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

PR7 (600 cc)

Library entry covers 2015-2024

49 factory 32 guideline

Published source

AJP PR7 User Manual (edition 01-2017), Chapter C periodic maintenance tables pp.37-39

Factory owner's handbook. Covers AJP PR7 User Manual, edition 01-2017; catalog row 2015-2024 is the same model, later editions not checked; engine table in km only, chassis and owner tables km or months whichever first.

81 items for a 2020 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
Liquid 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, single shock / cantilever
Front brake
Disc, hydraulic
Rear brake
Disc, hydraulic
Wheels
Spoked, tubed
Sidecar
No sidecar
Maintenance schedule

2020 AJP PR7 (600 cc)

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

2 items
  • Check lights, horn, brake light switches
    Pre-ride / on the road
    Guideline
  • Check tire pressures
    Pre-ride / on the road
    Guideline

On the road: every 800 km

1 item
  • Check coolant level
    Pre-ride / on the road
    Guideline

On the road: every 1,000 km

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

On the road: every 3,000 km or 6 months

1 item
  • Lubricate drive chain
    Pre-ride / on the road
    Factory

    Manual: Drive chain (clean/lubricate). Factory: Dealer table p.38 (columns first 1000 km or 1 month, each 500 km or 1 month, 3000 km or 6 months, 6000 km or 12 months, 12000 km or 24 months): C L at first service, 3000 km and 6000 km columns

Every 500 km or 1 month

5 items
  • Cooling liquid level (inspect, owner)
    Engine
    Factory

    Factory: Owner table p.39 (same columns as p.38): I at first service, each 500 km, 3000 km and 6000 km columns; refill if necessary

  • Engine oil level (inspect, owner)
    Engine
    Factory

    Factory: Owner table p.39 (same columns as p.38): I at first service and every column; refill if necessary

  • Clean / inspect air filter
    Fuel and air
    Factory

    Manual: Air filter (inspect/clean). Factory: Dealer table p.38 (columns first 1000 km or 1 month, each 500 km or 1 month, 3000 km or 6 months, 6000 km or 12 months, 12000 km or 24 months): I C at first service and each 500 km or 1 month and each 3000 km; clean or replace depending on filter condition

  • Drive chain (inspect)
    Final drive
    Factory

    Factory: Dealer table p.38 (columns first 1000 km or 1 month, each 500 km or 1 month, 3000 km or 6 months, 6000 km or 12 months, 12000 km or 24 months): I each 500 km or 1 month

  • Drive chain (inspect/clean/adjust/lubricate, owner)
    Final drive
    Factory

    Factory: Owner table p.39 (same columns as p.38): I at first service; I C A L each 500 km or 1 month, 3000 km and 6000 km columns

Every 3,000 km or 6 months

17 items
  • Braking fluid (inspect)
    Engine
    Factory

    Factory: Dealer table p.38 (columns first 1000 km or 1 month, each 500 km or 1 month, 3000 km or 6 months, 6000 km or 12 months, 12000 km or 24 months): I at 3000 km or 6 months

  • Braking system (inspect)
    Engine
    Factory

    Factory: Dealer table p.38 (columns first 1000 km or 1 month, each 500 km or 1 month, 3000 km or 6 months, 6000 km or 12 months, 12000 km or 24 months): I at first service and 3000, 6000, 12000 km columns

  • Braking system fluid level (inspect, owner)
    Engine
    Factory

    Factory: Owner table p.39 (same columns as p.38): I at 3000 and 6000 km columns

  • Electrical system (inspect)
    Engine
    Factory

    Factory: Dealer table p.38 (columns first 1000 km or 1 month, each 500 km or 1 month, 3000 km or 6 months, 6000 km or 12 months, 12000 km or 24 months): I at first service and 3000, 6000, 12000 km columns

  • Exhaust (inspect)
    Engine
    Factory

    Factory: Dealer table p.38 (columns first 1000 km or 1 month, each 500 km or 1 month, 3000 km or 6 months, 6000 km or 12 months, 12000 km or 24 months): I at first service and 3000, 6000, 12000 km columns

  • Inspect coolant hoses and clamps
    Engine
    Factory

    Manual: Cooling system tubes (inspect). Factory: Dealer table p.38 (columns first 1000 km or 1 month, each 500 km or 1 month, 3000 km or 6 months, 6000 km or 12 months, 12000 km or 24 months): I at 3000, 6000, 12000 km columns

  • Stop switches (inspect)
    Engine
    Factory

    Factory: Dealer table p.38 (columns first 1000 km or 1 month, each 500 km or 1 month, 3000 km or 6 months, 6000 km or 12 months, 12000 km or 24 months): I at 3000, 6000, 12000 km columns

  • Tightness review (nuts, bolts) (inspect/adjust)
    Engine
    Factory

    Factory: Dealer table p.38 (columns first 1000 km or 1 month, each 500 km or 1 month, 3000 km or 6 months, 6000 km or 12 months, 12000 km or 24 months): I/A at first service and 3000, 6000, 12000 km columns

  • Check throttle cable(s) free play and return
    Fuel and air
    Factory

    Manual: Throttle cable (adjust/lubricate). Factory: Dealer table p.38 (columns first 1000 km or 1 month, each 500 km or 1 month, 3000 km or 6 months, 6000 km or 12 months, 12000 km or 24 months): A L at 3000, 6000, 12000 km columns

  • Fuel injection system (inspect)
    Fuel and air
    Factory

    Factory: Dealer table p.38 (columns first 1000 km or 1 month, each 500 km or 1 month, 3000 km or 6 months, 6000 km or 12 months, 12000 km or 24 months): I at 3000, 6000, 12000 km columns

  • Clean battery terminals, check charge and strap
    Ignition and electrics
    Factory

    Manual: Battery (inspect). Factory: Dealer table p.38 (columns first 1000 km or 1 month, each 500 km or 1 month, 3000 km or 6 months, 6000 km or 12 months, 12000 km or 24 months): I at first service and 3000, 6000, 12000 km columns

  • Check steering head bearing adjustment
    Front end
    Factory

    Manual: Steering components (inspect). Factory: Dealer table p.38 (columns first 1000 km or 1 month, each 500 km or 1 month, 3000 km or 6 months, 6000 km or 12 months, 12000 km or 24 months): I at first service and 3000 km or 6 months

  • Front fork seals (inspect)
    Front end
    Factory

    Factory: Dealer table p.38 (columns first 1000 km or 1 month, each 500 km or 1 month, 3000 km or 6 months, 6000 km or 12 months, 12000 km or 24 months): I at 3000 km or 6 months

  • Grease and check center / side stand and springs
    Rear suspension and frame
    Factory

    Manual: Side stand (inspect/lubricate). Factory: Dealer table p.38 (columns first 1000 km or 1 month, each 500 km or 1 month, 3000 km or 6 months, 6000 km or 12 months, 12000 km or 24 months): I at first service; I L at 3000, 6000, 12000 km columns

  • Inspect rear shocks for leaks and damping
    Rear suspension and frame
    Factory

    Manual: Suspension (inspect). Factory: Dealer table p.38 (columns first 1000 km or 1 month, each 500 km or 1 month, 3000 km or 6 months, 6000 km or 12 months, 12000 km or 24 months): I at first service and 3000, 6000, 12000 km columns

  • Check brake pads and discs
    Brakes
    Factory

    Manual: Brake pads (inspect, owner). Factory: Owner table p.39 (same columns as p.38): I at 3000, 6000, 12000 km columns

  • Inspect tire tread, sidewalls and date codes
    Wheels and tires
    Factory

    Manual: Tires condition (inspect, owner). Factory: Owner table p.39 (same columns as p.38): I at first service and 3000, 6000, 12000 km columns

Every 5,000 km or 12 months

5 items
  • 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 fork seals, stanchions and fork boots
    Front end
    Guideline
  • Check footrests, pegs, rear brake and gear lever pivots
    Rear suspension and frame
    Guideline
  • Check spoke tension and wheel true
    Wheels and tires
    Guideline
  • Check wheel bearings for play
    Wheels and tires
    Guideline

Every 5,000 km

5 items
  • Change engine oil
    Engine
    Factory

    Manual: Engine oil (replace). Factory: Dealer table p.37 (engine; columns 1000/5000/10000/15000/20000 km): R at 1000 km and every 5000 km

  • Check and adjust valve clearances
    Engine
    Factory

    Manual: Valve clearance (inspect/adjust). Factory: Dealer table p.37 (engine; columns 1000/5000/10000/15000/20000 km): I/A at 1000 km and every 5000 km

  • Inspect, clean and gap spark plugs
    Engine
    Factory

    Manual: Spark plug (inspect). Factory: Dealer table p.37 (engine; columns 1000/5000/10000/15000/20000 km): I at 5000 and 15000 km, between replacements

  • Spark plug cap (inspect)
    Engine
    Factory

    Factory: Dealer table p.37 (engine; columns 1000/5000/10000/15000/20000 km): I at 5000, 10000, 15000, 20000 km

  • Timing chain tensioner (inspect)
    Final drive
    Factory

    Factory: Dealer table p.37 (engine; columns 1000/5000/10000/15000/20000 km): I at 5000, 10000, 15000 km

Every 6,000 km or 12 months

4 items
  • Replace air filter element
    Fuel and air
    Factory

    Manual: Air filter (replace). Factory: Dealer table p.38 (columns first 1000 km or 1 month, each 500 km or 1 month, 3000 km or 6 months, 6000 km or 12 months, 12000 km or 24 months): R at 6000 km or 12 months and 12000 km or 24 months; clean or replace depending on filter condition

  • Clutch pump oil (inspect)
    Primary and gearbox
    Factory

    Factory: Dealer table p.38 (columns first 1000 km or 1 month, each 500 km or 1 month, 3000 km or 6 months, 6000 km or 12 months, 12000 km or 24 months): I at 6000 km or 12 months

  • Front fork seals (lubricate)
    Front end
    Factory

    Factory: Dealer table p.38 (columns first 1000 km or 1 month, each 500 km or 1 month, 3000 km or 6 months, 6000 km or 12 months, 12000 km or 24 months): L at 6000 km or 12 months

  • Steering components (lubricate)
    Front end
    Factory

    Factory: Dealer table p.38 (columns first 1000 km or 1 month, each 500 km or 1 month, 3000 km or 6 months, 6000 km or 12 months, 12000 km or 24 months): L at 6000 km or 12 months and 12000 km or 24 months

Every 6,500 km or 12 months

1 item
  • Adjust clutch free play, lubricate cable and lever pivot
    Primary and gearbox
    Guideline

Every 9,500 km or 12 months

4 items
  • Check charging voltage and regulator / cut-out
    Ignition and electrics
    Guideline
  • Check swingarm bushes for play
    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 10,000 km

5 items
  • Clean oil strainers / mesh screens
    Engine
    Factory

    Manual: Oil strainer filter (clean). Factory: Dealer table p.37 (engine; columns 1000/5000/10000/15000/20000 km): C at 1000, 10000, 20000 km

  • Intake/exhaust rocker arm (inspect)
    Engine
    Factory

    Factory: Dealer table p.37 (engine; columns 1000/5000/10000/15000/20000 km): I at 10000 and 20000 km

  • Replace oil filter
    Engine
    Factory

    Manual: Main oil filter (replace). Factory: Dealer table p.37 (engine; columns 1000/5000/10000/15000/20000 km): R at 1000, 10000, 20000 km

  • Replace spark plugs
    Engine
    Factory

    Manual: Spark plug (replace). Factory: Dealer table p.37 (engine; columns 1000/5000/10000/15000/20000 km): R at 10000 and 20000 km

  • Clutch cush drive damper (inspect)
    Primary and gearbox
    Factory

    Factory: Dealer table p.37 (engine; columns 1000/5000/10000/15000/20000 km): I at 10000 and 20000 km

Every 12,000 km or 2 years

8 items
  • Braking system fluid (replace, owner)
    Engine
    Factory

    Factory: Owner table p.39 (same columns as p.38): R at 12000 km or 24 months

  • Replace coolant
    Engine
    Factory

    Manual: Cooling liquid (replace, owner). Factory: Owner table p.39 (same columns as p.38): R at 12000 km or 24 months

  • Clutch pump oil (replace)
    Primary and gearbox
    Factory

    Factory: Dealer table p.38 (columns first 1000 km or 1 month, each 500 km or 1 month, 3000 km or 6 months, 6000 km or 12 months, 12000 km or 24 months): R at 12000 km or 24 months

  • Drive chain (replace, owner)
    Final drive
    Factory

    Factory: Owner table p.39 (same columns as p.38): R at 12000 km or 24 months

  • Inspect chain and sprockets for wear (measure stretch)
    Final drive
    Factory

    Manual: Drive chain (replace). Factory: Dealer table p.38 (columns first 1000 km or 1 month, each 500 km or 1 month, 3000 km or 6 months, 6000 km or 12 months, 12000 km or 24 months): R at 12000 km or 24 months

  • Change fork oil
    Front end
    Factory

    Manual: Front fork oil (replace). Factory: Dealer table p.38 (columns first 1000 km or 1 month, each 500 km or 1 month, 3000 km or 6 months, 6000 km or 12 months, 12000 km or 24 months): R at 12000 km or 24 months

  • Front fork seals (replace)
    Front end
    Factory

    Factory: Dealer table p.38 (columns first 1000 km or 1 month, each 500 km or 1 month, 3000 km or 6 months, 6000 km or 12 months, 12000 km or 24 months): R at 12000 km or 24 months

  • Replace brake fluid
    Brakes
    Factory

    Manual: Braking fluid (replace). Factory: Dealer table p.38 (columns first 1000 km or 1 month, each 500 km or 1 month, 3000 km or 6 months, 6000 km or 12 months, 12000 km or 24 months): R at 12000 km or 24 months

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
  • Synchronize throttle bodies
    Fuel and air
    Guideline
  • Clean and grease rear suspension linkage
    Rear suspension and frame
    Guideline
  • Grease swingarm pivot
    Rear suspension and frame
    Guideline

Every 20,000 km

4 items
  • Timing gear (replace)
    Ignition and electrics
    Factory

    Factory: Dealer table p.37 (engine; columns 1000/5000/10000/15000/20000 km): R at 20000 km

  • Timing chain (replace)
    Final drive
    Factory

    Factory: Dealer table p.37 (engine; columns 1000/5000/10000/15000/20000 km): R at 20000 km

  • Timing chain guides (replace)
    Final drive
    Factory

    Factory: Dealer table p.37 (engine; columns 1000/5000/10000/15000/20000 km): R at 20000 km

  • Timing chain tensioner (replace)
    Final drive
    Factory

    Factory: Dealer table p.37 (engine; columns 1000/5000/10000/15000/20000 km): R at 20000 km

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 2 years

2 items
  • Inspect wiring, bullet connectors and ground points
    Ignition and electrics
    Guideline
  • Inspect frame, welds and lugs for cracks
    Rear suspension and frame
    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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