2005 Aprilia Pegaso 650 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Aprilia Model: Pegaso 650 Factory Year: 2005 Category: Motorcycle Vehicle Type: Dual-sport / Adventure Codes Engine Code Series: Rotax 654 👋 Introduction Market Position Segment: Adventure / Dual-Sport Motorcycle Target Audience: DIY owners, independent repair shops, professional technicians. Competitive Analysis Competitors 2005: BMW F650GS, Kawasaki KLR650, Suzuki DR650SE, Yamaha XT660R/X. Key Features Vehicle Engine Basis: Torquey Rotax single-cylinder engine, known for reliability and versatility. Design Philosophy: Blend of on-road comfort and off-road capability, suitable for touring and commuting. Key Features Manual Value Proposition: Authoritative, factory-level repair information for all aspects of the motorcycle. Accessibility: Instant digital download, accessible on multiple operating systems. 📋 Manual Details Coverage Areas Primary Coverage: Repair and Service Procedures Secondary Coverage: Maintenance, Troubleshooting, Diagnostics Page Count Estimated Page Count: Refer to dealer specific documentation for exact count, typically 300-500 pages for a complete factory manual. Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: PDF/ZIP 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, disassembly, assembly, tuning, lubrication, cooling system, fuel system, ignition system. Cycle Parts: Frame, suspension (front and rear forks, shock absorber), steering system, wheels, tires, brakes (hydraulic discs front and rear), clutch. Electrical System: Wiring diagrams, charging system (alternator, regulator/rectifier), starting system (starter motor, battery), lighting, ignition system components, instrumentation. Procedures Included Maintenance: Routine checks, oil changes, filter replacements, chain maintenance, brake pad inspection/replacement, valve clearance adjustment, spark plug replacement. Repair: Engine rebuild, transmission service, suspension overhaul, brake caliper rebuild, electrical component replacement, bodywork repair. Troubleshooting: Diagnosis of common problems, fault finding procedures based on symptoms, electrical troubleshooting charts. Technical Depth Depth: Comprehensive, covering basic maintenance to complete engine and chassis rebuilds. Includes detailed diagrams and specifications. 📊 Manual Specifications File Format Primary Format: PDF Compression Format: ZIP (requiring unzipper like WinRAR) Print Quality Quality: Digital (Represents factory documentation quality) Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder, DOHC, 4 valves Displacement: 652 cc (39.8 cu in) Bore X Stroke: 100 mm x 83 mm (3.94 in x 3.27 in) Compression Ratio: 10.0:1 Performance Horsepower: Approx. 48 hp (36 kW) @ 6,250 rpm (varies by market/tuning) Torque: Approx. 60 Nm (44.3 lb-ft) @ 5,250 rpm (varies by market/tuning) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) - Specific system details in manual. Fuel Type: Unleaded gasoline, minimum 91 octane (RON+MON)/2) Lubrication Oil Type: Semi-synthetic or fully synthetic motorcycle oil, API SG or higher, JASO MA certified. Specific viscosity (e.g., 10W-40 or 15W-50) to be confirmed in manual. Oil Capacity: Approx. 2.2 - 2.4 liters (with filter change) - Exact capacity in manual. Cooling System Cooling Method: Liquid-cooled Coolant Type: Ethylene glycol-based antifreeze/coolant mixture (e.g., 50/50 water/coolant). Specific part number or type to be confirmed in manual. 🔧 Transmission Standard Transmission Type: 5-speed sequential manual Features Clutch Type: Wet, multi-plate, hydraulically operated Final Drive: O-ring sealed chain drive Fluid Specifications Transmission Oil: Not typically required as transmission shares engine oil. Refer to manual for specific notes. 📐 Dimensions Exterior Length: Approx. 2215 mm (87.2 in) Width: Approx. 850 mm (33.5 in) Height: Approx. 1415 mm (55.7 in) Weights Dry Weight: Approx. 170 kg (375 lbs) Wet Weight: Approx. 186 kg (410 lbs) (fully fueled and ready to ride) Fuel Capacity: Approx. 14 liters (3.7 US gal) 🛡️ Safety Features Ratings Safety Standard: Meets relevant motorcycle safety regulations for its production year. Active Features Braking System Front: Dual hydraulic disc brakes, twin-piston calipers. Specific disc diameter and pad type detailed in manual. Braking System Rear: Single hydraulic disc brake, single-piston caliper. Specific disc diameter and pad type detailed in manual. ABS: Optional ABS system available on some models/markets. Confirmation required. Passive Features Lighting: Halogen headlight, LED taillight, turn signals. Electrical system details in manual. Instrumentation: Analog tachometer, digital speedometer, fuel gauge, odometer, trip meter, warning lights. 💡 Technology Features Infotainment Infotainment System: Basic motorcycle instrumentation focused on riding information, not advanced infotainment. Driver Assistance ABS Availability: Optional on some 2005 models, a significant driver assistance feature if equipped. Connectivity Connectivity Features: N/A (No Bluetooth or smartphone integration typical for this era) 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 6,000-10,000 km (3,700-6,200 miles) or annually, whichever comes first. Refer to manual for precise interval. Air Filter Cleaning: Every 12,000 km (7,500 miles) or annually. Replacement as needed. Valve Clearance Check: Typically at 12,000 km (7,500 miles) or 24,000 km (15,000 miles) intervals. Consult manual for specific timing. Spark Plug Replacement: Intervals vary, typically 10,000-20,000 km (6,200-12,500 miles). Check manual for type and recommended interval. Fluid Specifications Brake Fluid Type: DOT 4 hydraulic brake fluid. Replacement every 2 years recommended. Fork Oil Type: Specific viscosity (e.g., SAE 5W or 7.5W) and quantity for front forks. Refer to manual for exact specifications. Known Issues...
Electronic Fuel Injection (EFI) - Specific system details in manual.
Fuel Type:
Unleaded gasoline, minimum 91 octane (RON+MON)/2)
Lubrication
Oil Type:
Semi-synthetic or fully synthetic motorcycle oil, API SG or higher, JASO MA certified. Specific viscosity (e.g., 10W-40 or 15W-50) to be confirmed in manual.
Ethylene glycol-based antifreeze/coolant mixture (e.g., 50/50 water/coolant). Specific part number or type to be confirmed in manual.
🔧 Transmission
Standard
Transmission Type:
5-speed sequential manual
Features
Clutch Type:
Wet, multi-plate, hydraulically operated
Final Drive:
O-ring sealed chain drive
Fluid Specifications
Transmission Oil:
Not typically required as transmission shares engine oil. Refer to manual for specific notes.
📐 Dimensions
Exterior
Length:
Approx. 2215 mm (87.2 in)
Width:
Approx. 850 mm (33.5 in)
Height:
Approx. 1415 mm (55.7 in)
Weights
Dry Weight:
Approx. 170 kg (375 lbs)
Wet Weight:
Approx. 186 kg (410 lbs) (fully fueled and ready to ride)
Fuel Capacity:
Approx. 14 liters (3.7 US gal)
🛡️ Safety Features
Ratings
Safety Standard:
Meets relevant motorcycle safety regulations for its production year.
Active Features
Braking System Front:
Dual hydraulic disc brakes, twin-piston calipers. Specific disc diameter and pad type detailed in manual.
Braking System Rear:
Single hydraulic disc brake, single-piston caliper. Specific disc diameter and pad type detailed in manual.
ABS:
Optional ABS system available on some models/markets. Confirmation required.
Passive Features
Lighting:
Halogen headlight, LED taillight, turn signals. Electrical system details in manual.
Instrumentation:
Analog tachometer, digital speedometer, fuel gauge, odometer, trip meter, warning lights.
💡 Technology Features
Infotainment
Infotainment System:
Basic motorcycle instrumentation focused on riding information, not advanced infotainment.
Driver Assistance
ABS Availability:
Optional on some 2005 models, a significant driver assistance feature if equipped.
Connectivity
Connectivity Features:
N/A (No Bluetooth or smartphone integration typical for this era)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 6,000-10,000 km (3,700-6,200 miles) or annually, whichever comes first. Refer to manual for precise interval.
Air Filter Cleaning:
Every 12,000 km (7,500 miles) or annually. Replacement as needed.
Valve Clearance Check:
Typically at 12,000 km (7,500 miles) or 24,000 km (15,000 miles) intervals. Consult manual for specific timing.
Spark Plug Replacement:
Intervals vary, typically 10,000-20,000 km (6,200-12,500 miles). Check manual for type and recommended interval.
Fluid Specifications
Brake Fluid Type:
DOT 4 hydraulic brake fluid. Replacement every 2 years recommended.
Fork Oil Type:
Specific viscosity (e.g., SAE 5W or 7.5W) and quantity for front forks. Refer to manual for exact specifications.
Known Issues
Common Wear Items:
Clutch plates, chain and sprockets, wheel bearings, fork seals, regulator/rectifier.
Potential Electrical Concerns:
Regulator/rectifier failures and stator issues can occur over time, common in many bikes of this era. Wiring harness integrity checks are vital.
Engine Temperatures:
Proper functioning of the cooling system is crucial; overheating can lead to premature wear or damage. Manual provides troubleshooting for cooling issues.
📚 Vehicle History
Brand Heritage
Manufacturer:
Aprilia is an Italian manufacturer renowned for its sport motorcycles and scooters.
Model Evolution
Pegaso Lineage:
The Pegaso line originated in the early 1990s, evolving from a 650cc single-cylinder platform known for its versatility and reliability.
Factory Edition:
The 'Factory' designation typically implies a higher-spec version with premium components, lighter weight, or improved performance features compared to standard models.
Production
Manufacturing Location:
Primarily Italy.
🏆 Awards & Recognition
Recognitions
Awards General:
Specific awards for the 2005 Aprilia Pegaso 650 Factory are not widely publicized in generic automotive databases. Aprilia as a brand has received accolades in racing and design.
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