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2005 Aprilia Pegaso 650 Motorcycle Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Aprilia Model: Pegaso 650 Year: 2005 Vehicle Type: Motorcycle Codes Chassis Code: RL12 👋 Introduction Market Position Segment: Adventure Touring / Dual-Sport Lightweight Target Audience: Riders seeking a versatile motorcycle for commuting, touring, and light off-road use Competitive Analysis Competitors 2005: BMW F650GS, Kawasaki KLR650, Suzuki DR650SE, Honda Transalp XL650V Key Features Engine Type: Single-cylinder, four-stroke, liquid-cooled Frame Type: Steel double cradle Suspension Setup: Long-travel telescopic front forks, monoshock rear suspension Wheel Size Front: 19-inch Wheel Size Rear: 17-inch Fuel Capacity: Approx. 16 liters (4.2 US gal) 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive Service and Repair Page Count Estimated Pages: 300-400 Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine: Disassembly, assembly, inspection, diagnostics, tuning Fuel System: Fuel injection system (EFI), fuel pump, injectors, sensors Ignition System: Ignition coils, spark plugs, ECU control Cooling System: Radiator, coolant circulation, thermostat, fan operation Transmission And Drivetrain: Clutch operation, gearbox disassembly/assembly, chain drive maintenance Suspension Front: Fork disassembly, seals, oil changes, adjustments Suspension Rear: Shock absorber, linkage, bearings, adjustment Brakes Front: Brake caliper service, pad replacement, disc inspection, hydraulic system Brakes Rear: Brake caliper service, pad replacement, disc inspection, hydraulic system Electrical System: Battery, charging system, lighting, starter motor, wiring diagrams Fuel Tank And Lines: Removal, installation, cleaning Exhaust System: Inspection, component replacement Chassis And Frame: Frame inspection, steering head bearings Bodywork And Fairings: Removal, installation, repair considerations Procedures Included Maintenance: Oil changes, filter replacements, chain adjustment, spark plug replacement, fluid checks Troubleshooting: Diagnostic procedures for common faults, error code interpretation (if applicable) Repair: Detailed step-by-step repair instructions for all major components Rebuilds: Engine and transmission component rebuild procedures Wiring Diagrams: Comprehensive electrical system schematics Torque Specifications: Precise torque values for all fasteners Special Tools: Identification and usage of specialized tools required for specific procedures Technical Depth Depth: Comprehensive, from basic maintenance to complete engine rebuilds and diagnostics 📊 Manual Specifications File Format File Type: PDF Searchable: Yes Printable: Yes Print Quality Image Resolution: High-resolution diagrams and images Binding Type Binding: N/A (Digital) Paper Type Paper: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, four-stroke, DOHC, 4 valves Displacement: 652 cc Bore X Stroke: 100 mm x 83.7 mm Compression Ratio: 10.0:1 Cooling System: Liquid-cooled Performance Horsepower Approx: 48 HP @ 6,500 RPM Torque Approx: 57 Nm @ 5,250 RPM Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline (95 RON recommended) Lubrication System Oil Type: SAE 10W-40 or 15W-50, API SG/SH/SJ or JASO MA 🔧 Transmission Standard Transmission Type: 5-speed constant mesh Clutch Type: Wet multi-plate Final Drive: O-ring sealed chain Features Gear Ratios: Refer to manual for specific gear ratios Fluid Specification Transmission Oil: Refer to manual for specific transmission oil type and capacity (often shared engine oil) 📐 Dimensions Exterior Length Approx: 2200 mm Width Approx: 850 mm Height Approx: 1350 mm Seat Height Approx: 830 mm Weights Dry Weight Approx: 170 kg Wet Weight Approx: 185 kg Wheels Tires Front Tire Size: 90/90-19 Rear Tire Size: 130/80-17 Front Wheel Type: Spoked Rear Wheel Type: Spoked 🛡️ Safety Features Ratings Safety Features: ABS (Optional on some models), dual disc front brakes, single disc rear brake Active Features Braking System: Hydraulic disc brakes front and rear Passive Features Lighting: Halogen headlight, LED taillight 💡 Technology Features Infotainment Dashboard: Analog speedometer and tachometer, LCD multi-function display (odo, trip, clock) Driver Assistance ABS Availability: Optional ABS system on some 2005 models Connectivity Diagnostics Port: Diagnostic connector for ECU access (specific connector type and location detailed in manual) 🔧 Maintenance Service Intervals Oil Change Interval: Every 6,000 km (3,700 miles) or 12 months, whichever comes first Air Filter Cleaning: Every 6,000 km (3,700 miles) Spark Plug Replacement: Every 12,000 km (7,500 miles) Valve Clearance Check: Every 12,000 km (7,500 miles) Fluid Specifications Engine Oil Capacity: Approx. 2.4 liters (2.5 US qt) with filter change Coolant Type: Ethylene glycol-based antifreeze/coolant, 50/50 mix with distilled water Brake Fluid: DOT 4 Known Issues Common Wear Items: Clutch plates, fork seals, wheel bearings, rear shock absorber bushings Electrical Gremlins: Occasional issues with wiring connections or regulator/rectifier due to heat and vibration (refer to manual for diagnostics). Fuel Pump Reliability: Some owners report potential issues with the fuel pump over extended mileage, check fuel pressure as per manual. 📚 Vehicle History Brand Heritage Manufacturer: Aprilia is an Italian motorcycle manufacturer, known for its racing heritage and performance-oriented machines. Model Evolution Pegaso Lineage: The Pegaso line has a history dating back to the 1980s, evolving from smaller displacement models to the more versatile 650cc single-cylinder platform. 2005 Update: The 2005 model typically featured updates to electronics, styling, and potentially suspension components over earlier iterations. Production Manufacturing Location: Italy 🏆 Awards & Recognition Recognitions Industry Perception:...
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Type: Motorcycle
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2005 Aprilia Pegaso 650 Motorcycle Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
Pegaso 650
Year:
2005
Vehicle Type:
Motorcycle
Codes
Chassis Code:
RL12
👋 Introduction
Market Position
Segment:
Adventure Touring / Dual-Sport Lightweight
Target Audience:
Riders seeking a versatile motorcycle for commuting, touring, and light off-road use
Competitive Analysis
Competitors 2005:
BMW F650GS, Kawasaki KLR650, Suzuki DR650SE, Honda Transalp XL650V
Key Features
Engine Type:
Single-cylinder, four-stroke, liquid-cooled
Frame Type:
Steel double cradle
Suspension Setup:
Long-travel telescopic front forks, monoshock rear suspension
Wheel Size Front:
19-inch
Wheel Size Rear:
17-inch
Fuel Capacity:
Approx. 16 liters (4.2 US gal)
📋 Manual Details
Coverage Areas
Primary Coverage:
Comprehensive Service and Repair
Page Count
Estimated Pages:
300-400
Manual Type
Type:
Factory Service Manual / Workshop Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine:
Disassembly, assembly, inspection, diagnostics, tuning
Fuel System:
Fuel injection system (EFI), fuel pump, injectors, sensors
Ignition System:
Ignition coils, spark plugs, ECU control
Cooling System:
Radiator, coolant circulation, thermostat, fan operation
Transmission And Drivetrain:
Clutch operation, gearbox disassembly/assembly, chain drive maintenance
Suspension Front:
Fork disassembly, seals, oil changes, adjustments
Suspension Rear:
Shock absorber, linkage, bearings, adjustment
Brakes Front:
Brake caliper service, pad replacement, disc inspection, hydraulic system
Brakes Rear:
Brake caliper service, pad replacement, disc inspection, hydraulic system
Electrical System:
Battery, charging system, lighting, starter motor, wiring diagrams
Fuel Tank And Lines:
Removal, installation, cleaning
Exhaust System:
Inspection, component replacement
Chassis And Frame:
Frame inspection, steering head bearings
Bodywork And Fairings:
Removal, installation, repair considerations
Procedures Included
Maintenance:
Oil changes, filter replacements, chain adjustment, spark plug replacement, fluid checks
Troubleshooting:
Diagnostic procedures for common faults, error code interpretation (if applicable)
Repair:
Detailed step-by-step repair instructions for all major components
Rebuilds:
Engine and transmission component rebuild procedures
Wiring Diagrams:
Comprehensive electrical system schematics
Torque Specifications:
Precise torque values for all fasteners
Special Tools:
Identification and usage of specialized tools required for specific procedures
Technical Depth
Depth:
Comprehensive, from basic maintenance to complete engine rebuilds and diagnostics
📊 Manual Specifications
File Format
File Type:
PDF
Searchable:
Yes
Printable:
Yes
Print Quality
Image Resolution:
High-resolution diagrams and images
Binding Type
Binding:
N/A (Digital)
Paper Type
Paper:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Single-cylinder, four-stroke, DOHC, 4 valves
Displacement:
652 cc
Bore X Stroke:
100 mm x 83.7 mm
Compression Ratio:
10.0:1
Cooling System:
Liquid-cooled
Performance
Horsepower Approx:
48 HP @ 6,500 RPM
Torque Approx:
57 Nm @ 5,250 RPM
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline (95 RON recommended)
Lubrication System
Oil Type:
SAE 10W-40 or 15W-50, API SG/SH/SJ or JASO MA
🔧 Transmission
Standard
Transmission Type:
5-speed constant mesh
Clutch Type:
Wet multi-plate
Final Drive:
O-ring sealed chain
Features
Gear Ratios:
Refer to manual for specific gear ratios
Fluid Specification
Transmission Oil:
Refer to manual for specific transmission oil type and capacity (often shared engine oil)
📐 Dimensions
Exterior
Length Approx:
2200 mm
Width Approx:
850 mm
Height Approx:
1350 mm
Seat Height Approx:
830 mm
Weights
Dry Weight Approx:
170 kg
Wet Weight Approx:
185 kg
Wheels Tires
Front Tire Size:
90/90-19
Rear Tire Size:
130/80-17
Front Wheel Type:
Spoked
Rear Wheel Type:
Spoked
🛡️ Safety Features
Ratings
Safety Features:
ABS (Optional on some models), dual disc front brakes, single disc rear brake
Active Features
Braking System:
Hydraulic disc brakes front and rear
Passive Features
Lighting:
Halogen headlight, LED taillight
💡 Technology Features
Infotainment
Dashboard:
Analog speedometer and tachometer, LCD multi-function display (odo, trip, clock)
Driver Assistance
ABS Availability:
Optional ABS system on some 2005 models
Connectivity
Diagnostics Port:
Diagnostic connector for ECU access (specific connector type and location detailed in manual)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 6,000 km (3,700 miles) or 12 months, whichever comes first
Air Filter Cleaning:
Every 6,000 km (3,700 miles)
Spark Plug Replacement:
Every 12,000 km (7,500 miles)
Valve Clearance Check:
Every 12,000 km (7,500 miles)
Fluid Specifications
Engine Oil Capacity:
Approx. 2.4 liters (2.5 US qt) with filter change
Coolant Type:
Ethylene glycol-based antifreeze/coolant, 50/50 mix with distilled water
Brake Fluid:
DOT 4
Known Issues
Common Wear Items:
Clutch plates, fork seals, wheel bearings, rear shock absorber bushings
Electrical Gremlins:
Occasional issues with wiring connections or regulator/rectifier due to heat and vibration (refer to manual for diagnostics).
Fuel Pump Reliability:
Some owners report potential issues with the fuel pump over extended mileage, check fuel pressure as per manual.
📚 Vehicle History
Brand Heritage
Manufacturer:
Aprilia is an Italian motorcycle manufacturer, known for its racing heritage and performance-oriented machines.
Model Evolution
Pegaso Lineage:
The Pegaso line has a history dating back to the 1980s, evolving from smaller displacement models to the more versatile 650cc single-cylinder platform.
2005 Update:
The 2005 model typically featured updates to electronics, styling, and potentially suspension components over earlier iterations.
Production
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Industry Perception:
Generally well-regarded for its versatility and comfortable ride for its class.
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