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PEGASO 650 2002 APRILIA Service Repair Manual
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Basic Information Identification Make: Aprilia Model: Pegaso 650 Model Year: 2002 Product Name: PEGASO 650 2002 APRILIA Service Repair Manual Product Type: Service Repair Manual Introduction Market Position Vehicle Segment:...
Typ: Motorcycles
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Art.-Nr: 167739
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| Basic Information | |
| Identification | |
| Make: | Aprilia |
| Model: | Pegaso 650 |
| Model Year: | 2002 |
| Product Name: | PEGASO 650 2002 APRILIA Service Repair Manual |
| Product Type: | Service Repair Manual |
| Introduction | |
| Market Position | |
| Vehicle Segment: | Dual-sport / Adventure Motorcycle |
| Target Audience: | Riders seeking a versatile motorcycle for commuting, touring, and light off-road use. |
| Competitive Analysis | |
| Key Competitors: | BMW F650GS, Kawasaki KLR650, Suzuki DR650SE, Yamaha XT660R. |
| Key Features | |
| Engine Type: | Reliable and torquey single-cylinder Rotax engine. |
| Suspension Travel: | Generous suspension travel suitable for varied road conditions. |
| Ergonomics: | Comfortable riding position for long distances. |
| Styling: | Distinctive Italian styling characteristic of Aprilia. |
| Manual Details | |
| Coverage Areas | |
| Primary Coverage: | Aprilia Pegaso 650 (2002 Model Year) |
| Page Count | |
| Page Count: | 320 |
| Manual Type | |
| Manual Type: | Service and Repair Manual |
| Language | |
| Language: | English |
| Format | |
| Format: | PDF Download |
| Manual Coverage | |
| Systems Covered | |
| Engine Mechanical: | Detailed coverage of the Rotax 654cc single-cylinder engine, including disassembly, assembly, inspection, and repair of all components (cylinder head, cylinder, piston, crankshaft, camshaft, valve train). |
| Engine Fuel System: | Comprehensive information on the fuel injection system (MPI), including fuel pump, injectors, throttle body, sensors (MAP, TPS, temperature), and ECU diagnosis. |
| Engine Ignition System: | Detailed explanation of the ignition system, including ignition coil, spark plug, and CDI unit operation and testing. |
| Engine Cooling System: | Information on the liquid cooling system, including radiator, coolant pump, thermostat, hoses, and fan operation. |
| Transmission: | Coverage of the 5-speed gearbox, including clutch operation, gearbox disassembly, assembly, inspection, lubrication, and common issues. |
| Chassis Suspension: | In-depth details on the front telescopic fork (Marzocchi or Paioli depending on variant) and rear monoshock suspension, including adjustment, maintenance, and rebuild procedures. |
| Brakes: | Comprehensive coverage of the hydraulic brake system, including front and rear disc brake specifications, master cylinders, calipers, brake lines, brake fluid types, and bleeding procedures. |
| Electrical System: | Extensive information on the entire electrical system, including wiring diagrams, battery, starter motor, alternator, lighting (headlight, taillight, indicators), horn, and fuse box. |
| Instrumentation Controls: | Details on the instrument cluster functions, dashboard lights, switches, and control levers. |
| Fuel Tank Seat: | Procedures for removing and reinstalling the fuel tank, seat, and associated components. |
| Bodywork Fairings: | Instructions for the removal, installation, and repair of body panels, fairings, and aerodynamic components. |
| Procedures Included | |
| Routine Maintenance: | Detailed instructions for all scheduled maintenance tasks, including oil changes, filter replacements, chain adjustment, brake checks, and fluid level checks. |
| Troubleshooting: | Systematic diagnostic procedures for identifying and resolving common issues, with symptom-based troubleshooting charts. |
| Engine Repair: | Step-by-step guides for engine rebuilds, including piston ring replacement, valve adjustments, gasket replacements, and timing chain inspection. |
| Transmission Repair: | Procedures for clutch adjustment, gearbox disassembly and reassembly, and identification of worn components. |
| Suspension Fork Rebuild: | Detailed instructions for servicing and rebuilding the front forks, including oil changes and seal replacement. |
| Brake System Overhaul: | Procedures for brake caliper servicing, master cylinder overhaul, and brake line replacement. |
| Electrical Diagnostics: | Guidance on using multimeters and diagnostic tools to troubleshoot electrical faults, including circuit testing and sensor diagnosis. |
| Wheel And Tire Service: | Instructions for wheel bearing maintenance, tire changes, and balancing. |
| Technical Depth | |
| Depth Level: | Comprehensive: Covers everything from basic rider maintenance to complete engine and transmission overhauls, including advanced electrical diagnostics. |
| Diagnostic Procedures: | Includes detailed diagnostic trees and troubleshooting flowcharts for common performance issues. |
| Repair Techniques: | Provides specific torque values, clearances, and special tool requirements for all repair procedures. |
| Manual Specifications | |
| File Format | |
| File Format: | |
| PDF Quality: | High-resolution scans of original factory documentation, ensuring clarity and readability of text and diagrams. |
| Searchable Text: | Yes (OCR processed for keyword searchability) |
| Print Quality | |
| Print Quality: | N/A (Digital Download) |
| Binding Type | |
| Binding Type: | N/A (Digital Download) |
| Paper Type | |
| Paper Type: | N/A (Digital Download) |
| Engine Specifications | |
| Primary Engine | |
| Engine Type: | Four-stroke, single-cylinder, liquid-cooled, DOHC |
| Displacement: | 654 cc (ccm) |
| Bore X Stroke: | 100 mm x 83.6 mm |
| Compression Ratio: | 10.0:1 |
| Performance | |
| Horsepower: | Approx. 48 HP (36 kW) @ 6,250 rpm (specifications may vary slightly by market and specific tune) |
| Torque: | Approx. 61 Nm (45 lb-ft) @ 4,750 rpm (specifications may vary slightly by market and specific tune) |
| Fuel System | |
| Fuel Delivery: | Electronic Fuel Injection (MPI) with single throttle body |
| Fuel Type: | Unleaded gasoline (min. 95 RON recommended) |
| Lubrication System | |
| Oil Capacity: | Approx. 1.7 Liters (with filter change) |
| Recommended Oil: | API SG/SH/SJ or higher, JASO MA, SAE 10W-40 motorcycle engine oil (refer to manual for precise specifications and seasonal variations). |
| Transmission | |
| Standard | |
| Transmission Type: | Constant mesh, 5-speed gearbox |
| Clutch: | Wet, multi-plate clutch, hydraulically operated |
| Final Drive: | Chain drive |
| Features | |
| Gear Ratios: | Specific gear ratios are detailed within the manual for precise analysis and troubleshooting. |
| Transmission Fluid: | Refer to engine oil specifications for gearbox lubrication (common integrated oil system). |
| Dimensions | |
| Exterior | |
| Length: | Approx. 2180 mm |
| Width: | Approx. 870 mm |
| Height: | Approx. 1330 mm (seat height varies) |
| Wheelbase: | Approx. 1470 mm |
| Ground Clearance: | Approx. 220 mm |
| Weights | |
| Dry Weight: | Approx. 168 kg |
| Wet Weight: | Approx. 182 kg (fully fueled and serviced, without rider) |
| Fuel Tank Capacity: | 21 Liters (including approx. 3.5 Liter reserve) |
| Seat Height: | Approx. 870 mm |
| Safety Features | |
| Ratings | |
| Safety Ratings: | Not applicable in the same way as cars. Emphasis on rider skill and protective gear. |
| Active Features | |
| Brakes: | Disc brakes front and rear for effective stopping power. ABS was an option on some later models, but not standard on the 2002 base model. |
| Lighting: | Halogen headlight for good visibility, LED taillight and turn signals for conspicuity. |
| Passive Features | |
| Chassis Design: | Sturdy frame providing stability and rider feedback. |
| Protective Gear Emphasis: | Manual strongly emphasizes the importance of rider wearing appropriate protective gear (helmet, jacket, pants, gloves, boots). |
| Technology Features | |
| Infotainment | |
| Infotainment System: | No integrated infotainment system; basic instrument cluster with analog speedometer and tachometer. |
| Driver Assistance | |
| ABS Availability: | ABS was an optional feature on some variants, not standard on the 2002 model. |
| Connectivity | |
| Connectivity Features: | No specific connectivity features. |
| Maintenance | |
| Service Intervals | |
| Oil And Filter Change: | Recommended every 5,000 - 7,500 km or annually, whichever comes first (refer to manual for specific intervals). |
| Air Filter Cleaning Replacement: | Inspect every 5,000 km, clean or replace as needed. |
| Spark Plug Replacement: | Recommended every 10,000 - 15,000 km. |
| Valve Clearance Check: | Typically at 10,000 - 15,000 km intervals (critical for single-cylinder engine performance). |
| Chain And Sprockets Inspection Lubrication: | Lubricate every 500 km and inspect for wear and tension regularly. |
| Fluid Specifications | |
| Brake Fluid: | DOT 4 |
| Coolant: | Ethylene glycol-based coolant, 50% mixture with distilled water. |
| Known Issues | |
| Electrical Connections: | Corrosion or looseness in electrical connectors can lead to intermittent faults. |
| Regulator Rectifier: | Some owners have reported rectifier/regulator failures, leading to charging system issues. |
| Starter Clutch: | Potential for wear on the starter clutch mechanism over time. |
| Fuel Pump: | Occasional issues with the fuel pump assembly. |
| Vehicle History | |
| Brand Heritage | |
| Brand Origin: | Aprilia is an Italian manufacturer with a strong heritage in motorcycle racing and performance road bikes. |
| Model Evolution | |
| Pegaso Lineage: | The Pegaso line, introduced in the early 1990s, was Aprilia's entry into the dual-sport market, evolving through various engine sizes and configurations. |
| Rotax Engine: | The 654cc Rotax engine was a popular choice for Aprilia, known for its reliability and punchy torque delivery, used in various Aprilia models. |
| Production | |
| Manufacturing Location: | Typically manufactured in Italy. |
| Sales Period: | The Pegaso 650 was produced for many years, with significant updates and variations across its lifespan. |
| Awards & Recognition | |
| Recognitions | |
| Industry Recognition: | The Pegaso 650 was generally well-received for its versatility and Italian flair within the dual-sport segment. |
| Ratings | |
| Consumer Reviews: | Often praised for its character and handling by owners. |
| Certifications | |
| Emissions Compliance: | Compliant with European emissions standards for the model year. |