AJP PR4 125 / 200 / 240 ENDURO / ENDURO PRO / SUPERMOTO / SUPERMOTO PRO / EXTREME 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.
! 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: ! WARNING ! IGNORING THESE INSTRUCTIONS CAN ENDANGER YOUR BODY AND YOUR LIFE, AS WELL AS OTHER PEOPLE`S LIFES.
TABLE OF CONTENTS USER INFORMATION COMPONENTS LOCATION CONTROLS LOCATION CONTROLS KEYS IGNITION SWITCH/STEER LOCK DIGITAL SPEEDOMETER LEFT HANDLEBAR RIGHT HANDLEBAR FUEL FUEL TANK CAP FUEL TANK CHOKE KNOB KICK STARTER PEDAL GEARSHIFT LEVER REAR BRAKE PEDAL SIDE STAND SUSPENSION SET-UP ENGINE OIL BREAK-IN (RUNNING-IN) INSPECTIONS BEFORE RIDING RIDING TIPS ENGINE START STARTING OFF USING THE GEARBOX BRAKING STOPPING AND PARKING MAINTENANCE SERVICE MAINTENANCE SCHEDULE LUBRICATION POINTS CHECKING AND ADJUSTI
USER INFORMATION ACCESSORY INSTALLATION AND PRECAUTION SAFETY TIPS There is some variety of accessories for AJP motorcycles. AJP cannot have direct control over the quality or suitability of accessories you may want to 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.
MODIFICATION Modification of the motorcycle or removal of original equipment may render the vehicle unsafe or illegal. 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.
COMPONENTS LOCATION 15 2 3 4 5 1 1 2 3 4 5 6 7 8 9 Rear brake fluid reservoir Air filter Fuse Battery Spark plug Oil dipstick Kick-starter Rear brake pedal Oil level glass AJP PR4 User’s manual - 3rd Edition 6 7 8 9 10 11 12 13 14 15 16 Fuel tank cap Fuel tank Gearshift lever Foot-rest Side rest Fuel filter Oil filter Page 3
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. CONTROLS LOCATION 11 11 OFF position - all electrical circuits are cut off and the engine will not start. The key can be removed.
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. 7 – Horn To actuate horn, press this button.
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.
When the engine is warm - above 40ºyou do not need to use choke for starting (0). 5 4 3 2 N 2 1 1 0 KICK STARTER PEDAL To shift properly, pull the clutch lever and close he throttle at the same time you operate gearshift lever. Lift the lever to up-shift and depress to downshift. AJP PR4 are equipped with a kick-start lever, just in case electric start fails. REAR BRAKE PEDAL The kick-starter lever is mounted on the right side of the engine and its upper part can be swivelled.
have a harder response. Turn counter clockwise to have a softer response. To adjust rebound turn the screw (2) on the right leg clockwise to have a harder response. Turn counter clockwise to have a softer response. ! WARNING ! Always check if you have folded back the side stand before each ride.
Enduro and Supermoto: 1 These versions are equipped with a shock absorber which only allows spring pre-load adjustment. 2 To adjust middle speed, turn adjusting nut (2). To adjust rebound, turn the lower screw clockwise (3) for more rebound; turn counter clockwise for less rebound. 2 1 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. Tighten upper nut (1).
Compression: To adjust damping force, turn the button placed on the top of the gas reservoir (3) clockwise for more damping force or counter clockwise for less damping force. 3 ! WARNING ! Improper servicing of the rear shock absorber assembly is dangerous. The rear shock absorber contains high-pressured gas and can explode if improperly serviced. ENGINE OIL Recommendation Use only branded oil for four stroke engines, to ensure a long engine life.
! 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 nonadequate engine oil quality. BREAK-IN (RUNNING-IN) The following explains why is so important proper break-in to achieve maximum life and performance from your new AJP.
! 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. Manage for the brake system to be checked by an AJP dealer, as complete failure of the system can be avoided.
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 possible and in sitting position to improve your feeling of the motorcycle.
! WARNING ! - If you want to start the engine with kick start pedal, make sure you always put on rigid motorcycle boots in order to avoid injuries. You might slip off the kick-starter or the engine may kick back and hit your foot upward 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 the throttle open, kick back hazard will increase. - Do not start the engine or allow it to idle in a closed area.
! 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 control. Apply both brakes evenly and at the same time. 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.
require very special and careful servicing. For maximum safety we suggest that you have these items inspected and serviced by 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.
MAINTENANCE SCHEDULE A description of several necessary operations to a correct functioning of motorcycle and periods is as follows. DAILY Check engine oil level and refill if necessary. Check clearance of secondary chain. Check brake system functioning. AFTER FIRST 1.000 km – BREAK IN Replace spark plug; Replace engine oil; Clean engine oil filter; Check engine oil level; Clean air filter.
LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each working part of your motorcycle and also for safe riding. It is a good practice to lubricate the motorcycle after a long rough ride and after getting in snow, wet, mud or after washing it. Major lubrication points are indicated. ! WARNING ! Lubricant cannot spill over brake disk or tires, otherwise grip and braking capacity are considerably reduced and rider may lose motorcycle control.
! 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. 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. 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.
Drive chain maintenance 4 5 - Re-tighten the axle nut (5) securely and tighten fixing nuts (6). A good maintenance is very important for long chain life. Chains without orings 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.
Recommended brake fluid: ENI Brake Fluid DOT 4 (SAE J1703, FMVSS116) ! WARNING ! 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.
Refilling front brake fluid reservoir Loosen screws (1), remove cover (2) and membrane. 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. 1 ! WARNING ! Replace membrane, lid and tighten screws. Clear off spilled or overflowing brake fluid with water. ! CAUTION ! 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.
! 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. Clean the brake calliper and calliper support with compressed air. Check the sleeves of the guide bolts for damage and grease guide bolts if necessary.
! WARNING ! ! 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. 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.
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 ground. Note: Threaded spacer (3) must not be untighten neither removed from right leg end, once this is the part that positions front wheel on the front fork (Marzocchi 48mm) of PR4 EXTREME. If it is necessary to remove it, measure its position away of leg’s end and note it. This way, when placing it back, it must be with the same distance.
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.
These pressure values are indicated for road use. For an off-road use on Enduro and EXTREME 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.
Note: Do not forget that AJP PR4 uses only unleaded fuel, 95 octane minimum. Never use leaded fuel otherwise it will destroy catalytic converter. If necessary, perform glass replacement in an AJP dealer. fibre ! CAUTION ! Before proceeding with motorcycle cleaning, certify that engine is cold, otherwise thermal gradient may cause cracks. ! WARNING ! ! WARNING ! The use of non recommended fuel may cause serious damages in the engine.
burning yourself. Place the motorcycle on a horizontal surface, remove the oil filter cover (that works as drain plug) and allow the oil to drain into a receptacle. Never drain used oil to the ground, waste, water lines or sewage. Max Min If oil level is below Min, oil must be refilled immediately. If you check that engine is losing oil (for instance at oil radiator or oil tubes in 200/240 cc engines), contact your AJP dealer immediately.
! CAUTION ! When removing oil dipstick, be careful not to let any dirt enter the engine. 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. Use an adequate filler to introduce oil in the engine. 2 Tighten plastic dipstick. Start the engine and check for leaks. Finally, check the engine oil level and, if necessary, correct it. Remove metallic support inside air filter foam element.
1 1 Mount the filter together with the filter bracket and fix them with the rubber washer and the screw. ! WARNING ! Do not clean air-filter with fuel or petroleum since these will damage the foam. Never use fuel or diluent to clean air filter box, to avoid damage sealing silicon between box and cover. Keep air filter clean and lubricated (wet in oil) to assure a more effective protection of engine cylinder.
IDLE Idle speed: 1300 (+/-100) rpm Adjust idling Idling adjustment of the carburettor strongly affects the engine starting behaviour, that is, an engine whose idling speed is adjusted correctly will be easier to start. Adjustment: Smaller adjustment are made at lever tuner. 1 Pull rubber protection out; Untight fixation nut and rotate tuner; When free play is right, tight fixation nut and place rubber protection over tuner. The idle sped is controlled by means of the mixture control screw (1).
1 Note: in case of clutch cable replacement, certify that new cable is placed at the right position. If that does not happen, it may interfere with front fender, block handlebar/steering movement and cause an accident. By technical reasons we highly recommend that clutch cable replacement should be done only at a AJP dealer. Inspect visually spark plug.
Reusing a spark plug Clean spark plug electrodes with a wire brush or special plug cleaner. Replacing a spark plug Select a new spark plug; Set plug cap to specification with a feeler gauge. Assembly Place a spark plug and tight as far as possible by hand; If installing a new spark plug, turn a ½ further after washer mates surface. If it’s a old one, turn ¼ further. If it is possible to use a dynamometric key, torque to specification. Torque: 12 N.m (1,2 Kgf.
! WARNING ! - PR5 battery is sealed, it is not necessary to check electrolyte level therefore its covers must remain inviolate.
To recharge PR4 YTX5L-BS battery, use a appropriate 12V charger. Connect first charger terminals to battery and then plug charger plug to network electric power (220V). Read carefully charger instructions before use charge rand follow de specified charger method. Charge method Charge current Charge time Normal 0,6 Amps 5 to 10 hours Fast 3,0 Amps 1 hour ! WARNING ! Fast charge is not recommended.
When placing a new lamp, do not touch the glass body of the lamp so it remains free from fat. Note: After installing the lamp on lamp holder, clean it with a wet alcohol cloth, to clean any finger print that may origin hot spots that may reduce lifespan of headlight lamp. Engage retaining clip and mount rubber cap and connector. Reinsert parking light lamp together with holder and fix the mask by means of the rubber bands.
Press lamp, rotate it counter clockwise to remove it. STICKER REPLACEMENT Install a new lamp on blinker holder; Note: we recommend fully reading of this instructions before apply new stickers. Surface preparation Remove old stickers and wash plastics carefully with water and soap. Remove eventual grease sediments with an appropriate grease solvent (pay extra attention near fuel tank) After plastic cleaning, wash hands and dry them. We recommend apply new stickers in a clean, dry and warm place.
Note: For a long lifespan of stickers, do not apply water jets in them. MOTORCYCLE CLEANING Clean your motorcycle regularly 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.
! CAUTION ! Don’t 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.
TECHNICAL SPECIFICATIONS Engine Type Displacement Bore x stroke Cooling PR4 125 Power Torque Carburettor Start Intake valve clearance Exhaust valve clearance Min jet Max jet Carburettor screw Needle position Intake valve diameter Exhaust valve diameter Gearbox Frame Front brake Rear brake Seat height Wheel base Weight Fuel tank Fuel pump Engine oil Engine oil volume Spark plug Battery Fuse Road/high beam light Presence light Rear light Blinkers light Drive gear Wheel gear Chain Cylinder head bolt tighteni
PR4 WIRING SCHEME AJP PR4 User’s manual - 3rd Edition Page 42
