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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...
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Aprilia Pegaso 650 1999 Service Repair Workshop Manual
🏷️ 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 the early 1990s through the early 2000s.
Engine Source:
The 650cc engine for Aprilia was often sourced from Rotax (Bombardier Recreational Products).
🏆 Awards & Recognition
Recognitions
Type:
N/A (Specific awards not readily documented for this model year)
Ratings
Owner Satisfaction:
Generally well-regarded for its versatility and torque, often praised for its ruggedness.
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