AJP PR4 Service Manual
  1. Manuals
  2. Brands
  3. AJP Manuals
  4. Motorcycle
  5. PR4
  6. Service manual

AJP PR4 Service Manual

Hide thumbs Also See for PR4:
Table of Contents

Advertisement

Quick Links

See also: Owner's Manual
GENERAL SAFETY AND
GENERAL SAFETY AND
MAINTENANCE RULES
Carbon monoxide
If the engine has to work to carry out any
operation, make sure the space is ventilated.
Do not operate the engine in an closed space.
! DANGER !
The exhaust gas gives off carbon monoxide, a
toxic gas which may lead to poisoning and can
cause death.
Run the engine preferably outdoors. If not
possible, do it in a space with a ventilation
system connected to the exhaust system.
Fuel
Fuel is highly flammable and poisonous.
Extreme caution should be used when
handling fuel.
- Do not fill the motorcycle next to flames or
lighted cigarettes;
- Always stop the engine before refueling;
- Be careful not to spill fuel to the engine or
exhaust pipe while the engine is hot;
Service Manual AJP PR3/PR4
Chapter 1 - General information / Technical specifications
1 - 1
1 - 3
1 - 4
1 - 5
1 - 6
1 - 14
1 - 18
1 - 20
1 - 21
- Clean quickly spilled fuel;
- If the fuel is swallowed or contact with eyes,
seek medical attention immediately;
- Keep children and pets at a distance.
Gasoline
explosive under certain conditions. KEEP IT
AWAY FROM CHILDREN.
Components with high temperatures
The engine and exhaust system are hot when
the engine is running and maintains this high
temperature sometime after the engine stops.
Use insulated gloves or wait for the engine to
cool before handling the engine or exhaust
system.
Engine oil used
Follow the laws in force in your country for
collecting and treatment of waste oil. Never
dump used oil into the sewer or ground.
The oil is extremely toxic and contaminates
water and soils.
! DANGER !
is
extremely
flammable
! DANGER !
1 - 23
1 - 25
1 - 26
1 - 34
1 - 36
1 - 40
1 - 43
1 - 47
1 - 53
and
1 - 1

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the PR4 and is the answer not in the manual?

Questions and answers

Related Manuals for AJP PR4

Summary of Contents for AJP PR4

  • Page 1: Table Of Contents

    The oil is extremely toxic and contaminates - Always stop the engine before refueling; water and soils. - Be careful not to spill fuel to the engine or exhaust pipe while the engine is hot; Service Manual AJP PR3/PR4 1 - 1...

  • Page 2: Maintenance Rules

    KEEP USED OIL AWAY OF CHILDREN . 1. Use only components lubricants Brake dust approved by AJP, or their equivalents. Never use compressed air or a dry brush to Components that meet clean the brakes. requirements of AJP can damage the motorcycle.

  • Page 3: Model Identification

    (1). TABULATED INFORMATION In the following tables are information on technical data and specifications of the bikes AJP PR3 and PR4. As additional help, may also be included some specifications for the previous models / versions PR3 / PR4.

  • Page 4: General Information

    12V monophasic (ACG) Magnetic flywheel CFW type Alternator power 12V 120W (0,12Kw / 5.000rpm) Stator 8-Pole (12V8C) Rectifier / current regulator MT12V8 – ZO5B (XFT1QO7) Rectifier type Monophasic / half wave Starter motor MQ1351-CB 350W Service Manual AJP PR3/PR4 1 - 4...

  • Page 5: Motorcycle Dimensions

    Engine oil replacement The first change should occur at 500Kms. Then every 2000Kms Cooling Air and oil Air and oil Oil cooler (motor 200/240) GR 125 MOTORCYCLE DIMENSIONS PR4 (2001 – 2007) Element PR4-EN/TR PR4-SM PR4-SM-M Wheelbase 1410 1320 Seat height...

  • Page 6: Engine

    Screws in the rotors cover M4x10 Tightening of the cap screws 3N.m (0,3Kgf.m) Pump chain sprocket cover bolts M5x20 (engine 240) Tightening of the screws on the 5N.m (0,5Kgf.m) cover The pump mounting bolts M6x30 Service Manual AJP PR3/PR4 1 - 6...
  • Page 7 – Cylinder head Cylinder head height 200/240 81mm – Gasket thickness of the cylinder head 1,3 - 1,5mm – 58mm – I.D. Hole of the cylinder 63mm – head gasket 200/240 70mm – Service Manual AJP PR3/PR4 1 - 7...
  • Page 8 Rocker arm inside diameter 12,000 – 12,018 12,1mm Came rocker arm outsider 11,966 – 11,984 11,93mm diameter Rocker arms IN/EX Clearance 0,016 – 0,052mm 0,084mm Adjuster thread lead M6x0,75 – Adjuster nut torque 14N.m (1,4Kgf.m) – Service Manual AJP PR3/PR4 1 - 8...
  • Page 9 Pivot screw of the tensor guide 10N.m (1,0Kgf.m) – Screw in the protection of the timing chain in the 10N.m (1,0Kgf.m) – crankshaft Tensioner bolts 10N.m (1,0Kgf.m) – Tensioner cover 5N.m (0,5Kgf.m) – Service Manual AJP PR3/PR4 1 - 9...
  • Page 10 0,09 mm Clearance of the segments in the piston channel Secondary 0,015 – 0,050 0,08 mm 0,20 – 0,35 0,5 mm Clearance at the end of the segments Secondary 0,35 – 0,50 0,65 mm Service Manual AJP PR3/PR4 1 - 10...
  • Page 11 18mm Pin in the connecting rod / crankshaft 30x54mm Bearing of the connecting rod bottom 30x38x18mm Connecting rod Distance between holes 103,5mm 103,66mm I.D. Hole of the connecting rod bottom side 38mm 38,08mm Service Manual AJP PR3/PR4 1 - 11...
  • Page 12 Primary reduction Z70/Z21 (3,333) (secondary/primary) Z36/Z13 (2,769) Z32/Z17 (1,882) 200 Engine Z28/Z20 (1,400) Z26/Z23 (1,130) Z24/Z25 (0,960) Primary reduction Z70/Z21 (3,333) (secondary/primary) Z32/Z11 (2,090) Z28/Z15 (1,866) 240 Engine Z25/Z18 (1,388) Z23/Z20 (1,150) Z21/Z22 (0,954) Service Manual AJP PR3/PR4 1 - 12...
  • Page 13 Chapter 1 – General information / Technical specifications Final transmission By chain Drive sprocket (standard) Drive sprocket (optional) Z14 / Z16 / Z17 Drive sprocket PR4-Brazil / Extreme 520 – Z12 Sprocket PR3 Sprocket PR4 Z48/Z50 Z46 (Aluminum 7075 – 46) step...

  • Page 14: Clutch

    1,6mm 1,5mm Maximum permissible warping in the separators discs 0,2mm Outer diameter of the plate discs 110mm Larger inner diameter of the plate discs 90mm Smaller inner diameter of the plate discs 82mm Service Manual AJP PR3/PR4 1 - 14...
  • Page 15 Width of the ridges in the coated discs 16mm Width of the cutouts in the clutch basket 16,2mm 16,5mm Number of separator discs (plate) Disc plate thickness 1,6mm 1,5mm Maximum permissible warping in the separators discs 0,2mm Service Manual AJP PR3/PR4 1 - 15...
  • Page 16 Number of coated discs Thickness of the coated discs 3,00mm 2,85mm Inside diameter of the coated discs 91mm Outer diameter of the coated discs 109,5mm 110mm The ridges outer diameter of the coated discs 118,5mm Service Manual AJP PR3/PR4 1 - 16...
  • Page 17 Circlip 18mm Clutch thrust bearing 16003 Stud pressure Simple Sprocket / basket clutch Basket clutch With 8 + 8 cuts Total height of the clutch basket (outer) 41,9mm Inside height the basket clutch 39,5mm Service Manual AJP PR3/PR4 1 - 17...

  • Page 18: Bearings, Seals, Washers And Engine Bolts

    Sealing ring in the oil cap on the clutch cover 18x3 Sealing rings on the clutch lever 9x1,8 Sealing ring in the cylinder/cylinder head bushing guide (125) 10x1,6 Rectangular seal (200/240) 8x14x2,5 / 5,3x14x2,8 Service Manual AJP PR3/PR4 1 - 18...
  • Page 19 Cylinder studs on the right crankcase (240cc engine) side Exhaust Ø8,5x222mm side Cylinder studs on the left crankcase (240cc engine) Ø8,5x235mm 125cc M6x110 200cc Screw of the valve mechanism chamber M6x113 240cc M6x120 Service Manual AJP PR3/PR4 1 - 19...

  • Page 20: Alternator

    89mm Stator inside diameter 29mm Stator height 29mm Distance between the stator and the pick-up 15mm Fixing holes 6,3mm (x2) Stator fixing on the engine cover M6x30 w/phalange Pick-up fixing screws PH M4x12 Service Manual AJP PR3/PR4 1 - 20...

  • Page 21: Starter Motor

    Sealing ring of the starter covers 53x1,5 59x1,9mm Seal in the cap bolts Ó-ring 4x2 3,5x1,5 Screw caps / motor housing M5x90 (PH) Hole cover of the starter (2 version) 9,3x5 (10x6,8) 9,1x3,6mm Service Manual AJP PR3/PR4 1 - 21...
  • Page 22 Tightening of the fixing screws 14 – 17 N.m. (1,4 – 1,7 Kgf.m) Starter gear In the primary shaft In the secondary shaft Starter gear sleeve of the 16,5x20x7,8 secondary shaft In the kick shaft Service Manual AJP PR3/PR4 1 - 22...

  • Page 23: Fuel Feed System

    Outlet pipe between pump / bypass T Ø9x5x170mm Supply pipe between T / carburetor Ø9x5x60mm Return pipe between T / tank Ø9x5x385mm Vacuum pipe between pump / nozzle inlet Ø9x5x210mm Gasoline filter IDEAL 6mm Service Manual AJP PR3/PR4 1 - 23...
  • Page 24 O-ring from 4x1,5 4x1,5 4x1,5 the vat O-ring air 2,5x1 screw O-ring on the drain screw 4x1,2 Breather 4x6,5x370 pipe Air tab By cable Manual (chok) Ring air tab 5,3x9,8x0,9 Idling speed 1400(+/-100rpm) (rpm) Service Manual AJP PR3/PR4 1 - 24...

  • Page 25: Steering Stem

    Lower triple clam screw Fastace M8x25 Triple clamp tightening Fastace 22N.m (2,2Kgf.m) Screw of the shaft / table PR4 fork (Marzocchi 40mm) M20x1,5 Washer of the screw / triple clamp shaft (Marzocchi 40mm) 20x40x3 Washer of the lower bearing PR4 (Marzocchi 40mm)

  • Page 26: Front Suspension

    Chapter 1 – General information / Technical specifications FRONT SUSPENSION Element Specification Service limit Front wheel axle PR3 (FASTACE fork) M14x1,5 (galvanized steel) Front wheel axle PR4 EN/SM/TRAIL M14x1,5 (galvanized steel) Front wheel axle PR4 EXTREME M20x1,5 (anodized aluminum) Warping of the front axle Length 73mm (M20x1,5)
  • Page 27 Upper oil passage holes in the tube Ø4,7mm (x4) Lower oil passage holes in the tube 16,2x20x33mm Cone at the lower end of the hydraulic tube 25x51,5x1,6mm Cone centering washer at the end of the tube hidráulicthe o Service Manual AJP PR3/PR4 1 - 27...
  • Page 28 DIN 912 M3x20 Wheel axle fixing bolts 10N.m (10Kgf.m) Torque of the wheel axle retaining screws Polisport (DTR 125 type) Bellows protection forks (optional) PR4-EN/SM/TRAIL fork (2001 – 2010) PAIOLI 41mm Hydraulic Type 260mm Maximum stroke Height (between the cover of the forks and the...
  • Page 29 Seal scraper 38x49,3x14,5 Scraper ID NR9962 XICY (PIA) Retaining ring bushing guide fork (rectangular) 50x1,8x1,9mm Washer retaining fork bushing guide 39,5x48,6x2mm Lower Bushing guide (TEFLON coated) Ø38x42x23,8mm Upper Bushing guide (TEFLON coated) Ø36x38,2x11,8mm Service Manual AJP PR3/PR4 1 - 29...
  • Page 30 Return (on top) (Since all tight) Standard regulation FASTACE Compression (on the 5 Clicks bottom) (Since all tight) PR4 EN/SM/TRAIL fork (2012) MARZOCCHI USD 40mm Type Up side down Forks of the fork Ø 40x610mm Tubes of the outer forks 568mm...
  • Page 31 Ø 48mm Tubes of the outer forks 670x59xx54 Maximum warping of the tubes / forks fork Spring length (no load) 461mm 438,1mm Springs preload Springs constant K = 42N/mm (4,3Kgf/mm) Springs dimensions Ø 43,5x461x33,5 Service Manual AJP PR3/PR4 1 - 31...
  • Page 32 Ø 43,5x475x33,7 (Ø5mm) Springs type of material 55Cr Si6 Steel Oil seals retainers of the forks 48x58x11 Seals dust scrapers 48x58,5x13 Type of hydraulic cartridge Sealed cartridges Forks covers M61x3 (8 sides - 49mm) Service Manual AJP PR3/PR4 1 - 32...
  • Page 33 Spring preload Inside holding bridle 1st slot (on top) Exterior triangular External adjustment of All rotated to the left adjuster on the cover of the springs load the forks Service Manual AJP PR3/PR4 1 - 33...

  • Page 34: Rear Suspension

    Swing arm bearings PR3 HK2016RS Bushings of the swing arm shaft 20x15x40 Washers of the swing arm 20x41x3 Frame connecting rod PR4 (2001 – 2006) (short) Steel, zinced Frame connecting rod PR4 (2001 – 2006) (long) Steel, zinced Frame connecting rod bearings HK1814RS...
  • Page 35 Motor shaft / swing arm M14x1,5 (Ø15x255) Connecting rod bolt in the frame PR3/PR4 DIN 912 M10x90 Connecting rod bolt in the swing arm PR3/PR4 DIN 912 M12x105 Screw of the connecting rods union PR3/PR4 DIN 912 M12x80 PR3/PR4 – PRO rear shock absorber...

  • Page 36: Wheels And Tyres

    Michelin 90/90 – 21” ENDURO PR4 ENDURO Rear Michelin 120/80 – 18” ENDURO Front Michelin 90/90 – 21” PR4 TRAIL Rear Michelin 120/80 – 18” Front Michelin 100/80 – 17” PR4 SUPERMOTO Rear Michelin 130/70 – 17” Service Manual AJP PR3/PR4 1 - 36...
  • Page 37 175kPa (1,75Kgf/cm SUPERMOTO 200kPa (2,00Kgf/cm Rear tire pressure (cold) EXTREME/ SPECIAL 100kPa (1,00 EDITION 120kPa (1,20Kgf/cm Kgf/cm ULTRAPASSAR PR3 EN/MX/TRAIL 19” Front air tube PR3/PR4 SM 100/80 – 17” PR4 EN/TRAIL 90/90 – 21” Service Manual AJP PR3/PR4 1 - 37...
  • Page 38 PR4 wheels EXTREME 10º Wrench size to adjust the spokes 5,9mm 5,4mm PR3/PR4 front wheel bearings 6004 2RS (x2) PR4 front wheel bearing seals 25x42x7 (x2) Ø66mm (28x66x20,3) Spacer tube of the PR4 (UNISON hub) Ø62mm (27x62x21) wheels hub bearings PR4 (EXTREME) Ø66mm (28x66x21)
  • Page 39 PR3 w/ PAIOLLI 41mm Right side 29mm Left / disc side 8,6mm PR3 with FASTACE fork Right side 14mm Left / disc side PR4 with GRIMECA hub Right side 25mm Left / disc side 30mm PR4 with PAIOLLI 41mm fork Right side 16mm...

  • Page 40: Brake System

    Specification limit Brake fluid DOT 4 Replace every Recommended oil for brakes ENI-AGIP 2 years Front Ø 255mm PR3 (2007 – 2011) Rear Discs Ø 185mm PR3 (2012 - …) Front Ø 240mm Service Manual AJP PR3/PR4 1 - 40...
  • Page 41 Chapter 1 – General information / Technical specifications Rear Ø 220mm Front Ø 260mm PR4 (2009 – 2011) Rear Ø 210mm Front Ø 260mm PR4 (2012 - …) Rear Ø 220mm Front (… - 2014) Ø 260mm PR4 EXTREME Front (2014 -…) Ø...
  • Page 42 Retention of the piston in the pump Without elastic ring Brake lever Black, without impeller AJP (Ø12mm, front eyepiece, PR4 (2005 - 2011) – PR3 (2007-2011) short cover) Pump repair kit Ø 12mm piston Retention of the piston in the pump...

  • Page 43: Electric System

    Chapter 1 – General information / Technical specifications PR3 (2007 – 2012) / PR4 ( 2005 – 2012) AJP (w/ display, short cover) Distance between fixing holes 49mm Piston diameter Ø 11 mm Repair kit of the cover / diaphragm pump AJP 159.00.040C...
  • Page 44 12V 0,9W/0,6W Rear taillight Extreme version (white LED) 12V 1,1W/0,2W Turn signals lamps 12V 10W BA15S Turn signals relay 12V 20W (10+10W) DC Relay operating voltage 12,8V CC Load applied 12V 2x10W (Max.3,4W) Service Manual AJP PR3/PR4 1 - 44...
  • Page 45 Pick-up neutral Green / white wire Distance between pick-up and the ridge on the 0,7mm (+/-) wheel CDI drive coil Black / red wire Resistance exciter coil of the CDI 230Ω - 350Ω Service Manual AJP PR3/PR4 1 - 45...
  • Page 46 Color of the wires Function Resistance Pink Charge coil 0,6Ω - 1,2Ω Black / Red CDI drive coil 250 Ω - 350Ω Yellow Charge coil 0,6Ω - 1,2Ω Green / red Neutral contact Service Manual AJP PR3/PR4 1 - 46...

  • Page 47: Tightening Torques

    Torque Screw type N.m. Screw type N.m. (kgf.m) (kgf.m) 3mm hex head screw and nut 2 (0,2) 3mm screw 2 (0,2) 4mm hex head screw and nut 3 (0,3) 4mm screw 3 (0,3) Service Manual AJP PR3/PR4 1 - 47...
  • Page 48 Locknut adjustment of the valves (IN/EX) 14 (1,4) Spark plug 18 (1,8) Lubrication: Screws to fix the oil pump 12 (1,2) Cover screws of the pump rotors 3 (0,3) Pump sprocket cover screws (240) 5 (0,5) Service Manual AJP PR3/PR4 1 - 48...
  • Page 49 Right crankcase screws 12 (1,2) Alternator / Flywheel: Flywheel cover screws 12 (1,2) Screws of the left crankcase 12 (1,2) 26 – 32 M8x1,25 Magnetic flywheel screw (2,6 – 3,2) M10x1 39 (4,0) Service Manual AJP PR3/PR4 1 - 49...
  • Page 50 Nut of the side stand pivot 39 (4,0) Head of the front wheel spokes 32/36 3,8 (0,38) Head of the rear wheel spokes 32/36 5 (0,5) Screw of the inlet nozzle M6x20/25 12 (1,2) Service Manual AJP PR3/PR4 1 - 50...
  • Page 51 Screw / nut of the connecting rod to the arm 54 (5,5) Upper arm protection screw M6x12 12 (1,2) Lower arm protection screw M6x12 12 (1,2) Chain guide bolts 12 (1,2) Chain guide bracket screws 12 (1,2) Service Manual AJP PR3/PR4 1 - 51...
  • Page 52 (4) The stop switch front brake is plastic, so their tightness should be done carefully applying the maximum of 0.5 Nm (0.05 kgf.m). Service Manual AJP PR3/PR4 1 - 52...

  • Page 53: Lubrication Points And Sealing

    Valve mechanism sprocket bolt on the camshaft Screw thread of the gear lever cam Loctite 270 – Stator fixing thread Alternator and wires holder fixing bolt Threads of the screws / nuts of the frame connecting rod Service Manual AJP PR3/PR4 1 - 53...
  • Page 54 Thread of the rear brake pump fixing screws In the drive chain Chain lubricant – spray In all electrical switches Electrical contacts – spray In all wiring connectors of electrical components Battery terminals Battery terminals surfaces – protector spray Service Manual AJP PR3/PR4 1 - 54...
  • Page 55 Loosen the rubber clamps on the fork tubes, detach the terminal connections in the Service manual AJP PR3/PR4 2 - 1...

  • Page 56: Side Covers

    SIDE COVERS REMOVAL Remove the screws and washers (1). Remove the side cover (2). FRONT FENDER REMOVAL Remove the screws and washers (1). Service manual AJP PR3/PR4 2 - 2...

  • Page 57: Front Grid

    (2). INSTALLATION Installation is in the reverse order of removal. Be careful when installing new front grids, not the break in the bend zone. Tighten the screws with the M6 nuts. Service manual AJP PR3/PR4 2 - 3...

  • Page 58: Rear Fender

    / protection. Torque: M6x12 screws: 1,0Kgf.m MUD GARD REMOVAL Remove the screws (1). The flap is immediately released. Remove the screws (1) and the plate (2). Service manual AJP PR3/PR4 2 - 4...

  • Page 59: Crankcase Protection

    INSTALLATION Installation is in the reverse order of removal. NOTE: Use screws with the correct length Note that in the case of PR4 EXTREME first (M6x12) not to damage the tank when you rubber should be fitted within the support press the shock absorber flap / protection.
  • Page 60 Make sure the terminal of the muffler is damaged (melted or broken). Inspect the rivets, the connection between muffler and tube, the clamp and the muffler’s bushing holder. Service manual AJP PR3/PR4 2 - 6...
  • Page 61 When setting the exhaust system, first point the screws on the flange of the cylinder head; M8 nut on the exhaust tube flange: 20 Nm (2.0 kgf.m) M8 screw in tube flange: 18 Nm (2.0 kgf.m) Service manual AJP PR3/PR4 2 - 7...

  • Page 62: Frame Beams

    Release the return pipe in the flange of the fuel tank; Remove the exhaust muffler; If so, loose the clamp fixing the motor stator cables to the left beam, Remove the shock absorber reservoir holder (1) (if it exists); Service manual AJP PR3/PR4 2 - 8...
  • Page 63 Remove the frame reinforcement screw in the left beam (with 13mm box key machined in reduced outer diameter 17.5mm); Remove the M10 nut of the screw of the upper shock absorber fixation (with 17mm box Service manual AJP PR3/PR4 2 - 9...
  • Page 64 (with 13MM box key machined in reduced outer diameter 17.5mm); Remove the M10 nut of the screw of the upper shock absorber fixation (with 17mm box key machined in reduced outer diameter Service manual AJP PR3/PR4 2 - 10...

  • Page 65: Frame

    Tighten the motor shaft / swing arm and all the beam fixing screws to the frame with the specified torque, as for the left beam. Proceed with the installation by following the procedures in reverse order of removal. Service manual AJP PR3/PR4 2 - 11...
  • Page 66 Release the spark plug cable and the cable of the turn signals relay (if it exists); the starter; Remove the battery; Remove the frame reinforcement with the ignition coil, the petrol station and the horn; Service manual AJP PR3/PR4 2 - 12...
  • Page 67 (use a 32mm special key, downgraded to a thickness of 9.5 mm in the case of forks SACHS or MARZOCCHI 48mm) and untighten the four screws at the top of the triple clamps; Remove the carburetor; Service manual AJP PR3/PR4 2 - 13...
  • Page 68 Remove the shock absorber; Tighten the oil cooler tubes (in the case of engine 200 or 240cm3); Service manual AJP PR3/PR4 2 - 14...
  • Page 69 Tighten the banjos of oil tubes carefully not to damage the radiator; Make sure that the oil cooler is not in contact with the cylinder head; Service manual AJP PR3/PR4 2 - 15...
  • Page 70 Then mount the rear suspension connecting rod on the new frame; ! DANGER ! After perform all assembly operations, perform a static and dynamic test to check the perfect functioning of all motorcycle systems. Service manual AJP PR3/PR4 2 - 16...
  • Page 71 - If the fuel is swallowed or contact with eyes, recommended to wash hands thoroughly with seek medical attention immediately; soap and water after handling used motor oil. KEEP USED OIL AWAY FROM CHILDREN. Service manual AJP PR3/PR4 3 - 1...

  • Page 72: Maintenance Schedule

     Check the valve clearance and adjust if 1. Use only components lubricants necessary; approved by AJP or their equivalents.  Check brake pads and brake fluid level; Components that meet requirements of AJP can damage the  Check spoke tightness;...
  • Page 73  Check slack on the wheels; various components electrical  Check the operation of the side stand; system;  Lubricate the steering column bearings;  Check the condition and operation of the ignition system and electric starter; Service manual AJP PR3/PR4 3 - 3...
  • Page 74  Check the condition and operation of the ignition system and electric starter;  Check the tightness of bolts, nuts and clamps of the attachments of the various components. Note: After reaching the 12000km the maintenance should be performed again Service manual AJP PR3/PR4 3 - 4...

  • Page 75: Maintenance Operations For Racing

    Smooth operation Lubricate or replace Connecting rods bearings of the Smooth operation Lubricate or replace rear suspension Smooth operation, damages, folds and Cables Lubricate or replace correct connection Engine fixing bolts Tightness Tighten Service manual AJP PR3/PR4 3 - 5...

  • Page 76: Oil And Engine Oil Filter

    Recommended oil type: Stop the engine and remove the cover to the oil filler. Eni/Agip i-Ride moto SAE 20W-50 Specifications: API SG JASO MA, MA2 Note: In the case of the model PR4 OIL LEVEL EXTREME remove first crankcase...
  • Page 77 Assembly new O-ring. Install the oil filter and the spring in the correct position while keeping the rubber seal faced to the engine inside housing as shown in the following figure. Service manual AJP PR3/PR4 3 - 7...

  • Page 78: Oil Cooler And Centrifugal Oil Filter

    A clogged oil cooler with dirt or damaged may Lubrication System. cause the engine to overheat and may lead it to suffer serious damage. Use a small screwdriver to straighten the fins in the radiator honeycomb, if necessary. Service manual AJP PR3/PR4 3 - 8...

  • Page 79: Engine Breather

    Remove the seat (see Chapter 2 - Frame- Panels-Exhaust); Remove the fixing screw (1) and remove the cover over the air filter, if it exists; Wash the air filter with flammable solvent with a high flash point, such as kerosene. Service manual AJP PR3/PR4 3 - 9...
  • Page 80 Removal Remove the four screws, and disassemble the air filter box; Service manual AJP PR3/PR4 3 - 10...
  • Page 81 Install the cover over the filter (if applicable) inlet pipe is properly fixed in the carburetor; before introducing the fixing screw. Adjust the clamp position as shown in the following image and tighten gently to avoid damaging the rubber tube; Service manual AJP PR3/PR4 3 - 11...

  • Page 82: Fuel Supply System

    Fuel filter The fuel filter is transparent, this allows to see the presence of impurities inside. Always replace the fuel filter at the intervals specified in the Maintenance Schedule or more often if necessary. Service manual AJP PR3/PR4 3 - 12...
  • Page 83 For fixing the fuel tank, be careful and always screws with correct dimensions/length in order to avoid damage the tank when it is assembled in the rear frame. Specific screws type: oval head M6x12 Tightening torque: 10N.m (1,0Kgf.m) Service manual AJP PR3/PR4 3 - 13...

  • Page 84: Throttle Cable

    Work in a well-ventilated area with the engine stopped. Do not smoke, do not let flames or cause sparks in the work area or where the fuel is stored. Clean immediately any fuel spillage. Service manual AJP PR3/PR4 3 - 14...

  • Page 85: Carburator

    The adjustment of the idling on the carburetor affects the behavior of the engine at start, that is, an engine which idle speed is correctly regulated is more easily to start. Velocidade do ralenti: 1400 Rpm (+- 100) Service manual AJP PR3/PR4 3 - 15...

  • Page 86: Spark Plug

    Note: Before removing the spark plug, clean condition; thoroughly around it, using compressed air,  Too brightness indicate and make sure that no foreign material is malfunction of the ignition or lean introduced into the combustion chamber. mixture; Service manual AJP PR3/PR4 3 - 16...

  • Page 87: Valve Clearance

    Service manual AJP PR3/PR4 3 - 17...
  • Page 88 (TDC) in the compression stroke. The two valves are with clearance, and the two brands "—" "—" (dashes) in the camshaft gear must be aligned parallel to the face / surface of the cylinder head. Service manual AJP PR3/PR4 3 - 18...
  • Page 89 Loosen the lock nut (1) and enter the blade of the feeler gauge; Exhaust: 26N.m (2,6Kgf.m) Check if the O-rings (1) of the valve caps are in good condition, replace if necessary. Apply oil to the O-rings. Service manual AJP PR3/PR4 3 - 19...

  • Page 90: Drive Chain

    Adjustment Put the cover of the crankshaft (2) and the Loosen the nut on the rear axle (1); timing control point cover (3) and tighten Loosen the adjuster nuts (2) on both sides; Service manual AJP PR3/PR4 3 - 20...
  • Page 91 Replace the chain if it is with high wear or damaged. Measure the chain length by putting it on a flat surface and fully extended so that the links be aligned. Service manual AJP PR3/PR4 3 - 21...
  • Page 92 O-rings of the fixing link. Check that there is no clearance between the fixing link and the retaining clip. Note: Assemble the retaining clip on the fixing link always facing the direction of the chain rotation. Service manual AJP PR3/PR4 3 - 22...

  • Page 93: Suspension

    Service manual AJP PR3/PR4 3 - 23...
  • Page 94 REAR SUSPENSION damaged. Replace it if necessary. Check the operation of the rear suspension doing up and down on the back of the bike several times (5-10), as shown in the following figure. Service manual AJP PR3/PR4 3 - 24...

  • Page 95: Steering Stem Bearings

    (below 30°C).  Loose the fixing screws from the top triple clamp (1) on both sides and the nut (2) M28x1.  Tighten adjusting necessary to remove the clearance of the Service manual AJP PR3/PR4 3 - 25...
  • Page 96 Remove the front wheel carefully from the Tightening torque: fork. Spoke head: 3.8N.m (0,38Kgf.m) Air-tire chamber fixer: 15N.m (1,5Kgf.m) Pull and push the rear wheel sideways (in alignment with the axis) to check for clearance in swing arm. Service manual AJP PR3/PR4 3 - 26...
  • Page 97 If the wheel axle is removed, clean the thread center in the fork (Marzocchi 48mm) of PR4- and apply a layer of grease to prevent EXTREME bike. If it is necessary to remove deterioration of the thread.

  • Page 98: Brake System

    Tighten the axle nut with the proper torque. A If the level is near the lower mark, check the loose wheel can lead to an unstable behavior brake pads wear: of the motorcycle.  If the pads are worn, replace it; Service manual AJP PR3/PR4 3 - 28...
  • Page 99 (1). Rear brake: Remove the cover fixing screws (1). Remove the tank lid (2) and the pump diaphragm; Add DOT4 brake fluid up to the upper pump level mark. Service manual AJP PR3/PR4 3 - 29...
  • Page 100 Press the caliper piston to move away and retract in order to be able to put the new pads. Service manual AJP PR3/PR4 3 - 30...
  • Page 101 Chapter 3 – Maintenance Rear wheel To remove the rear brake pads, except for the case of PR4 EXTREME, rear wheel must removed "REAR WHEEL REMOVAL" in this chapter. After removal pads should be pushed with a key for this purpose in order to place the piston in its retract position.
  • Page 102 If the light does not turn on properly, adjust Note: In the case of PR4 EXTREME removal the adjuster in the lever to turn on the switch of the rear wheel is not required, since there...

  • Page 103: Side Stand

    The PR3 / PR4 side stand is designed to support only the motorcycle's weight. At any time someone should sit when the motorcycle...
  • Page 104 Installing the tool guide to assist in filling of ceramic wool and the assembly of the core, so that the entire inner space of the aluminum profile be filled;  Remove muffler end; Service manual AJP PR3/PR4 3 - 34...
  • Page 105 If not, you should use the pipe joint and the terminal and apply another bushing with superior size to the high temperature paste seal exhaust allow reuse of the MX exhaust muffler; tip; Service manual AJP PR3/PR4 3 - 35...
  • Page 106 MX EXHAUST TIP (2014 - …) which may exist; The new exhaust mufflers installed on bikes PR3 / PR4 MX since November 2014 have some differences:  Outside tube in stainless steel;...

  • Page 107: Electrical System

    BATTERY case should also open the holes with an Ø 5mm drill; The YTX5L-BS battery used in PR3 / PR4 has a closed system and does not require maintenance. After formatting...
  • Page 108 (alligator clips) on the charger to the battery terminals and then insert the plug of the battery charger unit to the network power socket (220V). Always read the battery charging instructions on a label or a user Service manual AJP PR3/PR4 3 - 38...

  • Page 109: Lamps Replacement

    Replace a damaged fuse by another of equal value. When you put a new fuse and he blows again, it is recommended that an AJP dealer be consulted for an inspection to the electrical system.
  • Page 110 Install the new lamp in the turn signal; Note: Use only 12V5W BA9S lamps. Fit the interior globe (orange) and the glass of the turn signal, aligning its slot by the housing / turn signal body. Service manual AJP PR3/PR4 3 - 40...

  • Page 111: Headlight Range

    If you turn in a clockwise direction the range will be higher, rotating counterclockwise the range will be less. Service manual AJP PR3/PR4 3 - 41...

  • Page 112: Digital Speedometer

    By heating these  Press the right button to change or components, the remaining water will activate the next digit (2, 3 or 4) which Service manual AJP PR3/PR4 3 - 42...
  • Page 113 On stickers without holes you can use paper stripes to help alignment. Take out one end of protective paper and start applying it at plastic part. Do not press immediately with confirming alignment. Service manual AJP PR3/PR4 3 - 43...
  • Page 114 O-ring pump seals on the engine 2 O-rings 9,4x2,4mm crankcase Thread type M12x1,5 Oil cooler (On Racord screws banjos on the 200/240cm M12x1,25X30 engines) radiator Tightening of the screws M12 29N.m (3,0Kgf.m) racord Sealing rings 12,3x20x16 Spacer 10mm Service manual AJP PR3/PR4 4 - 1...
  • Page 115 Note: For reasons of space, if necessary Remove the banjo bolt (1) in the inlet pipe on to remove both tubes it must first be the right crankcase; removed the oil outlet pipe (long) and then Service manual AJP PR3/PR4 4 - 2...
  • Page 116 Oil pipe banjo on the right crankcase between the front engine supports and the (M10x1,25): 34N.m (3,5Kgf.m) frame, as shown in the following image. Oil pipe racord on the clutch cover (M8x1): 26N.m (2,7Kgf.m) Service manual AJP PR3/PR4 4 - 3...
  • Page 117 Removal To remove this centrifugal rotor the following steps should be followed:  Support the motorcycle on its side stand;  Drain the engine oil (page 3-5);  Remove the brake pedal; Service manual AJP PR3/PR4 4 - 4...
  • Page 118  For some 240cm3 engines you must first remove the cover over the steel sprocket;  Finally remove the centrifugal impeller and clean all possible burrs and dirt that exist in their walls. Service manual AJP PR3/PR4 4 - 5...

  • Page 119: Oil Pump

    Note: Pay attention to the state of the gasket of the right crankcase cover, if necessary replace or apply a silicone wire. Pay attention to the tightening torque of each screw / nut by applying the specified tightening. Service manual AJP PR3/PR4 4 - 6...
  • Page 120 (if necessary use a impact wrench to loosen both screws). Remove the oil pump. Wash and dry all parts before inspecting the components of the oil pump. Service manual AJP PR3/PR4 4 - 7...
  • Page 121 Service limit: 0,15mm Removal Remove the following components:  Rotor cover;  Inner and outer rotor; Service limit: 0,20mm Measure the clearance between the outer rotor and the pump housing.  Rotor shaft; Service manual AJP PR3/PR4 4 - 8...
  • Page 122 Inspect the body of the oil pump for the existence of excessive wear signs. Apply oil on the inner and outer rotors and put it on the body of the oil pump. Service manual AJP PR3/PR4 4 - 9...
  • Page 123 Align the holes in the drive gear of the oil pump with the holes of the fixing screws of the oil pump. Service manual AJP PR3/PR4 4 - 10...
  • Page 124 Install the oil pump in the engine crankcase replace or apply silicone seal. and tighten the fixing screws. Pay attention to the tightness of all screws, applying the specified torque. Service manual AJP PR3/PR4 4 - 11...
  • Page 125 Chapter 4 – Lubrication LUBRICATION SCHEME CIRCUIT OF THE ENGINE WITHOUT OIL COOLER Service manual AJP PR3/PR4 4 - 12...
  • Page 126 Feeding tube from entering the engine. between T / Ø9x5x60mm carburetor PR3 / PR4 models only consumes unleaded gasoline with minimum 95 octane. Never use Return pipe leaded gasoline to not destroy the catalyst between T / Ø9x5x385mm and the exhaust system of the motorcycle.

  • Page 127: Troubleshooting

    Rich mixture  Closed air valve / CHOKE (malfunction of the air lever / CHOKE);  Air jet clogged;  Faulty float valve;  Very high float level;  Very dirty air filter; Service manual AJP PR3/PR4 5 - 2...

  • Page 128: Air Filter Box

    Remove the filter housing with the rubber tube included; Service manual AJP PR3/PR4 5 - 3...

  • Page 129: Fuel Tank

    Remove the suction pipe and the phalange of Installation the return tube with the respective gaskets. Installation is in the reverse order of removal. Service manual AJP PR3/PR4 5 - 4...

  • Page 130: Fuel Filter

    Note: Only use screws with the correct length (M6x12) to avoid damaging the tank when The fuel pump which PR3 / PR4 works by tightening the fuel tank to the rear frame and vacuum in the intake manifold created by the the rear fender in the fuel tank.
  • Page 131 Carefully separate the top cover from the body without damaging the gasket and plastic diaphragm. In the pump housing, inspect the pump membranes on the base side. Check the membranes on the side of the top cover. Service manual AJP PR3/PR4 5 - 6...
  • Page 132 Make the assembly in reverse order of removal. When tightening the fuel pump on the frame strengthening only apply the specified torque not to break the pump. Tightening torque: 12N.m (1,2Kgf.m) Connect the pipes in the correct position. Service manual AJP PR3/PR4 5 - 7...

  • Page 133: Carburetor

    Unscrew the nut on the adjuster holder of the "power jet" and release the cable into the auxiliary pump. Pull the carburetor up to remove it carefully (looking for the best position to pass the carburetor available space) Service manual AJP PR3/PR4 5 - 8...

  • Page 134: Carburetor Disassembly

    Remove the float chamber being careful not to lose the O-ring seal on the pump fuel passage of the auxiliary power jet. Remove the float shaft / pin and remove the float together with the respective conical valve. Service manual AJP PR3/PR4 5 - 9...
  • Page 135 Remove the dust cover bellow the diaphragm rod in the vat. On the auxiliary pump cover, remove carefully the valve composed by the injector, one spring and a small sphere. Service manual AJP PR3/PR4 5 - 10...
  • Page 136 O-ring which can sometimes be retained inside the hole in the carburetor. Be careful not to lose the positioning sphere which is housed in air lever. Service manual AJP PR3/PR4 5 - 11...
  • Page 137 If necessary, replace the gasket of the float chamber to assemble the set. Remove the drain screw in the float chamber and replace the sealing ring. Check the operation of air butterfly. Service manual AJP PR3/PR4 5 - 12...
  • Page 138 2011, the existing marking in the jets may not match the real diameter, since carburetors were intervened and jets were modified in AJP Motos to obtain the best regulation possible order to achieve more efficient operation of the motorcycle.

  • Page 139: Carburetor Assembly

    Tighten the main jet with a screwdriver without damaging it. The diffuser cap shall be assembled with the concave side facing down. Assemble the conical valve in the float. Then tighten the main diffuser with a 7mm key. Service manual AJP PR3/PR4 5 - 14...
  • Page 140 Install the air screw already with the spring, the washer and the respective O-ring and tighten the screw until it touches the end of the stroke, but without forcing to avoid damaging. Service manual AJP PR3/PR4 5 - 15...
  • Page 141 Assemble the arm / cam power jet pump in the correct position. You may need to apply contact adhesive (for rubber) to be able to keep the float chamber gasket in place. Service manual AJP PR3/PR4 5 - 16...
  • Page 142 Check the correct operation of the cam and jet, followed by nylon bushing guide. the power jet arm in the carburetor. Install the set in the respective pin on the right side of the carburetor. Service manual AJP PR3/PR4 5 - 17...

  • Page 143: Carburetor Adjustment

    In order to allow a setting as screw. accurate as possible, it is very important to closely follow the technical specifications recommended by AJP Motos, as shown in the specification table for regulation of carburetors (page 5-23) Carburetor installation on the bike...
  • Page 144 The pulley cable from the power jet pump has a mark (dash) reference to the cable adjuster. When the throttle is fully open, the raised Service manual AJP PR3/PR4 5 - 19...

  • Page 145: Adjustments

    If not within the specified, must be adjusted. Idling: 1.400 rpm (+/- 100 rpm) The idle speed is adjusted by the screw (1). Check the connection position of the fuel pipes in the tank. Service manual AJP PR3/PR4 5 - 20...
  • Page 146 To be easier to access and adjust the air / fuel ratio adjusting screw is recommended to use a special tool as shown in the above figure and should be identified in the following similar figure. Service manual AJP PR3/PR4 5 - 21...
  • Page 147 For improved regulation of the carburetors should be consulted the following table that meets the specifications of carburetors used in AJP models. Service manual AJP PR3/PR4 5 - 22...
  • Page 148 O-ring from the vat 4x1,5 4x1,5 4x1,5 O-ring air screw 2,5x1 O-ring on the drain 4x1,2 screw vat Breather pipe 4x6,5x370 Air tab (choke) By cable Manual Ring air tab 5,3x9,8x0,9 Idling speed (rpm) 1400 (+/-100) Service manual AJP PR3/PR4 5 - 23...
  • Page 149 Chapter 5 – Fuel feed system SPECIFICATIONS OF CARBURETORS SET-UP (CURRENT VERSIONS) PR4 Brasil (2011 / ...) PR3/PR4 (2013 / …) Model /Version (Year) Carburetor DE NI PZ30 Venturi diameter 30mm Main jet # 105 Idle jet # 48 Air screw...

  • Page 150: Assembly Schemes

    Chapter 5 – Fuel feed system ASSEMBLY SCHEMES CARBURETOR Please refer to parts list information regarding parts identification and part numbers. Service manual AJP PR3/PR4 5 - 25...
  • Page 151 Nut on the starter cable: 8N.m (0,8kgf.m)  Kick start shaft. Nuts on the carburetor flange to the intake nozzle: 10N.m (1,0kgf.m) Screws of the inlet nozzle: 10N.m (1,0kgf.m) Crankcase protection screws: 12N.m (1,2kgf.m) Service manual AJP PR3/PR4 6 - 1...

  • Page 152: Engine Removal

    Remove the air filter. Remove the filter housing with the rubber tube Note: In order to avoid removing the included; throttle cable, the carburettor assembly could be placed next to the right frame beam. Service manual AJP PR3/PR4 6 - 2...
  • Page 153 Remove the exhaust pipe and then the exhaust tube (page 2 – 6); Remove the gear pedal (1); Remove the screws on the drive sprocket cover; Remove the drive sprocket cover (2). Service manual AJP PR3/PR4 6 - 3...
  • Page 154 Disengage the connector on the stator cable wiring (you may need to loosen the clamps in Remove the spark plug cap; the shock absorber reservoir to release the cable); Loosen the cable on the clutch lever; Service manual AJP PR3/PR4 6 - 4...
  • Page 155 Unscrew 5mm the two lower fixing screws of the beams to the cradle of the frame to give clearance between the beams and the swing arm; Service manual AJP PR3/PR4 6 - 5...

  • Page 156: Engine Installation

    In the case of motor 200 or 240, the oil cooler simultaneously turning it to the left, until the should also be assembled and installed exhaust manifold bolt and oil tubes (in the together with the motor in the frame. Service manual AJP PR3/PR4 6 - 6...
  • Page 157 Tighten the front engine support bolts with the specified torque value. Assemble the engine front brackets with the longer end facing up, with the distance bushings into position by the right holder (the screws enter on the right side); Service manual AJP PR3/PR4 6 - 7...
  • Page 158 Note: Make sure that the radiator will never be placed flat against the cylinder head to prevent any damage due to vibration. Service manual AJP PR3/PR4 6 - 8...
  • Page 159 Appearance of different types of nozzles / inlet in the PRO version); flange and the respective joint, used in several models of PR3 and PR4. Connect the rear stop switch connector and put in its correct position on the ring of the rear engine support;...
  • Page 160 Assemble battery holder with and assemble the drive pinion on the output respective distance bushing in the upper shaft; fixation; Assemble flange record connecting pipe to the secondary air pump (if it exists). Service manual AJP PR3/PR4 6 - 10...
  • Page 161 Montar a caixa do filtro de ar juntamente com the engine: o tubo de borracha e de seguida o respetivo filtro de ar.  125cm engines: 1,1 Liters  200/240cm engines: 1,2 Liters Service manual AJP PR3/PR4 6 - 11...
  • Page 162 Assemble side covers; Remove the motorcycle out of the stand / support and assemble the sump protection, if applicable; Perform a dynamic test on the road to check the correct operation of the motorcycle. Service manual AJP PR3/PR4 6 - 12...

  • Page 163: Service Information General

    Covers of the crankcase cover holes: 8N.m head, they shall be thoroughly cleaned and (0,8kgf.m) clear before making the assembly of the Starter motor bolts: 12N.m (1,2Kgf.m) cylinder head. Manual de Oficina AJP PR3/PR4 (2015) 7 - 1...
  • Page 164 Height of the cams Camshaft 32,70 31,80 240 Racing 32,60 31,40 Warpage the camshaft 31,452 – 31,532 +- 0,1 4x98 Links Timing chain 7x100 Links Distribution 7x102 Links Timing sprocket 200 / 240 Manual de Oficina AJP PR3/PR4 (2015) 7 - 2...

  • Page 165: Removing Cylinder Head Cover

    Unscrew the four flange screws and the cap nuts on the cylinder head cover and remove the cover off the cylinder head. Manual de Oficina AJP PR3/PR4 (2015) 7 - 3...
  • Page 166 Remove the camshaft with the support bushing on the right side without losing the pin which can sometimes come off the bushing. Remove all components like this. Manual de Oficina AJP PR3/PR4 (2015) 7 - 4...

  • Page 167: Removing Cylinder Head

    Remove the cylinder head gasket with the two guide bushings. Remove the springs and the two existing rings at the base of each valve. Remove the seals on the valve guides in the cylinder head. Manual de Oficina AJP PR3/PR4 (2015) 7 - 5...
  • Page 168 Inspect the camshaft oil holes for the presence of foreign materials. Measure the height of each cam on the camshaft. Remove the pawl timing chain protection. Manual de Oficina AJP PR3/PR4 (2015) 7 - 6...
  • Page 169 The measurements of the inner and outer diameters as indicated in the figures shall comply with the use limit specified, as well as the subsequent calculation of the clearance between both components. Manual de Oficina AJP PR3/PR4 (2015) 7 - 7...
  • Page 170 Also inspect the teeth of the pinion gear on the crankshaft for wear or damage. Inspect the cylinder head about their warpage using a ruler of precision and feeler gauge between the bolt holes in the cylinder head. Manual de Oficina AJP PR3/PR4 (2015) 7 - 8...
  • Page 171 Manual de Oficina AJP PR3/PR4 (2015) 7 - 9...
  • Page 172 At the end give some knocks with the plastic is within specified range limits. hammer at the end of each valve to make sure the clips are firmly and do not jump off. Service limit: 1,5mm Manual de Oficina AJP PR3/PR4 (2015) 7 - 10...
  • Page 173 Install the gear / freewheel starter on the flywheel. Tightening torque: 10N.m (1,0Kgf.m) Note: When installing a new chain protection, you may need to adjust your profile, by folding Manual de Oficina AJP PR3/PR4 (2015) 7 - 11...

  • Page 174: Cylinder Head Installation

    M8 (nut and counter nut). The correct tightening should be 29N.m (3,0Kgf.m). Tightening torques: Manual de Oficina AJP PR3/PR4 (2015) 7 - 12...
  • Page 175 Except few units, almost all of PR3 / PR4- 240cc engines (2013) are equipped with the same cylinder head of the 200cc engines with combustion chamber recessed / flat and valves with a diameter smaller than the 240cc.

  • Page 176: Camshaft Installation

    200 / 240cc engines camshaft is not in the correct position, the circuit of lubrication will be blocked and will cause very serious damage to the cylinder head. Manual de Oficina AJP PR3/PR4 (2015) 7 - 14...

  • Page 177: Cylinder Head Cover Installation

    Note: In 125 and 150cc engines the shaft of reference mark wedge-shaped 'V' existing the inlet valve rocker arm is equal to the shaft outside the cylinder head. Manual de Oficina AJP PR3/PR4 (2015) 7 - 15...
  • Page 178 Flange screws M6: 12N.m (1,2kgf.m) the cylinder head cover, camshaft or the rocker arms shafts of the valves. Insert the screw of the timing chamber with washer plate 6mm hole in the cylinder head. Manual de Oficina AJP PR3/PR4 (2015) 7 - 16...
  • Page 179 After being tightened must be removed the chain tensioner locking lever, releasing it against the chain tensioner guide and then may be tight the top screw tightening with the specified torque. Manual de Oficina AJP PR3/PR4 (2015) 7 - 17...
  • Page 180 Service Manual AJP PR3/PR4 8 - 1...
  • Page 181 Smoke excess from the exhaust:  Valve seals are damaged;  Improper installation of piston rings;  Piston or cylinder rings worn or seized;  Damaged valve stem sealing. Service Manual AJP PR3/PR4 8 - 2...
  • Page 182 Oil (rail side) 0,20 – 0,70 Grey (DY) On top Assembly position of the rings on Black (D) Below the piston Facing the exhaust Offset between the ends of the cylinder rings 120º Service Manual AJP PR3/PR4 8 - 3...

  • Page 183: Cylinder Removal

    Note: A plastic / protection should be placed beneath the piston to prevent the piston pin circlip from fall inside engine crankcases during removal and installation. Using a pointy tips pliers remove the circlip from the piston pin; Service Manual AJP PR3/PR4 8 - 4...
  • Page 184 Finally should be removed the piston rings, by opening the ends to get out of the piston. Service Manual AJP PR3/PR4 8 - 5...
  • Page 185 In the case of the cylinder is damaged or its diameter is no longer in service limit, cylinder, piston and rings must be replaced all together. Service Manual AJP PR3/PR4 8 - 6...
  • Page 186 Note: Eliminate any type of coal in the ring Connecting rod cavities to avoid any incorrect measures. Note: Whenever it is verified that the service limit of the piston pin or pin housing cavity in Service Manual AJP PR3/PR4 8 - 7...
  • Page 187 Use limit of clearance between O.D. connecting rod head and O.D. piston pin: 0,10mm Apply a bit of silicone on the area of the gasket in the middle of the crankcases to ensure proper sealing. Service Manual AJP PR3/PR4 8 - 8...
  • Page 188 Oil segments (with expander) below; compression ring (black) in the middle; fire segment (chrome plated) on top. Notes:  When placing the rings must be careful not to damage them or damage the piston; Service Manual AJP PR3/PR4 8 - 9...
  • Page 189 The cylinder must be assembled on the piston while at the same time manually compressing each segment carefully to avoid damaging Service Manual AJP PR3/PR4 8 - 10...
  • Page 190 10x1,6 must be placed to the oil pass at the guide bushing of right rear stud at the cylinder. Install timing chain guide, certifying that it is perfectly fitted in the crankcase housing. Service Manual AJP PR3/PR4 8 - 11...
  • Page 191 Chapter 8 – Cylinder and Piston ASSEMBLY SCHEME Service Manual AJP PR3/PR4 8 - 12...

Table of Contents

Save PDF