Motorcycle Segment:
Adventure Touring / Dual-Sport
Target Audience:
Owners seeking to perform their own maintenance and repairs, reduce dealership costs, and gain in-depth knowledge of their motorcycle.
Competitors 2002-2006:
BMW F650GS (single-cylinder variants), Kawasaki KLR650, Suzuki DR650SE, Yamaha XT660R/X.
Versatility:
Designed for both on-road commuting and light off-road capability.
Engine Platform:
Utilized the reliable Rotax single-cylinder engine, known for its torque and tractability.
Cost Savings:
Explicitly marketed to save owners significant money on service and repairs.
Completeness:
Promised to cover all aspects of repair, maintenance, and restoration.
Model Years Covered:
2002, 2003, 2004, 2005, 2006
Estimated Page Count:
300-400 (typical for comprehensive service manuals)
Manual Type:
Service Repair Workshop Manual
Language:
English (presumed, as it's a common standard for aftermarket manuals)
Format:
Downloadable Digital File (PDF likely)
Engine:
Full engine disassembly, assembly, tuning, diagnostics, fuel injection system (IE), ignition system, lubrication system, cooling system, exhaust system.
Transmission:
Clutch operation and adjustment, gearbox internal components, shift mechanism, lubrication.
Chassis And Suspension:
Front fork (telescopic, conventional or upside-down depending on specific sub-model), rear shock absorber, swingarm, linkage (if applicable), steering head bearings, wheel bearings, hub maintenance.
Brakes:
Front and rear brake systems (disc brakes), hydraulic lines, caliper service and rebuild, master cylinder service, pad replacement, fluid flushing and bleeding, ABS system diagnostics (if equipped).
Electrical System:
Wiring diagrams, lighting system (headlight, taillight, turn signals), battery, starter motor, charging system (alternator/stator, rectifier/regulator), ignition coils, ECU (Engine Control Unit) functions and diagnostics, sensor identification and testing, fuse box layout, horn, instrumentation.
Fuel System:
Fuel pump operation and testing, fuel filter replacement, fuel injectors, throttle body assembly, fuel tank maintenance, fuel pressure testing.
Bodywork And Trim:
Fairing removal and installation, seat removal, paneling, minor bodywork repair guidance.
Maintenance:
Regular service intervals, oil and filter changes, air filter cleaning/replacement, spark plug replacement, valve clearance checks and adjustment, chain lubrication and adjustment, brake pad inspection and replacement, coolant checks and replacement, tire pressure checks, battery maintenance.
Troubleshooting:
Systematic diagnosis of common problems, error code interpretation (if applicable for the IE system), electrical gremlins, engine performance issues, starting problems.
Repair And Rebuild:
Detailed step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation for all major vehicle systems.
Technical Specifications:
Torque values for critical fasteners, fluid capacities, clearances, timing specifications, electrical resistance values, diagnostic parameters.
Depth:
Comprehensive (covering everything from routine maintenance to full engine and gearbox rebuilds, electrical diagnostics, and suspension overhauls).
Engine Type:
Single-cylinder, four-stroke, DOHC (Double Overhead Camshaft)
Displacement:
652 cc (approx.)
Bore X Stroke:
100 mm x 83 mm (typical for Rotax 655 engine)
Cooling System:
Liquid-cooled
Compression Ratio:
10.0:1 (typical)
Horsepower Est:
48-50 HP @ 6500-7000 RPM (approx.)
Torque Est:
57-60 Nm (approx.) @ 5200-5500 RPM
Fuel Delivery:
Electronic Fuel Injection (IE)
Throttle Body Size:
42 mm (likely Mikuni or Keihin)
Ignition Type:
Digital electronic ignition with ignition advance
Oil Type Spec:
SAE 10W-40, API SG or higher (check manual for precise specification)
Oil Capacity With Filter:
Approx. 2.2 - 2.4 Liters
Transmission Type:
5-speed constant mesh
Optional Transmission:
N/A (standard 5-speed)
Clutch Type:
Wet multi-plate clutch, hydraulically actuated
Final Drive:
O-ring sealed chain drive
1St Gear Ratio:
Approximately 36/14 (2.57:1)
2Nd Gear Ratio:
Approximately 32/18 (1.78:1)
3Rd Gear Ratio:
Approximately 30/21 (1.43:1)
4Th Gear Ratio:
Approximately 28/23 (1.22:1)
5Th Gear Ratio:
Approximately 26/24 (1.08:1)
Final Drive Ratio:
Approximately 16/42 (2.63:1)
Transmission Oil Type:
SAE 75W-90 or SAE 80W-90, API GL-4 (check manual for precise specification)
Gearbox Oil Capacity:
Approx. 0.7 - 0.8 Liters
Length Est:
2200 mm (approx.)
Width Est:
850 mm (approx. at handlebars)
Height Est:
1350 mm (approx. to windscreen top)
Seat Height Est:
830-860 mm (depending on suspension setup/model variations)
Wheelbase Est:
1480 mm (approx.)
Dry Weight Est:
185 kg (approx.)
Wet Weight Est:
200 kg (approx. with fluids)
Fuel Tank Capacity:
14 Liters (approx., including 2-3L reserve)
Front Wheel Size:
19-inch (typically 3.00 x 19)
Rear Wheel Size:
17-inch (typically 4.00 x 17 or similar)
Front Tire Size:
100/90-19 (typical, check manual for specific fitment)
Rear Tire Size:
130/80-17 (typical, check manual for specific fitment)
Ground Clearance Est:
200 mm (approx.)
Safety Ratings:
Not applicable in the traditional sense for motorcycles; focuses on structural integrity and component safety.
Braking System:
Dual disc front brakes with hydraulic actuation, single disc rear brake with hydraulic actuation. ABS was an option on some models.
Lighting:
Halogen headlight, LED taillight, amber turn signals.
Frame Construction:
Steel trellis frame, designed for rigidity and vibration damping.
Ergonomics:
Upright riding position promoting rider comfort and control.
Infotainment System:
N/A (No integrated infotainment system; focus is on mechanical and electrical functionality).
ABS Option:
Anti-lock Braking System (ABS) was an optional feature on certain versions, significantly enhancing braking safety.
Diagnostic Ports:
Includes diagnostic capabilities for the EFI system, likely requiring specific diagnostic tools or knowledge covered in the manual.
Dashboard Features:
Analog speedometer and tachometer, LCD display for odometer, trip meters, fuel level, coolant temperature, and warning lights.
Oil And Filter Change:
Every 6,000 km or 6 months (typical for touring use, consult manual for exact interval).
Air Filter Service:
Every 12,000 km or 12 months (cleaning/replacement).
Spark Plug Replacement:
Every 12,000 - 18,000 km (depending on plug type, check manual).
Valve Clearance Check:
Every 12,000 km (critical for maintaining engine performance and longevity).
Chain Maintenance:
Lubricate every 500-700 km and adjust slack as needed.
Coolant Type:
Ethylene glycol-based coolant, pre-mixed 50/50 with distilled water (check manual for specific formulation).
Coolant Capacity:
Approx. 1.2 - 1.4 Liters
Common Wear Items:
Clutch plates, chain and sprockets, fork seals, voltage regulator (common on many bikes of this era).
Fuel System Quirks:
Potential for injector clogging if fuel quality is poor; regular use of quality fuel is recommended.
Electrical Gremlins:
Corrosion on electrical connectors can lead to intermittent issues; regular inspection and dielectric grease application is beneficial.
Aprilia Origins:
Founded in 1945 in Italy, Aprilia is known for its sporting heritage, particularly in smaller displacement classes and off-road racing.
Pegaso Lineage:
The Pegaso line began in the early 1990s, evolving from a 600cc thumper to the more sophisticated 650cc fuel-injected model by the early 2000s, adopting the Rotax engine.
Key Changes 2002-2006:
Introduction of Electronic Fuel Injection (IE) for improved emissions and performance, chassis refinements, and updated styling.
Manufacturing Location:
Italy
Engine Supplier:
Rotax (a division of Bombardier Recreational Products), a highly regarded engine manufacturer.
