AJP PR4 User manual

Chapter 1 – General information / Technical specifications

Service Manual AJP PR3/PR4 1 - 1

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;

- Clean quickly spilled fuel;

- If the fuel is swallowed or contact with eyes,

seek medical attention immediately;

- Keep children and pets at a distance.

! DANGER !

Gasoline is extremely flammable and

explosive under certain conditions. KEEP IT

AWAY FROM CHILDREN.

Components with high temperatures

! DANGER !

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.

GENERAL SAFETY AND

MAINTENANCE RULES

1 – 1

FUEL FEED SYSTEM

1 – 23

MODEL IDENTIFICATION

1 – 3

STEERING STEM

1 – 25

GENERAL INFORMATION

1 – 4

FRONT SUSPENSION

1 – 26

MOTORCYCLE DIMENSIONS

1 – 5

REAR SUSPENSION

1 – 34

ENGINE

1 – 6

WHEELS AND TYRES

1 – 36

CLUTCH

1 – 14

BRAKE SYSTEM

1 – 40

BEARINGS, SEALS, WASHERS

AND ENGINE BOLTS

1 – 18

ELECTRIC SYSTEM

1 – 43

ALTERNATOR

1 – 20

TIGHTENING TORQUES

1 – 47

STARTER MOTOR

1 – 21

LUBRICATION POINTS AND

SEALING

1 – 53

Chapter 1 – General information / Technical specifications

Service Manual AJP PR3/PR4 1 - 2

! DANGER !

The engine oil may cause skin cancer if left in

contact with the skin repeatedly for a long

period of time. Usually it is not necessary to

handle used oil every day, but it is

recommended that wash hands thoroughly

with soap and water after handling used motor

oil. KEEP USED OIL AWAY OF CHILDREN .

Brake dust

Never use compressed air or a dry brush to

clean the brakes.

! DANGER !

Asbestos fibers, if inhaled, can cause

respiratory diseases or cancer.

Brake fluid

Follow the guidelines of your country for

collecting and treatment of waste fluid. Never

dump into the sewer or ground.

! WARNING !

If the brake fluid is spilled on painted, plastic

or rubber parts can damage them. If a spill

occurs, immediately flush with water. Put a

cover on top of these painted pieces to protect

them when handling the brake circuit. KEEP

THE BRAKE FLUID AWAY OF CHILDREN.

Compressed nitrogen

Regarding to shock absorbers with gas

reservoir:

! DANGER !

 Use only nitrogen to compression of the

shock absorbers. Using an unstable gas

may cause a fire or an explosion that can

lead to serious injury;

 The shock absorbers containing nitrogen

under high pressure. Should never be near

a flame or heat source, since there are

explosion hazards that can lead to serious

injury;

 Charging a damper with nitrogen carries a

risk of explosion which can lead to serious

injury if the damper is incorrectly heated or

bored.

To avoid risk of explosion, open the valve

mechanism and release nitrogen. The

remaining oil should be treated according to

the environmental legislation.

Before you discard a damper, open the valve

mechanism and release the nitrogen.

MAINTENANCE RULES

1. Use only components and lubricants

approved by AJP, or their equivalents.

Components that do not meet the

requirements of AJP can damage the

motorcycle.

2. Use only metric tools to perform

maintenance on the motorcycle. The

incorrect use of tools or attachments could

damage the motorcycle.

3. Always use O-rings, seals and gaskets for

new assembly.

4. When any part or component is attached

with several bolts (e.g. engine covers,

cylinder head, brake discs. sprocket, etc.)

begin tightening the inner screw largest

diameter, followed by pressing the opposite

diagonal, cross or X, gradually increasing

the torque to the specified value.

5. Clean the inside of the components with a

solvent after disassembly for inspection

and lubricate the friction surfaces before

proceeding to its assembly.

6. After installation, check that all parts are

installed correctly and working.

Chapter 1 – General information / Technical specifications

Service Manual AJP PR3/PR4 1 - 3

MODEL IDENTIFICATION

SERIAL NUMBER LOCATION

The serial number of the frame and / or

engine are used for motorcycle registration.

They are also used to help your dealer when

ordering parts or require any special

maintenance information.

Frame number

The frame number is stamped on the right

side of the steering stem tube (1).

Motor number

The engine number (1) is marked on the left

side of the motor under gear lever.

Approval plate

The approval plate (1) is placed in front of the

frame on the left side. It has marked the

approval number, the serial number of the

frame and the sound level at a specified

rotation.

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.

! WARNING !

Throughout this chapter it is necessary to

pay attention that some components may

have more than one specification. If you

have doubts to identify which is the right

specification of your motorcycle, please

contact AJP MOTOS.

! WARNING !

All dimensions listed in the following tables

are in millimeters (mm) unless otherwise

specified.

Chapter 1 – General information / Technical specifications

Service Manual AJP PR3/PR4 1 - 4

GENERAL INFORMATION

Element / Item

Specification

Engine

125cc

200cc

240cc

Engine (Type)

4 stroke; petrol; 1 cylinder; 2 valves.

Displacement

124cc

198cc

233cc

Power

9,3Kw (12,6Cv) at

8.500rpm

13,2Kw (18Cv) at

8.000rpm

14,7Kw (20Cv) at

8.000rpm

Torque

8,5N.m/8.000rpm

15,5N.m/7.000rpm

18N.m/7.000rpm

Bore and Stroke

56,6x49,5mm

69x53mm

69x62,5mm

Compression ratio

9,0:1

9,2:1

9,4:1

Compression in the cylinder

12,0Kg/cm2

13,0Kg/cm2

14,5Kg/cm2

Valve mechanism

2 Valves, 1 camshaft driven by chain with rocker arm

Valve clearance

0,05 (intake); 0,08 (exhaust)

Intake valve

Opens at 5o BTDC

Closes at 30o ABDC

Exhaust valve

Opens at 35o BBDC

Closes at 5o ATDC

Ignition

Electronics by CDI

Initial advance of the spark angle

10o BTDC (2.000 +/- 100rpm)

Full advance of spark angle

30o BTDC (4.000 +/- 100rpm)

Spark plug (standard)

LG D8TC

Spark plug (equivalents)

CHAMPION A8YC / NGK DR8ES / DPR8EA-9

Gap between the electrodes

0,6 - 0,7mm

Gear box

5-speed

Clutch

5 Discs/5 springs

5 Discs/4 springs

7 Discs/6 springs

Start

Electric / Pedal

CDI unit

MD125 – 3B

Ignition coil

MGO3A // MGE30

Spark plug cap (equivalents)

NGK LB05F / VD05F / YB05F

Alternator

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

Chapter 1 – General information / Technical specifications

Service Manual AJP PR3/PR4 1 - 5

Fuel supply

Carburetor

Fuel pump

By vacuum (Paiolli)

Fuel tank

6,5 Liters

Lubrication

Forced by trochoidal pump

Capacity / debit oil pump

> 5,6 Liters/min. at 4.500rpm

Flow suction oil pump

0,3 MPa > 5,2 L/min.

Maximum temperature of the engine

oil

90oC (194ºF)

Maximum oil consumption

8gr/100Km

The engine oil capacity

1,1 Liters

1,2 Liters

Recommended oil type

Eni/Agip i-Ride Moto SAE 20W-50 (API-SG JASO MA,MA2)

Main oil filter

Reusable; metal mesh, thimble type

Engine oil replacement

The first change should occur at 500Kms. Then every 2000Kms

Cooling

Air

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

920

910

905

Fuel tank capacity

9 Liters

Weight (dry)

99Kg

95Kg

PR3

Element

MX

MX/PRO

EN

SM

TR

Wheelbase

1320

1310

Seat height

860

840

810

Weight (with fuel) (240cm3)

104Kg

(108Kg)

107Kg

104Kg (108Kg)

PR4 (2007 – …)

Element

EN/TR

SM

EXTREME

Wheelbase

1380

Seat height

920

870

920

Weight (with fuel) (240cm3)

112Kg (113Kg)

(119Kg)

Chapter 1 – General information / Technical specifications

Service Manual AJP PR3/PR4 1 - 6

ENGINE

LUBRICATION SYSTEM

Element

Item

Specification

Service

limit

Lubrication

Forced by trochoidal oil pump

Z39

Z37

-

Oil capacity

Engine

125cc

200/240cc

Replace

every 2000km

Change / Replace

1 Liter

1,1Liters

When disassembling the engine

1,1 Liters

1,2 Liters

Recommended

engine oil

Brand

ENI-AGIP

Type

Classification API: SF ou SG

Viscosity: SAE 20W-50

Oil filter

Grid, “thimble” type

Reusable

Centrifugal filter

Rotor on the

crankshaft

125/200cc

Ø68mm

240cc

Ø58mm

Checking the

oil level

Display on the right engine cover

-

Oil pump

Mandate drive

gear

125 (1stversion)

Z39 (nylon)

-

Z37 (nylon)

200

240

Z37 (steel, with cover)

Pump rotors

125

Outside

8 teeth

23x13mm

-

Inside

7 teeth

200/240

Outside

5 teeth

23x13mm

Inside

4 teeth

Clearance in the tip

0,15

0,20

Clearance in the body

0,15 – 0,21

0,35

Clearance in the end

0,03 – 0,12

0,15

Ledge of the rotors cover

Aligned with mark on the

body of the pump

-

Screws in the rotors cover

M4x10

-

Tightening of the cap screws

3N.m (0,3Kgf.m)

-

Pump chain sprocket cover bolts

(engine 240)

M5x20

-

Tightening of the screws on the

cover

5N.m (0,5Kgf.m)

-

The pump mounting bolts

M6x30

-

Chapter 1 – General information / Technical specifications

Service Manual AJP PR3/PR4 1 - 7

Tightening of the screws fixing the

oil pump

12N.m (1,2Kgf.m)

-

O-ring seals the pump on the

engine crankcase

2 O-rings 9,4x2,4mm

-

Oil cooler (On

200/240cm3

engines)

Radiator type (GR 125)

Aluminum

-

Honeycomb radiator dimensions

155x70mm

-

Thread

M12x1,5

-

Racord screws Banjos on the

radiator

M12x1,5

-

Tightening of the screws M12

racord

29N.m (3,0Kgf.m)

-

Sealing rings

12,3x20x16

-

Spacer

10mm

-

Radiator fixing screws

M6x30 w/ tab

-

Oil pipes

Short pipe (output)

Bolt 10mm (or 8mm)

tightens on the engine

crankcase

-

Bolt 12mm tightens down on

oil cooler

-

Long pipe (input)

Screw M10 (or M8x1)

tightens on the clutch cover

-

Bolt 12mm tightens on top

of the oil cooler

-

Sealing washers 8mm

8,2x14,5x1,5

-

Sealing washers 10mm

10,2x16x1,2

-

Sealing washers 12mm

12,3x20x16

-

CYLINDER HEAD / VALVES / VALVE MECHANISM

Element

Item

Specification

Service

limit

Cylinder head

Compression in the cylinder

125cc engine

13,0 kgf/cm2

–

200cc engine

13,2Kgf/cm2

–

240cc engine

Warpage of the cylinder head

–

0,1mm

Cylinder head height

125

82,65mm

–

200/240

81mm

–

Gasket thickness of the cylinder head

1,3 - 1,5mm

–

I.D. Hole of the cylinder

head gasket

125

58mm

–

150

63mm

–

200/240

70mm

–

Chapter 1 – General information / Technical specifications

Service Manual AJP PR3/PR4 1 - 8

O-ring on the cap guide (125cc)

10x1,6mm

–

Retainer on the oil hole (125cc)

Rubber

–

Intake valve hole cover on the 240cc engine

Lowered 3mm

–

Stud on the exhaust

manifold

125/150

M8x35

–

200/240

M8x30

–

Valves and

valve guides

Valve clearances

IN

0,05mm

–

EX

0,08mm

Valve stem outside diameter

IN

5,450 – 5,465

5,42mm

EX

5,430 – 5,445

5,40mm

Valve stem inside diameter

IN/EX

5,475 – 5,485

5,50mm

Clearance on the tab - stem

IN

0,010 – 0,035

0,08mm

EX

0,030 – 0,055

0,10mm

Mark on the valves

“DC”

–

Ø Valves hat

IN

125

30mm

–

200

31,5mm

240

34mm

EX

125

25mm

200

26mm

240

28,5mm

Total height of the valves

IN (125)

91mm

–

EX (125)

90,3mm

–

IN (200/240)

91,5mm

–

EX (200/240)

90,7mm

–

Valve seat width

IN/EX

1,1 – 1,3mm

1,5mm

Groove height of the

retaining loops

125/150

3mm

–

200/240

5mm

–

Retaining loops position

125/150

Up

-

200/240

Down

-

Valve springs

Length (size)

IN/EX

Inside

39x17,5x12,5mm

39,3mm

Outside

44,5x26,5x19mm

43,7mm

Base washers valve springs

Inside

18x12,6x0,5mm

–

Outside

26x19x1mm

Rocker arms

Rocker arm inside diameter

IN/EX

12,000 – 12,018

12,1mm

Came rocker arm outsider

diameter

11,966 – 11,984

11,93mm

Clearance

0,016 – 0,052mm

0,084mm

Adjuster thread lead

M6x0,75

–

Adjuster nut torque

14N.m (1,4Kgf.m)

–

Chapter 1 – General information / Technical specifications

Service Manual AJP PR3/PR4 1 - 9

Rock hammer

shafts of the

valves

125/150

IN/EX

Passing fillister

Ø12x64mm

–

200/240

IN

Low fillister

–

EX

Deep fillister

Ø12x65,3mm

–

Lubrication holes

IN/EX

Ø3mm

–

Camshaft

Height of cams

125/200/240

IN

31,58mm

30,6

EX

31,40mm

30,2

Warpage

-

31,452 – 31,532

+- 0,1

Outside diameter of the

supports

Right

20,00mm

–

Left

16,60mm

–

Support on the left side

Bearing 6203

–

Support on the right side

Bushing (20x28x11)

–

Valve

mechanism

Timing chain

125

4x98 Links

–

200

7x100 Links

240

7x102 Links

Sprocket

125

Z34

–

200 / 240

Z34

Valve mechanism pinion

Z17

–

Mounting position of the pinion on the crankshaft

Tooth aligned with

the keyway

–

Sprocket fixing screws

125

M6x10

–

200 / 240

M6x12

Valve mechanism guide-

chain tensioner

125

Short (175mm)

–

200

Medium

–

240

Long

–

Timing chain tensioner 125/200/240

Ref. 547

–

Unlocking the tensor

Rotate right

–

Screws torque

12N.m (1,2Kgf.m)

–

Pivot screw of the tensor guide

10N.m (1,0Kgf.m)

–

Screw in the protection of the timing chain in the

crankshaft

10N.m (1,0Kgf.m)

–

Tensioner bolts

10N.m (1,0Kgf.m)

–

Tensioner cover

5N.m (0,5Kgf.m)

–

Chapter 1 – General information / Technical specifications

Service Manual AJP PR3/PR4 1 - 10

CYLINDER AND PISTON

Element

Item

Specification

Service

limit

Cylinder

Inside diameter

125

56,50 – 56,51 mm

56,60 mm

200/240

69,00 – 69,01 mm

69,10 mm

Inclination

15º

–

Roundness

–

0,05 mm

Warpage

–

0,05 mm

Cylinder height (between the

lower face and upper surface)

125

68,0mm

-

150

68,5mm

-

200

70,2mm

-

240

77,2mm

-

Cylinder gasket thickness

0,50mm

-

Piston and

segments

Direction of the piston mark

Marking "IN"

pointing to the

intake

–

Outer diameter of the piston

125

56,470 – 56,490

56,40 mm

150 (kit)

60,970 – 60,990

60,80mm

200/240

68,970 – 68,990

mm (10 mm from

the bottom of the

skirt)

68,80 mm

Clearance cylinder / piston

0,010 – 0,040

0,20 mm

Piston pin

125

Ø15x10x48

-

150 (kit)

Ø15x10x50

-

200/240

Ø17x12x55mm

-

Inside diameter of the pin hole

125

15,002 – 15,008

15,04mm

200/240

17,002 – 17,008

17,04mm

Outer diameter of the pin came

125

14,994 – 15,000

14,96 mm

200/240

17,994 – 17,000

16,96 mm

Clearance piston hole / pin came

0,002 – 0,014

0,02 mm

Clearance rod hole / pin

0,010 – 0,034

0,10 mm

Segment width

125/150

1,0mm

-

200

1,0mm

-

240

1,2mm

-

Clearance of the segments in the

piston channel

Top

0,025 – 0,060

0,09 mm

Secondary

0,015 – 0,050

0,08 mm

Clearance at the end of the

segments

Top

0,20 – 0,35

0,5 mm

Secondary

0,35 – 0,50

0,65 mm

Chapter 1 – General information / Technical specifications

Service Manual AJP PR3/PR4 1 - 11

Oil (rail side)

0,20 – 0,70

0,9 mm

Mounting position of the

segments in the piston

Grey (DY)

Up

-

Black (D)

Down

-

Oil

Facing the exhaust

-

Gap between the ends of the cylinder segments

120º

-

CRANKSHAFT

Element

Specification

Service

limit

Crankshaft stroke

125

49,5mm

–

200

53,0mm

–

240

62,5mm

–

Crankshaft mounting dimension

55mm

–

Diameter of the right crankshaft body (125)

111mm

–

Diameter of the left crankshaft body (125)

103mm

–

Diameter of the crankshaft body (engine 200/240)

111mm

–

Shaft diameter left / wheel side

20mm / 22mm

–

Total length of the crankshaft

210mm

–

Threaded on the right side

M16x1

–

Threaded on the left for the flywheel (1st version)

M8x1,25 or M10x1

–

Connecting rod radial clearance

0,000 – 0,008

0,05mm

Connecting rod lateral clearance

0,05 – 0,30

0,80mm

Connecting rod lateral clearance on the crankshaft

–

0,60mm

Backhand Stroke of the crankshaft

–

0,03mm

Pin size rod / crankshaft

30x54mm

–

Bearing of the connecting rod foot side

30x38x18mm

–

125 Connecting rod

Distance between holes

103,5mm

103,66mm

I.D. Hole of the connecting rod bottom side

38mm

38,08mm

I.D. Hole of the connecting rod top side

15mm

15,08mm

Width of the connecting rod

18mm

-

Pin in the connecting rod / crankshaft

30x54mm

-

Bearing of the connecting rod bottom

30x38x18mm

-

200 Connecting rod

Distance between holes

103,5mm

103,66mm

I.D. Hole of the connecting rod bottom side

38mm

38,08mm

Chapter 1 – General information / Technical specifications

Service Manual AJP PR3/PR4 1 - 12

I.D. Hole of the connecting rod top side

17mm

17,08mm

Width of the connecting rod

18mm

-

Pin in the connecting rod / crankshaft

Ø30x54mm

-

Bearing of the connecting rod foot

30x38x18mm

-

Dimensions of the rollers

Ø4x14,7mm

-

240 Connecting rod

Distance between holes

105mm

105,16mm

I.D. Hole of the connecting rod bottom side

41mm

41,08mm

I.D. Hole of the connecting rod top side

17mm

17,08mm

Width of the connecting rod

18mm

-

Pin in the connecting rod / crankshaft

Ø32x54mm

-

Bearing of the connecting rod foot

32x41x18

-

Dimensions of the rollers

Ø4,5x14,7mm

-

GEAR BOX

Element

Specification

Service

limit

Gear box ratio

Primary transmission

By gears

-

125 Engine

Primary reduction

Z73/Z18 (4,055)

-

1st (secondary/primary)

Z36/Z13 (2,769)

-

2nd

Z32/Z17 (1,882)

-

3rd

Z28/Z20 (1,400)

-

4th

Z26/Z23 (1,130)

-

5th

Z24/Z25 (0,960)

-

200 Engine

Primary reduction

Z70/Z21 (3,333)

-

1st (secondary/primary)

Z36/Z13 (2,769)

-

2nd

Z32/Z17 (1,882)

-

3rd

Z28/Z20 (1,400)

-

4th

Z26/Z23 (1,130)

-

5th

Z24/Z25 (0,960)

-

240 Engine

Primary reduction

Z70/Z21 (3,333)

-

1st (secondary/primary)

Z32/Z11 (2,090)

-

2nd

Z28/Z15 (1,866)

-

3rd

Z25/Z18 (1,388)

-

4th

Z23/Z20 (1,150)

-

5th

Z21/Z22 (0,954)

-

Chapter 1 – General information / Technical specifications

Service Manual AJP PR3/PR4 1 - 13

Final transmission

By chain

-

Drive sprocket (standard)

1Z5

-

Drive sprocket (optional)

Z14 / Z16 / Z17

-

Drive sprocket PR4-Brazil / Extreme

520 – Z12

-

Sprocket PR3

Z46

-

Sprocket PR4

Z48/Z50

-

Sprocket PR4-Brazil / Extreme

Z46 (Aluminum 7075 – 46) step

520

-

Chain PR3

428H – 124 Links

-

Chain PR4

428H - 132 Links

-

Chain PR4-Brazil / Extreme

Step 520

-

Dimensions

Gears inside diameter

(125_200/240)

M5 (Z25 / Z22)

23,020 – 23,041

-

C1 (Z36 / Z32)

19,520 – 19,541

-

C2 – 125/200 (Z32)

23,020 – 23,041

-

C2 – 240 (Z28)

22,020 – 22,041

-

C3 (Z28 / Z23)

22,020 – 22,041

-

C4 (Z26 / Z21)

20,020 – 20,041

-

C5 (Z24 / Z21)

20,020 – 20,041

-

Bushings in the

secondary

gears

C1 (16,5x19,5x7,3)

I.D.

16,516 – 16,534

-

O.D.

19,479 – 19,500

-

C2 (22x25x10) not

existing in 240

engine

I.D.

22,000 – 22,021

-

O.D.

24,979 – 25,000

-

Starter sprocket

(16,5x20x7,8)

O.D.

19,959 – 19,980

-

Outer diameter primary

shaft

M5 (Z13 / Z11)

19,959 – 19,980

-

Outer sleeve guide

clutch

19,959 – 19,980

-

Outer diameter

secondary shaft

Starter sprocket (Z29)

14,966 – 14,984

-

C1

17,966 – 17,984

-

C2, C4

21,959 – 21,980

-

C1

0,020 – 0,062

-

C2

0,020 – 0,062

-

C3

0,020 – 0,062

-

Pinion-shaft clearance

M5, C4

0,020 – 0,062

-

Bushing-shaft clearance

C1

0,016 – 0,052

-

C2 (125/200)

0,020 – 0,062

-

Startup wheel (Z29)

14,966 – 14,984

-

Chapter 1 – General information / Technical specifications

Service Manual AJP PR3/PR4 1 - 14

Gear shift drum

O.D. on the drum in support of the position on the

left crankcase

12.975 – 12.990

-

O.D. on the drum in support of the position on the

right crankcase

19,959 – 19,980

-

Distance between lateral supports

82,00 mm

-

Total length of the drum

106,8 mm

-

Width of the drum channels

7,25 mm

-

Forks, came forks, gearshift linkage

Forks

I.D. hole

12,000 – 12,021

12,05mm

Thickness of

the fork

Right

4,93 – 5,00

4,70mm

Left

Center

Thickness of the forks claw on the gears

5,3mm

-

Forks pin diameter on the drum

7mm

-

Forks shaft

Ø12x110,5mm

-

O.D. fork shaft

11,966 – 11,984

11,90

O.D. shaft gearshift linkage

14

-

CLUTCH

FOUR CLUTCH SPRINGS (ENGINES 125/200Cm3)

Item

Specifications

Service limit

Engines equipped with four clutch springs

ZS156FMI-2A (125Cm3)

/ ZS169YML (200Cm3)

-

Number of clutch plates (coated)

5

-

Thickness of the coated discs

3,0mm

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

-

Number of exterior ridges

8

-

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)

4

-

Disc plate thickness

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

-

Chapter 1 – General information / Technical specifications

Service Manual AJP PR3/PR4 1 - 15

Number of teeth in the separators discs

25

-

Width of teeth on drive plate

5,6mm

-

Cut width in the plate disc

6,3mm

-

Thickness of the coated discs 5 + 4 plate discs

21,5mm

21,4mm

Clutch hub Thickness

4,60mm

4,50mm

Hub height in grooved zone

26,0mm

-

Total height of the hub

30,4mm

-

Hub / pressure plate outer diameter

110mm

-

The thickness of the pressure plate

9,70mm

9,60mm

Inside diameter of the hole in the pressure plate

38mm

-

Total thickness of all the four springs clutch

35,5mm

-

Normal length of the springs

35,2mm

33,5mm

Springs dimensions

Ø18,5x35,2x13,3mm

-

Pressure plate screws

M6x22

-

Tightening torque of the screws on the table

1,2Kgf.m (12N.m)

-

Clutch fixing on the primary shaft

Castle nut (M16x1)

-

Locking ring with retaining tabs

(engine 200/240)

-

Mounting position of the taper washer

“Outside” out

-

Clutch nut torque

93 N.m (9,5 Kgf.m)

-

Clutch thrust bearing

16003

-

Stud pressure

Simple

-

FIVE CLUTCH SPRINGS (ENGINES 125/200Cm3)

Item

Specifications

Service limit

Engines equipped with five clutch springs

ZS156FMI-2A (125cm3 –

2012…)

-

Number of clutch plates (coated)

5

-

Thickness of the coated discs

3,0mm

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

-

Number of exterior ridges

8

-

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)

4

-

Disc plate thickness

1,6mm

1,5mm

Maximum permissible warping in the separators discs

-

0,2mm

Chapter 1 – General information / Technical specifications

Service Manual AJP PR3/PR4 1 - 16

Outer diameter of the plate discs

110mm

-

Smaller inner diameter of the plate discs

90mm

-

Larger inner diameter of the plate discs

82mm

-

Number of teeth in the separators discs

25

-

Width of teeth on drive plate

5,6mm

-

Cut width in the plate disc

6,3mm

-

Thickness of the coated discs 5 + 4 plate discs

21,2mm

21,0mm

Clutch hub Thickness

4,3mm

4,2mm

Hub height in grooved zone

26,0mm

-

Height of threaded bolts on the five springs hub

31mm

-

Total height of the hub

34,8mm

-

Hub / pressure plate outer diameter

110mm

-

Thickness of the five springs pressure plate

9,6mm

9,5mm

Inside diameter of the hole in the pressure plate

38mm

-

Mounting position of the plate on the five springs hub

With aligned points

-

Total thickness of all the five clutch springs

35,2mm

34,8mm

Springs dimensions

Ø18,5x35,2x13,3

-

Normal length of the springs

35,2mm

33,3mm

Pressure plate screws

M6x22

-

Tightening torque of the screws on the plate

1,2kgf.m (12N.m)

-

Clutch fixing on the primary shaft

Castle nut (M16x1)

-

Locking ring with retaining tabs

(engine 200/240)

-

Mounting position of the taper ring

“Outside” out

-

Clutch nut torque

93 N.m (9,5 Kgf.m)

-

Clutch thrust bearing

16003

-

Stud pressure in the five clutch springs

Linked with pin

-

SIX CLUTCH SPRINGS (ENGINE 240CM3)

Item

Specifications

Service limit

Engine equipped with six clutch springs

ZS169YMM (240Cm3

2013…)

-

Coated clutch discs

HMC - 301

-

Number of coated discs

7

-

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

-

Chapter 1 – General information / Technical specifications

Service Manual AJP PR3/PR4 1 - 17

Number of exterior ridges

8

-

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)

6

-

Disc plate thickness

1,20 – 1,15mm

1,10mm

Maximum permissible warping in the separators discs

-

0,2mm

Outer diameter of the plate discs

110mm

-

Smaller inner diameter of the plate discs

90mm

-

Larger inner diameter of the plate discs

82mm

-

Number of teeth in the separators discs

25

-

Width of teeth on drive plate

5,6mm

-

Cut width in the plate disc

6,3mm

-

Thickness of the coated discs 7 + 6 discs plate

27,3mm

-

Minimum width of the box between hub and clutch plate

25,6mm

-

Clutch hub Thickness

3,4mm

3,30mm

Hub height in grooved zone

31,1mm

-

Outside diameter of the grooved central ridge

39,95mm

-

Hub height (aluminum)

38,85mm

-

Total height of the hub clutch

40mm

-

Hub / pressure plate outer diameter

110mm

-

Thickness of the pressure plate

9,0mm

8,85mm

Inside diameter of the hole in the pressure plate

40mm

-

Height of the threaded bolts on the six springs plate

32,1mm

-

Diameter of M5 bolts

Ø10,7mm

-

Total height of the pressure plate

34,9mm

-

Total thickness of all the six clutch springs

39,7mm

-

Normal length of the springs

35mm

33,5mm

Dimensions of the springs (with 6/7 turns)

Ø17x35x12mm

-

Pressure table screws

M5x22

-

Tightening torque of the screws on the table

0,8kgf.m (8N.m)

-

Fixing six clutch springs on the primary shaft

Circlip 18mm

-

Clutch thrust bearing

16003

-

Stud pressure

Simple

-

Sprocket / basket clutch

Z70

-

Basket clutch

With 8 + 8 cuts

-

Total height of the clutch basket (outer)

41,9mm

-

Inside height the basket clutch

39,5mm

-

Chapter 1 – General information / Technical specifications

Service Manual AJP PR3/PR4 1 - 18

Height of the long cutouts

33,4mm

-

Height of the short cutouts

8,8mm

-

Width of the cutouts on the clutch basket

16,15mm

16,5mm

Total height of the basket with the clutch sprocket

61,5mm

-

Height in the center basket / clutch sprocket

20,90mm

-

Outer diameter of the clutch basket

120mm

-

Inside diameter of the clutch basket

112mm

-

Distance ring behind the clutch sprocket

30x42x1

-

Clutch lever

Long

-

Lever seal on the clutch cover

O-rings

-

Pin spring retaining on the clutch lever

Elastic pin

-

Pin mounting position on the lever

Protruding 4,7mm

-

Gap of the protrusions of the first coated disc

On the lower cutouts

-

Ring to fix the clearance on the pressure stud with

1.5mm discs

1.00mm thickness

-

BEARINGS, SEALS, WASHERS AND ENGINE BOLTS

Component

Dimensions

Crankshaft bearings

63/28 C3 (28x68x18)

Right crankcase bearing on the primary shaft

6006

Left crankcase bearing on the primary shaft

6202Z

Left crankcase bearing on the secondary shaft

6204

Right crankcase bearing on the secondary shaft

HK152315

Thrust bearing in the clutch

16003

Bearings / bushings of the start-up reductions support

HK101410

Camshaft Bearing

6203

Secondary shaft seal (pinion)

20x34x7

Gearshift shaft seal

14x28x7

Kick starter shaft seal

16x28x7

Sealing rings on the oil pump

Ó-rings 9,4x2,4

Sealing ring at the start reduction cover

63x3

Sealing ring camshaft cover

75x2,65

Seal ring in the valve caps

35x3

Sealing ring in the oil filter cover

35x3

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

Chapter 1 – General information / Technical specifications

Service Manual AJP PR3/PR4 1 - 19

Sealing ring in the neutral contact

7x1,7

Sealing ring in the timing chain tensioner cover

9x1,8

Sealing ring on the bolt kicks stopper

11,8x2,65

Screw sealing ring of the phase inspection hole of the engine

13,8x2,5

Screw sealing ring of the flywheel/crankshaft hole

27,4x2,4

Sealing ring on the start motor phalange

25x3

Sealing ring on the bolts of the starter cover

4x2

Rectangular seal on the cylinder head pin (200/240)

Rubber bushing with two tabs

Flat rubber washer

Stamped rectangular seal ring on the cylinder head pin

With tab

Aluminum washer to seal the pivot bolt tensioner guide

8,5x14x1,5

Copper washer to seal the exhaust manifold

31,8x38,6x1,6

Special washers to gearbox

C1 washers on the secondary shaft

16,5x24x0,5

C2 washers on the secondary shaft

20x27x1

C1 washer on the primary shaft

15,2x25x1

Sprocket ribbed washers on the gears shaft

20x17,3x26x1,6

Starter sprocket washer on the primary shaft

20,5x27x0,5

Starter sprocket washer on the secondary shaft

15,2x30x1

Washer at the end of the kicks shaft

12,2x17,9x1

Washers of the shaft in the startup reductions

10,5x17,7x0,5

Distance washer from the clutch sprocket 240

30x42x0,5

Washer pitch of the clutch pressure pin

17x24x1

Ring on the flywheel bolt

10,5x23,6x2,4

Dimensions of the cylinder / cylinder head studs

Cylinder studs on the right crankcase (125cc engine)

Intake

side

Ø6,5x212mm

Exhaust

side

Ø8,5x212mm

Cylinder studs on the left crankcase (125cc engine)

Ø8,5x224mm

Cylinder studs on the right crankcase (200cc engine)

Intake

side

Ø6,5x215mm

Exhaust

side

Ø8,5x215mm

Cylinder studs on the left crankcase (200cc engine)

Ø8,5x229mm

Cylinder studs on the right crankcase (240cc engine)

Intake

side

Ø6,5x222mm

Exhaust

side

Ø8,5x222mm

Cylinder studs on the left crankcase (240cc engine)

Ø8,5x235mm

Screw of the valve mechanism chamber

125cc

M6x110

200cc

M6x113

240cc

M6x120

Chapter 1 – General information / Technical specifications

Service Manual AJP PR3/PR4 1 - 20

ALTERNATOR

Item

Specifications

Service

limit

Alternator

12V monophasic (ACG)

-

Alternator power

12V 120W (0,12Kw / 5000rpm)

-

Rectifier / current regulator

MT12V8 – ZO5B (XFT1QO7)

-

Rectifier type

Monophasic / half wave

-

Magnetic flywheel

Type CFW

-

Rotor puller thread lead

M28x1 (right)

-

Inside diameter of the flywheel

91mm

-

Outside diameter of the flywheel

111.5mm

-

Outer cam height

1,6 – 2,0mm

-

Clearance between the cam and the pick-up

14mm (+/-)

-

Clearance between the stator and flywheel

1mm (+/-)

-

Manufacturer reference of the neutral position

“T”

-

Manufacturer reference of the ignition point advance

“F”

-

Rotational direction of the magnetic flywheel

Counterclockwise

-

Flywheel fixing bolt on the crankshaft

M8x1.25x35 or M10x1x40

-

Washer of the flywheel bolt

8,5x24x3,5 or 10,5x23,6x2,4

-

M8 bolt tightening of the flywheel M8

32.m (3,2Kgf.m)

-

M10 bolt tightening of the flywheel M10

39N.m (4,0Kgf.m)

-

Stator

8 Poles (12V8C)

-

Stator outside diameter

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

-

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