ADLY MOTO ATV-300 Service Manual Download

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ADLY MOTO

SERVICE MANUAL

ATV-300S/U(

҇ʼʳ

OCTOBER, 2006 High Power Engine

HER

CHEE INDUSTRIAL CO., LTD.

Summary of Contents for ATV-300

Page 1: ...ADLY MOTO SERVICE MANUAL ATV 300S U OCTOBER 2006 High Power Engine HER CHEE INDUSTRIAL CO LTD...

Page 2: ...ualified 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 man...

Page 3: ...st 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...

Page 4: ...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...

Page 5: ...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...

Page 6: ...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...

Page 7: ...rews 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 z All items must use original parts...

Page 8: ...performed by over 2 people the assignment shall be conducted in coordination and safety shall be the first priority z Definition of signs The sign given in the Service Manual shall refer to the operat...

Page 9: ...2 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 pul...

Page 10: ...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 El...

Page 11: ...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 bol...

Page 12: ...ADLY MOTO 1 6 INFORMATION FOR PREPARATION The following drawing that shows the disassembling situation of the cover parts for ATV 300U...

Page 13: ...ADLY MOTO 1 7 INFORMATION FOR PREPARATION The following drawing that shows the disassembling situation of the cover parts for ATV 300S...

Page 14: ...en 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...

Page 15: ...ng 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 ch...

Page 16: ...buretor 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...

Page 17: ...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 ta...

Page 18: ...inal 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 regu...

Page 19: ...on 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 loo...

Page 20: ...ance 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 P...

Page 21: ...em I I I D Suspension I I Re tighten up bolts and nuts I I Tire and Wheel I I I Steering system and shaft bearing I Service Interval 1 Initial Service 20 hours or 150km either earlier time for new veh...

Page 22: ...g will lock the brake The main adjusting nut for throttle play is located under the handle bar z Loose the fixed nut and adjust the play nut to proper position The throttle lever control bolt is locat...

Page 23: ...6 0 7 mm AIR CLEANER z Remove the seat z Pull to open 4 clips on air cleaner cover and remove the cover z Take out the air filter z Check the filter whether is dirty or damaged If it s dirty or damage...

Page 24: ...ion hole z Measure valve clearance with a feeler gauge of the specified thickness z To adjust the valve clearance loosen the locknut and turn the adjuster Attention When you adjusting the valve don t...

Page 25: ...e to correct this problem before proceeding z Adjust the idle speed adjust screw reach to the normal idle speed The idle speed is about 1400r100 rpm IGNITION TIMING The ignition system of this ATV is...

Page 26: ...k plug cap and spark plug z Install the pressure gauge z Rotate the throttle and press the electric start button The normal cylinder pressure is 12 14 kg cm2 If the cylinder pressure is too low then c...

Page 27: ...40 Re install the oil level gauge Change the engine oil z Take out the oil level gauge z Remove the oil release bolt underneath the engine and release the oil z Install the oil release bolt z Fill the...

Page 28: ...eck the play of brake lever normal play 10 20 mm z If the brake lever play is too much adjust the fix bolts on right brake lever z If the play of the rear brake over the normal value then adjust the a...

Page 29: ...parts if is loose or oil leaking Rear z Check the damping of rear suspension z Check the suspension bush function normally Inspect all suspension fasteners before riding TIRE RIM z Check the tires wh...

Page 30: ...O 2 11 CHECK AND ADJUST z Checking the shaft and nut of front wheel whether loosen z Checking the nut of rear wheel whether loosen Locking Torque Front wheel 18mm nut 14 kg m Rear wheel 18mm nut 14 kg...

Page 31: ...leaser Unit and take off seat assembly z Release the brake and throttle cables from handle bar then disconnect handle switch wires z Release the L R signal wires z Disassembly speedometer connection a...

Page 32: ...and release tail light connection then disconnect the tail light assembly z Taking off 8 pan phillips bolts and 2 ladder bolts z Remove the rear cover Attention When assembling the above parts please...

Page 33: ...fler blocking x Muffler with dent Remove the muffler x Taking off the 2 nuts that connect to the cylinder x Taking off the 1 hex flange bolts and 2 hex washer face bolts that fix to the frame x Pull t...

Page 34: ...hex flange bolts then remove front bumper and luggage rack z Release the brake and throttle cables then disconnect handle switch wires z Release the L R signal wires and light bracket then disconnect...

Page 35: ...ires and light bracket then disconnect signal assembly z Taking off 2 nylon nut and release tail light connection then disconnect the tail light assembly z Taking off 8 pan phillips bolts and 2 ladder...

Page 36: ...fler blocking x Muffler with dent Remove the muffler x Taking off the 2 nuts that connect to the cylinder x Taking off the 1 hex flange bolts and 2 hex washer face bolts that fix to the frame x Pull t...

Page 37: ...check the oil quantity z Remove the oil level gauge and check if the oil level under the lower limit then adds the standard oil to upper limit of gauge Oil Exchange The motor oil will flow more easil...

Page 38: ...Pan Philips bolts on the rear foot fender Remove foot peg and fender together z Take off 12 bolts on R crankcase cover and remove the cover z Remove the gasket and 2 dowel pins z Release the clutch c...

Page 39: ...er down the brake pedal for easier disassembly z Release brake pedal reset spring z Lift the vehicle from right side and flip over to left side Then remove the oil tube fix bolt on top of right crankc...

Page 40: ...contact switch connectors z Remove 10 M6 32mm 1 M6 40mm and 1 M6 50mm hex flange bolts z Put away all wires cables Slightly hit the right crankcase cover from side way and pull out to remove the cove...

Page 41: ...eware not to lost the dowel pins z Remove 4 M6 28mm hex bolts and 4 springs under the clutch lifter plate Hold the lifter plate together with the needle roller bearing z Before remove the locknut punc...

Page 42: ...il pipe from the crankcase remove these 2 bolts z Carefully pull the oil pipe off the crankcase z Remove this dowel pin and O ring from the oil pipe z Remove the oil pump mounting bolts Use reversed p...

Page 43: ...l Pump Disassembling x Remove the snap ring and washer x Remove the pump driven gear and shaft x Remove the pump cover bolts and separate the cover from the pump body z Remove the rotors wash all the...

Page 44: ...gap between the pump body and outer rotor The gap limit is 0 25 mm x Check the gap between inner and outer rotor The gap limit is 0 2 mm x Check the gap between the rotors and a straightedge laid acr...

Page 45: ...r rotor point to the outer rotor dot mark x Locking the screw After installed turning the pump slightly and confirm the function is normal Add the standard oil in pump then install it Installation x I...

Page 46: ...of airflow inside carburetor x Stock of air cleaner x Fuel level too high Muffler make explore noise when deceleration x Too much air too lean fuel x Air stop valve abnormal x Too thin of F A mixture...

Page 47: ...is not stable repeat above adjust procedure on fuel adjusting screw and throttle adjusting screw until the engine speed is normal FUEL CUP x Remove the fuel tube from carburetor Check Check the functi...

Page 48: ...ake clamp y Taking off the guide pipe clip y Remove the choke cable from carburetor y Remove the throttle cable Disassembly of carburetor y Remove the float chamber drain plug O ring and accelerator p...

Page 49: ...eedle jet holder unscrew the main jet then the needle jet holder and nut y Remove the needle jet y Unscrew and remove the slow jet y Remove the throttle valve cover screws then open the cover y Remove...

Page 50: ...ADLY MOTO 5 5 FUEL SYSTEM y Remove the jet needle y Set the cir clip position to adjust the jet needle y Remove the seal cover spring and plunger Seal cover Plunger...

Page 51: ...erse and neutral switches Starter cable x Disconnect the reverse cable x Remove the shift pedal x Disconnect the clutch cable from the lifter arm and detach the cable from the bracket x Remove the dri...

Page 52: ...unting bolt holes then install the brackets bolts and nuts x The remainder of installation is the reverse of the removal steps with the following additions a Use new gaskets at all exhaust pipe connec...

Page 53: ...of cylinder head gasket x Bottom of cylinder head damaged x Wrong installation of spark plug Valve gap adjustment 0 08 mm Compression Pressure too high x Too much carbon residue inside combustion cha...

Page 54: ...ad z Cleaning before check parts and smear motor oil appointed in sliding face before installing Remove Cylinder Head 5 4 3 2 1 SEQ Operation Parts Name Q ty Remarks 1 2 3 4 5 Disassembly Cap nut of e...

Page 55: ...olt Hex flange bolt Hex flange bolt Hex flange bolt Plain washer Cylinder head cover assembly Hex acorn washer face nut Plain washer Hex socket bolt Dowel pin Cylinder head Cylinder head gasket 1 3 3...

Page 56: ...shaft comp Valve arm rocket assembly Valve cotter Valve spring assembly Inlet Exhaust valve Valve stem seal Hex flange bolt Camshaft sprocket Camshaft comp 2 2 2 8 4 4 4 2 1 1 The dowel pins are loca...

Page 57: ...g Limit Replace if over 12 04mm x Check the rock arm shaft outside diameter Working Limit Replace if under 11 92mm Note If the sliding face of rock arm wear out then check the cam surface of the cam s...

Page 58: ...er working limit Replace under 5 45 mm Valve guide inside cylinder head working limit Replace if over 5 53 mm Cylinder head assembly x Install valve seal spring seat x x Install valve into cylinder he...

Page 59: ...NDER HEAD VALVE Camshaft adjustment x After install the cylinder head it s necessary to setup the camshaft timing x Before put the timing chain on cam sprocket turn the T mark on ACG flywheel aim at t...

Page 60: ...and piston wear out Disassembly of Cylinder Piston Operation Parts Name Q ty Remarks 1 2 3 4 5 Disassembly Cylinder Cylinder and gasket Hex flange bolt Cylinder Oil ring Cylinder gasket Dowel pin 2 1...

Page 61: ...Clean all old gasket material from the tensioner body and from its mating surface on the cylinder block Installation x Lubricate the friction surfaces of the components with moly based grease x Insta...

Page 62: ...th a pointed tool x Push the piston pin part way out then pull it the rest of the way Inspection of Piston x Remove the top and second piston rings x Remove the upper oil ring side rail and expander t...

Page 63: ...put into the bottom of cylinder Note Use piston to press the ring into cylinder x Measure the opening gap of the piston ring when pressed into cylinder Working limit Top ring replace above 0 5mm 2nd r...

Page 64: ...greased with oil Warning Do not scratch piston and do not band piston rings The mark on piston ring must face up Be sure the rings rotate freely after install into piston Piston installation x Clean...

Page 65: ...ace piston and piston rings must be greased with oil x Beware of the pressure from piston ring when install into cylinder Warning Be careful not to damage or band the piston ring The opening section o...

Page 66: ...assembly of right crankcase cover and clutch lever SEQ Operation Parts name Q ty Remarks 1 2 3 4 5 6 7 8 9 10 Disassembly Hex flange bolt R crankcase cover R crankcase cover gasket Dowel pin Clutch li...

Page 67: ...ng Lock nut Disc spring washer Clutch center Clutch friction disk Clutch plate Clutch pressure plate Plain washer Clutch cover comp assembly Oil bush 4 1 1 1 1 4 1 1 1 6 5 1 1 1 1 Beware not to damage...

Page 68: ...in the lifter plate taking out this stop ring x Measure the clutch spring free length Spring free length limit 34 9mm x Measure the thickness of the friction plates Working thickness limit Replace if...

Page 69: ...emarks 1 2 3 4 5 6 7 8 Disassembly Hex flange bolt Reduction cover Starter gear cover gasket Dowel pin Starter reduction gear comp Starter reduction gear shaft Hex flange bolt Starter motor assembly 6...

Page 70: ...Remarks 1 2 3 4 5 6 7 8 9 10 Disassembly Hex flange bolt L crankcase cover L cover gasket Dowel pin External cir clip Starter gear Starter reduction gear Hex socket bolt Hex socket bolt Stator comp 1...

Page 71: ...t Starting clutch outer comp Roller assembly Starter clutch assembly Starter driven gear comp Needle bearing Plain washer 1 1 1 6 1 1 1 1 1 1 M12 45 When pull out the flywheel beware not to lost the s...

Page 72: ...gear should turn smoothly clockwise but not all counter clock wise x Lift the driven gear off the rotor x Remove the 6 star socket bolts then remove the outer clutch and the roller assembly x Check t...

Page 73: ...reather plate gasket Left crankcase Crankcase gasket Right crankcase Dowel pin Hex flange bolt Plain washer Stud bolt Stud bolt 14 1 1 1 1 1 1 1 1 1 2 1 1 2 2 M6 35 M6 45 M6 65 M6 12 Use rubber hammer...

Page 74: ...Thrust washer Reverse idle gear Reverse idle gear bush Thrust washer 1 1 1 2 1 2 1 1 1 The gear assembly should pull out at the same time with drum shaft assembly Beware keep the washer and cir clip...

Page 75: ...ex socket bolt Hex washer face bolt Neutral switch rotor comp Reverse stopper cam comp Hex flange bolt Reverse shift stopper comp Gear shift fork assembly Gear shift spindle comp Hex socket bolt Gear...

Page 76: ...eter limit Replace if under 5 7mm x Check the inside diameter of the forks Working diameter limit Replace if over 13 04mm x Check the outside diameter of the forks Working diameter limit Replace if ov...

Page 77: ...ng Semi cycle key Radial ball bearing Radial ball bearing 1 1 1 1 1 1 The crankshaft assembly normally is not for disassembly It will generate more problems if the L R cranks are disassembled The semi...

Page 78: ...ith a feeler gauge The connecting rod side clearance limit is 0 80mm x Check the connecting rod radial clearance with a dial indicator The connecting rod big end radial clearance limit is 0 05mm x Pla...

Page 79: ...Check the connecting rod Working diameter limit Replace if over 17 10mm x Check the balancer gear and bearing journals for wear or damage x Use a special tool TLH3 01 to pull the crankshaft and push t...

Page 80: ...roken Brake efficiency abnormal x Brake lining wear out x Brake pads adjust not correct or wear out x Brake drum wear out x Tire wear out Steering handle not straight x Loose not correct adjustment or...

Page 81: ...Rubber cover Cotter pin Scotch nut Plain washer Wheel nut Front shaft hub Front rim Front tire Collar Collar Oil seal Radial ball bearing Hex socket bolt Brake disc 2 2 2 2 8 2 2 2 2 2 4 4 8 2 M18 18...

Page 82: ...1 2 3 4 5 6 7 8 9 Disassembly L R Hex flange lock nut Plain washer Hex washer face bolt L R down suspension arm Hex flange bolt Front cushion assembly Cotter pin Plain washer Scotch nut 2 2 1 2 1 2 2...

Page 83: ...4 5 6 7 8 9 10 11 12 13 14 15 Disassembly steering shaft Ass y Cotter pin Nylon nut Oil seal Steering shaft bushing Internal cir clip Oil seal Cotter pin Scotch nut Plain washer Tie rod assembly Hex...

Page 84: ...e Q ty Remarks 16 17 18 19 20 21 Disassembly knuckles Handle bar bottom clamp Steering shaft assembly Hex washer face bolt Bracket Steering shaft holder Holder spacer collar 2 1 2 1 2 2 10 65 Assembly...

Page 85: ...adjust not correct Brake efficiency abnormal z Brake lining wear out z Brake pads adjust not correct or wear out z Brake drum wear out z Tire wear out Assembly Disassembly Rear Wheel SEQ Operation Pa...

Page 86: ...Disassembly parking brake Rubber cover Cotter pin Scotch nut Plain washer Rear wheel assembly Hex nut Hex socket bolt Rear brake panel connector Rear brake disk Hex washer face bolt Rear brake calipe...

Page 87: ...Fix pin External cir clip Plain washer Oil ring Brake pedal comp Return spring Oil tube fixing bolt Hex flange bolt Hex washer face bolt Rear master cylinder sub assembly Copper plain washer Hex wash...

Page 88: ...mbly of Brake System SEQ Operation Parts name Q ty Remarks 18 19 20 21 Disassembly brake system Hex flange bolt Front brake caliper assembly Hex flange bolt Back hose 4 2 1 1 M8 22 M6 20 Assembly 21 1...

Page 89: ...ge bolt M8 15 Chain protect cover Hex flange bolt 6 30 Front chain protect Drive chain guide Hex bolt 6 10 Drive sprocket fixing plate Drive sprocket assembly Drive chain assembly Nylon nut M10 P1 25...

Page 90: ...Ass y Nylon nut Hex flange bolt Rear axle holder Hex flange bolt Hex flange bolt Nylon insert lock nut Plain washer Rear cushion assembly Disassembly swing arm sub Ass y Nylon nut Plain washer Swing...

Page 91: ...Do not unplug the electrical components from wire hardness when the current is working This will cause too high of voltage and damage other compounds such as rectifier light bulbs etc Turn off the mai...

Page 92: ...tatus NOTICE z Check battery voltage when battery charged completely over 12 8 V z Engine starting will consume a lot power of battery z Assembly voltmeter to terminal of main fuse start engine open l...

Page 93: ...coil resistance between high voltage terminal Standard valve 2 5 without spark plug cap Remove main switch Disconnect main switch wire Pull the main switch Bracket inside front cover Push the stopper...

Page 94: ...ad light and position light y Signal light switch y Engine stop switch Exchange of Bulbs Head light bulb z Remove handle bar and front cover z Press down the bulb base and turn left to change head lig...

Page 95: ......

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ADLY MOTO ATV-300, Service Manual

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Summary of Contents for ATV-300

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