2005 APRILIA PEGASO 650 Service Repair Manual

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The 2005 Aprilia Pegaso 650 is a versatile lightweight adventure touring and dual-sport motorcycle, designed to offer a blend of on-road comfort and off-road capability. It is powered by a...

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UGS: 131403

Mots clés: 2005 Aprilia Misc Motorcycle Motorcycles PEGASO 650

Variantes de produits

Description

The 2005 Aprilia Pegaso 650 is a versatile lightweight adventure touring and dual-sport motorcycle, designed to offer a blend of on-road comfort and off-road capability. It is powered by a proven single-cylinder engine, known for its torque and reliability, with a displacement of 652 cc. This Italian-manufactured machine, part of a lineage dating back to the early 1990s, was positioned to compete with models like the BMW F650GS and Kawasaki KLR650, offering a capable platform for commuting, light touring, and exploring varied terrain. Its design philosophy emphasizes practicality and adaptability, making it a suitable choice for riders seeking a dependable and enjoyable experience across different riding conditions. This comprehensive service and repair manual provides detailed guidance for the complete service and repair of the 2005 Aprilia Pegaso 650. It covers essential areas including engine overhaul, transmission maintenance, fuel system service, electrical system diagnostics, chassis and suspension repairs, brake system servicing, and bodywork procedures. The manual includes routine maintenance schedules, troubleshooting guides for common issues, and in-depth technical specifications. Its purpose is to empower owners, mechanics, and technicians with the knowledge required to maintain, diagnose, and repair the motorcycle effectively, ensuring its longevity and optimal performance.

🏷️ Basic Information

Identification

Make:

Aprilia

Model:

Pegaso 650

Year:

Codes

Engine Code:

Rotax 654 (typically)

Chassis Code:

Various, specific to generation

👋 Introduction

Market Position

Segment:

Lightweight adventure touring / dual-sport motorcycle

Competitive Analysis

Competitors 2005:

BMW F650GS, Kawasaki KLR650, Suzuki DR650, Yamaha XT660R

Key Features

Engine Platform:

Proven Rotax single-cylinder engine, known for torque and reliability

Design Philosophy:

Blend of on-road comfort and off-road capability, versatile for commuting and light touring.

📋 Manual Details

Coverage Areas

Overall Coverage:

Complete service and repair for the 2005 Aprilia Pegaso 650

Page Count

Estimated Page Count:

Likely 300-500 pages (typical for comprehensive service manuals)

Manual Type

Type:

Service Repair Manual (Factory Shop Manual Equivalent)

Language

Language:

English (typical for manuals distributed internationally)

Format

Format:

Digital (PDF assumed based on description for sales)

📖 Manual Coverage

Systems Covered

Engine:

Complete overhaul, diagnosis, tuning, cooling system, lubrication system

Transmission:

Clutch, gearbox, final drive maintenance and repair

Fuel System:

Carburetor (if applicable) or Fuel Injection system (EFI) components, fuel pump, filter

Electrical System:

Ignition, lighting, charging system (alternator, regulator/rectifier), starting system (starter motor, battery), wiring diagrams, electronic control unit (ECU)

Chassis And Suspension:

Front forks (seals, oil change, internal components), rear shock absorber, swingarm, linkage, steering head bearings

Brakes:

Front and rear brake systems, hydraulic lines, calipers, master cylinders, pads, discs, bleeding procedures

Wheels And Tires:

Wheel bearing replacement, tire mounting and balancing, spoke tensioning (if applicable)

Bodywork And Trim:

Fairings, seat, fuel tank, fenders, instrumentation removal and installation

Cooling System:

Radiator, fan, hoses, coolant type and capacity

Exhaust System:

Muffler, headers, gasket replacement

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain adjustment, spark plug checks, air filter cleaning/replacement

Troubleshooting:

Diagnostic flowcharts for common problems and system failures

Engine Rebuild:

Piston, rings, cylinder, valve servicing, camshaft timing

Suspension Overhaul:

Fork seal replacement, fork oil specification and level, rear shock absorber service

Brake System Repair:

Bleeding, caliper rebuild, master cylinder replacement

Electrical Diagnostics:

Wiring diagram interpretation, component testing, fault finding

Fuel System Service:

Carburetor cleaning/rebuilding or EFI component diagnosis

Technical Depth

Depth:

Comprehensive, covering everything from basic adjustments to complete engine and chassis overhauls, including advanced diagnostics.

📊 Manual Specifications

File Format

Digital Format:

PDF (Portable Document Format), allowing for searchable text and easy printing of individual pages or sections.

Print Quality

Print Quality Suitability:

High resolution, suitable for clear printing of diagrams, schematics, and detailed instructions.

Binding Type

Digital Binding:

N/A (Digital format)

Paper Type

Digital Paper Type:

N/A (Digital format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Single-cylinder, four-stroke

Displacement:

652 cc

Bore X Stroke:

100 mm x 83 mm (typical for Rotax 654)

Compression Ratio:

9.5:1 or 10.0:1 (depending on specific variant)

Valve Train:

SOHC, 4 valves per cylinder

Performance

Horsepower:

Approximately 48-50 HP (35-37 kW) at around 6500-7000 RPM

Torque:

Approximately 60-63 Nm (44-46 lb-ft) at around 5000-5500 RPM

Fuel System

Fuel Delivery:

Fuel Injection (EFI) or Carburetor (depending on market/specific model variant for 2005 - often Mikuni BSR40)

Fuel Type:

Unleaded gasoline, minimum 90 RON (Research Octane Number)

Cooling System

Cooling Method:

Liquid-cooled

Lubrication System

Oil Type:

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

Oil Capacity W Filter:

Approx. 2.0 - 2.2 liters

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Features

Clutch Type:

Wet multi-plate

Final Drive:

O-ring sealed chain

📐 Dimensions

Exterior

Length:

Approx. 2170 mm

Width:

Approx. 850 mm (at handlebars)

Height:

Approx. 1330 mm (at windscreen)

Wheelbase:

Approx. 1480 mm

Ground Clearance:

Approx. 220 mm

Weights

Dry Weight:

Approx. 166 kg

Wet Weight:

Approx. 182 kg (fully fueled, fluids, etc.)

Fuel Tank Capacity:

Approx. 14 liters (including 3-liter reserve)

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (Motorcycle, not subject to automotive crash testing standards)

Active Features

Braking System Front:

Dual disc, 298 mm diameter, 2-piston calipers

Braking System Rear:

Single disc, 240 mm diameter, 1-piston caliper

Optional on some versions, but not standard on all 2005 models.

Passive Features

Lighting:

Halogen headlight, LED tail light, standard turn signals

💡 Technology Features

Infotainment

Instrument Cluster:

Analog tachometer, digital speedometer, odometer, trip meter, fuel gauge, basic indicator lights.

Driver Assistance

ABS Availability:

Optional on certain trims, not a standard feature across all 2005 models.

Connectivity

Usb Charging:

N/A (Not equipped with factory USB charging)

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 - 7,500 km (3,000 - 5,000 miles) or annually, whichever comes first.

Air Filter Inspection:

Every 5,000 km (3,000 miles)

Spark Plug Replacement:

Every 10,000 - 15,000 km (6,000 - 10,000 miles)

Valve Clearance Check:

Every 10,000 - 20,000 km (6,000 - 12,000 miles)

Fluid Specifications

Fork Oil Type:

SAE 7.5W or 10W fork oil (check manual for exact specification and level)

Brake Fluid Type:

DOT 4

Coolant Type:

Ethylene glycol based coolant, with corrosion inhibitors (50% mix with distilled water)

Known Issues

Common Wear Items:

Clutch plates, steering head bearings, wheel bearings, fork seals, stator/regulator rectifier can be prone to failure on older models.

Engine Specific:

Potential for oil leaks around the cylinder head or base gasket, importance of regular oil level checks.

Electrical Specific:

Voltage regulator failures can lead to battery charging issues. Wiring harness integrity should be checked.

📚 Vehicle History

Brand Heritage

Manufacturer Origin:

Aprilia is an Italian manufacturer, part of the Piaggio Group.

Model Evolution

Pegaso Lineage:

The Pegaso line has a history dating back to the early 1990s, evolving through various iterations including the Pegaso 650 Trail, Factory, and Strada models.

Production

Manufacturing Location:

Typically produced in Italy.

🏆 Awards & Recognition

Recognitions

Motorcycle Awards:

While specific awards for the 2005 Pegaso 650 are not widely publicized, the model was generally well-regarded for its versatility and value in its class.