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File No.:SF-E175-WX-B01-D
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Raider Max 175 (single-seat, double-seat): Service Manual EEC Version:2.0 April 2005
2
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. Those who will service
this Buggy should carefully review this manual before performing any repair or service.
All information, illustrations, photographs and specifications contained in this manual are based on
the latest product information available at the time of publication. Due to the improvements or other
changes, there may be some discrepancies in this manual. Therefore, if the newest information is
requested in future, please contact the local distributor.
Distributors reverse the right to make production changes at any time, without prior notice or
incurring any obligation to make the same or similar changes for the vehicles previously built or sold.
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Raider Max 175 (single-seat, double-seat): Service Manual EEC Version:2.0 April 2005
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CONTENTS
1. General Information ------------------------------------------------------------------------4
2. Periodic Maintena nce 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 Generat or & Starting Cl utch---------------------------------------------------24
3.6 Crankcase & C r ankshaft- ------------------------------ -----------------------------2 6
3.7 Cooling System-------------------------------------------------------------------------28
3.8 Carburetor------------------------------------------------------------------------------31
4 Reve r se Gearbox--- ------------------- ----------------------------------------------------- 41
5 Wiring Dia gram ------------- ------------------------------------------------ --------------- 43
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1. General Information
1.1 Model Identification
1.1.1 Frame Number
The frame number or VIN is stamped under the seat on the frame and stuck behind the seat.
1.1.2 Engine Number
The engine number is located on the upper rear right engine case.
1.2 Fuel and Oil Recommendati ons
Be sure to use the specified fuel and oil
1.2.1 Fuel
Please use the gasoline of SAE 90# or above.
Also we recommend you to use the unleaded gasoline.
1.2.2 Engine Oil
Please use the high-quality engine oil of SAE 10w/30SF.
1.3 Break-in Procedure
For your first 2 hours of riding, don’t exceed 2/3 throttles.
Vary the engine speed for the first 5 hours.
Never hold the engine at full throttle for long periods of time.
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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
VIN Accord with GMVR A01-01
Statutory Plate& Safety Labels Accord with GB 7258-1997
ENGINE
Model PMI162MK
Type Forced water-cooled, single cylinder, 4-stroke
Engine Capacity 175cc
Displacement 174.5ml
Bore×Stroke 62mm×57.8mm
Max. Power 7.4kw or 7500r/m
Max. Torque 12.5N.m or 6500 r/m
Idle Speed 1500±100 r/m
CO Emission 7.0g/km
HC Emission 1.0 g/km
Fuel Type SAE 90# or above (unleaded)
Min. Fuel Consumption 354g/KW.h
Lubricate Oil Type SAE 15W / 40SF
Lubrication Pressure & splash
Cooling Fluid SHELL (Antifreeze)
Antifreeze Temperature of Cooling Fluid - 450C
Mixing Ratio (Cooling Fluid : Water ) 1:1
Cooling Water-cooled
Ignition C.D.I.
Starting Electric
Spark Plug D7
Spark Plug Gap 0.6~0.7mm
Transmission Chain transmission
Transmission Ratio F 1:1, B 1:1.758
Primary Transmission Ratio 2.2-0.9
Compression Ratio 10±0.1：1
Reduction Ratio 2.8
Clutch Automatic, centrifugal, dry, shoe type
Generator Outer rotor, flywheel
Carburetor Vacuum film type
Absorber Normal (in 10 5 times of experiments)
Air Cleaner Paper element, filtration type
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Gear-Shifting Automatic, centrifugal
CAPACITIES
Front/Rear Tire Load Coefficient 36
Front/Rear Tire Speed Level L
Fuel Tank 7.0L, 130kpa (no leakage in experiments)
Starting Time ≤15s
Climbing ≥20%
Top speed 63km/h
Tachometer 33-40km/h (meter scale:40km/h)
Turning Radius 3m / 3.5m
Acceleration Noise Level ≤80dB (A)
Horn DL80-90 12V 3A 105dB, 93<dB (A) <112
Headlight 12V 35W/35W
Headlight High Beam Intensity Accord with laws ®ulations
Taillight 12V 5W /21W
Turning Light 12V 10W
License Light 12V 5W
Battery 12V 8Ah
Anti-theft Lock ≥200N.m
Rearview Mirror Accord with laws ®ulations
CHASSIS
Front/Rear Brake Hydraulic disc, foot control
Front Wheel Brake Force 760N / 1140N
Rear Wheel Brake Force 832N / 1038N
Braking Distance ≤ 7 m@30km/h
Parking Brake Hydraulic disc, hand control
Front Tire 20.5 × 8.0–10
Rear Tire 20.5 × 8.0–10
TIRE PRESSURE
Front 175kpa
Rear 200kpa
WEIGHT
Net Weight 235kg / 255kg
z The specifications are subject to change without notice.
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2. Per io d ic Maint e nance an d Tune –up Pro c edures
2.1 Location of Parts
Double-seat
Headlight
Rearview Mirror
Roll Bar
Seat Belt
Seat
Steering
Wheel
Front
Wheel
Turning
Light
Front
Mudguard
Front Shock
Absorber
Awning
Control Panel
Brake
Handle
Reverse
Handle
Fan
Rear
Reflector
Rear
Wheel
Taillight
Rear Rack
Turning
light
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Single-seat
z
Please demand for a copy of the Parts Book from your dealer and locate each component location.
Roll Bar
Headlight
Tu rning Light
Fro nt Wh e el
Seat
Rear Rack
Seat Belt
Rear Wheel
Front
Shock
Absorber
Throttle Pedal
Rear Shock Absorber
Control Panel
Rearview Mirror
Steering Wheel
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Raider Max 175 (single-seat, double-seat): Service Manual EEC Version:2.0 April 2005
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2.2 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.
Items 1st Service of 1st week Daily Monthly Quarterly Yearly
Tire Press /Wear X X X X R
Handle Brake Cable A A A A
Brake Performance X X X X X
Brake Pad X X R R
Brake Fluid X X X X R
Nuts /Bolts X X X X X
Air Filter X X C R R
Carburetor A A A C
Spark Plug X CA CA R
Drive Chain CAL CAL CAL CAL CAL
Gear Box Oil X X X R
Engine Oil X X R R R
Chassis X X X X
Valve Clearance A A A A
Reverse Cable A A A A
Reverse Assy. X
Battery X X X R
Cooling Water X X X X X
Throttle Cable X X R
Drive Belt X R R
Driven Plate Sub Assy. X X R
Fuel Filter X C C R
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
a) find an approved DAZON dealer to carry out the 1
st
service and quarterly service;
b) keep the proof of any service carried out. As in the unlikely event of a warranty claim being necessary, the
service history needs to be available.
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2.3 Mainte nanc e 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.
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;
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.
2.3.2 Tire Pressure / Wear
Check the tire pressure before each of your driving.
The tire pressure is very important for the riding stability.
Specifications: Front Tire: 175kpa
Rear Tire: 200kpa
2.3.3 Brake Performance
a) Always check if there is plenty of brake fluid in the brake fluid
reservoir;
b) Check if the front/rear brake pad is in good condition;
c) Check the brake rotor for abnormal wear.
2.3.4 Air Cleaner
Clean the air cleaner quarterly, or more often when driving in dusty
conditions.
If the air cleaner is clogged with dust, its performance will be severely
decreased, even the engine damages will probably be caused.
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Inspection and Cleaning of Filters
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 solvent;
c) Submerge the filter in oil and squeeze it to remove excess oil;
d) Install the filter element back into the air box.
2.3.5 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.
2.3.6 Tightening Torque Table
Conventional Marked Bolt 8.8 Marked Bolt Bolt Diameter
(mm)
N•m Kg•m lb-ft N•m Kg•m lb-ft
4 1-2 0.1-0.2 0.7-1.5 1.5-3 0.15-0.3 1.0-2.0
5 1-4 0.2-0.4 1.5-3.0 3-6 0.3-0.6 2.0-4.5
6 4-7 0.4-0.7 3.0-5.0 8-12 0.8-1.2 6.0-8.5
8 10-16 1.0-1.6 7.0-11.5 18-28 1.8-2.8 13.0-20.0
10 22-35 2.2-3.5 16.0-25.5 40-60 4.0-6.0 29.0-43.5
12 35-55 3.5-5.5 25.5-40.0 70-100 7.0-10.0 50.5-72.5
14 50-80 5.0-8.0 36.5-58.0 110-160 11.0-16.0 79.5-115.5
16 80-130 8.0-13.0 58.0-94.0 170-250 17.0-25.0 123.0-181.0
18 130-190 13.0-19.0 94.0-137.5 200-280 20.0-28.0 144.5-202.5
2.3.7 Fuel Switch Inspection
a) Stop the engine, remove the gasoline tube from the carburetor, and check if the gasoline is
flowing;
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 p roperly and no fore ign m ateria l can pass by it
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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;
c) Remove the negative pressure tube from the gasoline supply tube, and suck it with mouth or
apply pressure on it with a vacuum pump, and then release the pressure;
If the gasoline flows out of the gasoline tube when under pressure, and stops flowing when
released from pressure, the switch is in good condition.
Note: a) Smoking and lighting fires are strictly forbidden.
b) Before the operation, blow enough air from the supply side of the negative pressure switch,
so as to eliminate the stuff sticking on the diaphragm.
2.3.8 Final Gear Oil
Inspect the final gear oil monthly and replace it quarterly.
a. Check the oil level: remove the oil level screw on the left rear
engine case;
b. Drain out the oil: remove the drain plug at the rear bottom of
the engine case;
Recommendation: before draining the final gear oil, please
warm the engine for at least 10 minutes.
Notes: We recommend the Mobile 85w/90 gear oil for the final drive case. However, in extreme
cold weather conditions, the vehicle may become hard to start, so we advise some lighter viscous
oil, such as 75 wt or the equivalent motorcycle transmission fluid.
2.3.9 Engine Oil
Inspect the engine oil before every riding and replace it monthly.
a) Remove the drain plug from the left side bottom of the engine,
and drain out the left oil into an oil pan for disposal;
b) Remove the large cap on the left bottom of the engine ,and
remove the screen;
c) Wash the screen with some cleaning solvent and reassemble it;
make sure that the O-ring is still in good conditions;
d) Refill the engine with the SAE10W/30SF engine oil and run the
engine for 5 minutes;
e) Check the oil level on the filler cap stick to assure that it’s proper;
Gear Oil Capacity 0.2L 85w/90
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f) 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;
b) If it’s used in extremely wet, muddy or dusty conditions, we recommend you to service it more
often.
2.3.11 Reverser Adjustment
a) Press down the reverse lever to the "FW" position so that the
units can move forward;
Pull back the lever to "BW" so that the units can move backward.
b) Adjusting Nut #1 on the top of the reverse cable can adjust the
mesh status inside the reverse gear box. In the forward position
there should be about 1/4 inch play in the cable for the correct
adjustment.
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3. Engine
3.1 Lubrication System
3.1.1 Lubrication diagram
3.1.2 Trouble shooting
z 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.
z The engine oil is dirty.
a) The engine oil isn’t replaced in time;
b) The cylinder head gasket is damaged.
z The lubrication isn’t good.
a) The engine oil level is too low;
b) The oil filter is clogged, or the oil pipes are clogged;
c)
The oil pump is damaged
3.1.3 Specifications
Engine Oil Capacity 1.0L (Disassembling) 0.8L (Replacing)
Engine Oil 10W/30SF
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3.1.4 Engine Oil
z 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.
z Replacement
a) Remove the oil filler cover, and drain out the oil remnant
when the engine is warm;
b) Reassemble the cover;
Torque: 18-20 N.m.
c) Check if the O-rings are damaged; replace if necessary;
d) Fill in the same type of engine oil;
Engine oil capacity: 1.0 L (Disassembling)
0.8L (Replacing)
Engine oil type: 10W/30SF
e) Start the engine to check if there is any oil leakage;
f) Stop the engine and check the oil level again.
z Engine Oil Screen
a) Drain out the oil;
b) Take out the spring filter;
c) Assemble the screen, spring and filter cap;
d) Add enough oil into the engine.
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3.2 Cylinder Head & Valve
3.2.1 Disassembly Diagram
1.
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.
9. Spark Plug 10. Exhaust Valve
11.Tensioner 12. Gasket, Tensioner
13. Cylinder 14. Gasket, Cylinder
15.Rubber Pipe, Water Inlet 16.Intake Valve
17.Intake Pipe Comp. 18.Thermostat Comp.
19. Temperature Sensor 20.Rubber Pipe, Water Return
21.Guide Bar 22.Valve Comp.
123
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
13
14
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3.2.2 Trouble Shoot ing
z The compression is too low or not st able.
a) Valve
The lifter isn’t adjusted well;
The valve is burnt or deformed;
The valve spring is damaged;
The valve timing is faulty;
The valve seat seal is faulty.
b) Cylinder Head
The cylinder head gasket leaks air;
The cylinder head is deformed or cracked.
c) Cylinder piston is faulty.
z The compression is too high.
There is carbon accumulation on the piston or in the combustion chamber.
z Noise
The lifter isn’t adjusted well.
The valve is burnt, or the valve spring is damaged or worn.
The rocker or the rocker shaft is damaged or worn.
3.2.3 Assemble Valve Rocker Arms & Shafts
a) Check if the seals on the valve rocker arm shafts are in good
condition; if damaged, replace them;
Put some engine oil on the surface of the rocker arm shafts and
the seals.
b) Assemble the two valve rocker arms (exchangeable) in the
place as shown in the picture;
Valve Rocker Arm
Seal
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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”
into the holes on the right side of the cylinder in the same way;
d) Turn the dials of the two rocker arms to the position as shown
in the picture;
Fasten the two dials.
3.2.4. Adjust Valve Clearance
a) Open the engine peephole cap;
Adjust the flywheel “ T ” to the maximum reading, while
the engine piston reaches the top dead point;
b) Loosen the lock bolts at the intake / exhaust valve dials;
;
Hole on Left Side
of Cylinder
Hole on Right Side
of Cylinder
Rocker Arm of
Ex. Valve
Rocker Arm of
In. Valve
Engine
Flywheel
In. Valve Dial
Ex. Valve Dial
Lock Bolt
Lock Bolt
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c) Turn fully outward the intake / exhaust valve dials until the
dials can’t be turned any more;
d) Turn inward the intake / exhaust valve dials for
1.5~ 2.0 scales (at this moment, the valve clearance
should be 0.08mm~0.1mm);
e) Fasten the lock bolts at the intake / exhaust valve dials.
Inward
Ex.
Valve
Dial
Outwar
d
In.
Valve
Dial
Outward
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3.3 Dr ive 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)
5
1
2
34
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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. Drive Surface
a) Check if the clutch cover is worn or damaged;
Measure the inner diameter;
Replace the clutch if its inner diameter is above 130.5 mm.
b) Check if the clutch shoes are worn or damaged;
Measure the thickness.
Replace the clutch shoes if the thickness is below 2.0 mm.
c) Check the free length of the drive spring;
Replace the spring if its free length is below 83.2 mm.
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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. Transmission Shaft, Counter 12.Washer 14.5*32*1
13. Transmission Shaft, Main 14.Oil Seal 20*32*6
15.Gearbox 16.Gasket, Gearbox
17.Bearing 6204 18.Breather Pipe, Gearbox
1
2
8
13
12 11
10
9
3
4
5
6
7
14
17
16
15
18
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3.4.2 Fin a l Transmission Box Oil
z 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.
z Replacement of Gear Oil.
Specifications: Oil Capacity: 0.2 L
Specified Gear Oil: Mobil 85w/90
Oil Level Bolt Torque: 14-18 N.m
a) Check if there is any oil leakage after running the engine;
b) Check the oil level again;
c) Check if the oil seal is damaged;
Replace it if necessary.
3.4.3 Troubl e Shooting
z The engine can be started, but the vehicle can’t run;
a) The gears are damaged;
b) The gears are burnt.
z There is noise when driving the vehicle.
a) The gears are worn or burnt, or the gear surface is damaged;
b) The bearing is worn or shaking.
z The oil leaks.
a) There is too much oil;
b) The oil seal is damaged or worn.
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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. Oil Pipe
9. Oil-Pass Bolt C 10.Cap, Oil Filter Screen
11.Spring, Oil Filter Screen 12.Oil Filter Screen
13.Crankcase Cover, Right 14.Gasket, Right Crankcase Cover
15.Breather Pipe, Right Crankcase Cover
1
2
3
15 4
5
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3.5.2 Troubl e Shooting
z 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.
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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. Crankcase, Left
9. Shock Absorber Sleeve, Rear
1
3
4
2
5
6
7
9
8
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3.6.2 Troubl e Shooting
z Engine noise
a) The bearing is loose.
b) The crankshaft pin bearing is loose.
c) The piston pin and the piston pinhole are loose.
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3.7 Cooling System
3.7.1 Disassembly Diagram
3.7.2 Specifications
Pressure of Water Tank
Cover Petcock
0.9+/-0.15 Kg/Cm2
Volume of Cooling Fluid About 1450cc Water Tank: 1100 Cc
Subsidiary Water Tank: 350 Cc
Notes:
a) Use the specified water tank fluid.
b) Don’t mix the fluid of different brands together.
c) The water tank fluid is poisonous, please don’t drink it.
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3.7.3 Points for Attention
z The water pump repair and other operations of the cooling system can be carried out on the
vehicle;
z Carry out the operations when the engine has cooled down;
z Don’t open the water tank cover when the water temperature is above 100℃;
z Don’t spread the water tank fluid onto the tank surface paint; if the fluid spreads out, clean up
the fluid with water;
z After the inspections and repairs, use a water tank pressure tester to check all the joints and oil
seals for leakage.
3.7.4 Cooli n g S y stem Pressure Test
a) Check the water tank cover;
b) Apply some water on the surface of the water tank cover oil seal,
and install the water tank cover on the water tank tester;
c) Apply the standard pressure on the water tank cover with the
tester for about 6 seconds to check its stability.
Note: Pressure for the opening and closing of the cover cock:
0.9+/- 0.15kg/cm2.
d) Check the water pipe joints for leakage.
Note: The test pressure shouldn’t exceed 1.05kg/cm2;
otherwise the joints of the water tank may be damaged.
3.7.5 Wate r Tank
a) Check the water tank fluid level;
b) Use the specified water tank fluid (standard concentration: 30%);
Note: the engine temperature doesn’t affect the fluid level.
c) Add some fluid up to “F” (the upper limit);
d) Replace the fluid when the engine is cold;
Specifications: Water tank capacity: about 1100cc
Subsidiary water tank: about 350cc
e) Check if the welding seam of the radiator is damaged or leaking;
f) Clean the radiator plates if they are clogged or dirty;
Repair if the radiator plates are deformed.
3.7.6 Wate r Pump
a) Check the water seal of the water pump;
Check the drain hole under the right crankcase cover for leakage;
If there is any leakage, the water seal of the water pump is faulty;
Remove the right crankcase cover and replace with a new water
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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;
d) Assemble the water pump shaft and the inner
bearing into the right crankcase;
Lock the bearing with the clip;
e) Assemble the right crankcase cover;
f) Assemble the water pump impeller;
Replace the water pump water seal together
with the impeller water seal if necessary;
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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;
Assemble a new water seal into the right crankcase cover;
Note: Apply the water seal agent on the mating surface of
the water seal and the right crankcase cover
before assembly.
i) Assemble water pump shaft;
Assemble a new outer bearing of the water pump shaft
inside the right crankcase cover.
3.7.7 Heat Sensor
z Disassemble
a) Remove the rear side cover on the right;
b) Drain out the water tank fluid;
c) Disconnect the heat sensor wires;
d) Remove the heat sensor.
z Inspection
a) Put the heat sensor into the testing container;
b) Raise the water temperature slowly;
c) Measure the resistance value of the heat sensor.
z Resistance Value
Temperature ( )℃ 50 80 100 120
Resistance value (Ω) 154 52 27 16
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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℃.
3.7.8 Trouble Shooting
z Water temperature rises.
a) The heat sensor of the thermometer is faulty.
b) The water tank cover is faulty.
c) The temperature petcock is faulty.
d) The tank fluid is insufficient.
e) The pump water pipe and water sleeve are clogged.
f) The radiator of the water tank is clogged.
g) The inner part of the water tank is clogged.
h) The water pump is faulty.
z The water temperature rises, but the thermometer doesn’t show any signs of rising.
a) The heat sensor of the thermometer is faulty.
b) The temperature petcock is faulty.
z Overheating.
a Water in the water tank is not enough. Please fill the water tank at 2~3 times.
b Water hoses are not correctly connected, or not properly connected.
c Fan is out of order.
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3.8 Carburetor
3.8.1 Disassembly Diagram
Carbureto r Hoses Position i ng
Picture 1. Picture 2.
1. Fuel Hose 7. Oil Drainage Screw; Carburetor
2. Breather Hose, Engine 8. Rubber Hose, Oil Drainage
3. Pressurized Hose (connecting with Air Intake Hose)
4. Three-Way Hose and Clamp
5. Thin Water Hose (connecting with Thermostat and
Thin Water-Inlet Hose of Water Tank);
1
2 3 4
3
5
6
7
8
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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 100
Low Speed Jet # 35
Idle Speed 1500+/-100rpm
3.8.3 Points for Attention
a) No smoke or fires in the working places.
b) Assemble the O-rings correctly and replace with new ones.
c) Drain out the fuel in the float chamber before disassembly.
d) Don’t disassemble the automatic choke by yourself.
3.8.4 Inspection of Automatic Fuel Cup
No smokes or fires!
a) Stop the engine and pull the fuel tube from the carburetor;
b) Check if the fuel flows out;
The fuel cup is normal if the fuel stops flowing after all the
remaining fuel in the fuel cup and tube (5-10cc) has been
drained out;
If the fuel continues to flow out, the negative pressure tube
is clogged.
c) Pull the negative pressure tube from the air intake pipe and
suck with mouth to produce negative pressure on the vacuum
film;
If when the vacuum film produces negative pressure, the fuel
flows out of the fuel tube, and when the negative pressure
stops, the fuel stops flowing, then the automatic fuel cup is
normal.
d) If the fuel doesn’t flow out when the negative pressure is
applied, please follow the following steps:
1.Clear the negative pressure tube if it is clogged;
2.Blow the film from the air intake pipe of the automatic fuel cup.
3.8.5 Automatic Side Circuit Starter
a) Check the automatic side circuit starter;
Check the conduction of all the automatic side circuit starter wires;
Replace the automatic choke if the resistance value exceeds the standard value.
Resistance value: below 10Ω (10 min after the engine stops)
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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.
If the air does not go smoothly, it is normal.
Remove the automatic choke wire from the battery.
Blow with mouth after 30 min.
If the air goes smoothly, it is normal.
3.8.6 Inspection of Fuel Level
a) Check the fuel level of the main jet.
b) Fuel level: 18.5+/-1.0mm
c) Check the float and assemble the float fuel tube.
3.8.7 Adjustment of Idle Speed
a) Adjust the idle speed after warming up the engine.
b) Close the fuel adjusting screw fully; turn back the standard 1
3/4 turning.
c) Adjust the adjusting screw to the specified idle speed.
d) Turn the adjusting screw left and right slightly.
e) Repeat the steps 2, 3.
f) Adjust the throttle adjusting screw to the idle speed position
(1,500+/-100rpm).
g) Run the engine from the low speed to high speed, run the
engine at the idle speed for 10 to 15 seconds to see if the idle
speed is stable;
If it changes, repeat the steps 2-5.
3.8.8 Air Cleaner
a) Check if the air cleaner is damaged;
Replace with a new one if necessary.
b) Clean the air cleaner every 1,000 km.
c) Replace the air cleaner every 5,000km.
3.8.9 Ignition Timing
The C.D.I. is used, so there is no need to adjust the ignition timing.
If the ignition timing is abnormal, check the C.D.I. and AC generator.
z Inspe ction of Ign i tion Timing
a) Use the ignition-timing lamp.
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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.
3.8.10 Spark Plug
a) Check if the spark plug is burnt or dirty.
b) Check if there is any carbon on the spark plug.
c) Clean the spark plug if necessary.
Specifications: Spark Plug: D7
Spark Plug Gap: 0.6-0.7mm
3.8.11 Inspection of Compression
z Compression: 11.0-15.0kg/cm2 (400rpm)
z Trouble Shooting
The compression is too low.
a) The valve leaks.
b) The valve clearance is too big.
c) The cylinder head gasket is damaged.
d) The piston rings are worn.
e) The piston rings and the cylinder are worn.
The compression is too high.
a) There is too much carbon in the combustion chamber and on the piston head.
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3.8.12 Troubl e Shooting
z The engine can’t start well.
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z 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.
d) The air cleaner is clogged.
e) Air is inhaled into the air suction system.
f) The fuel has deteriorated.
g) The air valve doesn’t work well.
h) The negative pressure tube is damaged.
i) The connecting pipe of the carburetor is damaged.
z The engine stalls when the throttle is fully open.
a) The negative pressure piston film is damaged.
b) The negative pressure tube is clogged.
z The mixture gas is too lean.
z The fuel jet is clogged.
z The air hole of the fuel tank cover is clogged.
z The fuel filter is clogged.
z The fuel tube is clogged.
z The float valve does not work well.
z The fuel level is too low.
z The mixture gas is too rich.
a) The automatic choke is opened too widely.
b) The float valve doesn’t work well.
c) The fuel level is too high.
d) The air cleaner is clogged.
e) The automatic chock isn’t assembled correctly.
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.
Solvent:
a. Check if there is any damage or leakage on the
pressurized tube of oil cock;
Pressurized
Tube
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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.
b) Spray a little carburetor cleanser into the
carburetor.
c) 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.
Connecting
Tube
Spray
Cleanser
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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.
c) In order to maintain the excellent performance and long service time of the reverse gear, please
don’t shift gear when traveling at high speed;
d) Service the reverse gear periodically. Replace the lubricant every 5000km or 6-month of running.
Lubricant: Lithium base grease.
Capacity 220ml
4.2 Precautions
a) Before servicing or maintaining., remove the reverse gear from the vehicle frame;
b) When assembling, make sure to insert the pin into the splined tube grooves, and meanwhile lock
the bolt in the corresponding positioning grooves of the fork shaft,
Note: Close the bolt fully, turn back the standard 1/2 turning, and tighten the lock nut.
4.3 Removal and Assembly
The picture below is the disassembly diagram of the reverse gearbox.
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4.3.1 Removal Sequence
Drive sprocket—Gearbox cover—I shaft—Center shaft—Lock bolt—Output shaft—Fork—Fork
shaft—Output Gear
4.3.2 Assembly Sequence
Reverse the removal sequence.
4.4 T r oubleshooting
z Gearshift is out of order.
a The adjustment of shifting cable is improper.
b The swing angle of the pin on the gearshift fork is too big.
c The brake is out of order, the lock bolt isn’t locked in the positioning grooves of the fork shaft,
and the fork shaft is caused to fall off the gearbox.
d The needle bearing of the output gear is damaged.
e The return spring cannot rebound well.
f The circlip on the I shaft or input shaft has fallen off, and the gear shaft is caused to move
axially.
g The splined tube is damaged.
h The grooves of the output gear are damaged.
z Abnormal noise in gearbox.
a. The circlip on the I shaft or intput shaft has fallen off, and the gear shaft is caused to move
axially.
b. The splined tube is damaged.
c. The output gear is damaged.
d. The lubricant loses efficacy, and the lubricating effect isn’t good.
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5. Wiring Diagram
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