Page 1 Pegaso 650 I.E. INTRODUCTION GENERAL INFORMATION SERVICE AND SETTING UP ENGINE FUEL SUPPLY SYSTEM COOLING SYSTEM ELECTRIC SYSTEM CHASSIS REPAIR INFORMATION ANALYTICAL INDEX 0EGASO 650 -1 WORKSHOP manual aprilia part# 8140638 - 00 Release 00/2002-02...
Page 2: Table Of Contents
INTRODUCTION Pegaso 650 I.E. INTRODUCTION 4!",% /& #/.4%.43 50$!4% /& 2%,%!3% ..0-3 0.1.1 INFORMATION ON THE UPDATING OF THE MANUAL ....0-3 0.1.2 UPDATED MANUAL GENERAL LIST ... 0-3 (/7 4/ #/.35,4 4(% -!.5!, ..0-5 &/2%7/2$ ..........
Page 3: Information On The Updating Of The Manual
INTRODUCTION Pegaso 650 I.E. 50$!4% /& 2%,%!3% page# Release page# Release 2 - 31 5 - 1 - 00 ....... - 00 ........ Date of the first edition (Release 00) and of the following 2 - 32 5 - 2 - 00 .......
Page 4 INTRODUCTION Pegaso 650 I.E. ã Follow page# Release page# Release 7 - 17 - 00 ........ 7 - 87 - 00 ....... 7 - 18 - 00 ........ 7 - 88 - 00 ....... 7 - 19 - 00 ........ 7 - 89 - 00 .......
Page 5 INTRODUCTION Pegaso 650 I.E. (/7 4/ #/.35,4 4(% -!.5!, 1) Vehicle (or engine) model 7) Updated page consecutive number 2) Section 8) Chapter title (numbered consecutively) 3) Release consecutive number (“00” indicates the first 9) Paragraph title (numbered consecutively) edition) 10) Description of the operation (always preceded by a 4) Year and month of publication of the Release...
Page 6: Engine Service And Repair Manuals
In order to grant its customers more and more satisfac- APRILIA part# (description) tion in the use of the vehicle, aprilia s.p.a. will keep 8104311 I f d improving its products and the relevant documenta- 8104312 p E U tion.
Page 7: Precautions And General Informations
The bearings must rotate freely, without halting a/o noise otherwise they must be replaced. WARNING – Use only original aprilia SPARE PARTS. Do not hold any mechanical piece or other parts of – Use the recommended lubricants. the vehicle with your mouth: the components are not –...
Page 8: Advice For Consultation
INTRODUCTION Pegaso 650 I.E. ã (/7 4/ 53% 9/52 3%26)#% !.$ 2%0!)2 Follow -!.5!, – When installing the bearings, lubricate them abundan- tly. 0.6.1 ADVICE FOR CONSULTATION – Make sure that each component has been reassem- bled correctly. – This manual is divided into section and chapters, each one of which corresponds to a category of main com- –...
Page 9 INTRODUCTION Pegaso 650 I.E. !""2%6)!4)/.3 39-"/,3 ).)4)!,3 PICK-UP = pick-up = bottom dead centre = number = top dead centre < = is less than = Pneumatic Power Clutch > = is greater than ≤ RIGHT = is equal to or less than SIDE = right side ≥...
Page 10 INTRODUCTION Pegaso 650 I.E. NOTE - 10 - 00 Release 00/2002-02...
Page 11 Pegaso 650 I.E. GENERAL INFORMATION - 00 Release 00/2002-02...
Page 12 GENERAL INFORMATION Pegaso 650 I.E. GENERAL INFORMATION 4!",% /& #/.4%.43 0/3)4)/. /& 4(% 3%2)!, .5-"%23 1-3 1.1.1 FRAME NUMBER ........1-3 1.1.2 ENGINE NUMBER ........1-3 ).3425#4)/.3 &/2 53% /& &5%, ,5"2)#!.43 #//,!.4 !.$ /4(%2 #/-0/.%.43 ....1-4 1.2.1 FUEL ............
Page 13: Frame Number
GENERAL INFORMATION Pegaso 650 I.E. 0/3)4)/. /& 4(% 3%2)!, .5-"%23 These numbers are necessary for the registration of the vehicle. Do not alter the identification numbers if you do not want to incur severe penal and administrative sanctions. In particular, the alteration of the frame number results in the immediate invalidity of the guarantee.
Page 14: Fuel
GENERAL INFORMATION Pegaso 650 I.E. ).3425#4)/.3 &/2 53% /& &5%, 1.2.2 ENGINE OIL ,5"2)#!.43 #//,!.4 !.$ /4(%2 #/-0/.%.43 WARNING Engine oil may cause serious damage to the skin if 1.2.1 FUEL handled daily and for long periods. Wash your hands carefully after use. WARNING Do not dispose of the oil in the environment.
Page 15: Brake Fluid
GENERAL INFORMATION Pegaso 650 I.E. 1.2.4 BRAKE FLUID 1.2.5 COOLANT NOTE This vehicle is provided with front and rear disc WARNING brakes, with separate hydraulic circuits. The following in- The coolant is noxious: do not swallow it; if the cool- formation refers to a single braking system, but is valid for ant gets in contact with the skin or the eyes, it can both.
Page 16: Clutch Fluid
GENERAL INFORMATION Pegaso 650 I.E. 1.2.6 CLUTCH FLUID 1.2.7 CARBON MONOXIDE NOTE This vehicle is provided with hydraulic clutch If it is necessary to let the engine run in order to carry out control. some work, make sure that the area in which you are op- erating is properly ventilated.
Page 17 CAUTION During running-in, change speed. Failure to use APRILIA Genuine Spare Parts may re- In this way the components are first “loaded” and then sult in incorrect performance and damages. “relieved” and the engine parts can thus cool down.
Page 18 GENERAL INFORMATION Pegaso 650 I.E. 4%#(.)#!, 30%#)&)#!4)/.3 DIMENSIONS Max. length 2214 mm Max. width 910 mm Max. height (front part of the fairing included) 1253 mm Seat height 815 mm Distance between centres 1466 mm Min. ground clearance 200 mm Weight ready for starting (fuel and fluid included) 200 kg ENGINE...
Page 19 GENERAL INFORMATION Pegaso 650 I.E. ã Follow CAPACITY 21 L Fuel (reserve included) Fuel reserve Engine oil oil change 2150 cm# - oil and oil filter change 2200 cm# Fork oil (per rod) 570 cm# 1.4 L (50% water + 50% antifreeze with ethylene gly- Coolant col) Seats...
Page 20 GENERAL INFORMATION Pegaso 650 I.E. ã Follow TYRES FRONT 100/90 – 19 57 H alternative 100/90 – R19 57 H; 100/90 – 19 57 S; 100/90 – 19 57 T Inflation pressure - solo rider off-road driving 190 kPa (1.9 bar) asphalted road 190 kPa (1.9 bar) Inflation pressure rider with passenger...
Page 21 GENERAL INFORMATION Pegaso 650 I.E. ,5"2)#!.4 #(!24 Engine oil (recommended): SUPERBIKE 4, SAE 5W-40 or 4T FORMULA RACING, SAE 5W-40. As an alternative to the recommended oil, it is possible to use high-quality oils with characteristics in compliance with or superior to the CCMC G-4, A.P.I.
Page 22: 30%#)!, 4//,3 M
Pegaso 650 I.E. 30%#)!, 4//,3 m In order to perform assembly, reassembly and settings If necessary, request the special tools, see aprilia part# 8202278 I f d E U. correctly, special tools suitable for the task must be used.
Page 23 8140427 {engine support to be used with: aprilia part# 8140187 (engine support stand), aprilia part# 8140428 (engine support kit), aprilia part# 8104101 [clamp support, to be applied to: aprilia part# 8140428 (engine support kit) + aprilia part# 8140187 (engine support stand)]}...
Page 24: Generic Tools
GENERAL INFORMATION Pegaso 650 I.E. 1.7.2 GENERIC TOOLS - 14 - 00 Release 00/2002-02...
Page 25 8705021 (rear support stand) 8140394 [tapered rubber sensor, spare part for: aprilia part# 8140196 (exhaust fume analyser)] 8104101 [clamp support, to be applied to: aprilia part# 8140428 (engine support kit) + aprilia part# 8140187 (engine support stand)] 8140428 (engine support kit)
Page 26: Tools Used For Other Vehicles
GENERAL INFORMATION Pegaso 650 I.E. 1.7.3 TOOLS USED FOR OTHER VEHICLES APRILIA part# (tool description) Pos. ® 0897651 [LOCTITE 243 Blue (10 cm³)] ® 0898011 (fluorescent green LOCTITE 275) 0294762 (Gaskets-set) 0297616 [Paste Klueber (60 gr)] ® 0297434 (LOCTITE 767 Anti-Seize 15378) 8116050 (engine oil) ®...
Page 27: Positioning The Vehicle On The Rear Support Stand M
NOTE Have the appropriate special tool m to hand: – aprilia part# 8146486 (front support stand); – aprilia part# 8140590 (washers for front support stand). Push the stand (11) downwards until it reaches the end Position the vehicle on the appropriate rear support of its stroke.
Page 28: Product Properties
APRILIA part# (product) Use and properties Adhesive in paste for screws and nuts up to M36 and for ® aprilia part# 0897651 [LOCTITE couplings with medium hold. 243 Blue (10 cm³)] It can be used on parts which have not been completely degreased.
Page 29: Joints With Hose Clamps And Screw Clamps
NOTE Have the appropriate special tool m to hand: – aprilia part# 0277295 (hose clamp installation pliers). CAUTION Upon installation, replace the hose clamp that has been removed with a new one having the same di- mensions, see 0.4.2 (SPARE PARTS CATALOGUES).
Page 30: General Specifications Of The Driving Torques
GENERAL INFORMATION Pegaso 650 I.E. 1.10.2 GENERAL SPECIFICATIONS OF THE DRIVING TORQUES The following table indicates the standard driving torques for screws and bolts with metric ISO thread. Driving torque Screw or Spanner bolt thread M 10 M 12 M 14 M 16 13.0 For specific joints or couplings of the vehicle, see 1.10.3...
Page 31 GENERAL INFORMATION Pegaso 650 I.E. FRAME Description Q.ty Screw/nut Note Plates/triangle frame fastening M10x100 Inner shock absorber support to side plates M10X45 Triangle frame/cradle M10X65 Shock absorber support inner screws to side plates M8X20 Right and left engine upper coupling plate M8X65 Fuel tank rear support M8X12...
Page 32 GENERAL INFORMATION Pegaso 650 I.E. REAR SUSPENSION Description Q.ty Screw/nut Note Shock absorber upper support M10X60 Shock absorber lower support M10X47 Inlet manifold M6X20 0.12 Cradle/engine M10X110 ENGINE Description Q.ty Screw/nut Note Inlet manifold M6X20 Cradle/engine M10X110 Cradle/engine M10X95 Pick up cover M6X12 Gear lever M6X20...
Page 33 GENERAL INFORMATION Pegaso 650 I.E. ã Follow REAR WHEEL Description Q.ty Screw/nut Note Wheel pin M16X1.5 10.0 Sprocket on sprocket holder – – – FRONT BRAKE Description Q.ty Screw/nut Note Brake caliper M10X35 REAR BRAKE Description Q.ty Screw/nut Note Brake pump M6X35 Brake lever ball joint Brake lever...
Page 34 GENERAL INFORMATION Pegaso 650 I.E. ã Follow FAIRING Description Q.ty Screw/nut Note M6X16 M5X12 Front fairing to tank M5X9 on clip M5X16 on clip Front transparent part of the fairing to dashboard fairing M5X16 on rubber 0.15 element Front transparent part of the fairing M5X16 on rubber 0.15 element...
Page 35 GENERAL INFORMATION Pegaso 650 I.E. ).3425#4)/.3 &/2 !00,9).' 42!.3&%23 When removing parts of the frame: CAUTION Handle the plastic and painted components with care to avoid scraping or damaging them. Proceed with care. Do not damage the tangs and/or their seats. When applying the transfers, follow the instructions given below carefully.
Page 36 GENERAL INFORMATION Pegaso 650 I.E. ã Follow NOTE Where the transfer features application tape ✱ , the tape must be removed 20-30 minutes after the application of the transfer. ✱ The application tape is used to facilitate the application of trademarks and letters, arranging them in the correct place on the surface to be decorated, and to give the self-adhesive more body during application.
Page 37 GENERAL INFORMATION Pegaso 650 I.E. NOTE - 27 - 00 Release 00/2002-02...
Page 38 GENERAL INFORMATION Pegaso 650 I.E. NOTE - 28 - 00 Release 00/2002-02...
Page 39: Service And Setting Up
Pegaso 650 I.E. SERVICE AND SETTING UP - 00 Release 00/2002-02...
Page 40 SERVICE AND SETTING UP Pegaso 650 I.E. 2%!2 &/2+ ........... 2-40 SERVICE AND SETTING UP 2.23.1 ADJUSTING THE REAR FORK ... 2-40 ).30%#4).' 4(% &2/.4 !.$ 2%!2 3530%.3)/......2-41 2.24.1 FRONT SUSPENSION ......2-41 4!",% /& #/.4%.43 ).30%#4).' 4(% 2%!2 3530%.3)/.
Page 41 In case any maintenance operation should be re- quired, it is advisable to use latex gloves. 0%2)/$)# 3%26)#% 0,!. aprilia recommends respecting the intervals indicated for the periodic service on the various components in order to ensure the best operating conditions of the vehicle, see 2.1.1 (REGULAR SERVICE INTERVALS CHART).
Page 42: Regular Service Intervals Chart
SERVICE AND SETTING UP Pegaso 650 I.E. 2.1.1 REGULAR SERVICE INTERVALS CHART OPERATIONS TO BE CARRIED OUT BY THE APRILIA Official Dealer (WHICH CAN BE CARRIED OUT EVEN BY THE USER). = check and clean, adjust, lubricate or change, if nec- essary;...
Page 43 SERVICE AND SETTING UP Pegaso 650 I.E. ã Follow OPERATIONS TO BE CARRIED OUT BY THE APRILIA Official Dealer. = check and clean, adjust, lubricate or change, if nec- essary; = clean; = change; = adjust.
Page 44 SERVICE AND SETTING UP Pegaso 650 I.E. 0/).43 2%15)2).' ,5"2)#!4)/. Correct lubrication is important for good performance and the long life of the vehicle. NOTE Before lubricating, completely clean all parts, re- moving rust, grease, dirt and dust. NOTE The exposed parts subject to rust are to be lu- bricated with motor oil or grease, see 1.6 (LUBRICANT CHART).
Page 45 SERVICE AND SETTING UP Pegaso 650 I.E. LUBRICATION CHART - 00 Release 00/2002-02...
Page 46: Checking The Electrolyte Level
SERVICE AND SETTING UP Pegaso 650 I.E. "!44%29 Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). There are two kinds of commercially available batter- ies: – batteries requiring maintenance featuring cell plugs; – maintenance-free batteries with no cell plugs as they do not call for the electrolyte level to be checked and topped up.
Page 47: Recharging The Battery
SERVICE AND SETTING UP Pegaso 650 I.E. ã Follow If necessary, proceed as follows: Remove the battery, see 7.1.8 (REMOVING THE BAT- TERY). Brush the cable terminals (2) and the battery terminals (3) with a wire brush, in order to eliminate any trace of corrosion.
Page 48 SERVICE AND SETTING UP Pegaso 650 I.E. *5-0 34!24).' Carefully read 2.3 (BATTERY). WARNING The vehicle should only be jump-started when the ve- hicles battery is partially/completely flat and recharg- ing is not possible. Do not attempt to start the vehicle by pushing or tow- ing it.
Page 49 SERVICE AND SETTING UP Pegaso 650 I.E. 30!2+ 0,5' Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). For the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART) under: – Spark plug. To reach the spark plug: CAUTION Let the engine cool down until it reaches room tem- perature.
Page 50 SERVICE AND SETTING UP Pegaso 650 I.E. ã Follow CAUTION To check the spark plug gap, use a wire thickness gauge (7) to avoid damaging the platinum covering. Check the spark plug gap with a wire thickness gauge (7). CAUTION Do not try to recover the spark plug gap in any way.
Page 51 SERVICE AND SETTING UP Pegaso 650 I.E. $2!).).' 4(% &5%, 4!.+ Carefully read 1.2.1 (FUEL). Fuel pipes: For the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART). WARNING Risk of fire. Wait until the engine and exhaust silencer have com- pletely cooled down.
Page 52: Fuel Supply System
SERVICE AND SETTING UP Pegaso 650 I.E. !)2 #,%!.%2 Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). For the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART) under: – Air cleaner. CAUTION The partial cleaning of the filter does not exclude or postpone the replacement of the filter itself.
Page 53: Checking The Operation Of The Accelerator Control
SERVICE AND SETTING UP Pegaso 650 I.E. !##%,%2!4/2 2.9.1 CHECKING THE OPERATION OF THE ACCELERATOR CONTROL For the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART) under: – Transmission cables and controls. For the check, proceed as follows: WARNING The use of the vehicle with damaged, excessively bent or twisted accelerator cable may hinder the reg- ular operation of the accelerator and make you lose...
Page 54: Idling Adjustment
SERVICE AND SETTING UP Pegaso 650 I.E. 2.9.2 IDLING ADJUSTMENT Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). NOTE In case of start at low ambient temperature [near or below 0 °C (32 °F)] and in any case if the normal operating temperature has not been reached, anomalies may be noticed in the engine idling speed.
Page 55 CO value suitable for the good operation of the vehicle. NOTE Have the appropriate special tools m to hand: – aprilia part# 8140196 (exhaust fume analyser) (5). WARNING Fuel vapours are noxious for your health. Before proceeding, make sure that the room in which you are working is properly ventilated.
Page 56: Adjusting The Accelerator Control
SERVICE AND SETTING UP Pegaso 650 I.E. 2.9.3 ADJUSTING THE ACCELERATOR CONTROL For the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART) under: – Transmission cables and controls. For the check, proceed as follows: The idle stroke of the throttle grip must be 2 – 3 mm, measured on the edge of the grip itself.
Page 57 SERVICE AND SETTING UP Pegaso 650 I.E. #(%#+).' 4(% %.').% /), ,%6%, !.$ 4/00).' 50 Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.2 (ENGINE OIL). For the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART) under: – Motor oil; –...
Page 58 SERVICE AND SETTING UP Pegaso 650 I.E. #(!.').' 4(% %.').% /), !.$ 4(% /), &),4%2 Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.2 (ENGINE OIL). For the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART) under: – Motor oil. ENGINE OIL DRAIN NOTE To warm the engine and have the engine oil...
Page 59 – Engine oil filter (on oil tank). NOTE Have the appropriate special tool m to hand: – aprilia part# 0277295 (hose clamp installation pliers). CAUTION Upon installation, replace the hose clamp that has been removed with a new one having the same di- mensions, see 0.4.2 (SPARE PARTS CATALOGUES).
Page 60: Bleeding The Oil Delivery Pump
SERVICE AND SETTING UP Pegaso 650 I.E. 2.12.1 BLEEDING THE OIL DELIVERY PUMP CAUTION The bleeding must be always carried out when the oil has been completely drained from the tank and from the engine (engine overhaul). CAUTION The following operations must be carried out during the oil change, after removing the engine oil filter and before installing a new one.
Page 61 SERVICE AND SETTING UP Pegaso 650 I.E. #(!.').' 4(% #//,!.4 Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.5 (COOLANT). For the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART) under: – Coolant. Remove the oil sump guard, see 7.1.3 (REMOVING THE OIL SUMP GUARD).
Page 62 SERVICE AND SETTING UP Pegaso 650 I.E. #(%#+).' 4(% &2/.4 "2!+% &,5)$ ,%6%, !.$ 4/00).' 50 Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.4 (BRAKE FLUID). For the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART) under: – Brake fluid. CAUTION If the brake lever features excessive free play, if it is excessively spongy or in the event of air bubbles in...
Page 63 SERVICE AND SETTING UP Pegaso 650 I.E. Leave the brake fluid tank open ONLY for the time necessary for topping up. Raise and remove the cover (3) together with the screws (1) (2). Remove the gasket (4). CAUTION In order not to spill the brake fluid while topping up, do not shake the vehicle.
Page 64 SERVICE AND SETTING UP Pegaso 650 I.E. #(%#+).' !.$ 4/00).' 50 4(% 2%!2 "2!+% &,5)$ For the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART) under: – Brake fluid. CAUTION If the brake lever features excessive free play, if it is excessively spongy or in the event of air bubbles in the circuit, bleed the system, see 2.17 (BLEEDING THE BRAKING SYSTEMS).
Page 65 SERVICE AND SETTING UP Pegaso 650 I.E. ",%%$).' 4(% "2!+).' 3934%-3 Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.6 (CLUTCH FLUID). For the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART) under: – Braking systems; – Brake fluid. The air present in the hydraulic system acts as a bearing, absorbing most of the pressure exerted by the brake pump and reducing the effectiveness of the caliper action...
Page 66: Bleeding Operations
SERVICE AND SETTING UP Pegaso 650 I.E. ã Follow 2.17.1 BLEEDING OPERATIONS There are three bleeding procedures to be carried out in the order indicated below: 1°) BLEEDING THE SYSTEMS NOTE The description of the system bleeding proce- dures also includes instructions on how to find out if it is necessary to bleed the brake caliper and the brake pump.
Page 67 SERVICE AND SETTING UP Pegaso 650 I.E. ã Follow BLEEDING THE SYSTEMS NOTE Do not work on both braking systems at the same time. The operations refer to a single braking sys- tem, but are valid for both (with the differences indicated). NOTE Do not close the brake fluid reservoir after top- ping up, since for the bleeding operations it is necessary...
Page 68 SERVICE AND SETTING UP Pegaso 650 I.E. ã Follow N ✱ Release the brake lever (8) (for the front brake, or the brake pump rod for the rear brake) and pull it three or four times. ✱ Repeat the operations marked with " ", until no air bub- bles can be seen in the brake fluid that flows out of the bleeder valve.
Page 69 SERVICE AND SETTING UP Pegaso 650 I.E. ã Follow BLEEDING THE BRAKE CALIPER NOTE Do not work on both braking systems at the same time. The operations refer to a single braking sys- tem, but are valid for both (with the differences indicated). For the front braking system, the operations described should be carried out on both brake calipers.
Page 70 SERVICE AND SETTING UP Pegaso 650 I.E. ã Follow BLEEDING THE FRONT BRAKE PUMP NOTE Do not close the front brake fluid reservoir after topping up, since for the bleeding operations it is neces- sary to top up the brake fluid reservoir more than once. Top up the brake fluid tank, see 2.15 (CHECKING THE FRONT BRAKE FLUID LEVEL AND TOPPING UP).
Page 71 SERVICE AND SETTING UP Pegaso 650 I.E. ã Follow BLEEDING THE REAR BRAKE PUMP NOTE Do not close the brake fluid reservoir after top- ping up, since for the bleeding operations it is necessary to top up the brake fluid reservoir more than once. Top up the rear brake fluid tank, see 2.16 (CHECKING AND TOPPING UP THE REAR BRAKE FLUID).
Page 72: Checks To Be Carried Out After Bleeding The Braking Systems
SERVICE AND SETTING UP Pegaso 650 I.E. ã Follow Put back the rear brake caliper, see 7.6.5 (REMOVING THE REAR BRAKE CALIPER). Reassemble the rear wheel, see 7.3.1 (REMOVING THE REAR WHEEL). Top up the rear brake fluid tank, see 2.16 (CHECKING AND TOPPING UP THE REAR BRAKE FLUID).
Page 73 SERVICE AND SETTING UP Pegaso 650 I.E. #(!.').' 4(% &2/.4 "2!+% &,5)$ Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.4 (BRAKE FLUID). For the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART) under: – Brake fluid. CAUTION Handle brake fluid with care; it may chemically alter painted surfaces and the parts in plastic, rubber, etc.
Page 74 SERVICE AND SETTING UP Pegaso 650 I.E. #(!.').' 4(% 2%!2 "2!+% &,5)$ Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.4 (BRAKE FLUID). For the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART) under: – Brake fluid. CAUTION Handle fluid with care; it may chemically alter painted surfaces and the parts in plastic, rubber, etc.
Page 75 SERVICE AND SETTING UP Pegaso 650 I.E. !$*534).' 4(% 2%!2 "2!+% #/.42/, ,%6%2 #,%!2!.#% The brake control lever is positioned ergonomically dur- ing the assembly of the vehicle. If necessary, it is possible to adjust the brake control lever clearance: Loosen the lock nut (1).
Page 76 FRONT BRAKE PADS (models up to 2001)). – for the rear brake caliper have both rear brake cal- iper pads changed, see 7.6.1 (CHANGING THE REAR BRAKE PADS). WARNING Have the pads changed by your APRILIA Official Deal- - 38 - 00 Release 00/2002-02...
Page 77: Checking The Bearing Slack Steering
SERVICE AND SETTING UP Pegaso 650 I.E. 34%%2).' Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). For the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART) under: – Steering bearings and steering clearance. To assure improved handling, the steering is equipped with rolling bearings.
Page 78: Adjusting The Rear Fork
Position the vehicle on the centre stand m. Lock the adjuster ring (1). NOTE Have the appropriate special tool m to hand: – aprilia part# 8101945 (rear fork pin metal ring span- ner). Use the special setscrew spanner to loosen the lock ring (2) completely.
Page 79: Front Suspension
SERVICE AND SETTING UP Pegaso 650 I.E. ).30%#4).' 4(% &2/.4 !.$ 2%!2 3530%.3)/. Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). 2.24.1 FRONT SUSPENSION The front suspension consists of an hydraulic fork con- nected to the steering column by means of two plates. The standard setting of the front fork is adjusted in such a way as to be suitable for most driving conditions, at high and low speed, for the transport of the rider with luggage.
Page 80: Rear Suspension
SERVICE AND SETTING UP Pegaso 650 I.E. ).30%#4).' 4(% 2%!2 3530%.3)/. 2.25.1 REAR SUSPENSION The rear suspension consists of a spring-shock absorber unit, fixed to the frame by means of a uni-ball and to the rear fork by means of lever systems. The rear suspension consists of a spring-shock absorber unit, fixed to the frame by means of a uni-ball and to the rear fork by means of lever systems.
Page 81 SERVICE AND SETTING UP Pegaso 650 I.E. ã Follow CAUTION Adjust the spring preload and the hydraulic braking with extended shock absorber according to the con- ditions of use of the vehicle. When the spring preload is increased, it is necessary to increase also the hydraulic braking with extended shock absorber, in order to avoid sudden jerks while riding.
Page 82: Rear Suspension With Hydraulic Preload Adjustment M
SERVICE AND SETTING UP Pegaso 650 I.E. 2.25.3 REAR SUSPENSION WITH HYDRAULIC PRELOAD ADJUSTMENT m With this type of suspension it is possible to adjust the spring preload and the hydraulic braking with extended shock absorber. CAUTION Adjust the spring preload and the hydraulic braking with extended shock absorber according to the con- ditions of use of the vehicle.
Page 83: Checking The Rear Suspension Linkage
SERVICE AND SETTING UP Pegaso 650 I.E. 2.25.4 CHECKING THE REAR SUSPENSION LINKAGE Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). For the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART) under: – Rear suspension linkage bearings. For the check, proceed as follows: NOTE Have someone help you keep the vehicle up- right during this operation.
Page 84 SERVICE AND SETTING UP Pegaso 650 I.E. 2%!2 7(%%, Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). For the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART) under: – Wheel bearings; – Wheel centering. For the check, proceed as follows: Position the vehicle on the appropriate rear support stand, see 1.8.1 (POSITIONING THE VEHICLE ON THE REAR SUPPORT STAND m).
Page 85: Checking The Drive Chain Slack
SERVICE AND SETTING UP Pegaso 650 I.E. $2)6% #(!). Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). For the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART) under: – Final transmission (chain, crown and pinion). The vehicle is equipped with an endless chain, in which a ring link joint is not used.
Page 86: Checking The Driving Chain, Pinion And Sprocket Wear
SERVICE AND SETTING UP Pegaso 650 I.E. 2.29.2 CHECKING THE DRIVING CHAIN, PINION AND SPROCKET WEAR To put a driving chain under tension, see 2.29.3 (AD- JUSTING THE DRIVING CHAIN). Count 21 pins (20 steps) on a branch of the chain and measure the distance between the two end pins.
Page 87: Drive Chain Tension And Lubrication
SERVICE AND SETTING UP Pegaso 650 I.E. 2.29.4 DRIVE CHAIN TENSION AND LUBRICATION For the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART) under: – Drive chain tension and lubrication. Never wash the chain with water jets, steam jets, high- pressure water jets and highly inflammable solvents.
Page 88: Condition Of Tread
2.30.2 INFLATION PRESSURE Use only tyres recommended by APRILIA, see 1.5 CAUTION (TECHNICAL SPECIFICATIONS). Periodically check the tyre inflation pressure at room For further information, see 7.4 (TYRES).
Page 89 SERVICE AND SETTING UP Pegaso 650 I.E. &5%, 0)0%3 Carefully read 1.2.1 (FUEL). For the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART) under: – Fuel pipes. If you should encounter signs of wear, cracking, etc., replace the fuel pipes. –...
Page 90 SERVICE AND SETTING UP Pegaso 650 I.E. #(%#+).' 4(% 34!.$ Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 6.8 (SWITCHES). The vehicle is provided with: – side stand (1); – centre stand (2) m (supplied as standard equipment in the countries where required). The stand has two positions: –...
Page 91 SERVICE AND SETTING UP Pegaso 650 I.E. CENTRE STAND m (supplied as standard equip- ment in the countries where required) Position the vehicle on the side stand. The springs (3) must not be damaged, worn, rusty or weakened. Make sure that when lifted the stand presents no slacks.
Page 92 SERVICE AND SETTING UP Pegaso 650 I.E. .54 "/,4 3#2%7 4)'(4%.).' Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.10 (FASTENING ELEMENTS). For the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART) under: – Nut, bolt, screw tightening. Check all the fastening elements carefully, especially all those components essential for safety, i.e: –...
Page 93 SERVICE AND SETTING UP Pegaso 650 I.E. NOTE - 55 - 00 Release 00/2002-02...
Page 94 SERVICE AND SETTING UP Pegaso 650 I.E. NOTE - 56 - 00 Release 00/2002-02...
Page 95: Engine
Pegaso 650 I.E. ENGINE - 00 Release 00/2002-02...
Page 96 ENGINE Pegaso 650 I.E. ENGINE 4!",% /& #/.4%.43 4%#(.)#!, ).&/2-!4)/....3-3 3.1.1 TECHNICAL DATA ......... 3-3 3.1.2 MAINTENANCE INTERVALS ....3-3 3.1.3 TROUBLESHOOTING ......3-3 3.1.4 SEALANTS ..........3-3 3.1.5 LUBRICANTS .......... 3-3 3.1.6 SPECIAL TOOLS ........3-3 3.1.7 DRIVING TORQUE ........
Page 97 ENGINE Pegaso 650 I.E. 4%#(.)#!, ).&/2-!4)/. 3.1.1 TECHNICAL DATA See 1.5 (TECHNICAL SPECIFICATIONS). 3.1.2 MAINTENANCE INTERVALS See 2.1.1 (REGULAR SERVICE INTERVALS CHART). 3.1.3 TROUBLESHOOTING See 8.1 (TROUBLESHOOTING). 3.1.4 SEALANTS See 1.9 (CONSUMABLES). 3.1.5 LUBRICANTS See 1.6 (LUBRICANT CHART). 3.1.6 SPECIAL TOOLS See 1.7 (SPECIAL TOOLS m).
Page 98 ENGINE Pegaso 650 I.E. %.').% 0!243 7()#( #!. "% $)3!33%-",%$ 7)4(/54 2%-/6).' 4(% %.').% &2/- 4(% &2!-% Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). The parts underlined can be removed and refitted without removing the engine from the frame. CAUTION This chapter describes the relevant procedures pro- gressively and in sequential order.
Page 99 ENGINE Pegaso 650 I.E. - 00 Release 00/2002-02...
Page 100 ENGINE Pegaso 650 I.E. 3.2.1 REMOVING THE EXHAUST PIPES Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). WARNING Let the engine cool down until it reaches room tem- perature. Remove the right panel, see 7.1.4 (REMOVING THE RIGHT AND LEFT SIDES). Remove the radiator, see 5.2 (REMOVING THE RADI- ATOR).
Page 101 ENGINE Pegaso 650 I.E. ã Follow Remove the exhaust pipe unit (12) by withdrawing it from its front part. NOTE Move the exhaust pipe unit (12) gradually, trying to find the best combination of movements and withdraw it correctly (raise the front part, lower the rear part and move the whole so that it carries out a forward screwing movement;...
Page 102 ENGINE Pegaso 650 I.E. 3.2.4 REMOVING THE CLUTCH LEVER Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). CAUTION Before removing the lever, mark lever and shaft (see figure), in order to be able to position it correctly upon reassembly. Release the clutch control cable (1) from the lever (2). Loosen and remove the screw (3).
Page 103 2%-/6).' 4(% 7(/,% %.').% &2/- 4(% &2!-% CAUTION The engine must be removed by an authorized centre or by an APRILIA Official Dealer only. Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). CAUTION The removal of the engine is a particularly complex operation.
Page 104 ENGINE Pegaso 650 I.E. ã Follow CAUTION To clean the outer parts of the engine use a degreas- er, brushes and wipers. Avoid damaging rubber and plastic parts with corro- sive or penetrating detergents and solvents. Should the use of a steam cleaner prove necessary, do not point the high-pressure jets of water, steam or air at the following parts: wheel hubs, controls on the right and left handlebars, brake pumps, instruments...
Page 105 Remove the complete throttle body, see 4.9.2 (RE- MOVING THE THROTTLE BODY). NOTE Have the appropriate special tool m to hand: – aprilia part# 0277295 (hose clamp installation pliers). CAUTION Upon reassembly, replace the hose clamps that have been removed with new ones having the same dimen- sions, see 0.4.2 (SPARE PARTS CATALOGUES).
Page 106 ENGINE Pegaso 650 I.E. ã Follow CAUTION Free all the cables and pipes from the respective clamps located at intervals along their routes. Procure an equal number of clamps to be used for re- fitting. Plug all openings on the engine, pipes and couplings to prevent foreign bodies getting in.
Page 107 ENGINE Pegaso 650 I.E. ã Follow ~ Unscrew and remove the nut (45) and withdraw the screw (46) that fastens the frame to the rear part of the cradle. Driving torque of the screw that fastens the rear part of the cradle: 50 Nm (5.0 kgm). Remove the cradle (47) (complete with side stand and expansion tank front support) by moving it forward.
Page 108 ENGINE Pegaso 650 I.E. ã Follow Unscrew and remove the nut (53) and withdraw the rear lower screw (51) that fastens the engine to the frame. Small pedal screw driving torque: 50 Nm (5.0 kgm). CAUTION Once the screw (51) has been withdrawn, the engine will tend to turn slightly forward with fulcrum on the screw (52).
Page 109 Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). NOTE Have the appropriate special tools m to hand: – aprilia part# 0277919 (type 655 engine support unit) (1); – aprilia part# 8140187 (engine support stand) (2). Remove the entire engine from the frame, see 3.3 (RE- MOVING THE WHOLE ENGINE FROM THE FRAME).
Page 110 ENGINE Pegaso 650 I.E. 2%&)44).' 4(% 7(/,% %.').% /. 4(% &2!-% Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). NOTE In order to refit the whole engine on the frame, the same procedure used for its removal must be fol- lowed in the reverse order, see 3.3 (REMOVING THE WHOLE ENGINE FROM THE FRAME).
Page 111 THE WHOLE ENGINE FROM THE FRAME). NOTE Have the appropriate special tool m to hand: – aprilia part# 0277295 (hose clamp installation pliers). CAUTION Upon reassembly, replace the hose clamps that have been removed with new ones having the same dimen- sions, see 0.4.2 (SPARE PARTS CATALOGUES).
Page 112 ENGINE Pegaso 650 I.E. NOTE - 18 - 00 Release 00/2002-02...
Page 113 Pegaso 650 I.E. FUEL SUPPLY SYSTEM - 00 Release 00/2002-02...
Page 114 FUEL SUPPLY SYSTEM Pegaso 650 I.E. FUEL SUPPLY SYSTEM 4!",% /& #/.4%.43 &5%, 4!.+ ..........4-3 4.1.1 MAINTENANCE ........4-4 4.1.2 CHECKING THE FUEL SUPPLY .... 4-4 $2!).).' 4(% &5%, 4!.+ ....4-4 2%-/6).' 4(% 7(/,% &5%, 3500,9 05-0 5.)4 ......
Page 115 FUEL SUPPLY SYSTEM Pegaso 650 I.E. &5%, 4!.+ The filler cap is to be found on the top of the tank, whilst the bottom part houses: – the fuel supply pump unit; – a pipe for draining water from the filler cap in the event of rain or during washing;...
Page 116: Maintenance
FUEL SUPPLY SYSTEM Pegaso 650 I.E. 4.1.1 MAINTENANCE When the fuel supply pump is to be removed, see 4.3 (REMOVING THE WHOLE FUEL SUPPLY PUMP UNIT), it is advisable to make sure the pipes (1) (2) are intact and that the following are working properly: –...
Page 117 FUEL SUPPLY SYSTEM Pegaso 650 I.E. 2%-/6).' 4(% 7(/,% &5%, 3500,9 05-0 5.)4 Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS), 1.2.1 (FUEL) and 4.1.1 (MAINTE- NANCE). Remove the fuel tank, see 7.1.1 (REMOVAL OF THE FUEL TANK). CAUTION Handle the fuel tank with care and avoid scraping or damaging them.
Page 118 MOVING THE WHOLE FUEL SUPPLY PUMP UNIT). NOTE Have the appropriate special tool m to hand: – aprilia part# 0277295 (hose clamp installation pliers). CAUTION Upon installation, replace the hose clamp that has been removed with a new one having the same di- mensions, see 0.4.2 (SPARE PARTS CATALOGUES).
Page 119 MOVING THE WHOLE FUEL SUPPLY PUMP UNIT). NOTE Have the appropriate special tool m to hand: – aprilia part# 0277295 (hose clamp installation pliers). CAUTION Upon installation, replace the hose clamp that has been removed with a new one having the same di- mensions, see 0.4.2 (SPARE PARTS CATALOGUES).
Page 120 FUEL SUPPLY SYSTEM Pegaso 650 I.E. 2%-/6).' 4(% 0%42/, 02%3352% 2%'5,!4/2 Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Remove the fuel tank, see 7.1.1 (REMOVAL OF THE FUEL TANK). Unscrew and remove the two screws (1), taking the washers. Pressure regulator screw driving torque: 3 Nm (0.3 kgm).
Page 121: Foreword
FUEL SUPPLY SYSTEM Pegaso 650 I.E. %.').% -!.!'%-%.4 4.8.1 FOREWORD The “heart” of the engine’s management consists in the electronic Engine Control Unit which manages and opti- mizes the ignition and injection of the fuel. – The ignition management depends on the specific consumption levels.
Page 122: Sensors
FUEL SUPPLY SYSTEM Pegaso 650 I.E. 4.8.2 SENSORS Driving shaft position sensor (2) Location: in the ignition cover (10). The signals are emitted by the transducers located on the rotor. The engine speed and the position of the driving shaft are calculated based on the signals emitted.
Page 123: Injection System Diagram
FUEL SUPPLY SYSTEM Pegaso 650 I.E. 4.8.3 INJECTION SYSTEM DIAGRAM 1) Electronic unit 7) To the throttle valve position sensor 2) To the ignition switch 8) To the injectors 3) To the fuel pump 9) To the coolant temperature sensor 4) To the dashboard (diagnostic warning light) 10) To the driving shaft position sensor 5) To the atmospheric pressure sensor (ECU inside)
Page 124: Electronic Unit Connector
FUEL SUPPLY SYSTEM Pegaso 650 I.E. 4.8.4 ELECTRONIC UNIT CONNECTOR For further information, see 6.5.1 (CONNECTIONS TO THE ENGINE CONTROL UNIT). Connector Terminal Connections labelling Diagnostic warning light Coolant temperature indicator Fuel pump Injector 2 Injector 1 Throttle valve position sensor Coolant temperature thermistor Air thermistor Coil...
Page 125: Automatic Testing
FUEL SUPPLY SYSTEM Pegaso 650 I.E. 4.8.5 AUTOMATIC TESTING See 6.5 (IGNITION/INJECTION SYSTEM). 4.8.6 ELECTRONIC SYSTEM TROUBLESHOOTING ACCORDING TO THE INFORMATION PROVIDED BY THE DIAGNOSTIC WARNING LIGHT WARNING Take care around the high voltage in the ignition sys- tem. Never disconnect connections with the engine run- ning.
Page 126: Removing The Injectors
FUEL SUPPLY SYSTEM Pegaso 650 I.E. 4(2/44,% "/$9 CAUTION The screw for the basic setting of the throttle valves (A) is painted and cannot be adjusted. The two screws (B) fastening the throttle valve sen- sor are painted and can only be removed in the event the actual sensor is replaced.
Page 127 FUEL SUPPLY SYSTEM Pegaso 650 I.E. To reassemble: CAUTION Replace all the gaskets, O-rings, torsion springs, bushes and seals. These components are supplied with the repair kit. NOTE The seals (14) (15) have different dimensions, therefore do not invert them upon reassembly. Fit the new seals (14) (15) on both injector.
Page 128: Removing The Throttle Body
FUEL SUPPLY SYSTEM Pegaso 650 I.E. 4.9.2 REMOVING THE THROTTLE BODY Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Remove the fuel tank, see 7.1.1 (REMOVAL OF THE FUEL TANK). Partially remove the saddle support, see 7.1.36 (RE- MOVING THE SADDLE SUPPORT). WARNING Mark the electrical connectors (1) (2) so as to prevent them being mixed up by mistake during refitting.
Page 129: Removing The Throttle Body Components
FUEL SUPPLY SYSTEM Pegaso 650 I.E. 4.9.3 REMOVING THE THROTTLE BODY COMPONENTS Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 4.9 (THROTTLE BODY). Remove the complete throttle body, see 4.9.2 (RE- MOVING THE THROTTLE BODY). REMOVING THE MANIFOLD (FUEL RAIL) TOGETHER WITH THE INJECTORS Unscrew and remove the two screws (1), taking the washers.
Page 130: Removing The Idling Speed Adjustment Cable
FUEL SUPPLY SYSTEM Pegaso 650 I.E. REMOVING THE COLD START LEVER Remove the snap ring (11), taking the washer (12). Release the spring (13) of the cold start control lever (14). Remove the cold start lever (14), trying to find the best position from which it can be withdrawn.
Page 131: Inspecting The Throttle Body
FUEL SUPPLY SYSTEM Pegaso 650 I.E. 4.9.5 INSPECTING THE THROTTLE BODY TESTING THE INJECTOR WARNING The fuel is explosive and highly inflammable. Keep fuel away from ignition sparks, heat and flames. NOTE The injection valves may also be checked whilst fitted.
Page 132: Assembling The Throttle Body
FUEL SUPPLY SYSTEM Pegaso 650 I.E. 4.9.6 ASSEMBLING THE THROTTLE BODY Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). CAUTION After disassembling the throttle body, replace all the gaskets, O-rings, torsion springs, bushes and seals. These components are supplied with the repair kit. REASSEMBLING THE COLD START LEVER Install the spring (2) and the cold start control (3) on the fulcrum pin (1).
Page 133: Checking Throttle Valve Control Shaft End Play
FUEL SUPPLY SYSTEM Pegaso 650 I.E. 4.9.7 CHECKING THROTTLE VALVE CONTROL SHAFT END PLAY Remove the throttle body, see 4.9.2 (REMOVING THE THROTTLE BODY). CAUTION For the correct measurement of the axial clearance of the throttle valve control shaft, it is necessary to re- move the spring (1), the bushes (2) (3) and the two washers (4) (5).
Page 134: Adjusting The Throttle Body
FUEL SUPPLY SYSTEM Pegaso 650 I.E. 4.9.8 ADJUSTING THE THROTTLE BODY Remove the throttle body, see 4.9.2 (REMOVING THE THROTTLE BODY). SETTING IDLING CAUTION The screw (1) of the throttle valve end of stroke is painted and must not be adjusted. The adjusting screw (1) can be set again only in case of complete replacement of the throttle valve lever and of the throttle body.
Page 135: Changing And Adjusting The Throttle Valve Potentiometer
FUEL SUPPLY SYSTEM Pegaso 650 I.E. 4.9.9 CHANGING AND ADJUSTING THE THROTTLE VALVE POTENTIOMETER With the engine switched off: Remove the throttle body, see 4.9.2 (REMOVING THE THROTTLE BODY). Disconnect the four-way connector (coloured black) (1). CAUTION The two screws (2) fastening the throttle valve poten- tiometer are painted and can only be removed or slacken in the event the actual sensor is replaced.
Page 136: Co Adjustment
– room temperature 20-30 °C (68-86 °F). NOTE Have the appropriate special tools m to hand: – aprilia part# 8140196 (exhaust fume analyser) (1). WARNING Fuel vapours are noxious for your health. Before proceeding, make sure that the room in which you are working is properly ventilated.
Page 137 FUEL SUPPLY SYSTEM Pegaso 650 I.E. NOTE - 25 - 00 Release 00/2002-02...
Page 138 FUEL SUPPLY SYSTEM Pegaso 650 I.E. NOTE - 26 - 00 Release 00/2002-02...
Page 139 Pegaso 650 I.E. COOLING SYSTEM - 00 Release 00/2002-02...
Page 140 COOLING SYSTEM Pegaso 650 I.E. COOLING SYSTEM 4!",% /& #/.4%.43 $%3#2)04)/..........5-3 2%-/6).' 4(% 2!$)!4/2 ....5-4 2%-/6).' 4(% #//,).' %,%#42/&!.3 ......... 5-6 2%-/6).' 4(% #//,!.4 4(%2-!, 37)4#( ......... 5-7 2%-/6).' 4(% #//,!.4 4(%2-)34/2 ........... 5-7 2%-/6).' 4(% %80!.3)/.
Page 141 COOLING SYSTEM Pegaso 650 I.E. $%3#2)04)/. The centrifugal pump (positioned inside the engine and To check and top up the coolant, refer to the “MIN” and driven by the latter) draws coolant and distributes it to the “MAX” reference marks, see 2.13 (CHECKING AND galleries in the cylinders and in the heads in order to cool TOPPING UP COOLANT).
Page 142 Release the pipes and the cables from the cable guide (9). NOTE Have the appropriate special tool m to hand: – aprilia part# 0277295 (hose clamp installation pliers). CAUTION Upon installation, replace the hose clamp that has been removed with a new one having the same di- mensions, see 0.4.2 (SPARE PARTS CATALOGUES).
Page 143 COOLING SYSTEM Pegaso 650 I.E. ã Follow Withdraw the screw (19), taking the cable guide (20), the washer and if necessary the bushing and the rub- ber element. NOTE Upon reassembly, position the cable guide ring (20) correctly. NOTE If the rubber element (21) is damaged, replace it. CAUTION Proceed with care.
Page 144 COOLING SYSTEM Pegaso 650 I.E. 2%-/6).' 4(% #//,).' %,%#42/&!.3 Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Turn the ignition switch to position “1”. Remove the front fairing, see 7.1.24 (REMOVING THE FRONT FAIRING). Disconnect the electric connector (1). CAUTION Upon reassembly, make sure that the electric con- nector (1) is correctly coupled.
Page 145 COOLING SYSTEM Pegaso 650 I.E. 2%-/6).' 4(% #//,!.4 4(%2-!, 37)4#( Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.5 (COOLANT). Turn the ignition switch to position “1”. Remove the front fairing, see 7.1.24 (REMOVING THE FRONT FAIRING). Disconnect the electric connectors (1) (2) from the ther- mal switch (3).
Page 146 COOLING SYSTEM Pegaso 650 I.E. 2%-/6).' 4(% %80!.3)/. 4!.+ Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.5 (COOLANT). Position the vehicle on the stand. WARNING Let the engine cool down until it reaches room tem- perature. Remove the oil sump guard, see 7.1.3 (REMOVING THE OIL SUMP GUARD).
Page 147 ã Follow NOTE Have the appropriate special tool m to hand: – aprilia part# 0277295 (hose clamp installation pliers). CAUTION Upon installation, replace the hose clamp that has been removed with a new one having the same di- mensions, see 0.4.2 (SPARE PARTS CATALOGUES).
Page 148 COOLING SYSTEM Pegaso 650 I.E. NOTE - 10 - 00 Release 00/2002-02...
Page 149: Electric System
Pegaso 650 I.E. ELECTRIC SYSTEM - 00 Release 00/2002-02...
Page 150 ELECTRIC SYSTEM Pegaso 650 I.E. #//,!.4 4%-0%2!452% ).$)#!4/2 ..........6-27 ELECTRIC SYSTEM 6.10.1 WIRING DIAGRAM ......6-27 6.10.2 CHECKING THE INSTRUMENT ..6-27 #(%#+).' 4(% %.').% /), 4!",% /& #/.4%.43 02%3352% 3%.3/2 ......6-28 &5%, ,%6%, #)2#5)4 ......6-29 ).42/$5#4)/.
Page 151 ELECTRIC SYSTEM Pegaso 650 I.E. ).42/$5#4)/. The following key will be useful in consulting this section. NOTE The numbering to be found on the specific wiring diagrams corresponds to that on the general wiring dia- gram. 6.1.1 CABLE COLOURS Orange Light blue Blue...
Page 152 ELECTRIC SYSTEM Pegaso 650 I.E. %,%#42)# #/-0/.%.43 ,!9/54 - 00 Release 00/2002-02...
Page 153 ELECTRIC SYSTEM Pegaso 650 I.E. NOTE The numbering corresponds to that on the gen- 34) Injection relay eral wiring diagram. 35) Start relay 36) Starter 1) Side stand switch 37) Battery 2) Multiple connectors 38) Voltage regulator 3) Clutch control lever switch 39) Fuses 4) Diode 1 40) Generator...
Page 154: Cable Colours
ELECTRIC SYSTEM Pegaso 650 I.E. #(%#+).' 4(% 2%#(!2').' 3934%- CABLE COLOURS Orange Light blue Blue White Yellow Grey Brown Black Pink Green Violet 6.3.1 CHECKING THE RECHARGING VOLTAGE Check the electrolyte level, see 2.3.1 (CHECKING THE ELECTROLYTE LEVEL). Check battery voltage, see 2.3.3 (RECHARGING THE BATTERY).
Page 155: Checking The Alternator Continuity
ELECTRIC SYSTEM Pegaso 650 I.E. 6.3.3 CHECKING THE ALTERNATOR CONTINUITY With the engine switched off: Remove the left cover, see 7.1.4 (REMOVING THE RIGHT AND LEFT SIDES). Disconnect the alternator cables connector (1). Using a pocket tester, check for breaks between the ca- bles of the stator [on the internal female terminals, yel- low cables (G)].
Page 156: Injection Power Supply Diagram
ELECTRIC SYSTEM Pegaso 650 I.E. ).*%#4)/. 3934%- 6.4.1 INJECTION POWER SUPPLY DIAGRAM 1) Battery 7) To the cooling fans 2) Ignition key 8) Kill switch 3) Unit 9) Light loads 4) Injection relay 10) To the water temperature thermistor, the air temperature thermistor, the accelerator sensor.
Page 157: Checking The Injection Relay
ELECTRIC SYSTEM Pegaso 650 I.E. 6.4.3 CHECKING THE INJECTION RELAY In order to check the operation of the relay: Remove the saddle, see p 7.1.7 (REMOVING THE SADDLE). Remove the injection relay (1) from its seat. Disconnect the connector (2). Power the two internal male terminals (85) (86) at 12 V.
Page 158: Connections To The Engine Control Unit
ELECTRIC SYSTEM Pegaso 650 I.E. )'.)4)/.).*%#4)/. 3934%- 6.5.1 CONNECTIONS TO THE ENGINE CONTROL UNIT NOTE See 6.2 (ELECTRIC COMPONENTS LAYOUT) for the positioning of the components. For further information, see 4.8.4 (ELECTRONIC UNIT CONNECTOR). Z) Electronic unit connector (32-way) B) Pick-up shielding C) To the ignition switch D) Injection relay...
Page 159 ELECTRIC SYSTEM Pegaso 650 I.E. Position Component Terminal Nominal value Cable colours Injection warning light Vi / N Coolant temperature indicator Bi / N Fuel pump R / N G / N 11 – 17 Ω Injector 2 R / N 11 –...
Page 160: Troubleshooting
ELECTRIC SYSTEM Pegaso 650 I.E. 6.5.2 TROUBLESHOOTING Position the vehicle on the stand. Turn the ignition switch to position “2”. The diagnostic warning light "û" (1) comes on. CAUTION Do not carry out any operation on the components of the vehicle with the ignition switch in position “2”. With the engine stop switch in position "1", it comes on whenever the ignition switch is brought to posi- tion "2"...
Page 161 ELECTRIC SYSTEM Pegaso 650 I.E. FAILURE CODE TABLE Blinks Fault Warning light on Failure description code long short barometric pressure sensor circuit TPS - throttle position sensor engine temperature sensor intake air temperature sensor wrong pick-up sensor signal sequence pick-up sensor circuit sensor power supply circuit, live battery voltage too low battery voltage too high...
Page 162: Eliminating Electronic System Faults
ELECTRIC SYSTEM Pegaso 650 I.E. 6.5.4 ELIMINATING ELECTRONIC SYSTEM FAULTS CAUTION Take care around the high voltage in the ignition sys- tem. Never disconnect connections with the engine run- ning. Whenever work is performed in the ignition system, always make sure the ignition switch is set to “1” and the battery disconnected, unless otherwise indi- cated (when disconnecting the battery, disconnect the negative pole “–”...
Page 163: Checking The Injectors
ELECTRIC SYSTEM Pegaso 650 I.E. 6.5.5 CHECKING THE INJECTORS With the engine switched off: Remove the saddle, see p 7.1.7 (REMOVING THE SADDLE). NOTE The following procedure refers to a single injec- tor, though it is applicable to both. Disconnect the two-way connector (1) (coloured black) and take the measurements (on the injector-side termi- nals).
Page 164: Checking The Air
ELECTRIC SYSTEM Pegaso 650 I.E. 6.5.7 CHECKING THE AIR THERMISTOR OPERATION Remove the saddle, see p 7.1.7 (REMOVING THE SADDLE). Disconnect the two-way connector (1) (coloured green). CAUTION Upon reassembly, make sure that the electric con- nector (1) is correctly coupled. Unscrew and remove the thermistor (2).
Page 165 ELECTRIC SYSTEM Pegaso 650 I.E. 6.5.8 CHECKING THE COOLANT THERMISTOR OPERATION Remove the thermistor (1), see 5.5 (REMOVING THE COOLANT THERMISTOR). Connect a tester (2) (set as an ohmmeter) to the ther- mistor (1), as illustrated in the figure. Immerse the thermistor (1) in a container (3) holding coolant.
Page 166 ELECTRIC SYSTEM Pegaso 650 I.E. 6.5.9 CHECKING THE IGNITION COIL Remove the fuel tank, see 7.1.1 (REMOVAL OF THE FUEL TANK). Disconnect the connector (1) from the ignition coil (2). CAUTION Upon reassembly, make sure that the electric con- nector (1) is correctly coupled. Pull the cable (3) of the coil (2).
Page 167 ELECTRIC SYSTEM Pegaso 650 I.E. &5%, 05-0 3934%- 6.6.1 CHECKING THE FUEL PUMP Remove the saddle, see p 7.1.7 (REMOVING THE SADDLE). Disconnect the four-way connector (1) positioned near the injectors. CAUTION When reassembling, make sure the connector (1) is plugged in properly.
Page 168 ELECTRIC SYSTEM Pegaso 650 I.E. )'.)4)/. 3!&%49 3934%- 6.7.1 WIRING DIAGRAM NOTE See 6.2 (ELECTRIC COMPONENTS LAYOUT) for the positioning of the components. Wiring diagram key 1) Battery 2) Starter 3) Start relay 4) Neutral gear switch 5) Clutch control lever switch 6) Diode module 7) Neutral warning light (LED) 8) Unit...
Page 169 ELECTRIC SYSTEM Pegaso 650 I.E. 6.7.2 STARTING SAFETY OPERATING LOGIC NOTE With the engine shutoff switch in position “1” the starter motor does not turn over. GEAR POSITION STAND POSITION CLUTCH LEVER ENGINE IGNITION STARTER PULLED UP RELEASED IN NEUTRAL PULLED UP TURNING OVER DOWN...
Page 170 ELECTRIC SYSTEM Pegaso 650 I.E. 6.7.4 CHECKING THE DIODE OPERATION Remove the fuel tank, see 7.1.1 (REMOVAL OF THE FUEL TANK). Disconnect the two-way connector (1). CAUTION Upon reassembly, make sure that the electric con- nector (1) is correctly coupled. Using a tester (in diode test mode), check the values be- tween the two male terminals in the diode, as illustrated in the figure.
Page 171 ELECTRIC SYSTEM Pegaso 650 I.E. 6.7.5 CHECKING THE SIDE STAND AND THE SAFETY SWITCH The side stand (1) must rotate without hindrances. Carry out the following checks: The springs (2) must not be damaged, worn, rusty or weakened. The side stand must rotate freely, if necessary grease the joint, see 1.6 (LUBRICANT CHART).
Page 172 ELECTRIC SYSTEM Pegaso 650 I.E. 37)4#(%3 Using a tester, check the continuity of the switches, refer- ring to the specific diagram below. Should any anomalies be encountered, change the corre- sponding switch set. 6.8.1 RIGHT SIDE SWITCH SET 1) Engine stop switch 2) Start push button 3) Light switch (not provided for e) Cables...
Page 173 ELECTRIC SYSTEM Pegaso 650 I.E. 6.8.3 SINGLE SWITCHES 1) Ignition switch Cables Pos. & 2) Front brake stoplight switch Cables Pos. Operating 3) Rear brake stoplight switch Cables Pos. Operating 4) Neutral gear switch Cables Pos. Screw Neutral 5) Stand switch Cables Stand Down...
Page 174 ELECTRIC SYSTEM Pegaso 650 I.E. #//,).' %,%#42/&!. 6.9.1 WIRING DIAGRAM Wiring diagram key 1) Electrofan 2) Thermal switch 3) Battery 4) Fuse (20A) 5) To voltage regulator 6) To the light loads 7) Ignition switch (2 – 1 – &) 6.9.2 CHECKING THE ELECTROFAN OPERATION To check operation of electrofan (1): Disconnect the two electric connectors (8) (9) from the...
Page 175: Wiring Diagram
ELECTRIC SYSTEM Pegaso 650 I.E. #//,!.4 4%-0%2!452% ).$)#!4/2 6.10.1 WIRING DIAGRAM Wiring diagram key 1) Coolant temperature indicator ()) 2) Air thermistor 3) Battery 4) To the cooling fan and voltage regulator 5) To the ignition 6) Resistance 6.10.2 CHECKING THE INSTRUMENT Remove the front fairing, see 7.1.24 (REMOVING THE FRONT FAIRING).
Page 176 ELECTRIC SYSTEM Pegaso 650 I.E. #(%#+).' 4(% %.').% /), 02%3352% 3%.3/2 To check operation of sensor: Slip off the rubber protection (1). Disconnect the electric terminal from the sensor (2). With a tester (scale x 100 Ω) check for breaks between the tongued terminal (3) and the casing of the sensor.
Page 177: Wiring Diagram
ELECTRIC SYSTEM Pegaso 650 I.E. &5%, ,%6%, #)2#5)4 6.12.1 WIRING DIAGRAM Wiring diagram key 1) Low fuel warning light (-) (coloured amber) 2) Fuel level sensor 3) Battery 4) Ignition switch (2 – 1 – &) 5) To voltage regulator 6) To ignition/injection 6.12.2 FUEL LEVEL INDICATOR Disconnect the electric connector (four-way) (7) of the...
Page 178: Checking The High Beam Relay
ELECTRIC SYSTEM Pegaso 650 I.E. ,)'(4 3934%- 6.13.1 WIRING DIAGRAM NOTE See 6.2 (ELECTRIC COMPONENTS LAYOUT) for the positioning of the components. Key: 1) Battery 9) High beam warning light 2) Fuses (20 A) 10) Bulbs for dashboard lighting 3) Fuses (15 A) 11) Front parking light bulb 4) Right dimmer switch...
Page 179 ELECTRIC SYSTEM Pegaso 650 I.E. !#/534)# !.$ 6)35!, 3)'.!,,).' 3934%- 6.14.1 WIRING DIAGRAM NOTE See 6.2 (ELECTRIC COMPONENTS LAYOUT) for the positioning of the components. Key: 1) Left dimmer switch 7) Blinking 2) Horn 8) Rear right direction indicator bulb 3) Fuse (15A) 9) Rear left direction indicator bulb 4) Fuse (20 A)
Page 180: Checking The Operation Of The Horn
ELECTRIC SYSTEM Pegaso 650 I.E. 6.14.2 CHECKING THE OPERATION OF THE HORN Remove the front fairing, see 7.1.24 (REMOVING THE FRONT FAIRING). Power the two internal horn connector (1) at 12 V. If necessary, use the appropriate screw adjuster. 6.14.3 CHECKING THE BLINKING OPERATION If none of the direction indicator bulbs works, this means that there probably is a problem in the blink- ing unit.
Page 181: Activating The Battery
ELECTRIC SYSTEM Pegaso 650 I.E. "!44%29 When changing batteries, replace with a battery of the same type, see 1.5 (TECHNICAL SPECIFICATIONS) Carefully read 2.3 (BATTERY). 6.15.1 ACTIVATING THE BATTERY Remove the battery, see 7.1.8 (REMOVING THE BAT- TERY). WARNING The electrolyte in the battery is toxic and caustic and may cause burns on contact with the skin as it con- tains sulphuric acid.
Page 182: Battery Maintenance
ELECTRIC SYSTEM Pegaso 650 I.E. ã Follow Remove the element plugs (1). Fill the cells with electrolyte until reaching the MAX lev- NOTE It is advisable to use an electrolyte with specifc weight 1.3. Subject the battery to a trickle charge cycle, see 2.3.3 (RECHARGING THE BATTERY).
Page 183: Changing The Headlight
ELECTRIC SYSTEM Pegaso 650 I.E. #(!.').' 4(% "5,"3 Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). WARNING Risk of fire. Keep fuel and other flammable substances away from the electrical components. CAUTION Before changing a bulb, move the ignition switch to position “1”...
Page 184 ELECTRIC SYSTEM Pegaso 650 I.E. ã Follow PARKING LIGHT BULB Move the protection element (8) with your hands. CAUTION To extract the bulb socket, do not pull the electric wires. Grasp the parking light bulb socket (9), pull it and re- move it from its seat.
Page 185: Changing The Front
ELECTRIC SYSTEM Pegaso 650 I.E. 6.16.2 CHANGING THE FRONT DIRECTION INDICATOR BULBS Carefully read 6.16 (CHANGING THE BULBS). Position the vehicle on the stand. Unscrew and remove the two screws (1). Remove the protection screen (2). CAUTION Upon reassembly, correctly position the protection screen in its seat.
Page 186: Changing The Rear Light Bulb
ELECTRIC SYSTEM Pegaso 650 I.E. 6.16.4 CHANGING THE REAR LIGHT BULB Carefully read 6.16 (CHANGING THE BULBS). NOTE The rear light houses two parking light/stoplight bulbs (1). The following operations refer to a single bulb, but are valid for both. Before changing a bulb, check the efficiency of the stop- light switches, see 6.8.3 (SINGLE SWITCHES).
Page 187: Changing The Dashboard Bulbs
ELECTRIC SYSTEM Pegaso 650 I.E. 6.16.6 CHANGING THE DASHBOARD BULBS To change, proceed as follows: Position the vehicle on the stand. Remove the front fairing, see 7.1.24 (REMOVING THE FRONT FAIRING). Slide out the relevant rubber bulb holder and, where necessary, replace the bulb.
Page 188 ELECTRIC SYSTEM Pegaso 650 I.E. !$*534).' 4(% 6%24)#!, (%!$,)'(4 "%!- NOTE To check the direction of the headlight beam, specific procedures must be adopted, in accordance with the regulations in force in the country where the vehicle is used. To rapidly check the correct direction of the beam, place the vehicle on flat ground, 10 m away from a wall.
Page 189 ELECTRIC SYSTEM Pegaso 650 I.E. #(!.').' 4(% &53%3 Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). CAUTION Do not repair faulty fuses. Never use fuses different from the recommended ones. The use of unsuitable fuses may cause damages to the electric system or, in case of short circuit, even a fire.
Page 190 ELECTRIC SYSTEM Pegaso 650 I.E. 7)2).' $)!'2!- - 42 - 00 Release 00/2002-02...
Page 191 ELECTRIC SYSTEM Pegaso 650 I.E. 1) Side stand switch 31) Rear stoplight switch 2) Multiple connectors 32) Thermal switch cooling electrofan 3) Clutch control lever switch 33) Cooling electrofan 4) Diode 1 34) Injection relay 5) Diode 2 35) Start relay 6) Engine oil pressure switch 36) Starter 7) Neutral gear switch...
Page 192 ELECTRIC SYSTEM Pegaso 650 I.E. NOTE - 44 - 00 Release 00/2002-02...
Page 193 Pegaso 650 I.E. CHASSIS - 00 Release 00/2002-02...
Page 194 CHASSIS Pegaso 650 I.E. 7.3.6 REAR WHEEL PIN ........... 7-47-00 7.3.7 REAR WHEEL RIM .......... 7-47-00 CHASSIS 7.3.8 REAR TYRE ............. 7-47-00 7.3.9 REAR BRAKE DISC ........7-47-00 7.3.10 FINAL DRIVE UNIT BEARINGS ....7-48-00 7.3.11 FLEXIBLE COUPLINGS ........ 7-49-00 7.3.12 SPROCKET ............
Page 195 CHASSIS Pegaso 650 I.E. "/$9 1) Front brake caliper 2) Front brake disc 3) Front fairing 4) Headlight 5) Dashboard 6) Ignition switch/steering lock 7) Left rear-view mirror 8) Controls on the left part of the handlebar 9) Left handgrip 10) Fuel tank 11) Shock absorber 12) Left side cover...
Page 196 CHASSIS Pegaso 650 I.E. 19) Drive chain 20) Rear wheel 21) Right exhaust silencer 22) Number plate holder 23) Rear luggage rack 24) Right side cover 25) Saddle 26) Fuel tank filler cap 27) Right handgrip (throttle grip) 28) Controls on the right part of the handlebar 29) Right rear-view mirror 30) Dashboard fairing 31) Front fork...
Page 197: Removal Of The Fuel Tank
CHASSIS Pegaso 650 I.E. 7.1.1 REMOVAL OF THE FUEL TANK Carefully read 1.2.1 (FUEL) and 4.1 (FUEL TANK). WARNING Risk of fire. Wait until the engine and the exhaust silencer have completely cooled down. Fuel vapours are noxious for your health. Before proceeding, make sure that the room in which you are working is properly ventilated.
Page 198: Removing The Fuel Tank Filler Cap
CHASSIS Pegaso 650 I.E. ã Follow WARNING Position the tank in a safe place, with the cap facing upwards; neither overturn, nor tilt it, since the filler- cap is not tight and the fuel would flow out of the tank. 7.1.2 REMOVING THE FUEL TANK FILLER CAP Carefully read 1.2.1 (FUEL) and 4.1 (FUEL TANK).
Page 199: Removing The Oil Sump Guard
Remove the oil sump guard (2). NOTE If the deadening material inside the oil sump guard (2) is deteriorated, contact an aprilia Official Dealer to have it changed. 7.1.4 REMOVING THE RIGHT AND LEFT SIDES Carefully read 0.5.4 (REASSEMBLING THE COMPO- NENTS).
Page 200: Removing The Rear Luggage Rack
CHASSIS Pegaso 650 I.E. 7.1.5 REMOVING THE REAR LUGGAGE RACK Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Remove the side panels, see 7.1.4 (REMOVING THE RIGHT AND LEFT SIDES). ~ Unscrew and remove the screw (1). Luggage rack side screw driving torque: 12 Nm (1.2 kgm).
Page 201: Removing The Battery
CHASSIS Pegaso 650 I.E. 7.1.8 REMOVING THE BATTERY Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 2.3 (BATTERY). Make sure that the ignition switch is in position “1”. Remove the left cover, see 7.1.4 (REMOVING THE RIGHT AND LEFT SIDES). Unscrew and remove the screw (1).
Page 202: Removing The Air Cleaner Case
ING THE EXHAUST SILENCERS). NOTE Have the appropriate special tool m to hand: – aprilia part# 0277295 (hose clamp installation pliers). CAUTION Upon installation, replace the hose clamp that has been removed with a new one having the same di- mensions, see 0.4.2 (SPARE PARTS CATALOGUES).
Page 203: Removing The Electronic Unit
CHASSIS Pegaso 650 I.E. 7.1.10 REMOVING THE ELECTRONIC UNIT Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Turn the ignition switch to position “1”. Put back the rider saddle, see 7.1.7 (REMOVING THE SADDLE). Disconnect the pipe (22). Unscrew and remove the screw (23), taking the rele- vant nut.
Page 204: Removing The Antivibration Weight
CHASSIS Pegaso 650 I.E. 7.1.11 REMOVING THE ANTIVIBRATION WEIGHT Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). NOTE The following information refers to one unit only, but is valid for both. Position the vehicle on the stand. Unscrew and remove the screw (1). Antivibration weight screw driving torque: 10 Nm (1.0 kgm).
Page 205: Removing The Handgrip
CHASSIS Pegaso 650 I.E. 7.1.14 REMOVING THE HANDGRIP Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). NOTE The following information refers to one unit only, but is valid for both. Remove the antivibration weight unit from the handle- bar, see 7.1.11 (REMOVING THE ANTIVIBRATION WEIGHT).
Page 206: Removing The Clutch Lever
CHASSIS Pegaso 650 I.E. 7.1.15 REMOVING THE CLUTCH LEVER Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). COMPLETE REMOVAL Remove the left hand guards, see 7.1.13 (REMOVING THE HAND GUARDS). Withdraw the protection element (1). Loosen the ring nut (2). Screw the adjuster (3) completely. Make the slots (4) (5) (6) coincide.
Page 207: Removing The Electric Controls On
CHASSIS Pegaso 650 I.E. 7.1.16 REMOVING THE ELECTRIC CONTROLS ON THE LEFT SIDE OF THE HANDLEBAR Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Position the vehicle on the stand. Turn the ignition switch to position “1”. PARTIAL REMOVAL NOTE The screw (1) is longer than the screw (2). Upon reassembly, take care to position them correctly.
Page 208: Removing The Throttle Grip
CHASSIS Pegaso 650 I.E. 7.1.17 REMOVING THE THROTTLE GRIP Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Remove the right antivibration weight unit, see 7.1.11 (REMOVING THE ANTIVIBRATION WEIGHT). Remove the right handgrip, see 7.1.14 (REMOVING THE HANDGRIP). NOTE The screw (1) is longer than the screw (2). Upon reassembly, take care to position them correctly.
Page 209 CHASSIS Pegaso 650 I.E. ã Follow Remove the right hand guards, see 7.1.13 (REMOV- ING THE HAND GUARDS). Unscrew and remove the two screws (10) that fasten the stop light switch (11) and take the nuts. NOTE Before removing the U bolt (12), mark its posi- tion on the handlebar so it can be refitted in the right place.
Page 210: Removing The Electric Controls On
CHASSIS Pegaso 650 I.E. 7.1.19 REMOVING THE ELECTRIC CONTROLS ON THE RIGHT SIDE OF THE HANDLEBAR Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Position the vehicle on the stand. Turn the ignition switch to position “1”. PARTIAL REMOVAL NOTE The screw (1) is longer than the screw (2). Upon reassembly, take care to position them correctly.
Page 211: Removing The Ignition Switch
CHASSIS Pegaso 650 I.E. 7.1.20 REMOVING THE IGNITION SWITCH/ STEERING LOCK Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Position the vehicle on the stand. Turn the steering all the way over to the left. Turn the ignition switch to position “1”. Release the wiring from the fastening clamp (1).
Page 212: Removing The Handlebar
CHASSIS Pegaso 650 I.E. 7.1.22 REMOVING THE HANDLEBAR Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Remove the grips, see 7.1.14 (REMOVING THE HANDGRIP). Partially remove the electric controls, see 7.1.19 (RE- MOVING THE ELECTRIC CONTROLS ON THE RIGHT SIDE OF THE HANDLEBAR) and 7.1.16 (RE- MOVING THE ELECTRIC CONTROLS ON THE LEFT SIDE OF THE HANDLEBAR).
Page 213: Removing The Front Fairing
CHASSIS Pegaso 650 I.E. 7.1.24 REMOVING THE FRONT FAIRING Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). WARNING Let the engine cool down until it reaches room tem- perature. Remove the dashboard fairing, see 7.1.27 (REMOV- ING THE DASHBOARD FAIRING). Disconnect the electric connector (1) of the headlight. ~ Disconnect the electric connectors of the front direc- tion indicators (2) (3).
Page 214: Removing The Headlight
CHASSIS Pegaso 650 I.E. 7.1.25 REMOVING THE HEADLIGHT Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Remove the front fairing, see 7.1.24 (REMOVING THE FRONT FAIRING). Unscrew and remove the four screws (1), taking the washers. Headlight screw driving torque: 2 Nm (0.2 kgm). CAUTION Upon reassembly, tighten the screws (1) moderately, since they are fixed on plastic.
Page 215: Removing The Dashboard Fairing
CHASSIS Pegaso 650 I.E. 7.1.27 REMOVING THE DASHBOARD FAIRING Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Position the vehicle on the stand. ~ Unscrew and remove the screw (1). Dashboard fairing lower screw driving torque: 25 Nm (2.5 kgm). ~ Unscrew and remove the screw (2). Fairing side screw driving torque: 1.5 Nm (0.15 kgm).
Page 216: Removing The Drive Chain Guards
CHASSIS Pegaso 650 I.E. 7.1.29 REMOVING THE DRIVE CHAIN GUARDS Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Position the vehicle on the stand. CAUTION Handle the plastic and painted components with care to avoid scraping or damaging them. DRIVE CHAIN UPPER GUARD Unscrew and remove the two screws (1).
Page 217: Removing The Number Plate Holder
CHASSIS Pegaso 650 I.E. 7.1.31 REMOVING THE NUMBER PLATE HOLDER Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Remove the panels, see 7.1.4 (REMOVING THE RIGHT AND LEFT SIDES). Disconnect the electric connector (1) (on left side of ve- hicle). Release the wiring from the two fastening clamps (2). NOTE Prepare the same number of clamps, which will be required for reassembly.
Page 218: Removing The Glove Compartment
CHASSIS Pegaso 650 I.E. 7.1.32 REMOVING THE GLOVE COMPARTMENT Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Remove the electronic unit, see 7.1.10 (REMOVING THE ELECTRONIC UNIT). Remove the number plate holder, see 7.1.31 (REMOV- ING THE NUMBER PLATE HOLDER). CAUTION Take note of the layout of the electric cables, in order to be able to position them correctly upon reassem- bly.
Page 219: Removing The Passenger Footrest Group
CHASSIS Pegaso 650 I.E. 7.1.33 REMOVING THE PASSENGER FOOTREST GROUP Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Remove the side panels, see 7.1.4 (REMOVING THE RIGHT AND LEFT SIDES). ~ Unscrew and remove the two screws (1). Passenger footrest screw driving torque: 25 Nm (2.5 kgm).
Page 220: Removing The Saddle Support
CHASSIS Pegaso 650 I.E. 7.1.36 REMOVING THE SADDLE SUPPORT Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Position the vehicle on the centre stand m . PARTIAL REMOVAL Remove the exhaust silencers, see 7.1.34 (REMOV- ING THE EXHAUST SILENCERS). Loosen the two clamps (1) (2). ~ Loosen the saddle pillar lower fastening screw (3), giving it approximately one turn.
Page 221 CHASSIS Pegaso 650 I.E. COMPLETE REMOVAL Slightly open the two tangs (7), releasing the pipe and the electric cable. Unscrew and remove the screw (8) and take the wash- Rear brake fluid tank screw driving torque: 3 Nm (0.3 kgm). CAUTION Take care to keep the rear brake reservoir (9) in verti- cal position, so that it does not overturn and the fluid...
Page 222: Removing The Rear Light
CHASSIS Pegaso 650 I.E. 7.1.37 REMOVING THE REAR LIGHT Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Remove the panels, see 7.1.4 (REMOVING THE RIGHT AND LEFT SIDES). ~ Unscrew and remove the nut (1), take the washer and if necessary the bush and the rubber element. Rear light side screw driving torque: 10 Nm (1.0 kgm).
Page 223: Removing The Chain Rollers And Shoe
CHASSIS Pegaso 650 I.E. 7.1.40 REMOVING THE CHAIN ROLLERS AND SHOE Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). REMOVING THE LOWER ROLLER Position the vehicle on the stand. Unscrew and partially withdraw the screw (1) (leave the screw inserted as much as necessary to keep the rear brake pedal in its position) and take the nut (2).
Page 224: Removing The Side Stand
CHASSIS Pegaso 650 I.E. 7.1.41 REMOVING THE SIDE STAND Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Position the vehicle on the centre stand m , or on an appropriate support stand fastened to the centre stand couplings. CAUTION Proceed with the stand up. Disconnect the two springs (1).
Page 225: Removing The Front Direction
CHASSIS Pegaso 650 I.E. 7.1.43 REMOVING THE FRONT DIRECTION INDICATORS Remove the front fairing, see 7.1.24 (REMOVING THE FRONT FAIRING). ~ Unscrew and remove the screw (1) and take the washer. Front direction indicator screw driving torque: 1.5 Nm (0.15 kgm). CAUTION Upon reassembly, tighten the screw (1) moderately, since it is fixed on plastic.
Page 226: Removing The Frame
Pegaso 650 I.E. 7.1.45 REMOVING THE FRAME CAUTION The frame (1) must be removed by an authorized cen- tre or by an APRILIA Official Dealer only. Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). CAUTION The removal of the frame is a particularly complex operation.
Page 227 CHASSIS Pegaso 650 I.E. ã Follow Do not attempt to reinstall the removed hose clamp, since it is unusable. Do not replace the removed hose clamp with a screw clamp or with other types of clamp. Cut the head of the pipe clamps (3) (4) (5) in the given order.
Page 228 CHASSIS Pegaso 650 I.E. &2/.4 7(%%, 1) Wheel pin 2) Speedometer/odometer control 3) Speedometer/odometer control sealing ring 4) Traction ring 5) Bearings 6) Inner spacer 7) Complete wheel 8) Outer spacer I = GREASE, see 1.6 (LUBRICANT CHART). - 36 - 00 Release 00/2002-02...
Page 229: Removing The Front Wheel
CHASSIS Pegaso 650 I.E. 7.2.1 REMOVING THE FRONT WHEEL Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 2.26 (FRONT WHEEL). CAUTION While disassembling and reassembling the wheel, be careful not to damage the brake pipes, the disc and the pads. WARNING Riding with damaged rims may be dangerous for the rider, other persons and the vehicle.
Page 230: Checking The Front Wheel
CHASSIS Pegaso 650 I.E. 7.2.2 CHECKING THE FRONT WHEEL COMPONENTS CAUTION Make sure that all the components are intact, particu- larly the following. 7.2.3 FRONT WHEEL BEARINGS Carry out the check with the bearings mounted on the wheel. CHECKING THE ROTATION Manually rotate the inner ring (1) of each single bear- ing.
Page 231: Front Wheel Gaskets
CHASSIS Pegaso 650 I.E. 7.2.4 FRONT WHEEL GASKETS Check the conditions of the gasket (1); if it is damaged or excessively worn, change it. WARNING Always change both seals. Always replace the gaskets with gaskets of the same type. 7.2.5 FRONT WHEEL PIN Check the eccentricity of the pin wheel (2) by means of a comparator.
Page 232: Disassembling The Front Wheel
Remove the traction ring (2). NOTE Have the appropriate special tool m to hand: – aprilia part# 8140180 (Kit for bearings in the range Ø10 mm to Ø 30 mm). Use a special extractor to extract the right bearing (3).
Page 233: Assembling The Front Wheel
Work from the right-hand side of the wheel: NOTE Have the appropriate special tool m to hand: – aprilia part# 8140180 (Kit for bearings in the range Ø10 mm to Ø 30 mm). Using the appropriate pad, insert the right bearing (1) completely.
Page 234 CHASSIS Pegaso 650 I.E. 7.2.12 INSTALLING THE FRONT WHEEL Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Spread a film of lubricating grease on the whole length of the wheel pin (1), grease the inside of the speedom- eter/odometer control (2), see 1.6 (LUBRICANT CHART).
Page 235 CHASSIS Pegaso 650 I.E. 2%!2 7(%%, 1) Nut 2) Washer 3) Right side spacer 4) Right seal 5) Right seeger ring 6) Flexible coupling bearing 7) Outer spacer 8) Crown complete with flexible coupling hub 9) Flexible couplings 10) Bearing 11) Central spacer 12) Complete wheel 13) Bearing...
Page 236 CHASSIS Pegaso 650 I.E. 7.3.1 REMOVING THE REAR WHEEL Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 2.27 (REAR WHEEL). WARNING Wait until the engine and the exhaust silencer have completely cooled down. While disassembling and reassembling the wheel, be careful not to damage the brake pipe, the disc and the pads.
Page 237 CHASSIS Pegaso 650 I.E. 7.3.2 REMOVING THE FINAL DRIVE UNIT Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Remove the rear wheel, see 7.3.1 (REMOVING THE REAR WHEEL). NOTE The support plate (8) complete with brake cali- per (9) remains mounted on the left side of the rear fork. Proceed with care.
Page 238 CHASSIS Pegaso 650 I.E. 7.3.3 CHECKING THE REAR WHEEL COMPONENTS CAUTION Make sure that all the components are intact, particu- larly the following. 7.3.4 REAR WHEEL BEARINGS Carry out the check with the bearings mounted on the wheel. CHECKING THE ROTATION Manually rotate the inner ring (1) of each single bear- ing.
Page 239: Rear Wheel Pin
CHASSIS Pegaso 650 I.E. 7.3.5 REAR WHEEL GASKETS Check the conditions of the gasket (1); if it is damaged or excessively worn, change it. WARNING Always change both seals. Always replace the gaskets with gaskets of the same type. 7.3.6 REAR WHEEL PIN Check the eccentricity of the pin wheel (2) by means of a comparator.
Page 240: Final Drive Unit Bearings
CHASSIS Pegaso 650 I.E. 7.3.10 FINAL DRIVE UNIT BEARINGS Carry out the check with the bearings mounted on the fi- nal drive unit. CHECKING THE ROTATION Remove the right spacer (1). Manually rotate the inner ring of each single bearing. The rotation must be regular, smooth and noiseless.
Page 241: Flexible Couplings
CHASSIS Pegaso 650 I.E. 7.3.11 FLEXIBLE COUPLINGS Make sure the rubber elements (1) of the flexible cou- plings are not damaged and/or feature excessive wear. If necessary, change the flexible coupling rubber ele- ments (1). Fit the whole final drive unit complet (2) on the wheel. Manually rotate the crown gear (3) in both directions and check the slack between the flexible coupling rub- ber elements (1) and the final drive unit (2).
Page 242: Disassembling The Rear Wheel
Work from the right-hand side of the wheel: NOTE Have the appropriate special tool m to hand: – aprilia part# 8140180 (Kit for bearings in the range Ø10 mm to Ø 30 mm). Use a special extractor to extract the right bearing (1).
Page 243: Assembling The Rear Wheel Bearings
Work from the left-hand side of the wheel: NOTE Have the appropriate special tool m to hand: – aprilia part# 8140180 (Kit for bearings in the range Ø10 mm to Ø 30 mm). Using the appropriate pad, insert the left bearing (1) completely.
Page 244: Disassembling The Final Drive Unit
NOTE Have the appropriate special tool m to hand: – aprilia part# 8140180 (Kit for bearings in the range Ø10 mm to Ø 30 mm). Use a special extractor to extract the right bearing (4).
Page 245: Assembling The Final Drive Unit
Insert the inner spacer (1). NOTE Have the appropriate special tool m to hand: – aprilia part# 8140180 (Kit for bearings in the range Ø10 mm to Ø 30 mm). Use a special pad to insert the bearing (2). NOTE...
Page 246: Removing The Crown Gear
CHASSIS Pegaso 650 I.E. 7.3.17 REMOVING THE CROWN GEAR Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Remove the final drive unit, see 7.3.2 (REMOVING THE FINAL DRIVE UNIT). Lock the rotation of the screw (1), unscrew and remove the six self-locking nuts (2). Crown gear self-locking nut driving torque: 50 Nm (5.0 kgm).
Page 247: Installing The Rear Wheel
CHASSIS Pegaso 650 I.E. 7.3.18 INSTALLING THE REAR WHEEL Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). If the final drive unit has been removed: Put back the final drive unit, see 7.3.2 (REMOVING THE FINAL DRIVE UNIT). CAUTION Before proceeding with the reassembly, make sure that support plate (8) of the brake caliper (9) is posi- tioned correctly;...
Page 248: Tyre Disassembly
CHASSIS Pegaso 650 I.E. 492%3 7.4.1 TYRE DISASSEMBLY Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 2.30 (TYRES). Unscrew and remove the closing cap (1). Deflate the inner tube completely. Unscrew and remove the valve lock ring (2). NOTE Mark the tyre with chalk, to show its position with respect to the rim and to the rotation direction.
Page 249: Assembling The Tyre
CHASSIS Pegaso 650 I.E. 7.4.3 ASSEMBLING THE TYRE Eliminate any trace of dirt or rust from the valve seat. Apply the special lubricant for tyres, or soapy water, to the beads of the tyre. CAUTION Never apply grease, oil or petrol to the beads of the tyre for any reason whatsoever.
Page 250 CHASSIS Pegaso 650 I.E. &2/.4 "2!+% The rear brake reservoir is positioned on the right side of the vehicle, near the rear brake control lever. NOTE This vehicle is provided with disc brakes with two, front and rear braking systems having separate hydraulic WARNING circuits.
Page 251: Changing The Front Brake Pads
CHASSIS Pegaso 650 I.E. 7.5.1 CHANGING THE FRONT BRAKE PADS (models up to 2001) Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 2.21 (CHECKING THE BRAKE PAD WEAR). Position the vehicle on the stand. Pull out the flexible stop pin (1). Push out the pin (2) with a punch (from the left towards the right).
Page 252: Checking The Front Brake Disc
CHASSIS Pegaso 650 I.E. 7.5.2 CHECKING THE FRONT BRAKE DISC For the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART) under: – Brake discs. 2.1.1 (REGULAR SERVICE INTERVALS CHART). Check the wear on the disc by measuring the minimum thickness in several places by means of a micrometer. If the minimum thickness is below the minimum value, even in a single point, change the disc.
Page 253: Removing The Front Brake Calipers
CHASSIS Pegaso 650 I.E. 7.5.5 REMOVING THE FRONT BRAKE CALIPERS Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). WARNING A dirty disc soils the pads, with consequent reduc- tion of the braking efficiency. Dirty pads must be re- placed, while dirty discs must be cleaned with a high- quality degreaser.
Page 254 CHASSIS Pegaso 650 I.E. ã Follow CAUTION Proceed with care, in order not to damage the brake pads. Withdraw the brake caliper (5) from the disc, leaving the caliper constrained to the pipe (6) (or releasing it if you are carrying out a COMPLETE REMOVAL). CAUTION Never pull the front brake lever after removing the calipers, otherwise the pistons may go out of their...
Page 255: Draining The Braking Systems
CHASSIS Pegaso 650 I.E. 7.5.6 DRAINING THE BRAKING SYSTEMS Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). CAUTION Use latex gloves. Handle brake fluid with care; it may chemically alter painted surfaces and the parts in plastic, rubber, etc. DO NOT DISPOSE OF THE FLUID IN THE ENVIRON- MENT.
Page 256 CHASSIS Pegaso 650 I.E. 2%!2 "2!+% NOTE This vehicle is provided with disc brakes with two, front and rear braking systems having separate hy- draulic circuits. The rear braking system is with single disc (right side). WARNING Do not use the vehicle if the braking system leaks flu- 1) Brake fluid tank 2) Brake fluid pipe from tank to pump 3) Pedal adjusting screw...
Page 257: Changing The Rear Brake Pads
CHASSIS Pegaso 650 I.E. 7.6.1 CHANGING THE REAR BRAKE PADS Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 2.21 (CHECKING THE BRAKE PAD WEAR). Position the vehicle on the stand. Pull out the flexible stop pin (1). Push out the pin (2) with a punch (from the left towards the right).
Page 258: Removing The Rear Brake Disc
CHASSIS Pegaso 650 I.E. 7.6.3 REMOVING THE REAR BRAKE DISC Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Remove the rear wheel, see 7.3.1 (REMOVING THE REAR WHEEL). NOTE To unscrew the screws (1), it is advisable to use a percussion screwdriver, thanks to which it will be possi- ®...
Page 259 CHASSIS Pegaso 650 I.E. CAUTION Prepare a new clamp to replace the original. Loosen and move the pipe clamp (9). Slide the pipe (10) from its fitting on the pump. Put a nylon bag on the pipe (10) and fix it to the pipe with adhesive tape.
Page 260: Removing The Rear Brake Caliper
CHASSIS Pegaso 650 I.E. 7.6.5 REMOVING THE REAR BRAKE CALIPER Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). WARNING A dirty disc soils the pads, with consequent reduc- tion of the braking efficiency. Dirty pads must be re- placed, while dirty discs must be cleaned with a high- quality degreaser.
Page 261: Draining The Rear Braking System
CHASSIS Pegaso 650 I.E. ã Follow PARTIAL REMOVAL Remove the rear wheel, see 7.3.1 (REMOVING THE REAR WHEEL). Withdraw the brake caliper (4) (complete with plate), leaving it constrained to the pipe (5) (or releasing it if you are carrying out a COMPLETE REMOVAL). CAUTION Never pull the rear brake lever after removing the cal- ipers, otherwise the pistons may go out of their...
Page 262 CHASSIS Pegaso 650 I.E. 34%%2).' For further details, see: 1) Rubber element – 2.22 (STEERING); – 2.24 (INSPECTING THE FRONT AND REAR SUS- 2) Steering tube screw PENSION). 3) Upper plate 4) Ring nut 5) Sealing ring 6) Bearing 7) Washer 8) Lower plate I = GREASE, see 1.6 (LUBRICANT CHART).
Page 263: Removing The Fork Together With The Front Wheel
CHASSIS Pegaso 650 I.E. 7.7.1 REMOVING THE FORK TOGETHER WITH THE FRONT WHEEL Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 2.22 (STEERING). WARNING Keep the lifting platform completely lowered, raising it only when indicated. Position the vehicle on the centre stand m on a lifting platform, with the front wheel sticking out over the edge of the platform.
Page 264 CHASSIS Pegaso 650 I.E. ã Follow CAUTION Due to the weight of the forecarriage, the following operations require the assistance of another opera- tor. Fix the operating procedure before starting work. The removal must be carried out with the greatest care.
Page 265: Checking The Components
CHASSIS Pegaso 650 I.E. 7.7.2 CHECKING THE COMPONENTS CAUTION Make sure that all the components are intact, particu- larly the following. 7.7.3 STEERING BEARINGS Carry out the check with the bearings mounted on the steering tube. CHECKING THE ROTATION Manually rotate the inner ring of each single bearing. The rotation must be regular, smooth and noiseless.
Page 266: Removing The Steering Bearings
CHASSIS Pegaso 650 I.E. 7.7.5 REMOVING THE STEERING BEARINGS Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Remove the fork together with the front wheel, see 7.7.1 (REMOVING THE FORK TOGETHER WITH THE FRONT WHEEL). Use a special extractor to extract the upper bearing (1). Use a special extractor to remove the lower bearing (2).
Page 267 CHASSIS Pegaso 650 I.E. &2/.4 &/2+ 1) Tube plug 11) Antidust 2) O-ring 12) Retainer ring 3) Preload tube 13) Sealing ring 4) Spring 14) Cap 5) Ring D39.5 15) Guide bush 6) Pumping element rod 16) Slider 7) Spring 17) Screw (for the right slider only) 8) Bottom pad 18) Washer...
Page 268: Checking The Oil Level
CHASSIS Pegaso 650 I.E. 7.8.1 CHECKING THE OIL LEVEL Carefully read 1.2.3 (FORK OIL) and 7.8 (FRONT FORK). If the fork reaches the end of stroke, this means that it is necessary to check the oil level in the fork tubes. ~ Unscrew and remove the plug (1) and retrieve the O- ring (2).
Page 269: Disassembling The Slider-Tube
CHASSIS Pegaso 650 I.E. 7.8.4 DISASSEMBLING THE SLIDER-TUBE ASSEMBLIES Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS), 1.2.3 (FORK OIL) and 2.24 (IN- SPECTING THE FRONT AND REAR SUSPENSION). NOTE The right and left slider-tube assemblies have the same inner components. The operations described below are referred to a single wheel-holder tube - slider unit, but are valid for both.
Page 270 CHASSIS Pegaso 650 I.E. ã Follow Remove the stop ring (8) by means of a cut-tipped screwdriver. CAUTION Wash all the components with a clean detergent. Position the slider-tube assembly in the vice as indicat- ed in the figure (B). CAUTION It may be difficult to unscrew the screw (9) complete- ly;...
Page 271: Checking The Components
CHASSIS Pegaso 650 I.E. 7.8.5 CHECKING THE COMPONENTS TUBE Check the sliding surface, which must be neither lined, nor scratched. Slight lines can be eliminated by sanding the surface with wet sandpaper (grain 1). If the lines are deep, change the tube (1). By means of a comparator, make sure that any curving of the tube (1) be lower than the limit value.
Page 272: Reassembling The Wheel-Holder Tube - Slider Unit
CHASSIS Pegaso 650 I.E. 7.8.6 REASSEMBLING THE WHEEL-HOLDER TUBE - SLIDER UNIT Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS), 1.2.3 (FORK OIL) and 2.24 (IN- SPECTING THE FRONT AND REAR SUSPENSION). NOTE ✱ The operations marked with the symbol “ ”...
Page 273 CHASSIS Pegaso 650 I.E. ã Follow NOTE Make sure that the gasket spring (11) is correct- ly positioned on the gasket (12). Insert the following components on the tube (1), in the given order: – stop ring (13). – antidust gasket (12); Insert the stop ring (13) in the appropriate seat on the slider (5).
Page 274: Installing The Slider-Tube Assemblies
CHASSIS Pegaso 650 I.E. 7.8.7 INSTALLING THE SLIDER-TUBE ASSEMBLIES Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 2.24 (INSPECTING THE FRONT AND REAR SUSPENSION). ~ Insert the tube (1) complete with slider (2) in the low- er plate (3) and in the upper plate (4). ~ Insert the wheel pin (5) on both tubes in order to align the hole of the wheel-holder tube (2) with the hole of the other wheel-holder tube.
Page 275: Removing The Rear Fork
CHASSIS Pegaso 650 I.E. 2%!2 &/2+ 7.9.1 REMOVING THE REAR FORK Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 2.23 (REAR FORK). Position the vehicle on the centre stand m . Remove the exhaust silencers, see 7.1.34 (REMOV- ING THE EXHAUST SILENCERS). Partially remove the rear brake pump, see 7.6.4 (RE- MOVING THE REAR BRAKE PUMP).
Page 276 CHASSIS Pegaso 650 I.E. ã Follow Loosen and remove the nut (9), taking the washer. Double connection element front nut-screw driving torque: 50 Nm (5.0 kgm). Unscrew the screw (10) and retrieve the bush. NOTE NOTA (A) For the reassembly the rear fork, from this point on follow the specific procedures, see 7.9.7 (REASSEMBLING THE REAR FORK).
Page 277: Checking The Components
CHASSIS Pegaso 650 I.E. 7.9.2 CHECKING THE COMPONENTS CAUTION Make sure that all the components are intact, particu- larly the following. 7.9.3 REAR FORK BEARINGS Carry out the check with the bearings mounted on the rear fork. CHECKING THE ROTATION Manually rotate the rollers (1) of each single bearing.
Page 278 (2). NOTE Have the appropriate special tool m to hand: – aprilia part# 8140180 (Kit for bearings in the range Ø10 mm to Ø 30 mm). Push outwards (from the outside towards the inside). –...
Page 279 (3) must be screwed man- ually. NOTE Have the appropriate special tool m to hand: – aprilia part# 8101945 (rear fork pin metal ring span- ner). Introduce and screw the pin (1) that fastens frame/en- gine/rear fork with the appropriate socket spanner, at the same time holding the adjusting bush (2) in its posi- tion, see 1.7 (SPECIAL TOOLS m).
Page 280 CHASSIS Pegaso 650 I.E. 2%!2 3530%.3)/. 7.10.1 REMOVING THE SHOCK ABSORBER Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 2.25.1 (REAR SUSPENSION). Remove the rear fork together with the wheel, the sus- pension unit and the brake unit, see 7.9.1 (REMOVING THE REAR FORK).
Page 281 CHASSIS Pegaso 650 I.E. 7.10.2 CHECKING THE COMPONENTS CAUTION Make sure that none of the components appear to be visibly distorted, broken, cracked and/or dented. Replace any damaged components. BEARINGS Manually rotate the rollers. It should rotate smoothly without jamming and/or noise. There should be no end play.
Page 282: Disassembling The Rear Suspension Linkage
50 Nm (5.0 kgm). NOTE Have the appropriate special tool m to hand: – aprilia part# 8140180 (Kit for bearings in the range CAUTION Ø10 mm to Ø 30 mm). The screw (3) on the left side of the vehicle is longer ~ Use a special extractor to extract the roller bearing than the screw (4) on the right side.
Page 283: Chain Breaker/Rivet Tool
Pegaso 650 I.E. $)3!33%-",).' 4(% $2)6).' #(!). 7.11.1 CHAIN BREAKER/RIVET TOOL m NOTE Have the appropriate special tool m to hand: – aprilia part# 8140192 (chain disassembly/reassembly tool). NOTE This tool is designed for breaking/rejoining chains with rivet-type connecting links.
Page 284: Breaking The Chain
CHASSIS Pegaso 650 I.E. 7.11.2 BREAKING THE CHAIN Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 2.29 (DRIVE CHAIN). Remove the pinion protection case, see 3.2.3 (RE- MOVING THE DRIVE PINION PROTECTION CAS- ING). Slacken the chain, see 2.29.3 (ADJUSTING THE DRIVING CHAIN).
Page 285: Positioning The Joining Link
CHASSIS Pegaso 650 I.E. 7.11.3 POSITIONING THE JOINING LINK CAUTION Make sure the joining link is of the same type as the chain to be joined up. Position the chain on the vehicle with the two ends to be joined up at a point between the sprocket and pinion on the chain’s lower course.
Page 286 CHASSIS Pegaso 650 I.E. NOTE - 94 - 00 Release 00/2002-02...
Page 287 Pegaso 650 I.E. REPAIR INFORMATION - 00 Release 00/2002-02...
Page 288 REPAIR INFORMATION Pegaso 650 I.E. REPAIR INFORMATION TABLE OF CONTENTS 4!",% /& #/.4%.43 42/5",%3(//4).' ......8-3 8.1.1 ENGINE ........... 8-3 8.1.2 ELECTRIC SYSTEM ....... 8-7 8.1.3 BATTERY ..........8-8 8.1.4 BRAKES ..........8-8 8.1.5 CHASSIS ..........8-9 25. &!34%.).' 7)2).' #!",%3 !.$ 0)0%3 ......
Page 289 REPAIR INFORMATION Pegaso 650 I.E. 42/5",%3(//4).' CAUTION Any damage to the ignition coil, the drive shaft position sensor and the thermistors is automatically detected by the electronic unit; blinking of the warning light "û" positioned on the dashboard. For this reason, the malfunctions of these compo- nents are not repeated in the troubleshooting table;...
Page 290 REPAIR INFORMATION Pegaso 650 I.E. ã Follow DEFECT SYMPTOM AND POSSIBLE CAUSES REMEDY The engine has trouble Idling rpm too low Adjust idling Air cleaner dirty Clean Intake coupling leaking Replace Throttle valve shaft/housing worn Replace CO content too low at idling speed Check the injectors (clogged) Air infiltrations through inlet flanges...
Page 291 REPAIR INFORMATION Pegaso 650 I.E. ã Follow DEFECT SYMPTOM AND POSSIBLE CAUSES REMEDY The engine overheats Insufficient coolant in the cooling system, system leaking Top up with coolant, sub- ject the system to a pres- sure test Coolant not to specification Use coolant conforming to specification Radiators dirty or coolant pipes clogged...
Page 292 REPAIR INFORMATION Pegaso 650 I.E. ã Follow DEFECT SYMPTOM AND POSSIBLE CAUSES REMEDY The engine runs too nois- Piston rings or grooves worn or broken Replace (*) The noise seems to be coming from the clutch or clutch casing Clutch discs worn Replace (*) Sides of primary drive teeth worn Change complete primary...
Page 293 REPAIR INFORMATION Pegaso 650 I.E. ã Follow DEFECT SYMPTOM AND POSSIBLE CAUSES REMEDY The gears disengage Gearshift gears worn Replace (*) when the vehicle is The gearshift forks are worn or distorted Replace (*) started or whilst acceler- The positioning springs are exhausted or broken Replace (*) ating hard Gearchanging lacks coordination or is incomplete;...
Page 294: Battery
REPAIR INFORMATION Pegaso 650 I.E. 8.1.3 BATTERY DEFECT SYMPTOM AND POSSIBLE CAUSES REMEDY Battery runs down too Recharging system defective Check the alternator, the quickly regulator/rectifier, the circuit connections and carry out operations necessary to restore correct recharge Battery elements have lost much active potential consequent Change the battery and on excessive charge repair charging system...
Page 295: Chassis
REPAIR INFORMATION Pegaso 650 I.E. 8.1.5 CHASSIS DEFECT SYMPTOM AND POSSIBLE CAUSES REMEDY Hard steering Steering adjustment ring nut too tight Adjust Steering bearings broken Replace Steering axis deformed Replace Insufficient front tyre pressure Adjust Steering not fluid Steering bearings damaged Replace Handlebar oscillates Fork tube adjustment incorrect...
Page 296: Front Brake Pipe
REPAIR INFORMATION Pegaso 650 I.E. 25. &!34%.).' 7)2).' #!",%3 !.$ 0)0%3 8.2.1 FRONT BRAKE PIPE 8.2.2 REAR BRAKE PIPES - 10 - 00 Release 00/2002-02...
Page 297: Fuel System Pipes
REPAIR INFORMATION Pegaso 650 I.E. 8.2.3 FUEL SYSTEM PIPES - 11 - 00 Release 00/2002-02...
Page 298: Engine Oil Pipes
REPAIR INFORMATION Pegaso 650 I.E. 8.2.4 ENGINE OIL PIPES - 12 - 00 Release 00/2002-02...
Page 299: Cooling System Pipes
REPAIR INFORMATION Pegaso 650 I.E. 8.2.5 COOLING SYSTEM PIPES 8.2.6 BREATHER AND IMPURITY DRAINAGE PIPES - 13 - 00 Release 00/2002-02...
Page 300: Clutch Control Cable
REPAIR INFORMATION Pegaso 650 I.E. 8.2.7 CLUTCH CONTROL CABLE 8.2.8 ACCELERATOR CONTROL CABLE AND COLD START CABLE - 14 - 00 Release 00/2002-02...
Page 301: Speedometer-Odometer Cable
REPAIR INFORMATION Pegaso 650 I.E. 8.2.9 SPEEDOMETER-ODOMETER CABLE 8.2.10 REVOLUTION COUNTER CABLE - 15 - 00 Release 00/2002-02...
Page 302: Electric Cables
REPAIR INFORMATION Pegaso 650 I.E. 8.2.11 ELECTRIC CABLES 1) Ignition switch 12) Battery 2) Light relay 13) Start relay 3) Front right direction indicator connectors 14) Starter 4) Horn 15) Coil 5) Blinking 16) Dashboard connector 6) Front left direction indicator connectors 17) Headlight connector 7) To the electrofan 18) To the clutch control lever switch...
Page 303 REPAIR INFORMATION Pegaso 650 I.E. ã Follow 1) Stoplight switch on the rear brake control lever 14) To the generator 2) Air thermistor connector 15) Rear left indicator connector 3) Driving shaft position connector 16) Rear right indicator connector 4) Fuel pump connector 17) Number plate light 5) Right injector connector 18) Rear light connector...
Page 304 REPAIR INFORMATION Pegaso 650 I.E. - 18 - 00 Release 00/2002-02...
Page 305 REPAIR INFORMATION Pegaso 650 I.E. - 19 - 00 Release 00/2002-02...
Page 306 REPAIR INFORMATION Pegaso 650 I.E. - 20 - 00 Release 00/2002-02...
Page 307 REPAIR INFORMATION Pegaso 650 I.E. - 21 - 00 Release 00/2002-02...
Page 308: Spark Plugs (No Spark)
REPAIR INFORMATION Pegaso 650 I.E. #(%#+).' 4(% %,%#42)#!, 3934%- 8.3.4 AUXILIARY SYSTEM PROBLEMS – See: See 6.2 (ELECTRIC COMPONENTS LAYOUT) and 8.2.11 (ELECTRIC CABLES) for the location of the (SWITCHES). electric components. 6.13.2 (CHECKING THE HIGH BEAM RELAY). 6.9.2 (CHECKING THE ELECTROFAN OPERATION). 6.9.3 (CHECKING THE THERMAL SWITCH OPERA- 8.3.1 SPARK PLUGS (no spark) TION).
Page 309: Engine
REPAIR INFORMATION Pegaso 650 I.E. 4%#(.)#!, $!4! !.$ 30%#)&)#!4)/.3 Rim eccentricity: See 7.2.2 (CHECKING THE FRONT WHEEL COMPO- NENTS). 8.4.1 ENGINE See 0.4.1 (ENGINE SERVICE AND REPAIR MANUALS) Wheel pin eccentricity: for the technical data and specifications. See 7.2.2 (CHECKING THE FRONT WHEEL COMPO- NENTS).
Page 310 REPAIR INFORMATION Pegaso 650 I.E. NOTE - 24 - 00 Release 00/2002-02...
Page 311 Pegaso 650 I.E. ANALYTICAL INDEX - 00 Release 00/2002-02...
Page 312 ANALYTICAL INDEX Pegaso 650 I.E. 2IF 0AGE ANALYTICAL INDEX 8-10-00 CABLE AND PIPE LAYOUT CABLES AND PIPES - (RUN, 8-10-00 FASTENING, WIRING) 6.1.1 6-3-00 2IF 0AGE CABLE COLOURS 0-9-00 CAPACITIES - FLUID PROPERTIES - ABBREVIATIONS 8.4.12 8-23-00 (TECHNICAL SPECIFICATIONS) 2-15-00 ACCELERATOR 1.2.7 1-6-00...
Page 313 ANALYTICAL INDEX Pegaso 650 I.E. 5-7-00 6-2-00 COOLANT THERMISTOR - (REMOVAL) ELECTRIC SYSTEM 5-2-00 8.1.2 8-7-00 COOLING ELECTRIC SYSTEM COOLING - (TECHNICAL 8.1.2 8-7-00 ELECTRIC SYSTEM - (FAULTS) 8.4.7 8-23-00 SPECIFICATIONS) ELECTRIC SYSTEM - (TECHNICAL 6-26-00 8.4.4 8-23-00 COOLING ELECTROFAN SPECIFICATIONS) 5-6-00 6.1.2...
Page 314 ANALYTICAL INDEX Pegaso 650 I.E. & 4-2-00 FUEL SUPPLY 2IF 0AGE 4.1.2 4-4-00 6.4.4 6-9-00 FUEL SUPPLY - (CHECK) FALL SENSOR - (CHECK) FUEL SUPPLY - (TECHNICAL 1.10 1-19-00 FASTENING ELEMENTS 8.4.3 8-23-00 SPECIFICATIONS) 8-3-00 FAULTS - (TROUBLESHOOTING) 4-7-00 FUEL SUPPLY PUMP - (REMOVAL) 4.8.1 4-9-00 FOREWORD...
Page 315 ANALYTICAL INDEX Pegaso 650 I.E. INJECTION SYSTEM - (SYSTEM 4.8.3 4-11-00 DIAGRAM) 2IF 0AGE 4.9.1 4-14-00 INJECTORS - (REMOVAL) 5-4-00 RADIATOR - (REMOVAL) 7-64-00 REAR BRAKE 2IF 0AGE 8.2.2 8-10-00 REAR BRAKE - (PIPES) 2-10-00 JUMP-STARTING REAR BRAKE CONTROL LEVER - 2.20 2-37-00 (SLACK ADJUSTMENT)
Page 316 ANALYTICAL INDEX Pegaso 650 I.E. TERMINALS AND CLAMPS - (CHECKING 2.3.2 2-8-00 AND CLEANING) 2IF 0AGE 5-9-00 THERMAL EXPANSION VALVE 7.1.30 7-24-00 SADDLE LOCK - (REMOVAL) 4-14-00 THROTTLE BODY 7.1.36 7-28-00 SADDLE SUPPORT - (REMOVAL) 4.9.8 4-22-00 THROTTLE BODY - (ADJUSTMENTS) 3.1.4 3-3-00 SEALANTS...
Page 317 ANALYTICAL INDEX Pegaso 650 I.E. 2IF 0AGE – – – 2IF 0AGE – – – - 00 Release 00/2002-02...
Page 318 ANALYTICAL INDEX Pegaso 650 I.E. NOTE - 00 Release 00/2002-02...
Page 319 ANALYTICAL INDEX Pegaso 650 I.E. NOTE - 00 Release 00/2002-02...
Page 320 ANALYTICAL INDEX Pegaso 650 I.E. NOTE - 10 - 00 Release 00/2002-02...

APRILIA pegaso 650 i.e. Service Manual

0 Introduction 4!",% /& #/.4%.43

General Information 4!",% /& #/.4%.43 1

Service and Setting up

Fuel Supply System 4!",% /& #/.4%.43

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Chassis

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Summary of Contents for APRILIA pegaso 650 i.e.

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