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APRILIA PEGASO 650 Workshop Repair Manual 1997-2004

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This manual covers the Pegaso 650, produced between 1997 and 2004. Known for its versatility, this dual-sport motorcycle is well-suited for commuting, touring, and light off-road adventures. An Italian manufacturer...
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APRILIA PEGASO 650 Workshop Repair Manual 1997-2004
This manual covers the Pegaso 650, produced between 1997 and 2004. Known for its versatility, this dual-sport motorcycle is well-suited for commuting, touring, and light off-road adventures. An Italian manufacturer with a strong racing heritage, engineered the Pegaso 650 to offer accessible ergonomics and capable handling. Its robust design and reliable performance made it a popular choice in the mid-weight dual-sport segment, competing with models from BMW, Kawasaki, Suzuki, and Yamaha. The motorcycle features a liquid-cooled, single-cylinder engine with a displacement of 652 cc, typically producing around 48 horsepower. This professional workshop manual provides comprehensive information for the maintenance, troubleshooting, diagnostics, and repair of the Pegaso 650. It details procedures for all major systems, including the engine, transmission, chassis, brakes, and electrical components. The manual covers routine maintenance tasks such as oil changes and valve adjustments, as well as in-depth repair instructions for engine rebuilds and electrical system diagnostics. With over 500 pages of dealer-level information, this English-language, text-searchable resource is an essential tool for owners, mechanics, and technicians aiming to maintain the peak performance and longevity of their Pegaso 650.
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
Pegaso 650
Year Range:
1997-2004
👋 Introduction
Market Position
Category:
Dual-Sport/Adventure Motorcycle
Target User:
Enthusiasts, DIY Mechanics, Professional Workshops
Competitive Analysis
Key Competitors:
BMW F650GS, Kawasaki KLR650, Suzuki DR650SE, Yamaha XT660R
Key Features
Manual Value:
Authentic dealer-level information, essential for maintaining peak performance and longevity
Vehicle Appeal:
Versatile for commuting, touring, and light off-road use
📋 Manual Details
Coverage Areas
Primary Coverage:
Workshop Service and Repair
Secondary Coverage:
Maintenance, Troubleshooting, Diagnostics, Overhaul
Page Count
Estimated Pages:
500+
Manual Type
Type:
Professional Workshop Manual
Language
Language:
English
Format
Format:
Downloadable PDF
📖 Manual Coverage
Systems Covered
Engine:
Complete Engine Assembly, Carburetor/Injection Systems, Ignition, Lubrication, Cooling
Transmission:
Clutch, Gearbox, Final Drive, Oil Specifications
Chassis:
Frame, Suspension (Front/Rear), Steering, Swingarm
Brakes:
Hydraulic System, Caliper Overhaul, Pad Replacement, Fluid Types, Troubleshooting
Electrical:
Wiring Diagrams, Lighting, Starting System, Charging System, Ignition System Components, Sensor Testing
Fuel System:
Fuel Tank, Fuel Pump, Carburetor/Injection System Service, Fuel Filter Replacement
Exhaust System:
Muffler, Exhaust Pipes, Heat Shields
Bodywork:
Fairings, Seat, Fuel Tank Cover, Fenders, Body Panel Removal/Installation
Procedures Included
Maintenance:
Oil Changes, Filter Replacements, Chain Adjustment, Spark Plug Service, Air Filter Cleaning/Replacement, Valve Clearance Checks
Troubleshooting:
Diagnostic Flowcharts, Symptom-Based Problem Identification, Common Faults and Solutions
Repair:
Engine Rebuilds, Transmission Overhauls, Suspension Component Replacement, Brake System Repairs, Electrical Component Diagnosis and Replacement
Assembly Disassembly:
Detailed step-by-step instructions with diagrams for all major components
Technical Depth
Depth:
Comprehensive, from basic maintenance to complete engine and transmission rebuilds
📊 Manual Specifications
File Format
Type:
PDF
Searchability:
Text-searchable
Print Quality
Quality:
High-resolution, clear diagrams and text
Binding Type
Type:
N/A (Digital Download)
Paper Type
Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Type:
Four-stroke, single-cylinder, DOHC
Displacement:
652 cc (39.8 cu in)
Bore X Stroke:
100 mm x 83 mm (3.94 x 3.27 in)
Compression Ratio:
10.0:1
Cooling System:
Liquid-cooled
Performance
Horsepower Approx:
48 hp (36 kW) @ 7000 rpm
Torque Approx:
57 Nm (42 lb-ft) @ 5500 rpm
Fuel System
Carburetor Models:
Mikuni BSR36 (specific model may vary by market)
Fuel Injection Models:
Optional on later models or specific variants (check manual for exact details)
Fuel Type:
Unleaded gasoline, 91-98 octane
Lubrication
Oil Type Spec:
API SG/SH/SJ or JASO MA certified 10W-40 or 15W-50 (refer to manual for precise specification based on climate)
🔧 Transmission
Standard
Type:
5-speed manual
Clutch:
Wet multi-plate, cable operated
Final Drive:
O-ring sealed chain, 16/47 gearing (typical)
Features
Gearbox Oil Spec:
API GL-4 or GL-5 SAE 80W-90 (verify in manual for exact type and quantity)
📐 Dimensions
Exterior
Length:
Approx. 2220 mm (87.4 in)
Width:
Approx. 860 mm (33.9 in)
Height:
Approx. 1260 mm (49.6 in)
Wheelbase:
Approx. 1470 mm (57.9 in)
Weights
Dry Weight:
Approx. 168 kg (370 lbs)
Wet Weight Approx:
Approx. 184 kg (405 lbs)
Capacities
Fuel Tank Capacity:
13 Liters (3.4 US gal)
Engine Oil Capacity:
Approx. 2.3 Liters (2.4 US qt) with filter change
🛡️ Safety Features
Ratings
NHTSA Rating:
Not Applicable (Motorcycle)
Active Features
Braking System:
Disc Brakes Front and Rear, Optional ABS on some models (verify specific bike)
Tire Sizes:
Front: 90/90-21, Rear: 130/80-17 (typical, verify for specific model year)
Passive Features
Lighting:
Halogen Headlight, LED Taillight (later models), Turn Signals
💡 Technology Features
Infotainment
Dashboard:
Analog speedometer, tachometer, odometer, trip meter, coolant temperature gauge, warning lights.
Driver Assistance
ABS:
Optional Anti-lock Braking System available on select models.
Connectivity
Bluetooth:
Not factory equipped.
🔧 Maintenance
Service Intervals
Oil Change:
Every 3,000 - 6,000 km (2,000 - 4,000 miles) or annually, whichever comes first (refer to manual for exact recommendation)
Air Filter Cleaning:
Every 6,000 km (4,000 miles)
Valve Clearance Check:
Every 12,000 km (7,500 miles)
Spark Plug Replacement:
Every 12,000 km (7,500 miles)
Fluid Specifications
Coolant Type:
Ethylene glycol based antifreeze/coolant, 50/50 mix with distilled water
Brake Fluid:
DOT 4 (verify in manual)
Known Issues
Charging System:
Stator or rectifier failures can occur with age and mileage.
Carburetor:
Older models with carburetors may require periodic cleaning and adjustment for optimal performance.
Rear Shock:
Original rear shock absorbers may degrade over time, affecting ride quality.
Electrical Connectors:
Corrosion in electrical connectors can lead to intermittent faults.
📚 Vehicle History
Brand Heritage
Manufacturer:
Aprilia, Italian motorcycle manufacturer known for performance and racing heritage
Model Evolution
Generation Notes:
The Pegaso 650 was Aprilia's entry into the mid-weight dual-sport segment, popular for its accessible ergonomics and versatility.
Key Changes 1997-2004:
Included carburetor and fuel-injected versions, slight styling updates, and potential suspension component revisions over the years. The Rotax engine was a common powerplant for this era.
Production
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Market Reputation:
Praised for its versatility and comfort for its class during its production run.
Ratings
Typical User Reviews:
Users often highlight its comfortable riding position for longer distances and its capable handling on varied terrain.
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