APRILIA PEGASO 650 1997-1999 Service Repair Manual Manual
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🏷️ Basic Information Identification Make: Aprilia Model: Pegaso 650 Model Variant: Pegaso 650 Production Years Covered: 1997-1999 Codes Chassis Codes: Likely AP8103559 (for specific components within these years, exact model codes may vary by sub-variant and market) 👋 Introduction Market Position Market Position: The Aprilia Pegaso 650, particularly in its 1997-1999 iteration, occupied a significant niche in the dual-sport/adventure motorcycle market. It appealed to riders seeking a capable on- and off-road machine with Italian flair and a distinctive single-cylinder engine character, often positioned as a more accessible alternative to larger adventure bikes. Competitive Analysis Competitive Analysis: Competed with models such as the BMW F650 Funduro, Honda Transalp 600/650, and Suzuki Freewind 650. The Pegaso differentiated itself with its Rotax-derived engine, agile handling, and unique styling. Key Features Key Features: Single-cylinder engine for torque and simplicity, comfortable riding position, versatile for commuting and light off-roading, capable suspension for varied terrain. 📋 Manual Details Coverage Areas Coverage Areas: Comprehensive service and repair across all major vehicle systems. Page Count Page Count: Estimated 300-500 pages (typical for a comprehensive service manual of this era) Manual Type Manual Type: Service Repair Manual Language Language: English (as indicated by product description, may have regional variations in original release) Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Systems Covered: Engine, Fuel System, Ignition System, Cooling System, Exhaust System, Transmission, Clutch, Drivetrain, Suspension (Front & Rear), Steering System, Braking System (Front & Rear), Electrical System (Wiring Diagrams, Components), Lighting System, Instruments & Controls, Chassis & Bodywork, Maintenance Procedures, Troubleshooting, Specifications. Procedures Included Procedures Included: Routine Maintenance (oil changes, filter replacements, chain adjustment), Engine Overhaul & Rebuild, Carburetor Adjustment & Rebuild, Ignition System Diagnostics & Repair, Cooling System Flush & Repair, Transmission Disassembly & Assembly, Clutch Service, Suspension Component Replacement, Brake Bleeding & Component Replacement, Electrical Component Testing & Replacement, Wiring Harness Repair, Troubleshooting Faults & Diagnostic Procedures. Technical Depth Technical Depth: Detailed diagnostics, component-level repair, complete rebuild procedures, torque specifications, clearances, and electrical schematics. Suitable for both experienced technicians and mechanically inclined owners. 📊 Manual Specifications File Format File Format: PDF (Portable Document Format) Print Quality Print Quality: High-resolution scans or original digital files, ensuring clarity of text and diagrams for printing. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, four-stroke Engine Displacement: 652 cc (cubic centimeters) Bore X Stroke: 100 mm x 83.5 mm (typical for this engine family) Valve Train: SOHC (Single Overhead Camshaft), 4 valves per cylinder Cooling System: Liquid-cooled Compression Ratio: Approximately 9.2:1 to 9.5:1 (may vary slightly) Performance Horsepower: Around 48-50 HP (36-37 kW) at ~6500 rpm Torque: Around 57-60 Nm (42-44 lb-ft) at ~4500-5500 rpm Fuel System Fuel Delivery: Carburetor (likely dual Mikuni VM34 or similar, specific model number in manual) Fuel Type: Unleaded Gasoline (91 octane or higher recommended) Engine Oil Oil Type: SAE 10W-40 API SG or higher motorcycle specific oil Oil Capacity W Filter: Approx. 2.3 - 2.5 Liters (consult manual for exact capacity) 🔧 Transmission Standard Transmission Type: 5-speed constant mesh manual transmission Optional Optional Transmission: N/A Features Clutch Type: Wet multi-plate clutch Final Drive: O-ring sealed chain drive Fluid Specifications Transmission Fluid Type: SAE 75W-90 or SAE 80W-90 API GL-4 gear oil (check manual for specific recommendation) 📐 Dimensions Exterior Length: Approx. 2170 mm (85.4 in) Width: Approx. 830 mm (32.7 in) Height: Approx. 1340 mm (52.8 in) Seat Height: Approx. 870 mm (34.3 in) Wheelbase: Approx. 1460 mm (57.5 in) Weights Dry Weight: Approx. 171 kg (377 lbs) Wet Weight: Approx. 185 kg (408 lbs) (with all fluids) Gross Vehicle Weight Rating: Consult manual (typically around 380 kg / 837 lbs) Cargo Fuel Tank Capacity: 20 Liters (5.3 US gal) 🛡️ Safety Features Ratings Safety Ratings: Motorcycle safety is primarily based on rider skill and active safety features; no formal crash test ratings like cars. Active Features Active Safety Features: Disc brakes front and rear, capable suspension geometry, and standard handguards for protection. Passive Features Passive Safety Features: Sturdy frame construction, impact-absorbing components where applicable. Brakes Front Brake Type: Dual Disc, hydraulic Front Brake Diameter: Likely dual 298 mm discs Rear Brake Type: Disc, hydraulic Rear Brake Diameter: Likely 220 mm disc Lighting Headlight Type: Halogen (specific bulb type in manual) Taillight Type: Bulb (specific type in manual) 💡 Technology Features Infotainment Infotainment Features: Basic analog instrumentation (speedometer, tachometer, fuel gauge, warning lights). No modern infotainment systems. Driver Assistance Driver Assistance Features: N/A (as this is a motorcycle) Connectivity Connectivity Features: N/A (as this is a motorcycle) Electrical System Ignition System: Electronic ignition (CDI type, specific module details in manual) Charging System: Alternator with voltage regulator (specific type and output in manual) Battery Type: 12V, sealed lead-acid (SLA) or AGM (YTX9-BS or similar, specific type and capacity in manual)...
Likely AP8103559 (for specific components within these years, exact model codes may vary by sub-variant and market)
👋 Introduction
Market Position
Market Position:
The Aprilia Pegaso 650, particularly in its 1997-1999 iteration, occupied a significant niche in the dual-sport/adventure motorcycle market. It appealed to riders seeking a capable on- and off-road machine with Italian flair and a distinctive single-cylinder engine character, often positioned as a more accessible alternative to larger adventure bikes.
Competitive Analysis
Competitive Analysis:
Competed with models such as the BMW F650 Funduro, Honda Transalp 600/650, and Suzuki Freewind 650. The Pegaso differentiated itself with its Rotax-derived engine, agile handling, and unique styling.
Key Features
Key Features:
Single-cylinder engine for torque and simplicity, comfortable riding position, versatile for commuting and light off-roading, capable suspension for varied terrain.
📋 Manual Details
Coverage Areas
Coverage Areas:
Comprehensive service and repair across all major vehicle systems.
Page Count
Page Count:
Estimated 300-500 pages (typical for a comprehensive service manual of this era)
Manual Type
Manual Type:
Service Repair Manual
Language
Language:
English (as indicated by product description, may have regional variations in original release)
Detailed diagnostics, component-level repair, complete rebuild procedures, torque specifications, clearances, and electrical schematics. Suitable for both experienced technicians and mechanically inclined owners.
📊 Manual Specifications
File Format
File Format:
PDF (Portable Document Format)
Print Quality
Print Quality:
High-resolution scans or original digital files, ensuring clarity of text and diagrams for printing.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Single-cylinder, four-stroke
Engine Displacement:
652 cc (cubic centimeters)
Bore X Stroke:
100 mm x 83.5 mm (typical for this engine family)
Valve Train:
SOHC (Single Overhead Camshaft), 4 valves per cylinder
Cooling System:
Liquid-cooled
Compression Ratio:
Approximately 9.2:1 to 9.5:1 (may vary slightly)
Performance
Horsepower:
Around 48-50 HP (36-37 kW) at ~6500 rpm
Torque:
Around 57-60 Nm (42-44 lb-ft) at ~4500-5500 rpm
Fuel System
Fuel Delivery:
Carburetor (likely dual Mikuni VM34 or similar, specific model number in manual)
Fuel Type:
Unleaded Gasoline (91 octane or higher recommended)
Engine Oil
Oil Type:
SAE 10W-40 API SG or higher motorcycle specific oil
Oil Capacity W Filter:
Approx. 2.3 - 2.5 Liters (consult manual for exact capacity)
🔧 Transmission
Standard
Transmission Type:
5-speed constant mesh manual transmission
Optional
Optional Transmission:
N/A
Features
Clutch Type:
Wet multi-plate clutch
Final Drive:
O-ring sealed chain drive
Fluid Specifications
Transmission Fluid Type:
SAE 75W-90 or SAE 80W-90 API GL-4 gear oil (check manual for specific recommendation)
📐 Dimensions
Exterior
Length:
Approx. 2170 mm (85.4 in)
Width:
Approx. 830 mm (32.7 in)
Height:
Approx. 1340 mm (52.8 in)
Seat Height:
Approx. 870 mm (34.3 in)
Wheelbase:
Approx. 1460 mm (57.5 in)
Weights
Dry Weight:
Approx. 171 kg (377 lbs)
Wet Weight:
Approx. 185 kg (408 lbs) (with all fluids)
Gross Vehicle Weight Rating:
Consult manual (typically around 380 kg / 837 lbs)
Cargo
Fuel Tank Capacity:
20 Liters (5.3 US gal)
🛡️ Safety Features
Ratings
Safety Ratings:
Motorcycle safety is primarily based on rider skill and active safety features; no formal crash test ratings like cars.
Active Features
Active Safety Features:
Disc brakes front and rear, capable suspension geometry, and standard handguards for protection.
Passive Features
Passive Safety Features:
Sturdy frame construction, impact-absorbing components where applicable.
Brakes
Front Brake Type:
Dual Disc, hydraulic
Front Brake Diameter:
Likely dual 298 mm discs
Rear Brake Type:
Disc, hydraulic
Rear Brake Diameter:
Likely 220 mm disc
Lighting
Headlight Type:
Halogen (specific bulb type in manual)
Taillight Type:
Bulb (specific type in manual)
💡 Technology Features
Infotainment
Infotainment Features:
Basic analog instrumentation (speedometer, tachometer, fuel gauge, warning lights). No modern infotainment systems.
Driver Assistance
Driver Assistance Features:
N/A (as this is a motorcycle)
Connectivity
Connectivity Features:
N/A (as this is a motorcycle)
Electrical System
Ignition System:
Electronic ignition (CDI type, specific module details in manual)
Charging System:
Alternator with voltage regulator (specific type and output in manual)
Battery Type:
12V, sealed lead-acid (SLA) or AGM (YTX9-BS or similar, specific type and capacity in manual)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 6,000 km (3,700 miles) or 12 months, whichever comes first (check manual for exact interval)
Spark Plug Replacement:
Every 12,000 km (7,500 miles) (check manual for exact interval and type)
Chain Adjustment Interval:
Every 3,000 km (1,800 miles) or as needed
Valve Clearance Check:
Every 12,000 km (7,500 miles) (critical for single-cylinder engines)
Fluid Specifications
Coolant Type:
Ethylene glycol-based coolant, 50/50 mix with distilled water (refer to manual for specific brand/type recommendation)
Brake Fluid Type:
DOT 4 (consult manual for specific requirement)
Fork Oil Type:
SAE 5W or 10W suspension fluid (specific type and volume in manual)
Known Issues
Known Issues:
Potential for starter motor issues, carburetor synchronization problems, rear shock absorber wear, and occasional electrical connector corrosion. The manual will detail specific troubleshooting for these.
Filters
Oil Filter Part Number:
Refer to manual for OEM or equivalent (e.g., Champion COF036, HiFlofiltro HF152, or similar)
Air Filter Part Number:
Refer to manual for OEM or equivalent
📚 Vehicle History
Brand Heritage
Brand Heritage:
Aprilia is an Italian manufacturer with a strong heritage in racing and performance motorcycles, known for innovative engineering and stylish designs.
Model Evolution
Model Evolution:
The Pegaso 650 line began in the early 1990s and evolved through various iterations. The 1997-1999 models represent a significant update, often featuring revised styling, improved suspension, and engine refinements based on the popular Rotax 654 engine.
Production
Production Location:
Italy
Engine Supplier:
The 650cc single-cylinder engine was originally developed by Rotax (Bombardier Recreational Products) and widely used by Aprilia, BMW, and others.
🏆 Awards & Recognition
Recognitions
Recognitions:
While specific awards for the 1997-1999 models are not prominently documented, the Pegaso line received generally positive reviews for its performance and versatility in its class during its production run.