Orion AGB-21G Service Manual
AGB-21G
SERVICE MANUAL
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 MAINTENANCE, ALONG WITH GOOD RIDING
SKILLS, WILL ENSURE THAT YOU SAFETY
ENJOY THE CAPABILITIES AND THE RELIABILITY 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 regulations 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 characteristics.
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 goggles or a face shield. Also wear heavy
boots, gloves, and protective clothing. Always wear proper fitting clothing 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 refueling. Take care to not spill any gasoline on the engine or exhaust system.
Never refuel in the vicinity of an open
flame, or while smoking.
SAFETY INFORMATION
II
INTRODUCTION
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 VENTILATION.
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 colorless. Carbon monoxide is a dangerous
gas which can cause unconsciousness 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, MUFFLER, 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.
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 permanent part of this machine and should remain
with it even if the machine is subsequently
sold.
NOTICE
Some data in this manual may become outdated 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 procedures easier or clearer.
WARNING
CAUTION:
MANUAL FORMAT
All of the procedures in this manual are organized
in a sequential, step-by-step format. The information 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.
INDEX
GENERAL INFORMATION
1
SPECIFICATIONS
2
REGULAR INSPECTION AND ADJUSTMENTS
ENGINE
CHASSIS
ELECTRICAL
3
4
5
6
7
1 - 1
DESCRIPTION
GENERAL INFORMATION
DESCRIPTION
2 Clutch lever
3 Engine stop switch
4 Front brake lever
5 Throttle grip
6 Fuel tank cap
7 Engine 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
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 ① is
stamped on the right of the steering head pipe.
ENGINE SERIAL NUMBER
The engine serial number ② is stamped into
the elevated part of the right-side of the
engine.
ķ
1 - 3
IMPORTANT INFORMATION
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Remove all dirt, mud, dust, and foreign
material before removal and disassembly.
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 equipment. Refer to “SPECIAL TOOLS” section.
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.
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 overhauled. 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 ① and 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) ① and oil seal(s) ②
with their manufacturer’s marks or numbers 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 lightweight 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 piston pin clips after one use. Replace distorted circlips. When installing a circlip
①, make sure that the sharp-edged cor-
ner ② is positioned opposite to the thrust
③ it receives. See the sectional view.
④ Shaft
1 - 5
CHECKING OF CONNECTION
CHECKING OF CONNECTION
Dealing with stains, rust, moisture, etc. on the
connector.
1. Disconnect:
Connector
2. Dry each terminal with an air blower.
3. Connect and disconnect the connector
two or three times.
4. Pull the lead to check that it will not come
off.
5. If the terminal comes off, bend up the pin
① and reinsert the terminal into the con-
nector.
6. Connect:
Connector
NOTE:
The two connectors “click” together.
7. Check for continuity with a tester.
NOTE:
If there in no continuity, clean the terminals.
Be sure to perform the steps 1 to 7 listed
above when checking the wireharness.
For a field remedy, use a contact revitalizer
available on the market.
Use the tester on the connector as shown.
1 - 6
SPECIAL TOOLS
SPECIAL TOOLS
The proper special tools are necessary for complete and accurate tune-up and assembly. Using the
correct special tool will help prevent damage caused by the use of improper tools or improvised
techniques. The shape and part number used for the special tool differ by country, so two types are
provided. Refer to the list provided to avoid errors when placing an order.
Tool name/How to us Illustration Tool name/How to us Illustration
Crankcase separating tool
These tool is used to remove the
crankshaft from either case.
Flywheel puller
This tool is used to remove the flywheel
magneto.
Rotor holding tool
This tool is used when loosening or
tightening the fly-wheel magneto
securing nut
Dial gauge and stand
Stand
These tools are used to check each part
for runout or bent.
Crankshaft installing tool/pot/bolt
Spacer (crankshaft installer)
Adapter (M12)
These tools are used to install the
crankshaft.
Piston pin puller set
This tool is used to remove the piston
pin.
Steering nut wrench
This tool is used when tighten the
steering ring nut to specification.
Pocket tester
Use this tool to inspect the coil
resistance, output voltage and amperage.
Valve spring compressor
This tool is needed to remove and
install the valve assemblies.
Clutch holding tool
This tool is used to hold the clutch
when removing or installing the clutch
boss securing nut.
Valve guide remover
This tool is needed to remove and
install the valve guide.
1 - 7
CONTROL FUNCTIONS
CONTROL FUNCTIONS
ENGINE STOP SWITCH
The engine stop switch ① is located on the left
handlebar. Continue pushing the engine stop
switch till the engine comes to a stop.
CLUTCH LEVER
The clutch lever ② is located on the left han-
dlebar; it disengages or engages the clutch.
Pull the clutch lever to the handlebar to disengage the clutch, and release the lever to
engage the clutch. The lever should be pulled
rapidly and released slowly for smooth starts.
SHIFT PEDAL
The gear ratios of the constant-mesh 4 speed
transmission are ideally spaced. The gears
can be shifted by using the shift pedal ① on
the left side of the engine.
KICKSTARTER CRANK
Rotate the kickstarter crank ① away from the
engine. Push the starter down lightly with your
foot until the gears engage, then kick smoothly
and forcefully to start the engine. This model
has a primary kickstarter crank so the engine
can be started in any gear if the clutch is disengaged. In normal practices, however, shift to
neutral before starting.
THROTTLE GRIP
The throttle grip ① is located on the right han-
dlebar; it accelerates or decelerates the
engine. For acceleration, turn the grip toward
you; for deceleration, turn it away from you.
1 - 8
CONTROL FUNCTIONS
FRONT BRAKE LEVER
The front brake lever ① is located on the right
handlebar. Pull it toward the handlebar to activate the front brake.
REAR BRAKE PEDAL
The rear brake pedal ① is located on the right
side of the machine. Press down on the brake
pedal to activate the rear brake.
FUEL COCK
The fuel cock supplies fuel from the tank to
carburetor while filtering the fuel. The fuel cock
has the two positions:
OFF:With the lever in this position, fuel will not
flow. Always return the lever to this position when the engine is not running.
ON: With the lever in this position, fuel flows
to the carburetor. Normal riding is done
with the lever in this position
SPARK PLUG WRENCH
This spark plug wrench ① is used to remove
and install the spark plug.
NIPPLE WRENCH
This nipple wrench ① is used to tighten the
spoke.
①
NO
OFF
2 - 1
SPECIFICATIONS
21G:emanledoM
:rebmunedocledoM
AGB-21G
Dimensions:
mm550,1,htgnelllarevO
mm006htdiwllarevO
mm038thgiehllarevO
mm096thgiehtaeS
mm501
,1esableehW
Minimum ground clearance 260 mm
Basic weight:
knatleufllufdnaliohtiW
Engine:
Air cooled 4-stroke epytenignE
denilcnidrawrof,rednilycelgniStnemegnarrarednilyC
m c3.6712t
nemecalpsiD
3
Bore s 0.54ekorts s 54 mm
1: 9oitarnoisserpmoC
retratskciKmetsysgnitratS
pmusyrD:metsysnoitacirbuL
Oil type or grade:
At 5 ˚C (40 ˚F) or higher
SF15W/40 type
SG motor oil
(Non-Friction modified)
At 15 ˚C (60 ˚F) or lower
2
2
GENERAL SPECIFICATIONS
66kg
and Electrical Starting
2 - 2
GENERAL SPECIFICATIONS
Oil capacity:
Engine oil
L8.0egnahcliocidoireP
With oil filter replacement 0.85 L
L9.0tnuomalatoT
tnemeleepytteW:retlifriA
Fuel:
ahtiwylnoenilosagdedaelnumuimerPepyT
research octane number of 90 or higher.
Premium gasoline
L5.3yticapacknaT
Carburetor:
Z26-5KPepyT
rerutcafunaM
Spark plug:
A7RTC/NGK
rerutcafunam/epyT
mm7.0~6.0paG
csid-elpitlum,teW:epythctulC
Transmission:
Primary reduction system Gear
)277
.3(81/76oitarnoitcuderyramirP
Secondary reduction system Chain drive
Secondary reduction ratio 43/15 (2.867)
deeps-4,hsemtnatsnoCepytnoissimsnarT
noitarepotooftfeLnoitarepO
)818.2(11
/63ts1:oitarraeG
)839.1(61/13dn2
)053.1(02/72dr3
)340.1
(32/42ht4
Chassis:
eldarcelbuodimeSepytemarF
3.72elgnarets
aC˚
Tire:
ebuthtiWepyT
)tnorf(eziS
)raer(eziS
Tire pressure (front and rear) 130 kPa (1.3 kgf/cm
2
)
JINGKE
60/100-14 30M
80/100-12 41M
2 - 3
GENERAL SPECIFICATIONS
Brake:
ekarbcsidelgniSepytekarbtnorF
noitarepodnahthgiRnoitarepO
ekarbcsidelgniSepytekarbraeR
noitarepotoofthg
iRnoitarepO
Suspension:
krofcipocseleTnoisnepsustnorF
)noisnepsusssorconomepytknil(mragniwSnoisnepsusraeR
Shock absorber:
repmadli
o/gnirpslioCrebrosbakcohstnorF
re
pm
a
dlio
/gnirpslioCrebrosbakcohsraeR
Wheel travel:
mm002levartleehwtnorF
mm002levartl
eehwraeR
Electrical:
otengamIDCmetsysnoitingI
2 - 4
MAINTENANCE SPECIFICATIONS
ENGINE
timiLdradnatSmetI
Cylinder head:
mm30.0----timilpraW
Cylinder:
mm150.45~00.45eziseroB ----
mm50.0----timildnuorfotuO
Camshaft:
----)tfeL(evirdn
iahCdohtemevirD
Camshaft cap inside diameter
31.963 ~ 31.979 mm
----
Camshaft outside diameter
32.009 ~ 32.034 mm
----
mm071.0~030.0ecnaraelcpac-ot-tfahS
Cam dimensions
Intake “A” 26.555 ~ 26.675 mm 26.30 mm
“B” 20.99 ~ 21.01 mm 20.95 mm
Exhaust “A” 26.316 ~ 26.436 mm 26.00 mm
“B” 20.99 ~ 21.01 mm 20.95 mm
mm30.0----timiltuonurtfahsmaC
A
B
2 - 5
MAINTENANCE SPECIFICATIONS
Timing chain:
Timing chain type / No. of links 90T/90 ----
----citamotuAdohtemtnemtsujdaniahcgnimiT
Valve, valve seat, valve guide:
Valve clearance (cold) IN 0.02 ~ 0.04 mm ----
EX 0.02 ~ 0.04 mm ----
Valve dimensions:
“A” head diameter IN 26.9 ~ 27.1 mm ----
EX 22.9 ~ 23.1 mm ----
“B” face width IN 1.1~1.5 mm ----
EX 1.1~1.5 mm ----
“C” seat width IN 0.9 ~ 1.1 mm 1.6 mm
EX 0.8 ~ 1.0 mm 1.6 mm
“D” margin thickness IN 0.65~0.95 mm ----
EX 0.65~0.95 mm ----
Stem outside diameter IN 4.97~4.985 mm 4.94 mm
EX 4.955 ~ 4.97 mm 4.925 mm
Guide inside diameter IN 5.000 ~ 5.012 mm 5.050 mm
EX 5.500 ~ 5.512 mm 5.550 mm
Stem-to-guide clearance IN 0.015 ~ 0.042 mm 0.08 mm
EX 0.030 ~ 0.057 mm 0.10 mm
timiLdradnatSmetI
Head Diameter
B
Face Width
C
Seat Width
D
Margin Thickness
A
2 - 6
MAINTENANCE SPECIFICATIONS
mm30.0----timiltuonurmetS
Valve seat width IN 0.8 ~ 1.2 mm 1.6 mm
EX 0.8 ~ 1.2 mm 1.6 mm
Valve spring:
mm5.23mm87.33NIhtgneleerF
EX 35.55 mm 34.0 mm
Set length (valve closed) IN 22.45 mm ----
EX 25.45 mm ----
Compressed force
mm54.22taN46~52NI)dellatsni( ----
EX 105 ~ 129 N at 25.45 mm ----
3.1----NItimilt
liT ˚/ 0.8 mm
35.1----XE ˚/0.8 mm
Direction of winding
----esiwkcolCNI)weivpot(
----esiwkcolCXE
Piston:
Piston to cylinder clearance 0.025 ~ 0.05 mm 0.1 mm
Piston size “D” 53.965 ~ 53.975 mm ----
Measuring point “H” 10 mm ----
----
edis-NI/
mm4.0tes-ffonotsiP
timiLdradnatSm
etI
H
D
2 - 7
MAINTENANCE SPECIFICATIONS
Piston pin bore inside diameter 14.002 ~ 14.013 mm 14.04 mm
Piston pin outside diameter 13.994 ~ 14.000 mm 13.98 mm
Piston rings:
Top ring:
----lerraBepyT
Dimensions (B s .980)T s 2.00mm ----
mm52.0~01.0)dellatsni(pagdnE 0.60 mm
Side clearance (installed) 0.040 ~ 0.080 mm 0.12 mm
2nd ring:
----repaTepyT
Dimensions (B s 98.0)T s 2.20 mm ----
mm03.0~51.0)dellatsni(
pagdnE 0.60 mm
mm080.0~040.0ecnaraelcediS 0.12 mm
Oil ring:
Dimensions (B s 29.1)T s 2.45 mm ----
mm05.0~02.0)dellatsni(pagdnE ----
Crankshaft:
Crank width “A” 40.15~ 40.20 mm ----
Runout limit “C” 0.03 mm 0.05 mm
Big end side clearance “D” 0.15 ~ 0.35mm 0.60 mm
Small end free play “F” 0.4 ~ 1.0 mm 2.0 mm
timiLdradnatSmetI
7
%
B
T
B
T
2 - 8
MAINTENANCE SPECIFICATIONS
Clutch:
mm95.2~85.2ssenkcihtetalpnoitcirF 2.7 mm
----3ytitnauQ
----mm6.1~4.1ssenkcihtetalphctulC
----3ytitnauQ
mm1.0----t
imilpraW
mm5.91mm5.02htgneleerfgnirpshctulC
----4ytitnauQ
----
----
----hsupmac,hsuprennIdohtemesaelerhctulC
Shifter:
---
-rabediugdnamurdmaCepytretfihS
mm50.0----timilgnidnebrabediuG
Kickstarter:
----epyttehctardnakciKepyT
:roterubraC
/Z26-5KP
rerutcafunam/epyT
JINGKE
¾
----KJkram.D.I
#58)J.M(tejniaM ¾ ----
)J.A.M(tejrianiaM ø1.0 ¾
¾
----
----26-5
38#
ø2.0
8 g
2.0 ~ 3.0 mm
)N.J(eldeenteJ
)
I.J(Idle jet
Float needle valve size (F.N.A)
Float weight (F.W)
Float height (F.H)
¾ ---¾ ---¾ ---¾ ----
Air throttle (A.T) B6L ¾ ----
timiLdradnatSmetI
3 - 1
MAINTENANCE INTERVALS
REGULAR INSPECTION AND ADJUSTMENTS
MAINTENANCE INTERVALS
The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind
that such factors as weather, terrain, geographical location, and individual usage will alter the
required maintenance and lubrication intervals. If you are a doubt as to what intervals to follow in
maintaining and lubricating your machine, consult your dealer.
Item
After
break-in
Every
race
Every
third
(or
500 km)
Every
fifth
(or
1,000 km)
As required
Remarks
ENGINE OIL
Replace
Inspect
ƽ
ƽ
ƽ
ƽ
OIL FILTER ELEMENT, OIL STRAINER
Clean
ƽ
VALVES
Check the valve clearances
Inspect
Replace
ƽ
ƽ
ƽ
ƽ
The engine must be cold.
Check the valve seats
and valve stems for wear.
VALVE SPRINGS
Inspect
Replace
ƽ
ƽ
Check the free length and
the tilt.
VALVE LIFTERS
Inspect
Replace
ƽ
ƽ
Check for scratches and
wear.
CAMSHAFTS
Inspect
Replace
ƽ
ƽ
Inspect the camshaft surface.
Inspect the decompres-
sion system.
TIMING CHAIN SPROCKETS, TIMING
CHAIN
Inspect
Replace
ƽ
ƽ
Check for wear on the
teeth and for damage.
PISTON
Inspect
Clean
Replace
ƽ
ƽ
ƽ
ƽ
Inspect crack
Inspect carbon deposits
and eliminate them.
PISTON RING
Inspect
Replace
ƽ
ƽ
ƽ
Check ring end gap
PISTON PIN
Inspect
Replace
ƽ
ƽ
CYLINDER HEAD
Inspect and clean
ƽ
Inspect carbon deposits
and eliminate them.
Change gasket
CYLINDER
Inspect and clean
Replace
ƽ
ƽ
Inspect score marks
Inspect wear
CLUTCH
Inspect and adjust
Replace
ƽ
ƽ
ƽ
Inspect housing, friction
plate, clutch plate and
spring
TRANSMISSION
Inspect
Replace bearing
ƽ
ƽ
3 - 2
MAINTENANCE INTERVALS
SHIFT FORK, SHIFT CAM, GUIDE BAR
Inspect
ƽ
Inspect wear
ROTOR NUT
Retighten
ƽ
ƽ
EXHAUST PIPE, SILENCER, PROTECTOR
Inspect and retighten
Clean
Replace
ƽ
ƽ
ƽ
ƽ
* Whichever comes first
CRANK
Inspect and clean
ƽ
ƽ
CARBURETOR
Inspect, adjust and clean
ƽ
ƽ
When using a high-pres-
sure washer, make sure
that water does not enter
the accelerator pump.
SPARK PLUG
Inspect and clean
Replace
ƽ
ƽ
ƽ
DRIVE CHAIN
Lubricate, slack, alignment
Replace
ƽ
ƽ
ƽ
Use chain lube
Chain slack: 30 ~ 40 mm
OUTSIDE NUTS AND BOLTS
Retighten
ƽ
ƽ
Refer to “STARTING
AND BREAK-IN” section
in the CHAPTER 1.
AIR FILTER
Clean and lubricate
Replace
ƽ
ƽ
ƽ
Use foam air-filter oil or
equivalent oil
OIL FILTER
Replace
ƽƽ
OIL STRAINER (frame)
Clean
ƽ
FRAME
Clean and inspect
ƽ
ƽ
FUEL TANK, COCK
Clean and inspect
ƽ
ƽ
BRAKES
Adjust lever position and pedal height
Lubricate pivot point
Check brake disc surface
Check fluid level and leakage
Retighten brake disc bolts, caliper
bolts, master cylinder bolts and union
bolts
Replace pads
Replace brake fluid
ƽ
ƽ
ƽ
ƽ
ƽ
ƽ
ƽ
ƽ
ƽ
ƽ
ƽ
ƽ
Every one year
Item
After
break-in
Every
race
Every
third
(or
500 km)
Every
fifth
(or
1,000 km)
As required
Remarks
3 - 3
MAINTENANCE INTERVALS
FRONT FORKS
Inspect and adjust
Replace oil
Replace oil seal
ƽ
ƽ
ƽ
ƽ
ƽ
FRONT FORK OIL SEAL AND DUST
SEAL
Clean and lube
ƽ
ƽ
esaerg esab muihtiL
REAR SHOCK ABSORBER
Inspect and adjust
Lube
Retighten
ƽ
ƽ
ƽ
ƽ
ƽ
(After
rain ride)
ƽ
Molybdenum disulfide
grease
DRIVE CHAIN GUIDE AND ROLLERS
Inspect
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SWINGARM
Inspect, lube and retighten
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Molybdenum disulfide
grease
RELAY ARM, CONNECTING ROD
Inspect, lube and retighten
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Molybdenum disulfide
grease
STEERING HEAD
Inspect free play and retighten
Clean and lube
Replace bearing
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Lithium base grease
TIRE, WHEELS
Inspect air pressure, wheel run-out,
tire wear and spoke looseness
Retighten sprocket bolt
Inspect bearings
Replace bearings
Lubricate
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Lithium base grease
THROTTLE, CONTROL CABLE
Check routing and connection
Lubricate
Inspect and clean (throttle cable)
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SAE 10W-30 motor oil
Inspect dirt and wear on
the throttle cable on the
carburetor side.
Item
After
break-in
Every
race
Every
third
(or
500 km)
Every
fifth
(or
1,000 km)
As required
Remarks
3 - 4
PRE-OPERATION INSPECTION AND MAINTENANCE
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation, practice or a race, make sure the machine is in good operating
condition.
Before using this machine, check the following points.
GENERAL INSPECTION AND MAINTENANCE
enituoRmetI
Fuel
Check that a fresh gasoline is filled in the fuel tank. Check the
fuel line for leakage.
Engine oil
Check that the oil level is correct. Check the crankcase and
frame oil line for leakage.
Gear shifter and clutch
Check that gears can be shifted correctly in order and that the
clutch operates smoothly.
Throttle grip/Housing
Check that the throttle grip operation and free play are correctly
adjusted. Lubricate the throttle grip and housing, if necessary.
.ekarb raer dna tnorf fo tceffe dna ekarb tnorf fo yalp eht kcehCsekarB
Drive chain
Check drive chain slack and alignment. Check that the drive
chain is lubricated properly.
Wheels
Check for excessive wear and tire pressure. Check for loose
spokes and have no excessive play.
Steering
Check that the handlebar can be turned smoothly and have no
excessive play.
Front forks and rear shock
absorber
Check that they operate smoothly and there is no oil leakage.
Cables (wires)
Check that the clutch and throttle cables move smoothly. Check
that they are not caught when the handlebars are turned or
when the front forks travel up and down.
Exhaust pipe
Check that the exhaust pipe is tightly mounted and has no
cracks.
Rear wheel sprocket Check that the rear wheel sprocket tightening bolt is not loose.
Lubrication Check for smooth operation. Lubricate if necessary.
Bolts and nuts Check the chassis and engine for loose bolts and nuts.
Lead connectors
Check that the CDI magneto, CDI unit, and ignition coil are con-
nected tightly.
3 - 5
CLUTCH ADJUSTMENT
CLUTCH ADJUSTMENT
1. Check:
Clutch lever free play $
Out of specification m Adjust.
Clutch lever free play $ :
5 ~ 10 mm
2. Adjust:
Clutch lever free play
NOTE:
Make minute adjustment on the lever side
using the adjuster ② .
After adjustment, check proper operation of
clutch lever.
Clutch lever free play adjustment steps:
Loosen the locknuts ① .
Adjust the free play by changing their
tightening position.
Tighten the locknuts.
THROTTLE CABLE ADJUSTMENT
1. Check:
Throttle grip free play a
Out of specification m Adjust.
Throttle grip free play a :
3 ~ 5 mm
2. Adjust:
Throttle grip free play
Throttle grip free play adjustment steps:
Slide the adjuster cover.
Turn the adjuster ① until the specified free
play is obtained.
Tighten the locknut.
NOTE:
Before adjusting the throttle cable free play,
the engine idle speed should be adjusted.
WARNING
After adjusting, turn the handlebar to
right and left and make sure that the
engine idling does not run faster.
①
3 - 6
THROTTLE CABLE ADJUSTMENT/
THROTTLE LUBRICATION
THROTTLE LUBRICATION
1. Remove:
Screw (throttle grip cap)
2. Apply:
Lithium soap base grease
On the throttle cable end
3. Install:
Screw (throttle grip cap)
T
R
.
.
4 Nm (0.4 m · kg)
AIR FILTER REPLACE
NOTE:
Proper air filter maintenance is the biggest key
to preventing premature engine wear and
damage.
CAUTION:
Never run the engine without the air filter
element in place; this would allow dirt and
dust to enter the engine and cause rapid
wear and possible engine damage.
1. Remove:
Screw
3 - 7
2. Install:
T
R
.
.
5 Nm (0.5 m · kg)
ENGINE OIL LEVEL INSPECTION
1. Start the engine, warm it up for several
minutes, and then turn off the engine and
wait for five minutes.
2. Place the machine on a level place and
hold it up on upright position by placing
the suitable stand under the engine.
3. Remove:
Oil tank cap ①
ENGINE OIL LEVEL INSPECTION
Fitting Screw
3 - 8
ENGINE OIL LEVEL INSPECTION
CAUTION:
Do not add any chemical additives or use
oils with a grade of CD D or higher.
Do not use oils labeled “ENERGY CONSERVING II” E or higher. Engine oil also
lubricates the clutch and additives could
cause clutch slippage.
Do not allow foreign materials to enter the
crankcase.
5. Install:
Oil tank cap
6. Start the engine and let it warm up for
several minutes.
7. Turn off the engine and inspect the oil
level once again.
NOTE:
Wait a few minutes until the oil settles before
inspecting the oil level.
Recommended oil:
Refer to the following chart for
selection of oils which are suited
to the atmospheric temperatures.
Recommended engine oil classification:
API STANDARD:
API “SG” or higher grade
(Designed primarily for motor-
cycles)
4. Inspect:
Oil level
Oil level should be between maximum
and minimum marks.
Oil level is low m Add oil to proper
level.
NOTE:
When inspecting the oil level, do not screw the
oil tank cap into the oil tank. Insert the gauge
lightly.
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104
122
oCTemp.
oF
10W-30
10W-40
20W-40
20W-50
15W-40
D
E
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