Aprilia Pegaso 650 i.e 2002 Service Repair Manual

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The Aprilia Pegaso 650 i.e. is a versatile dual-sport motorcycle, produced in 2002, known for its adaptability to various riding conditions. Built upon the reliable Rotax 654 engine platform, this...

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Tipo: Motorcycle

Proveedor:

SKU: 128925

Etiquetas: 2002 Aprilia Motorcycle Motorcycles Pegaso 650 i.e Pegaso Models

Variantes de producto

Descripción

The Aprilia Pegaso 650 i.e. is a versatile dual-sport motorcycle, produced in 2002, known for its adaptability to various riding conditions. Built upon the reliable Rotax 654 engine platform, this second-generation Pegaso offers an accessible and agile experience, making it suitable for commuting, light touring, and navigating diverse road surfaces. Its design emphasizes rider comfort and practicality, positioning it as a strong contender in its segment for riders seeking a capable and user-friendly machine. This comprehensive service and repair manual provides in-depth guidance for the maintenance, diagnosis, and repair of the 2002 Aprilia Pegaso 650 i.e. It covers essential areas including engine mechanicals, fuel and ignition systems, transmission, frame, suspension, wheels, brakes, and the complete electrical system. The manual includes detailed procedures for routine maintenance, tune-ups, and component overhauls, alongside troubleshooting guidance and technical specifications, empowering both dealer technicians and advanced enthusiasts to keep the motorcycle in optimal condition.

🏷️ Basic Information

Identification

Make:

Aprilia

Model:

Pegaso 650 i.e

Year:

Category:

Motorcycle

Generation

Generation Name:

Pegaso 650 (2nd Generation)

Codes

Engine Code Designation:

Rotax 654

👋 Introduction

Market Position

Segment:

Dual-sport / Adventure motorcycle, popular for its versatility and accessible power delivery.

Target Audience:

Commuters, light touring riders, and those seeking an agile motorcycle for varied road conditions.

Competitive Analysis

Key Competitors:

BMW F650GS, Suzuki DL650 V-Strom (later models), Honda Transalp.

Key Features

Versatility:

Designed to handle both paved roads and light off-road excursions.

Engine Platform:

Utilizes a proven Rotax single-cylinder engine, known for its reliability and torque.

Accessibility:

Relatively low seat height and manageable weight make it accessible to a wide range of riders.

📋 Manual Details

Coverage Areas

Primary Coverage:

North America, Europe, Asia

Regional Variants:

General specifications applicable to most international markets for the 2002 model year.

Page Count

Estimated Pages:

Approximately 300-500 pages (typical for comprehensive service manuals of this era, actual count not provided)

Manual Type

Type:

Service and Repair Manual

Purpose:

Diagnosis, maintenance, repair, troubleshooting, and technical specifications for dealer technicians and advanced enthusiasts.

Language

Primary Language:

English

Format

Digital Format:

Digital Delivery:

Free Download

Compatibility:

Windows, macOS, Linux

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, cylinder head, piston, crankshaft, camshaft, timing, valves, lubrication system, cooling system.

Fuel System:

Electronic Fuel Injection (EFI) system, fuel pump, injectors, throttle body, fuel pressure regulator, sensors (MAP, TPS, IAT, O2).

Ignition System:

ECU, ignition coils, spark plugs, timing.

Transmission Clutch:

Clutch operation, disassembly, inspection, replacement, gearbox, gear shifting mechanism.

Frame Suspension:

Frame construction, front fork (telescopic), rear shock absorber, swingarm, bearings.

Wheels Brakes:

Wheel removal/installation, tire mounting, brake system (front disc, rear disc), hydraulic system, pads, calipers, master cylinders, bleeding procedure.

Electrical System:

Wiring diagrams, battery, starter, alternator, lighting (headlight, taillight, indicators), fuses, relays, horn, instrumentation.

Bodywork Fittings:

Fairings, seat, fuel tank, fenders, mirrors, controls, levers.

Diagnostics Troubleshooting:

Common problems, symptom analysis, diagnostic codes (if applicable), specific troubleshooting trees for various systems.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain adjustment, lubrication, spark plug inspection/replacement, air filter cleaning/replacement, brake fluid check.

Tune Up:

Engine tune-up procedures, idle speed adjustment, EFI system checks.

Engine Repair:

Complete engine rebuild procedures, top-end and bottom-end repairs.

Brake Service:

Brake pad replacement, brake fluid flush and bleed, caliper service.

Suspension Service:

Front fork seal replacement, rear shock absorber inspection.

Electrical Repair:

Component testing, wiring harness repair, troubleshooting electrical faults.

Bodywork Repair:

Fairing repair, mounting point checks, panel replacement.

Technical Depth

Diagnostic Level:

Advanced diagnostics, including interpretation of sensor data and ECU functions for EFI systems.

Repair Scope:

Comprehensive, from routine maintenance to complete engine and component overhauls.

Illustrations:

Detailed diagrams and step-by-step illustrated procedures.

Specifications:

Includes all manufacturer specifications, torque values, clearances, and tolerances.

Additional Content

Scheduled Service:

Detailed schedule for all routine maintenance intervals.

Tech Service Bulletins:

Inclusion of relevant TSBs for the model year, addressing known issues and improvements.

Recall Information:

Information pertaining to any safety recalls issued for the 2002 Pegaso 650.

📊 Manual Specifications

File Format

Format:

Searchability:

Likely text-searchable if properly converted, enabling quick information retrieval.

Print Quality

Digital Quality:

Depends on the source scan quality; typically aims for high clarity of text and diagrams for professional use.

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Type:

Single-cylinder, four-stroke

Displacement:

652 cc (approx.)

Bore X Stroke:

100 mm x 83 mm (typical for Rotax 654)

Cooling System:

Liquid-cooled

Valve Train:

SOHC, 4 valves per cylinder

Performance

Horsepower Estimate:

Approx. 48-50 HP @ 6500-7000 RPM (subject to specific market tune)

Torque Estimate:

Approx. 60-62 Nm @ 5000 RPM (subject to specific market tune)

Fuel System

Induction:

Electronic Fuel Injection (EFI) with single throttle body

Fuel Type:

Unleaded gasoline

Fuel Capacity:

Approx. 15-17 Liters (depending on specific sub-model)

🔧 Transmission

Standard

Type:

5-speed manual

Clutch Type:

Wet multi-plate, cable-actuated

Features

Final Drive:

O-ring sealed chain drive

📐 Dimensions

Exterior

Length:

Approx. 2170 mm

Width:

Approx. 800 mm

Height:

Approx. 1300 mm

Weights

Dry Weight:

Approx. 160-165 kg

Wet Weight:

Approx. 175-180 kg (fully fueled and ready to ride)

🛡️ Safety Features

Ratings

Crash Test Data:

Motorcycle safety ratings are not standardized like automobiles; focus is on rider protection through design and equipment.

Active Features

Braking System:

Dual disc front brake, single disc rear brake, hydraulic actuation.

Lighting:

Halogen headlight, LED taillight and indicators (typical for the era).

Passive Features

Frame Structure:

Steel tube frame designed for stability and rider confidence.

Ergonomics:

Comfortable riding position for longer journeys and varied terrain.

💡 Technology Features

Infotainment

Instrument Cluster:

Analog tachometer, digital speedometer, odometer, trip meters, coolant temperature gauge, basic indicator lights.

Driver Assistance

ABS was an optional feature on some Pegaso 650 models, not standard on all.

Connectivity

Diagnostics Port:

Likely equipped with a diagnostic connector for ECU access, although specific protocols might require specialized tools.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 6,000 km or 12 months (refer to manual for precise intervals)

Air Filter Service:

Check every 6,000 km, clean/replace as needed.

Spark Plug Inspection:

Inspect every 12,000 km, replace as needed.

Valve Clearance Check:

Typically at 12,000 km or 24,000 km intervals (critical service)

Fluid Specifications

Engine Oil Type:

API SG/SH/SJ or JASO MA certified, viscosity SAE 10W-40 or 15W-50 (refer to manual for specific ambient temperature recommendations)

Coolant Type:

Ethylene glycol-based antifreeze mixture (50% water, 50% coolant)

Brake Fluid Type:

DOT 4 hydraulic brake fluid

Chain Lube:

High-quality motorcycle chain lubricant

Known Issues

Fuel Pump Reliability:

Some early models or units with prolonged storage may experience fuel pump issues.

Wiring Harness Wear:

As with many bikes of this era, checking the condition of the wiring harness, especially near moving parts like the steering head and swingarm, is prudent.

Clutch Cable Adjustment:

Regular adjustment may be required due to cable stretch.

📚 Vehicle History

Brand Heritage

Manufacturer:

Aprilia is an Italian manufacturer known for its performance-oriented motorcycles, particularly in the sport and off-road segments.

Model Evolution

Pegaso Lineage:

The Pegaso line has a history of dual-purpose motorcycles, evolving through various engine sizes and configurations. The 650 i.e represents a modern iteration with fuel injection.

Production

Production Period:

The Pegaso 650 was produced across multiple generations from the early 1990s through to the late 2000s. The 2002 model is part of the second generation.

🏆 Awards & Recognition

Recognitions

Segment Awards:

The Pegaso 650 was often praised for its value and versatility within the dual-sport segment, though specific industry awards are not widely documented for this model.

Ratings

Owner Satisfaction:

Generally positive owner satisfaction for its practicality and reliability, especially regarding the Rotax engine.