AJP PR4 User 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.
English version • JUNE 2009
OWNER’S MANUAL PR4
SUPERMOTO • ENDURO
Enduring Experience

! 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.
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TABLE OF CONTENTS
CONSUMER INFORMATION 1
COMPONENTS LOCATION 3
CONTROLS LOCATION 4
CONTROLS 4
KEYS 4
IGNITIONSWITCH 4
DIGITAL SPEEDOMETER 5
LEFTHANDLEBAR 5
RIGHT HANDLEBAR 6
FUEL 6
FUELTANKCAP 6
CHOKEKNOB 7
KICK STARTER LEVER 7
GEARSHIFT LEVER 7
REAR BRAKE PEDAL 7
SIDESTAND 8
SUSPENSION SET-UP 8
ENGINE OIL RECOMMENDATION 9
BREAK-IN (RUNNING-IN) 9
INSPECTIONS BEFORE RIDING 9
RIDINGTIPS 11
ENGINESTART 11
STARTINGOFF 12
USINGTHEGEARBOX 12
BRAKING 13
STOPPING AND PARKING 13
INSPECTION AND MAINTENANCE 15
MAINTENANCE SCHEDULE 15
MAINTENANCE SCHEDULE TABLE 16
MAINTENANCE WORK 17
LUBRICATION POINTS 17
DRIVE CHAIN 18
BRAKES 19
FRONT WHEEL REMOVAL 23
REAR WHEEL REMOVAL 24
TIRES 24
SPOKE TIGHTNESS 25
BATTERY 25
FUSE 26
LIGHT BULB REPLACEMENT 26
AIR FILTER 26
FUEL FILTER 27
THROTTLE CABLE 27
IDLING 27
ENGINE OIL 27
MOTORCYCLE CLEANING 28
CONSERVATION FOR WINTER OPERATION 29
STORAGE PROCEDURES 29
TECHNICAL SPECIFICATIONS 30

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.
! 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.
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!
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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.
to assist your
dealer when ordering parts or referring
to special service information.
Chassis numberChassis number
The chassis number is stamped on the
right side of the steering head tube.
The chassis number is stamped on the
right side of the steering head tube.
Chassis
number
Engine numberEngine number
The engine number is stamped into the
left side of the engine below the engine
sprocket, between gearshift lever and
the oil cap.
The engine number is stamped into the
left side of the engine below the engine
sprocket, between gearshift lever and
the oil cap.
Engine
number
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10 Fuel tank cap
11 Fuel tank
12 Gearshift lever
13 Foot-rest
14 Side rest
1 Rear brake fluid reservoir
2 Air filter
3 Fuse
4 Battery
5 Spark plug
6 Oil dipstick
7 Kick-starter
8 Rear brake pedal
9 Oil level glass
COMPONENTS LOCATION
ENDURO, SUPERMOTO
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2
4
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9
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10
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CONTROLS LOCATION
1 Clutch lever
2 Blinker, lights, horn switch
3 Front brake lever
4 Starter button and On-Off switch
5 Neutral sign
6 Headlight sign
7 Turn light sign
8 Digital speedometer
9 Ignition switch
10 Throttle grip
11 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
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
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.
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. 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.
LOCK
OFF ON
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DIGITAL SPEEDOMETER
The digital speedometer is not available
for the MX and MX PRO versions.
It 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.
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.
LEFT HANDLEBAR
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.
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.
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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.
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!
! 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!
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2
3
4
5
7
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RIGHT HANDLEBAR
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.
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!
! 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!
FUEL
PR4 125 and 200 engine needs
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 !
Using not recommend fuel can
cause severe damages on engine!
Be sure to use only unleaded
gasoline with an octane index equal
or higher than 95!
FUEL TANK CAP
Turn the fuel tank cap counter-
clockwise to open it. Turn clockwise to
close and tighten it securely.
! 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.
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! 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 KNOBCHOKE KNOB
PR4 125 and 200 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. When the engine is
warm- above 40º- you do not need to
use choke for starting (0).
PR4 125 and 200 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. When the engine is
warm- above 40º- you do not need to
use choke for starting (0).
KICK STARTER LEVERKICK STARTER LEVER
PR4 125 and 200 are equipped with a
kick-start lever, just in case electric start
fails. 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.
PR4 125 and 200 are equipped with a
kick-start lever, just in case electric start
fails. 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.
! 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
PR4 125 and 200 have 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.
2
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.
1
0
REAR BRAKE PEDAL
The foot brake pedal is disposed in
front of the right footrest. Depressing
the rear brake pedal will apply the rear
brake.
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