Aprilia Pegaso 650 2000 Full Service Repair Manual

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Type: Motorcycle

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Sku: 154866

Tags: 2000 Aprilia Misc Motorcycle Motorcycles Pegaso 650

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Description

The Aprilia Pegaso 650, produced around the year 2000, is a versatile mid-size dual-sport motorcycle designed for both commuting and adventure touring, with capabilities extending to light off-road use. Powered by a robust single-cylinder, four-stroke, liquid-cooled engine (M659) with a displacement of approximately 652 cc, it delivers around 48-50 HP and 60-62 Nm of torque. Known for its distinctive Italian styling and a strong emphasis on engineering quality, the Pegaso 650 offered a compelling blend of on-road comfort and off-road prowess, positioning it as a practical and capable option in its market segment. This comprehensive service repair manual provides in-depth coverage for the Aprilia Pegaso 650, focusing on full service repair and maintenance procedures. It details engine overhaul, fuel system servicing, ignition system adjustments, transmission and drivetrain maintenance, cooling system care, braking system repairs, suspension system servicing, and electrical system troubleshooting. The manual also includes routine maintenance schedules, troubleshooting guides for common issues, detailed torque specifications, and essential wiring diagrams, making it an indispensable resource for owners, mechanics, and technicians seeking to maintain, repair, and optimize their vehicle.

🏷️ Basic Information

Identification

Make:

Aprilia

Model:

Pegaso 650

Year:

Codes

Engine Code:

M659 (Rotax Design)

👋 Introduction

Market Position

Category:

Mid-size Dual-Sport / Adventure Motorcycle

Competitive Analysis

Competitors 2000:

Honda Transalp XL650, BMW F650GS, Suzuki DL650 V-Strom (though V-Strom debuted later, Pegaso occupied a similar niche).

Key Features

Engine Type:

Single-cylinder, four-stroke, liquid-cooled

Design Philosophy:

Versatile machine suitable for commuting, touring, and light off-road use.

📋 Manual Details

Coverage Areas

Primary Coverage:

Full Service Repair and Maintenance

Page Count

Estimated Pages:

300-400 (Estimate based on typical full service manuals for this era/type of vehicle)

Manual Type

Type:

Service Repair Manual

Language

Language:

English (Assumed, most common for international market manuals)

Format

Format:

Digital (PDF) - Printable, Searchable (Assumed for modern sales)

📖 Manual Coverage

Systems Covered

Engine Overhaul:

Complete engine disassembly, inspection, repair, and reassembly for the Rotax M659 engine.

Fuel System:

Carburetor (likely Dell'Orto PHM 40) tuning, maintenance, rebuilding, fuel pump, and fuel lines.

Ignition System:

Spark plugs, ignition coils, CDI unit, timing adjustments, and troubleshooting.

Transmission And Drivetrain:

Clutch operation and adjustment, gearbox internal inspection and repair, chain maintenance, sprockets.

Cooling System:

Radiator, hoses, thermostat, water pump inspection and replacement, coolant specifications.

Braking System:

Brake fluid replacement, caliper servicing, pad replacement, disc inspection, hydraulic system bleeding.

Suspension System:

Front fork (likely Marzocchi or Paioli) overhaul, oil seals, springs, rear shock absorber adjustment and servicing.

Electrical System:

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

Chassis And Frame:

Frame inspection, steering head bearing service, swingarm bush inspection, wheel bearing replacement.

Bodywork And Fairings:

Panel removal and installation, cosmetic repair guidance.

Procedures Included

Routine Maintenance:

Oil and filter changes, air filter cleaning/replacement, chain lubrication and adjustment, spark plug checks, brake and clutch lever adjustments.

Troubleshooting:

Diagnostic procedures for common starting, running, and electrical issues with clear symptom-cause-solution tables.

Rebuilds:

Detailed step-by-step instructions for major component rebuilds (engine, gearbox, forks).

Component Replacement:

Guidance on replacing wear items and common failure points such as brake pads, clutch plates, wheel bearings, and tires.

Technical Depth

Diagnostic Capabilities:

Advanced diagnostic procedures for electrical faults and engine performance issues, including timing checks and compression testing.

Torque Specifications:

Comprehensive list of torque values for all critical fasteners and engine components.

Tolerances And Clearances:

Engine component clearance specifications (piston-to-bore, valve clearances where applicable, bearing clearances).

Wiring Diagrams:

Detailed, high-quality wiring schematics for the entire motorcycle.

📊 Manual Specifications

File Format

File Type:

Print Quality

Resolution:

High resolution for clear text and image reproduction when printed.

Binding Type

Binding:

N/A (Digital Product)

Paper Type

Paper Quality:

N/A (Digital Product)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Single-cylinder, four-stroke, liquid-cooled, DOHC

Displacement:

652 cc (659cc often quoted due to bore/stroke)

Bore X Stroke:

100 mm x 83 mm (approximate)

Compression Ratio:

10.0:1 (approximate)

Performance

Horsepower:

Approx. 48-50 HP @ 6500 RPM

Torque:

Approx. 60-62 Nm @ 5000 RPM

Fuel System

Carburetor:

Dell'Orto PHM 40 DD (or similar variant)

Fuel Delivery:

Carbureted with accelerator pump

🔧 Transmission

Standard

Gearbox:

5-speed constant mesh

Optional

Transmission Options:

N/A (Standard 5-speed)

Features

Clutch Type:

Wet, multi-plate, cable operated

📐 Dimensions

Exterior

Length:

Approx. 2230 mm

Width:

Approx. 860 mm

Height:

Approx. 1420 mm

Wheelbase:

Approx. 1520 mm

Weights

Dry Weight:

Approx. 185 kg

Wet Weight:

Approx. 205 kg (fully fueled)

Fuel Capacity:

Approx. 18 Liters (including reserve)

🛡️ Safety Features

Ratings

Safety Features:

Disc brakes front and rear, robust chassis construction.

Active Features

Front Brake:

Single 300 mm disc with 2-piston caliper (Nissin or Brembo)

Rear Brake:

Single 220 mm disc with 1-piston caliper (Nissin or Brembo)

Passive Features

Lighting:

Halogen headlight, LED taillight, standard turn signals.

💡 Technology Features

Infotainment

Instrument Cluster:

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

Driver Assistance

ABS was typically an optional feature on the 2000 model.

Connectivity

Connectivity Features:

N/A (Basic motorcycle technology for its era)

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 6,000-10,000 km or annually (refer to manual for exact specification)

Valve Clearance Check:

Every 12,000-24,000 km (or as per manual, typically shim-under-bucket)

Chain Maintenance:

Lubricate and adjust every 1,000 km or as needed.

Fluid Specifications

Engine Oil Type:

SAE 10W-40, API SG/SH or JASO MA (refer to manual for exact specification)

Engine Oil Capacity:

Approx. 2.2 - 2.5 Liters with filter change

Coolant Type:

Ethylene glycol based antifreeze (e.g., Motul Motocool Expert, Castrol Radicool)

Brake Fluid Type:

DOT 4

Known Issues

Common Wear Item:

Cam chain tensioner (can become weak, leading to rattling noises).

Common Wear Item 2:

Water pump seal (potential for coolant leaks).

Electrical Concern:

Rectifier/regulator failure (leading to charging system issues), especially on early models.

📚 Vehicle History

Brand Heritage

Manufacturer Origin:

Italy

Model Evolution

Pegaso Lineage:

The Pegaso 650 was Aprilia's entry into the mid-size dual-purpose motorcycle market, known for its distinctive styling and Rotax single-cylinder engine.

Production

Production Years:

1990s - 2000s (with various iterations and engine updates)

🏆 Awards & Recognition

Recognitions

Market Perception:

Recognized for its robust Rotax engine and off-road capability compared to some competitors, though often perceived as having a more premium price point.