Adly Baboon 25 km/t (SF-50, SF-100) servicemanual
Contents
1. Tl2. Assembly e Assembly with sequence in reverse of 8 gt 1 disassembly ADLY MOTO 11 3 REAR WHEEL SUSPENSION BRAKE Disassembly of Rear Cushion Operation Parts name Q ty Remarks Disassembly Hex washer face bolt Nut nylon insert Plain washer Hex bolt Rear cushion A E L LA Re me Re PN t Assembly e Assembly with sequence in reverse of Sa 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 amp 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 Low voltage Poor charging of battery Poor contact Poor charging system Bad rectifier Current off and on Poor contact of battery wires Poor contact of discharging system Poor contact or short circuit of ignition system Light weak Battery discharging Resistance of wiring switch too big ADLY MOTO Poor changing system Fuse
3. 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 eTransmission gears broken eTransmission gears burns out Operate of noise Abrasion wore and teeth hurted of gear Bearing wore and loosened Gear oil leaking eToo much gear oil filled eOil seal wear out or damage ADLY MOTO 8 3 Final Transmission Mechanism Disassembly of primary drive gear final reduction mechanism Disassembly of rear tire gt 11 2 Disassembly of clutch drive face gt 7 6 WARNNING First drain the oil of transmission Main axle comp Check the wear amp damage of shaft Plain washer 8 Primary drive gear Assembly Operation with sequence in reverse 8 gt 1 of disassembly and gear Change new one gt 8 3 ADLY MOTO 8 3 Final Transmission Mechanism Change the Driving Shaft Remove the driving shaft from mission 8 NOT Driving shaft I cover WARNNING Don t damage joint face of mission cover cap of transmission case Oil seal bearing Remove the oil seal of primary drive gear Remove the bearing A outer handle A 17 mm guide rod of puncher Install the new bearing in the mission cover Jacket punc of bearing
4. frame check the spark plug sparking 7 no sparking or sparking GE Ss ee ae el r E test the compression pressure compression pressure is normal compression pressure too low or no pressure follow the standard stat up procedure and test again engine can not ignite engine can ignite but can not start spark plug is dry spark plug is wet continue ADLY MOTO 1 4 Reason of Trouble fuel tank without gasoline tubing to carburetor blocking float chamber tubing of carburetor blocking fuel filter blocking fuel cup blocking air hole of fuel tank blocking spark plug grimy or damage C D I damage main switch damage ACG fulser coil damage high tension coil damage or no gap ACG lighting coil damage valve set damage cylinder piston piston ring damage cylinder gasket leakage valve burn valve timing is not correct valve gap is too tight or no gap start clutch damage ignite timing is not correct fuel adjuste screw of carburetor isn t correct intake manifold sucking air auto plunger starter is damage fuel level of carburetor is too high auto plunger starter is damage throttle open angle is too wide INFORMATION FOR PREPARATION REVOLUTION NOT SMOOTH LOST POWER Diagnose Check and Adjust start engine and go up speed slight engine speed go up ignite timing is correct valve gap is correct compression pressure engine speed can t go up fully ign
5. WARNNING Install the bearing with facing outside Sleeve shaft of assembly tools Bearing of assebbly tools ADLY MOTO 8 3 Crank Case Crank Shaft Attention of Operation This chapter explain the necessary procedure of disassembling crank case due to repair amp 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 amp 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 Special tool I 6 Special tool Special tool es Special too Operation Parts name Q ty Remark Disas
6. too high battery have not battery have voltage normal over charge main switch at ON main switch at ON the battery have the battery have no voltage voltage normal socket loosen ADLY MOTO Check and Adjust Weg ee ea 7 start engine and measure voltage of the two a terminal for battery aoe ee eel measure the resistance of ACG coil l check socket of regulator loosen check the socket of regulator 1 8 Reason of Trouble battery damage coil damage terminal damage YL wire damage R wire damage regulator damage socket damage ACG damage GR wire broken socket damage regulator damage INFORMATION FOR PREPARATION SPARK PLUG NO SPARKING Diagnose Check and Adjust Reason of Trouble change spark plug and check again sparking strong the previous spark plug damage weak check spark plug cap ignition coil loosen check C D I unit socket loosen check the terminal of C D I unit unimpeded i measure resistance f check relate spare parts fen aa A ee ee main switch damage pulser coil damage coil damage lighten coil damage main switch damage socket joint connect abnormal the previous C D I unit damage ADLY MOTO 1 9 the previous coil damage ADLY MOTO 2 CHECK AND ADJUST Way of Check and Service 2 1 Disassembly of External Parts 2 3 Layout of Maintenance
7. Reed valve ass y 1 5 Reed valve gasket 1 Assembly Assembling with sequence in reverse 571 of disassembly WARNNING Using new washer the 4 Reed valve ass y washer must aim at hole of reed 5 Reed valve gasket valve WARNNING confirm no secondary air entering after installing ADLY MOTO 4 7 FUEL INSTALLATION Disassembly of Fuel Tank Disassembly of body cover Disassembly of tail light fix bracket Disassembly of inner carrier WARNNING No fire Shall be wiped off when fuel overflowed 4 1 1 1 1 1 4 1 4 Tail light fix bracket Inner carrier WARNNING Clip the tube avoid fuel over flow Operating with sequence in reverse of disassembly Change new one ADLY MOTO 4 8 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 Remarks 2 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 O ONDA WN BW YN a NO e BR e WO KR N Grommet Assembly Oper
8. broke Poor contact broke and short circuit of connection head or socket head Poor rectifier Poor ACG Spark plug no works Poor contact spark plug Poor contact broke and short circuit of main wire Between ACG amp C D Between CDI amp ignition coil Between CDI amp main switch Bad ignition coil Poor CDI set Poor ACG High low beams can t be changed Bad bulb Poor lighting switch ELECTRICAL DEVICE 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 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 Turn on main switch but no lighting Bad bulb Bad switch Guide wire broke Fuse broke Battery discharging Bad wiring Pointer of fuel gage unstable Loose socket head of guide wires Poor fuel gage Bad gage ADLY MOTO 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 s
9. 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 Fixed nut spanner B 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 Q ty Remarks Disassembly Muffler Hex washer face bolt Hex head phillips bolt Assembly of exhaust pipe Collar Gasket of exhaust pipe A E L LA Re Re Re LO LO Rear wheel nN Nut 1 Plain washer 1 Rear wheel 1 on Assembly e Assembling with sequence in reverse 8 gt 1 of disassembly ADLY MOTO 11 2 REAR WHEEL SUSPENSION BRAKE Disassembly Assembly of Rear Brake Disassembly of Rear Wheel _ Operation Parts name Remarks 2 Disassembly 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 GO J G Lh EL LA a N e e Ket e Ke N
10. 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 3 1 ADLY moto 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 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 T Fuel pipe WARNNING 3 2 2 Oil connection pipe 3 Pan phillips bolt 4 Motor oil pump 3 3 ADLY moto Clogging the pipe with clamp or plug for avoiding fuel flow out e Remove from both side of motor oil pump e Assembly with sequence in reverse of disassembly WARNNING Smear motor oil to new O ring then assembly
11. oil joint WARNNING Release air E FUEL INSTALLATION ADLY MOTO 4 4 Disassembly Assembly Carburetor Disassembling of carburetor Adjust the idle speed Adjust the air adjust screw WARNNING No fire 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 Start plug screw Oil ring O ON DN Float Chamber Pan phillips bolt Drain plug Over flow tube Pan phillips bolt Float pin Float Needle valve e d k e e A 11 12 13 Carburetor Ass y Throttle screw set Air adjust screw set Float chamber seal WARNNING Must confirm rerotation location before disassembling not locking too much avoid to hurt seat face 12 Assembly 131 Air adjust screw set Operating with sequence in reverse of Disassembling 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 l 2 Hex washer face bolt 4 3 Intake manifold l 4
12. AD CYLINDER PISTON Attention of Operation e Can be operated when engine installed on vehicle e Must cleaning before operating avoiding dust enter the engine e Remove the gasket dust stay on joint face e When remove the cylinder avoid to use screw driver to damage the joint face e Avoid to damage the cylinder inner surface and piston face e 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 e Air leakage of cylinder head gasket e Wear amp damage the piston ring e Wrong installation of spark plug e Wear amp damage the cylinder and piston s Inlet valve poor Compression pressure too high overheating locking e Piling up carbon of cylinder head or piston head Piston Knocking Noise e Wear the cylinder and piston e Wear the piston pin hole and piston pin e Wear the needle bearing of crank connecting rod small end Piston ring noise e Wear or damage the piston ring e Wear or damage the cylinder 6 1 ADLY moto Disassembly of Cylinder Head Cylinder Piston e Disassembly of L R side cover e Disassembly of generator e Disassembly of spark plug cap e Disassembly of cylinder air throud l 4kg a 6 2 ADLY moto Operation Parts Name 1 Nut of cylinder head 2 Cylinder head 3 Cylinder head gasket O oN AA Q ty Rem
13. ATION ADLY MOTO Front 120 90 10 Rear 130 90 10 Disc Drum 1 1 Front 120 90 10 Rear 130 90 10 LOCKING TORQUE Adopt the standard torque locking for the item unlisted STANDARD TORQUE Locking Torque kg m 6 mm Hex Washer Face Bolt Nut 8 mm Hex Washer Face Bolt Nut 10 mm Hex Washer Face Bolt Nut CHASSIS Spanner Nut of Handle Steering Steam 1 25 7 0 Front Wheel Axle Nut 1 f i o 45s Rear AxleNut a a Rear Brake T _o E Upper Screw of Rear Shock Absorber 1 10 40 Lower Screw of Rear Shock Absorber 1 8 27 ENGINE ee R S FlywheelNut y o 8 Clutch Jacket Nut oi 8 S 1 3 ke TT Oil chock Screw g 8 Joint Screw of Exhaust Manifold 2 6 12 Exhaust Pipe Support Screw of Muffler 2 6 12 Spak Pws Pt Bolt of Crank ShaftCase 6 6 1 Bolt of Engine Installation 1 8 5o Re NINJ ADLY MOTO 1 2 The following drawing that shows the disassembling situation of the cover parts for SF5 0 scuuter INFORMATION FOR PREPARATION 1 3 ADLY MOTO INFORMATION FOR PERPARATION DIFFICULT START OR CANN T START Diagnose Check and Adjuster loose the fuel release screw of caruretor and check if the fuel is inside of carburetor fuel supply to carburetor is sufficient no fuel supply to carburetor loosen the spark plug connect with the spark cap and contact with the
14. 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 Imm _ Jacket punch outer handle A it seal 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 Special tool Bearing puller TLJT 00 Install the new R oil seal to crank case Special tool 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 Fron
15. Items 2 6 Way of Check amp Adjustment 1 Mark is checking time 2 Mark Yx is the regular exchange of service items ADLY Moro 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 petor Ist each 6Jeach 12 riding Operating Device Handle Play loose tight o Operation P Wheels Right left turn round angle o Front Fork Damage o o Direction Post Installation of shaft Direction Post Shaft Gap O Brake Device Brake Play o o Try to run o 5 o Play of brake lever Correct brake E o 10 20 mm O O Wires Loose tight and damage S O O Gap of casing amp brake o o Wore of brake amp operating parts O Direction 2 1 ADLY Moro Wore amp Damage of casing Standard diameter 110mm o Limitation 110 5mm Riding Device front rear Tires Air pressure of tires o o o Air pressure 1 50 kg cm 1 75 kg cm tire 120 90 10 130 90 10 Service Time month Service Items Judgement Standard Remarks Pook Ist each 6Jeach 12 riding Riding Device Tires Ditch front and rear wheel S till 0 8 mm Check amp damage of tires E a 2 Abnormal amp d
16. RICAL DEVICE WARNNING Check in range of AC Check voltage adjuster when voltage Is not in the range controlling Control voltage 12 14V 5000rpm regulator 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 Operation Parts name Remarks Disassembly 2 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 12 Semi cycle of electric disc Whole body bolt Hexagon socket bolt OMANI G Lh E LA LA KR Et WARRNING Take the good care no hurt coil Ww d K LD t NO e ke ke E Ket ea LD Le PAS Assembly Assembling with sequence in reverse 14 gt 1 of disassembly ACG Charging Coil Check WARNNING Checking in the engine connected With start motor Disassembly ACG connection Check resistance of charging wire amp lighting wire Standard valve 20 C Charging wire 0 2 1 0 Lighting wire 0 1 0 8 ADLY MOTO 12 8 ELECTRICAL DEVICE Cneck twice coil EE between high voltage amp terminal Ignition Coil 8 Standard valve 5 7 KQ Disassembly without spark plug cap Disassembly spark plug cap Separating cable disa
17. SERVICE MANUAL SF 50 Baboon Z 25km OCT 2001 High power Engine HER CHEE INDUSTRLAL CO LTD INTRODUCTION This Service Manual is provided as the technical information for the check amp preparation of ADLY SF 50 S 25km 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 SF 50 25km 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 sese eee ee eee 1 Diagnose of Brake Dowty sisi casual ea eee 1 Check amp AdIuSHmmnent ss sese eee 2 Engine Installation of Lubrication sese esse eee 3 Eel SGD renr TE A EA 4 Engine assembling disassembling sse eee eee eee eee 5 Cylinder head Cylinder and Piston sss witnesses 6 Starter Driving N heel assonance RTRC nT 7 Clutch Driven Wheel Assembly sese 7 Final Transmission Mechanism sse eee eee eee eee 8 Crank Shaft Case Transmission BOX see 9 Chassis Front Wheel Front Suspension Front Brake sees eee ee eee 10 Rear Wheel Rear Suspension Rear Brake see 11 BAe iti Cal Device nenene E E E 12 Witing R TTT 13 INFORMATION FOR PREPARATION Attention on Operation All washers oil rings clamp rings opening pins shall be duly replaced by a new
18. arks WARNNING Cross loosing the nuts 2 3 times WARNNING Don t knock cooling fin WARNNING During cleaning the gasket beware not to damage joint face of cylinder and crank case 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 amp 2 piston ring into piston Press the ring on few points after installed into piston to ensure the ring goes deep enough into the ditch WARNNING Change whole set of piston ring with genuine parts Piston up piston ring 6 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 e Drive belt wear out e Drive face comp damage e Clutch lining wear out e Driven ass y spring defect Power insufficient e Drive belt wear out e Driven ass y spring defect e Drive face dirty or oily e gt Weight roller wear out ADLY MOTO 7 5 Starter Driving Disc Clutch Transmission Disc Disassembly of Left Crank Ca
19. ating with sequence in reverse of 0 1 disassembly ADLY MOTO 4 1 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 Q ty Remarks Disassembly 1 ACG wire wire of start motor 2 KWARNNING 2 Starter wire of carburetor 1 The oil over flow when remove the 3 Oil tube 1 joil 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 l 12 Bolt 1 13 Engine 1 KWARNNING 14 Nut 1 e Don t damage rear fender when remove 15 Engine bracket bolt 2 the engine 16 Engine bracket 1 e Actually for brace the frame avoid body turn inside out Assembly WARNNING Carry out following adjusting 16 gt 1 after installation Cable of throttle valve Oil pump control cable Rear break cable ADLY MOTO 5 2 ADLY moto 6 CYLINDER HE
20. ck 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 amp damaging of starting shaft or gear Check the tightness amp damage of starting shaft reset spring Check the wear amp damage of bush ADLY MOTO 7 5 Driving gear Friction spring SPO Convex 0 starting shaft resrt spring bushion Starter Driving Disc Clutch Transmission Disc Check the wear amp damage of kick pinion Check the wear amp damage of kick pinion spring clip Check the wear amp damage of starting shaft bearing and driving gear Bearing of main shaft Bearing of driving gear ADLY MOTO 7 5 Starter Driving Disc Clutch Transmission Disc Disassembly of Left Crank Case gt 7 2 Operation Parts name Q ty Remark CNN Lh E LA LA KR Z255 12 Ww 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 Clutch A bush Drive face ass y be p p ked pb ked ke e p ked ked ked WARNNING Don t hurt transmission belt Separation assembling gt 7 7 Separation assembling
21. gt 7 8 Assembly 13 gt 1 Operation with sequence in reverse of disassembly ADLY MOTO 7 5 Starter Driving Disc Clutch Transmission Disc Disassembly of Sliding Driving Disc es Operation Parts name Remark Disassembly Cam plate Cam plate sliding Weight roller Primary sliding slot wheel BRWN Re ODO We Assembly Operation with sequence in reverse 4 gt 1 of separating ADLY MOTO 7 5 Starter Driving Disc Clutch Transmission Disc Disassembly of Clutch Transmission Belt Disc Operation Parts name Q ty Remark Disassembly Clutch Nut C retaining ring Washer Clutch weight set Clutch weight spring Rubber buffer Driving plate of clutch WARNNING Must replacing when the buffer have damage hardening and distortion NYDN E LA LA KR K WW WW L a 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 Assembly Operation with sequence in reverse 18 gt 1 of separating ADLY MOTO 7 5 ADLY MOTO 7 5 Final Transmission Mechanism Attention of Operation This chapter explain that final reduction mechanism maintance Can be operated in the vehicle
22. he joint of inner parts and remove the cowling Floor panel Install with reverse sequence 2 4 To selftapping screw central cover side cap decoration strip decoration strip round bolt fender ATTENTION 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 After joining the pedal and the front interior covering mount it onto the chassis ADLY Moro Luggage case Open the luggage case cover Remove 4 tapping screws and Inut 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 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 2 5 assembly Follow the mounting sequence in reverse order ADLY Moro ATTENTION Match the rear guard holes and the convex of the chassis Handle covering Remove the rear mirror Remove 3 tapping screws separate the joint from the handle rear cover and rem
23. itch in tires o o O Bolt amp nut of tires locking o o Flocking torsion Front wheel 4 0 5 0 kg m Rear wheel 10 12 kg m Damage of wheels disc o o o Vibration of wheel Front wheel horizontal under 3 mm vertical under 3 mm Rear wheel horizontal under 3 mm vertical under 3 mm Tightness of front bearing O Tightness of rear bearing o Suspension device Spring damage o Spring of shock absorber Suspension arm damage of joint gap o amp arm Tightness of installation o Power transmission device Clutch action O o o Crankcase oil leakage or damage o 2 2 ADLY morto Transmission gear oil S o Electric device Ignition device condition of ignition o o Gap of spark plug 0 6 0 7 spark plug mm Battery connection of terminal o Wiring of electrical appliance damage o or loose in connection place Service Time month Service Items Judgement Standard Remarks Before bis Ist each 6Jeach 12 riding Engine Body starting amp abnormal noise o o low speed amp accelerating o J o lIdle 1800 100 rpm exhaust O O air filter O O Lubrication device Oil and oil filter 5 o Warning light lighting Oil leakage o o Fuel installation Gasoline filter is dirty o Leakage of fuel o o Throttle gate amp choke o Fuel filter i
24. ite timing isn t correct valve gap isn t correct compression pressure is too low l blocking 1 is normal loosen spark plug no blocking i and check spark plug normal spark plug stain check the oil quantiity of crankcase is too rich or dirty l oil quantity oil quantityis 7 l is normal too rich 1 Oa one AT increase engine speed or continue turning at high continue ADLY MOTO 1 5 Reason of Trouble air cleaner blocking fuel supply isn t smooth air hole of air tank blocking exhaust pipe blocking auto plunger starter damage film of carburetor damage fuel cup damage C D I damage pulser coil damage valve gap adjusting isn t correct valve set over abrade valve set damage cylinder piston abrade cylinder gasket leakage valve timing isn t correct cleaning carburetor cleaning the stain spark plug type isn t correct oil flowing is too rich oil flowing is too lean oil doesn t circulate oil tubing blocking oil supply is too lean cylinder piston abrade mixutre gases is too lean carbon residue in combustion chamber is too more igniting time is too earily fuel isn t good clutch sliding mixutre gases is too lean carbon residue in combustion chamber is too more igniting time is too earily fuel isn t good INFORMATION FOR PREPARATION REVOLUTION NOT STABLE LOW R P M Diagnose f adjusting is correct no sucking air sparking n
25. item when dismounted 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 All items must use original parts pure oil and greases L All service shall use special tools and general tools to repair 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 Certified lubricants in cans shall be used on all the elements to be lubricated ags E After assembly performance of all elements shall be duly checked and the locking shall be duly verified Incase of an operation is performed by over 2 people the assignment shall be conducted in coordination and safety shall be the first priority Definition of signs The sign given in the Service Manual shall refer to the operation methods and observation OIL Lubrication by designated lubricant 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 Dd mmn GREASE Lubrication by grease a Dangerous and important operations ADLY MOTO 1 2 INFORMATION FOR PREPARATION SPECIFICATION TIRE FRONT REAR FRONT BRAKE REAR BRAKE INFORMATION FOR PREPAR
26. ixed belt of steering handle Bracket of rear brake lever 10 11 12 Steering Handle Hex flange nut with serration Washer Hex washer face bolt Steering handle Handle grip _ ee ked 11 Assembly 12 gt 1 Steering handle Bracket of rear brake lever Rear brake cable 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 10 5 Disassembly of Steering Stem Disassembly of front wheel Disassembly of steering handle ADLY moro so intra Po 7 Akyn Operation Parts name Q ty Remarks Z D 9 4 Lh E UNE Disassembly 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 ra HA LA a HLA LA LA a WARNNING Not to damage steering stem WARNNING Remove L R tube by loose these two hex bolts Assembly 11 gt 1 Operation with sequence in reverse procedure 10 6 ADLY moro 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 Fixed nut Spanner A and backward about 1 8 turn U Confirm the steering rotation smooth and gap
27. minals 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 amp ground guide wires Check voltage when main switch is OFF 2 WARNNING e Check voltage according to sequence from big to small terminal s Voltmeter s fuse will be broke when check voltage over the under limitation ADLY MOTO 12 5 ELECTRICAL DEVICE Start engine turn ON light switch open high beam Check Charging Status Check voltage between green amp black guide wires WARNNING e Voltage will have big change following the charging status of battery in this check so must check with charging completely over 12 8 V e There will produce big current due to voltmeter ammeter start will consume the power in battery Assembly voltmeter to terminal of main fuse start engine open light rise running amount and check charging 42 voltage amp current main fuse Charging current 1 2 Amp S000rpm 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 ADLY MOTO 12 6 ELECT
28. motor oil pump The oil pump must installed correctly into crank case Dismounting of Oil Tank ADLY Moro Disassembly Fuel pipe Fuel connection pipe Pan phillips bolt Control cable Motor oil pump Assembly 51 Operation with sequence in reverse of disassembly 3 4 WARNNING Fill motor oil with clean container WARNNING Connect correct oil pipe after assembly release the air in motor oil pump FUEL INSTALLATION Attention in Operation Pay attention to the parts which using gasoline Pipes amp 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 e 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 e Gasoline level too low Air pipe is clogged Mixed air too thick Poor action of valve of float chambe
29. ormal normal end ADLY MOTO adjusting isn t correct sucking air sparking abnormal Check and Adjust adjust the carburetor fuel adjuste screw loosen spark plug connecct with spark cap and contract with frame check the spark plug sparking 1 6 Reason of Trouble _ C D I damage pulser coil damage mixture gases too lean loosing screw mixture gases too rich locking screw gasket damage the screw of carburetor is loosen pressure tube broken spark damage or stain C D I damage A C G damage coil damage spark plug cable damage odr short main switch damage A C G damage air hole damage or blocking pressure tube damage INFORMATION FOR PREPARATION REVOLUTION NOT SMOOTH HIGH SPEED Diagnose Check and Adjust Reason of Trouble normal abnormal C D I damage ACG pulse coil damage adjusting isn t correct normal abnormal valve set damage check fuel cup supply l normal fule filter blocking air hole of fuel tank blocking fuel cup damage fuel of tank is too less 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 f normal spring broken or spring damage elastic deformation pring g end ADLY MOTO dey INFORMATION FOR PREPARATION CHARGE ABNORMAL Diagnose voltage of battery voltage of battery can t go up is normal ee measure value
30. ove the cover Dismantle the speedometer cable adapter Remove the speedometer and head light assembly Dismantle the handle switch wiring Follow the reverse sequence for ass y Matching the joint of handle cover with the head light case Load the cables and wires accordingly After the assembly check the function of all switches ADLY Moro Adjustment of the head light hena S L C Adjustment of the beam of the head light is by loosening the screw underneath the head light Assembly screw set H of head light eet dees Serviceable parts layout The drawing shows the main serviceable parts Serviceable parts layout The drawing shows the main serviceable parts Y 4N N R 5 P v 5 gvelometer case E ADLY woto Throttle vale Pull rod of front brake play action play Spark plug gt U dirty damage felly damage slack L Front tire wore damage air pressure Rear tire Front shock mee Front felly wore damage air pressure Digs sta Minas onthe 2 8 ADLY woto 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
31. park plug Ignition time Bad ACG Poor installation of statue inductor Poor CDI Fuel direction light no working when without fuel Insufficient battery power Fuse broke Bad main switch Bad gage Bad switch of fuel height Flashing fuel direction light Loose connection head Guide wires broke Poor action of float Poor fuel gage ELECTRICAL DEVICE Solid Wiring Diagram light switch light adjusting switch Re of direction light start switch horn switch Start relay start motor Y pulse prodhce acs l LA Spark plug cape AD 0 N EZ ita l IN L T L R m T M 2 WL 7 OS d 9 N LY gt W horn ADLY MOTO 12 3 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 Self tapping screw 2 from end to end 5 Battery cover 1 6 Battery 1 Assembly e Assembling with sequence in reverse 6 gt 1 of disassembly S Battery terminal SENG Connect end first next end cover with cap ADLY MOTO 12 4 ELECTRICAL DEVICE choosed Check Voltage of Battery s No turn ON main switch when check current Remove helmet box mat and battery cap disassembly connection wires of Current Leakage under I mA battery check voltage between battery ter
32. r Gasoline level too high Air nozzle is clogged Auto side plunger poor FUEL INSTALLATION ADLY MOTO 4 1 Disassembly Assembly Valve Of Throttle Disassembly of left body covering Adjustment of play of throttle Adjustment of reverse rotation of idle speed o gt COE E L Y Disassembly Pan phillips bolt Throttle valve Throttle cable Throttle valve spring WARNNING Loosing top cap of carburetor and removing Carburetor gasket Throttle cover Including the reducer WARNNING Remove from guide wire of throttle valve 1 2 3 4 5 6 7 8 Se e e e Se Se eS eS RS RS PD ADLY MOTO 4 2 Retainer WARNNING Assembly of throttle valve Sealing set of guide wire Throttle cover WARNNING Assembly of throttle cable Carburetor gasket Throttle valve spring Throttle cable Throttle valve 1 1 1 1 1 1 1 1 WARNNING Ain the ditch of throttle Pan phillips bolt valve to chamber then install throttle valve into carburetor Lock the throttle cover FUEL INSTALLATION ADLY MOTO 4 3 Disassembly of Carburetor Remove the air cleaner ass y Remove the left body cover Disassembly Throttle valve set Gasoline pipe Motor oil joint Starter wire of carburetor Vacuum pressure tube Clip Intake manifold hose clamp WARNNING Don t let dust enter into carburetor GO unu G NN BW N a Carburetor Assembly 8 1 3 Motor
33. s clogged O Oil level O Alteration of pipes each 2 years Lights amp direction lights Action O o On off normal dirty damage o ADLY Moro Rear view mirror O O Instrument action O Exhaust pipe amp muffler Installation loosed or damage o Function of muffler o Frame amp body loose or damage o Abnormal from previous day confirm o normal Others greasing of each part o o Cleaning combustion chamber exhaust o pipe and carbon muck in muffler Disassembly of External Parts Remove the external parts for checking and adjustment Read cover Open the seat Front Cover Remove the 2 hex nuts 1 bolt to Remove 4 tapping screws and 3 hex remove the luggage rack nuts Remove 10 self tapping screws and 2 Separate the joint of inner parts and round headed bolts remove the cowling Remove the central and body cover Install with reverse sequence Install with reverse sequence ATTENTION E ENON Be sure of not damaging the front pane Please do keep away the unit of the body land the front inner union the convex and the pedal from damages and concave portions Before tightening the screws be sure of While tightening the screws be sure of correct matching of all units the matching with the luggage case Cowling Remove 4 tapping screws and 2 round head bolts Separate t
34. se 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 6 gt 1 of disassembly ADLY MOTO 7 5 Starter Driving Disc Clutch Transmission Disc Disassembly of Kick Starter Disassembly of left crank case cover Operation Parts name Q ty Remark 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 WARNNING Rotating pedal kick crank and remove the assembly O G 4 G Lh E LA LA a Kek Kk Ke Kek K Ke Ke Kt ADLY MOTO 7 5 Starter Driving Disc Clutch Transmission Disc Operation Parts name Q ty Remark Assembly 9 Washer 1 8 Starting shaft reset spring 1 amp 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 l flat driver will inside outside 4 Kick crank 1 l 3 Hex washer Pics boli 1 spring part then press main shaft 2 Kick pinion 1 1 Kick pinion spring clip 1 Installation of Kick Pinion Ki
35. sembly 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 12 Left oil seal 13 Radial ball bearing MO 9 4 G Lh E LA LA KR NOR RB Re RB RE NF NRF NK A Assembly 13 gt 1 ADLY MOTO 9 2 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 crank case puller Right crank case Left crank case Crank shaft crank case puller bearing puller Clean the crank case with gasoline and check the each part whether damaged or crack WARNNING ADLY MOTO 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
36. ssembling 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 O 0 3 0 5Q WARNNING Check ignition status with performance tester due to this test has its own stanard Check twice coil resistance between spark plug cap amp terminal Standard valve 9 5 11 KQ spark plug cap in team Remove spark plug cap from high Voltage coil ADLY MOTO 12 9 ignition coil spark plug s cap ADLY MOTO 12 10 ELECTRICAL DEVICE Assembly Separation of Starting Motor Disassembly of starting motor Operation Parts name Q ty Remarks Separation Bolt set Casing Armature rotor Carbon brash Oil ring Oil ring Front fixed seat 4 G Lh E LA LA KR ed POR N Assembly Assembling with sequence in reverse T T of disassembly ADLY MOTO 12 11 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 cnd of Downend Guide wire float of float Green amp black 0 200 90 1100 Check Main Switch Remove connection of main switch guide wire check conductivity between each terminal main
37. switch Color tea ora black red connection head of main switch LOCK o o OFF E o ON H a a E 2 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 12 ELECTRICAL DEVICE Switch of Lights Color Yellow red Blue OFF ON a o Power Switch Color blue white Black Up Down oo 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 en a ee Tic 7 est S P yen cota ee aae Y 9 ra lt i 0 e C head light bulb ELECTRICAL DEVICE rear direction rear light brake light bulb bulb rear light brake light covering 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 direction light covering disassembly light covering of direction light and bulb finally change bulb MENO ADLY MOTO 12 14
38. t rim defected Loose of front rim bearings Tire defect Bad adjustment of the front axle 10 1 ADLY moro Disassembly Assembly of Front Wheel Operation Parts name Q ty Hex washer face bolt Front collar Front fender Nn LA LA a Front brake disc Remarks Operation with sequence in reverse procedure WARNNING Assembly of right fork shall be aimed at convex of speedometer gear Assembly Disassembly of Front Rim 10 2 ADLY moro Disassembly of front wheel Remarks Radial ball bearing Front wheel spacer tube BRWN Re Operation with sequence in reverse procedure WARNNING Must change the R L bearing set Assembly Disassembly of Front Disk Assembly Disassembly of Front Disk 10 3 ADLY moto G Lh E L LA a Operation Parts name Q ty Remarks Disassembly Front collar Brake disc hex socket bolt Hex flange nut with serration Nylon insert lock nut Operation with sequence in reverse procedure 10 4 Disassembly of Steering Handle Disassembly of throttle handle Dismount rear brake cable ADLY moto Operation Parts name Q ty Remarks BRWN a Disassembly Rear brake lever Nut Left lever set bolt Rear brake lever Rear brake cable ee NN Bracket of rear brake lever Hex socket bolt F
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