Aprilia Pegaso 650 1997-2005 Full Service Repair Manual

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Art.-Nr: 148929

Stichworte: 1997 1998 1999 2000 2001 2002 2003 2004 2005 Aprilia Misc Motorcycle Motorcycles Pegaso 650

Produktvarianten

Beschreibung

The Aprilia Pegaso 650, produced between 1997 and 2005, is a versatile dual-sport motorcycle renowned for its capability on both paved roads and light off-road terrain. This Italian-engineered machine, often compared to models like the BMW F650 Funduro and Honda Transalp, features a liquid-cooled, 652cc single-cylinder engine with electronic fuel injection, delivering approximately 48-50 horsepower. Its robust construction, spoked wheels, and comfortable riding position make it well-suited for adventure touring and everyday commuting. The Pegaso 650 (chassis code RL) is recognized for its blend of practicality and performance, offering a reliable and enjoyable riding experience for a wide range of enthusiasts. This comprehensive English-language service manual provides detailed information for the maintenance, repair, and troubleshooting of the Aprilia Pegaso 650 models from 1997 to 2005. It covers all essential systems, including engine mechanicals, fuel injection, transmission, brakes, suspension, and the electrical system, with step-by-step repair procedures, diagnostic guides, and critical torque specifications. The manual also includes routine maintenance schedules, fluid specifications, and detailed wiring diagrams, making it an indispensable resource for owners, mechanics, and technicians aiming to keep their Pegaso 650 in optimal condition.

🏷️ Basic Information

Identification

Make:

Aprilia

Model:

Pegaso 650

Generation

Covered Years:

1997-2005

Codes

Chassis Codes:

👋 Introduction

Market Position

Category:

Dual-sport / Adventure Touring Motorcycle

Competitive Analysis

Competitors:

BMW F650 Funduro, Honda Transalp, Kawasaki KLR650, Yamaha Tenere.

Key Features

Vehicle Type:

Versatile, capable on-road and light off-road use, comfortable for touring.

📋 Manual Details

Coverage Areas

Vehicle Models:

Aprilia Pegaso 650 (all variants within 1997-2005)

Page Count

Estimated Pages:

300-500 (typical for comprehensive service manuals)

Manual Type

Type:

Full Service Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete engine overhaul, including cylinder head, pistons, connecting rods, crankshaft, valve train, timing system, lubrication system.

Engine Management:

Fuel injection system (EFI), ignition system, emissions control, sensor diagnostics and troubleshooting, ECU functions.

Transmission:

Gearbox disassembly, inspection, repair, clutch operation and adjustment, shift mechanism.

Brakes:

Front and rear brake system maintenance, caliper overhaul, master cylinder, bleeding procedures, pad and disc replacement.

Suspension And Steering:

Front forks (telescopic, possibly USD depending on variant), rear shock absorber, swingarm, steering head bearings, linkage.

Electrical System:

Wiring diagrams, battery maintenance, charging system (alternator/stator), starter motor, lighting, instrumentation, fuses, relays.

Cooling System:

Radiator, fan operation, coolant hoses, thermostat, water pump maintenance.

Fuel System:

Fuel tank, fuel pump, fuel filter, fuel injectors, fuel pressure regulation.

Exhaust System:

Exhaust pipe, muffler, catalytic converter (if applicable), mounting and inspection.

Bodywork And Frame:

Fairings, seat, fuel tank removal, frame inspection, bolt torque specifications.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug checks, chain adjustment, tire pressure, brake fluid checks.

Troubleshooting:

Diagnostic flowcharts for common starting, running, and electrical issues.

Repair Procedures:

Step-by-step guides for component removal, installation, and overhaul.

Torque Specifications:

Critical torque values for all major fasteners and components.

Wiring Diagrams:

Detailed electrical schematics for all systems.

Suspension Adjustment:

Instructions for adjusting rear shock pre-load and damping (if applicable), fork oil level and changes.

Technical Depth

Depth:

Comprehensive, covering from basic scheduled maintenance to full engine and transmission rebuilds, including electrical diagnostics.

Diagnostic Tools:

Details diagnostic procedures, including the use of basic tools and interpretation of fault codes if applicable to the EFI system.

📊 Manual Specifications

File Format

File Type:

Print Quality

Resolution:

High-resolution, suitable for printing all diagrams and text clearly.

Binding Type

Binding:

N/A (Digital format)

Paper Type

Paper Quality:

N/A (Digital format)

Completeness

Coverage Level:

Comprehensive, designed for professional technicians and advanced DIY enthusiasts.

⚙️ Engine Specifications

Primary Engine

Engine Type:

Single-cylinder, four-stroke

Displacement:

652 cc

Bore X Stroke:

100 mm x 82 mm (typical for Rotax 655 engine)

Cooling:

Liquid-cooled

Valve Train:

DOHC, 4 valves per cylinder

Compression Ratio:

Approx. 10.0:1

Performance

Horsepower:

Approx. 48-50 HP @ 6500-7000 RPM (varies slightly by year/market)

Torque:

Approx. 58-60 Nm @ 5000-5500 RPM (varies slightly by year/market)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded gasoline (95 RON recommended)

Ignition System:

Electronic ignition with dual spark plugs

🔧 Transmission

Standard

Type:

5-speed manual

Features

Clutch Type:

Wet, multi-plate

Final Drive:

O-ring sealed chain

📐 Dimensions

Exterior

Length:

Approx. 2200 mm

Width:

Approx. 860 mm (at handlebars)

Height:

Approx. 1390 mm (at seat)

Wheelbase:

Approx. 1480 mm

Weights

Dry Weight:

Approx. 180 kg

Gross Vehicle Weight:

Approx. 380 kg

Cargo

Fuel Tank Capacity:

Approx. 20 liters (including reserve)

Wheels And Tires

Front Tire Size:

90/90-21

Rear Tire Size:

130/80-17 or 140/80-17

Front Wheel Type:

Spoked

Rear Wheel Type:

Spoked

🛡️ Safety Features

Ratings

Crash Test Results:

Not applicable for motorcycles in the same way as cars.

Active Features

Braking System:

Disc brakes front and rear, optional ABS on some variants.

Passive Features

Lighting:

Halogen headlight, LED taillight/brake light.

💡 Technology Features

Infotainment

Instrument Cluster:

Analog tachometer and speedometer, LCD multi-function display (odometer, trip meter, coolant temp, clock).

Driver Assistance

Optional Anti-lock Braking System (ABS) available on some models.

Connectivity

Charging Port:

Some later models may feature a 12V accessory socket.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 - 7,500 km or annually.

Valve Clearance Check:

Every 10,000 - 15,000 km.

Chain Maintenance:

Clean and lubricate every 500 km or after riding in wet conditions. Adjust tension as needed (typically 20-30mm play).

Air Filter Replacement:

Check every 5,000 km, replace as needed or every 10,000-15,000 km.

Fluid Specifications

Engine Oil Type:

SAE 10W-40 or 15W-50, API SG or higher, JASO MA compatible.

Engine Oil Capacity:

Approx. 2.2 - 2.5 liters (with filter change).

Coolant Type:

Ethylene glycol-based coolant (e.g., Motul Motocool Expert, Castrol Radicool)

Coolant Capacity:

Approx. 1.2 - 1.5 liters.

Brake Fluid Type:

DOT 4

Transmission Oil Type:

SAE 75W-90 or 80W-90 GL-5 gear oil.

Transmission Oil Capacity:

Approx. 0.7 - 0.8 liters.

Known Issues

Common Problems:

Stator failure (charging system), voltage regulator issues, starter solenoid problems, occasional fuel pump issues, chain wear if not maintained.

Maintenance Tips:

Regular cleaning of the cooling system fins and diligent chain maintenance are crucial for longevity.

📚 Vehicle History

Brand Heritage

Manufacturer:

Aprilia is an Italian manufacturer known for performance motorcycles and scooters.

Model Evolution

Development:

The Pegaso 650 was introduced in the early 1990s as a versatile dual-sport machine, evolving over the years with engine updates and chassis refinements. This 1997-2005 generation features the Rotax-derived 650cc single-cylinder engine.

Production

Manufacturing Location:

Italy

🏆 Awards & Recognition

Recognitions

Awards:

The Pegaso 650 was generally well-regarded for its versatility and value, often praised by motorcycle journalists for its comfort and off-road capability within its class.