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Aprilia Pegaso 650 IE Service Repair Manual
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Basic Information Identification Make: Aprilia Model: Pegaso 650 IE Model Variant: Fuel Injected Codes Product Sku: AP650IE-SM Introduction Market Position Segment: Dual-sport / Adventure motorcycle Target Audience: Riders seeking a...
Taper: Motorcycles
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UGS: 142176
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| Basic Information | |
| Identification | |
| Make: | Aprilia |
| Model: | Pegaso 650 IE |
| Model Variant: | Fuel Injected |
| Codes | |
| Product Sku: | AP650IE-SM |
| Introduction | |
| Market Position | |
| Segment: | Dual-sport / Adventure motorcycle |
| Target Audience: | Riders seeking a versatile motorcycle for on-road touring and light off-road capability, with modern fuel injection. |
| Competitive Analysis | |
| Competitors: | BMW F650GS, Kawasaki KLR650, Suzuki DR650SE (competitors of its era with similar displacement and purpose). |
| Key Features | |
| Versatility: | Designed for a balance of on-road comfort and off-road usability, often favored for touring and adventure. |
| Engine Type: | Single-cylinder, liquid-cooled, fuel-injected engine providing usable torque. |
| Efi Technology: | Electronic Fuel Injection offers improved throttle response, fuel economy, and emissions compared to carbureted models. |
| Value Proposition | |
| Manual Value: | Essential for owners and technicians to maintain and repair the sophisticated fuel injection system and other components correctly. |
| Manual Details | |
| Coverage Areas | |
| Primary Coverage: | Service and Repair |
| Secondary Coverage: | Maintenance, Diagnostics, Specifications |
| Page Count | |
| Estimated Pages: | 300-500 (typical for factory service manuals of this era) |
| Manual Type | |
| Type: | Factory Service Manual |
| Language | |
| Language: | English (assumed, typical for international markets) |
| Format | |
| Format: | Digital (PDF) or Printed (depending on availability) |
| Manual Coverage | |
| Systems Covered | |
| Engine: | Complete overhaul, tuning, component testing, diagnostics (including fuel injection system) |
| Fuel Supply System: | Fuel pump, injectors, pressure regulator, throttle body, EFI control unit (ECU) diagnostics |
| Cooling System: | Radiator, fan, thermostat, water pump, coolant flow, bleeding procedures |
| Electrical System: | Wiring diagrams, battery, charging system, ignition system, lighting, starter, EFI sensors and actuators |
| Chassis: | Frame, suspension (front and rear), steering, wheels, tires, brakes (hydraulic system, components) |
| Procedures Included | |
| Maintenance: | Regular servicing, oil changes, filter replacements, lubrication, chain adjustment, valve clearance checks |
| Repair: | Component disassembly, reassembly, and replacement for all major systems |
| Troubleshooting: | Diagnostic procedures for common and complex issues, fault code interpretation (if applicable to EFI) |
| Setting Up: | Initial setup, adjustments, torque specifications for critical fasteners |
| Technical Depth | |
| Depth: | Comprehensive, suitable for professional technicians and experienced DIY mechanics. Covers everything from routine maintenance to complete engine rebuilds and EFI system diagnostics. |
| Manual Specifications | |
| File Format | |
| Digital Quality: | High-resolution, searchable text (if PDF), clear image reproduction. |
| Print Quality | |
| Print Options: | Printable pages, durable paper stock (if physical copy). |
| Binding Type | |
| Binding: | Professionally bound (if printed), ideally with a lay-flat capability for workshop use. |
| Paper Type | |
| Paper Quality: | Durable, oil-resistant paper recommended for workshop environments. |
| Engine Specifications | |
| Primary Engine | |
| Engine Configuration: | Single-cylinder, 4-stroke |
| Displacement: | 652 cc |
| Bore X Stroke: | 100 mm x 83 mm (typical for Rotax 654 engine) |
| Compression Ratio: | 10.0:1 (typical) |
| Valve Train: | SOHC, 4 valves per cylinder |
| Cooling System: | Liquid-cooled |
| Performance | |
| Horsepower: | Approximately 48-50 HP @ 7000 RPM (typical for this engine) |
| Torque: | Approximately 54-58 Nm @ 5500 RPM (typical for this engine) |
| Fuel System | |
| System Type: | Electronic Fuel Injection (EFI) |
| Throttle Body Size: | Typically 40-42mm |
| Fuel Type: | Unleaded gasoline, minimum 91 octane (RON+MON)/2) |
| Fluid Specs | |
| Engine Oil Type: | SAE 10W-40 or 15W-50, API SG or higher, JASO MA rated motorcycle oil |
| Engine Oil Capacity: | Approx. 2.5 Liters (with filter change) |
| Coolant Type: | Ethylene glycol-based antifreeze/coolant, 50/50 mix with distilled water |
| Transmission | |
| Standard | |
| Type: | 5-speed constant mesh |
| Features | |
| Clutch: | Wet multi-plate, cable-actuated |
| Final Drive: | O-ring sealed chain |
| Dimensions | |
| Exterior | |
| Length: | Approx. 2235 mm (variable by model year) |
| Width: | Approx. 870 mm (variable by model year) |
| Height: | Approx. 1340 mm (variable by model year) |
| Weights | |
| Dry Weight: | Approx. 170-180 kg (variable by model year) |
| Wet Weight: | Approx. 185-195 kg (variable by model year) |
| Fuel Tank Capacity: | Approx. 14 Liters (including reserve) |
| Wheels Tires | |
| Front Wheel: | 19-inch Spoked Wheel |
| Rear Wheel: | 17-inch Spoked Wheel |
| Front Tire Size: | 100/90-19 (common fitment) |
| Rear Tire Size: | 130/80-17 or 140/80-17 (common fitment) |
| Safety Features | |
| Ratings | |
| ABS Availability: | Optional on some later models (ABS) |
| Active Features | |
| Braking System: | Hydraulic disc brakes front and rear. Dual piston caliper front, single piston caliper rear (typical). |
| Front Brake Disc Size: | Approx. 300mm |
| Rear Brake Disc Size: | Approx. 240mm |
| Passive Features | |
| Lighting: | Halogen headlight, LED tail light (depending on year/spec). |
| Indicators: | Standard incandescent turn signals. |
| Technology Features | |
| Infotainment | |
| Dashboard Type: | Analog tachometer, digital speedometer, and multi-function display for odometer, trip meters, fuel level, coolant temperature, and warning lights. EFI system fault indicator. |
| Driver Assistance | |
| ABS: | Available as an option on some later models, providing anti-lock braking for enhanced safety, particularly in adverse conditions. |
| Connectivity | |
| Diagnostic Port: | Likely present for EFI system diagnostics, allowing connection to specialized diagnostic tools for reading fault codes and monitoring sensor data. |
| Maintenance | |
| Service Intervals | |
| Oil Change: | Every 5,000-7,500 km (3,000-5,000 miles) or annually, whichever comes first. |
| Air Filter Inspection: | Every 5,000 km (3,000 miles), replace as needed. |
| Spark Plug Replacement: | Every 10,000-15,000 km (6,000-10,000 miles), depending on plug type. |
| Valve Clearance Check: | Every 10,000-15,000 km (6,000-10,000 miles). |
| Chain Lubrication: | Every 500-750 km (300-500 miles) and after riding in wet conditions. |
| Fluid Specifications | |
| Brake Fluid Type: | DOT 4 |
| Clutch Fluid Type: | DOT 4 (if hydraulic, check specific model; some may be cable) |
| Known Issues | |
| Efi System: | Potential issues with fuel pump reliability, sensor failures (e.g., throttle position sensor), or injector clogging if fuel quality is poor. The manual would detail diagnostic procedures. |
| Starter Clutch: | Some owners report issues with the starter clutch mechanism, especially on higher mileage bikes. Manual would provide inspection and replacement steps. |
| Suspension Seals: | Fork seal leaks can occur over time, requiring replacement. Manual will cover fork disassembly and seal replacement. |
| Charging System: | Stator or regulator/rectifier failures can occur, impacting battery charging. The manual will provide testing procedures for these components. |
| Vehicle History | |
| Brand Heritage | |
| Manufacturer: | Aprilia is an Italian manufacturer renowned for its performance motorcycles, particularly in racing and sportbike segments. |
| Model Evolution | |
| First Generation: | The Pegaso line originated in the early 1990s, initially with carbureted models. The 'IE' designation signifies the introduction of Electronic Fuel Injection, representing a significant technological upgrade. |
| Engine Origin: | The 650cc single-cylinder engine used in the Pegaso was often based on or shared with Rotax (Bombardier Recreational Products), a well-respected engine manufacturer for various brands. |
| Production | |
| Production Years: | The Pegaso 650 IE was produced roughly from the early 2000s to around 2010-2014, depending on regional markets and model updates. |
| Awards & Recognition | |
| Recognitions | |
| General Reputation: | The Aprilia Pegaso 650 IE is generally well-regarded for its blend of performance, comfort, and off-road capability within the dual-sport segment. It's often praised for its distinctive styling and Italian flair. |
| Ratings | |
| Owner Satisfaction: | Owner satisfaction often hinges on proper maintenance and addressing specific model quirks. The availability of this comprehensive service manual greatly contributes to owner satisfaction by enabling effective upkeep. |