Raider Max 2 5 / D

(OFF ROAD BUGGY)

Raider Max 250 (single/double-seat): Assembly Instructions Version: 1..1 Oct. 2005

Assembly Instructions for Raider Max 250S&D

(for Off-road Use)

Pre-assembly Preparation
1. Check Package Box
a) Check the carton shipping mark, country &
city name;
1a)

b) Check the product description.

1b)
2. Open Package Box
a) Open the package box;

State of
Original
Top View of
Package
Internal Packing
in Box

2a)
b) Check for the essential parts in the package box;
Radiator

Seat Cushion Steering

Wheel
Rear Wheel

Front Wheel

2b)

Headlight
Rear Wheel

Front Shock Hub

Absorber Rear Wheel

Axle Cover

2b)
Raider Max 250 (single/double-seat): Assembly Instructions Version: 1..2 Oct. 2005

c) Check for the accessories in the package box.

Battery

Rearview
Mirror

Mudguard
Bracket

3. Prepare for Assembly

a) Cut the band on the shock absorber package;

b) Open the turning light package;

Turning
Light

c) Cut the band on the guard bar package;

Guard
Bar

Band

3)

d) Put the vehicle frame on the wooden rack

for assembly.
Vehicle
Frame

Wooden
Rack
3b)

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Raider Max 250 (single/double-seat): Assembly Instructions Version: 1..3 Oct. 2005

Assembly Procedure
1.Assemble Rear Absorber Hole of Rear Swing Arm

a) Align the lower end hole of the left/right rear

shock absorber with the hole of the rear swing
arm;

1a)

b) Insert 2 Flange bolts M12×65 and fasten with 2

Flange lock nuts M10.

2. Assemble Rear Wheel

a)Align the 4 holes on the left/right rear rim
with the 4 bolts of the left/right rear rim, and
fasten with 8 flat washers Ф 10 and 8 Flange
lock nuts M10×1.25;

b)Put on the rear axle cover.

2b)

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Raider Max 250 (single/double-seat): Assembly Instructions Version: 1..4 Oct. 2005

3. Assemble Front Wheel

a) Align the 4 holes on the left/right front rim
with the 4 bolts of the left/right front rim, and
fasten with 8 flat washers Ф 10 and 8 Flange
lock nuts M10×1.25;

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6a)

Bolt Hole Mounting Bolt

b) Put on the front axle cover.

3b)

4. Assemble Seat Assy.

a) Fix the seat assembly on the vehicle frame by
using 4 Flange bolts M8×16 and 4 Flange nuts
M8;

4a)

Flange Bolt M8 16

b) Fix the safety belt in its corresponding

position on the vehicle frame by using 3
Flange bolts M10 25 and 3 Flange nuts
M10 .

4b)

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Raider Max 250 (single/double-seat): Assembly Instructions Version: 1..5 Oct. 2005

5. Assemble Fuel Tank

a) Fix the fuel tank onto the vehicle frame by
using 4 Flange bolts M8 28,4 Flange nuts
M8 and 4 fuel tank mounting bushes.

5a)

Flange Bolt M8 28 Flange Nut M8

b) Insert the fuel pipe and breather pipe in the appropriate places on the carburetor;

5b)

5b)

Pressurized Pipe of Fuel Tank Cock Connected with One Pipe Three-way Pressurized Pipe of Carburetor

6. Assemble Water Tank Bracket

a) Fasten the water tank bracket on the vehicle frame
with 2 Flange bolts M8 40 and 2 Flange lock nuts
M8;

6a)

Flange Lock Nut M8 Vehicle Frame

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Raider Max 250 (single/double-seat): Assembly Instructions Version: 1..6 Oct. 2005

7. Assemble Water Inlet/Outlet Pipe of

Water Tank and Fan Connector
a) Fasten the water tank and cooling fan onto
the water tank brackets by using 4 Flange bolts
M6 20 and 4 Flan ge lo ck nu ts M8 ;

7a)
Vehicle Frame

b) Fix the water inlet/outlet pipe on the inlet/outlet port of water tank;

Water Outlet Pipe of Water Tank Connected with One Pipe Water Inlet Pipe of Engine 7
Raider Max 250 (single/double-seat): Assembly Instructions Version: 1..7 Oct. 2005

c) Connect the electric connector of fan with the

cable of main wire harness.

8. Assemble Rear Rack

a) Fasten the rear rack with the water tank brackets
by using 2 Flange bolts M8 25 and 2 Flange lock
nuts M8;

8a)

Flange Bolt M8 25 Water Tank Bracket

Rear Brush Guard Bar Rear Rack
b) Fasten the rear rack with the rear brush guard
bar by using 2 Flange bolts M8 25 and 2
Flange lock nuts M8;

8b)

Flange Bolt M8 25

Socket-head Bolt M6 12 Steering Wheel

9. Assemble Steering Wheel
a) Fasten the steering wheel onto the steering shaft
by using 6 socket-head bolts M6 12.

9a)

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Raider Max 250 (single/double-seat): Assembly Instructions Version: 1..8 Oct. 2005

10. Assemble Brush Guard Bar

a) Fix the rear part of brush guard bar by using

4 Flange bolts M6×25;

c) Fix the front part and rear part of left/right

long brush guard bar by using 4 socket-head
bolts M6×25;

Front Part Rear Part

c) Fix the rear end of left/right long brush guard

bar onto the vehicle frame by using 2 Flange
bolts M8 50 and 4 R-washers, but don’t
fasten;

10c)

d) Fix the lower end of left/right rear brush

guard bar onto the vehicle frame by bar using
2 Flange bolts M8 55 and 4 R-washers, but
don’t fasten;

10d)

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Raider Max 250 (single/double-seat): Assembly Instructions Version: 1..9 Oct. 2005

e) Fasten the center brush guard bar I onto the

left/right long brush guard bar by using 2
Flange bolts M8 55 and 4 R-washers;

g) Fasten the front end of left/right long brush

guard bar on the vehicle frame by using 2
Flange bolts M8 55 and 4 R-washers;

10f)

e) Fasten all the bolts and nuts on the brush guard bar assy..

11. Assemble Guard Bar Cover

a) Assemble the left/right rear guard bar cover
and center guard bar cover;

11a)

Left/Right Rear Guard Bar Cover

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Raider Max 250 (single/double-seat): Assembly Instructions Version: 1..10 Oct. 2005

c) Assemble the wrist strap.

Wrist Strap

12. Assemble rearview mirror

a) Insert the left/right rearview mirror
respectively into the fixing hole on the front
end of the guard bar frame, and fasten with 2
hex nuts M10×1.25;

12a)
Rearview Mirror

Rearview Mirror
b) Respectively insert the bar of the left/right rear
view mirror into the fixing hole on the front
part of the left/right guard bar, and fasten with
the 2 hex nuts M10×1.25 that have been
removed from the rearview mirror.

12b)

Front Mudguard Left Support

13. Assemble Left Front Mudguard
a) Install the left support of the front mudguard and
the front mudguard by using 4 Flange bolts
(convex) M6×16,4 Flange nuts M6, 4 washers6
and 4 spring washers 6;

13a)

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Raider Max 250 (single/double-seat): Assembly Instructions Version: 1..11 Oct. 2005

b) Fix the left support of the front mudguard and

the upper part of the left knuckle support by
using 2 socket-head bolts M8×18 and 2 spring
washers 8.

13b)

Left Support Left Knuckle Support

14. Assemble Right Front mudguard

a) Install the right support of the front mudguard
and the front mudguard by using 4 Flange bolts
(convex) M6×16,4 Flange nuts M6 ,4 washers
6 and 4 spring washers 6;

14a)

Right Support Right Knuckle Support

b) Fix the right support of the front mudguard

and the upper part of the right knuckle
support by using 2 socket-head bolts M8×18
and 2 spring washers 8.

Right Knuckle Support Right Support

15. Assemble Left Rear mudguard

a) Install the left support of the rear mudguard
and the rear mudguard by using 4 Flange
bolts (convex) M6×16,4 Flange nuts M6 ,4
washers 6 and 4 spring washers 6;
15a)

Rear Mudguard Left Support

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Raider Max 250 (single/double-seat): Assembly Instructions Version: 1..12 Oct. 2005

b) Fix the left support of the rear mudguard and the

rear swing arm by using 2 Flange bolts
(convex) M8×18 and 2 spring washers 8.

15b)

16. Assemble Right Rear Mudguard

a) Install the right support of the rear mudguard
and the rear mudguard by using 4 Flange bolts
(convex) M6×16, 4 Flange nuts M6, 4 washers
6 and 4 spring washers 6;

16a)

Right Support Rear Mudguard

b) Fix the right support of the rear mudguard and

the rear swing arm by using 2 Flange bolts
(convex) M8×18 and 2 spring washers 8.

16b)

Rear Swing Arm Right Support

17. Check Gear-shifting

17a)

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Raider Max 250 (single/double-seat): Assembly Instructions Version: 1..13 Oct. 2005
After the assembly is finished, if the gearshift
assy. doesn’t work smoothly, go on with the
steps below:
a) Remove the gearshift cable and fork plate;

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Raider Max 250 (single/double-seat): Assembly Instructions Version: 1..14 Oct. 2005

Fork Shaft
b) Turn the fork shaft with a spanner;
If it’s difficult to turn the fork shaft to
left/right, the fixing bolt of fork shaft is too
tight;

If the fork shaft jumps up/down in a large

clearance, the fixing bolt of fork shaft is
too loose, and need adjusting;

17b)

c) Loosen the fixing bolt of fork shaft; If

it’s difficult to turn the fork shaft to
left/right,

Turn the fixing bolt counterclockwise;

If the fork shaft jumps up /down in a large
clearance,

17c)
Fixing Bolt of Fork Shaft
Turn the fixing bolt clockwise;
When the fork shaft can move to left/right
freely without jumping up/down, the fixing
bolt is fastened properly.

18. Others
Should you encounter any difficulty during installation, please check with DAZON dealer
immediately. Do not force assemble or disassemble any component; otherwise the unit will be
damaged.

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Raider Max 250 (single/double-seat): Assembly Instructions Version: 1..15 Oct. 2005

Attachment: Tools for Assembly

9 10

12 11

1 .Socket Spanner Spec.: 14mm

2 Socket Spanner Spec.: 12mm
3 Socket Spanner Spec.: 10mm
4 Socket Spanner Spec.: 10mm~19mm
5 Tie Rod
6 Nipper Pliers
7 Minus Screw Driver
8 Phillips Screw Driver
9 Spanner Spec.: 10mm~19mm
10 Inner-hexagon Spanner Spec.: 5mm
11 Electric Gun
12 Rubber Hammer

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