Aprilia Pegaso 650 97 Service Manual-21821A320001.pdf
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TABLE OF CONTENTS

CHAPTER 1

	ENGLISH

		TABLE OF CONTENTS - Section 1

		1.1 position of serial numbers

			1.1.1 FRAME NUMBER

			1.1.2 ENGINE NUMBER

		1.2 INSTRUCTIONS FOR USE OF FUEL, LUBRICANTS AND COOLANT

			1.2.1 FUEL

			1.2.2 ENGINE OIL

			1.2.3 FORK OIL

			1.2.4 BRAKE FLUID

			1.2.5 COOLANT

		1.3 RUNNINGIN RULES

		1.4 PRECAUTIONS AND GENERAL INFORMATION

		1.5 spare parts

		1.6 TECHNICAL SPECIFICATIONS

		1.7 LUBRICANT CHART

		1.8 SPECIAL TOOLS

CHAPTER 2

	ENGLISH

		TABLE OF CONTENTS - Section 2

		2.1 PERIODIC SERVICE PLAN

			2.1.1 PERIODIC SERVICE CHART FOR THE COMPONENTS

		2.2 Points to lubricate

		2.3 BATTERY

			2.3.1 CHECKING THE ELECTROLYTE LEVEL

			2.3.2 RECHARGING THE BATTERY

			2.3.3 LONG INACTIVITY OF THE BATTERY

		2.4 exhaust manifold nuts

		2.5 AIR CLEANER

		2.6 SPARK PLUG

		2.7 CARBURETTORS

		2.8 FUEL TUBING

		2.9 ACCELERATOR CABLE

			2.9.1 ADJUSTING THE ACCELERATOR CONTROL

			2.9.2 ADJUSTMENT OF IDLING RPM

		2.10 COLD START CABLE

		2.11 CLUTCH CABLE

		2.12 CHECKING THE ENGINE OIL LEVEL ANDTOPPING UP

		2.13 CHANGING ENGINE OIL AND OIL FILTER

			2.13.1 AIR BLEEDING FROM OIL DELIVERY PUMP

		2.14 CHECKING AND TOPPING UP COOLANT

		2.15 CHANGING THE COOLANT

		2.16 DRIVING CHAIN

			2.16.1 CLEARANCE CONTROL

			2.16.2 CHECKING WEAR

			2.16.3 ADJUSTMENT

			2.16.4 CLEANING AND LUBRICATION

		2.17 CHECKING AND TOPPING UP THE FRONT BRAKE FLUID

		2.18 CHECKING AND TOPPING UP THE REAR BRAKE FLUID

		2.19 Bleeding the braking system

		2.20 rear brake pedal adjustment

		2.21 FRONT BRAKE LEVER ADJUSTMENT

		2.22 CHECKING THE BRAKE PAD WEAR

		2.23 tyres

			2.23.1 condition of tread

			2.23.2 inflation pressure

		2.24 steering

			2.24.1 CHECKING THE BEARING SLACKS

			2.24.2 ADJUSTING THE BEARING SLACKS

		2.25 front fork

		2.26 REAR FORK

			2.26.1 ADJUSTING THE REAR FORK

		2.27 REAR SUSPENSION

			2.27.1 ADJUSTING THE REAR SUSPENSION

			2.27.2 ADJUSTING THE REAR SUSPENSION WITH PRELOAD HYDRAULIC ADJUSTMENT &

			2.27.3 CHECKING THE REAR SUSPENSION LINKAGE

		2.28 FRONT WHEEL

		2.29 REAR WHEEL

		2.30 TIGHTENING screws and nuts

CHAPTER 3

	ENGLISH

		TABLE OF CONTENTS - Section 3

		3.1 COMPONENTS THAT CAN BE DISASSEMBLED WITHOUT REMOVING THE ENGINE

			3.1.1 REMOVING THE EXHAUST PIPES

			3.1.2 REMOVING THE GEARSHIFT FOOT LEVER

			3.1.3 REMOVING THE TRANSMISSION PINION PROTECTION CASE

		3.2 REMOVING THE ENGINE FROM THE FRAME

		3.3 REINSTALLING THE ENGINE ON THE FRAME

CHAPTER 4

	TABLE OF CONTENTS

	ENGLISH

		TABLE OF CONTENTS - Section 4

		4.1 FUEL TANK

			4.1.1 MAINTENANCE

			4.1.2 CHECKING THE FUEL SUPPLY

		4.2 DRAINING THE FUEL TANK AND THE CARBURETTORS

		4.3 REMOVING THE FUEL COCK

		4.4 REMOVING THE FUEL LEVEL GAUGE UNIT

		4.5 CARBURETTORS

			4.5.1 POSITION OF THE IDENTIFICATION NUMBER

			4.5.2 CHARACTERISTICS OF THE CARBURETTORS

			4.5.3 REMOVING THE CARBURETTORS

			4.5.4 REINSTALLING THE CARBURETTORS

			4.5.5 DISASSEMBLING THE MAIN COMPONENTS FROM THE CARBURETTORS

			4.5.6 CHECKING THE COMPONENTS

			4.5.7 CHECKING THE NEEDLE VALVE

			4.5.8 CHECKING THE COLD START DEVICE

CHAPTER 5

	ENGLISH

		TABLE OF CONTENTS - Section 5

		5.1 DESCRIPTION

			5.1.1 COOLANT

		5.2 REMOVING THE RADIATOR

		5.3 REMOVING THE COOLING ELECTROFAN

		5.4 REMOVING THE COOLANT THERMAL SWITCH

		5.5 REMOVING THE COOLANT THERMISTOR

		5.6 REMOVING THE EXPANSION TANK

		5.7 THERMOSTATIC VALVE

		5.8 COOLING PUMP

CHAPTER 6

	ENGLISH

		TABLE OF CONTENTS - Section 6

		6.1 CHECKING THE RECHARGING SYSTEM

			6.1.1 CHECKING THE RECHARGING VOLTAGE

			6.1.2 CHECKING THE ALTERNATOR LOADLESS OPERATION

			6.1.3 CHECKING THE ALTERNATOR CONTINUITY

			6.1.4 CHECKING THE VOLTAGE REGULATOR

		6.2 IGNITION SYSTEM

			6.2.1 WIRING DIAGRAM

			6.2.2 CHECKING THE H.V. COIL

			6.2.3 CHECKING THE PICK-UP

			6.2.4 CHECKING THE C.D.I

		6.3 CHECKING THE ELECTRICAL SYSTEM FROM THE C.D.I. CONNECTOR

		6.4 COOLANT TEMPERATURE INDICATOR

			6.4.1 WIRING DIAGRAM

			6.4.2 CHECKING THE INSTRUMENT

			6.4.3 CHECKING THE THERMISTOR OPERATION

		6.5 CHECKING THE ENGINE OIL LOW PRESSURE SENSOR

		6.6 COOLING ELECTROFAN

			6.6.1 WIRING DIAGRAM

			6.6.2 CHECKING THE ELECTROFAN OPERATION

			6.6.3 CHECKING THE THERMAL SWITCH OPERATION

		6.7 STARTING SAFETY SYSTEM

			6.7.1 WIRING DIAGRAM

			6.7.2 STARTING SAFETY OPERATING LOGIC

			6.7.3 CHECKING THE STARTING RELAY

			6.7.4 CHECKING THE STAND SWITCH

			6.7.5 CHECKING THE DIODES

		6.8 FUEL LEVEL CIRCUIT

			6.8.1 WIRING DIAGRAM

			6.8.2 FUEL LEVEL INDICATOR

		6.9 SWITCHES

		6.10 LIGHTS SYSTEM

			6.10.1 WIRING DIAGRAM

			6.10.2 CHECKING THE HIGH BEAM LIGHTS RELAY

		6.11 BATTERY

			6.11.1 ACTIVATING THE BATTERY

			6.11.2 MAINTENANCE

			6.11.3 CHECKING

			6.11.4 RETURN UNDER GUARANTEE

		6.12 CHANGING THE BULBS

			6.12.1 CHANGING THE headlight BULBS

			6.12.2 CHANGING THE REAR LIGHT BULB

			6.12.3 CHANGING THE FRONT DIRECTION INDICATOR BULBS

			6.12.4 CHANGING THE REAR DIRECTION INDICATOR BULBS

			6.12.5 CHANGING THE NUMBER PLATE BULB

			6.12.6 CHANGING THE DASHBOARD BULBS

		6.13 ADJUSTING HEADLIGHT BEAM

		6.14 CHANGING THE FUSES

		6.15 WIRING DIAGRAM Pegaso 650

CHAPTER 7

	ENGLISH

		TABLE OF CONTENTS - Section 7

		7.1 BODY

			7.1.1 REMOVING THE FUEL TANK

			7.1.2 REMOVING THE FILLER CAP

			7.1.3 REMOVING THE SADDLE

			7.1.4 REMOVING THE RIGHT AND LEFT SIDES

			7.1.5 REMOVING THE REAR LUGGAGE RACK

			7.1.6 REMOVING THE FRONT MUDGUARD UNIT

			7.1.7 REMOVING THE NUMBER PLATE HOLDER

			7.1.8 REMOVING THE GLOVE COMPARTMENT

			7.1.9 REMOVING THE OIL PAN GUARD

			7.1.10 REMOVING THE EXHAUST SILENCERS

			7.1.11 REMOVING THE SADDLE PILLAR

			7.1.12 REMOVING THE AIR CLEANER CASING

			7.1.13 REMOVING THE BATTERY

			7.1.14 REMOVING THE FRONT FAIRING

			7.1.15 REMOVING THE HEADLIGHT

			7.1.16 REMOVING THE DASHBOARD

			7.1.17 REMOVING THE DASHBOARD FAIRING

			7.1.18 REMOVING THE INSTRUMENTS

			7.1.19 REMOVING THE DASHBOARD SUPPORT

			7.1.20 REMOVING THE IGNITION SWITCH

			7.1.21 REMOVING THE CONTROLS

			7.1.22 REMOVING THE REAR LIGHT

			7.1.23 REMOVING THE GEARING CHAIN

			7.1.24 REMOVING THE CHAIN ROLLERS AND THE CHAIN SHOE

			7.1.25 REMOVING THE SIDE STAND

			7.1.26 REMOVING THE CENTRE STAND &

			7.1.27 REMOVING THE RIDER�S FOOTBOARD

			7.1.28 REMOVING THE HANDLEBARS

			7.1.29 REMOVING THE REAR-VIEW MIRRORS

			7.1.30 REMOVING THE FRONT DIRECTION INDICATORS

			7.1.31 REMOVING THE REAR DIRECTION INDICATORS

			7.1.32 REMOVING THE SADDLE LOCK

			7.1.33 REMOVING THE FRAME

		7.2 FRONT WHEEL

			7.2.1 DISASSEMBLY

			7.2.2 CHANGING THE BEARINGS

			7.2.3 CHECKING

			7.2.4 REASSEMBLY

		7.3 REAR WHEEL

			7.3.1 DISASSEMBLY

			7.3.2 CHANGING THE BEARINGS

			7.3.3 CHECKING

			7.3.4 REASSEMBLY

		7.4 TYRES

			7.4.1 DISASSEMBLY

			7.4.2 CHECKING

			7.4.3 ASSEMBLING THE INNER TUBE

			7.4.4 ASSEMBLING THE TYRE

		7.5 FRONT BRAKE

			7.5.1 CHANGING THE BRAKE PADS

			7.5.2 CHECKING THE BRAKE DISC

			7.5.3 REMOVING THE BRAKE DISC

		7.6 REAR BRAKE

			7.6.1 CHANGING THE BRAKE PADS

			7.6.2 CHECKING THE BRAKE DISC

			7.6.3 REMOVING THE BRAKE DISC

		7.7 STEERING

			7.7.1 DISASSEMBLY

			7.7.2 CHECKING THE BEARINGS

			7.7.3 REASSEMBLY

			7.7.4 ADJUSTMENT

		7.8 FRONT FORK

			7.8.1 CHECKING THE OIL LEVEL

			7.8.2 REMOVING THE WHOLE FORK

			7.8.3 REMOVING THE WHEEL-HOLDER TUBE

			7.8.4 DISASSEMBLING THE WHEEL-HOLDER TUBE

			7.8.5 CHECKING THE COMPONENTS

			7.8.6 REASSEMBLY

		7.9 REAR FORK

			7.9.1 REMOVAL

			7.9.2 CHANGING THE BEARINGS

			7.9.3 CHECKING

			7.9.4 REASSEMBLY

		7.10 REAR SUSPENSION

			7.10.1 REMOVAL

			7.10.2 CHECKING

			7.10.3 REASSEMBLY

CHAPTER 8

	ENGLISH

		TABLE OF CONTENTS - Section 8

		8.1 TROUBLE-SHOOTING

			8.1.1 ENGINE

			8.1.2 CARBURETTOR

			8.1.3 RADIATOR

			8.1.4 ELECTRIC SYSTEM

			8.1.5 BATTERY

			8.1.6 BRAKES

			8.1.7 CHASSIS

		8.3 POSITION OF ELECTRIC COMPONENTS

		8.4 CHECKING THE ELECTRIC SYSTEM

			8.4.1 See 6.1.1(CHECKING THE RECHARGING VOLTAGE)

			8.4.2 See 6.1.2(CHECKING THE ALTERNATOR LOADLESS OPERATION)

			8.4.3 See 6.1.3(CHECKING THE ALTERNATOR CONTINUITY)

			8.4.4 See 6.1.4(CHECKING THE VOLTAGE REGULATOR)

			8.4.5 SPARK PLUG (no spark)

			8.4.6 See 6.3(CHECKING THE ELECTRICAL SYSTEM FROM THE C.D.I. CONNECTOR)

		8.5 Technical data and specifications

			8.5.1 Engine components.

			8.5.2 CARBURETTORS COMPONENTS

			8.5.3 ELECTRIC SYSTEM

			8.5.4 ABSORPTIONS

			8.5.5 BRAKING SYSTEM.

			8.5.6 WHEELS

			8.5.7 SUSPENSIONS

			8.5.8 CAPACITIES - CHARACTERISTICS OFFLUIDS



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