HER CHEE ATV-50 II ANSI User manual

SERVICE MANUAL
ATV-50/90 II ANSI
September, 2005
High Power Engine
HER CHEE INDUSTRIAL CO., LTD.

Foreword
This service manual contains information on servicing ATV-50/90/100.
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-50/90/100.
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 Moto .

I N D E X
Initial Set-Up Information-------------------------------------------------1
Information for Preparation-----------------------------------------------2
Check and Adjust----------------------------------------------------------3
Engine-
Lubrication System---------------------------------------------------------4
Fuel System-----------------------------------------------------------------5
Remove of Engine----------------------------------------------------------6
Cylinder Head / Cylinder / Piston----------------------------------------7
Starter / Driving Disc / Clutch / Transmission Disc--------------------8
Final Transmission Mechanism-------------------------------------------9
Crank case / Crank shaft--------------------------------------------------10
Chassis-
Front wheel, Brake, Suspension------------------------------------------11
Rear heel, Brake, Suspension --------------------------------------------12
Electrical devices-----------------------------------------------------------13
Wiring diagram-------------------------------------------------------------14

1－1
Initial Set-Up Information
Injector Oil
Use a good grade of oil that is specially formulated for two-stroke engines, synthetic type is
recommended. JEHM recommends SAE 30.
Transmission Gear Oil
Use multi-grade motor oil of SAE 90 or 85W-140.
Break-In Procedure
To insure maximum durability and optimal performance and to avoid engine damage, please
pre-mix the first four tanks of fuel with two-stroke engine oil at 30:1 ratio. Do not operate
the ATV at more than half throttle for the first three hours. During the break-in period (the
first four tanks of fuel), operate the vehicle at various RPM’s and do not operate the vehicle
above half throttle for extended periods.
Engine
The ATV-50/90/100Ⅱhave a two-stroke, reed induction, piston port motor. It requires the
use of two-cycle oil and should never be run without oil in the oil tank. Extreme damage to
the motor will result.
Ignition System
The ignition system installed on ATV-50/90/100Ⅱis the Computerize Digital Ignition (CDI)
type. There is no maintenance required for this type of system.
Chassis
The chassis is constructed of mild steel tubing. If any frame repairs are necessary,
oxyacetylene welding can be used. If wire feed or arc welding is used, use extreme care and
disconnect the battery while welding.

1－2
Set-Up Procedure
The following instructions provided a general overview of the procedures needed to properly
set-up and deliver the ATV-50/90/100 to the retail customer.
1. Take out the battery and fill with acid liquid. Pre-charging the battery will extend its life.
The preparation and charge procedure is based on the battery’s instruction.
2. Install the rear wheels and parts in the following order:
A. 14x40x4.5mm washer (big)
B. 14mm hex-bolt (torque 450-550kg-cm, 44-54N-m)
C. Cotter pin (open up the end after installed)
D. Rubber cap
3. Install the front wheels and parts in the following order:
A. 12x40x4.5mm washer (big)
B. 12mm hex-bolt (torque 300-350kg-cm, 29.5-34N-m)
C. Cotter pin (open up the end after installed)
D. Rubber cap
4. Set the handle bar into the lock-pin of the steering base. Tie-up the 4 hex-socket bolts.
Install the rear cover into handle bar and adjust the cables and wires properly. Install the
front cover into the rear cover.
5. Pull the seat-lock cable and remove the seat. Install the battery with the red wire to
positive (+) and the black wire to the negative (-).
6. Remove the oil tank cap and fill with 2 stroke oil (SAE 30)of a synthetic and low-smoke
type, and enough unleaded gasoline to operate. Be sure the arrow mark on the fuel valve
arm (petcock) is set into the correct position (on).
7. Install the Front Bumper.
8. 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. Turn on the engine operation switch located on left handle bar
B. Pull the rear-brake lever
C. Push the electric starter bottom to left or right
9. If the vehicle is operating in a very dusty area, please add more oil on the air cleaner filter.

1－3
PDI (PRE DELIVERY INSPECTION)
(For ATV-50/90/100)
□ 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 lubrication oil (2 stroke, Grade SAE30) tank is filled.
□ 4. Battery is installed properly.
□ 5. All brake cables are adjusted properly.
□ 6. Fuel tank has enough gasoline to operate.
□7. Check the suspension and drive chain for proper setup.
□ 8. Check that all electrical components and lights are working properly.
□ 9. Make sure that the owner’s manual and tool bag are installed under the seat.
If there are any other questions, please check the owner’s manual for details.
CAUTION: Before install the front rim, beware the stopperof front brake plate assembly
must fit into the front knuckle 7-mm plate.

2-1
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.

2-2
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
Tool: General tools shall be used
New: Replace by new items after dismounting
Attention
Dangerous and important operations

2-2
INFORMATION FOR PREPARATION
SPECIFICATION
MODEL ATV-50 ATV-90
ENGINE 50 C.C. 90 C.C.
TYPE AIR-COOLED, 2-STROKE SINGLE CYLINDER
STARTING KICK & ELECTRIC
LUBRICATION OIL PUMP SEPARATE SUPPLY
TRANSMISSION AUTOMATIC (C.V.T. V-BELT)
SPARK PLUG NGK BP7HS
BATTERY 12V-4AH
OIL CAPACITY 1 LITER
FUEL TANK 4.5 LITER
OVERALL LENGTH 1270 mm 1540 mm
OVERALL WIDTH 875 mm 850 mm
OVERALL HEIGHT 860 mm 900 mm
SEAT HEIGHT 660 mm 700 mm
WHEEL BASE 955 mm
CLAIMED DRY WEIGHT 100 kg 105 kg
FRONT BRAKE DOUBLE DRUM
REAR BRAKE DRUM
FRONT SUSPENSION OIL DAMPED, INDEPENDENT, SINGLE A-ARM
REAR SUSPENSION OIL DAMPED, SWING SINGLE SHOCK
FRONT TIRE 16×8-7 20 ×7-8（19*8-7）
REAR TIRE 16×8-7 18.5×9.5-8（19*8-7）
☆SPECIFICATIONS SUBJECT TO CHANGE WITHOUT ANY NOTICE. ☆

2-4
INFORMATION FOR PREPARATION
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)
Front Wheel Axle Nut 1 12 3.5
Rear Axle Nut 1 14 5.0
Rear Brake Arm Screw 1 6 1.2
Front Shock Absorber 4 10 4.0
Rear Shock Absorber 2 10 4.0
Engine Mounting Nut – Front 1 10 4.5
Engine Mounting Nut – Rear 1 8 3.0
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 Cover Nut 1 10 3.8
Clutch Carrier Nut 1 28 5.5
Nut of Primary Fix Sheave 1 10 3.8
Oil-check Screw 1 8 1.3
Joint Screw of Exhaust Muffler 2 6 1.2
Exhaust Pipe Support Screw of Muffler 1 8 3.0
Spark Plug 1 14 1.4
Bolt of Crank Shaft Case 6 6 1.0

2-5
INFORMATION FOR PREPARATION
The following drawing that shows the disassembling situation of the cover parts for
ATV-50/90/100(II).

3-1
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 Judgement Standard Remarks
Operating Device
Handle- Play, loose/tight
Operation
○
○
○
○
○
○
Wheels- Right/left turn round angle ○
Front and Rear Cushion – Damage
InstallationofBolt
○
○
○
○
Brake Device
Brake- Play
TestRide
Adjust
○
○
○ ○
○
○
○
○
○
○
Play
Handle , handle front
10-20 mm
Wires- Loose / tight and damage ○ ○ ○
Wore of brake & operating parts ○
(mm) Front Rear
Standard
diameter 85 130
Brake Hub.
○
Limitation 85.5 130.7
Riding Device Tire
Size
20×7-8 19×7.5-8 19×7-8 16×8-7
Normal 8 psi 10 psi 2.2 psi 4.5 psi
Max. 9 psi 11 psi 2.6 psi 5 psi
Tirespressure ○ ○ ○
Min. 7 psi 9 psi 1.8 psi 4 psi

3-2
Service Time (month)
Service Items Before
riding 1st Each
6 each 12 Judgement Standard Remarks
Riding Device
Tire
Check & damage of tires
○○○Ditch--- front wheel till 3 mm
Rear wheel till 3 mm
Abnormal & ditch in tires ○○○
Bolt & nut of tires locking
○ ○
Blocking torque
Front wheel – 3.0~3.5 kg-m
Rear wheel – 4.5~5.5 kg-m
Tightness of front bearing ○
Tightness of rear bearing ○
Buffer device
Spring - damage ○ ○ Spring of shock absorber.
Suspension arm – damage of joint gap
&arm
○ ○
-oilleakageordamage ○ ○
Tightness of installation ○ ○
Power transmission device
Clutch - action ○○○
Gear Box ○ ○ SAE 90 or 85W-140
Electric device
Ignition device - 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
○
Engine
Body – starting & abnormal noise
Low speed & accelerating
exhaust
air filter
○
○
○
○
○
○
○
○
○
Idle : 1800±100 rpm

3-3
Service Time (month)
Service Items Before
riding 1st Each
6 each 12 Judgement Standard Remarks
Lubrication device
Oil and oil filter ○○ ○ ○Check the oil level
Oil leakage ○○
Fuel installation
Fuel filter is dirty / Clogged ○
Leakage of fuel ○○
Throttle gate & choke ○
Alteration of tubes ○
Lights
Action
○○
On/off normal , dirty , damage ○
Exhaust pipe & muffler
Installation loosed or damage ○
Function of muffler ○
Frame & body –loose or damage ○
Cleaning combustion chamber , exhaust
pipe , and carbon muck in muffler
6Each 2 years
DRIVE CHAIN
Check the tension of drive chain ○○Tolerance: 10~20mm
Others - greasing of each part ○○
Abnormal from previous day –confirm
normal
○

3-4
CHECK AND ADJUST
Disassembly of External Parts
zRemove the external parts for check
and adjustment.
Disassembly the Rear Cover:
zPull the Seat Releaser Unit and take
off Seat Ass’y.
zRemove 4 Pan Flat Head Phillips
Bolt.
zRemove 2 Ladder Bolt.
zRemove 4 Nylon Nut, 2 Plain Washer
and 2 Rubber Washer.
Remove Floor Panel:
zRemove 4 Pan Flat Head Phillips
Bolt.
Disassembly the Handle Bar:
zRemove 2 Tapping Screw Truss Head
Phillips and take off Front Handle
Bar Cover.
zRemove 2 Handle Grip.
zRemove 4 Hex Socket Bolt and take
off the Handle Bar.
zRelease 1 Hex Socket Bolt and take
off the R. Lever Ass’y.
zRelease 2 Pan Flat Head Phillips Bolt
and take off the L. Handle Switch
Ass’y.
zRelease 1 Hex Socket Bolt and take
off the L. Lever Ass’y.
Disassembly the Front Cover:
zDisassembly the Handle Bar.
zRemove the Fuel Tank Cap.
zPull the Seat Releaser Unit and take
off Seat Ass’y.
zRemove 2 Ladder Bolt. and 4 Pan
Flat Head Phillips Bolt.
zRemove 2 Hex Washer Face Bolt and
4 Plain Washer And 2 Hex Flange
Nut With Serration.
WARNNING:
＊Do not damage & break the cover.
＊Before locking screws, please confirm
the matching is correct of all parts.
zDisconnect Main Switch Wire and
head light wire.

3-5
zCHECK AND ADJUST
Adjustment of Oil Pump
＊WARNNING:
Going on this operation after adjusting
and checking the guide wiring of throttle.
•The tolerance within 1 mm of the oil
pump control cable is good. Starting
the engine, push slightly the throttle
to feed oil. At same time of rising the
engine rotation, confirm the function
of control rod.
•The condition will be appeared with bad synchronizing as follows :
＊Starting difficult and having smoke when opening degree of oil pump’s control
rod is too big.
＊Piston will be burnt when the opening degree of oil pump’s control rod is too
small.
Adjustment of Drive Chain
zLoose 4 Hex Bolts on Rear Brake Panel.
zAdjust the drive chain adjuster to proper chain tolerance 10 ~ 20 mm (unload).
zTie up 4 Hex bolt on Rear Brake Panel.
zLubricate the chain.
CANTION: Beware the direction of chain fix clip if disassembly the chain.

4－1
LUBRICANT SYSTEM
Attention of Operation
zPay attention to avoid dust enter to the interior of engine and oil tube when
disassembly the oil pump.
zNever disassembly oil pump.
zMust draw out the air in the pump if there have air in the pump when
disassembly tube of carburetor.
zAfter disconnect the oil tube, must fulfill the oil in the connection tube before
installation.
Diagnosis of Troubles
Too much smoke, means too much carbon muck piping up the spark plug.
zPoor synchronizing adjust of oil pump (too much exhaust gas).
zBad quality of engine oil.
Overheating
zPoor synchronizing adjustment of oil pump (too exhaust gas).
zBad quality of engine oil.
Piston burnt
zShort of engine oil, or engine oil tube is clogged.
zPoor adjustment of oil pump.
zAir in tube system or in oil pump.
zBad oil pump.
Clogging oil from oil tank
zVent of oil tank’s cap is blocked.
zOil Filter is clogged.
Preparation standard
zUse separating engine oil appointed (use for 2-stroke).
zOil tank capacity: 1.1 liter

4－2
LUBRICANT SYSTEM
Disassembly of Motor Oil Pump
zRemove Generator Cover.
zRemove A.C.G. fly wheel and fly wheel base.
＊WARNING:
Operating after cleaning motor oil pump around and no entering to the crank shaft
case.

4－3
LUBRICANT SYSTEM
Operation / Parts Name Q’ty Remarks
1
2
3
4
5
Disassembly
Fuel tube
Fuel connection tube
Pan phillips bolt
Control cable
Oil pump
1
1
2
1
1
4WARNING:
Clogging the tube to avoid fuel flow out.
•Remove from both side of oil pump.
•Remove from oil pump.
Assembly
5→1
•Assembly with sequence in reverse
of disassembly.
＊WARNING:
−Smear oil to new O ring ,before install
the oil pump into crank case.
−The oil pump must correctly installed
into crank case.
4WARNING:
−Don’t loosen adjusted screw on control
cable.
−Adjust the cable if it’s loose.

4－4
LUBRICANT SYSTEM
Disassembly of Oil Tank
Operation / Parts Name Q’ty Remarks
1
2
3
Disassembly
Hex Bolt
Joint of oil disassembly oil pipe
Oil tank
1
1
1
＊WARNING:
Fill motor oil with clean container.
Assembly
3→1
•Operation with sequence in reverse of
disassembly.
＊WARNING:
Connect correct oil pipe after
assembly , release the air in motor oil
pump.