Dazon Raider mini 90S Service Manual Download Page 3 | Manualshive

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Raider Mini 90 (single/double-seat): Service Manual Version

：

2.0 Feb. 2006

3

CONTENTS

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

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Summary of Contents for Raider mini 90S

Page 1: ......

Page 2: ...s 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...

Page 3: ...NTS 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 STA...

Page 4: ...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 pub...

Page 5: ...06 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...

Page 6: ...que 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 40S...

Page 7: ...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 abo...

Page 8: ...ble 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...

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: ...ch 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 Maint...

Page 11: ...e 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 Adjus...

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...

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...

Page 14: ...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 ca...

Page 15: ...djust 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 th...

Page 16: ...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...

Page 17: ...rd 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...

Page 18: ...ve 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 Cabl...

Page 19: ...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...

Page 20: ...ms 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 engi...

Page 21: ...MBUSTION 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...

Page 22: ...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...

Page 23: ...t 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 M...

Page 24: ...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 c...

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...

Page 26: ...ves 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 corre...

Page 27: ...ing 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 ou...

Page 28: ...E 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...

Page 29: ...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 I...

Page 30: ...arburetor 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 severa...

Page 31: ...ct 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 floa...

Page 32: ...ent 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...

Page 33: ...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...

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: ...n 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...

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...

Page 38: ...se 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 Di...

Page 39: ...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 zPOI...

Page 40: ...iner 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 o...

Page 41: ...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...

Page 42: ...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 wate...

Page 43: ...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 Secur...

Page 44: ...ox 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 condi...

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 ban...

Page 46: ...e 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 el...

Page 47: ...tized 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 couple...

Page 48: ...tall 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...

Page 49: ...lower 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 Instal...

Page 50: ...nical 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...

Page 51: ...e 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 o...

Page 52: ...le 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 sh...

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...

Page 54: ...ase 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 recomme...

Page 55: ...ng 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 Ch...

Page 56: ...or 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 cl...

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 engin...

Page 58: ...rect 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...

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 ov...

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

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