🏷️ 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 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...