ajp motos - pr5 user manual

8/8/2019 AJP MOTOS - PR5 User Manual

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OWNER’S MANUAL PR5 250SUPERMOTO • ENDURO

Enduring Experience

English version • May 2010AJP Motos, SA

This manual should be considered a permanent part of the motorcycle and should remain with themotorcycle when resold or otherwise transferred to a new owner or operator. The manual containsimportant safety information and instructions that should be read carefully before start operatingthe motorcycle.



i

! VERY IMPORTANT !

WE STRONGLY RECOMMEND YOU READ THIS MANUALCAREFULLY AND COMPLETELY BEFORE GOING ON YOURFIRST RIDE. IT COINTAINS A GREAT DEAL OF INFORMATIONAND ADVICE, WHICH WILL HELP YOU USE AND HANDLEYOUR BIKE PROPERLY. IN YOUR OWN INTEREST, PLEASEPAY ATTENTION TO NOTICES THAT ARE MARKED ASFOLLOWS:

! WARNING !

IGNORING THESE INSTRUCTIONS CAN ENDANGER YOURBODY AND YOUR LIFE, AS WELL AS OTHER PEOPLE`S LIFES.

! CAUTION !

IGNORING THESE INSTRUCTIONS COULD CAUSE DAMAGE TOPARTS 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 THESEGUIDELINES WILL SIGNIFICANTLY INCREASE THE LIFE OF YOURMOTORCYCLE. BE SURE TO HAVE ANY MAINTENANCE JOBSPERFORMED BY AN AUTHORIZED AJP DEALER.PLEASE DON`T FORGET TO WEAR A HELMET, EYE PROTECTION ANDPROTECTIVE CLOTHING WHEN GOING FOR A RIDE.

WE WISH YOU A LOT OF FUN RIDING YOUR AJP!

AJP MOTOS, SA RESERVES THE RIGHT TO MODIFY ANY EQUIPMENT,TECHNICAL SPECIFICATIONS, COLOURS AND MATERIALS USEDWITHOUT PREVIOUS ANNOUNCEMENT AND WITHOUT GIVINGREASONS, OR TO CANCEL ANY OF THE ABOVE ITEMS WITHOUTSUBSTITUTING THEM WITH OTHERS. IT SHALL BE ACCEPTABLE TOSTOP MANUFACTURING A CERTAIN MODEL WITHOUT PREVIOUSANNOUNCEMENT. IN THE EVENT OF SUCH MODIFICATIONS, PLEASECONTACT YOUR LOCAL AJP DEALER FOR INFORMATION. WE SHALLNOT BE HELD LIABLE FOR ANY PRINTING ERRORS.



ii

TABLE OF CONTENTS

CONSUMER INFORMATION 1COMPONENTS LOCATION 3CONTROLS LOCATION 5CONTROLS 5

KEYS 5IGNITION SWITCH 5DIGITAL SPEEDOMETER 6LEFT HANDLEBAR 6RIGHT HANDLEBAR 7FUEL 7FUEL TANK CAP 8GEARSHIFT LEVER 9REAR BRAKE PEDAL 9SIDE STAND 9

SUSPENSION SET-UP 10ENGINE OIL RECOMMENDATION 11BREAK-IN (RUNNING-IN) 11INSPECTIONS BEFORE RIDING 12RIDING TIPS 13

ENGINE START 13STARTING OFF 14USING THE GEARBOX 14BRAKING 15STOPPING AND PARKING 16

INSPECTION AND MAINTENANCE 17MAINTENANCE SCHEDULE 17MAINTENANCE SCHEDULE TABLE 18MAINTENANCE WORK 19LUBRICATION POINTS 19DRIVE CHAIN 21BRAKES 22FRONT WHEEL REMOVAL 25REAR WHEEL REMOVAL 26TIRES 26SPOKE TIGHTNESS 27BATTERY 27FUSE 28

LIGHT BULB REPLACEMENT 28AIR FILTER 28FUEL FILTER 29THROTTLE CABLE 29ENGINE OIL 30EXHAUST SYSTEM 31

MOTORCYCLE CLEANING 31CONSERVATION FOR WINTER OPERATION 32STORAGE PROCEDURES 32TECHNICAL SPECIFICATIONS 33



AJP PR5 User’s manual Page 1

CONSUMER INFORMATION

ACCESSORY INSTALLATION ANDPRECAUTION SAFETY TIPS

There is some variety of accessories forAJP motorcycles. AJP cannot havedirect control over the quality orsuitability of accessories you may wantto purchase. The addition of unsuitableaccessories can lead to unsafeoperating conditions. Please contactyour AJP dealer for assist you inselecting accessories and install themcorrectly.

! WARNING !

Improper accessories ormodifications can make yourmotorcycle unsafe and can lead toan accident. Never modify themotorcycle with improper or poorlyinstalled accessories. Follow allinstructions in this owner’s manualregarding accessories andmodifications. Consult your AJPdealer if you have any questions.

Certain accessories displace the riderfrom his normal position. This limits thefreedom of movement and may limit hiscontrol ability.

Additional electric accessories mayoverload the electric system. Severeoverloads may damage the wiringharness or create a dangerous situationdue to the loss of electric power duringthe operation of the motorcycle.

When carrying a load on themotorcycle, mount it as low as possibleto the machine. An improperly mountedload can create a high center of gravitythat is very dangerous and makes themotorcycle difficult to handle. The sizeof the load can also affect theaerodynamics and handling of themotorcycle. Balance the load betweenthe left and right sides of the motorcycle

and fasten it securely.

SAFE RIDING RECOMMENDATIONSFOR MOTORCYCLE RIDERS:

WEAR A HELMETMotorcycle safety equipments startswith a quality helmet. One of the mostserious injuries that can happen is ahead injury. ALWAYS wear a properlyapproved helmet.You should also wear suitable eyeprotection.

RIDING APPARELLoose, fancy clothing can beuncomfortable and unsafe formotorcycle riding. Choose good qualitymotorcycle riding apparel when riding

your motorcycle. Wear gloves, strongboots that fit over the ankle, long pantsand long sleeve shirt or jacket.

INSPECTION BEFORE RIDINGReview all the instructions in the“INSPECTION BEFORE RIDING”section in this manual. Do not forget toperform an entire safety inspection toensure safety of the rider.

FAMILIARIZE YOURSELF WITH THEMOTORCYCLEYour riding skill and your mechanicalknowledge form the basis for saferiding. We recommend you to practiceriding your motorcycle in an open areawithout obstacles until you are familiarwith your motorcycle and its controls.

KNOW YOUR OWN LIMITSAlways ride within the limits of yourskills. Knowing your limits and keep

within are the foundation to avoidaccidents and injuries.

BE EXTRA SAFETY CONSCIOUS ONBAD WEATHER DAYS OR BADROAD CONDITIONSRiding on bad weather days requiresextra attention. Braking distancesdouble in a rainy day. If you are notsure about road conditions ride slowerand with double care!




MODIFICATIONModification of the motorcycle orremoval of original equipment mayrender the vehicle unsafe or illegal.

ROAD USEMX and MX PRO versions are notallowed for road riding. These versionsdoesn’t have the required equipment forroad riding, such as front lights,blinkers, taillights, horn, speedometer,etc. You can only ride with MX and MXPRO versions on a private track.

SERIAL NUMBER LOCATION

The frame and/or engine serial numberare used to register the motorcycle.They are also used to assist yourdealer when ordering parts or referringto special service information.

Chassis number

The chassis number is stamped on theright side of the steering head tube.

Engine number

The engine number is stamped into theleft side of the engine below the enginesprocket, between gearshift lever and

the oil cap.

Chassisnumber




COMPONENTS LOCATION

1 Rear brake fluid reservoir2 Air filter3 Fuse4 Spark plug5 Oil cover

6 Rear brake pedal7 Oil level glass

8 Battery9 Fuel tank

10 Fuel tank cap11 Gear lever12 Footpeg13 Side rest




CONTROLS LOCATION

1 Clutch lever2 Blinker, lights, horn switch3 Front brake lever4 Starter button and On-Off switch5 Neutral sign6 Headlight sign7 Turn light sign8 Digital speedometer9 Ignition switch10 Throttle grip11 Rear view mirrors

CONTROLS

KEYSThis motorcycle comes with a pair ofkeys. Be aware to keep one of the keysin a safe place, at home for instance, inorder to let you access this key in caseof need.

IGNITION SWITCH

LOCK position – all electrical circuitsare cut off and the engine will not start.The steering lock is actuated and thehandlebar cannot turn. The key can beremoved. To pass to lock position, theswitch must be in OFF position and thepushed down and turned to the left. Thehandlebar must be turned all the way tothe left.

OFF position - all electrical circuits arecut off and the engine will not start. Thekey can be removed.

ON position – the ignition circuit is onand the engine can now be started. Thekey cannot be removed from the

ignition switch.

! CAUTION !

To activate LOCK position, theswitch must be in OFF position, thenpushed down and turned to the left.Handlebar should be turned all theway to the left. If not, the switch willnot pass to LOCK position.

! CAUTION !

Don’t try to ride with the switch onLOCK position. The steering islocked and control of the motorcycleis impossible.Don’t turn the ignition key to LOCKposition while driving!.

Note: Start engine as soon as you turn

key to ON position. Otherwise batterywill loose power due to theconsumption of the digital speedometerand headlight and taillight, if turned on.

LOCK

OFF ON

ENDURO, SUPERMOTO

10

11 11




DIGITAL SPEEDOMETER

The digital speedometer is not availablefor the MX and MX PRO versions.It gives information about instantaneous

speed and total or trip distancetravelled. Depending on the sellingmarket, speed and distance areindicated in Kilometres or miles. If youwant to switch between these units,please contact your AJP dealer.To switch from total to trip distancepush button 1. To reset trip distance thetrip distance must be selected; thenpush button 1 until the distance is resetto zero.

LEFT HANDLEBAR

1 – Clutch leverThe clutch lever is used for disengagingthe drive to the rear wheel whenstarting the engine or shifting thetransmission gear. Squeezing the leverdisengages the clutch.

2 – Parking light onWith the light knob in this position,parking lights in the headlight andtaillight will be switched on.

3 – Lights offIn this position, no lights will beswitched on.

4 – Low beam onIn this position, low beam light will beon in the headlight and presence lightwill be on in the taillight.5 – High beam onIn this position, high beam light will beon in the headlight and presence lightwill be on in the taillight.

6 – Turn sign onTurning this button left left turn lightswill be on. Turning right, right turn lightswill be on. To switch turn lights off,place the button in middle position.

7 – HornTo actuate horn, press this button.

! CAUTION !

In several countries, motorcycleriding is only allowed with low beamon! Respect your nationallegislation!

! CAUTION !

Turn lights are not switched offautomatically! Be aware to switchturn lights off after turning orovertaking! Otherwise you will give

wrong information about your ridingto other drivers!

1




RIGHT HANDLEBAR

1 – Throttle gripEngine speed is controlled by theposition of the throttle grip. Rotate ittoward you to increase engine speed;turn it away to decrease engine speed.

2 – Front brake leverFront brake is applied by squeezingbrake lever gently toward the throttlegrip.

3 – Electric start buttonThis button is used for turning thestarter motor. With the ignition switch inthe ON position, the transmission inneutral, starter switch on, pull the clutchlever and push the electric start buttonto engage the starter motor and startthe engine.

4 – Emergency switch

This switch has two positions: to the leftenables engine running, to the rightstops engine running. Be aware thatthis switch is switched ON for enginestarting.

! CAUTION !

If EMERGENCY SWITCH is not ON,engine will not start! Start motor willnot be actuated!

! CAUTION !

The EMERGENCY SWITCH shouldbe used to stop the engine inemergency situations! Do not use itto stop the engine when drivingotherwise the ignition system will bedestroyed!

FUEL

The PR5 250 engine needs unleadedpremium gasoline with an octanenumber of 95 or higher. Never useleaded fuel to avoid destroying catalyticconverter and the exhaust system.

! WARNING !

Using not recommend fuel cancause severe damages on engine!Be sure to use only unleadedgasoline with an octane index equalor higher than 95!

FUEL TANK CAP

Turn the fuel tank cap (1) counter-clockwise to open it. Turn clockwise toclose and tighten it securely.




! WARNING !

Gasoline is highly flammable andpoisonous. Extreme caution shouldbe used when handling gasoline.- Do not refuel motorcycle near openflames or burning cigarettes.- Always switch off engine beforerefuelling- Be careful not to spill gasoline onthe engine or exhaust pipe while theengine is hot- Wipe up spills promptly.- If gasoline is swallowed orsplashed in the eyes, seek a

doctor’s advice immediately.- Keep children and pets away.

! CAUTION !

Because of the transparent fueltank, there is not fuel indicator orlight warning! Control fuel levelwhen you start the motorcycle andwhen you are riding for some time!

GEARSHIFT LEVER

PR5 250 have a 6-speed transmission.Shift lever is mounted on the left side ofthe engine. The position of the gears isshown in the illustration. Neutral islocated between first and second gear.

To shift properly, pull the clutch leverand close he throttle at the same timeyou operate gearshift lever. Lift thelever to up-shift and depress todownshift.

REAR BRAKE PEDAL

The foot brake pedal is disposed infront of the right footrest. Depressingthe rear brake pedal will apply the rearbrake.

! WARNING !If opposition of hand brake lever orrear brake pedal fells “spongy” (toomuch give), this is an indication thatthe brake system is not functioningwell. Don’t ride anymore yourmotorcycle without first having thebrake system checked by an AJPdealer!

SIDE STAND

Push the side stand to the ground withyour foot and load it with themotorcycle. Make sure that you put themotorcycle on solid ground and in asecure position.




! WARNING !

Always check if you have foldedback the side stand before eachride. If the side stand touches theground while you drive, you mayloose control of your motorcycle!

! CAUTION !

The side stand was designed onlyfor the weight of the motorcycle. Ifyou get on the motorcycle and thusput additional weight, the side stand

or frame can be damaged and themotorcycle may fall on the side!

! CAUTION !

Park the motorcycle on solid levelground to help prevent it from fallingover.If you must park on an incline, aimthe front of the motorcycle uphill andput the transmission into 1 st gear to

reduce the chance of rolling off theside stand.

SUSPENSION SET-UP

PR5 is equipped with an up-side downfully adjustable front fork.

To adjust compression turn the screw(1) clockwise to have a harderresponse. Turn counter clockwise tohave a softer response.

To adjust rebound, turn the lower screwclockwise for more rebound; turncounter clockwise for less rebound.

! WARNING !

Unequal suspension adjustment cancause poor handling and loss ofstability.

Adjust the right and left front legs tothe same settings.

Rear suspension adjustment

PR5 is equipped with a fully adjustableshock absorber.

To adjust pre-charge loose first theupper nut (1), then turn adjusting nut (2)clockwise for more pre-charge or

counter clockwise for less pre-charge.




To adjust rebound, turn the screwplaced on the bottom of the shockabsorber (3) clockwise for morerebound or counter clockwise for lessrebound.

To adjust fast compression damping,turn the knob (4) clockwise for morerebound speed. To reduce reboundspeed turn counter clockwise.

To adjust low compression damping,turn the screw (5) clockwise for morerebound speed. To reduce reboundspeed turn counter clockwise.

Standard set-up:

- Spring length: Enduro 205mm;Supermoto 210mm

- Damping force: turn all to closeposition (+) and then turn 20 clicksto open (-)

- Rebound: turn all to close position(H) and then turn 10 clicks to open(S)

! WARNING !

Improper servicing of the rear shockabsorber assembly is dangerous.The rear shock absorber containshigh-pressured gas and can explode

if improperly serviced.

ENGINE OILRECOMMENDATION

Use a premium quality 4-stroke motoroil to ensure longer service life of yourmotorcycle. Use only oils that meet orsurpass quality requirements of APIclasses SF or SG:

SAE 10W/40 or 15W/40 API SF or SG

Oil level

Engine oil level can be checked in theglass in front of rear brake pedal. Oillevel should be between the two lines inthe glass. If oil level is below the lowerline, refill immediately. If your engine islosing oil, contact an AJP dealerimmediately.

! WARNING !

Insufficient oil or poor quality oilresults in premature wear of theengine and may cause severedamages!




BREAK-IN (RUNNING-IN)

The following explains why is soimportant proper break-in to achievemaximum life and performance from

your new AJP.

Even very precisely machined sectionsof engine components have roughersurfaces than components that havebeen sliding across one another forquite some time; therefore, everyengine needs to be broken in during thefirst 1,000Kms.

For this reason, do not load enginemore than 50% of its capacity duringthe first 500 kilometres, avoiding full-throttle. In the following 500 kilometres,you may load the engine up to 75% ofits capacity, using the gearboxfrequently.

Allow sufficient idling time, about 1-2minutes, after warm or cold engine startup before applying load or revving theengine. This allows time for thelubricating oil to reach all critical enginecomponents.

Observe your first and most criticalservice. The 1000 Kms service is themost important service your AJP willreceive. All adjustments will berestored, all fasteners and spokes willbe tightened and dirty oil and oil filterwill be replaced.

! WARNING !

Incorrect break-in may cause severedamage to your motorcycle orsignificantly reduce your motorcyclelifetime!

INSPECTIONS BEFORERIDING

Check the following before eachstart

When you start off, the motorcycle mustbe in perfect mechanical condition. Forsafety reasons, you should make a

habit of performing an overall checkbefore each start.The following checks should beperformed:

1 – Oil level . Insufficient oil results inpremature wear in engine componentsand damages in engine itself.2 - Fuel. Check there is enough fuel inthe tank;3 - Drive chain . A loose chain can fallfrom the chain wheels; an extremelyworn chain can tear and insufficientlubrication can result in excessive wearto the chain and chain wheels.Excessive tensioning of the chain willput additional load on the components

of the secondary drive train (chain,bearings of transmission and rearwheel). Aside from resulting prematurewear, the chain may even rupture or thetransmission axle may break.4 - Tyres . Check for cuts or dents andreplace tyres if necessary. The treadmust also comply with legal regulations.Check air pressure; insufficient treadand incorrect air pressure deterioratedriving performance.5 - Brakes . Check correct functioning

of the braking system and brake fluidlevel in both reservoirs. The reservoirshave been designed in such a way thatbrake fluid does not need to be refilledeven when brake pads are worn. If thelevel of brake fluid falls below theminimum value, this indicates apossible leak or completely worn pads.Manage for the brake system to bechecked by an AJP dealer, as completefailure of the system can be avoided.Also check status of the brake hosesand the thickness of brake linings, aswell as free travel of hand brake leverand foot brake pedal.6 - Electric system . Check correctfunctioning of headlamps, taillights,brake lights, indicators, control lampsand horn while the engine is running.7 - Luggage . If you are taking anyluggage with you, check that it issecurely fastened.8 – Steering – Check for smoothness,no restriction on movement and no playor looseness.




9 – Throttle – Check for correct play,smooth operation and positive return tothe closed position.10 – Clutch – Check for correct play,smoothness and progressive action.11 – Suspensions – Checksuspensions for smooth movement.12 – Engine stop switch – Check forcorrect function.

! WARNING !

Failure to run these inspections andmaintain your motorcycle properlyincreases the chance of an accidentor equipment damageAlways perform a pre-ride inspection

before each ride. Refer to the listbehind for check items. For furtherdetails, refer to the INSPECTIONAND MAINTENANCE section.

! WARNING !

Checking maintenance items whenthe engine is running can behazardous. You could be severelyinjured if your hands or clothing getcaught in moving parts!

RIDING TIPS

Instructions for initial operation

- Verify if your AJP dealer performed aprevious preparation of the motorcycle.- Read this manual carefully before youride.- Familiarize yourself with all theoperating controls.- Get used to the handling of themotorcycle on an empty parking lot oropen space, before going for a longerride. Try also to drive as slow as

possible and in sitting position toimprove your feeling of the motorcycle.- Hold the handlebar with both handsand leave your feet on the footrestswhile driving. – Remove your foot from the brakepedal when you are not braking. If thebrake pedal is not released the brakepads will rub continuously and thebraking system will overheat.- Do not make any changes to themotorcycle and use always AJP originalspare parts for safety reasons.- Motorcycles are sensitive to changes

in the weight distribution. If you aretaking any luggage with you, secure itas close as possible to the middle of

the motorcycle, in order to distribute theweight for both wheels.

! WARNING !

- Wear suitable clothing whendriving a motorcycle. Never forget towear a helmet, gloves and boots,even in short trips. Protectiveclothing should be brightly colouredto make you more visible to otherdrivers.- Always turn on the lights to makesure that other drivers becomeaware of you as early as possible.- Do not drive after havingconsumed alcohol or drugs.- Use only original spare parts andaccessories.- Front and rear tires are allowed tobe fitted only with tires having thesame original profile type.

ENGINE START

1- Swing up the side stand and turnthe ignition key on.

2- Put the gear in neutral (the neutralpilot lamp will light up).

3- Check if the emergency switch ison running position.

4- Operate the electric start buttonwithout throttle opening.

! WARNING !

Using worn, improperly inflated orincorrect tires will reduce stabilityand can cause an accident.Follow all instructions in the TIRES

section.




operation-related noise while riding,stop immediately, shut the engineoff and contact an authorized AJPdealer.- Never start your motorcycle

without air filter in place, otherwisedust and dirt may enter to theengine and cause increased wearor damage.

BRAKING

Apply both brakes at the same timewith the throttle closed. When drivingon sandy, wet or slippery ground usemainly the rear brake. Avoid blockingthe wheels, otherwise you may skid orfall; also you can change down to alower gear depending on your speed.

! WARNING !

Hard braking on wet, loose, rough orother slippery surfaces can causewheel skid and loss of control.Brake lightly and with care onslippery or irregular surfaces.

Use the braking effect of the enginewhen driving downhill to assist thebrakes; change down one or two gearsbut do not over-speed the engine. Thisway, you will not need to use thebrakes so much and avoid overheating.

! WARNING !

Each time you brake, brake discs,pads, callipers and brake fluid heatup. The hotter these parts get, theweaker the braking effect; inextreme cases, the entire brakingsystem can fail!

! WARNING !

- In case of rain, after washing themotorcycle, after rides through waterand wet off-roads tracks, wet or dirtydisc brakes can delay the brakingeffect. Brakes must be thenactuated until disc brakes are dry orclean.- Dirty brake discs cause increasedwear of brake pads and discs.

! WARNING !

Hard braking while turning maycause wheel skid and loss ofcontrol.Brake before you begin to turn.

! WARNING !

Inexperienced riders tend to underuse front brake. This can causeexcessive stopping distance andlead to a collision. Using only frontor rear brake can cause skiddingand loss of control.Apply both brakes evenly and at the

same time.

STOPPING AND PARKING

Apply the brakes fully and put theengine into neutral. To turn off theengine, apply the emergency off buttonor turn the key to OFF position on theignition switch with the engine at idlingspeed until the engine stops. Park onan area where the ground is firm andlock the motorcycle .




! WARNING !

- Never leave your motorcyclewithout supervision if the engine isrunning or with children nearby.- Motorcycle engines produce agreat amount of heat when running.Engine, exhaust pipe, muffler, brakecallipers and shock absorber canbecome very hot. Do not touch anyof these parts after operating themotorcycle or allow children to comenearby.- Take care to park the motorcyclewhere pedestrians are not likely totouch it and get burned.

- Never park your motorcycle inplaces where there is fire hazards,such as dry grass or other easilyflammable materials.

! WARNING !

- Observe traffic regulations anddrive defensively, trying to lookahead as far as possible so that anyhazards can be recognized as earlyas possible.- Adjust your driving speedaccording to the conditions and yourdriving skills.- Drive carefully in unknown roads orunfamiliar trials.- When driving off-road, always havea friend on a second motorcycle tomake you company, so you can helpeach other if some problemhappens.

- Replace helmet visor or gogglelens when scratched or damaged. Ifbright light shines through ascratched, the driver will be blinded.- In case of a fall, check all functionsthoroughly before start operating themotorcycle.- Do not repair twisted handlebar:Replace it immediately.

Note regarding side stand:

Push the side stand to the ground withyour foot and load it with themotorcycle. Make sure that you put themotorcycle on solid ground and in asecure position. Just in case, you canshift into first gear.

! CAUTION !

Side stand was designed only forthe weight of the motorcycle. If youget on the motorcycle and thus putadditional weight, side stand orframe can be damaged and themotorcycle may fall on the side.




INSPECTION ANDMAINTENANCE

MAINTENANCE SCHEDULE

The chart indicates intervals betweenperiodic services in Kilometres. At theend of each interval, be sure to inspect,check, lubricate and service asinstructed. If your motorcycle is usedunder high stress conditions such ascontinuous full throttle operation or isoperated in a dusty climate, certainservices should be performed moreoften to insure reliability of motorcycleas explained in maintenance section.

Your AJP dealer can provide you withfurther guidelines.

Steering components, suspension andwheel components are key items andrequire very special and carefulservicing. For maximum safety wesuggest that you have these itemsinspected and serviced by yourauthorized AJP dealer.

! WARNING !Do not start the engine or allow it toidle in a closed area. Exhaust gasesare poisonous and can cause loss ofconsciousness and even death.Always provide adequate ventilationwhile the engine is running.

! WARNING !

It is owner’s responsibility to assurethat motorcycle is serviced withinthis periodic maintenance schedule.AJP does not assume any damageif maintenance is not performed asschedule.

! WARNING !

Improper maintenance or failureperforms of recommendedmaintenance increases the chanceof accident or motorcycle damage.

Always follow inspection andmaintenance recommendations andschedules in this owner’s manual.Ask your AJP dealer to do themaintenance items marked with anasterisk (*). You may perform theunmarked maintenance items byreferring to instructions in thissection, if you have mechanical

experience. If you are not sure howto do any of the jobs, have your AJPdealer to do them.

! CAUTION !

Using poor quality replacementparts or materials can cause yourmotorcycle to wear more quicklyand may shorten its useful life.Use only genuine AJP replacementparts.




MAINTENANCE SCHEDULE TABLE

Note: I = Check, C = Clean, L = Lubricate, A = Set/Adjust, R = Replace

(1) IT IS VERY IMPORTANT TO CHECK THE ENGINE OIL LEVEL DAILY AND TOADD IF NECESSARY(2) ENGINE OIL MUST BE CHANGED EVERY 2,000 KMS AND THE OIL FILTERCLEANED(3) CLEAN MORE FREQUENTLY IF THE MOTORCYCLE IS USED IN DUSTY, WETOR MUDDY CONDITIONS(4) REPLACE BRAKE FLUID EVERY 2 YEAR

1.000 3.000 5.000 7.000 9.000 11.000 13.000 15.000KMS KMS KMS KMS KMS KMS KMS KMSENGINE OIL LEVEL (1) CHECK DAILY ENGINE OIL (2) R R R R R R R ROIL FILTER (2) C C C C C C C COIL FILTER ROTOR C CFUEL HOSES I I I I I I I IFUEL FILTER R I R I R I R IAIR FILTER (3) I C I C I C I RCARBURETOR, IDLE SPEED SETTING I C/A I C/A I C/A I C/AACCELERATOR CABLE I A/L A/L A/L A/L A/L A/L A/L

SPARK PLUG I R I R I R IVALVE CLEARANCE I I A I A I A IDISTRIBUTION CHAIN I A I A I A RTRANSMISSION CHAIN CHECK, LUBRICATE EACH 500KMS BRAKE PADS I I I I I I I IBRAKE FLUID (4) I I I I I I I IWHEELS, SPOKES A I I I I I I ITIRES I I I I I I I ICLUTCH CABLE I A/L I A/L I A/L I A/LSIDE STAND I I I I I I I ISTEERING BEARINGS I I I I I L I I

FRONT SUSPENSION I I I I R I I IBOLTS, NUTS, CLAMPS I I I I I I I IBATTERY I I I I I I I IEXHAUST SYSTEM I I I I I I I IELECTRIC SYSTEM I C I C I C I CLIGHTS, HORN I I I I I I I I




MAINTENANCE WORK

! WARNING !

Improper maintenance or failureperforms of recommendedmaintenance increases the chanceof accident or motorcycle damage.Always follow inspection andmaintenance recommendations andschedules in this owner’s manual.Ask your AJP dealer to do themaintenance items marked with anasterisk (*). You may perform theunmarked maintenance items byreferring to instructions in this

section, if you have mechanicalexperience. If you are not sure howto do any of the jobs, have your AJPdealer to do them.

! CAUTION !

- When cleaning your motorcycle,do not use a high-pressurecleaning unit, otherwise water willpenetrate bearings, carburettor,electric connectors, etc.- When transporting your AJP,ensure that it is held upright withrestraining straps.- Use only special screws with anappropriate thread length suppliedby AJP to fix fuel tank. Using otherscrews or longer ones can causecracks in the tank through whichfuel can flow out.- Let your motorcycle cool downbefore beginning any maintenancework in order to avoid get burned.- Remove oil, grease matters,filters, fuel, washing detergents,etc, orderly.- Under no circumstances mayused oil be disposed off in thesewage system or in the opencountryside. Remember: 1 litre ofused oil contaminates 1.000.000

litres of water!

LUBRICATION POINTS

Proper lubrication is important forsmooth operation and long life of eachworking part of your motorcycle and

also for safe riding. It is a good practiceto lubricate the motorcycle after a longrough ride and after getting in snow,wet, mud or after washing it. Majorlubrication points are indicated.




Checking and adjusting thesteering head bearings (*)

Check steering head bearings for playperiodically. For check put motorcycleon a stand so that the front wheel is offthe ground. Try to move the forkforward and backward. For readjusting,loosen top nut (2) and the four bolts (1)(two for PRO versions) of the top tripleclamp and turn steering stem bolt (3)clockwise until there is no more play.Don’t 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 releasetension and retighten the bolts. Thentight top nut (2) and the top triple clampscrews (1).Steering head bearings should begreased at least once a year.

! WARNING !

If steering head bearings are notadjusted to be free of play or too

tight, the motorcycle will becomeunstable and can get out of control.

! CAUTION !

If you drive with play in the steeringhead bearings for long periods,bearings and subsequently bearingseats in the frame will bedestroyed.

Cleaning the dust sleeves ofthe telescopic fork

The dust protection gaskets (1) are toremove dust and coarse dirt particlesfrom the fork tube. However, after sometime, dirt may also get behind the dustprotection gasket. If this dirt is notremoved, the oil sealing rings locatedbehind it may start to leak.Use a screwdriver to lever the dust-protection bellows out of the outertubes and slide them downward.Clean dust-protection gaskets, outertubes and fork tubes thoroughly, and oilthem with silicone spray or engine oil;then push dust-protection gaskets intothe outer tubes by hand.




DRIVE CHAIN

Drive chain adjustment

The chain slack must be of 15-30mm,

at the mid point between the chainbuffer and the rear sprocket.

To adjust the drive chain, follow theprocedure bellow:

1 - Place the motorcycle on the sidestand2 - Loose axle nut (1)3 – Loose fixing nuts on both sides (2)4 – Regulate adjuster screws (3) untilthe chain has 15-30mm of slack. At thesame time that the chain is beingadjusted, the rear sprocket must bekept in perfect alignment with the frontsprocket. Align both right and leftadjusters to the same position.4 - Re-tighten the axle nut securely andtighten fixing nuts (2).5- Recheck the chain slack aftertightening, lubricate and adjust ifnecessary.

! WARNING !

- Excessive tensioning of the chainwill put additional load on thecomponents of the secondary drivechain (chain, bearings and rearwheel). Aside from resultingpremature wear, chain may ruptureor transmission countershaft maybreak.- On the other hand, too much slackin the chain can result in chain

jumping off the chain wheels. If thishappens, chain could also block rearwheel or damage the engine.- In either case, operator is likely to

loose control of the motorcycle.Drive chain maintenance

A good maintenance is very importantfor long chain life. Chains without o-rings should be cleaned in fireproofsolvent regularly and afterwards treatedwith hot grease or chain spray. On theother hand, o-ring chains are verysimple to clean. The best way is to uselots of water but never use brushes orcleaning liquids. After letting the chaindry completely, use a chain spray tolubricate it.Also check sprockets and chain guidesfor wear and replace if necessary.

! CAUTION !

When mounting chain master linkclip, the closed side of the masterlink must point in the runningdirection.

! WARNING !

No lubrication should be allowed toreach rear tyre or rear brake disc,otherwise road adherence and rear

wheel braking effects will bestrongly reduced and themotorcycle can easily get out ofcontrol.




BRAKES

Brake pads

Brake pads used on front and rear

brake provide an optimal combinationof power, brake performance andlifecycle.

Brake discs

Due to wear, the thickness of brakediscs in the area of the contact face (1)of the brake pads decreases. At their

thinnest point (A), the brake discs mustnot be more than 0.50mm thinner thanthe pads nominal thickness. Measurethe nominal thickness in a location (B)outside the contact face and check forwear in several locations.

! WARNING !

- For your own safety, have thebrake discs replaced immediatelyas soon as they reach wear limit (3

mm thickness).- Have any repairs on brake systemperformed by an AJP authorizeddealer.

Brake fluid reservoirs

Brake fluid reservoirs have beendesigned in such a way that even if thebrake pads are worn it is not necessaryto refill brake fluid. If brake fluid level

drops below the minimum level, eitherthe brake system has a leak or thebrake pads are completely worn.

In this case, consult an authorized AJPdealer immediately.

Brake fluid

AJP fills the brake systems with DOT 4brake fluid; we recommend that youcontinue to use it.

Checking the brake fluid level – frontbrake

Brake fluid reservoir is linked with thehand brake cylinder at the handlebarand the reservoir is provided with aninspection glass (1). With the reservoir

in horizontal position, the brake fluidlevel should not drop below the middleof the glass.

! WARNING !

If brake fluid level drops belowminimum either brake system has aleak or the brake pads arecompletely worn. In this case,consult an authorized AJP dealerimmediately.

! WARNING !

Change brake fluid at least onceeach two years. If you wash yourmotorcycle often, brake fluid shouldbe changed even more often (oncea year), as brake fluid tends toabsorb water. Therefore, vapourpockets may form on “old” brakefluids even at low temperatures,causing brake system to fail.




Refilling front brake fluid reservoir(*)

Loosen screws (1), remove lid (2) andmembrane (3). Place hand brakecylinder in a horizontal position and fillthe brake fluid reservoir up to the MAXmark with clean brake fluid DOT 4.Replace membrane, lid and tightenscrews. Clear off spilled or overflowingbrake fluid with water.

! WARNING !

- Store brake fluid out of reach ofchildren.- Brake fluid can cause skinirritation. Avoid contact with skinand eyes. If you get brake fluid inyour eyes, clear with plenty ofwater and consult a doctor.

! CAUTION !

- Don’t let brake fluid get in contact

with paint; it is an effective paintremover.- Use only clean brake fluid from asealed or hermetic closedcontainer.

Checking front brake pads

The front brake pads can be inspectedfrom below. The linings must have atleast 1 mm thickness.

! WARNING !

At their most worn point brake pad

linings should not be thinner than1mm, otherwise can lead to brakingfailure.

! WARNING !

If brake pads are replaced too lateso that the lining is partly or entirelyworn, steel components of brakepad will rub against brake disc,thereby reducing braking effect anddestroying brake disc.

Replacing front brake pads (*)

Remove calliper assembly,unscrewing screws (1). Press thebrake calliper away from brake discto put the brake piston in its basicposition. Remove clips and thebrake pads from the calliper.

Clean the brake calliper and callipersupport with compressed air. Check

1




the sleeves of the guide bolts fordamage and grease guide bolts ifnecessary.Mount both brake pads and theninsert 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 andfatty materials; otherwise brakingeffect will be strongly reduced.- Having performed any work onthe braking system, one mustalways actuate hand brake lever or

foot brake pedal, to ensure thatbrake pads will fit against brakedisc and pressure is established.

Changing the basic position of thebrake pedal (*)

Free play can be changed by turningpiston (1).Measured on the outside, the foot brakepedal must have 3 to 5 mm of free play,before the piston rod can move thepiston in the rear brake cylinder.

Checking rear brake fluid level

The reservoir for the rear disc brake isintegrated in brake pump, placed in theright side of the engine, near exhaustpipe.Brake fluid level must not drop belowthe “MIN” marking when the vehicle isin an upright position.

! CAUTION !

- If free play is not present, thenpressure can build up in the brakesystem when driving, causing rearwheel to brake. Brake system canoverheat and may even completelyfail in extreme cases.- Don’t ride with foot pressing rearbrake pedal.

Refilling the rear brake fluidreservoir (*)

Unscrew the cap (1), diaphragm and

add brake fluid DOT 4 until it reachesthe MAX mark, then place diaphragmand cap back on. Clear off spilled oroverflowing brake fluid with water.

Checking the rear brake pads (*)

The brake pads can be inspected fromthe rear. The thickness of the liningscannot be less than 1mm.

! WARNING !

If brake fluid level drops below theminimum or brake system has aleak or brake pads are completelyworn. In this case, consult anauthorized dealer immediately.




! W RNING !

At their most worn point brake padlinings should not be thinner than1mm, otherwise can lead to brakefailure.

! WARNING !

- Store brake fluid out of reach ofchildren.- Brake fluid can cause skinirritation. Avoid contact with skinand eyes. If you get brake fluid inyour eyes, clear with plenty ofwater and consult a doctor.

! WARNING !

If brake pads are replaced too lateso that the lining is partly or entirelyworn, steel components of brakepad will rub against brake disc,thereby reducing braking effect anddestroying brake disc.

! CAUTION !

- Don’t place brake fluid in contactwith paint; it is a powerful paintremover- Use only clean break fluid or froma sealed container

Replacing the rear brake pads (*)

Remove the rear wheel – see “REARWHEEL REMOVAL” and with ascrewdriver push the brake pads tomove the pistons into their basicposition. Remove clip (1) and thenremove brake pads from the calliper.Clean the brake calliper thoroughly withcompressed air, insert brake pads andsecure them with the clip. Then placerear wheel back on.

FRONT WHEEL REMOVAL

Dismounting and mounting frontwheel

To remove the front wheel, jack themotorcycle up on its frame so that thefront wheel no longer touches theground.

Loosen the four screws (1) on bothsides of front fork, unscrew nut (2),hold the wheel remove front axle (3).Remove front wheel carefully from thefork.

! CAUTION !

- Do not operate hand brake leverwhen front wheel has been

removed.




Front wheel mounting

Place front wheel between front forksleeves in a way that brake disc isbetween brake pads.Tight front axle or the fixation nut andtight fixation screws.Check if front wheel rotates freelywithout any restrain.

! WARNING !

- After mounting front wheel,operate hand brake lever untilpressure point is established.

- Keep brake discs free from oil andfatty materials, otherwise brakingeffect will be strongly reduced.

REAR WHEEL REMOVAL

Dismounting and mounting the rearwheel

Jack the motorcycle up on its frame sothat the rear wheel no longer touchesthe ground. Loosen the collar nut (1) inthe right side, hold the rear wheel andpull out the wheel spindle (2) by the leftside until the rear wheel is free but thebrake calliper support is still held in theswing arm.Push the rear wheel as far forward aspossible, take out the chain from therear sprocket and carefully remove thewheel carefuly from the swing arm.

To mount rear wheel, follow the aboveprocedure in reverse order, beingcareful to place the brake disc correctlybetween the brake pads. Make surethat rear wheel guides are touching rear

wheel adjusters (3) and that both havesame setting.

! CAUTION !

- Do not operate rear brake pedalwhen rear wheel has beenremoved.- Make sure brake disc is alwayson top when you lay down the

wheel, otherwise brake disc can bedamaged.- If axle is dismounted, clean thethread of the wheel spindle andapply a new coat of grease toprevent thread from jamming.

TIRES

Tires, air pressure

Tire type, its condition and air pressure,affect the way your motorcyclebehaves; therefore, they must bechecked whenever you are gettingready to go anywhere on yourmotorcycle.- Tire size can be found in the technicalspecifications and registrationdocuments.- Before leaving, check tires forpunctures and nails or other sharpobjects that might have become

embedded in them. Refer to specific

! WARNING !- After mounting rear wheel,operate brake pedal until pressurepoint is established.- Keep brake discs free from oil andfatty materials, otherwise brakingeffect will be strongly reduced.- Tighten the collar nut withrequired torque. A loose wheelspindle may lead to unstablebehaviour of your motorcycle.




regulations in your country for minimumtire tread requirements.- Tire pressure should be checkedregularly on a “cold” tyre. Properpressure ensures optimum drivingcomfort and extends the life of yourtyres.

Model PneuPressure

in bar(psi)

MXMX PRO Only driver Front 1.5(21)

Rear 1.5(21)

EnduroEnduro PRO

Only driver Front 1.5(21)Rear 1.75(25)

Driver +passenger

Front 1.5(21)

Rear 1.75(25)

SupermotoSupermoto

PRO

Only driverFront 1.75(25)Rear 2.0(28)

Driver +passenger

Front 1.75(25)

Rear 2.25(32)

These pressure values are indicated forroad use. For an off-road use on MXand Enduro versions, we recommend alower pressure, to assure traction. Inthese conditions, we recommend 1,0bar (14 psi) in both tires.Please consider that these are

indicative values and that correctpressure depends on the ground whereyou drive.

! WARNING !

- Do not mount tires that are notapproved by AJP. Other tires couldhave adverse effects on the wayyour motorcycle behaves.- Front and rear wheels may onlybe fitted with tires having samelayout. Use homologated tires.- For your own safety replacedamaged tires immediately.- Worn tires can have a negativeeffect on how your motorcycleperforms, especially on wetsurfaces.- If air pressure is too low,abnormal wear and overheating of

tire can result.

SPOKE TIGHTNESS

Checking spoke tension

Correct spoke tension is very importantfor the stability of the wheels and thusfor riding safety. A loose spoke causesthe wheel to become unbalanced andbefore long other spokes will havecome loose. Check spoke tension,especially on a new motorcycle, inregular intervals. If necessary, have thespokes retightened and the wheel tocorrect by an AJP dealer.

! WARNING !

Spokes can tear if you continue toride with them loose. This may leadto an unstable handling of yourmotorcycle.

BATTERY

Battery has a closed system andtherefore requires no maintenance. It isnot necessary to check the electrolytelevel or to refill water; simply keep thebattery poles clean and slightly greasedwith acid-free grease if necessary.To access battery, remove the frontright plastic cover.To remove the battery, first disconnectthe negative and then the positive poleof the battery and then unhitch rubber

band.When replacing, connect first thepositive and then the negative pole.When preparing the motorcycle for alonger period of standstill, remove thebattery and recharge it every month in aslow charge. Storage temperature: 0-35ºC. Do not expose it to direct sunradiation.

! CAUTION !

- Never reverse polarity, otherwisebattery and rectifier-regulator will




be destroyed- Never disconnect battery whileengine is running. This will destroythe rectifier-regulator.

! WARNING !

- If electrolyte (sulphuric acid) leaksfrom battery, proceed with greatcare. Electrolyte can cause severeburns.- In case of skin contact, clearthoroughly with water.- In case of contact with eyes,thoroughly apply them water for atleast 15 minutes and immediatelyconsult a doctor.

- Battery is a closed model but cannevertheless emit explosive gases.Avoid sparks and open fire nearthe battery- Defected batteries must be storedout of reach of children. Ensureproper disposal of discardedbatteries.

FUSE

The fuse is disposed underneath theseat. Having removed the seat you willbe able to see the fuse.

Replace a blown fuse only with anequivalent one. If a new fuse that has

just been set in gets blown again, youare strongly advised to have itinspected by an AJP dealer.The fuse capacity is 20/15 Ampere.Always carry an extra fuse in the fuseholder with you whenever you are ridingthe motorcycle.

! CAUTION !

- Under no circumstances is astronger fuse allowed to be set inor a fuse to be “repaired”. Aninexpert treatment could damagethe whole electrical installation.

LIGHT BULB REPLACEMENT

Replacing headlight lamp/parkinglight lamp

Loosen both rubber bands and tiltheadlight mask to the front. Pull theparking light lamp with holder carefullyout of the reflector. Pull connector offthe headlamp and remove rubber cap.Disengage retaining clip and take bulbout of the reflector.

When placing a new lamp, do not touchthe glass body of the lamp so it remains

free from fat. Engage retaining clip andmount rubber cap and connector.Reinsert parking light lamp togetherwith holder and fix the mask by meansof the rubber bands.Use only 12V25/35W BA20d lamps.

Note: rear light is a set of LEDs anddoes not allow for replacing, becausethey are unchangeable. In the event ofa presence or stop light failure, it isnecessary to replace all the rear spoilerassembly.




AIR FILTER

Cleaning air-filter (*)

A dirty air filter restricts airflow rate,reduces the engine performance andincreases fuel consumption, thereforeclean it in regular intervals.

For this purpose, remove drivers seat,by unscrewing to screw (1) inside therear fender and pull it in to reardirection. Then remove air filter’s coverby unscrewing fixation screw (2).

Thoroughly wash the air-filter in specialcleaning fluid and allow it to dry well. Oilthe dry air filter with high-grade filter oiland clean the air filter box.For extra security, apply grease on theback side of the filter, which mates withair filter box.Mount the filter together with the filterbracket and fix them with the rubberwasher and the screw.

! WARNING !

- Do not clean air-filter with fuel orpetroleum since these will damagethe foam.- Never start your motorcyclewithout air filter, otherwise dust ordirt may penetrate in the engineand cause damage or severe wear.

THROTTLE CABLE

Adjusting throttle cable (*)

The throttle grip should always providefor a backlash of 2-6mm, measured inthe adjusting screw outside the throttlegrip. Besides, with the engine running,the idling speed must not change if youturn the handlebar all the way to the leftor right.To adjust throttle cable, draw back dustprotection, loosen the counter nut (1)and turn the adjusting screwaccordingly (2). Tighten the counter nut

and check whether the throttle grip canbe actuated




smoothly

.

ENGINE OIL

Checking engine oil level

Place the motorcycle in an uprightposition and on a horizontal surface.The engine oil level can be checkedthrough the oil glass level. If the engineis warm, the oil level should be near theMAX mark.

! CAUTION !

-If oil level drops quickly, do notoperate your motorcycle. Take yourmotorcycle to an authorized AJPdealer immediately, to a full checkof engine.

Engine oil quality

Use only branded oils for four strokeengines, meeting or surpassing thequality requirements of API classes SFor SG:

SAE 10W40/15W40 API-SF or SG

Capacity:o 1,4 litre

! WARNING !

- Insufficient engine oil or poorquality may cause severe damageto the engine.- Never operate your motorcyclewith low engine oil level or withnon-adequate engine oil quality.

! CAUTION !

- Engine oil level should bechecked daily or before anyride.

- If necessary you should add oilto keep always oil level betweenmaximum H mark and lower Lmark.

! WARNING !

- On PR5 250, if any oil pipe or oilradiator is damaged and present

leak, engine should be immediatelystopped.- Otherwise serious damages inengine will happen due to lack of oilin lubricating circuit.

Changing engine oil (*)

Engine oil has to be changed with theengine being at operating temperature.

Place the motorcycle on a horizontalsurface, remove the plug and allow theoil to drain into a receptacle. Neverdrain used oil to the ground, waste,water lines or sewage.

Take out the oil drain together with oilfilter, clean these components carefullyand blow with compressed air. Checko-ring and sealing and replace them ifnecessary.

Once the entire oil has been drained,clean the sealing surface, mount the oildrain together with spring, oil filter andsealing on the right position and tightenup to 15Nm (1,5 Kg.m).

! CAUTION !- An engine at operatingtemperature and engine oil itcontains are very hot. Please takeall cares to avoid burning yourself.




Screw aluminium drain carefully toavoid damaging carter’s thread.

Remove the oil cover (1) and fill in 1,4litres of the recommended engine oiltype.

Start the engine and check for leaks.

Finally, check the engine oil level and, ifnecessary, correct it.

EXAUST SYSTEM

Requires regular maintenance, the

more frequent and severe is the ridingof your motorcycle. The silencer fibre inis interior should be replaced each3.000 Km or 50 hours of use. If not,noise level will reach illegal anddisturbing levels.

MOTORCYCLE CLEANING

Clean your motorcycle oftenly in orderto maintain the beauty of its plasticsurfaces and avoid corrosion. The bestmanner would be to use warm waterthat has been mixed with a normalbrand-name washing detergent and asponge. The hard dirt can be removedbefore washing with the help of a softwater jet.

! CAUTION !

- Never clean your motorcycle withan high-pressured cleaner or anhigh-pressured water jet. Watercould run into electricalcomponents, connectors, cables,bearings, carburettor, etc, cancause operations mal-functions orlead to premature destruction ofthese parts.

- Use regular brand-name detergents to

clean the motorcycle. Especially dirtyparts should be cleaned additionallywith the help of a paintbrush.- Before cleaning with water, plug theexhaust pipe to prevent water goinginside.- After the motorcycle has been cleanedwith a soft water jet, it should be driedwith air pressure and a cloth. Take ashort drive until the engine has reachedthe working temperature and also usethe brakes. By warming thesecomponents, the residual water can




evaporate from inaccessible parts ofengine and brakes.- Once the motorcycle has cooleddown, oil or grease all sliding andbearing points; lubricate chain withchain spray.- To avoid any malfunction of theelectric system, you should treatemergency off button, light switch andsocket connectors with a contact spray.

CONSERVATION FORWINTER OPERATION

In the event that the motorcycle is alsoused in winter and on roads where onehas to expect salt spraying, you willhave to take precautions against theaggressive road salt.

- Clean motorcycle thoroughly and let itdry after each riding.- Treat engine, carburettor, swing armand all other bare galvanized parts(except for brake discs) with a wax-based anti-corrosion agent.

STORAGE PROCEDURES

Should you desire to make a pauseover a long period of time (more thanone month), please observe thefollowing instructions:

- Clean the motorcycle thoroughly (see

CLEANING).- Change engine oil and oil filter.- Remove spark plug and fill in approx.5ccm of engine oil into the cylinderthrough the opening. Actuate enginestart button in order to distribute the oilinto the cylinder walls and mount thespark plug.- Remove the fuel into an appropriatecontainer.- 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 (seeBATTERY)- Storage place should be dry and notsubject to excessive temperaturefluctuations. – Cover the motorcyclewith a blanket. Do not use airimpermeable materials as a possiblehumidity might not be able to escapeand could cause corrosion.

! CAUTION !

- Don’t let engine run for a shorttime period. Engine would not getwarmed enough and developedwater vapour would condensatewhen cooling, causing valve andexhaust corrosion

RE-INITIATION AFTER STORAGE:- Mount the charged battery (checkpolarity).- Fill up the tank with fresh fuel.- Check motorcycle as before each start(see DRIVING INSTRUCTIONS)- Take a short, careful test ride first andcheck all of your motorcycle systems.



TECHNICAL SPECIFICATIONS

Engine PR5 250Type 1 Cylinder, 4 strokes, SOHC, 4 ValvesDisplacement 249 cm 3 Bore x stroke 73 x 59,5 mmCooling Air + oil coolerPower 18,4KW (25 cv) / 8500 r.p.m.Torque 17,0 N.m / 7000 r.p.m.Carburettor Delphi Electronic Fuel Injection 34 mmStart ElectricGearbox 6 speeds

Frame Aluminium double beam + steel double cradle

Front fork ZF Sachs USD 48 mm - 300 mm stroke

Rear suspension ZF Sachs 300 mm stroke - Progressive system

Front brake Disc 260 mm, double piston calliperRear brake Disc 240 mm, simple piston calliperSeat height 940 mmWheel base 1460 mmWeight 115 KgFuel tank 7,5 litres

Engine oil SAE 15W-40 API –SE, SF or SGEngine oil volume 1,4 litresSpark plug LG D8TC (Champion A8YC or NGK DR8ES)Battery YTZ7S (12V 6Ah)Fuse 20ARoad/high beamlight

12V35/35W BA20d

Presence light 12V 5WBA 9SRear light LEDsBlinkers lght 12V10W BA 15SAxle gear 13 teethWheel gear 48 teethChain 520H / 112L

Tires ENDURO SUPERMOTOFront tire 90/90 – 21” 100/80 - 17Rear tire 120/80 – 18“ 130/70 - 17

ajp motos - pr5 user manual

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