ADLY MOTO ATV-300 User manual

ADLY MOTO
SERVICE MANUAL
ATV-300S/U(҇ʼʳ
ʳ
OCTOBER, 2006 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 armΰpetcockαis 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
zAll washers, oil rings, clamp rings, opening pins shall be duly replaced by a new item
when dismounted.
zLocking 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.
zAll items must use original parts, pure oil and greases.
zAll service shall use special tools and general tools to repair.
zAll 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
zCertified lubricants in cans shall be used on all the elements to be lubricated.
zAfter assembly, performance of all elements shall be duly checked and the locking shall
be duly verified.
zIn case of an operation is performed by over 2 people, the assignment shall be conducted
in coordination and safety shall be the first priority.
zDefinition 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.
BOREuSTROKE 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 1400²100 rpm
VALVE CLEARANCE 0.08Д0.12 mm
STARTING Electric starter and pull start
SPARK PLUG NGK DR8EA
SPARK PLUS GAP 0.6~0.7 mm
IGNITION C.D.I
SUSPENSION FrontΚDouble A-Arm with preload adjustable shock
RearΚSwing 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 22Ø8-10)
REAR TIRE 21×10-8 (Optional 22Ø11-10)
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.
BOREuSTROKE 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 1400²100 rpm
VALVE CLEARANCE 0.08Д0.12 mm
STARTING Electric starter and pull start
SPARK PLUG NGK DR8EA
SPARK PLUS GAP 0.6~0.7 mm
IGNITION C.D.I
SUSPENSION FrontΚDouble A-Arm with preload adjustable shock
RearΚSwing 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 22Ø8-10)
REAR TIRE 21×10-8 (Optional 22Ø11-10)

ADLY MOTO
1-5
INFORMATION FOR PREPARATION
LOCKING TORQUE
The standard locking torque shall apply in case of no specification.
STANDARD TORQUEΚ
Type Locking Torque (kg-m) Type Locking Torque (kg-m)
5mm Bolt, Nut 0.5 5 mm Screw 0.4
6mm Bolt, Nut 1.0 6 mm Screw 0.9
8mm Bolt, Nut 2.2 6 mm Flange Bolt, Nut 1.2
10mm Bolt, Nut 3.5 7 mm Flange Bolt, Nut 2.1
12mm Bolt, Nut 5.5 8 mm Flange Bolt, Nut 2.7
18mm Bolt, Nut 15.0 10 mm Flange Bolt, Nut 4.0
18mm Lock nut 11.0
CHASSISΚ
Locking Place Quantity Dia. (mm) Torque (kg-m) Remark
Handle bar bottom flange nut 2 10 4.0 Nylon insert type
Ball joint fixed nut 4 10 4.0 Nylon insert type
Engine mounting flange nut 4 8 3.5
Engine mounting bracket bolt 2 10 4.0
Foot rest flange bolt 6 8 4.0
Rear swing arm fixed nut 1 14 9 Nylon insert type
Rear brake panel flange bolt 4 12 7
Front suspension fixed nut 4 10 4.0 Nylon insert type
Rear suspension flange bolt 2 10 4.0
Front rim nut 2 18 15
Rear rim nut 2 18 15
ENGINEΚ
Locking Place Quantity Dia. (mm) Torque (kg-m) Remark
Breather separator Allen bolt 1 6 1.2 Hex socket flange bolt
Cam chain tensioner mounting bolt 2 6 1.2 Hex flange bolt
Cam sprocket bolts 2 7 2.1 Hex flange bolt
Clutch center locknut 1 18 11.0 Locknut
Clutch lifter plate bolts 4 6 1.2 Hex bolt
Crankcase cover bolts (L/R) 24 6 1.0
Crankcase bolts 14 6 1.2 Hex flange Bolt
Cylinder base bolts 2 6 1.0
Cylinder head cover flange bolts 13 6 1.2 Hex flange Bolt
Cylinder head cap nuts 4 10 4.0 Hex acorn washer face nut
1 6 1.0
Oil pipe bolts 1 7 1.2
Gearshift return spring pin 1 8 2.2
Gearshift drum shifter pin 2 8 2.2

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

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

ADLY MOTO
1-8
fuel supply to
carburetor is
sufficient
no fuel supply to
carburetor
loose the fuel release
screw of caruretor and
check if the fuel is inside
of carburetor ?
sparking no sparking or
weak
compression
pressure
is normal
compression
pressure too low
or no pressure
engine can not
ignite
engine can ignite
but can not start
spark plug is dry spark plug is wet
loosen the spark plug,
connect with the spark
cap and contact with the
frame, check the spark
plug sparking ?
test the compression
pressure
follow the standard
stat-up procedure and
test again
loosen the spark plug
and test
Diagnose Check and Adjust Reason of Trouble
fuel tank without gasoline
tubing to carburetor blocking
float chamber tubing blocking
fuel filter blocking
fuel cup blocking
air in fuel tank blocking
spark plug grimy or damage
C.D.I damage
main switch damage
ACG fulser coil damage
high tension coil damage
ACG lighting coil damage
valve set damage
cylinder, piston, piston ring damage
cylinder gasket leakage
valve burn
valve timing is not correct
valve gap is too tight or no gap
start clutch damage
ignition timing is not correct
carburetor fuel adjust screw isn't correct
intake manifold sucking air
fuel level of carburetor is too high
throttle open angle is too wide
DIFFICULT START OR CANN'T START
continue
INFORMATION FOR PERPARATION

ADLY MOTO
1-9
engine speed
goes up
engine speed can't
goes up fully
ignite timing is
correct
ignite timing isn't
correct
valve gap is correct valve gap
isn't correct
compression pressure
is normal
compression
pressure
is too low
no blocking blocking
spark plug normal spark plug stain
oil quantity
is normal
oil quantity is
too rich
normal abnormal
normal over heat
no knocking knocking
INFORMATION FOR PREPARATION
REVOLUTION NOT SMOOTH , LOST POWER
Diagnose
start engine and
go up speed slight
adjusting ignite
timing
adjusting valve gap
test compression
pressure
check carburetor
blocking ?
loosen spark plug
and check
check the oil
quantiity in
crankcase is too
rich or dirty?
check cylinder head
lubricating ?
engine over heat
increase engine
speed or continue
turning at high
speed
Check and Adjust
air cleaner blocking
fuel supply isn't smooth
air hole of air tank blocking
exhaust pipe blocking
manual choke stay on
fuel cup damage
C.D.I damage
pulser coil damage
valve gap adjusting isn't correct
valve seat over abrade
valve seat 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 much
ignition timing is too earily
fuel isn't good
clutch plate sliding
mixutre gases is too lean
carbon residue in combustion chamber
is too much
ignition timing is too earily
fuel isn't good
Reason of Trouble
continue

ADLY MOTO
1-10
normal abnormal
INFORMATION FOR PREPARATION
REVOLUTION NOT STABLE (LOW R.P.M.)
Diagnose Check and Adjust
adjusting is correct adjusting isn't
correct
no sucking air sucking air
sparking normal sparking abnormal
normal abnormal
ignition timing adjusting
adjust the carburetor fuel
adjuste screw
carburetor sucking air
loosen spark plug,
connecct with spark cap
and contract with frame,
check the spark plug
sparking ?
check A.C.G
end
Reason of Trouble
C.D.I damage
pulser coil damage
fuel mixture too lean
(locking screw)
fuel mixture too rich
(loosing screw)
spark damage or stain
C.D.I damage
A.C.G damage
coil damage
spark plug cable damage
main switch damage
A.C.G damage
air blocking of the fuel
system
gasket damage
the screw of carburetor is
loosen

ADLY MOTO
1-11
normal abnormal
INFORMATION FOR PREPARATION
REVOLUTION NOT SMOOTH(HIGH SPEED)
Diagnose Check and Adjust
normal abnormal
normal abnormal
no blocking blocking
valve timing is
correct
valve timing isn't
correct
adjusting ignition timing
adjusting valve gap
check fuel cup supply
normal ?
carburetor blocking
check and adjust valve
timing
Reason of Trouble
C.D.I damage
ACG pulse coil damage
fule filter blocking
air hole of fuel tank blocking
fuel cup damage
fuel in tank is not sufficient
camshaft gear mark position is
not correct
normal spring broken or
elastic deformation
end
check the spring of valve
adjusting isn't correct
valve seat damage
cleaning
spring damage

ADLY MOTO
1-12
voltage of battery
can't go up
voltage of battery
is normal
INFORMATION FOR PREPARATION
CHARGE ABNORMAL
Diagnose Check and Adjust
normal measure value
too high
battery have voltage battery have not
voltage
normal abnormal
start engine and measure
voltage of both terminal on
battery
measure the resistance of
ACG coil
check the regulator
check socket of regulator
loosen ?
Reason of Trouble
battery damage
coil damage
terminal damage
YL wire damage
Red wire damage
regulator damage
socket damage
ACG damage
(over charge)
main switch at ON
the battery have
voltage
main switch at ON
the battery have no
voltage
normal socket loosen
GR wire broken
regulator damage
socket damage
check the socket of
regulator
check the voltage between
regulator (+) and frame

ADLY MOTO
1-13
no sparking or
weak sparking strong
INFORMATION FOR PREPARATION
SPARK PLUG NO SPARKING
Diagnose Check and Adjust
loosen no loosen
normal abnormal
normal abnormal
normal abnormal
change spark plug and
check again
check spark plug, cap,
ignition coil loosen?
check C.D.I unit socket
loosen ?
check the terminal of
C.D.I unit unimpeded?
measure resistance
check relate spare parts
Reason of Trouble
the previous spark plug damage
spark plug cap loosen
main switch damage
pulser coil damage
coil damage
lighten coil damage
the previous C.D.I unit damage
socket damage
normal abnormal
main switch damage
socket, joint connect abnormal
change CDI unit
abnormal
change ignition coil
the previous coil damage

ADLY MOTO
2-1
CHECK AND ADJUST
INFORMATION
WARNNING
ϡʳDo 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.
ϡʳStrictly prohibit using any flammable thing in the working zone, because that can rise fire
easily.
ENGINEΚ
ITEM SPECIFICATION REMARK
Spark Plug Gap 0.6~0.7 mm
Spark Plug Type DR8EA without resistance
0.08mm intake valve
Valve Gap 0.12mm exhaust valve
Idle Speed 1400r100 rpm
Engine oil type SAE 10W/40 Synthetic
1.6 L At oil change
Engine Oil Capability 2.0 L After engine overhaul
Compression Pressure 13 kg/cm21400 rpm
Ignite Timing 17qBTDC 1400r100 rpm
CHASSISΚ
ITEM SPECIFICATION REMARK
Parking brake lever free play 10~20 mm
Left lever free play 5~10 mm
Throttle free play 2~6 mm
Front Tire Pressure 10 psi Check the mark on tire
Rear Tire Pressure 10 psi Check the mark on tire
Torque of Front Rim Nut 14 kg-m
Torque of Rear Rim Nut 14 kg-m
ϠʳDetailed tire pressure specification please check the marking on tires.