1997 APRILIA PEGASO 650 Service Repair Manual MULTI-LANGUAGE

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Art.-Nr: 123739

Stichworte: 1997 Aprilia Misc Motorcycle Motorcycles PEGASO 650

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Beschreibung

The Aprilia Pegaso 650, produced in 1997, is a versatile dual-sport motorcycle known for its Rotax engine, comfortable ergonomics, and adaptability for both on-road and light off-road excursions. This Italian-engineered machine offers a balance of performance and practicality, making it a capable companion for a variety of riding conditions. Its design emphasizes a reliable and torquey single-cylinder engine, providing a solid foundation for owners seeking adventure and everyday utility. This factory service repair manual provides comprehensive guidance for the mechanical repair and maintenance of the Aprilia Pegaso 650. Covering essential systems such as the engine, fuel system, clutch, cooling system, exhaust, electrical components, and chassis, this manual offers detailed procedures for routine service, component overhauls, and troubleshooting. With an estimated 300-400 pages of information available in English, Italian, and Spanish, it serves as an invaluable resource for owners and technicians alike to ensure the continued optimal performance and longevity of their vehicle.

🏷️ Basic Information

Identification

Make:

Aprilia

Model:

Pegaso 650

Year:

👋 Introduction

Market Position

Category:

Dual-Sport / Adventure Motorcycle

Target Audience:

Owners and independent mechanics seeking in-depth maintenance and repair guidance.

Competitive Analysis

Competitors 1997:

BMW F650GS, Kawasaki KLR650, Suzuki DR650SE, Yamaha XT600E.

Key Features

Aprilia Pegaso Identity:

Known for its Rotax engine, comfortable ergonomics, and versatility for both on-road and light off-road use.

📋 Manual Details

Coverage Areas

Primary Coverage:

Mechanical Repair and Maintenance

Secondary Coverage:

Engine, Fuel System, Electrical System, Chassis

Page Count

Estimated Page Count:

300-400

Manual Type

Type:

Factory Service Repair Manual

Language

Languages Included:

English, Italian, Spanish

Format

Format:

Digital (likely PDF)

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine disassembly, assembly, component checks, timing, lubrication, cooling.

Fuel System:

Carburetor tuning and overhaul, fuel pump, fuel lines, fuel tank.

Clutch:

Clutch inspection, adjustment, replacement, hydraulic system.

Radiator:

Cooling system, radiator inspection, leak testing, coolant replacement.

Exhaust System:

Exhaust pipe inspection, muffler, exhaust manifold.

Engine Electrics:

Ignition system, starter motor, alternator, wiring diagrams, sensor testing.

Chassis Systems:

Suspension (front and rear), steering system, braking system (front and rear), wheels and tires.

Procedures Included

Maintenance Procedures:

Regular service intervals, oil changes, filter replacements, chain adjustment, spark plug replacement, valve clearance adjustment.

Repair Procedures:

Step-by-step instructions for component removal, installation, and overhaul.

Troubleshooting:

Diagnostic flowcharts and common issue identification for various systems.

Technical Depth

Depth:

Comprehensive, covering routine maintenance to major component overhauls and electrical diagnostics.

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format)

Searchability:

Likely text-searchable, allowing for quick information retrieval.

Print Quality

Print Readability:

High, suitable for printing individual pages or the entire document.

Binding Type

Binding:

N/A (Digital)

Paper Type

Paper Quality:

N/A (Digital)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, Single Cylinder, Liquid-Cooled

Engine Displacement:

652 cc

Engine Bore X Stroke:

100 mm x 83.6 mm

Engine Compression Ratio:

9.8:1 (Typical)

Engine Valve Train:

SOHC, 4 valves per cylinder

Performance

Horsepower Estimated:

48-50 HP @ 6250 RPM

Torque Estimated:

60-62 Nm @ 5000 RPM

Fuel System

Fuel Delivery:

Carburetor (e.g., Dell'Orto PHM 40)

Fuel Type:

Unleaded gasoline (min 95 RON)

Fuel Tank Capacity:

17 Liters (approx.)

Lubrication

Oil Type:

SAE 10W-40 or 15W-50, API SG/SH or higher (JASO MA)

Oil Capacity:

2.2 Liters (with filter change)

🔧 Transmission

Standard

Transmission Type:

5-speed manual

Clutch Type:

Wet, multi-plate, cable-actuated

Final Drive:

O-ring sealed chain

Features

Gear Ratios:

Specific ratios provided in manual.

Transmission Oil Type:

SAE 80W-90 API GL-4

Transmission Oil Capacity:

0.9 Liters (approx.)

📐 Dimensions

Exterior

Length Overall:

2180 mm (approx.)

Width Overall:

840 mm (approx.)

Height Overall:

1260 mm (approx.)

Wheelbase:

1470 mm (approx.)

Seat Height:

870 mm (approx.)

Weights

Dry Weight:

186 kg (approx.)

Gross Vehicle Weight Rating:

Not specified, consult manual for limits.

Suspension

Front Suspension:

Telescopic fork, 41mm diameter, 170mm travel

Rear Suspension:

Monoshock with adjustable preload, 175mm travel

Wheels Tires

Front Tire Size:

90/90-21

Rear Tire Size:

130/80-17

Front Brake:

Single 300mm disc with 2-piston caliper

Rear Brake:

Single 220mm disc with 1-piston caliper

🛡️ Safety Features

Ratings

Safety Certifications:

CE, EPA (depending on market)

Active Features

Braking System:

Disc brakes front and rear, ABS not standard on this model year.

Passive Features

Lighting:

Halogen headlight, LED tail light

💡 Technology Features

Infotainment

Instrument Cluster:

Analog speedometer, tachometer, odometer, trip meter, engine temperature warning light, oil pressure warning light, neutral indicator.

Driver Assistance

ABS was not a standard feature on the 1997 model.

Connectivity

Connectivity Features:

None (analog systems)

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 km or 6 months

Air Filter Cleaning:

Every 5,000 km

Valve Clearance Check:

Every 10,000 km

Spark Plug Replacement:

Every 10,000 km

Fluid Specifications

Coolant Type:

Ethylene glycol-based antifreeze, 50% mix with distilled water

Brake Fluid Type:

DOT 4

Known Issues

Common Wear Items:

Clutch plates, fork seals, carburetor diaphragms, swingarm bearings.

Electrical Gremlins:

Occasional issues with rectifier, stator, or voltage regulator, especially on higher mileage units. Wiring connections can corrode.

Engine Performance Notes:

Carburetor synchronization is critical for smooth running. Check for vacuum leaks.

Torque Settings

Engine Mount Bolts:

Specific torque values for critical engine fasteners are detailed in the manual.

Wheel Axle Nuts:

Specific torque values for front and rear axle nuts are provided.

📚 Vehicle History

Brand Heritage

Aprilia Origins:

Italian manufacturer with a strong racing pedigree, transitioning into street bikes.

Model Evolution

Pegaso Lineage:

The Pegaso series aimed to combine off-road capability with on-road comfort and performance.

Engine Source:

Utilized the Austrian Rotax 654 engine, known for its reliability and torquey nature.

Production

Production Years First Gen:

1990-1997

Manufacturing Location:

Italy

🏆 Awards & Recognition

Recognitions

Motorcycle Reviews 1997:

Generally well-received for its practicality and comfort, often praised for its Rotax engine.

Ratings

Reliability Perception:

Considered reliable with proper maintenance, particularly the engine. Common issues are generally repairable.