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HER CHEE SS-50 Service Manual
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HER CHEE SS-50 Service Manual

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SERVICE MANUAL

SS-50/100
March, 2008
High Power Engine
HER CHEE INDUSTRIAL CO., LTD.

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Summary of Contents for HER CHEE SS-50

  • Page 1: Service Manual

    SERVICE MANUAL SS-50/100 March, 2008 High Power Engine HER CHEE INDUSTRIAL CO., LTD.
  • Page 2 Preface The Service Manual in reference is provided as the technical information for checking and preparation of ADLY SS-50/100 scooter and the edit description is given in diagrams with " Operation Sequence ", " Highlights " and " Checking Arrangement " for reference of the service staffs.
  • 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 All washers, oil rings, clamp rings, opening pins shall be duly replaced by a new 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.
  • Page 5 INFORMATION FOR PREPARATION Attention on Operation Certified lubricants in cans shall be used on all the elements to be lubricated. After assembly, performance of all elements shall be duly checked and the locking shall be duly verified. 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 SS-50Ⅰ/Ⅱ SS-100Ⅰ/Ⅱ 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...
  • 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：...
  • Page 8 INFORMATION FOR PREPARATION The following drawing that shows the disassembling situation of the cover parts for SS50/100 scuuter. ADLY MOTO...
  • Page 9 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 10 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 11 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 12 INFORMATION FOR PREPARATION REVOLUTION NOT SMOOTH(HIGH SPEED) Check and Adjust Reason of Trouble 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 13 INFORMATION FOR PREPARATION CHARGE ABNORMAL Check and Adjust Reason of Trouble 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 14 INFORMATION FOR PREPARATION SPARK PLUG NO SPARKING Check and Adjust Reason of Trouble Diagnose 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 15: Check And Adjust

    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 16 Riding Device Tire ○ ○ ○ Ditch-front wheel till 0.8mm Check & damage of tires Rear wheel till 0.8 mm ○ ○ ○ Abnormal & ditch in tires Bolt & nut of tires locking Flocking torsion ○ ○ Front wheel – 4.0~5.0 kg-m Rear wheel –10~12 kg-m ○...
  • Page 17 Check Items Before 1 st Judged standard remarks riding Engine ○ ○ Body – starting & abnormal noise ○ ○ ○ Idle : 1800±100 rpm low speed & accelerating ○ ○ exhaust ○ ○ air filter Lubrication device ○ Warning light lighting ○...
  • Page 18 CHECK AND ADJUST Disassembly of External Parts • Remove the external parts for check and adjustment. • Remove 4 hex washer face bolts, 4 space tubes , and then remove luggage carrier. • Remove 12 self-tapping screws and 2 pan flat bolts. •...
  • Page 19 CHECK AND ADJUST Disassembly of Pedal • Remove L/R body cover. • Remove 4 bolts, 6 self-tapping screws 2 pan flat bolts. • Separate the joint with luggage case (claw & groove)and remove the pedal • Install with the reverse sequence. WARNNING: Installing to the luggage box after composing confirming the pedal with...
  • Page 20 CHECK AND ADJUST Rear Light Assembly • Remove 2 hex bolts. • Remove 3 L/R sides body cover. • Disassembly the connection head of wireness rear light. • Assembly with the sequence in reverse of disassembly. WARNNING: Ensuring the joint of tail light hole correct with the bulge of truck.
  • Page 21 CHECK AND ADJUST Layout of Parts Maintenance The location of main parts of maintenance are showed as follows : ADLY MOTO...
  • Page 22 CHECK AND ADJUST Adjustment of Motor Oil Pump WARNNING: Going on this operation after adjusting and checking the guide wiring of throttle. • 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 23 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 24 INSTALLATION OF LUBRICATION Disassembly of Motor Oil Pump • Remove right side cover. • Remove stator cover. • Remove A.C.G WARNNING: Operating after cleaning motor oil pump around and no entering to the crank shaft case. ADLY MOTO...
  • Page 25 INSTALLATION OF LUBRICATION Operation / Parts Name Q’ty Remarks Disassembly Fuel pipe WARNNING: Clogging the pipe with clamp or plug for avoiding fuel flow out. • Remove from both side of motor oil Fuel connection pipe Pan phillips bolt pump. •...
  • Page 26 INSTALLATION OF LUBRICATION Disassembly of Oil Tank Operation / Parts Name Q’ty Remarks Disassembly ＊WARNNING: Joint of oil disassembly oil pipe Joint of wires Fill motor oil with clean container. Bolt Oil tank Grommet • Operation with sequence in reverse of Assembly 5→1 disassembly.
  • Page 27 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 28 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 29 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 Washer Throttle valve spring Throttle cable Throttle valve ＊WARNNING: Aim the ditch of throttle...
  • Page 30 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 31 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. ADLY MOTO...
  • Page 32 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 1 ＊WARNNING: Must confirm rerotation Air adjust screw set location before disassembling ,...
  • Page 33 FUEL INSTALLATION Disassembly of Inlet Valve 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.
  • Page 34 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 Disassembly Hex bolt Tail light fix bracket Inner carrier Oil tube Tube...
  • Page 35 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.
  • Page 36 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 ‧Operating with sequence in reverse of Assembly disassembly.
  • Page 37 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 38 DISASSEMBLY OF ENGINE Operation / Parts Name Q’ty Remarks Disassembly ＊WARNNING: ACG wire /wire of start motor 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 39 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. • Avoid to use driver harm the joint face when remove the cylinder & cylinder head. •...
  • Page 40 CYLINDER HEAD / CYLINDER / PISTON Disassembly of Cylinder Head / Cylinder / Piston • Disassembly of cover (→4-7) • Disassembly of cenerator cover (→12-7) • Disassembly of muffler (→11-2) • Disassembly of spark plug cap (→5-2) ADLY MOTO...
  • Page 41 CYLINDER HEAD / CYLINDER / PISTON Operation / Parts Name Q’ty Remarks Disassembly Cylinder head Nut of cylinder head WARNNING: Loosing nut 2-3 times. Cylinder head Cylinder head gasket Cylinder Cylinder WARNNING: Don’t knock cooling fin. Cylinder gasket WARNNING: Clean and not damage cylinder &...
  • Page 42 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 43 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 ＊WARNNING: Crankcase cover gasket Dowel pin Check the air cleaner whether Grommet...
  • Page 44 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 ＊WARNNING: Rotating pedal kick Kick pinion Hex washer face bolt crank and remove the assembly.
  • Page 45 Starter / Driving Disc / Clutch / Transmission Disc Operation / Parts name Q’ty Remark Assembly Washer ＊WARNNING: Unable into main Starting shaft reset spring 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 46 Starter / Driving Disc / Clutch / Transmission Disc ‧Check the wear & damage of kick Kick pinion pinion. ‧Check the wear & damage of kick pinion spring clip. Kick pinion spring clip ‧Check the wear & damage of starting shaft , bearing and driving gear.
  • Page 47 Starter / Driving Disc / Clutch / Transmission Disc Disassembly of Left Crank Case (→7-2) Operation / Parts name Q’ty Remark Disassembly ＊WARNNING: Don’t hurt transmission Hex washer face bolt Cone spring washer belt. One-way clutch Clamp washer Primary fixed sheave Bushing V-Belt Primary sliding slot wheel...
  • Page 48 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. ADLY MOTO...
  • Page 49 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 50: 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 51 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 52 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 53 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 54 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 55 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 56 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 57 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 58 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 Heavy steering movement Steering handle not straight •...
  • Page 59 Front Wheel / Front Suspension / Front Brake Disassembly of Front Wheel ‧Disassembly of front fender. Front Wheel – Single Disc / Iron 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...
  • Page 60 Front Wheel / Front Suspension / Front Brake Front Wheel – Double Disc / 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 (right) Front brake disc (left) ‧Assembling with sequence in reverse Assembly...
  • Page 61 Front Wheel / Front Suspension / Front Brake Disassembly of Front Wheel ‧Disassembly of front fender. Front Wheel – Single Disc / 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...
  • Page 62 Front Wheel / Front Suspension / Front Brake Assembly / Disassembly of Front Wheel ‧Disassembly of front wheel. Front Wheel – IRON RIM Operation / Parts name Q’ty Remarks Disassembly Oil seal Radial ball bearing(left) Front wheel spacer tube Radial ball bearing(right) ‧...
  • Page 63 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) ‧Assembling with sequence in Assembly 4→1 reverse of disassembly. ＊WARNNING: Must change the R/L bearing set.
  • Page 64 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 ‧Assembling with sequence in Assembly 4→1...
  • Page 65 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 66 Front Wheel / Front Suspension / Front Brake Disassembly of Steering Stem ‧Disassembly of front wheel. ‧Disassembly of steering handle. ADLY MOTO 10-9...
  • Page 67 Front Wheel / Front Suspension / Front Brake Operation / Parts name Q’ty Remarks Disassembly Steering Main rod Spaner nut ＊ WARNNING: No damage main Steering stem dust cover Lathe cone on steering top #2 rod & front brake. Race ball #5 Steel ball Lathe on steering inner #3 Bolt / washer...
  • Page 68 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 69 Front Wheel / Front Suspension / Front Brake Turning Front Fork to Right / Left ‧Turn the front fork several times, make the bearing smoothly. ‧Confirm the rotation smooth and gap of steering main rod. : fixed nut spanner B ‧For no back-turning together with up- cone seal ring, locking fixed screw to fix it.
  • Page 70 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 71 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 72 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 73 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 74 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 75 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 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. Battery • Assembling with sequence in reverse Assembly of disassembly. 4→1 ＊WARRNING: Battery terminal...
  • 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 ＊WARRNING: Semi-cycle of electric disc Whole body bolt Take the good care, no hurt coil.
  • Page 81 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 Solid Wiring Diagram ADLY MOTO...
  • Page 86 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...

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