APRILIA PEGASO 650 Service Repair Workshop Manual 2004
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Basic Information Identification Make: Aprilia Model: Pegaso 650 Model Year: 2004 Product Type: Service Repair Workshop Manual Introduction Market Position Market Position: The Aprilia Pegaso 650 (particularly the 2004 model year) represents Aprilia's entry into the versatile adventure-touring or dual-sport motorcycle segment, often competing with models like the BMW F650GS, Kawasaki KLR650, and Yamaha XT660R. It offers a blend of on-road comfort and off-road capability. Competitive Analysis Competitive Analysis: The Pegaso 650 distinguishes itself with Italian flair and often a more refined chassis and suspension compared to some of its single-cylinder competitors. Its Rotax-designed engine provided a good balance of power and torque, suitable for touring and light off-roading. Key Features Key Features: The 2004 model year typically features the Rotax 655cc single-cylinder engine, known for its reliability and torque delivery. It often came with features like a capable suspension for its class, good fuel range, and a comfortable riding position suitable for longer journeys. Manual Details Coverage Areas Coverage: Complete coverage for Aprilia Pegaso 650 2004 model. Page Count Page Count: Not explicitly stated, but described as 'Complete Manual - No Missing Pages'. Manual Type Manual Type: Workshop Service Repair Manual Language Language: Likely English, based on product description context. Format Format: Digital (likely PDF) given the sales platform (Tradebit). Manual Coverage Systems Covered Systems Covered: Engine mechanicals, fuel system, ignition system, cooling system, lubrication system, exhaust system, transmission, clutch, chassis, suspension (front and rear), brakes (front and rear), electrical system (wiring diagrams, components), instrument cluster, lighting, starting and charging system, bodywork, frame, maintenance procedures, troubleshooting, specifications. Procedures Included Procedures Included: Routine maintenance, scheduled servicing, engine overhaul and rebuilding, clutch inspection and replacement, transmission disassembly and assembly, suspension adjustments and repairs, brake system bleeding and component replacement, electrical system diagnosis and repair, carburetor tuning and cleaning, fuel injection system diagnostics (if applicable), wheel bearing replacement, chain and sprocket maintenance, troubleshooting common issues, torque specifications for all fasteners, detailed diagrams for assembly and disassembly. Technical Depth Technical Depth: Comprehensive, covering everything from basic maintenance checks and fluid changes to full engine and transmission rebuilds, and advanced electrical system diagnostics. Aimed at professional mechanics and experienced DIY enthusiasts. Manual Specifications File Format File Format: PDF (Assumed based on sales platform and common practice for workshop manuals). High-resolution for clarity. Print Quality Print Quality: Printable with clear, sharp diagrams and text. Suitable for professional workshop printing. Binding Type Binding Type: N/A (Digital Format). Paper Type Paper Type: N/A (Digital Format). Engine Specifications Primary Engine Engine Type: Single-cylinder, four-stroke, liquid-cooled, DOHC Engine Displacement: 650 cc (specifically 655 cc for many Pegaso models) Bore X Stroke: Approx. 100 mm x 83.7 mm (typical for this engine family) Performance Horsepower: Approximately 48-50 HP @ 7000 rpm (varies slightly by market and tuning) Torque: Approximately 5.5-6.0 kgf-m (around 54-59 Nm) @ 5200 rpm Fuel System Fuel Delivery: Carburetor (Mikuni VM34 or similar) or Electronic Fuel Injection (EFI) depending on exact sub-model and market. The 2004 model likely transitioned or used EFI. Fuel Type: Unleaded Gasoline Lubrication System Oil Type: API SG or higher, SAE 10W-40 or 10W-50 Motorcycle Oil (Specific viscosity recommended by manual). Oil Capacity: Approx. 2.0-2.5 liters (with oil filter change) Ignition System Ignition Type: Electronic Ignition (CDI or similar digital system) Cooling System Cooling Method: Liquid-cooled Coolant Type: Ethylene Glycol based coolant mixture (50% coolant, 50% distilled water). Transmission Standard Transmission Type: 5-speed constant mesh Optional Clutch Type: Wet, multi-plate, hydraulically actuated Features Final Drive: Chain drive Transmission Oil Type: SAE 75W/90 or SAE 80W/90 GL-5 Gear Oil (Specific recommendation in manual). Transmission Oil Capacity: Approx. 0.9 - 1.1 liters Dimensions Exterior Length: Approx. 2220 mm Width: Approx. 830 mm Height: Approx. 1330 mm Wheelbase: Approx. 1470 mm Weights Dry Weight: Approx. 168 kg Wet Weight: Approx. 186 kg (fully fueled and ready to ride) Fuel Capacity: Approx. 21 liters (including reserve) Suspension Front Suspension Type: Telescopic fork with anti-dive system (e.g., Marzocchi or Paioli) Front Suspension Travel: Approx. 165 mm Rear Suspension Type: Monoshock with progressive linkage Rear Suspension Travel: Approx. 175 mm Wheels And Tires Front Wheel Size: 19-inch spoke wheel Rear Wheel Size: 17-inch spoke wheel Front Tire Size: 100/90-19 Rear Tire Size: 130/80-17 Safety Features Ratings Safety Ratings: Motorcycles are not typically assigned formal crash test ratings like cars. Safety is assessed through rider skill, protective gear, and bike handling characteristics. Active Features Active Safety Features: Effective braking system (often with optional ABS on later models or specific trims), stable chassis geometry, responsive steering, reliable tires. Passive Features Passive Safety Features: Sturdy frame construction, engine crash protection (if fitted), general rider positioning for control. Technology Features Infotainment Infotainment System: Basic motorcycle instrumentation: speedometer, tachometer, odometer, trip meter, fuel gauge, warning lights. No advanced infotainment features. Driver Assistance Driver Assistance Systems: Optional ABS (Anti-lock Braking System) on some variants. No...
The Aprilia Pegaso 650 (particularly the 2004 model year) represents Aprilia's entry into the versatile adventure-touring or dual-sport motorcycle segment, often competing with models like the BMW F650GS, Kawasaki KLR650, and Yamaha XT660R. It offers a blend of on-road comfort and off-road capability.
Competitive Analysis
Competitive Analysis:
The Pegaso 650 distinguishes itself with Italian flair and often a more refined chassis and suspension compared to some of its single-cylinder competitors. Its Rotax-designed engine provided a good balance of power and torque, suitable for touring and light off-roading.
Key Features
Key Features:
The 2004 model year typically features the Rotax 655cc single-cylinder engine, known for its reliability and torque delivery. It often came with features like a capable suspension for its class, good fuel range, and a comfortable riding position suitable for longer journeys.
Manual Details
Coverage Areas
Coverage:
Complete coverage for Aprilia Pegaso 650 2004 model.
Page Count
Page Count:
Not explicitly stated, but described as 'Complete Manual - No Missing Pages'.
Manual Type
Manual Type:
Workshop Service Repair Manual
Language
Language:
Likely English, based on product description context.
Format
Format:
Digital (likely PDF) given the sales platform (Tradebit).
Routine maintenance, scheduled servicing, engine overhaul and rebuilding, clutch inspection and replacement, transmission disassembly and assembly, suspension adjustments and repairs, brake system bleeding and component replacement, electrical system diagnosis and repair, carburetor tuning and cleaning, fuel injection system diagnostics (if applicable), wheel bearing replacement, chain and sprocket maintenance, troubleshooting common issues, torque specifications for all fasteners, detailed diagrams for assembly and disassembly.
Technical Depth
Technical Depth:
Comprehensive, covering everything from basic maintenance checks and fluid changes to full engine and transmission rebuilds, and advanced electrical system diagnostics. Aimed at professional mechanics and experienced DIY enthusiasts.
Manual Specifications
File Format
File Format:
PDF (Assumed based on sales platform and common practice for workshop manuals). High-resolution for clarity.
Print Quality
Print Quality:
Printable with clear, sharp diagrams and text. Suitable for professional workshop printing.
Binding Type
Binding Type:
N/A (Digital Format).
Paper Type
Paper Type:
N/A (Digital Format).
Engine Specifications
Primary Engine
Engine Type:
Single-cylinder, four-stroke, liquid-cooled, DOHC
Engine Displacement:
650 cc (specifically 655 cc for many Pegaso models)
Bore X Stroke:
Approx. 100 mm x 83.7 mm (typical for this engine family)
Performance
Horsepower:
Approximately 48-50 HP @ 7000 rpm (varies slightly by market and tuning)
Torque:
Approximately 5.5-6.0 kgf-m (around 54-59 Nm) @ 5200 rpm
Fuel System
Fuel Delivery:
Carburetor (Mikuni VM34 or similar) or Electronic Fuel Injection (EFI) depending on exact sub-model and market. The 2004 model likely transitioned or used EFI.
Fuel Type:
Unleaded Gasoline
Lubrication System
Oil Type:
API SG or higher, SAE 10W-40 or 10W-50 Motorcycle Oil (Specific viscosity recommended by manual).
Oil Capacity:
Approx. 2.0-2.5 liters (with oil filter change)
Ignition System
Ignition Type:
Electronic Ignition (CDI or similar digital system)
Cooling System
Cooling Method:
Liquid-cooled
Coolant Type:
Ethylene Glycol based coolant mixture (50% coolant, 50% distilled water).
Transmission
Standard
Transmission Type:
5-speed constant mesh
Optional
Clutch Type:
Wet, multi-plate, hydraulically actuated
Features
Final Drive:
Chain drive
Transmission Oil Type:
SAE 75W/90 or SAE 80W/90 GL-5 Gear Oil (Specific recommendation in manual).
Transmission Oil Capacity:
Approx. 0.9 - 1.1 liters
Dimensions
Exterior
Length:
Approx. 2220 mm
Width:
Approx. 830 mm
Height:
Approx. 1330 mm
Wheelbase:
Approx. 1470 mm
Weights
Dry Weight:
Approx. 168 kg
Wet Weight:
Approx. 186 kg (fully fueled and ready to ride)
Fuel Capacity:
Approx. 21 liters (including reserve)
Suspension
Front Suspension Type:
Telescopic fork with anti-dive system (e.g., Marzocchi or Paioli)
Front Suspension Travel:
Approx. 165 mm
Rear Suspension Type:
Monoshock with progressive linkage
Rear Suspension Travel:
Approx. 175 mm
Wheels And Tires
Front Wheel Size:
19-inch spoke wheel
Rear Wheel Size:
17-inch spoke wheel
Front Tire Size:
100/90-19
Rear Tire Size:
130/80-17
Safety Features
Ratings
Safety Ratings:
Motorcycles are not typically assigned formal crash test ratings like cars. Safety is assessed through rider skill, protective gear, and bike handling characteristics.
Active Features
Active Safety Features:
Effective braking system (often with optional ABS on later models or specific trims), stable chassis geometry, responsive steering, reliable tires.
Passive Features
Passive Safety Features:
Sturdy frame construction, engine crash protection (if fitted), general rider positioning for control.
Optional ABS (Anti-lock Braking System) on some variants. No other electronic rider aids like traction control or multiple riding modes on this model year.
Connectivity
Connectivity Features:
None.
Maintenance
Service Intervals
Oil Change Interval:
Every 6,000 - 10,000 km or annually, whichever comes first (refer to manual for exact specification).
Spark Plug Replacement:
Every 12,000 - 24,000 km (depending on plug type and condition).
Valve Clearance Check:
Every 12,000 - 24,000 km.
Air Filter Cleaning Replacement:
Check every 6,000 km, clean or replace as needed based on operating conditions.
Fluid Specifications
Brake Fluid Type:
DOT 4
Coolant Type:
Ethylene Glycol based coolant mixture (50% coolant, 50% distilled water).
Engine Oil Grade:
SAE 10W-40 or 10W-50 Motorcycle Oil.
Known Issues
Known Issues:
Some models may experience issues with the fuel pump relay, charging system components (stator/regulator), or potential wear on the Rotax engine's camshaft chain tensioner over high mileage. Carburetor synchronization can be crucial for smooth running. Fork seals are a common wear item.
Vehicle History
Brand Heritage
Brand Heritage:
Aprilia is an Italian manufacturer with a rich history in racing and performance motorcycles, known for innovation and distinctive design.
Model Evolution
Model Evolution:
The Pegaso line began in the early 1990s. The 650cc single-cylinder models evolved significantly over the years, with the 2004 model representing a later iteration of the platform, often incorporating improvements in engine management (EFI), suspension, and styling from earlier versions.
Production
Production Location:
Italy
Production Years:
The Aprilia Pegaso 650 was produced from the early 1990s through the 2000s in various iterations (e.g., Pegaso 650, Pegaso 650 Trail, Pegaso 650 Strada).
Awards & Recognition
Recognitions
Recognitions:
The Aprilia Pegaso 650 was generally well-received for its blend of capability and style within the dual-sport market. Specific awards would need to be researched for the 2004 model year, but it was considered a strong contender against its European and Japanese rivals.
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