SERVICE MANUAL
Contents
1. CHECK AND ADJUST e Inspect the front sprocket teeth for turn direction excessive wear mark sure there s no play in the sprocket e When install the chain clip beware the clip fix clip direction parking brake adjustment Z BRAKE SYSTEM Parking brake and rear brake e Check all the brake shoes If the brake shoes have any dint or wearing very serious then change it Check the play of brake lever normal play 10 20 mm e If the brake lever play is too much adjust the fix bolts on right brake lever e If the play of the rear brake over the normal value then adjust the adjusting nut of rear brake caliper on swing arm Adjusting nut must be aligned with pin any slight deviation may result in braking play change cause danger as brake applied STEERING e Turning the steering from right side to left side check the steering operation Be sure the wiring and cable does not affect the steering handle 2 9 ADLY MOTO CHECK AND ADJUST FIXING OF NUTS AND BOLTS e Check the fixing nuts bolts on all parts If the nuts bolts loosen then tie up with certain locking torque SUSPENSION Front e Holding the brakeand push the handle bar Check the fork movement and other parts if is loose or oil leaking Rear e Check the damping of rear suspension e Check the suspension bush function normally X Inspect all suspension fasteners before riding TIRE RIM e Check the tires whether have an2. leakage Valve gap is too tie Cylinder head gasket is damage Piston ring wear out Piston cylinder wear out If the cylinder pressure is too high then check the combustion chamber and the top face of piston whether with too much carbon residue 2 7 ADLY MOTO CHECK AND ADJUST ENGINE OIL When you check the quantity of oil the High vehicle has to stay at the ground flat Low g level e Stop the engine and remove the oil level gauge e Unscrew the engine oil filler cap from the right front corner of the engine and pull out the dipstick If the oil level is stay within bottom mark of the gauge then the oil quantity is enough Refill the engine oil if it s too less The standard oil type is SAE 10W 40 Re install the oil level gauge Change the engine oil e Take out the oil level gauge e Remove the oil release bolt underneath the engine and release the oil e Install the oil release bolt e Fill the engine oil x Confirm the washer of the bolt whether damaged Engine oil quantity disassemble 2 0 Lit change 1 6 Lit e Check all parts whether leaking after assembly DRIVE CHAIN Check the drive chain condition e The drive chain should be check adjust and lubricate regularly e Inspect the drive chain at a point on the lower run about halfway between the sprockets The free play of the drive chain should be between 20 30mm up and down 2 8 ADLY MOTO
3. ADLY MOTO CHECK AND ADJUST INFORMATION WARNNING x Do not start the engine at a close zone because the exhaust gases from the engine including some noxious emission such as CO HC NOx etc that can result serious damage for health Strictly prohibit using any flammable thing in the working zone because that can rise fire easily ENGINE ITEM SPECIFICATION REMARK without resistance intake valve SAE 10W 40 lEngine Oil Capability Compression Pressure Ignite Timing CHASSIS Parking brake lever free play 10 20mm Left lever free play 5 10mm _ _ _ S E Torque of Front Rim Nut _ 14kgem oP Torque of RearRimNut_ t4kem J o oo Detailed tire pressure specification please check the marking on tires 2 1 ADLY MOTO CHECK AND ADJUST MAINTENANCE SCHEDULE Please follow the maintenance schedule to do the routine maintenance Service Interval C Clean up L Lubricate or Grease R Replace I Inspection check adjust and replace if necessary D Need some special tools or techniques suggest to be serviced on dealers site Inspection parts System C Note 1 I C I o S E R Air cleaner element Spark plug Re tighten up bolts and nuts I I Tire and Wheel Steering system and shaft bearing LS Service Interval 1 Initial Service 20 hours or 150km either earlier time for new vehicle 2 Regular Check Every 100 hours or 1000km earlier time 3 Regular Check E
4. EED e Connect with the rpm meter then starting the engine e Before adjusting the idle speed make sure the spark plug gap is correct Also turn the handlebars from left to right and note whether the idle speed changes If it does the throttle cable may be incorrectly routed Be sure to correct this problem before proceeding Warning Use screw driver to adjust the idle speed to avoid injury e Adjust the idle speed adjust screw reach to the normal idle speed The idle speed is about 1400 100 rpm IGNITION TIMING The ignition system of this ATV 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 e Remove the 14 mm A C G cap e Using the timing light to check the ignition timing When the engine speed running at idle the F mark of flywheel should aim at the inspection hole 2 6 ADLY MOTO CHECK AND ADJUST IGNITION TIMING e Using the timing light to check the ignition timing e Keep the engine speed about 4000 rpm if 2 mark lines on flywheel aim at center of inspection hole then the ignition timing 1s correct CYLINDER PRESSURE e Remove the spark plug cap and spark plug e Install the pressure gauge e Rotate the throttle and press the electric start button The normal cylinder pressure is 12 14 kg cm If the cylinder pressure is too low then check the following items Valve
5. e Pull to open 4 clips on air cleaner cover and remove the cover e Take out the air filter e Check the filter whether is dirty or damaged If it s dirty or damaged then clean it or change a new one Attention x Clean the element and frame in a high flash point solvent squeeze the solvent out of the foam and let the guide and element dry completely iu 4 air cleaner case Check period x Ifthe ATV often driving at the rainy or abominable surroundings please check the filter more frequently 2 4 ADLY MOTO CHECK AND ADJUST VALVE ADJUSTING Attention x When you check or adjust the valve do it when the engine temperature is low below 35 C e Remove the timing hole plug and the crankshaft hole plug with screwdriver e Rotate the flywheel and keep the T line aim at the centerline of the inspection hole e Measure valve clearance with a feeler gauge of the specified thickness e To adjust the valve clearance loosen the locknut and turn the adjuster Attention x When you adjusting the valve don t invert the crankshaft otherwise cannot adjust the exhaust valve Valve gap check and adjust Valve gap IN 0 08 mm EX 0 12 mm e Loose the fixed nut and rotating the adjusting nut reach to the proper gap e Tie up the fixing nut and check the gap again e Using the valve gap tool to adjust the valve Sap 2 5 ADLY MOTO CHECK AND ADJUST ADJUSTING IDLE SP
6. very 200 hours or 2000km earlier time Note 1 Used in dusty sandy snow area need to be inspected Note 2 Used in rainy muddy condition need to be inspected Note 3 Used after 50 hours or 500km need to be inspected Note 1 If the ATV is new then the motor oil have to replace at the first initial service 2 For safety reason we suggest the maintenance should be done at local service center 3 If the driving condition is very abominable such as rainy dust zone or heavy load that we suggest operating maintenance more frequency ADLY MOTO CHECK AND ADJUST praking brake PARKING BRAKE LEVER e Pull the right brake lever will perform brake function e Push the locking will lock the brake ad m a The main adjusting nut for throttle play is located under the handle bar e Loose the fixed nut and adjust the play nut to proper position The throttle lever control bolt is located on the throttle base The throttle lever free play 2 6 mm e Loose the fixed nut and adjust the screw to get proper position Adjust nut Fix nut 2 3 ADLY MOTO CHECK AND ADJUST SPARK PLUG e Pull to remove the spark plug cap e Use tools come with the vehicle to remove the spark plug e If the spark plug grimy or with carbon residue then using the copper brush to clean it Spark plug specification DR8EA Resistance Check the gap of spark plug Gap 0 6 0 7 mm AIR CLEANER e Remove the seat
7. y nail broken etc e Check tire pressure with a gauge that will read accurately at the low pressure used in ATV tires e The tire pressure can be very depends on different operation condition Please check the mark on tire for operation pressure tolerance 2 10 ADLY MOTO CHECK AND ADJUST e Checking the shaft and nut of front wheel whether loosen e Checking the nut of rear wheel whether loosen Locking Torque Front wheel 18mm nut 14 kg m Rear wheel 18mm nut 14 kg m MENO 2 11
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