1997 Aprilia Pegaso 650 Motorcycle Service Repair Manual
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Basic Information Identification Make: Aprilia Model: Pegaso 650 Year: 1997 Vehicle Type: Motorcycle Codes Engine Code: Rotax 654 Chassis Code: AP8100000 Introduction Market Position Segment: Lightweight adventure touring motorcycle Target Audience: Riders seeking versatility for commuting and light off-road excursions Competitive Analysis Competitors: BMW F650, Kawasaki KLR650, Suzuki DR650 Key Features Unique Selling Points: Italian design flair, Rotax engine reliability, dual-sport capability Manual Value Proposition: Empowers owners to perform maintenance and repairs, saving money and increasing understanding of their motorcycle. Manual Details Coverage Areas Primary Coverage: Complete Service and Repair Diagnostic Coverage: Detailed diagnostic procedures Maintenance Coverage: Scheduled maintenance, fluid changes, adjustments Disassembly Reassembly Coverage: Step-by-step guides for component removal and installation Page Count Total Pages: 311 Manual Type Type: Service Repair Manual Professional Equivalent: Workshop Manual used by Aprilia Repair Shops Language Language: English Format File Format: PDF Compatibility: Windows/Mac Manual Coverage Systems Covered Engine: Complete engine overhaul, performance tuning, fuel system, ignition system, cooling system, lubrication system Transmission: Clutch, gearbox, drive chain maintenance and adjustment Chassis: Frame, suspension (front and rear), steering, wheels, tires Brakes: Hydraulic brake systems (front and rear), brake caliper service, master cylinder service, brake fluid replacement Electrical System: Battery, charging system (alternator, rectifier/regulator), lighting, ignition system components, starter motor, wiring diagrams, troubleshooting electrical faults Bodywork: Fairings, body panels, seat, fuel tank removal and installation, minor cosmetic repairs Cooling System: Radiator, coolant, thermostat, fan operation Fuel System: Carburetor tuning and servicing, fuel pump, fuel lines Procedures Included Maintenance: Oil changes, filter replacements, chain adjustments, spark plug checks, coolant flushes, brake fluid changes, air filter cleaning/replacement Troubleshooting: Step-by-step guides for identifying and resolving common mechanical and electrical issues Repair: Detailed instructions for component repair and replacement Rebuilds: Comprehensive procedures for engine and transmission rebuilds Adjustments: Carburetor synchronization, valve clearance adjustments, chain slack adjustment, brake lever adjustment Special Tools: Identification and usage of specialized tools required for certain procedures Technical Depth Depth: Full technical specifications, torque values, tolerances, and diagnostic data Diagrams: Extensive use of diagrams, illustrations, and exploded views for clarity Skill Level: Suitable for DIY enthusiasts and professional mechanics alike, with easy-to-follow instructions Manual Specifications File Format Quality: High-resolution PDF, enabling clear viewing and printing Searchability: Likely searchable text content for quick information retrieval Print Quality Printability: All pages are printable, allowing for convenient use in a workshop environment Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) Engine Specifications Primary Engine Type: Four-stroke, single-cylinder, liquid-cooled Displacement: 652 cc Bore X Stroke: 100 mm x 83.2 mm Compression Ratio: 9.0:1 Valve Train: SOHC, 4 valves Performance Horsepower: Approx. 48 HP @ 6,000 RPM (Varies by region/market) Torque: Approx. 57 Nm @ 4,500 RPM (Varies by region/market) Fuel System Carburetor: Mikuni BSR32 (or similar, depending on market variant) Fuel Capacity: 12 Liters (approx. 3.2 US Gallons) Lubrication System Oil Type: API SG or higher, SAE 10W-40 motorcycle oil recommended (refer to manual for exact specifications) Cooling System Coolant Type: Ethylene glycol-based coolant with corrosion inhibitors (refer to manual for specific blend) Transmission Standard Type: 5-speed manual constant mesh Features Clutch: Wet multi-plate, cable-operated Final Drive: O-ring sealed chain, 520 pitch Dimensions Exterior Length: Approx. 2150 mm Width: Approx. 810 mm Height: Approx. 1360 mm (to top of windshield) Weights Dry Weight: Approx. 170 kg Wet Weight: Approx. 185 kg (with fluids) Wheels Tires Front Wheel Size: 19 inch Rear Wheel Size: 17 inch Front Tire Size: 100/90-19 Rear Tire Size: 130/80-17 Safety Features Ratings Crash Test Data: N/A (Motorcycles typically do not have standardized crash test ratings like cars) Active Features Braking System: Front: Single disc (298 mm) with 2-piston caliper; Rear: Single disc (240 mm) with 1-piston caliper Suspension Travel Front: Approx. 170 mm Suspension Travel Rear: Approx. 150 mm Technology Features Infotainment Dashboard: Analog speedometer, tachometer, odometer, trip meter, and essential indicator lights. Driver Assistance ABS: Optional ABS may have been available on some models, but is not standard on this 1997 version. Connectivity Bluetooth Usb: N/A (No modern connectivity features) Maintenance Service Intervals Engine Oil Change: Every 6,000 km or 12 months (refer to manual for specific mileage recommendations) Oil Filter Replacement: Every 6,000 km or 12 months (concurrent with oil change) Air Filter Cleaning: Every 6,000 km or 12 months, inspect and clean/replace as needed Spark Plug Check: Every 6,000 km or 12 months Chain Lubrication Adjustment: Every 1,000 km or as needed, especially after riding in wet conditions Valve Clearance Check: Every 12,000 km or 24 months (critical for engine health) Fluid Specifications Brake Fluid: DOT 4 (refer to manual for specific formulation and bleeding procedures) Coolant: 50/50 mix of ethylene glycol antifreeze and distilled water (refer to manual for specific ratios and types) Known Issues Common Wear Items: Clutch plates, swingarm bearings, fork seals, and chain/sprockets are common wear items requiring regular inspection and replacement. Electrical...
Identification and usage of specialized tools required for certain procedures
Technical Depth
Depth:
Full technical specifications, torque values, tolerances, and diagnostic data
Diagrams:
Extensive use of diagrams, illustrations, and exploded views for clarity
Skill Level:
Suitable for DIY enthusiasts and professional mechanics alike, with easy-to-follow instructions
Manual Specifications
File Format
Quality:
High-resolution PDF, enabling clear viewing and printing
Searchability:
Likely searchable text content for quick information retrieval
Print Quality
Printability:
All pages are printable, allowing for convenient use in a workshop environment
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
Engine Specifications
Primary Engine
Type:
Four-stroke, single-cylinder, liquid-cooled
Displacement:
652 cc
Bore X Stroke:
100 mm x 83.2 mm
Compression Ratio:
9.0:1
Valve Train:
SOHC, 4 valves
Performance
Horsepower:
Approx. 48 HP @ 6,000 RPM (Varies by region/market)
Torque:
Approx. 57 Nm @ 4,500 RPM (Varies by region/market)
Fuel System
Carburetor:
Mikuni BSR32 (or similar, depending on market variant)
Fuel Capacity:
12 Liters (approx. 3.2 US Gallons)
Lubrication System
Oil Type:
API SG or higher, SAE 10W-40 motorcycle oil recommended (refer to manual for exact specifications)
Cooling System
Coolant Type:
Ethylene glycol-based coolant with corrosion inhibitors (refer to manual for specific blend)
Transmission
Standard
Type:
5-speed manual constant mesh
Features
Clutch:
Wet multi-plate, cable-operated
Final Drive:
O-ring sealed chain, 520 pitch
Dimensions
Exterior
Length:
Approx. 2150 mm
Width:
Approx. 810 mm
Height:
Approx. 1360 mm (to top of windshield)
Weights
Dry Weight:
Approx. 170 kg
Wet Weight:
Approx. 185 kg (with fluids)
Wheels Tires
Front Wheel Size:
19 inch
Rear Wheel Size:
17 inch
Front Tire Size:
100/90-19
Rear Tire Size:
130/80-17
Safety Features
Ratings
Crash Test Data:
N/A (Motorcycles typically do not have standardized crash test ratings like cars)
Active Features
Braking System:
Front: Single disc (298 mm) with 2-piston caliper; Rear: Single disc (240 mm) with 1-piston caliper
Suspension Travel Front:
Approx. 170 mm
Suspension Travel Rear:
Approx. 150 mm
Technology Features
Infotainment
Dashboard:
Analog speedometer, tachometer, odometer, trip meter, and essential indicator lights.
Driver Assistance
ABS:
Optional ABS may have been available on some models, but is not standard on this 1997 version.
Connectivity
Bluetooth Usb:
N/A (No modern connectivity features)
Maintenance
Service Intervals
Engine Oil Change:
Every 6,000 km or 12 months (refer to manual for specific mileage recommendations)
Oil Filter Replacement:
Every 6,000 km or 12 months (concurrent with oil change)
Air Filter Cleaning:
Every 6,000 km or 12 months, inspect and clean/replace as needed
Spark Plug Check:
Every 6,000 km or 12 months
Chain Lubrication Adjustment:
Every 1,000 km or as needed, especially after riding in wet conditions
Valve Clearance Check:
Every 12,000 km or 24 months (critical for engine health)
Fluid Specifications
Brake Fluid:
DOT 4 (refer to manual for specific formulation and bleeding procedures)
Coolant:
50/50 mix of ethylene glycol antifreeze and distilled water (refer to manual for specific ratios and types)
Known Issues
Common Wear Items:
Clutch plates, swingarm bearings, fork seals, and chain/sprockets are common wear items requiring regular inspection and replacement.
Electrical Connections:
Corrosion or loose connections in the electrical system can lead to intermittent issues, requiring attention during maintenance.
Carburetor Tuning:
The carburetor may require periodic synchronization and cleaning to maintain optimal performance, especially with age and variable fuel quality.
Vehicle History
Brand Heritage
Manufacturer:
Aprilia is an Italian manufacturer of motorcycles and scooters, known for its performance-oriented and stylish designs.
Model Evolution
Lineage:
The Pegaso 650 was Aprilia's entry into the popular dual-sport motorcycle segment, leveraging the robust Rotax engine platform.
Production
Production Period:
The Pegaso 650 was produced through multiple iterations from the early 1990s into the 2000s.
Engine Source:
The 650cc engine was sourced from Austrian manufacturer Rotax (a division of Bombardier Recreational Products).
Awards & Recognition
Recognitions
Industry Acclaim:
While specific awards for this model year are not widely documented, the Aprilia Pegaso line has been generally well-regarded for its blend of performance, comfort, and style in the dual-sport category.
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