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ADLY MOTO SERVICE MANUAL ATV-300S/U(҇ʼʳʳOCTOBER, 2006 High Power Engine HERCHEE INDUSTRIAL CO., LTD.

ADLY MOTO 1-4INFORMATION FOR PREPARATION SPECIFICATION ( SPORTY ) TYPE ATV-300S (92/61) LENGTH 1740 mm WIDTH 1050 mm HEIGHT 1080 mm SEAT HEIGHT 820 m

ADLY MOTO 1-5INFORMATION FOR PREPARATION LOCKING TORQUE The standard locking torque shall apply in case of no specification. STANDARD TORQUEΚType Loc

ADLY MOTO 1-6INFORMATION FOR PREPARATION The following drawing that shows the disassembling situation of the cover parts for ATV-300U.

ADLY MOTO 1-7INFORMATION FOR PREPARATION The following drawing that shows the disassembling situation of the cover parts for ATV-300S.

ADLY MOTO 1-8fuel supply tocarburetor issufficientno fuel supply tocarburetorloose the fuel releasescrew of caruretor andcheck if the fuel is insideof

ADLY MOTO 1-9engine speedgoes upengine speed can'tgoes up fullyignite timing iscorrectignite timing isn'tcorrectvalve gap is correctvalve ga

ADLY MOTO 1-10normalabnormalINFORMATION FOR PREPARATIONREVOLUTION NOT STABLE (LOW R.P.M.)DiagnoseCheck and Adjustadjusting is correctadjusting isn&apo

ADLY MOTO 1-11normalabnormalINFORMATION FOR PREPARATIONREVOLUTION NOT SMOOTH(HIGH SPEED)DiagnoseCheck and Adjustnormal abnormalnormal abnormalno block

ADLY MOTO 1-12voltage of batterycan't go upvoltage of batteryis normalINFORMATION FOR PREPARATIONCHARGE ABNORMALDiagnoseCheck and Adjustnormalmea

ADLY MOTO 1-13no sparking orweaksparking strongINFORMATION FOR PREPARATIONSPARK PLUG NO SPARKINGDiagnoseCheck and Adjustloosen no loosennormal abnorma

ADLY MOTO ForewordThis service manual contains information on servicing ATV-300 This manual is written for use as a guideline only. It is recomme

ADLY MOTO 2-1CHECK AND ADJUST INFORMATIONWARNNING ϡʳ Do not start the engine at a close zone, because the exhaust gases from the engine including

ADLY MOTO 2-2CHECK AND ADJUST MAINTENANCE SCHEDULE Please follow the maintenance schedule to do the routine maintenance. Service Interval CΚClean

ADLY MOTO 2-3CHECK AND ADJUST PARKING BRAKE LEVER y Pull the right brake lever will perform brake function.y Push the locking will lock the brake. The

ADLY MOTO 2-4CHECK AND ADJUST SPARK PLUG z Pull to remove the spark plug cap. z Use tools come with the vehicle to remove the spark plug. z If the spa

ADLY MOTO 2-5CHECK AND ADJUSTVALVE ADJUSTING AttentionΚϡʳ When you check or adjust the valve, do it when the engine temperature is low ( below

ADLY MOTO 2-6CHECK AND ADJUSTADJUSTING IDLE SPEED ϡʳ Engine idle speed adjustment has to do it when the engine is warm. z Connect with the rpm meter

ADLY MOTO 2-7CHECK AND ADJUSTIGNITION TIMING z Using the timing light to check the ignition timing. z Keep the engine speed about 4000 rpm, if 2 mark-

ADLY MOTO 2-8CHECK AND ADJUSTENGINE OIL ϡʳ When you check the quantity of oil, the vehicle has to stay at the ground (flat) level. z Stop the engin

ADLY MOTO 2-9CHECK AND ADJUSTz Inspect the front sprocket teeth for excessive wear; mark sure there’s no play in the sprocket. z When install the chai

ADLY MOTO 2-10CHECK AND ADJUST FIXING OF NUTS AND BOLTS z Check the fixing nuts, bolts on all parts. If the nuts, bolts loosen then tie-up with cert

ADLY MOTO I N D E XAssembly Instruction / Pre-Delivery Information --------------------0Information for Preparation-----------------------------------

ADLY MOTO 2-11CHECK AND ADJUSTz Checking the shaft and nut of front wheel whether loosen. z Checking the nut of rear wheel whether loosen.Locking Torq

ADLY MOTO COVER PARTS, MUFFLER Information for preparation z Don‘t enforce to remove the cover parts of the ATV, otherwise will cause the connecting

ADLY MOTO COVER PARTS, MUFFLERRear cover z Release the L/R signal wires and light bracket then disconnect signal assembly. z Taking off 2 nylon nut an

ADLY MOTO COVER PARTS, MUFFLER MufflerLocking Torque: Muffler fixed boltΚ3.5 kg-m Muffler connect nutΚ1.2 kg-m Trouble Diagnose: Exhaust sound level i

ADLY MOTO COVER PARTS, MUFFLER Information for preparation z Don‘t enforce to remove the cover parts of the ATV, otherwise will cause the connecting

ADLY MOTO COVER PARTS, MUFFLERRear cover z Taking off 4 hex flange bolts then disconnect rear bumpers. z Release the L/R signal wires and light brac

ADLY MOTO COVER PARTS, MUFFLER MufflerLocking Torque: Muffler fixed boltΚ3.5 kg-m Muffler connect nutΚ1.2 kg-m Trouble Diagnose: Exhaust sound level i

ADLY MOTO LUBRICATION SYSTEM TROUBLE DIAGNOSE Oil quantity reduced x Normal consumption x Oil leaking x Piston ring wear-out or installed wrong x Valv

ADLY MOTO LUBRICATION SYSTEMCLUTCHRemovez Remove the seat and body cover. ( see 3-1, 3-2 ) z Remove 2Ø10mm Hex-flange bolts on left step bar (foot peg

ADLY MOTO LUBRICATION SYSTEMz Remove 2ØM8-25mm hex-flange bolts on master cylinder assembly. This is to lower down the brake pedal for easier. disas

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

ADLY MOTO LUBRICATION SYSTEMz Remove 2ØM6-12mm hex-flange bolts together with the switch cover.z Un-plug the contact switch connectors. z Remove 10 Ø

ADLY MOTO LUBRICATION SYSTEM z Remove the right crankcase cover gasket and beware not to lost the dowel pins.z Remove 4ØM6-28mm hex bolts and 4 spring

ADLY MOTO LUBRICATION SYSTEMz Take off the clutch center.Use reversed procedure to setup the parts that has been removed. OIL PUMP Removez Remove the

ADLY MOTO LUBRICATION SYSTEM Oil Pump Disassembling: x Remove the snap-ring and washer. x Remove the pump driven gear and shaft. x Remove the pump

ADLY MOTO LUBRICATION SYSTEMCheck:x Check the gap between the pump body and outer rotor. The gap limit is 0.25 mm. x Check the gap between inner and

ADLY MOTO LUBRICATION SYSTEMAssembling:x Mounting the inner and outer rotor, then install the pump shaft. When install the pump shaft, beware the d

ADLY MOTO 5-1FUEL SYSTEM TROUBLE DIAGNOSE Start-up function abnormal x No spark of spark plug x Compression pressure too low x No fuel in carbureto

ADLY MOTO 5-2FUEL SYSTEM CARBURETOR SET UP x Before remove the A/F adjusting screw, remember turns of setup into the end position. The normal setup

ADLY MOTO 5-3FUEL SYSTEM Remove the Carburetor y Loose the fuel releasing screw of the carburetor and release the fuel in float chamber. y Remove the

ADLY MOTO 5-4FUEL SYSTEM y Remove the needle valve y Using a backup wrench on the needle jet holder, unscrew the main jet, then the needle jet holder

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

ADLY MOTO 5-5FUEL SYSTEMy Remove the jet needle y Set the cir-clip position to adjust the jet needle.y Remove the seal cover, spring and plunger Seal

ADLY MOTO ENGINE REMOVE AND INSTALLATIONENGINE REMOVAL Remove Engine x Drain the engine oil. x Remove the seat and the left footpeg assembly. x Rem

ADLY MOTO ENGINE REMOVE AND INSTALLATION INSTALLATIONx Mounting the engine and tie-up fixed nuts with standard locking torque. Locking torqueΚ Fix

7-0CYLINDER HEAD, VALVE TROUBLE DIAGNOSE Idle Speed not Stable x Compression pressure too low x Bad adjustment of valve clearance x Valves banded o

ADLY MOTO 7-1CYLINDER HEAD / VALVE Attention of Operation z Can be operated when engine installed on vehicle. z Must cleaning before operating, avoidi

ADLY MOTO 7-2CYLINDER HEAD / VALVE Disassembly the cylinder head SEQ. Operation / Parts Name Q’ty Remarks 123456789101112131415Disassembly Spark plug

ADLY MOTO 7-3CYLINDER HEAD / VALVE Remove the camshaft and valve SEQ.Operation / Parts Name Q’ty Remarks 12345678910Disassembly Dowel pin Rocker arm

ADLY MOTO 7-4CYLINDER HEAD, VALVE damaged?x Check the cam surface to see if it’s wear out orWorking limit: Replace if IN. cam under 35.57 mm

ADLY MOTO 7-5CYLINDER HEAD, VALVECheck cylinder head x Check the hole of spark plug and valve guide to see if it’s damaged. Check valve spring free

ADLY MOTO 7-6CYLINDER HEAD, VALVE Camshaft adjustment x After install the cylinder head, it’s necessary to setup the camshaft timing. x Before put t

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 pre

ADLY MOTO 8-1CYLINDER, PISTON TROUBLE DIAGNOSE Low compression pressure x Piston ring wear-out, burn, or broken x Cylinder, piston wear out or damag

ADLY MOTO 8-2CYLINDER, PISTON Cam chain tensioner Removalx Loosen the cam chain tensioner sealing bolt and washer. x The cam chain tensioner lifter

ADLY MOTO 8-3CYLINDER, PISTON x Wear eye protection and pry the cir-clip out of its groove with a pointed tool. x Push the piston pin part-way out,

ADLY MOTO 8-4CYLINDER, PISTON x Measure the piston ring-to-groove clearance with a feeler gauge. Working limit: Top ring: replace above 0.11mm

ADLY MOTO 8-5CYLINDER, PISTON x Measure outside diameter of piston. NoteΚϠʳIt’s important to measure the outside diameter with vertical position. The

ADLY MOTO 8-6CYLINDER, PISTON Cylinder Installationx Put the dowel pins and gasket on top of crankcase. x Cylinder inside surface, piston, and pist

9-1CLUTCH, STARTING SYSTEM Trouble Diagnose Clutch sliding at accelerating y Clutch plate wearing. y Resilience of spring is fatigue. y Without the fr

ADLY MOTO 9-2CLUTCH, STARTING SYSTEMDisassembly of Clutch system SEQOperation / Parts name Q’ty Remarks 123456789101112131415DisassemblyHex bolts Clu

ADLY MOTO 9-3CLUTCH, STARTING SYSTEM Inspection of clutch x To replace the needle bearing in the lifter plate, taking out this stop-ring. x Measure

ADLY MOTO 9-4CLUTCH, STARTING SYSTEMDisassembly of Starter Reduction Gear and Starting Motor SEQOperation / Parts name Q’ty Remarks 12345678Disassemb

ADLY MOTO 1-1INFORMATION FOR PREPARATION Attention on Operation z All washers, oil rings, clamp rings, opening pins shall be duly replaced by a new it

ADLY MOTO 9-5CLUTCH, STARTING SYSTEMDisassembly of Starter Gear and Generator SEQOperation / Parts name Q’ty Remarks 12345678910DisassemblyHex flange

ADLY MOTO 9-6CLUTCH AND STARTING SYSTEMDisassembly of Starter Driven Gear and Starter Clutch assembly SEQOperation / Parts name Q’ty Remarks 12345678

ADLY MOTO 9-7CLUTCH, STARTING SYSTEM Disassembly the starter clutch x While holding the rotor, the gear should turn smoothly clockwise, but not all

ADLY MOTO 10-1CRANKCASE, CRANKSHAFT TROUBLE DIAGNOSE Engine noise x Loose of crankshaft bearings. x Loose of bearings inside crankshaft connecting r

ADLY MOTO 10-2CRANKCASE, CRANKSHAFTDISASSEMBLY OF THE TRANSMISSION GEAR SEQ Parts Name Q’ty Remarks 123456789DisassemblyHex socket bolt Bearing settin

ADLY MOTO 10-3CRANKCASE, CRANKSHAFTDISASSEMBLY OF THE GEAR SHAFT MECHANISM SEQ. Parts Name Q’ty Remarks 123456789101112131415161718192021DisassemblyG

ADLY MOTO 10-4CRANKCASE DISASSEMBLY GEAR SHIFT MECHANISM x Check the small spring locates on the gearshift arm to see if it’s too loose or not. x Ch

ADLY MOTO 10-5CRANKCASE, CRANKSHAFTREMOVE OF THE CRANK SHAFT SEQ Parts Name Q’ty Remarks 123456DisassemblyShaft comp assembly Crank shaft assembly Rad

ADLY MOTO 10-6CRANKCASE, CRANKSHAFTx Check the connecting rod side clearance with a feeler gauge. The connecting rod side clearance limit is 0.80mm x

ADLY MOTO 10-7CRANKCASE, CRANKSHAFTx Check the connecting rod. Working diameter limit: Replace if over 17.10mm x Check the balancer gear and bea

ADLY MOTO 1-2INFORMATION FOR PREPARATION Attention on Operation z Certified lubricants in cans shall be used on all the elements to be lubricated. z A

ADLY MOTO 11-1 FRONT WHEEL / SUSPENSION / STEERING Attention of Operation ΘRemove the body cover and support the frame body bottom before remove the f

ADLY MOTO 11-2 FRONT WHEEL / SUSPENSION / STEERING Disassembly of Front Wheels SEQOperation / Parts name Q’ty Remarks 1234567891011 121314Disassembly

ADLY MOTO 11-3 FRONT WHEEL / SUSPENSION / STEERING Disassembly of Suspension Arm Operation / Parts name Q’ty Remarks 123456789Disassembly (L/R) Hex f

ADLY MOTO 11-4 FRONT WHEEL / SUSPENSION / STEERING Disassembly of Steering Shaft Assembly SEQOperation / Parts name Q’ty Remarks 1234567891011 121314

ADLY MOTO 11-5 FRONT WHEEL / SUSPENSION / STEERING Disassembly of Steering Shaft Assembly SEQOperation / Parts name Q’ty Remarks 161718192021Disassem

ADLY MOTO 12-1REAR WHEEL / SUSPENSION / BRAKES Diagnosis of Troubles Rear wheel shaking or deviation z The shape of rear rim damaged. z Rear wheel axl

ADLY MOTO 12-2REAR WHEEL / SUSPENSION / BRAKES Disassembly of Parking Brake and Rear Disc SEQOperation / Parts name Q’ty Remarks 1234567891011 1213Di

ADLY MOTO 12-3REAR WHEEL / SUSPENSION / BRAKES Disassembly of Brake System SEQOperation / Parts name Q’ty Remarks 1234567891011 121314151617Disassemb

ADLY MOTO 12-4REAR WHEEL / SUSPENSION / BRAKES Disassembly of Brake System SEQOperation / Parts name Q’ty Remarks 18192021Disassembly brake system He

ADLY MOTO 12-5REAR WHEEL / SUSPENSION / BRAKES Disassembly / Assembly of Rear sprocket Assembly SEQOperation / Parts name Q’ty Remarks 1234567891011

ADLY MOTO 1-3INFORMATION FOR PREPARATION SPECIFICATION ( UTILITY ) TYPE ATV-300U (92/61) LENGTH 1800 mm WIDTH 1030 mm HEIGHT 930 mm SEAT HEIGHT 800 m

ADLY MOTO 12-6REAR WHEEL / SUSPENSION / BRAKES Disassembly / Assembly of Swing arm sub Assembly & Rear Cushion SEQOperation / Parts name Q’ty Rem

ADLY MOTO 13-1ELECTRICAL DEVICE Attention of Operation WARNINGΚϠʳBattery electrolyte contains sulfuric acid, which can cause severe burns. Avoid conta

ADLY MOTO 13-2ELECTRICAL DEVICE Check Voltage of Battery z Remove rubber strap on battery , disassembly connection wires of battery , check voltage be

ADLY MOTO 13-3ELECTRICAL DEVICEIgnition Coil Conduction Test Θʳ Check first coil resistance of ignition terminal. Standard valve (20к): 0.1̑˃ˁˆӨʳʳΘC

ADLY MOTO 13-4ELECTRICAL DEVICEy Head light and position light y Signal light switch y Engine stop switch Exchange of Bulbs Head light bulb z Remove h