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Aprilia Pegaso 650 Strada Trail Service Repair Manual

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The Aprilia Pegaso 650, available in Strada and Trail variants, represents a versatile and capable lightweight adventure-styled motorcycle. Produced approximately from 2000 to 2008, this model is powered by a...
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Type: Motorcycle
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Sku: 142404
Aprilia Pegaso 650 Strada Trail Service Repair Manual
The Aprilia Pegaso 650, available in Strada and Trail variants, represents a versatile and capable lightweight adventure-styled motorcycle. Produced approximately from 2000 to 2008, this model is powered by a robust 652cc single-cylinder, four-stroke engine, originally designed by Rotax, known for its reliability and suitability for both on-road commuting and light off-road exploration. Its comfortable ergonomics and dual-purpose capability made it a competitive offering in its segment, often compared to models from BMW, Kawasaki, Honda, and Suzuki. This comprehensive factory service and repair manual in English provides detailed information for the maintenance and repair of your Aprilia Pegaso 650. It covers essential areas including engine mechanicals, fuel and ignition systems, transmission, chassis, suspension, braking, and electrical systems. You will find step-by-step instructions for scheduled maintenance, detailed troubleshooting guides for common issues, and repair procedures with necessary specifications, ensuring the optimal performance and longevity of your vehicle.
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
Pegaso 650
Model Variants:
Strada, Trail
Codes
Chassis Code Range:
AP8100000 onwards
👋 Introduction
Market Position
Segment:
Lightweight adventure-styled motorcycle, dual-purpose capability.
Competitive Analysis
Competitors:
BMW F650GS, Kawasaki KLR650, Honda Transalp, Suzuki V-Strom 650 (contemporary models).
Key Features
Versatility:
Designed for both on-road commuting and light off-road exploration, comfortable ergonomics.
Engine Platform:
Robust and reliable Rotax-designed single-cylinder engine.
📋 Manual Details
Coverage Areas
Manual Type:
Factory Service and Repair Manual
Language:
English
Format:
Digital (PDF)
Page Count
Page Count:
Estimated 400+ pages (typical for comprehensive factory manuals)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete overhaul procedures, cylinder head, valve train, pistons, connecting rods, crankshaft, lubrication system, cooling system, fuel system (carburetor/injection specifics).
Engine Management:
Ignition system, fuel injection system (if applicable), ECU diagnostics, sensor testing, troubleshooting ignition and fuel delivery issues.
Transmission Drivetrain:
Clutch assembly, gearbox disassembly and reassembly, gear selection mechanism, final drive (chain and sprockets), bearing checks.
Chassis Suspension:
Front fork (Öhlins or Marzocchi variants), rear shock absorber (WP or Sachs variants), swingarm, linkage system (if applicable), wheel bearing replacement, steering head bearing maintenance.
Braking System:
Brake caliper overhaul, master cylinder replacement, brake line routing and bleeding, disc inspection and replacement, ABS system components and troubleshooting (if equipped).
Electrical System:
Wiring diagrams, starter motor, alternator, battery, lighting system (headlight, taillight, indicators), horn, instrument panel, fuse box, relay functions, ECU connectors.
Bodywork Trim:
Fairing removal and installation, seat removal, fuel tank removal, fender replacement, graphics, plastics, seat upholstery.
Procedures Included
Scheduled Maintenance:
Oil and filter changes, air filter replacement, spark plug replacement, valve clearance adjustment, chain adjustment and lubrication, brake pad inspection.
Troubleshooting:
Diagnostic flowcharts for common issues (starting problems, running issues, electrical faults), fault code interpretation.
Repair Rebuild:
Step-by-step instructions for component disassembly, cleaning, inspection, repair, and reassembly with torque specifications.
Diagnostics:
Testing procedures for electrical components, sensors, actuators, and mechanical systems.
Technical Depth
Depth Level:
Comprehensive factory-level detail, suitable for professional technicians and experienced DIY mechanics.
📊 Manual Specifications
File Format
Digital Format:
PDF
Searchability:
Text-searchable PDF for quick information retrieval.
Printability:
Printable pages for workshop use.
Print Quality
Image Resolution:
High-resolution diagrams, schematics, and photographic illustrations.
Binding Type
Binding:
N/A (Digital)
Paper Type
Paper Quality:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Single-cylinder, four-stroke
Displacement:
652 cc
Bore X Stroke:
100 mm x 83 mm
Compression Ratio:
10.0:1
Valve Train:
DOHC, 4 valves per cylinder
Performance
Horsepower Peak:
Approx. 48-50 hp @ 6500-7000 rpm (varies slightly by year/market)
Torque Peak:
Approx. 57-60 Nm @ 5500-6000 rpm (varies slightly by year/market)
Fuel System
Fuel Delivery:
Carburetor (early models), Electronic Fuel Injection (later models, e.g., Delphi)
Fuel Type:
Unleaded gasoline, minimum 91 RON
Cooling System
Cooling Method:
Liquid-cooled
Lubrication System
Oil Capacity:
Approx. 2.2 - 2.5 liters (with filter change)
Oil Specification:
SAE 10W-40 or 15W-50, API SG/SH/SJ or higher, JASO MA certified
🔧 Transmission
Standard
Transmission Type:
5-speed manual sequential gearbox
Optional
Optional Transmission:
N/A
Features
Clutch Type:
Wet multi-plate clutch, cable operated
Final Drive:
O-ring sealed chain, 520 pitch
📐 Dimensions
Exterior
Length:
Approx. 2170 mm (Strada), 2215 mm (Trail)
Width:
Approx. 840 mm (Strada), 860 mm (Trail)
Height:
Approx. 1210 mm (Strada), 1280 mm (Trail)
Wheelbase:
Approx. 1475 mm (Strada), 1485 mm (Trail)
Seat Height:
Approx. 830 mm (Strada), 870 mm (Trail)
Weights
Dry Weight:
Approx. 168 kg (Strada), 175 kg (Trail)
Wet Weight:
Approx. 185 kg (Strada), 192 kg (Trail) (estimated)
Fuel Tank Capacity:
13 liters (including 3.5 liter reserve)
Wheels Tires
Front Wheel Size:
17 inch (Strada), 19 inch (Trail)
Rear Wheel Size:
17 inch
Front Tire Size:
110/70-17 (Strada), 100/90-19 (Trail)
Rear Tire Size:
140/70-17
Wheel Type:
Cast aluminum alloy wheels
Suspension Travel
Front Suspension Travel:
130 mm (Strada), 160 mm (Trail)
Rear Suspension Travel:
140 mm (Strada), 160 mm (Trail)
🛡️ Safety Features
Ratings
Crash Safety Ratings:
N/A (Motorcycle specific safety standards apply)
Active Features
ABS:
Optional ABS available on some models/markets
Braking Power:
Dual 300mm discs with 2-piston calipers (front), Single 240mm disc with 1-piston caliper (rear).
Passive Features
Lighting:
Halogen headlight, LED taillight, incandescent turn signals.
💡 Technology Features
Infotainment
Infotainment System:
N/A (Basic instrumentation)
Driver Assistance
Assistance Features:
Optional ABS (Anti-lock Braking System).
Connectivity
Connectivity Options:
N/A
Instrumentation
Instrument Panel:
Analog tachometer, digital speedometer, odometer, trip meter, fuel gauge, coolant temperature warning light, oil pressure warning light, neutral indicator.
🔧 Maintenance
Service Intervals
Oil Filter Change Interval:
Every 6,000 km or 12 months, whichever comes first.
Engine Oil Change Interval:
Every 6,000 km or 12 months, whichever comes first.
Air Filter Cleaning Replacement:
Inspect every 6,000 km, replace as needed or every 18,000 km.
Spark Plug Replacement Interval:
Every 12,000 km (or as per specific plug type).
Valve Clearance Check Interval:
Every 12,000 km.
Chain Adjustment Lubrication Interval:
Every 1,000 km and after washing or riding in rain.
Fluid Specifications
Coolant Type:
Ethylene glycol based antifreeze/coolant (e.g., Motorex Coolant M3.0 or equivalent), 50% solution with distilled water.
Brake Fluid Type:
DOT 4
Fork Oil Type Level:
SAE 7.5W or 10W, level specified per fork type (e.g., 100mm from top when compressed).
Known Issues
Common Wear Items:
Chain and sprockets, rear brake pads, clutch plates (high mileage).
Electrical Gremlins:
Occasional stator issues, regulator/rectifier failures reported on some units.
Fuel System Issues:
Carburetor jetting can be sensitive to altitude, fuel injection sensor issues (TPS, MAP).
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
Italy
Brand Specialty:
Known for performance-oriented motorcycles, racing heritage.
Model Evolution
Introduction Year:
2000 (approximate, with earlier Pegaso models predating this generation)
Major Updates:
Transition from carburetor to fuel injection, refinement of suspension components, cosmetic updates.
Production
Production Years:
Circa 2000-2008 (generation covered by this manual)
Engine Supplier:
Rotax (Bombardier Recreational Products)
🏆 Awards & Recognition
Recognitions
Awards And Accolades:
While specific awards are not extensively documented for this model, it was generally well-regarded for its versatility and value in the middleweight adventure-touring segment.
Ratings
Reliability Perception:
Generally considered reliable with proper maintenance, leveraging the robust Rotax engine platform.
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