Since there is no such a thing as “Workshop Manual” for AJP PR7 just yet, i was given some pointers where to look for Torque values, nut and bolt sizes, Bearing and Seal sizes, Sensor Values and so on… Can’t say that these are 100% correct, so if you use these settings and strip or brake something – don’t blame me! Use it at your own risk! 

Table Of Content:

1. MISCELLANEOUS
2. REAR SHOCK ABSORBER
3. FUSES
4. FLUIDS
5. ENGINE OIL
6. CLUTCH
7. EXHAUST
8. REAR SUSPENSION & LINKAGE &…
   • SWINGARM
   • LINKAGE TO SWINGARM
   • LINKAGE TO DOGBONES  
   • DOGBONES TO FRAME
   • LINKAGE TO REAR SHOCK
   • REAR SHOCK TO FRAME
9. FUEL PUMP
10. FRONT WHEEL
11. REAR WHEEL
12. SPROCKET CARRIER
13. FRONT FORKS & STEERING
14. FRONT SUSPENSION
15. SENSORS + VALUES
16. SOURCES (Manuals & Download Link)

# MISCELLANEOUS

• HEADLIGHT BULB (H7 12V 55W) 2x
• Spark plug type NGK CR8EB
• Spark plug electrode gap 0.6–0.7 mm
• FUEL INJECTOR (DELPHI 25377439) PN: 00MTC01A0092 x1
• AIR FILTER PN: 00MTS01A0193
• Valve clearance (cold engine)
• Intake 0.10mm  (9.5mm Shims)
• Exhaust 0.15 mm  (9.5mm Shims)
• IN / EX Camshaft BALL BEARINGS  2x (6001/P6 12x28x8) on each PN: 800034317
• TIMING Chain Sprocket BALL BEARING  1x (6201/P6 12x28x8) PN: 800034317

# AJP PR7 REAR SHOCK ABSORBER

• STANDARD pre-loaded length of spring (TOP TO BOTTOM OF THE SPRING): 234,5-237,5 mm (9.23-9.35 in.) (SM610 Manual)
• BOTH RINGNUTS 5 Kgm; 49 Nm; 36.2 ft/lb (SM610 Manual)

# AJP PR7 FUSES

• 1.One 20A fuse (yellow) for the electric system;
• 2.One 15A fuse (blue) for the injection system;
• 3.One 10A fuse (red) for the tablet;

# AJP PR7 FLUIDS

• Fuel tank capacity 17 L (Unleaded fuel 95)
• Fuel reserve 3 L
• Coolant system capacity 1.3L (eni PERMANENT SPEZIAL)
• Coolant DRAIN SCREW (R/H SIDE CYLINDER) 9,3 Nm/ 0,95 Kgm/ 6.9 ft-lb
• WATER PUMP HOUSING 9,3 Nm-0,95 Kgm-6.8 ft/lb (SM610 Manual)
• THERMOSTAT(BEHR TH 5 80) PN: 00MTS01A0186

# AJP PR7 ENGINE OIL

• Engine oil replacement 1.6L (eni i-Ride MOTO 10W-50)
• ENGINE OIL WITH FILTER replacement 1.7L
• OIL FILTER (MAIN), PN: OIL8000B0593
• L.H. OIL (MESH) filter cover (6 Nm-0,6 Kgm-4.3 ft/lb)  (SM610 Manual)
• OIL PUMP COVER 9 Nm-0,9 Kgm-6.5 ft/lb (SM610 Manual)
• OIL Drain plug small (M14) torque:24 N.m (2.45 kgf.m)(PR7 MANUAL) (24 Nm – Superduel E4 MANUAL)
• OIL Drain plug big (M22) torque: (no need so tight) 60 N.m (6.1 kgf.m) (PR7 MANUAL) (30 Nm – Superduel E4 MANUAL)
• Main oil filter cover bolt torque: 9,3 N.m (0.95 Kgf.m) (10 Nm – Superduel E4 MANUAL)

# AJP PR7 CLUTCH

• Clutch Slave Cylinder o’ring size: 25mm ID 2mm Thickness (Replacement: Oberon CLU-1500)
• CLUTCH DISC KIT/SET PN: SET8000A9764 x1
• CLUTCH FRICTION PLATE (3.1 MM) PN: 8000A6916 x 8
• CLUTCH STEEL PLATE (1.7 MM) PN: 800088968 x7
• CLUTCH SIDE ENGINE COVER  9,3 Nm/ 0,95 Kgm/ 6.9 ft-lb
• CLUTCH BASKET 27mm NUT 61,8 Nm-6,3 Kgm-45.5 ft/lb (SM610 Manual)
• CLUTCH BASKET COVER 6x BOLTS 12mm (10 Nm-1 Kgm-7.4 ft/lb) (SM610 Manual)

# AJP PR7 EXHAUST

• EXHAUST PIPE GASKETS (38x31x4.5) PN: 8A00A0873
• Exhaust pipes to cylinder head fastening screw/ M6x1 10,4 Nm 1 Kgm 7.7 ft/lb (SM610 Manual)

# AJP PR7 REAR SUSPENSION & LINKAGE &…

• FRONT SPROCKET COVER 7,6÷8,4 Nm/ 0,80÷0,85 Kgm/ 5.8÷6.1 ft-lb  (SM610 Manual)
• NEUTRAL SENSOR (6 Nm-0,6 Kgm-4.3 ft/lb) (SM610 Manual)
• GEARSHIFT PEDAL (9 Nm-0,9 Kgm-6.5 ft/lb) (SM610 Manual)
• SWING ARM PROTECTION (Chain Guide) PN: 00PLS01A0121 x1
• GUIDE, DRIVE CHAIN (Shark Fin) PN: 00STS01B0007 x1

# AJP PR7 SWINGARM

• SWING PIVOT NEEDLE BEARING (HK2020RS) PN: RL00HK2020RS x4
• SWING PIVOT BEARING BUSH (20x60x15) PN: 00STS01A0096 x2 No dust seals (!!!)
• SWING ARM PIVOT BOLT 122,5 Nm/ 12,5 Kgm/ 90.3 ft-lb (+LOCTITE 243) (SM610 Manual)

# LINKAGE TO SWINGARM

• NEEDLE BEARING (HK2020RS) PN: RL00HK2020RS x2
• (Suggested to replace HK2020RS Bearings with HK2016 or HK2016-2rs + 20x26x4 Outer Seals)
• BUSH (20x42x12) PN: 00STS07A0085 x1
• BOLT 80 Nm/ 8,2 Kgm/ 59 ft-lb  (SM610 Manual)

# AJP PR7 LINKAGE TO DOGBONES

• NEEDLE BEARING (HK2020RS) PN: RL00HK2020RS x2
• (Suggested to replace HK2020RS Bearings with HK2016 or HK2016-2RS + 20x26x4 Outer seals)
• BUSH (20x42x12) PN: 00STS07A0085 x1
• BOLT 80 Nm/ 8,2 Kgm/ 59 ft-lb  (SM610 Manual)

# AJP PR7 DOGBONES TO FRAME

• NEEDLE BEARING (HK2020RS) PN: RL00HK2020RS x2
• (Suggested to replace HK2020RS Bearings with HK2016 or HK2016-2rs + 20x26x4 Outer seals)
• BUSH (20x57x12) PN: 00STS07A0072 x1
• BOLT 80 Nm/ 8,2 Kgm/ 59 ft-lb  (SM610 Manual)

# AJP PR7 LINKAGE TO REAR SHOCK

• SPHERICAL BEARING (26x16x10) PN: 00STS01A0074 x1
• O-RING (22×2) PN: 00STS01A0087 x2
• BUSH, SPHERICAL BEARING (4.5 MM) PN: 00STS07A0082 x2
• BOLT 52,4 Nm/ 5,35 Kgm/ 38.6 ft-lb  (SM610 Manual)

# AJP PR7 REAR SHOCK TO FRAME

• SPHERICAL BEARING (26x16x12) PN: 00STS01A0074 x1
• BUSH (2 MM) PN: 00STS07A0091 x2
• O-RING (18×2.6) PN: N/D x2
• CIRCLIP (INOX 26 MM) PN: N/D x1

# AJP PR7 FUEL PUMP

• Fuel pump model: DELPHI T12 (???) , or HFP-389 Upgrade
• PRESSURE VALVE(3.0 bar) PN: 00DES01A0098 x1, or Upgrade
• O-RING (8.5×2) PN: 00DES01A0088 x1 (or mod to delete o’ring)
• FUEL PUMP MOTOR PN: 00DES01A0075 x1
• Fuel system pressure at Injector inlet (with a T-joint) while engine is running at idle condition: Pressure between 220 ~ 270kPa @ 10-14V (?sounds very wrong this bit?)

# AJP PR7 FRONT WHEEL

• Pressure (road with maximum load) 2.3 bar (33 psi). 
• -Off road 1.5 bar (21 psi)
• Tires size 90/90 –21”
• FRONT WHEEL AXLE fastening screw M20  51,45 Nm 5,25 Kgm 38 ft/lb  (SM610 Manual +Superduel E4 MANUAL)
• FRONT WHEEL AXLE PINCH BOLTS (10,4 Nm/ 1,05 Kgm/ 7.7 ft-lb) (Superduel E4 MANUAL)
• Front brake DISC  fastening screw M6 (+LOCTITE 243) 14,7 Nm 1,5 Kgm 0.8 ft/lb (SM610 Manual)
• BRAKE PAD SET PN: 00TRS01B0074 x1 (Brembo Caliper – 2020 PR7 , Goldfren 106)
• DUST SEAL (30x47x7) PN: 00RTS01A0022 x2
• BEARING (60052RS) PN: RL00060052RS x2

# AJP PR7 REAR WHEEL

• Pressure (road with maximum load)2.3 bar (33 psi).
• Off road 1.5 bar (21 psi)
• Tires size 140/80 –18”
• DRIVE CHAIN ROLLER (35 MM) PN: 00QUS01A0022
• -Chain roller fastening screw M8x1,25 26,95 Nm 2,75 Kgm 19.9 ft/lb (SM610 Manual)
• -Rear sprocket fastening nut/ M8x1,25 (+LOCTITE 243) 34,3 Nm 3,5 Kgm 25.3 (SM610 Manual)
• CHAIN TENSION ADJUSTER NUT 22,5 Nm/ 2,3 Kgm/ 16.6 lb-ft (SM610 Manual)
• REAR WHEEL AXLE NUT 27mm (a bit overkill – do it up tight but not too tight) 142 Nm/ 14,5 Kgm/ 104.8 lb-ft (SM610 Manual)
• REAR BRAKE PAD SET PN: 00TRS01B0075 x1(Brembo Caliper – 2020 PR7 ,Goldfren 023)
• BEARING (60052RS) PN: RL000060052RS x2
• SEAL (30x47x7) PN: 00RTS01A0022 x1REAR
• BRAKE DISC (240 MM) PN: 00RTS01A0134

# AJP PR7 SPROCKET CARRIER

• DUST SEAL (40x55x7) PN: 00RTS01A0154 x1
• BEARING (60062RS) PN: RL00060062RS x2
• SPROCKET (T42) PN: 00RTS01A0137

# AJP PR7 FRONT FORKS & STEERING

• FRONT FORK SEAL 2x (48x58x11) PN: 00SFS01A0070
• FRONT FORK DUST SEAL 2x (48.5×58.5×13) PN: 00SFS01A0069
• STEERING STEM TAPERED ROLLER BEARINGS 2x(32006C) PN: RL00032006JR
• STEERING STEM NUT  57,9÷65,1 Lb/ft; (78,4÷88,3 Nm) (SM610 Manual)
• FORK LEG CLAMPS 22,5÷26,5 Nm (16.6÷19.5 Lb/ft) (SM610 Manual)
• STEERING STEM SEALS ??? 2x PN: 00SFS01A0065
• STEERING COLUMN SEAL CAP ??? 1x PN: 00SFS01A0064

# AJP PR7 FRONT SUSPENSION

• DAMPER ROD (BOTTOM OF THE FORK): 10 Nm. (SM610 Manual)
• PLUG CHECK NUT (FORK TOP): 30 Nm. (SM610 Manual)
• SLIDER PLUG : 25 Nm. (SM610 Manual)
• Tightening torque for rebound bumper: 30 Nm (SM610 Manual)
• Tightening torque for foot screw: 50 Nm (SM610 Manual)
• Tightening torque for damper rod plug: 10 Nm (SM610 Manual)
• Tightening torque for plug check nut: 30 Nm (SM610 Manual)
• Tightening torque for slider plug: 25 Nm (SM610 Manual)
• BRAKE HOSE CLAMP ON THE FORK TUBE GUARD 5,6÷6,2 Nm/ 0,57÷0,63 Kgm/ 4.1÷4.5 ft-lb (SM610 Manual)
• FORK TUBE GUARDS 7,85 Nm/ 0,8 Kgm/ 5.8 ft-lb (SM610 Manual)
• FRONT BRAKE CALIPER MOUNTING BOLTS 25,5 Nm/ 2,6 Kgm/ 18.8 ft-lb  (SM610 Manual)

# AJP PR7 SENSORS + VALUES

Throttle Position Sensor:

• Reference voltage: 5±0.1VDC
• Resistance between T1 and T2: 3k~12kΩ

Idle Air Control Valve:

• Operating voltage: 7.5~14.2 VDC
• Solenoid resistance: 53Ω±10%
• Solenoid inductance: 33mH±20%

Engine Oxygen Sensor (Exhaust)

• A/F ratio rich threshold: ＞750 mVDC
• A/F ratio lean threshold:＜120 mVDC
• Heater power: 7.0W (These parameters as above are measured basing on 450°C (engine dyno), typically on 70% duty at 10Hz and under 13.5V)
• Heater part resistance: 9.6±1.5Ω (This parameter is measured basing on 21°C)
• Operating temperature range: 260-850 °C
• Tightening Torque Requirement: 40-60 Nm

Ignition Coil

• Input voltage: 9~14VDC
• Output voltage: ~25~30KV
• Operating temperature: -30 ~110 °C
• Storage temperature: -40~155°C
• Mounting Torque: 8.8~11.8Nm

# SOURCES

• AJP PR7 MANUAL
• AJP PR7 PARTS MANUAL
• SWM Superdual E4 2017 MANUAL
• Husqvarna SM 610 2006 MANUAL
• AJP PR7 SPEEDOMETER – KOSO (DB01R) MANUAL
• AJP PR7 Wiring Diagram
• Delphi Manual

Download Manuals from Downloads Page!

Hope That Helps!

Explore more!

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All AJP PR7 MODS:

OR

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