SERVICE MANUAL

TB-50 (Gazelle) / 100

December, 1998

High Power Engine

HER CHEE INDUSTRIAL CO., LTD.

ADLY MOTO 1-1

 Preface

The Service Manual in reference is provided as the technical information for

checking and preparation of ADLY TB-50/100 scooter and the edit description
is given in diagrams with " Operation Sequence ", " Highlights " and " Checking
Arrangement " for reference of the service staffs.

The information, illustrations or contents included in this manual may be

different with the actual scooter in case specifications are changed. Your
understanding will be appreciated.

HER CHEE INDUSTRIAL CO., LTD.

ADLY MOTO 1-2

 INDEX

Information of preparation 1

Check and Adjust 2

Engine-

Installation of Lubricant 3

Fuel Installation 4

Engine dismounting/disassembling 5

Cylinder head, Cylinder and Piston 6

Starter / Driving Disc / Clutch / Transmission 7

Final Transmission Mechanism 8

Crankcase, Crankshaft and Transmission box 9

Chassis-

Front wheel, Brake, Suspension 10

Rear heel, Brake, Suspension 11

Electrical devices 12

Wiring diagram 13

ADLY MOTO 1-3

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.

ADLY MOTO 1-1

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

ADLY MOTO 1-2

 INFORMATION FOR PREPARATION

SPECIFICATION

TYPE TB50ൕ ൖ TB100ൕ ൖ

LENGTH 1780 mm 1780 mm
WIDTH 675 mm 675 mm
HEIGHT 1160 mm 1160 mm
WHEEL BASE 1250 mm 1250 mm
NET WEIGHT 75 kg 75 kg
ENGINE TYPE 4-STROKE, Single Cylinder 4-STROKE, Single Cylinder
COOLING AIR COOLED AIR COOLED
DISPLACEMENT 49.26 C.C. 95.57 C.C.
BOREuSTROKE 40.0u39.2 52u45
COMPRESSION RATIO 7.2:1 5.8:1
IGNITION C.D.I C.D.I
STARTER ELECTRIC / KICK ELECTRIC / KICK
SUSPENSION Hydraulic Shock Absorber Hydraulic Shock Absorber
TRANSMISSION AUTOMATIC AUTOMATIC
TIRE TB(ൕ ) 120/70-12 (Front & Rear) 120/70-12 (Front & Rear)
FRONT/REAR TB(ൖ  120/70-12 120/70-12
TB(ൕ ) Disc Disc
FRONT BRAKE
TB(ൖ  Double Disc Double Disc
REAR BRAKE Drum Drum
MAX. POWER 2.8Kw / 5500 rpm 5.26kw / 7000 rpm
MAX. TORQUE 4.75N-m / 5500 rpm 7.4N-m / 6500rpm

ADLY MOTO 1-2

INFORMATION FOR PREPARATION
LOCKING TORQUE

Adopt the standard torque locking for the item unlisted.

STANDARD TORQUE᧶
Type Locking Torque (kg-m)
5 mm 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

CHASSIS᧶
Locking Place Quantity Dia. (mm) Locking Torque (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

ENGINE᧶
Locking Place Quantity Dia. (mm) Locking Torque (kg-m)
Screw of Cylinder Cap 4 6 1.0
Flywheel Nut 1 10 3.8
Clutch Jacket Nut 1 11 3.8
Driving Disc Nut 1 28 5.5
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

ADLY MOTO 1-3

INFORMATION FOR PREPARATION
The following drawing that shows the disassembling situation of the cover parts
for TB50/100 scuuter.

ADLY MOTO 1-4

ADLY MOTO 1-5
INFORMATION FOR PERPARATION
DIFFICULT START OR CANN'T START

Diagnose Check and Adjuster Reason of Trouble

loose the fuel release

screw of caruretor and
check if the fuel is inside
of carburetor ?

fuel tank without gasoline

fuel supply to tubing to carburetor blocking
no fuel supply to
carburetor is float chamber tubing of carburetor blocking
carburetor
sufficient fuel filter blocking
fuel cup blocking
loosen the spark plug, air hole of fuel tank blocking
connect with the spark
cap and contact with the
frame, check the spark
plug sparking ? spark plug grimy or damage
C.D.I damage
no sparking or main switch damage
sparking
weak ACG fulser coil damage
high tension coil damage or no gap
ACG lighting coil damage

test the compression

pressure
valve set damage
cylinder, piston, piston ring damage
compression compression cylinder gasket leakage
pressure pressure too low valve burn
is normal or no pressure valve timing is not correct
valve gap is too tight or no gap
start clutch damage
follow the standard
stat-up procedure and
test again

ignite timing is not correct

engine can not engine can ignite fuel adjuste screw of carburetor isn't correct
ignite but can not start intake manifold sucking air
auto. plunger starter is damage

loosen the spark plug

and test

fuel level of carburetor is too high

spark plug is dry spark plug is wet auto. plunger starter is damage
throttle open angle is too wide

continue

ADLY MOTO 1-6

INFORMATION FOR PREPARATION
REVOLUTION NOT SMOOTH , LOST POWER
Diagnose Check and Adjust Reason of Trouble
start engine and
go up speed slight air cleaner blocking
fuel supply isn't smooth
air hole of air tank blocking
engine speed can't
engine speed go up exhaust pipe blocking
go up fully
auto.plunger starter damage
adjusting ignite film of carburetor damage
timing fuel cup damage

ignite timing is ignite timing isn't C.D.I damage

correct correct pulser coil damage
adjusting valve gap
is not correct
valve gap valve gap adjusting isn't correct
valve gap is correct valve set over abrade
isn't correct
testing compression
pressure
valve set damage
compression cylinder, piston abrade
compression pressure
pressure cylinder gasket leakage
is normal
is too low valve timing isn't correct
check carburetor
blocking ?

no blocking blocking cleaning carburetor

loosen spark plug
and check
cleaning the stain
spark plug normal spark plug stain spark plug type isn't correct
check the oil
quantiity of
crankcase is too
rich or dirty? oil flowing is too rich
oil quantity oil quantity is oil flowing is too lean
is normal too rich oil doesn't circulate
check cylinder head
lubricating ?

oil tubing blocking

normal abnormal
oil supply is too lean

engine over heat

cylinder, piston abrade
mixutre gases is too lean
normal over heat carbon residue in combustion chamber
is too more
increase engine igniting time is too earily
speed or continue fuel isn't good
turning at high clutch sliding
speed mixutre gases is too lean
carbon residue in combustion chamber
no knocking knocking
is too more
igniting time is too earily
fuel isn't good
continue
ADLY MOTO 1-7
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

abnormal
pulser coil damage

adjust the carburetor fuel

adjuste screw

mixture gases too lean

adjusting isn't (loosing screw)
adjusting is correct
correct mixture gases too rich
(locking screw)

carburetor sucking air

gasket damage
the screw of carburetor is
no sucking air sucking air loosen
(-) pressure tube broken
loosen spark plug,
connecct with spark cap
and contract with frame,
check the spark plug spark damage or stain
sparking ? C.D.I damage
A.C.G damage
sparking normal sparking abnormal coil damage
spark plug cable damage odr short
main switch damage
check A.C.G

A.C.G damage
normal abnormal air hole damage or blocking
(-) pressure tube damage

end

ADLY MOTO 1-8

INFORMATION FOR PREPARATION
REVOLUTION NOT SMOOTH(HIGH SPEED)

Diagnose &KHFNDQG$GMXVW 5HDVRQRI7URXEOH

adjusting ignite timeing

C.D.I damage
normal abnormal
ACG pulse coil damage

adjusting valve gap

adjusting isn't correct

normal abnormal valve set damage

check fuel cup supply

normal ? fule filter blocking
air hole of fuel tank blocking
fuel cup damage
fuel of tank is too less
normal abnormal

carburetor blocking

cleaning

no blocking blocking

check and adjust valve

timing

valve timing is valve timing isn't camshaft gear mark position is not
correct correct correct

check the spring of valve

spring broken or
normal spring damage
elastic deformation

end

ADLY MOTO 1-9

INFORMATION FOR PREPARATION
CHARGE ABNORMAL

Diagnose &KHFNDQG$GMXVW 5HDVRQRI7URXEOH

start engine and measure
voltage of the two
terminal for battery

voltage of battery voltage of battery

can't go up is normal
battery damage

measure the resistance of

ACG coil

coil damage
measure value
normal
too high
terminal damage
YL wire damage

check the regulator

battery have not

battery have voltage R wire damage
voltage

check socket of regulator

loosen ?

regulator damage
normal abnormal
socket damage

ACG damage
(over charge)
check the voltage between
regulator and frame
main switch at ON main switch at ON
the battery have the battery have no GR wire broken
voltage voltage

check the socket of

regulator

normal socket loosen socket damage

regulator damage

ADLY MOTO 1-10

INFORMATION FOR PREPARATION
SPARK PLUG NO SPARKING

Diagnose &KHFNDQG$GMXVW 5HDVRQRI7URXEOH

change spark plug and

check again

no sparking or
sparking strong the previous spark plug damage
weak

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

normal abnormal

check relate spare parts

main switch damage
pulser coil damage
normal abnormal coil damage
lighten coil damage

main switch damage

socket, joint connect abnormal

change CDI unit

normal abnormal the previous C.D.I unit damage

change ignition coil

abnormal the previous coil damage

ADLY MOTO 1-11

ADLY MOTO 1-12
CHECK AND ADJUST
Way of Check & Adjustment

1. Mark “Ⴜ ” is checking time.

2. Mark “ყ ” 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 Time (month)

Service Items Judgement Standard Remarks
Before
1 st each 6 each 12
riding
Operating Device
Handle- Play, loose/tight Ⴜ
Operation
Ⴜ
Wheels- Right/left turn round angle Ⴜ
Front Fork-Damage Ⴜ Ⴜ Direction Post
Installation of shaft Direction Post
Ⴜ Ⴜ
Shaft Gap
Ⴜ
Brake Device
Brake- Play Ⴜ Ⴜ Play
Handle , handle front
 
Try to run Ⴜ 10-20 mm
Ⴜ Ⴜ
Correct brake
Ⴜ Ⴜ
Ⴜ Ⴜ
Wires- Loose / tight and damage Ⴜ Ⴜ Ⴜ
Gap of casing & brake Ⴜ Ⴜ
Wore of brake & operating parts Ⴜ Direction

Wore & Damage of casing  Standard diameter 110 mm

Limitation 110.5mm
Ⴜ

ADLY MOTO 2-8

Riding Device front rear
Tires-Air pressure of tires Ⴜ Ⴜ Ⴜ air pressure NJFP NJFP
tire 120/70-12 120/70-12

Riding Device
Tire

Check & damage of tires Ⴜ Ⴜ Ⴜ Ditch-front wheel till 0.8mm

Rear wheel till 0.8 mm
Abnormal & ditch in tires Ⴜ Ⴜ Ⴜ
Bolt & nut of tires locking   Flocking torsion
Front wheel – 4.0~5.0 kg-m
Ⴜ Ⴜ
Rear wheel –10~12 kg-m
Damage of felly ,side ring , disc Ⴜ Ⴜ Ⴜ  Vibration of felly, in edge of felly
Front wheel – horizontal under 2.0
 mm
vertical under 2.0 mm
Rear wheel – horizontal under 2.0 mm
vertical under 2.0 mm
Tightness of front bearing Ⴜ
Tightness of rear bearing Ⴜ
Buffer device
Spring -damage Ⴜ Spring of
shock
absorber
Suspension arm – damage of joint gap Ⴜ
& arm
Buffer -oil leakage or damage Ⴜ
Tightness of installation Ⴜ
Power transmission device
Clutch -action Ⴜ Ⴜ Ⴜ

ADLY MOTO 2-8

Transmission Ⴜ Ⴜ Level : way of direction hole , oil It’s rear
fill to the mark of the hole Gear case
Electril device
Ignition device -condition of ignition Ⴜ Ⴜ Gap of spark plug 0.6~0.7 mm
spark plug
Battery -connection of terminal Ⴜ
Wiring of electrical appliance – damage Ⴜ
or loose in connection place

Check Items Before 1 st 6 12 Judged standard remarks

riding M M M

Engine
Body – starting & abnormal noise Ⴜ Ⴜ
low speed & accelerating Ⴜ Ⴜ Ⴜ Idle : 1800s100 rpm
exhaust
Ⴜ Ⴜ
air filter
Ⴜ Ⴜ
Lubrication device
Oil and oil filter Ⴜ Ⴜ Warning light lighting

Oil leakage Ⴜ Ⴜ
Oil level Ⴜ
Fuel installation
Gasoline filter is dirty Ⴜ
Leakage of fuel Ⴜ Ⴜ
Throttle gate & choke Ⴜ
Fuel filter is clogged Ⴜ
Oil level Ⴜ
Alteration of pipes ✶ each 2 years
Lights & direction lights
Action Ⴜ Ⴜ
On/off normal , dirty , damage Ⴜ

ADLY MOTO 2-8

Rear mirror – view Ⴜ Ⴜ
Reflector & license tag –dirty & damage
Instrument –action Ⴜ
Exhaust pipe & muffler
Installation loosed or damage Ⴜ
Function of muffler Ⴜ
Frame & body –loose or damage Ⴜ
Abnormal from previous day –confirm Ⴜ
normal
Others - greasing of each part Ⴜ Ⴜ
Cleaning combustion chamber , exhaust Ⴜ
pipe , and carbon muck in muffler

CHECK AND ADJUST ✳ Before locking screws , please

confirm the matching correct of all
parts.
Disassembly of External Parts

x Remove the external parts for check x Front cover.

and adjustment. x Remove 3 pan flat bolts , 1 hex bolt.
x Remove 12 self-tapping screws.
x Disconnect the light connectors.
x Install with the reverse sequence.

WARNNING:
x Remove 4 hex washer face bolts, ✳ Do not damage & break the joint of
4 space tubes , and then remove inner body and front damper.
luggage carrier.
✳ Before locking screws , please
x Remove 12 self-tapping screws and 2 confirm the matching correct of all
parts.
pan flat bolts.
x Remove central cover ,L/R side cover,
decoration strip and cowling.
x Install with the reverse sequence.

WARNNING:
✳ Do not break the union of body and
pedal.

ADLY MOTO 2-8

CHECK AND ADJUST 2 pan flat bolts.
x Separate the joint with luggage case
(claw & groove)and remove the pedal
Disassembly of Pedal x Install with the reverse sequence.

x Remove L/R body cover.

x Remove 4 bolts, 6 self-tapping screws WARNNING:
ADLY MOTO 2-8
᧦Installing to the luggage box after
composing confirming the pedal with the
joint of luggage case correctly.

Disassembly of Luggage Case

x Remove front fender.

x Disconnect the light connectors.
x Remove power switch cap.
x Remove edge nut on luggage case.
x Install with the reverse sequence.

WARNNING:
᧦ Going on the installation operation after
jointing correctly the luggage
case and front fender.

CHECK AND ADJUST x Disassembly the connection head of

wireness rear light.
x Assembly with the sequence in
Rear Light Assembly
reverse of disassembly.
x Remove 2 hex bolts.
x Remove 3 L/R sides body cover.
WARNNING:

ADLY MOTO 2-8

᧦Ensuring the joint of tail light hole
correct with the bulge of truck.

Handle Covering

x Remove 4 self-tapping screws ,

separate the joint with speedometer.
x Remove the handle covering.
x Assembly with the sequence in
reverse of disassembly.

WARNNING:
¼ Aim handle covering correctly the
handle covering back’s joint.

CHECK AND ADJUST

Layout of Parts Maintenance

The location of main parts of maintenance are showed as follows :

ADLY MOTO 2-8

ADLY MOTO 2-8
CHECK AND ADJUST
Adjustment of Motor Oil Pump

᧦WARNNING:
Going on this operation after adjusting
and checking the guide wiring of throttle.

x The tolerance within 1 mm of the adjust

O/P control cable is good. Starting the
engine, turn slightly the throttle to feed
motor oil idle-speed. At same time of
rising the rotation of engine, confirm
the working of control rod.

x The condition will be appeared with bad synchronizing as follows :

¼ Starting difficult and having smoke when opening degree of motor oil pump’s
connection rod is too big.
¼ Piston will be burnt when the opening degree of motor oil pump’s connection
rod is too small.

MENO

ADLY MOTO 2-8

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.

Overheating

಺ 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.

ADLY MOTO 3-4

಺ 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

INSTALLATION OF LUBRICATION

Disassembly of Motor Oil Pump

Remove right side cover.

Remove stator cover.
Remove A.C.G

✱WARNNING:
Operating after cleaning motor oil pump around and no entering to the crank shaft
case.

ADLY MOTO 3-4

INSTALLATION OF LUBRICATION

Operation / Parts Name Q’ty Remarks

Disassembly
1 Fuel pipe 1 ✱WARNNING:
Clogging the pipe with clamp or plug
for avoiding fuel flow out.
2 Fuel connection pipe 1 x Remove from both side of motor oil
3 Pan phillips bolt 2 pump.

4 Control cable 1/1 x Remove from oil pump.

5 Motor oil pump 1

ADLY MOTO 3-4

Assembly x Assembly with sequence in reverse
5o1 of disassembly.

✱WARNNING:
Smear motor oil to new O ring ,then,
assembly motor oil pump.
The oil pump must installed correctly
into crank case.
✱WARNNING:
Don’t loosen adjusted screw on control
cable, but must adjust oil pump after
assembling if need to loosen.

INSTALLATION OF LUBRICATION

Disassembly of Oil Tank

ADLY MOTO 3-4

 Operation / Parts Name Q’ty Remarks
Disassembly
1 Joint of oil disassembly oil pipe 1 ᧦WARNNING:
2 Joint of wires 1
Fill motor oil with clean container.
3 Bolt 1
4 Oil tank 1
5 Grommet 1
Assembly x Operation with sequence in reverse of
5o1 disassembly.

᧦WARNNING:
Connect correct oil pipe after
assembly , release the air in motor oil
pump.

ADLY MOTO 3-4

FUEL INSTALLATION

Attention in Operation

 Pay attention to the parts which using gasoline.

 Pipes & Cable must be in accordance with the location directed of wiring diagram.
 Release air in motor oil pump when remove motor oil pipe.

Diagnosis of Trouble

No starting
 No gasoline in tank
 Gasoline blocked
 Too much fuel in cylinder
 Air filter is clogged
Idle speed unstable , of carburetor rotation not smooth
 Poor idle speed adjustment of carburetor.
 Low compression pressure
 Poor ignition system
 Bad adjustment of air adjusting screw on carburetor
 Air filter is clogged
 Poor auto side-plunger on carburetor
 Idle speed nozzle is clogged
Mixed air too thin
 Nozzle of carburetor is clogged
 Gasoline filter is clogged
 Vent of gasoline tank is clogged
 Gasoline pipe cranked, broke, clogged
 Poor action of valve of float chamber
 Gasoline level too low
 Air pipe is clogged
Mixed air too thick
 Poor action of valve of float chamber
 Gasoline level too high
 Air nozzle is clogged
 Auto side-plunger poor

ADLY MOTO 4-1

FUEL INSTALLATION

Disassembly / Assembly Valve Of Throttle

 Disassembly of left body covering
 Adjustment of play of throttle
 Adjustment of reverse rotation of idle speed

Operation / Parts Name Q’ty Remarks

Disassembly
1 Pan phillips bolt 2 ᧦WARNNING:
2 Throttle valve 1
Loosing top cap of carburetor, and
3 Throttle cable 1
removing.
4 Throttle valve spring 1
5 Carburetor washer 1
᧦WARNNING:
6 Throttle cover(Including the reducer) 1
7 Sealing set 1 Remove from guide wire of throttle
8 Washer 1 valve.
9 Needle nozzle 1
10 Clamp 1
11 Adjusted screw 1

ADLY MOTO 4-2

FUEL INSTALLATION

Operation / Parts Name Q’ty Remarks

Assembly
11 Adjusted screw 1
10 Clamp 1 ᧦WARNNING: Assembly of needle nozzle.
9 Needle nozzle 1
᧦WARNNING: Assembly of throttle valve.
8 Washer 1
7 Sealing set of guide wire 1
6 Throttle cover 1 ᧦WARNNING: Assembly of throttle cable.
(Including the reducer) 1
5 Washer 1
4 Throttle valve spring 1
3 Throttle cable 1
2 Throttle valve
᧦WARNNING: Aim the ditch of throttle
valve to chamber then install throttle
1 Pan Phillips bolt 1 valve into carburetor.
Lock the throttle cover.

ADLY MOTO 4-3

FUEL INSTALLATION

Disassembly of Carburetor
 Remove the air cleaner ass’y .
 Remove the left body cover

Operation / Parts Name Q’ty Remarks

Disassembly
1 Throttle valve set 1
2 Gasoline pipe 1
3 Motor oil joint 1
4 Starter wire of carburetor 1
5 Vacuum pressure tube 1
6 Clip 1
7 Intake manifold hose clamp 1
8 Carburetor 1
Assembly
8o1 ᧦WARNNING: Don’t let dust enter
into carburetor.
3 Motor oil joint
᧦WARNNING: Release air.

ADLY MOTO 4-4

FUEL INSTALLATION

Disassembly / Assembly Carburetor

 Disassembling of carburetor.
 Adjust the idle speed.
 Adjust the air adjust screw.

᧦WARNNING:

 ɘ No fire.

 ɘ Before disassembling, loose oil-draining screw, draining out the gasoline from

carburetor.

ADLY MOTO 4-5

FUEL INSTALLATION

Operation / Parts Name Q’ty Remarks

Disassembly
Plunger starter

1 Pan Phillips bolt 2

2 Start plug screw 1
3 Oil ring 1
Float Chamber

4 Pan Phillips bolt 4

5 Drain plug 1
6 Over flow tube 1
7 Pan Phillips bolt 1
8 Float pin 1
9 Float 1
10 Needle valve 1
Carburetor Ass’y

11 Throttle screw set 1

12 Air adjust screw set 1 ᧦WARNNING: Must confirm rerotation
13 Float chamber seal location before disassembling ,
not locking too much avoid to
hurt seat face.

Assembly ಺ Operating with sequence in reverse of

13o1 Disassembling.
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.

ADLY MOTO 4-6

FUEL INSTALLATION

Disassembly of Inlet Valve

 Disassembly of body cover.
 Disassembly of carburetor.

Operation / Parts Name Q’ty Remarks

Disassembly
1 Intake manifold hose clamp 1
2 Hex washer face bolt 4
3 Intake manifold 1
4 Reed valve ass’y 1
5 Reed valve gasket 1
Assembly ಺ Assembling with sequence in reverse
5o1 of disassembly.
✱WARNNING: Using new washer , the
4 Reed valve ass’y washer must aim at hole of reed

ADLY MOTO 4-7

 5 Reed valve gasket valve.
✱WARNNING: confirm no secondary air
entering after installing.

FUEL INSTALLATION

Disassembly of Fuel Tank

಺ Disassembly of body cover.
಺ Disassembly of tail light fix bracket.
಺ Disassembly of inner carrier.

᧦WARNNING:

 ɘ No fire.

ɘ Shall be wiped off when fuel overflowed.

Operation / Parts Name Q’ty Remarks

Disassembly

1 Hex bolt 4
2 Tail light fix bracket 1
3 Inner carrier 1
4 Oil tube 1
5 Tube 1

ADLY MOTO 4-8

 Petrol gauge ass’y 1 ᧦WARNNING: Clip the tube, avoid fuel
6 Joint of petrol gauge wire 4
over-flow.
7 Round phillips bolt 1
8 Oil lever gauge gasket 4
9 Hex flat head phillips bolt
Assembly ಺ Operating with sequence in reverse of
9o1 disassembly.
8 Oil lever gauge gasket 1
಺ Change new one.

FUEL INSTALLATION

Disassembly of Petrol Gauge

಺ Disassembling wire joint of petrol
gauge and remove 4 hex phillips bolt.

᧦WARNNING:

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.

ADLY MOTO 4-9

FUEL INSTALLATION

Disassembly of Air Cleaner

Operation / Parts Name Q’ty Remarks

Disassembly
1 Hex socket bolt 2
2 Plain washer 1
3 Self-tapping screw 3
4 Air cleaner case cap 1
5 Air cleaner element 4
6 Air cleaner case 1
7 Air cleaner joint 1
8 Cleaner guide pipe 2
9 Grommet 1

ADLY MOTO 4-2

 Assembly ಺ Operating with sequence in reverse of
9o1 disassembly.

ADLY MOTO 4-2

DISASSEMBLY OF ENGINE

Attention of Operation
಺ Operation after disassembling the engine.

ದ Crank shaft case

ದ Crank shaft

ದ 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 Q’ty Remarks

Disassembly
1 ACG wire /wire of start motor 2 ᧦WARNNING:
2 Starter wire of carburetor 1
The oil over-flow when remove the
3 Oil tube 1
oil tube , so use clip or plug stop the seal.
4 Fuel tube 1
5 Vacuum pressure tube 1
6 Cap of spark plug 1
7 Hex washer face bolt of rear cushion 1
8 Oil pump control cable 1
9 Cable of rear brake 1
10 Throttle cable 1
11 Hex washer face bolt of engine 1
12 Bolt 1
13 Engine 1
᧦WARNNING:
14 Nut 1
15 Engine bracket bolt 2 x Don’t damage rear fender when remove
16 Engine bracket 1 the engine.
x Actually for brace the frame, avoid body
turn inside out.
Assembly ᧦WARNNING: Carry out following adjusting
16o1
after installation.
ದ Cable of throttle valve

ದ Oil pump control cable

ದ Rear break cable

ADLY MOTO 5-2

CYLINDER HEAD / CYLINDER / PISTON

Attention of Operation

x Can be operated when engine installed on vehicle.

x Must cleaning before operating , avoiding dust enter the engine.
x Remove the gasket dust stay on joint face.
x Avoid to use driver harm the joint face when remove the cylinder & cylinder head.
x Avoid to harm the cylinder inner and piston face.
x Cleaning before check parts, and smear motor oil appointed in sliding face before
installing.

Diagnosis of Troubles

Low compression pressure , poor start , idle speed not stable

x Air leakage of cylinder head washer.
x Wear & damage the piston ring.
x Wrong installation of spark plug
x Wear & damage the cylinder and piston.
x Inlet valve poor.

Compression pressure too high, overheating, locking

x Piling up carbon of cylinder head or piston head.

Piston Noise
x Wear the cylinder and piston.
x Wear the piston pin hole and piston pin.
x Wear the needle bearing of crank connecting rod (small end) .

Piston ring noise

x Wear or damage the piston ring.
x Wear or damage the cylinder.

ADLY MOTO 6-2

CYLINDER HEAD / CYLINDER / PISTON

Disassembly of Cylinder Head / Cylinder / Piston

x Disassembly of cover (ൺ 4-7) x Disassembly of cenerator cover (ൺ 12-7)

x Disassembly of muffler (ൺ 11-2) x Disassembly of spark plug cap (ൺ 5-2)

ADLY MOTO 6-2

CYLINDER HEAD / CYLINDER / PISTON

Operation / Parts Name Q’ty Remarks

Disassembly
Cylinder head

1 Nut of cylinder head 4 ✱WARNNING: Loosing nut 2-3 times.

2 Cylinder head 1
3 Cylinder head gasket 1
Cylinder

4 Cylinder 1 ✱WARNNING: Don’t knock cooling fin.

5 Cylinder gasket 1 ✱WARNNING: Clean and not damage
cylinder & washer of crank shaft
case.
Piston

6 Piston ring clip 2

7 Piston pin 1
8 Piston 1
9 Piston ring 2
10 needle bearing of small side 1
Assembly ಺ Operation with sequence in reverse of
10o1 disassembly.

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Installation of Piston Ring
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಺ Install top-piston ring & 2nd piston
ring in piston.

಺ Do not scratch piston and do not bend
piston rings. ✱WARNNING:
Change whole set of piston ring
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with same brand.

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ADLY MOTO 6-2

ADLY MOTO 6-2
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

x Drive belt wear-out
x Drive face comp. damage
x Clutch lining wear-out
x Driven ass’y spring defect

Power insufficient
x Drive belt wear-out
x Driven ass’y spring defect
x Drive face dirty or oily
x Weight roller wear-out

ADLY MOTO 7-1

Starter / Driving Disc / Clutch / Transmission Disc

Disassembly of Left Crank Case Cover

಺ Disassembly of air cleaner ass’y.

Operation / Parts name Q’ty Remark

Disassembly

1 Hex socket bolt 12

2 Carburetor tube bracket 1
3 Left crank case cover 1
4 Crankcase cover gasket 1 ᧦WARNNING:
5 Dowel pin 2
Check the air cleaner whether
6 Grommet 1
worsen or harm.

Assembly ಺ Operation with sequence in reverse

6ൺ  of disassembly.

ADLY MOTO 7-2

Starter / Driving Disc / Clutch / Transmission Disc

Disassembly of Kick Starter

಺ Disassembly of left crank case cover.

Operation / Parts name Q’ty Remark

Disassembly
1 Kick pinion spring clip 1
2 Kick pinion 1 ᧦WARNNING: Rotating pedal kick
3 Hex washer face bolt 1
crank and remove the assembly.
4 Kick crank 1
5 External ring clamp 1
6 Plain washer 1
7 Starting shaft ass’y 1
8 Starting shaft reset spring 1
9 Bushing 1

ADLY MOTO 7-3

Starter / Driving Disc / Clutch / Transmission Disc

Operation / Parts name Q’ty Remark

Assembly
9 Washer 1
8 Starting shaft reset spring 1 ᧦WARNNING: Unable into main
7 Starting shaft ass’y 1
shaft fix position when inside and
6 Plain washer 1
outside reset spring overlap, use
5 External ring clamp 1
4 Kick crank 1 flat-driver will insideᇬoutside
3 Hex washer face bolt 1 spring part, then press main shaft.
2 Kick pinion 1
1 Kick pinion spring clip 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 7-4

Starter / Driving Disc / Clutch / Transmission Disc

಺ Check the wear & damage of kick

pinion.
಺ Check the wear & damage of kick
pinion spring clip.

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ADLY MOTO 7-1

Starter / Driving Disc / Clutch / Transmission Disc

Disassembly of Left Crank Case (ൺ 7-2)

Operation / Parts name Q’ty Remark

Disassembly
1 Hex washer face bolt 1 ᧦WARNNING: Don’t hurt transmission
2 Cone spring washer 1
belt.
3 One-way clutch 1
4 Clamp washer 1
5 Primary fixed sheave 1
6 Bushing 1
7 V-Belt 1
8 Primary sliding slot wheel 1
9 Oil ring 1 Separation / assembling (ൺ  
10 Hex nut 1
11 Covering of clutch 1
12 Drive face ass’y 1 Separation / assembling (ൺ  )

ADLY MOTO 7-2

 Assembly ಺ Operation with sequence in reverse
12ൺ  of disassembly.

Starter / Driving Disc / Clutch / Transmission Disc

Disassembly of Sliding Driving Disc

Operation / Parts name Q’ty Remark

Disassembly

1 Cam plate 1
2 Cam plate sliding 3
3 Weight roller 6
4 Primary sliding slot wheel 1

Assembly ಺ Operation with sequence in reverse

4ൺ  of separating.

ADLY MOTO 7-2

Starter / Driving Disc / Clutch / Transmission Disc

Disassembly of Clutch / Transmission Belt Disc

Operation / Parts name Q’ty Remark

Disassembly
Clutch

1 Nut 1
2 C retaining ring 3
3 Washer 3
4 Clutch weight set 3
5 Clutch weight spring 3
6 Rubber buffer 3 ✱WARNNING: Must replacing when
7 Driving plate of clutch 1 the buffer have damage, hardening and
distortion.
Drive face ass’y
8 Axle ring of spring
9 Compression spring
10 Secondary spring seat
11 Guide pin
12 Secondary sliding slot wheel
13 Oil ring
14 Oil seal
15 Needle bearing
16 Internal circle clip
17 Radial ball bearing
18 Secondary fix slot wheel

ADLY MOTO 7-2

 Assembly ಺ Operation with sequence in reverse
18ൺ  of separating.

ADLY MOTO 7-2

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.

xTransmission gears broken.
xTransmission gears burns out.
Operate of noise

಺ Abrasionᇬwore and teeth hurted of gear

಺ Bearing wore and loosened.

Gear oil leaking
xToo much gear oil filled.
xOil seal wear-out or damage.

ADLY MOTO 8-3

Final Transmission Mechanism

Disassembly of primary drive gear / final reduction mechanism

಺ Disassembly of rear tire(ൺ 11-2).

಺ Disassembly of clutch / drive face(ൺ 7-6).

᧦WARNNING:

First drain the oil of transmission.

Operation / Parts name Q’ty Remark

ADLY MOTO 8-3

 Disassembly
1 Bolt 5
2 Mission cover 1
3 Washer 1
4 Dowel pin 2
5 Drive axle 1
6 Main axle comp. 1 ಺ Check the wear & damage of shaft
7 Plain washer 1
8 Primary drive gear 1 and gear. Change new one. (ൺ 8-3)
Assembly ಺ Operation with sequence in reverse
8ൺ  of disassembly.

Final Transmission Mechanism

᧦WARNNING:
Change the Driving Shaft
Install the bearing with facing
಺ Remove the driving shaft from mission outside.
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.

ADLY MOTO 8-3

ADLY MOTO 8-3
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.

ದ Disassembly of oil pump ( Chap. 3 )

ದ Disassembly of carburetor ( Chap. 4 )

ದ Disassembly of intake valve ( Chap. 4 )

ದ Dis-mounting of engine ( Chap. 5 )

ದ Disassembly of cylinder head and cylinder ( Chap. 6 )

ದ Disassembly of ACG ( Chap. 12 )

ದ Disassembly drive face ass’y ( Chap. 7 )

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಺ 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.

ADLY MOTO 9-4

 ಺ Damage of needle bearing of crankshaft pin.

Crank Case / Crank Shaft

Assembly / Disassembly of Crank Case

Operation / Parts name Q’ty Remark

ADLY MOTO 9-4

 Disassembly
1 Hex socket bolt 6
2 Right crank shaft case 1
3 Dowel pin 2
4 Fix shaft of crank shaft case 1
5 External circle clip 2
6 Crank shaft 1
7 Radial ball bearing (Right) 2
8 Radial ball bearing (Left) 1
9 Hex socket bolt 1
10 Oil seal bracket 1
11 Right oil seal 1
12 Left oil seal 1
13 Radial ball bearing 2
Assembly
13ൺ 

Crank Case / Crank Shaft

᧦WARNNING:
Disassembly of Crank Case
Must remove the oil seal when
಺ Install the puller on right crank case, separate the crank case, and never use the
separate the R. crank case and L. crank old oil seal.
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)

ADLY MOTO 9-4

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.

Crank Case / Crank Shaft

ADLY MOTO 9-4
಺ 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.

Crank Case / Crank Shaft

ADLY MOTO 9-4
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 9-4

Front Wheel / Front Suspension / Front Brake

Attention of Operation

಺ Remove 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
Steering handle not straight
Heavy steering movement x L/R suspension not balanced.
x Over tied of the steering ball race. x Front fork banded.
x Steel ball inside ball race broken. x Front tire axle banded, tire wear-out.
x Air too less inside of front tire.
Front wheel shaking
Brake efficiency abnormal x Front rim defected.
x Brake lining wear-out. x Loose of front rim bearings.
x Brake pads adjust not correct. x Tire defect.
x Brake disc attrition. x Bad adjustment of the front axle.
x Tire wear-out.

Poor Brake
಺ Bad adjustment of brake.
಺ Wear the brake pad.

ADLY MOTO 10-1

Front Wheel / Front Suspension / Front Brake

Front Wheel – Aluminum Rim

Operation / Parts name Q’ty Remarks

Disassembly of Front Wheel

1 Nut nylon 1
2 Brake hose 1
3 Hex washer face bolt 1
4 Front collar 1
5 Front fender 1
6 Front brake disc (left) 1

Assembly ವ Assembling with sequence in reverse

6ൺ  of disassembly.
 ᧦ ARNNING: Assembly of front fork
shall be aimed at convex of front fork
and brake arm.

ADLY MOTO 10-2

Front Wheel / Front Suspension / Front Brake

Front Wheel – Aluminum Rim

Operation / Parts name Q’ty Remarks

Disassembly

1 Oil seal 1
2 Radial ball bearing(left) 1
3 Front wheel spacer tube 1
4 Radial ball bearing(right) 1

Assembly ವ Assembling with sequence in

4ൺ  reverse of disassembly.

᧦WARNNING:
Must change the R/L bearing set.

ADLY MOTO 10-3

Front Wheel / Front Suspension / Front Brake

Assembly / Disassembly of Front Brake

಺ Disassembly of front disc.

Operation / Parts name Q’ty Remarks

Disassembly

1 Front collar 1
2 Brake disc hex socket bolt 3
3 Hex flange nut with serration 3
4 Front brake disc 1

Assembly ವ Assembling with sequence in

4ൺ  reverse of disassembly.

ADLY MOTO 10-4

Front Wheel / Front Suspension / Front Brake

Disassembly of Throttle Handle

಺ Disassembly of speedometer up/down lid.

Operation / Parts name Q’ty Remarks

Disassembly
1
1 Hex flange nut with serration 1
2 Right lever set bolt 1
3 Lever of front brake 1
Lever of front brake
4 Hex socket bolt 1
5 Master cylinder bracket 1
6 Master cylinder sub 1
7 Throttle cable 1
8 Handle 1
Assembly ವ Assembling with sequence in reverse
8ൺ  of disassembly.
7 1
Throttle cable ᧦WARNNING: Adjusting gap of throttle.
6 1
Master cylinder sub
᧦WARNNING: Install, make the convex
of master cylinder bracket and hole of
handle
aimed.

ADLY MOTO 10-5

Front Wheel / Front Suspension / Front Brake

Disassembly of Steering Stem

಺ Disassembly of front wheel.

಺ Disassembly of steering handle.

ADLY MOTO 10-6

Front Wheel / Front Suspension / Front Brake

Operation / Parts name Q’ty Remarks

Disassembly
Steering Main rod

1 Spaner nut 2
2 Steering stem dust cover 1 ᧦ WARNNING: No damage main
3 Lathe cone on steering top #2 1 rod & front brake.
4 Race ball #5 1
5 Steel ball 2
6 Lathe on steering inner #3 2
7 Bolt / washer 2/2
8 Front inner fender 1
9 Hex bolt 2
10 Hex bolt 2 ᧦WARNNING: Remove L/R tube by
11 Front fork 1
loose these two hex bolts.
Assembly
10ൺ 
5 2 ᧦WARNNING: Note the direction of
Steel ball
2 1
Steering stem dust cover installing bearing .
1 2
Spaner nut Assembly (ൺ 10-11)

ADLY MOTO 10-7

Front Wheel / Front Suspension / Front Brake

Disassembly of Steering Handle

಺ Disassembly of throttle handle. (ൺ 10-7)

Operation / Parts name Q’ty Remarks

Disassembly
Rear brake lever
1 Nut 1
2 Left lever set bolt 1
3 Rear brake lever 1
4 Rear brake cable 1
Bracket of rear brake lever
5 Hex socket bolt 1
6 Fixed belt of steering handle 1
7 Bracket of rear brake lever 1
Steering Handle
8 Hex flange nut with serration 1
9 Hex washer face bolt 1
10 Steering handle 1
11 Handle grip 1

ADLY MOTO 10-8

 Assembly ವ Assembling with sequence in
11ൺ  reverse of disassembly.
10 Steering handle 1
᧦WARNNING: Install steering handle
7 Bracket of rear brake lever 1
with handle convex at ditch of
4 Rear brake cable 1
main rod type part.

Front Wheel / Front Suspension / Front Brake

Turning Front Fork to Right / Left

಺ Turn the front fork several times,

make the bearing smoothly.
಺ Confirm the rotation smooth and gap
of steering main rod.

: fixed nut spanner B

಺ For no back-turning together with up-

cone seal ring, locking fixed screw to

fix it.
Locking Torque :7.0 kg-m

: Fixed nut spanner B

: Fixed nut spanner A

ADLY MOTO 10-9

ADLY MOTO 10-10
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 Q’ty Remarks

Disassembly
Muffler

1 Hex washer face bolt 2

2 Hex head phillips bolt 2
3 Assembly of exhaust pipe 1
4 Collar 1
5 Gasket of exhaust pipe 1
Rear wheel

6 Nut 1
7 Plain washer 1
8 Rear wheel 1
Assembly • Assembling with sequence in reverse
8ൺ  of disassembly.

ADLY MOTO 11-2

REAR WHEEL / SUSPENSION / BRAKE

Disassembly / Assembly of Rear Brake

಺ Disassembly of Rear Wheel.

Operation / Parts name Q’ty Remarks

Disassembly

1 Adjusted nut of rear brake 1

2 Rear brake fixture 1
3 Rear brake cable 1
4 shoe/shoe strain spring of rear brake 2/2
5 Hex washer face bolt 1
6 Rear brake arm 1
7 Reset spring 1
8 Brake cam shaft 1

Assembly • Assembly with sequence in reverse of

8ൺ 1 disassembly.

ADLY MOTO 11-3

REAR WHEEL / SUSPENSION / BRAKE

Disassembly of Rear Cushion



Operation / Parts name Q’ty Remarks

Disassembly

1 Hex washer face bolt 1

2 Nut (nylon insert) 2
3 Plain washer 2
4 Hex bolt 1
5 Rear cushion 1

Assembly • Assembly with sequence in reverse of

5ൺ 1 disassembly.

ADLY MOTO 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 Poor changing system

಺ Fuse broke.
No power ಺ Poor contact, broke and short circuit
಺ Battery discharging. of connection head or socket head.
಺ Fallening connection wire of battery. ಺ Poor rectifier.
಺ Fuse broke. ಺ Poor ACG.
಺ Poor main switch.
Spark plug no works
Low voltage ಺ Poor contact spark plug.
಺ Poor charging of battery. ಺ Poor contact, broke and short circuit
಺ Poor contact. of main wire.
಺ Poor charging system.
ದ Between ACG & C.D.I.
಺ Bad rectifier.
಺ Between CDI & ignition coil.
Current off and on
ದ Between CDI & main switch.
಺ Poor contact of battery wires.
಺ Poor contact of discharging system. ಺ Bad ignition coil.
಺ Poor contact or short circuit of ಺ Poor CDI set.
ignition system. ಺ Poor ACG.

Light weak High/low beams can’t be changed

಺ Battery discharging. ಺ Bad bulb.
಺ Resistance of wiring, switch too big. ಺ Poor lighting switch.

ADLY MOTO 12-13

 RPM unsmooth
ELECTRICAL DEVICE
಺ Ignition ಧ primary circuitry

Start motor no working

ದ Bad ignition coil.
಺ Fuse broke.
಺ Battery charging insufficiently.
ದ Wire or poor contact.
಺ Bad main switch.
಺ Poor start switch.
ದ Poor contact main switch.
಺ Poor front / rear brake switch.
಺ Poor start breaker.
಺ Ignition ಧ secondary circuitry
಺ Poor contact or broke of winding.
಺ Poor start motor.
ದ Bad ignition coil.

Powerless start motor

ದ Bad spark plug.
಺ Battery charging insufficiently.
಺ Bad contact of winding.
ದ Bad high voltage wires.
಺ Strange thing blocked in motor or
gear.
ದ Power leakage of spark plug.

Start motor return running without ಺ Ignition time

engine return running
ದ Bad ACG.
಺ Bad small gear of start motor.
಺ Counter rotation of start motor.
ದ Poor installation of statue inductor.
಺ Battery power insufficient.

ದ Poor CDI.
Turn on main switch, but no lighting
಺ Bad bulb.
಺ Bad switch. Fuel direction light no working (when
಺ Guide wire broke. without fuel)
಺ Fuse broke. ಺ Insufficient battery power.
಺ Battery discharging. ಺ Fuse broke.
಺ Bad wiring. ಺ Bad main switch.
಺ Bad gage.
Pointer of fuel gage unstable ಺ Bad switch of fuel height.
಺ Loose socket head of guide wires.
಺ Poor fuel gage. Flashing fuel direction light
಺ Bad gage. ಺ Loose connection head.
಺ Guide wires broke.
಺ Poor action of float.
಺ Poor fuel gage.

ADLY MOTO 12-13

ELECTRICAL DEVICE

Solid Wiring Diagram

ADLY MOTO 12-13

ELECTRICAL DEVICE

Disassembly Of Battery

Operation / Parts name Q’ty Remarks

Disassembly

1 Helmet box mat 1

2 Battery  end 1
3 Battery † end 1 ᧦WARRNING: Disassembly battery
4 Battery 1
from – end to † end.

Assembly • Assembling with sequence in reverse

4ൺ  of disassembly.
2 ᧦WARRNING:
Battery terminal
Connect † end first , next – end

ADLY MOTO 12-13

ELECTRICAL DEVICE
choosed.
Check Voltage of Battery
ವ No turn “ON” main switch when check

current.
಺ Remove helmet box mat and battery

cap , disassembly connection wires of Current Leakage : under 1 mA

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 (ದ  & ground guide wires.

಺ Check voltage when main switch is

“OFF ”.

᧦WARNNING:

ವ Check voltage according to sequence

from big to small.

ವ Voltmeter’s fuse will be broke when

check voltage over the under limitation

ADLY MOTO 12-13

ELECTRICAL DEVICE
಺ Start engine, turn “ON“ light switch,
open high beam.
Check Charging Status ಺ Check voltage between green (+) &
black (-) guide wires.

᧦WARNNING:

ವ Voltage will have big change following

the charging status of battery in this

check, so, must check with charging
completely, over 12.8 V.

ವ 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 : 1a2 Amp/5000rpm

Voltage of charging control:

14~15V/5000rpm

Check Voltage of Front Lighting

Control

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Check head light which wires connecting.

ADLY MOTO 12-13

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 12-13

 ELECTRICAL DEVICE

Operation / Parts name Q’ty Remarks

Disassembly

1 Hexagon socket bolt 2

2 Plain washer 2
3 Self-tapping screw 1
4 Cap of electric disc 1
5 Hexagon socket bolt 4
6 Plain washer 1
7 Fan 1
8 Hexagon nut 1
9 Spring washer 2
10 Plain washer 1
11 Fly wheel of generator 2
12 Semi-cycle of electric disc 1 ᧦WARRNING:
13 Whole body bolt 1
Take the good care, no hurt coil.
14 Hexagon socket bolt 1

Assembly ಺ Assembling with sequence in reverse

14ൺ  of disassembly.

Lighting wire: 0.1a0.8

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 (20ഒ)

Charging wire : 0.2a1.0

ADLY MOTO 12-13

 ಺ Check twice coil resistance between.
ELECTRICAL DEVICE high voltage & (-) terminal.
Ignition Coil
Standard valve : 5aN˖ 

Disassembly (without spark plug cap)

಺ 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 (20ഒ): 0.3a˖ 

᧦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 : 9.5aN˖ 

  VSDUNSOXJFDSLQWHDP

಺ Remove spark plug cap from high

Voltage coil.

ADLY MOTO 12-13

ELECTRICAL DEVICE

Assembly / Separation of Starting Motor

಺ Disassembly of starting motor.

Operation / Parts name Q’ty Remarks

Separation

1 Bolt set 2
2 Casing 1
3 Armature rotor 1
4 Carbon brash 2
5 Oil ring 1
6 Oil ring 1
7 Front fixed seat 1
Assembly ಺ Assembling with sequence in reverse
7ൺ  of disassembly.

ADLY MOTO 12-13

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 Up end of Down end

Guide wire float of float
Green &
black 0a20˖ 90a110˖

Check Main Switch

಺ Remove connection of main switch

guide wire, check conductivity
between each terminal.

black/ black
Color tea red
red
LOCK Ⴜ Ⴜ
OFF Ⴜ Ⴜ
ON Ⴜ Ⴜ

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 12-13

ELECTRICAL DEVICE

Switch of Lights

Color Yellow/red Blue

OFF
ON Ⴜ Ⴜ

Power Switch

Color blue/white Black

Up
Down Ⴜ Ⴜ

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 12-13

 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

ADLY MOTO 12-13
ELECTRICAL DEVICE

Attention of Operation

᧦Battery electrolyte contains sulfuric acid, which can cause severe burns. Avoid
contact of skin, eyes, or clothing
᧦When sulfuric acid water spill into clothing will stick to skin. Take off the clothing
and flush with water.

x Battery can be charged and discharged. Without charging, the battery will have
less lifetime and damaged after discharged.
x If the battery have short circuit inside, both terminal will not have voltage existed.
Besides, the regulator rectifier lost the function and shorter lifetime.
x 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.
x 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.
x 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.
x The Maintenance Free battery does not need to refill electrolyte or water.
x All charge system needs to be load before check.
x Do not use quick charge unless it’s in urgent.
x The battery needs to be taking out from vehicle when doing charge work.
x When checking the voltage, must use the electrical meter.

ADLY MOTO 12-7

ELECTRICAL DEVICE

TROUBLE DIAGNOSE

No Electrical Power No Continues Current

x Over discharged of the battery. x Bad contact of battery with main
x Wire hardness did not connected to wire hardness
the battery. x Bad connection of charge system
x Fuse broken. x Bad contact of the lighting system
x Main switch defect. cause short circuit

Low Voltage Charge System no function

x Battery charges insufficient. x Bad connection of the wire
x Bad connection hardness connectors
x Charge system defect. x Main wire hardness broken or
x Regulator rectifier defect. short-circuit
x Regulator rectifier defect.
x AC Generator defect.

ADLY MOTO 12-7

ELECTRICAL DEVICE

Solid Wiring Diagram

ADLY MOTO 12-7

ELECTRICAL DEVICE

Disassembly Of Battery

Operation / Parts name Q’ty Remarks

Disassembly

1 Helmet box mat 1

2 Self-tapping screw 1
3 Battery cover 1 ✱WARRNING: Disassembly battery
4 Battery  end 2 from – end to † end.
5 Battery † end 1
6 Battery 1
Assembly • Assembling with sequence in reverse
6ൺ  of disassembly.
2 ✱WARRNING:
Battery terminal
Connect † end first , next – end ,cover
both terminals with cap.

ADLY MOTO 12-7

ELECTRICAL DEVICE

ವ Don’t turn “ON” main switch when

Check Voltage of Battery
check current.

಺ Remove helmet box mat and battery

Current Leakage : under 1 mA
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 (ದ  & ground

guide wires.
಺ Check voltage when main switch is
“OFF ”.

✱WARNNING:

ವ Check voltage according to sequence

from big to small.

ವ Voltmeter’s fuse will be broke when

check voltage over the limitation

choosed.

ADLY MOTO 12-7

 

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Check head light which wires

connecting.
ELECTRICAL DEVICE
಺ Start engine, turn “ON“ light switch,
Check Charging Status open high beam.
಺ Check voltage between green (+) &
✱WARNNING: black (-) guide wires.

ವ Voltage will have big change following

the charging status of battery in this

check, so, must check with charging
completely, over 12.8 V.

ವ 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 : 1a2 Amp/5000rpm

Voltage of charging control:

14~15V/5000rpm

Check Voltage of Front Lighting

Control

಺ 'LVDVVHPEO\IURQWFRYHULQJRI

KDQGOH

ADLY MOTO 12-7

 Check the Rectifier

಺ Check the rectifier.

಺ Disassembly connector of rectifier.
಺ Check the terminal of connector.

ELECTRICAL DEVICE

✱WARNNING: Check in range of AC.

಺ Check voltage adjuster when voltage
is not in the range controlling.

Control voltage: 12~14V/5000rpm

Disassembly of ACG

ADLY MOTO 12-7

ELECTRICAL DEVICE

Operation / Parts name Q’ty Remarks

Disassembly

1 Hexagon socket bolt 2

2 Plain washer 2
3 Self-tapping screw 1
4 Cap of electric disc 1
5 Hexagon socket bolt 4
6 Plain washer 1
7 Fan 1
8 Hexagon nut 1
9 Spring washer 2
10 Plain washer 1
11 Fly wheel of generator 2
12 Semi-cycle of electric disc 1 ✱WARRNING:
13 A.C.G base 1 Beware not to damage the coil.
14 Hexagon socket bolt 1

Assembly ಺ Assembling with sequence in reverse

14ൺ  of disassembly.

ACG ( Charging Coil ) Check

✱WARNNING:
Checking in the engine connected
With start motor.

಺ Disassembly ACG connection.

಺ Check resistance of charging wire &
lighting wire.

ADLY MOTO 12-7

 Check ignition status with
performance tester due to this test has its
own stanard.

಺ Check second coil resistance between

spark plug cap & (-) terminal.

Standard valve : 9.5aN˖ 

  VSDUNSOXJFDSLQWHDP

಺ Remove spark plug cap from high

Voltage coil.
಺ Check second coil resistance between
ELECTRICAL DEVICE high voltage & (-) terminal.
Ignition Coil
Standard valve : 5aN˖ 

Disassembly (without spark plug cap)

಺ 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 first coil resistance of ignition
terminal.

Standard valve (20ഒ): 0.3a˖ 

✱WARNNING:

ADLY MOTO 12-7

ELECTRICAL DEVICE

Assembly / Separation of Starting Motor

಺ Disassembly of starting motor.

Operation / Parts name Q’ty Remarks

ADLY MOTO 12-7

 Separation

1 Bolt set 2
2 Casing 1
3 Armature rotor 1
4 Carbon brash 2
5 Oil ring 1
6 Oil ring 1
7 Front fixed seat 1
Assembly ಺ Assembling with sequence in reverse
7ൺ  of disassembly.

ELECTRICAL DEVICE

Check Fuel Gauge

಺ Remove fuel gauge.

಺ Put the float to up top bottom position
to check the resistance between each
terminal.

Terminal of Up end of Down end

Guide wire float of float
Green &
black 0a20˖ 90a110˖

Check Main Switch

಺ Remove connection of main switch

guide wire, check conductivity
between each terminal.

Color Brown black/ black red

red
LOCK Ⴜ Ⴜ
OFF Ⴜ Ⴜ
ON Ⴜ Ⴜ

ADLY MOTO 12-7

Exchange main switch
಺ Remove front cover.
಺ Remove 2 bolts, disassembly main switch.
಺ Installing with the sequence in reverse of disassembly.

Check switch of handle

಺ Remove the speedometer up/down lid.
಺ Disassembly connection of handle switch, check conductivity between each
terminal.

Dash light
಺ Remove the speedometer up lid pull
ELECTRICAL DEVICE out the connection of bulb, and replace
the bulb.
Switch of Lights

Color Yellow/red Blue

OFF
ON Ⴜ Ⴜ

Start Switch

Color blue/white Black

Up
Down Ⴜ Ⴜ

Exchange of Bulbs

Head light bulb

಺ Remove front covering of handle press
down the connection and press down
turn left to change head light bulb.

ADLY MOTO 12-7

 MENO

ELECTRICAL DEVICE

Rear light bulb / Brake light bulb /

Rear direction light bulb

಺ Remove 2 screws, pull out the light

cover then change bulb.
಺ Remove R/L screw on direction light
Cover, pull out the cover then replace
the bulb.

ADLY MOTO 12-7

Voltmeter ammeter
terminal of main fuse
main fuse

ADLY MOTO 12-7