Dazon Raider Extreme 1100D Owner'S Manual Download Page 10

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1100cc Double-seat buggy Owner’s Manual

Version 3.0 Dec.2006

SAFETY LABELS

The labels should be considered permanent parts of your BUGGY. If a label comes off or becomes difficult to read, please contact
your dealer for warning label replacements.

Summary of Contents for Raider Extreme 1100D

Page 1: ...1100cc Double seat buggy Owner s Manual Version 3 0 Dec 2006 1 ...

Page 2: ...operly use maintain and care for the vehicle as outlined in the DAZON owner s manual You must maintain a record of the vehicles service history Periodic service and inspection are considered regular maintenance and are not considered as warranty WHAT YOUR DEALER MUST DO All warranty repairs will be made at no cost to you for parts as related to the defect All parts will be replaced with genuine DA...

Page 3: ...ance Any damages that result from the passage of time such as fading peeling or other deterioration caused by outside elements Sensational phenomena that do not affect performance or function of the product such as engine noise vibration or seepages Consumable replacement parts damaged by normal wear Such as spark plugs drive chains belt drives air cleaner elements brake shoes cables fuses oils co...

Page 4: ...y Labels 10 5 Are You Ready to Drive 11 6 Is Your Vehicle Ready to Drive 15 7 Safe Driving Precautions 16 8 Components location 20 9 Adding oil before driving 40 10 Operation instruction 44 11 Pre drive instruction 53 12 Maintenance service instructions 55 13 Battery 71 14 Storage instruction 77 15 Periodical Checks and Services 78 16 Specifications 80 17 Buggy wiring diagram 85 ...

Page 5: ...lure to follow the warnings contained in this manual can result in serious injuries Be sure to follow the recommended maintenance schedule and service your vehicle accordingly Preventive maintenance is extremely important to the longevity of your BUGGY Beginners should drive this BUGGY in a large open area to practice handling this BUGGY Wear protective gears all the time when driving or riding th...

Page 6: ... BUGGY so you must use your own good judgments You will find important safety information in a variety of forms including Safety Labels on the BUGGY Safety Messages preceded by a safety alert symbol and one of the two signal words WARNING or CAUTION The meaning of these signal words WARNING Physical harm may result from the failure to follow the instructions that are described within the labels CA...

Page 7: ...e a few of the most important ones Always Wear a Helmet Facts have proven that helmets can significantly reduce the quantity and severity of head injuries so when you drive your BUGGY please always wear a DOT approved motorcycle helmet We also recommend that you wear approved goggles sturdy boots durable gloves and other protective gear Drive Off Road Only Your BUGGY is designed and manufactured o...

Page 8: ...cted turns drop offs rocks ruts and any other hazards Always keep your speed low enough to allow time for seeing and reacting Drive within Your Limits Pushing limits is another major cause of BUGGY accidents Never drive beyond your personal abilities or faster than conditions warrant Remember that alcohol drugs fatigue and inattention can significantly reduce your ability to make good judgments an...

Page 9: ... BUGGY in your lovely house Keep away from Moving Parts You should never place your hands or any other parts of your body near any moving parts of your BUGGY Failure to adhere to this warning will cause physical harm to your body Avoid Skidding or Sliding The terrain surface can be a major factor affecting turns Skidding or sliding a turn is more likely to occur on slippery surfaces such as snow i...

Page 10: ...y Owner s Manual Version 3 0 Dec 2006 10 SAFETY LABELS The labels should be considered permanent parts of your BUGGY If a label comes off or becomes difficult to read please contact your dealer for warning label replacements ...

Page 11: ...eniences and safety Before you drive your BUGGY for the first time we urge you to Carefully read this owner s manual and the labels on your BUGGY Make sure that you understand all the safety messages Learn how to operate all the controls on your BUGGY Before each of your drive we urge you to be sure that You feel well and you are in good physical and mental conditions You are wearing a DOT approve...

Page 12: ... can reduce the chances of injuries when you drive The following suggestion will help you choose the proper driving gear 1 Helmets and Eye Protection Gear Your helmet is your most important driving gear because it offers the best protection against head injuries Your helmet should fit your head comfortably and securely An open face helmet offers some protection but a full face helmet offers more R...

Page 13: ...ave driven other Buggies you still need take time to become familiar with how this BUGGY works Practice driving this BUGGY in a safe area to build your skills Don t drive on rough terrain surfaces until you ve gotten accustomed to all the controls on this BUGGY and felt comfortable with its size and weight z Operating this BUGGY without wearing a DOT approved motorcycle helmet eye protection gear ...

Page 14: ...rongly recommended that no one under the age of 18 be permitted to operate this BUGGY A child driving this BUGGY that is not recommended for his her age could lose BUGGY control resulting in severe injures or even death z Operating this BUGGY after consuming alcohol or drugs can seriously affect your judgments cause you to react more slowly affect your balance and perception and even could result ...

Page 15: ...htly step on the throttle pedal if the wheels do not get out from the bunker then stop stepping on the throttle pedal and call the service centre Excessively stepping on the engine may cause the engine overheat or damage If your BUGGY has overturned or has been involved in a collision please don t drive it until an authorized service center has inspected it There may be damages or other problems y...

Page 16: ...drive on private property Avoid posted areas and obey no trespassing signs Never drive your BUGGY on public streets roads or highways even if they are not paved Drivers of street vehicles may have difficulty in seeing and avoiding you which could easily lead to collisions In many states it is illegal to operate BUGGIES on public streets roads and highways z Operating your BUGGY on paved surfaces m...

Page 17: ...ds from the steering wheels or your feet from the foot controls during operation can reduce your ability of controlling your BUGGY or cause you to lose your balance and fall off your BUGGY z During operation always keep your both hands on the steering wheels and your both feet on the foot controls of your BUGGY While we want to shift the gear from forward to reverse or vice visa the gear shifter s...

Page 18: ...ometimes it s difficult to gain the reaction time before you see obstructions like hidden rocks bumps or holes with enough time to react z Operating your BUGGY at excessively high speed increases your chances of losing control which can easily result in an accident z Always drive at a speed that is proper for your BUGGY terrain visibility and other operating conditions plus your own skills and exp...

Page 19: ... or loose terrain could cause loss of traction or vehicle control which could result in accidents including an overturn z Don t operate on excessively rough slippery or loose terrain until you ve learned and practiced the skills necessary to control your BUGGY on such terrain z Always be especially cautious on these kinds of terrain z Always keep all wheels on the ground Attempting wheelies jumps ...

Page 20: ... LOCATION A Front view 1 Overhead canopy 2 Bucket seat 3 Steering wheel 4 Side canvas 5 Front wheel 6 Wheel rim 7 Front shock absorber 8 Brake cable 9 Front mudguard 10 Front turning signal 11 Front headlight 12 Rear mirror 13 Brush guard bar 11 1 2 3 4 5 6 7 8 9 10 11 12 13 ...

Page 21: ...B Rear view 1 Rear carrier 2 Tail lamp 3 Rear turning signal 4 Rear shock absorber 5 License plate bracket 6 Battery 7 Lower A Arm 8 Rear tires 9 Reflector 10 Mudguard 11 Muffler 12 Supplementary water tank 13 Cooling fan 14 Radiator 12 13 14 1 2 4 5 6 8 10 9 3 7 11 ...

Page 22: ...ersion 3 0 Dec 2006 22 CONTROL PANEL Consists of the following features 1 Steering wheel Ignition switch Key lock Cigarette ignition housing Fuel level gauge Multi function gauge Water temperature gauge Parking alarm flicker 2 4 Control Panel ...

Page 23: ...lease the key when the engine starts The engine will warm up within 5 minutes and the engine choke will close automatically and operate at formal RPM Warning Once the engine is started the key will move automatically to ON position Don t crank the starter more than 5 seconds at one time The ignition switch on the panel is having OFF ON and START OFF refers to kill the engine and stop the vehicle O...

Page 24: ...n to start the engine Otherwise the battery will become flat Never pull out the key during driving otherwise the vehicle will loss control KEYS The same key can be used for ignition and anti theft lock Never leave both keys unattended on the unit Keep the spare key in a safe place but not on the buggy Change the key if it is rusty ...

Page 25: ...maining in the fuel tank The fuel Level gauge will not work when the ignition switch is turned off After filling petrol into the fuel tank start the engine the red needle will move gradually to indicate the amount of fuel being filled It is normal to see the needle flirting during accelerating turning or applying brake due to vibration of fuel inside the fuel tank Fuel tank capacity 30 Liters NOTE...

Page 26: ... lamp The lamp will be on when the turning Signal is applied 4 Odometer The digital display at the bottom of the speedometer records accumulated mileage kilometer that the buggy has run 5 Engine oil warning lamp When engine oil falls below the required level the lamp will be on 6 Hydraulic oil level indicator Shows the level of hydraulic oil 7 Front high beam lamp The indicator will be on when you...

Page 27: ...erheating and you need to stop the engine for cooling If the engine always get heated check the water tank and water pipe condition MULTI FUNCTION LEVER It consists of the following features 1 Horn button The horn button is at the tip of the multi function lever As per arrow A When you need to apply horn just press the button disregarding whether the lever is at the On Off or any position DO NOT a...

Page 28: ...clockwise for switching on other functions Arrow C 3 Fog lamp switch Turn the multi function lever clockwise by one click the fog lamp will be on 4 Low beam lamp switch Press downward the multi function lever for low beam light As per arrow D 5 High beam lamp switch Push upward the multi function lever for high beam light As per arrow E E D C B ...

Page 29: ... lever for giving warning signal to the vehicles coming from opposite direction 7 Left right turning signal Push forward the multi function lever for right turning signal Arrow G Push backward for left turning signal Arrow H Check all the lighting condition before driving the buggy in the night Never drive without good lighting Never risk your life F G H ...

Page 30: ... depressing 1 Clutch pedal Must depress the pedal all the way while changing gear 2 Brake pedal Depress the pedal all the way down if urgent brake is required 3 Throttle pedal Depress the pedal according to the need Of acceleration Note Nothing shall be placed below the pedals otherwise it will obstruct the driving and cause danger to your life Not to wear slippery shoes Brake pedal Clutch pedal T...

Page 31: ... immediately FRONT HEAD LAMPS FOG LAMP The headlamps are screwed onto the lamp bracket There are two bulbs inside the lamp one is headlight the other is flog light The switch is on the multi function lever Voltage of each lamp 12 watts TURNING SIGNAL LAMPS Both left and right turning signals are screwed on the bracket For safety reason not to change the lamps to other color Capacity of turning sig...

Page 32: ...ts are in working condition before you drive the vehicle in the night Capacity of tail lamp 5 watts LICENSE PLATE LAMP The license plate lamp can be opened by removing the two nuts Capacity of license plate lamp 5 watts SEAT ADJUSTMENT The seat must always be securely adjusted to the positions which affords the best control of the foot pedals steering wheel for the operator 1 Pull the seat adjustm...

Page 33: ...t be adjusted Before attempting to adjust the seat ensure that the engine is not running Never operate your BUGGY when the seat is not securely adjusted Never adjust the seat when you are driving the BUGGY Otherwise it could result in personal injuries or loss of life SAFETY BELT Each single bucket seat comes with a safety belt For safety reason both driver and passenger MUST put on safety belt pr...

Page 34: ...e frame behind the seat 2 Put on the vertical across the chests safety belt tighten by pulling the strap downward 3 Put on the horizontal across the waist safety belt tighten by pulling the strap sideward 4 Release the safety belt by pressing the red button on the buckle with the left hand and pull out the hook from the buckle with the right hand ...

Page 35: ...t Do not modify the safety belt without the consent of the safety belt maker If the safety belt is too long defective or cannot be tightened it must be replaced immediately Never ride on the BUGGY without good safety belt MAINTENANCE OF SAFETY BELT 1 Make sure the buckle is free of dust all the time 2 Refrain from oil battery acid and other chemical 3 Clean it with soap regularly ...

Page 36: ...e is installed between the seats Please refer to Operating Instruction for operating hand brake MUFFLER The muffler is connected to exhaust pipe with noise control of 80 dba EXHAUST PIPE The exhaust pipe mouth shall not point to the engine otherwise the engine will get overheated Pipe exhaust ...

Page 37: ...l to three way catalytic converter and lighting system Use unleaded fuel only REAR CARRIER Limited Loadage The limited loadage on the rear rack is 40kg or 88 lbs NOTE Never exceeds the limit otherwise the vehicle will be overweighed at the rear and cause the vehicle over turn Three way catalytic converter Rear carrier ...

Page 38: ...outh is raised to a higher level at the right brush guard Following steps must be observed during fuelling 1 Turn off the engine 2 Open the fuel tank cap in anti clockwise direction 3 After fuelling close the fuel tank cap in clockwise direction Type of petrol Only high quality unleaded petrol is allowed The quality of petrol will affect the functioning and life of engine The engine will burn if t...

Page 39: ...ll dam WHEELS Off road tires for off road vehicle Picture A On road tires for on road vehicle Picture B Tubeless tires are used for both On road Off road tires Both front and rear wheels are having different sizes Front tires 25 x 8 12 Rear tires 25x 10 12 Size of wheel rim Front 12x6 Rear 12 x7 Note Special sand tire is to be used if the buggy is to run on desert for long hours A B ...

Page 40: ...to the brake oil Amount of brake oil shall fall between the upper limit marked with MAX and lower limit marked with MIN The following regular oil replacement should be observed Grade of oil DOT 3 Clean up all the dirt on the oil pump cap before adding brake oil Avoid contact with skin or eyes Antidote External flush with water Internal call physician immediately Brake oil will damage the paint of ...

Page 41: ... the oil drive back cap of the oil inlet and check the oil level inside the gear box The oil level shall reach the bottom neck of the oil inlet Grade of gear box oil 85W 90 Below regular replacement shall be observed Oil replacement interval period Volume of oil Every 3 months or 5000 kilometer 2 11 L Never make oil replacement before the gearbox is cooled down For environment protection purpose p...

Page 42: ...slower 3 Take out the oil dip rod and dry it with cloth then put it fully back to the engine for a second and take it out again Look for the position of oil if it falls below Marking A then top up to level B but never exceed level B otherwise the oil consumption rate will increase and cause carbon residue and spark plug fouling Warning Before operating your buggy for the first time please be sure ...

Page 43: ...il check stick Filling Method Unscrew the engine oil cap located on top of the engine camshaft cover Insert a clean funnel into the oil filling opening and slowly pour fresh engine oil into the camshaft cover Oil will drain down into the engine Once the recommended oil volume has been added remove the funnel and replace and tighten the engine oil cap Start the engine and let it idle for 30 seconds...

Page 44: ...e ignition all lightings and alarm system are working 3 Check the tire conditions and pressure 4 Adjust the seat to the desired position 5 Adjust the angle of rear view mirrors 6 Put on safety belt 7 Check the brake condition 8 Check the clutch condition by stepping on the clutch fully a few times 9 Check the gear shift condition by stepping on the clutch and shift the gear lever to neutral 1st 2n...

Page 45: ...ging the starter motor 3 Do not repeatedly turn on the ignition switch if the engine fails to immediately start Wait for 10 seconds before trying again Next time try turning the ignition switch with the throttle pedal slightly depressed 4 In cold weather warm up the engine for several minutes at idle speed Then speed up after the operation temperature is reached 5 In hot weather avoid running the ...

Page 46: ...at a slope do not release the brake handle lever until you have already shift the gearshift lever to 1st gear and ready to move the vehicle Step slightly on the accelerator pedal and then release the brake handle lever D GEARSHIFT OPERATING INSTRUCTIOIN Whenever you need to change gear always step on the clutch fully and shift the gear to the desired position at the same time After changing gear l...

Page 47: ...ission will be damaged Reduce speed before change to reverse gear Never step on the clutch when driving the buggy otherwise the clutch will be damaged The turning radius of your BUGGY is small and agile so the centrifugal force is very high when turning at high speed When turning you should slow down to a more controllable speed to prevent your BUGGY from rolling over Keep your heel on the floorbo...

Page 48: ... period please follow these instructions 1 Run the engine according to the requirements for the engine break in Do not overwork the engine Avoid keeping the throttle full open 2 Rotate the throttle slowly after starting the engine Do not speed up or speed down suddenly 3 Drive on smooth roads Do not drive uphill or on rough roads for extended periods 4 After approximately the first 500 miles of us...

Page 49: ...erform as the brake What you need to do is to depress harder on the brake pedal G BRAKE OPERATING SYSTEM When the brake is applied the rear wheels will be locked When the brake lever is pulled upward toward direction 1 the brake is applied and the rear wheels are locked Press the button 2 and depress the brake lever downward to 3 direction the brake is released and the rear wheels become unlocked ...

Page 50: ...e 4 Do not step on brake pedal unnecessarily otherwise the brake lining and brake lining disc will be damaged 5 Never drive the vehicle with the brake lever on Stop the buggy 1 Depress brake pedal pull the brake lever 2 When the Buggy is to be parked on a flat ground shift the gear to neutral position 3 When the Buggy is to be parked on a slope with the vehicle facing downhill shift the gear to re...

Page 51: ...ehicle on a solid road surface Turn the wheels to left or right when the vehicle is to be parked on a slope H POWER REDUCTION DEVICE The power reduction device is available only on ON ROAD model It is situated at the cable of the rail frame With power reduction device maximum engine speed 3500r min Without the device maximum engine speed 5500r min The power reduction device ...

Page 52: ... 2nd gear and accelerate slowly otherwise the front wheel will be slippy z Each time before starting the engine check the throttle assembly to ensure that when you push the pedal all the way forward the throttle assembly can work smoothly When the pedal is released the throttle assembly should return to the idle position automatically z Don t operate your BUGGY if the pedal or engine throttle link...

Page 53: ...e pedal if necessary Tires Check the tire conditions and pressures Front Tire Pressure 4 P S I Rear Tire Pressure 7 P S I Drive Chain Check for the chain conditions and tension lubricate it if necessary Throttle Check for the smooth operation assure that the throttle snaps back to the idle position Engine Stop Button Perform the engine stop button test repair it if necessary Nuts Bolts Fasteners C...

Page 54: ...ny dirt vegetation or any other debris that could cause fire hazards or interfere with the proper operation of your BUGGY and remove them Air Cleaner Housing Drain Tube Check for carbon deposits in the drain tube if necessary clean the tube and check the air cleaner housing Leaks Loose Parts Walk around your BUGGY and look for anything that appears unusual such as oil leak or a loose cable repair ...

Page 55: ...re the engine and exhaust pipes are cooled down 3 To avoid possibility of explosion always connect battery cable in the order specified 4 Keep children away from the servicing area to avoid touching engine oil grease and fuel 5 Park the buggy on a flat ground shift the gear to neutral position 6 All flammable items or movement must be away from the engine to avoid accident The running engine may c...

Page 56: ...maintenance Period Cleaning Every 1 month or 1500 kilometers Replacement of filter Every 3 months or 3000 kilometers 1 Open the cover take out the paper filter for cleaning 2 Replace the paper filter if it is too dirty to clean Note The performance of engine will decrease if the air cleaner is dirty Service more often when running under dusty sandy and muddy conditions Paper filter ...

Page 57: ...ngine is cooled If the temperature does not drop when the fan blade is running then stop the engine for cooling When the engine is cooled check the level of coolant If the coolant level is low check whether there is leakage at the water tank rubber tube or water pump If leakage is discovered do not run the engine anymore and call for repair services The heating gas coming out from the engine could...

Page 58: ...age and check the compression at the mating surface 1 4 Check the engine oil and add some if necessary z Don t clean the element with gasoline or solvent of low flash point The oil level should be between the upper index line and the lower index line of the gauge z Remove the dust in the air cleaner element replace the element if there is too much dust or any damp z Don t dip the element in water ...

Page 59: ...ove the oil drain bolt below the engine 2 8 Drain out all the engine oil Note When draining the oil the engine should be at room temperature which can ensure the quick and complete draining 3 100 Hour Maintenance 3 1 Finish the 50 hour maintenance 3 2 Remove the cylinder cover and cylinder body and clean out the carbon on the cylinder cover cylinder body piston top and in ex valve etc 3 3 Clean th...

Page 60: ...rankcase and replace oil 4 3 Check if there is any leakage on the oil seals replace the oil seals if necessary 5 300 Hour Maintenance 5 1 Finish 150 hour maintenance 5 2 Check if the parts of the clutch and the transmission are normal adjust or replace the parts if necessary 500 Hour Maintenance 6 1 Finish 300 hour maintenance Disassemble the engine except the crankshaft connecting rod check the p...

Page 61: ...he oil in the crankcase to insure the proper lubrication of internal parts and to prevent costly repairs due to excessive wear Steps to replace oil 1 Place the vehicle in a level position 2 Remove the filler plug located on the rear side of engine 3 Drain the oil into a suitable container 4 Refill the crankcase with specified oil Use the same grade of oil as used originally Engine oil drain ...

Page 62: ...er replacement period shall be shorter 1 Journey is mostly below 2000 km 2 The engine is operated under cold weather when outside temperature falls below the freezing point at this point of time the journey is below 2000 km 3 The engine is continually run at idle speed or low speed For example frequent on off of engine 4 The vehicle runs in dusty area 5 The engine is always being turned On and Off...

Page 63: ...ch or diluted with too much water or replaced by methanol or ethanol or other liquid otherwise its anti freezing and anti sepsis function will be affected However under extreme cold weather less water will be used Replacement of coolant 1 Open the container cap 2 Take out the bottle Pour away old coolant and add in new coolant to the level of upper marking The Thickness of Coolant Glycol content W...

Page 64: ...Call physician immediately Drink large quantity of water or milk E TRANSMISSION BELT Proper adjustment of belt will ensure normal functioning of motor Under normal circumstances deviation of 10 mm up or down is allowed when the middle of belt is gently pressed with the thumb If the belt is cracked or worn out replacement must be made Do not run the engine while checking the belt otherwise it may c...

Page 65: ...ning replacement 1 Clear the dust from the spark plug seat with a brush 2 Disconnect the high voltage cable 3 Remove the spark plug with a spark plug wrench 4 Carbon can be cleared by using a small brush or rasp off by using a small file 5 Check the spark plug gap area between the electrodes with a wire feeler gauge This standard gap is 0 7 0 9 mm 6 If the spark plug is worn out change a new one M...

Page 66: ...inder head cover Do not screw the spark plug too tight Standard torque 25 N m or use force otherwise the screw thread will be damaged 9 Put the high voltage cable back to its original position 10 Slowly turn the airscrew anticlockwise observe the RPM of the engine and stop the adjusting as the RPM reaches the top speed 11 Adjust the screw and adjust the idle speed to an ideal value 12 Repeat the s...

Page 67: ...n level with the faucet of the housing e Do not pull the high voltage cable directly you should pull it together with the sleeve f Do not use unknown brand spark plug g The spark plug or engine body could be hot observe safety measure to avoid getting your hands burnt G FUSE Fuse Box There are two fuse boxes in each buggy One is located at the left bottom corner of the control panel the other is i...

Page 68: ...oving the fuse box cover take out the fuse and check its surface b Replace it if it is melted or broken NOTE a Make sure the same specification standard of fuse is used Otherwise it will damage the entire electrical system or cause fire b Do not replace fuse with other type of wire coil or material ...

Page 69: ...res On road tires Off road tires Tire size 25 x 8 12 25 x 8 12 25 x 10 12 2 5 x 10 12 Full load 230 Kpa 23 psi 230 Kpa 23 psi 230 Kpa 23 psi 230 Kpa 23 psi 240 Kpa 24 psi The above figures are measured under normal air temperature If the tires are hot the pressure reading will slightly go up but it is within acceptable range and needs no adjustment to the tire pressure If winter tire is used each ...

Page 70: ...e turn on the flickering lamp 2 Turn off the engine and remove the key from the vehicle 3 Shift the gear to 1st or reverse position 4 Get all the passengers off the vehicle 5 Slightly lift the wheel up by using a jack 6 Remove the 4 lock bolts and lock nuts from the rim 7 Remove the old wheel and replace with a new wheel 8 Fasten the 4 lock bolts and lock nuts 9 Check tire pressure with precise ti...

Page 71: ...on bad terrain will cause air leak or other latent problem c When traveling on rugged road drive the vehicle slowly and in an appropriate angle d During parking do not let tires rest on accidented road surface e Pressure check should be conducted bi monthly or before every long distance trip BATTERY Free maintenance battery is installed at the rear of the vehicle Read the instructions carefully on...

Page 72: ... and have water available should electrolyte come in contact with skin or eyes KEEP ALL CHILDREN AWAY FROM THE AREA WHILE THIS PROCEDURE IS BEING PERFORMED z POISON CAUSES SEVERE BURNS Contains sulfuric acid Avoid contact with skin eyes or clothing TO prevent accidents rinse empty container with water z ANTIDOTE External flush with water Internal call physician immediately Drink large quantities o...

Page 73: ...tery is now sealed 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 NEVER REMOVE THE STRIP OF CAPS NOR ADD ANY WATER OR ELECTROLYTE z DO NOT smoke around batteries and keep away from open flame z Do not use fast charging unless it is an emergency z At...

Page 74: ...shipment and inland delivery might take more than six weeks thus the consumer is advised to charge the batter again before operating the vehicle Battery Replacement Observe following steps if replacement is necessary 1 Remove the screws left and right from the ends of tie rod below the battery and then lift up the tie rod from the battery mount Battery assembly Nappe nut to fix battery Nappe nut t...

Page 75: ...ery and replace it with new battery 4 Put dielectric grease on the battery terminals to avoid corrosion 5 Connect cables to the proper terminals positive cable to positive terminal and negative cable to negative terminal Note Positive cable is red and larger in diameter Negative y cable is black and smaller of the two in diameter CONNECT NEGATIVE CABLE LAST 6 Torque terminal bolts to 40 in lbs 7 P...

Page 76: ...s c Dispose the old battery to a safe area to protect the environment z To avoid possibility of explosion always connect battery cable in the order specified RED first BLACK last An exploding battery can cause serious injury or death z Batteries contain sulfuric acid z Always shield eyes with protective eyewear when working around battery acid z Battery acid is poisonous and can cause severe burns...

Page 77: ...k 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 affect the engine performance NOTE In very cold weather engine oil runs in the wrong direction and stays on one side of en...

Page 78: ...iding conditions Riding in unusually dusty areas requires more frequent services Interval Items 1st Service in 1st Week Daily Monthly Quarterly Yearly Air cleaner X X C R R Spark plug X C A R R Carburetor A A A C Gearbox oil X X R R Engine oil X X R R R Tire pressure wear X X X X R Brake pad X X X R R Drive chain CAL CAL CAL CAL CAL Brake cable A A A A Chassis X X X X ...

Page 79: ...Interval Items 1st Service in 1st Week Daily Monthly Quarterly Yearly Fuel switch 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 ...

Page 80: ...gth 2960mm Overall Width 1690mm Overall Height 1450mm Wheelbase 2320mm Ground Clearance 285mm VIN Start with L4V Statutory Plate Safety Labels According to standard ENGINE Model DZ465MYG Type Water cooled 4 cylinder 4 stroke Displacement 988CC Bore Stroke 65 5mm 78mm Max Power 38 5kw 5200rpm Max Torque 83N m 3000rpm ...

Page 81: ...oled Ignition Spark Ignition ECM Control Starting starting motor Spark Plug D7 1st Forward Gear Transmission Ratio 3 818 2nd Forward Gear Transmission Ratio 2 210 3rd Forward Gear Transmission Ratio 1 423 4th Forward Gear Transmission Ratio 1 033 5th Forward Gear Transmission Ratio 0 844 Backward Gear Transmission Ratio 3 583 Compression Ratio 9 1 Clutch Dry multi plate friction Non automatic Air ...

Page 82: ... Gap 0 05 0 02mm CAPACITIES Fuel Tank 30 L Engine Oil 3L Acceleration 15s Climbing 20 Top Speed 120 km h Turning Radius 9 8m Noise Level 80dB A Battery 12V 36Ah Fuse 15 A 10A 10A CHASSIS Brake System Front and Rear disk foot control Front Suspension Independent Dual A arm Rear Suspension Independent Dual A arm ...

Page 83: ...eat buggy Owner s Manual Version 3 0 Dec 2006 83 Front Tire 25 8 12 Rear Tire 25 10 12 TIRE PRESSURE Front 230kpa 230kpa Rear 230kpa 230kpa WEIGHT Net Weight 500kg THE SPECIFICATIONS ARE SUBJUET TO CHANGE WITHOUT NOTICE ...

Page 84: ...FICATION 1 You may identify your buggy by the Vehicle Identification Number VIN which is embossed on the frame behind the passenger seat This VIN number will be used in the communication with the dealer or manufacturer 2 The engine number is embossed under the vice driver seat VIN ...

Page 85: ...RE 1100cc Double seat buggy Owner s Manual Version 3 0 Dec 2006 85 BUGGY WIRING DIAGRAM ...

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