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APRILIA PEGASO 650 STRADA TRAIL Service Repair Manual 2002 Onward

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🏷️ Basic Information Identification Make: Aprilia Model: Pegaso 650 Strada / Trail Model Variants: Strada, Trail Model Years Covered: 2002 onward Codes Engine Code Family: Rotax 654 👋 Introduction Market Position Segment: Lightweight adventure/street motorcycle Target Audience: Riders seeking a versatile, manageable motorcycle for commuting, touring, and light off-road excursions (Trail model). Competitive Analysis Key Competitors: BMW F650GS (single cylinder variants), Kawasaki KLR650, Honda Transalp (though generally larger). Key Features Versatility: Dual character with Strada (street-focused) and Trail (off-road capable) variants. Engine Reliability: Proven Rotax engine known for its robustness and longevity. Handling: Agile and user-friendly handling characteristics. Manual Value Proposition Professional Grade: Provides the same depth of information used by certified Aprilia technicians. Diy Empowerment: Enables owners to perform a wide range of maintenance and repair tasks, saving time and money. 📋 Manual Details Coverage Areas Maintenance Coverage: Scheduled maintenance, routine servicing, inspections Repair Coverage: All major and minor repairs, diagnostics, component overhauls Troubleshooting Coverage: Systematic diagnostic procedures for common and rare issues Electrical System Coverage: Wiring diagrams, component testing, fault finding Body Chassis Coverage: Frame, fairings, suspension components, wheels, ergonomics Special Tools Coverage: Identification and usage of specialized tools required for repairs Page Count Estimated Page Count: Comprehensive (exact number not provided, typically 500+ pages for such manuals) Manual Type Type: Service Repair Workshop Manual Language Language: English (assumed, standard for most professional manuals) Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Cylinder head, valves, piston, crankshaft, lubrication system, cooling system, timing system, starter system Fuel System: Fuel injection system (EFI), fuel pump, injectors, throttle body, sensors, fuel tank, fuel lines Exhaust System: Exhaust manifold, catalytic converter, muffler, lambda sensor (O2 sensor) Transmission Drivetrain: Clutch operation and maintenance, gearbox internals, final drive (chain and sprockets) Braking System: Hydraulic system, brake calipers, master cylinders, brake discs, brake pads, ABS (if equipped) Suspension Steering: Front forks (telescopic), rear shock absorber, swingarm, steering head bearings, steering system Electrical System: Battery, alternator, starter motor, ignition system, lighting system (headlight, taillight, indicators), instrument cluster, wiring harness Body Frame: Chassis structure, fairings, seat, fuel tank mounting, fenders, handlebars, footpegs Procedures Included Engine Overhaul: Complete engine disassembly, inspection, repair, and reassembly procedures Transmission Repair: Gearbox inspection, gear replacement, clutch adjustment and replacement Suspension Servicing: Fork oil change, seal replacement, shock absorber servicing Brake System Maintenance: Brake fluid flush and replacement, pad and disc replacement, caliper service Electrical Diagnostics: Troubleshooting common electrical faults using wiring diagrams and test procedures Fuel System Cleaning: Injector cleaning, throttle body cleaning, fuel filter replacement Wheel Tire Service: Tire replacement, wheel balancing, spoke tensioning (for Trail model) Technical Depth Depth: Comprehensive: From basic maintenance and fluid changes to complete engine rebuilds and advanced electrical diagnostics. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable PDF, facilitating quick information retrieval. Print Quality Print Quality: High quality scans or digital creation, suitable for printing. Binding Type Binding Type: N/A (Digital PDF format) Paper Type Paper Type: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, four-stroke, liquid-cooled, DOHC Displacement: 652 cc (654 cc) Bore X Stroke: 100 mm x 83 mm (typical for this Rotax engine) Compression Ratio: 10.0:1 (typical) Valve Train: DOHC, 4 valves per cylinder Power Output Approx: Approximately 45-48 hp (33-36 kW) at 6,800 rpm Torque Output Approx: Approximately 5.2 - 5.5 kgm (51-54 Nm) at 5,200 rpm Performance Top Speed Approx: Around 160-170 km/h (100-106 mph) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline, minimum 95 RON Fuel Tank Capacity: Approximately 16.6 liters (4.4 US gal) Cooling System Cooling Type: Liquid-cooled Coolant Type: Ethylene glycol-based coolant (e.g., Motorex Coolant M3.0 or equivalent) Lubrication System Oil Type: API SG/SH/SJ or higher, JASO MA certified, SAE 10W-40 motorcycle oil Oil Capacity With Filter Change: Approximately 2.5 liters Oil Filter Part Number: Refer to manual for specific part numbers (e.g., HiFloFiltro HF152, K&N KN-152 or OEM equivalents) 🔧 Transmission Standard Transmission Type: 5-speed sequential manual gearbox Optional Optional Transmission: N/A Features Clutch Type: Wet, multi-plate, hydraulically operated Final Drive: O-ring sealed chain Transmission Oil Type: API GL-4 or GL-5, SAE 75W/90 or 80W/90 gear oil (refer to manual for specific recommendation) Transmission Oil Capacity: Approximately 0.9 liters 📐 Dimensions Exterior Length Approx: 2180 mm (Strada) / 2210 mm (Trail) - Subject to minor variations Width Approx: 800 mm (Strada) / 870 mm (Trail) - Subject to minor variations Height Approx: 1300 mm (Strada) / 1390 mm (Trail) - Subject to minor variations Seat Height Approx: 830 mm (Strada) / 850 mm (Trail) - Subject to minor variations Wheelbase Approx: 1465 mm (Strada) / 1475 mm (Trail) - Subject to minor variations Weights Dry Weight Approx: 170 kg (Strada) / 175 kg (Trail) - Subject to minor variations Gross Vehicle Weight Rating Gvwr Approx: 350 kg (Estimated) Curb Weight Approx: 185 kg...
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APRILIA PEGASO 650 STRADA TRAIL Service Repair Manual 2002 Onward
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
Pegaso 650 Strada / Trail
Model Variants:
Strada, Trail
Model Years Covered:
2002 onward
Codes
Engine Code Family:
Rotax 654
👋 Introduction
Market Position
Segment:
Lightweight adventure/street motorcycle
Target Audience:
Riders seeking a versatile, manageable motorcycle for commuting, touring, and light off-road excursions (Trail model).
Competitive Analysis
Key Competitors:
BMW F650GS (single cylinder variants), Kawasaki KLR650, Honda Transalp (though generally larger).
Key Features
Versatility:
Dual character with Strada (street-focused) and Trail (off-road capable) variants.
Engine Reliability:
Proven Rotax engine known for its robustness and longevity.
Handling:
Agile and user-friendly handling characteristics.
Manual Value Proposition
Professional Grade:
Provides the same depth of information used by certified Aprilia technicians.
Diy Empowerment:
Enables owners to perform a wide range of maintenance and repair tasks, saving time and money.
📋 Manual Details
Coverage Areas
Maintenance Coverage:
Scheduled maintenance, routine servicing, inspections
Repair Coverage:
All major and minor repairs, diagnostics, component overhauls
Troubleshooting Coverage:
Systematic diagnostic procedures for common and rare issues
Electrical System Coverage:
Wiring diagrams, component testing, fault finding
Body Chassis Coverage:
Frame, fairings, suspension components, wheels, ergonomics
Special Tools Coverage:
Identification and usage of specialized tools required for repairs
Page Count
Estimated Page Count:
Comprehensive (exact number not provided, typically 500+ pages for such manuals)
Manual Type
Type:
Service Repair Workshop Manual
Language
Language:
English (assumed, standard for most professional manuals)
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Cylinder head, valves, piston, crankshaft, lubrication system, cooling system, timing system, starter system
Fuel System:
Fuel injection system (EFI), fuel pump, injectors, throttle body, sensors, fuel tank, fuel lines
Exhaust System:
Exhaust manifold, catalytic converter, muffler, lambda sensor (O2 sensor)
Transmission Drivetrain:
Clutch operation and maintenance, gearbox internals, final drive (chain and sprockets)
Braking System:
Hydraulic system, brake calipers, master cylinders, brake discs, brake pads, ABS (if equipped)
Suspension Steering:
Front forks (telescopic), rear shock absorber, swingarm, steering head bearings, steering system
Electrical System:
Battery, alternator, starter motor, ignition system, lighting system (headlight, taillight, indicators), instrument cluster, wiring harness
Body Frame:
Chassis structure, fairings, seat, fuel tank mounting, fenders, handlebars, footpegs
Procedures Included
Engine Overhaul:
Complete engine disassembly, inspection, repair, and reassembly procedures
Transmission Repair:
Gearbox inspection, gear replacement, clutch adjustment and replacement
Suspension Servicing:
Fork oil change, seal replacement, shock absorber servicing
Brake System Maintenance:
Brake fluid flush and replacement, pad and disc replacement, caliper service
Electrical Diagnostics:
Troubleshooting common electrical faults using wiring diagrams and test procedures
Fuel System Cleaning:
Injector cleaning, throttle body cleaning, fuel filter replacement
Wheel Tire Service:
Tire replacement, wheel balancing, spoke tensioning (for Trail model)
Technical Depth
Depth:
Comprehensive: From basic maintenance and fluid changes to complete engine rebuilds and advanced electrical diagnostics.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable PDF, facilitating quick information retrieval.
Print Quality
Print Quality:
High quality scans or digital creation, suitable for printing.
Binding Type
Binding Type:
N/A (Digital PDF format)
Paper Type
Paper Type:
N/A (Digital PDF format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Single-cylinder, four-stroke, liquid-cooled, DOHC
Displacement:
652 cc (654 cc)
Bore X Stroke:
100 mm x 83 mm (typical for this Rotax engine)
Compression Ratio:
10.0:1 (typical)
Valve Train:
DOHC, 4 valves per cylinder
Power Output Approx:
Approximately 45-48 hp (33-36 kW) at 6,800 rpm
Torque Output Approx:
Approximately 5.2 - 5.5 kgm (51-54 Nm) at 5,200 rpm
Performance
Top Speed Approx:
Around 160-170 km/h (100-106 mph)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline, minimum 95 RON
Fuel Tank Capacity:
Approximately 16.6 liters (4.4 US gal)
Cooling System
Cooling Type:
Liquid-cooled
Coolant Type:
Ethylene glycol-based coolant (e.g., Motorex Coolant M3.0 or equivalent)
Lubrication System
Oil Type:
API SG/SH/SJ or higher, JASO MA certified, SAE 10W-40 motorcycle oil
Oil Capacity With Filter Change:
Approximately 2.5 liters
Oil Filter Part Number:
Refer to manual for specific part numbers (e.g., HiFloFiltro HF152, K&N KN-152 or OEM equivalents)
🔧 Transmission
Standard
Transmission Type:
5-speed sequential manual gearbox
Optional
Optional Transmission:
N/A
Features
Clutch Type:
Wet, multi-plate, hydraulically operated
Final Drive:
O-ring sealed chain
Transmission Oil Type:
API GL-4 or GL-5, SAE 75W/90 or 80W/90 gear oil (refer to manual for specific recommendation)
Transmission Oil Capacity:
Approximately 0.9 liters
📐 Dimensions
Exterior
Length Approx:
2180 mm (Strada) / 2210 mm (Trail) - Subject to minor variations
Width Approx:
800 mm (Strada) / 870 mm (Trail) - Subject to minor variations
Height Approx:
1300 mm (Strada) / 1390 mm (Trail) - Subject to minor variations
Seat Height Approx:
830 mm (Strada) / 850 mm (Trail) - Subject to minor variations
Wheelbase Approx:
1465 mm (Strada) / 1475 mm (Trail) - Subject to minor variations
Weights
Dry Weight Approx:
170 kg (Strada) / 175 kg (Trail) - Subject to minor variations
Gross Vehicle Weight Rating Gvwr Approx:
350 kg (Estimated)
Curb Weight Approx:
185 kg (Strada) / 190 kg (Trail) - Estimated with fluids
Payload Capacity Approx:
165 kg (Estimated)
Front Tire Size:
110/70-17 (Strada) / 90/90-21 (Trail)
Rear Tire Size:
130/70-17 (Strada) / 130/80-17 (Trail)
Wheel Bolt Pattern:
N/A (Spoked or Cast Wheels typical for this class)
Front Suspension Travel:
130 mm (Strada) / 200 mm (Trail)
Rear Suspension Travel:
135 mm (Strada) / 190 mm (Trail)
Ground Clearance:
170 mm (Strada) / 220 mm (Trail) - Approximate
🛡️ Safety Features
Ratings
Crash Safety Ratings:
Motorcycles are not typically rated by standardized agencies like NHTSA or Euro NCAP. Safety relies on rider skill and protective gear.
Active Features
Braking System:
Hydraulic disc brakes front and rear. ABS was an option on some models.
Lighting:
Halogen headlight, LED taillight and indicators (depending on specific year/model). Daytime running lights may be present.
Passive Features
Frame Construction:
Steel trellis frame offering good rigidity and rider protection.
Ergonomics:
Comfortable riding position designed for longer journeys and better control.
💡 Technology Features
Infotainment
Instrument Cluster:
Digital-analog combination display with tachometer, speedometer, odometer, trip meters, fuel gauge, and warning lights.
Driver Assistance
ABS Availability:
Optional ABS system available on some models, providing enhanced braking control.
Connectivity
Usb Charging Port:
Not typically factory fitted; aftermarket options exist.
Engine Management
ECU:
Electronic Control Unit (ECU) manages fuel injection and ignition timing.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 6,000 km or 12 months, whichever comes first. (Refer to manual for precise intervals).
Air Filter Check Interval:
Every 6,000 km or 12 months. Replacement as needed.
Spark Plug Replacement Interval:
Every 12,000 km or 24 months. (Refer to manual for specific plug type and gap).
Valve Clearance Check Interval:
Every 12,000 km or 24 months. (Requires specific feeler gauges and procedure).
Chain Lubrication And Adjustment:
Regularly, every 500-1000 km, and before long trips. Adjustment as needed based on slack.
Fluid Specifications
Brake Fluid:
DOT 4
Coolant:
Ethylene glycol-based, 50% mixture with distilled water (e.g., Motorex Coolant M3.0)
Known Issues
Common Wear Items:
Clutch plates, wheel bearings, steering head bearings, fork seals, chain and sprockets.
Electrical Gremlins:
Some owners report occasional issues with wiring connections or electrical components; diligent maintenance is key.
Fuel Pump Reliability:
Early models might have had fuel pump concerns; later revisions and proper fuel filtering mitigate this.
📚 Vehicle History
Brand Heritage
Manufacturer:
Aprilia is an Italian manufacturer with a strong heritage in motorcycle racing and performance bikes.
Model Evolution
Predecessors:
The Pegaso line has a history dating back to the early 1990s with earlier 650cc models.
Positioning:
The 650 Strada and Trail models were designed to offer a more accessible and versatile single-cylinder alternative in the adventure-touring segment.
Production
Manufacturing Location:
Primarily Italy
🏆 Awards & Recognition
Recognitions
Motorcycle Journal Reviews:
Consistently reviewed as a capable and versatile all-rounder, praised for its balance of performance and practicality.
Ratings
Reliability Reputation:
Generally good reliability due to the robust Rotax engine, with common maintenance addressing most wear items.
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