Aprilia Pegaso 650 1992 Service Repair Manual

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Type: Motorcycle

Vendor:

Sku: 90011

Tags: 1992 Aprilia Misc Motorcycle Motorcycles Pegaso 650

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Description

Welcome to the comprehensive service and repair manual for the 1992 Aprilia Pegaso 650. This versatile dual-sport motorcycle, known for its capable single-cylinder engine and comfortable riding posture, is designed for both on-road commuting and light off-road adventures. An Italian manufacturer with a rich heritage in performance motorcycling, engineered the Pegaso 650 to be a practical and reliable option in the mid-weight adventure segment, competing with other notable models of its era. Its robust construction and adaptable nature make it a favored choice for riders seeking a blend of utility and enjoyment. This manual provides detailed guidance across all essential systems, including the engine, fuel, ignition, electrical, transmission, drivetrain, suspension, brakes, and chassis. It covers routine maintenance procedures, complex troubleshooting steps, and in-depth repair instructions for major components. Whether you are performing basic service like oil changes and chain adjustments or undertaking significant overhauls of the engine or suspension, this resource offers the clarity and technical detail required. With approximately 300-400 pages of information, this English-language manual is an indispensable tool for owners and technicians aiming to maintain the performance and longevity of their Aprilia Pegaso 650.

🏷️ Basic Information

Identification

Make:

Aprilia

Model:

Pegaso 650

Year:

Codes

Chassis Code:

Engine Code:

AP105

👋 Introduction

Market Position

Segment:

Dual-sport / Adventure Motorcycle

Competitive Analysis

Competitors:

BMW F650 Funduro, Honda Transalp, Yamaha Tenere.

Key Features

Features:

Versatile for both on-road commuting and light off-road touring, capable single-cylinder engine, comfortable riding posture.

📋 Manual Details

Coverage Areas

Systems Covered:

Engine, Fuel System, Ignition System, Electrical System, Transmission, Drivetrain, Suspension, Brakes, Steering, Cooling System, Exhaust System, Chassis, Bodywork, Maintenance, Troubleshooting, Specifications

Page Count

Estimated Pages:

300-400

Manual Type

Type:

Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed disassembly, inspection, and reassembly of engine components including cylinder head, pistons, connecting rods, crankshaft, and valve train.

Fuel System:

Carburetor service (Dell'Orto PHM40), fuel pump, fuel lines, and tank maintenance.

Ignition System:

CDI ignition system troubleshooting, spark plug specifications, and timing adjustments.

Electrical System:

Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), lighting, starter motor, and fuse identification.

Transmission Drivetrain:

Clutch operation, gear shifting mechanism, chain drive maintenance, and rear sprocket replacement.

Suspension Steering:

Front fork (Marzocchi) overhaul, rear shock absorber adjustment and replacement, steering head bearing service.

Brakes:

Front and rear brake system service, including caliper overhaul, brake pad replacement, hydraulic fluid bleeding, and disc inspection.

Chassis Bodywork:

Frame inspection, body panel removal and installation, seat, fairing, and luggage rack components.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain lubrication and adjustment, brake fluid checks, tire pressure monitoring.

Troubleshooting:

Diagnostic flowcharts for common starting issues, running problems, and electrical faults.

Major Repairs:

Engine rebuilds, transmission overhauls, carburetor tuning, fork seal replacement.

Diagnostic Procedures:

Spark plug reading, compression testing, ignition timing verification.

Technical Depth

Depth:

Comprehensive, covering everything from basic maintenance to complete engine and transmission overhauls. Suitable for both DIY enthusiasts and professional mechanics.

📊 Manual Specifications

File Format

File Type:

Digital PDF

Print Quality

Quality:

High-resolution scans with clear text and legible diagrams. Printable.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Single-cylinder, four-stroke, SOHC

Displacement:

652 cc

Bore X Stroke:

100 mm x 83.7 mm

Compression Ratio:

9.5:1

Cooling System:

Liquid-cooled

Performance

Horsepower:

Approx. 45 hp @ 6500 rpm

Torque:

Approx. 52 Nm @ 5000 rpm

Fuel System

Carburetor:

1 x Dell'Orto PHM40 (flat slide)

Fuel Tank Capacity:

18 Liters (4.75 US gal)

🔧 Transmission

Standard

Transmission Type:

5-speed manual

Final Drive:

Chain drive

Features

Clutch Type:

Wet, multi-plate

📐 Dimensions

Exterior

Length:

Approx. 2200 mm

Width:

Approx. 850 mm

Height:

Approx. 1300 mm

Weights

Dry Weight:

Approx. 170 kg

Wet Weight:

Approx. 185 kg (with all fluids)

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (Motorcycle specific safety standards apply)

Active Features

Brakes:

Disc brakes front and rear. Optional ABS may be available on some models/regions, but not standard on the 1992 model.

Passive Features

Lighting:

Halogen headlamp, LED tail light.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Analog instrumentation typical for this era)

Driver Assistance

Not standard on the 1992 model, optional on later versions.

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Oil Change:

Every 5,000 km (3,100 miles) or annually, whichever comes first.

Air Filter Cleaning:

Every 5,000 km (3,100 miles).

Spark Plug Replacement:

Every 10,000 km (6,200 miles).

Valve Clearance Check:

Every 10,000 km (6,200 miles).

Chain Adjustment:

Every 1,000 km (600 miles) or as needed.

Fluid Specifications

Engine Oil Type:

SAE 10W-40 API SG or higher (e.g., Motul 5100 10W-40)

Engine Oil Capacity:

Approx. 2.2 Liters (2.3 US qt) with filter change.

Coolant Type:

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

Brake Fluid Type:

DOT 4

Transmission Oil Type:

Refer to manual; typically SAE 75W-90 or similar for chain case lubrication.

Known Issues

Common Problems:

Carburetor jetting can require fine-tuning, voltage regulator failure, occasional electrical connector issues, wear on the rear shock linkage bearings.

📚 Vehicle History

Brand Heritage

Heritage:

Aprilia is an Italian manufacturer with a strong heritage in motorcycle racing and performance street bikes.

Model Evolution

Evolution:

The Pegaso 650 was Aprilia's entry into the popular mid-weight dual-sport segment, designed to offer versatility and practicality. It utilized a Rotax engine (often sourced from BMW's F650 platform) which contributed to its reliability and performance.

Production

Production Years:

The Pegaso 650 line was produced from the early 1990s through the 2000s, with several iterations and engine updates.

🏆 Awards & Recognition

Recognitions

Awards:

While specific awards for the 1992 model are not widely documented, the Pegaso line was generally well-received for its versatility and value in the dual-sport market.