Aprilia Pegaso 650 Workshop Service Manual Repair Manual
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Basic Information Identification Make: Aprilia Model: Pegaso 650 Type: Motorcycle Product Name: Aprilia Pegaso 650 Workshop Service Manual Repair Manual Download Introduction Market Position Vehicle Segment: Dual-sport / Adventure motorcycle Target User: Touring, commuting, light off-road capability Competitive Analysis Competitors: BMW F650GS, Yamaha XT660R/X, Suzuki DR650, Kawasaki KLR650 Key Features Engine Type: Single-cylinder, 4-stroke Engine Size: 652cc Chassis Design: Steel frame, adjustable suspension Versatility: Suitable for both on-road and moderate off-road use Manual Value Proposition: Provides dealership-level diagnostic and repair information, ensuring accurate and efficient maintenance. Manual Details Coverage Areas Manual Type: Workshop Service Manual / Repair Manual Language: English Format: Digital Download (likely PDF) Page Count: Estimated 300-500+ pages (typical for comprehensive workshop manuals) Intended Audience: Dealership Technicians, Professional Mechanics, Advanced DIY Enthusiasts Manual Coverage Systems Covered Engine: Complete overhaul, component testing, lubrication, cooling system, fuel system, ignition system, exhaust system Transmission: Gearbox, clutch, shifting mechanism, lubrication, adjustments, rebuild procedures Drivetrain: Chain drive, sprockets, rear wheel hub, final drive maintenance Suspension: Front fork (telescopic), rear shock absorber, linkage (if applicable), adjustments, seal replacement, oil levels Brakes: Front and rear brake systems, caliper service, pad replacement, fluid bleeding, master cylinder overhaul, hydraulic lines Electrical System: Wiring diagrams, battery, charging system (alternator/stator, regulator/rectifier), ignition coils, starter motor, lighting, instrumentation, fuses, relays Fuel System: Carburetor (if applicable, e.g. Dell'Orto PHM 40) or Fuel Injection (EFI) system components, fuel pump, injectors, fuel lines, fuel filter Cooling System: Radiator, cooling fan, coolant hoses, thermostat, coolant specifications Chassis Frame: Frame inspection, steering head bearings, swingarm, maintenance Bodywork: Fairings, body panels, seat, tank, removal and installation procedures Wheels Tires: Wheel bearing service, tire pressure recommendations, rim specifications Procedures Included Maintenance: Scheduled maintenance tasks, lubrication points, filter replacements, fluid changes Troubleshooting: Diagnostic charts, symptom analysis, common fault finding Repair: Step-by-step instructions for component replacement and repair Diagnostics: Procedures for checking component operation, electrical system testing Assembly Disassembly: Detailed instructions for dismantling and reassembling major components and the entire motorcycle Torque Specifications: Specific torque values for all critical fasteners Technical Depth Depth: Comprehensive, from basic checks to complete engine and transmission rebuilds Diagnostic Tools: Information on necessary special tools and diagnostic equipment Manual Specifications File Format File Type: PDF Searchable: Likely (if properly OCR'd PDF) Print Quality Image Resolution: High (typical for professional manuals, allowing clear viewing of diagrams) Diagrams Illustrations: Detailed schematics, exploded views, and repair diagrams Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) Engine Specifications Primary Engine Engine Type: 4-stroke, single-cylinder, SOHC, 4 valves per cylinder Bore X Stroke: 100 mm x 82 mm (typical for Rotax 654 engine) Displacement: 652 cc Compression Ratio: Approx. 9.0:1 (varies slightly by year/model) Cooling System: Liquid-cooled Performance Horsepower: Approx. 48-50 HP @ 6500-7000 RPM (varies by year/model and tuning) Torque: Approx. 58-60 Nm @ 5000-5500 RPM (varies by year/model and tuning) Fuel System Fuel Delivery: Carburetor (e.g., Dell'Orto PHM 40) or Fuel Injection (EFI) depending on year and variant Fuel Type: Unleaded gasoline (95 RON recommended) Fuel Tank Capacity: Approx. 14-16 Liters (varies by model variant) Lubrication Oil Type: SAE 10W-40 API SG or higher, motorcycle specific (e.g., Motul 5100 10W-40) Oil Capacity: Approx. 1.8 - 2.2 Liters (check dipstick/sight glass) Transmission Standard Type: 5-speed manual constant mesh Clutch: Wet multi-plate clutch Final Drive: Sealed O-ring chain Features Gear Ratios: Specific ratios detailed within the manual Transmission Oil Type: API GL-4 SAE 75W-90 (or as specified in manual) Dimensions Exterior Length: Approx. 2150 mm Width: Approx. 830 mm Height: Approx. 1320 mm Wheelbase: Approx. 1460 mm Weights Dry Weight: Approx. 167-175 kg (varies by model variant) Wet Weight: Approx. 185-195 kg (fully fueled, fluids) Safety Features Ratings NHTSA Rating: N/A (Motorcycle safety ratings differ from automobiles) Active Features Braking System: Disc brakes, front and rear, often with ABS as an option on later models Suspension Stability: Adjustable suspension for ride height and damping Passive Features Lighting: Headlight, taillight, brake lights, turn signals Frame Integrity: Robust steel frame construction Technology Features Infotainment Instrument Cluster: Analog tachometer, digital/analog speedometer, odometer, trip meter, fuel gauge, warning lights. Driver Assistance ABS: Optional on certain model years/trims. Connectivity Charging Port: Often not standard, but aftermarket options exist. Maintenance Service Intervals Oil Change: Every 5,000 - 7,500 km or annually (refer to manual for precise interval) Air Filter: Inspect every 5,000 km, clean/replace as needed Spark Plug: Replace every 10,000 - 15,000 km (refer to manual for specific plug type and gap) Chain Lubrication: Every 500 km and after washing/rain Valve Clearance: Inspect every 10,000 - 15,000 km (refer to manual for procedure and specs) Fluid Specifications Brake Fluid: DOT 4 (or as specified for the specific model year) Coolant: Ethylene glycol-based antifreeze mixture (50/50 with distilled water recommended) Known Issues Electrical Connections: Corrosion or loose connections on stator, rectifier, and battery terminals can cause charging issues. Fuel System...
Often not standard, but aftermarket options exist.
Maintenance
Service Intervals
Oil Change:
Every 5,000 - 7,500 km or annually (refer to manual for precise interval)
Air Filter:
Inspect every 5,000 km, clean/replace as needed
Spark Plug:
Replace every 10,000 - 15,000 km (refer to manual for specific plug type and gap)
Chain Lubrication:
Every 500 km and after washing/rain
Valve Clearance:
Inspect every 10,000 - 15,000 km (refer to manual for procedure and specs)
Fluid Specifications
Brake Fluid:
DOT 4 (or as specified for the specific model year)
Coolant:
Ethylene glycol-based antifreeze mixture (50/50 with distilled water recommended)
Known Issues
Electrical Connections:
Corrosion or loose connections on stator, rectifier, and battery terminals can cause charging issues.
Fuel System Early Models:
Carburetor adjustments and occasional clogging on older models.
Suspension Seals:
Fork seals can wear over time, leading to leaks.
Clutch Cable:
Clutch cable adjustment and replacement due to wear.
Vehicle History
Brand Heritage
Manufacturer:
Aprilia is an Italian manufacturer renowned for its sport motorcycles and scooters.
Model Evolution
Generation 1:
Launched in the mid-1990s, often utilizing the Rotax 654 engine.
Variants:
Evolutions included different carburetor/injection systems, suspension updates, and styling changes across various model years and regions (e.g., Pegaso 650, Pegaso Strada, Pegaso Trail).
Production
Production Period:
Approximately 1992/1993 to 2013 (across all Pegaso 650 variants).
Awards & Recognition
Recognitions
Industry Recognition:
While specific awards for the Pegaso 650 might be scarce, Aprilia as a brand is recognized for performance and innovation in motorcycle design.
Ratings
Owner Satisfaction:
Generally positive for its versatility and reliability, though specific data varies by model year and maintenance.