AJP PR4 Owner`s manual

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. The manual contains important safety information and instructions that
should be read carefully before start operating the motorcycle
3rd Edition - English version
AJP MOTOS, SA
OCTOBER 2013
! 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.
! CAUTION !
IGNORING THESE INSTRUCTIONS COULD CAUSE DAMAGE TO
PARTS OF YOUR MOTORCYCLE OR THAT THE MOTORCYCLE
IS NO LONGER SAFE TO RIDE ANYMORE.
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.
WE WISH YOU A LOT OF FUN RIDING YOUR AJP!
AJP MOTOS LDA 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 WITH OTHERS. 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
NOT BE HELD LIABLE FOR ANY PRINTING ERRORS.
i
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
RIDING TIPS
ENGINE START
STARTING OFF
USING THE GEARBOX
BRAKING
STOPPING AND PARKING
MAINTENANCE SERVICE
MAINTENANCE SCHEDULE
LUBRICATION POINTS
CHECKING AND ADJUSTING STEERING HEAD BEARINGS
DRIVE CHAIN
BRAKES
FRONT WHEEL REMOVAL
REAR WHEEL REMOVAL
TIRES
SPOKE TIGHTNESS
EXHAUST SYSTEM
ENGINE OIL
AIR FILTER
FUEL FILTER
THROTTLE CABLE
IDLE
CLUTCH CABLE
SPARK PLUG
BATTERY
FUSE
LIGHT BULB REPLACEMENT
STICKER REPLACEMENT
MOTORCYCLE CLEANING
CONSERVATION FOR WINTER OPERATION
STORAGE PROCEDURES
TECHNICAL SPECIFICATIONS
PR4 WIRING SCHEME
1
3
4
4
4
4
4
5
5
6
6
6
6
7
7
7
7
8
10
11
11
12
13
14
14
14
15
15
17
18
18
19
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25
26
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31
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36
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42
ii
USER 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.
! WARNING !
Improper
accessories
or
modifications can make your
motorcycle unsafe and can lead to
an accident. Never modify the
motorcycle with improper or poorly
installed accessories. Follow all
instructions in this owner’s manual
regarding
accessories
and
modifications. Consult your AJP
dealer if you have any questions.
Certain accessories displace the rider
from his normal position. This limits the
freedom of movement and may limit his
control ability.
Additional electric accessories may
overload the electric system. Severe
overloads may damage the wiring
harness or create a dangerous situation
due to the loss of electric power during
the operation of the motorcycle.
When carrying a load on the
motorcycle, mount it as low as possible
to the machine. An improperly mounted
load can create a high center of gravity
that is very dangerous and makes the
motorcycle difficult to handle. The size
of the load can also affect the
aerodynamics and handling of the
motorcycle. Balance the load between
the left and right sides of the motorcycle
and fasten it securely.
AJP PR4 User’s manual - 3rd Edition
SAFE RIDING RECOMMENDATIONS
FOR MOTORCYCLE RIDERS:
WEAR A HELMET
Motorcycle safety equipments starts
with a quality helmet. One of the most
serious injuries that can happen is a
head injury. ALWAYS wear a properly
approved helmet.
You should also wear suitable eye
protection.
RIDING APPAREL
Loose,
fancy
clothing
can
be
uncomfortable
and
unsafe
for
motorcycle riding. Choose good quality
motorcycle riding apparel when riding
your motorcycle. Wear gloves, strong
boots that fit over the ankle, long pants
and long sleeve shirt or jacket.
INSPECTION BEFORE RIDING
Review all the instructions in the
“INSPECTION
BEFORE
RIDING”
section in this manual. Do not forget to
perform an entire safety inspection to
ensure safety of the rider.
FAMILIARIZE YOURSELF WITH THE
MOTORCYCLE
Your riding skill and your mechanical
knowledge form the basis for safe
riding. We recommend you to practice
riding your motorcycle in an open area
without obstacles until you are
familiarize with your motorcycle and its
controls.
KNOW YOUR LIMITS
Always ride within the limits of your
skills. Knowing your limits and keep
within are the foundation to avoid
accidents and injuries.
BE EXTRA SAFETY CONSCIOUS ON
BAD WEATHER DAYS OR BAD
ROAD CONDITIONS
Riding on bad weather days requires
extra attention. Braking distances
double in a rainy day. If you are not
sure about road conditions ride slower
and with double care!
Page 1
MODIFICATION
Modification of the motorcycle or
removal of original equipment may
render the vehicle unsafe or illegal.
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.
Chassis number
The chassis number is stamped on the
right side of the steering head tube.
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 - 3rd Edition
Page 2
COMPONENTS LOCATION
15
2
3
4
5
1
1
2
3
4
5
6
7
8
9
Rear brake fluid reservoir
Air filter
Fuse
Battery
Spark plug
Oil dipstick
Kick-starter
Rear brake pedal
Oil level glass
AJP PR4 User’s manual - 3rd Edition
6
7 8
9
10
11
12
13
14
15
16
Fuel tank cap
Fuel tank
Gearshift lever
Foot-rest
Side rest
Fuel filter
Oil filter
Page 3
switch must be in OFF position and the
pushed down and turned to the left. The
handlebar must be turned all the way to
the left.
CONTROLS LOCATION
11
11
OFF position - all electrical circuits are
cut off and the engine will not start. The
key can be removed.
10
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
KEYS
This motorcycle comes with a pair of
keys. Be aware to keep one of the keys
in a safe place, at home for instance, in
order to let you access this key in case
of need.
IGNITION SWITCH/STEER LOCK
ON position – the ignition circuit is on
and the engine can now be started. The
key cannot be removed from the
ignition switch.
! CAUTION !
To activate LOCK position, the
switch must be in OFF position, then
pushed down and turned to the left.
Handlebar should be turned all the
way to the left. If not, the switch will
not pass to LOCK position.
! CAUTION !
Don’t try to ride with the switch on
LOCK position. The steering is
locked and control of the motorcycle
is impossible.
Don’t turn the ignition key to LOCK
position while driving!
Note: Start engine as soon as you turn
key to ON position. Otherwise battery
will loose power due to the
consumption of the digital speedometer
and headlight and taillight, if turned on.
DIGITAL SPEEDOMETER
OFF
ON
1
LOCK
LOCK position – all electrical circuits
are cut off and the engine will not start.
The steering lock is actuated and the
handlebar cannot turn. The key can be
removed. To pass to lock position, the
AJP PR4 User’s manual - 3rd Edition
It gives information about instantaneous
speed and total or trip distance
travelled. Depending on the selling
market, speed and distance are
Page 4
indicated in Kilometres or miles. If you
want to switch between these units,
please contact your AJP dealer.
To switch from total to trip distance
push button 1. To reset trip distance the
trip distance must be selected; then
push button 1 until the distance is reset
to zero.
7 – Horn
To actuate horn, press this button.
! CAUTION !
In several countries, motorcycle
riding is only allowed with low beam
on!
Respect
your
national
legislation!
LEFT HANDLEBAR
5
1
4
3
2
! CAUTION !
Turn lights are not switched off
automatically! Be aware to switch
turn lights off after turning or
overtaking! Otherwise you will give
wrong information about your riding
to other drivers!
RIGHT HANDLEBAR
6
1
7
2
1 – Clutch lever
The clutch lever is used for disengaging
the drive to the rear wheel when
starting the engine or shifting the
transmission gear. Squeezing the lever
disengages the clutch.
3
4
2 – Parking light on
With the light knob in this position,
parking lights in the headlight and
taillight will be switched on.
3 – Lights off
In this position, no lights will be
switched on.
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.
5 – High beam on
In this position, high beam light will be
on in the headlight and presence light
will be on in the taillight.
6 – Turn sign on
Turning this button left left turn lights
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 - 3rd Edition
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.
2 – Front brake lever
Front brake is applied by squeezing
brake lever gently toward the throttle
grip.
3 – Electric start button
This button is used for turning the
starter motor. With the ignition switch in
the ON position, the transmission in
neutral, starter switch on, pull the clutch
lever and push the electric start button
to engage the starter motor and start
the engine.
Page 5
4 – Emergency switch
This switch has two positions: to the left
enables engine running, to the right
stops engine running. Be aware that
this switch is switched ON for engine
starting.
! CAUTION !
If EMERGENCY SWITCH is not ON,
engine will not start! Start motor will
not be actuated!
! WARNING !
Using not recommend fuel can
cause severe damages on engine!
Be sure to use always only
unleaded gasoline with an octane
index equal or higher than 95!
FUEL TANK CAP
Turn the fuel tank cap (1) counterclockwise to open it. Turn clockwise to
close and tighten it securely.
! CAUTION !
The EMERGENCY SWITCH should
be used to stop the engine in
emergency situations! Do not use it
to stop the engine when driving
otherwise the ignition system will be
destroyed!
1
FUEL
AJP PR4 engines need unleaded
premium gasoline with an octane
number of 95 or higher. Never use
leaded fuel to avoid destroying catalytic
converter and the exhaust system.
! WARNING !
Gasoline is highly flammable and
poisonous. Extreme caution should
be used when handling gasoline.
- Do not refuel motorcycle near open
flames or burning cigarettes.
- Always switch off engine before
refuelling
- Be careful not to spill gasoline on
the engine or exhaust pipe while the
engine is hot
- Wipe up spills promptly.
- If gasoline is swallowed or
splashed in the eyes, seek a
doctor’s advice immediately.
- Keep children and pets away.
AJP PR4 User’s manual - 3rd Edition
FUEL TANK
! CAUTION !
The use of longer bolts to hold fuel
tank, side panels or rear fender, can
cause permanent damages on the
fuel tank.
! CAUTION !
Because of the transparent fuel
tank, there is not fuel indicator or
light warning! Control fuel level
when you start the motorcycle and
when you are riding for some time!
CHOKE KNOB
The AJP PR4 carburettor is equipped
with a choke system to provide easy
starting when the engine is cold. When
the engine is cold, pull the lever up; it
has two positions: the first (1) is for
when engine temperature is more than
20º; the second (2) is for when engine
temperature is below 20º. Choke works
best when throttle is on closed position.
Page 6
When the engine is warm - above 40ºyou do not need to use choke for
starting (0).
5
4
3
2
N
2
1
1
0
KICK STARTER PEDAL
To shift properly, pull the clutch lever
and close he throttle at the same time
you operate gearshift lever. Lift the
lever to up-shift and depress to
downshift.
AJP PR4 are equipped with a kick-start
lever, just in case electric start fails.
REAR BRAKE PEDAL
The kick-starter lever is mounted on the
right side of the engine and its upper
part can be swivelled. To be actuated it
should be rotated outside.
The foot brake pedal is disposed in
front of the right footrest. Depressing
the rear brake pedal will apply the rear
brake.
! WARNING !
If you want to start engine, make
sure you always wear rigid footwear,
like motorcycle boots, in order to
avoid injuries. You might slip of the
kick-starter or engine may kick back
and hit your leg very strongly!
Always kick kick-starter briskly all
the way without opening the throttle;
if you don’t do it with enough
momentum and with throttle open,
kick back hazard will increase!
! WARNING !
Be sure kick-starter lever is returned
to its home position after starting the
engine.
An improperly retracted kick-starter
lever can interfere with rider control!
GEARSHIFT LEVER
AJP PR4 has a 5-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.
AJP PR4 User’s manual - 3rd Edition
! WARNING !
If opposition of hand brake lever or
rear brake pedal fells “spongy” (too
much smooth), this is an indication
that the brake system is not
functioning well. Don’t ride anymore
your motorcycle without first having
the brake system checked by an
AJP dealer!
SIDE STAND
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.
Page 7
have a harder response. Turn counter
clockwise to have a softer response.
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.
! WARNING !
Always check if you have folded
back the side stand before each
ride. If the side stand touches the
ground while you drive, you may
loose control of your motorcycle!
1
2
Screw (3) placed on the lower end of
the legs of 40mm Marzocchi has no
adjusting function; it should only be
removed for front fork disassembly.
! CAUTION !
The side stand was designed only
for the weight of the motorcycle. If
you get on the motorcycle and thus
put additional weight, the side stand
or frame can be damaged and the
motorcycle may fall on the side!
! CAUTION !
Park the motorcycle on solid level
ground to help prevent it from falling
over.
If you must park on an incline, aim
the front of the motorcycle uphill and
put the transmission into 1st gear to
reduce the chance of rolling off the
side stand.
SUSPENSION SET-UP
Front suspension adjustment
Enduro/Supermoto (Marzocchi
40mm)
3
Front
Fork
Extreme
(Marzocchi 48mm)
Set-up
To adjust compression turn the inner
screw (1) clockwise to have a harder
response. Turn counter clockwise to
have a softer response.
To adjust compression turn the inner
screw (1) on the left leg clockwise to
AJP PR4 User’s manual - 3rd Edition
Page 8
Enduro and Supermoto:
1
These versions are equipped with a
shock absorber which only allows
spring pre-load adjustment.
2
To adjust middle speed, turn adjusting
nut (2).
To adjust rebound, turn the lower screw
clockwise (3) for more rebound; turn
counter clockwise for less rebound.
2
1
To adjust pre-charge loose first the
upper nut (1), then turn adjusting nut (2)
clockwise for more pre-charge or
counter clockwise for less pre-charge.
Tighten upper nut (1).
Enduro PRO,
EXTREME:
Supermoto
PRO,
These versions are equipped with a
fully adjustable shock absorber.
3
To adjust pre-charge loose first the
upper nut (1), then turn adjusting nut (2)
clockwise for more pre-charge or
counter clockwise for less pre-charge.
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
2
AJP PR4 User’s manual - 3rd Edition
1
Page 9
Compression:
To adjust damping force, turn the
button placed on the top of the gas
reservoir (3) clockwise for more
damping force or counter clockwise for
less damping force.
3
! 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.
ENGINE OIL
Recommendation
Use only branded oil for four stroke
engines, to ensure a long engine life.
Use only oils meeting or surpassing the
quality requirements of API classes SF
or SG:
Recommended oil:
ENI / Agip i-Ride moto SAE 20W-50
Specification: API SG JASO MA, MA2.
Rebound:
To adjust rebound, turn the screw (4)
clockwise for more rebound speed. To
reduce rebound speed turn counter
clockwise.
Checking engine oil level
Engine oil level is checked in a glass
placed in front of rear brake pedal.
Level should be between Min and Max.
Max
Min
4
Standard Sachs Shock absorber
(PRO Versions) settings:
Spring length:
- Enduro 205mm;
- Supermoto 210mm.
Damping force: turn all to close position
(+) and then turn 20 clicks to open (-).
Rebound: turn all to close position (H)
and then turn 11 clicks to open (S).
AJP PR4 User’s manual - 3rd Edition
If oil level is below Min, oil must be
refilled immediately. If you check that
engine is losing oil (for instance at oil
radiator or oil tubes in 200/240 cc
engines), contact your AJP dealer
immediately.
! CAUTION !
Engine oil level should be checked
everyday or before start any trip. If
necessary, add oil to keep oil level
between H mark and L mark.
Page 10
! WARNING !
Insufficient engine oil or poor
quality may cause severe damage
to the engine.
Never operate your motorcycle with
low engine oil level or with nonadequate engine oil quality.
BREAK-IN (RUNNING-IN)
The following explains why is so
important proper break-in to achieve
maximum life and performance from
your new AJP.
Even very precisely machined sections
of engine components have rougher
surfaces than components that have
been sliding across one another for
quite some time; therefore, every
engine needs to be broken in during the
first 1.000 Km.
For this reason, do not load engine
more than 50% of its capacity during
the first 500 kilometres, avoiding fullthrottle. In the following 500 kilometres,
you may load the engine up to 75% of
its capacity, using the gearbox
frequently.
Allow sufficient idling time, about 1-2
minutes, after warm or cold engine start
up before applying load or revving the
engine. This allows time for the
lubricating oil to reach all critical engine
components.
Note: Be aware of your first and most
critical service. The 1.000 Km service is
the most important service your AJP
PR4 will receive. All adjustments will be
restored, all fasteners and spokes will
be tightened, engine oil will be
replaced, oil filter cleaned and air filter
cleaned and lubricated.
INSPECTIONS BEFORE
RIDING
Check the following before each
start
When you start off, the motorcycle must
be in perfect mechanical condition. For
safety reasons, you should make a
habit of performing an overall check
before each start.
The following checks should be
performed:
1 – Oil level. Insufficient oil quantity
results in premature wear in engine
components and damages in engine
itself.
2 - Fuel. Check there is sufficient fuel in
the tank;
3 - Drive chain. A loose chain can fall
from the chain wheels; an extremely
worn chain can tear and insufficient
lubrication can result in excessive wear
to the chain and chain wheels.
Excessive tensioning of the chain will
put additional load on the components
of the secondary drive train (chain,
bearings of transmission and rear
wheel). Aside from resulting premature
wear, the chain may even rupture or the
transmission axle may break.
4 - Tires. Check for cuts or dents and
replace tires if necessary. The tread
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.
! WARNING !
Incorrect break-in may cause severe
damage to your motorcycle or
significantly reduce your motorcycle
lifetime!
AJP PR4 User’s manual - 3rd Edition
Page 11
! WARNING !
Failure to run these inspections and
maintain your motorcycle properly
increases the chance of an accident
or equipment damage
Always perform a pre-ride inspection
before each ride. Refer to the list
behind for check items. For further
details, refer to the INSPECTION
AND MAINTENANCE section.
Manage for the brake system to be
checked by an AJP dealer, as complete
failure of the system can be avoided.
Also check status of the brake hoses
and the thickness of brake linings, as
well as free travel of hand brake lever
and foot brake pedal.
6 - Electric system. Check correct
functioning of headlamps, taillights,
brake lights, indicators, control lamps
and horn while the engine is running.
7 - Luggage. If you are taking any
luggage with you, check that it is
securely fastened.
8 – Steering – Check for smoothness,
no restriction on movement and no play
or looseness.
9 – Throttle – Check for correct play,
smooth operation and positive return to
the closed position.
10 – Clutch – Check for correct play,
smoothness and progressive action.
11 – Suspensions – Check
suspensions for smooth movement.
12 – Engine stop switch – Check for
correct function.
! WARNING !
Using worn, improperly inflated or
non-homologated tires will reduce
stability and can cause an accident.
Follow all instructions in the TIRES
section.
! WARNING !
Checking maintenance items when
the engine is running can be
hazardous. You could be severely
injured if your hands or clothing get
caught in moving parts!
AJP PR4 User’s manual - 3rd Edition
RIDING TIPS
! WARNING !
- Wear suitable clothing when
driving a motorcycle. Never forget to
wear a helmet, gloves and boots,
even in short trips. Protective
clothing should be brightly coloured
to make you more visible to other
drivers.
- Always turn on the lights to make
sure that other drivers become
aware of you as early as possible.
- Do not drive after having
consumed alcohol or drugs.
- Use only original spare parts and
accessories.
- Front and rear tires are allowed to
be fitted only with tires having the
same
original
profile
type
(homologated).
! WARNING !
- Observe traffic regulations and
drive defensively, trying to look
ahead as far as possible so that any
hazards can be recognized as early
as possible.
- Adjust your driving speed
according 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.
- Do not repair twisted handlebar:
Replace it immediately.
Page 12
Instructions for initial operation
- Verify if your AJP dealer performed a
previous preparation of the motorcycle.
- Read this manual carefully before you
ride.
- Familiarize yourself with all the
operating controls.
- Get used to the handling of the
motorcycle on an empty parking lot or
open space, before going for a longer
ride. Try also to drive as slow as
possible and in sitting position to
improve your feeling of the motorcycle.
- Hold the handlebar with both hands
and leave your feet on the footrests
while driving.
– Remove your foot from the brake
pedal when you are not braking. If the
brake pedal is not released the brake
pads will rub continuously and the
braking system will overheat.
- Do not make any changes to the
motorcycle and use always AJP original
spare parts for safety reasons.
- Motorcycles are sensitive to changes
in the weight distribution. If you are
taking any luggage with you, secure it
as close as possible to the middle of
the motorcycle, in order to distribute the
weight for both wheels.
ENGINE START
Starting when the engine is cold
1- Swing up the side stand and turn
the ignition key on.
2- Put the gear in neutral (the neutral
pilot lamp will light up).
3- Operate the choke lever all the way
up.
4- Check if the emergency switch is
on running position.
5- Operate the electric start button or
kick the kick-starter briskly all the
way without touching the throttle.
! CAUTION !
Never actuate electric starter for
more than 5 seconds and with
lights on. Wait at least 5 seconds
before trying again.
AJP PR4 User’s manual - 3rd Edition
! WARNING !
Before you start off, check the side
stand has been fully swung up. If
the side stand drags on the ground,
the motorcycle goes out of control.
Always turn on the light to make
sure that other drivers become
aware of you as early as possible.
! WARNING !
Never ride your motorcycle with full
load or rev the engine when cold.
Because the piston is warming up
faster than the cylinder, it can
cause engine damage.
Starting when the engine is warm
1- Swing up the side stand and turn
the ignition key on
2- Put the gear in neutral
3- Check if the emergency switch is
on running position.
4- Operate the electric start button or
kick the kick-starter briskly all the
way without touching the throttle.
What to do when the engine is
“flooded”
In the event of a fall, more fuel than
necessary may get into the engine. In
order to “pump the engine free”, fully
rev up the engine, actuate the kickstarter 5 to 10 times or actuate the
electric starter twice for 5 seconds
each. Then, start the engine as
described above.
If the engine fails to start, unscrew the
spark plug and dry it.
NOTE: PR4 carburettor is equipped
with an acceleration pump (Power Jet).
Each time you open the throttle, extra
fuel is pumped to engine inlet.
Therefore, when starting, you should
take care to open the throttle
progressively (or full) in one time.
Page 13
! WARNING !
- If you want to start the engine with
kick start pedal, make sure you
always put on rigid motorcycle boots
in order to avoid injuries. You might
slip off the kick-starter or the engine
may kick back and hit your foot
upward very strongly.
- Always kick kick-starter briskly all
the way without opening the throttle;
if you don’t do it with enough
momentum and with the throttle
open, kick back hazard will increase.
- Do not start the engine or allow it
to idle in a closed area. Exhaust
gases are poisonous and can cause
loss of consciousness and even
death. Always provide adequate
ventilation while the engine is
running.
- Never leave engine running for a
more than 5 minutes while the
motorcycle is parked: engine will
overheat and severe damage may
occur.
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. If you
turned on the choke lever, make sure
you turn it off again as soon as engine
is warm.
When you reach full speed by opening
the throttle all the way, turn throttle
back to ¾; the speed hardly decreases
and the engine will use less fuel.
Only give as much gas as the engine
can handle. Through quick and high
AJP PR4 User’s manual - 3rd Edition
revving of throttle, the fuel consumption
increases.
By shifting down, use the brakes if
necessary and close throttle at the
same time. Pull clutch lever and shift
down to the next gear. Let clutch lever
go slowly and open throttle or shift
down again.
! CAUTION !
- High RPM speed when engine is
cold have an adverse effect on the
life of your engine. We recommend
you to run the engine in a
moderate RPM range for 5/10
Kilometers/miles giving it the
chance to warm up.
- Never have the throttle wide open
when shifting down a gear. The
engine will over-rev, damaging the
valves.
- If any abnormal vibrations occur
while driving, check that the engine
fastening bolts are tight. If it
remains contact an authorized AJP
dealer.
- If you notice any unusual
operation-related noise while riding,
stop immediately, shut the engine
off and contact an authorized AJP
dealer.
- Never start your motorcycle
without air filter in place, otherwise
dust and dirt may enter to the
engine and cause increased wear
or damage.
BRAKING
Apply both brakes at the same time
with the throttle closed. When driving
on sandy, wet or slippery ground use
mainly the rear brake. Avoid blocking
the wheels, otherwise you may skid or
fall; also you can change down to a
lower gear depending on your speed.
Page 14
! 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.
Use the braking effect of the engine
when driving downhill to assist the
brakes; change down one or two gears
but do not over-speed the engine. This
way, you will not need to use the
brakes so much and avoid overheating.
! WARNING !
Hard braking while turning may
cause wheel skid and loss of
control.
Brake before you begin to turn.
of these parts after operating the
motorcycle or allow children to come
nearby.
- Take care to park the motorcycle
where pedestrians are not likely to
touch it and get burned.
- Never park your motorcycle in
places where there is fire hazards,
such as dry grass or other easily
flammable materials.
Actuate the engine kill button to shut off
the engine.
Note regarding side stand:
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. Just in case, you can
shift into first gear.
! CAUTION !
! WARNING !
Hard braking on wet, loose, rough or
other slippery surfaces can cause
wheel skid and loss of control.
Brake lightly and with care on
slippery or irregular surfaces.
Side stand was designed only for
the weight of the motorcycle. If you
get on the motorcycle and thus put
additional weight, side stand or
frame can be damaged and the
motorcycle may fall on the side.
STOPPING AND PARKING
MAINTENANCE SERVICE
Apply the brakes fully and put the
engine into neutral. To turn off the
engine, apply the emergency off button
or turn the key to OFF position on the
ignition switch with the engine at idling
speed until the engine stops. Park on
an area where the ground is firm and
lock the motorcycle.
! WARNING !
- Never leave your motorcycle
without supervision if the engine is
running or with children nearby.
- Motorcycle engines produce a
great amount of heat when running.
Engine, exhaust pipe, muffler, brake
callipers and shock absorber can
become very hot. Do not touch any
AJP PR4 User’s manual - 3rd Edition
Maintenance
schedule
indicates
intervals between periodic services in
Kilometres. At the end of each interval,
have the care to go to an AJP dealer 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.
Your AJP dealer can provide you with
further guidelines.
Steering components, suspension and
wheel components are key items and
Page 15
require very special and careful
servicing. For maximum safety we
suggest that you have these items
inspected and serviced by your
authorized AJP dealer.
! WARNING !
Do not start the engine or allow it to
idle in a closed area. Exhaust gases
are poisonous and can cause loss of
consciousness and even death.
Always provide adequate ventilation
while the engine is running.
! WARNING !
It is owner’s responsibility to assure
that motorcycle is serviced within
this periodic maintenance schedule.
AJP does not assume any damage
if maintenance is not performed as
schedule.
! WARNING !
An intense riding, with high
revolutions, tracks with dust and
mud, demands air filter cleaning and
maintenance more frequent than
recommended, to assure correct
motorcycle functioning.
! 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. If you are not sure how
to do any of the jobs, have your AJP
dealer to do them.
AJP PR4 User’s manual - 3rd Edition
! CAUTION !
Using poor quality replacement
parts or materials can cause your
motorcycle to wear more quickly
and may shorten its useful life.
Use only genuine AJP replacement
parts.
! CAUTION !
- When cleaning your motorcycle,
be careful when using a highpressure cleaning unit, in order to
avoid water to penetrate air filter,
bearings,
carburettor,
electric
connectors, etc.
- When transporting your AJP PR4,
ensure that it is held upright with
restraining straps.
- Use only special screws with an
appropriate thread length supplied
by AJP to fix fuel tank. Using other
screws or longer ones can cause
cracks in the tank through which
fuel can flow out.
- Let your motorcycle cool down
before beginning any maintenance
work in order to avoid get burned.
- Remove oil, grease matters,
filters, fuel, washing detergents,
etc, orderly.
- Under no circumstances may
used oil be disposed off in the
sewage system or in the open
countryside. Remember: 1 litre of
used oil contaminates 1.000.000
litres of water!
Page 16
MAINTENANCE SCHEDULE
A description of several necessary
operations to a correct functioning of
motorcycle and periods is as follows.
DAILY
Check engine oil level and refill if
necessary.
Check clearance of secondary chain.
Check brake system functioning.
AFTER FIRST 1.000 km – BREAK
IN
Replace spark plug;
Replace engine oil;
Clean engine oil filter;
Check engine oil level;
Clean air filter. Wash and wet in oil;
Check valve clearance;
Check correct functioning of: braking
system, spoke tightness; tire condition;
clutch cable; side stand; steering stem
suspensions;
battery;
bearings;
exhaust; electrical system.
Check secondary chain;
Check wheel gear bolts tightening;
Check tightness of several components
bolts and clamps.
EACH 500 km OR MONTH
Check oil level and refill if necessary.
Check air filter. Clean and wet in oil;
Check, adjust, clean and lubricate
secondary chain;
Check wheel gear bolts tightening;
EACH 3.000 km OR 6 MONTHS
Replace spark plug;
Replace engine oil and clean engine oil
filter;
Check engine oil level;
Check valve clearance;
Check timing chain clearance;
Check timing tensioner;
Check ignition system functioning;
Clean carburetor;
Clean air filter and wet in oil or replace;
Replace fuel filter;
Check fuel feed hoses,
Check tubes and oil radiator (200 and
240cc engines)
Adjust and lubricate throttle cable;
Adjust and lubricate clutch cable;
AJP PR4 User’s manual - 3rd Edition
Check condition and functioning of
several component of electrical system;
Check condition and functioning of
battery charge system;
Check battery. Control voltage with or
without charge;
Check braking system functioning and
stop switches;
Check brake pads,
Check brake fluid level;
Check, adjust, clean and lubricate
secondary chain;
Check wheel gear bolts tightening;
Check wheels bearings;
Check tires condition;
Check spoke tightness;
Check side stand functioning;
Check steering functioning;
Check suspensions functioning;
Check exhaust: condition, leaks and
noise level;
Check tightness of bolts, nuts, clamps
of diverse components.
EACH 6.000 km OR 12 MONTHS
Perform operations indicated for each
3.000 km, plus:
Replace spark plug;
Clean carburetor and check the right
settings;
Clean air filter box and replace sealing
silicon at the cover;
Clean and lubricate or replace air filter;
Check intake manifold (between air
filter box and carburetor);
Replace fuel filter;
Check fuel feed hoses;
Check functioning of fuel cap valve;
Lubricate steering stem bearings;
Lubricate rear suspension links;
Lubricate swing arm bearings.
Check wheels bearings;
Check/replace front fork sealings (if
necessary).
EACH 12.000 km OR 24 MONTHS
Perform operations indicated for each
3.000 and 6.000 kms, plus:
Clean fuel tank;
Replace engine timing chain;
Replace brake fluids;
Replace front fork oil and/or
fork seals (if necessary).
Page 17
LUBRICATION POINTS
Proper lubrication is important for
smooth operation and long life of each
working part of your motorcycle and
also for safe riding. It is a good practice
to lubricate the motorcycle after a long
rough ride and after getting in snow,
wet, mud or after washing it. Major
lubrication points are indicated.
! WARNING !
Lubricant cannot spill over brake
disk or tires, otherwise grip and
braking capacity are considerably
reduced and rider may lose
motorcycle control.
CHECKING
AND
ADJUSTING
STEERING HEAD BEARINGS (*)
Check steering head bearings for play
periodically.
For
check,
place
motorcycle on a stand so that the front
wheel is off the ground. Try to move the
fork forward and backward.
Check if handlebar rotates freely.
Check if control cables don’t interfere
with handlebar rotation.
For readjusting, loosen top nut (2) and
the two bolts (1) of the top triple clamp
and turn steering stem bolt (3)
clockwise until there is no more play.
2
1
3
If handlebar rotates in a not even way,
grips or has vertical movement, check
and adjust steering stem bearings.
Note: If you press brake lever and
compress
several
times
front
suspension, while with left hand fingers
positioned between adjusting nut and
steering stem, may be detected any
bearings clearance.
Don’t tighten the steering stem bolt (3)
all the way; otherwise the bearings will
be damaged. With a plastic hammer,
lightly rap on the triple clamp to relief
tension and retighten the bolts. Then
tight top nut (2) and the top triple clamp
screws (1).
Steering head bearings should be
greased at least once a year.
! WARNING !
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 - 3rd Edition
Page 18
! 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.
DRIVE CHAIN
Drive chain adjustment
The chain slack must be of 15-30mm,
at the mid point between the chain
buffer and the rear sprocket.
Cleaning the dust sleeves of the
telescopic fork
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.
15 – 30 mm
To adjust the drive chain, follow the
procedure bellow:
1
1 - Place the motorcycle on the side
stand
2 - Loose axle nut (1)
3 – Loose fixing nuts on both sides (2)
4 – Regulate adjuster screws (3) until
the chain has 15-30mm of slack.
Use a screwdriver to lever the dustprotection bellows out of the outer
tubes and slide them downward.
1
3
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 - 3rd Edition
2
At the same time that the chain is being
adjusted, the rear sprocket must be
kept in perfect alignment with the front
sprocket. Align both right and left
adjusters (4) to the same position.
Page 19
Drive chain maintenance
4
5 - Re-tighten the axle nut (5) securely
and tighten fixing nuts (6).
A good maintenance is very important
for long chain life. Chains without orings should be cleaned in fireproof
solvent regularly and afterwards treated
with hot grease or chain spray. On the
other hand, o-ring chains are very
simple to clean. The best way is to use
lots of water but never use brushes or
cleaning liquids. After letting the chain
dry completely, use a chain spray to
lubricate it.
Also check sprockets and chain guides
for wear and replace if necessary.
! CAUTION !
When mounting chain master link
clip, the closed side of the master
link must point in the running
direction.
5
6
5- Recheck the chain slack after
tightening, lubricate and adjust if
necessary.
! WARNING !
! 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.
No lubrication should be allowed to
reach rear tyre or rear brake disc,
otherwise road grip and rear wheel
braking effects will be strongly
reduced and the motorcycle can
easily get out of control.
BRAKES
Brake pads
Brake pads used on front and rear
brake provide an optimal combination
of power, brake performance and
lifecycle.
Brake discs (*)
AJP PR4 User’s manual - 3rd Edition
Page 20
Recommended brake fluid:
ENI Brake Fluid DOT 4 (SAE J1703,
FMVSS116)
! WARNING !
Due to wear, the thickness of brake
discs in the area of the contact face (1)
of the brake pads decreases. At their
thinnest point (A), the brake discs must
not be more than 0.50mm thinner than
the pads nominal thickness. Measure
the nominal thickness in a location (B)
outside the contact face and check for
wear in several locations.
! WARNING !
For your own safety, have the
brake discs replaced immediately
as soon as they reach wear limit (3
mm thickness).
Have any repairs on brake system
performed by an AJP authorized
dealer.
Brake fluid reservoirs
Change brake fluid at least once
each two years. If you ride in wet
conditions or wash your motorcycle
often, brake fluid should be
changed even more often (once a
year), as brake fluid tends to
absorb water. Therefore, vapour
pockets may form on “old” brake
fluids even at low temperatures,
causing brake system to fail.
! WARNING !
Store brake fluid out of reach of
children.
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.
Checking the brake fluid level – front
brake
Brake fluid reservoir is linked with the
hand brake cylinder at the handlebar
and the reservoir is provided with an
inspection glass (1). With the reservoir
in horizontal position, the brake fluid
level should not drop below the middle
of the glass.
Brake fluid reservoirs have been
designed in such a way that even if the
brake pads are worn it is not necessary
to refill brake fluid. If brake fluid level
drops below the minimum level, either
the brake system has a leak or the
brake pads are completely worn.
In this case, consult an authorized AJP
dealer immediately.
Brake fluid
1
AJP fills the brake systems with DOT 4
brake fluid; we recommend that you
continue to use it.
AJP PR4 User’s manual - 3rd Edition
Page 21
Refilling front brake fluid reservoir
Loosen screws (1), remove cover (2)
and membrane. Place hand brake
cylinder in a horizontal position and fill
the brake fluid reservoir up to the MAX
mark with clean brake fluid DOT 4.
1
! WARNING !
Replace membrane, lid and tighten
screws. Clear off spilled or overflowing
brake fluid with water.
! CAUTION !
Don’t let brake fluid get in contact
with paint; it is an effective paint
remover.
Use only clean brake fluid from a
sealed
or
hermetic
closed
container.
! CAUTION !
Do not remove front or rear brake
cover while handlebar is not in a
position where reservoir is leveled
and motorcycle vertical.
Avoid actuate brake lever with cover
removed. Brake fluid will spill over if
lever is actuated.
Do not mix different fluids, once they
can be incompatible.
Avoid spill fluid over painted parts,
plastic or rubber. Place a cover over
those parts whenever braking system
is under maintenance.
Checking front brake pads
The front brake pads can be inspected
from below. The linings must have at
least 1 mm thickness.
AJP PR4 User’s manual - 3rd Edition
At their most worn point brake pad
linings should not be thinner than
1mm, otherwise can lead to braking
failure.
! WARNING !
If brake pads are replaced too late
so that the lining is partly or entirely
worn, steel components of brake
pad will rub against brake disc,
thereby reducing braking effect and
destroying brake disc.
Replacing front brake pads
Remove calliper assembly, unscrewing
screws (1).
1
Press the brake calliper away from
brake disc to put the brake piston in its
basic position. Remove clips and the
brake pads from the calliper.
Page 22
! WARNING !
Keep brake discs free from oil and
fatty materials; otherwise braking
effect will be strongly reduced.
Having performed any work on the
braking system, one must always
actuate hand brake lever or foot
brake pedal, to ensure that brake
pads will fit against brake disc and
pressure is established.
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.
Changing the basic position of the
brake pedal
Free play can be changed by turning
piston (1).
Measured on the outside, the foot brake
pedal must have 3 to 5 mm of free play,
before the piston rod can move the
piston in the rear brake cylinder.
! CAUTION !
Install front calliper at the front fork,
placing disc between pads.
Apply thread glue at the bolts end
and tight them correctly.
If
necessary,
readjust
digital
speedometer sensor positioning in
order to have the correct gap 0,7 ~1,0mm - between magnetic
insert and sensor
AJP PR4 User’s manual - 3rd Edition
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.
Checking rear brake fluid level
The reservoir for the rear disc brake is
integrated in brake pump, placed in the
right side of the engine, near exhaust
pipe.
Brake fluid level must not drop below
the “MIN” marking when the vehicle is
in an upright position.
Page 23
! WARNING !
! WARNING !
If brake fluid level drops below the
minimum or brake system has a
leak or brake pads are completely
worn. In this case, consult an
authorized dealer immediately.
If brake pads are replaced too late
so that the lining is partly or entirely
worn, steel components of brake
pad will rub against brake disc,
thereby reducing braking effect and
destroying brake disc.
Refilling
reservoir
the
rear
brake
fluid
! CAUTION !
Unscrew the cap (1), diaphragm and
add brake fluid DOT 4 until it reaches
the MAX mark, then place diaphragm
and cap back on. Clear off spilled or
overflowing brake fluid with water.
Don’t place brake fluid in contact
with paint; it is a powerful paint
remover
Use only clean break fluid or from a
sealed container
Replacing the rear brake pads
1
Remove the rear wheel – see “REAR
WHEEL REMOVAL” and with a
screwdriver push the brake pads to
move the pistons into their basic
position. Remove clip (1) and then
remove brake pads from the calliper.
Checking the rear brake pads (*)
1
The brake pads can be inspected from
the rear. The thickness of the linings
cannot be less than 1mm.
! WARNING !
At their most worn point brake pad
linings should not be thinner than
1mm, otherwise can lead to brake
failure.
! WARNING !
Store brake fluid out of reach of
children.
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 - 3rd Edition
Clean the brake calliper thoroughly with
compressed air, insert brake pads and
secure them with the clip. Then place
rear wheel back on.
Note: if necessary, push pads with an
appropriate key in order to place brake
piston away to let brake pads to pass
brake disc.
Page 24
FRONT WHEEL REMOVAL
Dismounting and mounting front
wheel
To remove the front wheel, jack the
motorcycle up on its frame so that the
front wheel no longer touches ground.
Note: Threaded spacer (3) must not be
untighten neither removed from right
leg end, once this is the part that
positions front wheel on the front fork
(Marzocchi 48mm) of PR4 EXTREME.
If it is necessary to remove it, measure
its position away of leg’s end and note
it. This way, when placing it back, it
must be with the same distance.
! CAUTION !
Do not operate hand brake lever
when front wheel has been
removed.
ENDURO / SUPERMOTO
Loosen the 2 clamping screws (1) on
the right side of the fork, hold the wheel
and unscrew the front axle (2). Remove
the front wheel carefully from the fork.
3
Note:
Reference
position
when
assembling threaded bush at the lower
right leg end: 10mm away of outer side
of leg’s end.
Front wheel mounting
Place front wheel between front fork
sleeves in a way that brake disc is
between brake pads.
Tighten front axle or the fixation nut and
tight fixation screws.
2
1
EXTREME
Loosen the 2 clamping screws (1) on
the left side of the fork, hold the wheel
and unscrew the front axle (2). Remove
the front wheel carefully from the fork.
Check if front wheel rotates freely
without any restrain.
Actuate several times front brake lever
until you certify that front brake is
working.
! WARNING !
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.
1
2
AJP PR4 User’s manual - 3rd Edition
Page 25
REAR WHEEL REMOVAL
Dismounting and mounting the rear
wheel
Jack the motorcycle up on its frame so
that the rear wheel no longer touches
the ground. Loosen the collar nut (1) in
the right side, hold the rear wheel and
pull out the wheel spindle (2) by the left
side until the rear wheel is free but the
brake calliper support is still held in the
swing arm.
Push the rear wheel as far forward as
possible, take out the chain from the
rear sprocket and carefully remove the
wheel carefuly from the swing arm.
Check if rear wheel spins freely with no
constraint.
Actuate several times brake lever to
certify that rear brake is working
properly.
! WARNING !
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. A loose wheel spindle may
lead to unstable behaviour of your
motorcycle.
TIRES
Tires, air pressure
3
2
1
! CAUTION !
Do not operate rear brake pedal
when rear wheel has been
removed.
Make sure brake disc is always on
top when you lay down the wheel,
otherwise brake disc can be
damaged.
If axle is dismounted, clean the
thread of the wheel spindle and
apply a new coat of grease to
prevent thread from jamming.
To mount rear wheel, follow the above
procedure in reverse order, being
careful to place the brake disc correctly
between the brake pads. Make sure
that rear wheel guides are touching rear
wheel adjusters (3) and that both have
same setting.
Tight collar nut (1).
AJP PR4 User’s manual - 3rd Edition
Tire type, its condition and air pressure,
affect the way your motorcycle
behaves; therefore, they must be
checked whenever you are getting
ready to go anywhere on your
motorcycle.
- Tire size can be found in the technical
specifications
and
registration
documents.
- Before leaving, check tires for
punctures and nails or other sharp
objects that might have become
embedded in them. Refer to specific
regulations in your country for minimum
tire tread requirements.
- Tire pressure should be checked
regularly on a “cold” tyre. Proper
pressure ensures optimum driving
comfort and extends the life of your
tyres.
Model
Enduro
EXTREME
Only driver
Driver +
passenger
Only driver
Supermoto
Front
Pressure
in bar (psi)
1.5(21)
Rear
1.75(25)
Front
Rear
Front
Rear
Front
Rear
1.5(21)
1.75(25)
1.75(25)
2.0(28)
1.75(25)
2.25(32)
Tire
Driver +
passenger
Page 26
These pressure values are indicated for
road use. For an off-road use on
Enduro and EXTREME versions, we
recommend a lower pressure, to assure
traction. In these conditions, we
recommend 1,0 bar (14 psi) in both
tires.
Please consider that these are
indicative values and that correct
pressure depends on the ground where
you drive.
! WARNING !
- Do not mount tires that are not
approved by AJP. Other tires could
have adverse effects on the way
your motorcycle behaves.
- Front and rear wheels may only
be fitted with tires having same
layout. Use homologated tires.
- For your own safety replace
damaged tires immediately.
- Worn tires can have a negative
effect on how your motorcycle
performs,
especially
on
wet
surfaces.
- If air pressure is too low,
abnormal wear and overheating of
tire can result.
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.
TORQUE:
Spoke head: 3.8 N.m (0,38 Kgf.m)
Tire fixation: 15 N.m (1,5 Kgf.m
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. This may lead
to an unstable handling of your
motorcycle.
EXHAUST SYSTEM
Maintenance
While cleaning your motorcycle, certify
yourself that no water enters in the
muffler. To avoid that, place a
plug/cover at the muffler’s hole.
Catalysed exhaust
Catalysed exhaust does not require
specific maintenance, only take care
when refuelling.
Tight spoke heads and tire fixation (if
exists).
AJP PR4 User’s manual - 3rd Edition
Page 27
Note: Do not forget that AJP PR4 uses
only unleaded fuel, 95 octane minimum.
Never use leaded fuel otherwise it will
destroy catalytic converter.
If necessary, perform glass
replacement in an AJP dealer.
fibre
! CAUTION !
Before proceeding with motorcycle
cleaning, certify that engine is cold,
otherwise thermal gradient may
cause cracks.
! WARNING !
! WARNING !
The use of non recommended fuel
may cause serious damages in the
engine. Certify yourself that you use
always unleaded fuel with a level of
octanes equal or higher than 95
octanes.
Aluminium muffler
Requires a regular maintenance, as
much frequently and as much severe
and intense riding.
Exhaust system reaches high
temperatures that may origin
serious skin burnings.
Before perform any operation at
exhaust system, certify that engine
and exhaust components are
already cold.
ENGINE OIL
Recommendation
Use only branded oil for four stroke
engines, to ensure a long engine life.
Use only oils meeting or surpassing the
quality requirements of API classes SF
or SG:
Recommended oil:
ENI / Agip i-Ride moto SAE 20W-50
Specification: API SG JASO MA,
MA2.
Capacity:
- 1,0 Liters at 125 engine.
- 1,1 Liters at 200 engine.
- 1,1 Liters at 240 engine.
Checking engine oil level
A wet glass fibre will increase noise
level and a lower performance due to
oil saturation or coal deposited at
muffler’s core.
Engine oil level is checked in a glass
placed in front of rear brake pedal.
Level should be between Min and Max.
Glass fibre should be replaced each
3.000Km or 50 hours of use. Otherwise,
noise level will increase to illegal and
painful levels and leading to destruction
of muffler components.
AJP PR4 User’s manual - 3rd Edition
Page 28
burning yourself.
Place the motorcycle on a horizontal
surface, remove the oil filter cover (that
works as drain plug) and allow the oil to
drain into a receptacle. Never drain
used oil to the ground, waste, water
lines or sewage.
Max
Min
If oil level is below Min, oil must be
refilled immediately. If you check that
engine is losing oil (for instance at oil
radiator or oil tubes in 200/240 cc
engines), contact your AJP dealer
immediately.
! WARNING !
Take out the oil drain together with oil
filter, clean these components carefully
and blow with compressed air. Check
o-ring and sealing and replace them if
necessary.
Once the entire oil has been drained,
clean the sealing surface, mount the oil
drain (1) together with spring (2), oil
filter (3) and sealing (4) on the right
position and tighten up to 15Nm (1,5
Kg.m).
Insufficient engine oil or poor
quality may cause severe damage
to the engine.
Never operate your motorcycle with
low engine oil level or with nonadequate engine oil quality.
! 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 H mark and
lower L mark.
! WARNING !
On PR3 200/240, if any oil pipe or oil
radiator is damaged and present leak,
engine should be immediately stopped.
Otherwise serious damages in engine
will happen due to lack of oil in
lubricating circuit.
4
1
2
3
Screw aluminium drain carefully to
avoid damaging carter’s thread.
Remove the oil dipstick (1) and fill in
with recommended quantities:
Changing engine oil (*)
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 - 3rd Edition
1
Page 29
! CAUTION !
When removing oil dipstick, be
careful not to let any dirt enter the
engine.
If oil level drops quickly, do not
operate your motorcycle. Take your
motorcycle to an authorized AJP
dealer immediately, to a full check
of engine.
Use an adequate filler to introduce oil in
the engine.
2
Tighten plastic dipstick.
Start the engine and check for leaks.
Finally, check the engine oil level and, if
necessary, correct it.
Remove metallic support inside air filter
foam element.
AIR FILTER
Cleaning air-filter
A dirty air filter restricts airflow rate,
reduces the engine performance and
increases fuel consumption, therefore
clean it in regular intervals.
Note: air filter requires a more frequent
service
as
indicated
on
MAINTENANCE
SCHEDULE,
if
motorcycle is used on dusty, muddy or
wet conditions (off road use)
For this purpose, remove driver’s seat,
by unscrewing to screw (1) in the back
of the seat and pull it in to rear
direction. Then remove air filter’s cover
by unscrewing fixation screw (2).
Thoroughly wash the air-filter in special
cleaning fluid, squeeze it and dry it with
compressed air.
Install metallic support inside air filter
foam.
Oil the dry air filter with high-grade filter
oil and clean the air filter box.
For extra security, apply grease on the
back side of the filter, which mates with
air filter box.
1
AJP PR4 User’s manual - 3rd Edition
Page 30
1
1
Mount the filter together with the filter
bracket and fix them with the rubber
washer and the screw.
! WARNING !
Do not clean air-filter with fuel or
petroleum since these will damage
the foam.
Never use fuel or diluent to clean
air filter box, to avoid damage
sealing silicon between box and
cover.
Keep air filter clean and lubricated
(wet in oil) to assure a more
effective protection of engine
cylinder.
Never start your motorcycle without
air filter, otherwise dust or dirt may
penetrate in the engine and cause
damage or severe wear.
It should be replaced whenever there
is dirt on it, because dirt can reduce or
block fuel flow producing loss of power
or irregular engine functioning.
THROTTLE CABLE
Adjusting throttle cable
The throttle grip should always provide
for a backlash of 2-6mm, measured in
the adjusting screw outside the throttle
grip. Besides, with the engine running,
the idling speed must not change if you
turn the handlebar all the way to the left
or right.
To adjust throttle cable, draw back dust
protection, loosen the counter nut (1)
and
turn
the
adjusting
screw
accordingly (2). Tighten the counter nut
and check whether the throttle grip can
be actuated smoothly.
FUEL FILTER
Fuel filter is placed between right beam
and carburettor, below driver’s seat.
1
2
AJP PR4 User’s manual - 3rd Edition
Page 31
IDLE
Idle speed: 1300 (+/-100) rpm
Adjust idling
Idling adjustment of the carburettor
strongly affects the engine starting
behaviour, that is, an engine whose
idling speed is adjusted correctly will be
easier to start.
Adjustment:
Smaller adjustment are made at lever
tuner.
1
Pull rubber protection out;
Untight fixation nut and rotate tuner;
When free play is right, tight fixation nut
and place rubber protection over tuner.
The idle sped is controlled by means of
the mixture control screw (1). Turning
the mixture control screw clockwise
reduces the fuel quantity (lean mixture);
turning counter-clockwise increases the
fuel quantity (rich mixture).
Note: by technical reasons and specific
carburettor adjustment, we highly
recommend that any intervention done
at carburettor should be done only by
an experient technician or at a AJP
dealer.
Check clutch functioning.
CLUTCH CABLE
Whenever is needed to replace clutch
cable, use an original AJP cable.
Clutch cable must have a 10-20mm
free play. Clutch actuation must not be
affected by the complete turning of
handlebar to the top left or top right.
Lubricate and install a new clutch cable
on the right position, in a way to avoid
bends that turn clutch harder to use.
Keep always clean and lubricated
clutch cable for a smoother functioning.
Apply lubricant grease in the contact
area between lever and tuner.
Major adjustments are performed at the
tuner of clutch cable bracket (1).
Measure free play at the end of clutch
lever.
Free play: 10 – 20 mm.
AJP PR4 User’s manual - 3rd Edition
Page 32
1
Note: in case of clutch cable
replacement, certify that new cable is
placed at the right position. If that does
not happen, it may interfere with front
fender,
block
handlebar/steering
movement and cause an accident.
By technical reasons we highly
recommend
that
clutch
cable
replacement should be done only at a
AJP dealer.
Inspect visually spark plug.
Check following and replace if
necessary:
• Ceramic insulator broken or cracked;
• Worn electrodes;
• Electrode color:
o Slightly
dark
means
good
condition;
o Too much bright means bad
functioning or lean air fuel ratio
o Wet or with coal deposit means
rich air fuel ratio.
SPARK PLUG
Removal
Clean around spark plug base with
compressed air.
Disconnect spark plug cap (1) and
remove spark plug with an appropriate
16mm key.
Recommended spark plug
Standard: LG D8TC
Equivalente: Champion A8YC ou NGK
DR8ES
Adjustment
Measure spark plug gap with a
feeler gauge (1).
Adjust the gap by
electrode carefully.
bending
side
1
Inspection
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 - 3rd Edition
Page 33
Reusing a spark plug
Clean spark plug electrodes with a wire
brush or special plug cleaner.
Replacing a spark plug
Select a new spark plug;
Set plug cap to specification with a
feeler gauge.
Assembly
Place a spark plug and tight as far as
possible by hand;
If installing a new spark plug, turn a ½
further after washer mates surface. If
it’s a old one, turn ¼ further.
If it is possible to use a dynamometric
key, torque to specification.
Torque: 12 N.m (1,2 Kgf.m)
! WARNING !
Do not over tight spark plug torque.
Applying a higher torque may
damage engine head thread or
make impossible to remove later
spark plug.
BATTERY
Battery has a closed system and
therefore requires no maintenance
(MF). It is not necessary to check the
electrolyte level or to refill water; simply
keep the battery poles clean and
slightly greased with acid-free grease if
necessary.
To access battery, remove the front
right plastic cover.
When replacing, connect first the
positive and then the negative pole.
When preparing the motorcycle for a
longer period of standstill, remove the
battery and recharge it every month in a
slow charge. Storage temperature: 035ºC. Do not expose it to direct sun
radiation.
! WARNING !
When disconnecting battery cables,
disconnect first black one, of the
negative (-) battery pole.
Note: When replacing battery, use only
and fully electrolyte supplied with a new
battery YTX5L-B.
When preparing a new battery, follow
manufacturer instructions to introduce
electrolyte.
Seal battery definitively with the sealing
cover band apply an initial charge as
manufacturer’s instructions.
Do not forget that PR4 battery is sealed
and there is no need to check
electrolyte level, nor add distilled water,
therefore covers must remain inviolate.
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 - 3rd Edition
Page 34
! WARNING !
- PR5 battery is sealed, it is not
necessary to check electrolyte level
therefore its covers must remain
inviolate.
- Battery electrolyte is a extremely
acid liquid and dangerous to health,
therefore it can be done no attempt
to open battery cover
- Battery will lose its charge,
approximately, if motorcycle doesn’t
run for a month;
- If motorcycle is left with no use for
long periods of time, remove battery
and charge it, to avoid sulfation and
battery lost;
- If battery is left on a unused
motorcycle, black cables must be
disconnected from battery
- Even with a regular use, after 2/3
years, battery will lose performance.
- If stabilized voltage in open circuit
is below 12.3 V, it is necessary to
recharge;
- Battery will lose performance if
charged
with
insufficient
or
excessive current;
- During recharge some poisonous
and explosive gases may be
released;
- Always read battery recharge
instructions;
- Use an adequate 12V recharger
and follow specified recharge
method;
- After charge, battery voltage can
be recovered but if consumption is
excessive, voltage can drop quickly
or vanish. Basic cause is a defective
battery. Replace battery;
- Some electric components and
injection system may be seriously
damaged if terminals or connectors
are connected / disconnected while
ignition key is on and there is
voltage in the circuits.
- When replacing with a new battery
and if it requires filling with
electrolyte, this will produce an initial
voltage high. To ensure a maximum
AJP PR4 User’s manual - 3rd Edition
performance it is necessary to
recharge battery after electrolyte
introduction, applying an initial
charge.
! WARNING !
- If electrolyte (sulphuric acid) leaks
from battery, proceed with great
care. Electrolyte can cause severe
burns.
- In case of skin contact, clear
thoroughly with water.
- In case of contact with eyes,
thoroughly apply them water for at
least 15 minutes and immediately
consult a doctor.
- Battery is a closed model but can
nevertheless emit explosive gases.
Avoid sparks and open fire near
the battery
- Defected batteries must be stored
out of reach of children. Ensure
proper disposal of discarded
batteries.
Seal battery definitely with sealing
covers strip.
Battery should be recharged out of
motorcycle, in a well ventilated space,
dry, clean and far away from any
ignition
source
or
flammable
substances.
Charge method
Page 35
To recharge PR4 YTX5L-BS battery,
use a appropriate 12V charger.
Connect first charger terminals to
battery and then plug charger plug to
network electric power (220V).
Read carefully charger instructions
before use charge rand follow de
specified charger method.
Charge
method
Charge
current
Charge
time
Normal
0,6 Amps
5 to 10
hours
Fast
3,0 Amps
1 hour
! WARNING !
Fast charge is not recommended.
Use this method only in emergency
cases;
When replacing, if new battery is
already charged, always apply an
initial
charge,
according
to
manufacturer’s instructions.
Always carry an extra fuse in the fuse
holder with you whenever you are riding
the motorcycle.
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.
! CAUTION !
Under no circumstances is a
stronger fuse allowed to be set in
or a fuse to be “repaired”. An
inadequate
treatment
could
damage the whole electrical
installation.
Plastic covers should always be
correctly placed in their correspondent
support in order to avoid any fuse to be
lost.
LIGHT BULB REPLACEMENT
Low beam light
!WARNING!
When assembling, never switch
polarity, once you may destroy battery
and rectifier
Never disconnect battery when engine
is running. Rectifier may be destroyed.
Use only 12V35/35W BA20d lamps.
Loosen both rubber bands and tilt
headlight mask to the front.
FUSE
The fuse is disposed underneath the
seat. Having removed the seat you will
be able to see the fuse.
The fuse capacity is 20 Ampere.
AJP PR4 User’s manual - 3rd Edition
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.
Page 36
When placing a new lamp, do not touch
the glass body of the lamp so it remains
free from fat.
Note: After installing the lamp on lamp
holder, clean it with a wet alcohol cloth,
to clean any finger print that may origin
hot spots that may reduce lifespan of
headlight lamp.
Engage retaining clip and mount rubber
cap and connector. Reinsert parking
light lamp together with holder and fix
the mask by means of the rubber
bands.
Parking light
Use only 12V5W BA9S lamps
Taillight (LED)
Note: rear light is a set of LEDs and
does not allow for replacing, because
they are unchangeable. In the event of
a presence or stop light failure, it is
necessary to replace all the rear spoiler
assembly.
1
Blinkers lamps
Use only 12V10W BA15S lamps
Blinkers lamp replacement
Remove screw, glass and internal
globe.
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 - 3rd Edition
Page 37
Press lamp, rotate it counter clockwise
to remove it.
STICKER REPLACEMENT
Install a new lamp on blinker holder;
Note: we recommend fully reading of
this instructions before apply new
stickers.
Surface preparation
Remove old stickers and wash plastics
carefully with water and soap.
Remove eventual grease sediments
with an appropriate grease solvent (pay
extra attention near fuel tank)
After plastic cleaning, wash hands and
dry them.
We recommend apply new stickers in a
clean, dry and warm place.
Note: After installing the lamp on lamp
holder, clean it with a wet alcohol cloth,
to clean any finger print that may origin
hot spots that may reduce lifecycle of
headlight lamp.
Sticker application:
Start by graphic alignment.
In stickers with holes, start with them. In
stickers without holes, use paper strip
to limit.
Fit inner globe (Orange) and blinker
glass, aligning groove by blinker body.
Peel off one end of the protective role
of the sticker and start gluing it on the
plastic
part.
Do not press immediately without
confirming
the
alignment;
Once properly aligned, continue with
the removal of paper / glue sticker.
Press the adhesive from the interior to
the edges to avoid formation of air
balls, using a spatula.
For a perfect grip, use a hot air blower
(ordinary hair dryer); Apply hot air for 5
seconds at a distance of 5-7 cm and
pressing
with
a
spatula.
then
Note: Drain groove in each blinker must
be facing down.
AJP PR4 User’s manual - 3rd Edition
Let stand for 48 hours the stickers
before starting any sporting activity or
cleaning.
Page 38
Note: For a long lifespan of stickers, do
not apply water jets in them.
MOTORCYCLE CLEANING
Clean your motorcycle regularly in
order to maintain the beauty of its
plastic surfaces and avoid corrosion.
The best manner would be to use warm
water that has been mixed with a
normal brand-name washing detergent
and a sponge. The hard dirt can be
removed before washing with the help
of a soft water jet.
! CAUTION !
When cleaning your motorcycle
with a high-pressured cleaner or a
high-pressured water jet never
point
directly
to
electrical
components, switches, relays and
electric
connectors,
headlight
lamps, air filter, control cables, oil
radiator, mufller’s hole, steering
stem and wheels bearings.
When water penetrates in these
components, can cause oxidation
or
corrosion and bad electric
contacts, causing operations malfunctions or lead to premature
destruction of these parts.
- Use regular brand-name detergents to
clean the motorcycle. Especially dirty
parts should be cleaned additionally
with the help of a paintbrush.
- Before cleaning with water, plug the
exhaust pipe to prevent water going
inside.
- After the motorcycle has been cleaned
with a soft water jet, it should be dried
with air pressure and a cloth. Take a
short drive or let engine running in idle
until the engine has reached the
working temperature and also use the
brakes. By warming these components,
the residual water can evaporate from
inaccessible parts of engine and
brakes.
- Once the motorcycle has cooled
down, oil or grease all sliding and
AJP PR4 User’s manual - 3rd Edition
bearing points; lubricate chain with
chain spray.
- To avoid any malfunction of the
electric system, you should treat
emergency off button, light switch and
socket connectors with a contact spray.
CONSERVATION FOR
WINTER OPERATION
In the event that the motorcycle is also
used in winter and on roads where one
has to expect salt spraying, you will
have to take precautions against the
aggressive road salt.
- Clean motorcycle thoroughly and let it
dry after each riding.
- Treat engine, carburettor, swing arm
and all other bare galvanized parts
(except for brake discs) with a waxbased anti-corrosion agent.
STORAGE PROCEDURES
Should you desire to make a pause
over a long period of time (more than
one month), please observe the
following instructions:
- Clean the motorcycle thoroughly (see
CLEANING).
- Change engine oil and oil filter.
- Remove spark plug and fill in approx.
5ccm of engine oil into the cylinder
through the opening. Actuate kickstarter 10 times in order to distribute the
oil into the cylinder walls and mount the
spark plug.
- Remove the fuel into an appropriate
container.
- Correct the tyre pressure.
- Lubricate pivot points of control levers,
foot rests, etc. as well as the chain.
- Service the shock absorber linkage.
- Disconnect battery cables from poles.
- Storage place should be dry and not
subject to excessive temperature
fluctuations. – Cover the motorcycle
with a blanket. Do not use air
impermeable materials as a possible
humidity might not be able to escape
and could cause corrosion.
Page 39
! CAUTION !
Don’t let engine run for a short time
period. Engine would not get
warmed enough and developed
water vapour would condensate
when cooling, causing valve and
exhaust corrosion
RE-INITIATION AFTER STORAGE:
- Mount the charged battery (check
polarity).
- 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 - 3rd Edition
Page 40
TECHNICAL SPECIFICATIONS
Engine
Type
Displacement
Bore x stroke
Cooling
PR4 125
Power
Torque
Carburettor
Start
Intake valve clearance
Exhaust valve clearance
Min jet
Max jet
Carburettor screw
Needle position
Intake valve diameter
Exhaust valve diameter
Gearbox
Frame
Front brake
Rear brake
Seat height
Wheel base
Weight
Fuel tank
Fuel pump
Engine oil
Engine oil volume
Spark plug
Battery
Fuse
Road/high beam light
Presence light
Rear light
Blinkers light
Drive gear
Wheel gear
Chain
Cylinder head bolt
tightening
PR4 200
PR4 240
1 Cylinder, 4 strokes, SOHC, 2 Valves
3
3
3
124 cm
198 cm
233 cm
56,5 x 49,5 mm
69 x 53
69 x 62.5
Air
Air + oil radiator
9,3KW (12,6 cv) /
13,2KW (18 Cv) /
14.7 KW (20 CV) /
8500 r.p.m.
8000 r.p.m.
8000 r.p.m
8,5 N.m / 8000 r.p.m. 15,5 N.m / 7000 r.p.m.
18 N.m / 7000 r.p.m
PZ 30 mm
Electric + kick starter
0,05 mm
0,08 mm
45
115
2½
3rd
30 mm
31,5 mm
25 mm
26 mm
5 speeds
Aluminium double beam + steel double cradle
Disc 260 mm, double piston calliper
Disc 220 mm, simple piston calliper
9200 mm
1380 mm
105 Kg
7 litres
Paioli (vacuum type)
ENI i-Ride SAE 20W-50 API SF or SG
1 litre
1,1 litres
LG D8TC (Champion A8YC or NGK DR8ES)
YTX5L-BS (12V 4Ah)
20A
12V35/35W BA20d
12V 5WBA 9S
LEDs
12V10W BA 15S
Z15 (Z13 – Brazil)
Z50 (EN) / Z48 (SM) (Z46 - Brazil)
428H /132L (520H 110L - Brazil)
38 N.m (3,9 kg.m)
Triple clamps tightening
(Extreme)
VERSION
Front
suspension
Rear
suspension
Front brake
Rear brake
Front tire
Rear tire
Upper triple clamp: 20 N.m (2.0 kgf.m)
Lower triple clamp: 12 N.m (1,2kgf.m)
SUPERMOTO (PRO)
ENDURO (PRO)
EXTREME
USD MARZOCCHI 48 mm,
fully adjustable. Double
cartridge. Stroke 300 mm
Progressive system. ZF SACHS shock absorber.
Progressive system.
Stroke 280 mm
ZF SACHS shock absorber,
(ZF SACHS shock absorber, adjustable, stroke 300mm)
adjustable, stroke 300mm
Double piston calliper, disc 260mm
Simple piston calliper, disc 220mm
MICHELIN 100/80 - 17
MICHELIN ENDURO COMPETITION III 90/90 – 21
MICHELIN 130/70 – 17
MICHELIN ENDURO COMPETITION III 120/80 – 18
USD MARZOCCHI 40 mm, adjustable.
Stroke 280 mm
AJP PR4 User’s manual - 3rd Edition
Page 41
PR4 WIRING SCHEME
AJP PR4 User’s manual - 3rd Edition
Page 42