Market Segment:
The Aprilia Pegaso 650 was positioned as a versatile dual-sport motorcycle, appealing to riders seeking a capable on-road touring machine with some off-road pretensions. It competed in a segment with bikes like the BMW F650GS, Honda Transalp, and Yamaha TDM.
Key Competitors:
BMW F650 Funduro/GS, Honda Transalp 600/650, Yamaha TDM 850, Suzuki DR650.
Versatility:
Its primary selling point was its adaptability for commuting, touring, and light off-road riding. Different versions (e.g., Strada, Trail) further emphasized this versatility.
Engine Reliability:
The Rotax-derived engine, while sometimes considered vibey, was generally robust and offered good fuel economy for its class. The manual would detail its specific care requirements.
Handling:
Known for its agile handling characteristics, a hallmark of Aprilia's sporty heritage, facilitated by its relatively light weight and well-sorted chassis.
Systems Covered:
Engine (including internals, fuel, cooling), Fuel Supply System, Electrical System, Chassis (frame, suspension, wheels, brakes), Repair Information (general procedures, troubleshooting).
Page Count:
Not explicitly stated, but factory service manuals are typically extensive, ranging from 300 to 800+ pages.
Manual Type:
Factory Service Repair Manual
Language:
Likely English (as standard for factory service manuals aimed at global markets). May also exist in Italian or other European languages.
Format:
Likely a printable manual, potentially available as a PDF. The 'FACTORY MANUAL!' designation implies an official, comprehensive document.
Engine Mechanical:
Detailed breakdown of the Rotax 655cc V2 engine, including cylinder head, piston, crankshaft, valves, camshafts, timing, lubrication system, and cooling system.
Fuel System:
Carburetor (likely Keihin CVK) or fuel injection system (depending on year/model), fuel pump, fuel lines, fuel filter, and associated sensors.
Ignition System:
CDI ignition, spark plugs, ignition coils, timing adjustments, and troubleshooting.
Electrical System:
Wiring diagrams, battery, charging system (alternator, rectifier/regulator), starter motor, lighting, indicators, instrumentation, and accessory circuits.
Chassis Suspension:
Front fork (e.g., Marzocchi, Paioli), rear shock absorber (e.g., Sachs, Öhlins on higher trims), linkages, settings, and rebuild procedures.
Braking System:
Front and rear brake calipers, discs, master cylinders, brake lines, bleeding procedures, and troubleshooting. Likely includes specifications for brands like Brembo or Grimeca.
Wheels Tires:
Wheel types (spoked or cast), bearing maintenance, tire sizes, pressures, and installation.
Cooling System:
Radiator, cooling fan, coolant hoses, coolant type, and capacity.
Exhaust System:
Exhaust pipes, mufflers, and emissions-related components.
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, brake pad inspection, fluid level checks, spark plug replacement.
Troubleshooting:
Diagnostic procedures for common problems related to engine, electrical, and chassis systems. Symptom-based troubleshooting guides.
Engine Rebuild:
Complete engine disassembly, inspection, component replacement, and reassembly instructions with torque specifications.
Carburetor Adjustment:
Idle speed and mixture adjustment, synchronisation (if applicable).
Suspension Service:
Fork oil change, seal replacement, rear shock servicing.
Electrical Diagnostics:
Using multimeters, tracing faults in wiring harnesses, testing components like stators, regulators, and starter solenoids.
Brake System Overhaul:
Caliper rebuilding, master cylinder replacement, brake line replacement.
Depth:
Comprehensive. Covers everything from basic maintenance and adjustments to in-depth engine rebuilding, electrical system diagnosis, and chassis component overhauls. Suitable for professional mechanics and experienced enthusiasts.
File Format:
Likely PDF, or high-quality scanned pages. Searchable text is a strong possibility for official digital releases.
Print Quality:
If printed, expect high-resolution images, clear diagrams, and readable text. Factory manuals are typically produced with excellent print quality.
Binding Type:
If physical, likely spiral-bound or saddle-stitched for ease of use in a workshop environment. Perfect binding is also possible.
Paper Type:
If physical, durable, often glossy or semi-gloss paper to withstand workshop conditions and frequent handling. Diagrams and schematics are typically printed on high-quality paper.
Engine Type:
4-stroke, 4-valve per cylinder, SOHC V2 (or DOHC depending on specific engine variant across generations).
Displacement:
652cc (approximate, based on Rotax 650 platform)
Bore X Stroke:
Typically around 82mm x 60.3mm (subject to minor variations across models).
Horsepower:
Generally in the 45-50 hp range, depending on year and specific tuning.
Torque:
Around 50-55 Nm, with peak delivery in the mid-range.
Carburetion:
Typically dual Keihin CVK 32mm carburetors for earlier models, potentially transitioning to fuel injection on later iterations (e.g., models post-2007).
Cooling Method:
Liquid-cooled
Oil Capacity With Filter:
Approximately 2.5 - 3.0 liters (specific value in manual).
Recommended Oil:
Fully synthetic 10W-40 or 20W-50 motorcycle oil meeting API SG/SH or higher specifications (manual will specify exact grade).
Recommended Spark Plugs:
NGK CR9EB or equivalent (manual will confirm exact type and gap).
Length:
Varies by model year and variant (approx. 2100-2200 mm).
Width:
Varies by model year and variant (approx. 800-850 mm).
Height:
Varies by model year and variant (approx. 1300-1450 mm).
Dry Weight:
Approx. 170-180 kg (depending on model variant and equipment).
Fuel Tank Capacity:
Typically 16-20 liters, depending on the specific sub-model (e.g., Strada vs. Trail).
Seat Height:
Varies by model, generally around 820-860 mm.
Instrumentation:
Analog tachometer, digital or analog speedometer, odometer, trip meter, fuel gauge, and various warning lights. Manual covers dashboard diagnostics.
ABS System:
Available as an option on later models. The manual provides detailed diagnostics and service procedures for the ABS unit, sensors, and hydraulic control unit if equipped.
Charging Port:
Some models may feature a 12V accessory socket for charging devices. Manual will detail its wiring and fuse.
Oil Change Interval:
Typically every 5,000 - 7,500 km or annually (manual will confirm exact mileage and time-based intervals).
Valve Clearance Check:
Often at 10,000 - 15,000 km, but can vary significantly based on engine revisions (critical to check manual).
Spark Plug Replacement Interval:
Typically every 10,000 - 15,000 km, or based on inspection.
Brake Fluid Type:
DOT 4 or DOT 5.1 (manual will specify the exact requirement).
Coolant Type:
Ethylene glycol-based antifreeze, mixed 50/50 with distilled water. Manual will provide specific Aprilia-approved coolant.
Fork Oil Type:
Specific suspension oil viscosity (e.g., 10W or 15W), manual will detail type and quantity.
Electrical Connections:
Corrosion or looseness in wiring connectors, particularly at the stator, regulator/rectifier, and CDI unit can lead to charging or ignition problems.
Carburetor Synchronization:
Carburetors can go out of sync, leading to rough idling, poor throttle response, and uneven power delivery. Regular checks are recommended.
Cam Chain Tensioner:
Some early Rotax engines could develop a noisy cam chain tensioner, requiring inspection and potential replacement.
Fuel Pump Reliability:
On fuel-injected models, the fuel pump can be a point of failure, leading to starting or running issues.
Suspension Seals:
Front fork seals can be prone to leaks, especially with off-road use. Regular maintenance is key.
Aprilia Motorsport:
Aprilia has a rich history in motorcycle racing, particularly in smaller displacement categories, influencing their road bike design with a focus on handling and performance.
Pegaso Lineage:
The Pegaso line started in the early 1990s and evolved through several iterations, including the 650cc V-twin which became its defining feature. Models like the Pegaso 650, Pegaso Strada, and Pegaso Trail represent different takes on the adventure touring/supermoto concept.
Production Years:
The 650cc Pegaso was produced from the mid-1990s through to around 2014 (when it was largely replaced by the Caponord 1200 and other models, though the 650 platform continued in other forms).
Manufacturing Location:
Primarily Italy, as Aprilia is an Italian manufacturer.
