Aggrevating!!

[gabb]

So i am trying to get the plastic off the handlebars on the aa500. To do this i have to take off the front legsheild so i can get to the screw that holds the cover on the airbag.

After i take out the screws in legsheild (3 on bottom each side, 1 phillips midway up, 3 in glove box and 2 under each speaker grille, I still cant get the legsheild to even budge.! Managed to break several of the plastic slots in the process! Absolutely asinine assembly techniques.


So what else could be holding this thing on?
Also, i cant figure out how to get the ignition key fat grommet with all the graphics to come off. Can anyone offer any pointers?
This is soooooooooooo damn frustrating!!!!!!!!!!!!!!!!!!!!

[morsmith]

To remove the ignition key fat grommet you twist it anticklockwise. You have to push and twist. I have removed the legshield several times and it workes fine for me if I follow the Workshop Manual sequence, i.e. start bending it up with a flat iron where it is shown on the picture (I assume that you have access to the WM).

[gabb]

thanks! Key grommet came off no problem!

However, i never did get the knee sheild off. seems to be held somehow at the base around the glove box arms. Do they need to be disconnected or something?

Anyway, i got the shield out enough to get to the screw that holds the airbag cover on. Was able to remove it and get the plastics off the bars.

Sure enough, the handlebars have a big rip in the steel where they connect to the shaft. unlike most bars i have dealt with, these are not held on by any visible triple clamp setup.

The bars simply tighten down like a hose clamp, onto a shaft that disappears into the frame. Removal should pretty straight ahead.

Called and ordered a set of bars.
According to my dealer, (which is the largest Aprilia dealership in the US) :

$149
not in stock down in Georgia (aprilia usa)
shipment on way from Italy
could easily be a month away

Bummer, I'll keep ya posted!

gabb

[Richard fssnoc#]

gabb - My dealer, Salina powersports has a wrecked A500 (maroon '03") in their shop that has been there for ages. The owner hit a car that pulled out in front of him as I understand. They tell me it is now technically owned by the insurance company. This is just a thought for you guys out there that may need a part here or there .... you might call them and ask about buying whatever .......it doesn't appear that they have any plans to rebuild it. Seems a shame to have those parts available when someone may be in great need of them. Forks, fairing and bodywork seem to be all that is injured. Don't recall the bars being damaged the last time I saw it. Just a thought.

[gabb]

Thanks Richard. I will check with them tomorrow.

I did just order, but if i find that Salina Powersports is willing to deal, i can check with Scuderia and see if they would let me un-order the order i just placed. You're right, they could help a lot of people out, and make some good money. I'll post what i find out.

Thanks for the tip

[sanatanadharma]

Gabb, you need to remove the tunnel. It tabs into, under, the legshield, there are more breakable tabs there. Tunnel has total six screws, two at front under legshield lowers. If this isn't it, something is caught that shouldnot be.

So i am trying to get the plastic off the handlebars on the aa500. To do this i have to take off the front legsheild so i can get to the screw that holds the cover on the airbag.

[This legshield is like the keystone part for popping off the plastic.]

After i take out the screws in legsheild (3 on bottom each side,

[two allen head under floormat, one philips at inside lowest point, each side]

1 phillips midway up,

[??????????????????????????]

3 in glove box

[one allen head (two in center don't count), two philips]

and 2 under each speaker grille,
I still cant get the legsheild to even budge.! Managed to break several of the plastic slots in the process! Absolutely asinine assembly techniques.

[SUGGESTION use a spray bottle (preferably in stream mode) of soapy water to get the tabs and slots slippey wet]

So what else could be holding this thing on?

[We haven't yet mentioned the 12-volt power plug wiring]

Also, i cant figure out how to get the ignition key fat grommet with all the graphics to come off. Can anyone offer any pointers?
This is soooooooooooo damn frustrating!

[The grommet is no longer an issue. But don't get me started on the weak front suspension/ steering]

[gabb]

thanks for the reply.


In the manual it shows the knee sheild removed but the tunnel still in place. Maybe that was just for photo reasons, but i took it to mean that the tunnel could stay on while the sheild was removed? no?

either way, i managed to get where i needed to be, and am now waiting on handlebars. Love the soapy water idea, and will use it in the future!

I will try to get a picture of the ripped steel on my handlebars soon.

I am hoping that there will be enough slack in the brake lines that i will not have to disconnect them. I am hoping i can just slide the entire grip/brake mechanism off and slide onto new bars,but i knowthis is probly a dream!