AJP PR5 250 User manual

AJP PR5 250
ENDURO / SUPERMOTO
OWNER’S MANUAL
English version
AJP MOTOS, SA
MAR H 2012
2
nd
Edition
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

i
! 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.
! AUTION !
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, SA 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.

ii
TABLE OF CONTENTS
CONSUMER INFORMATION 1
COMPONENTS LOCATION 3
CONTROLS LOCATION 4
CONTROLS 4
KEYS 4
IGNITION SWITCH 4
DIGITAL SPEEDOMETER 5
LEFT HANDLEBAR 5
RIGHT HANDLEBAR 6
FUEL 6
FUEL TANK CAP 6
GEARSHIFT LEVER 7
REAR BRAKE PEDAL 7
SIDE STAND 7
SUSPENSION SET-UP 8
ENGINE OIL RECOMMENDATION 9
BREAK-IN (RUNNING-IN) 10
INSPECTIONS BEFORE RIDING 10
RIDING TIPS 11
ENGINE START 11
STARTING OFF 12
USING THE GEARBOX 12
BRAKING 13
STOPPING AND PARKING 13
INSPECTION AND MAINTENANCE 15
MAINTENANCE SCHEDULE 16
MAINTENANCE WORK 17
LUBRICATION POINTS 17
DRIVE CHAIN 19
BRAKES 20
FRONT WHEEL REMOVAL 23
REAR WHEEL REMOVAL 24
TIRES 24
SPOKE TIGHTNESS 25
BATTERY 25
FUSE 26
LIGHT BULB REPLACEMENT 26
AIR FILTER 27
THROTTLE CABLE 27
ENGINE OIL 27
EXHAUST SYSTEM 29
MOTORCYCLE CLEANING 29
CONSERVATION FOR WINTER OPERATION 29
STORAGE PROCEDURES 29
TECHNICAL SPECIFICATIONS 31

AJP PR5 User’s manual – 2nd Edition Page
1
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 familiar
with your motorcycle and its controls.
KNOW YOUR OWN 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!

AJP PR5 User’s manual – 2nd Edition Page
2
MODIFICATION
Modification of the motorcycle or
removal of original equipment may
render the vehicle unsafe or illegal.
ROAD USE
MX and MX PRO versions are not
allowed for road riding. These versions
doesn’t have the required equipment for
road riding, such as front lights,
blinkers, taillights, horn, speedometer,
etc. You can only ride with MX and MX
PRO versions on a private track.
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.
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.
Chassis
number