Positioning:
The Aprilia Pegaso 650 was positioned as an accessible, versatile adventure touring motorcycle, blending on-road comfort with light off-road capability. This manual caters to owners seeking to maintain or repair their machine themselves.
Competition:
Competed against models like the BMW F650 Funduro, Kawasaki KLR650, and Suzuki DR650 in the dual-sport/adventure touring segment.
Vehicle Highlights:
Single-cylinder Rotax engine (known for durability and torque), comfortable ergonomics, capable suspension for varied terrain, and classic Aprilia styling.
Primary Coverage:
Maintenance, repair, and troubleshooting for the 1997 Aprilia Pegaso 650.
Secondary Coverage:
Electrical system diagnostics, chassis components, bodywork, and specifications.
Estimated Pages:
Likely between 200-400 pages, typical for a comprehensive service manual of this era.
Type:
Service Repair Manual
Language:
English (most common for international distribution, though Italian origin may suggest Italian versions exist)
Format:
Likely a digital format (PDF) for ease of distribution and searchability, though printed versions were standard.
Engine Mechanical:
Detailed procedures for engine disassembly, assembly, inspection, and component replacement (e.g., piston rings, valves, camshaft).
Fuel System:
Carburetor (likely Mikuni BSR42) adjustment, cleaning, rebuild, fuel pump, and fuel lines.
Ignition System:
Spark plug specifications, ignition timing, coil testing, and CDI unit diagnostics.
Cooling System:
Radiator, coolant, fan operation, thermostat replacement, and flushing procedures.
Exhaust System:
Inspection, gasket replacement, and potential component diagnostics.
Transmission:
Clutch operation, gear shifting mechanisms, transmission oil specifications and replacement, gearbox disassembly and assembly.
Suspension:
Front fork (likely upside-down type) servicing, oil replacement, seal replacement, rear shock absorber adjustment and removal.
Brakes:
Brake fluid specifications, bleeding procedures, pad replacement, caliper servicing, disc inspection, and master cylinder diagnostics.
Electrical System:
Wiring diagrams, component testing (lights, horn, starter, charging system), battery maintenance, fuse identification and replacement.
Chassis And Frame:
Frame inspection, steering head bearing service, wheel bearing replacement, spoke tensioning.
Bodywork And Fairings:
Fairing removal and installation, seat removal, minor bodywork repair guidance.
Routine Maintenance:
Oil and filter changes, air filter cleaning/replacement, spark plug gap adjustment, chain lubrication and adjustment, brake checks.
Troubleshooting:
Systematic diagnostic procedures for common issues (e.g., starting problems, poor running, electrical faults).
Engine Rebuild:
Detailed instructions for engine overhaul, including torque specifications and critical clearances.
Suspension Servicing:
Fork seal replacement, oil level adjustment, rear shock servicing.
Electrical Diagnostics:
Testing relays, solenoids, charging system components, and interpreting wiring diagrams.
Brake System Maintenance:
Bleeding, pad and fluid replacement, caliper overhaul.
Depth Of Information:
Comprehensive, covering everything from basic adjustments to complete engine and component overhauls.
Diagnostic Capabilities:
Detailed fault finding charts and diagnostic procedures for common and uncommon issues.
Component Specifications:
Precise measurements, tolerances, torque values, and wear limits for all major components.
Digital Format Details:
Searchable PDF with bookmarked sections for easy navigation. May include high-resolution scans of original factory manuals.
Print Quality Description:
If printed, expect clear black and white diagrams and text, suitable for workshop use. High-quality paper stock often used.
Binding Description:
If printed, typically a spiral-bound or comb-bound format for lay-flat use in a workshop environment.
Paper Description:
Durable paper stock resistant to grease and workshop chemicals, or standard quality for digital reproduction.
Engine Type:
4-stroke, single-cylinder, liquid-cooled, DOHC (Double Overhead Camshaft)
Bore X Stroke:
100 mm x 83.6 mm
Compression Ratio:
9.5:1 (typical for this engine)
Horsepower Output:
Approx. 49 hp @ 6,250 rpm (actual figures may vary slightly by market/tuning)
Torque Output:
Approx. 60 Nm (44 lb-ft) @ 4,000 rpm
Carburetor Type:
Mikuni BSR42 CV (Constant Velocity) carburetor
Fuel Type:
Unleaded gasoline, minimum 91 RON (87 AKI)
Oil Type:
SAE 10W-40 or 15W-50, JASO MA certified motorcycle oil
Oil Capacity:
Approx. 2.5 liters (2.6 US qt) with filter change
Coolant Type:
Ethylene glycol based antifreeze mixture (50/50 with distilled water)
Safety Certifications:
As a motorcycle, it conforms to applicable international safety standards for two-wheeled vehicles of its class.
Braking System:
Disc brakes front and rear. Front typically dual discs, rear single disc.
Lighting:
Headlight, taillight, brake lights, turn signals, and instrument cluster illumination.
Chassis Design:
Steel tube frame providing rigidity and rider protection.
Instrument Cluster:
Analog speedometer, tachometer, odometer, trip meter, and indicator lights for turn signals, high beam, neutral, oil pressure, and engine temperature (if applicable).
ABS Availability:
ABS was an optional feature on some Pegaso models, but likely not standard on the 1997 model. Manual will indicate if applicable.
Connectivity Features:
None, as this is a 1997 model motorcycle. Focus is purely on mechanical and electrical operation.
Oil Change Interval:
Every 5,000-7,500 km (3,000-5,000 miles) or annually, whichever comes first. Check manual for exact recommendation.
Air Filter Service:
Inspect every 5,000 km (3,000 miles), clean or replace as needed. Check manual for specific interval.
Spark Plug Replacement:
Typically every 10,000-15,000 km (6,000-9,000 miles). Consult manual for specific plug type and gap.
Chain Maintenance:
Lubricate and adjust chain every 1,000 km (600 miles) or after riding in wet conditions. Check for wear and tension regularly.
Valve Clearance Check:
Typically at 10,000-20,000 km (6,000-12,000 miles) intervals. Critical for engine performance and longevity.
Engine Oil Spec:
SAE 10W-40 or 15W-50, API SG/SH or higher, JASO MA certified
Brake Fluid Spec:
DOT 4 or DOT 5.1 (check manual for precise recommendation, typically DOT 4 is used).
Coolant Spec:
50% Ethylene Glycol Antifreeze / 50% Distilled Water
Fork Oil Spec:
Typically SAE 7.5W or 10W fork oil. Capacity will be specified in the manual.
Common Wear Items:
Clutch plates, wheel bearings, steering head bearings, fork seals, and exhaust gaskets can be common wear items over time.
Electrical Concerns:
While generally robust, electrical connections and regulators can be points of attention on older bikes. The manual's electrical diagnostics are invaluable.
Carburetor Idling:
The Mikuni BSR42 carburetor can sometimes require fine-tuning for smooth idling, especially with age and use. Manual will detail adjustment procedures.
Aprilia Legacy:
Aprilia is an Italian manufacturer renowned for its sporty motorcycles and racing heritage, particularly in smaller displacement classes and off-road racing.
Pegaso Lineage:
The Pegaso line, particularly the 650, debuted in the early 1990s and was Aprilia's foray into the adventure touring segment, utilizing the robust Rotax engine.
1997 Updates:
The 1997 model year typically represents refinements to earlier versions, potentially including minor styling tweaks, improved suspension components, or updated electrical systems based on owner feedback.
Manufacturing Location:
Italy
