Dazon Raider Classic 150 Electric System

1. Electric System

1.1 Inspection of Charging System

1.1.1 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.

In general, it demands the number less than lmA if it is unusual, inspect if there is short circuit of the main switch or the main wiring.

1.1.2 Inspection of Charging Status

a) Install the fully charged battery.

b) Connect the voltmeter between the binding posts of the battery.

c) Remove the fuse, and connect the ammeter with the two ends of the fuse.

d) Connect the tachometer with the engine (it’s not needed when there is an rpm indicator on the vehicle).

e) Start the engine, and accelerate slowly;

Measure the charging voltage and current.

Charging voltage (V)       13.5-15.5

Charging current (A)       0.5

Note: Measuring condition: 5000 r/min

If the voltage isn’t in the range of the above-specified value, please inspect the voltage regulator.

1.2 Battery

The battery is an important component of the electric system. This battery used on the vehicle is a maintenance-free battery. For long periods of storage, the battery will discharge by itself, so it should be charged every 3 months. After 2 – 3 years of regular usage, the capacity of the battery will descend, so it will need to be replaced with a new one of the same type.

1.2.1 Removal

• Shut down the main switch to make sure that no electric current goes through the vehicle.

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.

1.2.2 Installation

a) Connect the positive cable;

b) Connect the negative cable.

1.2.3 Inspection of Battery Open-Circuit Voltage

a) Disconnect the cable on the battery terminals.

• Disconnect the negative pole first, and then the positive pole.

b) Measure the voltage between the two poles of the battery.

                Full charging         13.1V

                Under charging   12.3V

1.2.4 Battery Charging

a) Lift the battery out of the vehicle.

b) Connect the positive pole of the charger with the positive pole of the battery;

      Connect the negative pole of the charger with the negative pole of the battery.

c) Charge the battery for the charging time marked on the battery.

     • Don’t use fast charging unless it is emergent.

     • No smoking or open fire near the battery when charging.

      • At the beginning or the end of charging, turn off the charger first to avoid the connecting part arcing.

d) Measure the voltage 30 minutes after the charging is finished;

      It should reach the specified value; otherwise it needs recharging.

                Charging                               Normal   0.7A

                Current                                 Fast          3.OA

Charging Time                                   Normal     5-10 hours

                                                                 Fast           30 minutes

Charging              Result   Open-circuit voltage >=12.8V

1.3 Primary Coil

1.3.1 Structure

The picture shows structure of a common generator.

 

                               

1. Cooling fan                                                                     6. Bolt

2. Generator assembly 3 Flywheel comp.              7. Nut

4. Stator comp.                                                                 8. Bolt

5. Washer                                                                            9. Bolt

1.3.2 Primary Coil Inspection

• The inspection work can be done on the engine, and there is no need to remove the generator.

a) Remove the 4-core connector of the generator.

b) Measure the resistance value between the white wire of the generator and the connecting wire of the vehicle body.

Standard value  1 0.2-0.4 20LI)

c) When the actual value is more than the standard value, the coil should be replaced.

 

 

1.4 Generator

1.4.1 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.

e) Remove the generator wire holder;

      Remove the generator coil bolt;

      Remove the generator wire rubber bushing from the right crankcase;

      Remove the coil set.

Don’t damage the coil when removing.

1.42 Generator Installation

Reverse the removal procedure for installation.

• When installing the flywheel, make sure that there are no metal pieces, such as bolts or nuts, attaching to the inner wall of the flywheel.

• After the installation is finished, start the engine to inspect and adjust the ignition timing.

1.5 Regulator -Rectifier

1.5.1 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.

b) Measure the conducting status between the main wiring terminals according to the previous wiring diagram.

Connecting Type              Normal Condition

Battery (The Red Wire) –Vehicle Body   Battery Voltage Value

Connecting Wire (the Green Wire) –Vehicle Body            Conductive

Lighting Wire (the Yellow Wire)—Vehicle Body (Remove the resistor, side auto-starter plug, and turn the lighting switch to off)        Generally: 0. 1-0.8 Ω

Charging Wire (the White Wire)—Vehicle Body Generally: 0.2-2.0Ω

 

1.5.2 Inspection of Regular -Rectifier

• When the main wiring—sub electric circuit condition is normal, inspect the regulator-rectifier.

a) Inspect if the regulator- rectifier plug contacts well.

b) Measure the resistance value between every regulator- rectifier terminal.

c) If the resistance value between the terminals is unusual, replace the regulator- rectifier.

1.6 Resistor

1.6.1 Resistor Resistance Value Measurement

a) Measure the resistance value between the resistor wire and vehicle body;

If the actual value is in the range of +/- 1Ω  In value marked on the diagram or the resistor, it’s normal; if not, it should be replaced.

 

1.7 Ignition System

1.7.1 Working Principle

The circuit working principle is shown in the picture.

1.7.2 Ignition Timing Inspection

• The CDI ignition system has already been adjusted in the factory, so there is no need to readjust it. If the ignition function inspection is necessary, take following steps to inspect the ignition timing.

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.

c) Clip the ignition timing indicator light wire clip on the high-voltage end of the ignition coil.

d) Start the engine and let it run at idle; at this time, observe if the mark on the crankcase aligns with the “F” mark on the rotor;

If the difference is between +/-3°, it indicates the ignition timing is correct; otherwise it should be adjusted.

e) Slowly increase the engine rpm (when the 150 model increases to 5000 r/min); at this time, if the mark on the crankcase aligns with the rotor ignition advance angle mark, the advance angle device is good; if not, it should be adjusted or replaced;

When adjusting, the trigger winding can be loosened to adjust the angle ‚and the ignition-charging coil can be loosened to adjust the ignition timing.

1.7.3 Ignition System Inspection

When the spark plug does not spark, first inspect the wires, and if the connecting part is loose or contacts bad, you can follow the electric circuit and take the method of measuring the voltage of every point to find out the trouble. Please refer to the previous picture for the following inspection.

a) Remove the original spark plug and install a new one if the plug is bad;

•It is important that every electric circuit wire connects correctly.

• It is important that the cylinder compression pressure is normal.

Connect the negative end of the multi-meter with the positive connecting iron of the primary ignition coil (the black/yellow wire);

Press the starting button or use the kick starter, and read the voltage value on the multi-meter. Note: The highest voltage value should be above 112V.

• When measuring the voltage, don’t touch the metal part of the multi-meter you’re your finger; otherwise an electric shock can happen.

b) Remove the 4-core and 2-core connector of the CDI component;

Connect the positive end of the multi-meter with the ignition charging coil (the black/red wire end) of the 2-core connector, and connect the negative end with the ground wire end (the green end) of the 4-core connector;

Press the starting button, or use the kick starter, and measure the highest voltage of the ignition charging coil. lt should be more than 122V.

c) If the measured highest voltage of the ignition charging coil isn’t normal, disconnect the generator connector to make further measurement;

If the measured terminal voltage of CDI component end is abnormal, but the terminal voltage of the generator is normal, there is a bad wire or bad connection;

If both are abnormal, the ignition charging coil is bad.

d) Remove the 4-core and 2-core of the CDI component;

Connect the positive end of the multi-meter with the trigger winding (the greenlred wire terminal) on the 4-core connector, and connect the negative end with the green wire terminal on the 4-core connector;

Press the starting button or kick starter, and measure the highest voltage of the trigger winding; it should be more than 2.1V.

e) If the measured highest voltage of the trigger winding is abnormal, remove the generator connector, and make further measurement;

If the measured terminal voltage of the CDI component is abnormal, but the generator terminal

voltage is normal, there is a bad wire or bad connection. If both aren’t normal, the trigger winding isn’t good.

1.7.4 Ignition Charging Coil

a) Remove the connector of the ignition charging coil wire.

b) Measure the resistance value between the ignition charging coil (the black red wire) and body ground wire.

c) When the actual value is more than the standard value, it should be replaced.

Standard value  1 300-1000 Ω     

1.7.5 Trigger Winding Inspection

a) Remove the connector of the trigger winding wire.

b) Measure the resistance value between the trigger winding (the green red wire) and body ground wire.

c) When the actual value is more than the standard value, it should be replaced.

Standard value  4-300 Ω

1.7.6 CDI Component Inspection

• It is similar with the regulator inspection. The CDI component inspection is also divided into two step:

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.

c) Inspect the conduction condition and the resistance value of the main switch, ignition charging coil, trigger winding and ignition coil;

When the main switch is at the “OFF” position, it should be conducted, and the resistance value of every coil should be the standard value.

e) Inspect the resistance value between every CDI component terminal;

If the actual value isn’t in the range of the value in the chart, the CDI component is faulty.

 Note: The CDI component can also be inspected and measured with the CDI testing instrument.

• Please carefully read the instrument specification so as to operate properly.

a) Connect the CDI component with the special wire of the testing instrument.

b) Observe the spark condition on the instrument when the switch is turned at different positions.

 

1.8 Ignition Coil

1.8.1 Removal

a) Remove the spark plug cap.

b) Remove the primary ignition coil wire.

c) Remove the ignition coil positioning bolt and ignition coil.

1.8.2 Installation

Reverse the removal procedure for installation.

• When installing, connect the black/yellow wire of the primary ignition coil with the

Black/yellow connector of CDI, and the green wire with the green connector of CDI.

1.8.3 Primary Ignition Coil Inspection

Standard value 0. 1 ~1.0 KΩ

If the resistance value is c, the coil is bad and should be replaced.

1.8.4 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.

Standard value  7-9 kΩ

b) Remove the spark plug cap, and measure the resistance value of the secondary ignition coil; If the resistance value is in the standard range, it indicates it is good; however, ccindicates the coil is bad.

Standard value  2-4 kΩ

Note: The ignition coil also can be inspected and measured with the ignition testing instrument

•Please operate properly according to the instructions.              

a) Set the measuring switch of the ignition coil on the 1.2V position, and connect the ignition coil.

b) Turn the switch of the testing instrument to the “ON” position;

Observe the spark over window and inspect the spark over the ignition coil;

If it is a normal consistent spark, it is good; if the spark doesn’t flash consistently, it is bad.

1.9 Spark Plug

a) Clean the carbon around the spark plug to prevent it from dropping into the cylinder when removing the spark plug.

b) Remove the spark plug.

• When installing, connect the black/yellow wire of the primary ignition coil with the black/yellow connector of CDI, and the green wire with the green connector of CDI.

In general it should be about 0.6 – 0.7 mm.

e) When the carbon accumulation and wear of the spark plug are too much, replace the spark plug with a new one of the same specification

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Contacts

Store Address:
AJ USA, Inc. 129 Bethea Rd
Suite 405

Fayetteville, GA 30214

Office Hours:
Mon thru Fri - 9:00 am till 5:00 pm EST
Saturday and Sunday - CLOSED

Phones:
(678) 489-2368