Aprilia Pegaso 650 1997-2000 Chassis & Engine Service Repair Manual

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This manual covers the Aprilia Pegaso 650, a dual-sport motorcycle produced for the model years 1997 through 2000. Known for its versatility, the Pegaso 650 features a robust Rotax 655...

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Typ: Motorcycle

Anbieter:

Art.-Nr: 117891

Stichworte: 1997 1998 1999 2000 655 Aprilia Engines Motorcycle Pegaso 650 Rotax

Produktvarianten

Beschreibung

This manual covers the Aprilia Pegaso 650, a dual-sport motorcycle produced for the model years 1997 through 2000. Known for its versatility, the Pegaso 650 features a robust Rotax 655 single-cylinder engine, liquid-cooled and displacing 652 cc. This Italian-manufactured motorcycle was designed to offer adventure-capable performance, competing with models like the BMW F650GS and Suzuki DR650 of the era. Its engineering quality and reliability are supported by genuine factory service data, providing owners and mechanics with comprehensive information for maintenance and repair. This comprehensive 460-page factory service repair manual, including a dedicated Rotax 655 engine repair manual, provides in-depth coverage for all aspects of the Aprilia Pegaso 650. It details engine systems, chassis components, and electrical systems with hundreds of photos illustrating disassembly and reassembly procedures. The manual includes routine maintenance tasks such as oil changes and chain adjustments, as well as more complex repair procedures like engine rebuilds and carburetor overhauls. Troubleshooting guides for common issues and detailed technical specifications, including torque values and special tool requirements, are also featured, making it an indispensable resource for owners and technicians.

🏷️ Basic Information

Identification

Make:

Aprilia

Model:

Pegaso 650

Years Covered:

1997, 1998, 1999, 2000

Codes

Engine Code Family:

Rotax 655

👋 Introduction

Market Position

Segment:

Dual-sport / Adventure Motorcycle

Target Audience:

Owners and mechanics seeking in-depth service information for the Aprilia Pegaso 650 from the late 1990s.

Competitive Analysis

Competitors:

BMW F650GS (funduro era), Suzuki DR650, Kawasaki KLR650, Honda Transalp.

Key Features

Manual Value:

Genuine factory service data for accurate maintenance and repairs, covering both chassis and the specific Rotax 655 engine.

Visual Aid Quality:

Hundreds of photos demonstrating complete disassembly and reassembly procedures.

📋 Manual Details

Coverage Areas

Manual Type:

Factory Service Repair Manual & Engine Rotax 655 Repair Manual

Page Count

Total Pages:

Chassis Engine Pages:

Engine Rotax Pages:

Language

Language:

English

Format

File Type:

PDF (Zip Archive)

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine disassembly and reassembly, lubrication system, cooling system, fuel system (carburetor, fuel pump, fuel tank), ignition system, exhaust system, engine management (if applicable), internal engine components (pistons, rings, crankshaft, camshafts, valves).

Chassis Systems:

Frame, suspension (front forks, rear shock absorber), steering system, braking system (front and rear brakes, hydraulic lines), wheels and tires, electrical system (wiring diagrams, battery, lighting, ignition, starter, charging system), drive chain and sprockets.

Procedures Included

Maintenance Procedures:

Oil changes, filter replacements, chain lubrication and adjustment, spark plug replacement, air filter cleaning/replacement, brake fluid flush, coolant flush, valve clearance adjustment.

Repair Procedures:

Engine top-end rebuild, engine bottom-end rebuild, carburetor overhaul, fork seal replacement, shock absorber service, brake caliper overhaul, electrical component diagnosis and repair, clutch replacement, starter motor service.

Troubleshooting:

Diagnostic guides for common engine and electrical issues, performance problems, starting difficulties, and braking concerns.

Technical Depth

Depth Of Coverage:

Comprehensive factory-level detail suitable for professional mechanics and experienced DIY enthusiasts. Includes torque specifications, special tool requirements, and detailed diagrams.

📊 Manual Specifications

File Format

Print Quality:

High Quality

Printability:

Fully Printable

Binding Type

Binding Type:

Digital PDF (Zip)

Paper Type

Paper Type:

N/A (Digital)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Single-cylinder, four-stroke

Engine Displacement:

652 cc

Engine Manufacturer:

Rotax

Engine Code:

Rotax 655

Bore X Stroke:

100 mm x 83 mm (approx.)

Compression Ratio:

9.5:1 (typical)

Performance

Horsepower Output:

Approx. 48 HP @ 6500 RPM (varies by specific model/market)

Torque Output:

Approx. 5.8 kgf·m (57 Nm) @ 5000 RPM (varies by specific model/market)

Fuel System

Fuel Delivery:

Carburetor (e.g., Mikuni BST40 twin-choke)

Fuel Type:

Unleaded gasoline

Cooling System

Cooling Method:

Liquid-cooled

🔧 Transmission

Standard

Transmission Type:

5-speed manual

Clutch Type:

Wet, multi-plate

Features

Final Drive:

Chain drive

📐 Dimensions

Exterior

Length:

Approx. 2200 mm (varies slightly)

Width:

Approx. 850 mm (at handlebars)

Height:

Approx. 1300 mm (to top of screen)

Weights

Dry Weight:

Approx. 180 kg

Wet Weight:

Approx. 195 kg (fully fueled)

Fuel Tank Capacity:

22 Liters

🛡️ Safety Features

Ratings

Safety Standards:

Manufacturer specific, adherence to relevant European/international motorcycle safety standards of the era.

Active Features

Braking System:

Hydraulic disc brakes, front and rear. Specific caliper configurations and disc sizes are detailed in the manual.

Lighting:

Headlight, taillight, brake lights, turn signals. Wiring and bulb specifications covered.

Passive Features

Frame Construction:

Steel trellis frame designed for durability and rigidity.

💡 Technology Features

Infotainment

Infotainment System:

Not applicable for this model; basic analog instrumentation.

Driver Assistance

Driver Assistance Features:

Connectivity

Connectivity Features:

Electrical System

Charging System:

Alternator, rectifier/regulator. Detailed diagrams for diagnosis and repair are present in the manual.

Ignition System:

Electronic ignition (CDI or similar). Manual provides specifications for spark plugs and ignition timing.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Refer to manual for specific mileage/time recommendations (typically 5,000-7,500 km or annually).

Valve Clearance Check:

Refer to manual for specific mileage/time recommendations (typically 10,000-15,000 km).

Chain Adjustment Interval:

Regular checks recommended, typically every 1,000-2,000 km or as needed based on slack.

Fluid Specifications

Engine Oil Type:

API SG/SH/SJ, JASO MA compliant motorcycle oil, SAE 10W-40 or 15W-50 (refer to manual for exact specifications and seasonal recommendations).

Engine Oil Capacity:

Approx. 2.4 Liters (with filter change).

Coolant Type:

Ethylene glycol-based antifreeze, mixed with distilled water (typically 50/50 ratio). Refer to manual for specific formulation.

Brake Fluid Type:

DOT 4 hydraulic brake fluid.

Known Issues

Common Wear Items:

Fork seals, steering head bearings, wheel bearings, voltage regulator (can be a point of failure on older bikes), carburetor diaphragms.

Engine Reliability:

The Rotax 655 is generally considered a robust engine, but proper maintenance is crucial. Early models might have had minor electrical gremlins or wear on specific components.

📚 Vehicle History

Brand Heritage

Brand Origin:

Aprilia is an Italian manufacturer known for its performance motorcycles, particularly in the off-road and sportbike segments.

Model Evolution

Pegaso Lineage:

The Pegaso line aimed to offer versatile, adventure-capable motorcycles. The 650cc models utilized the robust Rotax engine, sharing lineage with other manufacturers.

Production

Manufacturing Location:

Italy

Production Period:

The 650cc Pegaso was produced through various iterations from the early 1990s into the early 2000s.

🏆 Awards & Recognition

Recognitions

Motorcycle Awards:

No widely publicized specific awards for this particular model year, but the Pegaso line was generally well-regarded for its versatility and value in the adventure segment.