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APRILIA PEGASO 650 1997 Service Repair Manual

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🏷️ Basic Information Identification Make: Aprilia Model: Pegaso 650 Year: 1997 Codes Engine Code: Not explicitly specified in product information, but typically Rotax 654 👋 Introduction Market Position Segment: Adventure/Dual-Sport Motorcycle Target Audience: Riders seeking a versatile motorcycle for on-road commuting and light off-road exploration Competitive Analysis Competitors: BMW F650 Funduro, Yamaha Ténéré 660, Suzuki DR650SE, Kawasaki KLR650 Key Features Engine Type: Single-cylinder, four-stroke, liquid-cooled Design Philosophy: Blend of sporty handling and off-road capability Frame Type: Steel trellis frame 📋 Manual Details Coverage Areas General Coverage: Maintenance and repair procedures for the Aprilia Pegaso 650 (1997 model year) Page Count Page Count: Unknown (PDF format, actual page count not provided in product description) Manual Type Type: Service Repair Manual Language Language: Likely English (standard for most service manuals, but not explicitly stated) Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Engine disassembly, assembly, inspection, and repair procedures for the 650cc single-cylinder engine Fuel System: Carburetor (likely Dell'Orto PHM 40) tuning, cleaning, and repair; fuel tank and petcock maintenance Ignition System: Ignition system components, timing, and troubleshooting Exhaust System: Exhaust system inspection and repair Transmission: Gearbox disassembly, assembly, inspection, and repair; clutch operation and adjustment Cooling System: Radiator, fan, thermostat, and coolant flow maintenance and repair Electrical System: Wiring diagrams, battery, charging system (alternator/stator, regulator/rectifier), starter motor, lighting, and indicators Suspension: Front fork (Telescopic, possibly Marzocchi or Paioli) overhaul, oil changes, and damper adjustments; rear shock absorber maintenance and adjustment Braking System: Front and rear brake caliper inspection, pad replacement, fluid bleeding, master cylinder maintenance, and disc inspection Wheel Hubs: Wheel bearing inspection and replacement, hub maintenance Steering: Handlebar, steering stem bearings inspection and adjustment Frame Chassis: Frame inspection and any minor repair procedures Bodywork Fittings: Fairing, tank, seat, and other body panel removal, installation, and minor repair Procedures Included Preventive Maintenance: Scheduled maintenance tasks, lubrication points, and component checks Troubleshooting: Diagnostic procedures for common faults and symptoms Repair Procedures: Step-by-step instructions for component removal, repair, and reinstallation Technical Specifications: Torque values, clearances, fluid capacities, and other critical data Wiring Diagrams: Detailed electrical system schematics Technical Depth Depth: Comprehensive, covering routine maintenance to major component overhaul and repair 📊 Manual Specifications File Format File Type: PDF Searchability: Likely searchable text if OCR was performed on the original document Print Quality Image Display: Requires Adobe PDF Reader for correct display of images/graphics Binding Type Binding: Not applicable (Digital PDF format) Paper Type Paper Quality: Not applicable (Digital PDF format) ⚙️ Engine Specifications Primary Engine Type: Single-cylinder, four-stroke, liquid-cooled, SOHC, 4 valves Bore X Stroke: 100 mm x 83.6 mm (typical for Rotax 654) Displacement: 652 cc (typical for Rotax 654) Compression Ratio: 10.0:1 (typical for Rotax 654) Performance Horsepower: Approx. 48-50 HP at 6500 RPM (typical for Rotax 654) Torque: Approx. 60 Nm (44 lb-ft) at 5200 RPM (typical for Rotax 654) Fuel System Carburetor: Dell'Orto PHM 40 (common for this model) Fuel Type: Unleaded gasoline Lubrication System Oil Capacity: Approx. 2.2 Liters (dry fill, consult manual for exact capacity and service fill) Oil Type: API SG or higher, JASO MA, SAE 10W-40 or 10W-50 (recommended, consult manual for precise specification) 🔧 Transmission Standard Type: 5-speed constant mesh Clutch Type: Wet multi-plate Features Final Drive: O-ring sealed chain Transmission Fluid Type: Gear Oil SAE 75W-90 API GL-4 or GL-5 (consult manual for exact specification) 📐 Dimensions Exterior Length: Approx. 2180 mm Width: Approx. 850 mm Height: Approx. 1330 mm Wheelbase: Approx. 1480 mm Weights Dry Weight: Approx. 170 kg Wet Weight: Approx. 185-190 kg (depending on fuel and accessories) Fuel Capacity: Approx. 21 Liters Wheels Tires Front Tire Size: 90/90-21 Rear Tire Size: 130/80-17 Wheel Type: Spoked wheels Wheel Bolt Pattern: Not applicable (motorcycle spoke wheels) 🛡️ Safety Features Active Features Braking System: Front: Single disc with 2-piston caliper; Rear: Single disc with 1-piston caliper Passive Features Lighting: Halogen headlight, taillight, brake light, front and rear turn signals Instrumentation: Analog speedometer and tachometer, basic indicator lights (oil, neutral, turn signals, high beam) 💡 Technology Features Infotainment Features: Basic analog instrumentation; no advanced infotainment systems present on this model. Driver Assistance Features: No electronic driver assistance systems (e.g., ABS, traction control) typically found on this model year. 🔧 Maintenance Service Intervals Oil Change: Every 5,000-7,500 km or annually (consult manual for exact interval and engine operating conditions) Air Filter Cleaning: Every 5,000 km or as needed in dusty conditions Spark Plug Replacement: Every 10,000-15,000 km Valve Clearance Check: Every 10,000-15,000 km Fluid Specifications Coolant: Ethylene glycol-based coolant, 50% mixture with distilled water (consult manual for specific type) Brake Fluid: DOT 4 (recommended, consult manual for precise specification) Known Issues Charging System: Occasional regulator/rectifier failures reported on some Rotax-powered bikes. Carburetor: Dell'Orto carburetors can be sensitive to dirt and require regular cleaning and adjustment for optimal performance. Cam Chain Tensioner: Some older Rotax...
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APRILIA PEGASO 650 1997 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
Pegaso 650
Year:
1997
Codes
Engine Code:
Not explicitly specified in product information, but typically Rotax 654
👋 Introduction
Market Position
Segment:
Adventure/Dual-Sport Motorcycle
Target Audience:
Riders seeking a versatile motorcycle for on-road commuting and light off-road exploration
Competitive Analysis
Competitors:
BMW F650 Funduro, Yamaha Ténéré 660, Suzuki DR650SE, Kawasaki KLR650
Key Features
Engine Type:
Single-cylinder, four-stroke, liquid-cooled
Design Philosophy:
Blend of sporty handling and off-road capability
Frame Type:
Steel trellis frame
📋 Manual Details
Coverage Areas
General Coverage:
Maintenance and repair procedures for the Aprilia Pegaso 650 (1997 model year)
Page Count
Page Count:
Unknown (PDF format, actual page count not provided in product description)
Manual Type
Type:
Service Repair Manual
Language
Language:
Likely English (standard for most service manuals, but not explicitly stated)
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Engine disassembly, assembly, inspection, and repair procedures for the 650cc single-cylinder engine
Fuel System:
Carburetor (likely Dell'Orto PHM 40) tuning, cleaning, and repair; fuel tank and petcock maintenance
Ignition System:
Ignition system components, timing, and troubleshooting
Exhaust System:
Exhaust system inspection and repair
Transmission:
Gearbox disassembly, assembly, inspection, and repair; clutch operation and adjustment
Cooling System:
Radiator, fan, thermostat, and coolant flow maintenance and repair
Electrical System:
Wiring diagrams, battery, charging system (alternator/stator, regulator/rectifier), starter motor, lighting, and indicators
Suspension:
Front fork (Telescopic, possibly Marzocchi or Paioli) overhaul, oil changes, and damper adjustments; rear shock absorber maintenance and adjustment
Braking System:
Front and rear brake caliper inspection, pad replacement, fluid bleeding, master cylinder maintenance, and disc inspection
Wheel Hubs:
Wheel bearing inspection and replacement, hub maintenance
Steering:
Handlebar, steering stem bearings inspection and adjustment
Frame Chassis:
Frame inspection and any minor repair procedures
Bodywork Fittings:
Fairing, tank, seat, and other body panel removal, installation, and minor repair
Procedures Included
Preventive Maintenance:
Scheduled maintenance tasks, lubrication points, and component checks
Troubleshooting:
Diagnostic procedures for common faults and symptoms
Repair Procedures:
Step-by-step instructions for component removal, repair, and reinstallation
Technical Specifications:
Torque values, clearances, fluid capacities, and other critical data
Wiring Diagrams:
Detailed electrical system schematics
Technical Depth
Depth:
Comprehensive, covering routine maintenance to major component overhaul and repair
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely searchable text if OCR was performed on the original document
Print Quality
Image Display:
Requires Adobe PDF Reader for correct display of images/graphics
Binding Type
Binding:
Not applicable (Digital PDF format)
Paper Type
Paper Quality:
Not applicable (Digital PDF format)
⚙️ Engine Specifications
Primary Engine
Type:
Single-cylinder, four-stroke, liquid-cooled, SOHC, 4 valves
Bore X Stroke:
100 mm x 83.6 mm (typical for Rotax 654)
Displacement:
652 cc (typical for Rotax 654)
Compression Ratio:
10.0:1 (typical for Rotax 654)
Performance
Horsepower:
Approx. 48-50 HP at 6500 RPM (typical for Rotax 654)
Torque:
Approx. 60 Nm (44 lb-ft) at 5200 RPM (typical for Rotax 654)
Fuel System
Carburetor:
Dell'Orto PHM 40 (common for this model)
Fuel Type:
Unleaded gasoline
Lubrication System
Oil Capacity:
Approx. 2.2 Liters (dry fill, consult manual for exact capacity and service fill)
Oil Type:
API SG or higher, JASO MA, SAE 10W-40 or 10W-50 (recommended, consult manual for precise specification)
🔧 Transmission
Standard
Type:
5-speed constant mesh
Clutch Type:
Wet multi-plate
Features
Final Drive:
O-ring sealed chain
Transmission Fluid
Type:
Gear Oil SAE 75W-90 API GL-4 or GL-5 (consult manual for exact specification)
📐 Dimensions
Exterior
Length:
Approx. 2180 mm
Width:
Approx. 850 mm
Height:
Approx. 1330 mm
Wheelbase:
Approx. 1480 mm
Weights
Dry Weight:
Approx. 170 kg
Wet Weight:
Approx. 185-190 kg (depending on fuel and accessories)
Fuel Capacity:
Approx. 21 Liters
Wheels Tires
Front Tire Size:
90/90-21
Rear Tire Size:
130/80-17
Wheel Type:
Spoked wheels
Wheel Bolt Pattern:
Not applicable (motorcycle spoke wheels)
🛡️ Safety Features
Active Features
Braking System:
Front: Single disc with 2-piston caliper; Rear: Single disc with 1-piston caliper
Passive Features
Lighting:
Halogen headlight, taillight, brake light, front and rear turn signals
Instrumentation:
Analog speedometer and tachometer, basic indicator lights (oil, neutral, turn signals, high beam)
💡 Technology Features
Infotainment
Features:
Basic analog instrumentation; no advanced infotainment systems present on this model.
Driver Assistance
Features:
No electronic driver assistance systems (e.g., ABS, traction control) typically found on this model year.
🔧 Maintenance
Service Intervals
Oil Change:
Every 5,000-7,500 km or annually (consult manual for exact interval and engine operating conditions)
Air Filter Cleaning:
Every 5,000 km or as needed in dusty conditions
Spark Plug Replacement:
Every 10,000-15,000 km
Valve Clearance Check:
Every 10,000-15,000 km
Fluid Specifications
Coolant:
Ethylene glycol-based coolant, 50% mixture with distilled water (consult manual for specific type)
Brake Fluid:
DOT 4 (recommended, consult manual for precise specification)
Known Issues
Charging System:
Occasional regulator/rectifier failures reported on some Rotax-powered bikes.
Carburetor:
Dell'Orto carburetors can be sensitive to dirt and require regular cleaning and adjustment for optimal performance.
Cam Chain Tensioner:
Some older Rotax engines may benefit from an updated manual cam chain tensioner for improved reliability.
Fuel Lines:
Aging fuel lines can become brittle and require replacement.
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
Aprilia is an Italian manufacturer known for performance motorcycles and scooters.
Model Evolution
Generation:
The Pegaso 650 was introduced in the early 1990s and saw various updates and engine revisions over its lifespan. The 1997 model represents a refinement of this platform.
Production
Production Period:
The Pegaso 650 was produced from the early 1990s through the early 2000s, with the Rotax engine being a common powerplant for much of this period.
🏆 Awards & Recognition
Recognitions
Award History:
Specific awards for the 1997 Aprilia Pegaso 650 are not widely documented, but the model was generally well-regarded for its versatility.
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