🏷️ Basic Information Identification Make: Aprilia Model: Pegaso 650 Product Name: APRILIA PEGASO 650 Service Repair Workshop Manual 1997-2004 Product Type: Service Repair Workshop Manual 👋 Introduction Market Position Vehicle Segment: Dual-sport / Adventure motorcycle, known for versatility on and off-road. Target Audience: Riders seeking a capable and reliable machine for commuting, touring, and light off-roading. Competitive Analysis Key Competitors: BMW F650 Funduro, Yamaha XT660, Kawasaki KLR650. Key Features Engine Configuration: Robust single-cylinder engine, known for torque and simplicity. Suspension Design: Long-travel suspension suitable for varied terrain. Frame Type: Steel trellis frame for rigidity. 📋 Manual Details Coverage Areas Model Years Covered: 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004 Model Variants Covered: All models Repair Scope: A-Z (All Repairs) Page Count Estimated Page Count: Likely 500+ pages (typical for comprehensive service manuals) Manual Type Manual Type: Workshop Service Repair Manual Language Language: English Format Format: Digital (likely PDF) 📖 Manual Coverage Systems Covered Engine System: Detailed diagnosis, repair, overhaul, and specifications for the Rotax 654cc single-cylinder engine. Fuel System: Carburetor (Mikuni BSR42) or fuel injection system (depending on specific model variant), fuel pump, lines, and tank maintenance. Ignition System: Ignition timing, spark plug specifications, coil testing, CDI unit diagnostics. Cooling System: Radiator, fan, thermostat, coolant flow, bleeding procedures, fluid specifications. Exhaust System: Exhaust pipe, muffler, lambda sensor (if applicable) inspection and replacement. Transmission System: Clutch operation, gear shifting mechanism, transmission oil change and checks, internal transmission repair. Drivetrain: Chain and sprocket maintenance, adjustment, and replacement, rear wheel hub, swingarm bearing service. Suspension System: Front fork (telescopic, possibly with adjustable preload/damping) overhaul, seals, oil, and rear shock absorber service/replacement. Braking System: Front and rear brake caliper service, pad replacement, fluid flush and bleeding (including ABS if equipped), master cylinder, brake lines. Wheel And Tire System: Wheel bearing inspection and replacement, tire pressure, wear limits, and fitting. Electrical System: Battery maintenance, charging system (alternator/stator), starter motor, lighting circuits, wiring diagrams, fuse box, instrument panel. Frame And Bodywork: Chassis inspection, frame alignment (if necessary), fairing removal/installation, seat, tank, and fender maintenance. Controls And Cables: Throttle control, clutch cable, brake levers, and all associated linkage adjustments and lubrication. Diagnostic Procedures: Troubleshooting guides for common faults, error code interpretation (if applicable). Procedures Included Scheduled Maintenance: Detailed intervals and procedures for oil changes, filter replacements, chain lubrication, brake checks, etc. Engine Overhaul: Complete engine disassembly, inspection, component replacement, and reassembly instructions. Suspension Rebuild: Fork seal replacement, damping rod service, shock absorber overhaul. Brake System Repair: Caliber rebuilds, master cylinder replacement, bleeding procedures. Electrical Troubleshooting: Step-by-step guides for diagnosing electrical faults using wiring diagrams. Carburetor Rebuild: Complete disassembly, cleaning, adjustment, and reassembly of the Mikuni BSR42 carburetor. Fuel Injection Service: Diagnostics and basic service for fuel-injected models (if applicable). Wheel Bearing Replacement: Correct procedures for removing and installing wheel bearings. Chain And Sprocket Replacement: Correct installation and alignment of drivetrain components. Bodywork Repair: Removal and installation of fairings, panels, and other cosmetic components. Technical Depth Depth Level: Comprehensive (suitable for dealership technicians, covering everything from basic maintenance to complete engine rebuilds). Diagnostic Capability: Advanced troubleshooting and diagnostic procedures, including component testing and fault finding. Rebuild Instructions: Detailed, step-by-step instructions for complete disassembly and reassembly of major mechanical and electrical components. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) is most common for digital manuals. Searchability: Likely text-searchable PDF for easy information retrieval. Print Quality: High-resolution digital images and clear text, optimized for printing. Binding Type Binding Type: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder, liquid-cooled, DOHC Displacement: 654 cc Bore X Stroke: 100 mm x 83.7 mm (typical for Rotax 654) Compression Ratio: Approximately 10.5:1 (typical) Performance Horsepower: Approx. 48-50 HP at 6,500 RPM (depending on model year and specific tune) Torque: Approx. 60 Nm (44 lb-ft) at 5,000 RPM (depending on model year and specific tune) Fuel System Fuel Delivery: Mikuni BSR42 CV Carburetor (for most models) or Electronic Fuel Injection (EFI) on later variants. Fuel Type: Unleaded gasoline (91 octane or higher) Lubrication Oil Type: SAE 10W-40, API SG or higher, JASO MA compliant motorcycle oil Oil Capacity: Approx. 2.5 - 2.8 Liters (with filter change) 🔧 Transmission Standard Transmission Type: 5-speed constant mesh Optional Optional Features: No automatic or CVT options typically available for this model. Features Clutch Type: Wet multi-plate clutch, cable operated Final Drive: O-ring sealed chain drive Transmission Oil Type: SAE 75W-90, API GL-4 or GL-5 Gear Oil Transmission Oil Capacity: Approx. 0.7 - 0.8 Liters 📐 Dimensions Exterior Length: Approx. 2,200 mm Width: Approx. 850 mm Height: Approx. 1,350 mm Wheelbase: Approx. 1,500 mm Weights Dry Weight: Approx. 180 kg Wet Weight: Approx. 195 kg (with all fluids) Fuel Capacity: Approx. 21 Liters Seat Height: Approx. 860 mm 🛡️ Safety Features Ratings Safety Certification:...