Aprilia Pegaso 650 1997-2005 Online Service Repair Manual

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Taper: Motorcycle

Distributeur:

UGS: 145357

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

Variantes de produits

Description

The Aprilia Pegaso 650, produced from 1997 to 2005, is a versatile dual-sport motorcycle engineered for riders seeking a capable machine for both on-road commuting and light off-road adventures. Known for its robust, liquid-cooled, single-cylinder 652cc engine, which shares heritage with BMW models, the Pegaso 650 offers a compelling blend of practicality and performance. Its design emphasizes versatility, making it a suitable choice for daily use, touring, and exploring varied terrain. The model's Italian manufacturing and focus on affordability positioned it as a competitive option within the middleweight adventure-touring segment. This comprehensive Service and Repair Manual in English provides detailed guidance for the maintenance and repair of the Aprilia Pegaso 650. It covers all essential systems, including engine mechanicals, fuel, ignition, cooling, exhaust, transmission, chassis, electrical components, and bodywork. The manual includes routine maintenance procedures, troubleshooting guides for common issues, major repair instructions, and detailed specifications and tolerances, with full-color wiring diagrams. This resource is invaluable for owners, mechanics, and technicians aiming to ensure the optimal performance, reliability, and longevity of their Pegaso 650.

🏷️ Basic Information

Identification

Make:

Aprilia

Model:

Pegaso 650

Generation

Model Years Covered:

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

Codes

Platform Code:

M1 (various sub-variants exist)

👋 Introduction

Market Position

Category:

Dual-sport / Adventure Touring Motorcycle

Target Audience:

Riders seeking a versatile motorcycle for commuting, touring, and light off-road use, with an emphasis on affordability and practicality.

Competitive Analysis

Key Competitors:

BMW F650GS, Honda Transalp, Kawasaki KLR650, Suzuki DR650SE.

Key Features

Versatility:

Designed for a blend of on-road comfort and off-road capability.

Engine Durability:

Shares its engine with popular BMW models, known for reliability.

Affordability:

Positioned as a more budget-friendly alternative to some European competitors.

📋 Manual Details

Coverage Areas

Manual Type:

Service and Repair Manual

Language:

English

Format:

Online / Digital (likely PDF)

Page Count

Estimated Page Count:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete disassembly, inspection, repair, and reassembly of engine components including cylinder head, pistons, connecting rods, crankshaft, valves, camshafts, timing system.

Fuel System:

Carburetor (Mikuni BSR 32) overhaul, adjustment, jetting, fuel pump, fuel lines, fuel tank.

Ignition System:

Spark plugs, ignition coils, CDI unit, wiring diagrams, timing adjustments.

Cooling System:

Radiator, coolant hoses, thermostat, water pump, fan operation, coolant specifications.

Exhaust System:

Exhaust manifold, muffler, lambda sensor (if applicable), gasket replacement.

Transmission And Drivetrain:

Clutch operation, gear selection mechanism, chain drive maintenance, sprocket replacement, gearbox disassembly and assembly.

Chassis And Frame:

Frame inspection, steering head bearings, swingarm bearings, rear shock absorber, front forks (disassembly, service, seals, oil).

Wheels And Tires:

Wheel bearing maintenance, tire inspection, recommended tire pressures, wheel balancing.

Brakes:

Front and rear brake caliper overhaul, brake pad replacement, brake fluid bleeding and replacement, master cylinders, brake lines.

Electrical System:

Battery, alternator, starter motor, lighting system, horn, fuses, relays, wiring diagrams for all circuits.

Instrumentation And Controls:

Speedometer, tachometer, dashboard indicators, control levers, throttle, clutch cables.

Bodywork And Trim:

Fairing removal and installation, seat, fuel tank mounting, fenders, plastic components.

Procedures Included

Routine Maintenance:

Oil changes, filter replacement, air filter cleaning/replacement, chain lubrication and adjustment, spark plug checks, brake fluid checks, coolant level checks.

Troubleshooting:

Diagnostic procedures for common performance issues, starting problems, electrical faults, and operational anomalies, with symptom-based troubleshooting guides.

Major Repairs:

Detailed step-by-step instructions for engine rebuilds, transmission overhauls, suspension component replacement, and electrical system repairs.

Component Disassembly Reassembly:

Comprehensive guidance on taking apart and putting back together all major motorcycle systems and components.

Specifications And Tolerances:

Precise torque values, clearances, fluid capacities, and wear limits for all critical parts.

Technical Depth

Depth Of Coverage:

Comprehensive, covering everything from basic owner maintenance to full workshop-level rebuilds and diagnostics.

Diagnostic Procedures:

Detailed diagnostic trees and methods for identifying root causes of malfunctions.

Wiring Diagrams:

Full-color, detailed electrical wiring diagrams for all model years and configurations.

📊 Manual Specifications

File Format

File Type:

Digital (PDF)

Searchability:

Likely searchable text, allowing for quick navigation and information retrieval.

Print Quality

Print Recommendation:

Optimized for digital viewing, but printable for workshop use. Print quality depends on user's printer.

Binding Type

Binding Format:

N/A (Digital Product)

Paper Type

Paper Quality:

N/A (Digital Product)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, single-cylinder, liquid-cooled, DOHC

Displacement:

652 cc (652 cm³)

Bore X Stroke:

100 mm x 83 mm

Compression Ratio:

10.0:1

Performance

Horsepower Approx:

48 hp (36 kW) at 6500 rpm (Note: specific output can vary slightly by year/market)

Torque Approx:

57 Nm (42 lb-ft) at 5000 rpm (Note: specific output can vary slightly by year/market)

Fuel System

Carburetor Type:

Mikuni BSR 32 (flat-slide, constant velocity)

Fuel Type:

Unleaded gasoline

Fuel Capacity:

14 liters (approx. 3.7 US gallons)

🔧 Transmission

Standard

Transmission Type:

5-speed manual

Clutch Type:

Wet multi-plate clutch

Optional

Optional Transmission:

Features

Final Drive:

Chain drive

📐 Dimensions

Exterior

Length:

Approx. 2160 mm (85 in)

Width:

Approx. 830 mm (32.7 in) (excluding mirrors)

Height:

Approx. 1360 mm (53.5 in) (to windscreen)

Wheelbase:

Approx. 1465 mm (57.7 in)

Ground Clearance:

Approx. 220 mm (8.7 in)

Weights

Dry Weight:

Approx. 170 kg (375 lbs)

Wet Weight:

Approx. 185 kg (408 lbs) (fully fueled)

Max Load:

Approx. 190 kg (419 lbs) (rider + luggage)

Cargo

Cargo Capacity:

N/A (designed for aftermarket luggage systems)

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (Motorcycle safety ratings are typically not directly comparable to automotive standards)

Active Features

Braking System:

Hydraulic disc brakes front and rear. ABS was an optional feature on some later models or specific markets.

ABS Availability:

Optional on select versions

Passive Features

Lighting:

Halogen headlamp, LED tail lamp, turn signals.

💡 Technology Features

Infotainment

Dashboard Features:

Analog speedometer, analog tachometer, fuel gauge, odometer, trip meter, indicator lights (neutral, oil pressure, turn signals, high beam).

Driver Assistance

Optional on some models/markets

Connectivity

Connectivity Features:

N/A (No modern smart device integration or Bluetooth)

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 km or 6 months (whichever comes first)

Oil Filter Replacement:

At every oil change

Air Filter Cleaning:

Every 5,000 km; replacement as needed

Spark Plug Replacement:

Every 10,000 km (NGK CR9EKB or equivalent recommended)

Chain Lubrication:

Every 500 km and after washing/rain

Chain Adjustment:

Every 5,000 km or as needed to maintain specified slack

Fluid Specifications

Engine Oil Type:

SAE 10W-40, API SG or higher, JASO MA certified motorcycle oil

Engine Oil Capacity:

Approx. 2.3 liters (2.4 US qt) with filter change

Coolant Type:

Ethylene glycol-based antifreeze, 50/50 mix with distilled water

Brake Fluid Type:

DOT 4

Fork Oil Type:

SAE 10W (Specific brand/model may vary, consult manual for exact specification)

Fork Oil Quantity:

Approx. 460 ml per fork leg (Check manual for precise quantity)

Known Issues

Common Wear Items:

Clutch plates, brake pads, chain and sprockets, steering head bearings, fork seals, voltage regulator.

Potential Electrical Issues:

Voltage regulator failure, stator winding issues, wiring harness wear.

Carburetor Tuning:

Mikuni BSR 32 can be sensitive to altitude and temperature changes, requiring periodic adjustment or re-jetting.

Suspension Performance:

While capable, stock suspension can be firm for some riders and may benefit from aftermarket upgrades for extended touring or aggressive riding.

📚 Vehicle History

Brand Heritage

Manufacturer:

Aprilia is an Italian motorcycle manufacturer known for its sporting heritage and innovative designs.

Model Evolution

Development:

The Pegaso 650 was Aprilia's entry into the popular middleweight adventure-touring segment, leveraging the robust Rotax single-cylinder engine platform co-developed with BMW.

Key Updates:

Minor updates across the production run included styling refinements, suspension improvements, and occasional component upgrades. Early models often featured a different headlight design and instrument cluster compared to later ones.

Production

Manufacturing Location:

Italy

Production Period:

Mid-1990s to mid-2000s, with this specific manual covering the 1997-2005 era which represents a significant evolution of the model.

🏆 Awards & Recognition

Recognitions

Motorcycle Reviews:

Generally well-received for its blend of performance, versatility, and value, often praised for its engine character and road manners.

Ratings

Reliability Perception:

Considered reliable, especially due to the BMW-derived engine, but like any motorcycle of this age, requires diligent maintenance.

Certifications

Emissions Compliance:

Compliant with prevailing emissions standards of its era; manual will detail procedures for maintaining compliance.