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Aprilia Pegaso 650 2005-2011 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Aprilia Model: Pegaso 650 Model Variant: Strada / Trail (implied by year range and common Pegaso variants) Production Years Covered: 2005, 2006, 2007, 2008, 2009, 2010, 2011 Codes Engine Code Family: Rotax 655 / 654 (common for this era Aprilia single-cylinder) 👋 Introduction Market Position Segment: Mid-weight adventure touring / dual-sport motorcycle Aprilia Strategy: Aprilia aimed to offer a versatile and reliable single-cylinder motorcycle with accessible performance and a focus on European styling and engineering. Competitive Analysis Key Competitors: BMW F650GS/GS Dakar, Kawasaki KLR650, Suzuki DR650SE, Yamaha XT660R/X Key Features Engine Type: Single-cylinder, four-stroke engine known for its torquey nature and simplicity. Suspension Options: Available in 'Strada' (road-biased, cast wheels) and 'Trail' (off-road biased, spoked wheels, longer travel suspension) variants. Design Philosophy: Designed for versatility, capable of commuting, touring, and light off-road use. 📋 Manual Details Coverage Areas Geographic Coverage: Global (standard service procedures) Target Audience: Mechanical technicians, Aprilia authorized service centers, experienced DIY mechanics Page Count Estimated Page Count: Extensive (typically 500+ pages for a comprehensive workshop manual) Manual Type Manual Type: Workshop Service Repair Manual Language Language: English (presumed primary language for international sales) Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, disassembly, assembly, component testing, timing, valve clearance adjustment, fuel injection system, ignition system, lubrication system, cooling system Transmission: Gearbox internal inspection, clutch service and adjustment, shift mechanism, lubrication Chassis And Suspension: Front fork overhaul (damping, seals), rear shock absorber service, swingarm maintenance, wheel bearings, steering head bearings Brakes: Brake system inspection, hydraulic system bleeding, caliper service, disc replacement, pad replacement, ABS system (if equipped) Electrical System: Wiring diagrams, lighting circuits, charging system (stator, regulator/rectifier), starting system (starter motor, battery), ignition coil testing, sensor diagnostics (TPS, MAP, Crank Position), ECU troubleshooting, fuse and relay identification Fuel System: Fuel pump operation, injector cleaning and testing, fuel pressure regulation, fuel tank inspection, evaporative emissions control system Bodywork And Trim: Fairing removal and installation, seat removal, tank cover access, panel fastener locations Procedures Included Routine Maintenance: Oil and filter changes, air filter replacement, spark plug replacement, chain adjustment and lubrication, brake fluid flush, coolant replacement, tire pressure checks Troubleshooting Guides: Diagnostic flowcharts for common performance issues, starting problems, electrical faults, and braking system malfunctions Repair Procedures: Step-by-step instructions for major component repairs, including engine rebuilds, suspension overhauls, and electrical system diagnostics Technical Specifications: Torque specifications for all fasteners, fluid capacities, engine clearances, electrical system voltages, performance data Technical Depth Depth Of Coverage: Comprehensive, covering everything from basic maintenance to full engine and gearbox rebuilds. Detailed diagnostic procedures and component-level repair instructions. 📊 Manual Specifications File Format File Format: PDF (Portable Document Format) Print Quality Image Resolution: High-resolution, suitable for printing individual pages or the entire manual. Clear, legible diagrams and illustrations. Searchability Text Searchability: Searchable text for quick access to specific information and keywords (assuming OCR processing). Usability Navigation: Likely includes a table of contents and section links for easy navigation within the PDF. ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, four-stroke, single-cylinder, DOHC, 4 valves Displacement: 652 cc Bore X Stroke: 100 mm x 83 mm (typical for this engine family) Compression Ratio: 10.0:1 (typical) Performance Horsepower: Approximately 48-50 HP @ 6500-7000 RPM (variations by market and specific tuning) Torque: Approximately 57-60 Nm @ 5000-5500 RPM (variations by market and specific tuning) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI), typically single throttle body Fuel Type: Unleaded gasoline (95 RON or higher recommended) Ignition Ignition System: Digital CDI with electronic advance Cooling Cooling System: Liquid-cooled Lubrication Lubrication System: Wet sump 🔧 Transmission Standard Transmission Type: 5-speed manual gearbox Clutch Type: Wet, multi-plate clutch Features Final Drive: Chain drive 📐 Dimensions Exterior Length: Approx. 2200 mm (variable by model variant) Width: Approx. 850 mm (variable by model variant) Height: Approx. 1250 mm (variable by model variant, including windscreen) Weights Dry Weight: Approx. 160-170 kg (depending on variant and equipment) Wet Weight: Approx. 185-195 kg (fully fueled and with fluids) Fuel Tank Capacity: 14 Liters Wheels Tires Front Wheel Size: 19-inch (Trail) or 17-inch (Strada) Rear Wheel Size: 17-inch Front Tire Size: 90/90-19 (Trail) or 110/70-17 (Strada) Rear Tire Size: 130/80-17 🛡️ Safety Features Ratings ABS Availability: Optional ABS available on some models/markets within this range. Active Features Braking System: Hydraulic disc brakes front and rear. Dual piston caliper front, single piston caliper rear (typical). Passive Features Lighting: Halogen headlight, LED taillight Instrumentation: Digital speedometer, analog tachometer, fuel gauge, gear indicator (may vary by trim/year). 💡 Technology Features Infotainment Instrument Cluster: Combination of digital display for speed, odometer, trip meters, and fuel level, with an analog tachometer. Warning lights for various systems. Driver Assistance ABS: Optional Anti-lock Braking System (ABS) was available, offering enhanced safety. Connectivity Charging Port: May have an accessory charging socket (e.g., 12V socket) for GPS units or...
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Aprilia Pegaso 650 2005-2011 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
Pegaso 650
Model Variant:
Strada / Trail (implied by year range and common Pegaso variants)
Production Years Covered:
2005, 2006, 2007, 2008, 2009, 2010, 2011
Codes
Engine Code Family:
Rotax 655 / 654 (common for this era Aprilia single-cylinder)
👋 Introduction
Market Position
Segment:
Mid-weight adventure touring / dual-sport motorcycle
Aprilia Strategy:
Aprilia aimed to offer a versatile and reliable single-cylinder motorcycle with accessible performance and a focus on European styling and engineering.
Competitive Analysis
Key Competitors:
BMW F650GS/GS Dakar, Kawasaki KLR650, Suzuki DR650SE, Yamaha XT660R/X
Key Features
Engine Type:
Single-cylinder, four-stroke engine known for its torquey nature and simplicity.
Suspension Options:
Available in 'Strada' (road-biased, cast wheels) and 'Trail' (off-road biased, spoked wheels, longer travel suspension) variants.
Design Philosophy:
Designed for versatility, capable of commuting, touring, and light off-road use.
📋 Manual Details
Coverage Areas
Geographic Coverage:
Global (standard service procedures)
Target Audience:
Mechanical technicians, Aprilia authorized service centers, experienced DIY mechanics
Page Count
Estimated Page Count:
Extensive (typically 500+ pages for a comprehensive workshop manual)
Manual Type
Manual Type:
Workshop Service Repair Manual
Language
Language:
English (presumed primary language for international sales)
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Complete engine overhaul, disassembly, assembly, component testing, timing, valve clearance adjustment, fuel injection system, ignition system, lubrication system, cooling system
Transmission:
Gearbox internal inspection, clutch service and adjustment, shift mechanism, lubrication
Chassis And Suspension:
Front fork overhaul (damping, seals), rear shock absorber service, swingarm maintenance, wheel bearings, steering head bearings
Brakes:
Brake system inspection, hydraulic system bleeding, caliper service, disc replacement, pad replacement, ABS system (if equipped)
Electrical System:
Wiring diagrams, lighting circuits, charging system (stator, regulator/rectifier), starting system (starter motor, battery), ignition coil testing, sensor diagnostics (TPS, MAP, Crank Position), ECU troubleshooting, fuse and relay identification
Fuel System:
Fuel pump operation, injector cleaning and testing, fuel pressure regulation, fuel tank inspection, evaporative emissions control system
Bodywork And Trim:
Fairing removal and installation, seat removal, tank cover access, panel fastener locations
Procedures Included
Routine Maintenance:
Oil and filter changes, air filter replacement, spark plug replacement, chain adjustment and lubrication, brake fluid flush, coolant replacement, tire pressure checks
Troubleshooting Guides:
Diagnostic flowcharts for common performance issues, starting problems, electrical faults, and braking system malfunctions
Repair Procedures:
Step-by-step instructions for major component repairs, including engine rebuilds, suspension overhauls, and electrical system diagnostics
Technical Specifications:
Torque specifications for all fasteners, fluid capacities, engine clearances, electrical system voltages, performance data
Technical Depth
Depth Of Coverage:
Comprehensive, covering everything from basic maintenance to full engine and gearbox rebuilds. Detailed diagnostic procedures and component-level repair instructions.
📊 Manual Specifications
File Format
File Format:
PDF (Portable Document Format)
Print Quality
Image Resolution:
High-resolution, suitable for printing individual pages or the entire manual. Clear, legible diagrams and illustrations.
Searchability
Text Searchability:
Searchable text for quick access to specific information and keywords (assuming OCR processing).
Usability
Navigation:
Likely includes a table of contents and section links for easy navigation within the PDF.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, four-stroke, single-cylinder, DOHC, 4 valves
Displacement:
652 cc
Bore X Stroke:
100 mm x 83 mm (typical for this engine family)
Compression Ratio:
10.0:1 (typical)
Performance
Horsepower:
Approximately 48-50 HP @ 6500-7000 RPM (variations by market and specific tuning)
Torque:
Approximately 57-60 Nm @ 5000-5500 RPM (variations by market and specific tuning)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI), typically single throttle body
Fuel Type:
Unleaded gasoline (95 RON or higher recommended)
Ignition
Ignition System:
Digital CDI with electronic advance
Cooling
Cooling System:
Liquid-cooled
Lubrication
Lubrication System:
Wet sump
🔧 Transmission
Standard
Transmission Type:
5-speed manual gearbox
Clutch Type:
Wet, multi-plate clutch
Features
Final Drive:
Chain drive
📐 Dimensions
Exterior
Length:
Approx. 2200 mm (variable by model variant)
Width:
Approx. 850 mm (variable by model variant)
Height:
Approx. 1250 mm (variable by model variant, including windscreen)
Weights
Dry Weight:
Approx. 160-170 kg (depending on variant and equipment)
Wet Weight:
Approx. 185-195 kg (fully fueled and with fluids)
Fuel Tank Capacity:
14 Liters
Wheels Tires
Front Wheel Size:
19-inch (Trail) or 17-inch (Strada)
Rear Wheel Size:
17-inch
Front Tire Size:
90/90-19 (Trail) or 110/70-17 (Strada)
Rear Tire Size:
130/80-17
🛡️ Safety Features
Ratings
ABS Availability:
Optional ABS available on some models/markets within this range.
Active Features
Braking System:
Hydraulic disc brakes front and rear. Dual piston caliper front, single piston caliper rear (typical).
Passive Features
Lighting:
Halogen headlight, LED taillight
Instrumentation:
Digital speedometer, analog tachometer, fuel gauge, gear indicator (may vary by trim/year).
💡 Technology Features
Infotainment
Instrument Cluster:
Combination of digital display for speed, odometer, trip meters, and fuel level, with an analog tachometer. Warning lights for various systems.
Driver Assistance
ABS:
Optional Anti-lock Braking System (ABS) was available, offering enhanced safety.
Connectivity
Charging Port:
May have an accessory charging socket (e.g., 12V socket) for GPS units or phone chargers.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 6,000 km or 12 months (typical recommendation, consult manual for specifics)
Valve Clearance Check:
Every 12,000 km or 24 months (typical recommendation)
Air Filter Replacement:
Every 6,000 km or as needed based on operating conditions
Fluid Specifications
Engine Oil Type:
SAE 10W-40 or 15W-50, API SG/SH/SJ or JASO MA/MA2 certified motorcycle oil
Engine Oil Capacity:
Approx. 1.6 Liters (without filter change), 1.8 Liters (with filter change)
Coolant Type:
Ethylene glycol based coolant, mixed 50/50 with distilled water
Brake Fluid Type:
DOT 4
Gearbox Oil Type:
SAE 75W-90 API GL-4
Known Issues
Common Wear Items:
Clutch plates, swingarm bushings, steering head bearings, front fork seals, regulator/rectifier can be prone to failure over time.
Common Issues
Engine Performance Variations:
Potential for occasional running issues related to the fuel injection system (e.g., dirty injectors, faulty sensors) if not maintained.
Electrical Reliability:
While generally robust, specific electrical connectors or the charging system might require attention on higher-mileage examples.
📚 Vehicle History
Brand Heritage
Manufacturer:
Aprilia is an Italian manufacturer known for its performance-oriented motorcycles, particularly in the off-road and sportbike segments.
Model Evolution
Pegaso Lineage:
The Pegaso name has been used by Aprilia for a range of single-cylinder motorcycles since the early 1990s, evolving over generations to meet market demands.
Production
Manufacturing Location:
Italy (Aprilia's primary manufacturing base)
Engine Source:
Utilizes the robust Rotax single-cylinder engine, widely adopted by various manufacturers for its reliability and performance.
🏆 Awards & Recognition
Recognitions
Market Reception:
Generally well-regarded for its versatility and capable Rotax engine, providing a good balance of performance and practicality in its class.
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