Dazon Raider-Classic 150, Service Manual

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Page 2: ... carefully review this 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 future please contact t...

Page 3: ... Valve Guide 29 3 9 Valve Seat 30 3 10 Lubrication System 33 3 11 Fuel Supply System 37 3 12 Automatic Side Starter 38 3 13 Float Chamber 39 3 14 Air Cut Valve 40 3 15 Air Check Valve 41 3 16 Electrical Starting Mechanism 41 3 17 Reduction Mechanism 44 3 18 Engaging Mechanism 45 3 19 Belt Driven CTV Mechanism 48 3 20 Rear Transmission Mechanism 57 4 Electric System 62 4 1 Charging System 62 4 2 Ba...

Page 4: ...number is located on the lower front left side of the engine case 1 2 Fuel and Oil Recommendations Be sure to use the specified fuel and oil 1 2 1 Fuel Please use the gasoline of SAE 90 or above Also we recommend you to use the unleaded gasoline 1 2 2 Engine Oil Please use the high quality engine oil of SAE 10w 30SF 1 3 Break in Procedure For your first 2 hours of riding don t exceed 2 3 throttles...

Page 5: ...ke 57 4mm X 57 8mm Max Power 7 0kw or 7000r m Max Torque 10 0N m or 6500 r m Idle Speed 1700 100 r m CO Emission 7 0g km HC Emission 1 0g km Fuel Type SAE 90 or above unleaded Lubricate Oil Type SAE 10W 30SF Lubrication Force Splash Cooling Oil cooled Ignition C D I Starting Electric Spark Plug C7HSA NGK Spark Plug Gap 0 6 0 7mm Transmission Chain Transmission Gearbox Transmission Ratio F 7 8 1 B ...

Page 6: ...lations Taillight 12V 21W 5W Turning Light 12V 10W License Light 12V 5W Battery 12V 8Ah Anti theft Lock 200N m Rearview Mirror Accord with laws regulations CHASSIS Front Rear Brake Hydraulic disc foot control Front Wheel Brake Force 764N 1117N Rear Wheel Brake Force 1000N 1176N Parking Brake Hydraulic disc hand control Braking Distance 7 m 30km h Front Tire 20 5 X 8 0 10 Rear Tire 20 5 X 8 0 10 PR...

Page 7: ...Raider Classic 150 Oil cooled Internal Gearbox Service Manual single double seat EEC Version 3 0 Feb 2005 7 1 5 Location of Parts Double seat ...

Page 8: ... Book from your dealer and locate each component location Turning light Headlight Rearview mirror Front wheel Control panel Steering wheel Roll bar Awning Seat Safety belt Rear rack Rear wheel Front shock absorber Brake pedal Throttle pedal Turning light Taillight Muffler Chain Engine Rear reflector Rear rack Rear shock absorber Reverse handle Brake handle ...

Page 9: ...witch Fuel Tank C Chassis I I Engine Oil R Valve Clearance Of Engine A Notes A Adjust C clean I inspect clean or replace if necessary 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 plug to prevent it from dripping into t...

Page 10: ...n c Check the brake rotor for abnormal wear 2 2 4 Air Cleaner Clean the air cleaner quarterly or more often when driving in dusty conditions If the air cleaner is clogged with dust its performance will be severely decreased even the engine damages will probably be caused Inspection and Cleaning of Filters Paper Filter a Remove the filter from its housing b Lightly tap the filter on an object to kn...

Page 11: ... rear bottom of the engine case Recommendation before draining the final gear oil please warm the engine for at least 10 minutes Notes We recommend the Mobile 85w 90 gear oil for the final drive case However in extreme cold weather conditions the vehicle may becomehard to start so we advise some lighter viscous oil such as 75 wt or the equivalent motorcycle transmission fluid Conventional marked b...

Page 12: ...h some cleaning solvent and reassemble it make sure that the O ring is still in good conditions d Refill the engine with the SAE10W 30SF engine oil and run the engine for 5 minutes e Check the oil level on the filler cap stick to assure that it s proper f Screw back the large cap 2 2 10 Chassis Inspect clean or replace it monthly if necessary and lubricate it quarterly a Grease the chassis bushing...

Page 13: ...Raider Classic 150 Oil cooled Internal Gearbox Service Manual single double seat EEC Version 3 0 Feb 2005 13 3 Engine Troubleshooting for Failure in Starting Engine ...

Page 14: ...Raider Classic 150 Oil cooled Internal Gearbox Service Manual single double seat EEC Version 3 0 Feb 2005 14 ...

Page 15: ...he engine stops soon after starting Solvent a Check if there is any damage or leakage on the pressurized tube of oil cock b Clean the carburetor and readjust the idle speed according to the steps below a Open the connecting tube between the air cleaner and carburetor b Spray a little carburetor cleanser into the carburetor c Start the engine and run for a while then quickly step on the throttle pe...

Page 16: ...e the difference of diameter between the two points mutually perpendicular which is the circularity of the cylinder In the situation without a dial gauge a feeler gauge can be used to make the relativity measurement Put a new piston into the cylinder and use the feeler gauge to measure the gap between the piston skirt and the cylinder wall and then figure out the abrasion loss of the cylinder If t...

Page 17: ...the piston pin and pinhole must comply with the requirement d Measure the inner diameter of the piston pin If the result is more than the service limit it should be replaced e After replacement the clearance between the pinhole of the piston and the piston pin must comply with the requirement 3 2 2 Inspection and Service of Piston Rings a Inspect if there is a flaw serious wear or serious congluti...

Page 18: ...l on every piston ring and then enlarge the piston rings AT the same time cover them on the piston and move forwards gradually until the piston rings fall into the ring groove 3 2 5 Installation of Piston Ring a Remove the gasket attached to the crankcase b Mount the piston onto the small end of the connecting rod c Mount the piston pin and piston pin clip The top of the piston with IN mark should...

Page 19: ...hat links the piston and crank The picture shows the structure and assembly relations of the crank connecting rod component 1 Shock Absorber Cover Rear 2 Shock Absorber Cover Front 3 Starter Gear 4 Oil Seal 19 8 30 5 5 Timing Chain 6 Stud Bolt M8 208 7 Crankcase Body Left 8 Crankshaft 9 Crankcase Paper Washer 10 Stud Bolt M8 198 11 Crankcase Body Right 1 2 3 4 5 6 7 11 10 8 9 ...

Page 20: ...inder and piston one by one b Remove the drive plate driven plate AC generator starting motor and oil pump c Remove the cam chain tensioner bolt and cam chain tensioner d Use the special tools to remove the starting driven gear e Remove the crankcase positioning bolts Separate the right crankcase and the left crankcase g Remove the gasket and the dowel pins The joint face can t be damaged ...

Page 21: ...set of the crankshaft if any serious wear is found while inspecting a Measure the axial clearance of the big end of the connecting rod When measuring make one side of the connecting rod big end close to the crank and insert the feeler gauge between the other side and crank and get the correct end play b Measure the radial X Y clearance of the big end of the connecting rod c Measure the main shaft ...

Page 22: ...embling g After the above inspection use the oilstone to furnish the crankcase if it has some surface damages Replace the cover if the damages are too severe 3 3 3 Installation of Crankshaft and Crankcase a Mount the crankcase oil seal b Put the cam chain and crankshaft into the left crankcase c Mount the new dowel pins and gasket on the left crankcase Join the right crankcase and left crankcase t...

Page 23: ... stroke engine This is a kind of overhead valve its intake port exhaust port camshaft are all located in the cylinder head the valve bottoms up over the combustion chamber 1 Exhaust Port 2 Clamp Intake Pipe 3 Intake Pipe 4 Heat Insulating Washer 5 Camshaft Carrier Outer 6 Rockshaft Intake Port 7 Rockshaft Exhaust Port 8 Rocker Arm 9 Cover Cylinder Head 10 Sealing Washer Cylinder Head Cover 11 Limi...

Page 24: ...ine is running the valve clearance should be neither too big nor too small So the valve clearance adjustment is an important procedure in the valve maintenance a Remove the cylinder head cover b Turn the cooling fan clockwise until the mark of the timing drive sprocket on the camshaft is at the top dead center and the T symbol or other mark of the magneto flywheel aligns with the crankcase mark c ...

Page 25: ...1 Removal a Loosen the valve cover bolts and remove the cover b Remove the cam chain tensioner screw and the O ring c Tighten the cam chain tensioner adjusting bolt clockwise d Turn the flywheel counterclockwise to make the T mark on the flywheel align with the mark on the crankcase When the hole on the cam chain timing drive chain wheel is up it is the top dead center position e Remove the cylind...

Page 26: ...on the cam chain wheel should be up and the left and right should be parallel with the cylinder head the lobes of the camshaft are down b Install the camshaft on the cylinder head Mount the cam chain on the cam chain wheel Install the dowel pins b Mount the camshaft holder washer and nut on the cylinder head Tighten the cylinder head bolt and nut c Turn the cam chain tensioner adjusting bolt antic...

Page 27: ...iameter of the rocker arm Service limit 10 10 mm c Measure the outer diameter of the rockshaft Service limit 9 91 mm 3 6 3 Installation a Read the EX mark on the camshaft holder then mount the exhaust port rocker arm and the rockshaft b Mount the inlet port rocker arm and rockshaft 3 6 4 Cam Chain Tensioner The chain tensioner must be in good working order for the proper chain tension 1 Cam chain ...

Page 28: ...ce and valve stem oil seal c Remove the valve from the other side 3 7 2 Inspection a Inspect if the valve is bent or burned b Inspect if the action is smooth between the valve and the valve guide c Measure the outer diameter of the valve stem Service limit 4 9 mm d Measure the free length of the inner and outer valve spring Valve Inlet Valve Exhaust Valve Inner Spring 31 2mm 31 2mm Outer Spring 34...

Page 29: ...e fuming white smoke 3 8 1 Clean of Carbon Accumulation a Remove the valve and valve springs b Clean the carbon accumulation with a valve guide reamer 3 8 2 Measurement of Inner Diameter a Calculate the clearance between the valve stem and valve guide The inner diameter of the guide subtracts the outer diameter of the valve stem Valve Inlet Valve Exhaust Valve Service Limit 0 08mm 0 10mm Service l...

Page 30: ...1 Width Measurement a Clean the carbon accumulation in the combustion chamber b Measure the width of the valve seat with a vernier caliper When the abrasion causes the valve seat width uneven too wide or too narrow it will result in bad contact between the valve and valve seat and can t seal tightly At this time it must be reamed with a customized valve seat grinding cutter Standard 1 0mm Service ...

Page 31: ...ith a 45º coarse tooth grinding cutter b Ream the upper angle of the valve seat working surface with a 30º grinding cutter c Ream the lower angle of the valve seat working surface with a 60º grinding cutter d Ream the valve seat to the specific seat width with a 45º grinding cutter 3 9 3 Touching Position Inspection a Apply a thin layer of the fluid on the valve seat and put the valve on the seat ...

Page 32: ...on carbide on the working bevel of the valve and repeatedly rotate the valve suction cup to lap the valve and valve seat evenly until they match tightly 3 9 5 Inspection of Valve and Valve Seat Air Impermeability After lapping the valve and valve seat the air impermeability of their joint surface should be inspected Method one the same as the method of valve seat contact position inspection Method...

Page 33: ...nd splashes on the cylinder wall and the small end of the connecting rod all the other goes through the oil passages such as the shaft neck of the camshaft and splashes on the cam rockshaft and cam chain The lubrication oil that falls back into the oil groove can be re circulated 3 10 2 Inspection and Replacement of Oil a Tighten the dipstick Remove the oil filter screen cap and screen to let the ...

Page 34: ...0 3 Rotary Oil Pump The oil pump is the critical component of the lubrication system so it should be maintained periodically and should be replaced as a unit if damaged seriously Oil Pump Removal a Remove the flywheel of the magneto Remove the stator coil and trigger winding b Remove the right crankcase cover bolts and right crankcase cover Remove the gasket and dowel pins c Remove the starting re...

Page 35: ...tor Service limit 0 12 mm c Inspect the clearance between the rotor plane and the oil pump Service limit 0 20 mm Oil Pump Assembly a Assemble the inner and outer rotors of the oil pump and mount the oil pump shaft b Mount the dowel pin After aligning the oil pump plate with the dowel pin install the oil pump plate If the inspection result exceeds the above stated service limit the whole set should...

Page 36: ...ner and then assemble the drive gear and chain c Install the partition board and tighten the bolts d Install the starting reduction gear and starting clutch Assemble the gasket and dowel pins e Assemble the right crankcase cover positioning bolt Assemble the trigger winding and stator coil Tighten the right crankcase cover positioning bolt Before installing fill the oil pump with oil When installi...

Page 37: ...y to find the highest position of the rpm Add throttle quickly and gently the rpm is from low to high and return the throttle immediately and then observe for 10 to 15 minutes to check if the idle remains the same 3 11 2 Vacuum Chamber The picture shows the structure of the vacuum chamber of the CV carburetor Removal a Remove the body cover Remove the automatic choke lead wire b Loosen the fuel dr...

Page 38: ...irection of the vacuum chamber cover to make the carburetor jet tube totally open c Put the spring in d Align the bulge part of the vacuum membrane with the fillister of the carburetor body e Assemble the vacuum chamber cover Tighten the bolt 3 12 Inspection of Automatic Side Starter Choke a Remove the fuel hose from the carburetor Turn out the carburetor float chamber drain screw and drain the fu...

Page 39: ...fuel in the float b Inspect the float valve and float valve seat for wear If there is any wear they should be replaced c Clear every fuel line and airline on the carburetor body with the compressed air 3 13 3 Installation a Install the main fuel injection nozzle and fuel injection needle seat b Install the air adjusting screw and choke adjusting screw and turn them according to the noted number of...

Page 40: ... position 3 14 Air Cut Valve ACV 3 14 1 General Information The air cut valve can avoid some abnormity once the throttle closes too quickly for example when the mixed gases are too thin The structure of the air cut valve is shown in the picture 3 14 2 Removal a Remove the air inlet manifold of the air cut valve b Remove the bolt vacuum membrane cover spring and vacuum membrane 3 14 3 Installation ...

Page 41: ...otor holding bolt and starter motor b Roll up the rubber water resistance cover and remove the starter motor joint Remove the motor case bolt carbon brush seat and motor case etc The bottom side of the vacuum membrane should be aligned with the carburetor and the topside should be aligned with the vacuum membrane When installing make sure every connecting pipes are connected properly and they cann...

Page 42: ...ing to the right picture it should be non conductive If not it should be replaced Carbon Brush Inspection a Inspect the insulating condition between the connecting wire terminal and starter motor case it should be non conductive b Inspect the conducting condition between the connecting wire terminal and the carbon brush and it should be conductive c Measure the length of the carbon brush Replace i...

Page 43: ...n the moving part of the armature ends Put the carbon brush into the bracket and then install the carbon brush base c Assemble the new O ring on the carbon brush base Install the armature into the starter motor case making sure not to damage the carbon brush Tighten the motor case bolts Before installing apply a little grease on the groove of the rotary retaining spring on the idler shaft The rota...

Page 44: ...11 Clamp 2 Starter reduction gear shaft 12 21 Bolt 3 Starting clutch gear comp 13 Nut 4 Starting clutch outer comp 14 Washer 5 Flange starting clutch 15 Dowel pin 6 Starting clutch roller spring 16 Key woodruff 7 Spring holder 17 Roller 8 Starter motor 18 Needle bearing 9 Starter motor lead wire 19 O ring Make sure the starter motor case is free of metal particles because it is magnetic Before ins...

Page 45: ...utch Removal a Remove the right crankcase cover Remove the left crankcase cover b Hold the drive face with a universal set wrench c Remove the starting clutch fixing nut d Remove the starting clutch the whole set Inspection a Inspect if the movement between the clutch and the driving gear is normal The driving gear should smoothly turn clockwise and should not move anticlockwise Inspect if there i...

Page 46: ...pect if there is any distortion on the spring If the damage is serious it should be replaced d Measure the inner diameter of the flange clutch It should be replaced when the diameter is more than 27 94mm Installation a Install the spring roller and top pin on the body of the clutch b Align the dowel pin on the flange clutch with the hole on the clutch body and then install the dowel pin c Apply so...

Page 47: ...starter 3 18 2 Controlling Mechanism Starter Relay Inspection a Turn the main switch to the ON position and press down the starting motor button and listen if there is a click sound If there is it is normal if there isn t follow the below procedures b Inspect if the brake switch is conductive at this time turn the main switch on and hold the brake lever d Measure the voltage between the inlet line...

Page 48: ...nd and the D end of the starting relay with the battery and the A and B end with the millimeter At this time the millimeter should indicate the conductive condition otherwise the starting relay is not good 3 19 Belt Driven CVT Mechanism 3 19 1 General Introduction The belt driven CVT mechanism is made up of two belt pulleys the drive belt pulley and the driven belt pulley whose diameter can be cha...

Page 49: ...m small to big proportionally the diameter of the driven belt pulley changes from big to small because the perimeter of the driven belt is constant AT this time the speed increases on the contrary the speed decreases The structure of the driving belt pulley is shown in the picture The picture shows the working theory of the driving belt pulley Drive Plate Assembly ...

Page 50: ... Drive Belt Pulley Removal a Remove the left crankcase air pipe lock bolt Remove the kick starter and left crankcase fixing bolt b Remove the left crankcase cover Hold the drive plate with a universal wrench and then remove the nuts and gasket on the drive plate shaft Remove the drive plate Remove the driven belt from the drive plate Remove the gasket and dowel pin c Remove the movable drive plate...

Page 51: ...ifugal roller b Measure the inner diameter of the movable drive plate Service limit 24 06mm c Inspect if there is any abrasion or damage on the drive plate hub Measure the outer diameter of the drive plate hubs movable surface Service limit 23 94mm Installation a Apply some grease evenly in the movable drive plate Put the centrifugal roller into the movable drive plate b Install the ramp plate c P...

Page 52: ... drive plate washer and nut f Hold the drive plate with a multiuse holder to make it unmovable At the same time fasten the nut on the shaft 3 19 3 Clutch Removal a Remove the left crankcase cover b Remove the drive plate and driven belt c Hold the clutch friction plate with a multiuse holder and remove the nut d Remove the clutch friction plate Inspection a Inspect if there is any abrasion or dama...

Page 53: ...e clutch a Remove the clutch friction plate Remove the whole set of clutch driven plate b Compress the driven pulley spring with the clutch spring compressor and at the same time remove the nut on the shaft c Disassemble the clutch with the driven pulley d Remove the circlip and remove the connecting piece e Remove the clutch centrifugal weight set and spring Installation a Mount the clutch damper...

Page 54: ...9 4 Driven Belt Pulley Removal a After removing the clutch friction plate remove the guide pin roller and movable driven plate b Remove the oil seal on the movable driven plate Inspection a Measure the free length of the driven belt pulley spring Service limit 163 7mm When assembling the clutch and driven plate you must use a clutch spring compressor otherwise it will damage the spring No grease o...

Page 55: ...acement of Driven Plate Bearing a Remove the needle bearing from the driven plate b Remove the circlip from the driven plate c Drive the ball bearing out d y some grease on the new ball bearing e Drive the ball bearing into the driven plate with its front face upwards e Assemble the circlip g Apply grease evenly on the inner wall of the driven plate Service limit 33 94mm Service limit 34 06mm If t...

Page 56: ...ate After applying some grease on the roller and guide pin assemble them into the driven plate hole c Install the oil seal collar Remove the excessive grease d Assemble the clutch on the left crankcase 3 19 5 Transmission Belt Inspection a Remove the left crankcase cover Inspect if the transmission belt is chapped or worn Measure the width of the belt Service limit 19 0mm b Replace the belt if its...

Page 57: ...the following picture 1 Cover Gear Box 14 Flat Washer 6 4 18 1 2 Gasket Gear Box Cover 15 Pin 3 Shaft Drive 16 O ring 9 4 2 4 4 Shaft Counter 17 Fork 5 Shaft Center 18 Ring Pin 6 Axle Rear Wheel 19 Flat Washer 8 5 12 0 5 7 Bearing 6201 20 Shaft Circlip ჶ 8 8 Bearing 6202 21 Dowel Pin 8 14 9 Oil Seal 30 47 7 22 Round head Screw M5 25 10 Bearing 6005LLU 23 Hex Nut M5 11 Shaft Fork 24 Breather Pipe R...

Page 58: ...bolt b Remove the oil drain bolt to drain the oil c Mount the drain bolt and its oil seal and fasten d Supply the oil with the prescribed specification and oil level e Mount the level bolt f After replacing the oil inspect for any oil leakage 3 20 3 Transmission Case Transmission Case Removal a Remove the driven belt pulley Drain out the oil in the transmission case b Remove the drive sprocket Rem...

Page 59: ...ear gear and rear gear shaft are damaged or worn b Inspect if the center shaft idle gear and idle gear shaft are damaged or worn Replacement of Bearing on Left Crankcase Body a Press the driven belt pulley shaft out of the left crankcase body b Remove the oil seal and drive out the bearing When removing or installing the bearing on the transmission case cover you must use the special tool shown in...

Page 60: ...er a Inspect the bearing and oil seal on the transmission case cover for wear and damage If they are damaged they must be replaced Remove the oil seal Drive out the rear gear shaft bearing b Remove the other 3 bearings c Assemble the new bearings and oil seals d Assemble the rear wheel axle comp e Assemble the fork shaft comp g Assemble nut M5 and screws When removing or installing the bearing on ...

Page 61: ...reverse gear can work agilely and smoothly b For the safety of traveling the vehicle must be in the parking state when the reverse gear is working c In order to maintain the excellent performance and long service time of the reverse gear please don t shift gear when traveling at high speed d Service the reverse gear periodically Replace the gear oil every 5000km or 6 month of running Capacity 200m...

Page 62: ...ry c Remove the fuse and connect the ammeter with the two ends of the fuse d Connect the tachometer with the engine it s not needed when there is a rpm indicator on the vehicle e Start the engine and accelerate slowly Measure the charging voltage and current Charging voltage V 13 5 15 5 Charging current A 0 5 Note Measuring condition 5000 r min If the voltage isn t in the range of the above specif...

Page 63: ...Connect the negative pole of the charger with the negative pole of the battery c Charge the battery for the charging time marked on the battery g Measure the voltage 30 minutes after the charging is finished It should reach the specified value otherwise it needs recharging Normal 0 7A Charging Current Fast 3 0A The disconnecting order can t be reversed When disconnecting the positive cable don t t...

Page 64: ...ling fan 2 Generator assembly 6 Bolt 3 Flywheel comp 7 Nut 4 Stator comp 8 Bolt 5 Washer 9 Bolt 4 3 2 Primary Coil Inspection a Remove the 4 core connector of the generator b Measure the resistance value between the white wire of the generator and the connecting wire of the vehicle body c When the actual value is more than the standard value the coil should be replaced Standard value 0 2 0 4 Ω 20 ...

Page 65: ...eel with a flywheel puller Remove the solid key d Remove the generator wire connector e Remove the generator wire holder Remove the generator coil bolt Remove the generator wire rubber bushing from the right crankcase Remove the coil set 4 4 2 Generator Installation Reverse the removal procedure for installation Don t damage the coil when removing When installing the flywheel make sure that there ...

Page 66: ... Battery The Red Wire Vehicle Body Battery Voltage Value Connecting Wire the Green Wire Vehicle Body Conductive Lighting Wire the Yellow Wire Vehicle Body Remove the resistor side auto starter plug and turn the lighting switch to off Generally 0 1 0 8Ω Charging Wire the White Wire Vehicle Body Generally 0 2 2 0Ω W White Y Yellow R Red G Green W White 3 100 KΩ Y Yellow 5 100 KΩ R Red Take the volta...

Page 67: ...surement a Measure the resistance value between the resistor wire and vehicle body If the actual value is in the range of 1Ω value marked on the diagram or the resistor it s normal if not it should be replaced 4 7 Ignition System 4 7 1 Working Principle The circuit working principle is shown in the picture 4 7 2 Ignition Timing Inspection When the main wiring sub electric circuit condition is norm...

Page 68: ... trigger winding can be loosened to adjust the angle and the ignition charging coil can be loosened to adjust the ignition timing 4 7 3 Ignition System Inspection When the spark plug does not spark first inspect the wires and if the connecting part is loose or contacts bad you can follow the electric circuit and take the method of measuring the voltage of every point to find out the trouble Please...

Page 69: ...ith the trigger winding the green red wire terminal on the 4 core connector and connect the negative end with the green wire terminal on the 4 core connector Press the starting button or kick starter and measure the highest voltage of the trigger winding it should be more than 2 1V e If the measured highest voltage of the trigger winding is abnormal remove the generator connector and make further ...

Page 70: ... the CDI testing instrument a Connect the CDI component with the special wire of the testing instrument c Observe the spark condition on the instrument when the switch is turned at different positions 4 8Ignition Coil 4 8 1 Removal a Remove the spark plug cap b Remove the primary ignition coil wire c Remove the ignition coil positioning bolt and ignition coil 4 8 2 Installation Reverse the removal...

Page 71: ...nect the ignition coil b Turn the switch of the testing instrument to the ON position Observe the spark over window and inspect the spark over the ignition coil If it is a normal consistent spark it is good if the spark doesn t flash consistently it is bad 4 9 Spark Plug a Clean the carbon around the spark plug to prevent it from dropping into the cylinder when removing the spark plug b Remove the...

Page 72: ... the nuts on the bearing carrier and remove the bolts h Remove the axle and bearing carriers as a unit 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 Note Don t remove the brake hose c Unplug the brake light wiring from the electrical box d Remove the throttle cable e Remove th...

Page 73: ...e tension of the shock spring would increase as you turn the screw left and decrease as you turn the screw right 5 5 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 5 6 Front Hubs a Check the sea...

Page 74: ... 5 8 Steering Shaft a Remove the nuts on the steering block and grease the inside of the steering block periodically b Loosen the steering shaft and clamp nut on the steering gear box c Remove the steering shaft 5 9 Steering Gear Box and Ball Head a Remove the four bolts of the LH RH clamp nuts on the steering gear box b Remove and check the ball head dust cover on the steering gear box for wear c...

Page 75: ... b Remove the bolts on the upper lower a arms of the front wheel c Check the nylon bushing of the upper lower a arms on the front wheel for wear Replace them immediately if any wear is present 5 12 Steering Knuckle Support a Remove the rubber dust cover of the knuckle support b Check the grease of the ball joint Clean it if it s dirty and fill with grease c Replace the steering knuckle support if ...

Page 76: ...move the air cleaner element 2 3 Note Service more often when driving in dusty conditions Service Foam Filter Paper Filter a Clean the foam filter with the no flammable cleaner If the filter is paper tap it on an object to knock out the dust or replace it with a new one c Dry the filter after cleaning dip it into the engine oil specified by the manufacturer and wring the excess oil out of the filt...

Page 77: ...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 To make Dimension B shorter screw the rod left if Dimension B needs to be longer screw the rod right Tighten the jam nut tightly against the rod end recheck the distance and repeat the above steps until the Dimensions are the same as the required 5 18 Chain Adjustment...

Page 78: ...Raider Classic 150 Oil cooled Internal Gearbox Service Manual single double seat EEC Version 3 0 Feb 2005 78 ...

Page 79: ...Raider Classic 150 Oil cooled Internal Gearbox Service Manual single double seat EEC Version 3 0 Feb 2005 79 6 Wiring Diagram ...