HER CHEE ADLY RT-50 Service Manual
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HER CHEE ADLY RT-50 Service Manual

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SERVICE MANUAL

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

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  • Page 1: Service Manual

    SERVICE MANUAL RT-50 January 2008 High power Engine HER CHEE INDUSTRLAL CO., LTD.
  • Page 2 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.
  • Page 3 CONTENTS Chapter 01 Chapter 1 INFORMATION FOR PREPARATION………… 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………………………………………………..
  • Page 4 Chapter 1 Information for Preparation Attention on Operation All washers, oil rings, clamp rings, opening pins shall be duly replaced by a new item when dismounted. Locking 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.
  • Page 5 Attention on Operation Certified lubricants in cans shall be used on all the elements to be lubricated. After assembly, performance of all elements shall be duly checked and the locking shall be duly verified. In case of an operation is performed by over 2 people, the assignment shall be conducted in coordination and safety shall be the first priority.
  • Page 6 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...
  • Page 7 LOCKING TORQUE Adopt the standard torque locking for the item unlisted. STANDARD TORQUE： Type Locking Torque (kg-m) 5 mm Screw 6 mm Screw 6 mm Hex Washer Face Bolt / Nut 8 mm Hex Washer Face Bolt / Nut 10 mm Hex Washer Face Bolt / Nut CHASSIS：...
  • Page 8 The following drawing that shows the disassembling situation of the cover parts for RT50 scooter. Chapter 1 Information for Preparation...
  • Page 9 INFORMATION FOR PREPARATION REVOLUTION NOT STABLE (LOW R.P.M.) Diagnose Check and Adjust Reason of Trouble ignition timing adjusting C.D.I damage normal abnormal pulser coil damage adjust the carburetor fuel adjuste screw mixture gases too lean adjusting isn't (loosing screw) adjusting is correct correct mixture gases too rich (locking screw)
  • Page 10 Chapter 1 Information for Preparation INFORMATION FOR PREPARATION REVOLUTION NOT SMOOTH(HIGH SPEED) Check and Adjust Reason of Trouble Diagnose adjusting ignite timeing C.D.I damage normal abnormal ACG pulse coil damage adjusting valve gap adjusting isn't correct normal abnormal valve set damage check fuel cup supply normal ? fule filter blocking...
  • Page 11 Chapter 1 Information for Preparation INFORMATION FOR PREPARATION CHARGE ABNORMAL Check and Adjust Reason of Trouble Diagnose start engine and measure voltage of the two terminal for battery voltage of battery voltage of battery battery damage can't go up is normal measure the resistance of ACG coil coil damage...
  • Page 12 Chapter 1 Information for Preparation INFORMATION FOR PREPARATION SPARK PLUG NO SPARKING Check and Adjust Reason of Trouble Diagnose change spark plug and check again no sparking or the previous spark plug damage sparking strong weak check spark plug, cap, ignition coil loosen? loosen no loosen...
  • Page 13 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.
  • Page 14 Service Time (month) Service Items Judgement Standard Remarks Before each 6 each 12 riding Riding Device Tires Ditch-front and rear wheel till 0.8 mm Check & damage of tires ○ ○ ○ Abnormal & ditch in tires ○ ○ ○ Bolt &...
  • Page 15 Service Time (month) Service Items Judgement Standard Remarks Before each 6 each 12 riding Engine Body – starting & abnormal ○ ○ noise Idle : 1800±100 rpm low speed & accelerating ○ ○ ○ exhaust ○ ○ air filter ○ ○...
  • Page 16 Disassembly of External Parts Remove the external parts for checking and adjustment separate the join with the chassis (the Read cover * Open the seat. concave and the convex) and remove * Remove the 2 hex-nuts, 1 bolt to the front cover. remove the luggage rack.
  • Page 17 Serviceable parts layout The drawing shows the main serviceable parts. Front brake lever Rear brake lever Head light Rear shock absorber Front shock Rear tire Front tire Transmission Air filter Front brake Rear brake...
  • Page 18 Chapter 2 Check and Adjust Serviceable parts layout The drawing shows the main serviceable parts. Oil level sensor Main switch Starter relay Battery Main fuse Flash relay Regulator Horn Coil & Spark plug cap...
  • Page 19 Chapter 3 Engine Removal 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. •...
  • Page 20 Chapter 4 Engine Removal Operation / Parts Name Q’ty Remarks Disassembly ACG wire /wire of start motor WARNNING: • The oil over-flow when remove the oil Starter wire of carburetor Oil tube tube, so use clip or plug stop the seal. Fuel tube Vacuum pressure tube Cap of spark plug...
  • Page 21 Chapter 4 Engine Removal Engine Removal Remove L/R step bar. Remove air filter and muffler. Disconnect fuel/oil/vacuum tube on the carburetor. Disconnect throttle cable. Disconnect all electrical connectors and spark plug cap from engine to main wire harness. Step Bar Disconnect rear wheel brake cable.
  • Page 22 Chapter 4 Cylinder Head / Cylinder / Piston Attention of Operation • Can be operating when engine on the vehicle. • Must cleaning before operating, avoiding dust enter to engine. • Remove the gasket dust stay on joint face. • When remove the cylinder, avoid to using screw driver to damage the joint face. •...
  • Page 23 Chapter 4 Cylinder Head / Cylinder / Piston...
  • Page 24 Chapter 4 Cylinder Head / Cylinder / Piston Operation / Parts Name Q’ty Remarks Disassembly Cylinder head WARNNING: –Cross loosing the nuts 2-3 times. Nut of cylinder head Cylinder head Cylinder head gasket Cylinder WARNNING: Cylinder –Don’t knock cooling fin. Cylinder gasket –During cleaning the gasket beware not to damage joint face of cylinder and...
  • Page 25 Chapter 4 Cylinder Head / Cylinder / Piston Remove cylinder head, cylinder and piston Loosen then remove four cylinder head fixed nuts. Remove the cylinder head and gasket Remove the cylinder head. Pull the cylinder out of engine. Remove piston pin clip by using a long nose pliers.
  • Page 26 Chapter 4 Cylinder Head / Cylinder / Piston Notice: Always replace a new cylinder head Installation Remove carbon muck inside ring ditch gasket. and piston ring during disassembly. Do not scratch piston and do not bend Tighten the cylinder head fix nuts piston rings.
  • Page 27 Arrow mark Chapter 4 Cylinder Head / Cylinder / Piston Install the air shroud and cover in the reverse order of removal. Notice: Do not bend the oil tube.
  • Page 28 Chapter 4 Cylinder Head / Cylinder / Piston Lubrication System Attention of Operation ‧ Pay attention to avoid dust enter to the interior of engine and motor oil pipe when disassembly the motor oil pump. ‧ Never disassembly motor oil pump. ‧...
  • Page 29 ‧ There have air in the motor oil pipes system. ‧ Bad motor oil pump. Clogging oil from oil tank ‧ Vent of motor oil c ase’s cap is clogged. ‧ Filter of motor oil is clogged. Preparation standard ‧ Use separating motor oil appointed (use for 2 -stroke).
  • Page 30 Oil tube from oil tank WARNNING: Clogging the pipe with clamp or plug for avoiding fuel flow out. Oil tube to carburetor Remove from both side of motor oil Pan phillips bolt pump. Control cable • Assembly with sequence in reverse Assembly of disassembly.
  • Page 31 Assembly WARNNING: Connect correct oil pipe after assembly, release the air in Operation with sequence in motor oil pump. reverse of disassembly.
  • Page 32 Chapter 5 CRANK CASE & CRANK SHAFT Attention of Operation This chapter explaining the necessary procedure of disassembling crank case due to repair & maintain the crank shaft. Before disassembling of crank case, please refer related articles of following procedures. –Disassembly of oil pump –Disassembly of carburetor –Disassembly of reed valve...
  • Page 33 Chapter 6 CRANK CASE & CRANK SHAFT Disassembly of ACG Remove fan cover air shroud. Fan cover Remove cooling fan Flywheel ACG coil & bracket Cooling fan Loosen the flywheel fix nut Use special puller to remove the Flywheel flywheel. puller Disassembly oil pump Remove oil drive gear cover gasket.
  • Page 34 Chapter 6 CRANK CASE & CRANK SHAFT Operation / Parts name Q’ty Remark Disassembly Hex socket bolt Right crank shaft case Dowel pin Fix shaft of crank shaft case External circle clip Crank shaft Radial ball bearing (Right) Radial ball bearing (Left) Hex socket bolt seal bracket Right oil seal...
  • Page 35 Chapter 6 CRANK CASE & CRANK SHAFT Disassembly of Crank Case Loosen all fixed bolts on crank case. Install the puller on right crank case, separate the R. crank case and L. crank case. : Crank case puller (TLJT-03) Install the puller on left crank case, remove the crank shaft from the crank case.
  • Page 36 Chapter 6 CRANK CASE & CRANK SHAFT Assembly of Crank Case Clean the crank case with gasoline, and Liquid seal check the each part whether damaged or crack. Dowel pins Notice: Smear of oil on sliding surface of each shaft in crank case after checking. Cleaning the washer dust of joint face, and amend the part damage with oil stone.
  • Page 37 Chapter 6 CRANK CASE & CRANK SHAFT Assembly of ACG Install oil pump drive gear. Install oil pump Install new cover gasket. Connect oil tubes and pump cable. Oil tube Notice: Gasket Grease oil pump and drive gears before covering the gasket. Install generator bracket and coil.
  • Page 38 Chapter 6 Transmission Attention of Operation Don’t make greases stick to surface of transmission belt or belt plate. Otherwise, the efficiency of power transmission will be lowered by skid. Don’t switching the starter when remove the front cap of left crankshaft case. Diagnosis of Trouble Vehicle does not move after engine start up Drive belt wear-out...
  • Page 39 Chapter 6 Transmission Disassembly of Left Crankcase Cover Remove air cleaner first before start to disassembly CVT cover. Operation / Parts name Q’ty Remark Disassembly Hex socket bolt Carburetor tube bracket Left crank case cover Crankcase cover gasket WARNNING: Dowel pin Check the air cleaner whether worsen Grommet or harm.
  • Page 40 Chapter 6 Transmission Disassembly of Kick Starter Operation / Parts name Q’ty Remark Disassembly Kick pinion spring clip Kick pinion WARNNING: Hex washer face bolt Rotating pedal kick crank and remove Kick crank the assembly. External ring clamp Plain washer Starting shaft ass’y Starting shaft reset spring Bushing...
  • Page 41 Chapter 6 Transmission Check of Starting Shaft & Kick Pinion Check the wear and/or damaging of starting shaft and gear. Check the tightness and/or damage of starting shaft reset spring. Check the wear and/or damage of bush. Check the wear and/or damage of kick pinion.
  • Page 42 Chapter 6 Transmission Disassembly of Left Crank Case (→7-2) Operation / Parts name Q’ty Remark Disassembly Hex washer face bolt WARNNING: Cone spring washer Don’t hurt transmission belt. One-way clutch Clamp washer Primary fixed sheave Bushing V-Belt Primary sliding slot wheel Separation / assembling (→...
  • Page 43 Chapter 6 Transmission Disassembly Driver and Driven Pulley Driven pulley Remove driver and driven pulley fixed Driver pulley nuts. Remove driver pulley fix sheave. Remove driven pulley ass’y with V belt. Pull up driven pulley sliding slot from driven pulley ass’y to remove the V belt. V belt Inspection Measure the width of V belt.
  • Page 44 Chapter 6 Transmission Disassembly of Sliding Driving Disc Operation / Parts name Q’ty Remark Disassembly Cam plate Cam plate sliding Weight roller Primary sliding slot wheel ‧Operation with sequence in reverse Assembly 4→1 of separating.
  • Page 45 Chapter 6 Transmission Disassembly Driver Pulley Sliding Ass’y Remove driver pulley sliding ass’y from driver shaft. Detach the bushing, cam plate and weight roller from driver pulley sliding ass’y. Inspection Check the bushing sliding smoothly or not. Measure the width of weight roller. Standard: 15.0 mm Wear Limited: 14.5 mm Replace all six roller at same time.
  • Page 46 Chapter 6 Transmission Disassembly of Clutch / Transmission Belt Disc Operation / Parts name Q’ty Remark Disassembly Clutch C retaining ring Washer Clutch weight set Clutch weight spring WARNNING: Rubber buffer Must replacing when the buffer have Driving plate of clutch damage, hardening and distortion.
  • Page 47 Chapter 6 Transmission Disassembly Driven Pulley Sliding Ass’y Notice: Use a bench pliers to fix the sliding ass’y before loosen nut. Inspection Measure the thickness of clutch pads. Standard: 4.0 mm Wear Limited: 2.5 mm Measure the length of clutch reducer spring.
  • Page 48 Chapter 7 Final Transmission Mechanism Attention of Operation This chapter explaining the final reduction mechanism maintenance. The operating can be done that engine in the vehicle. For no hurting case cap, changing the bearing of left crank shaft case after removing the rear break of engine.
  • Page 49 Chapter 7 Final Transmission Mechanism Disassembly of primary drive gear / final reduction mechanism Disassembly of rear tire(→11-2). Disassembly of clutch / drive face(→7-6). Notice: First drain the oil of transmission. Operation / Parts name Q’ty Remark Disassembly Bolt Mission cover Washer Dowel pin Drive axle...
  • Page 50 Chapter 7 Final Transmission Mechanism Change the Driving Shaft Remove the driving shaft from mission cover. Notice: Don’t damage joint face of mission cover. Remove the oil seal of primary drive gear. Remove the bearing. Install the new bearing in the mission cover.
  • Page 51 Chapter 8 Fuel System Attention in Operation Fuel is flammable and explosive under certain conditions. Ensure work area is well ventilated. Do not smoke or allow open flames or sparks in the vicinity. When draining a fuel tank or whenever a fuel line is disconnected, obstruct line with a hose pincher or equivalent device.
  • Page 52 Chapter 8 Fuel System Disassembly / Assembly Valve of Throttle Disassemble of left body covering Adjust the free play of throttle Adjust of reverse rotation of idle speed Operation / Parts Name Q’ty Remarks Disassembly Pan phillips bolt WARNNING: Throttle valve Loosing top cap of carburetor, and Throttle cable removing.
  • Page 53 Chapter 8 Fuel System Disassembly of Carburetor Remove the air cleaner ass’y . Remove the left body cover Operation / Parts Name Q’ty Remarks Disassembly Throttle valve set Gasoline pipe Motor oil joint Starter wire of carburetor Vacuum pressure tube Clip Intake manifold hose clamp Carburetor...
  • Page 54 Chapter 8 Fuel System Disassembly / Assembly Carburetor Disassemble of carburetor. Adjust the idle speed. Adjust the air adjust screw. WARNNING: Fuel is flammable and explosive under certain conditions. Ensure work area is well ventilated. Do not smoke or allow open flames or sparks in the vicinity. Before disassembling, loose oil-draining screw, draining out the gasoline from carburetor.
  • Page 55 Carburetor Ass’y Air adjust screw set Throttle screw set WARNNING: Pilot jet Must confirm rotation location before disassembling, not locking too much Needle nozzle avoid to hurt seat face. Main nozzle Assembly 15→1 WARNNING: Install carburetor in reverse order Use high pressure air clean each way of of disassembly.
  • Page 56 Chapter 8 Fuel System Disassembly of Inlet Valve Disassemble of body cover. Disassemble of carburetor. Operation / Parts Name Q’ty Remarks Disassembly Intake manifold hose clamp Hex washer face bolt Intake manifold Reed valve ass’y Reed valve gasket Assembly Assembling with sequence in reverse of disassembly.
  • Page 57 Chapter 8 Fuel System Disassembly of Fuel Tank WARNNING: When draining a fuel tank or whenever Body cover fix bolts a fuel line is disconnected, obstruct line with a hose pincher or equivalent de- vice. Shall be wiped off when fuel overflowed. Disassemble of body cover.
  • Page 58 Chapter 8 Fuel System Disassembly of Air Cleaner Operation / Parts Name Q’ty Remarks Disassembly Hex socket bolt Plain washer Self-tapping screw Air cleaner case cap Air cleaner element Air cleaner case Air cleaner joint Cleaner guide pipe Grommet Install air cleaner in reverse order of Assembly disassembly.
  • Page 59 Chapter 9 Front Wheel / Front Suspension / Front Brake Attention of Operation Support the frame body steady before remove the front wheel. Don’t invert the front wheel when installing. Diagnosis of Trouble Heavy steering movement Steering handle not straight Over tied of the steering ball race L/R suspension not balanced Steel ball inside ball race broken...
  • Page 60 Chapter 9 Front Wheel / Front Suspension / Front Brake Disassembly / Assembly of Front Wheel Operation / Parts name Q’ty Remarks Disassembly of Front Wheel Nut nylon Speedometer gear Hex washer face bolt Front collar Front fender Front brake disc Operation with sequence in reverse Assembly 6→1...
  • Page 61 Chapter 9 Front Wheel / Front Suspension / Front Brake Assembly / Disassembly of Front Rim Disassembly of front wheel. Operation / Parts name Q’ty Remarks Disassembly Front collar Oil seal Radial ball bearing Front wheel spacer tube Operation with sequence in reverse Assembly 4→1 procedure.
  • Page 62 Chapter 9 Front Wheel / Front Suspension / Front Brake Assembly / Disassembly of Front Disk Operation / Parts name Q’ty Remarks Disassembly Front collar Brake disc hex socket bolt Hex flange nut with serration Nylon insert lock nut Plain washer Front brake disc Operation with sequence in reverse Assembly...
  • Page 63 Chapter 9 Front Wheel / Front Suspension / Front Brake Disassembly of Steering Handle Disassembly of throttle handle Dismount rear brake cable Operation / Parts name Q’ty Remarks Disassembly Rear brake lever Left lever set bolt Rear brake lever Rear brake cable Bracket of rear brake lever Hex socket bolt Fixed belt of steering handle...
  • Page 64 Chapter 9 Front Wheel / Front Suspension / Front Brake Disassembly of Steering Stem Disassembly of front wheel. Disassembly of steering handle Operation / Parts name Q’ty Remarks Disassembly Spanner nut WARNNING: Steering stem dust cover Not to damage steering stem. Lathe cone on steering top #2 Steel ball race Lathe on steering inner #3...
  • Page 65 Chapter 9 Front Wheel / Front Suspension / Front Brake Turning Front Fork to Left / Right Turn the front fork several times to make the ball race rotate smoothly. Slightly tie-up the bottom spanner nut then backward the nut about 1/8 turn. Confirm the steering rotation smooth and gap of steering stem.
  • Page 66 Chapter 10 Rear Wheel / Suspension / Brake Attention of Operation WARNNING: The dusts inside brake hub are containing harmful material. Do not use air to blow the dusts. Use specified detersive or clean cloth to wipe off those dusts. Diagnosis of Troubles Rear wheel shaking Brake efficiency abnormal...
  • Page 67 Chapter 10 Rear Wheel / Suspension / Brake Disassembly of Rear Wheel Operation / Parts name Q’ty Remarks Disassembly Muffler Hex washer face bolt Hex socket bolt Muffler Rear wheel Rear wheel –Operation with sequence in reverse Assembly 5→1 procedure.
  • Page 68 Chapter 10 Rear Wheel / Suspension / Brake Disassembly / Assembly of Rear Brake Disassemble rear wheel first before this operation. Operation / Parts name Q’ty Remarks Disassembly Adjusted nut of rear brake Rear brake fixture Rear brake cable shoe/shoe strain spring of rear brake Hex washer face bolt Rear brake arm...
  • Page 69 Chapter 11 Electrical Device Attention of Operation Remove battery for charging. Do not charge battery in fast speed if it’s not urgent necessary. Check voltage with multi-meter. Replace the battery with same specification. Due to CDI ignition device is not adjustable. Check CDI set & ACG if ignition is poor. Replacing it if it’s poor, confirm ignition time with original service meter.
  • Page 70 Chapter 11 Electrical Device Starter motor no working RPM unsmooth Fuse burn down Ignition — primary circuitry Battery charging insufficient –Bad ignition coil. Bad main switch –Wire or poor contact. Poor start switch –Poor contact main switch. Poor front / rear brake switch. Ignition —...
  • Page 71 Chapter 11 Electrical Device Solid Wiring Diagram...
  • Page 72 Chapter 11 Electrical Device Disassembly of Battery Remove seat Battery Remove rear fender Disconnect battery wires from negative (-) terminal first. Check Voltage of Battery Remove seat and remove battery connection wires. Rear fender Check voltage between battery terminals. Charging sufficiently : over 12.8 V Charging insufficiently : 11.5-12.8V WARNNING: Check battery voltage with digital...
  • Page 73 Chapter 11 Electrical Device Check Charging Status WARNNING: Voltage will have big change by following the charging status of battery. Therefore the check must process after battery completely charging and the voltage over 12.8 V. There will produce big current in battery when using electrical starter.
  • Page 74 Chapter 11 Electrical Device Disassembly of ACG Operation / Parts name Q’ty Remarks Disassembly Hexagon socket bolt Plain washer Self-tapping screw Cap of electric disc Hexagon socket bolt Plain washer Hexagon nut Spring washer Plain washer Fly wheel of generator Semi-cycle of electric disc WARRNING: Whole body bolt...
  • Page 75 Chapter 11 Electrical Device ACG ( Charging Coil ) Check WARNNING: Checking the engine connected with starter motor. Disconnect ACG connector. Check resistance of charging wire & lighting wire. Standard valve (20 ) ℃ Charging wire : 0.2~1.0 Lighting wire: 0.1~0.8 Ignition Coil Disassembly Disconnect the spark plug cap.
  • Page 76 Chapter 11 Electrical Device WARNNING: Check ignition status with performance tester due to this test has its own standard. Check twice of coil resistance between spark plug cap & (-) terminal. Standard valve : 9.5~11 kΩ (spark plug cap in team) Remove spark plug cap from high Voltage coil.
  • Page 77 Chapter 11 Electrical Device Starting motor Operation / Parts name Q’ty Remarks Separation Bolt set Casing Armature rotor Carbon brash Oil ring Oil ring Front fixed seat Assembly 7→1 Install in reverse order of disassembly.
  • Page 78 Chapter 11 Electrical Device Fuel Gage Switch of Lights Remove fuel gage. Color Yellow/red Blue Put the float to up end down end to check the resistance between each ○ ○ terminal. Power Switch Terminal of Up end of Down end Color blue/white Black...

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