APRILIA PEGASO 650 STRADA Service Station Manual

SERVICE STATION MANUAL

854110

PEGASO 650 STRADA - TRAIL - FACTORY

SERVICE STATION

MANUAL

PEGASO 650 STRADA - TRAIL - FACTORY

THE VALUE OF SERVICE

Thanks to continuous technical updates and specific training programs on aprilia products, only aprilia

Official Network mechanics know this vehicle fully and have the special tools necessary to carry out

maintenance and repair operations correctly.

The reliability of the vehicle also depends on its mechanical conditions. Checking the vehicle before

riding, its regular maintenance and the use of Original aprilia Spare Parts only are essential factors!

For information about the nearest Official Dealer and/or Service Centre, consult the Yellow Pages or

search directly on the inset map in our Official Website:

www.aprilia.com

Only aprilia Original Spare Parts ensure products already studied and tested during the vehicle design

stage. All aprilia Original Spare Parts undergo quality control procedures to guarantee full reliability and

duration.

The descriptions and illustrations given in this publication are not binding; While the basic characteristics

as described and illustrated in this manual remain unchanged, aprilia reserves the right, at any time and

without being required to update this publication beforehand, to make any changes to components, parts

or accessories, which it considers necessary to improve the product or which are required for

manufacturing or construction reasons.

Not all versions shown in this publication are available in all countries. The availability of individual

versions should be confirmed with the official aprilia sales network.

prohibited. aprilia - After sales service.

aprilia trademark is property of Piaggio & C. S.p.A.

SERVICE STATION MANUAL

PEGASO 650 STRADA - TRAIL

- FACTORY

NOTE Provides key information to make the procedure easier to understand and carry out.

CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.

WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.

Personal safety Failure to completely observe these instructions will result in serious risk of personal

injury.

Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle

to prevent damaging the environment.

Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious

damage to the vehicle and sometimes even the invalidity of the guarantee.

INDEX OF TOPICS

CHARACTERISTICS CHAR

SPECIAL TOOLS S-TOOLS

MAINTENANCE MAIN

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

ENGINE ENG

POWER SUPPLY P SUPP

SUSPENSIONS SUSP

BRAKING SYSTEM BRAK SYS

COOLING SYSTEM COOL SYS

BODYWORK BODYW

PRE-DELIVERY PRE DE

INDEX OF TOPICS

CHARACTERISTICS CHAR

Rules

Safety rules

Carbon monoxide

If you need to keep the engine running while working on the vehicle, please ensure that you do so in

an open or very well ventilated area. Never let the engine run in an enclosed area. If you do work in an

enclosed area, make sure to use a fume extraction system.

CAUTION

EXHAUST EMISSIONS CONTAIN CARBON MONOXIDE, A POISONOUS GAS WHICH CAN CAUSE

LOSS OF CONSCIOUSNESS AND EVEN DEATH.

Fuel

CAUTION

THE FUEL USED TO POWER INTERNAL COMBUSTION ENGINES IS HIGHLY FLAMMABLE AND

MAY BE EXPLOSIVE UNDER CERTAIN CONDITIONS. IT IS THEREFORE RECOMMENDED TO

CARRY OUT REFUELLING AND MAINTENANCE PROCEDURES IN A VENTILATED AREA WITH

THE ENGINE SWITCHED OFF. DO NOT SMOKE DURING REFUELLING OR NEAR FUEL VAPOUR.

AVOID ANY CONTACT WITH NAKED FLAME, SPARKS OR OTHER HEAT SOURCES WHICH MAY

CAUSE IGNITION OR EXPLOSION.

DO NOT ALLOW FUEL TO DISPERSE INTO THE ENVIRONMENT.

KEEP OUT OF THE REACH OF CHILDREN.

Hot components

The engine and the exhaust system components become very hot and remain hot for some time after

the engine has been switched off. Before handling these components, make sure that you are wearing

insulating gloves or wait until the engine and the exhaust system have cooled down.

Coolant

The coolant contains ethylene glycol which, under certain conditions, can become flammable.

When it burns, ethylene glycol produces an invisible flame which however can cause burns.

CAUTION

TAKE CARE NOT TO SPILL COOLANT ONTO HOT ENGINE OR EXHAUST SYSTEM COMPO-

NENTS; THE FLUID MAY IGNITE AND BURN WITH AN INVISIBLE FLAME. WHEN CARRYING

OUT MAINTENANCE, IT IS ADVISABLE TO WEAR LATEX GLOVES. EVEN THOUGH IT IS TOXIC,

COOLANT HAS A SWEET FLAVOUR WHICH MAKES IT VERY ATTRACTIVE TO ANIMALS. NEV-

ER LEAVE THE COOLANT IN OPEN CONTAINERS IN AREAS ACCESSIBLE TO ANIMALS AS

THEY MAY DRINK IT.

Characteristics PEGASO 650 STRADA - TRAIL - FACTORY

CHAR - 6

KEEP OUT OF THE REACH OF CHILDREN.

DO NOT REMOVE THE RADIATOR CAP WHEN THE ENGINE IS STILL HOT. THE COOLANT IS

PRESSURISED AND MAY CAUSE SCALDING.

Used engine oil and transmission oil

CAUTION

IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN SERVICING THE VEHICLE.

THE ENGINE OR GEARBOX OIL MAY CAUSE SERIOUS INJURIES TO THE SKIN IF HANDLED

FOR PROLONGED PERIODS OF TIME AND ON A REGULAR BASIS.

WASH YOUR HANDS CAREFULLY AFTER HANDLING OIL.

HAND THE OIL OVER TO OR HAVE IT COLLECTED BY THE NEAREST USED OIL RECYCLING

COMPANY OR THE SUPPLIER.

DO NOT DISPOSE OF OIL IN THE ENVIRONMENT

KEEP OUT OF THE REACH OF CHILDREN.

Brake and clutch fluid

BRAKE AND CLUTCH FLUIDS CAN DAMAGE THE PLASTIC OR RUBBER PAINTED SURFACES.

WHEN SERVICING THE BRAKING OR THE CLUTCH SYSTEM PROTECT THESE COMPONENTS

WITH A CLEAN CLOTH. ALWAYS WEAR PROTECTIVE GOGGLES WHEN SERVICING THESE

SYSTEMS. BRAKE AND CLUTCH FLUIDS ARE EXTREMELY HARMFUL FOR YOUR EYES. IN

THE EVENT OF ACCIDENTAL CONTACT WITH THE EYES, RINSE THEM IMMEDIATELY WITH

PLENTY OF COLD, CLEAN WATER AND SEEK MEDICAL ADVICE.

KEEP OUT OF THE REACH OF CHILDREN.

Battery electrolyte and hydrogen gas

CAUTION

THE BATTERY ELECTROLYTE IS TOXIC, CORROSIVE AND, AS IT CONTAINS SULPHURIC

ACID, MAY CAUSE BURNING IF IT COMES INTO CONTACT WITH THE SKIN. WHEN HANDLING

BATTERY ELECTROLYTE, WEAR TIGHT-FITTING GLOVES AND PROTECTIVE APPAREL. IN

THE EVENT OF SKIN CONTACT WITH THE ELECTROLYTIC FLUID, RINSE WELL WITH PLENTY

OF CLEAN WATER. IT IS PARTICULARLY IMPORTANT TO PROTECT YOUR EYES BECAUSE

EVEN TINY AMOUNTS OF BATTERY ACID MAY CAUSE BLINDNESS. IN THE EVENT OF CON-

TACT WITH THE EYES, RINSE WITH PLENTY OF WATER FOR FIFTEEN MINUTES AND CON-

SULT AN EYE SPECIALIST IMMEDIATELY. IF THE FLUID IS ACCIDENTALLY SWALLOWED,

DRINK LARGE QUANTITIES OF WATER OR MILK, FOLLOWED BY MILK OF MAGNESIA OR

VEGETABLE OIL AND SEEK MEDICAL ADVICE IMMEDIATELY. THE BATTERY RELEASES EX-

PLOSIVE GASES; KEEP IT AWAY FROM FLAMES, SPARKS, CIGARETTES OR ANY OTHER

HEAT SOURCES. ENSURE ADEQUATE VENTILATION WHEN SERVICING OR RECHARGING

THE BATTERY.

KEEP OUT OF THE REACH OF CHILDREN.

BATTERY LIQUID IS CORROSIVE. DO NOT POUR IT OR SPILL IT, PARTICULARLY ON PLASTIC

COMPONENTS. ENSURE THAT THE ELECTROLYTIC ACID IS COMPATIBLE WITH THE BAT-

TERY BEING ACTIVATED.

Maintenance rules

GENERAL PRECAUTIONS AND INFORMATION

PEGASO 650 STRADA - TRAIL - FACTORY Characteristics

CHAR - 7

When repairing, dismantling and reassembling the vehicle, follow the recommendations given below

carefully.

BEFORE DISASSEMBLING COMPONENTS

•

Before dismantling components, remove dirt, mud, dust and foreign bodies from the vehicle.

Use the special tools designed for this bike, as required.

COMPONENTS REMOVAL

•

Do not loosen and/or tighten screws and nuts using pliers or any other tools than the specific

wrench.

•

Mark the positions on all connection joints (pipes, cables, etc.) before separating them, and

identify them with different distinctive symbols.

•

Each component needs to be clearly marked to enable identification during reassembly.

•

Clean and wash the dismantled components carefully using a low-flammability detergent.

•

Keep mated parts together since they have "adjusted" to each other due to normal wear.

•

Some components must be used together or replaced altogether.

•

Keep away from heat sources.

REASSEMBLING COMPONENTS

CAUTION

BEARINGS MUST ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTHERWISE, THEY

NEED TO BE REPLACED.

•

Only use ORIGINAL Aprilia SPARE PARTS.

•

Comply with lubricant and consumables use guidelines.

•

Lubricate parts (whenever possible) before reassembling them.

•

When tightening nuts and screws, start either from the components with the largest diameter

or from the innermost components, proceeding diagonally. Tighten nuts and screws in suc-

cessive steps before applying the tightening torque.

•

Always replace self-locking nuts, washers, sealing rings, circlips, O-rings (OR), cotter pins

and screws with new parts if the thread is damaged.

•

When assembling the bearings, make sure to lubricate them well.

•

Check that each component is assembled correctly.

•

After a repair or routine maintenance, carry out pre-ride checks and test the vehicle on

private grounds or in an area with low traffic.

•

Clean all mating surfaces, oil seal rims and gaskets before refitting. Smear a light layer of

lithium-based grease on the oil guard rims. Reassemble oil seals and bearings with the

brand or batch number facing outward (visible side).

ELECTRIC CONNECTORS

Electric connectors must be disconnected as described below; failure to comply with this procedure

causes irreparable damage to both the connector and the wiring harness:

Press the relative safety clips, if applicable.

Characteristics PEGASO 650 STRADA - TRAIL - FACTORY

CHAR - 8

•

Grip the two connectors and disconnect them by pulling them in opposite directions.

•

If any signs of dirt, rust, moisture, etc. are noted, clean the inside of the connector carefully

with a jet of compressed air.

•

Ensure that the cables are correctly fastened to the internal connector terminals.

•

Then connect the two connectors, ensuring that they couple correctly (if fitted with clips, you

will hear them "click" into place).

CAUTION

DO NOT DISCONNECT CONNECTORS BY PULLING THE CABLES.

NOTE

THE TWO CONNECTORS CAN ONLY BE CONNECTED IN ONE DIRECTION: CONNECT THEM

THE RIGHT WAY ROUND.

TIGHTENING TORQUES

CAUTION

REMEMBER THAT THE TIGHTENING TORQUES FOR ALL FASTENING ELEMENTS ON WHEELS,

BRAKES, WHEEL AXLES AND ANY OTHER SUSPENSION COMPONENTS PLAY A KEY ROLE

IN ENSURING VEHICLE SAFETY AND MUST COMPLY WITH SPECIFIED VALUES. CHECK THE

TIGHTENING TORQUES OF FASTENING ELEMENTS ON A REGULAR BASIS AND ALWAYS USE

A TORQUE WRENCH TO REASSEMBLE THESE COMPONENTS. FAILURE TO COMPLY WITH

THESE RECOMMENDATIONS MAY CAUSE ONE OF THESE COMPONENTS TO LOOSEN OR

EVEN DETACH, CAUSING A WHEEL TO LOCK OR COMPROMISING VEHICLE HANDLING. THIS

MAY LEAD TO FALLS, WITH THE RISK OF SERIOUS INJURY OR DEATH.

Running-in

Engine run-in is essential to ensure engine long life and correct operation. Twisty roads and gradients

are ideal to run in engine, brakes and suspensions effectively. Vary your riding speed during the run-

in. This ensures that components operate under both "loaded" and "unloaded" conditions, allowing the

engine components to cool.

CAUTION

THE CLUTCH MAY EMIT A SLIGHT BURNING SMELL WHEN FIRST USED. THIS PHENOMENON

SHOULD BE CONSIDERED NORMAL AND WILL DISAPPEAR AS SOON AS THE CLUTCH DISCS

GET ADAPTED.

IT IS IMPORTANT TO STRAIN ENGINE COMPONENTS DURING RUN-IN, HOWEVER, MAKE SURE

NOT TO OVERDO THIS.

CAUTION

THE FULL PERFORMANCE OF THE VEHICLE IS ONLY AVAILABLE AFTER THE SERVICE AT

THE END OF THE RUNNING IN PERIOD.

Follow the guidelines detailed below:

•

Do not twist the throttle grip abruptly and completely when the engine is working at a low

revs, either during or after run-in.

•

During the first 500 km (312 miles) step carefully on the brakes to avoid rough and long

braking. That is to permit the adequate adjustment of the pad friction material to the brake

discs.

•

During the first 500 km (312 miles), never exceed 4000 rpm.

PEGASO 650 STRADA - TRAIL - FACTORY Characteristics

CHAR - 9

•

Between the 500 km (312 miles) and the 1000 km (625 miles) travelled, never exceed 5000

rpm.

AFTER THE SPECIFIED MILEAGE, TAKE YOUR VEHICLE TO AN Official Aprilia Dealer FOR THE

CHECKS INDICATED IN THE "AFTER-RUN-IN" TABLE IN THE SCHEDULED MAINTENANCE

SECTION TO AVOID INJURING YOURSELF, OTHERS AND /OR DAMAGING THE VEHICLE.

•

Between 1000 km (625 miles) and 2000 km (1250 miles) travelled, ride more vigourously,

vary speeds and twist throttle fully for some short periods for best coupling of the compo-

nents; do not exceed 5500 rpm.

•

After 2000 km (1250 miles) a better engine performance may be expected but without ex-

ceeding the engine maximum rpm.

Vehicle identification

SERIAL NUMBER LOCATION

These numbers are necessary for vehicle registration.

NOTE

ALTERING IDENTIFICATION NUMBERS MAY BE SERIOUSLY PUNISHABLE BY LAW. IN PAR-

TICULAR, MODIFYING THE CHASSIS NUMBER IMMEDIATELY VOIDS THE WARRANTY.

This number is composed by numbers and letters,

as in the example shown below.

ZGULP0000YMXXXXXX

KEY:

ZGU: WMI (World manufacturer identifier) code;

LP: model;

000: version variation;

0: digit free

Y year of manufacture

M: production plant (M= Mandello del Lario);

XXXXXX: progressive number (6 digits);

CHASSIS NUMBER

The chassis number is stamped on the right side

of the headstock.

Characteristics PEGASO 650 STRADA - TRAIL - FACTORY

CHAR - 10

ENGINE NUMBER

The engine number is stamped on the left side,

close to the engine oil level check cap.

Dimensions and mass

WEIGHT AND DIMENSIONS

Specification Desc./Quantity

Max. length Strada 2173 mm (85.55 in)

Max. length Trail 2232 mm (87.87 in)

Max. length Factory 2173 mm (85.55 in)

Max. width Strada 810 mm (31.89 in)

Max. width Factory 860 mm (33.86 in)

Max. width Trail 820 mm (32.28 in)

Max. height (to windscreen) Strada - Factory 1150 mm (45.27 in)

Max. height (to windscreen) Trail 1180 mm (46.46 in)

Saddle height Strada 780 mm (30.71 in)

Saddle height Trail 810 mm (31.89 in)

Saddle height Factory 800 mm (31.49 in)

Centre to centre distance Strada - Factory 1490 mm (58.66 in)

Centre to centre distance Trail 1510 mm (59.45 in)

Minimum ground clearance Strada - Factory 200 mm (7.87 in)

Minimum ground clearance Trail 230 mm (9.05 in)

Dry weight Strada - Factory 179 kg (394.63 lb)

Dry weight Trail 183 kg (403.44 lb)

Engine

ENGINE

Specification

Desc./Quantity

Model MY 660

Type 4-stroke single-cylinder, 4 valves per cylinder, single camshaft

per cylinder

Cylinder quantity 1

Overall engine capacity 660 cm³ (40.27 cu.in)

Bore / stroke 100 mm / 84 mm (3.93 in / 3.31 in)

Maximum torque 59.0 Nm (6.02 kgm) at 5250 rpm

Compression ratio 10.0 ± 0.5:1

Start-up electric

Ignition transistorised coil ignition (digital)

Revs at idle speed 1500 ± 100 rpm

Maximum rated power to the crankshaft 35 kW (47 HP) at 6250 rpm

Cooling liquid

Lubrication Dry sump system with separate oil tank

Type: oil filter Paper

Cooling system Fluid

Water pump Single centrifugal intake pump

Reduction ratio: 27/28 (0.964)

Thermostatic valve Opening start temperature: 71 °C (160 °F)

Full opening temperature: 85 °C (185 °F)

Air filter with dry filtration cartridge

PEGASO 650 STRADA - TRAIL - FACTORY Characteristics

CHAR - 11

Specification Desc./Quantity

Clutch multiple-disc, oil-bathed clutch with hydraulic control on the left

side of the handlebar

Driven plates 6 plates

Thickness: 1.50 - 1.70 mm (0.059 - 0.067 in)

Maximum distortion: 0.20 mm (0.0079 in)

Driving plates 1 4 plates

Inside diameter: 128 mm (5.039 in)

Thickness: 2.90 - 3.10 mm (0.114 - 0.122 in)

Driving plates 2 2 plates

Thickness: 2.92 - 3.08 mm (0.115 - 0.121 in)

Driving plates 3 1 plate

Inside diameter: 128 mm (5.039 in)

Thickness: 2.90 - 3.10 mm (0.114 - 0.122 in)

Clutch springs Number of springs: 5

Unloaded spring length: 55.6 mm (2.19 in)

Maximum limit: 52.82 mm (2.08 in)

Ignition advance 9.0 °C before TDC at 1400 rpm

Valve clearance at outlet 0.16 - 0.20 mm (0.0063 - 0.0079 in)

Valve clearance at intake 0.09 - 0.13 mm (0.0035 - 0.0051 in)

Valve timing: Intake opening - 25° before TDC

Intake closing - 55° after BDC

Outlet opening - 60° before BDC

Outlet closing - 20° after TDC

Standard compression pressure (at sea level) 650 kPa (92.4 PSI) at 800 rpm

Oil temperature 55 °C - 60 °C (131 °F - 140 °F)

Transmission

GEAR RATIOS

Specification

Desc./Quantity

Main transmission 36/75 = 1:2.083

Transmission: secondary first gear: 12/30 = 1:2.500

second gear: 16/26 = 1:1.625

third gear: 20/23 = 1:1.150

fourth gear: 22/20 = 1:0.909

fifth gear: 26/20 = 1:0.769

Final ratio 15/44 = 1:2.933

Total ratio first gear: 15.278

second gear: 9.930

third gear: 7.028

fourth gear: 5.556

fifth gear: 4.700

Capacities

CAPACITY

Specification

Desc./Quantity

Fuel (reserve included) 15 +/- 0.5 l (3.96 +/- 0.13 USgal)

Fuel reserve 3 l approx. (0.79 USgal approx.)

Engine oil oil change: 2500 cm³ (152.56 cu.in)

oil and oil filter change: 2700 cm³ (164.76 cu.in)

Fork oil for Strada - Factory 105 mm (4.13 in) of clearance (for each stem, measured with-

out spring and under compression)

Fork oil for Trail 570 cm³ (34.78 cu.in) for each stem

Coolant 1.2 l (0.32 USgal) (50% water + 50% ethylene glycol antifreeze

fluid)

Seats 2

Vehicle max. load 210 Kg (462.97 lb) (rider + passenger + fluids)

Characteristics PEGASO 650 STRADA - TRAIL - FACTORY

CHAR - 12

Drive chain

TRANSMISSION CHAIN

Specification Desc./Quantity

Chain type Endless (without master link) and with sealed links

Electrical system

IGNITION

Specification Desc./Quantity

Type DENSO - inductive discharge system

SPARK PLUGS

Specification Desc./Quantity

Standard spark plugs NGK CR7E

Electrode gap 0.7 - 0.8 mm (10.15 - 11.60 in)

Spark plug resistance 5 kOhm

ELECTRICAL SYSTEM

Specification Desc./Quantity

1 Battery 12V - 12 Ah

2 Fuses 7.5A - 15A - 20A

3 (Permanent magnet) Generator 12V - 290W

BULBS

Specification

Desc./Quantity

1 Low beam light 12V - 55W

2 High beam light 12V - 60W

3 Front tail light 12V - 5W

4 Turn indicator lights with micro bulbs (not replaceable)

5 Rear daylight running light /stop light LED

6 License plate light 12V - 5W

7 Rpm indicator lighting LED

WARNING LIGHTS

Specification

Desc./Quantity

1 Gear in neutral LED

2 Turn indicators LED

3 Fuel reserve LED

4 High-beam light LED

5 Alarm LED

6 Side stand LED

7 ABS LED

8 Heated handgrips LED

Frame and suspensions

CHASSIS

Specification

Desc./Quantity

Type composite steel frame with removable saddle pillar

Headstock angle 27°

SUSPENSIONS

Specification

Desc./Quantity

Front: hydraulic telescopic fork, Ø 45 mm (1.77 in) stems

Travel for Strada - Factory 140 mm (5.51 in)

PEGASO 650 STRADA - TRAIL - FACTORY Characteristics

CHAR - 13

Specification Desc./Quantity

Travel for Trail 170 mm (6.69 in)

Rear oscillating swingarm and adjustable hydraulic single shock ab-

sorber

Wheel travel for Strada - Factory 130 mm (5.12 in)

Wheel travel for Trail 170 mm (6.69 in)

Brakes

BRAKES

Specification Desc./Quantity

Front in Strada - Factory Ø 320 mm (12.60 in) disc brake

Front in Trail Ø 300 mm (11.81 in) disc brake - with hydraulic transmission

Rear Ø 240 mm (9.45 in) disc brake, with hydraulic transmission

Wheels and tyres

WHEELS AND TYRES

Specification Desc./Quantity

Strada type made of light alloy

Trail - Factory type with spokes

Front in Strada - Factory 3.5 x 17"

Front in Trail 2.15 x 19"

Rear in Strada - Factory 4.5 x 17"

Rear in Trail 3.00 x 17"

Rear in Strada 110/70 ZR 17 54W

alternatively: 110/70 R 17 54H - 120/65 ZR 17 56W - 120/65 R

17 56H

Front in Trail 100/90 M/C 19 57H

Front in Factory 110/70 ZR 17 54 W or 120/70 - 17 Pirelli Diablo

alternatively: 110/70 R 17 54H - 120/65 ZR 17 56W - 120/65 R

17 56H

Driver only inflation pressure (front) in Strada - Factory 1.8 bar (26.10 PSI)

Driver only inflation pressure (front) in Trail 1.9 bar (27.56 PSI)

Driver and passenger inflation pressure (front) in Strada / Fac-

tory

1.9 bar (27.56 PSI)

Driver and passenger inflation pressure (front) in Trail 2.0 bar (29.01 PSI)

Rear in Strada - Factory 160/60 ZR 17 69W

alternatively: 160/60 R 17 69H - 150/60 ZR 17 66W - 150/60 R

17 66H

Rear in Trail 130/80 M/C R 17 65H

alternatively: 140/80 M/C R 17 69H

Driver only inflation pressure (rear) in Strada / Factory 2.0 bar (29.01 PSI)

Driver only inflation pressure (rear) in Trail 2.1 bar (30.46 PSI)

Driver and passenger inflation pressure (rear) in Strada / Fac-

tory

2.2 bar (31.91 PSI)

Driver and passenger inflation pressure (rear) in Trail 2.3 bar (33.36 PSI)

Supply

FUEL SUPPLY SYSTEM

Specification

Desc./Quantity

Type by electronic injection with Ø 45.5 mm (1.79 in) diffuser

FUEL SUPPLY

Specification

Desc./Quantity

Fuel Premium unleaded petrol as per DIN 51 607, minimum octane

rating of 95 (NORM) and 85 (NOMM).

Characteristics PEGASO 650 STRADA - TRAIL - FACTORY

CHAR - 14

Tightening Torques

HANDLEBAR AND CONTROLS

Name Torque in Nm

vibration-damping weight screw M6 10 Nm - loctite 243

Handlebar and collars screws M8 25 Nm - manual

Front brake pump screws M6 12 Nm

ELECTRICAL SYSTEM

Name Torque in Nm

Battery clamping bracket screws M5 3 Nm

Horn to horn support screw M6 12 Nm

Rear turn indicator screws M6 3 Nm

Voltage regulator screws M6 12 Nm - loctite 243

Front turn indicator screws M6 3 Nm

Rear light fixing screws M5 1 Nm

Ground to engine retainer M6 15 Nm

Relay cable on starter motor retainer M6 5 Nm

Retainer for relay cables M6 4 Nm

SADDLE

Name Torque in Nm

Hinge on saddle fixing nuts M6 7+/-20% Nm

LOCKS

Name

Torque in Nm

Rear lock screws M6 10 Nm

CHASSIS

Name

Torque in Nm

Oil sump guard screws M6 8 Nm

Voltage regulator support screw M6 12 Nm - loctite 243

Coils to chassis fixing screws M5 6 Nm - Loctite 243

Map sensor fixing screws M6 12 Nm

Saddle pillar fixing screws M8 25 Nm - Loctite 243

Cradle to chassis fixing screws M10 50 Nm

FUEL TANK

Name

Torque in Nm

Flange to tank fixing screws M5 6 Nm

CENTRAL BODYWORK

Name

Torque in Nm

Radiator spoiler screws M6 5 Nm

Radiator protection screws M6 3 Nm

License plate holder to lower saddle pillar clamp screw M6 3 Nm

Retroreflector holder to license plate fixing screws M5 6 Nm

Front mudguard screw M5 5 Nm

Rear mudguard screw M5 3 Nm

Frontal fairing to bow M6 3 Nm

Internal deflectors to chassis screws M6 3 Nm

External deflector screws M5, M6 3 Nm - manual

Instrument panel windshield clamp screws M6 2 Nm

Lug screws M6 3 Nm

Fairing side support to chassis screws M6 10 Nm - Loctite 243

Side fairings to fairing side support screws M5 5 Nm

Bushing and saddle pillar lower clamp screws M6 5 Nm

Saddle pillar lower clamp to saddle pillar screws M6 4 Nm

Tail section - passenger seat strap fixing screws M6 12 Nm

PEGASO 650 STRADA - TRAIL - FACTORY Characteristics

CHAR - 15

Name Torque in Nm

Tail section front clamp screws M4 0.5 Nm - manual

Tail section clamp to saddle pillar screws M5 3 Nm

Tail section to saddle pillar lower clamp fixing screws M5 2 Nm

Saddle pillar lower clamp to chassis screws M6 4 Nm

Fairings - undertail fixing screws M6 7 Nm

Lower - front fairing clamp screws M6 7 Nm

Front fairing windshield screws - M4 0.5 Nm - manual

Bow instrument panel screws M6 5 Nm

BRAKING SYSTEM

Name Torque in Nm

Rear brake lever pin M8 20 Nm

Front brake calliper to calliper support screw, M10x1.25 (Fac-

tory)

50 Nm

Support to fork M10x1.25 (Factory) 50 Nm

Rear brake oil reservoir screw M5 6 Nm

Rear brake rod lock nut M6 manual

Brake calliper on stem screws, M10x1.25 (Strada - Trail) 50 Nm

COOLING SYSTEM

Name Torque in Nm

Expansion tank screw + carbon protection to coil support - M5 6 Nm

Head pipe to radiator fixing screw manual

FRONT WHEEL

Name

Torque in Nm

Wheel pin nut 80 Nm

EXHAUST

Name

Torque in Nm

Mufflers to saddle pillar fixing screw - M8 25 Nm

Exhaust pipe clamp fixing screw M5 16 Nm

Exhaust pipes to engine fixing screw M8 25 Nm

REAR WHEEL

Name

Torque in Nm

Crown on sprocket carrier fixing screw M10 50 Nm

Wheel pin nut 80 Nm

SIDE STAND

Name

Torque in Nm

Side stand retaining bolt M10x1.25 10 Nm - loctite 243

Switch screw M6 10 Nm

Lock nut M10x1.25 30 Nm - Loctite 243

ENGINE

Name

Torque in Nm

Spark plug 13 Nm

Pinion case M6 10 Nm

Countershaft nut 70 Nm - 10W-40 Engine oil on thread

Valve set nuts 13 Nm

Drum nut 90 Nm - 10W-40 Engine oil on thread

Engine pinion nut 80 Nm - Molykote G-plus grease on thread

Chain pinion nut 12 Nm - 10W-40 Engine oil on thread

Flywheel nut 80 Nm - 10W-40 Engine oil on thread

Gear shift lever retainer M6 10 Nm

Threaded pin 22 Nm - Loctite 620 on thread

Exhaust stud bolts 15 Nm

Probe 18 Nm

Cylinder screws 50 Nm - 10W-40 Engine oil on thread, cylinder head and wash-

er

Characteristics PEGASO 650 STRADA - TRAIL - FACTORY

CHAR - 16

Name Torque in Nm

Distributor cover and valve covers screws 10 Nm

Oil filter cover and speed sensor screws 10 Nm

Clutch cover screws 1 and 2 10 Nm

Gear cover screws E/S 10 Nm

Oil pump gear cover screws 4 Nm - Loctite 620 on thread

Thermostat cover screws 10 Nm

Flywheel cover screws 10 Nm

Timing system gear screws 20 Nm

Chain tensioner body screws 10 Nm

Inlet manifold clamp screws 3 Nm

Clutch screws 9 Nm - 10W-40 Engine oil on thread

Chain guide screws 1 8 Nm

Neutral warning light switch screws 4 Nm - Loctite 620 on thread

Oil passage pipe side screws 2 10 Nm

Cylinder side screws 10 Nm

Cylinder head side screws 10 Nm

Starter motor screws 9 Nm

Lower support to chassis fixing screws M10 50 Nm

Upper supports to chassis fixing screws M10 50 Nm

Engine lower fixing screw M10 50 Nm

Engine to cradle fixing screws M10 50 Nm

Engine upper fixing screw M10 50 Nm

PK screws 7 Nm - Loctite 620 on thread

Camshaft plate screws 10 Nm - Loctite 242 on thread

Stator cable plate screw 10 Nm - Loctite 620 on thread

Clutch cover plate screw 1 10 Nm - Loctite 620 on thread

Bearing retention plate and oil filter screws 10 Nm - Loctite 620 on thread

Oil seal retention plate screws 10 Nm - Threebond TB 1215 liquid sealant on thread

Oil pump screws 10 Nm

Water pump fitting and water pump screws 10 Nm

Water pipe fitting screws 10 Nm

Rotor - freewheel screws 30 Nm - Loctite 620 on thread

Head cylinder inverted screws 37 Nm - 10W-40 Engine oil on thread, head and washer

Oil drain screw 30 Nm

Clutch crankcase half and flywheel crankcase halves screws 10 Nm

Oil filter bleed screw 5 Nm

Stator screws 10 Nm - Loctite 620 on thread

Chain tensioner screw 20 Nm

Head screws 50 Nm - 10W-40 Engine oil on thread, cylinder head and wash-

er

AIS Pipe screws 10 Nm

Oil intake pipe screw 10 Nm - Loctite 620 on thread

Oil outlet pipe screws 10 Nm - Threebond TB1215 liquid sealant on thread

Oil passage pipe 2 screws 20 Nm

Oil passage pipe 1 screws 18 Nm

REAR SUSPENSION

Name

Torque in Nm

Shock absorber to chassis retainer M10 50 Nm - Loctite 243

Single connecting rod to chassis retainer M10 50 Nm

Single connecting rod/double connecting rod retainer M10 50 Nm

Double connecting rod/swingarm retainer M10 50 Nm

Double connecting rod/shock absorber retainer M10 50 Nm

SWINGARM

Name

Torque in Nm

Swingarm pin ring nut M17x1 35 Nm

Swingarm pin adjustment bushing M25x1.5 12 Nm

Swingarm pin 100 Nm

Shock absorber protection retainer 4.8x13 20 Nm

Chain tensioner screw and nut M8 Manual

Chain slider retainer 4.8x13 20 Nm

Rear stand bushing M6 12 Nm

Rear brake pipe positioning plate fixing screw M5 6 Nm

Chain casing retainer M5 6 Nm

PEGASO 650 STRADA - TRAIL - FACTORY Characteristics

CHAR - 17

FRONT SUSPENSION

Name Torque in Nm

Fork stem on upper plate fixing screws M8 25 Nm

Fork stem on lower plate fixing screws M8 25 Nm

Headstock ring nut M25x1.5 7 Nm

Upper plate fixing cover M22x1 100 Nm

Fork hub clamp screws M6 12 Nm

Cable guide for front brake pipe screw M6 12 Nm

Stiffening plate fixing screw, M6x20 12 Nm

FOOTRESTS

Name Torque in Nm

Driver footrests to chassis fixing screws M10 50 Nm

Rear footrests to saddle pillar fixing screws M8 25 Nm

APRILIA PEGASO 650 STRADA Service Station Manual

APRILIA PEGASO 650 STRADA Service Station Manual

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