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Aprilia Pegaso 650 1997-2001 Service Repair Manual

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The Aprilia Pegaso 650, a dual-sport motorcycle produced for the early second generation from 1997 to 2001, is celebrated for its versatility and robust Italian engineering. Powered by a 652...
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Tipo: Motorcycle
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SKU: 144355
Aprilia Pegaso 650 1997-2001 Service Repair Manual
The Aprilia Pegaso 650, a dual-sport motorcycle produced for the early second generation from 1997 to 2001, is celebrated for its versatility and robust Italian engineering. Powered by a 652 cc Rotax single-cylinder engine, it offers a balanced blend of performance and practicality for both commuting and adventure touring. Its design philosophy emphasizes a capable chassis with long-travel suspension and a steel frame, making it suitable for varied terrain, from city streets to light off-road excursions. The Pegaso 650 was positioned to compete with other popular dual-sport machines of its time, offering a unique combination of everyday usability and the potential for exploration. This comprehensive service repair manual provides detailed guidance for the maintenance, diagnosis, and repair of the Aprilia Pegaso 650 models from 1997 through 2001. It covers all essential systems, including the engine, transmission, chassis, brakes, and electrical components, with in-depth procedures for routine maintenance, scheduled servicing, and troubleshooting. The manual includes crucial technical specifications, torque values, and clear wiring diagrams, making it an indispensable resource for technicians and owners. Its primary purpose is to ensure the longevity, reliability, and optimal performance of the vehicle through accurate and detailed information.
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
Pegaso 650
Model Designation:
Pegaso 650
Model Variant:
Standard / Strada / Trail (depending on year and market)
Model Generations:
First Generation (1990-1996) and Second Generation (1997-2004), this manual covers the early part of the second generation.
Production Years Covered:
1997, 1998, 1999, 2000, 2001
Codes
Vin Code Interpretation:
Specific VIN decoding details for this era are typically found within the manual's introductory sections.
👋 Introduction
Market Position
Motorcycle Segment:
Dual-sport / Adventure Touring motorcycle.
Target Audience:
Riders seeking a versatile motorcycle for commuting, touring, and light off-road use.
Competitive Analysis
Key Competitors:
BMW F650 Funduro, Honda Transalp, Suzuki DR650, Yamaha XT600/XT660.
Key Features
Engine Type:
Single-cylinder, four-stroke engine.
Design Philosophy:
Combines practical everyday usability with the capability for adventure touring and off-road excursions.
Frame Construction:
Steel frame, offering a balance of rigidity and compliance.
Suspension Setup:
Long-travel suspension designed for varied terrain.
📋 Manual Details
Coverage Areas
Geographical Coverage:
Likely global due to Aprilia's export markets, but may contain regional variations in specifications or parts.
Market Focus:
Primarily European market, with potential applicability to other regions where the Pegaso 650 was officially sold.
Page Count
Estimated Pages:
Typically 400-600 pages for comprehensive service manuals of this era.
Manual Type
Manual Category:
Service Repair Manual
Manual Purpose:
Detailed diagnostic, repair, maintenance, and overhaul procedures for technicians and advanced DIY enthusiasts.
Language
Primary Language:
English
Format
Digital Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Complete engine overhaul, including cylinder head, pistons, crankshaft, lubrication system, cooling system, and fuel injection.
Transmission:
Gearbox disassembly, inspection, repair, clutch operation, and final drive (chain/sprockets).
Chassis:
Frame, subframe, swingarm, suspension (front forks, rear shock), steering system.
Brakes:
Front and rear brake systems, including caliper overhaul, master cylinder, fluid lines, and bleeding procedures.
Electrical System:
Wiring diagrams, battery, charging system (alternator, regulator/rectifier), ignition system, starter motor, lighting, and instrumentation.
Fuel System:
Fuel tank, fuel pump, fuel injection system (throttle body, injectors, ECU mapping basics), and emissions controls.
Cooling System:
Radiator, fan, thermostat, coolant circulation, and troubleshooting coolant leaks.
Exhaust System:
Exhaust manifold, catalytic converter (if applicable), muffler, and mounting hardware.
Bodywork And Trim:
Fairings, seats, fuel tank cover, fenders, and other body panels removal and installation.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, chain lubrication and adjustment, tire pressure checks, spark plug replacement, and air filter cleaning/replacement.
Scheduled Maintenance:
Detailed maintenance schedule with mileage/time intervals for all major components and systems.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon issues, fault code interpretation (if applicable).
Engine Repair:
Top-end rebuilds, bottom-end overhauls, valve adjustments, timing chain replacement.
Transmission Repair:
Gear selection issues, clutch engagement problems, bearing replacements.
Brake System Overhaul:
Brake pad replacement, caliper sealing, hydraulic system bleeding, master cylinder rebuild.
Suspension Servicing:
Fork oil changes, seal replacement, rear shock absorber maintenance.
Electrical Diagnostics:
Fault finding on charging system, ignition, starter, and lights using wiring diagrams.
Fuel Injection Tuning:
Basic adjustments, sensor checks, and troubleshooting fuel delivery issues.
Technical Depth
Diagnostic Tools:
May reference specialized tools required for specific diagnostics and repairs.
Specifications And Tolerances:
Detailed torque specifications, clearances, and wear limits for all critical components.
Wiring Diagrams:
Comprehensive, often color-coded, wiring diagrams for all electrical systems.
Troubleshooting Flowcharts:
Systematic flowcharts to diagnose faults based on symptoms.
📊 Manual Specifications
File Format
Document Type:
PDF
Searchability:
Likely text-searchable for quick information retrieval.
Print Quality
Image Clarity:
High-resolution images, diagrams, and schematics.
Layout:
Organized into logical sections and chapters with clear headings and indexing.
Binding Type
Binding Method:
N/A (Digital PDF)
Paper Type
Paper Quality:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Rotax 4-stroke, liquid-cooled, single-cylinder, DOHC, 4 valves per cylinder.
Engine Displacement:
652 cc (652 cubic centimeters).
Bore X Stroke:
100 mm x 83.5 mm (typical for this engine platform).
Compression Ratio:
Approximately 10.0:1 (subject to minor variations).
Performance
Peak Horsepower:
Around 48-50 HP at 6500-7000 RPM (figures may vary slightly by market and specific tuning).
Peak Torque:
Approximately 56-58 Nm (41-43 lb-ft) at 4000-4500 RPM.
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) - likely Keihin or similar.
Fuel Type:
Unleaded gasoline, 91-98 octane rating (RON+MON)/2 or AKI.
Fuel Tank Capacity:
Approximately 17-20 liters (4.5-5.3 US gallons), depending on the specific model variant.
🔧 Transmission
Standard
Transmission Type:
5-speed constant mesh gearbox.
Optional
Optional Gearbox:
N/A (Manual transmission only).
Features
Clutch Type:
Wet, multi-plate clutch, hydraulically operated.
Final Drive:
O-ring sealed chain drive.
📐 Dimensions
Exterior
Overall Length:
Approximately 2150 mm (84.6 inches).
Overall Width:
Approximately 860 mm (33.9 inches) excluding mirrors.
Overall Height:
Approximately 1370 mm (53.9 inches).
Wheelbase:
Approximately 1470 mm (57.9 inches).
Ground Clearance:
Around 220 mm (8.7 inches), suitable for light off-road use.
Weights
Dry Weight:
Approximately 170 kg (375 lbs).
Curb Weight:
Approximately 185 kg (408 lbs) with fluids and ready to ride.
Load Capacity:
Typically rated for a rider and passenger plus luggage, around 180-200 kg total.
🛡️ Safety Features
Ratings
Crash Test Ratings:
Motorcycles of this era typically do not undergo standardized crash testing in the same way as cars.
Active Features
Braking System:
Hydraulic disc brakes front and rear. Front usually dual discs, rear single disc. ABS was an option on some later models, but less common on this 1997-2001 range.
Lighting System:
Halogen headlamp, tail light, brake lights, and turn signals.
Passive Features
Frame Strength:
Robust steel frame designed to withstand typical road and light off-road stresses.
Ergonomics:
Upright riding position for rider comfort and control.
💡 Technology Features
Infotainment
Infotainment System:
N/A (This era of motorcycle is not equipped with infotainment systems).
Driver Assistance
ABS:
Optional on some later models, not standard on most 1997-2001 variants.
Connectivity
Connectivity Features:
N/A (No electronic connectivity features such as Bluetooth or smartphone integration).
Instrumentation
Dashboard:
Analog speedometer and tachometer, with a basic LCD display for odometer, trip meter, and warning lights.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000 - 7,500 km (3,000 - 4,500 miles) or annually, whichever comes first.
Air Filter Cleaning:
Check every 5,000 km, clean/replace as needed.
Spark Plug Replacement:
Recommended around 10,000 - 15,000 km.
Valve Adjustment Interval:
Typically every 10,000 - 15,000 km, depending on wear and manufacturer recommendations.
Chain And Sprockets Inspection:
Regular inspection for wear and adjustment, replacement as needed.
Fluid Specifications
Engine Oil Type:
API SG/SH/SJ or higher, SAE 10W-40 or 15W-50 motorcycle specific oil.
Engine Oil Capacity:
Approximately 2.4 - 2.6 liters with filter change.
Coolant Type:
Ethylene glycol-based antifreeze, mixed with distilled water in a 50/50 ratio.
Brake Fluid Type:
DOT 4 or DOT 5.1 hydraulic fluid.
Fork Oil Type And Viscosity:
Typically SAE 10W or 15W fork oil, capacity around 450-500 ml per leg (refer to manual for exact amount).
Known Issues
Fuel Pump Reliability:
Some early models might experience fuel pump issues; regular maintenance and clean fuel are key.
Regulator Rectifier:
As with many bikes of this era, the R/R unit can be a point of failure; checking voltage output is recommended.
Clutch Slave Cylinder Leaks:
Occasional leaks from the clutch slave cylinder seal can occur.
Chain Wear:
Regular chain maintenance and timely replacement prevent premature sprocket wear.
Idle Stability:
Maintaining clean throttle bodies and a properly functioning idle control system is important for smooth idling.
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
Aprilia is an Italian manufacturer with a strong heritage in racing and performance motorcycles.
Model Evolution
First Generation Pegaso:
The original Pegaso 650 was introduced in 1990, also utilizing a Rotax engine, and established the model's reputation for versatility.
Second Generation Changes:
The 1997 models represented a significant update, including revised styling, improved chassis components, and refinements to the fuel injection system.
Trail Variant:
Later models in this generation (and beyond) often included a 'Trail' variant with spoked wheels and longer-travel suspension for enhanced off-road capability.
Production
Manufacturing Location:
Primarily Italy.
🏆 Awards & Recognition
Recognitions
Bike Magazine Reviews:
The Pegaso 650 was generally well-received for its versatility and value for money in its segment during its production run.
Ratings
Owner Satisfaction:
Owner satisfaction is typically high for riders who appreciate its all-around capabilities and robust Italian character.
Certifications
Emission Standards:
Compliant with European emission standards of the era; specific certifications would be detailed in the manual.
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