3. engine
Contents
1. I I 13 1 Lubrication System 13 2 Cylinder Head A Valve 15 3 Drive Pulley Clutch amp Driven Pulley 20 4 Gearbox 21 5 AC Generator amp Starting Clutch 23 6 Crankcase amp Crankshaft 25 7 Cooling System 27 8 Carburetor 33 4 Reverse Gear Service 41 5 Brake System 43 6 Wiring Diagram 47 Raider Pro 250 single seat double seat Service Manual EEC Version 1 5 April 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 vehicle frame and 1s stuck behind the seat 1 1 2Engine Number The engine number is located on the upper right rear engine case 1 2 Fuel and Oil R2. Raider Pro 250 single seat double seat Service Manual EEC Version 1 5 April 2005 a Turn on the ignition timing lamp b Align the mark F within the range of 3 at the rotation of 1 700rpm Ignition Timing B T D C 13 3 1700rpm c If the rotation is above 3 000rpm the aligning mark should be located before the advanced ignition mark 3 8 10 Inspection of Spark Plug a Check if the spark plug is burnt or has become dirty Check if there is any carbon on the spark plug b Clean the spark plug if necessary Specifications Spark Plug D7 Spark Plug Gap 0 6 0 7mm Wear 3 8 11 Compression Specification 11 0 15 0kg cm2 400rpm Trouble Shooting The compression is too low a The valve leaks b The valve clearance 1s too big c The cylinder head gasket is damaged d The piston rings are worn d 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 36 Raider Pro 250 single seat double seat Service Manual EEC Version 1 5 April 2005 3 8 12 Trouble Shooting The engine can t start well Troubleshooting for failure in starting the engine Analysis of potential causes i _ Check if the crank zami Does nat work works heck I ihe staring gear and the Check ifthe battery speeding clutch of the starting
3. SERVICE MANUAL Raider Pro 250S D Single Double Seat EEC APPROVED ON ROAD Raider Pro 250 single seat double seat Service Manual EEC Version 1 5 April 2005 FOREWORD This service manual has been specially prepared to provide all the necessary information for the proper maintenance and repair of the RAIDER PRO 250 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 Raider Pro 250 single seat double seat Service Manual EEC Version 1 5 April 2005 CONTENTS 1 General Information 4 2 Periodic Maintenance and Tune up Procedures 9 3 Engine
4. property changed suffer critical wear if yes inbet of fuel Ta 2 2 re ER Charge the battery or heck UT lace in case of poor water or other harging in addition bo inthe acharging check the carburetor buoyant hanging system of the harging system of er plami lor failure GE m e Lo the power plant for tank L engine rand spending Hie the staring gear Starting carburetor md the With fuel filter switch motor for abnormal Lo pistes b Starting L Addin replace de heck th the fuel wan hers fusi pw in shart iter and the be Canc urit ubing failure L place LE rumes ke EN ew ugs c el Poor Fair buoyant nd npadi valve s So A m fuel Correct the irc de filter and fue en B ss tubing or tubing for sum starting motor i replacement ructian 5 nag check Tar _ T E r wits 2 Refer ta 2 he speeding 8 3 Skip clutch in Spark Plugs for Poor Fair checking T Clean oF Poor Fair e ventilation replacement tubing arburetor buoyant Check Replace the valve pistons original beangs and starting motor others or repair 37 Raider Pro 250 single seat double seat Servi
5. B 8 Oil Pipe 9 Oil Pass Bolt C 10 Cap Oil Filter Screen Il Spring Oil Filter Screen 12 01 Filter Screen 13 Crankcase Cover Right 14 Gasket Right Crankcase Cover 15 Breather Pipe Right Crankcase Cover 23 Raider Pro 250 single seat double seat Service Manual 3 5 2 Trouble Shooting The AC generator is faulty a The starter reduction gear 15 faulty b The starter motor revolves conversely c The wires haven t been connected well d The starter clutch spring 1s broken dirty or locked 24 EEC Version 1 5 April 2005 Raider Pro 250 single seat double seat Service Manual EEC Version 1 5 April 2005 3 6 Crankcase amp Crankshaft 3 6 1 Disassembly Diagram Torque 8 12 N m 1 1 Shock Absorber Sleeve Front 2 Stud Bolt M8 172 3 Stud Bolt 8 162 4 Crankcase Right 5 Connecting Rod Crankshaft 6 Gasket Left Crankcase 7 Stud Bolt M8 162 5 Crankcase Left 9 Shock Absorber Sleeve Rear 22 Raider Pro 250 single seat double seat Service Manual EEC Version 1 5 April 2005 3 6 2 Trouble Shooting Engine noise a The bearing 1s loose b The crankshaft pin bearing 1s loose c The piston pin and the piston pinhole are loose 26 Raider Pro 250 single seat double seat Service Manual EEC Version 1 5 April 2005 3 7 Cooling System 3 7 1 Disassembly Diagram Subsidiary Radiator water tank Ment sensor _ fonperniure adjuster Impelicr left thread
6. Oil level gauge Drain out the engine oil when the engine is warm 13 Raider Pro 250 single seat double seat Service Manual EEC Version 1 5 April 2005 Reassemble the filler cover Torque 18 20 N m b Check if the O rings are damaged replace them if necessary c Fill in the new engine oil Engine oil capacity 1 0 L Disassembling 0 8L Replacing Engine oil type SAE 10W 30SF d Start the engine to check if there is any leakage Stop the engine and check the oil level again Engine Oil Screen Replacement a Drain out the engine oil and take out the filter cap and spring b Replace the engine oil screen c Reassemble the spring and filter cap d Add the specified engine oil into the engine e Recheck the engine oil level 3 1 4 Trouble Shooting The engine oil level is too low a The engine oil has been consumed naturally b The engine oil has leaked c The piston rings are worn The engine oil is dirty a The engine oil hasn t been replaced in time b The cylinder head gasket is damaged The lubrication isn t good a The engine oil level 1s too low b The oil filter or oil pipe 15 clogged c The oil pump is damaged Raider Pro 250 single seat double seat Service Manual EEC Version 1 5 April 2005 3 2 Cylinder head amp Valve 3 2 1 Disassembly Diagram 22 1 Timing Sprocket 3 Tension Bar 5 Rocker Arm Air Exhaust 7 Rocker Arm Valve 9 Spark Plug 1
7. Tensioner 13 Cylinder 5 Rubber Pipe Water Inlet 17 Intake Pipe Comp 19 Temperature Sensor 21 Guide Bar 2 Timing Chain 4 Air Cleaner Bracket 6 Rocker Arm Air Intake 8 Cam Shaft Comp 10 Exhaust Valve 12 Gasket Tensioner 14 Gasket Cylinder 16 Intake Valve 18 Thermostat Comp 20 Rubber Pipe Water Return 22 Valve Comp Torque 8 102 A p 5 Raider Pro 250 single seat double seat Service Manual EEC Version 1 5 April 2005 3 2 2 Trouble Shooting The compression is too low or not stable a Valve The lifter hasn t been adjusted well The valve is burnt or deformed The valve spring is damaged The valve timing 15 faulty The valve seat seal 15 faulty b Cylinder Head The cylinder head gasket leaks air The cylinder head is deformed or cracked c Cylinder Piston is faulty The compression is too high a There is a carbon accumulation on the piston or in the combustion chamber Noise a The lifter hasn t been adjusted well b The valve is burnt or the valve spring is damaged or worn d The rocker or the rocker shaft is damaged or worn 3 2 3 Assemble Valve Rocker Arms amp 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 ofthe rocker arm shafts and the seals b Assemble the two valve rocker arms exchangeable in the place as shown in the picture 16 Valve
8. Torque 80 14 wm 3 7 2 Points for Attention The water pump repair and other operations of the cooling system can be carried out on the vehicle Carry out the operations when the engine has cooled down Don t open the water tank cover when the water temperature is above 100 Don t spread the water tank fluid onto the tank surface paint if the fluid spreads out clean up the fluid with water After the inspections and repairs use a water tank pressure tester to check all the joints and oil 21 Raider Pro 250 single seat double seat Service Manual EEC Version 1 5 April 2005 seals for leakage 3 7 3 Specifications Pressure of Water Tank Cover Petcock 0 9 0 15 kg cm2 rrr Temperature at Beginning of Opening 72 2 of Adjuster Full Opening Cock Full Opening Volume 3 5 4 5 mm Volume Of Cooling Fluid about 1190cc Water inte 750 Sub Water Tank 420 300 cc Notes a Use the specified water tank fluid b Don t mix the fluid of different brands c The water tank fluid is poisonous so don t drink tt 3 7 4 Water Tank Inspection of Water Tank Cover Cooling System Pressure Test Fewer mter tank a Apply some water on the surface of the water tank cover oil Kay seal b Install the water tank cover on the water tank tester c Use the tester to apply the standard pressure on the water tank cover for about 6 seconds to check its stability Cover water
9. chamber c Remove the front brake chamber Take out the brake pad Inspect for the wear condition on the surface of the brake pad If there are deep dents on the surface of the brake pad or the thickness of the brake pad surface 15 less than 2 0mm replace 44 Brake Pad Raider Pro 250 single seat double seat Service Manual EEC Version 1 5 April 2005 the brake pad Note When disassembling the rear brake chamber only need to Rear Brake Chamber remove the 2 lock nuts on it 1 Lock Nuts 5 2 4 Check Brake Disc n Disc a Check for the wear condition on the surface of the brake disc e M If there deep dents or burn scars on the surface replace the brake disc 5 2 5 Check Brake Chamber a Check if there is any leakage on the piston of the brake chamber Check if the movable brake caliper can move swiftly er If there is any leakage or the brake caliper can t move replace the brake chamber Movable Brake Caliper L2 pt E T a d i RES j Piston 5 2 6 Check Brake Pump a Check if there is any leakage on the piston of the brake pump b Press hard on the brake pedal Inspect if the piston can return to its original position automatically c Ifthere is any leakage or the piston can t return automatically the brake pump is damaged and need replacing Brake Pump 45 Raider Pro 250 single seat double seat Service Manual EEC Version 1 5 Apr
10. electrode Blow the choke with mouth 5 minutes later If the air doesn t go smoothly it is normal c Remove the automatic choke wire from the battery Blow the choke with mouth 30 minutes later If the air goes smoothly it is normal 3 8 6 Inspection of Fuel Level a Check the fuel level of the main jet Standard Fuel Level 18 5 1 0mm b Check the float and assemble the float fuel tube 3 8 7 Adjustment of Idle Speed a Start the engine and warm up for several minutes b Fasten the fuel adjusting screw fully and turn back the standard 1 3 4 turns c Adjust the fuel adjusting screw to the specified idle speed d Turn the fuel adjusting screw left and right slightly e Repeat steps c d f Adjust the throttle adjusting screw to the idle speed position g 1 500 100rpm g Run the engine from low speed to high speed Run the engine at the idle speed for 10 15 seconds to see if the idle speed is stable h If the idle speed changes repeat steps cf 3 8 8 Inspection of Air Cleaner a Check if the air cleaner 1s damaged b Replace it with a new one if necessary c Clean the air cleaner every 1 000 km of running d Replace the air cleaner every 5 000km of running 8 3 8 9 Ignition Timing Adjustment of Ignition Timing The C D I is used so there is no need to adjust the ignition timing If the ignition timing isn t normal check C D I and AC generator Inspection of Ignition Timing
11. lever to the RES position to use the reserved fuel supply and refuel as soon as possible b OFF position It s the closing position When the vehicle is not in use always make sure that the petcock 15 in the OFF position 2 2 7 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 11 Raider Pro 250 single seat double seat Service Manual EEC Version 1 5 April 2005 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 Gear Oil Capacity 0 20 85w 90 2 2 8 Engine Oil Inspect the engine oil before every riding and replace it 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 COME vv screen Dil jawal gauge c Wash the screen with some cleaning solvent and reassemble it make sure that the O ring 15 still in good conditions d Refill the engine with the SAEI0W 30S
12. replace it if it s torn 2 Make sure that the element is seated properly and no foreign material can pass by it Raider Pro 250 single seat double seat Service Manual EEC Version 1 5 April 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 5 Tightening Torque Table Bolt Diameter mm C s fue fos usse fs fosos foss _ 6 47 0407 3050 80 0812 6085 8 tie 1016 70115 1808 1828 130200 Fuel Pipe 2 2 6 Fuel Pipe amp Pressurized Pipe FuelPipe connects with the carburetor Pressurized Pipe connects with the engine air inlet pipe and controls the fuel outlet When the pipe 1s pressurized the fuel valve 1s open then the fuel runs out of the fuel pipe but if there is no pressure in the pipe the fuel valve is closed so the fuel cannot run of the fuel pipe Pressurized Pipe e Fuel Valve Lever On this vehicle there is a manually operated fuel valve lever with three positions M cpm pcm ec d EE D 4d ie 29 a ON position It s the normal operating position where the fuel d TD vw flows inio the carburetor gi A bm b RES position If the fuel lever is in the ON position and it is too ell RES OFF ON low for the engine to operate turn the fuel
13. the fuel tube from the carburetor b Drain out all the remaining fuel in the fuel cup and tube 5 10cc c the fuel stops flowing the fuel cup is normal If the fuel continues to flow out the negative pressure tube 15 clogged Inspection of Negative Pressure Tube a Pull out the negative pressure tube from the air intake pipe and suck with mouth to produce the negative pressure on the vacuum film b If when the vacuum film produces the negative pressure the fuel flows out of the fuel tube and when the negative pressure stops the fuel stops flowing the automatic fuel cup is normal otherwise it is abnormal c If the automatic fuel cup is abnormal firstly check if the negative pressure tube is clogged and clean it at once then blow the film from the air intake pipe of the automatic fuel cup 3 8 5 Automatic Side circuit Starter Inspection of Automatic Side circuit Starter a Check the conduction of all the automatic side circuit starter wires Standard Resistance Value below 100 10 minutes after the engine stops b Replace the automatic choke if the resistance value exceeds the standard value 34 Raider Pro 250 single seat double seat Service Manual EEC Version 1 5 April 2005 Inspection of Automatic Choke a Connect a tube with the fuel adding line of the carburetor b Connect the yellow wire of the choke with the battery electrode Connect the green wire of the choke with the battery
14. water temperature rises a The heat sensor of the thermometer 15 faulty b The temperature petcock 1s faulty Overheating a The water in the water tank 1s not enough Please fill the water tank at 2 3 times b The water hoses are not correctly connected or not properly connected c The fan is out of order 32 Raider Pro 250 single seat double seat Service Manual EEC Version 1 5 April 2005 3 8 Carburetor 3 8 1 Disassembly Diagram Carburetor Hoses Positioning 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 6 Thick Water Hose 33 Raider Pro 250 single seat double seat Service Manual EEC Version 1 5 April 2005 3 8 2 Points for Attentions No smokes or fires in the working places Assemble the O rings correctly and replace them with new ones if necessary Drain out the fuel in the float chamber before disassembly Don t disassemble the automatic choke by yourself 3 8 3 Specifications Body Mark BS26 1245 Low Speed Jet Fuel Level 18 5 1 0mm Idle Speed 1500 100rpm Air Adjusting Screw 1 3 4 NENNEN 3 8 4 Automatic Fuel Cup No smokes or fires Inspection of Automatic Fuel Cup a Stop the engine and pull out
15. 005 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 Time of Service Initial Service Monthly Quarterly Yearly First Week Tire Pressure Wear Carburetor I C Spark Plug Brake Fluid Replacement Of Gearbox Oil Chassis Fuel Switch Fuel Tank C Chassis Engine Oil Valve Clearance Of Engine EM NM Lu EN Drive Chain EM oaf gt EN LR NM NM Notes A Adjust clean I inspect clean or replace if necessary L lubricate 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 a Removing steps In general it should be carried out after the engine has become cold a Ifthe spark plug is too tight to remove spray some rust inhibiter on the spark plug washer and the thread part after the inhibiter has 9 Raider Pro 250 single seat double seat Service Manual EEC Version 1 5 April 2005 soaked the washer and thread part rotate the spark plug b Clear up the filth and carbon accumulation on the spark plug wi
16. 44 3ml 72mm x 60mm 12 5kw or 6500rpm 17 6N m or 6000 rpm 1500 100rpm 7 0g km 1 5g km SAE 90 or Above Unleaded 354g KW h SAE 10W 30 Pressure amp Splash SHELL Antifreeze 45 C 1 1 Water cooled Electric C D I Electric D7 0 6 0 7mm Chain Transmission F Ll B 1 1 758 2 2 0 9 10 00 1 6 6 Automatic Centrifugal Dry Shoe Type Outer Rotor Flywheel Vacuum Film Type Normal in 10 X10 times of experiments Paper Element Filtration Type Automatic Centrifugal EEC Version 1 5 April 2005 Raider Pro 250 single seat double seat Service Manual Fuel Tank Starting Time Climbing Top speed Tachometer Turning Radius Acceleration Noise Level Horn Headlight Headlight High Beam Intensity Taillight Turning Light License Light Battery Anti theft Lock Rearview Mirror CHASSIS Front Rear Brake Front Wheel Brake Force Rear Wheel Brake Force Braking Distance Parking Brake Front Tire Rear Tire TIRE PRESSURE Front Rear WEIGHT Net Weight 9 5L 130kpa no leakage in experiments 15s gt 20 70kph 33 40kph 6m 5m lt 80dB A 12V 3A 105dB 93 lt db A lt 112 12V 35W 35W regulations law oriented 12V 5W 21W 12V 10W 12V 5W 12 9A 2 200N m accord with EEC standards Hydraulic Disc Foot Control gt 923 21258N gt 1288 14883 7m 30kmph Hydraulic Disc Hand Control 20 5 X 8 0 10 20 5 X 8 0 10 175kpa 200kpa 295kg 320kg The specific
17. 5 3 3 Drive Pulley Clutch amp Driven Pulley 3 3 1 Disassembly Diagram Torque 51 60 DS 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 Raider Pro 250 single seat double seat Service Manual EEC Version 1 5 April 2005 3 3 2 Inspection of Drive Belt a Check if the belt is cracked and check if there 15 abnormal worn b Measure the width of the drive belt Replace the belt 1f 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 1s above 130 5 mm b Check if the clutch shoes are worn or damaged Measure the thickness Replace the clutch shoes if the thickness 1s below 2 0 mm c Check the free length of the drive spring Replace the spring if its free length 1s below 83 2 mm 20 Raider Pro 250 single seat double seat Service Manual EEC Version 1 5 April 2005 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 8 Bearing 6203 9 Needle Bearing NK 1412 9 Washer 14 5 28 11 Transmission Shaft Counter 12 Washer 14 5 32 13 Transmission Shaft Main 14 01 Seal 20 32 6 15 Gearbox 16 Gasket Gearb
18. F engine oil and run the engine for 5 minutes Check the oil level on the filler cap stick to assure that it s proper Screw back the large cap 2 2 9 Chassis Inspect clean or replace it monthly 1f 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 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 ofthe 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 EEC Version 1 5 April 2005 Raider Pro 250 single seat double seat Service Manual 3 ENGINE 3 1 Lubrication System 3 1 1 Lubrication Diagram 3 1 2 Specifications Engine Oil Capacity 1 0L Disassembling 0 8L Replacing Engine Oil Type SAE 10W 30SF 3 1 3 Engine Oil Services Engine Oil Level Inspection a Stop the engine b Stay the vehicle on the flat ground for 2 3 minutes c Inspect the engine oil level Notes The engine oil level gauge shouldn t be screwed in Engine Oil Replacement a Remove the engine oil filler cover
19. Rocker Arm Raider Pro 250 single seat double seat Service Manual EEC Version 1 5 April 2005 c Insert the rocker arm shaft with the mark IN into the hole on p the left side of the cylinder head cover and the hole of the rocker e 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 Hole on Left Side Hole on Right Side of Cylinder of Cylinder d Turn the dials of the two rocker arms to the position as shown in the picture Fasten the two dials Rocker Arm of Rocker Arm of In Valve Ex Valve 3 2 4 Adjust Valve Clearance Flywheel a Open the engine peephole cap Adjust the flywheel T to the maximum reading while the engine piston reaches the top dead point Engine b Loosen the lock bolts at the intake exhaust valve dials 3 Lock Bolt In Valve Dial Raider Pro 250 single seat double seat Service Manual EEC Version 1 5 April 2005 c Turn fully outward the intake exhaust valve dials until the dials can t be turned any more e P d 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 eler Ex Valve Dial d P A E d x z i i Raider Pro 250 single seat double seat Service Manual EEC Version 1 5 April 200
20. ar 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 250ml 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 15 the disassembly diagram of the reverse gearbox Sealing washer Box Gear Input shaft shaft Fark splined Tube Output shaft eA Li Box Cover Hex Screw 41 Raider Pro 250 single seat double seat Service Manual EEC Version 1 5 April 2005 4 3 1 Removal Sequence Drive sprocket Gearbox cover Input shaft Center shaft Lock bolt Output shaft Fork Fork shaft 4 3 2 Assembly Sequence Reverse the removal sequence 4 4 Troubleshooting Gearshift is out of order a b C The adjustment of shifting lever 1s improper The swing angle of the pin on the gearshift fork 1s too big The brake 1s out of order the lock bolt isn t locked in the positioning groov
21. ations are subject to change without prior notice EEC Version 1 5 April 2005 Raider Pro 250 single seat double seat Service Manual EEC Version 1 5 April 2005 1 5 Location of Parts Double seat Awning Brush Guard Steering wheel Control Panel Rear rack Rearview mirror Head ligh Seatbelt Seat Turning light Brake pe dal Throttle control pedal Shock Absorber Front wheel Fan Radiator A Sub Water Tank Fuel Tank Muffler Rear Shock Turning Absorber Light Taillight Rear Reflector Segen emm n AN 1 i be Kk Engine Trailer Hook Drive Chain Raider Pro 250 single seat double seat Service Manual EEC Version 1 5 April 2005 Sinole seat wni Awning a Brush Guard Control Pane g Rear rack C D Steering wheel Rearview mirror Head light Seatbelt BW gt Seal Turning light Ce o A 5 Rear wheel Front wheel Throttle control pedal Brake pedal Shock Absorber Radiator Sub Water Tank Fuel Tank Muffler Turning E Light Taillight Rear Shock Absorber Rear Reflector Engine Drive Chain Disc Brake Trailer Hook Please demand for a copy ofthe Parts Book from your dealer and locate each component location Raider Pro 250 single seat double seat Service Manual EEC Version 1 5 April 2
22. ce Manual Check spark plug for cleanliness Normal gap pollution by gasoline es check the choke of the Check choke of Readjustment he carburetor or troubles P or correct replace h new threshold or obstruction djustment or replacement EEC Version 1 5 April 2005 Raider Pro 250 single seat double seat Service Manual EEC Version 1 5 April 2005 The engine can t run stably or smoothly at the idle speed a The idle speed hasn t been adjusted well b The gas mixture in the carburetor is too dense c The gas mixture in the carburetor is too lean d The air cleaner is clogged e Some air has been 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 The engine stalls when the throttle 1s fully open a The negative pressure piston film is damaged b The negative pressure tube 1s clogged The gas mixture is too lean a The fuel jet is clogged b The air hole of the fuel tank cover is clogged c The fuel filter 1s clogged d The fuel tube is clogged e The float valve doesn t work well f The fuel level is too low The gas mixture 15 too dense 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 aut
23. ecommendations 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 1 4 Specifications DIMENSIONS SINGLE SEAT DOUBLE SEAT Overall Length 2250mm 2270mm Overall Width 1360mm 1610mm Overall Height 1550mm 1533mm Raider Pro 250 single seat double seat Service Manual Wheelbase Ground Clearance VIN Statutory Plate amp Safety Labels ENGINE Model Type Engine Capacity Displacement BoreX Stroke Max Power Max Torque Idle Speed CO Emission HC Emission Fuel Type Min Fuel Consumption Lubricate Oil Type Lubrication Cooling Fluid Antifreeze Temperature of Cooling Fluid Mixing Ratio Cooling Fluid Water Cooling Ignition Starting Spark Plug Spark Plug Gap Transmission Transmission Ratio Primary Transmission Ratio Compression Ratio Reduction Ratio Clutch Generator Carburetor Absorber Air Cleaner Gear Shifting CAPACITIES Front Rear Tire Load Coefficient Front Rear Tire Speed Level 1700mm 250mm accord with GMVR 01 01 accord with GB 7258 1997 PMII 72MM Forced Water cooled Single Cylinder 4 stroke 250cc 2
24. embly apply some water seal agent on the mating surface of the water seal and the right crankcase cover Inspection of Water Pump a Remove the water pump impeller b Check the impeller water seal and water seal washer for damages and wears Replace the impeller water seal together with the water seal washer if necessary c Assemble the water pump shaft and the inner bearing into the right crankcase Lock the bearing with the clip EP d ah aft IW ig e re a ie 29 Raider Pro 250 single seat double seat Service Manual EEC Version 1 5 April 2005 d Assemble the right crankcase cover e Assemble the water pump impeller f Replace the water pump water seal together with the impeller water seal if necessary g Assemble the impeller pin on the shaft Torque 10 N m Notes Fasten the impeller with the left thread Assemble the water pump shaft h Assemble a new outer bearing of water pump shaft inside the Ce ec AS right crankcase cover e E bh Ti 1 Guter 1 D Pm j 1 SI A 30 Raider Pro 250 single seat double seat Service Manual EEC Version 1 5 April 2005 3 7 6 Heat sensor Disassembly of Heat Sensor 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
25. es of the fork shaft and the fork shaft 1s caused to fall off the gearbox The circlip on the input shaft or output shaft is fallen off and the gear shaft 1s caused to move axially The splined tube is damaged The output gear is damaged Abnormal noise in gearbox a The circlip on the input shaft or output shaft is fallen off and the gear shaft 1s caused to move axially b The splined tube 1s damaged c The output gear is damaged d The lubricant loses efficacy and the lubricating effect isn t good 42 Raider Pro 250 single seat double seat Service Manual EEC Version 1 5 April 2005 5 Brake System 5 1 Parking Brake System Adjust Hand Brake Cable a Loosen the 2 lock nuts at the front end of the hand brake cable If the cable is too loose turn the follow up coil counterclockwise If the cable is too tight turn the follow up coil clockwise If the cable is still too loose tight after the follow up coil is turned to the last thread fasten the 2 lock nuts and go on with the next step Follow up Coil Lock Nuts Follow up Coil b Loosen the 2 lock nuts at the rear end of the hand brake cable If the cable is too loose turn the follow up coil clockwise If the cable 15 too tight turn the follow up coil counterclockwise If the cable is still too loose tight after the follow up coil is turned to the last thread fasten the 2 lock nuts and go on with the next step c Loosen the lock nut at the adj
26. heat sensor sensar Inspection of Heat Sensor a Put the heat sensor into the testing container b Raise the water temperature slowly c Measure the resistance value of the heat sensor Resistance Value of Heat Sensor Temperature Q 50 80 100 120 154 Inspection of Temperature Adjuster a Put the temperature adjuster into the testing container b Raise the water temperature slowly c Measure the temperature of the opening valve Valve Specifications Temperature of Opening Valve 72 2 Temperature of Full opening Valve oo Rising Volume of Full opening Valve 3 5 4 5mm Notes The heat adjuster shouldn t touch the testing container directly b If the heat sensor opens at the normal temperature replace it with a new one c When the temperature adjuster has been open for 5 minutes at the temperature of 70 measure again the temperature of the opening valve 3 7 7 Trouble Shooting The water temperature rises a The heat sensor of the thermometer 15 faulty b The water tank cover is faulty c The temperature petcock 15 faulty d The tank fluid is insufficient e The water pipe and water sleeve are clogged f The radiator is clogged g The inner part of the water tank 1s clogged 3l Raider Pro 250 single seat double seat Service Manual EEC Version 1 5 April 2005 h The water pump 1s faulty The thermometer doesn t show any signs of rising but the
27. il 2005 5 3 Troubleshooting 5 3 1 The brake system is out of order and can t function at all a Check if the brake fluid is enough If it isn t add some If it is go on with the next step b Check if the brake pump brake chamber and fuel pipes are damaged and if there is any leakage If damaged need repairing c After the repair remove all the left air out of the brake system Otherwise the brake system will not work Lock Nut 5 3 2 The front and rear brake forces are not even a Loosen the lock nut at the roof bar of the brake pump Adjust the bar If the front brake works well but the rear brake doesn t turn the right roof bar clockwise If the rear brake works well but the front brake doesn t turn the left roof bar clockwise If the front rear brake is blocked turn respectively the right left roof bar counterclockwise Right Roof Bar b Fasten the lock nut 5 3 3 How to exhaust the air in the brake system a Check if the brake fluid is enough If it isn t add some b Quickly press down the brake pedal and release it Repeat the action for over ten times c Stepon the brake pedal again Meanwhile loosen the exhaust lock nut on the left front brake cha d After the air is vented out of the brake system fasten the exhaust lo E 46 Exhaust Nut Raider Pro 250 single seat double seat Service Manual EEC Version 1 5 April 2005 e Repeat the steps above until no air ru
28. lank Cover Cock Opening and Closing Pressure 0 9 0 15kg cm2 d Check the water pipe joints for leakage Notes The pressure shouldn t exceed 1 05kg cm2 Otherwise the joints of the water pipe may be damaged Inspection of Water Tank Fluid Level a Check the water tank fluid level b If the fluid level is lower than F the upper limit add the specified water tank fluid standard concentration 30 up the upper limit Notes the engine temperature doesn t affect the water tank fluid level Replacement of Water Tank Fluid Specifications Water Tank Capacity about 800cc Sub Water Tank Capacity about 350cc Inspection of Radiator a Check if the welding seam of the radiator is damaged or leaking b Clean the radiator plates if they are clogged or dirty c Repair the radiator plates if they are deformed 28 Raider Pro 250 single seat double seat Service Manual EEC Version 1 5 April 2005 Radiator 3 7 5 Water pump Inspection of Water Pump Water Seal a Check if the drain hole under the right crankcase cover leaks If it leaks the water seal of the water pump is faulty and needs to be replaced b Remove the right crankcase cover and replace with a new water seal Replacement of Water Pump Water Seal a Take out the water seal from the inside of the right crankcase cover b Assemble a new water seal into the right crankcase cover Notes Before the ass
29. ns out of the brake chamber Exhaust the air out of the right front rear brake chamber in the same way Wiring Diagram 1 E E u e k Tach singt ia brei ps Lamm 5 BiB E Perl T Ek a E as Z ee Hem TAi Faidh
30. omatic chock hasn t been assembled correctly 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 39 Raider Pro 250 single seat double seat Service Manual EEC Version 1 5 April 2005 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 Connecting Tube b Spray a little carburetor cleanser into the carburetor Spray Cleanser 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 40 Raider Pro 250 single seat double seat Service Manual EEC Version 1 5 April 2005 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 ge
31. ox 17 Bearing 6204 18 Breather Pipe Gearbox 21 Raider Pro 250 single seat double seat Service Manual EEC Version 1 5 April 2005 3 4 2 Inspection and Replacement of Gearbox Oil Inspection of Gearbox Oil level a Stay the vehicle on the flat ground b Stop the engine and remove the oil level bolt c Inspect the gearbox oil level If the oil level parallels with the oil level bolt hole it s normal Replacement of Gearbox Oil a Replace the gearbox oil with the specified type Gearbox Oil Capacity 0 2 L Specified Gearbox Oil Mobil 85w 90 Gearbox Oil Level Bolt Torque 14 18 N m b Check if there is any oil leakage after running the engine Check the oil level again c Check if the gearbox oil seal is damaged and replace it if necessary 3 4 3 Trouble Shooting The engine can be started but the vehicle can t run a The gears are damaged b The gears are burnt Noise a The gears are worn or burnt or the gear surface is damaged b The bearing is worn or shaking Oil Leakage a There is too much oil in the gearbox b The oil seal is damaged or worn 22 Raider Pro 250 single seat double seat Service Manual EEC Version 1 5 April 2005 3 5 AC Generator amp Starter Clutch Torque 18 22 wm 3 5 1 Disassembly Diagram 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
32. th a steel brush or a blade c Inspect the spark plug gap in general it should be about 0 6 0 7 mm d If the carbon accumulation or the wear of the spark plug is 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 175kpa Rear Tire 200kpa 2 2 3 Brake Performance a Always check if there is plenty of brake fluid in the brake fluid reservoir T b Check if the front rear brake pad is in good condition mm L M Check the brake rotor for abnormal wear 2 2 4 Air Cleaner Clean the air cleaner quarterly or more often when driving in dusty conditions If the air cleaner 1s clogged with dust its performance will be severely decreased even the engine damages will probably be caused Inspection and Cleaning of Filters 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 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 CAUTION 1 Before and during the cleaning inspect the element for tears
33. ust bolt of the rear brake chamber If the cable is too loose turn the adjust bolt counterclockwise If the cable is too tight turn the adjust bolt clockwise Fasten the lock nut Note The adjust bolt adjusts the gap 1 2mm between the brake pad and brake disc If the adjust bolt is too tight the rear brake will get blocked and the parking brake system will not function If after the hand brake handle is pulled 4 7 scales the brake system starts functioning and the vehicle is locked in the original position without any moving the brake system is in good condition 43 Raider Pro 250 single seat double seat Service Manual EEC Version 1 5 April 2005 5 2 Traveling Brake System Peephole 5 2 1 Check Brake Fluid a Look through the peephole of the brake pump assy Observe if the surface of the brake fluid is at the 1 2 2 3 of the peephole b Ifit is the brake fluid is enough If it is below the 1 2 2 3 of the peephole the brake fluid is not enough and needs adding 5 2 2 Check Sealing of Brake System a The brake system need good sealing Replace or repair at once if the brake hose is damaged or there is any leakage on the brake pump Note Before replacing or repairing exhaust the air in the brake system otherwise the brake system will not function 5 2 3 Check Brake Pad a Loosen the 4 lock nuts of the front tire Remove the tire Lock Nuts Lock Nuts b Loosen the 2 lock nuts of the front brake
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