Dazon Raider Pro 250 S User manual

Raider Pro 250 (single-seat / double-seat): Service Manual EEC Version: 1.0 Oct.. 2004
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FOREWORD
This service manual has been specially prepared to provide all the necessary information for the
proper maintenance and repair of the RAIDER PRO 250 (EEC-approved for on-road use).
The Buggy fits the needs of a wide variety of buggy users above 16 years old. Those who will service
this Buggy should carefully review 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 distributor.
Distributors reverse the right to make production changes at any time, without prior notice or
incurring any obligation to make the same or similar changes for the vehicles previously built or sold.

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

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1. General Information
1.1 Model Identification
1.1.1 Frame Number
The frame number or VIN is stamped under the seat on the vehicle frame and is stuck behind the
seat.
1.1.2Engine Number
The engine number is located on the upper right rear 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 for the first 5 hours.
Never hold the engine at full throttle for long periods of time.
1.4 Specifications
DIMENSIONS SINGLE-SEAT / DOUBLE-SEAT
Overall Length 2250mm / 2270mm
Overall Width 1360mm / 1610mm
Overall Height 1550mm / 1533mm

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Wheelbase 1700mm
Ground Clearance 250mm
VIN accord with GMVR A01-01
Statutory Plate & Safety Labels accord with GB 7258-1997
ENGINE
Model PMI172MM
Type Forced Water-cooled, Single Cylinder, 4-stroke
Engine Capacity 250cc
Displacement 244.3ml
Bore×Stroke 72mm×60mm
Max. Power 12.5kw or 6500rpm
Max. Torque 17.6N.m or 6000 rpm
Idle Speed 1500±100rpm
COEmission 7.0g/km
HCEmission 1.5g/km
Fuel Type SAE 90# or Above (Unleaded)
Min. Fuel Consumption 354g/KW.h
Lubricate Oil Type SAE 10W / 30SF
Lubrication Pressure&Splash
Cooling Fluid Anti-corrosive, Anti-freeze
Cooling Water-cooled, Electric
Ignition C.D.I.
Starting Electric
SparkPlug D7
SparkPlugGap 0.6-0.7mm
Transmission ChainTransmission
Transmission Ratio F 1:1, B 1:1.758
Primary Transmission Ratio 2.2-0.9
CompressionRatio 10.0：1
Reduction Ratio 6.6
Clutch Automatic, Centrifugal, Dry, Shoe Type
Generator OuterRotor,Flywheel
Carburetor Vacuum Film Type
Absorber Normal(in10
6X104times of experiments)
Air Cleaner Paper Element, Filtration Type
Gear-Shifting Automatic, Centrifugal
CAPACITIES
Front/Rear Tire Load Coefficient 77
Front/RearTireSpeedLevel M
Fuel Tank 9.5L, 130kpa (no leakage in experiments)
StartingTime ≤15s

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Climbing ≥20%
Top speed 70kmph
Tachometer 33-40kmph
TurningRadius 6m / 5m
Acceleration Noise Level ≤80dB (A)
Horn 12V 3A 105dB, 93<db (A) <112
Headlight 12V35W/35W
Headlight High Beam Intensity regulations/law-oriented
Taillight 12V 5W /21W
TurningLight 12V10W
LicenseLight 12V5W
Battery 12V9A
Anti-theftLock ≥200N.m
Rearview Mirror accord with EEC standards
CHASSIS
Front/RearBrake HydraulicDisc,FootControl
FrontWheelBrakeForce ≥923N / ≥1258N
RearWheelBrakeForce ≥1288N / ≥1488N
BrakingDistance ≤7 m@30kmph
ParkingBrake HydraulicDisc,HandControl
FrontTire 20.5X8.0 –10
RearTire 20.5X8.0 –10
TIRE PRESSURE
Front 175kpa
Rear 200kpa
WEIGHT
Net Weight 295kg / 320kg
* The specifications are subject to change without prior notice.

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1.5 Location of Parts
Double-seat

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Single-seat
* Please demand for a copy of the Parts Book from your dealer and locate each component location.

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2. Periodic Maintenance and Tune-up Procedures
2.1 Periodical Checks and Services
The maintenance intervals in the following table are based upon average riding conditions.
Riding in unusually dusty areas requires more frequent services.
TimeofService
Items
Initial Service
(First Week)
Monthly Quarterly Yearly
Tire Pressure/Wear I I
Brake Performance I I
Bolt Tightness 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
Replacement Of Gearbox Oil I R
Chassis C, I L
Fuel Switch/Fuel Tank C
Chassis I I
Engine Oil R
Valve Clearance Of Engine A
Notes: A: Adjust; C: clean; I: inspect, clean or replace if necessary; L: lubricate; R: replace.
2.2 Maintenance and Tune-up Procedures
This section describes the servicing procedures of every item in the Periodic Maintenance
Intervals Table above.
2.2.1 Spark Plug
Clear up the carbon around the spark plug to prevent it from
dripping into the cylinder when removing the spark plug.
Removing steps:
In general, it should be carried out after the engine has become
cold.
a. If the spark plug is too tight to remove, spray some rust inhibiter
on the spark plug washer and the thread part; after the inhibiter has

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soaked the washer and thread part, rotate the spark plug;
b. Clear up the filth and carbon accumulation on the spark plug with a steel brush or a blade;
c. Inspect the spark plug gap (in general it should be about 0.6 - 0.7 mm.);
d. If the carbon accumulation or the wear of the spark plug is too serious, replace the spark plug
with a new one of the same specification.
2.2.2 Tire Pressure / Wear
Check the tire pressure before each of your driving.
The tire pressure is very important for the riding stability.
Specifications: Front Tire: 175kpa
Rear Tire: 200kpa
2.2.3 Brake Performance
a. Always check if there is plenty of brake fluid in the brake fluid
reservoir;
b. Check if the front/rear brake pad is in good condition;
c. Check the brake rotor for abnormal wear.
2.2.4 Air Cleaner
Clean the air cleaner quarterly, or more often when driving in dusty conditions.
If the air cleaner is clogged with dust, its performance will be
severely decreased, even the engine damages will probably be
caused.
Inspection and Cleaning of Filters
 PaperFilter
a. Remove the filter from its housing;
b. Lightly tap the filter on an object to knock out the dust;
c. Replace the filter element if it is wrinkled or torn.
 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 back into the air box.
1. Before and during the cleaning, inspect the element for tears; replace it if it’s torn.
2. Make sure that the element is seated properly and no foreign material can pass by it

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2.2.5 Nuts and Bolts in Chassis
Inspect the nuts and bolts in the chassis during the first week and every month thereafter.
The nuts and bolts become loose normally after use, please check for the looseness regularly.
2.2.5 Tightening Torque Table
2.2.6 Fuel Switch (Petcock)
 Fuel Switch Service
a. Periodically clean the petcock outside with the grease remover and water;
b. Check for any leak or seeping fuel;
c. Replace the petcock if there is any leakage.
 Fuel Valve Lever
On this vehicle, there is a manually-operated fuel valve lever with three positions:
a. “ON” position: It’s the normal operating position where the fuel flows into
the carburetor;
b. “RES” position: If the fuel lever is in the “ON” position and it is too low
for the engine to operate, turn the fuel lever to the “RES” position to use
the reserved fuel supply, and refuel as soon as possible;
c. "OFF" position: It’s the closing position. When the vehicle is not in use, always make sure that the petcock is in
the "OFF" position
2.2.7 Final Gear Oil
Inspect the final gear oil monthly and replace it quarterly.
a. Check the oil level: remove the oil level screw on the left rear engine case;
b. Drain out the oil: remove the drain plug at the rear bottom of the engine case;
Recommendation: before draining the final gear oil, please warm the engine
for at least 10 minutes.
Conventionally Marked Bolt 8.8 Marked BoltBolt 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 79.5-115.5
16 80-130 8.0-13.0 58.0-94.0 170-250 17.0-25.0 123.0-181.0
18 130-190 13.0-19.0 94.0-137.5 200-280 20.0-28.0 144.5-202.5

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Notes: We recommend the Mobile 85w/90 gear oil for the final drive case. However, in extreme cold
weather conditions, the vehicle may become hard to start, so we advise some lighter viscous oil, such
as 75 wt or the equivalent motorcycle transmission fluid.
2.2.8 Engine Oil
Inspect the engine oil before every riding and replace it monthly.
a. Remove the drain plug from the left side bottom of the engine, and drain
out the left oil into an oil pan for disposal;
b. Remove the large cap on the left bottom of the engine ,and remove the
screen;
c. Wash the screen with some cleaning solvent and reassemble it; make sure that the O-ring is still in
good conditions;
d. Refill the engine with the SAE10W/30SF engine oil and run the engine for 5 minutes;
e. Check the oil level on the filler cap stick to assure that it’s proper;
f. Screw back the large cap.
2.2.9 Chassis
Inspect, 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 can
operate smoothly 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.
Gear Oil Capacity 0.2L 85w/90

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3. ENGINE
3.1 Lubrication System
3.1.1 Lubrication Diagram

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3.1.2 Trouble Shooting
 The engine oil level is too low.
a. The engine oil has been consumed naturally;
b. The engine oil has leaked;
c. The piston rings are worn.
 The engine oil is dirty.
a. The engine oil hasn’t been replaced in time;
b. The cylinder head gasket is damaged.
 The lubrication isn’t good.
a. The engine oil level is too low;
b. The oil filter or oil pipe is clogged;
c. The oil pump is damaged.
3.1.3 Specifications
Engine Oil Capacity 1.0L (Disassembling) 0.8L (Replacing)
Engine Oil Type SAE 10W/30SF
3.1.4 Engine Oil Services
 Engine Oil Level Inspection
a. Stop the engine;
b. Stay the vehicle on the flat ground for 2-3 minutes;
c. Inspect the engine oil level.
Notes: The engine oil level gauge shouldn’t be screwed in.
 Engine Oil Replacement
a. Remove the engine oil filler cover;
Drain out the engine oil when the engine is warm;
Reassemble the filler cover (Torque: 18-20 N.m.);
b. Check if the O-rings are damaged; replace them if necessary;
c. Fill in the new engine oil;
Engine oil capacity: 1.0 L (Disassembling)
0.8L (Replacing)
Engine oil type: SAE 10W/30SF
d. Start the engine to check if there is any leakage;.
Stop the engine and check the oil level again.
 Engine Oil Screen Replacement
a. Drain out the engine oil, and take out the filter cap and spring;
b.. Replace the engine oil screen;
c. Reassemble the spring and filter cap;
d. Add the specified engine oil into the engine;
e. Recheck the engine oil level.

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3.2 Cylinder Head & Valve
3.2.1 Disassembly Diagram
3.2.2 Trouble Shooting
 The compression is too low or not stable.
a. Valve
The lifter hasn’t been adjusted well;
The valve is burnt or deformed;
The valve spring is damaged;
The valve timing is faulty;
The valve seat seal is faulty.
b. Cylinder Head
The cylinder head gasket leaks air;
The cylinder head is deformed or cracked.
c. Cylinder Piston is faulty.
 The compression is too high.
a. There is a carbon accumulation on the piston or in the combustion chamber.
 Noise
a. The lifter hasn’t been adjusted well;
b. The valve is burnt, or the valve spring is damaged or worn;
c. The rocker or the rocker shaft is damaged or worn.

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3.3 Drive Pulley, Clutch & Driven Pulley
3.3.1 Disassembly Diagram
3.3.2 Inspection and Service
 Drive Belt
a. Check if the drive belt is cracked;
Check if there is abnormal worn;
b. Measure the width of the drive belt;
Service limit: replace if below 17.5 mm.
 Clutch.
a. Check if the clutch cover is worn or damaged;
b. Measure the inner diameter of the clutch cover;
Service limit: replace if above 130.5 mm.;
c. Check if the clutch shoes are worn or damaged;
d. Measure the thickness of the clutch shoes;
Service limit: replace if below 2.0 mm.
 Drive Spring
a. Check the free length of the drive spring;
Service limit: replace if below 83.2 mm.

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3.4 Gearbox
3.4.1 Disassembly Diagram

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3.4.2 Inspection and Replacement of Gearbox Oil
 Inspection of Gearbox Oil level
a. Stay the vehicle on the flat ground;
b. Stop the engine and remove the oil level bolt;
c. Inspect the gearbox oil level;
If the oil level parallels with the oil level bolt hole, it’s normal.
 Replacement of Gearbox Oil
a. Replace the gearbox oil with the specified type;
Gearbox Oil Capacity: 0.2 L
Specified Gearbox Oil: Mobil 85w/90
Gearbox Oil Level Bolt Torque: 14-18 N.m
b. Check if there is any oil leakage after running the engine;
Check the oil level again;
c. Check if the gearbox oil seal is damaged, and replace it if
necessary.
3.4.2 Trouble Shooting
 The engine can be started, but the vehicle can’t run.
a. The gears are damaged;
b. The gears are burnt.
 Noise
a .The gears are worn or burnt ,or the gear surface is damaged;
b. The bearing is worn or shaking.
 Oil Leakage
a. There is too much oil in the gearbox;
b. The oil seal is damaged or worn.

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3.5 AC Generator & Starter Clutch
3.5.1 Disassembly Diagram
3.5.2 Trouble Shooting
 The AC generator is faulty;
 The starter reduction gear is faulty;
 The starter motor revolves conversely;
 The wires haven’t been connected well;
 The starter clutch spring is broken, dirty or locked.

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3.6 Crankcase & Crankshaft
3.6.1 Disassembly Diagram
3.6.2 Trouble Shooting
 Engine Noise
a. The bearing is loose;
b. The crankshaft pin bearing is loose.
c. The piston pin and the piston pin hole are loose.