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Aprilia Pegaso 650 2005 Factory Service Repair Manual

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The Aprilia Pegaso 650, produced in 2005, is a versatile lightweight adventure-touring and dual-sport motorcycle designed for riders who navigate both urban environments and light off-road trails. This second-generation model,...
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类型: Motorcycle
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斯库: 149959
Aprilia Pegaso 650 2005 Factory Service Repair Manual
The Aprilia Pegaso 650, produced in 2005, is a versatile lightweight adventure-touring and dual-sport motorcycle designed for riders who navigate both urban environments and light off-road trails. This second-generation model, part of the post-2003 facelift, embodies a design philosophy that balances on-road comfort with off-road capability. It features a robust single-cylinder, four-stroke, liquid-cooled engine with electronic fuel injection, long-travel suspension suitable for varied terrain, and a steel tube frame contributing to rider control and stability. Known for its practicality and comfortable riding position, the Pegaso 650 was positioned to compete with other dual-sport offerings of its time, appealing to riders seeking a capable and adaptable machine. This Factory Service Repair Manual provides comprehensive guidance for the Aprilia Pegaso 650, covering all essential aspects of its maintenance, repair, and technical specifications. It details engine service, fuel and ignition systems, transmission and drivetrain, as well as brake, suspension, and electrical systems. The manual includes scheduled maintenance procedures, component repair instructions, diagnostic methods for troubleshooting, and critical technical data such as torque specifications and fluid capacities. With hundreds of pages of detailed information, including wiring diagrams and specialized tool usage, this manual serves as an indispensable resource for owners, mechanics, and technicians aiming to ensure the optimal performance and longevity of their 2005 Aprilia Pegaso 650.
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
Pegaso 650
Year:
2005
Codes
Chassis Code Series:
AP810000 Series (indicative, manual will specify exact)
Generation
Model Generation:
Second Generation (post-2003 facelift, including Trail and Factory variants)
👋 Introduction
Market Position
Vehicle Segment:
Lightweight Adventure-Touring / Dual-Sport Motorcycle
Target Audience:
Riders seeking versatility for commuting, touring, and light off-road excursions
Competitive Analysis
Key Competitors 2005:
BMW F650GS, Kawasaki KLR650, Suzuki DL650 V-Strom
Key Features
Engine Configuration:
Single-cylinder, four-stroke, liquid-cooled
Suspension Features:
Long-travel front forks, adjustable rear monoshock, suited for mixed terrain
Design Philosophy:
Balancing on-road comfort with off-road capability and practicality
📋 Manual Details
Coverage Areas
Manual Type:
Factory Service Repair Manual
Language:
English (assumed for primary distribution, manual may contain multiple languages)
Format:
Downloadable PDF
Page Count
Estimated Page Count:
Hundreds of pages (specific count may vary, typically 300-600 for comprehensive manuals)
📖 Manual Coverage
Systems Covered
Engine Service:
Complete engine overhaul, troubleshooting, component testing, disassembly and reassembly
Fuel System:
Fuel injection system (EFI), throttle body, fuel pump, injectors, fuel pressure regulation, diagnostics
Exhaust System:
Exhaust manifold, catalytic converter, muffler inspection and replacement
Cooling System:
Radiator, cooling fan, thermostat, coolant hoses, coolant flow diagnostics
Ignition System:
Spark plugs, ignition coils, ignition timing, ECU control
Transmission And Drivetrain:
Clutch operation, gearbox inspection, chain drive maintenance, final drive
Brake System:
Front and rear brake caliper overhaul, master cylinder service, brake fluid replacement, ABS system (if equipped), bleeding procedures
Suspension System:
Front fork service (oil changes, seal replacement), rear shock absorber adjustment and overhaul, swingarm maintenance
Steering System:
Handlebar, steering head bearing inspection and adjustment, steering lock
Electrical System:
Battery, charging system (alternator, regulator/rectifier), starter motor, lighting system, wiring diagrams, fuses, relays
Instrumentation And Controls:
Dashboard displays, switchgear operation, cable routing
Bodywork And Chassis:
Fairing removal and installation, seat, fuel tank, fenders, frame inspection
Wheels And Tires:
Wheel bearing replacement, tire mounting and balancing, spoke tensioning (if applicable)
Troubleshooting:
Diagnostic flowcharts for common problems, fault codes (if applicable)
Procedures Included
Scheduled Maintenance:
Detailed service intervals, recommended checks, and replacements
Component Repair:
Step-by-step instructions for major component overhauls and repairs
Diagnostic Procedures:
Methods for identifying and resolving mechanical and electrical issues
Specification Updates:
Torque specifications, clearances, fluid capacities, and wear limits
Technical Depth
Diagnostic Capability:
Advanced diagnostics, including electronic system analysis and interpretation of sensor data
Rebuild Instructions:
Comprehensive procedures for complete engine, transmission, and suspension rebuilds
Special Tools:
Identification and usage instructions for specialized tools required for specific tasks
Wiring Diagrams:
Detailed, color-coded electrical schematics for all vehicle systems
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Searchability:
Likely searchable text, allowing for quick information retrieval
Print Quality
Printable:
Yes, designed for printing individual pages or the entire manual
Binding Type
Physical Manual Binding:
N/A (Digital Download - PDF)
Paper Type
Physical Manual Paper:
N/A (Digital Download - PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Single-cylinder, 4-stroke, DOHC, 4 valves
Engine Displacement:
652 cc (652 cubic centimeters)
Bore X Stroke:
100 mm x 83 mm (typical for this engine platform)
Compression Ratio:
10.0:1 (typical for this engine platform)
Performance
Horsepower:
Approximately 47-50 HP @ 6500-7000 RPM (manufacturer specific, manual will confirm exact)
Torque:
Approximately 57-60 Nm @ 5000-5500 RPM (manufacturer specific, manual will confirm exact)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with single throttle body
Fuel Type:
Unleaded gasoline, minimum 91 RON (Research Octane Number)
Lubrication
Oil Type:
API SG/SH/SJ or higher, SAE 10W-40 motorcycle specific (refer to manual for exact)
Oil Capacity:
Approx. 2.4 - 2.7 Liters with filter change (refer to manual for exact)
🔧 Transmission
Standard
Transmission Type:
5-speed manual gearbox
Optional
Transmission Options:
None (standard 5-speed manual)
Features
Clutch Type:
Wet multi-plate clutch, cable-actuated
Final Drive:
O-ring sealed chain drive
Gear Ratios
Gear Ratios:
Detailed ratios available in manual (e.g., 1st: 2.46, 2nd: 1.73, 3rd: 1.35, 4th: 1.13, 5th: 0.96)
Transmission Fluid
Transmission Oil Type:
SAE 75W/90 or SAE 80W API GL-4 (refer to manual for exact and capacity)
📐 Dimensions
Exterior
Overall Length:
Approx. 2180 mm (manual will confirm exact)
Overall Width:
Approx. 870 mm (at handlebars, manual will confirm exact)
Seat Height:
Approx. 870 mm (adjustable in some variants, manual will confirm exact)
Ground Clearance:
Approx. 190 mm (manual will confirm exact)
Weights
Dry Weight:
Approx. 170 kg (manual will confirm exact)
Wet Weight:
Approx. 185 kg (with all fluids, manual will confirm exact)
Fuel Tank Capacity:
Approx. 14 Liters (including reserve, manual will confirm exact)
🛡️ Safety Features
Ratings
Crash Test Ratings:
N/A (Motorcycle safety is assessed differently than cars; manual will cover safe operating practices)
Active Features
Braking System:
Hydraulic disc brakes front and rear, potential for ABS on certain models/trims (manual will specify)
Lighting:
Halogen headlight, LED taillight (common for the era), turn signals
Passive Features
Chassis Design:
Steel tube frame, designed for stability and rider control
💡 Technology Features
Infotainment
Instrument Cluster:
Analog tachometer, digital speedometer, odometer, trip meter, fuel gauge, warning lights (ABS indicator if equipped).
Driver Assistance
ABS System:
Optional Anti-lock Braking System available on some 2005 models, manual will detail its function and diagnostics.
Connectivity
Connectivity Features:
N/A (No modern connectivity features like Bluetooth or smartphone integration typical for this era of motorcycle).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 - 7,500 km or annually (refer to manual for precise recommendations)
Chain Lubrication:
Every 500 km and after riding in wet conditions
Valve Clearance Check:
Every 10,000 - 15,000 km (manual will specify exact procedure and shims)
Fluid Specifications
Brake Fluid Type:
DOT 4 (refer to manual for specific Aprilia recommendation)
Coolant Type:
Ethylene glycol-based antifreeze, 50% mixture with distilled water (refer to manual for specific)
Fork Oil Type Viscosity:
SAE 5W or 10W (specific type and quantity in manual)
Known Issues
Common Wear Items:
Clutch plates, brake pads, chain and sprockets, fork seals, regulator/rectifier can be prone to failure on older models.
Electrical Gremlins:
Wiring harness corrosion or loose connections can sometimes lead to intermittent electrical faults (manual will aid diagnosis).
Maintenance Schedule Detail
Major Service Points:
Engine tune-up, spark plug replacement, air filter service, brake system inspection, suspension check typically at 10,000-20,000 km intervals.
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
Aprilia is an Italian motorcycle manufacturer with a strong racing heritage, particularly in smaller displacement classes.
Model Evolution
Pegaso Lineage:
The Pegaso line, introduced in the early 1990s, was Aprilia's entry into the dual-sport market, evolving significantly over its production run.
2005 Updates:
The 2005 model represents the second generation of the Pegaso 650, featuring a revised chassis, updated styling, and often incorporating the Rotax engine, known for its reliability and performance in this segment.
Production
Production Location:
Primarily Italy (specific plant may vary, handled by Aprilia/Piaggio Group)
🏆 Awards & Recognition
Recognitions
Bike Magazine Reviews:
While specific awards for the 2005 model are hard to pinpoint, the Pegaso 650 was generally well-regarded by motorcycle publications for its versatility and comfortable riding position.
Ratings
Reliability Perception:
Generally considered reliable, especially with the Rotax engine, but regular maintenance is key.
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