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Aprilia Pegaso 650 Motorcycle Complete Workshop Service Repair Manual 2005 2006 2007 2008 2009

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🏷️ Basic Information Identification Make: Aprilia Model: Pegaso 650 Model Variant: Street/Trail (specific variant not explicitly stated, but implied by model name) Production Years Covered: 2005, 2006, 2007, 2008, 2009 Codes Vin Code Prefix Example: AP81... 👋 Introduction Market Position Positioning: The Aprilia Pegaso 650 series was positioned as a versatile dual-sport or supermoto motorcycle, blending on-road usability with light off-road capability. It appealed to riders seeking a practical, stylish, and engaging machine for commuting, touring, and light adventure. Competitive Analysis Competitors: Competed against models like the BMW F650GS, Suzuki DR650, Kawasaki KLR650, and Yamaha XT660R/X in its segment. Key Features Features: Reliable single-cylinder engine, comfortable ergonomics, capable suspension, stylish Italian design, adaptability for commuting and touring. Manual Value Proposition Value: This comprehensive workshop manual is an essential tool for any Pegaso 650 owner or mechanic, providing the in-depth technical knowledge required for proper maintenance, troubleshooting, and repair, ensuring the longevity and optimal performance of the motorcycle. 📋 Manual Details Coverage Areas Primary Coverage: Complete workshop service and repair Page Count Estimated Page Count: Likely 300-500 pages (typical for comprehensive motorcycle workshop manuals) Manual Type Type: Workshop Service Repair Manual Language Language: English (assumed based on product description, common for international markets) Format Format: Downloadable (PDF implied) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine disassembly, inspection, assembly, valve clearance, timing, piston, rings, crankshaft, lubrication system, cooling system. Fuel System: Fuel injection system (EFI), fuel pump, injectors, throttle body, fuel pressure regulator, fuel filter, fuel tank, lines. Ignition System: Ignition coils, spark plugs, ECU control, wiring diagrams. Transmission And Drivetrain: Clutch operation and adjustment, gearbox disassembly and assembly, gear selection mechanism, final drive (chain/sprocket inspection and replacement). Suspension System: Front fork (oil change, seal replacement, internal component service), rear shock absorber service, linkage maintenance. Braking System: Front and rear brake systems, caliper service, brake pad replacement, brake fluid bleeding and replacement, master cylinders, brake lines. Electrical System: Battery, starter motor, alternator, lighting (headlight, tail light, signals), wiring harnesses, fuses, relays, instrument cluster, sensors. Cooling System: Radiator, cooling fan, coolant circulation, thermostat, hoses. Exhaust System: Exhaust pipe, muffler inspection and replacement, lambda sensor (if applicable). Chassis And Bodywork: Frame inspection, body panel removal and installation, seat, handlebars, footpegs. Wheels And Tires: Wheel bearing inspection and replacement, tire pressure, tire replacement, spoke tension (if applicable). Procedures Included Preventative Maintenance: Regular service intervals, oil changes, filter replacements, chain lubrication and adjustment, brake inspection, tire checks. Troubleshooting: Diagnostic procedures for common issues, symptom-based troubleshooting guides, fault code interpretation (if ECU controlled). Major Repairs: Engine rebuilds, transmission overhauls, suspension component replacement, electrical system diagnostics and repair. Component Replacement: Step-by-step instructions for replacing parts like brake pads, clutch plates, spark plugs, filters, bulbs, etc. Adjustments: Carburetor/throttle body synchronization, clutch lever free play, brake lever free play, chain slack, idle speed. Wiring Diagrams: Detailed electrical schematics for all systems. Technical Depth Depth: Comprehensive from basic rider maintenance to full engine and transmission rebuilds, including electrical diagnostics. 📊 Manual Specifications File Format Format: PDF (Downloadable) Print Quality Quality: High-resolution, clear text and diagrams suitable for printing. Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Searchability Text Search: Likely fully searchable text for quick information retrieval. ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, four-stroke, liquid-cooled, DOHC Displacement: 652 cc (approx.) Bore X Stroke: Refer to manual for exact specifications (typically around 100 mm x 83 mm for Rotax engines) Compression Ratio: Refer to manual for exact specifications (typically around 10.0:1 to 11.5:1) Engine Management: Electronic Fuel Injection (EFI) Performance Horsepower: Approximately 45-50 HP (Varies slightly by year and specific tune) Torque: Approximately 60-65 Nm (Varies slightly by year and specific tune) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline, minimum 91 octane (RON + MON / 2) Lubrication Oil Type: Semi-synthetic or Fully-synthetic SAE 10W-40 motorcycle oil meeting API SG or higher and JASO MA specifications. (Always confirm with manual). Oil Capacity: Approximately 2.0 - 2.5 liters with filter change (Refer to manual for exact capacity). Cooling System Coolant Type: Ethylene glycol-based antifreeze mixture with distilled water (50/50 ratio). (Refer to manual for specific recommendations). 🔧 Transmission Standard Type: 5-speed constant mesh Optional Type: N/A Features Clutch Type: Wet, multi-plate Final Drive: Chain drive Transmission Oil Type: SAE 75W/90 or SAE 80W/90 gear oil (API GL-4 or GL-5). (Always confirm with manual). Transmission Oil Capacity: Refer to manual for exact capacity. 📐 Dimensions Exterior Length: Refer to manual for exact specifications. Width: Refer to manual for exact specifications. Height: Refer to manual for exact specifications. Seat Height: Approximately 820-840 mm (Varies by model year/variant). Weights Dry Weight: Approximately 160-170 kg (Varies by model year/variant). Wet Weight: Approximately 180-190 kg (with fluids). Gross Vehicle Weight Rating: Refer to manual for exact specifications. Payload Capacity: Refer to manual for exact specifications....
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Aprilia Pegaso 650 Motorcycle Complete Workshop Service Repair Manual 2005 2006 2007 2008 2009
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
Pegaso 650
Model Variant:
Street/Trail (specific variant not explicitly stated, but implied by model name)
Production Years Covered:
2005, 2006, 2007, 2008, 2009
Codes
Vin Code Prefix Example:
AP81...
👋 Introduction
Market Position
Positioning:
The Aprilia Pegaso 650 series was positioned as a versatile dual-sport or supermoto motorcycle, blending on-road usability with light off-road capability. It appealed to riders seeking a practical, stylish, and engaging machine for commuting, touring, and light adventure.
Competitive Analysis
Competitors:
Competed against models like the BMW F650GS, Suzuki DR650, Kawasaki KLR650, and Yamaha XT660R/X in its segment.
Key Features
Features:
Reliable single-cylinder engine, comfortable ergonomics, capable suspension, stylish Italian design, adaptability for commuting and touring.
Manual Value Proposition
Value:
This comprehensive workshop manual is an essential tool for any Pegaso 650 owner or mechanic, providing the in-depth technical knowledge required for proper maintenance, troubleshooting, and repair, ensuring the longevity and optimal performance of the motorcycle.
📋 Manual Details
Coverage Areas
Primary Coverage:
Complete workshop service and repair
Page Count
Estimated Page Count:
Likely 300-500 pages (typical for comprehensive motorcycle workshop manuals)
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English (assumed based on product description, common for international markets)
Format
Format:
Downloadable (PDF implied)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine disassembly, inspection, assembly, valve clearance, timing, piston, rings, crankshaft, lubrication system, cooling system.
Fuel System:
Fuel injection system (EFI), fuel pump, injectors, throttle body, fuel pressure regulator, fuel filter, fuel tank, lines.
Ignition System:
Ignition coils, spark plugs, ECU control, wiring diagrams.
Transmission And Drivetrain:
Clutch operation and adjustment, gearbox disassembly and assembly, gear selection mechanism, final drive (chain/sprocket inspection and replacement).
Suspension System:
Front fork (oil change, seal replacement, internal component service), rear shock absorber service, linkage maintenance.
Braking System:
Front and rear brake systems, caliper service, brake pad replacement, brake fluid bleeding and replacement, master cylinders, brake lines.
Electrical System:
Battery, starter motor, alternator, lighting (headlight, tail light, signals), wiring harnesses, fuses, relays, instrument cluster, sensors.
Cooling System:
Radiator, cooling fan, coolant circulation, thermostat, hoses.
Exhaust System:
Exhaust pipe, muffler inspection and replacement, lambda sensor (if applicable).
Chassis And Bodywork:
Frame inspection, body panel removal and installation, seat, handlebars, footpegs.
Wheels And Tires:
Wheel bearing inspection and replacement, tire pressure, tire replacement, spoke tension (if applicable).
Procedures Included
Preventative Maintenance:
Regular service intervals, oil changes, filter replacements, chain lubrication and adjustment, brake inspection, tire checks.
Troubleshooting:
Diagnostic procedures for common issues, symptom-based troubleshooting guides, fault code interpretation (if ECU controlled).
Major Repairs:
Engine rebuilds, transmission overhauls, suspension component replacement, electrical system diagnostics and repair.
Component Replacement:
Step-by-step instructions for replacing parts like brake pads, clutch plates, spark plugs, filters, bulbs, etc.
Adjustments:
Carburetor/throttle body synchronization, clutch lever free play, brake lever free play, chain slack, idle speed.
Wiring Diagrams:
Detailed electrical schematics for all systems.
Technical Depth
Depth:
Comprehensive from basic rider maintenance to full engine and transmission rebuilds, including electrical diagnostics.
📊 Manual Specifications
File Format
Format:
PDF (Downloadable)
Print Quality
Quality:
High-resolution, clear text and diagrams suitable for printing.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Searchability
Text Search:
Likely fully searchable text for quick information retrieval.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Single-cylinder, four-stroke, liquid-cooled, DOHC
Displacement:
652 cc (approx.)
Bore X Stroke:
Refer to manual for exact specifications (typically around 100 mm x 83 mm for Rotax engines)
Compression Ratio:
Refer to manual for exact specifications (typically around 10.0:1 to 11.5:1)
Engine Management:
Electronic Fuel Injection (EFI)
Performance
Horsepower:
Approximately 45-50 HP (Varies slightly by year and specific tune)
Torque:
Approximately 60-65 Nm (Varies slightly by year and specific tune)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline, minimum 91 octane (RON + MON / 2)
Lubrication
Oil Type:
Semi-synthetic or Fully-synthetic SAE 10W-40 motorcycle oil meeting API SG or higher and JASO MA specifications. (Always confirm with manual).
Oil Capacity:
Approximately 2.0 - 2.5 liters with filter change (Refer to manual for exact capacity).
Cooling System
Coolant Type:
Ethylene glycol-based antifreeze mixture with distilled water (50/50 ratio). (Refer to manual for specific recommendations).
🔧 Transmission
Standard
Type:
5-speed constant mesh
Optional
Type:
N/A
Features
Clutch Type:
Wet, multi-plate
Final Drive:
Chain drive
Transmission Oil Type:
SAE 75W/90 or SAE 80W/90 gear oil (API GL-4 or GL-5). (Always confirm with manual).
Transmission Oil Capacity:
Refer to manual for exact capacity.
📐 Dimensions
Exterior
Length:
Refer to manual for exact specifications.
Width:
Refer to manual for exact specifications.
Height:
Refer to manual for exact specifications.
Seat Height:
Approximately 820-840 mm (Varies by model year/variant).
Weights
Dry Weight:
Approximately 160-170 kg (Varies by model year/variant).
Wet Weight:
Approximately 180-190 kg (with fluids).
Gross Vehicle Weight Rating:
Refer to manual for exact specifications.
Payload Capacity:
Refer to manual for exact specifications.
Fuel Tank Capacity:
Approximately 14-15 liters (including reserve).
Wheels Tires
Front Tire Size:
100/80-17 or 110/80-17 (typical for the era, manual confirms).
Rear Tire Size:
130/70-17 or 140/70-17 (typical for the era, manual confirms).
Wheel Type:
Cast aluminum alloy wheels.
Wheelbase:
Refer to manual for exact specifications (typically around 1450-1500 mm).
🛡️ Safety Features
Ratings
Crash Test Ratings:
N/A (Motorcycle safety ratings are not standardized like automotive).
Active Features
Braking System:
Hydraulic disc brakes front and rear. Optional ABS available on some models/regions (verify with manual).
Lighting:
Halogen headlight, LED tail light, turn signals.
Passive Features
Frame Construction:
Steel tube frame for rigidity and impact absorption.
Ergonomics:
Upright riding position for improved rider control and comfort.
💡 Technology Features
Infotainment
Infotainment System:
N/A (Basic motorcycle instrumentation - speedometer, tachometer, odometer, trip meter, fuel gauge, warning lights).
Driver Assistance
ABS:
Optional Anti-lock Braking System (ABS) may be present on some models.
Connectivity
Connectivity:
N/A
Engine Management
ECU:
Engine Control Unit (ECU) manages fuel injection, ignition timing, and other engine parameters.
🔧 Maintenance
Service Intervals
Oil Change:
Every 5,000 - 7,500 km or annually (whichever comes first). Refer to manual for precise intervals.
Oil Filter Replacement:
At every oil change.
Air Filter Cleaning/Replacement:
Every 5,000 - 10,000 km, or more frequently in dusty conditions.
Spark Plug Replacement:
Every 10,000 - 15,000 km. Check condition and gap more frequently.
Valve Clearance Check:
Every 10,000 - 15,000 km.
Chain Lubrication And Adjustment:
Every 500 - 1,000 km, and after washing or riding in rain.
Brake Fluid Replacement:
Every 2 years, or as specified in the manual.
Coolant Replacement:
Every 2-3 years, or as specified in the manual.
Fluid Specifications
Engine Oil:
SAE 10W-40 Motorcycle Oil (API SG/JASO MA)
Transmission Oil:
SAE 75W/90 or SAE 80W/90 Gear Oil (API GL-4/GL-5)
Brake Fluid:
DOT 4
Coolant:
50/50 Ethylene Glycol / Distilled Water mix
Known Issues
Common Wear Items:
Clutch wear, chain and sprockets, fork seals, brake pads, wheel bearings.
Engine Specific:
Some early Rotax 654 engines could experience oil consumption or potential cam chain tensioner issues, though later iterations were generally robust. Valve seat wear can occur with very high mileage.
Electrical Specific:
Corrosion in connectors, rectifier/regulator issues are not uncommon on bikes of this age.
Fuel System Specific:
Fuel pump reliability can be a concern; injector clogging can occur if fuel quality is poor.
📚 Vehicle History
Brand Heritage
Heritage:
Aprilia, an Italian manufacturer, has a rich racing heritage and a reputation for producing sporty and stylish motorcycles with innovative engineering.
Model Evolution
Evolution Of Pegaso:
The Pegaso line has evolved over many years, with the 650cc single-cylinder platform being a consistent feature. The models from 2005-2009 represent a specific iteration of this popular dual-sport/supermoto concept, often utilizing a Rotax-sourced engine.
Production
Manufacturing Location:
Typically manufactured in Italy.
Market Release Year:
The Pegaso 650 model line was introduced in the early 1990s, with continuous updates and variations.
🏆 Awards & Recognition
Recognitions
Awards:
The Pegaso line has been well-regarded for its balance of performance, style, and practicality within its segment, though specific industry awards for this model are not widely documented.
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