AJP PR4 125 Owner's Manual
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AJP PR4 125 Owner's Manual

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  • Page 2 AJP PR4 125 / 200 / 240 ENDURO / ENDURO PRO / SUPERMOTO / SUPERMOTO PRO / EXTREME OWNER’S MANUAL This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when resold or otherwise transferred to a new owner or operator.
  • Page 3 PERFORMED BY AN AUTHORIZED AJP DEALER. PLEASE DON`T FORGET TO WEAR A HELMET, EYE PROTECTION AND PROTECTIVE CLOTHING WHEN GOING FOR A RIDE. WE WISH YOU A LOT OF FUN RIDING YOUR AJP! AJP MOTOS LDA RESERVES THE RIGHT TO MODIFY ANY EQUIPMENT, TECHNICAL...

  • Page 4: Table Of Contents

    TABLE OF CONTENTS USER INFORMATION COMPONENTS LOCATION CONTROLS LOCATION CONTROLS KEYS IGNITION SWITCH/STEER LOCK DIGITAL SPEEDOMETER LEFT HANDLEBAR RIGHT HANDLEBAR FUEL FUEL TANK CAP FUEL TANK CHOKE KNOB KICK STARTER PEDAL GEARSHIFT LEVER REAR BRAKE PEDAL SIDE STAND SUSPENSION SET-UP ENGINE OIL BREAK-IN (RUNNING-IN) INSPECTIONS BEFORE RIDING...

  • Page 5: User Information

    You should also wear suitable eye to purchase. The addition of unsuitable protection. accessories lead unsafe operating conditions. Please contact RIDING APPAREL your AJP dealer for assist you in Loose, fancy clothing selecting accessories and install them uncomfortable unsafe correctly.
  • Page 6 Chassis number Engine number The engine number is stamped into the left side of the engine below the engine sprocket, between gearshift lever and the oil cap. Engine no AJP PR4 User’s manual - 3 Edition Page 2...

  • Page 7: Components Location

    Air filter 11 Fuel tank Fuse 12 Gearshift lever Battery 13 Foot-rest Spark plug 14 Side rest Oil dipstick 15 Fuel filter Kick-starter 16 Oil filter Rear brake pedal Oil level glass AJP PR4 User’s manual - 3 Edition Page 3...

  • Page 8: Controls Location

    The steering lock is actuated and the travelled. Depending on the selling handlebar cannot turn. The key can be market, speed distance removed. To pass to lock position, the AJP PR4 User’s manual - 3 Edition Page 4...

  • Page 9: Left Handlebar

    Turning this button left left turn lights the engine. will be on. Turning right, right turn lights will be on. To switch turn lights off, place the button in middle position. AJP PR4 User’s manual - 3 Edition Page 5...

  • Page 10: Fuel

    - Wipe up spills promptly. CHOKE KNOB gasoline swallowed splashed in the eyes, seek a The AJP PR4 carburettor is equipped doctor’s advice immediately. with a choke system to provide easy starting when the engine is cold. When - Keep children and pets away.

  • Page 11: Kick Starter Pedal

    KICK STARTER PEDAL downshift. AJP PR4 are equipped with a kick-start REAR BRAKE PEDAL lever, just in case electric start fails. The foot brake pedal is disposed in The kick-starter lever is mounted on the front of the right footrest. Depressing...

  • Page 12: Suspension Set-Up

    (1) clockwise to have a harder response. Turn counter clockwise to have a softer response. Front suspension adjustment Enduro/Supermoto (Marzocchi 40mm) To adjust compression turn the inner screw (1) on the left leg clockwise to AJP PR4 User’s manual - 3 Edition Page 8...
  • Page 13 Tighten upper nut (1). ! WARNING ! Unequal suspension adjustment can cause poor handling and loss of stability. Adjust the right and left front legs to the same settings. Rear suspension adjustment AJP PR4 User’s manual - 3 Edition Page 9...

  • Page 14: Engine Oil

    If necessary, add oil to keep oil level Rebound: turn all to close position (H) between H mark and L mark. and then turn 11 clicks to open (S). AJP PR4 User’s manual - 3 Edition Page 10...

  • Page 15: Break-In (Running-In)

    The reservoirs critical service. The 1.000 Km service is have been designed in such a way that the most important service your AJP brake fluid does not need to be refilled PR4 will receive. All adjustments will be even when brake pads are worn.

  • Page 16: Riding Tips

    - Always turn on the lights to make Manage for the brake system to be sure that other drivers become checked by an AJP dealer, as complete aware of you as early as possible. failure of the system can be avoided.

  • Page 17: Engine Start

    Instructions for initial operation ! WARNING ! Before you start off, check the side - Verify if your AJP dealer performed a stand has been fully swung up. If previous preparation of the motorcycle. the side stand drags on the ground, - Read this manual carefully before you the motorcycle goes out of control.

  • Page 18: Starting Off

    STARTING OFF operation-related noise while riding, stop immediately, shut the engine Pull the clutch lever and put the engine off and contact an authorized AJP into first gear. Slowly release the clutch dealer. lever and open the throttle at the same - Never start your motorcycle time.

  • Page 19: Stopping And Parking

    OFF position on the Kilometres. At the end of each interval, ignition switch with the engine at idling have the care to go to an AJP dealer to speed until the engine stops. Park on inspect, check, lubricate and service as an area where the ground is firm and instructed.
  • Page 20 If you are not sure how to do any of the jobs, have your AJP dealer to do them. AJP PR4 User’s manual - 3 Edition Page 16...

  • Page 21: Maintenance Schedule

    Check tubes and oil radiator (200 and Replace brake fluids; 240cc engines) Replace front fork oil and/or Adjust and lubricate throttle cable; fork seals (if necessary). Adjust and lubricate clutch cable; AJP PR4 User’s manual - 3 Edition Page 17...

  • Page 22: Lubrication Points

    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. Also they might be permanently damaged. AJP PR4 User’s manual - 3 Edition Page 18...

  • Page 23: Drive Chain

    (4) to the same position. Clean dust-protection gaskets, outer tubes and fork tubes thoroughly, and oil them with silicone spray or engine oil; then push dust-protection gaskets into the outer tubes by hand. AJP PR4 User’s manual - 3 Edition Page 19...

  • Page 24: Brakes

    - In either case, operator is likely to lifecycle. loose control of the motorcycle. Brake discs (*) AJP PR4 User’s manual - 3 Edition Page 20...
  • Page 25 In this case, consult an authorized AJP dealer immediately. Brake fluid AJP fills the brake systems with DOT 4 brake fluid; we recommend that you continue to use it. AJP PR4 User’s manual - 3...
  • Page 26 Checking front brake pads basic position. Remove clips and the brake pads from the calliper. The front brake pads can be inspected from below. The linings must have at least 1 mm thickness. AJP PR4 User’s manual - 3 Edition Page 22...
  • Page 27 - Brake fluid level must not drop below between magnetic 0,7 ~1,0mm - the “MIN” marking when the vehicle is insert and sensor in an upright position. AJP PR4 User’s manual - 3 Edition Page 23...
  • Page 28 Brake fluid can cause skin irritation. Avoid contact with skin and eyes. If you get brake fluid in your eyes, clear with plenty of water and consult a doctor. AJP PR4 User’s manual - 3 Edition Page 24...

  • Page 29: Front Wheel Removal

    After mounting front wheel, operate hand brake lever several times until pressure point is established. Keep brake discs free from oil and fatty materials; otherwise braking effect will be strongly reduced. AJP PR4 User’s manual - 3 Edition Page 25...

  • Page 30: Rear Wheel Removal

    Rear 1.75(25) wheel adjusters (3) and that both have Front 1.75(25) Only driver same setting. Rear 2.0(28) Supermoto Front 1.75(25) Driver + Tight collar nut (1). passenger Rear 2.25(32) AJP PR4 User’s manual - 3 Edition Page 26...

  • Page 31: Spoke Tightness

    ! WARNING ! TORQUE: - Do not mount tires that are not Spoke head: 3.8 N.m (0,38 Kgf.m) Tire fixation: 15 N.m (1,5 Kgf.m approved by AJP. Other tires could have adverse effects on the way necessary, have spokes your motorcycle behaves.

  • Page 32: Engine Oil

    Note: Do not forget that AJP PR4 uses only unleaded fuel, 95 octane minimum. necessary, perform glass fibre Never use leaded fuel otherwise it will replacement in an AJP dealer. destroy catalytic converter. ! CAUTION ! Before proceeding with motorcycle...
  • Page 33 Engine oil has to be changed with the engine being at operating temperature. ! CAUTION ! An engine at operating temperature and engine oil it contains are very hot. Please take all cares to avoid AJP PR4 User’s manual - 3 Edition Page 29...

  • Page 34: Air Filter

    Then remove air filter’s cover by unscrewing fixation screw (2). For extra security, apply grease on the back side of the filter, which mates with air filter box. AJP PR4 User’s manual - 3 Edition Page 30...

  • Page 35: Fuel Filter

    FUEL FILTER Fuel filter is placed between right beam and carburettor, below driver’s seat. AJP PR4 User’s manual - 3 Edition Page 31...

  • Page 36: Idle

    AJP Check clutch functioning. dealer. Whenever is needed to replace clutch CLUTCH CABLE cable, use an original AJP cable.

  • Page 37: Spark Plug

    Place spark plug cap and make contact with spark plug thread and engine head. Actuate starter engine or kick start pedal to test spark plug spark. SPARK PLUG GAP: 0,6 – 0,7 mm AJP PR4 User’s manual - 3 Edition Page 33...

  • Page 38: Battery

    To remove the battery, first disconnect the negative (-) and then the positive (+) pole of the battery and then free rubber band. AJP PR4 User’s manual - 3 Edition Page 34...
  • Page 39 - When replacing with a new battery requires filling with electrolyte, this will produce an initial voltage high. To ensure a maximum AJP PR4 User’s manual - 3 Edition Page 35...

  • Page 40: Fuse

    Remove rubber cover, lose retaining clip and remove carefully lamp support out of headlight glass. Press lamp inside, rotate it counter clockwise and remove it away from holder. The fuse capacity is 20 Ampere. AJP PR4 User’s manual - 3 Edition Page 36...
  • Page 41 Remove lamp holder away headlight, press lamp inside, rotate it counter clockwise and remove it away from holder. Install a new lamp on the holder and put it back on the headlight hole. AJP PR4 User’s manual - 3 Edition Page 37...

  • Page 42: Sticker Replacement

    5-7 cm and then pressing with spatula. Note: Drain groove in each blinker must Let stand for 48 hours the stickers be facing down. before starting any sporting activity or cleaning. AJP PR4 User’s manual - 3 Edition Page 38...

  • Page 43: Motorcycle Cleaning

    - Once the motorcycle has cooled and could cause corrosion. down, oil or grease all sliding and AJP PR4 User’s manual - 3 Edition Page 39...
  • Page 44 - Fill up the tank with fresh fuel. - Check motorcycle as before each start (see DRIVING INSTRUCTIONS) - Take a short, careful test ride first and check all of your motorcycle systems. AJP PR4 User’s manual - 3 Edition Page 40...

  • Page 45: Technical Specifications

    Simple piston calliper, disc 220mm MICHELIN 100/80 - 17 MICHELIN ENDURO COMPETITION III 90/90 – 21 Front tire MICHELIN 130/70 – 17 MICHELIN ENDURO COMPETITION III 120/80 – 18 Rear tire AJP PR4 User’s manual - 3 Edition Page 41...

  • Page 46: Pr4 Wiring Scheme

    PR4 WIRING SCHEME AJP PR4 User’s manual - 3 Edition Page 42...

This manual is also suitable for:

Pr4 240Pr4 200SupermotoEnduroEnduro proExtreme

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