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

PR5 250

Library entry covers 2015-2020

25 factory 48 guideline

Published source

AJP PR5 250 Owner's Manual (2nd edition), Inspection and maintenance pp.15-16 (ManualsLib 744659)

Factory source. Covers AJP PR5 250 user's manual, 2nd edition (no edition date seen in the pages read).

73 items for a 2015 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
Fuel injection
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

2015 AJP PR5 250

On the road: every 300 km

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 500 km

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 1,000 km

1 item
  • Check chain slack and rear wheel alignment
    Pre-ride / on the road
    Guideline

Every 500 km or 1 month

2 items
  • Engine oil level (check, refill if necessary)
    Engine
    Factory

    Factory: Inspection and maintenance schedule (AJP PR5 250 user's manual, 2nd edition, English, printed pp.15-16, ManualsLib viewer pp.18-19): each 500 km or month. Services as printed: after the 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 (the 3,000 km items plus extras); each 12,000 km or 24 months (the 3,000 and 6,000 km items plus extras). Service more often under continuous full throttle or in dusty conditions. Items marked * are for an AJP dealer. No model year printed in the pages read.

  • Drive chain (check, adjust, clean, lubricate)
    Final drive
    Factory

    Factory: Inspection and maintenance schedule (AJP PR5 250 user's manual, 2nd edition, English, printed pp.15-16, ManualsLib viewer pp.18-19): each 500 km or month. Services as printed: after the 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 (the 3,000 km items plus extras); each 12,000 km or 24 months (the 3,000 and 6,000 km items plus extras). Service more often under continuous full throttle or in dusty conditions. Items marked * are for an AJP dealer. No model year printed in the pages read.

Every 1,600 km or 6 months

1 item
  • Inspect tire tread, sidewalls and date codes
    Wheels and tires
    Guideline

Every 3,000 km or 6 months

16 items
  • Bolts, nuts and clamps (check tightness)
    Engine
    Factory

    Factory: Inspection and maintenance schedule (AJP PR5 250 user's manual, 2nd edition, English, printed pp.15-16, ManualsLib viewer pp.18-19): each 3,000 km or 6 months. Services as printed: after the 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 (the 3,000 km items plus extras); each 12,000 km or 24 months (the 3,000 and 6,000 km items plus extras). Service more often under continuous full throttle or in dusty conditions. Items marked * are for an AJP dealer. No model year printed in the pages read.

  • Electrical system components (check condition and function)
    Engine
    Factory

    Factory: Inspection and maintenance schedule (AJP PR5 250 user's manual, 2nd edition, English, printed pp.15-16, ManualsLib viewer pp.18-19): at 1,000 km, then each 3,000 km or 6 months. Services as printed: after the 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 (the 3,000 km items plus extras); each 12,000 km or 24 months (the 3,000 and 6,000 km items plus extras). Service more often under continuous full throttle or in dusty conditions. Items marked * are for an AJP dealer. No model year printed in the pages read.

  • Engine oil (replace)
    Engine
    Factory

    Factory: Inspection and maintenance schedule (AJP PR5 250 user's manual, 2nd edition, English, printed pp.15-16, ManualsLib viewer pp.18-19): at 1,000 km, then each 3,000 km or 6 months. Services as printed: after the 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 (the 3,000 km items plus extras); each 12,000 km or 24 months (the 3,000 and 6,000 km items plus extras). Service more often under continuous full throttle or in dusty conditions. Items marked * are for an AJP dealer. No model year printed in the pages read.

  • Engine oil filter (replace)
    Engine
    Factory

    Factory: Inspection and maintenance schedule (AJP PR5 250 user's manual, 2nd edition, English, printed pp.15-16, ManualsLib viewer pp.18-19): at 1,000 km, then each 3,000 km or 6 months. Services as printed: after the 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 (the 3,000 km items plus extras); each 12,000 km or 24 months (the 3,000 and 6,000 km items plus extras). Service more often under continuous full throttle or in dusty conditions. Items marked * are for an AJP dealer. No model year printed in the pages read.

  • Exhaust: condition, leaks and noise level (check)
    Engine
    Factory

    Factory: Inspection and maintenance schedule (AJP PR5 250 user's manual, 2nd edition, English, printed pp.15-16, ManualsLib viewer pp.18-19): at 1,000 km, then each 3,000 km or 6 months. Services as printed: after the 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 (the 3,000 km items plus extras); each 12,000 km or 24 months (the 3,000 and 6,000 km items plus extras). Service more often under continuous full throttle or in dusty conditions. Items marked * are for an AJP dealer. No model year printed in the pages read.

  • Spark plug (replace)
    Engine
    Factory

    Factory: Inspection and maintenance schedule (AJP PR5 250 user's manual, 2nd edition, English, printed pp.15-16, ManualsLib viewer pp.18-19): at 1,000 km, then each 3,000 km or 6 months. Services as printed: after the 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 (the 3,000 km items plus extras); each 12,000 km or 24 months (the 3,000 and 6,000 km items plus extras). Service more often under continuous full throttle or in dusty conditions. Items marked * are for an AJP dealer. No model year printed in the pages read.

  • Valve clearance (check)
    Engine
    Factory

    Factory: Inspection and maintenance schedule (AJP PR5 250 user's manual, 2nd edition, English, printed pp.15-16, ManualsLib viewer pp.18-19): at 1,000 km, then each 3,000 km or 6 months. Services as printed: after the 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 (the 3,000 km items plus extras); each 12,000 km or 24 months (the 3,000 and 6,000 km items plus extras). Service more often under continuous full throttle or in dusty conditions. Items marked * are for an AJP dealer. No model year printed in the pages read.

  • Air filter (check; clean and wet in oil)
    Fuel and air
    Factory

    Factory: Inspection and maintenance schedule (AJP PR5 250 user's manual, 2nd edition, English, printed pp.15-16, ManualsLib viewer pp.18-19): at 1,000 km, then each 3,000 km or 6 months. Services as printed: after the 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 (the 3,000 km items plus extras); each 12,000 km or 24 months (the 3,000 and 6,000 km items plus extras). Service more often under continuous full throttle or in dusty conditions. Items marked * are for an AJP dealer. No model year printed in the pages read.

  • Fuel feed, lubrication and oil cooler tubes (check)
    Fuel and air
    Factory

    Factory: Inspection and maintenance schedule (AJP PR5 250 user's manual, 2nd edition, English, printed pp.15-16, ManualsLib viewer pp.18-19): each 3,000 km or 6 months. Services as printed: after the 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 (the 3,000 km items plus extras); each 12,000 km or 24 months (the 3,000 and 6,000 km items plus extras). Service more often under continuous full throttle or in dusty conditions. Items marked * are for an AJP dealer. No model year printed in the pages read.

  • Fuel injection system (check function)
    Fuel and air
    Factory

    Factory: Inspection and maintenance schedule (AJP PR5 250 user's manual, 2nd edition, English, printed pp.15-16, ManualsLib viewer pp.18-19): each 3,000 km or 6 months. Services as printed: after the 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 (the 3,000 km items plus extras); each 12,000 km or 24 months (the 3,000 and 6,000 km items plus extras). Service more often under continuous full throttle or in dusty conditions. Items marked * are for an AJP dealer. No model year printed in the pages read.

  • Battery (check voltage with and without charge)
    Ignition and electrics
    Factory

    Factory: Inspection and maintenance schedule (AJP PR5 250 user's manual, 2nd edition, English, printed pp.15-16, ManualsLib viewer pp.18-19): at 1,000 km, then each 3,000 km or 6 months. Services as printed: after the 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 (the 3,000 km items plus extras); each 12,000 km or 24 months (the 3,000 and 6,000 km items plus extras). Service more often under continuous full throttle or in dusty conditions. Items marked * are for an AJP dealer. No model year printed in the pages read.

  • Throttle cable and clutch cable (adjust, lubricate)
    Primary and gearbox
    Factory

    Factory: Inspection and maintenance schedule (AJP PR5 250 user's manual, 2nd edition, English, printed pp.15-16, ManualsLib viewer pp.18-19): at 1,000 km, then each 3,000 km or 6 months. Services as printed: after the 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 (the 3,000 km items plus extras); each 12,000 km or 24 months (the 3,000 and 6,000 km items plus extras). Service more often under continuous full throttle or in dusty conditions. Items marked * are for an AJP dealer. No model year printed in the pages read.

  • Timing chain and timing tensioner (check)
    Final drive
    Factory

    Factory: Inspection and maintenance schedule (AJP PR5 250 user's manual, 2nd edition, English, printed pp.15-16, ManualsLib viewer pp.18-19): each 3,000 km or 6 months. Services as printed: after the 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 (the 3,000 km items plus extras); each 12,000 km or 24 months (the 3,000 and 6,000 km items plus extras). Service more often under continuous full throttle or in dusty conditions. Items marked * are for an AJP dealer. No model year printed in the pages read.

  • Side stand, steering and suspension (check function)
    Front end
    Factory

    Factory: Inspection and maintenance schedule (AJP PR5 250 user's manual, 2nd edition, English, printed pp.15-16, ManualsLib viewer pp.18-19): at 1,000 km, then each 3,000 km or 6 months. Services as printed: after the 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 (the 3,000 km items plus extras); each 12,000 km or 24 months (the 3,000 and 6,000 km items plus extras). Service more often under continuous full throttle or in dusty conditions. Items marked * are for an AJP dealer. No model year printed in the pages read.

  • Brake pads, brake fluid level, braking system and stop switches (check)
    Brakes
    Factory

    Factory: Inspection and maintenance schedule (AJP PR5 250 user's manual, 2nd edition, English, printed pp.15-16, ManualsLib viewer pp.18-19): at 1,000 km, then each 3,000 km or 6 months. Services as printed: after the 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 (the 3,000 km items plus extras); each 12,000 km or 24 months (the 3,000 and 6,000 km items plus extras). Service more often under continuous full throttle or in dusty conditions. Items marked * are for an AJP dealer. No model year printed in the pages read.

  • Tire condition and spoke tightness (check)
    Wheels and tires
    Factory

    Factory: Inspection and maintenance schedule (AJP PR5 250 user's manual, 2nd edition, English, printed pp.15-16, ManualsLib viewer pp.18-19): at 1,000 km, then each 3,000 km or 6 months. Services as printed: after the 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 (the 3,000 km items plus extras); each 12,000 km or 24 months (the 3,000 and 6,000 km items plus extras). Service more often under continuous full throttle or in dusty conditions. Items marked * are for an AJP dealer. No model year printed in the pages read.

Every 5,000 km or 12 months

10 items
  • Check throttle cable(s) free play and return
    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 6,000 km or 12 months

4 items
  • Air filter (replace)
    Fuel and air
    Factory

    Factory: Inspection and maintenance schedule (AJP PR5 250 user's manual, 2nd edition, English, printed pp.15-16, ManualsLib viewer pp.18-19): each 6,000 km or 12 months. Services as printed: after the 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 (the 3,000 km items plus extras); each 12,000 km or 24 months (the 3,000 and 6,000 km items plus extras). Service more often under continuous full throttle or in dusty conditions. Items marked * are for an AJP dealer. No model year printed in the pages read.

  • Fuel cap valve (check function)
    Fuel and air
    Factory

    Factory: Inspection and maintenance schedule (AJP PR5 250 user's manual, 2nd edition, English, printed pp.15-16, ManualsLib viewer pp.18-19): each 6,000 km or 12 months. Services as printed: after the 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 (the 3,000 km items plus extras); each 12,000 km or 24 months (the 3,000 and 6,000 km items plus extras). Service more often under continuous full throttle or in dusty conditions. Items marked * are for an AJP dealer. No model year printed in the pages read.

  • Steering stem bearings (lubricate)
    Front end
    Factory

    Factory: Inspection and maintenance schedule (AJP PR5 250 user's manual, 2nd edition, English, printed pp.15-16, ManualsLib viewer pp.18-19): each 6,000 km or 12 months. Services as printed: after the 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 (the 3,000 km items plus extras); each 12,000 km or 24 months (the 3,000 and 6,000 km items plus extras). Service more often under continuous full throttle or in dusty conditions. Items marked * are for an AJP dealer. No model year printed in the pages read.

  • Rear suspension links and swing arm bearings (lubricate)
    Rear suspension and frame
    Factory

    Factory: Inspection and maintenance schedule (AJP PR5 250 user's manual, 2nd edition, English, printed pp.15-16, ManualsLib viewer pp.18-19): each 6,000 km or 12 months. Services as printed: after the 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 (the 3,000 km items plus extras); each 12,000 km or 24 months (the 3,000 and 6,000 km items plus extras). Service more often under continuous full throttle or in dusty conditions. Items marked * are for an AJP dealer. No model year printed in the pages read.

Every 6,500 km 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 8,000 km 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 9,500 km or 12 months

6 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.

  • 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 12,000 km or 2 years

3 items
  • Drive chain (replace)
    Final drive
    Factory

    Factory: Inspection and maintenance schedule (AJP PR5 250 user's manual, 2nd edition, English, printed pp.15-16, ManualsLib viewer pp.18-19): each 12,000 km or 24 months. Services as printed: after the 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 (the 3,000 km items plus extras); each 12,000 km or 24 months (the 3,000 and 6,000 km items plus extras). Service more often under continuous full throttle or in dusty conditions. Items marked * are for an AJP dealer. No model year printed in the pages read.

  • Front fork seals and fork oil (replace)
    Front end
    Factory

    Factory: Inspection and maintenance schedule (AJP PR5 250 user's manual, 2nd edition, English, printed pp.15-16, ManualsLib viewer pp.18-19): each 12,000 km or 24 months. Services as printed: after the 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 (the 3,000 km items plus extras); each 12,000 km or 24 months (the 3,000 and 6,000 km items plus extras). Service more often under continuous full throttle or in dusty conditions. Items marked * are for an AJP dealer. No model year printed in the pages read.

  • Brake fluid (replace)
    Brakes
    Factory

    Factory: Inspection and maintenance schedule (AJP PR5 250 user's manual, 2nd edition, English, printed pp.15-16, ManualsLib viewer pp.18-19): each 12,000 km or 24 months. Services as printed: after the 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 (the 3,000 km items plus extras); each 12,000 km or 24 months (the 3,000 and 6,000 km items plus extras). Service more often under continuous full throttle or in dusty conditions. Items marked * are for an AJP dealer. No model year printed in the pages read.

Every 13,000 km or 2 years

1 item
  • Check and adjust valve clearances
    Engine
    Guideline

Every 16,000 km or 2 years

1 item
  • Compression test (or leak-down)
    Engine
    Guideline

Every 19,500 km or 2 years

3 items
  • Replace air filter element
    Fuel and air
    Guideline
  • Synchronize throttle bodies
    Fuel and air
    Guideline
  • Grease swingarm pivot
    Rear suspension and frame
    Guideline

Every 24,000 km 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 25,500 km or 4 years

1 item
  • Replace spark plugs
    Engine
    Guideline

Every 29,000 km

1 item
  • Replace chain and sprockets (wear based)
    Final drive
    Guideline

Every 32,000 km 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 38,500 km or 4 years

1 item
  • Replace fuel filter
    Fuel and air
    Guideline

Every 40,000 km or 6 years

1 item
  • Replace swingarm bushes / bearings
    Rear suspension and frame
    Guideline

Every 48,500 km 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.

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