🏷️ Basic Information Identification Make: Aprilia Model: Pegaso 650 Model Variant: Multiple (based on factory manual coverage; likely includes different iterations of the 650 engine and chassis) Codes Chassis Code: Typically varies by year and sub-model (e.g., AP810000 for early models, specific codes for Strada, Trail variants). Engine Code: Rotax 655cc V2 (specific codes may vary by production year and internal Aprilia designations). 👋 Introduction Market Position Market Segment: The Aprilia Pegaso 650 was positioned as a versatile dual-sport motorcycle, appealing to riders seeking a capable on-road touring machine with some off-road pretensions. It competed in a segment with bikes like the BMW F650GS, Honda Transalp, and Yamaha TDM. Competitive Analysis Key Competitors: BMW F650 Funduro/GS, Honda Transalp 600/650, Yamaha TDM 850, Suzuki DR650. Key Features Versatility: Its primary selling point was its adaptability for commuting, touring, and light off-road riding. Different versions (e.g., Strada, Trail) further emphasized this versatility. Engine Reliability: The Rotax-derived engine, while sometimes considered vibey, was generally robust and offered good fuel economy for its class. The manual would detail its specific care requirements. Handling: Known for its agile handling characteristics, a hallmark of Aprilia's sporty heritage, facilitated by its relatively light weight and well-sorted chassis. 📋 Manual Details Coverage Areas Systems Covered: Engine (including internals, fuel, cooling), Fuel Supply System, Electrical System, Chassis (frame, suspension, wheels, brakes), Repair Information (general procedures, troubleshooting). Page Count Page Count: Not explicitly stated, but factory service manuals are typically extensive, ranging from 300 to 800+ pages. Manual Type Manual Type: Factory Service Repair Manual Language Language: Likely English (as standard for factory service manuals aimed at global markets). May also exist in Italian or other European languages. Format Format: Likely a printable manual, potentially available as a PDF. The 'FACTORY MANUAL!' designation implies an official, comprehensive document. 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed breakdown of the Rotax 655cc V2 engine, including cylinder head, piston, crankshaft, valves, camshafts, timing, lubrication system, and cooling system. Fuel System: Carburetor (likely Keihin CVK) or fuel injection system (depending on year/model), fuel pump, fuel lines, fuel filter, and associated sensors. Ignition System: CDI ignition, spark plugs, ignition coils, timing adjustments, and troubleshooting. Electrical System: Wiring diagrams, battery, charging system (alternator, rectifier/regulator), starter motor, lighting, indicators, instrumentation, and accessory circuits. Chassis Suspension: Front fork (e.g., Marzocchi, Paioli), rear shock absorber (e.g., Sachs, Öhlins on higher trims), linkages, settings, and rebuild procedures. Braking System: Front and rear brake calipers, discs, master cylinders, brake lines, bleeding procedures, and troubleshooting. Likely includes specifications for brands like Brembo or Grimeca. Wheels Tires: Wheel types (spoked or cast), bearing maintenance, tire sizes, pressures, and installation. Cooling System: Radiator, cooling fan, coolant hoses, coolant type, and capacity. Exhaust System: Exhaust pipes, mufflers, and emissions-related components. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, brake pad inspection, fluid level checks, spark plug replacement. Troubleshooting: Diagnostic procedures for common problems related to engine, electrical, and chassis systems. Symptom-based troubleshooting guides. Engine Rebuild: Complete engine disassembly, inspection, component replacement, and reassembly instructions with torque specifications. Carburetor Adjustment: Idle speed and mixture adjustment, synchronisation (if applicable). Suspension Service: Fork oil change, seal replacement, rear shock servicing. Electrical Diagnostics: Using multimeters, tracing faults in wiring harnesses, testing components like stators, regulators, and starter solenoids. Brake System Overhaul: Caliper rebuilding, master cylinder replacement, brake line replacement. Technical Depth Depth: Comprehensive. Covers everything from basic maintenance and adjustments to in-depth engine rebuilding, electrical system diagnosis, and chassis component overhauls. Suitable for professional mechanics and experienced enthusiasts. 📊 Manual Specifications File Format File Format: Likely PDF, or high-quality scanned pages. Searchable text is a strong possibility for official digital releases. Print Quality Print Quality: If printed, expect high-resolution images, clear diagrams, and readable text. Factory manuals are typically produced with excellent print quality. Binding Type Binding Type: If physical, likely spiral-bound or saddle-stitched for ease of use in a workshop environment. Perfect binding is also possible. Paper Type Paper Type: If physical, durable, often glossy or semi-gloss paper to withstand workshop conditions and frequent handling. Diagrams and schematics are typically printed on high-quality paper. ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, 4-valve per cylinder, SOHC V2 (or DOHC depending on specific engine variant across generations). Displacement: 652cc (approximate, based on Rotax 650 platform) Bore X Stroke: Typically around 82mm x 60.3mm (subject to minor variations across models). Performance Horsepower: Generally in the 45-50 hp range, depending on year and specific tuning. Torque: Around 50-55 Nm, with peak delivery in the mid-range. Fuel System Carburetion: Typically dual Keihin CVK 32mm carburetors for earlier models, potentially transitioning to fuel injection on later iterations (e.g., models post-2007). Cooling System Cooling Method: Liquid-cooled Lubrication System Oil Capacity With Filter: Approximately 2.5 - 3.0 liters (specific value in manual). Oil Type Recommended Oil: Fully synthetic 10W-40 or 20W-50 motorcycle...
Multiple (based on factory manual coverage; likely includes different iterations of the 650 engine and chassis)
Codes
Chassis Code:
Typically varies by year and sub-model (e.g., AP810000 for early models, specific codes for Strada, Trail variants).
Engine Code:
Rotax 655cc V2 (specific codes may vary by production year and internal Aprilia designations).
👋 Introduction
Market Position
Market Segment:
The Aprilia Pegaso 650 was positioned as a versatile dual-sport motorcycle, appealing to riders seeking a capable on-road touring machine with some off-road pretensions. It competed in a segment with bikes like the BMW F650GS, Honda Transalp, and Yamaha TDM.
Its primary selling point was its adaptability for commuting, touring, and light off-road riding. Different versions (e.g., Strada, Trail) further emphasized this versatility.
Engine Reliability:
The Rotax-derived engine, while sometimes considered vibey, was generally robust and offered good fuel economy for its class. The manual would detail its specific care requirements.
Handling:
Known for its agile handling characteristics, a hallmark of Aprilia's sporty heritage, facilitated by its relatively light weight and well-sorted chassis.
Not explicitly stated, but factory service manuals are typically extensive, ranging from 300 to 800+ pages.
Manual Type
Manual Type:
Factory Service Repair Manual
Language
Language:
Likely English (as standard for factory service manuals aimed at global markets). May also exist in Italian or other European languages.
Format
Format:
Likely a printable manual, potentially available as a PDF. The 'FACTORY MANUAL!' designation implies an official, comprehensive document.
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed breakdown of the Rotax 655cc V2 engine, including cylinder head, piston, crankshaft, valves, camshafts, timing, lubrication system, and cooling system.
Fuel System:
Carburetor (likely Keihin CVK) or fuel injection system (depending on year/model), fuel pump, fuel lines, fuel filter, and associated sensors.
Ignition System:
CDI ignition, spark plugs, ignition coils, timing adjustments, and troubleshooting.
Electrical System:
Wiring diagrams, battery, charging system (alternator, rectifier/regulator), starter motor, lighting, indicators, instrumentation, and accessory circuits.
Chassis Suspension:
Front fork (e.g., Marzocchi, Paioli), rear shock absorber (e.g., Sachs, Öhlins on higher trims), linkages, settings, and rebuild procedures.
Braking System:
Front and rear brake calipers, discs, master cylinders, brake lines, bleeding procedures, and troubleshooting. Likely includes specifications for brands like Brembo or Grimeca.
Wheels Tires:
Wheel types (spoked or cast), bearing maintenance, tire sizes, pressures, and installation.
Cooling System:
Radiator, cooling fan, coolant hoses, coolant type, and capacity.
Exhaust System:
Exhaust pipes, mufflers, and emissions-related components.
Diagnostic procedures for common problems related to engine, electrical, and chassis systems. Symptom-based troubleshooting guides.
Engine Rebuild:
Complete engine disassembly, inspection, component replacement, and reassembly instructions with torque specifications.
Carburetor Adjustment:
Idle speed and mixture adjustment, synchronisation (if applicable).
Suspension Service:
Fork oil change, seal replacement, rear shock servicing.
Electrical Diagnostics:
Using multimeters, tracing faults in wiring harnesses, testing components like stators, regulators, and starter solenoids.
Brake System Overhaul:
Caliper rebuilding, master cylinder replacement, brake line replacement.
Technical Depth
Depth:
Comprehensive. Covers everything from basic maintenance and adjustments to in-depth engine rebuilding, electrical system diagnosis, and chassis component overhauls. Suitable for professional mechanics and experienced enthusiasts.
📊 Manual Specifications
File Format
File Format:
Likely PDF, or high-quality scanned pages. Searchable text is a strong possibility for official digital releases.
Print Quality
Print Quality:
If printed, expect high-resolution images, clear diagrams, and readable text. Factory manuals are typically produced with excellent print quality.
Binding Type
Binding Type:
If physical, likely spiral-bound or saddle-stitched for ease of use in a workshop environment. Perfect binding is also possible.
Paper Type
Paper Type:
If physical, durable, often glossy or semi-gloss paper to withstand workshop conditions and frequent handling. Diagrams and schematics are typically printed on high-quality paper.
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-stroke, 4-valve per cylinder, SOHC V2 (or DOHC depending on specific engine variant across generations).
Displacement:
652cc (approximate, based on Rotax 650 platform)
Bore X Stroke:
Typically around 82mm x 60.3mm (subject to minor variations across models).
Performance
Horsepower:
Generally in the 45-50 hp range, depending on year and specific tuning.
Torque:
Around 50-55 Nm, with peak delivery in the mid-range.
Fuel System
Carburetion:
Typically dual Keihin CVK 32mm carburetors for earlier models, potentially transitioning to fuel injection on later iterations (e.g., models post-2007).
Cooling System
Cooling Method:
Liquid-cooled
Lubrication System
Oil Capacity With Filter:
Approximately 2.5 - 3.0 liters (specific value in manual).
Oil Type
Recommended Oil:
Fully synthetic 10W-40 or 20W-50 motorcycle oil meeting API SG/SH or higher specifications (manual will specify exact grade).
Spark Plugs
Recommended Spark Plugs:
NGK CR9EB or equivalent (manual will confirm exact type and gap).
🔧 Transmission
Standard
Transmission Type:
5-speed constant mesh, sequential gearbox.
Optional
Clutch Type:
Wet, multi-plate, hydraulically operated clutch.
Features
Final Drive:
Chain drive, with specifications for chain type (e.g., 520 O-ring chain) and adjustment procedures.
📐 Dimensions
Exterior
Length:
Varies by model year and variant (approx. 2100-2200 mm).
Width:
Varies by model year and variant (approx. 800-850 mm).
Height:
Varies by model year and variant (approx. 1300-1450 mm).
Weights
Dry Weight:
Approx. 170-180 kg (depending on model variant and equipment).
Fuel Tank Capacity:
Typically 16-20 liters, depending on the specific sub-model (e.g., Strada vs. Trail).
Seat Height:
Varies by model, generally around 820-860 mm.
🛡️ Safety Features
Ratings
Braking Performance:
Disc brakes front and rear. Front typically dual discs, rear single. ABS was an option on later models.
Active Features
ABS Availability:
Optional on certain model years (e.g., post-2007 models). The manual will specify systems covered if ABS is present.
Passive Features
Lighting:
Halogen headlight, LED taillight (on later models), standard turn signals. Manual covers bulb types and electrical diagnostics.
💡 Technology Features
Infotainment
Instrumentation:
Analog tachometer, digital or analog speedometer, odometer, trip meter, fuel gauge, and various warning lights. Manual covers dashboard diagnostics.
Driver Assistance
ABS System:
Available as an option on later models. The manual provides detailed diagnostics and service procedures for the ABS unit, sensors, and hydraulic control unit if equipped.
Connectivity
Charging Port:
Some models may feature a 12V accessory socket for charging devices. Manual will detail its wiring and fuse.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000 - 7,500 km or annually (manual will confirm exact mileage and time-based intervals).
Valve Clearance Check:
Often at 10,000 - 15,000 km, but can vary significantly based on engine revisions (critical to check manual).
Spark Plug Replacement Interval:
Typically every 10,000 - 15,000 km, or based on inspection.
Fluid Specifications
Brake Fluid Type:
DOT 4 or DOT 5.1 (manual will specify the exact requirement).
Coolant Type:
Ethylene glycol-based antifreeze, mixed 50/50 with distilled water. Manual will provide specific Aprilia-approved coolant.
Fork Oil Type:
Specific suspension oil viscosity (e.g., 10W or 15W), manual will detail type and quantity.
Known Issues
Electrical Connections:
Corrosion or looseness in wiring connectors, particularly at the stator, regulator/rectifier, and CDI unit can lead to charging or ignition problems.
Carburetor Synchronization:
Carburetors can go out of sync, leading to rough idling, poor throttle response, and uneven power delivery. Regular checks are recommended.
Cam Chain Tensioner:
Some early Rotax engines could develop a noisy cam chain tensioner, requiring inspection and potential replacement.
Fuel Pump Reliability:
On fuel-injected models, the fuel pump can be a point of failure, leading to starting or running issues.
Suspension Seals:
Front fork seals can be prone to leaks, especially with off-road use. Regular maintenance is key.
📚 Vehicle History
Brand Heritage
Aprilia Motorsport:
Aprilia has a rich history in motorcycle racing, particularly in smaller displacement categories, influencing their road bike design with a focus on handling and performance.
Model Evolution
Pegaso Lineage:
The Pegaso line started in the early 1990s and evolved through several iterations, including the 650cc V-twin which became its defining feature. Models like the Pegaso 650, Pegaso Strada, and Pegaso Trail represent different takes on the adventure touring/supermoto concept.
Production
Production Years:
The 650cc Pegaso was produced from the mid-1990s through to around 2014 (when it was largely replaced by the Caponord 1200 and other models, though the 650 platform continued in other forms).
Manufacturing Location:
Primarily Italy, as Aprilia is an Italian manufacturer.
🏆 Awards & Recognition
Recognitions
Motorcycle Press:
The Pegaso 650 received positive reviews from motorcycle publications for its handling and versatility, often praised as a practical all-rounder for its era.
Ratings
Reliability Index:
While Aprilia's reputation for reliability has improved significantly, older models like the Pegaso were sometimes seen as requiring more diligent maintenance than some Japanese competitors. This manual is crucial for addressing this.