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! 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 5
CONTROLS 5
KEYS 5
IGNITION SWITCH 5
DIGITAL SPEEDOMETER 6
LEFT HANDLEBAR 6
RIGHT HANDLEBAR 7
FUEL 7
FUEL TANK CAP 8
GEARSHIFT LEVER 9
REAR BRAKE PEDAL 9
SIDE STAND 9
SUSPENSION SET-UP 10
ENGINE OIL RECOMMENDATION 11
BREAK-IN (RUNNING-IN) 11
INSPECTIONS BEFORE RIDING 12
RIDING TIPS 13
ENGINE START 13
STARTING OFF 14
USING THE GEARBOX 14
BRAKING 15
STOPPING AND PARKING 16
INSPECTION AND MAINTENANCE 17
MAINTENANCE SCHEDULE 17
MAINTENANCE SCHEDULE TABLE 18
MAINTENANCE WORK 19
LUBRICATION POINTS 19
DRIVE CHAIN 21
BRAKES 22
FRONT WHEEL REMOVAL 25
REAR WHEEL REMOVAL 26
TIRES 26
SPOKE TIGHTNESS 27
BATTERY 27
FUSE 28
LIGHT BULB REPLACEMENT 28
AIR FILTER 28
FUEL FILTER 29
THROTTLE CABLE 29
ENGINE OIL 30
EXHAUST SYSTEM 31
MOTORCYCLE CLEANING 31
CONSERVATION FOR WINTER OPERATION 32
STORAGE PROCEDURES 32
TECHNICAL SPECIFICATIONS 33
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
installed accessories. Follow all “INSPECTION BEFORE RIDING”
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 familiar
Additional electric accessories may with your motorcycle and its controls.
overload the electric system. Severe
overloads may damage the wiring KNOW YOUR OWN LIMITS
harness or create a dangerous situation Always ride within the limits of your
due to the loss of electric power during skills. Knowing your limits and keep
the operation of the motorcycle. within are the foundation to avoid
accidents and injuries.
When carrying a load on the
motorcycle, mount it as low as possible BE EXTRA SAFETY CONSCIOUS ON
to the machine. An improperly mounted BAD WEATHER DAYS OR BAD
load can create a high center of gravity ROAD CONDITIONS
that is very dangerous and makes the Riding on bad weather days requires
motorcycle difficult to handle. The size extra attention. Braking distances
of the load can also affect the double in a rainy day. If you are not
aerodynamics and handling of the sure about road conditions ride slower
motorcycle. Balance the load between and with double care!
the left and right sides of the motorcycle
and fasten it securely.
Chassis number
Chassis
number
1 Clutch lever
2 Blinker, lights, horn switch
! CAUTION !
3 Front brake lever To activate LOCK position, the
4 Starter button and On-Off switch switch must be in OFF position, then
5 Neutral sign pushed down and turned to the left.
6 Headlight sign Handlebar should be turned all the
7 Turn light sign way to the left. If not, the switch will
8 Digital speedometer not pass to LOCK position.
9 Ignition switch
10 Throttle grip
11 Rear view mirrors
! CAUTION !
Don’t try to ride with the switch on
CONTROLS
LOCK position. The steering is
locked and control of the motorcycle
KEYS
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.
5 – High beam on
The digital speedometer is not available In this position, high beam light will be
for the MX and MX PRO versions. on in the headlight and presence light
It gives information about instantaneous will be on in the taillight.
speed and total or trip distance
travelled. Depending on the selling 6 – Turn sign on
market, speed and distance are Turning this button left left turn lights
indicated in Kilometres or miles. If you will be on. Turning right, right turn lights
want to 1 switch between these units, will be on. To switch turn lights off,
please contact your AJP dealer. place the button in middle position.
To switch from total to trip distance
push button 1. To reset trip distance the 7 – Horn
trip distance must be selected; then To actuate horn, press this button.
push button 1 until the distance is reset
to zero.
! CAUTION !
LEFT HANDLEBAR In several countries, motorcycle
riding is only allowed with low beam
on! Respect your national
legislation!
! CAUTION !
Turn lights are not switched off
automatically! Be aware to switch
turn lights off after turning or
overtaking! Otherwise you will give
wrong information about your riding
to other drivers!
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.
! CAUTION !
The EMERGENCY SWITCH should
be used to stop the engine in
emergency situations! Do not use it
to stop the engine when driving
otherwise the ignition system will be
destroyed!
FUEL
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.
! CAUTION !
If EMERGENCY SWITCH is not ON,
engine will not start! Start motor will
not be actuated!
! CAUTION !
Because of the transparent fuel
tank, there is not fuel indicator or
light warning! Control fuel level
when you start the motorcycle and
when you are riding for some time!
! WARNING !
GEARSHIFT LEVER
If opposition of hand brake lever or
PR5 250 have a 6-speed transmission. rear brake pedal fells “spongy” (too
Shift lever is mounted on the left side of much give), this is an indication that
the engine. The position of the gears is the brake system is not functioning
shown in the illustration. Neutral is well. Don’t ride anymore your
located between first and second gear. motorcycle without first having the
brake system checked by an AJP
dealer!
SIDE STAND
! CAUTION !
The side stand was designed only
for the weight of the motorcycle. If
you get on the motorcycle and thus
put additional weight, the side stand
or frame can be damaged and the
motorcycle may fall on the side!
! CAUTION !
Park the motorcycle on solid level
ground to help prevent it from falling
over. ! WARNING !
If you must park on an incline, aim Unequal suspension adjustment can
the front of the motorcycle uphill and cause poor handling and loss of
put the transmission into 1st gear to stability.
reduce the chance of rolling off the Adjust the right and left front legs to
side stand. the same settings.
PR5 is equipped with an up-side down PR5 is equipped with a fully adjustable
fully adjustable front fork. shock absorber.
To adjust compression turn the screw To adjust pre-charge loose first the
(1) clockwise to have a harder upper nut (1), then turn adjusting nut (2)
response. Turn counter clockwise to clockwise for more pre-charge or
have a softer response. counter clockwise for less pre-charge.
! 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.
! WARNING !
Insufficient oil or poor quality oil
results in premature wear of the
engine and may cause severe
damages!
! 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!
! WARNING !
If steering head bearings are not
adjusted to be free of play or too
tight, the motorcycle will become
unstable and can get out of control.
! 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.
! WARNING !
No lubrication should be allowed to
1 - Place the motorcycle on the side
reach rear tyre or rear brake disc,
stand otherwise road adherence and rear
2 - Loose axle nut (1) wheel braking effects will be
3 – Loose fixing nuts on both sides (2) strongly reduced and the
4 – Regulate adjuster screws (3) until motorcycle can easily get out of
the chain has 15-30mm of slack. At the control.
same time that the chain is being
adjusted, the rear sprocket must be
kept in perfect alignment with the front ! CAUTION !
sprocket. Align both right and left When mounting chain master link
adjusters to the same position. clip, the closed side of the master
4 - Re-tighten the axle nut securely and link must point in the running
tighten fixing nuts (2). direction.
5- Recheck the chain slack after
tightening, lubricate and adjust if
necessary.
Brake discs
! WARNING !
Change brake fluid at least once
each two years. If you wash your
motorcycle often, brake fluid should
be changed even more often (once
a year), as brake fluid tends to
absorb water. Therefore, vapour
pockets may form on “old” brake
fluids even at low temperatures,
causing brake system to fail.
! WARNING !
- For your own safety, have the
brake discs replaced immediately
as soon as they reach wear limit (3
mm thickness).
- Have any repairs on brake system
performed by an AJP authorized
dealer.
! WARNING !
At their most worn point brake pad
linings should not be thinner than
Loosen screws (1), remove lid (2) and 1mm, otherwise can lead to braking
membrane (3). Place hand brake failure.
cylinder in a horizontal position and fill
the brake fluid reservoir up to the MAX
mark with clean brake fluid DOT 4. ! WARNING !
Replace membrane, lid and tighten If brake pads are replaced too late
screws. Clear off spilled or overflowing so that the lining is partly or entirely
brake fluid with water. worn, steel components of brake
pad will rub against brake disc,
! WARNING ! thereby reducing braking effect and
- Store brake fluid out of reach of destroying brake disc.
children.
- Brake fluid can cause skin Replacing front brake pads (*)
irritation. Avoid contact with skin
and eyes. If you get brake fluid in Remove calliper assembly,
your eyes, clear with plenty of unscrewing screws (1). Press the
water and consult a doctor. brake calliper away from brake disc
to put the brake piston in its basic
position. Remove clips and the
! CAUTION ! brake pads from the calliper.
- 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.
1
Checking front brake pads
The reservoir for the rear disc brake is Checking the rear brake pads (*)
integrated in brake pump, placed in the
right side of the engine, near exhaust The brake pads can be inspected from
pipe. the rear. The thickness of the linings
Brake fluid level must not drop below cannot be less than 1mm.
the “MIN” marking when the vehicle is
in an upright position.
! WARNING !
- Store brake fluid out of reach of
children.
- Brake fluid can cause skin
irritation. Avoid contact with skin
and eyes. If you get brake fluid in FRONT WHEEL REMOVAL
your eyes, clear with plenty of
water and consult a doctor. Dismounting and mounting front
wheel
! WARNING ! To remove the front wheel, jack the
If brake pads are replaced too late motorcycle up on its frame so that the
so that the lining is partly or entirely front wheel no longer touches the
worn, steel components of brake ground.
pad will rub against brake disc,
thereby reducing braking effect and
destroying brake disc. Loosen the four screws (1) on both
sides of front fork, unscrew nut (2),
hold the wheel remove front axle (3).
! CAUTION ! Remove front wheel carefully from the
- Don’t place brake fluid in contact fork.
with paint; it is a powerful paint
remover
- Use only clean break fluid or from
a sealed container
! CAUTION !
- Do not operate hand brake lever
when front wheel has been
removed.
FUSE
THROTTLE CABLE
! CAUTION !
- Engine oil level should be
checked daily or before any
ride.
- If necessary you should add oil
to keep always oil level between
maximum H mark and lower L
mark.
.
! WARNING !
ENGINE OIL - On PR5 250, if any oil pipe or oil
radiator is damaged and present
Checking engine oil level leak, engine should be immediately
stopped.
Place the motorcycle in an upright - Otherwise serious damages in
position and on a horizontal surface. engine will happen due to lack of oil
The engine oil level can be checked in lubricating circuit.
through the oil glass level. If the engine
is warm, the oil level should be near the Changing engine oil (*)
MAX mark.
Engine oil has to be changed with the
! CAUTION ! engine being at operating temperature.
-If oil level drops quickly, do not
operate your motorcycle. Take your ! CAUTION !
motorcycle to an authorized AJP - An engine at operating
dealer immediately, to a full check temperature and engine oil it
of engine. contains are very hot. Please take
all cares to avoid burning yourself.
Engine oil quality
Place the motorcycle on a horizontal
Use only branded oils for four stroke surface, remove the plug and allow the
engines, meeting or surpassing the oil to drain into a receptacle. Never
quality requirements of API classes SF drain used oil to the ground, waste,
or SG: water lines or sewage.
SAE 10W40/15W40 API-SF or SG Take out the oil drain together with oil
filter, clean these components carefully
Capacity: and blow with compressed air. Check
o 1,4 litre o-ring and sealing and replace them if
necessary.
! WARNING !
Once the entire oil has been drained,
- Insufficient engine oil or poor clean the sealing surface, mount the oil
quality may cause severe damage drain together with spring, oil filter and
to the engine. sealing on the right position and tighten
- Never operate your motorcycle up to 15Nm (1,5 Kg.m).
with low engine oil level or with
non-adequate engine oil quality.
MOTORCYCLE CLEANING
Clean your motorcycle oftenly in order
to maintain the beauty of its plastic
surfaces and avoid corrosion. The best
manner would be to use warm water
that has been mixed with a normal
brand-name washing detergent and a
sponge. The hard dirt can be removed
before washing with the help of a soft
water jet.
! CAUTION !
- Never clean your motorcycle with
an high-pressured cleaner or an
high-pressured water jet. Water
Start the engine and check for leaks. could run into electrical
components, connectors, cables,
Finally, check the engine oil level and, if
necessary, correct it. bearings, carburettor, etc, can
cause operations mal-functions or
lead to premature destruction of
EXAUST SYSTEM these parts.