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Apollo Orion AGB-21G User manual

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AGB-21G
SERVICE MANUAL
All manuals and user guides at all-guides.com
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All manuals and user guides at all-guides.com
Congratulations on your purchase of an
Apollo AGB-21G.
127(
As improvements are made on this model,
some data in this manual may become out-
dated. If you have any questions, please con-
sult your dealer.
WARNING
PLEASE READ THIS MANUAL CAREFULLY
AND COMPLETELY BEFORE OPERATING
THIS MACHINE. DO NOT ATTEMPT TO
OPERATE THIS MACHINE UNTIL YOU
HAVE ATTAINED A SATISFACTORY
KNOWLEDGE OF ITS CONTROLS AND
OPERATING FEATURES AND UNTIL YOU
HAVE BEEN TRAINED IN SAFE AND
PROPER RIDING TECHNIQUES. REGULAR
INSPECTIONS AND CAREFUL MAINTE-
NANCE, ALONG WITH GOOD RIDING
SKILLS, WILL ENSURE THAT YOU SAFETY
ENJOY THE CAPABILITIES AND THE RELI-
ABILITY OF THIS MACHINE.
IMPORTANT NOTICE
THIS MACHINE IS DESIGNED STRICTLY
FOR COMPETITION USE, ONLY ON A
CLOSED COURSE. It is illegal for this
machine to be operated on any public street,
road, or highway. Off-road use on public lands
may also be illegal. Please check local regula-
tions before riding.
1. THIS MACHINE IS TO BE OPERATED
BY AN EXPERIENCED RIDER ONLY.
Do not attempt to operate this
machine at maximum power until you
are totally familiar with its character-
istics.
2. THIS MACHINE IS DESIGNED TO BE
RIDDEN BY THE OPERATOR ONLY.
Do not carry passengers on this
machine.
3. ALWAYS WEAR PROTECTIVE
APPAREL.
When operating this machine, always
wear an approved helmet with gog-
gles or a face shield. Also wear heavy
boots, gloves, and protective cloth-
ing. Always wear proper fitting cloth-
ing that will not be caught in any of
the moving parts or controls of the
machine.
4. ALWAYS MAINTAIN YOUR MACHINE
IN PROPER WORKING ORDER.
For safety and reliability, the machine
must be properly maintained. Always
perform the pre-operation checks
indicated in this manual. Correcting a
mechanical problem before you ride
may prevent an accident.
5. GASOLINE IS HIGHLY FLAMMABLE.
Always turn off the engine while refu-
eling. Take care to not spill any gaso-
line on the engine or exhaust system.
Never refuel in the vicinity of an open
flame, or while smoking.
SAFETY INFORMATION
II
INTRODUCTION
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6. GASOLINE CAN CAUSE INJURY.
If you should swallow some gasoline,
inhale excess gasoline vapors, or
allow any gasoline to get into your
eyes, contact a doctor immediately. If
any gasoline spills onto your skin or
clothing, immediately wash skin areas
with soap and water, and change your
clothes.
7. ONLY OPERATE THE MACHINE IN AN
AREA WITH ADEQUATE VENTILA-
TION.
Never start the engine or let it run for
any length of time in an enclosed area.
Exhaust fumes are poisonous. These
fumes contain carbon monoxide,
which by itself is odorless and color-
less. Carbon monoxide is a dangerous
gas which can cause unconscious-
ness or can be lethal.
8. PARK THE MACHINE CAREFULLY;
TURN OFF THE ENGINE.
Always turn off the engine if you are
going to leave the machine. Do not
park the machine on a slope or soft
ground as it may fall over.
9. THE ENGINE, EXHAUST PIPE, MUF-
FLER, AND OIL TANK WILL BE VERY
HOT AFTER THE ENGINE HAS BEEN
RUN.
Be careful not to touch them or to
allow any clothing item to contact
them during inspection or repair.
10. PROPERLY SECURE THE MACHINE
BEFORE TRANSPORTING IT.
When transporting the machine in
another vehicle, always be sure it is
properly secured and in an upright
position and that the fuel cock is in
the “ OFF ” position. Otherwise, fuel
may leak out of the carburetor or fuel
tank.
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TO THE NEW OWNER
This manual will provide you with a good basic
understanding of features, operation, and
basic maintenance and inspection items of this
machine. Please read this manual carefully
and completely before operating your new
machine. If you have any questions regarding
the operation or maintenance of your machine,
please consult your dealer.
NOTE:
This manual should be considered a perma-
nent part of this machine and should remain
with it even if the machine is subsequently
sold.
NOTICE
Some data in this manual may become out-
dated due to improvements made to this
model in the future. If there is any question
you have regarding this manual or your
machine, please consult your dealer.
F.I.M. MACHINE WEIGHTS:
Weights of machines without fuel
The minimum weights for motocross
machines are:
for the class 125cc.......................minimum
64 kg
In modifying your machine (e.g., for weight
reduction), take note of the above limits of
weight.
HOW TO USE
THIS MANUAL
PARTICULARLY IMPORTANT
INFORMATION
The Safety Alert Symbol means ATTENTION!
BECOME ALERT! YOUR SAFETY IS
INVOLVED!
Failure to follow WARNING instructions could
result in severe injury or death to the machine
operator, a bystander, or a person inspecting
or repairing the machine.
A CAUTION indicates special precautions that
must be taken to avoid damage to the
machine.
NOTE:
A NOTE provides key information to make pro-
cedures easier or clearer.
WARNING
CAUTION:
MANUAL FORMAT
All of the procedures in this manual are organized
in a sequential, step-by-step format. The informa-
tion has been complied to provide the mechanic
with an easy to read, handy reference that contains
comprehensive explanations of all disassembly,
repair, assembly, and inspection operations.
In this revised format, the condition of a faulty
component will precede an arrow symbol and the
course of action required will follow the symbol, e.g.,
Bearings
Pitting/damage →Replace.
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INDEX
GENERAL INFORMATION 1
SPECIFICATIONS 2
REGULAR INSPECTION AND ADJUSTMENTS
ENGINE
CHASSIS
ELECTRICAL
3
4
5
6
7
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1 - 1
DESCRIPTION
GENERAL INFORMATION
DESCRIPTION
2Clutch lever
3Engine stop switch
4Front brake lever
5Throttle grip
6Fuel tank cap
7Engine start switch
8
9
:
Fuel tank
21
Air filter
22
Left side cover
23
Drive chain
24
Shift pedal
25
Side stand
26
Fuel cock
27
Spark plug
28
Right side cover
29
Kick starter cank
2:
Front fork
NOTE:
The machine you have purchased may differ
slightly from those shown in the following.
Designs and specifications are subject to
change without notice.
Rear brake pedal
Front axle
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1 - 2
MACHINE IDENTIFICATION
MACHINE IDENTIFICATION
There are two significant reasons for knowing
the serial number of your machine:
1. When ordering parts, you can give the
number to your dealer for positive
identification of the model you own.
2. If your machine is stolen, the authorities
will need the number to search for and
identify your machine.
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number ①is
stamped on the right of the steering head pipe.
ENGINE SERIAL NUMBER
The engine serial number ②is stamped into
the elevated part of the right-side of the
engine.
ķ
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1 - 3
IMPORTANT INFORMATION
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Remove all dirt, mud, dust, and foreign
material before removal and disassem-
bly.
When washing the machine with high
pressured water, cover the parts follows.
Silencer exhaust port
Side cover air intake port
2. Use proper tools and cleaning equip-
ment. Refer to “SPECIAL TOOLS” sec-
tion.
3. When disassembling the machine, keep
mated parts together. They include
gears, cylinders, pistons, and other
mated parts that have been “mated”
through normal wear. Mated parts must
be reused as an assembly or replaced.
4. During the machine disassembly, clean
all parts and place them in trays in the
order of disassembly. This will speed up
assembly time and help assure that all
parts are correctly reinstalled.
5. Keep away from fire.
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1 - 4
IMPORTANT INFORMATION
GASKETS, OIL SEALS AND O-RINGS
1. All gaskets, oil seals, and O-rings should
be replaced when an engine is over-
hauled. All gasket surfaces, oil seal lips,
and O-rings must be cleaned.
2. Properly oil all mating parts and bearings
during reassembly. Apply grease to the
oil seal lips.
LOCK WASHERS/PLATES AND COTTER
PINS
1. All lock washers/plates ①and cotter pins
must be replaced when they are
removed. Lock tab(s) should be bent
along the bolt or nut flat(s) after the bolt
or nut has been properly tightened.
BEARINGS AND OIL SEALS
1. Install the bearing(s) ①and oil seal(s) ②
with their manufacturer’s marks or num-
bers facing outward. (In other words, the
stamped letters must be on the side
exposed to view.) When installing oil
seal(s), apply a light coating of light-
weight lithium base grease to the seal
lip(s). Oil the bearings liberally when
installing.
CAUTION:
Do not use compressed air to spin the
bearings dry. This causes damage to the
bearing surfaces.
CIRCLIPS
1. All circlips should be inspected carefully
before reassembly. Always replace pis-
ton pin clips after one use. Replace dis-
torted circlips. When installing a circlip
①, make sure that the sharp-edged cor-
ner ②is positioned opposite to the thrust
③ it receives. See the sectional view.
④ Shaft
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