Professional Documents
Culture Documents
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.
! 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.
i
TABLE OF CONTENTS
CONSUMER INFORMATION 1
COMPONENTS LOCATION 3
CONTROLS LOCATION 5
CONTROLS 5
KEYS 5
IGNITION SWITCH 5
DIGITAL SPEEDOMETER 6
LEFT HANDLEBAR 6
RIGHT HANDLEBAR 7
FUEL 7
FUEL TANK CAP 8
CHOKE KNOB 8
KICK STARTER LEVER 8
GEARSHIFT LEVER 9
REAR BRAKE PEDAL 9
SIDE STAND 9
SUSPENSION SET-UP 10
ENGINE OIL RECOMMENDATION 11
BREAK-IN (RUNNING-IN) 11
INSPECTIONS BEFORE RIDING 12
RIDING TIPS 13
ENGINE START 13
STARTING OFF 14
USING THE GEARBOX 14
BRAKING 15
STOPPING AND PARKING 16
INSPECTION AND MAINTENANCE 17
MAINTENANCE SCHEDULE 17
MAINTENANCE SCHEDULE TABLE 18
MAINTENANCE WORK 19
LUBRICATION POINTS 19
DRIVE CHAIN 21
BRAKES 22
FRONT WHEEL REMOVAL 25
REAR WHEEL REMOVAL 26
TIRES 26
SPOKE TIGHTNESS 27
BATTERY 27
FUSE 28
LIGHT BULB REPLACEMENT 28
AIR FILTER 28
FUEL FILTER 29
THROTTLE CABLE 29
IDLING 29
ENGINE OIL 30
EXHAUST SYSTEM 31
MOTORCYCLE CLEANING 31
CONSERVATION FOR WINTER OPERATION 32
STORAGE PROCEDURES 32
TECHNICAL SPECIFICATIONS 33
ii
CONSUMER INFORMATION ! WARNING !
MX and MX PRO versions are not
ACCESSORY INSTALLATION AND
designed or prepared to carry a
PRECAUTION SAFETY TIPS
passenger!
There is some variety of accessories for
AJP motorcycles. AJP cannot have SAFE RIDING RECOMMENDATIONS
direct control over the quality or FOR MOTORCYCLE RIDERS:
suitability of accessories you may want
to purchase. The addition of unsuitable WEAR A HELMET
accessories can lead to unsafe Motorcycle safety equipments starts
operating conditions. Please contact with a quality helmet. One of the most
your AJP dealer for assist you in serious injuries that can happen is a
selecting accessories and install them head injury. ALWAYS wear a properly
correctly. approved helmet.
You should also wear suitable eye
protection.
! WARNING !
Improper accessories or RIDING APPAREL
modifications can make your Loose, fancy clothing can be
motorcycle unsafe and can lead to uncomfortable and unsafe for
an accident. Never modify the motorcycle riding. Choose good quality
motorcycle with improper or poorly motorcycle riding apparel when riding
your motorcycle. Wear gloves, strong
installed accessories. Follow all
boots that fit over the ankle, long pants
instructions in this owner’s manual and long sleeve shirt or jacket.
regarding accessories and
modifications. Consult your AJP INSPECTION BEFORE RIDING
dealer if you have any questions. Review all the instructions in the
“INSPECTION BEFORE RIDING”
Certain accessories displace the rider section in this manual. Do not forget to
from his normal position. This limits the perform an entire safety inspection to
freedom of movement and may limit his ensure safety of the rider.
control ability.
FAMILIARIZE YOURSELF WITH THE
Additional electric accessories may MOTORCYCLE
overload the electric system. Severe Your riding skill and your mechanical
overloads may damage the wiring knowledge form the basis for safe
harness or create a dangerous situation riding. We recommend you to practice
due to the loss of electric power during riding your motorcycle in an open area
the operation of the motorcycle. without obstacles until you are
familiarize with your motorcycle and its
When carrying a load on the controls.
motorcycle, mount it as low as possible
to the machine. An improperly mounted KNOW YOUR LIMITS
load can create a high center of gravity Always ride within the limits of your
that is very dangerous and makes the skills. Knowing your limits and keep
motorcycle difficult to handle. The size within are the foundation to avoid
of the load can also affect the accidents and injuries.
aerodynamics and handling of the
motorcycle. Balance the load between
the left and right sides of the motorcycle
and fasten it securely.
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, Chassis
blinkers, taillights, horn, speedometer, number
! WARNING !
MX and MX PRO versions are not
equipped for road riding!
Engine number
These versions can only circulate on
a private track! 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
MX, MX PRO
10
11
12
13
10
11
12
13
14
KEYS
MX, MX PRO 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
OFF ON
LOCK
1 Clutch
2 Front brake lever
3 Starter button and On-Off switch
4 On-Off switch
1 5
1 4
3
2
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
6 7
market, speed and distance are
indicated in Kilometres or miles. If you
want to switch between these units, 1 – Clutch lever
please contact your AJP dealer. The same as MX and MX PRO.
To switch from total to trip distance
push button 1. To reset trip distance the 2 – Parking light on
trip distance must be selected; then With the light knob in this position,
push button 1 until the distance is reset parking lights in the headlight and
to zero. taillight will be switched on.
4 – Emergency switch
! CAUTION ! This switch has two positions: to the left
In several countries, motorcycle enables engine running, to the right
riding is only allowed with low beam stops engine running. Be aware that
on! Respect your national this switch is switched ON for engine
legislation! starting.
! CAUTION !
! CAUTION !
Turn lights are not switched off
automatically! Be aware to switch If EMERGENCY SWITCH is not ON,
turn lights off after turning or engine will not start! Start motor will
overtaking! Otherwise you will give not be actuated!
wrong information about your riding
to other drivers! ! CAUTION !
The EMERGENCY SWITCH should
be used to stop the engine in
RIGHT HANDLEBAR emergency situations! Do not use it
to stop the engine when driving
3 2 otherwise the ignition system will be
destroyed!
FUEL
! WARNING !
1 – Throttle grip
Engine speed is controlled by the Using not recommend fuel can
position of the throttle grip. Rotate it cause severe damages on engine!
toward you to increase engine speed; Be sure to use only unleaded
turn it away to decrease engine speed. gasoline with an octane index equal
or higher than 95!
Turn the fuel tank cap counter- The PR3 125 and 200 carburettor is
clockwise to open it. Turn clockwise to equipped with a choke system to
close and tighten it securely. 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
1 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).
2
! WARNING !
Gasoline is highly flammable and 1
poisonous. Extreme caution should
be used when handling gasoline. 0
- Do not refuel motorcycle near open
flames or burning cigarettes.
- Always switch off engine before
refuelling
- Be careful not to spill gasoline on KICK STARTER LEVER
the engine or exhaust pipe while the
engine is hot PR3 125 and 200 are equipped with a
- Wipe up spills promptly. kick-start lever, just in case electric start
- If gasoline is swallowed or fails.
The kick-starter lever is mounted on the
splashed in the eyes, seek a
right side of the engine and its upper
doctor’s advice immediately. part can be swivelled. To be actuated it
- Keep children and pets away. should be rotated outside.
! WARNING !
! CAUTION ! If you want to start engine, make
Because of the transparent fuel sure you always wear rigid footwear,
tank, there is not fuel indicator or like motorcycle boots, in order to
light warning! Control fuel level avoid injuries. You might slip of the
when you start the motorcycle and kick-starter or engine may kick back
when you are riding for some time! 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!
! CAUTION !
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!
2
4
Standard set-up:
ENGINE START
! WARNING !
- Wear suitable clothing when Starting when the engine is cold
driving a motorcycle. Never forget to
wear a helmet, gloves and boots, 1- Swing up the side stand and turn
even in short trips. Protective the ignition key on.
2- Put the gear in neutral (the neutral
clothing should be brightly coloured
pilot lamp will light up).
to make you more visible to other 3- Operate the choke lever all the way
drivers. up.
- Always turn on the lights to make 4- Check if the emergency switch is
sure that other drivers become on running position.
aware of you as early as possible. 5- Operate the electric start button or
- Do not drive after having kick the kick-starter briskly all the
consumed alcohol or drugs. way without touching the throttle.
- Use only original spare parts and
accessories. ! CAUTION !
- Front and rear tires are allowed to Never actuate electric starter for
be fitted only with tires having the more than 5 seconds and with
same original profile type. lights on. Wait at least 5 seconds
before trying again.
Instructions for initial operation
! 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.
(1) IT IS VERY IMPORTANT TO CHECK THE ENGINE OIL LEVEL DAILY AND TO
ADD IF NECESSARY
(2) ENGINE OIL MUST BE CHANGED EVERY 2,000 KMS AND THE OIL FILTER
CLEANED
(3) CLEAN MORE FREQUENTLY IF THE MOTORCYCLE IS USED IN DUSTY, WET
OR MUDDY CONDITIONS
(4) REPLACE BRAKE FLUID EVERY 2 YEAR
! CAUTION !
- 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!
! CAUTION !
If you drive with play in the steering
head bearings for long periods,
bearings and subsequently bearing
seats in the frame will be
destroyed.
Brake discs
! WARNING !
Change brake fluid at least once
each two years. If you wash your
motorcycle often, brake fluid should
be changed even more often (once
a year), as brake fluid tends to
absorb water. Therefore, vapour
pockets may form on “old” brake
fluids even at low temperatures,
causing brake system to fail.
! WARNING !
- For your own safety, have the
brake discs replaced immediately
as soon as they reach wear limit (3
mm thickness). 1
- Have any repairs on brake system
performed by an AJP authorized
dealer.
! WARNING !
At their most worn point brake pad
linings should not be thinner than
1mm, otherwise can lead to braking
failure.
! WARNING !
If brake pads are replaced too late
so that the lining is partly or entirely
Loosen screws (1), remove lid (2) and worn, steel components of brake
membrane (3). Place hand brake pad will rub against brake disc,
cylinder in a horizontal position and fill thereby reducing braking effect and
the brake fluid reservoir up to the MAX destroying brake disc.
mark with clean brake fluid DOT 4.
Replace membrane, lid and tighten Replacing front brake pads (*)
screws. Clear off spilled or overflowing
brake fluid with water. Remove calliper assembly,
unscrewing screws (1). Press the
! WARNING ! brake calliper away from brake disc
- Store brake fluid out of reach of to put the brake piston in its basic
children. position. Remove clips and the
- Brake fluid can cause skin brake pads from the calliper.
irritation. Avoid contact with skin
and eyes. If you get brake fluid in
your eyes, clear with plenty of
water and consult a doctor.
! CAUTION !
1
- Don’t let brake fluid get in contact
with paint; it is an effective paint
remover.
- Use only clean brake fluid from a
sealed or hermetic closed Clean the brake calliper and calliper
container. support with compressed air. Check
the sleeves of the guide bolts for
Checking rear brake fluid level Checking the rear brake pads (*)
The reservoir for the rear disc brake is The brake pads can be inspected from
integrated in brake pump, placed in the the rear. The thickness of the linings
right side of the engine, near exhaust cannot be less than 1mm.
pipe.
Brake fluid level must not drop below ! WARNING !
the “MIN” marking when the vehicle is At their most worn point brake pad
in an upright position.
linings should not be thinner than
1mm, otherwise can lead to brake
failure.
! CAUTION !
- Don’t place brake fluid in contact
with paint; it is a powerful paint
remover
- Use only clean break fluid or from
a sealed container
FUSE
Replace a blown fuse only with an Note: rear light is a set of LEDs and
equivalent one. If a new fuse that has does not allow for replacing, because
just been set in gets blown again, you they are unchangeable. In the event of
are strongly advised to have it a presence or stop light failure, it is
inspected by an AJP dealer. necessary to replace all the rear spoiler
The fuse capacity is 20/15 Ampere. assembly.
Always carry an extra fuse in the fuse
holder with you whenever you are riding AIR FILTER
the motorcycle.
Cleaning air-filter (*)
! CAUTION ! ! CAUTION !
- When removing oil dipstick, be - An engine at operating
careful not to let any dirt enter the temperature and engine oil it
engine. contains are very hot. Please take
- If oil level drops quickly, do not all cares to avoid burning yourself.
operate your motorcycle. Take your
motorcycle to an authorized AJP Place the motorcycle on a horizontal
dealer immediately, to a full check surface, remove the plug and allow the
of engine. oil to drain into a receptacle. Never
drain used oil to the ground, waste,
Engine oil quality water lines or sewage.
Use only branded oils for four stroke Take out the oil drain together with oil
engines, meeting or surpassing the filter, clean these components carefully
quality requirements of API classes SF and blow with compressed air. Check
or SG: o-ring and sealing and replace them if
necessary.
SAE 10W40/15W40 API-SF or SG
Once the entire oil has been drained,
Capacity: clean the sealing surface, mount the oil
o 1 litre – 125 cc engine drain together with spring, oil filter and
o 1,1 litres – 200 cc engine sealing on the right position and tighten
up to 15Nm (1,5 Kg.m).
! CAUTION !
1 - Never clean your motorcycle with
an high-pressured cleaner or an
high-pressured water jet. Water
EXAUST SYSTEM could run into electrical
components, connectors, cables,
MX e MX PRO
bearings, carburettor, etc, can
Requires regular maintenance, the cause operations mal-functions or
more frequent and severe is the riding lead to premature destruction of
of your motorcycle. The silencer fibre in these parts.
is interior should be replaced each
3.000 Km or 50 hours of use. If not, - Use regular brand-name detergents to
noise level will reach illegal and clean the motorcycle. Especially dirty
disturbing levels. parts should be cleaned additionally
with the help of a paintbrush.
- Before cleaning with water, plug the
exhaust pipe to prevent water going
inside.
- After the motorcycle has been cleaned
with a soft water jet, it should be dried
with air pressure and a cloth. Take a
short drive until the engine has reached
the working temperature and also use
the brakes. By warming these
components, the residual water can
evaporate from inaccessible parts of
engine and brakes.
- Once the motorcycle has cooled
down, oil or grease all sliding and
bearing points; lubricate chain with
chain spray.
- To avoid any malfunction of the
electric system, you should treat
emergency off button, light switch and
socket connectors with a contact spray.