APRILIA Pegaso 650 Workshop Manual 2005

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The Aprilia Pegaso 650, produced in 2005, is an adventure touring motorcycle renowned for its blend of Italian styling and the reliable Rotax 654 engine. Designed for riders seeking versatility,...

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Typ: Motorcycle

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Art.-Nr: 153225

Stichworte: 2005 Aprilia Misc Motorcycle Motorcycles Pegaso 650

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Beschreibung

The Aprilia Pegaso 650, produced in 2005, is an adventure touring motorcycle renowned for its blend of Italian styling and the reliable Rotax 654 engine. Designed for riders seeking versatility, it offers the comfort and practicality for long-distance journeys along with the agility suitable for light off-road excursions. Its distinctive attributes include comfortable ergonomics and a robust steel tube frame, making it a capable and enjoyable machine for a wide range of riding conditions and applications, positioning it as a strong contender in the dual-sport segment. This workshop manual provides comprehensive service and repair information for the Aprilia Pegaso 650. It covers essential areas such as periodic maintenance, detailed diagnostics, and troubleshooting procedures for all major systems, including the engine, fuel system, electrical components, chassis, and brakes. With step-by-step instructions, detailed diagrams, and technical specifications, this manual is an indispensable resource for owners, mechanics, and technicians aiming to maintain, repair, and optimize the performance and longevity of their vehicle.

🏷️ Basic Information

Identification

Make:

Aprilia

Model:

Pegaso 650

Year:

Codes

Chassis Code Prefix:

Engine Code General:

Rotax 654

👋 Introduction

Market Position

Segment:

Adventure Touring / Dual-Sport Motorcycle

Target Audience:

Riders seeking a versatile motorcycle for commuting, touring, and light off-road use.

Competitive Analysis

Key Competitors:

BMW F650GS, Yamaha XT660R/X, Suzuki V-Strom 650 (later models)

Key Features

Design Philosophy:

Combines comfort and practicality of a tourer with the agility and capability of a dual-sport.

Distinctive Attributes:

Italian styling, Rotax engine reliability, comfortable ergonomics for long distances.

📋 Manual Details

Coverage Areas

Primary Coverage:

Service and Repair

Secondary Coverage:

Periodic Maintenance, Diagnostics, Troubleshooting

Page Count

Estimated Pages:

Manual Type

Type:

Workshop Manual

Language

Language:

English (assumed, typical for international markets)

Format

Format:

Digital (likely PDF, common for workshop manuals)

📖 Manual Coverage

Systems Covered

Engine:

Engine overhaul, top-end, bottom-end, timing, valve adjustments

Fuel System:

Fuel injection system, injectors, fuel pump, pressure regulator, throttle body

Exhaust System:

Exhaust manifold, catalytic converter, mufflers, lambda sensors

Cooling System:

Radiator, coolant, water pump, thermostat, hoses, fan

Lubrication System:

Oil pump, oil filter, oil passages, lubrication intervals

Chassis:

Frame, subframe, suspension (front and rear), steering components

Brakes:

Brake system hydraulics, calipers, rotors, master cylinder, brake fluid, bleeding procedures

Electrical System:

Wiring diagrams, battery, charging system, ignition system, starter motor, lighting, instrumentation

Bodywork:

Fairings, body panels, seating, storage, fasteners

Procedures Included

Maintenance:

Oil changes, filter replacements, chain adjustment, brake pad replacement, spark plug service

Repair:

Engine rebuild, transmission service, suspension overhaul, electrical component replacement

Diagnostics:

Fault finding for engine, electrical, and mechanical systems, troubleshooting common issues

Technical Data:

Torque specifications, clearances, fluid capacities, electrical schematics

Technical Depth

Depth:

Comprehensive (suitable for professional technicians and experienced DIY enthusiasts)

Detail Level:

Step-by-step instructions with detailed diagrams and illustrations

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text for quick information retrieval

Print Quality

Resolution:

High-resolution scans of original factory documentation

Binding Type

Binding:

N/A (for digital format)

Paper Type

Paper Quality:

N/A (for digital format)

⚙️ Engine Specifications

Primary Engine

Type:

Single-cylinder, four-stroke, liquid-cooled

Displacement:

652 cc

Bore X Stroke:

100 mm x 83 mm

Compression Ratio:

10.0:1

Valve Train:

SOHC, 4 valves per cylinder

Performance

Horsepower:

Approx. 48 hp @ 7000 rpm

Torque:

Approx. 57 Nm @ 5200 rpm

Fuel System

Induction:

Electronic Fuel Injection (EFI), Single Throttle Body (approx. 42mm)

Fuel Type:

Unleaded gasoline

Lubrication System

Oil Type:

Semi-synthetic or fully synthetic motorcycle oil (e.g., 10W-40 or 15W-50, check specific manual for SAE viscosity)

Oil Capacity With Filter:

Approx. 2.2 liters (check manual for precise capacity)

🔧 Transmission

Standard

Type:

5-speed manual gearbox

Optional

Optional Transmission:

Features

Clutch:

Wet multi-plate clutch

Final Drive:

O-ring sealed chain drive

📐 Dimensions

Exterior

Length:

Approx. 2180 mm

Width:

Approx. 850 mm (at handlebars)

Height:

Approx. 1240 mm (at windshield)

Seat Height:

Approx. 840 mm

Weights

Dry Weight:

Approx. 170 kg

Wet Weight:

Approx. 185 kg (with fluids)

Gross Vehicle Weight Rating:

Not officially specified, but safe to assume payload around 180-200kg.

Cargo

Storage:

Under-seat storage, optional luggage rack and pannier mounts.

🛡️ Safety Features

Ratings

Crash Test Ratings:

Motorcycles are not subjected to standardized crash testing like cars.

Active Features

Braking System:

Dual disc front, single disc rear. ABS was an optional feature on some versions.

Lighting:

Halogen headlight, LED tail light, standard turn signals.

Passive Features

Frame Construction:

Steel tube frame, designed for rigidity and rider comfort.

Ergonomics:

Upright riding position, adjustable levers for improved control.

💡 Technology Features

Infotainment

Display:

Analog tachometer, digital speedometer, fuel gauge, and indicator lights.

Driver Assistance

Optional ABS system available on some 2005 models.

Connectivity

Connectivity Features:

N/A (basic motorcycle technology for this era)

🔧 Maintenance

Service Intervals

Oil Change:

Every 5,000 - 7,500 km or annually (refer to manual for exact interval based on usage).

Air Filter Check:

Every 5,000 km or annually.

Spark Plug Replacement:

Every 10,000 - 15,000 km (depending on plug type).

Valve Clearance Check:

Every 10,000 - 15,000 km.

Chain Adjustment Lubrication:

Every 1,000 km or as needed based on slack.

Fluid Specifications

Coolant Type:

Ethylene glycol based coolant with corrosion inhibitors (e.g., Motul Motocool Expert or equivalent).

Brake Fluid Type:

DOT 4 (refer to manual for specific fluid type and replacement interval).

Fork Oil Type:

Specific fork oil viscosity, typically 5W or 10W (check manual for precise type and level).

Known Issues

Electrical Connections:

Corrosion on connectors, particularly in the headstock area, can lead to intermittent electrical faults.

Fuel Pump Reliability:

Some earlier models experienced fuel pump issues, though later iterations were generally improved.

Water Pump Seal:

Potential for water pump seal leaks requiring replacement.

Cam Chain Tensioner:

Wear can lead to rattling noises; automatic tensioners may require occasional inspection/replacement.

📚 Vehicle History

Brand Heritage

Manufacturer:

Aprilia is an Italian manufacturer known for its performance motorcycles, particularly in racing and sportbike segments.

Model Evolution

Pegaso Lineage:

The Pegaso line has a history dating back to the early 1990s, evolving through various iterations and engine displacements, often featuring the Rotax engine.

Production

Production Years:

The Pegaso 650 was produced in various forms from the mid-1990s through to the late 2000s, with the 2005 model representing a significant iteration.

Manufacturing Location:

Italy

🏆 Awards & Recognition

Recognitions

Motorcycle Press Reviews:

Generally well-received for its versatility and comfort, though often noted for its slightly underpowered feel compared to twin-cylinder competitors.