Atlantic 125-200 USA

INTRODUCTION
ATLANTIC 125 - 200
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
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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.
For more details see 0.1.2.

First edition: December 2002
Produced and printed by:
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
0.1.2. REFERENCE MANUALS

ENGINE WORKSHOP MANUALS
aprilia part# (description)
8140680
8140681
8140682
8140683
8140684
PARTS CATALOGS
6642
SPECIAL TOOLS CATALOGS

001M
USE AND MAINTENANCE MANUALS

8104577
8104575
8104576
8104582
CYCLE PARTS WORKSHOP MANUALS

8140670
8140671
8140672
8140673
8140674
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INTRODUCTION
ATLANTIC 125 - 200
0.1.3. ABBREVIATIONS / SYMBOLS / CONVENTIONS

# = number
< = is less than
> = is more than
≤ = is less than or equal to
≥ = is more than or equal to
~ = approximately
∞ = infinite
°C = degrees Celsius (centigrade)
°F = degrees Fahrenheit
± = plus or minus
AC = Alternated Current
A = Ampere
Ah = Ampere per hour
API = American Petroleum Institute
HT = High Tension
AV/DC = Anti-Vibration Double Countershaft
bar = pressure measurement (1 bar =100 kPa)
DC = Direct Current
cm³ = cubic centimeters
CO = carbon monoxide
CPU = Central Processing Unit
DIN = German industrial standards (Deutsche Industrie Norm)
DOHC = Double Overhead Camshaft
ECU = Electronic Control Unit
rpm = revolutions per minute
HC = unburned hydrocarbons
ISC = Idle Speed Control
ISO = International Standardization Organization
kg = kilograms
kgm = kilograms per meter (1 kgm =10 Nm)
km = kilometers
kph = kilometers per hour
kΩ = kiloOhm
kPa = kiloPascal (1 kPa =0.01 bar)
KS = clutch side (from the German "Kupplung seite")
kW = kiloWatt
l = liters
LAP = racetrack lap
LED = Light Emitting Diode
LEFT
SIDE = left-hand side
m/s = meters per second
max = maximum
mbar = millibar (1 mbar =0.1 kPa)
mi = miles
MIN = minimum
MPH = miles per hour
MS = flywheel side (from the German "Magnetoseite")
MΩ = megaOhm
N.A. = Not Available
N.O.M.M. = Motor Octane Number
N.O.R.M. = Research Octane Number
Nm = Newton per meter (1 Nm =0.1 kgm)
Ω = ohm
PICK-UP = pick-up
BDC = Bottom Dead Centre
TDC = Top Dead Centre
PPC = Pneumatic Power Clutch
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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
1.1. STRUCTURE OF THE MANUAL

1.1.1. CONVENTIONS USED IN THE MANUAL
• This manual is divided in sections and subsections, each covering a set of the most significant components. For
quick reference, see the summary of sections.
• Unless expressly specified otherwise, assemblies are reassembled by reversing the disassembly procedure.
• The terms "left" and "right" are referred to the motorcycle when viewed from the riding position.
• Motorcycle operation and basic maintenance are covered in the “USE AND MAINTENANCE” manual.
In this manual any variants are identified with these symbols:
Frame # ZD4MP......(STARTING FROM MODEL YEAR 2001)

optional
catalytic version
- all versions
11kW derated version 11 kW
80km speed 80 kph
f.p. full power version
MP national certification
SF European certification (EURO 1 limits)
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
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GENERAL INFORMATION
ATLANTIC 125 - 200
1.1.2. SAFETY WARNINGS

The following precautionary warnings are used throughout this manual in order to convey the following messages:
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.
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GENERAL INFORMATION
ATLANTIC 125 - 200
1.2. GENERAL WARNINGS

1.2.1. GENERAL SAFETY RULES
CARBON MONOXIDE
When an operation must be performed with the engine running, position the motorcycle outdoors or in a well-ventilated
area.
Never run the engine in an enclosed place.
Use an exhaust emission extraction plant when working indoors.
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.
DO NOT RELEASE FUEL INTO THE ENVIRONMENT.
KEEP AWAY FROM CHILDREN.
HOT COMPONENT PARTS

The engine and exhaust component parts become hot when the engine is running and will stay hot for some time after
the engine has been stopped.
Wear insulating gloves before handling these components or allow for the engine and exhaust system to cool down
before proceeding.
EXHAUSTED GEARBOX AND FORK OIL
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.
DO NOT RELEASE OIL INTO THE ENVIRONMENT.
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.
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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.
HYDROGEN GAS AND BATTERY ELECTROLYTE
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.
Battery fluid is corrosive.

Avoid spillage. Take special care not to spill battery fluid on plastic parts.
Ensure that the electrolyte fluid you are using is the suitable type for your battery.
GENERAL PRECAUTIONS AND INFORMATION

Follow these instructions closely when repairing, disassembling or reassembling the motorcycle or its components.
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.
BEFORE DISASSEMBLING ANY COMPONENTS

• Clean off all dirt, mud, and dust and clear any foreign objects from the vehicle before disassembling any
components.
• Use the model-specific special tools where specified.
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GENERAL INFORMATION
ATLANTIC 125 - 200
DISASSEMBLING THE COMPONENTS

- Never use pliers or similar tools to slacken and/or tighten nuts and bolts. Always use a suitable spanner.
- Mark all connections (hoses, wiring, etc.) with their positions before disconnecting them. Identify each connection
using a distinctive symbol or convention.
- Mark each part clearly to avoid confusion when refitting.
- Thoroughly clean and wash any components you have removed using a detergent with low flash point.
- Mated parts should always be kept together. These parts will have seated themselves against one another in
service as a result of normal wear and tear.
- Certain components are matched-pair parts and should always be used together or replaced as a set.
- Keep the motorcycle and its components well away from heat sources.
REASSEMBLING THE COMPONENTS
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
1.3. HAZARDOUS SUBSTANCES

1.3.1. WARNINGS CONCERNING FUEL, LUBRICANTS, COOLANT AND OTHER COMPONENT PARTS
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.
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.
Do not release oil into the environment.
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
Do not release oil into the environment.
Change engine oil after the first 621 mi (1000 km) and successively every 3728 mi (6000 km), 2.11.2.
FRONT FORK OIL
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.
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..
(Recommended) brake fluid: see 1.8.1..
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.
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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.
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:
Freezing point F° (°C) Coolant % of volume

-4° (-20°) 35
-22° (-30°) 45
-40° (-40°) 55
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.
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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).
Observe the following instructions:

• Avoid harsh accelerations and do not flip the throttle open abruptly when the engine is running at low speed, both
during and after the running-in period.
• Apply the brakes gently and avoid hard, prolonged braking until covering the first 62 mi (100 km). This will allow the
brake pad lining to wear in properly rubbing on the brake discs.
• During the first 621 mi (1000 km) do not drive the vehicle at more than 80% of the maximum prescribed speed,
avoid opening the throttle fully or driving at constant speed for long periods.
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.
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GENERAL INFORMATION
ATLANTIC 125 - 200
1.5. VEHICLE IDENTIFICATION

1.5.1. LOCATION OF SERIAL NUMBERS
These numbers are necessary for vehicle registration.
IMPORTANT: Altering the identification numbers of vehicle
or engine is a legal offence punishable by heavy fines and
penalties. In addition, altering the frame number (VIN) results
in immediate warranty invalidation.
FRAME NUMBER
The frame number (Vehicle Identification Number) is etched
on the headstock.
ENGINE NUMBER
The engine number is etched at the rear end of engine, near
to the suspension.
MANUFACTURER IDENTIFICATION PLATE

• Remove the right hand rubber mat.
• Raise the plinth (1)
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
1.6. USING TOOLS AND SPARE PARTS

1.6.1. SPARE PARTS
Use original aprilia spare parts only to replace original components.
Original aprilia spare parts are high-quality components designed and built expressly for aprilia motorcycles.
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
1.7.2. HOW TO APPLY THE DECALS

Whenever you remove any body parts:
WARNING
Handle the plastic and painted
components with care to avoid scraping
or damaging them.
Proceed with care.
Do not damage the snap-on tangs and
matching recesses.
Strictly follow the instructions below
We recommend using:
- - a medium spatula (1);
IMPORTANT: Soft spatulas – such as those commonly

used on windscreen wipers - will leave excess water
under the decal.
- a sponge or spray dispenser (2) and water.
IMPORTANT: Add water with 1-3% detergent and
shake to obtain frothing.
Apply the decals as follows:
• Place a decal (3) on a bench with the adhesive
face up.
• Keep the decal well stretched on the bench and
remove the protective film (4).
IMPORTANT: A spray dispenser (2) will work best.
If you are using a sponge, dab the decal surface lightly

or the adhesive will deteriorate.
• Wet the adhesive face with soap water.
• Place the decal (3) in the proper position on the
part you wish to decorate.
IMPORTANT: Always apply the spatula to the decal
centre and move it towards the edges with regular
movements.
• Rub the spatula (1) across the decal surface

pressing moderately until removing excess soap
and water from under the decal.
IMPORTANT: Take care not to lift the decal corners
and edges in the process.
• Dry up the decal with an absorbent cloth. Apply
cloth in the centre and move outwards.
• Rub the decal using the spatula with firm, regular
strokes. Apply the spatula in the centre and move
outwards. Take special care with corners and
edges to ensure proper adhesion across the
whole surface.
1 - 17
GENERAL INFORMATION
ATLANTIC 125 - 200
IMPORTANT: Where decals come with application

tape (5), remove tape 20-30 minutes after decal
application.
• Peel off the application tape (5) from decal
surface.
• Pass the spatula across the decal again –
particularly over corners and edges – to ensure
proper adhesion.
IMPORTANT: Decals applied using water will take

about 48 hours to stick to part permanently.
• Once you have removed the application tape,
check for any air trapped underneath the decal.
If there are any air bubbles:
• Prick a hole on the edge (7) of the air bubble
using a pin or a cutter (6).
• Apply the spatula (1) at the opposite end and
move it across the bubble to squeeze air out.
The application tape serves to facilitate applying

trademarks and letters by keeping them aligned as
well as giving more consistency to the adhesive during
application.
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
1.8.2. PRODUCT APPLICATIONS

Use only the products specified below for motorcycle maintenance.
These products have demonstrated suitability for all usage conditions specified by the manufacturer after long-time
testing.
IMPORTANT: The products for which a part number is given are available at request, (see table).
PRODUCT FEATURES
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.
Lubricate - All ball bearings, sintered disks, gear sets, cylinder

walls, unless otherwise specified.
Grease - Oil seal edges, unless otherwise specified.
Gearbox oil - Engine oil SAE 30, 0.6 l
Engine oil - Super 2-stroke oil
LOCTITE 221 / N. ROTAX 899,785 - Flush-head countershaft bearing lockring screw.
Flush-head starter pedal gear bearing lockring screw
(RX only).
- Starter gear retainer hex bolt
- Electric starter locking hex bolts.
- Oil pump locking hex bolts.
- All Taptite screws for reassembly of the clutch cover
and casing.
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)
Silastic 732 RTV / N. ROTAX 297386 - Idler indicator contact screw.

- Ignition cable grommet.
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.
Screw or bolt Spanner Tightening torque

thread ftlb Nm
M4 7 2.2 3
M5 8 4.4 6
M6 10 7.4 10
M8 12 18.4 25
M 10 14 36.9 50
M 12 17 59 80
M 14 19 100 135
M 16 22 155 210
For vehicle-specific fastenings see 2.3.2.
Unless otherwise specified, torque figures are intended for
application to clean, dry threads at room temperature.
IMPORTANT: Follow the instructions below to avoid
distortion and/or improper fit:
• Screw all fasteners finger-tight.
• Tighten down the opposing parts to half the prescribed
torque: (A) and (B); (C) and (D).
• Repeat sequence tightening to specified torque.
IMPORTANT: This way, the load generated by the fasteners
is applied evenly across joint surface.
1 - 21
GENERAL INFORMATION
ATLANTIC 125 - 200
1.10. POSITION OF THE WARNING ADHESIVE

LABELS
1.10.1. POSITION OF THE WARNING ADHESIVE
LABELS
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
1.10.2. CALIFORNIA EVAPORATIVE EMISSION

SYSTEM
FOR STATE OF CALIFORNIA ONLY.
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
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
ATLANTIC 125 - 200
2.1. PERIODIC MAINTENANCE

2.1.1. INTRODUCTION
In order to preserve the motorcycle in sleek running order, aprilia recommends that you strictly observe the periodic
maintenance intervals recommended for the different components.
Outlined in this section are the recommended procedures for the periodic maintenance of the key components of the
motorcycle.
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
ATLANTIC 125 - 200
2.1.2. PERIODIC MAINTENANCE CHART

Post running-in
Every 3728 mi Every 7456 mi
checks
Components (6,000 km) or (12000 km) or
[621 mi
8 months 16 months
(1000 km)]
Rear shock absorbers 1 1 -
Battery – electrolyte level 1 1 -
Spark plug 1 1 3
Carburetor - idling 4 - 1
Belt – Variator rollers – plastic variator guide - 1 3
Variator belt 125-200 - 3 -
Headstock bearings 1 1 -
Wheel hub bearings - 1 -
Air cleaner - 2 -
Engine oil filter 3 3 -
Variator filter - 2 -
Throttle operation 1 1 -
Brake locking operation 1 1 -
Clutch jaws - - 1
Variator grease - 3 -
Brake light switch - 1 -
Brake fluid 1 1 1 every 2 years: 3
Every 1243 mi (2000 km): 1 Every 16
Coolant 1
months: 3
Every 1864 mi (3000 km): 1 – Every 3728 mi
Engine oil 3
(6000 km): 3
Front suspension fluid 1 1 3
Every 3728 mi (6000 km): 1 – Every 14913
Transmission oil 3
mi (24000 km): 3
Lamps: direction/operation - 1 -
Tires – Inflation pressure every month: 1
Engine oil filter meshing and magnetic screw 1 1 -
Variator rollers and plastic guide 125 - 200 - 1 3
Wheels/Tires - 1 -
Nut, screw and bolt tightening 1 1 -
Cylinder head nut fastening 1 - -
FRONT SUSPENSION 1 1 -
Brake fluid bleeding 1 - -
Fuel hoses - 1 every two years: 3
Brake pad wear 1 every 2,000.41 km (2,000 km): 1
Fuel filter - 1 3
Cleaning the radiator - 2 -
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.
( ) = THESE OPERATIONS CAN BE CARRIED OUT BY THE OWNER

(**) = Check every two weeks or at the indicated interval.
2-4
ATLANTIC 125 - 200
KEY TO THE LAYOUT OF LUBRICATION POINTS

2.2. LUBRICATION POINTS 1. Steering bearings
2.2.1. LUBRICATION POINTS 2. Rear wheel spindle and hub bearings
3. Central stand shaft
Proper lubrication is critical to ensuring smooth operation 4. Side stand spindle
and preserving vehicle life. 5. Front wheel spindle and hub bearings
= Grease
IMPORTANT: Before lubricating any part, clean off any
= Oil
oxidation deposits, grease, dirt or dust.
Lubrication points are shown in the "LUBRICATION POINTS
CHART".
2-5
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
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
Center stand to engine fastening 1 M10 27 19.9
Side stand to engine fastening M10 20 14.7
CONNECTING RODS
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
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
Airbox to engine fastening 1 M6x45 8 5.9
Airbox to engine fastening 1 M6x55 8 5.9
EXHAUST SYSTEM
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
Wheel spindle 1 M12 40 29.5
Safety screw M6 12 8.8
REAR WHEEL
Wheel nut M16x1.5 110 81.1
2-7
ATLANTIC 125 - 200
FRONT AND REAR BRAKE

Front caliper fastening 1 M8x40 25 18.4
Rear caliper fastening 2 M8x40 25 18.4
Rear brake hose clip fastening 1 M6x20 12 8.8
HANDLEBAR AND CONTROLS
Clamp screw 1 M10 45 33.2
Safety screw 1 M8 20 14.7
Front bodywork
Mudguard to fork fastening M5 collar 0,7 0.5
Rear view mirrors to bridge fastening M6x30 10 7.4
CENTRAL BODYWORK
Self-starting screw 4,2 0,3 0,2
Screw with collar M5
Rear bodywork
Grab rail to frame fastening 2 M8x60 24 17.7
Grab rail to frame fastening 2 M6x40 10 7.4
2-8
ATLANTIC 125 - 200
2.4. BATTERY
2.4.1. BATTERY
Read carefully 1.2.1.
There are two types of batteries available in the market:

- batteries that require maintenance, fitted with cell plugs;
- maintenance-free batteries, which have no cell plugs as
they do not need inspecting or topping-up.
After the first 621 mi (1000 km) and every 3728 mi (6000 km)
or 8 months thereafter, check the electrolyte level and the
tightness of the battery terminal clamps.
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
ATLANTIC 125 - 200
2.4.2. CHECKING AND CLEANING THE TERMINALS

AND CLAMPS
• Make sure that the ignition switch is set to " ".

• Raise the seat.
• Release and remove the two screws (1).
• Remove the battery cover.
• 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
ATLANTIC 125 - 200
2.4.3. CHECKING THE ELECTROLYTE LEVEL

To check the electrolyte level:

• Place the motorcycle on the center stand.
• Raise the seat.
• Remove the battery cover.
• 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.
• Top up with distilled water.
2 - 11
ATLANTIC 125 - 200
2.4.4. RECHARGING THE BATTERY

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.
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ATLANTIC 125 - 200
2.4.5. LONG INACTIVITY OF THE BATTERY

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.
• If the vehicle remains unused for more than fifteen

days, it is necessary to recharge the battery, in order to
prevent its sulphation, see 2.4.4.
• Remove the battery, see 7.2.1. and store it in a
cool, dry place.
• It is important to check the charge periodically (about
once a month), during the winter or when the vehicle
remains unused, in order to prevent the deterioration of
the battery.
• Recharge it completely with a normal charger, see
2.4.4.
IMPORTANT If the battery remains on the vehicle,
disconnect the cables from the terminals.
2 - 13
ATLANTIC 125 - 200
2.5. ELECTRIC COMPONENTS

2.5.1. ELECTRIC COMPONENTS
Read carefully 1.2.1..
• Place the motorcycle on the stand.

• Check all lights for proper operation.
• Check for proper front beam setting, see 8.13.1.
and 8.13.2.
• Ensure all connectors are fitted securely in place.
• Ensure switches are properly fastened and check for
proper operation:
- 8.4.1.
- 8.10.1.
• Ensure the air and speedometer sensors are properly
fastened and check for proper operation.
WARNING
The sensing area of the sensors must be kept
clean. Any mud, dirt deposits, etc. will lead to
misreading.
2 - 14
ATLANTIC 125 - 200
2.6. SPARK PLUG

2.6.1. SPARK PLUG
TIGHTENING TORQUES
Spark plug: 14.7 ftlb (20 Nm).
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.
• Make sure that there are neither carbon deposits, nor

corrosion marks on the electrode and on the spark plugs
ceramics; if necessary, clean with a plug cleaner or wire
brush.
• If the spark plug insulating material is cracked, if the
electrodes are corroded, with excessive deposits or the
tip of the central electrode (3) is rounded, it must be
changed.
WARNING
When changing the spark plug, check the
thread pitch and length.
If the threaded part is too short, the carbon
deposits will accumulate on the thread seat,
and therefore the engine may be damaged
during the installation of the right spark plug.
Use recommended spark plugs only. A spark
plug of the wrong grade may shorten engine
life and cause loss of performance.
To check the spark plug gap, use a wire
thickness gauge to avoid damaging the
platinum covering.
• Check the electrode gap with a wire feeler gauge.
• Electrode gap should be 0.028 – 0.031 in (0.7 – 0.8
mm). If it needs adjusting, bend the earth electrode
carefully.
• Make sure the washer is in good condition. Fit the
washer and screw the spark plug finger-tight to avoid
damaging the thread.
• Tighten the spark plug with the spanner you will find in
the tool kit, giving it half a turn to compress the washer.
2 - 15
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.
• Position the spark plug (2) cap (1) properly, so that it

does not come off due to the vibrations of the engine.
DANGER
Ensure the spark plug cap (1) is properly in
place on the spark plug (2).
•
2 - 16
ATLANTIC 125 - 200
2.7. AIR CLEANER

2.7.1. AIR CLEANER
Clean the air filter every 3728 mi (6000 km) or 8 months.
Run maintenance operations more frequently if the vehicle is
driven in rainy or dusty areas, or on rough surfaces; in such
cases the air filter should be partly cleaned at the end of
each ride.
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.
• Replace the air cleaner with a new one of the same

type.
2 - 17
ATLANTIC 125 - 200
2.8. TUBES
2.8.1. TUBES
Read carefully 1.2.1..
FUEL
Check the fuel lines every 3728 km (6000 km) or 8 months.

Change them every two years.
WARNING
Always change a worn, cracked or damaged
fuel line.
See Section 4 (FUEL SYSTEM) for more details.
BRAKES
WARNING
line.
-
COOLING SYSTEM
WARNING
coolant line. Maintaining fasteners at the
correct tightening torque.
-
2 - 18
ATLANTIC 125 - 200
2.9. COOLANT
2.9.1. CHECKING AND TOPPING UP COOLANT
LEVEL
Carefully read 1.2.1. and 1.3.1.
• Check coolant level before each ride. Change coolant

every 2 years.
WARNING
Check and top up coolant level when the
engine is cold.
• The engine should be off and completely cold.
IMPORTANT Place the motorcycle on firm and level ground.
• Raise the seat.
• Release and remove the screw (1).
• Remove the guard.
• Keep the motorcycle upright with both wheels on the

ground.
• Check that the coolant level in the expansion reservoir
is between the MAX and MIN marks (see figure).
If not, proceed as follows:
• Release and remove the filler cap (2).
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.
• Add coolant mixture until the level reaches just below

the MAX mark, see 1.8.1.
• Never overfill (top up beyond the MAX mark), or coolant
will leak out when the engine is running.
• Refit the filler cap (2).
WARNING
In the event the motorcycle is using up
exceeding coolant or the expansion reservoir is
empty, check the circuit for leaks.
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ATLANTIC 125 - 200
2.9.2. CLEANING THE RADIATOR

IMPORTANT It is not necessary to remove the radiator.
• Clean with a jet of pressurized water through the air intakes behind the front wheel.
• Blow through from beneath with compressed air.
2 - 20
ATLANTIC 125 - 200
2.10. BRAKE FLUID

2.10.1. CHECKING AND TOPPING UP BRAKE FLUID
LEVEL
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.
• 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
ATLANTIC 125 - 200
• Lift and remove the cap (2).

• Remove the seal (3).
IMPORTANT Do not rock the motorcycle from side to side
when topping up or brake fluid will spill out.
• Top up the reservoir with brake fluid, see 1.8.1.
until the correct level is reached.
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
ATLANTIC 125 - 200
2.10.2. CHANGING THE BRAKE FLUID

Carefully read 1.2.1.and 1.3.1..
• Change the brake fluid every two years.
IMPORTANT The following procedure can be applied to

either brake.
WARNING
Handle with care: contact with clutch fluid will
alter the chemical properties of paintwork,
plastic and rubber parts, etc.
• Remove the rubber cap.
• Insert one end of a transparent plastic tubing inside the
caliper bleed valve (1-2) and the other end in a
container for collection.
• Loosen the bleed valve (1-2) of about one turn.
IMPORTANT Ensure that there is fluid in the reservoir at all
times during the operation, or you will have to bleed the
system when finished, see 2.10.4.
• Check that the fluid is flowing on the tank and, before
emptying, tighten the bleed valve (1-2).
• Top up the reservoir, see 2.10.1.
• Loosen again the bleed valve (1-2) by about half of a
turn.
• Check that the fluid comes out of the plastic tubing and,
as soon as the fluid color changes (from a darker to a
lighter color) tighten the bleed valve (1-2) and remove
the tubing.
• Refit the rubber cap.

• Add fluid to the reservoir until the correct level is
reached, see 2.10.1.
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ATLANTIC 125 - 200
2.10.3. CHECKING BRAKE PADS FOR WEAR

Carefully read 1.2.1., 1.3.1. and 2.1.2..
IMPORTANT The following information refer to a single
braking system, but are valid for both.
Check the brake pad wear after the first 621 mi (1000 km)
and every 1242 mi (2000 km) thereafter.
The wear of the disk brake pads depends on the use, on the
kind of drive and on the road.
WARNING
Check the wear of the brake pads, especially
before every trip.
To carry out a rapid checking of the wear of the pads,

proceed as follows:
• Place the motorcycle on the centre stand.
• Carry out a visual check between the brake caliper and
the pads, proceeding as follows:
from below, on the front part, for the front brake calipers (1);
from below, on the rear part, for the rear brake caliper (2).
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.
• When the lining material of even just one of the brake

pads is worn down to nearly 0.05 in (1.5 mm), change
both brake pads.
- Front brake pad (3).
- Rear brake pad (4).
2 - 24
ATLANTIC 125 - 200
2.10.4. BLEEDING THE BRAKE CIRCUITS

For the service intervals, see 2.1.2..

Any air trapped in the hydraulic circuit will act as a cushion
and take up most of the pressure applied by the master
cylinder. This will hamper the operation of the brake calipers
and reduce braking efficiency.
A spongy feel of the brake lever and loss of braking mean
that there is air in the circuit.
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.
Do not spill brake fluid on plastic or paint-
finished parts or they will damage.
IMPORTANT This motorcycle is fitted with:

- one front disk brake;
- one rear disk brake;
- a delay valve under the dashboard.
Operating the right hand (front) brake lever delivers pressure

to the front brake caliper pistons A and C via the brake hose
(1).
Operating the left hand (rear) brake lever actuates both front
brake caliper piston B and the rear brake caliper, via the
delay valve.
IMPORTANT Bleed the air in the following order: delay
valve, front brake caliper and rear brake caliper.
DELAY VALVE
• Remove the dashboard, 7.2.6.

• Remove the rubber cap (1) from the bleed valve (2).
• Attach a clear plastic hose to the delay valve bleed
nipple (2). Insert the other end of the hose into a
container.
• Pump the rear brake lever quickly. Repeat several
times, then keep the lever pulled in.
• Slacken the bleed nipple by one quarter of a turn to let
the brake fluid drain into the container. This will remove
any tension from the lever and help it travel fully home.
2 - 25
ATLANTIC 125 - 200
• Repeat process until the fluid draining into the

container is totally clear of air bubbles.
IMPORTANT When bleeding the hydraulic circuit, fill the tank
with the suitable quantity of brake fluid. Make sure that
during this procedure some brake fluid is always present
inside the tank.
• Tighten the bleed nipple and disconnect the hose.
FRONT BRAKE
• Remove the bleed valve rubber cap (3).

• Attach a clear plastic hose to the front brake caliper
bleed nipple (3). Insert the other end of the hose into a
container.
• Operate the front brake lever repeatedly, then keep it
fully pulled.

inside the tank.
REAR BRAKE
• Remove the rear brake caliper without detaching it

from its hoses, 7.7.5.
• Place the rear brake caliper in a raised position so as
to facilitate bleeding.
• Remove the bleed valve rubber cap (4).
• Attach a clear plastic hose to the rear brake caliper
bleed nipple (4). Insert the other end of the hose into a
container.
• Pump the rear brake lever quickly. Repeat several
times, then keep the lever pulled in.
2 - 26
ATLANTIC 125 - 200

inside the tank.
2 - 27
ATLANTIC 125 - 200
2.11. ENGINE OIL

2.11.1. CHECKING AND TOPPING UP THE ENGINE
OIL
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.
WARNING
Allow the engine and exhaust system to cool
down before proceeding.
• Stop the engine and allow it to cool, before draining the

oil in the crankcase, so that the oil itself is also cool.
IMPORTANT Proceeding without the preceding precautions
risks mistaking the engine oil level.
• Unscrew and remove the cap/dipstick (1).
• Clean off any oil with a clean cloth.
• Completely screw the cap/dipstick (1) into the filler hole
(2).
• Now remove the cap/dipstick (1) and read the oil level
off the dipstick:
Max = maximum level
Min = minimum level.
• The difference between the "Min" and "Max" levels is

about – 14.6 cu.in (240 cc).
• The correct level is just below the "Max" mark.
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
ATLANTIC 125 - 200
2.11.2. ENGINE OIL AND FILTER CHANGE

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

• Place a container under the engine oil filter.

• Unscrew and remove the engine oil filter cartridge (2).
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
ATLANTIC 125 - 200
2.12. TRANSMISSION OIL

2.12.1. CHECKING AND TOPPING UP THE
TRANSMISSION OIL
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
WARNING

• Clean off any oil with a clean cloth.
• Completely screw the cap/dipstick (1) into the filler hole
(2).
• Now remove the cap/dipstick (1) and read the oil level
off the dipstick:
Max = maximum level
Min = minimum level.
• The correct level is just below the "Max" mark.
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
ATLANTIC 125 - 200
2.12.2. TRANSMISSION OIL CHANGE

end of running-in) and every 3728 mi (6000 km) or 8 months
thereafter. Change the oil every 14913 mi (24000 km).

WARNING

• Place a container having a capacity greater than 18.3

3 3
in (300 cm ) beneath the drain cap (2) before
proceeding.
• Unscrew and remove the drain cap (2).
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.
• Screw and tighten the cap (2).
• Refill through the transmission oil filler hole with 15.2

3
cu.in (250 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 transmission oil level, 2.12.1.
2 - 31
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.
THROTTLE OPERATION CHECK
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.
• Turn the handlebars and ensure that idling speed is

unaffected by handlebar movement. Open the throttle
and ensure that the twistgrip snaps closed smoothly
when released.
If necessary, proceed as follows:
• Make sure the components listed below are in the
proper position and well lubricated:
- cable housing;
- twistgrip adjuster (1);
Lubricate the flexible drive with a silicon spray if necessary.
- throttle body adjuster (2), beneath the seat;
ADJUSTING THE THROTTLE CONTROL

IMPORTANT The throttle control can be adjusted either at
the twistgrip (1) or the throttle body (2).
The idle stroke of the throttle grip must be 0.07 ÷ 0.11 in (2 ÷
3 mm), measured on the edge of the grip itself.
If this is not the case, proceed as follows:
• Withdraw the protection element (3).
• Loosen the lock nut (4).
• Rotate the adjuster (1) in such a way as to restore the
prescribed value.
• After the adjustment, tighten the lock nut (4) and check
the idle stroke again.
• Put back the protection element (3).
2 - 32
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.
If the grip adjuster is completely screwed in or out or the

correct idle stroke cannot be set:
• Raise the seat.

• Rotate the adjuster (2) in such a way as to restore the
prescribed value.
• After the adjustment, tighten the lock nut (6) and check
the idle stroke again.
2 - 33
ATLANTIC 125 - 200
2.13.2. IDLING ADJUSTMENT

Adjust the idling every time it is irregular.
To carry out this operation, proceed as follows:
• Take a short ride (allow a few kilometers’ riding
distance) to warm engine up to normal operating
temperature.
• Raise the seat.
• Connect an electronic revolution counter to the
sparkplug cable.
• Start the engine.
The engine idling speed must be around:
- 1750 ± 100 rpm
At this speed the rear wheel is not driven by the engine.

• Adjust the screw (2).
- ROTATE CLOCKWISE to decrease the engine speed.
- ROTATE COUNTERCLOCKWISE to increase the
engine speed.
• Twist the throttle grip, accelerating and decelerating a
few times to make sure that it functions correctly and to
check if the idling speed is constant.
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ATLANTIC 125 - 200
2.14. FRONT END

2.14.1. STEERING
The steering is fitted with rolling bearings to ensure smooth
handling.
Proper steering adjustment is vital to smooth steering
movement and safe riding. Any hardness in the steering will
impair handling, whereas a soft steering will result in poor
stability.
CHECKING PLAY IN THE BEARINGS

• Place a support under the frame.
• Rock the forks back and forth in the direction of travel.
• If you feel any play, adjust the bearings.
ADJUSTING PLAY IN THE BEARINGS
TIGHTENING TORQUES
Locknut (1): 81.1 ftlb (110 Nm).
• Remove the leg protector, 7.1.9.

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
ATLANTIC 125 - 200
2.14.2. FRONT SUSPENSION

The front suspension consists of an hydraulic fork connected
to the steering column by a plate.
IMPORTANT The vehicle steering angle may not be
modified.
Change front fork oil every 7456 mi (12000 km) or 16
months.
Carry out the following checks:
• Keep the brake lever squeezed in and press down
repeatedly on the handlebars to compress the front
fork. The stroke must be gentle and there must be no
trace of oil on the rods.
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
ATLANTIC 125 - 200
2.15. TAIL SECTION

2.15.1. CHECKING THE ENGINE AXLE
Periodically check the play between the engine axle
bushings and the engine axle itself.
For the check, proceed as follows:

• Rock the wheel from side to side.
• If any play is evident, check that all engine axle
fastenings are fully tightened down.
2 - 37
ATLANTIC 125 - 200
2.15.2. REAR SUSPENSION INSPECTION

Check that the shock absorbers are not leaking oil.
Ensure that all parts are properly tightened and check the
joints of the rear suspension for proper operation.
ADJUSTING THE REAR SUSPENSION
The rear suspension is composed of a dual-effect shock

absorber (in compression and extension) mounted to the
engine by silent-blocks.
Factory setting is designed to suit the broadest possible
range or riding conditions, meaning low and high speed,
whether riding solo or carrying a full load.
However, the setting may be modified to suit specific needs
in accordance with vehicle usage:
adjust the nut, thus setting the ideal driving conditions (see
table).
REAR SUSPENSION ADJUSTMENTS TABLE
Adjuster nut Tighten Slacken
Increases spring Reduces spring

Function
preload preload
Riding Ride with
Solo ride
characteristics passenger
2 - 38
ATLANTIC 125 - 200
2.16. WHEELS
2.16.1. WHEELS
Read carefully 1.2.1
FRONT WHEEL
Check every 3728 mi (6000 km).

• Rotate the wheel manually in both directions.
• The wheel should be spinning smoothly, with no
hardness or unusual noise. If not so, change the
bearings, see 7.5.3.
• If you detect any wobble, inspect the wheel
components, see 7.5.4.
• A spinning wheel that always stops in exactly the same
position needs balancing.
REAR WHEEL
Check every 3728 mi (6000 km).

• Rotate the wheel manually in both directions.
• The wheel should be spinning smoothly, with no
hardness or unusual noise. If not so, change the
bearings, see 7.6.3.
• If you detect any wobble, inspect the wheel
components, see 7.6.5.
• A spinning wheel that always stops in exactly the same
position needs balancing.
2 - 39
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.
Inflation pressure, see 1.7.1.
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.
Minimum recommended tread depth (A):

Front and rear tire 0.07 in (2 mm).
2 - 40
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.
• Tighten the two exhaust manifold nuts (1).
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
4.3. FUEL CIRCUIT

4.3.1. FUEL CIRCUIT DIAGRAM
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
4.3.2. REPLACING THE FUEL FILTER

• Place a cloth beneath the fuel filter.
• Remove the two clips (1).
• Remove the fuel filter (2).
IMPORTANT Replace the fuel filter with a new one of the
same type
4-4
FUEL SYSTEM
ATLANTIC 125 - 200
4.3.3. FUEL TANK REMOVAL

• Lower the radiator, 5.3.1. while keeping it
attached to the coolant delivery and return hoses.
• Disconnect the fuel delivery hose (1).
• Disconnect the fuel probe connector (2).
• Release and remove the two rear screws (3) and

collect the washers.
• Lower and remove the fuel tank.
4-5
FUEL SYSTEM
ATLANTIC 125 - 200
4.3.4. REMOVING THE FUEL SENSOR

• Remove the central tunnel, 7.1.7.
• Disconnect the fuel delivery hose (1).
• Disconnect the fuel probe connector (2).
• Release and remove the nut (3).
• Turn the fuel sensor and extract it upwards.
4-6
FUEL SYSTEM
ATLANTIC 125 - 200
4.4. AIR CLEANER

4.4.1. AIRBOX REMOVAL
TIGHTENING TORQUES
Screws (4) 5.9 ftlb (8 Nm).

• Remove the engine bleed hose guard (3).
• Slacken clip (5) and extract the intake hose from the
carburetor.
• Move away the airbox.

• Extract the engine bleed hose (6) from the filter
housing.
• Remove the airbox.
4-7
FUEL SYSTEM
ATLANTIC 125 - 200
4.4.2. AIR CLEANER REMOVAL

• Remove the airbox, 4.2.1.
• Release and remove the nine screws (1).
• Open the airbox.

• Remove the air cleaner (2).
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.

• Remove the throttle cable from the carburetor.
• Crimp the two cooling system hoses (3).

• Extract the two cooling system hoses (3) from the
carburetor.
• Plug the ends of the two hoses (3) to stop the coolant
issuing from them.
• Disconnect the starter connector.
4-9
FUEL SYSTEM
ATLANTIC 125 - 200
• Slacken off the clip and disconnect the fuel hose.
• Slacken off the intake manifold clip (4).

• Remove the carburetor.
4 - 10
FUEL SYSTEM
ATLANTIC 125 - 200
4.5.2. REMOVING THE CARBURETOR

• Remove the guard, bracket and starter by releasing the
two screws (1).
• Remove the screw (2), rocker arm and acceleration

pump control spring.
• Remove the two fastening screws, vacuum chamber

cover and spring.
IMPORTANT While removing the cover take care that the
spring does not jump out unexpectedly.
• Remove the vacuum valve complete with membrane.
• Remove the four screws (3) and sump together with its
gasket.
4 - 11
FUEL SYSTEM
ATLANTIC 125 - 200
• Remove the acceleration pump piston from the sump

together with the nut, boot, O-ring and spring.
• Support the carburetor and use a drift and mallet to

remove the float spindle working from the gas control
side.
• Remove the float and pin.
• Remove the starter jet fuel conveyor cap (4)

• Remove the main jet (5).
• Remove the emulsioner.
• Remove the fuel nozzle.

IMPORTANT This is required to avoid losing the fuel nozzle
when the carburetor body is being cleaned. If the fuel nozzle
is jammed in its seat, do not proceed with the disassembly to
avoid damaging it.
• Remove the idling jet (6).
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
4.5.3. REASSEMBLING THE CARBURETOR

• Before reassembling, clean the carburetor body
thoroughly with petrol and compressed air.
• Pay special attention to the fuel duct and needle seat.
• For the maximum circuit, check the air calibration with
care.
• For the idle circuit, take care that the following

elements are clean: air calibration, flow screw
controlled outlet section, regulation holes next to the
throttle valve.
IMPORTANT On the 200 cc model, the idle air is controlled
by two calibrators. The cut-off calibrator is located in the
carburetor body itself.
• Check that the carburetor body is equipped with five

balls closing the machining ducts.
• Check that the mating surfaces for the sump and
membrane are not dented.
• Check that the vacuum pump seat is not scored.
• Check that the throttle and spindle are not over worn.
• Check that the needle seat is not over worn.
• If there are any irregularities, replace the carburetor.
IMPORTANT Do not insert metal objects into the calibrated
sections as this may damage them.
• Carefully clean and blow through the idling jet (1) and
refit it.
4 - 14
FUEL SYSTEM
ATLANTIC 125 - 200
• Carefully clean and blow through the maximum circuit,

fuel nozzle, emulsioner and jet.
• Fit the fuel nozzle into the carburetor body with its
shorter cylindrical section towards the emulsioner.
• Fit the emulsioner while checking the fuel nozzle
orientation and lock it down.
• Fit the main jet.
• Check that the taper needle is not worn where it seals

against the dampened pin and return spring.
• If it is worn, replace the needle.
• Check that the float is not worn where the pin seats or
at the needle contact plate and that no fuel is leaking
into it.
• Replace in case of anomalies.
• Fit the float with the needle, and fit the pin from the fuel
delivery hose side.
IMPORTANT Take care that the return spring is correctly
seated on the float plate.
LEVEL CHECK
• Make sure that the float coupling surface is parallel to

the sump surface with the carburetor upside down.
• If this condition is not met, modify the position of the
needle control plate until the above positioning is
obtained.
• If the plate has to be modified, check that it remains
parallel to the float spindle.
IMPORTANT With the carburetor upside down, the weight of
the float must not overcome the thrust of the taper needle
spring. If it does, check that the float is not too heavy due to
fuel inside it; replace the float and taper needle if necessary.
• 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.
• Check that the acceleration pump piston and its seat in

the sump are not worn.
• Replace defective or worn parts.
• Check that the acceleration pump contract spring is not
worn.
• Fit a new O-ring and bellows seal and fit the piston unit
into the sump.
• Fit a new O-ring to the sump drain screw and tighten it
down.
• Check the seal of the screw by filling the sump with a

small amount of fuel.
• Fit a new sump gasket.
• Fit the sump to the carburetor body and tighten down
the four screws securing it.
• 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 acceleration pump control rocker arm is

not over worn.
• Check that the rocker arm limit screw protrudes to the
following extent:
- 125 cc engine: 0.15 in (3.7 mm)

- 200 cc engine: 0.13 in (3.2 mm).
• Check that the rocker return spring is not yielded.

• Preassemble the spring and rocker arm.
• Fit the rocker arm to the carburetor with the throttle
valve held open.
• Tighten down the rocker arm screw.
• Check that the mechanism functions correctly.
CHECKING THE VACUUM VALVE AND TAPER NEEDLE

th
• Unscrew the bayonet fitting by 1/8 of a turn and
remove it, extract the vacuum valve needle and spring.
• 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
• Check that the membrane is neither hardened nor

broken. Otherwise replace it.
• Refit the taper needle and membrane to the vacuum
valve.
• Check that the spring is correctly located on the needle
and that it is snugly seated.
• Fit the fitting by turning it 1/8th of a turn.
• Refit the gas vacuum valve to the carburetor body

taking care that the taper needle is located in the fuel
nozzle.
• Locate the vacuum valve by seating the membrane tab
correctly. When the membrane is correctly seated to
the valve, the main vacuum delivery hole is aligned
with the choke, from the throttle side (see figure).
• Refit the spring to the valve.
• Refit the vacuum chamber cover and align the
reference with the membrane locator.
• Tighten the screws down to their prescribed torque.
• For the 200 cc version only, check that the cut-off valve
is operational. Check that the membrane is neither
hardened nor broken. Check the free length of the
spring.
Standard length: 0.94 in (24 mm)
• Refit the membrane with the metal pin located on the

valve. Refit the spring and cover. The latter must have
its vacuum fitting uppermost.
• Clean and blow through the starter mount.
• Fit a new gasket to the carburetor body and tighten
down the two screws securing it.
4 - 18
FUEL SYSTEM
ATLANTIC 125 - 200
4.5.4. CHECKING THE AUTOMATIC STARTER

• Check that the automatic starter piston is not scored or
rusted.
• Check that the piston runs freely in its seat in the
mount.
• Check that the piston gasket is not deformed.
• The starter must be more or less inserted according to
ambient temperature conditions.
• Measure the protrusion of the piston as indicated in the
figure and verify the resulting value.
• Check that the starter is correctly set to the ambient
temperature.
Protrusion value: 0.49 ÷ 0.51 in (12.5 ÷ 13 mm) at 68 F°

(20°C)
• The starter should withdraw progressively due to the

electrical heating.
• Check the starter resistance when it is set to the
ambient temperature.
Resistance: approx. 30 .
• use a 12V battery to power the automatic starter and
check that the piston protrudes to its maximum extent.
Maximum protrusion: 0.73 ÷ 0.75 in (18,5 ÷ 19 mm)

Max. time: 5 min
• The actual heating time depends on the ambient

temperature.
• If the protrusion, resistance or time are very different
from those given above, replace the starter.
• Fit the starter to the carburetor paying attention to the

position of the O-ring; locate the knurled plate on the
starter and tighten down the two screws (1).
• Locate the starter as shown in the figure.
• Fit the dust cover.
4 - 19
FUEL SYSTEM
ATLANTIC 125 - 200
4.5.5. IDLING ADJUSTMENT

• The engine does not require frequent idling adjustment,
but it is very important that the adjustment be done in
accordance with regulations.
• Before adjusting the carburetor, make sure that it is
well lubricated, valve play and timing are correct,
sparkplugs in excellent condition and the exhaust
system completely sealed.
• Run the engine for at least five minutes at around 30

mph (50 kph).
• Connect the vehicle to the exhaust gas analyzer by
fitting the analyzer probe in an extension tube tightly
mounted to the silencer output.
Optimal tube dimensions: Ø 1.6 in (Ø 40 mm

length 19.7 ÷ 23.6 in (500 ÷ 600 mm)
IMPORTANT The extension tube is essential to avoid

analyzing exhaust gas polluted by ambient oxygen.
The analyzer must be heated up previously so as to ensure
that the gas reading and flow rate can be correctly reset.
Failure to comply with these rules will lead to incorrect
readings.
• Connect the analyzer thermometer to the sump, using

a cap with oil filler specifically designed for insertion of
the probe.
• Start the engine and make sure the oil temperature is
158 ÷ 176 F° (70 ÷ 80 °C) before starting the idling
adjustment procedure.
4 - 20
FUEL SYSTEM
ATLANTIC 125 - 200
• Use the analyzer’s (or other) revolution counter to

adjust the idling screw until the engine is running at
1600 ÷ 1700 rpm.
IMPORTANT The ignition system is of the wasted spark type
and delivers a powerful shock. It may be difficult to read the
revolutions with an inappropriate revolution counter. The
combination with the revolution counter is correct when the
latter is able to read high engine speeds (6000 – 8000 rpm)
correctly.
• Adjust the flow screw until the CO level is 3.1 ÷ 4.5%,

slackening the screw off increases the CO (rich
mixture) while screwing it in decreases it (lean
mixture).
• If adjusting the flow screw position increases the
engine speed, readjust the rpm and if necessary the
screw until the values stabilize.
• Idling carburetion is correct when the oil temperature,

engine speed and CO percentage all match.
• The analyzer also gives further information:
percentage of carbon dioxide (CO2), the carbon dioxide
percentage has a different curve from the CO
percentage, correct values are above 12.5%.
nonconforming values are an indication of a bad seal on
the exhaust system.
• Uncombusted hydrocarbons (HC) are measured in
parts per million (ppm), the HC value decreases with
increasing engine speed, when the engine is idling it is
normal to read 200 – 400 ppm, this range is normal for
motorcycle engine timing. Much higher values may be
due to misfiring due to a too lean mixture (low CO),
ignition defects or incorrect timing or exhaust valve
jammed or not tight.
If it is difficult to adjust the CO level, check carefully:

Cleanliness of the carburetor
Operation of the automatic starter
Efficiency of the taper needle/seat assembly
Sump level adjustment.
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
5.1. SYSTEM CONFIGURATION

5.1.1. SYSTEM CONFIGURATION
An engine-driven centrifugal pump accommodated in the engine circulates coolant through the system. The pump takes
in the coolant from the radiator and directs it through the ducts into the cylinders and cylinder heads to cool down the
engine internals.
When coolant expands from heat, the expansion reservoir takes up excess coolant.
"LOW" and "FULL" level marks facilitate coolant level inspection and top-up, see 2.9.1.
For more details on the coolant, see 1.3.1.
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
• Remove the expansion reservoir cap, 5.5.1.

• Release the clip (2) and detach the hose (1).
• Allow the coolant to drain off into a suitable container.
FILLING
• Fit the sleeve (1) and secure it with the clip (2).
• Top up coolant level in the expansion reservoir,
2.9.1.
• Start the engine and keep it running until the cooling

fans switch on. Allow engine to cool down and check
coolant level in the expansion reservoir again.
• Start the engine and keep it running until the cooling
• Top up if needed, 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.
• Disconnect the two thermal switch connectors.
• Working from both sides, cut the clip (1).

• Remove both air scoops from the radiator.
• Working from both sides, remove the two screws (2).
• Unscrew and remove the central screw (3).

• Remove the clips.
5-5
COOLING SYSTEM
ATLANTIC 125 - 200
• Withdraw the hoses (4) from the radiator.

• Remove the radiator.
5-6
COOLING SYSTEM
ATLANTIC 125 - 200
5.3.2. REMOVING THE COOLING FAN

• Lower the radiator 5.3.1. while keeping it
connected to the hoses.
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.
• Remove the conveyor box.
5-7
COOLING SYSTEM
ATLANTIC 125 - 200

• Remove the cooling fan.
5-8
COOLING SYSTEM
ATLANTIC 125 - 200
5.4. WATER TEMPERATURE SENSOR

5.4.1. REMOVING THE WATER TEMPERATURE
SENSOR
• Disconnect the connector from the water temperature

sensor.
• Unscrew and remove the water temperature sensor.
5-9
COOLING SYSTEM
ATLANTIC 125 - 200
5.5. REMOVING THE EXPANSION RESERVOIR

5.5.1. REMOVING THE EXPANSION RESERVOIR
• Drain the cooling system, 5.2.1.
• Free the expansion reservoir from the helmet
compartment, 5.2.1.
• Remove the two cooling system hoses.
• Remove the expansion reservoir.
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
6.1. EXHAUST SYSTEM

6.1.1. EXHAUST SILENCER REMOVAL
TIGHTENING TORQUES
Clip (1) 14.7 ftlb (20 Nm)
Screws (2) 18.4 ftlb (25 Nm)
DANGER
Allow for the engine and exhaust silencer to
cool down completely.
• Slacken off the clip (1) mounting the silencer to the

manifold.
• Release and remove the three fastening screws (2).
• Remove the exhaust silencer.
6-3
ENGINE
ATLANTIC 125 - 200
6.1.2. REMOVING THE EXHAUST SYSTEM

TIGHTENING TORQUES
Nuts (1) 13.3 ftlb (18 Nm)
DANGER
Allow for the engine and exhaust silencer to
cool down completely.
• Remove the lower guard.

• Release and remove the two nuts (1).
• Release and remove the three fastening screws (2).

• Remove the exhaust system.
6-4
ENGINE
ATLANTIC 125 - 200
6.1.3. ENGINE COMPONENTS WHICH CAN BE

REMOVED WITHOUT REMOVING THE ENGINE
ITSELF.
The parts listed below can be removed leaving the engine in
the frame.
LEFT SIDE OF ENGINE

• Transmission casing cover
• Speed variator unit
• Clutch unit
• Drive belt
RIGHT SIDE OF ENGINE

• Spark plug
• Flywheel magneto
• Ignition casing
• Stator coil
• Pulse generator (Pick up)
• Coolant pump
• Secondary air
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
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.
Before removing the engine from the frame, clean it

thoroughly with a steam cleaner and drain the coolant, see
5.2.1.
IMPORTANT Where a procedure is cross-referred to
relevant sections in the manual, proceed sensibly to avoid
disturbing any parts unless strictly necessary.
Remove the engine from the frame as follows.
• Remove the helmet compartment, 7.1.16.
• Remove the carburetor, 4.3.1..
• Remove the exhaust system, 6.1.2.
• Remove the rear brake caliper from the brake disk,
7.6.2.
• Release and remove screw (1) disconnect the ground
clamp from the starter motor.
• Release and remove nut (2) and disconnect the cable
from the starter motor.
• Disconnect the water temperature sensor connector

(3).
• Disconnect the pick-up (4).
6-6
ENGINE
ATLANTIC 125 - 200
• Extract the vacuum hose (5) from the intake manifold.

• Extract the bleed hose (6) from the head.
• Detach the hose (7) from the thermal expansion valve.
• Pull the hose (8) off the coolant pump.
• Release and remove the lower screw (9).
• Disconnect the spark plug cap.
6-7
ENGINE
ATLANTIC 125 - 200
IMPORTANT You will need a hoist and suitable slings to lift

the engine.
• Connect the belts to the rear of the frame.
• Raise the hoist arm until stretching the slings taut.
• Working from the right-hand side, undo and remove the

nut (10).
• 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
6.2.2. FITTING THE ENGINE TO THE FRAME

TIGHTENING TORQUES
DANGER
Handle with care. Be careful to avoid injury to
your finger and limbs.
• Shift the frame gradually, with minimal movements,

until the engine fixing holes align perfectly.
• Fit the spindle (1) from the left side and fit the washer
and spacer.
• Working from the opposite side, tighten down the nut

(2).
• Fit the hose (3) to the coolant pump.
• Secure the hose (3) with the clip.
• Tighten down the lower shock absorber screw (4).
• Fit the vacuum hose (5) to the intake manifold.

• Fit the bleed hose (6) to the head.
• Fit the hose (7) to the thermal expansion valve.
6-9
ENGINE
ATLANTIC 125 - 200
• Connect the sparkplug cap.
• Connect the following electrical connectors in the

order:
- Pick-up (8).
• Water temperature sensor (9)
• Fit the starter motor ground cable.

• Tighten the screw (10).
• Fit the starter motor power cable.
• Tighten the nut (11).
• Fit the caliper to the rear brake disk. 7.6.2.
• Fit the exhaust system, 6.1.2.
• Install the carburetor, 4.3.1.
• Remove the helmet compartment, 7.1.16.
• Top up the coolant, see 2.9.1.
6 - 10
ENGINE
ATLANTIC 125 - 200
IMPORTANT Inspect any parts you have removed, paying

special attention to these components:
- wiring must be properly fastened with wire ties;
WARNING
Wires and hoses must not be twisted and/or
crushed.
- electrical connectors must be fitted to the matching

connectors;
- hoses, pipes and couplings must be securely in place
and fastened with suitable clips;
- The throttle cable must slide smoothly inside its housing
and must not bind when handlebars are turned.
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
7.9.1. FRONT FORK CONFIGURATION .................................................................................... 66

7.9.2. REMOVING THE STANCHION TUBES - SLIDERS .......................................................... 67
7.9.3. DISASSEMBLING THE STANCHION TUBES - SLIDERS................................................. 68
7.9.4. DRAINING THE OIL.......................................................................................................... 71
7.9.5. FILLING THE OIL ............................................................................................................. 73
7.9.6. COMPONENT INSPECTION ............................................................................................ 75
7.9.7. REASSEMBLING THE STANCHION TUBE /SLIDER ASSEMBLY.................................... 76
7.10. REAR SUSPENSION............................................................................................................ 78
7.10.1. REMOVING THE REAR SHOCK ABSORBER.................................................................. 78
7.10.2. REMOVING THE LINKAGE SYSTEM............................................................................... 79
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
7.1.2. SEAT REMOVAL

• Insert the key into the seat lock.
• Press and turn the ignition key clockwise.
• Raise the seat.
• Release and remove the four screws.

• Remove the seat.
7-6
CYCLE PARTS
ATLANTIC 125 - 200
7.1.3. REMOVING THE UNDERSEAT PROTECTION

SCREEN
IMPORTANT The procedure described below applies to both
protection screens.
• Remove the underseat protection screen.
7-7
CYCLE PARTS
ATLANTIC 125 - 200
7.1.4. REMOVING THE CARRIER RACK

TIGHTENING TORQUES

• Remove the carrier rack panel.
• Unscrew and remove the two screws (1) and collect

the washers.
• Remove the carrier rack.
7-8
CYCLE PARTS
ATLANTIC 125 - 200
7.1.5. REMOVING THE REAR FAIRING

• Remove the carrier rack, 7.1.4.
• Remove both seat protection screens, 7.1.3.
• Working from both sides, remove the three upper
screws (1).
• Working from both sides, release and remove the

lower screw (2).
• Move aside the rear fairing and disconnect the tail light
connector.
• Release the seat anchoring cable.

• Remove the entire rear fairing.
7-9
CYCLE PARTS
ATLANTIC 125 - 200
7.1.6. REMOVING THE NUMBER PLATE BRACKET

• Working from both sides, remove the four screws (1).
• Move the number plate bracket aside.

• Release and remove the two bulb mount screws (2).
• Remove the number plate bracket.
7 - 10
CYCLE PARTS
ATLANTIC 125 - 200
7.1.7. REMOVING THE CENTRAL TUNNEL

• Remove the rear fairing, 7.1.5.
WARNING
Proceed with care. Do not damage the snap-on
tangs and matching recesses.
• Working from both sides, remove the mat, raising it

with both hands.
• Working from both sides, remove the five screws (1).
• Working from both sides, remove the six screws (2).
• Insert the key into the fuel tank lock.

• Raise the fuel tank hatch.
• Undo and remove the fuel tank cap.
7 - 11
CYCLE PARTS
ATLANTIC 125 - 200
• Remove the gasket under the cap.

IMPORTANT Place a clean cloth into the fuel tank opening.
WARNING
• Pull the central tunnel off towards the rear.
7 - 12
CYCLE PARTS
ATLANTIC 125 - 200
7.1.8. REMOVING THE LOWER GUARD

• Working from both sides, remove the front mat, raising
it with both hands.
• Working from both sides, remove the rear mat, raising

it with both hands.
• Working from both sides, remove the six screws (1).
• Working from both sides, remove the lower screw (2).
7 - 13
CYCLE PARTS
ATLANTIC 125 - 200
• Unscrew and remove the three front screws (3).

• Let the side stand down.
• Remove the lower guard.
7 - 14
CYCLE PARTS
ATLANTIC 125 - 200
7.1.9. REMOVING THE LEG GUARDS

• Unscrew and remove the eight side screws (1).
• Insert the key into the fuel tank lock.

• Raise the fuel tank hatch.
• Raise the front panel.

WARNING
• Remove the leg guard.
7 - 15
CYCLE PARTS
ATLANTIC 125 - 200
7.1.10. REMOVING THE FRONT PANEL

• Working from both sides, remove the rear screw (1).
• Unscrew and remove the two front screws (2).
• Unscrew and remove the two lower screws (3).

• Remove the front panel.
7 - 16
CYCLE PARTS
ATLANTIC 125 - 200
7.1.11. REMOVING THE WINDSCREEN

• Remove the front panel, 7.1.10.
• Remove both rear view mirrors, 7.1.12.
• Unscrew and remove the two front screws (1).
• Remove the windscreen.
7 - 17
CYCLE PARTS
ATLANTIC 125 - 200
7.1.12. REMOVING THE REARVIEW MIRRORS

TIGHTENING TORQUES

rearview mirrors.
• Raise the rubber joint.
• Remove the external protection.

• Remove the mirror.
7 - 18
CYCLE PARTS
ATLANTIC 125 - 200
7.1.13. REMOVING THE SIDE FAIRINGS

side fairings.
• Working from both sides, remove the upper screw (1).
• Working from both sides, remove screw (2).
• Release and remove the four inner screws (3).

• Remove the side fairing.
7 - 19
CYCLE PARTS
ATLANTIC 125 - 200
7.1.14. REMOVING THE FRONT MUDGUARD

TIGHTENING TORQUES

• Remove the front mudguard.
7 - 20
CYCLE PARTS
ATLANTIC 125 - 200
7.1.15. REMOVING THE REAR MUDGUARD

TIGHTENING TORQUES
Filter housing screws (1) 5.9 ftlb (8 Nm)
• Unscrew the two filter housing screws (1).
• Unscrew the three screws (2) and collect the cable

clamp.
• Remove the rear mudguard.
7 - 21
CYCLE PARTS
ATLANTIC 125 - 200
7.1.16. REMOVING THE HELMET COMPARTMENT

• Remove the battery and extract the main fuse holder,
7.2.1.Unscrew and remove the two front screws
(1).
• Release and remove the two rear screws (2).
• Raise the helmet compartment.

• Release and remove the two screws (3) securing the
expansion reservoir.
• Move aside the expansion reservoir while keeping it
attached to the cooling system hoses.
• Disconnect the two power connectors (4).

• Remove the helmet compartment.
7 - 22
CYCLE PARTS
ATLANTIC 125 - 200
7.1.17. REMOVING THE HANDLEBAR COVER

• Remove the upper cover.
• Working from both sides, remove the front screw (2).
• Working from both sides, remove the lower screw (3).
• Release and remove the three screws (4).
7 - 23
CYCLE PARTS
ATLANTIC 125 - 200
• Remove the upper handlebar cover.

• Remove the lower handlebar cover.
7 - 24
CYCLE PARTS
ATLANTIC 125 - 200
7.1.18. REMOVING THE SPLASHGUARDS

• Remove the entire steering assembly 7.8.1.
• Working from both sides, cut the clip (1).
• Remove both air scoops from the radiator.
• Working from both sides, remove the four side screws

(2).
• Unscrew and remove the central screw (3).

• Remove the splashguard.
7 - 25
CYCLE PARTS
ATLANTIC 125 - 200
7.2. ELECTRIC COMPONENTS

7.2.1. REMOVING THE BATTERY
• Run the first four operations described in 2.4.2.
• Disconnect the negative (-) and positive (+) leads in
that order.
• Extract the bleed hose from the battery.
• Remove the battery.
7 - 26
CYCLE PARTS
ATLANTIC 125 - 200
7.2.2. REMOVING THE ECU

• Disconnect the ECU connector (1).
• Remove the ECU.
7 - 27
CYCLE PARTS
ATLANTIC 125 - 200
7.2.3. REMOVING THE VOLTAGE RECTIFIER

• Disconnect the rectifier connector (1).
• Remove the voltage rectifier.
7 - 28
CYCLE PARTS
ATLANTIC 125 - 200
7.2.4. REMOVING THE RIGHT COMMUTATOR

• Unscrew and remove the three lower screws (1).
• Remove the lower commutator cover.
• Disconnect the engine kill connector.
• Disconnect the engine starter connector.

• Remove the upper commutator cover.
7 - 29
CYCLE PARTS
ATLANTIC 125 - 200
7.2.5. REMOVING THE LEFT COMMUTATOR

• Unscrew and remove the three lower screws (1).
• Remove the lower commutator cover.
• Disconnect the lights connector (3).

• Disconnect the direction indicator connector (4).
• Disconnect the horn connector (5).
• Remove the upper commutator cover.
7 - 30
CYCLE PARTS
ATLANTIC 125 - 200
7.2.6. REMOVING THE DASHBOARD

• Remove the windscreen, 7.1.11.
• Working from both sides, remove the dashboard
fastener screw (1).
• Remove the dashboard.
• Disconnect the odometer cable.
• Disconnect the three dashboard connectors (2-3-4)

making sure not to tear the flexible PCB.
7 - 31
CYCLE PARTS
ATLANTIC 125 - 200
• Remove the dashboard.
7 - 32
CYCLE PARTS
ATLANTIC 125 - 200
7.2.7. REMOVING THE HEADLIGHT

• Remove both side fairings, 7.1.13.
• Unscrew and remove the two upper screws (1).
• Unscrew and remove the two lower screws (2).
• Working from both sides, disconnect the two direction

indicator connectors.
• Disconnect the headlight connector.

• Remove the headlight.
7 - 33
CYCLE PARTS
ATLANTIC 125 - 200
7.2.8. REMOVING THE FRONT DIRECTION

INDICATORS
direction indicators.
• Remove both side fairings, 7.1.13.
• Disconnect both direction indicator connectors.
7 - 34
CYCLE PARTS
ATLANTIC 125 - 200
7.2.9. REMOVING THE TAIL LIGHT UNIT

RIGHT
• Disconnect the connector (1).
• Extract the number plate bulb (2).

• Remove the right lights unit.
LEFT
• Disconnect the connector (1).
• Remove the left lights unit.
7 - 35
CYCLE PARTS
ATLANTIC 125 - 200
7.2.10. REMOVING THE COIL

• Disconnect the spark plug cap.
• Disconnect the two coil connectors (1).

• Release and remove the screw (2) and collect the nut.
7 - 36
CYCLE PARTS
ATLANTIC 125 - 200
7.3. CONTROLS
7.3.1. REMOVING THE THROTTLE CONTROL
• Remove the right commutator, 7.2.5.
• Lower the brake pump clamp.
• Disconnect both throttle cables (2).

• Remove the brake pump clamp.
• Remove the rear brake master cylinder, making sure
not to extract the brake hose.
• Release and remove the counterweight retaining

screw.
• Remove the counterweight.
• Remove the throttle control.
7 - 37
CYCLE PARTS
ATLANTIC 125 - 200
7.3.2. REMOVING THE REAR BRAKE MASTER

CYLINDER
• Remove the left hand commutator, 7.2.5.
• Remove the brake pump clamp.
• Remove the rear brake master cylinder, making sure
not to extract the brake hose.
If you need to remove the cylinder completely:
• Disconnect the two rear stop light switch connectors
(2).
• Drain the braking system, 2.10.2.
• Release and remove screw (3) and collect the
washers.
• Remove the brake master cylinder.
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)
• Remove the handlebar cover, 7.1.17.

• Remove the throttle control, 7.3.1.
• Remove the rear brake master cylinder, 7.3.2.
• Remove the left grip.
• Release the handlebar from its clips.
• Loosen the clamp screw (1).
• Unscrew and remove the safety screw (2).

• Remove the handlebar.
7 - 39
CYCLE PARTS
ATLANTIC 125 - 200
7.4.2. REMOVING THE DASHBOARD/WINDSCREEN

SUBFRAME
TIGHTENING TORQUES
• Remove the headlight, 7.2.7.

• Release the dashboard/windscreen subframe from its
clips.
• Disconnect the right commutator connector.
• Disconnect the left commutator connector.
• Disconnect the ignition switch assembly connector (1).
• Remove the secondary fuse holder from its mount.
7 - 40
CYCLE PARTS
ATLANTIC 125 - 200
• Remove the safety relay from its mount.
• Unscrew and remove the two screws (2) securing the

braking distributor.
• Release and remove the three screws (3) retaining the

upper headlight mount.
• Release and remove the two screws (4) retaining the

lower headlight mount.
7 - 41
CYCLE PARTS
ATLANTIC 125 - 200
• Undo and remove the four screws (5) securing the

dashboard/windscreen subframe to the frame.
• Remove the dashboard/windscreen subframe
7 - 42
CYCLE PARTS
ATLANTIC 125 - 200
7.4.3. REMOVING THE SIDE STAND

TIGHTENING TORQUES

• Disconnect the side stand connector.
• Unhook the two springs from the stand.

• From the opposite side, remove the following

components in sequence: screw, washer, stand switch
and stand.
7 - 43
CYCLE PARTS
ATLANTIC 125 - 200
7.4.4. REMOVING THE CENTER STAND

TIGHTENING TORQUES
Nut (1) 19.9 ftlb (27 Nm)
• Place the motorcycle on the side stand.

• Release the two springs.

• Withdraw the bolt on the opposite side.
• Remove the center stand.
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
7.4.5. REMOVING THE FRAME

TIGHTENING TORQUES
Screw (6) 8.8 ftlb (12 Nm)
IMPORTANT Where a procedure is cross-referred to

relevant sections in the manual, proceed sensibly to avoid
disturbing any parts unless strictly necessary.
• Remove the splashguard, 7.1.18.
• Remove the headlight, 7.2.7.
• Disconnect the two connectors (1) of the warning horn.
• Disconnect the ignition switch assembly connector (3).

• Remove the fuel tank, 4.1.3.
• Remove the side stand, 7.4.3.
• Remove the radiator; see 5.3.1.
• Remove the seat protection screen, 7.1.3.
• Remove the connecting rods, 7.10.2.
• Remove the shock absorber, 7.10.1.
• Remove the throttle cable (5) from the carburetor.

• Remove the caliper from the rear brake disk,
7.7.5.

NOTE Release all cables and hoses from the ties and clips
along their full length.
• Remove the coil, 7.2.10.
7 - 45
CYCLE PARTS
ATLANTIC 125 - 200
• Disconnect the following connectors:

- Voltage rectifier;
- ECU;
- starter connector (7);

- disconnect the two starter relay connectors (8).

• Remove the ECU frame.
• Raise and remove the frame.
7 - 46
CYCLE PARTS
ATLANTIC 125 - 200
7.5. FRONT WHEEL

7.5.1. FRONT WHEEL CONFIGURATION
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
7.5.2. REMOVING THE FRONT WHEEL

TIGHTENING TORQUES
Retaining screw (1) 8.8 ftlb (12 Nm)
Wheel spindle 29.5 ftlb (40 Nm)
WARNING
While disassembling and reassembling the
wheel, be careful not to damage the brake pipe,
the disk and the pads.

• Remove the brake calliper, 7.7.2.
• Loosen the retaining screw (1).
• Release and remove the wheel spindle.
• Collect the odometer sprocket.
• Remove the wheel.
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
• Recover the spacer from the left side of the wheel.
7 - 49
CYCLE PARTS
ATLANTIC 125 - 200
7.5.3. DISASSEMBLING THE FRONT WHEEL

• Remove the front wheel, see 7.5.2.

• Clean the wheel hub at both ends with a cloth.
• Remove the RH oil seal (1).
• Remove the right-hand bearing (2) using a suitable
bearing extractor.
• Remove the LH oil seal (3).
• Remove the left-hand bearing (4) using a suitable
bearing extractor.
WARNING
Inspect the bearings after each removal and
replace as required. See 7.5.4..
• Collect the inner spacer (5).

• Clean the hub bore thoroughly.
• Wash all components using clean detergent.
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
7.5.4. CHECKING FRONT WHEEL PARTS

WARNING
Check that all components are in perfect
condition. Inspect the following components
with special care.
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
Exceeding run-out is normally due to worn or damaged

20 120
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
Check tire condition, see 2.17.1.
7 - 51
CYCLE PARTS
ATLANTIC 125 - 200
7.5.5. REFITTING THE FRONT WHEEL

TIGHTENING TORQUES
Retaining screw (1) 8.8 ftlb (12 Nm)
Wheel spindle 29.5 ftlb (40 Nm)
Screws (2) 18. ftlb (25 Nm)
• Place the wheel between the fork legs.

• Fit the odometer sprocket to the wheel.
• Smear a light coat of grease over the total length of the

wheel spindle (1); see 1.8.1..
• Tighten down the wheel spindle from the right side.
• Tighten down the retaining screw (1).
• Install the brake caliper to the brake disk.

• Tighten the two screws (2).
7 - 52
CYCLE PARTS
ATLANTIC 125 - 200
7.6. REAR WHEEL

7.6.1. REAR WHEEL CONFIGURATION
Key:
1. Wheel
2. Circlip
3. Bearing
4. Silencer / brake caliper plate
5. Nut
7 - 53
CYCLE PARTS
ATLANTIC 125 - 200
7.6.2. REMOVING THE REAR WHEEL

TIGHTENING TORQUES
Screw (1) 18.4 ftlb (25 Nm)
Wheel spindle nut 81.1 ftlb (110 Nm)
• Remove the exhaust assembly, 6.1.2.

• Remove the rear mudguard, 7.1.15.
• Extract the rear brake caliper, keeping it attached to
the brake fluid hose, 7.7.5.
• Extract the split pin on the wheel spindle.
• Remove the nut cover.
• Release and remove the wheel spindle nut.

• Remove the exhaust mount plate.
7 - 54
CYCLE PARTS
ATLANTIC 125 - 200
• Remove the spacer (2) on the wheel spindle.

• Remove the rear wheel.
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
7.7.2. REPLACING THE FRONT BRAKE PADS

TIGHTENING TORQUES

• Extract the caliper from the disk by opening the pistons
to their maximum extent and rotating the caliper
outwards to protect the rim (use tape to protect it if
necessary).
• Release and remove the grub screw (2).
• Release and remove the pivot bolt (3).
• Extract the brake pads.
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.
• Fit two new brake pads.

• Tighten the spindle (3).
• Tighten the grub screw (2).
• Locate the brake caliper on the disk.
• Tighten the two screws (1).
7 - 57
CYCLE PARTS
ATLANTIC 125 - 200
7.7.3. CHECKING THE FRONT BRAKE DISK

IMPORTANT These operations are to be performed with the
brake disk installed to the wheel.
• Check for wear measuring disk thickness with a
micrometer gauge at different positions along the disk.
When a disk is worn beyond the service limit even at
just one position, the disk must be replaced.
Service limit: 3.3 in (4.5 mm).
• Check for disk run-out using a dial gauge. Replace disk
when the maximum run-out measured exceeds the
disk run-out limit; see 7.7.4.
Disk run-out limit: o.2 in (0.3 mm).
7 - 58
CYCLE PARTS
ATLANTIC 125 - 200
7.7.4. REMOVING THE FRONT BRAKE DISK

• Unscrew and remove the five brake disk screws (1).
IMPORTANT To refit, start all screws (1) manually in their

holes and tighten in a cross pattern.
WARNING
®
Apply LOCTITE 270 to the brake disk screw
threads (1) on assembly.
• Remove the brake disk.
7 - 59
CYCLE PARTS
ATLANTIC 125 - 200
7.7.5. REPLACING THE REAR BRAKE PADS

TIGHTENING TORQUES

• Remove the caliper from the brake disk.
• Remove the retaining ring (2).

• Remove the spindle (3).
• Remove the spring (4).
• Extract the brake pads (5) one at a time.
WARNING
Do not operate the brake lever with the pads
removed.
Otherwise the pistons could issue from their
seats and leak brake fluid.
• Replace both pads (5).
WARNING
The brake pads must always be replaced in
pairs. Ensure they become properly seated in
the brake caliper.
• Fit two new brake pads.

• Fit the spring (4).
• Refit the spindle (3).
• Fit the retaining ring (2).
• Check the brake fluid level, 2.10.1.
7 - 60
CYCLE PARTS
ATLANTIC 125 - 200
7.7.6. CHECKING THE REAR BRAKE DISK

IMPORTANT These operations are to be performed with the
brake disk installed to the wheel.
• Check for wear measuring disk thickness with a
micrometer gauge at different positions along the disk.
IMPORTANT Replace the disk if worn beyond the service
limit even at just one position. See 7.8.4..

• Check for disk run-out using a dial gauge. Replace disk
when the maximum run-out measured exceeds the
disk run-out limit; see 7.8.4.
Disk run-out limit: 0.2 in (0.3 mm).
7 - 61
CYCLE PARTS
ATLANTIC 125 - 200
7.7.7. REMOVING THE REAR BRAKE DISK

• Remove the rear wheel, 7.5.2.
• Unscrew and remove the three brake disk screws (1).
IMPORTANT To refit, start all screws (1) manually in their

holes and tighten in a cross pattern.
WARNING
Apply LOCTITE(r) 270 to the brake disk screw
threads (1) on assembly.
• Remove the brake disk.
7 - 62
CYCLE PARTS
ATLANTIC 125 - 200
7.7.8. REMOVING THE BRAKING DISTRIBUTOR

TIGHTENING TORQUES

• Drain the braking system, , 2.10.2.
• Unscrew and remove the two screws (1) and bleed
valve and collect the gaskets.
IMPORTANT Mark the brake hoses to guard against
inverting them during reassembly.
• Remove the three brake hoses with care to guard
against fluid spillage.
• Unscrew and remove the two screws (2) securing the
distributor.
• Remove the distributor.
IMPORTANT Bleed the brake circuit during reassembly,

2.10.4.
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)
• Place the motorcycle on a lift with the front wheel

protruding over the runway edge. Put the motorcycle
on the centre stand .
• Remove the handlebar, 7.4.1.
• Remove the caliper from the rear brake disk,
7.7.2.
• Release and remove the locknut (1).

IMPORTANT Take care that the lower ball bearings do not

fall out when extracting the fork.
• Extract the entire fork assembly including the front
wheel from the headstock.
• Slide out and remove the plastic gasket (3).

• Remove the upper bearing race (4) and balls (5).
• Remove the lower bearing race (6) and balls (7).
• Clean all bearing parts of grease including the fixed
races (8) and (9).
• Remove the dust seal (10).
• Check all parts for wear and replace if necessary.
IMPORTANT For recommended bearing greases,
1.8.1.
• After refitting all components, adjust the bearing play.
7 - 64
CYCLE PARTS
ATLANTIC 125 - 200
7.8.2. COMPONENT INSPECTION
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
7.9. FRONT FORK

7.9.1. FRONT FORK CONFIGURATION
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
7.9.2. REMOVING THE STANCHION TUBES -

SLIDERS
stanchion tube/slider assemblies.
• Remove the front mudguard, 7.1.14.
• Remove the upper circlip (2).

• Remove the stanchion tube/slider assembly.
7 - 67
CYCLE PARTS
ATLANTIC 125 - 200
7.9.3. DISASSEMBLING THE STANCHION TUBES -

SLIDERS
• Drain the oil off, 7.9.4.
• Place the fork leg in a vice with soft (aluminium) jaws.
• Remove the leg and collect the centring bush.

IMPORTANT Take care not to damage the slider inner
seating surface during removal of the different components.
• Withdraw the damping cylinder assembly (2) from the

stanchion tube and retain the spring (3).
7 - 68
CYCLE PARTS
ATLANTIC 125 - 200
• Remove the dust seal from the slider.
• Remove the steel ring.
• Remove the oil seal.
• Remove the washer.
7 - 69
CYCLE PARTS
ATLANTIC 125 - 200
• Also remove the spacer (4) (optional).
7 - 70
CYCLE PARTS
ATLANTIC 125 - 200
7.9.4. DRAINING THE OIL

IMPORTANT Make sure to have a suitable container ready
at hand before proceeding with capacity of at least
1.7.1.
• Place the slider in a vice with soft aluminum jaws.
WARNING
The stanchion-and-slider assembly contains
oil. Do not turn it over or tilt it exceedingly
during removal.
• Unscrew the upper cap.
• Push in the damping cylinder until it is possible to

extract the circlip (1).
• Remove the circlip (1).
• Remove the cap complete with O-ring.
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
7.9.5. FILLING THE OIL

• Place the stanchion tube/slider assembly in a vice with
soft (aluminum) jaws.
• Fit the spring.
• Pour the fork oil into the stanchion tube / slider

assembly.
WARNING
Never reuse the oil you have drained from the
fork
• Remove the cap complete with O-ring.
7 - 73
CYCLE PARTS
ATLANTIC 125 - 200
• Refit the damping cylinder (1).
• Push in the damping cylinder until it is possible to fit the

circlip (2).
• Fit the circlip (2).
• Fit the upper cap.
7 - 74
CYCLE PARTS
ATLANTIC 125 - 200
7.9.6. COMPONENT INSPECTION

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.
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).
- oil seal (2);

- dust seal (3);
7 - 75
CYCLE PARTS
ATLANTIC 125 - 200
7.9.7. REASSEMBLING THE STANCHION TUBE

/SLIDER ASSEMBLY
• Place the slider in a vice with soft (aluminium) jaws.
• Fit the spacer (1).
WARNING
Take care to prevent the ingress of dirt inside
the slider and the stanchion.
IMPORTANT Apply a light film of fork oil to the bushes and

seals before assembly.
• Fit the washer.
• Fit the oil seal.
• Fit the circlip.
7 - 76
CYCLE PARTS
ATLANTIC 125 - 200
• Fit the dust seal.
• Fit the damping cylinder and the spring into the

stanchion.
• Fit the following parts to the slider in order: centring

bush (2) and stanchion tube.
• Tighten the lower screw (3).

• Refill with oil, 7.9.5.
7 - 77
CYCLE PARTS
ATLANTIC 125 - 200
7.10. REAR SUSPENSION

7.10.1. REMOVING THE REAR SHOCK ABSORBER
TIGHTENING TORQUES
Upper nut (1) 36.9 ftlb (50 Nm)

• Release and remove the upper nut (1).
• Remove the upper screw.
• Remove the shock absorber.
7 - 78
CYCLE PARTS
ATLANTIC 125 - 200
7.10.2. REMOVING THE LINKAGE SYSTEM

TIGHTENING TORQUES
Nut (2) 29.5 ftlb (40 Nm)
Shock absorber screw (4) 36.8 ftlb (50 Nm)
Nut (9) 44.2 ftlb (60 Nm)

• Remove both seat protection screens, 7.1.3.
• Remove the spring (1).
• Connect the belts to the grab rail.

• Raise the hoist arm until the slings are taut.
WARNING
An assistant is required to perform the
following operations.

nut (2).
• 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
• Collect the following parts in the order: the inner nut

(6), screw (5) and washer.

nut (7).
• Withdraw the bolt from the left side and collect the
washer.
• Remove the connecting rods.
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
8.1. COMPONENT LOCATION

8.1.1. LAYOUT OF ELECTRICAL COMPONENTS
Key: 15. ECU

1. Headlight 16. Coolant temperature thermistor
2. Battery 17. ECU relay
3. Spark plug 18. Front brake light switch
4. Main fuses 19. Dashboard
5. Coil 20. Front right direction indicator
6. Secondary fuses 21. Rear brake light switch
7. Rectifier 22. Rear right direction indicator
8. Tail light 23. Cooling fan
9. Rear left-hand turn signal 24. Fuel sensor
10. Side stand switch
11. Starter
12. Horn
13. Starter relay
14. Front left direction indicator
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.
• Grasp both connectors and pull them in opposite

directions until they become separated.
• Remove any dirt, rust, moisture, etc. from inside the
connector blowing 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 (the locking tab should click audibly
into place).
8-4
ELECTRICAL SYSTEM
ATLANTIC 125 - 200
8.3. BATTERY
8.3.1. BATTERY
Battery rating: 12 V -9 Ah
ACTIVATION AND SERVICE
• Remove the battery from the motorcycle, see

7.2.1.
• Remove the cell caps and bleed cap.
• Fill the cells with electrolyte with a specific weight of
1.3.
• Charge the battery slowly (amperage 1/10 of the
battery capacity) for at least 10 hours. Install the
battery in the motorcycle at the time of delivery to the
customer, that is, when the vehicle is to be ridden.
• Install the battery in the motorcycle and connect the
terminals and bleed tube.
• In case of prolonged disuse, periodically recharge the
battery (at least once a month) for 10 hours. This would
typically be necessary during the winter.
• Periodically top up the electrolyte level with distilled
water (once a month).
INSPECTION
• In case malfunction, check that the recharge system is

operating correctly first, see 8.5.1.
• To check the battery,
• Remove the battery from the motorcycle, see
7.2.1., and proceed as follows:
Visually check that:
- there are no evident signs of sulphation (white color of
one or more cells);
- that the electrolyte level is between the MIN and MAX
marks.
- the housing (outer shell) is not leaking.
• Charge the battery slowly for at least 10 hours.
• Check the electrolyte density for each battery element
with a densitometer after recharging. If the density is
less than 1.26 in any element or the no-load voltage is
less than 12V, the battery must be replaced.
RETURN UNDER WARRANTY
Batteries returned in the following condition are not covered

by the warranty:
- mechanically damaged (dented housing, bent terminals,
etc.);
- extensive sulphation (normally due to improper
installation procedure and/or use)
- insufficient electrolyte level (simply fit the bleed with the
provided rubber cap for shipping).
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
8.4. IGNITION SYSTEM AND STAND LOGIC

8.4.1. IGNITION SYSTEM AND STAND LOGIC
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
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
Ignition coil test

Use a pocket tester for the check. Check for continuity of the
primary and secondary windings. The resistance readings
found need not match standard values exactly, but if the
windings are in good working order, resistance readings
should approximate the standard values as follows:
Coil winding resistance

Primary 0.2 ohm ± 10%
secondary 2.9 KOhm ± 10%
Warning: Before measuring, disconnect the spark plug cap.
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.
Checking the CDI ECU

The ignition ECU is of the capacitive discharge type with rpm
digital spark advance control. The ECU has two connectors
of which the 8-pin one is used.
The pinout is as follows.

1. Direction indicators
2. n/a
3. ignition coil
4. n/a
5. input +15
6. pick-up input
7. starter
8. earth
CHECK DATA
Starter relay test

Test the relay for proper operation as follows:
• Feed 12 Volts to the two male terminals (85-86).
• Check for continuity between the other two terminals
(8730) using a multimeter set to the Ohm range.
Correct value with relay powered : 0 ohm

Correct reading when relay is not fed: ∞ ohm
Change the relay if the reading found deviates from the

specified reading.
8-8
ELECTRICAL SYSTEM
ATLANTIC 125 - 200
Side stand switch test

The side stand (1) must rotate without hindrances.
Carry out the following checks:
• The springs (2) must not be damaged, worn, rusty or
weakened.
• The stand must rotate freely: Grease the joint, see
2.2.1.
The side stand (1) is provided with a safety switch (3) that
prevents or interrupts the operation of the engine with the
stand lowered.
To check the proper functioning of the safety switch (3),
proceed as follows:
• Sit on the vehicle in the driving position.
• Fold the side stand (1).
• Start the engine.
• With the throttle released and engine idling, lower the

side stand (1), thus operating the safety switch (3).
At this point:
- the engine must stop;
- the side stand light " " on the instrument panel should
light up.
IMPORTANT When this is not the case, replace the switch
(3).
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
8.5. CHARGING CIRCUIT

8.5.1. GENERAL RECHARGE AND POWER
DIAGRAM
Key:
38. Main fuses
39. Power outlet
40. Battery
48. Alternator
49. Rectifier
CHECKING CHARGE VOLTAGE

• Check the electrolyte level, 2.4.3.
• Check the battery voltage, see 2.4.1.
• Start the engine and rev it up to 5000 rpm (throttle grip
turned through 1/4 of its travel).
• Set the light dip switch to “ ”.
• Measure DC voltage across the positive (+) and
negative (–) battery terminals using a multimeter.
• If the reading found is less than 13 V or more than 15
V:
• Check the no-load operation and continuity of the
alternator and rectifier.
Correct charge voltage: 13 -15 V(DC) at 5000 rpm.
8 - 10
ELECTRICAL SYSTEM
ATLANTIC 125 - 200
ALTERNATOR NO-LOAD TEST

• Start the engine and rev it up to 5000 rpm (throttle grip
turned through 1/4 of its travel).
• Use a multimeter to measure the voltage across the
three yellow wires in turn (G). If the multimeter reading
is less than 50V, the alternator is faulty.
ALTERNATOR CONTINUITY TEST

With the engine off:
• Use a multimeter to test the continuity between the
yellow stator cables (G).
• Also check the stator mount insulation.
Correct resistance reading: 0.1 – 1 ohm
Correct resistance reading between wires and stator
mount: ∞ (infinite)
8 - 11
ELECTRICAL SYSTEM
ATLANTIC 125 - 200
8.6. STARTER CIRCUIT

8.6.1. STARTER CIRCUIT
Key:
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
STARTER RELAY TEST

• Disconnect the two-way connector (1) (colored white).
• Extract the relay (2) from its retainers.
• Slide off the two rubber boots (3-4).

• Disconnect the cables from the relay terminals (2).
• Supply 12 V DC to the two inner terminals in the

connector (1) at the relay end.
• Check for continuity between the two contact screws of
the relay (2) using a multimeter set to the Ohm range.
Correct value with relay powered : 0 ohm

Correct reading when relay is not fed: ∞ ohm
• Replace the relay (2) if the readings obtained deviate

from those specified.
CHECKING THE STARTER MOTOR

• Remove the starter motor and power it directly from a
fully charged 12V battery.
• If the motor does not turn normally, check the brushes
for wear and the condition of the collector.
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
Dashboard indicator test

• Disconnect the water thermistor connector and connect
a resistance on the connector side.
• Turn the ignition key to ON and check the dashboard
indicator.
Resistances to be fitted to the connector
- resistance <75 Ω full scale reading
- resistance 105 Ω start of red zone ± 5°
- resistance <1000 Ω start of scale reading
8 - 15
ELECTRICAL SYSTEM
ATLANTIC 125 - 200
Coolant thermistor test

• Remove the thermistor (1), 5.4.1.
• Set a multimeter (2) to the Ohm range and attach the
multimeter leads to the thermistor (3) as shown in the
figure.
• Suspend the thermistor (1) in a container (3) filled with
coolant.
• Place a thermometer (4) with range 32 - 302°F (0 –150
°C) in the container.
• Place the container on a gas burner (5) and heat up
the coolant gradually.
• Check the temperature reading of the thermometer (4)
and the thermistor (1) output indicated by the
multimeter.
Thermistor output should vary with temperature as indicated
in the table below.
Temperature Resistance (Ω)
212 (°F) 100 (°C) 144
176 (°F) 80 (°C) 262
140 (°F) 60 (°C) 512
104 (°F) 40 (°C) 1090
IMPORTANT Change the thermistor (1) when meter reading
does not vary with temperature, or when the readings found
deviate too much from the values indicated in the table.
FUEL LEVEL
Dashboard indicator test

• Disconnect the sensor connector and connect a
resistance between the yellow/green and blue cables
on the connector side.
• Turn the ignition key to ON and check the dashboard
indicator.
Resistances to be fitted to the connector:
- resistance 10 ohm full tank indication
- resistance 38 ohm 1/2 scale ± -5°
- resistance 90 Ω empty tank with led on.
Fuel level sensor check

• Disconnect connector, 4.1.3.
• Connect an ohmmeter to the yellow/green and blue
cable sensor terminals. Check the readings at various
fuel levels.
- Correct value with full tank, less than 10 Ω
- Correct value with 8 liters: 38 Ω ± 10%
- Correct value with 0 liters: greater than 90 Ω
8 - 16
ELECTRICAL SYSTEM
ATLANTIC 125 - 200
Fuel reserve indicator test

• Disconnect connector, 4.1.3.
• Connect an ohmmeter to the orange/black and blue
cable sensor terminals.
• Check that there is continuity between the two
terminals when the fuel in the tank is below the 1.5 liter
level. In all other cases the resistance reading should
be infinite (open circuit).
Oil pressure sensor test

• Disconnect the sensor from the system, see engine
workshop manual 0.1.2.
• Check that there is no continuity towards earth when
the engine is running. Otherwise check the engine oil
level and replace the sensor.
8 - 17
ELECTRICAL SYSTEM
ATLANTIC 125 - 200
8.8. COOLING FAN AND HELMET

COMPARTMENT LIGHT
8.8.1. COOLING FAN AND HELMET COMPARTMENT
LIGHT SYSTEM
Key:
38. Main fuses
40. Battery
50. Thermistor
51. Fan
52. Helmet compartment light switch
53. Helmet compartment light
COOLING FAN SYSTEM TEST
Cooling fan check:

Check the cooling fan as follows:
• Disconnect the fan control connector (1).
• Power the fan directly, with the correct polarity, with 12
V DC. Check cooling fan operation as follows:
8 - 18
ELECTRICAL SYSTEM
ATLANTIC 125 - 200
Thermistor test
• Disconnect the two connectors.
• Release and remove the thermistor (2).
• Set a multimeter (3) to the Ohm range and attach the

multimeter leads to the thermistor (2) as shown in the
figure.
• Suspend the thermistor (2) in a container (4) filled with
coolant.
• Place a thermometer (5) with range 32 - 302°F (0 –150
°C) in the container.
• Place the container on a gas burner (6) and heat up
the coolant gradually.
• Check the temperature reading of the thermometer (4)
and the thermistor resistance reading.
• When the thermistor trip threshold is exceeded, in the
range 194 - 212°F (90 - 100 °C), the multimeter
reading should move from ∞ to 0 ohm.
HELMET COMPARTMENT LIGHT SWITCH TEST

• Raise the seat and check for continuity between the
two terminals using a multimeter set to the Ohm range.
With the switch released (seat open): reading = 0 ohm
With the switch depressed (seat closed): reading =
∞ ohm
8 - 19
ELECTRICAL SYSTEM
ATLANTIC 125 - 200
8.9. LIGHTS SYSTEM

8.9.1. LIGHTS SYSTEM
Key:
2. High beam warning light
4. Parking light indicator
5. Dashboard backlighting
15. Dashboard
18. Left-hand lights dip switch
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
8.10. VISUAL AND ACOUSTIC INDICATORS

8.10.1. VISUAL AND ACOUSTIC SIGNALING SYSTEM
Key:
7. Right direction indicator warning light
8. Left direction indicator warning light
15. Dashboard
19. Horn
20. Horn button
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
TROUBLESHOOTING THE DIRECTION INDICATORS

• Check that all bulbs are in perfect condition, 8.11.1.
• If a single bulb is burnt out, the rest flash at double the
normal frequency.
• Check the direction indicators switch.
• Inspect the CDI ECU and replace as required,
7.2.2.
The flasher is integrated into the CDI ECU.
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
8.11. BULB REPLACEMENT

8.11.1. BULB REPLACEMENT
Read carefully. 1.2.1., 1.7.1.
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.
• Place the motorcycle on the stand.

IMPORTANT Before changing a bulb, check the fuses,
8.12.1.
PARKING LIGHT BULB
To change the bulbs, proceed as follows:

WARNING
Proceed with care.
matching recesses.
• Working from the rear of the bulb socket, turn and

extract the entire socket.
• Extract the bulb from its seat.
IMPORTANT Insert the bulb in the bulb socket, making the

two bulb pins coincide with the relevant guides on the
socket.
• Correctly install a new bulb of the same type.
HIGH AND LOW BEAM BULBS

Open the glove compartment (1) and disengage the side
limit rods by pushing them gently downwards.
8 - 24
ELECTRICAL SYSTEM
ATLANTIC 125 - 200
• Grasp the bulb connector (2), pull it and disconnect it

from the bulb.
• Twist the bulb socket (3) counterclockwise and extract
it from the reflector mount.
• Remove the bulb.
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).
TAIL LIGHT BULBS
The tail light accommodates:

- two bulbs for parking / brake lights (4).
- Two bulbs for the rear direction indicators (5).
IMPORTANT The following information applies to both
indicators.
• Unscrew the two screws (6) and remove the lens (7).
WARNING
Proceed with care.
Do not damage the snap-on tangs and matching
recesses.
• Twist the bulb (4: parking/stop or 5: direction indicator)

counterclockwise and extract it.
IMPORTANT Upon reassembly, make sure to seat the lens
(7) securely.
WARNING
Proceed with care.
matching recesses.
• Tighten the screws (6) carefully, without exerting too

much pressure, in order to avoid damaging the lens
(7).
8 - 25
ELECTRICAL SYSTEM
ATLANTIC 125 - 200
FRONT DIRECTION INDICATOR BULBS

• Working from the front of the vehicle, twist the socket
(8) and bulb (9) assembly clockwise and remove it
from its mount.
• Press the bulb (9) slightly and rotate it anticlockwise.
• Extract the bulb from its seat.
IMPORTANT Insert the bulb in the bulb socket, making the
two bulb pins coincide with the relevant guides on the
socket.
NUMBER PLATE LIGHT BULB
• Grasp the bulb holder (10) and pull to extract.

• Extract and replace the bulb with another of the same
type.
DASHBOARD INDICATOR BULBS

• Twist the bulb socket clockwise and extract it.
• Extract the bayonet-fitting bulb from its mount and
replace it.
• Locate the bulb socket in its mount and twist it
clockwise to seat it.
REPLACING THE CLOCK BATTERY

• Rimuovere il cruscotto in modo da accedere alla parte
posteriore, 7.2.6.
• Remove the push-on cover.
• Replace the button cell
• Refit the push-on cover
8 - 26
ELECTRICAL SYSTEM
ATLANTIC 125 - 200
8.12. CHANGING THE FUSES

8.12.1. CHANGING THE FUSES
WARNING
Do not repair faulty fuses.
Never use fuses different from the
recommended ones.
This could damage the electrical system or
cause a short circuit, with the risk of fire.
IMPORTANT If a fuse blows frequently, there probably is a
short circuit or an overload in the electric system.
Checking the fuses is recommended whenever an electrical
component fails to operate or is malfunctioning, or when the
engine does not start.
Check the 3 A and 15 A fuses first and then the 30 A fuses.

• Turn the ignition switch to position " ", to avoid any
accidental short circuit.
For the main fuses:
• Run the first four operations described in 2.4.3.
For the secondary fuses:
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.
• Replace the damaged fuse with a new one having the

same amperage.
IMPORTANT If one of the spare fuses is used, replace it
with an identical one.
Secondary fuse layout (front fairing):
- 15A fuse (1)

From ignition switch to: lights, horn, stop lights
- 7.5A fuse (2)
From ignition switch to: ignition safety logic, automatic
starter.
- 7.5A fuse (3)
Spare.
- 15A fuse (4)
Spare.
Main fuse layout (battery compartment):
- 20A fuse (5)

From battery to: ignition switch, helmet compartment light.
- 15A fuse (6)
From battery to: power socket.
- 15A fuse (7)
Spare.
8 - 27
ELECTRICAL SYSTEM
ATLANTIC 125 - 200
8.13. ADJUSTING THE HEADLIGHT BEAM

8.13.1. ADJUSTING THE VERTICAL HEADLIGHT
BEAM 10 m
To quickly check the head lamp beam, position the vehicle
32.8 ft (10 m) from a vertical wall on level ground. Turn on
the low beam, sit on the vehicle and make sure that the
beam projected on the wall is slightly under the horizontal
line of the headlight (about 9/10th of the total height).
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.
• Use a screwdriver to adjust the lower adjuster screws

(2) on both lamps:
By SCREWING IT IN (clockwise), you set the beam

downwards.
By UNSCREWING IT (anti-clockwise), you set the beam
upwards.
8 - 28
ELECTRICAL SYSTEM
ATLANTIC 125 - 200
8.13.2. ADJUSTING THE HORIZONTAL HEADLIGHT

BEAM
To adjust the headlight beam:
• Open the glove compartment (1) and disengage the
side limit rods by pushing them gently downwards.
• Use a screwdriver to adjust the upper adjuster screws

(2) on both lamps:
SCREW IN clockwise to move the beam to the right (relative

to the direction of drive).
SCREW OUT counterclockwise to move the beam to the left
(relative to the direction of drive).
8 - 29
ELECTRICAL SYSTEM
ATLANTIC 125 - 200
8.14. SYSTEM CONFIGURATION

8.14.1. WIRING DIAGRAM
8 - 30
ELECTRICAL SYSTEM
ATLANTIC 125 - 200
Key: CABLE COLORS

1. Multiple connectors Ar orange
2. High beam warning light Az light blue
3. Fuel reserve indicator B blue
4. Parking light indicator Bi white
5. Dashboard backlighting G yellow
6. Check indicator (not assigned) Gr grey
7. Right direction indicator warning light M brown
8. Left direction indicator warning light N black
9. Oil pressure indicator R red
10. ABS indicator (not assigned) Ro pink
11. Side stand indicator V green
12. Anti-theft indicator (not assigned) Vi purple
13. Water temperature gauge
14. Fuel level
15. Dashboard
16. Water thermistor
17. Oil pressure sensor
18. Left light dip switch
19. Horn
20. Horn button
21. Keyswitch
22. Direction indicators switch
23. Starter button
24. -
25. Engine kill
26. Rear left direction indicator
28. -
30. Rear right direction indicator
31. -
32. Number plate light
33. Front brake light switch
34. Rear brake light switch
35. Stop light / starter permissive relay
36. Start relay
37. Starter motor
38. Main fuses
39. Socket
40. Battery
41. Secondary fuses
42. HT coil
43. Spark plug
44. Automatic starter
45. CDI ECU
47. Pick up
48. Generator
49. Rectifier
50. Thermistor
51. Fan
52. Helmet compartment light switch
53. Helmet compartment light
54. Front right direction indicator
55. High beam indicator
56. Low beam indicator
57. Parking light
58. Headlight assembly
59. Front left direction indicator
60. Fuel level sensor
61. Starter relay
8 - 31

Atlantic 125-200 USA

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Atlantic 125-200 USA

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INTRODUCTION

ATLANTIC 125 - 200

For more details see 0.1.2.

Produced and printed by:

0.1.2. REFERENCE MANUALS

SPECIAL TOOLS CATALOGS

USE AND MAINTENANCE MANUALS

CYCLE PARTS WORKSHOP MANUALS

0.1.3. ABBREVIATIONS / SYMBOLS / CONVENTIONS

1.1. STRUCTURE OF THE MANUAL

In this manual any variants are identified with these symbols:

Frame # ZD4MP......(STARTING FROM MODEL YEAR 2001)

1.1.2. SAFETY WARNINGS

1.2. GENERAL WARNINGS

DO NOT RELEASE FUEL INTO THE ENVIRONMENT.

KEEP AWAY FROM CHILDREN.

HOT COMPONENT PARTS

EXHAUSTED GEARBOX AND FORK OIL

DO NOT RELEASE OIL INTO THE ENVIRONMENT.

KEEP AWAY FROM CHILDREN.

KEEP AWAY FROM CHILDREN.

KEEP AWAY FROM CHILDREN.

HYDROGEN GAS AND BATTERY ELECTROLYTE

KEEP AWAY FROM CHILDREN.

Battery fluid is corrosive.

GENERAL PRECAUTIONS AND INFORMATION

BEFORE DISASSEMBLING ANY COMPONENTS

DISASSEMBLING THE COMPONENTS

REASSEMBLING THE COMPONENTS

1.3. HAZARDOUS SUBSTANCES

FRONT FORK OIL

(Recommended) brake fluid: see 1.8.1..

Freezing point F° (°C) Coolant % of volume

Observe the following instructions:

1.5. VEHICLE IDENTIFICATION

MANUFACTURER IDENTIFICATION PLATE

1.6. USING TOOLS AND SPARE PARTS

1.7.2. HOW TO APPLY THE DECALS

IMPORTANT: Soft spatulas – such as those commonly

If you are using a sponge, dab the decal surface lightly

• Rub the spatula (1) across the decal surface

IMPORTANT: Where decals come with application

IMPORTANT: Decals applied using water will take

The application tape serves to facilitate applying

1.8.2. PRODUCT APPLICATIONS

Lubricate - All ball bearings, sintered disks, gear sets, cylinder

Silastic 732 RTV / N. ROTAX 297386 - Idler indicator contact screw.

Screw or bolt Spanner Tightening torque

1.10. POSITION OF THE WARNING ADHESIVE

1.10.2. CALIFORNIA EVAPORATIVE EMISSION

2.1. PERIODIC MAINTENANCE

2.1.2. PERIODIC MAINTENANCE CHART

( ) = THESE OPERATIONS CAN BE CARRIED OUT BY THE OWNER

KEY TO THE LAYOUT OF LUBRICATION POINTS

FRONT AND REAR BRAKE

There are two types of batteries available in the market:

2.4.2. CHECKING AND CLEANING THE TERMINALS

• Make sure that the ignition switch is set to " ".

2.4.3. CHECKING THE ELECTROLYTE LEVEL

To check the electrolyte level:

• Top up with distilled water.

2.4.4. RECHARGING THE BATTERY

2.4.5. LONG INACTIVITY OF THE BATTERY