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Dazon Raider Pro 250 S Service Manual

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  • Page 2 Raider Pro 250 (single-seat / double-seat): Service Manual EEC Version: 1.0 Oct.. 2004 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.

  • Page 3: Table Of Contents

    Raider Pro 250 (single-seat / double-seat): Service Manual EEC Version: 1.0 Oct.. 2004 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.

  • Page 4: General Information

    Raider Pro 250 (single-seat / double-seat): Service Manual EEC Version: 1.0 Oct.. 2004 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.
  • Page 5 Raider Pro 250 (single-seat / double-seat): Service Manual EEC Version: 1.0 Oct.. 2004 Wheelbase 1700mm Ground Clearance 250mm 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...
  • Page 6 Raider Pro 250 (single-seat / double-seat): Service Manual EEC Version: 1.0 Oct.. 2004 Climbing ≥20% Top speed 70kmph Tachometer 33-40kmph Turning Radius 6m / 5m Acceleration Noise Level ≤80dB (A) Horn 12V 3A 105dB, 93<db (A) <112 Headlight 12V 35W/35W Headlight High Beam Intensity regulations/law-oriented Taillight...
  • Page 7 Raider Pro 250 (single-seat / double-seat): Service Manual EEC Version: 1.0 Oct.. 2004 1.5 Location of Parts Double-seat...
  • Page 8 Raider Pro 250 (single-seat / double-seat): Service Manual EEC Version: 1.0 Oct.. 2004 Single-seat * Please demand for a copy of the Parts Book from your dealer and locate each component location.

  • Page 9: Periodic Maintenance And Tune-Up Procedures

    Raider Pro 250 (single-seat / double-seat): Service Manual EEC Version: 1.0 Oct.. 2004 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. Time of Service Initial Service Monthly Quarterly Yearly...
  • Page 10 Raider Pro 250 (single-seat / double-seat): Service Manual EEC Version: 1.0 Oct.. 2004 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.
  • Page 11 Raider Pro 250 (single-seat / double-seat): Service Manual EEC Version: 1.0 Oct.. 2004 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 Bolt Diameter Conventionally Marked Bolt...
  • Page 12 Raider Pro 250 (single-seat / double-seat): Service Manual EEC Version: 1.0 Oct.. 2004 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.

  • Page 13: Engine

    Raider Pro 250 (single-seat / double-seat): Service Manual EEC Version: 1.0 Oct.. 2004 3. ENGINE 3.1 Lubrication System 3.1.1 Lubrication Diagram...
  • Page 14 Raider Pro 250 (single-seat / double-seat): Service Manual EEC Version: 1.0 Oct.. 2004 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.

  • Page 15: Cylinder Head & Valve

    Raider Pro 250 (single-seat / double-seat): Service Manual EEC Version: 1.0 Oct.. 2004 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;...

  • Page 16: Drive Pulley, Clutch & Driven Pulley

    Raider Pro 250 (single-seat / double-seat): Service Manual EEC Version: 1.0 Oct.. 2004 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.

  • Page 17: Gearbox

    Raider Pro 250 (single-seat / double-seat): Service Manual EEC Version: 1.0 Oct.. 2004 3.4 Gearbox 3.4.1 Disassembly Diagram...
  • Page 18 Raider Pro 250 (single-seat / double-seat): Service Manual EEC Version: 1.0 Oct.. 2004 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.

  • Page 19: Ac Generator & Starting Clutch

    Raider Pro 250 (single-seat / double-seat): Service Manual EEC Version: 1.0 Oct.. 2004 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;...

  • Page 20: Crankcase & Crankshaft

    Raider Pro 250 (single-seat / double-seat): Service Manual EEC Version: 1.0 Oct.. 2004 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.

  • Page 21: Cooling System

    Raider Pro 250 (single-seat / double-seat): Service Manual EEC Version: 1.0 Oct.. 2004 3.7 Cooling System 3.7.1 Disassembly Diagram 3.7.2 Trouble Shooting The water temperature rises. a. The heat sensor of the thermometer is faulty; b. The water tank cover is faulty; c.
  • Page 22 Raider Pro 250 (single-seat / double-seat): Service Manual EEC Version: 1.0 Oct.. 2004 f. The radiator is clogged; g. The inner part of the water tank is clogged; h. The water pump is faulty. The thermometer doesn’t show any signs of rising, but the water temperature rises. a.
  • Page 23 Raider Pro 250 (single-seat / double-seat): Service Manual EEC Version: 1.0 Oct.. 2004 Inspection of Water Tank Fluid Level a. Check the water tank fluid level; b. .If the fluid level is lower than “F” (the upper limit), add the specified water tank fluid (standard concentration: 30%) up to “F”...
  • Page 24 Raider Pro 250 (single-seat / double-seat): Service Manual EEC Version: 1.0 Oct.. 2004 c. Replace the impeller water seal together with the water seal washer if necessary; d. Assemble the water pump shaft and the inner bearing into the right crankcase;...
  • Page 25 Raider Pro 250 (single-seat / double-seat): Service Manual EEC Version: 1.0 Oct.. 2004 b. Raise the water temperature slowly; c. Measure the temperature of the opening valve. Valve Specifications: Temperature of Opening Valve 72+/- 2 ℃ Temperature of Full-opening Valve 90℃...

  • Page 26: Carburetor

    Raider Pro 250 (single-seat / double-seat): Service Manual EEC Version: 1.0 Oct.. 2004 3.8 Carburetor 3.8.1 Disassembly Diagram 3.8.2 Trouble Shooting The engine can’t start well. a. There is no fuel in the fuel tank; b. The fuel tube is clogged; c.
  • Page 27 Raider Pro 250 (single-seat / double-seat): Service Manual EEC Version: 1.0 Oct.. 2004 b. The gas mixture in the carburetor is too dense; c. The gas mixture in the carburetor is too lean. d. The air cleaner is clogged; e. Some air has been inhaled into the air suction system; f.
  • Page 28 Raider Pro 250 (single-seat / double-seat): Service Manual EEC Version: 1.0 Oct.. 2004 3.8.5 Automatic Fuel Cup No smokes or fires! Inspection of Automatic Fuel Cup a. Stop the engine and pull out the fuel tube from the carburetor; b Drain out all the remaining fuel in the fuel cup and tube (5-10cc); c.
  • Page 29 Raider Pro 250 (single-seat / double-seat): Service Manual EEC Version: 1.0 Oct.. 2004 d. Turn the fuel adjusting screw left and right slightly; e. Repeat steps c, d; f. Adjust the throttle adjusting screw to the idle speed position (1,500+/-100rpm); g.
  • Page 30 Raider Pro 250 (single-seat / double-seat): Service Manual EEC Version: 1.0 Oct.. 2004 3.8.11 Inspection of Spark Plug a. Check if the spark plug is burnt or has become dirty. Check if there is any carbon on the spark plug; b.

  • Page 31: Wiring Diagram

    Raider Pro 250 (single-seat / double-seat): Service Manual EEC Version: 1.0 Oct.. 2004 4. Wiring Diagram...

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