2002 Aprilia Pegaso 650 IE Workshop Service Repair Manual

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Tipo: Motorcycle

Proveedor:

SKU: 132595

Etiquetas: 2002 Aprilia Motorcycle Motorcycles Pegaso 650 IE Pegaso Models

Variantes de producto

Descripción

The 2002 Aprilia Pegaso 650 IE is a mid-range dual-sport motorcycle engineered for versatility, adept at urban commuting, touring, and light off-road excursions. Building on a rich heritage in performance motorcycle manufacturing, this model features a liquid-cooled, 652cc single-cylinder engine with electronic fuel injection, delivering approximately 48 HP and 57 Nm of torque. Its robust chassis, comfortable ergonomics, and capable suspension make it a balanced option for riders seeking a machine that can handle both paved roads and light trails, competing effectively with other dual-sport offerings of its era. This comprehensive workshop service repair manual provides detailed information for the maintenance and repair of your 2002 Aprilia Pegaso 650 IE. It covers a wide array of systems, including General Information, Engine, Fuel Supply, Cooling, Electrical, and Chassis. Within these sections, you will find detailed repair instructions, service procedures, setting up guidelines, troubleshooting steps, and essential technical specifications. This manual is designed to assist both DIY enthusiasts and professional technicians in keeping the motorcycle in optimal condition.

🏷️ Basic Information

Identification

Make:

Aprilia

Model:

Pegaso 650 IE

Year:

Engine Type:

Fuel Injected (IE)

👋 Introduction

Market Position

Market Position:

Mid-range dual-sport motorcycle, catering to riders seeking versatility for commuting and light off-road use.

Competitive Analysis

Competitive Analysis:

Competed with models like BMW F650GS, Kawasaki KLR650, and Yamaha XT660R, offering a balance of on-road comfort and off-road capability.

Key Features

Key Features:

Fuel-injected 650cc engine, robust chassis, comfortable ergonomics for touring, capable of both pavement and mild trail riding.

Versatility:

Designed as a versatile all-rounder, suitable for urban commuting, touring, and light adventure riding.

📋 Manual Details

Coverage Areas

Manual Coverage Areas:

Comprehensive service and repair for the 2002 Aprilia Pegaso 650 IE

Page Count

Page Count:

Not Specified

Manual Type

Manual Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Systems Covered:

General Information, Service and Setting up, Engine, Fuel Supply System, Cooling System, Electrical System, Chassis, Repair Information, Analytical Index

Chassis Systems:

Frame, suspension (front forks and rear shock absorber), wheels, brakes (front and rear calipers, discs, master cylinders), steering system, and bodywork.

Procedures Included

Procedures Included:

Detailed repair instructions, service procedures, setting up, troubleshooting, and maintenance

Engine Procedures:

Engine removal/installation, top-end overhaul (cylinder head, valves, piston), bottom-end overhaul (crankshaft, connecting rod), lubrication system, timing chain inspection and adjustment.

Fuel System Procedures:

Fuel pump testing, fuel injector cleaning/replacement, throttle body inspection and adjustment, fuel pressure regulation.

Cooling System Procedures:

Radiator inspection and cleaning, water pump overhaul, thermostat replacement, coolant flush and refill.

Electrical System Procedures:

Wiring diagrams, starter motor testing, alternator/stator testing, battery maintenance, ignition system troubleshooting, lighting circuit diagnostics, instrument cluster repair.

Troubleshooting Guide:

Systematic troubleshooting steps for common operational problems, diagnostic fault codes (if applicable for IE model).

Technical Depth

Technical Depth:

Detailed, suitable for DIY repairs and professional workshop use, covering a wide range of maintenance to component-level repair

Engine Rebuild Depth:

Covers complete engine disassembly, inspection, repair, and reassembly to factory specifications.

Diagnostic Capability:

Includes diagnostic procedures for the electronic fuel injection system, often requiring basic electrical testing equipment.

📊 Manual Specifications

File Format

File Format:

PDF (Searchable Text)

Compatibility:

Windows (Win) / Macintosh (Max)

Print Quality

Print Quality:

High Quality Digital Reproduction, suitable for printing

Binding Type

Binding Type:

Digital Download (No physical binding)

Paper Type

Paper Type:

N/A (Digital File)

⚙️ Engine Specifications

Primary Engine

Engine Make Model:

Aprilia (based on Rotax single-cylinder)

Engine Displacement:

652cc

Engine Configuration:

Single-cylinder, four-stroke

Engine Cooling:

Liquid-cooled

Engine Bore X Stroke:

100 mm x 83 mm (approximate)

Engine Compression Ratio:

9.2:1 (typical for this era engine)

Performance

Engine Horsepower:

Approx. 48 HP @ 6800 rpm

Engine Torque:

Approx. 57 Nm @ 5200 rpm

Fuel System

Fuel System Type:

Electronic Fuel Injection (IE)

Fuel Delivery:

Single throttle body, multi-point injection

Fuel Type:

Unleaded gasoline

Valvetrain

Valvetrain Type:

SOHC, 4 valves per cylinder

Valve Actuation:

Camshaft driven via timing chain

🔧 Transmission

Standard

Transmission Type:

5-speed manual

Clutch Type:

Wet multi-plate

Features

Final Drive:

Chain drive

📐 Dimensions

Exterior

Length:

Approx. 2200 mm

Width:

Approx. 850 mm

Height:

Approx. 1400 mm

Wheelbase:

Approx. 1510 mm

Ground Clearance:

Approx. 180 mm (typical for dual-sport)

Weights

Dry Weight:

Approx. 185 kg

Fuel Tank Capacity:

14 Liters (approx.)

Gross Vehicle Weight Rating:

Refer to manual for specific load capacity

🛡️ Safety Features

Ratings

Safety Ratings:

N/A (Motorcycle, subject to road safety regulations)

Active Features

Active Features:

Disc brakes (front and rear), robust suspension for stability

Passive Features

Passive Features:

Headlight, taillight, turn signals, mirrors

💡 Technology Features

Infotainment

Infotainment System:

Basic analog/digital instrument cluster with speedometer, tachometer, odometer, trip meter, and indicator lights.

Driver Assistance

Driver Assistance Features:

None specific to electronic driver aids beyond standard lighting and controls.

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically 5,000 - 7,500 km or annually (refer to manual for exact specification)

Spark Plug Replacement:

Refer to manual for specific mileage interval

Valve Clearance Adjustment:

Typically every 10,000 - 15,000 km (refer to manual)

Fluid Specifications

Engine Oil Type:

SAE 10W-40, API SG or higher, JASO MA certified motorcycle oil recommended

Coolant Type:

Ethylene glycol-based coolant with corrosion inhibitors (specific Aprilia recommendation should be consulted)

Brake Fluid Type:

DOT 4

Known Issues

Common Issues:

Potential for stator failure, voltage regulator issues, occasional fuel injector clogging, and wear on the rear shock absorber linkage.

Maintenance Tips:

Regular cleaning of the fuel injector, checking electrical connections, and proper chain maintenance are crucial.

📚 Vehicle History

Brand Heritage

Brand Heritage:

Aprilia is an Italian manufacturer with a strong heritage in racing and sport motorcycles, known for innovative engineering.

Model Evolution

Model Evolution:

The Pegaso line has been produced since the early 1990s, evolving from carbureted models to the fuel-injected IE version for improved efficiency and emissions. It represented Aprilia's entry into the dual-sport market.

Production

Production Period:

The Pegaso 650 IE was produced through the early to mid-2000s.