Aprilia Pegaso 650 Strada Trail 1997-2005 Factory Service Repair Manual Pdf

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🏷️ Basic Information Identification Make: Aprilia Model: Pegaso 650 Strada / Trail Generation Generation Designation: First Generation Codes Engine Code Primary: M502N (Rotax 654) 👋 Introduction Market Position Market Segment: Dual-sport motorcycle, bridging the gap between street and light off-road capability. Competitive Analysis Competitors: BMW F650GS, Yamaha XT660R, Suzuki DR650SE, Kawasaki KLR650. Key Features Versatility: Designed for both comfortable commuting and adventurous touring, handling various road surfaces. Engine Design: Single-cylinder, liquid-cooled Rotax engine known for its torquey character and reliability. Suspension Setup: Upside-down front forks and adjustable rear monoshock offer capable and compliant ride quality. 📋 Manual Details Coverage Areas Covered Model Years: 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005 Page Count Estimated Page Count: 500+ Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, including cylinder head, pistons, crankshaft, valves, camshafts, lubrication system, cooling system, fuel injection system (electronic), ignition system. Transmission: Clutch system, gearbox assembly, gear shifting mechanism, lubrication. Chassis And Suspension: Front forks (upside-down), rear shock absorber, swingarm, steering system, wheel bearings, spokes. Brakes: Front and rear hydraulic disc brakes, brake caliper maintenance, master cylinders, brake lines, ABS system (if equipped). Electrical System: Battery, charging system (alternator, regulator), starter motor, lighting system (headlight, taillight, indicators), instrumentation, wiring diagrams, fuses, relays, ECU, sensors. Fuel System: Fuel tank, fuel pump, fuel filter, fuel injection system components, throttle body, injectors. Exhaust System Exhaust: Exhaust pipes, muffler, catalytic converter (if fitted). Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, spark plug replacement, air filter cleaning/replacement, brake fluid flush, coolant replacement. Troubleshooting: Diagnostic charts for common problems, fault code interpretation (if applicable), step-by-step diagnosis for various systems. Repair And Rebuild: Detailed instructions for engine disassembly and reassembly, transmission overhaul, suspension component replacement, electrical component...

Type: Motorcycle

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Sku: 144480

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Tags: 1997 1998 1999 2000 2001 2002 2003 2004 2005 Aprilia Misc Motorcycle Motorcycles Pegaso 650 Strada Pegaso 650 Trail

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Description

🏷️ Basic Information

Identification

Make:

Aprilia

Model:

Pegaso 650 Strada / Trail

Generation

Generation Designation:

First Generation

Codes

Engine Code Primary:

M502N (Rotax 654)

👋 Introduction

Market Position

Market Segment:

Dual-sport motorcycle, bridging the gap between street and light off-road capability.

Competitive Analysis

Competitors:

BMW F650GS, Yamaha XT660R, Suzuki DR650SE, Kawasaki KLR650.

Key Features

Versatility:

Designed for both comfortable commuting and adventurous touring, handling various road surfaces.

Engine Design:

Single-cylinder, liquid-cooled Rotax engine known for its torquey character and reliability.

Suspension Setup:

Upside-down front forks and adjustable rear monoshock offer capable and compliant ride quality.

📋 Manual Details

Coverage Areas

Covered Model Years:

1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005

Page Count

Estimated Page Count:

Manual Type

Type:

Factory Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Complete engine overhaul, including cylinder head, pistons, crankshaft, valves, camshafts, lubrication system, cooling system, fuel injection system (electronic), ignition system.

Transmission:

Clutch system, gearbox assembly, gear shifting mechanism, lubrication.

Chassis And Suspension:

Front forks (upside-down), rear shock absorber, swingarm, steering system, wheel bearings, spokes.

Brakes:

Front and rear hydraulic disc brakes, brake caliper maintenance, master cylinders, brake lines, ABS system (if equipped).

Electrical System:

Battery, charging system (alternator, regulator), starter motor, lighting system (headlight, taillight, indicators), instrumentation, wiring diagrams, fuses, relays, ECU, sensors.

Fuel System:

Fuel tank, fuel pump, fuel filter, fuel injection system components, throttle body, injectors.

Exhaust System

Exhaust:

Exhaust pipes, muffler, catalytic converter (if fitted).

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain adjustment, spark plug replacement, air filter cleaning/replacement, brake fluid flush, coolant replacement.

Troubleshooting:

Diagnostic charts for common problems, fault code interpretation (if applicable), step-by-step diagnosis for various systems.

Repair And Rebuild:

Detailed instructions for engine disassembly and reassembly, transmission overhaul, suspension component replacement, electrical component repair.

Special Tools:

Identification and usage of specialized tools required for specific procedures.

Technical Depth

Depth:

Comprehensive, covering everything from basic checks to full engine and chassis rebuilds. Includes detailed torque specifications, clearances, and diagnostic procedures.

📊 Manual Specifications

File Format

File Quality:

High-resolution, searchable PDF

Printability:

Printable pages

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper Quality:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Type:

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

Displacement:

652 cc

Bore X Stroke:

100 mm x 83 mm

Compression Ratio:

10.0:1

Performance

Horsepower Approximate:

48 hp @ 6500 rpm

Torque Approximate:

60 Nm @ 5000 rpm

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) - Mikuni or Dell'Orto variants depending on year/market

Fuel Type:

Unleaded gasoline (95 RON recommended)

Ignition

Ignition System:

Digital electronic ignition with variable ignition timing

Lubrication

Oil Type Recommendation:

Semi-synthetic or fully synthetic 10W-40 motorcycle oil (e.g., API SG, JASO MA)

Cooling System

Coolant Type:

Ethylene glycol-based coolant with corrosion inhibitors (50% mix with distilled water)

🔧 Transmission

Standard

Transmission Type:

Constant mesh, 5-speed sequential manual gearbox

Optional

Optional Transmission:

Features

Clutch Type:

Wet multi-plate clutch, hydraulically operated

Final Drive:

O-ring sealed chain

Transmission Oil Type:

API GL-4 or GL-5, SAE 80W-90 gear oil

📐 Dimensions

Exterior

Length Approximate:

2150 mm

Width Approximate:

850 mm

Height Approximate:

1250 mm

Wheelbase Approximate:

1450 mm

Ground Clearance Approximate:

200 mm

Seat Height Approximate:

870 mm

Cargo

Fuel Tank Capacity:

14 liters (including 3-liter reserve)

Weights

Dry Weight Approximate:

180 kg

Wet Weight Approximate:

195 kg

🛡️ Safety Features

Ratings

Crash Safety Rating:

N/A (Motorcycle classification not typically rated by automotive bodies)

Active Features

Braking System:

Dual hydraulic disc brakes front, single hydraulic disc brake rear. ABS was an optional feature on some models.

Lighting:

Halogen headlight, LED taillight and indicators (depending on specific year/market).

Passive Features

Frame Construction:

Steel trellis frame for rigidity and safety.

Handguards:

Standard on many models to protect hands from elements and impacts.

💡 Technology Features

Infotainment

Infotainment System:

Basic analog instrumentation: speedometer, tachometer, odometer, trip meter, coolant temperature gauge, and warning lights.

Driver Assistance

ABS Availability:

Optional ABS system on select models and markets.

Connectivity

Connectivity Features:

None (This era of motorcycle predates widespread digital connectivity).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 km or annually, whichever comes first.

Oil Filter Replacement Interval:

With every oil change.

Air Filter Cleaning Interval:

Every 5,000 km; replacement as needed.

Spark Plug Replacement Interval:

Every 10,000 km (refer to manual for exact type and gap).

Chain Lubrication And Adjustment:

Lubricate every 1,000 km or after riding in wet conditions; adjust chain slack every 5,000 km or as needed.

Brake Fluid Flush Interval:

Every 2 years or as recommended by fluid manufacturer.

Coolant Replacement Interval:

Every 2-3 years or as per manual recommendation.

Fluid Specifications

Engine Oil Capacity:

2.2 liters (with filter change)

Transmission Oil Capacity:

0.75 liters

Coolant Capacity:

1.8 liters

Known Issues

Common Wear Items:

Clutch wear, rear shock absorber damping, wheel bearings, voltage regulator failure.

Fuel System Issues:

Potential for fuel pump or injector issues, often related to fuel quality or age.

Electrical System Quirks:

Occasional issues with the charging system (stator/regulator) and corrosion on electrical connectors.

📚 Vehicle History

Brand Heritage

Manufacturer:

Aprilia is an Italian motorcycle manufacturer with a strong racing heritage, founded in 1945.

Model Evolution

Model Introduction:

The Pegaso 650 line was introduced in the early 1990s, with the Strada and Trail variants becoming prominent in the late 1990s and early 2000s.

Strada Vs Trail:

The Strada featured lighter alloy wheels and street-biased tires, while the Trail typically came with spoked wheels and dual-purpose tires, offering slightly more off-road capability.

Production

Manufacturing Location:

Primarily Italy.

Engine Supplier:

Rotax (Bombardier Recreational Products)

🏆 Awards & Recognition

Recognitions

Motorcycle Awards:

While not a recipient of specific major awards, the Pegaso 650 was generally well-regarded for its versatility and European styling.

Ratings

User Reviews General Sentiment:

Praised for its comfortable riding position, strong mid-range torque, and ability to handle various conditions. Criticisms often related to maintenance costs compared to some Japanese competitors and occasional electrical gremlins.