Adly 300 S/U Factory Service & Work Shop Manual

ADLY MOTO SERVICE MANUAL ATV-300S/U( High Power Engine HER CHEE INDUSTRIAL CO., LTD.

ADLY MOTO Foreword This service manual contains information on servicing ATV-300 This manual is written for use as a guideline only. It is recommended that any mechanic, with or without sufficient experience, thoroughly read through the manual and only attempt to service those areas that are fully understood in accordance with the guidelines provided by this manual. For fully qualified mechanics, this manual supplies service data necessary for repairs and maintenance. It is highly recommended that a qualified mechanic, regardless of technical level, should study the service manual in full before attempting service on ATV-300 All the data and diagrams provided in this service manual are valid at the time of publication. Information may be updated without notice due to improvements or upgrades. No quotation, reproduction, or reprint of the service manual, as a whole or in part, will be permitted without the express written consent from ADLY Motor sports.

ADLY MOTO I N D E X Assembly Instruction / Pre-Delivery Information --------------------0 Information for Preparation-----------------------------------------------1 Check and Adjust-----------------------------------------------------------2 Cover parts / Muffler-------------------------------------------------------3 Engine- Lubrication System---------------------------------------------------------4 Fuel System------------------------------------------------------------------5 Engine remove and installation-------------------------------------------6 Cylinder Head / Valve------------------------------------------------------7 Cylinder / Piston------------------------------------------------------------8 Clutch / Starting System---------------------------------------------------9 Crank case / Crank shaft--------------------------------------------------10 Chassis- Front wheel / Brake / Suspension / Steering----------------------------11 Rear wheel / Brake / Suspension ----------------------------------------12 Electrical devices-----------------------------------------------------------13 Wiring diagram-------------------------------------------------------------14

ADLY MOTO MAINTENANCE SPECIAL TOOLS Install crankshaft tool (TLH3-01) Bearing puller set (TLH3-04) Fly wheel puller (TLH3-02) Valve install / remove tool (TLH3-03) Valve adjustment tool (TLH3-05)

ADLY MOTO ASSEMBLY INSTRUCTION 1. 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. 2. Install the front and rear wheels and parts in the following order: A. 18×40×4.5mm washer B. 18mm hex-bolt (torque 14 kg-m, 135 N-m) C. Cotter pin (open up the end after installed) D. Rubber cap. 3. Install the front bumper. 4. Set the handle bar into the lock-pin of the steering base. Tie-up the 4 hex-socket bolts. Install the front cover into the handlebar. 5. Install battery with the red wire to positive (+) first and the black wire to the negative (-). Use rubber strip to fix the battery onto frame. 6. Check the oil gage to see if the oil quantity is on the upper position. The oil type is 10W/40 for normal condition. It would be better for the engine to choose synthetic type. Fill up unleaded gasoline to operate. Be sure the arrow mark on the fuel valve arm petcock is set into the correct position.(ON). 7. Turn on the main switch and try to start-up the engine. In order to use the electric starter, you need to check the following: A. Check the neutral indication light should be on. B Press the electric starter bottom to start.

ADLY MOTO P.D.I. (Pre-Delivery Inspection) 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 is enough. 4. Battery is installed properly. 5. All cables are adjusted properly. (brake, throttle, choke) 6. Fuel tank has enough gasoline to operate. 7. Check the suspension and drive chain for proper setup. 8. Check all electrical components and lights are working properly. 9. Make sure that the owner’s manual and tool bag are installed on left side of the seat in the tool box.

ADLY MOTO 1-1 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. All items must use original parts, pure oil and greases. All service shall use special tools and general tools to repair. All dismounted items requiring for checks shall be duly cleaned and for assembly, all items shall be duly lubricated.

ADLY MOTO 1-2 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. 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 Dangerous and important operations

ADLY MOTO 1-3 INFORMATION FOR PREPARATION SPECIFICATION ( UTILITY ) TYPE ATV-300U (92/61) LENGTH 1800 mm WIDTH 1030 mm HEIGHT 930 mm SEAT HEIGHT 800 mm WHEEL BASE 1150 mm NET WEIGHT 200 kg ENGINE TYPE 4-STROKE, Single Cylinder COOLING AIR COOLED DISPLACEMENT 282 c.c. BORE STROKE Ø 74 × 65.5 mm TRANSMISSION Manuel , 5 speed First gear 0.095 Second gear 0.139 Third gear 0.190 Forth gear 0.242 Fifth gear 0.299 Reverse gear 0.065 CLUTCH TYPE Wet, Multi-disc ENGINE OIL (CHANGE) 10W/40 (Standard), 2.0 Lit ENGINE IDLE SPEED 1400 100 rpm VALVE CLEARANCE 0.08 0.12 mm STARTING Electric starter and pull start SPARK PLUG NGK DR8EA SPARK PLUS GAP 0.6~0.7 mm IGNITION C.D.I SUSPENSION Front Double A-Arm with preload adjustable shock Rear Swing arm with preload adjustable shock BRAKE Front : Double Disc , Rear: Disc BATTERY 8 Amps/h, Maintenances Free FINAL DRIVE Chain FRONT TIRE 21×7-10 (Optional 22 8-10) REAR TIRE 21×10-8 (Optional 22 11-10) FRONT BUMPER (LOAD)) 30kg REAR BUMPER (LOAD)) 45kg

ADLY MOTO 1-4 INFORMATION FOR PREPARATION SPECIFICATION ( SPORTY ) TYPE ATV-300S (92/61) LENGTH 1740 mm WIDTH 1050 mm HEIGHT 1080 mm SEAT HEIGHT 820 mm WHEEL BASE 1150 mm NET WEIGHT 190 kg ENGINE TYPE 4-STROKE, Single Cylinder COOLING AIR COOLED DISPLACEMENT 282 c.c. BORE STROKE Ø 74 × 65.5 mm TRANSMISSION Manuel , 5 speed First gear 0.095 Second gear 0.139 Third gear 0.190 Forth gear 0.242 Fifth gear 0.299 Reverse gear 0.065 CLUTCH TYPE Wet, Multi-disc ENGINE OIL (CHANGE) 10W/40 (Standard), 1.6 Lit ENGINE IDLE SPEED 1400 100 rpm VALVE CLEARANCE 0.08 0.12 mm STARTING Electric starter and pull start SPARK PLUG NGK DR8EA SPARK PLUS GAP 0.6~0.7 mm IGNITION C.D.I SUSPENSION Front Double A-Arm with preload adjustable shock Rear Swing arm with preload adjustable shock BRAKE Front : Double Disc , Rear: Disc BATTERY 8 Amps/h,, Maintenances Free FINAL DRIVE Chain FRONT TIRE 21×7-10 (Optional 22 8-10) REAR TIRE 21×10-8 (Optional 22 11-10)

Adly 300 S/U Factory Service & Work Shop Manual

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