Adly Motor GTA-50 Service manual

SERVICE MANUAL
GTC-50
January, 2011
High power Engine
HER CHEE INDUSTRLAL CO., LTD.
INTRODUCTION
This Service Manual is provided as the technical information for the
check & preparation of ADLY GTC-50 scooter, and the direction edited
is given in diagrams with "Operation Sequence", "Key Points", and
"Adjustment of Check" for reference of the service staffs.
This Service Manual is finished in accordance with the model of
GTC-50 Taking new model as standard if there are differences between
the model described in this manual and the actual scooter.
HER CHEE INDUSTRIAL CO., LTD.
CONTENTS
Chapter
Information for Preparation........................................................... 1
Diagnose of Brake Down.........................................................…. 1
Check & Adjustment.................................................................... 2
Engine Installation of Lubrication ............................................................ 3
Fuel system .................................................................................
Engine assembling/disassembling ................................................ 5
Cylinder head, Cylinder, and Piston ............................................. 6
Starter / Driving Wheel ................................................................ 7
Clutch / Driven Wheel Assembly ................................................. 7
Final Transmission Mechanism .................................................... 8
Crank Shaft Case, Transmission Box ........................................... 9
4
Chassis Front Wheel, Front Suspension, Front Brake ............................... 10
Rear Wheel, Rear Suspension, Rear Brake .................................
11
Electrical Device ........................................................................... 12
Wiring Diagram ........................................................................... 13
ADLY MOTO
1. INFORMATION FOR PREPARATION
*** Attention of Operation ***

All the washers, oil rings, clamping rings, cotter pins, etc., shall be replaced by new one when
they have been disassembled.

After slightly locking the screws, bolts and nuts, etc., first, tighten them according to the
tightening tension stipulated with the opposite angle's way from big diameter's screw to small
diameter's screw, and from inside to outside.

Must use the pure and original oil, grease, and parts.

Must use the professional tools and the general tools to repair.

Must clean the parts checked after disassembling the parts, and put the grease to lubricate the
operation face when assemble the parts.
1-1
ADLY MOTO
*** Attention of Operation ***
 Must lubricate to the appointed part with grease oil, and the canned lubrication.

To confirm the locking parts and check the operation of each part after assembling.

Must coordinate with each other and pay attention to the safety when working over 2 people.
 Meaning of Pattern and Notes
The patterns and notes below are the direction and attentions of this service manual.
Lubrication
Use the appointed lubricant in the appointed part.
Use the lubricant to lubricate
The part of using special tools.
Use the general tools.
Use new one after disassembling.
Attention!
Danger and important operation!
1-2
ADLY MOTO
SPECIFICATIONS
TYPE
50 CC
LENGTH
1750 mm
WIDTH
685 mm
HEIGHT
1140 mm
WHEEL BASE
1220 mm
NET WEIGHT
75Kg
DISPLACEMENT
49.3 c.c.
BORE X STROKE
40 x 39.2mm
ENGINE TYPE
2 Stroke ,Single cylinder, AIR COOLED
COMPRESSION RATIO
7:1
IGNITION
C.D.I. IGNITION
STARTER
ELECTRIC & KICK
SUSPENSION
Oil Damped shock absorber FRONT / REAR
TRANSMISSION
AUTOMATIC, CVT type
TIRE
120/70-12
FRONT BRAKE
DISC
REAR BRAKE
DRUM
1-3
ADLY MOTO
Locking Torque
Adopt the standard torque locking for the item unlisted.
Engine
Place of Locking
Q'ty Screw Diameter Locking Torque
(mm)
(Kg-m)
Screw of Cylinder Cap
4
6
1.0
Flywheel Nut
1
10
3.8
Clutch Jacket Nut
1
1
3.8
Driving Disc Nut
1
28
5.5
Special Screw of Sliding Driving Disc
3
5
0.45
Nut of Transmission Disc
1
10
3.8
Oil-check Screw
1
8
1.3
Joint Screw of Exhaust manifold
2
6
1.2
Exhaust Pipe Support Screw of Muffler
2
6
1.2
Spark Plug
1
14
1.4
Bolt of Crank Shaft Case
6
6
10
Bolt of Engine Installation
1
8
5.0
Chassis
Place of Locking
Q'ty Screw Diameter Locking Torque
(mm)
(Kg-m)
Spanner Nut of Handle Steering Steam
1
25
7.0
Front Wheel Axle Nut
1
10
4.5
Rear Axle Nut
1
14
11
Rear Brake Arm Screw
1
5
0.6
Upper Screw of Rear Shock Absorber
1
10
4.0
Lower Screw of Rear Shock Absorber
1
8
2.7
Engine Mounting Bracket
1
8
6.0
Standard Locking Torque
Type
Locking Torsion(Kg-m)
5mm Screw
0.4
6 mm Screw
1.0
6 mm Hex Washer Face Bolt / Nut
1.2
8 mm Hex Washer Face Bolt / Nut
2.7
10 mm Hex Washer Face Bolt / Nut
4.0
1-4
ADLY MOTO
The following drawing that shows the disassembling situation of the cover parts for Fox Plus scooters.
1-5
ADLY MOTO
1-6
ADLY MOTO
1-7
ADLY MOTO
1-8
ADLY MOTO
DIAGNOSIS OF BREAKDOWN
Start-up difficult or can not start
This content is the explanation of diagnosis of the engine‘s breakdown, please see each content for
reference of the breakdown diagnosis not mentioned here.
Loose carburetor cup screw and check if
the fuel arrive carburetor

no fuel


Fuel


Remove spark plug, put into the cap, and
connect the spark plug to ground (negative),
check the spark condition.

Spark weak or
no spark



spark strong


Check compression pressure

Weak or no


pressure is good


Start-up engine base on the instruction

Igniting but no
start


Fuel tank has no fuel
Blocking of fuel tube
Blocking of float valve
Blocking air of fuel tank cap
Blocking of fuel filter
Spark plug defect or dirty
CDI defect
ACG defect
Short circuit of H.T. coil
Ignition wire broken or short
Main switch defect
Piston ring too weak
Reed valve defect
Cylinder and piston ring wear out
Leaking of cylinder gasket
L/R crankcase leaking
Bad adjustment of idle screw
Air leaking from intake manifold
Bad ignition timing

without exploration
Remove spark plug and check again

Wet

Over flow in carburetor
Throttle valve opened too much

spark plug is dry
Wait for 30 min. and remove carburetor,
connect tube to fuel-adding path and blow

can not pass
1-9
Starter plunge defect
ADLY MOTO
Engine operation is not smooth after starting
Loose carburetor cup bottom screw and
check if the fuel arrive carburetor

no fuel
fuel



Remove spark plug and check

Dirty or
discolor

Fuel tank has no fuel
Blocking of fuel tube
Blocking of float valve
Blocking air of fuel tank cap
Spark plug is dirty
Wrong type of spark plug
clean
Check the spark condition by put the spark
plug into cap and connect to ground

Weak or no
spark fair


ACG defect
Short circuit of H.T. coil
Ignition wire broken or short
Main switch defect

Cylinder and piston ring wear out



Check compression pressure
compressing
Check carburetor is blocked or not
not blocked
no compression  Leaking of cylinder gasket
 Reed valve leaking
 L/R crankcase leaking
Incorrect
Adjust Air screw of carburetor
adjust well
Bad adjustment
Carburetor clip leaking air or not
no

Vent tube blocked

Check CDI

ACG defect

A/F mixture too thick (loose screw)

A/F mixture too thin (tighten screw)

Intake clip loose

Air intake loose air
Blocked
Check ignition timing
correct
Spark plug is defect or dirty
CDI defect
Yes

Remove starter plunger wire and check

no resistance
1-10
Plunger defect
ADLY MOTO
Lost power on high speed
Speeding up slightly on flat road
RPM rising
RPM not rise
Remove spark plug and check
clean
Dirty or
discolor
Check ignition timming (with timming
light)
correct
Check compression pressure
compressing
Timing
incorrect

Air filter blocked


Fuel blocked, Fuel tank cap blocked
Muffler is blocked

Spark plug is dirty

Wrong type of spark plug

CDI defect

ACG defect

Cylinder and piston ring wear out
no compression  Leaking of cylinder gasket
 Reed valve leaking

Check carburetor is blocked or not ?
not blocked
Air or Fuel path blocked

A/F mixture too thin


Fuel quality is bad
Carbon deposit in combustion
chamber

Ignition timing too early
Blocked
Check engine is over heat or not ?
not

Over heating

Continuously running with high speed or
acceleration without over heating

Knocking
no knocking
1-11
Carbon deposit in combustion
chamber
ADLY MOTO
Bad idle, not smooth at low speed
Check ignition timming (with timming
light)
Correct
Incorrect
Adjust carburetor air screw
Adjusted well
bad adjustment
Check carburetor clip leaking or not ?
not leaking
Remove spark plug, put into the cap, and
connect the spark plug to ground (negative),
check the spark condition.
Leaking
Spark weak or
no spark
spark strong

CDI defect

ACG defect

A/F mixture too rich (loose screw)

A/F mixture too lean (tighten
screw)

Bad carburetor locking

Intake manifold leaking

Spark plug dirty or defect
CDI defect
ACG defect



Short circuit of H.T. coil
Ignition wire broken or short
Main switch defect

Connection

Plunger defect

Plunger defect


Remove starter plunger wire and check
with resistance
Connect starter plunger with 12V battery
for 5 Min. tubing pipe with fuel-adding
return, yhen blow it
No resistance
Blowing
not blown
1-12
wire is bad
ADLY MOTO
Engine running not smooth with middle ~ high RPM
Check ignition timming (with timming
light)
correct
Incorrect
Check fuel flow
well
Poor
Check carburetor nozzle blocked or not ?
not blocked
Connect starter plunger with 12V battery
for 5 Min. tubing pipe with fuel-adding
return, yhen blow it
CDI defect

ACG defect

Low fuel level


Tube and fuel filter blocked
Fuel tank cap is blocked

Cleaning

Connection wire is bad

Plunger defect

Plunger defect
Blocked
Remove starter plunger wire and check
with resistance

No resistance
Blowing
not blown
1-13
ADLY MOTO
Spark plug has no spark
Change new spark plug and check again
Spark weak or no spark
Check loosing between spark plug cap and
high tension coil

Original spark plug defect

Spark plug cap defect
High tension coil defect
Spark strong
Loosing

Abnormal
Check concerned parts

Bad Main switch
No loose
Remove CDI unit over the plug cap,
connect ground and check spark

Bad high tension coil
Bad pulse coil
Wire broken
Bad connection

CDI unit defect

Ignition coil defect

Normal

Normal
Check Cdi with CDI tester or replace new
CDI unit to test

Abnormal
Normal
Check ignition timing
Abnormal
1-14
ADLY MOTO
Charging poor
Start engine to check voltage among
terminals of battery
High voltage
Voltage in normal
Voltage not boost
Check ACG charging coil resistance
Normal range
Check voltage of red and green wiring on
rectifier connector
Out of range

Rectifier
Battery aging

Bad battery

Bad starter


Yellow wiring broken
Connection poor

Wire broken

Bad rectifier

Plunger defect

Wire broken

No voltage
Battery with voltage
Remove rectifier connector and check each
device
Normal
Abnormal
Check ACG coil resistance value
Normal
Abnormal

1-15
AC Generator defect
ADLY MOTO
2. CHECK AND ADJUST
Way of Check and Service……………………2-1
Disassembly of External Parts………………..2-3
Layout of Maintenance Items…………………2-6
Way of Check & Adjustment
1. Mark “○” is checking time.
2. Mark “☆” is the regular exchange of service items.
This exchange time is just for general riding of the majority not for the special use, please arrange with
this principle according to the difference of the riding condition.
Service Items
Service Time (month)
Before
riding
Judgement Standard
Remarks
1st each 6 each 12
Operating Device
○
Handle- Play, loose/tight
○
Operation
○
Wheels- Right/left turn round angle
Front Fork-Damage
Installation of shaft
○
○
Direction Post
○
○
Direction Post
○
Shaft Gap
Brake Device
○
○
○
○
○
○
○
○
○
○
○
○
Brake- Play
Try to run
○
Correct brake
○
Wires- Loose / tight and damage
Gap of casing & brake
Play of brake lever
10-20 mm
○
Wore of brake & operating parts
Wore & Damage of casing
○
Direction
Standard diameter
110 mm
Limitation
110.5mm
front
Riding Device
Tires-Air pressure of tires
○
○
○
Air pressure 1.50 kg/cm2 1.75 kg/cm2
tire
2-1
rear
120/90-10
130/90-10
ADLY MOTO
Service Items
Service Time (month)
Before
riding
Judgement Standard
Remarks
1st each 6 each 12
Riding Device
Tires
Check & damage of tires
○
○
○
Abnormal & ditch in tires
○
○
○
○
○
Bolt & nut of tires locking
Ditch-front and rear wheel
till 0.8 mm
Flocking torsion
Front wheel – 4.0~5.0 kg-m
Rear wheel –10~12 kg-m
Damage of wheels ,disc
○
○
○
Tightness of front bearing
○
Tightness of rear bearing
○
Vibration of wheel
Front wheel – horizontal under
3 mm, vertical under 3 mm,
Rear wheel – horizontal under
3 mm, vertical under 3 mm
Suspension device
Spring
○
-damage
Spring of
shock
absorber
○
Suspension arm – damage of joint gap
& arm
○
Tightness of installation
Power transmission device
Clutch
○
-action
Crankcase
○
○
oil leakage or damage
Transmission gear oil
○
○
○
○
○
Electric device
Ignition device
-condition of ignition
spark plug
Battery
○
-connection of terminal
○
Wiring of electrical appliance – damage
or loose in connection place
2-2
Gap of spark plug 0.6~0.7
mm
ADLY MOTO
Service Items
Service Time (month)
Before
riding
Judgement Standard
1st each 6 each 12
Engine
○
○
○
○
exhaust
○
○
air filter
○
○
Oil and oil filter
○
○
Oil leakage
○
○
Body – starting & abnormal noise
○
low speed & accelerating
Idle : 1800±100 rpm
Lubrication device
Warning light lighting
Fuel installation
○
Gasoline filter is dirty
○
Leakage of fuel
○
Throttle gate & choke
○
Fuel filter is clogged
○
○
Oil level
Alteration of pipes
each 2 years
Lights & direction lights
○
Action
On/off normal , dirty , damage
○
Rear view mirror
○
○
○
○
Instrument –action
Exhaust pipe & muffler
Installation loosed or damage
○
Function of muffler
○
Frame & body –loose or damage
○
Abnormal from previous day –confirm
normal
Others
○
- greasing of each part
○
○
○
Cleaning combustion chamber , exhaust
pipe , and carbon muck in muffler
Disassembly of External Parts
Remove the external parts for checking and adjustment
2-3
Remarks
ADLY MOTO
Read cover
* Open the seat.
* Remove the 2 hex-nuts, 1 bolt to
remove the luggage rack.
* Remove 10 self-tapping screws and 2
round-headed bolts..
* Remove the central and body cover
* Install with reverse sequence.
*ATTENTION:
- Please do keep away the unit of the body
and the pedal from damages.
- Before tightening the screws, be sure of
correct matching of all units.
Cowling
* Remove 4 tapping screws and 2 roundhead bolts.
* Separate the joint of inner parts and
remove the cowling.
* Install with reverse sequence.
Front Cover
* Remove 4 tapping screws and 3 hexnuts.
* Separate the joint of inner parts and
remove the cowling.
* Install with reverse sequence.
*ATTENTION:
- Be sure of not damaging the front pane
land the front inner union (the convex
and concave portions).
- While tightening the screws, be sure of
the matching with the luggage case.
2-4
ADLY MOTO
Floor panel
* Remove the L/R side cover and body
cover.
* Remove 4 hex bolts.
* Separate the front interior covering joint
(the claw and the groove) and remove
the pedal.
* Follow the sequence in reverse order for
assembly.
*ATTENTION:
- After joining the pedal and the front
interior covering, mount it onto the
chassis.
Luggage case
* Open the luggage case cover.
* Remove 4 tapping screws and 1nut,
separate the join with the chassis (the
concave and the convex) and remove
the front cover.
* Remove the main switch cap.
* Follow the sequence in reverse order for
assembly.
*ATTENTION:
- Be sure the joint of front cover and
cowling jointing correctly before tie-up
the screws and nuts.
2-5
ADLY MOTO
Tail light assembly
* Remove 2 hex bolts and rear fender
assembly.
* Remove the left and right body covers.
* Remove 2 hex bolts and the tail light
assembly.
* Follow the mounting sequence in
reverse order.
*ATTENTION:
- Match the rear guard holes and the
convex of the chassis.
Adjustment of the head light
* Adjustment of the beam of the head
light is by loosening the screw
underneath the head light
2-6
ADLY MOTO
Serviceable parts layout
The drawing shows the main serviceable parts.
Throttle vale (action,play)
Pull rod of rear brake (play)
Front shock absorber
(damage,slack)
Rear felly
(damage,slack)
Spark plug
(dirty,damage)
Front felly
(damage,slack)
2-7
Front tire
(wore,damage,air pressure)
ADLY MOTO
Serviceable parts layout
The drawing shows the main serviceable parts.
Pull rod of front brake (play)
Front shock absorber
(damage,slack)
Head light
Air filter
(dirty,clogged,
changed)
Transmission case
(oil leaking &oil level)
Rear brake
Motor oil pump
Front brake
2-8
ADLY MOTO
Serviceable parts layout
The drawing shows the main serviceable parts.
2-9
Final Transmission Mechanism
Attention of Operation
‧This chapter explain that final reduction mechanism maintance. Can be operated in
the vehicle.
‧For no hurting case cap, changing the bearing of left crank shaft case after
removing the rear break of engine.
‧Use professional tool to change driving shaft and pull out the shaft after fixing
inner ring of bearing.
Diagnosis of Trouble
Engine starts but vehicle does not move.
•Transmission gears broken.
•Transmission gears burns out.
Operate of noise
‧Abrasion、wore and teeth hurted of gear
‧Bearing wore and loosened.
Gear oil leaking
•Too much gear oil filled.
•Oil seal wear-out or damage.
ADLY MOTO
8-3
Final Transmission Mechanism
Disassembly of primary drive gear / final reduction mechanism
‧Disassembly of rear tire(→11-2).
‧Disassembly of clutch / drive face(→7-6).
4WARNNING:
First drain the oil of transmission.
1
2
3
4
5
6
7
8
Operation / Parts name
Disassembly
Bolt
Mission cover
Washer
Dowel pin
Drive axle
Main axle comp.
Plain washer
Primary drive gear
Assembly
8→1
ADLY MOTO
Q’ty
5
1
1
2
1
1
1
1
Remark
‧Check the wear & damage of shaft
and gear. Change new one. (→8-3)
‧Operation with sequence in reverse
of disassembly.
8-3
Final Transmission Mechanism
Change the Driving Shaft
‧Remove the driving shaft from mission
cover.
*WARNNING:
Don’t damage joint face of mission
cover.
‧Remove the oil seal of primary drive
gear.
‧Remove the bearing.
‧Install the new bearing in the mission
cover.
*WARNNING:
Install the bearing with facing
outside.
ADLY MOTO
8-3
Starter / Driving Disc / Clutch / Transmission Disc
Attention of Operation
‧Don’t make greases stick to surface of transmission belt or belt plate. Otherwise ,
the efficiency of power transmission will be lowered by skid.
‧Don’t rotation the starter when remove the front cap of left crankshaft case.
Diagnosis of Trouble
Vehicle does not move after engine start up
•
•
•
•
Drive belt wear-out
Drive face comp. damage
Clutch lining wear-out
Driven ass’y spring defect
Power insufficient
•
•
•
•
Drive belt wear-out
Driven ass’y spring defect
Drive face dirty or oily
Weight roller wear-out
ADLY MOTO
7-5
Starter / Driving Disc / Clutch / Transmission Disc
Disassembly of Left Crank Case Cover
‧Disassembly of air cleaner ass’y.
Operation / Parts name
Disassembly
1
2
3
4
5
6
Hex socket bolt
Carburetor tube bracket
Left crank case cover
Crankcase cover gasket
Dowel pin
Grommet
Q’ty
12
1
1
1
2
1
4WARNNING:
Check the air cleaner whether
worsen or harm.
‧Operation with sequence in reverse
of disassembly.
Assembly
6→1
ADLY MOTO
Remark
7-5
Starter / Driving Disc / Clutch / Transmission Disc
Disassembly of Kick Starter
‧Disassembly of left crank case cover.
1
2
3
4
5
6
7
8
9
Operation / Parts name
Disassembly
Kick pinion spring clip
Kick pinion
Hex washer face bolt
Kick crank
External ring clamp
Plain washer
Starting shaft ass’y
Starting shaft reset spring
Bushing
ADLY MOTO
Q’ty
1
1
1
1
1
1
1
1
1
7-5
Remark
4WARNNING: Rotating pedal kick
crank and remove the assembly.
Starter / Driving Disc / Clutch / Transmission Disc
9
8
7
6
5
4
3
2
1
Operation / Parts name
Assembly
Washer
Starting shaft reset spring
Starting shaft ass’y
Plain washer
External ring clamp
Kick crank
Hex washer face bolt
Kick pinion
Kick pinion spring clip
Q’ty
1
1
1
1
1
1
1
1
1
Installation of Kick Pinion
/ Kick Pinion Spring Clip
‧Set kick starter shaft first.
‧Turning starter, hang kick pinion spring
clip on crank shaft case convex and
assembly of kick pinion to the location
of removing.
‧Turning starter, let starting shaft and
kick pinion conjoin.
Check of Starter
‧Check the wear & damaging of starting
shaft or gear.
‧Check the tightness & damage of
starting shaft reset spring.
‧Check the wear & damage of bush.
ADLY MOTO
7-5
Remark
4WARNNING: Unable into main
shaft fix position when inside and
outside reset spring overlap, use
flat-driver will inside、outside
spring part, then press main shaft.
Starter / Driving Disc / Clutch / Transmission Disc
‧Check the wear & damage of kick
pinion.
‧Check the wear & damage of kick
pinion spring clip.
‧Check the wear & damage of starting
shaft , bearing and driving gear.
ADLY MOTO
7-5
Starter / Driving Disc / Clutch / Transmission Disc
Disassembly of Left Crank Case (→7-2)
1
2
3
4
5
6
7
8
9
10
11
12
Operation / Parts name
Disassembly
Hex washer face bolt
Cone spring washer
One-way clutch
Clamp washer
Primary fixed sheave
Bushing
V-Belt
Primary sliding slot wheel
Oil ring
Hex nut
Covering of clutch
Drive face ass’y
Assembly
12→1
ADLY MOTO
Q’ty
Remark
1
1
1
1
1
1
1
1
1
1
1
1
4WARNNING: Don’t hurt transmission
belt.
Separation / assembling (→ 7-7)
Separation / assembling (→ 7-8)
‧Operation with sequence in reverse
of disassembly.
7-5
Starter / Driving Disc / Clutch / Transmission Disc
Disassembly of Sliding Driving Disc
Operation / Parts name
Disassembly
1
2
3
4
Cam plate
Cam plate sliding
Weight roller
Primary sliding slot wheel
Q’ty
1
3
6
1
‧Operation with sequence in reverse
of separating.
Assembly
4→1
ADLY MOTO
Remark
7-5
Starter / Driving Disc / Clutch / Transmission Disc
Disassembly of Clutch / Transmission Belt Disc
Operation / Parts name
Disassembly
Clutch
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Nut
C retaining ring
Washer
Clutch weight set
Clutch weight spring
Rubber buffer
Driving plate of clutch
Q’ty
1
3
3
3
3
3
1
Drive face ass’y
Axle ring of spring
Compression spring
Secondary spring seat
Guide pin
Secondary sliding slot wheel
Oil ring
Oil seal
Needle bearing
Internal circle clip
Radial ball bearing
Secondary fix slot wheel
Assembly
18→1
ADLY MOTO
Remark
4WARNNING: Must replacing when
the buffer have damage, hardening and
distortion.
‧Operation with sequence in reverse
of separating.
7-5
ADLY MOTO
6. CYLINDER HEAD / CYLINDER / PISTON
Attention of Operation
• Can be operated when engine installed on vehicle.
• Must cleaning before operating , avoiding dust enter the engine.
• Remove the gasket dust stay on joint face.
• When remove the cylinder , avoid to use screw driver to damage the joint face.
• Avoid to damage the cylinder inner surface and piston face.
• Cleaning before check parts, and smear motor oil appointed in sliding face before
the installation.
Diagnosis of Troubles
Low compression pressure, poor start, idle speed not stable
• Air leakage of cylinder head gasket
• Wear & damage the piston ring
• Wrong installation of spark plug
• Wear & damage the cylinder and piston
• Inlet valve poor.
Compression pressure too high, overheating, locking
• Piling up carbon of cylinder head or piston head.
Piston Knocking Noise
• Wear the cylinder and piston
• Wear the piston pin hole and piston pin
• Wear the needle bearing of crank connecting rod (small end)
Piston ring noise
• Wear or damage the piston ring
• Wear or damage the cylinder
6-1
ADLY MOTO
Disassembly of Cylinder Head / Cylinder / Piston
• Disassembly of L/R side cover
• Disassembly of generator
• Disassembly of spark plug cap
• Disassembly of cylinder air-throud
6-2
ADLY MOTO
Operation / Parts Name
Q’ty
Remarks
Disassembly
Cylinder head
1 Nut of cylinder head
2 Cylinder head
3 Cylinder head gasket
Cylinder
4 Cylinder
5 Cylinder gasket
4WARNNING:
4 –Cross loosing the nuts 2-3 times.
1
1
4WARNNING:
1 –Don’t knock cooling fin.
1 4WARNNING:
–During cleaning the gasket beware not
to damage joint face of cylinder and
crank case.
Piston
6
7
8
9
10
Piston ring clip
Piston pin
Piston
Piston ring
needle bearing of small side
Assembly
10→1
2
1
1
2
1
–Operation with sequence in reverse
procedure.
Installation of Piston Ring
‧Remove carbon muck inside ring
ditch and piston ring during
disassembly.
‧Do not scratch piston and do not bend
piston rings.
‧Install top-piston ring & 2nd piston
ring into piston.
‧Press the ring on few points after
installed into piston to ensure the ring
goes deep enough into the ditch
4WARNNING:
Change whole set of piston ring
with genuine parts.
6-3
DISASSEMBLY OF ENGINE
Attention of Operation
‧Operation after disassembling the engine.
–Crank shaft case
–Crank shaft
–Exchange bearing of final transmission mechanisms.
Disassembly of Engine
‧Disassembly of external cap of body.
‧Disassembly of luggage case.
‧Disassembly of throttle valve.
‧Adjustment the throttle cable.
‧Adjustment the rear break cable.
‧Adjustment the oil pump control cable.
ADLY MOTO
5-2
DISASSEMBLY OF ENGINE
Operation / Parts Name
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Q’ty
Disassembly
ACG wire /wire of start motor
Starter wire of carburetor
Oil tube
Fuel tube
Vacuum pressure tube
Cap of spark plug
Hex washer face bolt of rear cushion
Oil pump control cable
Cable of rear brake
Throttle cable
Hex washer face bolt of engine
Bolt
Engine
Nut
Engine bracket bolt
Engine bracket
Remarks
2 4WARNNING:
1
The oil over-flow when remove the
1 oil tube , so use clip or plug stop the seal.
1
1
1
1
1
1
1
1
1
1 4WARNNING:
1 • Don’t damage rear fender when remove
2
the engine.
1 • Actually for brace the frame, avoid body
turn inside out.
Assembly
16→1
4WARNNING: Carry out following adjusting
after installation.
–Cable of throttle valve
–Oil pump control cable
–Rear break cable
ADLY MOTO
5-2
FUEL INSTALLATION
Attention in Operation
h Pay attention to the parts which using gasoline.
h Pipes & Cable must be in accordance with the location directed of wiring diagram.
h Release air in motor oil pump when remove motor oil pipe.
Diagnosis of Trouble
No starting
h No gasoline in tank
h Gasoline blocked
h Too much fuel in cylinder
h Air filter is clogged
Idle speed unstable , of carburetor rotation not smooth
h Poor idle speed adjustment of carburetor.
h Low compression pressure
h Poor ignition system
h Bad adjustment of air adjusting screw on carburetor
h Air filter is clogged
h Poor auto side-plunger on carburetor
h Idle speed nozzle is clogged
Mixed air too thin
h Nozzle of carburetor is clogged
h Gasoline filter is clogged
h Vent of gasoline tank is clogged
h Gasoline pipe cranked, broke, clogged
h Poor action of valve of float chamber
h Gasoline level too low
h Air pipe is clogged
Mixed air too thick
h Poor action of valve of float chamber
h Gasoline level too high
h Air nozzle is clogged
h Auto side-plunger poor
ADLY MOTO
4-1
FUEL INSTALLATION
Disassembly / Assembly Valve Of Throttle
h Disassembly of left body covering
h Adjustment of play of throttle
h Adjustment of reverse rotation of idle speed
Operation / Parts Name
1
2
3
4
5
6
7
8
9
10
11
Disassembly
Pan phillips bolt
Throttle valve
Throttle cable
Throttle valve spring
Carburetor washer
Throttle cover(Including the
reducer)
Sealing set
Washer
Needle nozzle
Clamp
Adjusted screw
ADLY MOTO
Q’ty
Remarks
2 *WARNNING:
1 Loosing top cap of carburetor, and
1 removing.
1
1 *WARNNING:
1 Remove from guide wire of throttle
valve.
1
1
1
1
1
4-2
FUEL INSTALLATION
Operation / Parts Name
11
10
9
8
7
6
5
4
3
2
Assembly
Adjusted screw
Clamp
Needle nozzle
Washer
Sealing set of guide wire
Throttle cover(Including the
reducer)
Washer
Throttle valve spring
Throttle cable
Throttle valve
Q’ty
1
1
1
1
1
1
1
1
1
1
*WARNNING: Assembly of needle nozzle.
*WARNNING: Assembly of throttle valve.
*WARNNING: Assembly of throttle cable.
*WARNNING: Aim the ditch of throttle
valve to chamber then install throttle
valve into carburetor.
Lock the throttle cover.
1
1 Pan phillips bolt
ADLY MOTO
Remarks
4-3
FUEL INSTALLATION
Disassembly of Carburetor
h Remove the air cleaner ass’y .
h Remove the left body cover
Operation / Parts Name
1
2
3
4
5
6
7
8
Disassembly
Throttle valve set
Gasoline pipe
Motor oil joint
Starter wire of carburetor
Vacuum pressure tube
Clip
Intake manifold hose clamp
Carburetor
Q’ty
Remarks
1
1
1
1
1
1
1
1
Assembly
*WARNNING: Don’t let dust enter
into carburetor.
8→1
*WARNNING: Release air.
3 Motor oil joint
ADLY MOTO
4-4
FUEL INSTALLATION
Disassembly / Assembly Carburetor
h Disassembling of carburetor.
h Adjust the idle speed.
h Adjust the air adjust screw.
* WARNNING:
․No fire.
․Before disassembling, loose oil-draining screw, draining out the gasoline from
carburetor.
FUEL INSTALLATION
ADLY MOTO
4-5
Operation / Parts Name
Q’ty
Remarks
Disassembly
Plunger starter
1 Pan phillips bolt
2 Start plug screw
3 Oil ring
2
1
1
Float Chamber
4
5
6
7
8
9
10
Pan phillips bolt
Drain plug
Over flow tube
Pan phillips bolt
Float pin
Float
Needle valve
4
1
1
1
1
1
1
Carburetor Ass’y
11 Throttle screw set
12 Air adjust screw set
13 Float chamber seal
1
1 *WARNNING: Must confirm rerotation
location before disassembling ,
not locking too much avoid to
hurt seat face.
‧Operating with sequence in reverse of
Assembly
Disassembling.
13→1
12 Air adjust screw set
* WARNNING: use high pressure
air clean each way of carburetor.
* WARNNING: must adjust air screw
when changing air screw and
carburetor ass’y.
FUEL INSTALLATION
Disassembly of Inlet Valve
ADLY MOTO
4-6
h Disassembly of body cover.
h Disassembly of carburetor.
Operation / Parts Name
1
2
3
4
5
Q’ty
Disassembly
Intake manifold hose clamp
Hex washer face bolt
Intake manifold
Reed valve ass’y
Reed valve gasket
Remarks
1
4
1
1
1
‧Assembling with sequence in reverse
of disassembly.
Assembly
5→1
*WARNNING: Using new washer , the
4 Reed valve ass’y
5 Reed valve gasket
washer must aim at hole of reed
valve.
*WARNNING: confirm no secondary
air entering after installing.
FUEL INSTALLATION
Disassembly of Fuel Tank
ADLY MOTO
4-7
‧Disassembly of body cover.
‧Disassembly of tail light fix bracket.
‧Disassembly of inner carrier.
* WARNNING:
․No fire.
․Shall be wiped off when fuel overflowed.
Operation / Parts Name
Disassembly
1
2
3
4
5
6
7
8
9
8
Q’ty
Hex bolt
Tail light fix bracket
Inner carrier
Oil tube
Tube
Petrol gauge ass’y
Joint of petrol gauge wire
Round phillips bolt
Oil lever gauge gasket
Hex flat head phillips bolt
Assembly
9→1
Oil lever gauge gasket
Remarks
4
1
1
1
1
1 *WARNNING: Clip the tube, avoid fuel
4
over-flow.
1
4
‧Operating with sequence in reverse of
disassembly.
1 ‧Change new one.
FUEL INSTALLATION
‧Disassembling wire joint of petrol
gauge and remove 4 hex phillips bolt.
Disassembly of Petrol Gauge
* WARNNING:
ADLY MOTO
4-8
Don’t damage petrol gauge wires.
‧Remove the petrol gauge.
* WARNNING:
Don’t curving float arm of petrol
gauge.
‧Operation with sequence in reverse
of disassembly.
FUEL INSTALLATION
Disassembly of Air Cleaner
ADLY MOTO
4-9
Operation / Parts Name
1
2
3
4
5
6
7
8
9
Q’ty
Disassembly
Hex socket bolt
Plain washer
Self-tapping screw
Air cleaner case cap
Air cleaner element
Air cleaner case
Air cleaner joint
Cleaner guide pipe
Grommet
2
1
3
1
4
1
1
2
1
‧Operating with sequence in reverse of
disassembly.
Assembly
9→1
ADLY MOTO
Remarks
4-2
ADLY MOTO
3. INSTALLATION OF LUBRICATION
Attention of Operation
‧Pay attention to avoid dust enter to the interior of engine and motor oil pipe when
disassembly the motor oil pump.
‧Never disassembly motor oil pump.
‧Must draw out the air on the pump if there have air in the pump when disassembly
pipe of carburetor.
‧After disassembling the motor oil connection tube, must fulfill the motor oil in the
connection pipe, then, connect the tube.
Diagnosis of Troubles
Too much smoke, means too much carbon muck piping up the spark plug.
‧Poor synchronizing adjust of motor oil pump (too much exhaust).
‧Bad quality of engine motor oil.
Over heating
‧Poor synchronizing adjustment of motor oil pump (too much exhaust).
‧Bad quality of engine motor oil.
Piston burnt
‧Short of engine oil, or engine oil pipe is clogged.
‧Poor adjustment of motor oil pump (lesser the exhaust).
‧There have air in the motor oil pipes system.
‧Bad motor oil pump.
Clogging oil from oil tank
‧Vent of motor oil case’s cap is clogged.
‧Filter of motor oil is clogged.
Preparation standard
‧Use separating motor oil appointed (use for 2-stroke).
‧Content of motor oil tank : 1.1 liter
3-1
ADLY MOTO
Dismounting of Oil Pump
* Remove the R side body cover and helmet box.
* Remove the cooling fan cover and cylinder head cover.
*WARNNING:
Operating after cleaning motor oil pump around and no dirt enter into the crankcase.
Operation / Parts Name
1 Fuel pipe
2 Oil connection pipe
3 Pan phillips bolt
4 Motor oil pump
Assembly
4→1
Q’ty
Remarks
1 *WARNNING:
Clogging the pipe with clamp or plug
for avoiding fuel flow out.
1 • Remove from both side of motor oil
2 pump.
1
• Assembly with sequence in reverse
of disassembly.
*WARNNING:
−Smear motor oil to new O ring ,then
assembly motor oil pump.
−The oil pump must installed correctly
into crank case.
3-2
ADLY MOTO
Dismounting of Oil Tank
Operation / Parts Name
1
2
3
4
5
Q’ty
Disassembly
Fuel pipe
Fuel connection pipe
Pan phillips bolt
Control cable
Motor oil pump
Assembly
5→1
Operation with sequence in
reverse of disassembly.
1
1
2
1/1
1
Remarks
*WARNNING:
Fill motor oil with clean
container.
*WARNNING:
Connect correct oil pipe
after assembly, release the air
in motor oil pump.
3-3
Crank Case / Crank Shaft
Attention of Operation
‧This chapter explain the necessary procedure of disassembling crank case due
to repair & maintain the crank shaft.
‧Before disassembling of crank case , must operation with sequence of each
chapter to disassembly.
–Disassembly of oil pump
( Chap. 3 )
–Disassembly of carburetor
( Chap. 4 )
–Disassembly of intake valve
( Chap. 4 )
–Dis-mounting of engine
( Chap. 5 )
–Disassembly of cylinder head and cylinder ( Chap. 6 )
–Disassembly of ACG
( Chap. 12 )
–Disassembly drive face ass’y
( Chap. 7 )
‧Must disassembly of final reduction mechanism when change the left crank case.
‧Must use special tool into the inner ring of crank shaft bearing , and pull in crank
shaft to assembly when assembly crank case & crank shaft , put new bearing into
crank case, and put into new oil seal after assembling crank case.
Diagnosis of Troubles
Noise of Engine
‧Damage of crankshaft bearing.
‧Damage of needle bearing of crankshaft pin.
ADLY MOTO
9-1
Crank Case / Crank Shaft
Assembly / Disassembly of Crank Case
1
2
3
4
5
6
7
8
9
10
11
12
13
Operation / Parts name
Disassembly
Hex socket bolt
Right crank shaft case
Dowel pin
Fix shaft of crank shaft case
External circle clip
Crank shaft
Radial ball bearing (Right)
Radial ball bearing (Left)
Hex socket bolt
Oil seal bracket
Right oil seal
Left oil seal
Radial ball bearing
Assembly
13→1
Q’ty
ADLY MOTO
9-2
6
1
2
1
2
1
2
1
1
1
1
1
2
Remark
Crank Case / Crank Shaft
Disassembly of Crank Case
‧Install the puller on right crank case,
separate the R. crank case and L. crank
case.
: Crank case puller (TLJT-03)
‧Install the puller on left crank case,
remove the crank shaft from the crank
case.
: Crank case puller (TLJT-03)
*WARNNING:
Don’t knock the crank shaft when
disassembling.
‧Use the bearing puller to remove the
crankshaft bearing from crank shaft,
then remove the R/L crank case.
: Bearing puller ( TLJT-00)
*WARNNING:
Must remove the oil seal when
separate the crank case, and never use the
old oil seal.
Assembly of Crank Case
‧Clean the crank case with gasoline, and check the each part whether damaged or
crack.
*WARNNING:
**Smear of oil on sliding surface of each shaft in crank case after checking.
**Cleaning the washer dust of joint face, and amend the part damage with oil stone.
ADLY MOTO
9-3
Crank Case / Crank Shaft
‧Put new crank shaft into right crank
case.
‧Put crank shaft assembly into left
crank case.
*WARNNING:
** Smear the 2-stroke oil to main
bearing and big end of connecting
rod.
** Note the position of connecting rod.
‧Put left oil seal into L. crank shaft
case, surface depth under 1.0 mm.
ADLY MOTO
9-4
Crank Case / Crank Shaft
Assembly of Crank Case
‧Install the dowel pins in the joint face
of left crank case.
‧Install the right crank case.
: Bearing puller (TLJT-00)
‧Install the new R. oil seal to crank case.
: Bearing puller (TLJT-00)
ADLY MOTO
9-5
ADLY MOTO
10. Front Wheel / Front Suspension / Front Brake
Attention of Operation
‧Support the bottom side of frame body before remove the front wheel, don’t invert
the front wheel when front wheel depart ground.
Diagnosis of Trouble
Heavy steering movement
‧Over tied of the steering ball race
‧Steel ball inside ball race broken
‧Tire pressure insufficient
Brake efficiency abnormal
‧Brake lining wear-out
‧Brake pads adjust not correct
‧Brake disc attrition
‧Tire wear-out
Poor Brake
‧Bad adjustment of brake
‧Wear the brake pad
Steering handle not straight
‧L/R suspension not balanced
‧Front fork banded
‧Front tire axle banded, tire wear-out
Front wheel shaking
‧Front rim defected
‧Loose of front rim bearings
‧Tire defect
‧Bad adjustment of the front axle
10-1
ADLY MOTO
Disassembly / Assembly of Front Wheel
Operation / Parts name
Disassembly of Front Wheel
1
2
3
4
5
6
Nut nylon
Speedometer gear
Hex washer face bolt
Front collar
Front fender
Front brake disc
Assembly
6→1
Q’ty
Remarks
1
1
1
1
1
1
– Operation with sequence in reverse
procedure.
WARNNING:
–Assembly of right fork, shall be aimed
at convex of speedometer gear.
10-2
ADLY MOTO
Assembly / Disassembly of Front Rim
‧Disassembly of front wheel.
Operation / Parts name
Disassembly
1
2
3
4
Front collar
Oil seal
Radial ball bearing
Front wheel spacer tube
Q’ty
Remarks
1
1
2
1
–Operation with sequence in reverse
procedure.
Assembly
4→1
WARNNING:
–Must change the R/L bearing set.
10-3
ADLY MOTO
Assembly / Disassembly of Front Disk
Operation / Parts name
Disassembly
1
2
3
4
Front collar
Brake disc hex socket bolt
Nylon insert lock nut
Front brake disc
Q’ty
Remarks
1
3
1
1
–Operation with sequence in reverse
procedure.
Assembly
4→1
10-4
ADLY MOTO
Disassembly of Steering Handle
‧Disassembly of throttle handle
‧Dismount rear brake cable
1
2
3
4
5
6
7
8
9
10
11
Operation / Parts name
Disassembly
Rear brake lever
Nut
Left lever set bolt
Rear brake lever
Rear brake cable
Bracket of rear brake lever
Hex socket bolt
Fixed belt of steering handle
Bracket of rear brake lever
Steering Handle
Hex flange nut with serration
Hex washer face bolt
Steering handle
Handle grip
Assembly
11→1
10 Steering handle
7 Bracket of rear brake lever
4 Rear brake cable
Q’ty
Remarks
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
10-5
–Operation with sequence in reverse
procedure.
WARNNING:
–Install steering handle with handle
convex at ditch of steering stem.
–The convex of brake lever bracket
should be fit into handle bar.
ADLY MOTO
Disassembly of Steering Stem
‧Disassembly of front wheel.
‧Disassembly of steering handle
Operation / Parts name
Disassembly
1
2
3
4
5
6
7
8
9
10
11
Spanner nut
Steering stem dust cover
Lathe cone on steering top #2
Race ball #5
Steel ball race
Lathe on steering inner #3
Bolt
Front inner fender
Hex bolt
Washer
Front fork
Assembly
11→1
Q’ty
2
1
1
1
2
2
2
1
2
2
1
10-6
Remarks
WARNNING:
–Not to damage steering stem.
WARNNING:
–Remove L/R tube by loose these two
hex bolts.
–Operation with sequence in reverse
procedure.
ADLY MOTO
Turning Front Fork to Left / Right
‧Turn the front fork several times,
make the ball race rotate smoothly.
‧Slightly tie-up the bottom spanner nut
and backward about 1/8 turn.
‧Confirm the steering rotation smooth
and gap of steering stem.
Special Tool: fixed nut spanner
‧Keep the bottom spanner nut fixed to
avoid the nut rotate with the upper
spanner nut.
Locking Torque: 7.0 kg-m
Special Tool: Fixed nut spanner
10-7
REAR WHEEL / SUSPENSION / BRAKE
Diagnosis of Troubles
Rear wheel shaking
‧ The shape of rear rim damaged.
‧ Tire defected.
Rear suspension too soft
‧ Spring too soft.
Brake efficiency abnormal
‧ Brake pad adjust not correct.
‧ Brake pad attrition.
‧ Brake pad cam part wear.
‧ Brake cam wear.
‧ The tooth groove setting poor of break arm.
ADLY MOTO
11-1
REAR WHEEL / SUSPENSION / BRAKE
Disassembly of Rear Wheel
Operation / Parts name
Disassembly
Muffler
1
2
3
4
5
Hex washer face bolt
Hex head phillips bolt
Assembly of exhaust pipe
Collar
Gasket of exhaust pipe
Rear wheel
6 Nut
7 Plain washer
8 Rear wheel
Assembly
8→1
ADLY MOTO
Q’ty
Remarks
2
2
1
1
1
1
1
1
• Assembling with sequence in reverse
of disassembly.
11-2
REAR WHEEL / SUSPENSION / BRAKE
Disassembly / Assembly of Rear Brake
‧Disassembly of Rear Wheel.
1
2
3
4
5
6
7
8
Operation / Parts name
Disassembly
Q’ty
Adjusted nut of rear brake
Rear brake fixture
Rear brake cable
shoe/shoe strain spring of rear brake
Hex washer face bolt
Rear brake arm
Reset spring
Brake cam shaft
1
1
1
2/2
1
1
1
1
• Assembly with sequence in reverse of
disassembly.
Assembly
8→1
ADLY MOTO
Remarks
11-3
REAR WHEEL / SUSPENSION / BRAKE
Disassembly of Rear Cushion
Operation / Parts name
Disassembly
1
2
3
4
5
Hex washer face bolt
Nut (nylon insert)
Plain washer
Hex bolt
Rear cushion
Q’ty
1
2
2
1
1
• Assembly with sequence in reverse of
disassembly.
Assembly
5→1
ADLY MOTO
Remarks
11-4
ELECTRICAL DEVICE
Attention of Operation
‧Remove battery from truck for charging.
‧No charging with fast speed if it’s not urgent necessary.
‧Must check voltage with Watt-hour meter.
‧Must replace the battery with tranditional battery.
‧Due to it’s CDI ignition device, so, no adjusting ignition time. Check CDI set
& ACG if ignition time is poor. And replacing it if it’s poor, confirm ignition
time with original service meter.
‧Disassembly start motor without disassembling the engine.
Diagnosis of Trouble
No power
‧Battery discharging.
‧Fallening connection wire of battery.
‧Fuse broke.
‧Poor main switch.
Poor changing system
‧Fuse broke.
‧Poor contact, broke and short circuit
of connection head or socket head.
‧Poor rectifier.
‧Poor ACG.
Low voltage
‧Poor charging of battery.
‧Poor contact.
‧Poor charging system.
‧Bad rectifier.
Spark plug no works
‧Poor contact spark plug.
‧Poor contact, broke and short circuit
of main wire.
–Between ACG & C.D.I.
Current off and on
‧Poor contact of battery wires.
‧Poor contact of discharging system.
‧Poor contact or short circuit of
ignition system.
‧Between CDI & ignition coil.
–Between CDI & main switch.
Light weak
‧Battery discharging.
‧Resistance of wiring, switch too big.
High/low beams can’t be changed
‧Bad bulb.
‧Poor lighting switch.
ADLY MOTO
‧Bad ignition coil.
‧Poor CDI set.
‧Poor ACG.
12-1
ELECTRICAL DEVICE
RPM unsmooth
‧Ignition — primary circuitry
–Bad ignition coil.
–Wire or poor contact.
–Poor contact main switch.
‧Ignition — secondary circuitry
–Bad ignition coil.
–Bad spark plug.
–Bad high voltage wires.
–Power leakage of spark plug.
Start motor no working
‧Fuse broke.
‧Battery charging insufficiently.
‧Bad main switch.
‧Poor start switch.
‧Poor front / rear brake switch.
‧Poor start breaker.
‧Poor contact or broke of winding.
‧Poor start motor.
‧Ignition time
–Bad ACG.
–Poor installation of statue inductor.
–Poor CDI.
Powerless start motor
‧Battery charging insufficiently.
‧Bad contact of winding.
‧Strange thing blocked in motor or
gear.
Start motor return running without
engine return running
‧Bad small gear of start motor.
‧Counter rotation of start motor.
‧Battery power insufficient.
Fuel direction light no working (when
without fuel)
‧Insufficient battery power.
‧Fuse broke.
‧Bad main switch.
‧Bad gage.
‧Bad switch of fuel height.
Turn on main switch, but no lighting
‧Bad bulb.
‧Bad switch.
‧Guide wire broke.
‧Fuse broke.
‧Battery discharging.
‧Bad wiring.
Flashing fuel direction light
‧Loose connection head.
‧Guide wires broke.
‧Poor action of float.
‧Poor fuel gage.
Pointer of fuel gage unstable
‧Loose socket head of guide wires.
‧Poor fuel gage.
‧Bad gage.
ADLY MOTO
12-2
ELECTRICAL DEVICE
Solid Wiring Diagram
ADLY MOTO
12-3
ELECTRICAL DEVICE
Disassembly Of Battery
Operation / Parts name
Disassembly
1
2
3
4
5
6
Helmet box mat
Battery  end
Battery  end
Self-tapping screw
Battery cover
Battery
Q’ty
1
1
1
2
1
1
WARRNING: Disassembly battery
from – end to  end.
• Assembling with sequence in reverse
of disassembly.
WARRNING:
Connect  end first , next – end ,cover
 with cap.
Assembly
6→1
2 Battery terminal
ADLY MOTO
Remarks
12-4
ELECTRICAL DEVICE
Check Voltage of Battery
‧Remove helmet box mat and battery
cap , disassembly connection wires of
battery , check voltage between battery
terminals.
Charging sufficiently : over 12.8 V
Charging insufficiently : 11.5-12.8V
*WARNNING:
Must check battery voltage with
digital voltmeter.
Check Charging System
Power leakage test
‧Disassembly ground guide wire from
battery after turning “OFF ” main
switch, next, connect voltmeter to the
end between terminal (–) & ground
guide wires.
‧Check voltage when main switch is
“OFF ”.
*WARNNING:
‧Check voltage according to sequence
from big to small.
‧Voltmeter’s fuse will be broke when
check voltage over the under limitation
choosed.
‧No turn “ON” main switch when check
current.
Current Leakage : under 1 mA
ADLY MOTO
12-5
ELECTRICAL DEVICE
Check Charging Status
*WARNNING:
‧Voltage will have big change following
the charging status of battery in this
check, so, must check with charging
completely, over 12.8 V.
‧There will produce big current due to
start-will consume the power in battery.
‧Assembly voltmeter to terminal of
main fuse, start engine, open light, rise
running amount, and check charging
voltage & current.
Charging current : 1~2 Amp/5000rpm
Voltage of charging control:
14~15V/5000rpm
Check Voltage of Front Lighting
Control
‧Disassembly front covering of handle.
*WARNNING:
Check head light which wires
connecting.
‧Start engine, turn “ON“ light switch,
open high beam.
‧Check voltage between green (+) &
black (-) guide wires.
ADLY MOTO
12-6
ELECTRICAL DEVICE
WARNNING: Check in range of AC.
‧Check voltage adjuster when voltage
Is not in the range controlling.
Control voltage: 12~14V/5000rpm
Check Voltage Adjuster
‧Check voltage adjuster.
‧Disassembly connection head of
voltage adjuster.
‧Check return of wiring edge connection
head.
Disassembly of ACG
ADLY MOTO
12-7
ELECTRICAL DEVICE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Operation / Parts name
Disassembly
Q’ty
Hexagon socket bolt
Plain washer
Self-tapping screw
Cap of electric disc
Hexagon socket bolt
Plain washer
Fan
Hexagon nut
Spring washer
Plain washer
Fly wheel of generator
Semi-cycle of electric disc
Whole body bolt
Hexagon socket bolt
2
2
1
1
4
1
1
1
2
1
2
1
1
1
WARRNING:
Take the good care, no hurt coil.
‧Assembling with sequence in reverse
of disassembly.
Assembly
14→1
ACG ( Charging Coil ) Check
WARNNING:
Checking in the engine connected
With start motor.
‧Disassembly ACG connection.
‧Check resistance of charging wire &
lighting wire.
‧Standard valve (20℃)
Charging wire : 0.2~1.0
Lighting wire: 0.1~0.8
ADLY MOTO
Remarks
12-8
ELECTRICAL DEVICE
Ignition Coil
Disassembly
‧Disassembly spark plug cap.
‧Separating cable, disassembling
installed bolt, then, disassembly
ignition coil.
Assembly
‧Assembly with sequence in reverse of
disassembly.
WARNNING:
Guide wire must be installed in the
right place.
Conduction Test
‧Check once coil resistance of ignition
terminal.
Standard valve (20℃): 0.3~0.5Ω
WARNNING:
Check ignition status with
performance tester due to this test has its
own stanard.
‧Check twice coil resistance between
spark plug cap & (-) terminal.
Standard valve : 9.5~11 kΩ
(spark plug cap in team)
‧Remove spark plug cap from high
Voltage coil.
‧Check twice coil resistance between.
high voltage & (-) terminal.
Standard valve : 5~7 kΩ
(without spark plug cap)
ADLY MOTO
12-9
ELECTRICAL DEVICE
Assembly / Separation of Starting Motor
‧Disassembly of starting motor.
Operation / Parts name
Separation
1
2
3
4
5
6
7
Bolt set
Casing
Armature rotor
Carbon brash
Oil ring
Oil ring
Front fixed seat
Assembly
7→1
ADLY MOTO
Q’ty
Remarks
2
1
1
2
1
1
1
‧Assembling with sequence in reverse
of disassembly.
12-10
ELECTRICAL DEVICE
Check Fuel Gage
‧Remove fuel gage.
‧Put the float to up end down end to
check the resistance between each
terminal.
Terminal of
Guide wire
Green &
black
Up end of
float
Down end
of float
0~20Ω
90~110Ω
Check Main Switch
‧Remove connection of main switch
guide wire, check conductivity
between each terminal.
Color
tea
LOCK
○
OFF
ON
black/ black
red
○
○
○
red
○
○
Exchange
‧Remove front covering.
‧Remove 2 bolts, disassembly main switch.
‧Installing with the sequence in reverse of disassembly.
Check switch of handle
‧Remove front covering.
‧Disassembly connection of handle switch, check conductivity between each
terminal.
ADLY MOTO
12-11
ELECTRICAL DEVICE
Switch of Lights
Color
Yellow/red
Blue
OFF
ON
○
○
Color
blue/white
Black
Up
Down
○
○
Power Switch
Exchange of Bulbs
Head light bulb
‧Remove front covering of handle press
down the connection and turn it to
change head light bulb.
Dash light
‧Remove rear covering of handle pull
out the connection of bulb, and replace
the bulb.
ADLY MOTO
12-12
ELECTRICAL DEVICE
Rear light / Brake light / Rear direction
light bulb
‧Remove 2 screws, pull out the light
Covering to front, disassembly hook on
light / brake light covering, and
disassembly light covering of direction
light and bulb, finally change bulb.
MENO
ADLY MOTO
12-13