Vehicle Segment:
Adventure Sport Touring Motorcycle
Key Competitors:
BMW F650GS, Kawasaki KLR650, Suzuki V-Strom 650 (though later models are larger displacement), Honda Transalp.
Engine Configuration:
Single-cylinder, 4-stroke engine known for its torquey delivery and reliability.
Versatility:
Designed for a blend of on-road comfort and light off-road capability, making it a versatile choice.
Reliability:
Often praised for its robust and reliable mechanical components, particularly the Rotax engine.
Dealer Level Information:
This manual provides the same in-depth technical information used by authorized Aprilia service technicians.
Completeness:
Comprehensive A-Z coverage ensures that virtually any maintenance, repair, or diagnostic procedure can be performed by the user.
Engine Mechanical:
Complete overhaul, diagnostics, tuning, component testing, torque specifications, valve clearances, timing procedures, piston/cylinder inspection, crankshaft/connecting rod assembly.
Engine Fuel System:
Fuel injection system (EFI), injectors, throttle body, fuel pump, fuel pressure regulator, fuel filter replacement, troubleshooting fuel delivery issues.
Ignition System:
Ignition coils, spark plugs, ECU control, timing adjustments, troubleshooting ignition faults.
Cooling System:
Radiator, coolant pump, thermostat, hoses, fan operation, coolant flushing and filling procedures, troubleshooting overheating.
Exhaust System:
Exhaust manifold, catalytic converter, muffler replacement, gasket specifications, leak testing.
Transmission And Clutch:
Clutch operation, hydraulic system, clutch plate replacement, gearbox disassembly/reassembly, gear selection mechanism, transmission fluid specifications and change intervals.
Brakes:
Brake caliper servicing, hydraulic system bleeding, brake pad and disc replacement, master cylinder inspection, ABS system diagnostics (if equipped).
Suspension And Steering:
Front fork servicing (oil levels, seals, spring rates), rear shock absorber adjustment/replacement, steering head bearing maintenance, wheel bearing servicing, swingarm pivot.
Electrical System:
Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), starter motor, lighting circuits, instrument panel functions, fuse/relay identification and testing, fault finding.
Chassis And Frame:
Frame inspection, headstock, swingarm, footpeg mounts, general chassis component checks.
Bodywork And Fairings:
Panel removal and installation, seat removal, tank removal, fairing component replacement, graphics application.
Routine Maintenance:
Oil changes, filter replacements, chain adjustment and lubrication, tire pressure checks, brake fluid checks, coolant checks, spark plug replacement, air filter service.
Troubleshooting Diagnostics:
Step-by-step diagnostic procedures for common and complex issues across all major systems, symptom-based troubleshooting guides.
Major Repairs:
Engine rebuilds, transmission overhauls, suspension component replacement, electrical system diagnostics and repair, fuel system servicing.
Assembly Disassembly:
Detailed instructions for the removal and installation of all major components and sub-assemblies.
Diagnostic Tools Required:
Information on necessary diagnostic tools, including specialized tools for Aprilia models. May reference diagnostic software if applicable.
Service Bulletins Recalls:
Likely includes references or summaries of relevant manufacturer service bulletins and recall information applicable to the model years covered.
Torque Specifications:
Comprehensive list of all critical torque specifications for fasteners and assembly points.
Wiring Diagrams:
Detailed and clear electrical wiring schematics for all systems.
Schematics And Illustrations:
Exploded views, detailed illustrations, and schematics for component identification and assembly guidance.
Engine Type:
Single-cylinder, 4-stroke
Displacement:
652cc (approximately)
Bore X Stroke:
100 mm x 83 mm (typical for this engine)
Engine Manufacturer:
Rotax
Cooling System:
Liquid-cooled
Valvetrain:
DOHC, 4 valves per cylinder
Horsepower:
Approx. 45-48 HP @ 6200-6800 RPM (depending on specific model variant and market) - Exact figures will be in the manual.
Torque:
Approx. 57-60 Nm @ 4500-5000 RPM (depending on specific model variant and market) - Exact figures will be in the manual.
Fuel Delivery:
Electronic Fuel Injection (EFI) - Typically Bosch or similar system.
Fuel Type:
Unleaded gasoline (95 RON recommended)
Fuel Tank Capacity:
Approx. 14-16 Liters (depending on variant, e.g., ES, ST, Factory)
Oil Change Interval:
Typically every 6,000 - 10,000 km or annually, as specified in the manual.
Valve Clearance Check:
Typically at 12,000 - 24,000 km intervals, depending on usage. Specific procedures and clearances are in the manual.
Spark Plug Replacement:
Recommended at 12,000 - 24,000 km intervals. Manual will specify plug type and gap.
Engine Oil Type:
Semi-synthetic or fully synthetic motorcycle oil, SAE 10W-40 or 15W-50 (refer to manual for exact specification and API rating).
Engine Oil Capacity:
Approx. 2.0 - 2.4 Liters (with filter change) - Refer to manual.
Coolant Type:
Ethylene glycol-based antifreeze mixture (50% water/50% coolant) for -37°C protection. Refer to manual for specific type.
Brake Fluid Type:
DOT 4 or DOT 5.1, depending on ABS system presence and manufacturer recommendation. Refer to manual.
Common Wear Items:
Clutch plates, chain and sprockets, wheel bearings, steering head bearings, fork seals are common wear items, detailed replacement procedures are in the manual.
Electrical Gremlins:
As with many European bikes of this era, electrical connectors and grounds can be a source of intermittent issues. The manual's comprehensive wiring diagrams are crucial for diagnosis.
Fuel Pump Reliability:
Early fuel pump designs could be a point of failure; manual covers diagnosis and replacement.
