APRILIA PEGASO 650 STRADA Service Station Manual Download Page 159

Page: 159 / 236

•

By using the connecting rod locking

tool, fasten the connecting rod and un-

screw and remove the balancer driving

gear nut at the same time.

•

Collect the washer.

Specific tooling

8140840

Connecting rod locking

•

Remove the washer.

•

Remove the water pump driving gear.

•

Remove the main transmission driving

gear.

PEGASO 650 STRADA - TRAIL - FACTORY

Engine

ENG - 159

Summary of Contents for PEGASO 650 STRADA

Page 1: ...SERVICE STATION MANUAL 854110 PEGASO 650 STRADA TRAIL FACTORY ...

Page 2: ...ied 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 upd...

Page 3: ...o 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 ...

Page 4: ...CS 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 ...

Page 5: ...INDEX OF TOPICS CHARACTERISTICS CHAR ...

Page 6: ...PLOSION 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 cool...

Page 7: ... 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 T...

Page 8: ...S 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 ci...

Page 9: ... 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 ...

Page 10: ...er 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...

Page 11: ...mum 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 cm 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 r...

Page 12: ...r 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 1...

Page 13: ...V 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 handgr...

Page 14: ... 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 1...

Page 15: ...s 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 ...

Page 16: ...w 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 ...

Page 17: ...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 scre...

Page 18: ...esired the products can be mixed as follows SAE 10W 67 AGIP 5W 33 AGIP 20W SAE 15W 33 AGIP 5W 67 AGIP 20W AGIP GREASE 30 Bearings and other lubrication points Alternatively to the recommended prod uct use top branded grease for roller bearings useful temperature range 30 C 140 C 22 F 284 F drop point 150 230 C 302 446 F high anti corrosive protection good water and rust resistance NEUTRAL GREASE O...

Page 19: ...INDEX OF TOPICS SPECIAL TOOLS S TOOLS ...

Page 20: ...P8101945 Fork pin ring nut AP8140179 Valve spring compressor 8140837 Flywheel extractor AP8140838 Flywheel rotor locking 8140839 Engine supporting plate 8140840 Connecting rod locking Special tools PEGASO 650 STRADA TRAIL FACTORY S TOOLS 20 ...

Page 21: ...oil seal fitting tool Ø 63 mm 2 48 in H 125 mm 4 92 in 8140844 Adaptor for crankshaft 8140845 Crankshaft spacer 8140846 Crankshaft fitting tool 8140847 Crankshaft fitting tool 8140848 Rocking lever shaft extractor PEGASO 650 STRADA TRAIL FACTORY Special tools S TOOLS 21 ...

Page 22: ... shaft extractor weight 8140850 Flywheel cover opening 8140853 Crankcase separator 8163500 Fork sleeve ring nut 8600388 Pin piston extractor 8600391 Clutch locking 0276357 Piston ring clamp Special tools PEGASO 650 STRADA TRAIL FACTORY S TOOLS 22 ...

Page 23: ...Stores code Description AP0276474 Valve spring compressor adaptor PEGASO 650 STRADA TRAIL FACTORY Special tools S TOOLS 23 ...

Page 24: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Page 25: ... Engine revs and CO at idle speed adjust Wheels Tyres check replace if necessary Bolts nuts and screws tightening Check and clean adjust grease or replace if necessary Battery terminals tightening Check and clean adjust grease or replace if necessary Suspensions and setting Check and clean adjust grease or replace if necessary Wheel spokes tension check and clean grease or replace if necessary Bra...

Page 26: ...ck and clean adjust grease or replace if necessary Suspensions and setting Check and clean adjust grease or replace if necessary Wheel spokes tension check and clean grease or replace if necessary Fuel pipes Check and clean adjust grease or replace if necessary Clutch wear Check and clean adjust grease or replace if necessary Brake pad wear Check and clean adjust or replace if necessary EVERY 2000...

Page 27: ...le on a support Shut off the engine and let it cool down so that the crankshaft oil drains out and cools down Unscrew and take out the measuring cap dipstick Place a collection container under the engine oil drainage plug Unscrew and remove the oil drainage plug and then drain all engine oil PEGASO 650 STRADA TRAIL FACTORY Maintenance MAIN 27 ...

Page 28: ...he engine oil filter Fit a new engine oil filter Place the engine oil filter cover and tighten the three fixing screws Screw and tighten the oil drainage plug Fill up through the engine oil fill open ing Screw and tighten the measuring cap dipstick Start the engine and let it run for sev eral minutes Shut it off and let it cool down Check the engine oil level Maintenance PEGASO 650 STRADA TRAIL FA...

Page 29: ...ean the filtering element Checking the valve clearance CAUTION VALVE CLEARANCE SHOULD BE ADJUSTED WHEN THE ENGINE IS COLD AT AMBIENT TEM PERATURE CAUTION WHEN MEASURING OR ADJUSTING VALVE CLEARANCE THE PISTON MUST BE AT THE TOP DEAD CENTRE TDC IN COMPRESSION STROKE Undo and remove the four screws and remove the intake tappet cover PEGASO 650 STRADA TRAIL FACTORY Maintenance MAIN 29 ...

Page 30: ...he camshaft anticlockwise until the movable reference on the camshaft toothed wheel is aligned to the station ary reference on the cylinder head The piston should be at TDC during the compression stroke Undo and remove the screw 3 to ac cess the reference for timing and the screw 4 for a final access to the crankshaft Specific tooling 8140850 Flywheel cover opening Maintenance PEGASO 650 STRADA TR...

Page 31: ...ow Loosen the lock nut 5 Place a thickness gauge of suitable measure see valve clearance when cold between the end of set screw 6 and the valve point Use the thickness gauge to turn the set screw until the pre set clearance is ob tained Turn the set screw 6 anticlockwise to increase clearance Turn the set screw 6 clockwise to reduce clear ance Block the set screw 6 to prevent any movement and tigh...

Page 32: ...ance until the pre set clearance is obtained NOTE LUBRICATE THE VALVE SET SCREWS WITH RECOM MENDED LUBRICANTS Maintenance PEGASO 650 STRADA TRAIL FACTORY MAIN 32 ...

Page 33: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 34: ...Components arrangement Key 1 Coil 2 Fuel pump 3 Fall sensor Electrical system PEGASO 650 STRADA TRAIL FACTORY ELE SYS 34 ...

Page 35: ...r temperature sensor 9 Starter motor 10 Pick up sensor 11 Generator 12 Coolant temperature sensor 13 Front headlamp 14 Intake air pressure sensor 15 Sas valve actuator Electrical system installation PEGASO 650 STRADA TRAIL FACTORY Electrical system ELE SYS 35 ...

Page 36: ...General wiring diagram Key 1 Multiple connectors 2 Gear in neutral switches 3 Clutch switch 4 Fall sensor Electrical system PEGASO 650 STRADA TRAIL FACTORY ELE SYS 36 ...

Page 37: ...19 Rear stop switch 20 Front stop switch 21 Electric lock 22 Immobilizer aerial 23 Key switch 24 Fan 25 Fan control relay 26 Injection relay 27 Start up relay 28 Starter motor 29 Fuses 30 Battery 31 Voltage regulator 32 Generator 33 Pick up 34 Fuel pump 35 Fuel level sensor 36 Map sensor 37 Secondary air 38 Injector 39 Throttle sensor TPS 40 Water temperature sensor 41 Air temperature sensor 42 Sp...

Page 38: ...y blue B blue Bi white G yellow Gr grey M brown N black R red Ro pink V green Vi purple Checks and inspections Dashboard INSTRUMENT PANEL OPERATION By turning the ignition key to KEY ON the follow ing indicators on the instrument panel are lit for two seconds the PEGASO 650 logo all the warning lights except the Hea ted handgrips warning light the backlighting Electrical system PEGASO 650 STRADA T...

Page 39: ...and it is possible to scroll up the drop down menu options while at the central position values are confirmed by pressing the key Operating the selector the LCD display shows the screens that indicate the following values in the F zone A TRIP ODOMETER 1 B TRAVELLING TIME 1 C TRIP ODOMETER 2 D TRAVELLING TIME 2 E MAXIMUM SPEED F CHRONOMETER G BATTERY VOLTAGE H KM IN RESERVE kilometres trav elled wi...

Page 40: ...K ADJUSTMENT GEAR SHIFT THRESHOLD BACKLIGHTING BRIGHTNESS CODE MODIFICATION UNLOCK SAFETY LOCKS Once the operation is finished the instrument pan el goes back to the main menu Time adjustment The clock can be programmed with this option The main screen shows the message CLOCK ADJUSTMENT The hour indicator is no longer displayed when this function is activated only the minutes indicator is shown Ea...

Page 41: ...he minute adjustment function starts Gear shift threshold The gear shift threshold can be set in this mode The main screen shows the message GEAR SHIFT THRESHOLD Each time the MODE selector is pressed to the right the threshold value increases by 100 rpm conversely each time the MODE selector is press ed to the left the threshold value decreases by 100 rpm After reaching either the highest or lowe...

Page 42: ...dification This function is used when the old CODE needs to be changed in this case the old code should be available or rather the instrument panel must be started with one of the programmed key The fol lowing message is first displayed Enter the old code After the old code is recognised the new code is requested with the following message Enter new code Once the operation is finished the instrume...

Page 43: ...S menu Unlock safety locks In case of failure of the stand sensor the neutral or clutch switch the Unlock safety locks function excludes the safety logic so that the motorbike can be started The word SERVICE is shown on the display When the vehicle is turned off the safety logic is enabled again CAUTION THIS FUNCTION SHOULD ONLY BE USED FOR EMER GENCIES CHRONOMETER When the CHRONOMETER function is...

Page 44: ...e central position again within 10 seconds of the start to stop the op eration store the time and begin a new measure ment The series of measurements is interrupted by pressing and holding down the MODE selector at the central position After storing 40 times this function is over and the word FULL is displayed in order to read the chronometer times it is necessary to stop the mo torbike and displa...

Page 45: ...tioning FUNCTIONAL CHARACTERISTICS Speedometer The speed value is displayed is a nnn format and with the indication of the unit of measurement km h or mph The accuracy must be better than that set by the European Directive 2000 7 CE dated 20 03 00 and between 0 and 2 The measurement is carried out by reading the number of impulses between readings in the Denso control unit There are 20 impulses pe...

Page 46: ...ble Resistance 22 5 Ohm warning light off with fuel level of 15 8 litres 4 17 USgal Resistance 240 0 Ohm warning light on with fuel level of 3 8 litres 1 00 USgal Resistance 296 0 Ohm warning light on with fuel level of 0 0 litres 0 0 USgal Distance travelled with low fuel The display shows the indication related to how many km have been covered after the low fuel warning light turned on The value...

Page 47: ...e quantities of that relevant trip odometer should be reset Trip odometer The trip odometer value is calculated from the last reset The value is shown in the graphic display in a nnn format followed by the indication of the unit of measurement km h or MPH The value should be updated every 10 seconds max Saturation occurs when shifting from 999 9 to 0 0 Travelling time The travelling time is calcul...

Page 48: ...n When the odometer reaches a multiple of 10000 km 6213 71 mi the next vehicle servicings will be indicated The service can be reset from 300 km 186 41 mi before the natural expiry date and during this interval the service icon flashes for 5 seconds and then goes off Turn indicators The instrument panel functions as control driver for the turn indicators either as a single channel control or a syn...

Page 49: ...ecommunications of the different countries and for sticking the adequate system certification labels on the instrument panel Operation Upon starting the vehicle the instrument panel will read the key code If it corresponds to one of the stored codes the instrument panel will carry out the initial check and enable the vehicle start up Up to four keys should be stored If the key code is not recognis...

Page 50: ...able and replace the whole key set by changing the key lock Diagnosis The instrument panel should signal when the component related to the immobilizer function is mal functioning the aerial is broken and a transponder reads a code different from the one stored in which case entering the access code is required CONNECTOR The connector diagram on the instrument panel and the relevant pin configurati...

Page 51: ... INDICATOR ACTIVATION PIN 23 LEFT REAR INDICATOR AC TIVATION PIN 24 AERIAL PIN 25 CONTACT 1 ECU NEUTRAL INPUT PIN 26 PIN 27 INDICATOR RESET PIN 28 PIN 29 SIDE STAND PIN 30 SELECT 2 UP PIN 31 BATTERY PIN 32 RIGHT FRONT INDICATOR ACTIVATION PIN 33 RIGHT REAR INDICATOR ACTIVATION PIN 34 AERIAL 2 PIN 35 CONTACT 2 ECU SIDE STAND INPUT PIN 36 PIN 37 HAZARD PIN 38 START UP RELAY ACTIVA TION PEGASO 650 ST...

Page 52: ...n on the relevant warning light When the lights are off there is no voltage when the lights are on there is battery voltage or a signal coming directly from the regulator and therefore this is a pulse signal and can reach high values If the signal is detected directly by the generator its minimum frequency can be 100 Hz considering an idle speed of 600 rpm and with only one pole piece If the bulb ...

Page 53: ...185 F Operating temperature calibrated 18 C 65 C 0 4 F 149 F Storage temperature 30 C 90 C 22 F 194 F Flame resistant slow burning materials in compliance with the UL94 HB V2 standard Vehicle performance profile The performance profile must not be lower than 50000 km 31068 or 8 years LCD specifications The display used has a 128x112 pixel resolution X axis Y axis the visible area is 62x55 mm 2 44x...

Page 54: ... code is incorrect the following message is displayed Incorrect code The instrument panel shows the main menu Otherwise the following menu is displayed EXIT ECU ACTIVATIONS ECU PARAMETERS ECU ERRORS INSTRUMENT PANEL ERRORS DELETE ERRORS CO ADJUSTMENT RESET SERVICE DISCONNECTION UPDATE CHANGE KEYS KM MILES Once the operation is finished the instrument panel goes back to the main menu There are two ...

Page 55: ...t and or stored Code 60 EEPROM Error Code 61 Error FLAG CODE Delete errors this screen gives the possibility to delete stored errors Deletion is effective at KEY OFF Code 62 Error FLAG CODE clear Ecu activations The following message is displayed Turn the key to stop Once the key extraction is been detected the following message is displayed Turn the key to run Turn the engine RUN engine STOP swit...

Page 56: ...ill then be activated 5 times Fans The following message is displayed Turn the engine RUN engine STOP switch first to RUN and then to STOP The fan control relay will then be activated 5 times Lights The following message is displayed Turn the engine RUN engine STOP switch first to RUN and then to STOP The light relay will then be activated 5 times Ecu errors This screen displays both current and s...

Page 57: ...rn the key to stop Once the key extraction is been detected the following message is displayed Turn the key to run Once the key reinsertion is detected while waiting to get the connection with the engine control unit the following message is displayed Wait for the connection Once the connection is completed the following messages are displayed Connection completed Set value CO _ _ _ Turn the key t...

Page 58: ...rument panel disconnected Now connect the diagnosis instrument The instrument panel will restart to work normally after the key is inserted extracted Update This function is used to program the instrument panel again This screen shows the software version that is currently loaded The LCD shows Instrument panel disconnected Now connect the diagnosis instrument The instrument panel will restart to w...

Page 59: ...power 290 Watt Recharging voltage 14V 5000 rpm measured at battery poles Stator coil resistance 0 224 0 336 Ohm at 20 C 68 F between white cable and white cable Start up system check Power supply 12V Maximum input 0 8 kW level indicators Fuel pressure 324 kPa 46 1 PSI PEGASO 650 STRADA TRAIL FACTORY Electrical system ELE SYS 59 ...

Page 60: ...LED Fuses Fuse distribution A 20A fuse yellow From battery to ignition switch voltage regulator cooling electrical fan B 15A fuse sky blue From ignition switch to all lights loads C 7 5A fuse red From ignition switch to igni tion start up safety logic NOTE THERE ARE THREE SPARE FUSES Electrical system PEGASO 650 STRADA TRAIL FACTORY ELE SYS 60 ...

Page 61: ...up 11 Earth connection 12 Not used 13 Injection sensor 5V 14 Secondary air 15 Key 16 Not used 17 Coil 18 Not used 19 Not used 20 Neutral from instrument panel 21 From injection relay 22 Not used 23 Side stand from instrument panel 24 Water temperature signal 25 Air temperature signal 26 Intake pressure signal PEGASO 650 STRADA TRAIL FACTORY Electrical system ELE SYS 61 ...

Page 62: ...jection relay 30 Electric fan relay 31 Light relay 32 Not used 33 Injectors 34 Earth connection Battery 12 V 10 Amp h MF Engine rpm sensor 192 288 Ohm at 20 C 68 F between blue yellow and green white Electrical system PEGASO 650 STRADA TRAIL FACTORY ELE SYS 62 ...

Page 63: ... at 110 C 230 F Air temperature sensor Intake air temperature sensor resistance 2 21 2 69 Ohm at 20 C 68 F Lambda sensor Oxygen sensor with heater Sensor voltage between 0 2 and 0 7 V to be measured between the white blue wires at 370 C 698 F sensor temperature Heater resistance 13 Ohm 2 5 1 3 to be measured between black black wires at 20 C 68 F Power supply voltage 12V PEGASO 650 STRADA TRAIL FA...

Page 64: ... and spark plug cable Spark plug tube resistance 10 0 kOhm at 20 C 68 F Bank angle sensor Voltage to be detected between yellow green ca ble and black blue cable Less than 65 tilting 0 4 1 4 V Over 65 inclination 3 7 4 4 V NOTE SENSOR FUNCTIONING CAN ALSO BE DETECTED THROUGH THE INSTRUMENT PANEL SAS valve actuator Resistance of the Secondary air system solenoid 18 22 Ohm at 20 C 68 F between brown...

Page 65: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 66: ... remove the battery Remove the exhaust pipes Remove the rear fairings Remove the oil sump guard Removing the engine from the vehicle Remove both clamps and slide off both pipes Disconnect the filter casing connector Remove the petrol vapour recovery pipe clamp Remove the two clamps on the cable harness Engine from vehicle PEGASO 650 STRADA TRAIL FACTORY ENG VE 66 ...

Page 67: ... Disconnect the speed sensor Disconnect the neutral sensor connec tor Disconnect the alternator connectors PEGASO 650 STRADA TRAIL FACTORY Engine from vehicle ENG VE 67 ...

Page 68: ...o and remove the screw and dis connect the ground connections Disconnect the starter motor power supply cable Loosen the nut and slide off the clutch wire from its fitting Engine from vehicle PEGASO 650 STRADA TRAIL FACTORY ENG VE 68 ...

Page 69: ... linkage system Disconnect the spark plug tube Loosen the secondary air pipe clamp Slide off the pipe from the throttle body Disconnect the engine temperature sensor connector PEGASO 650 STRADA TRAIL FACTORY Engine from vehicle ENG VE 69 ...

Page 70: ...ank breath er pipe Release the cable harness from the clamp Disconnect the alternator connectors Place a container to collect the engine oil Undo and remove the screw Engine from vehicle PEGASO 650 STRADA TRAIL FACTORY ENG VE 70 ...

Page 71: ...e engine oil Undo and remove the two screws and collect the spacers Remove the pinion cover Remove the guiding plate Straighten the safety washer tongues PEGASO 650 STRADA TRAIL FACTORY Engine from vehicle ENG VE 71 ...

Page 72: ...and col lect the safety washer Remove the pinion and free it from the drive chain Undo and remove the screw collect the washer and slide off the cable guide Disconnect the neutral sensor Engine from vehicle PEGASO 650 STRADA TRAIL FACTORY ENG VE 72 ...

Page 73: ... pipe from the filter casing Hold the scooter with belts Unscrew and remove the swingarm pin ring nut Loosen the swingarm adjustment bushing Slide off the pin from the left side PEGASO 650 STRADA TRAIL FACTORY Engine from vehicle ENG VE 73 ...

Page 74: ... posite side Working from the right side unscrew and remove the two screws on the en gine Slide off the two screws from the op posite side Remove the engine front support Working from the right side unscrew and remove the upper nut From the opposite side slide off the screw Engine from vehicle PEGASO 650 STRADA TRAIL FACTORY ENG VE 74 ...

Page 75: ...ashers Loosen the clamps and slide off the in let manifold Lower the engine Installing the engine to the vehicle With vehicle chassis properly secured lift the engine up to the desired posi tion PEGASO 650 STRADA TRAIL FACTORY Engine from vehicle ENG VE 75 ...

Page 76: ...dy in the inlet manifold and fasten the clamp Tighten the two lower fixing screws Fit the fixing screw Tighten the upper fixing nut Fit the engine front support Engine from vehicle PEGASO 650 STRADA TRAIL FACTORY ENG VE 76 ...

Page 77: ...tighten the two screws on the engine Fit the two screws Working from the opposite side tighten the two nuts Remove the engine hoister Fit the pin Fit the bushing and fasten it Fasten the pin PEGASO 650 STRADA TRAIL FACTORY Engine from vehicle ENG VE 77 ...

Page 78: ... and fasten it Remove the support belts Fit the filter casing pipe and fasten the clamp Connect the neutral sensor Fit the cable guide and tighten the fix ing screw with the washer Engine from vehicle PEGASO 650 STRADA TRAIL FACTORY ENG VE 78 ...

Page 79: ...sert the crown pinion Engage first gear Fit the safety washer and tighten the nut Fold the safety washer tongues again Refit the guiding plate PEGASO 650 STRADA TRAIL FACTORY Engine from vehicle ENG VE 79 ...

Page 80: ... tighten the two screws with the spacers Fit the screw and tighten it Connect the alternator connectors Clamp the cable harness Connect the expansion tank breather pipe Engine from vehicle PEGASO 650 STRADA TRAIL FACTORY ENG VE 80 ...

Page 81: ...re sen sor connector Insert the pipe in the throttle body Fasten the secondary air pipe clamp Connect the spark plug pipe Connect the clutch cable to the linkage system PEGASO 650 STRADA TRAIL FACTORY Engine from vehicle ENG VE 81 ...

Page 82: ...le in its fitting and tighten the nut Connect the starter motor power sup ply cable Connect the ground leads and tighten the fixing screw Connect the stand sensor Engine from vehicle PEGASO 650 STRADA TRAIL FACTORY ENG VE 82 ...

Page 83: ... Connect the alternator connectors Connect the neutral sensor connector Connect the speed sensor Fix the cable harnesses with the clamps PEGASO 650 STRADA TRAIL FACTORY Engine from vehicle ENG VE 83 ...

Page 84: ... Refit the fuel vapour recovery pipe clamp Connect the filter casing connector Refit the two pipes and fasten the rel evant clamps Engine from vehicle PEGASO 650 STRADA TRAIL FACTORY ENG VE 84 ...

Page 85: ...INDEX OF TOPICS ENGINE ENG ...

Page 86: ...Gearbox Engine PEGASO 650 STRADA TRAIL FACTORY ENG 86 ...

Page 87: ...t 2 Main shaft 3 Secondary shaft 4 Chain 5 Wheel axle 6 C Gear fork 7 R Gear fork 8 L Gear fork 9 Gear drum 10 Main axle unit 11 Spacer 12 Secondary axle unit Gearbox shafts PEGASO 650 STRADA TRAIL FACTORY Engine ENG 87 ...

Page 88: ...ase halves Block the gear shafts with the circlips Remove the gear shaft unit See also Splitting the crankcase halves Removing the primary shaft Remove the gear main shaft Remove the safety circlip Engine PEGASO 650 STRADA TRAIL FACTORY ENG 88 ...

Page 89: ...e second gear Remove the toothed retaining washer Slide off the gear of the fifth gear and collect the retaining element the spacer and the toothed washer Remove the safety circlip PEGASO 650 STRADA TRAIL FACTORY Engine ENG 89 ...

Page 90: ... Slide off gear of the third gear Remove the safety circlip Remove the splined washer Slide off the gear of the fourth gear See also Removing the crankshaft Engine PEGASO 650 STRADA TRAIL FACTORY ENG 90 ...

Page 91: ...t Remove the gear secondary shaft Remove the safety circlip Slide off the gear of the first gear and collect the washer Slide off the gear of the fourth gear Remove the safety circlip PEGASO 650 STRADA TRAIL FACTORY Engine ENG 91 ...

Page 92: ...he splined washer Slide off the gear of the fifth gear Remove the safety circlip and slide off the gear of the second gear collect the splined washer and the circular gasket See also Removing the crankshaft Engine PEGASO 650 STRADA TRAIL FACTORY ENG 92 ...

Page 93: ...on shaft with a dial gauge and a centring device and re place it if not complying with specifications Characteristic Shaft coaxiality limit 0 08 mm 0 0031 in Check transmission gears for signs of pitting and wear and replace damaged gears if necessary Check the gear fitting teeth for cracks damage and wear and replace those damaged if necessary Check the transmission gears movement and if it is no...

Page 94: ...damage distortion and wear Replace the transmission fork if necessary Check the transmission fork movement and if it is not regular replace the transmission forks Fitting the primary shaft Fit the gear of the fourth gear Insert the splined washer Engine PEGASO 650 STRADA TRAIL FACTORY ENG 94 ...

Page 95: ... safety circlip Fit the gear of the third gear Replace the safety circlip Insert the toothed washer the spacer the retaining element and fit the gear of the fifth gear PEGASO 650 STRADA TRAIL FACTORY Engine ENG 95 ...

Page 96: ...e gear of the second gear Replace the safety circlip NOTE MAKE SURE THAT THE SHARP EDGE a OF THE SAFETY CIRCLIPS 2 IS FITTED ON THE SIDE OPPOSITE THE RELEVANT TOOTHED WASHERS 1 AND THE RELEVANT GEARS Engine PEGASO 650 STRADA TRAIL FACTORY ENG 96 ...

Page 97: ...RE AT THE CENTER OF EACH GROOVE Fitting the secondary shaft Fit the gear of the second gear together with the circular gasket and the splined washer Replace the safety circlip Fit the gear of the fifth gear PEGASO 650 STRADA TRAIL FACTORY Engine ENG 97 ...

Page 98: ...it the gear of the third gear and the splined washer Replace the safety circlip Fit the gear of the fourth gear Fit the gear of the first gear and the washer Engine PEGASO 650 STRADA TRAIL FACTORY ENG 98 ...

Page 99: ...THE RELEVANT TOOTHED WASHERS 1 AND THE RELEVANT GEARS NOTE INSERT THE SAFETY CIRCLIPS SO THAT BOTH ENDS ARE AT THE CENTER OF EACH GROOVE Assembling the gearbox Follow the operations described for removal but in reverse order Check that the shafts rotate correctly Gear selector PEGASO 650 STRADA TRAIL FACTORY Engine ENG 99 ...

Page 100: ...ng Working from the clutch side slide off the gear selector and collect the wash er and the oil seal GEAR SELECTOR REMOVAL Slide off the two washers 1 and 2 Remove the safety ring 3 Slide off the washer 4 Slide off the stop lever 5 Slide off the spacer 6 Slide off the washer 7 Remove the lever spring 8 See also Disassembling the clutch Removing the Engine PEGASO 650 STRADA TRAIL FACTORY ENG 100 ...

Page 101: ... ball rotates freely If necessary replace the parts Check the gear selector spring for damage and wear If necessary replace the part Reassembling the gear selector To refit first lubricate the oil seal and carry out the removal operations but in reverse order See also Removing the gear selector Starter motor Removing the starter motor Disconnect the starter motor power supply cable Undo and remove...

Page 102: ...ving the starter gear Remove the flywheel Remove the tab Remove the starting ring gear and the roller cage Remove the washer See also Magneto flywheel removal Engine PEGASO 650 STRADA TRAIL FACTORY ENG 102 ...

Page 103: ...Fit the timing chain if previously re moved Insert the washer Fit the needle cage Fit the gear of the starting ring gear Insert the tab on the crankshaft See also Installing the chain PEGASO 650 STRADA TRAIL FACTORY Engine ENG 103 ...

Page 104: ...together with the torque limiter Collect the centring dowel Loosen the nine screws operating di agonally Mark the screws with different lengths Remove the flywheel cover together with the gasket the starter motor neu tral gear the four dowels and the two O rings See also Engine PEGASO 650 STRADA TRAIL FACTORY ENG 104 ...

Page 105: ...WITH THE FLYWHEEL UPPER PROTRUSION Specific tooling AP8140838 Flywheel rotor locking Warm the flywheel with a specific heater Using the flywheel extractor remove it from the crankshaft Specific tooling 8140837 Flywheel extractor See also Removing the flywheel cover Installing the flywheel Fit the starting ring gear if previously removed Fit the flywheel paying attention to the correct position of ...

Page 106: ...838 Flywheel rotor locking Insert the washer on the crankshaft Tighten the nut to the specified torque See also Removing the flywheel cover Flywheel cover installation Refit the flywheel if previously re moved Fit the two front and two rear dowels together with the O rings on the crank case Fit a new gasket Fit the starter motor neutral gear Insert the pin Engine PEGASO 650 STRADA TRAIL FACTORY EN...

Page 107: ...rectly fit and tighten the nine screws operating diagonally Fit the centring dowel of the starter mo tor cover Install the torque limiter on the starter motor cover Fit the starter motor cover with a new gasket PEGASO 650 STRADA TRAIL FACTORY Engine ENG 107 ...

Page 108: ...Af ter loosening all the screws complete ly remove them Place a container of suitable capacity underneath the clutch Remove the clutch crankcase half and collect the gasket and the two centring dowels Undo and remove the nine screws by loosening them 1 4 of a turn at a time operating in stages and diagonally Af ter loosening all the screws complete ly remove them Remove the lower clutch crankcase ...

Page 109: ...rn at a time operating in stages and diagonally Collect the clutch springs Remove the pressure plate and collect the disengaging shaft and the pressure block rod Remove the thirteen clutch discs Remove the clutch damper spring and its fitting PEGASO 650 STRADA TRAIL FACTORY Engine ENG 109 ...

Page 110: ...sher unscrew and remove the clutch hub nut with the universal clutch locking tool and collect the lock ing washer Specific tooling 8600391 Clutch locking Remove the clutch hub and collect the thrust washer Engine PEGASO 650 STRADA TRAIL FACTORY ENG 110 ...

Page 111: ...ecifications CAUTION THE STEEL DISCS MUST SHOW NO SCORES OR TEM PERING COLOUR Measure the driving plate thickness at four positions replace them all if not complying with specifications Characteristic 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 diamete...

Page 112: ...e and wear and if necessary replace the main transmission driving gear and the clutch bell all together Make sure there is not excessive noise during op eration if necessary replace the main transmis sion driving gear and the clutch bell all together Checking the pusher plate Check the thrust plate and the bearing for damage and wear If necessary replace the parts Engine PEGASO 650 STRADA TRAIL FA...

Page 113: ...loaded if necessary replace the springs all together Characteristic Clutch springs Number of springs 5 Unloaded spring length 55 6 mm 2 19 in Maximum limit 52 82 mm 2 08 in Checking the clutch actuator Check the toothing of the release lever shaft pinion 1 and the unlocking rod 2 for damage or wear Replace the components all together if necessary Check the unlocking rod support and replace it if i...

Page 114: ...Assembling the clutch Install the clutch bell Insert the washer Install the clutch hub Insert the new locking washer Engine PEGASO 650 STRADA TRAIL FACTORY ENG 114 ...

Page 115: ...ing 8600391 Clutch locking Fold the locking washer Rotate the clutch bell with the arrows facing upwards Use engine oil to lubricate the driving plates and the driven plates Fit the damper spring fitting as well as the spring with the reference mark OUTSIDE facing outwards PEGASO 650 STRADA TRAIL FACTORY Engine ENG 115 ...

Page 116: ... Insert the thirteen clutch discs paying attention to their position Engine PEGASO 650 STRADA TRAIL FACTORY ENG 116 ...

Page 117: ...PEGASO 650 STRADA TRAIL FACTORY Engine ENG 117 ...

Page 118: ...Engine PEGASO 650 STRADA TRAIL FACTORY ENG 118 ...

Page 119: ... Fit the clutch plate together with the disengagement shaft Fit the springs PEGASO 650 STRADA TRAIL FACTORY Engine ENG 119 ...

Page 120: ...lutch cover Replace the gasket and insert the right crankcase half Correctly fit the screws and tighten them operating diagonally Fit the centring dowels Rotate the disengagement shaft so that the teeth face towards the back of the motorbike Engine PEGASO 650 STRADA TRAIL FACTORY ENG 120 ...

Page 121: ...ELEASE LEVER PAY ATTENTION TO FIT IT WITH THE WORD UP FACING UPWARDS Head and timing Removing the cylinder head Using the suitable special tool un screw and remove the flywheel cover to access the crankshaft Specific tooling 8140850 Flywheel cover opening PEGASO 650 STRADA TRAIL FACTORY Engine ENG 121 ...

Page 122: ...te the crankshaft counterclock wise to move the piston to the top dead centre in combustion phase This position is indicated by aligning the reference mark I on the flywheel and the reference on the flywheel cov er Undo and remove the two screws Remove the toothed wheel inspection cover and collect the gasket Engine PEGASO 650 STRADA TRAIL FACTORY ENG 122 ...

Page 123: ... on the head Undo and remove the two screws and remove the timing chain tensioner Keeping the wheel nut locked with a wrench undo and remove the two screws of the camshaft toothed wheel Remove the camshaft toothed wheel Fasten the timing chain with a clamp PEGASO 650 STRADA TRAIL FACTORY Engine ENG 123 ...

Page 124: ...in stages Undo and remove the two screws Remove the head paying attention to the timing chain and to the decompres sion system as it is free and can move inside its own seat Collect the gasket and the two centring dowels Engine PEGASO 650 STRADA TRAIL FACTORY ENG 124 ...

Page 125: ...s suitably shaped for its removal Slide off the camshaft with caution pay ing attention to the decompression lev er pin See also Removing the rocker arms Removing the rocker arms Remove the head Working from both sides undo and re move the four screws PEGASO 650 STRADA TRAIL FACTORY Engine ENG 125 ...

Page 126: ...collect the O ring Undo and remove the two set screws Remove the snap ring from the bear ing Using the suitable extractor remove the decompression shaft Specific tooling 8140848 Rocking lever shaft extractor Engine PEGASO 650 STRADA TRAIL FACTORY ENG 126 ...

Page 127: ...lever Using the suitable extractor remove the inlet rocking lever shaft Specific tooling 8140848 Rocking lever shaft extractor Remove inlet rocking lever Removing the valves CAUTION THE FOLLOWING PROCEDURE APPLIES TO ALL VALVES AND THEIR COMPONENTS Remove the rocking levers and the camshafts CAUTION PEGASO 650 STRADA TRAIL FACTORY Engine ENG 127 ...

Page 128: ...RDER TO PLACE THEM IN THEIR ORIGINAL POSITION UPON FITTING Use the valve springs compressor and the valve springs compressor adaptor to remove the valve cotters Specific tooling AP8140179 Valve spring compressor AP0276474 Valve spring compressor adaptor Remove the valve spring retaining el ement Remove the valve spring Remove valve stem oil seal 1 and the valve spring 2 seat Engine PEGASO 650 STRA...

Page 129: ...overhead camshaft Check that the camshaft toothed wheel works properly if it is damaged or does not move smoothly replace both the timing chain and the camshaft toothed wheel CAMSHAFT LOBES Check that they do not show blue col ouring pitting or scratches otherwise replace the camshaft and the relevant toothed wheel Use a micrometer to check the sizes a and b of the camshaft lobes Camshaft lobes si...

Page 130: ...PROCEDURE APPLIES TO ROCKING LEVERS AND ROCKING LEVER SHAFTS Use an internal micrometer to measure the rocking lever inside diameter and replace the lever if necessary Rocking lever inside diameter 12 000 12 018 mm 0 4724 0 4731 in Maximum limit 12 036 mm 0 4739 in Check that the outside diameter of the rocking lever shaft does not show blue colouring pitting or scratches other wise replace the co...

Page 131: ... the valve stem C diameter Use an internal micrometer to measure the valve guide D inside diameter Calculate the clearance Z between the stem and the valve guide Z c d Clearance between the stem and the valve guide Inlet 0 010 0 037 mm 0 0004 0 0015 in Limit 0 08 mm 0 0031 in Outlet 0 025 0 025 mm 0 0010 0 0020 in Limit 0 10 mm 0 0039 in If the clearance is not within the specified values replace ...

Page 132: ...F THE VALVE IS REMOVED OR RE PLACED ALWAYS REPLACE THE VALVE STEM OIL GUARD AS WELL Maximum stem eccentricity 0 010 mm 0 0004 in VALVE SEATS CHECK CAUTION THE FOLLOWING PROCEDURE APPLIES TO ALL VALVES AND VALVE GUIDES Clean off any carbon deposits from the valve face and valve seat Check the valve seat for pitting and signs of wear If there are replace the head Observing the following indications ...

Page 133: ...between the stem and the valve guide 2 Apply lubricating oil containing molybdenum disulphide on the valve stem 3 Fit the valve to the cylinder head 4 Turn the valve until the valve face and the valve seat are evenly lapped then wipe off any trace of lapping abrasive To obtain better lapping results tap the valve seat while it is turned forwards and back wards between the hands 5 Use a fine abrasi...

Page 134: ...5 00 mm 1 38 in If the length measured is not within the specified values replace the valve spring Compressed valve spring strength fitted 171 197 N at 35 00 mm 17 44 20 09 Kg at 35 00 mm 38 44 44 29 lb at 1 38 in On a contrasting surface use a square to measure the valve spring angle H If the length measured is not within the specified values replace the valve spring Checking the cylinder head Us...

Page 135: ...ING PROCEDURE APPLIES TO ALL VALVES AND THEIR COMPONENTS Deburr the valve stem end Lubricate the valve stem and the valve stem oil seal with oil Fit the valve Fit the valve spring seat 1 and the oil seal 2 CAUTION LUBRICATE THE OIL SEAL BEFORE INSTALLING IT APPLY AN EMULSIFIED SOLUTION ON THE OIL SEAL OUTSIDE DIAMETER TO FACILITATE INSERTION Fit the valve spring CAUTION FIT THE VALVE SPRING WITH T...

Page 136: ...ix the valve cotters on the valve stem slightly hit the valve head with a soft head mallet HITTING THE VALVE HEAD EXCESSIVELY MAY DAMAGE THE VALVE Installing the overhead camshaft CAUTION BEFORE FITTING THE BEARING APPLY ENGINE OIL MOUNT IT SO THAT THE OIL SEAL FACES a THE CAM SHAFT LUBRICATE THE OIL SEAL BEFORE INSTALLING IT APPLY AN EMULSIFIED SOLUTION ON THE OIL SEAL OUTSIDE DIAMETER TO FACILIT...

Page 137: ...ver to the camshaft as indicated Fit the camshaft facing upwards CAUTION FIT THE CAMSHAFT WITH CAUTION PAYING ATTENTION TO THE DECOMPRESSOR LEVER PIN LUBRICATE SHAFTS AND ROCKING LEVERS BEFORE FITTING THEM Timing Chain removal Remove the flywheel and the free wheel Remove the chain slider Remove the timing chain from the crankshaft See also Removing the chain sliders PEGASO 650 STRADA TRAIL FACTOR...

Page 138: ...damage replace the component if re quired Check the correct operation of the one way chamber if the movement is not smooth replace the timing chain ten sioner housing Check that the timing chain tensioner threaded cap the copper washer the spring the one way cam the gasket the timing chain tensioner rod are not damaged or worn replace the defec tive parts if required Engine PEGASO 650 STRADA TRAIL...

Page 139: ...cket wheels Check the timing chain guide for damage If necessary replace the parts Installing sliders Fit the rear chain slider Tighten the two screws See also Removing the starter gear Installing the chain Remove the chain slider Fit the timing chain on the crankshaft See also Installing sliders PEGASO 650 STRADA TRAIL FACTORY Engine ENG 139 ...

Page 140: ... the cylinder block and tighten the two screws to prescri bed torque CAUTION INSERT THE GASKET WITH THE MOULDED SIDE FACING THE TIMING CHAIN TENSIONER END Fit the spring 3 and the threaded cap 1 of the timing chain tensioner tighten the cap to the pre set torque Cam timing Timing FOR THE NEXT OPERATIONS PAY ATTENTION NOT TO TURN THE CRANKSHAFT IN ORDER TO AVOID DAMAGES OR A WRONG VALVE ADJUSTMENT ...

Page 141: ...he stationary reference mark f on the cylinder head Pre tighten the camshaft toothed wheel screws Fit the chain tensioner Turn the crankshaft anticlockwise several times and check the reference mark I CAUTION PLACE THE FLYWHEEL SO THAT THE REFERENCE MARK I b ON IT IS ALIGNED WITH THE STATIONARY REFERENCE c ON THE FLYWHEEL COVER CAUTION MAKE SURE THAT THE REFERENCE MARK I E ON THE TOOTHED WHEEL IS ...

Page 142: ...its position Working from both sides tighten the four screws of the two covers Position the cover of the camshaft toothed wheel Tighten the two screws Cylinder piston assembly Removing the cylinder The cylinder head should be removed before removing the cylinder Remove the timing chain slider on the exhaust side Undo and remove the screws fixing the cooling system union Remove the cooling system u...

Page 143: ... Unscrew and remove the four stud bolts in the sequence indicated and collect the washers PEGASO 650 STRADA TRAIL FACTORY Engine ENG 143 ...

Page 144: ...linder Mark the piston crown on the exhaust side so as to remember the fitting direction CAUTION BEFORE TAKING OUT THE PIN LOCKING RING COVER THE CRANKCASE OPENING WITH A CLEAN CLOTH SO THAT THE RING DOES NOT FALL INTO THE CRANKCASE Take out the pin locking ring Use a piston pin extractor to remove the pin Do not use a hammer to remove the pin Specific tooling 8600388 Pin piston extractor Remove t...

Page 145: ...hreads are in proper conditions Check cylinder sliding surface for signs of friction and scratches Also check the seal sur faces for damages CAUTION IF THE GROOVES ON THE CYLINDER LINER ARE EVIDENT REPLACE THE CYLINDER AND THE PISTON PEGASO 650 STRADA TRAIL FACTORY Engine ENG 145 ...

Page 146: ...m 0 002 in R D1 D3 D5 max D2 D4 D6 min Replace the cylinder the piston and the piston ring all together if not com plying with specifications Checking the piston Measure the piston skirt diameter P with a micrometer a 10 mm 0 39 in from the piston lower border Calculate the clearance between pis ton and cylinder as follows Piston cylinder clearance C C P Piston cylinder clearance 0 030 0 055 mm 0 ...

Page 147: ...ring port and replace it if not complying with specifications CAUTION IT IS NOT POSSIBLE TO MEASURE THE GAP OF THE OIL SCRAPER RING END IF CLEARANCE IS EXCESSIVE RE PLACE THE THREE PISTON RINGS Piston ring end gap Top ring 0 25 0 35 mm 0 0079 0 0138 in Limit 0 60 mm 0 0236 in Intermediate ring 0 35 0 50 mm 0 0138 0 0197 in Limit 0 85 mm 0 0335 in Oil scraper ring 0 20 0 70 mm 0 0079 0 0276 in PIN ...

Page 148: ...in Calculate the clearance between pin and pin hole and if not complying with specifications replace both pin and piston Pin piston clearance C b a 0 004 0 024 mm 0 0002 0 0009 in Limit 0 074 mm 0 0029 in Fitting the piston CAUTION WHEN FITTING THE PISTON RINGS MAKE SURE THAT THEY ARE REFITTED WITH THE MAN UFACTURER REFERENCES OR MARKING FACING UPWARDS Fit the top ring the intermediate ring the oi...

Page 149: ...PISTON FACES THE CYLINDER EXHAUST SIDE LUBRICATE THE PIN WITH ENGINE OIL BEFORE INSERTING IT CAUTION BEFORE INSERTING THE PIN LOCKING RING COVER THE CRANKCASE OPENING WITH A CLEAN CLOTH SO THAT THE RING DOES NOT FALL INTO THE CRANKCASE PEGASO 650 STRADA TRAIL FACTORY Engine ENG 149 ...

Page 150: ...ylinder Using the special tool compress the piston rings and fit the cylinder Specific tooling 0276357 Piston ring clamp Fit the timing chain guide exhaust side CAUTION LEAD THE TIMING CHAIN AND THE RELEVANT GUIDE EXHAUST SIDE THROUGH THE TIMING CHAIN NOTCH Fit four new washers with their rounded surface facing upwards THE CYLINDER STUD BOLTS ARE DIFFERENT IN PAIRS THOSE ON THE TIMING SYSTEM SIDE ...

Page 151: ... Tighten the four cylinder stud bolts to the different prescribed torques PEGASO 650 STRADA TRAIL FACTORY Engine ENG 151 ...

Page 152: ...system joint Installing the cylinder head Fit the two centring dowels Fit a new cylinder head gasket CAUTION aprilia SUPPLIES AN ADDITIONAL GASKET TO BE FITTED UNDER THE CYLINDER HEAD TO COMPENSATE FOR ANY POTENTIAL TOLERANCE INACCURACIES FOR CRANKCASE COUPLING Engine PEGASO 650 STRADA TRAIL FACTORY ENG 152 ...

Page 153: ... PAYING ATTENTION TO THE TIGHTENING SE QUENCE AND THE CORRECT TORQUE IN TWO STAGES Tighten the two longest cylinder head screws on the left side to the prescri bed torque Tighten the two shortest cylinder head screws on the right side to the prescri bed torque Tighten the two lower cylinder head screws to the prescribed torque Carry out the operations described in the Timing section See also Timin...

Page 154: ...gnition spark plug Undo and remove the two screws re move the secondary air pipe and col lect the metal gasket Remove the oil delivery pipe and col lect the O Ring Release the clamp and remove the oil reservoir flexible breather pipe Undo and remove the two screws re move the oil pipe and collect the four washers Engine PEGASO 650 STRADA TRAIL FACTORY ENG 154 ...

Page 155: ...se the fastening clamp and re move the crankcase breather chamber flexible pipe Undo and remove the screw and re move the speed sensor Loosen the screw and disconnect the neutral sensor PEGASO 650 STRADA TRAIL FACTORY Engine ENG 155 ...

Page 156: ...and remove the screw and re move the cable guide Undo and remove the two screws re move the oil delivery pipe and collect the four washers Remove the water pump Remove the cylinder Remove the engine oil filter Remove the oil pump Remove the gear selector Remove the alternator Engine PEGASO 650 STRADA TRAIL FACTORY ENG 156 ...

Page 157: ...Remove the guide of the timing chain on the intake side sliding it off from above Remove the timing chain Straighten the washer tongues Unscrew and remove the nut and col lect the washer Remove the chain pinion PEGASO 650 STRADA TRAIL FACTORY Engine ENG 157 ...

Page 158: ...nd in stages Loosen and then remove all the screws Working from the right side straighten the safety washer tongues Unscrew and remove the balancer driven gear nut collect the washer Remove the driven gear and collect the tab Engine PEGASO 650 STRADA TRAIL FACTORY ENG 158 ...

Page 159: ...n screw and remove the balancer driving gear nut at the same time Collect the washer Specific tooling 8140840 Connecting rod locking Remove the washer Remove the water pump driving gear Remove the main transmission driving gear PEGASO 650 STRADA TRAIL FACTORY Engine ENG 159 ...

Page 160: ...f a turn at a time operating diagonally and in stages Loosen and then remove all the screws By using the connecting rod locking tool and the crankcase separator open the two crankcase halves Specific tooling 8140840 Connecting rod locking 8140853 Crankcase separator Engine PEGASO 650 STRADA TRAIL FACTORY ENG 160 ...

Page 161: ...o tools Remove the right crankcase half See also Removing the throttle body Spark plug Cooling system Removing the cylinder Engine oil filter Removing Removing the gear selector Magneto flywheel removal Removing the chain sliders Chain removal Start up system check PEGASO 650 STRADA TRAIL FACTORY Engine ENG 161 ...

Page 162: ...ase halves Inspecting the crankcase halves BEARINGS AND OIL SEAL CHECK Using a non aggressive solvent thoroughly clean both sections of the engine crankcase the ball bear ings and all the bearing seats Clean the seal surfaces and check that they are not damaged CAUTION TO AVOID DAMAGING BOTH CRANKCASE HALVES PLACE THEM ON A FLAT SURFACE Check that both crankcase halves are not cracked or damaged C...

Page 163: ...that the oil delivery pipe holes are not ob structed and if required clean with compressed air Checking the counter shaft Check that the countershaft driven gear the countershaft driving gear the water pump driving gear the main transmission driving gear are not damaged or show signs of wear If necessary replace the damaged or worn components Refitting the crankcase halves CAUTION REPLACE AND LUBR...

Page 164: ...giving a few taps with a rubber mallet CAUTION CHECK THE CORRECT SHAFT ROTATION Correctly fit the six fixing screws for the left crankcase half Tighten the six screws to the prescri bed torque operating diagonally Locking torques N m Clutch crankcase half and flywheel crankcase halves screws 10 Nm Fit the washer Engine PEGASO 650 STRADA TRAIL FACTORY ENG 164 ...

Page 165: ...t the countershaft driving gear Fit the cotter with its rounded surface facing upwards Fit the main transmission driving gear Fit the water pump driving gear PEGASO 650 STRADA TRAIL FACTORY Engine ENG 165 ...

Page 166: ...UTION MAKE SURE THAT THE WASHER TONGUE IS INSERTED IN THE TAB SLOT Tighten the driving gear nut of the main transmission to the prescribed torque and fold the tongues Insert the tab and fit the countershaft driven gear Engine PEGASO 650 STRADA TRAIL FACTORY ENG 166 ...

Page 167: ...afety washer tabs Fit the right crankcase cover Fit the clutch Install the water pump unit Correctly fit the seven fixing screws for the right crankcase half Tighten the seven screws to the pre scribed torque operating diagonally Locking torques N m Clutch crankcase half and flywheel crankcase halves screws 10 Nm Fit the pinion PEGASO 650 STRADA TRAIL FACTORY Engine ENG 167 ...

Page 168: ... the engine oil filter Fit the water pump Fit the flexible oil delivery pipe Fit the pipe and the cable guide Fit the neutral sensor Fit the speed sensor Fit the crankcase chamber breather pipe Fit the starter motor Fit the oil tank flexible breather pipe Fit the oil delivery pipe Fit the secondary air pipe Fit the ignition spark plug Fit the throttle body Lubrication Engine PEGASO 650 STRADA TRAI...

Page 169: ...Conceptual diagrams PEGASO 650 STRADA TRAIL FACTORY Engine ENG 169 ...

Page 170: ...y pipe 2 2 Oil delivery pipe 2 3 Oil filter 4 Oil pump rotor 1 5 Oil pump rotor 2 6 Main axle 7 Oil delivery pipe 3 8 Camshaft 9 Oil delivery pipe 1 10 Oil filter 11 Main shaft 12 Secondary shaft Engine PEGASO 650 STRADA TRAIL FACTORY ENG 170 ...

Page 171: ... container of suitable capacity underneath the engine Remove the clutch Undo and remove the two screws and remove the oil deflector Remove the safety circlip 1 and slide off the oil pump gear 2 Undo and remove the two screws PEGASO 650 STRADA TRAIL FACTORY Engine ENG 171 ...

Page 172: ...ing Undo and remove the screw Remove the oil pump unit and collect the two O rings Should the oil intake filter be removed separate the crankcase Undo and remove the three screws and remove the filter Engine PEGASO 650 STRADA TRAIL FACTORY ENG 172 ...

Page 173: ... replace the part Check oil pump works properly If it does not re place the oil pump all together Installing Replace the two O rings and fit the oil pump unit Tighten the screw Replace the O ring Fit the oil deflector and tighten the two screws PEGASO 650 STRADA TRAIL FACTORY Engine ENG 173 ...

Page 174: ... combustion process as am bient air rich in oxygen is supplied to the flow of burned gases This system is particularly neces sary when the engine is idling and at the warming up stage as given these conditions the catalytic converter is not able to activate the post combus tion reaction freely Thanks to the secondary air system SAS the post combustion reaction is immediately activated outside the ...

Page 175: ...exhaust valves and the catalytic converter When riding the valve remains closed At low rpm the valve is activated to reduce carbon monoxide emissions WHEN ADJUSTING CO DEACTIVATE THE SECONDARY AIR SYSTEM AS THE EXHAUST FUMES DILUTED BY THE SYSTEM DISTORT THE READING OF THE CARBON MON OXIDE PERCENTAGE SEE THE CO ADJUSTMENT SECTION TO DEACTIVATE THE SAS AFTER ADJUSTING CO REMEMBER TO RESTORE THE SEC...

Page 176: ...Inspecting the cut off Resistance of the Secondary air system solenoid 18 22 Ohm at 20 C 68 F between brown red cable and red white cable Engine PEGASO 650 STRADA TRAIL FACTORY ENG 176 ...

Page 177: ...INDEX OF TOPICS POWER SUPPLY P SUPP ...

Page 178: ...Fuel tank 2 Fuel tank cap 3 Rubber ring 4 Spacer 5 TE flanged screw 6 Fuel level sensor 7 Fuel filter 8 Fuel pump flange gasket 9 TE flanged screw 10 Fuel delivery pipe Power supply PEGASO 650 STRADA TRAIL FACTORY P SUPP 178 ...

Page 179: ... in 5 Preformed pipe Ø 13x18 mm 0 51x0 71 in 6 Pressure sensor pipe 7 Throttle body pipe 8 Retaining clip Ø 11 5 mm 0 45 in 9 Retaining clip Ø 11 5 mm 0 45 in 10 Yellow retaining clip Ø 8 5 mm 0 33 in 11 Retaining clip Ø 18 mm 0 71 in 12 Air pressure sensor MAP Sensor 13 TE flanged screw PEGASO 650 STRADA TRAIL FACTORY Power supply P SUPP 179 ...

Page 180: ...l shows the set value The set value will be stored by the ECU at KEY OFF The engine revs are shown at this stage The following message is displayed Turn the key to stop Once the key extraction is been detected the following message is displayed Turn the key to run Once the key reinsertion is detected while waiting to get the connection with the engine control unit the following message is displaye...

Page 181: ...READING This screen page shows the parameters meas ured by the several sensors engine revs engine temperature etc or values set by the control unit injection time ignition advance etc ENGINE PARAMETER READING SCREEN PAGE Specification Desc Quantity Throttle opening Example value 16 6 Intake air pressure Example value 102 kPa 14 8 PSI Air temperature Example value 18 C 64 4 F Water temperature C F ...

Page 182: ...r this Neutral sensor Example ON The sensor status can only be displayed when the instrument panel is active therefore Axone cannot be used for this Devices activation screen page DEVICES ACTIVATION This screen page is used to delete errors in the control unit memory and to activate some systems controlled by the control unit DEVICES ACTIVATION SCREEN PAGE Specification Desc Quantity Error clearin...

Page 183: ...very value of 80 C 176 F Air temperature sensor Error 22 interruption or short circuit in the sensor circuit The control unit sets a recovery value of 22 C 68 F Fall sensor Error 30 sensor overturned Fall sensor Error 41 interruption or short circuit in the sensor circuit Coil Error 33 malfunction detected in the coil primary circuit Speed sensor neutral sensor Error 42 Battery supply Error 43 the...

Page 184: ...een page ADJUSTABLE PARAMETERS This screen page is used to adjust some control unit parameters ADJUSTABLE PARAMETERS SCREEN PAGE Specification Desc Quantity CO adjustment Power supply PEGASO 650 STRADA TRAIL FACTORY P SUPP 184 ...

Page 185: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 186: ...sleeve 3 Right sleeve 4 Sliding bushing 5 Pumping member 6 Pumping member ring 7 Counter spring 8 Bottom buffer 9 Sealing washer 10 TCEI screw M12x1 25x25 11 Guide bushing 12 Ring 13 Oil seal 14 Snap ring Suspensions PEGASO 650 STRADA TRAIL FACTORY SUSP 186 ...

Page 187: ...ctory 26 Brake calliper attachment plate Factory Removing the fork legs Remove the front headlight assembly Remove the reservoir Hold the stand front part using the front service stand OPT Undo and remove both screws fixing the half mudguards Working from both sides undo and re move the screw fixing the front half mudguard and remove it PEGASO 650 STRADA TRAIL FACTORY Suspensions SUSP 187 ...

Page 188: ...on not to operate the front brake control lever to avoid lock ing the pads The following operation should be considered valid for the FACTORY version only Undo and remove both screws fixing the front brake calliper flange The following operation should be considered valid for the FACTORY version only Remove the front brake calliper with the flange paying special attention not to operate the front ...

Page 189: ...w the wheel pin clamp screws and unscrew the wheel pin completely Hold the front wheel and slide off the wheel pin manually Remove the wheel by sliding it off for wards Hold the stem and loosen the three stem fixing screws on the lower steer ing plate PEGASO 650 STRADA TRAIL FACTORY Suspensions SUSP 189 ...

Page 190: ...HANGE THE FORK OIL PERIODICALLY CAUTION DURING OIL DRAINAGE AND REFILLING OPERATIONS THE STEM AND ITS INNER PARTS SHOULD BE LOCKED IN A VICE BE VERY CAREFUL NOT TO DAMAGE THEM BY EXERTING AN EXCESSIVE FORCE ALWAYS USE ALUMINIUM JAW CAPS Remove the fork stem Unscrew and remove the upper cap paying attention to the O ring and be ing careful not to damage the stem surface Suspensions PEGASO 650 STRAD...

Page 191: ...he spring Drain off the oil into a collecting con tainer CAUTION FOR EASY DRAINAGE OF THE OIL INSIDE THE PUMPING MEMBER ROD PRESS THE STEM IN THE WHEEL HOLD ER SLEEVE TO PUMP OIL OUT See also Removing the fork legs PEGASO 650 STRADA TRAIL FACTORY Suspensions SUSP 191 ...

Page 192: ...a vice in a vertical position Remove the dust scraper using a screwdriver as a lever BE CAREFUL NOT TO DAMAGE THE SLEEVE RIM AND THE DUST SCRAPER Slide the dust scraper off and upwards Remove the locking ring inside the sleeve using a thin screwdriver BE CAREFUL NOT TO DAMAGE THE SLEEVE RIM Suspensions PEGASO 650 STRADA TRAIL FACTORY SUSP 192 ...

Page 193: ...off the pumping member together with the bottom buffer Place the sleeve on the vice in a verti cal position Firmly slide off the stem together with the lower sliding bushing Remove the oil seal PEGASO 650 STRADA TRAIL FACTORY Suspensions SUSP 193 ...

Page 194: ...ce the stem Use a dial gauge to check that the stem bending is below the limit value If over the value replace the stem CAUTION A BENT STEM SHOULD NEVER BE STRAIGHTENED BECAUSE ITS STRUCTURE WOULD BE WEAKENED AND USING THE VEHICLE MAY BECOME DANGEROUS Characteristic Bending limit 0 2 mm 0 00787 in Sleeve Check that there are no damages and or cracks otherwise replace it Spring Check the spring is ...

Page 195: ...are signs of excessive wear or damage replace the affected component CAUTION REMOVE ANY IMPURITY IN THE BUSHINGS TAKING CARE NOT TO SCRATCH THEIR SURFACE Replace the following components with new ones seal ring PEGASO 650 STRADA TRAIL FACTORY Suspensions SUSP 195 ...

Page 196: ... dust gaiter O Ring on the cap Reassembling the fork Place the upper sliding bushing Place the oil seal on the fork stem Suspensions PEGASO 650 STRADA TRAIL FACTORY SUSP 196 ...

Page 197: ...ttom buffer on the stem Fit the fork stem on the sleeve insert ing the shim washer and the oil seal in their seats on the sleeve BE CAREFUL NOT TO DAMAGE THE SLEEVE RIM Place the snap ring inside the sleeve using a thin screwdriver PEGASO 650 STRADA TRAIL FACTORY Suspensions SUSP 197 ...

Page 198: ... holder sleeve on the vice in a vertical position Fill with oil See also Filling oil Filling oil Lock the wheel holder sleeve on the vice in a vertical position Pour oil into the stem Pump the stem making sure the oil has completely filled the pumping member rod Suspensions PEGASO 650 STRADA TRAIL FACTORY SUSP 198 ...

Page 199: ...asher and the spring preloading spacer in this order Fit the plug on the holding tube taking care not to damage the O ring Then tighten the plug to the prescribed torque PEGASO 650 STRADA TRAIL FACTORY Suspensions SUSP 199 ...

Page 200: ...wer steer ing plate Spread a thin layer of lubricating grease all along the wheel pin Position the front wheel between the fork stems over the support Move the wheel until the central hole is aligned with the holes on the fork Fit one of the two spacers between the wheel hub and the right fork stem Fit the other spacer between the wheel hub and the left fork stem Suspensions PEGASO 650 STRADA TRAI...

Page 201: ...ten the left side wheel pin clamp screws Loosen the right side wheel pin clamp screws Align the stems by exerting some pres sure on the forecarriage Tighten the right side wheel pin clamp screws Upon removal take out the stand fitted under the tyre Place the brake calliper and tighten the fixing screws PEGASO 650 STRADA TRAIL FACTORY Suspensions SUSP 201 ...

Page 202: ...and Operating the brake lever press the handlebar repeatedly to make the fork go fully down In this way the fork stems will be correctly adjusted Place the vehicle on the service stand Tighten the wheel pin clamp screws from both sides Place the fork reinforcing plate and tighten the two fixing screws Place the rear half mudguard and tighten the two fixing screws Suspensions PEGASO 650 STRADA TRAI...

Page 203: ...nd Working from both sides loosen the screw fixing the fork stem to the upper fork plate Locking torques N m Fork stem on upper plate fixing screws M8 25 Nm Unscrew and remove the upper plate fixing cover Slide off the plate and the handlebar from the fork stems Adjust the bearing loading using the specific tool Specific tooling 8163500 Fork sleeve ring nut PEGASO 650 STRADA TRAIL FACTORY Suspensi...

Page 204: ...Locking torques N m Upper plate fixing cover M22x1 100 Nm Head stock ring nut M25x1 5 7 Nm Suspensions PEGASO 650 STRADA TRAIL FACTORY SUSP 204 ...

Page 205: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 206: ...sions WARNING IT IS NOT NECESSARY TO REMOVE THE BRAKE CALLIPER IN ORDER TO REMOVE THE PADS Turn the pins and remove both split pins Remove both pins Remove the vibration damping plate Braking system PEGASO 650 STRADA TRAIL FACTORY BRAK SYS 206 ...

Page 207: ...versions WARNING IT IS NOT NECESSARY TO REMOVE THE BRAKE CALLIPER IN ORDER TO REMOVE THE PADS Slide off the safety seeger ring Unscrew and remove the pin Slide off the pad by rotating it down and backwards WARNING TAKE CARE NOT TO DAMAGE THE VIBRATION DAMPING PLATES WHEN TAKING OUT THE PADS Installing Strada Trail versions PEGASO 650 STRADA TRAIL FACTORY Braking system BRAK SYS 207 ...

Page 208: ...AUTION ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED INSIDE THE CALLIPER Place the vibration damping plate Insert both pins Place both split pins Check the brake fluid level in the res ervoir Factory versions Braking system PEGASO 650 STRADA TRAIL FACTORY BRAK SYS 208 ...

Page 209: ...th the cal liper holes CAUTION ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED INSIDE THE CALLIPER Tighten the pin Fit the safety seeger ring Rear brake pads Removal Remove the split pin PEGASO 650 STRADA TRAIL FACTORY Braking system BRAK SYS 209 ...

Page 210: ... FLUID LEAKS Installing Insert two new pads placing them so that the holes are aligned with the cal liper holes CAUTION ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED INSIDE THE CALLIPER Insert the pin Place the split pin Check the brake fluid level in the res ervoir Bleeding the braking system Braking system PEGASO 650 STRADA TRAIL FACTORY BRAK SYS 210 ...

Page 211: ... WHILE PURGING THE HYDRAULIC SYSTEM FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID CHECK THAT DURING THE OPERA TION THERE IS ALWAYS BRAKE FLUID IN THE RESER VOIR Remove the rubber protection cover from the bleed valve Insert the transparent plastic pipe in the front brake calliper bleed valve and slide the other end of this pipe in a con tainer to collect the fluid Remove the front ...

Page 212: ...s of the brake control and poor braking effi ciency CAUTION CONSIDERING THE DANGER FOR VEHICLE AND RIDER IT IS STRICTLY NECESSARY AFTER REFITTING BRAKES AND RESTORING THE BRAKING SYSTEM TO THE REGU LAR USE CONDITIONS THAT THE HYDRAULIC CIRCUIT BE AIR PURGED THE VEHICLE MUST BE ON LEVEL GROUND TO BE PURGED WHILE PURGING THE HY DRAULIC SYSTEM FILL THE RESERVOIR WITH THE NEC ESSARY QUANTITY OF BRAKE ...

Page 213: ...id draining into the container is air bubble free NOTE WHILE PURGING THE HYDRAULIC SYSTEM FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID CHECK THAT DURING THE OPERATION THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR Screw the bleed valve and remove the pipe Top up the reservoir until the right brake fluid level is obtained Refit and lock the rear brake oil reservoir cap Refit the rubb...

Page 214: ...INDEX OF TOPICS COOLING SYSTEM COOL SYS ...

Page 215: ... tank to facilitate coolant drain age Refit the drainage screw with a new copper washer Top up through the circuit filler Press the sleeves repeatedly with your hands to drain off the coolant in the pipes THE CORRECT LEVEL IS REACHED WHEN THE COOLANT STABILISES RIGHT BELOW THE FILLER Top up again Tighten the circuit filler cap A Unscrew the expansion tank cap and top up the fluid in the expansion ...

Page 216: ...HEN THE COOLANT DOES NOT HAVE ENGINE OIL CAUTION PLACE A CLOTH UNDER THE PUMP BEFORE REMOVING ITS COMPONENTS Undo and remove the two screws 1 Collect the washer 2 Undo and remove the three screws 3 Remove the water pump cover 4 Remove the gasket 5 Undo and remove the two screws Remove the pump unit Release and remove the clamps Cooling system PEGASO 650 STRADA TRAIL FACTORY COOL SYS 216 ...

Page 217: ... off the flexible breather pipe of the water pump 7 Unscrew and remove the screw Slide off the water pump outlet pipe and collect the O ring Remove the seeger ring Remove the engine gear PEGASO 650 STRADA TRAIL FACTORY Cooling system COOL SYS 217 ...

Page 218: ...rubber damper 9 from the ro tor using a screwdriver for plain slot screws CAUTION REMOVE THE COMPONENT WITH CARE SO AS NOT TO DAMAGE THE ROTOR Remove the water pump gasket using a thin screwdriver OPERATE WITH CAUTION IN THE DIRECTION INDICATED BY THE ARROW SO AS NOT TO DAMAGE THE WATER PUMP GASKET RIM Cooling system PEGASO 650 STRADA TRAIL FACTORY COOL SYS 218 ...

Page 219: ...t pipe and the water cooled jacket outlet housing are not damaged or excessively worn Replace them if they are GASKETS Check that the gaskets are in good conditions replace them if they show signs of damage or excessive wear BEARINGS Manually rotate the internal ring which must turn smoothly without obstacles and or noise There must be no axial clearance The bearings presenting these problems must...

Page 220: ...1 Water pump fitting tool CAUTION BEFORE FITTING THE RUBBER DAMPER APPLY AN EMULSIFIED SOLUTION ON THE EXTER NAL SURFACE TO FACILITATE INSERTION Fit a new rubber damper 9 and a new rubber damper support 8 CAUTION MAKE SURE THAT THE RUBBER DAMPER AND THE DAMPER SUPPORT ARE FLUSH TO THE ROTOR Check the rotor shaft angle by placing a ruler on the damper which must be flush with the rotor Place a gaug...

Page 221: ...amper support 8 Fit the rotor shaft unit Insert the washer and the pin Fit the engine gear so that the marks are visible Insert a new seeger ring CAUTION ONCE THE INSTALLATION IS FINISHED MANUALLY RO TATE THE ROTOR SHAFT WHICH MUST TURN SMOOTH LY WITHOUT OBSTACLES AND OR NOISE PEGASO 650 STRADA TRAIL FACTORY Cooling system COOL SYS 221 ...

Page 222: ...INDEX OF TOPICS BODYWORK BODYW ...

Page 223: ...ews Remove the front cowl Disconnect the instrument panel con nector The right bracket remains on the scoot er because the cable harness goes through it Undo and remove the two external screws PEGASO 650 STRADA TRAIL FACTORY Bodywork BODYW 223 ...

Page 224: ...acket remains fixed to the front headlight Undo and remove the two internal screws Undo and remove the external screw Release the headlight cable harness connector Bodywork PEGASO 650 STRADA TRAIL FACTORY BODYW 224 ...

Page 225: ...ody panels Removal Remove the saddle Working from both sides unscrew and remove the two side fairing fixing screws and remove the side fairings Lower cowl Removal Undo and remove the oil sump guard front fixing screw PEGASO 650 STRADA TRAIL FACTORY Bodywork BODYW 225 ...

Page 226: ...pe Fuel tank Remove the front headlamp Remove the saddle Undo and remove the two fixing screws and remove the right support cover to free the cable harnesses Lift the glove compartment cover through the relevant control on the switch Unscrew and remove the six screws Bodywork PEGASO 650 STRADA TRAIL FACTORY BODYW 226 ...

Page 227: ...lift it and disconnect the connector Remove the fuel tank cap Lift the glove compartment and slide off the fuel breather pipe Remove the three clamps fixing the fuel breather pipe Slide off the fuel breather pipe Screw the fuel tank cap PEGASO 650 STRADA TRAIL FACTORY Bodywork BODYW 227 ...

Page 228: ...ove compartment to gether with the motor Disconnect the fuel pipe Unscrew and remove the front screw fixing the tank Undo and remove the two side screws one per side Bodywork PEGASO 650 STRADA TRAIL FACTORY BODYW 228 ...

Page 229: ...he side fairings Undo and remove the three screws fix ing the passenger grab handle Remove the passenger grab handle See also Side body panels Tail guard Removal Remove the passenger grab handle Working from both sides undo and re move the front fixing screw PEGASO 650 STRADA TRAIL FACTORY Bodywork BODYW 229 ...

Page 230: ...per fixing screws Working from both sides undo and re move the two rear lower fixing screws Lift the tail section Disconnect the saddle unlocking ca ble Remove the tail section See also Rear grab rail Bodywork PEGASO 650 STRADA TRAIL FACTORY BODYW 230 ...

Page 231: ...INDEX OF TOPICS PRE DELIVERY PRE DE ...

Page 232: ...rews Electrical system Main switch Headlamps high beam lights low beam lights tail lights front and rear and their warning lights Headlight adjustment according to regulations in force Front and rear stop light switches and their bulbs Turn indicators and their warning lights Instrument panel lights Instrument panel fuel and temperature indicator if present Instrument panel warning lights Horn Ele...

Page 233: ...CT WITH YOUR EYES OR SKIN WASH WITH ABUNDANT WATER FOR AP PROX 15 MIN AND SEEK MEDICAL ATTENTION IMMEDIATELY IF ACCIDENTALLY SWALLOWED IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL SEEK IMMEDIATE MEDICAL ATTENTION BATTERIES PRODUCE EXPLOSIVE GASES KEEP CLEAR OF NAKED FLAMES SPARKS OR CIGARETTES VENTILATE THE AREA WHEN RECHARGING INDOORS ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE...

Page 234: ...ctional inspection Hydraulic braking system Stroke of brake and clutch levers if present Clutch Check for correct operation Engine Check for correct general operation and absence of abnormal noise Other Documentation check Chassis and engine numbers check Supplied tools check License plate fitting Locks checking Tyre pressure check Installation of mirrors and any possible accessories NEVER EXCEED ...

Page 235: ...nt 215 Countershaft 162 Crankcase 88 153 154 162 163 Crankshaft 90 92 101 153 162 Cylinder 121 125 134 142 145 150 152 161 D Desmodromic drum 93 Display 183 Drive chain 13 E Electrical system 13 34 35 232 Engine oil 27 Engine temperature sensor 63 Exhaust F Fork 186 187 191 192 196 200 Forks 94 Front wheel Fuel 190 226 Fuses 60 H Handlebar Headlight 223 229 I Identification 10 Intake pressure sens...

Page 236: ...94 R Rear wheel Recommended products 18 S Saddle SAS valve actuator 64 Secondary shaft 91 93 97 Side stand Spark plug 27 161 Spark plugs Stand Start up 59 161 Starter motor 101 105 T Tank 190 226 Throttle body 161 180 Transmission 12 Tyres 14 W Warning lights Water pump 216 Wiring diagram 36 ...

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APRILIA PEGASO 650 STRADA, Service Station Manual

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