Aprilia Pegaso 650 1997-2005 WSM Service Manual Repair
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Basic Information Identification Make: Aprilia Model: Pegaso 650 Model Variant: Standard / Strada / Trail (depending on specific sub-model within years) Codes Chassis Code Range: RPV650 (general designation for the Pegaso 650 family) Engine Code Family: Rotax 654 (single-cylinder, four-stroke) Introduction Market Position Category: Dual-sport / Adventure Motorcycle Target Audience: Riders seeking a versatile motorcycle for commuting, touring, and light off-road use. Competitive Analysis Competitors: BMW F650GS, Kawasaki KLR650, Honda Transalp (similar displacement class dual-sports). Key Features Versatility: Capable of handling both paved roads and unpaved trails. Engine Durability: Proven Rotax single-cylinder engine known for its robustness. Reliability: Designed for dependable performance over extended periods. Manual Details Coverage Areas Applicable Years: 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005 Page Count Estimated Pages: 400-600 (typical for a comprehensive WSM) Manual Type Type: Workshop Service Manual (WSM) Language Language: Likely English (common for international service manuals) Format Format: Digital (PDF) or Printed Manual Coverage Systems Covered Engine: Engine disassembly, assembly, diagnosis, tuning, lubrication system, cooling system, fuel system (carburetor/injection depending on specific sub-model and year), ignition system, exhaust system. Transmission: Clutch operation, gearbox overhaul, gear selection mechanisms, final drive (chain and sprocket). Chassis And Suspension: Front fork (telescopic), rear shock absorber and linkage (monoshock), frame inspection and repair, swingarm, wheel bearings, steering head bearings. Brakes: Front and rear brake systems (hydraulic disc brakes), caliper overhaul, master cylinder, brake lines, brake fluid specifications and bleeding procedures. Electrical System: Wiring diagrams, battery, starter system, charging system (alternator/stator), lighting circuits (headlight, tail light, indicators), ignition coil, CDI unit, instrument cluster, fuses, relays, horn. Fuel And Emission Control: Fuel tank, fuel pump (if applicable), fuel lines, carburetor(s) or fuel injection system (components, settings, and troubleshooting), emission control systems (if equipped). Bodywork And Trim: Fairings, seat, fuel tank cover, fenders, mirrors, grips, footpegs, luggage rack (if applicable). Procedures Included Maintenance: Scheduled maintenance intervals, oil and filter changes, spark plug replacement, air filter cleaning/replacement, chain adjustment and lubrication, brake pad inspection and replacement, coolant checks, valve clearance adjustment. Troubleshooting: Diagnostic flowcharts for common problems (e.g., starting issues, engine misfires, electrical faults, braking problems). Repair: Detailed step-by-step instructions for component removal, repair, and reassembly. Diagnostics: Specifications for testing electrical components (resistance, voltage, amperage), engine compression testing, carburetor synchronization (if applicable). Technical Depth Depth: Comprehensive: Covers everything from basic user maintenance to complete engine rebuilds, electrical system diagnostics, and chassis component overhauls. Manual Specifications File Format Digital Format Details: High-resolution PDF, searchable text, bookmarked sections, printable pages. Print Quality Print Quality Description: Clear black and white diagrams, sharp text, professional layout. Binding Type Binding Description: If printed: Perfect bound or spiral bound for ease of use in a workshop setting. Paper Type Paper Type Description: If printed: Durable, coated paper to withstand workshop conditions. Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder, liquid-cooled, DOHC Displacement: 652 cc (approximately) Bore X Stroke: 100 mm x 83 mm (typical for this engine family) Compression Ratio: Approximately 10.0:1 Performance Horsepower Output: Around 48-50 hp at 6500-7000 rpm (variations may exist across years/sub-models) Torque Output: Around 55-60 Nm at 5000-5500 rpm (variations may exist across years/sub-models) Fuel System Fuel Delivery: Carburetor (e.g., Mikuni BSR33 or similar) or potentially fuel injection on later models/specific markets. The manual will detail the specific system. Fuel Type: Unleaded gasoline (Octane rating specified in manual) Lubrication System Oil Type: Motorcycle-specific 4-stroke engine oil, API SG/SH or higher, JASO MA specification. Viscosity typically 10W-40 or 15W-50 as per manual. Oil Capacity With Filter Change: Approximately 2.0 - 2.2 liters (refer to manual for exact capacity and fill level check). Cooling System Coolant Type: Ethylene glycol based coolant with corrosion inhibitors. Typically a 50/50 mix with distilled water. Manual will specify Aprilia or equivalent OEM coolant. Coolant Capacity: Approximately 1.2 - 1.4 liters (refer to manual for exact capacity). Transmission Standard Transmission Type: 5-speed constant mesh gearbox Clutch Type: Wet multi-plate, cable-operated Features Final Drive: O-ring sealed chain drive Gear Ratios: Specific ratios are detailed in the manual, crucial for performance tuning and troubleshooting. Dimensions Exterior Seat Height: Varies by sub-model (Trail models typically higher), around 850-880 mm. Ground Clearance: Adequate for dual-sport use, detailed in manual. Weights Dry Weight: Approximately 170-180 kg (variations by model year and equipment) Fuel Tank Capacity: Approximately 14-18 liters (variations by sub-model) Safety Features Ratings Safety Features: Standard motorcycle safety features: effective braking system, stable chassis, appropriate lighting. Active Features Braking System: Dual hydraulic disc brakes front and rear, with specific caliper and disc dimensions detailed in the manual. Passive Features Frame Construction: Steel tube frame providing rigidity and impact resistance. Technology Features Infotainment Instrument Cluster: Analog speedometer and tachometer, odometer, trip meter, neutral indicator, oil pressure warning light, high beam indicator, turn signal indicators. Manual provides diagnostics for cluster components. Driver Assistance ABS: Not standard on all models in this range; if...
Likely English (common for international service manuals)
Format
Format:
Digital (PDF) or Printed
Manual Coverage
Systems Covered
Engine:
Engine disassembly, assembly, diagnosis, tuning, lubrication system, cooling system, fuel system (carburetor/injection depending on specific sub-model and year), ignition system, exhaust system.
Transmission:
Clutch operation, gearbox overhaul, gear selection mechanisms, final drive (chain and sprocket).
Chassis And Suspension:
Front fork (telescopic), rear shock absorber and linkage (monoshock), frame inspection and repair, swingarm, wheel bearings, steering head bearings.
Brakes:
Front and rear brake systems (hydraulic disc brakes), caliper overhaul, master cylinder, brake lines, brake fluid specifications and bleeding procedures.
Fuel tank, fuel pump (if applicable), fuel lines, carburetor(s) or fuel injection system (components, settings, and troubleshooting), emission control systems (if equipped).
Comprehensive: Covers everything from basic user maintenance to complete engine rebuilds, electrical system diagnostics, and chassis component overhauls.
Clear black and white diagrams, sharp text, professional layout.
Binding Type
Binding Description:
If printed: Perfect bound or spiral bound for ease of use in a workshop setting.
Paper Type
Paper Type Description:
If printed: Durable, coated paper to withstand workshop conditions.
Engine Specifications
Primary Engine
Engine Type:
Four-stroke, single-cylinder, liquid-cooled, DOHC
Displacement:
652 cc (approximately)
Bore X Stroke:
100 mm x 83 mm (typical for this engine family)
Compression Ratio:
Approximately 10.0:1
Performance
Horsepower Output:
Around 48-50 hp at 6500-7000 rpm (variations may exist across years/sub-models)
Torque Output:
Around 55-60 Nm at 5000-5500 rpm (variations may exist across years/sub-models)
Fuel System
Fuel Delivery:
Carburetor (e.g., Mikuni BSR33 or similar) or potentially fuel injection on later models/specific markets. The manual will detail the specific system.
Fuel Type:
Unleaded gasoline (Octane rating specified in manual)
Lubrication System
Oil Type:
Motorcycle-specific 4-stroke engine oil, API SG/SH or higher, JASO MA specification. Viscosity typically 10W-40 or 15W-50 as per manual.
Oil Capacity With Filter Change:
Approximately 2.0 - 2.2 liters (refer to manual for exact capacity and fill level check).
Cooling System
Coolant Type:
Ethylene glycol based coolant with corrosion inhibitors. Typically a 50/50 mix with distilled water. Manual will specify Aprilia or equivalent OEM coolant.
Coolant Capacity:
Approximately 1.2 - 1.4 liters (refer to manual for exact capacity).
Transmission
Standard
Transmission Type:
5-speed constant mesh gearbox
Clutch Type:
Wet multi-plate, cable-operated
Features
Final Drive:
O-ring sealed chain drive
Gear Ratios:
Specific ratios are detailed in the manual, crucial for performance tuning and troubleshooting.
Dimensions
Exterior
Seat Height:
Varies by sub-model (Trail models typically higher), around 850-880 mm.
Ground Clearance:
Adequate for dual-sport use, detailed in manual.
Weights
Dry Weight:
Approximately 170-180 kg (variations by model year and equipment)
Fuel Tank Capacity:
Approximately 14-18 liters (variations by sub-model)
Dual hydraulic disc brakes front and rear, with specific caliper and disc dimensions detailed in the manual.
Passive Features
Frame Construction:
Steel tube frame providing rigidity and impact resistance.
Technology Features
Infotainment
Instrument Cluster:
Analog speedometer and tachometer, odometer, trip meter, neutral indicator, oil pressure warning light, high beam indicator, turn signal indicators. Manual provides diagnostics for cluster components.
Driver Assistance
ABS:
Not standard on all models in this range; if equipped, the manual will detail its operation and maintenance.
Connectivity
Diagnostic Ports:
Likely features a diagnostic connector for specialized electronic diagnostic tools, details found in the manual.
Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000 km or 6 months, whichever comes first. Manual will provide exact mileage and time intervals.
Valve Clearance Check:
Typically around 10,000-15,000 km. Crucial for engine performance and longevity, detailed in the manual.
Chain Adjustment:
Regular checks and adjustments needed, typically every 1,000 km or as per slack measurement. Manual will specify tolerance.
Brake Fluid Change:
Recommended every 2 years due to hygroscopic nature of brake fluid. Manual specifies interval and procedure.
Fluid Specifications
Engine Oil Specifications:
As per engine_specs.oil_type: API SG/SH or higher, JASO MA, viscosity 10W-40 or 15W-50.
Coolant Specifications:
As per engine_specs.coolant_type: Ethylene glycol based, 50/50 mix with distilled water.
Brake Fluid Type:
DOT 4 hydraulic brake fluid. Manual will specify exact type and replacement procedure.
Fork Oil Type:
Specific viscosity and type (e.g., SAE 10W) will be detailed in the manual for front fork service.
Known Issues
Common Wear Items:
Clutch plates, wheel bearings, steering head bearings, fork seals, chain and sprockets.
Electrical Gremlins:
Occasional issues with wiring harness connections or charging system components can occur; manual is key for diagnosis.
Carburetor Tuning:
May require periodic cleaning and synchronization for optimal performance, especially if not regularly maintained.
Vehicle History
Brand Heritage
Manufacturer:
Aprilia is an Italian motorcycle manufacturer known for performance and racing heritage.
Model Evolution
Generations:
The Pegaso line has evolved over the years, with the 650cc single-cylinder model being a significant iteration for the adventure/dual-sport segment. This WSM covers the later stages of this model's life cycle.
Production
Manufacturing Location:
Italy
Awards & Recognition
Recognitions
Market Reception:
The Pegaso 650 was generally well-regarded for its versatility and robust single-cylinder engine, making it a popular choice for touring and everyday use.
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