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AJS Highway Star 125, Owner'S Manual, Page: 4 / 61

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AJS Highway Star 125 Owner'S Manual Download Page 4

FOREWORD

Thank you for choosing the AJS Highway Star 125 motorcycle. To ensure enjoyable and safe

riding, please be sure to read this manual carefully before operation.

This manual summarises the method of how to use and maintain your motorcycle correctly. If you

follow the guidelines of this manual carefully, your motorcycle should be reliable and will be kept

in a good and safe condition.

Your AJS Dealer should service, and carry out specialised tasks for you. If you are unsure of any

aspects, consult your AJS Dealer for advice or service.

Pictures and specifications are correct at the time of publication.

Due to the continuous development and improvement of the motorcycle, there maybe some

discrepancies in this manual.

AJS Motorcycles Ltd. reserves the right to alter the specifications of its motorcycles without prior

notice.

Errors and omissions expected.

Summary of Contents for Highway Star 125

Page 1: ...Owners Manual Please study this manual carefully before riding the motorcycle for the rst time...

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Page 4: ...d be reliable and will be kept in a good and safe condition Your AJS Dealer should service and carry out specialised tasks for you If you are unsure of any aspects consult your AJS Dealer for advice o...

Page 5: ...4 Fuse 27 Gear lever 13 Handle bar controls 9 Headlight bulb 42 Ignition switch and lock 7 Inspection and maintenance 25 Inspection before riding 19 Instruments 8 Key components 4 Oil renewal 31 Ridin...

Page 6: ...uality motorcycle riding apparel when riding your motorcycle Ask your dealer for advice Inspection before riding Please read all the instructions in the INSPECTION BEFORE RIDING section starting on Pa...

Page 7: ...e vehicle in front Watch out for oil and diesel spills Allow extra distance in adverse weather conditions Do not overload your motorcycle The maximum load is 150kg Overloading may cause instability an...

Page 8: ...r motorcycle and for optimum performance and reliability you should take action Severe damage to you motorcycle may be caused if you do not heed this message Notice means Take these tips to get the be...

Page 9: ...uel tank 3 VIN number 4 FR R turning lamp 5 RR R turning lamp 6 RR Brake calliper 7 Exhaust muffler 8 RR shock absorber 9 Pillion footrest 10 Battery cover 11 Fuel injector assy 12 Driver footrest 13...

Page 10: ...1 Rearview mirror 2 Headlight 3 Vehicle data plate 4 FR L turning lamp 5 Air filter cover 6 Seat 7 RR L Turning lamp 8 Taillight 9 Gear shift lever 10 Driver footrest 11 Engine number 12 Side stand 13...

Page 11: ...6 KEY COMPONENTS 1 Clutch lever 2 L switch assy 3 Meter clock 4 Ignition switch lock 5 R switch assy 6 Throttle grip 7 FR brake lever...

Page 12: ...he handle bars fully to the Left In the lock position insert the key and push in let the key pop back out then turn the key anti clockwise until the lock engages Rock the handlebars a little to assist...

Page 13: ...ght turn signals are being operated this green indicator light will flash 8 Speedometer The speedometer indicates how fast the motorcycle is travelling It is equipped with a switch able display Miles...

Page 14: ...move forward Pull in and apply the brakes to stop Risk of injury Always use the indicators prior to changing direction or turning but do not forget to cancel them after your manoeuvre WARNING 1 2 Tur...

Page 15: ...apply the front brake more so Use with care in slippery conditions As you apply the front brake the rear brake light will illuminate 1 2 3 4 3 Throttle grip Rotate the grip towards you from the top to...

Page 16: ...room for fuel expansion in hot conditions Only refuel when the ignition switch is turned to OFF WARNING FUEL FILLER CAP To open 1 Lift the latch 2 Insert the key 3 Turn the key fully clockwise 4 Lift...

Page 17: ...er will return to the horizontal position after each gear change ready for the next selection Risk of damage Always use the clutch when shifting gear Never stamp or jerk the gear lever aggressively CA...

Page 18: ...This motorcycle is fitted with a Side Stand for your convenience To use the Side Stand for quick and easy parking on flat firm soil or asphalt Caution Do not park the motorcycle facing downhill It may...

Page 19: ...hill face the motorcycle uphill to avoid it slipping off of its stand CAUTION Use Only Unleaded petrol Gasoline Damage to the catalytic converter will occur otherwise CAUTION FUEL AND ENGINE OIL RECOM...

Page 20: ...ycle WARNING ENGINE LUBRICATION OIL Lubrication is a main factor that affects the performance and the engine s service life It also has an effect on the engine s emission levels Therefore the oil shou...

Page 21: ...INE Careful running in will prolong the service life if your engine For the first 500 miles do not use full throttle and avoid high engine speeds at all times You should also avoid aggressive starts a...

Page 22: ...ling time for the engine to warm up and the oil to circulate around the engine before you head off at speed Over revving a cold engine causes excessive wear and will shorten the life of the engine THE...

Page 23: ...l 1 Check the fuel level 2 Add fuel when necessary 3 Check the fuel pipe condition Test Item Test details Engine oil Tyres Brakes 1 Check the engine oil level 2 Add oil if necessary 3 Check for oil le...

Page 24: ...Check the function of the turning lamps 1 Make sure the safety cut out switch is working correctly 2 Check for smooth operation 3 Lubricate the pivot as necessary Check the following lamps 1 High bea...

Page 25: ...ge gear before entering a corner Your motorcycle s braking and cornering ability will be reduced in wet or slippery conditions Slow down accordingly Obey traffic rules and speed limits STARTING THE EN...

Page 26: ...a colourless and odourless gas Never leave the motorcycle running unattended WARNING Do not allow the motorcycle to idle for long periods or overheating could occur NOTICE STARTING OFF With the engine...

Page 27: ...he tachometer WARNING Do not coast in neutral or with the clutch disengaged You may loose control You may cause engine damage WARNING RIDING ON HILLS When climbing steep hills the motorcycle will star...

Page 28: ...ng 8 Turn the ignition lock to the steering lock position to secure the motorcycle Remove the key and take it with you Always lock you motorcycle to prevent theft Use a secondary locking device such a...

Page 29: ...ead extra maintenance and preparation will be required Salt is very corrosive even in powder form when roads have dried after icy conditions Bright parts should be protected before your journey with c...

Page 30: ...osion USE AND MAINTENANCE OF THE BATTERY 1 Each electric starter session should not last longer than 5 seconds If the engine fails to start check the fuel level supply Allow 10 seconds between retries...

Page 31: ...part that has a short circuit 2 Open the Fuse Holder and replace the blown Fuse 3 Switch the ignition to ON If the replacement Fuse also blows do not ride the motorcycle Contact your dealer and seek p...

Page 32: ...o the service schedule and driving conditions TO CHANGE CLEAN THE FILTER 1 Remove the left frame cover to reveal the air filter case 2 Remove the case cover screws Remove the air filter element 3 Tap...

Page 33: ...They are easy to check and should be kept in good condition and changed according to the Service Schedule Over time the electrodes will erode and the gap will change The plug will then loose some of...

Page 34: ...use seek professional advice from your dealer Brown indicates normal conditions CAUTION 1 Install a new spark plug by hand until it seats fig 1 a length of rubber tubing pushed over the insulator can...

Page 35: ...ark the motorcycle on flat level ground on a low level paddock stand 2 Place a suitable receptacle under the crankcases and remove the crankcase drain plug Allow all of the oil to drain out 3 Replace...

Page 36: ...ARNING ADJUSTING THE CLUTCH CABLE The clutch lever should have approximately 5mm free play at the ball end This is essential to avoid the clutch from slipping and wearing out prematurely If the clutch...

Page 37: ...links 5 Rusty links 6 Excessive wear 7 Improper adjustment Risk of injury To ensure safety the drive chain must be adjusted lubricated and constantly maintained If adjustment has reached the end of i...

Page 38: ...n the working temperature of the components This will result in the lubricant burning and becoming less effective therefore increasing chain wear Risk of injury Excessive Chain Tension An over tight c...

Page 39: ...nd evenly until the correct chain tension is achieved Ensure the rear wheel is in alignment 6 Re tighten the rear axle nut to the correct torque setting and chain puller locknuts 7 Re check the drive...

Page 40: ...rake lever and foot brake pedal action The action should not feel spongy or soft HYDRAULIC FLUID Keep regular checks on the level of the fluid in the master cylinder reservoirs As the brake pads wear...

Page 41: ...can cause ineffective brakes and can damage the surface of the brake discs Consult your AJS Dealer if you do not feel confident to make these checks yourself Do not ride the motorcycle if the braking...

Page 42: ...mm thick Risk of injury or death If the braking system is not functioning correctly DO NOT ride the motorcycle Contact your AJS Dealer for assistance WARNING Do not apply grease oil or water repellant...

Page 43: ...pin After adjusting the brake free play check that the rear brake lamp operates correctly WARNING FRONT BRAKE LIGHT SWITCH The front brake light switch is located under the brake lever When the lever...

Page 44: ...not overload your motorcycle The maximum total load is 140kg 2 Be sure to always use the correct tyre pressures 3 Do not carry goods in a loose package or bag Shifting luggage will cause instability 4...

Page 45: ...pth of at least 1 5 mm across three quarters of the breadth of the tread and in a continuous band around the entire circumference Replace the tyres for new if this limit is approaching or reached BULB...

Page 46: ...E HEAD LIGHT BULB The headlight bulb is a double filament bulb One filament provides the high bean whilst the other provides the low beam The filaments are located at different positions from the refl...

Page 47: ...43...

Page 48: ...r Death Do Not spill fuel Waste fuel should be collected in a suitable fuel proof container Dispose of carefully and legally Do not allow fuel to spill onto a hot engine or exhaust Do not allow fumes...

Page 49: ...5 Fuel level is low 6 Water or Diesel in the fuel 7 No spark at the plug 8 Faulty fuel pump relay 9 Battery leads are loose 10 The fuse is blown 1 Check replace side stand switch 2 Set the switch to...

Page 50: ...eplace 2 Check fuel pipes for kinks 3 Drain and replenish fuel Contact your AJS Dealer 4 Check intake hoses for air leaks 5 Check the air filter for contamination and blockages 6 Check the exhaust sys...

Page 51: ...on 9 TPS faulty eng Light on 10 Faulty spark plug s 1 Replace the spark plug 2 Service the brakes contact your AJS Dealer 3 Replace the air filter 4 Replace the exhaust muffler 5 Replace the spark pl...

Page 52: ...nkshaft bearings worn 6 Clutch worn 7 Worn balance shaft bearings gears 8 Magneto flywheel loose 1 Adjust the tappets to 0 15mm clearance each Inlet and Exhaust 2 Tighten the spark plug 3 Replace the...

Page 53: ...ot use washing up liquid or other household detergents as they contain salt Use only high quality automotive shampoo Rinse thoroughly with clean water Towel off with a micro fibre towel and allow to d...

Page 54: ...d grit CAUTION STORING THE MOTORCYCLE Long term storage of the motorcycle requires some preparation Take the following measures 1 Repair and service the motorcycle prior to storage 2 Wash and dry it S...

Page 55: ...verall Length 2 135mm Overall width 810mm Overall height 1 160mm Wheelbase 1 330mm Ground clearance 150mm Mass in running order 164kg Max load 140kg Max speed 96km h 60mph Drive by noise level 74 5dB...

Page 56: ...ning angle Left right 43 Front tyre 120 80 17 Rear tyre 140 70 17 Front tyre pressure 33psi Rear tyre pressure 36psi Wheel rim material Light aluminium alloy Front rim size 17 x MT3 00 Rear rim size 1...

Page 57: ...roke 2 x 44mm x 41mm Compression ratio 9 1 Power 8 4 kW 9000 r min Max torque 9 4 NM 7500 r min Spark Plug NGK CR7HS Firing order Simultaneous wasted spark Ignition method CDI Lubrication method Press...

Page 58: ...et type multi plate Gearbox shift pattern International 1 N 2 3 4 5 Primary ratio 3 833 Final drive ratio 2714 1st ratio 2 767 2nd ratio 1 882 3rd ratio 1 400 4th ratio 1 217 5th ratio 1 0835 Front sp...

Page 59: ...c kickstart Headlight bulb 12v 35w 35w Front position light bulb 12v 4w Tail brake light bulb LED Unit Turning lamp bulb 12v 10w Instrument bulb 12v 0 2w Horn 12v 3A Battery 12v 9Ah Fuse 15A Fuel type...

Page 60: ...S Dealer or visit www ajs shop co uk AJS Highway Star 125 Owner s Manual 2nd edition July 2019 All rights reserved Any reprinting copying digitally sharing or unauthorised use without the written perm...

Page 61: ...AJS Motorcycles Ltd Unit 3 Balksbury Ind Est Upper Clatford Andover Hants SP11 7LW UK Website www ajsmotorcycles co uk Spares www ajs shop co uk...

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