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APRILIA PEGASO 655 ROTAX Engine Service Repair Manual 1995 ONWARD

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🏷️ Basic Information Identification Make: Aprilia Model: Pegaso 655 Engine Manufacturer: Rotax Year Coverage: 1995 Onward Codes Engine Code Family: Rotax 655 👋 Introduction Market Position Target Audience: Aprilia Pegaso 655 owners and independent workshops seeking professional-grade repair and maintenance information Competitive Analysis Value Proposition: Provides factory-level diagnostic and repair procedures, enabling significant cost savings on workshop visits and empowering users to maintain their vehicle effectively. Key Features Ease Of Use: Very easy to use, designed for clarity and efficiency. Completeness: The ONLY Service Repair Workshop Manual You Will Ever Need; all repair procedures covered. Delivery Method: Instant download, eliminating shipping costs and delivery delays. 📋 Manual Details Coverage Areas Primary Coverage: Full vehicle service, repair, and maintenance Page Count Estimated Page Count: Varies by specific edition, but typically extensive for a full service manual (e.g., 300-600+ pages) Manual Type Type: Factory-type Service Repair Workshop Manual Language Language: English (implied by product description and typical market availability) Format Format: PDF (Digital Download) 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, diagnostics, tuning, lubrication system, cooling system, fuel system (carburetion/injection), ignition system, exhaust system Transmission: Gearbox service, clutch operation and replacement, final drive maintenance Chassis: Frame, suspension (front forks, rear shock absorber), steering, wheels, tires Brakes: Hydraulic brake system (front and rear calipers, master cylinders, lines, bleeding procedures), brake pad/disc replacement Electrical: Wiring diagrams, battery, lighting system, starting system, charging system, instrumentation, fault finding Bodywork: Body panel removal and installation, fairings, seating, fuel tank, accessories Procedures Included Maintenance: Routine servicing, oil changes, filter replacements, chain adjustment, spark plug checks, brake fluid changes, coolant flushes Repair: Engine rebuilds, transmission overhauls, suspension component replacement, electrical component repair, brake system servicing Diagnostics: Troubleshooting guides, identification of common faults, diagnostic flowcharts Special Tools: Identification and usage of specialized tools required for specific repairs Technical Depth Depth: Comprehensive, from basic maintenance to full engine and component overhauls, suitable for professional mechanics and advanced DIY enthusiasts 📊 Manual Specifications File Format Compatibility: PC & MAC Compatible Print Quality Printability: Printable pages (allows users to print specific sections as needed) Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Quality Quality Description: Professional Quality, highly detailed, with step-by-step instructions and exploded pictures/diagrams ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, four-stroke Engine Displacement: Approximately 650cc (specific variant may exist, but commonly 650cc class) Bore X Stroke: Typically around 100mm x 83mm (common for Rotax 655 variants) Compression Ratio: Likely around 9.5:1 to 10.5:1, depending on specific model variant Valve Train: SOHC (Single Overhead Camshaft), 4 valves Performance Horsepower Range: Typically 48-55 HP (approx. 36-41 kW) @ 6500-7500 RPM Torque Range: Typically 60-65 Nm (approx. 44-48 lb-ft) @ 5000-6000 RPM Fuel System Fuel Delivery: Carburetor (e.g., Dell'Orto PHM40) or Electronic Fuel Injection (EFI) depending on the specific 1995 onward variant. Recommended Fuel: Unleaded gasoline (RON 95 or higher) Lubrication Oil Type: Synthetic or semi-synthetic motorcycle oil, SAE 10W-40 or 20W-50 (refer to specific manual for exact specifications) Cooling System Cooling Method: Liquid-cooled Coolant Type: Ethylene glycol-based antifreeze mixture (50/50 with distilled water) 🔧 Transmission Standard Type: 5-speed constant mesh gearbox Optional Optional Transmission: N/A (Typically single transmission option for this model) Features Clutch Type: Wet, multi-plate clutch, hydraulically operated Final Drive: O-ring sealed chain drive Fluid Specifications Transmission Oil Type: API GL-4 or GL-5, SAE 75W-90 or 80W-90 gear oil (refer to specific manual for exact specifications) 📐 Dimensions Exterior Length: Varies by specific model year and configuration, generally around 2200mm (approx. 86.6 inches) Width: Varies by specific model year and configuration, generally around 830mm (approx. 32.7 inches) Height: Varies by specific model year and configuration, generally around 1370mm (approx. 53.9 inches) Weights Dry Weight: Approximately 170-180 kg (approx. 375-397 lbs) Wet Weight: Approximately 190-200 kg (approx. 419-441 lbs) Fuel Tank Capacity: Approximately 20-24 Liters (approx. 5.3-6.3 Gallons) 🛡️ Safety Features Ratings Safety Standard Compliance: Built to meet relevant European motorcycle safety standards of the era (e.g., Euro 1 emissions if applicable). Active Features Braking System: Disc brakes (dual front discs, single rear disc) with hydraulic actuation. Lighting: Halogen headlight, LED or incandescent tail light and indicators. Passive Features Frame Construction: Steel perimeter frame 💡 Technology Features Infotainment Instrument Cluster: Analog speedometer, tachometer, odometer, trip meter, and warning lights. Some later models might have digital elements. Driver Assistance ABS: ABS was an optional feature on some later models, but not standard across all 1995 onward variants. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 5,000 - 7,500 km (3,000 - 4,500 miles) or annually, whichever comes first. Air Filter Cleaning: Inspect every 5,000 km (3,000 miles), clean or replace as needed. More frequent cleaning for dusty conditions. Spark Plug Replacement: Inspect every 10,000 km (6,000 miles), replace if necessary. Check gap regularly. Chain Lubrication Adjustment: Lubricate chain every 1,000 km (600 miles)...
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APRILIA PEGASO 655 ROTAX Engine Service Repair Manual 1995 ONWARD
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
Pegaso 655
Engine Manufacturer:
Rotax
Year Coverage:
1995 Onward
Codes
Engine Code Family:
Rotax 655
👋 Introduction
Market Position
Target Audience:
Aprilia Pegaso 655 owners and independent workshops seeking professional-grade repair and maintenance information
Competitive Analysis
Value Proposition:
Provides factory-level diagnostic and repair procedures, enabling significant cost savings on workshop visits and empowering users to maintain their vehicle effectively.
Key Features
Ease Of Use:
Very easy to use, designed for clarity and efficiency.
Completeness:
The ONLY Service Repair Workshop Manual You Will Ever Need; all repair procedures covered.
Delivery Method:
Instant download, eliminating shipping costs and delivery delays.
📋 Manual Details
Coverage Areas
Primary Coverage:
Full vehicle service, repair, and maintenance
Page Count
Estimated Page Count:
Varies by specific edition, but typically extensive for a full service manual (e.g., 300-600+ pages)
Manual Type
Type:
Factory-type Service Repair Workshop Manual
Language
Language:
English (implied by product description and typical market availability)
Format
Format:
PDF (Digital Download)
📖 Manual Coverage
Systems Covered
Engine:
Complete engine overhaul, diagnostics, tuning, lubrication system, cooling system, fuel system (carburetion/injection), ignition system, exhaust system
Transmission:
Gearbox service, clutch operation and replacement, final drive maintenance
Chassis:
Frame, suspension (front forks, rear shock absorber), steering, wheels, tires
Brakes:
Hydraulic brake system (front and rear calipers, master cylinders, lines, bleeding procedures), brake pad/disc replacement
Electrical:
Wiring diagrams, battery, lighting system, starting system, charging system, instrumentation, fault finding
Bodywork:
Body panel removal and installation, fairings, seating, fuel tank, accessories
Procedures Included
Maintenance:
Routine servicing, oil changes, filter replacements, chain adjustment, spark plug checks, brake fluid changes, coolant flushes
Repair:
Engine rebuilds, transmission overhauls, suspension component replacement, electrical component repair, brake system servicing
Diagnostics:
Troubleshooting guides, identification of common faults, diagnostic flowcharts
Special Tools:
Identification and usage of specialized tools required for specific repairs
Technical Depth
Depth:
Comprehensive, from basic maintenance to full engine and component overhauls, suitable for professional mechanics and advanced DIY enthusiasts
📊 Manual Specifications
File Format
Compatibility:
PC & MAC Compatible
Print Quality
Printability:
Printable pages (allows users to print specific sections as needed)
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Quality
Quality Description:
Professional Quality, highly detailed, with step-by-step instructions and exploded pictures/diagrams
⚙️ Engine Specifications
Primary Engine
Engine Type:
Single-cylinder, four-stroke
Engine Displacement:
Approximately 650cc (specific variant may exist, but commonly 650cc class)
Bore X Stroke:
Typically around 100mm x 83mm (common for Rotax 655 variants)
Compression Ratio:
Likely around 9.5:1 to 10.5:1, depending on specific model variant
Valve Train:
SOHC (Single Overhead Camshaft), 4 valves
Performance
Horsepower Range:
Typically 48-55 HP (approx. 36-41 kW) @ 6500-7500 RPM
Torque Range:
Typically 60-65 Nm (approx. 44-48 lb-ft) @ 5000-6000 RPM
Fuel System
Fuel Delivery:
Carburetor (e.g., Dell'Orto PHM40) or Electronic Fuel Injection (EFI) depending on the specific 1995 onward variant.
Recommended Fuel:
Unleaded gasoline (RON 95 or higher)
Lubrication
Oil Type:
Synthetic or semi-synthetic motorcycle oil, SAE 10W-40 or 20W-50 (refer to specific manual for exact specifications)
Cooling System
Cooling Method:
Liquid-cooled
Coolant Type:
Ethylene glycol-based antifreeze mixture (50/50 with distilled water)
🔧 Transmission
Standard
Type:
5-speed constant mesh gearbox
Optional
Optional Transmission:
N/A (Typically single transmission option for this model)
Features
Clutch Type:
Wet, multi-plate clutch, hydraulically operated
Final Drive:
O-ring sealed chain drive
Fluid Specifications
Transmission Oil Type:
API GL-4 or GL-5, SAE 75W-90 or 80W-90 gear oil (refer to specific manual for exact specifications)
📐 Dimensions
Exterior
Length:
Varies by specific model year and configuration, generally around 2200mm (approx. 86.6 inches)
Width:
Varies by specific model year and configuration, generally around 830mm (approx. 32.7 inches)
Height:
Varies by specific model year and configuration, generally around 1370mm (approx. 53.9 inches)
Weights
Dry Weight:
Approximately 170-180 kg (approx. 375-397 lbs)
Wet Weight:
Approximately 190-200 kg (approx. 419-441 lbs)
Fuel Tank Capacity:
Approximately 20-24 Liters (approx. 5.3-6.3 Gallons)
🛡️ Safety Features
Ratings
Safety Standard Compliance:
Built to meet relevant European motorcycle safety standards of the era (e.g., Euro 1 emissions if applicable).
Active Features
Braking System:
Disc brakes (dual front discs, single rear disc) with hydraulic actuation.
Lighting:
Halogen headlight, LED or incandescent tail light and indicators.
Passive Features
Frame Construction:
Steel perimeter frame
💡 Technology Features
Infotainment
Instrument Cluster:
Analog speedometer, tachometer, odometer, trip meter, and warning lights. Some later models might have digital elements.
Driver Assistance
ABS:
ABS was an optional feature on some later models, but not standard across all 1995 onward variants.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000 - 7,500 km (3,000 - 4,500 miles) or annually, whichever comes first.
Air Filter Cleaning:
Inspect every 5,000 km (3,000 miles), clean or replace as needed. More frequent cleaning for dusty conditions.
Spark Plug Replacement:
Inspect every 10,000 km (6,000 miles), replace if necessary. Check gap regularly.
Chain Lubrication Adjustment:
Lubricate chain every 1,000 km (600 miles) or after riding in rain. Adjust tension as needed.
Fluid Specifications
Brake Fluid Type:
DOT 4 hydraulic brake fluid
Coolant Capacity:
Approximately 1.5 - 2.0 Liters (refer to manual for exact capacity and fill procedure)
Known Issues
Common Wear Items:
Clutch plates, brake pads, fork seals, wheel bearings, and chain/sprockets are common wear items requiring regular inspection and replacement.
Electrical Gremlins:
Older models may experience minor electrical connection issues if not maintained; regular cleaning and dielectric grease application can prevent this.
Carburetor Tuning:
Carbureted models may require periodic synchronization and jetting adjustments for optimal performance and fuel economy.
📚 Vehicle History
Brand Heritage
Brand Origin:
Aprilia is an Italian manufacturer with a strong racing heritage and a focus on sporty motorcycles.
Model Evolution
Pegaso Lineage:
The Pegaso line has historically been Aprilia's dual-sport or adventure-touring offering, known for its versatility and Rotax engine.
Rotax Engine Partnership:
Aprilia's long-standing use of Rotax engines, particularly the 654/655 series, is a hallmark of these models, valued for their reliability and performance characteristics.
Production
Production Period:
The Pegaso 655, powered by the Rotax engine, saw production through the late 1990s and into the early 2000s, evolving with various updates and styling changes.
🏆 Awards & Recognition
Recognitions
Market Reputation:
The Aprilia Pegaso with the Rotax engine has been recognized for its robustness, versatility as a lightweight adventure tourer, and the reliable performance of the Rotax powerplant.
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