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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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006

e) Reassemble the adjust nut of brake cable.

Notice: The return spring of brake should be
assembled in the exact direction as shown in
the picture.

Adjust Nut of Brake Cable

Adjust Nut of Brake Cable

Return Spring

Rear Brake Swing Arm

Fastening Nut

2.1.15 Storage

In the event your vehicle isn’t to be operated for periods in excess of 30 days or at the
end of each driving season, prepare for the storage as follows:

1) Drain (or use a fuel stabilizer) all the fuel out of the fuel tank and carburetor;

2) Remove the spark plug; pour one ounce of clean cylinder lubricating oil through

the spark 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.

z Don’t drain the fuel while the engine is hot.
z Be sure to move your BUGGY outside before draining the fuel.

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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006

Notice: In storage and during service, please
put your buggy with its four wheels on the
ground.

All the other ways are wrong, and should be forbidden.

Wrong way to set your buggy during storage and service may cause the problems
below:

a) Carburetor gas flows into the engine, which makes starting very difficult;

b) Gas flows out through carburetor drain tube, which may cause a potential safety

problem;

c) In very cold weather, engine oil runs in the wrong direction and stays on one side of

engine, not on engine bottom; if you start the buggy immediately after taking it out,
engine oil won’t have enough time to flow back to the engine bottom, which may
cause starting failure and improper engine lubrication.

Wrong

Wrong

Correct

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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006

3 ENGINE

3.1

ENGINE COMBUSTION SYSTEM

3.1.1 Troubleshooting

LOW

COMPRESSION

HIGH

COMPRESSION

EXCESSIVE

NOISE

EXCESSIVE

SMOKE

OVERHEATING

z CYLINDER HEAD
z LEAKAGE OR DAMAGE OF HEAD GASKET
z WARPED OR CRACKED CYLINDER HEAD
z WORN-OUT CYLINDER OR PISTON RINGS

z EXCESSIVE CARBON ACCUMULATION ON PISTON HEAD OR

IN COMBUSTION CHAMBER

z WORN OUT PISTON AND CYLINDER
z EXCESSIVE CARBON ACCUMULATION

z WORN OUT CYLINDER OR PISTON RINGS
z IMPROPER INSTALLATION OF PISTON RINGS
z SCORED OR CRATCHED PISTON OR CYLINDER WALL

z EXCESSIVE CARBON ACCUMULATION ON PISTON OR IN

COMBUSTION CHAMBER

z BLOCKAGE OF AIR TO THE ENGINE COOLING SYSTEM

(FAN, CYLINDER COVER…)

z IMPROPER OIL SUPPLY
z INCORRECT IGNITION TIMING

3.1.2 Cylinder and Piston Removal

a) Remove the engine;

Disassemble the air cleaner and carburetor;
Remove the intake pipe mounting bolts;
Remove the cylinder head cover;

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Bolt

Cylinder head

Cylinder head nut

Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006

b) Remove the cylinder head;

Remove the cylinder carefully to see the whole
piston;
Remove one piston pin clip, and remove the piston
and piston pin;
Spread and remove each piston ring.

Locating pin

Bush

NOTE: Don’t let the clip drop into the engine

crankcase.

3.1.3 Cylinder and Piston Inspection

a) Inspect the cylinder bore for wear or damage;

Measure the cylinder inner diameter at three levels
in X and Y-Axis;
Taper limit: 0.05 mm
Out of round limit: 0.05 mm

b) Check the cylinder head mating surface for warp

with a straight edge and feeler gauge;

Service limit: 0.05 mm

c) Insert each piston ring into the cylinder;

Measure the end gap;

Service limit: 0.45 mm

Cylinder Body

Cylinder Head Mating Surface

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End Gap

Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006

d) Measure the clearance between the ring and groove;

Service limit: 0.12 mm

Piston Ring Piston

e) Measure the piston outer diameter at 10 mm high

from the skirts bottom;

Service limit: 49.90 mm

Piston Outer Diameter Measurement

f) Measure the piston pin bore, and the piston pin outer

diameter;

Pin outer diameter: Service limit: 12.98 mm
Pin bore: Service limit: 13.055mm

Piston Piston Pin

g) Measure the connecting rod small end inner diameter

with a small hole-gauge.

Service limit: 13.10 mm

Connecting Rod

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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006

3.1.4 Installation

a) Install the piston rings with the marks facing up;

NOTE: Do not damage the piston rings by
spreading the ends too far.
The piston ring gap must align with the ring pin
in the ring groove of piston.

b) Clean the cylinder gasket surface;

NOTE: Be careful. Do not drop any gasket material

into the crankcase.

c) Apply some oil to the inside of the connecting rod

small end;

d) Install the piston, piston pin and clip;

Install the piston with the arrow mark facing the exhaust
pipe;
NOTE: Do not align the piston pin clip end gap with the
piston cutout

e) Install a new cylinder gasket;

Apply a thin coat of engine oil to the piston rings and cylinder wall;

f) Compress the piston rings and install the cylinder;

g) Replace the cylinder head gasket;

Install the cylinder head;
Tighten the cylinder-mounting bolt;

Torque Value: 15-18 N. m.

h) Install the cylinder head cover.

Piston

Ring

Ring

Groove

Cylinder Gasket

Cylinder

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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006

3.2 CLUTCH

Plank Cover, Limited

3.2.1 Dismantle

a) Dismantle the following parts:

---Lever Comp., Clutch

---Plate Comp. , Clutch Lifter Cam

---Plank Comp., Limited

---Spring, Plate Side

---Through, Oil

---Spring, Oil Through

b) Remove the four screws, cover and

gasket;

c) Lift the connecting tongue of the locking

bush;
Detach the centrifugal clutch locking
nut by using a special tool ;
Detach the clutch;

d) Dismantle the following parts:

---Gear, Primary Drive

---Guide, Clutch Center

---Collar

Lever Comp., Clutch

Clutch Cover, Outer Clutch

Locking Nut

Gear

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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006

e) Dismantle the following parts:

---Circlip, External

---Gear, Primary Drive

3.2.2 Troubleshooting

When the engine works at the idle speed, the vehicle moves slowly.

z The clutch has not been adjusted properly;
z The clutch disc is warped;
z The clutch lock nut is loose;
z There is too much oil in the crankcase;
z The clutch rod has not been installed correctly.

When accelerating, the clutch slips.

z The clutch has not been adjusted properly;
z The clutch disc is worn out;
z The clutch spring is loose;
z The gearshift oil is mixed with copper or graphite additive.

Circlip Gear

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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006

3.3 TRANSMISSION /CRANKCASE

3.3.1 Trouble Shooting

Difficulty in gearshift:

z The clutch was not adjusted properly;
z The gear shifter is bent;
z The guide pin is broken;
z The gear guard is worn out.

Transmission dislocation:

z The guide pin is worn out;
z The gear shifter is bent.

Too much noise:

z The shaft neck bearing is worn out;
z The transmission bearing is worn out.

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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006

Engine vibration:

z The crankshaft radial run-out is too great.

3.3.2 Transmission Device Assembly

Assemble the transmission device by reversing the disassembly procedure.

NOTE: Align the head of the snap ring with the center of the key slot as shown in the
picture.

3.3.3 Path of Power Transmission

a) The torque of crankshaft drives the clutch.
b) The torque of clutch transmits the main shaft by gear.
c) The torque of main shaft transmits the counter shaft by gear.
d) The counter shaft drives the small sprocket.

e) The small sprocket drives the rear sprocket by chain, and transmits the rear-axle

shaft to move the rear wheel.

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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006

3.4 FUEL SYSTEM

3.4.1 Trouble Shooting

ENGINE

STARTING

DIFFICULTY

UNSTEADY,

STALLING

OR

POORLY-RUNNING

ENGINE IDLES

LEAN

MIXTURE

RICH

MIXTURE

z NO FUEL IN TANK
z NO FUEL TO CYLINDER
z TOO MUCH FUEL IN CYLINDER
z NO SPARK AT SPARK PLUG
z CLOGGED AIR CLEANER FILTER

z IMPROPER ADJUSTMENT OF IDLE SPEED SCREW AT

CARBURETOR

z IGNITION MALFUNCTION
z TOO LEAN OR TOO RICH FUEL/AIR MIXTURE
z DIRTY AIR CLEANER
z INSULATOR LEAKAGE
z CLOGGED BREATHING HOLE OF FUEL TANK CAP

z CLOGGED FUEL JET OF CARBURETOR
z CLOGGED TREATHING HOLE OF FUEL TANK CAP
z CLOGGED FUEL FILTER
z UNSMOOTH FLOWING OF FUEL IN THE TUBE
z TOO LOW FLOAT LEVEL IN CARBURETOR

z FAULTY FLOAT NEEDLE VALVE IN CARBURETOR
z TOO HIGH FLOAT LEVEL
z CLOGGED AIR DUCT IN CARBURETOR
z DIRTY AIR CLEANER

z The carburetor can’t start, or becomes difficult to start.

Reason Analysis: After the tryout, the carburetor has been exposed in the air for a
long period, so that a layer of mucous membrane has formed and blocked the main jet.
As a result, the oil can’t flow smoothly and the engine starting becomes difficult, or
the engine stops soon after starting.

Solution

a) Check if there is any damage or leakage on the

pressurized tube of oil cock;

Pressurized Tube

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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006

b) Clean the carburetor and readjust the idle speed

according to the steps below:

Open the connecting tube between the air cleaner

and carburetor.

Air Cleaner

c) Spray a little carburetor cleanser into the
carburetor.

Spray Cleanser

d) Start the engine and run for a while, then quickly step on the throttle pedal for

several times .If the engine works well, assemble the connecting tube; otherwise,
repeat the steps above several times.

Readjust the idle speed if it is unstable.

3.4.2 Carburetor

z Removal

a) Remove the air cleaner;

Disconnect the fuel line;
Unscrew the intake pipe mounting bolts
at the carburetor, and then remove the
carburetor;

Intake Tube Carburetor

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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006

b) Remove the carburetor cap;

Remove the throttle cable from the
throttle valve while depressing the
throttle valve spring;

c) Remove the needle clip retainer, the jet

needle and needle clip;
Inspect the throttle valve and the jet
needle surface for wear, scratches or dirt.

z Disassembly

a) Unscrew the float chamber screws

and remove the float chamber:

b) Disassemble the float arm pin, float and

float needle valve. Inspect the seat of the

float needle valve for wear or damage:

Disassemble the idle jet, main jet, idle
speed;
Adjust screw and idle mixture
adjustment screw:

Throttle Cable

Jet Needle

Float Float Needle Pin

Throttle Valve Spring

Carburetor Float Chamber

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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006

c) Inspect all the jets and screws for wear or damage;

Clean the passages and jets with compressed air.

Carburetor

z Assembly

Clean all parts in solvent and blow it dry with compressed air.
Assembly is essentially the reverse order of disassembly.

3.4.3 Throttle Valve Assembly

a) Install the needle clip on the jet needle;
b) Install the jet needle into the throttle valve;
c) Assemble the throttle cable, spring and the throttle valve;
d) Align the throttle valve groove with the idle speed;
e) Adjust screw and install the carburetor cap to the carburetor.

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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006

3.5. ENGINE LUBRICATION & COOLING SYSTEM

3.5.1 Troubleshooting

INSUFFICIENT OIL SUPPLY
TO ENGINE

ALWAYS INSUFFICIENT OIL
LEVEL

ENGINE ALWAYS RUNS HOT

z TOO LOW OIL LEVEL IN OIL TANK
z IMPROPER FIXED OIL TUBES
z OIL LEAKAGE FROM TUBE ENDS
z DAMAGED OIL TUBES
z CLOGGED OIL TUBES
z BROKEN-DOWN OIL PUMP

z EXTERNAL OIL LEAKAGE
z WORN CYLINDER HEAD GASKET
z WORN PISTON RINGS

z IMPROPER ADJUSTMENT OF OIL

PUMP

z POOR OIL QUALITY

3.5.2 Caution

Supplying enough oil to the engine is very important. If the oil quantity is not enough,
the engine will be severely scored and will most likely seize the motor.

When the upper end of the engine is in need of replacement, change the piston, piston
rings, piston pin clips, and the cylinder all at the same time.

3.5.3 Cooling System

When the buggy is running, the wind blowing towards it will cool down the cylinder
head and cylinder body through the cooling fins. So, the cylinder and piston will not
overheat.

The cooling fins should be kept clean.

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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006

3.6 Starting Failure

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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006

4. ELECTRIC SYSTEM

Troubleshooting

4.1

ENGINE STOPPING

AFTER STARTING

NO SPARK AT PLUG

POOR RUNNING OF ENGINE AFTER

STARTING

CHARGING SYSTEM FAILURE

INTERMITTENT ENGINE POWER

STARTER MOTOR TURNING

FAILURE

z IMPROPER IGNITION TIMING
z FAULTY SPARK PLUG

z ENGINE STOP SWITCH AT “OFF”
z FAULTY IGNITION COIL
z FAULTY GENERATOR
z FAULTY CDI UNIT
z POOR CONNECTION:

z PRIMARY IGNITION CIRCUIT TROUBLE:

z SECONDARY IGNITION CIRCUIT TROUBLE:

z IMPROPER IGNITION TIMING:

z LOOSE, BROKEN OR SHORT WIRES
z FAULTY ALTERNATER
z FAULTY IGNITION SWITCH

z LOOSE BATTERY CONNECTION
z LOOSE CHARGING SYSTEM CONNECTION

z DEAD BATTERY
z FAULTY IGNITION SWITCH
z LOOSE OR DISCONNECTED WIRES

Between CDI and Ignition Coil

Between Alternator and CDI Unit

Between CDI and Engine Stop Switch

Between Ignition Coil and Spark Plug

Between Generator and CDI Unit

Faulty Generator

Faulty CDI Unit

Faulty Alternator Exciter Coil

Loose Connect ion between Terminals

Faulty Ignition Coil

Faulty Plug

Loose Connect ion at Spark Plug Wires

Faulty Generator

Faulty CDI Unit

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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006

(When Starter Motor And Engine Can

Turn )

ENGINE STARTING FAILURE

SLOW MOVEMENT OF STARTER

(When the starter runs,)

ENGINE FAILURE

KATA SOUNDS FROM STARTING

RELAY SWITCH & ENGINE

FAILURE

z FAULTY IGNITION SYSTEM
z
z ENGINE PROBLEMS

z FAULTY ENGINE STOP SWITCH
z OVERLOW ELECTROLYTE SPECIFIC

GRAVITY IN BATTERY or USED UP BATTERY

z POOR CONTACT BETWEEN CONNECTING

TERMINALS OF BATTERY WIRES

z BROKEN STARTING RELAY
z POOR GROUNDING OF BATTERY
z BROKEN STARTER BRUSH

z ELECTRIC STARTER RUNNING IN AN

INVERTED ORDER:

Improper Assembly Of Starter Case

Improper Connection Of Terminal

z BROKEN STARTING RELAY
z BROKEN DRIVE CHAIN OF STARTER

(DUE TO ENGINE PROBLEM) FAILURE OF

CRANKSAHFT MOVEMENT

4.2 Ignition Coil

a) Remove the spark plug cap from the spark plug;

Disconnect the primary ignition coil wire;

b) Measure the primary coil resistance;

Standard: 0.1-1.0 Ω

Ignition Coil

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Ignition Coil

Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006

c) Measure the secondary coil resistance with the

spark plug cap in place.

Standard: 7-9 KΩ

4.3 Ignition Timing

The ignition advance is 15º± 1º B.T.D.C /1700rpm.
The Capacitive Discharge Ignition (CDI) system is factory pre-set and does not
require adjustment.

4.4 Starter Motor

z Remove

a) Remove the left crankcase cover;

Remove the snap ring from the follower gear of the electric starter;

b) Pull off the wire connector of the electric starter;

Remove the 3 bolts; remove the electric starter;
Remove the O-ring.

z Disassembly

a) Remove all the bolts;

b) Disassemble the electric starter.

NOTE: Assemble the starter back with the same amount of washers.

4.5 Battery

z Initial Service

z The following procedure is very dangerous and should be performed with

utmost care and attention. Wear protective eyewear, rubber gloves, and have
water available should electrolyte come in contact with skin or eyes.

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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006

KEEP 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 with water for 15 minutes and get prompt medical attention.

z KEEP OUT OF THE REACH OF CHILDREN

z Battery Installation

NOTE: The following page is for vehicles with battery’s containing separate
electrolyte pack. Most battery’s will come with the electrolyte already sealed into the
battery.

a) Place battery on level surface;

Remove sealing tape from top;

b) Take the electrolyte container out of the plastic bag;

c) Place electrolyte container upside down with the

sealed silver mouths of the electrolyte bottles in
line with the six filler holes of the battery;

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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006

d) Push the container down strongly enough to break

the silver seals;

e) As electrolyte starts flowing into battery, air bubbles will come up from the mouths

of the plastic electrolyte bottles;

f) Leave bottles upside down in battery holes until electrolyte is completely drained;
NOTE: Never leave children unattended around battery.

g) 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.

h) After all the electrolyte has drained from the bottles into the battery, pull plastic

electrolyte bottles gently out of the battery;

i) Discard empty electrolyte bottles in a waste area that is inaccessible to children and

animals;

j) After filling, let battery stand for at least 30 minutes before charging (This allows

the electrolyte to penetrate plates for optimum performance and ensures longer
battery life);

k) After 30 minutes the battery is ready for its initial

charge, place cap strip loosely over the filling holes

as shown in the picture.

z Initial Charge

a) Connect the red positive (+) cable to the red

positive (+) pole of the battery;

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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006

b) Connect the black negative (-) cable to the

black negative (-) pole of the battery;
NOTE: The red positive (+) cable has a larger
diameter than the black negative y cable.

c) Charging rate: Charge battery @ 0.7 Amps for 5 ~ 10 hours;

d) After charging is complete, press down firmly with both hands to seat the caps.

Do not pound or hammer.
The battery is now sealed;

.

NEVER REMOVE THE STRIP OF CAPS NOR ADD ANY WATER OR
ELECTROLYTE.

e) 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.

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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006

f) 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;

g) Then attach the black negative wire to the black

negative terminal on the battery;

.

h) Place grey plastic battery cover on top of the

battery and thread wires through the cover cuts –
outs.

Finally, secure 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 in a ventilated area.
z If battery gets hot to the touch, discontinue charging and allow battery to

cool down.

z Do not use fast charging unless it is an emergency.
z At the beginning or end of charging, turn off the charger first, in order to

prevent electric spark and explosion.

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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006

p

z Charge in a well ventilated area.

z DO NOT smoke around batteries and keep away from open flame.

z Battery Replacement:

a) Remove old battery;

Mark which cable is connected to the positive terminal (+) and which cable is

connected to the negative (-) terminal;
b) Clean cable connectors with wire brush or sandpaper to remove oxidation;
c) After charging, install new battery;

Put dielectric grease on the battery terminals to avoid corrosion;

d) Connect cables to the proper terminals: positive cable to positive terminal, and

negative cable to negative terminal;

NOTE: Positive (+) cable is red and larger in diameter; Negative y cable is black and
smaller of the two in diameter.

CONNECT NEGATIVE CABLE LAST.

e) Torque terminal bolts to 40 in. / lbs;
f) Place rubber pad in bottom of battery tray;
. Securely fasten battery to the vehicle using cover and 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 kee

away from open flame.

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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006

z Trouble Shooting

Battery Short Circuit Solution

Problem: battery short circuit

Purpose: to prevent battery electrodes touch battery box cover and cause battery short

circuit

Solution:

Battery Band

1. Inspect Battery

a) Remove the battery band;

Steel Battery Box Cover

b) Remove the steel battery box cover;

c) Inspect if the rubber pad in the battery

box cover is in good condition;

Replace the rubber pad if necessary;

e) Suggest to replace the steel battery box

cover with a plastic one
(part no. 50320-BDD0-0000 ).

.

Plastic Battery Box Cover

Rubber Pad

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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006

2. Replace Battery Box Cover
a) Assemble the battery + /－ electrode;

b) Put the battery into the battery box;

c) Put on the plastic battery box cover (part no.

50320-BDD0-0000), or add one rubber

pad in the steel battery box cover;

f) Put the battery band on the battery, and

fasten the band;

+ Electrode

Plastic Battery Box Cover

Battery Band

－ Electrode

Battery

Tel.: (8

Battery Box

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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006

e) The replacement is finished.

Replaced Battery Box Cover

4.6 Starter Motor / Starting Clutch

4.6.1 Starter Motor

z Maintenance Warning

Turn off the ignition switch before maintaining the electric starter. The sudden
starting of the electric starter could cause severe injuries or death.

a) If the battery can’t provide enough electric charges, the electric starter can’t run

fast enough, or the provided ignition currents are not enough.

b) If the electric starter is started continually when the engine can’t work, the electric

starter will be damaged.

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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006

z Spec. Unit: mm (in)

Item Standard value Limit value

Length of electric starter carbon brush 12.0mm 4.0mm

z Trouble Shooting

NOTE: Check the following items before looking

for the system failure:

a) If the main fuse has been burned (10A);
b) If the wire of the battery or electric starter

has

got loose;

c) If the battery is leaking.

The electric starter doesn’t work

Undercharged: Below 12.0 V

z Check

a) Check the carbon brush and measure the length of the brush;

Limit value: 4.0mm

b) Check if the rectifier bar has depigmentized;
The depigmentation of couples of rectifier bars shows the armature coil has

earthed;

NOTE: The rectifier bar can’t be burnished by emery cloth or sand paper.

c) Check the connectivity between couples of rectifier bars;

Check the connectivity between the rectifier bar and the armature shaft;
Rectifier bars: connected;
Armature ---shaft: disconnected;

d) Check the connectivity between the cable terminal and the black wire brush;

Check the connectivity between the cable terminal and the electric starter shell;

If the connecting wire is broken or disconnected with the starter shell, the wire

needs repairing.
Cable terminal --- starter shell: disconnected;
Cable terminal ---brush: connected.

Electric Starter

z Assembly

a) Assemble the electric starter;

Align the carbon brush pin with the shell groove;

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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006

b) Align the rear shell groove with the carbon brush pin;

Install the rear shell;

c) Check if the O-ring is in good condition; replace it if it is defective.
Lubricate the O-ring;

Install the electric starter and fasten the bolt;

Connect the connector of the electric starter;

d) Install the snap ring into the shaft groove;
Install the left crankcase cover.

4.6.2 Starting Clutch

z Remove Main/Follower Sprocket
a) Remove the following parts:

--- Flywheel;

---Drive chain slide plate

---Screw and locating plate;

---Snap ring;

b) Remove the starting chain and sprocket

Assembly:
c) Install by reversing the dismantling procedure.

z Remove Starting Clutch

a) Remove the 3 screws and starting clutch

shell;

b) Remove the roller, spring cap and spring.

Starting Clutch

Shell

z Check

a) Check if the roller runs smoothly;

Check if the roller has been over abraded;

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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006

b) Check the abrasion and damage of the

Main/follower sprocket and chain:
Measure the outer diameter of the main
Sprocket.

z Assembly

a) Install the starting clutch shell;

Apply the locking agent to the screw
threads of the starting clutch shell;
Install the screws and fasten them;

b) Put a mark on every screw of the clutch

shell;

c) Install the spring, spring cap and roller;

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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006

4.6.3 Starting Relay
z System Check

a) Turn on the ignition switch;

Press the starting switch;

It is normal if the starting relay makes

“Kata” Sounds.

b) Pull out the connector from the starting

relay;
Measure the voltage of the connection

terminal;
Check the connectivity of the connection
terminal;

Item Connection Terminal Technical Criterion

Starting relay coil Yellow/red wire and

ground wire
Battery voltage
input wire
Electric starter
input wire

Black wire(+)and

ground wire(-)

Red wire (+)and ground

wire(-)

Turn on the starting switch: it
should be connected.
Turn on the ignition switch: the
battery should be connected.
The battery should be connected.

z Elements Check

a) Connect a DC12V battery between the black wire and yellow/red wire;
b) Connect an ohmmeter between the red wire and red/white wire of the starting

relay; at this time, the circuit should be connected;

c) If the circuit is disconnected, replace the starting relay.

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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006

z Troubleshooting

Turn on the ignition switch

and press the starting

switch; check if there is a

“Kata” sound from the

starting relay switch.

“Kata”

sounds

Connect the electric starter terminal

with the positive terminal of the

battery (a thin wire can’t be used

because of the high currents).

Starter runs. Starter doesn’t run.

No “Kata” sounds

---The electric starter connector

is loose or disconnected;

---The starting relay switch is

broken.

The electric

starter is

out of order.

Remove the starting relay

connector; check the wire

connection of the relay coil

(yellow/red).

Connected

Disconnected

---The starting switch

is broken;

---The yellow/red

wire or green wire

is open;

---The connector is

loose or has poor contact.

Connect the starting relay connector,

turn on the ignition switch and press

the starting switch; measure the

starting relay voltage at the starting

switch connector [yellow/red(+) and

ground wire(-) ].

No

voltage

---The ignition switch is broken;

---The connector is loose or has

poor contact;

---The bundling point of wires is

open.

Voltage exists

Check the starting relay Normal

---The connector is loose

or has poor contact;

Abnormal

---The starting relay

is defective.

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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006

5. CHASSIS

5.1 Rear Axle Removal

a) Disassemble the rear Wheel.
b) Remove the cotter pins on the rear wheel axle nut.
c) Remove the axle nut.
d) Block up the rear end of the machine.
e) Remove the rear wheel and hub assembly by sliding off splines of the axle.
f) Remove the chain.
g) Loosen the nuts on the bearing carrier, and remove the bolts.
h) Remove the axle and bearing carriers as a unit.
i) Remove the brake caliper bolt and brake caliper/

Brake Caliper

Brake Disc Sprocket

Rear Wheel Axle

Rear Wheel

5.2 Rear Swing Arm Removal

z Please operate properly according to the instructions.

NOTE: The swing arm, axle and motor can be removed as a unit if needed.

a) Remove the rear. shock.
b) Remove the rear brake caliper, and set it aside.
c) Unplug the brake light wiring from the electrical box.
d) Remove the throttle cable.
e) Remove the bolts from the swing arm pivot
f) Check the buffer rubber bushing for wear;

If there is any wear on the bushing, it should be replaced.

Chain

Rear Wheel Hub

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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006

Shock Absorber

Rear Swing Arm

Chain Guard

Electric Box

Cover

Battery

5.3 Front & Rear Shocks

The front and rear shocks are oil dampened units.

They are non-re-build able.

If any oil seepage is noticed, the shock should be replaced.

5.4 Front Wheel Replacement

Don’t disassemble the castle nuts when you replace the front wheels.

It is only necessary to tighten the nuts so that the wheel turns freely on the axle with

the minimum end play. Please tighten the nuts after replacing the wheels.

Shock Absorber

Front Wheel

Front Wheel Hub

Front A-arm

Assy., Left

Steering Knuckle

Front A-arm

Assy., Right

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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006

5.5Front Hubs

a) Check the seals for rips or tears, and replace them if

any exist.

b) Remove the bearings with a punch from the opposite

side.

c) Inspect the bearings for easy movements;

If any dirt or mud has gotten into them, wash them in

the cleaning solvent and spin with your finger.

NOTE: Never spin them with the compressed air.

d) Apply an ample amount of grease to the bearing and reinstall it with a bearing tool,

making sure that they go in straight;

If the bearing isn’t straight, damages to the hubs can occur.

e) Install the seals into the hubs;

It is recommended to apply a small amount of grease to the lip of the seal;

If the retention spring is in bad shape, replace the seal with a new one.

5.6 Seat

a) Remove all the nuts and bolts underneath the

seat rail.

b) Remove the seat.

5.7 Steering Shaft

a) Remove the nuts on the steering block, and grease the inside of the steering block

periodically.

b) Loosen the steering shaft and clamp nut on the steering gear box.
c) Remove the steering shaft.

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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006

Steering Comp.

Steering Shaft

Steering Ball Joint, Right

Steering Ball Joint, Left

Dust Cover

Steering Gear

5.8 Steering Gear Box and Ball Head

a) Remove the four bolts of the LH&RH clamp nuts on the steering gear box.
b) Remove and check the ball head dust cover on the steering gear box for wear.
c) Check the steering cover on both sides of the steering gear box and grease the ball

head.

d) Fill the steering gear box with Grease after cleaning the dust; It is recommended

to replace the ball joint if it is loose or not smooth.

5.9 Throttle & Brake Pedal

a) Remove the throttle, throttle pedal and axle nut.
b) Check the throttle and brake pedal for signs of wear;

Replace if any wear is present.

c) Before installation, apply enough grease on the throttle and brake pedal in order to

make them swing more flexibly.

Throttle Pedal

Brake Pedal

Pedal Link Bolt

Pedal Link Bolt

Spring

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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006

5.10 Steering Knuckle Support

a) Remove the rubber dust cover of the knuckle support.
b) Check the grease of the ball joint;

Clean it if it’s dirty and fill with grease.

c) Replace the steering knuckle support if the ball joint is loose or the steering isn't

flexible

5.11 Tie Rod

a) The tie rods should be checked for the ease of movement

in their full rotation.

b) Remove the protective boot and apply some grease.
c) Check the tie rod ends periodically for tightness at their

adjusting nuts.

d) Always use a new cotter pin after the removal.

5.12 Service Air Cleaner

Service the air cleaner every 100 hours.

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;

e) Dry it after cleaning, and dip it into the engine oil

f) specified by the manufacturer, then dry it again.

NOTE: Service more often when driving in dusty

conditions.

z Service Foam Filter / Paper Filter

a) Clean the foam filter with the no-flammable cleaner;

If the filter is paper, tap it on an object to knock out the dust, or replace it with a

new one.

Air Cleaner

Cover

Air Cleaner

Element

Air Cleaner

Screen

Remove Air Cleaner Cover

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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006

b) Dry the filter after cleaning, dip it into the engine oil specified by the manufacturer

and wring the excess oil out of the filter.

5.13 Spark Plug

a) Remove the spark plug and inspect it with a

spark plug wrench each time you change the oil;

If possible, check the spark plug gap (the area

between the two electrodes)with a wire feeler

gauge, and this specification should be

0.6-0.7mm.

NOTE: The electrodes should be kept clean and

free of carbon. The presence of carbon or excess

oil will greatly deter the proper engine

performance.

b) Before installing the spark plug, apply some graphite grease on the threads if

possible to ensure the 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 insure the easy

starting and good engine performance.

5.14 Ignition System Check

1. Remove the spark plug and reattach it to the spark plug lead.

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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006

2．Push the electric button “START” ( Yellow button). Apply the rear brake lever to

make sure the rear wheels are locked. If the ignition system is operating properly, a

blue mark should jump across the spark plug gap. If there is no spark, take your

machine to your service center.

Performing the spark test improperly could be hazardous.

You could get a higher voltage electrical shock if you are not familiar with this
procedure.

Do not perform this check if you are not familiar with the procedure. Do not point the
spark plug near the spark plug hole during this test. Do not do this test if you have a
heart condition or wear a pacemaker. Do not perform this test is any near any open fuel
containers for near fuel which has spilled on the ground, on the engine, or any part of
the ATV.

COMPLAINT: Engine stalls

1. Make sure there is enough fuel in the fuel tank.

2. Check to see that the spark plug is not fouled. Removed the spark plug and clean

it. Replace it, if necessary.

3. Make sure the fuel valve is not clogged, and the fuel tank is not clogged, either.

4. Check the idle speed. If necessary, adjust it using a tachometer. The correct idle

speed is 1400~1600r/min.

5.15 Front Wheel Alignment

a) The front wheels should be "toed-in" from 1/8" to 1/4"; for the proper toe-in

dimension, Dimension A should be 1/8"-1/4"longer than Dimension B.

b) Check the alignment measure distance from A /B to the centerline (CL) of the

tires with the wheels pointed straight ahead.

c) Loosen the lock nuts on both sides of the front tie rods;

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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006

To make Dimension B shorter, screw the rod left; if Dimension B needs to be

longer, screw the rod right;

Tighten the jam nut tightly against the rod end, recheck the distance and repeat the

above steps until the Dimensions are the same as the required.

5.16 Gearshift Lever
Caution: Proper operation of this vehicle requires that the driver shift from 1

gear. When the engine reaches a high RPM in 1
accelerator pedal and push the shift lever forward into 2

st

gear, the driver should release the

nd

gear. Then, press back

st

into 2nd

down on the accelerator pedal to continue driving forward. Failure to properly shift
may result in engine overheating, which may damage the engine and poses a fire
hazard.

How to shift from 1

st

into 2nd gear:

1) When the vehicle is running, stepping on the accelerator pedal provides

st

acceleration…UNTIL the limit of speed in 1

gear has been reached. At this point

the vehicle will no longer accelerate in speed, and the engine will be very loud.

2) To change gears:
a. Release the accelerator pedal;

nd

b. Press the shift lever forward until it engages 2

gear;

c. Press back down on the accelerator pedal to resume driving.

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Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006

Wiring diagram:

60