APRILIA PEGASO 650 Service Repair Workshop Manual 1997-2004

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Taper: Motorcycle

Distributeur:

UGS: 131581

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

Variantes de produits

Description

The Aprilia Pegaso 650 is a versatile dual-sport motorcycle produced from 1997 to 2004, celebrated for its robust single-cylinder Rotax engine and long-travel suspension, making it adept for both on-road commuting and light off-road excursions. Its engineering quality is highlighted by a steel trellis frame and a reliable 654cc liquid-cooled engine, which provides ample torque and a dependable performance for riders seeking a capable machine. The Pegaso 650 was designed to compete with other popular adventure bikes of its era, offering a blend of practicality and engaging riding dynamics. This comprehensive workshop service repair manual provides in-depth guidance for all models of the Aprilia Pegaso 650 from 1997 through 2004. It covers every aspect of the motorcycle, from routine scheduled maintenance, including oil changes and chain adjustments, to complete engine overhauls and detailed troubleshooting procedures for electrical and mechanical systems. This manual is an essential resource for owners, mechanics, and technicians, offering the necessary information for accurate diagnostics, efficient repairs, and overall maintenance to ensure the longevity and optimal performance of the vehicle.

🏷️ Basic Information

Identification

Make:

Aprilia

Model:

Pegaso 650

Product Name:

APRILIA PEGASO 650 Service Repair Workshop Manual 1997-2004

Product Type:

Service Repair Workshop Manual

👋 Introduction

Market Position

Vehicle Segment:

Dual-sport / Adventure motorcycle, known for versatility on and off-road.

Target Audience:

Riders seeking a capable and reliable machine for commuting, touring, and light off-roading.

Competitive Analysis

Key Competitors:

BMW F650 Funduro, Yamaha XT660, Kawasaki KLR650.

Key Features

Engine Configuration:

Robust single-cylinder engine, known for torque and simplicity.

Suspension Design:

Long-travel suspension suitable for varied terrain.

Frame Type:

Steel trellis frame for rigidity.

📋 Manual Details

Coverage Areas

Model Years Covered:

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

Model Variants Covered:

All models

Repair Scope:

A-Z (All Repairs)

Page Count

Estimated Page Count:

Likely 500+ pages (typical for comprehensive service manuals)

Manual Type

Manual Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

Digital (likely PDF)

📖 Manual Coverage

Systems Covered

Engine System:

Detailed diagnosis, repair, overhaul, and specifications for the Rotax 654cc single-cylinder engine.

Fuel System:

Carburetor (Mikuni BSR42) or fuel injection system (depending on specific model variant), fuel pump, lines, and tank maintenance.

Ignition System:

Ignition timing, spark plug specifications, coil testing, CDI unit diagnostics.

Cooling System:

Radiator, fan, thermostat, coolant flow, bleeding procedures, fluid specifications.

Exhaust System:

Exhaust pipe, muffler, lambda sensor (if applicable) inspection and replacement.

Transmission System:

Clutch operation, gear shifting mechanism, transmission oil change and checks, internal transmission repair.

Drivetrain:

Chain and sprocket maintenance, adjustment, and replacement, rear wheel hub, swingarm bearing service.

Suspension System:

Front fork (telescopic, possibly with adjustable preload/damping) overhaul, seals, oil, and rear shock absorber service/replacement.

Braking System:

Front and rear brake caliper service, pad replacement, fluid flush and bleeding (including ABS if equipped), master cylinder, brake lines.

Wheel And Tire System:

Wheel bearing inspection and replacement, tire pressure, wear limits, and fitting.

Electrical System:

Battery maintenance, charging system (alternator/stator), starter motor, lighting circuits, wiring diagrams, fuse box, instrument panel.

Frame And Bodywork:

Chassis inspection, frame alignment (if necessary), fairing removal/installation, seat, tank, and fender maintenance.

Controls And Cables:

Throttle control, clutch cable, brake levers, and all associated linkage adjustments and lubrication.

Diagnostic Procedures:

Troubleshooting guides for common faults, error code interpretation (if applicable).

Procedures Included

Scheduled Maintenance:

Detailed intervals and procedures for oil changes, filter replacements, chain lubrication, brake checks, etc.

Engine Overhaul:

Complete engine disassembly, inspection, component replacement, and reassembly instructions.

Suspension Rebuild:

Fork seal replacement, damping rod service, shock absorber overhaul.

Brake System Repair:

Caliber rebuilds, master cylinder replacement, bleeding procedures.

Electrical Troubleshooting:

Step-by-step guides for diagnosing electrical faults using wiring diagrams.

Carburetor Rebuild:

Complete disassembly, cleaning, adjustment, and reassembly of the Mikuni BSR42 carburetor.

Fuel Injection Service:

Diagnostics and basic service for fuel-injected models (if applicable).

Wheel Bearing Replacement:

Correct procedures for removing and installing wheel bearings.

Chain And Sprocket Replacement:

Correct installation and alignment of drivetrain components.

Bodywork Repair:

Removal and installation of fairings, panels, and other cosmetic components.

Technical Depth

Depth Level:

Comprehensive (suitable for dealership technicians, covering everything from basic maintenance to complete engine rebuilds).

Diagnostic Capability:

Advanced troubleshooting and diagnostic procedures, including component testing and fault finding.

Rebuild Instructions:

Detailed, step-by-step instructions for complete disassembly and reassembly of major mechanical and electrical components.

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format) is most common for digital manuals.

Searchability:

Likely text-searchable PDF for easy information retrieval.

Print Quality:

High-resolution digital images and clear text, optimized for printing.

Binding Type

Binding Type:

N/A (Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

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

Displacement:

654 cc

Bore X Stroke:

100 mm x 83.7 mm (typical for Rotax 654)

Compression Ratio:

Approximately 10.5:1 (typical)

Performance

Horsepower:

Approx. 48-50 HP at 6,500 RPM (depending on model year and specific tune)

Torque:

Approx. 60 Nm (44 lb-ft) at 5,000 RPM (depending on model year and specific tune)

Fuel System

Fuel Delivery:

Mikuni BSR42 CV Carburetor (for most models) or Electronic Fuel Injection (EFI) on later variants.

Fuel Type:

Unleaded gasoline (91 octane or higher)

Lubrication

Oil Type:

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

Oil Capacity:

Approx. 2.5 - 2.8 Liters (with filter change)

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Optional

Optional Features:

No automatic or CVT options typically available for this model.

Features

Clutch Type:

Wet multi-plate clutch, cable operated

Final Drive:

O-ring sealed chain drive

Transmission Oil Type:

SAE 75W-90, API GL-4 or GL-5 Gear Oil

Transmission Oil Capacity:

Approx. 0.7 - 0.8 Liters

📐 Dimensions

Exterior

Length:

Approx. 2,200 mm

Width:

Approx. 850 mm

Height:

Approx. 1,350 mm

Wheelbase:

Approx. 1,500 mm

Weights

Dry Weight:

Approx. 180 kg

Wet Weight:

Approx. 195 kg (with all fluids)

Fuel Capacity:

Approx. 21 Liters

Seat Height:

Approx. 860 mm

🛡️ Safety Features

Ratings

Safety Certification:

Meets relevant European (CE) and national safety standards for motorcycles.

Active Features

Braking System Type:

Disc brakes front and rear. Optional ABS available on some variants.

Lighting:

Halogen headlamp, LED tail light, front and rear turn signals.

Passive Features

Frame Construction:

High-strength steel trellis frame designed for rider safety and handling.

Handguards:

Standard on many models for hand protection from elements and debris.

💡 Technology Features

Infotainment

Instrument Panel:

Analog tachometer, digital speedometer, odometer, trip meter, fuel gauge, engine temperature warning light, neutral indicator.

Driver Assistance

Optional Anti-lock Braking System (ABS) available on some models within this range.

Connectivity

Charging System:

AC generator (stator) with a voltage regulator/rectifier.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 5,000 km or 6 months, whichever comes first.

Oil Filter Replacement:

Every 10,000 km or 12 months (often performed concurrently with oil change).

Air Filter Cleaning Replacement:

Inspect every 5,000 km; clean or replace as needed. Replace every 15,000-20,000 km.

Spark Plug Replacement:

Every 10,000-15,000 km (specific type and gap critical).

Chain Lubrication Adjustment:

Every 1,000 km or after riding in wet conditions.

Brake Fluid Flush:

Every 24 months (regardless of mileage).

Fluid Specifications

Coolant Type:

Ethylene glycol based coolant, mixed 50/50 with distilled water.

Brake Fluid Type:

DOT 4

Known Issues

Common Wear Items:

Clutch plates, fork seals, wheel bearings, chain and sprockets.

Carburetor Issues:

Mikuni BSR42 can require periodic cleaning and adjustment for optimal performance. Diaphragm wear can occur.

Electrical Gremlins:

As with many bikes of this era, electrical connections may require cleaning or dielectric grease for reliability.

📚 Vehicle History

Brand Heritage

Manufacturer:

Aprilia is an Italian manufacturer renowned for its sport motorcycles and racing heritage.

Model Evolution

First Generation Introduction:

The Aprilia Pegaso lineage began in the early 1990s, evolving over the years.

Engine Source:

The 654cc engine is based on the reliable Rotax single-cylinder unit, also used in other manufacturers' models.

Production

Production Period:

1997-2004 covers a significant phase of the Pegaso 650's development, preceding later updates and fuel-injected models.

Manufacturing Location:

Primarily Italy

🏆 Awards & Recognition

Recognitions

Model Reputation:

Praised for its robust single-cylinder engine and dual-purpose capability, making it a popular choice for everyday riding and light touring.

Ratings

Reliability Perception:

Generally considered reliable with proper maintenance, particularly the Rotax engine.

Certifications

Emissions Standards:

Compliant with Euro 2 emissions standards for its production period.