APRILIA PEGASO 650 Service Manual Repair Manual 1997-1999 FSM Online
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Basic Information Identification Make: Aprilia Model: Pegaso 650 Model Years Covered: 1997, 1998, 1999 Engine Variant: 650cc Common Names: Aprilia Pegaso 650 Strada, Aprilia Pegaso 650 Trail (variants within this generation) Codes Vin Code Country Origin: Italy (IT) Introduction Market Position Target Audience: Do-it-yourself (DIY) enthusiasts and experienced professional mechanics. Value Proposition: Inexpensive way to keep the vehicle working properly, provides factory-level repair information. Competitive Analysis Differentiation: Official factory documentation ensures accuracy and completeness, superior to aftermarket guides for detailed procedures. Key Features Content Highlight 1: Hundreds of photos and illustrations for visual guidance. Content Highlight 2: Numbered instructions and bold figure numbers for quick reference. Content Highlight 3: Detailed substeps, notes, cautions, and warnings for critical information. Content Highlight 4: Combined electrical troubleshooting and detailed wiring diagrams. Content Highlight 5: Numbered table of contents for fast information retrieval. Manual Details Coverage Areas Primary Coverage: Complete factory service and repair Page Count Total Pages: 311 Manual Type Type: Factory Service Manual (FSM) Additional Types: Repair Manual, Workshop Manual Language Language: English (Assumed based on typical market availability, though original may have multiple) Format Format: Digital (Online, Printable) Manual Coverage Systems Covered Engine: Complete engine overhaul, disassembly, assembly, tuning, troubleshooting, lubrication, cooling system, fuel system (carburetor likely for this era), exhaust system. Transmission: Gearbox overhaul, clutch operation, shifting mechanisms, lubrication, maintenance. Chassis: Frame inspection, swingarm, suspension (front forks, rear shock absorber), steering system, bearings, general chassis component maintenance. Electrical: Full electrical system diagnostics, wiring diagrams, lighting, ignition system, charging system (alternator/stator, regulator/rectifier), starting system (starter motor, solenoid), battery maintenance, troubleshooting electrical faults. Brakes: Brake system overhaul (front and rear calipers, master cylinders, brake lines, fluid replacement), parking brake mechanism (if applicable). Wheels And Tires: Wheel bearing maintenance, spoke tension (if applicable), tire inspection and replacement, wheel mounting procedures. Bodywork And Trim: Fairing removal and installation, seat, fuel tank, body panels, general cosmetic component service. Procedures Included Routine Maintenance: Oil changes, filter replacement, chain adjustment, spark plug service, brake fluid flush, coolant checks, air filter cleaning/replacement. Troubleshooting: Step-by-step diagnostic procedures for common and uncommon issues across all systems, including fault code identification (if applicable to the electrical system). Repair Overhaul: Complete disassembly and reassembly instructions for all major components, including engine internals, transmission, suspension, and brakes. Adjustments: Carburetor synchronization and adjustment, valve clearance checks and adjustment, throttle cable adjustment, clutch cable adjustment. Technical Depth Depth: Comprehensive, from basic service to complete engine rebuilds and advanced electrical diagnostics. Detail Level: Detailed substeps, notes, cautions, and warnings. Hundreds of photos and illustrations. Manual Specifications File Format Digital Format: Printable PDF (implied by description allowing printing in entirety or by page) Print Quality Printability: High quality, suitable for printing individual pages or the entire manual. Binding Type Binding Type For Print: Coil-bound or comb-bound recommended for ease of use while working (user-dependent). Paper Type Paper Type For Print: Standard printer paper (8.5x11 inch or A4) suitable for printing. Engine Specifications Primary Engine Engine Type: Single-cylinder, Four-stroke (likely Rotax-derived, common for Aprilia in this era) Displacement: 650cc (approx.) Bore X Stroke: Not specified in product info, but typically available in FSMs. Example for a similar Rotax: 100mm x 83mm Cooling System: Liquid-cooled Valve Train: SOHC (Single Overhead Camshaft), 4 valves per cylinder (typical) Performance Horsepower Approx: 45-50 HP (Estimate, specific dyno figures vary) Torque Approx: 55-60 Nm (Estimate) Fuel System Fuel Delivery: Carburetor (likely, for 1997-1999 models). Specific carburetor model (e.g., Dell'Orto PHM 40) would be detailed in the manual. Ignition System: Electronic ignition, CDI (Capacitor Discharge Ignition) Lubrication System Oil Capacity: Approx. 2.0-2.5 Liters (specifics in manual), dry sump or wet sump variant. Transmission Standard Transmission Type: 5-speed manual sequential gearbox Optional Optional Transmission: N/A (Standard for this model) Features Clutch Type: Wet multi-plate clutch, hydraulically operated (common for Aprilia) Final Drive: Chain drive Dimensions Exterior Length Approx: Approx. 2100-2200 mm (Varies by Strada/Trail variant) Width Approx: Approx. 850-900 mm Height Approx: Approx. 1200-1300 mm (Seat height varies) Weights Dry Weight Approx: Approx. 170-180 kg Fuel Tank Capacity: Approx. 14-16 Liters Safety Features Ratings Safety Certification: CE marking (European Conformity) Active Features Braking System Front: Disc brake, dual piston caliper (typical) Braking System Rear: Disc brake, single piston caliper (typical) Passive Features Lighting: Halogen headlamp, LED/incandescent tail and indicator lights (typical for the era). Technology Features Infotainment Infotainment System: N/A (Basic motorcycle electronics for this era) Driver Assistance Driver Assistance Features: N/A (No electronic rider aids like ABS, traction control, etc.) Connectivity Connectivity Features: N/A Maintenance Service Intervals Oil Change Interval: Typically every 5,000-7,500 km or 6-12 months, refer to manual for exact specification. Valve Check Interval: Typically every 10,000-15,000 km, refer to manual for exact specification. Spark Plug Replacement: Typically every 10,000-15,000 km, refer to manual for exact specification. Fluid Specifications Engine Oil Type: API SG/SH or higher, SAE 10W-40 or 15W-50 (Specific API/JASO...
Step-by-step diagnostic procedures for common and uncommon issues across all systems, including fault code identification (if applicable to the electrical system).
Repair Overhaul:
Complete disassembly and reassembly instructions for all major components, including engine internals, transmission, suspension, and brakes.
Adjustments:
Carburetor synchronization and adjustment, valve clearance checks and adjustment, throttle cable adjustment, clutch cable adjustment.
Technical Depth
Depth:
Comprehensive, from basic service to complete engine rebuilds and advanced electrical diagnostics.
Detail Level:
Detailed substeps, notes, cautions, and warnings. Hundreds of photos and illustrations.
Manual Specifications
File Format
Digital Format:
Printable PDF (implied by description allowing printing in entirety or by page)
Print Quality
Printability:
High quality, suitable for printing individual pages or the entire manual.
Binding Type
Binding Type For Print:
Coil-bound or comb-bound recommended for ease of use while working (user-dependent).
Paper Type
Paper Type For Print:
Standard printer paper (8.5x11 inch or A4) suitable for printing.
Engine Specifications
Primary Engine
Engine Type:
Single-cylinder, Four-stroke (likely Rotax-derived, common for Aprilia in this era)
Displacement:
650cc (approx.)
Bore X Stroke:
Not specified in product info, but typically available in FSMs. Example for a similar Rotax: 100mm x 83mm
Cooling System:
Liquid-cooled
Valve Train:
SOHC (Single Overhead Camshaft), 4 valves per cylinder (typical)
Performance
Horsepower Approx:
45-50 HP (Estimate, specific dyno figures vary)
Torque Approx:
55-60 Nm (Estimate)
Fuel System
Fuel Delivery:
Carburetor (likely, for 1997-1999 models). Specific carburetor model (e.g., Dell'Orto PHM 40) would be detailed in the manual.
Approx. 2.0-2.5 Liters (specifics in manual), dry sump or wet sump variant.
Transmission
Standard
Transmission Type:
5-speed manual sequential gearbox
Optional
Optional Transmission:
N/A (Standard for this model)
Features
Clutch Type:
Wet multi-plate clutch, hydraulically operated (common for Aprilia)
Final Drive:
Chain drive
Dimensions
Exterior
Length Approx:
Approx. 2100-2200 mm (Varies by Strada/Trail variant)
Width Approx:
Approx. 850-900 mm
Height Approx:
Approx. 1200-1300 mm (Seat height varies)
Weights
Dry Weight Approx:
Approx. 170-180 kg
Fuel Tank Capacity:
Approx. 14-16 Liters
Safety Features
Ratings
Safety Certification:
CE marking (European Conformity)
Active Features
Braking System Front:
Disc brake, dual piston caliper (typical)
Braking System Rear:
Disc brake, single piston caliper (typical)
Passive Features
Lighting:
Halogen headlamp, LED/incandescent tail and indicator lights (typical for the era).
Technology Features
Infotainment
Infotainment System:
N/A (Basic motorcycle electronics for this era)
Driver Assistance
Driver Assistance Features:
N/A (No electronic rider aids like ABS, traction control, etc.)
Connectivity
Connectivity Features:
N/A
Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000-7,500 km or 6-12 months, refer to manual for exact specification.
Valve Check Interval:
Typically every 10,000-15,000 km, refer to manual for exact specification.
Spark Plug Replacement:
Typically every 10,000-15,000 km, refer to manual for exact specification.
Fluid Specifications
Engine Oil Type:
API SG/SH or higher, SAE 10W-40 or 15W-50 (Specific API/JASO rating and viscosity grade will be in the manual).
Coolant Type:
Ethylene glycol based antifreeze, 50/50 mix with distilled water (Specify brand/type if available in manual, e.g., Motul Motocool Factory Line).
Brake Fluid Type:
DOT 4 or DOT 5.1 (Refer to manual for exact specification).
Transmission Oil Type:
Specific gear oil (e.g., SAE 75W-90 or similar) or engine oil depending on design, capacity to be verified in manual.
Known Issues
Common Wear Items:
Clutch wear, fork seal leaks, carburetor jetting sensitivity, electrical connector corrosion, regulator/rectifier failure (common in many bikes of this era).
Maintenance Tips:
Regular chain lubrication and adjustment, thorough cleaning of the air filter, checking all electrical connections, ensuring cooling system is properly bled.
Vehicle History
Brand Heritage
Manufacturer:
Aprilia is an Italian motorcycle manufacturer with a strong heritage in racing and performance motorcycles.
Model Evolution
Pegaso Lineage:
The Pegaso line started in the early 1990s, evolving into the 650cc model. This generation is known for its versatile on/off-road capability. Variants like Strada (road-focused) and Trail (more off-road oriented) exist.
Production
Production Period:
1997-1999 for this specific manual coverage. The Pegaso model line continued with updates and different engine configurations beyond this period.
Awards & Recognition
Recognitions
Awards Received:
Specific awards for the 1997-1999 Pegaso 650 are not readily available in general product information, but the model was recognized for its versatility and adventure-touring capabilities.