HER CHEE GTC-50 Service Manual
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HER CHEE GTC-50 Service Manual

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SERVICE MANUAL

GTC-50
January, 2011
High power Engine
HER CHEE INDUSTRLAL CO., LTD.

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  • Page 1: Service Manual

    SERVICE MANUAL GTC-50 January, 2011 High power Engine HER CHEE INDUSTRLAL CO., LTD.
  • Page 2 INTRODUCTION This Service Manual is provided as the technical information for the check & preparation of ADLY GTC-50 scooter, and the direction edited is given in diagrams with "Operation Sequence", "Key Points", and "Adjustment of Check" for reference of the service staffs.

  • Page 3: Table Of Contents

    CONTENTS Chapter Information for Preparation............1 Diagnose of Brake Down............…. 1 Check & Adjustment..............2 Engine - Installation of Lubrication ............3 Fuel system ................. Engine assembling/disassembling ..........5 Cylinder head, Cylinder, and Piston ..........6 Starter / Driving Wheel ..............7 Clutch / Driven Wheel Assembly ..........

  • Page 4: Information For Preparation

    ADLY MOTO 1. INFORMATION FOR PREPARATION *** Attention of Operation ***  All the washers, oil rings, clamping rings, cotter pins, etc., shall be replaced by new one when they have been disassembled.  After slightly locking the screws, bolts and nuts, etc., first, tighten them according to the tightening tension stipulated with the opposite angle's way from big diameter's screw to small diameter's screw, and from inside to outside.
  • Page 5 ADLY MOTO *** Attention of Operation ***  Must lubricate to the appointed part with grease oil, and the canned lubrication.  To confirm the locking parts and check the operation of each part after assembling.  Must coordinate with each other and pay attention to the safety when working over 2 people. ...
  • Page 6 ADLY MOTO SPECIFICATIONS TYPE 50 CC 1750 mm LENGTH 685 mm WIDTH 1140 mm HEIGHT 1220 mm WHEEL BASE NET WEIGHT 75Kg DISPLACEMENT 49.3 c.c. BORE X STROKE 40 x 39.2mm ENGINE TYPE 2 Stroke ,Single cylinder, AIR COOLED COMPRESSION RATIO 7 : 1 IGNITION C.D.I.
  • Page 7 ADLY MOTO Locking Torque Adopt the standard torque locking for the item unlisted. Engine Place of Locking Q'ty Screw Diameter Locking Torque (mm) (Kg-m) Screw of Cylinder Cap Flywheel Nut Clutch Jacket Nut Driving Disc Nut Special Screw of Sliding Driving Disc 0.45 Nut of Transmission Disc Oil-check Screw...
  • Page 8 ADLY MOTO The following drawing that shows the disassembling situation of the cover parts for Fox Plus scooters.
  • Page 9 ADLY MOTO...
  • Page 10 ADLY MOTO...
  • Page 11 ADLY MOTO...
  • Page 12 ADLY MOTO DIAGNOSIS OF BREAKDOWN Start-up difficult or can not start This content is the explanation of diagnosis of the engine‘s breakdown, please see each content for reference of the breakdown diagnosis not mentioned here. Loose carburetor cup screw and check if Fuel tank has no fuel ...
  • Page 13 ADLY MOTO Engine operation is not smooth after starting Loose carburetor cup bottom screw and Fuel tank has no fuel  check if the fuel arrive carburetor no fuel Blocking of fuel tube  fuel Blocking of float valve  Blocking air of fuel tank cap ...
  • Page 14 ADLY MOTO Lost power on high speed Speeding up slightly on flat road Air filter blocked  RPM rising RPM not rise Fuel blocked, Fuel tank cap blocked  Muffler is blocked  Remove spark plug and check Spark plug is dirty ...
  • Page 15 ADLY MOTO Bad idle, not smooth at low speed Check ignition timming (with timming CDI defect  light) Correct Incorrect ACG defect  Adjust carburetor air screw A/F mixture too rich (loose screw)  Adjusted well bad adjustment A/F mixture too lean (tighten ...
  • Page 16 ADLY MOTO Engine running not smooth with middle ~ high RPM Check ignition timming (with timming CDI defect  light) correct Incorrect ACG defect  Check fuel flow Low fuel level  well Poor Tube and fuel filter blocked  Fuel tank cap is blocked ...
  • Page 17 ADLY MOTO Spark plug has no spark Change new spark plug and check again Original spark plug defect  Spark weak or no spark Spark strong Check loosing between spark plug cap and Spark plug cap defect  high tension coil Loosing High tension coil defect ...
  • Page 18 ADLY MOTO Charging poor Start engine to check voltage among High voltage Rectifier  terminals of battery Voltage in normal Battery aging  Voltage not boost Bad battery  Check ACG charging coil resistance Bad starter  Normal range Out of range Yellow wiring broken ...

  • Page 19: Check & Adjustment

    ADLY MOTO 2. CHECK AND ADJUST Way of Check and Service……………………2-1 Disassembly of External Parts………………..2-3 Layout of Maintenance Items…………………2-6 Way of Check & Adjustment 1. Mark “○” is checking time. 2. Mark “☆” is the regular exchange of service items. This exchange time is just for general riding of the majority not for the special use, please arrange with this principle according to the difference of the riding condition.
  • Page 20 ADLY MOTO Service Time (month) Service Items Judgement Standard Remarks Before 1st each 6 each 12 riding Riding Device Tires Ditch-front and rear wheel till 0.8 mm ○ ○ ○ Check & damage of tires ○ ○ ○ Abnormal & ditch in tires ○...

  • Page 21: Engine

    ADLY MOTO Service Time (month) Service Items Judgement Standard Remarks Before 1st each 6 each 12 riding Engine ○ ○ Body – starting & abnormal noise ○ ○ ○ Idle : 1800±100 rpm low speed & accelerating ○ ○ exhaust ○...

  • Page 22: Front Cover

    ADLY MOTO Read cover * Open the seat. * Remove the 2 hex-nuts, 1 bolt to remove the luggage rack. * Remove 10 self-tapping screws and 2 round-headed bolts.. * Remove the central and body cover * Install with reverse sequence. ：...

  • Page 23: Floor Panel

    ADLY MOTO Floor panel * Remove the L/R side cover and body cover. * Remove 4 hex bolts. * Separate the front interior covering joint (the claw and the groove) and remove the pedal. * Follow the sequence in reverse order for assembly.
  • Page 24 ADLY MOTO Tail light assembly * Remove 2 hex bolts and rear fender assembly. * Remove the left and right body covers. * Remove 2 hex bolts and the tail light assembly. * Follow the mounting sequence in reverse order. ：...
  • Page 25 ADLY MOTO Serviceable parts layout The drawing shows the main serviceable parts. Throttle vale (action，play) Pull rod of rear brake (play) Front shock absorber (damage，slack) Rear felly (damage，slack) Spark plug Front tire (dirty，damage) (wore，damage，air pressure) Front felly (damage，slack)
  • Page 26 ADLY MOTO Serviceable parts layout The drawing shows the main serviceable parts. Pull rod of front brake (play) Front shock absorber (damage，slack) Head light Air filter (dirty，clogged， changed) Transmission case (oil leaking &oil level) Rear brake Motor oil pump Front brake...
  • Page 27 ADLY MOTO Serviceable parts layout The drawing shows the main serviceable parts.

  • Page 28: 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 29 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 Disassembly Bolt Mission cover Washer Dowel pin Drive axle ‧Check the wear &...
  • Page 30 Final Transmission Mechanism Change the Driving Shaft ‧Remove the driving shaft from mission cover. ＊WARNNING: Don’t damage joint face of mission cover. ‧Remove the oil seal of primary drive gear. ‧Remove the bearing. ‧Install the new bearing in the mission cover.
  • Page 31 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 •...
  • Page 32 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 33 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 34 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 35 Starter / Driving Disc / Clutch / Transmission Disc ‧Check the wear & damage of kick pinion. ‧Check the wear & damage of kick pinion spring clip. ‧Check the wear & damage of starting shaft , bearing and driving gear. ADLY MOTO...
  • Page 36 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...
  • Page 37 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 ‧ Operation with sequence in reverse Assembly 4 →1 of separating.
  • Page 38 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 Rubber buffer WARNNING: Must replacing when Driving plate of clutch the buffer have damage, hardening and distortion.
  • Page 39 ADLY MOTO 6. CYLINDER HEAD / CYLINDER / PISTON Attention of Operation • Can be operated when engine installed on vehicle. • Must cleaning before operating , avoiding dust enter the engine. • Remove the gasket dust stay on joint face. •...
  • Page 40 ADLY MOTO Disassembly of Cylinder Head / Cylinder / Piston • Disassembly of L/R side cover • Disassembly of generator • Disassembly of spark plug cap • Disassembly of cylinder air-throud...
  • Page 41 ADLY MOTO Operation / Parts Name Q’ty Remarks Disassembly Cylinder head WARNNING: –Cross l oosing the nuts 2-3 times. Nut of cylinder head Cylinder head Cylinder head gasket Cylinder WARNNING: Cylinder – Don’t knock cooling fin. Cylinder gasket WARNNING: –During c leaning the gasket beware not to damage joint face of cylinder and crank case.
  • 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 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 FUEL INSTALLATION Attention in Operation h Pay attention to the parts which using gasoline. h Pipes & Cable must be in accordance with the location directed of wiring diagram. h Release air in motor oil pump when remove motor oil pipe. Diagnosis of Trouble No starting h No gasoline in tank...
  • Page 45 FUEL INSTALLATION Disassembly / Assembly Valve Of Throttle h Disassembly of left body covering h Adjustment of play of throttle h Adjustment of reverse rotation of idle speed Operation / Parts Name Q’ty Remarks Disassembly ＊WARNNING: Pan phillips bolt Throttle valve Loosing top cap of carburetor, and Throttle cable removing.
  • Page 46 FUEL INSTALLATION Operation / Parts Name Q’ty Remarks Assembly Adjusted screw ＊WARNNING: Assembly of needle nozzle. Clamp Needle nozzle ＊WARNNING: Assembly of throttle valve. Washer Sealing set of guide wire ＊WARNNING: Assembly of throttle cable. Throttle cover(Including the reducer) Washer Throttle valve spring Throttle cable ＊WARNNING: Aim the ditch of throttle...
  • Page 47 FUEL INSTALLATION Disassembly of Carburetor h Remove the air cleaner ass’y . h 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 48 FUEL INSTALLATION Disassembly / Assembly Carburetor h Disassembling of carburetor. h Adjust the idle speed. h Adjust the air adjust screw. ＊ WARNNING: ․No fire. ․Before disassembling, loose oil-draining screw, draining out the gasoline from carburetor. FUEL INSTALLATION ADLY MOTO...
  • Page 49 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 1 ＊WARNNING: Must confirm rerotation Air adjust screw set location before disassembling ,...
  • Page 50 h Disassembly of body cover. h 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 ‧Assembling with sequence in reverse Assembly of disassembly. 5→1 ＊...
  • Page 51 ‧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 Disassembly Hex bolt Tail light fix bracket Inner carrier Oil tube Tube ＊WARNNING: Clip the tube, avoid fuel...
  • Page 52 Don’t damage petrol gauge wires. ‧Remove the petrol gauge. ＊ WARNNING: Don’t curving float arm of petrol gauge. ‧Operation with sequence in reverse of disassembly. FUEL INSTALLATION Disassembly of Air Cleaner ADLY MOTO...
  • Page 53 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 ‧Operating with sequence in reverse of Assembly disassembly. 9→1 ADLY MOTO...
  • Page 54 ADLY MOTO 3. INSTALLATION OF LUBRICATION Attention of Operation ‧Pay attention to avoid dust enter to the interior of engine and motor oil pipe when disassembly the motor oil pump. ‧Never disassembly motor oil pump. ‧Must draw out the air on the pump if there have air in the pump when disassembly pipe of carburetor.
  • Page 55 ADLY MOTO Dismounting of Oil Pump * Remove the R side body cover and helmet box. * Remove the cooling fan cover and cylinder head cover. ＊WARNNING: Operating after cleaning motor oil pump around and no dirt enter into the crankcase. Operation / Parts Name Q’ty Remarks...
  • Page 56 ADLY MOTO Dismounting of Oil Tank Operation / Parts Name Q’ty Remarks ＊WARNNING: Disassembly Fuel pipe Fill motor oil with clean Fuel connection pipe container. Pan phillips bolt Control cable Motor oil pump ＊WARNNING: Assembly 5→1 Connect correct oil pipe after assembly, release the air Operation with sequence in in motor oil pump.
  • Page 57 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 58 Crank Case / Crank Shaft Assembly / Disassembly of Crank Case Operation / Parts name Q’ty Remark 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...
  • Page 59 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.
  • Page 60 Crank Case / Crank Shaft ‧Put new crank shaft into right crank case. ‧Put crank shaft assembly into left crank case. ＊WARNNING: ** Smear the 2-stroke oil to main bearing and big end of connecting rod. ** Note the position of connecting rod. ‧Put left oil seal into L.
  • Page 61 Crank Case / Crank Shaft Assembly of Crank Case ‧Install the dowel pins in the joint face of left crank case. ‧Install the right crank case. : Bearing puller (TLJT-00) ‧Install the new R. oil seal to crank case. : Bearing puller (TLJT-00) ADLY MOTO...

  • Page 62: Front Wheel, Front Suspension, Front Brake

    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...
  • Page 63 ADLY MOTO Disassembly / Assembly of Front Wheel Operation / Parts name Q’ty Remarks Disassembly of Front Wheel Nut nylon Speedometer gear Hex washer face bolt Front collar Front fender Front brake disc – Operation with sequence in reverse Assembly 6→1 procedure.
  • Page 64 ADLY MOTO Assembly / Disassembly of Front Rim ‧Disassembly of front wheel. Operation / Parts name Q’ty Remarks Disassembly Front collar Oil seal Radial ball bearing Front wheel spacer tube –Operation with sequence in reverse Assembly 4→1 procedure. WARNNING: –Must change the R/L bearing set. 10-3...
  • Page 65 ADLY MOTO Assembly / Disassembly of Front Disk Operation / Parts name Q’ty Remarks Disassembly Front collar Brake disc hex socket bolt Nylon insert lock nut Front brake disc –Operation with sequence in reverse Assembly 4→1 procedure. 10-4...
  • Page 66 ADLY MOTO Disassembly of Steering Handle ‧Disassembly of throttle handle ‧Dismount rear brake cable 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 Steering Handle...
  • Page 67 ADLY MOTO Disassembly of Steering Stem ‧Disassembly of front wheel. ‧Disassembly of steering handle Operation / Parts name Q’ty Remarks Disassembly Spanner nut Steering stem dust cover WARNNING: –Not to damage steering stem. Lathe cone on steering top #2 Race ball #5 Steel ball race Lathe on steering inner #3 Bolt...
  • Page 68 ADLY MOTO Turning Front Fork to Left / Right ‧Turn the front fork several times, make the ball race rotate smoothly. ‧Slightly tie-up the bottom spanner nut and backward about 1/8 turn. ‧Confirm the steering rotation smooth and gap of steering stem. Special Tool: fixed nut spanner ‧Keep the bottom spanner nut fixed to avoid the nut rotate with the upper...
  • Page 69 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. ‧...
  • Page 70 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 71 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 72 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. 5→1 ADLY MOTO 11-4...

  • Page 73: Electrical Device

    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 74 ELECTRICAL DEVICE Start motor no working RPM unsmooth ‧Ignition — primary circuitry ‧Fuse broke. –Bad ignition coil. ‧Battery charging insufficiently. –Wire or poor contact. ‧Bad main switch. –Poor contact main switch. ‧Poor start switch. ‧Ignition — secondary circuitry ‧Poor front / rear brake switch. –Bad ignition coil.

  • Page 75: Wiring Diagram

    ELECTRICAL DEVICE Solid Wiring Diagram ADLY MOTO 12-3...
  • Page 76 ELECTRICAL DEVICE Disassembly Of Battery Operation / Parts name Q’ty Remarks Disassembly Helmet box mat Battery  end Battery  end WARRNING: Disassembly battery from – end to  end. Self-tapping screw Battery cover Battery Assembly • Assembling with sequence in reverse of disassembly.
  • Page 77 ELECTRICAL DEVICE Check Voltage of Battery ‧Remove helmet box mat and battery cap , disassembly connection wires of battery , check voltage between battery terminals. Charging sufficiently : over 12.8 V Charging insufficiently : 11.5-12.8V ＊WARNNING: Must check battery voltage with digital voltmeter.
  • Page 78 ELECTRICAL DEVICE Check Charging Status ＊WARNNING: ‧Voltage will have big change following the charging status of battery in this check, so, must check with charging completely, over 12.8 V. ‧There will produce big current due to start-will consume the power in battery. ‧Assembly voltmeter to terminal of main fuse, start engine, open light, rise running amount, and check charging...
  • Page 79 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 80 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 81: Ignition Coil

    ELECTRICAL DEVICE Ignition Coil Disassembly ‧Disassembly spark plug cap. ‧Separating cable, disassembling installed bolt, then, disassembly ignition coil. Assembly ‧Assembly with sequence in reverse of disassembly.  WARNNING: Guide wire must be installed in the right place. Conduction Test ‧Check once coil resistance of ignition terminal.
  • Page 82 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 ‧Assembling with sequence in reverse Assembly 7→1 of disassembly.
  • Page 83 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 & 0~20Ω 90~110Ω black Check Main Switch ‧Remove connection of main switch guide wire, check conductivity...
  • Page 84 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...
  • Page 85 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...

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