APRILIA PEGASO 650 Service Repair Manual 1997-2005
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🏷️ Basic Information Identification Make: Aprilia Model: Pegaso 650 Production Years: 1997-2005 Category: Motorcycle 👋 Introduction Market Position Motorcycle Type: Adventure Touring / Dual-Sport Target Audience: Riders seeking versatility for on-road and light off-road use. Competitive Analysis Key Competitors: BMW F650 Funduro, Yamaha TDM850, Honda Transalp. Key Features Engine Configuration: Single-cylinder, liquid-cooled Frame Design: Robust chassis for stability and handling. Suspension Setup: Long-travel suspension suitable for varied terrain. 📋 Manual Details Coverage Areas Primary Coverage: Service, Repair, Maintenance Model Years Covered: 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005 Page Count Estimated Pages: Comprehensive (factory equivalent) Manual Type Type: Service Repair Manual Comparison: Factory Shop Manual, CD-ROM Manual Language Language: English (likely, common for such manuals) Format Format: Digital (PDF/similar, based on description) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete disassembly, assembly, inspection, and repair of engine components. Fuel System: Carburetor (or EFI if applicable for specific models within range) overhaul, fuel pump, lines, tank. Ignition System: Spark plugs, ignition coils, CDI unit, wiring diagrams. Cooling System: Radiator, coolant, thermostat, fan, hoses. Exhaust System: Muffler, exhaust pipes, catalytic converter (if fitted). Transmission And Clutch: Clutch operation, gearbox inspection, gear ratios, lubrication. Frame And Suspension: Front forks (telescopic/upside-down), rear shock absorber, swingarm, bearings. Brakes: Hydraulic systems (front and rear), calipers, master cylinders, discs, pads, bleeding procedures. Wheels And Tires: Wheel bearings, tire replacement, balancing, spoke tension (if applicable). Electrical System: Battery, charging system (stator, regulator/rectifier), starter motor, lighting, indicators, horn, wiring harnesses. Instrumentation And Controls: Speedometer, tachometer, indicators, throttle, clutch lever, brake lever operation. Bodywork And Fairings: Removal, installation, and repair of plastic body panels, seats, fuel tank. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, lubrication points, spark plug checks. Troubleshooting: Diagnostic procedures for common and uncommon issues, fault finding guides. Component Overhaul: Detailed step-by-step instructions for rebuilding major components. Electrical Diagnostics: Wiring diagrams, testing procedures for electrical components. Suspension Adjustment And Rebuild: Fork seal replacement, rear shock service. Wheel And Tire Service: Mounting, dismounting, balancing, spoke tensioning. Technical Depth Diagnostic Level: Advanced diagnostics and troubleshooting Rebuild Depth: Complete engine and component rebuilds Specification Detail: Torque specifications, clearances, fluid capacities, electrical values. 📊 Manual Specifications File Format Format Type: Likely PDF (searchable, printable) Print Quality Quality: High-resolution scans or professionally formatted digital document Binding Type Binding: N/A (Digital Format) Paper Type Paper: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, 4-stroke, DOHC, 4 valves Displacement: 652 cc (actual displacement may vary slightly across early/late models) Bore X Stroke: Approx. 100 mm x 83 mm (specifications may vary slightly) Compression Ratio: Typically around 9.7:1 or 10.0:1 Performance Horsepower: Approx. 48-50 HP @ 6500-7000 RPM (varies slightly by market and tuning) Torque: Approx. 56-58 Nm @ 4500-5000 RPM (varies slightly) Fuel System Fuel Delivery: Carburetor (likely Mikuni BST series) or potentially early EFI on some later models. Fuel Type: Unleaded gasoline, minimum 95 RON (octane rating) Cooling System Cooling Method: Liquid-cooled Lubrication Oil Type: SAE 10W-40 or 20W-50 API SG or higher motorcycle-specific oil. Oil Capacity: Approx. 2.0 - 2.2 liters (check manual for exact capacity with filter change) 🔧 Transmission Standard Gearbox Type: Constant mesh, 5-speed sequential Clutch Type: Wet multi-plate Features Final Drive: Chain drive 📐 Dimensions Exterior Length: Approx. 2230 mm (varies slightly by variant) Width: Approx. 800 mm (excluding mirrors) Height: Approx. 1350 mm (to top of windshield/fairing) Wheelbase: Approx. 1510 mm Weights Dry Weight: Approx. 185 kg Wet Weight: Approx. 200-205 kg (with fluids) Payload Capacity: Check manual, typically around 180-200 kg for rider and luggage. 🛡️ Safety Features Ratings Crash Test Results: Not applicable (motorcycle specific, no standardized automotive crash ratings) Active Features Braking System: Dual hydraulic disc front brake, single hydraulic disc rear brake. ABS: Optional on some later models or specific markets. Passive Features Lighting: Halogen headlamp, LED tail lamp, standard indicator lights. Fluorescent Elements: Reflective decals and potential for high-visibility paint schemes. 💡 Technology Features Infotainment Display Type: Analog speedometer and tachometer, with indicator lights for turn signals, high beam, oil pressure, etc. Audio System: Not applicable (standard motorcycle features) Driver Assistance ABS Availability: Optional on select models/markets, significantly enhances braking safety. Connectivity Smartphone Integration: Not applicable (standard motorcycle features) 🔧 Maintenance Service Intervals Oil Change Interval: Every 6,000 km or 12 months, whichever comes first. Air Filter Check: Every 6,000 km, clean or replace as needed. Spark Plug Replacement: Every 12,000 km or as specified by the manual. Chain Lubrication Adjustment: Every 1,000 km and after washing/rain. Valve Clearance Check: Every 12,000 km. Fluid Specifications Coolant Type: Ethylene glycol-based antifreeze coolant, 50/50 mix with distilled water. Brake Fluid Type: DOT 4 hydraulic brake fluid. Fork Oil Type: SAE 10W or 15W suspension fluid (check manual for specific grade). Known Issues Electrical Connections: Corrosion or loose connections in wiring harness, particularly around the regulator/rectifier and stator....
Carburetor (likely Mikuni BST series) or potentially early EFI on some later models.
Fuel Type:
Unleaded gasoline, minimum 95 RON (octane rating)
Cooling System
Cooling Method:
Liquid-cooled
Lubrication
Oil Type:
SAE 10W-40 or 20W-50 API SG or higher motorcycle-specific oil.
Oil Capacity:
Approx. 2.0 - 2.2 liters (check manual for exact capacity with filter change)
🔧 Transmission
Standard
Gearbox Type:
Constant mesh, 5-speed sequential
Clutch Type:
Wet multi-plate
Features
Final Drive:
Chain drive
📐 Dimensions
Exterior
Length:
Approx. 2230 mm (varies slightly by variant)
Width:
Approx. 800 mm (excluding mirrors)
Height:
Approx. 1350 mm (to top of windshield/fairing)
Wheelbase:
Approx. 1510 mm
Weights
Dry Weight:
Approx. 185 kg
Wet Weight:
Approx. 200-205 kg (with fluids)
Payload Capacity:
Check manual, typically around 180-200 kg for rider and luggage.
🛡️ Safety Features
Ratings
Crash Test Results:
Not applicable (motorcycle specific, no standardized automotive crash ratings)
Active Features
Braking System:
Dual hydraulic disc front brake, single hydraulic disc rear brake.
ABS:
Optional on some later models or specific markets.
Passive Features
Lighting:
Halogen headlamp, LED tail lamp, standard indicator lights.
Fluorescent Elements:
Reflective decals and potential for high-visibility paint schemes.
💡 Technology Features
Infotainment
Display Type:
Analog speedometer and tachometer, with indicator lights for turn signals, high beam, oil pressure, etc.
Audio System:
Not applicable (standard motorcycle features)
Driver Assistance
ABS Availability:
Optional on select models/markets, significantly enhances braking safety.
Connectivity
Smartphone Integration:
Not applicable (standard motorcycle features)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 6,000 km or 12 months, whichever comes first.
Air Filter Check:
Every 6,000 km, clean or replace as needed.
Spark Plug Replacement:
Every 12,000 km or as specified by the manual.
Chain Lubrication Adjustment:
Every 1,000 km and after washing/rain.
Valve Clearance Check:
Every 12,000 km.
Fluid Specifications
Coolant Type:
Ethylene glycol-based antifreeze coolant, 50/50 mix with distilled water.
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Fork Oil Type:
SAE 10W or 15W suspension fluid (check manual for specific grade).
Known Issues
Electrical Connections:
Corrosion or loose connections in wiring harness, particularly around the regulator/rectifier and stator. Vibration can exacerbate issues.
Carburetor Issues:
Carburetor can become gummed up if the bike sits for extended periods, leading to starting and running problems. Jetting might need adjustment for altitude or modifications.
Suspension Seals:
Fork seals can wear over time, leading to oil leaks. Rear shock absorber may lose damping over high mileage.
Clutch Slippage:
Clutch plates can wear, leading to slippage, especially if the bike is used aggressively or ridden with a passenger frequently.
Chain And Sprockets:
Wear on chain and sprockets is normal, requiring regular adjustment and eventual replacement. Proper lubrication is key.
📚 Vehicle History
Brand Heritage
Manufacturer:
Aprilia is an Italian manufacturer with a strong racing heritage, known for performance motorcycles.
Model Evolution
Development:
The Pegaso 650 was developed as Aprilia's entry into the popular mid-weight adventure/dual-sport segment.
Engine Source:
The Rotax 654cc engine (often based on Rotax design, manufactured by Aprilia or Rotax) was a key component, known for its reliability and torque.
Variants:
The Pegaso 650 saw several iterations and updates during its production run, including the 'i.e.' (fuel injected) versions later in its life.
Production
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
Widely recognized as a capable and versatile dual-sport motorcycle for its era, praised for its balance of on-road comfort and off-road ability.
Ratings
User Reviews:
Generally positive user reviews highlighting its reliability, torque, and suitability for touring and commuting.
Certifications
Emissions Standards:
Compliance with European emission standards relevant to the production years (e.g., Euro 1, Euro 2).