Dazon Raider Max 175D Service Manual Download Page 1

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File No.:SF-E175-WX-B01-D

Summary of Contents for Raider Max 175D

Page 1: ...File No SF E175 WX B01 D ...

Page 2: ...iew 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 distr...

Page 3: ...iodic Maintenance and Tune Up Procedures 7 3 Engine 14 3 1 Lubrication System 14 3 2 Cylinder Head Valve 16 3 3 Drive Pulley Clutch Driven Pulley 21 3 4 Final Transmission Box 22 3 5 Ac Generator Starting Clutch 24 3 6 Crankcase Crankshaft 26 3 7 Cooling System 28 3 8 Carburetor 31 4 Reverse Gearbox 41 5 Wiring Diagram 43 ...

Page 4: ...ated on the upper rear right 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 Vary the engine speed fo...

Page 5: ...r 6500 r m Idle Speed 1500 100 r m CO Emission 7 0g km HC Emission 1 0 g km Fuel Type SAE 90 or above unleaded Min Fuel Consumption 354g KW h Lubricate Oil Type SAE 15W 40SF Lubrication Pressure splash Cooling Fluid SHELL Antifreeze Antifreeze Temperature of Cooling Fluid 450 C Mixing Ratio Cooling Fluid Water 1 1 Cooling Water cooled Ignition C D I Starting Electric Spark Plug D7 Spark Plug Gap 0...

Page 6: ...05dB 93 dB A 112 Headlight 12V 35W 35W Headlight High Beam Intensity Accord with laws regulations Taillight 12V 5W 21W 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 760N 1140N Rear Wheel Brake Force 832N 1038N Braking Distance 7 m 30km h Park...

Page 7: ...nance and Tune up Procedures 2 1 Location of Parts Double seat Headlight Rearview Mirror Roll Bar Seat Belt Seat Steering Wheel Front Wheel Turning Light Front Mudguard Front Shock Absorber Awning Control Panel Brake Handle Reverse Handle Fan Rear Reflector Rear Wheel Taillight Rear Rack Turning light ...

Page 8: ...gle seat z Please demand for a copy of the Parts Book from your dealer and locate each component location Roll Bar Headlight Turning Light Front Wheel Seat Rear Rack Seat Belt Rear Wheel Front Shock Absorber Throttle Pedal Rear Shock Absorber Control Panel Rearview Mirror Steering Wheel ...

Page 9: ... R Carburetor A A A C Spark Plug X CA CA R Drive Chain CAL CAL CAL CAL CAL Gear Box Oil X X X R Engine Oil X X R R R Chassis X X X X Valve Clearance A A A A Reverse Cable A A A A Reverse Assy X Battery X X X R Cooling Water X X X X X Throttle Cable X X R Drive Belt X R R Driven Plate Sub Assy X X R Fuel Filter X C C R Note X inspect clean or replace if necessary C clean A adjust L lubricate R repl...

Page 10: ...n accumulation on the spark plug with a steel brush or a blade d Inspect the spark plug gap in general it should be about 0 6 0 7 mm e When the carbon accumulation and wear of the spark plug are too serious replace the spark plug with a new one of the same specification 2 3 2 Tire Pressure Wear Check the tire pressure before each of your driving The tire pressure is very important for the riding s...

Page 11: ...he looseness regularly 2 3 6 Tightening Torque Table Conventional Marked Bolt 8 8 Marked Bolt Bolt Diameter mm N m Kg m lb ft N m Kg m lb ft 4 1 2 0 1 0 2 0 7 1 5 1 5 3 0 15 0 3 1 0 2 0 5 1 4 0 2 0 4 1 5 3 0 3 6 0 3 0 6 2 0 4 5 6 4 7 0 4 0 7 3 0 5 0 8 12 0 8 1 2 6 0 8 5 8 10 16 1 0 1 6 7 0 11 5 18 28 1 8 2 8 13 0 20 0 10 22 35 2 2 3 5 16 0 25 5 40 60 4 0 6 0 29 0 43 5 12 35 55 3 5 5 5 25 5 40 0 70...

Page 12: ...rterly 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 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 become h...

Page 13: ...thly 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 3 11 Reverser Adjustment a Press down the reverse lever to the FW position so that the units can move forward Pull back the lever to BW so that the units can move backward b Adjusting Nut 1 on the top of the reverse cable can adjust the mesh status inside the revers...

Page 14: ...is consumed naturally b The engine oil leaks c The piston rings are worn z The engine oil is dirty a The engine oil isn t replaced in time b The cylinder head gasket is damaged z The lubrication isn t good a The engine oil level is too low b The oil filter is clogged or the oil pipes are clogged c The oil pump is damaged 3 1 3 Specifications Engine Oil Capacity 1 0L Disassembling 0 8L Replacing En...

Page 15: ...ain out the oil remnant when the engine is warm b Reassemble the cover Torque 18 20 N m c Check if the O rings are damaged replace if necessary d Fill in the same type of engine oil Engine oil capacity 1 0 L Disassembling 0 8L Replacing Engine oil type 10W 30SF e Start the engine to check if there is any oil leakage f Stop the engine and check the oil level again z Engine Oil Screen a Drain out th...

Page 16: ...t 5 Rocker Arm Air Exhaust 6 Rocker Arm Air Intake 7 Rocker Arm Valve 8 Cam Shaft Comp 9 Spark Plug 10 Exhaust Valve 11 Tensioner 12 Gasket Tensioner 13 Cylinder 14 Gasket Cylinder 15 Rubber Pipe Water Inlet 16 Intake Valve 17 Intake Pipe Comp 18 Thermostat Comp 19 Temperature Sensor 20 Rubber Pipe Water Return 21 Guide Bar 22 Valve Comp 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 13 ...

Page 17: ... c Cylinder piston is faulty z The compression is too high There is carbon accumulation on the piston or in the combustion chamber z Noise The lifter isn t adjusted well The valve is burnt or the valve spring is damaged or worn The rocker or the rocker shaft is damaged or worn 3 2 3 Assemble Valve Rocker Arms Shafts a Check if the seals on the valve rocker arm shafts are in good condition if damag...

Page 18: ...of the cylinder in the same way d Turn the dials of the two rocker arms to the position as shown in the picture Fasten the two dials 3 2 4 Adjust Valve Clearance a Open the engine peephole cap Adjust the flywheel T to the maximum reading while the engine piston reaches the top dead point b Loosen the lock bolts at the intake exhaust valve dials Hole on Left Side of Cylinder Hole on Right Side of C...

Page 19: ...d the intake exhaust valve dials until the dials can t be turned any more d Turn inward the intake exhaust valve dials for 1 5 2 0 scales at this moment the valve clearance should be 0 08mm 0 1mm e Fasten the lock bolts at the intake exhaust valve dials Inward Ex Valve Dial Outward In Valve Dial Outward ...

Page 20: ... Version 2 0 April 2005 20 3 3 Drive Pulley Clutch Driven Pulley 3 3 1 Disassembly Diagram 1 Crankecase Right 2 Driven Pulley Comp 3 Belt 4 Drive Pulley Comp 5 Gasket Left Crankcase 6 Crankcase Left 7 Special Screw Set 8 Shroud Left Crankcase Cover 5 1 2 3 4 ...

Page 21: ...elt if its width is below 17 5 mm 3 3 3 Inspection of Clutch Drive Surface a Check if the clutch cover is worn or damaged Measure the inner diameter Replace the clutch if its inner diameter is above 130 5 mm b Check if the clutch shoes are worn or damaged Measure the thickness Replace the clutch shoes if the thickness is below 2 0 mm c Check the free length of the drive spring Replace the spring i...

Page 22: ... Sleeve Rear 3 Bearing 6004LU 4 Oil Seal 27 42 7 5 Final Shaft 6 Gear Final Shaft 7 Washer 17 2 25 1 8 Bearing 6203 9 Needle Bearing NK 1412 9 Washer 14 5 28 1 11 Transmission Shaft Counter 12 Washer 14 5 32 1 13 Transmission Shaft Main 14 Oil Seal 20 32 6 15 Gearbox 16 Gasket Gearbox 17 Bearing 6204 18 Breather Pipe Gearbox 1 2 8 13 12 11 10 9 3 4 5 6 7 14 17 16 15 18 ...

Page 23: ...0 2 L Specified Gear Oil Mobil 85w 90 Oil Level Bolt Torque 14 18 N m a Check if there is any oil leakage after running the engine b Check the oil level again c Check if the oil seal is damaged Replace it if necessary 3 4 3 Trouble Shooting z The engine can be started but the vehicle can t run a The gears are damaged b The gears are burnt z There is noise when driving the vehicle a The gears are w...

Page 24: ...tch Starting 2 Reduction Gear Shaft Starting 3 Reduction Gear Starting 4 Magneto 5 Oil Level Dip Stick 6 Oil Pass Bolt A 7 Oil Pass Bolt B 8 Oil Pipe 9 Oil Pass Bolt C 10 Cap Oil Filter Screen 11 Spring Oil Filter Screen 12 Oil Filter Screen 13 Crankcase Cover Right 14 Gasket Right Crankcase Cover 15 Breather Pipe Right Crankcase Cover 1 2 3 15 4 5 ...

Page 25: ... EEC Version 2 0 April 2005 25 3 5 2 Trouble Shooting z The AC generator is faulty a The starter reduction gear is faulty b The starter motor revolves conversely c The wires haven t been connected well d The starter clutch spring is broken dirty or locked ...

Page 26: ...005 26 3 6 Crankcase Crankshaft 3 6 1 Disassembly Diagram 1 Shock Absorber Sleeve Front 2 Stud Bolt M8 172 3 Stud Bolt M8 162 4 Crankcase Right 5 Connecting Rod Crankshaft 6 Gasket Left Crankcase 7 Stud Bolt M8 162 8 Crankcase Left 9 Shock Absorber Sleeve Rear 1 3 4 2 5 6 7 9 8 ...

Page 27: ...single seat double seat Service Manual EEC Version 2 0 April 2005 27 3 6 2 Trouble Shooting z Engine noise a The bearing is loose b The crankshaft pin bearing is loose c The piston pin and the piston pinhole are loose ...

Page 28: ...y Diagram 3 7 2 Specifications Pressure of Water Tank Cover Petcock 0 9 0 15 Kg Cm2 Volume of Cooling Fluid About 1450cc Water Tank 1100 Cc Subsidiary Water Tank 350 Cc Notes a Use the specified water tank fluid b Don t mix the fluid of different brands together c The water tank fluid is poisonous please don t drink it ...

Page 29: ...he tester for about 6 seconds to check its stability Note Pressure for the opening and closing of the cover cock 0 9 0 15kg cm2 d Check the water pipe joints for leakage Note The test pressure shouldn t exceed 1 05kg cm2 otherwise the joints of the water tank may be damaged 3 7 5 Water Tank a Check the water tank fluid level b Use the specified water tank fluid standard concentration 30 Note the e...

Page 30: ...nd the water seal washer for damages and wear Replace the water seal together with the water seal washer if necessary d Assemble the water pump shaft and the inner bearing into the right crankcase Lock the bearing with the clip e Assemble the right crankcase cover f Assemble the water pump impeller Replace the water pump water seal together with the impeller water seal if necessary ...

Page 31: ... mating surface of the water seal and the right crankcase cover before assembly i Assemble water pump shaft Assemble a new outer bearing of the water pump shaft inside the right crankcase cover 3 7 7 Heat Sensor z Disassemble 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 z Inspection a Put the heat sensor into...

Page 32: ... b The water tank cover is faulty c The temperature petcock is faulty d The tank fluid is insufficient e The pump water pipe and water sleeve are clogged f The radiator of the water tank is clogged g The inner part of the water tank is clogged h The water pump is faulty z The water temperature rises but the thermometer doesn t show any signs of rising a The heat sensor of the thermometer is faulty...

Page 33: ...m Carburetor Hoses Positioning Picture 1 Picture 2 1 Fuel Hose 7 Oil Drainage Screw Carburetor 2 Breather Hose Engine 8 Rubber Hose Oil Drainage 3 Pressurized Hose connecting with Air Intake Hose 4 Three Way Hose and Clamp 5 Thin Water Hose connecting with Thermostat and Thin Water Inlet Hose of Water Tank 1 2 3 4 3 5 6 7 8 ...

Page 34: ...e fuel cup and tube 5 10cc has been drained out If the fuel continues to flow out the negative pressure tube is clogged c Pull the negative pressure tube from the air intake pipe and suck with mouth to produce negative pressure on the vacuum film If when the vacuum film produces negative pressure the fuel flows out of the fuel tube and when the negative pressure stops the fuel stops flowing then t...

Page 35: ...rming up the engine b Close the fuel adjusting screw fully turn back the standard 1 3 4 turning c Adjust the adjusting screw to the specified idle speed d Turn the adjusting screw left and right slightly e Repeat the steps 2 3 f Adjust the throttle adjusting screw to the idle speed position 1 500 100rpm g Run the engine from the low speed to high speed run the engine at the idle speed for 10 to 15...

Page 36: ...ug is burnt or dirty b Check if there is any carbon on the spark plug c Clean the spark plug if necessary Specifications Spark Plug D7 Spark Plug Gap 0 6 0 7mm 3 8 11 Inspection of Compression z Compression 11 0 15 0kg cm2 400rpm z 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 p...

Page 37: ...Raider Max 175 single seat double seat Service Manual EEC Version 2 0 April 2005 37 3 8 12 Trouble Shooting z The engine can t start well ...

Page 38: ...Raider Max 175 single seat double seat Service Manual EEC Version 2 0 April 2005 38 ...

Page 39: ...is too lean z The fuel jet is clogged z The air hole of the fuel tank cover is clogged z The fuel filter is clogged z The fuel tube is clogged z The float valve does not work well z The fuel level is too low z The mixture gas is too rich 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 isn...

Page 40: ...necting 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 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 Connecting Tube Spray Cleanser ...

Page 41: ... please don t shift gear when traveling at high speed d Service the reverse gear periodically Replace the lubricant every 5000km or 6 month of running Lubricant Lithium base grease Capacity 220ml 4 2 Precautions a Before servicing or maintaining remove the reverse gear from the vehicle frame b When assembling make sure to insert the pin into the splined tube grooves and meanwhile lock the bolt in ...

Page 42: ...lock bolt isn t locked in the positioning grooves of the fork shaft and the fork shaft is caused to fall off the gearbox d The needle bearing of the output gear is damaged e The return spring cannot rebound well f The circlip on the I shaft or input shaft has fallen off and the gear shaft is caused to move axially g The splined tube is damaged h The grooves of the output gear are damaged z Abnorma...

Page 43: ...Raider Max 175 single seat double seat Service Manual EEC Version 2 0 April 2005 43 5 Wiring Diagram ...

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