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

AJP PR5 User’s manual – 2nd Edition Page
3
COMPONENTS LOCATION
1 Rear brake fluid reservoir
2 Air filter
3 Fuse
4 Spark plug
5 Oil cover
6 Rear brake pedal
7 Oil level glass
8 Battery
9 Fuel tank
10 Fuel tank cap
11 Gear lever
12 Footpeg
13
Side rest

AJP PR5 User’s manual – 2nd Edition Page
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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.
! AUTION !
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.
! AUTION !
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
ENDURO, SUPERMOTO
10
11 11

AJP PR5 User’s manual – 2nd Edition Page
5
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.
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.
!
AUTION !
In several countries, motorcycle
riding is only allowed with low beam
on! Respect your national
legislation!
! AUTION !
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!
1

AJP PR5 User’s manual – 2nd Edition Page
6
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.
! AUTION !
If EMERGENCY SWITCH is not ON,
engine will not start! Start motor will
not be actuated!
! AUTION !
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
The PR5 250 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 (1) counter-
clockwise to open it. Turn clockwise to
close and tighten it securely.

AJP PR5 User’s manual – 2nd Edition Page
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! 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.
! AUTION !
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!
GEARSHIFT LEVER
PR5 250 have a 6-speed transmission.
Shift lever is mounted on the left side of
the engine. The position of the gears is
shown in the illustration. Neutral is
located between first and second gear.
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.
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.
! WARNING !
If opposition of hand brake lever or
rear brake pedal fells “spongy” (too
much give), 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.

AJP PR5 User’s manual – 2nd Edition Page
8
! 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!
! AUTION !
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!
! AUTIO
N !
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 1
st
gear to
reduce the chance of rolling off the
side stand.
SUSPENSION SET-UP
PR5 is equipped with an up-side down
fully adjustable front fork.
To adjust compression turn the screw
(1) clockwise to have a harder
response. Turn counter clockwise to
have a softer response.
To adjust rebound, turn the lower screw
clockwise for more rebound; turn
counter clockwise for less rebound.
! 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
PR5 is equipped with a fully adjustable
shock absorber.
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.

AJP PR5 User’s manual – 2nd Edition Page
9
To adjust rebound, turn the screw
placed on the bottom of the shock
absorber (3) clockwise for more
rebound or counter clockwise for less
rebound.
To adjust fast compression damping,
turn the knob (4) clockwise for more
rebound speed. To reduce rebound
speed turn counter clockwise.
To adjust low compression damping,
turn the screw (5) clockwise for more
rebound speed. To reduce rebound
speed turn counter clockwise.
Standard set-up:
- 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 10 clicks to open
(S)
! WARNING !
Improper servicing of the rear shock
absorber assembly is dangerous.
The rear shock absorber contains
high-pressured gas and can explode
if improperly serviced.
ENGINE OIL
RECOMMENDATION
Use a premium quality 4-stroke motor
oil to ensure longer service life of your
motorcycle. Use only oils that meet or
surpass quality requirements of API
classes SF or SG:
SAE 10W/40 or 15W/40 API SF or SG
Oil level
Engine oil level can be checked in the
glass in front of rear brake pedal. Oil
level should be between the two lines in
the glass. If oil level is below the lower
line, refill immediately. If your engine is
losing oil, contact an AJP dealer
immediately.
! WARNING !
Insufficient oil or poor quality oil
results in premature wear of the
engine and may cause severe
damages!

AJP PR5 User’s manual – 2nd Edition Page
10
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 1,000Kms.
For this reason, do not load engine
more than 50% of its capacity during
the first 500 kilometres, avoiding full-
throttle. 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.
Observe your first and most critical
service. The 1000 Kms service is the
most important service your AJP will
receive. All adjustments will be
restored, all fasteners and spokes will
be tightened and dirty oil and oil filter
will be replaced.
! WARNING !
Incorrect break-in may cause severe
damage to your motorcycle or
significantly reduce your motorcycle
lifetime!
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 results in
premature wear in engine components
and damages in engine itself.
2 - Fuel. Check there is enough 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 - Tyres. Check for cuts or dents and
replace tyres 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.
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.

AJP PR5 User’s manual – 2nd Edition Page
11
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 !
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.
! 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!
RIDING TIPS
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.
! 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.
ENGINE START
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- Check if the emergency switch is
on running position.
4- Operate the electric start button
without throttle opening.
! WARNING !
Using worn, improperly inflated or
incorrect tires will reduce stability
and can cause an accident.
Follow all instructions in the TIRES
section.

AJP PR5 User’s manual – 2nd Edition Page
12
! AUTION !
Never actuate electric starter for
more than 5 seconds and with
lights on. Wait at least 5 seconds
before trying again.
! 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.
What to do when the engine is
“flooded”
In some particular conditions, some
extra fuel may go to the engine. If
engine “floods”, try to start engine for
10 seconds; if engine does not start,
wait 10 seconds and try again. After
five trials, if engine does not start,
check spark plug, dry it and try again. If
engine does not start replace spark
plug for a new one.
! 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.
- 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
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.
! AUTION !
- High RPM rates 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

AJP PR5 User’s manual – 2nd Edition Page
13
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.
! 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.
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 !
Each time you brake, brake discs,
pads, callipers and brake fluid heat
up. The hotter these parts get, the
weaker the braking effect; in
extreme cases, the entire braking
system can fail!
! WARNING !
- In case of rain, after washing the
motorcycle, after rides through water
and wet off-roads tracks, wet or dirty
disc brakes can delay the braking
effect. Brakes must be then
actuated until disc brakes are dry or
clean.
- Dirty brake discs cause increased
wear of brake pads and discs.
! WARNING !
Hard braking while turning may
cause wheel skid and loss of
control.
Brake before you begin to turn.
! 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.
STOPPING AND PARKING
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 .

AJP PR5 User’s manual – 2nd Edition Page
14
! 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
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.
! 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.
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.
! AUTION !
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.

AJP PR5 User’s manual – 2nd Edition Page
15
INSPECTION AND
MAINTENANCE
MAINTENANCE SCHEDULE
The chart indicates intervals between
periodic services in Kilometres. At the
end of each interval, be sure to inspect,
check, lubricate and service as
instructed. If your motorcycle is used
under high stress conditions such as
continuous full throttle operation or is
operated in a dusty climate, certain
services should be performed more
often to insure reliability of motorcycle
as explained in maintenance section.
Your AJP dealer can provide you with
further guidelines.
Steering components, suspension and
wheel components are key items and
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 !
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.
! AUTION !
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.

AJP PR5 User’s manual – 2nd Edition Page
16
AFTER FIRST 1.000 km – BREAK
IN
Replace spark plug;
Replace engine oil;
Replace engine oil filter;
Check engine oil level;
Check air filter. Clean and wet in oil;
Check drive chain;
Check valve clearance;
Check correct functioning of: braking
system, spoke tightness; tire
condition; clutch cable;
side stand; steering stem bearings;
suspensions; battery; exhaust;
electrical system.
EACH 500 km OR MONTH
Check, adjust, clean and lubricate
drive chain;
Check oil level and refill if
necessary.
EACH 3.000 km OR 6 MONTHS
Replace spark plug;
Replace engine oil;
Replace engine oil filter;
Check engine oil level;
Check air filter. Clean and wet in oil;
Check drive chain;
Check valve clearance;
Check fuel feed, lubrication and oil
cooler tubes;
Check fuel injection system
functioning;
Adjust and lubricate throttle cable;
Adjust and lubricate clutch cable;
Check timing chain;
Check timing tensioner;
Check brake pads,
Check brake fluid level;
Check braking system functioning
and stop switches;
Check tires condition;
Check spoke tightness;
Check side stand functioning;
Check steering functioning;
Check suspensions functioning;
Check battery. Control voltage with
or without charge;
Check exhaust: condition, leaks and
noise level;
Check condition and functioning of
several component of electrical
system;
Check tightness of bolts, nuts,
clamps of diverse components.
EACH 6.000 km OR 12 MONTHS
Perform operations indicated for
each 3.000 kms, plus:
Replace spark plug;
Replace air filter;
Check functioning of fuel cap valve;
Lubricate steering stem bearings;
Lubricate rear suspension links;
Lubricate swing arm bearings.
EACH 12.000 km OR 24 MONTHS
Perform operations indicated for
each 3.000 and 6.000 kms, plus:
Replace brake fluids;
Replace front fork seals;
Replace front fork oil;
Replace drive chain.

AJP PR5 User’s manual – 2nd Edition Page
17
MAINTENANCE WORK
! WARNING !
Improper maintenance or failure
performs of recommended
maintenance increases the chance
of accident or motorcycle damage.
Always follow inspection and
maintenance recommendations and
schedules in this owner’s manual.
Ask your AJP dealer to do the
maintenance items marked with an
asterisk (*). You may perform the
unmarked maintenance items by
referring to instructions in this
section, if you have mechanical
experience. If you are not sure how
to do any of the jobs, have your AJP
dealer to do them.
! AUTION !
- When cleaning your motorcycle,
do not use a high-pressure
cleaning unit, otherwise water will
penetrate bearings, carburettor,
electric connectors, etc.
- When transporting your AJP,
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!
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.