APRILIA PEGASO 650 STRADA Leitfaden

SERVICE STATION MANUAL

854110

PEGASO 650 STRADA - TRAIL - FACTORY

SERVICE STATION

MANUAL

PEGASO650STRADA-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 Sectionsmarkedwiththis 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

EXHAUSTEMISSIONSCONTAINCARBONMONOXIDE,APOISONOUSGASWHICHCANCAUSE

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

THEENGINESWITCHED OFF. DONOTSMOKE DURING REFUELLINGORNEARFUEL VAPOUR.

AVOIDANY CONTACTWITH NAKED FLAME, SPARKS OR OTHER HEAT SOURCES WHICHMAY

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

•Beforedismantling components, remove dirt, mud, dust and foreign bodies from the vehicle.

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

COMPONENTS REMOVAL

•Donotloosenand/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.

•Whentightening nutsandscrews, starteitherfrom thecomponentswith thelargestdiameter

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

REMEMBERTHATTHETIGHTENING TORQUES FORALLFASTENINGELEMENTS 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.

ITISIMPORTANTTOSTRAIN ENGINE COMPONENTS DURINGRUN-IN,HOWEVER,MAKESURE

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

Yyear 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

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