Service Repair Manual Engine Rotax 655 Aprilia Pegaso 650 1995-2000
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🏷️ Basic Information
Identification
Make:
Aprilia
Model:
Pegaso 650
Year:
1995-2000
Engine Code:
Rotax 655
Generation
Generation Identifier:
First Generation (Pre-2001 Models)
Codes
Vin Code Range:
Not explicitly provided, but typically specific to Aprilia VIN structure for these years.
👋 Introduction
Market Position
Market Segment:
Dual-sport motorcycle, adventure touring.
Competitive Analysis
Competitors:
BMW F650 Funduro, Honda Transalp, Yamaha TDM.
Key Features
Unique Selling Points:
Robust Rotax engine, distinctive Italian styling, capable for both on-road and light off-road use.
📋 Manual Details
Coverage Areas
Coverage:
Exclusively covers the Rotax 655 engine for Aprilia Pegaso 650 models (1995-2000).
Page Count
Page Count:
149
Manual Type
Type:
Factory Service Repair Manual
Language
Language:
English, German (Bilingual)
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine mechanical (cylinder head, cylinder, piston, crankshaft, connecting rod), lubrication system, cooling system, fuel system (carburetor specific details), ignition system, exhaust system.
Procedures Included
Maintenance:
Routine maintenance checks, oil changes, filter replacements, spark plug service, valve clearance adjustment.
Repair Disassembly Reassembly:
Complete step-by-step procedures for engine disassembly and reassembly with detailed illustrations.
Troubleshooting:
Diagnostic procedures for common engine issues, fault finding guides.
Technical Depth
Depth:
Comprehensive, covering from basic maintenance to in-depth engine rebuilds and repairs.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Print Quality:
High Quality, Fully Printable
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Single-cylinder, four-stroke
Engine Manufacturer:
Rotax
Engine Code:
655
Displacement:
652 cc (approx.)
Bore X Stroke:
100 mm x 83 mm (typical for this engine)
Compression Ratio:
10.0:1 (typical)
Valve Train:
SOHC, 4 valves per cylinder
Performance
Horsepower:
Approx. 48-50 HP at 6500 RPM (varies by specific model year and tuning)
Torque:
Approx. 58-60 Nm at 5500 RPM (varies)
Fuel System
Fuel Delivery:
Carburetor (e.g., Dell'Orto PHM 40 DD)
Fuel Type:
Unleaded gasoline, octane rating 91 or higher
Lubrication System
Oil Type:
API SG or higher, SAE 10W-40 or 15W-50 motorcycle oil.
Oil Capacity:
Approx. 1.7 - 1.9 liters (with filter change)
Cooling System
Cooling Method:
Liquid-cooled
Coolant Type:
Ethylene glycol-based antifreeze mixture (50/50 with distilled water)
Ignition System
Ignition Type:
Electronic CDI (Capacitor Discharge Ignition)
Spark Plug Type:
NGK CR9EK or equivalent
Spark Plug Gap:
0.7 - 0.8 mm
🔧 Transmission
Standard
Transmission Type:
5-speed manual constant mesh
Clutch Type:
Wet multi-plate clutch
Features
Final Drive:
Chain drive
📐 Dimensions
Exterior
Length:
Not specified in product info, refer to specific model year data.
Width:
Not specified in product info, refer to specific model year data.
Height:
Not specified in product info, refer to specific model year data.
Weights
Dry Weight:
Approx. 175 kg (varies by year/trim)
Wet Weight:
Approx. 190 kg (with fluids, varies)
Fuel Tank Capacity:
Approx. 16 liters
🛡️ Safety Features
Ratings
Safety Ratings:
N/A (Motorcycle safety ratings are typically not standardized like automotive).
Active Features
Braking System Front:
Disc brake, dual piston caliper (e.g., Brembo or Grimeca)
Braking System Rear:
Disc brake, single piston caliper
Passive Features
Lighting:
Halogen headlight, LED taillight (typical for later models in the range).
💡 Technology Features
Infotainment
Infotainment System:
N/A (Basic analog instrumentation: speedometer, tachometer, odometer, engine temperature gauge, indicator lights).
Driver Assistance
Driver Assistance Features:
N/A
Connectivity
Connectivity Options:
N/A
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 6,000 km or 12 months, whichever comes first.
Valve Clearance Check:
Every 12,000 km or 24 months.
Air Filter Cleaning:
Every 6,000 km, replace as needed.
Fluid Specifications
Engine Oil Specification:
SAE 10W-40 or 15W-50, API SG or higher.
Coolant Specification:
50/50 mix of ethylene glycol antifreeze and distilled water.
Brake Fluid Specification:
DOT 4
Known Issues
Common Engine Problems:
Carburetor tuning and synchronization can be sensitive; potential for wear on the cam chain tensioner; stator or regulator/rectifier failure can occur with age.
Typical Wear Items:
Clutch plates, spark plugs, chain and sprockets, fork seals.
📚 Vehicle History
Brand Heritage
Aprilia Heritage:
Founded in 1945, Aprilia has a strong racing pedigree and a history of producing innovative motorcycles, particularly in the smaller displacement and performance segments.
Model Evolution
Pegaso Evolution Overview:
The Pegaso line began in the early 1990s, evolving into a versatile dual-sport offering. The 650cc single-cylinder Rotax engine proved to be a reliable and torquey powerplant, making the Pegaso popular for commuting and light adventure touring.
Production
Production Period:
1995-2000 (for this specific engine and model variant).
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Awards And Recognitions:
No specific widely publicized awards are associated with this model, but it gained a strong following among owners for its versatility and the robustness of the Rotax engine.
Complete step-by-step procedures for engine disassembly and reassembly with detailed illustrations.
Troubleshooting:
Diagnostic procedures for common engine issues, fault finding guides.
Technical Depth
Depth:
Comprehensive, covering from basic maintenance to in-depth engine rebuilds and repairs.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Print Quality:
High Quality, Fully Printable
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Single-cylinder, four-stroke
Engine Manufacturer:
Rotax
Engine Code:
655
Displacement:
652 cc (approx.)
Bore X Stroke:
100 mm x 83 mm (typical for this engine)
Compression Ratio:
10.0:1 (typical)
Valve Train:
SOHC, 4 valves per cylinder
Performance
Horsepower:
Approx. 48-50 HP at 6500 RPM (varies by specific model year and tuning)
Torque:
Approx. 58-60 Nm at 5500 RPM (varies)
Fuel System
Fuel Delivery:
Carburetor (e.g., Dell'Orto PHM 40 DD)
Fuel Type:
Unleaded gasoline, octane rating 91 or higher
Lubrication System
Oil Type:
API SG or higher, SAE 10W-40 or 15W-50 motorcycle oil.
Oil Capacity:
Approx. 1.7 - 1.9 liters (with filter change)
Cooling System
Cooling Method:
Liquid-cooled
Coolant Type:
Ethylene glycol-based antifreeze mixture (50/50 with distilled water)
Ignition System
Ignition Type:
Electronic CDI (Capacitor Discharge Ignition)
Spark Plug Type:
NGK CR9EK or equivalent
Spark Plug Gap:
0.7 - 0.8 mm
🔧 Transmission
Standard
Transmission Type:
5-speed manual constant mesh
Clutch Type:
Wet multi-plate clutch
Features
Final Drive:
Chain drive
📐 Dimensions
Exterior
Length:
Not specified in product info, refer to specific model year data.
Width:
Not specified in product info, refer to specific model year data.
Height:
Not specified in product info, refer to specific model year data.
Weights
Dry Weight:
Approx. 175 kg (varies by year/trim)
Wet Weight:
Approx. 190 kg (with fluids, varies)
Fuel Tank Capacity:
Approx. 16 liters
🛡️ Safety Features
Ratings
Safety Ratings:
N/A (Motorcycle safety ratings are typically not standardized like automotive).
Active Features
Braking System Front:
Disc brake, dual piston caliper (e.g., Brembo or Grimeca)
Braking System Rear:
Disc brake, single piston caliper
Passive Features
Lighting:
Halogen headlight, LED taillight (typical for later models in the range).
💡 Technology Features
Infotainment
Infotainment System:
N/A (Basic analog instrumentation: speedometer, tachometer, odometer, engine temperature gauge, indicator lights).
Driver Assistance
Driver Assistance Features:
N/A
Connectivity
Connectivity Options:
N/A
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 6,000 km or 12 months, whichever comes first.
Valve Clearance Check:
Every 12,000 km or 24 months.
Air Filter Cleaning:
Every 6,000 km, replace as needed.
Fluid Specifications
Engine Oil Specification:
SAE 10W-40 or 15W-50, API SG or higher.
Coolant Specification:
50/50 mix of ethylene glycol antifreeze and distilled water.
Brake Fluid Specification:
DOT 4
Known Issues
Common Engine Problems:
Carburetor tuning and synchronization can be sensitive; potential for wear on the cam chain tensioner; stator or regulator/rectifier failure can occur with age.
Typical Wear Items:
Clutch plates, spark plugs, chain and sprockets, fork seals.
📚 Vehicle History
Brand Heritage
Aprilia Heritage:
Founded in 1945, Aprilia has a strong racing pedigree and a history of producing innovative motorcycles, particularly in the smaller displacement and performance segments.
Model Evolution
Pegaso Evolution Overview:
The Pegaso line began in the early 1990s, evolving into a versatile dual-sport offering. The 650cc single-cylinder Rotax engine proved to be a reliable and torquey powerplant, making the Pegaso popular for commuting and light adventure touring.
Production
Production Period:
1995-2000 (for this specific engine and model variant).
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Awards And Recognitions:
No specific widely publicized awards are associated with this model, but it gained a strong following among owners for its versatility and the robustness of the Rotax engine.
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