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Aprilia Pegaso 650 1999 Service Repair Manual

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The Aprilia Pegaso 650, produced in 1999, is a versatile dual-sport motorcycle designed for riders who appreciate a blend of on-road comfort and off-road capability. Featuring a robust 654cc Rotax...
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Aprilia Pegaso 650 1999 Service Repair Manual
The Aprilia Pegaso 650, produced in 1999, is a versatile dual-sport motorcycle designed for riders who appreciate a blend of on-road comfort and off-road capability. Featuring a robust 654cc Rotax single-cylinder engine, this model offers a balanced performance suitable for both daily commuting and exploring less-traveled paths. Its engineering emphasizes reliability and practicality, making it a competent machine for a variety of riding conditions. The Pegaso 650 is recognized for its substantial suspension travel and a design philosophy that bridges the gap between street-focused motorcycles and more rugged adventure bikes. This comprehensive service and repair manual provides in-depth information essential for the maintenance and repair of your 1999 Aprilia Pegaso 650. It covers all major systems, including the engine, transmission, chassis, suspension, braking, fuel, and electrical systems, offering detailed procedures, diagnostic guidance, and technical specifications. With clear, step-by-step instructions and diagrams, this manual is an invaluable resource for owners and technicians alike, ensuring the optimal performance and longevity of the vehicle.
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
Pegaso 650
Year:
1999
Engine Variant:
650cc Single-Cylinder
Codes
Chassis Code:
RL1
👋 Introduction
Market Position
Category:
Dual-sport / Adventure Motorcycle
Target Audience:
Riders seeking versatility for commuting and light off-road use
Competitive Analysis
Competitors:
BMW F650 Funduro, Kawasaki KLR650, Suzuki DR650SE
Key Features
Engine Type:
Liquid-cooled, four-stroke, single-cylinder
Suspension Travel:
Generous travel for off-road capability
Design Philosophy:
Blend of on-road comfort and off-road ruggedness
📋 Manual Details
Coverage Areas
Primary Coverage:
Service and Repair
Diagnostic Coverage:
Troubleshooting and fault diagnosis
Maintenance Coverage:
Scheduled maintenance procedures and intervals
Engine Coverage:
Complete engine overhaul and component repair
Transmission Coverage:
Gearbox inspection, maintenance, and repair
Electrical Coverage:
Wiring diagrams, component testing, and electrical system repair
Chassis Suspension Coverage:
Front and rear suspension, steering, and frame components
Braking System Coverage:
Brake system service, bleeding, and component replacement
Fuel System Coverage:
Fuel injection system, fuel pump, and tank service
Cooling System Coverage:
Radiator, fan, and coolant system maintenance
Bodywork Coverage:
Body panel removal, installation, and adjustments
Wheels Tires Coverage:
Wheel bearing service and tire pressure specifications
Page Count
Estimated Pages:
Over 300
Manual Type
Type:
Service and Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, transmission, clutch, final drive
Chassis:
Frame, suspension, steering, wheels, tires
Electrical:
Ignition, lighting, starting, charging, instrumentation, ECU
Fuel Induction:
Carburetor settings (if applicable), fuel pump, injectors
Braking:
Hydraulic system, discs, pads, lines
Exhaust:
Exhaust system components and routing
Cooling:
Radiator, fan, water pump, thermostat
Controls:
Throttle, clutch, brake levers and cables
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, spark plug checks
Troubleshooting:
Diagnostic flowcharts and symptom-based problem solving
Engine Repair:
Top-end rebuilds, piston and cylinder replacement, valve adjustments
Transmission Repair:
Gear selection issues, clutch replacement, gearbox disassembly/reassembly
Electrical Diagnostics:
Wiring harness testing, sensor diagnostics, battery and charging system checks
Suspension Fork Service:
Fork oil changes, seal replacement, damping adjustments
Brake System Maintenance:
Brake fluid flush, pad and disc replacement, caliper service
Carburetor Tuning:
Idle speed adjustment, jetting information (if applicable)
Wheel Bearing Replacement:
Hub and bearing service procedures
Technical Depth
Depth:
Comprehensive, suitable for professional technicians and experienced DIYers
Detail Level:
Includes detailed diagrams, torque specifications, and step-by-step instructions
📊 Manual Specifications
File Format
File Type:
Digital PDF
Searchability:
Searchable text for quick information retrieval
Print Quality
Printability:
Optimized for printing by the user
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Rotax 654cc liquid-cooled 4-stroke single-cylinder
Bore X Stroke:
100 mm x 82 mm
Displacement:
654 cc
Compression Ratio:
9.7:1
Valvetrain:
SOHC, 4 valves per cylinder
Performance
Horsepower:
~48 hp (36 kW) @ 7000 rpm
Torque:
~53 Nm (39 lb-ft) @ 5500 rpm
Fuel System
Fuel Delivery:
Carbureted (likely Mikuni BSR34 or similar for 1999)
Ignition:
Electronic ignition system
Fluid Specifications
Engine Oil Type:
SAE 10W-40 API SG or higher (check manual for specific grade)
Engine Oil Capacity:
~2.0 Liters (with filter change)
Coolant Type:
Ethylene glycol based antifreeze (50/50 mix)
🔧 Transmission
Standard
Type:
5-speed manual transmission
Features
Clutch Type:
Wet multi-plate clutch
Final Drive:
O-ring sealed chain drive
Fluid Specifications
Gearbox Oil Type:
SAE 80W/90 API GL-4 or GL-5 (check manual for specific grade)
Gearbox Oil Capacity:
~0.6 Liters
📐 Dimensions
Exterior
Length:
~2170 mm
Width:
~850 mm
Height:
~1360 mm
Weights
Dry Weight:
~170 kg
Wet Weight:
~185 kg (approximate, with fluids)
Fuel Tank Capacity:
17 Liters (including 3-liter reserve)
Wheels Tires
Front Tire Size:
90/90-21
Rear Tire Size:
130/80-17
Wheel Type:
Spoked wheels
🛡️ Safety Features
Ratings
Crash Test Ratings:
N/A (Motorcycle safety is assessed differently)
Active Features
Braking System:
Hydraulic disc brakes front and rear
Lighting:
Halogen headlight, LED taillight, turn signals
Passive Features
Frame Construction:
Steel tube frame
Handguards:
Standard for protection from elements and impacts
💡 Technology Features
Infotainment
Instrument Cluster:
Analog tachometer, speedometer, basic indicator lights
Driver Assistance
ABS:
Not typically standard on this model year, check specific trim.
Connectivity
Usb Charging:
Not standard, typically aftermarket addition
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 - 7,500 km or annually (refer to manual for exact interval)
Air Filter Cleaning Replacement:
Every 5,000 - 10,000 km or as needed based on conditions
Spark Plug Check Replacement:
Every 10,000 - 15,000 km
Valve Clearance Check:
Every 10,000 - 15,000 km
Chain Lubrication Adjustment:
Every 500 - 1,000 km and before long trips
Fluid Specifications
Brake Fluid Type:
DOT 4
Known Issues
Common Wear Items:
Clutch plates, chain and sprockets, fork seals, voltage regulator/rectifier
Potential Electrical Problems:
Weak charging system (rectifier failure) leading to battery drain
Carburetor Issues:
Can be prone to gumming up if not used regularly, requiring cleaning and syncing.
📚 Vehicle History
Brand Heritage
Manufacturer:
Aprilia, an Italian manufacturer known for performance motorcycles
Model Evolution
Pegaso Lineage:
The Pegaso line has a history of single-cylinder models targeting the dual-sport market.
Engine Source:
Engine often derived from Rotax (part of Bombardier Recreational Products), a common supplier for many manufacturers.
Production
Production Period:
The Pegaso 650 was produced from the early 1990s through various iterations until the mid-2000s.
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Motorcycle Awards:
No specific major industry awards readily documented for this particular model year, but appreciated for its versatility.
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