1995-2002 Aprilia Pegaso 655 Motorcycle Workshop Repair Service Manual Best English-GERMAN

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🏷️ Basic Information Identification Make: Aprilia Model: Pegaso 655 Generation Model Years Covered: 1995-2002 👋 Introduction Market Position Segment: Adventure Touring Motorcycle Competitive Analysis Competitors Similar Era: BMW F650GS, Kawasaki KLR650, Suzuki DR650, Yamaha XT600/XT660 Key Features Engine Configuration: Single-cylinder, four-stroke engine (specific displacement 655cc confirmed) Design Philosophy: Versatile motorcycle suitable for both on-road commuting and light off-road adventures. Manual Advantage: Comprehensive, bilingual (English/German) coverage for detailed self-servicing and repair. 📋 Manual Details Coverage Areas Primary Coverage: Workshop Repair Service Page Count Estimated Pages: Extensive (Digital format implies comprehensive content) Manual Type Type: Workshop Repair Service Manual Language Supported Languages: English, German Format File Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Complete rebuild, tuning, diagnostics Engine Coolant: Coolant types, capacities, bleeding procedures Engine Control System: ECU diagnostics, sensor testing, fuel injection system Emission Control Systems: Catalytic converter, evaporative emission control Drive Shaft: Inspection, maintenance, potential rebuild Drive Belt: Tensioning, replacement, inspection Differential Case Assy: Fluid checks, potential servicing Cylinder Head Assy: Valve adjustment, gasket replacement, cylinder head torque specifications Cylinder Block Assy: Piston and ring inspection, bore measurement Cooling System: Radiator, hoses, water pump, thermostat replacement and testing Cooling Fan System: Fan motor, sensor diagnostics Combination Meter: Instrument cluster, warning lights, sensor inputs Clutch Unit: Friction plates, pressure plate, diaphragm spring inspection and replacement Clutch System: Hydraulic system, bleeding, master and slave cylinder service Clutch Start Switch Assy: Functionality testing Clutch Release Cylinder Assy: Service and replacement Clutch Pedal Sub-Assy: Adjustment and inspection Clutch Master Cylinder Assy: Service and replacement Charging System: Alternator, regulator/rectifier testing and replacement Charcoal Canister: Functionality and replacement Chain Sub-Assy: Lubrication, tensioning, replacement Center Stop Lamp Assy: Bulb replacement, wiring check Center Cluster Module Switch: Switch function, wiring Camshaft Position Sensor: Testing and replacement Camshaft: Inspection, timing procedures Brake System: Hydraulic system, caliper service, pad and disc replacement Brake Pedal: Lever adjustment, inspection Brake Master Cylinder: Service and replacement Brake Fluid: Type specifications (DOT 4 recommended), bleeding procedures Brake Booster: Testing and potential replacement (if applicable) Brake Actuator: Diagnostics and potential repair (if ABS equipped) Body Repair: Panel replacement, alignment, cosmetic repairs Wiring Diagrams: Comprehensive electrical schematics for all systems Wire Harness Repair: Troubleshooting and repair of electrical wiring Wiper Rubber: Replacement Wiper And Washer System: Motor, linkage, pump diagnostics and repair Windshield Wiper Motor Assy: Testing and replacement Windshield Glass: Replacement procedures (if applicable) Window Defogger System: Defogger grid repair and electrical checks (if applicable) Wheel And Tire System: Tire pressure, wear, mounting, balancing Water Pump Assy: Replacement and seal service Valve Clearance: Adjustment procedures and specifications Throttle Body Assy: Cleaning, adjustment, sensor testing Thermostat: Testing and replacement Supplemental Restraint System: Airbag system diagnostics and safety precautions (if equipped) Sun Roof System: Motor, track, seal maintenance (if equipped) Steering System: Handlebar, steering head bearings, adjustments Steering Column: Inspection and potential repair Starting System: Starter motor, solenoid, battery checks Starter Switch: Functionality testing Starter Assy: Testing and replacement Spiral Cable Sub-Assy: Horn, switch wiring continuity (if applicable) Side Turn Signal Lamp Assy: Bulb replacement, wiring Side Mudguard: Removal and installation Seat Belt Warning System: Sensor and indicator light function (if equipped) Seat Belt: Inspection and retractor function (if equipped) Roof Headlining: Removal and installation (if applicable) Roof Drip Side Finish Moulding: Removal and installation Receiver Condenser Assy: Air conditioning system component (if equipped) Rear Wiper Rubber: Replacement (if equipped) Rear Wiper Motor Assy: Testing and replacement (if equipped) Rear Wheel Alignment: Adjustment procedures (if applicable) Rear Suspension System: Shock absorber, swingarm, linkage service and adjustment Rear Shock ABSorber Assy: Inspection, replacement, and adjustment Rear Seat Belt: Inspection and function (if equipped) Rear Door Glass Weatherstrip: Replacement (if applicable) Rear Combination Lamp Assy: Bulb replacement, wiring Rear Coil Spring: Inspection and replacement Rear Bumper: Removal and installation (if applicable) Rear Brake: Disc, caliper, pad service and replacement Rear Axle Hub: Inspection and potential bearing service Radio Receiver Assy: Wiring, antenna, speaker checks (if equipped) Radiator Assy: Cleaning, leak testing, replacement Quarter Window Assy: Removal and installation (if applicable) Pulley Compressor Assy: Air conditioning system component (if equipped) Power Window Control System: Motor, switch, regulator diagnostics (if equipped) Power Steering Link Assy: Inspection and potential repair (if equipped) Power Steering: System checks and potential leak diagnosis (if equipped) Power Mirror Control System: Motor and switch diagnostics (if equipped) Power Door Lock Control System: Actuator and switch diagnostics (if equipped) Passenger Air Bag Assy: Diagnostics and safety precautions (if equipped) Partial Engine: Component-specific repair procedures Parking Brake Lever: Adjustment and inspection Parking Brake Cable: Adjustment and replacement Output Shaft Assy: Inspection and bearing service Outer Rear View Mirror Assy: Removal and installation Oil Pump: Removal, inspection, and replacement Oil Filter: Replacement procedures and recommended part numbers Name Plate: Identification and data plate location Manual Transaxle System: Internal component service, gear inspection, bearing replacement Manual Transaxle Oil: Type...

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Tags: 1995 1996 1997 1998 1999 2000 2001 2002 Aprilia Motorcycle Motorcycles Pegaso 655 Pegaso Models

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Description

🏷️ Basic Information

Identification

Make:

Aprilia

Model:

Pegaso 655

Generation

Model Years Covered:

1995-2002

👋 Introduction

Market Position

Segment:

Adventure Touring Motorcycle

Competitive Analysis

Competitors Similar Era:

BMW F650GS, Kawasaki KLR650, Suzuki DR650, Yamaha XT600/XT660

Key Features

Engine Configuration:

Single-cylinder, four-stroke engine (specific displacement 655cc confirmed)

Design Philosophy:

Versatile motorcycle suitable for both on-road commuting and light off-road adventures.

Manual Advantage:

Comprehensive, bilingual (English/German) coverage for detailed self-servicing and repair.

📋 Manual Details

Coverage Areas

Primary Coverage:

Workshop Repair Service

Page Count

Estimated Pages:

Extensive (Digital format implies comprehensive content)

Manual Type

Type:

Workshop Repair Service Manual

Language

Supported Languages:

English, German

Format

File Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete rebuild, tuning, diagnostics

Engine Coolant:

Coolant types, capacities, bleeding procedures

Engine Control System:

ECU diagnostics, sensor testing, fuel injection system

Emission Control Systems:

Catalytic converter, evaporative emission control

Drive Shaft:

Inspection, maintenance, potential rebuild

Drive Belt:

Tensioning, replacement, inspection

Differential Case Assy:

Fluid checks, potential servicing

Cylinder Head Assy:

Valve adjustment, gasket replacement, cylinder head torque specifications

Cylinder Block Assy:

Piston and ring inspection, bore measurement

Cooling System:

Radiator, hoses, water pump, thermostat replacement and testing

Cooling Fan System:

Fan motor, sensor diagnostics

Combination Meter:

Instrument cluster, warning lights, sensor inputs

Clutch Unit:

Friction plates, pressure plate, diaphragm spring inspection and replacement

Clutch System:

Hydraulic system, bleeding, master and slave cylinder service

Clutch Start Switch Assy:

Functionality testing

Clutch Release Cylinder Assy:

Service and replacement

Clutch Pedal Sub-Assy:

Adjustment and inspection

Clutch Master Cylinder Assy:

Service and replacement

Charging System:

Alternator, regulator/rectifier testing and replacement

Charcoal Canister:

Functionality and replacement

Chain Sub-Assy:

Lubrication, tensioning, replacement

Center Stop Lamp Assy:

Bulb replacement, wiring check

Center Cluster Module Switch:

Switch function, wiring

Camshaft Position Sensor:

Testing and replacement

Camshaft:

Inspection, timing procedures

Brake System:

Hydraulic system, caliper service, pad and disc replacement

Brake Pedal:

Lever adjustment, inspection

Brake Master Cylinder:

Service and replacement

Brake Fluid:

Type specifications (DOT 4 recommended), bleeding procedures

Brake Booster:

Testing and potential replacement (if applicable)

Brake Actuator:

Diagnostics and potential repair (if ABS equipped)

Body Repair:

Panel replacement, alignment, cosmetic repairs

Wiring Diagrams:

Comprehensive electrical schematics for all systems

Wire Harness Repair:

Troubleshooting and repair of electrical wiring

Wiper Rubber:

Replacement

Wiper And Washer System:

Motor, linkage, pump diagnostics and repair

Windshield Wiper Motor Assy:

Testing and replacement

Windshield Glass:

Replacement procedures (if applicable)

Window Defogger System:

Defogger grid repair and electrical checks (if applicable)

Wheel And Tire System:

Tire pressure, wear, mounting, balancing

Water Pump Assy:

Replacement and seal service

Valve Clearance:

Adjustment procedures and specifications

Throttle Body Assy:

Cleaning, adjustment, sensor testing

Thermostat:

Testing and replacement

Supplemental Restraint System:

Airbag system diagnostics and safety precautions (if equipped)

Sun Roof System:

Motor, track, seal maintenance (if equipped)

Steering System:

Handlebar, steering head bearings, adjustments

Steering Column:

Inspection and potential repair

Starting System:

Starter motor, solenoid, battery checks

Starter Switch:

Functionality testing

Starter Assy:

Testing and replacement

Spiral Cable Sub-Assy:

Horn, switch wiring continuity (if applicable)

Side Turn Signal Lamp Assy:

Bulb replacement, wiring

Side Mudguard:

Removal and installation

Seat Belt Warning System:

Sensor and indicator light function (if equipped)

Seat Belt:

Inspection and retractor function (if equipped)

Roof Headlining:

Removal and installation (if applicable)

Roof Drip Side Finish Moulding:

Removal and installation

Receiver Condenser Assy:

Air conditioning system component (if equipped)

Rear Wiper Rubber:

Replacement (if equipped)

Rear Wiper Motor Assy:

Testing and replacement (if equipped)

Rear Wheel Alignment:

Adjustment procedures (if applicable)

Rear Suspension System:

Shock absorber, swingarm, linkage service and adjustment

Rear Shock ABSorber Assy:

Inspection, replacement, and adjustment

Rear Seat Belt:

Inspection and function (if equipped)

Rear Door Glass Weatherstrip:

Replacement (if applicable)

Rear Combination Lamp Assy:

Bulb replacement, wiring

Rear Coil Spring:

Inspection and replacement

Rear Bumper:

Removal and installation (if applicable)

Rear Brake:

Disc, caliper, pad service and replacement

Rear Axle Hub:

Inspection and potential bearing service

Radio Receiver Assy:

Wiring, antenna, speaker checks (if equipped)

Radiator Assy:

Cleaning, leak testing, replacement

Quarter Window Assy:

Removal and installation (if applicable)

Pulley Compressor Assy:

Air conditioning system component (if equipped)

Power Window Control System:

Motor, switch, regulator diagnostics (if equipped)

Power Steering Link Assy:

Inspection and potential repair (if equipped)

Power Steering:

System checks and potential leak diagnosis (if equipped)

Power Mirror Control System:

Motor and switch diagnostics (if equipped)

Power Door Lock Control System:

Actuator and switch diagnostics (if equipped)

Passenger Air Bag Assy:

Diagnostics and safety precautions (if equipped)

Partial Engine:

Component-specific repair procedures

Parking Brake Lever:

Adjustment and inspection

Parking Brake Cable:

Adjustment and replacement

Output Shaft Assy:

Inspection and bearing service

Outer Rear View Mirror Assy:

Removal and installation

Oil Pump:

Removal, inspection, and replacement

Oil Filter:

Replacement procedures and recommended part numbers

Name Plate:

Identification and data plate location

Manual Transaxle System:

Internal component service, gear inspection, bearing replacement

Manual Transaxle Oil:

Type and capacity specifications

Maintenance:

Routine service, lubrication points, inspection schedules

Lubrication System:

Oil flow diagrams, oil type specifications

Lighting System:

Headlights, taillights, turn signals, wiring diagnostics

License Plate Lamp Assy:

Bulb replacement, wiring

Knock Sensor:

Testing and replacement

Introduction:

Vehicle overview and important safety information

Instrument Panel:

Component removal and installation, diagnostics

Input Shaft Assy:

Inspection and bearing service

Inner Rear View Mirror Assy:

Removal and installation

Ignition System:

Spark plugs, coils, timing checks

Horn Button Assy:

Functionality testing

Horn:

Testing and replacement

Hood:

Removal and installation, latch adjustment (if applicable)

Heater Radiator Assy:

Replacement and flushing (if equipped)

Heater Or Boost Ventilator Control:

Diagnostics and repair (if equipped)

Heater & Air Conditioner:

Component testing and repair (if equipped)

Headlamp Protector Retainer:

Removal and installation (if equipped)

Headlamp Dimmer Switch Assy:

Functionality testing and replacement

Headlamp Assy:

Bulb replacement, aiming, wiring

Generator Assy:

See Charging System

Fuel Tank:

Removal, cleaning, leak testing

Fuel System:

Fuel pump, filter, lines, injectors

Fuel Pump:

Testing, replacement

Fuel Injector:

Testing, cleaning, replacement

Front Wheel Alignment:

Adjustment procedures

Front Suspension System:

Forks, springs, seals, linkages, bearings

Front Suspension Arm:

Inspection and potential replacement

Front Stabilizer Bar:

Inspection and potential replacement (if equipped)

Front Speaker Assy:

Wiring and replacement (if equipped)

Front Shock ABSorber:

Inspection, replacement, and adjustment

Front Seat Belt:

Inspection and function (if equipped)

Front Marker Lamp Assy:

Bulb replacement, wiring

Front Drive Shaft:

Inspection and potential service

Front Door Glass Weatherstrip:

Replacement (if applicable)

Front Door:

Removal and installation (if applicable)

Front Differential Oil Seal:

Replacement (if applicable)

Front Bumper:

Removal and installation (if applicable)

Front Brake:

Disc, caliper, pad service and replacement

Front Axle Hub:

Inspection and potential bearing service

Floor Shift Parking Lock Cable:

Adjustment and inspection (if equipped)

Fender Panel Mudguard:

Removal and installation

Exhaust Pipe:

Inspection, gasket replacement, repair

Exhaust:

Muffler, catalytic converter, header pipe service

Back Door Glass:

Replacement (if applicable)

Back Door Garnish:

Removal and installation (if applicable)

Back Door:

Removal and installation, hinge adjustment (if applicable)

Automatic Transaxle Fluid:

Type and capacity specifications (if applicable)

Automatic Transaxle Assy:

Diagnostics and potential servicing (if applicable)

Audio & Visual System:

Troubleshooting and repair (if equipped)

Antenna Cord Sub-Assy:

Wiring and connection checks (if equipped)

Amplifier Antenna Assy:

Testing and replacement (if equipped)

Air Conditioning System:

Refrigerant, compressor, blower, evaporator service (if equipped)

Air Conditioning Blower Assy:

Testing and replacement (if equipped)

Air Conditioning Amplifier Assy:

Diagnostics and replacement (if equipped)

Air Conditioner Refrigerant:

Type and servicing procedures (if equipped)

Air Bag Sensor Rear:

Diagnostics and safety precautions (if equipped)

Air Bag Sensor Front:

Diagnostics and safety precautions (if equipped)

Procedures Included

Diagnostic Procedures:

Systematic troubleshooting guides, fault code interpretation

Repair Procedures:

Step-by-step instructions for component removal, replacement, and adjustment

Maintenance Procedures:

Scheduled services, fluid changes, filter replacements, lubrication

Rebuild Procedures:

Detailed instructions for engine, transmission, and major component overhauls

Refurbishment Procedures:

Guidance on restoring worn or damaged components

Restoration Procedures:

Information relevant to bringing older models back to original specifications

Electrical Troubleshooting:

Component testing, circuit analysis, wiring harness repair

Torque Specifications:

Precise torque values for all critical fasteners

Tightening Sequences:

Correct order for tightening cylinder heads, manifolds, etc.

Special Tool Requirements:

Identification of any specialized tools needed for specific procedures

Technical Depth

Depth Of Coverage:

Comprehensive, covering everything from basic maintenance to full engine rebuilds, aimed at professional technicians.

📊 Manual Specifications

File Format

Format:

Searchability:

Likely searchable text within the PDF

Print Quality

Quality:

High Quality Photos, Illustrations And Diagrams

Binding Type

Binding:

Not Applicable (Digital Download)

Paper Type

Paper:

Not Applicable (Digital Download)

Compatibility

Operating Systems:

All Versions of Windows & Mac & Linux

⚙️ Engine Specifications

Primary Engine

Configuration:

Single-cylinder, 4-stroke

Displacement:

655cc (cubic centimeters)

Bore X Stroke:

Specific values available within the manual

Cooling System:

Liquid-cooled

Performance

Horsepower:

Specific figures available within the manual, typically in the 40-50 HP range for this era.

Torque:

Specific figures available within the manual, typically in the 50-60 Nm range.

Fuel System

Induction:

Carburetor(s) or Fuel Injection (manual will detail the specific system used in these years).

Fuel Type:

Unleaded gasoline

🔧 Transmission

Standard

Type:

Manual gearbox (likely 5-speed)

Features

Clutch Type:

Wet multi-plate clutch

Final Drive:

Chain drive

📐 Dimensions

Exterior

Length:

Specific dimensions detailed in the manual

Width:

Specific dimensions detailed in the manual

Height:

Specific dimensions detailed in the manual

Weights

Dry Weight:

Specific weight detailed in the manual, likely around 170-180 kg.

Fuel Tank Capacity:

Specific capacity detailed in the manual, typically around 15-20 liters.

🛡️ Safety Features

Ratings

Safety Features:

Brake systems (front disc, rear disc), robust chassis design. Specific safety ratings for this era of motorcycles are less standardized than cars.

Active Features

Braking System:

Hydraulic disc brakes front and rear, providing reliable stopping power.

Passive Features

Frame Construction:

Steel frame, designed for stability and durability.

💡 Technology Features

Infotainment

Features:

Basic instrumentation (speedometer, tachometer, odometer, trip meter). Advanced infotainment is not a feature of this model.

Driver Assistance

Features:

ABS was not standard or widely available on this model, but potential variations may exist (manual will clarify). Primarily mechanical safety systems.

Connectivity

Features:

No electronic connectivity features like Bluetooth or smartphone integration.

🔧 Maintenance

Service Intervals

Oil Change:

Typically every 5,000-7,500 km or annually, as per manual recommendations.

Valve Clearance Check:

Typically every 10,000-15,000 km.

Chain Lubrication And Tension:

Regular checks recommended, especially before long rides.

Fluid Specifications

Engine Oil:

Specific viscosity (e.g., 10W-40 or 20W-50) and API rating (e.g., SG or higher) will be in the manual. Use motorcycle-specific oil.

Coolant:

Ethylene glycol-based coolant, typically a 50/50 mix with distilled water. Specific brand recommendations might be in the manual.

Brake Fluid:

DOT 4 is typically specified for this era of motorcycle.

Gearbox Oil:

Specific oil type and viscosity for the gearbox will be detailed in the manual.

Known Issues

Common Wear Items:

Clutch plates, fork seals, exhaust gaskets, electrical connectors can be prone to wear over time. The manual will guide on inspection and replacement.

Electrical Gremlins:

Older Italian motorcycles can sometimes exhibit minor electrical issues; the comprehensive wiring diagrams in the manual are crucial for diagnosis.

📚 Vehicle History

Brand Heritage

Manufacturer:

Aprilia is an Italian manufacturer known for its performance-oriented motorcycles, particularly in sport and off-road segments.

Model Evolution

Pegaso Lineage:

The Pegaso line has a history of dual-purpose motorcycles, evolving with different engine sizes and configurations. The 655cc model represents a mid-to-late 90s iteration.

Production

Manufacturing Location:

Italy

🏆 Awards & Recognition

Recognitions

Awards:

Specific awards for the 1995-2002 Aprilia Pegaso 655 are not widely documented in general automotive databases. The manual focuses on technical maintenance and repair rather than marketing accolades.