AJS Highway Star 125 User manual

Owners Manual
Please study this manual carefully before
riding the motorcycle for the first time

FOREWORD
Thank you for choosing the AJS Highway Star 125 motorcycle. To ensure enjoyable and safe
riding, please be sure to read this manual carefully before operation.
This manual summarises the method of how to use and maintain your motorcycle correctly. If you
follow the guidelines of this manual carefully, your motorcycle should be reliable and will be kept
in a good and safe condition.
Your AJS Dealer should service, and carry out specialised tasks for you. If you are unsure of any
aspects, consult your AJS Dealer for advice or service.
Pictures and specifications are correct at the time of publication.
Due to the continuous development and improvement of the motorcycle, there maybe some
discrepancies in this manual.
AJS Motorcycles Ltd. reserves the right to alter the specifications of its motorcycles without prior
notice.
Errors and omissions expected.

CONTENTS
Notice to user..…….….….….….…….….….…....….….1
Air filter.….….………………….….………….…..…….28
Battery.….….….….….….….….….….….….….………26
Brakes.….….….….………………….….……..….……38
Chain.….….….….………….………….….……...….….35
Cleaning.…….…….….….….……….….……….….….49
Fuel and oil…….……….………….…….………….….15
Fuel filler cap.….….….….….….….….….….….….….11
Foot brake pedal.….….….….….….….….……………14
Fuse.…….….….….….….….….….….…………..……27
Gear lever.….….….….….….…………….….….….….13
Handle bar controls.….….….….….….….….….………9
Headlight bulb.….….….………….….………….……..42
Ignition switch and lock...…….….….….….…..….….…7
Inspection and maintenance.….….….….….….….…25
Inspection before riding.….….….….….….…..…..….19
Instruments.…………….….…..…….….………...….….8
Key components.…….….….….….….….………………4
Oil renewal.…………….………….….….….….………31
Riding tips.….….….….………….….….…..……..……21
Running In.….….….….………….….….….….……….17
Service Schedule ...…..…..…...….….……..….…….. 18
Spark plug.….….….….….….….….……….…………..29
Specification.…….….….….….….….…….…….…..…51
Stand..….….….….….….….….….….…..….….….….14
Starting the engine..….……….…….….…….….……..21
Troubleshooting.….…….….…….….….….…..…...….43
Tyres.….….….….……….….….….….….….….………40

Instructions for safe operation
Motorcycle riding is great fun and exciting.
However, safe riding requires that some
extra precautions are taken and certain
observations are made. You must obey the
highway rules and observe traffic conditions.
Always wear an approved safety helmet.
Safe riding starts with wearing an approved
safety helmet.
This is an important factor of riding a
motorcycle. You must always wear a helmet that
meets current safety standards and is in good
condition. Always replace a helmet that has had a
knock or has been dropped.
Riding apparel
Wear suitable boots, gloves and jacket. Loose,
or unsuitable clothing can be uncomfortable and
unsafe when riding your motorcycle.
Always wear good quality motorcycle riding
apparel when riding your motorcycle.
Ask your dealer for advice.
Inspection before riding
Please read all the instructions in the INSPECTION
BEFORE RIDING section starting on Page 19.
Familiarise yourself with your motorcycle
Your riding skill and your mechanical knowledge is the
foundation for safe and reliable riding practices. We
suggest that you practice riding your motorcycle in a
non-traffic situation until you are thoroughly familiar
with your machine and its controls. Remember:
practice makes perfect. Learn how to confidently
operate, maintain and make adjustments to your
motorcycle.
Aftermarket and spare parts
Only fit genuine AJS approved parts and accessories.
To do otherwise, may be dangerous and may
invalidate your warranty. Seek advice from your
dealer. You can purchase AJS parts from your AJS
Dealer or directly from our web shop:
www.ajs-shop.co.uk
NOTICE TO USER
1

2
NOTICE TO USER
Ride within your limits
Do not ride with excessive speed. Look ahead and
plan your route. Keep both hands on the handle bars.
Do not ride after consuming alcohol or drugs.
Take extra care in wet or adverse weather conditions.
Slow down and allow longer to stop. Road surfaces
will be slippery when wet or icy. Look out for pot
holes and keep away from manhole covers and
painted lines. Approach kerb edges, such as the
entrances to filling stations, square on and not at an
angle.
Don’t make a sudden turn. Be very careful when
crossing railway lines and bridges. Remember to
keep a safe distance from the vehicle in front. Watch
out for oil and diesel spills. Allow extra distance in
adverse weather conditions.
Do not overload your motorcycle.
The maximum load is 150kg. Overloading may cause
instability and cause structural damage to the
motorcycle. Do not drive with an insecure load.
Secure your luggage on a purpose built luggage rack
or inside a top box.
Vehicle Identification Number (VIN)
The 17 digit Vehicle Identification Number (VIN)
and engine serial numbers are used to register the
motorcycle. The numbers will also assist your
dealer to provide you with better service when
ordering spare parts or providing special information.
The VIN is located on the right side of the
steering head-stock tube. The engine number
is engraved on the bottom, left side of the crankcase.
NOTICE TO USER
VIN number Engine number

3
Information about using this manual
Read and observe this Manual carefully. Terms
such as “Warning”, “Caution” and “Notice”are
used to emphasize the intensity of precaution
required. Please study and understand their
meanings thoroughly.
Warning means: Your safety or other people’s
safety is at risk or you may seriously damage
your motorcycle.
Caution means: In order to extend the service
life of your motorcycle and for optimum
performance and reliability, you should take
action. Severe damage to you motorcycle may
be caused if you do not heed this message.
Notice means: Take these tips to get the best
out of your motorcycle or motorcycling
experience.
“Warning”
“Caution”
“Notice”
Write down the numbers below for your
future reference.
Always quote your 17 digit VIN (Vehicle Identification
Number) when ordering spare parts. Your VIN will be
stamped on the right hand side of you motorcycle’s
head stock-tube. Alternatively, you can find it on your
registration document.
Frame number (VIN)
Engine number

4
KEY COMPONENTS
1. Rearview mirror
2. Fuel tank
3. VIN number
4. FR.R turning lamp
5. RR.R turning lamp
6. RR. Brake calliper
7. Exhaust muffler
8. RR. shock absorber
9. Pillion footrest
10. Battery cover
11. Fuel injector assy
12. Driver footrest
13. Brake foot pedal
14. FR. brake calliper

5
KEY COMPONENTS
1. Rearview mirror
2. Headlight
3. Vehicle data plate
4. FR.L turning lamp
5. Air filter cover
6. Seat
7. RR.L Turning lamp
8. Taillight
9. Gear shift lever
10. Driver footrest
11. Engine number
12. Side stand
13. Pillion footrest

6
KEY COMPONENTS
1. Clutch lever
2. L switch assy
3. Meter clock
4. Ignition switch & lock
5. R switch assy
6. Throttle grip
7. FR brake lever

7
IGNITION SWITCH AND LOCK
“ ”
This motorcycle is supplied with two keys.
Keep one in a safe place as a spare.
The ignition switch has three positions:
(OFF POSITION)
In this position the engine cannot be started. The key
can be inserted and removed.
(ON POSITION)
In this position the engine can be started. The key can
not be removed.
“ ”
“ ” (STEERING LOCK POSITION)
To lock the steering, turn the handle bars fully to the
Left. In the lock position, insert the key and push in, let
the key pop back out, then turn the key anti-clockwise
until the lock engages.
Rock the handlebars a little to assist.
Remove the key.
Risk of injury.
Do not attempt to move the motorcycle whilst the
steering lock is activated.
WARNING!
IGNITION SWITCH
Risk of injury.
Never turn the ignition switch to “OFF” or “LOCK”
whilst the vehicle is moving. To do so may result in
loss of control or an accident.
Make sure the vehicle is fully stopped before turning
the ignition switch to “OFF” or “LOCK”
WARNING!

8
INSTRUMENTS L Turning light indicator Light
When the left turn signals are being
operated, this green indicator light will flash.
4
Neutral Indicator Light
When illuminated green, the engine is not in
gear and the clutch can be released without
forward movement of the motorcycle.
5
High/Main Beam Light
When using the high beam and pressing
the overtaking button, this lamp will be
illuminated blue.
6
R Turning light indicator Light
When the right turn signals are being
operated, this green indicator light will flash.
8
Speedometer
The speedometer indicates how fast the motorcycle is
travelling. It is equipped with a switch able display.
Miles per Hour or Kilometres per Hour .
1
Engine Management Light
When illuminated contact your AJS Dealer.
7
Fuel Level Indicator
Displays the remaining amount of fuel in the tank.
9
Gear Indicator
Displays the selected gear. (if fitted)
10
Tachometer
Displays the engine speed rev/min
11
Voltage meter
if the battery voltage is too low, this light will illuminate red.
3
Odometer
The odometer shows the total distance travelled in
Kilometres (1.6Km = 1mile)
2

LEFT HANDLEBAR CONTROL
9
Main Beam/Dip Switch
Toggle between Main and Dipped headlight
beam to avoid dazzling oncoming traffic. When
main beam is selected the blue light will
illuminate on the tachometer. (see P8)
Clutch Lever
When pulled in, the clutch is disengaged. The engine
can be started in gear, when this lever is pulled in.
Slowly release to engage the clutch and move
forward. Pull in and apply the brakes to stop.
Risk of injury.
Always use the indicators prior to changing
direction or turning, but do not forget to cancel
them after your manoeuvre.
WARNING!
1
2
Turn signal operation
Moving the switch to the “ “ position will
flash the left turn signal. Moving the switch to the
“ “ position will flash the right turn signal.
The green indicator light on the tachometer will
also flash intermittently. (see P8)
3
Horn button
Press the button to sound the horn.
4
Pass button
Press the button to flash the
headlight when overtaking.
5
1
2
3
4
5

10
RIGHT HANDLEBAR CONTROL
Engine stop switch
If your press the switch to the “ ” position, the
engine can not be started. When pressing the
switch to the “ ” position, and the ignition is
switched ON the engine can be started. This is the
emergency OFF switch.
Front Brake Lever
The front brake lever is on the right handle bar.
Squeeze the lever towards the handle bar to operate
the front brake only. Pulling the lever harder will apply
the front brake more so. Use with care in slippery
conditions. As you apply the front brake the rear brake
light will illuminate.
1
2
3
4
3
Throttle grip
Rotate the grip towards you from the top to
increase the engine speed and also the speed of
the motorcycle when it is in gear. Rotate the grip
away from you to decrease the engine speed.
Starting switch
Use this switch to activate the electric starter.
Do not activate the starter for more than 5 seconds
at a time.
If the motorcycle will not start. Wait a few minutes
and
try again. Over use of the starter motor may cause
overheating of the electrical circuit.
2
1
4

11
Do not activate the starter for more than 5
seconds at a time.
If the motorcycle will not start. Wait a few minutes
and try again. Over use of the starter motor may
cause overheating of the electrical circuit.
CAUTION!
Risk of injury.
Do not over fill with fuel.
Do not smoke whilst re fuelling.
Do not spill fuel onto a hot engine.
Allow room for fuel expansion in hot conditions.
Only refuel when the ignition switch is turned to
“OFF”
WARNING!
FUEL FILLER CAP
To open
1) Lift the latch.
2) Insert the key.
3) Turn the key fully clockwise.
4) Lift the fuel cap out and away from the fuel tank.
To replace
1) Position the filler cap back in its place.
2) Push the cap down firmly using both thumbs.
3) The key will automatically return to its starting
Use only Unleaded Petrol. The use of leaded
petrol will
cause un repairable damage to
the catalytic converters.
CAUTION!
Fuel Filler Cap

13
GEAR LEVER
This model is equipped with 5 gears and a Neutral
position. Press the lever down with your left foot to
select lower gears, lift the lever up to select higher
gears. The gear lever will return to the horizontal
position after each gear change ready for the next
selection.
Risk of damage.
Always use the clutch when shifting gear.
Never stamp or jerk the gear lever aggressively.
CAUTION!
Risk of injury.
When Neutral is selected a green light will be
illuminated on the speedometer.
However, release the clutch with caution in case a
gear is still partially selected.
WARNING!

14
Foot Brake Pedal
FOOT BRAKE PEDAL
Pressing the pedal with your foot will apply the front
brake and the rear brake simultaneously, according
to the pressure you exert on the pedal.
The more you press, the harder the brakes will be
applied.
SIDE STAND
This motorcycle is fitted with a Side Stand for your
convenience.
To use the Side Stand for quick and easy parking on
flat, firm soil or asphalt.
Caution: Do not park the motorcycle facing downhill. It
may roll forwards and fall over.
Turn the handle bars and apply the steering lock (see
P7)
Note:The Side Stand is fitted with a safety engine cut
out switch. With the Stand in the “down” position.
engine will not start or run.
Side StandSafety cut out switch

15
The side stand is fitted with a Cut Out Switch for
your safety. If the stand is put in the down position,
the engine will not start or will cut out.
NOTICE!
Risk of injury.
Do not use the motorcycle if the side stand cut out
switch is disconnected or malfunctioning.
Be very careful not to ride the motorcycle with the
side stand in the Down position.
WARNING!
When parking on a hill, face the motorcycle uphill
to avoid it slipping off of its stand
CAUTION!
Use Only Unleaded petrol (Gasoline).
Damage to the catalytic converter will occur
otherwise.
CAUTION!
FUEL AND ENGINE OIL
RECOMMENDATIONS
Use only Unleaded or E5 Petrol (gasoline).
Use 10W40 semi synthetic engine oil to API SF, SG &
SH JASO MA2
specification such as Silkolene Super 4 10w40.
Fully synthetic oil should not be used as it may cause
the clutch to slip.
Tip
When washing the motorcycle, do not use high
pressure water. Avoid getting water into the fuel
tank, carburetter or electrical system.
NOTICE!

16
Example
20W 50
15W 40 15W 50
10W 40 10W 50
° C
° F
- 30
- 20 - 10 0 10 20 30 40
- 22
- 414 32 50 68 86 104
Temperature
Dynamic
viscosity
10W 30
Risk of fire!
Do not fill the tank beyond level the level shown in
the diagram below. When hot, the fuel will expand
and if the upper level is exceeded, fuel might
overflow and cause a fire.
Never refuel the motorcycle with the engine running.
Always turn the ignition switch to OFF first.
Never refuel whilst sitting astride the motorcycle.
WARNING! ENGINE LUBRICATION OIL
Lubrication is a main factor that affects the
performance and the engine’s service life. It also has
an effect on the engine’s emission levels. Therefore
the oil should be selected according to these
recommendations and changed at the correct service
intervals. It is also very important to keep a regular
check on the oil level, as some oil may be consumed
during service. If the engine runs low on oil, it will
overheat and cause damage to the engine’s internal
parts. Select a good quality 10w40 4 stroke
motorcycle oil, such as Silkolene Super 4. or an
alternative approved to API SF, SG & SH, JASO MA2
specification.
Maximum fuel level