Dazon Raider Classic 250 Owner'S Manual Download

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Summary of Contents for Raider Classic 250

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Page 2: ...manship under the following terms and conditions This warranty covers the engine and engine related components for a period of 90 days from the date of purchase This warranty does not apply to any parts that in the seller s opinion were defective because of improper maintenance improper assembly alterations abuse negligence usage of non genuine parts or accidents Should warranty service be require...

Page 3: ...st properly 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 genui...

Page 4: ...ny way so as to adversely affect its safety or reliability c Competition or racing The warranty does not cover any losses of the seller vehicle use any losses of time any inconveniences or any other consequential damages which include but are not limited to the losses or damages to any persons property or expenses of returning damaged units to the vehicle distributor or any DAZON authorized dealer...

Page 5: ...s made to the vehicle to increase performance 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 ...

Page 6: ... 10 4 Safety Labels 15 5 Are You Ready to Drive 16 6 Is Your Vehicle Ready to Drive 20 7 Safe Driving Precautions 21 8 Identify Components 22 9 Add Oil Before Driving 45 10 Pre Drive Instruction 49 11 Operation Instruction 51 12 Battery 58 13 Maintenance Service Instruction 69 14 Storage Instruction 90 15 Periodic Check Service 91 16 Specification 92 17 Buggy identification 98 ...

Page 7: ... follow the warnings contained in this manual could lead to personal injuries or damages to the unit 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 of it and wear protective gear at all time when drivin...

Page 8: ... information on the labels and in this manual All these information alerts you to the potential hazards that could hurt you or others It isn t practical or possible to warn you against all the hazards associated with operating or maintaining your 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 vehicle Saf...

Page 9: ...to your Buggy and possible subsequent personal injuries or death could result from the failure to take proper precautions described within the CAUTION labels Safety Headings such as Important Safety Reminders or Important Safety Precautions Safety Sections such as Buggy Safety Instructions how to use your Buggy correctly and safely This entire manual is filled with important safety information ple...

Page 10: ...r Buggy You ll find many helpful recommendations throughout this manual The following are a few of the most important ones Follow the Age Recommendation It is strongly recommended that no one under age of 16 be permitted to drive this Buggy 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 alw...

Page 11: ...s will prevent injuries to your wrists arms fingers etc Follow the photos below when using the wrist straps Drive Off Road Only Your BUGGY is designed and manufactured for off road use only The tires are not made for pavements and your BUGGY doesn t have the turn signals or any other features required for use on public roads If You need to cross a pave or public road please get off and walk your B...

Page 12: ... the Buggy Safety Institute Check with your dealer for more information on the training course Be Alert to Hazards The terrain can present a variety of challenges when you drive Continually read the terrain for unexpected turns drop offs rocks ruts and any other hazards Always keep your speed low enough to allow time for seeing and reacting to hazards Drive within Your Limits Pushing limits is ano...

Page 13: ...ther Avoid Operating at Night Nighttime driving conditions can greatly reduce your visibility and judgments Driving at night is hazardous and can increase the possibility of accidents Never Run Indoors or in an Enclosed Area The exhaust from the engine contains the carbon monoxide a poisonous tasteless and odorless gas that may be lethal Keep away from Moving Parts You should never place your hand...

Page 14: ...ce mud and loose gravel If you skid or slide on ice you may lose all directional controls To avoid skidding or sliding on slippery terrain surfaces you should keep your speed low and drive carefully Age recommendation It is strongly recommended that no one under the age of 18 be permitted to operate this BUGGY A child driving this BUGGY that is not recommended to his her age could lose BUGGY contr...

Page 15: ...at Owner s Manual EEC Version 2 0 Feb 2007 15 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 16: ... your Buggy for the first time we urge you to Carefully read this owner s manual and the labels on your vehicle Make sure that you understand all the safety messages Learn how to operate all the controls on your vehicle Ask for adult supervision if you are under 16 years old 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 a...

Page 17: ... protective apparel 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 h...

Page 18: ...ve 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 an approved motorcycle helmet eye protection gear or a...

Page 19: ...ur doctor for the assurance that it is safe to operate your vehicle after taking some kind of medication z Operating this BUGGY without proper instructions could increase your risks of accidents that could lead to serious injuries 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 percepti...

Page 20: ...ion and slightly 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 vehicle has overturned or has been involved in a collision please don t drive it until your dealer has inspected it There may be damages or other problems you ...

Page 21: ...ission to 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 ...

Page 22: ...r hands 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 shif...

Page 23: ...h Terrain Before driving in a new area always check the terrain thoroughly Don t drive fast on unfamiliar terrain or when the visibility is limited Sometimes 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 ...

Page 24: ... especially careful and always be alert to changing terrain conditions z Failure to use your extra care when operating on excessively rough slippery 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 yo...

Page 25: ...50 double seat Owner s Manual EEC Version 2 0 Feb 2007 25 IDENTIFY COMPONENTS Seat Belt Brush Guard Bar Control Panel Turning Light Seat Headlight Front Shock Absorber Front Wheel Rear Wheel Front Wheel Steering Wheel ...

Page 26: ...sic 250 double seat Owner s Manual EEC Version 2 0 Feb 2007 26 Water Tank Rear Shock Absorber Sub Water Tank Trailer Hook Support Fan Engine Rear Reflector Rear Mudguard Rear Wheel Rear Rack Taillight Air Cleaner ...

Page 27: ...tely familiar with the location and use of each control that is necessary to operate your Buggy You must know how to stop your vehicle before starting and driving Headlamp H L beam Switch Tachometer Turning Indicator Coolant Temperature Gauge Fog Lamp Switch Head Lamp Switch Horn Switch Engine Stop Switch Turning Lamp Switch Flickering Lampswitch Key Switch ...

Page 28: ...ur horn whenever necessary z Engine Stop Switch In case your vehicle comes across some emergency in traveling and you need to stop the engine immediately you can use this switch z Key Switch Insert the key into the key switch turn the key clockwise and release the key when the engine starts The engine will warm up within few minutes and the engine choke will close automatically and operate at norm...

Page 29: ...our vehicle speed As the engine speed is above idle the Brake Pedal clutch automatically engages and moves the vehicle forward To disengage the clutch at any time allow the throttle to return to the idle position BRAKE The brake pedal is located on the left side of the vehicle Applying pressure to the pedal can draw the brake calipers around the brake cylinders one at the rear wheel two at the fro...

Page 30: ...ly when stepped on and rebound to the idle speed position when released z Do not drive if the pedal fails to return to the idle speed position as a result of throttle leakage If problems can not be solved by adding lubricant and by adjusting or replacing worn parts you can turn to our dealers for help z When the brake is applied don t step on the throttle pedal too hard otherwise the clutch will g...

Page 31: ...d immediately TURNING SIGNAL LAMPS Available on On road buggy only 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 signal lamp 5 watts LICENSE PLATE LAMP Available on On road buggy only It is available as an optional item at a surcharge for Off road model The license plate lamp can be opened by removing the...

Page 32: ... brake light the other is normal light Make sure both lights are in working condition before you drive the vehicle in the night Capacity of tail lamp 5 watts PASSENGERS SEATS The vehicle allows for two riders only for the double seat unit the combined maximum weight of the driver and passenger for the double seat unit should not exceed 180kg or 400lbs Seat Adjuster Locating screw ...

Page 33: ...lide 2 Move the seat forward or backward to the desired position 3 Be sure that the seat adjustment handle snaps back into place and that the seat is locked into position The seat upright angle is fixed it cannot be adjusted NOTE 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 ...

Page 34: ...UST put on safety belt provided on each seat Inspect and test the safety belt before you drive the BUGGY 1 Check and make sure the terminals of the safety belt are firmly affixed on the 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 ...

Page 35: ...e with the right hand Never let safety belt touch the chassis it might be pulled away by the tree branches during speeding in the forest 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 Note After adjusting the seat belt tie up t...

Page 36: ... portion will hit the ground and obstruct the moving of the vehicle 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 AUTOMATIC CARBURETOR The throttle and negative engine pressure adjust the fuel quantity Automatic ...

Page 37: ... bore opens automatically to let in large quantities of fuel for starting After starting the pre heated electric enrichment device automatically closes the idle speed bore GASOLINE FUEL TANK The gasoline fuel tank is located at the rear carrier above the engine The fuelling mouth is on top the fuel tank There is a short rubber tube attached to the fuel tank cap for letting out the heat inside the ...

Page 38: ... petrol is allowed The quality of petrol will affect the functioning and life of engine The engine will burn if the petrol octane rating is too low Recommended grade Unleaded 95 Do not use leaded petrol otherwise it will damage the Engine Fuel pipe petcock There is a fuel pipe petcock below the fuel tank Make sure the fuel valve lever is always at OFF position when the vehicle is not in used WHEEL...

Page 39: ...r wheels are having different sizes Note Special sand tire is to be used if the buggy is to run on desert for long hours Type of vehicle Wheel position Tire Rim Front wheel 20 5 x 8 10 or 21x7 10 10 6 ON ROAD Rear wheel 20 5 x 10 10 or 20x11 10 or 22x11 10 10 8 Front wheel 21x7 10 10 6 OFF ROAD Rear wheel 22x11 10 10 8 RADIATOR WATER TANK a The radiator is situated behind the seat head rest It is ...

Page 40: ...ng system is using closed cooling forced circulation system which mainly consists of radiator sub water tank water pump heat sensor switch water holes fan blade and fan motor c The double valves inside the radiator cap give the effect of closed cooling box system Cooling fan Fan motor Radiator ...

Page 41: ...ze into radiator i Remove radiator cap ii Pinch the rubber pipe to expel air bubble meanwhile fill in antifreeze up to the top of the rubber pipe iii Fasten radiator cap Radiator cap z Don t open the radiator cap when the engine temperature is high Otherwise the spilling of hot water may cause injuries Cap valve ...

Page 42: ...h 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 3 Close and tighten the container cap The Thickness of Coo...

Page 43: ...ion box which is connected to the engine is installed on the chassis and behind the brake lever It consists of forward neutral and reverse gear only BRAKE LEVER The front rear wheel of the buggy comes with diagonal intercrossing braking system Both front and rear wheels are installed with brake disk If any one of them fails to function the other will perform as the brake What you need to do is to ...

Page 44: ...the required minimum level or the two pistons connecting to the brake oil pump are defective the brake system will be affected REAR CARRIER RACK It is installed between the engine and radiator for putting traveling bag Limited loadage 10kg or 22lbs NOTE NEVER EXCEEDS LIMIT OTHERWISE THE VEHICLE WILL BECOME OVERWEIGHED AT THE REAR AND CAUSE OVER TURN Brake fluid tank Rear Rack ...

Page 45: ...he 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 Oil replacement interval period Volume Normal condition Every 1000 km or 3 months Bad condition Every 800 km or 2 months 0 25 L or 0 07 gallon Grade of oil DOT 3 Clean up all the dirt on the oil pump cap before adding brake oil...

Page 46: ...n 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 SAE85W 95 Below regular replacement shall be observed Oil replacement interval period Volume of oil Every 3 months or 1000 km 621 miles 0 18 L or 0 05 gal Never make oil replacement before the gearbox is cooled down For environment p...

Page 47: ...will be much slower 3 Take out the oil dip stick 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 ...

Page 48: ...ew 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 in order to distribute the engine ...

Page 49: ...ake pedal adjust the brake pedal if necessary Make sure there is no brake fluid leakage d Tires Check the tire conditions and pressures e Drive Chain Check for the chain conditions and tension lubricate it if necessary f Throttle Check for the smooth operation assure that the throttle snaps back to the idle position g Engine Stop Button Perform the engine stop button test repair it if necessary h ...

Page 50: ... Lights Check the headlights taillights rear license lights and turning lights etc for proper work n Horn Make sure that the horn works properly o Cooling System Make sure that the cooling system works properly after the engine has been started Preparation before Starting the Engine 1 Check the engine fasteners before starting 2 Fill in the fuel lubrication oil and anticorrosive antifreeze as spec...

Page 51: ...e check 1 Check the engine oil level add oil if required check for oil leaks 2 Turn the key to ON position ensure the 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 gear shift condition ensure the shift gear is ...

Page 52: ...ignition switch while the engine is already running to prevent damaging the starter motor 3 Do not repeatedly turn on ignition switch if the engine fails to have quick start Wait for 10 seconds before second try On the second try turn ignition switch with the throttle pedal slightly depressed 4 In cold weather warm up the engine for several minutes at idle speed before driving the buggy Then speed...

Page 53: ...h it After starting the engine shift the gearshift lever from neutral to forward position and ready to move the vehicle If you want to reverse the vehicle shift the gearshift lever from neutral to reverse position Never move the gear shift lever to reverse gear when the buggy is running otherwise the engine and transmission will be damaged Reduce speed before change to reverse gear Forward Reverse...

Page 54: ...is very high when turning at high speed During turning you should slow down to a more controllable speed to prevent your BUGGY from rolling over Keep your heel on the floorboard for proper pedal control any attempt to turn sharply at high speed is dangerous because the tires can easily catch an edge which can result in a rollover D STOPPING ENGINE 1 Release the throttle 2 Turn off the engine for a...

Page 55: ...l or on rough roads for a long time 4 Keep the oil lines smooth 5 Avoid speeding up suddenly or running the engine at a high speed without loading 6 Maintain your vehicle according to the service intervals and if necessary repair it as soon as possible 7 After the running in period clean the crankcase and replace the oil remove the carbon on the top of the piston and in the combustion chamber adju...

Page 56: ... to drive Note 1 Brake effect will decrease when the brake mechanism get over heated Thus not to continuously depress the brake pedal 2 If the brake mechanism gets wet the brake effect will be affected Test the brake system after vehicle washing or going through a pool of water by slightly depress on the brake pedal 3 Maintain certain distance behind the front vehicle so that you have enough time ...

Page 57: ... shift the gear to reverse position 4 When the Buggy is to be parked on a slope with the vehicle facing uphill shift the gear to forward position 5 Turn the ignition key to OFF position then pull out the key 6 Before you walk away make sure the vehicle is not in a movable condition Never park the vehicle near the flammable object Brake must be on when the vehicle is not in use Park the vehicle on ...

Page 58: ... battery is required if the vehicle is received within 6 weeks after the ex factory date what you need to do is to pour electrolyte into the battery If you feel the battery is weak you may check its voltage with a multi meter If the reading exceeds 9V it is normal If the reading falls below 9V service is required Read the instructions carefully on all the labels and follow the practice accordingly...

Page 59: ...P 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 of water or milk Follow with milk of magnesia beaten eggs or vegetable Eyes Flush w...

Page 60: ...ate electrolyte pack Most battery s will come with the electrolyte already sealed into the battery 2 1 Place battery on level surface Remove sealing tape from top 2 2 Take the electrolyte container out of the plastic bag 2 3 Place electrolyte container upside down with the sealed silver mouths of the electrolyte bottles in line with the six filler holes of the battery ...

Page 61: ...il electrolyte is completely drained Note Never leave children unattended around battery 2 7 If air bubbles cease to float to the top of the electrolyte bottles tap lightly on top Note DO NOT remove container from battery while it is draining Never cut or pierce electrolyte container 2 8 After all the electrolyte has drained from the bottles into the battery pull plastic electrolyte bottles gently...

Page 62: ... charging This allows the electrolyte to penetrate plates for optimum performance and ensures longer battery life 2 11 After 30 minutes the battery is ready for its initial charge place cap strip loosely over the filling holes as shown in the picture 3 Initial Charge 3 1 Connect the red positive cable to the red positive pole of the battery ...

Page 63: ...ttery Note The red positive cable has a larger diameter than the black negative y cable 3 3 Charging rate Charge battery 0 7 Amps for 5 10 hours 3 4 After charging is complete press down firmly with both hands to seat the caps and the battery is now sealed Note Do not pound or hammer NEVER REMOVE THE STRIP OF CAPS NOR ADD ANY WATER OR ELECTROLYTE ...

Page 64: ...ble seat Owner s Manual EEC Version 2 0 Feb 2007 64 3 5 Install battery into battery tray making sure that the rubber mat is in place Note The warning label on the battery should be facing the warning label on the gray tray ...

Page 65: ...ersion 2 0 Feb 2007 65 3 6 Once battery is firmly seated in gray tray with rubber mat under it attach the red positive wire to the red positive terminal on the battery 3 7 Then attach the black negative wire to the black negative terminal on the battery ...

Page 66: ...cure the battery with the wide black rubber strap using the hooks on both ends z DO NOT open sealed caps to add water to battery z Always wear safety glasses and charge the battery in a ventilated area z If battery gets hot discontinue charging and allow battery to cool down z Do not use fast charging unless it is an emergency z DO NOT smoke around batteries and keep away from open flame ...

Page 67: ...1 Remove old battery Mark which cable is connected to the positive terminal and which cable is connected to the negative terminal 4 2 Clean cable connectors with wire brush or sandpaper to remove oxidation 4 3 After charging install new battery put dielectric grease on the battery terminals to avoid corrosion 4 4 Connect cables to the proper terminals positive cable to positive terminal and negati...

Page 68: ... strap 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 z DO NOT smoke around batteries and keep away from open flame ...

Page 69: ...e sure 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 m...

Page 70: ...cement of filter Every 3 months or 1500 kilometers 932 miles a Remove the air cleaner cover b Remove the air cleaner element c Fill the non flammable cleaning agent into a basin and dip the element in it d Dry it after cleaning and dip it into the engine oil specified by the manufacture then dry it again Note The performance of engine will decrease if the air cleaner is dirty Service more often wh...

Page 71: ... the proper engine performance If possible check the spark plug gap area between the electrodes with a wire feeler gauge This specification is 0 6 0 8 mm b Before installing the spark plug coat the threads lightly with the graphite grease if possible to ensure easy removal next time when the spark plug needs inspection c It is advisable to replace the spark plug at least once a year to ensure easy...

Page 72: ...eter before the adjustment a Warm up the engine for about 5 10 minutes b Tighten the airscrew gently and back out 2 3 8 turns anticlockwise c Connect the tachometer and adjust the throttle to limit the idle speed the standard value is 1500 100 RPM d Slowly turn the airscrew anticlockwise observe the RPM of the engine and stop the adjusting as the RPM reaches the top speed e Adjust the screw and ad...

Page 73: ...ontrols and wipe off any spilled fuel and oil Keep the engine clean of foreign objects and be sure that the water tank fan is free of debris for proper cooling E VEHICLE LUBRICATION Lubricate your vehicle every 90 days of use Apply several drops of oil in the specific points F CHAIN LUBRICATION Fill a spray atomizer with the specified chain lubrication and lubricate the chain Chain ...

Page 74: ... chain adjustment after the first two hours of use and readjust the chain if it has over 1 2 flex a Loosen Nut 1 b Turn Nut 2 clockwise in 1 2 turn increments then turn nut 1 until it is tightened c Repeat the two steps a b until the chain is adjusted to the desired tension Drive Nut 1 Nut 2 Drive Chain ...

Page 75: ... ABSOBER ADJUSTMENT There are five adjustable positions on each shock The default position is in the middle set by the manufacturer Use a round nut wrench as you adjust the shock The tension of the shock spring will increase as you screw to the left and decrease as you screw to the right ...

Page 76: ...ssary to loosen the nuts so that the wheels turn freely on the axle with minimum endplay Tighten the nuts after replacing the wheels 2 Rear Wheel Replacement Don t disassemble the castle nuts M8 when replacing the rear wheels It is only necessary to loosen the nuts so that the wheels turn freely on the axle with minimum endplay Tighten the nuts M5 and put on the cotter pins after replacing the whe...

Page 77: ...s Off road tires On road tires Off road tires Tire size 21 x7 10 21 x7 10 21 x 11 10 22 x 11 11 Full load 175 Kpa 17 5 psi 175 Kpa 17 5 psi 175 Kpa 17 5 psi 175 Kpa 17 5 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 ea...

Page 78: ...by the manufacturer because its dimension and technical specification must match the technical specification of carburetor muffler air filter and gear transmission otherwise engine vibration oil leaking engine under powered strange noise disturbance with other portion of the frame body will happen B Engine serial number Each engine is embossed with a serial number on the side cover 4 3 Serial Numb...

Page 79: ...0 Feb 2007 79 C Engine components 1 Aeration pipe of gear case 2 Cylinder head 3 Spark plug D8RTC 4 Cylinder head cover 5 Carburetor 6 Cylinder body 7 Left case cover 8 Special bolt subassembly 1 7 6 11 8 Figure I Outline of the engine Left view 1 7 4 5 3 2 6 8 ...

Page 80: ...0 Feb 2007 80 9 Secondary wire 10 Right case body 11 Air input hole of carburetor 12 Temperature sensor 13 Water inflow rubber pipe Water hose B 14 Starting motor 15 Magneto winding 15 14 13 12 10 9 Figure II Outline of the engine front view 15 14 13 12 10 9 11 ...

Page 81: ...16 Linking hole of vent pipe 17 Chain regulator 18 Left case body 19 Output axle 20 Dipstick 21 Oil filter gauge cover 22 Right case cover 23 Water pump cover 24 Fuel pipe 25 Aeration pipe cylinder head cover 24 Figure III Engine outline right view 19 18 17 22 23 21 20 16 25 ...

Page 82: ...il the engine 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 engi...

Page 83: ... plug located on the rear side of engine remove the drain plug tip the vehicle backwards slightly by blocking up the front end drain the oil into a suitable container 2 Place the vehicle in a level position replace the filler plug and tighten it securely 3 Refill the crankcase with the same grade of engine oil approximately 1 1 4 pint originally used 4 Check the oil level before each drive add the...

Page 84: ...he surface b Check all the exterior fasteners at the joints and fasten or replace them if necessary c Check for the oil leakage and check the compression at the mating surface d Check the engine oil and add some if necessary Note The oil level should be between the upper index line and the lower index line of the gauge Lowe Index Upper Index Line ...

Page 85: ...ote Don t dip the element in water or oil Don t apply any lubrication oil or any other oil on the element Otherwise it may cause damages to the transmission belt c Remove the carbon on the spark plug d Clean the crankcase and replace the oil e Clean the transmission box and replace the gear oil z Remove the cap z Remove the filling bolt z Remove the drain bolt z Don t clean the element with gasoli...

Page 86: ...ature to achieve quick and complete draining f Check the cooling devices z Check for leakage on the water tank and water pipe z Check if the water level in the subsidiary water tank is between the upper limit and lower limit z If water level is low open the cap and add some water until the water level reaches the upper limit ...

Page 87: ...uring the cleaning to clean the main bearing and connecting rod big end needle bearing d Check if the fixed screw of the generator stator is loose e Keep the connectors and electric parts dry and clean 4 150 Hour Maintenance a Finish 100 hour maintenance b Clean the crankcase and replace oil c Check if there is any leakage on the oil seals replace the oil seals if necessary 5 300 Hour Maintenance ...

Page 88: ...L After running the new engine for the first 5 hours and for every 10 hours thereafter change the oil in the crankcase to insure 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 the engine 3 Remove the drain plug 4 Drain the oil into a suitable c...

Page 89: ...period and oil filter replacement period shall be shorter 1 Journey is mostly below 2000 km 2 The engine is to run under cold weather and outside temperature falls below the freezing point at this point of time the journey is below 2000 km 3 The engine is continually running at idle speed or low speed For example when engine is always being turned On and Off many times 4 The vehicle runs in dusty ...

Page 90: ...rk 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 e...

Page 91: ...eas requires more frequent services Items First week Monthly Quarterly Yearly Tire pressure wear Brake performance Tightness of screws I I Air cleaner C C I Carburetor I A C Spark plug C A Drive chain I I C A L Brake fluid I Replace gearbox oil I R Chassis C I L Fuel switch fuel tank C Battery I I Engine oil R Valve clearance of engine A Note A adjust C clean I inspect clean or replace if necessar...

Page 92: ...450 mm 4 76ft Off road Overall Height 1630 mm 5 35 ft On road 1475mm 4 84ft Off road Wheelbase 1560 mm 5 12 ft Ground Clearance 250 mm 0 82 ft VIN L4VMB1FF Statutory Plate Safety Labels Accord with GB 7258 1997 ENGINE Model PMI172MM Type Water cooled single cylinder 4 stroke Engine Capacity 244cc Displacement 244 3 ml Bore Stroke 72 mm 60 mm or 0 24 ft X 0 20 ft Standard Power 11 5kw 7000 rpm or 1...

Page 93: ...r above unleaded Min Fuel Consumption 354 g kw h Fuel consumption rate Approximately 87 ml per second Lubricate Oil Type SAE 15W 40SF winter 10W 30SF Summer Lubrication Pressure splash Cooling Fluid SHELL Antifreeze Antifreeze Temperature of Cooling Fluid 450 C Mixing Ratio Cooling Fluid Water 1 1 Cooling Water cooled electric fan Ignition C D I Starting Electric Spark Plug D8RTC Spark Plug Gap 0 ...

Page 94: ...o 10 1 Reduction Ratio 6 6 Clutch Automatic centrifugal dry shoe type Generator Outer rotor flywheel Carburetor Vacuum Film Type Absorber Normal in 10 6 X104 times of experiments Air Cleaner Paper element filtration type Gear Shifting Automatic centrifugal Engine Net Weight 31 5 kg or 69 5 lbs Brake Oil Model DOT 3 Noise grade 80Db A CAPACITIES Fuel Tank 9 0 0 1L 130 kpa Starting Time 15s ...

Page 95: ...0kph Turning Radius 3 m or 9 85 ft Acceleration 16 Sec Horn 12V 3A 105dB 93 db A 112 Headlight 12V 35W Headlight High Beam Intensity 10000 cd Taillight 12V 5W 21W Turning Light 12V 10W License Light 12V 5W Battery 12V 8Ah Fuse 12A Anti theft Lock 200N m Rearview Mirror Accord with EEC standards Cooling fluid capacity 2L ...

Page 96: ... 1288N Braking Distance 7 m 30kmph Parking Brake Hydraulic disc hand control Front Tire 20 5x8 10 On road 21 X 7 10 Off road Rear Tire 20 5 10 10 On road 22 X11 10 Off road Max Load of Rear Cargo Rack 20 kg or 44 lbs Anti theft Lock 200N m TIRE PRESSURE Front 175 kpa Rear 200 kpa WEIGHT Net Weight 328 kg or 723 lbs z The specifications are subject to change without prior notice ...

Page 97: ...bolts 8 8 Marked bolts 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 70 100 7 0 10 0 50 5 72 5 14 50 80 5 0 8 0 36 5 58 0 110 160 11 0 16 0 79...

Page 98: ...tification Number VIN which is embossed on the frame behind the passenger seat This VIN number will be used in communication with the dealer import custom office service centre forwarder or manufacturer 2 Supplier Label A piece of metal plate showing the date of production name of supplier is affixed at the front chassis For On road model only VIN ...

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