🏷️ Basic Information Identification Make: Aprilia Model: Pegaso 650 IE Model Variant: Fuel Injected Codes Product Sku: AP650IE-SM 👋 Introduction Market Position Segment: Dual-sport / Adventure motorcycle Target Audience: Riders seeking a versatile motorcycle for on-road touring and light off-road capability, with modern fuel injection. Competitive Analysis Competitors: BMW F650GS, Kawasaki KLR650, Suzuki DR650SE (competitors of its era with similar displacement and purpose). Key Features Versatility: Designed for a balance of on-road comfort and off-road usability, often favored for touring and adventure. Engine Type: Single-cylinder, liquid-cooled, fuel-injected engine providing usable torque. Efi Technology: Electronic Fuel Injection offers improved throttle response, fuel economy, and emissions compared to carbureted models. Value Proposition Manual Value: Essential for owners and technicians to maintain and repair the sophisticated fuel injection system and other components correctly. 📋 Manual Details Coverage Areas Primary Coverage: Service and Repair Secondary Coverage: Maintenance, Diagnostics, Specifications Page Count Estimated Pages: 300-500 (typical for factory service manuals of this era) Manual Type Type: Factory Service Manual Language Language: English (assumed, typical for international markets) Format Format: Digital (PDF) or Printed (depending on availability) 📖 Manual Coverage Systems Covered Engine: Complete overhaul, tuning, component testing, diagnostics (including fuel injection system) Fuel Supply System: Fuel pump, injectors, pressure regulator, throttle body, EFI control unit (ECU) diagnostics Cooling System: Radiator, fan, thermostat, water pump, coolant flow, bleeding procedures Electrical System: Wiring diagrams, battery, charging system, ignition system, lighting, starter, EFI sensors and actuators Chassis: Frame, suspension (front and rear), steering, wheels, tires, brakes (hydraulic system, components) Procedures Included Maintenance: Regular servicing, oil changes, filter replacements, lubrication, chain adjustment, valve clearance checks Repair: Component disassembly, reassembly, and replacement for all major systems Troubleshooting: Diagnostic procedures for common and complex issues, fault code interpretation (if applicable to EFI) Setting Up: Initial setup, adjustments, torque specifications for critical fasteners Technical Depth Depth: Comprehensive, suitable for professional technicians and experienced DIY mechanics. Covers everything from routine maintenance to complete engine rebuilds and EFI system diagnostics. 📊 Manual Specifications File Format Digital Quality: High-resolution, searchable text (if PDF), clear image reproduction. Print Quality Print Options: Printable pages, durable paper stock (if physical copy). Binding Type Binding: Professionally bound (if printed), ideally with a lay-flat capability for workshop use. Paper Type Paper Quality: Durable, oil-resistant paper recommended for workshop environments. ⚙️ Engine Specifications Primary Engine Engine Configuration: Single-cylinder, 4-stroke Displacement: 652 cc Bore X Stroke: 100 mm x 83 mm (typical for Rotax 654 engine) Compression Ratio: 10.0:1 (typical) Valve Train: SOHC, 4 valves per cylinder Cooling System: Liquid-cooled Performance Horsepower: Approximately 48-50 HP @ 7000 RPM (typical for this engine) Torque: Approximately 54-58 Nm @ 5500 RPM (typical for this engine) Fuel System System Type: Electronic Fuel Injection (EFI) Throttle Body Size: Typically 40-42mm Fuel Type: Unleaded gasoline, minimum 91 octane (RON+MON)/2) Fluid Specs Engine Oil Type: SAE 10W-40 or 15W-50, API SG or higher, JASO MA rated motorcycle oil Engine Oil Capacity: Approx. 2.5 Liters (with filter change) Coolant Type: Ethylene glycol-based antifreeze/coolant, 50/50 mix with distilled water 🔧 Transmission Standard Type: 5-speed constant mesh Features Clutch: Wet multi-plate, cable-actuated Final Drive: O-ring sealed chain 📐 Dimensions Exterior Length: Approx. 2235 mm (variable by model year) Width: Approx. 870 mm (variable by model year) Height: Approx. 1340 mm (variable by model year) Weights Dry Weight: Approx. 170-180 kg (variable by model year) Wet Weight: Approx. 185-195 kg (variable by model year) Fuel Tank Capacity: Approx. 14 Liters (including reserve) Wheels Tires Front Wheel: 19-inch Spoked Wheel Rear Wheel: 17-inch Spoked Wheel Front Tire Size: 100/90-19 (common fitment) Rear Tire Size: 130/80-17 or 140/80-17 (common fitment) 🛡️ Safety Features Ratings ABS Availability: Optional on some later models (ABS) Active Features Braking System: Hydraulic disc brakes front and rear. Dual piston caliper front, single piston caliper rear (typical). Front Brake Disc Size: Approx. 300mm Rear Brake Disc Size: Approx. 240mm Passive Features Lighting: Halogen headlight, LED tail light (depending on year/spec). Indicators: Standard incandescent turn signals. 💡 Technology Features Infotainment Dashboard Type: Analog tachometer, digital speedometer, and multi-function display for odometer, trip meters, fuel level, coolant temperature, and warning lights. EFI system fault indicator. Driver Assistance ABS: Available as an option on some later models, providing anti-lock braking for enhanced safety, particularly in adverse conditions. Connectivity Diagnostic Port: Likely present for EFI system diagnostics, allowing connection to specialized diagnostic tools for reading fault codes and monitoring sensor data. 🔧 Maintenance Service Intervals Oil Change: Every 5,000-7,500 km (3,000-5,000 miles) or annually, whichever comes first. Air Filter Inspection: Every 5,000 km (3,000 miles), replace as needed. Spark Plug Replacement: Every 10,000-15,000 km (6,000-10,000 miles), depending on plug type. Valve Clearance Check: Every 10,000-15,000 km (6,000-10,000 miles). Chain Lubrication: Every 500-750 km (300-500 miles) and after riding in wet conditions. Fluid Specifications Brake Fluid Type: DOT 4 Clutch Fluid Type: DOT 4 (if...
Component disassembly, reassembly, and replacement for all major systems
Troubleshooting:
Diagnostic procedures for common and complex issues, fault code interpretation (if applicable to EFI)
Setting Up:
Initial setup, adjustments, torque specifications for critical fasteners
Technical Depth
Depth:
Comprehensive, suitable for professional technicians and experienced DIY mechanics. Covers everything from routine maintenance to complete engine rebuilds and EFI system diagnostics.
📊 Manual Specifications
File Format
Digital Quality:
High-resolution, searchable text (if PDF), clear image reproduction.
Print Quality
Print Options:
Printable pages, durable paper stock (if physical copy).
Binding Type
Binding:
Professionally bound (if printed), ideally with a lay-flat capability for workshop use.
Paper Type
Paper Quality:
Durable, oil-resistant paper recommended for workshop environments.
⚙️ Engine Specifications
Primary Engine
Engine Configuration:
Single-cylinder, 4-stroke
Displacement:
652 cc
Bore X Stroke:
100 mm x 83 mm (typical for Rotax 654 engine)
Compression Ratio:
10.0:1 (typical)
Valve Train:
SOHC, 4 valves per cylinder
Cooling System:
Liquid-cooled
Performance
Horsepower:
Approximately 48-50 HP @ 7000 RPM (typical for this engine)
Torque:
Approximately 54-58 Nm @ 5500 RPM (typical for this engine)
Fuel System
System Type:
Electronic Fuel Injection (EFI)
Throttle Body Size:
Typically 40-42mm
Fuel Type:
Unleaded gasoline, minimum 91 octane (RON+MON)/2)
Fluid Specs
Engine Oil Type:
SAE 10W-40 or 15W-50, API SG or higher, JASO MA rated motorcycle oil
Engine Oil Capacity:
Approx. 2.5 Liters (with filter change)
Coolant Type:
Ethylene glycol-based antifreeze/coolant, 50/50 mix with distilled water
🔧 Transmission
Standard
Type:
5-speed constant mesh
Features
Clutch:
Wet multi-plate, cable-actuated
Final Drive:
O-ring sealed chain
📐 Dimensions
Exterior
Length:
Approx. 2235 mm (variable by model year)
Width:
Approx. 870 mm (variable by model year)
Height:
Approx. 1340 mm (variable by model year)
Weights
Dry Weight:
Approx. 170-180 kg (variable by model year)
Wet Weight:
Approx. 185-195 kg (variable by model year)
Fuel Tank Capacity:
Approx. 14 Liters (including reserve)
Wheels Tires
Front Wheel:
19-inch Spoked Wheel
Rear Wheel:
17-inch Spoked Wheel
Front Tire Size:
100/90-19 (common fitment)
Rear Tire Size:
130/80-17 or 140/80-17 (common fitment)
🛡️ Safety Features
Ratings
ABS Availability:
Optional on some later models (ABS)
Active Features
Braking System:
Hydraulic disc brakes front and rear. Dual piston caliper front, single piston caliper rear (typical).
Front Brake Disc Size:
Approx. 300mm
Rear Brake Disc Size:
Approx. 240mm
Passive Features
Lighting:
Halogen headlight, LED tail light (depending on year/spec).
Indicators:
Standard incandescent turn signals.
💡 Technology Features
Infotainment
Dashboard Type:
Analog tachometer, digital speedometer, and multi-function display for odometer, trip meters, fuel level, coolant temperature, and warning lights. EFI system fault indicator.
Driver Assistance
ABS:
Available as an option on some later models, providing anti-lock braking for enhanced safety, particularly in adverse conditions.
Connectivity
Diagnostic Port:
Likely present for EFI system diagnostics, allowing connection to specialized diagnostic tools for reading fault codes and monitoring sensor data.
🔧 Maintenance
Service Intervals
Oil Change:
Every 5,000-7,500 km (3,000-5,000 miles) or annually, whichever comes first.
Air Filter Inspection:
Every 5,000 km (3,000 miles), replace as needed.
Spark Plug Replacement:
Every 10,000-15,000 km (6,000-10,000 miles), depending on plug type.
Valve Clearance Check:
Every 10,000-15,000 km (6,000-10,000 miles).
Chain Lubrication:
Every 500-750 km (300-500 miles) and after riding in wet conditions.
Fluid Specifications
Brake Fluid Type:
DOT 4
Clutch Fluid Type:
DOT 4 (if hydraulic, check specific model; some may be cable)
Known Issues
Efi System:
Potential issues with fuel pump reliability, sensor failures (e.g., throttle position sensor), or injector clogging if fuel quality is poor. The manual would detail diagnostic procedures.
Starter Clutch:
Some owners report issues with the starter clutch mechanism, especially on higher mileage bikes. Manual would provide inspection and replacement steps.
Suspension Seals:
Fork seal leaks can occur over time, requiring replacement. Manual will cover fork disassembly and seal replacement.
Charging System:
Stator or regulator/rectifier failures can occur, impacting battery charging. The manual will provide testing procedures for these components.
📚 Vehicle History
Brand Heritage
Manufacturer:
Aprilia is an Italian manufacturer renowned for its performance motorcycles, particularly in racing and sportbike segments.
Model Evolution
First Generation:
The Pegaso line originated in the early 1990s, initially with carbureted models. The 'IE' designation signifies the introduction of Electronic Fuel Injection, representing a significant technological upgrade.
Engine Origin:
The 650cc single-cylinder engine used in the Pegaso was often based on or shared with Rotax (Bombardier Recreational Products), a well-respected engine manufacturer for various brands.
Production
Production Years:
The Pegaso 650 IE was produced roughly from the early 2000s to around 2010-2014, depending on regional markets and model updates.
🏆 Awards & Recognition
Recognitions
General Reputation:
The Aprilia Pegaso 650 IE is generally well-regarded for its blend of performance, comfort, and off-road capability within the dual-sport segment. It's often praised for its distinctive styling and Italian flair.
Ratings
Owner Satisfaction:
Owner satisfaction often hinges on proper maintenance and addressing specific model quirks. The availability of this comprehensive service manual greatly contributes to owner satisfaction by enabling effective upkeep.
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