AJS Geared Motorcycle Maintenance Operations and Service Schedule

IMPORTANT NOTE: For frequently used vehicles, the service schedule may be determined by the mileage which is every 2,500 miles (4,000km)
To keep within the requirements of the AJS Warranty, this schedule must be adhered to within 150 miles (240km) of the Distance Travelled or one week of the called for Time Period.

Task
Distance Travelled (not to 500 miles 1,000 miles 2,500 miles 5,000 miles 7,500 miles 10,000 miles 12,500 miles 15,000 miles 17,500 miles 20,000 miles Completed
be exceeded) 800km 1,600 km 4,000km 8,000km 12,000km 16,000km 20,000km 24,000km 28,000km 32,000km (tick)
Time Period (alternative) - - 12 months - 24 months - 36 months - 48 months Service Notes
Item
BATTERY I I I I I I I I I Check for corrosion, leaks and correct voltage and if secure
AIR CLEANER I/C/R I/C/R R I/C/R R I/C/R R I/C/R R Replace as necessary
VALVE CLEARANCE I/A I/A I/A I/A I/A I/A I/A I/A I/A Inlet 0.1mm to 0.15mm - Exhaust 0.1mm to 0.15mm
SPARK PLUG I/A I/A/R R I/A/R R I/A/R R I/A R Replace as necessary
FUEL HOSES I I I I I I I I I Check for leaks and damage/perishing/replace as necessary
FUEL FILTER I I I I I I I I I Replace as necessary
INTAKE HOSES/MANIFOLDS I I I I I I I I I Replace if split/perished
FUEL INJECTION SYSTEM I I I I I I I I I Check/clear fault codes
ENGINE/TRANSMISSION OIL (except JSM50) R R I/A R I/A R I/A R I/A R Top up as necessary/replace as necessary
JSM50 TRANSMISSION OIL R I/A R I/A R I/A R I/A R Top up as necessary/replace as necessary
TWO STROKE OIL (IF NECESSARY) I/A I/A I/A I/A I/A I/A I/A I/A I/A Top up as necessary
SUMP OIL FILTER (GAUZE) C/R C/R C/R C/R Clean or replace as necessary
CENTRIFUGAL OIL FILTER (IF FITTED) R YB/F28 type engines (Heritage bikes included)
OIL FILTER (IF FITTED) R R R R Refers to paper cartridge type if fitted
COOLANT (IF APPLICABLE) I/A I/A I/A I/A R I/A I/A I/A R Top up as necessary/ replace as necessary
CLUTCH ADJUSTMENT I/A I/A I/A I/A I/A I/A I/A I/A I/A Adjust as necessary
DRIVE CHAIN I/A/L/R I/A/L/R I/A/L/R I/A/L/R I/A/L/R I/A/L/R I/A/L/R I/A/L/R I/A/L/R Inspect for wear and damage/lubricate. Replace as necessary
REAR WHEEL NUT/S I/T I/T I/T I/T I/T I/T I/T I/T I/T Check tightness and split pin if fitted
FRONT WHEEL NUT/S I/T I/T I/T I/T I/T I/T I/T I/T I/T Check tightness and split pin if fitted
FRONT SPROCKET I/A/R I/A/R I/A/R I/A/R I/A/R I/A/R I/A/R I/A/R I/A/R Replace as necessary
SPROCKET COVER SCREWS I/T I/T I/T I/T I/T I/T I/T I/T I/T Use Loc-Tite/spring washers as necessary
REAR SPROCKET I/A/R I/A/R I/A/R I/A/R I/A/R I/A/R I/A/R I/A/R I/A/R Replace as necessary
REAR SPROCKET BOLTS/NUTS I/T I/T I/T I/T I/T I/T I/T I/T I/T Replace tab washers as necessary
BRAKE PADS - FRONT I/C/R I/C/R I/C/R I/C/R I/C/R I/C/R I/C/R I/C/R I/C/R Replace as necessary
BRAKE PADS - REAR I/C/R I/C/R I/C/R I/C/R I/C/R I/C/R I/C/R I/C/R I/C/R Replace as necessary
BRAKE DISCS - FRONT I/R I/R I/R I/R I/R I/R I/R I/R I/R Replace as necessary
BRAKE DISCS - REAR I/R I/R I/R I/R I/R I/R I/R I/R I/R Replace as necessary
BRAKE HOSES/PIPES I/R I/R I/R I/R I/R I/R I/R I/R I/R Check for leaks and damage/perishing
BRAKE FLUID I/A I/A I/A I/A R I/A I/A I/A R Adjust fluid level as necessary, replace every 2 years
DRL/PARKING LIGHT I I I I I I I I I Inspect, replace bulbs as necessary
HEAD LIGHT I/A/R I/A/R I/A/R I/A/R I/A/R I/A/R I/A/R I/A/R I/A/R Inspect, adjust beam, replace bulbs as necessary
REAR LIGHT/STOP LIGHT I I I I I I I I I Inspect, replace bulbs as necessary
INDICATOR LAMPS, LEFT AND RIGHT I I I I I I I I I Check correct function, replace bulbs as necessary
TYRE - FRONT I I I I I I I I I Check pressure, tread depth and condition, replace as necessary
TYRE - REAR I I I I I I I I I Check pressure, tread depth and condition, replace as necessary
TYRES VALVES - FRONT AND REAR I I I I I I I I I Inspect, replace as necessary
STEERING BEARINGS I/A I/A I/A I/A I/A I/A I/A I/A I/A Inspect, adjust, replace bearings as necessary
FRONT FORKS - CONDITION I I I I I I I I I Check for leaks/stone chips/action
FRONT FORK - OIL R R Replace every two years
SWINGING ARM PLAY INSPECTION I/A I/A I/A I/A I/A I/A I/A I/A I/A Check for play, tighten/replace bearings as necessary
REAR SUSPENSION I I I I I I I I I Check for leaks/ correct action
EXHAUST SYSTEM I I I I I I I I I Check for effectiveness and condition
EXHAUST FASTENERS I/T I/T I/T I/T I/T I/T I/T I/T I/T Use Loc-Tite or spring washers as necessary
THROTTLE GRIP I I I I I I I I I Check for self return and condition
THROTTLE CABLE I/A I/A I/A/R I/A/R I/A/R I/A/R I/A/R I/A/R I/A/R Check for smooth action and free play, adjust/replace as necessary
LEFT GRIP I I I I I I I I I Check for tightness on the handlebar and condition
CLUTCH CABLE I/A I/A I/A/R I/A/R I/A/R I/A/R I/A/R I/A/R I/A/R Check for smooth action and free play, replace as necessary
SPEEDOMETER CABLE/DRIVE/CLOCK I I I I I I I I I Check for correct function
CLUTCH LEVER I/L I/L I/L I/L I/L I/L I/L I/L I/L Lubricate pivot bolt and nipple
FRONT BRAKE LEVER I/L I/L I/L I/L I/L I/L I/L I/L I/L Lubricate pivot
KICKSTART LEVER (IF FITTED) I/T/L I/T/L I/T/L I/T/L I/T/L I/T/L I/T/L I/T/L I/T/L Lubricate pivot bolt - check for tightness on spline
GEAR SHIFT LEVER AND LINKAGE I/T/L I/T/L I/T/L I/T/L I/T/L I/T/L I/T/L I/T/L I/T/L Lubricate pivots - check for tightness on spline
BRAKE PEDAL AND LINKAGE I/L I/A/L I/A/L I/A/L I/A/L I/A/L I/A/L I/A/L I/A/L Lubricate pivot bush and joints, replace as necessary
CENTRE STAND I/L I/L I/L I/L I/L I/L I/L I/L I/L Lubricate pivot and spring anchor points
SIDE STAND I/L I/L I/L I/L I/L I/L I/L I/L I/L Lubricate pivot and spring anchor points
SIDE STAND KILL SWITCH I I I I I I I I I Replace if faulty
CLUTCH LEVER KILL SWITCH I I I I I I I I I Replace if faulty
ENGINE KILL SWITCH I I I I I I I I I Replace if faulty
FRONT WHEEL I/A I/A I/A I/A I/A I/A I/A I/A I/A Check trueness. If wire spokes check spoke tension.
REAR WHEEL I/A I/A I/A I/A I/A I/A I/A I/A I/A Check trueness. If wire spokes check spoke tension.
FRONT WHEEL BEARINGS I I I I I I I I I Check for play/wear, replace as necessary
REAR WHEEL BEARINGS I I I I I I I I I Check for play/wear, replace as necessary
FRONT AXLE REMOVE AND GREASE EVERY TWO YEARS
REAR AXLE REMOVE AND GREASE EVERY TWO YEARS
Copyright AJS Motorcycles Ltd. 2020
I INSPECT L LUBRICATE
A ADJUST R REPLACE
C CLEAN T TIGHTEN