New Pegaso - use and maintenance aprilia part# 8102759 · 2014. 8. 9. · Pegaso 650. 3 This manual must be considered as an integral part of the vehicle and must always accompany

Pegaso 650

use and maintenance

DTP03aprilia part# 8102759

2 use and maintenance Pegaso 650

© 1996 aprilia s.p.a. - Noale (VE)

First edition: december 1996

Reprint: january 2000

Produced and printed by:editing division

Soave (VERONA) - ItalyTel. +39 - 045 76 11 911Fax +39 - 045 76 12 241E-mail: [email protected]

On behalf of:aprilia s.p.a.via G. Galilei, 1 - 30033 Noale (VE) - ItalyTel. +39 - 041 58 29 111Fax +39 - 041 44 10 54www.aprilia.com

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The following precautionary warnings areused throughout this manual in order toconvey the following messages:

Safety warning. When you find thissymbol on the vehicle or in the

manual, be careful to the potential riskof personal injury. Non-compliance withthe indications given in the messagespreceded by this symbol may result ingrave risks for your and other people’ssafety and for the vehicle!

Indications to make the opera-tions easier. Technical informa-

tion.

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The operations preceded by thissymbol must be repeated also on

the opposite side of the vehicle.

If not expressly indicated otherwise, for thereassembly of the units repeat the disas-sembly operations in reverse order.

The terms “right” and “left” are referred tothe rider seated on the vehicle in the nor-mal riding position.

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Before starting the engine, carefully readthis manual and in particular the section“SAFE DRIVE”.

Your and other people’s safety dependsnot only on your quickness of reflexes andon your agility, but also on what you knowabout the vehicle, on its efficiency and onyour knowledge of the basic information for“SAFE DRIVE”. Therefore, get a thoroughknowledge of the vehicle, in such a way asto be able to drive in the traffic safely.

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use and maintenance Pegaso 650 3

This manual must be consideredas an integral part of the vehicle

and must always accompany it, even incase of resale.

aprilia has carried out this manual with themaximum attention, in order to supply theuser with correct and updated information.However, since aprilia constantly im-proves the design of its products, theremay be slight discrepancies between thecharacteristics of your vehicle and thosedescribed in this manual. For any clarifica-tion concerning the information containedin this manual, do not hesitate to contactyour aprilia Official Dealer.For control and repair operations not ex-pressly described in this publication, for thepurchase of aprilia genuine spare parts,accessories and other products, as well asfor specific advice, contact exclusivelyaprilia Official Dealers and Service Cent-ers, which guarantee prompt and accurateassistance.

Thank you for choosing aprilia. We wishyou a nice ride.All rights as to electronic storage, repro-duction and total or partial adaptation, withany means, are reserved for all Countries.

In some countries the antipollutionand noise regulations in force re-

quire periodical inspections.

The user of the vehicle in these countriesmust:– contact an aprilia Authorized Dealer to

have the non-homologated componentsreplaced with others homologated foruse in the country in question;

– carry out the required periodical inspec-tions.

When asking your Dealer for spareparts, specify the spare parts code

indicated on the SPARE PARTS IDENTIFI-CATION LABEL.

Write down the identification code in thespace here below, in order to remember italso in case of loss or deterioration of thelabel. The label is positioned under the rider sad-dle, stuck to the frame.

In this manual the various versions are in-dicated by the following symbols:� �

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� optional

� catalytic version

VERSION:

� Italy � Poland

� United Kingdom � Israel

� Austria � South Korea

Portugal Malaysia

� Finland � Chile

Belgium � Bermuda

� Germany � United Statesof America

� France � Australia

� Spain � Brazil

� Greece � South Africa

� Holland � New Zealand

� Switzerland � Canada

� Denmark � Croatia

� Japan � Slovenia

� Singapore


��SAFE DRIVE .....................................................................................................5

BASIC SAFETY RULES: ............................................................................6CLOTHING .................................................................................................9ACCESSORIES........................................................................................10LOAD ........................................................................................................10

ARRANGEMENT OF THE MAIN ELEMENTS ...............................................12ARRANGEMENT OF THE INSTRUMENTS ...................................................14INSTRUMENTS AND INDICATORS ..............................................................14

INSTRUMENTS AND INDICATORS TABLE............................................15MAIN INDEPENDENT CONTROLS ...............................................................16

CONTROLS ON THE LEFT SIDE OF THE HANDLEBAR.......................16CONTROLS ON THE RIGHT SIDE OF THE HANDLEBAR ....................17IGNITION SWITCH...................................................................................18STEERING LOCK.....................................................................................18

AUXILIARY EQUIPMENT ...............................................................................19UNLOCKING/LOCKING THE SADDLE....................................................19GLOVE/TOOL KIT COMPARTMENT.......................................................19CRASH HELMET HOOK ..........................................................................20ANTI-THEFT HOOK .................................................................................20REAR LUGGAGE RACK ..........................................................................20

MAIN COMPONENTS.....................................................................................21FUEL.........................................................................................................21ENGINE OIL .............................................................................................21BRAKE FLUID (recommendations) ..........................................................22DISC BRAKES..........................................................................................22FRONT BRAKE ........................................................................................23REAR BRAKE...........................................................................................24ADJUSTING THE REAR BRAKE .............................................................24CLUTCH ...................................................................................................25COOLANT ................................................................................................26TYRES......................................................................................................27EXHAUST SILENCERS � ....................................................................28CATALYTIC SILENCERS � .................................................................28

INSTRUCTIONS FOR USE.............................................................................29PRELIMINARY CHECKING OPERATIONS.............................................29STARTING................................................................................................30DEPARTURE AND DRIVE .......................................................................32RUNNING-IN ............................................................................................34STOPPING ...............................................................................................34PARKING..................................................................................................34SUGGESTIONS TO PREVENT THEFT...................................................35

MAINTENANCE ..............................................................................................36REGULAR SERVICE INTERVALS CHART .............................................36IDENTIFICATION DATA...........................................................................37AIR CLEANER..........................................................................................38

CHECKING THE ENGINE OIL LEVEL AND TOPPING UP .................... 39CHANGING THE ENGINE OIL AND THE OIL FILTER........................... 40FRONT WHEEL....................................................................................... 42REAR WHEEL ......................................................................................... 44CHAIN...................................................................................................... 46REMOVING THE FUEL TANK................................................................. 48REMOVING THE RIGHT AND LEFT SIDES................................................................ 48CHECKING THE STEERING................................................................... 49CHECKINGTHE REAR FORK FULCRUM AXIS ........................................................ 49INSPECTING THE FRONT AND REAR SUSPENSIONS....................... 49REAR SUSPENSION............................................................................... 50REAR SUSPENSIONWITH HYDRAULIC PRELOAD ADJUSTMENT � ............................... 50IDLING ADJUSTMENT............................................................................ 52ADJUSTING THE ACCELERATOR CONTROL...................................... 52ADJUSTING THE COLD START CONTROL ( )................................... 52SPARK PLUG .......................................................................................... 53BATTERY................................................................................................. 54CHECKING THE ELECTROLYTE LEVEL.............................................. 55RECHARGING THE BATTERY............................................................... 55LONG INACTIVITY OF THE BATTERY ................................................. 55CHANGING THE FUSES......................................................................... 56CHECKING THE SIDE STAND AND THE SAFETY SWITCH ................ 57ADJUSTING THE HEADLIGHT BEAM ......................................................................... 58BULBS ..................................................................................................... 58CHANGING THE HEADLIGHT BULBS ................................................... 59CHANGING THE REAR LIGHT BULB.................................................... 60CHANGING THE FRONT DIRECTION INDICATOR BULBS.................. 60CHANGING THE REAR DIRECTION INDICATOR BULBS .................... 61CHANGINGTHE NUMBER PLATE BULB................................................................... 61

TRANSPORT.................................................................................................. 62DRAINING THE FUEL TANK................................................................... 62

CLEANING ..................................................................................................... 63LONG PERIODS OF INACTIVITY........................................................... 64

TECHNICAL DATA ........................................................................................ 65LUBRICANT TABLE ................................................................................ 68Importers ............................................................................................. 70-71WIRING DIAGRAM - Pegaso 650............................................................ 72WIRING DIAGRAM KEY - Pegaso 650 ................................................... 73

safe drive


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To drive the vehicle it is necessary to be inpossession of all the requirements pre-scribed by law (driving licence, minimumage, psychophysical ability, insurance,state taxes, vehicle registration, numberplate, etc.).

Gradually get to know the vehicle by driv-ing it first in areas with low traffic and/or pri-vate areas.

The use of medicins, alcohol and drugs orpsychotropic substances notably increasesthe risk of accidents.Be sure that you are in good psychophysi-cal conditions and fit for driving and payparticular attention to physical wearinessand drowsiness.

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

7use and maintenance Pegaso 650

Rigorously observe all road signs and na-tional and local road regulations.Avoid abrupt movements that can be dan-gerous for yourself and other people (forexample: rearing up on the back wheel,speeding, etc.), and give due considerationto the road surface, visibility and other driv-ing conditions.

Avoid obstacles that could damage the ve-hicle or make you lose control.Avoid riding in the slipstream created bypreceding vehicles in order to increaseyour speed.

Always drive with both hands on the han-dlebars and both feet on the footrests (oron the rider’s footboards), in the correctdriving posture.

Avoid standing up or stretching your limbswhile driving.


COOLEROIL

The driver should pay attention and avoiddistractions caused by people, things andmovements (never smoke, eat, drink, read,etc.) while driving.

Use only the vehicle’s specific fuels and lu-bricants indicated in the "LUBRICANTCHART"; check the oil, fuel and coolantlevels regularly.

If the vehicle has been involved in an acci-dent, make sure that no damage has oc-curred to the control levers, pipes, wires,braking system and vital parts.If necessary, have the vehicle inspected byan aprilia Official Dealer, who should care-fully check the frame, handlebars, suspen-sions, safety parts and all the devices thatyou cannot check by yourself.

Always remember to report any malfunc-tion to the technicians to help them in theirwork.

Never use the vehicle when the amount ofdamage it has suffered endangers yoursafety.


ONLY ORIGINALS

Never change the position, inclination orcolour of: number plate, direction indica-tors, lights and horns.

Any modification of the vehicle will result inthe invalidity of the guarantee.

Any modification of the vehicle and/or theremoval of original components can com-promise vehicle performance levels andsafety or even make it illegal.

We recommend respecting all regulationsand national and local provisions regardingthe equipment of the vehicle.

In particular, avoid all modifications that in-crease the vehicle’s performance levels oralter its original characteristics.

Never race with other vehicles.

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Before starting, always wear a correctlyfastened crash helmet. Make sure that it ishomologated, in good shape, of the rightsize and that the visor is clean.

Wear protective clothing, preferably in lightand/or reflecting colours. In this way youwill make yourself more visible to the otherdrivers, thus notably reducing the risk ofbeing knocked down, and you will be moreprotected in case of fall.

This clothing should be very tight-fittingand fastened at the wrists and ankles.Strings, belts and ties should not be hang-ing loose; prevent these and other objectsfrom interfering with driving by getting en-tangled with moving parts or driving mech-anisms.

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Do not keep objects that can be dangerousin case of fall, for example pointed objectslike keys, pens, glass vials etc. in yourpockets (the same recommendations alsoapply to passengers).

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The owner of the vehicle is responsible forthe choice, installation and use of any ac-cessory.Avoid installing accessories that coverhorns or lights or that could impair theirfunctions, limit the suspension stroke andthe steering angle, hamper the operation ofthe controls and reduce the distance fromthe ground and the angle of inclination inturns.Avoid using accessories that hamper ac-cess to the controls, since this can prolongreaction times during an emergency.Large fairings and windscreens assembledon the vehicle can produce aerodynamicforces capable of compromising the stabili-ty of the vehicle while driving.

Make sure that the equipment is well fas-tened to the vehicle and not dangerousduring driving. Do not install electrical de-vices and do not modify those already ex-isting to avoid electrical overloads, be-cause the vehicle could suddenly stop orthere could be a dangerous current short-age in the horn and in the lights. apriliarecommends the use of genuine accesso-ries (aprilia genuine accessories).

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Be careful and moderate when loadingyour luggage. Keep any luggage loaded asclose as possible to the centre of the vehi-cle and distribute the load uniformly onboth sides, in order to reduce imbalance tothe minimum. Furthermore, make sure thatthe load is firmly secured to the vehicle, es-pecially during long trips.


KG!

Avoid hanging bulky, heavy and/or danger-ous objects on the handlebars, mudguardsand forks, because the vehicle might re-spond more slowly in turns and its ma-noeuvrability could be unavoidably im-paired.

Do not place bags that are too bulky on thevehicle sides and do not ride with the crashhelmet hanging from its string, because itcould hit people or obstacles making youlose control of the vehicle.

Do not carry any bag if it is not tightly se-cured to the vehicle.Do not carry bags which protrude too muchfrom the luggage rack or which cover thelights, horn or indicators.Do not carry animals or children on theglove compartment or on the luggage rack.

Do not exceed the maximum load allowedfor each side-bag.When the vehicle is overloaded, its stabilityand its manoeuvrability can be compro-mised.


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1) Ignition switch/steering lock2) Fuel tank plug3) Fuel cock4) Battery5) Fuses6) Glove/tool kit compartment7) Passenger grab rail

8) Rear luggage rack9) Passenger footrest

10) Central stand �11) Side stand12) Shifting lever13) Expansion tank


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1) Front brake master cylinder2) Engine oil level plug-dipstick3) Horn4) Engine oil filter5) Rear brake control lever6) Anti-theft hook (for the aprilia “Body-

Guard” armored cable �)

7) Rear brake master cylinder8) Passenger footrest9) Passenger grab rail

10) Saddle lock11) Crash helmet hook12) Rear brake fluid tank13) Air cleaner


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1) Horn push button (�)2) Direction indicator switch (�)3) Dimmer switch (� - �)4) High beam signalling push button (�)5) Cold start lever (�)6) Clutch lever7) Left rear-view mirror8) Instruments and indicators9) Right rear-view mirror

10) Front brake lever11) Engine stop switch (� - �)12) Throttle grip13) Light switch ( - - •)14) Start push button (�)15) Ignition switch/steering lock (� - � - �)

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1) Green direction indicator warning light (�)2) Green neutral indicator warning light ()3) Red engine oil pressure warning light (�)4) Blue high beam warning light (�)5) Green low beam and parking light warning light ()6) Amber low fuel warning light (�)7) Revolution counter8) Total kilometres odometer9) Speedometer9) Speedometer - only km/h scale �

10) Coolant temperature indicator (�)11) Partial kilometres odometer12) Odometer trip control


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Description Function

Direction indicatorwarning light � It blinks when the direction indicators are on.

Neutral indicator warning light It comes on when the gear is in neutral.

Engine oil pressure warning light �

It comes on every time the ignition switch is brought to position "�" and the engine is not run-ning, thus checking the proper functioning of the lamp. If during this phase the lamp does not turn on, it must be replaced. The warning light must go off when the engine is running.

If the warning light comes on during the normal running of the engine, thismeans that the oil pressure in the circuit is insufficient. In this case, immediate-ly stop the engine and contact your �� Official Dealer.

High beam warning light � It comes on when the headlight is in "high beam" position or when the high beam signalling is operated.Parking light and low beam warning light It comes on when the lights are on.

Low fuel warning light � It comes on when the quantity of fuel left in the tank is about 6 � (electrical reserve). In this case, provide for immediate topping up, see p. 21 (FUEL).

Revolution counter

It indicates the number of revolutions of the engine per minute.

Never exceed the engine max. rpm, see p. 34 (RUNNING-IN).

Total kilometres odometer It indicates the total number of kilometres covered.Speedometer It indicates the driving speed.

Coolant temperature indicator �

It indicates the approximate temperature of the coolant in the engine. When the pointer starts moving beyond level "40", the temperature is sufficient for driving the vehicle. The normal running temperature range is indicated by the graduated area of the scale. If the pointer reaches the red area, stop the engine and check the coolant level, see p. 26 (COOLANT).

If the maximum allowed temperature is exceeded (red area of the scale), the en-gine may be seriously damaged.

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

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The electrical parts work only when the ignitionswitch is in position "�".

1) HORN PUSH BUTTON (�)The horn is activated when the push button is pressed.

2) DIRECTION INDICATOR SWITCH (�)To indicate the turn to the left, move the switch to the left; toindicate the turn to the right, move the switch to the right. Toturn off the direction indicator, press the switch on its centre.

3) DIMMER SWITCH (� - �)When the light switch (right side of the handlebar) is in posi-tion "", if the dimmer switch is in position "�", the highbeam comes on, while if it is in position "�", the low beamcomes on.

4) HIGH BEAM SIGNALLING PUSH BUTTON (�)It makes it possible to use the high beam for signalling toforthcoming vehicles while overtaking and in case of periland/or emergency.

5) COLD START LEVER (�)The starter for the cold start of the engine is operated by rotat-ing the lever "�" downwards.To disconnect the starter, move the lever "�" to its initial po-sition.

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The electrical parts work only when the ignitionswitch is in position "�".

1) ENGINE STOP SWITCH (� - �)

Do not operate the engine stop switch “��- �” inrunning conditions.

This is a safety or emergency switch.With the switch in position "�", it is possible to start the en-gine; the engine can be stopped by moving the switch to posi-tion "�".

With stopped engine and ignition switch in posi-tion "�", the battery may discharge.When the vehicle has come to rest, after stopping

the engine, move the ignition switch to position "�".

2) HEADLIGHT SWITCH ( - - •)When the light switch is in position "•", the lights are off; whenthe switch is in position "", the parking lights are on; whenthe switch is in position "", the low beam or the high beam ison.The high/low beam can be operated by means of the dimmerswitch, see p. 16 (CONTROLS ON THE LEFT SIDE OF THEHANDLEBAR).

3) START PUSH BUTTON (�)When the start push button "�" is pressed, the starter makesthe engine run. For the starting, see p. 30 (STARTING).

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The ignition switch is positioned on thesteering column plate.

The key (1) operates the ignitionswitch/steering lock, the saddle

lock and the fuel tank lock.Two keys are supplied together with thevehicle (one spare key).

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Never turn the key to position "�" in run-ning conditions, in order to avoid losingcontrol of the vehicle.

OPERATIONTo lock the steering:� Turn the handlebar completely leftwards.� Turn the key (1) to position “�” and

press it.� Release the key.

Turn the key and steer the han-dlebar at the same time.

� Rotate the key (1) anticlockwise (left-wards), steer the handlebar slowly untilthe key (1) reaches position “�”.

� Extract the key.

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Position Function Key removal

Steering lock

The steer-ing is locked.It is neither possible to start the engine, nor to switch on the lights.

It is possi-ble to remove the key.

Neither the engine, nor the lights can be switched on.

It is possi-ble to remove the key.

The engine and the lights can be switched on.

It is not pos-sible to remove the key.


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�� Position the vehicle on the stand, see

p. 35 (POSITIONING THE VEHICLE ONTHE STAND).

� Insert the key (1) in the saddle lock (2).� Turn the key (1) clockwise and raise and

remove the saddle.

Before lowering and locking thesaddle, make sure that you have

not left the key in the glove/tool kit com-partment.

� To lock the saddle, position the tang (3)in its seat, then lower and press the sad-dle, thus making the lock snap shut.

Before leaving, make sure thatthe saddle is properly locked.

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The compartment is positioned under therear part of the saddle;to reach it:� Unlock and raise the saddle.

The tool kit (4) includes:

– 3, 4, 5, 6, 8 mm Allen spanners– 5,5-7 mm double fork spanner– 8-11 mm double fork spanner– 10-13 mm double fork spanner– 19 mm simple fork spanner– 24 mm simple fork spanner– double-ended, cross-/cut-headed screw-

driver– screwdriver handle– 18 mm spark plug socket spanner– socket spanner rod– tool case

Max. allowed weight: 1.5 kg

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Thanks to the crash helmet hook, you nolonger have to carry the crash helmet withyou every time you park the vehicle.

Do not ride with the crash helmethanging from the hook, as thismay seriously compromise your

safety.

To hang the crash helmet:� Raise the saddle.� Withdraw the eyelet (1) of the cable (2)

from the hook (3).� Pass the cable (2) through the visor

opening or through the apposite loop onthe crash helmet.

� Insert the eyelet (1) completely in thehook (3).

� Lower the saddle and lock it.

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The anti-theft hook (4) is positioned on theright side of the vehicle, near the rider’sfootboard.

To prevent the vehicle from being stolen, itis advisable to secure it with the aprilia“Body-Guard” armored cable � (5), avail-able at any aprilia Official Dealer.

Do not use the hook to lift the ve-hicle or for any purpose otherthan securing the vehicle once it

has been parked.

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Max. allowed weight: 9 kg

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The fuel used for internal com-bustion engines is extremely in-flammable and in particular con-

ditions it can become explosive. It isimportant to carry out the refuelling andthe maintenance operations in a well-ventilated area, with the engine off. Donot smoke while refuelling or near fuelvapours, in any case avoid any contactwith naked flames, sparks and any oth-er heat source to prevent the fuel fromcatching fire or from exploding. Further,prevent fuel from flowing out of the fuelfiller, as it could catch fire when gettingin contact with the red-hot surfaces ofthe engine.In case some fuel has accidentally beenspilt, make sure that the area has com-pletely dried and before starting the ve-hicle verify that there is no fuel insidethe fuel filler neck.Since petrol expands under the heat ofthe sun and due to the effects of sun ra-diation, never fill the tank to the brim.Screw the plug up carefully after refuel-ling. Avoid any contact of the fuel withthe skin and the inhalation of vapours;do not swallow fuel or pour it from a re-ceptacle into another by means of atube.

KEEP AWAY FROM CHILDREN

Use on ly p remium grade pe t ro l(4 Stars �), in conformity with the DIN51600 standard, min. O.N. 98 (N.O.R.M.)and 88 (N.O.M.M.).� �: Use only unleaded petrol, in con-formity with the DIN 51607 standard, min.O.N. 95 (N.O.R.M.) and 85 (N.O.M.M.).FUEL TANK CAPACITY(reserve included): 22 �TANK RESERVE:5 � (mechanical reserve).To refuel, proceed as follows:� Insert the key (1) in the tank plug lock(2).� Turn the key clockwise, pull and open

the fuel flap.

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Remember:1 miles = 1.6 km1 km = 0.625 miles

Check the engine oil level every 500 km,see p. 39 (CHECKING THE ENGINE OILLEVEL AND TOPPING UP).It is necessary to change the engine oil af-ter the first 1000 km and successively eve-ry 6000 km, see p. 40 (CHANGING THEENGINE OIL AND THE OIL FILTER).

Use high-quality 5W-40 oil, seep. 68 (LUBRICANT TABLE).

Engine oil can cause seriousdamage to the skin if handledevery day and for long periods.

Wash your hands carefully after usingthe oil.

Do not dispose of the oil in the environ-ment.Put it in a sealed container and take it tothe filling station where you usually buyit or to an oil salvage center.

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This vehicle is provided withfront and rear disc brakes, with

separate hydraulic circuits.The following information refers to asingle braking system, but is valid forboth.

Sudden resistance or clearanceproblems on the brake lever maybe due to troubles in the hydrau-

lic system.For any doubt regarding the perfectfunctioning of the braking system andin case you are not able to carry out theusual checking operations, contactyour �� Official Dealer.

Make sure that the brake disc isneither oily nor greasy, especial-ly after maintenance or checking

operations.Check that the brake cable is neithertwisted nor worn out.Prevent water or dust from accidentallygetting into the circuit.

In case maintenance operations are tobe performed on the hydraulic circuit, itis advisable to use latex gloves.

If the brake fluid gets in contact with theskin or the eyes, it can cause serious ir-ritations.Carefully wash the parts of your bodythat get in contact with the liquid. Con-sult a doctor or an oculist if the liquidgets in contact with your eyes.

Do not dispose of the brake fluid in theenvironment.


When using the brake fluid, takecare not to spill it on the plasticor painted parts, since it can

damage them.

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The brakes are the parts thatmost ensure your safety and forthis reason they must always be

perfectly working.

The brake fluid must be changed once ayear by an �� Official Dealer.

This vehicle is provided with front and rearhydraulic disc brakes.When the disc pads wear out, the level ofthe fluid decreases to automatically com-pensate for their wear.

The front brake fluid tank is positioned onthe handlebar, near the front brake levercoupling.

The rear brake fluid tank is positioned un-der the right side; to reach it, remove theright side, see p. 48 (REMOVING THERIGHT AND LEFT SIDES).

Periodically check the brake fluid level inthe tanks, see p. 23 (FRONT BRAKE) andthe wear of the pads, see p. 51 (CHECK-ING THE BRAKE PAD WEAR).

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Checking

Position the vehicle on firm andflat ground.

� Keep the vehicle in vertical position androtate the handlebar, so that the fluidcontained in the tank is parallel to thebrake fluid tank cover.

� Make sure that the fluid level exceedsthe "MIN" mark.

� If the fluid does not reach the "MIN"mark, provide for topping up.

Topping up:

The brake fluid may flow out ofthe tank. Do not operate the frontbrake lever if the screws (2) are

loose or, most important, if the brakefluid tank cover has been removed.

� Unscrew the two screws (2) of the brakefluid tank (3).

� Remove the cover (4).

In order not to spill the brake flu-id while topping up, keep the flu-

id in the tank parallel to the tank rim (inhorizontal position).

� Remove the gasket (5).� Fill the tank (3) with brake fluid, see p. 68

(LUBRICANT TABLE), until it covers theglass (1) completely.

� To reassemble the components, followthe reverse order.

Check the braking efficiency. Ifnecessary, contact your ��Official Dealer.

In case of excessive stroke of the brakelever, of excessive elasticity or in casethere is air in the circuit, contact your�� Official Dealer, since it may benecessary to bleed the system.

In any case, the bleeding must be car-ried out after the first 1000 km.


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Checking


� Keep the vehicle in vertical position, sothat the fluid contained in the tank (1) isparallel to the plug (2).

� Make sure that the fluid level exceedsthe "MIN" mark.

� If the fluid does not reach the "MIN"mark, provide for topping up.

Topping up:

� Remove the right side, see p. 48 (RE-MOVING THE RIGHT AND LEFTSIDES).

The brake fluid may flow out ofthe tank. Do not operate the rearbrake lever if the brake fluid tank

plug is loose or has been removed.

� Unscrew and remove the plug (2).

In order not to spill the brake flu-id while topping up, keep the flu-

id in the tank parallel to the tank rim (inhorizontal position).

� Remove the gasket (3).� Fill the tank (1) with brake fluid, see p. 68

(LUBRICANT TABLE), until it reachesthe "MAX" mark.

� To reassemble the components, followthe reverse order.

Check the braking efficiency. I f necessary, contact your�� Official Dealer.

In case of excessive stroke of the brakelever, of excessive elasticity or in casethere is air in the circuit, contact your�� Official Dealer, since it may benecessary to bleed the system.

In any case, the bleeding must be car-ried out after the first 1000 km.


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The brake pedal is positioned ergonomical-ly during the assembly of the vehicle.If necessary, it is possible to adjust theheight of the brake pedal:� Loosen the lock nut (4).� Screw the brake adjuster (5) completely.� Screw the lock nut (6) completely on the

pump control rod (7).� Screw the pump control rod (7) com-

pletely, then unscrew it by giving 3-4turns.

� Unscrew the brake adjuster (5) until thebrake pedal reaches the desired height.

� Lock the brake adjuster (5) by means ofthe lock nut (4).

� Unscrew the pump control rod (7) andbring it in contact with the pump piston.

� Screw the rod in order to ensure a mini-mum clearance of 0.5÷1 mm betweenthe pump control rod (7) and the pumppiston.

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Make sure that there is a certainclearance between the brake ad-juster (5) and the point of con-

tact, to prevent the brake from remain-ing operated and the consequentuntimely wear of the braking elements.

Clearance between brake adjuster andpoint of contact: 0.5 ÷ 1 mm.

� Lock the pump control rod by means ofthe lock nut (6).

Check the braking efficiency.If necessary, contact an ��Official Dealer.

After the adjustment, make sure that thewheel rotates freely with releasedbrake.

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ADJUSTING THE CLUTCH


Adjust the clutch every 6000 km and if theengine stops or tends to advance when theclutch lever is pulled and the gears are en-gaged, or if the clutch slips causing a delayin the acceleration in comparison with theengine speed.

Carry out the adjustment by means of theadjuster (1).� Withdraw the protection element (2).� Loosen the lock nut (3).� Rotate the adjuster (1) until the idle

stroke of the clutch lever is about 10 mm.� Tighten the lock nut (3) and check the

adjustment again.

� Start the engine, see p. 30 (STARTING).� Operate the clutch completely and and

engage the 1st gear.

Make sure that the engine does not stop,that the vehicle does not tend to advanceor that the clutch does not slip during theacceleration phase or while the vehicle isrunning.

If it is not possible to obtain acorrect adjustment or if theclutch does not function proper-

ly, contact your �� Official Dealer.

Make sure that the clutch cableis intact: it must not present flat-

tened parts and the sheath must not beworn out in any point.

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Do not use the vehicle if thecoolant is below the minimumprescribed level.


Check the coolant level every 1000 km andafter long rides; change it every 2 years.

Have the coolant changed by an�� Official Dealer.

The coolant is made up of 50% water and50% antifreeze. This mixture is ideal formost running temperatures and ensuresgood protection against corrosion.Ii is advisable to keep the same mixturealso in the hot season, since in this waylosses due to evaporation are reduced andit is not necessary to top up very frequent-ly.The mineral salt deposits left in the radiatorby evaporated water are thus reduced andthe efficiency of the cooling system re-mains unchanged.If the outdoor temperature is below 0°,check the cooling circuit frequently and ifnecessary increase the antifreeze concen-tration (up to maximum 60%).For the cooling solution use distilled water,in order not to damage the engine.

Do not remove the expansiontank cap when the engine is hot,since the coolant is under pres-

sure and its temperature is high.If it gets in contact with the skin or withclothes it may cause severe burnsand/or damages.

The coolant is noxious:

DO NOT SWALLOW IT


Checking and topping up

Check the coolant level and topup the expansion tank with coldengine.

� Stop the engine and wait until it hascooled down.


� Keep the vehicle in vertical position, withthe two wheels resting on the ground.

� Make sure that the level of the fluid con-tained in the expansion tank (1) is includ-ed between the "MIN" and "MAX" marks(see figure).

� If not, unscrew and remove the fillingplug (2).

� Top up until the fluid reaches approx. the"MAX" mark. Do not exceed this level,otherwise the fluid will flow out of thetank when the engine is running.

� Put back the filling plug (2).

In case of excessive consump-tion of coolant and in case theexpansion tank (1) remains emp-

ty, make sure that there are no leaks inthe circuit. Have it repaired by an �� Official Dealer.

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This vehicle is provided with tyres with in-ner tube.

Periodically check the tyre infla-tion pressure at room tempera-ture.

If the tyres are hot, the measurement isnot correct.

Carry out the measurement especiallybefore and after long rides.If the inflation pressure is too high, theground unevenness cannot be damp-ened and is therefore transmitted to thehandlebar, thus compromising the driv-ing comfort and reducing the road hold-ing during turns.

If, on the contrary, the inflation pressureis too low, the tyre sides are undergreater stress and the tyre itself mayslip on the rim or it may become loose,with consequent loss of control of thevehicle. In case of sudden braking thetyres could even get out of the rims.Further, the vehicle could skid whileturning.Check the surface and the wear of thetyres, since tyres in bad conditions canimpair both the grip and the controlla-bility of the vehicle.Change the tyre when it is worn out orin case of puncture on the tread side, ifthe puncture is larger than 5 mm. Afterrepairing a tyre, have the wheels bal-anced. Use only tyres in the size sug-gested by aprilia, see p. 65 (TECHNICALDATA).Make sure that the tyres always havetheir valve sealing caps on, to preventthem from suddenly going flat. Change,repair, maintenance and balancing op-erations are very important and shouldbe carried out by qualified technicianswith appropriate tools.For this reason, it is advisable to havethe above mentioned operations carriedout by an �� Official Dealer or by aqualified tyre repairer.

If the tyres are new, they may still becovered with a slippery film: drive care-fully for the first miles. Do not oil thetyres with unsuitable fluids.If the tyres are old, even if not complete-ly worn out, they may become hard andmay not ensure good road holding.In this case, replace them.

INFLATION PRESSURESOLO RIDERfront:off-road ...........................180 kPa (1.8 bar)asphalted road................180 kPa (1.8 bar)

rear: off-road ...........................190 kPa (1.9 bar)asphalted road ...............190 kPa (1.9 bar)

RIDER AND PASSENGERfront:off-road ...........................180 kPa (1.8 bar) asphalted road................180 kPa (1.8 bar)rear: off-road ...........................190 kPa (1.9 bar) asphalted road................220 kPa (2.2 bar)

MINIMUM TREAD DEPTH LIMITfront: 2 mmrear: 2 mm

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Tampering with noise controlsystem prohibited.

Owner’s are warned that the law may pro-hibit:� The removal or rendering inoperative by

any person other than for purposes ofmaintenance, repair or replacement, ofany device or element of design incorpo-rated into any new vehicle for the pur-pose of noise control prior to its sale ordelivery to the ultimate purchaser orwhile it is in use; and

� the use of the vehicle after such deviceor element of design has been removedor rendered inoperative by any person.

Check the exhaust silencer and the silenc-er pipes, making sure that there are neithersigns of rust, nor holes and that the ex-haust system can work effectively.If the noise produced by the exhaust sys-tem increases, immediately contact youraprilia Official Dealer.

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Avoid parking the vehicle-cata-lytic version near dry brushwood or in places easily accessi-

ble to children, as the catalytic silenc-ers becomes extremely hot during use;be very careful and avoid any kind ofcontact before they are completelycooled down.

The catalytic vehicle is fitted with a silencerwith metal catalytic converter of the "plati-num-rhodium bivalent" type.This device provides for the oxidation ofthe CO (carbon monoxide) and of the HC(unburned hydrocarbons) contained in theexhaust gases, changing them into carbondioxide and steam, respectively.

Do not use leaded petrol, since itcauses the destruction of thecatalytic converter.

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Before departure, always carryout a preliminary checking of thevehicle to make sure that it func-

tions correctly and safely, see the fol-lowing table (PRELIMINARY CHECKINGOPERATIONS). The non-performance ofthese checking operations can causesevere personal injuries or damages tothe vehicle.

Do not hesitate to consult your ��Official Dealer in case there is some-thing you do not understand about thefunctioning of some controls or in caseyou suspect or discover some irregular-ities.It does not take long to carry out acheck-up and this operation ensuresyou much more safety.

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Component Check PageFront and rear discbrakes

Check the functioning, the idle stroke of the controllevers, the fluid level and make sure there are no leaks.Check the wear of the pads. If necessary, top up the fluidtank.

22-2324-51

Accelerator Make sure that it works smoothly and that it is possible toopen and close it completely, in all steering positions. If necessary, adjust and/or lubricate it.

52

Engine oil Check and/or top up if necessary. 21-39-40Wheel/tyres Check the tyre surface, the inflation pressure, wear and

tear and any damage. 27

Brake levers Make sure that they work smoothly. If necessary, lubri-cate the articulations and adjust the stroke. 22-23-24

Steering Make sure that the steering rotates smoothly, without anyclearance or slackening. 49

Clutch The idle stroke at the end of the clutch lever must beabout 10 mm; the clutch must operate without jerkingand/or slipping.

25

Side stand and center stand �

Make sure that it works smoothly and that the spring ten-sion brings it back to its normal position. If necessary,lubricate joints and hinges. Make sure that the safetyswitch on the side stand operates correctly.

57

Fastening elements Make sure that the fastening elements are not loose. If necessary, adjust or tighten them. –

Drive chain Check the slack. 46-47Fuel tank Check the fuel level and top up, if necessary. Make sure

there are no leaks or air bubbles in the circuit. 21-48-62

Coolant The coolant level in the expansion tank must be includedbetween the "MIN" and "MAX" marks. 26

Lights, warning lights, horn and electric devices

Check the proper functioning of the acoustic and visualdevices. Change the bulbs or intervene in case of failure. 54÷61


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Exhaust gases contain carbonmonoxide, which is extremelynoxious if inhaled.

Avoid starting the engine in closed orbadly-ventilated rooms.The non-observance of this warningmay cause loss of consciousness oreven lead to death by asphyxia.

With the side stand down, theengine can be started only if the

gears are in neutral; in this case, if youtry to engage the gears, the enginestops.With the side stand up, it is possible tostart the engine either in neutral gear orwith engaged gears and pulled clutchlever.

� Let the stand up.� Get on the vehicle.� Move the fuel tap lever (1) to position

"ON".� Rotate the key (2) and move the ignition

switch to position "!".At this point the engine oil pressurewarning light """ must come on.

� Lock at least one wheel, by pulling abrake lever.

� Position the shifting lever in neutral(green warning light "#" on).

� Move the engine stop switch (3) to posi-tion "!".

� Make sure that the light switch (4) is inposition “•”.

To avoid excessive wear on thebattery, do not keep the start

push button "$" pressed for more thanfifteen seconds. If the engine does notstart in this lapse of time, wait ten sec-onds and then press the start push but-ton "$" again.

� Press the start push button "$" (5) with-out accelerating, then release it as soonas the engine starts.

As soon as the engine has start-ed, the engine oil pressure warn-ing light """ must go out. If this

does not occur, or if the warning lightcomes on while the engine is running,this means that there is no sufficientpressure in the circuit. In this case, stopthe engine immediately and contact an�� Official Dealer.

� If the vehicle is started with cold engine,rotate the cold start lever " " (6) down-wards.

Never press the start push button"$" (5) with the engine running:you may damage the starter.

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� Keep at least one brake lever pulled anddo not accelerate until you start.

Never leave abruptly with coldengine.To reduce the emission of pollut-

ing substances and the consumption offuel, warm the engine up by proceedingat low speed for the first miles.

� Ride at reduced speed for the first miles,in order to warm the engine up.

� Rotate the cold start lever " " (6) up-wards after the engine has warmed up.

Starting with flooded engineIf the starting is not carried out properly or ifthere is too much fuel in the intake ductsand in the carburettor, the engine may getflooded.

To clean a flooded engine:� Carry out the first eight operations de-

scribed for the starting.� Rotate the cold start lever " " (6) up-

wards.� Press the start push button "$" (5) for a

few seconds (letting the engine spinover) with completely open throttle(Pos. B).

Starting with cold engineWhen the room temperature is low (about0° C), it may be difficult to start the engineat the first attempt.

In this case:� Rotate the cold start lever " " (6) down-

wards.� Press the start button "$" (5) for at least

ten seconds and at the same time rotatethe throttle grip slightly.

If the engine starts� Release the start push button "$" (5)

and the throttle grip.� Rotate the cold start lever " " (6) up-

wards.If the idling is unstable, twist the throttlegrip slightly and frequently.

If the engine does not startWait f or a few seconds and then repeatthe starting procedure.

STARTING AFTER A LONG PERIOD OFINACTIVITYAfter a long period of inactivity, make thestarter run for about ten seconds withoutaccelerating, in order to ensure the filling ofthe float chamber. To start the engine,slightly open the throttle and carry out thestarting procedure.

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Before departure, carefully readthe "RIDING SAFELY" chapter,

see p. 5 (RIDING SAFELY).

If you run out of the "standard" fuel quantitywhile riding, move the fuel tap lever (1) toposition "RES", in order to use the fuel re-serve.Fuel reserve: 5 � (mechanical reserve).

Immediately provide for toppingup, see p. 21 (FUEL).

Properly adjust the inclination ofthe rear-view mirrors. If youdrive without passenger, make

sure that the rear foot rests are closed.

If you drive with a passenger, in-struct him/her so that he/shedoes not create problems during

manouvres. Before leaving, make surethat the stands are completely folded.

To leave:� Ride at reduced speed for the first miles,

in order to warm the engine up.� With released throttle grip (Pos. A) and

engine idling, pull the clutch lever (2)completely.

� Engage the first gear, by pressing theshifting lever (3) downwards.

� Release the brake lever (pulled on thestarting).

On departure, the abrupt releaseof the clutch lever may cause theengine to stall or the vehicle to

jerk forwards.

Never accelerate abruptly or ex-cessively when releasing theclutch lever, in order to prevent

the clutch from "slipping" (slow re-lease) or the front wheel from raising(rearing up) (quick release).

� Slowly release the clutch lever (2) and atthe same time accelerate by rotating thethrottle grip moderately (Pos. B).The vehicle will start moving.

Never exceed the recommendedrpm, see p. 34 (RUNNING-IN).

� Increase the speed by gradually rotatingthe throttle grip (Pos. B), without ex-ceeding the recommended rpm, seep. 34 (RUNNING-IN).

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To engage the second gear:

Proceed quickly.Never ride the vehicle at too lowrpm.

� Release the throttle grip (Pos. A), pullthe clutch lever (2) and lift the shifting le-ver (3). Release the clutch lever (2) andaccelerate.

� Repeat the last two operations and shiftup.

The downshifting should be carried out inthe following situations:� When riding downhill or when braking, in

order to increase the braking action byusing the compression of the engine.

� When riding uphill, if the gear engaged isnot suitable to the speed (high gear,moderate speed) and the engine rpm de-creases.

Shift the gears one by one; thesimultaneous downshifting ofmore than one gear may make

you exceed the maximum rpm (red line).

Before and during the downshifting, re-lease the throttle grip and decelerate, inorder to avoid the "red line".

To shift down, proceed as follows:� Release the throttle grip (Pos. A).� If necessary, pull the brake levers mod-

erately and decrease the speed of thevehicle.

� Pull the clutch lever (2) and lower theshifting lever (3) to shift down.

� If the brake levers are pulled, releasethem.

� Release the clutch lever and acceleratemoderately.

Avoid opening and closing thethrottle grip repeatedly and con-tinuously, so that you do not ac-

cidentally lose control of the vehicle.If you have to brake, close the throttleand put on both brakes in order to ob-tain uniform deceleration, properly ex-erting pressure on the braking parts.

By putting on the front brake only or therear brake only, you reduce the brakingforce considerably, thus running therisk of locking one wheel and conse-quently losing grip.

If you stop uphill, decelerate completelyand use the brakes only to keep the ve-hicle steady.The use of the engine to keep the vehi-cle steady may cause the overheating ofthe clutch.

Before beginning to turn, slowdown or brake driving at moder-ate and constant speed or accel-

erating slightly; avoid braking at the lastmoment: it would be very easy to skid.

If the brakes are operated continuouslyon downhill stretches, the friction sur-faces may overheat, thus reducing thebraking efficiency. Exploit the enginecompression and shift down by puttingon both brakes intermittently.Never drive downhill with the engineoff!

When visibility is insufficient, switch onthe low beam even during the day, in or-der to make your vehicle more visible.In case of wet ground or scarce wheelgrip (snow, ice, mud, etc.), drive slowly,avoiding sudden brakings or manoeu-vres that could make you lose grip andfall down.

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Pay the utmost attention to anyobstacle or variation of theground. Uneven roads, rails,

manhole covers, indications painted onthe road surface, building site metalplates become rather slippery by rain.For this reason all these obstacles haveto be carefully avoided, driving smooth-ly and bending the vehicle as little aspossible. Always use the turn indicatorsin time when you intend to change laneor direction, avoiding sharp and dan-gerous movements.Switch off the direction indicators assoon as you have changed direction.Be extremely careful when you overtakeother vehicles or are overtaken.In case of rain, the water cloud createdby big vehicles reduces visibility; theair shift may make you lose control ofthe vehicle.

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The running-in of the engine is important toensure its correct functioning.If possible, drive on hilly roads and/orroads with many bends, so that the engine,the suspensions and the brakes undergo amore effective running-in.

Keep to the following indications:� Do not open the throttle completely if the

speed is low, both during and after therunning-in.


� During the first 100 km put on the brakeswith caution, avoiding sharp and pro-longed brakings. This ensures a correctbedding-in of the pads on the brake disc.

� During the first 500 km, never exceed4000 rpm.

� Between the first 500 and 1000 km, nev-er exceed 5000 rpm.

After the first 1000 km, carry outthe checking operations indicat-ed in the column "After running-

in" of the REGULAR SERVICE INTER-VALS CHART, see p. 36 (REGULARSERVICE INTERVALS CHART), in orderto avoid hurting yourself or other peo-ple and/or damaging the vehicle.

� Between the first 1000 and 2000 kmdrive more briskly, change speed anduse the maximum acceleration only for afew seconds, in order to ensure bettercoupling of the components; never ex-ceed 5500 rpm.

� After the first 2000 km you can expectbetter performance from the engine,however, without exceeding the max rpm(6250 rpm).

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I f possible, avoid stoppingabruptly, slowing down suddenlyand braking at the last moment.

� Release the throttle grip, gradually puton the brakes and at the same time shiftdown in order to decrease the speed,see p. 32 (DEPARTURE AND DRIVE).

Once the speed has decreased, beforestopping the vehicle:� Pull the clutch lever in order to prevent

the stopping of the engine.

When the vehicle has come to rest:� Position the shifting lever in neutral

(green warning light "#" on).� Release the clutch lever.� While the vehicle is at rest, keep at least

one brake on.

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Park the vehicle on firm and flatground, to prevent it from fallingdown.

Neither lean the vehicle against walls,nor lay it on the ground.Make sure that the vehicle and especial-ly its red-hot parts do not represent adanger for persons and children. Do notleave the vehicle unattended when theengine is on or the key is inserted intothe ignition switch.Do not sit on the vehicle when the standis down.

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Engine maximum rpm for the running-in

Mileage km Max. rpm0 - 500 4000

500 - 1000 50001000 - 2000 5500

over 2000 6250

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� Stop the vehicle, see p. 34 (STOPPING).� Move the engine stop switch (1) to posi-

tion "%".� Rotate the key (2) and move the ignition

switch (3) to position "%".� Position the vehicle on the stand, see

beside (POSITIONING THE VEHICLEON THE STAND).

� Move the fuel tap lever (4) to position"OFF".

Never leave the key in the igni-tion switch.

� Lock the steering, see p. 18 (STEERINGLOCK) and extract the key (2).

POSITIONING THE VEHICLE ON THESTAND

CENTRAL STAND �� Seize the left grip and the left passenger

grab rail (5).� Press the stand lever (6) downwards.

SIDE STAND� Seize the left grip and the left passenger

grab rail (5).� Press the side stand with your right foot

and extend it completely (7).� Incline the vehicle until the stand rests

on the ground (8).� Steer the handlebar completely left-

wards.

Make sure that the vehicle is sta-ble.

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NEVER leave the ignition key inserted andalways use the steering lock.Park the vehicle in a safe place, possibly ina garage or a protected place.

If possible, use the appropriate aprilia“Body-Guard” armored cable �, or an ad-ditional anti-theft device.

Make sure that all documents are in orderand the road tax has been paid.Write down your personal data and tele-phone number in this page, to facilitate theidentification of the owner in case of findingafter theft.

SURNAME: ...............................................

NAME: .......................................................

ADDRESS: ................................................

...................................................................

TELEPHONE NO.: ....................................

Very often stolen vehicles areidentified thanks to the data writ-

ten in the use/maintenance manual.

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Before beginning any mainte-nance operation or any inspec-tion of the vehicle, stop the en-

gine, extract the key from the ignitionblock, wait until the engine and the ex-haust system have cooled down and ifpossible lift the vehicle by means of theproper equipment, on firm and flatground. Keep away from the red-hotparts of the engine and of the exhaustsystem, in order to avoid burns.The vehicle is made up of not edibleparts. Never bite, suck, chew or swallowany part of the vehicle for any reason.

If not expressly indicated other-wise, for the reassembly of theunits repeat the disassembly op-

erations in reverse order.

Ordinary maintenance operations can usu-ally be carried out by the user, but some-times a basic knowledge of mechanics andspecific tools are required. If you need as-sistance or technical advice, consult youraprilia Official Dealer, who can ensure youprompt and accurate servicing.After any maintenance operation, carry outthe "Preliminary checking operations", seep. 29 (PRELIMINARY CHECKING OPER-ATIONS).


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Component After running-in (1000 km)Every 6000 km

or 8 monthsEvery 12000 km

or 16 months

Battery - electrolyte level � �Spark plug � �Carburettors � �Drive chain every 500 km: �Timing chain �Wheel centering �Steering bearings and steering � �Wheel bearings �Air cleaner � �Engine oil filter � �Engine oil filter (on the frame) �Clutch clearance � �Tappet clearance � �Braking systems � �Cooling system � �Light system � �Brake fluid � every year: �Brake fluid �Coolant every 1000 km:�/every 2 years:�Fork oil �Engine oil � every 500 km:�/every 6000 km:�Tyre pressure � every month: �Engine idling rpm � �Fuel cock � �Nut, bolt, screw tightening � �Suspensions and attitude � �Brake fluid bleeding �Spoke tension � �Fuel pipes � every 4 years: �Front and rear brake pad wear � �� = check, clean, adjust, lubricate or change, if necessary. � = clean; � = change; � = adjust.Carry out the maintenance operations more frequently if you use the vehicle in rainy and dusty areas oron uneven ground. Have maintenance operations on the components indicated by carried out by�� Official Dealers ONLY.


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It is a good rule to write down the frameand engine numbers in the space providedin this manual.

The frame number can be used for the pur-chase of spare parts.

Do not alter the identificationnumbers if you do not want to in-

cur severe penal and administrativesanctions. In particular, the alteration ofthe frame number results in the immedi-ate invalidity of the guarantee.

ENGINE NUMBER

The engine number is stamped on the rearpart of the left engine crankcase.

Engine no.

FRAME NUMBER

The frame number is stamped on the rightside of the steering column.

Frame no.

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Check the air cleaner every 6000 km or 8months, change it every 12000 km or morefrequently if the vehicle is used on dusty orwet roads.It is possible to clean the air cleaner partial-ly after using the vehicle on this kind ofroads.

The partial cleaning of the filterdoes not exclude or postponethe replacement of the filter it-self.

REMOVAL� Remove the saddle, see p. 19 (UN-

LOCKING/LOCKING THE SADDLE).� Rotate the air cleaner conveyor (1)

clockwise, raise and remove it.� Extract the air cleaner (2).

Partial cleaning

Do not press or strike the metalnet of the air cleaner.Do not use screwdrivers or alike.

� Seize the air cleaner vertically and strikeit more than once on a clean surface.

� If necessary, clean the filter with a com-pressed air jet (directing it from the in-side towards the outside of the filter).

� Clean the outer part of the air cleanerwith a cloth.

Changing

� Replace the air cleaner with a new oneof the same type.

� Make sure that the gasket (3) is intact; ifit is damaged, change it.

� Every 6000 km, remove the plug (4), sothat any impurity that may have accumu-lated inside the filter case can be dis-charged.

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Carefully read p. 21 (ENGINE OIL) andp. 36 (MAINTENANCE).


Check the engine oil level every 500 km,change it after the first 1000 km and suc-cessively every 6000 km, see p. 40(CHANGING THE ENGINE OIL AND THEOIL FILTER).

To carry out the checking:


� Stop the engine and let it cool down forat least ten minutes, in order to allow theoil to flow back to the oil pan and to cooldown.

� Start the engine, see p. 30 (STARTING)and let it idle for about one minute, in or-der to ensure the filling up of the oil tank.

� Stop the engine.� Keep the vehicle in vertical position, with

the two wheels resting on the ground.

The non-performance of the op-erations described above may

result in a wrong measurement of thelevel.

� Unscrew and extract the plug/dipstick(1).

� Clean the part in contact with the oil witha clean cloth.

� Insert the plug/dipstick in the filling hole(2) completely, without tightening it.

� Withdraw the plug/dipstick (1) again andread the oil level on the graduated mark-ing:MAX = maximum levelMIN = minimum levelThe difference between "MAX" and"MIN" is about 300 cm�.

� The level is correct if the oil reaches ap-prox the "MAX" mark on the dipstick.

Never exceed the "MAX" mark,nor leave the oil below the "MIN"mark, in order to avoid serious

damage to the engine.

� If necessary, top up the engine oil tankthrough the filling hole (2), after extract-ing the plug/dipstick (1).

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Carefully read p. 21 (ENGINE OIL) andp. 36 (MAINTENANCE).


Check the engine oil level every 500 km,change it after the first 1000 km and suc-cessively every 6000 km.

To change the oil, proceed as follows:


� Stop the engine and let it cool down forat least ten minutes, in order to allow theoil to flow back to the oil pan and to cooldown.

� Start the engine, see p. 30 (STARTING)and let it idle for a few minutes, in orderto facilitate the outflow of the oil duringthe draining phase.

� Stop the engine.� Keep the vehicle in vertical position, with

the two wheels resting on the ground.

When warmed up, the enginecontains hot oil; therefore, whilecarrying out the operations de-

scribed here below be particularly care-ful, in order to avoid burns.


� Unscrew and remove the four screws(2).

� Remove the oil pan guard (3).� Put a container (4) with at least 2500 cm�

capacity in correspondence with thedrain plug on the frame (5).

� Unscrew and remove the drain plug posi-tioned on the frame (5).

� Drain the oil and let it drip into the con-tainer (4) for a few minutes.

� Check and if necessary change the seal-ing washer of the drain plug positionedon the frame (5).

� Screw and tighten the drain plug posi-tioned on the frame (5).

Driving torque of the drain plug posi-tioned on the frame: 27 Nm (2.7 kgm).

� Move the container (4) and position it un-der the engine base, in correspondencewith the drain plug positioned on the en-gine (6).

� Unscrew and remove the drain plug posi-tioned on the engine (6).

� Drain the oil and let it drip inside the con-tainer (4) for a few minutes.

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5


� Remove the metal residues from thedrain plug (6) magnet.

� Check and if necessary replace the seal-ing washer of the drain plug (6).

Change the sealing washer of the drainplug (6) every 12000 km (or every sec-ond engine oil change).

� Screw and tighten the drain plug (6).

Driving torque of the drain plug (6) posi-tioned on the engine: 40 Nm (4 kgm).

Clean the engine oil filter positioned onthe frame (7) every 12000 km (or everysecond engine oil change).

Prepare a pipe clamp (8) to re-place the original one (special

type).

� Loosen the clamp (9) and disconnect thepipe (10).

� Unscrew and remove the engine oil filterpositioned on the frame (7) and clean itwith a compressed air jet.

� Check the seal of the engine oil filter po-sitioned on the frame (7), screw andtighten it.

Driving torque of the engine oil filter po-sitioned on the frame: 35 Nm (3.5 kgm).

� Connect the pipe (10) and tighten thenew clamp (8).

Change the engine oil filter after thefirst 1000 km and successively every6000 km (or every time you change theoil).

� Unscrew the two screws (11) and re-move the cover (12).

� Remove the engine oil filter (13).� Spread an oil film on the sealing ring of

the new engine oil filter.� Fit the new engine oil filter.� Put back the cover (12), screw and tight-

en the two screws (11).� Pour about 1600 cm� of engine oil

through the filling opening (14), see p. 68(LUBRICANT TABLE).

� Tighten the plug/dipstick (1).� Start the engine, see p. 30 (STARTING)

and let it idle for about one minute, in or-der to ensure the filling up of the engineoil circuit.


� Pour other 600 cm� of oil through the fill-ing opening (14).

� Check the oil level, see p. 39 (CHECK-ING THE ENGINE OIL LEVEL ANDTOPPING UP)).

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The disassembly and reassem-bly of the front wheel may be dif-ficult for unskilled operators. If

necessary, contact an �� OfficialDealer.If you want to perform these operationspersonally, keep to the following in-structions.

Carefully read p. 36 (MAINTENANCE).

While disassembling and reassemblingthe wheel, be careful not to damage thebrake pipe, the disc and the pads.Before performing the operations de-scribed here below, let the engine andthe silencer cool down until they reachroom temperature, in order to avoidburns.

DISASSEMBLY� Position the vehicle on the stand, see


� Unscrew and remove the four screws (1).� Remove the oil pan guard (2).

Due to the weight and dimen-sions of the vehicle, the follow-ing operation cannot be per-

formed by one person only.Proceed with care and make sure thatyou can support the weight of the vehi-cle.

Weight of the vehicle withoutdriver (ready for starting): 200 kg

� Raise the front part of the vehicle and havea suitable support (the weight of whichshould be about 350 mm) placed under theengine, so that the front wheel can rotatefreely and the vehicle cannot fall down.

The vehicle may fall down.Provide for balancing the vehi-cle, in order to prevent it from

falling down.

� Position and fix a load weighing about 40kg on the rear luggage rack, in order tosupport the front part of the vehicle.

Make sure that the vehicle is sta-ble.

� Have the handlebar held still in drivingposition, so that the steering is locked.

� Loosen the two screws (3) of the wheelpin clamp.

� Unscrew and remove the two screws (4).� Move the mudguard support (5) as much as

necessary and unscrew the wheel pin (6).

To facilitate the extraction of thewheel pin, slightly lift the wheel.

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� Manually extract the wheel pin (6).� Take the spacer ring (left side).

Upon removal, check the posi-tion of the speedometer/odome-

ter control: it will be useful during thereassembly.

� Remove the speedometer/odometercontrol (7) from the wheel seat.

� Remove the wheel, carefully withdrawingthe disc from the brake caliper.

Never pull the front brake leverafter removing the wheel, other-wise the caliper pistons may go

out of their seats, thus causing the out-flow of the brake fluid. In this case con-sult your �� Official Dealer, whowill carry out the proper maintenanceoperation.

REASSEMBLY


While reassembling the wheel,be careful not to damage thebrake pipe, the disc and thepads.

Insert the disc in the brake cali-per with care.

� Position the wheel between the forkrods.

Grease the inside of the speed-ometer/odometer control, seep. 68 (LUBRICANT TABLE).

� Position the speedometer/odometer con-trol tang (7) in the relevant seat in thewheel hub.

� Correctly position the odometer controlseat in correspondence with the specialantirotation pin (8).

� Shift the mudguard support (5) as muchas necessary to insert the wheel pin (6)partially (from the right side of the vehi-cle).

� Insert the spacer ring between the wheelhub and the fork left rod.

Grease the wheel pin, see p. 68(LUBRICANT TABLE).

� Insert the wheel pin (6) completely (fittingthe spacer ring) and tighten it.

Wheel pin nut driving torque: 80 Nm (8 kgm).

� Correctly position the mudguard support(5).



Weight of the vehicle withoutdr iver ( ready for start ing):200 kg.

� Raise the front part of the vehicle and re-move the support positioned under theengine during disassembly.

� Lower the vehicle and position it on thestand.

� Correctly position the oil pan guard (2).� Screw and tighten the four screws (1).� With pulled front brake lever, press the

handlebar repeatedly, thrusting the forkdownwards. In this way the fork rods willsettle properly.

� Screw and tighten the two screws (4).� Tighten the wheel pin clamp screws (3).

Wheel pin clamp screw driving torque:10 Nm (1 kgm).

After reassembly, pull the frontbrake lever repeatedly andcheck the correct functioning of

the braking system.

Check the wheel centering.

Have the driving torques, centering andbalancing of the wheel checked by your�� Official Dealer, in order to avoidaccidents that may be harmful for youand/or other people.

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The disassembly and reassem-bly of the rear wheel may be diffi-cult for unskilled operators. If

necessary, contact an �� OfficialDealer.

If you want to perform these operationspersonally, keep to the following in-structions.


Before carrying out the following opera-tions, let the engine and the silencercool down until they reach room tem-perature, in order to avoid burns.

While disassembling and reas-sembling the wheel, be carefulnot to damage the brake pipe,

the disc and the pads.

DISASSEMBLY� Position the vehicle on the stand, see


� Unscrew and remove the four screws (1).� Remove the oil pan guard (2).



Weight of the vehicle withoutdriver (ready for starting): 200 kg.

� Raise the rear part of the vehicle, have asuitable support (the height of whichshould be 350 mm) placed under the en-gine, so that the rear wheel can rotatefreely and the vehicle cannot fall down.

The vehicle may fall down.Provide for balancing the vehi-cle, in order to prevent it from

falling down.Make sure that the vehicle is stable.

� Lock the wheel pin (3) rotation, bymeans of the suitable spanner.

� Unscrew and remove the nut (4) andtake the washer (5).

Wheel nut driving torque: 100 Nm (10 kgm).

To facilitate the extraction of thewheel pin, slightly raise thewheel.

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� Extract the wheel pin (3) manually andtake the washer (6).

� Make the rear wheel advance and re-lease the drive chain (7) from the crowngear (8).

� Withdraw the wheel from the rear forkfrom behind, carefully withdrawing thedisc from the brake caliper.

Never pull the rear brake leverafter removing the wheel, other-wise the caliper piston may go

out of its seat, thus causing the outflowof the brake fluid. In this case consultyour �� Official Dealer, who willcarry out the proper maintenance oper-ation.

REASSEMBLY

Carefully insert the disc in thebrake caliper.

� Position the rear wheel between the rodsof the rear fork.

� Make the wheel advance and positionthe drive chain (7) on the crown gear (8).

Risk of injuries.Do not use your fingers to alignthe seats.

� Make the wheel move backwards andalign the pin seat on the wheel hub withthe pin seats on the rods of the rear fork.

Grease the wheel pin, see p. 68(LUBRICANT TABLE).

To facilitate the insertion of thewheel pin, slightly raise thewheel.

� Insert the wheel pin (3) complete withwasher (6) from the left side of the vehi-cle.

Make sure that the wheel pin hasbeen inserted completely.

� Fit the washer (5) and screw the nut (4)completely.

� Check the chain tension, see p. 46(CHAIN).

� Lock the wheel pin (3) rotation by meansof the suitable spanner and tighten thenut (4).

Wheel pin-nut driving torque: 100 Nm (10 kgm).



Weight of the vehicle withoutdriver (ready for starting): 200 kg.

� Raise the rear part of the vehicle and re-move the support positioned under theengine during disassembly.

� Lower the vehicle and position it on thestand.

� Correctly position the oil pan guard (2).� Screw and tighten the four screws (1).

After reassembly, pull the rearbrake lever repeatedly andcheck the correct functioning of

the braking system.

Check the wheel centering.

Have the driving torques, centering andbalancing of the wheel checked by your�� Official Dealer, in order to avoidaccidents that may be harmful for youand/or other people.

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The vehicle is equipped with an endlesschain, in which the ring link joint is notused.

An excessive slackening of thechain can cause it to come off ofthe sprockets, which often re-

sults in accidents or serious damage tothe vehicle.Periodically check the slack and adjustit if necessary, see beside (ADJUST-MENT).To change the chain, contact an ��Official Dealer, who will ensure youprompt and accurate servicing.

Incorrect maintenance maycause the untimely wear of thechain and/or damages to the pin-

ion and/or the crown.Carry out the maintenance operationsmore frequently if you use the vehicle indifficult conditions or on dusty and/ormuddy roads.

CHECKING THE SLACKTo check the slack, proceed as follows:� Stop the engine.� Position the vehicle on the stand, see


� Position the shifting lever in neutral.� Make sure that the vertical oscillation, in

an intermediate point between pinionand crown in the lower part of the chain,is about 35 ÷ 45 mm.

� Move the vehicle forwards, or turn thewheel, in order to be able to check the ver-tical oscillation of the chain even when thewheel turns; the slack must be constant inall the rotation phases of the wheel.

If in some positions the slack ishigher than in others, this meansthat there are crushed or seized

links; in this case, contact an �� Of-ficial Dealer. To prevent the risk of sei-zures, lubricate the chain frequently, seep. 47 (LUBRICATION AND CLEANING).

If the slack is uniform, but higher or lowerthan 35 ÷ 45 mm, adjust it, see beside (AD-JUSTMENT).

ADJUSTMENTIf after the check it is necessary to adjustthe chain tension, proceed as follows:� Lock the rotation of the wheel pin (1) by

means of the suitable spanner.� Loosen the nut (2).

For the wheel centering num-bered reference marks are pro-

vided, which are connected with themovement of the adjusters (3) and (4).These reference marks can be seen in-side two slots (5) and (6) positioned onthe rods of the rear fork, before thewheel pin.

� Act on the left (3) and right (4) adjustersand adjust the chain slack, making surethat the slots (5) and (6) coincide with thesame reference marks on both sides ofthe vehicle.

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� Lock the wheel pin (1) rotation by meansof the suitable spanner.

� Tighten the nut (2).

Wheel pin-nut driving torque: 100 Nm (10 kgm).

� Check the chain slack, see p. 46(CHECKING THE SLACK).

CHECKING THE WEAR OF CHAIN, PINION AND CROWNFurther, check the chain and sprocketsand make sure that they do not present:� Damaged rollers.� Loose pins.� Dry, rusty, crushed or seized links.� Excessive wear.� Lacking O rings.� Sprocket or teeth excessively worn or

damaged.

If the chain rollers are damaged,the pins are loose and/or the Orings are damaged or lacking, it

is necessary to change the whole chainunit (both sprockets and chain).

Lubricate the chain frequently,especially if there are dry orrusty parts. The crushed or

seized links must be lubricated andmade work again.If this is not possible, contact an�� Official Dealer, who will providefor changing the chain.

� Finally, check the wear of the rear forkprotection shoe.

LUBRICATION AND CLEANING

The drive chain is provided withO rings among the links, in orderto keep the grease inside them.

Carry out the adjustment, lubrication,cleaning and change of the chain withgreat care.


Lubricate the chain every 500 km or when-ever necessary.Lubricate the chain with spray grease forchains only, see p. 68 (LUBRICANT TA-BLE).Never wash the chain with water jets,steam jets, high-pressure water jets andhighly inflammable solvents.

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Carefully read p. 21 (FUEL) and p. 36(MAINTENANCE).

� Position the vehicle on the stand, seep. 35 (POSITIONING THE VEHICLE ONTHE STAND).

Risk of fire.Wait until the engine and the ex-haust silencer have completely

cooled down.

Fuel vapours are noxious foryour health.Before proceeding, make sure

that the room in which you are workingis properly ventilated.Do not inhale fuel vapours.Do not smoke and do not use nakedflames. Do not dispose of fuel in the en-vironment.

� Remove the saddle, see p. 19 (UN-LOCKING/LOCKING THE SADDLE).

� Move the fuel tap lever (1) to position"OFF".

� Unscrew and remove the central screw(2).

� Take the rubber element (3).� � Unscrew and remove the three screws

(4).� Disconnect the electric connector (5) of

the low fuel sensor.� Disconnect the water drain pipe (7) from

the fuel tank plug.� Disconnect the fuel breather pipe (7).� Lift the tank and remove it.

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� Remove the saddle, see p. 19 (UN-LOCKING/LOCKING THE SADDLE).

� Unscrew and remove the four screws(8).

� Remove the side (9).

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Every now and then it is advisable to checkthe steering, in order to verify if there areslacks.To check the steering it is necessary to:� Carry out the first four operations rele-

vant to the disassembly of the frontwheel,

Documents

New Pegaso - use and maintenance aprilia part# 8102759 · 2014. 8. 9. · Pegaso 650. 3 This manual must be considered as an integral part of the vehicle and must always accompany