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Orion AGB-21G User Manual

Orion AGB-21G
156 pages
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AGB-21G
SERVICE MANUAL

Table of Contents

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Orion AGB-21G Specifications

General IconGeneral
Starting SystemElectric and kick start
Front SuspensionTelescopic fork
Front BrakeDisc
Rear BrakeDrum
Rear SuspensionTwin Shock Absorbers

Summary

Introduction

Important Notice

Use of vehicle for competition only on closed courses. Illegal on public roads.

Safety Information

Crucial safety warnings and guidelines for operating the machine.

How to Use This Manual

Particularly Important Information

Explains safety alerts, warnings, cautions, and notes used in the manual.

Manual Format

Describes the structure and symbols used in procedures for clarity.

Specifications

General Specifications

Provides overall dimensions, engine type, displacement, and other key technical details.

Maintenance Specifications

Engine

Lists standard and limit values for engine components like cylinder head and camshaft.

Regular Inspection and Adjustments

Maintenance Intervals

Schedule for regular service based on usage intervals (break-in, race, mileage).

Pre-Operation Inspection and Maintenance

General Inspection and Maintenance

Routine checks required before operating the machine.

Clutch Adjustment

Throttle Cable Adjustment

Procedure for checking and adjusting throttle grip free play.

Pilot Screw Adjustment

Engine Idling Speed Adjustment

Steps to adjust the engine's idle speed and related settings.

Chassis

Brake System Air Bleeding

Process to remove air from the hydraulic brake system for optimal performance.

Front Brake Adjustment

Rear Brake Adjustment

Steps for adjusting the rear brake pedal height.

Sprockets Inspection/Drive Chain Inspection

Drive Chain Slack Adjustment

Method for checking and adjusting the drive chain's slack.

Front Fork Inspection

Front Fork Smooth Action

Inspecting the front fork for proper operation and oil leaks.

Electrical System

Checking the Battery

Guidelines for inspecting, charging, and maintaining the battery.

Checking the Fuses

Rear Shock Absorber Inspection

Procedure for inspecting the rear shock absorber for wear or damage.

Tire Pressure Check/Spokes Inspection and Tightening/Wheel Inspection

Wheel Inspection

Inspecting wheel runout, spokes, and bearings for proper condition.

Steering Head Inspection and Adjustment

Steering Stem

Checking the steering stem for bends, damage, or free play.

Electrical

Spark Plug Inspection

How to inspect the spark plug's electrode and insulator color.

Ignition Timing Check

Engine

Seat, Fuel Tank and Side Covers

Part diagrams and removal procedures for these body components.

Exhaust Pipe and Silencer

Assembly and Installation

Steps for correctly installing the exhaust muffler and pipe.

Carburetor & Air-Fiter

Carburetor Disassembly

Detailed breakdown of the carburetor for cleaning and inspection.

Sprocket Replacement

Cylinder Head

Checking the Cylinder Head

Inspecting the cylinder head for warpage and damage.

Camshaft /Valves and Valve Springs

Checking the Camshafts

Inspecting camshaft lobe dimensions and oil passages.

Cylinder and Piston

Checking the Piston Rings

Measuring piston ring side and end gap for wear.

Clutch

Checking the Friction Plates

Inspecting friction plates for damage, wear, and thickness.

Oil Pump

Removing the Oil Pump

Steps for safely removing the oil pump assembly.

Magneto and Starter Gear

Installing the Starter Clutch

Procedure for installing the starter clutch assembly.

Cam Chain-Tensior

Installing the Cam Chain Tensior

Steps for installing the cam chain tensioner assembly.

Crankshaft and Gearshift Arm

Disassembling the Crankcase

Process for separating the crankcase halves.

Crankshaft

Checking the Crankshaft and Connecting Rod

Measures for crankshaft runout, axial clearance, and width.

Transmission Device,Shift Drum ,Gear Forks

Checking the Transmission

Inspecting transmission gears, engagement, and movement for proper function.

Front Wheel and Rear Wheel

Front Wheel

Procedures for removing and installing the front wheel.

Front Brake and Rear Brake

Front Brake

Details on the front brake system components and assembly.

Steering

Front Fork

Front Fork and Steering

Installation

Steps for installing the front fork and related steering components.

Handlebar

Removal Points

How to remove the brake master cylinder and grips from the handlebar.

Swingarm and Rear Shock Absorber

Rear Shock Absorber and Swingarm

Procedures for removing the rear shock absorber and swingarm assembly.

Electrical Components and Wiring Diagram

Electrical

Overview of electrical components and the wiring diagram for the motorcycle.

Ignition System

Inspection Steps

Troubleshooting steps for diagnosing ignition system malfunctions.