Dazon Raider Pro 250 S, Service Manual

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Page 2: ...ew 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 the local distri...

Page 3: ...neral Information 4 2 Periodic Maintenance and Tune up Procedures 8 3 Engine 12 1 Lubrication System 12 2 Cylinder Head Valve 14 3 Drive Pulley Clutch Driven Pulley 15 4 Gearbox 16 5 AC Generator Starting Clutch 18 6 Crankcase Crankshaft 19 7 Cooling System 20 8 Carburetor 25 4 Wiring Diagram 30 ...

Page 4: ...dations 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 Vary the engine speed for the first 5 hours Never hold the engine at full throttle for lon...

Page 5: ...W h Lubricate Oil Type SAE 10W 30SF Lubrication Pressure Splash Cooling Fluid Anti corrosive Anti freeze Cooling Water cooled Electric Ignition C D I Starting Electric Spark Plug D7 Spark Plug Gap 0 6 0 7mm Transmission Chain Transmission Transmission Ratio F 1 1 B 1 1 758 Primary Transmission Ratio 2 2 0 9 Compression Ratio 10 0 1 Reduction Ratio 6 6 Clutch Automatic Centrifugal Dry Shoe Type Gen...

Page 6: ...V 5W 21W Turning Light 12V 10W License Light 12V 5W Battery 12V 9A Anti theft Lock 200N m Rearview Mirror accord with EEC standards CHASSIS Front Rear Brake Hydraulic Disc Foot Control Front Wheel Brake Force 923N 1258N Rear Wheel Brake Force 1288N 1488N Braking Distance 7 m 30kmph Parking Brake Hydraulic Disc Hand Control Front Tire 20 5 X 8 0 10 Rear Tire 20 5 X 8 0 10 TIRE PRESSURE Front 175kpa...

Page 7: ...Raider Pro 250 single seat double seat Service Manual EEC Version 1 0 Oct 2004 7 1 5 Location of Parts Double seat ...

Page 8: ...Raider Pro 250 single seat double seat Service Manual EEC Version 1 0 Oct 2004 8 Single seat Please demand for a copy of the Parts Book from your dealer and locate each component location ...

Page 9: ...Brake Fluid I Replacement Of Gearbox Oil I R Chassis C I L Fuel Switch 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 th...

Page 10: ...oir b Check if the front rear brake pad is in good condition 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 f...

Page 11: ...he reserved fuel supply and refuel as soon 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 7 Final Gear Oil Inspect the final gear oil monthly and replace it quarterly a Check the oil level remove the oil level screw on the left rear engine case b Drain out the oil remove the drain plug at the rear bot...

Page 12: ... Remove the large cap on the left bottom of the engine and remove the screen c Wash the screen with 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 9 Chassis Inspect...

Page 13: ...Raider Pro 250 single seat double seat Service Manual EEC Version 1 0 Oct 2004 13 3 ENGINE 3 1 Lubrication System 3 1 1 Lubrication Diagram ...

Page 14: ... a Stop the engine b Stay the vehicle on the flat ground for 2 3 minutes c Inspect the engine oil level Notes The engine oil level gauge shouldn t be screwed in Engine Oil Replacement a Remove the engine oil filler cover Drain out the engine oil when the engine is warm Reassemble the filler cover Torque 18 20 N m b Check if the O rings are damaged replace them if necessary c Fill in the new engine...

Page 15: ...med The valve spring is damaged The valve timing is faulty The valve seat seal is faulty b Cylinder Head The cylinder head gasket leaks air The cylinder head is deformed or cracked c Cylinder Piston is faulty The compression is too high a There is a carbon accumulation on the piston or in the combustion chamber Noise a The lifter hasn t been adjusted well b The valve is burnt or the valve spring i...

Page 16: ... worn b Measure the width of the drive belt Service limit replace if below 17 5 mm Clutch a Check if the clutch cover is worn or damaged b Measure the inner diameter of the clutch cover Service limit replace if above 130 5 mm c Check if the clutch shoes are worn or damaged d Measure the thickness of the clutch shoes Service limit replace if below 2 0 mm Drive Spring a Check the free length of the ...

Page 17: ...Raider Pro 250 single seat double seat Service Manual EEC Version 1 0 Oct 2004 17 3 4 Gearbox 3 4 1 Disassembly Diagram ...

Page 18: ...ox oil with the specified type Gearbox Oil Capacity 0 2 L Specified Gearbox Oil Mobil 85w 90 Gearbox Oil Level Bolt Torque 14 18 N m b Check if there is any oil leakage after running the engine Check the oil level again c Check if the gearbox oil seal is damaged and replace it if necessary 3 4 2 Trouble Shooting The engine can be started but the vehicle can t run a The gears are damaged b The gear...

Page 19: ...04 19 3 5 AC Generator Starter Clutch 3 5 1 Disassembly Diagram 3 5 2 Trouble Shooting The AC generator is faulty The starter reduction gear is faulty The starter motor revolves conversely The wires haven t been connected well The starter clutch spring is broken dirty or locked ...

Page 20: ...Service Manual EEC Version 1 0 Oct 2004 20 3 6 Crankcase Crankshaft 3 6 1 Disassembly Diagram 3 6 2 Trouble Shooting Engine Noise a The bearing is loose b The crankshaft pin bearing is loose c The piston pin and the piston pin hole are loose ...

Page 21: ... Cooling System 3 7 1 Disassembly Diagram 3 7 2 Trouble Shooting The water temperature rises a The heat sensor of the thermometer is faulty b The water tank cover is faulty c The temperature petcock is faulty d The tank fluid is insufficient e The water pipe and water sleeve are clogged ...

Page 22: ...sure tester to check all the joints and oil seals for leakage 3 7 4 Specifications Pressure of Water Tank Cover Petcock 0 9 0 15 kg cm2 at Beginning of Opening 72 2 Full Opening 90 Temperature of Adjuster Cock Full Opening Volume 3 5 4 5 mm Volume Of Cooling Fluid about 1190cc Water Tank 750 cc Sub Water Tank 420 300 cc Notes a Use the specified water tank fluid b Don t mix the fluid of different ...

Page 23: ...damaged or leaking b Clean the radiator plates if they are clogged or dirty c Repair the radiator plates if they are deformed 3 7 6 Water pump Inspection of Water Pump Water Seal a Check if the drain hole under the right crankcase cover leaks If it leaks the water seal of the water pump is faulty and needs to be replaced b Remove the right crankcase cover and replace with a new water seal Replacem...

Page 24: ... Notes Fasten the impeller with the left thread j Assemble the water pump shaft k Assemble a new outer bearing of the water pump shaft inside the right crankcase cover 3 7 7 Heat sensor Disassembly of Heat Sensor a Remove the rear side cover on the right b Drain out the water tank fluid c Disconnect the heat sensor wires d Remove the heat sensor Inspection of Heat Sensor a Put the heat sensor into...

Page 25: ...The heat adjuster shouldn t touch the testing container directly b If the heat sensor opens at the normal temperature replace it with a new one c When the temperature adjuster has been open for 5 minutes at the temperature of 70 measure again the temperature of the opening valve Temperature of Opening Valve 72 2 Temperature of Full opening Valve 90 Rising Volume of Full opening Valve 3 5 4 5mm ...

Page 26: ...agram 3 8 2 Trouble Shooting The engine can t start well a There is no fuel in the fuel tank b The fuel tube is clogged c There is too much fuel in the fuel tank d The air cleaner is clogged e The fuel has deteriorated The engine can t run stably or smoothly at the idle speed a The idle speed hasn t been adjusted well ...

Page 27: ...ged b The air hole of the fuel tank cover is clogged c The fuel filter is clogged d The fuel tube is clogged e The float valve doesn t work well f The fuel level is too low The gas mixture is too dense a The automatic choke is opened too widely b The float valve doesn t work well c The fuel level is too high d The air cleaner is clogged e The automatic chock hasn t been assembled correctly 3 8 3 P...

Page 28: ...ke pipe of the automatic fuel cup 3 8 6 Automatic Side circuit Starter Inspection of Automatic Side circuit Starter a Check the conduction of all the automatic side circuit starter wires Standard Resistance Value below 10Ω 10 minutes after the engine stops b Replace the automatic choke if the resistance value exceeds the standard value Inspection of Automatic Choke a Connect a tube with the fuel a...

Page 29: ...stment of Ignition Timing The C D I is used so there is no need to adjust the ignition timing If the ignition timing isn t normal check the C D I and AC generator Inspection of Ignition Timing a Turn on the ignition timing lamp b Align the mark F within the range of 3º at the rotation of 1 700rpm Ignition Timing B T D C 13º 3 1700rpm C If the rotation is above 3 000rpm the aligning mark should be ...

Page 30: ...lug if necessary Specifications Spark Plug D7 Spark Plug Gap 0 6 0 7mm 3 8 13 Compression Specification 11 0 15 0kg cm2 400rpm Trouble Shooting The compression is too low a The valve leaks b The valve clearance is too big c The cylinder head gasket is damaged d The piston rings are worn e The piston rings and the cylinder are worn The compression is too high a There is too much carbon in the combu...

Page 31: ...Raider Pro 250 single seat double seat Service Manual EEC Version 1 0 Oct 2004 31 4 Wiring Diagram ...