APRILIA Pegaso 650 2005 Manual
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APRILIA Pegaso 650 2005 Manual

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INTRODUCTION
PEGASO 650
INTRODUCTION
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Summary of Contents for APRILIA Pegaso 650 2005

  • Page 1 INTRODUCTION PEGASO 650 INTRODUCTION 0 - 1...
  • Page 2 INTRODUCTION PEGASO 650 SUMMARY 0.1. INTRODUCTION .............................. 3 0.1.1. FOREWORD ............................. 3 0.1.2. REFERENCE MANUALS .......................... 4 0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS ..................5 0 - 2...

  • Page 3: Introduction

    manual.

  • Page 4: Reference Manuals

    INTRODUCTION PEGASO 650 0.1.2. REFERENCE MANUALS OWNER'S MANUALS aprilia part# (description) 8104896 8104895 8104897 8104894 CHASSIS WORKSHOP MANUAL aprilia part# (description) 8140874 8140877 8140875 8140876 8140878 ENGINE TECHNICAL MANUAL aprilia part# (description) 8140880 8140883 8140881 8140882 8140884 CD FOR THE NETWORK - ENGINE...

  • Page 5: Abbreviations/Symbols/Conventions

    INTRODUCTION PEGASO 650 0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS = number < = less than > = greater than ≤ = less than or equal to ≥ = more than or equal to = approximately ∞ = infinity °C = degrees Celsius (centigrade) °F = degrees Fahrenheit ±...
  • Page 6 INTRODUCTION PEGASO 650 RIGHT SIDE = right side = Society of Automotive Engineers TEST = diagnostic check T.B.E.I. = crown-head Allen screw T.C.E.I. = cheese-head Allen screw T.E. = hexagonal head T.P. = flat head screw = Twin Spark Ignition UPSIDE- DOWN = inverted fork...
  • Page 7 GENERAL INFORMATION PEGASO 650 GENERAL INFORMATION 1 - 1...

  • Page 8: Table Of Contents

    GENERAL INFORMATION PEGASO 650 SUMMARY 1.1. STRUCTURE OF THE MANUAL........................3 1.1.1. CONVENTIONS USED IN THE MANUAL ....................3 1.1.2. SAFETY WARNINGS ..........................4 1.2. GENERAL RULES............................5 1.2.1. BASIC SAFETY RULES ..........................5 1.3. DANGEROUS ELEMENTS..........................8 1.3.1. WARNINGS ............................... 8 1.4.

  • Page 9: Structure Of The Manual

    GENERAL INFORMATION PEGASO 650 1.1. STRUCTURE OF THE MANUAL 1.1.1. CONVENTIONS USED IN THE MANUAL • This manual is divided in sections and subsections, each covering a set of the most significant components. Refer to the index of sections when consulting the manual. •...

  • Page 10: Safety Warnings

    GENERAL INFORMATION PEGASO 650 1.1.2. SAFETY WARNINGS The following precautionary warnings are used throughout this manual in order to convey the following messages: Safety warning. This symbol appears, whether in the manual or on the vehicle itself, to indicate a personal injury hazard.

  • Page 11: General Rules

    GENERAL INFORMATION PEGASO 650 1.2. GENERAL RULES 1.2.1. BASIC SAFETY RULES CARBON MONOXIDE Should it be necessary to perform some operations with the vehicle running, make sure to work outdoors or in a well- aerated room. Avoid starting the engine indoors. In case you are working indoors, use a gas exhaust system.
  • Page 12 GENERAL INFORMATION PEGASO 650 DANGER Take care not to spill coolant onto hot engine parts and exhaust system. It may ignite and produce invisible flames. Wear latex gloves when servicing. Although toxic, it has a sweet taste that might attract animals. Never leave coolant in open container or in a position easily reachable by animals.
  • Page 13 NOTE All bearings must rotate freely with no hard spots or noise. Replace any bearings that do not meet these requirements. Use ORIGINAL aprilia SPARE PARTS only. Use the specified lubricants and consumables. Where possible, lubricate a part before assembly.

  • Page 14: Dangerous Elements

    GENERAL INFORMATION PEGASO 650 1.3. DANGEROUS ELEMENTS 1.3.1. WARNINGS FUEL DANGER The fuel used to operate engines is highly flammable and becomes explosive under particular conditions. Refuelling and engine service should take place in a well-ventilated area with the engine stopped. Do not smoke when refuelling or in the proximity of sources of fuel vapours, avoid flames, sparks and any element that could ignite fuel or provoke explosions.
  • Page 15 GENERAL INFORMATION PEGASO 650 BRAKE FLUID NOTE This vehicle is fitted with front and rear disc brakes. Each braking system is operated by an independent hydraulic circuit. The information provided below applies to both braking systems. DANGER Do not use the vehicle in case brakes are worn out or do not work properly. The brakes are the parts that most ensure your safety and for this reason they must always be perfectly working.
  • Page 16 GENERAL INFORMATION PEGASO 650 COOLANT DANGER Coolant is toxic when ingested, contact with eyes or skin may cause irritation. In the event of contact with your skin or eyes, rinse repeatedly with abundant water and seek medical advice. In the event of ingestion, induce vomiting, rinse mouth and throat with abundant water and seek medical advice immediately.
  • Page 17 GENERAL INFORMATION PEGASO 650 TYRES WARNING If tyres are excessively inflated, the vehicle will be hard, difficult and uncomfortable to ride. In addition, the roadworthiness, mainly on wet surfaces and during cornering, will be impaired. Flat tyres (insufficient pressure) can slip on the rim and make you lose the control of the vehicle. In this case too, both vehicle roadworthiness, manoeuvrability and brake efficiency will be impaired.

  • Page 18: Running-In

    After the first 1000 km (621 mi), have the checking operations indicated in the column "After running- in" carried out by an aprilia Authorised Dealer, see REGULAR SERVICE INTERVALS CHART, in order to avoid hurting yourself or other people and/or damaging the vehicle.

  • Page 19: Vehicle Identification

    GENERAL INFORMATION PEGASO 650 1.5. VEHICLE IDENTIFICATION 1.5.1. POSITION OF THE SERIAL NUMBERS These numbers are necessary for vehicle registration. NOTE Altering the vehicle identification numbers is a legal offence. Altering the frame number invalidates the warranty. FRAME NUMBER The frame number (A) is stamped on the right side of the steering column.
  • Page 20 GENERAL TECHNICAL INFORMATION PEGASO 650 GENERAL TECHNICAL INFORMATION 2 - 1...
  • Page 21 GENERAL TECHNICAL INFORMATION PEGASO 650 SUMMARY 2.1. GENERAL TECHNICAL INFORMATION ......................3 2.1.1. TECHNICAL DATA............................ 3 2.1.2. REGULAR SERVICE INTERVALS CHART....................5 2.1.3. LUBRICANT TABLE ..........................7 2.1.4. TIGHTENING TORQUE SETTINGS ......................8 2.1.5. SPECIAL TOOLS ............................ 11 2.1.6. ARRANGEMENT OF THE ELEMENTS OF THE INSTRUMENT PANEL ..........12 2.1.7.

  • Page 22: General Technical Information

    GENERAL TECHNICAL INFORMATION PEGASO 650 2.1. GENERAL TECHNICAL INFORMATION 2.1.1. TECHNICAL DATA DIMENSIONS Max. length 2173 mm Max. width 810 mm Max. height (front fairing included) 1150 mm Seat height 780 mm Wheelbase 1490 mm Minimum ground clearance 200 mm Dry weight 180 kg ENGINE...
  • Page 23 GENERAL TECHNICAL INFORMATION PEGASO 650 Wheel stroke 130 mm (useful) BRAKES Front disc brake – Ø 320 mm – with hydraulic transmission Rear disc brake – Ø 240 mm – with hydraulic transmission WHEEL RIMS Type in light alloy Front 3.50 x 17"...
  • Page 24 PEGASO 650 2.1.2. REGULAR SERVICE INTERVALS CHART OPERATIONS TO BE CARRIED OUT BY THE aprilia Authorised Dealer (WHICH CAN BE CARRIED OUT EVEN BY THE USER). 1 = check and clean, adjust, lubricate or change, if necessary; 2 = clean;...
  • Page 25 GENERAL TECHNICAL INFORMATION PEGASO 650 OPERATIONS TO BE CARRIED OUT BY THE aprilia Authorised Dealer. 1 = check and clean, adjust, lubricate or change, if necessary (follow Workshop Manual specifications); 2 = clean; 3 = change; 4 = adjust. (*) = Check every two weeks or according to the intervals indicated.

  • Page 26: Lubricant Table

    GENERAL TECHNICAL INFORMATION PEGASO 650 2.1.3. LUBRICANT TABLE LUBRICANT PRODUCT RECOMMENDED: EXTRARIDE 4, SAE 15W – 50. Engine oil As an alternative to recommended oils, top brand oils meeting or exceeding CCMC G-4, A.P.I. SG specifications can be used. RECOMMENDED: F.A.

  • Page 27: Tightening Torque Settings

    GENERAL TECHNICAL INFORMATION PEGASO 650 2.1.4. TIGHTENING TORQUE SETTINGS DESCRIPTION HANDLEBAR AND CONTROLS counterweight loctite 243 Manual with handlebar and clamps torque wrench front brake master cylinder ELECTRIC SYSTEM battery bracket horn / horn mount rear direction indicators Voltage regulator loctite 243 front direction indicators tail light fastener...
  • Page 28 GENERAL TECHNICAL INFORMATION PEGASO 650 CENTRE BODYWORK radiator spoiler radiator cowling number plate holder to seat support lower cover cat's eye holder to number plate holder front mudguard rear mudguard front fairing to arch inner conveyors to frame 4 and external conveyors M5 AND M6 3 and 3...
  • Page 29 GENERAL TECHNICAL INFORMATION PEGASO 650 REAR WHEEL rear sprocket to sprocket holder fastener wheel shaft nut SIDE STAND side stand pin M10X1.25 loctite 243 switch screw lock nut M10X1.25 loctite 243 ENGINE engine to cradle fastener engine lower fastener engine upper fastener lower connection plate to frame fastener upper connection plates to frame fastener gear shift lever...

  • Page 30: Special Tools

    GENERAL TECHNICAL INFORMATION PEGASO 650 2.1.5. SPECIAL TOOLS In order to perform assembly, reassembly and settings correctly, special tools suitable for the task must be used. The use of special tools avoids the potential risk of damage as a result of inappropriate tools and/or improvised methods.

  • Page 31: Arrangement Of The Elements Of The Instrument Panel

    GENERAL TECHNICAL INFORMATION PEGASO 650 2.1.6. ARRANGEMENT OF THE ELEMENTS OF THE INSTRUMENT PANEL KEY - PEGASO 650 Headlight Ignition switch/steering lock Left rear-view mirror Fuel tank filler cap Fuel tank Battery Electronic control unit Fuse carrier Passenger grab rail Glove compartment Swinging arm Passenger left footrest (snapping, closed/open)
  • Page 32 GENERAL TECHNICAL INFORMATION PEGASO 650 KEY - PEGASO 650 Tail light Passenger grab rail Seat Rear brake fluid tank Air filter Rear shock absorber Engine oil level plug-dipstick Front brake fluid tank Right rear-view mirror 10. Horn 11. Engine oil filter 12.

  • Page 33: Instrument Panel Operation

    GENERAL TECHNICAL INFORMATION PEGASO 650 2.1.7. INSTRUMENT PANEL OPERATION When you turn the ignition key to " ", the following will turn on for two seconds on the instrument panel: • The "PEGASO 650 STRADA" logo • All lights, except “Heated handgrips light” •...
  • Page 34 GENERAL TECHNICAL INFORMATION PEGASO 650 Turn selector (2) to display on the LCD the pages indicating in zone (F) the following quantities: A) TRIP METER 1 B) TRIP TIME 1 C) TRIP METER 2 D) TRIP TIME 2 E) MAXIMUM SPEED LAP TIMER G) BATTERY VOLTAGE H) KM COVERED W/FUEL RESERVE (distance covered...
  • Page 35 GENERAL TECHNICAL INFORMATION PEGASO 650 TIME SETTINGS This mode allows you to set the clock. The main page with "TIME SETTINGS" is displayed. As soon as you enter this mode, indication of minutes disappears and only hours are displayed. Value increases every time the MODE selector is pressed to the right, once the value reaches 12, it goes back to 0.
  • Page 36 GENERAL TECHNICAL INFORMATION PEGASO 650 BACK LIGHTING This function allows you to set backlighting: three levels are available. Every time the MODE selector is pressed to the right or to the left, the following icons are displayed: • • MEAN •...
  • Page 37 GENERAL TECHNICAL INFORMATION PEGASO 650 UNLOCK SAFETY LOCKS In case of failure to the stand sensor, the neutral and clutch switch, use function "UNLOCK SAFETY LOCKS" to disable the safety logic and be able to start the engine. The display will show "SERVICE". The safety logic is re-enabled when turning the key off.
  • Page 38 PEGASO 650 DIAGNOSIS This menu interfaces with the systems fitted to the motorcycle to carry out diagnosis. To enable the menu, a password is needed that is available only to aprilia service centres. • Insert the service code It is a 5 digit code, for Pegaso the code is: 25973 If code is wrong, appears the message: •...
  • Page 39 GENERAL TECHNICAL INFORMATION PEGASO 650 Parameters necessary for actuations are the following: Part number Description Ignition coil Injector AIS solenoid Main relay Fan relay Headlight relay Errors: This page shows all present and/or stored errors Part number Description EEPROM Error Error FLAG ∆...
  • Page 40 GENERAL TECHNICAL INFORMATION PEGASO 650 ECU actuations The following message is displayed: • Turn the key to stop Once the key is turned off, the following message is displayed: • Set the key to run Set the ENGINE-ON switch to STOP. Once the key is turned on, the following menu is displayed: •...
  • Page 41 GENERAL TECHNICAL INFORMATION PEGASO 650 • AIS solenoid The following message is displayed: • Set the ENGINE-ON switch first to RUN and then to STOP. The secondary air system solenoid valve will be activated for 5 times. • Injection relay The following message is displayed: •...
  • Page 42 GENERAL TECHNICAL INFORMATION PEGASO 650 ECU errors This page displays both current (live) errors and stored ones. The following message is displayed: • Turn the key to stop Once the key is turned off, the following message is displayed: • Turn the key to Drive Once the key is turned on, the table of errors read by the ECU is displayed.
  • Page 43 GENERAL TECHNICAL INFORMATION PEGASO 650 Dashboard errors In this mode, a table is displayed indicating possible immobilizer errors or errors related to sensors connected to it. Following is the error decoding table: ESCRIPTION RROR CODE Immobilizer failure: Key code was read but DSB 01 not acknowledged Immobilizer failure: Key code not read (Key...
  • Page 44 GENERAL TECHNICAL INFORMATION PEGASO 650 Update This function allows reprogramming of the instrument panel. This page shows the currently loaded software version. The LCD shows: • Dashboard disabled. Now it is possible to connect the diagnostic tool. The instrument panel will start operating in a normal way after one cycle of key on-off.
  • Page 45 GENERAL TECHNICAL INFORMATION PEGASO 650 SERVICE INTERVAL When the scheduled service intervals are reached, an icon is displayed (symbol of a spanner). ALARM DISPLAY In case a serious failure is detected, one that might jeopardise the vehicle or the rider's safety, the display will show an icon indicating the failure cause, in the area where the odometer usually is.
  • Page 46 GENERAL TECHNICAL INFORMATION PEGASO 650 Revolution counter Engine rpm indication is on the left side of the instrument. • Accuracy: 0/+5% with respect to input signal. • The instrument panel should filter the signal to avoid index oscillation, especially at idle speed. •...
  • Page 47 GENERAL TECHNICAL INFORMATION PEGASO 650 Odometer Selection between Km and Miles is made via user interface. • Value should be given with an accuracy of 6 digits and [Km] or [Miles] indication. Saturation occurs when shifting from 999998 to 999999 with count block; the digits that are not used, are not displayed.
  • Page 48 GENERAL TECHNICAL INFORMATION PEGASO 650 Trip time Trip time value is calculated since last trip meter reset. This calculation also includes stops (zero speed and engine running) while does not include intervals with key-on and engine off. Count stops with engine off. The value is indicated in the display in [hh:mm] format, with [TIME] written before.
  • Page 49 GENERAL TECHNICAL INFORMATION PEGASO 650 Service intervals The S icon coming on to indicate that the vehicle is ERVICE due for first service coupon occurs when odometer reaches 1000 km. The next service intervals are indicated when odometer will reach a multiple of 10000 km. The service warning can be reset from 300 Km before the scheduled interval and in this condition the service icon should flash for 5 seconds and then go off.
  • Page 50 GENERAL TECHNICAL INFORMATION PEGASO 650 Automatic switch-off The automatic switch-off of direction indicators is required. If vehicle is stopped, so with speed equal to zero, the direction indicators carry on flashing indefinitely; if the vehicle is in motion, the indicators switch-off automatically when one of the following two conditions is true: •...
  • Page 51 GENERAL TECHNICAL INFORMATION PEGASO 650 Memorisation of keys at first start-up The customer will receive two keys fitted with transponder. Upon instrument panel first start-up, it should request key memorisation. The display shows: • Insert the X key. • Memorised X+1 key. At least one key should be stored, then the procedure is ended if no further key is inserted within 20 seconds or in case power is missing or after the fourth key.
  • Page 52 GENERAL TECHNICAL INFORMATION PEGASO 650 CONNECTOR The figure shows the connector diagram, on instrument panel, and its pin layout. The numbers are printed on the plastic element of the pins and on the connector body. The grey end pin layout is as follows: Service IGHT DIRECTION INDICATOR CONTROL IGH BEAM INPUT...
  • Page 53 GENERAL TECHNICAL INFORMATION PEGASO 650 CONNECTIONS Following are input and output lines and their electrical features; all inputs, outputs and lights should be controlled by microprocessor. Power lines should be equipped with devices limiting current in case of failure. • K-line The interface line consists in a line with physical level complying to ISO-9141, to be used for communication with...
  • Page 54 GENERAL TECHNICAL INFORMATION PEGASO 650 • Select 1÷3 These inputs are used for user interface controls and should be fitted with a 1KΩ pull-up resistor powered by inner power supply. • High beam input It is the signal indicating high beam on to the instrument panel and should switch on the relevant warning light.
  • Page 55 GENERAL TECHNICAL INFORMATION PEGASO 650 • Contact 1, Contact 2 These are two contacts providing for engine disable, piloted both by the immobilizer and by the engine control logic. These contacts shall be properly sized for a loop current equal to 200 mA, while current at start-up is 500 mA and should be protected to allow inductive loads piloting.
  • Page 56 Labelling A label should be stuck at the back of every component; it shall be indelible and water proof, indicating the following details: • supplier code • Aprilia code • hardware board version • software version • production date The Supplier shall add more labels for DOT certification or immobilizer system homologation.
  • Page 57 GENERAL TECHNICAL INFORMATION PEGASO 650 2.2. SCHEDULED MAINTENANCE 2.2.1. CHANGING ENGINE OIL AND OIL FILTER Change the oil filter after the first 1000 km (621 mi), end of running-in, and then every 10000 km (6250 mi). • Position the vehicle on firm and flat ground. •...
  • Page 58 GENERAL TECHNICAL INFORMATION PEGASO 650 • Loosen and remove the three oil filter cover screws. • Remove the oil filter cover with gasket, collect the O- ring. • Remove the oil filter. • Install a new oil filter. • Fit the oil filter cover and tighten the three screws. •...
  • Page 59 GENERAL TECHNICAL INFORMATION PEGASO 650 2.2.2. CLEANING THE AIR FILTER • Remove the right side body panel, see (REMOVING THE REAR FAIRING). • Loosen and remove the four screws. • Slide out the filter mount and air filter. • Remove the air filter from its mount and clean the filtering element.
  • Page 60 GENERAL TECHNICAL INFORMATION PEGASO 650 2.2.3. CHANGING THE COOLANT • Remove headlight, (REMOVING HEADLIGHT). • Remove the fuel tank, see (REMOVING THE FUEL TANK). • Set a container of suitable capacity under drain screw to collect exhausted fluid. WARNING Do not remove the filler plug with hot engine. Coolant is hot and under pressure.
  • Page 61 GENERAL TECHNICAL INFORMATION PEGASO 650 • Tighten circuit filler plug (A). • Release expansion tank plug and top up fluid in the expansion tank until level is between MIN and MAX notches. • Tighten the expansion tank plug (B). • Start the engine and let it idle for a few minutes, stop it and let it cool down.
  • Page 62 GENERAL TECHNICAL INFORMATION PEGASO 650 2.2.4. FRONT BRAKE BLEEDING The air, if any, present inside the hydraulic circuit will serve as "pad" by absorbing most of the pressure coming from the brake master cylinder and thus reducing the calliper efficiency during braking. If some air is present inside the circuit, the brake control is "spongy"...
  • Page 63 GENERAL TECHNICAL INFORMATION PEGASO 650 • Remove both pins. • Remove the vibration damper. • Remove one pad at a time. WARNING Do not operate the brake lever when the pads are not in place or the calliper pistons might come off their housing, thus causing brake fluid leakage.
  • Page 64 GENERAL TECHNICAL INFORMATION PEGASO 650 2.2.5. REAR BRAKE BLEEDING The air, if any, present inside the hydraulic circuit will serve as "pad" by absorbing most of the pressure coming from the brake master cylinder and thus reducing the calliper efficiency during braking. If some air is present inside the circuit, the brake control is "spongy"...
  • Page 65 GENERAL TECHNICAL INFORMATION PEGASO 650 • Remove the pin. • Remove one pad at a time. WARNING Do not operate the brake lever when the pads are not in place or the calliper pistons might come off their housing, thus causing brake fluid leakage.
  • Page 66 GENERAL TECHNICAL INFORMATION PEGASO 650 2.2.6. ADJUSTING THE VALVE CLEARANCE NOTE The following procedure applies to all valves. Adjust clearance when the engine is cold, at ambient temperature. Measure or adjust valve clearance with the piston at top dead centre (TDC) during the compression stroke. •...
  • Page 67 GENERAL TECHNICAL INFORMATION PEGASO 650 • Loosen and remove the two screws (1), collect the washers. • Remove the camshaft gearwheel cover (2). • Release and remove the spark plug. • Release and remove the timing reference screw (3) and crankshaft screw (4). •...
  • Page 68 GENERAL TECHNICAL INFORMATION PEGASO 650 NOTE To set piston at TDC in the compression stroke, align reference “I” on camshaft gearwheel to the fixed reference on the cylinder head. • 3 - Using a feeler gauge, check that valve clearance stays within the indicated values and possibly adjust it.
  • Page 69 GENERAL TECHNICAL INFORMATION PEGASO 650 • 3 - Using the feeler gauge, check again that valve clearance is within the indicated values and possibly repeat all steps relevant to valve clearance adjustment until obtaining the prescribed clearance. NOTE Lubricate the valve shims, see (LUBRICANT TABLE). •...
  • Page 70 GENERAL TECHNICAL INFORMATION PEGASO 650 • Install the intake tappet cover and tighten the four screws. 2 - 51...
  • Page 71 FUEL SYSTEM PEGASO 650 FUEL SYSTEM 3 - 1...
  • Page 72 FUEL SYSTEM PEGASO 650 SUMMARY 3.1. FUEL SYSTEM ..............................3 3.1.1. DIAGRAM ..............................3 3.1.2. REMOVING THE FUEL TANK ........................4 3.2. INJECTION ............................... 7 3.2.1. INJECTION SYSTEM DIAGRAM ......................7 3 - 2...

  • Page 73: Fuel System

    FUEL SYSTEM PEGASO 650 3.1. FUEL SYSTEM 3.1.1. DIAGRAM Key: Fuel tank Fuel tank plug Rubber block Spacer Flanged screw Fuel level sensor Fuel filter Fuel pump flange seal Flanged screw 10. Fuel delivery hose 3 - 3...

  • Page 74: Removing The Fuel Tank

    FUEL SYSTEM PEGASO 650 3.1.2. REMOVING THE FUEL TANK • Remove headlight, (REMOVING HEADLIGHT). • Remove the seat. • Release and remove the two screws, remove the right support cover to release the wiring. • Raise the glove compartment cover using the suitable control.
  • Page 75 FUEL SYSTEM PEGASO 650 • Remove the fuel filler plug. • Raise the glove compartment and slide out the fuel breather hose. • Remove the three fuel breather hose clamps. • Slide out the fuel breather hose. • Remove the glove compartment with motor. •...
  • Page 76 FUEL SYSTEM PEGASO 650 • Release and remove the fuel tank front screw. • Release and remove the two side screws (one on each side). • Disconnect the fuel pump connector. • Remove the fuel tank. 3 - 6...

  • Page 77: Injection

    FUEL SYSTEM PEGASO 650 3.2. INJECTION 3.2.1. INJECTION SYSTEM DIAGRAM Key: Throttle body Manifold D.46 Clamp for manifold D.72 Preformed tube D.5.5x11.5 Preformed tube D.13x18 Pressure sensor tube Throttle body tube Elastic clip D.11.5 Elastic clip D.11.5 10. Yellow elastic clip D.8.5 11.
  • Page 78 ENGINE PEGASO 650 ENGINE 4 - 1...
  • Page 79 ENGINE PEGASO 650 SUMMARY 4.1. REMOVING AND REFITTING THE ENGINE ....................3 4.1.1. REMOVING THE ENGINE ........................3 4.1.2. REFITTING THE ENGINE ........................15 4.2. SECONDARY AIR SYSTEM........................... 26 4.2.1. SECONDARY AIR ........................... 26 4 - 2...

  • Page 80: Removing And Refitting The Engine

    ENGINE PEGASO 650 4.1. REMOVING AND REFITTING THE ENGINE 4.1.1. REMOVING THE ENGINE • To remove the engine, first remove the fuel tank, the rear fairing panels, the sump guard, the battery and the exhausts. • Remove the clamp and slide off the hose. •...
  • Page 81 ENGINE PEGASO 650 • Remove the clamp from “fuel vapour recycle” hose. • Remove the tie from wiring. • Disconnect the speed sensor. 4 - 4...
  • Page 82 ENGINE PEGASO 650 • Disconnect the neutral sensor connector. • Disconnect the generator connectors. • Disconnect the stand sensor. 4 - 5...
  • Page 83 ENGINE PEGASO 650 • Loosen and remove the screw and disconnect the ground cables. • Disconnect the starter motor power cable. • Loosen the nut and slide out the clutch cable from its housing. 4 - 6...
  • Page 84 ENGINE PEGASO 650 • Disconnect the clutch cable from its lever. • Disconnect the spark plug cap. • Loosen the secondary air system tube tie. • Slide out the tube from the throttle body. 4 - 7...
  • Page 85 ENGINE PEGASO 650 • Disconnect the engine temperature sensor connector. • Disconnect the expansion tank breather hose. • Remove the tie from wiring. • Disconnect the generator connectors. 4 - 8...
  • Page 86 ENGINE PEGASO 650 • Prepare a container for collecting engine oil. • Unscrew and remove the screw. • Drain all engine oil. • Loosen and remove the two screws, collect the spacers. • Remove the sprocket cover. 4 - 9...
  • Page 87 ENGINE PEGASO 650 • Remove the guide plate. • Straighten the safety washer. • Engage the first gear. • Loosen and remove the nut and collect the safety washer. 4 - 10...
  • Page 88 ENGINE PEGASO 650 • Remove the chain from the sprocket and remove the sprocket. • Loosen and remove the screw, collect the washer and slide out the cable guides. • Disconnect the neutral sensor. 4 - 11...
  • Page 89 ENGINE PEGASO 650 • Loosen the ties and disconnect the tube from the air box. • Support the engine with slings. • Loosen and remove the ring nut on swinging arm shaft. • Loosen the swinging arm adjuster bush. 4 - 12...
  • Page 90 ENGINE PEGASO 650 • Slide out the shaft from the left side. • Support the engine using a lift. • Working on the right side, loosen and remove the two nuts. • Slide out the two screws, on the opposite side. •...
  • Page 91 ENGINE PEGASO 650 • Working on the right side, loosen and remove the top nut. • Slide out the screw, on the opposite side. • Loosen and remove the two lower screws, collect the washers. • Loosen the ties and remove the intake manifold. •...

  • Page 92: Refitting The Engine

    ENGINE PEGASO 650 4.1.2. REFITTING THE ENGINE • Suitably fix the vehicle frame and lift the engine to desired position. • Set the throttle body in the intake manifold and tighten the clamp. • Tighten the two lower screws. • Set the screw.
  • Page 93 ENGINE PEGASO 650 • Fit the engine front support. • Fit the two screws. • Working on the right side, tighten the two nuts on engine. • Fit the two screws. • Working on the opposite side, tighten the two nuts. •...
  • Page 94 ENGINE PEGASO 650 • Fit the bushing and tighten it. • Tighten the pin. • Set the ring nut to the centring bush and tighten it. • Remove the slings. • Set the air box hose and tighten the clamp. •...
  • Page 95 ENGINE PEGASO 650 • Fit the cable guides and tighten the screw with washer. • Install the sprocket. • Engage the first gear. • Fit the safety washer and tighten the nut. 4 - 18...
  • Page 96 ENGINE PEGASO 650 • Bend the safety washer. • Refit the guide plate. 4 - 19...
  • Page 97 ENGINE PEGASO 650 • Refit the sprocket cover. • Fit and tighten the two screws with spacers. • Fit and tighten the screw. • Connect the generator connectors. • Fit a tie to the wiring. 4 - 20...
  • Page 98 ENGINE PEGASO 650 • Connect the expansion tank breather hose. • Connect the engine temperature sensor connector. • Fit the tube to the throttle body. • Tighten the secondary air system tube tie. 4 - 21...
  • Page 99 ENGINE PEGASO 650 • Connect the spark plug cap • Connect the clutch cable to its lever. • Fit the clutch cable in its housing and tighten the nut. • Connect the starter motor power cable. 4 - 22...
  • Page 100 ENGINE PEGASO 650 • Connect the ground cables and tighten the screw. • Connect the stand sensor. • Connect the generator connectors. 4 - 23...
  • Page 101 ENGINE PEGASO 650 • Connect the neutral sensor connector. • Connect the speed sensor. • Fit ties to the wiring. • Refit the clamp to fuel vapour recycle hose. 4 - 24...
  • Page 102 ENGINE PEGASO 650 • Refit the air box connector. • Fit the hose and tighten the clamp. • Fit the hoses and tighten the clamp. 4 - 25...

  • Page 103: Secondary Air System

    ENGINE PEGASO 650 4.2. SECONDARY AIR SYSTEM 4.2.1. SECONDARY AIR The Secondary Air System (SAS) has been developed to reduce carbon oxide and unburnt hydrocarbon emissions in vehicles that are not equipped with a lambda sensor. Natural air (which is rich in oxygen) is channelled into the exhaust stream to trigger a post-combustion process.
  • Page 104 ENGINE PEGASO 650 At low rpm the valve is activated to bring down carbon monoxide emissions. WARNING When adjusting the CO rate, disable the Secondary Air System or exhaust gas dilution caused by the system would give a wrong reading of the carbon monoxide percentage. See CO ADJUSTMENT for instructions on how to disable the SAS.
  • Page 105 CYCLE PARTS PEGASO 650 CYCLE PARTS 5 - 1...
  • Page 106 CYCLE PARTS PEGASO 650 SUMMARY 5.1. OUTER STRUCTURES............................ 3 5.1.1. REMOVING THE HEADLIGHT........................3 5.1.2. REMOVING THE REAR FAIRING......................6 5.1.3. REMOVING THE OIL SUMP GUARD ....................... 8 5.2. FRONT FORK..............................9 5.2.1. DIAGRAM ..............................9 5.2.2. REMOVING THE FORK LEGS........................ 10 5.2.3.

  • Page 107: Outer Structures

    CYCLE PARTS PEGASO 650 5.1. OUTER STRUCTURES 5.1.1. REMOVING THE HEADLIGHT • Release and remove the six screws. • Remove the unit. • Disconnect the instrument panel connector. 5 - 3...
  • Page 108 CYCLE PARTS PEGASO 650 • The right bracket stays on the vehicle because wiring is routed inside it. Release and remove the two outer screws. • The left bracket stays secured to the headlight. Release and remove the two inner screws. •...
  • Page 109 CYCLE PARTS PEGASO 650 • Release the headlight wiring connector. • Remove the headlight together with left mount. 5 - 5...

  • Page 110: Removing The Rear Fairing

    CYCLE PARTS PEGASO 650 5.1.2. REMOVING THE REAR FAIRING • Remove the seat. • Working on either side, release and remove the two side body panel screws and remove the side body panels. • Loosen and remove the three passenger grab handle screws.
  • Page 111 CYCLE PARTS PEGASO 650 • Working on either side, loosen and remove the top screw. • Working on either side, loosen and remove the two rear bottom screws. • Raise the rear fairing. • Disconnect the seat release cable. • Remove the rear fairing.

  • Page 112: Removing The Oil Sump Guard

    CYCLE PARTS PEGASO 650 5.1.3. REMOVING THE OIL SUMP GUARD • Release and remove the sump guard front screw. • Release and remove the sump guard rear screw. • Remove the sump guard, pay attention to the breather hose. 5 - 8...

  • Page 113: Front Fork

    CYCLE PARTS PEGASO 650 5.2. FRONT FORK 5.2.1. DIAGRAM Key: Stiffening plate Left sleeve Right sleeve Sliding bush Damping rod Damper rod ring Counter spring Buffer Washer Allen cheese-headed screw M12x1.25x25 Guide bush Ring Oil seal Snap ring Dust seal Spring Spring seat Spacer...

  • Page 114: Removing The Fork Legs

    CYCLE PARTS PEGASO 650 5.2.2. REMOVING THE FORK LEGS • Remove headlight, (REMOVING HEADLIGHT). • Remove the fuel tank, see (REMOVING THE FUEL TANK). • Support the stand front part using stand (OPT). • Loosen and remove the two mudguard shell screws. •...
  • Page 115 CYCLE PARTS PEGASO 650 • Loosen and remove the two screws securing the front brake calliper. • Remove the front brake calliper, pay special attention not to pull the front brake lever to avoid pad jamming. • Unscrew the wheel shaft nut, collect the washer. •...
  • Page 116 CYCLE PARTS PEGASO 650 • Support the stanchion and loosen the three screws securing stanchions to bottom yoke. • Loosen the screw securing stanchion to top yoke. • Slide out the stanchion, be careful not to damage it. 5 - 12...

  • Page 117: Installing The Fork Legs

    CYCLE PARTS PEGASO 650 5.2.3. INSTALLING THE FORK LEGS • Install the stanchion, be careful not to damage it. • Take the stanchion in position and tighten the screw securing stanchion to top yoke. • Support the stanchion and loosen the three screws securing stanchion to bottom yoke.
  • Page 118 CYCLE PARTS PEGASO 650 • Tighten the wheel shaft clamp bolts to the right. • Install the washer to the shaft and tighten the wheel shaft nut. • Tighten the wheel shaft clamp bolts to the left. • Loosen the wheel shaft clamp bolts to the right. •...
  • Page 119 CYCLE PARTS PEGASO 650 • Fit the fork plate and tighten the two screws. • Fit the rear mudguard shell and tighten the two screws. • Fit the front mudguard shell and tighten the two screws, working on either side. •...

  • Page 120: Changing Fork Fluid

    CYCLE PARTS PEGASO 650 5.2.4. CHANGING FORK FLUID NOTE The following procedure applies to both fork legs. Periodically change the fork fluid, see (REGULAR SERVICE INTERVALS CHART). NOTE While draining and filling fork fluid, the stanchion and its parts should be clamped in a vice; be careful not to tighten them too much and damage them;...
  • Page 121 CYCLE PARTS PEGASO 650 • Collect the spring. • Drain oil in a container. NOTE Pump the tube inside the stanchion to help oil drain out completely from the damper rod. FILLING UP: • Tighten the sleeve in a vice in vertical position. •...

  • Page 122: Disassembly

    CYCLE PARTS PEGASO 650 5.2.5. DISASSEMBLY • Drain fluid from the fork leg. • Clamp the sleeve in a vice, in horizontal position. • Loosen the bottom screw. • Clamp the sleeve in a vice, in vertical position. • Remove the dust seal, prise with a screwdriver. WARNING Be careful not to damage the tube edge and the dust seal.
  • Page 123 CYCLE PARTS PEGASO 650 • Unclamp the sleeve from the vice and remove the damper rod with bottom buffer. • Clamp the sleeve in a vice, in vertical position. • Firmly remove the tube with lower sliding bush. • Remove the oil seal. 5 - 19...
  • Page 124 CYCLE PARTS PEGASO 650 • Remove the shim. • Remove the top sliding bush. 5 - 20...

  • Page 125: Reassembly

    CYCLE PARTS PEGASO 650 5.2.6. REASSEMBLY • Fit the top sliding bush. • Fit the oil seal to the fork leg. • Fit the shim to the fork leg. • Install the damper rod with bottom buffer to the tube. 5 - 21...
  • Page 126 CYCLE PARTS PEGASO 650 • Install the tube to the sleeve, fit the shim and oil seal in the relevant seats in the sleeve. WARNING Be careful not to damage the sleeve edge. • Fit the snap ring from inside the sleeve, using a screwdriver.
  • Page 127 CYCLE PARTS PEGASO 650 • Clamp the sleeve in vertical position. • Pour oil inside the stanchion, ensure it fills up all damper rod channels. • Pump with the stanchion, ensure that oil completely filled the damper rod. • Insert the spring. •...

  • Page 128: Check

    CYCLE PARTS PEGASO 650 5.2.7. CHECK STANCHION Inspect the sliding surface for scoring and/or scratching. Eliminate minor scoring with wet sand paper (grain size 1). Replace the stanchion if badly scored. Check for stanchion buckling using a dial gauge. Replace the stanchion if buckled beyond the service limit. Buckling limit: 0.2 mm (0.00787 in.) DANGER NEVER...
  • Page 129 CYCLE PARTS PEGASO 650 • damper rod. Change any component which is badly worn or damaged. WARNING Remove any residues from the bushes, be careful not to scratch the surface. Renew the following components on assembly: • seal; • dust seal; •...

  • Page 130: Steering Bearings

    CYCLE PARTS PEGASO 650 5.3. STEERING BEARINGS 5.3.1. ADJUSTING THE STEERING BEARINGS • Position the vehicle on the rear stand. • Working on either side, loosen the screw securing the fork leg to the top yoke. Tightening torque: 5 kgm (50 Nm). •...
  • Page 131 WIRING DIAGRAM PEGASO 650 WIRING DIAGRAM 6 - 1...
  • Page 132 WIRING DIAGRAM PEGASO 650 INDICE 6.1. ELECTRIC SYSTEM ............................3 6.1.1. CHECKING THE ELECTRICAL COMPONENTS ..................3 6.1.2. WIRING DIAGRAM............................ 8 6 - 2...
  • Page 133 WIRING DIAGRAM PEGASO 650 6.1. ELECTRIC SYSTEM 6.1.1. CHECKING THE ELECTRICAL COMPONENTS 6 - 3...
  • Page 134 WIRING DIAGRAM PEGASO 650 1 COIL Primary coil resistance 3.4 ~ 4.6 ohm at 20 °C (68 °F) (across red/black cable and orange cable) Secondary coil resistance 10.4 ~ 15.6 kohm at 20 °C (68 °F) (across red/black cable and spark plug cable) Spark plug resistance 10.0% kohm at 20°C (68°F) 2 FUEL PUMP Fuel pressure 324 kPa (3.24 kg/sq.
  • Page 135 WIRING DIAGRAM PEGASO 650 5 BATTERY 12 V – 10Amp/h MF 6 FUSES 20 A Fuse (yellow): From battery to: ignition switch, voltage regulator, electric cooling fan. 15A Fuse: From ignition switch to: all light loads. 7,5A Fuse: From ignition switch to: ignition, starting safety logic.
  • Page 136 WIRING DIAGRAM PEGASO 650 8 INTAKE AIR TEMPERATURE SENSOR Intake air temperature sensor resistance: 2.21 ~ 2.69 ohm at 20 °C 9 STARTER MOTOR 12V Power supply Max. absorption 0.8 kW 10 PICK UP SENSOR 192 ~ 288 ohm at 20°C (across blue/yellow and green/white) 11 GENERATOR Max.
  • Page 137 WIRING DIAGRAM PEGASO 650 12 COOLANT TEMPERATURE SENSOR Coolant temperature sensor resistance: 2.21 ~ 2.69% kohm at 20°C (68°F) 0.310 ~ 0.326 kohm at 80°C (176°F) 0.140 ~ 0.145 kohm at 110°C (230°F) 13 HEADLIGHT Low beam: 12 V – 55 W in H11 High beam: 12 V –...
  • Page 138 WIRING DIAGRAM PEGASO 650 6.1.2. WIRING DIAGRAM 6 - 8...
  • Page 139 WIRING DIAGRAM PEGASO 650 Key: Multiple connectors Neutral switches Clutch switch Water sensor Side stand switch Speed sensor Instrument panel Light relay ---- Warning horn Left dimmer switch Right dimmer switch HAZARD button back lighting Rear left direction indicator Tail light Number plate light Rear right direction indicator ----...

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