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Aprilia Pegaso 650 2002 All Service Repair Manual

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🏷️ Basic Information Identification Make: Aprilia Model: Pegaso 650 Year: 2002 Generation Generation Designation: Pegaso 650 'Street' (Second Generation) Codes Vin Code: WP... 👋 Introduction Market Position Segment: Adventure Touring / Dual-Sport Target Audience: Riders seeking a versatile motorcycle for commuting, light touring, and off-road excursions. Competitive Analysis Competitors: BMW F650GS, Kawasaki KLR650, Honda Transalp (though generally lower displacement). Key Features Versatility: Capable of handling both paved roads and unpaved trails. Engine Character: Torquey single-cylinder engine providing usable power across a wide RPM range. Ergonomics: Comfortable upright riding position suitable for longer journeys. 📋 Manual Details Coverage Areas Coverage Type: Comprehensive Service and Repair Page Count Estimated Pages: 300+ Manual Type Type: Service Manual / Repair Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Top-end overhaul, piston and ring replacement, cylinder head service, valve adjustment, crankshaft and connecting rod inspection/replacement. Fuel System: Carburetor (Dell'Orto PHM 40 ND) inspection, cleaning, adjustment, jetting, float level setting, fuel pump and filter service. Ignition System: Spark plug diagnosis, ignition coil testing, CDI unit troubleshooting, timing adjustment procedures. Cooling System: Radiator inspection, coolant flush and fill, thermostat replacement, water pump service, fan operation check. Exhaust System: Exhaust pipe and muffler inspection for leaks and damage, gasket replacement. Transmission Drivetrain: Clutch inspection and adjustment, gear shifting mechanism troubleshooting, chain and sprocket maintenance, lubrication. Brakes: Hydraulic system bleeding, brake pad replacement, caliper service, rotor inspection, brake lever and pedal adjustment. Suspension Front: Telescopic fork service (oil change, seal replacement), spring inspection, steering head bearing adjustment. Suspension Rear: Monoshock absorber inspection and adjustment, swingarm bearing service, rear linkage lubrication. Wheels Tires: Spoke tensioning, wheel bearing inspection, tire pressure recommendations, tire wear diagnosis. Electrical System: Wiring diagram analysis, battery maintenance and testing, charging system (stator, regulator/rectifier) troubleshooting, lighting system diagnostics, starter motor operation. Bodywork Frame: Fairing removal and installation, seat service, fuel tank maintenance, chassis inspection. Procedures Included Routine Maintenance: Oil and filter changes, air filter cleaning/replacement, chain adjustment and lubrication, brake system checks, tire pressure checks, bolt torque checks. Troubleshooting: Systematic diagnostic guides for common performance issues, starting problems, electrical faults, and unusual noises. Engine Repair: Step-by-step instructions for engine disassembly, component inspection, reassembly, and critical torque specifications. Suspension Overhaul: Detailed procedures for fork seal replacement, shock absorber service, and steering bearing maintenance. Electrical Diagnostics: Utilizing wiring diagrams to trace faults, test components like CDI, stator, and rectifier, and repair wiring harness issues. Carburetor Tuning: Comprehensive guidance on cleaning, rebuilding, adjusting fuel mixture, idle speed, and float levels for optimal performance. Technical Depth Depth Level: Complete Professional Level - suitable for DIY enthusiasts and independent workshops. 📊 Manual Specifications File Format Format Details: Searchable PDF, high-resolution scans, printable pages. Print Quality Quality: N/A (Digital Download) Binding Type Type: N/A (Digital Download) Paper Type Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, four-stroke, liquid-cooled Displacement: 652 cc Bore X Stroke: 100 mm x 82 mm Compression Ratio: 10.0:1 Valve Train: SOHC, 4 valves per cylinder Performance Horsepower: Approx. 47 hp (35 kW) @ 7000 rpm (European Spec) Torque: Approx. 57 Nm (42 lb-ft) @ 5500 rpm (European Spec) Fuel System Carburetor Model: Dell'Orto PHM 40 ND (single) Fuel Type: Unleaded gasoline Fuel Tank Capacity: 14 liters (3.7 US gal) 🔧 Transmission Standard Type: 5-speed manual Optional Type: N/A Features Clutch: Wet, multi-plate, cable-actuated Final Drive: O-ring sealed chain 📐 Dimensions Exterior Length: Approx. 2170 mm (85.4 in) Width: Approx. 870 mm (34.3 in) Height: Approx. 1340 mm (52.8 in) (to handlebars) Wheelbase: Approx. 1480 mm (58.3 in) Ground Clearance: Approx. 200 mm (7.9 in) Seat Height: Approx. 865 mm (34.1 in) Weights Dry Weight: Approx. 172 kg (379 lbs) Wet Weight: Approx. 193 kg (425 lbs) 🛡️ Safety Features Ratings Crash Test Results: N/A (Motorcycle) Active Features Braking System: Front: 300 mm disc with 2-piston caliper. Rear: 240 mm disc with 1-piston caliper. Optional ABS: No ABS available for the 2002 model year. Passive Features Lighting: Halogen headlight, LED taillight. 💡 Technology Features Infotainment Instrument Cluster: Analog speedometer and tachometer, digital odometer, trip meter, coolant temperature gauge, and warning lights. Driver Assistance ABS: Not equipped. Connectivity Usb Charging: Not equipped. 🔧 Maintenance Service Intervals Oil Filter Change: Every 6,000 km (3,750 miles) or annually. Valve Clearance Check: Every 12,000 km (7,500 miles). Spark Plug Replacement: Every 12,000 km (7,500 miles). Air Filter Cleaning: Every 6,000 km (3,750 miles), clean more frequently in dusty conditions. Fluid Specifications Engine Oil Type: SAE 10W-40 API SG or higher (check manual for exact specification and viscosity based on climate). Engine Oil Capacity: Approx. 2.3 liters (2.4 US qt) with filter change. Coolant Type: Ethylene glycol-based antifreeze/coolant with corrosion inhibitors. Brake Fluid Type: DOT 4 Known Issues Cam Chain Tensioner: Early models could suffer from a weak automatic cam chain tensioner. Manual...
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Aprilia Pegaso 650 2002 All Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
Pegaso 650
Year:
2002
Generation
Generation Designation:
Pegaso 650 'Street' (Second Generation)
Codes
Vin Code:
WP...
👋 Introduction
Market Position
Segment:
Adventure Touring / Dual-Sport
Target Audience:
Riders seeking a versatile motorcycle for commuting, light touring, and off-road excursions.
Competitive Analysis
Competitors:
BMW F650GS, Kawasaki KLR650, Honda Transalp (though generally lower displacement).
Key Features
Versatility:
Capable of handling both paved roads and unpaved trails.
Engine Character:
Torquey single-cylinder engine providing usable power across a wide RPM range.
Ergonomics:
Comfortable upright riding position suitable for longer journeys.
📋 Manual Details
Coverage Areas
Coverage Type:
Comprehensive Service and Repair
Page Count
Estimated Pages:
300+
Manual Type
Type:
Service Manual / Repair Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Top-end overhaul, piston and ring replacement, cylinder head service, valve adjustment, crankshaft and connecting rod inspection/replacement.
Fuel System:
Carburetor (Dell'Orto PHM 40 ND) inspection, cleaning, adjustment, jetting, float level setting, fuel pump and filter service.
Ignition System:
Spark plug diagnosis, ignition coil testing, CDI unit troubleshooting, timing adjustment procedures.
Cooling System:
Radiator inspection, coolant flush and fill, thermostat replacement, water pump service, fan operation check.
Exhaust System:
Exhaust pipe and muffler inspection for leaks and damage, gasket replacement.
Transmission Drivetrain:
Clutch inspection and adjustment, gear shifting mechanism troubleshooting, chain and sprocket maintenance, lubrication.
Brakes:
Hydraulic system bleeding, brake pad replacement, caliper service, rotor inspection, brake lever and pedal adjustment.
Suspension Front:
Telescopic fork service (oil change, seal replacement), spring inspection, steering head bearing adjustment.
Suspension Rear:
Monoshock absorber inspection and adjustment, swingarm bearing service, rear linkage lubrication.
Wheels Tires:
Spoke tensioning, wheel bearing inspection, tire pressure recommendations, tire wear diagnosis.
Electrical System:
Wiring diagram analysis, battery maintenance and testing, charging system (stator, regulator/rectifier) troubleshooting, lighting system diagnostics, starter motor operation.
Bodywork Frame:
Fairing removal and installation, seat service, fuel tank maintenance, chassis inspection.
Procedures Included
Routine Maintenance:
Oil and filter changes, air filter cleaning/replacement, chain adjustment and lubrication, brake system checks, tire pressure checks, bolt torque checks.
Troubleshooting:
Systematic diagnostic guides for common performance issues, starting problems, electrical faults, and unusual noises.
Engine Repair:
Step-by-step instructions for engine disassembly, component inspection, reassembly, and critical torque specifications.
Suspension Overhaul:
Detailed procedures for fork seal replacement, shock absorber service, and steering bearing maintenance.
Electrical Diagnostics:
Utilizing wiring diagrams to trace faults, test components like CDI, stator, and rectifier, and repair wiring harness issues.
Carburetor Tuning:
Comprehensive guidance on cleaning, rebuilding, adjusting fuel mixture, idle speed, and float levels for optimal performance.
Technical Depth
Depth Level:
Complete Professional Level - suitable for DIY enthusiasts and independent workshops.
📊 Manual Specifications
File Format
Format Details:
Searchable PDF, high-resolution scans, printable pages.
Print Quality
Quality:
N/A (Digital Download)
Binding Type
Type:
N/A (Digital Download)
Paper Type
Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Single-cylinder, four-stroke, liquid-cooled
Displacement:
652 cc
Bore X Stroke:
100 mm x 82 mm
Compression Ratio:
10.0:1
Valve Train:
SOHC, 4 valves per cylinder
Performance
Horsepower:
Approx. 47 hp (35 kW) @ 7000 rpm (European Spec)
Torque:
Approx. 57 Nm (42 lb-ft) @ 5500 rpm (European Spec)
Fuel System
Carburetor Model:
Dell'Orto PHM 40 ND (single)
Fuel Type:
Unleaded gasoline
Fuel Tank Capacity:
14 liters (3.7 US gal)
🔧 Transmission
Standard
Type:
5-speed manual
Optional
Type:
N/A
Features
Clutch:
Wet, multi-plate, cable-actuated
Final Drive:
O-ring sealed chain
📐 Dimensions
Exterior
Length:
Approx. 2170 mm (85.4 in)
Width:
Approx. 870 mm (34.3 in)
Height:
Approx. 1340 mm (52.8 in) (to handlebars)
Wheelbase:
Approx. 1480 mm (58.3 in)
Ground Clearance:
Approx. 200 mm (7.9 in)
Seat Height:
Approx. 865 mm (34.1 in)
Weights
Dry Weight:
Approx. 172 kg (379 lbs)
Wet Weight:
Approx. 193 kg (425 lbs)
🛡️ Safety Features
Ratings
Crash Test Results:
N/A (Motorcycle)
Active Features
Braking System:
Front: 300 mm disc with 2-piston caliper. Rear: 240 mm disc with 1-piston caliper.
Optional ABS:
No ABS available for the 2002 model year.
Passive Features
Lighting:
Halogen headlight, LED taillight.
💡 Technology Features
Infotainment
Instrument Cluster:
Analog speedometer and tachometer, digital odometer, trip meter, coolant temperature gauge, and warning lights.
Driver Assistance
ABS:
Not equipped.
Connectivity
Usb Charging:
Not equipped.
🔧 Maintenance
Service Intervals
Oil Filter Change:
Every 6,000 km (3,750 miles) or annually.
Valve Clearance Check:
Every 12,000 km (7,500 miles).
Spark Plug Replacement:
Every 12,000 km (7,500 miles).
Air Filter Cleaning:
Every 6,000 km (3,750 miles), clean more frequently in dusty conditions.
Fluid Specifications
Engine Oil Type:
SAE 10W-40 API SG or higher (check manual for exact specification and viscosity based on climate).
Engine Oil Capacity:
Approx. 2.3 liters (2.4 US qt) with filter change.
Coolant Type:
Ethylene glycol-based antifreeze/coolant with corrosion inhibitors.
Brake Fluid Type:
DOT 4
Known Issues
Cam Chain Tensioner:
Early models could suffer from a weak automatic cam chain tensioner. Manual inspection and replacement with a higher-quality unit are recommended.
Electrical Connector Corrosion:
Some owners report corrosion issues in electrical connectors, particularly the main wiring harness, requiring cleaning and dielectric grease.
Carburetor Icing:
In very cold, humid conditions, the large single carburetor can be susceptible to icing.
📚 Vehicle History
Brand Heritage
Manufacturer:
Aprilia is an Italian manufacturer known for its racing heritage and performance-oriented motorcycles, particularly in the smaller displacement categories.
Model Evolution
Pegaso Lineage:
The Pegaso line began in the early 1990s, evolving through various iterations to meet changing market demands and regulations. The 2002 model is part of the second generation, often referred to as the 'Street' or 'Fun Ride' variant, featuring a revised chassis and engine tuning compared to earlier models.
Production
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Market Reception:
Generally well-regarded for its versatility and value for money in the adventure-touring segment.
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