Aprilia Pegaso 650 1997 Factory Service Repair Manual

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Type: Motorcycle

Vendor:

Sku: 136916

Tags: 1997 Aprilia Motorcycle Motorcycles Pegaso 650 Pegaso Models

Product variants

Description

The Aprilia Pegaso 650, produced in 1997, is an adventure-touring motorcycle known for its versatility and capability in both on-road and light off-road conditions. Powered by a robust 4-stroke, single-cylinder, liquid-cooled engine with a displacement of 652 cc, this Italian-designed machine offers approximately 48 horsepower and 60 Nm of torque, providing ample performance for its intended use. The Pegaso 650 features a 5-speed transmission, disc brakes front and rear, and a comfortable riding posture, making it a reliable choice for riders seeking a capable and cost-effective dual-sport experience. This Factory Service Repair Manual provides comprehensive guidance for the maintenance and repair of the 1997 Aprilia Pegaso 650. It covers essential areas including detailed engine removal, disassembly, and reassembly procedures for all major internal components, as well as the lubrication, cooling, ignition, and clutch systems. The manual also includes a maintenance schedule and outlines specific fluid requirements for optimal performance and longevity. By offering in-depth, step-by-step instructions, this manual serves as an invaluable resource for owners and technicians aiming to keep the Pegaso 650 in peak operating condition.

🏷️ Basic Information

Identification

Make:

Aprilia

Model:

Pegaso 650

Year:

Model Variant:

Factory Service Repair Manual

Codes

Engine Code Type:

Not explicitly stated in product info, but typically Rotax 655

Chassis Code Type:

Not explicitly stated in product info, but often derived from frame numbers

👋 Introduction

Market Position

Vehicle Segment:

Adventure Touring / Dual-Sport Motorcycle

Competitive Analysis

Key Competitors:

BMW F650 Funduro, Suzuki DR650, Kawasaki KLR650, Yamaha XT600/XT660

Key Features

Value Proposition:

Provides a cost-effective solution for maintaining and repairing the Aprilia Pegaso 650 by enabling DIY repairs.

📋 Manual Details

Coverage Areas

General Coverage:

Comprehensive maintenance and repair procedures

Engine Coverage:

Engine removal, disassembly, cylinder head, cylinder, piston, ignition unit, oil pump, clutch, water pump, crankshaft, engine reassembly, engine installation

Maintenance Schedule:

Includes maintenance schedule

Page Count

Page Count:

Unknown (PDF download, page count not specified)

Manual Type

Manual Type:

Factory Service Repair Manual

Language

Language:

English

Format

File Format:

Compatibility

Operating Systems:

WINDOWS and MAC

Requirements

Software Requirements:

Adobe PDF Reader

📖 Manual Coverage

Systems Covered

Engine Systems:

Internal engine components, lubrication system, cooling system, ignition system, clutch system

Procedures Included

Diagnostic Procedures:

Implied through repair procedures, not explicitly detailed as a separate section.

Repair Procedures:

Detailed step-by-step repair instructions for all listed engine components

Maintenance Procedures:

Includes maintenance schedule and implied maintenance tasks

Technical Depth

Depth Of Coverage:

Comprehensive, covering detailed component disassembly, reassembly, and installation. Suitable for in-depth engine overhauls.

📊 Manual Specifications

File Format

File Format:

Print Quality

Printability:

Yes, printable

Binding Type

Binding Type:

Digital Download (PDF)

Paper Type

Paper Type:

Not applicable (digital file)

⚙️ Engine Specifications

Primary Engine

Engine Type:

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

Engine Displacement:

652 cc (cubic centimeters)

Bore X Stroke:

100 mm x 83.2 mm (typical for Rotax 655)

Compression Ratio:

9.0:1 (typical for Rotax 655)

Performance

Horsepower:

Approx. 48 HP (36 kW) at 6,250 RPM (typical for 1997 model)

Torque:

Approx. 60 Nm (44 lb-ft) at 5,000 RPM (typical for 1997 model)

Fuel System

Fuel Delivery:

Carburetor (likely Mikuni BST40 or similar)

Fuel Type:

Unleaded gasoline

Cooling System

Cooling Method:

Liquid-cooled

Lubrication System

Oil Capacity:

Approx. 2.2 liters (typical, including filter)

Oil Type:

Motorcycle-specific 10W-40 or 10W-50, JASO MA certified (refer to manual for exact spec)

Ignition System

Ignition Type:

Electronic CDI (Capacitor Discharge Ignition)

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Optional

Transmission Options:

Features

Final Drive:

O-ring sealed chain

Clutch Type:

Wet, multi-plate, cable-actuated

Fluid Specs

Transmission Fluid Type:

API GL-4 or GL-5 gear oil (refer to manual for exact specification and viscosity)

📐 Dimensions

Exterior

Length:

Approx. 2200 mm (refer to manual for exact spec)

Width:

Approx. 820 mm (refer to manual for exact spec)

Height:

Approx. 1370 mm (refer to manual for exact spec)

Wheelbase:

Approx. 1460 mm (refer to manual for exact spec)

Weights

Dry Weight:

Approx. 174 kg (refer to manual for exact spec)

Wet Weight:

Approx. 192 kg (refer to manual for exact spec)

Fuel Tank Capacity:

Approx. 15 liters (refer to manual for exact spec)

🛡️ Safety Features

Ratings

Safety Ratings:

Not applicable for motorcycle safety ratings in the same way as cars.

Active Features

Braking System:

Disc brakes front and rear

Front Brake Spec:

Single 300 mm disc, 2-piston caliper (typical)

Rear Brake Spec:

Single 220 mm disc, 1-piston caliper (typical)

Passive Features

Lighting:

Halogen headlamp, LED tail light (typical)

Mirrors:

Adjustable handlebar mirrors

💡 Technology Features

Infotainment

Infotainment System:

Not applicable for this model year; basic analog instrumentation.

Driver Assistance

ABS Availability:

ABS was an optional feature on some Pegaso 650 models, availability for the 1997 model depends on specific market/trim.

Connectivity

Connectivity Features:

Not applicable.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 6,000 km or 12 months (refer to manual for precise interval)

Valve Clearance Interval:

Typically every 12,000 km (refer to manual for precise interval)

Air Filter Service:

Inspect every 6,000 km, clean or replace as needed (refer to manual)

Fluid Specifications

Coolant Type:

Ethylene glycol-based antifreeze with corrosion inhibitors, mixed with distilled water (refer to manual for exact ratio and specification)

Brake Fluid Type:

DOT 4 (refer to manual for exact specification)

Known Issues

Common Wear Items:

Clutch wear, front fork seals, cam chain tensioner, electrical connector corrosion.

Engine Reliability:

Generally reliable with proper maintenance; early models sometimes had issues with the stock cam chain tensioner, which can be upgraded.

Troubleshooting

Troubleshooting Guide:

The manual provides detailed repair procedures which inherently support troubleshooting of common faults.

📚 Vehicle History

Brand Heritage

Manufacturer Origin:

Italy

Brand Focus:

Sport motorcycles, scooters, and performance bikes

Model Evolution

Pegaso Lineage:

The Pegaso line has been Aprilia's offering in the adventure-touring segment, evolving from earlier models to incorporate improvements in chassis, engine, and features.

1997 Model Context:

The 1997 model typically features the Rotax 655 engine, a robust and proven single-cylinder unit known for its reliability and torque.

Production

Production Years:

The Aprilia Pegaso 650 was produced from the early 1990s through the mid-2000s in various iterations.

🏆 Awards & Recognition

Recognitions

Awards:

Specific awards for the 1997 Pegaso 650 are not widely documented, but the model was generally well-regarded for its versatility and value in the adventure-touring segment.