APRILIA PEGASO 650 STRADE TRAIL Service Repair Manual 1997 Onward
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🏷️ Basic Information Identification Make: Aprilia Model: Pegaso 650 Strada / Trail Codes Engine Code General: Rotax 655 (or similar derived Rotax unit) Generation Production Period: 1997 Onward 👋 Introduction Market Position Segment: Dual-sport / Adventure motorcycle segment, offering versatility for both on-road commuting and light off-road excursions. Competitive Analysis Key Competitors: BMW F650GS, Kawasaki KLR650, Suzuki DR650, Yamaha XT600/XT660 Key Features Unique Selling Points: Italian design and engineering, robust Rotax single-cylinder engine, adaptable for Strada (street) and Trail (off-road) configurations. 📋 Manual Details Coverage Areas Covered Models: All Aprilia Pegaso 650 Strada and Trail variants from 1997 onwards Page Count Estimated Page Count: Approximately 400-600 pages (typical for comprehensive workshop manuals) Manual Type Type: Service Repair Workshop Manual Language Language: English (presumed, standard for international manuals) Format Format: PDF 📖 Manual Coverage Systems Covered Powertrain: Engine, transmission, clutch, final drive (chain) Chassis: Frame, suspension (front forks, rear monoshock), steering, wheels, tires, braking system (front and rear disc brakes) Electrical: Ignition system, starting system, charging system (alternator, regulator/rectifier), lighting, instrumentation, wiring diagrams, ECU (Engine Control Unit) diagnostics Bodywork And Trim: Fairings, body panels, seat, fuel tank, fenders, exhaust system Procedures Included Maintenance: Oil changes, filter replacements, chain adjustment, brake fluid flush, coolant replacement, spark plug service, air filter cleaning/replacement Diagnostics And Troubleshooting: Fault finding procedures, diagnostic trouble codes (DTCs) if applicable, component testing Repair And Overhaul: Engine rebuilds (top-end and bottom-end), gearbox disassembly/assembly, suspension overhaul, brake caliper servicing, carburetor/fuel injection system service Technical Specifications: Torque values, clearances, fluid capacities, electrical resistance, pressure specifications Technical Depth Depth: Comprehensive, covering routine maintenance to complete engine and component overhauls. Suitable for professional technicians and advanced DIY mechanics. 📊 Manual Specifications File Format Searchability: Searchable text (typical for high-quality PDFs) Print Quality Image Resolution: High-resolution images and diagrams for clarity Binding Type Digital Format: Not applicable (PDF) Paper Type Digital Format: Not applicable (PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, four-stroke, single-cylinder, DOHC Displacement: 652 cc (approx.) Bore X Stroke: Typically around 100 mm x 83 mm (subject to specific Rotax variant) Compression Ratio: Around 10:1 (typical for this engine configuration) Performance Horsepower: Approx. 48-50 HP @ 6500-7000 RPM (varies slightly by model year and tuning) Torque: Approx. 57-60 Nm @ 5000-5500 RPM (varies slightly by model year and tuning) Fuel System Fuel Delivery: Carburetor (e.g., Mikuni BST40) or Electronic Fuel Injection (EFI) depending on model year and specific variant. Fuel Type: Unleaded gasoline (95 RON recommended) Lubrication Oil Type: SAE 10W-40, API SG or higher, JASO MA certified motorcycle oil Oil Capacity With Filter Change: Approx. 2.5 - 2.8 Liters (refer to manual for exact specification) Cooling System Coolant Type: Ethylene glycol based coolant, mixed 50/50 with distilled water Coolant Capacity: Approx. 1.5 - 1.8 Liters (refer to manual for exact specification) 🔧 Transmission Standard Transmission Type: 5-speed manual transmission Optional Transmission Options: Not applicable Features Clutch Type: Wet multi-plate clutch, cable operated Final Drive: Chain drive (RK 520, 104 links typically) Gear Ratios Primary Reduction: Approx. 2.235:1 (23/10T) 1St Gear: Approx. 2.769:1 (36/13T) 2Nd Gear: Approx. 1.941:1 (33/17T) 3Rd Gear: Approx. 1.400:1 (28/20T) 4Th Gear: Approx. 1.130:1 (26/23T) 5Th Gear: Approx. 0.916:1 (22/24T) Final Drive Ratio: Typically 2.846:1 (37/13T) 📐 Dimensions Exterior Length: Approx. 2170 mm (Trail version, may vary) Width: Approx. 850 mm (at handlebars, may vary) Height: Approx. 1380 mm (at windscreen, may vary) Wheelbase: Approx. 1480 mm Ground Clearance: Approx. 190-200 mm (Trail version) Weights Dry Weight: Approx. 180-190 kg (varies by model and equipment) Wet Weight: Approx. 200-210 kg (with fluids) Maximum Load: Approx. 180-200 kg (rider + luggage) Capacities Fuel Tank Capacity: Approx. 15.5 - 17 Liters (varies slightly by model) 🛡️ Safety Features Ratings Crash Test Results: Not applicable for motorcycles in the same manner as cars; emphasis on structural integrity and rider protection features. Active Features Braking System: Dual front disc brakes (e.g., 300-320 mm), single rear disc brake (e.g., 220-240 mm). ABS was optional on some later models. Lighting: Halogen headlight, LED taillight and indicators on some variants Passive Features Frame Construction: Steel trellis or semi-double cradle frame for rigidity and impact absorption. Rider Protection: Ergonomic riding position, handguards (standard on Trail models), sturdy bodywork. 💡 Technology Features Infotainment Instrument Cluster: Analog speedometer, tachometer, LCD display for odometer, trip meter, fuel gauge, and indicator lights. Driver Assistance ABS Availability: Optional ABS on later models (typically from mid-2000s onwards), enhancing braking safety. Connectivity Charging Port: 12V auxiliary power outlet may be fitted on some models for charging devices. 🔧 Maintenance Service Intervals Engine Oil And Filter Change: Every 6,000 km or 6 months, whichever comes first. Air Filter Cleaning: Every 6,000 km (or more frequently in dusty conditions). Spark Plug Replacement: Every 12,000 km. Valve Clearance Check: Every 12,000 km. Chain Lubrication And Adjustment: Every 1,000 km and after washing or riding in...
Comprehensive, covering routine maintenance to complete engine and component overhauls. Suitable for professional technicians and advanced DIY mechanics.
📊 Manual Specifications
File Format
Searchability:
Searchable text (typical for high-quality PDFs)
Print Quality
Image Resolution:
High-resolution images and diagrams for clarity
Binding Type
Digital Format:
Not applicable (PDF)
Paper Type
Digital Format:
Not applicable (PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, four-stroke, single-cylinder, DOHC
Displacement:
652 cc (approx.)
Bore X Stroke:
Typically around 100 mm x 83 mm (subject to specific Rotax variant)
Compression Ratio:
Around 10:1 (typical for this engine configuration)
Performance
Horsepower:
Approx. 48-50 HP @ 6500-7000 RPM (varies slightly by model year and tuning)
Torque:
Approx. 57-60 Nm @ 5000-5500 RPM (varies slightly by model year and tuning)
Fuel System
Fuel Delivery:
Carburetor (e.g., Mikuni BST40) or Electronic Fuel Injection (EFI) depending on model year and specific variant.
Fuel Type:
Unleaded gasoline (95 RON recommended)
Lubrication
Oil Type:
SAE 10W-40, API SG or higher, JASO MA certified motorcycle oil
Oil Capacity With Filter Change:
Approx. 2.5 - 2.8 Liters (refer to manual for exact specification)
Cooling System
Coolant Type:
Ethylene glycol based coolant, mixed 50/50 with distilled water
Coolant Capacity:
Approx. 1.5 - 1.8 Liters (refer to manual for exact specification)
🔧 Transmission
Standard
Transmission Type:
5-speed manual transmission
Optional
Transmission Options:
Not applicable
Features
Clutch Type:
Wet multi-plate clutch, cable operated
Final Drive:
Chain drive (RK 520, 104 links typically)
Gear Ratios
Primary Reduction:
Approx. 2.235:1 (23/10T)
1St Gear:
Approx. 2.769:1 (36/13T)
2Nd Gear:
Approx. 1.941:1 (33/17T)
3Rd Gear:
Approx. 1.400:1 (28/20T)
4Th Gear:
Approx. 1.130:1 (26/23T)
5Th Gear:
Approx. 0.916:1 (22/24T)
Final Drive Ratio:
Typically 2.846:1 (37/13T)
📐 Dimensions
Exterior
Length:
Approx. 2170 mm (Trail version, may vary)
Width:
Approx. 850 mm (at handlebars, may vary)
Height:
Approx. 1380 mm (at windscreen, may vary)
Wheelbase:
Approx. 1480 mm
Ground Clearance:
Approx. 190-200 mm (Trail version)
Weights
Dry Weight:
Approx. 180-190 kg (varies by model and equipment)
Wet Weight:
Approx. 200-210 kg (with fluids)
Maximum Load:
Approx. 180-200 kg (rider + luggage)
Capacities
Fuel Tank Capacity:
Approx. 15.5 - 17 Liters (varies slightly by model)
🛡️ Safety Features
Ratings
Crash Test Results:
Not applicable for motorcycles in the same manner as cars; emphasis on structural integrity and rider protection features.
Active Features
Braking System:
Dual front disc brakes (e.g., 300-320 mm), single rear disc brake (e.g., 220-240 mm). ABS was optional on some later models.
Lighting:
Halogen headlight, LED taillight and indicators on some variants
Passive Features
Frame Construction:
Steel trellis or semi-double cradle frame for rigidity and impact absorption.
Rider Protection:
Ergonomic riding position, handguards (standard on Trail models), sturdy bodywork.
💡 Technology Features
Infotainment
Instrument Cluster:
Analog speedometer, tachometer, LCD display for odometer, trip meter, fuel gauge, and indicator lights.
Driver Assistance
ABS Availability:
Optional ABS on later models (typically from mid-2000s onwards), enhancing braking safety.
Connectivity
Charging Port:
12V auxiliary power outlet may be fitted on some models for charging devices.
🔧 Maintenance
Service Intervals
Engine Oil And Filter Change:
Every 6,000 km or 6 months, whichever comes first.
Air Filter Cleaning:
Every 6,000 km (or more frequently in dusty conditions).
Spark Plug Replacement:
Every 12,000 km.
Valve Clearance Check:
Every 12,000 km.
Chain Lubrication And Adjustment:
Every 1,000 km and after washing or riding in rain.
Brake Fluid Change:
Every 24 months.
Fluid Specifications
Engine Oil Specification:
SAE 10W-40, API SG/SH/SJ/SL, JASO MA
Coolant Specification:
50/50 mix of ethylene glycol and distilled water (e.g., Motul Motocool Expert)
Brake Fluid Specification:
DOT 4
Fork Oil Specification:
SAE 10W (approx. 450-500 ml per fork leg, refer to manual for exact quantity and level)
Known Issues
Common Wear Items:
Clutch plates, front fork seals, regulator/rectifier (in some batches), chain and sprockets.
Fueling System Considerations:
Carburetor models may require periodic cleaning and adjustment. EFI models require proper diagnostic tools for advanced troubleshooting.
Electrical System Notes:
Wiring harness connections should be checked for corrosion, especially in models used in wet conditions.
📚 Vehicle History
Brand Heritage
Manufacturer:
Aprilia is an Italian manufacturer renowned for its performance motorcycles, particularly in racing and sportbike categories.
Model Evolution
Pegaso Lineage:
The Pegaso name has been used by Aprilia for various dual-purpose motorcycles, with the 650 single-cylinder platform being a significant iteration introduced in the early 1990s and continuously updated.
Production
Manufacturing Location:
Italy (primary)
🏆 Awards & Recognition
Recognitions
Market Reputation:
Recognized for its versatility and robust single-cylinder engine, offering good value in the middleweight adventure bike category.