Aprilia Pegaso 650 2002 Service Repair Manual

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Type: Motorcycle

Vendor:

Sku: 148782

Tags: 2002 Aprilia Misc Motorcycle Motorcycles Pegaso 650

Product variants

Description

The Pegaso 650, produced in 2002, is a versatile dual-sport motorcycle designed for riders seeking capability across various terrains, from urban commuting to light off-road adventures and touring. It is powered by a robust four-stroke, single-cylinder engine with a displacement of 652 cc, known for its reliable performance and adaptable nature. The Pegaso 650 features a steel tube frame for durability, long-travel suspension for comfort and off-road capability, and a 5-speed manual transmission with a wet, multi-plate clutch. Its Italian heritage from a manufacturer with a strong racing background, contributes to its engineered quality and performance focus. This comprehensive English-language Service Repair Manual is meticulously crafted for professional technicians and experienced DIY enthusiasts. It covers an extensive range of maintenance, diagnostic, and repair procedures for the Pegaso 650. Key areas detailed include complete engine mechanicals, fuel and ignition systems, cooling, lubrication, exhaust, transmission, drive system, front and rear suspension, braking systems, wheels and tires, and the entire electrical system. The manual provides step-by-step instructions for routine maintenance, engine rebuilds, suspension overhauls, electrical diagnostics, and troubleshooting, supported by critical technical specifications, torque values, and clear wiring diagrams, ensuring the vehicle remains in optimal condition.

🏷️ Basic Information

Identification

Make:

Aprilia

Model:

Pegaso 650

Year:

Product Type:

Service Repair Manual

Product Format:

PDF Download

👋 Introduction

Market Position

Segment:

Dual-sport/Adventure Motorcycle

Target User:

Riders seeking versatility for commuting, light off-roading, and touring.

Competitive Analysis

Key Competitors:

BMW F650GS, Kawasaki KLR650, Suzuki DR650SE.

Key Features

Vehicle Focus:

Robust single-cylinder engine, long-travel suspension, adaptable for various terrains.

📋 Manual Details

Coverage Areas

Manual Type:

Service Manual / Repair Manual

Language:

English

Target Audience:

Professional Technicians and Experienced DIYers

Page Count

Estimated Page Count:

Likely comprehensive, exceeding 300 pages (typical for detailed service manuals)

Format

File Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete overhaul, disassembly, assembly, inspection, and adjustment of all engine components.

Fuel System:

Carburetor (or injection system if applicable for 2002 models) diagnosis, cleaning, adjustment, and repair; fuel pump, fuel filter, fuel lines.

Ignition System:

Spark plugs, ignition coils, CDI unit, wiring, timing.

Cooling System:

Radiator, fan, coolant, hoses, thermostat, water pump inspection and replacement.

Lubrication System:

Oil pump, oil filter, oil passages, lubrication points.

Exhaust System:

Exhaust pipes, muffler, catalytic converter (if equipped), gaskets.

Transmission Clutch:

Clutch operation, adjustment, replacement; gearbox disassembly, assembly, inspection of gears, shafts, and bearings.

Drive System:

Chain and sprockets inspection, adjustment, and replacement; rear hub and axle.

Front Suspension:

Front fork, springs, dampers, seals, steering head bearings, adjustment, and rebuild.

Rear Suspension:

Rear shock absorber, swingarm, linkage (if applicable), bearings, adjustment, and rebuild.

Braking System Front:

Brake calipers, discs, pads, master cylinder, brake lines, bleeding procedure.

Braking System Rear:

Brake caliper, disc, pads, master cylinder, brake lines, bleeding procedure.

Wheels Tires:

Wheel bearings, tire replacement, balancing, wheel specifications.

Electrical System Charging:

Stator, rotor, regulator/rectifier, battery testing and replacement.

Electrical System Starting:

Starter motor, starter relay, ignition switch.

Electrical System Lighting:

Headlight, taillight, turn signals, brake light, dashboard illumination.

Electrical System Instruments:

Speedometer, tachometer, fuel gauge, indicator lights.

Electrical System Wiring Diagrams:

Comprehensive wiring schematics for all electrical components and circuits.

Bodywork Chassis:

Frame inspection, body panels removal and installation, fairings, seat, fuel tank.

Controls:

Handlebar, levers, pedals, cables, throttle control, clutch cable adjustment.

Procedures Included

Routine Maintenance:

Oil and filter changes, chain adjustment, brake pad inspection, tire pressure checks, spark plug replacement.

Troubleshooting:

Diagnostic charts and symptom-based troubleshooting guides for common and uncommon issues.

Engine Rebuild:

Detailed steps for complete engine disassembly, cleaning, inspection of wear limits, and reassembly.

Suspension Overhaul:

Front fork seal replacement, rear shock absorber service, steering head bearing adjustment.

Brake System Service:

Brake fluid flush and bleed, caliper rebuild, disc replacement.

Electrical Diagnostics:

Testing of charging system, starting system, ignition system, and lighting circuits using multimeters.

Carburetor Tuning:

Cleaning, rebuilding, and synchronization procedures for the carburetor.

Wheel And Tire Service:

Wheel bearing replacement, tire mounting and balancing.

Technical Depth

Diagnostic Capabilities:

Advanced diagnostic procedures, including electrical circuit tracing and component testing.

Repair Procedures:

Detailed step-by-step instructions for mechanical and electrical repairs, from minor adjustments to major component overhauls.

Specification Data:

Includes critical torque specifications, clearances, fluid capacities, and measurement tolerances.

Wiring Diagrams Quality:

Clear and detailed wiring schematics for accurate electrical troubleshooting.

📊 Manual Specifications

File Format

File Type:

Searchable PDF

Printability:

Printable

Print Quality

Image Resolution:

High-resolution images and diagrams for clarity.

Binding Type

Format Description:

Digital Download (PDF)

Paper Type

Format Description:

N/A (Digital)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, single-cylinder, liquid-cooled, DOHC

Displacement:

652 cc

Bore X Stroke:

100 mm x 82 mm (typical for this engine family)

Compression Ratio:

10.0:1 (typical)

Power Output:

Approx. 48 hp @ 6500 rpm (specific to model year and tuning)

Torque Output:

Approx. 60 Nm @ 5200 rpm (specific to model year and tuning)

Fuel System

Fuel Delivery:

Carburetor (likely Mikuni BSR40 or similar for 2002)

Fuel Type:

Unleaded gasoline

Fuel Tank Capacity:

Approx. 14 liters (including reserve)

🔧 Transmission

Standard

Transmission Type:

5-speed manual

Clutch Type:

Wet, multi-plate, cable-operated

Features

Final Drive:

Chain drive

📐 Dimensions

Exterior

Length:

Approx. 2200 mm

Width:

Approx. 850 mm

Height:

Approx. 1300 mm

Wheelbase:

Approx. 1470 mm

Weights

Dry Weight:

Approx. 165 kg

Wet Weight:

Approx. 185 kg (fully fueled and ready to ride)

Seat Height:

Approx. 870 mm

🛡️ Safety Features

Ratings

Optional on some models/markets

Active Features

Braking System:

Dual disc front, single disc rear, hydraulic actuation.

Passive Features

Chassis Design:

Steel tube frame for rigidity and durability.

💡 Technology Features

Infotainment

Dashboard Instruments:

Analog tachometer, speedometer, fuel gauge, odometer, trip meter, indicator lights.

Driver Assistance

Available as an option on certain production runs.

Connectivity

Charging System:

Standard alternator and regulator/rectifier setup.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 5,000-7,500 km or annually, whichever comes first.

Spark Plug Replacement:

Typically every 10,000-15,000 km.

Valve Clearance Check:

Typically every 10,000-20,000 km.

Fluid Specifications

Engine Oil Type:

API SG or higher, SAE 10W-40 or 15W-50 (check manual for specific grade).

Engine Oil Capacity:

Approx. 2.2 - 2.5 liters (with filter change).

Coolant Type:

Ethylene glycol-based coolant, mixed with distilled water (typically 50/50).

Brake Fluid Type:

DOT 4 (or specified by Aprilia).

Known Issues

Common Wear Items:

Clutch plates, front fork seals, chain and sprockets, steering head bearings.

Electrical Gremlins:

Potential for wiring harness issues or connector corrosion, common in older European bikes.

Carburetor Performance:

Can be sensitive to dirt and require periodic cleaning and synchronization for optimal performance.

📚 Vehicle History

Brand Heritage

Manufacturer:

Aprilia, an Italian manufacturer with a strong racing heritage in motorcycles.

Model Evolution

Pegaso Lineage:

The Pegaso line has evolved over the years, transitioning from earlier models to the 650cc platform, known for its versatility.

Production

Manufacturing Location:

Primarily Italy.

🏆 Awards & Recognition

Recognitions

Market Reputation:

Recognized for its robust engine and comfortable riding position for its class.