Segment:
Dual-sport / Adventure Motorcycle
Target Audience:
Owners and independent workshops seeking comprehensive repair and maintenance information.
Competitors 1999:
BMW F650GS, Kawasaki KLR650, Suzuki DR650SE
Motorcycle Usp:
Versatile platform combining on-road comfort with off-road capability, powered by a reliable Rotax engine.
Value Proposition:
Provides essential, in-depth technical data to maintain and repair the Aprilia Pegaso 650 effectively, reducing reliance on expensive dealerships.
Systems Covered:
Engine, Transmission, Clutch, Fuel System, Ignition System, Cooling System, Electrical System, Chassis, Suspension, Brakes, Bodywork, Troubleshooting, Maintenance
Type:
Workshop Manual / Service Manual
Engine Mechanics:
Detailed disassembly, inspection, repair, and reassembly of the engine. Includes cylinder head, pistons, crankshaft, camshafts, valves, timing components.
Fuel System:
Carburetor (Mikuni BSR32) adjustment, overhaul, and troubleshooting. Fuel pump and filter service.
Ignition System:
CDI unit, spark plugs, ignition coils, wiring and troubleshooting.
Cooling System:
Radiator, coolant hoses, thermostat, water pump maintenance and repair.
Transmission And Clutch:
Gearbox disassembly and reassembly, clutch operation, adjustment, and replacement. Gear ratio information.
Electrical System:
Wiring diagrams, starter motor, alternator, battery, lighting, instruments, fuses, relays, and troubleshooting of electrical faults.
Chassis And Suspension:
Frame inspection, front fork service, rear shock absorber maintenance, swingarm, and bearings.
Braking System:
Front and rear brake caliper service, master cylinder overhaul, brake fluid replacement, and bleeding procedures.
Bodywork And Fairings:
Removal and installation of body panels, fairings, seat, and minor bodywork repairs.
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, lubrication, spark plug replacement, air filter cleaning/replacement, brake checks.
Troubleshooting Guides:
Systematic diagnostic procedures for common problems, fault identification, and repair solutions.
Rebuilds And Overhauls:
Comprehensive instructions for engine, transmission, and carburetor rebuilds.
Component Replacement:
Step-by-step guidance for replacing major and minor components.
Depth:
Complete, from basic maintenance to full engine and gearbox rebuilds, including electrical diagnostics.
Engine Type:
Four-stroke, single-cylinder
Displacement:
652 cc (39.8 cu in)
Bore X Stroke:
100 mm x 83.5 mm
Engine Code:
Rotax 654 F (common variant)
Valve Train:
SOHC, 4 valves per cylinder
Cooling System:
Liquid-cooled
Horsepower:
Approximately 48-50 hp @ 6,200 rpm
Torque:
Approximately 60 Nm (44 lb-ft) @ 5,000 rpm
Carburetor:
Mikuni BSR32, constant velocity
Fuel Type:
Unleaded gasoline
Fuel Tank Capacity:
Approximately 15 liters (3.96 US gal)
Length:
Approximately 2,180 mm (85.8 in)
Width:
Approximately 850 mm (33.5 in)
Height:
Approximately 1,370 mm (53.9 in)
Wheelbase:
Approximately 1,470 mm (57.9 in)
Dry Weight:
Approximately 184 kg (405.7 lbs)
Wet Weight:
Approximately 198 kg (436.5 lbs)
Max Load Capacity:
Refer to vehicle VIN plate, typically around 180-200 kg including rider and luggage.
Front Suspension Travel:
Approximately 170 mm (6.7 in)
Rear Suspension Travel:
Approximately 175 mm (6.9 in)
Safety Standard:
Motorcycle safety standards of the late 1990s.
Braking System Front:
Dual discs, hydraulic, often 2-piston calipers.
Braking System Rear:
Single disc, hydraulic, 1 or 2-piston caliper.
ABS:
Not typically available or standard on this model year.
Lighting:
Halogen headlamp, LED tail light (typical).
Instrumentation:
Analog speedometer and tachometer, odometer, trip meter, neutral indicator, oil pressure warning light, turn signal indicators.
Rider Aids:
None (basic motorcycle design for the era).
Connectivity Features:
None.
Oil Change Interval:
Every 5,000-7,500 km (3,000-4,500 miles) or annually.
Oil Filter Change:
Recommended with every oil change.
Air Filter Service:
Inspect every 5,000 km, clean or replace as needed. Replace every 10,000-15,000 km.
Spark Plug Replacement:
Every 10,000-12,000 km.
Chain Maintenance:
Lubricate and adjust every 1,000 km or more frequently in adverse conditions.
Engine Oil Type:
SAE 10W-40 API SG, SH, SJ motorcycle-specific 4-stroke engine oil.
Engine Oil Capacity:
Approximately 2.4 liters (with filter change).
Coolant Type:
Ethylene glycol-based antifreeze with corrosion inhibitors, mixed 50/50 with distilled water.
Common Wear Items:
Clutch wear, chain and sprockets, fork seals, voltage regulator/rectifier failure (typical of the era), exhaust header pipe cracking (less common but possible).
Carburetor Issues:
Tendency for pilot jets to clog if fuel sits for extended periods; requires regular cleaning/maintenance.
Electrical Gremlins:
As with many bikes of this age, electrical connections can corrode, leading to intermittent issues.
Manufacturer:
Aprilia is an Italian manufacturer known for its performance-oriented motorcycles and scooters, with a strong racing pedigree.
Pegaso Lineage:
The Pegaso line has a history of dual-purpose motorcycles, evolving from earlier models. The 650cc platform, utilizing Rotax engines, was a key offering in the mid-weight adventure segment.
Production Years Approx:
The Pegaso 650 was produced for many years, with significant updates. The 1999 model is part of the later generation of the Pegaso 650 using the established Rotax engine.
Assembly Location:
Primarily Italy.
