AJP SPR 250 2022 User manual

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AJP Motos, SA –Disclaims all liabilities for any errors or omissions present in this manual and
reserves the right to make changes that reflect the on-going development. Illustrations and
diagrams in this document can differ from the genuine components. The partial or full
reproduction of this document is not allowed without written authorization.
1st. Edition (January 2022)

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Copyright by
AJP Motos, SA
Technical Service
Rua de Santana, 91
4620-510 Pias, Lousada
Portugal
Tel: [phone]
Fax: [phone]
Website: www.ajpmotos.com
1st. Edition (January 2022)

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! IMPORTANT INFORMATION !
WE STRONGLY RECOMMEND YOU TO READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE GOING ON YOUR FIRST RIDE. THE MANUAL COINTAINS
A GREAT DEAL OF INFORMATION AND ADVICES, WHICH WILL HELP YOU USE AND HANDLE YOUR MOTORCYCLE PROPERLY. IN YOUR OWN INTEREST,
PLEASE PAY ATTENTION TO NOTICES THAT ARE MARKED AS FOLLOWS:
DANGER
IGNORING THESE INSTRUCTIONS CAN ENDANGER YOUR PHYSICAL INTEGRETY AND YOUR LIFE, AS WELL AS OTHERS.
WARNING
IGNORING THESE INSTRUCTIONS CAN DAMAGE PARTS OF YOUR MOTORCYCLE AND/OR MAKE THE MOTORCYCLE 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.
AJP MOTOS 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.

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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 NO BE HELD LIABLE FOR ANY PRINTING ERRORS
WE WISH YOU ENJOY YOUR AJP!

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TABLE OF CONTENTS
TABLE OF CONTENTS......................................................................................................................................................................................................................vi
Chapter A. CONSUMER INFORMATION........................................................................................................................................................... A.1
ACCESSORY INSTALLATION AND SAFETY TIPS.............................................................................................................................................................................. A.2
SAFE RIDING RECOMMENDATIONS............................................................................................................................................................................................. A.4
MOTORCYCLE IDENTIFICATION ................................................................................................................................................................................................... A.5
BREAKING-IN ............................................................................................................................................................................................................................... A.6
INSPECTIONS BEFORE RIDING ..................................................................................................................................................................................................... A.7
RIDING TIPS ................................................................................................................................................................................................................................. A.9
MOTORCYCLE CLEANING........................................................................................................................................................................................................... A.14
STORAGE PROCEDURES............................................................................................................................................................................................................. A.16
CONSERVATION FOR WINTER OPERATION................................................................................................................................................................................ A.17
Chapter B. COMPONENTS LOCATION ............................................................................................................................................................. B.1
CONTROLS ................................................................................................................................................................................................................................... B.5
Chapter C. MAINTENANCE SCHEDULE .............................................................................................................................................................C.1
Chapter D. MAINTENANCE AND ADJUSTMENTS ............................................................................................................................................. D.1
LUBRIFICATION POINTS ............................................................................................................................................................................................................... D.2
CHECKING ENGINE OIL LEVEL ......................................................................................................................................................................................................D.3
CHANGING ENGINE OIL ............................................................................................................................................................................................................... D.4
REPLACING OIL FILTERS ............................................................................................................................................................................................................... D.5
CHECKING SPARK PLUG ............................................................................................................................................................................................................... D.6

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CHECKING COOLANT LEVEL.........................................................................................................................................................................................................D.7
REPLACING COOLANT LIQUID......................................................................................................................................................................................................D.8
RADIATOR FAN ............................................................................................................................................................................................................................ D.8
CHECKING AND ADJUSTING THE STEERING HEAD BEARINGS......................................................................................................................................................D.9
CLEANING FRONT FORK DUST SEALS...........................................................................................................................................................................................D.9
ADJUSTING FRONT FORK SUSPENSION...................................................................................................................................................................................... D.10
ADJUSTING REAR SUSPENSION.................................................................................................................................................................................................. D.11
ADJUSTING DRIVE CHAIN........................................................................................................................................................................................................... D.12
DRIVE CHAIN MAINTENANCE .................................................................................................................................................................................................... D.13
CONDIÇÃO DOS PNEUS.............................................................................................................................................................................................................. D.14
TIRES PRESSURE......................................................................................................................................................................................................................... D.14
CHECKING SPOKES TENSION...................................................................................................................................................................................................... D.15
BRAKE DISCS.............................................................................................................................................................................................................................. D.16
BRAKE PADS............................................................................................................................................................................................................................... D.16
CHECKING FRONT BRAKE PADS ................................................................................................................................................................................................. D.17
CHECKING REAR BRAKE PADS.................................................................................................................................................................................................... D.17
FRONT BRAKE MASTER CYLINDER ............................................................................................................................................................................................. D.18
CHECKING FRONT BRAKE FLUID LEVEL ...................................................................................................................................................................................... D.18
REFILLING FRONT BRAKE FLUID................................................................................................................................................................................................. D.19
CHECKING REAR BRAKE FLUID LEVEL......................................................................................................................................................................................... D.19
REFILLING REAR BRAKE FLUID ................................................................................................................................................................................................... D.20
CHANGING REAR BRAKE PEDAL POSITION ................................................................................................................................................................................ D.20

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REMOVING THE BATTERY.......................................................................................................................................................................................................... D.21
RECHARGING THE BATTERY....................................................................................................................................................................................................... D.22
FUSES......................................................................................................................................................................................................................................... D.23
REPLACING HEADLIGHT LAMP................................................................................................................................................................................................... D.24
REPLACING TAILIGHT (1)............................................................................................................................................................................................................ D.25
REPLACING LED TURN SIGNALS (2)............................................................................................................................................................................................ D.25
CLEANING AIR FILTER ................................................................................................................................................................................................................ D.26
CHECKING EXHAUST SYSTEM..................................................................................................................................................................................................... D.27
Chapter E. TECHNICAL SPECIFICATIONS...........................................................................................................................................................E.1

Chapter A.
CONSUMER INFORMATION

A.2
ACCESSORY INSTALLATION AND SAFETY TIPS
ACESSORIES AND MODIFICATIONS
In the market there is a variety of accessories for SPR 250 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. Contact your AJP dealer to assist you
in selecting accessories and install them correctly.
DANGER
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 manual regarding accessories and modifications.
Consult your AJP dealer if you have any questions.
Certain accessories displace the rider from his normal position, which limit the freedom of movement and may limit the motorcycle 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 additional load on the motorcycle, mount the load as low as possible. An improperly mounted load can create a high center of
gravity, making the motorcycle dangerous and 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.
WARNING
Unauthorized modifications to the ECU parameters, air filter and/or any other electronic injection system components can
severely damage the engine, and consequently imply the immediate loss of warranty.

A.3
BURNS
Some vehicle components become very hot when the vehicle is operated.
PERIGO
Do not touch any parts such as exhaust system, radiator, engine, shock absorber, or brake system before the vehicle parts have
cooled down.
Let the vehicle parts cool down before you perform any work on the vehicle.
ENVIRONMENT
If you use your motorcycle responsibly, you can ensure that problems and conflicts do not occur. Make sure that you use your motorcycle legally,
display environmental consciousness, and respect the right of others.
WARNING
When disposing of used oil, other operating and auxiliary fluids, and used components, comply with the laws and regulations of
the respective country.
Note: For addition information consult our website: www.ajpmotos.com

A.4
SAFE RIDING RECOMMENDATIONS
WEAR A HELMET
Motorcycle safety equipment starts with a quality helmet. One of the most serious injuries that can happen is a head injury. ALWAYS wear a
properly homologated helmet. You should also wear suitable eyes protection.
RIDING CLOTHING
Loose or inappropriate clothing can be uncomfortable and unsafe for motorcycle riding. Choose good quality motorcycle riding apparel when riding
your motorcycle. Wear gloves, strong boots that protect the ankle, long pants and long sleeve shirt/jacket. Never wear loose-fitting clothes,
otherwise they could catch on the control levers, footrests or wheels and cause injury or an accident.
INSPECTION BEFORE RIDING
Review all the instructions in the “INSPECTIONS BEFORE RIDING” section in this manual. Do not forget to perform an entire inspection to ensure
the safety of the motorcycle.
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 them 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 caution!

A.5
MOTORCYCLE IDENTIFICATION
Chassis and engine serial numbers are used for the motorcycle registration. Alongside, it
should be used by the AJP dealers to perform the request AJP MOTOS spare parts.
HOMOLOGATION PLATE
Homologation plate (1) of the motorcycle is located on the steering column left side. The
plate contains the homologation number, serial number and the noise level at a specified
engine rpm.
CHASSIS/FRAME NUMBER
Chassis number (2) is engraved on the right side of the steering column.
ENGINE SERIAL NUMBER
Engine serial number (3) is engraved on the left side of the engine, immediately below the
engine cylinder.
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2
1

A.6
BREAKING-IN
The following recommendations show the importance of a proper break-in to achieve maximum life and performance for the new AJP model.
Even high precision machined sections of engine components have rougher surfaces that require be operated with the other component surfaces,
in order to adjust to each other. Therefore, every engine needs to be broken-in during the first 1000 km.
For this reason, do not load the engine more than 50% of its capacity during the first 500 kilometers and avoid full throttle. After 500 km, you can
load the engine up to 75% of its capacity, using the gearbox frequently.
Allow sufficient idling time (1-2 minutes) with a cold or warm engine start up, before applying load or revving the engine. This procedure allows
the lubrication oil to reach all critical engine components.
The first 1000 km maintenance service is the most important maintenance that your AJP will receive. The motorcycle must be checked carefully,
restoring all the adjustments, retightening fasteners and updating the injection system condition.
WARNING
Incorrect break-in may cause severe damage of components or significantly reduce the motorcycle life time.

A.7
INSPECTIONS BEFORE RIDING
In each start off, the engine must be in perfect mechanical conditions. For safety reasons, the owner/driver should make overall check routine
before each ride. The following inspections should be performed:
1. Oil level: Insufficient oil quantity will result in premature wear in engine components, damaging the engine itself;
2. Fuel: Check if there is enough fuel in the tank;
3. Drive chain: Verify the drive chain clearance and condition. A chain with incorrect tension or lack of lubricant can result in excessive
wear and damage other components. Aside from resulting in premature wear, the chain or transmission axle may break;
4. Tires: Check the air pressure and the existence of cuts or punctures in the tires, replace the tires if necessary. The tread must also
follow the legal restrictions. Insufficient tread and incorrect air pressure will reduce the driving performance;
5. Brakes: Inspect the braking system and brake fluid level. The fluid level below the minimum mark can indicate a possible fluid leak or
completely worn pads. Also check the brake hoses and the brake linings thickness, as well the free play of the brake lever and pedal;
6. Electric system: Check correct function lights, indicators and horn while the engine is running;
7. Steering: Check for smoothness, restriction of movement and steering column bearings looseness;
8. Throttle: With the engine off, inspect the correct play, smooth operation and the return to close position. The throttle grip must rotate
freely without any obstacle;
9. Clutch: Examine for correct play, smoothness and progressive action;
10. Suspension: Inspect suspensions for soft movements;
11. Emergency switch: Check for the correct function of the emergency switch, by turning off the engine with the switch.
12. Luggage: In case of taking any luggage, check if it is safety secured.

A.8
DANGER
Ignoring these inspections or improperly preserve the motorcycle will increase the chance of an accident or component damage.
DANGER
Using worn, improperly inflated or incorrect tires will reduce motorcycle stability and potentiate an accident.
Front and rear tires are only allowed to be fitted with same homologated original profile tires.
DANGER
Wear suitable clothing when driving a motorcycle. Never forget to wear helmet, gloves and boots, even in short trips. Protective
clothing should be brightly colored to make you visible to other drivers.
Do not drive after consuming alcohol.
DANGER
Never ride your motorcycle on full throttle or high rotations while the engine is cold. Otherwise the piston will be warming up
faster that the cylinder, which can cause severe engine damage.
Checking maintenance items with a running engine can be dangerous. You can be severely injured if your hands or clothing get
caught in moving parts, such as tires or drive chain.
DANGER
Observe the traffic regulation and drive defensively, trying to look ahead as far as possible to early recognize any possible obstacle.
Adjust your driving speed according to the conditions and driving skills. Drive carefully in unknown roads or trails, if possible with
company in case of any problem occur.
Replace helmet visor or goggle lens when scratched or damaged. Do not repair twisted handlebar, replace it immediately.

A.9
INSTRUCTIONS FOR INITIAL OPERATION
‒Verify if your AJP dealer performed a previous preparation of the motorcycle.
‒Familiarize yourself with all operating motorcycle controls. Get used to the handling on an empty and open space before longer rides. Try
also drive as slow as possible to improve your feeling of the motorcycle.
‒Hold the handlebar with both hands and maintain your feet on the footrest while driving.
‒Remove your foot from the brake pedal when you are not braking. Otherwise the brake system overheat.
‒For safety reasons do not modified the vehicle and always use AJP original spare parts.
‒Motorcycle are sensitive to changes in weight distribution. In case of caring luggage with you, secure it as close as possible to the middle to
distribute weight on both sides.
ENGINE START
1. Raise up the side stand and turn the ignition key to ON position.
2. Engage the neutral gear (the neutral indicator should be on).
3. Check if the emergency switch is in the ON position.
4. Actuate the electric starter motor button without operating the throttle grip.
DANGER
Before start off check if the side stand is fully folded up. Otherwise, the side stand can drag on the ground causing control loss.
Always turn on the lights to make sure that other drivers become aware of you as early as possible.
Never ride your motorcycle with full load or rev the engine when cold. Due to premature heating of the piston under these
conditions, the engine can suffer serious damage.
WARNING
Never operate the electric starter more than 5 seconds. Wait at least 10 seconds before trying again.
RIDING TIPS

A.10
In some particular conditions, some extra fuel may go to the engine. If engine “floods”, open throttle during 3 seconds before start engine; 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.
PERIGO
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
1. Press the clutch lever and put the engine in first gear.
2. Slowly release the clutch lever and open the throttle at the same time.

A.11
USING THE GEARBOX
The first gear is referred as the start off or uphill gear. Depending on the conditions (traffic, surface inclination, etc.) you should shift to the
suitable gear. To shift between gears, simultaneously close throttle and operate the clutch lever, while operating the gearshift pedal to switch
gears.
Let clutch go again and give gas. 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.
WARNING
High rpm rates in a cold engine will reduce the engine lifetime. We recommend to run the engine in moderate rpm on first 10 km
(6 miles), giving it the chance to warm up.
Never shift down gears with throttle wide open. The engine will over-rev, damaging the valves and the gearbox.
If any abnormal vibrations occur while driving, check for loosen bolts in the engine. If the vibration remains contact an AJP dealer.
If noticed any unusual operation-related noise while riding, stop immediately. Shut the engine off and contact an AJP dealer, and
if necessary/possible tow the motorcycle up to the dealer.
Never start your motorcycle without air filter placed, otherwise dust and dirt may penetrate the engine creating premature wear
or damaging it.

A.12
BRAKING
Apply both brakes at the same time while closing the throttle. When driving on sandy, wet or slippery ground use mainly the rear brake. Avoid
blocking the wheels, otherwise you may lose control of the motorcycle.
Use the engine brake effect when driving downhill to assist the brakes. Lower one or two gears without over-speeding the engine. Therefore, you
will not need to use continuously the brakes, avoiding overheat.
DANGER
Each time you brake, brake discs, pads, calipers and brake fluid heat up. The hotter these parts get, the weaker the braking
effect; in extreme cases, the entire braking system can fail.
DANGER
In case of rain, washing the motorcycle or ride through wet off-road tracks, the wet or dirty brake discs can delay the braking
effect. Brakes must be actuated until the brake discs are dry and/or clean.
Dirty brakes cause increased wear of brake pads and discs.
DANGER
Hard braking on wet, rough or slippery surfaces can cause wheel skid and control loss. Brake slightly and carefully on adverse or
irregular surfaces.
Hard braking while turning may cause wheel slide and control loss. Brake before starting to turn.
DANGER
Using only front or rear brake can cause skidding and control loss. Inexperienced riders tend to under use the front brake. This
can cause increased braking distance and lead to collisions.