1. Manuals
  2. Brands
  3. ADLY MOTO Manuals
  4. Scooter
  5. TB-50 Gazelle
  6. Service manual

ADLY MOTO TB-50 (Gazelle) Service Manual

Hide thumbs Also See for TB-50 (Gazelle):
Table of Contents

Advertisement

Quick Links

See also: Owner's Booklet
SERVICE MANUAL
TB-50 (Gazelle) / 100
December, 1998
High Power Engine
HER CHEE INDUSTRIAL CO., LTD.
ADLY MOTO
1-1

Advertisement

Table of Contents
loading

Related Manuals for ADLY MOTO TB-50 (Gazelle)

Summary of Contents for ADLY MOTO TB-50 (Gazelle)

  • Page 1 SERVICE MANUAL TB-50 (Gazelle) / 100 December, 1998 High Power Engine HER CHEE INDUSTRIAL CO., LTD. ADLY MOTO...
  • Page 2 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...
  • Page 3 I N D E X Information of preparation Check and Adjust Engine- Installation of Lubricant Fuel Installation Engine dismounting/disassembling Cylinder head, Cylinder and Piston Starter / Driving Disc / Clutch / Transmission Final Transmission Mechanism Crankcase, Crankshaft and Transmission box Chassis- Front wheel, Brake, Suspension Rear heel, Brake, Suspension...
  • Page 4 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.
  • Page 5 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.
  • Page 6 INFORMATION FOR PREPARATION SPECIFICATION TB50  TB100  TYPE 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...
  • Page 7 INFORMATION FOR PREPARATION LOCKING TORQUE Adopt the standard torque locking for the item unlisted. STANDARD TORQUE Type Locking Torque (kg-m) 5 mm Screw 6 mm Screw 6 mm Hex Washer Face Bolt / Nut 8 mm Hex Washer Face Bolt / Nut 10 mm Hex Washer Face Bolt / Nut CHASSIS Locking Place...
  • Page 8 INFORMATION FOR PREPARATION The following drawing that shows the disassembling situation of the cover parts for TB50/100 scuuter. ADLY MOTO...
  • Page 9 ADLY MOTO...
  • Page 10 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 tubing to carburetor blocking fuel supply to no fuel supply to float chamber tubing of carburetor blocking...

  • Page 11: Check And Adjust

    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...
  • Page 12 INFORMATION FOR PREPARATION REVOLUTION NOT STABLE (LOW R.P.M.) Diagnose Check and Adjust Reason of Trouble ignition timing adjusting C.D.I damage normal 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)
  • Page 13 INFORMATION FOR PREPARATION REVOLUTION NOT SMOOTH(HIGH SPEED) &KHFN DQG $GMXVW 5HDVRQ RI 7URXEOH Diagnose 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...
  • Page 14 INFORMATION FOR PREPARATION CHARGE ABNORMAL &KHFN DQG $GMXVW 5HDVRQ RI 7URXEOH Diagnose start engine and measure voltage of the two terminal for battery voltage of battery voltage of battery battery damage can't go up is normal measure the resistance of ACG coil coil damage measure value...
  • Page 15 INFORMATION FOR PREPARATION SPARK PLUG NO SPARKING Diagnose &KHFN DQG $GMXVW 5HDVRQ RI 7URXEOH change spark plug and check again no sparking or the previous spark plug damage sparking strong weak check spark plug, cap, ignition coil loosen? loosen no loosen spark plug cap loosen check C.D.I unit socket loosen ?
  • Page 16 ADLY MOTO 1-12...
  • Page 17 CHECK AND ADJUST Way of Check & Adjustment 1. Mark “ ” is checking time. 2. Mark “ ” is the regular exchange of service items. This exchange time is just for general riding of the majority not for the special use , please arrange with this principle according to the difference of the riding condition.
  • Page 18 Riding Device front rear air pressure Tires-Air pressure of tires  NJFP  NJFP tire 120/70-12 120/70-12 Riding Device Tire Check & damage of tires Ditch-front wheel till 0.8mm Rear wheel till 0.8 mm Abnormal & ditch in tires Bolt & nut of tires locking Flocking torsion Front wheel –...
  • Page 19 Transmission 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 Gap of spark plug 0.6~0.7 mm spark plug Battery -connection of terminal Wiring of electrical appliance – damage or loose in connection place Check Items Before...
  • Page 20 Rear mirror – view Reflector & license tag –dirty & damage Instrument –action Exhaust pipe & muffler Installation loosed or damage Function of muffler Frame & body –loose or damage Abnormal from previous day –confirm normal Others - greasing of each part Cleaning combustion chamber , exhaust pipe , and carbon muck in muffler CHECK AND ADJUST...

  • Page 21: Table Of Contents

    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...

  • Page 22: Check And Adjust

    Installing to the luggage box after composing confirming the pedal with the joint of luggage case correctly. Disassembly of Luggage Case Remove front fender. x Disconnect the light connectors. Remove power switch cap. Remove edge nut on luggage case. x Install with the reverse sequence. WARNNING: Going on the installation operation after jointing correctly the luggage...

  • Page 23: Remove 4 Bolts, 6 Self-Tapping Screws

    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...
  • Page 24 ADLY MOTO...

  • Page 25: Warnning

    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.
  • Page 26 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.
  • Page 27 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.
  • Page 28 INSTALLATION OF LUBRICATION Operation / Parts Name Q’ty Remarks Disassembly ✱WARNNING: Fuel pipe Clogging the pipe with clamp or plug for avoiding fuel flow out. x Remove from both side of motor oil Fuel connection pipe Pan phillips bolt pump. x Remove from oil pump.
  • Page 29 x Assembly with sequence in reverse Assembly 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.
  • Page 30 Operation / Parts Name Q’ty Remarks Disassembly Joint of oil disassembly oil pipe WARNNING: Joint of wires Fill motor oil with clean container. Bolt Oil tank Grommet x Operation with sequence in reverse of Assembly disassembly. WARNNING: Connect correct oil pipe after assembly , release the air in motor oil pump.

  • Page 31: Fuel Installation

    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...

  • Page 32: Operation / Parts Name Disassembly

    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 Pan phillips bolt WARNNING: Throttle valve Loosing top cap of carburetor, and Throttle cable removing.

  • Page 33: Bolt

    FUEL INSTALLATION Operation / Parts Name Q’ty Remarks Assembly Adjusted screw Clamp WARNNING: Assembly of needle nozzle. Needle nozzle WARNNING: Assembly of throttle valve. Washer Sealing set of guide wire Throttle cover WARNNING: Assembly of throttle cable. (Including the reducer) Washer Throttle valve spring Throttle cable...
  • Page 34 FUEL INSTALLATION Disassembly of Carburetor  Remove the air cleaner ass’y .  Remove the left body cover Operation / Parts Name Q’ty Remarks Disassembly Throttle valve set Gasoline pipe Motor oil joint Starter wire of carburetor Vacuum pressure tube Clip Intake manifold hose clamp Carburetor...

  • Page 35: Fuel Installation

    FUEL INSTALLATION 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...
  • Page 36 FUEL INSTALLATION Operation / Parts Name Q’ty Remarks Disassembly Plunger starter Pan Phillips bolt Start plug screw Oil ring Float Chamber Pan Phillips bolt Drain plug Over flow tube Pan Phillips bolt Float pin Float Needle valve Carburetor Ass’y Throttle screw set Air adjust screw set WARNNING: Must confirm rerotation Float chamber seal...

  • Page 37: Assembly 5O1

    FUEL INSTALLATION Disassembly of Inlet Valve  Disassembly of body cover.  Disassembly of carburetor. Operation / Parts Name Q’ty Remarks Disassembly Intake manifold hose clamp Hex washer face bolt Intake manifold Reed valve ass’y Reed valve gasket Assembly Assembling with sequence in reverse of disassembly.
  • Page 38 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: No fire. Shall be wiped off when fuel overflowed. Operation / Parts Name Q’ty Remarks...
  • Page 39 Petrol gauge ass’y WARNNING: Clip the tube, avoid fuel Joint of petrol gauge wire over-flow. Round phillips bolt Oil lever gauge gasket Hex flat head phillips bolt Assembly Operating with sequence in reverse of disassembly. Oil lever gauge gasket Change new one. FUEL INSTALLATION Disassembly of Petrol Gauge Disassembling wire joint of petrol...
  • Page 40 FUEL INSTALLATION Disassembly of Air Cleaner Operation / Parts Name Q’ty Remarks Disassembly Hex socket bolt Plain washer Self-tapping screw Air cleaner case cap Air cleaner element Air cleaner case Air cleaner joint Cleaner guide pipe Grommet ADLY MOTO...
  • Page 41 Assembly Operating with sequence in reverse of disassembly. ADLY MOTO...
  • Page 42 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.

  • Page 43: Starter Wire Of Carburetor

    DISASSEMBLY OF ENGINE Operation / Parts Name Q’ty Remarks Disassembly ACG wire /wire of start motor WARNNING: Starter wire of carburetor The oil over-flow when remove the Oil tube oil tube , so use clip or plug stop the seal. Fuel tube Vacuum pressure tube Cap of spark plug...
  • Page 44 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.
  • Page 45 CYLINDER HEAD / CYLINDER / PISTON Disassembly of Cylinder Head / Cylinder / Piston x Disassembly of cover ( 4-7) x Disassembly of cenerator cover ( 12-7) x Disassembly of muffler ( 11-2) x Disassembly of spark plug cap ( 5-2) ADLY MOTO...
  • Page 46 CYLINDER HEAD / CYLINDER / PISTON Operation / Parts Name Q’ty Remarks Disassembly Cylinder head ✱WARNNING: Loosing nut 2-3 times. Nut of cylinder head Cylinder head Cylinder head gasket Cylinder ✱WARNNING: Don’t knock cooling fin. Cylinder ✱WARNNING: Clean and not damage Cylinder gasket cylinder &...
  • Page 47 ADLY MOTO...

  • Page 48: Starter / Driving Disc / Clutch / Transmission

    Starter / Driving Disc / Clutch / Transmission Disc Attention of Operation Don’t make greases stick to surface of transmission belt or belt plate. Otherwise , the efficiency of power transmission will be lowered by skid. Don’t rotation the starter when remove the front cap of left crankshaft case. Diagnosis of Trouble Vehicle does not move after engine start up Drive belt wear-out...
  • Page 49 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 Hex socket bolt Carburetor tube bracket Left crank case cover Crankcase cover gasket WARNNING: Dowel pin Check the air cleaner whether...
  • Page 50 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 WARNNING: Rotating pedal kick Hex washer face bolt crank and remove the assembly.
  • Page 51 Starter / Driving Disc / Clutch / Transmission Disc Operation / Parts name Q’ty Remark Assembly Washer Starting shaft reset spring WARNNING: Unable into main Starting shaft ass’y shaft fix position when inside and Plain washer outside reset spring overlap, use External ring clamp flat-driver will inside outside Kick crank...
  • Page 52 Starter / Driving Disc / Clutch / Transmission Disc Check the wear & damage of kick pinion. Check the wear & damage of kick pinion spring clip. &KHFN WKH ZHDU GDPDJH RI VWDUWLQJ VKDIW  EHDULQJ DQG GULYLQJ JHDU ADLY MOTO...
  • Page 53 Starter / Driving Disc / Clutch / Transmission Disc Disassembly of Left Crank Case ( 7-2) Operation / Parts name Q’ty Remark Disassembly Hex washer face bolt WARNNING: Don’t hurt transmission Cone spring washer belt. One-way clutch Clamp washer Primary fixed sheave Bushing V-Belt Primary sliding slot wheel...
  • Page 54 Assembly Operation with sequence in reverse 12  of disassembly. Starter / Driving Disc / Clutch / Transmission Disc Disassembly of Sliding Driving Disc Operation / Parts name Q’ty Remark Disassembly Cam plate Cam plate sliding Weight roller Primary sliding slot wheel Assembly Operation with sequence in reverse of separating.
  • Page 55 Starter / Driving Disc / Clutch / Transmission Disc Disassembly of Clutch / Transmission Belt Disc Operation / Parts name Q’ty Remark Disassembly Clutch C retaining ring Washer Clutch weight set Clutch weight spring ✱WARNNING: Must replacing when Rubber buffer Driving plate of clutch the buffer have damage, hardening and distortion.
  • Page 56 Assembly Operation with sequence in reverse 18  of separating. ADLY MOTO...

  • Page 57: Final Transmission Mechanism

    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.
  • Page 58 Final Transmission Mechanism Disassembly of primary drive gear / final reduction mechanism Disassembly of rear tire( 11-2). Disassembly of clutch / drive face( 7-6). WARNNING: First drain the oil of transmission. Operation / Parts name Q’ty Remark ADLY MOTO...
  • Page 59 Disassembly Bolt Mission cover Washer Dowel pin Drive axle Main axle comp. Check the wear & damage of shaft Plain washer and gear. Change new one. ( 8-3) Primary drive gear Assembly Operation with sequence in reverse of disassembly. Final Transmission Mechanism WARNNING: Change the Driving Shaft Install the bearing with facing...
  • Page 60 ADLY MOTO...
  • Page 61 Crank Case / Crank Shaft Attention of Operation This chapter explain the necessary procedure of disassembling crank case due to repair & maintain the crank shaft. Before disassembling of crank case , must operation with sequence of each chapter to disassembly. Disassembly of oil pump ( Chap.
  • Page 62 Damage of needle bearing of crankshaft pin. Crank Case / Crank Shaft Assembly / Disassembly of Crank Case Operation / Parts name Q’ty Remark ADLY MOTO...
  • Page 63 Disassembly Hex socket bolt Right crank shaft case Dowel pin Fix shaft of crank shaft case External circle clip Crank shaft Radial ball bearing (Right) Radial ball bearing (Left) Hex socket bolt Oil seal bracket Right oil seal Left oil seal Radial ball bearing Assembly 13 ...
  • Page 64 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...
  • Page 65 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.
  • Page 66 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...
  • Page 67 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 L/R suspension not balanced.
  • Page 68 Front Wheel / Front Suspension / Front Brake Front Wheel – Aluminum Rim Operation / Parts name Q’ty Remarks Disassembly of Front Wheel Nut nylon Brake hose Hex washer face bolt Front collar Front fender Front brake disc (left) Assembly Assembling with sequence in reverse of disassembly.
  • Page 69 Front Wheel / Front Suspension / Front Brake Front Wheel – Aluminum Rim Operation / Parts name Q’ty Remarks Disassembly Oil seal Radial ball bearing(left) Front wheel spacer tube Radial ball bearing(right) Assembly Assembling with sequence in reverse of disassembly. WARNNING: Must change the R/L bearing set.
  • Page 70 Front Wheel / Front Suspension / Front Brake Assembly / Disassembly of Front Brake Disassembly of front disc. Operation / Parts name Q’ty Remarks Disassembly Front collar Brake disc hex socket bolt Hex flange nut with serration Front brake disc Assembly Assembling with sequence in reverse of disassembly.
  • Page 71 Front Wheel / Front Suspension / Front Brake Disassembly of Throttle Handle Disassembly of speedometer up/down lid. Operation / Parts name Q’ty Remarks Disassembly Hex flange nut with serration Right lever set bolt Lever of front brake Lever of front brake Hex socket bolt Master cylinder bracket Master cylinder sub...
  • Page 72 Front Wheel / Front Suspension / Front Brake Disassembly of Steering Stem Disassembly of front wheel. Disassembly of steering handle. ADLY MOTO 10-6...
  • Page 73 Front Wheel / Front Suspension / Front Brake Operation / Parts name Q’ty Remarks Disassembly Steering Main rod Spaner nut Steering stem dust cover WARNNING: No damage main Lathe cone on steering top #2 rod & front brake. Race ball #5 Steel ball Lathe on steering inner #3 Bolt / washer...
  • Page 74 Front Wheel / Front Suspension / Front Brake Disassembly of Steering Handle Disassembly of throttle handle. ( 10-7) Operation / Parts name Q’ty Remarks Disassembly Rear brake lever Left lever set bolt Rear brake lever Rear brake cable Bracket of rear brake lever Hex socket bolt Fixed belt of steering handle Bracket of rear brake lever...
  • Page 75 Assembly Assembling with sequence in 11  reverse of disassembly. Steering handle WARNNING: Install steering handle Bracket of rear brake lever with handle convex at ditch of Rear brake cable 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.
  • Page 76 ADLY MOTO 10-10...
  • Page 77 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.
  • Page 78 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 Rear wheel Plain washer Rear wheel Assembly •...
  • Page 79 REAR WHEEL / SUSPENSION / BRAKE Disassembly / Assembly of Rear Brake Disassembly of Rear Wheel. Operation / Parts name Q’ty Remarks 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...
  • Page 80 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 Assembly • Assembly with sequence in reverse of disassembly. ADLY MOTO 11-4...

  • Page 81: Electrical Devices

    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 &...
  • Page 82 RPM unsmooth ELECTRICAL DEVICE Ignition primary circuitry Start motor no working Bad ignition coil. Fuse broke. Battery charging insufficiently. Wire or poor contact. Bad main switch. Poor start switch. Poor contact main switch. Poor front / rear brake switch. Poor start breaker. Ignition secondary circuitry Poor contact or broke of winding.

  • Page 83: Wiring Diagram

    ELECTRICAL DEVICE Solid Wiring Diagram ADLY MOTO 12-13...
  • Page 84 ELECTRICAL DEVICE Disassembly Of Battery Operation / Parts name Q’ty Remarks Disassembly Helmet box mat Battery  end Battery † end WARRNING: Disassembly battery Battery from – end to † end. • Assembling with sequence in reverse Assembly of disassembly. WARRNING: Battery terminal Connect †...
  • Page 85 ELECTRICAL DEVICE choosed. Check Voltage of Battery 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:...
  • Page 86 ELECTRICAL DEVICE Start engine, turn “ON“ light switch, open high beam. Check Charging Status Check voltage between green (+) & black (-) guide wires. WARNNING: Voltage will have big change following the charging status of battery in this check, so, must check with charging completely, over 12.8 V.
  • Page 87 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.
  • Page 88 ELECTRICAL DEVICE Operation / Parts name Q’ty Remarks Disassembly Hexagon socket bolt Plain washer Self-tapping screw Cap of electric disc Hexagon socket bolt Plain washer Hexagon nut Spring washer Plain washer Fly wheel of generator Semi-cycle of electric disc WARRNING: Whole body bolt Take the good care, no hurt coil.
  • Page 89 Check twice coil resistance between. ELECTRICAL DEVICE high voltage & (-) terminal. Ignition Coil a N Standard valve : 5 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.
  • Page 90 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 Assembly Assembling with sequence in reverse of disassembly. ADLY MOTO 12-13...
  • Page 91 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 & 0a20 90a110 black Check Main Switch Remove connection of main switch guide wire, check conductivity...
  • Page 92 ELECTRICAL DEVICE Switch of Lights Color Yellow/red Blue Power Switch Color blue/white Black Down 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.
  • Page 93 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.
  • Page 94 ADLY MOTO 12-13...
  • Page 95 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. Battery can be charged and discharged.
  • Page 96 ELECTRICAL DEVICE TROUBLE DIAGNOSE No Electrical Power No Continues Current Over discharged of the battery. Bad contact of battery with main wire hardness Wire hardness did not connected to the battery. Bad connection of charge system Fuse broken. Bad contact of the lighting system cause short circuit Main switch defect.
  • Page 97 ELECTRICAL DEVICE Solid Wiring Diagram ADLY MOTO 12-7...
  • Page 98 ELECTRICAL DEVICE Disassembly Of Battery Operation / Parts name Q’ty Remarks Disassembly Helmet box mat Self-tapping screw ✱WARRNING: Disassembly battery Battery cover Battery  end from – end to † end. Battery † end Battery • Assembling with sequence in reverse Assembly of disassembly.
  • Page 99 ELECTRICAL DEVICE 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...
  • Page 100 :$511,1* ✱ 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. Voltage will have big change following the charging status of battery in this check, so, must check with charging completely, over 12.8 V.
  • Page 101 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...
  • Page 102 ELECTRICAL DEVICE Operation / Parts name Q’ty Remarks Disassembly Hexagon socket bolt Plain washer Self-tapping screw Cap of electric disc Hexagon socket bolt Plain washer Hexagon nut Spring washer Plain washer Fly wheel of generator ✱WARRNING: Semi-cycle of electric disc A.C.G base Beware not to damage the coil.

  • Page 103: Ignition Coil

    Check ignition status with performance tester due to this test has its own stanard. Check second coil resistance between spark plug cap & (-) terminal. a N Standard valve : 9.5 VSDUN SOXJ FDS LQ WHDP Remove spark plug cap from high Voltage coil.
  • Page 104 ELECTRICAL DEVICE Assembly / Separation of Starting Motor Disassembly of starting motor. Operation / Parts name Q’ty Remarks ADLY MOTO 12-7...
  • Page 105 Separation Bolt set Casing Armature rotor Carbon brash Oil ring Oil ring Front fixed seat Assembly Assembling with sequence in reverse 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.

  • Page 106: Start Switch

    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...
  • Page 107 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...
  • Page 108 Voltmeter ammeter terminal of main fuse main fuse ADLY MOTO 12-7...

This manual is also suitable for:

Tb-100

Table of Contents