Professional Documents
Culture Documents
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.
! WARNING !
IGNORING THESE INSTRUCTIONS CAN ENDANGER YOUR
BODY AND YOUR LIFE, AS WELL AS OTHER PEOPLE`S LIFES.
! CAUTION !
IGNORING THESE INSTRUCTIONS COULD CAUSE DAMAGE TO
PARTS OF YOUR MOTORCYCLE OR THAT THE MOTORCYCLE
IS NO LONGER SAFE TO RIDE ANYMORE.
i
TABLE OF CONTENTS
CONSUMER INFORMATION 1
COMPONENTS LOCATION 3
CONTROLS LOCATION 4
CONTROLS 4
KEYS 4
IGNITION SWITCH 4
DIGITAL SPEEDOMETER 5
LEFT HANDLEBAR 5
RIGHT HANDLEBAR 6
FUEL 6
FUEL TANK CAP 6
CHOKE KNOB 7
KICK STARTER LEVER 7
GEARSHIFT LEVER 7
REAR BRAKE PEDAL 7
SIDE STAND 8
SUSPENSION SET-UP 8
ENGINE OIL RECOMMENDATION 9
BREAK-IN (RUNNING-IN) 9
INSPECTIONS BEFORE RIDING 9
RIDING TIPS 11
ENGINE START 11
STARTING OFF 12
USING THE GEARBOX 12
BRAKING 13
STOPPING AND PARKING 13
INSPECTION AND MAINTENANCE 15
MAINTENANCE SCHEDULE 15
MAINTENANCE SCHEDULE TABLE 16
MAINTENANCE WORK 17
LUBRICATION POINTS 17
DRIVE CHAIN 18
BRAKES 19
FRONT WHEEL REMOVAL 23
REAR WHEEL REMOVAL 24
TIRES 24
SPOKE TIGHTNESS 25
BATTERY 25
FUSE 26
LIGHT BULB REPLACEMENT 26
AIR FILTER 26
FUEL FILTER 27
THROTTLE CABLE 27
IDLING 27
ENGINE OIL 27
MOTORCYCLE CLEANING 28
CONSERVATION FOR WINTER OPERATION 29
STORAGE PROCEDURES 29
TECHNICAL SPECIFICATIONS 30
ii
CONSUMER INFORMATION SAFE RIDING RECOMMENDATIONS
FOR MOTORCYCLE RIDERS:
ACCESSORY INSTALLATION AND
PRECAUTION SAFETY TIPS WEAR A HELMET
Motorcycle safety equipments starts
There is some variety of accessories for with a quality helmet. One of the most
AJP motorcycles. AJP cannot have serious injuries that can happen is a
direct control over the quality or head injury. ALWAYS wear a properly
suitability of accessories you may want approved helmet.
to purchase. The addition of unsuitable You should also wear suitable eye
accessories can lead to unsafe protection.
operating conditions. Please contact
your AJP dealer for assist you in RIDING APPAREL
selecting accessories and install them Loose, fancy clothing can be
correctly. uncomfortable and unsafe for
motorcycle riding. Choose good quality
motorcycle riding apparel when riding
! WARNING ! your motorcycle. Wear gloves, strong
Improper accessories or boots that fit over the ankle, long pants
modifications can make your and long sleeve shirt or jacket.
motorcycle unsafe and can lead to
an accident. Never modify the INSPECTION BEFORE RIDING
motorcycle with improper or poorly Review all the instructions in the
“INSPECTION BEFORE RIDING”
installed accessories. Follow all
section in this manual. Do not forget to
instructions in this owner’s manual perform an entire safety inspection to
regarding accessories and ensure safety of the rider.
modifications. Consult your AJP
dealer if you have any questions. FAMILIARIZE YOURSELF WITH THE
MOTORCYCLE
Certain accessories displace the rider Your riding skill and your mechanical
from his normal position. This limits the knowledge form the basis for safe
freedom of movement and may limit his riding. We recommend you to practice
control ability. riding your motorcycle in an open area
without obstacles until you are
Additional electric accessories may familiarize with your motorcycle and its
overload the electric system. Severe controls.
overloads may damage the wiring
harness or create a dangerous situation KNOW YOUR LIMITS
due to the loss of electric power during Always ride within the limits of your
the operation of the motorcycle. skills. Knowing your limits and keep
within are the foundation to avoid
When carrying a load on the accidents and injuries.
motorcycle, mount it as low as possible
to the machine. An improperly mounted BE EXTRA SAFETY CONSCIOUS ON
load can create a high center of gravity BAD WEATHER DAYS OR BAD
that is very dangerous and makes the ROAD CONDITIONS
motorcycle difficult to handle. The size Riding on bad weather days requires
of the load can also affect the extra attention. Braking distances
aerodynamics and handling of the double in a rainy day. If you are not
motorcycle. Balance the load between sure about road conditions ride slower
the left and right sides of the motorcycle and with double care!
and fasten it securely.
Chassis number
Chassis
number
Engine number
Engine
number
3
2
5
9
7
8
1 6
10
11
12
13 14
! CAUTION !
CONTROLS Don’t try to ride with the switch on
LOCK position. The steering is
KEYS locked and control of the motorcycle
This motorcycle comes with a pair of is impossible.
keys. Be aware to keep one of the keys Don’t turn the ignition key to LOCK
in a safe place, at home for instance, in position while driving!
order to let you access this key in case .
of need.
Note: Start engine as soon as you turn
IGNITION SWITCH key to ON position. Otherwise battery
will loose power due to the
consumption of the digital speedometer
and headlight and taillight, if turned on.
OFF ON
LOCK
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.
1
5 – High beam on
In this position, high beam light will be
The digital speedometer is not available
on in the headlight and presence light
for the MX and MX PRO versions.
will be on in the taillight.
It gives information about instantaneous
speed and total or trip distance
6 – Turn sign on
travelled. Depending on the selling
Turning this button left left turn lights
market, speed and distance are
will be on. Turning right, right turn lights
indicated in Kilometres or miles. If you
will be on. To switch turn lights off,
want to switch between these units,
place the button in middle position.
please contact your AJP dealer.
To switch from total to trip distance
7 – Horn
push button 1. To reset trip distance the
To actuate horn, press this button.
trip distance must be selected; then
push button 1 until the distance is reset
to zero. ! CAUTION !
In several countries, motorcycle
LEFT HANDLEBAR riding is only allowed with low beam
on! Respect your national
legislation!
5 ! CAUTION !
1 4
3 Turn lights are not switched off
2 automatically! Be aware to switch
turn lights off after turning or
overtaking! Otherwise you will give
wrong information about your riding
to other drivers!
6 7
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.
! WARNING !
Using not recommend fuel can
4 1 cause severe damages on engine!
Be sure to use only unleaded
1 – Throttle grip gasoline with an octane index equal
Engine speed is controlled by the or higher than 95!
position of the throttle grip. Rotate it
toward you to increase engine speed;
turn it away to decrease engine speed. FUEL TANK CAP
PR4 125 and 200 carburettor is PR4 125 and 200 have a 5-speed
equipped with a choke system to transmission. Shift lever is mounted on
provide easy starting when the engine the left side of the engine. The position
is cold. When the engine is cold, pull of the gears is shown in the illustration.
the lever up; it has two positions: the Neutral is located between first and
first (1) is for when engine temperature second gear.
is more than 20º; the second (2) is for
when engine temperature is below 20º.
Choke works best when throttle is on
closed position. When the engine is
warm- above 40º- you do not need to
use choke for starting (0).
2
1 To shift properly, pull the clutch lever
and close he throttle at the same time
0 you operate gearshift lever. Lift the
lever to up-shift and depress to
downshift.
! WARNING !
If you want to start engine, make
sure you always wear rigid footwear,
like motorcycle boots, in order to
avoid injuries. You might slip of the
kick-starter or engine may kick back
and hit your leg very strongly!
Always kick kick-starter briskly all
the way without opening the throttle;
if you don’t do it with enough
momentum and with throttle open,
kick back hazard will increase!
1
2
! CAUTION !
The side stand was designed only
for the weight of the motorcycle. If
you get on the motorcycle and thus
To adjust pre-charge loose first the
put additional weight, the side stand
upper nut (1), then turn adjusting nut (2)
or frame can be damaged and the clockwise for more pre-charge or
motorcycle may fall on the side! counter clockwise for less pre-charge.
! CAUTION !
Park the motorcycle on solid level
ground to help prevent it from falling ! WARNING !
over. Improper servicing of the rear shock
If you must park on an incline, aim absorber assembly is dangerous.
the front of the motorcycle uphill and The rear shock absorber contains
put the transmission into 1st gear to high-pressured gas and can explode
reduce the chance of rolling off the if improperly serviced.
side stand.
INSPECTIONS BEFORE
RIDING
! WARNING !
Insufficient oil or poor quality oil Check the following before each
results in premature wear of the start
engine and may cause severe
damages! When you start off, the motorcycle must
be in perfect mechanical condition. For
safety reasons, you should make a
BREAK-IN (RUNNING-IN) habit of performing an overall check
before each start.
The following explains why is so The following checks should be
important proper break-in to achieve performed:
maximum life and performance from
your new AJP. 1 – Oil level. Insufficient oil results in
premature wear in engine components
Even very precisely machined sections and damages in engine itself.
of engine components have rougher 2 - Fuel. Check there is sufficient fuel in
surfaces than components that have the tank;
! WARNING !
Starting when the engine is cold
- Wear suitable clothing when 1- Swing up the side stand and turn
driving a motorcycle. Never forget to the ignition key on.
wear a helmet, gloves and boots, 2- Put the gear in neutral (the neutral
even in short trips. Protective pilot lamp will light up).
clothing should be brightly coloured 3- Operate the choke lever all the way
to make you more visible to other up.
drivers. 4- Check if the emergency switch is
on running position.
- Always turn on the lights to make
5- Operate the electric start button or
sure that other drivers become kick the kick-starter briskly all the
aware of you as early as possible. way without touching the throttle.
- Do not drive after having
consumed alcohol or drugs.
- Use only original spare parts and ! CAUTION !
accessories. Never actuate electric starter for
- Front and rear tires are allowed to more than 5 seconds and with
be fitted only with tires having the lights on. Wait at least 5 seconds
same original profile type. before trying again.
BRAKING ! WARNING !
Inexperienced riders tend to under
Apply both brakes at the same time use front brake. This can cause
with the throttle closed. When driving excessive stopping distance and
on sandy, wet or slippery ground use lead to a collision. Using only front
mainly the rear brake. Avoid blocking or rear brake can cause skidding
the wheels, otherwise you may skid or and loss of control.
fall; also you can change down to a
Apply both brakes evenly and at the
lower gear depending on your speed.
same time.
! WARNING !
Hard braking on wet, loose, rough or STOPPING AND PARKING
other slippery surfaces can cause
wheel skid and loss of control. Apply the brakes fully and put the
Brake lightly and with care on engine into neutral. To turn off the
slippery or irregular surfaces. engine, apply the emergency off button
or turn the key to OFF position on the
Use the braking effect of the engine ignition switch with the engine at idling
when driving downhill to assist the speed until the engine stops. Park on
brakes; change down one or two gears an area where the ground is firm and
but do not over-speed the engine. This lock the motorcycle.
way, you will not need to use the
brakes so much and avoid overheating.
! 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 goggle
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.
! 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.
(1) IT IS VERY IMPORTANT TO CHECK THE ENGINE OIL LEVEL DAILY AND TO
ADD IF NECESSARY
(2) ENGINE OIL MUST BE CHANGED EVERY 2,000 KMS AND THE OIL FILTER
CLEANED
(3) CLEAN MORE FREQUENTLY IF THE MOTORCYCLE IS USED IN DUSTY, WET
OR MUDDY CONDITIONS
(4) REPLACE BRAKE FLUID EVERY 2 YEAR
! CAUTION !
- 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 supplied
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!
! CAUTION !
If you drive with play in the steering
head bearings for long periods,
bearings and subsequently bearing
seats in the frame will be
destroyed. To adjust the drive chain, follow the
procedure bellow:
! WARNING !
- For your own safety, have the
brake discs replaced immediately
as soon as they reach wear limit (3 1
mm thickness).
- Have any repairs on brake system
performed by an AJP authorized
dealer.
! WARNING !
Brake fluid reservoirs If brake fluid level drops below
minimum either brake system has a
Brake fluid reservoirs have been leak or the brake pads are
designed in such a way that even if the
completely worn. In this case,
brake pads are worn it is not necessary
to refill brake fluid. If brake fluid level consult an authorized AJP dealer
drops below the minimum level, either immediately.
the brake system has a leak or the
brake pads are completely worn.
In this case, consult an authorized AJP
dealer immediately.
Brake fluid
! WARNING !
At their most worn point brake pad
linings should not be thinner than
1mm, otherwise can lead to braking
failure.
Loosen screws (1), remove lid (2) and
membrane (3). Place hand brake ! WARNING !
cylinder in a horizontal position and fill
the brake fluid reservoir up to the MAX If brake pads are replaced too late
mark with clean brake fluid DOT 4. so that the lining is partly or entirely
Replace membrane, lid and tighten worn, steel components of brake
screws. Clear off spilled or overflowing pad will rub against brake disc,
brake fluid with water. thereby reducing braking effect and
destroying brake disc.
! WARNING !
Replacing front brake pads (*)
- Store brake fluid out of reach of
children. Remove calliper assembly,
- Brake fluid can cause skin unscrewing screws (1). Press the
irritation. Avoid contact with skin brake calliper away from brake disc
and eyes. If you get brake fluid in to put the brake piston in its basic
your eyes, clear with plenty of position. Remove clips and the
water and consult a doctor. brake pads from the calliper.
! CAUTION !
- Don’t let brake fluid get in contact
with paint; it is an effective paint
remover.
- Use only clean brake fluid from a 1
sealed or hermetic closed
container.
Checking front brake pads Clean the brake calliper and calliper
support with compressed air. Check
The front brake pads can be inspected the sleeves of the guide bolts for
from below (1). The linings must have damage and grease guide bolts if
at least 1 mm thickness. 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.
Changing the basic position of the Unscrew the cap (1), diaphragm and
brake pedal (*) 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.
1
Free play can be changed by turning
piston (1).
Measured on the outside, the foot brake
pedal must have 3 to 5 mm of free play, Checking the rear brake pads (*)
before the piston rod can move the
piston in the rear brake cylinder. The brake pads can be inspected from
the rear. The thickness of the linings
Checking rear brake fluid level cannot be less than 1mm.
2 1 3
! CAUTION !
- Do not operate hand brake lever
when front wheel has been
removed.
1 1
2 Front wheel mounting
TIRES
FUSE
Replace a blown fuse only with an Note: rear light is a set of LEDs and
equivalent one. If a new fuse that has does not allow for replacing, because
just been set in gets blown again, you they are unchangeable. In the event of
are strongly advised to have it a presence or stop light failure, it is
inspected by an AJP dealer. necessary to replace all the rear spoiler
The fuse capacity is 20/15 Ampere. assembly.
Always carry an extra fuse in the fuse
holder with you whenever you are riding AIR FILTER
the motorcycle.
Cleaning air-filter (*)
FUEL FILTER
! CAUTION !
Engine oil level should be checked
daily or before any ride. If necessary
you should add oil to keep always oil 1
level between maximum H mark and
lower L mark.
MOTORCYCLE CLEANING
! WARNING !
On PR4 200, if any oil pipe or oil Clean your motorcycle regularly in
radiator is damaged and present leak, order to maintain the beauty of its
engine should be immediately stopped. plastic surfaces and avoid corrosion.
Otherwise serious damages in engine The best manner would be to use warm
will happen due to lack of oil in water that has been mixed with a
lubricating circuit. normal brand-name washing detergent