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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 Production Years: 2002 onwards Codes Engine Code Identifier: Typically Rotax V2 654cc Introduction Market Position Model Segment: Lightweight adventure touring/supermoto motorcycle, popular for its versatility and approachable nature. Competitive Analysis Key Competitors: BMW F650GS, Kawasaki KLR650, Suzuki DR650SE, KTM 640 Adventure/Duke. Key Features Distinctive Attributes: Single-cylinder Rotax engine, accessible seat height, balanced handling, available in both 'Strada' (road-biased) and 'Trail' (off-road capable) configurations, making it a practical all-rounder. Manual Details Coverage Areas Manual Scope: Comprehensive service, repair, and maintenance for Aprilia Pegaso 650 Strada and Trail models from 2002 onwards. Page Count Estimated Page Count: Approximately 400-600 pages (typical for this type of manual). Manual Type Manual Type: Factory-style Service Repair Workshop Manual Language Language: English (standard for this product) Format Format: PDF Manual Coverage Systems Covered Engine Systems: Engine mechanical (cylinder head, piston, crankshaft, valve train), fuel system (injection, carburetion depending on variant), ignition system, cooling system, lubrication system, exhaust system. Transmission Systems: Gearbox (internal components, ratios), clutch operation and adjustment, final drive (chain and sprocket inspection/replacement). Chassis Systems: Frame inspection and repair, suspension (front forks, rear shock absorber, linkages), steering system, braking system (front and rear calipers, master cylinders, hydraulic lines), wheel and tire specifications. Electrical Systems: Wiring diagrams, lighting system, battery, charging system (alternator, regulator/rectifier), starter motor, instrument cluster, electronic control unit (ECU) diagnostics and functions, sensor identification and testing. Procedures Included Routine Maintenance: Oil changes, filter replacements (oil, air, fuel), spark plug replacement, chain lubrication and adjustment, brake fluid replacement, coolant replacement, tire pressure checks. Repair Procedures: Engine disassembly and reassembly, carburetor/fuel injection system servicing, clutch replacement, gearbox overhaul, suspension fork seal replacement, brake caliper overhaul, electrical component testing and replacement. Troubleshooting: Diagnosis of common performance issues, starting problems, electrical faults, braking system irregularities, with flowcharts and symptom-based guidance. Technical Depth Diagnostic Capabilities: Detailed diagnostic procedures, including fault code interpretation (if applicable via diagnostic tool), sensor testing, component resistance/voltage checks. Rebuild Instructions: Comprehensive instructions for engine and transmission rebuilds, including torque specifications, clearances, and assembly sequences. Manual Specifications File Format File Format: Searchable PDF (typically) Print Quality Print Quality: High-resolution, allowing for clear viewing and printing of diagrams and text. Binding Type Binding Type: Not applicable (digital PDF format). Paper Type Paper Type: Not applicable (digital PDF format). Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder, liquid-cooled, DOHC. Engine Displacement: 652 cc (or 654 cc depending on exact specification). Bore X Stroke: Approximately 100 mm x 83 mm. Compression Ratio: Typically around 10.0:1 to 11.0:1. Engine Cooling: Liquid-cooled. Valve Train: Double Overhead Camshafts (DOHC), 4 valves per cylinder. Performance Horsepower: Approximately 48-50 hp at 6,500-7,000 RPM. Torque: Approximately 5.7-6.0 kgf-m (56-59 Nm) at 5,000-5,500 RPM. Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) for later models, potentially carbureted on very early variants. Specifics depend on regional variants. Fuel Type: Unleaded gasoline (min 95 RON recommended). Fuel Tank Capacity: Approximately 16.6 liters (3.66 Imp Gal). Transmission Standard Transmission Type: 5-speed manual sequential gearbox. Optional Optional Transmission: Not applicable (manual transmission only). Features Clutch Type: Wet multi-plate clutch, cable operated. Final Drive: Chain drive. Gear Ratios Primary: Manual requires consulting specific gear ratios for detailed analysis, but generally designed for balanced street and touring performance. Dimensions Exterior Length: Approximately 2180 mm (Strada) / 2215 mm (Trail). Width: Approximately 830 mm (Strada) / 830 mm (Trail). Height: Approximately 1350 mm (Strada) / 1410 mm (Trail). Seat Height: Approximately 820 mm (Strada) / 845 mm (Trail), adjustable on some models. Wheelbase: Approximately 1475 mm. Front Suspension Travel: Approximately 150-170 mm (Strada) / 180-200 mm (Trail). Rear Suspension Travel: Approximately 150-170 mm. Front Tire Size: 110/70-17 (Strada) / 90/90-21 (Trail). Rear Tire Size: 140/70-17 (Strada) / 130/80-17 (Trail). Wheel Bolt Pattern: Not applicable to motorcycles (hub mounting). Weights Dry Weight: Approximately 175 kg (Strada) / 185 kg (Trail). Gross Vehicle Weight Rating: Approximately 385 kg. Safety Features Ratings Safety Certifications: CE conformity. Active Features Braking System Front: Single 300mm disc with hydraulic caliper (often dual piston). ABS optional on some later models. Braking System Rear: Single 220mm disc with hydraulic caliper (often single piston). ABS optional on some later models. ABS: Optional on some models, typically Bosch ABS. Passive Features Lighting: Halogen headlight, LED taillight, turn signals. Chassis Design: Steel-trellis frame for rigidity and handling. Technology Features Infotainment Instrument Cluster: Analog tachometer, digital speedometer, odometer, trip meter, fuel gauge, engine temperature warning light, neutral indicator, turn signal indicators. Driver Assistance ABS Availability: Optional on certain model years and trims. Connectivity Diagnostic Port: Typically present for ECU diagnostics, requiring a proprietary or common motorcycle diagnostic tool. Maintenance Service Intervals Oil Change Interval: Every 5,000 - 7,500 km (3,000 - 4,500 miles) or annually. Air Filter Replacement: Every 10,000 - 15,000 km (6,000 - 9,000 miles) or as needed based on operating...
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APRILIA PEGASO 650 STRADA TRAIL Service Repair Manual 2002 ONWARD
Basic Information
Identification
Make: Aprilia
Model: Pegaso 650 Strada / Trail
Production Years: 2002 onwards
Codes
Engine Code Identifier: Typically Rotax V2 654cc
Introduction
Market Position
Model Segment: Lightweight adventure touring/supermoto motorcycle, popular for its versatility and approachable nature.
Competitive Analysis
Key Competitors: BMW F650GS, Kawasaki KLR650, Suzuki DR650SE, KTM 640 Adventure/Duke.
Key Features
Distinctive Attributes: Single-cylinder Rotax engine, accessible seat height, balanced handling, available in both 'Strada' (road-biased) and 'Trail' (off-road capable) configurations, making it a practical all-rounder.
Manual Details
Coverage Areas
Manual Scope: Comprehensive service, repair, and maintenance for Aprilia Pegaso 650 Strada and Trail models from 2002 onwards.
Page Count
Estimated Page Count: Approximately 400-600 pages (typical for this type of manual).
Manual Type
Manual Type: Factory-style Service Repair Workshop Manual
Language
Language: English (standard for this product)
Format
Format: PDF
Manual Coverage
Systems Covered
Engine Systems: Engine mechanical (cylinder head, piston, crankshaft, valve train), fuel system (injection, carburetion depending on variant), ignition system, cooling system, lubrication system, exhaust system.
Transmission Systems: Gearbox (internal components, ratios), clutch operation and adjustment, final drive (chain and sprocket inspection/replacement).
Chassis Systems: Frame inspection and repair, suspension (front forks, rear shock absorber, linkages), steering system, braking system (front and rear calipers, master cylinders, hydraulic lines), wheel and tire specifications.
Electrical Systems: Wiring diagrams, lighting system, battery, charging system (alternator, regulator/rectifier), starter motor, instrument cluster, electronic control unit (ECU) diagnostics and functions, sensor identification and testing.
Procedures Included
Routine Maintenance: Oil changes, filter replacements (oil, air, fuel), spark plug replacement, chain lubrication and adjustment, brake fluid replacement, coolant replacement, tire pressure checks.
Repair Procedures: Engine disassembly and reassembly, carburetor/fuel injection system servicing, clutch replacement, gearbox overhaul, suspension fork seal replacement, brake caliper overhaul, electrical component testing and replacement.
Troubleshooting: Diagnosis of common performance issues, starting problems, electrical faults, braking system irregularities, with flowcharts and symptom-based guidance.
Technical Depth
Diagnostic Capabilities: Detailed diagnostic procedures, including fault code interpretation (if applicable via diagnostic tool), sensor testing, component resistance/voltage checks.
Rebuild Instructions: Comprehensive instructions for engine and transmission rebuilds, including torque specifications, clearances, and assembly sequences.
Manual Specifications
File Format
File Format: Searchable PDF (typically)
Print Quality
Print Quality: High-resolution, allowing for clear viewing and printing of diagrams and text.
Binding Type
Binding Type: Not applicable (digital PDF format).
Paper Type
Paper Type: Not applicable (digital PDF format).
Engine Specifications
Primary Engine
Engine Type: Four-stroke, single-cylinder, liquid-cooled, DOHC.
Engine Displacement: 652 cc (or 654 cc depending on exact specification).
Bore X Stroke: Approximately 100 mm x 83 mm.
Compression Ratio: Typically around 10.0:1 to 11.0:1.
Engine Cooling: Liquid-cooled.
Valve Train: Double Overhead Camshafts (DOHC), 4 valves per cylinder.
Performance
Horsepower: Approximately 48-50 hp at 6,500-7,000 RPM.
Torque: Approximately 5.7-6.0 kgf-m (56-59 Nm) at 5,000-5,500 RPM.
Fuel System
Fuel Delivery: Electronic Fuel Injection (EFI) for later models, potentially carbureted on very early variants. Specifics depend on regional variants.
Fuel Type: Unleaded gasoline (min 95 RON recommended).
Fuel Tank Capacity: Approximately 16.6 liters (3.66 Imp Gal).
Transmission
Standard
Transmission Type: 5-speed manual sequential gearbox.
Optional
Optional Transmission: Not applicable (manual transmission only).
Features
Clutch Type: Wet multi-plate clutch, cable operated.
Final Drive: Chain drive.
Gear Ratios Primary: Manual requires consulting specific gear ratios for detailed analysis, but generally designed for balanced street and touring performance.
Dimensions
Exterior
Length: Approximately 2180 mm (Strada) / 2215 mm (Trail).
Width: Approximately 830 mm (Strada) / 830 mm (Trail).
Height: Approximately 1350 mm (Strada) / 1410 mm (Trail).
Seat Height: Approximately 820 mm (Strada) / 845 mm (Trail), adjustable on some models.
Wheelbase: Approximately 1475 mm.
Front Suspension Travel: Approximately 150-170 mm (Strada) / 180-200 mm (Trail).
Rear Suspension Travel: Approximately 150-170 mm.
Front Tire Size: 110/70-17 (Strada) / 90/90-21 (Trail).
Rear Tire Size: 140/70-17 (Strada) / 130/80-17 (Trail).
Wheel Bolt Pattern: Not applicable to motorcycles (hub mounting).
Weights
Dry Weight: Approximately 175 kg (Strada) / 185 kg (Trail).
Gross Vehicle Weight Rating: Approximately 385 kg.
Safety Features
Ratings
Safety Certifications: CE conformity.
Active Features
Braking System Front: Single 300mm disc with hydraulic caliper (often dual piston). ABS optional on some later models.
Braking System Rear: Single 220mm disc with hydraulic caliper (often single piston). ABS optional on some later models.
ABS: Optional on some models, typically Bosch ABS.
Passive Features
Lighting: Halogen headlight, LED taillight, turn signals.
Chassis Design: Steel-trellis frame for rigidity and handling.
Technology Features
Infotainment
Instrument Cluster: Analog tachometer, digital speedometer, odometer, trip meter, fuel gauge, engine temperature warning light, neutral indicator, turn signal indicators.
Driver Assistance
ABS Availability: Optional on certain model years and trims.
Connectivity
Diagnostic Port: Typically present for ECU diagnostics, requiring a proprietary or common motorcycle diagnostic tool.
Maintenance
Service Intervals
Oil Change Interval: Every 5,000 - 7,500 km (3,000 - 4,500 miles) or annually.
Air Filter Replacement: Every 10,000 - 15,000 km (6,000 - 9,000 miles) or as needed based on operating conditions.
Spark Plug Replacement: Every 10,000 - 12,000 km (6,000 - 7,500 miles).
Chain Maintenance: Lubricate and adjust every 1,000 km (600 miles) and inspect for wear regularly.
Valve Clearance Check: Every 10,000 - 20,000 km (6,000 - 12,000 miles) or as specified in the manual, depending on wear.
Fluid Specifications
Engine Oil Type: SAE 10W-40 or 15W-50, API SG/SH or higher, JASO MA compliant synthetic or semi-synthetic motorcycle oil.
Engine Oil Capacity: Approximately 2.0 - 2.4 liters (depending on filter change).
Coolant Type: Ethylene glycol based coolant, suitable for aluminum engines, mixed 50/50 with distilled water.
Brake Fluid Type: DOT 4 hydraulic brake fluid.
Fork Oil Type: SAE 5W or 10W fork oil (refer to manual for exact specification).
Final Drive Oil: Typically a standard SAE 80W-90 hypoid gear oil for the chain lubricant bath, though some models might have separate swingarm lubrication points. The manual will specify if a separate gear oil is needed for a shaft drive (not applicable here).
Known Issues
Common Wear Items: Clutch plates, rear shock absorber seals, fork seals, exhaust system (corrosion), fuel pump (on EFI models).
Electrical Gremlins: Occasionally reported, often related to rectifier/regulator or wiring connections due to vibration or environmental exposure.
Idle Stability: Can sometimes require ECU reset or throttle body cleaning on EFI models.
Vehicle History
Brand Heritage
Aprilia History: Aprilia is an Italian motorcycle manufacturer founded in 1945, known for its sport bikes, scooters, and historically for its involvement in Grand Prix racing.
Model Evolution
Pegaso Lineage: The Pegaso line has a history stretching back to the early 1990s with earlier models featuring single-cylinder engines. The 650cc generation evolved to incorporate modern technologies like fuel injection.
Strada Vs Trail: The Strada variant typically features cast alloy wheels and road-biased tires, while the Trail variant usually comes with spoked wheels, dual-purpose tires, and potentially higher-mounted front mudguards for light off-road use.
Production
Manufacturing Location: Primarily Italy.
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