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    2005 Aprilia Pegaso 650 Motorcycle Service Repair Workshop Manual

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    The Aprilia Pegaso 650, produced in 2005, is a versatile motorcycle designed for adventure touring and dual-sport riding. Featuring a liquid-cooled, single-cylinder, four-stroke engine with electronic fuel injection, it delivers...
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    Taper: Motorcycle
    Distributeur:
    UGS: 134176
    The Aprilia Pegaso 650, produced in 2005, is a versatile motorcycle designed for adventure touring and dual-sport riding. Featuring a liquid-cooled, single-cylinder, four-stroke engine with electronic fuel injection, it delivers approximately 48 horsepower and 57 Nm of torque. Its robust steel double cradle frame, long-travel suspension, and 19-inch front and 17-inch rear spoked wheels provide capability for both on-road commuting and light off-road excursions. With a fuel capacity of around 16 liters, the Pegaso 650 is engineered for riders seeking a dependable and adaptable machine for a variety of riding conditions. This comprehensive factory service manual provides detailed instructions for the maintenance, repair, and diagnostics of the Aprilia Pegaso 650. It covers all major systems, including the engine, fuel, ignition, cooling, transmission, suspension, brakes, and electrical systems. The manual includes procedures for routine maintenance, component disassembly and assembly, troubleshooting common issues, and rebuilding major parts, all supported by high-resolution diagrams and precise torque specifications. This resource is essential for owners, mechanics, and technicians to ensure the optimal performance and longevity of the vehicle.
    🏷️ Basic Information
    Identification
    Make:
    Aprilia
    Model:
    Pegaso 650
    Year:
    2005
    Vehicle Type:
    Motorcycle
    Codes
    Chassis Code:
    RL12
    👋 Introduction
    Market Position
    Segment:
    Adventure Touring / Dual-Sport Lightweight
    Target Audience:
    Riders seeking a versatile motorcycle for commuting, touring, and light off-road use
    Competitive Analysis
    Competitors 2005:
    BMW F650GS, Kawasaki KLR650, Suzuki DR650SE, Honda Transalp XL650V
    Key Features
    Engine Type:
    Single-cylinder, four-stroke, liquid-cooled
    Frame Type:
    Steel double cradle
    Suspension Setup:
    Long-travel telescopic front forks, monoshock rear suspension
    Wheel Size Front:
    19-inch
    Wheel Size Rear:
    17-inch
    Fuel Capacity:
    Approx. 16 liters (4.2 US gal)
    📋 Manual Details
    Coverage Areas
    Primary Coverage:
    Comprehensive Service and Repair
    Page Count
    Estimated Pages:
    300-400
    Manual Type
    Type:
    Factory Service Manual / Workshop Manual
    Language
    Language:
    English
    Format
    Format:
    Digital (PDF)
    📖 Manual Coverage
    Systems Covered
    Engine:
    Disassembly, assembly, inspection, diagnostics, tuning
    Fuel System:
    Fuel injection system (EFI), fuel pump, injectors, sensors
    Ignition System:
    Ignition coils, spark plugs, ECU control
    Cooling System:
    Radiator, coolant circulation, thermostat, fan operation
    Transmission And Drivetrain:
    Clutch operation, gearbox disassembly/assembly, chain drive maintenance
    Suspension Front:
    Fork disassembly, seals, oil changes, adjustments
    Suspension Rear:
    Shock absorber, linkage, bearings, adjustment
    Brakes Front:
    Brake caliper service, pad replacement, disc inspection, hydraulic system
    Brakes Rear:
    Brake caliper service, pad replacement, disc inspection, hydraulic system
    Electrical System:
    Battery, charging system, lighting, starter motor, wiring diagrams
    Fuel Tank And Lines:
    Removal, installation, cleaning
    Exhaust System:
    Inspection, component replacement
    Chassis And Frame:
    Frame inspection, steering head bearings
    Bodywork And Fairings:
    Removal, installation, repair considerations
    Procedures Included
    Maintenance:
    Oil changes, filter replacements, chain adjustment, spark plug replacement, fluid checks
    Troubleshooting:
    Diagnostic procedures for common faults, error code interpretation (if applicable)
    Repair:
    Detailed step-by-step repair instructions for all major components
    Rebuilds:
    Engine and transmission component rebuild procedures
    Wiring Diagrams:
    Comprehensive electrical system schematics
    Torque Specifications:
    Precise torque values for all fasteners
    Special Tools:
    Identification and usage of specialized tools required for specific procedures
    Technical Depth
    Depth:
    Comprehensive, from basic maintenance to complete engine rebuilds and diagnostics
    📊 Manual Specifications
    File Format
    File Type:
    PDF
    Searchable:
    Yes
    Printable:
    Yes
    Print Quality
    Image Resolution:
    High-resolution diagrams and images
    Binding Type
    Binding:
    N/A (Digital)
    Paper Type
    Paper:
    N/A (Digital)
    ⚙️ Engine Specifications
    Primary Engine
    Engine Type:
    Single-cylinder, four-stroke, DOHC, 4 valves
    Displacement:
    652 cc
    Bore X Stroke:
    100 mm x 83.7 mm
    Compression Ratio:
    10.0:1
    Cooling System:
    Liquid-cooled
    Performance
    Horsepower Approx:
    48 HP @ 6,500 RPM
    Torque Approx:
    57 Nm @ 5,250 RPM
    Fuel System
    Fuel Delivery:
    Electronic Fuel Injection (EFI)
    Fuel Type:
    Unleaded gasoline (95 RON recommended)
    Lubrication System
    Oil Type:
    SAE 10W-40 or 15W-50, API SG/SH/SJ or JASO MA
    🔧 Transmission
    Standard
    Transmission Type:
    5-speed constant mesh
    Clutch Type:
    Wet multi-plate
    Final Drive:
    O-ring sealed chain
    Features
    Gear Ratios:
    Refer to manual for specific gear ratios
    Fluid Specification
    Transmission Oil:
    Refer to manual for specific transmission oil type and capacity (often shared engine oil)
    📐 Dimensions
    Exterior
    Length Approx:
    2200 mm
    Width Approx:
    850 mm
    Height Approx:
    1350 mm
    Seat Height Approx:
    830 mm
    Weights
    Dry Weight Approx:
    170 kg
    Wet Weight Approx:
    185 kg
    Wheels Tires
    Front Tire Size:
    90/90-19
    Rear Tire Size:
    130/80-17
    Front Wheel Type:
    Spoked
    Rear Wheel Type:
    Spoked
    🛡️ Safety Features
    Ratings
    Safety Features:
    ABS (Optional on some models), dual disc front brakes, single disc rear brake
    Active Features
    Braking System:
    Hydraulic disc brakes front and rear
    Passive Features
    Lighting:
    Halogen headlight, LED taillight
    💡 Technology Features
    Infotainment
    Dashboard:
    Analog speedometer and tachometer, LCD multi-function display (odo, trip, clock)
    Driver Assistance
    ABS Availability:
    Optional ABS system on some 2005 models
    Connectivity
    Diagnostics Port:
    Diagnostic connector for ECU access (specific connector type and location detailed in manual)
    🔧 Maintenance
    Service Intervals
    Oil Change Interval:
    Every 6,000 km (3,700 miles) or 12 months, whichever comes first
    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)
    Fluid Specifications
    Engine Oil Capacity:
    Approx. 2.4 liters (2.5 US qt) with filter change
    Coolant Type:
    Ethylene glycol-based antifreeze/coolant, 50/50 mix with distilled water
    Brake Fluid:
    DOT 4
    Known Issues
    Common Wear Items:
    Clutch plates, fork seals, wheel bearings, rear shock absorber bushings
    Electrical Gremlins:
    Occasional issues with wiring connections or regulator/rectifier due to heat and vibration (refer to manual for diagnostics).
    Fuel Pump Reliability:
    Some owners report potential issues with the fuel pump over extended mileage, check fuel pressure as per manual.
    📚 Vehicle History
    Brand Heritage
    Manufacturer:
    Aprilia is an Italian motorcycle manufacturer, known for its racing heritage and performance-oriented machines.
    Model Evolution
    Pegaso Lineage:
    The Pegaso line has a history dating back to the 1980s, evolving from smaller displacement models to the more versatile 650cc single-cylinder platform.
    2005 Update:
    The 2005 model typically featured updates to electronics, styling, and potentially suspension components over earlier iterations.
    Production
    Manufacturing Location:
    Italy
    🏆 Awards & Recognition
    Recognitions
    Industry Perception:
    Generally well-regarded for its versatility and comfortable ride for its class.
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