APRILIA PEGASO 650 STRADA Service Station Manual
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APRILIA PEGASO 650 STRADA Service Station Manual

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SERVICE STATION MANUAL
854110
PEGASO 650 STRADA - TRAIL - FACTORY

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Summary of Contents for APRILIA PEGASO 650 STRADA

  • Page 1 SERVICE STATION MANUAL 854110 PEGASO 650 STRADA - TRAIL - FACTORY...
  • Page 2 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.
  • Page 3 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.
  • Page 4 INDEX OF TOPICS CHAR HARACTERISTICS S-TOOLS PECIAL TOOLS MAIN AINTENANCE ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE P SUPP OWER SUPPLY SUSP USPENSIONS BRAK SYS RAKING SYSTEM COOL SYS OOLING SYSTEM BODYW ODYWORK PRE DE DELIVERY...
  • Page 5 INDEX OF TOPICS CHAR HARACTERISTICS...

  • Page 6: Safety Rules

    PEGASO 650 STRADA - TRAIL - FACTORY Characteristics 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.
  • Page 7 PEGASO 650 STRADA - TRAIL - FACTORY Characteristics 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.
  • Page 8 PEGASO 650 STRADA - TRAIL - FACTORY Characteristics 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.
  • Page 9 PEGASO 650 STRADA - TRAIL - FACTORY Characteristics • 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.

  • Page 10: Vehicle Identification

    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.
  • Page 11 PEGASO 650 STRADA - TRAIL - FACTORY Characteristics 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.

  • Page 12: Gear Ratios

    PEGASO 650 STRADA - TRAIL - FACTORY Characteristics 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)

  • Page 13: Drive Chain

    PEGASO 650 STRADA - TRAIL - FACTORY Characteristics 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...
  • Page 14 PEGASO 650 STRADA - TRAIL - FACTORY Characteristics 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)

  • Page 15: Tightening Torques

    PEGASO 650 STRADA - TRAIL - FACTORY Characteristics 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...

  • Page 16: Braking System

    PEGASO 650 STRADA - TRAIL - FACTORY Characteristics 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...

  • Page 17: Rear Suspension

    PEGASO 650 STRADA - TRAIL - FACTORY Characteristics 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...

  • Page 18: Front Suspension

    PEGASO 650 STRADA - TRAIL - FACTORY Characteristics 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...
  • Page 19 INDEX OF TOPICS S-TOOLS PECIAL TOOLS...
  • Page 20 PEGASO 650 STRADA - TRAIL - FACTORY Special tools PECIAL TOOLS Stores code Description AP8101945 Fork pin ring nut AP8140179 Valve spring compressor 8140837 Flywheel extractor AP8140838 Flywheel rotor locking 8140839 Engine supporting plate 8140840 Connecting rod locking S-TOOLS - 20...
  • Page 21 PEGASO 650 STRADA - TRAIL - FACTORY Special tools Stores code Description 8140841 Water pump fitting tool 8140843 Fork oil seal fitting tool, Ø 63 mm (2.48 in), H 125 mm (4.92 in) 8140844 Adaptor for crankshaft 8140845 Crankshaft spacer...
  • Page 22 PEGASO 650 STRADA - TRAIL - FACTORY Special tools Stores code Description 8140849 Rocking lever 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...
  • Page 23 PEGASO 650 STRADA - TRAIL - FACTORY Special tools Stores code Description AP0276474 Valve spring compressor adaptor S-TOOLS - 23...
  • Page 24 INDEX OF TOPICS MAIN AINTENANCE...

  • Page 25: Maintenance Chart

    PEGASO 650 STRADA - TRAIL - FACTORY Maintenance Maintenance chart AT EVERY START-UP Action Alarm warning light - check and replace if necessary Brake pad wear - check and clean or replace if necessary EVERY 500 (375 MILES Action Drive chain tension and lubrication - Check and clean, adjust, grease and replace if necessary...
  • Page 26 PEGASO 650 STRADA - TRAIL - FACTORY Maintenance Action Brake discs - Check and clean, replace if necessary. Air filter - Check and clean, replace if necessary Engine oil filter - Replace General vehicle operation - Check and clean, adjust, grease or replace if necessary.

  • Page 27: Spark Plug

    PEGASO 650 STRADA - TRAIL - FACTORY Maintenance Spark plug • Remove the ignition tube. • Remove the ignition spark plug. Engine oil Replacement • Place the vehicle on solid flat ground. • Rest the vehicle on a support. •...

  • Page 28: Engine Oil Filter

    PEGASO 650 STRADA - TRAIL - FACTORY Maintenance Engine oil filter • Drain the engine oil completely. • Loosen and remove the three screws fixing the engine oil filter cover. • Remove the engine oil filter cover to- gether with the gasket and collect the O-ring.

  • Page 29: Air Filter

    PEGASO 650 STRADA - TRAIL - FACTORY Maintenance Air filter • Remove the right side fairing. • Undo and remove the four fixing screws. • Slide off the filter support together with the air filter. • Remove the air filter from its support to clean the filtering element.
  • Page 30 PEGASO 650 STRADA - TRAIL - FACTORY Maintenance • Undo and remove the four screws and remove the outlet tappet cover. • Undo and remove the two screws (1) and collect the washers. • Remove the camshaft toothed wheel cover (2).
  • Page 31 PEGASO 650 STRADA - TRAIL - FACTORY Maintenance • Check that the reference mark (b) on the magneto rotor is aligned to the sta- tionary reference mark (a) on the mag- neto cover. The piston is at TDC. • With a thickness gauge check that the valve clearance is within the indicated values and adjust it if required.
  • Page 32 PEGASO 650 STRADA - TRAIL - FACTORY Maintenance ance until the pre-set clearance is obtained. NOTE LUBRICATE THE VALVE SET SCREWS WITH RECOM- MENDED LUBRICANTS. MAIN - 32...
  • Page 33 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 34 PEGASO 650 STRADA - TRAIL - FACTORY Electrical system Components arrangement Key: 1. Coil 2. Fuel pump 3. Fall sensor ELE SYS - 34...
  • Page 35 PEGASO 650 STRADA - TRAIL - FACTORY Electrical system 4. Rear light 5. Battery 6. Fuses 7. Control unit 8. Intake air 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...
  • Page 36 PEGASO 650 STRADA - TRAIL - FACTORY Electrical system General wiring diagram Key: 1. Multiple connectors 2. Gear in neutral switches 3. Clutch switch 4. Fall sensor ELE SYS - 36...
  • Page 37 PEGASO 650 STRADA - TRAIL - FACTORY Electrical system 5. Side stand switch 6. Speed sensor 7. Instrument panel 8. Light logic relay 9. Lambda Probe 10.Horn 11.Left light switch 12.Right light switch 13.Hazard button backlighting 14.Left rear turn indicator 15.Rear light...
  • Page 38 PEGASO 650 STRADA - TRAIL - FACTORY Electrical system 43.Coil 44.ECU 45.Right turn indicator 46.Low-beam bulb 47.Tail light bulb 48.High-beam bulb 49.Front headlamp 50.Left front turn indicator 51.Self-diagnosis connector 52.Diode 53.Diode module Cable colour: Ar orange Az sky blue B blue...
  • Page 39 PEGASO 650 STRADA - TRAIL - FACTORY Electrical system the rpm indicator pointer moves to the maximum value, set by the user After the initial check, all instruments immediately show the current value of the measurements de- tected. The standard indications displayed are:...
  • Page 40 PEGASO 650 STRADA - TRAIL - FACTORY Electrical system with low fuel (KM IN RESERVE), the screen shows the MENU, only if the vehicle is no longer in mo- tion. MENU If the vehicle is stopped, press the MODE selector at central position to access the configuration menu on the MENU screen.
  • Page 41 PEGASO 650 STRADA - TRAIL - FACTORY Electrical system ches zero, it goes to 12 the next time the MODE selector is pressed to the left. A confirmation signal stores the set value and then the minute adjustment function starts.
  • Page 42 PEGASO 650 STRADA - TRAIL - FACTORY Electrical system • RUN-IN REVOLUTIONS: 5000 rpm • MINIMUM REVOLUTIONS: 4000 rpm • MAXIMUM REVOLUTIONS: 8000 rpm If the set threshold value is exceeded, the alarm warning light on the instrument panel starts to flash.
  • Page 43 PEGASO 650 STRADA - TRAIL - FACTORY Electrical system After the first key has been inserted, the second one is requested with the following message: insert key II In between the two keys, the instrument panel should not go off; if the second key is not inserted within 20 seconds, the operation finishes.
  • Page 44 PEGASO 650 STRADA - TRAIL - FACTORY Electrical system Delete times This option deletes the stored chronometer times. A deletion confirmation is requested. Once the op- eration is finished, the display goes back to the CHRONOMETER menu. Operation To use the chronometer, the display should show the main menu with the word CHRONO, waiting for the count to start.
  • Page 45 PEGASO 650 STRADA - TRAIL - FACTORY Electrical system When the threshold of the maintenance intervals is exceeded, an icon with a spanner is shown. VIEW ALARMS If a serious failure which may jeopardise the in- tegrity of the vehicle or the rider is detected, an icon indicating the cause is displayed on the area where the odometer is generally shown.
  • Page 46 PEGASO 650 STRADA - TRAIL - FACTORY Electrical system Maximum pointer oscillation at maximum speed: +/- 0.5° with respect to the received signal. Uphill speed - steady pointer from the start to the end of the scale or vice versa: 0.6 sec.
  • Page 47 PEGASO 650 STRADA - TRAIL - FACTORY Electrical system Clock It is displayed only when the vehicle is on; when it is turned off, the indication remains visible for 5 seconds. The precision must be better than 30 ppm. Do not reset the clock in case there is a sudden voltage drop in the electrical system (see rating test).
  • Page 48 PEGASO 650 STRADA - TRAIL - FACTORY Electrical system • Range: 9.0 - 16.0 [V]. For voltage values below 9V or over 16V the accuracy can exceed the required tolerances but it should have an increasing monotonic course. • Accuracy: +/- 0.2V with respect to the battery voltage (corrective factors should be intro- duced, as in the table, which will vary according to the vehicle on which the instrument panel has been installed).
  • Page 49 PEGASO 650 STRADA - TRAIL - FACTORY Electrical system • For the USA version, the instrument panel must comply with the DOT marking requirements (SAE Standards J590b, October 1965). Hazard The hazard control device is a button. The hazard can be activated or deactivated only with the key set to KEY ON.
  • Page 50 PEGASO 650 STRADA - TRAIL - FACTORY Electrical system Programming keys at first start-up The customer is provided with two keys, both with transponder in the handgrip. The instrument panel requests programming the keys when it is turned on for the first time.
  • Page 51 PEGASO 650 STRADA - TRAIL - FACTORY Electrical system • PIN 13: - • PIN 14: - • PIN 15: - • PIN 16: GENERAL GROUND • PIN 17: ABS INPUT • PIN 18: SENSORS GROUND • PIN 19: GENERAL GROUND (OP- TIONAL) •...
  • Page 52 PEGASO 650 STRADA - TRAIL - FACTORY Electrical system • PIN 39: CLUTCH SENSOR • PIN 40: SELECT 3 - SET Pins marked with '' - '' are present but not used. CONNECTIONS The input and output lines and their electrical characteristics are shown below; all the inputs, outputs and warning lights are controlled by the microprocessor.
  • Page 53 PEGASO 650 STRADA - TRAIL - FACTORY Electrical system This input controls the state of the ABS warning light. This light must be on, on the ABS control unit, with input open or at a high level; with input at a low level, the warning light is off.
  • Page 54 Diagnosis DIAGNOSIS This menu interfaces with the systems in the motorbike and diagnoses them. To enable this menu, enter an access code available only from aprilia service centres. • Enter service code This is a 5-digit code, fixed for each vehicle. The Pegaso code is: 25973 If the code is incorrect, the following message is displayed: •...
  • Page 55 PEGASO 650 STRADA - TRAIL - FACTORY Electrical system • Code 01: Throttle opening angle • Code 03: Air intake pressure • Code 05: Air intake temperature • Code 06: Water temperature • Code 07: Vehicle speed pulse • Code 08: Turnover sensor •...
  • Page 56 PEGASO 650 STRADA - TRAIL - FACTORY Electrical system • Turn the key to stop to exit Ignition coil The following message is displayed: • Turn the engine RUN/engine STOP switch first to RUN and then to STOP. The ignition coil will then be activated 5 times.
  • Page 57 PEGASO 650 STRADA - TRAIL - FACTORY Electrical system This screen displays the parameters read by the engine control unit. The following message is dis- played: • Turn the key to stop Once the key extraction is been detected, the following message is displayed: •...
  • Page 58 PEGASO 650 STRADA - TRAIL - FACTORY Electrical system • Error code: DSB 03 Immobilizer failure: Internal controller failure • Error code: DSB 04 Fuel sensor failure • Error code: DSB 05 The instrument panel must keep all previous errors stored in its memory. In case of fuel sensor failure, the relative icon on the display should flash.
  • Page 59 PEGASO 650 STRADA - TRAIL - FACTORY Electrical system Km / miles This menu selects the unit of measurement for the speed. • • MILES Battery recharge circuit Checking the stator Maximum power 290 Watt Recharging voltage: 14V 5000 rpm (measured at battery poles) Stator coil resistance: 0.224 - 0.336 Ohm at 20 °C (68 °...
  • Page 60 PEGASO 650 STRADA - TRAIL - FACTORY Electrical system Lights list FRONT HEADLAMP Low-beam light: 12 V - 55 W H11 connection High-beam light: 12 V - 55 W H11 connection Front tail light: 12V - 5W REAR LIGHT Fuses...

  • Page 61: Control Unit

    PEGASO 650 STRADA - TRAIL - FACTORY Electrical system Control unit Engine control unit Pin Use 1. Not used 2. Not used 3. Not used 4. Starter button 5. Not used 6. K line 7. Fall signal 8. Lambda probe signal 9.
  • Page 62 PEGASO 650 STRADA - TRAIL - FACTORY Electrical system 27. TPS signal 28. (-) Injection control ground connections 29. (-) Injection relay 30. Electric fan relay 31. (-) Light relay 32. Not used 33. (-) Injectors 34. Earth connection Battery...
  • Page 63 PEGASO 650 STRADA - TRAIL - FACTORY Electrical system Intake pressure sensor Intake air pressure sensor voltage: from 3.4 to 3.8 V engine off - key ON. Engine temperature sensor Coolant temperature sensor resistance: 2.21 - 2.69 kOhm at 20°C (68 °F) 0.310 - 0.326 kOhm at 80°C (176 °F)

  • Page 64: Bank Angle Sensor

    PEGASO 650 STRADA - TRAIL - FACTORY Electrical system WARNING ONLY IN EXTREMELY UNUSUAL AND SPECIFIC SITUATIONS CAN THE LAMBDA PROBE OP- ERATION AFFECT VEHICLE PERFORMANCE. Coil Primary coil resistance 3.4 - 4.6 Ohm at 20 °C (68 °F) (between red/black cable and orange cable).
  • Page 65 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 66 PEGASO 650 STRADA - TRAIL - FACTORY Engine from vehicle Vehicle preparation To remove the engine from the chassis proceed as follows: • Remove the fuel tank. • Disconnecting the cables at both poles (positive / negative) and then remove the battery.
  • Page 67 PEGASO 650 STRADA - TRAIL - FACTORY Engine from vehicle • Disconnect the speed sensor. • Disconnect the neutral sensor connec- tor. • Disconnect the alternator connectors. ENG VE - 67...
  • Page 68 PEGASO 650 STRADA - TRAIL - FACTORY Engine from vehicle • Disconnect the stand sensor. • Undo 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.
  • Page 69 PEGASO 650 STRADA - TRAIL - FACTORY Engine from vehicle • Disconnect the clutch wire from the linkage system. • Disconnect the spark plug tube. • Loosen the secondary air pipe clamp. • Slide off the pipe from the throttle body.
  • Page 70 PEGASO 650 STRADA - TRAIL - FACTORY Engine from vehicle • Disconnect the expansion tank breath- er pipe. • Release the cable harness from the clamp. • Disconnect the alternator connectors. • Place a container to collect the engine oil.
  • Page 71 PEGASO 650 STRADA - TRAIL - FACTORY Engine from vehicle • Drain off the 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.
  • Page 72 PEGASO 650 STRADA - TRAIL - FACTORY Engine from vehicle • Engage first gear. • Unscrew and remove the nut 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.
  • Page 73 PEGASO 650 STRADA - TRAIL - FACTORY Engine from vehicle • Loosen the clamps and disconnect the pipe from the filter casing. • Hold the scooter with belts. • Unscrew and remove the swingarm pin ring nut. • Loosen the swingarm adjustment bushing.
  • Page 74 PEGASO 650 STRADA - TRAIL - FACTORY Engine from vehicle • Hold the engine block with a hoister. • Working from the right side, unscrew and remove the two nuts. • Slide off the two screws from the op- posite side.
  • Page 75 PEGASO 650 STRADA - TRAIL - FACTORY Engine from vehicle • Undo and remove the two lower screws and collect the washers. • Loosen the clamps and slide off the in- let manifold. • Lower the engine. Installing the engine to the vehicle •...
  • Page 76 PEGASO 650 STRADA - TRAIL - FACTORY Engine from vehicle • Fit the throttle body in the inlet manifold and fasten the clamp. • Tighten the two lower fixing screws. • Fit the fixing screw. • Tighten the upper fixing nut.
  • Page 77 PEGASO 650 STRADA - TRAIL - FACTORY Engine from vehicle • Insert the two screws. • Working from the right side, tighten the two screws on the engine. • Fit the two screws. • Working from the opposite side, tighten the two nuts.
  • Page 78 PEGASO 650 STRADA - TRAIL - FACTORY Engine from vehicle • Fit the ring nut on the centring bushing and fasten it. • Remove the support belts. • Fit the filter casing pipe and fasten the clamp. • Connect the neutral sensor.
  • Page 79 PEGASO 650 STRADA - TRAIL - FACTORY Engine from vehicle • Insert the crown pinion. • Engage first gear. • Fit the safety washer and tighten the nut. • Fold the safety washer tongues again. • Refit the guiding plate.
  • Page 80 PEGASO 650 STRADA - TRAIL - FACTORY Engine from vehicle • Fit the pinion cover. • Fit and tighten the two screws with the spacers. • Fit the screw and tighten it. • Connect the alternator connectors. • Clamp the cable harness.
  • Page 81 PEGASO 650 STRADA - TRAIL - FACTORY Engine from vehicle • Connect the engine temperature sen- sor connector. • Insert the pipe in the throttle body. • Fasten the secondary air pipe clamp. • Connect the spark plug pipe. •...
  • Page 82 PEGASO 650 STRADA - TRAIL - FACTORY Engine from vehicle • Insert the clutch cable in its fitting and tighten the nut. • Connect the starter motor power sup- ply cable. • Connect the ground leads and tighten the fixing screw.
  • Page 83 PEGASO 650 STRADA - TRAIL - FACTORY Engine from vehicle • Connect the alternator connectors. • Connect the neutral sensor connector. • Connect the speed sensor. • Fix the cable harnesses with the clamps. ENG VE - 83...
  • Page 84 PEGASO 650 STRADA - TRAIL - FACTORY Engine from vehicle • Refit the fuel vapour recovery pipe clamp. • Connect the filter casing connector. • Refit the two pipes and fasten the rel- evant clamps. ENG VE - 84...
  • Page 85 INDEX OF TOPICS NGINE...
  • Page 86 PEGASO 650 STRADA - TRAIL - FACTORY Engine Gearbox ENG - 86...
  • Page 87 PEGASO 650 STRADA - TRAIL - FACTORY Engine Key: 1. Countershaft 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...
  • Page 88 PEGASO 650 STRADA - TRAIL - FACTORY Engine Disassembling the gearbox • Open the crankcase halves. • Block the gear shafts with the circlips. • Remove the gear shaft unit. See also Splitting the crankcase halves Removing the primary shaft •...
  • Page 89 PEGASO 650 STRADA - TRAIL - FACTORY Engine • Slide off the gear of the 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.
  • Page 90 PEGASO 650 STRADA - TRAIL - FACTORY Engine • 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...
  • Page 91 PEGASO 650 STRADA - TRAIL - FACTORY Engine Removing the secondary shaft • 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.
  • Page 92 PEGASO 650 STRADA - TRAIL - FACTORY Engine • Slide off the gear of the third gear and collect the 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.
  • Page 93 PEGASO 650 STRADA - TRAIL - FACTORY Engine Checking the primary shaft Measure coaxiality of the main shaft with a dial gauge and a centring device and replace 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.
  • Page 94 PEGASO 650 STRADA - TRAIL - FACTORY Engine Checking the forks Check the transmission fork cam roller (1) and the gear fork tooth (2) for 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.
  • Page 95 PEGASO 650 STRADA - TRAIL - FACTORY Engine • Replace the 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.
  • Page 96 PEGASO 650 STRADA - TRAIL - FACTORY Engine • Insert the toothed retaining washer. • Fit the 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.
  • Page 97 PEGASO 650 STRADA - TRAIL - FACTORY Engine NOTE INSERT THE SAFETY CIRCLIPS SO THAT BOTH ENDS ARE 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.
  • Page 98 PEGASO 650 STRADA - TRAIL - FACTORY Engine • Fit 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.
  • Page 99 PEGASO 650 STRADA - TRAIL - FACTORY Engine • 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.
  • Page 100 PEGASO 650 STRADA - TRAIL - FACTORY Engine Removing the gear selector • Remove the clutch. • Remove the right crankcase. • Working from the clutch side, release the spring of the gear selector. • Working from the alternator side, re- move the safety ring.

  • Page 101: Starter Motor

    PEGASO 650 STRADA - TRAIL - FACTORY Engine crankshaft Checking the gear selector SELECTOR CHECK Check the selector shaft and its teeth for damage and wear. If necessary, replace the part. Check the lever spring for damage and wear. If necessary, replace the part.
  • Page 102 PEGASO 650 STRADA - TRAIL - FACTORY Engine Removing 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 ENG - 102...
  • Page 103 PEGASO 650 STRADA - TRAIL - FACTORY Engine Installing the starter gear • Fit the timing chain, if previously re- moved. • Insert the washer. • Fit the needle cage. • Fit the gear of the starting ring gear. •...
  • Page 104 PEGASO 650 STRADA - TRAIL - FACTORY Engine Generator side Removing the flywheel cover • Remove the starter motor. • Undo and remove the four screws. • Remove the cover together with the torque limiter. • Collect the centring dowel.
  • Page 105 PEGASO 650 STRADA - TRAIL - FACTORY Engine Removing the starter motor Magneto flywheel removal • Remove the flywheel cover. • Unscrew and remove the flywheel fix- ing nut. • Collect the washer. • Place the flywheel locking tool. •...
  • Page 106 PEGASO 650 STRADA - TRAIL - FACTORY Engine • Place the special tools to lock the pis- ton and the flywheel. DO NOT ALLOW THE LOCKING TOOLS TO COME INTO CONTACT WITH THE FLYWHEEL UPPER PROTRUSION. Specific tooling 8140840 Connecting rod locking AP8140838 Flywheel rotor locking •...
  • Page 107 PEGASO 650 STRADA - TRAIL - FACTORY Engine • Insert the flywheel cover together with the stator. • Correctly 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.
  • Page 108 PEGASO 650 STRADA - TRAIL - FACTORY Engine • Correctly fit and tighten the four screws, operating diagonally. See also Installing the flywheel Clutch side Removing the clutch cover • Undo and remove the seven screws by loosening them 1/4 of a turn at a time, operating in stages and diagonally.
  • Page 109 PEGASO 650 STRADA - TRAIL - FACTORY Engine Disassembling the clutch • Undo and remove the five screws by loosening on fourth of a turn 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.
  • Page 110 PEGASO 650 STRADA - TRAIL - FACTORY Engine • After straightening the tongues of the locking washer, unscrew and remove the clutch hub nut with the universal clutch locking tool and collect the lock- ing washer. Specific tooling 8600391 Clutch locking •...

  • Page 111: Checking The Clutch Plates

    PEGASO 650 STRADA - TRAIL - FACTORY Engine • Remove the clutch bell. Checking the clutch plates • Lay the friction discs and steel discs on a level surface and check them for cracks and potential distortions. Maximum distortion allowed: 0.20 mm (0.0079 •...
  • Page 112 PEGASO 650 STRADA - TRAIL - FACTORY Engine Checking the clutch housing Check the clutch bell for damage and wear that may result in clutch irregular operation. Deburr the teeth or replace the bell. MAIN DRIVEN GEAR CHECK Check the main driven gear for damage and wear and, if necessary, replace the main transmission driving gear and the clutch bell all together.
  • Page 113 PEGASO 650 STRADA - TRAIL - FACTORY Engine Checking the clutch hub Check the clutch hub for damage and wear that may result in clutch irregular operation. If neces- sary, replace the bell. Checking the springs • Check the springs for damage and, if necessary, replace the them all togeth- •...
  • Page 114 PEGASO 650 STRADA - TRAIL - FACTORY Engine Assembling the clutch • Install the clutch bell. • Insert the washer. • Install the clutch hub. • Insert the new locking washer. ENG - 114...
  • Page 115 PEGASO 650 STRADA - TRAIL - FACTORY Engine • Using the universal clutch locking tool, tighten the clutch hub nut to the pre- scribed tightening torque. Specific tooling 8600391 Clutch locking • Fold the locking washer. • Rotate the clutch bell with the arrows facing upwards.
  • Page 116 PEGASO 650 STRADA - TRAIL - FACTORY Engine • Insert the thirteen clutch discs paying attention to their position. ENG - 116...
  • Page 117 PEGASO 650 STRADA - TRAIL - FACTORY Engine ENG - 117...
  • Page 118 PEGASO 650 STRADA - TRAIL - FACTORY Engine ENG - 118...
  • Page 119 PEGASO 650 STRADA - TRAIL - FACTORY Engine • Fit the clutch plate together with the disengagement shaft. • Fit the springs. ENG - 119...

  • Page 120: Installing The Clutch Cover

    PEGASO 650 STRADA - TRAIL - FACTORY Engine • Tighten the screws together with the washers to the prescribed torque. Installing the clutch cover • Replace the gasket and insert the right crankcase half. • Correctly fit the screws and tighten them operating diagonally.

  • Page 121: Removing The Cylinder Head

    PEGASO 650 STRADA - TRAIL - FACTORY Engine • Fit a new gasket. • Place the clutch cover. • Tighten the screws operating diagonal- WHEN FITTING THE RELEASE LEVER, PAY ATTENTION TO FIT IT WITH THE WORD "UP" FACING UPWARDS.
  • Page 122 PEGASO 650 STRADA - TRAIL - FACTORY Engine • Using the suitable special tool, un- screw and remove the flywheel cover to access the timing reference. Specific tooling 8140850 Flywheel cover opening • Rotate the crankshaft counterclock- wise to move the piston to the top dead centre in combustion phase.
  • Page 123 PEGASO 650 STRADA - TRAIL - FACTORY Engine • Check that the reference mark "I" on the camshaft toothed wheel is aligned to the stationary reference on the head. • Undo and remove the two screws and remove the timing chain tensioner.
  • Page 124 PEGASO 650 STRADA - TRAIL - FACTORY Engine • Unscrew and remove the four stud bolts, operating diagonally and 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.
  • Page 125 PEGASO 650 STRADA - TRAIL - FACTORY Engine Cylinder head Removing the overhead camshaft • Remove the rocking levers. • The camshaft outlet hole is suitably shaped for its removal. • Slide off the camshaft with caution pay- ing attention to the decompression lev- er pin.
  • Page 126 PEGASO 650 STRADA - TRAIL - FACTORY Engine • Working from both sides, remove the tappet cover and 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.

  • Page 127: Removing The Valves

    PEGASO 650 STRADA - TRAIL - FACTORY Engine • Using the adequate extractor remove the outlet rocking lever shaft. Specific tooling 8140848 Rocking lever shaft extractor • Remove outlet rocking lever. • Using the suitable extractor, remove the inlet rocking lever shaft.
  • Page 128 PEGASO 650 STRADA - TRAIL - FACTORY Engine BEFORE REMOVING THE CYLINDER HEAD COMPONENTS (VALVES, VALVE SPRINGS, VALVE SEATS), MAKE SURE THAT THE VALVES ARE PROPERLY CLOSED AND SEALED. CAUTION WHEN REMOVING THE COMPONENTS, MARK THE POSITION OF EACH PART VERY CARE- FULLY IN ORDER TO PLACE THEM IN THEIR ORIGINAL POSITION UPON FITTING.
  • Page 129 PEGASO 650 STRADA - TRAIL - FACTORY Engine • Remove the valve. Checking the decompression system • Check the decompression system with both the camshaft toothed wheel and the decompression pin fitted on the camshaft. • Check that the decompression lever pin (1) protrudes from the camshaft.
  • Page 130 PEGASO 650 STRADA - TRAIL - FACTORY Engine • b: 36.959 / 37.059 mm (1.4551 / 1.4590 in); Limit 36.840 mm (1.4504 in) Outlet • a: 43.129 / 43.229 mm (1.6980 / 1.7019 in); Limit 42.983 mm (1.6922 in) •...
  • Page 131 PEGASO 650 STRADA - TRAIL - FACTORY Engine • Calculate the rocking lever - rocking lever shaft clearance. CAUTION CALCULATE THE CLEARANCE SUBTRACTING THE OUT- SIDE DIAMETER OF THE ROCKING LEVER SHAFT FROM THE INSIDE DIAMETER OF THE ROCKING LEVER •...
  • Page 132 PEGASO 650 STRADA - TRAIL - FACTORY Engine a diameter larger than that of the stem body; otherwise, replace the valve. • Check that the valve rim thickness (E) is within the specified values and re- place the valve if required.
  • Page 133 PEGASO 650 STRADA - TRAIL - FACTORY Engine the valve seat and the valve face are in con- tact. 4. With a gauge, measure the valve seat width. If the measurement is not within the speci- fied values, lap the valve face and observe the following instructions.

  • Page 134: Checking The Cylinder Head

    PEGASO 650 STRADA - TRAIL - FACTORY Engine 10.With a gauge, measure the valve seat width again. If the measurement is not within the values previously specified, reface and lap the valve seat. VALVE SPRINGS CHECK CAUTION THE FOLLOWING PROCEDURE APPLIES TO ALL VALVES AND VALVE SEATS.

  • Page 135: Installing The Valves

    PEGASO 650 STRADA - TRAIL - FACTORY Engine • Use a checking ruler and a thickness gauge positioned diagonally to the ruler to measure the cylinder head distortion. Maximum cylinder head distortion: 0.03 mm (0.0012 in) • Check that the tappet covers and the camshaft toothed wheel cover are not damaged or worn;...
  • Page 136 PEGASO 650 STRADA - TRAIL - FACTORY Engine • Fit the valve spring retaining element. • Compress the valve spring with the spring compressor and use the valve spring compressor adapter to fit the valve cotters. Specific tooling AP8140179 Valve spring compressor AP0276474 Valve spring compressor adaptor •...
  • Page 137 PEGASO 650 STRADA - TRAIL - FACTORY Engine • Insert the bearing in the camshaft so that the size (a) is equal to=0 mm (0 in). • Lubricate the camshaft (1), the decom- pressor lever pin (2) and the decom- pressor lever (3).
  • Page 138 PEGASO 650 STRADA - TRAIL - FACTORY Engine Removing the chain sliders • Remove the start-up crown. • Undo and remove the two screws. • Remove the rear chain slider. See also Removing the starter gear Checking the chain tensioner •...
  • Page 139 PEGASO 650 STRADA - TRAIL - FACTORY Engine Checking the chain Check the timing chain for damage or stiffness while moving. If required, replace both the timing chain and the camshaft sprocket wheels. Check the timing chain guide for damage. If necessary, replace the parts.
  • Page 140 PEGASO 650 STRADA - TRAIL - FACTORY Engine Installing the chain tensioner • Fit the timing chain tensioner, follow the instructions below: • A - Remove the chain tensioner threa- ded cap (1), the copper washer (2) and the spring (3).
  • Page 141 PEGASO 650 STRADA - TRAIL - FACTORY Engine • Place the flywheel rotor so that the ref- erence mark (I) (b) on it is aligned with the stationary reference (c) on the magneto cover. • Fit the timing chain to the camshaft toothed wheel.
  • Page 142 PEGASO 650 STRADA - TRAIL - FACTORY Engine • Tighten the two toothed wheel screws. TIGHTEN THE TWO SCREWS TO THE PRE-SET TORQUE IN ORDER TO AVOID ALIGNMENTS THAT COULD SERIOUSLY DAMAGE THE ENGINE. • Measure the valve clearance and adjust it if required.
  • Page 143 PEGASO 650 STRADA - TRAIL - FACTORY Engine • Unscrew and remove the four stud bolts in the sequence indicated and collect the washers. ENG - 143...
  • Page 144 PEGASO 650 STRADA - TRAIL - FACTORY Engine • Undo and remove the two screws. • Remove the cylinder paying attention to the timing chain and the piston; col- lect the centring dowel and the gasket. 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.
  • Page 145 PEGASO 650 STRADA - TRAIL - FACTORY Engine Checking the cylinder • All seal surfaces must be clean and flat. • Make sure all threads are in proper conditions. • Check cylinder sliding surface for signs of friction and scratches. Also check the seal sur- faces for damages.
  • Page 146 PEGASO 650 STRADA - TRAIL - FACTORY Engine • Clean off lime scales on the cylinder cooling slots. • Measure the cylinder bore on the upper edge at three points, 42 mm (1.65 in) from the upper edge (1) and on the lower edge;...
  • Page 147 PEGASO 650 STRADA - TRAIL - FACTORY Engine PISTON RINGS • Clean off any carbon deposits from the grooves in the piston rings and from the rings themselves. • Measure the piston ring side clearance and replace the piston and the piston rings all together if not complying with specifications.
  • Page 148 PEGASO 650 STRADA - TRAIL - FACTORY Engine • Measure the pin outside diameter (a) and if not complying with specifica- tions, replace the pin. Pin outside diameter: 22.991 - 23.000 mm (0.9052 - 0.9055 in) Limit: 22.971 mm (0.9044 in) •...
  • Page 149 PEGASO 650 STRADA - TRAIL - FACTORY Engine • Position the piston and fit the pin. CAUTION MAKE SURE THAT THE PUNCHING ON THE 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.
  • Page 150 PEGASO 650 STRADA - TRAIL - FACTORY Engine • Replace the pin locking ring. • Fit a new cylinder gasket. • Fit the centring dowels. • Lubricate the piston, the piston rings and the cylinder with engine oil. • Check the piston ring misalignment by...
  • Page 151 PEGASO 650 STRADA - TRAIL - FACTORY Engine • Tighten the four cylinder stud bolts to the different prescribed torques. ENG - 151...

  • Page 152: Installing The Cylinder Head

    PEGASO 650 STRADA - TRAIL - FACTORY Engine • Tighten the two screws. • After replacing the circular gasket, tighten the two screws and fasten the cooling system joint. Installing the cylinder head • Fit the two centring dowels. •...
  • Page 153 PEGASO 650 STRADA - TRAIL - FACTORY Engine • Fit the head. • Fit four new washers. CAUTION FIT THE WASHERS WITH THEIR ROUNDED SURFACE FACING THE BOLT SEAT. LUBRICATE THE HEAD BOLT THREADS AND THE SEAL SURFACES WITH ENGINE OIL.
  • Page 154 PEGASO 650 STRADA - TRAIL - FACTORY Engine Splitting the crankcase halves • Before removing the components, place a container of suitable capacity underneath the engine. • Remove the throttle body. • Remove the ignition spark plug. • Undo and remove the two screws; re- move the secondary air pipe and col- lect the metal gasket.
  • Page 155 PEGASO 650 STRADA - TRAIL - FACTORY Engine • Remove the starter motor. • Release the fastening clamp and re- move the crankcase breather chamber flexible pipe. • Undo and remove the screw and re- move the speed sensor. •...
  • Page 156 PEGASO 650 STRADA - TRAIL - FACTORY Engine • Undo and remove the screw and re- move the cable guide. • Remove the pipe and collect the dowel and the safety circlip. • Undo and remove the screw and re- move the cable guide.
  • Page 157 PEGASO 650 STRADA - TRAIL - FACTORY Engine • Undo and remove the two screws and collect the washers. • Remove the guide of the timing chain, on the intake side, sliding it off from above. • Remove the timing chain.
  • Page 158 PEGASO 650 STRADA - TRAIL - FACTORY Engine • Loosen the seven screws 1/4 of a turn at a time, operating diagonally and in stages. • Loosen and then remove all the screws. • Working from the right side, straighten the safety washer tongues.
  • Page 159 PEGASO 650 STRADA - TRAIL - FACTORY Engine • 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 •...
  • Page 160 PEGASO 650 STRADA - TRAIL - FACTORY Engine • Remove the balancer driving gear and slide off the key. • Slide off the washer. • Loosen the six screws one fourth of a turn at a time, operating diagonally and in stages.
  • Page 161 PEGASO 650 STRADA - TRAIL - FACTORY Engine • Separate the two crankcase halves giving a few taps with a hammer. Once the halves are separated, remove the two tools. • Remove the right crankcase half. See also Removing the...
  • Page 162 PEGASO 650 STRADA - TRAIL - FACTORY Engine Removing the crankshaft • Before removing the crankshaft, sepa- rate the crankcase halves, remove the countershaft and remove the gear shaft unit. • Use the crankcase separator tool to take out the crankshaft.
  • Page 163 PEGASO 650 STRADA - TRAIL - FACTORY Engine CAUTION LUBRICATE BALL BEARINGS WITH ENGINE OIL BEFORE FURTHER CHECKING. If the internal ring does not rotate smoothly and silently or if there is some noise while it turns, it means that the bearing is faulty and must be replaced.
  • Page 164 PEGASO 650 STRADA - TRAIL - FACTORY Engine • Fit the gearbox unit. • Fit the countershaft. • Apply sealant on the seal surfaces of both crankcase halves. • Fit the right crankcase half on the left crankcase half, giving a few taps with a rubber mallet.
  • Page 165 PEGASO 650 STRADA - TRAIL - FACTORY Engine • Fit 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. ENG - 165...
  • Page 166 PEGASO 650 STRADA - TRAIL - FACTORY Engine • Insert a new washer. • Insert a new locking washer and the nut. CAUTION 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.
  • Page 167 PEGASO 650 STRADA - TRAIL - FACTORY Engine CAUTION ALIGN THE REFERENCE ON THE COUNTERSHAFT DRIV- ING GEAR WITH THE REFERENCE ON THE DRIVEN GEAR. • Tighten the countershaft driven gear nut to the specified torque. • Fold the safety washer tabs.
  • Page 168 PEGASO 650 STRADA - TRAIL - FACTORY Engine • Fit the washer and the nut. • Fold the tongue. • Fit the timing chain. • Insert the chain slider into its seat. • Place the two washers and tighten the two screws.
  • Page 169 PEGASO 650 STRADA - TRAIL - FACTORY Engine Conceptual diagrams ENG - 169...
  • Page 170 PEGASO 650 STRADA - TRAIL - FACTORY Engine Key: A - To oil tank 1. Flexible oil delivery pipe 2 2. Oil delivery pipe 2 3. Oil filter 4. Oil pump rotor 1 5. Oil pump rotor 2 6. Main axle 7.

  • Page 171: Oil Pump

    PEGASO 650 STRADA - TRAIL - FACTORY Engine 13. Crankshaft Oil pump Removing • Before removing the components, place a container of suitable capacity underneath the engine. • Remove the clutch. • Undo and remove the two screws and remove the oil deflector.
  • Page 172 PEGASO 650 STRADA - TRAIL - FACTORY Engine • Remove the oil deflector and collect the O-ring. • 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.
  • Page 173 PEGASO 650 STRADA - TRAIL - FACTORY Engine Inspection Check the oil pump driven gear for damage, signs of wear or cracks. If necessary, replace the part. Check oil pump works properly. If it does not, re- place the oil pump all together.
  • Page 174 PEGASO 650 STRADA - TRAIL - FACTORY Engine • Tighten the two screws. • Fit the oil pump gear (2) and replace the safety circlip (1). • Fit the oil deflector and tighten the two screws. SAS valve In order to limit CO and HC emissions in vehicles...
  • Page 175 PEGASO 650 STRADA - TRAIL - FACTORY Engine chamber, reducing CO and HC first, and thanks to the heat produced, accelerating the thermal ad- justment of the catalytic converter. The SAS takes advantage of the pressure fluctuation at the ex- haust.
  • Page 176 PEGASO 650 STRADA - TRAIL - FACTORY Engine 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) ENG - 176...
  • Page 177 INDEX OF TOPICS P SUPP OWER SUPPLY...
  • Page 178 PEGASO 650 STRADA - TRAIL - FACTORY Power supply Circuit diagram Key: 1. 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.
  • Page 179 PEGASO 650 STRADA - TRAIL - FACTORY Power supply Injection Diagram Key: 1. Throttle body 2. Manifold Ø 46 mm (1.81 in) 3. Clamp for manifold Ø 72 mm (2.83 in) 4. Preformed pipe Ø 5.5x11.5 mm (0.22x0.45 in) 5. Preformed pipe Ø 13x18 mm (0.51x0.71 in) 6.
  • Page 180 PEGASO 650 STRADA - TRAIL - FACTORY Power supply Removing the throttle body • Fit the engine block on the engine support plate. Specific tooling 8140839 Engine supporting plate • Undo the two screws and loosen the piston rings. •...
  • Page 181 PEGASO 650 STRADA - TRAIL - FACTORY Power supply Using axone for injection system Injection Iso screen page This screen page shows general data regarding the control unit, for example software type, map- ping, control unit programming date SCREEN PAGE Specification Desc./Quantity...
  • Page 182 PEGASO 650 STRADA - TRAIL - FACTORY Power supply Device status screen page DEVICE STATUS This screen page shows the status (usually ON/ OFF) of the vehicle devices or the operation con- dition of some vehicle systems (for example, lamb- da probe functioning status).
  • Page 183 PEGASO 650 STRADA - TRAIL - FACTORY Power supply Errors display screen page ERRORS DISPLAY This screen page shows potential errors detected in the vehicle (ATT) or stored in the control unit (MEM) and it allows to check error clearing (STO).
  • Page 184 PEGASO 650 STRADA - TRAIL - FACTORY Power supply Adjustable parameters screen page ADJUSTABLE PARAMETERS This screen page is used to adjust some control unit parameters. DJUSTABLE PARAMETERS SCREEN PAGE Specification Desc./Quantity CO adjustment P SUPP - 184...
  • Page 185 INDEX OF TOPICS SUSP USPENSIONS...
  • Page 186 PEGASO 650 STRADA - TRAIL - FACTORY Suspensions Front Front fork Diagram Key: 1. Stiffening plate 2. Left 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...

  • Page 187: Removing The Fork Legs

    PEGASO 650 STRADA - TRAIL - FACTORY Suspensions 15.Dust guard 16.Spring 17.Spring seat 18.Spacer 19.O-ring 20.Stem cap 21.Stem protection 22.TCEI screw M6x20 23.Complete stem 24.Front brake calliper (Factory) 25.Flanged screw M10x1.25x40 (Factory) 26.Brake calliper attachment plate (Factory) Removing the fork legs •...
  • Page 188 PEGASO 650 STRADA - TRAIL - FACTORY Suspensions • Undo and remove the two screws fixing the rear half-mudguard and remove it. • Undo and remove the two screws fixing the fork reinforcing plate and remove the fork reinforcing plate.
  • Page 189 PEGASO 650 STRADA - TRAIL - FACTORY Suspensions • Unscrew the wheel pin tightening nut and collect the washer. • Working from both sides partially un- screw the wheel pin clamp screws and unscrew the wheel pin completely. • Hold the front wheel and slide off the wheel pin manually.
  • Page 190 PEGASO 650 STRADA - TRAIL - FACTORY Suspensions • Loosen the stem fixing screw on the upper steering plate. • Slide off the stem paying attention not to damage it. See also Fuel tank Draining oil CAUTION THE OPERATIONS DESCRIBED REFER TO A SINGLE STEM BUT THEY APPLY TO BOTH.
  • Page 191 PEGASO 650 STRADA - TRAIL - FACTORY Suspensions • Remove the spring preloading spacer. • Collect the washer. • Collect the 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.
  • Page 192 PEGASO 650 STRADA - TRAIL - FACTORY Suspensions Disassembling the fork • Empty all the stem oil. • Lock the sleeve on a vice in a horizon- tal position. • Unscrew the bottom screw. • Place the sleeve on a vice in a vertical position.
  • Page 193 PEGASO 650 STRADA - TRAIL - FACTORY Suspensions • Take out the sleeve from the vice and slide off the pumping member together with the bottom buffer. • Place the sleeve on the vice in a verti- cal position. •...
  • Page 194 PEGASO 650 STRADA - TRAIL - FACTORY Suspensions • Remove the shim washer. • Remove the upper sliding bushing. See also Draining oil Checking the components Stem Check the sliding surface for scorings and/or scratches. These scorings can be eliminated by rubbing them with wet sandpaper (grain 1).
  • Page 195 PEGASO 650 STRADA - TRAIL - FACTORY Suspensions • lower sliding bushing. • upper sliding bushing. • piston. If there 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.
  • Page 196 PEGASO 650 STRADA - TRAIL - FACTORY Suspensions • dust gaiter; • O-Ring on the cap. Reassembling the fork • Place the upper sliding bushing. • Place the oil seal on the fork stem. SUSP - 196...
  • Page 197 PEGASO 650 STRADA - TRAIL - FACTORY Suspensions • Place the shim washer on the fork stem. • Fit the pumping member together with the bottom 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.
  • Page 198 PEGASO 650 STRADA - TRAIL - FACTORY Suspensions • Fit the dust scraper. • Lock the sleeve on a vice in a horizon- tal position. • Tighten the bottom screw. • Lock the wheel holder sleeve on the vice in a vertical position.
  • Page 199 PEGASO 650 STRADA - TRAIL - FACTORY Suspensions • Fit the spring, the washer 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.

  • Page 200: Installing The Fork Legs

    PEGASO 650 STRADA - TRAIL - FACTORY Suspensions Installing the fork legs • Insert the stem being careful not to damage it. • Position the stem and tighten the stem fixing screw on the upper steering plate. • Hold the stem and tighten the three stem fixing screws on the lower steer- ing plate.
  • Page 201 PEGASO 650 STRADA - TRAIL - FACTORY Suspensions • Fully insert the wheel pin on the right side. • Tighten the right side wheel pin clamp screws • Insert the washer on the pin and tighten the wheel pin nut.
  • Page 202 PEGASO 650 STRADA - TRAIL - FACTORY Suspensions The following operation should be considered valid for the Factory version only. • Place the brake calliper together with its flange and tighten the fixing screws. • Remove the front service stand.
  • Page 203 PEGASO 650 STRADA - TRAIL - FACTORY Suspensions • Place the front half-mudguard and working from both sides, tighten the two fixing screws. • Tighten the two screws fixing the half- mudguards. Steering bearing Adjusting play • Rest the vehicle on the rear service stand.
  • Page 204 PEGASO 650 STRADA - TRAIL - FACTORY Suspensions Locking torques (N*m) Upper plate fixing cover M22x1 Head- 100 Nm stock ring nut M25x1.5 7 Nm SUSP - 204...
  • Page 205 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...

  • Page 206: Front Brake Pads

    PEGASO 650 STRADA - TRAIL - FACTORY Braking system Front brake pads Removal Strada - Trail versions WARNING IT IS NOT NECESSARY TO REMOVE THE BRAKE CALLIPER IN ORDER TO REMOVE THE PADS. • Turn the pins and remove both split pins.
  • Page 207 PEGASO 650 STRADA - TRAIL - FACTORY Braking system • Extract one pad at a time. CAUTION AFTER REMOVING THE PADS, DO NOT OPERATE THE BRAKE LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKS.
  • Page 208 PEGASO 650 STRADA - TRAIL - FACTORY Braking system • 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.

  • Page 209: Rear Brake Pads

    PEGASO 650 STRADA - TRAIL - FACTORY Braking system • 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.
  • Page 210 PEGASO 650 STRADA - TRAIL - FACTORY Braking system • Remove the pin. • Extract one pad at a time. CAUTION AFTER REMOVING THE PADS, DO NOT OPERATE THE BRAKE LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKS.
  • Page 211 PEGASO 650 STRADA - TRAIL - FACTORY Braking system Front Any air trapped in the hydraulic circuit acts as a cushion, absorbing much of the pressure applied by the brake pump and minimising the braking power of the calliper. The presence of air is signalled by the "spongi- ness"...
  • Page 212 PEGASO 650 STRADA - TRAIL - FACTORY Braking system • Repeat the operation until the fluid 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.
  • Page 213 PEGASO 650 STRADA - TRAIL - FACTORY Braking system • Loosen the bleed valve 1/4 of a turn so that the brake fluid flows into the con- tainer. This will release the tension on the brake lever and will make it reach the end of stroke.
  • Page 214 INDEX OF TOPICS COOL SYS OOLING SYSTEM...

  • Page 215: Coolant Replacement

    PEGASO 650 STRADA - TRAIL - FACTORY Cooling system Coolant replacement • Remove the head light assembly. • Remove the reservoir. • Place a container of suitable capacity under the drainage screw in order to collect the fluid. DO NOT REMOVE THE FILLER PLUG WHEN THE ENGINE IS HOT AS THE COOLANT IS UNDER PRESSURE AND AT A HIGH TEMPERATURE.

  • Page 216: Water Pump

    PEGASO 650 STRADA - TRAIL - FACTORY Cooling system • Check the coolant level in the expansion tank again and eventually top up. Water pump CAUTION IT IS NOT NECESSARY TO REMOVE THE COOLANT PUMP UNLESS THE COOLANT LEVEL IS EXTREMELY LOW OR WHEN THE COOLANT DOES NOT HAVE ENGINE OIL.
  • Page 217 PEGASO 650 STRADA - TRAIL - FACTORY Cooling system • Remove the water cooled jacket joint (6). • Slide 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.
  • Page 218 PEGASO 650 STRADA - TRAIL - FACTORY Cooling system • Slide off the pin and the washer. • Remove the rotor shaft unit. REMOVE THE COMPONENT WITH CAUTION SO AS NOT TO DAMAGE IT. • Remove the rubber damper support (8)
  • Page 219 PEGASO 650 STRADA - TRAIL - FACTORY Cooling system • Remove the oil seal (10) and the bear- ing (11). OPERATE WITH CAUTION, IN THE DIRECTION INDICATED BY THE ARROW, SO AS NOT TO DAMAGE THE COMPO- NENTS. • Slide off the circular gasket.
  • Page 220 PEGASO 650 STRADA - TRAIL - FACTORY Cooling system • Insert a new oil seal (10) in the water pump housing. Fit the oil seal using a buffer of suitable diameter. CAUTION LUBRICATE ALL THE BEARING BALLS WITH ENGINE OIL.
  • Page 221 PEGASO 650 STRADA - TRAIL - FACTORY Cooling system Rotor shaft angle limit: 0.15 mm (0.006 in) • In case the measurement is not within the set limits, refit the rubber damper (9) and the rubber damper support (8). •...
  • Page 222 INDEX OF TOPICS BODYW ODYWORK...
  • Page 223 PEGASO 650 STRADA - TRAIL - FACTORY Bodywork Headlight assy. • Undo and remove the six screws. • 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.
  • Page 224 PEGASO 650 STRADA - TRAIL - FACTORY Bodywork • The left bracket 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.
  • Page 225 PEGASO 650 STRADA - TRAIL - FACTORY Bodywork • Remove the front headlight together with the left support. Side body panels Removal • Remove the saddle. • Working from both sides, unscrew and remove the two side fairing fixing screws and remove the side fairings.
  • Page 226 PEGASO 650 STRADA - TRAIL - FACTORY Bodywork • Undo and remove the oil sump guard rear fixing screw. • Remove the oil sump guard paying at- tention to the breather pipe. Fuel tank • Remove the front headlamp. •...
  • Page 227 PEGASO 650 STRADA - TRAIL - FACTORY Bodywork • Undo and remove the two screws so as to free the motor to open the glove compartment, lift it and disconnect the connector. • Remove the fuel tank cap. • Lift the glove compartment and slide off the fuel breather pipe.
  • Page 228 PEGASO 650 STRADA - TRAIL - FACTORY Bodywork • Remove the glove 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).
  • Page 229 PEGASO 650 STRADA - TRAIL - FACTORY Bodywork • Disconnect the fuel pump connector. • Remove the tank. See also Headlight assy. Rear grab rail Removal • Remove the side fairings. • Undo and remove the three screws fix- ing the passenger grab handle.
  • Page 230 PEGASO 650 STRADA - TRAIL - FACTORY Bodywork • Working from both sides, unscrew and remove the upper fixing screws. • Working from both sides, undo and re- move the two rear lower fixing screws. • Lift the tail section.
  • Page 231 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 232 PEGASO 650 STRADA - TRAIL - FACTORY Pre-delivery Carry out the listed checks before delivering the motorcycle. WARNING HANDLE FUEL WITH CARE. Aesthetic inspection - Paintwork - Fitting of Plastic Parts - Scratches - Dirt Tightening torques inspection - Safety fasteners:...

  • Page 233: Road Test

    PEGASO 650 STRADA - TRAIL - FACTORY Pre-delivery - Through the diagnosis tool, check that the last mapping version is present in the control unit/s and, if required, program the control unit/s again: consult the technical service website to know about available upgrades and details regarding the operation.
  • Page 234 PEGASO 650 STRADA - TRAIL - FACTORY Pre-delivery - Response to throttle control - Stability when accelerating and braking - Front and rear brake efficiency - Front and rear suspension efficiency - Abnormal noise Static test Static check after test drive:...
  • Page 235 Air filter: 29 Air temperature sensor: 63 Battery: 59, 62 Brake: 206, 209 Brake pads: 206, 209 Bulbs: Chain: 13, 103, 137–140, 161 Chain tensioner: 138, 140 Clutch: 100, 108, 109, 111–114, 120 Coil: 64 coolant: 215 Coolant: 215 Countershaft: 162 Crankcase: 88, 153, 154, 162, 163 Crankshaft: 90, 92, 101, 153, 162 Cylinder: 121, 125, 134, 142, 145, 150, 152, 161...
  • Page 236 Magneto flywheel: 102, 105, 161 Maintenance: 7, 25 Oil filter: 28, 161 Primary shaft: 88, 93, 94 Rear wheel: Recommended products: 18 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...

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