Aprilia Pegaso 650 2004 Service Repair Manual

Precio habitual: $16.99
Precio de venta: $16.99
Precio habitual
Precio unitario: por

This manual covers the Aprilia Pegaso 650 motorcycle, produced in 2004. Designed as a versatile adventure touring and dual-sport machine, the Pegaso 650 offers a blend of off-road capability and...

18 people are viewing this right now

Tipo: Motorcycle

Proveedor:

SKU: 148784

Etiquetas: 2004 Aprilia Misc Motorcycle Motorcycles Pegaso 650

Variantes de producto

Descripción

This manual covers the Aprilia Pegaso 650 motorcycle, produced in 2004. Designed as a versatile adventure touring and dual-sport machine, the Pegaso 650 offers a blend of off-road capability and on-road comfort. It is powered by a liquid-cooled, four-stroke, single-cylinder engine, featuring long-travel suspension for tackling varied terrain. Known for its robust and practical design, the Pegaso 650 has been recognized for its versatility and affordability within its market segment, making it a capable all-rounder for riders. This comprehensive Service Repair Manual is designed for professional technicians and advanced DIY users, providing detailed information for the maintenance and repair of the 2004 Aprilia Pegaso 650. The manual covers all essential systems, including the engine, fuel system, transmission, brakes, suspension, and electrical components. It offers step-by-step repair instructions, diagnostic procedures, scheduled maintenance guidelines, and precise technical specifications, including torque values. This resource is intended to assist owners and mechanics in effectively maintaining, troubleshooting, and repairing the motorcycle to ensure optimal performance and longevity.

🏷️ Basic Information

Identification

Make:

Aprilia

Model:

Pegaso 650

Year:

Type:

Motorcycle

Category:

Adventure Touring / Dual-Sport

👋 Introduction

Market Position

Segment:

Versatile middleweight adventure touring motorcycle, known for its off-road capability and urban usability.

Competitive Analysis

Key Competitors 2004:

BMW F650GS, Kawasaki KLR650, Honda Transalp.

Key Features

Engine Type:

Liquid-cooled, four-stroke, single-cylinder.

Suspension Type:

Long-travel telescopic front forks and monoshock rear suspension.

Design Philosophy:

Robust and practical, offering comfort for longer journeys and agility for varied terrain.

📋 Manual Details

Coverage Areas

Primary Coverage:

Service and Repair

Scope:

Comprehensive for professional technicians and advanced DIY users

Page Count

Estimated Pages:

Manual Type

Type:

Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Detailed overhaul, diagnosis, and tuning of the Rotax 654cc single-cylinder engine.

Fuel System:

Carburetor (Mikuni BSR42) or Fuel Injection system servicing, adjustment, and troubleshooting.

Ignition System:

Spark plug inspection, coil replacement, timing adjustments.

Cooling System:

Radiator, coolant, fan, thermostat, and associated plumbing.

Exhaust System:

Inspection, repair, and replacement of exhaust components.

Transmission:

Clutch operation, gearbox disassembly/assembly, gear selection mechanism.

Drivetrain:

Chain and sprockets maintenance, inspection, and replacement.

Suspension Front:

Fork servicing, oil changes, seal replacement, spring inspection.

Suspension Rear:

Monoshock unit inspection, linkage lubrication, adjustment procedures.

Brakes Front:

Disc, caliper, master cylinder, brake lines, fluid replacement, bleeding.

Brakes Rear:

Disc, caliper, master cylinder, brake lines, fluid replacement, bleeding.

Wheels Tires:

Rim inspection, bearing maintenance, tire changing, balancing.

Electrical System:

Battery, charging system (alternator, regulator/rectifier), starter motor, lighting, wiring diagrams.

Instrumentation:

Speedometer, tachometer, warning lights, diagnostics.

Frame Chassis:

Frame inspection, steering head bearing service, swingarm maintenance.

Bodywork:

Fairing removal/installation, seat, fuel tank, paneling.

Procedures Included

Maintenance:

Scheduled maintenance checks, oil changes, filter replacements, chain adjustment.

Troubleshooting:

Systematic diagnostic procedures for common and uncommon faults.

Repair:

Step-by-step instructions for component disassembly, repair, and reassembly.

Adjustment:

Carburetor synchronization, throttle cable slack, clutch lever play.

Diagnostics:

Fault finding using symptom-based analysis and diagnostic flowcharts.

Torque Specifications:

Precise torque values for critical fasteners across all systems.

Technical Depth

Depth:

Full mechanical and electrical overhaul, including engine rebuilds and electrical system diagnostics.

Target Audience:

Professional motorcycle technicians and experienced home mechanics.

📊 Manual Specifications

File Format

Format:

Searchability:

Searchable text for quick information retrieval.

Print Quality

Quality:

High-resolution for clear diagrams and text.

Binding Type

Type:

N/A (Digital Download)

Paper Type

Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code:

Rotax 654cc (often referred to by its designer)

Engine Displacement:

652 cc

Bore X Stroke:

100 mm x 83 mm

Compression Ratio:

10.0:1

Valve Train:

SOHC, 4 valves per cylinder

Performance

Horsepower:

Approx. 48 hp @ 6,500 rpm

Torque:

Approx. 57 Nm (42 lb-ft) @ 5,000 rpm

Fuel System

Fuel Delivery:

Carburetor (Mikuni BSR42) or Electronic Fuel Injection (depending on specific market variant)

Fuel Type:

Unleaded Gasoline (91 RON or higher recommended)

Lubrication

Oil Type:

API SG or higher, JASO MA certified motorcycle oil

Oil Viscosity:

10W-40 or 15W-50 (depending on ambient temperature)

Oil Capacity W Filter:

Approx. 2.5 Liters (2.6 US qt)

🔧 Transmission

Standard

Type:

5-speed manual

Clutch Type:

Wet, multi-plate, cable-actuated

Features

Gear Ratios:

Specific ratios detailed within the manual.

Lubrication

Transmission Oil Type:

API GL-4 or GL-5 gear oil

Transmission Oil Capacity:

Approx. 0.7 Liters (0.7 US qt)

📐 Dimensions

Exterior

Length:

Approx. 2,200 mm (86.6 in)

Width:

Approx. 880 mm (34.6 in) (at handlebars)

Height:

Approx. 1,280 mm (50.4 in) (at seat)

Wheelbase:

Approx. 1,480 mm (58.3 in)

Ground Clearance:

Approx. 220 mm (8.7 in)

Weights

Dry Weight:

Approx. 174 kg (383.6 lbs)

Wet Weight:

Approx. 192 kg (423.3 lbs) (fully fueled)

Load Capacity:

Detailed in manual, typically around 180-200 kg (rider + luggage).

🛡️ Safety Features

Ratings

Crash Test Info:

N/A (Motorcycle - safety assessed through design and handling characteristics)

Active Features

Braking System:

Dual hydraulic disc brakes front, single hydraulic disc brake rear. ABS was an optional feature on some models.

Lighting:

Halogen headlight, LED taillight, standard turn signals.

Passive Features

Frame Construction:

Steel perimeter frame for rigidity and impact absorption.

💡 Technology Features

Infotainment

Type:

Basic motorcycle instrumentation. No advanced infotainment systems.

Driver Assistance

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

Connectivity

Type:

None (mechanical and analog systems).

🔧 Maintenance

Service Intervals

Oil Change:

Every 6,000 km (3,700 miles) or 12 months.

Air Filter Cleaning:

Every 6,000 km (3,700 miles).

Spark Plug Replacement:

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

Valve Clearance Check:

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

Chain Lubrication:

Every 500 km (300 miles) and after washing/rain.

Fluid Specifications

Coolant Type:

Ethylene glycol-based antifreeze/coolant mixture (50% water, 50% coolant).

Brake Fluid Type:

DOT 4 hydraulic brake fluid.

Known Issues

Electrical Connections:

Corrosion in connectors, particularly around the regulator/rectifier and stator wiring, can lead to charging issues.

Fuel Pump Reliability:

In earlier carbureted models, fuel pump diaphragm issues could occur. EFI models have a more robust system but can suffer from clogged injectors.

Suspension Seals:

Front fork seal leaks are not uncommon, especially with spirited riding or off-road use.

Cam Chain Tensioner:

Some models may benefit from an upgraded or manually adjustable cam chain tensioner to prevent rattling.

📚 Vehicle History

Brand Heritage

Manufacturer:

Aprilia is an Italian motorcycle manufacturer with a strong racing pedigree, founded in 1945.

Model Evolution

Pegaso Lineage:

The Pegaso line was introduced in the late 1980s, evolving through various engine sizes and configurations, with the 650cc single-cylinder becoming a staple.

2004 Update:

The 2004 model typically featured fuel injection in many markets, an updated chassis, and revised styling compared to earlier iterations.

Production

Manufacturing Location:

Primarily Italy.

🏆 Awards & Recognition

Recognitions

Industry Acclaim:

The Pegaso 650 was widely praised for its versatility and affordability in the adventure touring segment, making it a popular choice for riders seeking a capable all-rounder.