12.2. TRANSMISSION OIL CHANGE.........................................................................................31
2.13. THROTTLE............................................................................................................................32
2.13.1. THROTTLE .......................................................................................................................32
2.13.2. IDLING ADJUSTMENT......................................................................................................34
2.14. FRONT END..........................................................................................................................35
2.14.1. STEERING ........................................................................................................................35
2.14.2. FRONT SUSPENSION ......................................................................................................36
2.15. TAIL SECTION ......................................................................................................................37
2.15.1. CHECKING THE ENGINE AXLE .......................................................................................37
2.15.2. REAR SUSPENSION INSPECTION ..................................................................................38
2.16. WHEELS ...............................................................................................................................39
2.16.1. WHEELS ...........................................................................................................................39
2.17. TIRES....................................................................................................................................40
2.17.1. TIRES................................................................................................................................40
2.18. EXHAUST..............................................................................................................................41
2.18.1. EXHAUST MANIFOLD NUTS ............................................................................................41
2-2
PERIODIC MAINTENANCE
ATLANTIC 125 - 200
DANGER
Before proceeding to maintain or inspect the motorcycle, stop the engine and remove the ignition switch
key. Ensure that the engine and exhaust system have cooled down. Wherever possible, place the
motorcycle on firm and level ground and lift it using suitable equipment. Pay particular attention to any
parts of the engine or exhaust system that may still be hot to the touch to avoid burns. All component
parts of the vehicle are inedible. Do not bite, suck, chew or swallow any vehicle parts. If not expressly
indicated otherwise, for the reassembly of the units repeat the disassembly operations in reverse order.
2-3
PERIODIC MAINTENANCE
ATLANTIC 125 - 200
1 = check and clean, adjust, lubricate or change, if necessary; 2 = clean; 3 = change; 4 = adjust.
Service the motorcycle more frequently when you ride in the rain, on dusty or bumpy roads, or in competition trials.
2-4
PERIODIC MAINTENANCE
ATLANTIC 125 - 200
2-5
PERIODIC MAINTENANCE
ATLANTIC 125 - 200
2.3. TIGHTENING
2.3.1. TORQUE OF NUTS AND BOLTS
Ensure that all fasteners are properly tightened. Take special
care with safety-related items, namely:
- Handlebar-to-upper plate fastener;
- front brake lever;
- clutch lever;
- fuel delivery pipe;
- front fork to yoke;
- front fork to front wheel spindle clamps;
- front wheel;
- front brake line fittings;
- front brake disk;
- front brake caliper;
- engine;
- sprocket;
- rear brake lever;
- swinging arm;
- swinging arm levers;
- rear shock absorber;
- rear wheel;
- rear brake disk;
- rear brake caliper;
- rear brake line fittings.
WARNING
All fasteners must be tightened to the specified
torque. Use LOCTITE ONLY where specified,
see 2.3.2.
Lubricate only those parts indicated in the
relevant chart, see 2.3.2.
2-6
PERIODIC MAINTENANCE
ATLANTIC 125 - 200
2.3.2. FASTENERS
Check and tighten as required after the first 1000 km (621 mi) and every 6000 km (3728 mi) or 8 months afterwards.
WARNING
The fastening elements specified in the table must be tightened to the specified torque value using a
®
torque wrench and, where recommended, applying LOCTITE .
Safety-related items ( ) are in brackets.
NOTE:
®
L243 = tighten with Loctite 243
lub = lubricate
FRAME
Description Qty Screw/Nut Nm ftlb Notes
Braking distributor to frame fastening M6 10 7.4
Bridge to frame fastening M6 12 8.8
Lockring 3 M25x1.5 45 33.2
To breaking To breaking
Key switch fastening shear rivet 1 M6x25
point point
Ignition keyswitch screw 4 M6x25 8,5 6.3
STAND
Description Qty Screw/Nut Nm ftlb Notes
Center stand to engine fastening 1 M10 27 19.9
Side stand to engine fastening M10 20 14.7
CONNECTING RODS
Description Qty Screw/Nut Nm ftlb Notes
Connecting rods to frame fastening M12 pin 60 44.2
Connecting rod to engine fastening M10 pin 40 29.5
Connecting rod / connecting rod
M12 pin 60 44.2
fastening
Silencer fastening M8 25 18.4
REAR SUSPENSION
Description Qty Screw/Nut Nm ftlb Notes
Rear shock absorber-to- frame fastener M10 50 36.9
Rear shock absorber to engine fastening M10 50 36.9
Shock absorber mount to engine
M8x50 25 18.4
fastening
AIRBOX
Description Qty Screw/Nut Nm ftlb Notes
Airbox to engine fastening 1 M6x45 8 5.9
Airbox to engine fastening 1 M6x55 8 5.9
EXHAUST SYSTEM
Description Qty Screw/Nut Nm ftlb Notes
Manifold to head fastening 2 M7 nut 17 12.5
Silencer plate fastening 3 M8x40 25 18.4
Manifold clamp fastening 1 10 7.4
Silencer plate fastening 2 M8x40 25 18.4
FRONT WHEEL
Description Qty Screw/Nut Nm ftlb Notes
Wheel spindle 1 M12 40 29.5
Safety screw M6 12 8.8
REAR WHEEL
Description Qty Screw/Nut Nm ftlb Notes
Wheel nut M16x1.5 110 81.1
2-7
PERIODIC MAINTENANCE
ATLANTIC 125 - 200
2-8
PERIODIC MAINTENANCE
ATLANTIC 125 - 200
2.4. BATTERY
2.4.1. BATTERY
Read carefully 1.2.1.
DANGER
The battery electrolyte is a toxic, caustic
substance containing sulphuric acid and thus
able to cause severe burns in case of contact.
Always wear protective clothes, a mask and/or
safety goggles when handling this fluid.
If any battery fluid gets on your skin, rinse the
affected area with abundant fresh water.
If battery fluid is spilled into your eyes, flush
with abundant water for fifteen minutes and
contact an eye specialist immediately.
If battery fluid is swallowed accidentally, drink
abundant water or milk. Seek medical attention
immediately and keep drinking milk of
magnesia or vegetable oil in the meantime.
The battery gives off explosive gases. Keep the
battery well away from any sources of ignition,
such as flames, sparks, or any heat sources.
Charge or use the battery in a well-ventilated
place. Do not inhale the gases produced by the
battery under charging.
KEEP AWAY FROM CHILDREN
Take care not to tilt the vehicle too far as the
battery fluid may spill out.
WARNING
Never invert the connection of the battery
cables.
Set the ignition switch to " " before
connecting or disconnecting the battery.
Connect first the positive cable (+) and then the
negative cable (-).
Disconnect in the reverse order.
-
2-9
PERIODIC MAINTENANCE
ATLANTIC 125 - 200
• Make sure that the cable terminals (2) and the battery
terminals (3) are:
- in good conditions (and not corroded or covered with
deposits);
- covered with neutral grease or vaseline.
If necessary, proceed as follows:
• Disconnect the negative (-) and positive (+) leads in
that order.
• Clean off corrosion deposits using a wire brush.
• Reconnect the positive (+) and negative (-) leads in the
order.
• Cover the terminals of the cables and of the battery
with neutral grease or vaseline.
2 - 10
PERIODIC MAINTENANCE
ATLANTIC 125 - 200
• Check that the fluid level is between the MIN and MAX
marks printed on the side of the battery.
If not:
• Remove the battery, see 7.2.1.
• Remove the cell plugs.
WARNING
Top up the electrolyte using distilled water
only. Do not fill above the "MAX" mark as the
level increases during recharging.
2 - 11
PERIODIC MAINTENANCE
ATLANTIC 125 - 200
IMPORTANT You can tell that the battery is nearly flat when
you hear a rattling sound from the starter relay when
pressing the starter button " ".
Do not remove the battery plugs or the battery may damage.
• Remove the battery, see 7.2.1.
• Remove the cell plugs.
• Check the battery fluid level, see 2.4.3.
• Connect the battery to a battery charger.
• We recommend using a battery charger with amperage
rating 1/10 that of the battery itself.
• After the battery is fully charged, check the fluid level
and top up with distilled water if necessary.
• Refit the cell plugs.
WARNING
Reassemble the battery only 5/10 minutes after
disconnecting the recharge apparatus, since
the battery continues to produce gas for a short
lapse of time.
2 - 12
PERIODIC MAINTENANCE
ATLANTIC 125 - 200
WARNING
If the vehicle is not used for more than twenty
days, remove the 20 A fuse to avoid the battery
running down.
The removal of the 20A fuses requires the
setting to zero of the following functions:
digital clock and red line setting.
2 - 13
PERIODIC MAINTENANCE
ATLANTIC 125 - 200
WARNING
The sensing area of the sensors must be kept
clean. Any mud, dirt deposits, etc. will lead to
misreading.
2 - 14
PERIODIC MAINTENANCE
ATLANTIC 125 - 200
Check the spark plug after the first 621 mi (1000 km) and
then after 3728 mi (6000 km), change it every 7456 mi
(12000 km).
• Check the spark plug regularly, remove carbon deposits
and replace if necessary.
To reach the spark plugs:
DANGER
Allow the engine to cool down to ambient
temperature.
• Remove the seat protection screen, 7.1.3.
Removal and cleaning:
DANGER
Never remove a spark plug cap while the
engine is running. Shock hazard: the ignition
system produces high voltages.
• Remove the cap (1) of the spark plug (2).
• Remove any trace of dirt from the spark plug base.
• Introduce the special spanner provided in the tool kit
on the spark plug.
• Unscrew the spark plug and extract it from its seat,
taking care to prevent dust or other substances from
getting inside the cylinder.
2 - 15
PERIODIC MAINTENANCE
ATLANTIC 125 - 200
WARNING
The spark plug must be well tightened,
otherwise the engine may overheat and be
seriously damaged.
Use recommended spark plugs only. A
spark plug of the wrong grade may shorten
engine life and cause loss of performance.
DANGER
Ensure the spark plug cap (1) is properly in
place on the spark plug (2).
•
2 - 16
PERIODIC MAINTENANCE
ATLANTIC 125 - 200
WARNING
Cleaning the filter does not eliminate the need
to change the filter at the specified intervals.
Do not start the engine if the air cleaner has
been removed.
Do not clean the filter element with petrol or
solvents. These products may cause the fuel to
ignite in the fuel system, leading to personal
injury and vehicle damage.
-
CLEANING
• Remove the cleaner, see 4.2.2.
• Wash the filter element with clean, non-flammable or
high flashpoint solvent, and dry it carefully.
• Apply a film of filter oil or dense oil (SAE 80W – 90),
then wring out excess oil.
WARNING
When cleaning the filtering element, make sure
that there are no tears.
Otherwise, change the filtering element.
IMPORTANT The filtering element must be wet but not
dripping.
• Clean the outer part of the air cleaner with a clean
cloth.
• Clean the inside of the filter box with a clean cloth.
• Clean the intake ducts.
CHANGING
WARNING
Do not use filters that have already been used.
2 - 17
PERIODIC MAINTENANCE
ATLANTIC 125 - 200
2.8. TUBES
2.8.1. TUBES
Read carefully 1.2.1..
FUEL
WARNING
Always change a worn, cracked or damaged
fuel line.
BRAKES
WARNING
Always change a worn, cracked or damaged
line.
-
COOLING SYSTEM
WARNING
Always change a worn, cracked or damaged
coolant line. Maintaining fasteners at the
correct tightening torque.
-
2 - 18
PERIODIC MAINTENANCE
ATLANTIC 125 - 200
2.9. COOLANT
2.9.1. CHECKING AND TOPPING UP COOLANT
LEVEL
Carefully read 1.2.1. and 1.3.1.
DANGER
Coolant is toxic when ingested and is an
irritant, contact with eyes or skin may cause
irritation.
Do not put your fingers or any tools into the
filler opening to check coolant level.
WARNING
Do not add any additives or other products.
If you use a funnel or other similar items, make
sure that they are perfectly clean.
WARNING
In the event the motorcycle is using up
exceeding coolant or the expansion reservoir is
empty, check the circuit for leaks.
2 - 19
PERIODIC MAINTENANCE
ATLANTIC 125 - 200
2 - 20
PERIODIC MAINTENANCE
ATLANTIC 125 - 200
Check the brake fluid after the first 621 mi (1000 km) and
every 3728 mi (6000 km) or 8 months thereafter. Replace
every 2 years.
IMPORTANT The following procedure can be applied to
either brake.
WARNING
Bleed the circuit when the brake lever has
excessive travel or feels spongy or whenever you
suspect that there might be air trapped in the
circuit; see 2.10.4..
Plastic or paint-finished parts will damage if brake
fluid is spilt on them.
Before each ride, ensure that the clutch lines are
not twisted or cracked and check the fittings for
leaks.
Never top up with or mix different types of silicone
or petroleum-based fluids.
Never use brake fluid from containers which have
been open or kept in storage for long periods.
Avoid accidental ingress of water or dust into the
circuit.
INSPECTION
IMPORTANT Place the motorcycle on firm and level ground.
• Place the motorcycle on the center stand.
• Check that fluid level in the reservoir is above the "MIN"
mark.
• Top up when level is below the "MIN" mark:
WARNING
Brake fluid level decreases gradually as brake
pads wear down.
• Check the wear of the brake pads, see 2.10.3..
• If the pads/disk do not require replacement, top up the
fluid.
TOP-UP
WARNING
Danger: brake fluid could leak out. Never
operate the front brake lever when the screws
(1) have been loosened or when the reservoir
cover is not in place. Use a cloth under the
brake fluid tank.
• Release and remove the four screws (1).
WARNING
Avoid long exposure of brake fluid to air.
Brake fluid is hygroscopic and will absorb
moisture from the air.
Keep the brake fluid reservoir open JUST LONG
ENOUGH to top up level.
2 - 21
PERIODIC MAINTENANCE
ATLANTIC 125 - 200
WARNING
Do not overfill (top up beyond the "Max" level).
To achieve the correct level, always renew the
brake pads before topping up to "MAX" level.
Brake fluid level decreases gradually as brake
pads wear down.
Do not top up to the MAX level with worn brake
pads installed, as the fluid will leak out when
new pads are fitted.
• Reverse the disassembly procedure to reassemble.
2 - 22
PERIODIC MAINTENANCE
ATLANTIC 125 - 200
2 - 23
PERIODIC MAINTENANCE
ATLANTIC 125 - 200
WARNING
Check the wear of the brake pads, especially
before every trip.
WARNING
The excessive wear of the friction material
would cause the contact of the pad metal
support with the disk, with consequent metallic
noise and production of sparks from the
caliper; braking efficiency, safety and
soundness of the disk would thus be negatively
affected.
2 - 24
PERIODIC MAINTENANCE
ATLANTIC 125 - 200
DANGER
This is a dangerous condition that makes the
vehicle unsafe to ride. Each time the brakes are
removed, it is indispensable to bleed the
hydraulic circuit once the brakes have been
refitted and the braking system is back to
normal operating conditions.
Brake fluid is an irritant. Avoid contact with
eyes or skin.
In the event of accidental contact, wash
affected body parts thoroughly. In the event of
accidental contact with eyes, contact an eye
specialist or seek medical advice.
WARNING
Handle with care: contact with brake fluid will
alter the chemical properties of paintwork,
plastic and rubber parts, etc.
Wear latex gloves during servicing.
Do not spill brake fluid on plastic or paint-
finished parts or they will damage.
DELAY VALVE
2 - 25
PERIODIC MAINTENANCE
ATLANTIC 125 - 200
FRONT BRAKE
REAR BRAKE
2 - 26
PERIODIC MAINTENANCE
ATLANTIC 125 - 200
2 - 27
PERIODIC MAINTENANCE
ATLANTIC 125 - 200
Replace the engine oil after the first 625 mi (1000 km) (at the
end of running-in) and every 1864 mi (3000 km) thereafter.
Change the oil every 3728 mi (6000 km).
IMPORTANT Use only recommended engine oil,
1.8.1.
Do not overfill (top up beyond the "Max" level).
INSPECTION
• Place the motorcycle on firm and level ground.
• Place the motorcycle on the center stand.
WARNING
Allow the engine and exhaust system to cool
down before proceeding.
• Now remove the cap/dipstick (1) and read the oil level
off the dipstick:
Max = maximum level
Min = minimum level.
DANGER
Do not overfill (beyond the "MAX" mark) or let level
drop below the "MIN" mark, as this will cause severe
engine damage.
• Top up as necessary.
TOP-UP
• Pour a small quantity of oil into the filler hole (2) and
wait a minute to allow the oil to flow into the crankcase.
• Check the oil level, and top up again as necessary.
• Top up with small amounts of oil until the prescribed
level is reached.
• Tighten the cap/dipstick (1) securely at the end of the
operation.
IMPORTANT Do not use the vehicle if insufficiently
lubricated or if the oil is dirty or of the wrong type, as this will
increase the wear of moving parts and can result in serious
damage.
2 - 28
PERIODIC MAINTENANCE
ATLANTIC 125 - 200
Replace the engine oil filter after the first 621 mi (1000 km)
(at the end of running-in) and every 3728 mi (6000 km)
thereafter.
WARNING
Allow the engine and exhaust system to cool
down before proceeding.
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.
• Unscrew and remove the oil drain cap (3) and allow all
the engine oil to drain out.
• Fit a new oil filter cartridge (2), and oil the filter’s o-
rings with care.
• Refit and tighten the drain plug (3).
• Refill through the engine oil filler hole with 61 in3 (1000
3
cm ) of oil.
• Refit and tighten the cap/dipstick (1).
• Start the engine and allow it to run for a few minutes.
Switch off and allow to cool.
• Check the engine oil level, 2.11.1.
2 - 29
PERIODIC MAINTENANCE
ATLANTIC 125 - 200
Replace the engine oil after the first 625 mi (1000 km) (at the
end of running-in) and every 3728 mi (6000 km) or 8 months
thereafter. Change the oil every 14913 mi (24000 km),
2.12.2..
IMPORTANT Use only recommended engine oil, 1.8.1.
• Ride for a few miles until reaching the normal running
temperature, then stop the engine.
INSPECTION
• Place the motorcycle on firm and level ground.
• Place the motorcycle on the center stand.
WARNING
Allow the engine and exhaust system to cool
down before proceeding.
DANGER
Do not overfill (beyond the "MAX" mark) or let
level drop below the "MIN" mark, as this will
cause severe engine damage.
• Top up as necessary.
TOP-UP
• Pour a small quantity of oil into the filler hole (2) and
wait a minute to allow the oil to flow into the crankcase.
• Check the oil level, and top up again as necessary.
• Top up with small amounts of oil until the prescribed
level is reached.
• Tighten the cap/dipstick (1) securely at the end of the
operation.
IMPORTANT Do not use the vehicle if insufficiently
lubricated or if the oil is dirty or of the wrong type, as this will
increase the wear of moving parts and can result in serious
damage.
2 - 30
PERIODIC MAINTENANCE
ATLANTIC 125 - 200
Replace the engine oil after the first 625 mi (1000 km) (at the
end of running-in) and every 3728 mi (6000 km) or 8 months
thereafter. Change the oil every 14913 mi (24000 km).
WARNING
Allow the engine and exhaust system to cool
down before proceeding.
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.
2 - 31
PERIODIC MAINTENANCE
ATLANTIC 125 - 200
2.13. THROTTLE
2.13.1. THROTTLE
Inspect after the first 621 mi (1000 km) and every 3728 mi
(6000 km) or 8 months afterwards.
DANGER
Throttle operation may be impaired when the
throttle cables are damaged, bent in tight turns
or twisted. Using the motorcycle in this
condition may lead to loss of control while
riding.
2 - 32
PERIODIC MAINTENANCE
ATLANTIC 125 - 200
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 - 33
PERIODIC MAINTENANCE
ATLANTIC 125 - 200
2 - 34
PERIODIC MAINTENANCE
ATLANTIC 125 - 200
TIGHTENING TORQUES
Locknut (1): 81.1 ftlb (110 Nm).
WARNING
Do not force the adjuster nut (2) as this can
damage the headstock bearing.
• Screw the adjuster nut (2) until the play in the bearing
is taken up.
• Check the play by rocking the forks in the drive
direction while ensuring the steering turns smoothly
and fluidly.
• Hold the adjuster nut (2) in position and tighten down
the locknut (1) with a wrench.
• Repeat the penultimate step.
2 - 35
PERIODIC MAINTENANCE
ATLANTIC 125 - 200
If the front fork has a tendency to bottom out, the oil needs
changing, see 7.9.4. and 7.9.5.
Check the front fork for oil leaks and inspect the surface of
the fork legs for cracks or scoring.
Any damaged components should be repaired or – where
repair is not feasible – renewed, see 7.9.6.
• Ensure that all parts are properly tightened and test the
front suspension for proper operation.
2 - 36
PERIODIC MAINTENANCE
ATLANTIC 125 - 200
2 - 37
PERIODIC MAINTENANCE
ATLANTIC 125 - 200
2 - 38
PERIODIC MAINTENANCE
ATLANTIC 125 - 200
2.16. WHEELS
2.16.1. WHEELS
Read carefully 1.2.1
FRONT WHEEL
REAR WHEEL
2 - 39
PERIODIC MAINTENANCE
ATLANTIC 125 - 200
2.17. TIRES
2.17.1. TIRES
Check the tires monthly.
Take care to check tires pressures before and after a long
journey.
Tire inflation pressures should be checked monthly with the
tires at room temperature.
This vehicle is fitted with tubeless tires.
TREAD CONDITION
WARNING
Inspect tread surface and check for wear. Badly
worn tires adversely affect traction and
handling.
Always change a worn tire. A tire that becomes
punctured in the tread area should be changed
when the puncture is larger than 5 mm.
Some of the tire types approved for this vehicle
are fitted with wear indicators.
There are various types of wear indicators.
Enquire about correct wear inspection
procedure with your supplier.
Never use tube tires on tubeless tire rims, or
vice versa.
Always check that the caps are in place on the
valves (1), or the tires may deflate suddenly.
Tire replacement and repair, and wheel
servicing and balancing are delicate
operations. They should be carried out using
adequate tools and are best left to experienced
mechanics.
The wheel must be balanced after each tire
repair.
New tires may be coated with an oily film. Drive
carefully until covering several kilometers. Do
not oil the tires with unsuitable fluids.
Approved tire sizes are reported in the
registration document. Installing non-approved
tires is a legal offence.
Using tires other than the specified sizes may
change vehicle behavior, impair handling and
make the vehicle unsafe to ride.
Use only the tire types selected at the origin by
aprilia, see 1.7.1.
2 - 40
PERIODIC MAINTENANCE
ATLANTIC 125 - 200
2.18. EXHAUST
2.18.1. EXHAUST MANIFOLD NUTS
Tighten the exhaust manifold nuts after the first 621 mi (1000
km) and every 3728 mi (6000 km) or 8 months thereafter.
DANGER
Allow the engine to cool down to ambient
temperature.
2 - 41
LUBRICATION
ATLANTIC 125 - 200
LUBRICATION 3
3-1
LUBRICATION
ATLANTIC 125 - 200
SUMMARY
3.1. LUBRICATION.............................................................................................................................3
3.1.1. LUBRICATION ....................................................................................................................3
3-2
LUBRICATION
ATLANTIC 125 - 200
3.1. LUBRICATION
3.1.1. LUBRICATION
The lubrication system is described in the engine workshop manual, see 0.1.2.
3-3
FUEL SYSTEM
ATLANTIC 125 - 200
FUEL SYSTEM 4
4-1
FUEL SYSTEM
ATLANTIC 125 - 200
SUMMARY
4.3. FUEL CIRCUIT ............................................................................................................................3
4.3.1. FUEL CIRCUIT DIAGRAM...................................................................................................3
4.3.2. REPLACING THE FUEL FILTER .........................................................................................4
4.3.3. FUEL TANK REMOVAL.......................................................................................................5
4.3.4. REMOVING THE FUEL SENSOR........................................................................................6
4.4. AIR CLEANER.............................................................................................................................7
4.4.1. AIRBOX REMOVAL.............................................................................................................7
4.4.2. AIR CLEANER REMOVAL...................................................................................................8
4.5. CARBURETOR............................................................................................................................9
4.5.1. CARBURETOR REMOVAL..................................................................................................9
4.5.2. REMOVING THE CARBURETOR......................................................................................11
4.5.3. REASSEMBLING THE CARBURETOR .............................................................................14
4.5.4. CHECKING THE AUTOMATIC STARTER.........................................................................19
4.5.5. IDLING ADJUSTMENT......................................................................................................20
4-2
FUEL SYSTEM
ATLANTIC 125 - 200
Key:
1. Vacuum fittings.
2. SAI valve.
3. Fuel tank fitting.
4. Pump delivery.
5. Fuel filter.
6. Anti-flowback valve
7. Vacuum-membrane pump.
4-3
FUEL SYSTEM
ATLANTIC 125 - 200
4-4
FUEL SYSTEM
ATLANTIC 125 - 200
4-5
FUEL SYSTEM
ATLANTIC 125 - 200
4-6
FUEL SYSTEM
ATLANTIC 125 - 200
• Slacken clip (5) and extract the intake hose from the
carburetor.
4-7
FUEL SYSTEM
ATLANTIC 125 - 200
4-8
FUEL SYSTEM
ATLANTIC 125 - 200
4.5. CARBURETOR
4.5.1. CARBURETOR REMOVAL
• Remove the airbox, 4.2.1.
• Remove the seat 7.1.2.
• Release and remove the screw (1).
• Remove the guard.
4-9
FUEL SYSTEM
ATLANTIC 125 - 200
4 - 10
FUEL SYSTEM
ATLANTIC 125 - 200
• Remove the four screws (3) and sump together with its
gasket.
4 - 11
FUEL SYSTEM
ATLANTIC 125 - 200
4 - 12
FUEL SYSTEM
ATLANTIC 125 - 200
• Remove the idle flow screw with its O-ring, washer and
spring.
WARNING
Do not attempt to remove components driven
into the carburetor body, such as: fuel supply
duct, starter jet, regulation sump plug and
acceleration jet, main and idling air calibrator,
throttle spindle. Do not disassemble the screws
connecting the throttle with the spindle. The
screws are caulked after assembly and
removing them damages the spindle.
4 - 13
FUEL SYSTEM
ATLANTIC 125 - 200
• Carefully clean and blow through the idling jet (1) and
refit it.
4 - 14
FUEL SYSTEM
ATLANTIC 125 - 200
LEVEL CHECK
• Clean and blow through the fuel duct cap (2) and fit it
to the starter jet.
IMPORTANT Failure to fit this part worsens cold starting
performance, inasmuch as the starter takes cold fuel from
the bottom of the sump.
4 - 15
FUEL SYSTEM
ATLANTIC 125 - 200
• Remove the sump drain screw (3) and wash and blow
through the sump, paying special attention to the
acceleration pump delivery and intake valves.
• Since the valves are one-way , blow them through
carefully with compressed air, from the interior of the
sump for the intake valve and from the pump piston
seat for the delivery valve.
• Wash and blow through the flow screw and fit a new O-
ring.
• Prefit the following components to the screw in this
order: spring, washer and O-ring.
• Screw the flow screw into the carburetor body.
• The final position of the screw is determined by an
analysis of the exhaust gases.
• Prepare the carburetor for adjustment with the screw
turned three full turns from the closed position.
4 - 16
FUEL SYSTEM
ATLANTIC 125 - 200
• Check that the needle is not worn and that the locator
is on the third of the three notches.
• Check that the vacuum valve is not scored around its
perimeter.
• Check that the two vacuum delivery holes are not
blocked.
IMPORTANT The 2 holes are of different diameters.
4 - 17
FUEL SYSTEM
ATLANTIC 125 - 200
4 - 18
FUEL SYSTEM
ATLANTIC 125 - 200
Resistance: approx. 30 .
• use a 12V battery to power the automatic starter and
check that the piston protrudes to its maximum extent.
4 - 19
FUEL SYSTEM
ATLANTIC 125 - 200
4 - 20
FUEL SYSTEM
ATLANTIC 125 - 200
4 - 21
COOLING SYSTEM
ATLANTIC 125 - 200
COOLING SYSTEM 5
5-1
COOLING SYSTEM
ATLANTIC 125 - 200
SUMMARY
5.1. SYSTEM CONFIGURATION........................................................................................................3
5.1.1. SYSTEM CONFIGURATION ...............................................................................................3
5.2. COOLANT ...................................................................................................................................4
5.2.1. COOLANT CHANGE ...........................................................................................................4
5.3. RADIATOR ..................................................................................................................................5
5.3.1. REMOVING THE RADIATOR ..............................................................................................5
5.3.2. REMOVING THE COOLING FAN ........................................................................................7
5.4. WATER TEMPERATURE SENSOR.............................................................................................9
5.4.1. REMOVING THE WATER TEMPERATURE SENSOR.........................................................9
5.5. REMOVING THE EXPANSION RESERVOIR.............................................................................10
5.5.1. REMOVING THE EXPANSION RESERVOIR ....................................................................10
5-2
COOLING SYSTEM
ATLANTIC 125 - 200
Key:
1. Expansion reservoir connection tubing
2. Cooling fan
3. Centrifugal pump
4. Pump – cylinder pipe
5. Expansion reservoir
6. Radiator
7. Cylinder head cover
8. Engine bleed
5-3
COOLING SYSTEM
ATLANTIC 125 - 200
5.2. COOLANT
5.2.1. COOLANT CHANGE
EMPTYING
FILLING
• Fit the sleeve (1) and secure it with the clip (2).
• Top up coolant level in the expansion reservoir,
2.9.1.
5-4
COOLING SYSTEM
ATLANTIC 125 - 200
5.3. RADIATOR
5.3.1. REMOVING THE RADIATOR
• Drain the circuit, 2.12.2.
• Remove the lower guard 7.1.8.
• Disconnect the cooling fan.
5-5
COOLING SYSTEM
ATLANTIC 125 - 200
5-6
COOLING SYSTEM
ATLANTIC 125 - 200
WARNING
Handle the radiators carefully taking care not to
damage the fins.
• Undo and remove the two nuts (1) on the front and
collect the screws.
• Undo and remove the two nuts (2) on the rear and
collect the screws.
5-7
COOLING SYSTEM
ATLANTIC 125 - 200
5-8
COOLING SYSTEM
ATLANTIC 125 - 200
5-9
COOLING SYSTEM
ATLANTIC 125 - 200
5 - 10
ENGINE
ATLANTIC 125 - 200
ENGINE 6
6-1
ENGINE
ATLANTIC 125 - 200
SUMMARY
6.1. EXHAUST SYSTEM ....................................................................................................................3
6.1.1. EXHAUST SILENCER REMOVAL .......................................................................................3
6.1.2. REMOVING THE EXHAUST SYSTEM ................................................................................4
6.1.3. ENGINE COMPONENTS WHICH CAN BE REMOVED WITHOUT REMOVING THE
ENGINE ITSELF..................................................................................................................5
6.2. ENGINE.......................................................................................................................................6
6.2.1. REMOVING THE ENGINE...................................................................................................6
6.2.2. FITTING THE ENGINE TO THE FRAME .............................................................................9
6-2
ENGINE
ATLANTIC 125 - 200
DANGER
Allow for the engine and exhaust silencer to
cool down completely.
6-3
ENGINE
ATLANTIC 125 - 200
DANGER
Allow for the engine and exhaust silencer to
cool down completely.
6-4
ENGINE
ATLANTIC 125 - 200
TOP OF ENGINE
• Carburetor
• Intake manifold
• Starter
• Coolant temperature thermistor
• Thermal expansion valve
• Timing chain tensioner
FRONT OF ENGINE
• Tappets cover
• Camshaft
• Testa
• Cylinder
• Piston
BOTTOM OF ENGINE
• Exhaust silencer
• Engine oil filter
6-5
ENGINE
ATLANTIC 125 - 200
6.2. ENGINE
6.2.1. REMOVING THE ENGINE
Read carefully 1.2.1.
TIGHTENING TORQUES
Lower screw (9) 36.9 ftlb (50 Nm)
WARNING
The engine is removed by lowering it from the
frame. Make sure to have all necessary
equipment ready at hand and in place before
proceeding.
6-6
ENGINE
ATLANTIC 125 - 200
6-7
ENGINE
ATLANTIC 125 - 200
• Extract the spindle (11) from the other side and collect
the washer and spacer.
• Remove the engine complete with centre stand and
rear wheel.
6-8
ENGINE
ATLANTIC 125 - 200
TIGHTENING TORQUES
Lower screw (4) 36.9 ftlb (50 Nm)
DANGER
Handle with care. Be careful to avoid injury to
your finger and limbs.
6-9
ENGINE
ATLANTIC 125 - 200
6 - 10
ENGINE
ATLANTIC 125 - 200
WARNING
Wires and hoses must not be twisted and/or
crushed.
6 - 11
CYCLE PARTS
ATLANTIC 125 - 200
CYCLE PARTS 7
7-1
CYCLE PARTS
ATLANTIC 125 - 200
SUMMARY
7.1. BODYWORK ...............................................................................................................................4
7.1.1. BODYWORK .......................................................................................................................4
7.1.2. SEAT REMOVAL.................................................................................................................6
7.1.3. REMOVING THE UNDERSEAT PROTECTION SCREEN ...................................................7
7.1.4. REMOVING THE CARRIER RACK......................................................................................8
7.1.5. REMOVING THE REAR FAIRING .......................................................................................9
7.1.6. REMOVING THE NUMBER PLATE BRACKET..................................................................10
7.1.7. REMOVING THE CENTRAL TUNNEL...............................................................................11
7.1.8. REMOVING THE LOWER GUARD....................................................................................13
7.1.9. REMOVING THE LEG GUARDS .......................................................................................15
7.1.10. REMOVING THE FRONT PANEL......................................................................................16
7.1.11. REMOVING THE WINDSCREEN ......................................................................................17
7.1.12. REMOVING THE REARVIEW MIRRORS ..........................................................................18
7.1.13. REMOVING THE SIDE FAIRINGS.....................................................................................19
7.1.14. REMOVING THE FRONT MUDGUARD.............................................................................20
7.1.15. REMOVING THE REAR MUDGUARD...............................................................................21
7.1.16. REMOVING THE HELMET COMPARTMENT....................................................................22
7.1.17. REMOVING THE HANDLEBAR COVER ...........................................................................23
7.1.18. REMOVING THE SPLASHGUARDS .................................................................................25
7.2. ELECTRIC COMPONENTS .......................................................................................................26
7.2.1. REMOVING THE BATTERY ..............................................................................................26
7.2.2. REMOVING THE ECU.......................................................................................................27
7.2.3. REMOVING THE VOLTAGE RECTIFIER ..........................................................................28
7.2.4. REMOVING THE RIGHT COMMUTATOR.........................................................................29
7.2.5. REMOVING THE LEFT COMMUTATOR ...........................................................................30
7.2.6. REMOVING THE DASHBOARD ........................................................................................31
7.2.7. REMOVING THE HEADLIGHT ..........................................................................................33
7.2.8. REMOVING THE FRONT DIRECTION INDICATORS........................................................34
7.2.9. REMOVING THE TAIL LIGHT UNIT ..................................................................................35
7.2.10. REMOVING THE COIL......................................................................................................36
7.3. CONTROLS...............................................................................................................................37
7.3.1. REMOVING THE THROTTLE CONTROL..........................................................................37
7.3.2. REMOVING THE REAR BRAKE MASTER CYLINDER......................................................38
7.4. FRAME......................................................................................................................................39
7.4.1. REMOVING THE HANDLEBAR.........................................................................................39
7.4.2. REMOVING THE DASHBOARD/WINDSCREEN SUBFRAME ...........................................40
7.4.3. REMOVING THE SIDE STAND .........................................................................................43
7.4.4. REMOVING THE CENTER STAND ...................................................................................44
7.4.5. REMOVING THE FRAME..................................................................................................45
7.5. FRONT WHEEL.........................................................................................................................47
7.5.1. FRONT WHEEL CONFIGURATION ..................................................................................47
7.5.2. REMOVING THE FRONT WHEEL.....................................................................................48
7.5.3. DISASSEMBLING THE FRONT WHEEL ...........................................................................50
7.5.4. CHECKING FRONT WHEEL PARTS.................................................................................51
7.5.5. REFITTING THE FRONT WHEEL .....................................................................................52
7.6. REAR WHEEL ...........................................................................................................................53
7.6.1. REAR WHEEL CONFIGURATION.....................................................................................53
7.6.2. REMOVING THE REAR WHEEL .......................................................................................54
7.7. BRAKES ....................................................................................................................................56
7.7.1. BRAKES CONFIGURATION..............................................................................................56
7.7.2. REPLACING THE FRONT BRAKE PADS..........................................................................57
7.7.3. CHECKING THE FRONT BRAKE DISK.............................................................................58
7.7.4. REMOVING THE FRONT BRAKE DISK ............................................................................59
7.7.5. REPLACING THE REAR BRAKE PADS ............................................................................60
7.7.6. CHECKING THE REAR BRAKE DISK ...............................................................................61
7.7.7. REMOVING THE REAR BRAKE DISK...............................................................................62
7.7.8. REMOVING THE BRAKING DISTRIBUTOR......................................................................63
7.8. STEERING ................................................................................................................................64
7.8.1. REMOVING THE STEERING ASSEMBLY.........................................................................64
7.8.2. COMPONENT INSPECTION .............................................................................................65
7.9. FRONT FORK............................................................................................................................66
7-2
CYCLE PARTS
ATLANTIC 125 - 200
7-3
CYCLE PARTS
ATLANTIC 125 -200
7.1. BODYWORK
7.1.1. BODYWORK
1. Headlamp unit
2. Front fairing panel
3. Left rear view mirror
4. Rear brake lever
5. Rear brake master cylinder
6. Left-hand commutator
7. Glove compartment
8. Leg guard
9. Central tunnel
10. Seat lock
11. Carrier rack
12. Rear fairing
13. Tail light
14. Number plate holder
15. Mudguard
16. Air cleaner
17. Transmission oil level
18. Engine oil level
19. Center stand
20. Passenger footpegs
21. Side stand
22. Rider foot plates
23. Horn
24. Front brake caliper
25. Front brake disk
26. Front fork
27. Front mudguard
28. LH fairing
7-4
CYCLE PARTS
ATLANTIC 125 -200
29. Seat
30. Underseat
31. Battery
32. Throttle control
33. RH commutator
34. Front brake lever
35. Right rear view mirror
36. Front windscreen
37. Secondary fuses
38. Braking distributor
39. Right side panel
40. Front wheel
41. Front brake pump
42. Splash guard
43. Fuel tank
44. Main fuses
45. Expansion reservoir
46. Exhaust
47. Rear brake disk
48. Rear wheel
49. Rear brake caliper
50. ECU
7-5
CYCLE PARTS
ATLANTIC 125 - 200
7-6
CYCLE PARTS
ATLANTIC 125 - 200
7-7
CYCLE PARTS
ATLANTIC 125 - 200
7-8
CYCLE PARTS
ATLANTIC 125 - 200
• Move aside the rear fairing and disconnect the tail light
connector.
7-9
CYCLE PARTS
ATLANTIC 125 - 200
7 - 10
CYCLE PARTS
ATLANTIC 125 - 200
WARNING
Proceed with care. Do not damage the snap-on
tangs and matching recesses.
7 - 11
CYCLE PARTS
ATLANTIC 125 - 200
WARNING
Proceed with care. Do not damage the snap-on
tangs and matching recesses.
7 - 12
CYCLE PARTS
ATLANTIC 125 - 200
7 - 13
CYCLE PARTS
ATLANTIC 125 - 200
7 - 14
CYCLE PARTS
ATLANTIC 125 - 200
WARNING
Proceed with care. Do not damage the snap-on
tangs and matching recesses.
7 - 15
CYCLE PARTS
ATLANTIC 125 - 200
7 - 16
CYCLE PARTS
ATLANTIC 125 - 200
7 - 17
CYCLE PARTS
ATLANTIC 125 - 200
7 - 18
CYCLE PARTS
ATLANTIC 125 - 200
7 - 19
CYCLE PARTS
ATLANTIC 125 - 200
7 - 20
CYCLE PARTS
ATLANTIC 125 - 200
7 - 21
CYCLE PARTS
ATLANTIC 125 - 200
7 - 22
CYCLE PARTS
ATLANTIC 125 - 200
7 - 23
CYCLE PARTS
ATLANTIC 125 - 200
7 - 24
CYCLE PARTS
ATLANTIC 125 - 200
7 - 25
CYCLE PARTS
ATLANTIC 125 - 200
7 - 26
CYCLE PARTS
ATLANTIC 125 - 200
7 - 27
CYCLE PARTS
ATLANTIC 125 - 200
7 - 28
CYCLE PARTS
ATLANTIC 125 - 200
7 - 29
CYCLE PARTS
ATLANTIC 125 - 200
7 - 30
CYCLE PARTS
ATLANTIC 125 - 200
7 - 31
CYCLE PARTS
ATLANTIC 125 - 200
7 - 32
CYCLE PARTS
ATLANTIC 125 - 200
7 - 33
CYCLE PARTS
ATLANTIC 125 - 200
7 - 34
CYCLE PARTS
ATLANTIC 125 - 200
RIGHT
• Disconnect the connector (1).
• Extract the number plate bulb (2).
LEFT
• Disconnect the connector (1).
• Release and remove the three screws (4).
• Remove the left lights unit.
7 - 35
CYCLE PARTS
ATLANTIC 125 - 200
7 - 36
CYCLE PARTS
ATLANTIC 125 - 200
7.3. CONTROLS
7.3.1. REMOVING THE THROTTLE CONTROL
• Remove the right commutator, 7.2.5.
• Release and remove the two screws (1).
• Lower the brake pump clamp.
7 - 37
CYCLE PARTS
ATLANTIC 125 - 200
7 - 38
CYCLE PARTS
ATLANTIC 125 - 200
7.4. FRAME
7.4.1. REMOVING THE HANDLEBAR
TIGHTENING TORQUES
Clamp screw (1) 33.2 ftlb (45 Nm)
Safety screw (2) 14.7 ftlb (20 Nm)
7 - 39
CYCLE PARTS
ATLANTIC 125 - 200
7 - 40
CYCLE PARTS
ATLANTIC 125 - 200
7 - 41
CYCLE PARTS
ATLANTIC 125 - 200
7 - 42
CYCLE PARTS
ATLANTIC 125 - 200
7 - 43
CYCLE PARTS
ATLANTIC 125 - 200
WARNING
When refitting, grease the races and take care
to ruin the seals. Tighten down the nut and
make sure the stand returns to its stowed
position.
7 - 44
CYCLE PARTS
ATLANTIC 125 - 200
7 - 45
CYCLE PARTS
ATLANTIC 125 - 200
- ECU;
7 - 46
CYCLE PARTS
ATLANTIC 125 - 200
Key:
1. Wheel spindle
2. Speedometer drive
3. RH oil seal
4. RH bearing
5. Wheel
6. Inner spacer
7. LH bearing
8. LH oil seal
9. Brake disk
10. Spacer
IMPORTANT Grease the wheel spindle (1).
7 - 47
CYCLE PARTS
ATLANTIC 125 - 200
WARNING
While disassembling and reassembling the
wheel, be careful not to damage the brake pipe,
the disk and the pads.
WARNING
Do not operate the front brake lever when the
wheel is not in place, or the calliper piston
might fall out leading to brake fluid spillage.
7 - 48
CYCLE PARTS
ATLANTIC 125 - 200
7 - 49
CYCLE PARTS
ATLANTIC 125 - 200
WARNING
Inspect the bearings after each removal and
replace as required. See 7.5.4..
WARNING
Refit the bearings using a drift with the same
diameter as the bearing outer ring.
Do not tap the balls or the inner ring.
Ensure that:
- the left-hand bearing (4) is fully home on
the hub;
- the spacer (5) is fully home on the left-
hand bearing (6);
- the RH bearing (2) is fully home on the
spacer (5).
7 - 50
CYCLE PARTS
ATLANTIC 125 - 200
BEARINGS
Rotate the inner ring (1) manually. The ring should turn
smoothly, with no hardness or noise.
There should be no end float.
Replace any bearings that do not meet the above
requirements.
SEALS
Inspect the seals for damage or wear and replace as
required.
WHEEL SPINDLE
Check spindle (2) run-out using a dial gauge. Replace the
spindle (2) when run-out exceeds the maximum limit
allowed.
Wheel spindle run-out limit: 0.010 in (0.25 mm).
WHEEL RIM
Use a dial gauge to ensure that wheel rim (3) radial (A) and
axial (B) run-out does not exceed the maximum limit 50
60 70
80
90
allowed.
40 100
30 110
10
bearings.
Replace the bearings first, then re-check run-out. Replace
the wheel rim (3) if it still exceeds the maximum limit
allowed.
Wheel rim radial and axial run-out limit: 0.079 in (2
021
mm).
011
3
0
001
01
09
02
08
TIRE
03
07
04
06
05
7 - 51
CYCLE PARTS
ATLANTIC 125 - 200
7 - 52
CYCLE PARTS
ATLANTIC 125 - 200
Key:
1. Wheel
2. Circlip
3. Bearing
4. Silencer / brake caliper plate
5. Nut
7 - 53
CYCLE PARTS
ATLANTIC 125 - 200
7 - 54
CYCLE PARTS
ATLANTIC 125 - 200
7 - 55
CYCLE PARTS
ATLANTIC 125 - 200
7.7. BRAKES
7.7.1. BRAKES CONFIGURATION
Key:
1. Front brake lever
2. Front brake master cylinder / reservoir
3. Front brake lever – front caliper hose
4. Braking distributor
5. Front brake caliper
6. Front brake pads
7. Braking distributor / front caliper hose
8. Braking distributor / rear caliper hose
9. Rear brake caliper
10. Rear brake pads
11. Rear brake lever – braking distributor hose
12. Rear brake lever
13. Rear brake master cylinder / reservoir
7 - 56
CYCLE PARTS
ATLANTIC 125 - 200
WARNING
Do not operate the brake lever with the brake
pads removed, or the brake caliper pistons
might fall out leading to loss of brake fluid.
WARNING
The brake pads must always be replaced in
pairs. Ensure they become properly seated in
the brake caliper.
7 - 57
CYCLE PARTS
ATLANTIC 125 - 200
7 - 58
CYCLE PARTS
ATLANTIC 125 - 200
7 - 59
CYCLE PARTS
ATLANTIC 125 - 200
WARNING
Do not operate the brake lever with the pads
removed.
Otherwise the pistons could issue from their
seats and leak brake fluid.
WARNING
The brake pads must always be replaced in
pairs. Ensure they become properly seated in
the brake caliper.
7 - 60
CYCLE PARTS
ATLANTIC 125 - 200
7 - 61
CYCLE PARTS
ATLANTIC 125 - 200
7 - 62
CYCLE PARTS
ATLANTIC 125 - 200
7 - 63
CYCLE PARTS
ATLANTIC 125 - 200
7.8. STEERING
7.8.1. REMOVING THE STEERING ASSEMBLY
TIGHTENING TORQUES
Locknut (1) 81.1 ftlb (110 Nm)
7 - 64
CYCLE PARTS
ATLANTIC 125 - 200
WARNING
Check that all components are in perfect
condition.
Check that the bearing (1) running surfaces on the rotary (2)
and fixed (3) races are not damaged or excessively worn.
Replace the entire bearing assembly if necessary.
WARNING
Apply grease to the running surfaces on both
races (2-3), 1.8.1.
7 - 65
CYCLE PARTS
ATLANTIC 125 - 200
Key:
1. Fork base
2. Fork clamp screws
3. Circlip
4. Rubber cap
5. Cap
6. O-ring
7. Spring
8. Damping cylinder assembly
9. Rebound spring
10. Foot pad
11. LH fork leg
12. Dust seal
13. Circlip
14. Seal
15. Retainer
16. Bushing
17. LH stanchion
18. Seal ring
19. Lower screw
20. RH fork leg
21. RH stanchion
22. Screw
7 - 66
CYCLE PARTS
ATLANTIC 125 - 200
7 - 67
CYCLE PARTS
ATLANTIC 125 - 200
7 - 68
CYCLE PARTS
ATLANTIC 125 - 200
7 - 69
CYCLE PARTS
ATLANTIC 125 - 200
7 - 70
CYCLE PARTS
ATLANTIC 125 - 200
WARNING
The stanchion-and-slider assembly contains
oil. Do not turn it over or tilt it exceedingly
during removal.
7 - 71
CYCLE PARTS
ATLANTIC 125 - 200
• Remove the spring and allow the oil on it to drip off for
a few seconds.
• Drain the oil into the container, pumping the fork leg to
force it out.
7 - 72
CYCLE PARTS
ATLANTIC 125 - 200
WARNING
Never reuse the oil you have drained from the
fork
7 - 73
CYCLE PARTS
ATLANTIC 125 - 200
7 - 74
CYCLE PARTS
ATLANTIC 125 - 200
STANCHION TUBE
• Inspect the sliding surface for scoring and/or
scratching. Eliminate minor scoring with wet sand
paper (grain size 1).
• Replace the stanchion if badly scored.
• Check for stanchion buckling using a dial gauge.
• Replace the stanchion if buckled beyond the service
limit.
Service limit: 0.008 in (0.2 mm).
DANGER
NEVER attempt to straighten a buckled
stanchion as this would weaken the overall
structure leading to a dangerous riding
condition.
SLIDER
• Inspect for damage and/or cracking. Replace if
damaged.
• Replace any component which shows excessive wear
or damage.
Renew the following components on assembly:
- O-ring fitted to the top cap (1).
7 - 75
CYCLE PARTS
ATLANTIC 125 - 200
WARNING
Take care to prevent the ingress of dirt inside
the slider and the stanchion.
7 - 76
CYCLE PARTS
ATLANTIC 125 - 200
7 - 77
CYCLE PARTS
ATLANTIC 125 - 200
7 - 78
CYCLE PARTS
ATLANTIC 125 - 200
WARNING
An assistant is required to perform the
following operations.
• Withdraw the engine bolt (3) from the left and collect
the washer.
• Release and remove the lower shock absorber screw
(4).
• Working from both sides, remove the silent block screw
(5).
7 - 79
CYCLE PARTS
ATLANTIC 125 - 200
7 - 80
ELECTRICAL SYSTEM
ATLANTIC 125 - 200
ELECTRICAL SYSTEM 8
8-1
ELECTRICAL SYSTEM
ATLANTIC 125 - 200
SUMMARY
8.1. COMPONENT LOCATION...........................................................................................................3
8.1.1. LAYOUT OF ELECTRICAL COMPONENTS........................................................................3
8.2. INTRODUCTION..........................................................................................................................4
8.2.1. INTRODUCTION .................................................................................................................4
8.3. BATTERY ....................................................................................................................................5
8.3.1. BATTERY............................................................................................................................5
8.4. IGNITION SYSTEM AND STAND LOGIC.....................................................................................7
8.4.1. IGNITION SYSTEM AND STAND LOGIC ............................................................................7
8.5. CHARGING CIRCUIT ................................................................................................................10
8.5.1. GENERAL RECHARGE AND POWER DIAGRAM .............................................................10
8.6. STARTER CIRCUIT...................................................................................................................12
8.6.1. STARTER CIRCUIT...........................................................................................................12
8.7. SENSORS .................................................................................................................................15
8.7.1. SENSOR CIRCUIT ............................................................................................................15
8.8. COOLING FAN AND HELMET COMPARTMENT LIGHT............................................................18
8.8.1. COOLING FAN AND HELMET COMPARTMENT LIGHT SYSTEM....................................18
8.9. LIGHTS SYSTEM ......................................................................................................................20
8.9.1. LIGHTS SYSTEM ..............................................................................................................20
8.10. VISUAL AND ACOUSTIC INDICATORS ................................................................................22
8.10.1. VISUAL AND ACOUSTIC SIGNALING SYSTEM ...............................................................22
8.11. BULB REPLACEMENT..........................................................................................................24
8.11.1. BULB REPLACEMENT......................................................................................................24
8.12. CHANGING THE FUSES.......................................................................................................27
8.12.1. CHANGING THE FUSES...................................................................................................27
8.13. ADJUSTING THE HEADLIGHT BEAM...................................................................................28
8.13.1. ADJUSTING THE VERTICAL HEADLIGHT BEAM.............................................................28
8.13.2. ADJUSTING THE HORIZONTAL HEADLIGHT BEAM .......................................................29
8.14. SYSTEM CONFIGURATION..................................................................................................30
8.14.1. WIRING DIAGRAM............................................................................................................30
8-2
ELECTRICAL SYSTEM
ATLANTIC 125 - 200
8-3
ELECTRICAL SYSTEM
ATLANTIC 125 - 200
8.2. INTRODUCTION
8.2.1. INTRODUCTION
Please read the following information before reading this
section.
IMPORTANT For ease of reference, the same numbering is
used in the specific wiring diagrams and in the general
schematics.
CABLE COLORS
Ar orange
Az light blue
B blue
Bi white
G yellow
Gr grey
M brown
N black
R red
Ro pink
V green
Vi purple
ELECTRICAL CONNECTORS
Disconnect the electrical connectors as follows:
• Press down on the locking tab, where fitted.
WARNING
Never separate two connectors by pulling on
the wiring.
8-4
ELECTRICAL SYSTEM
ATLANTIC 125 - 200
8.3. BATTERY
8.3.1. BATTERY
Battery rating: 12 V -9 Ah
INSPECTION
8-5
ELECTRICAL SYSTEM
ATLANTIC 125 - 200
SAFETY REGULATIONS
WARNING
Note that the electrolyte contains suplhuric
acid. Avoid contact with the skin and clothes
and keep the battery away from heat sources
and sparks, especially during recharging, since
the hydrogen liberated by the process is
explosive.
8-6
ELECTRICAL SYSTEM
ATLANTIC 125 - 200
Key:
21. Ignition keyswitch
25. Engine kill
38. Main fuses
40. Battery
41. Secondary fuses
42. HT coil
43. Spark plug
44. Automatic starter
45. CDI ECU
46. Side stand switch
47. Pick up
61. Starter relay
TROUBLESHOOTING
• Check that the 7.5 A and 15 A fuses are in good
condition.
• Inspect the spark plug and replace as required.
• Check the condition of the high tension cable and
spark plug cap.
• Check the coil.
• Check the pick-up.
• Connect the green/brown wire to earth. If ignition is
successful check the stand logic.
• Replace the CDI ECU with an operational one.
8-7
ELECTRICAL SYSTEM
ATLANTIC 125 - 200
CHECK DATA
Pick-up check
• Disconnect the pick-up connector.
• Use the multimeter (1000 ohm range) to measure the
resistance across the yellow/blue and yellow/green
cable terminals. The measured resistance must be in
the range 105 ohm ± 10% at 68 °F (20 °C).
• Replace the pick-up when infinite resistance is
detected or when the reading is below the specified
range.
CHECK DATA
8-8
ELECTRICAL SYSTEM
ATLANTIC 125 - 200
Wires
Stand position
M V N
Up
Down
CHECK SWITCHES
Check switches for continuity using a multimeter. Please
refer to the relevant diagram.
Replace any switch found to deviate from the specified mode
of operation.
Wires
Starter commutator
V R
ON
OFF
LOCK
Wires
Engine kill
Bi/B M/V
OFF
ON
8-9
ELECTRICAL SYSTEM
ATLANTIC 125 - 200
Key:
38. Main fuses
39. Power outlet
40. Battery
48. Alternator
49. Rectifier
8 - 10
ELECTRICAL SYSTEM
ATLANTIC 125 - 200
8 - 11
ELECTRICAL SYSTEM
ATLANTIC 125 - 200
Key:
21. Ignition keyswitch
23. Starter button
27. Parking light/left stop light bulb
29. Parking light/right stop light bulb
33. Front brake light switch
34. Rear brake light switch
35. Stop light / starter permissive relay
36. Starter motor relay
37. Starter motor
38. Main fuses
41. Secondary fuses
IMPORTANT The Bi/N wire (1) is powered by ignition relay
61 (see ignition system diagram).
TROUBLESHOOTING
• Check the battery condition, see 2.4.1.
• Check that all fuses are in perfect condition
8.12.1.
• Check the ignition commutator.
• Check the engine kill switch.
• Stop light / starter permissive relay 8.4.1.
• Check the ignition relay 8.4.1.
• Check the start button
• Check the starter relay
• Check the starter motor
8 - 12
ELECTRICAL SYSTEM
ATLANTIC 125 - 200
8 - 13
ELECTRICAL SYSTEM
ATLANTIC 125 - 200
CHECK SWITCHES
Check switches for continuity using a multimeter. Please
refer to the relevant diagram.
Replace any switch found to deviate from the specified mode
of operation.
Wires
Starter button
G/R R/N
Starter request
Wires
Front brake light switch
R/N Bi/n
Lever operated
Lever released
Wires
Rear brake light switch
R/N Bi/n
Lever operated
Lever released
8 - 14
ELECTRICAL SYSTEM
ATLANTIC 125 - 200
8.7. SENSORS
8.7.1. SENSOR CIRCUIT
Key:
14. Fuel level
15. Dashboard
16. Water thermistor
17. Oil pressure sensor
60. Fuel level sensor
IMPORTANT Terminal 2 of the 7-way connector is powered
by a positive voltage controlled by the commutator.
COOLANT TEMPERATURE
8 - 15
ELECTRICAL SYSTEM
ATLANTIC 125 - 200
FUEL LEVEL
8 - 16
ELECTRICAL SYSTEM
ATLANTIC 125 - 200
8 - 17
ELECTRICAL SYSTEM
ATLANTIC 125 - 200
Key:
38. Main fuses
40. Battery
50. Thermistor
51. Fan
52. Helmet compartment light switch
53. Helmet compartment light
8 - 18
ELECTRICAL SYSTEM
ATLANTIC 125 - 200
Thermistor test
• Remove the lower guard 7.1.8.
• Disconnect the two connectors.
• Release and remove the thermistor (2).
8 - 19
ELECTRICAL SYSTEM
ATLANTIC 125 - 200
Key:
2. High beam warning light
4. Parking light indicator
5. Dashboard backlighting
15. Dashboard
18. Left-hand lights dip switch
21. Ignition keyswitch
27. Parking light/left stop light bulb
29. Parking light/right stop light bulb
32. Number plate light
38. Main fuses
40. Battery
41. Secondary fuses
55. High beam indicator
56. Low beam indicator
57. Parking light
58. Headlight assembly
TROUBLESHOOTING
Check the battery condition, see , 2.4.1.
- Check that all fuses are in perfect condition 8.12.1.
- check the dip switch
- check that all bulbs are in perfect condition 8.11.1.
8 - 20
ELECTRICAL SYSTEM
ATLANTIC 125 - 200
CHECK SWITCHES
• Check switches for continuity using a multimeter.
Please refer to the relevant diagram.
• Replace any switch found to deviate from the specified
mode of operation.
Wires
Dip switch
V N Bi V
8 - 21
ELECTRICAL SYSTEM
ATLANTIC 125 - 200
Key:
7. Right direction indicator warning light
8. Left direction indicator warning light
15. Dashboard
19. Horn
20. Horn button
21. Ignition keyswitch
22. Direction indicators switch
26. Rear left direction indicator
30. Rear right direction indicator
38. Main fuses
40. Battery
41. Secondary fuses
45. CDI ECU
54. Front right direction indicator
8 - 22
ELECTRICAL SYSTEM
ATLANTIC 125 - 200
HORN TEST
• Supply the horn directly with 12 V DC at the terminals.
• Adjust as needed.
• Replace with a new horn if necessary.
CHECK SWITCHES
• Check switches for continuity using a multimeter.
Please refer to the relevant diagram.
• Replace any switch found to deviate from the specified
mode of operation.
Cavi
Direction indicators switch
B/N Az r
Left direction indicator
Right direction indicator
Wires
Horn button
Gr V
ON
OFF
8 - 23
ELECTRICAL SYSTEM
ATLANTIC 125 - 200
WARNING
Before proceeding to change a bulb, rotate the
ignition switch to " ". 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.
WARNING
Proceed with care.
Do not damage the snap-on tangs and
matching recesses.
8 - 24
ELECTRICAL SYSTEM
ATLANTIC 125 - 200
Upon reassembly:
IMPORTANT Insert the bulb into the bulb socket, making the
three bulb pins coincide with the guides on the socket itself.
• Locate the bulb socket (3) in the reflector mount and
twist it clockwise to seat it.
• Connect the bulb connector (2).
• Unscrew the two screws (6) and remove the lens (7).
WARNING
Proceed with care.
Do not damage the snap-on tangs and matching
recesses.
8 - 25
ELECTRICAL SYSTEM
ATLANTIC 125 - 200
8 - 26
ELECTRICAL SYSTEM
ATLANTIC 125 - 200
Inspection:
• Extract the fuses one by one and check if the filament is
broken.
• When you find a blown fuse, determine and rectify the
cause (if possible) before fitting a new fuse.
8 - 27
ELECTRICAL SYSTEM
ATLANTIC 125 - 200
9/10 H
H
To adjust the headlight beam:
• Open the glove compartment (1) and disengage the
side limit rods by pushing them gently downwards.
8 - 28
ELECTRICAL SYSTEM
ATLANTIC 125 - 200
8 - 29
ELECTRICAL SYSTEM
ATLANTIC 125 - 200
8 - 30
ELECTRICAL SYSTEM
ATLANTIC 125 - 200
8 - 31