Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 FOREWORD This service manual has been specially prepared to provide all the necessary information for the proper maintenance and repair of the RAIDER CLASSIC 150 (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.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 CONTENTS 1. General Information -------------------------------------------------------------------------------------4 2. Periodic Maintenance and Tune-up Procedures -----------------------------------9 3. Engine --------------------------------------------------------------------------------------13 3.1.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 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 cross member and stuck behind the seat. 1.1.2 Engine Number The engine number is located on the lower front left side of the engine case. 1.2 Fuel and Oil Recommendations Be sure to use the specified fuel and oil 1.2.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) 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 VIN Accord with GMVR A01-01 Statutory Plate& Safety Labels Accord with GB 7258-1997 ENGINE Model DZ1P57QMJ Type Oil-cooled, single cylinder, 4-Stroke Engine Capacity 150cc Displacement 149.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) Top Speed EEC Version;3.0 Feb..2005 60kmph Tachometer 33~40km/h (meter scale: 40km/h) Turning Radius 3m Acceleration Noise Level ≤80dB(A) / 3.5m Horn DL80-90 12V 3A 105dB, 93
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) 1.5 Location of Parts Double-seat: 7 EEC Version;3.0 Feb..
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) Awning Single-seat: Roll bar Steering wheel Control panel EEC Version;3.0 Feb..
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 2. Periodic Maintenance and Tune –up Procedures 2.1 Periodical Checks and Services The maintenance intervals in the following table are based upon average riding conditions. Riding in unusually dusty areas requires more frequent services.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 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.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 2.2.5 Nuts and Bolts in Chassis Inspect the nuts and bolts in the chassis during the first week and every month thereafter. The nuts and bolts become loose normally after use, please check for the looseness regularly. 2.2.6 Tightening Torque Table Bolt Diameter (mm) 4 5 6 8 10 12 14 16 18 Conventional marked bolt N•m Kg•m lb-ft 1-2 0.1-0.2 0.7-1.5 1-4 0.2-0.4 1.5-3.0 4-7 0.4-0.7 3.0-5.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 2.2.9 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.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) 3. Engine Troubleshooting for Failure in Starting Engine 13 EEC Version;3.0 Feb..
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) 14 EEC Version;3.0 Feb..
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 Troubleshooting for Failure in Starting Carburetor 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.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 3.1 Cylinder 3.1.1 Cylinder Removal The removal can be done on the vehicle body. a) Remove the cylinder head; b) Remove the cylinder; c) Remove the cylinder gasket and bolts; d) Clean the cylinder gasket. Don’t damage the bond area of the cylinder. Don’t drop sundries like the cylinder gasket material into the crankcase. 3.1.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 If the wear is too severe and cannot be reworked, a new cylinder should be installed. Cylinder bore 57.4mm Cylindricality 0.05mm Circularity 0.05mm 3.2 Crank Connecting Rod Mechanism 3.2.1 Piston Set Inspection and Service of Piston Pin a) Insert the piston pin horizontally into the pinhole of the piston, and inspect the clearance between the piston and piston pin.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 3.2.3 Inspection of Connecting Rod End a) Put the piston ring and bearing into the connecting rod end; inspect the tightness degree of the piston pin in connecting rod end. b) Measure the inner diameter of the connecting rod end. Service limit 15.06 mm c) When the abrasion of the bore exceeds the limitation, it should be replaced. 3.2.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 3.2.6 Crank Connecting Rod Set The connecting rod is the component that links the piston and crank. The picture shows the structure and assembly relations of the crank connecting rod component. 3 2 1 4 5 6 7 8 9 10 11 1. Shock Absorber Cover, Rear. 2. Shock Absorber Cover, Front. 3. Starter Gear 5.Timing Chain 7. Crankcase Body, Left 9. Crankcase Paper Washer 11.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) 3.3 Crankcase and Crankshaft 3.3.1 Removal a) Remove the engine, cylinder cover, cylinder and piston one by one. b) Remove the drive plate, driven plate, AC generator, starting motor and oil pump. c) Remove the cam chain tensioner bolt and cam chain tensioner. d) Use the special tools to remove the starting driven gear. e) Remove the crankcase positioning bolts; Separate the right crankcase and the left crankcase.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 h) Remove the crankshaft from the crankcase; Take out the cam chain. i) Clean up the gasket on the crankcase joint face; Pay attention not to damage the joint face. j) Remove the oil seal from the left crankcase. j) Remove the oil seal from the right crankcase. 3.3.2 Inspection of Crankshaft and Crankcase Replace the whole set of the crankshaft if any serious wear is found while inspecting.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) Service limit EEC Version;3.0 Feb..2005 0.10mm (A = 90) 0.10mm (B = 105) e) Examine if there is any looseness or unusual sound when the crank journal bearing turns; If there is, the whole set should be replaced. f) Inspect if the joint face of the crankcase is smooth and clean; Notice if it will affect the sealing performance between the left and right crankcase while reassembling.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 e) Mount the starting driven gear. f) Mount the cam chain tensioner; Mount the new O-ring on the cam chain tensioner bolt; Apply some oil on the O-ring; Tighten the cam chain tensioner bolt. The o-ring must be mounted in the groove. 3.4 Valve Mechanism The picture shows the common valve train of a four-stroke engine.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) 15 Valve Spring Holder, Outer 17 Spark Plug 19 Cylinder 21Chain Adjustor EEC Version;3.0 Feb..2005 16 Guide Pipe, Valve 18 Intake Port 20 Washer 3.4.1 General Introduction The four-stroke engine completes its four strokes with one piston stroke. The four strokes: Intake stroke, Compression stroke, Expansion stroke, and Exhaust stroke. 3.4.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 Sometimes when tightening the lock nuts, it will change the clearance. So it must be rechecked for the proper clearance. Valve clearance 0.06~0.07 mm 3.5 Camshaft The camshaft is a main driving unit of the valve train. There are the air inlet cam, the exhaust cam, and the cam journal on the shaft. It controls the intake and exhaust valves to open and close at the correct time.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 f) Remove the camshaft holder and dowel pin; Remove the cam chain wheel from the cam chain, and remove the camshaft. 3.5.2 Inspection a) Inspect the camshaft bearings for play. If there is any play, replace the whole set; b) Inspect the cam surface for damages; c) Measure the height of the cam. Inlet Cam 25.96 mm Exhaust Cam 25.815 mm 3.5.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 e) Replace the valve cover gasket; Mount the cover. The valve cover gasket must be mounted properly in the groove. f) Tighten the valve cover-positioning bolt 3.6 Rocker Arm and Rockshaft 3.6.1 Removal a) Remove the camshaft holder; b) Take out the rockshaft by removing the bolt; c) Remove the rocker arm. 3.6.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 The operational principle of the tensioner is as shown in the picture. As for the adjustment of the cam chain tensioner, turning clockwise is tightening, and turning anticlockwise is loosening. 3.7 Valve and Valve Spring 3.7.1 Removal a) Remove the cylinder head.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 b) After applying oil on the valve stem, mount it into the valve guide. c) Mount the inner and outer valve springs; Mount the valve lock with a spring compressor. When mounting, the twisting direction of the inner and outer springs must be opposite, and can’t be the same. d) Tap the valve gently two or three times with a rubber hammer to make the valve and valve lock match well.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 3.8.3 Replacement a) Heat the cylinder head to 100 – 150 ºC. The cylinder head must be wholly and quickly heated to the specific degree, and can’t be heated partly; otherwise it'll cause the cylinder head distortion. The temperature is very high, so two technicians are recommended. b) Tap the valve guide out with a valve guide remover or the similar tool. Don’t damage the cylinder joint face.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) The valve seat-grinding cutter is the customized trimming tool for the valve seat, and it has three cutting angles: 32º, 45º, and 60º. While trimming, press the valve seat-grinding cutter to make the rotary motion with 40 - 50N force. Some oil must be applied on the valve seat-grinding cutter to eliminate scraps when trimming. 3.9.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 b) If the contact position is too high, then cut out some of the upper part of the valve seat with a 32º grinding cutter to reduce the working face of the valve seat; if the contact position is too low, then cut out some of the lower part of the valve seat with a 60º grinding cutter to raise the working face of the valve seat.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 3.10 Lubrication System 3.10.1 General Introduction The picture shows the functional diagram of the lubrication system.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 e) Install the oil filter screen and screen cover, and tighten them. e) Supply the specified oil to the specified level. Oil level Disassembling Replacing 1.0 L 0.8 L f) Start the engine and run for several minutes in the idle position to make sure there is no oil leakage. g) Stop the engine and inspect if the oil level is proper. 3.10.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 f) Remove the screws, and disassemble the oil pump. Oil Pump Inspection a) Inspect the clearance between the oil pump body and outer rotator. Service limit: 0.12 mm b) Inspect the clearance between the inner rotor and outer rotor. Service limit: 0.12 mm c) Inspect the clearance between the rotor plane and the oil pump. Service limit: 0.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 c) Tighten the oil pump plate screws; After assembling, gently turn the oil pump shaft, and make sure the oil pump can turn smoothly. Oil Pump Installation a) Install the oil pump on the crankcase. Before installing, fill the oil pump with oil. When installing the oil pump on the crankcase, the arrow of the oil pump body must be upwards. b) Tighten the oil pump positioning bolts.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 3.11 Fuel Supply System 3.11.1 Carburetor Idling Adjustment Air Adjusting Screw Adjustment Step one: Turn on the air adjusting screw in, then turn out by the prescribed number of turns; Turn out numbers of turns 3 1/8 +/- 3/4 Step two: Adjust the throttle adjusting screw to the prescribed idle rpm; Step three: Adjust the air adjusting screw slightly to find the highest position of the rpm.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 Remove the carburetor; Remove the vacuum cover bolt and vacuum cover. Notice: Move slowly to prevent the spring from ejecting. g) Take out the spring, the vacuum membrane and the plunger; Press down the holding clamp of the needle valve top, and turn left to take out the clamp; Take out the spring and needle valve. Don’t damage the vacuum membrane.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 e) Remove the auto side starter cover, positioning bolts and pieces; Remove the auto side starter; Inspect the auto side starting valve and fuel injection needle for wear. Inspect the O-ring for wear. 3.13 Float Chamber 3.13.1 Removal a) Remove the carburetor. b) Remove the clamp and float chamber. c) Remove the O-ring, and turn out the float chamber screw.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 3.13.4 Carburetor Installation Reverse the removal procedure for installation. After installing, make sure that all carburetor linkages and cables are in correct position, and the carburetor is in idle position. 3.14 Air Cut Valve (ACV) 3.14.1 General Information The air cut valve can avoid some abnormity once the throttle closes too quickly; for example, when the mixed gases are too thin.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 The bottom side of the vacuum membrane should be aligned with the carburetor, and the topside should be aligned with the vacuum membrane. 3.15 Air Check Valve The air check valve starts working under 50km/h, impels the second air inlet to burn, and reduce the CO displacement. 3.15.1 Installation Reverse the removal procedure for installation.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 Armature Inspection a) Inspect the armature surface for uneven wear or damages or burn; When where are metal fines attached to the gap of the armature surface, use a cleaning cloth to remove them. Please don’t use the sandpaper to grind the armature, or wash it in any solvent that can dissolve or damage its insulation.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 e) Inspect the needle bearing in the carbon brush base; it should be able to move smoothly with no play. Before installing, apply a little grease on the groove of the rotary retaining spring on the idler shaft. The rotary retaining spring should be aligned with the specific groove of the crankcase for installation. f) Inspect the dust seal for wear and damages; If so, it should be replaced.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 Make sure the starter motor case is free of metal particles, because it is magnetic. Before installing the starter motor on the vehicle after assembling it, first connect the lead wires and inspect if the motor runs normally. d) Apply oil on the O-ring, and install the starter motor; Tighten the holding bolts. 3.17 Reduction Mechanism 3.17.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) 10. Clamp 20. Screw 3.17.2 Reduction Gear Inspection a) Remove the starting clutch. Remove the reduction gear to inspect its wearing degree. b) Measure the inner diameter of the reduction gear. It should be replaced when the diameter is more than 10.05 mm. c) Measure the outer diameter of the reduction gear shaft. It should be replaced when the diameter is less than 9.94mm. 3.18 Engaging Mechanism 3.18.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 b) Inspect the condition of the needle bearing. It should be replaced if there is any damage. c) Inspect if there is any abrasion or damage on the contact surface between the outer clutch component and roller; Inspect if there is any injury on the roller; Inspect if there is any distortion on the spring. If the damage is serious,it should be replaced.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 e) Align the groove of the woodruff key on the crank, and install the starting clutch. f) Apply some oil on the reduction gear and reduction gear shaft, and then install them. g) Hold the drive face with a universal wrench. At the same time fasten the clutch nut. Notice that the thread of the nut should be left-handed rotation.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 d) Inspect if the start button is conductive; at this time, remove the starting relay inlet line (the green/yellow line. e) Connect the yellow/red line with the ground wire, and press the start button. It should be conductive between the yellow/red line and the ground wire; otherwise the start button, its wire, or the wire connector is not good.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 When the diameter of the driving belt pulley changes form small to big, proportionally the diameter of the driven belt pulley changes from big to small (because the perimeter of the driven belt is constant). AT this time the speed increases; on the contrary, the speed decreases. The structure of the driving belt pulley is shown in the picture.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 The picture shows the structure of the driven belt pulley. The clutch showed in the picture is the automatic dry centrifugal weight clutch. Clutch Assembly 3.19.2 Drive Belt Pulley Removal a) Remove the left crankcase air pipe lock bolt; Remove the kick-starter and left crankcase fixing bolt.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) e) Remove the centrifugal rollers. Inspection a) Inspect if there is any abrasion or damage on the centrifugal roller; Measure the outer diameter of the centrifugal roller. Service limit 17.0mm Service limit b) Measure the inner diameter of the movable drive plate. 24.06mm c) Inspect if there is any abrasion or damage on the drive plate hub; Measure the outer diameter of the drive plate hubs movable surface.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) d) Install the movable drive plate on the crankshaft. e) Enlarge the driven plate belt groove, and mount on the driven belt; Mount the other end of the driven belt on the drive plate hub. f) Assemble the drive plate, the drive plate washer and nut. f) Hold the drive plate with a multiuse holder to make it unmovable; At the same time fasten the nut on the shaft.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 b) Measure the inner diameter of the clutch friction plate. Service limit 125.5mm b) Inspect if there is any abrasion or damage on the clutch centrifugal weight friction piece. d) Measure the thickness of the clutch centrifugal weight friction piece. Service limit 1.5mm Disassembly If it is needed to replace the centrifugal weight set, you must disassemble the clutch.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 c) Install the connecting piece, circlip and bottom plate. d) Reverse the removal procedure for installation. When assembling the clutch and driven plate, you must use a clutch spring compressor; otherwise it will damage the spring. No grease on the driven pulley. 3.19.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 b) Inspect if there is any abrasion or damage on the driven plate; Measure the outer diameter of the driven plate pulley hub. Service limit 33.94mm c) Inspect if there is any abrasion or damage on the movable driven plate; Measure the inner diameter of the movable driven plate. Service limit 34.06mm d) Inspect if the groove of the guide pin is worn.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) h) Drive the new needle bearing into with its mark upwards. Use the special tool. i) Apply some grease around the bearing. Installation a) Remove the grease on the driven plate; Assemble the oil seal. Apply a little grease on the O-ring. b) Assemble the movable driven plate into the driven plate; After applying some grease on the roller and guide pin, assemble them into the driven plate hole.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 c) See the drive pulley removal and installation procedure for the replacement. 3.20 Rear Transmission Mechanism 3.20.1 General Information The structure of the rear transmission mechanism is shown in the following picture. 1.Cover, Gear Box 2.Gasket, Gear Box Cover 3. Shaft, Drive 4. Shaft, Counter 5. Shaft, Center 6. Axle, Rear Wheel 7. Bearing 6201 8.Bearing 6202 9. Oil Seal 30*47*7 10.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 3.20.2 Transmission Case Oil Inspection When inspecting the oil level of the transmission case, stay the vehicle on the flat ground and keep the body level. a) Inspect if there is oil leakage around the transmission case. b) After the engine stops, remove the transmission case oil level bolt.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 d) Remove the center shaft comp. and idle gear comp.; Idle gear comp. Center gear comp. e) Remove the nut M5 and bolt M5*25; Nut M5. Bolt M5*25 f) Remove the fork comp. and rear gear shaft comp.. Transmission Case Gear Inspection a) Inspect if the rear gear and rear gear shaft are damaged or worn. b) Inspect if the center shaft, idle gear and idle gear shaft are damaged or worn.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 c) Remove the other 3 bearings; d) Assemble the new bearings; e) Install the driven belt pulley shaft on the left crankcase; Driven belt pulley shaft Left Crankcase f) Assemble the oil seal; Idle gear comp. g) Assemble the idle gear shaft comp. and center shaft comp.. Center gear comp.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) a) b) c) d) EEC Version;3.0 Feb..2005 Check and Service Every time before driving, check if the forward gear and backward gear/reverse gear can work agilely and smoothly; For the safety of traveling, the vehicle must be in the parking state when the reverse gear is working.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 4. Electric System 4.1 Inspection of Charging System 4.1.1 Electric Leakage Test a) Turn the main switch to the "OFF" position. b) Disconnect the negative ground wire from the battery. c) Connect the positive end of the ammeter with the negative end of the battery; Connect the negative end of the ammeter with the ground wire. d) Test the electric leakage.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 a) Disconnect the negative battery lead wire; b) Disconnect the positive battery; The disconnecting order can’t be reversed. When disconnecting the positive cable, don’t touch the body of the vehicle with the removal tool; otherwise the short circuit will occur and the gas will be ignited to damage the battery. 4.2.2 Installation a) Connect the positive cable; b) Connect the negative cable. 4.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) Charging Time Charging Normal 5-10 hours Fast 30 minutes Result EEC Version;3.0 Feb..2005 Open-circuit voltage >=12.8V 4.3 Primary Coil 4.3.1 Structure The picture shows structure of a common generator. 1. Cooling fan 2. Generator assembly 3. Flywheel comp. 4. Stator comp. 5. Washer 6. Bolt 7. Nut 8. Bolt 9. Bolt 4.3.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 4.4 Generator 4.4.1 Generator Removal a) Remove the cooling fan cover bolt and screw; Remove the cooling fan cover; Remove the cooling fan bolt and cooling fan. b) Hold the flywheel with a universal holding wrench; at the same time, remove the flywheel nut. c) Remove the flywheel with a flywheel puller; Remove the solid key. d) Remove the generator wire connector.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 4.5 Regulator –Rectifier 4.5.1 Inspection of Main Wiring-Sub Electric Circuit Condition Take the voltage regulate rectifier inspection procedure by two steps: First inspect the main wiring—sub electric circuit condition, and then inspect the voltage regulator. Inspect only when the engine is cold. a) Remove the 4-core connector of the regulate rectifier.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) G (Green) ∞ 5 - 100 KΩ EEC Version;3.0 Feb..2005 ∞ 4.5.2 Inspection of Regular -Rectifier When the main wiring—sub electric circuit condition is normal, inspect the regulatorrectifier. a) Inspect if the regulator- rectifier plug contacts well. b) Measure the resistance value between every regulator- rectifier terminal. b) If the resistance value between the terminals is unusual, replace the regulator- rectifier. 4.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 a) Remove the ignition timing hole cover (or remove the fan cover). b) Rotate the generator rotor, and align the “F” mark on the motor with the crankcase timing ignition mark. b) Clip the ignition timing indicator light wire clip on the high-voltage end of the ignition coil.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) Standard value EEC Version;3.0 Feb..2005 4-300Ω(20℃) 4.7.6 CDI Component Inspection It is similar with the regulator inspection. The CDI component inspection is also divided into two steps: first, inspect every wiring, winding or coil connected with CDI; then, inspect the CDI component. a) Remove the CDI component. b) Inspect if the connector is loose or eroded.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 If the resistance value is ∞, the coil is bad and should be replaced. 4.8.4 Secondary Ignition Coil Inspection a) Install the spark plug cap, and measure the resistance value of the secondary ignition coil; If the resistance value is in the standard range, the coil is good; otherwise the coil is bad.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) 5. Chassis 5.1 Rear Axle Removal a) b) c) d) e) Disassemble the rear Wheel. Remove the cotter pins on the rear wheel axle nut. Remove the axle nut. Block up the rear end of the machine. 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. 5.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) 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 Adjustment of Front Shock There are 5 adjustment positions on the front shock. The default position would be set by the manufacture in the middle (the third position).
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 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.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 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. 5.11 A-Arms a) Grease the nipples of the upper & lower a-arms on the front wheel periodically. b) Remove the bolts on the upper & lower a-arms of the front wheel.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 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. 5.14 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.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) EEC Version;3.0 Feb..2005 c) It is advisable to replace the spark plug at least once a year to insure the easy starting and good engine performance. 5.17 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.
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) 78 EEC Version;3.0 Feb..
Raider-Classic 150 (Oil-cooled&Internal Gearbox): Service Manual (single/ double-seat) 6. Wiring Diagram 79 EEC Version;3.0 Feb..
