APRILIA PEGASO 650 - 1996 User manual

Pegaso 650
use and maintenance
aprilia part# 8102759

2use and maintenance Pegaso 650
© 1996 aprilia s.p.a. - Noale (VE)
First edition: decem er 1996
Reprint: january 2000
Produced and printed y:
editing division
Soave (VERONA) - Italy
Tel. +39 - 045 76 11 911
Fax +39 - 045 76 12 241
E-mail: [email protected]
www.stp.it
On ehalf of:
aprilia s.p.a.
via G. Galilei, 1 - 30033 Noale (VE) - Italy
Tel. +39 - 041 58 29 111
Fax +39 - 041 44 10 54
www.aprilia.com
3!&%497!2.).'3
The following precautionary warnings are
used throughout this manual in order to
convey the following messages:
Safety warning. When you find this
symbol on the vehicle or in the
manual, be careful to the potential risk
of personal injury. Non-compliance with
the indications given in the messages
preceded by this symbol may result in
grave risks for your and other people’s
safety and for the vehicle
Indications to make the opera-
tions easier. Technical informa-
tion.
4%#(.)#!,
The operations preceded y this
sym ol must e repeated also on
the opposite side of the vehicle.
If not expressly indicated otherwise, for the
reassem ly of the units repeat the disas-
sem ly operations in reverse order.
The terms “right” and “left” are referred to
the rider seated on the vehicle in the nor-
mal riding position.
7!2.).'302%#!54)/.3
'%.%2!,!$6)#%
Before starting the engine, carefully read
this manual and in particular the section
“SAFE DRIVE”.
Your and other people’s safety depends
not only on your quickness of reflexes and
on your agility, ut also on what you know
a out the vehicle, on its efficiency and on
your knowledge of the asic information for
“SAFE DRIVE”. Therefore, get a thorough
knowledge of the vehicle, in such a way as
to e a le to drive in the traffic safely.
a
c
(

use and maintenance Pegaso 650 3
This manual must e considered
as an integral part of the vehicle
and must always accompany it, even in
case of resale.
aprilia has carried out this manual with the
maximum attention, in order to supply the
user with correct and updated information.
However, since aprilia constantly im-
proves the design of its products, there
may e slight discrepancies etween the
characteristics of your vehicle and those
descri ed in this manual. For any clarifica-
tion concerning the information contained
in this manual, do not hesitate to contact
your aprilia Official Dealer.
For control and repair operations not ex-
pressly descri ed in this pu lication, for the
purchase of aprilia genuine spare parts,
accessories and other products, as well as
for specific advice, contact exclusively
aprilia Official Dealers and Service Cent-
ers, which guarantee prompt and accurate
assistance.
Thank you for choosing aprilia. We wish
you a nice ride.
All rights as to electronic storage, repro-
duction and total or partial adaptation, with
any means, are reserved for all Countries.
In some countries the antipollution
and noise regulations in force re-
quire periodical inspections.
The user of the vehicle in these countries
must:
– contact an aprilia Authorized Dealer to
have the non-homologated components
replaced with others homologated for
use in the country in question;
– carry out the required periodical inspec-
tions.
When asking your Dealer for spare
parts, specify the spare parts code
indicated on the SPARE PARTS IDENTIFI-
CATION LABEL.
Write down the identification code in the
space here elow, in order to remem er it
also in case of loss or deterioration of the
la el.
The la el is positioned under the rider sad-
dle, stuck to the frame.
In this manual the various versions are in-
dicated y the following sym ols:
cc
c
&optional
2catalytic version
VERSION:
I Italy V Poland
U United Kingdom % Israel
A Austria K South Korea
P Portugal M Malaysia
" Finland R Chile
B Belgium QBermuda
D Germany -United States
of America
F France ^Australia
E Spain ]Brazil
G Greece °South Africa
O Holland ÎNew Zealand
C Switzerland [Canada
 Denmark `Croatia
J Japan ÑSlovenia
S Singapore

4use and maintenance Pegaso 650
4!",%/&#/.4%.43
SAFE DRIVE .....................................................................................................5
BASIC SAFETY RULES: ............................................................................6
CLOTHING .................................................................................................9
ACCESSORIES........................................................................................10
LOAD ........................................................................................................10
ARRANGEMENT OF THE MAIN ELEMENTS ...............................................12
ARRANGEMENT OF THE INSTRUMENTS ...................................................14
INSTRUMENTS AND INDICATORS ..............................................................14
INSTRUMENTS AND INDICATORS TABLE............................................15
MAIN INDEPENDENT CONTROLS ...............................................................16
CONTROLS ON THE LEFT SIDE OF THE HANDLEBAR.......................16
CONTROLS ON THE RIGHT SIDE OF THE HANDLEBAR ....................17
IGNITION SWITCH...................................................................................18
STEERING LOCK.....................................................................................18
AUXILIARY EQUIPMENT...............................................................................19
UNLOCKING/LOCKING THE SADDLE....................................................19
GLOVE/TOOL KIT COMPARTMENT.......................................................19
CRASH HELMET HOOK ..........................................................................20
ANTI-THEFT HOOK .................................................................................20
REAR LUGGAGE RACK ..........................................................................20
MAIN COMPONENTS.....................................................................................21
FUEL.........................................................................................................21
ENGINE OIL .............................................................................................21
BRAKE FLUID (recommendations) ..........................................................22
DISC BRAKES..........................................................................................22
FRONT BRAKE ........................................................................................23
REAR BRAKE...........................................................................................24
ADJUSTING THE REAR BRAKE .............................................................24
CLUTCH ...................................................................................................25
COOLANT ................................................................................................26
TYRES......................................................................................................27
EXHAUST SILENCERS ^....................................................................28
CATALYTIC SILENCERS 2.................................................................28
INSTRUCTIONS FOR USE.............................................................................29
PRELIMINARY CHECKING OPERATIONS.............................................29
STARTING................................................................................................30
DEPARTURE AND DRIVE .......................................................................32
RUNNING-IN ............................................................................................34
STOPPING ...............................................................................................34
PARKING..................................................................................................34
SUGGESTIONS TO PREVENT THEFT...................................................35
MAINTENANCE ..............................................................................................36
REGULAR SERVICE INTERVALS CHART .............................................36
IDENTIFICATION DATA...........................................................................37
AIR CLEANER..........................................................................................38
CHECKING THE ENGINE OIL LEVEL AND TOPPING UP .................... 39
CHANGING THE ENGINE OIL AND THE OIL FILTER........................... 40
FRONT WHEEL....................................................................................... 42
REAR WHEEL ......................................................................................... 44
CHAIN...................................................................................................... 46
REMOVING THE FUEL TANK................................................................. 48
REMOVING
THE RIGHT AND LEFT SIDES................................................................ 48
CHECKING THE STEERING................................................................... 49
CHECKING
THE REAR FORK FULCRUM AXIS ........................................................ 49
INSPECTING THE FRONT AND REAR SUSPENSIONS ....................... 49
REAR SUSPENSION............................................................................... 50
REAR SUSPENSION
WITH HYDRAULIC PRELOAD ADJUSTMENT &............................... 50
IDLING ADJUSTMENT............................................................................ 52
ADJUSTING THE ACCELERATOR CONTROL ...................................... 52
ADJUSTING THE COLD START CONTROL ( )................................... 52
SPARK PLUG .......................................................................................... 53
BATTERY................................................................................................. 54
CHECKING THE ELECTROLYTE LEVEL.............................................. 55
RECHARGING THE BATTERY ............................................................... 55
LONG INACTIVITY OF THE BATTERY ................................................. 55
CHANGING THE FUSES......................................................................... 56
CHECKING THE SIDE STAND AND THE SAFETY SWITCH ................ 57
ADJUSTING
THE HEADLIGHT BEAM ......................................................................... 58
BULBS ..................................................................................................... 58
CHANGING THE HEADLIGHT BULBS ................................................... 59
CHANGING THE REAR LIGHT BULB.................................................... 60
CHANGING THE FRONT DIRECTION INDICATOR BULBS.................. 60
CHANGING THE REAR DIRECTION INDICATOR BULBS .................... 61
CHANGING
THE NUMBER PLATE BULB................................................................... 61
TRANSPORT.................................................................................................. 62
DRAINING THE FUEL TANK................................................................... 62
CLEANING ..................................................................................................... 63
LONG PERIODS OF INACTIVITY........................................................... 64
TECHNICAL DATA ........................................................................................ 65
LUBRICANT TABLE ................................................................................ 68
Importers............................................................................................. 70-71
WIRING DIAGRAM - Pegaso 650............................................................ 72
WIRING DIAGRAM KEY - Pegaso 650 ................................................... 73

safe drive

6use and maintenance Pegaso 650
"!3)#3!&%4925,%3
To drive the vehicle it is necessary to e in
possession of all the requirements pre-
scri ed y law (driving licence, minimum
age, psychophysical a ility, insurance,
state taxes, vehicle registration, num er
plate, etc.).
Gradually get to know the vehicle y driv-
ing it first in areas with low traffic and/or pri-
vate areas.
The use of medicins, alcohol and drugs or
psychotropic su stances nota ly increases
the risk of accidents.
Be sure that you are in good psychophysi-
cal conditions and fit for driving and pay
particular attention to physical weariness
and drowsiness.
Most road accidents are caused y the
driver’s lack of experience.
NEVER lend the vehicle to eginners and,
in any case, make sure that the driver has
all the requirements for driving.

7
use and maintenance Pegaso 650
Rigorously o serve all road signs and na-
tional and local road regulations.
Avoid a rupt movements that can e dan-
gerous for yourself and other people (for
example: rearing up on the ack wheel,
speeding, etc.), and give due consideration
to the road surface, visi ility and other driv-
ing conditions.
Avoid o stacles that could damage the ve-
hicle or make you lose control.
Avoid riding in the slipstream created y
preceding vehicles in order to increase
your speed.
Always drive with oth hands on the han-
dle ars and oth feet on the footrests (or
on the rider’s foot oards), in the correct
driving posture.
Avoid standing up or stretching your lim s
while driving.

8use and maintenance Pegaso 650
COOLER
OIL
The driver should pay attention and avoid
distractions caused y people, things and
movements (never smoke, eat, drink, read,
etc.) while driving.
Use only the vehicle’s specific fuels and lu-
ricants indicated in the "LUBRICANT
CHART"; check the oil, fuel and coolant
levels regularly.
If the vehicle has een involved in an acci-
dent, make sure that no damage has oc-
curred to the control levers, pipes, wires,
raking system and vital parts.
If necessary, have the vehicle inspected y
an aprilia Official Dealer, who should care-
fully check the frame, handle ars, suspen-
sions, safety parts and all the devices that
you cannot check y yourself.
Always remem er to report any malfunc-
tion to the technicians to help them in their
work.
Never use the vehicle when the amount of
damage it has suffered endangers your
safety.

9
use and maintenance Pegaso 650
ONLY ORIGINALS
Never change the position, inclination or
colour of: num er plate, direction indica-
tors, lights and horns.
Any modification of the vehicle will result in
the invalidity of the guarantee.
Any modification of the vehicle and/or the
removal of original components can com-
promise vehicle performance levels and
safety or even make it illegal.
We recommend respecting all regulations
and national and local provisions regarding
the equipment of the vehicle.
In particular, avoid all modifications that in-
crease the vehicle’s performance levels or
alter its original characteristics.
Never race with other vehicles.
#,/4().'
Before starting, always wear a correctly
fastened crash helmet. Make sure that it is
homologated, in good shape, of the right
size and that the visor is clean.
Wear protective clothing, prefera ly in light
and/or reflecting colours. In this way you
will make yourself more visi le to the other
drivers, thus nota ly reducing the risk of
eing knocked down, and you will e more
protected in case of fall.
This clothing should e very tight-fitting
and fastened at the wrists and ankles.
Strings, elts and ties should not e hang-
ing loose; prevent these and other o jects
from interfering with driving y getting en-
tangled with moving parts or driving mech-
anisms.
A12
345

10 use and maintenance Pegaso 650
Do not keep o jects that can e dangerous
in case of fall, for example pointed o jects
like keys, pens, glass vials etc. in your
pockets (the same recommendations also
apply to passengers).
!##%33/2)%3
The owner of the vehicle is responsi le for
the choice, installation and use of any ac-
cessory.
Avoid installing accessories that cover
horns or lights or that could impair their
functions, limit the suspension stroke and
the steering angle, hamper the operation of
the controls and reduce the distance from
the ground and the angle of inclination in
turns.
Avoid using accessories that hamper ac-
cess to the controls, since this can prolong
reaction times during an emergency.
Large fairings and windscreens assem led
on the vehicle can produce aerodynamic
forces capa le of compromising the sta ili-
ty of the vehicle while driving.
Make sure that the equipment is well fas-
tened to the vehicle and not dangerous
during driving. Do not install electrical de-
vices and do not modify those already ex-
isting to avoid electrical overloads, e-
cause the vehicle could suddenly stop or
there could e a dangerous current short-
age in the horn and in the lights. aprilia
recommends the use of genuine accesso-
ries (aprilia genuine accessories).
,/!$
Be careful and moderate when loading
your luggage. Keep any luggage loaded as
close as possi le to the centre of the vehi-
cle and distri ute the load uniformly on
oth sides, in order to reduce im alance to
the minimum. Furthermore, make sure that
the load is firmly secured to the vehicle, es-
pecially during long trips.

11
use and maintenance Pegaso 650
KG
Avoid hanging ulky, heavy and/or danger-
ous o jects on the handle ars, mudguards
and forks, ecause the vehicle might re-
spond more slowly in turns and its ma-
noeuvra ility could e unavoida ly im-
paired.
Do not place ags that are too ulky on the
vehicle sides and do not ride with the crash
helmet hanging from its string, ecause it
could hit people or o stacles making you
lose control of the vehicle.
Do not carry any ag if it is not tightly se-
cured to the vehicle.
Do not carry ags which protrude too much
from the luggage rack or which cover the
lights, horn or indicators.
Do not carry animals or children on the
glove compartment or on the luggage rack.
Do not exceed the maximum load allowed
for each side- ag.
When the vehicle is overloaded, its sta ility
and its manoeuvra ility can e compro-
mised.

12 use and maintenance Pegaso 650
!22!.'%-%.4/&4(%-!).%,%-%.43
+%9
1) Ignition switch/steering lock
2) Fuel tank plug
3) Fuel cock
4) Battery
5) Fuses
6) Glove/tool kit compartment
7) Passenger gra rail
8) Rear luggage rack
9) Passenger footrest
10) Central stand &
11) Side stand
12) Shifting lever
13) Expansion tank

13
use and maintenance Pegaso 650
+%9
1) Front rake master cylinder
2) Engine oil level plug-dipstick
3) Horn
4) Engine oil filter
5) Rear rake control lever
6) Anti-theft hook (for the aprilia “Body-
Guard” armored ca le &)
7) Rear rake master cylinder
8) Passenger footrest
9) Passenger gra rail
10) Saddle lock
11) Crash helmet hook
12) Rear rake fluid tank
13) Air cleaner

14 use and maintenance Pegaso 650
!22!.'%-%.4/&4(%).3425-%.43
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1) Horn push utton (f)
2) Direction indicator switch (c)
3) Dimmer switch (b - a)
4) High eam signalling push utton (a)
5) Cold start lever (e)
6) Clutch lever
7) Left rear-view mirror
8) Instruments and indicators
9) Right rear-view mirror
10) Front rake lever
11) Engine stop switch (n - m)
12) Throttle grip
13) Light switch (o - p - •)
14) Start push utton (r)
15) Ignition switch/steering lock (n - m - s)
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1) Green direction indicator warning light (c)
2) Green neutral indicator warning light (q)
3) Red engine oil pressure warning light (j)
4) Blue high eam warning light (a)
5) Green low eam and parking light warning light (p)
6) Am er low fuel warning light (g)
7) Revolution counter
8) Total kilometres odometer
9) Speedometer
9) Speedometer - only km/h scale ^
10) Coolant temperature indicator (h)
11) Partial kilometres odometer
12) Odometer trip control

15
use and maintenance Pegaso 650
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Description Function
Direction indicator
warning light cIt links when the direction indicators are on.
Neutral indicator warning light qIt comes on when the gear is in neutral.
Engine oil pressure
warning light j
It comes on every time the ignition switch is rought to position "n" and the engine is not run-
ning, thus checking the proper functioning of the lamp. If during this phase the lamp does not
turn on, it must e replaced. The warning light must go off when the engine is running.
If the warning light comes on during the normal running of the engine, this
means that the oil pressure in the circuit is insufficient. In this case, immediate-
ly stop the engine and contact your APRILIA Official Dealer.
High beam warning light aIt comes on when the headlight is in "high eam" position or when the high eam signalling is
operated.
Parking light
and low beam warning light pIt comes on when the lights are on.
Low fuel warning light gIt comes on when the quantity of fuel left in the tank is a out 6 L (electrical reserve).
In this case, provide for immediate topping up, see p. 21 (FUEL).
Revolution counter
It indicates the num er of revolutions of the engine per minute.
Never exceed the engine max. rpm, see p. 34 (RUNNING-IN).
Total kilometres odometer It indicates the total num er of kilometres covered.
Speedometer It indicates the driving speed.
Coolant temperature indicator h
It indicates the approximate temperature of the coolant in the engine. When the pointer starts
moving eyond level "40", the temperature is sufficient for driving the vehicle. The normal
running temperature range is indicated y the graduated area of the scale. If the pointer
reaches the red area, stop the engine and check the coolant level, see p. 26 (COOLANT).
If the maximum allowed temperature is exceeded (red area of the scale), the en-
gine may be seriously damaged.
Partial kilometres odometer It indicates the partial num er of kilometres covered. To set it to zero, use the odometer trip control.
Odometer trip control Rotate it anticlockwise to set the partial kilometres odometer to zero.
a
a
a

16 use and maintenance Pegaso 650
-!).).$%0%.$%.4#/.42/,3
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The electrical parts work only when the ignition
switch is in position "n".
1) HORN PUSH BUTTON (f)
The horn is activated when the push utton is pressed.
2) DIRECTION INDICATOR SWITCH (c)
To indicate the turn to the left, move the switch to the left; to
indicate the turn to the right, move the switch to the right. To
turn off the direction indicator, press the switch on its centre.
3) DIMMER SWITCH (b - a)
When the light switch (right side of the handle ar) is in posi-
tion "o", if the dimmer switch is in position "a", the high
eam comes on, while if it is in position "b", the low eam
comes on.
4) HIGH BEAM SIGNALLING PUSH BUTTON (a)
It makes it possi le to use the high eam for signalling to
forthcoming vehicles while overtaking and in case of peril
and/or emergency.
5) COLD START LEVER (e)
The starter for the cold start of the engine is operated y rotat-
ing the lever "e" downwards.
To disconnect the starter, move the lever "e" to its initial po-
sition.
c

17
use and maintenance Pegaso 650
#/.42/,3/.4(%2)'(43)$%
/&4(%(!.$,%"!2
The electrical parts work only when the ignition
switch is in position "n".
1) ENGINE STOP SWITCH (n - m)
Do not operate the engine stop switch “n - m” in
running conditions.
This is a safety or emergency switch.
With the switch in position "n", it is possi le to start the en-
gine; the engine can e stopped y moving the switch to posi-
tion "m".
With stopped engine and ignition switch in posi-
tion "n", the battery may discharge.
When the vehicle has come to rest, after stopping
the engine, move the ignition switch to position "m".
2) HEADLIGHT SWITCH (o - p - •)
When the light switch is in position "•", the lights are off; when
the switch is in position "p", the parking lights are on; when
the switch is in position "o", the low eam or the high eam is
on.
The high/low eam can e operated y means of the dimmer
switch, see p. 16 (CONTROLS ON THE LEFT SIDE OF THE
HANDLEBAR).
3) START PUSH BUTTON (r)
When the start push utton "r" is pressed, the starter makes
the engine run. For the starting, see p. 30 (STARTING).
c
a
a

18 use and maintenance Pegaso 650
)'.)4)/.37)4#(
The ignition switch is positioned on the
steering column plate.
The key (1) operates the ignition
switch/steering lock, the saddle
lock and the fuel tank lock.
Two keys are supplied together with the
vehicle (one spare key).
34%%2).',/#+
Never turn the key to position "s" in run-
ning conditions, in order to avoid losing
control of the vehicle.
OPERATION
To lock the steering:
UTurn the handle ar completely leftwards.
UTurn the key (1) to position “m” and
press it.
URelease the key.
Turn the key and steer the han-
dlebar at the same time.
URotate the key (1) anticlockwise (left-
wards), steer the handle ar slowly until
the key (1) reaches position “s”.
UExtract the key.
c
c
Position Function Key
removal
Steering
lock
The steer-
ing is
locked.
It is neither
possi le to
start the
engine, nor
to switch on
the lights.
It is possi-
le to
remove the
key.
Neither the
engine, nor
the lights
can e
switched on.
It is possi-
le to
remove the
key.
The engine
and the
lights can e
switched on.
It is not pos-
si le to
remove the
key.

19
use and maintenance Pegaso 650
!58),)!29%15)0-%.4
5.,/#+).' ,/#+).'
4(% 3!$$,%
UPosition the vehicle on the stand, see
p. 35 (POSITIONING THE VEHICLE ON
THE STAND).
UInsert the key (1) in the saddle lock (2).
UTurn the key (1) clockwise and raise and
remove the saddle.
Before lowering and locking the
saddle, make sure that you have
not left the key in the glove/tool kit com-
partment.
UTo lock the saddle, position the tang (3)
in its seat, then lower and press the sad-
dle, thus making the lock snap shut.
Before leaving, make sure that
the saddle is properly locked.
',/6% 4//,+)4#/-0!24-%.4
The compartment is positioned under the
rear part of the saddle;
to reach it:
UUnlock and raise the saddle.
The tool kit (4) includes:
– 3, 4, 5, 6, 8 mm Allen spanners
– 5,5-7 mm dou le fork spanner
– 8-11 mm dou le fork spanner
– 10-13 mm dou le fork spanner
– 19 mm simple fork spanner
– 24 mm simple fork spanner
– dou le-ended, cross-/cut-headed screw-
driver
– screwdriver handle
– 18 mm spark plug socket spanner
– socket spanner rod
– tool case
Max. allowed weight: 1.5 kg
c
a

20 use and maintenance Pegaso 650
#2!3((%,-%4(//+
Thanks to the crash helmet hook, you no
longer have to carry the crash helmet with
you every time you park the vehicle.
Do not ride with the crash helmet
hanging from the hook, as this
may seriously compromise your
safety.
To hang the crash helmet:
URaise the saddle.
UWithdraw the eyelet (1) of the ca le (2)
from the hook (3).
UPass the ca le (2) through the visor
opening or through the apposite loop on
the crash helmet.
UInsert the eyelet (1) completely in the
hook (3).
ULower the saddle and lock it.
!.4)4(%&4(//+
The anti-theft hook (4) is positioned on the
right side of the vehicle, near the rider’s
foot oard.
To prevent the vehicle from eing stolen, it
is advisa le to secure it with the aprilia
“Body-Guard” armored ca le & (5), avail-
a le at any aprilia Official Dealer.
Do not use the hook to lift the ve-
hicle or for any purpose other
than securing the vehicle once it
has been parked.
2%!2,5''!'%2!#+
Max. allowed weight: 9 kg
a
a