Aprilia Pegaso 650 1992 Workshop Service Manual for Repair

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Stichworte: 1992 Aprilia Misc Motorcycle Motorcycles Pegaso 650

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Beschreibung

The Aprilia Pegaso 650, first introduced in 1990, is a versatile dual-sport motorcycle designed for riders seeking a capable machine for commuting, touring, and light off-road excursions. This first-generation model, produced until 1996, features a robust Rotax 4-stroke single-cylinder engine, telescopic front forks, and a monoshock rear suspension, complemented by disc brakes front and rear. Known for its agile handling and distinctive styling, the Pegaso 650 offered a compelling package that competed effectively in its segment. This workshop service manual provides comprehensive guidance for the repair and maintenance of the Aprilia Pegaso 650. It covers essential systems including the engine, fuel, ignition, transmission, chassis, brakes, and electrical components. Detailed procedures for scheduled maintenance, component overhaul, and troubleshooting common issues are included, along with vital technical specifications, torque values, and clearances. This manual is an indispensable resource for owners, mechanics, and technicians to ensure the optimal performance and longevity of their vehicle.

🏷️ Basic Information

Identification

Make:

Aprilia

Model:

Pegaso 650

Year:

Generation

First Generation Start Year:

Generation Identifier:

First Generation (1990-1996)

Codes

Chassis Code Prefix:

👋 Introduction

Market Position

Segment:

Dual-sport / Adventure Motorcycle

Target Audience:

Riders seeking a versatile motorcycle for commuting, touring, and light off-road use.

Competitive Analysis

Key Competitors 1992:

Honda Transalp 600, Yamaha Ténéré 660, BMW F650 Funduro (launched slightly later but relevant).

Aprilia Pegaso 650 Advantages:

Agile handling, distinctive styling, often more affordable than European competitors, strong Rotax engine heritage.

Key Features

Engine Platform:

Rotax 4-stroke single-cylinder engine.

Suspension Type:

Telescopic front forks, monoshock rear suspension.

Braking System:

Disc brakes front and rear.

📋 Manual Details

Coverage Areas

Primary Regions Of Operation:

Europe (primarily Italy, UK, Germany, France), North America, Asia

Page Count

Total Pages:

Manual Type

Type:

Workshop Service Manual

Purpose:

Repair and Maintenance

Language

Language:

English

Format

Digital Format:

📖 Manual Coverage

Systems Covered

Engine:

Included: Engine overhaul, cylinder head, piston, crankshaft, connecting rods, valve train, cooling system, lubrication system.

Fuel System:

Included: Carburetor (Mikuni BSR32/34), fuel pump, fuel lines, fuel tank, fuel filter replacement.

Ignition System:

Included: Ignition timing, spark plugs, CDI unit, coils.

Transmission:

Included: Gearbox operation, clutch operation, clutch cable adjustment, gearbox oil change.

Chassis And Frame:

Included: Frame inspection, steering head bearings, swingarm, rear shock absorber, front forks (Marzocchi M1 41mm or Paioli).

Brakes:

Included: Front disc brake system (Brembo or Grimeca), rear disc brake system, brake fluid replacement, caliper service, pad replacement.

Electrical System:

Included: Wiring diagrams, lighting, horn, starter motor, battery, alternator, fuses, relays.

Bodywork And Trim:

Included: Fairing removal and installation, seat, tank cover, fenders, graphics.

Procedures Included

Scheduled Maintenance:

Included: Oil changes, filter replacements, chain adjustment, spark plug replacement, air filter cleaning/replacement, brake fluid flush.

Troubleshooting:

Included: Diagnosis of common problems, diagnostic charts, symptom-based troubleshooting.

Repair Procedures:

Included: Detailed step-by-step instructions for engine, transmission, suspension, brake, and electrical system repairs.

Component Overhaul:

Included: Engine rebuild, carburetor tuning and rebuilding, fork seal replacement.

Diagnostics:

Included: Basic electrical diagnostics, carburetor performance checks.

Technical Depth

Depth Of Coverage:

Comprehensive workshop level, suitable for independent mechanics and experienced DIY enthusiasts.

Diagnostic Charts:

Included for common issues and system malfunctions.

Torque Specifications:

Included for critical fasteners across all systems.

Clearances And Tolerances:

Included for engine components and critical assemblies.

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable if scanned professionally, but not guaranteed without explicit mention.

Print Quality

Print Readability:

Assumed high quality for digital reproduction, facilitating printing.

Binding Type

Binding Original Manual:

Stapled or perfect bound (typical for OEM manuals)

Binding Digital Version:

N/A (digital file)

Paper Type

Paper Type Original Manual:

Standard paper stock, often with glossy pages for diagrams.

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, liquid-cooled, single-cylinder, DOHC

Displacement:

652 cc

Bore X Stroke:

100 mm x 83 mm

Compression Ratio:

9.5:1

Engine Code:

Rotax 654F

Performance

Horsepower Approx:

48 hp @ 6,250 rpm

Torque Approx:

57 Nm @ 4,750 rpm

Fuel System

Carburetor Model:

Mikuni BSR32 (early models) or BSR34 (later models), dual throttle valves

Fuel Type:

Unleaded gasoline

Fuel Capacity:

20 Liters (approx. 5.3 US gallons)

🔧 Transmission

Standard

Gearbox Type:

5-speed manual

Clutch Type:

Wet multi-plate, cable-actuated

Optional

Transmission Options:

Features

Final Drive:

O-ring sealed chain

📐 Dimensions

Exterior

Length Approx:

2210 mm (87 in)

Width Approx:

870 mm (34.25 in)

Height Approx:

1360 mm (53.5 in)

Wheelbase Approx:

1480 mm (58.25 in)

Weights

Dry Weight Approx:

160 kg (353 lbs)

Wet Weight Approx:

182 kg (401 lbs)

Max Load Capacity:

N/A (typically 180-200kg for rider and luggage)

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (Motorcycle industry standards differ from automobiles)

Active Features

Braking System Type:

Hydraulic disc front and rear

Optional ABS:

Not commonly available on this specific model year.

Passive Features

Lighting System:

Halogen headlight, LED tail light (standard on many models)

💡 Technology Features

Infotainment

Infotainment System:

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

Driver Assistance

Rider Aids:

None (ABS was not standard or common on this model).

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 - 6,000 km (3,000 - 3,700 miles) or annually.

Air Filter Cleaning:

Every 6,000 km (3,700 miles).

Spark Plug Replacement:

Every 10,000 - 12,000 km (6,200 - 7,500 miles).

Brake Fluid Flush:

Every 2 years or as per manual.

Valve Clearance Check:

Every 12,000 - 15,000 km (7,500 - 9,300 miles).

Fluid Specifications

Engine Oil Type:

SAE 10W-40 or 15W-50 motorcycle-specific, API SG/SH or JASO MA rated.

Engine Oil Capacity:

Approx. 2.2 Liters (with filter change).

Coolant Type:

Ethylene glycol-based antifreeze mixture with distilled water (50/50).

Brake Fluid Type:

DOT 4.

Gearbox Oil Type:

SAE 75W-90 or 80W-90 GL-4 motorcycle gear oil.

Known Issues

Common Wear Items:

Clutch plates, chain and sprockets, fork seals, rear shock absorber (especially on higher mileage bikes).

Carburetor Issues:

Can be prone to clogging if fuel is left sitting, especially the pilot circuit.

Electrical Gremlins:

Older wiring can degrade; check connections, especially for the starter circuit and ignition.

Fuel Tap Issues:

Vacuum-operated fuel tap diaphragm can fail.

📚 Vehicle History

Brand Heritage

Aprilia Origin:

Italian manufacturer, founded in 1945, known for racing heritage and innovative motorcycles.

Model Evolution

Pegaso Line Introduction:

The Pegaso line was Aprilia's entry into the popular dual-sport market.

Pegaso 650 Significance:

The Pegaso 650 was a key model for Aprilia, utilizing the reliable Rotax engine and establishing the brand's presence in the adventure touring segment.

Production

Manufacturing Location:

Italy

Production Years First Gen:

1990-1996

🏆 Awards & Recognition

Recognitions

Motorcycle Awards:

No specific widely publicized awards for this model year, but generally praised for its versatility and performance relative to its price point.