Aprilia PEGASO 650 IE User Manual Part3 11-1999

aCAUTION

Never touch the rear brake pedal after removing the wheel. If you do, the caliper pistons may be pushed o ut of thei r seats, and brake fluid wil l be spilled. Should you accidentally do this, take your vehicle to your Local APRILIADealer who will know how to repair this damage.

REASSEMBLY

◆

Apply a thin film of grease to the outer seals of the rear wheel hub.

aCAUTION

While reassembling the wheel, be careful not to damage the brake line, the disc and the pads.

◆

Position the wheel centrally in the swinging arm, on the support (1).

aWAR NING

Keep your fing ers well away from the chain and sprocket. You could ea sily lose a finger if it becomes pinched between thes e two pa rts. Us e heavy work gloves while installing the rear wheel. Never attempt to line the rear wheel up using your fingers. Failure to heed this warning can result in serious personal injury.

◆

Move the wheel as f ar for war d as po ssible, to install the drive chain (6) on the rear sprocket (7).

◆

Pull the rear wheel backwards until the bearing holes are lined up with the holes in the swinging arm.

◆

Lightly grease the outside of the axle (2).

◆

Install the washer (5) on the axle (2).

NOTE To facilitate the insertion of the

axle (2), slightly raise the wheel.

◆

Install the axle (2) completely through the wheel from the left side.

NOTE Ensure that the ax le (2) is pushe d

all the way home with the head in the appropriate seat on the left chain tightener.

◆

Install the washer (4) and tighten the nut (3) finger tight.

◆

Remove the support (1) from under the rear tire.

◆

Check the chain tension, see p. 78 (DRIVE CHAIN).

◆

Tighten the nut (3).

Wheel nut (3) tightening torque:

72.33 ftlb (100 Nm).

aWARNING

After servicing t he brakes, always check them for function. If the stroke of the lever or pedal is excessive, or if you detect that the effect iveness of the brakes is reduced in any way, have y our vehicle serviced by your Local APRILIA Dealer. It may be necessary to ha ve your dealer bleed the sy stem, or ther e may be some other problem with the brake system.

Never ride your veh i c le in traffic immediately after servicing the brakes. Always apply the brake pedal or lever several times before riding your vehicle . Then, try yo ur v eh i cl e in a park ing lo t or other safe area with little t raff ic to ens ure that the brakes are working properly. Failure to observe this warning can lead to a serious accident with subsequent serious injury or death.

Check the wheel centering. Have the t ightening torques, centerin g

and balancing of the wheel checked by your Local APRILIA Dealer. These are critical safety operations, and failure to observe this warning could lead to an upset with subsequent serious injury or death.

use and maintenance Pegaso 650

$2)6%#(!).

Carefully read p. 61 (MAINTENANCE).

Every 312 mi (50 0 km) check the conditions, the wear, the play (tension) and the lubrication of the drive chain. The vehicle is equipped with an endle ss chain. There is no master link used.

aWARNING

An excessively loose cha in can come off the sprocket which can result in a serious accident and serio us dama ge to the vehicle from the upset and subsequent serious injury or even death. Do not ride your vehicle with an improperly adjusted chain, see p. 79 (ADJUSTMENT). To inspect the conditio n of the chain, grasp the chain where it goes around the sprocket and try to pull it away from the sprocket. If you can move it more than one-eighth of a n inch away from the sprocket, the chain is worn out and the chain and both front and rear

use and maintenance Pegaso 650

sprockets must be replaced. See your Local APRILIADealer.

aCAUTION

Lack of maintenance can cause premature wear of the chain an d damage to the sprockets.

Maintain your chain more often if your vehicle is used on dusty or muddy roads.

aWAR NING

Before carring out the following operations, let the engine and the exhaust silencer cool down until they reach room temperature, in order to avoid burns.

aWAR NING

Keep your fingers well clea r of the chain and sprocket, especially if you are turning the rear wheel while working on the vehicle. You can easily be seriously injured if a finger is caught between the chain and sprocket. Use work-gloves to

carrying out these operation. CHECKING THE PLAY

To check the play:

◆

Stop the engine.

◆

Place the vehicle on the center stand, see p. 59 (POSITIONING THE VEHICLE ON THE STAND).

◆

Shift to neutral.

◆

Check the chain p lay. It shoul d be 1 .38 –

1.77 in (35 – 45 mm) at mid-bottom span

as shown abov e.

◆

Move the vehicle forward or backward, or support the rear wheel in the air and turn the wheel to several positions, to check the chain slack at several locations. If the slack is markedly different with the wheel in different positions, the chain and sprockets must be replaced.

aWARNING

Do not ever operate your vehicle with a damaged chain. This could cause wheel seizure which could lead to an

upset with subsequent serious injury or death. Lubricate your chain frequently to minimize the possibility of this kind of damage, see p. 79 (CLEANING AND LUBRICATION).

If the play is the same at several locati ons, but is more or less than 1.38 – 1.77 in (35 – 45

mm), adjust it, see p. 79 (ADJUSTMENT).

ADJUSTMENT

To adjust the chain tension:

◆

Place the vehicle on the center stand,see p. 59 (POSITIO NING THE VEHICLE ON THE STAND).

◆

Hold the axle (1) from rotating with an appropriate Allen wrench.

Wheel nut (2) tightening torque:

72.33 ftlb (100 Nm).

◆

Loosen the nut (2) to several turns.

NOTE In order to facilitate whe el c en ter-

ing, numbered reference mark s are prov ided on the swinging arm, which correspond with marks on the adjusters (3) and (4). These marks may be seen through the slots (5) and (6).

◆

Adjust the left (3) and right (4) tension adjusters to obtain the appropriate chain play, ensuring that the slot (5) and (6) coincide with the same reference marks on each side of your vehicle.

◆

Hold the axle (1) from rotating with an appropriate Allen wrench.

◆

Tighten the nut (2).

Wheel nut (2) tightening torque:

72.33 ftlb (100 Nm).

◆

Check the chain play again, see p. 78 (CHECKING THE PLAY).

CHECKING THE WEAR OF THE CHAIN AND SPROCKETS

In addition to the check, see p. 78 (CHECKING THE PLAY), inspect the chain an d sprockets to make sure that there are no: – damaged rollers; – loose pins; – dry,

rusty, crushed or seized links; – excessive wear; – missing “O” rings; – sprock-

et or teeth excessively worn or damaged. You may check the wear of the chain and sprocket by grasping the chain where it con-

tacts the rear sproc ket, and pull ing it away from the sprocket as far as you can. If you are able to pul l the chai n far enough away from the sprocket so that you can see light between the side plates of the chain and the sprocket teeth, the chain and sprocket are worn out and should be replaced.

NOTE Always replace both sprockets

and the chain wh en any of these co mponents are replaced.

aCAU TION

If chain rollers are d amaged, the pins and/or the O rings are loose or missing, both sprockets as well as the chain must be replaced.

aCAU TION

Lubricate the chain frequently, especially if it displays any rust or if it is dry to the touch. If, after lubricating the chain, it still has li nks which ca nnot be tu rned easily, the chain must be replaced.

◆

Finally, check the wear of the rear fork protection shoe.

CLEANING AND LUBRICATION

aCAUTION

The drive chain is provided with O ri ngs among the links, in order to keep the grease inside them. Carry out chain adjustment, lubrication, cleaning and replacement with great care. Remember to keep your fingers clear of the chain and sprocket.

Never wash the chain with water jets, steam jets, high-pressure water jets and highly inflammable solvents.

◆

Wash the chain with a non-flammable solvent. If your chain rusts quickly, lubricate it more often.

Lubricate the chain every 312 mi (500 km) or whenever it appears dry. After washing the chain and letting it dry, lubricate it exclusively with spray grease for chains provided with sealing rings, see p. 104 (LUBRICANT CHART).

aCAUTION

Make sure that the chain lubric ant you use is appropriate for “O” ring chains. There are some lub ricants available which contain subst ances which will destroy the “O” rings in your chain. If you have any question, contact your Local APRILIADealer.

NOTE Do not use the vehicle immedi-

ately after lubricat ing the ch ain , gi ve the lubricant a chance to dry, otherwise the chain will spray the lubricant all over you and your vehicle.

use and maintenance Pegaso 650

2%-/6).'4(%&5%,4!.+

Carefully read p. 35 (FUEL) and p. 61 (MAINTENANCE).

aWARNING

Risk of fire. Wait until the engine and th e exhau st silencer have completely cooled down. Fuel vapors are noxious for your health . Make sure that the room in which you are working is properly ventilated. Do not inhale fuel vapours. Do not smoke and do not use naked flames.

DISPOSE OF UNWANTED FUEL PROPERLY.

◆

Remove the saddle, see p. 81 (REMOVING THE SADDLE).

◆

Drain the fuel tank completely, see p. 97 (DRAINING THE FUEL TANK).

◆

Move the fuel valve leve r (1) to the “OFF” position.

use and maintenance Pegaso 650

aCAUTION

Handle the plastic and painted components with care and avoid scraping or damaging them. Be careful do n ot damage the electric cables.

NOTE To release th e clam ps , us e a p air

of pliers. Working from the left side of the vehicle:

◆

Disconnect the electric connector (2) of the low fuel sensor.

◆

Release the clamp (3) and disconnect the water drain line (4 ) from the fuel tank.

◆

Release the clamp (5) and remove the fuel line (6) from the fuel valve.

aWAR NING

Danger! Some fuel may spill.

◆

Plug the free end of the fuel line (6) and attach it to the vehicle with a wire or ta pe in the vertical position.

◆

Release the clamp (7) and remove the breather line (8) from the fuel tank.

aCAU TION

Upon reassem bly, be sure that the line s (4) and (8), the cl amp (3) and (7) and, m ost im portant the fuel line (6) and clamp (5), are properly in stal led.

◆

Unscrew and remove the central screw (9).

◆

Take the rubber element (10) complete of the washer and the bush.

◆

★ Unscrew and remove the three

screws (11).

◆

Slightly raise the rear part o f the fuel t ank and at the same time withdraw it from its two seats (i n the front part), by pulling it backwards.

NOTE Upon reassembly, make sure

that the fuel tank fits correctly into the relative seats in the front part.

2%-/6).'4(%3!$$,%

Carefully read p. 61 (MAINTENANCE).

◆

Place the vehicle on the center or side stand, see p. 59 (POSIT IONING THE VEHICLE ON THE STAND).

◆

Insert the key (1) in the lock (2).

◆

Turn the key (1) clockwise.

◆

Raise and remove the saddle (3).

Upon reassembly:

NOTE Before l owering and locking the

saddle, make sure that you have not left the key in the glove/tool kit compart ment.

◆

Insert the tang (4) of th e saddle in the appropriate seats (see figure).

◆

Lower the saddle and press the its rear part.

aCAUTION

Do not leave you r vehicle unatte nded without ensuring that the saddle (3) is properly positioned and l ocked. Should you forget and ride away with the saddle loose, you could be injured.

2%-/6).'4(%2)'(4!.$ ,%&4

3)$%0!.%,3

Carefully read p. 61 (MAINTENANCE).

aWAR NING

Before carrying out the following operations, let the engine and the exhaust silencer cool down until they reach room temperature, in order to avoid burns.

◆

Remove the saddle, see beside (REMOVING THE SADDLE).

◆

Place the vehicle on the center stand, see p. 59 (POSITIONING THE VEHICLE ON THE STAND).

◆

Unscrew and remove the four screws (5).

aCAUTION

Handle the plastic and painted components with care and avoid scraping or damaging them.

◆

Remove the side panel (6).

use and maintenance Pegaso 650

2%-/6).'4(%/),0!.'5!2$

Carefully read p. 61 (MAINTENANCE).

◆

Place the vehicle on the center stand, see p. 59 (POSITIONING THE VEHICLE ON THE STAND).

◆

Unscrew and remove the four screws (1).

aCAUTION

While removing the oil pan guard (2), pay extra care not to pull, force or damage the three lines (3), (4), (5) of the carbon canister (6).

◆

Remove the oil pan guard (2) only as much as necessary to disconnect the three lines (3), (4), (5) of the carbon canister.

aCAUTION

WHILE REASSEMBLING, PA Y EXTRA CARE NOT TO INVERT THE LIN ES OF THE CARBON CANISTER.

◆

Mark the lines and the relevant couplings, in order to be able to reassemble them correctly.

NOTE To release th e clam ps , us e a p air

of pliers.

◆

Release the clamps and remove the lines (3), (4), (5).

◆

Remove completely the oil pan guard (2).

aCAUTION

While reassembling the oil pan guard (2), pay extra care and ensure not to crash the lines (3), (4), (5).

2%-/6).'4(%(!.$'5!2$3

Carefully read p. 61 (MAINTENANCE).

◆

Hold the nut (7) from rotating with an appropriate Allen wrench.

◆

Remove the screw (8) the washer (9).

◆

Remove the hand-guard (10).

use and maintenance Pegaso 650

)$,).'!$*534-%.4

Carefully read p. 61 (MAINTENANCE).

If the idle becomes irregular, too fast, or too slow, it must be adjusted.

To adjust the idle:

aWAR NING

Exhaust gases co ntain carbon monoxide, which is extremely poisonous if inhaled. Do not start the engine in closed or badly-ventilated rooms. Failure to observe this warning may cause loss of consciousness or even lead to death by asphyxia.

◆

Ride for a few miles until the engine reaches normal running temperature, see p. 15 (Coolant temperature indicator

h”).

“

◆

Pull in the clutch lever (1) c ompletely an d put the shift lever (2) in neutral so that the green “

◆

Keep the vehicle in vertical position, with both wheels resting on the ground.

◆

Observe the tachometer.

The engine must idle 1,400 ± 100 rpm, CO 1% [+ 1% – 0.5% (total range from 0.5% to 2%)].

q” light (3) is on.

If it does not:

aWAR NING

Do not adjust the air adjusting screw. Doing so will upset t he idling performance of your engine, as well as increasing exhaust emissions.

◆

Adjust the knob (4) positioned on the left side of the vehicle.

Rotate the knob clockw ise to increase engine rpm.

Rotate the knob counterclockwise to decrease the engine rpm.

◆

Accelerate and decelerate the engine a few times to make sure, when the throt tle returns to idle, that the engine idle speed is still correct.

NOTE If necessary, contact your Local

aprilia Dealer.

use and maintenance Pegaso 650

!$*534).' 4(%4(2/44,%#/.42/,

Carefully read p. 61 (MAINTENANCE).

This vehicle is equipped with two throttle cables.

The following information may refer to just one throttle cable but should be observed with regard to both throttle cables.

aWARNING

If the throttle sticks open, it may cause a collision with another ve hicle, or an upset.

If the throttle sticks, kill the engine with the engine stop switch located on the right handlebar. Do not attempt to restart the engine until the throttle has been repaired and works perfectly. Failure to obey this warning can lead to a runaway with se riously injuries or even death.

If any fastener in the throttle system becomes loose, likewise you w ill lose control of your vehicle.

Either si tuation c an lead to an upset or collision with subsequent serious injury or death.

Your vehicle is equipped with a double cable throttle. One cable opens the throttle when you rotate the throttle grip toward you; the other closes the throttle when you rotate th e gr ip aw ay from y ou. I t i s es sen tial, when you release the throttle grip, that it automatically return to the idle position. This double cable arrangement enhances safety by providing for positive closing of the throttle.

aWAR NING

In the event of a throttle sticking emergency, always kill the engine using the engine stop switch located ne ar the throttle grip on the right handlebar.

Never use your vehicle if the throttle does not automatically fully return to the idle position whe n the throttle gr ip is released. Contact your Local APRILIA Dealer for repairs. Failure to heed this warning can lead to a serious accident and subsequent injury or even death.

The play of the throttle cable must be between 0.08 – 0.12 in (2 – 3 mm), measured at the edge of the grip, see the illustration above.

To adjust the cable:

◆

Place the vehicle on the center stand, see p. 59 (POSITIONING THE VEHICLE ON THE STAND).

◆

Pull back the rubber boot (1).

◆

Loosen the lock nut (2).

◆

Rotate the adjuster (3) in such a way as to restore the prescribed value.

◆

After the adjustment, tighten the lock nut (2) and check the play again.

◆

Replace the rubber boot (1).

◆

Repeat the adjustment for the second cable.

aWARNING

Exhaust gases contain carbon monoxide, which is extremely poisonous if inhaled. Do not start the engine in c losed or badly-ventilated rooms. Failure to observe this warning may cause loss of consciousness or even lead to death by asphyxia.

use and maintenance Pegaso 650

aWAR NING

After you have adjusted the throttle, rotate the handlebars full left and full right with the engine idling. Check to ensure that the idle sound is not affected by this. Also check that the throttle smoothly and fully closes when released.

!$*534).'4(%#/,$34!24 #(/+%#/.42/,

Carefully read p. 61 (MAINTENANCE).

The play of the c old s tart ca ble m ust b e between 0.08 – 0.12 in (2 – 3 mm), measured on the lever (1).

To adjust the cable:

◆

Place the vehicle on the center stand, see p. 59 (POSITIONING THE VEHICLE ON THE STAND).

◆

Pull back the rubber boot (2).

◆

Loosen the lock nut (3).

◆

Rotate the adjuster (4) in such a way as to restore the prescribed value.

◆

After the adjustment, tighten the lock nut (3) and check the play again.

◆

Replace the rubber boot (2).

e

aWAR NING

After you have adjus ted the cold start, rotate the handlebars full left and full right with the engine idling. Check to ensure that the idle sound is not affected by this.

use and maintenance Pegaso 650

30!2+0,5'

Carefully read p. 61 (MAINTENANCE).

Clean the spark plug every 3,750 mi (6,000 km); change it every 7,500 mi (12,000 km).

Periodically remo ve the spark plug and clean it carefully, removing carbon deposits; change it if necessary.

To reach the spark plug:

◆

Remove the fuel tank, see p. 80 (REMOVING THE FUEL TANK).

To remove and clean the spark plug:

aWARNING

Before carrying out the following ope rations, let the engine and the exhaust silencer cool down until they reach room temperature, in order to avoid burns.

◆

Remove the spark plug cap (1).

use and maintenance Pegaso 650

aWARNING

During this operation, always wear goggles which provide your eyes with 360° protection. Be very careful using compressed air jets, they can cause serious personal injury if directed towards your body.

◆

Using compressed air, blow all the dirt away from the base of the spark plug. Using the special spark plug wrench from the tool kit, unscrew the spark plug. Make sure that no dirt falls into the cylinder through the spark plug hole.

◆

Inspect the spark plug, and insure that there are no carbon deposits nor corrosion marks on either electrode or the ceramic nose that surrounds the center electrode. If necessary, clean the spark plug with a proprietary spark plug cleaner, and a stainless steel brush.

◆

Using compressed air, carefully blow out the spark plug after you have cleaned it. Inspect for cracks on the insulating mate rial, electrode corrosion or erosion, or deposits that you cannot remove. If the spark plug shows any of these defects, it must be replaced.

◆

Check the spark plug gap with a thickness gauge.

◆

The gap must be 0.024 – 0.028 in (0.6 –

0.7 mm); if necessary adjust it, carefully

bending the ground (outside) electrode.

◆

Make sure the gasket is in good condition. With the gaske t on, screw th e spark plug into the head by hand.

◆

Tighten the spark plug with the spark plug wrench, approxim ately one-ha lf tur n after it first snugly contacts the cylin der head.

Spark plug tightening torque:

14.47 ftlb (20 Nm).

aCAU TION

The spark plug must be well tightened, otherwise the engine may overheat and be seriously damag ed. Use the recommended type of spark plug only, see p. 100 (TECHNICAL DATA), in order not to compromise the life and performance of the engine.

◆

Position the spark plug cap (1) properly, so that it does not come off du e to the vi brations of the engine.

◆

Replace the fuel tank, see p. 80 (REMOVING THE FUEL TANK).

"!44%29

Carefully read p. 61 (MAINTENANCE).

Check the electrolyte level and the tightness of the terminals after the first 62 5 mi (1,000 km) and su ccessively every 3 ,750 mi (6,000 km) or 8 months.

aWAR NING

Batteries, when charged, give off hydrogen gas, which is highly explosive. Therefore, do not smoke while working on or around the battery, and keep naked flames or sparks away from the battery. Keep gasoli ne and o ther flammabl e substances well away from the battery, since a battery spa rk could easi ly ignit e them and cause a devastating fire.

Battery electro lyte is toxic and cau stic and can seve rely burn your eyes or skin. Always wear tight fitting goggles and protective clothing when handling battery electrolyte. It is particularly important for you to protect your eyes since even a minuscule amount of battery acid could destroy your vision.

Should you accidentally get even the smallest amount of battery electrolyte on your skin or eyes, immediately flush with large quantities of clear cool water and immediately seek professional medical attention.

If someone should accidentally swallow battery electrolyte, drink a large quantity of milk or cool cle ar water a nd conti nue with milk of magnesia or vegetable oil. Seek pro fessional medi cal assistance immediately.

Since the battery gives off exp losive hy drogen gas, especially when it is being charged, when you are charging a battery, make sure that the room is properly ventilated. Do not inhale the gases released during charging. Do not permit any open flames , sparks or cigarettes or any other source of heat anywhere near the battery while it is charging.

Do not tip the vehicle too much, or tip the battery too much , to avoid electrolyte leaking out. Should you accid entally spill battery electrolyte on any part of your vehicle, immediately wa sh it off with lots of cool clear water. Spills may be neutralized with a mixture of baking soda and water, as we ll. Th is is particularly important, as the battery electrolyte will severely corrode metallic parts and destroy t he finish of plas tic and painted parts.

aCAU TION

Never invert the battery cables. Observe the proper polarity of the battery. Incorrectly attaching the battery to your vehicle will irreparably destroy the electrical system of your vehicle.

Connect and disc onnect the battery only with the ignition switch (1) in the

m” (OFF) position.

“

First connect the positive cable red (+), then the negative (–).

Disconnect the negative cabl e (–) first, then the positive red (+).

If your battery needs to be charged, use a constant voltage, or “taper” charger, with a current rating no greater than 1/10th the capacity of the battery (i.e., for a 50 amp hour battery, th e ma xim um charging current should be 5 amps). Use of a more powerful charger can not only damage the battery irrepara bly, but could cause it to overheat and explode.

If your battery is equipped with an overflow tube, always ensure that it is properly installed, and properly routed. Failure to adhere to this instruction can cause corrosive fumes from the battery to cause serious damage to your vehicle.

use and maintenance Pegaso 650

+ 25 hidden pages