Table Of Contents - Orion AGB-21G Service Manual

Table of Contents

Important Notice3
Particularly Important Information5
Manual Format5
F.i.m. Machine Weights5
Weights Of Machines Without Fuel5
Index6
Table Of Contents6
General Information7
Description7
Machine Identification8
Vehicle Identification Number8
Engine Serial Number8
Important Information9
Preparation For Removal And Disassembly9
Gaskets, Oil Seals And O-Rings10
Lock Washers/Plates And Cotter Pins10
Bearings And Oil Seals10
Circlips10
Checking Of Connection11
Special Tools12
Control Functions13
Engine Stop Switch13
Clutch Lever13
Shift Pedal13
Front Brake Lever14
Rear Brake Pedal14
Fuel Cock14
Spark Plug Wrench14
Specifications15
Engine15
Chassis16
Electrical17
Maintenance Specifications18
Regular Inspection And Adjustments23
Maintenance Intervals23
Pre-Operation Inspection And Maintenance26
General Inspection And Maintenance26
Clutch Adjustment27
Throttle Cable Adjustment27
Throttle Lubrication28
Air Filter Replace28
Engine Oil Level Inspection29
Engine Oil Replacement31
Oil Pressure Inspection31
Pilot Screw Adjustment32
Engine Idling Speed Adjustment32
Brake System Air Bleeding33
Rear Brake Adjustment34
Pedal Height Adjustment Steps34
Front Brake Pad Inspection And Replacement35
Rear Brake Pad Inspection And Replacement36
Brake Fluid Level Inspection37
Sprockets Inspection38
Drive Chain Inspection38
Drive Chain Slack Adjustment39
Front Fork Inspection40
Electrical System41
Checking The Battery41
Checking The Fuse43
Rear Shock Absorber Inspection43
Rear Shock Absorber Spring Preload Adjustment44
Tire Pressure Check45
Spokes Inspection And Tightening45
Wheel Inspection45
Steering Head Inspection And Adjustment46
Spark Plug Inspection48
Ignition Timing Check49
Seat, Fuel Tank And Side Covers50
Fuel Tank, Side Covers And Seat51
Exhaust Pipe And Silencer52
Inspection53
Silencer And Exhaust Pipe53
Crburetor & Air-Fiter54
Carburetor Disassembly55
Carburetor57
Needle Valve57
Jet Needle57
Sprocket Replacement58
Cylinder Head59
Removing The Cylinder Head60
Checking The Cylinder Head62
Checking The Timing Chain Tensioner63
Checking The Tappet Covers And Camshaft Sprocket Cover63
Installing The Cylinder Head63
Installing The Camshaft Sprocket64
Camshaft /Valves And Valve Springs65
Removing The Rocker Arms And Camshaft66
Checking The Camshafts66
Checking The Rocker Arms And Rocker Arm Shafts67
Installing The Camshaft And Rocker Arms68
Intake Rocker Arm Shaft 168
Exhaust Rocker Arm Shaft68
Intake Rocker Arm68
Exhaust Rocker Arm68
Removing The Valves69
Checking The Valves And Valve Guides70
Checking The Valve Seats71
Checking The Valve Springs73
Installing The Valves74
Cylinder And Piston75
Removing The Piston And Piston Rings76
Checking The Cylinder And Piston76
Checking The Piston Rings77
Checking The Piston Pin78
Installing The Piston And Cylinder79
Clutch81
Removing The Clutch84
Checking The Friction Plates84
Checking The Clutch Plates84
Checking The Clutch Springs85
Checking The Clutch Outer Case85
Checking The Clutch Center Sleeve85
Installing The Clutch Assy86
Checking The Clutch Push Rods87
Installing The Clutch87
Oil Pump89
Removing The Oil Pump90
Magneto And Starter Gear91
Removing The Generator Rotor92
Installing The Starter Clutch93
Installing The Generator Rotor94
Cam Chain-Tensior95
Cam Chain Tension96
Installing The Cam Chain Tension96
Crankshaft And Gearshift Arm97
Disassembling The Crankcase99
Crankshaft101
Checking The Crankshaft And Connecting Rod102
Checking The Bearings And Oil Seals103
Installing The Crankshaft104
Assembling The Crankcase104
Transmission Device, Shift Drum, Gear Forks105
Removing The Transmission107
Checking The Shift Forks108
Checking The Shift Drum108
Checking The Transmission109
Installing The Transmission, Shift Forks And Shift Drum110
Front Wheel And Rear Wheel111
Rear Wheel112
Removal Points113
Wheel Bearing113
Wheel113
Wheel Axle114
Brake Disc114
Front Brake And Rear Brake120
Rear Brake121
Brake Fluid122
Brake Caliper Piston123
Brake Caliper Piston And Spring Plate123
Brake Master Cylinder123
Brake Hose124
Front Braker Caliper125
Rear Braker Caliper126
Brake Master Cylinder Kit127
Front Brake Master Cylinder128
Rear Brake Master Cylinder128
Front Brake Hose129
Rear Brake Hose130
Streering133
Front Fork134
Front Fork And Steering135
Steering Ring Nut136
Lower Bearing136
Ball Race136
Steering Stem136
Bearing And Ball Race137
Lower Bracket137
Handlebar140
Grip141
Swingarm And Rear Shock Absorber145
Removing The Rear Shock Absorber Assembly146
Removing The Drive Chain146
Rear Shock Absorber And Swingarm146
Removing The Swingarm147
Checking The Rear Shock Absorber Assembly148
Checking The Swingarm148
Checking The Drive Chain149
Installing The Rear Shock Absorber Assembly150
Installing The Swingarm151
Installing The Drive Chain151
Electrical Components And Wiring Diagram153
Ignition System154
Inspection Steps154
Spark Gap Test155
Couplers, Leads And Ignition Coil Connection Inspection155
Engine Start Stop Switch Inspection155