Service Station Manual: Pegaso 650 Strada - Trail - Factory

SERVICE STATION MANUAL
854110
PEGASO 650 STRADA - TRAIL - FACTORY

SERVICE STATION
MANUAL
PEGASO 650 STRADA - TRAIL - FACTORY
THE VALUE OF SERVICE

Thanks to continuous technical updates and specific training programs on aprilia products, only aprilia
Official Network mechanics know this vehicle fully and have the special tools necessary to carry out
maintenance and repair operations correctly.
The reliability of the vehicle also depends on its mechanical conditions. Checking the vehicle before
riding, its regular maintenance and the use of Original aprilia Spare Parts only are essential factors!
For information about the nearest Official Dealer and/or Service Centre, consult the Yellow Pages or
search directly on the inset map in our Official Website:
www.aprilia.com
Only aprilia Original Spare Parts ensure products already studied and tested during the vehicle design
stage. All aprilia Original Spare Parts undergo quality control procedures to guarantee full reliability and
duration.
The descriptions and illustrations given in this publication are not binding; While the basic characteristics
as described and illustrated in this manual remain unchanged, aprilia reserves the right, at any time and
without being required to update this publication beforehand, to make any changes to components, parts
or accessories, which it considers necessary to improve the product or which are required for
manufacturing or construction reasons.
Not all versions shown in this publication are available in all countries. The availability of individual
versions should be confirmed with the official aprilia sales network.
© Copyright 2007- aprilia. All rights reserved. Reproduction of this publication in whole or in part is
prohibited. aprilia - After sales service.
aprilia trademark is property of Piaggio & C. S.p.A.
SERVICE STATION MANUAL
PEGASO 650 STRADA - TRAIL
- FACTORY
NOTE Provides key information to make the procedure easier to understand and carry out.
CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.
WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.
Personal safety Failure to completely observe these instructions will result in serious risk of personal
injury.
Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle
to prevent damaging the environment.
Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious
damage to the vehicle and sometimes even the invalidity of the guarantee.
INDEX OF TOPICS
CHARACTERISTICS CHAR
SPECIAL TOOLS S-TOOLS
MAINTENANCE MAIN
ELECTRICAL SYSTEM ELE SYS
ENGINE FROM VEHICLE ENG VE
ENGINE ENG
POWER SUPPLY P SUPP
SUSPENSIONS SUSP
BRAKING SYSTEM BRAK SYS
COOLING SYSTEM COOL SYS
BODYWORK BODYW
PRE-DELIVERY PRE DE
INDEX OF TOPICS
CHARACTERISTICS CHAR
Characteristics PEGASO 650 STRADA - TRAIL - FACTORY
Rules
Safety rules
Carbon monoxide
If you need to keep the engine running while working on the vehicle, please ensure that you do so in
an open or very well ventilated area. Never let the engine run in an enclosed area. If you do work in an
enclosed area, make sure to use a fume extraction system.
CAUTION
EXHAUST EMISSIONS CONTAIN CARBON MONOXIDE, A POISONOUS GAS WHICH CAN CAUSE
LOSS OF CONSCIOUSNESS AND EVEN DEATH.
Fuel
CAUTION
THE FUEL USED TO POWER INTERNAL COMBUSTION ENGINES IS HIGHLY FLAMMABLE AND
MAY BE EXPLOSIVE UNDER CERTAIN CONDITIONS. IT IS THEREFORE RECOMMENDED TO
CARRY OUT REFUELLING AND MAINTENANCE PROCEDURES IN A VENTILATED AREA WITH
THE ENGINE SWITCHED OFF. DO NOT SMOKE DURING REFUELLING OR NEAR FUEL VAPOUR.
AVOID ANY CONTACT WITH NAKED FLAME, SPARKS OR OTHER HEAT SOURCES WHICH MAY
CAUSE IGNITION OR EXPLOSION.
DO NOT ALLOW FUEL TO DISPERSE INTO THE ENVIRONMENT.
KEEP OUT OF THE REACH OF CHILDREN.
Hot components
The engine and the exhaust system components become very hot and remain hot for some time after
the engine has been switched off. Before handling these components, make sure that you are wearing
insulating gloves or wait until the engine and the exhaust system have cooled down.
Coolant
The coolant contains ethylene glycol which, under certain conditions, can become flammable.
When it burns, ethylene glycol produces an invisible flame which however can cause burns.
CAUTION
TAKE CARE NOT TO SPILL COOLANT ONTO HOT ENGINE OR EXHAUST SYSTEM COMPO-
NENTS; THE FLUID MAY IGNITE AND BURN WITH AN INVISIBLE FLAME. WHEN CARRYING
OUT MAINTENANCE, IT IS ADVISABLE TO WEAR LATEX GLOVES. EVEN THOUGH IT IS TOXIC,
COOLANT HAS A SWEET FLAVOUR WHICH MAKES IT VERY ATTRACTIVE TO ANIMALS. NEV-
ER LEAVE THE COOLANT IN OPEN CONTAINERS IN AREAS ACCESSIBLE TO ANIMALS AS
THEY MAY DRINK IT.
CHAR - 6
PEGASO 650 STRADA - TRAIL - FACTORY Characteristics

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
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.
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.
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
CHAR - 7
When repairing, dismantling and reassembling the vehicle, follow the recommendations given below
carefully.
BEFORE DISASSEMBLING COMPONENTS

• Before dismantling components, remove dirt, mud, dust and foreign bodies from the vehicle.
Use the special tools designed for this bike, as required.
COMPONENTS REMOVAL
• Do not loosen and/or tighten screws and nuts using pliers or any other tools than the specific
wrench.
• Mark the positions on all connection joints (pipes, cables, etc.) before separating them, and
identify them with different distinctive symbols.
• Each component needs to be clearly marked to enable identification during reassembly.
• Clean and wash the dismantled components carefully using a low-flammability detergent.
• Keep mated parts together since they have "adjusted" to each other due to normal wear.
• Some components must be used together or replaced altogether.
• Keep away from heat sources.
REASSEMBLING COMPONENTS
CAUTION
BEARINGS MUST ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTHERWISE, THEY
NEED TO BE REPLACED.
• Only use ORIGINAL Aprilia SPARE PARTS.
• Comply with lubricant and consumables use guidelines.
• Lubricate parts (whenever possible) before reassembling them.
• When tightening nuts and screws, start either from the components with the largest diameter
or from the innermost components, proceeding diagonally. Tighten nuts and screws in suc-
cessive steps before applying the tightening torque.
• Always replace self-locking nuts, washers, sealing rings, circlips, O-rings (OR), cotter pins
and screws with new parts if the thread is damaged.
• When assembling the bearings, make sure to lubricate them well.
• Check that each component is assembled correctly.
• After a repair or routine maintenance, carry out pre-ride checks and test the vehicle on
private grounds or in an area with low traffic.
• Clean all mating surfaces, oil seal rims and gaskets before refitting. Smear a light layer of
lithium-based grease on the oil guard rims. Reassemble oil seals and bearings with the
brand or batch number facing outward (visible side).
ELECTRIC CONNECTORS
Electric connectors must be disconnected as described below; failure to comply with this procedure
causes irreparable damage to both the connector and the wiring harness:
Press the relative safety clips, if applicable.
CHAR - 8
• Grip the two connectors and disconnect them by pulling them in opposite directions.
• If any signs of dirt, rust, moisture, etc. are noted, clean the inside of the connector carefully
with a jet of compressed air.
• Ensure that the cables are correctly fastened to the internal connector terminals.
• Then connect the two connectors, ensuring that they couple correctly (if fitted with clips, you
will hear them "click" into place).
CAUTION
DO NOT DISCONNECT CONNECTORS BY PULLING THE CABLES.
NOTE
THE TWO CONNECTORS CAN ONLY BE CONNECTED IN ONE DIRECTION: CONNECT THEM
THE RIGHT WAY ROUND.
TIGHTENING TORQUES
CAUTION
REMEMBER THAT THE TIGHTENING TORQUES FOR ALL FASTENING ELEMENTS ON WHEELS,
BRAKES, WHEEL AXLES AND ANY OTHER SUSPENSION COMPONENTS PLAY A KEY ROLE
IN ENSURING VEHICLE SAFETY AND MUST COMPLY WITH SPECIFIED VALUES. CHECK THE
TIGHTENING TORQUES OF FASTENING ELEMENTS ON A REGULAR BASIS AND ALWAYS USE
A TORQUE WRENCH TO REASSEMBLE THESE COMPONENTS. FAILURE TO COMPLY WITH
THESE RECOMMENDATIONS MAY CAUSE ONE OF THESE COMPONENTS TO LOOSEN OR
EVEN DETACH, CAUSING A WHEEL TO LOCK OR COMPROMISING VEHICLE HANDLING. THIS
MAY LEAD TO FALLS, WITH THE RISK OF SERIOUS INJURY OR DEATH.
Running-in
Engine run-in is essential to ensure engine long life and correct operation. Twisty roads and gradients
are ideal to run in engine, brakes and suspensions effectively. Vary your riding speed during the run-
in. This ensures that components operate under both "loaded" and "unloaded" conditions, allowing the
engine components to cool.
CAUTION
THE CLUTCH MAY EMIT A SLIGHT BURNING SMELL WHEN FIRST USED. THIS PHENOMENON
SHOULD BE CONSIDERED NORMAL AND WILL DISAPPEAR AS SOON AS THE CLUTCH DISCS
GET ADAPTED.
IT IS IMPORTANT TO STRAIN ENGINE COMPONENTS DURING RUN-IN, HOWEVER, MAKE SURE
NOT TO OVERDO THIS.
CAUTION
THE FULL PERFORMANCE OF THE VEHICLE IS ONLY AVAILABLE AFTER THE SERVICE AT
THE END OF THE RUNNING IN PERIOD.
Follow the guidelines detailed below:
• Do not twist the throttle grip abruptly and completely when the engine is working at a low
revs, either during or after run-in.
• During the first 500 km (312 miles) step carefully on the brakes to avoid rough and long
braking. That is to permit the adequate adjustment of the pad friction material to the brake
discs.
• During the first 500 km (312 miles), never exceed 4000 rpm.
CHAR - 9
• Between the 500 km (312 miles) and the 1000 km (625 miles) travelled, never exceed 5000
rpm.
AFTER THE SPECIFIED MILEAGE, TAKE YOUR VEHICLE TO AN Official Aprilia Dealer FOR THE
CHECKS INDICATED IN THE "AFTER-RUN-IN" TABLE IN THE SCHEDULED MAINTENANCE
SECTION TO AVOID INJURING YOURSELF, OTHERS AND /OR DAMAGING THE VEHICLE.
• Between 1000 km (625 miles) and 2000 km (1250 miles) travelled, ride more vigourously,
vary speeds and twist throttle fully for some short periods for best coupling of the compo-
nents; do not exceed 5500 rpm.
• After 2000 km (1250 miles) a better engine performance may be expected but without ex-
ceeding the engine maximum rpm.
Vehicle identification
SERIAL NUMBER LOCATION

These numbers are necessary for vehicle registration.
NOTE
ALTERING IDENTIFICATION NUMBERS MAY BE SERIOUSLY PUNISHABLE BY LAW. IN PAR-
TICULAR, MODIFYING THE CHASSIS NUMBER IMMEDIATELY VOIDS THE WARRANTY.
This number is composed by numbers and letters,
as in the example shown below.
ZGULP0000YMXXXXXX
KEY:
ZGU: WMI (World manufacturer identifier) code;
LP: model;
000: version variation;
0: digit free
Y year of manufacture
M: production plant (M= Mandello del Lario);
XXXXXX: progressive number (6 digits);
CHASSIS NUMBER
The chassis number is stamped on the right side
of the headstock.
CHAR - 10
ENGINE NUMBER
The engine number is stamped on the left side,
close to the engine oil level check cap.
Dimensions and mass
WEIGHT AND DIMENSIONS

Specification Desc./Quantity
Max. length Strada 2173 mm (85.55 in)
Max. length Trail 2232 mm (87.87 in)
Max. length Factory 2173 mm (85.55 in)
Max. width Strada 810 mm (31.89 in)
Max. width Factory 860 mm (33.86 in)
Max. width Trail 820 mm (32.28 in)
Max. height (to windscreen) Strada - Factory 1150 mm (45.27 in)
Max. height (to windscreen) Trail 1180 mm (46.46 in)
Saddle height Strada 780 mm (30.71 in)
Saddle height Trail 810 mm (31.89 in)
Saddle height Factory 800 mm (31.49 in)
Centre to centre distance Strada - Factory 1490 mm (58.66 in)
Centre to centre distance Trail 1510 mm (59.45 in)
Minimum ground clearance Strada - Factory 200 mm (7.87 in)
Minimum ground clearance Trail 230 mm (9.05 in)
Dry weight Strada - Factory 179 kg (394.63 lb)
Dry weight Trail 183 kg (403.44 lb)
Engine
ENGINE
Model MY 660
Type 4-stroke single-cylinder, 4 valves per cylinder, single camshaft
per cylinder
Cylinder quantity 1
Overall engine capacity 660 cm³ (40.27 cu.in)
Bore / stroke 100 mm / 84 mm (3.93 in / 3.31 in)
Maximum torque 59.0 Nm (6.02 kgm) at 5250 rpm
Compression ratio 10.0 ± 0.5:1
Start-up electric
Ignition transistorised coil ignition (digital)
Revs at idle speed 1500 ± 100 rpm
Maximum rated power to the crankshaft 35 kW (47 HP) at 6250 rpm
Cooling liquid
Lubrication Dry sump system with separate oil tank
Type: oil filter Paper
Cooling system Fluid
Water pump Single centrifugal intake pump
Reduction ratio: 27/28 (0.964)
Thermostatic valve Opening start temperature: 71 °C (160 °F)
Full opening temperature: 85 °C (185 °F)
Air filter with dry filtration cartridge
CHAR - 11
Clutch multiple-disc, oil-bathed clutch with hydraulic control on the left
side of the handlebar
Driven plates 6 plates
Thickness: 1.50 - 1.70 mm (0.059 - 0.067 in)
Maximum distortion: 0.20 mm (0.0079 in)
Driving plates 1 4 plates
Inside diameter: 128 mm (5.039 in)
Thickness: 2.90 - 3.10 mm (0.114 - 0.122 in)
Driving plates 2 2 plates
Thickness: 2.92 - 3.08 mm (0.115 - 0.121 in)
Driving plates 3 1 plate
Thickness: 2.90 - 3.10 mm (0.114 - 0.122 in)
Clutch springs Number of springs: 5
Unloaded spring length: 55.6 mm (2.19 in)
Maximum limit: 52.82 mm (2.08 in)
Ignition advance 9.0 °C before TDC at 1400 rpm
Valve clearance at outlet 0.16 - 0.20 mm (0.0063 - 0.0079 in)
Valve clearance at intake 0.09 - 0.13 mm (0.0035 - 0.0051 in)
Valve timing: Intake opening - 25° before TDC
Intake closing - 55° after BDC
Outlet opening - 60° before BDC
Outlet closing - 20° after TDC
Standard compression pressure (at sea level) 650 kPa (92.4 PSI) at 800 rpm
Oil temperature 55 °C - 60 °C (131 °F - 140 °F)
Transmission
GEAR RATIOS
Main transmission 36/75 = 1:2.083
Transmission: secondary first gear: 12/30 = 1:2.500
second gear: 16/26 = 1:1.625
third gear: 20/23 = 1:1.150
fourth gear: 22/20 = 1:0.909
fifth gear: 26/20 = 1:0.769
Final ratio 15/44 = 1:2.933
Total ratio first gear: 15.278
second gear: 9.930
third gear: 7.028
fourth gear: 5.556
fifth gear: 4.700
Capacities
CAPACITY
Fuel (reserve included) 15 +/- 0.5 l (3.96 +/- 0.13 USgal)
Fuel reserve 3 l approx. (0.79 USgal approx.)
Engine oil oil change: 2500 cm³ (152.56 cu.in)
oil and oil filter change: 2700 cm³ (164.76 cu.in)
Fork oil for Strada - Factory 105 mm (4.13 in) of clearance (for each stem, measured with-
out spring and under compression)
Fork oil for Trail 570 cm³ (34.78 cu.in) for each stem
Coolant 1.2 l (0.32 USgal) (50% water + 50% ethylene glycol antifreeze
fluid)
Seats 2
Vehicle max. load 210 Kg (462.97 lb) (rider + passenger + fluids)
CHAR - 12
Drive chain
TRANSMISSION CHAIN
Chain type Endless (without master link) and with sealed links
Electrical system
IGNITION
Type DENSO - inductive discharge system
SPARK PLUGS
Standard spark plugs NGK CR7E
Electrode gap 0.7 - 0.8 mm (10.15 - 11.60 in)
Spark plug resistance 5 kOhm
ELECTRICAL SYSTEM
1 Battery 12V - 12 Ah
2 Fuses 7.5A - 15A - 20A
3 (Permanent magnet) Generator 12V - 290W
BULBS
1 Low beam light 12V - 55W
2 High beam light 12V - 60W
3 Front tail light 12V - 5W
4 Turn indicator lights with micro bulbs (not replaceable)
5 Rear daylight running light /stop light LED
6 License plate light 12V - 5W
7 Rpm indicator lighting LED
WARNING LIGHTS
1 Gear in neutral LED
2 Turn indicators LED
3 Fuel reserve LED
4 High-beam light LED
5 Alarm LED
6 Side stand LED
7 ABS LED
8 Heated handgrips LED
Frame and suspensions
CHASSIS
Type composite steel frame with removable saddle pillar
Headstock angle 27°
SUSPENSIONS
Front: hydraulic telescopic fork, Ø 45 mm (1.77 in) stems
Travel for Strada - Factory 140 mm (5.51 in)
CHAR - 13
Travel for Trail 170 mm (6.69 in)
Rear oscillating swingarm and adjustable hydraulic single shock ab-
sorber
Wheel travel for Strada - Factory 130 mm (5.12 in)
Wheel travel for Trail 170 mm (6.69 in)
Brakes
BRAKES
Front in Strada - Factory Ø 320 mm (12.60 in) disc brake
Front in Trail Ø 300 mm (11.81 in) disc brake - with hydraulic transmission
Rear Ø 240 mm (9.45 in) disc brake, with hydraulic transmission
Wheels and tyres
WHEELS AND TYRES

Strada type made of light alloy
Trail - Factory type with spokes
Front in Strada - Factory 3.5 x 17"
Front in Trail 2.15 x 19"
Rear in Strada - Factory 4.5 x 17"
Rear in Trail 3.00 x 17"
Rear in Strada 110/70 ZR 17 54W
alternatively: 110/70 R 17 54H - 120/65 ZR 17 56W - 120/65 R
17 56H
Front in Trail 100/90 M/C 19 57H
Front in Factory 110/70 ZR 17 54 W or 120/70 - 17 Pirelli Diablo
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- 1.9 bar (27.56 PSI)
tory
Driver and passenger inflation pressure (front) in Trail 2.0 bar (29.01 PSI)
Rear in Strada - Factory 160/60 ZR 17 69W
17 66H
Rear in Trail 130/80 M/C R 17 65H
alternatively: 140/80 M/C R 17 69H
Driver only inflation pressure (rear) in Strada / Factory 2.0 bar (29.01 PSI)
Driver only inflation pressure (rear) in Trail 2.1 bar (30.46 PSI)
Driver and passenger inflation pressure (rear) in Strada / Fac- 2.2 bar (31.91 PSI)
tory
Driver and passenger inflation pressure (rear) in Trail 2.3 bar (33.36 PSI)
Supply
FUEL SUPPLY SYSTEM

Type by electronic injection with Ø 45.5 mm (1.79 in) diffuser
FUEL SUPPLY
Fuel Premium unleaded petrol as per DIN 51 607, minimum octane
rating of 95 (NORM) and 85 (NOMM).
CHAR - 14
Tightening Torques
HANDLEBAR AND CONTROLS

Name Torque in Nm
vibration-damping weight screw M6 10 Nm - loctite 243
Handlebar and collars screws M8 25 Nm - manual
Front brake pump screws M6 12 Nm
ELECTRICAL SYSTEM
Name Torque in Nm
Battery clamping bracket screws M5 3 Nm
Horn to horn support screw M6 12 Nm
Rear turn indicator screws M6 3 Nm
Voltage regulator screws M6 12 Nm - loctite 243
Front turn indicator screws M6 3 Nm
Rear light fixing screws M5 1 Nm
Ground to engine retainer M6 15 Nm
Relay cable on starter motor retainer M6 5 Nm
Retainer for relay cables M6 4 Nm
SADDLE
Name Torque in Nm
Hinge on saddle fixing nuts M6 7+/-20% Nm
LOCKS
Name Torque in Nm
Rear lock screws M6 10 Nm
CHASSIS
Name Torque in Nm
Oil sump guard screws M6 8 Nm
Voltage regulator support screw M6 12 Nm - loctite 243
Coils to chassis fixing screws M5 6 Nm - Loctite 243
Map sensor fixing screws M6 12 Nm
Saddle pillar fixing screws M8 25 Nm - Loctite 243
Cradle to chassis fixing screws M10 50 Nm
FUEL TANK
Name Torque in Nm
Flange to tank fixing screws M5 6 Nm
CENTRAL BODYWORK
Name Torque in Nm
Radiator spoiler screws M6 5 Nm
Radiator protection screws M6 3 Nm
License plate holder to lower saddle pillar clamp screw M6 3 Nm
Retroreflector holder to license plate fixing screws M5 6 Nm
Front mudguard screw M5 5 Nm
Rear mudguard screw M5 3 Nm
Frontal fairing to bow M6 3 Nm
Internal deflectors to chassis screws M6 3 Nm
External deflector screws M5, M6 3 Nm - manual
Instrument panel windshield clamp screws M6 2 Nm
Lug screws M6 3 Nm
Fairing side support to chassis screws M6 10 Nm - Loctite 243
Side fairings to fairing side support screws M5 5 Nm
Bushing and saddle pillar lower clamp screws M6 5 Nm
Saddle pillar lower clamp to saddle pillar screws M6 4 Nm
Tail section - passenger seat strap fixing screws M6 12 Nm
CHAR - 15
Name Torque in Nm
Tail section front clamp screws M4 0.5 Nm - manual
Tail section clamp to saddle pillar screws M5 3 Nm
Tail section to saddle pillar lower clamp fixing screws M5 2 Nm
Saddle pillar lower clamp to chassis screws M6 4 Nm
Fairings - undertail fixing screws M6 7 Nm
Lower - front fairing clamp screws M6 7 Nm
Front fairing windshield screws - M4 0.5 Nm - manual
Bow instrument panel screws M6 5 Nm
BRAKING SYSTEM
Name Torque in Nm
Rear brake lever pin M8 20 Nm
Front brake calliper to calliper support screw, M10x1.25 (Fac- 50 Nm
tory)
Support to fork M10x1.25 (Factory) 50 Nm
Rear brake oil reservoir screw M5 6 Nm
Rear brake rod lock nut M6 manual
Brake calliper on stem screws, M10x1.25 (Strada - Trail) 50 Nm
COOLING SYSTEM
Name Torque in Nm
Expansion tank screw + carbon protection to coil support - M5 6 Nm
Head pipe to radiator fixing screw manual
FRONT WHEEL
Name Torque in Nm
Wheel pin nut 80 Nm
EXHAUST
Name Torque in Nm
Mufflers to saddle pillar fixing screw - M8 25 Nm
Exhaust pipe clamp fixing screw M5 16 Nm
Exhaust pipes to engine fixing screw M8 25 Nm
REAR WHEEL
Name Torque in Nm
Crown on sprocket carrier fixing screw M10 50 Nm
Wheel pin nut 80 Nm
SIDE STAND
Name Torque in Nm
Side stand retaining bolt M10x1.25 10 Nm - loctite 243
Switch screw M6 10 Nm
Lock nut M10x1.25 30 Nm - Loctite 243
ENGINE
Name Torque in Nm
Spark plug 13 Nm
Pinion case M6 10 Nm
Countershaft nut 70 Nm - 10W-40 Engine oil on thread
Valve set nuts 13 Nm
Drum nut 90 Nm - 10W-40 Engine oil on thread
Engine pinion nut 80 Nm - Molykote G-plus grease on thread
Chain pinion nut 12 Nm - 10W-40 Engine oil on thread
Flywheel nut 80 Nm - 10W-40 Engine oil on thread
Gear shift lever retainer M6 10 Nm
Threaded pin 22 Nm - Loctite 620 on thread
Exhaust stud bolts 15 Nm
Probe 18 Nm
Cylinder screws 50 Nm - 10W-40 Engine oil on thread, cylinder head and wash-
er
CHAR - 16
Name Torque in Nm
Distributor cover and valve covers screws 10 Nm
Oil filter cover and speed sensor screws 10 Nm
Clutch cover screws 1 and 2 10 Nm
Gear cover screws E/S 10 Nm
Oil pump gear cover screws 4 Nm - Loctite 620 on thread
Thermostat cover screws 10 Nm
Flywheel cover screws 10 Nm
Timing system gear screws 20 Nm
Chain tensioner body screws 10 Nm
Inlet manifold clamp screws 3 Nm
Clutch screws 9 Nm - 10W-40 Engine oil on thread
Chain guide screws 1 8 Nm
Neutral warning light switch screws 4 Nm - Loctite 620 on thread
Oil passage pipe side screws 2 10 Nm
Cylinder side screws 10 Nm
Cylinder head side screws 10 Nm
Starter motor screws 9 Nm
Lower support to chassis fixing screws M10 50 Nm
Upper supports to chassis fixing screws M10 50 Nm
Engine lower fixing screw M10 50 Nm
Engine to cradle fixing screws M10 50 Nm
Engine upper fixing screw M10 50 Nm
PK screws 7 Nm - Loctite 620 on thread
Camshaft plate screws 10 Nm - Loctite 242 on thread
Stator cable plate screw 10 Nm - Loctite 620 on thread
Clutch cover plate screw 1 10 Nm - Loctite 620 on thread
Bearing retention plate and oil filter screws 10 Nm - Loctite 620 on thread
Oil seal retention plate screws 10 Nm - Threebond TB 1215 liquid sealant on thread
Oil pump screws 10 Nm
Water pump fitting and water pump screws 10 Nm
Water pipe fitting screws 10 Nm
Rotor - freewheel screws 30 Nm - Loctite 620 on thread
Head cylinder inverted screws 37 Nm - 10W-40 Engine oil on thread, head and washer
Oil drain screw 30 Nm
Clutch crankcase half and flywheel crankcase halves screws 10 Nm
Oil filter bleed screw 5 Nm
Stator screws 10 Nm - Loctite 620 on thread
Chain tensioner screw 20 Nm
Head screws 50 Nm - 10W-40 Engine oil on thread, cylinder head and wash-
er
AIS Pipe screws 10 Nm
Oil intake pipe screw 10 Nm - Loctite 620 on thread
Oil outlet pipe screws 10 Nm - Threebond TB1215 liquid sealant on thread
Oil passage pipe 2 screws 20 Nm
Oil passage pipe 1 screws 18 Nm
REAR SUSPENSION
Name Torque in Nm
Shock absorber to chassis retainer M10 50 Nm - Loctite 243
Single connecting rod to chassis retainer M10 50 Nm
Single connecting rod/double connecting rod retainer M10 50 Nm
Double connecting rod/swingarm retainer M10 50 Nm
Double connecting rod/shock absorber retainer M10 50 Nm
SWINGARM
Name Torque in Nm
Swingarm pin ring nut M17x1 35 Nm
Swingarm pin adjustment bushing M25x1.5 12 Nm
Swingarm pin 100 Nm
Shock absorber protection retainer 4.8x13 20 Nm
Chain tensioner screw and nut M8 Manual
Chain slider retainer 4.8x13 20 Nm
Rear stand bushing M6 12 Nm
Rear brake pipe positioning plate fixing screw M5 6 Nm
Chain casing retainer M5 6 Nm
CHAR - 17
FRONT SUSPENSION
Name Torque in Nm
Fork stem on upper plate fixing screws M8 25 Nm
Fork stem on lower plate fixing screws M8 25 Nm
Headstock ring nut M25x1.5 7 Nm
Upper plate fixing cover M22x1 100 Nm
Fork hub clamp screws M6 12 Nm
Cable guide for front brake pipe screw M6 12 Nm
Stiffening plate fixing screw, M6x20 12 Nm
FOOTRESTS
Name Torque in Nm
Driver footrests to chassis fixing screws M10 50 Nm
Rear footrests to saddle pillar fixing screws M8 25 Nm
Recommended products chart
RECOMMENDED PRODUCTS
Product Description Specifications
AGIP RACING 4T, SAE 15W-50 Engine oil Use top-branded oils that meet or exceed
the requirements of CCMC G-4 API SG
specifications.
AGIP 5W or AGIP 20W Fork oil When an intermediate performance
among those offered by the specified
products is desired, 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 OR PETROLEUM Battery poles Neutral grease or petroleum jelly.
JELLY
AGIP CHAIN GREASE SPRAY Recommended CHAIN oil Grease
AGIP BRAKE 4 Brake fluid As an alternative to the recommended
fluid, other fluids that meet or exceed the
required specifications may be used.
SAE J1703, NHTSA 116 DOT 4, ISO
4925 Synthetic fluid
AGIP PERMANENT SPEZIAL Recommended ENGINE COOLANT Biodegradable coolant, ready for use,
with "long life" technology and character-
istics (pink). Freezing protection up to
-40° (-40°F). In compliance with the CU-
NA 956-16 standard.
CHAR - 18
INDEX OF TOPICS
SPECIAL TOOLS S-TOOLS

Special tools PEGASO 650 STRADA - TRAIL - FACTORY
SPECIAL 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
PEGASO 650 STRADA - TRAIL - FACTORY Special tools

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
8140846 Crankshaft fitting tool
8140848 Rocking lever shaft extractor
S-TOOLS - 21
Special tools PEGASO 650 STRADA - TRAIL - FACTORY

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
S-TOOLS - 22
PEGASO 650 STRADA - TRAIL - FACTORY Special tools

AP0276474 Valve spring compressor adaptor
S-TOOLS - 23
INDEX OF TOPICS
MAINTENANCE MAIN
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 KM (375 MILES)

Action
Drive chain tension and lubrication - Check and clean, adjust, grease and replace if necessary
AFTER 1000 KM (625 MILES) RUN-IN

Action
Carburetion and CO adjustment - check and clean, adjust
Transmission cables and controls - Check and clean, adjust, grease or replace if necessary
Steering bearings and steering clearance - Check and clean, adjust, grease or replace if necessary.
Engine oil filter - Replace
Engine oil filter (on oil reservoir) - Clean
Fork - Check and clean, adjust and lubricate
General vehicle operation - Check and clean, adjust, grease or replace if necessary.
Clutch backlash - adjust.
Braking systems/brake discs - Check and clean, adjust, grease or replace if necessary
Braking systems - Check and clean, adjust, grease or replace if necessary
Light circuit - Check and clean, adjust or replace if necessary
Safety switches - Check and clean, adjust, grease or replace if necessary
Brake fluid - Check, top-up or change if necessary.
Break pads (if worn) - replace
Tyres - Check and clean, adjust, grease or replace if necessary
Tyre pressure - Adjust
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.
Brake pad wear - Check and clean, adjust or replace if necessary

Action
Brake pad wear - check and clean or replace if necessary

Action
Front brake pads - Check and clean, replace if necessary
Final transmission (chain, crown and pinion) - Check and clean, adjust, grease or replace if necessary
EVERY TIME THE FINAL TRANSMISSION IS REPLACED

Action
Anti-vibration mountings and sliding roller - replacement
EVERY 10000 KM (6250 MILES) OR 12 MONTHS

Action
Spark plug - check and clean or replace if necessary
Timing chain - check and clean, adjust, grease or replace if necessary
Carburetion and CO adjustment - check and clean, adjust
Transmission cables and controls - Check and clean, adjust, grease or replace if necessary
Wheels centring - check and clean, adjust
Wheel bearings - Check and clean, adjust, grease or replace if necessary
Steering bearings and steering clearance - Check and clean, adjust, grease or replace if necessary.
MAIN - 25
Maintenance PEGASO 650 STRADA - TRAIL - FACTORY
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.
Light operation/aiming - check and clean, adjust or replace if necessary
Clutch backlash - adjust.
Braking systems/brake discs - Check and clean, adjust, grease or replace if necessary
Safety switches - Check and clean, adjust, grease or replace if necessary
Cooling system - check and clean, adjust, grease or replace if necessary.
Light circuit - Check and clean, adjust or replace if necessary
Braking systems - Check and clean, adjust, grease or replace if necessary
Brake fluid - Check, top-up or change if necessary.
Engine oil - Change
Side pannier coupling pins (if fitted) - check and clean, adjust or replace if necessary
Tyres - Check and clean, adjust, grease or replace if necessary
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
Securing locks for side panniers and rear case (if fitted) - check and clean, grease or replace if necessary
Battery terminals tightening - 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 20000 KM (12500 MILES) OR 24 MONTHS

Action
Spark plug - Replace
Fork - Check and clean, adjust and lubricate
Coolant - Check and top-up
Anti-vibration mountings and mounting assembly backslash - check and clean, adjust, replace if necessary
Rear shock absorber - Check and clean, adjust, grease or replace if necessary
Rear suspension connecting rod bearings - Check and clean, adjust or replace if necessary
Fuel pump filter - check and clean, adjust, replace if necessary
Air filter - Replace
Engine oil filter (on oil reservoir) - Clean
Valve clearance adjustment - Adjust
Engine oil - Change
EVERY 2 YEARS
Action
Brake fluid - change
Coolant - change
AFTER THE FIRST 30000 KM (18750 MILES) AND THEN AFTER EVERY 20000 KM (12500
MILES)
Action
Fork oil seals (after the first 30000 km (18750 miles) and then after every 20000 km (12500 miles) - replace
EVERY 4 YEARS
Action
Fuel pipes - Replace
MAIN - 26
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.
• 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.
MAIN - 27
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.
• Remove the 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.
MAIN - 28
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.
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.
MAIN - 29
• 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).
• Unscrew and remove the ignition spark

plug.
• Rotate the 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
MAIN - 30
• 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.
Characteristic
Valve clearance at intake
0.09 - 0.13 mm (0.0035 - 0.0051 in)
Valve clearance at outlet
0.16 - 0.20 mm (0.0063 - 0.0079 in)
Adjust valve clearance by following the instruc-

tions given below:
• 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 tighten the lock nut (5)
to the specified torque.
• With the thickness gauge check again
that the valve clearance is within the
indicated values and, if required, re-
peat all the steps to adjust valve clear-
MAIN - 31
ance until the pre-set clearance is

obtained.
NOTE
LUBRICATE THE VALVE SET SCREWS WITH RECOM-
MENDED LUBRICANTS.
MAIN - 32
INDEX OF TOPICS
ELECTRICAL SYSTEM ELE SYS

Electrical system PEGASO 650 STRADA - TRAIL - FACTORY
Components arrangement
Key:
1. Coil
2. Fuel pump
3. Fall sensor
ELE SYS - 34
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
Electrical system installation
ELE SYS - 35
General wiring diagram
Key:
1. Multiple connectors
2. Gear in neutral switches
3. Clutch switch
4. Fall sensor
ELE SYS - 36
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
16.License plate light
17.Right rear turn indicator
18.----
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.Spark plug
ELE SYS - 37
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
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;
ELE SYS - 38
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:
A) coolant temperature
B) fuel quantity
C) clock
D) speedometer
E) odometer
F) trip computer and additional functions
The MODE Selector has three positions: to the left,

numerical values decrease and it is possible to
scroll down the drop-down menu options; to the
right, numerical values increase 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 with low fuel for distances over 2
km - 1.24 mi)
Trip odometer 1 and trip odometer 2 can be reset:

press and hold down the selector at the central
position to reset all the values for the active trip
odometer. After displaying the distance travelled
ELE SYS - 39
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. When riding the ve-
hicle, the TRIP ODOMETER 1 is displayed again.
The configuration menu options are:
• EXIT;
• SETTINGS;
• CHRONOMETER;
• DIAGNOSIS;
• LANGUAGES.
SETTINGS
When the SETTINGS function is selected the dis-
play shows the following options:
• EXIT
• CLOCK 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.
Each time the MODE selector is pressed to the
right, the value increases; it goes back to zero
when it reaches twelve.
Likewise, each time the MODE selector is pressed
to the left, the value decreases and when it rea-
ELE SYS - 40
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.
The hour indicator is no longer displayed when this
function is activated; only the minutes indicator is
shown.
right, the minute value increases and when the
value reaches 59, it goes back to 0 the next time
the MODE selector is pressed to the right.
Likewise, each time the MODE selector is pressed
to the left, the value decreases and when it rea-
ches 0, it goes to 59 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.
Gear shift threshold
The gear shift threshold can be set in this mode.
The main screen shows the message ''GEAR
SHIFT THRESHOLD''.
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 lowest limit, the
next time the selector is pressed will produce no
effect.
The procedure ends when the MODE selector is
pressed at the central position, which stores the
set value, the pointer goes back to zero and the
instrument panel goes back to the configuration
menu.
When the battery is first activated, the instrument
panel is set to the run-in revolutions value. The
subsequent times it is operated, the last set value
is displayed.
ELE SYS - 41
• 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. It turns off when the value goes back below
the threshold limit.
Backlighting brightness
This function adjusts the backlighting brightness to
three levels. Each time the MODE selector is
pressed to the right or left, the following icons are
shown:
• LOW
• MEAN
• HIGH
Once the operation is finished, when the MODE

selector is pressed at central position, the instru-
ment panel shows the SETTINGS menu.
Code modification
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
el goes back to the DIAGNOSIS menu.
If the user has used the code, this operation is not
allowed.
el goes back to the SETTINGS menu.
This function is used when the old CODE is not
available and it needs to be changed. In this case,
two programmed keys will have to be inserted.
ELE SYS - 42
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. After the
second key is recognised, the new code is reques-
ted with the message:
Enter new code
el goes back to the DIAGNOSIS menu. If the user
has used the code or if only one key is stored, this
operation is not allowed.
el goes back to the SETTINGS 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 selected,
the display shows the following options:
• EXIT
• VIEW TIMES
• DELETE TIMES
View times
This option shows the stored chronometer times.
Press the MODE selector for a couple of seconds
to the right or left to scroll the times screens; hold
it down to display the CHRONOMETER menu. If
the battery is removed, the stored times are lost.
ELE SYS - 43
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. Press the MODE selector at
the central position for a couple of seconds and the
chronometer starts to time. Press the MODE se-
lector at the central position again within 10 sec-
onds of the start to cancel the timing operation and
to begin a new measurement.
Press the MODE selector at the 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 display the VIEW TIMES function of
the CHRONOMETER menu. It is possible to carry
out a new measurement only after all the stored
times have been deleted: select the DELETE
TIMES function of the CHRONOMETER menu.
LANGUAGES
Select the user's interface language from this
menu:
• ITALIANO
• ENGLISH
• FRANCAIS
• DEUTSCH
• ESPAGNOL
SERVICE THRESHOLD
ELE SYS - 44
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.
The alarms are subdivided into two groups ac-
cording to their priority:
• High priority: overheating, Control unit

errors, Instrument panel errors;
• Low priority: Turn indicators.
The turn indicator failure signal is displayed only

when the failure affects all the indicator LEDs.
If there are more than one alarm of equal priority
simultaneously, the corresponding icons are dis-
played alternately.
High priority alarms inhibit the displaying of low
priority alarms.
Brief warning light and SERVICE icon lighting do
not signal malfunctioning
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 per revolution. The pinion has 15 teeth while the crown has 44, the
wheel circumference is 1926 mm (75.83 in).
Due to homologation requirements, the value indicated on the instrument panel must be 6% higher than
the one read by the control unit.
Rpm indicator
The engine revs are indicated on the instrument panel left dial.
Accuracy: 0/+5% with respect to the received signal.
The instrument panel will have to filter the signal so that the pointer does not oscillates, mainly at idle
speed.
Maximum pointer oscillation at idle speed: +/- 1° with respect to the received signal.
ELE SYS - 45
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.
The measurement is carried out through reading the Denso control unit. The relation between the engine
revs and the value from the control unit is: RPMx1000 = VALUE1x(189/7) = VALUE1x27
The pointer recovery logic: the pointer is moved to the start of the scale each time the vehicle is turned
off. Each time the battery is connected, the full parking is performed, which brings the pointer back to
zero, regardless of its position. Each time the vehicle is started, the recovery is 20°.
Engine temperature gauge
Temperature is measured by the Denso control unit. The warning light turns on when the coolant rea-
ches 120 °C (248 °F).
Fuel gauge
The instrument panel should be able to interface with a resistive level sensor, either potentiometric or
resistive-pulse type. The measurement of values exceeding the sensor limits should be considered
failures and indicated by the diagnosis. The indication is shown in the LCD display and signalled by the
corresponding low fuel warning light. The characteristics and the calibration curves are indicated in the
following table:
• 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 is shown in a [nn.n] format followed by the indication of the unit of measure-
ment, [km] or [mi].
The count starts when the warning light has been on for 5 seconds and stops when the warning light
has been off for 30 seconds. In any case the value should only be displayed after the count exceeds 2
km (1.24 mi).
The value is displayed 40 seconds after the key is set to KEY ON so that you can read the total odometer
even if the vehicle is in reserve.
Total odometer
The selection between [km] and [mi] is carried out by the interface user.
• The indication should be displayed with an accuracy of 6 digits, in [Km] or [Miles]. Saturation
occurs when shifting from 999998 to 999999 and the count blocks, the digits which are not
used are not shown.
• Precision: +/- 0.5%
• The value of total kilometres covered is stored for at least 5 years, with an instrument panel
not powered.
• Data are saved every 2 km (1.24 mi).
Odometer information should not be lost regardless of any power supply situation.
ELE SYS - 46
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).
The adjustment is lost when the battery is disconnected; the next time the vehicle is started, the clock
will constantly display ''0:00'' until the new adjustment is made.
Trip computer
At the bottom of the display, trip computer indications are displayed with 2 trip odometer indications and
their mean and high speeds, travelling time and consumption.
When each odometer is reset, all its associated values are reset too.
The selection between kilometres and miles is carried out by the user's interface and it is related to the
size selected for the total odometer.
In the case of a temporary power drop, for instance after starting the vehicle, the instrument panel must
not lose the data. Data can be lost when the battery is disconnected. For further information see the
rating test.
When the trip odometer gets to its saturation point, from 999.9 to 0.0, or the travelling time gets ti its
saturation point, from 99:59 to 00:00, all the 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 calculated from the last trip odometer reset. This calculation also includes the
stops (zero speed and vehicle on) but not the KEY ON intervals, with shut off engine. The count stops
when the vehicle is off. The value is shown in the graphic display in [hh:mm] format preceded by the
word [TIME]. Saturation occurs when shifting from 99:59 to 00:00.
Maximum speed
The maximum speed is calculated from the last reset. The value is shown in the graphic display in a
[nnn] format preceded by the word [MAX] and followed by the unit of measurement indication, [Km/h]
or [MPH].
The speed is stored only if the information remains for at least 3 samples separated by 0.5 seconds.
Or rather, values Sn, Sn+1, Sn+2
If (Sn<= Sn+1) & (Sn<=Sn+2) then MAXS= Sn
Battery voltage
This function measures the battery voltage. The value is shown in the graphic display in a [nn.n] format
preceded by an icon showing a battery and followed by the indication of the unit of measurement, [V].
ELE SYS - 47
• 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).
Indication refresh: every 10 sec. A suitable software damping should be foreseen to avoid oscillating
indications.
Safety logic
The activation of the safety logic and the immobilizer occurs by means of the CONTACT 1 and CON-
TACT 2 signals of the instrument panel that must be closed, enabling ignition. The immobilisation will
be carried out by opening these contacts.
The vehicle is immobilised by keeping the CONTACT 1 and CONTACT 2 signal at a high logic level
(contacts open) and the START-UP RELAY ACTIVATION signal at a low logic level (contact open).
To unlock safety locks set the CONTACT 1 and CONTACT 2 signals at a low logic level (contacts
closed) and the START-UP RELAY ACTIVATION signal at a high logic level (contact closed).
Service intervals
When the odometer reaches 1000 km (621.37 mi), the SERVICE icon indicating the first servicing turns
on.
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 synchronised control of both channels ("Hazard" function).
The required characteristics are the following:
• The hazard control device is a switch.

• Flashing frequency during regular operation: complying with the FMVSS 108 standard
(60-120 flash/min) and in any case about 87 flash/min.
• The instrument panel must directly control a bulb load of up to 4x21W. Anticipate however
the possibility of controlling mixed loads (for example front bulbs and rear LEDs) or just LEDs
for the 4 outputs. Therefore, it is necessary to have 4 separated control channels. The min-
imum current per channel will be 1 mA.
• Failure signal (burned out or short-circuited bulb) through doubling (approx. 175 flash/min)
the warning light flashing frequency.
• Short circuit protection (with indefinite short circuit stay time) for all the outputs. Hazard
operating logic: activated/deactivated only with key set to ON. It also remains operative after
being activated if the key is set to KEY OFF
ELE SYS - 48
• 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. When it is activated, the indicators also remain active when the key is extracted. To deac-
tivate it, set the key back to KEY ON.
Automatic deactivation
It is necessary the implement the automatic deactivation of the turn indicators. If the vehicle is stopped,
with zero speed, the indicators continue to flash indefinitely. If the vehicle is moving, the indicators are
automatically deactivated when one of these situations occurs:
• After a time (t) = 40 sec.
• After riding 500 m (0.31 mi).
Immobilizer
The immobilizer system is integrated to the instrument panel electronic card. The card structure should
admit instrument panels without immobilizer or with the immobilizer function disabled, to be used in
countries where immobilizer systems are not allowed or not fitted.
The supplier shall be responsible for homologating the instrument panel immobilizer device according
to the regulations set by the Ministry of Post & Telecommunications 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 recognised, the instrument panel disables the vehicle start-up, the display shows
the request of the manual unlocking code; in this case the menu should be accessed through the di-
agnosis function.
Code
This function is used to manually unlock the immobilizer by entering a code. If the instrument panel
does not recognise the key inserted, entering the access code is requested, and the following message
is displayed:
• Enter the code
The code must have 5 characters selected between 0-9. At the end of the line, the code will be empty
(five 0 digits or rather 00000) and it will be programmed by the user. If the code is not entered within
10 seconds, an alarm message is displayed:
• Remember to enter the user code
This code can be modified by the user after re-entering of the old code, and if the user has lost the
access code, by means of a code entering procedure requiring inserting both keys the user has.
ELE SYS - 49
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.
The display shows the following message:
• Insert the X key

• X+1 key programmed
At least one key must be stored, for the next start-ups. If no other keys are inserted within 20 seconds
or if there is lack of power or after the fourth key is programmed, the procedure finishes and all the
functions of the vehicle and the instrument panel must be enabled (even if only one key has been
programmed).
Programming new keys

If one key is lost, the customer can disable the lost key or disable 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 configuration are shown in the
figure.
The numbers are also stamped on the plastic part
of the connectors and also on the connector body.
The pin configuration of the grey-bodied connector
is as follows:
• PIN 1: +KEY
• PIN 2: RIGHT CONTROL INDICATOR
• PIN 3: HIGH-BEAM LIGHTS INPUT
• PIN 4:
• PIN 5: HEATED HANDGRIPS INPUT
• PIN 6: K LINE
• PIN 7: NEUTRAL
• PIN 8: SELECT 1 - DOWN
• PIN 9: FUEL LEVEL SENSOR
• PIN 10:
• PIN 11: +BATTERY
• PIN 12: LEFT CONTROL INDICATOR
ELE SYS - 50
• PIN 13: -
• PIN 14: -
• PIN 15: -
• PIN 16: GENERAL GROUND
• PIN 17: ABS INPUT
• PIN 18: SENSORS GROUND
• PIN 19: GENERAL GROUND (OP-
TIONAL)
• PIN 20: GENERAL GROUND (OP-
TIONAL)
The pin configuration of the black-bodied connec-

tor is as follows:

• PIN 22: LEFT FRONT 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 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
ELE SYS - 51
• 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. Devices to limit current in case of failure must
be fitted on the power supply lines.
K Line
The interface line consists of a line with physical level complying with the ISO-9141 standard and should
be used to open the Denso injection control unit session . The speed must be 15.625 kbit/sec. The line
must have a 1-kOhm pull-up resistor powered by the live battery, which must have a diode as standard
to prevent reverse current feeding through the signal lines.
Select 1-3
These inputs are used for the user's interface commands and must be fitted with a 1-kOhm pull-up
resistor powered with internal power supply voltage.
High-beam lights input
It is the signal that warns the instrument panel that the high-beam lights are on and that it must turn 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 is interrupted, the warning light must remain off, then a pull-down resistance is required.
Right indicator control / Left indicator control / Indicator reset control / Hazard control
These signals indicate the arrow status to the instrument panel; these are normally open switches and
they are earthed when pressed.
Fuel level sensor
This sensor has a resistive track of 12-296 Ohm, with one end connected to earth.
Neutral
This contact, present only when the vehicle is moving, signals whether the motorbike gear is engaged
or not. It is earthed when the vehicle is in neutral and, when this occurs, the relevant warning light turns
on.
Stand
This contact, present only on vehicles fitted with side stand, signals whether the side stand is lowered
or not.
ABS
ELE SYS - 52
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.
Aerial 1/ Aerial 2
Contact 1 / Contact 2
Two contacts that lock the vehicle, controlled by the immobilizer or by the engine control logic. These
contacts should be suitably sized to allow a 200 mA current at closed circuit, whereas the pickup current
is 500 mA. The contacts should be protected to allow controlling inductive loads.
Start-up relay activation
It should be able to control a relay with maximum current of 4A.
STRUCTURAL REQUIREMENTS
• Operating conditions
• Rated voltage: 13.5 +/- 0.5 V
• Effective operating voltage (not calibrated): 6V +/- 18V (data preservation must be ensured
in case of temporary power loss, for example when starting the vehicle with a flat battery).
• Effective operating voltage (calibrated): 9 - 16 V
• Input with key extracted (immobilizer LED excluded, if fitted): <1mA
• Operating temperature (not calibrated): -20 °C / +85 °C (- 4 °F / 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
(2.44x2.16 in), while the active area (the one actually occupied by pixels) is 56x49 mm (2.20x1.92 in)
(X-axis - Y-axis).
The visualisation cone is the following one: On the horizontal plane (x-z), it is +45° -45°; on the vertical
plane (y-z), it is +10° -30°. Contrast must be over 5 in the whole visualisation cone.
It should be possible to read all the LCD displays with Polaroid glasses up to 35° with respect to the
horizontal surface.
Temperature display
The operating specifications considering temperature on the display are as follows:
• Effective temperature (no ghost effect): -20°C +/- +85°C (-4 °F +/- 185°F)
• Storage temperature: -30°C +/- +90°C (86°F +/- 365°F)
A display compensation system should therefore be implemented on the instrument panel to account
for ambient temperature variations.
Labelling
ELE SYS - 53
An adhesive label should be stuck to the back of all the components. This label should be indelible and
water resistant and should indicate:
• supplier's code
• aprilia code
• hardware card version
• software version
• production date
It is the supplier's responsibility to add any other labels relating to DOT certificates or immobilizer system
homologations.
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:
• 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 types of ECU diagnosis, passive and active. In the passive diagnosis, the user simply
reads the data from the ECU- the battery voltage, throttle opening angle, atmospheric pressure or the
reading of present or past errors. In the active mode, the ECU carries out such operations as producing
5 sparks or 5 injections.
The values to be transmitted to read the parameters are:
ELE SYS - 54
• 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
• Code 09: Fuel system voltage
• Code 20: Side stand switch
• Code 21: Neutral switch
• Code 70: Program Ver. No.
The parameters to be transmitted for the activations are:
• Code 30: Ignition coil
• Code 36: Injector
• Code 48: AIS solenoid
• Code 50: Main relay
• Code 51: Fan relay
• Code 52: Headlight relay
Errors: this screen displays all the errors present 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 switch to STOP. Once the key reinsertion is detected, the following
menu is displayed:
• EXIT
• COIL
• INJECTOR
• AIS SOLENOID
• INJECTION RELAY
• FANS
• LIGHTS
You can exit only by turning the key to stop. For this purpose, the following message is displayed:
ELE SYS - 55
• Turn the key to stop to exit
Ignition coil
• Turn the engine RUN/engine STOP switch first to RUN and then to STOP.
The ignition coil will then be activated 5 times.
Injector
The injector will then be activated 5 times.
AIS solenoid
• Turn the engine RUN/engine STOP switch first to RUN and then to STOP. The secondary
air solenoid will then be activated 5 times.
Injection relay
Turn the engine RUN/engine STOP switch first to RUN and then to STOP. The injection relay will then
be activated 5 times.
Fans
The fan control relay will then be activated 5 times.
Lights
The light relay will then be activated 5 times.
Ecu errors
This screen displays both current and stored errors. The following message is displayed:
Once the key reinsertion is detected, the table of the errors read by the engine control unit is displayed.
You can exit only by turning the key to stop. For this purpose, the following message is displayed:
Ecu parameters
ELE SYS - 56
This screen displays the parameters read by the engine control unit. The following message is dis-
played:
Once the key reinsertion is detected, the parameter table is displayed. You can exit only by turning the
key to stop. For this purpose, the following message is displayed:
CO adjustment
In this screen, the instrument panel sends the packages to increase or decrease the CO value. To
increase or decrease the value, use the UP and DOWN buttons in the control selector; the instrument
panel shows the set value. The set value will be stored by the ECU at KEY OFF.
The engine revs are shown at this stage.
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 to stop to save and exit
The value of the parameter that adjusts the CO should be expressed within the range between -127
and +128.
Instrument panel errors

In this mode, a chart is displayed showing the potential errors in the immobilizer and its sensors. This
is the error transcoding chart:
Immobilizer failure: Key code read but not recognised
• Error code: DSB 01
Immobilizer failure: Key code not read (Key not present or transponder not working)
Immobilizer failure: Aerial not working (Open or short-circuited)
ELE SYS - 57
Immobilizer failure: Internal controller failure

Fuel sensor failure

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.
Delete errors
This option deletes all the errors, both control unit and instrument panel errors; a further confirmation
is requested.
Reset service
This function is used to reset the service interval.
Disconnection
For collection data on Pegaso models, the instrument panel uses the K line for communicating with the
diagnosis instruments. To avoid any interference, the instrument panel should be in a status at which
no interference is possible, by the user's interface setting. Through the external devices, the control unit
will be reset and be also able to start interfacing with the diagnosis instrument.
The LCD shows:
• Instrument 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 work normally after the key is inserted-extracted.
Modify Keys
With this function the instrument can update the keys. Up to 4 keys can be stored.
The user code is first requested to be entered:
• Enter the code.
After entering the correct code, the following message should be shown on the display:
• Enter the X key.
• X+1 programmed.
At least one key must be stored, for the next start-ups. If no other keys are inserted within 20 seconds
or if there is lack of power or after the fourth key is programmed, the procedure finishes and all the
functions of the vehicle and the instrument panel must be enabled (even if only one key has been
programmed).
ELE SYS - 58
Km / miles
This menu selects the unit of measurement for the speed.
• KM
• 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 °
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)
ELE SYS - 59
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
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.
ELE SYS - 60
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. Speed signal
10. (+) Pick 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
ELE SYS - 61
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
12 V - 10 Amp/h MF
Engine rpm sensor
192 - 288 Ohm at 20 °C (68 °F) (between blue/

yellow and green/white)
ELE SYS - 62
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)
0.140 - 0.145 kOhm 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
ELE SYS - 63
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).
Secondary coil resistance 10.4 - 15.6 kOhm at 20
°C (68 °F) (between red/black cable 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/red
cable and red/white cable)
ELE SYS - 64
INDEX OF TOPICS
ENGINE FROM VEHICLE ENG VE

Engine from vehicle PEGASO 650 STRADA - TRAIL - FACTORY
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.
• 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.
ENG VE - 66
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
• 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.
ENG VE - 68
• 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.
• Disconnect the engine temperature

sensor connector.
ENG VE - 69
• 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.
• Undo and remove the screw.
ENG VE - 70
• 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.
ENG VE - 71
• 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.
• Disconnect the neutral sensor.
ENG VE - 72
• 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.
• Slide off the pin from the left side.
ENG VE - 73
• 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.

and remove the two screws on the en-
gine.
• Slide off the two screws from the op-
posite side.
• Remove the engine front support.

and remove the upper nut.
• From the opposite side, slide off the
screw.
ENG VE - 74
• 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
• With vehicle chassis properly secured,

lift the engine up to the desired posi-
tion.
ENG VE - 75
• 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.
• Fit the engine front support.
ENG VE - 76
• 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.
• Remove the engine hoister.

• Fit the pin.
• Fit the bushing and fasten it.

• Fasten the pin.
ENG VE - 77
• 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.
• Fit the cable guide and tighten the fix-

ing screw with the washer.
ENG VE - 78
• 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.
ENG VE - 79
• 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.
• Connect the expansion tank breather

pipe.
ENG VE - 80
• 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.

• Connect the clutch cable to the linkage
system.
ENG VE - 81
• 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.
• Connect the stand sensor.
ENG VE - 82
• Connect the alternator connectors.
• Connect the neutral sensor connector.
• Connect the speed sensor.

• Fix the cable harnesses with the
clamps.
ENG VE - 83
• 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
INDEX OF TOPICS
ENGINE ENG
Engine PEGASO 650 STRADA - TRAIL - FACTORY
Gearbox
ENG - 86
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
12.Secondary axle unit
Gearbox shafts
ENG - 87
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
• Remove the gear main shaft.

• Remove the safety circlip.
ENG - 88
• 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.
ENG - 89
• Slide off gear of the third gear.
• Remove the splined washer.
• Slide off the gear of the fourth gear.
See also
Removing the
crankshaft
ENG - 90
Removing the secondary shaft
• Remove the gear secondary shaft.

• Slide off the gear of the first gear and

collect the washer.
• Slide off the gear of the fourth gear.
ENG - 91
• 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.
See also
Removing the
crankshaft
ENG - 92
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.
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 not regular, replace the damaged part.
Checking the secondary shaft
Measure the coaxiality of the transmission 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 not regular, replace the damaged part.
Checking the desmodromic drum
Check gear drum for damage, scratches and wear

and replace the desmodromic if necessary.
Check the desmodromic segment (1) for damage
and wear and replace it if necessary.
Check the desmodromic bearing (2) for damage
and pitting and replace it if necessary.
ENG - 93
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.
Fitting the primary shaft
• Fit the gear of the fourth gear.
• Insert the splined washer.
ENG - 94
• Replace the safety circlip.
• Fit the gear of the third gear.
• Insert the toothed washer, the spacer,

the retaining element and fit the gear of
the fifth gear.
ENG - 95
• Insert the toothed retaining washer.
• Fit the gear of the second gear.
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.
ENG - 96
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.
• Fit the gear of the fifth gear.
ENG - 97
• Fit the gear of the third gear and the

splined washer.
• Fit the gear of the fourth gear.
• Fit the gear of the first gear and the

washer.
ENG - 98
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.
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
ENG - 99
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.
• 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
ENG - 100
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.
STOP LEVER CHECK

Check the stop lever for damage and wear and make sure the 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
Starter motor
Removing the starter motor
• Disconnect the starter motor power

supply cable.

remove the starter motor.
ENG - 101
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
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.
• Insert the tab on the crankshaft.
See also
Installing the
chain
ENG - 103
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.
• 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
ENG - 104
Removing the
starter motor
• Remove the flywheel cover.

• Unscrew and remove the flywheel fix-
ing nut.
• Collect the washer.
• Place the flywheel locking tool.

• Check the flywheel is adequately
locked.
DO NOT ALLOW THE LOCKING TOOLS TO COME INTO

CONTACT WITH THE FLYWHEEL UPPER PROTRUSION.
Specific tooling
• Warm the flywheel with a specific heater.
• Using the flywheel extractor, remove it from the crankshaft.
Specific tooling
8140837 Flywheel extractor
See also
Installing the flywheel
• Fit the starting ring gear, if previously

removed.
• Fit the flywheel paying attention to the
correct position of the tab in its slot.
ENG - 105
• 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
• Insert the washer on the crankshaft.
• Tighten the nut to the specified torque.
See also
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.
ENG - 106
• 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.
• Fit the starter motor cover with a new
gasket.
ENG - 107
• 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. 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 .
ENG - 108
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.
• Remove the thirteen clutch discs.
• Remove the clutch damper spring and

its fitting.
ENG - 109
• 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
• Remove the clutch hub and collect the

thrust washer.
ENG - 110
• 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

in)
• Measure the driving plate thickness at

four positions, replace them all if not
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
Characteristic
Driving plates 1
4 plates
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
Thickness: 2.90 - 3.10 mm (0.114 - 0.122 in)
ENG - 111
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.
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.
ENG - 112
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-
er.
• Measure the clutch spring length when
unloaded; if necessary, replace the
springs all together.
Characteristic
Clutch springs
Number of springs: 5
Unloaded spring length: 55.6 mm (2.19 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 it
is shows signs of wear or damage.
ENG - 113
Assembling the clutch
• Install the clutch bell.
• Insert the washer.
• Install the clutch hub.
• Insert the new locking washer.
ENG - 114
• Using the universal clutch locking tool,

tighten the clutch hub nut to the pre-
scribed tightening torque.
Specific tooling
• 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.
ENG - 115
• Insert the thirteen clutch discs paying

attention to their position.
ENG - 116
ENG - 117
ENG - 118
• Fit the clutch plate together with the

disengagement shaft.
• Fit the springs.
ENG - 119
• 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.
• Fit the centring dowels.
• Rotate the disengagement shaft so

that the teeth face towards the back of
the motorbike.
ENG - 120
• Fit a new gasket.
• Place the clutch cover.
• Tighten the screws operating diagonal-

ly.
WHEN FITTING THE RELEASE 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
ENG - 121
• Using the suitable special tool, un-

screw and remove the flywheel cover
to access the timing reference.
Specific tooling
• Rotate 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.
ENG - 122
• Check that the reference mark "I" on

the camshaft toothed wheel is aligned
to the stationary reference on the head.

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.
ENG - 123
• Unscrew and remove the four stud

bolts, operating diagonally and in
stages.
• 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.
ENG - 124
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.
See also
Removing the rocker arms
Removing the rocker arms
• Remove the head.

• Working from both sides, undo and re-
move the four screws.
ENG - 125
• 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.
Specific tooling
ENG - 126
• Using the adequate extractor remove

the outlet rocking lever shaft.
Specific tooling
• Remove outlet rocking lever.
• Using the suitable extractor, remove

the inlet rocking lever shaft.
Specific tooling
• 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
ENG - 127
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.
• Use the valve springs compressor and
the valve springs compressor adaptor
to remove the valve cotters.
Specific tooling
• Remove the valve spring retaining el-

ement.
• Remove the valve spring.
• Remove valve stem oil seal (1) and the

valve spring (2) seat.
ENG - 128
• 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.
• Check that decompression cam (2) is
free to move without obstacles.
Checking the 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 sizes:

Inlet
• a: 43.488 / 43.588 mm (1.7121 / 1.7161

in); Limit 43.388 mm (1.7062 in)
ENG - 129
• 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)
• b: 37.007 / 37.107 mm (1.4570 / 1.4609
in); Limit 36.886 mm (1.4522 in)
• Fasten the camshaft in horizontal po-

sition, as shown in the figure, and make
it spin to check the eccentricity with a
dial gauge; if necessary, replace the
component.
Camshaft eccentricity maximum limit 0.040

mm (0.0016 in)
Checking the rocker arms

CAUTION
THE FOLLOWING 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).
• Check that the outside diameter of the

rocking lever shaft does not show blue
colouring, pitting or scratches; other-
wise, replace the component.
• Use a micrometer to measure the rock-
ing lever shaft outside diameter and
replace the component if necessary.
Rocking lever inside diameter: 11.981 / 11.991

mm (0.4717 / 0.4721 in).
ENG - 130
• 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
• Replace the component if the calculated clearance value exceeds the limit value indicated
in the table.
Rocking lever - rocking lever shaft clearance: 0.009 / 0.037 mm (0.0004 / 0.0015 in).
Valve check
CAUTION
THE FOLLOWING PROCEDURE APPLIES TO ROCKING LEVERS AND ROCKING LEVER
SHAFTS.
• Use a micrometer to measure 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 the valve guide.
• Continue checking the valve and the

guide valve and clean off any carbon
deposits from the valve face and seat.
• Check the valve face for pitting and
signs of wear; if there are, reface the
valve face.
• Check that the valve stem end does not
have an abnormal mushroom shape or
ENG - 131
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.
Valve rim thickness: 0.80 / 1.20 mm (0.0315 /

0.0472 in).
• Check that the valve stem eccentricity

is within the specified values and re-
place the valve if required.
• Fix the valve in a horizontal position, as
shown in figure, and rotate. Check the
eccentricity with a dial gauge; if neces-
sary, replace the component.
CAUTION
WHEN FITTING A NEW VALVE, ALWAYS REPLACE THE
VALVE GUIDE. IF 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,
check that the valve seat is within the
specified values and replace the head
if required.
1. Apply (Dykem) Prussian blue on the valve

face.
2. Fit the valve to the head.
3. Press the valve through the valve guide and
on its seat in order to leave a clear mark.
There will be no Prussian blue on the areas
ENG - 132
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.
Valve seat width:

Inlet: 1.00 / 1.20 mm (0.0394 / 0.0472 in).
Outlet: 1.00 / 1.20 mm (0.0394 / 0.0472 in).
• Lap the valve face and the valve seat,

observing the following instructions.
CAUTION
AFTER REPLACING THE HEAD OR THE VALVE AND THE
VALVE GUIDE, LAP THE VALVE SEAT AND FACE.
1. Use a coarse abrasive grain for lapping the

valve face (G). make sure that the lapping
abrasive does not get into the opening
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 abrasive grain for lapping the
valve face and repeat steps 2, 3 and 4.
6. After every lapping operation, make sure to
remove any trace of lapping abrasive from
the valve face and seat.
7. Apply (Dykem) Prussian blue on the valve
face.
8. Fit the valve to the cylinder head.
9. Press the valve through the valve guide and
on its seat in order to leave a clear mark.
ENG - 133
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.
• Use a gauge to measure the unloaded

valve spring length. If the length meas-
ured is not within the specified values,
replace the valve spring.
Unloaded valve spring length:
• Inlet: 40.38 mm (1.59 in); Maximum

limit: 38.36 mm (1.51 in)
• Outlet: 40.38 mm (1.59 in); Maximum
limit: 38.36 mm (1.51 in)
With a dynamometer, measure the compressed

spring strength, with fitted spring length 35.00 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
• Using a round scraper, clean off any carbon deposits in the combustion chamber.
CAUTION
DO NOT USE A POINTED INSTRUMENT TO AVOID DAMAGING OR SCRATCHING THE SPARK
PLUG THREADS OR THE VALVE SEATS.
• Check the head for damage or scratches and replace it if necessary.
• Check there are no mineral deposits or rust in the head water cooled jacket; clean off if
required.
ENG - 134
• 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; replace the defective part(s).
Installing the valves

CAUTION
THE FOLLOWING 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 THE LARGEST PITCH FAC-
ING UPWARDS. FIT THE SPRING WITH THE COLOURED
END FACING UPWARDS.
ENG - 135
• 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
• To fix 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.
APPLY AN EMULSIFIED SOLUTION ON THE OIL SEAL
OUTSIDE DIAMETER TO FACILITATE INSERTION.
ENG - 136
• 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).
• Fit the compressor lever pin and the
decompressor lever 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
ENG - 137
Removing the chain sliders
• Remove the start-up crown.

• Remove the rear chain slider.
See also
Checking the chain tensioner
• Check that there are no blowholes or

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.
ENG - 138
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.
Installing sliders
• Fit the rear chain slider.
• Tighten the two screws.
See also
Installing the chain
• Remove the chain slider.

• Fit the timing chain on the crankshaft .
See also
Installing sliders
ENG - 139
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).
• B - Release the chain tensioner one-
way cam (4) and push its rod (5) fully
into the chain tensioner housing.
• C - Fit the tensioner and the timing
chain gasket (6) in 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.
• Make sure that the slot (a) in the de-
compressor lever is in the specified po-
sition.
ENG - 140
• 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.

• Fit the toothed wheel to the camshaft, inserting the wheel protrusion (d) in the compression
lever slot (a).
CAUTION
WHEN FITTING THE TOOTHED WHEEL, MAKE SURE TO KEEP THE TIMING CHAIN TAUT ON
THE CHAIN EXHAUST END.
• Make sure that the reference mark
"I" (e) on the toothed wheel is aligned
to the 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 ALIGNED TO
THE STATIONARY REFERENCE MARK (F) ON THE CYLINDER HEAD.
• If these two alignments are incorrect, correct them by repeating the same operations de-
scribed, starting from the fitting of the camshaft toothed wheel.
ENG - 141
• 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.
CAUTION
GREASE THE O-RING.
• After replacing the O-ring, fit the tappet
cover to its position.
• Working from both sides, tighten the
four screws of the two covers.
• Position the cover of the camshaft

toothed wheel.
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 union and
collect the circular gasket.
ENG - 142
• Unscrew and remove the four stud

bolts in the sequence indicated and
collect the washers.
ENG - 143

• 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.
Disassembling the piston
• Remove the cylinder.

• 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 the piston.
• Remove the top ring, the intermediate

ring and the three oil scraper rings.
ENG - 144
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.
CAUTION
IF THE GROOVES ON THE CYLINDER LINER ARE EVIDENT, REPLACE THE CYLINDER AND
THE PISTON.
ENG - 145
• 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; the highest value should
be considered to estimate wear limits.
Cylinder bore "C": 100.000 - 100.010 mm

(3.9370 - 3.9374 in) C= D1 or D2 max.
Taper limit "T": 0.05 mm (0.002 in) T = D1 or D2
max. - D5 or D6 max.
Eccentricity limit "R": 0.05 mm (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
(0.0012 - 0.0022 in) Limit: 0.13 mm (0.0051 in)
• Replace the cylinder, the piston and

the piston ring all together if not com-
plying with specifications.
ENG - 146
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.
Piston ring side clearance:

Top ring: 0.030 - 0.080 mm (0.0012 - 0.0031 in)
Limit: 0.13 mm (0.0051 in)
Intermediate ring: 0.030 - 0.070 mm (0.0012 -
0.0028 in) Limit: 0.11 mm (0.0051 in)
• Fit the piston ring to the cylinder.

• Level the installed piston ring with the
piston crown.
• Measure piston 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
• Clean off combustion residues from the piston crown and from the area above the top ring.
• Check for cracks on the piston and for compression on the piston sliding surface (seizing);
Replace the piston if required.
CAUTION
SMALL STRIATIONS ON THE PISTON LINER ARE ADMISSIBLE.
ENG - 147
• 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)
• Measure the pin inside diameter (b)

and replace the pin if not complying
with specifications.
Pin inside diameter: 23.004 - 23.015 mm (0.9057

- 0.9061 in) Limit: 23.045 mm (0.9073 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 oil scraper ring expander, the lower
oil scraper ring element and the upper
oil scraper ring element.
ENG - 148
• 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.
ENG - 149
• 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

measuring the angles among the ring
ports, according to the diagram below:
• a - top ring.
• b - upper oil scraper ring element.
• c - oil scraper ring expander.
• d - lower oil scraper ring element.
• e - intermediate ring.
• f - 20 mm (0.79 in).
• A - exhaust side.
Installing the cylinder
• 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
ARE LONGER.
• Position the four cylinder stud bolts, fitting the two punched stud bolts on the timing system
side.
CAUTION
LUBRICATE THE CYLINDER STUD BOLTS AND THE SEAL SURFACES WITH ENGINE OIL.
ENG - 150
• Tighten the four cylinder stud bolts to

the different prescribed torques.
ENG - 151
• After replacing the circular gasket,

tighten the two screws and fasten the
cooling 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.
ENG - 152
• 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.
• Tighten the four head screws in the shown sequence.
CAUTION
TIGHTEN THE CYLINDER HEAD SCREWS 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
Timing
Crankcase - crankshaft
ENG - 153
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.
• Remove the oil delivery pipe and col-

lect the O-Ring.
• Release the clamp and remove the oil

reservoir flexible breather pipe.

move the oil pipe and collect the four
washers.
ENG - 154
• 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.
• Loosen the screw and disconnect the

neutral sensor.
ENG - 155

move the cable guide.
• Remove the pipe and collect the dowel

and the safety circlip.

move the cable guide.
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.
ENG - 156

collect the washers.
• 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.
ENG - 157
• 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.
• Unscrew and remove the balancer

driven gear nut; collect the washer.
• Remove the driven gear and collect the

tab.
ENG - 158
• 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.
Specific tooling
• Remove the washer.
• Remove the water pump driving gear.
• Remove the main transmission driving

gear.
ENG - 159
• 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.
• 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
ENG - 160
• 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
throttle body
Spark plug
Cooling system
Removing the
cylinder
Engine
oil filter
Removing

Removing the
chain sliders
Chain removal
Start-up system check
ENG - 161
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.
Specific tooling
See also
Splitting the
crankcase halves
Removing the
countershaft
Disassembling the gearbox
Removing the countershaft
• Open the crankcase halves.

• Remove the countershaft.
See also
Splitting the
crankcase 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.
Check that all threads are in proper conditions.
Check that all oil seals remaining in their position are not worn or damaged.
Check all ball bearings for clearance, smoothness and potential distortions.
ENG - 162
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.
OIL FILTER AND OIL DELIVERY PIPE CHECK

Check the oil filter for damage. If necessary, re-
place the part.
Clean the oil net with petrol and inspect the net
links for potential damage.
Check the oil delivery pipe for damage. If neces-

sary, replace the part.
Check 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 LUBRICATE THE OIL SEAL AND THE BEARING BALLS BEFORE REFITTING.
• Fit the oil seals and the bearings on the
crankcase halves.
• Using the special tool, install the crank-
shaft on the left crankcase half.
Specific tooling
ENG - 163
• 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.
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.
ENG - 164
• 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
• 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.
• Insert the tab and fit the countershaft

driven gear.
ENG - 166
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.
• 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.

Clutch crankcase half and flywheel crankcase
halves screws 10 Nm
• Fit the pinion.
ENG - 167
• 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.
• Fit the alternator.

• Remove the gear selector.
• Fit the oil pump.
• Fit 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
ENG - 168
Conceptual diagrams
ENG - 169
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
8. Camshaft
10. Oil filter
11. Main shaft
12. Secondary shaft
ENG - 170
13. Crankshaft
Oil pump
Removing
• Before removing the components,

place a container of suitable capacity
underneath the engine.
• Remove the clutch.
remove the oil deflector.
• Remove the safety circlip (1) and slide

off the oil pump gear (2).
ENG - 171
• 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.
• Undo and remove the three screws
and remove the filter.
ENG - 172
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.
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.
ENG - 173
• 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

that are not fitted with lambda probe, exhaust
fumes undergo a post-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 combustion
ENG - 174
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. At the low-pressure stages (when clean-
ing), the exhaust sucks in fresh air from the
secondary air circuit; the unburned gases leaving
the combustion chamber, warm and still active,
continue and complete combustion when in a high-
ly oxidising environment. At overpressure stages,
the secondary air (reed) valve closes the circuit,
thus blocking return flows.
The secondary air valve is fitted with a cut-off de-
vice, activated by a low-pressure intake on the inlet
manifold. This device cuts off the circulation of
secondary air when released to avoid excess lean-
ing of the exhaust fumes that might cause bursts
in the muffler which may damage the 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

SECONDARY AIR SYSTEM AS THE VEHICLE WORKS
REGULARLY ALSO WITH THE SYSTEM DEACTIVATED
BUT, GIVEN THESE CONDITIONS, THE HARMFUL EMIS-
SIONS INCREASE. LACK OF AIR CIRCULATION MAY AL-
SO RESULT IN OVERHEATING AND THIS IN TURN COULD
DAMAGE THE SAS COUPLINGS AND PIPING.
TO BLOCK AIR CIRCULATION USE SUITABLE SYSTEMS

ONLY; USING PLUGS TO BLOCK THE AIR INTAKE IN THE
FILTER HOUSING MAY DAMAGE THE SECONDARY AIR
SYSTEM DUE TO OVERHEATING. IF YOU FORGET A
PLUG FITTED, IT MAY GET INTO THE INTAKE DUCT WHEN
THE VEHICLE IS USED, THUS BLOCKING THE THROTTLE
VALVE AND RESULTING IN LOSS OF CONTROL OVER
THE VEHICLE.
ENG - 175
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
INDEX OF TOPICS
POWER SUPPLY P SUPP

Power supply PEGASO 650 STRADA - TRAIL - FACTORY
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. TE flanged screw
10.Fuel delivery pipe
P SUPP - 178
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. 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
P SUPP - 179
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.
• Remove the throttle body.
Co rate adjustment
WARNING
DESPITE THE PRESENCE OF THE LAMBDA PROBE, IT IS STILL NECESSARY TO ADJUST CO
AS DESCRIBED BELOW.
CO adjustment
In this screen, the instrument panel sends the packages to increase or decrease the CO value. To
increase or decrease the value, use the UP and DOWN buttons in the control selector; the instrument
panel shows the set value. The set value will be stored by the ECU at KEY OFF.
The engine revs are shown at this stage.
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 to stop to save and exit
The value of the parameter that adjusts the CO should be expressed within the range between -127
and +128.
P SUPP - 180
Using axone for injection system
Injection
Iso screen page
ISO
This screen page shows general data regarding
the control unit, for example software type, map-
ping, control unit programming date
ISO SCREEN PAGE

Software version 00
Engine parameter reading screen page
ENGINE PARAMETER 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

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)
Vehicle speed pulse -
Supply system Example value: 12.2 V
P SUPP - 181
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).
DEVICE STATUS SCREEN PAGE

Fall sensor Example: Normal / Tip over / Disconnected
The control unit takes this as a status; therefore, it is not stored
in the memory: if the circuit is interrupted or the sensor is dis-
connected, "Disconnected" is displayed and the engine does
not start.
Side stand Example: ON
The sensor status can only be displayed when the instrument
panel is active; therefore, Axone cannot be used for 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

Error clearing By pressing the ''enter'' button, the stored errors (MEM) be-
come part of the historical data (STO). The next time Axone is
connected to the ECU, the errors in the historical record (STO)
will no longer be displayed
Reading stored errors To display the errors on the error screen page, select this line
and then go to the error screen page
Ignition coil
Injector
SAS solenoid valve
Cooling fan relay
P SUPP - 182
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).
ERRORS DISPLAY SCREEN PAGE

Intake air pressure sensor Error 13: interruption or short circuit in the sensor circuit. The
control unit sets a recovery value of 101 kPa (1464.88 PSI).
Intake air pressure sensor Error 14: obstructed sensor or sensor not positioned, the con-
trol unit detects pressure constant in time. The control unit sets
a recovery value of 101 kPa (1464.88 PSI).
Throttle position sensor Error 15: interruption or short circuit in the sensor circuit. The
control unit sets a recovery value equal to throttle fully open.
Throttle position sensor Error 16: value measured by the control unit always the same.
The control unit sets a recovery value equal to throttle fully open
Side stand Error 19
Water temperature sensor Error 21: interruption or short circuit in the sensor circuit. The
control unit sets a recovery 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 control unit cannot detect battery voltage (may be
cable interrupted). The control unit sets a recovery value of 12
V
ECU errors Error 44 or 50 or ER1, ER2, …..: internal control unit error
Injection relay error Error 46: The electrical power supply to the injection system
relay is not normal
Lambda probe signal not probable Error 24: The error is detected only in extremely dangerous
conditions of use of the vehicle and it does not affect vehicle
performance
High lambda probe signal Error 31: The error is detected only in extremely dangerous
performance
Low lambda probe signal Error 32: The error is detected only in extremely dangerous
performance
P SUPP - 183
Adjustable parameters screen page
ADJUSTABLE PARAMETERS
This screen page is used to adjust some control
unit parameters.
ADJUSTABLE PARAMETERS SCREEN PAGE

CO adjustment
P SUPP - 184
INDEX OF TOPICS
SUSPENSIONS SUSP
Suspensions PEGASO 650 STRADA - TRAIL - FACTORY
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
11.Guide bushing
12.Ring
13.Oil seal
14.Snap ring
SUSP - 186
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
• 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.
SUSP - 187
• Undo and remove the two screws fixing

the rear half-mudguard and remove it.

the fork reinforcing plate and remove
the fork reinforcing plate.

the front brake calliper.
• Remove the front brake calliper, pay-
ing special attention 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.

valid for the FACTORY version only.
• Remove the front brake calliper with

the flange, paying special attention not
to operate the front brake control lever
to avoid locking the pads.
SUSP - 188
• 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.
• 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.
SUSP - 189
• 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.
CHANGE 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.
SUSP - 190
• Remove the spring preloading spacer.
• 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.
See also
Removing the
fork legs
SUSP - 191
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.
• 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.
SUSP - 192
• 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.
• Firmly slide off the stem together with
the lower sliding bushing.
• Remove the oil seal.
SUSP - 193
• 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).
If the scorings are deep, replace 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 in good conditions.
SUSP - 194
• 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.
Replace the following components with new ones:
• seal ring;
SUSP - 195
• 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
• 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.
BE CAREFUL NOT TO DAMAGE THE SLEEVE RIM.
• Place the snap ring inside the sleeve

using a thin screwdriver.
SUSP - 197
• 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.

• 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.
SUSP - 198
• 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.
SUSP - 199
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.
• 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.
SUSP - 200
• 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.
• Tighten 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.
SUSP - 201

valid for the Factory version only.
• Place the brake calliper together with

its flange and tighten the fixing screws.
• Remove the front service stand.

• Remove the rear service stand.
• 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.
SUSP - 202
• 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.
• Working from both sides, loosen the
screw fixing the fork stem to the upper
fork plate.

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
SUSP - 203

Upper plate fixing cover M22x1 100 Nm Head-
stock ring nut M25x1.5 7 Nm
SUSP - 204
INDEX OF TOPICS
BRAKING SYSTEM BRAK SYS

Braking system PEGASO 650 STRADA - TRAIL - FACTORY
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.
• Remove both pins.
• Remove the vibration-damping plate.
BRAK SYS - 206

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.
Factory 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
BRAK SYS - 207

• 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.
• Place the vibration-damping plate.

• Insert both pins.
• Place both split pins.
• Check the brake fluid level in the res-
ervoir.
Factory versions
BRAK SYS - 208


liper holes.
CAUTION

• Tighten the pin.
• Fit the safety seeger ring.
Rear brake pads
Removal
• Remove the split pin.
BRAK SYS - 209

• 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.
Installing

liper holes.
CAUTION

• Insert the pin.

• Place the split pin.
• Check the brake fluid level in the res-
ervoir.
Bleeding the braking system
BRAK SYS - 210

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" of the brake control and poor braking effi-
ciency.
CONSIDERING THE DANGER FOR VEHICLE AND RIDER,

IT IS STRICTLY NECESSARY, AFTER REFITTING BRAKES
AND RESTORING THE BREAKING SYSTEM TO THE REG-
ULAR USE CONDITIONS, THAT THE HYDRAULIC CIRCUIT
BE AIR PURGED.
NOTE
THE FOLLOWING OPERATIONS REFER TO ONLY ONE
FRONT BRAKE CALLIPER BUT APPLY TO BOTH CALLIP-
ERS. THE VEHICLE MUST BE ON LEVEL GROUND TO BE
PURGED. 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 brake fluid reservoir
cap.
• Quickly press and release the front
brake lever several times and then
keep it fully pressed.
• 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.
• Close the bleed valve before the lever
reaches its end of stroke.
BRAK SYS - 211

• 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.
• Screw the bleeding valve and remove the pipe.

• Top-up the reservoir until the correct brake fluid level is obtained.
• Refit and block the front brake oil reservoir cap.
• Refit the rubber protection cover.
Rear
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" 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 FLUID. CHECK THAT,
DURING THE OPERATION, THERE IS ALWAYS BRAKE
FLUID IN THE RESERVOIR.
• Remove the rubber protection cover

from the bleed valve.
• Insert the transparent plastic pipe in
the rear brake calliper bleed valve and
insert the other end of this pipe into a
container to collect the fluid.
• Remove the rear brake fluid reservoir
cap.
• Quickly press and release the rear
brake lever several times and then
keep it fully pressed.
BRAK SYS - 212

• 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.
• Close the bleed valve before the lever
reaches its end of stroke.
• 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.
• 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 rubber protection cover.
BRAK SYS - 213

INDEX OF TOPICS
COOLING SYSTEM COOL SYS

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.
• Unscrew and remove the drainage
screw and collect the copper washer.
• Remove the circuit filler cap (A) on the

radiator and the filler cap (B) on the ex-
pansion 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 tank until a level
between MIN and MAX is reached.
• Tighten the expansion tank filler cap (B).
• Start up the engine and let it run for some minutes; shut it off and let it cool down.
COOL SYS - 215

Cooling system PEGASO 650 STRADA - TRAIL - FACTORY
• 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.
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).

• Remove the pump unit.
• Release and remove the clamps.
COOL SYS - 216

• 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.
• Remove the seeger ring.
• Remove the engine gear.
COOL SYS - 217

• 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)

and the 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.
COOL SYS - 218

• 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.
COMPONENTS CHECK
Check that the water pump housing cover, the water pump housing, the rotor and the rubber damper
are not damaged or excessively worn. Replace them if they are.
Check that the water pump outlet pipe, the radiator flexible outlet 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 be replaced.
CAUTION
APPLY AN EMULSIFIED SOLUTION ON THE OIL SEAL OUTSIDE DIAMETER TO FACILITATE
INSERTION.
COOL SYS - 219

• 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.
• Fit the bearing (11).

• Use the water pump fitting tool (12) to
fit a new water pump gasket.
CAUTION
BEFORE REFITTING THE WATER PUMP APPLY AN EMUL-
SIFIED SOLUTION ON THE OUTSIDE DIAMETER TO FA-
CILITATE INSERTION.
NEVER LUBRICATE THE WATER PUMP GASKET SUR-

FACE WITH OIL OR GREASE.
Specific tooling
8140841 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 gauge on the reference ruler to
measure the depth of the left and right
ends with reference to the damper.
• Repeat the same check rotating the
reference ruler by 90° with respect to
the present position.
COOL SYS - 220

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).
• 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.
COOL SYS - 221

INDEX OF TOPICS
BODYWORK BODYW
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.
• Undo and remove the two external
screws.
BODYW - 223
Bodywork PEGASO 650 STRADA - TRAIL - FACTORY
• 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.
BODYW - 224
• 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.
Lower cowl
Removal
• Undo and remove the oil sump guard

front fixing screw.
BODYW - 225
• 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.

• 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.
BODYW - 226
• 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.
• Remove the three clamps fixing the
fuel breather pipe.
• Slide off the fuel breather pipe.
• Screw the fuel tank cap
BODYW - 227
• 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).
BODYW - 228
• 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.
• Remove the passenger grab handle.
See also
Side body panels
Tail guard
Removal
• Remove the passenger grab handle.

move the front fixing screw.
BODYW - 229
• Working from both sides, unscrew and

remove the upper fixing screws.

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
BODYW - 230
INDEX OF TOPICS
PRE-DELIVERY PRE DE
Pre-delivery PEGASO 650 STRADA - TRAIL - FACTORY
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:
front and rear suspension unit
front and rear brake calliper retainer unit
front and rear wheel unit
engine - chassis retainers
steering assembly
- Plastic parts fixing screws
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
- Electric starter
- Engine stop via emergency stop switch and side stand
- Helmet compartment electrical opening switch (if present)
PRE DE - 232
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.
CAUTION
TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.

INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE
IT IS FIRST USED SHORTENS BATTERY LIFE.
CAUTION
UPON INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG-
ATIVE ONE, AND PERFORM THE REVERSE OPERATION UPON REMOVAL.
WARNING
THE BATTERY ELECTROLYTE IS POISONOUS AS IT MAY CAUSE SERIOUS BURNS. IT CON-

TAINS SULPHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING.
IN CASE OF CONTACT 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 PROXIMITY OF BATTERIES.
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING
A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE
A FIRE.
Levels check
- Hydraulic braking system fluid level
- Clutch system fluid level (if present)
- Gearbox oil level (if present)
- Transmission oil level (if present)
- Engine coolant level (if present)
- Engine oil level
- Mixer oil level (if present)
Road test
- Cold start
- Instrument panel operation
PRE DE - 233
Pre-delivery PEGASO 650 STRADA - TRAIL - FACTORY
- 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:

- Restarting when warmed up
- Starter operation (if present)
- Minimum holding (turning the handlebar)
- Uniform turning of the steering
- Possible leaks
- Radiator electric fan operation (if present)
Functional 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 THE RECOMMENDED INFLATION PRESSURES AS TYRES MAY BURST.

CAUTION
CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.
PRE DE - 234
A
Air filter: 29
Air temperature sensor: 63
B
Battery: 59, 62
Brake: 206, 209
Brake pads: 206, 209
Bulbs:
C
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
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 sensor: 63
M
Magneto flywheel: 102, 105, 161
Maintenance: 7, 25
O
Oil filter: 28, 161
P
Primary shaft: 88, 93, 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

Service Station Manual: Pegaso 650 Strada - Trail - Factory

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Service Station Manual: Pegaso 650 Strada - Trail - Factory

Uploaded by

SERVICE STATION MANUAL

PEGASO 650 STRADA - TRAIL - FACTORY

PEGASO 650 STRADA - TRAIL - FACTORY

THE VALUE OF SERVICE

SPECIAL TOOLS S-TOOLS

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

POWER SUPPLY P SUPP

BRAKING SYSTEM BRAK SYS

COOLING SYSTEM COOL SYS

KEEP OUT OF THE REACH OF CHILDREN.

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

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

GENERAL PRECAUTIONS AND INFORMATION

BEFORE DISASSEMBLING COMPONENTS

SERIAL NUMBER LOCATION

Dimensions and mass

WEIGHT AND DIMENSIONS

Frame and suspensions

Wheels and tyres

WHEELS AND TYRES

FUEL SUPPLY SYSTEM

HANDLEBAR AND CONTROLS

Recommended products chart

SPECIAL TOOLS S-TOOLS

AP8140179 Valve spring compressor

8140837 Flywheel extractor

AP8140838 Flywheel rotor locking

8140839 Engine supporting plate

8140840 Connecting rod locking

Stores code Description

8140843 Fork oil seal fitting tool, Ø 63 mm (2.48

8140844 Adaptor for crankshaft

8140845 Crankshaft spacer

8140846 Crankshaft fitting tool

8140847 Crankshaft fitting tool

8140848 Rocking lever shaft extractor

Stores code Description

8140850 Flywheel cover opening

8140853 Crankcase separator

8163500 Fork sleeve ring nut

8600388 Pin - piston extractor

8600391 Clutch locking

0276357 Piston ring clamp

Stores code Description

EVERY 500 KM (375 MILES)

AFTER 1000 KM (625 MILES) RUN-IN

EVERY 2000 KM (1250 MILES)

EVERY 5000 KM (3125 MILES)

EVERY TIME THE FINAL TRANSMISSION IS REPLACED

EVERY 10000 KM (6250 MILES) OR 12 MONTHS

EVERY 20000 KM (12500 MILES) OR 24 MONTHS

• Remove the ignition tube.

• Place the vehicle on solid flat ground.

• Place a collection container under the

Engine oil filter

• Drain the engine oil completely.

• Remove the engine oil filter cover to-

• Remove the engine oil filter.

• Remove the right side fairing.

• Slide off the filter support together with

Checking the valve clearance

• Undo and remove the four screws and

• Undo and remove the two screws (1)

• Unscrew and remove the ignition spark

• Undo and remove the screw (3) to ac-

• Check that the reference mark (b) on

Adjust valve clearance by following the instruc-

• Loosen the lock nut (5).

- Turn the set screw (6) anticlockwise to increase

• Block the set screw (6) to prevent any

ance until the pre-set clearance is

ELECTRICAL SYSTEM ELE SYS

Electrical system installation

General wiring diagram

5. Side stand switch