SS&ST 50 SERVICE MANUAL
Contents
1. Disassembly Clutch Nut C retaining ring Washer Clutch weight set Clutch weight spring Rubber buffer Driving plate of clutch me WW WW We t WARNNING Must replacing when the buffer have damage hardening and distortion 10 12 13 14 15 16 17 18 Drive face Axle ring of spring Compression spring Secondary spring seat Guide pin Secondary sliding slot wheel Oil ring Oil seal Needle bearing Internal circle clip Radial ball bearing Secondary fix slot wheel Assembly 18 gt Operation with sequence in reverse of separating ADLY MOTO 7 8 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 Diagnosis of Trouble Engine starts but vehicle does not move e Transmission gears broken eTransmission gears burns out Operate of noise Abrasion wore and teeth hurted of gear Bearing wore and loosened Gear oil leaking eToo much gear oil filled eOil seal wear out or damage ADLY MOTO 8 1 Final Transmission Mechanism Disassembly of primary drive gear final reduction mechanism Disassembly of rear tir2. Install the new R oil seal to crank case Special tool Bearing puller TLJT 00 oi seal ADLY MOTO 9 5 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 Over tied of the steering ball race Steel ball inside ball race broken Air too less inside of front tire Brake efficiency abnormal Brake lining wear out Brake pads adjust not correct Brake disc attrition Tire wear out Poor Brake Bad adjustment of brake Wear the brake pad ADLY MOTO Steering handle not straight L R suspension not balanced Front fork banded Front tire axle banded tire wear out Front wheel shaking 10 1 Front rim defected Loose of front rim bearings Tire defect Bad adjustment of the front axle 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 Assembly Assembling with sequence in reverse 6 1 of disassembly WARNNING Assembly of front fork shall
3. fuel cup blocking loosen the spark plug air hole of fuel tank blocking connect with the spark cap and contact with the frame check the spark Plugsparking spark plug grimy or damage C D I damage Sad no sparking or main switch damage P 9 weak fulser coil damage high tension coil damage or no gap ACG lighting coil damage test the compression pressure valve set damage cylinder piston piston ring damage compression compression cylinder gasket leakage pressure pressure too low valve burn is normal or no pressure valve timing is not correct valve gap is too tight or no gap SSS SS SS SSS start clutch damage follow the standard stat up procedure and test again ignite timing is not correct engine can not engine can ignite fuel adjuste screw of carburetor isn t correct ignite but can not start intake manifold sucking air auto plunger starter is damage loosen the spark plug and test fuel level of carburetor is too high spark plug is dry spark plug is wet auto plunger starter is damage throttle open angle is too wide continue ADLY MOTO 1 7 INFORMATION FOR PREPARATION REVOLUTION NOT SMOOTH LOST POWER Diagnose Check and Adjust start engine and go up speed slight engine speed up ignite timing is correct valve gap is correct compression pressure engine speed can t go up fully ignite timing isn t correct valve g
4. Idle speed nozzle is clogged Mixed air too thin Nozzle of carburetor is clogged Gasoline filter is clogged Vent of gasoline tank is clogged Gasoline pipe cranked broke clogged Poor action of valve of float chamber Gasoline level too low Air pipe is clogged Mixed air too thick Poor action of valve of float chamber Gasoline level too high Air nozzle is clogged Auto side plunger poor ADLY MOTO 4 FUEL INSTALLATION Disassembly Assembly Valve Of Throttle Disassembly of left body covering Adjustment of play of throttle Adjustment of reverse rotation of idle speed Disassembly Pan phillips bolt WARNNING Throttle valve l Loosing top cap of carburetor and Throttle cable Throttle valve spring removing Carburetor washer x WARNNING Throttle cover Remove from guide wire of throttle valve 0o tn BPW E E eO Em 11 Adjusted screw ADLY MOTO 4 2 FUEL INSTALLATION Assembly 11 Adjusted screw WARNNING Assembly of needle nozzle Needle nozzle x 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 ED RE WARNNING Aim the ditch of throttle valve to chamber then install throttle valve into carburetor Pan Phillips bolt Lock the throttle cover
5. Assembly Assembling with sequence in 4 1 reverse of disassembly x WARNNING Must change the R L bearing set ADLY MOTO 10 5 Front Wheel Front Suspension Front Brake Front Wheel Aluminum Rim Operation Parts name Q ty Remarks Disassembly 1 Oil seal 1 2 Radial ball bearing left 1 3 Front wheel spacer tube 1 4 Radial ball bearing right 1 Assembly Assembling with sequence in 4 1 reverse of disassembly x WARNNING Must change the R L bearing set ADLY MOTO 10 6 Front Wheel Front Suspension Front Brake Assembly Disassembly of Front Brake Disassembly of front disc 3 4 KO 2 Operation Parts name Q ty Remarks Disassembly 1 Front collar 1 2 Brake disc hex socket bolt 3 3 Hex flange nut with serration 3 4 Front brake disc 1 Assembly Assembling with sequence in 4 1 reverse of disassembly ADLY MOTO 10 7 Front Wheel Front Suspension Front Brake Disassembly of Throttle Handle Disassembly of speedometer up down lid Operation Parts name Q ty Remarks Disassembly E Hex flange nut with serration Right lever set bolt Lever of front brake WN Lever of front brake Hex socket bolt 1 Master cylinder bracket 1 Master cylinder sub 1 Throttle cable 1 Handle 1 tA Assembly Assembling with sequence in reverse 8 of disassembly Thrott
6. 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 gt eR e gt LO Rear wheel ON Nut 1 Plain washer 1 Rear wheel 1 Assembly Assembling with sequence in reverse 8 1 of disassembly on ADLY MOTO 11 2 REAR WHEEL SUSPENSION BRAKE Disassembly Assembly of Rear Brake Disassembly of Rear Wheel Operation Parts name Disassembly Remarks Q gt lt 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 Brake cam shaft N N Assembly e Assembly with sequence in reverse of 8 1 disassembly ADLY MOTO 11 3 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 rR NN Assembly Assembly with sequence in reverse of 5 gt 1 disassembly ADLY MOTO 11 4 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 t
7. ADLY MOTO 4 3 FUEL INSTALLATION Disassembly of Carburetor Remove the air cleaner ass y Remove the left body cover Operation Parts Name Q ty Disassembly Throttle valve set Gasoline pipe Motor oil joint Starter wire of carburetor Vacuum pressure tube Clip Intake manifold hose clamp CONN tn BW Carburetor WARNNING Don t let dust enter into carburetor WARNNING Release air o Re eee Motor oil joint ADLY MOTO 4 4 FUEL INSTALLATION Disassembly Assembly Carburetor Disassembling of carburetor Adjust the idle speed Adjust the air adjust screw x WARNNING No fire Before disassembling loose oil draining screw draining out the gasoline from carburetor Y 95 E 79 o ant ADLY MOTO 4 5 FUEL INSTALLATION Operation Parts Name Disassembly Plunger starter 1 Pan Phillips bolt Start plug screw Oil ring Q ty Remarks O RA Float Chamber Pan Phillips bolt Drain plug Over flow tube Pan Phillips bolt Float pin Float Needle valve _ A 11 12 13 Carburetor Ass y Throttle screw set Air adjust screw set Float chamber seal WARNNING Must confirm rerotation location before disassembling not locking too much avoid to hurt seat face 12 Assembly 131 Air adjust screw set Operating with sequence in reverse
8. be aimed at convex of front fork ADLY MOTO 10 2 Front Wheel Front Suspension Front Brake Front Wheel Double Disc Aluminum Rim Operation Parts name Q ty Remarks Disassembly of Front Wheel Nut nylon 1 2 Brake hose 1 3 Hex washer face bolt 1 4 Front collar 1 5 Front fender 1 6 Front brake disc right 1 7 Front brake disc left 1 Assembly Assembling with sequence in reverse Tel of disassembly ARNNING Assembly of front fork shall be aimed at convex of front fork and brake arm ADLY MOTO 10 3 Front Wheel Front Suspension Front Brake Disassembly of Front Wheel Disassembly of front fender Front Wheel Single Disc Aluminum Rim Operation Parts name Disassembly of Front Wheel Nut nylon Brake hose Hex washer face bolt Front collar Front fender Front brake disc Remarks Assembly 6 1 Assembling with sequence in reverse of disassembly WARNNING Assembly of front fork shall be aimed at convex of front fork ADLY MOTO 10 4 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 1 Oil seal 1 2 ball bearing left 1 3 Front wheel spacer tube 1 4 Radial ball bearing right 1
9. breaker Poor contact or broke of winding Poor start motor Powerless start motor Battery charging insufficiently Bad contact of winding Strange thing blocked in motor or gear Start motor return running without engine return running Bad small gear of start motor Counter rotation of start motor Battery power insufficient Turn on main switch but no lighting Bad bulb Bad switch Guide wire broke Fuse broke Battery discharging Bad wiring Pointer of fuel gage unstable Loose socket head of guide wires Poor fuel gage Bad gage ADLY MOTO RPM unsmooth Ignition primary circuitry Bad ignition coil Wire or poor contact Poor contact main switch Ignition secondary circuitry Bad ignition coil Bad spark plug Bad high voltage wires Power leakage of spark plug Ignition time Bad Poor installation of statue inductor Poor CDI Fuel direction light no working when without fuel Insufficient battery power Fuse broke Bad main switch Bad gage Bad switch of fuel height Flashing fuel direction light Loose connection head Guide wires broke Poor action of float Poor fuel gage ELECTRICAL DEVICE Disassembly Of Battery Operation Parts name Q ty Remarks Disassembly Helmet box mat 1 2 Battery end 1 3 end 1 x
10. bushion ADLY MOTO 7 4 Starter Driving Disc Clutch Transmission Disc Check the wear amp damage of kick pinion Check the wear amp damage of kick pinion spring clip Check the wear amp damage of starting shaft bearing and driving gear ADLY MOTO 7 5 Starter Driving Disc Clutch Transmission Disc Disassembly of Left Crank Case 7 2 Operation Parts name Q ty Remark 12 Disassembly Hex washer face bolt Cone spring washer One way clutch Clamp washer Primary fixed sheave Bushing V Belt Primary sliding slot wheel Oil ring Hex nut Covering of clutch Drive face ass y I m m LR Lm m Lm Lm m mE xm WARNNING Don t hurt transmission belt Separation assembling 7 7 Separation assembling 7 8 Assembly 121 Operation with sequence in reverse of disassembly ADLY MOTO 7 6 Starter Driving Disc Clutch Transmission Disc Disassembly of Sliding Driving Disc A Operation Parts name Q ty Remark Disassembly Cam plate Cam plate sliding Weight roller Primary sliding slot wheel BRWN _ Ov WD Assembly Operation with sequence in reverse 4 of separating ADLY MOTO 7 7 Starter Driving Disc Clutch Transmission Disc Disassembly of Clutch Transmission Belt Disc Operation Parts name
11. ADJUST Way of Check amp Adjustment 1 Mark is checking time 2 Mark yx 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 Service Items Judgement Standard Remarks PSOE 1 st each 6Jeach 12 riding Operating Device Handle Play loose tight Operation Wheels Right left turn round angle Front Fork Damage Direction Post Installation of shaft 5 Direction Post Shaft Gap Brake Device Brake Play O Play Handle handle front Try to run O O 10 20 mm Correct brake O OLO O Wires Loose tight and damage O O O Gap of casing amp brake O O Wore of brake amp operating parts O Direction Wore amp Damage of casing Standard diameter 110 mm O Limitation 110 5mm Riding Device frear Tires Air pressure of tires 120 70 12 120 70 12 ADLY MOTO 2 1 Riding Device Tire Check amp damage of tires Ditch front wheel till 0 8mm Rear wheel till 0 8 mm Abnormal amp ditch in tires Bolt amp nut of tires locking Flocking torsion Front wheel 4 0 5 0 kg m Rear wheel 10 12 kg m Damage of felly side ring disc Vibration of felly in edge of felly Front whee
12. SERVICE MANUAL 55 50 100 2008 High Power Engine HER CHEE INDUSTRIAL CO LTD 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 The information illustrations or contents included in this manual may be different with the actual scooter in case specifications are changed Your understanding will be appreciated HER CHEE INDUSTRIAL CO LTD 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 Electrical devices Wiring diagram 10 12 13 INFORMATION FOR PREPARATION Attention on Operation washers oil rings clamp rings opening pins shall be duly replaced by a new item when dismounted o 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 items must use original parts pure oil
13. WARRNING Disassembly battery 4 Battery 1 from end to Assembly Assembling with sequence in reverse 4 of disassembly 2 Battery terminal x WARRNING Connect end first next end ADLY MOTO 12 4 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 x WARNNING Must check battery voltage with digital voltmeter Check Charging System Power leakage test Disassembly ground guide wire from battery after turning OFF main switch next connect voltmeter to the end between terminal amp ground guide wires Check voltage when main switch is OFF WARNNING Check voltage according to sequence from big to small Voltmeter s fuse will be broke when check voltage over the under limitation choosed No turn ON main switch when check current Current Leakage under 1 mA ADLY MOTO 12 5 terminal ELECTRICAL DEVICE Check Charging Status x WARNNING Voltage will have big change following Voltmeter the charging status of battery in this ammeter check so must check with charging completely over 12 8 V There will produce big current due to terminal of start will consume the power in battery main fuse Assembly voltmeter
14. amp damage of broke shell Rear rim damage slack NM Air aur e mack x dirty clogged changed a MEM N Front brake Mator oil pump 1 1 E Lg bag E L Front shock absorber Y Front rim damage slack Front tire wore damage air pressure ADLY MOTO 2 7 CHECK AND ADJUST control rod Adjustment of Motor Oil Pump 7WARNNING Going on this operation after adjusting and checking the guide wiring of throttle e The tolerance within 1 mm of the adjust O P control cable is good Starting the adjust nut engine turn slightly the throttle to feed _ motor oil idle speed At same time of rising the rotation of engine confirm the working of control rod e The condition will be appeared with bad synchronizing as follows 9 Starting difficult and having smoke when opening degree of motor oil pump s connection rod is too big 9 Piston will be burnt when the opening degree of motor oil pump s connection rod is too small MENO ADLY MOTO 2 9 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 After disassembling the motor oil connection tube must fulfill
15. and greases service shall use special tools and general tools to repair dismounted items requiring for checks shall be duly cleaned and for assembly all items shall be duly lubricated ADLY MOTO 1 1 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 Incase of an operation is performed by over 2 people the assignment shall be conducted in coordination and safety shall be the first priority Definition of signs The sign given in the Service Manual shall refer to the operation methods and observation OIL Lubrication by designated lubricant GREASE Lubrication by grease Special Tool Parts on which special tools shall be used General Tool General tools shall be used New Replace by new items after dismounting Attention e T Dangerous and important operations ADLY MOTO 1 2 INFORMATION FOR PREPARATION SPECIFICATION COOLING AIR COOLED AIR COOLED DISPLACEMENT 49 26 95 57 BORExSTROKE 40 0x39 2 52x45 COMPRESSION RATIO 7 2 1 ELECTRIC KICK Hydraulic Shock Absorber AUTOMATIC ADLY MOTO 1 3 INFORMATION FOR PREPARATION LOCKING TORQUE Adopt the standard torque locking for the item unlisted STANDARD TORQUE Locking Torq
16. ap isn t correct compression pressure is normal is too low loosen spark plug no blocking blocking spark plug normal spark plug stain AT 1 check the oil quantiity of crankcase is too rich or dirty oil quantity oilquantityis is normal too rich E tie iat amet OS increase engine speed or continue turning at high continue ADLY MOTO 1 8 Reason of Trouble air cleaner blocking fuel supply isn t smooth air hole of air tank blocking exhaust pipe blocking auto plunger starter damage film of carburetor damage fuel cup damage C D I damage pulser coil damage valve gap adjusting isn t correct valve set over abrade valve set damage cylinder piston abrade cylinder gasket leakage valve timing isn t correct cleaning carburetor cleaning the stain spark plug type isn t correct oil flowing is too rich oil flowing is too lean oil doesn t circulate oil tubing blocking oil supply is too lean cylinder piston abrade mixutre gases is too lean carbon residue in combustion chamber is too more igniting time is too earily fuel isn t good clutch sliding mixutre gases is too lean carbon residue in combustion chamber is too more igniting time is too earily fuel isn t good INFORMATION FOR PREPARATION REVOLUTION NOT STABLE LOW R P M Diagnose Check and Adjust Reason of Trouble C D I da
17. d Adjust Reason of Trouble ES VE E ae CEA ee 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 normal terminal damage too high YL wire damage battery have voltage R wire damage voltage check socket of regulator loosen bao SSS 1 normal abnormal regulator damage socket damage ACG damage over charge ESSO ee REVUES E 9 main switch at ON mainswithatON 7 77 TTT TTT TT the battery have the battery have no GR wire broken voltage voltage check the socket of regulator socket damage socket loosen regulator damage ADLY MOTO 1 11 INFORMATION FOR PREPARATION SPARK PLUG NO SPARKING Diagnose Check and Adjust Reason of Trouble change spark plug check again sparking strong the previous spark plug damage weak check spark plug ignition coilloosen check C D I unit socket loosen check the terminal of C D I unit unimpeded measure resistance r check relate spare parts RAPERE main switch damage pulser coil damage normal abnormal coil damage lighten coil damage main switch damage socket joint connect abnormal the previous C D I unit damage abnormal abnormal ADLY MOTO 1 12 the previous coil damage CHECK AND
18. e 11 2 Disassembly of clutch drive face 7 6 WARNNING First drain the oil of transmission Operation Parts name Main axle comp Check the wear amp damage of shaft Plain washer and gear Change new one 8 3 8 Primary drive gear Assembly Operation with sequence in reverse 8 of disassembly ADLY MOTO 8 2 Final Transmission Mechanism Change the Driving Shaft Remove the driving shaft from mission 7 Driving shaft c 3 cover WARNNING Don t damage joint face of mission cover cap of transmission case Oil seal bearing Remove the oil seal of primary drive gear e Remove the bearing A outer handle A 17mm guide rod of Install the new bearing in the mission puncher 2 cover dum eu WARNNING Jacket puncher WSS of bearing 37X 400 C Install the bearing with facing outside ADLY MOTO 8 3 Crank Case Crank Shaft Attention of Operation This chapter explain the necessary procedure of disassembling crank case due to repair amp maintain the crank shaft Before disassembling of crank case must operation with sequence of each chapter to disassembly Disassembly of oil pump Chap 3 Disassembly of carburetor Chap 4 Disassembly of intake valve Chap 4 Dis mounting of engine Chap 5 Disassembly of cylinder head and cylinder Chap 6 Disassembly of ACG Chap 12 Disassembly dr
19. en o OIL LIGHT J Y qo m XT t iad NIGHT LIGHT BL c en n 5 BR BR FUEL METE CER CR DGR METER o 25 ES i g OR Hee LL LIPS DGR DC m SIGNAL I DBR DIRECTOR li visa HIGH BEAN BK DIRECTION am YL HIGH BEAM YL RR RS M GR Olen ee qL LOW maa il ag if DBR K x TEN p 4 aloo BKH OF e M li um cD F L SIGNAL BK HIGH TENSION START R L SINGNAL 000000lo MOTOR REGULATER BATTERY C D I UNIT GENERATOR
20. er head light wire PL ELECTRICAL DEVICE Solid Wiring Diagram Light adjusting switch Light switch Switch of direction light Start switch horn switch start relay main switch start motor wires spark plug rectifier Ignition coil horn Throttle cable ADLY MOTO 12 3 ELECTRICAL DEVICE Rear light Brake light Rear direction light bulb rear light signal lens 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 O tail light lens rear direction light D 22 brake light bulb rear light bulb Y self screw MENO ADLY MOTO 12 13 ST50 100 WIRING DIAGRAM HORN SWITCH HORN BRAKE SWITCH START SWITCH TNT FLASHER FUEL OIL START RELAY FLOAT FLOAT CARBURETOR R R SIGNAL ES SWITCH START DGR BK o CY F R SIGNAL ate oles s F r1 Be m X M x Ls 5 xU SPEEDOMETER ae alo el ai SiS e To m e
21. he battery with tranditional battery Due to it s CDI ignition device so no adjusting ignition time Check CDI set amp if ignition time is poor And replacing it if it s poor confirm ignition time with original service meter Disassembly start motor without disassembling the engine Diagnosis of Trouble No power Battery discharging Fallening connection wire of battery Fuse broke Poor main switch Low voltage Poor charging of battery Poor contact Poor charging system Bad rectifier Current off and on Poor contact of battery wires Poor contact of discharging system Poor contact or short circuit of ignition system Light weak Battery discharging Resistance of wiring switch too big ADLY MOTO Poor changing system Fuse broke Poor contact broke and short circuit of connection head or socket head Poor rectifier Poor Spark plug no works Poor contact spark plug Poor contact broke and short circuit of main wire Between ACG amp C D I Between CDI amp ignition coil Between CDI amp main switch Bad ignition coil Poor CDI set Poor High low beams can t be changed Bad bulb Poor lighting switch ELECTRICAL DEVICE Start motor no working Fuse broke Battery charging insufficiently Bad main switch Poor start switch Poor front rear brake switch Poor start
22. ive face ass y Chap 7 Must disassembly of final reduction mechanism when change the left crank case Must use special tool into the inner ring of crank shaft bearing and pull in crank shaft to assembly when assembly crank case amp crank shaft put new bearing into crank case and put into new oil seal after assembling crank case Diagnosis of Troubles Noise of Engine Damage of crankshaft bearing Damage of needle bearing of crankshaft pin ADLY MOTO 9 1 Crank Case Crank Shaft Assembly Disassembly of Crank Case Special tool Special tool L 1 6 Special tool co Special tool 1 Special too Operation Parts name Q gt lt Remark 12 13 Disassembly Hex socket bolt Right crank shaft case Dowel pin Fix shaft of crank shaft case External circle clip Crank shaft Radial ball bearing Right Radial ball bearing Left Hex socket bolt Oil seal bracket Right oil seal Left oil seal Radial ball bearing NK A Assembly 13 9 ADLY MOTO 9 2 Crank Case Crank Shaft Disassembly of Crank Case nstall 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 cran
23. k case remove the crank shaft from the crank case Crank case puller TLJT 03 WARNNING Don t knock the crank shaft when disassembling Use the bearing puller to remove the crankshaft bearing from crank shaft then remove the R L crank case Bearing puller TLJT 00 WARNNING Must remove the oil seal when separate the crank case and never use the old oil seal Assembly of Crank Case crank case puller Right crank case Left crank case Crank shaft crank case puller bearing puller Clean the crank case with gasoline and check the each part whether damaged or crack x WARNNING Smear of oil on sliding surface of each shaft in crank case after checking Cleaning the washer dust of joint face and amend the part damage with oil stone ADLY MOTO 9 3 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 crank shaft case surface depth under 1 0 mm ADLY MOTO 9 4 1mm Jacket punch outer handle A i seal 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 1 Special tool Bearing puller TLJT 00
24. l horizontal under 2 0 mm vertical under 2 0 mm Rear wheel horizontal under 2 0 mm vertical under 2 0 mm Tightness of front bearing Tightness of rear bearing Buffer device Spring damage Spring of shock absorber Suspension arm damage of joint gap amp arm Buffer oilleakage or damage Tightness of installation Power transmission device Clutch action Transmission e Level way of direction hole oil It s rear fill to the mark of the hole Gear case Electril device Ignition device condition of ignition Gap of spark plug 0 6 0 7 mm spark plug Battery connection of terminal Wiring of electrical appliance damage or loose in connection place ADLY MOTO 2 2 Check Items Engine Before riding 1 st zZ lt 12 Judged standard remarks Body starting amp abnormal noise low speed amp accelerating exhaust air filter Idle 1800 100 rpm Lubrication device Oil and oil filter Warning light lighting Oil leakage Oil level Fuel installation Gasoline filter is dirty Leakage of fuel Throttle gate amp choke Fuel filter is clogged level Alteration of pipes Lights amp direction lights m cach 2 years Action On off normal dirty damage Rear mirror view Reflector amp license tag dirty amp damage Instrument action Exhaust pipe amp
25. l gauge and remove 4 hex phillips bolt x 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 ADLY MOTO 4 9 FUEL INSTALLATION Disassembly of Air Cleaner Operation Parts Name Q lt Remarks BP vc 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 Assembly 91 Se N e SF A e KF N disassembly Operating with sequence in reverse of ADLY MOTO 4 10 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 Adjustment the oil pump control cable ADLY MOTO 5 1 DISASSEMBLY OF ENGINE O HNN BW e e e e e A U Ne 16 Operation Parts Name Disassembly ACG wire wire of start motor Starter wire of carburetor Oil tube Fuel tube Vacuum pressure tube Cap of spark plug Hex washer face bolt of rear cushion Oil pu
26. l into piston t WARNNING Change whole set of piston ring with same brand ADLY MOTO 6 3 Piston up piston ring 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 e Drive belt wear out e Drive face comp damage e Clutch lining wear out e Driven ass y spring defect Power insufficient e Drive belt wear out e Driven ass y spring defect e Drive face dirty or oily e Weight roller wear out ADLY MOTO 7 1 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 1 Hex socket bolt 12 2 Carburetor tube bracket 1 3 crank case cover 1 4 Crankcase cover gasket 1 x WARNNING 5 Dowel pin 2 Check the air cleaner whether 6 Grommet l worsen or harm Assembly Operation with sequence in reverse 6 1 of disassembly ADLY MOTO 7 2 Starter Driving Disc Clutch Transmission Disc Disassembly of Kick Starter Disassembly of left crank case cover Operation Parts name Q ty Remark Disassembl
27. le cable X WARNNING Adjusting gap of throttle Master cylinder sub x WARNNING Install make the convex of master cylinder bracket and hole of handle aimed N ADLY MOTO 10 8 Front Wheel Front Suspension Front Brake Disassembly of Steering Stem Disassembly of front wheel Disassembly of steering handle special tool 1 2 ADLY MOTO 10 9 Front Wheel Front Suspension Front Brake Operation Parts name Q ty Remarks Disassembly Steering Main rod Spaner nut Steering stem dust cover Lathe cone on steering top 2 WARNNING No damage main rod amp front brake Race ball 5 Steel ball Lathe on steering inner 3 rbd Bolt washer Front inner fender N N N 0 t amp UO Hex bolt Hex bolt Front fork N Nj x WARNNING Remove L R tube by loose these two hex bolts _ Nv Assembly 10 1 Steel ball Steering stem dust cover Spaner nut _ t WARNNING Note the direction of installing bearing Assembly 10 11 ADLY MOTO 10 10 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 Nut Left lever set bolt Rear brake lever Rear brake cable Bracket of rear brake lever Hex s
28. mage normal abnormal pulser coil damage adjust the carburetor fuel adjuste screw mixture gases too lean V adjusting isn t i adjusting is correct J 5 loosing screw correct mixture gases too rich locking screw gasket damage the screw of carburetor is no sucking air sucking air loc en pressure tube broken loosen spark plug connecct with spark cap and contract with frame check the spark plug spark damage or stain sparking C D I damage A C G damage sparking normal sparking abnormal coil damage spark plug cable damage odr short Du LL P Ti main switch damage A C G damage normal abnormal air hole damage or blocking pressure tube damage end ADLY MOTO 1 9 INFORMATION FOR PREPARATION REVOLUTION NOT SMOOTH HIGH SPEED Diagnose Check and Adjust Reason of Trouble normal abnormal C D I damage pulse coil damage adjusting isn t correct normal abnormal valve set damage check fuel cup supply normal fule filter blocking Sa M l air hole of fuel tank blocking fuel cup damage fuel of tank is too less cleaning no blocking blocking check and adjust valve timing valve timing is valve timing isn t camshaft gear mark position is not correct correct correct normal spring broken spring damage elastic deformation pring g end ADLY 1 10 INFORMATION FOR PREPARATION CHARGE ABNORMAL Diagnose Check an
29. mp control cable Cable of rear brake Throttle cable Hex washer face bolt of engine Bolt Engine Nut Engine bracket bolt Engine bracket Assembly 16 gt 1 N mA e Lm Lm om Remarks WARNNING The oil over flow when remove the oil tube so use clip or plug stop the seal x WARNNING Don t damage rear fender when remove the engine e Actually for brace the frame avoid body turn inside out WARNNING Carry out following adjusting after installation Cable of throttle valve Oil pump control cable Rear break cable ADLY MOTO 5 2 CYLINDER HEAD CYLINDER PISTON Attention of Operation e Can be operated when engine installed on vehicle e Must cleaning before operating avoiding dust enter the engine e Remove the gasket dust stay on joint face e Avoid to use driver harm the joint face when remove the cylinder amp cylinder head e Avoid to harm the cylinder inner and piston face e Cleaning before check parts and smear motor oil appointed in sliding face before installing Diagnosis of Troubles Low compression pressure poor start idle speed not stable e Air leakage of cylinder head washer e Wear amp damage the piston ring e Wrong installation of spark plug e Wear amp damage the cylinder and piston e Inlet valve poor Compression pressure too high overheating locking e Piling up carbon of cylinder head or piston head Pi
30. muffler Installation loosed or damage Function of muffler Frame amp body loose or damage OOJO Abnormal from previous day confirm normal Others greasing of each part Cleaning combustion chamber exhaust pipe and carbon muck in muffler ADLY MOTO 2 3 CHECK AND ADJUST Disassembly of External Parts e Remove the external parts for check and adjustment e Remove 4 hex washer face bolts 4 space tubes and then remove luggage carrier Remove 12 self tapping screws and 2 pan flat bolts e Remove central cover L R side cover decoration strip and cowling e Install with the reverse sequence WARNNING 9 Do not break the union of body and pedal 9 Before locking screws please confirm the matching correct of all parts e Front cover e Remove 3 pan flat bolts 1 hex bolt e Remove 12 self tapping screws Disconnect the light connectors e Install with the reverse sequence WARNNING 9 Do not damage amp break the joint of inner body and front damper 9 Before locking screws please confirm the matching correct of all parts ADLY MOTO 2 4 CHECK AND ADJUST Disassembly of Pedal e Remove L R body cover e Remove 4 bolts 6 self tapping screws 2 pan flat bolts e Separate the joint with luggage case claw amp groove and remove the pedal e Install with the reverse sequence WARNNING 9 Installing to the luggage b
31. n reverse Tex of disassembly ADLY MOTO 12 10 ELECTRICAL DEVICE Check Fuel Gage e Remove fuel gage Put the float to up end down end to check the resistance between each terminal Terminal of Up end of Down Guide wire float of float Green amp black 0 20 90 1100 Check Main Switch Remove connection of main switch guide wire check conductivity main switch between each terminal connection head of main switch Color tea black black red red LOCK 0 ON Exchange Remove front covering Remove 2 bolts disassembly main switch Installing with the sequence in reverse of disassembly Check switch of handle Remove front covering Disassembly connection of handle switch check conductivity between each terminal ADLY MOTO 12 11 ELECTRICAL DEVICE Switch of Lights Color Yellow red Blue OFF ON O Power Switch Color blue white Black Up Down O_O Exchange of Bulbs Head light bulb Remove front covering of handle press down the connection and turn it to change head light bulb Dash light Remove rear covering of handle pull out the connection of bulb and replace the bulb ADLY MOTO 12 12 peach green Ne yellow green am yellow Y green red zz d yellow X die red empty head light cov
32. ocket bolt 1 Fixed belt of steering handle 1 7 Bracket of rear brake lever 1 BRWN Re QN tA Steering Handle 8 Hex flange nut with serration 9 Hex washer face bolt 10 Steering handle 11 Handle grip Assembly Assembling with sequence in 11 gt 1 reverse of disassembly 10 Steering handle 1 WARNNING Install steering handle 7 Bracket of rear brake lever 1 with handle convex at ditch of 4 Rear brake cable 1 main rod type part m ADLY MOTO 10 11 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 Fixed not spanner of steering main rod seres ool amp fixed nut spanner B For no back turning together with up cone seal ring locking fixed screw to fix it Locking Torque 7 0 kg m Fixed nut spanner B seres Itool Fixed nut spanner B I tool Fixed nut spanner A ADLY MOTO 10 12 REAR WHEEL SUSPENSION BRAKE Diagnosis of Troubles Rear wheel shaking The shape of rear rim damaged Tire defected Rear suspension too soft Spring too soft Brake efficiency abnormal Brake pad adjust not correct Brake pad attrition Brake pad cam part wear Brake cam wear The tooth groove setting poor of break arm ADLY MOTO 11 1 REAR WHEEL SUSPENSION BRAKE Disassembly of Rear Wheel
33. of Disassembling WARNNING use high pressure air clean each way of carburetor WARNNING must adjust air screw when changing air screw and carburetor ass y ADLY MOTO 4 6 FUEL INSTALLATION Disassembly of Inlet Valve Disassembly of body cover Disassembly of carburetor Operation Parts Name Q ty Remarks Disassembly Intake manifold hose clamp Hex washer face bolt Intake manifold Reed valve ass y amp Ne Reed valve gasket Assembly 51 4 Reed valve ass y 5 Reed valve gasket Se LR me Assembling with sequence in reverse of disassembly t WARNNING Using new washer the washer must aim at hole of reed valve t WARNNING confirm secondary air entering after installing ADLY MOTO 4 7 FUEL INSTALLATION Disassembly of Fuel Tank Disassembly of body cover Disassembly of tail light fix bracket Disassembly of inner carrier x WARNNING No fire Shall be wiped off when fuel overflowed Remarks Tail light fix bracket Inner carrier WARNNING Clip the tube avoid fuel Joint of petrol gauge wire over flow Round phillips bolt Oil lever gauge gasket Hex flat head phillips bolt Assembly 91 Oil lever gauge gasket Operating with sequence in reverse of disassembly Change new one ADLY MOTO 4 8 FUEL INSTALLATION Disassembly of Petrol Gauge Disassembling wire joint of petro
34. ox after composing confirming the pedal with the joint of luggage case correctly Disassembly of Luggage Case Remove front fender e Disconnect the light connectors Remove power switch cap Remove edge nut on luggage case e Install with the reverse sequence WARNNING 9 Going on the installation operation after jointing correctly the luggage case and front fender ADLY MOTO 2 5 CHECK AND ADJUST Rear Light Assembly Wireness rear light A WARNNING 9 Handle Covering 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 hex boit Ensuring the joint of tail light hole correct with the bulge of truck Remove 4 self tapping screws separate the joint with speedometer Remove the handle covering Assembly with the sequence in reverse of disassembly WARNNING 9 Aim handle covering correctly the handle covering back s joint ADLY MOTO 2 6 CHECK AND ADJUST Layout of Parts Maintenance The location of main parts of maintenance are showed as follows Throttle valve gt Rear brake lever play rhovernent N me ront brake lever play Head light po Rear shock absorber damage slack rensmission Gil leaking amp olf level L Rear tire wore damage oir pressure Rear brake wore
35. sembly with sequence in reverse 551 of disassembly t WARNNING Smear motor oil to new ring assembly motor oil pump The oil pump must installed correctly into crank case t WARNNING Don t loosen adjusted screw on control cable but must adjust oil pump after assembling if need to loosen ADLY MOTO 3 4 INSTALLATION OF LUBRICATION Disassembly of Oil Tank Operation Parts Name Q ty Remarks Disassembly 1 Joint of oil disassembly oil pipe 1 x WARNNING 2 Joint of wires 1 Fill motor oil with clean container 3 Bolt 1 4 Oil tank 1 5 Grommet 1 Assembly e Operation with sequence in reverse of 5251 disassembly x WARNNING Connect correct oil pipe after assembly release the air in motor oil pump ADLY MOTO 3 4 FUEL INSTALLATION Attention in Operation Pay attention to the parts which using gasoline Pipes amp Cable must be in accordance with the location directed of wiring diagram Release air in motor oil pump when remove motor oil pipe Diagnosis of Trouble No starting No gasoline in tank Gasoline blocked much fuel in cylinder Air filter is clogged Idle speed unstable of carburetor rotation not smooth Poor idle speed adjustment of carburetor Low compression pressure Poor ignition system Bad adjustment of air adjusting screw on carburetor Air filter is clogged Poor auto side plunger on carburetor
36. ston Noise e Wear the cylinder and piston e Wear the piston pin hole and piston pin e Wear the needle bearing of crank connecting rod small Piston ring noise e Wear or damage the piston ring e Wear or damage the cylinder ADLY MOTO 6 1 CYLINDER HEAD CYLINDER PISTON Disassembly of Cylinder Head Cylinder Piston e Disassembly of cover 4 7 e Disassembly of cenerator cover 12 7 Disassembly of muffler 11 2 e Disassembly of spark plug cap 5 2 1 4kg m 2 Xw gt 9 O ADLY MOTO 6 2 CYLINDER HEAD CYLINDER PISTON Operation Parts Name Disassembly Cylinder head Nut of cylinder head Cylinder head Cylinder head gasket Q ty Remarks t WARNNING Loosing nut 2 3 times Cylinder Cylinder Cylinder gasket t WARNNING Don t knock cooling fin t WARNNING Clean and not damage cylinder amp washer of crank shaft case 10 Piston Piston ring clip Piston pin Piston Piston ring needle bearing of small side Re N e e N Assembly 1021 Operation with sequence in reverse of disassembly Installation of Piston Ring Install top piston ring amp 2 piston ring in piston Do not scratch piston and do not bend piston rings Remove carbon muck inside ring ditch and piston ring when not installed Be sure the rings rotate freely after instal
37. t WARNNING Checking in the engine connected With start motor Disassembly ACG connection Check resistance of charging wire amp lighting wire Standard valve 20 Charging wire 0 2 1 0 Lighting wire 0 1 0 8 ADLY MOTO ACG connector 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 Standard valve 20 C 0 3 0 5Q x WARNNING Check ignition status with performance tester due to this test has its own stanard Check twice coil resistance between spark plug cap amp terminal Standard valve 9 5 11 kQ spark plug cap in team Remove spark plug cap from high Voltage coil Check twice coil resistance between high voltage amp terminal Standard valve 5 7 KQ without spark plug cap ADLY MOTO ignition coil spark plug s cap 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 d Ne N Assembly Assembling with sequence i
38. the motor oil in the connection pipe then connect the tube Diagnosis of Troubles Too much smoke means too much carbon muck piping up the spark plug Poor synchronizing adjust of motor oil pump too much exhaust Bad quality of engine motor oil Overheating Poor synchronizing adjustment of motor oil pump too much exhaust Bad quality of engine motor oil Piston burnt Short of engine oil or engine oil pipe is clogged Poor adjustment of motor oil pump lesser the exhaust There have air in the motor oil pipes system Bad motor oil pump Clogging oil from oil tank Vent of motor oil case s cap is clogged Filter of motor oil is clogged Preparation standard Use separating motor oil appointed use for 2 stroke Content of motor oil tank 1 1 liter ADLY MOTO 3 4 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 3 4 INSTALLATION OF LUBRICATION Operation Parts Name Q ty Remarks Disassembly 1 Fuel pipe 2 Fuel connection pipe WARNNING Clogging the pipe with clamp or plug for avoiding fuel flow out e Remove from both side of motor oil 3 Pan phillips bolt 2 pump 4 Control cable 1 1 Je Remove from oil pump 5 Motor oil pump 1 Assembly e As
39. to terminal of main fuse main fuse start engine open light rise running amount and check charging voltage amp current Charging current 1 2 Amp 5000rpm Voltage of charging control 14 15V 5000rpm Check Voltage of Front Lighting Control Disassembly front covering of handle WARNNING Check head light which wires connecting Start engine turn ON light switch open high beam Check voltage between green amp black guide wires ADLY MOTO 12 6 ELECTRICAL DEVICE x 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 regulator Check voltage adjuster Disassembly connection head of voltage adjuster Check return of wiring edge connection head Disassembly of ACG ADLY MOTO 12 7 ELECTRICAL DEVICE Operation Parts name Disassembly Hexagon socket bolt Plain washer Self tapping screw Cap of electric disc Hexagon socket bolt Plain washer Fan Hexagon nut Spring washer Plain washer Fly wheel of generator Semi cycle of electric disc Whole body bolt Hexagon socket bolt See Q ty Rea Re ENF NR RP RF hr KF NY Remarks x WARRNING Take the good care no hurt coil Assembly 14 Assembling with sequence in reverse of disassembly ACG Charging Coil Check
40. ue kg m 6 mm Hex Washer Face Bolt Nut 8 mm Hex Washer Face Bolt Nut 10 mm Hex Washer Face Bolt Nut CHASSIS Front Wheel Axle Nut 10 45 RearAxeNu 1 10 RearBrkeAmScrew 1 5 06 Upper Screw of Rear Shock Absorber 1 10 40 Lower Screw of Rear Shock Absorber 1 8 27 ____ Engine Mounting Bracket 1 8 1 60 ENGINE Screw ofCylinderCap J af mo EywedNa 1 38 CuhAkeaNa 1 n 38 28 Nut of Transmission Due 38 p OicheckSerew ___ 1 8 J 13 Joint Screw of Exhaust Manifold 2 6 12 Exhaust Pipe Support Screw of Muffler 2 6 ___12 SprkPug __ 1 __ ___ Bolt of Crank ShaftCase 6 6 tO Bolt of Engine Installation ___ __ 1 8 50 ADLY MOTO 1 4 INFORMATION FOR PREPARATION The following drawing that shows the disassembling situation of the cover parts for SS50 100 scuuter ADLY MOTO 1 5 INFORMATION FOR PERPARATION DIFFICULT START OR CANN T START Diagnose Check and Adjuster Reason of Trouble loose the fuel release screw of caruretor check if the fuel is inside of carburetor fuel tank without gasoline tubing to carburetor blocking float chamber tubing of carburetor blocking fuel supply to carburetor is no fuel supply to sufficient carburetor fuel filter blocking
41. y Kick pinion spring clip Kick pinion Hex washer face bolt Kick crank External ring clamp Plain washer Starting shaft ass y Starting shaft reset spring Bushing WARNNING Rotating pedal kick crank and remove the assembly ADLY MOTO 7 3 Starter Driving Disc Clutch Transmission Disc Operation Parts name Q ty Remark Assembly 9 Washer 1 8 Starting shaft reset spring x WARNNING Unable into main 7 Starting shaft ass y 1 shaft fix position when inside and 6 Plain washer 1 outside reset spring overlap use 5 External ring clamp 1 flat driver will inside outside 4 Kick crank 1 spring part then press main shaft 3 Hex washer face bolt 1 2 Kick pinion 1 1 Kick pinion spring clip 1 Installation of Kick Pinion Kick Pinion Spring Clip small gear of pedal kick pinion spring clip Set kick starter shaft first oe d COVer Turning starter hang kick pinion spring Wee 5 clip on crank shaft case convex 1 SA assembly of kick pinion to the location 2 A v 3 of removing TN DP Turning starter let starting shaft and WS 9 X kick pinion conjoin LN Pe Check of Starter Check the wear amp damaging of starting shaft or gear Check the tightness amp damage of starting shaft reset spring Check the wear amp damage of bush starting shaft spring
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