Dazon Raider mini 90S, Raider mini 90D, Buggy Raider mini 90S, Buggy Raider mini 90D Service Manual
Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006
FOREWORD
This service manual has been specially prepared to provide all the necessary
information for the proper maintenance and repair of the Raider Mini 90.
The Raider Mini 90 fits the needs of a wide variety of users. Those who will be
servicing this Raider Mini 90 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 the future, please contact us.
We reserve the right to make production changes at any time, without notice and
without incurring any obligation to make same or similar changes for vehicles
previously built or sold.
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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006
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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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006
1. INFORMATION
SAFETY
z Gasoline is extremely flammable and is explosive under certain conditions.
z Do not smoke or allow sparks of flames in your work area.
z Never run the engine in a closed area. The exhaust contains poisonous carbon
monoxide gas that may cause loss of consciousness and lead to death.
z The battery electrolyte contains sulfuric acid. Protect your eyes, skin 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 publication
are based on the latest product information available at the time of approval for
printing.
We reserve the right to make changes at any time without notice and without incurring
any obligation whatever.
No part of this publication may be reproduced without written permission.
1.3 SERIAL NUMBERS
z Frame Serial Number
The frame serial number is stamped under the seat on the frame cross member and
stuck behind the seat.
Frame serial number
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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006
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 lower front left side of the engine
crankcase.
Engine serial number
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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006
1.4 SPECIFICATIONS
DIMENSIONS SINGLE-SEAT / DOUBLE-SEAT
Overall Length 1550mm / 1550mm
Overall Width 1000mm / 1100mm
Overall Height 1200mm / 1200mm
Wheelbase 1100mm / 1100mm
Ground Clearance 100mm / 100mm
VIN Accord with GMVR A01-01
Statutory Plate & Safety Labels Accord with GB 7258-1997
ENGINE
Model DZIP47FMF
Type Air-cooled, single cylinder, 4-stroke
Engine Capacity 90cc
Displacement 85.8 ml
Bore×Stroke 47mm×49.5mm
Standard Power 3.8/7500 Kw/rpm
Max. Power 4.0 /8000 Kw/rpm
Max. Torque 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 / 40SF
Lubrication Pressure & splash
Cooling Air-cooled
Ignition C.D.I.
Starting Electric
Spark Plug A7RTC
Spark Plug Gap 0.6~0.7mm
Transmission OHC chain drive
1st Forward Gear Transmission Ratio 3.182
2nd Forward Gear Transmission Ratio 1.238
Backward Gear Transmission Ratio 2.583
Compression Ratio 8.8：1
Primary Reduction Ratio 3.416
Clutch Wet, multi-plate, friction (automatic)
Air Cleaner Filter sponge element
Gear-Shifting Four gears, hand control
Valve Gap 0.05±0.02mm
Engine Size (Length×Width×Height) 430mm×320mm×270mm
Engine Net Weight 20.5 kg
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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006
CAPACITIES
Fuel Tank 4.5L
Engine Oil 0.7~0.9L
Acceleration ≤15s
Climbing ＞180
Top Speed 25km/h
Turning Radius 1.7m
Noise Level ≤80dB
Battery 12V 8Ah
CHASSIS
Brake System Rear disk, foot control
Front Suspension Single A-arm 30 Travel
Rear Suspension Swing arm 30 Travel
Front Tire 145/70–6
Rear Tire 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 above.
Also we recommend you to use the unleaded gasoline.
z Engine Oil
Please use the high-quality engine oil of SAE 10w/40SF.
1.2.3 Gear oil
Please use 130# gear oil for reverser gear.
z 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.
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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006
1.6 PARTS LOCATION
Double-seat
Single-seat
Steering Wheel
Control Panel
Roll Bar
Seat
Safety Belt
Rear Rack
Rear Wheel
Throttle Pedal
Front Shock Absorber
Brake Pedal
Front Wheel
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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006
Rear View
Rear Rack
Fuel Tank Cap
Fuel Tank
Air Cleaner
Engine
Muffler
Chain
Reverse lever
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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006
LCAL
2. MAINTENANCE
2.1 MAINTENANCE SCHEDULE
The maintenance interval in the follow table is based upon average riding conditions.
Riding in unusually dusty areas requires more frequent servicing.
Interval
Items
Air cleaner X X C R R
Spark plug XC，AR R
Carburetor
Gearbox oil X X R R
Engine oil X X R R R
Tire pressure/wear XXXX R
Brake pad X X X R R
Drive chain CAL CAL CA
Brake cable A A A A
Chassis X X X X
Fuel switch/fuel tank XX X
Battery X X X R
Valve clearance of engine A A A
Throttle cable A A A A
Absorber X X X R
1st Service in
st
Wee k
1
AAA C
NOTE: X：inspect，clean or replace if necessary ; A: adjust;
C: clean; 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.
Remove the spark plug:
a) In general, it should be carried on after the engine has cooled down;
b) 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 soaked the washer and thread
part, rotate the spark plug;
Daily Monthly Quarterly Yearly
CAL
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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006
c) Clear up the filth and carbon
accumulation on the spark plug with a steel
brush or a blade;
d) Inspect the spark plug gap (in general, it should be
about 0.6 - 0.7 mm.);
e) When the carbon accumulation and wear of the
spark plug are 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: 28 Kpa
Rear Tire: 50 Kpa
Brake Rotor
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 Adjustment
a) If the brake cable is too loose, adjust the adjust nut
of the brake cable clockwise;
If the brake cable is too tight, adjust the adjust nut
of the brake cable counterclockwise;
If the adjustment doesn’t work, go on with the next
step;
b) Loosen the nut M6 at the adjust bolt of the brake
caliper;
If the brake cable is too loose, adjust the adjust bolt
clockwise;
If the brake cable is too tight, adjust the adjust bolt
counterclockwise;
Fasten the nut M6.
Adjust Bolt Nut M6
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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006
p
2.2.4 Air Cleaner
Clean the air cleaner quarterly, or more often when
Air Cleaner
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
Remove Air Cleaner Cover
z Paper Filter
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.
z Foam Filter
a) Remove the filter out of its steel cage;
b) Wash the filter in non-flammable cleaning
Air Cleaner
Cover
solvent;
c) Submerge the filter in oil and squeeze it to
remove excess oil;
d) Install the filter element back into the air box.
Air Cleaner
Element
Air Cleaner
Screen
z Before and during the cleaning, inspect the element for tears; replace it if
it’s torn.
z Make sure that the element is seated properly and no foreign material can
ass by it
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.
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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006
2.2.6 Tightening Torque Table
Bolt
Diameter
Conventional marked bolt 8.8 marked bolt
N•m Kg•m lb-ft N•m Kg•m lb-ft
(mm)
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
2.2.7 Fuel Switch (Petcock)
y 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.
z 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
2.2.8 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;
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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006
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/40SF 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.
2.2.10. A-arm Lubrication
Lubricate the left/right front A-arm periodically.
Left A-arm Grease Nipple
2.2.11 Chain Adjustment
a) Loosen the 4 bolts M8*16 on the rear wheel axle
holder, and lift up the engine support so as to raise
the rear wheel above the ground;
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Bolt M8*16
Rear Wheel Axle Holder
Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006
b) If the chain is too loose, adjust the left and right
rear wheel bearing holders counterclockwise at
the same time;
If the chain is too tight, adjust the left and right rear
wheel bearing holders clockwise at the same
time;
Bearing Holder
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 the chain;
Remove the chain;
b) Loosen the adjust nut on the brake cable;
Take out the brake cable;
Chain
Brake Cable Adjust Nut
c) Remove the cotter pin on the bracket of the
rake caliper;
Cotter Pin
Bracket
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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006
Castle Nut
d) Remove the cotter pin, castle nut, left rear tire,
right rear tire and rear wheel hub in order;
Rear Wheel Hub Cotter Pin
e) Loosen the 4 bolts on the left/right holder of
Bolt
Rear Wheel Axle Holder
the rear wheel axle;
Remove the left/right holder of the rear wheel
axle;
Remove the rear wheel axle together with the
brake caliper assy.;
f) Remove the lower right connecting bush, bearing
seat of the right rear wheel axle and bearing;
Remove the brake caliper bracket ;
Replace the brake shoe;
g) Assemble in the reversed order of removal.
Connecting Bush
Bearing Seat of
Rear Wheel Axle
2.2.13 Idle Speed Adjustment
If the rotate speed of the engine is not stable (either
too low or too high) after the engine has started,
adjust the idle speed adjust screw on the carburetor.
If the engine rotate speed is too high, turn the adjust
screw counterclockwise;
If the engine rotate speed is too low, turn the adjust
screw clockwise;
NOTE: Idle Speed: 1500±100r/M
Idle Speed Adjust Screw
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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006
2.2.14 Rear Brake Swing Arm Solution & Replacement
Problem: Rear brake swing arm becomes loose, and is hard 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 Brake Swing Arm Rear Brake Caliper Assy.
Adjust Bolt Fastening Nut
Rear Brake Swing Arm Rear Brake Caliper Assy.
Adjust Nut of
Brake Cable
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Welding Spot
Rear Brake
Caliper Assy.
Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006
2. Replacement
a) Remove the adjust nut of brake cable;
Adjust Nut of Brake Cable
b) Remove the fastening nut of rear brake
swing arm ;
Rear Brake Swing Arm
Fastening Nut
c) Remove the rear brake swing arm;
Rear Brake Swing Arm
d) Assemble the new rear brake swing arm and
fastening nut;
Rear Brake Swing Arm
Fastening Nut
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