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APRILIA PEGASO 650 Service Repair Manual 2005 Onward

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🏷️ Basic Information Identification Make: Aprilia Model: Pegaso 650 Model Variant: Factory, Trail, Strada (Common variants for this generation) Year: 2005 onwards Codes Chassis Codes: Likely includes AP813xxx series or similar, specific to the 650cc platform. 👋 Introduction Market Position Segment: Dual-sport / Adventure motorcycle, known for its versatility and Italian flair. Competitive Analysis Competitors: Competed against models like the BMW F650GS, Kawasaki KLR650, and Yamaha XT660R during its production run. Key Features Defining Characteristics: A balanced blend of on-road comfort and off-road capability, a characteristic Italian design, and the use of a Rotax-derived engine. Value Proposition Manual Benefit: Empowers owners and technicians with the knowledge to perform all maintenance and repairs, reducing reliance on specialized workshops and enhancing vehicle longevity and performance. 📋 Manual Details Coverage Areas General Coverage: All major repair topics covered A-Z, all models covered within the 2005 onward range. Page Count Estimated Pages: Likely 500+ pages, typical for a comprehensive workshop manual. Manual Type Type: Service Repair Workshop Manual Language Language: English (Assumed, standard for international manuals of this type unless otherwise specified) Format Format: PDF 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanicals, fuel injection system (EFI), ignition system, cooling system, lubrication system, exhaust system, engine diagnostics. Drivetrain Systems: Clutch operation and adjustment, gearbox (transmission) internal components, final drive (chain and sprockets), lubrication. Chassis Systems: Frame and subframe inspection, suspension (forks, rear shock absorber, linkages), steering system, wheel bearings, braking system (front and rear discs, calipers, master cylinders), ABS (if equipped). Electrical Systems: Wiring diagrams, lighting system (headlight, taillight, indicators), battery, charging system (alternator/stator, regulator/rectifier), starter motor, instrumentation, sensors, ECU (Engine Control Unit) and related sensors. Bodywork And Trim: Fairings, fuel tank, seat, luggage system mounting points, body panel removal and installation. Procedures Included Routine Maintenance: Oil and filter changes, air filter replacement, spark plug inspection/replacement, chain adjustment and lubrication, brake fluid checks, coolant checks, tire pressure checks. Troubleshooting: Diagnostic procedures for common faults, fault code lookup (if applicable), symptom-based troubleshooting guides. Component Overhaul: Detailed steps for engine disassembly and reassembly, gearbox repair, suspension fork rebuild, brake caliper overhaul, carburetor cleaning/rebuild (if applicable to specific models within the range), fuel injection system components. Special Procedures: Valve clearance adjustment, timing chain inspection, ECU remapping (if applicable), electrical component testing, ABS bleeding procedures. Technical Depth Depth: Comprehensive: From basic servicing and routine maintenance to complete engine rebuilds, electrical system diagnostics, and advanced component overhauls. Comparable to official factory service manuals used by dealerships and independent specialists. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Print Quality Readability: High resolution for clear text and diagrams, optimized for digital viewing and printing. Binding Type Binding: N/A (Digital PDF format) Paper Type Paper Quality: N/A (Digital PDF format, printable on various paper types) ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, four-stroke, liquid-cooled, DOHC Engine Capacity: 652 cc Bore X Stroke: 100 mm x 83 mm (Typical for the Rotax 654 engine). Compression Ratio: Approximately 10.0:1 to 11.5:1 (Varies slightly by model year and specific variant). Performance Horsepower: Approximately 48-50 HP (at crankshaft) @ 6500-7000 rpm. Torque: Approximately 57-60 Nm (at crankshaft) @ 5000-6000 rpm. Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) - typically Weber Marelli or similar system. Fuel Type: Unleaded gasoline (95 RON recommended) Ignition System Ignition Type: Digital electronic ignition Cooling System Cooling Method: Liquid-cooled Lubrication System Oil Capacity: Approximately 2.2 - 2.5 Liters (including oil filter, refer to manual for exact spec). Oil Grade: 10W-40 or 15W-50 Synthetic Motorcycle Oil (API SG/SH/SJ/SL/SM rated). 🔧 Transmission Standard Type: 5-speed sequential manual gearbox Optional Options: N/A (Standard 5-speed transmission) Features Clutch Type: Wet multi-plate clutch Final Drive: O-ring sealed chain drive 📐 Dimensions Exterior Length: Approx. 2150 mm (Varies slightly by model variant - Trail vs. Strada) Width: Approx. 850 mm (Varies slightly by model variant) Height: Approx. 1250 mm (Varies slightly by model variant) Seat Height: Approx. 850-870 mm (Adjustable or varies by suspension setup) Weights Dry Weight: Approx. 160-170 kg (Varies by model variant and standard equipment) Wet Weight: Approx. 175-185 kg (with all fluids) Gross Vehicle Weight Rating: Typically around 370-390 kg (including rider and luggage) Fluid Capacities Fuel Tank Capacity: 16 Liters (approx. 3.0 Liter reserve) Coolant Capacity: Approx. 1.3 Liters 🛡️ Safety Features Ratings Crash Safety: N/A (Motorcycles are not typically subjected to the same crash testing standards as cars) Active Features Braking System: Hydraulic disc brakes front and rear. ABS was optional on some models. Lighting: Halogen headlight, LED taillight, amber turn signals. Passive Features Frame Construction: Steel frame for rigidity and durability. Ergonomics: Designed for a comfortable riding position suitable for commuting and touring. 💡 Technology Features Infotainment Instrument Cluster: Analog tachometer, digital speedometer, odometer, trip meters, fuel gauge, coolant temperature gauge, and warning lights. Driver Assistance ABS System: Optional Anti-lock Braking System (ABS) available...
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APRILIA PEGASO 650 Service Repair Manual 2005 Onward
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
Pegaso 650
Model Variant:
Factory, Trail, Strada (Common variants for this generation)
Year:
2005 onwards
Codes
Chassis Codes:
Likely includes AP813xxx series or similar, specific to the 650cc platform.
👋 Introduction
Market Position
Segment:
Dual-sport / Adventure motorcycle, known for its versatility and Italian flair.
Competitive Analysis
Competitors:
Competed against models like the BMW F650GS, Kawasaki KLR650, and Yamaha XT660R during its production run.
Key Features
Defining Characteristics:
A balanced blend of on-road comfort and off-road capability, a characteristic Italian design, and the use of a Rotax-derived engine.
Value Proposition
Manual Benefit:
Empowers owners and technicians with the knowledge to perform all maintenance and repairs, reducing reliance on specialized workshops and enhancing vehicle longevity and performance.
📋 Manual Details
Coverage Areas
General Coverage:
All major repair topics covered A-Z, all models covered within the 2005 onward range.
Page Count
Estimated Pages:
Likely 500+ pages, typical for a comprehensive workshop manual.
Manual Type
Type:
Service Repair Workshop Manual
Language
Language:
English (Assumed, standard for international manuals of this type unless otherwise specified)
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine mechanicals, fuel injection system (EFI), ignition system, cooling system, lubrication system, exhaust system, engine diagnostics.
Drivetrain Systems:
Clutch operation and adjustment, gearbox (transmission) internal components, final drive (chain and sprockets), lubrication.
Chassis Systems:
Frame and subframe inspection, suspension (forks, rear shock absorber, linkages), steering system, wheel bearings, braking system (front and rear discs, calipers, master cylinders), ABS (if equipped).
Electrical Systems:
Wiring diagrams, lighting system (headlight, taillight, indicators), battery, charging system (alternator/stator, regulator/rectifier), starter motor, instrumentation, sensors, ECU (Engine Control Unit) and related sensors.
Bodywork And Trim:
Fairings, fuel tank, seat, luggage system mounting points, body panel removal and installation.
Procedures Included
Routine Maintenance:
Oil and filter changes, air filter replacement, spark plug inspection/replacement, chain adjustment and lubrication, brake fluid checks, coolant checks, tire pressure checks.
Troubleshooting:
Diagnostic procedures for common faults, fault code lookup (if applicable), symptom-based troubleshooting guides.
Component Overhaul:
Detailed steps for engine disassembly and reassembly, gearbox repair, suspension fork rebuild, brake caliper overhaul, carburetor cleaning/rebuild (if applicable to specific models within the range), fuel injection system components.
Special Procedures:
Valve clearance adjustment, timing chain inspection, ECU remapping (if applicable), electrical component testing, ABS bleeding procedures.
Technical Depth
Depth:
Comprehensive: From basic servicing and routine maintenance to complete engine rebuilds, electrical system diagnostics, and advanced component overhauls. Comparable to official factory service manuals used by dealerships and independent specialists.
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Print Quality
Readability:
High resolution for clear text and diagrams, optimized for digital viewing and printing.
Binding Type
Binding:
N/A (Digital PDF format)
Paper Type
Paper Quality:
N/A (Digital PDF format, printable on various paper types)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Single-cylinder, four-stroke, liquid-cooled, DOHC
Engine Capacity:
652 cc
Bore X Stroke:
100 mm x 83 mm (Typical for the Rotax 654 engine).
Compression Ratio:
Approximately 10.0:1 to 11.5:1 (Varies slightly by model year and specific variant).
Performance
Horsepower:
Approximately 48-50 HP (at crankshaft) @ 6500-7000 rpm.
Torque:
Approximately 57-60 Nm (at crankshaft) @ 5000-6000 rpm.
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) - typically Weber Marelli or similar system.
Fuel Type:
Unleaded gasoline (95 RON recommended)
Ignition System
Ignition Type:
Digital electronic ignition
Cooling System
Cooling Method:
Liquid-cooled
Lubrication System
Oil Capacity:
Approximately 2.2 - 2.5 Liters (including oil filter, refer to manual for exact spec).
Oil Grade:
10W-40 or 15W-50 Synthetic Motorcycle Oil (API SG/SH/SJ/SL/SM rated).
🔧 Transmission
Standard
Type:
5-speed sequential manual gearbox
Optional
Options:
N/A (Standard 5-speed transmission)
Features
Clutch Type:
Wet multi-plate clutch
Final Drive:
O-ring sealed chain drive
📐 Dimensions
Exterior
Length:
Approx. 2150 mm (Varies slightly by model variant - Trail vs. Strada)
Width:
Approx. 850 mm (Varies slightly by model variant)
Height:
Approx. 1250 mm (Varies slightly by model variant)
Seat Height:
Approx. 850-870 mm (Adjustable or varies by suspension setup)
Weights
Dry Weight:
Approx. 160-170 kg (Varies by model variant and standard equipment)
Wet Weight:
Approx. 175-185 kg (with all fluids)
Gross Vehicle Weight Rating:
Typically around 370-390 kg (including rider and luggage)
Fluid Capacities
Fuel Tank Capacity:
16 Liters (approx. 3.0 Liter reserve)
Coolant Capacity:
Approx. 1.3 Liters
🛡️ Safety Features
Ratings
Crash Safety:
N/A (Motorcycles are not typically subjected to the same crash testing standards as cars)
Active Features
Braking System:
Hydraulic disc brakes front and rear. ABS was optional on some models.
Lighting:
Halogen headlight, LED taillight, amber turn signals.
Passive Features
Frame Construction:
Steel frame for rigidity and durability.
Ergonomics:
Designed for a comfortable riding position suitable for commuting and touring.
💡 Technology Features
Infotainment
Instrument Cluster:
Analog tachometer, digital speedometer, odometer, trip meters, fuel gauge, coolant temperature gauge, and warning lights.
Driver Assistance
ABS System:
Optional Anti-lock Braking System (ABS) available on certain models, which would be detailed in the manual.
Connectivity
ECU Functions:
Engine Control Unit (ECU) manages fuel injection, ignition timing, and other engine parameters. Manual provides diagnostic access.
Lighting Technology
Headlight Type:
Halogen bulb (e.g., H4 type), manual covers replacement and aiming.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 6,000 - 10,000 km or annually, whichever comes first (refer to manual for exact specification).
Air Filter Check:
Every 6,000 km or annually.
Spark Plug Inspection:
Every 12,000 - 18,000 km.
Valve Clearance Check:
Every 12,000 - 18,000 km.
Chain Maintenance:
Lubricate and adjust every 1,000 km or as needed. Replace when worn.
Fluid Specifications
Coolant Type:
Ethylene glycol based coolant, mixed with distilled water (50/50 ratio).
Brake Fluid:
DOT 4 Hydraulic Brake Fluid.
Known Issues
Common Problems:
Potential for stator/regulator issues (common in many motorcycles of this era), minor electrical gremlins, front fork seal leaks, and chain/sprocket wear. The manual will detail how to diagnose and fix these.
Specific Component Wear:
Water pump seals and clutch slave cylinder seals can be wear items over time.
📚 Vehicle History
Brand Heritage
Manufacturer:
Aprilia is an Italian manufacturer known for its performance-oriented motorcycles, particularly in the sportbike and off-road segments. Founded in 1945.
Model Evolution
Lineage:
The Pegaso 650 line has a history dating back to the early 1990s, evolving through various engine configurations and styling updates. The 2005 onward models represent a significant update, often featuring fuel injection and updated chassis components.
Production
Manufacturing Location:
Italy
Production Years:
The Pegaso 650 platform was in production in various forms from the early 1990s through the late 2000s, with the 650cc Rotax-engined version being prevalent from the mid-2000s onwards.
🏆 Awards & Recognition
Recognitions
Motorcycle Reviews:
While specific awards might be scarce, the Pegaso 650 was generally well-regarded for its versatility and enjoyable riding characteristics in its segment during its production years.
Ratings
Owner Satisfaction:
Owner satisfaction often tied to its balanced performance and the appeal of the Aprilia brand.
Certifications
Manual Standard:
Designed to meet or exceed the standards of professional automotive repair documentation.
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