APRILIA PEGASO 650 STRADA TRAIL Workshop Manual 2002 ONWARDS

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Type: Motorcycle

Vendor:

Sku: 131350

Tags: 2002 Aprilia Misc Motorcycle Motorcycles PEGASO 650 STRADA PEGASO 650 TRAIL

Product variants

Description

The Aprilia Pegaso 650, produced from 2002 onwards, is a versatile mid-size motorcycle offered in two distinct variants: the street-oriented Strada and the off-road capable Trail. Powered by a proven Rotax 654cc single-cylinder engine featuring electronic fuel injection, this Italian-designed machine is known for its torque, reliability, and aggressive styling. It appeals to riders seeking a capable and engaging motorcycle for both daily commuting and light adventure touring, blending performance with a unique European character. This comprehensive workshop service repair manual provides extensive coverage for the Aprilia Pegaso 650 Strada and Trail models. It details all mechanical and electrical systems, offering step-by-step procedures for routine maintenance, major repairs, and component installation. The manual includes essential technical specifications, torque values, fluid recommendations, and troubleshooting guides to assist owners, mechanics, and technicians in maintaining the optimal performance and longevity of their vehicle.

🏷️ Basic Information

Identification

Make:

Aprilia

Model:

Pegaso 650 Strada / Trail

Model Variant:

Strada (Street-oriented) / Trail (Off-road oriented)

Year:

2002 onwards

Codes

Engine Code Family:

Rotax 654 (e.g., 654N)

Chassis Code:

👋 Introduction

Market Position

Segment:

Mid-size dual-sport/adventure motorcycle

Target Audience:

Riders seeking versatility for both urban commuting and light off-road exploration

Competitive Analysis

Key Competitors:

BMW F650GS, Kawasaki KLR650, Suzuki V-Strom DL650 (though often compared to single-cylinder counterparts)

Key Features

Versatility:

Distinct Strada (road-biased) and Trail (off-road biased) variants cater to different rider preferences

Engine Platform:

Proven Rotax single-cylinder engine known for its torque and reliability

Design:

Aggressive styling, comfortable ergonomics for longer rides

Value Proposition:

Offers a blend of performance, versatility, and European design flair at a competitive price point

📋 Manual Details

Coverage Areas

Global Coverage:

Yes, covers all models and repairs A-Z

Repair Scope:

Mechanical and Electrical

Page Count

Estimated Pages:

Likely extensive, hundreds of pages (specific count not provided, but implied by A-Z coverage)

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English (implied by typical workshop manual language and product description)

Format

Format:

Digital (Printable)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, overhaul, valve train, piston/rings, crankshaft, camshafts, cooling system, lubrication system

Engine Electrical:

Ignition system, starting system, charging system, fuel injection system (EFI), sensors, ECU diagnostics

Transmission:

Clutch operation, gear shifting mechanism, gearbox internal components, maintenance and repair

Fuel System:

Fuel tank, fuel pump, fuel injectors, fuel pressure regulator, fuel lines, filters

Exhaust System:

Exhaust pipes, muffler, catalytic converter (if applicable), lambda sensors

Brakes:

Hydraulic system, brake fluid, master cylinder, brake calipers, brake pads, brake discs, ABS system (if equipped)

Suspension:

Front forks (USD telescopic for Strada, USD long-travel for Trail), rear shock absorber, linkages, swingarm, adjustments

Wheels Tires:

Wheel bearings, tire pressure recommendations, wheel removal/installation, spoke tension (Trail models)

Steering:

Handlebar, steering head bearings, steering lock, troubleshooting

Electrical System:

Wiring diagrams, battery, charging system, lighting, horn, instruments, fuses, relays

Bodywork Chassis:

Frame, fairings, body panels, seat, luggage systems, fasteners

Diagnostic Troubleshooting:

Fault codes, symptom-based troubleshooting guides

Procedures Included

Routine Maintenance:

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

Major Repairs:

Engine rebuild, transmission overhaul, fork seal replacement, shock absorber replacement, electrical component repair

Component Removal Installation:

Step-by-step guides for all major components

Troubleshooting Diagnostics:

Systematic identification and resolution of common and uncommon problems

Specifications Settings:

Torque values, clearances, fluid levels, pressure settings

Technical Depth

Depth:

Comprehensive from basic checks to full engine and gearbox rebuilds

Detail Level:

Detailed procedures with explanatory text and accompanying diagrams/pictures

Diagnostics Focus:

Emphasis on electrical diagnostics and EFI system troubleshooting

📊 Manual Specifications

File Format

File Type:

PDF (Printable)

Print Quality

Image Quality:

High-quality images and diagrams (as described)

Text Searchability:

Likely searchable text within the PDF for efficient information retrieval

Binding Type

Binding:

N/A (Digital format - buyer prints as needed)

Paper Type

Paper Recommendation:

Recommend durable paper for workshop use

⚙️ 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:

Approximately 10.0:1

Performance

Horsepower Peak:

~47 hp (35 kW) at 7000 rpm (approximate, may vary slightly)

Torque Peak:

~57 Nm (42 lb-ft) at 5200 rpm (approximate, may vary slightly)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) - Bosch Motronic or similar

Fuel Type:

Unleaded gasoline, minimum 95 RON

Lubrication System

Oil Type:

Synthetic motorcycle oil, SAE 10W-40 or 15W-50 (refer to manual for specific API/JASO ratings)

Oil Capacity:

~2.3 liters (with filter change)

Cooling System

Coolant Type:

Ethylene glycol based coolant (e.g., Motul Motocool Expert or equivalent)

Coolant Capacity:

~1.2 liters

🔧 Transmission

Standard

Type:

Constant mesh, 5-speed manual

Clutch Type:

Wet, multi-plate, cable-actuated

Optional

Optional Transmission:

N/A (Only manual offered)

Features

Final Drive:

O-ring sealed chain

Transmission Oil Type:

API GL-4 SAE 75W/90 synthetic gear oil (check manual for specific)

Transmission Oil Capacity:

~1.1 liters (check manual for exact)

📐 Dimensions

Exterior

Length:

Approx. 2170 mm (Strada) / 2220 mm (Trail)

Width:

Approx. 860 mm (Strada) / 880 mm (Trail)

Height:

Approx. 1370 mm (Strada) / 1400 mm (Trail)

Seat Height:

Approx. 870 mm (Strada) / 890 mm (Trail) - adjustable on some models

Ground Clearance:

Approx. 170 mm (Strada) / 220 mm (Trail)

Cargo

Luggage Capacity:

Provisions for Aprilia-branded panniers and top box (optional)

Weights

Dry Weight:

~170 kg (Strada) / ~177 kg (Trail)

Gross Vehicle Weight Rating:

Approx. 350 kg

Wheels Tires

Front Wheel Size:

19-inch (Strada) / 21-inch (Trail)

Rear Wheel Size:

17-inch (Strada) / 17-inch (Trail)

Front Tire Size:

e.g., 110/80-19 (Trail) / 110/70-17 (Strada)

Rear Tire Size:

e.g., 130/80-17 (Trail/Strada)

Wheel Bolt Pattern:

N/A (Spoked wheels common)

Fuel Capacity

Fuel Tank Capacity:

~16.5 liters

🛡️ Safety Features

Ratings

Crash Test Ratings:

Motorcycle safety is assessed differently; focus on component integrity and rider aids.

Active Features

Optional ABS available on some models/years

Braking System:

Dual front discs, single rear disc. Brembo or Grimeca components commonly used.

Passive Features

Lighting:

Halogen headlight, LED tail light (on later models), turn signals

Frame Construction:

Steel tubular double cradle frame

💡 Technology Features

Infotainment

Dashboard:

Analog tachometer, digital speedometer, odometer, trip meters, fuel gauge, coolant temperature gauge, warning lights

Driver Assistance

ABS Availability:

Optional, typically on later models or specific trims

Connectivity

Charging Port:

Optional accessory socket for charging devices (check for factory fitment)

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 6,000 km or annually (refer to manual for exact)

Oil Filter Change:

With every oil change

Air Filter Cleaning:

Every 12,000 km, replacement every 24,000 km or as needed

Spark Plug Replacement:

Every 12,000 km (e.g., NGK CR9EB or equivalent)

Chain Adjustment:

Every 6,000 km or as needed (15-25 mm slack)

Valve Clearance Check:

Every 12,000 km

Brake Fluid Flush:

Every 24,000 km or every two years

Coolant Flush:

Every 24,000 km or every two years

Fluid Specifications

Engine Oil Specification:

SAE 10W-40 or 15W-50, API SG or higher, JASO MA

Brake Fluid Specification:

DOT 4

Coolant Specification:

50/50 mix of ethylene glycol and distilled water

Known Issues

Common Complaints:

Stalling at low RPM (often EFI mapping related), premature fork seal wear, occasional electrical connector corrosion, clutch slave cylinder leaks

Maintenance Tips:

Regular chain maintenance and proper cleaning are crucial. Keep EFI connectors clean and dry. Monitor coolant levels closely.

📚 Vehicle History

Brand Heritage

Manufacturer:

Aprilia is an Italian manufacturer known for performance motorcycles and racing pedigree.

Model Evolution

First Generation:

The Pegaso line originated in the early 1990s, evolving significantly over its production run.

2002 Update:

The 2002 onwards models feature the fuel-injected Rotax engine, a significant upgrade from earlier carbureted versions. Introduction of distinct Strada and Trail versions.

Production

Manufacturing Location:

Italy

Production Period:

The Pegaso 650 was produced for many years, with the Rotax 654 engine platform in use from the early 2000s onwards.

🏆 Awards & Recognition

Recognitions

Industry Awards:

While specific awards for this model are not widely publicized, the Aprilia brand has a strong heritage in motorsport, contributing to its perceived quality and performance.

Ratings

Owner Satisfaction:

Generally positive, appreciated for its unique Italian character and versatility.

Certifications

Emissions Compliance:

Euro 2/3 compliant for models produced during relevant periods.