Dazon Buggy Raider mini 90D, Service Manual

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Page 2: ...is manual before performing any repair or service All information illustrations photographs and specifications contained in this manual are based on the latest product information available at the time of publication Due to the improvements or other changes there may be some discrepancies in this manual Therefore if the newest information is requested in the future please contact us We reserve the...

Page 3: ...ENTS 1 GENERAL INFORMATION 4 2 MAINTENANCE 10 3 ENGINE 21 3 1 ENGINE COMBUSTION SYSTEM 21 3 2 CLUTCH 25 3 3 TRANSMISSION CRANKCASE 27 3 4 FUEL SYSTEM 29 3 5 ENGINE LUBRICATION COOLING SYSTEM 33 3 6 STARTING FAILURE 34 4 ELECTRIC SYSTEM 36 5 CHASSIS 52 Attachment WIRING DIAGRAM ...

Page 4: ...n and clothing If you contact it flush thoroughly with water and call a doctor if electrolyte gets in your eyes 1 2 NOTE All information illustrations directions and specifications included in this publication are based on the latest product information available at the time of approval for printing We reserve the right to make changes at any time without notice and without incurring any obligatio...

Page 5: ...006 5 z Vehicle Identification Number VIN The VIN is stamped on the nameplate that is stuck on the left front of the vehicle frame VIN z Engine Serial Number The engine serial number is stamped on the lower front left side of the engine crankcase Engine serial number ...

Page 6: ...rque 5 7 5500 N m rpm Idle Speed 1500 100rpm Idle Speed CO Pollutant 3 8 Idle Speed HC Pollutant 800 ppm Fuel Type SAE 90 or above unleaded Min Fuel Consumption 367g kW h Lubricate Oil Type SAE 15W 40SF Lubrication Pressure splash Cooling Air cooled Ignition C D I Starting Electric Spark Plug A7RTC Spark Plug Gap 0 6 0 7mm Transmission OHC chain drive 1st Forward Gear Transmission Ratio 3 182 2nd ...

Page 7: ...e 16X8 7 TIRE PRESSURE Front 28 Kpa Rear 50 Kpa WEIGHT Net Weight 125kg 130kg THE SPECIFICATIONS ARE SUBJUET TO CHANGE WITHOUT NOTICE 1 5 RECOMMENDATIONS z Fuel Please use the gasoline of SAE 90 or above Also we recommend you to use the unleaded gasoline z Engine Oil Please use the high quality engine oil of SAE 10w 40SF 1 2 3 Gear oil Please use 130 gear oil for reverser gear z Break in Procedure...

Page 8: ...uble seat Service Manual Version 2 0 Feb 2006 8 1 6 PARTS LOCATION Double seat Single seat Control Panel Roll Bar Steering Wheel Throttle Pedal Brake Pedal Front Wheel Rear Wheel Rear Rack Safety Belt Seat Front Shock Absorber ...

Page 9: ...Raider Mini 90 single double seat Service Manual Version 2 0 Feb 2006 9 Rear View Rear Rack Chain Fuel Tank Engine Fuel Tank Cap Muffler Air Cleaner Reverse lever ...

Page 10: ...tch fuel tank X X X Battery X X X R Valve clearance of engine A A A Throttle cable A A A A Absorber X X X R NOTE X inspect clean or replace if necessary A adjust C clean L lubricate R replace 2 2 Maintenance and Tune Up Procedures This section describes the servicing procedures of every item in the Periodic Maintenance Intervals Table above 2 2 1 Spark Plug Clear up the carbon around the spark plu...

Page 11: ...he riding stability Specifications Front Tire 28 Kpa Rear Tire 50 Kpa 2 2 3 Brake Performance a Check if the brake pad is in good condition b Check the brake rotor for abnormal wear z Brake Cable Adjustment a If the brake cable is too loose adjust the adjust nut of the brake cable clockwise If the brake cable is too tight adjust the adjust nut of the brake cable counterclockwise If the adjustment ...

Page 12: ... Foam Filter a Remove the filter out of its steel cage b Wash the filter in non flammable cleaning solvent c Submerge the filter in oil and squeeze it to remove excess oil d Install the filter element back into the air box 2 2 5 Nuts and Bolts in Chassis Inspect the nuts and bolts in the chassis during the first week and every month thereafter The nuts and bolts become loose normally after use ple...

Page 13: ... as possible c OFF position It s the closing position When the vehicle is not in use always make sure that the petcock is in the OFF position 2 2 8 Engine Oil Inspect the engine oil before every riding and replace it monthly a Remove the drain plug from the left side bottom of the engine and drain out the left oil into an oil pan for disposal Conventional marked bolt 8 8 marked bolt Bolt Diameter ...

Page 14: ...k the large cap 2 2 9 Chassis Inspect clean or replace it monthly if necessary and lubricate it quarterly a Grease the chassis bushings and bearings with some grease quarterly to make sure that they can operate smoothly and enjoy an extended life b If it s used in extremely wet muddy or dusty conditions we recommend you to service it more often 2 2 10 A arm Lubrication Lubricate the left right fro...

Page 15: ...adjust the left and right rear wheel bearing holders clockwise at the same time c Fasten the 4 bolts M8 16 on the rear wheel axle holder 2 2 12 Brake Shoe Replacement a Loosen the connecting clip on the chain Remove the chain b Loosen the adjust nut on the brake cable Take out the brake cable c Remove the cotter pin on the bracket of the rake caliper Bearing Holder Chain Brake Cable Adjust Nut Cot...

Page 16: ...r wheel axle and bearing Remove the brake caliper bracket Replace the brake shoe g Assemble in the reversed order of removal 2 2 13 Idle Speed Adjustment If the rotate speed of the engine is not stable either too low or too high after the engine has started adjust the idle speed adjust screw on the carburetor If the engine rotate speed is too high turn the adjust screw counterclockwise If the engi...

Page 17: ...ard to fix when vehicle brakes in suddenly Solution a Weld the rear brake swing arm adjust bolt and fastening nut together b When adjusting the brake only need adjust the adjust nut of brake cable Rear Brake Swing Arm Rear Brake Caliper Assy Adjust Bolt Fastening Nut Rear Brake Swing Arm Rear Brake Caliper Assy Welding Spot Adjust Nut of Brake Cable Rear Brake Caliper Assy ...

Page 18: ...ove the adjust nut of brake cable b Remove the fastening nut of rear brake swing arm c Remove the rear brake swing arm d Assemble the new rear brake swing arm and fastening nut Adjust Nut of Brake Cable Rear Brake Swing Arm Fastening Nut Rear Brake Swing Arm Fastening Nut Rear Brake Swing Arm ...

Page 19: ...f the fuel tank and carburetor 2 Remove the spark plug pour one ounce of clean cylinder lubricating oil through the spark plug hole into the cylinder and crank the engine slowly to spread the oil so as to lubricate the cylinder better replace the spark plug 3 Don t save or store gasoline over winter because the old gasoline has deteriorated in the winter storage and will cause hard starting and af...

Page 20: ...ems below a Carburetor gas flows into the engine which makes starting very difficult b Gas flows out through carburetor drain tube which may cause a potential safety problem c In very cold weather engine oil runs in the wrong direction and stays on one side of engine not on engine bottom if you start the buggy immediately after taking it out engine oil won t have enough time to flow back to the en...

Page 21: ...OMBUSTION CHAMBER z WORN OUT PISTON AND CYLINDER z EXCESSIVE CARBON ACCUMULATION z WORN OUT CYLINDER OR PISTON RINGS z IMPROPER INSTALLATION OF PISTON RINGS z SCORED OR CRATCHED PISTON OR CYLINDER WALL z EXCESSIVE CARBON ACCUMULATION ON PISTON OR IN COMBUSTION CHAMBER z BLOCKAGE OF AIR TO THE ENGINE COOLING SYSTEM FAN CYLINDER COVER z IMPROPER OIL SUPPLY z INCORRECT IGNITION TIMING 3 1 2 Cylinder ...

Page 22: ...o the engine crankcase 3 1 3 Cylinder and Piston Inspection a Inspect the cylinder bore for wear or damage Measure the cylinder inner diameter at three levels in X and Y Axis Taper limit 0 05 mm Out of round limit 0 05 mm b Check the cylinder head mating surface for warp with a straight edge and feeler gauge Service limit 0 05 mm c Insert each piston ring into the cylinder Measure the end gap Serv...

Page 23: ...at 10 mm high from the skirts bottom Service limit 49 90 mm f Measure the piston pin bore and the piston pin outer diameter Pin outer diameter Service limit 12 98 mm Pin bore Service limit 13 055mm g Measure the connecting rod small end inner diameter with a small hole gauge Service limit 13 10 mm Piston Ring Piston Piston Outer Diameter Measurement Piston Piston Pin Connecting Rod ...

Page 24: ...c Apply some oil to the inside of the connecting rod small end d Install the piston piston pin and clip Install the piston with the arrow mark facing the exhaust pipe NOTE Do not align the piston pin clip end gap with the piston cutout e Install a new cylinder gasket Apply a thin coat of engine oil to the piston rings and cylinder wall f Compress the piston rings and install the cylinder g Replace...

Page 25: ... Limited Spring Plate Side Through Oil Spring Oil Through b Remove the four screws cover and gasket c Lift the connecting tongue of the locking bush Detach the centrifugal clutch locking nut by using a special tool Detach the clutch d Dismantle the following parts Gear Primary Drive Guide Clutch Center Collar Lever Comp Clutch Plank Cover Limited Clutch Cover Outer Clutch Locking Nut Gear ...

Page 26: ...oves slowly z The clutch has not been adjusted properly z The clutch disc is warped z The clutch lock nut is loose z There is too much oil in the crankcase z The clutch rod has not been installed correctly When accelerating the clutch slips z The clutch has not been adjusted properly z The clutch disc is worn out z The clutch spring is loose z The gearshift oil is mixed with copper or graphite add...

Page 27: ...ting Difficulty in gearshift z The clutch was not adjusted properly z The gear shifter is bent z The guide pin is broken z The gear guard is worn out Transmission dislocation z The guide pin is worn out z The gear shifter is bent Too much noise z The shaft neck bearing is worn out z The transmission bearing is worn out ...

Page 28: ...TE Align the head of the snap ring with the center of the key slot as shown in the picture 3 3 3 Path of Power Transmission a The torque of crankshaft drives the clutch b The torque of clutch transmits the main shaft by gear c The torque of main shaft transmits the counter shaft by gear d The counter shaft drives the small sprocket e The small sprocket drives the rear sprocket by chain and transmi...

Page 29: ...z CLOGGED FUEL JET OF CARBURETOR z CLOGGED TREATHING HOLE OF FUEL TANK CAP z CLOGGED FUEL FILTER z UNSMOOTH FLOWING OF FUEL IN THE TUBE z TOO LOW FLOAT LEVEL IN CARBURETOR z FAULTY FLOAT NEEDLE VALVE IN CARBURETOR z TOO HIGH FLOAT LEVEL z CLOGGED AIR DUCT IN CARBURETOR z DIRTY AIR CLEANER z The carburetor can t start or becomes difficult to start Reason Analysis After the tryout the carburetor has...

Page 30: ...carburetor d Start the engine and run for a while then quickly step on the throttle pedal for several times If the engine works well assemble the connecting tube otherwise repeat the steps above several times Readjust the idle speed if it is unstable 3 4 2 Carburetor z Removal a Remove the air cleaner Disconnect the fuel line Unscrew the intake pipe mounting bolts at the carburetor and then remove...

Page 31: ...ect the throttle valve and the jet needle surface for wear scratches or dirt z Disassembly a Unscrew the float chamber screws and remove the float chamber b Disassemble the float arm pin float and float needle valve Inspect the seat of the float needle valve for wear or damage Disassemble the idle jet main jet idle speed Adjust screw and idle mixture adjustment screw Throttle Valve Spring Throttle...

Page 32: ...vent and blow it dry with compressed air Assembly is essentially the reverse order of disassembly 3 4 3 Throttle Valve Assembly a Install the needle clip on the jet needle b Install the jet needle into the throttle valve c Assemble the throttle cable spring and the throttle valve d Align the throttle valve groove with the idle speed e Adjust screw and install the carburetor cap to the carburetor C...

Page 33: ...z WORN PISTON RINGS z IMPROPER ADJUSTMENT OF OIL PUMP z POOR OIL QUALITY 3 5 2 Caution Supplying enough oil to the engine is very important If the oil quantity is not enough the engine will be severely scored and will most likely seize the motor When the upper end of the engine is in need of replacement change the piston piston rings piston pin clips and the cylinder all at the same time 3 5 3 Coo...

Page 34: ...Raider Mini 90 single double seat Service Manual Version 2 0 Feb 2006 34 3 6 Starting Failure ...

Page 35: ...Raider Mini 90 single double seat Service Manual Version 2 0 Feb 2006 35 ...

Page 36: ...on Coil Between Alternator and CDI Unit Between CDI and Engine Stop Switch Between Ignition Coil and Spark Plug Between Generator and CDI Unit z PRIMARY IGNITION CIRCUIT TROUBLE Faulty Generator Faulty CDI Unit Faulty Alternator Exciter Coil Loose Connect ion between Terminals Faulty Ignition Coil z SECONDARY IGNITION CIRCUIT TROUBLE Faulty Plug Loose Connect ion at Spark Plug Wires z IMPROPER IGN...

Page 37: ...RY or USED UP BATTERY z POOR CONTACT BETWEEN CONNECTING TERMINALS OF BATTERY WIRES z BROKEN STARTING RELAY z POOR GROUNDING OF BATTERY z BROKEN STARTER BRUSH z ELECTRIC STARTER RUNNING IN AN INVERTED ORDER Improper Assembly Of Starter Case Improper Connection Of Terminal z BROKEN STARTING RELAY z BROKEN DRIVE CHAIN OF STARTER DUE TO ENGINE PROBLEM FAILURE OF CRANKSAHFT MOVEMENT 4 2 Ignition Coil a...

Page 38: ...case cover Remove the snap ring from the follower gear of the electric starter b Pull off the wire connector of the electric starter Remove the 3 bolts remove the electric starter Remove the O ring z Disassembly a Remove all the bolts b Disassemble the electric starter NOTE Assemble the starter back with the same amount of washers 4 5 Battery z Initial Service zThe following procedure is very dang...

Page 39: ...r upside down with the sealed silver mouths of the electrolyte bottles in line with the six filler holes of the battery KEEP ALL CHILDREN AWAY FROM THE AREA WHILE THIS PROCEDURE IS BEING PERFORMED zPOISON CAUSES SEVERE BURNS Contains sulfuric acid Avoid contact with skin eyes or clothing TO prevent accidents rinse empty container with water zANTIDOTE External flush with water Internal call physici...

Page 40: ...ainer from battery while it is draining Never cut or pierce electrolyte container h After all the electrolyte has drained from the bottles into the battery pull plastic electrolyte bottles gently out of the battery i Discard empty electrolyte bottles in a waste area that is inaccessible to children and animals j After filling let battery stand for at least 30 minutes before charging This allows th...

Page 41: ...y cable c Charging rate Charge battery 0 7 Amps for 5 10 hours d After charging is complete press down firmly with both hands to seat the caps Do not pound or hammer The battery is now sealed e Install battery into battery tray making sure that the rubber mat is in place NOTE The warning label on the battery should be facing the warning label on the gray tray NEVER REMOVE THE STRIP OF CAPS NOR ADD...

Page 42: ...y cover on top of the battery and thread wires through the cover cuts outs Finally secure the battery with the wide black rubber strap using the hooks on both ends z DO NOT open sealed caps to add water to battery z Always wear safety glasses and charge in a ventilated area z If battery gets hot to the touch discontinue charging and allow battery to cool down z Do not use fast charging unless it i...

Page 43: ...d and larger in diameter Negative y cable is black and smaller of the two in diameter CONNECT NEGATIVE CABLE LAST e Torque terminal bolts to 40 in lbs f Place rubber pad in bottom of battery tray Securely fasten battery to the vehicle using cover and strap z To avoid possibility of explosion always connect battery cable in the order specified RED first BLACK last An exploding battery can cause ser...

Page 44: ...box cover and cause battery short circuit Solution 1 Inspect Battery a Remove the battery band b Remove the steel battery box cover c Inspect if the rubber pad in the battery box cover is in good condition Replace the rubber pad if necessary e Suggest to replace the steel battery box cover with a plastic one part no 50320 BDD0 0000 Battery Band Steel Battery Box Cover Rubber Pad Plastic Battery Bo...

Page 45: ... battery electrode b Put the battery into the battery box Tel 8 c Put on the plastic battery box cover part no 50320 BDD0 0000 or add one rubber pad in the steel battery box cover f Put the battery band on the battery and fasten the band Electrode Electrode Battery Battery Box Plastic Battery Box Cover Battery Band ...

Page 46: ...de enough electric charges the electric starter can t run fast enough or the provided ignition currents are not enough b If the electric starter is started continually when the engine can t work the electric starter will be damaged Turn off the ignition switch before maintaining the electric starter The sudden starting of the electric starter could cause severe injuries or death Replaced Battery B...

Page 47: ...ntized The depigmentation of couples of rectifier bars shows the armature coil has earthed NOTE The rectifier bar can t be burnished by emery cloth or sand paper c Check the connectivity between couples of rectifier bars Check the connectivity between the rectifier bar and the armature shaft Rectifier bars connected Armature shaft disconnected d Check the connectivity between the cable terminal an...

Page 48: ...stall the snap ring into the shaft groove Install the left crankcase cover 4 6 2 Starting Clutch z Remove Main Follower Sprocket a Remove the following parts Flywheel Drive chain slide plate Screw and locating plate Snap ring b Remove the starting chain and sprocket Assembly c Install by reversing the dismantling procedure z Remove Starting Clutch a Remove the 3 screws and starting clutch shell b ...

Page 49: ...llower sprocket and chain Measure the outer diameter of the main Sprocket z Assembly a Install the starting clutch shell Apply the locking agent to the screw threads of the starting clutch shell Install the screws and fasten them b Put a mark on every screw of the clutch shell c Install the spring spring cap and roller ...

Page 50: ...hnical Criterion Starting relay coil Yellow red wire and ground wire Turn on the starting switch it should be connected Battery voltage input wire Black wire and ground wire Turn on the ignition switch the battery should be connected Electric starter input wire Red wire and ground wire The battery should be connected z Elements Check a Connect a DC12V battery between the black wire and yellow red ...

Page 51: ...se or disconnected The starting relay switch is broken The electric starter is out of order Disconnected The starting switch is broken The yellow red wire or green wire is open The connector is loose or has poor contact Connected Connect the starting relay connector turn on the ignition switch and press the starting switch measure the starting relay voltage at the starting switch connector yellow ...

Page 52: ...xle and bearing carriers as a unit i Remove the brake caliper bolt and brake caliper 5 2 Rear Swing Arm Removal NOTE The swing arm axle and motor can be removed as a unit if needed a Remove the rear shock b Remove the rear brake caliper and set it aside c Unplug the brake light wiring from the electrical box d Remove the throttle cable e Remove the bolts from the swing arm pivot f Check the buffer...

Page 53: ... 5 4 Front Wheel Replacement Don t disassemble the castle nuts when you replace the front wheels It is only necessary to tighten the nuts so that the wheel turns freely on the axle with the minimum end play Please tighten the nuts after replacing the wheels Chain Guard Electric Box Cover Battery Rear Swing Arm Shock Absorber Front Wheel Front Wheel Hub Front A arm Assy Left Shock Absorber Steering...

Page 54: ...ease to the bearing and reinstall it with a bearing tool making sure that they go in straight If the bearing isn t straight damages to the hubs can occur e Install the seals into the hubs It is recommended to apply a small amount of grease to the lip of the seal If the retention spring is in bad shape replace the seal with a new one 5 6 Seat a Remove all the nuts and bolts underneath the seat rail...

Page 55: ...ing gear box with Grease after cleaning the dust It is recommended to replace the ball joint if it is loose or not smooth 5 9 Throttle Brake Pedal a Remove the throttle throttle pedal and axle nut b Check the throttle and brake pedal for signs of wear Replace if any wear is present c Before installation apply enough grease on the throttle and brake pedal in order to make them swing more flexibly S...

Page 56: ...for tightness at their adjusting nuts d Always use a new cotter pin after the removal 5 12 Service Air Cleaner Service the air cleaner every 100 hours a Remove the air cleaner cover b Remove the air cleaner element c Fill the non flammable cleaning agent into a basin and dip the element in it e Dry it after cleaning and dip it into the engine oil f specified by the manufacturer then dry it again N...

Page 57: ... with a wire feeler gauge and this specification should be 0 6 0 7mm NOTE The electrodes should be kept clean and free of carbon The presence of carbon or excess oil will greatly deter the proper engine performance b Before installing the spark plug apply some graphite grease on the threads if possible to ensure the easy removal next time when the spark plug needs inspection c It is advisable to r...

Page 58: ...rrect idle speed is 1400 1600r min 5 15 Front Wheel Alignment a The front wheels should be toed in from 1 8 to 1 4 for the proper toe in dimension Dimension A should be 1 8 1 4 longer than Dimension B b Check the alignment measure distance from A B to the centerline CL of the tires with the wheels pointed straight ahead c Loosen the lock nuts on both sides of the front tie rods Performing the spar...

Page 59: ... release the accelerator pedal and push the shift lever forward into 2nd gear Then press back down on the accelerator pedal to continue driving forward Failure to properly shift may result in engine overheating which may damage the engine and poses a fire hazard How to shift from 1st into 2nd gear 1 When the vehicle is running stepping on the accelerator pedal provides acceleration UNTIL the limit...

Page 60: ...Raider Mini 90 single double seat Service Manual Version 2 0 Feb 2006 60 Wiring diagram ...