Adly Motor AS-50LC Service manual

ADLY MOTO
SERVICE MANUAL
ATV-300S/U(҇ʼʳ
ʳ
OCTOBER, 2006 High Power Engine
HER
CHEE INDUSTRIAL CO., LTD.
ADLY MOTO
Foreword
This service manual contains information on servicing ATV-300
This manual is written for use as a guideline only. It is recommended that any
mechanic, with or without sufficient experience, thoroughly read through the
manual and only attempt to service those areas that are fully understood in
accordance with the guidelines provided by this manual. For fully qualified
mechanics, this manual supplies service data necessary for repairs and
maintenance. It is highly recommended that a qualified mechanic, regardless of
technical level, should study the service manual in full before attempting service
on ATV-300
All the data and diagrams provided in this service manual are valid at the time of
publication. Information may be updated without notice due to improvements or
upgrades.
No quotation, reproduction, or reprint of the service manual, as a whole or in part,
will be permitted without the express written consent from ADLY Motor sports.
ADLY MOTO
INDEX
Assembly Instruction / Pre-Delivery Information --------------------0
Information for Preparation-----------------------------------------------1
Check and Adjust-----------------------------------------------------------2
Cover parts / Muffler-------------------------------------------------------3
EngineLubrication System---------------------------------------------------------4
Fuel System------------------------------------------------------------------5
Engine remove and installation-------------------------------------------6
Cylinder Head / Valve------------------------------------------------------7
Cylinder / Piston------------------------------------------------------------8
Clutch / Starting System---------------------------------------------------9
Crank case / Crank shaft--------------------------------------------------10
ChassisFront wheel / Brake / Suspension / Steering----------------------------11
Rear wheel / Brake / Suspension ----------------------------------------12
Electrical devices-----------------------------------------------------------13
Wiring diagram-------------------------------------------------------------14
ADLY MOTO
MAINTENANCE SPECIAL TOOLS
Install crankshaft tool
(TLH3-01)
Bearing puller set
(TLH3-04)
Fly wheel puller
(TLH3-02)
Valve install / remove tool
(TLH3-03)
Valve adjustment tool
(TLH3-05)
ADLY MOTO
ASSEMBLY INSTRUCTION
1.
Take out the battery and fill with acid liquid.
Pre-charge the battery will extend its life.
The preparation and charge procedure is based on the battery’s instruction.
2.
Install the front and rear wheels and parts in the following order:
A. 18×40×4.5mm washer
B. 18mm hex-bolt (torque 14 kg-m, 135 N-m)
C. Cotter pin (open up the end after installed)
D. Rubber cap.
3. Install the front bumper.
4. Set the handle bar into the lock-pin of the steering base.
Tie-up the 4 hex-socket bolts.
Install the front cover into the handlebar.
5.
Install battery with the red wire to positive (+) first and the black wire to the
negative (-).
Use rubber strip to fix the battery onto frame.
6.
Check the oil gage to see if the oil quantity is on the upper position.
The oil type is 10W/40 for normal condition.
It would be better for the engine to choose synthetic type.
Fill up unleaded gasoline to operate.
Be sure the arrow mark on the fuel valve armΰpetcockαis set into the correct
position.(ON).
7. Turn on the main switch and try to start-up the engine.
In order to use the electric starter, you need to check the following:
A.
Check the neutral indication light should be on.
B
Press the electric starter bottom to start.
ADLY MOTO
P.D.I. (Pre-Delivery Inspection)
…
…
1. Record the frame and engine number into the owner’s manual.
…
…
…
…
…
…
…
3. Engine oil is enough.
2. Check that all tires have correct pressure specified on the tire or in the
owner’s manual.
4. Battery is installed properly.
5. All cables are adjusted properly. (brake, throttle, choke)
6. Fuel tank has enough gasoline to operate.
7. Check the suspension and drive chain for proper setup.
8. Check all electrical components and lights are working
properly.
9. Make sure that the owner’s manual and tool bag are installed on left
side of the seat in the tool box.
ADLY MOTO
INFORMATION FOR PREPARATION
Attention on Operation
z
All washers, oil rings, clamp rings, opening pins shall be duly replaced by a new item
when dismounted.
z
Locking of all screws, nuts, cross screws shall be performed in the order of first the large
screws and then the small ones and from inside to outside in opposite angles by tightening
the torque locks.
z
All items must use original parts, pure oil and greases.
z
All service shall use special tools and general tools to repair.
z
All dismounted items requiring for checks shall be duly cleaned and for assembly, all
items shall be duly lubricated.
1-1
ADLY MOTO
INFORMATION FOR PREPARATION
Attention on Operation
z
Certified lubricants in cans shall be used on all the elements to be lubricated.
z
After assembly, performance of all elements shall be duly checked and the locking shall
be duly verified.
z
In case of an operation is performed by over 2 people, the assignment shall be conducted
in coordination and safety shall be the first priority.
z
Definition of signs:
The sign given in the Service Manual shall refer to the operation methods and observation.
OIL: Lubrication by designated lubricant.
GREASE: Lubrication by grease
Special Tool: Parts on which special tools shall be used
General Tool: General tools shall be used
New: Replace by new items after dismounting
Attention
Dangerous and important operations
1-2
ADLY MOTO
INFORMATION FOR PREPARATION
SPECIFICATION ( UTILITY )
TYPE
ATV-300U (92/61)
LENGTH
1800 mm
WIDTH
1030 mm
HEIGHT
930 mm
SEAT HEIGHT
800 mm
WHEEL BASE
1150 mm
NET WEIGHT
200 kg
ENGINE TYPE
4-STROKE, Single Cylinder
COOLING
AIR COOLED
DISPLACEMENT
282 c.c.
BOREuSTROKE
Ø 74 × 65.5 mm
TRANSMISSION
Manuel , 5 speed
First gear 0.095
Second gear 0.139
Third gear 0.190
Forth gear 0.242
Fifth gear 0.299
Reverse gear 0.065
CLUTCH TYPE
Wet, Multi-disc
ENGINE OIL (CHANGE)
ENGINE IDLE SPEED
10W/40 (Standard), 2.0 Lit
1400²100 rpm
VALVE CLEARANCE
0.08Д0.12 mm
STARTING
Electric starter and pull start
SPARK PLUG
NGK DR8EA
SPARK PLUS GAP
0.6~0.7 mm
IGNITION
SUSPENSION
C.D.I
FrontΚDouble A-Arm with preload adjustable shock
RearΚSwing arm with preload adjustable shock
BRAKE
Front : Double Disc , Rear: Disc
BATTERY
8 Amps/h, Maintenances Free
FINAL DRIVE
FRONT TIRE
Chain
21×7-10 (Optional 22Ø8-10)
REAR TIRE
21×10-8 (Optional 22Ø11-10)
FRONT BUMPER (LOAD))
30kg
REAR BUMPER (LOAD))
45kg
1-3
ADLY MOTO
INFORMATION FOR PREPARATION
SPECIFICATION ( SPORTY )
TYPE
ATV-300S (92/61)
LENGTH
1740 mm
WIDTH
1050 mm
HEIGHT
1080 mm
SEAT HEIGHT
820 mm
WHEEL BASE
1150 mm
NET WEIGHT
190 kg
ENGINE TYPE
4-STROKE, Single Cylinder
COOLING
AIR COOLED
DISPLACEMENT
282 c.c.
BOREuSTROKE
Ø 74 × 65.5 mm
TRANSMISSION
Manuel , 5 speed
First gear 0.095
Second gear 0.139
Third gear 0.190
Forth gear 0.242
Fifth gear 0.299
Reverse gear 0.065
CLUTCH TYPE
Wet, Multi-disc
ENGINE OIL (CHANGE)
ENGINE IDLE SPEED
10W/40 (Standard), 1.6 Lit
1400²100 rpm
VALVE CLEARANCE
0.08Д0.12 mm
STARTING
Electric starter and pull start
SPARK PLUG
NGK DR8EA
SPARK PLUS GAP
0.6~0.7 mm
IGNITION
SUSPENSION
C.D.I
FrontΚDouble A-Arm with preload adjustable shock
RearΚSwing arm with preload adjustable shock
BRAKE
Front : Double Disc , Rear: Disc
BATTERY
8 Amps/h,, Maintenances Free
FINAL DRIVE
FRONT TIRE
Chain
21×7-10 (Optional 22Ø8-10)
REAR TIRE
21×10-8 (Optional 22Ø11-10)
1-4
ADLY MOTO
INFORMATION FOR PREPARATION
LOCKING TORQUE
The standard locking torque shall apply in case of no specification.
STANDARD TORQUEΚ
Type
Locking Torque (kg-m)
5mm Bolt, Nut
0.5
6mm Bolt, Nut
1.0
8mm Bolt, Nut
2.2
10mm Bolt, Nut
3.5
12mm Bolt, Nut
5.5
18mm Bolt, Nut
15.0
18mm Lock nut
11.0
Type
Locking Torque (kg-m)
5 mm Screw
0.4
6 mm Screw
0.9
6 mm Flange Bolt, Nut
1.2
7 mm Flange Bolt, Nut
2.1
8 mm Flange Bolt, Nut
2.7
10 mm Flange Bolt, Nut
4.0
CHASSISΚ
Locking Place
Handle bar bottom flange nut
Ball joint fixed nut
Engine mounting flange nut
Engine mounting bracket bolt
Foot rest flange bolt
Rear swing arm fixed nut
Rear brake panel flange bolt
Front suspension fixed nut
Rear suspension flange bolt
Front rim nut
Rear rim nut
Quantity Dia. (mm) Torque (kg-m)
2
10
4.0
4
10
4.0
4
8
3.5
2
10
4.0
6
8
4.0
1
14
9
4
12
7
4
10
4.0
2
10
4.0
2
18
15
2
18
15
Remark
Nylon insert type
Nylon insert type
Nylon insert type
Nylon insert type
ENGINEΚ
Locking Place
Breather separator Allen bolt
Cam chain tensioner mounting bolt
Cam sprocket bolts
Clutch center locknut
Clutch lifter plate bolts
Crankcase cover bolts (L/R)
Crankcase bolts
Cylinder base bolts
Cylinder head cover flange bolts
Cylinder head cap nuts
Oil pipe bolts
Gearshift return spring pin
Gearshift drum shifter pin
Quantity Dia. (mm) Torque (kg-m)
Remark
Hex socket flange bolt
1
6
1.2
Hex flange bolt
2
6
1.2
2
7
2.1
Hex flange bolt
1
18
11.0
Locknut
4
6
1.2
Hex bolt
24
6
1.0
14
6
1.2
Hex flange Bolt
2
6
1.0
13
6
1.2
Hex flange Bolt
Hex acorn washer face nut
4
10
4.0
1
6
1.0
1
7
1.2
1
8
2.2
2
8
2.2
1-5
ADLY MOTO
INFORMATION FOR PREPARATION
The following drawing that shows the disassembling situation of the cover parts
for ATV-300U.
1-6
ADLY MOTO
INFORMATION FOR PREPARATION
The following drawing that shows the disassembling situation of the cover parts for ATV-300S.
1-7
ADLY MOTO
INFORMATION FOR PERPARATION
DIFFICULT START OR CANN'T START
Diagnose
Check and Adjust
Reason of Trouble
loose the fuel release
screw of caruretor and
check if the fuel is inside
of carburetor ?
fuel supply to
carburetor is
sufficient
no fuel supply to
carburetor
loosen the spark plug,
connect with the spark
cap and contact with the
frame, check the spark
plug sparking ?
sparking
no sparking or
weak
fuel tank without gasoline
tubing to carburetor blocking
float chamber tubing blocking
fuel filter blocking
fuel cup blocking
air in fuel tank blocking
spark plug grimy or damage
C.D.I damage
main switch damage
ACG fulser coil damage
high tension coil damage
ACG lighting coil damage
test the compression
pressure
compression
pressure
is normal
compression
pressure too low
or no pressure
follow the standard
stat-up procedure and
test again
engine can not
ignite
valve set damage
cylinder, piston, piston ring damage
cylinder gasket leakage
valve burn
valve timing is not correct
valve gap is too tight or no gap
start clutch damage
ignition timing is not correct
carburetor fuel adjust screw isn't correct
intake manifold sucking air
engine can ignite
but can not start
loosen the spark plug
and test
spark plug is dry
fuel level of carburetor is too high
throttle open angle is too wide
spark plug is wet
continue
1-8
ADLY MOTO
INFORMATION FOR PREPARATION
REVOLUTION NOT SMOOTH , LOST POWER
Diagnose
Check and Adjust
start engine and
go up speed slight
engine speed
goes up
engine speed can't
goes up fully
adjusting ignite
timing
ignite timing is
correct
Reason of Trouble
air cleaner blocking
fuel supply isn't smooth
air hole of air tank blocking
exhaust pipe blocking
manual choke stay on
fuel cup damage
C.D.I damage
pulser coil damage
ignite timing isn't
correct
adjusting valve gap
valve gap is correct
valve gap adjusting isn't correct
valve seat over abrade
valve gap
isn't correct
test compression
pressure
compression pressure
is normal
compression
pressure
is too low
check carburetor
blocking ?
no blocking
blocking
valve seat damage
cylinder, piston abrade
cylinder gasket leakage
valve timing isn't correct
cleaning carburetor
loosen spark plug
and check
spark plug normal
cleaning the stain
spark plug type isn't correct
spark plug stain
check the oil
quantiity in
crankcase is too
rich or dirty?
oil quantity
is normal
oil quantity is
too rich
oil flowing is too rich
oil flowing is too lean
oil doesn't circulate
check cylinder head
lubricating ?
normal
oil tubing blocking
oil supply is too lean
abnormal
engine over heat
normal
over heat
increase engine
speed or continue
turning at high
speed
no knocking
knocking
continue
1-9
cylinder, piston abrade
mixutre gases is too lean
carbon residue in combustion chamber
is too much
ignition timing is too earily
fuel isn't good
clutch plate sliding
mixutre gases is too lean
carbon residue in combustion chamber
is too much
ignition timing is too earily
fuel isn't good
ADLY MOTO
INFORMATION FOR PREPARATION
REVOLUTION NOT STABLE (LOW R.P.M.)
Diagnose
Check and Adjust
Reason of Trouble
ignition timing adjusting
normal
C.D.I damage
pulser coil damage
abnormal
adjust the carburetor fuel
adjuste screw
adjusting is correct
fuel mixture too lean
(locking screw)
fuel mixture too rich
(loosing screw)
adjusting isn't
correct
carburetor sucking air
no sucking air
gasket damage
the screw of carburetor is
loosen
sucking air
loosen spark plug,
connecct with spark cap
and contract with frame,
check the spark plug
sparking ?
sparking normal
sparking abnormal
spark damage or stain
C.D.I damage
A.C.G damage
coil damage
spark plug cable damage
main switch damage
check A.C.G
normal
A.C.G damage
air blocking of the fuel
system
abnormal
end
1-10
ADLY MOTO
INFORMATION FOR PREPARATION
REVOLUTION NOT SMOOTH(HIGH SPEED)
Diagnose
Check and Adjust
Reason of Trouble
adjusting ignition timing
normal
C.D.I damage
ACG pulse coil damage
abnormal
adjusting valve gap
normal
adjusting isn't correct
valve seat damage
abnormal
check fuel cup supply
normal ?
normal
fule filter blocking
air hole of fuel tank blocking
fuel cup damage
fuel in tank is not sufficient
abnormal
carburetor blocking
cleaning
no blocking
blocking
check and adjust valve
timing
valve timing is
correct
camshaft gear mark position is
not correct
valve timing isn't
correct
check the spring of valve
normal
spring broken or
elastic deformation
spring damage
end
1-11
ADLY MOTO
INFORMATION FOR PREPARATION
CHARGE ABNORMAL
Check and Adjust
Diagnose
Reason of Trouble
start engine and measure
voltage of both terminal on
battery
voltage of battery
can't go up
voltage of battery
is normal
battery damage
measure the resistance of
ACG coil
coil damage
terminal damage
YL wire damage
measure value
too high
normal
check the regulator
battery have voltage
battery have not
voltage
Red wire damage
check socket of regulator
loosen ?
normal
regulator damage
socket damage
abnormal
ACG damage
(over charge)
check the voltage between
regulator (+) and frame
main switch at ON
the battery have
voltage
main switch at ON
the battery have no
voltage
GR wire broken
check the socket of
regulator
normal
socket loosen
socket damage
regulator damage
1-12
ADLY MOTO
INFORMATION FOR PREPARATION
SPARK PLUG NO SPARKING
Diagnose
Check and Adjust
Reason of Trouble
change spark plug and
check again
no sparking or
weak
the previous spark plug damage
sparking strong
check spark plug, cap,
ignition coil loosen?
loosen
no loosen
spark plug cap loosen
check C.D.I unit socket
loosen ?
normal
abnormal
socket damage
check the terminal of
C.D.I unit unimpeded?
measure resistance
abnormal
normal
check relate spare parts
normal
main switch damage
pulser coil damage
coil damage
lighten coil damage
abnormal
main switch damage
socket, joint connect abnormal
change CDI unit
normal
the previous C.D.I unit damage
abnormal
change ignition coil
abnormal
the previous coil damage
1-13
ADLY MOTO
CHECK AND ADJUST
INFORMATION
WARNNING
ϡʳ
Do not start the engine at a close zone, because the exhaust gases from the engine including
some noxious emission such as CO, HC, NOx... etc. that can result serious damage for health.
ϡʳ
Strictly prohibit using any flammable thing in the working zone, because that can rise fire
easily.
ENGINEΚ
ITEM
Spark Plug Gap
SPECIFICATION
0.6~0.7 mm
Spark Plug Type
DR8EA
without resistance
0.08mm
0.12mm
1400r100 rpm
SAE 10W/40
1.6 L
2.0 L
13 kg/cm2
17q BTDC
intake valve
exhaust valve
Valve Gap
Idle Speed
Engine oil type
Engine Oil Capability
Compression Pressure
Ignite Timing
REMARK
Synthetic
At oil change
After engine overhaul
1400 rpm
1400r100 rpm
CHASSISΚ
ITEM
Parking brake lever free play
Left lever free play
Throttle free play
Front Tire Pressure
Rear Tire Pressure
Torque of Front Rim Nut
Torque of Rear Rim Nut
SPECIFICATION
10~20 mm
5~10 mm
2~6 mm
10 psi
10 psi
14 kg-m
14 kg-m
REMARK
Check the mark on tire
Check the mark on tire
Ϡʳ Detailed tire pressure specification please check the marking on tires.
2-1
ADLY MOTO
CHECK AND ADJUST
MAINTENANCE SCHEDULE
Please follow the maintenance schedule to do the routine maintenance.
Service Interval
CΚClean up
LΚLubricate or Grease
RΚReplace
IΚInspection, check, adjust and replace if necessary
DΚNeed some special tools or techniques, suggest to be serviced on dealers site.
Inspection parts / System
Air cleaner element
Spark plug
Petrol filter/Fuel tube
Valve clearance
Engine oil
Eng. oil filter screen
Engine idle speed
Drive chain
Brake shoe wear / Brake system
Clutch system
Suspension
Re-tighten up bolts and nuts
Tire and Wheel
Steering system and shaft bearing
(1)
(2)
C
I
I
I
R
I
R
I
I,L
I
I
I
I
I
I
I
I
(3)
C
I
I
I
R
C
I
I,L(Note 3)
I
I,D
I
I
I
I
Ref.
(Note 1)
D
D
D
(Note 1,2)
(Note 2)
Service Interval
(1) Initial Service…20 hours or 150km either earlier time for new vehicle
(2) Regular Check…Every 100 hours or 1000km, earlier time
(3) Regular Check…Every 200 hours or 2000km, earlier time
Note 1ΚUsed in dusty, sandy, snow area need to be inspected.
Note 2ΚUsed in rainy, muddy condition need to be inspected.
Note 3ΚUsed after 50 hours or 500km need to be inspected.
NoteΚ
(1) If the ATV is new then the motor oil have to replace at the first initial service.
(2) For safety reason, we suggest the maintenance should be done at local service center.
(3) If the driving condition is very abominable such as rainy, dust zone or heavy load...that
we suggest operating maintenance more frequency.
2-2
ADLY MOTO
CHECK AND ADJUST
PARKING BRAKE LEVER
y
Pull the right brake lever will perform brake
function.
y Push the locking will lock the brake.
The main adjusting nut for throttle play is located
under the handle bar
z
Loose the fixed nut and adjust the play nut
to proper position.
The throttle lever control bolt is located on the
throttle base.
The throttle lever free playΚ2~6 mm
z
Loose the fixed nut and adjust the screw to
get proper position.
2-3
ADLY MOTO
CHECK AND ADJUST
SPARK PLUG
z
z
z
Pull to remove the spark plug cap.
Use tools come with the vehicle to remove
the spark plug.
If the spark plug grimy or with carbon
residue then using the copper brush to clean
it.
Spark plug specification
DR8EAΚResistance
Check the gap of spark plug
GapΚ0.6~0.7 mm
AIR CLEANER
z
z
z
z
Remove the seat.
Pull to open 4 clips on air cleaner cover and
remove the cover.
Take-out the air filter.
Check the filter whether is dirty or
damaged. If it‘s dirty or damaged then clean
it or change a new one.
AttentionΚ
Clean the element and frame in a high flash
point solventΔsqueeze the solvent out of
the foam and let the guide and element dry
completely.
ϡʳ
Check periodΚ
ϡʳ If the ATV often driving at the rainy or
abominable surroundings, please check
the filter more frequently.
2-4
ADLY MOTO
CHECK AND ADJUST
VALVE ADJUSTING
AttentionΚ
ϡʳ When you check or adjust the valve, do it
when the engine temperature is low
( below 35qC)
z
Remove the timing hole plug and the
crankshaft hole plug with screwdriver.
z
Rotate the flywheel and keep the “T” line
aim at the centerline of the inspection hole.
z
Measure valve clearance with a feeler gauge
of the specified thickness.
z
To adjust the valve clearance, loosen the
locknut and turn the adjuster.
AttentionΚ
ϡʳ When you adjusting the valve, don’t
invert the crankshaft, otherwise cannot
adjust the exhaust valve.
Valve gap check and adjust
Valve gapΚ IN. Κ0.08 mm
EX. Κ0.12 mm
z
Loose the fixed nut and rotating the
adjusting nut reach to the proper gap.
z
Tie up the fixing nut and check the gap
again.
z
Using the valve gap tool to adjust the valve
gap.
2-5
ADLY MOTO
CHECK AND ADJUST
ADJUSTING IDLE SPEED
ϡʳ
Engine idle speed adjustment has to do it
when the engine is warm.
z
Connect with the rpm meter then starting
the engine.
z
Before adjusting the idle speed, make sure the
spark plug gap is correct. Also, turn the
handlebars from left to right and note
whether the idle speed changes. If it does,
the throttle cable may be incorrectly
routed. Be sure to correct this problem
before proceeding.
WarningΚ
Use screw driver to adjust the idle speed
to avoid injury.
z
Adjust the idle speed adjust screw reach to
the normal idle speed.
The idle speed is about
1400r100 rpm.
IGNITION TIMING
The ignition system of this ATV is controlled by
C.D.I unit, thus don‘t need to adjust anything. If
the ignition timing isn’t correct then checking
the ignition system whether normally.
z
z
Remove the 14 mm A.C.G. cap.
Using the timing light to check the ignition
timing. When the engine speed running at
idle, the “F” mark of flywheel should aim at
the inspection hole.
2-6
ADLY MOTO
CHECK AND ADJUST
IGNITION TIMING
z
z
Using the timing light to check the ignition
timing.
Keep the engine speed about 4000 rpm, if 2
mark-lines on flywheel aim at center of
inspection hole then the ignition timing is
correct.
CYLINDER PRESSURE
z
Remove the spark plug cap and spark plug.
Install the pressure gauge.
Rotate the throttle and press the electric
start button.
The normal cylinder pressure is 12~14 kg/cm2.
z
z
If the cylinder pressure is too low then check the
following itemsΚ
- Valve leakage?
- Valve gap is too tie?
- Cylinder head gasket is damage?
- Piston ring wear-out?
- Piston, cylinder wear-out?
If the cylinder pressure is too high then check the
combustion chamber and the top face of piston
whether with too much carbon residue.
2-7
ADLY MOTO
CHECK AND ADJUST
ENGINE OIL
When you check the quantity of oil, the
vehicle has to stay at the ground (flat)
level.
z
Stop the engine and remove the oil level
gauge.
z
Unscrew the engine oil filler cap from the
right front corner of the engine and pull out
the dipstick.
If the oil level is stay within bottom mark of the
gauge, then the oil quantity is enough.
ϡʳ
Refill the engine oil if it’s too less.
The standard oil type is SAE 10W/40
Re-install the oil level gauge.
Change the engine oilΚ
z
Take-out the oil level gauge.
z
Remove the oil-release bolt underneath the
engine and release the oil.
z
Install the oil-release bolt.
z
Fill the engine oil.
ϡʳ
Confirm the washer of the bolt whether
damaged.
Engine oil quantityΚ
disassembleΚ2.0 Lit
changeΚ1.6 Lit
20~30mm
z
Check all parts whether leaking, after
assembly.
DRIVE CHAIN
Check the drive chain condition.
z
The drive chain should be check, adjust, and
lubricate regularly.
z
Inspect the drive chain at a point on the
lower run about halfway between the
sprockets.
The free play of the drive chain should be
between 20~30mm up and down.
2-8
ADLY MOTO
CHECK AND ADJUST
z
Inspect the front sprocket teeth for
excessive wear; mark sure there’s no play in
the sprocket.
z
When install the chain clip, beware the clip
direction.
BRAKE SYSTEM
Parking brake and rear brake
z
Check all the brake shoes. If the brake shoes
have any dint or wearing very serious then
change it.
Check the play of brake lever
normal playΚ10~20 mm
z
If the brake lever play is too much, adjust
the fix bolts on right brake lever.
z
If the play of the rear brake over the normal
value then adjust the adjusting nut of rear
brake caliper on swing arm.
ϡʳ
Adjusting nut must be aligned with pin, any
slight deviation may result in braking play
change cause danger as brake applied.
STEERING
Turning the steering from right side to left
side, check the steering operation.
Be sure the wiring and cable does not affect the
steering handle.
z
2-9
ADLY MOTO
CHECK AND ADJUST
FIXING OF NUTS AND BOLTS
z
Check the fixing nuts, bolts on all parts.
If the nuts, bolts loosen then tie-up with certain
locking torque.
SUSPENSION
Front
z
Holding the brake lever and push the handle
bar. Check the fork movement and other
parts if is loose or oil leaking.
Rear
z
Check the damping of rear suspension
z
Check the suspension bush function
normally.
ϡ Inspect all suspension fasteners before
riding.
TIRE, RIM
z
z
z
Check the tires whether have any nail,
broken…etc.
Check tire pressure with a gauge that will
read accurately at the low pressure used in
ATV tires.
The tire pressure can be very depends on
different operation condition. Please check
the mark on tire for operation pressure
tolerance.
2-10
ADLY MOTO
CHECK AND ADJUST
z
z
Checking the shaft and nut of front wheel
whether loosen.
Checking the nut of rear wheel whether
loosen.
Locking Torque:
Front wheel 18mm nutΚ14 kg-m
Rear wheel 18mm nutΚ14 kg-m
MENO
2-11
ADLY MOTO
COVER PARTS, MUFFLER
Information for preparation
z
z
Don‘t enforce to remove the cover parts of the ATV, otherwise will cause the
connecting nail of cover parts broken.
Please according to the operating instruction when assembling the cables and
wires
Remove cover parts of the ATV-300S
Front cover
z
z
z
z
z
z
z
z
Pull the Seat Releaser Unit and take off seat assembly.
Release the brake and throttle cables from handle bar then disconnect handle
switch wires.
Release the L/R signal wires.
Disassembly speedometer connection and taking off 2 nylon nuts then disconnect
speedometer assembly.
Taking off 4 hex-socket bolts and remove the handle bar.
Remove 6 pan-phillips bolts and 2 ladder bolts.
Disconnect the head light wire.
Remove the front cover.
Note: When you assembling the above parts that follow the opposite sequence of
disassembling.
3-1
ADLY MOTO
COVER PARTS, MUFFLER
Rear cover
z
z
z
z
Release the L/R signal wires and light bracket then disconnect signal assembly.
Taking off 2 nylon nut and release tail light connection then disconnect the tail
light assembly.
Taking off 8 pan-phillips bolts and 2 ladder bolts.
Remove the rear cover.
Attention:
Ϡ When assembling the above parts, please confirm the connecting status of join
parts.
L/R Rear fender
z Remove 2 ladder bolts and 2 hex
washer face bolt.
z Taking-off the L/R rear fender.
3-2
ADLY MOTO
COVER PARTS, MUFFLER
Muffler
Locking Torque:
Muffler fixed boltΚ3.5 kg-m
Muffler connect nutΚ1.2 kg-m
Trouble Diagnose:
Exhaust sound level is too high
x Muffler broken
x Muffler leakage
Power isn‘t enough
x Muffler leakage
x Muffler blocking
x Muffler with dent
Remove the muffler:
x Taking-off the 2 nuts that connect to the cylinder.
x Taking-off the 1 hex flange bolts and 2 hex washer face bolts that fix to the frame.
x Pull to open 1 exhaust clip and to loose the reed valve comp EX. Pipe.
x Remove the muffler and gasket.
Note:When you assembling the muffler, don't forget to put gasket on muffler first.
Replace a new gasket after dismounting the muffler.
MEMO
3-3
ADLY MOTO
COVER PARTS, MUFFLER
Information for preparation
Don‘t enforce to remove the cover parts of the ATV, otherwise will cause the
connecting nail of cover parts broken.
z Please according to the operating instruction when assembling the cables and
wires
z
Remove cover parts of the ATV-300U
Front cover
z Pull the Seat Releaser Unit and take off Seat assembly.
z Taking off 8 hex flange bolts then remove front bumper and luggage rack.
z Release the brake and throttle cables then disconnect handle switch wires.
z Release the L/R signal wires and light bracket then disconnect signal assembly.
z Disassembly speedometer connection and taking off 2 nylon nuts then disconnect
speedometer assembly.
z Taking off 4 hex-socket bolts and remove the handle bar.
z Remove 6 pan-phillips bolts and 2 ladder bolts.
z Disconnect the head light wire.
z Remove the front cover.
Note: When you assembling the above parts that follow the opposite sequence of
disassembling.
3-1
ADLY MOTO
COVER PARTS, MUFFLER
Rear cover
z
z
z
z
z
Taking off 4 hex flange bolts then disconnect rear bumpers.
Release the L/R signal wires and light bracket then disconnect signal assembly.
Taking off 2 nylon nut and release tail light connection then disconnect the tail
light assembly.
Taking off 8 pan-phillips bolts and 2 ladder bolts.
Remove the rear cover.
Attention:
Ϡ When assembling the above parts, please confirm the connecting status of
join parts.
3-2
ADLY MOTO
COVER PARTS, MUFFLER
Muffler
Locking Torque:
Muffler fixed boltΚ3.5 kg-m
Muffler connect nutΚ1.2 kg-m
Trouble Diagnose:
Exhaust sound level is too high
x Muffler broken
x Muffler leakage
Power isn‘t enough
x Muffler leakage
x Muffler blocking
x Muffler with dent
Remove the muffler:
x Taking-off the 2 nuts that connect to the cylinder.
x Taking-off the 1 hex flange bolts and 2 hex washer face bolts that fix to the frame.
x Pull to open 1 exhaust clip and to loose the reed valve comp EX. Pipe.
x Remove the muffler and gasket.
Note:When you assembling the muffler, don't forget to put gasket on muffler first.
Replace a new gasket after dismounting the muffler.
MEMO
3-3
ADLY MOTO
LUBRICATION SYSTEM
TROUBLE DIAGNOSE
Oil quantity reduced
x Normal consumption
x Oil leaking
x Piston ring wear-out or installed wrong
x Valve seal wear-out
Engine burn
x No oil pressure or pressure too low
x Oil thoroughfare blocking
x Oil type incorrect
ENGINE OIL & FILTER
Oil quantity
Ϡ When you check the oil quantity, the
vehicle has to stand on flat ground.
Ϡ Starting the engine about 2~3 min. then
stop it. After 2~3 min. check the oil
quantity.
z
Upper Limit
Remove the oil level gauge and check if
the oil level under the lower limit then
adds the standard oil to upper limit of
gauge.
Lower Limit
Oil Exchange
Ϡ The motor oil will flow more easily if the
engine is warm.
ϠThe oil release bolt is under R crankcase.
Locking torqueΚ 1.5 kg-m
z
Remove the right crankcase cover to
check and clean the oil filter. Replace
new filter if it’s damaged.
z
Adding the proper oil quantity
Engine disassemblyΚ2.0L.
Oil changeΚ1.6L
z
Check the engine oil whether leaking. If
not then starting the engine at idle speed
for few minutes and checking the oil
level again.
4-1
ADLY MOTO
LUBRICATION SYSTEM
CLUTCH
Remove
z Remove the seat and body cover. ( see
3-1, 3-2 )
z
Remove 2Ø10mm Hex-flange bolts on
left step bar (foot peg) and 2 Pan-Philips
bolts on the rear foot fender. Remove
foot peg and fender together.
R. crankcase
Gasket
dowel pin
z
z
z
Take-off 12 bolts on R. crankcase cover
and remove the cover.
Remove the gasket and 2 dowel pins.
Release the clutch cable fix nut from the
left side of the engine. Pull out the cable
from the clutch lever on top of right
crankcase cover.
4-2
ADLY MOTO
LUBRICATION SYSTEM
z
z
z
Remove 2ØM8-25mm hex-flange bolts
on master cylinder assembly. This is to
lower down the brake pedal for easier.
disassembly.
Release brake pedal reset spring.
Lift the vehicle from right side and flip
over to left side. Then remove the oil
tube fix bolt on top of right crankcase
cover.
ϡBeware not to lost the copper washers.
z Remove the nylon insert bolt on reverse
stopper lever.
4-3
ADLY MOTO
LUBRICATION SYSTEM
z Remove 2ØM6-12mm hex-flange bolts
together with the switch cover.
z
Un-plug the contact switch connectors.
AttentionΚ
* Beware the light green wire is for the
neutral signal, the gray wire is for the
reverse signal.
z Remove 10 Ø M6-32mm, 1 Ø M6-40mm
and 1ØM6-50mm hex-flange bolts.
z Put away all wires, cables. Slightly hit
the right crankcase cover from side way
and pull out to remove the cover.
4-4
ADLY MOTO
LUBRICATION SYSTEM
z
Remove the right crankcase cover gasket
and beware not to lost the dowel pins.
z
Remove 4ØM6-28mm hex bolts and 4
springs under the clutch lifter plate. Hold
the lifter plate together with the needle
roller bearing.
z
Before remove the locknut, punch out
the lock section on the nut.
z
Remove the locknut and clutch center.
4-5
ADLY MOTO
LUBRICATION SYSTEM
z
Take off the clutch center.
Use reversed procedure to setup the parts that
has been removed.
AttentionΚ
* Beware all dowel pins are located into
the crankcase.
* Replace new gasket of the right
crankcase cover after dis-assembly.
OIL PUMP
Remove
z Remove the O-ring from the oil pipe.
z To detach the oil pipe from the
crankcase, remove these 2 bolts.
z Carefully pull the oil pipe off the
crankcase.
z Remove this dowel pin and O-ring from
the oil pipe.
z
Oil pipe
Remove the oil pump mounting bolts.
Use reversed procedure to setup the parts that
has been removed.
4-6
ADLY MOTO
LUBRICATION SYSTEM
Oil Pump Disassembling:
x Remove the snap-ring and washer.
x Remove the pump cover bolts and separate
the cover from the pump body.
x Remove the pump driven gear and shaft.
z
Remove the rotors , wash all the
components in solvent.
rotor
4-7
ADLY MOTO
LUBRICATION SYSTEM
Check:
x Check the gap between the pump body and
outer rotor.
The gap limit is 0.25 mm.
x Check the gap between inner and outer
rotor.
The gap limit is 0.2 mm.
x Check the gap between the rotors and a
straightedge laid across the pump body.
The gap limit is 0.1 mm.
4-8
ADLY MOTO
LUBRICATION SYSTEM
Assembling:
x Mounting the inner and outer rotor, then install the pump shaft.
When install the pump shaft, beware the dot mark on inner rotor point to the outer rotor dot mark.
x Locking the screw.
After installed, turning the pump slightly and confirm the function is normal.
Add the standard oil in pump then install it.
Installation:
x Install the pump back to crankcase based on reversed sequence.
x Install the dowel pin.
x Discard the old gasket and replace with new R. case cover gasket.
MENO
4-9
ADLY MOTO
FUEL SYSTEM
TROUBLE DIAGNOSE
Ignition not continuously when accelerate
x Ignition system abnormal
x Too thin of F/A mixture
Start-up function abnormal
x No spark of spark plug
x Compression pressure too low
x No fuel in carburetor
x Air stock inside air cleaner
x Stock of fuel pipe
x Defect of rubber film in carburetor
x Bad adjustment of fuel level
Difficult to start, Engine stops after start-up,
Idle speed not stable
x Stock of fuel system
x Ignition system abnormal
x Fuel/Air mixture too rich or lean
x Degeneration of gasoline
x Bad adjustment of idle speed
x Bad adjustment of fuel quantity
x Fuel or airflow stock of idle speed
x Too much fuel cause over flow
x Stock of starter plunger system
x Bad adjustment of fuel level
Too much fuel inside combustion chamber
x Air stock inside air cleaner
x Too much fuel cause over flow
x By passed air sock into fuel system
x Degeneration of gasoline
x Starter plunger defect
x Stock of idle system or chock system
Too thin of Fuel/Air mixture
x Stock of nozzles inside carburetor
x Stock of float valve
x Fuel level too low
x Stock of fuel system
x Throttle valve abnormal
Too thick of Fuel/Air mixture
x Starter plunger defect
x Choke cable clagged
x Float needle valve abnormal
x Too much fuel cause over flow
x Stock of airflow inside carburetor
x Stock of air cleaner
x Fuel level too high
Muffler make explore noise when
deceleration
x Too much air, too lean fuel
x Air stop valve abnormal
x Too thin of F/A mixture at idle speed.
5-1
ADLY MOTO
FUEL SYSTEM
CARBURETOR SET UP
x
Before remove the A/F adjusting screw, remember turns of setup into the end position.
The normal setup isΚ1 to 1 1/4 turns out
x After engine warm up, adjust the throttle valve adjusting screw to setup the standard idle speed.
Idle engine rev.Κ1400²100 rpm
x Slightly increase the engine speed for few times and release the throttle at idle engine speed.
x If the engine rev. is not stable, repeat above adjust procedure on fuel adjusting screw and throttle
adjusting screw until the engine speed is normal.
WarningΚ
Smoking prohibited
FUEL CUP
x Remove the fuel tube from carburetor.
Check
Check the function of fuel cup is normal or
not.
AIR CLEANER ASSEMBLY
x Pull to open 4 clips on air cleaner cover and
remove the cover.
x Loose 4 fixed bolts on the frame to
dismount the air cleaner.
Check
x Check the cleaner element to see if any dirt
or blocking.
x Replace the filter element if necessary.
x Install with the reverse procedure.
x Clean the element with solvent and sock
with clean engine oil.
5-2
ADLY MOTO
FUEL SYSTEM
Remove the Carburetor
y
y
y
y
y
y
Loose the fuel releasing screw of the
carburetor and release the fuel in float
chamber.
Remove the fuel tube and vacuum (-)
pressure tube.
Taking off the intake clamp.
Taking off the guide pipe clip.
Remove the choke cable from carburetor.
Remove the throttle cable.
Disassembly of carburetor
y
Remove the float chamber drain plug,
O-ring and accelerator pump cover screws
y
Remove the float chamber screws, the float
chamber and its O-ring
y
Remove the accelerator pump cover,
diaphragm spring and diaphragm
y
Remove the screw and float pin, then
remove the float.
5-3
ADLY MOTO
FUEL SYSTEM
y
Remove the needle valve
y
y
Using a backup wrench on the needle jet
holder, unscrew the main jet, then the
needle jet holder and nut.
y Remove the throttle valve cover screws,
then open the cover
WarningΚ
Be ware not to damage the main jet.
y
y
Unscrew and remove the slow jet
Remove the throttle valve
Remove the needle jet
Needle jet
Needle jet
5-4
ADLY MOTO
FUEL SYSTEM
y
y
Remove the jet needle
Set the cir-clip position to adjust the jet
needle.
y
Remove the seal cover, spring and plunger
Plunger
Seal cover
5-5
ADLY MOTO
ENGINE REMOVE AND INSTALLATION
ENGINE REMOVAL
Remove Engine
x Drain the engine oil.
x Remove the seat and the left footpeg
assembly.
x Remove the body cover assembly.
x Disconnect the negative battery cable.
x Remove the fuel tank.
x Disconnect the crankcase breather tube from
cylinder head cover and on cylinder.
x Remove the carburetor.
x Remove the exhaust system.
x Label and disconnect the following wires:
Spark plug wire
Alternator (there-pin connector)
Reverse and neutral switches
Starter cable
x Disconnect the reverse cable.
x Remove the shift pedal.
x Disconnect the clutch cable from the lifter
arm and detach the cable from the bracket.
x Remove the drive sprocket cover, remove the
drive sprocket and pull the drive chain back
so that it doesn’t interfere with engine
removal.
x Remove the engine mounting bolts, nuts and
brackets at the upper front, upper rear, lower
front and lower rear.
x Have an assistant help you lift the engine and
remove it from the left side.
x Slowly lower the engine to a suitable
working area.
y Remove the external oil pipe on cylinder
head cover for bigger clearance to remove
the engine.
6-1
ADLY MOTO
ENGINE REMOVE AND INSTALLATION
INSTALLATION
x Mounting the engine and tie-up fixed nuts with standard locking torque.
Locking torqueΚ
Fixed M10 nuts on bracketΚ 4.0 kg-m
x Place a floor jack under the engine. Again, be sure to protect the engine from the jack head with
a block of wood. Lift the engine to align the mounting bolt holes, then install the brackets, bolts
and nuts.
x The remainder of installation is the reverse of the removal steps, with the following additions:
a) Use new gaskets at all exhaust pipe connections.
b) Adjust the clutch cable and the throttle cable.
c) Fill the engine with oil. Run the engine and check for leaks.
x Finish mounting the engine; be sure to check the throttle cable tolerance.
Use reversed procedure to setup the parts that has been removed.
NOTEΚ
ϡʳ All cables and wiring has to be set into correct position
6-2
CYLINDER HEAD, VALVE
TROUBLE DIAGNOSE
Compression Pressure too high
x Too much carbon-residue inside
combustion chamber.
Emission with White Smoke
x Valves or valve guide attrition
x Oil seal on valve attrition
x Piston ring attrition
Noise
x Bad adjustment of valve gap
x Valve burn or spring damaged
x Camshaft or rock arm attrition
x Attrition of cam-chain guide comp.
Idle Speed not Stable
x Compression pressure too low
x Bad adjustment of valve clearance
x Valves banded or burn
x Valve timing not correct
x Damage of valve spring
x Sealing of valves and seats abnormal
x Leaking of cylinder head gasket
x Bottom of cylinder head damaged
x Wrong installation of spark plug
Valve gap adjustment 0.08 mm
7-0
ADLY MOTO
CYLINDER HEAD / VALVE
Attention of Operation
z Can be operated when engine installed on vehicle.
z Must cleaning before operating, avoiding dust enter the engine.
z Remove the gasket dust stay on joint face.
z Avoid to use screwdriver harm the joint face when remove the cylinder & cylinder head.
z Cleaning before check parts, and smear motor oil appointed in sliding face before installing.
Remove Cylinder Head
4
5
3
SEQ
Operation / Parts Name
Q’ty
2
1
Remarks
Disassembly
1
2
3
4
5
Cap nut of exhaust pipe ( 8mm )
Exhaust pipe of front section
Exhaust pipe gasket
Hex flange bolt
Intake manifold assembly
Assembly
5o1
2
1
1
2
1
ϡʳ
Unscrew the bolts cross-wise for 2~3 times.
ϡʳ
WARNING: Don’t knock cooling fin.
ϡʳ
Operation with sequence in reverse of disassembly.
ϡʳ
Tie-up nuts on cylinder head cover 2~3 times.
7-1
ADLY MOTO
CYLINDER HEAD / VALVE
Disassembly the cylinder head
SEQ.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Operation / Parts Name
Disassembly
Spark plug
Hex flange bolt
Hex flange bolt
Hex flange bolt
Hex flange bolt
Hex flange bolt
Hex flange bolt
Plain washer
Cylinder head cover assembly
Hex acorn washer face nut
Plain washer
Hex socket bolt
Dowel pin
Cylinder head
Cylinder head gasket
Assembly
15o1
Q’ty
1
3
3
1
2
1
1
5
1
4
6
2
2
1
1
Remarks
ϡʳ
ϡʳ
ϡʳ
ϡʳ
ϡʳ
ϡʳ
ϡʳ
6Ø28
6Ø52
6Ø35
6Ø80
6Ø115
6Ø136
6.5Ø14Ø1.6
ϡʳ
M10ØP1.5
10Ø20Ø2
10Ø105ØP1.25
8Ø12
ϡʳ
Check the gasket if wear out or damaged
ϡʳ
ϡʳ
ϡʳ
ϡʳ
Operation with sequence in reverse of
disassembly.
7-2
ADLY MOTO
CYLINDER HEAD / VALVE
Remove the camshaft and valve
SEQ.
1
2
3
4
5
6
7
8
9
10
Operation / Parts Name
Disassembly
Dowel pin
Rocker arm shaft comp.
Valve arm rocket assembly
Valve cotter
Valve spring assembly
Inlet/Exhaust valve
Valve stem seal
Hex flange bolt
Camshaft sprocket
Camshaft comp
Q’ty
2
2
2
8
4
4
4
2
1
1
Remarks
ϡʳ
ϡʳ
ϡʳ
The dowel pins are located underneath the
cylinder head cover.
Using 8mm bolt to pull out the shaft from R
side.
38T
Assembly
10o1
Operation with sequence in reverse of
disassembly.
ϡʳ
7-3
ADLY MOTO
CYLINDER HEAD, VALVE
damaged?
x Check the cam surface to see if it’s wear out
or
Working limit:
Replace if IN. cam under 35.57 mm
EX. cam under 35.58 mm
x Check the camshaft bearings to see if it’s
wear out or loose. If it’s loose or damaged then
change whole set of camshaft
x Check the rock arm and shaft
x Check rock arm inside diameter
Working Limit:
Replace if over 12.04mm
x Check the rock arm shaft outside diameter.
Working Limit:
Replace if under 11.92mm
NoteΚ
ϡʳ If the sliding face of rock arm wear out
then check the cam surface of the cam shaft
x Check the gap between rock arm and shaft.
Working Limit:
Replace if over 0.07 mm
Remove valves
Use valve spring holder tool to remove the
spring holder, cotter, spring, valve, and seal.
NoteΚ
ϡʳ Valve spring must use special tool to
disassembly.
ϡʳ Parts removed have to place in certain
order, assembly in opposite order.
special
Valve spring holder toolΚTLH3-03
7-4
ADLY MOTO
CYLINDER HEAD, VALVE
Check cylinder head
x Check the hole of spark plug and valve guide
to see if it’s damaged.
Check valve spring free length
Working limit:
Outer spring: Replace under 39.8 mm
Inner spring: Replace under 37.8 mm
Check valve and valve guide
x Check valve to see if it’s burned or banded.
x Check the movement between valve and
guide is smooth or not.
Valve outside diameter working limit:
Replace under 5.45 mm
Valve guide inside cylinder head working
limit:
Replace if over 5.53 mm
Cylinder head assembly
x Install valve seal, spring seat
NoteΚ
x ϡʳ Install new valve seal after removed.
x Install valve into cylinder head with some
lubrication oil on seal and spring seat
x Install springs, spring holder, cotter and use
special tool to assembly.
NoteΚ
ϡʳ Must use the special tool.
ϡʳ Valve cotter sharp edge face toward
cylinder head bottom.
special
Valve spring holder toolΚTLH3-03
x Use rubber hammer hit the valve top for
2 ~ 3 times to have better contact between
valve and cotter.
7-5
ADLY MOTO
CYLINDER HEAD, VALVE
Camshaft adjustment
x After install the cylinder head, it’s necessary
to setup the camshaft timing.
x Before put the timing chain on cam sprocket,
turn the “T” mark on ACG flywheel aim at
the crankcase sign.
7-6
ADLY MOTO
CYLINDER, PISTON
TROUBLE DIAGNOSE
Low compression pressure
x Piston ring wear-out, burn, or broken
x Cylinder, piston wear out or damaged.
Compression pressure too high
x Piston or combustion chamber stocks
with carbon material.
x Avoid to harm the cylinder inner surface and
piston face.
Exhaust with white smoke
x Piston ring wear-out, burn, or broken
x Cylinder, piston wear out or damaged.
Piston noise
x Piston, cylinder, or piston ring damaged.
x Piston pin and piston wear out
Disassembly of Cylinder / Piston
Operation / Parts Name
1
2
3
4
5
6
7
8
9
Disassembly Cylinder
Cylinder and gasket
Hex flange bolt
Cylinder
Oil ring
Cylinder gasket
Dowel pin
Disassembly Piston
Piston pin clip
Piston pin
Piston ring set
Piston
Assembly
Q’ty
2
1
1
1
2
2
1
1
1
Remarks
ϡʳ
WARNING: Don’t knock the cooling fin.
ϡʳ
ϡʳ
Clean the gasket stick on crank case.
Replace if necessary
Replace if deformed
ϡʳ
WARNING: Don’t knock the piston when remove the
ϡʳ
pin.
ϡʳ
Check the piston, piston pin, and piston rings.
Clean the carbon residual on ring and ditch on piston.
Beware not to break or damage the piston rings.
ϡʳ
Operation with sequence in reverse of disassembly.
ϡʳ
ϡʳ
9o1
8-1
ADLY MOTO
CYLINDER, PISTON
Cam chain tensioner
Removal
x Loosen the cam chain tensioner sealing bolt
and washer.
x The cam chain tensioner lifter shaft must be
retracted and locked into place before
removing the tensioner.
x Remove the tensioner mounting bolts and
detach the tensioer from the cylinder block.
x Clean all old gasket material from the
tensioner body and from its mating surface
on the cylinder block.
Installation
x Lubricate the friction surfaces of the
components with moly-based grease.
x Install a new tensioner gasket on the
cylinder.
x Cut the cable tie and remove the coat hanger
wire.
x Install the tensioner sealing bolt and a new
sealing washer and tighten the sealing bolt
to toque.
Disassembly of Piston
x The piston should have an IN mark on its
crown that goes toward the intake side of the
engine.
8-2
ADLY MOTO
CYLINDER, PISTON
x Wear eye protection and pry the cir-clip out
of its groove with a pointed tool.
x Push the piston pin part-way out, then pull it
the rest of the way.
Inspection of Piston
x Remove the top and second piston rings.
x Remove the upper oil ring side rail and
expander, then remove the lower side rail.
ϠWarningΚ
Be-ware not to scratch the piston during
ring removal.
8-3
ADLY MOTO
CYLINDER, PISTON
x Measure the piston ring-to-groove clearance
with a feeler gauge.
Working limit:
Top ring: replace above 0.11mm
2nd ring: replace above 0.09 mm
x Take-off piston rings and put into the
bottom of cylinder.
NoteΚ
ϠUse piston to press the ring into cylinder.
x Measure the opening gap of the piston ring
when pressed into cylinder.
Working limit:
Top ring: replace above 0.5mm
2nd ring: replace above 0.5mm
x Measure the hole of the piston pin.
Working limit:
Replace if inside diameter is over
17.04 mm
x Measure outside diameter of piston pin.
Working limit:
Replace if under 16.96 mm
8-4
ADLY MOTO
CYLINDER, PISTON
x Measure outside diameter of piston.
NoteΚ
ϠʳIt’s important to measure the outside
diameter with vertical position. The measure
point is about 5mm away from the bottom.
Working limit:
Replace if under 73.9 mm
Piston rings installation
x Each ring should be greased with oil.
WarningΚ
ϠʳDo not scratch piston and do not band piston
rings.
ϠʳThe mark on piston ring must face up.
ϠʳBe sure the rings rotate freely after install
into piston.
Piston installation
x Clean the gasket stick on top of crankcase.
x Install piston, piston pin, and clips.
WarningΚ
ϠʳThe “IN” mark on top of cylinder must aim
at the intake valve direction.
ϠʳPiston pin clip must not drop into crankcase.
Use cloth to seal the crankcase.
ϠʳCheck the piston clips is located in fix
position
8-5
ADLY MOTO
CYLINDER, PISTON
Cylinder Installation
x Put the dowel pins and gasket on top of
crankcase.
x Cylinder inside surface, piston, and piston
rings must be greased with oil.
x Beware of the pressure from piston ring
when install into cylinder.
WarningΚ
ϠʳBe careful not to damage or band the piston
ring.
ϠʳThe opening section of piston rings should
not be the same with piston pin and set into
120° to each other.
x Fit the cylinder into correct position.
8-6
CLUTCH, STARTING SYSTEM
Trouble Diagnose
Gear shafting is difficult
y Clutch gap is not setup properly.
y Clutch plate banded.
Clutch sliding at accelerating
y Clutch plate wearing.
y Resilience of spring is fatigue.
y Without the free play.
Clutch plate not opening
y The free play is too big.
y Clutch plate banded.
L. side level is too tight
y Clutch wire is damage.
y Connecting-rod institution is damage.
Disassembly of right crankcase cover and clutch lever
SEQ
1
2
3
4
5
6
7
8
9
10
Operation / Parts name
Disassembly
Hex flange bolt
R. crankcase cover
R. crankcase cover gasket
Dowel pin
Clutch lifter guide pin
Split spring pin
Clutch lever comp.
Oil seal
Needle bearing
Clutch lever spring
Assembly
Q’ty
12
1
1
2
1
1
1
1
2
1
Remarks
ϡʳ
ϡʳ
ϡʳ
ϡʳ
ϡʳ
ϡʳ
10o1
9-1
Use rubber hammer slightly hit the cover from
side way for easier removal.
Replace new gasket after disassembly.
Beware not to damage the pin.
Clean the plate if there is any grimy or dusty
material.
Beware not to damage the spring.
Operation with sequence in reverse of
disassembly.
ADLY MOTO
CLUTCH, STARTING SYSTEM
Disassembly of Clutch system
SEQ
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Operation / Parts name
Disassembly
Hex bolts
Clutch lifter plate
Cir clip
Needle bearing
Thrust washer
Clutch spring
Lock nut
Disc spring washer
Clutch center
Clutch friction disk
Clutch plate
Clutch pressure plate
Plain washer
Clutch cover comp assembly
Oil bush
Assembly
Q’ty
4
1
1
1
1
4
1
1
1
6
5
1
1
1
1
Remarks
ϡʳ
ϡʳ
ϡʳ
Beware not to damage the washer, replace if
damaged.
Open the lock section on the nut before
removal.
Band the washer open from the spanner nut
first.
ϡʳ
Check the friction plate wear out or not.
ϡʳ
Operation with sequence in reverse of
disassembly.
15o1
9-2
ADLY MOTO
CLUTCH, STARTING SYSTEM
Inspection of clutch
x To replace the needle bearing in the lifter
plate, taking out this stop-ring.
x Measure the clutch spring free length.
Spring free length limit: 34.9mm
x Measure the thickness of the friction plates.
Working thickness limit:
Replace if under 2.6mm
x Check the metal plates for warpage.
Clutch metal plate warpage limit: 0.20mm
9-3
ADLY MOTO
CLUTCH, STARTING SYSTEM
Disassembly of Starter Reduction Gear and Starting Motor
SEQ
1
2
3
4
5
6
7
8
Operation / Parts name
Disassembly
Hex flange bolt
Reduction cover
Starter gear cover gasket
Dowel pin
Starter reduction gear comp.
Starter reduction gear shaft
Hex flange bolt
Starter motor assembly
Q’ty
6
1
1
2
1
1
2
1
Remarks
ϡʳ
M6×32, M6×25
ϡʳ
Do not damage the dowel pins
ϡʳ
M6×25
ϡʳ
Operation with sequence in reverse of
disassembly.
Assembly
8o1
9-4
ADLY MOTO
CLUTCH, STARTING SYSTEM
Disassembly of Starter Gear and Generator
SEQ
1
2
3
4
5
6
7
8
9
10
Operation / Parts name
Disassembly
Hex flange bolt
L. crankcase cover
L cover gasket
Dowel pin
External cir-clip
Starter gear
Starter reduction gear
Hex socket bolt
Hex socket bolt
Stator comp.
Q’ty
12
1
1
2
2
1
1
2
3
1
Remarks
ϡʳM6×20
ϡʳSTW-15
ϡʳ M5Ø14
ϡʳM6Ø30
Assembly
10o1
ϡʳ
9-5
Operation with sequence in reverse of
disassembly.
ADLY MOTO
CLUTCH AND STARTING SYSTEM
Disassembly of Starter Driven Gear and Starter Clutch assembly
SEQ
1
2
3
4
5
6
7
8
9
10
Operation / Parts name
Disassembly
Hex flange bolt
Plain washer
Generator flywheel
Star socket bolt
Starting clutch outer comp.
Roller assembly
Starter clutch assembly
Starter driven gear comp.
Needle bearing
Plain washer
Q’ty
1
1
1
6
1
1
1
1
1
1
Remarks
ϡʳM12×45
ϡʳWhen
pull out the flywheel, beware not to lost the
semi-cycle key on crankshaft.
ϡʳUse special tool (TLH3-02) to pull out the
flywheel
ϡʳ Start socket boltΚM6×20
ϡʳReplace starter clutch set if the roller is damage.
ϡʳ26Ø31Ø24
ϡʳ26.5Ø40Ø2.5
Assembly
10o1
ϡʳ
9-6
Operation with sequence in reverse of
disassembly.
ADLY MOTO
CLUTCH, STARTING SYSTEM
Disassembly the starter clutch
x While holding the rotor, the gear should
turn smoothly clockwise, but not all
counter clock wise.
x Lift the driven gear off the rotor.
x Remove the 6 star socket bolts then remove
the outer clutch and the roller assembly.
x Check the outer clutch and one-way clutch
for wear and damage and replace them if any
problems are found.
9-7
ADLY MOTO
CRANKCASE, CRANKSHAFT
TROUBLE DIAGNOSE
Engine noise
x Loose of crankshaft bearings.
x Loose of bearings inside crankshaft connecting rod.
DISASSEMBLY OF THE CRANKCASE
SEQ
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Parts Name
Disassembly
Hex flange bolt
Breather tube clamp
Clutch wire receiver
Oil filter screen
Hex socket flange bolt
Breather plate
Breather plate gasket
Left crankcase
Crankcase gasket
Right crankcase
Dowel pin
Hex flange bolt
Plain washer
Stud bolt
Stud bolt
Q’ty
14
1
1
1
1
1
1
1
1
1
2
1
1
2
2
Remarks
ϡʳ M6Ø35, M6Ø45, M6Ø65
ϡʳ M6Ø12
ϡʳ Use rubber hammer slightly hit the gear to remove the
ϡʳ
ϡʳ
ϡʳ
ϡʳ
ϡʳ
ϡʳ
crankcase.
Scratch off the gasket which between crankcases and use
new gasket after disassembly.
Do not damage the crankcase surrounding edge.
Check the oil seal is attrition or not.
M12Ø15
12.5Ø20Ø2
The stud bolts are not necessary to remove unless it’s
banded or defect
Assembly
15o1
ϡʳ Operation with sequence in reverse of disassembly.
10-1
ADLY MOTO
CRANKCASE, CRANKSHAFT
DISASSEMBLY OF THE TRANSMISSION GEAR
SEQ
Parts Name
Q’ty
Remarks
Disassembly
1
2
3
4
5
6
7
8
9
Hex socket bolt
Bearing setting plate
Main shaft assembly
Counter shaft assembly
Reverse idle gear shaft
Thrust washer
Reverse idle gear
Reverse idle gear bush
Thrust washer
1
1
1
2
1
2
1
1
1
ϡʳ The gear assembly should pull out at the same
time with drum shaft assembly.
ϡʳ Beware keep the washer and cir-clip in
original order.
ϡʳ The ball and needle bearings are located on
crankcase. Check the bearing is functioning
well or not.
ϡʳ Be-ware of the gear set sequence and assembly
direction.
Assembly
9o1
ϡʳ
Operation with sequence in reverse of
disassembly.
10-2
ADLY MOTO
CRANKCASE, CRANKSHAFT
DISASSEMBLY OF THE GEAR SHAFT MECHANISM
SEQ.
Parts Name
Q’ty
Remarks
1
1
1
1
1
1
2
1
1
1
1
2
1
1
1
2
1
2
1
1
1
ϡʳ Parts from sequence 1 to 11 are removed during previous
Disassembly
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Gear shift arm assembly
Shifter collar
Hex flange bolt
Guide plate
Rotor assembly
Bushing
Bearing holder plate
Shift pin
Shift drum center
Hex flange bolt
Gear shift drum stopper assembly
Hex socket bolt
Hex washer face bolt
Neutral switch rotor comp.
Reverse stopper cam comp.
Hex flange bolt
Reverse shift stopper comp.
Gear shift fork assembly
Gear shift spindle comp
Hex socket bolt
Gear shift drum assembly
Assembly
21o1
L crankcase disassembly.
ϡʳ Parts from sequence 12 to 17 are removed during
previous R crankcase disassembly.
ϡʳ Check the tolerance between the forks and drum.
ϡʳ Operation with sequence in reverse of disassembly.
ϡʳ Apply oil during assembly.
10-3
ADLY MOTO
CRANKCASE DISASSEMBLY
GEAR SHIFT MECHANISM
x Check the small spring locates on the
gearshift arm to see if it’s too loose or not.
x Check the stopper plate is loose or not.
x Check the roller guide.
Working diameter limit:
Replace if under 5.7mm
x Check the inside diameter of the forks.
Working diameter limit:
Replace if over 13.04mm
x Check the outside diameter of the forks.
Working diameter limit:
Replace if over 12.96mm
x Check the fork ear thickness applied to gear
shaft area.
Working diameter limit:
Replace if under 4.50mm
Center gear shift fork
x Check the shift drum grooves for wear,
especially at the points.
10-4
R/L gear shift fork
ADLY MOTO
CRANKCASE, CRANKSHAFT
REMOVE OF THE CRANK SHAFT
SEQ
Parts Name
Q’ty
Remarks
Disassembly
1
2
3
4
5
6
Shaft comp assembly
Crank shaft assembly
Radial ball bearing
Semi-cycle key
Radial ball bearing
Radial ball bearing
1
1
1
1
1
1
ϡʳ The crankshaft assembly normally is not for
disassembly. It will generate more problems if
the L/R cranks are disassembled.
ϡʳ The semi-cycle key normally was took out
when disassembly the flywheel. Beware keep it
in certain place to avoid lost.
Assembly
6o1
ϡʳ Operation with sequence in reverse of
disassembly.
10-5
ADLY MOTO
CRANKCASE, CRANKSHAFT
x Check the connecting rod side clearance
with a feeler gauge.
The connecting rod side clearance
limit is 0.80mm
x Check the connecting rod radial clearance
with a dial indicator.
The connecting rod big end radial clearance
limit is 0.05mm
x Place a V-block on each side of the
crankshaft (A) and measure run-out at the
ends (B)
10-6
ADLY MOTO
CRANKCASE, CRANKSHAFT
x Check the connecting rod.
Working diameter limit:
Replace if over 17.10mm
x Check the balancer gear and bearing
journals for wear or damage.
x Use a special tool (TLH3-01) to pull the
crankshaft and push the left crankcase onto
the crankshaft.
10-7
ADLY MOTO
FRONT WHEEL / SUSPENSION / STEERING
Attention of Operation
ΘRemove the body cover and support the frame body bottom before remove the front wheel, don’t
invert the front wheel when front wheel depart ground.
Diagnosis of Trouble
Heavy steering movement
Steering handle not straight
x
x
x
Loose, not correct adjustment or damaged,
right (or left) link Assembly.
x
x
Steering shaft bended.
Suspension arm, knuckle damaged.
Air pressure too low of front tire.
Rim radial ball bearing broken.
Brake efficiency abnormal
x
x
x
x
Brake lining wear-out.
Brake pads adjust not correct or wear out.
Brake drum wear-out.
Tire wear-out.
Front wheel shaking or deviation
x
x
x
x
Front rim defected.
Loose or damaged of front rim bearings.
Tire defect.
Bad adjustment or defected of the right (or
left) link assembly.
x
Bad adjustment or defected of the right (or
left) knuckle.
11-1
ADLY MOTO
FRONT WHEEL / SUSPENSION / STEERING
Disassembly of Front Wheels
SEQ
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Operation / Parts name
Disassembly front wheels (L/R)
Rubber cover
Cotter pin
Scotch nut
Plain washer
Wheel nut
Front shaft hub
Front rim
Front tire
Collar
Collar
Oil seal
Radial ball bearing
Hex socket bolt
Brake disc
Assembly wheels
˄ˇШ˄ʳ
ʳ
Q’ty
2
2
2
2
8
2
2
2
2
2
4
4
8
2
Remarks
ϡʳ
ϡʳ
ϡʳ
M18
18ͪ40ͪ4.5
M10ͪ15
ϡʳ
29.3ͪ43.6ͪ4.5
6004ZZCM/2A-TO
ϡʳ
Diameter=164mm
ϡʳ
ϡʳ
Assembling with sequence in reverse of
disassembly.
WARNING:
Change the R/L bearing set if necessary.
11-2
ADLY MOTO
FRONT WHEEL / SUSPENSION / STEERING
Disassembly of Suspension Arm
Operation / Parts name
Disassembly (L/R)
1
2
3
4
5
6
7
8
9
Hex flange lock nut
Plain washer
Hex washer face bolt
L/R down suspension arm
Hex flange bolt
Front cushion assembly
Cotter pin
Plain washer
Scotch nut
Assembly
9Ш1
Q’ty
2
2
1
2
1
2
2
2
2
Remarks
ϡʳ
ϡʳ
ϡʳ
ϡʳ
ϡʳ
ϡʳ
ϡʳ
ϡʳ
M10
10ͪ20ͪ2
10ͪ55
M10ͪ40
3ͪ32
12ͪ22ͪ2
M12
Assembling with sequence in reverse of
disassembly.
11-3
ADLY MOTO
FRONT WHEEL / SUSPENSION / STEERING
Disassembly of Steering Shaft Assembly
SEQ
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Operation / Parts name
Disassembly steering shaft Ass’y
Cotter pin
Nylon nut
Oil seal
Steering shaft bushing
Internal cir-clip
Oil seal
Cotter pin
Scotch nut
Plain washer
Tie-rod assembly
Hex socket bolt
Handle bar clamp
Handle bar
Nylon nut
Plain washer
Q’ty
1
1
1
1
1
1
2
2
2
2
4
2
1
2
2
Remarks
ϡʳ
M10
10ͪ20ͪ2
ϡʳ
6ͪ25
ϡʳ
M10ͪP1.25
10ͪ22ͪ2.5
ϡʳ
ϡʳ
11-4
ADLY MOTO
FRONT WHEEL / SUSPENSION / STEERING
Disassembly of Steering Shaft Assembly
SEQ
16
17
18
19
20
21
Operation / Parts name
Disassembly knuckles
Handle bar bottom clamp
Steering shaft assembly
Hex washer face bolt
Bracket
Steering shaft holder
Holder spacer collar
Assembly steering shaft Ass’y
21Ш˄
Q’ty
2
1
2
1
2
2
Remarks
ϡʳ
10ͪ65
ϡʳ
Assembling with sequence in reverse of
disassembly.
WARNING: Adjusting gap of throttle.
ϡʳ
11-5
ADLY MOTO
REAR WHEEL / SUSPENSION / BRAKES
Diagnosis of Troubles
Rear wheel shaking or deviation
z
The shape of rear rim damaged.
z
Rear wheel axle damaged.
Brake efficiency abnormal
z
Brake lining wear-out.
z
Brake pads adjust not correct or wear out.
z
Swing arm sub Ass’y damaged
z
Brake drum wear-out.
z
Rear rim bearing defected.
z
Tire wear-out.
z
Rear suspension too soft
Spring too soft or adjust not correct.
z
Assembly/Disassembly Rear Wheel
SEQ
Operation / Parts name
Disassembly Wheels
Q’ty
1
2
3
4
5
6
7
8
Rubber cover
Cotter pin 3*32
Scotch nut
Plate washer 18*40*4.5
Hex washer face bolt 10*20
Shaft connector
Rear rim
Rear tire
2
2
2
2
4
2
2
2
Assembly
8Ш1
Remarks
Assembling with sequence in reverse of
disassembly.
ϡʳ
12-1
ADLY MOTO
REAR WHEEL / SUSPENSION / BRAKES
Disassembly of Parking Brake and Rear Disc
SEQ
1
2
3
4
5
6
7
8
9
10
11
12
13
Operation / Parts name
Disassembly parking brake
Rubber cover
Cotter pin
Scotch nut
Plain washer
Rear wheel assembly
Hex nut
Hex socket bolt
Rear brake panel connector
Rear brake disk
Hex washer face bolt
Rear brake caliper assembly
Parking brake cable
Right lever assembly
Assembly
13Ш1ʳ
Q’ty
1
1
1
1
1
2
3
1
1
2
1
1
1
Remarks
ϡʳ
M8ͪ18
ϡʳ
10ͪ28
ϡʳ
Assembling with sequence in reverse of
disassembly.
12-2
ADLY MOTO
REAR WHEEL / SUSPENSION / BRAKES
Disassembly of Brake System
SEQ
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Operation / Parts name
Disassembly brake system
Cotter pin
Fix pin
External cir-clip
Plain washer
Oil ring
Brake pedal comp
Return spring
Oil tube fixing bolt
Hex flange bolt
Hex washer face bolt
Rear master cylinder sub assembly
Copper plain washer
Hex washer face bolt
Brake hose hex bolt
Rear brake hose
Hex washer face bolt
Rear brake caliper assembly
Q’ty
1
1
1
1
2
1
1
1
2
1
1
9
5
3
1
2
1
Remarks
ϡʳ
2ͪ20
ϡʳ
STW-16
ϡʳ
ϡʳ
10ͪ35
M8ͪ25
6ͪ15
10.2ͪ15ͪ1
6ͪ12
10ͪ22
ϡʳ
10ͪ28
ϡʳ
ϡʳ
ϡʳ
ϡʳ
12-3
ADLY MOTO
REAR WHEEL / SUSPENSION / BRAKES
Disassembly of Brake System
SEQ
Operation / Parts name
Disassembly brake system
Q’ty
18
19
20
21
Hex flange bolt
Front brake caliper assembly
Hex flange bolt
Back hose
4
2
1
1
Assembly
21Ш1ʳ
Remarks
ϡʳ
M8ͪ22
ϡʳ
M6ͪ20
ϡʳ
12-4
Assembling with sequence in reverse of
disassembly.
ADLY MOTO
REAR WHEEL / SUSPENSION / BRAKES
Disassembly / Assembly of Rear sprocket Assembly
SEQ
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Operation / Parts name
Disassembly Rear Brake
Hex flange bolt M8*15
Chain protect cover
Hex flange bolt 6*30
Front chain protect
Drive chain guide
Hex bolt 6*10
Drive sprocket fixing plate
Drive sprocket assembly
Drive chain assembly
Nylon nut M10*P1.25
Hex socket flat head bolt
M10*27
Drive sprocket
Rear sprocket flange
External cir-clip
Rear wheel axle
Assembly
15Ш1
Q’ty
Remarks
3
1
2
1
1
2
1
1
1
4
4
1
1
1
1
Assembly with sequence in reverse of
disassembly.
ϡʳ
12-5
ADLY MOTO
REAR WHEEL / SUSPENSION / BRAKES
Disassembly / Assembly of Swing arm sub Assembly & Rear Cushion
SEQ
Operation / Parts name
1 Rear wheel axle
2
3
4
5
6
7
8
9
Disassembly rear cushion Ass’y
Nylon nut
Hex flange bolt
Rear axle holder
Hex flange bolt
Hex flange bolt
Nylon insert lock nut
Plain washer
Rear cushion assembly
10
11
12
13
14
15
Disassembly swing arm sub Ass’y
Nylon nut
Plain washer
Swing arm seal cover
Swing arm bolt
Collar
Swing arm sub assembly
16 Hex flange bolt
17 Bushing
18 Rubber bushing
Assembly
Rear cushion 9Ш2
Swing arm sub 15Ш˄˃
Q’ty
1
Remarks
1
1
1
1
1
2
2
1
1
1
2
1
1
1
2
2
1
ϡʳ
12-6
Assembly with sequence in reverse of
disassembly.
ADLY MOTO
ELECTRICAL DEVICE
Attention of Operation
WARNINGΚ
ϠʳBattery electrolyte contains sulfuric acid, which can cause severe burns. Avoid contact of skin,
eyes, or clothing
ϠʳWhen sulfuric acid water spill into clothing will stick to skin. Take off the clothing and flush
with water.
z
Battery can be charged and discharged. Without charging, the battery will have less lifetime.
z
If the battery have short circuit inside, both terminal will not have voltage existed. Besides, the
regulator rectifier lost the function and shorter lifetime.
If the battery stay too long without use, it will lost power and have less capacity. The battery
need to charge each 2~3 months.
z
z
After fill up the electrolyte, the new battery will generate voltage. It’s necessary to recharge if
the voltage is low. It’s necessary to leave the battery for more than 20 minutes before sealing
the cap. It will increase the lifetime of new battery if recharged before installed.
z
Do not unplug the electrical components from wire hardness when the current is working. This
will cause too high of voltage and damage other compounds such as rectifier, light bulbs…etc.
Turn off the main switch to OFF before the operation.
z
z
The Maintenance Free battery does not need to refill electrolyte or water.
All charge system needs to be installed before check.
z
Do not use quick charge unless it’s in urgent.
z
The battery needs to be taking out from vehicle when doing charge work.
z
When checking the voltage, must use the electrical meter.
Diagnosis of troubles
No Electrical Power
x
x
x
x
Over discharged of the battery
Wire hardness did not connected to
the battery
Bad connection of charge system
Bad contact of the lighting system
cause short circuit
x
Fuse broken
x
Main switch defect
Low Voltage
Charge System no function
x
Bad connection of the wire hardness
connectors
x
Battery charges insufficient
x
Bad connection
x
Regulator rectifier defect
No Continues Current
x
Main wire hardness broken or
short-circuit
x
x
x
Regulator rectifier defect
AC Generator defect
Fuse broken
x
Bad contact of battery with main wire
hardness
13-1
ADLY MOTO
ELECTRICAL DEVICE
Check Voltage of Battery
z
Remove rubber strap on battery ,
disassembly connection wires of
battery , check voltage between battery
terminals.
Charging sufficiently: over 12.8 V
Charging insufficiently: 11.5-12.8V
ϡʳ
WARNING:
z
Must check battery voltage with
digital voltmeter.
z
Remove the negative (-) cable first.
Check Charging Status
NOTICE:
z Check battery voltage when battery
charged completely, over 12.8 V.
z Engine starting will consume a lot
power of battery.
z Assembly voltmeter to terminal of main
fuse, start engine, open light, raising
RPM and check charging voltage &
current.
Charging current: 0.5̑˅ Amp/5000rpm
Voltage of charging control:
14~15V/5000rpm
Check Voltage of Head Light
Operation procedure:
Check head light with wires connecting.
z Start engine, turn “ON“ light switch,
open high beam.
ϡʳ
z
z
Check voltage between green (+) &
black (-) guide wires.
Control Voltage: 11~15V.AC/5000rpm
13-2
ADLY MOTO
ELECTRICAL DEVICE
Ignition Coil Conduction Test
Θʳ Check first coil resistance of ignition
terminal.
Standard valve (20к): 0.1̑˃ˁˆӨʳ
WARNING:
Check ignition status with
performance tester due to this test has its
own standard.
ʳ
ΘCheck second coil resistance between
spark plug cap & (-) terminal.
Standard valve : 10.5̑˄ˈˁˈʳ˾Өʳ
ʳ ʳ ʻ̆̃˴̅˾ʳ̃˿̈˺ʳ˶˴̃ʳ˼́̆̇˴˿˿˸˷ʼʳ
ΘRemove spark plug cap from high tension
coil.
ΘCheck second coil resistance between high
voltage & (-) terminal.
Standard valve : 2.5̑ˇʳ˾Өʳ
(without spark plug cap)
Remove main switch
ΘDisconnect main switch wire.
ΘPull the main switch Bracket inside front cover.
ΘPush the stopper on main switch underneath front cover then push out the main switch.
Check main switch
Remove connector of main switch wire, check conductivity between each terminal.
Color
R
Bk
Ϥ
Ϥ
OFF
ON
13-3
ADLY MOTO
ELECTRICAL DEVICE
y Head light and position light
y Start switch
y Horn switch
y Signal light switch
y Engine stop switch
Exchange of Bulbs
Head light bulb
z Remove handle bar and front cover
z Press down the bulb base and turn left to change
head light bulb.
13-4