Aprilia Pegaso 655 1998 Full Service Repair Manual
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🏷️ Basic Information Identification Make: Aprilia Model: Pegaso 655 Year: 1998 Codes Engine Code: Likely Rotax 654cc Single-Cylinder (common for this era Pegaso) Chassis Code: RL (common for Aprilia dual-sport models) 👋 Introduction Market Position Description: The Aprilia Pegaso 655 was positioned as a versatile dual-sport motorcycle, blending on-road civility with off-road capability. It appealed to riders seeking a practical and engaging machine for commuting, touring, and light off-road excursions. Competitive Analysis Competitors: Competed with other single-cylinder dual-sport bikes of the era, such as certain Yamaha XT models, Suzuki DR models, and potentially some KTM models. Its Italian heritage and styling set it apart. Key Features Features: Robust single-cylinder engine, long-travel suspension, upright riding position, capable chassis for mixed terrain use. Manual Value Proposition Value: Provides professional-level repair and maintenance information, empowering owners to maintain their '98 Pegaso 655 effectively, reducing reliance on potentially scarce specialized technicians. 📋 Manual Details Coverage Areas Primary Coverage: Aprilia Pegaso 655 (1998 Model Year) Page Count Estimated Page Count: Variable, but comprehensive manuals typically range from 300-600+ pages. Manual Type Type: Full Service Repair Manual Language Language: English Format Digital Format: PDF Delivery Method: Instant Download Print Capability: Full Printable Requirements Software Requirements: Adobe PDF Reader, WinRAR Operating System Compatibility: All Versions of Windows & Mac 📖 Manual Coverage Systems Covered Engine System: Complete overhaul, top-end (cylinder head, valves), bottom-end (crankshaft, connecting rod, pistons), lubrication system, cooling system. Fuel System: Carburetor (likely Dell'Orto PHM 40), fuel tank, fuel lines, fuel pump, fuel filter replacement and cleaning. Transmission System: Gearbox overhaul, clutch assembly (operation, adjustment, replacement), shifting mechanism, transmission oil change and specifications. Electrical System: Wiring diagrams, ignition system (coil, CDI, spark plug), starting system (starter motor, battery), charging system (alternator, regulator/rectifier), lighting, instrumentation, fuses, relays. Braking System: Front and rear brake caliper service, master cylinder overhaul, brake pad replacement, brake line bleeding, brake fluid specifications and replacement intervals. Suspension System: Front forks (oil change, seal replacement, spring replacement), rear shock absorber servicing or replacement, linkage lubrication and adjustment. Wheel And Tire System: Wheel bearing replacement, tire mounting and balancing, recommended tire pressures, wheel specifications. Exhaust System: Exhaust pipe and muffler inspection, gasket replacement, clamp tightening. Bodywork And Frame: Fairing removal and installation, seat, fuel tank mounting, frame inspection, body panel alignment. Diagnostic Systems: Troubleshooting guides, common issues, fault finding procedures, electrical system diagnostics. Procedures Included Maintenance Procedures: Scheduled maintenance, oil and filter changes, air filter cleaning/replacement, spark plug inspection/replacement, chain adjustment, brake fluid flush. Repair Procedures: Step-by-step instructions for all major components, including engine rebuilds, carburetor tuning, suspension overhauls, electrical component replacement. Troubleshooting Procedures: Systematic approach to identifying and resolving mechanical and electrical problems, including common symptoms and their causes. Diagnostic Procedures: Electrical diagnostics with wiring diagrams, component testing, troubleshooting flowcharts. Refurbishment Restoration: Guidance for bringing a used motorcycle back to excellent working order, including parts identification and assembly. Technical Depth Depth: Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds. Suitable for professional technicians and experienced DIY mechanics. 📊 Manual Specifications File Format Format: PDF Searchability: Likely searchable text within the PDF for quick information retrieval. Print Quality Printability: All pages printable. Binding Type Binding: Not applicable (Digital PDF) Paper Type Paper Type: Not applicable (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder, OHC, 4-valve Displacement: 654 cc (approximate) Bore X Stroke: Likely around 100 mm x 84 mm (typical for Rotax 654) Cooling System: Liquid-cooled Compression Ratio: Likely in the range of 9.5:1 to 10.5:1 Performance Horsepower: Approximately 45-50 HP (at ~6500 rpm) Torque: Approximately 50-55 Nm (at ~5000 rpm) Fuel System Carburetor Type: Single Dell'Orto PHM 40 (or similar) Fuel Type: Unleaded gasoline (minimum 95 RON) Lubrication System Oil Type: Motorcycle-specific 4-stroke engine oil, likely SAE 10W-40 or 20W-50, meeting API SG or higher and JASO MA specifications. Oil Capacity: Approximately 2.0 - 2.5 liters (check manual for exact capacity with filter change). 🔧 Transmission Standard Type: 5-speed constant mesh Clutch Type: Wet multi-plate Optional Optional Transmission: N/A (Single configuration for this model) Features Final Drive: Chain drive Transmission Oil Type: Motorcycle-specific gear oil, e.g., SAE 75W-90 or 80W-90, API GL-4. 📐 Dimensions Exterior Length: Varies by specific configuration, typically around 2200 mm Width: Varies by specific configuration, typically around 850 mm Height: Varies by specific configuration, typically around 1350 mm Wheelbase: Approximately 1480 mm Weights Dry Weight: Approximately 165-175 kg Gross Vehicle Weight Rating: Not typically specified for motorcycles in this manner, but rider + luggage capacity is a consideration. Fuel Tank Capacity: Approximately 18 liters 🛡️ Safety Features Ratings Safety Ratings: Motorcycles are not typically assigned NCAP-style safety ratings. Focus is on rider protection through vehicle design and rider awareness. Active Features Braking System: Hydraulic disc brakes front and rear for strong stopping power. Suspension Compliance: Long-travel suspension provides stability and control over...
Likely Rotax 654cc Single-Cylinder (common for this era Pegaso)
Chassis Code:
RL (common for Aprilia dual-sport models)
👋 Introduction
Market Position
Description:
The Aprilia Pegaso 655 was positioned as a versatile dual-sport motorcycle, blending on-road civility with off-road capability. It appealed to riders seeking a practical and engaging machine for commuting, touring, and light off-road excursions.
Competitive Analysis
Competitors:
Competed with other single-cylinder dual-sport bikes of the era, such as certain Yamaha XT models, Suzuki DR models, and potentially some KTM models. Its Italian heritage and styling set it apart.
Wiring diagrams, ignition system (coil, CDI, spark plug), starting system (starter motor, battery), charging system (alternator, regulator/rectifier), lighting, instrumentation, fuses, relays.
Braking System:
Front and rear brake caliper service, master cylinder overhaul, brake pad replacement, brake line bleeding, brake fluid specifications and replacement intervals.
Suspension System:
Front forks (oil change, seal replacement, spring replacement), rear shock absorber servicing or replacement, linkage lubrication and adjustment.
Exhaust pipe and muffler inspection, gasket replacement, clamp tightening.
Bodywork And Frame:
Fairing removal and installation, seat, fuel tank mounting, frame inspection, body panel alignment.
Diagnostic Systems:
Troubleshooting guides, common issues, fault finding procedures, electrical system diagnostics.
Procedures Included
Maintenance Procedures:
Scheduled maintenance, oil and filter changes, air filter cleaning/replacement, spark plug inspection/replacement, chain adjustment, brake fluid flush.
Repair Procedures:
Step-by-step instructions for all major components, including engine rebuilds, carburetor tuning, suspension overhauls, electrical component replacement.
Troubleshooting Procedures:
Systematic approach to identifying and resolving mechanical and electrical problems, including common symptoms and their causes.
Diagnostic Procedures:
Electrical diagnostics with wiring diagrams, component testing, troubleshooting flowcharts.
Refurbishment Restoration:
Guidance for bringing a used motorcycle back to excellent working order, including parts identification and assembly.
Technical Depth
Depth:
Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds. Suitable for professional technicians and experienced DIY mechanics.
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Likely searchable text within the PDF for quick information retrieval.
Print Quality
Printability:
All pages printable.
Binding Type
Binding:
Not applicable (Digital PDF)
Paper Type
Paper Type:
Not applicable (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, single-cylinder, OHC, 4-valve
Displacement:
654 cc (approximate)
Bore X Stroke:
Likely around 100 mm x 84 mm (typical for Rotax 654)
Cooling System:
Liquid-cooled
Compression Ratio:
Likely in the range of 9.5:1 to 10.5:1
Performance
Horsepower:
Approximately 45-50 HP (at ~6500 rpm)
Torque:
Approximately 50-55 Nm (at ~5000 rpm)
Fuel System
Carburetor Type:
Single Dell'Orto PHM 40 (or similar)
Fuel Type:
Unleaded gasoline (minimum 95 RON)
Lubrication System
Oil Type:
Motorcycle-specific 4-stroke engine oil, likely SAE 10W-40 or 20W-50, meeting API SG or higher and JASO MA specifications.
Oil Capacity:
Approximately 2.0 - 2.5 liters (check manual for exact capacity with filter change).
🔧 Transmission
Standard
Type:
5-speed constant mesh
Clutch Type:
Wet multi-plate
Optional
Optional Transmission:
N/A (Single configuration for this model)
Features
Final Drive:
Chain drive
Transmission Oil Type:
Motorcycle-specific gear oil, e.g., SAE 75W-90 or 80W-90, API GL-4.
📐 Dimensions
Exterior
Length:
Varies by specific configuration, typically around 2200 mm
Width:
Varies by specific configuration, typically around 850 mm
Height:
Varies by specific configuration, typically around 1350 mm
Wheelbase:
Approximately 1480 mm
Weights
Dry Weight:
Approximately 165-175 kg
Gross Vehicle Weight Rating:
Not typically specified for motorcycles in this manner, but rider + luggage capacity is a consideration.
Fuel Tank Capacity:
Approximately 18 liters
🛡️ Safety Features
Ratings
Safety Ratings:
Motorcycles are not typically assigned NCAP-style safety ratings. Focus is on rider protection through vehicle design and rider awareness.
Active Features
Braking System:
Hydraulic disc brakes front and rear for strong stopping power.
Suspension Compliance:
Long-travel suspension provides stability and control over uneven surfaces.
Passive Features
Frame Design:
Robust frame construction for chassis rigidity and rider safety.
Lighting:
Headlight, taillight, and turn signals for visibility.
💡 Technology Features
Infotainment
Infotainment System:
Basic instrumentation: speedometer, tachometer, odometer, trip meter, neutral indicator, turn signal indicators, oil pressure warning light. No advanced infotainment systems.
Driver Assistance
Driver Assistance Features:
None (as this is a 1998 motorcycle).
Connectivity
Connectivity:
None.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 - 7,500 km or annually, whichever comes first.
Air Filter Cleaning:
Every 5,000 km or as needed based on operating conditions (dusty environments require more frequent checks).
Spark Plug Replacement:
Every 10,000 - 15,000 km or as per manual recommendation.
Valve Clearance Check:
Every 10,000 - 15,000 km (critical for single-cylinder performance).
Chain Lubrication Adjustment:
Every 1,000 km and after washing or riding in the rain.
Fluid Specifications
Coolant Type:
Ethylene glycol based antifreeze coolant, mixed with distilled water at a 50/50 ratio.
Brake Fluid Type:
DOT 4 brake fluid (or DOT 5.1 if specified).
Known Issues
Common Wear Items:
Clutch plates, swingarm pivot bearings, fork seals, regulator/rectifier (common on many bikes of this era).
Electrical Gremlins:
Corrosion on connectors, voltage regulator failure, can be mitigated with proper maintenance and dielectric grease.
📚 Vehicle History
Brand Heritage
Heritage:
Aprilia, an Italian manufacturer, has a strong racing pedigree and a history of producing innovative and performance-oriented motorcycles, often featuring unique designs and engine configurations.
Model Evolution
Pegaso Lineage:
The Pegaso line has a history dating back to the early 1990s, evolving through various engine sizes and configurations (e.g., 600cc, 650cc, 125cc) as a dual-sport offering.
Production
Manufacturing Location:
Primarily Italy
Production Period For 655:
The 655cc engine was a significant update in the Pegaso line, with production spanning several years in the late 1990s and early 2000s.
🏆 Awards & Recognition
Recognitions
Awards And Recognition:
While specific awards for the '98 Pegaso 655 are not widely documented, Aprilia's dual-sport models are generally recognized for their capable chassis and engaging ride characteristics.