Segment:
Dual-sport / Adventure Motorcycle
Target Audience:
Owners and independent mechanics seeking to perform maintenance, repairs, and diagnostics on the Aprilia Pegaso 650.
Competitors:
BMW F650GS, Honda Transalp, Kawasaki KLR650, Yamaha XT660R/X.
Value Proposition:
Provides comprehensive, factory-level repair and maintenance information essential for the longevity and performance of the Aprilia Pegaso 650.
Manual Years Covered:
1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005
Estimated Page Count:
400-600 (estimated, depending on specific print run and inclusion of supplements)
Manual Type:
Workshop Service Manual / Repair Manual
Language:
English (most likely, common for international service manuals of this era)
Engine Systems:
Engine disassembly, assembly, tuning, lubrication, cooling system, fuel system (carburetor/injection depending on specific sub-model), ignition system, exhaust system, oil pressure checks.
Transmission Drivetrain:
Clutch operation and adjustment, gearbox disassembly and reassembly, final drive maintenance and inspection, chain and sprockets.
Chassis Suspension:
Front fork disassembly, service, and adjustment, rear shock absorber replacement and setup, swingarm maintenance, wheel bearing service, steering head bearing service.
Braking System:
Brake caliper service, master cylinder overhaul, brake line replacement, bleeding procedures, pad and disc inspection and replacement.
Electrical System:
Wiring diagrams, component testing (stator, regulator/rectifier, battery, starter motor, ignition coil), lighting system, instrument cluster troubleshooting, fuses and relays.
Bodywork Fittings:
Fairing removal and installation, seat maintenance, fuel tank removal and installation, minor body panel repairs, care and cleaning.
Maintenance Procedures:
Routine service checks, oil changes, filter replacements, spark plug replacement, chain lubrication and adjustment, brake fluid changes, coolant flushes, air filter cleaning/replacement.
Troubleshooting Guide:
Diagnostic charts for common running issues, electrical faults, starting problems, and performance complaints.
Repair Instructions:
Step-by-step instructions for major component overhauls and replacements, including engine rebuilds, suspension component servicing, and electrical system repairs.
Diagnostic Capabilities:
Detailed diagnostic procedures, specifications for testing components (e.g., stator output, compression tests), and identification of common failure modes.
Rebuild Information:
Comprehensive information for complete engine and transmission rebuilds, including torque specifications, clearance measurements, and assembly sequences.
File Type:
Portable Document Format (PDF)
Searchability:
Likely searchable text-based PDF, allowing for keyword searches.
Image Resolution:
High-resolution for clear diagrams and illustrations (typical for professional service manuals).
Binding Type:
Not applicable (Digital Download)
Paper Type:
Not applicable (Digital Download)
Engine Type:
Single-cylinder, four-stroke
Displacement:
652 cc (652cc)
Bore X Stroke:
100 mm x 83.6 mm (typical for Rotax 654 engine)
Cooling System:
Liquid-cooled
Valve Train:
SOHC, 4 valves per cylinder
Horsepower:
Approximately 48-50 HP (depending on market and specific sub-model)
Torque:
Approximately 58-60 Nm (depending on market and specific sub-model)
Fuel Delivery:
Carburetor (Mikuni BSR 40) for most models in this range; some later models may have had fuel injection (check specific sub-model). The manual will cover the prevalent system for the years listed.
Fuel Type:
Unleaded gasoline (95 RON recommended)
Fuel Tank Capacity:
Approx. 15-17 Liters (depending on sub-model and tank design)
Length:
Approx. 2180 mm (depending on sub-model)
Width:
Approx. 850 mm (depending on sub-model)
Height:
Approx. 1360 mm (depending on sub-model)
Dry Weight:
Approx. 175 kg (depending on sub-model)
Gross Vehicle Weight:
Approx. 375 kg (typical for motorcycles)
Front Wheel Size:
19-inch (typical for dual-sport)
Rear Wheel Size:
17-inch (typical for dual-sport)
Front Tire Size:
90/90-19 (typical)
Rear Tire Size:
130/80-17 (typical)
Bolt Pattern:
Not applicable (spoked wheels, single center hub)
Safety Certification:
CE, EPA (depending on market)
Braking System Front:
Hydraulic disc brake (single or dual disc depending on sub-model)
Braking System Rear:
Hydraulic disc brake
ABS Availability:
Optional on some later models, not standard across all years/variants.
Lighting:
Halogen headlamp, LED tail light (likely on later models), incandescent turn signals.
Instrument Cluster:
Analog speedometer, tachometer, odometer, trip meter, fuel gauge, warning lights for oil pressure, neutral, turn signals, high beam, and engine faults.
ABS:
Optional ABS on some models; manual will detail its operation and servicing if equipped.
Diagnostic Ports:
Standard diagnostic connector (likely an OBD-I or proprietary connector) for fault code reading and potentially basic parameter monitoring.
Oil Change Interval:
Every 5,000 - 7,500 km or annually (refer to manual for precise interval).
Valve Clearance Check:
Every 10,000 - 15,000 km (critical for single-cylinder engine health).
Spark Plug Replacement:
Every 10,000 - 15,000 km.
Air Filter Cleaning:
Every 5,000 km or as needed in dusty conditions.
Engine Oil Type:
SAE 10W-40 or 15W-50, API SG or higher, JASO MA (motorcycle specific oil)
Engine Oil Capacity:
Approx. 2.5 - 2.8 Liters (with filter change)
Coolant Type:
Ethylene glycol-based antifreeze coolant (50/50 mixture with distilled water)
Brake Fluid Type:
DOT 4 brake fluid
Common Wear Items:
Clutch plates, chain and sprockets, wheel bearings, fork seals, voltage regulator/rectifier (can be a weak point on many bikes of this era).
Engine Specific Notes:
Rotax single cylinder engines are generally robust, but proper maintenance of the cooling system and regular oil changes are crucial. Valve clearance adjustments are particularly important to maintain performance and prevent damage.
Manufacturer Origin:
Italy
Aprilia Legacy:
Aprilia has a strong history in motorcycle racing and sport-oriented street bikes, bringing a performance-oriented approach to their dual-sport offerings.
Pegaso Lineage:
The Pegaso nameplate has been used by Aprilia for various models, with the 650cc single-cylinder becoming a popular choice in the adventure touring segment.
Engine Source:
The 650cc engine used in the Pegaso 650 was largely based on the Rotax 654 engine, known for its robustness and reliability, also found in BMW's F650 models of the era.
Production Period:
The Aprilia Pegaso 650 was produced in various forms from the early 1990s through the mid-2000s, with this manual specifically covering the 1997-2005 generation.
