Aprilia Pegaso 650 1999 Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: Aprilia Model: Pegaso 650 Year: 1999 Type: Motorcycle Codes Chassis Code: RL 👋 Introduction Market Position Segment: Adventure Touring / Dual-Sport Motorcycle Target Audience: Owners and independent repair shops seeking detailed service information. Competitive Analysis Competitors 1999: BMW F650 Funduro, Honda Transalp, Kawasaki KLR650 Key Features Vehicle Emphasis: Versatility for both on-road and light off-road use. Manual Emphasis: Factory-level repair and maintenance procedures for DIY and professional use. 📋 Manual Details Coverage Areas Primary Coverage: Service, Repair, Maintenance Secondary Coverage: Troubleshooting, Diagnostics Page Count Estimated Pages: Comprehensive (exact count not specified, typical for workshop manuals) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: Digital (likely PDF, common for online sales) 📖 Manual Coverage Systems Covered Engine: Complete overhaul, top-end, bottom-end, timing, cooling, lubrication Fuel System: Carburetor (Mikuni BSR32/33), fuel pump, lines, filter, diagnostics Transmission: Clutch, gearbox, shifting mechanism, lubrication, troubleshooting Chassis: Frame inspection, swingarm, bearings, steering head Suspension: Front forks (Marzocchi M45 or similar), rear shock absorber, adjustments, seals, oil change Brakes: Front (Brembo twin-piston caliper), rear (Brembo single-piston caliper), hydraulic system, bleeding, pad replacement, disc inspection Electrical System: Ignition system, stator, rotor, battery, starter motor, lighting, wiring diagrams, fuse box, ECU diagnostics Exhaust System: Muffler, header pipes, gaskets, inspection Bodywork: Fairings, seat, fuel tank, mudguards, panel removal and installation Wheels Tires: Spoke wheel maintenance, tire pressure, rotation, balancing Procedures Included Preventative Maintenance: Oil changes, filter replacement, chain adjustment, spark plug checks, brake fluid flush Troubleshooting: Fault diagnosis for starting issues, engine performance, electrical faults, braking problems Repair: Engine rebuilding, transmission overhaul, suspension fork service, brake caliper rebuilding Adjustments: Carburetor idle speed and mixture, clutch cable, throttle cable, suspension preload Diagnostics: Electrical system checks, ignition timing verification, fuel delivery testing Technical Depth Depth: Comprehensive, covering routine maintenance to complete engine and chassis overhauls 📊 Manual Specifications File Format Format Details: Likely PDF, optimized for digital viewing and printing. Searchable text functionality is common. Print Quality Quality: High resolution for clear diagrams and text. Professional layout. Binding Type Type: N/A (Digital Format) Paper Type Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Configuration: Single-cylinder, four-stroke Displacement: 652 cc Bore X Stroke: 100 mm x 82 mm Compression Ratio: 9.1:1 (approximate, may vary by market spec) Valve Train: SOHC, 4 valves per cylinder Cooling System: Liquid-cooled Performance Horsepower: Approx. 48-50 HP @ 6,500 RPM Torque: Approx. 58 Nm (43 lb-ft) @ 5,000 RPM Fuel System Carburetor Model: Mikuni BSR32/33 (specific model may vary slightly) Fuel Type: Unleaded gasoline (minimum 95 RON recommended) Engine Oil Capacity: Approx. 2.0 - 2.2 Liters (with filter change) Specification: API SG or higher, SAE 10W-40 or 15W-50 (depending on climate) 🔧 Transmission Standard Type: 5-speed manual sequential gearbox Optional Type: N/A Features Clutch: Wet multi-plate clutch, hydraulically operated Transmission Oil Capacity: Approx. 0.9 Liters Specification: API GL-4 or GL-5 gear oil (e.g., SAE 75W-90) 📐 Dimensions Exterior Length: Approx. 2200 mm Width: Approx. 850 mm Height: Approx. 1340 mm Wheels Tires Front Tire Size: 90/90-21 Rear Tire Size: 130/80-17 Weights Dry Weight: Approx. 173 kg Wet Weight: Approx. 190 kg (fully fueled) 🛡️ Safety Features Ratings Type: N/A (Motorcycle safety ratings differ from cars) Active Features Braking: Hydraulic disc brakes front and rear. Lighting: Halogen headlight, taillight, turn signals. Passive Features Chassis Design: Steel trellis frame providing rigidity. Ergonomics: Upright riding position for rider comfort and control. 💡 Technology Features Infotainment System: N/A (Basic motorcycle instrumentation) Features: Analog speedometer, tachometer, odometer, trip meter, indicator lights. Driver Assistance Features: N/A (No electronic rider aids like ABS or traction control on base models of this year) 🔧 Maintenance Service Intervals Oil Change: Every 6,000 km or 6 months, whichever comes first. Air Filter Cleaning: Every 6,000 km. Spark Plug Check: Every 12,000 km. Valve Clearance Check: Every 12,000 km. Brake Fluid Flush: Every 24,000 km or 2 years. Fluid Specifications Coolant Type: Ethylene glycol-based antifreeze, 50% solution with distilled water. Fork Oil Type: SAE 7.5W or 10W (refer to manual for exact grade based on suspension model) Fork Oil Quantity: Approx. 400-450 ml per fork leg (refer to manual) Known Issues Cam Chain Tensioner: Some models may experience wear in the automatic cam chain tensioner, leading to rattling noise. Manual covers inspection and replacement. Carburetor Icing: Under certain cold and humid conditions, carburetors can experience icing. Manual offers diagnostic and adjustment guidance. Wiring Loom Wear: As with many bikes of this era, inspection of the wiring loom for chafing or corrosion is recommended. Manual provides diagrams. 📚 Vehicle History Brand Heritage Aprilia Origin: Italian manufacturer known for performance motorcycles, particularly in racing. Model Evolution Pegaso Lineage: The Pegaso line has a history of single-cylinder engines, evolving from smaller displacements to the 650cc Rotax-derived unit in this era. Production Production Period: The 650 Pegaso was produced in various iterations from...