Aprilia Pegaso 650 1997-2005 Workshop Service Repair Manual

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Typ: Motorcycle

Anbieter:

Art.-Nr: 154264

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

Produktvarianten

Beschreibung

The Aprilia Pegaso 650 is a versatile dual-sport motorcycle, produced between 1997 and 2005, designed to excel in both urban commuting and light off-road adventures. Sharing its robust single-cylinder Rotax engine with contemporary BMW models, the Pegaso 650 features a steel tubular frame and long-travel suspension, making it adept at handling diverse terrains. Its engineering emphasizes reliability and practical performance, positioning it as a capable and enduring option within its segment, comparable to models like the BMW F650 and Yamaha XT series. This comprehensive workshop service repair manual provides in-depth guidance for the Aprilia Pegaso 650, covering the model years 1997 through 2005. It details essential maintenance procedures, troubleshooting techniques, and complete overhaul instructions for all major systems, including the engine, fuel, ignition, cooling, transmission, suspension, brakes, and electrical systems. With over 300 pages of searchable and printable English content, this manual is an indispensable resource for owners, mechanics, and technicians seeking to maintain, diagnose, and repair their Pegaso 650 with precision and efficiency.

🏷️ Basic Information

Identification

Make:

Aprilia

Model:

Pegaso 650

Product Name:

Aprilia Pegaso 650 1997-2005 Workshop Service Repair Manual

Codes

Vehicle Code:

Pegaso 650

👋 Introduction

Market Position

Segment:

Dual-sport / Adventure motorcycle

Competitive Analysis

Competitors:

BMW F650, Honda Transalp, Yamaha XT600/XT660

Key Features

Versatility:

Designed for both on-road commuting and light off-road excursions.

Engine Type:

Single-cylinder Rotax engine (shared with BMW F650 models of the era).

Frame:

Steel tubular frame for robustness.

Suspension:

Long-travel suspension for accommodating varied terrain.

📋 Manual Details

Coverage Areas

Model Years Covered:

1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005

Page Count

Estimated Pages:

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine:

Comprehensive coverage of the Aprilia Pegaso 650's single-cylinder, liquid-cooled engine.

Fuel System:

Details on carburetor systems (likely Mikuni) including tuning, cleaning, and component replacement.

Ignition System:

Information on the electronic ignition system, spark plug specifications, and troubleshooting.

Cooling System:

Radiator, fan, thermostat, coolant types, and procedures for flushing and refilling.

Transmission:

Coverage of the gearbox, clutch operation, lubrication, and internal components.

Suspension:

Front fork (likely Marzocchi or Paioli) and rear shock absorber (likely Sachs or similar) service, adjustments, and rebuilds.

Brakes:

Front and rear brake systems, including caliper service, pad replacement, fluid changes, and bleeding procedures.

Electrical System:

Wiring diagrams, battery maintenance, lighting, starter motor, charging system, and fuse box.

Chassis And Frame:

Frame inspection, component mounting, and alignment.

Wheels And Tires:

Tire pressure recommendations, wheel bearing service, and spoke tensioning.

Bodywork And Plastics:

Fairing removal and installation, seat, and other external panels.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain lubrication and adjustment, air filter service, spark plug replacement.

Troubleshooting:

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

Engine Overhaul:

Detailed steps for engine disassembly, inspection, component replacement (pistons, rings, valves), and reassembly.

Carburetor Rebuild:

Step-by-step instructions for carburetor disassembly, cleaning, jetting, and reassembly.

Suspension Service:

Fork seal replacement, oil level checks and changes, shock absorber adjustment.

Brake System Maintenance:

Brake pad replacement, fluid flushing and bleeding, caliper seal replacement.

Electrical Component Testing:

Testing of stator, regulator/rectifier, and ignition coil.

Wheel Bearing Replacement:

Proper procedure for removing and installing wheel bearings.

Chain And Sprocket Replacement:

Guidance on replacing drive chain and sprockets.

Technical Depth

Depth:

Comprehensive, covering everything from basic maintenance to complete engine and component overhauls.

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text content for quick information retrieval.

Print Quality

Printability:

Printable pages for physical workshop use.

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Quality:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Single-cylinder, four-stroke, liquid-cooled, DOHC

Displacement:

652 cc

Bore X Stroke:

100 mm x 83 mm

Performance

Horsepower:

Approx. 48 HP (36 kW) @ 6500 RPM (varies slightly by year/market)

Torque:

Approx. 57 Nm (42 lb-ft) @ 5200 RPM (varies slightly by year/market)

Fuel System

Carburetor:

Mikuni BSR42

Fuel Capacity:

14 liters (approx. 3.7 US gallons)

Lubrication

Oil Type:

API SG/SH/SJ, JASO MA, SAE 10W-40 or 15W-50 motorcycle oil

Spark Plug

Recommendation:

NGK CR8E or equivalent

🔧 Transmission

Standard

Transmission Type:

5-speed manual

Optional

Transmission Options:

N/A (Standard 5-speed)

Features

Clutch:

Wet, multi-plate clutch

Final Drive:

O-ring sealed chain drive

📐 Dimensions

Exterior

Length:

Approx. 2160 mm (85.0 in)

Width:

Approx. 840 mm (33.1 in)

Height:

Approx. 1300 mm (51.2 in)

Seat Height:

Approx. 870 mm (34.3 in)

Weights

Dry Weight:

Approx. 170 kg (375 lbs)

Wet Weight:

Approx. 192 kg (423 lbs)

Max Load Capacity:

Approx. 200 kg (440 lbs)

🛡️ Safety Features

Ratings

Crash Safety:

Motorcycle safety is primarily rider-dependent; no formal automotive crash ratings apply.

Active Features

Brakes:

Disc brakes front and rear. Optional ABS available on some models/markets.

Lighting:

Halogen headlight, LED tail light.

Passive Features

Frame Construction:

Steel perimeter frame designed for rigidity and rider protection.

Handguards:

Standard handguards to protect hands from elements and minor impacts.

💡 Technology Features

Infotainment

Display:

Analog speedometer and tachometer, with LCD display for odometer and trip meters.

Driver Assistance

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

Connectivity

Connectivity Features:

No modern digital connectivity features; focused on core mechanical and electrical systems.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 6,000 km (3,700 miles) or annually, whichever comes first.

Air Filter Service:

Every 6,000 km (3,700 miles) or more frequently in dusty conditions.

Spark Plug Replacement:

Every 12,000 km (7,500 miles).

Valve Clearance Check:

Every 12,000 km (7,500 miles).

Fluid Specifications

Coolant Type:

Ethylene glycol-based antifreeze coolant, 50% mixture with distilled water.

Brake Fluid Type:

DOT 4

Fork Oil Type:

SAE 10W (check manual for exact viscosity and quantity).

Transmission Oil Type:

EPX 80W-90 gear oil

Known Issues

Electrical Connectors:

Corrosion or loose connections in the wiring harness can cause intermittent electrical faults.

Regulator Rectifier:

Can be prone to failure, leading to charging system issues.

Carburetor Idle:

Carburetors may require periodic adjustment for stable idle, especially with age.

Suspension Leaks:

Front fork seals can degrade over time, leading to oil leaks.

📚 Vehicle History

Brand Heritage

Manufacturer:

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

Model Evolution

Introduction Year:

The Pegaso 650 was first introduced in the early 1990s, with this manual covering the significantly updated second generation.

Rotax Engine Link:

The Pegaso 650 shared its core Rotax engine with the popular BMW F650 Funduro, highlighting a strong collaborative development.

Production

Manufacturing Location:

Italy

🏆 Awards & Recognition

Recognitions

Awards:

While specific awards for the Pegaso 650 are not widely publicized, it was generally well-regarded for its value and versatility in the dual-sport segment.