Precision Repair & Diagnostic Guide: Aprilia Pegaso 650 (1997)

Aprilia Pegaso 650 Service and Repair Manual (1997)

This is the definitive Service and Repair Manual for the Aprilia Pegaso 650, specifically the 942V series. Released in March 1997, this comprehensive technical guide is the primary resource for professional mechanics and dedicated owners who demand factory-level precision for maintenance and restoration.

This manual covers the core models of the 1997 production year, including specific data for regional variants:

• Pegaso 650 (1997) - Standard Version
• Pegaso 650 (1997) - Catalytic Version
• Pegaso 650 (1997) - UK Version (United Kingdom)
• Pegaso 650 (1997) - A Version (Austria)
• Pegaso 650 (1997) - CH Version (Switzerland)

Deep-Dive Technical Specifications

The Pegaso 650 is powered by the legendary ROTAX 655 engine, a high-performance single-cylinder 4-stroke with a unique 5-valve head and dual overhead camshafts (DOHC). This manual provides the exact parameters required to keep this sophisticated engine at peak performance.

• Engine Type: ROTAX 655, 651.88 cm³, liquid-cooled.
• Bore and Stroke: 100 mm / 83 mm.
• Compression Ratio: 9 ± 0.5:1.
• Carburetion: Twin Mikuni BST 33 (31.5 mm choke).
• Ignition: NIPPONDENSO C.D.I. (Capacitive Discharge).
• Serial Number Locations: The Frame Number is located on the right side of the steering tube, and the Engine Number is printed high on the rear part of the engine block.

Comprehensive Content & Maintenance Value

This manual is optimized for mobile viewing, featuring clear sections and high-value technical data that goes far beyond a basic owner's manual.

1. General Information & Setup

• Essential serial number identification for registration and parts ordering.
• Detailed lubricant chart featuring specialized IP products (Superbike 4 SAE 5W-40, ECOBLU coolant).
• Full technical data sheets for dimensions, capacities, and torque settings.

2. Engine & Transmission

• ROTAX 655 Top-End: Procedures for valve adjustments (Tappet clearance) and cam timing.
• Clutch & Gearbox: Maintenance of the 5-speed mechanical gearbox and multiple-disc oil bath clutch.
• Cooling System: Detailed flow diagrams, radiator removal, and thermostatic valve testing.

3. Chassis, Suspension & Brakes

• Advanced Suspension: Servicing the 40mm hydraulically operated telescopic front fork (180mm stroke) and the rear hydraulic shock absorber with linkage.
• Braking System: Service data for the 300mm front disc (Brembo/Aprilia components) and 220mm rear disc, including bleeding and pad replacement limits (1 mm min thickness).
• Wheels: Maintenance for the aluminum tangent spoke wheels (19" front / 17" rear).

4. Electrical System & Troubleshooting

• Wiring Diagrams: Complete schematics for the ignition, lighting, and safety logic systems.
• Component Testing: Step-by-step testing for the alternator (0.1 - 1 Ohm resistance), voltage regulator, and CDI unit.
• Fuses: Full breakdown of the 20A, 15A, and 7.5A circuits.

Added Professional Value

• Torque Specifications: Includes a complete table of frame and engine driving torques (e.g., 100 Nm for the steering head nut, 25 Nm for exhaust manifolds).
• Special Tools: Identification of the factory-required tools, such as the 90-degree screwdriver for carburetor adjustment and the rear fork pin locking ring spanner.
• Troubleshooting Guide: A professional-grade diagnostic section covering engine noise, starting issues, and handling anomalies.

Whether you are performing a simple oil change (2200 cm³ capacity) or a full engine overhaul, this manual provides the exact factory specifications needed to ensure the longevity and safety of your Aprilia Pegaso 650.