APRILIA PEGASO 650 IE - PART2 02-2001 Manual
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APRILIA PEGASO 650 IE - PART2 02-2001 Manual

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Carefully read p. 2 (SAFETY WARN-
INGS), (TECHNICAL INFORMATION)
and (WARNINGS - PRECAUTIONS -
GENERAL ADVICE).
a
WARNING
Risk of fire.
Keep fuel and other flammable sub-
stances away from the electrical com-
ponents.
Before beginning any maintenance op-
eration or any inspection of the vehicle,
stop the engine, extract the key from
the ignition block, wait until the engine
and the exhaust system have cooled
down and if possible lift the vehicle by
means of the proper equipment, on firm
and flat ground.
a
WARNING
Before proceeding, make sure that the
room in which you are working is prop-
erly ventilated.
Keep away from the red-hot parts of the
engine and of the exhaust system, in or-
der to avoid burns.
Do not hold any mechanical piece or
other parts of the vehicle with your
mouth: the components are not edible
and some of them are noxious or even
toxic.
a
CAUTION
If not expressly indicated otherwise, for
the reassembly of the units repeat the
disassembly operations in reverse or-
der.
In case any maintenance operation
should be required, it is advisable to
use latex gloves.
Routine maintenance operations can usu-
ally be carried out by the user, but some-
times specific tools and specific technical
skills may be required.
In case periodic maintenance operations,
assistance or technical advice are needed,
contact an aprilia Official Dealer, who will
ensure you prompt and accurate servicing.
Ask your aprilia Official Dealer to test the
vehicle on the road after a repair or period-
ic maintenance operation.
In any case, personally carry out the "Pre-
liminary checking operations" after any
maintenance operation, see p. 43 (PRE-
LIMINARY CHECKING OPERATIONS).
use and maintenance Pegaso 650 I.E.
55

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Summary of Contents for APRILIA PEGASO 650 IE - PART2 02-2001

  • Page 1 GENERAL ADVICE). erly ventilated. Ask your aprilia Official Dealer to test the WARNING Keep away from the red-hot parts of the vehicle on the road after a repair or period- engine and of the exhaust system, in or- Risk of fire.
  • Page 2 After run- Every 6000 Every 12000 Component ning-in [1000 km (3750 mi) km (7500 mi) km (625 mi)] or 12 months or 24 months OPERATIONS TO BE CARRIED OUT BY Official Dealer (WHICH Battery – electrolyte level – CAN BE CARRIED OUT EVEN BY THE Spark plug –...
  • Page 3 OPERATIONS TO BE CARRIED OUT BY After running- Every 6000 km Every 12000 Official Dealer Component in [1000 km (3750 mi) or 12 km (7500 mi) (625 mi)] months or 24 months Rear shock absorber – – = check and clean, adjust, lubricate or Timing chain –...

  • Page 4: Frame Number

    FRAME NUMBER ENGINE NUMBER The frame number is stamped on the right The engine number is stamped on the rear It is a good rule to write down the frame side of the steering column. part of the engine, near the pinion. and engine numbers in the space provided in this manual.

  • Page 5: Maintenance

    Stop the engine, see p. 51 (STOPPING). If necessary, top up the engine oil by Keep the vehicle in vertical position, with proceeding as follows: the two wheels resting on the ground. CAUTION Carefully read p. 37 (ENGINE OIL) and p. Insert the plug-dipstick (1) completely in 55 (MAINTENANCE).
  • Page 6 CAUTION The engine oil and the oil filter change operations may be difficult for unskilled operators. If necessary, contact your Offi- cial Dealer. If you want to perform these operations personally, keep to the following in- structions. Carefully read p. 37 (ENGINE OIL) and p. To change, proceed as follows: Unscrew and remove the drain plug (2) 55 (MAINTENANCE).

  • Page 7: Changing The Engine Oil Filter

    CAUTION CHANGING THE ENGINE OIL FILTER CLEANING THE ENGINE OIL FILTER ON THE TANK Change the engine oil filter after the Do not dispose of the oil in the environ- first 1000 km (625 mi) and successively Clean the engine oil filter (9) on the tank ment.

  • Page 8: Lubricant Chart

    Pull the engine oil filter (9) and clean it Screw the plug-dipstick (3). with a jet of compressed air. Put back the fuel tank, see p. 72 (RE- Check the air cleaner every 6000 km (3750 Check the seal of the engine oil filter (9) MOVAL OF THE FUEL TANK).

  • Page 9: Partial Cleaning

    REMOVAL PARTIAL CLEANING CHANGING Remove the rider saddle, see p. 21 (UN- CAUTION CAUTION LOCKING/LOCKING THE SADDLE). Do not press or strike the metal net of Do not use filters that have already Rotate the air conveyor (1) clockwise, the air cleaner (3). been used.
  • Page 10 CAUTION The disassembly and reassembly of the front wheel may be difficult for unskilled operators. If necessary, contact your Offi- cial Dealer. If you want to perform these operations personally, keep to the following in- structions. Carefully read p. 55 (MAINTENANCE). While disassembling and reassembling Put a support (1) under the tyre, in such Remove...

  • Page 11: Positioning The Vehicle On The Stand)

    With pulled front brake lever, press the CAUTION handlebar repeatedly, thrusting the fork Proceed with care while inserting the downwards. In this way the fork rods will disc in the brake caliper. settle properly. Position the vehicle on the stand, see p. WARNING 52 (POSITIONING THE VEHICLE ON Danger of injury.
  • Page 12 NOTE WARNING To facilitate the extraction of the wheel pin, slightly raise the wheel. Riding with damaged rims may be dan- CAUTION gerous for the rider, other persons and Withdraw the wheel pin (2) from the left The disassembly and reassembly of the the vehicle.

  • Page 13: Regular Service Intervals Chart)

    NOTE CAUTION The removal of the final drive unit REASSEMBLY isn’t necessary if the wheel is in the normal NOTE Do not operate the rear brake lever after Insert the final transmission unit, running position (vertical) or in horizontal removing the wheel, since the pins may parallel to the wheel axis, introducing the position with the rear sprocket facing up- go out of their seats and cause brake...
  • Page 14 WARNING CAUTION Wheel nut driving torque (2–3): 100 Nm (10 kgm). Danger of injury. Before proceeding with the reassembly, make sure that support plate (8) of the Do not introduce your fingers to align Make sure that the following components brake caliper (9) is positioned correctly;...
  • Page 15 support pins (3) rest on the lower part of the rear fork rods: NOTE Loosen the knob (1). – the right support (Pos.A); To position the vehicle on the Withdraw the fork support (2) and extract – the left support (Pos.B). front support stand it is necessary to use it from the stand seat.
  • Page 16 CAUTION Carry out the maintenance operations more frequently if you use the vehicle in difficult conditions or on dusty and/or muddy roads. CHECKING THE SLACK To check the slack, proceed as follows: Stop the engine, see p. 51 (STOPPING). Position the vehicle on the appropriate rear support stand, see p.

  • Page 17: Checking The Driving Chain, Pin- Ion And Sprocket Wear

    CHECKING THE DRIVING CHAIN, PIN- CLEANING AND LUBRICATION ION AND SPROCKET WEAR CAUTION Further, check the chain and sprockets The drive chain is provided with O rings and make sure that they do not present: among the links, in order to keep the –...
  • Page 18 Turn the ignition switch to position “ ”. Release and disconnect the rapid cou- Remove the rider saddle, see p. 21 (UN- plings (6) (7). Carefully read p. 27 (FUEL) and p. 55 LOCKING/LOCKING THE SADDLE). (MAINTENANCE). WARNING Unscrew and remove the centre screw (1).
  • Page 19 If the heat-resistant material in- If the deadening material inside side the oil sump guard (4) is deteriorated, the oil sump guard (2) is deteriorated, con- contact an aprilia Official Dealer to have it tact an aprilia Official Dealer to have it changed. changed.
  • Page 20 CAUTION Handle the plastic and painted compo- nents with care to avoid scraping or Carefully read 55 (MAINTENANCE). damaging them. Position the vehicle on the stand, see p. NOTE If also the rear case supports Lift and remove the upper guard (3). 52 (POSITIONING THE VEHICLE ON must be installed beside the side bag sup- Unscrew and remove the two screws (4).
  • Page 21 NOTE The operations marked with Put back the nut (10) and screw it Put back the bag support (11). not necessary if the rear case supports are manually. Insert and tighten the screws (5) (6), installed. Position the spacer ring (7). applying the torque prescribed.
  • Page 22 (8). 6000 km (3750 mi) or 12 months, and if installed. Insert one of the screws (2), with the necessary have it changed by an aprilia relevant washer (3). Remove the side panels, see p. 73 Official Dealer. Working on the lower side, position the (REMOVING THE RIGHT AND LEFT nut (5) and tighten it manually.
  • Page 23 Carry out the following checks after the first rear fork fulcrum axis require specific 1000 km (625 mi) and successively every knowledge and experience, therefore it Have the fork oil seals changed by a aprilia 12000 km (7500 mi): is advisable to contact an Offi-...

  • Page 24: Adjusting The Rear Shock Absorber

    If your weight and needs are different, for example in case of ride with passenger and full load, it is advisable to contact an aprilia Official Dealer. CAUTION According to the conditions of use of the The rear suspension consists of a spring-...
  • Page 25 REAR SHOCK ABSORBER ADJUSTMENT TABLE Standard HARD adjustment adjustment SOFT adjustment for heavy load (for With this type of suspension it is possible Rear shock (INTERMEDIATE) for light load (for example, rider, to adjust the spring preload and the hy- absorber for normal load (for example, rider...
  • Page 26 To carry out a rapid checking of the If the thickness of the friction material wear of the pads, proceed as follows: [even of one front (3) or rear pad (4) only] Carefully read p. 29 (BRAKE FLUID - has reduced to about 1 mm (or even if only Position the vehicle on the stand, see p.
  • Page 27 Turn the adjusting knob (1). CAUTION Have the accelerator control cables – BY SCREWING IT (clockwise), you in- checked by an aprilia Official Dealer after After the adjustment, make sure that the crease the rpm; the first 1000 km (625 mi) and successively rotation of the handlebar does not mod- –...
  • Page 28 THE STAND). Have the accelerator control cables Withdraw the protection element (2). checked by an aprilia Official Dealer after Loosen the lock nut (3). the first 1000 km (625 mi) and successively Rotate the adjuster (4) in such a way as every 6000 km (3750 mi).

  • Page 29: Removing The Rear-View Mirrors

    REMOVING THE REAR-VIEW MIRRORS ADJUSTMENT OF THE REAR-VIEW MIRRORS Position the vehicle on the stand, see p. WARNING 52 (POSITIONING THE VEHICLE ON Get on the vehicle in riding position, see Do not use the vehicle with the rear- THE STAND). p.
  • Page 30 For the removal, proceed as follows: For the check and cleaning: Remove the cap (1) of the spark plug (2). Carefully read p. 55 (MAINTENANCE). Key: Remove any trace of dirt from the spark – centre electrode (3); Check the spark plug every 6000 km (3750 plug base.
  • Page 31 For the installation: CAUTION CAUTION With the washer on (7), screw the spark When changing the spark plug, check Make sure that the cap (1) is correctly plug by hand in order not to damage the the thread pitch and length. connected to the spark plug (2).

  • Page 32: Side Stand

    SIDE STAND Position the vehicle on the centre stand, see p. 52 (POSITIONING THE VEHICLE ON THE STAND). The springs (3) must not be damaged, worn, rusty or weakened. Make sure that the stand presents no slack in either position (extended and lift- ed).
  • Page 33 If the electrolyte is accidentally swal- CAUTION lowed, drink a lot of water or milk, then Carefully read p. 55 (MAINTENANCE). Never invert the connection of the bat- continue drinking milk of magnesia or tery cables. vegetable oil and consult a doctor with- WARNING Connect and disconnect the battery out delay.
  • Page 34 CAUTION Remove the red protection element (1). Make sure that the cable terminals (2) and Do not exceed the “MAX” mark, since the battery terminals (3) are: the electrolyte level increases during Carefully read p. 87 (BATTERY). – in good conditions (and not corroded or the recharge.
  • Page 35 WARNING CAUTION Do not force the electric cables. Upon reassembly, connect first the pos- Carefully read p. 87 (BATTERY). itive cable (+) and then the negative ca- Withdraw the breather pipe (8). Make sure that the ignition switch is in ble (–).
  • Page 36 Carefully read p. 87 (BATTERY). Remove the battery, see p. 89 (REMOV- ING THE BATTERY). Prepare an appropriate battery charger. Set the charger for the desired type of re- charge. NOTE A recharge with an amperage equal to 1/10th of the battery capacity is recommended.
  • Page 37 Make sure that there are no dirt or mud deposits on the switch; the pin must be Carefully read p. 55 (MAINTENANCE). able to move without interferences, re- If the vehicle remains unused for more turning automatically to its initial position. than fifteen days, it is necessary to re- The vehicle is provided w ith four Make sure that the cables are connected...

  • Page 38: Arrangement Of The Fuses

    In this case it is advisable to consult an aprilia Official Dealer. If an electric component does not work or works irregularly, or if the vehicle fails to start, it is necessary to check the fuses.
  • Page 39 If you need assistance or technical advice, 52 (POSITIONING THE VEHICLE ON NOTE To check the direction of the consult your aprilia Official Dealer, who THE STAND). headlight beam, specific procedures must can ensure you prompt and accurate serv- Working on the lower side of the front be adopted, in accordance with the regula- icing.
  • Page 40 If you touch the bulb with bare hands, remove any fingerprint with alcohol, in Carefully read p. 55 (MAINTENANCE). order to avoid any damage. Carefully read p. 94 (BULBS). WARNING DO NOT FORCE THE ELECTRIC CA- The headlight contains: BLES. Risk of fire.

  • Page 41: High Beam Bulbs

    HIGH BEAM BULBS PARKING LIGHT BULB LOW BEAM BULB/HIGH BEAM Move the protection element (4) with Move the protection element (8) with Move the protection element (10) with your hands. your hands. your hands. Grasp the electric terminal (5), pull it and CAUTION CAUTION disconnect it from the bulb (1).
  • Page 42 Carefully read p. 94 (BULBS). Position the vehicle on the stand, see p. 52 (POSITIONING 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. Tighten the screw (1) moderately and carefully, to avoid damaging the protection Press the bulb (6) slightly and rotate it...
  • Page 43 NOTE Upon reassembly, correctly posi- tion the protection screen in its seat. Carefully read p. 94 (BULBS). Tighten the screw (2) carefully, without ex- Carefully read p. 94 (BULBS). erting too much pressure, in order to avoid NOTE The rear light houses two parking To change, proceed as follows: damaging the protection screen.

  • Page 44: Checking Operations)

    NOTE During transport, the vehicle must Clean the vehicle frequently if it used in WARNING be kept in vertical position, it must be firmly particular areas or conditions, such as: After the vehicle has been washed, its anchored and the 1st gear must be en- –...
  • Page 45 CAUTION CAUTION To remove dirt and mud from the painted surfaces use a low- pressure water jet, Do not direct high-pressure water or air To clean the lights, use a sponge carefully wet the dirty parts, remove mud jets or steam jets on to the following soaked with water and a neutral deter- and filth with a soft car sponge impregnat- components: wheel hubs, controls on...

  • Page 46: After A Period Of Inactivity

    Place the vehicle in an unheated, not-hu- AFTER A PERIOD OF INACTIVITY mid room, away from sunlight, with mini- NOTE After a long period of inactivity of the vehi- Withdraw the plastic bags from mum temperature variations. cle some precautions are necessary to the exhaust tailpipes.
  • Page 47 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........200 kg ENGINE Model ..............
  • Page 48 GEAR RATIOS Ratio Primary Secondary Final ratio Total ratio 1ª 37/72 = 1 : 1.946 12/33 = 1 : 2.750 16/46 = 1 : 2.875 15.385 2ª 16/28 = 1 : 1.750 9.791 3ª 16/21 = 1 : 1.312 7.34 4ª...

  • Page 49: Electric System

    TYRES REAR ..............130/80 – R17 65 H – alternative............140/70 – 17 66 H; 130/80 – 17 65 S; 130/80 – 17 65 T; 130/80 – 17 65 H – Inflation pressure - solo rider – off-road driving ..........210 kPa (2.1 bar) –...
  • Page 50 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. SG specifications. Fork oil (recommended): F.A.
  • Page 51 use and maintenance Pegaso 650 I.E.
  • Page 52 use and maintenance Pegaso 650 I.E.
  • Page 53 use and maintenance Pegaso 650 I.E.
  • Page 54 use and maintenance Pegaso 650 I.E.
  • Page 55 1) Side stand switch 35) Start relay 2) Multiple connectors 36) Starter Orange 3) Clutch control lever switch 37) Battery Light blue 4) Diode 1 38) Voltage regulator Blue 5) Diode 2 39) Fuses White 6) Engine oil pressure switch 40) Generator Yellow 7) Neutral gear switch...
  • Page 56 use and maintenance Pegaso 650 I.E.
  • Page 57 use and maintenance Pegaso 650 I.E.
  • Page 58 – Do not dispose of oil, fuel, polluting substances and components in the envi- ronment. – Do not keep the engine running if it isn’t necessary. – Avoid disturbing noises.

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