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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...
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Aprilia Pegaso 655 1998 Full Service Repair Manual
🏷️ 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 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.
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