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AJP PR7 ADVENTURE 2022 Workshop Manual

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Summary of Contents for AJP PR7 ADVENTURE 2022

  • Page 1 Chapter AError! Reference source not found. - roubleshooting www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 2 Chapter AError! Reference source not found. - roubleshooting 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.
  • Page 3 Chapter AError! Reference source not found. - roubleshooting 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 (11-2022) www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 4 ONTENTS Foreword This publication is designed for use by AJP Motos Service Centers to assist authorized personnel in the maintenance and repair of the models covered in this manual. The technical information provided in this manual is a critical complement to operator training and operators should become thoroughly familiar with it.

  • Page 5: Table Of Contents

    Countershaft removal ....................33 Gearbox disassembly ....................33 Crankshaft removal ..................... 34 Crankshaft components removal ..................35 Chapter C........................38 ....................39 NFORMATION AND SAFETY TIPS ..................... 40 NGINE COMPONENTS AND DETAILS Cylinder head......................40 www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 6 Assembly and Lubrication Instructions ................61 Crankshaft assembly ..................... 69 Input shaft ......................... 72 Output shaft ....................... 73 Crankcase assembly ...................... 74 Gear sensor installation ....................80 Gear shift control assembly ..................... 81 www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 7 Crank gear ........................ 108 Transmission ......................108 Distribution ....................... 108 Base ........................109 Lubrication System ...................... 109 Electrical System ......................109 Clutch ........................109 Gear shift control ......................110 Cooling System ......................110 www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 8: Chapter A

    Chapter AError! Reference source not found. - roubleshooting Chapter A. Troubleshooting www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 9 3. Incorrect battery voltage Replace 4. ECU defective Replace 5. Fuel pump malfunction Replace The noise seems to come from the piston Engine excessively noisy 1. Excessive clearance between piston and cylinder Replace www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 10 2. ECU defective Replace 3. Low idle Adjust 1. Drive chain stretched or incorrectly adjusted Adjust/ The noise seems to come Replace from the secondary drive chain 2. Gearbox output pinion and crown worn Replace www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 11 1. Excessive accumulation of carbon deposits in Clean combustion chamber or piston crown Refill/ 2. Not enough or not recommended engine oil Engine overheats Replace 3. Radiator dirty Clean 4. Cylinder head gasket defective Replace www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 12 1. Wheel rim damaged Replace 2. Wheel bearings worn Replace 3. Incorrect spoke tension Adjust Wheels vibration 4. Wheel axle nut loose Adjust 5. Swing arm bearings worn Replace 6. Drive chain incorrectly adjusted Adjust www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 13 Insufficient brake 4. Brake pads or disk worn Replace 5. Brake disk damaged Replace 6. Wrong brake pedal setup Adjust 1. Exhaust system broken Replace Excessive exhaust noise 2. Exhaust system leak Check www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 14: Chapter B

    Chapter AError! Reference source not found. - roubleshooting Chapter B. Engine Components and Disassembly Process www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 15: Engine Components

    The coolant must be completely drained, as well as the used oil, before removing the engine www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 16: Engine Skid Plate

    The large plug in the right crankcase, drains the existing oil in the gearbox and clutch compartment and it is unscrewed with a 10MM wrench. www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 17: Air Filter Box And Injection Throttle Body

    Therefore, the assembly can be kept tied with a wire around the inner frames, so that it does not fall down and difficult the removal or installation of the engine. www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 18: Foreword , Table Of Contents

    Loosen the starter and ground cables terminals on  the engine (2). Remove the spark plug cap (3)  Remove the Lambda sensor on the exhaust, which  can be unscrewed with a 22MM spanner, or disconnect the connectors www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 19: Table Of Contents

    (with the muffler included). www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 20: Remove The Engine

     washer get out of the place until it is possible to remove the engine Raise the engine until dismount it from the tabs on  the lower fastening of the steel frame www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 21 Reinsert the shaft or a steel rod into the beams  hole to keep the arm and rear wheel assembly with the chassis, so that the motorcycle can be handled if necessary while the engine remains removed www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 22: Removing The Cylinder Head Cover

    Screws 1a and 1b are longer (65mm) and must be placed in the same position. Pay attention to the bush (5). Remove it from the flange (6) and insert in the pin (7) of the starter motor gear. www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 23 In this condition the notch (8) located on the cylinder head should be aligned with the notch (9) on the camshaft gear (10). 24mm Remove the timing chain tensioner (11) as follows:  o Unscrew the screw (12). www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 24 Unscrew the eight screws (15) securing the bearing  brackets (16) of the camshafts (17). 5 mm Remove the bearing brackets (16) by tightening  manually one of screws (15) in the threaded holes (18). www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 25 Chapter AError! Reference source not found. - roubleshooting Remove the lubrication tubes (19) and the camshaft  (17). www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 26: Removing The Water Pump

    Loosen the screw (8) to open the water pump body.  Unscrew the nut (10) to remove the impeller (11).  Remove the bolt (12) to replace the bearing (13) and  the seal (14). www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 27: Cylinder Head Removal

     the M8 nuts (2) located up front and at the rear under the head Use a 5 mm Allen wrench to loosen the screw (3) and  remove the chain slider (4). www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 28 Chapter AError! Reference source not found. - roubleshooting Remove the four stud bolts (5) inside cylinder head  (6) (10 mm Allen wrench - 0.39 in.) in a cross pattern. Remove the cylinder head and its gasket (7).  www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 29: Valve Removal

    Make sure the valve spring compressor is aligned  straight on the spring, or you might bend the valve stem. Do not compress the springs too much or they will weaken. www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 30 If the valve collets (7) have caused burrs on the valve stems, remove them before removing the valves. Remove the seals (8) from the valve guides.  Remember that seals must be replaced on assembly.  www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 31: Cylinder Removal

    Remove the head as described in the relevant  paragraph. Loosen the cylinder retaining screw (1) using an 8 mm  (0.31 in.) wrench. Remove the centering bushings (2).  Remove the cylinder (3) with its gasket (4).  www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 32: Piston Removal

    Remove the generator cover as described in the  relevant paragraph. Loosen the nut (1) and washer (2) securing the rotor  (3) (24 mm wrench - 0.94 in.). Fit guard (4) to the crankshaft.  www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 33 Chapter AError! Reference source not found. - roubleshooting Remove the rotor (3) using the puller (5).  Remove the flywheel (3) together with freewheel and  idler gear (6). Remove the roller cage (7) and the washer (8);  www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 34 Heat and remove the screws (9) (5 mm - 0.19 in.  Allen screws) and check the freewheel status: the rollers courses of action must not be worn or damaged. Ensure that all gears are in good condition.  www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 35: Clutch Cover Removal

    Remove the eleven M6x30 screws (1) and the two  M6x40 screws (2) M6x40 which fix the cover (3); remove the cover (3) with the related seal (4). Remove the bushings (5).  www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 36: Oil Filters Removal

    (3), spring (4) and filter (5). Replace the filter (5) and make sure to fit it with the  rubber end (6) facing into the engine. Check the O-ring (7) and replace it if damaged.  www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 37 Remove the clutch cover as described in the relevant  paragraph. Using an 8 mm (0.31 in.) wrench, unscrew the six  screws (1) securing the clutch springs. Remove springs, pressure plate (2) with actuator (3)  bearing (4) and shim. www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 38  Remove clutch housing (10) and clutch pushrod (11).  Clutch housing and drive gear (12) must always be replaced as a set. Remove the compass (13) with the related shim (14).  www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 39: Starter Motor Flange Removal

    (3) from the opposite end. Starter motor removal Remove the starter motor flange as described in the  relevant paragraph. Loosen the two screws (1) and remove the starter  motor (2). www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 40: Gearbox Drive Shaft Removal

    Pull out the selector shaft (1).  Loosen the two 4 mm (0.157 in.) socket head screws  (2) and remove plate (3) and selector sector gear (4). Be careful not to lose sector gear assembly components. www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 41 Chapter AError! Reference source not found. - roubleshooting Remove the drum (5) loosening the central shaft (6).  Loosen the retaining screw (7) of the ratchet (8) and  remove ratchet and spring (9). www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 42: Gear Sensor Removal

    Chapter AError! Reference source not found. - roubleshooting Gear sensor removal Loosen the screws (1) using an 8 mm Allen wrench and  remove the sensor (2). Remove pushrod (3) and spring (4).  www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 43: Crankcase, Crankshaft And Countershaft Disassembly

    Lift the tab of the lock washer (3).  Place the engine in the dead centre.  Loosen the countershaft nut (4) using an impact  screwdriver and remove counterweight (5) and washer (3). www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 44 (8) and washer (6). Lift the tab of the lock washer (9).  Hold the connecting rod with one hand and loosen the  crankshaft gear nut (10) using an impact screwdriver. www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 45 12a= M6x55 mm 12b= M6x55 mm + copper washer 12c= M6x55 mm 12d= M6x65 mm Secure the puller to the left crankcase and separate  the two crankcase halves. www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 46  Loosen the screws (2) and remove the plate (3)  retaining the crankshaft seal (4). On assembly, position the seal flush with the crankcase. Remove the seal (4) with a screwdriver.  www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 47: Countershaft Removal

    Remove the shaft (1) of the output shaft shifter forks.  Release the forks (2) and (3) from the drum (4) and  remove them. Remove the input shaft fork shaft (5) and remove the  drum (4). www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 48: Crankshaft Removal

    (if fitted). Crankshaft removal Slide the puller (1) over the right end of the  crankshaft. Secure the puller to the crankcase half and remove  the crankshaft (2) from the opposite side. www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 49: Crankshaft Components Removal

    Remove the crank pin from one of the flywheel  halves using a press. Remove connecting rod and needle roller bearing. Turn the shaft and remove the crank pin (2).  Remove the threaded cap and clean the crank pin.  www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 50 Remove the retaining plates (1) and (2) from the  crankcase halves. Heat up the crankcase halves to around 125 °C in a  furnace and extract the bearings using a suitable driver tool. www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 51 (2). Stator removal Take the ignition cover (which you have removed  previously) and remove the screws (1) and (2); Remove stator (3) and pick-up sensor (4) from the left  cover. www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 52: Chapter C

    Chapter AError! Reference source not found. - roubleshooting Chapter C. Engine Components and Details www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 53: Information And Safety Tips

    Flammable vapors develop during this procedure and metal filings blown by compressed air may get into your eyes. Perform this procedure away from open flames or sources of ignition and wear an eye protection. www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 54: Engine Components And Details

    0.9 - 1.0 mm (0.035 - 0.039 in.) 36.60 – 36.65 mm (1.441 – 1.443 in.) 30.60 – 30.65 (1.205 – 1.207 in.) 33 mm (1.229 in.) 27.5 mm (1.083 in.) Table 1 – Standard measurements for Valve seat refacing. www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 55 73° and 45° cutters. If the contact surface is too high on valve face,  reface the seat with 20° and 45°cutters. Ensure that seat contact surface is the correct width.  www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 56: Valve Guide

    Heat up the head in a furnace up to 170 °C.  Install the new guide from the top of the head using a  suitable punch. Smear the guide with oil before installation. Fit new sealing rings. www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 57 Ream the valve guide using a suitable reamer and lubricate with cutting fluid. Rotate the reamer when extracting it to avoid scoring the valve guide. When a valve guide is changed, the valve seat must be refaced. www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 58: Valve Guide Replacement

    (1.614 in.) Replace all valve springs whenever anyone spring exceeds the service limit.  Check the valve springs for proper squareness. Maximum acceptable deviation is 1.5 mm (0.059 in.)  on each side. www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 59: Valve Installation

    Maximum clearance 0.1 mm (0.004 in.). If the limit is exceeded, replace both rocker arms. On assembly, tighten shaft bolts to 25 Nm (2.55 Kgm or 18.4 ft/lb). (+LOCTITE 243).  www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 60: Camshaft

    Service limit: 0.1 mm (0.004 in.). Check that the lobes are in pristine conditions, without signs of scoring or distortion. Height "H" of lobes when new:  o Intake = 36.57 mm (1.44 in.) o Exhaust = 35.94 mm (1.415 in.) www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 61 Chapter AError! Reference source not found. - roubleshooting www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 62: Timing Chain And Gears

    Clean off any carbon deposits from piston crown and  grooves. Perform a careful visual inspection of the piston and check its dimensions. There should be no signs of forcing, scuffing, cracking or other damage. www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 63: Cylinder To Piston Clearance

    Clearance (Dc-Dp) Service Limit 0.025-0.055 mm 0.12 mm (0.0010-0.0022 in.) (0.0047 in) Piston pin The piston pin must be perfectly smooth, with no signs  of scoring, dents or bluing due to overheating. www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 64: Piston Rings

    Piston Mounting Clearance Service Limit Ring 0.20-0.45 mm 0.7 mm (0.00787-0.0177 in.) (0.027 in.) 0.20-0.45 mm 0.7 mm (0.00787-0.0177 in.) (0.027 in.) 0.10-0.20 mm 0.35 mm (0.00394-0.00787 in.) (0.014 in.) www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 65: Piston Ring To Groove Clearance

    * - position of end gap "d"  Piston Ring Mounting Clearance (H) Service Limit 0.030-0.065 mm 0.13 mm (0.00012-0.0025 in.) (0.0051 in.) 0.020-0.055 mm 0.11 mm (0.0008-0.0022 in.) (0.0043 in.) 0.010-0.180 mm 0.35 mm (0.0004-0.0071 in.) (0.0138 in.) www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 66: Small End And Big End Rod Clearance

    0.026-0.036 mm 0.080 mm (0.001-0.0014 in.) (0.0031 in.) Big end radial clearance Standard Wear Limit 0.02-0.028 mm 0.04 mm (0.0008-0.00112 in.) (0.0016 in) Standard Wear Limit 0.50-0.70 mm 0.080 mm (0.0197-0.0275 in.) (0.00315 in) www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 67: Big End Radial Clearance

    ØA wear limit = 16.945 mm (0.6671 in.). o ØB wear limit = 19.965 mm (0.786. in.). o ØC wear limit = 19.965 mm (0.786. in.). o ØD wear limit = 19.960 mm (0.7858 in.). www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 68: Crankshaft

    +0.022 connecting rod; ream the bushing bore to 20 mm +0.012 +0,00088 (0,79 in. +0,00048 Check bore concentricity as shown in the diagram.  www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 69: Clutch

    Measure the free length “L” of each spring with a calliper.  New spring L= 41 mm (1.61 in.). Service limit: 39 mm (1.38 in.).   Change any spring that is outside the service limit. www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 70 Check the needle roller bearing seats for signs of wear. If any are found, replace the part; 7- Primary drive gear pair: Check gear teeth for signs of wear or failure. If any are found, replace  the part. www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 71: Shifter Forks And Gears

    If service limit is exceeded, compare the components with new parts to determine which one needs to be removed.  Shifter fork to drum groove clearance (from new): 0.15-0.35 mm (0.006-0.014 in.)  Service limit: 0.5 mm (0.02 in.) www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 72: Oil Pump Disassembly

    Side Clearance: 0.10 mm (0.0039 in.)  On assembly, inspect the seals (3) and make sure the pins (4) are located correctly; for tightening torque figures, see Sections "H" and "X". www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 73: Chapter D

    Chapter AError! Reference source not found. - roubleshooting Chapter D. Engine Reassembly www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 74: General Information

    Cleaning all components thoroughly is critical to reliability; bearings and any wear parts must be lubricated with engine oil before assembly.  Screws, nuts and bolts must be tightened to the specified torque (see Tightening_Torque_Figures) www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 75: Assembly And Lubrication Instructions

    Chapter AError! Reference source not found. - roubleshooting Assembly and Lubrication Instructions  Crank – Alternator – Lubrication - Left Crankcase Half www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 76 20 Nm (2 Kgm- 14.75 ft/lb) Lubrication Notes:  Lubricant - Installation Instructions Lubrication Points-Notes Degrease Apply engine oil on installation Line up stator mark with cover mark WATER RESISTANT grease Engine oil www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 77 Chapter AError! Reference source not found. - roubleshooting Assembly and Lubrication Instructions  Gearbox - Gear Shift Control www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 78 M5 x 0.8 (+LOCTITE 243) 8 Nm (0.8 Kgm- 5.90 ft/lb  Lubrication Notes: Lubricant - Installation Instructions Lubrication Points-Notes Install with open end pointing to engine centre Engine oil Engine oil or WATER RESISTANT grease www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 79 Chapter AError! Reference source not found. - roubleshooting Assembly and Lubrication Instructions Clutch - Kick Start – Lubrication - Right Crankcase Half  www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 80 15 Nm (1.5 Kgm- 3.69 ft/lb) M14x1.5 24 Nm (2.45 Kgm- 17.70 ft/lb) M22x1.5 30 Nm (3 Kgm- 22.13 ft/lb) Lubrication Notes:  Lubricant - Installation Instructions Lubrication Points-Notes Engine oil Join crankcase halves using Loctite 5205 www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 81 Chapter AError! Reference source not found. - roubleshooting Assembly and Lubrication Instructions Head - Cylinder - Piston - Timing System - Water Pump - Spark Plug  www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 82 6 Nm (0.6 Kgm - 4.43 ft/lb) M6x1 (+LOCTITE 542) 8 Nm (0.8 Kgm - 5.90 ft/lb)  Lubrication Notes: Lubrication Points-Notes Lubricant - Installation Instructions Use sealant "AREXONS RHODORSEAL 5552" on installation Engine oil www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 83: Crankshaft Assembly

    Fit the needle roller bearing (3) and lubricate it the  engine oil. Install the connecting rod (4) and the second flywheel half (5) and align the two flywheel halves using a square. www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 84 0.45-0.7 mm (0.018-0.03 in.). Measure crankshaft run-out at the bearing locations  “C”. Run-out must not exceed 0.03 mm (0.0012 in).  Straighten the crankshaft using a copper hammer. www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 85 Chapter AError! Reference source not found. - roubleshooting  Input shaft  Output shaft www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 86: Input Shaft

    Fit 3 gear (9).  Fit spacer (10) and 2 gear (11).  Gear Number of teeth B: Control dimension with 4 gear engaged.  C: Control dimension with 3 gear engaged.  www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 87: Output Shaft

    - Fit bushing (14) to the input shaft (1). Lubricate inner and outer face with Molikote G-n plus  grease (or equivalent) before installation. - Fit 1 gear (15) with the bevelled edge facing 4 gear.  www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 88: Crankcase Assembly

    Heat up to around 125 °C and drive the ball bearings  into each crankcase half using a suitable driver tool. Fit the retaining plates (1) and (2) to the crankcase  bearings. www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 89 (3) and output shaft (4) gears are flush. Lubricate the shifter forks (5) with engine oil and  install them. Insert the selector drum (6) into its seat.  www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 90  the drum grooves (6). Rotate the selector drum to test operation.   Heat up the crankshaft bearing (10) and install the crankshaft (11).  Fit the countershaft (12) onto its bearing. www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 91 Make sure both crankcase locating bushings (13) are  in place. Apply a layer of “LOCTITE 5205” on the right  crankcase mating surface (14). Heat up the left crankcase bearing locations and  install the crankcase. www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 92  screws in the correct positions according the pattern shown. 12a= M6x55 mm (2.165 in.) 12b= M6x55 mm (2.165 in.) + copper washer 12c= M6x55 mm (2.165 in.) 12d= M6x65 mm (2.559 in.) www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 93 Cover the upper section of the engine with a cloth, a  sponge or the like to prevent screws or other parts from accidentally falling into the engine. www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 94: Gear Sensor Installation

    Insert spring (1) and pushrod (2) into their seat (3).  Fit the sensor (4); make sure to install the gasket.  Tighten the screws (5) 8 Nm (0.8 Kgm or 5.8 ft/lb). www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 95: Gear Shift Control Assembly

    Install the selector drum (4) making sure the tab (5)  locates in the recess (6) and secure drum with its screw (7). (Apply Loctite 243, tighten to 28 Nm; 2.8 Kgm; 20.65 ft/lb). www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 96 Tighten the screws (9) of plate (10), with Loctite 243, to 9.3 Nm (0.93 Kgm or 6.85 ft/lb). Make sure the spring (11) of the gear shift lever shaft  is positioned correctly. www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 97 Lubricate the shaft with engine oil and insert the  shaft (12) into the crankcase so that the teeth (13) mesh with sector gear (8) teeth and spring (14) locates to its abutment pin. www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 98: Install The Gear Shift Lever (15) And Operate The Gearbox Manually (9 Nm; 0.9 Kgm; 6.64 Ft/Lb)

    Fit the input shaft driving gear (2) with the bevelled  side facing out. Countershaft weight/gear installation Fit the countershaft gear (1) line up its dot with that  of the crankshaft gear (2) to set timing. www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 99 (5) between countershaft gear (1) and crankshaft gear (2). Bend the lock washer (3).  Fit the lock washer (6) onto the crankshaft gear  making sure the tab locates into the keyway. www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 100 Tighten the nut (11) to 70 Nm (7 Kgm or 51.58 ft/lb)  placing a half gear at the opposite side of the engine between countershaft gear (1) and crankshaft gear (2).  Bend the lock washer (10). www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 101: Clutch Assembly

    (lubricate with engine oil). Lubricate the shaft with engine oil and fit the clutch  housing (3). Fit the splined spacer (4).  Fit the clutch hub (5) and its lock washer (6).  www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 102 Refit the plates (9) (install a friction plate first and  then a steel plate and keep alternating between friction and steel plates; the last to go in should be a steel plate). www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 103: Piston Ring Installation

    Piston and cylinder installation  Remove the cylinder protection (1).  Install a new cylinder foot gasket (2).  www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 104 Lubricate the cylinder wall (7) with engine oil and  slide it over the piston rings. Fit the two locating bushings (8).  Secure the cylinder (7) to the crankcase tightening  screw (9) www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 105 Measure distance "A" on the two machined faces "B"  of the piston and choose the appropriate head gasket according to the table.  Remove spacers and screws (13) and fit the appropriate head gasket. www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 106: Cylinder Head Gasket Selection Table

    Gasket part no. -0.4 ± 0.05 mm 1.2 mm 8000 H0937 Piston lower than cylinder -0.5 ± 0.05 mm 1.1 mm 8A00 H0937 mating face -0.6 ± 0.05 mm 1 mm 8B00 H0937 www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 107: Cylinder Head Installation

    (see Section "X" for tightening torque figures). Refit the cooling water temperature sensor (4A) and  tighten to 15 Nm (1.5 Kgm or 11.6 ft/lb).  Tighten the two head to cylinder bolts (5) www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 108 Fit the shafts (9) of the rocker arms (10) as marked  on removal with the slotted end facing outwards. Tighten the screws (11)   Fit the two spring spacers (12). www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 109: Water Pump Installation

    Fit the water pump (5) to the head; check the O-ring (6) for damage.  Tighten the screws (7) to 8 Nm (0.8 Kgm or 5.8 ft/lb) + Loctite 542.  Connect the rubber hose (8) and tighten the clamp (9). www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 110: Timing Chain Tensioner Installation

     the two screws (2) to 10 Nm (1.0 Kgm or 7.25 ft/lb). Release the chain tensioner (1) using a screwdriver  (turn counter clockwise). Refit the screw (3) with its washer.  www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 111: Camshaft Installation

    Refit the oil pipe (7) with the curved end (7a) at the  intake camshaft end.  Lubricate lobes, springs and rocker arms with engine oil. Make sure that the centring bushings are in place in  the caps. www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 112  follows: S= (G1-G)+S1   S= Thickness of new shim  G1= Measured valve clearance  G= Specified valve clearance  S1= Thickness of old shim On assembly, check valve clearances.  www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 113: Cylinder Head Cover And Spark Plug Installation

    Refit the lubrication pipe to the head (4) and tighten  the drilled bolt (5) to 8 Nm (0.8 Kgm or 5.90 ft/lb).  Refit the Spark plug (6); 10-12 Nm (1.0-1.2 Kgm or 7.2-8.9 ft/lb). www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 114: Flywheel And Flywheel Cover Installation

    (7) to its flange (8) and install on the crankcase. Make sure the two locating bushings (9) are  positioned correctly. Fit washer (10) and roller cage (11) to the crankshaft.  www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 115 Fit the free-wheel gear (12) to the flywheel (13) and  tighten the screws (14). Degrease crankshaft taper end and flywheel bore and  smear crankshaft taper end with Loctite 270. Install flywheel (13) together with drive gear (14).  www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 116 Fit washer (15) and nut (16) and tighten to 130 Nm  (13.0 Kgm or 95.89 ft/lb) fitting a dummy gear to the crankshaft gears at the opposite end.  Fit bushing (17) and starter motor drive gear (18). www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 117 (20) in a cross pattern The two longer screws (20a) and (20b) (L=65mm) must be refitted in their original positions. Secure starter motor (7) tightening screw (21). 8 mm  (0.31 in.) wrench www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 118: Sprocket Installation

    9 Nm (0.9 Kgm or 6.5 ft/lb).  Fit a new gasket and install the complete cover (3) using the thirteen retaining screws up to 9 Nm (0.9 Kgm or 6.5 ft/lb). www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 119: Right Crankcase Assembly

    (gently rock the sprocket to facilitate installation). Tighten the screws (7) in a cross pattern  Note: Screws (7) are not all the same length; make sure to refit them in their original positions. www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 120: Chapter E

    Chapter AError! Reference source not found. - roubleshooting Chapter E. Bolts and Screws tightening torque www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 121: General Information

    Listed in the table are the tightening torque figures for the most important nuts and screws, which have determined in accordance with thread diameter, pitch and specific application.  These figures are obtained after cleaning the threads with solvent.  Tightening torque figures (+/- 5%). www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 122: Engine

    Size Obs. Z00055699 Centrifugal disc screw M6 x 1 Loctite nº243 161535902 Slider fastening screw M8 x 1.25 1.23 Z00062728 Seal plug for tensioner spring M6 x 1 1 Nm = 0.73756 ft/lb www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 123: Base

    Rotor ring screw M6 x 1 1040 Loctite nº270 Clutch Ultimate Torque settings Strength Reference Description Size Obs. 800036856 Hub and housing nut M18 x 1 835 – 1130 61.7 1 Nm = 0.73756 ft/lb www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

  • Page 124: Gear Shift Control

    Size M5 x 0.8 M6 x 1 M8 x 1.25 2.55 1 Nm = 0.73756 ft/lb NOTE: Unless otherwise specified, standard torque values for the different thread sizes are as follows (+/- 5%) www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 125 Steel screws on iron, steel 10.5 Steel screws on brass, copper, aluminum 11.8 Steel screws on iron, steel 19.1 Steel screws on iron, steel 38.3 Steel screws on iron, steel 73.8 Steel screws on iron, steel 14.5 www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...
  • Page 126 Chapter AError! Reference source not found. - roubleshooting www.ajpmotos.com WORKSHOP MANUAL AJP PR7 ADVENTURE |...

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