HER CHEE ADLY RT-50 User manual

SERVICE MANUAL
RT-50
January 2008
High power Engine
HER CHEE INDUSTRLAL CO., LTD.

INTRODUCTION
This Service Manual is provided as the technical information
for the check & preparation of ADLY RT-50 scooter, and the
direction edited is given in diagrams with "Operation Sequence",
"Key Points", and "Adjustment of Check" for reference of the
service staffs.
This Service Manual is finished in accordance with the model
of RT-50. Taking new model as standard if there are differences
between the models described in this manual and the actual
scooter.
HER CHEE INDUSTRIAL CO., LTD.

CONTENTS
Chapter 01 Chapter 1 INFORMATION FOR PREPARATION………… 1
Chapter 02 CHECK AND ADJUST………………………………………….
Chapter 03 ENGINE REMOVAL…………………………………………….
Chapter 04 CYLINDER HEAD / CYLINDER / PISTON…………………..
Chapter 05 CRANK CASE & CRANK SHAFT…………………………….
Chapter 06 Transmission……………………………………………………
Chapter 07 Final Transmission Mechanism……………………………..
Chapter 08 Fuel System……………………………………………….........
Chapter 09 Front Wheel / Front Suspension / Front Brake……………
Chapter 10 Rear Wheel / Suspension / Brake……………………………
Chapter 11 Electrical Device………………………………………………..

Chapter1 InformationforPreparation
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.
Chapter1 InformationforPreparation

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
Chapter1 InformationforPreparation

SPECIFICATION
TYPE RT 50
LENGTH 1585mm
WIDTH 700 mm
HEIGHT 960 mm
WHEEL BASE 1070 mm
NET WEIGHT
ENGINE TYPE 2-STROKE, Single Cylinder
COOLING AIR COOLED
DISPLACEMENT 49.26 C.C.
BORE×STROKE 40.0×39.2
COMPRESSION RATIO 7.2:1
IGNITION C.D.I
STARTER ELECTRIC / KICK
SUSPENSION Hydraulic Shock Absorber
TRANSMISSION AUTOMATIC
TIRE
FRONT/REAR Front 120/90-10 (Option
Rear 120/90-10 (Option
FRONT BRAKE Disc
REAR BRAKE Drum
Chapter1 InformationforPreparation

LOCKING TORQUE
Adopt the standard torque locking for the item unlisted.
STANDARD TORQUE：
Type Locking Torque (kg-m)
5 mm Screw 0.4
6 mm Screw 1.0
6 mm Hex Washer Face Bolt / Nut 1.2
8 mm Hex Washer Face Bolt / Nut 2.7
10 mm Hex Washer Face Bolt / Nut 4.0
CHASSIS：
Locking Place Quantity Dia. (mm) Locking Torque (kg-m)
Spanner Nut of Handle Steering
Steam 1 25 7.0
Front Wheel Axle Nut 1 10 4.5
Rear Axle Nut 1 14 11
Rear Brake Arm Screw 1 5 0.6
Upper Screw of Rear Shock Absorber 1 10 4.0
Lower Screw of Rear Shock Absorber 1 8 2.7
Engine Mounting Bracket 1 8 6.0
ENGINE：Locking Place Quantity Dia. (mm) Locking Torque
(kg-m)
Screw of Cylinder Cap 4 6 1.0
Flywheel Nut 1 10 3.8
Clutch Jacket Nut 1 11 3.8
Driving Disc Nut 1 28 5.5
Nut of Transmission Disc 1 10 3.8
Oil-check Screw 1 8 1.3
Joint Screw of Exhaust Manifold 2 6 1.2
Exhaust Pipe Support Screw of
Muffler 2 6 1.2
Spark Plug 1 14 1.4
Bolt of Crank Shaft Case 6 6 10
Bolt of Engine Installation 1 8 5.0
Chapter1 InformationforPreparation

The following drawing that shows the disassembling situation of the cover parts for
RT50 scooter.
Chapter1 InformationforPreparation

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
mixture gases too lean
(loosing screw)
mixture gases too rich
(locking screw)
spark damage or stain
C.D.I damage
A.C.G damage
coil damage
spark plug cable damage odr short
main switch damage
A.C.G damage
air hole damage or blocking
(-) pressure tube damage
gasket damage
the screw of carburetor is
loosen
(-) pressure tube broken

Chapter1 InformationforPreparation
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 ignite timeing
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 of tank is too less
camshaft gear mark position is not
correct
normal spring broken or
elastic deformation
end
check the spring of valve
adjusting isn't correct
valve set damage
cleaning
spring damage

Chapter1 InformationforPreparation
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 the two
terminal for 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
R 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

Chapter1 InformationforPreparation
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

2-1
Chapter 2 Check and Adjust
Way of Check & Adjustment
1. Mark “○” is checking time.
2. Mark “☆” 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 Time (month)
Service Items Before
riding 1st each 6 each 12
Judgment
Standard
Remarks
Operating Device
Handle- Play, loose/tight
Operation
○
○
Wheels- Right/left turn
round angle
○
Front Fork-Damage
Installation of shaft
Shaft Gap
○
○
○
○
○
Direction Post
Direction Post
Brake Device
Brake- Play
Try to run
Correct brake
○
○ ○
○
○
○
○
○
○
Play of brake
lever 10-20 mm
Wires- Loose / tight and
damage
○○○
Gap of casing & brake ○○
Wore of brake & operating
parts
○Direction
Wore & Damage of casing
○
Standard diameter 110 mm
Limitation 110.5mm
Riding Device front rear
Air
pressur
e
1.50 kg/cm21.75 kg/cm2
Tires-Air pressure of tires ○○○
tire 120/90-10 130/90-10
Chapter 2 Check and Adjust

2-2
Service Time (month)
Service Items Before
riding 1st each 6 each 12
Judgement Standard Remarks
Riding Device
Tires
Check & damage of tires ○ ○ ○
Ditch-front and rear
wheel till 0.8 mm
Abnormal & ditch in tires ○○○
Bolt & nut of tires locking ○○Flocking torsion
Front wheel – 4.0~5.0
kg-m
Rear wheel –10~12
kg-m
Damage of wheels ,disc ○○○Vibration of wheel
Front wheel – horizontal
under 3 mm, vertical
under 3 mm,
Rear wheel – horizontal
under 3 mm, vertical
under 3 mm
Tightness of front bearing ○
Tightness of rear bearing ○
Suspension device
Spring -damage ○Spring of
shock
absorber
Suspension arm – damage
of joint gap
& arm
○
Tightness of installation ○
Power transmission device
Clutch -action ○○○
Crankcase oil leakage or
damage
○
Transmission gear oil ○○
Electric device
Ignition device -condition
of ignition
spark plug
○○Gap of spark plug
0.6~0.7 mm
Battery -connection of
terminal
○
Wiring of electrical
appliance – damage or
loose in connection place
○
Chapter 2 Check and Adjust

2-3
Service Time (month)
Service Items Before
riding 1st each 6 each 12
Judgement Standard Remarks
Engine
Body – starting & abnormal
noise
low speed & accelerating
exhaust
air filter
○
○
○
○
○
○
○
○
○
Idle : 1800±100 rpm
Lubrication device
Oil and oil filter ○○Warning light lighting
Oil leakage ○○
Fuel installation
Gasoline filter is dirty ○
Leakage of fuel ○○
Throttle gate & choke ○
Fuel filter is clogged ○
Oil level ○
Alteration of pipes each 2 years
Lights & direction lights
Action ○○
On/off normal , dirty ,
damage
○
Rear view mirror ○○
Instrument –action ○
Exhaust pipe & muffler
Installation loosed or
damage
○
Function of muffler ○
Frame & body –loose or
damage
○
Abnormal from previous
day –confirm
normal
○
Others- greasing of each
part
○○
Cleaning combustion
chamber , exhaustpipe ,
and carbon muck in muffler
○
Chapter 2 Check and Adjust

2-4
Disassembly of External Parts
Remove the external parts for checking and adjustment
Read cover
* Open the seat.
* Remove the 2 hex-nuts, 1 bolt to
remove the luggage rack.
* Remove 10 self-tapping screws and 2
round-headed bolts..
* Remove the central and body cover
* Install with reverse sequence.
ATTENTION：
- Please do keep away the unit of the
body and the pedal from damages.
- Before tightening the screws, be
sure of correct matching of all units.
Cowling
* Remove 4 tapping screws and 2
round-head bolts.
* Separate the joint of inner parts and
remove the cowling.
* Install with reverse sequence.
Front Cover
* Remove 4 tapping screws and 3 hex-
nuts.
* Separate the joint of inner parts and
remove the cowling.
* Install with reverse sequence.
ATTENTION：
- Be sure of not damaging the front
pane land the front inner union (the
convex and concave portions).
- While tightening the screws, be sure
of the matching with the luggage
case.
Floor panel
* Remove the L/R side cover and body
cover.
* Remove 4 hex bolts.
* Separate the front interior covering
joint (the claw and the groove) and
remove the pedal.
* Follow the sequence in reverse order
for assembly.
ATTENTION：
- After joining the pedal and the front
interior covering, mount it onto the
chassis.
Luggage case
* Open the luggage case cover.
* Remove 4 tapping screws and 1nut,
separate the join with the chassis (the
concave and the convex) and remove
the front cover.
* Remove the main switch cap.
* Follow the sequence in reverse order
for assembly.
ATTENTION：
- Be sure the joint of front cover and
cowling jointing correctly before
tie-up the screws and nuts.
Tail light assembly
* Remove 2 hex bolts and rear fender
assembly.
* Remove the left and right body
covers.
* Remove 2 hex bolts and the tail light
assembly.
* Follow the mounting sequence in
reverse order.
ATTENTION：
- Match the rear guard holes and the
convex of the chassis.
Handle covering
* Remove the rear mirror
* Remove 3 tapping screws, separate
the joint from the handle rear cover
and remove the cover.
* Dismantle the speedometer cable
adapter.
* Remove the speedometer and head
light assembly.
* Dismantle the handle switch wiring.
* Follow the reverse sequence for ass’y
ATTENTION：
- Matching the joint of handle cover
with the head light case.
- Load the cables and wires
accordingly.
- After the assembly, check the
function of all switches.
Adjustment of the head light
* Adjustment of the beam of the head
light is by loosening the screw
underneath the head light
Chapter 2 Check and Adjust

Serviceable parts layout
The drawing shows the main serviceable parts.
Rear shock absorber
Rear tire
Front shock
Head light
Front brake lever Rear brake lever
A
ir filter
Front brake Rear brake
Transmission
Front tire

Chapter 2 Check and Adjust
Serviceable parts layout
The drawing shows the main serviceable parts.
Main switch
Regulator
Battery
Starter relay
CDI
Oil level sensor
Flash relay
Horn
Coil & Spark plug cap
Main fuse

4-1
Chapter3 EngineRemoval
Attention of Operation
•Following operation needs remove the engine from frame body.
–Disassembly crank shaft case
–Remove 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.

4-2
Chapter4 EngineRemoval
Operation / Parts Name Q’ty Remarks
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
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 pump control cable
Cable of rear brake
Throttle cable
Hex washer face bolt of engine
Bolt
Engine
Nut
Engine bracket bolt
Engine bracket
2
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
WARNNING:
•The oil over-flow when remove the oil
tube, so use clip or plug stop the seal.
WARNNING:
•Don’t damage rear fender when remove
the engine.
•Actually for brace the frame, avoid body
turn inside out.
Assembly
16→1 WARNNING:
Carry out following adjusting after
installation.
–Cable of throttle valve
–Oil pump control cable
–Rear break cable