Aprilia Pegaso 650 Part 1 2001 Owner's manual

PEGASO I.E.

650

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aprilia part# 8104312

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First edition: february 2001 Reprint:

Produced and printed by:

editing division Soave (VERONA) - Italy Tel. +39 - 045 76 11 911 Fax +39 - 045 76 12 241 E-mail: customer@stp.it www.stp.it

On behalf 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

The following pr ecautionary w arnings are used throughout this manual in order to convey the following me ss age s:

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 sym bol 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 damage to the vehicle.

NOTE The word “NOTE” in this manual

precedes important information or instructions.

The operations preceded by this symbol must be repeated also on

the opposite side of the vehicle. If not expressly indicate d oth erw ise, for the

reassembly of the units repeat the disassembly operations in reverse order.

The terms “right” and “left” are refer red to the rider seated on the vehicle in the normal riding position.

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Before starting the engine, carefully read this manual and in particula r the section “SAFE DRIVE”.

Your and other pe ople’s safety de pends not only on your quickness of reflexes and on your agility, but also on what you know about the vehicle, on its efficiency and on your knowledge of the basic information for “SAFE DRIVE”. Therefore, get a thorough knowledge of the vehicle, in such a way as to be able to drive in the traffic safely.

NOTE Keep a stock of one bulb per type

with the vehicle (see technical data).

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NOTE This manual must be 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 improves the design of its products, there may be slight discrepancies between the characteristics of your vehicle and those described in this manual. For any clarification concerning the in formation contained in this manual, do not hesitate to contact your aprilia Official Dealer.

For control and repair operations not expressly described in t his pub lication , fo r the purchase of aprilia genuine spare par ts, accessories and other products, as well as for specific advice, contact exclusively aprilia Official Dealers and Service Centers, which guarantee prompt and accurate assistance.

Thank you for choosing aprilia. We wish you a nice ride.

All rights as to ele ctronic storage, reproduction and total or partial adaptation, with any means, are reserved for all Countries.

NOTE In some countries the antipollu-

tion and noise regulations in force require periodical inspections.

The user of the vehicle in these countries must:

– contact an aprilia O ff ic ial Deal er to have

the non-homologated components re-

placed with others homologated for use

in the country in question;

– carry out th e required pe riodical in spec-

tions.

NOTE Soon after purchasing the vehi-

cle, write d own the id entificat ion data indicated on the SPARE PARTS IDENTIFICATION LABEL in the table here below. This label is positioned on the left side of the saddle support; to r ead it, i t is nec es sa ry t o remove the saddle, see p. 21 (UNLOCKING/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 suppl ied to the aprilia Officia l Dealer as reference data for the purchase of spare parts or spe cific accessories of the model you have acquired.

In this manual the various versions are indicated by the following symb ols :

automatic light switching version

(Automatic Switch-on Device) optional

catalytic version

VERSION:

Italy United King-

dom Austria

Portugal Finland Belgium Germany France Spain

Greece Holland Switzerland Denmark Japan

Singapore

Slovenia

Israel

South Korea

Malaysia

Chile

Croatia

Australia

United States of

America Brazil

South Africa

New Zealand

Canada

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SAFE DRIVE

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

ACCESSORIES ................................. ................ 23

SIDE BAGS

equipment in the countries where required) ....... 24

REAR CASE

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 CATALYTIC EXHAUST SILENCERS

............................. ........... 23

(supplied as standard

.................................................... 39

......... 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

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 POSITIONING THE VEHICLE ON THE FRONT SUPPORT STAND

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 (supplied as standard equipment in the

countries where required) ................................. 74

INSTALLING THE REAR CASE SUPPORTS

(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

.......................... 69

........................ 69

REAR SUSPENSION ........................................ 78

REAR SUSPENSION WITH HYDRAULIC PRELOAD ADJUSTMENT

CHECKING THE BRAKE PAD WEAR .............. 80

IDLING ADJUSTMENT ..................................... 81

ADJUSTING THE ACCELERATOR CONTROL 81 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

.......................... 79

use and maintenance P egaso 650 I.E.

safe drive

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To drive the vehicle it is necessary to be in possession of all the r equirements prescribed by law (driving licence, minimum age, psychophysical ability, insurance, state taxes, vehic le registration , number plate, etc.).

Gradually get to know the vehicle by driving it first in areas with low tra ffic and/or pri vate areas.

use and maintenance Pegaso 650 I.E.

The use of medicins, alcohol and drugs or psychotropic su bstanc es no tably incre ase s the risk of accidents.

Be sure that yo u are in go od psyc hophy sical conditions and f it for driving and pay particular attention to physical weariness and drowsiness.

Most road accident s are caused by the driver’s lack of experience. NEVER lend the vehicle to beginners and, in any case, make sure that the driver has all the requirements for driving.

Rigorously observe all road signs and national and local road regulations.

Avoid abrupt movements that can be dangerous for yourself and other people (for example: rearing up on the back wheel, speeding, etc.), an d giv e due co nside ration to the road surface, visib ility and ot her dri ving conditions.

Avoid obstacles that could damage the vehicle or make you lose contro l.

Avoid riding in the slipstream created by preceding vehicles in order to increase your speed.

Always drive with both hands on the handlebars and both feet on the footrests (or on the ride r’s footboards ), in the correc t driving posture.

Avoid standing up or stretching your limbs while driving.

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OIL

COOLER

The driver should pay attention and avoid distractions caused by people, things and movements (never smok e, eat, drink , read, etc.) while driving.

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Use only the veh ic le’ s s pe cif ic fuels and lubricants indicated in the “LUBRICANT CHART”; check all oil, fuel and coolant levels regularly.

If the vehicle has been involved in an accident, make sure that no damage has occurred to the control levers, pipes, wires, braking system and vital parts.

If necessary, have the ve hicle inspe cted by an aprilia Official Dealer who should carefully check the frame, handlebars, suspensions, safety parts an d all the de vices that you cannot check by yourself.

Always remember to report any malfunction to the technicians to help them in their work.

Never use the vehicle when the amount of damage it has suffered endangers your safety.

A12

345

ONLY ORIGINALS

Never change the position, inclination or colour of: number plate, direction indicators, lights and horns.

Any modification of the vehi cle will result in the invalidity of the guarantee.

Any modification of the vehicle and/or the removal of original components can compromise vehicle performance levels and safety or even make it illegal.

We recommend respecting all regulations and national an d l oc al pro vi sions regarding the equipment of the vehicle.

In particular, avoid all modifications that increase the vehi cle’s pe rforman ce levels or alter its original characteristics.

Never race with other vehicles.

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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 visor is clean.

Wear protective clothing, preferably in light and/or reflecting colours. In this way you will make yourself more visible to the other drivers, thus notably reducin g the risk of being knocked down, and you will be more protected in case of fall.

This clothing should be very tight-fitting and fastened at the wrists and ankles; strings, belts and ties should not be hanging loose; prevent these and other objects from interfering with driving by getting entangled with moving parts or driving mechanisms.

use and maintenance Pegaso 650 I.E.

Do not keep objects tha t can be dan gerous in case of fall, for example pointed objects like keys, pens, glass vials etc. in your pockets (the same recommendations also apply to passengers).

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The owner of the vehicle is responsible for the choice, installation and use of any accessory. Avoid installing accessories that cover horns or lights or that could impair their functions, limit the suspension stroke and the steering ang le, h amper the o peratio n of the controls and reduce the distance from the ground and the angle of inclination in turns. Avoid using accessories that hamper access to the co n tro l s, sinc e t h is can pr ol on g reaction times during an emergency. Big fairings and windshiel ds installed on the vehicle may p roduce aerodyna mic forces that affect the sta bility of the v ehic le, especially when riding at high speed.

Make sure that the equipment is well fastened to the vehicle and not dangerous during driving. Do not install electrical devices and do not modify those alread y existing to av oid electrical over load s, b ecau se t he v ehic le c ould suddenly stop or there could be a dangerous current sh ort a ge in th e hor n an d in t he lights. aprilia recommends the use of genuine accessories (aprilia genuine accessories).

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Be careful and moderate when loading your luggage. Kee p any luggage loa ded as close as possible to the center of gravity of the vehicle and distribute the load uniformly on both sides, in order to reduce umbalance to the minimum. Furthermore, make sure that the load is firmly secur ed to the vehicle, especially during long trips.

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Avoid hanging bulky, hea vy and/ or dangerous objects on the handlebars, mudguards and forks, because the vehicle might respond more slowly in turns and its manoeuvrability could be una voidably impaired.

Do not place bags th at are too bulky o n the vehicle sides an d do not ride with the crash helmet, because they could hit people or obstacles, making you lose control of the vehicle.

Do not carry any bag if it is not tightly secured to the vehicle.

Do not carry bags which protrude too m uch from the luggage- rack or which cover the lights, horn or indicators.

Do not carry animals or childre n on the glove compartment or o n the luggage rack.

Do not exceed the maximum load allowed for each side-bag.

When the vehicle is overlo aded, it s stab ili ty and its manoeuvrability can be compromised.

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1) Headlight

2) Ignition switch/steering lock

3) Left rear-view mirror

4) Fuel tank filler cap

5) Fuel tank

6) Coolant expansion tank cap

7) Battery

9) Fuse carrier

10) Passenger grab rail

11) Glove/tool kit compartment

12) Rear luggage rack

13) Rear fork

14) Passenger left footrest (snapping, closed/open)

8) Electronic unit

15) Centre stand m (supplie d as standard equipment i n the countries where required)

16) Side s tand

17) Rider left footrest

18) Shifting lever

19) Coolant expansion

20) Rear luggage rack m (supplied as standa rd equipment in the countries where required)

21) Left side bag m (supplied as standard equi pment in the countries where r equired)

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1) Rear light

2) Passenger grab rail

3) Saddle lock

4) Saddle

5) Rear brake fluid tank

6) Air cleaner

7) Rear shock absorber

8) Engine oil level plug-dipstick

9) Front brake fluid tank

10) Right rear-view mirror

11) Horn

12) Engine oil tank

13) Idle speed adjusting knob

14) Engine oil filter

15) Rear brake control lever

16) Rider right footrest

17) Anti-theft hook (for shielded cable “Body-Guard” aprilia m)

18) Rear brake pump

19) Passenger right footrest

(snapping, closed/open)

20) Drive chain

21) Right side bag m (supplied as standard equipment in the countries where required)

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1) Clutch lever

2) Instruments and indicators

3) Ignition switch/steering lock (2 - 1 - &)

4) Front brake lever

5) Throttle grip

6) Engine stop switch (2 - 1)

7) Start push button (+)

8) Light switch (( - ' -

9) Direction indicator switch (6)

10) Horn push button (*)

11) Dimmer switch (8 - 7)

12) High beam signalling push button (7)

13) Cold start lever (0)

) (not provided for e)

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1) Revolution counter

2) Speedometer

3) Total kilometres odometer

4) Coolant temperature indicator ())

5) Partial kilometres odometer

6) Odometer trip control

7) Red engine oil pressure warning light (.)

8) Blue high beam warning light (7)

9) Red diagnostic warning light (û)

10) Amber low fuel warning light (-)

11) Green direction indicator warning light (6)

12) Green neutral indicator warning light (/)

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Description Function Direction indicator warning light High beam warning light

Revolution counter rpm

Low fuel warning light

Engine oil pressure Warning light

Neutral indicator warning light

Blinks when the direction indicators are on.

Comes on when the high beam bulbs are on or when the headlight signaller is operat ed.

Indicates the number of revolutions of the engine per minute.

aCAUTION

It comes on when the quantity of fuel still available in th e fu el ta nk is l ess than 5 L.

In this case, top up as soon as possible, see p. 27 (FUEL).

Comes on whenever the ignition switch is in position “2” and the engine is not running, thus checking the functionality of the bulb.

If the light does not come on i n th is phase, contact an aprilia Official Dealer.

aCAUTION

means that the engine oil pressure in the circuit is insuffic ie nt. In this case, stop the eng in e imm ediately and contact an

Comes on when the ge ar is in ne ut ra l.

It comes on whenever the ignition switch is positioned on “2” and goes out a few seconds after the engine st art.

aCAUTION

With the engine stop switch in position “

Diagnostic warning light

position ed on “

eration of the injection circuit. If the light does not come on i n th is phase, contact an aprilia Official Dealer.

aCAUTION

means that the electronic unit has detected an anomaly. In many cases the engine keeps running with limited functions; contact an

Never exceed the engine max. speed rate, see p. 50 (RUNNING-IN).

If the engine oil pressure warning light “ start or comes on during the norma l operation of the engine, this

Do not carry out any operation on the component s of the vehicle with the ignition switch in position “

.” remains on after the

APRILIA

Official Dealer.

2”.

1”, it comes on when ever the ignition swit ch is

2” and remains on, with low light intensity, thus checking the correct op-

If the diagnostic warning light “ start or comes on during the norma l operation of the engine, this

APRILIA

û” remains on after the engine

Official Dealer immediate l y.

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Description Function Speedometer (km/h) It indicates the driving speed. Total kilometres odomet er It indicates the total number of kilometres covered.

It indicates the approxi m at e temperature of the coolant in the engine. When the pointer starts moving beyond the “40” level, the temperature is sufficient for driving the vehicle. The normal operating tem perature ap pears on the gr aduated area of t he scale.

aCAUTION

the cooling fan works even when the engine is off and it is disconnected automatically.

Coolant temperat ure indicator

Partial kilometres odometer Odometer trip control Rotate it anticlockwise to set the partial kilometres odometer to zero.

)

aCAUTION

If the pointer gets near the red ar ea, stop the en gine, wait unt il the cooling fa n is disconn ected and check the coolant level, see p. 34 (COOLANT).

If the pointer reaches the red area, stop the vehicle and let the engine idle for approximately two minutes, thus perm itting the regular cir culation of the c oolant in the system ; then, position t he engine stop switch on “ the dashboard rema ins the s ame af ter the coola nt leve l has be en chec ked , do not st art the vehicle and contact an aprilia Official Dealer.

It indicates the partial number of kilometres covered. To set it to zero, use the odometer trip control.

The switching on and off of the cooling fan does not depend on the position of the ignitio n switch. To lower the co olant temperatur e,

If the maximum allowed tem perature is exceede d (red area of the scale), the engine may be seriously damaged.

1” and check t he coola nt le vel , se e p. 34 (COO LANT). I f t he si tuat io n on

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