Segment:
Lightweight dual-sport/adventure touring motorcycle
Competitors:
BMW F650GS (single-cylinder), Kawasaki KLR650, Suzuki DR650SE, Honda XR650L
Engine Type:
Single-cylinder, liquid-cooled, fuel-injected Rotax engine.
Design Philosophy:
Versatile platform combining on-road comfort with light off-road capability, known for its torquey engine and accessible ergonomics.
Purpose:
To empower owners and technicians with the complete, official factory information needed for accurate maintenance, troubleshooting, and repair, ensuring the longevity and optimal performance of the Aprilia Pegaso 650 IE.
Primary Coverage:
Complete factory service and repair for Aprilia Pegaso 650 IE 2002
Estimated Pages:
Hundreds (specific count not provided, but described as 'complete' and 'hundreds of pages')
Type:
Factory Service Repair Manual
Language:
English (Assumed, standard for factory manuals of this era and market)
Engine System:
Detailed disassembly, assembly, inspection, and repair of the Rotax 655cc engine, including top-end, bottom-end, lubrication, cooling, and fuel injection systems.
Fuel System:
Comprehensive coverage of the electronic fuel injection (IE) system, including fuel pump, injectors, throttle body, sensors (MAP, TPS, IAT, Lambda), ECU diagnosis, and troubleshooting.
Transmission System:
Repair and maintenance of the gearbox, clutch, and related components, including lubrication and adjustment procedures.
Chassis Suspension:
Front fork (Marzocchi), rear shock absorber (Sachs), swingarm, bearings, and associated adjustments and service procedures.
Braking System:
Front and rear brake systems, including caliper overhaul, master cylinder service, bleeding procedures, pad replacement, and disc inspection.
Electrical System:
Wiring diagrams, component testing, battery, charging system (alternator, regulator/rectifier), starter motor, ignition system, lighting, and instrumentation.
Bodywork And Trim:
Panel removal and installation, fairings, seat, fuel tank, fenders, and associated hardware.
Diagnostic Procedures:
Troubleshooting guides for common electrical and mechanical issues, fault code interpretation (if applicable to the IE system).
Scheduled Maintenance:
Detailed maintenance schedules, including oil changes, filter replacements, chain adjustment, spark plug replacement, valve clearance checks, and more.
Disassembly Reassembly:
Step-by-step instructions for component removal, overhaul, and reinstallation with torque specifications.
Troubleshooting:
Systematic diagnostic procedures for identifying and rectifying common faults and performance issues.
Wiring Diagrams:
Comprehensive and detailed electrical schematics for all vehicle systems.
Depth:
Comprehensive. Covers everything from basic rider maintenance to complete engine rebuilds, electrical diagnostics, and suspension tuning.
File Type:
PDF (Portable Document Format)
Printability:
High quality, designed for printing individual pages or the entire manual.
Binding Recommendation:
Not applicable for PDF download, but implies professional binding if printed.
Paper Recommendation:
Not applicable for PDF download, but implies durable paper for workshop use.
Engine Type:
Single-cylinder, four-stroke, liquid-cooled, DOHC, 4 valves per cylinder
Displacement:
652 cc (approx.)
Bore X Stroke:
100 mm x 83 mm (typical for this Rotax variant)
Compression Ratio:
10.0:1 (typical)
Horsepower:
Approx. 48-50 hp @ 6,250 rpm (varies slightly by market/tuning)
Torque:
Approx. 6.2 kgf·m (61 Nm) @ 5,200 rpm (typical)
Fuel Delivery:
Electronic Fuel Injection (IE) with single throttle body and injectors
Fuel Type:
Unleaded gasoline, 95 RON recommended
Ignition Type:
Digital CDI with electronic advance
Oil Type:
API SG or higher, JASO MA certified motorcycle oil, SAE 10W-40 recommended
Coolant Type:
Ethylene glycol-based coolant with corrosion inhibitors, 50% concentration recommended
Gearbox Type:
5-speed constant mesh sequential gearbox
Clutch Type:
Wet, multi-plate, cable-operated
Final Drive:
O-ring sealed chain
Gear Ratios:
Specific ratios are detailed within the manual (e.g., 1st: 2.35, 2nd: 1.61, 3rd: 1.25, 4th: 1.04, 5th: 0.88)
Transmission Oil Type:
API GL-4 or GL-5 gear oil (specific viscosity grade provided in manual, e.g., 75W-90)
Width:
Approx. 840 mm (at handlebars)
Height:
Approx. 1370 mm (at windshield)
Wheelbase:
Approx. 1450 mm
Dry Weight:
Approx. 170 kg
Wet Weight:
Approx. 185 kg (fully fueled)
Payload Capacity:
Not explicitly stated, but typical for this class is ~180-200 kg.
Fuel Tank Capacity:
Approx. 15 liters (including 3-liter reserve)
Coolant Capacity:
Approx. 1.2 liters
Engine Oil Capacity:
Approx. 2.5 liters (with filter change)
Crash Test Ratings:
Motorcycles of this era are not subject to standardized crash test ratings like automobiles.
Braking System Type:
Dual disc front, single disc rear
Brake Component Manufacturer Front:
Brembo (typically)
Brake Disc Diameter Front:
Approx. 300 mm
Brake Caliper Type Front:
2-piston calipers (typically)
Brake Component Manufacturer Rear:
Brembo (typically)
Brake Disc Diameter Rear:
Approx. 220 mm
Tire Size Front:
90/90-21
Tire Size Rear:
130/80-17
Lighting:
Halogen headlamp, LED tail light
Instrumentation:
Analog tachometer, digital speedometer, odometer, trip meter, fuel gauge, warning lights.
Oil Change Interval:
Every 6,000 km or 12 months, whichever comes first
Air Filter Cleaning Interval:
Every 6,000 km, or more frequently in dusty conditions
Spark Plug Replacement Interval:
Every 12,000 km
Valve Clearance Check Interval:
Every 12,000 km
Chain Lubrication Interval:
Every 1,000 km, and after riding in rain or wet conditions
Coolant Replacement Interval:
Every 24,000 km or 24 months
Engine Oil Specification:
SAE 10W-40, API SG/SH/SJ or higher, JASO MA certified motorcycle oil
Fork Oil Type:
SAE 5W or 7.5W (specific grade and quantity provided in manual)
Common Wear Items:
Clutch plates, swingarm bearings, wheel bearings, stator/regulator rectifier (common on many bikes of this era).
Fuel Injection Quirks:
Occasional idle issues or hesitation if not maintained properly; sensor cleaning/testing is key.
Electrical Component Reliability:
While generally robust, specific attention to connections and grounds is advised, as is common for any older European motorcycle.
Manufacturer:
Aprilia is an Italian motorcycle manufacturer with a strong racing pedigree, founded in 1945.
Pegaso Lineage:
The Pegaso line began in the early 1990s with carbureted versions, evolving to the fuel-injected 'IE' models to meet emissions standards and improve performance. The 650cc engine platform, often based on Rotax designs, has been a cornerstone of Aprilia's single-cylinder offerings for adventure and dual-sport use.
Manufacturing Location:
Italy
Production Years For Model:
The Pegaso 650 IE was produced from the early 2000s, with the 2002 model being a key iteration.
