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Table of Contents
Related Manuals for AJP PR7
Summary of Contents for AJP PR7
- Page 1 AJP PR7 User manual...
- Page 2 AJP Motos, SA – Disclaims all liabilities for any errors or omissions present in this manual and reserves the right to make changes that reflect the on-going development. Illustrations and diagrams in this document can differ from the genuine components. The partial or full reproduction of this document is not allowed without written authorization.
- Page 3 Copyright by AJP Motos, SA Technical Service Rua de Santana, 91 4620-510 Pias, Lousada Portugal Tel: +351 255 815 122 Fax: +351 255 815 123 Website: www.ajpmotos.com . Edition (01-2017)
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Page 4: Important Information
TAKE SPECIAL CARE TO FOLLOW THE RECOMMENDED RUN IN, INSPECTION AND MAINTENANCE INTERVALS. FOLLOWING THESE GUIDELINES WILL SIGNIFICANTLY INCREASE THE LIFE OF YOUR MOTORCYCLE. BE SURE TO HAVE ANY MAINTENANCE JOBS PERFORMED BY AN AUTHORIZED AJP DEALER. PLEASE DON’T FORGET TO WEAR A HELMET, EYE PROTECTION AND PROTECTIVE CLOTHING WHEN GOING FOR A RIDE. -
Page 5: Table Of Contents
TABLE OF CONTENTS TABLE OF CONTENTS ............................................iv Chapter A. CONSUMER INFORMATION ................................A.1 ACCESSORY INSTALLATION AND SAFETY TIPS ....................................A.2 SAFE RIDING RECOMMENDATIONS ......................................A.3 MOTORCYCLE IDENTIFICATION ........................................A.4 BREAKING-IN ..............................................A.5 INSPECTIONS BEFORE RIDING ........................................A.6 RIDING TIPS ..............................................A.8 MOTORCYCLE CLEANING ..........................................A.12 STORAGE PROCEDURES ..........................................A.13 CONSERVATION FOR WINTER OPERATION ....................................A.14 Chapter B. - Page 6 REPLACING COOLANT LIQUID ........................................D.7 RADIATOR FAN ............................................D.7 CHECKING AND ADJUSTING THE STEERING HEAD BEARINGS ..............................D.8 CLEANING FRONT FORK DUST SEALS ......................................D.8 ADJUSTING FRONT FORK SUSPENSION ......................................D.9 ADJUSTING REAR SUSPENSION ........................................D.10 ADJUSTING DRIVE CHAIN........................................... D.11 DRIVE CHAIN MAINTENANCE ........................................
- Page 7 REMOVING THE BATTERY .......................................... D.20 RECHARGING THE BATTERY ........................................D.21 CHECKING SPARK PLUG ..........................................D.22 FUSES ................................................. D.22 REPLACING HEADLIGHT LAMP ........................................D.23 REPLACING TAILLIGHT ..........................................D.24 REPLACING TURN INDICATOR LIGHTS ....................................... D.24 CLEANING AIR FILTER ..........................................D.25 CHECKING EXHAUST SYSTEM........................................D.26 Chapter E.
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Page 8: Chapter A. Consumer Information
Chapter A. CONSUMER INFORMATION... -
Page 9: Accessory Installation And Safety Tips
ACCESSORY INSTALLATION AND SAFETY TIPS In the market there is a 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. Contact your AJP dealer to assist you in selecting accessories and install them correctly. -
Page 10: Safe Riding Recommendations
SAFE RIDING RECOMMENDATIONS WEAR A HELMET Motorcycle safety equipment starts with a quality helmet. One of the most serious injuries that can happen is a head injury. ALWAYS wear a properly homologated helmet. You should also wear suitable eyes protection. RIDING CLOTHING Loose or inappropriate clothing can be uncomfortable and unsafe for motorcycle riding. -
Page 11: Motorcycle Identification
MOTORCYCLE IDENTIFICATION Chassis and engine serial numbers are used for the motorcycle registration. Also they should be used by the AJP dealers to perform the request AJP MOTOS spare parts. HOMOLOGATION PLATE Homologation plate (1) of the motorcycle is located in the right side of the chassis, close to the steering column. -
Page 12: Breaking-In
The first 1000 km maintenance service is the most important maintenance that your AJP will receive. The motorcycle must be checked carefully, restoring all the adjustments, retightening fasteners and updating the injection system condition. -
Page 13: Inspections Before Riding
INSPECTIONS BEFORE RIDING In each start off, the engine must be in perfect mechanical conditions. For safety reasons, you should make overall check routine before each ride. The following inspections should be performed: Oil level: Insufficient oil quantity will result in premature wear in engine components, damaging the engine itself; Fuel: Check if there is enough fuel in the tank;... - Page 14 Using worn, improperly inflated or incorrect tires will reduce motorcycle stability and can cause an accident. Front and rear tires are only allowed to be fitted with same homologated original profile tires. Wear suitable clothing when driving a motorcycle. Never forget to wear helmet, gloves and boots, even in short trips. Protective clothing should be brightly colored to make you visible to other drivers.
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Page 15: Riding Tips
Remove your foot from the brake pedal when you are not braking. Otherwise the brake system overheat. ― For safety reasons do not modified the vehicle and always use AJP original spare parts. ― Motorcycle are sensitive to changes in weight distribution. In case of caring luggage with you, secure it as close as possible to the middle to distribute weight on both sides. - Page 16 Never shift down gears with throttle wide open. The engine will over-rev, damaging the valves and the gearbox. If any abnormal vibrations occur while driving, check for loosen bolts in the engine. If the vibration remains contact an AJP dealer.
- Page 17 BRAKING Apply both brakes at the same time while closing the throttle. When driving on sandy, wet or slippery ground use mainly the rear brake. Avoid blocking the wheels, otherwise you may lose control of the motorcycle. Use the engine brake effect when driving downhill to assist the brakes. Lower one or two gears without over-speeding the engine. Therefore, you will not need to use continuously the brakes, avoiding overheat.
- Page 18 STOPPING AND PARKING In order to stop apply the brakes until the motorcycle is immobilized. To turn off the engine turn the key to OFF position on the ignition switch or press the emergency switch to the OFF position. Park the vehicle on solid ground and in a secure position. Lock the steering. Never leave the motorcycle without supervision while the engine is running or with children nearby.
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Page 19: Motorcycle Cleaning
MOTORCYCLE CLEANING Clean your motorcycle often in order to maintain the appearance of plastic surfaces and avoid corrosion. The recommended method would be to use a sponge and warm water at 30-35⁰C mixed with a regular washing detergent. The hard dirt can be removed before washing with the help of a soft water jet. -
Page 20: Storage Procedures
STORAGE PROCEDURES In case of motorcycle storage for long period of time, the following instructions should be take: ― Clean the motorcycle thoroughly (see MOTORCYCLE CLEANING); Remove the spark plug and fill the cylinder with approximately 5 cc of engine oil through the opening. Assembly the spark plug, without ―... -
Page 21: Conservation For Winter Operation
CONSERVATION FOR WINTER OPERATION In case of using the motorcycle in winter and on road where salt spray was applied, additional precautions measures must be taken against the aggressive road salt. Clean the motorcycle thoroughly and dry completely after each ride; ―... -
Page 22: Chapter B. Components Location
Chapter B. COMPONENTS LOCATION... - Page 23 Windshield Fuel tank Chassis Front suspension Turn indicators (blinkers) Rear suspension Air filter cover Brake caliper Side stand Fuel tank cap Coolant expansion tank Drive chain Seat Gearshift pedal Swing arm...
- Page 24 Number-plate holder Air filter Rear brake pedal Taillight Headlights Engine Battery Brake disc Engine skid plate Fuses Exhaust system Radiators Spark plug Foot-rest...
- Page 25 Rear view mirrors Front brake master cylinder Turn indicator switch Low/High beam switch Emergency switch Ignition switch and steering lock Clutch master cylinder Hand protection Electric start button Dashboard Clutch lever Throttle grip Tablet (optional) Horn button Front brake lever...
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Page 26: Controls
CONTROLS KEYS This motorcycle comes with a pair of keys. Be aware to keep one of the keys in safe place, at home for instance, in order to access this key in case of need. IGNITION SWITCH AND STEERING LOCK LOCK ON –... - Page 27 INSTRUMENT PANEL Turn indicator light (Green) Flashes when the right/left turn indicator switch is operated. High beam indicator light (Blue) Turns on when the light switch is on the high beam position. Tachometer Indicates the engine revolutions per minute (rpm). Speedometer Indicates the instantaneous vehicle speed.
- Page 28 INSTRUMENT PANEL SETTINGS Background color Press the Select button in the main screen to switch the background color (blue-orange-purple). Odometer/trip meter In order to switch between total and trip function press the Adjust buttons in the main screen. Hold down the button for 3 seconds to reset the trip distance. Clock setting In the main screen press simultaneously the Select and Adjust button for 3 seconds.
- Page 29 OBD SYSTEM The AJP PR7 model is equipped with OBD system for the fuel injection system diagnosis. Located on the motorcycle right side, near to the instrument panel, is the OBD connector (1), which allows to get access to the injection system and its components information.
- Page 30 LEFT HANDLEBAR Clutch lever The clutch lever has the function of disengaging the driving system from rear wheel, mainly used in case of starting the engine or shifting gears. Gripping the clutch lever (1) disengages the clutch. High beam flash button The high beam flash when the button (2) is pressed.
- Page 31 RIGHT HANDLEBAR Emergency switch (kill switch) The emergency switch (1) has two positions: ― ON position ( ) enables engine running. OFF position ( ) stop the engine from running, cutting off the engine ― electric circuit. To switch to the OFF position press down the switch. Front brake lever Operate the front brake by gripping brake lever (2) toward the throttle grip.
- Page 32 FUEL The AJP PR7 engine requires unleaded gasoline with a 95 or higher octane index (containing up to 5% of ethanol). Never use lead fuel to avoid the destruction of the catalytic converter and the exhaust system. Using non-recommended fuel can cause severe damages on engine. Ensure to use only unleaded gasoline with an octane index equal or higher than 95.
- Page 33 GEARSHIFT PEDAL The PR7 model is equipped with 6-speed transmission. On the left side of the engine is located the gearshift pedal (1). To shift gear properly: ― Actuate the clutch lever and close the throttle simultaneously to operate the gearshift pedal;...
- Page 34 SIDE STAND The motorcycle is equipped with a side stand on the left side. To place the motorcycle in side stand (1) push downwards using your foot until it stops. Then lean the motorcycle to the left. Ensure that the motorcycle is placed on solid ground and in a secure position. To raise the side stand, hold the motorcycle in upright position, the side stand should fold automatically.
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Page 35: Chapter C. Maintenance Schedule
Chapter C. MAINTENANCE SCHEDULE... - Page 36 It is owner’s responsibility to assure that the motorcycle is serviced within the periodic maintenance schedule, in an authorized dealer workshop. AJP does not take responsibility for any damage if maintenance was not performed as schedule. Improper or absence of recommended maintenance will increase the chance of accident or motorcycle damage.
- Page 37 The following table refers to the maintenance schedule that should be performed by AJP dealer to ensure correct operation. Periodic maintenance tables (to be carried out at AJP Motos dealer) 1000 km 5000 km 10000 km 15000 km 20000 km...
- Page 38 Periodic maintenance tables (to be carried out at AJP Motos dealer) After first Each 500 km Each 3000 km Each 6000 km Each 12000 km 1000 km or 1 month or 6 months or 12 months or 24 months Air filter...
- Page 39 The following table refers to the maintenance schedule that should be performed by the owner to ensure the correction operation. Periodic maintenance table (to be carried out by the owner) After first 1000 Each 500 km Each 3000 km Each 6000 km Each 12000 km or 1 month or 6 month...
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Page 40: Chapter D. Maintenance And Adjustments
Chapter D. MAINTENANCE AND ADJUSTMENTS... -
Page 41: Lubrification Points
Use only special screws with an appropriate thread length, supplied by AJP, to fix the fuel tank. Using other screws or longer ones can cause cracks in the tank, which fuel can flow out through. -
Page 42: Checking Engine Oil Level
If oil level drops quickly, do not ride your motorcycle. Consult an authorized AJP dealer immediately to full check the engine. In order to refill the engine oil: Remove the oil filler cap (2);... -
Page 43: Changing Engine Oil
CHANGING ENGINE OIL Engine oil must be changed with the engine in operating temperature. If the engine is not warm, start the engine and let it work for 5 minutes. To change the oil, follow this procedure: Unscrew the screw (1) and remove the engine skid plate (2); ―... -
Page 44: Replacing Main Oil Filter
Main oil filter cover bold (1) torque: 9,3 N.m (0.95 Kgf.m) Note: We recommend that oil filters maintenance should be performed by an authorized AJP dealer. Avoid damaging the engine due insufficient lubrication. It is important to assure the correct position of the main oil filter. -
Page 45: Checking Coolant Level
CHECKING COOLANT LEVEL The coolant expansion reservoir (1) ensure that the cooling liquid remains in the system when the liquid volume expands due the increment of the pressure/temperature. Inspect the coolant level often. Always control the coolant level with the engine cold. To inspect the coolant quantity: ―... -
Page 46: Replacing Coolant Liquid
REPLACING COOLANT LIQUID In order to replace the cooling liquid, follow the next procedure: ― Remove the screw (1); Collect the liquid to an appropriate recipient ; ― Place back the screw (1); ― Fill the radiator with approximately 1.3 liters of recommended coolant liquid; ―... -
Page 47: Checking And Adjusting The Steering Head Bearings
CHECKING AND ADJUSTING THE STEERING HEAD BEARINGS Verify steering head bearings clearance regularly. To check, place the motorcycle on a stand so that the front wheel is off the ground. Try to move the fork forward and backward; ― Loosen top nut (3) and the four screw (1) of the top triple clamp; ―... -
Page 48: Adjusting Front Fork Suspension
ADJUSTING FRONT FORK SUSPENSION To adjust rebound of the suspension system: Turn the screw (1) clockwise in order to decrease the rebound speed. ― Turn the screw (1) counter-clockwise increase the rebound speed. ― Standard setting: 12 clicks from the fully closed position To adjust compression of suspension system: Turn the screw (2) clockwise to a harder response. -
Page 49: Adjusting Rear Suspension
ADJUSTING REAR SUSPENSION The AJP PR7 model is equipped with a fully adjustable shock absorber. To adjust the preload: Loose the upper nut (1); ― ― Turn the adjusting nut (2) clockwise for more preload. Turn the adjusting nut (2) counter-clockwise for less preload. -
Page 50: Adjusting Drive Chain
ADJUSTING DRIVE CHAIN The drive chain clearance must between the 30 to 45mm interval, at the half way between the drive sprocket and rear sprocket. To adjust the tightness, place the motorcycle on the side stand. Loosen the axle nut (1); ―... -
Page 51: Drive Chain Maintenance
DRIVE CHAIN MAINTENANCE A good maintenance is extremely important for long chain life. O-ring chains are simple to clean. Clean with water and never use brushes or cleaning liquids. After letting dry completely, use a chain spray to lubricate it. Also check sprockets and chain guides wear, replace if necessary. -
Page 52: Tires Pressure
TIRES CONDITION Tire model, condition and air pressure affect the motorcycle behavior. Therefore, tires must be checked before riding. Tire size can be found in the technical specifications and registration documents. ― Before riding, inspect the tires for punctures and nails or other sharp objects that ―... -
Page 53: Checking Spokes Tension
Check spokes tension, especially on a new motorcycle, in regular intervals. To inspect use a screwdriver to slightly sweep the spokes. Spokes with same dimensions should have the same sound. If necessary, have the spokes retightened and wheel correction by an AJP dealer. -
Page 54: Brake Disc
4.5 mm for the rear disc). Any repair on brake system should be performed by an authorized AJP dealer. BRAKE DISC The sintered brake pads used on the PR7 front and rear brake systems provide an optimal combination of brake power, performance and lifecycle. D.15... -
Page 55: Checking Front Brake Pads
CHECKING FRONT BRAKE PADS The front brake pads can be inspected through the spokes on the opposite side of the brake system, as showed in the picture. The linings must have at least 1mm thickness. At their most worn point, brake pad linings should not be thinner than 1mm, otherwise can lead to braking failure. -
Page 56: Brake Fluid Reservoir
If brake fluid level drops below the minimum level either there is a leak or the brake pads are completely worn. In this case, consult an authorized AJP dealer immediately. Change brake fluid at least once each two years. If you wash your motorcycle often or wet environments, brake fluid should be changed even more often (once a year), since the brake fluid tends to absorb water. -
Page 57: Refilling Front Brake Fuild
REFILLING FRONT BRAKE FUILD ― Remove the screws (1); Remove the reservoir cover (2) and the diaphragm (3); ― Place front brake reservoir in a horizontal position and fill up the reservoir until the ― MIN mark with clean brake fluid DOT 4; ―... -
Page 58: Refilling Rear Brake Fuild
REFILLING REAR BRAKE FUILD ― Remove the master cylinder cover (1); Place rear brake master in a horizontal position and fill up the reservoir until the MIN ― mark with clean brake fluid DOT 4; Replace diaphragm and reservoir cover if damaged; ―... -
Page 59: Removing The Battery
REMOVING THE BATTERY The battery (2) has a closed system and therefore requires no maintenance (MF). Keep the battery poles clean and put slightly acid free grease if necessary. To remove the battery: Turn the seat lock (1) with ignition key and remove the motorcycle seat. The battery ―... -
Page 60: Recharging The Battery
RECHARGING THE BATTERY Motorcycles stored for long periods or equipped with additional electronic accessories will cause battery discharge. The battery should be charged when identified issues as instrument panel malfunction, electronic starter motor malfunction or engine power loss due the injection system errors. In case of home battery recharge: ―... -
Page 61: Checking Spark Plug
Replace a blown fuse only with an equivalent one. If a new fuse recently installed gets blown, are identified with the respective color of we recommend that your motorcycle be inspected by an AJP dealer. the fuses. Under none circumstances allow the installation of a stronger fuse or repair a damaged one. -
Page 62: Replacing Headlight Lamp
In order to assembly, reverse the previous procedure. Do not replace H7 headlight lamp for another model or with different power that the one specified to AJP PR7 model. Do not touch lamp glass, otherwise some substances can cause overheating and lamp lifetime reduction. -
Page 63: Replacing Taillight
Assembly the new turn indicator lamp; ― Clean the lamp with alcohol; Place the inner glass and the turn indicator lens; ― Tight again the screw. ― The fully replacement of the turn indicator assembly should be performed by an authorized AJP dealer. D.24... -
Page 64: Cleaning Air Filter
CLEANING AIR FILTER Dirty air filters (4) causes airflow restriction, reducing the engine performance and increasing fuel consumption. Therefore, clean regularly the air filter. To access the air filter: Release the two rubber bands (3); ― Unscrew the screws (1); ―... -
Page 65: Checking Exhaust System
CHECKING EXHAUST SYSTEM The exhaust system (1) requires regular maintenance, especially when often exposed to severe condition of motorcycle riding. Exhaust system can reach high temperature in operation. Be careful handling the motorcycle even after parking in order to avoid burns. Wear suitable clothes and boots to protect you from the high temperatures of the exhaust system. -
Page 66: Chapter E. Technical Specifications
Chapter E. TECHNICAL SPECIFICATIONS... - Page 67 Electric FUEL SYSTEM Fuel Unleaded fuel 95 Type Electronic fuel injection, Fuel consumption 3.7 L/100 km AJP Ø45 mm throttle body emission 83 g/km CLUTCH Type Oil bath multiple disc clutch, hydraulic control TIMING SYSTEM 4 valves, dual overhead camshaft...
- Page 68 Rim size 18”x2.50 REAR SUSPENSION Tires Continental – Michelin - Desert TKC Twinduro Type AJP progressive linkage system, ZF SACHS Piggyback shock Tires size 140/80 – 18” 140/80 – 18” Stroke 280 mm – Fully adjustable Pressure (road with 2.3 bar...
- Page 69 LUBRICANT TABLE, SUPPLIERS Engine and gearbox eni i-Ride MOTO 10W-50 lubricant Coolant liquid eni PERMANENT SPEZIAL Air filter lubricant Green Filter oil Brake fluid eni DOT 4 SAE J 1704 Clutch fluid Multi-tech CT 10 W Lubricant grease eni AGIP GR MU EP 2 Drive chain lubricant AGIP CHAIN GREASE SPRAY Suspension oil...
- Page 70 1530 mm 920 mm 310 mm 1540 mm 810 mm 2270 mm...
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Questions and answers
what is the correct sag for rear suspension
The correct rider sag for the rear suspension of the AJP PR7 is approximately 92–94 mm, based on suspension tuning examples given. Static sag values mentioned include 45 mm in one setup. Rider sag is prioritized for setup accuracy.
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