The Aprilia Pegaso 650 Factory, a 2005 model, is a versatile dual-sport adventure motorcycle renowned for its blend of on-road comfort and off-road capability. Powered by a torquey Rotax 654 series single-cylinder engine, this Italian-engineered machine offers a reliable platform for both touring and daily commuting. Its design philosophy emphasizes a balance between practicality and performance, making it a competitive choice within its segment, competing with models from BMW, Kawasaki, Suzuki, and Yamaha. The 'Factory' designation indicates a premium version, often featuring enhanced components and performance characteristics.
This comprehensive service repair manual, provided in English, covers all essential aspects of maintaining and repairing the Aprilia Pegaso 650 Factory. It details repair and service procedures, routine maintenance, troubleshooting, and diagnostics for the engine, cycle parts, and electrical systems. Within its extensive coverage, you will find information on engine overhaul, suspension systems, braking, fuel, ignition, and lubrication, along with specific maintenance tasks like oil changes, filter replacements, and valve adjustments. The manual is designed to assist DIY owners, independent repair shops, and professional technicians in ensuring the optimal performance and longevity of their motorcycle.
Model:
Pegaso 650 Factory
Vehicle Type:
Dual-sport / Adventure
Engine Code Series:
Rotax 654
Segment:
Adventure / Dual-Sport Motorcycle
Target Audience:
DIY owners, independent repair shops, professional technicians.
Competitors 2005:
BMW F650GS, Kawasaki KLR650, Suzuki DR650SE, Yamaha XT660R/X.
Engine Basis:
Torquey Rotax single-cylinder engine, known for reliability and versatility.
Design Philosophy:
Blend of on-road comfort and off-road capability, suitable for touring and commuting.
Value Proposition:
Authoritative, factory-level repair information for all aspects of the motorcycle.
Accessibility:
Instant digital download, accessible on multiple operating systems.
Primary Coverage:
Repair and Service Procedures
Secondary Coverage:
Maintenance, Troubleshooting, Diagnostics
Estimated Page Count:
Refer to dealer specific documentation for exact count, typically 300-500 pages for a complete factory manual.
Type:
Factory Service Repair Manual
Engine:
Complete engine overhaul, disassembly, assembly, tuning, lubrication, cooling system, fuel system, ignition system.
Cycle Parts:
Frame, suspension (front and rear forks, shock absorber), steering system, wheels, tires, brakes (hydraulic discs front and rear), clutch.
Electrical System:
Wiring diagrams, charging system (alternator, regulator/rectifier), starting system (starter motor, battery), lighting, ignition system components, instrumentation.
Maintenance:
Routine checks, oil changes, filter replacements, chain maintenance, brake pad inspection/replacement, valve clearance adjustment, spark plug replacement.
Repair:
Engine rebuild, transmission service, suspension overhaul, brake caliper rebuild, electrical component replacement, bodywork repair.
Troubleshooting:
Diagnosis of common problems, fault finding procedures based on symptoms, electrical troubleshooting charts.
Depth:
Comprehensive, covering basic maintenance to complete engine and chassis rebuilds. Includes detailed diagrams and specifications.
Compression Format:
ZIP (requiring unzipper like WinRAR)
Quality:
Digital (Represents factory documentation quality)
Binding:
N/A (Digital Download)
Paper Type:
N/A (Digital Download)
Engine Type:
Four-stroke, single-cylinder, DOHC, 4 valves
Displacement:
652 cc (39.8 cu in)
Bore X Stroke:
100 mm x 83 mm (3.94 in x 3.27 in)
Compression Ratio:
10.0:1
Horsepower:
Approx. 48 hp (36 kW) @ 6,250 rpm (varies by market/tuning)
Torque:
Approx. 60 Nm (44.3 lb-ft) @ 5,250 rpm (varies by market/tuning)
Fuel Delivery:
Electronic Fuel Injection (EFI) - Specific system details in manual.
Fuel Type:
Unleaded gasoline, minimum 91 octane (RON+MON)/2)
Oil Type:
Semi-synthetic or fully synthetic motorcycle oil, API SG or higher, JASO MA certified. Specific viscosity (e.g., 10W-40 or 15W-50) to be confirmed in manual.
Oil Capacity:
Approx. 2.2 - 2.4 liters (with filter change) - Exact capacity in manual.
Cooling Method:
Liquid-cooled
Coolant Type:
Ethylene glycol-based antifreeze/coolant mixture (e.g., 50/50 water/coolant). Specific part number or type to be confirmed in manual.
Transmission Type:
5-speed sequential manual
Clutch Type:
Wet, multi-plate, hydraulically operated
Final Drive:
O-ring sealed chain drive
Transmission Oil:
Not typically required as transmission shares engine oil. Refer to manual for specific notes.
Length:
Approx. 2215 mm (87.2 in)
Width:
Approx. 850 mm (33.5 in)
Height:
Approx. 1415 mm (55.7 in)
Dry Weight:
Approx. 170 kg (375 lbs)
Wet Weight:
Approx. 186 kg (410 lbs) (fully fueled and ready to ride)
Fuel Capacity:
Approx. 14 liters (3.7 US gal)
Safety Standard:
Meets relevant motorcycle safety regulations for its production year.
Braking System Front:
Dual hydraulic disc brakes, twin-piston calipers. Specific disc diameter and pad type detailed in manual.
Braking System Rear:
Single hydraulic disc brake, single-piston caliper. Specific disc diameter and pad type detailed in manual.
ABS:
Optional ABS system available on some models/markets. Confirmation required.
Lighting:
Halogen headlight, LED taillight, turn signals. Electrical system details in manual.
Instrumentation:
Analog tachometer, digital speedometer, fuel gauge, odometer, trip meter, warning lights.
Infotainment System:
Basic motorcycle instrumentation focused on riding information, not advanced infotainment.
ABS Availability:
Optional on some 2005 models, a significant driver assistance feature if equipped.
Connectivity Features:
N/A (No Bluetooth or smartphone integration typical for this era)
Oil Change Interval:
Typically every 6,000-10,000 km (3,700-6,200 miles) or annually, whichever comes first. Refer to manual for precise interval.
Air Filter Cleaning:
Every 12,000 km (7,500 miles) or annually. Replacement as needed.
Valve Clearance Check:
Typically at 12,000 km (7,500 miles) or 24,000 km (15,000 miles) intervals. Consult manual for specific timing.
Spark Plug Replacement:
Intervals vary, typically 10,000-20,000 km (6,200-12,500 miles). Check manual for type and recommended interval.
Brake Fluid Type:
DOT 4 hydraulic brake fluid. Replacement every 2 years recommended.
Fork Oil Type:
Specific viscosity (e.g., SAE 5W or 7.5W) and quantity for front forks. Refer to manual for exact specifications.
Common Wear Items:
Clutch plates, chain and sprockets, wheel bearings, fork seals, regulator/rectifier.
Potential Electrical Concerns:
Regulator/rectifier failures and stator issues can occur over time, common in many bikes of this era. Wiring harness integrity checks are vital.
Engine Temperatures:
Proper functioning of the cooling system is crucial; overheating can lead to premature wear or damage. Manual provides troubleshooting for cooling issues.
Manufacturer:
Aprilia is an Italian manufacturer renowned for its sport motorcycles and scooters.
Pegaso Lineage:
The Pegaso line originated in the early 1990s, evolving from a 650cc single-cylinder platform known for its versatility and reliability.
Factory Edition:
The 'Factory' designation typically implies a higher-spec version with premium components, lighter weight, or improved performance features compared to standard models.
Manufacturing Location:
Primarily Italy.
Awards General:
Specific awards for the 2005 Aprilia Pegaso 650 Factory are not widely publicized in generic automotive databases. Aprilia as a brand has received accolades in racing and design.
