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APRILIA PEGASO 650 STRADE TRAIL Service Repair Manual 1997 Onward

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The Aprilia Pegaso 650 Strada and Trail models, produced from 1997 onward, represent a versatile offering in the dual-sport and adventure motorcycle segment. Powered by a robust Rotax 655 engine,...
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Type: Motorcycle
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Sku: 137881
APRILIA PEGASO 650 STRADE TRAIL Service Repair Manual 1997 Onward
The Aprilia Pegaso 650 Strada and Trail models, produced from 1997 onward, represent a versatile offering in the dual-sport and adventure motorcycle segment. Powered by a robust Rotax 655 engine, these bikes are celebrated for their Italian design and engineering, providing a capable platform for both urban commuting and light off-road exploration. The Pegaso line is known for its adaptable nature, with distinct Strada (street-focused) and Trail (off-road oriented) variants, both benefiting from the reliable single-cylinder configuration and a comfortable riding position. This comprehensive service repair workshop manual covers all Aprilia Pegaso 650 Strada and Trail variants from 1997 onwards. It provides detailed guidance on all major systems, including the powertrain, chassis, and electrical components, along with extensive maintenance procedures, diagnostic information, and repair instructions. With approximately 400-600 pages of content, this manual serves as an essential resource for owners, mechanics, and technicians, ensuring the proper upkeep, troubleshooting, and repair of the vehicle. It includes technical specifications, torque values, and detailed diagrams to facilitate accurate work.
🏷️ 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 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.
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