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APRILIA PEGASO 650 2005 Full Service Repair Manual

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Basic Information Identification Make: Aprilia Model: Pegaso 650 Year: 2005 Product Type: Full Service Repair Manual Introduction Market Position Segment: Dual-sport / Adventure Motorcycle Target Audience: Riders seeking versatility for on-road and light off-road use Competitive Analysis Key Competitors: BMW F 650 GS, Kawasaki KLR650, Suzuki DR650SE Key Features Engine Type: Single-cylinder, Rotax-designed Suspension Type: Telescopic front forks, Monoshock rear suspension Fueling: Fuel Injection Manual Value Proposition Benefit To Owner: Enables DIY maintenance and repairs, saving time and money, and fostering a deeper understanding of the motorcycle. Manual Details Coverage Areas Engine Service: Comprehensive Transmission Service: Comprehensive Electrical System: Comprehensive Chassis And Suspension: Comprehensive Bodywork And Fairings: Comprehensive Troubleshooting Guides: Extensive Page Count Estimated Pages: 500+ Manual Type Type: Professional Technical Manual / Workshop Manual Language Primary Language: English Format Digital Format: PDF Searchable: Yes Printable: Yes Manual Coverage Systems Covered Engine Mechanical: Top End (Cylinder Head, Valves), Bottom End (Crankshaft, Connecting Rods, Pistons), Lubrication System, Cooling System Fuel System: Fuel Injection System (ECU, Injectors, Fuel Pump, Pressure Regulator), Carburetor (if applicable variant) Ignition System: Ignition Coils, Spark Plugs, ECU Control Exhaust System: Exhaust Pipes, Muffler, Lambda Sensor (if equipped) Transmission And Drivetrain: Clutch System (Operation, Adjustment, Replacement), Gearbox (Internal Components, Shifting Mechanism), Final Drive (Chain/Belt, Sprockets/Pulleys) Suspension: Front Forks (Oil, Seals, Spring Rates, Adjustment), Rear Shock Absorber (Spring, Damping, Adjustment), Linkages Brakes: Brake Calipers, Master Cylinders, Brake Lines, Pads, Discs, ABS System (if equipped) Electrical System: Battery, Charging System (Alternator, Regulator/Rectifier), Starter Motor, Lighting System, Instrumentation, Wiring Harness Diagrams, ECU Diagnostics Wheels And Tires: Wheel Bearings, Tire Pressure Specifications, Wheel Balancing Frame And Body: Frame Inspection, Fairing Removal/Installation, Seat, Handlebars, Footpegs Procedures Included Routine Maintenance: Oil and Filter Changes, Air Filter Cleaning/Replacement, Spark Plug Service, Chain Adjustment, Brake Fluid Flush, Coolant Flush, Tire Pressure Checks Engine Overhaul: Top End Rebuild, Bottom End Rebuild, Piston Ring Replacement, Valve Adjustment, Gasket Replacement Transmission Repair: Clutch Replacement, Gearbox Disassembly/Reassembly, Bearing Replacement Suspension Service: Fork Seal Replacement, Fork Oil Change, Shock Absorber Servicing Brake System Maintenance: Brake Pad Replacement, Brake Bleeding, Master Cylinder Rebuild, Line Replacement Electrical Troubleshooting: Wiring Diagram Interpretation, Fault Diagnosis for Charging/Starting Systems, Light Malfunctions, Sensor Issues Fuel System Diagnostics: Injector Cleaning, Fuel Pressure Testing, ECU Fault Code Reading Diagnostic Procedures: Troubleshooting common symptoms, fault code interpretation Reassembly Instructions: Torque specifications for all critical fasteners Technical Depth Depth: Comprehensive rebuilds, advanced diagnostics, detailed component removal and installation Diagrams: Detailed exploded views, wiring diagrams, schematics Specifications: All factory specifications, tolerances, fluid capacities, torque values Manual Specifications File Format Type: Portable Document Format (PDF) Quality: High-resolution scans, clear text and images Print Quality Image Clarity: Excellent Text Readability: High Binding Type Digital Format Benefit: No physical binding required, instantly accessible Paper Type Digital Format Benefit: N/A (digital file) Engine Specifications Primary Engine Type: Single-cylinder, Four-stroke Displacement: 652 cc (39.8 cu in) Bore X Stroke: 100 mm x 83 mm (3.94 x 3.27 in) Cooling System: Liquid-cooled Valve Train: SOHC, 4 valves per cylinder Performance Horsepower Claimed: 48 hp (36 kW) @ 6500 rpm Torque Claimed: 57 Nm (42 lb-ft) @ 5000 rpm Fuel System Injection Type: Electronic Fuel Injection (EFI) Fuel Requirement: Unleaded gasoline, minimum 91 octane (RON+MON)/2 Lubrication System Oil Type: API SG or higher, SAE 10W-40 motorcycle specific oil recommended Oil Capacity W Filter: Approx. 2.0 liters (2.1 US qt) Oil Filter Part Number Example: Hiflofiltro HF152 or OEM equivalent Transmission Standard Type: 5-speed constant mesh Features Clutch Type: Wet, multi-plate Final Drive: Chain Drive Fluid Type Transmission Oil: SAE 75W-90 or 80W-90 GL-4 gear oil (check manual for specific recommendation) Dimensions Exterior Length: Approx. 2235 mm (88.0 in) Width: Approx. 870 mm (34.3 in) at handlebars Height: Approx. 1320 mm (52.0 in) at seat Wheelbase: Approx. 1470 mm (57.9 in) Weights Dry Weight Claimed: Approx. 166 kg (366 lbs) Gross Vehicle Weight Rating Gvwr: Refer to vehicle VIN plate/manual Capacities Fuel Tank Capacity: Approx. 17 liters (4.5 US gal) Coolant Capacity: Approx. 1.2 liters (1.3 US qt) Safety Features Ratings Crash Test Data: Not applicable to motorcycles in the same way as cars. Active Features Braking System: Dual Disc Front, Single Disc Rear. ABS available on some variants. Lighting: Halogen Headlight, LED Taillight (model dependent) Passive Features Frame Construction: Steel, Trellis frame Technology Features Infotainment Instrumentation: Digital speedometer, analog tachometer, odometer, trip meter, fuel gauge, indicator lights. Driver Assistance ABS: Optional Anti-lock Braking System (ABS) available on certain 2005 models. Connectivity Diagnostic Ports: Diagnostic connector for ECU access (requires specific tools/software). Maintenance Service Intervals Oil Change Interval: Every 6,000 km (3,700 miles) or annually Air Filter Service: Every 12,000 km (7,500 miles) or annually Spark Plug Replacement: Every 12,000 km (7,500 miles) Valve Clearance Check: Every 18,000 km (11,000 miles) Fluid Specifications Brake Fluid: DOT 4 Coolant Type: Ethylene glycol-based antifreeze with corrosion inhibitors (typically a 50/50 mix with...
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APRILIA PEGASO 650 2005 Full Service Repair Manual
Basic Information
Identification
Make: Aprilia
Model: Pegaso 650
Year: 2005
Product Type: Full Service Repair Manual
Introduction
Market Position
Segment: Dual-sport / Adventure Motorcycle
Target Audience: Riders seeking versatility for on-road and light off-road use
Competitive Analysis
Key Competitors: BMW F 650 GS, Kawasaki KLR650, Suzuki DR650SE
Key Features
Engine Type: Single-cylinder, Rotax-designed
Suspension Type: Telescopic front forks, Monoshock rear suspension
Fueling: Fuel Injection
Manual Value Proposition
Benefit To Owner: Enables DIY maintenance and repairs, saving time and money, and fostering a deeper understanding of the motorcycle.
Manual Details
Coverage Areas
Engine Service: Comprehensive
Transmission Service: Comprehensive
Electrical System: Comprehensive
Chassis And Suspension: Comprehensive
Bodywork And Fairings: Comprehensive
Troubleshooting Guides: Extensive
Page Count
Estimated Pages: 500+
Manual Type
Type: Professional Technical Manual / Workshop Manual
Language
Primary Language: English
Format
Digital Format: PDF
Searchable: Yes
Printable: Yes
Manual Coverage
Systems Covered
Engine Mechanical: Top End (Cylinder Head, Valves), Bottom End (Crankshaft, Connecting Rods, Pistons), Lubrication System, Cooling System
Fuel System: Fuel Injection System (ECU, Injectors, Fuel Pump, Pressure Regulator), Carburetor (if applicable variant)
Ignition System: Ignition Coils, Spark Plugs, ECU Control
Exhaust System: Exhaust Pipes, Muffler, Lambda Sensor (if equipped)
Transmission And Drivetrain: Clutch System (Operation, Adjustment, Replacement), Gearbox (Internal Components, Shifting Mechanism), Final Drive (Chain/Belt, Sprockets/Pulleys)
Suspension: Front Forks (Oil, Seals, Spring Rates, Adjustment), Rear Shock Absorber (Spring, Damping, Adjustment), Linkages
Brakes: Brake Calipers, Master Cylinders, Brake Lines, Pads, Discs, ABS System (if equipped)
Electrical System: Battery, Charging System (Alternator, Regulator/Rectifier), Starter Motor, Lighting System, Instrumentation, Wiring Harness Diagrams, ECU Diagnostics
Wheels And Tires: Wheel Bearings, Tire Pressure Specifications, Wheel Balancing
Frame And Body: Frame Inspection, Fairing Removal/Installation, Seat, Handlebars, Footpegs
Procedures Included
Routine Maintenance: Oil and Filter Changes, Air Filter Cleaning/Replacement, Spark Plug Service, Chain Adjustment, Brake Fluid Flush, Coolant Flush, Tire Pressure Checks
Engine Overhaul: Top End Rebuild, Bottom End Rebuild, Piston Ring Replacement, Valve Adjustment, Gasket Replacement
Transmission Repair: Clutch Replacement, Gearbox Disassembly/Reassembly, Bearing Replacement
Suspension Service: Fork Seal Replacement, Fork Oil Change, Shock Absorber Servicing
Brake System Maintenance: Brake Pad Replacement, Brake Bleeding, Master Cylinder Rebuild, Line Replacement
Electrical Troubleshooting: Wiring Diagram Interpretation, Fault Diagnosis for Charging/Starting Systems, Light Malfunctions, Sensor Issues
Fuel System Diagnostics: Injector Cleaning, Fuel Pressure Testing, ECU Fault Code Reading
Diagnostic Procedures: Troubleshooting common symptoms, fault code interpretation
Reassembly Instructions: Torque specifications for all critical fasteners
Technical Depth
Depth: Comprehensive rebuilds, advanced diagnostics, detailed component removal and installation
Diagrams: Detailed exploded views, wiring diagrams, schematics
Specifications: All factory specifications, tolerances, fluid capacities, torque values
Manual Specifications
File Format
Type: Portable Document Format (PDF)
Quality: High-resolution scans, clear text and images
Print Quality
Image Clarity: Excellent
Text Readability: High
Binding Type
Digital Format Benefit: No physical binding required, instantly accessible
Paper Type
Digital Format Benefit: N/A (digital file)
Engine Specifications
Primary Engine
Type: Single-cylinder, Four-stroke
Displacement: 652 cc (39.8 cu in)
Bore X Stroke: 100 mm x 83 mm (3.94 x 3.27 in)
Cooling System: Liquid-cooled
Valve Train: SOHC, 4 valves per cylinder
Performance
Horsepower Claimed: 48 hp (36 kW) @ 6500 rpm
Torque Claimed: 57 Nm (42 lb-ft) @ 5000 rpm
Fuel System
Injection Type: Electronic Fuel Injection (EFI)
Fuel Requirement: Unleaded gasoline, minimum 91 octane (RON+MON)/2
Lubrication System
Oil Type: API SG or higher, SAE 10W-40 motorcycle specific oil recommended
Oil Capacity W Filter: Approx. 2.0 liters (2.1 US qt)
Oil Filter Part Number Example: Hiflofiltro HF152 or OEM equivalent
Transmission
Standard
Type: 5-speed constant mesh
Features
Clutch Type: Wet, multi-plate
Final Drive: Chain Drive
Fluid Type
Transmission Oil: SAE 75W-90 or 80W-90 GL-4 gear oil (check manual for specific recommendation)
Dimensions
Exterior
Length: Approx. 2235 mm (88.0 in)
Width: Approx. 870 mm (34.3 in) at handlebars
Height: Approx. 1320 mm (52.0 in) at seat
Wheelbase: Approx. 1470 mm (57.9 in)
Weights
Dry Weight Claimed: Approx. 166 kg (366 lbs)
Gross Vehicle Weight Rating Gvwr: Refer to vehicle VIN plate/manual
Capacities
Fuel Tank Capacity: Approx. 17 liters (4.5 US gal)
Coolant Capacity: Approx. 1.2 liters (1.3 US qt)
Safety Features
Ratings
Crash Test Data: Not applicable to motorcycles in the same way as cars.
Active Features
Braking System: Dual Disc Front, Single Disc Rear. ABS available on some variants.
Lighting: Halogen Headlight, LED Taillight (model dependent)
Passive Features
Frame Construction: Steel, Trellis frame
Technology Features
Infotainment
Instrumentation: Digital speedometer, analog tachometer, odometer, trip meter, fuel gauge, indicator lights.
Driver Assistance
ABS: Optional Anti-lock Braking System (ABS) available on certain 2005 models.
Connectivity
Diagnostic Ports: Diagnostic connector for ECU access (requires specific tools/software).
Maintenance
Service Intervals
Oil Change Interval: Every 6,000 km (3,700 miles) or annually
Air Filter Service: Every 12,000 km (7,500 miles) or annually
Spark Plug Replacement: Every 12,000 km (7,500 miles)
Valve Clearance Check: Every 18,000 km (11,000 miles)
Fluid Specifications
Brake Fluid: DOT 4
Coolant Type: Ethylene glycol-based antifreeze with corrosion inhibitors (typically a 50/50 mix with distilled water)
Known Issues
Electrical Connections: Some owners report corrosion or looseness in electrical connectors, especially in wet conditions. Regular inspection and dielectric grease application are recommended.
Fuel Pump Reliability: Occasional reports of fuel pump issues, though not widespread. Proper fuel quality and avoiding running the tank dry can help.
Rear Shock ABSorber: As with many motorcycles of this era, the rear shock absorber may require rebuilding or replacement due to wear after high mileage.
Vehicle History
Brand Heritage
Manufacturer: Aprilia is an Italian motorcycle manufacturer known for its sporting heritage and innovative designs, particularly in smaller displacement categories.
Model Evolution
Pegaso Lineage: The Pegaso line has a history of dual-purpose motorcycles, evolving from earlier models to incorporate modern technology and styling.
Production
Manufacturing Location: Italy
Production Years
General Range: The Pegaso 650 platform has been produced in various iterations since the 1990s, with the 2005 model representing a significant update.
Awards & Recognition
Recognitions
Motorcycle Type Accolades: The Aprilia Pegaso 650 has generally received positive reviews for its versatility, handling, and comfort for its class, often cited as a competent all-rounder.
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