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AJP · Overhead-cam four-stroke single, wet sump, gearbox shares engine oil, chain drive

PR3 240

Library entry covers 2015-2020

33 factory 48 guideline

Published source

AJP PR3 125/200/240 Owner's Manual, 2nd edition July 2013, Maintenance schedule (printed pp.17-18, ManualsLib)

Factory source. Covers AJP PR3 125/200/240 owner's manual, 2nd edition, July 2013 (English); a carburetor edition older than this row, so later changes may not be reflected; the cover names the PR3 125 / 200 / 240.

81 items for a 2019 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Four-stroke
Engine lubrication: Wet sump (oil in crankcase)
Oil filtration: Replaceable cartridge or spin-on filter
Valve gear: Overhead cam, screw/locknut adjusters
Ignition: Electronic (CDI / transistor / ECU)
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Single carburetor
Cooling: Air / oil cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Shares engine oil
Clutch control: Hand lever, cable
Final drive: Chain
Front suspension: Telescopic fork
Rear suspension: Swingarm, twin shocks
Front brake: Disc, hydraulic
Rear brake: Disc, hydraulic
Wheels: Spoked, tubed
Sidecar: No sidecar

Maintenance schedule

2019 AJP PR3 240

On the road: every 200 mi

1 item

Check engine oil level

Pre-ride / on the road

Guideline

Each fuel stop on old machines. Dry sump: check the tank hot, engine idling or just stopped, per your manual.

On the road: every 300 mi

3 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline
Lubricate drive chain

Pre-ride / on the road

Guideline

Lube warm, ideally at the end of the riding day so it soaks in overnight. Sooner after rain.

On the road: every 600 mi

1 item

Check chain slack and rear wheel alignment

Pre-ride / on the road

Guideline

Every 311 mi or 1 month

5 items

Engine oil level (check and refill if necessary)

Engine

Factory

Factory: Maintenance schedule (owner manual printed pp.17-18, ManualsLib viewer pp.21-22): daily; each 500 km or month; each 3.000 km or 6 months. Sections as printed: daily; after first 1.000 km (break-in); each 500 km or month; each 3.000 km or 6 months; each 6.000 km or 12 months (adds to the 3.000 km list); each 12.000 km or 24 months (adds to the 3.000 and 6.000 km lists). Items marked (*) in the manual are for the AJP dealer.
Air filter (check, clean and wet in oil)

Fuel and air

Factory

Factory: Maintenance schedule (owner manual printed pp.17-18, ManualsLib viewer pp.21-22): each 500 km or month; each 3.000 km or 6 months; also after the first 1.000 km. Sections as printed: daily; after first 1.000 km (break-in); each 500 km or month; each 3.000 km or 6 months; each 6.000 km or 12 months (adds to the 3.000 km list); each 12.000 km or 24 months (adds to the 3.000 and 6.000 km lists). Items marked (*) in the manual are for the AJP dealer.
Drive chain (check, adjust, clean and lubricate)

Final drive

Factory

Factory: Maintenance schedule (owner manual printed pp.17-18, ManualsLib viewer pp.21-22): each 500 km or month; each 3.000 km or 6 months; also after the first 1.000 km. Sections as printed: daily; after first 1.000 km (break-in); each 500 km or month; each 3.000 km or 6 months; each 6.000 km or 12 months (adds to the 3.000 km list); each 12.000 km or 24 months (adds to the 3.000 and 6.000 km lists). Items marked (*) in the manual are for the AJP dealer.
Secondary chain clearance (check)

Final drive

Factory

Factory: Maintenance schedule (owner manual printed pp.17-18, ManualsLib viewer pp.21-22): daily; check, adjust, clean and lubricate each 500 km or month and each 3.000 km or 6 months. Sections as printed: daily; after first 1.000 km (break-in); each 500 km or month; each 3.000 km or 6 months; each 6.000 km or 12 months (adds to the 3.000 km list); each 12.000 km or 24 months (adds to the 3.000 and 6.000 km lists). Items marked (*) in the manual are for the AJP dealer.
Wheel gear bolts tightening (check)

Wheels and tires

Factory

Factory: Maintenance schedule (owner manual printed pp.17-18, ManualsLib viewer pp.21-22): each 500 km or month; each 3.000 km or 6 months; also after the first 1.000 km. Sections as printed: daily; after first 1.000 km (break-in); each 500 km or month; each 3.000 km or 6 months; each 6.000 km or 12 months (adds to the 3.000 km list); each 12.000 km or 24 months (adds to the 3.000 and 6.000 km lists). Items marked (*) in the manual are for the AJP dealer.

Every 1,000 mi or 6 months

1 item

Inspect tire tread, sidewalls and date codes

Wheels and tires

Guideline

Every 1,864 mi or 6 months

18 items

Bolts, nuts and clamps of various components (check tightness)

Engine

Factory

Factory: Maintenance schedule (owner manual printed pp.17-18, ManualsLib viewer pp.21-22): each 3.000 km or 6 months; also after the first 1.000 km. Sections as printed: daily; after first 1.000 km (break-in); each 500 km or month; each 3.000 km or 6 months; each 6.000 km or 12 months (adds to the 3.000 km list); each 12.000 km or 24 months (adds to the 3.000 and 6.000 km lists). Items marked (*) in the manual are for the AJP dealer.
Electrical system components (check condition and functioning)

Engine

Factory

Factory: Maintenance schedule (owner manual printed pp.17-18, ManualsLib viewer pp.21-22): each 3.000 km or 6 months; also after the first 1.000 km. Sections as printed: daily; after first 1.000 km (break-in); each 500 km or month; each 3.000 km or 6 months; each 6.000 km or 12 months (adds to the 3.000 km list); each 12.000 km or 24 months (adds to the 3.000 and 6.000 km lists). Items marked (*) in the manual are for the AJP dealer.
Engine oil (replace) and engine oil filter (clean)

Engine

Factory

Factory: Maintenance schedule (owner manual printed pp.17-18, ManualsLib viewer pp.21-22): each 3.000 km or 6 months; also after the first 1.000 km. Sections as printed: daily; after first 1.000 km (break-in); each 500 km or month; each 3.000 km or 6 months; each 6.000 km or 12 months (adds to the 3.000 km list); each 12.000 km or 24 months (adds to the 3.000 and 6.000 km lists). Items marked (*) in the manual are for the AJP dealer.
Exhaust condition, leaks and noise level (check)

Engine

Factory

Factory: Maintenance schedule (owner manual printed pp.17-18, ManualsLib viewer pp.21-22): each 3.000 km or 6 months; also after the first 1.000 km. Sections as printed: daily; after first 1.000 km (break-in); each 500 km or month; each 3.000 km or 6 months; each 6.000 km or 12 months (adds to the 3.000 km list); each 12.000 km or 24 months (adds to the 3.000 and 6.000 km lists). Items marked (*) in the manual are for the AJP dealer.
Spark plug (replace)

Engine

Factory

Factory: Maintenance schedule (owner manual printed pp.17-18, ManualsLib viewer pp.21-22): each 3.000 km or 6 months; also after the first 1.000 km. Sections as printed: daily; after first 1.000 km (break-in); each 500 km or month; each 3.000 km or 6 months; each 6.000 km or 12 months (adds to the 3.000 km list); each 12.000 km or 24 months (adds to the 3.000 and 6.000 km lists). Items marked (*) in the manual are for the AJP dealer.
Valve clearance (check)

Engine

Factory

Factory: Maintenance schedule (owner manual printed pp.17-18, ManualsLib viewer pp.21-22): each 3.000 km or 6 months; also after the first 1.000 km. Sections as printed: daily; after first 1.000 km (break-in); each 500 km or month; each 3.000 km or 6 months; each 6.000 km or 12 months (adds to the 3.000 km list); each 12.000 km or 24 months (adds to the 3.000 and 6.000 km lists). Items marked (*) in the manual are for the AJP dealer.
Carburetor (clean)

Fuel and air

Factory

Factory: Maintenance schedule (owner manual printed pp.17-18, ManualsLib viewer pp.21-22): each 3.000 km or 6 months; check the settings each 6.000 km or 12 months. Sections as printed: daily; after first 1.000 km (break-in); each 500 km or month; each 3.000 km or 6 months; each 6.000 km or 12 months (adds to the 3.000 km list); each 12.000 km or 24 months (adds to the 3.000 and 6.000 km lists). Items marked (*) in the manual are for the AJP dealer.
Fuel feed, lubrication and oil cooler tubes; oil radiator on 200 and 240 cc engines (check)

Fuel and air

Factory

Factory: Maintenance schedule (owner manual printed pp.17-18, ManualsLib viewer pp.21-22): each 3.000 km or 6 months. Sections as printed: daily; after first 1.000 km (break-in); each 500 km or month; each 3.000 km or 6 months; each 6.000 km or 12 months (adds to the 3.000 km list); each 12.000 km or 24 months (adds to the 3.000 and 6.000 km lists). Items marked (*) in the manual are for the AJP dealer.
Fuel filter (replace)

Fuel and air

Factory

Factory: Maintenance schedule (owner manual printed pp.17-18, ManualsLib viewer pp.21-22): each 3.000 km or 6 months; also listed each 6.000 km or 12 months. Sections as printed: daily; after first 1.000 km (break-in); each 500 km or month; each 3.000 km or 6 months; each 6.000 km or 12 months (adds to the 3.000 km list); each 12.000 km or 24 months (adds to the 3.000 and 6.000 km lists). Items marked (*) in the manual are for the AJP dealer.
Ignition system functioning (check)

Ignition and electrics

Factory

Factory: Maintenance schedule (owner manual printed pp.17-18, ManualsLib viewer pp.21-22): each 3.000 km or 6 months. Sections as printed: daily; after first 1.000 km (break-in); each 500 km or month; each 3.000 km or 6 months; each 6.000 km or 12 months (adds to the 3.000 km list); each 12.000 km or 24 months (adds to the 3.000 and 6.000 km lists). Items marked (*) in the manual are for the AJP dealer.
Throttle cable and clutch cable (adjust and lubricate)

Primary and gearbox

Factory

Factory: Maintenance schedule (owner manual printed pp.17-18, ManualsLib viewer pp.21-22): each 3.000 km or 6 months; clutch cable also checked after the first 1.000 km. Sections as printed: daily; after first 1.000 km (break-in); each 500 km or month; each 3.000 km or 6 months; each 6.000 km or 12 months (adds to the 3.000 km list); each 12.000 km or 24 months (adds to the 3.000 and 6.000 km lists). Items marked (*) in the manual are for the AJP dealer.
Timing chain clearance and timing tensioner (check)

Final drive

Factory

Factory: Maintenance schedule (owner manual printed pp.17-18, ManualsLib viewer pp.21-22): each 3.000 km or 6 months. Sections as printed: daily; after first 1.000 km (break-in); each 500 km or month; each 3.000 km or 6 months; each 6.000 km or 12 months (adds to the 3.000 km list); each 12.000 km or 24 months (adds to the 3.000 and 6.000 km lists). Items marked (*) in the manual are for the AJP dealer.
Side stand, steering and suspension functioning (check)

Front end

Factory

Factory: Maintenance schedule (owner manual printed pp.17-18, ManualsLib viewer pp.21-22): each 3.000 km or 6 months; also after the first 1.000 km. Sections as printed: daily; after first 1.000 km (break-in); each 500 km or month; each 3.000 km or 6 months; each 6.000 km or 12 months (adds to the 3.000 km list); each 12.000 km or 24 months (adds to the 3.000 and 6.000 km lists). Items marked (*) in the manual are for the AJP dealer.
Brake system functioning (check)

Brakes

Factory

Factory: Maintenance schedule (owner manual printed pp.17-18, ManualsLib viewer pp.21-22): daily; each 3.000 km or 6 months; also after the first 1.000 km. Sections as printed: daily; after first 1.000 km (break-in); each 500 km or month; each 3.000 km or 6 months; each 6.000 km or 12 months (adds to the 3.000 km list); each 12.000 km or 24 months (adds to the 3.000 and 6.000 km lists). Items marked (*) in the manual are for the AJP dealer.
Braking system and stop switches (check); brake pads (check); brake fluid level (check)

Brakes

Factory

Factory: Maintenance schedule (owner manual printed pp.17-18, ManualsLib viewer pp.21-22): each 3.000 km or 6 months. Sections as printed: daily; after first 1.000 km (break-in); each 500 km or month; each 3.000 km or 6 months; each 6.000 km or 12 months (adds to the 3.000 km list); each 12.000 km or 24 months (adds to the 3.000 and 6.000 km lists). Items marked (*) in the manual are for the AJP dealer.
Tire condition and spoke tightness (check)

Wheels and tires

Factory

Factory: Maintenance schedule (owner manual printed pp.17-18, ManualsLib viewer pp.21-22): each 3.000 km or 6 months; also after the first 1.000 km. Sections as printed: daily; after first 1.000 km (break-in); each 500 km or month; each 3.000 km or 6 months; each 6.000 km or 12 months (adds to the 3.000 km list); each 12.000 km or 24 months (adds to the 3.000 and 6.000 km lists). Items marked (*) in the manual are for the AJP dealer.
Wheel bearings (check)

Wheels and tires

Factory

Factory: Maintenance schedule (owner manual printed pp.17-18, ManualsLib viewer pp.21-22): each 3.000 km or 6 months; also listed each 6.000 km or 12 months. Sections as printed: daily; after first 1.000 km (break-in); each 500 km or month; each 3.000 km or 6 months; each 6.000 km or 12 months (adds to the 3.000 km list); each 12.000 km or 24 months (adds to the 3.000 and 6.000 km lists). Items marked (*) in the manual are for the AJP dealer.
Battery (check; control voltage with or without charge)

Controls and cables

Factory

Factory: Maintenance schedule (owner manual printed pp.17-18, ManualsLib viewer pp.21-22): each 3.000 km or 6 months; also after the first 1.000 km. Sections as printed: daily; after first 1.000 km (break-in); each 500 km or month; each 3.000 km or 6 months; each 6.000 km or 12 months (adds to the 3.000 km list); each 12.000 km or 24 months (adds to the 3.000 and 6.000 km lists). Items marked (*) in the manual are for the AJP dealer.

Every 3,000 mi or 12 months

11 items

Check throttle cable(s) free play and return

Fuel and air

Guideline
Clean fuel tap filter / sediment bowl

Fuel and air

Guideline
Clean drive chain thoroughly (remove and soak, re-lube)

Final drive

Guideline

Non O-ring chains on old machines: remove, clean, soak in hot chain grease or lube, refit with the master link clip closed end leading.
Inspect chain and sprockets for wear (measure stretch)

Final drive

Guideline
Check steering head bearing adjustment

Front end

Guideline
Inspect fork seals, stanchions and fork boots

Front end

Guideline
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline
Grease and check center / side stand and springs

Rear suspension and frame

Guideline
Check brake pads and discs

Brakes

Guideline
Check spoke tension and wheel true

Wheels and tires

Guideline
Check wheel bearings for play

Wheels and tires

Guideline

Every 3,728 mi or 12 months

6 items

Air filter (clean and lubricate or replace)

Fuel and air

Factory

Factory: Maintenance schedule (owner manual printed pp.17-18, ManualsLib viewer pp.21-22): each 6.000 km or 12 months. Sections as printed: daily; after first 1.000 km (break-in); each 500 km or month; each 3.000 km or 6 months; each 6.000 km or 12 months (adds to the 3.000 km list); each 12.000 km or 24 months (adds to the 3.000 and 6.000 km lists). Items marked (*) in the manual are for the AJP dealer.
Air filter box (clean) and cover sealing silicone (replace)

Fuel and air

Factory

Factory: Maintenance schedule (owner manual printed pp.17-18, ManualsLib viewer pp.21-22): each 6.000 km or 12 months. Sections as printed: daily; after first 1.000 km (break-in); each 500 km or month; each 3.000 km or 6 months; each 6.000 km or 12 months (adds to the 3.000 km list); each 12.000 km or 24 months (adds to the 3.000 and 6.000 km lists). Items marked (*) in the manual are for the AJP dealer.
Fuel feed hoses and fuel cap valve (check)

Fuel and air

Factory

Factory: Maintenance schedule (owner manual printed pp.17-18, ManualsLib viewer pp.21-22): each 6.000 km or 12 months. Sections as printed: daily; after first 1.000 km (break-in); each 500 km or month; each 3.000 km or 6 months; each 6.000 km or 12 months (adds to the 3.000 km list); each 12.000 km or 24 months (adds to the 3.000 and 6.000 km lists). Items marked (*) in the manual are for the AJP dealer.
Intake manifold between air filter box and carburetor (check)

Fuel and air

Factory

Factory: Maintenance schedule (owner manual printed pp.17-18, ManualsLib viewer pp.21-22): each 6.000 km or 12 months. Sections as printed: daily; after first 1.000 km (break-in); each 500 km or month; each 3.000 km or 6 months; each 6.000 km or 12 months (adds to the 3.000 km list); each 12.000 km or 24 months (adds to the 3.000 and 6.000 km lists). Items marked (*) in the manual are for the AJP dealer.
Front fork seals (check/replace)

Front end

Factory

Factory: Maintenance schedule (owner manual printed pp.17-18, ManualsLib viewer pp.21-22): each 6.000 km or 12 months. Sections as printed: daily; after first 1.000 km (break-in); each 500 km or month; each 3.000 km or 6 months; each 6.000 km or 12 months (adds to the 3.000 km list); each 12.000 km or 24 months (adds to the 3.000 and 6.000 km lists). Items marked (*) in the manual are for the AJP dealer.
Steering stem bearings, rear suspension links and swing arm bearings (lubricate)

Front end

Factory

Factory: Maintenance schedule (owner manual printed pp.17-18, ManualsLib viewer pp.21-22): each 6.000 km or 12 months. Sections as printed: daily; after first 1.000 km (break-in); each 500 km or month; each 3.000 km or 6 months; each 6.000 km or 12 months (adds to the 3.000 km list); each 12.000 km or 24 months (adds to the 3.000 and 6.000 km lists). Items marked (*) in the manual are for the AJP dealer.

Every 4,000 mi or 12 months

2 items

Inspect, clean and gap spark plugs

Engine

Guideline
Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Guideline

Every 5,000 mi or 12 months

2 items

Change engine oil

Engine

Guideline

Pre-1970 machines: many owners run non-detergent or classic-spec oil with no filter, so short intervals matter. Dry sump: drain the tank and the crankcase/sump, flush the tank and clean the feed and return screens.
Replace oil filter

Engine

Guideline

Every 6,000 mi or 12 months

7 items

Clean / inspect air filter

Fuel and air

Guideline

Mesh or oiled foam: clean and re-oil. Paper: blow out or replace. Some very early machines have no filter at all.
Clean carburetor float bowl(s), check float level and jets

Fuel and air

Guideline

Ethanol fuel varnishes old carbs quickly in storage.
Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Inspect rear shocks for leaks and damping

Rear suspension and frame

Guideline
Lubricate control cables and lever pivots

Controls and cables

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

A dry speedo cable whips the needle and eventually kills the instrument.

Every 7,456 mi or 2 years

4 items

Fuel tank (clean)

Fuel and air

Factory

Factory: Maintenance schedule (owner manual printed pp.17-18, ManualsLib viewer pp.21-22): each 12.000 km or 24 months. Sections as printed: daily; after first 1.000 km (break-in); each 500 km or month; each 3.000 km or 6 months; each 6.000 km or 12 months (adds to the 3.000 km list); each 12.000 km or 24 months (adds to the 3.000 and 6.000 km lists). Items marked (*) in the manual are for the AJP dealer.
Drive chain (replace)

Final drive

Factory

Factory: Maintenance schedule (owner manual printed pp.17-18, ManualsLib viewer pp.21-22): each 12.000 km or 24 months. Sections as printed: daily; after first 1.000 km (break-in); each 500 km or month; each 3.000 km or 6 months; each 6.000 km or 12 months (adds to the 3.000 km list); each 12.000 km or 24 months (adds to the 3.000 and 6.000 km lists). Items marked (*) in the manual are for the AJP dealer.
Front fork oil and/or fork seals (replace)

Front end

Factory

Factory: Maintenance schedule (owner manual printed pp.17-18, ManualsLib viewer pp.21-22): each 12.000 km or 24 months. Sections as printed: daily; after first 1.000 km (break-in); each 500 km or month; each 3.000 km or 6 months; each 6.000 km or 12 months (adds to the 3.000 km list); each 12.000 km or 24 months (adds to the 3.000 and 6.000 km lists). Items marked (*) in the manual are for the AJP dealer.
Brake fluid (replace)

Brakes

Factory

Factory: Maintenance schedule (owner manual printed pp.17-18, ManualsLib viewer pp.21-22): each 12.000 km or 24 months. Sections as printed: daily; after first 1.000 km (break-in); each 500 km or month; each 3.000 km or 6 months; each 6.000 km or 12 months (adds to the 3.000 km list); each 12.000 km or 24 months (adds to the 3.000 and 6.000 km lists). Items marked (*) in the manual are for the AJP dealer.

Every 8,000 mi or 2 years

1 item

Check and adjust valve clearances

Engine

Guideline

Every 10,000 mi or 2 years

1 item

Compression test (or leak-down)

Engine

Guideline

Every 12,000 mi or 2 years

2 items

Replace air filter element

Fuel and air

Guideline
Grease swingarm pivot

Rear suspension and frame

Guideline

Every 15,000 mi or 3 years

1 item

Change fork oil

Front end

Guideline

Some early telescopic forks are grease filled or use very small oil quantities. Check your manual.

Every 16,000 mi or 4 years

1 item

Replace spark plugs

Engine

Guideline

Every 18,000 mi

1 item

Replace chain and sprockets (wear based)

Final drive

Guideline

Every 20,000 mi or 4 years

2 items

Repack / replace steering head bearings

Front end

Guideline

Many old machines use loose balls in cups and cones. Taper roller conversions are common.
Repack / replace wheel bearings

Wheels and tires

Guideline

Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 25,000 mi or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 30,000 mi or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 2 years

3 items

Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline
Replace brake fluid

Brakes

Guideline

Every 4 years

3 items

Replace fuel lines

Fuel and air

Guideline

Old rubber and modern ethanol fuel do not mix well.
Inspect brake hoses; replace old rubber

Brakes

Guideline
Rebuild calipers and master cylinders (seals)

Brakes

Guideline

Every 6 years

2 items

Replace inner tubes and rim tape with tires

Wheels and tires

Guideline
Replace tires on age (regardless of tread)

Wheels and tires

Guideline

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.

Keep up with this schedule on your phone

Add the bike in the app and this chart loads itself, ready to log against and edit.

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