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APRILIA PEGASO 650 Workshop Repair Manual 1997-2004

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🏷️ Basic Information Identification Make: Aprilia Model: Pegaso 650 Year Range: 1997-2004 👋 Introduction Market Position Category: Dual-Sport/Adventure Motorcycle Target User: Enthusiasts, DIY Mechanics, Professional Workshops Competitive Analysis Key Competitors: BMW F650GS, Kawasaki KLR650, Suzuki DR650SE, Yamaha XT660R Key Features Manual Value: Authentic dealer-level information, essential for maintaining peak performance and longevity Vehicle Appeal: Versatile for commuting, touring, and light off-road use 📋 Manual Details Coverage Areas Primary Coverage: Workshop Service and Repair Secondary Coverage: Maintenance, Troubleshooting, Diagnostics, Overhaul Page Count Estimated Pages: 500+ Manual Type Type: Professional Workshop Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine: Complete Engine Assembly, Carburetor/Injection Systems, Ignition, Lubrication, Cooling Transmission: Clutch, Gearbox, Final Drive, Oil Specifications Chassis: Frame, Suspension (Front/Rear), Steering, Swingarm Brakes: Hydraulic System, Caliper Overhaul, Pad Replacement, Fluid Types, Troubleshooting Electrical: Wiring Diagrams, Lighting, Starting System, Charging System, Ignition System Components, Sensor Testing Fuel System: Fuel Tank, Fuel Pump, Carburetor/Injection System Service, Fuel Filter Replacement Exhaust System: Muffler, Exhaust Pipes, Heat Shields Bodywork: Fairings, Seat, Fuel Tank Cover, Fenders, Body Panel Removal/Installation Procedures Included Maintenance: Oil Changes, Filter Replacements, Chain Adjustment, Spark Plug Service, Air Filter Cleaning/Replacement, Valve Clearance Checks Troubleshooting: Diagnostic Flowcharts, Symptom-Based Problem Identification, Common Faults and Solutions Repair: Engine Rebuilds, Transmission Overhauls, Suspension Component Replacement, Brake System Repairs, Electrical Component Diagnosis and Replacement Assembly Disassembly: Detailed step-by-step instructions with diagrams for all major components Technical Depth Depth: Comprehensive, from basic maintenance to complete engine and transmission rebuilds 📊 Manual Specifications File Format Type: PDF Searchability: Text-searchable Print Quality Quality: High-resolution, clear diagrams and text Binding Type Type: N/A (Digital Download) Paper Type Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Type: Four-stroke, single-cylinder, DOHC Displacement: 652 cc (39.8 cu in) Bore X Stroke: 100 mm x 83 mm (3.94 x 3.27 in) Compression Ratio: 10.0:1 Cooling System: Liquid-cooled Performance Horsepower Approx: 48 hp (36 kW) @ 7000 rpm Torque Approx: 57 Nm (42 lb-ft) @ 5500 rpm Fuel System Carburetor Models: Mikuni BSR36 (specific model may vary by market) Fuel Injection Models: Optional on later models or specific variants (check manual for exact details) Fuel Type: Unleaded gasoline, 91-98 octane Lubrication Oil Type Spec: API SG/SH/SJ or JASO MA certified 10W-40 or 15W-50 (refer to manual for precise specification based on climate) 🔧 Transmission Standard Type: 5-speed manual Clutch: Wet multi-plate, cable operated Final Drive: O-ring sealed chain, 16/47 gearing (typical) Features Gearbox Oil Spec: API GL-4 or GL-5 SAE 80W-90 (verify in manual for exact type and quantity) 📐 Dimensions Exterior Length: Approx. 2220 mm (87.4 in) Width: Approx. 860 mm (33.9 in) Height: Approx. 1260 mm (49.6 in) Wheelbase: Approx. 1470 mm (57.9 in) Weights Dry Weight: Approx. 168 kg (370 lbs) Wet Weight Approx: Approx. 184 kg (405 lbs) Capacities Fuel Tank Capacity: 13 Liters (3.4 US gal) Engine Oil Capacity: Approx. 2.3 Liters (2.4 US qt) with filter change 🛡️ Safety Features Ratings NHTSA Rating: Not Applicable (Motorcycle) Active Features Braking System: Disc Brakes Front and Rear, Optional ABS on some models (verify specific bike) Tire Sizes: Front: 90/90-21, Rear: 130/80-17 (typical, verify for specific model year) Passive Features Lighting: Halogen Headlight, LED Taillight (later models), Turn Signals 💡 Technology Features Infotainment Dashboard: Analog speedometer, tachometer, odometer, trip meter, coolant temperature gauge, warning lights. Driver Assistance ABS: Optional Anti-lock Braking System available on select models. Connectivity Bluetooth: Not factory equipped. 🔧 Maintenance Service Intervals Oil Change: Every 3,000 - 6,000 km (2,000 - 4,000 miles) or annually, whichever comes first (refer to manual for exact recommendation) Air Filter Cleaning: Every 6,000 km (4,000 miles) Valve Clearance Check: Every 12,000 km (7,500 miles) Spark Plug Replacement: Every 12,000 km (7,500 miles) Fluid Specifications Coolant Type: Ethylene glycol based antifreeze/coolant, 50/50 mix with distilled water Brake Fluid: DOT 4 (verify in manual) Known Issues Charging System: Stator or rectifier failures can occur with age and mileage. Carburetor: Older models with carburetors may require periodic cleaning and adjustment for optimal performance. Rear Shock: Original rear shock absorbers may degrade over time, affecting ride quality. Electrical Connectors: Corrosion in electrical connectors can lead to intermittent faults. 📚 Vehicle History Brand Heritage Manufacturer: Aprilia, Italian motorcycle manufacturer known for performance and racing heritage Model Evolution Generation Notes: The Pegaso 650 was Aprilia's entry into the mid-weight dual-sport segment, popular for its accessible ergonomics and versatility. Key Changes 1997-2004: Included carburetor and fuel-injected versions, slight styling updates, and potential suspension component revisions over the years. The Rotax engine was a common powerplant for this era. Production Manufacturing Location: Italy 🏆 Awards & Recognition Recognitions Market Reputation: Praised for its versatility and comfort for its class during its production run. Ratings Typical User Reviews: Users often highlight its comfortable riding position for longer distances and its capable handling on varied terrain.
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APRILIA PEGASO 650 Workshop Repair Manual 1997-2004
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
Pegaso 650
Year Range:
1997-2004
👋 Introduction
Market Position
Category:
Dual-Sport/Adventure Motorcycle
Target User:
Enthusiasts, DIY Mechanics, Professional Workshops
Competitive Analysis
Key Competitors:
BMW F650GS, Kawasaki KLR650, Suzuki DR650SE, Yamaha XT660R
Key Features
Manual Value:
Authentic dealer-level information, essential for maintaining peak performance and longevity
Vehicle Appeal:
Versatile for commuting, touring, and light off-road use
📋 Manual Details
Coverage Areas
Primary Coverage:
Workshop Service and Repair
Secondary Coverage:
Maintenance, Troubleshooting, Diagnostics, Overhaul
Page Count
Estimated Pages:
500+
Manual Type
Type:
Professional Workshop Manual
Language
Language:
English
Format
Format:
Downloadable PDF
📖 Manual Coverage
Systems Covered
Engine:
Complete Engine Assembly, Carburetor/Injection Systems, Ignition, Lubrication, Cooling
Transmission:
Clutch, Gearbox, Final Drive, Oil Specifications
Chassis:
Frame, Suspension (Front/Rear), Steering, Swingarm
Brakes:
Hydraulic System, Caliper Overhaul, Pad Replacement, Fluid Types, Troubleshooting
Electrical:
Wiring Diagrams, Lighting, Starting System, Charging System, Ignition System Components, Sensor Testing
Fuel System:
Fuel Tank, Fuel Pump, Carburetor/Injection System Service, Fuel Filter Replacement
Exhaust System:
Muffler, Exhaust Pipes, Heat Shields
Bodywork:
Fairings, Seat, Fuel Tank Cover, Fenders, Body Panel Removal/Installation
Procedures Included
Maintenance:
Oil Changes, Filter Replacements, Chain Adjustment, Spark Plug Service, Air Filter Cleaning/Replacement, Valve Clearance Checks
Troubleshooting:
Diagnostic Flowcharts, Symptom-Based Problem Identification, Common Faults and Solutions
Repair:
Engine Rebuilds, Transmission Overhauls, Suspension Component Replacement, Brake System Repairs, Electrical Component Diagnosis and Replacement
Assembly Disassembly:
Detailed step-by-step instructions with diagrams for all major components
Technical Depth
Depth:
Comprehensive, from basic maintenance to complete engine and transmission rebuilds
📊 Manual Specifications
File Format
Type:
PDF
Searchability:
Text-searchable
Print Quality
Quality:
High-resolution, clear diagrams and text
Binding Type
Type:
N/A (Digital Download)
Paper Type
Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Type:
Four-stroke, single-cylinder, DOHC
Displacement:
652 cc (39.8 cu in)
Bore X Stroke:
100 mm x 83 mm (3.94 x 3.27 in)
Compression Ratio:
10.0:1
Cooling System:
Liquid-cooled
Performance
Horsepower Approx:
48 hp (36 kW) @ 7000 rpm
Torque Approx:
57 Nm (42 lb-ft) @ 5500 rpm
Fuel System
Carburetor Models:
Mikuni BSR36 (specific model may vary by market)
Fuel Injection Models:
Optional on later models or specific variants (check manual for exact details)
Fuel Type:
Unleaded gasoline, 91-98 octane
Lubrication
Oil Type Spec:
API SG/SH/SJ or JASO MA certified 10W-40 or 15W-50 (refer to manual for precise specification based on climate)
🔧 Transmission
Standard
Type:
5-speed manual
Clutch:
Wet multi-plate, cable operated
Final Drive:
O-ring sealed chain, 16/47 gearing (typical)
Features
Gearbox Oil Spec:
API GL-4 or GL-5 SAE 80W-90 (verify in manual for exact type and quantity)
📐 Dimensions
Exterior
Length:
Approx. 2220 mm (87.4 in)
Width:
Approx. 860 mm (33.9 in)
Height:
Approx. 1260 mm (49.6 in)
Wheelbase:
Approx. 1470 mm (57.9 in)
Weights
Dry Weight:
Approx. 168 kg (370 lbs)
Wet Weight Approx:
Approx. 184 kg (405 lbs)
Capacities
Fuel Tank Capacity:
13 Liters (3.4 US gal)
Engine Oil Capacity:
Approx. 2.3 Liters (2.4 US qt) with filter change
🛡️ Safety Features
Ratings
NHTSA Rating:
Not Applicable (Motorcycle)
Active Features
Braking System:
Disc Brakes Front and Rear, Optional ABS on some models (verify specific bike)
Tire Sizes:
Front: 90/90-21, Rear: 130/80-17 (typical, verify for specific model year)
Passive Features
Lighting:
Halogen Headlight, LED Taillight (later models), Turn Signals
💡 Technology Features
Infotainment
Dashboard:
Analog speedometer, tachometer, odometer, trip meter, coolant temperature gauge, warning lights.
Driver Assistance
ABS:
Optional Anti-lock Braking System available on select models.
Connectivity
Bluetooth:
Not factory equipped.
🔧 Maintenance
Service Intervals
Oil Change:
Every 3,000 - 6,000 km (2,000 - 4,000 miles) or annually, whichever comes first (refer to manual for exact recommendation)
Air Filter Cleaning:
Every 6,000 km (4,000 miles)
Valve Clearance Check:
Every 12,000 km (7,500 miles)
Spark Plug Replacement:
Every 12,000 km (7,500 miles)
Fluid Specifications
Coolant Type:
Ethylene glycol based antifreeze/coolant, 50/50 mix with distilled water
Brake Fluid:
DOT 4 (verify in manual)
Known Issues
Charging System:
Stator or rectifier failures can occur with age and mileage.
Carburetor:
Older models with carburetors may require periodic cleaning and adjustment for optimal performance.
Rear Shock:
Original rear shock absorbers may degrade over time, affecting ride quality.
Electrical Connectors:
Corrosion in electrical connectors can lead to intermittent faults.
📚 Vehicle History
Brand Heritage
Manufacturer:
Aprilia, Italian motorcycle manufacturer known for performance and racing heritage
Model Evolution
Generation Notes:
The Pegaso 650 was Aprilia's entry into the mid-weight dual-sport segment, popular for its accessible ergonomics and versatility.
Key Changes 1997-2004:
Included carburetor and fuel-injected versions, slight styling updates, and potential suspension component revisions over the years. The Rotax engine was a common powerplant for this era.
Production
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Market Reputation:
Praised for its versatility and comfort for its class during its production run.
Ratings
Typical User Reviews:
Users often highlight its comfortable riding position for longer distances and its capable handling on varied terrain.
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