ADLY MOTO GK-125R Service Manual
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ADLY MOTO GK-125R Service Manual

ADLY MOTO GK-125R Service Manual

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SERVICE MANUAL
GK-125R【92/61】
July 04
High Power Engine
HER CHEE INDUSTRIAL CO., LTD.

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Summary of Contents for ADLY MOTO GK-125R

  • Page 1 SERVICE MANUAL GK-125R【92/61】 July 04 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 GK-125R GO-KART and the edit description is given in diagrams with " Operation Sequence ", " Highlights " and " Checking Arrangement " for reference of the service staffs.

  • Page 3: Table Of Contents

    I N D E X Information for preparation Muffler, Cover parts Check and Adjust Lubricant system Fuel system Remove of engine Cylinder head, Valve Cylinder, Piston Transmission, Kick start Final transmission Crankcase, Crankshaft Front wheel, Brake, Suspension, steering Rear wheel, Brake, Suspension Battery, Charge, and Ignition system Starting system Wiring diagram...
  • Page 4 ASSEMBLY INSTRUCTION (For GK-125R ) Take out the battery and fill with acid liquid. Pre-charge the battery will extend its life. The preparation and charge procedure is based on the battery’s instruction. Install the rear wheels and parts in the following order: A.
  • Page 5 P.D.I. (Pre-Delivery Inspection) (For GK-125R ) 1. Record the frame and engine number into the owner’s manual. 2. Check that all tires have correct pressure specified on the tire or in the owner’s manual. 3. Engine oil ( 4 stroke, 10W/40 ) is enough.

  • Page 6: Information For Preparation

    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 7 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 8 INFORMATION FOR PREPARATION SPECIFICATION TYPE GK-125R LENGTH 1780 mm WIDTH 675 mm HEIGHT 1160 mm WHEEL BASE 1255 mm NET WEIGHT 160 kg ENGINE TYPE 4-STROKE, Single Cylinder COOLING AIR COOLED DISPLACEMENT 124 C.C. BORE×STROKE 52.4×57.8 COMPRESSION RATIO 9.2:1 IGNITION C.D.I...
  • Page 9 INFORMATION FOR PREPARATION LOCKING TORQUE The standard locking torque shall apply in case of no specification. STANDARD TORQUE： Type Locking Torque (kg-m) Type Locking Torque (kg-m) 5mm Bolt, Nut 5 mm Screw 6mm Bolt, Nut 6 mm Screw 8mm Bolt, Nut 6 mm Face Bolt, Nut 10mm Bolt, Nut 8 mm Face Bolt, Nut...
  • Page 10 INFORMATION FOR PREPARATION The following drawing that shows the disassembling situation of the cover parts for GK-125R Go-Gart.

  • 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 exhaust pipe blocking engine speed go up 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) 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 14 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 15 INFORMATION FOR PREPARATION SPARK PLUG NO SPARKING Diagnose Check and Adjust Reason of Trouble change spark plug and check again the previous spark plug damage no sparking or weak sparking strong check spark plug, cap, ignition coil loosen? loosen no loosen spark plug cap loosen check C.D.I unit socket loosen ?
  • Page 16 CHECK AND ADJUST INFORMATION WARNNING ＊ Do not start the engine at a close zone, because the exhaust gases from the engine including some noxious emission such as CO, HC, NO ... etc. that can result serious damage for ealth. ＊...
  • Page 17 CHECK AND ADJUST MAINTENANCE SCHEDULE Please follow the maintenance schedule to do the routine maintenance. I: Inspection and clean, lubricate, correct, replace if necessary. A: Adjust. R: Replace. C: Clean Regular Service Mileage (km) 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 Engine oil Oil filter Fuel filter...
  • Page 18 CHECK AND ADJUST FUEL FILTER • The filter is located underneath the fuel filter carburetor. • Check the fuel pipe. If the tube has any damage then change it. WARNNING ＊ Smoking prohibited fuel cup THROTTLE LEVER PLAY • Check the operating throttle lever whether is smoothly.

  • Page 19: Spark Plug

    CHECK AND ADJUST AIR CLEANER screw • Take-off the tapping screws of air cleaner cover and remove the cover. • Take-off two screws of air filter. • Check the filter whether is dirty or damaged. If it‘s dirty or damaged then clean it or change a new one.
  • Page 20 CHECK AND ADJUST VALVE ADJUSTING ＊ When you check or adjust the valve, do it at the low engine temperature (about 35°C) • Remove cylinder head cover. • Rotate the cooling fan and keep the gear mark of camshaft aim at the TDC position and the ACG flywheel “T”...

  • Page 21: Ignition Timing

    CHECK AND ADJUST IGNITION TIMING The ignition system of this vehicle is controlled by C.D.I unit, thus don‘t need to adjust anything. If the ignition timing isn’t correct then checking the ignition system whether normally. • Removing the L side cover. •...
  • Page 22 CHECK AND ADJUST GEAR OIL Oil quantity check bolt / washer ＊ When you will check the quantity of gear oil, the main stand have to rise at the ground (flat) level. • Stop the engine and removing the quantity check bolt. If the oil level is around the bottom of bolt hole, then the gear oil quantity is enough.

  • Page 23: Brake System

    CHECK AND ADJUST BRAKE SYSTEM Front brake • Check the brake pads If the brake pad has any dint or wearing very serious then change it. • Check the quantity of brake oil Make the steering straightly, check the brake fluid whether keep between the upper and lower level.
  • Page 24 CHECK AND ADJUST TIRE, RIM • Check the tires whether have any nail, broken…etc. • Check the tire pressure. ＊ The normal tire pressure （24psi） Front tire ：1.68 kg/cm 24psi） 2（ Rear tire：1.68 kg/cm • Checking the shaft and nut of front wheel whether loosen.

  • Page 25: Drive Chain

    CHECK AND ADJUST DRIVE CHAIN Check the drive chain condition. The drive chain should be check, adjust, and lubricate regularly. The free play of the drive chain should be between 20~30mm up and down. When install the chain clip, beware the clip direction.
  • Page 26 ADLY MOTO STEERING WHEEL, MUFFLER Information for preparation Don‘t enforce to remove the cover parts of the GK-125, otherwise will cause the connecting nail of cover parts broken. Please according to the operating instruction when assembling the cables and wires...
  • Page 27 ADLY MOTO STEERING WHEEL, MUFFLER Muffler: Locking Torque: Muffler fixed bolt：3.5 kg-m Muffler connect nut：1.2 kg-m Trouble Diagnose: Exhaust sound level is too high • Muffler broken • Muffler leakage Power isn‘t enough • Muffler leakage • Muffler blocking • Muffler with dent Remove the muffler: •...

  • Page 28: Lubricant System

    LUBRICANT SYSTEM TROUBLE DIAGNOSE Engine burn Oil quantity reduced • No oil pressure or pressure too low • Normal consumption • Oil thoroughfare blocking • Oil leaking • Oil type isn‘t correct • Piston ring wear-out or installed wrong • Rubber seal of valve wear-out...
  • Page 29 LUBRICANT SYSTEM Information for Operation ENGINE OIL & FILTER Oil quantity ＊ When you check the oil quantity, the vehicle have to stand on flat ground. ＊ Starting the engine about 2~3 min.. then stop it. After 2~3 min. check the oil quantity.

  • Page 30: Oil Pump

    LUBRICANT SYSTEM Pulsar coil OIL PUMP Remove • Remove the fan and ACG. • Take-off 5 bolts on R. crankcase cover and remove it. ACG coil R crankcase cover • Remove the gasket and the dowel pin • Remove the starting clutch gear and Dowel pin starter clutch TLCT125-04...
  • Page 31 LUBRICANT SYSTEM • Take-off the fixed bolts on oil pump and remove the oil pump ass’y. Disassembling: • Take-off the screw on oil pump and disassembling the oil pump. bolt Check: • Check the gap between the pump body and outer rotor. The gap limit is 0.10 mm.
  • Page 32 install it. LUBRICANT SYSTEM • Check the gap between the top face of rotor and the pump body The gap limit is 0.2 mm Outer Assembling: • Mounting the inner and outer rotor, then install the pump shaft. ＊ When install the pump shaft, beware the angle position match with the Inner rotor dowel pin...
  • Page 33 LUBRICANT SYSTEM • Install the pump then tie-up the bolts. oil separator • The pump gear has to fit into the shaft, then install the gear and chain. • Install the nut and tie-up. drive gear Locking torque: 1.0 kg-m bolts •...

  • Page 34: Fuel System

    FUEL SYSTEM TROUBLE DIAGNOSE Ignition not continuously when Start-up function abnormal accelerate • No spark of spark plug • Ignition system abnormal • Compression pressure too low • Too thin of F/A mixture • No fuel in carburetor • Air stock inside air cleaner Difficult to start, Engine stops after •...
  • Page 35 Auto-plunger wire FUEL SYSTEM CARBURETOR Removing • Remove the R/L side, body cover, center cover, rear carrier, seat, and helmet box • Remove the auto-plunger wire from carburetor. fuel tube vacuum tube • Loose the fuel releasing screw of the carburetor and release the fuel in float chamber •...
  • Page 36 Auto-plunger starter FUEL SYSTEM Disassembling: • Remove 1 screw and mounting screw bracket. • Remove the auto. plunger starter form carburetor bracket Check: Needle • Check the auto-plunger starter needle and valve whether wear-out? • If it’s damaged then change the plunger.
  • Page 37 FUEL SYSTEM AIR VALVE Disassembling: • Remove the vacuum (-) pressure tube. • Take-off 2 screws and remove the (-) pressure film cover, spring and film. Film cover spring screws Assembling: • Mounting the film into carburetor. • Put the spring，cover back then locking 2 screws.

  • Page 38: Float Chamber

    FUEL SYSTEM • Push the fixed clamp and turn L side to take-out the clamp. • Remove the spring and needle ＊ Beware not to damage the vacuum film. vacuum chamber cover Check: • Check the needle whether wears • Check the piston whether damaged •...
  • Page 39 FUEL SYSTEM float pin Check: float valve • Check the float valve and valve set whether damage or blocking • Check the surface of float needle and valve seat whether grimy or wear-out. ＊ If the float valve or valve seat is grimy or wear-out that will cause the fuel level higher and leakage.
  • Page 40 FUEL SYSTEM Assembling Drawing • Install the pilot jet, main jet seat, main jet and fuel adjusting screw. ＊ Before remove the fuel adjusting screw, remember turns of setup into the end position. The normal setup is: 3 1/8±3/4 turns out float pin •Install the float, float valve and float float...
  • Page 41 FUEL SYSTEM Mounting the carburetor • When install the carburetor, the embossment of carburetor have to fit into the correct position of intake manifold. • Locking the screws of 2 clamps. • Mounting the throttle cable on the control wheel. Throttle tube •...
  • Page 42 FUEL SYSTEM FUEL CUP • Install with the reverse procedure. ＊ Smoking prohibited • Remove the fuel tube and vacuum tube from carburetor. Check screws If the fuel cup have no vacuum pressure and the fuel come out then the valve film inside the fuel cup is damaged.
  • Page 43 FUEL SYSTEM Disassembly of Fuel Tank Disassembly of handle bar and front cover. ＊ WARNING: ․No fire. ․Shall be wiped off when fuel overflowed. Operation / Parts Name Q’ty Remarks Disassembly Pan phillips bolt 6*15 Fuel tank net Hex bolt 6*16 Clip Fuel tube Hex washer face bolt 6*16...

  • Page 44: Remove Of Engine

    REMOVE 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 cover of body. ‧Disassembly of throttle valve and cable. Operation / Parts Name Q’ty Remarks Disassembly...
  • Page 45 ＊ Drive Sprocket Ass’y WARNING: Nylon nut of engine Actually for brace the frame, avoid body turn inside out. plain washer of engine Hex washer face bolt of engine Hex washer face bolt of engine Engine ＊ Assembly WARNING: Carry out following adjusting after installation.
  • Page 46 REMOVE OF ENGINE Disassembly of Muffler Operation / Parts name Q’ty Remarks Disassembly Take off the engine Ass’y Nut cap 6mm Hex washer face bolt 8*32 Exhaust bracket Muffler • Assembling with sequence in reverse Assembly of disassembly. 5→1...

  • Page 47: Cylinder Head, Valve

    CYLINDER HEAD, VALVE 0.9kg-m 1.2kg-m 1.2kg-m TROUBLE DIAGNOSE Valve gap adjustment 0.12 mm Idle Speed not Stable • Compression pressure too low Compression Pressure too high • Too much carbon-residue inside Compression Pressure too low • Bad adjustment of valve tolerance combustion chamber.
  • Page 48 Cylinder head cover CYLINDER HEAD, VALVE Remove the camshaft • Take-off 4 bolts on cylinder head cover and remove the head cover • Removing the cam-chain adjuster cover screw O-ring bolt • Locking the inside small screw of the cam-chain adjuster that the locking direction is clock wise Camshaft sprocket cam-chain...
  • Page 49 CYLINDER HEAD, VALVE • Remove 2 fixed bolts on cylinder head. washer • Remove hex-nuts and washers on camshaft holder. ＊ Unscrew the bolts cross-wise for 2~3 times. • Remove the camshaft holder and dowel pins • Remove the cam-chain gear from cam chain then take out camshaft.
  • Page 50 CYLINDER HEAD, VALVE Camshaft bearing • Check the camshaft bearing to see if it’s wear out or loose. If it’s loose or damaged then change whole set of camshaft Stopper plate Disassembling the camshaft holder • Using 5 mm bolt to screw in and pull out the rock arm shaft.
  • Page 51 CYLINDER HEAD, VALVE Check the stopper plate One-way plate • Check the stopper plate and spring • Check the movement of the one-way plate. Disassembly the cylinder head • Remove camshaft • Remove carburetor • Remove exhaust muffler stopper plate •...
  • Page 52 CYLINDER HEAD, VALVE • Remove cylinder head Fixed bolts Cylinder head Dowel pin • Remove dowel pins, gasket • Remove cam-chain guide comp. Cylinder head gasket • Clean the dirt on cylinder surface Cam-chain guide comp. Attestation Valve spring holder tool ＊...
  • Page 53 CYLINDER HEAD, VALVE • Clean carbon material inside combustion chamber. • Clean gasket material stick on cylinder head surface. Attention： ＊ Beware not to damage the contact surface of cylinder head Check cylinder head Check the hole of spark plug and valve guide to see if it’s damaged.
  • Page 54 CYLINDER HEAD, VALVE • Use rubber hammer hit the valve top for 2 ~ 3 times to have better contact between valve and cotter. ＊ Beware not to damage the valve. Cylinder head installation • Install dowel pins and new gasket. •...
  • Page 55 CYLINDER HEAD, VALVE camshaft sprocket cam-chain Installation of camshaft holder • Rotate ACG flywheel, let the “T” mark aim to crankcase. Make the big straight line hole on camshaft-gear face to the top and two small holes on L/R side straight horizontally to the cylinder top edge (camshaft cam direction face down).
  • Page 56 CYLINDER HEAD, VALVE New O-ring should be greased before tie up the cover screw. ＊ ring must put into the correct position O-ring Replace new O-ring on cylinder head cover before assembly the cover, O-ring ＊ The O-ring must fit into the cover with correct position.

  • Page 57: Cylinder, Piston

    CYLINDER, PISTON TROUBLE DIAGNOSE Exhaust with white smoke Low compression pressure • Piston ring wear-out, burn, or broken • Piston ring wear-out, burn, or broken • Cylinder, piston wear out or damaged. • Cylinder, piston wear out or damaged. Piston noise Compression pressure too high •...
  • Page 58 CYLINDER, PISTON REMOVE CYLINDER • Remove cylinder head • Remove the cam chain guide comp. • Remove the cylinder dowel pin gasket • Remove the cylinder gasket and dowel pins. • Clean the gasket stick on cylinder. REMOVE THE PISTON •...
  • Page 59 CYLINDER, PISTON • Mounting the piston rings and measuring the gap between piston ring and piston ditch. Working limit: Top ring: replace above 0.09mm ring: replace above 0.09mm • Take-off piston rings and put into the bottom of cylinder. ＊ Use piston to press the ring into cylinder.
  • Page 60 CYLINDER, PISTON Piston rings installation • Each ring should be greased with oil. ＊ Do not scratch piston and do not band piston rings. ＊ The mark on piston ring must face up. ＊ Be sure the rings rotate freely after install into piston.
  • Page 61 CYLINDER, PISTON Dowel pin Cylinder Installation • Put the dowel pins and gasket on top of crankcase. gasket • Cylinder inside surface, piston, and piston rings must be greased with oil. • Beware of the pressure from piston ring and install into cylinder. ＊...
  • Page 62 TRANMISSION, KICK START TROUBLE DIAGNOSE Power insufficient Vehicle does not move after engine • Drive belt wear-out start up • Driven ass’y spring defect • Drive belt wear-out • Drive face dirty or oily • Drive face comp. damage • Weight roller wear-out •...

  • Page 63: Left Crankcase Cover

    TRANMISSION, KICK START LEFT CRANKCASE COVER Disassembly • Remove the kick-starter arm. • Take-off fixed bolts and remove the L crankcase cover. • Remove the gasket and dowel pins. L. crankcase cover bolt Assembly • Install the gasket and dowel pins. Dowel pin •...
  • Page 64 TRANMISSION, KICK START drive face Drive face disassembly • Remove L crankcase cover. • Use fixture to hold the drive face and take-off screw, washer, and drive face. • Take-off drive belt from movable drive face assembly. Boss, movable drive face drive belt Check •...
  • Page 65 TRANMISSION, KICK START cam plate Disassembly • Remove the cam plate. • Remove the weight roller. Check • Check the wear-out and damage of weight roller. weight roller • Measure outside diameter of weight rollers. Working limit : Replace if outside diameter is under 17.3 mm . Check •...
  • Page 66 TRANMISSION, KICK START Assembly diagram • Put the weight rollers into movable drive face. cam plate • Install the cam plate. • Put the boss into drive face assembly. boss, movable drive face...
  • Page 67 TRANMISSION, KICK START Installation • Put the movable drive face assembly movable drive face into the crank shaft. • Put the drive belt into rear driven face assembly. • Put the drive belt on the boss of movable drive face assembly. drive belt clutch cover •...
  • Page 68 TRANMISSION, KICK START clutch cover CLUTCH/ DRIVEN FACE ASS’Y • Remove the L crank case cover. (9-1) • Remove the fixed drive face and drive belt. (9-2) • Use fixture to hold the clutch cover and loose the nut. • Remove the clutch cover. Check •...

  • Page 69: Kick Starter

    TRANMISSION, KICK START KICK STARTER Disassembly washer • Remove L crank case cover (9-1) • Remove gasket and dowel pins. • Remove drive-face and belt. (9-2) • Remove the washer on starter spindle assembly. starter spindle • Remove the kick starter stop plate and Starter spring stopper plate the starter spring.
  • Page 70 TRANMISSION, KICK START • Disassembly the starter idle gear to check if there is any damage. • Assembly the gear should base on reversed procedure. Check • Check the contact surface of L crankcase and crank case cover if there is any damage or wear-out. bush Installation •...

  • Page 71: Final Transmission

    FINAL TRANSMISSION 【GK-125R】 TROUBLE DIAGNOSE Gear oil leaking Engine starts but vehicle does not • Too much gear oil filled. move. • Oil seal wear-out or damage. • Transmission gears broken. • Transmission gears burns out. 10-0...
  • Page 72 FINAL TRANSMISSION DISASSEMBLY TRANSMISSION GEAR BOX • Remove, drive chain and sprocket. • Drain transmission gear oil. • Remove the bolts and pull-out mission cover. bolt • Remove the mission cover together with the gear set. mission cover • Remove the gasket and dowel pins. •...
  • Page 73 FINAL TRANSMISSION DISASSEMBLY TRANSMISSION GEAR BOX • Remove the hex socket bolt then pull out the shaft. • pull outer in remedial shaft and find drive gears. Final gear shaft Reverse idle gear shaft dowel idle gear shaft • Take-out the final gear and gear shaft •...
  • Page 74 FINAL TRANSMISSION Bearing installation • Use the tool press the bearing outer ring when install into crankcase or mission cover. Attention： ＊ The bearings have to be pressed on outer ring to avoid damage of bearings. Final transmission installation • Install the main gear assembly and final gear shaft into crankcase.

  • Page 75: Crankcase, Crankshaft

    CRANKCASE, CRANKSHAFT TROUBLE DIAGNOSE Engine noise • Loose of crankshaft bearings. • Loose of bearings inside crankshaft connecting rod. 11-0...

  • Page 76: Crankcase Disassembly

    CRANKCASE, CRANKSHAFT Cam-chain fixed CRANKCASE DISASSEMBLY • Remove the cam-chain tensioner by unscrew the fixed bolt. • Use special tool to pull out the kick- start driven gear. gear puller special TLCT125-05 Kick-start driven gear puller Kick start drive gear Crankcase fixed bolt •...
  • Page 77 CRANKCASE, CRANKSHAFT • Loose the cam-chain and remove crankshaft from crankcase. • Take out cam-chain. crankshaft cam-chain • Scratch off the gasket which between crankcases. Oil seal ＊ Do not damage the gasket area of the crankcases. • Remove both oil seals from L/R crankcases.
  • Page 78 CRANKCASE, CRANKSHAFT • Rotate the bearings to check if any abnormal noise or loose. • Use special tool if need to pull out bearings. special TLCT125-00 Bearing puller Replace complete crankshaft assembly if necessary. Crankcase assembly • Press in the oil seal for L/R crankcases and do not damage the inner part of the seals.
  • Page 79 CRANKCASE, CRANKSHAFT • Tie-up 2 bolts on L crankcase. Locking torque: 0.9 kg-m • Install the kick-start driven gear. crankcase fixed bolt • Install the cam-chain adjuster guide. • Install the new O ring on the fixed kick start drive bolt for cam-chain adjuster.
  • Page 80 ADLY MOTO FRONT WHEEL / SUSPENSION / BRAKE / STEERING 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 •...
  • Page 81 ADLY MOTO FRONT WHEEL / SUSPENSION / BRAKE / STEERING Disassembly of Front Wheels Operation / Parts name Q’ty Remarks Disassembly front wheels (L/R) Rubber cover Cotter pin Slotted nut Plain washer 12*40*4.5 Disassembly front brake drum Spacer tube Hex washer face bolt 10*20 Front brake drum Rim 7*5.2...
  • Page 82 ADLY MOTO FRONT WHEEL / SUSPENSION / BRAKE / STEERING Disassembly of Front Brake Operation / Parts name Q’ty Remarks Disassembly front brake drum (L/R) Nylon nut 10mm Hex washer face bolt 10*175 Cotter pin 2*19 Scotch flange nut 10mm Plain washer 10*20*2 Upper a-arm ass’y...
  • Page 83 ADLY MOTO FRONT WHEEL / SUSPENSION / BRAKE / STEERING Disassembly of Suspension Arm Operation / Parts name Q’ty Remarks Disassembly (L/R) Hex washer face bolt 10*40 Nylon nut 10mm Front cushion Hex washer face bolt 10*179 ＊ Assembling with sequence in reverse of Assembly disassembly.
  • Page 84 ADLY MOTO FRONT WHEEL / SUSPENSION / BRAKE / STEERING Disassembly of Steering Shaft Ass’y Operation / Parts name Q’ty Remarks Disassembly steering shaft Ass’y Handle Wheel A’ssy Hex flange nut with serration 8mm Steering shaft holder Steering shaft ass’y...
  • Page 85 ADLY MOTO FRONT WHEEL / SUSPENSION / BRAKE / STEERING Disassembly of pedal system Operation / Parts name Q’ty Remarks Disassembly reverse Hex washer face bolt 10*70 Brake arm Cotter pin 2*15 Brake pedal comp. Hex washer face bolt 6*16...
  • Page 86 ADLY MOTO FRONT WHEEL / SUSPENSION / BRAKE / STEERING Assembly/Disassembly of reverse Operation / Parts name Q’ty Remarks Disassembly reverse Pan Phillips bolt 5*10 Outer cover Fix shift Reset spring Collar Hex flange nut with serration Shift lever Shift plate Seat lock ass’y...
  • Page 87 REAR WHEEL / SUSPENSION / BRAKE Diagnosis of Troubles Rear wheel shaking or deviation The shape of rear rim damaged. Rear wheel axle damaged. Swing arm sub Ass’y damaged Rear rim bearing defected. Rear suspension too soft Spring too soft or adjust not correct. Brake efficiency abnormal Brake lining wear-out.
  • Page 88 REAR WHEEL / SUSPENSION / BRAKE Assembly/Disassembly Rear Wheel Operation / Parts name Q’ty Remarks Disassembly (L/R) Rubber cover Cotter pin 3*32 Scotch nut12mm Plain washer 12*40*4.5 Front brake drum Hex washer face bolt Nylon nut 8mm Spring washer 8.5*13*2 Hex washer face bolt 8*20 Bearing holder Radial ball bearing...
  • Page 89 REAR WHEEL / SUSPENSION / BRAKE Disassembly / Assembly of Rear Brake Operation / Parts name Q’ty Remarks Disassembly Rear Brake Hex washer face bolt 8*12 Rear brake cylinder sub ass’y Ladder bolt 6*14*2.5 Front brake disc cover Brake hose hex nut 10*22 Plain washer 10*/14.5*5 Rear brake hose Hex washer face bolt 10*87...
  • Page 90 REAR WHEEL / SUSPENSION / BRAKE Disassembly / Assembly of rear axle Operation / Parts name Q’ty Remarks Disassembly rear axle Plastic spacer Hex washer face bolt 8*20 Brake disc Retainer Rear sprocket hub Hex nut M33*14 Hex washer face bolt 8*20 Rear sprocket Rear sprocket hub Plastic spacer...
  • Page 91 REAR WHEEL / SUSPENSION / BRAKE Disassembly / Assembly of chain Operation / Parts name Q’ty Remarks Disassembly chain removal Hex flange nut with serration Hex washer face bolt 6*30 Rear chain cover Idle sprocket spring Nylon nut 10mm Hex washer face bolt 10*32 Spacer tube Idle sprocket Radial ball bearing...
  • Page 92 REAR WHEEL / SUSPENSION / BRAKE Disassembly / Assembly of chain ( chain roller ) Operation / Parts name Q’ty Remarks Disassembly chain removal Hex flange nut with serration Hex washer face bolt 6*30 Rear chain cover External cir clip Plain washer 12*18*1.2 Chain roller Nylon nut 8mm...
  • Page 93 REAR WHEEL / SUSPENSION / BRAKE Assembly/Disassembly of engine mounting bracket & Rear Cushion Operation / Parts name Q’ty Remarks Disassembly engine mounting bracket Nylon nut 10mm Plain washer 10*22*2 Hex washer face bolt 10*55 Hex washer face bolt 8*40 Hex washer face bolt 8*20 R.
  • Page 94 REAR WHEEL / SUSPENSION / BRAKE Assembly/Disassembly of engine rack ass’y Seq. Operation / Parts name Q’ty Remarks Disassembly engine rack Nylon nut 10mm Plain washer 10*22*1.5 Hex washer face bolt 10*48 （※ replace if necessary） Rubber bush Hex flange nut with serration 12mm Hex washer face bolt 12*65 Engine bracket ass’y...
  • Page 95 BATTERY, CHARGE AND IGNITION SYSTEM INFORMATION FOR PREPARATION ＊ 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.

  • Page 96: Battery, Charge, And Ignition System

    BATTERY, CHARGE, AND IGNITION SYSTEM BATTERY Remove the battery • Take off the battery fixed plate. • Disconnect the − wire (GR) than the + battery fixed plate wire (RD). ＊ Beware not to contact with frame body when disconnect the + terminal. It will damage the battery even the flaming will cause fire with gasoline.
  • Page 97 BATTERY, CHARGE, AND IGNITION SYSTEM CHARGE SYSTEM Check the charge condition • The battery must be full charged in order to check the charge condition. Use electrical meter for measuring. • After engine warm up and use the full charged battery to check. •...
  • Page 98 BATTERY, CHARGE, AND IGNITION SYSTEM Check the coils of AC Generator Charge coil • The check for charge coil of ACG can be done on engine assembly. • Disconnect the 4P connector of ACG. • Measure the resistance between ACG white wire and ground green wire.
  • Page 99 BATTERY, CHARGE, AND IGNITION SYSTEM • Use fixed spanner to hold the flywheel of generator. • Unscrew the nut on flywheel. • Use flywheel puller to remove the generator flywheel. TLPT-01 special • Remove the semi-cycle key. • Unplug the AC generator connecting wires.
  • Page 100 BATTERY, CHARGE, AND IGNITION SYSTEM semi-Cycle key • Follow the reverse sequence to do the assembly operation. • When install the flywheel, be sure the semi-cycle key is installed into crankshaft at correct position. ＊ Be sure inside of the flywheel do not have any nuts or screws which will damage the generator coil.
  • Page 101 BATTERY, CHARGE, AND IGNITION SYSTEM • Primary coil is measured 2 terminals behind ignition coil. • Remove the spark plug cap and 2 wires behind the coil. • Check the resistance of primary coil. Standard: 0.1~1.0 Ω (20 °C) • If the resistance reads “∞” then replace new coil.
  • Page 102 ELECTRICAL DEVICE Check Main Switch ‧Remove connector of main switch wire, check conductivity between each terminal. Color BK/W GR/W ○ ○ ○ ○ ○ ○ ○ ○ START Remove main switch ‧Disconnect main switch wire. ‧Pull the main switch Bracket inside front cover. ‧Push the stopper on main switch underneath front cover then push out the main switch.
  • Page 103 ELECTRICAL DEVICE Check Left Switch HORN Color FREE ○ ○ PUSH WARNING LIGHT Color BR/W ○ ○ ○ Engine start Color BK/W Restore ○ ○ Pull 14-8...
  • Page 104 ELECTRICAL DEVICE Head Light Witch Color BL/W ○ ○ ○ ○ Exchange of Bulbs Head light bulb Press down the bulb base and turn left to change head light bulb. head light wire head light cover head light bulb 14-9...
  • Page 105 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. SIGNAL Light Witch Color BR/W...
  • Page 106 ELECTRICAL DEVICE pilot lamp Press down the bulb base and turn left to change bulb. SPEEDOMETER Remove speedometer bracket BOLT speedometer 14-11...

  • Page 107: Starting System

    STARTING SYSTEM TROUBLE DIAGNOSE Low Power of Starting Motor Can Not Start • Low power of the battery • Fuse broken • Bad contact of wire connectors • Low power of the battery • Starting motor gear abnormally stock. • Starter clutch defect •...

  • Page 108: Starter Relay

    STARTING SYSTEM STARTER RELAY Function check • Remove the R body cover. • Turn on main switch and hold the brake lever then press the start bottom. • The starter relay will make “CLICK” sound. The “CLICK” sound is normal. •...
  • Page 109 STARTING SYSTEM Check the starter clutch assembly • Put the starter clutch together with drive gear to check the movement. • The starter drive gear can only rotate in clock-wise direction. Counter clock-wise rotation will fixed to hold the clutch body. Disassembly •...
  • Page 110 STARTING SYSTEM Assembly and Installation • Install the springs and rollers into clutch body. • The dowel pin must fit into correct position between the clutch body and cover. The clutch cover or 3 bolts should use dowel pin lock-tie glue to ensure the tightness. •...

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