AJP PR5 250 TRAIL / ENDURO / SUPERMOTO / 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.
! VERY IMPORTANT ! WE STRONGLY RECOMMEND YOU READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE GOING ON YOUR FIRST RIDE. IT COINTAINS A GREAT DEAL OF INFORMATION AND ADVICE, WHICH WILL HELP YOU USE AND HANDLE YOUR BIKE PROPERLY. IN YOUR OWN INTEREST, PLEASE PAY ATTENTION TO NOTICES THAT ARE MARKED AS FOLLOWS: ! WARNING ! IGNORING THESE INSTRUCTIONS CAN ENDANGER YOUR BODY AND YOUR LIFE, AS WELL AS OTHER PEOPLE`S LIFES.
TABLE OF CONTENTS CONSUMER INFORMATION COMPONENTS LOCATION CONTROLS LOCATION CONTROLS KEYS IGNITION SWITCH / STEERING LOCK DIGITAL SPEEDOMETER LEFT HANDLEBAR RIGHT HANDLEBAR FUEL FUEL TANK CAP GEARSHIFT LEVER REAR BRAKE PEDAL SIDE STAND SUSPENSION SET-UP ENGINE OIL RECOMMENDATION LIQUID COOLING BREAK-IN (RUNNING-IN) INSPECTIONS BEFORE RIDING RIDING TIPS ENGINE START STARTING OFF USING THE GEARBOX BRAKING STOPPING AND PARKING INSPECTION AND MAINTENANCE MAINTENANCE SCHEDULE MAINTENANCE WORK LUBRICATION POIN
CONSUMER INFORMATION ACCESSORY INSTALLATION AND PRECAUTION SAFETY TIPS There is some 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. Please contact your AJP dealer for assist you in selecting accessories and install them correctly.
MODIFICATION Modification of the motorcycle or removal of original equipment may render the vehicle unsafe or illegal. Engine number The engine number is stamped into the left side of the engine below the engine cylinder. SERIAL NUMBER LOCATION The frame and/or engine serial number are used to register the motorcycle. They are also used to assist your dealer when ordering parts or referring to special service information.
COMPONENTS LOCATION 3 2 4 1 7 6 5 10 9 8 11 1 2 3 4 5 6 7 Rear brake fluid reservoir Air filter Fuse Spark plug Oil cap Rear brake pedal Oil level glass AJP PR5 User’s manual – 3rd Edition – Rev 1 12 13 8 9 10 11 12 13 Battery Fuel tank Fuel tank cap Gear lever Footpeg Side rest Page 3
CONTROLS LOCATION 11 9 6 11 8 7 5 1 3 10 2 4 1 2 3 4 5 6 7 8 9 10 11 Clutch lever Blinker, lights, horn switch Front brake lever Starter button and On-Off switch Neutral sign Headlight sign Turn light sign Digital speedometer Ignition switch Throttle grip Rear view mirrors CONTROLS OFF position - all electrical circuits are cut off and the engine will not start. The key can be removed. ON position – the ignition circuit is on and the engine can now be started.
3 – Lights off In this position, no lights will be switched on. DIGITAL SPEEDOMETER 1 4 – Low beam on In this position, low beam light will be on in the headlight and presence light will be on in the taillight. Digital speedometer gives information about instantaneous speed and total or trip distance travelled. Depending on the selling market, speed and distance are indicated in Kilometres or miles. If you want to switch between these units, please contact your AJP dealer.
1 – Throttle grip Engine speed is controlled by the position of the throttle grip. Rotate it toward you to increase engine speed; turn it away to decrease engine speed. FUEL TANK CAP 2 – Front brake lever Front brake is applied by squeezing brake lever gently toward the throttle grip. Note: check that fuel cap is clear of dirt or water in order to let cap breather to work properly, avoiding injection malfunction or engine to stop. Turn the fuel tank cap (1) counterclockwise to open it.
GEARSHIFT LEVER SIDE STAND PR5 250 has a 6-speed transmission. Shift lever is mounted on the left side of the engine. The position of the gears is shown in the illustration. Neutral is located between first and second gear. Push the side stand to the ground with your foot and load it with the motorcycle. Make sure that you put the motorcycle on solid ground and in a secure position.
Front Fork Extreme (Marzocchi 48mm) SUSPENSION SET-UP Front Fork Enduro and Supermoto Set-up (Sachs 48mm) To adjust rebound turn the inner screw (1) clockwise to have a harder response. Turn counter clockwise to have a softer response. Set-up To adjust compression turn the inner screw (1) clockwise to have a harder response. Turn counter clockwise to have a softer response. 1 1 2 2 To adjust spring load, turn adjusting nut (2).
have a harder response. Turn counter clockwise to have a softer response. 1 2 To adjust rebound turn the screw (2) on the right leg clockwise to have a harder response. Turn counter clockwise to have a softer response. 3 1 To adjust rebound, turn the screw placed on the bottom of the shock absorber (3) clockwise for more rebound or counter clockwise for less rebound.
- - Low compression: turn all to close position (+) and then turn 8 clicks to open (-) Rebound: turn all to close position (H) and then turn 12 clicks to open (S) ! WARNING ! Improper servicing of the rear shock absorber assembly is dangerous. The rear shock absorber contains high-pressured gas and can explode if improperly serviced. Trail Version PR5 Trail shock absorber only allows spring pre-load.
Recommended liquid: Agip - SPEZIAL PERMANET – 40OC Note: Antifreeze Coolant temperature depends on the lower temperature that motorcycle will operate. Choose an anti-freezing coolant which resists to a range of temperatures 5/10 ºC below the minimum expected temperature in Winter. To check coolant level, never perform it with a hot engine. Liquid in radiator is under 1.1 bar of pressure and when the cap is opened, liquid may spill off and cause injuries and burns.
shuts off when temperature goes down to 80ºC. lubricating oil to reach all critical engine components. Observe your first and most critical service. The 1000 Kms service is the most important service your AJP will receive. Your motorcycle will be checked carefully, injection system controlled and updated, all adjustments will be restored, all fasteners and spokes will be tightened, dirty oil will be replaced and oil filters cleaned. ! WARNING ! ! WARNING ! Never cover front and/or rear sides of radiators.
must also comply with legal regulations. Check air pressure; insufficient tread and incorrect air pressure deteriorate driving performance. 5 - Brakes. Check correct functioning of the braking system and brake fluid level in both reservoirs. The reservoirs have been designed in such a way that brake fluid does not need to be refilled even when brake pads are worn. If the level of brake fluid falls below the minimum value, this indicates a possible leak or completely worn pads.
to the conditions and your driving skills. Drive carefully in unknown roads or unfamiliar trials. When driving off-road, always have a friend on a second motorcycle to make you company, so you can help each other if some problem happens. Replace helmet visor or goggle lens when scratched or damaged. If bright light shines through a scratched, the driver will be blinded. In case of a fall, check all functions thoroughly before start operating the motorcycle.
STARTING OFF Pull the clutch lever and put the engine into first gear. Slowly release the clutch lever and open the throttle at the same time. USING THE GEARBOX The first gear is referred as the drive or uphill gear. Depending on the conditions (traffic, hill size, etc.), you can shift to a higher gear. Close throttle, at the same time you pull clutch lever and shift to the next higher gear. Let clutch go again and give gas.
! WARNING ! Inexperienced riders tend to under use front brake. This can cause excessive stopping distance and lead to a collision. Using only front or rear brake can cause skidding and loss of control. Apply both brakes evenly and at the same time. ! WARNING ! Each time you brake, brake discs, pads, callipers and brake fluid heat up.
INSPECTION AND MAINTENANCE MAINTENANCE SCHEDULE The list indicates intervals between periodic services in Kilometres. At the end of each interval, be sure to inspect, check, lubricate and service as instructed. If your motorcycle is used under high stress conditions such as continuous full throttle operation or is operated in a dusty climate, certain services should be performed more often to insure reliability of motorcycle as explained in maintenance section.
MAINTENANCE SCHEDULE AFTER FIRST 1.000 km – BREAK IN Replace spark plug; Replace engine oil; Check 3 oil filters. Clean and wet in oil; Check engine oil level; Check air filter. Clean and wet in oil.
MAINTENANCE WORK ! WARNING ! Improper maintenance or failure performs of recommended maintenance increases the chance of accident or motorcycle damage. Always follow inspection and maintenance recommendations and schedules in this owner’s manual. Ask your AJP dealer to do the maintenance items marked with an asterisk (*). You may perform the unmarked maintenance items by referring to instructions in this section, if you have mechanical experience.
! CAUTION ! If you drive with play in the steering head bearings for long periods, bearings and subsequently bearing seats in the frame will be destroyed. 15 – 30 mm Cleaning the dust sleeves of the telescopic fork 1 The dust protection gaskets (1) are to remove dust and coarse dirt particles from the fork tube. However, after some time, dirt may also get behind the dust protection gasket. If this dirt is not removed, the oil sealing rings located behind it may start to leak.
! WARNING ! Excessive tensioning of the chain will put additional load on the components of the secondary drive chain (chain, bearings and rear wheel). Aside from resulting premature wear, chain may rupture or transmission countershaft may break. On the other hand, too much slack in the chain can result in chain jumping off the chain wheels. If this happens, chain could also block rear wheel or damage the engine. In either case, operator is likely to loose control of the motorcycle.
In this case, consult an authorized AJP dealer immediately. Refilling front brake fluid reservoir (*) Brake fluid AJP fills the brake systems with DOT 4 brake fluid. Recommended brake fluid: AGIP Brake Fluid DOT4 ! WARNING ! Change brake fluid at least once each two years. If you wash your motorcycle often, brake fluid should be changed even more often (once a year), as brake fluid tends to absorb water.
1 Clean the brake calliper and calliper support with compressed air. Check the sleeves of the guide bolts for damage and grease guide bolts if necessary. Mount both brake pads and then insert the clips the right way, to allow brake pads to jump off or lose, in order to avoid accidents. Tight the pegs over the clips at the front calliper (if exist in the model). Press brake lever several times until brake gets tough and certify that front wheel spins freely.
Brake fluid level must not drop below the “MIN” marking when the vehicle is in an upright position. ! CAUTION ! If free play is not present, then pressure can build up in the brake system when driving, causing rear wheel to brake. Brake system can overheat and may even completely fail in extreme cases. Don’t ride with foot pressing rear brake pedal.
FRONT WHEEL REMOVAL Front wheel mounting Front wheel dismounting To remove the front wheel, jack the motorcycle up on its frame so that the front wheel no longer touches the ground. Loosen the two screws (1) on left leg of front fork, unscrew front axle (2), hold the wheel and remove front axle. Remove front wheel carefully from the fork. If it is necessary to remove it, measure with a caliper the distance out of axle holder, in order to place it correctly later in assembly.
between the brake pads. Make sure that rear wheel guides are touching rear wheel adjusters (3) and that both have same setting. pressure ensures optimum driving comfort and extends the life of your tyres. ! WARNING ! Model After mounting rear wheel, operate brake pedal until pressure point is established. Keep brake discs free from oil and fatty materials, otherwise braking effect will be strongly reduced. Tighten the collar nut with required torque.
SPOKE TIGHTNESS Checking spoke tension Correct spoke tension is very important for the stability of the wheels and thus for riding safety. A loose spoke causes the wheel to become unbalanced and before long other spokes will have come loose. Check spoke tension, especially on a new motorcycle, in regular intervals. If necessary, have the spokes retightened and the wheel to correct by an AJP dealer. ! WARNING ! Spokes can tear if you continue to ride with them loose.
Replace a blown fuse only with an equivalent one. If a new fuse that has just been set in gets blown again, you are strongly advised to have it inspected by an AJP dealer. mount rubber cap and connector. Reinsert parking light lamp together with holder and fix the mask by means of the rubber bands. Use only 12V25/35W BA20d lamps. ! CAUTION ! Under no circumstances is a stronger fuse allowed to be set in or a fuse to be “repaired”. An inexpert treatment could damage the whole electrical installation.
! WARNING ! Do not clean air-filter with fuel or petroleum since these will damage the foam. Keep air filter clean and lubricated (oil wet) to assure a more effective protection to engine cylinder. Never start your motorcycle without air filter, otherwise dust or dirt may penetrate in the engine and cause damage or severe wear. THROTTLE CABLE Throttle grip and cable must be cleaned and lubricated often, if motorcycle is used or ride frequently off road (wet or dusty areas), to keep a smooth functioning.
Máx . Min . 2 1 . CLUTCH CABLE Clutch cable must have 10-20 of free play. Clutch functioning should not be affected if handlebar is turned completely left or right. Keep clutch cable always clean. Lubricate with grease at the contact area of lever and tuner for a smooth functioning. ENGINE OIL ! CAUTION ! Engine oil level should be checked daily or before any ride. If necessary you should add oil to keep always oil level between maximum and lower mark.
Remove oil drain plug (1) placed at the lower part of crankcase and the sealing washer; 2 1 1 Clean main oil filter and cover and blow with compressed air. Drain oil to an appropriate container in a way to avoid spill to the ground; OIL DRAINING PLUG This plug is located below the engine, at left crankcase, near the frame tube.
! CAUTION ! Kgf.m) Note: Certify yourself that main oil filter is placed in the right position Oil filter end with the hole must be facing inside the engine. Tight aluminum plug gently, to avoid damaging the thread on the crankcase. Remove cover (1) and fill with 1.7 liters of recommended engine oil. 1 Start the engine, let it idle for about two minutes and check for leaks. Finally, check the engine oil level and, if necessary, correct it.
- Clean motorcycle thoroughly and let it dry after each riding. - Treat engine, swing arm and all other bare galvanized parts (except for brake discs) with a wax-based anti-corrosion agent. - 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.
TECHNICAL SPECIFICATIONS Engine Type Displacement Bore x stroke Power Torque Carburettor Start Gearbox PR5 250 LC 1 Cylinder, 4 strokes, SOHC, 4 Valves 3 249 cm 77 x 53,6 mm 20,2KW (27,5 cv) / 8.000 r.p.m. 23,0 N.m / 7.000 r.p.m.
