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ADLY MOTO TB-50 (Gazelle) User Manual

ADLY MOTO TB-50 (Gazelle)
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ADLY MOTO
1-1
SERVICE MANUAL
TB-50 (Gazelle) / 100
December, 1998
High Power Engine
HER CHEE INDUSTRIAL CO., LTD.
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ADLY MOTO TB-50 (Gazelle) Specifications

General IconGeneral
BrandADLY MOTO
ModelTB-50 (Gazelle)
CategoryScooter
LanguageEnglish

Summary

Service Manual TB-50 (Gazelle) / 100

Preface

Information for Preparation

Specifications

Technical specifications for TB50 and TB100 models, including dimensions, engine details, and performance.

Locking Torque Standards

Standard torque values for screws, nuts, and bolts used in chassis and engine assembly.

Troubleshooting: Difficult Start or No Start

Diagnostic flowchart for identifying and resolving issues preventing the engine from starting.

Troubleshooting: Rough Running and Lost Power

Diagnostic guide for engine performance issues like rough idling and lack of power.

Troubleshooting: Unstable RPM (Low RPM)

Diagnostic steps for unstable engine speed at low RPM, covering ignition and fuel systems.

Troubleshooting: Rough Running (High Speed)

Diagnostic guide for engine performance issues at high speeds, focusing on smooth operation.

Troubleshooting: Charging System Abnormalities

Diagnosing abnormal charging system behavior, including battery voltage and ACG coil issues.

Troubleshooting: No Spark Plug Sparking

Steps to diagnose and resolve issues related to the spark plug not producing a spark.

Check and Adjustment

Methods of Check and Adjustment

Explanation of service item checking methods and regular exchange of parts.

Disassembly of External Parts

Procedure for removing external body panels for inspection and adjustment.

Disassembly of Pedal Components

Steps for disassembling the pedal assembly, including covers and connection points.

Disassembly of Luggage Case

Procedure for removing the luggage case, including related connectors and fasteners.

Handle Covering Removal and Installation

Instructions for removing and installing the handle covering, including speedometer connection.

Motor Oil Pump Adjustment

Procedure and precautions for adjusting the motor oil pump for correct lubrication.

Installation of Lubrication

Disassembly of Motor Oil Pump

Steps for safely disassembling the motor oil pump, including necessary precautions.

Disassembly of Oil Tank

Procedure for removing the oil tank, including associated pipes and connections.

Fuel Installation

Throttle Valve Disassembly and Assembly

Detailed steps for disassembling and reassembling the throttle valve mechanism.

Carburetor Disassembly and Reassembly

Procedures for removing and reinstalling the carburetor, including related components.

Inlet Valve Disassembly

Steps for disassembling the inlet valve system, including the carburetor connection.

Fuel Tank Disassembly

Procedure for removing the fuel tank, including associated components like the oil tube.

Petrol Gauge Disassembly

Steps for removing the petrol gauge and its associated wiring, with safety warnings.

Air Cleaner Disassembly

Procedure for removing the air cleaner assembly and its components for maintenance.

Disassembly of Engine

Disassembly of Engine Components

General steps for engine disassembly, including external parts, luggage case, and throttle/brake cables.

Cylinder Head, Cylinder, and Piston

Cylinder Head, Cylinder, Piston Disassembly

Detailed instructions for disassembling the cylinder head, cylinder, and piston assembly.

Piston Ring Installation

Procedure for correctly installing piston rings into the piston, with specific warnings.

Starter, Driving Disc, Clutch, and Transmission Disc

Left Crank Case Cover Disassembly

Steps for removing the left crank case cover, including air cleaner assembly connection.

Kick Starter Disassembly

Procedure for disassembling the kick starter mechanism, with specific warnings.

Kick Pinion and Spring Clip Installation

Instructions for installing the kick pinion and its spring clip, including checks.

Left Crank Case Disassembly

Detailed steps for disassembling the left crank case, including related components like the V-belt.

Sliding Driving Disc Disassembly

Procedure for disassembling the sliding driving disc, including cam plates and rollers.

Clutch and Transmission Belt Disc Disassembly

Steps for disassembling the clutch assembly and the transmission belt disc.

Final Transmission Mechanism

Primary Drive Gear and Final Reduction Mechanism Disassembly

Procedure for disassembling the primary drive gear and the final reduction mechanism.

Driving Shaft Replacement

Instructions for removing and installing the driving shaft, including bearing replacement and precautions.

Crank Case and Crank Shaft

Crank Case Assembly and Disassembly

Steps for assembling and disassembling the crank case, including special tools and warnings.

Front Wheel, Front Suspension, and Front Brake

Front Wheel (Aluminum Rim) Disassembly

Procedure for disassembling the front wheel with an aluminum rim, including brake disc and fork assembly.

Front Brake Assembly and Disassembly

Procedure for assembling and disassembling the front brake system, including the brake disc and collar.

Throttle Handle Disassembly

Procedure for disassembling the throttle handle, including levers, master cylinder, and cables.

Steering Stem Disassembly

Instructions for disassembling the steering stem, including the front wheel and handle connections.

Steering Main Rod Assembly

Details on assembling the steering main rod, including bearings and stem dust covers.

Steering Handle Disassembly

Procedure for disassembling the steering handle, including brake levers, cables, and mounting hardware.

Front Fork Turning and Adjustment

Procedure for turning the front fork to ensure smooth bearing operation and proper gap adjustment.

Rear Wheel, Suspension, and Brake

Rear Wheel Disassembly

Steps for disassembling the rear wheel, including muffler and exhaust pipe removal.

Rear Brake Assembly and Disassembly

Procedure for assembling and disassembling the rear brake system, including cable and cam shaft.

Rear Cushion Disassembly

Instructions for disassembling the rear shock absorber (cushion), including mounting bolts and nuts.

Electrical Device

Troubleshooting: Electrical System Issues

Diagnosing common electrical problems including power loss, low voltage, and intermittent operation.

Troubleshooting: Charging and Ignition Systems

Diagnosing issues with the charging system, spark plug, and ignition coil.

Solid Wiring Diagram

Schematic diagram illustrating the electrical connections and layout of the vehicle's components.

Battery Disassembly and Assembly

Procedure for safely removing and reinstalling the battery, including terminal connections and warnings.

Battery Voltage Check

Method for checking battery voltage using a voltmeter, including sufficient and insufficient charging levels.

Charging Status Check

Procedure for checking the charging status of the battery and the charging system's voltage and current.

Rectifier Check and Voltage Adjuster

Procedures for checking the rectifier and voltage adjuster, including control voltage parameters.

ACG (Charging Coil) Disassembly and Check

Steps for disassembling the ACG (Alternating Current Generator) and checking its resistance.

Ignition Coil Disassembly and Conduction Test

Procedure for disassembling the ignition coil and performing conduction tests on its resistance.

Starting Motor Assembly and Separation

Procedure for assembling and separating the starting motor, including its components.

Fuel Gauge Check

Method for checking the fuel gauge resistance by measuring the float's position.

Lights and Power Switch Operation

Description of light switch and power switch functions and color coding.

Bulb Replacement for Rear and Direction Lights

Instructions for replacing bulbs in the rear light, brake light, and direction lights.

Electrical System Trouble Diagnosis Summary

Summary of common electrical system faults, including power, voltage, current, and charging system issues.

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