INTRODUCTION
PEGASO 650
INTRODUCTION
0
0-1
INTRODUCTION
PEGASO 650
SUMMARY
0.1.
INTRODUCTION .............................................................................................................................................. 3
0.1.1.
FOREWORD ............................................................................................................................................. 3
0.1.2.
REFERENCE MANUALS .......................................................................................................................... 4
0.1.3.
ABBREVIATIONS/SYMBOLS/CONVENTIONS ........................................................................................ 5
0-2
PEGASO 650
0.1.
0.1.1.
INTRODUCTION
INTRODUCTION
FOREWORD
This manual provides the information required for normal servicing.
This publication is intended for use by aprilia Dealers and their qualified mechanics; many concepts have been omitted
on purpose as their inclusion would be superfluous. Since complete mechanical explanations have not been included in
this manual, the reader must be familiar with basic notions of mechanics, as well as with basic repair procedures.
Without such familiarity, repairs and checks could be ineffective and even hazardous. Since the repair and vehicle check
instructions are not exhaustive, special care must be taken to avoid damage and injury. To ensure maximum customer
satisfaction with the vehicle, aprilia s.p.a. continuously improves its products and their documentation. The main
technical modifications and changes in repair procedures are communicated to all aprilia dealers and agencies
worldwide. Such modifications will be entered in subsequent editions of the manual. Should you need assistance or
clarifications about the inspection and repair procedures, please contact the aprilia SERVICE DEPT., they will be glad to
give you any information on the matter, or supply you with any detail on updates and technical changes applied to the
vehicle.
aprilia s.p.a. reserves the right to make changes to its products at any time, barring any such changes as may alter the
essential features of a product as specified in the relevant manual.
All rights of storage using electronic means, reproduction and total or partial adaptation, whatever the means adopted,
are reserved in all countries.
Third parties' products are only mentioned for information purposes, and constitute no engagement.
aprilia s.p.a. is not liable in any way for the performance or use of these products.
First edition: April 2005
Produced and printed by:
DECA s.r.l.
via Vincenzo Giardini, 11 - 48022 Lugo (RA) - Italy
Tel. +39 - 0545 216611
Fax +39 - 0545 216610
E-mail: deca@vftis.spx.com
www.vftis.com
on behalf of:
aprilia s.p.a.
via G. Galilei, 1 - 30033 Noale (VE) - Italy
Tel. +39 – (0)41 58 29 111
Fax +39 – (0)41 58 29 190
www.aprilia.com
www.serviceaprilia.com
0-3
INTRODUCTION
0.1.2.
REFERENCE MANUALS
OWNER'S MANUALS
aprilia part# (description)
8104896
8104895
8104897
8104894
CHASSIS WORKSHOP MANUAL
aprilia part# (description)
8140874
8140877
8140875
8140876
8140878
ENGINE TECHNICAL MANUAL
aprilia part# (description)
8140880
8140883
8140881
8140882
8140884
CD FOR THE NETWORK - ENGINE
aprilia part# (description)
8CM0086
CD FOR THE NETWORK - CHASSIS
aprilia part# (description)
8CM0084
0-4
PEGASO 650
PEGASO 650
0.1.3.
#
<
>
≤
≥
~
∞
°C
°F
±
a.c
A
Ah
API
AT
AV/DC
bar
d.c.
cc
CO
CPU
DIN
DOHC
ECU
rpm
HC
ISC
ISO
kg
kgm
km
km/h
kΩ
kPa
KS
kW
ℓ
LAP
LED
LEFT
SIDE
m/s
max
mbar
mi
MIN
MPH
MS
MΩ
N.A.
N.O.M.M.
N.O.R.M.
Nm
Ω
PICK-UP
BDC
TDC
PPC
INTRODUCTION
ABBREVIATIONS/SYMBOLS/CONVENTIONS
= number
= less than
= greater than
= less than or equal to
= more than or equal to
= approximately
= infinity
= degrees Celsius (centigrade)
= degrees Fahrenheit
= plus or minus
= alternating current
= Ampere
= Ampere per hour
= American Petroleum Institute
= high voltage
= Anti-Vibration Double Countershaft
= pressure measurement unit (1 bar = 100 kPa)
= direct current
= cubic centimetres
= carbon monoxide
= Central Processing Unit
= German industrial standards (Deutsche Industrie Norm)
= Double Overhead Camshaft
= Electronic Control Unit
= revolutions per minute
= unburnt hydrocarbons
= Idle Speed Control
= International Standardisation Organisation
= kilograms
= kilograms per metre (1 kgm = 10 Nm)
= kilometres
= kilometres per hour
= kilo Ohm
= kiloPascal (1 kPa = 0.01 bar)
= clutch side (from the German "Kupplungsseite")
= kilowatt
= litres
= racetrack lap
= Light Emitting Diode
= left side
= metres per second
= maximum
= millibar (1 mbar = 0.1 kPa)
= miles
= minimum
= miles per hour
= flywheel side (from the German "Magnetoseite")
= MegaOhm
= Not Available
= Motor Octane Number
= Research Octane Number
= Newton metre (1 Nm = 0.1 kgm)
= ohm
= pick-up
= Bottom Dead Centre
= Top Dead Centre
= Pneumatic Power Clutch
0-5
INTRODUCTION
RIGHT
SIDE
= right side
SAE
= Society of Automotive Engineers
TEST
= diagnostic check
T.B.E.I.
= crown-head Allen screw
T.C.E.I.
= cheese-head Allen screw
T.E.
= hexagonal head
T.P.
= flat head screw
TSI
= Twin Spark Ignition
UPSIDEDOWN
= inverted fork
V
= volt
W
= watt
Ø
= diameter
0-6
PEGASO 650
PEGASO 650
GENERAL INFORMATION
GENERAL INFORMATION
1
1-1
GENERAL INFORMATION
PEGASO 650
SUMMARY
1.1.
STRUCTURE OF THE MANUAL...................................................................................................................... 3
1.1.1.
CONVENTIONS USED IN THE MANUAL ................................................................................................. 3
1.1.2.
SAFETY WARNINGS ................................................................................................................................ 4
1.2.
GENERAL RULES............................................................................................................................................ 5
1.2.1.
BASIC SAFETY RULES ............................................................................................................................ 5
1.3.
DANGEROUS ELEMENTS............................................................................................................................... 8
1.3.1.
WARNINGS ............................................................................................................................................... 8
1.4.
RUNNING-IN .................................................................................................................................................. 12
1.4.1.
RUNNING-IN ........................................................................................................................................... 12
1.5.
VEHICLE IDENTIFICATION ........................................................................................................................... 13
1.5.1.
POSITION OF THE SERIAL NUMBERS ................................................................................................. 13
1-2
GENERAL INFORMATION
PEGASO 650
1.1.
STRUCTURE OF THE MANUAL
1.1.1.
CONVENTIONS USED IN THE MANUAL
•
This manual is divided in sections and subsections, each covering a set of the most significant components.
Refer to the index of sections when consulting the manual.
•
Unless expressly specified otherwise, assemblies are reassembled by reversing the dismantling procedure.
•
The terms "right" and "left" are referred to the rider seated on the vehicle in the normal riding position.
•
Motorcycle operation and basic maintenance are covered in the "OWNER'S MANUAL".
In this manual any variants are identified with these symbols:
optional
catalytic version
-
all versions
MP
national certification
SF
European certification (EURO 2 limits)
VERSION:
Italy
United
Kingdom
Austria
Portugal
Finland
Greece
Holland
Malaysia
Chile
Switzerland
Denmark
Japan
Belgium
Germany
France
Singapore
Slovenia
Israel
Spain
South
Korea
Croatia
Australia
United
States of
America
Brazil
South Africa
New
Zealand
Canada
1-3
GENERAL INFORMATION
1.1.2.
PEGASO 650
SAFETY WARNINGS
The following precautionary warnings are used throughout this manual in order to convey the following messages:
Safety warning. This symbol appears, whether in the manual or on the vehicle itself, to indicate a
personal injury hazard. Non-compliance with the indications given in the messages preceded by this
symbol may result in serious risks for your and other people’s safety and for the vehicle!
DANGER
Indicates a potential hazard which may result in serious injury or even death.
WARNING
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.
1-4
PEGASO 650
1.2.
1.2.1.
GENERAL INFORMATION
GENERAL RULES
BASIC SAFETY RULES
CARBON MONOXIDE
Should it be necessary to perform some operations with the vehicle running, make sure to work outdoors or in a wellaerated room.
Avoid starting the engine indoors.
In case you are working indoors, use a gas exhaust system.
DANGER
Exhaust gases contain carbon monoxide, which is extremely toxic if inhaled and may cause loss of
consciousness or even lead to death.
FUEL
DANGER
The fuel used in internal combustion engines is highly flammable and can become explosive under
particular conditions.
Refuelling and engine service should take place in a well-ventilated area with the engine stopped.
Do not smoke when refuelling or in the proximity of sources of fuel vapours, avoid flames, sparks and
any element that could ignite fuel or provoke explosions.
DO NOT DISPOSE OF FUEL IN THE ENVIRONMENT.
KEEP AWAY FROM CHILDREN.
HIGH-TEMPERATURE COMPONENTS
The engine and the components of the exhaust system become very hot and remain hot for some time after the engine
has been stopped.
Before handling these components, wear insulating gloves or wait until the engine and the exhaust system have cooled
down.
USED GEARBOX AND FORK FLUIDS
DANGER
Wear latex gloves when servicing.
Gear fluid may cause serious damage to the skin if handled daily and for long periods.
Wash your hands carefully after handling engine oil.
Take it to the filling station where you usually buy it or to an oil salvage centre.
Wear latex gloves when servicing.
DO NOT DISPOSE OF FLUID IN THE ENVIRONMENT
KEEP AWAY FROM CHILDREN.
BRAKE FLUID
WARNING
When handling the brake fluid, take care not to spill it on the plastic, rubber or painted parts, since it
can damage them. When carrying out the maintenance operations on the braking system, use a clean
cloth to cover these parts.
Always wear safety goggles when working on the braking system.
The brake fluid is highly irritant. Avoid contact with your eyes.
If the brake fluid gets in contact with your eyes, carefully wash them with fresh water and immediately
seek medical advice.
KEEP AWAY FROM CHILDREN.
COOLANT
Coolant contains ethylene glycol that is flammable, under certain conditions. When ignited, ethylene glycol produces
invisible flames that might cause burns.
1-5
GENERAL INFORMATION
PEGASO 650
DANGER
Take care not to spill coolant onto hot engine parts and exhaust system. It may ignite and produce
invisible flames.
Wear latex gloves when servicing.
Although toxic, it has a sweet taste that might attract animals. Never leave coolant in open container
or in a position easily reachable by animals.
KEEP AWAY FROM CHILDREN.
Do not remove radiator cap when engine is still hot. Coolant is under pressure and might cause burns.
HYDROGEN GAS AND BATTERY ELECTROLYTE
DANGER
The battery electrolyte is a toxic, caustic substance containing sulphuric acid and thus able to cause
severe burns in case of contact with the skin.
Always wear tight gloves and protective clothes when handling this fluid.
In case of contact with skin, rinse with plenty of fresh water.
Always use a protection for your eyes since even a very small amount of the battery fluid can cause
blindness. In the event of contact with your eyes, carefully wash them with water for fifteen minutes
and then consult immediately an eye specialist.
Should you accidentally drink some fluid, drink abundant water or milk, then drink magnesia milk or
vegetable oil and immediately seek medical advice.
The battery gives off explosive gases and must be kept away from flames and sources of ignition or
heat; do not smoke near the battery.
KEEP AWAY FROM CHILDREN.
Battery fluid is corrosive.
Do not spill it, especially on plastic parts.
Make sure that the electrolyte acid is suitable for the type of battery used.
GENERAL PRECAUTIONS AND INFORMATION
Follow these instructions closely when repairing, disassembling or reassembling the motorcycle or its components.
DANGER
Using bare flames is strictly forbidden when working on the motorcycle. Before servicing or
inspecting the motorcycle: stop the engine and remove the key from the ignition switch; allow for the
engine and exhaust system to cool down; where possible, lift the motorcycle using adequate
equipment placed on firm and level ground. Be careful of any parts of the engine or exhaust system
which may still be hot to the touch to avoid scalds or burns.
Do not put any vehicle parts into your mouth: vehicle components are not edible and some of them
are harmful or even toxic.
Unless expressly specified otherwise, assemblies are reassembled by reversing the dismantling
procedure. Where a procedure is cross-referred to relevant sections in the manual, proceed sensibly
to avoid disturbing any parts unless strictly necessary. Do not polish matt-painted surfaces with
polishing paste.
Never use fuel instead of solvent to clean the motorcycle.
Do not clean any rubber or plastic parts or the seat with alcohol, petrol or solvents. Clean with water
and mild detergent.
Always disconnect the battery negative (-) lead before soldering any electrical components.
When two or more persons service the same motorcycle together, special care must be taken to avoid
personal injury.
BEFORE DISASSEMBLING ANY COMPONENTS
•
Clean off all dirt, mud, and dust and clear any foreign objects from the vehicle before disassembling any
components.
•
Use the model-specific special tools where specified.
1-6
PEGASO 650
GENERAL INFORMATION
DISASSEMBLING THE COMPONENTS
Never use pliers or similar tools to slacken and/or tighten nuts and bolts. Always use the suitable spanner.
Mark all connections (hoses, wiring, etc.) with their positions before disconnecting them. Identify each connection
using a distinctive symbol or convention.
Mark each part clearly to avoid confusion when refitting.
Thoroughly clean and wash any components you have removed using a detergent with low flash point.
Mated parts should always be refitted together. These parts will have seated themselves against one another in
service as a result of normal wear and tear and should never be mixed up with other similar parts on refitting.
Certain components are matched-pair parts and should always be replaced as a set.
Keep away from heat sources.
REASSEMBLING THE COMPONENTS
DANGER
Never reuse a circlip or snap ring. These parts must always be renewed once they have been
disturbed.
When fitting a new circlip or snap ring, take care to move the open ends apart just enough to allow
fitment to the shaft.
Make it a rule to check that a newly-fitted circlip or snap ring has located fully into its groove.
Never clean a bearing with compressed air.
NOTE All bearings must rotate freely with no hard spots or noise. Replace any bearings that do not meet these
requirements.
-
Use ORIGINAL aprilia SPARE PARTS only.
Use the specified lubricants and consumables.
Where possible, lubricate a part before assembly.
When tightening nuts and bolts, start with the largest or innermost nut/bolt and observe a cross pattern. Tighten
evenly, in subsequent steps until achieving the specified torque.
Replace any self-locking nuts, gaskets, seals, circlips or snap rings, O-rings, split pins, bolts and screws which
have a damaged thread.
Lubricate the bearings abundantly before assembly.
Make it a rule to check that all components you have fitted are correctly in place.
After repairing the motorcycle and after each service inspection, perform the preliminary checks, and then test ride
the motorcycle in a private estate area or in a safe area away from traffic.
Clean all mating surfaces, oil seal edges and gaskets before assembly. Apply a thin layer of lithium grease along
the edges of oil seals. Fit oil seals and bearings with the marking or serial number facing outwards (in view).
ELECTRICAL CONNECTORS
To disconnect the electrical connectors, follow the procedures below. Failure to comply with these procedures may lead
to irreparable damage to the connector and the wiring as well.
If present, press the special safety hooks.
WARNING
Do not pull cables to disconnect the two connectors.
•
•
•
Grasp the two connectors and disconnect them by pulling them in the two opposite directions.
In case of dirt, rust, moisture, etc., thoroughly clean the inside of the connectors with compressed air.
Make sure that the cables are correctly fitted inside the connector terminals.
NOTE The two connectors have just one correct positioning. Make sure to position them in the right direction.
•
Then fit the two connectors. Make sure they are correctly coupled (a click will be heard if hooks are present).
TIGHTENING TORQUE SETTINGS
DANGER
Always remember that the tightening torque settings of all wheel, brake, wheel shaft and other
suspension parts play a fundamental role to ensure vehicle safety. Make sure that these values are
always within the specified limits.
Check fastening parts tightening torque settings at regular intervals. Upon reassembly, always use a
torque wrench.
Failure to comply with these recommendations could lead to the loosening and detachment of one of
these parts with a consequent locking of the wheel or other serious troubles affecting the vehicle
manoeuvrability, and thus the risk of falls and serious injuries or death.
1-7
GENERAL INFORMATION
1.3.
1.3.1.
PEGASO 650
DANGEROUS ELEMENTS
WARNINGS
FUEL
DANGER
The fuel used to operate engines is highly flammable and becomes explosive under particular
conditions.
Refuelling and engine service should take place in a well-ventilated area with the engine stopped.
Do not smoke when refuelling or in the proximity of sources of fuel vapours, avoid flames, sparks and
any element that could ignite fuel or provoke explosions.
Take care not to spill fuel out of the filler, or it may ignite when in contact with hot engine parts.
In the event of accidental fuel spillage, make sure the affected area is fully dry before starting the
engine. Fuel expands from heat and when left under direct sunlight.
Never fill the fuel tank up to the brim. Tighten the filler cap securely after each refuelling.
Avoid contact with skin. Do not inhale vapours. Do not swallow fuel. Do not transfer fuel between
different containers using a hose.
DO NOT DISPOSE OF FUEL IN THE ENVIRONMENT.
KEEP AWAY FROM CHILDREN.
Use only premium grade unleaded petrol, min. O.N. 95 (RON) and 85 (MON).
LUBRICANTS
DANGER
A good lubrication ensures the vehicle safety.
Failure to keep the lubricants at the recommended level or the use of a non-suitable new and clean
type of lubricant can lead to the engine or gearbox seizure, thus causing serious accidents, personal
injury or even death.
Gear fluid may cause serious damage to the skin if handled daily and for long periods.
Wash your hands carefully after use.
Do not dispose of oil in the environment.
Take it to the filling station where you usually buy it or to an oil salvage centre.
WARNING
When filling the vehicle with this oil, take care not to spill it out. Immediately clean spilt oil, or it might
damage the vehicle paintwork.
In case of contact with oil, the tyres surface will become very slippery, thus becoming a serious
danger for your safety.
In case of leaks, do not use the vehicle. Check and trace the cause of leaks and proceed to repair.
ENGINE OIL
DANGER
Engine oil may cause serious damage to the skin if handled daily and for long periods.
Wash your hands carefully after use.
Do not dispose of oil in the environment.
Dispose of engine oil through the nearest waste oil reclamation firm or through the supplier.
Wear latex gloves when servicing.
FRONT FORK FLUID
DANGER
Front suspension response can be modified to a certain extent by changing damping settings and/or
selecting a particular grade of oil. Standard oil viscosity: SAE 20 W. Different oil grades can be
selected to obtain a particular suspension response (choose SAE 5W for a softer suspension, 20W for
a stiffer suspension).
The two grades can also be mixed in varying solutions to obtain the desired response.
1-8
PEGASO 650
GENERAL INFORMATION
BRAKE FLUID
NOTE This vehicle is fitted with front and rear disc brakes. Each braking system is operated by an independent hydraulic
circuit. The information provided below applies to both braking systems.
DANGER
Do not use the vehicle in case brakes are worn out or do not work properly. The brakes are the parts
that most ensure your safety and for this reason they must always be perfectly working. Failure to
comply with these recommendations will probably lead to a crash or an accident, with a consequent
risk of personal injury or death.
A wet surface reduces brakes efficiency.
DANGER
In case of wet ground the braking distance will be doubled, since both brakes and tyre grip on the
road surface are extremely reduced by the water present on the road surface.
Any water on brakes, after washing the vehicle or driving on a wet road surface or crossing puddles
or gips, can wet brakes so as to greatly reduce their efficiency.
Failure to comply with these recommendations may lead to serious accidents, with a consequent risk
of severe personal injuries or death.
Brakes are critical safety components. Do not ride the vehicle in case brakes are not working at their
best.
Check for brakes proper operation before every trip.
Brake fluid is an irritant. Avoid contact with eyes or skin.
In the event of accidental contact, wash affected body parts thoroughly. In the event of accidental
contact with eyes, contact an eye specialist or seek medical advice.
DO NOT RELEASE BRAKE FLUID INTO THE ENVIRONMENT.
KEEP AWAY FROM CHILDREN.
When handling brake fluid, take care not to spill it onto plastic or paint-finished parts or they will
damage.
DANGER
Do not use any brake fluids other than the specified type. Never mix different types of fluids to top up
level, as this will damage the braking system.
Do not use brake fluid from containers which have been kept open or in storage for long periods.
Any sudden changes in play or hardness in the brake levers are warning signs of problems with the
hydraulic circuits.
Ensure that the brake discs and brake linings have not become contaminated with oil or grease. This
is particularly important after servicing or inspections.
Make sure the brake lines are not twisted or worn.
Prevent accidental entering of water or dust into the circuit.
Wear latex gloves when servicing the hydraulic circuit.
DISC BRAKES
DANGER
The brakes are the parts that most ensure your safety and for this reason they must always be
perfectly working; check them before every trip.
A dirty disc soils the pads.
Dirty pads must be replaced, while dirty discs must be cleaned with a high-quality degreaser.
Perform the maintenance operations with half the indicated frequency if the vehicle is used in rainy or
dusty areas, on uneven surfaces or for racing.
Check brake pads for wear.
When the brake pads wear out, the level of the fluid decreases to automatically compensate for their
wear.
The front brake fluid reservoir is located on the right handlebar, near the front brake lever.
The rear brake fluid reservoir is located under the right fairing.
Do not use the vehicle if the braking system leaks fluid.
1-9
GENERAL INFORMATION
PEGASO 650
COOLANT
DANGER
Coolant is toxic when ingested, contact with eyes or skin may cause irritation.
In the event of contact with your skin or eyes, rinse repeatedly with abundant water and seek medical
advice. In the event of ingestion, induce vomiting, rinse mouth and throat with abundant water and
seek medical advice immediately.
DO NOT RELEASE INTO THE ENVIRONMENT.
KEEP AWAY FROM CHILDREN.
DANGER
Take care not to spill coolant onto hot engine parts. It may ignite and produce invisible flames. Wear
latex
gloves
when
servicing.
Do not ride when coolant is below the minimum level.
Coolant mixture is a 50% solution of water and antifreeze. This is the ideal solution for most operating temperatures and
provides good corrosion protection.
This solution is also suited to the warm season, as it is less prone to evaporative loss and will reduce the need for topups.
In addition, less water evaporation means fewer minerals salts depositing in the radiator, which helps preserve the
efficiency of the cooling system.
When the temperature drops below zero degrees centigrade, check the cooling system frequently and add more
antifreeze (up to 60% maximum) to the solution, if needed.
Use distilled water in the coolant mixture. Tap water will damage the engine.
Refer to the chart given below and add water with the quantity of antifreeze to obtain a solution with the desired freezing
point:
Freezing point °C
-20°
-30°
-40°
Coolant % of volume
35
45
55
NOTE Coolants have different specifications. The protection degree is written on the label.
WARNING
Use nitrite-free coolant only, with a protection until at least -35°C.
DRIVE CHAIN
Check drive chain operation, wear, slack and lubrication at regular intervals.
The vehicle is equipped with an endless chain with a joint link.
WARNING
If too slack, the chain can come off the front or rear sprockets thus leading to serious accidents and
damage to the vehicle, with consequent serious personal injury or death.
Do not use the vehicle if the chain slack has not been correctly adjusted.
To check the chain, take it with your hand where it turns on the rear sprocket and pull it as to separate
it from the sprocket itself.
If you can move the chain apart of the front sprocket for more than 3 mm (0.125 in), change chain,
front and rear sprocket.
DANGER
If not properly maintained, chain can early wear out and lead to the damage of both front and rear
sprockets.
Perform chain maintenance operations more frequently if the vehicle is used on dusty or muddy
areas.
1 - 10
PEGASO 650
GENERAL INFORMATION
TYRES
WARNING
If tyres are excessively inflated, the vehicle will be hard, difficult and uncomfortable to ride.
In addition, the roadworthiness, mainly on wet surfaces and during cornering, will be impaired.
Flat tyres (insufficient pressure) can slip on the rim and make you lose the control of the vehicle.
In this case too, both vehicle roadworthiness, manoeuvrability and brake efficiency will be impaired.
Tyres changing, repair, maintenance and balancing must be carried out by specialized technicians
using suitable equipment.
When new, tyres can have a thin slippery protective coating. Drive carefully for the first kilometres
(miles).
Never use rubber treating substances on tyres.
In particular, avoid contact with fluid fuels, leading to a rapid wear.
In case of contact with oil or fuel, do not clean but change the tyres.
DANGER
Some of the factory-assembled tyres of this vehicle are provided with wear indicators.
There are several kinds of wear indicators.
For more information on how to check the wear, contact your Dealer.
Visually check if the tyres are worn and in this case have them changed.
If a tyre deflates while driving, stop immediately.
Avoid hard brakings or moves and do not close throttles too abruptly.
Slowly close the throttle grip, move to the edge of the road and use the engine brake to slow down
until coming to a halt.
Failure to comply with these recommendations may lead to accidents, with a consequent risk of
personal injuries or death.
Do not install tyres with air tube on rims for tubeless tyres and vice versa.
1 - 11
GENERAL INFORMATION
1.4.
1.4.1.
PEGASO 650
RUNNING-IN
RUNNING-IN
Correct engine running-is essential to ensuring proper performance and durability.
If possible, drive on hilly roads and/or roads with many bends, so that the engine, the suspensions and the brakes
undergo a more effective running-in.
During running-in, change speed.
In this way the components are first "loaded" and then "relieved" and the engine parts can thus cool down.
Even if it is important to stress the engine components during running-in, take care not to exceed.
WARNING
Only after the first 2000 km (1250 mi) of running-in is it possible to obtain the best acceleration
performance from the vehicle.
Keep to the following indications:
•
Do not open the throttle completely if the speed is low, both during and after running-in.
•
During the first 500 km (312 mi) pull the brakes with caution, avoiding sharp and prolonged brakings. This ensures a
correct bedding-in of the pads on the brake discs.
•
During the first 500 km (312 mi), never exceed 4000 rpm (see table).
•
From 500 km (312 mi) up to 1000 km (625 mi), never exceed 5000 rpm.
DANGER
After the first 1000 km (621 mi), have the checking operations indicated in the column "After runningin" carried out by an aprilia Authorised Dealer, see REGULAR SERVICE INTERVALS CHART, in order
to avoid hurting yourself or other people and/or damaging the vehicle.
•
Between the first 1000 km (625 mi) and 2000 km (1250 mi) drive more briskly, change speed and use the maximum
acceleration only for a few seconds, in order to ensure better coupling of the components; never exceed 5500 rpm (see
table).
•
After 2000 km (1250 mi) you can squeeze some more power out of your engine.
Recommended maximum rpm
Mileage Km (mi)
0-500 (0 - 312)
500-1000 (312-625)
1000 – 2000 (625-1250)
1 - 12
rpm
4000
5000
5500
PEGASO 650
1.5.
1.5.1.
GENERAL INFORMATION
VEHICLE IDENTIFICATION
POSITION OF THE SERIAL NUMBERS
These numbers are necessary for vehicle registration.
NOTE Altering the vehicle identification numbers is a legal
offence. Altering the frame number invalidates the warranty.
FRAME NUMBER
The frame number (A) is stamped on the right side of the
steering column.
ENGINE NUMBER
The engine number (B) is stamped on the rear right part,
near the starter motor.
.
1 - 13
PEGASO 650
GENERAL TECHNICAL INFORMATION
GENERAL TECHNICAL INFORMATION
2
2-1
GENERAL TECHNICAL INFORMATION
PEGASO 650
SUMMARY
2.1.
GENERAL TECHNICAL INFORMATION ......................................................................................................... 3
2.1.1.
TECHNICAL DATA.................................................................................................................................... 3
2.1.2.
REGULAR SERVICE INTERVALS CHART............................................................................................... 5
2.1.3.
LUBRICANT TABLE .................................................................................................................................. 7
2.1.4.
TIGHTENING TORQUE SETTINGS ......................................................................................................... 8
2.1.5.
SPECIAL TOOLS .................................................................................................................................... 11
2.1.6.
ARRANGEMENT OF THE ELEMENTS OF THE INSTRUMENT PANEL ............................................... 12
2.1.7.
INSTRUMENT PANEL OPERATION....................................................................................................... 14
2.2.
SCHEDULED MAINTENANCE....................................................................................................................... 38
2.2.1.
CHANGING ENGINE OIL AND OIL FILTER ........................................................................................... 38
2.2.2.
CLEANING THE AIR FILTER .................................................................................................................. 40
2.2.3.
CHANGING THE COOLANT ................................................................................................................... 41
2.2.4.
FRONT BRAKE ....................................................................................................................................... 43
2.2.5.
REAR BRAKE.......................................................................................................................................... 45
2.2.6.
ADJUSTING THE VALVE CLEARANCE ................................................................................................. 47
2-2
GENERAL TECHNICAL INFORMATION
PEGASO 650
2.1.
GENERAL TECHNICAL INFORMATION
2.1.1.
TECHNICAL DATA
DIMENSIONS
Max. length
Max. width
Max. height (front fairing included)
Seat height
Wheelbase
Minimum ground clearance
Dry weight
ENGINE
Model
Type
2173 mm
810 mm
1150 mm
780 mm
1490 mm
200 mm
180 kg
Lubricating system
Air filter
Cooling
MY 660
one-cylinder, 4-stroke with 4 valves per cylinder, single overhead
camshaft
1
660 cu. cm.
100 mm/84 mm
10.0 ± 0.5: 1
Electric starter
1500 ± 100 rpm
Multiplate, wet clutch with hydraulic control on the left side of the
handlebar
dry pan with separate oil tank
with dry filter cartridge
Liquid
TRANSMISSION
Type
mechanical, 5 gears with foot control on the left side of the engine
CAPACITY
Fuel (reserve included)
Fuel reserve
Engine oil
Fork oil
Coolant
Seats
Vehicle max. load
15 ± 0.5 l
3l
oil change 2500 cu. cm – oil and oil filter change 2700 cu. cm
105 mm of air (per leg, measured without spring and compressed rod)
1.2 l (50% water + 50% antifreeze with ethylene glycol)
2
210 kg (rider + passenger + luggage + fluids)
Number of cylinders
Total displacement
Bore/stroke
Compression ratio
Starting
Engine idling speed
Clutch
GEAR RATIOS
Ratio
1st
2nd
3rd
4th
5th
Primary
36/75 = 1: 2.083
Secondary
12/30 = 1: 2.500
16/26 = 1: 1.625
20/23 = 1: 1.150
22/20 = 1: 0.909
26/20 = 1: 0.769
Final ratio
15/44 = 1: 2.933
Total ratio
1 : 15.278
1: 9.930
1 : 7.028
1 : 5.556
1 : 4.700
DRIVE CHAIN
Type
endless (with no connection link) with sealed links
FUEL SYSTEM
Type
Throttle
Electronic injection
Ø 45.5 mm
FUEL SYSTEM
Fuel
premium grade unleaded petrol, min. O.N. 95 (RON) and 85 (MON).
FRAME
Type
with steel composite structure with seat support that can be removed
SUSPENSIONS
Front
Stroke
Rear
telescopic Ø 45 mm fork with hydraulic operation
140 mm
swinging arm and hydraulic adjustable monoshock
2-3
GENERAL TECHNICAL INFORMATION
Wheel stroke
130 mm (useful)
BRAKES
Front
Rear
disc brake – Ø 320 mm – with hydraulic transmission
disc brake – Ø 240 mm – with hydraulic transmission
WHEEL RIMS
Type
Front
Rear
in light alloy
3.50 x 17"
4.50 x 17"
FRONT TYRE
Type
As an alternative
Inflation pressure - solo
rider
Inflation pressure - rider
with passenger
REAR TYRE
Type
As an alternative
Inflation pressure - solo
rider
Inflation pressure - rider
with passenger
IGNITION
Type
110/70 ZR 17 54 W
110/70 R 17 54H – 120/65 ZR 17 56W – 120/65 R 17 56H
180 kPa (1.8 bar)
190 kPa (1.9 bar)
160/60 ZR 17 69W
160/60 R 17 69H – 150/60 ZR 17 66W – 150/60 R 17 66H
200 kPa (2.0 bar)
220 kPa (2.2 bar)
DENSO - inductive ignition system
SPARK PLUGS
Standard
Spark plug electrode gap
Resistance
NGK CR7E
0.7 – 0.8 mm
5 KΩ
ELECTRIC SYSTEM
Battery
Auxiliary fuses
Generator (with permanent magnet)
12 V - 12 Ah
5 A, 15 A, 20 A
12 V – 290 W
BULBS
Low beam
High beam
Front parking light
Turn indicator light
Number plate light
Rear parking lights/Stoplight
Revolution counter
12 V – 55 W
12 V – 60 W
12 V – 3 W
MICRO LAMPS
12 V – 5 W
LED
LED
WARNING LIGHTS
Neutral
Direction indicators
Fuel reserve
High beam
Alarm
Side stand
ABS
Heated handgrips
LED
LED
LED
LED
LED
LED
LED
LED
2-4
PEGASO 650
GENERAL TECHNICAL INFORMATION
PEGASO 650
2.1.2.
REGULAR SERVICE INTERVALS CHART
OPERATIONS TO BE CARRIED OUT BY THE aprilia Authorised Dealer (WHICH CAN BE CARRIED OUT EVEN BY
THE USER).
Key
1 = check and clean, adjust, lubricate or change, if necessary;
2 = clean;
3 = change;
4 = adjust.
(*) = Check every two weeks or according to the intervals indicated.
(**) = OPT (as standard in the countries where required)
CO = carbon monoxide
NOTE Carry out the maintenance operations halving the intervals indicated, if the vehicle is used in rainy or dusty areas
or on uneven surfaces, or in competitions.
After running-in
[1000 km (625 mi)]
Every 10000 km
(6250 mi) or 12
months
Every 20000 km
(12500 mi) or 24
months
Battery - Clamp tightening
1
1
-
Spark plug
-
1
3
Fork
1
-
1
Light operation/direction
-
1
-
1
1
-
Brake fluid
1
1
-
Coolant
Side panniers coupling pins
(**)
Tyres
-
-
1
Component
Light system
Safety switches
1
every 1000 km (625 mi): 1
Tyre pressure *
every 1000 km (625 mi): 4
Engine idling rpm and CO
Securing locks for the side
panniers and the top case
(**)
Warning light
Cush drive dampers and
sliding roll
Chain tension and lubrication
4
4
-
-
1
-
Brake pads wear
1
Flexible coupling wear and
flexible coupling unit slack
-
at every start: 1
upon each final transmission change : 3
every 500 km (375 mi): 1
before every trip and every 2000 km
(1250 mi): 1
-
1
WARNING
Have the final drive checked (rear, front sprockets and chain) every 5000 km
(3125 mi) by an aprilia Authorised Dealer.
2-5
GENERAL TECHNICAL INFORMATION
PEGASO 650
OPERATIONS TO BE CARRIED OUT BY THE aprilia Authorised Dealer.
Key
1 = check and clean, adjust, lubricate or change, if necessary (follow Workshop Manual specifications);
2 = clean;
3 = change;
4 = adjust.
(*) = Check every two weeks or according to the intervals indicated.
(**) = OPT (as standard in the countries where required)
CO = carbon monoxide
NOTE Carry out the maintenance operations halving the intervals indicated, if the vehicle is used in rainy or dusty areas
or on uneven surfaces, or in competitions.
Component
Rear shock absorber
Battery
Carburetion,
CO
adjustment
Timing chain
Transmission cables and
controls
Wheel truing
Rear suspension linkage
bearings
Steering bearings and
steering clearance
Wheel bearings
Brake discs
Fuel pump filter
Air filter
Engine oil filter
Engine oil filter (on oil
tank)
General running of the
vehicle
Clutch clearance
Braking systems
Cooling system
Brake fluid
Coolant
Fork oil
Engine oil
Fork oil seals
Brake pads
Adjusting
the
valve
clearance
Wheels/tyres (*)
Nut, bolt, screw tightening
Suspensions and track
alignment
Spoke tension
Final transmission (chain,
rear sprocket and front
sprocket)
Fuel pipes
Clutch wear
2-6
1
1
Every 10000 km
(6250 mi) or 12
months
1
Every 20000 km
(12500 mi) or 24
months
1
-
1
1
1
-
-
1
-
1
1
1
-
1
3
2
1
1
1
3
-
1
3
2
1
1
-
After running-in
[1000 km (625 mi)]
4
1
4
1
1
every 24 months: 3
every 24 months: 3
3
3
3 (*)
after the first 30000 km (18650 mi) and successively every 20000
km (12500 mi): 3
if worn: 3
4
4
1
1
1
1
1
1
every 5000 km (3125 mi): 1
1
1
every 4 years: 3
GENERAL TECHNICAL INFORMATION
PEGASO 650
2.1.3.
LUBRICANT TABLE
LUBRICANT
PRODUCT
Engine oil
RECOMMENDED:
EXTRARIDE 4, SAE 15W – 50.
As an alternative to recommended oils, top brand oils meeting or exceeding
CCMC G-4, A.P.I. SG specifications can be used.
RECOMMENDED:
F.A. 5W or
F.A. 20W.
When you wish to obtain an intermediate response between those offered
Fork oil
by
F.A. 5W and
follows:
F.A. 20W oils, you may mix the different products as
SAE 10W =
F.A. 5W 67% of volume, +
F.A. 20W 33% of volume,
SAE 15W =
F.A. 5W 33% of volume, +
F.A. 20W 67% of volume,
Bearings and other lubrication points
AUTOGREASE MP.
RECOMMENDED:
As an alternative to recommended grease, use top brand rolling bearing
grease that will resist a temperature range of -30 °C to +140 °C (-22 °F to
+284 °F), with dripping point 150 °C to 230 °C (302 °F to 446 °F), high
corrosion protection, good resistance to water and oxidisation.
Battery lead protection
Use neutral grease or Vaseline.
Chains
RECOMMENDED spray grease:
Brake fluid
RECOMMENDED:
with DOT 5).
F.F. DOT 4 (the braking system is also compatible
NOTE Use new brake fluid only. Do not mix different makes or types of oil
without having checked bases compatibility.
RECOMMENDED:
Engine coolant
CHAIN SPRAY.
ECOBLU – 40° C (- 40°F).
NOTE Use only nitrite-free antifreeze and corrosion inhibitors with a
freezing point of - 35°C (- 31°F) as a minimum.
2-7
GENERAL TECHNICAL INFORMATION
NOTES
DESCRIPTION
TIGHTENING
TORQUES
(Nm)
SCREW / NUT
TIGHTENING TORQUE SETTINGS
QUANTITY
2.1.4.
PEGASO 650
HANDLEBAR AND CONTROLS
counterweight
1+1
M6
10
loctite 243
handlebar and clamps
4
M8
25
Manual with
torque
wrench
front brake master cylinder
2
M6
12
battery bracket
1
M5
3
horn / horn mount
1
M6
12
rear direction indicators
2
M6
3
Voltage regulator
2
M6
12
ELECTRIC SYSTEM
loctite 243
front direction indicators
2
M6
3
tail light fastener
2
M5
1
Ground fastener onto engine
1
M6
15
Relay cable to starter motor fastener
1
M6
5
cables to relay fastener
2
M6
4
4
NUT M6
7±20%
2
M6
10
sump guard
3
M6
8
Voltage regulator support
2
M6
12
loctite 243
coils to frame
2
M5
6
loctite 243
Map sensor
2
M6
12
seat support
4
M8
25
Cradle fastener onto frame
2
M10
50
6
M5
6
SEAT
Hinge to seat fastener
LOCKS
rear lock
FRAME
FUEL TANK
flange to tank
2-8
loctite 243
GENERAL TECHNICAL INFORMATION
PEGASO 650
CENTRE BODYWORK
radiator spoiler
radiator cowling
3
4
M6
M6
5
3
number plate holder to seat support lower cover
2
M6
3
cat's eye holder to number plate holder
2
M5
6
front mudguard
4
M5
5
rear mudguard
4
M5
3
front fairing to arch
4
M6
3
inner conveyors to frame
3 and 3
instrument panel fairing cover
2
M6
4 and
M5 AND M6
2
4
M6
lug
4
M6
3
fairing side support to frame
4
M6
10
side fairings to fairing side support
6
M5
5
bush and seat support lower cover
2
M6
5
seat support lower cover to seat support
4
M6
4
seat support lower cover to frame
2
M6
4
tail guard to seat support lower cover
4
M5
2
tail guard front cover
4
M4
0.5
tail guard to seat support
4
M5
3
tail guard-passenger belt
2
M6
12
external conveyors
3
Manual
2
under-seat side body panels
2
M6
7
front fairing lower cover
3
M6
7
windshield to front fairing
6
M4
0.5
instrument panel to arch
3
M6
5
Front brake calliper
2
M10X1.25
50
Rear brake lever pin
1
M8
20
rear brake fluid tank
1
M5
6
rear brake rod lock nut
1
M6
Manual
expansion tank + carbon protection to coil support
2
M5
6
Head pipe fastener onto radiator
2
Manual
1
80
loctite 243
Manual
Manual
BRAKING SYSTEM
COOLING SYSTEM
FRONT WHEEL
wheel shaft nut
EXHAUST
muffler to seat support fastener
1+1
exhaust pipe clamps fastener
2+1
exhaust pipes to engine fastener
2+2
M8
25
16
M8
25
2-9
GENERAL TECHNICAL INFORMATION
PEGASO 650
REAR WHEEL
rear sprocket to sprocket holder fastener
5
wheel shaft nut
1
M10
50
80
SIDE STAND
side stand pin
switch screw
lock nut
1
1
1
M10X1.25
M6
M10X1.25
10
10
30
loctite 243
2
1
1
2
2
1
2
M10
M10
M10
M10
M10
M6
M6
50
50
50
50
50
10
10
-
REAR SUSPENSION
Shock absorber fastener onto frame
1
Single connecting rod fastener onto frame
1
single connecting rod / double connecting rod fastener
1
double connecting rod / swinging arm fastener
1
double connecting rod / shock absorber fastener
1
M10
M10
M10
M10
M10
50
50
50
50
50
loctite 243
M17X1
M25X1.5
35
12
100
20
Man.
20
12
6
6
loctite 243
ENGINE
engine to cradle fastener
engine lower fastener
engine upper fastener
lower connection plate to frame fastener
upper connection plates to frame fastener
gear shift lever
front sprocket case
SWINGING ARM
swinging arm shaft ring nut
swinging arm shaft adj. bush
swinging arm shaft
shock absorber guard fastener
chain tensioner screw and nut
chain slider fastener
rear stand bush
rear brake hose posit.plate fastener
chain guard fastener
1
1
1
2
1+1
1
1+1
1
2
4.8X13
M8
4.8X13
M6
M5
M5
FRONT SUSPENSION
fork leg fastener to top yoke
fork leg fastener to bottom yoke
steering tube ring nut
top yoke plug
fork hub plug
cable guide for front brake line
stiffening plate
1+1 M8
3+3 M8
1 M25X1.5
1 M22X1
2+2 M6
1 M6
4 M8
25
25
7
100
12
12
25
2+2 M10
2+2 M8
50
25
FOOTRESTS
rider footrests to frame
rear footrests to seat support
2 - 10
GENERAL TECHNICAL INFORMATION
PEGASO 650
2.1.5.
SPECIAL TOOLS
In order to perform assembly, reassembly and settings correctly, special tools suitable for the task must be used.
The use of special tools avoids the potential risk of damage as a result of inappropriate tools and/or improvised
methods.
The special tools developed specifically for this vehicle are listed below.
Ask for the general special tools, if necessary.
Pos.
Description
1
2
3
Fork shaft ring nut
Fork tube ring nut
Tool to fit fork oil seal D.63 H.125
Part
number
8101945
8163500
8140843
2 - 11
GENERAL TECHNICAL INFORMATION
2.1.6.
ARRANGEMENT OF THE ELEMENTS OF THE INSTRUMENT PANEL
KEY - PEGASO 650
1.
Headlight
2.
Ignition switch/steering lock
3.
Left rear-view mirror
4.
Fuel tank filler cap
5.
Fuel tank
6.
Battery
7.
Electronic control unit
8.
Fuse carrier
9.
Passenger grab rail
10.
Glove compartment
11.
Swinging arm
12.
Passenger left footrest (snapping, closed/open)
13.
Side stand
14.
Rider left footrest
15.
Gear shift lever
16.
Seat lock
17.
Drive chain
18.
Engine oil tank
19.
Tool kit
20.
Idle speed adjuster
21.
Oil drain plugs
22.
Underseat compartment
2 - 12
PEGASO 650
PEGASO 650
GENERAL TECHNICAL INFORMATION
KEY - PEGASO 650
1. Tail light
2. Passenger grab rail
3. Seat
4. Rear brake fluid tank
5. Air filter
6. Rear shock absorber
7. Engine oil level plug-dipstick
8. Front brake fluid tank
9. Right rear-view mirror
10. Horn
11. Engine oil filter
12. Rear brake control lever
13. Rider right footrest
14. Rear brake master cylinder
15. Passenger right footrest (snapping, closed/open)
16. Coolant expansion tank cap
17. Coolant expansion tank
18. CO sensor plug
2 - 13
GENERAL TECHNICAL INFORMATION
2.1.7.
INSTRUMENT PANEL OPERATION
When you turn the ignition key to " ", the following will turn
on for two seconds on the instrument panel:
•
•
•
The "PEGASO 650 STRADA" logo
All lights, except “Heated handgrips light”
Backlighting
Rev counter index (1) moves to maximum value, as set by
the user.
During the initial check-up, all instruments will briefly show
the current values of the corresponding parameters.
The display shows the following standard settings:
A)
B)
C)
D)
E)
F)
coolant temperature;
fuel quantity;
clock;
speedometer;
odometer;
on-board computer and accessories functions.
MODE selector (2) features three positions: a left one to
decrease values and scroll the drop-down menus, a right one
to increase values and scroll the drop-down menus in the
other direction, and a centre one to confirm values by
pressing the button.
2 - 14
PEGASO 650
PEGASO 650
GENERAL TECHNICAL INFORMATION
Turn selector (2) to display on the LCD the pages indicating
in zone (F) the following quantities:
A)
B)
C)
D)
E)
F)
G)
H)
TRIP METER 1
TRIP TIME 1
TRIP METER 2
TRIP TIME 2
MAXIMUM SPEED
LAP TIMER
BATTERY VOLTAGE
KM COVERED W/FUEL RESERVE (distance covered
on fuel reserve for trips longer than 2 km).
Trip meter 1 and 2 can be reset: press selector (2) for a
certain time in the centre position to reset all quantities
concerning the active trip meter.
After the distance covered on fuel reserve (KM COVERED
W/FUEL RESERVE), the display shows the MENU page, but
only if vehicle is not moving.
MENU
If vehicle is stopped, it is possible to gain access to the
configuration menu from the MENU page by pressing the
MODE selector in the centre position; while if vehicle is
moving, go back to the TRIP METER 1 page.
Configuration menu options are:
•
•
•
•
•
EXIT
SETTINGS
LAP TIMER
DIAGNOSIS
LANGUAGE
SETTINGS
When the SETTINGS function is selected the following
options are displayed:
•
•
•
•
•
•
EXIT
TIME SETTINGS
GEAR SHIFT INDICATOR
BACK LIGHTING
CHANGE THE CODE
UNLOCK SAFETY LOCKS
Once the operation is over, the instrument panel goes back
to main menu.
2 - 15
GENERAL TECHNICAL INFORMATION
TIME SETTINGS
This mode allows you to set the clock.
The main page with "TIME SETTINGS" is displayed.
As soon as you enter this mode, indication of minutes
disappears and only hours are displayed.
Value increases every time the MODE selector is pressed to
the right, once the value reaches 12, it goes back to 0.
In the same way, value decreases every time the MODE
selector is pressed to the left, once the value reaches zero, it
goes to 59 when the MODE selector is again pressed to the
left.
A Confirmation signal stores the set value and lets you quit
clock setting mode.
As soon as you enter this mode, indication of hours
disappears and only minutes are displayed.
Minutes value increases every time the MODE selector is
pressed to the right, once the value reaches 59, it goes to 0
when the MODE selector is again pressed to the right.
In the same way, value decreases every time the MODE
selector is pressed to the left, once the value reaches zero, it
goes to 59 when the MODE selector is again pressed to the
left.
A Confirmation signal stores the set value and lets you quit
clock setting mode.
GEAR SHIFT THRESHOLD
This function allows you to set the value for the Gear shift
indicator threshold. The main page with "GEAR SHIFT
THRESHOLD" message is displayed.
Threshold value is increased by 100 RPM every time the
MODE selector is pressed to the right, vice versa, threshold
value is decreased by 100 RPM every time the MODE
selector is pressed to the left.
If the upper or lower limit is reached and you further press
the selector, nothing will happen.
Press the MODE selector to the centre position to end the
operation and store the set value, the index goes back to
zero and the instrument panel goes back to configuration
menu page.
When battery is connected for the first time, the instrument
panel sets to running-in rpm value, the next time battery is
connected it sets to last set value.
RUNNING-IN RPM: 5000
MINIMUM RPM: 4000
MAXIMUM RPM: 8000
When the set threshold is exceeded, the alarm light (3) on
the instrument panel flashes until the value goes below the
threshold.
2 - 16
PEGASO 650
PEGASO 650
GENERAL TECHNICAL INFORMATION
BACK LIGHTING
This function allows you to set backlighting: three levels are
available. Every time the MODE selector is pressed to the
right or to the left, the following icons are displayed:
•
•
•
LOW
MEAN
HIGH
Press the MODE selector to the centre position to set the
instrument panel back to SETTINGS MENU.
CHANGE THE CODE
This function is used when the old CODE is available and you
want to change it; in this case the instrument panel should be
turned on using a stored key. The following message is first
displayed:
Insert the old code
Once the code has been recognised, you are prompted to
enter the new code:
Insert the new code
Once the operation is over, the instrument panel goes back
to diagnosis menu. This operation is not allowed in case the
user entered with the code.
Once the operation is over, the instrument panel goes back
to settings menu.
This function is used when the old CODE is not available and
you want to change it; in this case two stored keys should be
inserted. The first one is already in and you will be prompted
to insert the second key:
insert the II key
The instrument panel should not switch off in-between one
key and the other, operation is aborted if the second is not
inserted within 20 seconds. Once the key has been
recognised, you are prompted to enter the new code:
Insert the new code
Once the operation is over, the instrument panel goes back
to diagnosis menu. This operation is not allowed if the user
entered with the code or only one key is stored.
Once the operation is over, the instrument panel goes back
to settings menu.
2 - 17
GENERAL TECHNICAL INFORMATION
UNLOCK SAFETY LOCKS
In case of failure to the stand sensor, the neutral and clutch
switch, use function "UNLOCK SAFETY LOCKS" to disable
the safety logic and be able to start the engine.
The display will show "SERVICE".
The safety logic is re-enabled when turning the key off.
DANGER
This function should be used only in an
emergency.
LAP TIMER
When the LAP TIMER function is selected the following
options are displayed:
•
•
•
EXIT
VIEW TIMES
DELETE TIMES
VIEW TIMES
This function also displays the acquired lap times. Briefly
press the MODE selector to the right and to the left to scroll
the time pages, press it for a certain time to set the display
back to the LAP TIMER menu. If the battery is disconnected,
stored times are lost.
DELETE TIMES
This function deletes the acquired lap times. Deletion should
be confirmed. Once the operation is over, the display goes
back to LAP TIMER menu.
Operation
To use the lap timer, set the display to the main page
indicating CHRONO. Briefly press the MODE selector to the
centre position, the lap timer starts recording. Press again
the MODE selector to the centre position before 10 seconds
have elapsed from timer start, time measurement is
cancelled and a new one is started.
Press again the MODE selector to the centre position after
10 seconds have elapsed from timer start, time
measurement is interrupted, stored and a new one is started.
Press the MODE selector for a certain time to the centre
position to interrupt lap time set.
Once 40 lap times have been recorded, acquisition ends and
"FULL" is displayed: stop the vehicle to read recorded lap
times, enter VIEW TIMES option in the LAP TIMER menu.
A new timer session can be started only if all previously
recorded lap times are deleted: enter the DELETE TIMES
function in the LAP TIMER menu.
2 - 18
PEGASO 650
GENERAL TECHNICAL INFORMATION
PEGASO 650
DIAGNOSIS
This menu interfaces with the systems fitted to the
motorcycle to carry out diagnosis. To enable the menu, a
password is needed that is available only to aprilia service
centres.
•
Insert the service code
It is a 5 digit code, for Pegaso the code is: 25973
If code is wrong, appears the message:
•
Incorrect code
The instrument panel goes back to main menu; if not, the
menu appears:
•
EXIT
•
ECU ACTUATIONS
•
ECU PARAMETERS
•
ECU ERRORS
•
DASHBOARD ERRORS
•
DELETE ERRORS
•
CO ADJUSTMENT
•
SERVICE RESET
•
DISCONNECT
•
UPDATE
•
UPDATE KEYS
•
KM / MILES
Once the operation is over, the instrument panel goes back
to main menu.
There are two types of ECU diagnosis, the passive one and
the active one. During passive diagnosis, the user simply
reads data from the ECU, such as: battery voltage, throttle
opening angle, atmospheric pressure or error reading
(current or stored). During active diagnosis, the ECU
performs operations such as: generate 5 sparks or 5 fuel
injections.
Parameters necessary for parameter reading are the
following:
Part number
01
03
05
06
07
08
09
20
21
70
Description
Throttle opening angle
Air intake pressure
Air intake temperature
Water temperature
Vehicle speed pulse
Turnover sensor
Fuel system voltage
Side stand switch
Neutral switch
Program Ver. No.
2 - 19
GENERAL TECHNICAL INFORMATION
Parameters necessary for actuations are the following:
Part number
30
36
48
50
51
52
Description
Ignition coil
Injector
AIS solenoid
Main relay
Fan relay
Headlight relay
Errors: This page shows all present and/or stored errors
Part number
60
61
Description
EEPROM Error
Error FLAG ∆ CODE
Delete errors: this page allows you to delete stored errors.
Deletion will be effective upon key OFF.
Part number
62
2 - 20
Description
Error FLAG ∆ CODE clear
PEGASO 650
PEGASO 650
GENERAL TECHNICAL INFORMATION
ECU actuations
The following message is displayed:
•
Turn the key to stop
Once the key is turned off, the following message is
displayed:
•
Set the key to run
Set the ENGINE-ON switch to STOP.
Once the key is turned on, the following menu is displayed:
•
•
•
•
•
•
•
EXIT
COIL
INJECTOR
AIS SOLENOID
INJECTION RELAY
FANS
LIGHTS
Turn the key to stop to quit, the following message will be
displayed:
•
Turn the key to stop to quit
•
Ignition coil
The following message is displayed:
•
Set the ENGINE-ON switch first to RUN and then to
STOP.
The coil will be activated for 5 times.
•
Injector
The following message is displayed:
•
Set the ENGINE-ON switch first to RUN and then to
STOP.
The injector will be activated for 5 times.
2 - 21
GENERAL TECHNICAL INFORMATION
•
AIS solenoid
The following message is displayed:
•
Set the ENGINE-ON switch first to RUN and then to
STOP.
The secondary air system solenoid valve will be activated for
5 times.
•
Injection relay
The following message is displayed:
•
Set the ENGINE-ON switch first to RUN and then to
STOP.
The injection relay will be activated for 5 times.
•
Fans
The following message is displayed:
•
Set the ENGINE-ON switch first to RUN and then to
STOP.
The fan piloting relay will be activated for 5 times.
•
Lights
The following message is displayed:
•
Set the ENGINE-ON switch first to RUN and then to
STOP.
The lights relay will be activated for 5 times.
2 - 22
PEGASO 650
PEGASO 650
GENERAL TECHNICAL INFORMATION
ECU errors
This page displays both current (live) errors and stored ones.
The following message is displayed:
•
Turn the key to stop
Once the key is turned off, the following message is
displayed:
•
Turn the key to Drive
Once the key is turned on, the table of errors read by the
ECU is displayed. Turn the key to stop to quit, the following
message will be displayed:
•
Turn the key to stop to quit
ECU parameters
This page displays parameters read by the ECU. The
following message is displayed:
•
Turn the key to stop
Once the key is turned off, the following message is
displayed:
•
Turn the key to Drive
Once the key is turned on, the following table is displayed.
Turn the key to stop to quit, the following message will be
displayed:
•
Turn the key to stop to quit
CO adjustment
In this page the instrument panel increases or decreases the
CO rate. Press the UP or DOWN buttons on the control
switch to increase or decrease the value. The instrument
panel should display the set value; the ECU shall store the
set value upon key OFF.
At this stage, the rpm are displayed.
The following message is displayed:
•
Turn the key to stop
Once the key is turned off, the following message is
displayed:
•
Turn the key to Drive
Once the key is turned on, the following message is
displayed, while waiting for the connection with the ECU:
•
Wait for the connection
Once connection is established, the following messages are
displayed:
•
Connection established
•
Set value
•
CO = !!!
•
Turn the key to stop to set in memory and exit
The value of the parameter setting the CO rate should be
within –127 and +128.
2 - 23
GENERAL TECHNICAL INFORMATION
PEGASO 650
Dashboard errors
In this mode, a table is displayed indicating possible
immobilizer errors or errors related to sensors connected to
it. Following is the error decoding table:
DESCRIPTION
Immobilizer failure: Key code was read but
not acknowledged
Immobilizer failure: Key code not read (Key
not present or transponder faulty)
Immobilizer failure: Antenna faulty (Open
or short-circuited)
Immobilizer failure: Inner controller fault
Fuel sensor failure
ERROR CODE
DSB 01
DSB 02
DSB 03
DSB 04
DSB 05
The instrument panel should store past errors in memory.
In case of fuel sensor failure, the relevant icon on the display
should be flashing.
Delete errors
Use this option to delete all errors, both from the ECU and
the instrument panel; a confirmation is needed.
Service reset
This function resets the service interval.
Disconnect
On the Pegaso, the instrument panel uses diagnostics
instruments communication K line for gathering data. To
avoid any interference, use the user's interface settings to
set the instrument panel in such a status for which there is
no interference. Using the outer devices, the ECU will be
reset and can start communication with the diagnostics tool.
The LCD shows:
•
Dashboard disabled. Now it is possible to connect the
diagnostic tool.
The instrument panel will start operating in a normal way
after one cycle of key on-off.
2 - 24
PEGASO 650
GENERAL TECHNICAL INFORMATION
Update
This function allows reprogramming of the instrument panel.
This page shows the currently loaded software version.
The LCD shows:
•
Dashboard disabled. Now it is possible to connect the
diagnostic tool.
The instrument panel will start operating in a normal way
after one cycle of key on-off.
Update keys
This function allows the instrument panel to update the keys.
It is possible to store up to 4 keys.
You will be prompted to enter the user code:
•
Insert the code
If the code is correct, the display should show the message:
•
Insert the X key.
•
Memorised X+1 key.
At least one key should be stored, then the procedure is
ended if no further key is inserted within 20 seconds or in
case power is missing or after the fourth key. All vehicle and
instrument panel functions should be enabled (even with just
one key stored).
Km / miles
This menu allows selection of the unit of measurement for
speed.
KM
MILES
Language
This menu allows you to choose the user's interface
language.
•
•
•
•
•
ITALIANO
ENGLISH
FRANCAIS
DEUTSCH
ESPAGNOL
2 - 25
GENERAL TECHNICAL INFORMATION
SERVICE INTERVAL
When the scheduled service intervals are reached, an icon is
displayed (symbol of a spanner).
ALARM DISPLAY
In case a serious failure is detected, one that might
jeopardise the vehicle or the rider's safety, the display will
show an icon indicating the failure cause, in the area where
the odometer usually is.
Alarms are divided in two groups depending on their priority:
High priority: overtemperature, ECU errors, Instrument panel
errors;
Low priority: Direction indicators.
Direction indicators fault is indicated only when all indicator
leds are faulty.
Should there be many alarms with same priority level, the
relevant icons are displayed alternately.
High priority alarms do not allow you to display low priority
ones.
If the alarm light and the SERVICE icon briefly come on it
does not mean that there is a failure.
FUNCTION FEATURES
Speedometer
The speed value is shown on the display with [nnn] format
and with indication of unit of measurement [km/h] or [MPH].
Accuracy should be higher than required by Directive
2000/7/CE dated 20/03/00 and in any case between +0%
and +2%.
Measurement is taken with a reading in the Denso ECU of
the number of pulses in-between the readings. 20
pulses/revolution are set, front sprocket has 15 teeth while
rear sprocket has 44, wheel development is 1926 mm.
For homologation reasons, the data indicated by the
instrument should be 6% higher than the date read by the
ECU.
2 - 26
PEGASO 650
GENERAL TECHNICAL INFORMATION
PEGASO 650
Revolution counter
Engine rpm indication is on the left side of the instrument.
•
Accuracy: 0/+5% with respect to input signal.
•
The instrument panel should filter the signal to avoid
index oscillation, especially at idle speed.
•
Maximum index oscillation at idle speed: ± 1° with
respect to input signal.
•
Maximum index oscillation at maximum rpm: ± 0.5°
with respect to input signal.
•
Index increasing speed, smooth from scale start to end
or vice versa: 0.6 sec.
Measurement is taken by reading the value in the Denso
ECU. The relationship between engine speed and data from
ECU is:
RPMx1000 = DATA1x(189/7) = DATA1x27
Index recovery logic: index is taken to scale start every time
the vehicle is switched off. Every time the battery is
reconnected, index is taken back to zero, regardless of its
current position. At every ignition, a 20° recovery is
performed.
Engine temperature indicator
Temperature measurement is done by Denso ECU.
The light turns on when coolant reaches temperature of
120°.
Fuel level indicator
The instrument panel should interface to a resistive level
sensor both of the potentiometric type and the resistive steps
type. The measurement of values exceeding the sensor
limits should be considered as faults and be signalled by the
diagnostic. Indication is given in the LCD and with relevant
reserve light. The features and calibration curves are
indicated in the following table:
LEVEL
15.8 litres
3.8 litres
0.0 litres
RESISTANCE
22.5 Ohm
240.0 Ohm
296.0 Ohm
WARNING LIGHT
off
on
on
Distance covered w/fuel reserve
The display should show how many km have been covered
since the fuel reserve light came on. The value is indicated in
[nn.n] format followed by the unit of measurement [km] or
[mi].
The counter starts when it detects that the light has been on
for 5 seconds in a row and count is stopped when it detects
that the light has been off for 30 seconds in a row. In any
case, data should be shown only after count has exceeded 2
km.
Value is displayed after 40 seconds from key-on so that the
odometer value can be viewed even with vehicle on fuel
reserve.
2 - 27
GENERAL TECHNICAL INFORMATION
Odometer
Selection between Km and Miles is made via user interface.
•
Value should be given with an accuracy of 6 digits and
[Km] or [Miles] indication. Saturation occurs when
shifting from 999998 to 999999 with count block; the
digits that are not used, are not displayed.
•
Accuracy: ±0.5%
•
The value of total kilometres covered should be stored
for at least 5 years, with instrument not powered.
•
Data are saved at least every 2 km.
Odometer data should not be lost whatever the power supply
condition.
Clock
It is displayed only when vehicle is on, indication stays
displayed for 5 seconds upon switching-off.
•
Accuracy should be higher than 30ppm.
The clock should not reset in case of temporary voltage drop
in the electric system (see qualification test). Settings are lost
upon battery disconnection; upon following key-on the clock
will constantly display “0:00” until a new setting is performed.
On-board Computer
In the display bottom are the on-board computer indications,
i.e. two trip meters with relevant maximum speed and
average speed, trip time and fuel consumption. When
resetting one trip meter, all connected values are reset.
Km and miles selection is made via user interface and is
connected to the unit set for odometer.
The instrument panel should not lose data in case of
temporary voltage drops, for example due to vehicle start-up;
Data might be lost in case of battery disconnection. See the
qualification tests for further details.
Upon saturation of trip meter, i.e. from 999.9 to 0.0, or upon
saturation of the trip times, from 99:59 to 00:00, all values of
relevant trip meter should be reset.
Trip meter
Trip meter value is calculated since last reset. The value is
shown on the display with [nnn.n] format, with indication of
unit of measurement [km/h] or [MPH]. Value is refreshed at
least every 10 seconds. Saturation occurs from 999.9 to 0.0.
2 - 28
PEGASO 650
PEGASO 650
GENERAL TECHNICAL INFORMATION
Trip time
Trip time value is calculated since last trip meter reset. This
calculation also includes stops (zero speed and engine
running) while does not include intervals with key-on and
engine off. Count stops with engine off.
The value is indicated in the display in [hh:mm] format, with
[TIME] written before. Saturation occurs from 99:59 to 00:00.
Maximum speed
Maximum speed is calculated since last reset. The value is
shown on the display with [nnn] format, with [MAX] written
before and the unit of measurement [km/h] or [MPH]
indicated after it.
Speed value is stored only if it stays the same for at least 3
samplings taken at intervals of 0.5 seconds.
I.e., given Vn, Vn+1, Vn+2
If (Vn<= Vn+1) & (Vn<=Vn+2) then VMAX= Vn
Battery voltage
This function measures battery voltage. The value is shown
in the display with [nn.n] format, the battery icon precedes
the value and the unit of measurement [V] follows the value.
•
Range: 9.0 ÷ 16.0 [V]. If voltage is lower than 9V or
higher than 16V, accuracy might exceed required
tolerances but should have a constant increasing trend.
•
Accuracy: ±0.2V with respect to voltage at the battery
(correction factors should then be added, as per table,
varying according to the vehicle the instrument is fitted
to).
Refresh: every 10 secs. To avoid indication oscillation, a
suitable software damping should be set.
Safety logic
Immobilizer and safety logic actuation are performed through
the CONTACT 1 and CONTACT 2 signals from the instrument
panel and should be closed to enable ignition. Immobilisation
is performed by opening all contacts.
Vehicle is immobilised maintaining at high logic level (open
contacts) CONTACT 1 and CONTACT 2 signals and at low logic
level (open contact) the STARTER RELAY ACTUATION signal.
Safety devices are released setting at low logic level (closed
contact) CONTACT 1 and CONTACT 2 signals and at high logic
level (closed contact) the STARTER RELAY ACTUATION signal.
2 - 29
GENERAL TECHNICAL INFORMATION
Service intervals
The SERVICE icon coming on to indicate that the vehicle is
due for first service coupon occurs when odometer reaches
1000 km. The next service intervals are indicated when
odometer will reach a multiple of 10000 km.
The service warning can be reset from 300 Km before the
scheduled interval and in this condition the service icon
should flash for 5 seconds and then go off.
Direction indicators
The instrument panel works as a control driver for direction
indicators, as single channel control and as synchronised
control for both channels ("Hazard"). Required features are
the following:
The hazard control device is a push-button.
Flashing frequency in normal operation: as per FMVSS 108
standard (60÷120 blinks/min.) and anyway ≈ 87 blinks/min.
The instrument panel should be able to directly pilot a lamp
load up to 4x21W. Consider in any case the chance of
piloting even sundry loads (such as front lamps and rear
LEDs) or LEDs only for all 4 outputs. It is then necessary to
have 4 separate control channels. Minimum current per
channel will be 1mA.
Failure signal (burnt-out or short-circuited bulb) by doubling
the light flashing frequency (≈175 blinks/min.).
Protection against short-circuit (with indefinite short-circuit
stay time) for all outputs.
Hazard operation logic: can be enabled/disabled with key ON
only. After activation, it stays active even when taking the
key to OFF.
For the USA version, the instrument panel should be marked
DOT (SAE J590b standard, October 1965).
Hazard
The hazard control device is a push-button. It can be
enabled or disabled only with KEY-ON. When activated, the
direction indicators stay active even when removing the key.
To disable them, turn the key back to ON.
2 - 30
PEGASO 650
PEGASO 650
GENERAL TECHNICAL INFORMATION
Automatic switch-off
The automatic switch-off of direction indicators is required. If
vehicle is stopped, so with speed equal to zero, the direction
indicators carry on flashing indefinitely; if the vehicle is in
motion, the indicators switch-off automatically when one of
the following two conditions is true:
•
After a set time t = 40 sec.
After covering 500 m.
Immobilizer
The immobilizer system is integrated in the instrument panel
electronic board. Board design allows manufacturing
instrument panels without immobilizer, or with immobilizer
function disabled, so that they can be used in countries
where immobilizer system is not allowed or not fitted.
The supplier shall have the instrument panel immobilizer
device homologated according to the standards of the
relevant Ministries of the various countries and shall stick the
suitable label indicating system certification on the
instrument panel itself.
Operation
The instrument panel reads key code upon switch-on. If this
code matches one of the memorised codes, the instrument
panel shall perform the initial check routine and enable
engine start.
The system should be able to store up to four keys.
If the key code is not acknowledged, the instrument panel
should inhibit engine starting and the display should show
manual override code request. In this case it should be
possible to gain access to the menu via the diagnosis
functions.
Code
This function allows immobilizer manual override through a
code. In case the instrument panel does not acknowledge
inserted key, access code is requested with the message:
•
Insert the code
The code should be made of 5 digits, 0 to 9. At line output,
code will be empty (5 digits equal to 0, i.e. 00000) and will be
programmed by the user, upon switch-on an alarm message
should be displayed for 10 seconds, until code is entered:
•
Remember to insert your user code
This code can be changed by the user, in this case the old
code should be entered and if the user loses the access
code, it can be changed through a procedure requiring
insertion of both keys.
2 - 31
GENERAL TECHNICAL INFORMATION
Memorisation of keys at first start-up
The customer will receive two keys fitted with transponder.
Upon instrument panel first start-up, it should request key
memorisation.
The display shows:
•
Insert the X key.
•
Memorised X+1 key.
At least one key should be stored, then the procedure is
ended if no further key is inserted within 20 seconds or in
case power is missing or after the fourth key. All vehicle and
instrument panel functions should be enabled (even with just
one key stored).
Memorisation of new keys
In case one key is lost, the customer can disable the lost key
or disable and completely change the set of keys by
changing the complete ignition switch.
Diagnosis
The instrument panel should indicate the failure of the
component controlling the immobilizer function, failure of the
antenna and reading fault because of transponder with code
not stored, in this case the access code is requested.
2 - 32
PEGASO 650
GENERAL TECHNICAL INFORMATION
PEGASO 650
CONNECTOR
The figure shows the connector diagram, on instrument
panel, and its pin layout.
The numbers are printed on the plastic element of the pins
and on the connector body.
The grey end pin layout is as follows:
PIN
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Service
+KEY
RIGHT DIRECTION INDICATOR CONTROL
HIGH BEAM INPUT
*
HEATED HANDGRIPS INPUT
K-LINE
NEUTRAL
SELECT 1 - DOWN
FUEL LEVEL SENSOR
*
+BATTERY
LEFT DIRECTION INDICATOR CONTROL
*
*
*
GENERAL GROUND
ABS INPUT
SENSORS GROUND
MAIN GROUND (OPTION)
MAIN GROUND (OPTION)
The black end pin layout is as follows:
PIN
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Service
+BATTERY
FRONT LEFT DIRECTION INDICATOR ACTUATION
REAR LEFT DIRECTION INDICATOR ACTUATION
ANTENNA 1
CONTACT 1 (NEUTRAL ECU INPUT)
*
INDICATORS RESET
*
STAND
SELECT 2 - UP
+BATTERY
FRONT RIGHT DIRECTION INDICATOR ACTUATION
REAR RIGHT DIRECTION INDICATOR ACTUATION
ANTENNA 2
CONTACT 2 (ECU STAND INPUT)
*
HAZARD
STARTER RELAY ACTUATION
CLUTCH SENSOR
SELECT 3 - SET
Pins marked with * are available but not used.
2 - 33
GENERAL TECHNICAL INFORMATION
CONNECTIONS
Following are input and output lines and their electrical
features; all inputs, outputs and lights should be controlled by
microprocessor. Power lines should be equipped with
devices limiting current in case of failure.
•
K-line
The interface line consists in a line with physical level
complying to ISO-9141, to be used for communication with
the Denso ECU. Speed shall be 15.625 Kbit/sec. The line
shall be fitted with a 1KΩ pull-up resistor powered by battery
(according to key position), it should feature a diode
connected in series to avoid backflow of power through the
signal lines.
2 - 34
PEGASO 650
PEGASO 650
•
GENERAL TECHNICAL INFORMATION
Select 1÷3
These inputs are used for user interface controls and should
be fitted with a 1KΩ pull-up resistor powered by inner power
supply.
•
High beam input
It is the signal indicating high beam on to the instrument
panel and should switch on the relevant warning light. With
lights off there is no power, while when lights are on there is
either the battery voltage or a signal directly derived from the
regulator, therefore it is a pulsating signal that might reach
high values.
In case the signal is taken directly from the generator, its
minimum frequency can be 100Hz with an idle speed of 600
rpm and one polar expansion only.
In case the bulb is failed, the warning light should stay off: a
pull-down resistor is required.
•
•
•
•
Right indicator control
Left indicator control
Indicators reset control
Hazard control
These are signals indicating the status of direction indicators
to the instrument panel, they are NO push-buttons that give a
ground contact when pressed.
•
Heated handgrips
When handgrip heating is on, battery voltage is input to this
input. Since they are an option item, it is necessary to fit a
pull-down resistor so that light stays off when heated
handgrips are not fitted.
•
Fuel level sensor
It is a sensor with a 12-296 ohm resistive race, and one end
connected to ground.
•
Neutral
It is a contact, present only on vehicles with selectable
speeds, signalling if the gear is engaged or not. It is
grounded when the vehicle is in neutral and in this condition
the relevant warning light shall be on.
•
Stand
It is a contact, present only on vehicles fitted with side stand,
signalling if the side stand is down or not.
•
ABS
This input controls the ABS light status. With input open or
with level high, light shall be on, on ABS control unit control,
the light is off with input at low level.
•
•
Antenna 1
Antenna 2
2 - 35
GENERAL TECHNICAL INFORMATION
•
Contact 1, Contact 2
These are two contacts providing for engine disable, piloted
both by the immobilizer and by the engine control logic.
These contacts shall be properly sized for a loop current
equal to 200 mA, while current at start-up is 500 mA and
should be protected to allow inductive loads piloting.
•
Starter relay actuation
Shall be able to pilot a relay with maximum current of 4A.
DESIGN REQUIREMENTS
Operating conditions
•
•
•
•
•
•
•
•
Nominal voltage: 13.5±0.5 V
Operating voltage (not calibrated): 6V÷18V (it is in any
case necessary to ensure data storage in case of
temporary power failure such as upon start-up with flat
battery).
Operating voltage (calibrated): 9÷16 V
Absorption with key not inserted (excluded immobilizer
led, where fitted): <1mA
Operating temperature (not calibrated): -20°C ÷ +85°C
Operating temperature (calibrated): -18°C ÷+65°C
Stocking temperature: -30°C ÷ +90°C
Materials with slow combustion, resistant to fire as per
UL94-HB V2 standard.
Vehicle mission profile
Forecast life-span shall not be shorter than 50000 km or 8
years.
LCD Specifications
The display has a resolution of 128x112 pixel (X-axis - Yaxis), the visible area is 62x55mm while active area (the one
actually covered by pixels) is 56x49 mm (X-axis - Y-axis).
Display cone is: On the horizontal surface (x-z) it is +45° 45°, on the vertical surface (y-z) it is +10° -30°. The contrast
shall be more than 5 in the whole display cone.
All LCD shall be legible with Polaroid glasses up to 35° with
respect to the horizontal line.
Display temperatures
The display operating temperature specifications are the
following:
•
Operating temperature (with no ghost effect): -20°C ÷
+85°C
•
Stocking temperature: -30°C ÷ +90°C
The instrument panel shall therefore implement a display
compensation system upon ambient temperature variation.
2 - 36
PEGASO 650
PEGASO 650
GENERAL TECHNICAL INFORMATION
Labelling
A label should be stuck at the back of every component; it
shall be indelible and water proof, indicating the following
details:
•
supplier code
•
Aprilia code
•
hardware board version
•
software version
•
production date
The Supplier shall add more labels for DOT certification or
immobilizer system homologation.
2 - 37
GENERAL TECHNICAL INFORMATION
2.2.
SCHEDULED MAINTENANCE
2.2.1.
CHANGING ENGINE OIL AND OIL FILTER
Change the oil filter after the first 1000 km (621 mi), end of
running-in, and then every 10000 km (6250 mi).
•
•
Position the vehicle on firm and flat ground.
Position the vehicle on the stand.
WARNING
Allow several minutes for the engine and
exhaust system to cool down.
•
Stop the engine and let it cool down, in order to allow
the oil to flow into the crankcase and to cool down.
NOTE Failure to perform the operations described above
may result in the incorrect measurement of the engine oil
level.
•
Unscrew and extract the plug/dipstick.
•
•
Place a container under engine oil drain plug.
Loosen and remove the oil drain plug and let oil drain
off completely.
WARNING
Used oil contains substances that are very
dangerous for the environment. Dispose of
used oil in accordance with applicable
regulations.
2 - 38
PEGASO 650
PEGASO 650
•
Loosen and remove the three oil filter cover screws.
•
Remove the oil filter cover with gasket, collect the Oring.
•
•
•
•
•
•
•
Remove the oil filter.
Install a new oil filter.
Fit the oil filter cover and tighten the three screws.
Screw and tighten the oil drain plug.
Fill up with about 1500 cu.cm of engine oil (91.5 cu.in.).
Screw and tighten the plug/dipstick.
Start the engine and let it run for a few minutes. Stop
the engine and let it cool down.
Check engine oil level.
•
GENERAL TECHNICAL INFORMATION
2 - 39
GENERAL TECHNICAL INFORMATION
2.2.2.
•
CLEANING THE AIR FILTER
•
Remove the right side body panel, see (REMOVING
THE REAR FAIRING).
Loosen and remove the four screws.
•
Slide out the filter mount and air filter.
•
Remove the air filter from its mount and clean the
filtering element.
2 - 40
PEGASO 650
PEGASO 650
2.2.3.
•
•
•
GENERAL TECHNICAL INFORMATION
CHANGING THE COOLANT
Remove the headlight, see (REMOVING THE
HEADLIGHT).
Remove the fuel tank, see (REMOVING THE FUEL
TANK).
Set a container of suitable capacity under drain screw
to collect exhausted fluid.
WARNING
Do not remove the filler plug with hot engine.
Coolant is hot and under pressure.
•
Release and remove the drain screw, collect the
copper washer.
•
To help coolant draining off completely, remove circuit
filler plug (A) on radiator and expansion tank filler plug
(B) on expansion tank.
•
•
•
Refit the drain screw with a new copper washer.
Pour fluid into filler until full.
Repeatedly press with your hand on the unions to
allow fluid to fill in all channels.
NOTE The correct level is when fluid gets just below the
filler.
•
Top up again until full.
2 - 41
GENERAL TECHNICAL INFORMATION
•
•
•
•
•
Tighten circuit filler plug (A).
Release expansion tank plug and top up fluid in the
expansion tank until level is between MIN and MAX
notches.
Tighten the expansion tank plug (B).
Start the engine and let it idle for a few minutes, stop it
and let it cool down.
Check again fluid level in the expansion tank and top
up if necessary.
2 - 42
PEGASO 650
PEGASO 650
2.2.4.
GENERAL TECHNICAL INFORMATION
FRONT BRAKE
BLEEDING
The air, if any, present inside the hydraulic circuit will serve
as "pad" by absorbing most of the pressure coming from the
brake master cylinder and thus reducing the calliper
efficiency during braking.
If some air is present inside the circuit, the brake control is
"spongy" and the braking efficiency is reduced.
DANGER
It is fundamental that air is bled off the
hydraulic circuit after the brakes have been
refitted and the braking system has been
restored to its standard operating conditions,
since it would be very dangerous for the
vehicle and the rider not to do so.
NOTE The following procedure applies to both front brake
callipers.
Bleed
air
with
vehicle
on
flat
ground.
While bleeding the hydraulic circuit, top up reservoir with
brake fluid as required. Make sure there is always some fluid
in the reservoir throughout the process.
•
•
•
•
•
•
Remove the bleed valve rubber cap.
Insert one end of a transparent plastic tubing inside the
front brake calliper bleed valve and the other end in a
container for collection.
Pull and quickly release the front brake lever a few
times, then keep it pulled.
Loosen the bleed valve by 1\4 of a turn so as the brake
fluid flows in the container, this will remove any
tension from the lever and help it travel fully home.
Retighten the bleed valve before the lever is fully
squeezed in.
Repeat process until the fluid draining into the
container is totally clear of air bubbles.
NOTE While bleeding the hydraulic circuit, top up reservoir
with brake fluid as required. Make sure there is always some
fluid in the reservoir throughout the process.
•
•
•
Tighten the bleed valve and remove the tubing.
Top up fluid inside tank.
Refit the rubber cap.
CHANGING THE PADS
•
Turn the pins and slide out both slit pins.
2 - 43
GENERAL TECHNICAL INFORMATION
•
Remove both pins.
•
Remove the vibration damper.
•
Remove one pad at a time.
WARNING
Do not operate the brake lever when the pads
are not in place or the calliper pistons might
come off their housing, thus causing brake
fluid leakage.
•
Install two new pads, fit them so as the holes match
those on the calliper.
WARNING
Always change both pads and ensure they are
correctly in place inside the calliper.
•
•
•
•
Fit the vibration damper.
Fit both pins.
Fit both split pins.
Check brake fluid level.
2 - 44
PEGASO 650
PEGASO 650
2.2.5.
GENERAL TECHNICAL INFORMATION
REAR BRAKE
BLEEDING
The air, if any, present inside the hydraulic circuit will serve
as "pad" by absorbing most of the pressure coming from the
brake master cylinder and thus reducing the calliper
efficiency during braking.
If some air is present inside the circuit, the brake control is
"spongy" and the braking efficiency is reduced.
DANGER
It is fundamental that air is bled off the
hydraulic circuit after the brakes have been
refitted and the braking system has been
restored to its standard operating conditions,
since it would be very dangerous for the
vehicle and the rider not to do so.
NOTE Bleed air with vehicle on flat ground.
While bleeding the hydraulic circuit, top up reservoir with
brake fluid as required. Make sure there is always some fluid
in the reservoir throughout the process.
•
•
•
•
•
•
Remove the bleed valve rubber cap.
Insert one end of a transparent plastic tubing inside the
rear brake calliper bleed valve and the other end in a
container for collection.
Pull and quickly release the rear brake lever a few
times, then keep it pulled.
Loosen the bleed valve by 1\4 of a turn so as the brake
fluid flows in the container, this will remove any
tension from the lever and help it travel fully home.
Retighten the bleed valve before the lever is fully
squeezed in.
Repeat process until the fluid draining into the
container is totally clear of air bubbles.
NOTE While bleeding the hydraulic circuit, top up reservoir
with brake fluid as required. Make sure there is always some
fluid in the reservoir throughout the process.
•
•
•
Tighten the bleed valve and remove the tubing.
Top up fluid inside tank.
Refit the rubber cap.
CHANGING THE PADS
•
•
Turn pin and slide out split pin.
Remove the split pin.
2 - 45
GENERAL TECHNICAL INFORMATION
•
Remove the pin.
•
Remove one pad at a time.
WARNING
Do not operate the brake lever when the pads
are not in place or the calliper pistons might
come off their housing, thus causing brake
fluid leakage.
•
Install two new pads, fit them so as the holes match
those on the calliper.
WARNING
Always change both pads and ensure they are
correctly in place inside the calliper.
•
•
•
Insert the pin.
Fit the split pin.
Check brake fluid level.
2 - 46
PEGASO 650
PEGASO 650
2.2.6.
GENERAL TECHNICAL INFORMATION
ADJUSTING THE VALVE CLEARANCE
NOTE The following procedure applies to all valves.
Adjust clearance when the engine is cold, at ambient
temperature.
Measure or adjust valve clearance with the piston at top
dead centre (TDC) during the compression stroke.
•
Release and remove the four screws.
•
Remove the intake tappet cover.
•
Loosen and remove the four screws and remove the
exhaust tappet cover.
2 - 47
GENERAL TECHNICAL INFORMATION
•
•
Loosen and remove the two screws (1), collect the
washers.
Remove the camshaft gearwheel cover (2).
•
Release and remove the spark plug.
•
Release and remove the timing reference screw (3)
and crankshaft screw (4).
•
•
•
Measure the valve clearance as follows:
1 - Turn the crankshaft counter clockwise.
2 - With piston at TDC, in the compression stroke,
align reference “I” (a) on magnet rotor to the fixed
reference (b) onto magnet cover.
2 - 48
PEGASO 650
GENERAL TECHNICAL INFORMATION
PEGASO 650
NOTE To set piston at TDC in the compression stroke, align
reference “I” on camshaft gearwheel to the fixed reference
on the cylinder head.
•
3 - Using a feeler gauge, check that valve clearance
stays within the indicated values and possibly adjust it.
Valve clearance (from cold)
Intake valve:
0.09 ÷ 0.13 mm (0.0035 ÷ 0.0051 in.)
Exhaust valve:
0.16 ÷ 0.20 mm (0.0063 ÷ 0.0079 in.)
•
•
•
Adjust the valve clearance as follows:
1 - Loosen the lock nut (5).
2 – Insert a suitably sized feeler gauge (see valve
clearance from cold) in-between the adjuster screw
end (6) and the valve tip.
•
3 – Turn the adjuster screw in direction (d) or (e), until
obtaining prescribed clearance using the feeler gauge.
•
Direction d
Valve clearance increases.
Direction e
Valve clearance decreases.
4 – Hold the adjuster screw (6) to prevent it from
moving and tighten the lock nut (5) to the specified
torque.
2 - 49
GENERAL TECHNICAL INFORMATION
•
3 - Using the feeler gauge, check again that valve
clearance is within the indicated values and possibly
repeat all steps relevant to valve clearance adjustment
until obtaining the prescribed clearance.
NOTE Lubricate the valve shims, see (LUBRICANT TABLE).
•
Using the suitable special tool (no. 8140850), tighten
the flywheel cover giving access to the timing
reference mark (3) and the flywheel cover giving
access to the crankshaft (4).
•
Install camshaft gearwheel cover (2) in its seat and
secure it with two washers and tighten the two screws
(1).
•
Install the exhaust tappet cover and tighten the four
screws.
2 - 50
PEGASO 650
PEGASO 650
•
GENERAL TECHNICAL INFORMATION
Install the intake tappet cover and tighten the four
screws.
2 - 51
FUEL SYSTEM
PEGASO 650
FUEL SYSTEM
3
3-1
FUEL SYSTEM
PEGASO 650
SUMMARY
3.1.
FUEL SYSTEM ................................................................................................................................................. 3
3.1.1.
DIAGRAM .................................................................................................................................................. 3
3.1.2.
REMOVING THE FUEL TANK .................................................................................................................. 4
3.2.
INJECTION ....................................................................................................................................................... 7
3.2.1.
INJECTION SYSTEM DIAGRAM .............................................................................................................. 7
3-2
PEGASO 650
3.1.
FUEL SYSTEM
FUEL SYSTEM
3.1.1.
DIAGRAM
Key:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Fuel tank
Fuel tank plug
Rubber block
Spacer
Flanged screw
Fuel level sensor
Fuel filter
Fuel pump flange seal
Flanged screw
Fuel delivery hose
3-3
FUEL SYSTEM
3.1.2.
•
•
•
•
•
•
3-4
REMOVING THE FUEL TANK
Remove the headlight, see (REMOVING THE
HEADLIGHT).
Remove the seat.
Release and remove the two screws, remove the right
support cover to release the wiring.
Raise the glove compartment cover using the suitable
control.
Release and remove the five screws.
Release and remove the two screws on motor for
opening the glove compartment, raise it and
disconnect the connector.
PEGASO 650
PEGASO 650
•
Remove the fuel filler plug.
•
•
•
Raise the glove compartment and slide out the fuel
breather hose.
Remove the three fuel breather hose clamps.
Slide out the fuel breather hose.
•
•
Remove the glove compartment with motor.
Tighten the fuel tank plug.
•
Disconnect the fuel tube.
FUEL SYSTEM
3-5
FUEL SYSTEM
•
Release and remove the fuel tank front screw.
•
Release and remove the two side screws (one on each
side).
•
Disconnect the fuel pump connector.
•
Remove the fuel tank.
3-6
PEGASO 650
PEGASO 650
3.2.
FUEL SYSTEM
INJECTION
3.2.1.
INJECTION SYSTEM DIAGRAM
Key:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Throttle body
Manifold D.46
Clamp for manifold D.72
Preformed tube D.5.5x11.5
Preformed tube D.13x18
Pressure sensor tube
Throttle body tube
Elastic clip D.11.5
Elastic clip D.11.5
Yellow elastic clip D.8.5
Elastic clip D.18
Air pressure sensor (MAP Sensor)
Flanged screw
3-7
ENGINE
PEGASO 650
ENGINE
4
4-1
ENGINE
PEGASO 650
SUMMARY
4.1.
REMOVING AND REFITTING THE ENGINE ................................................................................................... 3
4.1.1.
REMOVING THE ENGINE ........................................................................................................................ 3
4.1.2.
REFITTING THE ENGINE ....................................................................................................................... 15
4.2.
SECONDARY AIR SYSTEM........................................................................................................................... 26
4.2.1.
SECONDARY AIR ................................................................................................................................... 26
4-2
PEGASO 650
4.1.
4.1.1.
•
ENGINE
REMOVING AND REFITTING THE ENGINE
REMOVING THE ENGINE
•
To remove the engine, first remove the fuel tank, the
rear fairing panels, the sump guard, the battery and the
exhausts.
Remove the clamp and slide off the hose.
•
Remove the clamp and slide off the hose.
•
Remove the air box connector.
4-3
ENGINE
•
Remove the clamp from “fuel vapour recycle” hose.
•
Remove the tie from wiring.
•
Disconnect the speed sensor.
4-4
PEGASO 650
PEGASO 650
•
Disconnect the neutral sensor connector.
•
Disconnect the generator connectors.
•
Disconnect the stand sensor.
ENGINE
4-5
ENGINE
•
Loosen and remove the screw and disconnect the
ground cables.
•
Disconnect the starter motor power cable.
•
Loosen the nut and slide out the clutch cable from its
housing.
4-6
PEGASO 650
PEGASO 650
•
Disconnect the clutch cable from its lever.
•
Disconnect the spark plug cap.
•
Loosen the secondary air system tube tie.
•
Slide out the tube from the throttle body.
ENGINE
4-7
ENGINE
•
Disconnect the engine temperature sensor connector.
•
Disconnect the expansion tank breather hose.
•
Remove the tie from wiring.
•
Disconnect the generator connectors.
4-8
PEGASO 650
PEGASO 650
•
•
Prepare a container for collecting engine oil.
Unscrew and remove the screw.
•
Drain all engine oil.
•
Loosen and remove the two screws, collect the
spacers.
•
Remove the sprocket cover.
ENGINE
4-9
ENGINE
•
Remove the guide plate.
•
Straighten the safety washer.
•
•
Engage the first gear.
Loosen and remove the nut and collect the safety
washer.
4 - 10
PEGASO 650
PEGASO 650
•
Remove the chain from the sprocket and remove the
sprocket.
•
Loosen and remove the screw, collect the washer and
slide out the cable guides.
•
Disconnect the neutral sensor.
ENGINE
4 - 11
ENGINE
•
Loosen the ties and disconnect the tube from the air
box.
•
•
Support the engine with slings.
Loosen and remove the ring nut on swinging arm shaft.
•
Loosen the swinging arm adjuster bush.
4 - 12
PEGASO 650
PEGASO 650
•
Slide out the shaft from the left side.
•
•
Support the engine using a lift.
Working on the right side, loosen and remove the two
nuts.
Slide out the two screws, on the opposite side.
•
•
•
Working on the right side, loosen and remove the two
nuts from engine.
Slide out the two screws, on the opposite side.
•
Remove the engine front support.
ENGINE
4 - 13
ENGINE
•
•
Working on the right side, loosen and remove the top
nut.
Slide out the screw, on the opposite side.
•
Loosen and remove the two lower screws, collect the
washers.
•
Loosen the ties and remove the intake manifold.
•
Lower the engine.
4 - 14
PEGASO 650
PEGASO 650
4.1.2.
ENGINE
REFITTING THE ENGINE
•
Suitably fix the vehicle frame and lift the engine to
desired position.
•
Set the throttle body in the intake manifold and tighten
the clamp.
•
Tighten the two lower screws.
•
•
Set the screw.
Tighten the top nut.
4 - 15
ENGINE
•
Fit the engine front support.
•
•
Fit the two screws.
Working on the right side, tighten the two nuts on
engine.
•
•
Fit the two screws.
Working on the opposite side, tighten the two nuts.
•
•
Remove the engine lift.
Fit the shaft.
4 - 16
PEGASO 650
PEGASO 650
•
•
Fit the bushing and tighten it.
Tighten the pin.
•
Set the ring nut to the centring bush and tighten it.
•
•
Remove the slings.
Set the air box hose and tighten the clamp.
•
Connect the neutral sensor.
ENGINE
4 - 17
ENGINE
•
Fit the cable guides and tighten the screw with washer.
•
•
Install the sprocket.
Engage the first gear.
•
Fit the safety washer and tighten the nut.
4 - 18
PEGASO 650
PEGASO 650
•
Bend the safety washer.
•
Refit the guide plate.
ENGINE
4 - 19
ENGINE
•
Refit the sprocket cover.
•
Fit and tighten the two screws with spacers.
•
Fit and tighten the screw.
•
•
Connect the generator connectors.
Fit a tie to the wiring.
4 - 20
PEGASO 650
PEGASO 650
•
Connect the expansion tank breather hose.
•
Connect the engine temperature sensor connector.
•
Fit the tube to the throttle body.
•
Tighten the secondary air system tube tie.
ENGINE
4 - 21
ENGINE
•
Connect the spark plug cap
•
Connect the clutch cable to its lever.
•
Fit the clutch cable in its housing and tighten the nut.
•
Connect the starter motor power cable.
4 - 22
PEGASO 650
PEGASO 650
•
Connect the ground cables and tighten the screw.
•
Connect the stand sensor.
•
Connect the generator connectors.
ENGINE
4 - 23
ENGINE
•
Connect the neutral sensor connector.
•
•
Connect the speed sensor.
Fit ties to the wiring.
•
Refit the clamp to fuel vapour recycle hose.
4 - 24
PEGASO 650
PEGASO 650
•
Refit the air box connector.
•
Fit the hose and tighten the clamp.
•
Fit the hoses and tighten the clamp.
ENGINE
4 - 25
ENGINE
4.2.
4.2.1.
SECONDARY AIR SYSTEM
SECONDARY AIR
The Secondary Air System (SAS) has been developed to
reduce carbon oxide and unburnt hydrocarbon emissions in
vehicles that are not equipped with a lambda sensor. Natural
air (which is rich in oxygen) is channelled into the exhaust
stream to trigger a post-combustion process.
The secondary air system is especially useful when the
engine is idling and during warm-up, as the catalyst alone is
not capable of triggering post-combustion under these
operating conditions.
The post-combustion process is activated just outside of the
combustion chamber and raises the temperature of the
exhaust gasses for a quick light-off of the catalyst.
The secondary air system operates on pressure fluctuation
in the exhaust system.
During depression stages, the exhaust takes in oxygen-rich
air from the secondary air system so unburnt gasses in the
exhaust stream -hot and active- can complete the
combustion.
During overpressure stages, the secondary air reed valve
cuts air supply to prevent backflow.
The reed valve is equipped with a cut-off device -controlled
by a vacuum pick-up point on the intake manifold- that shuts
down additional air during cut-off stages, as exceedingly lean
exhaust gasses would lead to exhaust blowing, resulting in
exhaust valve and catalytic converter damage.
Valve stays closed when engine is running.
4 - 26
PEGASO 650
PEGASO 650
ENGINE
At low rpm the valve is activated to bring down carbon
monoxide emissions.
WARNING
When adjusting the CO rate, disable the
Secondary Air System or exhaust gas dilution
caused by the system would give a wrong
reading of the carbon monoxide percentage.
See CO ADJUSTMENT for instructions on how
to disable the SAS.
WARNING
After setting the CO rate, remember to reenable the Secondary Air System. The vehicle
will operate regularly even with system
disabled but in this case the harmful emissions
will be higher. Moreover, overheating might
derive due to air not circulating, thus causing
damages to SAS tubes and unions.
DANGER
Stop air from circulating using only suitable
equipment; using plugs to block off the air box
scoop might overheat and damage the
secondary air system and, if left there for a
certain time, the plug might enter the intake
channel while the vehicle is running, thus
jamming the throttle and making the vehicle
impossible to control.
4 - 27
CYCLE PARTS
PEGASO 650
CYCLE PARTS
5
5-1
CYCLE PARTS
PEGASO 650
SUMMARY
5.1.
OUTER STRUCTURES.................................................................................................................................... 3
5.1.1.
REMOVING THE HEADLIGHT.................................................................................................................. 3
5.1.2.
REMOVING THE REAR FAIRING............................................................................................................. 6
5.1.3.
REMOVING THE OIL SUMP GUARD ....................................................................................................... 8
5.2.
FRONT FORK................................................................................................................................................... 9
5.2.1.
DIAGRAM .................................................................................................................................................. 9
5.2.2.
REMOVING THE FORK LEGS................................................................................................................ 10
5.2.3.
INSTALLING THE FORK LEGS .............................................................................................................. 13
5.2.4.
CHANGING FORK FLUID ....................................................................................................................... 16
5.2.5.
DISASSEMBLY ....................................................................................................................................... 18
5.2.6.
REASSEMBLY ........................................................................................................................................ 21
5.2.7.
CHECK .................................................................................................................................................... 24
5.3.
STEERING BEARINGS .................................................................................................................................. 26
5.3.1.
ADJUSTING THE STEERING BEARINGS.............................................................................................. 26
5-2
PEGASO 650
5.1.
5.1.1.
CYCLE PARTS
OUTER STRUCTURES
REMOVING THE HEADLIGHT
•
Release and remove the six screws.
•
Remove the unit.
•
Disconnect the instrument panel connector.
5-3
CYCLE PARTS
•
The right bracket stays on the vehicle because wiring
is routed inside it. Release and remove the two outer
screws.
•
The left bracket stays secured to the headlight.
Release and remove the two inner screws.
•
Unscrew and remove the outer screw.
5-4
PEGASO 650
PEGASO 650
•
Release the headlight wiring connector.
•
Remove the headlight together with left mount.
CYCLE PARTS
5-5
CYCLE PARTS
5.1.2.
REMOVING THE REAR FAIRING
•
•
Remove the seat.
Working on either side, release and remove the two
side body panel screws and remove the side body
panels.
•
Loosen and remove the three passenger grab handle
screws.
Remove the grab handle.
•
•
5-6
Working on either side, loosen and remove the front
screw.
PEGASO 650
PEGASO 650
•
Working on either side, loosen and remove the top
screw.
•
Working on either side, loosen and remove the two
rear bottom screws.
•
Raise the rear fairing.
•
•
Disconnect the seat release cable.
Remove the rear fairing.
CYCLE PARTS
5-7
CYCLE PARTS
5.1.3.
REMOVING THE OIL SUMP GUARD
•
Release and remove the sump guard front screw.
•
Release and remove the sump guard rear screw.
•
Remove the sump guard, pay attention to the breather
hose.
5-8
PEGASO 650
PEGASO 650
5.2.
5.2.1.
CYCLE PARTS
FRONT FORK
DIAGRAM
Key:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
Stiffening plate
Left sleeve
Right sleeve
Sliding bush
Damping rod
Damper rod ring
Counter spring
Buffer
Washer
Allen cheese-headed screw M12x1.25x25
Guide bush
Ring
Oil seal
Snap ring
Dust seal
Spring
Spring seat
Spacer
O-ring
Plug
Protection
Allen cheese-headed screw M6x20
Complete fork leg
5-9
CYCLE PARTS
5.2.2.
•
•
•
•
REMOVING THE FORK LEGS
Remove the headlight, see (REMOVING THE
HEADLIGHT).
Remove the fuel tank, see (REMOVING THE FUEL
TANK).
Support the stand front part using stand (OPT).
Loosen and remove the two mudguard shell screws.
•
Working on either side, loosen and remove the screw
securing the front mudguard shell.
•
Loosen and remove the two screws securing the rear
mudguard shell.
•
Loosen and remove the two screws securing fork plate
and remove it.
5 - 10
PEGASO 650
PEGASO 650
•
•
Loosen and remove the two screws securing the front
brake calliper.
Remove the front brake calliper, pay special attention
not to pull the front brake lever to avoid pad jamming.
•
Unscrew the wheel shaft nut, collect the washer.
•
Working on either side, partially loosen the wheel shaft
pinch bolts and completely loosen the wheel shaft.
•
Support the front wheel and manually withdraw the
wheel shaft.
Remove the wheel by withdrawing it from the front.
•
CYCLE PARTS
5 - 11
CYCLE PARTS
•
Support the stanchion and loosen the three screws
securing stanchions to bottom yoke.
•
Loosen the screw securing stanchion to top yoke.
•
Slide out the stanchion, be careful not to damage it.
5 - 12
PEGASO 650
PEGASO 650
5.2.3.
INSTALLING THE FORK LEGS
•
Install the stanchion, be careful not to damage it.
•
Take the stanchion in position and tighten the screw
securing stanchion to top yoke.
•
Support the stanchion and loosen the three screws
securing stanchion to bottom yoke.
•
•
Smear some grease all along the wheel shaft.
Position the front wheel between the fork legs on the
support.
Move the wheel until its central hole and the holes on
the fork are aligned.
Set one of the two spacers between wheel hub and
fork right leg.
Position the other spacer between the wheel hub and
the fork left leg.
Push the wheel shaft fully home from the right side.
•
•
•
•
CYCLE PARTS
5 - 13
CYCLE PARTS
•
Tighten the wheel shaft clamp bolts to the right.
•
Install the washer to the shaft and tighten the wheel
shaft nut.
Tighten the wheel shaft clamp bolts to the left.
Loosen the wheel shaft clamp bolts to the right.
Press on the front end to settle the fork legs.
Tighten the wheel shaft clamp bolts to the right.
Remove the support that upon disassembly was put
under the tyre.
•
•
•
•
•
•
•
•
•
•
•
Fit the brake calliper, tighten the screws.
Remove the front support stand.
Remove the rear support stand.
With pulled brake lever, press the handlebar
repeatedly, thrusting the fork downwards. In this way
the fork legs will settle properly.
Position the vehicle on the stand.
Tighten the wheel shaft clamp bolts on either side.
5 - 14
PEGASO 650
PEGASO 650
•
Fit the fork plate and tighten the two screws.
•
Fit the rear mudguard shell and tighten the two screws.
•
Fit the front mudguard shell and tighten the two
screws, working on either side.
•
Tighten the two mudguard shell screws.
CYCLE PARTS
5 - 15
CYCLE PARTS
5.2.4.
CHANGING FORK FLUID
NOTE The following procedure applies to both fork legs.
Periodically change the fork fluid, see (REGULAR SERVICE
INTERVALS CHART).
NOTE While draining and filling fork fluid, the stanchion and
its parts should be clamped in a vice; be careful not to
tighten them too much and damage them; always use
aluminium protections.
DRAINING
Drain oil as follows:
•
Remove the fork leg, see (REMOVING THE FORK
LEGS).
•
Release and remove the top cap, be careful not to
damage the surface and the O-ring.
•
Remove the spring preload spacer.
•
Collect the washer.
5 - 16
PEGASO 650
PEGASO 650
•
Collect the spring.
•
Drain oil in a container.
CYCLE PARTS
NOTE Pump the tube inside the stanchion to help oil drain
out completely from the damper rod.
FILLING UP:
•
Tighten the sleeve in a vice in vertical position.
•
Pour oil in the tube.
•
Pump with the stanchion, ensure that oil completely
filled the damper rod.
•
Install the spring, the washer and the spring preload
spacer in this order.
•
Tighten the top cap.
5 - 17
CYCLE PARTS
5.2.5.
DISASSEMBLY
•
•
•
Drain fluid from the fork leg.
Clamp the sleeve in a vice, in horizontal position.
Loosen the bottom screw.
•
•
Clamp the sleeve in a vice, in vertical position.
Remove the dust seal, prise with a screwdriver.
WARNING
Be careful not to damage the tube edge and the
dust seal.
•
Pull up the dust seal to remove it.
•
Remove the snap ring from inside the sleeve, using a
screwdriver.
WARNING
Be careful not to damage the sleeve edge.
5 - 18
PEGASO 650
PEGASO 650
•
Unclamp the sleeve from the vice and remove the
damper rod with bottom buffer.
•
•
Clamp the sleeve in a vice, in vertical position.
Firmly remove the tube with lower sliding bush.
•
Remove the oil seal.
CYCLE PARTS
5 - 19
CYCLE PARTS
•
Remove the shim.
•
Remove the top sliding bush.
5 - 20
PEGASO 650
PEGASO 650
5.2.6.
CYCLE PARTS
REASSEMBLY
•
Fit the top sliding bush.
•
Fit the oil seal to the fork leg.
•
Fit the shim to the fork leg.
•
Install the damper rod with bottom buffer to the tube.
5 - 21
CYCLE PARTS
•
Install the tube to the sleeve, fit the shim and oil seal in
the relevant seats in the sleeve.
WARNING
Be careful not to damage the sleeve edge.
•
Fit the snap ring from inside the sleeve, using a
screwdriver.
•
Install the dust seal.
•
•
Clamp the sleeve in a vice, in horizontal position.
Tighten the bottom screw.
5 - 22
PEGASO 650
PEGASO 650
•
•
•
Clamp the sleeve in vertical position.
Pour oil inside the stanchion, ensure it fills up all
damper rod channels.
Pump with the stanchion, ensure that oil completely
filled the damper rod.
Insert the spring.
•
Insert the washer.
•
Install the spring preload spacer.
•
Start the plug onto stanchion tube, be careful not to
damage the O-ring. Tighten the plug to the specified
torque.
•
CYCLE PARTS
5 - 23
CYCLE PARTS
5.2.7.
CHECK
STANCHION
Inspect the sliding surface for scoring and/or scratching.
Eliminate minor scoring with wet sand paper (grain size 1).
Replace the stanchion if badly scored.
Check for stanchion buckling using a dial gauge.
Replace the stanchion if buckled beyond the service limit.
Buckling limit: 0.2 mm (0.00787 in.)
DANGER
NEVER attempt to straighten a buckled
stanchion as this would weaken the overall
structure leading to a dangerous riding
condition.
SLIDER
Inspect for damage and/or cracking. Replace if damaged.
SPRING
Check spring conditions and straightness.
Ensure that there is no interference between one winding
and the other.
Check conditions of the following components:
•
top sliding bush;
•
bottom sliding bush;
5 - 24
PEGASO 650
PEGASO 650
CYCLE PARTS
•
damper rod.
Change any component which is badly worn or damaged.
WARNING
Remove any residues from the bushes, be
careful not to scratch the surface.
Renew the following components on assembly:
•
seal;
•
dust seal;
•
O-ring on the plug.
5 - 25
CYCLE PARTS
5.3.
STEERING BEARINGS
5.3.1.
•
•
ADJUSTING THE STEERING BEARINGS
Position the vehicle on the rear stand.
Working on either side, loosen the screw securing the
fork leg to the top yoke.
Tightening torque: 5 kgm (50 Nm).
•
Remove the nut from the steering tube.
Tightening torque: 10 kgm (100 Nm).
•
•
Slide out the yoke complete with handlebar from the
fork legs.
Adjust bearing load, using the suitable tool (no.
8163500).
Tightening torque: 10 kgm (100 Nm).
5 - 26
PEGASO 650
WIRING DIAGRAM
PEGASO 650
WIRING DIAGRAM
6
6-1
WIRING DIAGRAM
PEGASO 650
INDICE
6.1.
ELECTRIC SYSTEM ........................................................................................................................................ 3
6.1.1.
CHECKING THE ELECTRICAL COMPONENTS ...................................................................................... 3
6.1.2.
WIRING DIAGRAM.................................................................................................................................... 8
6-2
PEGASO 650
6.1.
6.1.1.
WIRING DIAGRAM
ELECTRIC SYSTEM
CHECKING THE ELECTRICAL COMPONENTS
6-3
WIRING DIAGRAM
1 COIL
Primary coil resistance 3.4 ~ 4.6 ohm at 20 °C (68 °F)
(across red/black cable and orange cable)
Secondary coil resistance 10.4 ~ 15.6 kohm at 20 °C (68 °F)
(across red/black cable and spark plug cable)
Spark plug resistance 10.0% kohm at 20°C (68°F)
2 FUEL PUMP
Fuel pressure 324 kPa (3.24 kg/sq. cm, 46.1 psi)
3 BANK ANGLE SENSOR
Voltage to be measured (across yellow/green and black/blue
cable)
Less than 65° slant 0.4 ~ 1.4 V
More than 65° slant 3.7 ~ 4.4 V
Note: the sensor correct operation can also be checked via
the instrument panel.
4 TAIL LIGHT
Led
6-4
PEGASO 650
WIRING DIAGRAM
PEGASO 650
5 BATTERY
12 V – 10Amp/h MF
6 FUSES
20 A Fuse (yellow):
From battery to:
ignition switch, voltage regulator, electric cooling fan.
15A Fuse:
From ignition switch to:
all light loads.
7,5A Fuse:
From ignition switch to:
ignition, starting safety logic.
7 CONTROL UNIT
ECU
Pin
Pin
nr
nr
1
(-) Bobina
14
15
(-) iniettori
3
(+) Chiave
16
(+) in da rel.iniezione
4
(-) aria sec
17
(-) rel. luce
5
(+) sens.iniez. 5V
2
6
7
Massa
Massa
18
(-) rel. ventola
19
(-) rel. iniezione
20
(-) masse contr.iniez.
8
(+) Pick-up
21
Segnale TPS
9
Segnale vel.
22
Segnale press.asp.
23
Segnale Temp. Aria
10
11
Segnale caduta
24
Segnale Temp. Acqua
12
Linea k
25
Stamp.lat. da crusc.
13
In pulsante avv.
26
Neutral da crusc.
6-5
WIRING DIAGRAM
8 INTAKE AIR TEMPERATURE SENSOR
Intake air temperature sensor resistance:
2.21 ~ 2.69 ohm at 20 °C
9 STARTER MOTOR
12V Power supply
Max. absorption 0.8 kW
10 PICK UP SENSOR
192 ~ 288 ohm at 20°C (across blue/yellow and green/white)
11 GENERATOR
Max. power 290 Watt
Recharge voltage: 14V 5000 rpm (measured at battery
terminals)
Stator coil resistance 0.224 ~ 0.336 ohm at 20 °C (68 °F)
(across white cable and white cable)
6-6
PEGASO 650
PEGASO 650
WIRING DIAGRAM
12 COOLANT TEMPERATURE SENSOR
Coolant temperature sensor resistance:
2.21 ~ 2.69% kohm at 20°C (68°F)
0.310 ~ 0.326 kohm at 80°C (176°F)
0.140 ~ 0.145 kohm at 110°C (230°F)
13 HEADLIGHT
Low beam: 12 V – 55 W in H11
High beam: 12 V – 55 W in H11
Front parking light: 12 V – 5 W
14 INTAKE AIR PRESSURE SENSOR
Intake air pressure sensor voltage: 3.4 to 3.8 V with engine
off and key ON
15 SAS VALVE ACTUATOR
SAS solenoid valve resistance
18 ~ 22 ohm at 20 °C (68 °F) (across brown/red cable and
red/white cable)
6-7
WIRING DIAGRAM
6.1.2.
6-8
WIRING DIAGRAM
PEGASO 650
PEGASO 650
WIRING DIAGRAM
Key:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
Multiple connectors
Neutral switches
Clutch switch
Water sensor
Side stand switch
Speed sensor
Instrument panel
Light relay
---Warning horn
Left dimmer switch
Right dimmer switch
HAZARD button back lighting
Rear left direction indicator
Tail light
Number plate light
Rear right direction indicator
---Rear stoplight switch
Front stoplight switch
Electric lock
Immobilizer antenna
Key-operated switch
Fan
Fan relay
Injection relay
Starter relay
Starter motor
Fuses
Battery
Voltage regulator
Generator
Pick up
Fuel pump
Fuel level sensor
Map sensor
Secondary air
Injector
Throttle Position Sensor (TPS)
Water temperature sensor
Air temperature sensor
Spark plug
Coil
ECU
Right direction indicator
Low beam bulb
Parking light bulb
High beam bulb
Headlight
Front left direction indicator
Self-diagnosis connector
Diode
Diode module
WIRE COLOUR CODING
Ar
Az
B
Bi
G
Gr
M
N
R
Ro
V
Vi
Orange
Light blue
Blue
White
Yellow
Grey
Brown
Black
Red
Pink
Green
Violet
6-9