APRILIA PEGASO 650 Service Repair Manual 1997-2001

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Art.-Nr: 137207

Stichworte: 1997 1998 1999 2000 2001 Aprilia Misc Motorcycle Motorcycles PEGASO 650

Produktvarianten

Beschreibung

The Aprilia Pegaso 650, produced from 1997 to 2001, is a versatile dual-sport motorcycle known for its torquey Rotax-designed single-cylinder engine and comfortable, upright riding position. This first-generation model, spanning chassis codes AP02, AP06, and AP07, was engineered to offer capable performance on various terrains, making it a popular choice for riders seeking adventure and everyday usability. Its long-travel suspension and robust construction contribute to its reliability and suitability for both on-road commuting and light off-road excursions, positioning it as a practical and enjoyable machine in its segment. This workshop service repair manual provides comprehensive guidance for the Aprilia Pegaso 650, covering model years 1997 through 2001. It details essential maintenance procedures, including oil changes, filter replacements, and chain adjustments, alongside in-depth troubleshooting steps for common and complex issues across all major systems. The manual also includes rebuild procedures, component replacement instructions, and precise technical specifications such as torque values and fluid capacities. With over 300 pages of information, this English-language resource is designed to empower owners and technicians to effectively maintain, diagnose, and repair the vehicle, ensuring its optimal performance and longevity.

🏷️ Basic Information

Identification

Make:

Aprilia

Model:

Pegaso 650

Product Name:

APRILIA PEGASO 650 Service Repair Manual 1997-2001

Generation

Model Generation:

First Generation (AP02/AP06/AP07)

Codes

Chassis Codes:

AP02, AP06, AP07

👋 Introduction

Market Position

Segment:

Dual-sport / Adventure motorcycle

Target Audience:

Riders seeking versatile on-road and light off-road capability, DIY mechanics, and restoration enthusiasts.

Competitive Analysis

Key Competitors:

BMW F650 Funduro, Yamaha XT660, Honda Transalp, Suzuki DR650.

Key Features

Vehicle Highlight:

Torquey Rotax-designed single-cylinder engine, long-travel suspension, comfortable riding position, capable on various terrains.

Manual Value Proposition:

Empowers owners to perform essential maintenance and repairs, significantly reducing reliance on costly dealership services.

📋 Manual Details

Coverage Areas

Years Covered:

1997, 1998, 1999, 2000, 2001

Page Count

Estimated Page Count:

Manual Type

Manual Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

Digital Download (PDF)

📖 Manual Coverage

Systems Covered

Engine:

Engine disassembly, assembly, tuning, diagnostics, lubrication system, cooling system, fuel system (carburetor/injection), ignition system, exhaust system.

Transmission:

Gearbox operation, clutch assembly, gear shift mechanism, lubrication, troubleshooting.

Chassis And Suspension:

Frame, front fork (telescopic, upside-down variants), rear shock absorber, swingarm, wheel bearings, steering system.

Brakes:

Hydraulic system, brake discs, calipers, master cylinders, brake fluid, bleeding procedures, maintenance.

Electrical System:

Wiring diagrams, battery, starter motor, alternator, lighting system, ignition switch, fuses, relays, instrumentation, diagnostic codes (if applicable).

Bodywork And Trim:

Fairings, body panels, seat, fuel tank, fenders, indicators, mirrors, removal and installation procedures.

Procedures Included

Maintenance:

Regular servicing, oil changes, filter replacements, chain adjustment, spark plug checks, brake pad replacement, coolant checks, tire pressure.

Troubleshooting:

Step-by-step diagnostic guides for common and uncommon problems across all major systems.

Rebuild Procedures:

Detailed instructions for complete engine rebuilds, gearbox overhauls, and suspension component refurbishment.

Component Replacement:

Guidance on replacing specific parts such as bearings, seals, cables, and electrical components.

Technical Depth

Depth Of Coverage:

Comprehensive, covering everything from basic rider maintenance to full workshop-level repairs and diagnostics.

Diagnostic Capabilities:

Includes diagnostic procedures, fault finding charts, and identification of common failure points.

Specifications Detail:

Provides precise technical data, torque values, clearances, fluid types, and capacities.

📊 Manual Specifications

File Format

File Format:

Portable Document Format (PDF)

Searchability:

Text-searchable PDF for quick information retrieval.

Print Quality

Print Quality:

High-resolution scans ensuring clarity of diagrams and text.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Single-cylinder, four-stroke

Engine Manufacturer:

Rotax (BMW Group)

Displacement:

652 cc (approx.)

Bore X Stroke:

100 mm x 83 mm (approx.)

Compression Ratio:

10.0:1 (approx.)

Valve Train:

DOHC, 4 valves per cylinder

Performance

Horsepower:

Approx. 48-50 hp @ 6500 rpm

Torque:

Approx. 57-60 Nm @ 5000 rpm

Fuel System

Fuel Delivery:

Carburetor (Mikuni BSR36/42) or Fuel Injection (depending on specific sub-model/market)

Fuel Type:

Unleaded gasoline (91+ RON recommended)

🔧 Transmission

Standard

Transmission Type:

5-speed manual sequential

Optional

Optional Transmission:

Features

Clutch Type:

Wet multi-plate, cable operated

Final Drive:

O-ring sealed chain

📐 Dimensions

Exterior

Length:

Approx. 2230 mm (varies slightly by sub-model)

Width:

Approx. 860 mm (at handlebars, varies)

Height:

Approx. 1400 mm (at windshield, varies)

Wheelbase:

Approx. 1560 mm

Weights

Dry Weight:

Approx. 168 kg

Wet Weight:

Approx. 185 kg (fully fueled)

Gross Vehicle Weight Rating:

Approx. 380 kg

Cargo

Fuel Tank Capacity:

17 Liters (approx. 4.5 US gallons)

🛡️ Safety Features

Ratings

Safety Ratings:

N/A (Motorcycle safety is typically assessed differently than cars)

Active Features

Braking System:

Front: Single Disc (e.g., 300mm) with 2-piston caliper. Rear: Single Disc (e.g., 220mm) with 1 or 2-piston caliper. Optional ABS available on some models.

Passive Features

Lighting:

Halogen headlight, LED tail light/brake light, incandescent turn signals.

Ergonomics:

Upright riding position, handguards for protection from elements.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic instrumentation: speedometer, tachometer, odometer, fuel gauge, warning lights).

Driver Assistance

ABS Availability:

Optional ABS system on some later models within this range.

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 6,000 km or 6 months (whichever comes first). Manual specifies precise intervals.

Air Filter Cleaning Interval:

Every 6,000 km (or more frequently in dusty conditions).

Spark Plug Replacement Interval:

Every 12,000 km (approx., check manual for specific plug type and gap).

Chain Lubrication Adjustment Interval:

Every 1,000 km and after washing/rain.

Fluid Specifications

Engine Oil Type:

API SG or higher, SAE 10W-40 or 15W-50 (consult manual for precise ambient temperature recommendations).

Engine Oil Capacity:

Approx. 2.0 - 2.4 Liters (with filter change, check dipstick).

Coolant Type:

Ethylene glycol based coolant, 50% mixture with distilled water.

Brake Fluid Type:

DOT 4 hydraulic brake fluid.

Fork Oil Type:

SAE 10W or 15W (consult manual for specific fork model and capacity).

Known Issues

Common Wear Items:

Clutch plates, wheel bearings, fork seals, regulator/rectifier, chain and sprockets.

Potential Electrical Gremlins:

Wiring harness chafing, intermittent electrical connections, especially around the stator and regulator/rectifier.

Carburetor Tuning Challenges:

Carburetors can require periodic cleaning and adjustment, particularly if the motorcycle has been sitting.

📚 Vehicle History

Brand Heritage

Brand Origin:

Aprilia is an Italian manufacturer with a strong racing heritage, particularly in smaller displacement categories.

Model Evolution

Pegaso Lineage:

The Pegaso 650 was Aprilia's entry into the popular mid-weight dual-sport segment, utilizing the well-regarded Rotax engine.

Key Upgrades 1997-2001:

Introduction of fuel injection on some models (e.g., Pegaso i.e.), minor styling updates, suspension refinements.

Production

Production Period:

1992 - 2004 (First Generation)

Manufacturing Location:

Italy

🏆 Awards & Recognition

Recognitions

Motorcycle Reviews:

Generally well-received for its versatility, comfortable ergonomics, and robust Rotax engine, praised for its adventure capabilities.