Aprilia Pegaso 650 1997 Full Service Repair Manual
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🏷️ Basic Information Identification Make: Aprilia Model: Pegaso 650 Year: 1997 Codes Chassis Code: AP8104800 👋 Introduction Market Position Market Segment: Adventure Touring / Dual-Sport Motorcycle Competitive Analysis Key Competitors: BMW F650, Honda Transalp, Kawasaki KLR650, Suzuki DR650 Key Features Motorcycle Characteristics: Versatile, capable on-road and light off-road, comfortable for touring, reliable single-cylinder engine. Value Proposition Manual Benefit: Empowers owners and technicians to perform all necessary maintenance and repairs, reducing reliance on expensive dealerships and ensuring longevity. 📋 Manual Details Coverage Areas Market Coverage: Global (English Language Edition) Page Count Page Count: Detailed (Specific count not provided in product info, but described as 'very detailed') Manual Type Manual Type: Full Service Repair Manual Language Language: English Format Format: Digital (likely PDF, as typical for this type of product) 📖 Manual Coverage Systems Covered Engine Systems: Engine disassembly, assembly, tuning, troubleshooting, component identification, lubrication system, cooling system, fuel system (carburetor), ignition system, exhaust system. Transmission Systems: Gearbox internals, clutch operation, shift mechanism, maintenance, repair, fluid specifications. Chassis And Suspension: Front forks (telescopic), rear shock absorber, swingarm, bearings, linkage, maintenance, adjustment, troubleshooting. Braking Systems: Front and rear disc brakes, hydraulic system, caliper maintenance, pad replacement, fluid specifications, bleeding procedures. Electrical Systems: Wiring diagrams, lighting, ignition switch, starter system, charging system (alternator, regulator/rectifier), battery maintenance, fuses, relays, instrument panel. Bodywork And Frame: Frame inspection, fairing removal and installation, seat maintenance, fuel tank service, body panel repair and replacement. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment and lubrication, spark plug inspection/replacement, air filter cleaning/replacement, brake pad inspection. Troubleshooting Guides: Diagnostic procedures for common starting, running, and electrical issues, symptom-based troubleshooting. Rebuilding Procedures: Detailed instructions for engine component rebuilds, carburetor overhaul, suspension fork rebuild. Technical Adjustments: Carburetor jetting and synchronization, valve clearance adjustment, chain slack, steering head bearing adjustment. Technical Depth Depth Of Coverage: Comprehensive: Covers basic to advanced repair, including full engine teardown and rebuild, electrical system diagnostics, and chassis overhauls. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: High-resolution scans suitable for clear printing and digital viewing. Binding Type Binding Type: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: Single-Cylinder, Four-Stroke, Liquid-Cooled Displacement: 652 cc (652 cubic centimeters) Bore X Stroke: 100 mm x 82 mm (approximate) Compression Ratio: 9.1:1 (typical for this model) Valvetrain: SOHC, 4 Valves per cylinder Performance Horsepower: Approx. 48-50 HP @ 6,500 RPM (peak, varies slightly by market/tuning) Torque: Approx. 56 Nm (41.3 lb-ft) @ 5,500 RPM (peak, varies slightly) Fuel System Carburetor Type: Mikuni BSR42 (or similar 42mm constant velocity carburetor) Fuel Type: Unleaded Gasoline (Octane Rating 90 or higher recommended) Lubrication System Oil Type: SAE 10W-40, API SG or higher, JASO MA certified motorcycle oil recommended. Oil Capacity Oil Capacity With Filter Change: Approximately 2.3 - 2.5 Liters (check manual for exact specification) 🔧 Transmission Standard Transmission Type: 5-Speed Manual Synchromesh Features Clutch Type: Wet, Multi-plate Final Drive: O-Ring Sealed Chain Drive Fluid Specification Transmission Oil Type: API GL-4 or GL-5 Gear Oil, SAE 80W/90 recommended. 📐 Dimensions Exterior Length: Approx. 2,180 mm Width: Approx. 840 mm (at handlebars) Height: Approx. 1,380 mm (at windshield) Wheelbase: Approx. 1,470 mm Weights Dry Weight: Approx. 170 kg Wet Weight: Approx. 185 kg (fully fueled and ready to ride) Tires Front Tire Size: 90/90-21 M/C 54S Rear Tire Size: 130/80-17 M/C 65S Wheels Wheel Type: Spoked Wheels Fuel Capacity Fuel Tank Capacity: 24 Liters (including reserve) 🛡️ Safety Features Ratings Safety Standards: Meets all relevant European (EC) and US (EPA/DOT where applicable) safety and emissions standards for its model year. Active Features Braking System: Dual Disc Front Brake, Single Disc Rear Brake. ABS was not a standard feature on the 1997 model, but may have been an option on some variants. Passive Features Lighting System: Halogen Headlight, LED Taillight, Indicator Lights. 💡 Technology Features Infotainment Instrument Cluster: Analog speedometer and tachometer, fuel gauge, coolant temperature warning light, oil pressure warning light, turn signal indicators, high beam indicator. Driver Assistance ABS: Optional on some models, not standard on the 1997 model. Connectivity Charging System: 12V Electrical System, Alternator with Regulator/Rectifier. 🔧 Maintenance Service Intervals Oil Change Interval: Every 6,000 km (3,700 miles) or annually, whichever comes first. Valve Clearance Check: Every 12,000 km (7,500 miles) or as specified in the manual for first checks. Chain Maintenance: Lubricate and adjust chain every 1,000 km (600 miles) or after riding in wet conditions. Spark Plug Replacement: Inspect every 6,000 km (3,700 miles), replace as needed. Fluid Specifications Brake Fluid Type: DOT 4 Coolant Type: Ethylene Glycol based antifreeze/coolant mixture (50/50 with distilled water recommended). Known Issues Common Wear Items: Clutch plates, chain and sprockets, wheel bearings, fork seals, regulator/rectifier. Carburetor Tuning: Can be sensitive to altitude and temperature changes, requiring occasional re-jetting or adjustment for optimal...
Mikuni BSR42 (or similar 42mm constant velocity carburetor)
Fuel Type:
Unleaded Gasoline (Octane Rating 90 or higher recommended)
Lubrication System
Oil Type:
SAE 10W-40, API SG or higher, JASO MA certified motorcycle oil recommended.
Oil Capacity
Oil Capacity With Filter Change:
Approximately 2.3 - 2.5 Liters (check manual for exact specification)
🔧 Transmission
Standard
Transmission Type:
5-Speed Manual Synchromesh
Features
Clutch Type:
Wet, Multi-plate
Final Drive:
O-Ring Sealed Chain Drive
Fluid Specification
Transmission Oil Type:
API GL-4 or GL-5 Gear Oil, SAE 80W/90 recommended.
📐 Dimensions
Exterior
Length:
Approx. 2,180 mm
Width:
Approx. 840 mm (at handlebars)
Height:
Approx. 1,380 mm (at windshield)
Wheelbase:
Approx. 1,470 mm
Weights
Dry Weight:
Approx. 170 kg
Wet Weight:
Approx. 185 kg (fully fueled and ready to ride)
Tires
Front Tire Size:
90/90-21 M/C 54S
Rear Tire Size:
130/80-17 M/C 65S
Wheels
Wheel Type:
Spoked Wheels
Fuel Capacity
Fuel Tank Capacity:
24 Liters (including reserve)
🛡️ Safety Features
Ratings
Safety Standards:
Meets all relevant European (EC) and US (EPA/DOT where applicable) safety and emissions standards for its model year.
Active Features
Braking System:
Dual Disc Front Brake, Single Disc Rear Brake. ABS was not a standard feature on the 1997 model, but may have been an option on some variants.
Passive Features
Lighting System:
Halogen Headlight, LED Taillight, Indicator Lights.
💡 Technology Features
Infotainment
Instrument Cluster:
Analog speedometer and tachometer, fuel gauge, coolant temperature warning light, oil pressure warning light, turn signal indicators, high beam indicator.
Driver Assistance
ABS:
Optional on some models, not standard on the 1997 model.
Connectivity
Charging System:
12V Electrical System, Alternator with Regulator/Rectifier.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 6,000 km (3,700 miles) or annually, whichever comes first.
Valve Clearance Check:
Every 12,000 km (7,500 miles) or as specified in the manual for first checks.
Chain Maintenance:
Lubricate and adjust chain every 1,000 km (600 miles) or after riding in wet conditions.
Spark Plug Replacement:
Inspect every 6,000 km (3,700 miles), replace as needed.
Fluid Specifications
Brake Fluid Type:
DOT 4
Coolant Type:
Ethylene Glycol based antifreeze/coolant mixture (50/50 with distilled water recommended).
Known Issues
Common Wear Items:
Clutch plates, chain and sprockets, wheel bearings, fork seals, regulator/rectifier.
Carburetor Tuning:
Can be sensitive to altitude and temperature changes, requiring occasional re-jetting or adjustment for optimal performance.
Electrical Connections:
Corrosion on connectors, particularly around the regulator/rectifier and stator, can lead to charging issues.
📚 Vehicle History
Brand Heritage
Aprilia Legacy:
Aprilia is an Italian motorcycle manufacturer with a strong history in racing and performance-oriented street bikes, known for innovative engineering.
Model Evolution
Pegaso Lineage:
The Pegaso line was Aprilia's entry into the adventure/dual-sport market, offering versatility and a distinctive Italian style. The 650 was a popular model that underwent several updates over its production life.
Production
Manufacturing Origin:
Italy
Production Years
Model Production Span:
The Pegaso 650 was produced from the early 1990s through the early 2000s, with various engine updates and revisions.
🏆 Awards & Recognition
Recognitions
Market Reception:
Generally well-regarded for its versatility and value, often praised for its comfortable riding position and good fuel range. It established Aprilia as a contender in the adventure-touring segment.