APRILIA PEGASO 650 IE - 2003 User manual

use maintenance+ book
PEGASO I.E.650
aprilia part# 8104312

2use and maintenance Pegaso 650 I.E.
© 2001 aprilia s.p.a. - Noale (VE)
First edition: february 2001
Reprint: january 2002, february 2002,
no ember 2002, may 2003
Produced and printed by:
editing di ision
Soa e (VERONA) - Italy
Tel. +39 - 045 76 11 911
Fax +39 - 045 76 12 241
E-mail: [e-mail]
www.stp.it
On behalf of:
aprilia s.p.a.
ia 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
con ey 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
aWARNING
Indicates a potential hazard which may
result in serious injury or even death.
aCAUTION
Indicates a potential hazard which may
result in minor personal injury or dam-
age to the vehicle.
NOTE The word “NOTE” in this manual
precedes important information or instruc-
tions.
4%#(.)#!,).&/2-!4)/.
The operations preceded by this
symbol must be repeated also on
the opposite side of the ehicle.
If not expressly indicated otherwise, for the
reassembly of the units repeat the disas-
sembly operations in re erse order.
The terms “right” and “left” are referred to
the rider seated on the ehicle in the nor-
mal riding position.
7!2.).'302%#!54)/.3
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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, but also on what you know
about the ehicle, on its efficiency and on
your knowledge of the basic information for
“SAFE DRIVE”. Therefore, get a thorough
knowledge of the ehicle, in such a way as
to be able to dri e in the traffic safely.
NOTE Keep a stock of one bulb per type
with the ehicle (see technical data).
a
★

3
use and maintenance Pegaso 650 I.E.
NOTE This manual must be considered
as an integral part of the ehicle and must
always accompany it, e en in case of re-
sale.
aprilia has carried out this manual with the
maximum attention, in order to supply the
user with correct and updated information.
Howe er, since aprilia constantly im-
pro es the design of its products, there
may be slight discrepancies between the
characteristics of your ehicle and those
described 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 described in this publication, for the
purchase of aprilia genuine spare parts,
accessories and other products, as well as
for specific ad ice, contact exclusi ely
aprilia Official Dealers and Ser ice 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 reser ed for all Countries.
NOTE In some countries the antipollu-
tion and noise regulations in force require
periodical inspections.
The user of the ehicle in these countries
must:
– contact an aprilia Official Dealer to ha e
the non-homologated components re-
placed with others homologated for use
in the country in question;
– carry out the required periodical inspec-
tions.
NOTE Soon after purchasing the ehi-
cle, write down the identification data indi-
cated on the SPARE PARTS IDENTIFICA-
TION LABEL in the table here below. This
label is positioned on the left side of the
saddle support; to read it, it is necessary to
remo e the saddle, see p. 21 (UNLOCK-
ING/LOCKING THE SADDLE).
These data indicate:
– YEAR = year of manufacture (Y, 1, 2, ...);
– I.M. = modification code (A, B, C, ...);
– COUNTRY CODES = homologation coun-
try (I, UK, A, ...).
and are to be supplied to the aprilia Official
Dealer as reference data for the purchase
of spare parts or specific accessories of
the model you ha e acquired.
In this manual the arious ersions are in-
dicated by the following symbols:
eautomatic light switching version
(Automatic Switch-on Device)
moptional
TIBET version
coolant expansion version
ocatalytic version
VERSION:
IItaly SSingapore
UUnited King-
dom sSlovenia
aAustria iIsrael
pPortugal ¬South Korea
FFinland MMalaysia
BBelgium cChile
dGermany HCroatia
fFrance AAustralia
ESpain uUnited States of
America
GGreece ÄBrazil
OHolland RSouth Africa
YSwitzerland nNew Zealand
DDenmark CCanada
JJapan

4use and maintenance Pegaso 650 I.E.
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/CONTROLS .................................. 14
INSTRUMENTS AND INDICATORS ....................... 15
INSTRUMENTS AND INDICATORS TABLE ..... 16
MAIN INDEPENDENT CONTROLS ........................ 18
CONTROLS ON THE LEFT PART OF
THE HANDLEBAR ............................................. 18
CONTROLS ON THE RIGHT PART
OF THE HANDLEBAR ....................................... 19
IGNITION SWITCH ............................................ 20
STEERING LOCK .............................................. 21
AUXILIARY EQUIPMENT ....................................... 21
UNLOCKING/LOCKING THE SADDLE ............. 21
GLOVE/TOOL KIT COMPARTMENT ................ 22
ANTI-THEFT HOOK .......................................... 22
REAR LUGGAGE RACK ................................... 22
SPECIAL TOOLS
m ........................................ 23
ACCESSORIES ................................................. 23
SIDE BAGS
m (supplied as standard
equipment in the countries where required) ....... 24
REAR CASE
m (supplied as standard
equipment in the countries where required) ....... 26
MAIN COMPONENTS ............................................. 27
FUEL .................................................................. 27
BRAKE FLUID - recommendations .................... 29
DISC BRAKES ................................................... 30
FRONT BRAKE ................................................. 31
REAR BRAKE .................................................... 33
COOLANT .......................................................... 34
TYRES ............................................................... 36
ENGINE OIL ...................................................... 37
CLUTCH ............................................................ 38
ADJUSTING THE REAR BRAKE CONTROL
LEVER CLEARANCE ........................................ 39
AUTOMATIC LIGHT SWITCHING
VERSION
e .................................................... 39
CATALYTIC EXHAUST SILENCERS
o ......... 40
EXHAUST SILENCERS .................................... 40
INSTRUCTIONS FOR USE .................................... 40
GETTING ON AND OFF THE VEHICLE .......... 40
PRELIMINARY CHECKING OPERATIONS ..... 42
PRELIMINARY CHECKING OPERATIONS ..... 43
STARTING ........................................................ 44
DEPARTURE AND DRIVE ............................... 47
RUNNING-IN ..................................................... 50
STOPPING ........................................................ 51
PARKING .......................................................... 51
POSITIONING THE VEHICLE ON THE
STAND .............................................................. 52
SUGGESTIONS TO PREVENT THEFT ........... 54
MAINTENANCE ..................................................... 55
REGULAR SERVICE INTERVALS CHART ...... 56
IDENTIFICATION DATA ................................... 58
JOINTS WITH CLICK CLAMPS AND
WITH SCREW CLAMPS ................................... 58
CHECKING THE ENGINE OIL LEVEL
AND TOPPING UP ........................................... 59
CHANGING THE ENGINE OIL AND THE OIL
FILTER .............................................................. 60
AIR CLEANER .................................................. 62
FRONT WHEEL ................................................ 64
REAR WHEEL .................................................. 66
POSITIONING THE VEHICLE ON THE
REAR SUPPORT STAND
m .......................... 69
POSITIONING THE VEHICLE ON THE
FRONT SUPPORT STAND
m ........................ 69
DRIVE CHAIN ................................................... 70
REMOVAL OF THE FUEL TANK ...................... 72
REMOVING THE OIL SUMP GUARD .............. 73
REMOVING THE RIGHT AND LEFT SIDES .... 73
REMOVING THE DRIVE CHAIN
GUARDS ........................................................... 74
INSTALLING THE SIDE BAG SUPPORTS
m
(supplied as standard equipment in the
countries where required) ................................. 74
INSTALLING THE REAR CASE SUPPORTS
m (supplied as standard equipment in the
countries where required) ................................. 76
CHECKING THE STEERING ............................ 77
CHECKING THE REAR FORK
FULCRUM AXIS .............................................. 77
INSPECTING THE FRONT AND REAR
SUSPENSIONS ................................................ 77
FRONT SUSPENSION ..................................... 77
REAR SUSPENSION ........................................ 78
REAR SUSPENSION WITH HYDRAULIC
PRELOAD ADJUSTMENT
m .......................... 79
CHECKING THE BRAKE PAD WEAR .............. 80
IDLING ADJUSTMENT ..................................... 81
ADJUSTING THE ACCELERATOR CONTROL 82
ADJUSTING THE COLD START
CONTROL ......................................................... 82
REAR-VIEW MIRRORS .................................... 83
SPARK PLUG ................................................... 84
CHECKING THE STAND .................................. 86
BATTERY .......................................................... 87
CHECKING THE ELECTROLYTE LEVEL ........ 88
CHECKING AND CLEANING THE
TERMINALS ...................................................... 88
REMOVING THE BATTERY ............................. 89
RECHARGING THE BATTERY ........................ 90
INSTALLING THE BATTERY ............................ 90
LONG INACTIVITY OF THE BATTERY ............ 91
CHECKING THE SWITCHES ........................... 91
CHANGING THE FUSES .................................. 92
ADJUSTING THE VERTICAL
HEADLIGHT BEAM ........................................... 93
DASHBOARD LIGHTING .................................. 93
BULBS ............................................................... 94
CHANGING THE HEADLIGHT BULBS ............ 94
CHANGING THE FRONT DIRECTION
INDICATOR BULBS .......................................... 96
CHANGING THE REAR DIRECTION
INDICATOR BULBS .......................................... 96
CHANGING THE REAR LIGHT
BULB ................................................................. 97
CHANGING THE NUMBER PLATE BULB ....... 97
TRANSPORT .......................................................... 98
CLEANING ............................................................. 98
LONG PERIODS OF INACTIVITY .................. 100
TECHNICAL DATA .............................................. 101
LUBRICANT CHART ....................................... 104
Importers .................................................. 106-107
WIRING DIAGRAM - Pegaso 650 I.E. ............ 108

safe drive

6use and maintenance Pegaso 650 I.E.
"!3)#3!&%4925,%3
To dri e the ehicle it is necessary to be in
possession of all the requirements pre-
scribed by law (dri ing licence, minimum
age, psychophysical ability, insurance,
state taxes, ehicle registration, number
plate, etc.).
Gradually get to know the ehicle by dri -
ing it first in areas with low traffic and/or pri-
ate areas.
The use of medicins, alcohol and drugs or
psychotropic substances notably increases
the risk of accidents.
Be sure that you are in good psychophysi-
cal conditions and fit for dri ing and pay
particular attention to physical weariness
and drowsiness.
Most road accidents are caused by the
dri er’s lack of experience.
NEVER lend the ehicle to beginners and,
in any case, make sure that the dri er has
all the requirements for dri ing.

7
use and maintenance Pegaso 650 I.E.
Rigorously obser e all road signs and na-
tional and local road regulations.
A oid abrupt mo ements that can be dan-
gerous for yourself and other people (for
example: rearing up on the back wheel,
speeding, etc.), and gi e due consideration
to the road surface, isibility and other dri -
ing conditions.
A oid obstacles that could damage the e-
hicle or make you lose control.
A oid riding in the slipstream created by
preceding ehicles in order to increase
your speed.
Always dri e with both hands on the han-
dlebars and both feet on the footrests (or
on the rider’s footboards), in the correct
dri ing posture.
A oid standing up or stretching your limbs
while dri ing.

8use and maintenance Pegaso 650 I.E.
The dri er should pay attention and a oid
distractions caused by people, things and
mo ements (ne er smoke, eat, drink, read,
etc.) while dri ing.
Use only the ehicle’s specific fuels and lu-
bricants indicated in the “LUBRICANT
CHART”; check all oil, fuel and coolant le -
els regularly.
If the ehicle has been in ol ed in an acci-
dent, make sure that no damage has oc-
curred to the control le ers, pipes, wires,
braking system and ital parts.
If necessary, ha e the ehicle inspected by
an aprilia Official Dealer who should care-
fully check the frame, handlebars, suspen-
sions, safety parts and all the de ices that
you cannot check by yourself.
Always remember to report any malfunc-
tion to the technicians to help them in their
work.
Ne er use the ehicle when the amount of
damage it has suffered endangers your
safety.
COOLER
OIL

9
use and maintenance Pegaso 650 I.E.
Ne er change the position, inclination or
colour of: number plate, direction indica-
tors, lights and horns.
Any modification of the ehicle will result in
the in alidity of the guarantee.
Any modification of the ehicle and/or the
remo al of original components can com-
promise ehicle performance le els and
safety or e en make it illegal.
We recommend respecting all regulations
and national and local pro isions regarding
the equipment of the ehicle.
In particular, a oid all modifications that in-
crease the ehicle’s performance le els or
alter its original characteristics.
Ne er race with other ehicles.
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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 isor is clean.
Wear protecti e clothing, preferably in light
and/or reflecting colours. In this way you
will make yourself more isible to the other
dri ers, thus notably reducing the risk of
being knocked down, and you will be more
protected in case of fall.
This clothing should be ery tight-fitting
and fastened at the wrists and ankles;
strings, belts and ties should not be hang-
ing loose; pre ent these and other objects
from interfering with dri ing by getting en-
tangled with mo ing parts or dri ing mech-
anisms.
ONLY ORIGINALS
A12
345

10 use and maintenance Pegaso 650 I.E.
Do not keep objects that can be dangerous
in case of fall, for example pointed objects
like keys, pens, glass ials etc. in your
pockets (the same recommendations also
apply to passengers).
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The owner of the ehicle is responsible for
the choice, installation and use of any ac-
cessory.
A oid installing accessories that co er
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.
A oid using accessories that hamper ac-
cess to the controls, since this can prolong
reaction times during an emergency.
Big fairings and windshields installed on
the ehicle may produce aerodynamic forc-
es that affect the stability of the ehicle, es-
pecially when riding at high speed.
Make sure that the equipment is well fas-
tened to the ehicle and not dangerous
during dri ing.
Do not install electrical de ices and do not
modify those already existing to a oid elec-
trical o erloads, because the ehicle could
suddenly stop or there could be a danger-
ous current shortage in the horn and in the
lights.
aprilia recommends the use of genuine
accessories (aprilia genuine accessories).
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Be careful and moderate when loading
your luggage. Keep any luggage loaded as
close as possible to the center of gra ity of
the ehicle and distribute the load uniform-
ly on both sides, in order to reduce umbal-
ance to the minimum. Furthermore, make
sure that the load is firmly secured to the
ehicle, especially during long trips.