AJP PR7 650 Adventure Simplified Maintenance Schedule and Service Intervals
This is the maintenance schedule and service intervals for the AJP PR7 Adventure, the thumper-powered adventurer from Portuguese manufacturer AJP.
Because the PR7’s maintenance schedule is not well-structured, we’ve included a simplified form so the service intervals are easier to follow.
The AJP PR7 is a lightweight single-cylinder adventure motorcycle. It’s powered by a liquid-cooled 600cc DOHC 4-valve single with a 100 mm bore and 76.4mm stroke. In base trim the bike makes a modest and learner-friendly 48 hp, but with the power-up kit (exhaust, intake, and re-mapped ECU) it makes just shy of 60 hp, which really livens it up.
The basic engine is the same as that used in the SWM Superdual X / T and the Husqvarna TE630.
The final drive is via a six-speed box and chain drive.
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AJP PR7 650 Service Intervals
The AJP PR7 650 has very aggressive 5000 km / 3000 mile service intervals between oil changes and valve clearance inspections.
Luckily, the valve clearance check is easy, as you don’t need to remove the camshaft.
AJP also recommends you change the air filter at every service, and clean it between services.
Every two services, replace the spark plug, fluids, and grease major components like the steering head bearings.
AJP PR7 Maintenance Schedule (Simplified)
Below is the simplified version of the AJP PR7’s maintenance schedule.
In base form, the PR7’s maintenance schedule is unnecessarily complicated, with some parts needing attention every 3000 km, and some needing attention every 5000 km. The result of this is odd timing of service due at 3, 5, 6, 9, 10 thousand kilometres and so on. On top of that, parts have non-standard time-based intervals. So we’ve simplified it, based on common sense and many, many other similar motorcycles’ maintenance schedule, also referring to the SWM Superdual X, with which the AJP PR7 shares an engine.
If you want the original maintenance schedule, see the “Reference” section at the bottom, or use the one in the manual.
The below maintenance schedule is broken into three parts
- Regular service — Air filter and chain
- The “Periodic service” schedule of major items, and
- A standard list of items to inspect
AJP recommends that every 500 km / 300 mi or one month, you do the following.
|AJP PR7 Regular Maintenance|
|Engine oil — Check level. Top up as necessary|
|Coolant — Check level. Top up as necessary|
|Air filter — Clean / lubricate. (Lubricate using Green filter oil)|
|Chain — Inspect wear, clean, and lubricate. Check tension and adjust as necessary.|
See below for chain tension notes
The drive chain clearance on the AJP PR7 is measured as the distance between the chain and the swingarm,measured halfway along the chain. The clearance should be should be between 30 and 45 mm.
To adjust the chain tension on the AJP PR7:
- Place the motorcycle on the side stand.
- Loosen the axle nut.
- Loosen the lock nuts on both sides.
- Adjust the adjuster screws until the clearance of drive chain is within specifications.
- Ensure that the rear sprocket remains aligned with drive sprocket.
- Check if the chain tensioners are aligned with the reference marks on swing arm. If they are not visible, measure the distance between tensioners and swing arm end to check alignment.
- Tighten the axle nut and the fixing nuts.
- Verify the chain clearance again after tightening up the nuts.
Lubricate and adjust the chain as necessary.
Periodic service schedule
Below is the periodic service schedule of major components of the AJP PR7.
- Follow the earlier of time-based or distance-based service intervals
- At the end of the service schedule, continue following it in the pattern shown.
- Some of these items are quite aggressive. For example, most motorcycle manufacturers don’t recommend changing the fork seals on a periodic basis, nor do they recommend changing hte brake / clutch fluid on a distance basis.
|km x 1000||5||10||15||20|
|mi x 1000||3||6||9||12||Every|
|Standard inspection checklist (see below) — Perform||✓||✓||✓||✓||6 months|
|Engine oil — Replace (ENI i-Ride 10W-50)||✓||✓||✓||✓|
|Oil strainer filter — Clean||✓||✓|
|Main oil filter — Replace||✓||✓|
|Air filter — Replace||✓||✓||✓||✓|
|Valve clearances — Inspect / adjust when engine is cold|
|Intake/exhaust rocker arm — Inspect||✓||✓|
|Timing system (chain, chain guides, gear) — Replace||✓|
|Timing chain tensioner — Inspect||✓||✓||✓||✓|
|Spark plug — Inspect (Gap: 0.6-0.7mm)||✓||✓|
|Spark plug — Replace (NGK CR8EB)||✓||✓|
|Spark plug cap — Inspect||✓||✓||✓||✓|
|Clutch cush drive damper — Inspect||✓||✓|
|Steering head bearing — Lubricate||Year|
|Clutch fluid — Replace (Multi-tech CT 10W)||✓||✓||2 years|
|Brake fluid — Replace (Castrol DOT 4)||✓||✓||2 years|
|Front fork oil — Replace||✓||✓||2 years|
|Front fork seals — Replace||✓||✓||2 years|
|Drive chain — Replace||✓||✓||2 years|
|Coolant — Replace (eni Permanent Spezial or equivalent)||✓||✓||2 years|
Standard Inspection Checklist
|Engine oil — Check level. Top up as necessary|
|Cooling liquid — Check level. Top up as necessary|
|Brake pads — Check thickness. (Pad minimum thickness: 1mm)|
|Brake discs — Check thickness. (Front minimum thickness: 3.8mm; rear 4.5mm)|
|Drive chain — Inspect, clean, adjust tension, and lubricate (see below)|
Also check every 500 km / month
|Wheels — Check spoke tension, and tighten as necessary.|
|Tire condition — Inspect|
|Cooling system tubes — Check condition, routing|
|Suspension — Check smooth operation|
|Front forks — Check for leaks, smooth operation|
|Fork seals — Clean|
|Rear suspension — Check for leaks, smooth operation|
|Braking system — Check correct function|
|Battery — Check charge state and correct charging|
|Fuel injection — Check correct idle speed|
|Stop switches — Check function|
|Steering bearing — Check smooth operation and for play. Tighten as necessary.|
|Exhaust — Check condition|
|Bolts and nuts — Check tightness|
About the AJP PR7
The AJP PR7 650 is a lightweight dual-sport bike that attempts to combine all the benefits of a thumper off-road bike with the manners of an on-road motorcycle.
The heart of the PR7 650 is a 600 cc single-cylinder engine. It’s the same engine used in the SWM Superdual X, and was previously used in the Husqvarna TE630. This means the engine is well supported and has a long track history.
In base trim, the AJP PR7 makes around 48 hp, but it’s also available with a high-power kit that raises it up to a much feistier 60 hp.
Where the AJP PR7 is distinct from many other lightweight single-cylinder motorcycles is that it comes with everything you need for adventure, but nothing more and remains lightweight.
For example, look at the instrument display. Yes, you have a minimalist LCD, as you’d expect; but there’s also a standard 7-inch tablet with Android that you can use for anything, including your own apps.
It’s a similar story with the suspension. The PR7 has long-stroke Sachs ZF suspension front and rear, with full adjustability. The 48mm fork (quite thick for a lightweight bike) has a whopping 300mm stroke, while the rear has a 280mm stroke.
The front brake has a 300mm disc and a Brembo 2-piston caliper.
What’s most impressive is that fully fuelled (with 17 L / 4.5 US Gallons), the AJR PR7 weighs just 165 kg or 363 lb. That’s VERY light! With most adventure bikes weighing something like 80-100 kg more, the weight advantage is exactly what a lot of adventure riders look for.
Of course, the AJP PR7 does lack a lot of the niceties you might expect from a semi-premium adventure motorcycle. There’s no cruise control, in case that’s a thing you wanted, and there’s definitely no cornering ABS. There’s no traction control, nor power modes (why would you want less power?). But it does have ABS, and it is switchable.
The main fly in the ointment from a travel perspective is that you do need to inspect the valves every 5000 km or 3000 miles (after the first 1000 km / 600 mile service), similar to a Royal Enfield Himalayan for what it’s worth. This is annoying. But to counter this, it’s at least easy even to do a change — you don’t have to remove the cams to adjust the clearances!
Reference — Screenshots from the AJP PR7 owner’s manual
The above maintenance schedule came from the user’s manual for the AJP PR7 650. You can see screenshots from the manual below.
You can download manuals for AJP motorcycles from their website here.