OWNER`S MANUAL - AJP Moto Italia
Contents
1. AJP PR5 250 ENDURO SUPERMOTO OWNER S MANUAL This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when resold or otherwise transferred to a new owner or operator The manual contains important safety information and instructions that should be read carefully before start operating the motorcycle English version AJP MOTOS SA MARCH 2012 2 Edition VERY IMPORTANT WE STRONGLY RECOMMEND YOU READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE GOING ON YOUR FIRST RIDE IT COINTAINS A GREAT DEAL OF INFORMATION AND ADVICE WHICH WILL HELP YOU USE AND HANDLE YOUR BIKE PROPERLY IN YOUR OWN INTEREST PLEASE PAY ATTENTION TO NOTICES THAT ARE MARKED AS FOLLOWS IGNORING THESE INSTRUCTIONS CAN ENDANGER YOUR BODY AND YOUR LIFE AS WELL AS OTHER PEOPLE 5 LIFES IGNORING THESE INSTRUCTIONS COULD CAUSE DAMAGE TO PARTS OF YOUR MOTORCYCLE OR THAT THE MOTORCYCLE IS NO LONGER SAFE TO RIDE ANYMORE TAKE SPECIAL CARE TO FOLLOW THE RECOMMENDED RUN IN INSPECTION AND MAINTENANCE INTERVALS FOLLOWING THESE GUIDELINES WILL SIGNIFICANTLY INCREASE THE LIFE OF YOUR MOTORCYCLE BE SURE TO HAVE ANY MAINTENANCE JOBS PERFORMED BY AN AUTHORIZED AJP DEALER PLEASE DON T FORGET TO WEAR A HELMET EYE PROTECTION AND PROTECTIVE CLOTHING WHEN GOING FOR A RIDE WE WISH YOU ALOT OF FUN RIDING YOUR AJP AJP MOTOS SA RESERVES THE RIGHT TO MODIFY ANY EQUIPMENT TECHNICAL SPECIFICATIONS COLOURS AND MA2. The digital soeedometer is not available for the MX and MX PRO versions It gives information about instantaneous speed and total or trip distance travelled Depending on the selling market speed and distance indicated in Kilometres or miles If you want to switch between these units please contact your AJP dealer To switch from total to trip distance push button 1 To reset trip distance the trip distance must be selected then push button 1 until the distance is reset to zero LEFT HANDLEBAR J 5 4 KL 4 271 ATA I ye ku L 2 1 Clutch lever The clutch lever is used for disengaging the drive to the rear wheel when starting the engine or shifting the transmission gear Squeezing the lever disengages the clutch AJP PR5 User s manual 2nd Edition 2 Parking light on With the light knob in this position parking lights in the headlight and taillight will be switched on 3 Lights off In this position no lights will be switched on 4 Low beam on In this position low beam light will be on in the headlight and presence light will be on in the taillight 5 High beam on In this position high beam light will be on in the headlight and presence light will be on in the taillight 6 Turn sign on Turning this button left left turn lights will be on Turning right right turn lights will be on To switch turn lights off place the but
3. Then remove air filter s cover by unscrewing fixation screw 2 Thoroughly wash the air filter in special cleaning fluid and allow it to dry well Oil the dry air filter with high grade filter oil and clean the air filter box For extra security apply grease on the back side of the filter which mates with air filter box Mount the filter together with the filter bracket and fix them with the rubber washer and the screw AJP PR5 User s manual 2nd Edition WARNING Do not clean air filter with fuel or petroleum since these will damage the foam Never start your motorcycle without air filter otherwise dust or dirt may penetrate in the engine and cause damage or severe wear THROTTLE CABLE Adjusting throttle cable The throttle grip should always provide for a backlash of 2 6mm measured in the adjusting screw outside the throttle grip Besides with the engine running the idling speed must not change if you turn the handlebar all the way to the left or right To adjust throttle cable draw back dust protection loosen the counter nut 1 and turn the adjusting screw accordingly 2 Tighten the counter nut and check whether the throttle grip can be actuated smoothly ENGINE OIL Checking engine oil level Place the motorcycle in upright position and on a horizontal surface The engine oil level can be checked through the oil glass level If the engine is warm the oil level should be near
4. Torque Carburetor Stan Gearbox 6 speeds Aluminium double beam steel double cradle Front fork ZF Sachs USD 48 mm 300 mm stroke TS Front brake Rear brake Seat height Wheelbase ee ee Road high beam 12V35 35W BA20d light EEE ENDURO SUPERMOTO 90 90 21 100 80 17 120 80 18 130 70 17 AJP PR5 User s manual 2nd Edition Page 31
5. head bearings for long periods bearings and subsequently bearing seats in the frame will be destroyed AJP PR5 User s manual 2nd Edition Cleaning the dust sleeves of the telescopic fork The dust protection gaskets 1 are to remove dust and coarse dirt particles from the fork tube However after some time dirt may also get behind the dust protection gasket If this dirt is not removed the oil sealing rings located behind it may start to leak Use a screwdriver to lever the dust protection bellows out of the outer tubes and slide them downward Clean dust protection gaskets outer tubes and fork tubes thoroughly and oil them with silicone spray or engine oil then push dust protection gaskets into the outer tubes by hand Page 18 DRIVE CHAIN Drive chain adjustment The chain slack must be of 15 30mm at the mid point between the chain buffer and the rear sprocket 3 E EET T ID Ra To adjust the drive chain follow the procedure bellow 1 Place the motorcycle on the side stand 2 Loose axle nut 1 3 Loose fixing nuts on both sides 2 4 Regulate adjuster screws 3 until the chain has 15 30mm of slack At the same time that the chain is being adjusted the rear sprocket must be kept in perfect alignment with the front sprocket Align both right and left adjusters to the same position 4 Re tighten the axle nut securely and tig
6. 2 25 32 These pressure values are indicated for road use For an off road use on MX and Enduro versions we recommend a lower pressure to assure traction In these conditions we recommend 1 0 bar 14 psi in both tires Please consider that these are indicative values and that correct pressure depends on the ground where you drive WARNING Do not mount tires that are not approved by AJP Other tires could have adverse effects on the way your motorcycle behaves Front and rear wheels may only be fitted with tires having same layout Use homologated tires For your own safety replace damaged tires immediately Worn tires can have a negative effect on how your motorcycle performs Surfaces H air pressure is too low abnormal wear and overheating of tire can result especially on wet AJP PR5 User s manual 2nd Edition especially on a new motorcycle in regular intervals If necessary have the spokes retightened and the wheel to correct by an AJP dealer WARNING Spokes can tear if you continue to ride with them loose This may lead to an unstable handling of your motorcycle BATTERY Battery has a closed system and therefore requires no maintenance It is not necessary to check the electrolyte level or to refill water simply keep the battery poles clean and slightly greased with acid free grease if necessary To access battery remove the front right plastic cover To r
7. Lubricate rear Suspension links Lubricate swing arm bearings EACH 12 000 km OR 24 MONTHS Perform operations indicated for each 3 000 and 6 000 kms plus Replace brake fluids Replace front fork seals Replace front fork oil Replace drive chain Page 16 MAINTENANCE WORK WARNING Improper maintenance or failure LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each performs of working part of your motorcycle maintenance Increases the chance also for safe riding It is a good practice of accident or motorcycle damage to lubricate the motorcycle after a long Always follow inspection and rough ride and after getting in snow maintenance recommendations and wet mud or after washing it Major schedules in this owners manual lubrication points are indicated Ask your AJP dealer to do the maintenance items marked with an asterisk You may perform the unmarked maintenance items by referring to instructions in this section if you have mechanical experience If you are not sure how to do any of the jobs have your AJP dealer to do them I When cleaning your motorcycle do not use a_ high pressure cleaning unit otherwise water will penetrate bearings carburettor electric connectors etc When transporting your AJP ensure that it is held upright with restraining straps Use only special screws with an appropriate thread length sup
8. be inspected from below The linings must have at least 1 mm thickness AJP PR5 User s manual 2nd Edition WARNING At their most worn point brake pad linings should not be thinner than 1mm otherwise can lead to braking failure WARNING If brake pads are replaced too late so that the lining is partly or entirely worn steel components of brake pad will rub against brake disc thereby reducing braking effect and destroying brake disc Replacing front brake pads Remove calliper assembly unscrewing screws 1 Press the brake calliper away from brake disc to put the brake piston in its basic position Remove clips and the brake pads from the calliper Clean the brake calliper and calliper Support with compressed air Check Page 21 the sleeves of the guide bolts for damage and grease guide bolts if necessary Mount both brake pads and then insert the clips the right way to allow brake pads to jump off or lose in order to avoid accidents WARNING Keep brake discs free from oil and fatty materials otherwise braking effect will be strongly reduced Having performed any work on the braking system one must always actuate hand brake lever or foot brake pedal to ensure that brake pads will fit against brake disc and pressure is established Changing the basic position of the brake pedal Free play can be changed by turning piston 1 Measured on the out
9. changes to the motorcycle and use always AJP original Spare parts for safety reasons Motorcycles are sensitive to changes in the weight distribution If you are taking any luggage with you secure it as close as possible to the middle of the motorcycle in order to distribute the weight for both wheels WARNING Wear suitable clothing when driving a motorcycle Never forget to wear a helmet gloves and boots even in short trips Protective clothing should be brightly coloured to make you more visible to other drivers Always turn on the lights to make sure that other drivers become aware of you as early as possible Do not drive after having consumed alcohol or drugs Use only original spare parts and accessories Front and rear tires are allowed to be fitted only with tires having the same original profile type ENGINE START 1 Swing up the side stand and turn the ignition key on 2 Put the gear in neutral the neutral pilot lamp will light up 3 Check if the emergency switch is on running position 4 Operate the electric start button without throttle opening Page 11 Never actuate electric starter for more than 5 seconds and with lights on Wait at least 5 seconds before trying again WARNING Before you start off check the side stand has been fully swung up If the side stand drags on the ground the motorcycle goes out of control Always turn on the light to make sure tha
10. front fork To adjust compression turn the screw 1 clockwise to have harder response Turn counter clockwise to have a softer response AJP PR5 User s manual 2nd Edition To adjust rebound turn the lower screw clockwise for more rebound turn counter clockwise for less rebound WARNING Unequal suspension adjustment can cause poor handling and loss of Stability Adjust the right and left front legs to the same settings Rear suspension adjustment PR5 is equipped with a fully adjustable shock absorber To adjust pre charge loose first the upper nut 1 then turn adjusting nut 2 clockwise for more pre charge or counter clockwise for less pre charge Page 8 To adjust rebound turn the screw placed on the bottom of the shock absorber 3 clockwise for more rebound or counter clockwise for less rebound To adjust fast compression damping turn the knob 4 clockwise for more rebound speed To reduce rebound speed turn counter clockwise To adjust low compression damping turn the screw 5 clockwise for more rebound speed To reduce rebound speed turn counter clockwise AJP PR5 User s manual 2nd Edition Standard set up Spring length Enduro 205mm Supermoto 210mm Damping force turn all to close position and then turn 20 clicks to open Rebound turn all to close position H and then turn 10 clicks to open S WARNING Improper servicing of the rea
11. items inspected serviced your authorized AJP dealer WARNING Do not start the engine or allow it to idle in a closed area Exhaust gases are poisonous and can cause loss of consciousness and even death Always provide adequate ventilation while the engine is running WARNING It is owner s responsibility to assure that motorcycle is serviced within this periodic maintenance schedule AJP does not assume any damage if maintenance is not performed as schedule AJP PR5 User s manual 2nd Edition WARNING Improper maintenance or failure performs of recommended maintenance increases the chance of accident or motorcycle damage Always follow inspection and maintenance recommendations and schedules in this owners manual Ask your AJP dealer to do the maintenance items marked with an asterisk You may perform the unmarked maintenance items by referring to instructions in this section if you have mechanical experience If you are not sure how to do any of the jobs have your AJP dealer to do them Using poor quality replacement parts or materials can cause your motorcycle to wear more quickly and may shorten its useful life Use only genuine AJP replacement parts Page 15 AFTER FIRST 1 000 km BREAK IN Replace spark plug Replace engine oil Replace engine oil filter Check engine oil level Check air filter Clean and wet in oil Check drive chain Check valve clea
12. lever and close he throttle at the same time you operate gearshift lever Lift the lever to up shift and depress to downshift REAR BRAKE PEDAL The foot brake pedal is disposed in front of the right footrest Depressing the rear brake pedal will apply the rear brake WARNING If opposition of hand brake lever or rear brake pedal fells spongy too much give this is an indication that the brake system is not functioning well Dont ride anymore your motorcycle without first having the brake system checked by an AJP dealer SIDE STAND Push the side stand to the ground with your foot and load it with the motorcycle Make sure that you put the motorcycle on solid ground and in a secure position Page 7 WARNING Always check if you have folded back the side stand before each ride If the side stand touches the ground while you drive you may loose control of your motorcycle The side stand was designed only for the weight of the motorcycle you get on the motorcycle and thus put additional weight the side stand or frame can be damaged and the motorcycle may fall on the side Park the motorcycle on solid level ground to help prevent it from falling over lf you must park on an incline aim the front of the motorcycle uphill and put the transmission into 1 gear to reduce the chance of rolling off the side stand SUSPENSION SET UP PR5 is equipped with an up side down fully adjustable
13. motorcycle thoroughly see CLEANING Change engine oil and oil filter Remove spark plug and fill in approx sccm of engine oil into the cylinder through the opening Actuate engine Start button in order to distribute the oil into the cylinder walls and mount the spark plug Remove the fuel into an appropriate container Correct the tyre pressure Lubricate pivot points of control levers foot rests etc as well as the chain Service the shock absorber linkage Disassemble and charge battery see BATTERY Storage place should be dry and not subject to excessive temperature fluctuations Cover the motorcycle with blanket Do not use air Page 29 impermeable materials as a possible humidity might not be able to escape and could cause corrosion Dont let engine run for a short time period Engine would not get warmed enough and developed water vapour would condensate when cooling causing valve and exhaust corrosion RE INITIATION AFTER STORAGE Mount the charged battery check polarity Fill up the tank with fresh fuel Check motorcycle as before each start see DRIVING INSTRUCTIONS Take a short careful test ride first and check all of your motorcycle systems AJP PR5 User s manual 2nd Edition Page 30 TECHNICAL SPECIFICATIONS Engine PR5 250 PPR 250 Type 1 Cylinder 4 strokes SOHC 4 Valves Displacement 249 cm Bore x stroke 73 x 59 5 mm Cooling Power
14. the MAX mark Page 27 If oil level drops quickly do not operate your motorcycle Take your motorcycle to an authorized AJP dealer immediately to a full check of engine Engine oil quality Use only branded oils for four stroke engines meeting or surpassing the quality requirements of API classes SF or SG SAE 10W40 15W40 API SF or SG Capacity o 61 4 litre WARNING Insufficient engine oil or poor quality may cause severe damage to the engine Never operate your motorcycle with low engine oil level or with non adequate engine oil quality Engine oil level should be checked daily or before any ride If necessary you should add to keep always oil level between maximum H mark and lower L mark WARNING On PR5 250 if any oil pipe or oil radiator is damaged and present leak engine should be immediately stopped Otherwise serious damages in engine will happen due to lack of oil in lubricating circuit Changing engine oil AJP PR5 User s manual 2nd Edition Engine oil has to be changed with the engine being at operating temperature engine at operating temperature and engine oil it contains are very hot Please take all cares to avoid burning yourself Place the motorcycle on horizontal surface remove the plug and allow the oil to drain into a receptacle Never drain used oil to the ground waste water lines or sewage Take out the oil drain t
15. Always carry an extra fuse in the fuse holder with you whenever you are riding the motorcycle Under no circumstances is a stronger fuse allowed to be set in AJP PR5 User s manual 2nd Edition or a fuse to be repaired An inexpert treatment could damage the whole electrical installation LIGHT BULB REPLACEMENT Replacing headlight lamp parking light lamp Loosen both rubber bands and tilt headlight mask to the front Pull the parking light lamp with holder carefully out of the reflector Pull connector off the headlamp and remove rubber cap Disengage retaining clip and take bulb out of the reflector When placing a new lamp do not touch the glass body of the lamp so it remains free from fat Engage retaining clip and mount rubber cap connector Reinsert parking light lamp together with holder and fix the mask by means of the rubber bands Use only 12V25 35W BA20d lamps Note rear light is a set of LEDs and does not allow for replacing because they are unchangeable In the event of a presence or stop light failure it is necessary to replace all the rear spoiler assembly AIR FILTER Cleaning air filter A dirty air filter restricts airflow rate reduces the engine performance and increases fuel consumption therefore clean it in regular intervals Page 26 For this purpose remove drivers seat by unscrewing to screw 1 inside the rear fender and pull it in to rear direction
16. MX PRO versions are not allowed for road riding These versions doesn t have the required equipment for road riding such as front lights blinkers taillights horn speedometer etc You can only ride with MX and MX PRO versions on a private track SERIAL NUMBER LOCATION The frame and or engine serial number are used to register the motorcycle They are also used to assist your dealer when ordering parts or referring to special service information Chassis number The chassis number is stamped on the right side of the steering head tube Chassis number AJP PR5 User s manual 2nd Edition Engine number The engine number is stamped into the left side of the engine below the engine sprocket between gearshift lever and the oil cap Motor Page 2 COMPONENTS LOCATION Rear brake fluid reservoir Air filter Fuse Spark plug Oil cover Rear brake pedal Oil level glass NOOR WD AJP PR5 User s manual 2nd Edition gen a X Z 2 Kad 4 ES an 10 11 12 13 5 oe y at Battery Fuel tank Fuel tank cap Gear lever Footpeg Side rest S 1 we Page 3 CONTROLS LOCATION ENDURO SUPERMOTO Clutch lever Blinker lights horn switch Front brake lever Starter button and On Off switch Neutral sign 6 Headlight sign 8 Digital speedometer 9 Ign
17. TERIALS USED WITHOUT PREVIOUS ANNOUNCEMENT AND WITHOUT GIVING REASONS OR TO CANCEL ANY OF THE ABOVE ITEMS WITHOUT SUBSTITUTING THEM WITH OTHERS IT SHALL BE ACCEPTABLE TO STOP MANUFACTURING A CERTAIN MODEL WITHOUT PREVIOUS ANNOUNCEMENT IN THE EVENT OF SUCH MODIFICATIONS PLEASE CONTACT YOUR LOCAL AJP DEALER FOR INFORMATION WE SHALL NOT BE HELD LIABLE FOR ANY PRINTING ERRORS TABLE OF CONTENTS CONSUMER INFORMATION COMPONENTS LOCATION CONTROLS LOCATION CONTROLS KEYS IGNITION SWITCH DIGITAL SPEEDOMETER LEFT HANDLEBAR RIGHT HANDLEBAR FUEL FUEL TANK CAP GEARSHIFT LEVER REAR BRAKE PEDAL SIDE STAND SUSPENSION SET UP ENGINE OIL RECOMMENDATION BREAK IN RUNNING IN INSPECTIONS BEFORE RIDING RIDING TIPS ENGINE START STARTING OFF USING THE GEARBOX BRAKING STOPPING AND PARKING INSPECTION AND MAINTENANCE MAINTENANCE SCHEDULE MAINTENANCE WORK LUBRICATION POINTS DRIVE CHAIN BRAKES FRONT WHEEL REMOVAL REAR WHEEL REMOVAL TIRES SPOKE TIGHTNESS BATTERY FUSE LIGHT BULB REPLACEMENT AIR FILTER THROTTLE CABLE ENGINE OIL EXHAUST SYSTEM MOTORCYCLE CLEANING CONSERVATION FOR WINTER OPERATION STORAGE PROCEDURES TECHNICAL SPECIFICATIONS l O O O QI QI A HPO CONSUMER INFORMATION ACCESSORY INSTALLATION AND PRECAUTION SAFETY TIPS There is some variety of accessories for AJP motorcycles AJP cannot have direct control over the quality Suitability of accessories you may want t
18. disc is between brake pads Tight front axle or the fixation nut and tight fixation screws Check if front wheel rotates freely without any restrain WARNING After mounting front wheel operate hand brake lever until pressure point is established Keep brake discs free from oil and fatty materials otherwise braking effect will be strongly reduced REAR WHEEL REMOVAL Dismounting and mounting the rear wheel Jack the motorcycle up on its frame so that the rear wheel no longer touches the ground Loosen the collar nut 1 in the right side hold the rear wheel and pull out the wheel spindle 2 by the left side until the rear wheel is free but the brake calliper support is still held in the swing arm Push the rear wheel as far forward as possible take out the chain from the rear sprocket and carefully remove the wheel carefuly from the swing arm To mount rear wheel follow the above procedure in reverse order being careful to place the brake disc correctly AJP PR5 User s manual 2nd Edition between the brake pads Make sure that rear wheel guides are touching rear wheel adjusters 3 and that both have same setting WARNING After mounting rear wheel operate brake pedal until pressure point is established Keep brake discs free from oil and fatty materials otherwise braking effect will be strongly reduced Tighten the collar nut with required torque A loose wheel spindle may l
19. e may break 4 Tyres Check for cuts or dents and replace tyres if necessary The tread must also comply with legal regulations Check air pressure insufficient tread and incorrect air pressure deteriorate driving performance 5 Brakes Check correct functioning of the braking system and brake fluid level in both reservoirs The reservoirs have been designed in such a way that brake fluid does not need to be refilled even when brake pads are worn If the level of brake fluid falls below the minimum value this indicates a possible leak or completely worn pads Manage for the brake system to be checked by an AJP dealer as complete failure of the system can be avoided Also check status of the brake hoses and the thickness of brake linings as well as free travel of hand brake lever and foot brake pedal 6 Electric system Check correct functioning of headlamps taillights brake lights indicators control lamps and horn while the engine is running 7 Luggage If you are taking any luggage with you check that it is securely fastened 8 Steering Check for smoothness no restriction on movement and no play or looseness Page 10 9 Throttle Check for correct play smooth operation and positive return to the closed position 10 Clutch Check for correct play smoothness and progressive action 11 Suspensions Check suspensions for smooth movement 12 Engine stop switch Check for c
20. e parts Use regular brand name detergents to clean the motorcycle Especially dirty parts should be cleaned additionally with the help of a paintbrush Before cleaning with water plug the exhaust pipe to prevent water going inside After the motorcycle has been cleaned with a soft water jet it should be dried with air pressure and a cloth Take a short drive until the engine has reached the working temperature and also use the brakes By warming these components the residual water can evaporate from inaccessible parts of engine and brakes AJP PR5 User s manual 2nd Edition Once the motorcycle has cooled down oil or grease all sliding and bearing points lubricate chain with chain spray To avoid any malfunction of the electric system you should treat emergency off button light switch and socket connectors with a contact spray CONSERVATION FOR WINTER OPERATION In the event that the motorcycle is also used in winter and on roads where one has to expect salt spraying you will have to take precautions against the aggressive road salt Clean motorcycle thoroughly and let it dry after each riding Treat engine carburettor swing arm and all other bare galvanized parts except for brake discs with a wax based anti corrosion agent STORAGE PROCEDURES Should you desire to make a pause over a long period of time more than one month please observe the following instructions Clean the
21. ead to unstable behaviour of your motorcycle Do not operate rear brake pedal when rear wheel has been removed Make sure brake disc is always on top when you lay down the wheel otherwise brake disc can be damaged If axle is dismounted clean the thread of the wheel spindle and apply a new coat of grease to prevent thread from jamming TIRES Tires air pressure Tire type its condition and air pressure affect the your motorcycle behaves therefore they must be checked whenever you getting ready to go anywhere on your motorcycle Tire size can be found in the technical specifications and registration documents Before leaving check tires for punctures and nails or other sharp objects that might have become embedded in them Refer to specific regulations in your country for minimum tire tread requirements Tire pressure should be checked regularly on a cold tyre Proper Page 24 pressure ensures optimum driving SPOKE TIGHTNESS comfort and extends the life of your tyres Checking spoke tension Pressure psi MX MX PRO J Correct spoke tension is very important for the stability of the wheels and thus for riding safety A loose spoke causes the wheel to become unbalanced and before long other spokes will have 1 75 25 come loose Check spoke tension Enduro Enduro PRO Driver 1 5 21 passenger 1 75 25 Supermoto 2 0 28 Supermoto Driver 1 75 25 passenger
22. em will be destroyed FUEL The PR5 250 engine needs unleaded premium gasoline with an octane number of 95 or higher Never use leaded fuel to avoid destroying catalytic converter and the exhaust system WARNING Using not recommend fuel can Cause severe damages on engine Be sure to use only unleaded gasoline with an octane index equal or higher than 95 FUEL TANK CAP Turn the fuel tank cap 1 counter clockwise to open it Turn clockwise to close and tighten it securely Page 6 WARNING Gasoline is highly flammable and poisonous Extreme caution should be used when handling gasoline Do not refuel motorcycle near open flames or burning cigarettes Always switch off engine before refuelling Be careful not to spill gasoline on the engine or exhaust pipe while the engine is hot Wipe up spills promptly lf gasoline is swallowed or splashed in the eyes seek a doctor s advice immediately Keep children and pets away Because of the transparent fuel tank there is not fuel indicator or light warning Control fuel level when you start the motorcycle and when you are riding for some time GEARSHIFT LEVER PR5 250 have a 6 speed transmission Shift lever is mounted on the left side of the engine The position of the gears is shown in the illustration Neutral is located between first and second gear AJP PR5 User s manual 2nd Edition To shift properly pull the clutch
23. emove the battery first disconnect the negative and then the positive pole of the battery and then unhitch rubber band When replacing connect first the positive and then the negative pole When preparing the motorcycle for a longer period of standstill remove the battery and recharge it every month ina slow charge Storage temperature 0 35 C Do not expose it to direct sun radiation Never reverse polarity otherwise battery and rectifier regulator will be destroyed Never disconnect battery while engine is running This will destroy the rectifier regulator Page 25 WARNING If electrolyte Sulphuric acid leaks from battery proceed with great care Electrolyte can cause severe burns In case of skin contact clear thoroughly with water In case of contact with eyes thoroughly apply them water for at least 15 minutes and immediately consult a doctor Battery is a closed model but can nevertheless emit explosive gases Avoid sparks and open fire near the battery Defected batteries must be stored out of reach of children Ensure proper disposal of discarded batteries FUSE The fuse is disposed underneath the seat Having removed the seat you will be able to see the fuse Replace a blown fuse only with an equivalent one If a new fuse that has just been set in gets blown again you are strongly advised to have it inspected by an AJP dealer The fuse capacity is 20 15 Ampere
24. gas If you turned on the choke lever make sure you turn it off again as soon as engine is warm When you reach full speed by opening the throttle all the way turn throttle back to 3 4 the speed hardly decreases and the engine will use less fuel Only give as much gas as the engine can handle Through quick and high revving of throttle the fuel consumption increases By shifting down use the brakes if necessary and close throttle at the same time Pull clutch lever and shift down to the next gear Let clutch lever go slowly and open throttle or shift down again High RPM rates when engine is cold have an adverse effect on the life of your engine We recommend you to run the engine in a moderate RPM range for 5 10 Kilometers miles giving it the chance to warm up Never have the throttle wide open when shifting down a gear The engine will over rev damaging the valves If any abnormal vibrations occur while driving check that the engine fastening bolts are tight If it remains contact an authorized AJP dealer lf you notice any unusual Page 12 operation related noise while riding stop immediately shut the engine off and contact an authorized AJP dealer Never start your motorcycle without air filter in place otherwise dust and dirt may enter to the engine and cause increased wear or damage BRAKING Apply both brakes at the same time with the throttle closed When driving on sandy wet or sl
25. gle lens when scratched or damaged If bright light shines through a scratched the driver will be blinded In case of a fall check all functions thoroughly before start operating the motorcycle Do not repair twisted handlebar Replace it immediately AJP PR5 User s manual 2nd Edition Note regarding side stand Push the side stand to the ground with your foot and load it with the motorcycle Make sure that you put the motorcycle on solid ground and in a secure position Just in case you can shift into first gear side stand was designed only for the weight of the motorcycle If you get on the motorcycle and thus put additional weight side stand or frame can be damaged and the motorcycle may fall on the side Page 14 INSPECTION AND MAINTENANCE MAINTENANCE SCHEDULE The chart indicates intervals between periodic services in Kilometres At the end of each interval be sure to inspect check lubricate and service as instructed If your motorcycle is used under high stress conditions such as continuous full throttle operation or is operated in a dusty climate certain services should be performed more often to insure reliability of motorcycle as explained in maintenance section Your AJP dealer can provide you with further guidelines Steering Components suspension and wheel components are key items and require very special and careful servicing For maximum safety we suggest that you have these
26. hten fixing nuts 2 5 Recheck the chain slack after tightening lubricate and adjust if necessary AJP PR5 User s manual 2nd Edition WARNING Excessive tensioning of the chain will put additional load on the components of the secondary drive chain chain bearings and rear wheel Aside from resulting premature wear chain may rupture or transmission countershaft may break On the other hand too much slack in the chain can result chain jumping off the chain wheels If this happens chain could also block rear wheel or damage the engine In either case operator is likely to loose control of the motorcycle Drive chain maintenance A good maintenance is very important for long chain life Chains without o rings should be cleaned in fireproof solvent regularly and afterwards treated with hot grease or chain spray On the other hand o ring chains are very simple to clean The best way is to use lots of water but never use brushes or cleaning liquids After letting the chain dry completely use a chain spray to lubricate it Also check sprockets and chain guides for wear and replace if necessary WARNING No lubrication should be allowed to reach rear tyre or rear brake disc otherwise road adherence and rear wheel braking effects will be strongly reduced and the motorcycle can easily get out of control When mounting chain master link clip the closed side of the master link must
27. ippery ground use mainly the rear brake Avoid blocking the wheels otherwise you may skid or fall also you can change down to a lower gear depending on your speed WARNING Hard braking on wet loose rough or other slippery surfaces can cause wheel skid and loss of control Brake lightly and with care on slippery or irregular surfaces Use the braking effect of the engine when driving downhill to assist the brakes change down one or two gears but do not over speed the engine This way you will not need to use the brakes so much and avoid overheating WARNING Each time you brake brake discs pads callipers and brake fluid heat up The hotter these parts get the weaker the braking effect in extreme cases the entire braking system can fail AJP PR5 User s manual 2nd Edition WARNING In case of rain after washing the motorcycle after rides through water and wet off roads tracks wet or dirty disc brakes can delay the braking effect Brakes must then actuated until disc brakes are dry or clean Dirty brake discs cause increased wear of brake pads and discs WARNING Hard braking while turning may cause wheel skid and loss control Brake before you begin to turn WARNING Inexperienced riders tend to under use front brake This can cause excessive stopping distance and lead to a collision Using only front or rear brake can cause skidding and loss of c
28. ition switch CONTROLS KEYS This motorcycle comes with a pair of keys Be aware to keep one of the keys in a safe place at home for instance in order to let you access this key in case of need IGNITION SWITCH AJP PR5 User s manual 2nd Edition LOCK position all electrical circuits are cut off and the engine will not start The steering lock is actuated and the handlebar cannot turn The key can be removed To pass to lock position the switch must be in OFF position and the pushed down and turned to the left The handlebar must be turned all the way to the left OFF position all electrical circuits are cut off and the engine will not start The key can be removed ON position the ignition circuit is on and the engine can now be started The key cannot be removed from the ignition switch To activate LOCK position the switch must be in OFF position then pushed down and turned to the Handlebar should be turned all the way to the left If not the switch will not pass to LOCK position Don t try to ride with the switch on LOCK position The steering is locked and control of the motorcycle is impossible Don t turn the ignition key to LOCK position while driving Note Start engine as soon as you turn key to ON position Otherwise battery will loose power due to the consumption of the digital soeedometer and headlight and taillight if turned on Page 4 DIGITAL SPEEDOMETER
29. o purchase The addition of unsuitable accessories can lead to unsafe operating conditions Please contact your AJP dealer for assist you in selecting accessories and install them correctly WARNING Improper accessories or modifications can your motorcycle unsafe and can lead to an accident Never modify the motorcycle with improper or poorly installed accessories Follow all instructions in this owner s manual regarding accessories and modifications Consult your AJP dealer if you have any questions Certain accessories displace the rider from his normal position This limits the freedom of movement and may limit his control ability Additional electric accessories may overload the electric system Severe overloads may damage the wiring harness or create a dangerous situation due to the loss of electric power during the operation of the motorcycle When carrying load the motorcycle mount it as low as possible to the machine An improperly mounted load can create a high center of gravity that is very dangerous and makes the motorcycle difficult to handle The size of the load can also affect the aerodynamics and handling of the motorcycle Balance the load between the left and right sides of the motorcycle and fasten it securely AJP PR5 User s manual 2nd Edition SAFE RIDING RECOMMENDATIONS FOR MOTORCYCLE RIDERS WEAR A HELMET Motorcycle safety equipments starts with a quality helme
30. ogether with oil filter clean these components carefully and blow with compressed air Check o ring and sealing and replace them if necessary Once the entire oil has been drained clean the sealing surface mount the oil drain together with spring oil filter and sealing on the right position and tighten up to 15Nm 1 5 Kg m Screw aluminium drain carefully to avoid damaging carter s thread Remove the oil cover 1 and fill in 1 4 litres of the recommended engine oll Start the engine and check for leaks Page 28 Finally check the engine oil level and if necessary correct it EXHAUST SYSTEM Requires regular maintenance the more frequent and severe is the riding of your motorcycle The silencer fibre in is interior should be replaced each 3 000 Km or 50 hours of use If not noise level will reach illegal and disturbing levels MOTORCYCLE CLEANING Clean your motorcycle oftenly in order to maintain the beauty of its plastic surfaces and avoid corrosion The best manner would be to use warm water that has been mixed with a normal brand name washing detergent and a sponge The hard dirt can be removed before washing with the help of a soft water jet Never clean your motorcycle with an high pressured cleaner or an high pressured water jet Water could run into electrical components connectors cables bearings carburettor etc can Cause operations mal functions or lead to premature destruction of thes
31. ontrol Apply both brakes evenly and at the same time STOPPING AND PARKING Apply the brakes fully and put the engine into neutral To turn off the engine apply the emergency off button or turn the key to OFF position on the ignition switch with the engine at idling speed until the engine stops Park on an area where the ground is firm and lock the motorcycle Page 13 WARNING Never leave your motorcycle without supervision if the engine is running or with children nearby Motorcycle engines produce a great amount of heat when running Engine exhaust pipe muffler brake callipers and shock absorber can become very hot Do not touch any of these parts after operating the motorcycle or allow children to come nearby Take care to park the motorcycle where pedestrians are not likely to touch it and get burned Never park your motorcycle in places where there is fire hazards such as dry grass or other easily flammable materials WARNING Observe traffic regulations and drive defensively trying to look ahead as far as possible so that any hazards can be recognized as early as possible Adjust your driving speed according to the conditions and your driving skills Drive carefully in unknown roads or unfamiliar trials When driving off road always have a friend on a second motorcycle to make you company so you can help each other if some problem happens Replace helmet visor or gog
32. orb water Therefore vapour pockets may form on old brake fluids even at low temperatures causing brake system to fail Checking the brake fluid level front brake Brake fluid reservoir is linked with the hand brake cylinder at the handlebar and the reservoir is provided with an inspection glass 1 With the reservoir in horizontal position the brake fluid level should not drop below the middle of the glass WARNING lf brake fluid level drops below minimum either brake system has a leak or the brake pads are completely worn In this case consult an authorized AJP dealer immediately Page 20 Refilling front brake fluid reservoir Loosen screws 1 remove lid 2 and membrane 3 Place hand brake cylinder in a horizontal position and fill the brake fluid reservoir up to the MAX mark with clean brake fluid DOT 4 Replace membrane lid and tighten screws Clear off spilled or overflowing brake fluid with water WARNING Store brake fluid out of reach of children Brake fluid can cause skin irritation Avoid contact with skin and eyes If you get brake fluid in your eyes clear with plenty of water and consult a doctor Don t let brake fluid get in contact with paint it is an effective paint remover Use only clean brake fluid from a sealed or hermetic closed container Checking front brake pads The front brake pads can
33. orrect function WARNING Failure to run these inspections and maintain your motorcycle properly increases the chance of an accident or equipment damage Always perform a pre ride inspection before each ride Refer to the list behind for check items For further details refer to the INSPECTION AND MAINTENANCE section WARNING Using worn improperly inflated or incorrect tires will reduce stability and can cause an accident Follow all instructions in the TIRES section WARNING Checking maintenance items when the engine is running can be hazardous You could be severely injured if your hands or clothing get caught in moving parts RIDING TIPS Instructions for initial operation Verify if your AJP dealer performed a previous preparation of the motorcycle Read this manual carefully before you ride Familiarize yourself with all the operating controls Get used to the handling of the motorcycle on an empty parking lot or open space before going for a longer ride Try also to drive as slow as AJP PR5 User s manual 2nd Edition possible and sitting position to improve your feeling of the motorcycle Hold the handlebar with both hands and leave your feet on the footrests while driving Remove your foot from the brake pedal when you are not braking If the brake pedal is not released the brake pads will rub continuously and the braking system will overheat Do not make any
34. plied by AJP to fix fuel tank Using other screws or longer ones can cause cracks in the tank through which fuel can flow out Let your motorcycle cool down before beginning any maintenance work in order to avoid get burned Remove oil grease matters filters fuel washing detergents etc orderly Under no circumstances may used oil be disposed off in the sewage system or in the open countryside Remember 1 litre of used oil contaminates 1 000 000 litres of water AJP PR5 User s manual 2nd Edition Page 17 Checking and adjusting the steering head bearings Check steering head bearings for play periodically For check put motorcycle on a stand so that the front wheel is off the ground Try to move the fork forward and backward For readjusting loosen top nut 2 and the four bolts 1 two for PRO versions of the top triple clamp and turn steering stem bolt 3 clockwise until there is no more play Dont tighten the steering stem bolt 3 all the way otherwise the bearings will be damaged With a plastic hammer lightly rap on the triple clamp to release tension and retighten the bolts Then tight top nut 2 and the top triple clamp screws 1 Steering head bearings should be greased at least once a year WARNING lf steering head bearings are not adjusted to be free of play or too tight the motorcycle will become unstable and can get out of control If you drive with play in the steering
35. point in the running direction Page 19 BRAKES Brake pads Brake pads used on front and rear brake provide an optimal combination of power brake performance and lifecycle Brake discs Due to wear the thickness of brake discs in the area of the contact face 1 of the brake pads decreases At their thinnest point A the brake discs must not be more than 0 50mm thinner than the pads nominal thickness Measure the nominal thickness in a location B outside the contact face and check for wear in several locations WARNING For your own safety have the brake discs replaced immediately as soon as they reach wear limit 3 mm thickness Have any repairs on brake system performed by an AJP authorized dealer Brake fluid reservoirs Brake fluid reservoirs have been designed in such a way that even if the brake pads are worn it is not necessary to refill brake fluid If brake fluid level drops below the minimum level either the brake system has a leak or the brake pads are completely worn AJP PR5 User s manual 2nd Edition In this case consult an authorized AJP dealer immediately Brake fluid AJP fills the brake systems with DOT 4 brake fluid we recommend that you continue to use it WARNING Change brake fluid at least once each two years If you wash your motorcycle often brake fluid should be changed even more often once a year as brake fluid tends to abs
36. r shock absorber assembly is dangerous The rear shock absorber contains high pressured gas and can explode if improperly serviced ENGINE OIL RECOMMENDATION Use a premium quality 4 stroke motor oil to ensure longer service life of your motorcycle Use only oils that meet or Surpass quality requirements of API classes SF or SG SAE 10W 40 or 15W 40 API SF or SG Oil level Engine oil level can be checked in the glass in front of rear brake pedal Oil level should be between the two lines in the glass If oil level is below the lower line refill immediately If your engine is losing oil contact an AJP dealer immediately WARNING Insufficient oil or poor quality oil results in premature wear of the engine and may cause severe damages Page 9 BREAK IN RUNNING IN The following explains why is so important proper break in to achieve maximum life and performance from your new AJP Even very precisely machined sections of engine components have rougher surfaces than components that have been sliding across one another for quite some time therefore every engine needs to be broken in during the first 1 000Kms For this reason do not load engine more than 50 of its capacity during the first 500 kilometres avoiding full throttle In the following 500 kilometres you may load the engine up to 75 of ts capacity using the gearbox frequently Allow sufficient idling time about 1 2 minutes after wa
37. rance Check correct functioning of braking system spoke _ tightness tire condition clutch cable side stand steering stem bearings Suspensions battery exhaust electrical system EACH 500 km OR MONTH Check adjust clean and lubricate drive chain Check oil level refill if necessary EACH 3 000 km OR 6 MONTHS Replace spark plug Replace engine oil Replace engine oil filter Check engine oil level Check air filter Clean and wet in oil Check drive chain Check valve clearance Check fuel feed lubrication and oil cooler tubes Check fuel functioning Adjust and lubricate throttle cable Adjust and lubricate clutch cable Check timing chain Check timing tensioner Check brake pads Check brake fluid level Check braking system functioning and stop switches Check tires condition Check spoke tightness Check side stand functioning Check steering functioning Check suspensions functioning Check battery Control voltage with or without charge injection system AJP PR5 User s manual 2nd Edition Check exhaust condition leaks and noise level Check condition and functioning of several component of electrical system Check tightness of bolts nuts clamps of diverse components EACH 6 000 km OR 12 MONTHS Perform operations indicated for each 3 000 kms plus Replace spark plug Replace air filter Check functioning of fuel cap valve Lubricate steering stem bearings
38. rm or cold engine start up before applying load or revving the engine This allows time for the lubricating oil to reach all critical engine components Observe your first and most critical service The 1000 Kms service is the most important service your AJP will receive All adjustments will be restored all fasteners and spokes will be tightened and dirty oil and oil filter will be replaced WARNING Incorrect break in may cause severe damage to your motorcycle significantly reduce your motorcycle lifetime INSPECTIONS BEFORE RIDING Check the following before each start When you start off the motorcycle must be in perfect mechanical condition For safety reasons you should make a AJP PR5 User s manual 2nd Edition habit of performing an overall check before each start The following checks should be performed 1 Oil level Insufficient oil results in premature wear in engine components and damages in engine itself 2 Fuel Check there is enough fuel in the tank Drive chain A loose chain can fall from the chain wheels an extremely worn chain can tear and insufficient lubrication can result in excessive wear to the chain and chain wheels Excessive tensioning of the chain will put additional load on the components of the secondary drive train chain bearings of transmission and rear wheel Aside from resulting premature wear the chain may even rupture or the transmission axl
39. side the foot brake pedal must have 3 to 5 mm of free play before the piston rod can move the piston in the rear brake cylinder Checking rear brake fluid level The reservoir for the rear disc brake is integrated in brake pump placed in the right side of the engine near exhaust pipe Brake fluid level must not drop below the MIN marking when the vehicle is in an upright position AJP PR5 User s manual 2nd Edition If free play is not present then pressure can build up in the brake system when driving causing rear wheel to brake Brake system can overheat and may even completely fail in extreme cases Don t ride with foot pressing rear brake pedal WARNING If brake fluid level drops below the minimum or brake system has a leak or brake pads are completely worn In this case consult an authorized dealer immediately Refilling the rear brake fluid reservoir Unscrew the cap 1 diaphragm and add brake fluid DOT 4 until it reaches the MAX mark then place diaphragm and cap back on Clear off spilled or overflowing brake fluid with water Checking the rear brake pads The brake pads can be inspected from the rear The thickness of the linings cannot be less than 1mm Page 22 WARNING At their most worn point brake pad linings should not be thinner than 1mm otherwise can lead to brake failure WARNING Store brake fluid out of reach of children Brake fl
40. t One of the most serious injuries that can happen is a head injury ALWAYS wear a properly approved helmet You should also wear suitable eye protection RIDING APPAREL Loose fancy clothing can be uncomfortable and unsafe for motorcycle riding Choose good quality motorcycle riding apparel when riding your motorcycle Wear gloves strong boots that fit over the ankle long pants and long sleeve shirt or jacket INSPECTION BEFORE RIDING Review all the instructions in the INSPECTION BEFORE RIDING section in this manual Do not forget to perform an entire safety inspection to ensure safety of the rider FAMILIARIZE YOURSELF WITH THE MOTORCYCLE Your riding skill and your mechanical knowledge form the basis for safe riding We recommend you to practice riding your motorcycle in an open area without obstacles until you are familiar with your motorcycle and its controls KNOW YOUR OWN LIMITS Always ride within the limits of your skills Knowing your limits and keep within are the foundation to avoid accidents and injuries BE EXTRA SAFETY CONSCIOUS ON BAD WEATHER DAYS BAD ROAD CONDITIONS Riding on bad weather days requires extra attention Braking distances double in a rainy day you are not sure about road conditions ride slower and with double care Page 1 MODIFICATION Modification of the motorcycle removal of original equipment may render the vehicle unsafe or illegal ROAD USE MX and
41. t other drivers become aware of you as early as possible WARNING Never ride your motorcycle with full load or rev the engine when cold Because the piston is warming up faster than the cylinder it can cause engine damage What to do when the engine is flooded In some particular conditions some extra fuel may go to the engine If engine floods try to start engine for 10 seconds if engine does not start wait 10 seconds and try again After five trials if engine does not start check spark plug dry it and try again If engine does not start replace spark plug for a new one WARNING Do not start the engine or allow it to idle in a closed area Exhaust gases are poisonous and can cause loss of consciousness and even death Always provide adequate ventilation while the engine 15 running Never leave engine running for a more than 5 minutes while the motorcycle is parked engine will overheat and severe damage may occur AJP PR5 User s manual 2nd Edition STARTING OFF Pull the clutch lever and put the engine into first gear Slowly release the clutch lever and open the throttle at the same time USING THE GEARBOX The first gear is referred as the drive or uphill gear Depending on the conditions traffic hill size etc you can shift to a higher gear Close throttle at the same time you pull clutch lever and shift to the next higher gear Let clutch go again and give
42. ton in middle position 7 Horn To actuate horn press this button In several countries motorcycle riding is only allowed with low beam on Respect your national legislation Turn lights are not switched off automatically Be aware to switch turn lights off after turning or overtaking Otherwise you will give wrong information about your riding to other drivers Page 5 RIGHT HANDLEBAR 1 Throttle grip Engine speed is controlled by the position of the throttle grip Rotate it toward you to increase engine speed turn it away to decrease engine speed 2 Front brake lever Front brake is applied by squeezing brake lever gently toward the throttle grip Electric start button This button is used for turning the starter motor With the ignition switch in the ON position the transmission in neutral starter switch on pull the clutch lever and push the electric start button to engage the starter motor and start the engine 4 Emergency switch This switch has two positions to the left enables engine running to the right stops engine running Be aware that this switch is switched ON for engine starting lf EMERGENCY SWITCH is not ON engine will not start Start motor will not be actuated AJP PR5 User s manual 2nd Edition The EMERGENCY SWITCH should be used to stop the engine in emergency situations Do not use it to stop the engine when driving otherwise the ignition syst
43. uid can cause skin irritation Avoid contact with skin and eyes If you get brake fluid in your eyes clear with plenty of water and consult a doctor WARNING If brake pads are replaced too late so that the lining is partly or entirely worn steel components of brake pad will rub against brake disc thereby reducing braking effect and destroying brake disc Dont place brake fluid in contact with paint it is a powerful paint remover Use only clean break fluid or from a sealed container Replacing the rear brake pads Remove the rear wheel see REAR WHEEL REMOVAL and with a screwdriver push the brake pads to move the pistons into their basic position Remove clip 1 and then remove brake pads from the calliper Clean the brake calliper thoroughly with compressed air insert brake pads and secure them with the clip Then place rear wheel back on AJP PR5 User s manual 2nd Edition FRONT WHEEL REMOVAL Dismounting and mounting front wheel To remove the front wheel jack the motorcycle up on its frame so that the front wheel no longer touches the ground Loosen the four screws 1 on both sides of front fork unscrew nut 2 hold the wheel remove front axle 3 Remove front wheel carefully from the fork Do not operate hand brake lever when front wheel has been removed Page 23 Front wheel mounting Place front wheel between front fork sleeves in a way that brake
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