APRILIA PEGASO 655 1995 Engine Service Repair Manual
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๐ท๏ธ Basic Information Identification Make: Aprilia Model: Pegaso 655 Year: 1995 Codes Engine Code: Likely a Rotax-derived single-cylinder engine (specific code not provided in product info, but common for this era Aprilia) ๐ Introduction Market Position Segment: Adventure Touring / Dual-Sport Motorcycle Aprilia Heritage: Aprilia is renowned for its sporty motorcycles, particularly in the off-road and performance street segments. The Pegaso line represented their foray into the adventure touring category. Competitive Analysis Competitors: BMW F650 Funduro, Cagiva Elefant, Suzuki DR650, Yamaha TDM850. Key Features Design Philosophy: A blend of off-road capability with on-road comfort, suitable for long-distance touring and light off-road excursions. Emphasis on a robust single-cylinder engine. Manual Value Proposition: Empowers owners to perform detailed maintenance and repairs, saving significant costs and extending the lifespan of their motorcycle. ๐ Manual Details Coverage Areas Primary Coverage: Engine Service and Repair Secondary Coverage: Maintenance, Fuel Supply, Cooling System, Electrical System, Chassis Parts, General Information Page Count Estimated Page Count: Precise page count not specified, but detailed content implies a substantial manual, likely 200+ pages based on scope. Manual Type Type: Service Repair Manual Language Language: English Format File Format: PDF ๐ Manual Coverage Systems Covered Engine Mechanical: Engine disassembly, reassembly, individual component maintenance, internal inspections, tolerances, torque specifications. Fuel System: Carburetor system (likely Dell'Orto or similar), fuel pump, fuel lines, fuel tank maintenance. Cooling System: Radiator, coolant circulation, thermostat operation, fan system (if applicable). Electrical System: Ignition system, lighting, charging system (alternator/stator), starter motor, wiring diagrams, component testing. Chassis And Suspension: Basic chassis component information, potentially front fork and rear shock absorber maintenance/adjustment procedures. Electrical Diagnostics: Includes troubleshooting procedures for common electrical faults, testing of ignition coil, starter solenoid, and battery charging system. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, spark plug servicing, chain adjustment, brake fluid flush. Repair: Detailed step-by-step repair instructions for engine internal components, fuel system, electrical faults, etc. Troubleshooting: Diagnostic procedures for common engine performance issues, electrical problems, and starting difficulties. Disassembly Reassembly: Comprehensive procedures for engine removal, complete engine disassembly, and reassembly with detailed diagrams. Engine Removal Installation: Step-by-step instructions for the removal and re-installation of the engine from the motorcycle frame. Technical Depth Depth: Advanced engine rebuilding and component-level diagnostics. Covers detailed specifications and procedures beyond basic owner's manual. Diagrams Illustrations: Contains highly detailed exploded pictures and diagrams for all covered systems, aiding in component identification and assembly sequence. ๐ Manual Specifications File Format Compatibility: All Versions of Windows & Mac Software Requirements: Adobe PDF Reader Print Quality Printability: Printable without any restriction Binding Type Binding: Digital Download (PDF format) Paper Type Paper Quality: Not applicable (digital format) โ๏ธ Engine Specifications Primary Engine Engine Type: Single-cylinder, four-stroke Displacement: Likely around 650cc (e.g., 652cc or similar variant). Exact specification would be detailed in the manual. Bore X Stroke: Specific dimensions would be found in the manual; typically around 100mm x 83mm for this displacement range. Cooling System: Liquid-cooled Valve Train: SOHC (Single Overhead Camshaft), 4 valves (common configuration for this engine type). Performance Horsepower: Approx. 45-50 HP (depending on exact tuning and market regulations). Manual will provide precise figures. Torque: Approx. 50-55 Nm. Manual will provide precise figures. Fuel System Fuel Delivery: Carburetor (likely single large-bore, e.g., 40mm Dell'Orto PHM or similar). Fuel Type: Unleaded gasoline Engine Rebuild Torque Specs Engine: Detailed torque specifications for cylinder head bolts, connecting rod caps, main bearings, etc., will be in the manual. ๐ง Transmission Standard Type: 5-speed manual transmission Optional Variants: No automatic or DCT variants typically offered for this model. Features Clutch Type: Wet, multi-plate clutch Maintenance Transmission Fluid Type: Manual recommends specific motorcycle transmission oil or SAE 10W/40 engine oil, as per common practice for wet clutches. Manual will specify exact type and capacity. ๐ Dimensions Exterior Wheelbase: Approximately 1470-1500 mm. Exact figure in manual. Seat Height: Around 830-850 mm. Manual will provide precise spec. Weights Dry Weight: Approximately 170-180 kg. Manual will list exact weight. Fuel Capacity: Around 18-20 liters. Manual will list exact capacity. ๐ก๏ธ Safety Features Ratings Crash Safety: No official NHTSA or Euro NCAP ratings for motorcycles. Manual focuses on mechanical safety and proper operation. Active Features Braking System: Front: Disc brake (likely single or dual disc), Rear: Disc brake. Manual covers brake system maintenance, bleeding, pad replacement. Suspension Type: Front: Telescopic forks (likely conventional or possibly upside-down), Rear: Monoshock swingarm. Manual covers adjustment and maintenance. Passive Features Lighting: Headlight, taillight, brake light, turn signals. Manual includes electrical diagnostics for these components. ๐ก Technology Features Infotainment Features: Basic analog instrumentation (speedometer, tachometer, odometer, fuel gauge). No advanced infotainment systems. Driver Assistance Features: None. Connectivity Features: None. ๐ง Maintenance Service Intervals Oil Change Interval: Typically 3,000-5,000 km or annually. Manual will provide precise interval. Valve Clearance Check: Likely every 6,000-10,000 km. Manual will detail the exact interval and procedure. Fluid Specifications Engine...
Likely a Rotax-derived single-cylinder engine (specific code not provided in product info, but common for this era Aprilia)
๐ Introduction
Market Position
Segment:
Adventure Touring / Dual-Sport Motorcycle
Aprilia Heritage:
Aprilia is renowned for its sporty motorcycles, particularly in the off-road and performance street segments. The Pegaso line represented their foray into the adventure touring category.
Competitive Analysis
Competitors:
BMW F650 Funduro, Cagiva Elefant, Suzuki DR650, Yamaha TDM850.
Key Features
Design Philosophy:
A blend of off-road capability with on-road comfort, suitable for long-distance touring and light off-road excursions. Emphasis on a robust single-cylinder engine.
Manual Value Proposition:
Empowers owners to perform detailed maintenance and repairs, saving significant costs and extending the lifespan of their motorcycle.
๐ Manual Details
Coverage Areas
Primary Coverage:
Engine Service and Repair
Secondary Coverage:
Maintenance, Fuel Supply, Cooling System, Electrical System, Chassis Parts, General Information
Page Count
Estimated Page Count:
Precise page count not specified, but detailed content implies a substantial manual, likely 200+ pages based on scope.
Detailed step-by-step repair instructions for engine internal components, fuel system, electrical faults, etc.
Troubleshooting:
Diagnostic procedures for common engine performance issues, electrical problems, and starting difficulties.
Disassembly Reassembly:
Comprehensive procedures for engine removal, complete engine disassembly, and reassembly with detailed diagrams.
Engine Removal Installation:
Step-by-step instructions for the removal and re-installation of the engine from the motorcycle frame.
Technical Depth
Depth:
Advanced engine rebuilding and component-level diagnostics. Covers detailed specifications and procedures beyond basic owner's manual.
Diagrams Illustrations:
Contains highly detailed exploded pictures and diagrams for all covered systems, aiding in component identification and assembly sequence.
๐ Manual Specifications
File Format
Compatibility:
All Versions of Windows & Mac
Software Requirements:
Adobe PDF Reader
Print Quality
Printability:
Printable without any restriction
Binding Type
Binding:
Digital Download (PDF format)
Paper Type
Paper Quality:
Not applicable (digital format)
โ๏ธ Engine Specifications
Primary Engine
Engine Type:
Single-cylinder, four-stroke
Displacement:
Likely around 650cc (e.g., 652cc or similar variant). Exact specification would be detailed in the manual.
Bore X Stroke:
Specific dimensions would be found in the manual; typically around 100mm x 83mm for this displacement range.
Cooling System:
Liquid-cooled
Valve Train:
SOHC (Single Overhead Camshaft), 4 valves (common configuration for this engine type).
Performance
Horsepower:
Approx. 45-50 HP (depending on exact tuning and market regulations). Manual will provide precise figures.
Torque:
Approx. 50-55 Nm. Manual will provide precise figures.
Fuel System
Fuel Delivery:
Carburetor (likely single large-bore, e.g., 40mm Dell'Orto PHM or similar).
Fuel Type:
Unleaded gasoline
Engine Rebuild
Torque Specs Engine:
Detailed torque specifications for cylinder head bolts, connecting rod caps, main bearings, etc., will be in the manual.
๐ง Transmission
Standard
Type:
5-speed manual transmission
Optional
Variants:
No automatic or DCT variants typically offered for this model.
Features
Clutch Type:
Wet, multi-plate clutch
Maintenance
Transmission Fluid Type:
Manual recommends specific motorcycle transmission oil or SAE 10W/40 engine oil, as per common practice for wet clutches. Manual will specify exact type and capacity.
๐ Dimensions
Exterior
Wheelbase:
Approximately 1470-1500 mm. Exact figure in manual.
Seat Height:
Around 830-850 mm. Manual will provide precise spec.
Weights
Dry Weight:
Approximately 170-180 kg. Manual will list exact weight.
Fuel Capacity:
Around 18-20 liters. Manual will list exact capacity.
๐ก๏ธ Safety Features
Ratings
Crash Safety:
No official NHTSA or Euro NCAP ratings for motorcycles. Manual focuses on mechanical safety and proper operation.
Active Features
Braking System:
Front: Disc brake (likely single or dual disc), Rear: Disc brake. Manual covers brake system maintenance, bleeding, pad replacement.
Suspension Type:
Front: Telescopic forks (likely conventional or possibly upside-down), Rear: Monoshock swingarm. Manual covers adjustment and maintenance.
Passive Features
Lighting:
Headlight, taillight, brake light, turn signals. Manual includes electrical diagnostics for these components.
๐ก Technology Features
Infotainment
Features:
Basic analog instrumentation (speedometer, tachometer, odometer, fuel gauge). No advanced infotainment systems.
Driver Assistance
Features:
None.
Connectivity
Features:
None.
๐ง Maintenance
Service Intervals
Oil Change Interval:
Typically 3,000-5,000 km or annually. Manual will provide precise interval.
Valve Clearance Check:
Likely every 6,000-10,000 km. Manual will detail the exact interval and procedure.
Fluid Specifications
Engine Oil Type:
API SG, JASO MA, SAE 10W-40 or 15W-50. Manual will confirm viscosity and specifications.
Coolant Type:
Ethylene glycol-based antifreeze mixture (typically 50/50 with distilled water). Manual will specify the correct type and capacity.
Brake Fluid Type:
DOT 4.
Known Issues
Common Wear Items:
Cam chain wear, clutch wear, carburetor synchronization issues, stator/regulator issues are not uncommon on older Italian bikes. Manual helps diagnose and repair.
Parts Replacement
Spark Plug Type:
Specific NGK or Denso plug. Manual will list the exact part number and gap.
Air Filter Type:
Likely a foam or paper element. Manual will specify replacement intervals and part number.
๐ Vehicle History
Brand Heritage
Aprilia Motorsport:
Aprilia has a rich history in Grand Prix motorcycle racing, winning numerous championships, which informs their road-going models.
Model Evolution
Pegaso Line:
The Pegaso line evolved through various iterations, with engine sizes and styling changes. The 655 represents a significant iteration of their single-cylinder adventure platform.
Production
Manufacturing Origin:
Italy
๐ Awards & Recognition
Recognitions
Model Specific Awards:
Specific awards for the 1995 Pegaso 655 are not widely documented in mainstream automotive press. The manual's value lies in practical application, not award recognition.