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.
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.
Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006 1. INFORMATION SAFETY z z z Gasoline is extremely flammable and is explosive under certain conditions. Do not smoke or allow sparks of flames in your work area. 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.
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.
Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006 1.4 SPECIFICATIONS DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Ground Clearance VIN Statutory Plate & Safety Labels SINGLE-SEAT / DOUBLE-SEAT 1550mm / 1550mm 1000mm / 1100mm 1200mm / 1200mm 1100mm / 1100mm 100mm / 100mm Accord with GMVR A01-01 Accord with GB 7258-1997 ENGINE Model Type Engine Capacity Displacement Bore×Stroke Standard Power Max. Power Max.
Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006 CAPACITIES Fuel Tank Engine Oil Acceleration Climbing Top Speed Turning Radius Noise Level Battery 4.5L 0.7~0.9L ≤15s ＞180 25km/h 1.
Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006 1.
Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb.
Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006 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.
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.
Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006 2.2.4 Air Cleaner 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.
Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006 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 1-4 4-7 10-16 22-35 35-55 50-80 80-130 130-190 0.1-0.2 0.2-0.4 0.4-0.7 1.0-1.6 2.2-3.5 3.5-5.5 5.0-8.0 8.0-13.0 13.0-19.0 0.7-1.5 1.5-3.0 3.0-5.0 7.0-11.5 16.0-25.5 25.5-40.0 36.5-58.0 58.0-94.0 94.0-137.5 N•m 1.5-3 3-6 8-12 18-28 40-60 70-100 110-160 170-250 200-280 8.8 marked bolt Kg•m lb-ft 0.15-0.3 0.3-0.6 0.
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.
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.
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 e) Loosen the 4 bolts on the left/right holder of 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.
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. Rear Brake Swing Arm Rear Brake Caliper Assy. Adjust Bolt Fastening Nut Solution: a) Weld the rear brake swing arm, adjust bolt, and fastening nut together ; Rear Brake Swing Arm Rear Brake Caliper Assy.
Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006 2.
Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006 e) Reassemble the adjust nut of brake cable. Adjust Nut of Brake Cable Adjust Nut of Brake Cable Return Spring Notice: The return spring of brake should be assembled in the exact direction as shown in the picture. Rear Brake Swing Arm Fastening Nut 2.1.
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. Correct All the other ways are wrong, and should be forbidden.
Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006 3 ENGINE 3.1 ENGINE COMBUSTION SYSTEM 3.1.
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.
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.
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. Piston Ring b) Clean the cylinder gasket surface; NOTE: Be careful. Do not drop any gasket material into the crankcase.
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 Lever Comp.
Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006 e) Dismantle the following parts: ---Circlip, External ---Gear, Primary Drive Circlip 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.
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.
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) b) c) d) e) The torque of crankshaft drives the clutch. The torque of clutch transmits the main shaft by gear.
Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006 3.4 FUEL SYSTEM 3.4.
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 .
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; Throttle Cable 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.
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.
Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006 3.5. ENGINE LUBRICATION & COOLING SYSTEM 3.5.1 Troubleshooting z z INSUFFICIENT OIL SUPPLY z TO ENGINE z z z TOO LOW OIL LEVEL IN OIL TANK IMPROPER FIXED OIL TUBES OIL LEAKAGE FROM TUBE ENDS DAMAGED OIL TUBES CLOGGED OIL TUBES BROKEN-DOWN OIL PUMP z ALWAYS INSUFFICIENT OIL z LEVEL z EXTERNAL OIL LEAKAGE WORN CYLINDER HEAD GASKET WORN PISTON RINGS ENGINE ALWAYS RUNS HOT z z IMPROPER ADJUSTMENT OF OIL PUMP POOR OIL QUALITY 3.5.
Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006 3.
Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb.
Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006 4. ELECTRIC SYSTEM 4.
Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb.
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.
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.
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.
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; .
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. .
Raider Mini 90 (single/double-seat): Service Manual z z Version：2.0 Feb. 2006 Charge in a well ventilated area. DO NOT smoke around batteries and keep away from open flame.
Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006 Trouble Shooting Battery Short Circuit Solution Problem: battery short circuit z Purpose: to prevent battery electrodes touch battery box cover and cause battery short circuit Solution: Battery Band 1.
Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006 2. Replace Battery Box Cover a) Assemble the battery + /－ electrode; + Electrode － Electrode Battery b) Put the battery into the battery box; Tel.: (8 Battery Box Plastic Battery Box Cover c) Put on the plastic battery box cover (part no.
Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006 Replaced Battery Box Cover e) The replacement is finished. 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.
Raider Mini 90 (single/double-seat): Service Manual z Version：2.0 Feb. 2006 Spec. Item Length of electric starter carbon brush Standard value 12.0mm Unit: mm (in) Limit value 4.0mm z Trouble Shooting NOTE: Check the following items before looking for the system failure: a) b) c) If the main fuse has been burned (10A); If the wire of the battery or electric starter has got loose; If the battery is leaking. The electric starter doesn’t work Undercharged: Below 12.
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.
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.
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.
Raider Mini 90 (single/double-seat): Service Manual z Version：2.0 Feb. 2006 Troubleshooting Turn on the ignition switch and press the starting switch; check if there is a “Kata” sound from the starting relay switch. Connect the electric starter terminal with the positive terminal of the battery (a thin wire can’t be used because of the high currents). “Kata” sounds Starter runs. Starter doesn’t run.
Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006 5. CHASSIS 5.1 Rear Axle Removal a) b) c) d) 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. e) f) g) h) Remove the rear wheel and hub assembly by sliding off splines of the axle. Remove the chain. Loosen the nuts on the bearing carrier, and remove the bolts. Remove the axle and bearing carriers as a unit.
Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb. 2006 Rear Swing Arm Shock Absorber 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.
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.
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.
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.
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.
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.
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 1st into 2nd gear.
Raider Mini 90 (single/double-seat): Service Manual Version：2.0 Feb.
