AJP SPR 250 2022 User Manual
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AJP SPR 250 2022 User Manual

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  • 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 (January 2022)
  • Page 4 PLEASE DON’T FORGET TO WEAR A HELMET, EYE PROTECTION AND PROTECTIVE CLOTHING WHEN GOING FOR A RIDE.  AJP MOTOS RESERVES THE RIGHT TO MODIFY ANY EQUIPMENT, TECHNICAL SPECIFICATIONS, COLOURS AND MATERIALS USED WITHOUT PREVIOUS ANNOUNCEMENT AND WITHOUT GIVING REASONS, OR TO CANCEL ANY OF THE ABOVE ITEMS WITHOUT SUBSTITUTING THEM...
  • Page 5  IT SHALL BE ACCEPTABLE TO STOP MANUFACTURING A CERTAIN MODEL WITHOUT PREVIOUS ANNOUNCEMENT. IN THE EVENT OF SUCH MODIFICATIONS, PLEASE CONTACT YOUR LOCAL AJP DEALER FOR INFORMATION.  WE SHALL NO BE HELD LIABLE FOR ANY PRINTING ERRORS WE WISH YOU ENJOY YOUR AJP!

  • Page 6: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS ............................................vi Chapter A. CONSUMER INFORMATION ................................A.1 ACCESSORY INSTALLATION AND SAFETY TIPS ....................................A.2 SAFE RIDING RECOMMENDATIONS ......................................A.4 MOTORCYCLE IDENTIFICATION ........................................A.5 BREAKING-IN ............................................... A.6 INSPECTIONS BEFORE RIDING ........................................A.7 RIDING TIPS ..............................................A.9 MOTORCYCLE CLEANING ...........................................
  • Page 7 CHECKING COOLANT LEVEL ......................................... D.7 REPLACING COOLANT LIQUID ........................................D.8 RADIATOR FAN ............................................D.8 CHECKING AND ADJUSTING THE STEERING HEAD BEARINGS ..............................D.9 CLEANING FRONT FORK DUST SEALS ......................................D.9 ADJUSTING FRONT FORK SUSPENSION ...................................... D.10 ADJUSTING REAR SUSPENSION ........................................D.11 ADJUSTING DRIVE CHAIN...........................................
  • Page 8 REMOVING THE BATTERY .......................................... D.21 RECHARGING THE BATTERY ........................................D.22 FUSES ................................................. D.23 REPLACING HEADLIGHT LAMP ........................................D.24 REPLACING TAILIGHT (1) ..........................................D.25 REPLACING LED TURN SIGNALS (2) ......................................D.25 CLEANING AIR FILTER ..........................................D.26 CHECKING EXHAUST SYSTEM........................................D.27 Chapter E. TECHNICAL SPECIFICATIONS ................................

  • Page 9: Chapter A. Consumer Information

    Chapter A. CONSUMER INFORMATION...

  • Page 10: Accessory Installation And Safety Tips

    ACESSORIES AND MODIFICATIONS In the market there is a variety of accessories for SPR 250 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 11 BURNS Some vehicle components become very hot when the vehicle is operated. Do not touch any parts such as exhaust system, radiator, engine, shock absorber, or brake system before the vehicle parts have cooled down. Let the vehicle parts cool down before you perform any work on the vehicle. ENVIRONMENT If you use your motorcycle responsibly, you can ensure that problems and conflicts do not occur.

  • Page 12: 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 13: Motorcycle Identification

    MOTORCYCLE IDENTIFICATION Chassis and engine serial numbers are used for the motorcycle registration. Alongside, it 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 on the steering column left side. The plate contains the homologation number, serial number and the noise level at a specified engine rpm.

  • Page 14: 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 15: Inspections Before Riding

    INSPECTIONS BEFORE RIDING In each start off, the engine must be in perfect mechanical conditions. For safety reasons, the owner/driver 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 16 Ignoring these inspections or improperly preserve the motorcycle will increase the chance of an accident or component damage. Using worn, improperly inflated or incorrect tires will reduce motorcycle stability and potentiate 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.

  • Page 17: 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 18 In some particular conditions, some extra fuel may go to the engine. If engine “floods”, open throttle during 3 seconds before start engine; if engine does not start, wait 10 seconds and try again. After five trials, if engine does not start, check spark plug, dry it and try again. If engine does not start replace spark plug for a new one.
  • Page 19 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 20 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 21 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.

  • Page 22: Motorcycle Cleaning

    MOTORCYCLE CLEANING Clean your motorcycle often in order to maintain the appearance of plastic surfaces and avoid corrosion. During cleaning avoid direct sunshine on the motorcycle. Materials damages Avoid using a high pressure washer. Never direct a high pressure jet to some sensitive points of motorcycle, such as electronic components (ECU, throttle body sensor, switches, relays, connectors, controls cables, among others), wheels and steering column bearings.
  • Page 23  Take a short drive until the engine reach the operating temperature and use the brakes. Doing this procedure the residual water will evaporate due the warm parts off engine and brakes;  Once the motorcycle has cooled down, lubricate all sliding and bearings points. Lubricate as well the chain with a chain spray; ...

  • Page 24: 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 the spark plug cap connected, and actuate the start motor in order to distribute the oil into the cylinder walls;...

  • Page 25: 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. Treat the engine, swing arm and all other galvanized parts (except for brake disks) with a wax based anti-corrosion agent.

  • Page 26: Chapter B. Components Location

    Chapter B. COMPONENTS LOCATION...
  • Page 27 Headlight Fuel tank cap Gearshift pedal Front suspension Turn signals (blinkers) Chassis Air filter box cap Front Tire Rear suspension Air filter box Front brake caliper Drive chain Fuel tank Engine Swing Arm...
  • Page 28 Number-plate holder Fuses Foot-rest Taillight Battery Rear brake pedal Seat Front Fender Engine Skid Plate Coolant expansion reservoir Rear brake disc Radiators Spark plug Exhaust system From rim...
  • Page 29 Clutch lever Front brake lever Electric starter button Low/High beam switch Turn signal switch Throttle grip Instrument Panel Horn button Ignition switch and steering lock Radiator cap Front brake master-cylinder Emergency switch...

  • Page 30: 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 in case of loss, among others. IGNITION SWITCH AND STEERING LOCK LOCK ON –...
  • Page 31 INSTRUMENT PANEL Left turn signal light (Green) Flashes when the turn signal switch is operated to the left. High beam indicator light (Blue) Turns on when the light switch is on the high beam position. Fuel reserve (Amber yellow) The warning light turns on when the fuel level is below 3 liters. Tachometer Indicates the engine revolutions per minute (rpm).
  • Page 32 INSTRUMENT PANEL SETTINGS 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. Home screen tachometer/fuel level gauge Press the Adjust button in the main screen for 3 seconds to switch between the rpm gauge (tachometer) or the fuel level gauge.
  • Page 33 (2) on the instrument panel will automatically activate. In this case, it will be require to schedule a motorcycle inspection by your AJP dealer, to correct the issue and erase the stored errors recorded in the ECU.
  • Page 34 LEFT HANDLEBAR Clutch lever The clutch lever has the function of disengaging the transmission system from rear wheel, mainly used on starting the engine or shifting gears. Griping the clutch lever (1) disengages the clutch. Low/High beam switch The low beam ( ) was designed to be turned on whenever the engine runs.
  • Page 35 RIGHT HANDLEBAR Electric start button Use the electric start button (1) to activate the starter motor. To start the engine, place the ignition key in the ON position and engage the neutral gear. Throttle grip The engine speed is controlled through the throttle grip (2) position. To increase the speed, rotate counter-clockwise (+).
  • Page 36 FUEL The AJP SPR 250 engine requires unleaded gasoline with a 95 or higher octane index (containing up to 10% of ethanol). Never use lead fuel to avoid the destruction of the catalytic converter and the exhaust system. Using non-recommended, adulterated or water contaminated fuel can cause severe damage on fuel pump and engine.
  • Page 37 At the same time, the stop light in the taillight will switch on. A “spongy” front brake lever or rear brake pedal are indicators of a problem in the braking system. For safety reasons, do not ride the motorcycle until the braking system be checked by an AJP dealer. B.12...
  • Page 38 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.

  • Page 39: Chapter C. Maintenance Schedule

    Chapter C. MAINTENANCE SCHEDULE...
  • Page 40 It is owner’s responsibility to assure that the SPR 250 motorcycle is serviced within the periodic maintenance schedule, in an authorized dealer workshop (preferably at the dealership where the vehicle was purchased). AJP does not take responsibility for any damage if maintenance was not performed as recommended schedule, which can lead to lose the warranty.
  • Page 41 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) Every 3000 Km Every 6000 Km Every 12000 Km After first 1000 Km...
  • Page 42 Periodic maintenance tables (to be carried out at AJP Motos dealer) After first 1000 Every 500 Km Every 3000 Km Every 6000 Km Every 12000 Km or 1 Month or 6 Month or 12 Month or 12 Month Air filter...
  • Page 43 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 Every 500 Km Every 3000 Km Every 6000 Km Every 12000 Km 1000 Km or 1 Month...

  • Page 44: Chapter D. Maintenance And Adjustments

    Chapter D. MAINTENANCE AND ADJUSTMENTS...

  • Page 45: 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 46: Checking Engine Oil Level

    If oil level drops quickly, do not operate 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 47: Changing Engine Oil

    CHANGING ENGINE OIL Engine oil must be changed with the engine warm, 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), (3) and (5) and remove the engine skid plate (2); ‒...

  • Page 48: Replacing Oil Filters

    Main oil filter cover screws (2) torque: 8,0 N.m (0,8 kgf.m) be performed by an authorized AJP Strainer filters cover (3)(4) torque: 25 N.m (2,5 kgf.m) Motos dealer. Avoid damaging the engine due to insufficient lubrication. It’s important to ensure the main filter is placed in the right position - the end with the hole must face inside engine crankcase.

  • Page 49: Checking Spark Plug

    Electrode clearance: 0.7 – 0.8 mm Spark Plug (3) torque: 10.0-12.0 N.m (1.0 -1.2 kgf.m) Incorrect spark plug clearance or maintenance procedures can reduce the performance or cause engine malfunction. Spark plug replacement should be only done by an AJP Motos dealer.

  • Page 50: 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 51: Replacing Coolant Liquid

    REPLACING COOLANT LIQUID In order to replace the cooling liquid, follow the next procedure : ‒ Remove the drain screw (1) from the water pump; ‒ Collect the liquid to an appropriate recipient ; ‒ Place back the screw (1); ‒...

  • Page 52: Checking And Adjusting The Steering Head Bearings

    CHECKING AND ADJUSTING THE STEERING HEAD BEARINGS Verify steering head bearings clearance regularly. To inspect: ‒ Set the motorcycle on a central stand to keep the front wheel off the ground. ‒ Holding the front fork bottom, try to move the fork forward and backwards; ‒...

  • Page 53: 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 settings: 10 clicks from the fully closed position. To adjust compression of suspension system : ‒...

  • Page 54: Adjusting Rear Suspension

    ADJUSTING REAR SUSPENSION The AJP SPR 250 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 55: Adjusting Drive Chain

    ADJUSTING DRIVE CHAIN The drive chain clearance must between the 30 to 45 mm 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 56: 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. Verify also the wearing status of the engine sprocket, rear wheel sprocket, swingarm protection and drive chain guide, replacing if necessary.

  • Page 57: Condição Dos Pneus

    CONDIÇÃO DOS PNEUS 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, nails or other sharp objects that might have stick.

  • Page 58: 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 59: Brake Discs

    For your own safety replace the brake discs as soon as they reach wear limit (3.8 mm for the front disc and 4.5 mm for the rear disc). Any repair on brake system should be performed by an authorized AJP dealer. BRAKE PADS The semi-metallic brake pads used on the SPR 250 front and rear brake systems provide an optimal combination of brake power, performance and lifecycle.

  • Page 60: Checking Front Brake Pads

    CHECKING FRONT BRAKE PADS The front brake pads (1) can be inspected through the spokes on the opposite side of the brake system, as illustrated. The linings must have at least 1 mm thickness. At their most worn point, brake pad linings should not be thinner than 1 mm, otherwise can lead to braking failure.

  • Page 61: Front Brake Master Cylinder

    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 62: Refilling Front Brake Fluid

    REFILLING FRONT BRAKE FLUID ‒ 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 63: Refilling Rear Brake Fluid

    REFILLING REAR BRAKE FLUID ‒ Remove the master cylinder cover with diaphragm (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 64: Removing The Battery

    REMOVING THE BATTERY The battery (1) 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: ‒ Rotate the lock system tab (3) under the seat and remove the seat from the motorcycle; ‒...

  • Page 65: 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 66: Fuses

    Replace a blown fuse only with an equivalent one. If a new fuse recently installed gets blown, we recommend that your motorcycle be inspected by an AJP dealer. Under none circumstances allow the installation of a stronger fuse or repair a damaged one.

  • Page 67: Replacing Headlight Lamp

    REPLACING HEADLIGHT LAMP To replace the headlight bulbs ensure that the ignition key is in the OFF or LOCK position. ‒ Release the rubber clamps (1) on the left and right side of the headlight assembly; ‒ Detach the connector (2) from the lamp and remove the rubber protection (3); ‒...

  • Page 68: Replacing Tailight (1)

    REPLACING LED TURN SIGNALS (2) The LED turn signals (2) on the AJP SPR 250 are not repairable. Replacement of turn signals should only be performed by an authorized AJP dealer.

  • Page 69: Cleaning Air Filter

    CLEANING AIR FILTER Dirty air filters (3) cause restriction of air flow, reducing engine performance and increasing fuel consumption. Therefore, it is high recommendable clean regularly the air filter. To access the air filter: ‒ Remove the air filter cover (1); ‒...

  • Page 70: Checking Exhaust System

    Regularly check the exhaust muffler alignment/fixation ensuring that it does not touch the swingarm under full suspension compression. In the event of a fall, head to your AJP dealer to inspect the exhaust muffler support. If damaged it is necessary your replacement and/or adjust the muffler position on the fixing clamp to maintain the correct alignment.

  • Page 71: Chapter E. Technical Specifications

    Chapter E. TECHNICAL SPECIFICATIONS...
  • Page 72 FUEL SYSTEM Stroke 53.6 mm Compression ratio 11.6:1 Electronic fuel injection, Type Start AJP Ø34 mm throttle body Electric Fuel Unleaded fuel 95 Fuel pump system Electric pump w/ Mahle KL13 Fuel consumption 3.7 L/100 Km Fuel pump system pressure 2.5 bar...
  • Page 73 REAR WHEEL Stroke 300 mm – Fully adjustable Rim size 18”x2.15 17”x3.50 REAR SUSPENSION Michelin Enduro Continental Tires AJP progressive linkage system, Medium Conti-Twist SM Type fully adjustable ZF SACHS Piggyback 120/90 – 18” 130/70 – 17” Tires size shock Stroke 300 mm –...
  • Page 74 LUBRICANT TABLE, SUPPLIERS Engine and gearbox ENI i-Ride MOTO 10W-50 lubricant Coolant liquid ENI PERMANENT SPEZIAL Air filter lubricant GREEN FILTER – AIR FILTER CLEANER Brake fluid ENI DOT 4 SAE J 1704 Lubricant grease ENI AGIP GR MU EP 2 Drive chain lubricant AGIP CHAIN GREASE SPRAY Suspension oil...
  • Page 75 OVERALL DIMMENSIONS 820 mm 1290 mm 960 mm 340 mm 1460 mm 2150 mm...
  • Page 76 HARNESS DIAGRAMS – ELECTRIC HARNESS...
  • Page 77 HARNESS DIAGRAMS – INJECTION HARNESS...
  • Page 78 HARNESS DIAGRAMS – DESCRIPTION REF. ELECTRIC HARNESS REF. CABLAGEM INJEÇÃO REF. LIGHTS RELAY YELLOW INJECTION RELAY INTERFACE B FUEL PUMP RELAY INTERFACE A BLACK FAN RELAY INJECTOR BLUE H4 CONNECTOR FUEL PUMP BROWN IGNITION KEY SWITCH NEUTRAL SENSOR GREEN HEADLIGHT SWITCH CRANKSHAFT POSITION SENSOR VIOLET LIGHTS/DIGITAL DASHBOARD...

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