Aprilia Pegaso 650 1997 1998 1999 Workshop Service Repair Manual

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Art.-Nr: 156881

Stichworte: 1997 1998 1999 Aprilia Misc Motorcycle Motorcycles Pegaso 650

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Beschreibung

The Aprilia Pegaso 650, produced from 1997 to 1999, is a versatile adventure touring and dual-sport motorcycle known for its capable single-cylinder, liquid-cooled 652 cc engine. This model, chassis code RD06, offers a balanced performance suitable for both daily commuting and light off-road exploration. An Italian manufacturer with a rich racing heritage, engineered the Pegaso 650 to provide reliability and adaptable performance, making it a strong competitor in its segment against models like the BMW F650 Funduro and Kawasaki KLR650. Its design emphasizes practical utility and a comfortable riding experience, empowering owners to tackle a variety of riding conditions. This comprehensive workshop service repair manual, written in English, provides detailed guidance for the mechanical service and repair of the Aprilia Pegaso 650. Covering over 300 pages, it offers step-by-step instructions for a wide range of procedures, including complete engine overhauls, fuel and ignition system servicing, transmission and drivetrain maintenance, brake system repairs, suspension adjustments, and electrical system diagnostics. It also includes scheduled maintenance procedures, troubleshooting guides for common issues, and essential technical specifications such as torque values and fluid capacities. This manual is an indispensable resource for owners, mechanics, and technicians aiming to maintain, troubleshoot, and repair their Pegaso 650 effectively and accurately.

🏷️ Basic Information

Identification

Make:

Aprilia

Model:

Pegaso 650

Generation

Model Years Covered:

1997, 1998, 1999

Codes

Chassis Codes:

RD06 (primarily, with potential minor variations across years)

👋 Introduction

Market Position

Segment:

Adventure Touring / Dual-Sport Motorcycle

Target Audience:

Owners seeking to perform their own maintenance and repairs, independent workshops, and enthusiasts.

Competitive Analysis

Competitors:

BMW F650 Funduro, Kawasaki KLR650, Yamaha XT660 (though XT660 is later).

Key Features

Vehicle Focus:

Versatile performance for both on-road commuting and light off-road excursions.

Manual Value Proposition:

Empowers owners with the knowledge to maintain and repair their Pegaso 650, saving time and money while ensuring longevity.

📋 Manual Details

Coverage Areas

Primary Coverage:

Mechanical Service and Repair

Page Count

Estimated Page Count:

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete engine overhaul, cylinder head, valve train, pistons, crankshaft, lubrication system, cooling system, timing components.

Fuel System:

Carburetor (likely Mikuni BSR33 or similar), fuel pump, fuel lines, fuel filter replacement and cleaning.

Ignition System:

Spark plugs, ignition coils, CDI unit, wiring diagrams, timing adjustment.

Transmission Drivetrain:

Clutch operation and adjustment, gearbox disassembly and reassembly, chain drive maintenance, final drive inspection.

Brakes:

Front and rear brake systems, hydraulic lines, caliper service, master cylinder maintenance, brake pad and rotor replacement, bleeding procedures.

Suspension:

Front fork service (oil change, seal replacement), rear shock absorber inspection and adjustment, linkage lubrication.

Electrical System:

Battery, charging system (alternator, regulator/rectifier), starter motor, lighting system, horn, wiring diagrams for all circuits.

Chassis Frame:

Frame inspection, steering head bearing service, wheel bearing replacement, swingarm maintenance.

Bodywork Plastics:

Fairing removal and installation, seat removal, minor bodywork repairs.

Procedures Included

Scheduled Maintenance:

Detailed maintenance schedules, oil and filter changes, air filter cleaning/replacement, spark plug checks, chain lubrication and adjustment, brake fluid checks.

Troubleshooting:

Diagnostic flowcharts and symptom-based problem identification for common issues.

Repair Procedures:

Step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, and reassembly.

Specifications Data:

Torque specifications, clearances, fluid capacities, electrical values, and other critical data for accurate service.

Technical Depth

Depth:

Comprehensive, covering from basic routine maintenance to complex engine and transmission overhauls.

Diagnostic Level:

Includes diagnostic procedures for electrical and mechanical issues, without requiring specialized electronic diagnostic tools beyond standard multimeter use.

📊 Manual Specifications

File Format

PDF Quality:

High-resolution scans or native digital format, ensuring clear text and images for readability and printing.

Searchability:

Typically OCR-enhanced for searchable text, allowing users to quickly find specific information.

Print Quality

Print Recommendation:

Designed for clear printing on standard office printers, with legible diagrams and text.

Binding Type

Binding:

N/A (Digital PDF format)

Paper Type

Paper Type:

N/A (Digital PDF format)

⚙️ Engine Specifications

Primary Engine

Type:

Single-cylinder, four-stroke

Displacement:

652 cc

Bore X Stroke:

100 mm x 82.5 mm

Compression Ratio:

9.1:1 (typical)

Valve Train:

SOHC, 4 valves per cylinder

Cooling System:

Liquid-cooled

Performance

Horsepower:

Approx. 48-50 HP (36-37 kW) at around 6500 RPM

Torque:

Approx. 56 Nm (41 lb-ft) at around 5200 RPM

Fuel System

Carburetor Model:

Mikuni BSR33 (common)

Fuel Type:

Unleaded gasoline

Fuel Capacity:

Approx. 15-18 liters (3.3-3.9 US gal)

🔧 Transmission

Standard

Type:

5-speed manual

Optional

Type:

Features

Clutch Type:

Wet multi-plate

Final Drive:

Chain drive

📐 Dimensions

Exterior

Length:

Approx. 2150 mm

Width:

Approx. 850 mm

Height:

Approx. 1350 mm (seat height variable by suspension adjustment)

Wheelbase:

Approx. 1480 mm

Weights

Dry Weight:

Approx. 165-170 kg

Wet Weight:

Approx. 185-190 kg (fully fueled)

Payload Capacity:

Typically around 180-200 kg (rider + luggage)

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (Motorcycles generally do not have standardized crash test ratings like cars)

Active Features

Braking System:

Disc brakes front and rear, often with optional ABS depending on market/trim.

Lighting:

Halogen headlight, taillight, turn signals.

Passive Features

Frame Construction:

Steel trellis frame for rigidity and rider protection.

💡 Technology Features

Infotainment

Instrument Cluster:

Analog speedometer, tachometer, fuel gauge, odometer, trip meter, coolant temperature warning light, oil pressure warning light, neutral indicator, turn signal indicators.

Driver Assistance

Optional Anti-lock Braking System (ABS) may be present on some models, particularly those sold in specific markets.

Connectivity

Connectivity Features:

N/A (No modern connectivity features like Bluetooth or smartphone integration).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 - 7,500 km or annually, whichever comes first (refer to manual for exact specification).

Air Filter Service:

Check every 5,000 km, clean/replace as needed.

Spark Plug Replacement:

Every 10,000 - 15,000 km (depending on spark plug type).

Chain Lubrication Adjustment:

Every 1,000 km and after washing or riding in the rain.

Fluid Specifications

Engine Oil Type:

API SG or higher, JASO MA rated, SAE 10W-40 or 15W-50 (refer to manual for precise recommendation based on temperature).

Engine Oil Capacity:

Approx. 2.0 - 2.2 liters (with filter change).

Coolant Type:

Ethylene glycol-based antifreeze mixture (50% coolant, 50% distilled water).

Brake Fluid Type:

DOT 4

Known Issues

Common Wear Items:

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

Common Issues

Carburetor Tuning:

Can be sensitive to altitude and temperature; requires periodic cleaning and adjustment for optimal performance.

Electrical Connections:

Corrosion in connectors can sometimes lead to intermittent electrical issues; periodic inspection and cleaning are beneficial.

Charging System:

The regulator/rectifier unit is a known failure point on many bikes of this era; proactive replacement or monitoring is advised.

📚 Vehicle History

Brand Heritage

Manufacturer:

Aprilia is an Italian motorcycle manufacturer with a strong racing pedigree, known for performance and innovative designs.

Model Evolution

Pegaso Lineage:

The Pegaso line has a history dating back to the early 1990s, evolving through various iterations. The 650cc single-cylinder engine, often sourced from Rotax, became a hallmark of this model.

Production

Manufacturing Location:

Italy

Key Market Regions:

Europe, North America, other global markets.

🏆 Awards & Recognition

Recognitions

Motorcycle Awards:

While specific awards for this particular model year are not widely documented, the Aprilia Pegaso line generally received positive reviews for its versatility and performance in its class.

Ratings

Customer Satisfaction:

Often praised by owners for its robust engine and comfortable riding position for touring and commuting.