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APRILIA PEGASO 650 IE - 2004, Manual

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APRILIA PEGASO 650 IE - 2004 Manual Download Page 36

36

use and maintenance   

Pegaso 650 I.E.

ADJUSTING THE REAR BRAKE 
CONTROL LEVER CLEARANCE 

The brake control lever is positioned
ergonomically during the assembly of the
vehicle. 
If necessary, it is possible to adjust the
brake control lever clearance:

u

Loosen the lock nut (1).

u

Screw the brake adjuster (2) completely.

u

Screw the lock nut (3) completely on the
pump control rod (4).

u

Screw the pump control rod (4)
completely, then unscrew it by giving 3 –
4 turns.

u

Screw the brake adjuster (2) until the
brake pedal reaches the desired height.

u

Lock the brake adjuster (2) by means of
the lock nut (1).

u

Unscrew the pump control rod (4) and
bring it in contact with the pump piston.

u

Screw the rod in order to ensure a
minimum clearance of 

0.5 – 1 

mm

between the pump control rod (4) and
the pump piston.

CAUTION

Make sure that there is a certain idle
stroke in the movement of the lever (5),
to prevent the brake from remaining
applied and the consequent untimely
wear of the braking elements.

Lever (5) idle stroke: 4 mm (measured at
the lever end).

u

Lock the pump control rod (4) by means
of the lock nut (3).

CAUTION

After the adjustment, make sure that the
wheel rotates freely with released
brake.

Check the braking efficiency.
If necessary, contact your 

aprilia

Official Dealer.

CATALYTIC EXHAUST SILENCERS 

L

NOTE 

The following information refers

to a single exhaust silencer, but is valid for
both.

WARNING

Avoid parking the vehicle catalytic
version near dry brush wood or in
places easily accessible to children, as
t h e   c a t a l y t i c   s i l e n c e r   b e c o m e s
extremely hot during use; be very
careful and avoid any kind of contact
before it has completely cooled down.

The catalytic vehicle is fitted with a silencer
with metal catalytic converter of the
“platinum-rhodium bivalent” type.

Summary of Contents for PEGASO 650 IE - 2004

Page 1: ...use maintenance book PEGASO I E 650 aprilia part 8104312 ...

Page 2: ...erious injury or even death CAUTION 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 TECHNICAL INFORMATION The operations preceded by this symbol must be repeated also on the opposite side of the vehicle If not expressly indicated otherwise for the reassembly of the units...

Page 3: ...lution and noise regulations in force require periodical inspections The user of the vehicle in these countries must contact an aprilia Official Dealer to have the non homologated components replaced with others homologated for use in the country in question carry out the required periodical inspections NOTE Soon after purchasing the vehicle write down the identification data indicated on the SPAR...

Page 4: ...ULAR SERVICE INTERVALS CHART 52 IDENTIFICATION DATA 54 JOINTS WITH CLICK CLAMPS AND WITH SCREW CLAMPS 54 CHECKING THE ENGINE OIL LEVEL AND TOPPING UP 55 FRONT WHEEL 56 REAR WHEEL 58 POSITIONING THE VEHICLE ON THE REAR SUPPORT STAND J 61 POSITIONING THE VEHICLE ON THE FRONT SUPPORT STAND J 61 DRIVE CHAIN 62 REMOVAL OF THE FUEL TANK 64 REMOVING THE OIL SUMP GUARD 65 REMOVING THE RIGHT AND LEFT SIDES...

Page 5: ...safe drive SAFE DRIVE ...

Page 6: ...ccidents 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 and give due consideration ...

Page 7: ...s 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 Never change the position inclination or colour of number plate direction indicators lights and horns Any modification of the vehicle will result in the invalidity of the guarantee Any modif...

Page 8: ... moving parts or driving mechanisms Do not keep objects that can be dangerous in case of fall for example pointed objects like keys pens glass vials etc in your pockets the same recommendations also apply to passengers ACCESSORIES 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...

Page 9: ...hermore make sure that the load is firmly secured to the vehicle especially during long trips Avoid hanging bulky heavy and or dangerous objects on the handlebars mudguards and forks because the vehicle might respond more slowly in turns and its manoeuvrability could be unavoidably impaired Do not place bags that are too bulky on the vehicle sides and do not ride with the crash helmet because they...

Page 10: ...ery 8 Electronic unit 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 15 Centre stand J 16 Side stand 17 Rider left footrest 18 Shifting lever 19 Not present Coolant expansion tank 19A Coolant expan sion tank 20 Rear luggage rack J 21 Left side bag J Supplied as standard equipment in the countries...

Page 11: ...ront 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 J 18 Rear brake pump 19 Passenger right footrest snapping closed open 20 Drive chain 21 RightsidebagJ supplied as standard equipment in the countries where required ...

Page 12: ... KEY 1 Clutch lever 2 Instruments and indicators 3 Ignition switch steering lock 4 Front brake lever 5 Throttle grip 6 Engine stop switch 7 Start push button 8 Direction indicator switch 9 Horn push button 10 Dimmer switch 11 High beam signalling push button 12 Cold start lever ...

Page 13: ...rature indicator 5 Partial kilometres odometer 6 Trip meter resetting knob 7 Red engine oil pressure warning light 8 Blue high beam warning light 9 Red diagnostic warning light c 10 Amber low fuel warning light 11 Green direction indicator warning light 12 Green neutral indicator warning light INSTRUMENTS AND INDICATORS ...

Page 14: ...n during the normal operation of the engine this means that the engine oil pressure in the circuit is insufficient In this case stop the engine immediately and contact an aprilia Official Dealer Neutral indicator warning light Comes on when the gear is in neutral Diagnostic warning light c It comes on whenever the ignition switch is positioned on and goes out a few seconds after the engine start D...

Page 15: ...aximum allowed temperature is exceeded red area of the scale the engine may be seriously damaged If the pointer gets near the red area stop the engine wait until the cooling fan is disconnected and check the coolant level see p 31 COOLANT If the pointer reaches the red area stop the vehicle and let the engine idle for approximately two minutes thus permitting the regular circulation of the coolant...

Page 16: ...rgency Press the push button to operate the high beam blinking NOTE To disconnect the high beam blinking release the push button 5 COLD START LEVER The starter for the cold start of the engine is operated by rotating the lever downwards To disconnect the starter move the lever to its initial position CONTROLS ON THE RIGHT PART OF THE HANDLEBAR NOTE The electrical parts work only when the ignition ...

Page 17: ...k lock 2 and the saddle lock 3 Two keys are supplied together with the vehicle one spare key NOTE Do not keep the spare key on the vehicle Position Function Key removal Steering lock The steering is locked It is not possible to start the engine It is possible to remove the key The engine cannot be started It is possible to remove the key The engine can be started It is not possible to remove the k...

Page 18: ...key 1 AUXILIARY EQUIPMENT UNLOCKING LOCKING THE SADDLE u Position the vehicle on the stand see p 49 POSITIONING THE VEHICLE ON THE STAND u Insert the key 1 in the saddle lock 2 u Turn the key 1 clockwise and raise and remove the saddle NOTE Before lowering and locking the saddle make sure that you have not left the key in the glove tool kit compartment To lock the saddle u Position the tangs 3 in ...

Page 19: ...ark plug 8 socket spanner rod 9 double ended cross cut headed screwdriver 10 tool case 11 Maximum allowed weight 1 5 kg ANTI THEFT HOOK The anti theft hook 12 is positioned on the right side of the vehicle near the rider footboard To prevent the vehicle from being stolen it is advisable to secure it with the shielded cable Body Guard aprilia J 13 available at the aprilia Official Dealers WARNING D...

Page 20: ...e required centre stand J supplied as standard equipment in the countries where required Tool Operations Support pins 1 for the rear support stand see p 61 POSITIONING THE VEHICLE ON THE REAR SUPPORT STAND J Positioning of the vehicle on the rear stand Rear support stand 2 see p 61 POSITIONING THE VEHICLE ON THE REAR SUPPORT STAND J Rear wheel disassembly Drive chain adjustment Front support stand...

Page 21: ...o one unit only but is valid for both To open the side bag proceed as follows u Position the vehicle on the stand see p 49 POSITIONING THE VEHICLE ON THE STAND u Introduce the key 1 in the lock u Turn the key 1 anticlockwise u Extract the key 1 and insert it in the other lock u Turn the key 1 anticlockwise u Lift the two parts of the lock 2 u Open the case 3 Two keys are supplied together with the...

Page 22: ...upling seats 5 on the bag support Two keys are supplied together with the vehicle one spare key NOTE Do not keep the spare key on the vehicle CAUTION Handle the plastic and painted components with care to avoid scraping or damaging them WARNING Upon reassembly make sure that the bag is properly anchored to its support Upper part perfect fitting of the bag coupling pins in the coupling seats provid...

Page 23: ...kwise u Remove the handle 2 u Lift the lock 3 u Release the upper part 4 of the lock 3 from the case 5 u Lift the upper part of the case to open it 5 NOTE The case can contain two FULL FACE helmets Two keys are supplied together with the vehicle one spare key NOTE Do not keep the spare key on the vehicle WARNING Do not load the rear case excessively Maximum allowed weight 5 kg To remove the rear c...

Page 24: ...er as it could catch fire when getting in contact with the red hot surfaces of the engine In case some fuel has accidentally been spilt make sure that the area has completely dried and before starting the vehicle verify that there is no fuel inside the fuel filler neck Since petrol expands under the heat of the sun and due to the effects of sun radiation never fill the tank to the brim WARNING Scr...

Page 25: ...other similar items make sure that they are perfectly clean WARNING Do not fill the tank completely the maximum fuel level must remain below the lower edge of the filler neck see figure CAUTION During the refilling operations be careful to avoid damaging the inner parts of the tank with the fuel pump u Refuel After refuelling NOTE The cap can be closed only when the key 2 is inserted u With insert...

Page 26: ...ke discs are neither oily nor greasy especially after maintenance or checking operations Check that the brake cables are neither twisted nor worn out Prevent water or dust from accidentally getting into the circuit In case maintenance operations are to be performed on the hydraulic circuit it is advisable to use latex gloves If the brake fluid gets in contact with the skin or the eyes it can cause...

Page 27: ...following information refers to a single braking system but is valid for both When the disc pads wear out the level of the fluid decreases to automatically compensate for their wear The front brake fluid tank is positioned on the right part of the handlebar near the front brake lever coupling The rear brake reservoir is positioned on the right side of the vehicle near the rear brake control lever ...

Page 28: ... up TOPPING UP Carefully read p 26 BRAKE FLUID recommendations CAUTION The brake fluid may flow out of the tank Do not operate the front brake lever if the screws 1 and 2 are loose or most important if the brake fluid tank cover has been removed CAUTION Position a cloth under the brake reservoir in case some fluid should be spilled u Keep the vehicle in vertical position and turn the handlebar so ...

Page 29: ...und u Top up the reservoir 6 by adding brake fluid see p 93 LUBRICANT CHART until reaching the correct level CAUTION Do not exceed the MAX level while topping up It is advisable to top up until reaching the MAX level only with new pads Do not reach the MAX level with worn out pads since this will cause a fluid outflow when the pads are changed u Put back the gasket 4 in its seat correctly u Put ba...

Page 30: ... to the air The brake fluid is hygroscopic and when in contact with the air it absorbs its humidity Leave the brake fluid tank open ONLY for the time necessary for topping up u Unscrew and remove the plug 1 u Remove the gasket 2 CAUTION In order not to spill the brake fluid while topping up keep the fluid in the tank parallel to the tank rim in horizontal position Do not put additives or other sub...

Page 31: ...s of the engine it may catch fire and send out invisible flames In case any maintenance operation should be required it is advisable to use latex gloves CAUTION Have the pads changed by your aprilia Official Dealer The coolant is composed of 50 water and 50 antifreeze This mixture is ideal for most running temperatures and ensures good protection against corrosion It is advisable to keep the same ...

Page 32: ... The coolant is noxious do not swallow it if the coolant gets in contact with the skin or the eyes it can cause serious irritations Do not use your fingers or any other object to check if there is enough coolant CAUTION Do not put additives or other subtances into the fluid If you use a funnel or other similar items make sure that they are perfectly clean u Top up the expansion tank by adding cool...

Page 33: ... case of sudden braking the tyres could even come off the rims Further the vehicle could skid while turning WARNING Check the surface and the wear of the tyres since tyres in bad conditions can impair both the grip and the controllability of the vehicle Some types of tyres homologated for this vehicle are provided with wear indicators There are several kinds of wear indicators For more information...

Page 34: ...RONMENT Put it in a sealed container and take it to the filling station where you usually buy it or to an oil salvage center In case any maintenance operation should be required it is advisable to use latex gloves CAUTION If the engine oil pressure warning light comes on during the normal operation of the engine this means that the engine oil pressure in the circuit is insufficient In this case ch...

Page 35: ...the lock nut 2 u Rotate the adjuster 3 until the idle stroke of the clutch lever is about 10 mm u Tighten the lock nut 2 and check the adjustment again u Start the engine see p 41 STARTING u Pull the clutch control lever completely and engage the 1st gear Make sure that the engine does not stop that the vehicle does not tend to move forward or that the clutch does not slip during the acceleration ...

Page 36: ...pump piston CAUTION Make sure that there is a certain idle stroke in the movement of the lever 5 to prevent the brake from remaining applied and the consequent untimely wear of the braking elements Lever 5 idle stroke 4 mm measured at the lever end u Lock the pump control rod 4 by means of the lock nut 3 CAUTION After the adjustment make sure that the wheel rotates freely with released brake Check...

Page 37: ...t of design has been removed or rendered inoperative by any person Check the exhaust silencer and the silencer pipes making sure that there are neither signs of rust nor holes and that the exhaust system works effectively If the noise produced by the exhaust system increases immediately contact your aprilia Official Dealer INSTRUCTIONS FOR USE GETTING ON AND OFF THE VEHICLE The instructions below ...

Page 38: ...hicle may cause an unbalance and the consequent loss of equilibrium and the vehicle may fall or overturn NOTE The rider must always be the first person to get on the vehicle and the last to get off and it is the rider who controls the balance and stability of the vehicle when the passenger gets on and off When getting on and off the vehicle the passenger must make careful movements in order to mai...

Page 39: ...If it is impossible for you to place both feet on the ground place the right foot on the ground in case of unbalance the left side of the vehicle is prevented from falling over by the side stand and keep the left foot ready to rest on the ground u Place both feet on the ground keeping the vehicle in balance in riding position u Instruct the passenger how to safely get off the vehicle CAUTION Risk ...

Page 40: ...pproximately 10 mm the clutch must work without jerking and or slipping 35 CLUTCH Steering Make sure that the steering rotates smoothly without any clearance or slackening Side stand and centre stand J supplied as standard equipment in the countries where required Make sure that it operates correctly Make sure that when the stand is let up or down there is no friction and that the spring tension b...

Page 41: ...ge the gears the engine stops With the side stand up it is possible to start the engine either in neutral gear or with engaged gears and pulled in clutch lever u Get on the vehicle in riding position see p 37 GETTING ON AND OFF THE VEHICLE u Make sure that the stand is completely up u Make sure that the dimmer switch 2 is in position u Move the engine stop switch 3 to position u Rotate the key 4 a...

Page 42: ... when the engine is running since you may damage the starter If the engine oil pressure warning light 5 remains on or if it comes on during the normal operation of the engine this means that the oil pressure in the circuit is insufficient In this case stop the engine immediately and contact an aprilia Official Dealer u Keep at least one brake lever pulled and do not accelerate until you start CAUT...

Page 43: ...ards u Insist for at least ten seconds with the start push button 11 pressed and at the same time moderately rotate the throttle grip 13 If the engine starts u Release the start push button 11 and the throttle grip 13 u Rotate the cold start lever 12 upwards u If the idling is unstable twist the throttle grip 13 slightly and frequently If the engine does not start Wait a few seconds and repeat the...

Page 44: ...s and your feet on the footrests NEVER RIDE IN ANY POSITION OTHER THAN THOSE INDICATED WARNING If you drive with a passenger instruct him her so that he she does not create problems during manouvres Before leaving make sure that the stand is completely up To leave u Start the engine see p 41 STARTING u Adjust the inclination of the rear view mirrors correctly CAUTION With the vehicle at rest try t...

Page 45: ... ride the vehicle at too low rpm u Release the throttle grip 2 Pos A pull the clutch lever 3 and lift the shifting lever 4 Release the clutch lever 3 and accelerate u Repeat the last two operations and shift up CAUTION If the engine oil pressure warning light 5 comes on during the normal operation of the engine this means that the engine oil pressure in the circuit is insufficient In this case sto...

Page 46: ...id the overheating of the clutch keep the engine running with vehicle at rest engaged gears and pulled clutch lever for the shortest possible time WARNING Avoid opening and closing the throttle grip repeatedly and continuously so that you do not accidentally lose control of the vehicle If you have to brake close the throttle and put on both brakes in order to obtain uniform deceleration properly e...

Page 47: ...running in take care not to exceed NOTE Only after the first 2000 km 1250 mi of running in you can expect the best performance levels from the vehicle Keep to the following indications u Do not open the throttle completely if the speed is low both during and after the running in u During the first 500 km 312 mi put on the brakes with caution avoiding sharp and prolonged brakings This ensures a cor...

Page 48: ... do not represent a danger for persons and children Do not leave the vehicle unattended when the engine is on or the key is inserted into the ignition switch Do not get too near the cooling fan even if it is not in operation since it may start and parts of clothes hair etc may get entangled in it WARNING The fall or excessive inclination of the vehicle may cause the fuel to flow out of the tank Th...

Page 49: ...er the handlebar completely leftwards WARNING Make sure that the vehicle is stable CENTRE STAND J supplied as standard equipment in the countries where required WARNING It is forbidden to position the vehicle on the centre stand while seated astride the vehicle in riding position WARNING Make sure that the parking surface is free from obstacles firm and flat u Choose a suitable parking area see p ...

Page 50: ...t use any brake lock devices Failure to heed this warning can seriously damage the braking system and lead to an accident thus provoking serious injuries or death NEVER leave the ignition key 1 inserted and always use the steering lock Park the vehicle in a safe place possibly in a garage or a protected place When possible use an additional anti theft device Make sure that all documents are in ord...

Page 51: ...t hold any mechanical piece or other parts of the vehicle with your mouth the components are not edible and some of them are noxious or even toxic CAUTION If not expressly indicated otherwise for the reassembly of the units repeat the disassembly operations in reverse order In case any maintenance operation should be required it is advisable to use latex gloves Routine maintenance operations can u...

Page 52: ... monoxide Component After run ning in 1000 km 625 mi Every 6000 km 3750 mi or 12 months Every 12000 km 7500 mi or 24 months Battery Clamp tightening electrolyte level Spark plug Fork Light operation direction Light system Safety switches Brake fluid Coolant Side bag coupling pins Tyres every 1000 km 625 mi Tyre pressure every 1000 km 625 mi Engine idling rpm and CO Securing locks for the side bags...

Page 53: ...tment Drive chain Transmission cables and controls Wheel centering Rear suspension linkage bearings Steering bearings and steering clearance Wheel bearings Brake discs Fuel pump filter every 15000 km 9375 mi Air cleaner Engine oil filter Engine oil filter on oil tank General running of the vehicle Clutch clearance Adjusting the valve clearance Braking systems Cooling system Brake fluid every 2 yea...

Page 54: ...leakages and protect the components positioned near the joint CLICK CLAMPS For the removal it is sufficient to use simple pliers while for the installation it is necessary to use a special tool see below Before removing a clamp prepare the material necessary for the correct reassembly NOTE Have the appropriate special tool J to hand clamp installation pliers see p 20 SPECIAL TOOLS J CAUTION Upon i...

Page 55: ...e p 48 STOPPING u Keep the vehicle in vertical position with the two wheels resting on the ground u Insert the plug dipstick 1 completely in the inlet hole 2 without screwing it u Extract the plug dipstick 1 again and read the oil level on the dipstick MAX maximum level MIN minimum level The difference between MAX and MIN amounts to approximately 300 cm u The level is correct when the oil almost r...

Page 56: ...under the tyre in such a way as to keep the wheel in its position after loosening it CAUTION Make sure that the vehicle is stable u Partially unscrew the two wheel pin clamp screws 2 right side u Unscrew the wheel pin 3 completely NOTE To facilitate the extraction of the wheel pin slightly raise the wheel u Support the front wheel and manually withdraw the wheel pin 3 u Take the left spacer ring 4...

Page 57: ...g torque 3 80 Nm 8 kgm u Remove the support 1 that upon disassembly was put under the tyre WARNING Due to the weight and dimensions of the vehicle the following operation must be performed by two persons NOTE Weight without driver ready for starting 200 kg u Remove the front support stand see p 61 POSITIONING THE VEHICLE ON THE FRONT SUPPORT STAND J u Remove the rear support stand see p 61 POSITIO...

Page 58: ...change it if it is damaged DISASSEMBLY u Position the vehicle on the appropriate rear support stand see p 61 POSITIONING THE VEHICLE ON THE REAR SUPPORT STAND J u Put a support 1 under the tyre in such a way as to keep the wheel in its position after loosening it u Lock the rotation of the wheel pin 2 with the appropriate key u Unscrew and remove the nut 3 and retrieve the washer 4 Wheel nut 3 dri...

Page 59: ...sary if the wheel is in the normal running position vertical or in horizontal position with the rear sprocket facing upwards and in both cases secured against overturning NOTE Do not unscrew the six nuts 12 The whole final drive unit must be withdrawn from the flexible coupling holder u Withdraw the final transmission unit 10 keeping it parallel to the wheel axis u Remove the four flexible couplin...

Page 60: ...ards until its central hole and the holes on the rear fork are aligned u Rotate the support plate 8 complete with brake caliper 9 and with fulcrum on the stop pin until it is aligned with the holes u Insert the washer 5 in the wheel pin 2 u Introduce the wheel pin 2 completely from the left side NOTE Make sure that the wheel pin 2 is completely inserted u Position the washer 4 and tighten the whee...

Page 61: ...3 and make them hit against the rear fork u Tighten the two knobs 1 u Push the stand forward 7 until the support pin 3 rests on the right side against the rear fastening plate of the lower chain guard NOTE Have someone help you keep the vehicle in vertical position with the two wheels on the ground u Rest one foot on the rear part of the stand 7 u Push the stand 7 downwards until it reaches the en...

Page 62: ...VEHICLE ON THE REAR SUPPORT STAND J u Position the shifting lever in neutral u Make sure that the vertical oscillation in an intermediate point between pinion and crown in the lower part of the chain is included between 35 45 mm u Rotate the wheel manually in such a way as to check the vertical oscillation of the chain even in other positions the slack must be constant in all the wheel rotation ph...

Page 63: ...prockets and chain CAUTION Lubricate the chain frequently especially if there are dry or rusty parts The crushed or seized links must be lubricated and made work again If this is not possible contact an aprilia Official Dealer who will provide for changing the chain u Finally check the wear of the rear fork protection shoe CLEANING AND LUBRICATION CAUTION The drive chain is provided with O rings a...

Page 64: ...emove the three screws 4 u Disconnect the electric connector 5 from the fuel pump CAUTION Upon reassembly make sure that the electric connector 5 is correctly coupled WARNING Position a clean cloth under the rapid couplings 6 and 7 in order to absorb the small quantity of fuel that will flow out of them after disconnection u Release and disconnect the rapid couplings 6 7 WARNING Upon reassembly ma...

Page 65: ...NG THE VEHICLE ON THE STAND u Unscrew and remove the four screws 1 CAUTION Handle the plastic and painted components with care to avoid scraping or damaging them u Remove the oil sump guard 2 NOTE If the deadening material inside the oil sump guard 2 is deteriorated contact an aprilia Official Dealer to have it changed REMOVING THE RIGHT AND LEFT SIDES Carefully read 51 MAINTENANCE WARNING Wait un...

Page 66: ...ove the lower protection element 5 INSTALLING THE SIDE BAG SUPPORTS J supplied as standard equipment in the countries where required NOTE If also the rear case supports must be installed beside the side bag supports it is necessary to install the former first see p 68 INSTALLING THE REAR CASE SUPPORTS J supplied as standard equipment in the countries where required Carefully read 51 MAINTENANCE Th...

Page 67: ...pacer ring 7 Insert the screws 5 6 and screw them manually Tighten the screws 5 6 and the nut 10 without applying the torque prescribed Tighten the screw 1 and the screw 2 applying the torque prescribed Driving torque of screws 1 2 25 Nm 2 5 kgm Unscrew and remove the screws 5 6 and the nut 10 Remove the bag support 11 Put back the side cover see p 65 REMOVING THE RIGHT AND LEFT SIDES CAUTION Hand...

Page 68: ... screw B and the washer C will be reused in the following operations dPosition the rear coupling 7 dInsert the screw B with the relevant washer C and screw it manually Position the spacer ring 6 Position the case side support 8 Insert the screws 1 4 and screw them manually Position the plate 9 on the two side supports 8 Insert one of the screws 2 with the relevant washer 3 Working on the lower sid...

Page 69: ...ely 70 kg If your weight and needs are different for example in case of ride with passenger and full load it is advisable to contact an aprilia Official Dealer According to the conditions of use of the vehicle it is possible to adjust the hydraulic braking with extended shock absorber by adjusting the screw 1 for the adjustment keep to the following indications Uneven or irregular road surface HAR...

Page 70: ...d sudden jerks while riding REAR SHOCK ABSORBER ADJUSTMENT TABLE Rear shock absorber Standard adjustment INTERMEDIATE for normal load for example rider and passenger SOFT adjustment for light load for example rider only HARD adjustment for heavy load for example rider passenger and luggage Hydraulic adjustment with extended shock absorber screw 1 starting from the SOFT adjustment position rotate t...

Page 71: ...ICLE ON THE STAND u Carry out a visual check between the disc and the pads proceeding from below on the front part for the front brake caliper 1 from above on the rear part for the rear brake calipers 2 CAUTION The excessive wear of the friction material would cause the contact of the pad metal support with the disc with consequent metallic noise and production of sparks from the caliper braking e...

Page 72: ...a Official Dealer An excessive increase in the engine idling rpm may cause irregularities in the operation of the engine and damage the engine itself and other components It is advisable to change the setting only when it is really necessary if when the throttle grip is released the engine stops or keeps running at higher rpm than prescribed and it is impossible to reach an aprilia Official Dealer...

Page 73: ...tation of the handlebar does not modify the engine idling rpm and that the throttle grip returns smoothly and automatically to its original position after being released ADJUSTING THE COLD START CONTROL Carefully read p 51 MAINTENANCE Have the accelerator control cables checked by an aprilia Official Dealer after the first 1000 km 625 mi and successively every 6000 km 3750 mi The idle stroke of th...

Page 74: ...follows u Remove the cap 1 of the spark plug 2 u Remove any trace of dirt from the spark plug base u Introduce the special spanner provided in the tool kit on the spark plug u Unscrew the spark plug and extract it from its seat taking care to prevent dust or other substances from getting inside the cylinder For the check and cleaning Key centre electrode 3 insulating 4 side electrode 5 u Make sure...

Page 75: ...ake sure that the washer 7 is in good conditions For the installation u With the washer on 7 screw the spark plug by hand in order not to damage the thread u Tighten the spark plug by means of the spanner you will find in the tool kit giving it half a turn to compress the washer Spark plug driving torque 20 Nm 2 0 kgm CAUTION The spark plug must be well tightened otherwise the engine may overheat ...

Page 76: ...yte is accidentally swallowed drink a lot of water or milk then continue drinking milk of magnesia or vegetable oil and consult a doctor without delay The battery gives off explosive gases keep it away from flames sparks cigarettes and any other source of heat During the recharging or the use make sure that the room is properly ventilated and avoid inhaling the gases released during the recharging...

Page 77: ...only distilled water u Put back the left cover see p 65 REMOVING THE RIGHT AND LEFT SIDES CHECKING AND CLEANING THE TERMINALS Carefully read p 76 BATTERY u Make sure that the ignition switch is in position u Remove the left cover see p 65 REMOVING THE RIGHT AND LEFT SIDES u Remove the red protection element 1 u Make sure that the cable terminals 2 and the battery terminals 3 are in good conditions...

Page 78: ...the positive terminal u Move the positive cable 7 sidewards CAUTION Do not force the electric cables u Withdraw the breather pipe 8 u Grasp the battery 9 firmly and remove it from its compartment by bending it towards the outside and lifting it WARNING Once it has been removed the battery must be stored in a safe place and kept away from children u Position the battery on a flat surface in a cool ...

Page 79: ...e gas for a short lapse of time INSTALLING THE BATTERY Carefully read p 76 BATTERY u Make sure that the ignition switch is in position u Remove the left cover see p 65 REMOVING THE RIGHT AND LEFT SIDES NOTE The battery 1 must be positioned in its compartment with the terminals directed towards the outside part of the vehicle u Put the battery 1 in its compartment WARNING Upon reassembly connect fi...

Page 80: ...harge it completely with a trickle charge see p 79 RECHARGING THE BATTERY If the battery remains on the vehicle disconnect the cables from the terminals CHECKING THE SWITCHES Carefully read p 51 MAINTENANCE The vehicle is provided with four switches 1 Stoplight switch on the rear brake control lever 2 Stoplight switch on the front brake control lever 3 Safety switch on the side stand 4 Switch on t...

Page 81: ...y to check the fuses For the check proceed as follows u Turn the ignition switch to position to avoid any accidental short circuit u Remove the rider saddle see p 18 UNLOCKING LOCKING THE SADDLE u Extract the fuses one by one and check if the filament 1 is broken u Before replacing a fuse try to find out the cause of the trouble if possible u Replace the damaged fuse with a new one having the same...

Page 82: ...e horizontal line of the headlight about 9 10th of the total height To adjust the headlight beam u Position the vehicle on the stand see p 49 POSITIONING THE VEHICLE ON THE STAND u Working on the lower side of the front part of the fairing act on the appropriate screw 1 with the spanner 8 mm provided in the tool kit BY ROTATING IT CLOCKWISE you set the beam upwards BY ROTATING IT ANTICLOCKWISE you...

Page 83: ...these may cause its overheating and consequent breakage If you touch the bulb with bare hands remove any fingerprint with alcohol in order to avoid any damage DO NOT FORCE THE ELECTRIC CABLES NOTE Before changing a bulb check the fuses see p 81 CHANGING THE FUSES CHANGING THE HEADLIGHT BULBS Carefully read p 83 BULBS The headlight contains one high beam bulb 1 left side one parking light bulb 2 lo...

Page 84: ...pull the electric wires u Grasp the parking light bulb socket 9 pull it and remove it from its seat u Withdraw the bulb 2 and replace it with one of the same type LOW BEAM BULB HIGH BEAM u Move the protection element 10 with your hands CAUTION To extract the bulb electric connector do not pull its electric wires u Grasp the bulb electric connector 11 pull it and disconnect it from the bulb 3 u Rot...

Page 85: ...e same type CHANGING THE REAR DIRECTION INDICATOR BULBS Carefully read p 83 BULBS u Position the vehicle on the stand see p 49 POSITIONING THE VEHICLE ON THE STAND u Unscrew and remove the screw 4 CAUTION While removing the protection screen proceed carefully in order not to break the cog u Remove the protection screen 5 CAUTION Upon reassembly correctly position the protection screen in its seat ...

Page 86: ...ully without exerting too much pressure in order to avoid damaging the protection screen u Press the bulb 1 slightly and rotate it anticlockwise u Extract the bulb 1 from its seat CAUTION Insert the bulb in the bulb socket making the two bulb pins coincide with the relevant guides on the socket u Correctly install a new bulb of the same type CHANGING THE NUMBER PLATE BULB Carefully read p 83 BULBS...

Page 87: ...nd humid climates Particular conditions use of salt and anti ice chemical products on the roads during the winter Avoid leaving deposits of industrial and polluting powders tar spots dead insects bird droppings etc on the body Avoid parking the vehicle under trees since in some seasons residues resins fruits or leaves fall down which contain substances that may damage the paint WARNING After the v...

Page 88: ... plenty of water Polish with silicone wax only after having carefully washed the vehicle Do not use polishing pastes on matt paints Do not wash the vehicle under the sun especially during the summer when the body is still warm since if the shampoo dries before being rinsed away it can damage the paint Do not use liquids at a temperature exceeding 40 C to clean the plastic components of the vehicle...

Page 89: ...OTE Position the vehicle on the front J and rear J support stands so that both tyre are raised from the ground u Set the vehicle on the relevant front support stand see 61 POSITIONING THE VEHICLE ON THE FRONT SUPPORT STAND J u Put a plastic bag on each exhaust tailpipe and bind it around it in order to prevent moisture from getting into the tailpipe u Cover the vehicle avoiding the use of plastic ...

Page 90: ... 9 0 5 1 Starting electric Engine idling rpm 1300 100 rpm Clutch multidisc in oil bath with control on the left side of the handlebar Lubrication system dry pan with separate oil tank Air cleaner with dry filter cartridge Cooling liquid cooled TRANSMISSION Type mechanical 5 gears with foot control on the left side of the engine CAPACITY Fuel reserve included 21 b Fuel reserve 5 b Engine oil oil ch...

Page 91: ...e and saddle pillar Steering inclination angle 28 Fore stroke 109 mm SUSPENSIONS Front upside down telescopic adjustable fork with hydraulic operation rod Ø 45 mm Stroke 170 mm Rear oscillating rear fork with differentiated profile arms and hydraulic adjustable mono shock absorber Wheel stroke 165 mm BRAKES Front disc brake Ø 300 mm with hydraulic transmission Rear disc brake Ø 240 mm with hydraul...

Page 92: ...tandard NGK R DR8EB Spark plug gap 0 6 0 7 mm Resistance 5 kΩ ELECTRIC SYSTEM Battery 12 V 12 Ah Fuses 7 5 A 15 A 20 A Generator with permanent magnet 12 V 270 W BULBS Low beam bulb high beam 12 V 55 60 W High beam 12 V 60 W Front parking light 12 V 3 W Direction indicators 12 V 10 W Rear parking lights Stoplight 12 V 5 21 W Number plate light 12 V 3 W Revolution counter 12 V 2 W Speedometer 12 V ...

Page 93: ...f the volume F A 20W 67 of the volume or FORK 5W 33 of the volume FORK 20W 67 of the volume Bearings and other lubrication points recommended AUTOGREASE MP or GREASE 30 As an alternative to the recommended product use high quality grease for rolling bearings working temperature range 30 C 140 C dripping point 150 C 230 C high protection against corrosion good resistance to water and oxidation Prot...

Page 94: ...94 use and maintenance Pegaso 650 I E WIRING DIAGRAM Pegaso 650 I E ...

Page 95: ...ronic unit 27 Rear light 28 Number plate bulb 29 Rear right direction indicator 30 Front stoplight switch 31 Rear stoplight switch 32 Thermal switch cooling electrofan 33 Cooling electrofan 34 Injection relay 35 Start relay 36 Starter 37 Battery 38 Voltage regulator 39 Fuses 40 Generator 41 Pick up 42 Fuel pump 43 Low fuel sensor 44 Injector 2 45 Injector 1 46 Throttle valve position sensor 47 Coo...

Page 96: ...r key factors To find contact information of the Official Dealer and or Service Centre nearest you please consult the Yellow Pages or the map provided at our web site www aprilia com When you demand aprilia Original Parts you are purchasing products that have been developed and tested as early as the vehicle design stage aprilia Original Parts systematically undergo strict quality control procedur...

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