Dazon Raider Max 175S Service Manual
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Dazon Raider Max 175S Service Manual

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

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Summary of Contents for Dazon Raider Max 175S

  • Page 1 File No.:SF-E175-WX-B01-D...
  • Page 2 Raider Max 175 (single-seat, double-seat): Service Manual EEC Version:2.0 April 2005 FOREWORD This service manual has been specially prepared to provide all the necessary information for the proper maintenance and repair of the RAIDER Max 175 (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 Max 175 (single-seat, double-seat): Service Manual EEC Version:2.0 April 2005 CONTENTS 1. General Information ------------------------------------------------------------------------4 2. Periodic 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 &...

  • Page 4: General Information

    Raider Max 175 (single-seat, double-seat): Service Manual EEC Version:2.0 April 2005 General Information 1.1 Model Identification 1.1.1 Frame Number The frame number or VIN is stamped under the seat on the frame and stuck behind the seat. 1.1.2 Engine Number The engine number is located on the upper rear right engine case.

  • Page 5: Specifications

    Raider Max 175 (single-seat, double-seat): Service Manual EEC Version:2.0 April 2005 1.4 Specifications DIMENSIONS SINGLE-SEAT/ DOUBLE-SEAT Overall Length 2330mm / 2300mm Overall Width 1310mm / 1460mm Overall Height 1425mm / 1425mm Wheelbase 1475mm / 1520mm Ground Clearance 200mm / 250mm Accord with GMVR A01-01 Statutory Plate&...
  • Page 6 Raider Max 175 (single-seat, double-seat): Service Manual EEC Version:2.0 April 2005 Gear-Shifting Automatic, centrifugal CAPACITIES Front/Rear Tire Load Coefficient Front/Rear Tire Speed Level Fuel Tank 7.0L, 130kpa (no leakage in experiments) Starting Time ¡ Ü 15s Climbing ¡ Ý 20% Top speed 63km/h Tachometer...

  • Page 7: Periodic Maintenance And Tune-Up Procedures

    Raider Max 175 (single-seat, double-seat): Service Manual EEC Version:2.0 April 2005 2. Periodic Maintenance and Tune –up Procedures 2.1 Location of Parts Double-seat Awning Roll Bar Seat Control Panel Rearview Mirror Seat Belt Steering Wheel Headlight Front Mudguard Front Turning Wheel Light Front...
  • Page 8 Raider Max 175 (single-seat, double-seat): Service Manual EEC Version:2.0 April 2005 Single-seat Steering Wheel Control Panel Seat Roll Bar Rear Rack Rearview Mirror Seat Belt Headlight Rear Shock Absorber Turning Light Rear Wheel Front Wheel Front Throttle Pedal Shock Absorber Please demand for a copy of the Parts Book from your dealer and locate each component location.
  • Page 9 Note: X: inspect, clean or replace if necessary; C: clean; A: adjust; L: lubricate; R: replace. Attention: In order to keep the 6-month warranty valid, please find an approved DAZON dealer to carry out the 1 service and quarterly service;...
  • Page 10 Raider Max 175 (single-seat, double-seat): Service Manual EEC Version:2.0 April 2005 2.3 Maintenance and Tune-up Procedures This section describes the servicing procedures of every item in the Periodic Maintenance Intervals Table above. 2.3.1 Spark Plug Clear up the carbon around the spark plug to prevent it from dripping into the cylinder when removing the spark plug.
  • Page 11 Raider Max 175 (single-seat, double-seat): Service Manual EEC Version:2.0 April 2005 Inspection and Cleaning of Filters Paper Filter a) Remove the filter from its housing; 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;...
  • Page 12 Raider Max 175 (single-seat, double-seat): Service Manual EEC Version:2.0 April 2005 b) After expelling the gasoline remnant (about 5-10 ml) from the negative pressure switch and negative pressure tube, if the gasoline doesn’t flow, the switch is in good condition; otherwise, the negative pressure tube needs cleaning;...
  • Page 13 Raider Max 175 (single-seat, double-seat): Service Manual EEC Version:2.0 April 2005 Screw in the large cap. 2.3.10 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;...

  • Page 14: Engine

    Raider Max 175 (single-seat, double-seat): Service Manual EEC Version:2.0 April 2005 3. Engine 3.1 Lubrication System 3.1.1 Lubrication diagram 3.1.2 Trouble shooting The engine oil level is too low. a) The engine oil is consumed naturally; b) The engine oil leaks; c) The piston rings are worn.
  • Page 15 Raider Max 175 (single-seat, double-seat): Service Manual EEC Version:2.0 April 2005 3.1.4 Engine Oil Inspection a) Stop the engine; b) Stay the vehicle on the flat ground for 2-3 minutes; c) Inspect the oil level. Note: The oil level gauge shouldn’t be screwed in. Replacement a) Remove the oil filler cover, and drain out the oil remnant when the engine is warm;...

  • Page 16: Cylinder Head & Valve

    Raider Max 175 (single-seat, double-seat): Service Manual EEC Version:2.0 April 2005 3.2 Cylinder Head & Valve 3.2.1 Disassembly Diagram Timing Sprocket 2. Timing Chain 3. Tension Bar 4.Air Cleaner Bracket 5. Rocker Arm, Air Exhaust 6. Rocker Arm, Air Intake 7.Rocker Arm, Valve 8.Cam Shaft Comp.
  • Page 17 Raider Max 175 (single-seat, double-seat): Service Manual EEC Version:2.0 April 2005 3.2.2 Trouble Shooting The compression is too low or not stable. a) Valve The lifter isn’t adjusted well; The valve is burnt or deformed; The valve spring is damaged; The valve timing is faulty;...
  • Page 18 Raider Max 175 (single-seat, double-seat): Service Manual EEC Version:2.0 April 2005 c) Insert the rocker arm shaft with the mark “IN” into the hole on the left side of the cylinder head cover and the hole of the rocker arm; At the same time, insert the rocker arm shaft with the mark “EX”...
  • Page 19 Raider Max 175 (single-seat, double-seat): Service Manual EEC Version:2.0 April 2005 c) Turn fully outward the intake / exhaust valve dials until the dials can’t be turned any more; ward Valve Outward Dial Valve Dial d) Turn inward the intake / exhaust valve dials for Inward 1.5~ 2.0 scales (at this moment, the valve clearance should be 0.08mm~0.1mm);...

  • Page 20: Drive Pulley, Clutch & Driven Pulley

    Raider Max 175 (single-seat, double-seat): Service Manual EEC Version:2.0 April 2005 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)
  • Page 21 Raider Max 175 (single-seat, double-seat): Service Manual EEC Version:2.0 April 2005 3.3.2 Inspection of Drive Belt. a) Check if the belt is cracked and check if there is abnormal worn. b) Measure the width of the drive belt; Replace the belt if its width is below 17.5 mm 3.3.3 Inspection of Clutch.

  • Page 22: Final Transmission Box

    Raider Max 175 (single-seat, double-seat): Service Manual EEC Version:2.0 April 2005 3.4 Final Transmission Box 3.4.1 Disassembly Diagram 1.Crankcase, Left 2.Shock Absorber 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.
  • Page 23 Raider Max 175 (single-seat, double-seat): Service Manual EEC Version:2.0 April 2005 3.4.2 Final Transmission Box Oil Inspection of Gear Oil Level. a) Stay the vehicle on the flat ground; b) Stop the engine and remove the oil level bolt; c) It is normal if the oil level parallels with the bolthole. Replacement of Gear Oil.

  • Page 24: Ac Generator & Starting Clutch

    Raider Max 175 (single-seat, double-seat): Service Manual EEC Version:2.0 April 2005 3.5 AC Generator & Starting Clutch 3.5.1 Disassembly Diagram 1.Clutch,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.
  • Page 25 Raider Max 175 (single-seat, double-seat): Service Manual EEC Version:2.0 April 2005 3.5.2 Trouble Shooting 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: Crankcase & Crankshaft

    Raider Max 175 (single-seat, double-seat): Service Manual EEC Version:2.0 April 2005 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.
  • Page 27 Raider Max 175 (single-seat, double-seat): Service Manual EEC Version:2.0 April 2005 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 pinhole are loose.

  • Page 28: Cooling System

    Raider Max 175 (single-seat, double-seat): Service Manual EEC Version:2.0 April 2005 3.7 Cooling System 3.7.1 Disassembly Diagram 3.7.2 Specifications Pressure of Water Tank 0.9+/-0.15 Kg/Cm2 Cover Petcock Volume of Cooling Fluid About 1450cc Water Tank: 1100 Cc Subsidiary Water Tank: 350 Cc Notes: a) Use the specified water tank fluid.
  • Page 29 Raider Max 175 (single-seat, double-seat): Service Manual EEC Version:2.0 April 2005 3.7.3 Points for Attention The water pump repair and other operations of the cooling system can be carried out on the vehicle; Carry out the operations when the engine has cooled down; Don’t open the water tank cover when the water temperature is above 100¡...
  • Page 30 Raider Max 175 (single-seat, double-seat): Service Manual EEC Version:2.0 April 2005 seal; b) Disassemble the water pump impeller; Remove the water pump impeller; c) Check the water seal and the water seal washer for damages and wear; Replace the water seal together with the water seal washer if necessary;...
  • Page 31 Raider Max 175 (single-seat, double-seat): Service Manual EEC Version:2.0 April 2005 g) Assemble the impeller pin on the shaft. Torque: 10 N.m Note: Fasten the impeller with the left thread. h) Replace the water pump water seal; Take out the water seal from the inside of the right crankcase cover;...
  • Page 32 Raider Max 175 (single-seat, double-seat): Service Manual EEC Version:2.0 April 2005 Note: a) The heat adjuster shouldn’t touch the container directly. b) If the heat sensor opens at the normal temperature, replace with a new one. c) When the temperature adjuster has been open for 5 minutes, measure again at the temperature of 70¡...

  • Page 33: Carburetor

    Raider Max 175 (single-seat, double-seat): Service Manual EEC Version:2.0 April 2005 3.8 Carburetor 3.8.1 Disassembly Diagram Carburetor Hoses Positioning Picture 1. Picture 2. 1. Fuel Hose 7. Oil Drainage Screw; Carburetor 2. Breather Hose, Engine 8. Rubber Hose, Oil Drainage .
  • Page 34 Raider Max 175 (single-seat, double-seat): Service Manual EEC Version:2.0 April 2005 6. Thick Water Hose 3.8.2 Specifications Pipe Diameter 22mm Body Mark BS26-1245 Fuel Level 18.5+/-1.0mm Air Adjusting Screw 1 3/4 Main Jet Low Speed Jet # 35 Idle Speed 1500+/-100rpm 3.8.3 Points for Attention a) No smoke or fires in the working places.
  • Page 35 Raider Max 175 (single-seat, double-seat): Service Manual EEC Version:2.0 April 2005 b) Connect a tube with the fuel-adding line of the carburetor; Connect the yellow wire of the choke with the battery + electrode; Connect the green wire of the choke with the battery - electrode. Blow with mouth after 5 min.
  • Page 36 Raider Max 175 (single-seat, double-seat): Service Manual EEC Version:2.0 April 2005 b) Align the mark “F” within the range of +/-3º at the rotation of 1,700rpm. Ignition timing: B.T.D.C 13º+/-3 1700rpm. c) If the rotation is above 3,000rpm, the aligning mark should be located before the advanced ignition mark.
  • Page 37 Raider Max 175 (single-seat, double-seat): Service Manual EEC Version:2.0 April 2005 3.8.12 Trouble Shooting The engine can’t start well.
  • Page 38 Raider Max 175 (single-seat, double-seat): Service Manual EEC Version:2.0 April 2005...
  • Page 39 Raider Max 175 (single-seat, double-seat): Service Manual EEC Version:2.0 April 2005 The engine doesn’t run stably or smoothly at the idle speed. a) The idle speed hasn’t been adjusted well. b) The mixture gas in the carburetor is too rich. c) The mixture gas in the carburetor is too lean.
  • Page 40 Raider Max 175 (single-seat, double-seat): Service Manual EEC Version:2.0 April 2005 b. Clean the carburetor and readjust the idle speed according to the steps below: a) Open the connecting tube between the air cleaner and carburetor. Connecting Tube b) Spray a little carburetor cleanser into the carburetor.

  • Page 41: Reverse Gearbox

    Raider Max 175 (single-seat, double-seat): Service Manual EEC Version:2.0 April 2005 4.Reverse Gearbox 4.1 Check and Service a) Every time before driving, check if the forward gear and backward gear/reverse gear can work agilely and smoothly; b) For the safety of traveling, the vehicle must be in the parking state when the reverse gear is working.

  • Page 42: Troubleshooting

    Raider Max 175 (single-seat, double-seat): Service Manual EEC Version:2.0 April 2005 4.3.1 Removal Sequence Drive sprocket¡ ª Gearbox cover¡ ª I shaft¡ ª Center shaft¡ ª Lock bolt¡ ª Output shaft¡ ª Fork¡ ª Fork shaft¡ ª Output Gear 4.3.2 Assembly Sequence Reverse the removal sequence.

  • Page 43: Wiring Diagram

    Raider Max 175 (single-seat, double-seat): Service Manual EEC Version:2.0 April 2005 5. Wiring Diagram...

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