Zontes ZT180MN, Maintenance Manual

Page 1: ...ZT180MN Engine EuroIV_V Maintenance Manual 2021 4 19 ...

Page 2: ...f camshaft 2 10 Disassemble camshaft 2 4 Disassembling the camshaft 3 11 Camshaft assembly 2 5 Cylinder head assembly 1 12 Remove the cylinder head 2 6 Cylinder head assembly 2 13 Remove the cylinder head 2 7 Cylinder head assembly 3 14 Cylinder head assembly 2 8 Disassembling the valve 15 Valve assembly 2 9 Adjust the valve clearance 16 2 10 Description of after sales parts 17 3 3 cylinder block ...

Page 3: ...sembly 3 26 Bearing and oil seal assembly 4 6 Remove the noise reduction component of the right cover 27 Right cover noise reduction component 4 7 Disassembling the clutch lever 28 Clutch lever assembly 4 8 Right cover bearing and oil seal 29 Right cover bearing and oil seal parts 4 9 Right cover parts 30 Right cover parts 4 10 Clutch assembly 1 31 Clutch assembly 4 11 Clutch assembly 2 32 Frictio...

Page 4: ...41 Electric bridge gear assembly magneto rotor assembly 7 2 Disassemble the large starting gear and the output sprocket 42 Start big gear assembly output sprocket assembly 7 3 Remove the gear switch 43 Gear switch assembly 8 8 Crankcase disassembly 8 1 Crankcase disassembly 1 44 8 2 Crankcase disassembly 2 45 8 3 Crankcase disassembly 3 46 8 4 Crankcase disassembly 4 47 9 9 Right crankshaft case a...

Page 5: ...2 11 2 Spindle assembly relationship 53 11 3 Countershaft assembly relationship 54 Guangdong Daye Motorcycle Technology Co Ltd all rights reserved This manual is suitable for ZT180MN series engines All the materials illustrations photos etc collected in this manual are compiled according to the latest products However due to the continuous improvement of the product and other changes there may be ...

Page 6: ... crankcase 1 and remove the gasket 2 Unscrew the oil dipstick 3 on the right crankcase cover take out the sealing ring 4 and wait for the oil to drain from the oil drain CAUTION Combined gasket It is recommended to replace it after disassembly to avoid oil leakage and oil leakage due to damage caused during disassembly After removing the oil drain bolt check whether the magnet on the bolt has adso...

Page 7: ...e 2 bolts on the engine oil outlet pipe and the engine oil inlet pipe and remove the O ring Wait for the oil to flow out CAUTION 1 Because there may be multiple states for different models colors status changes etc only the name is reserved here and the corresponding correct state can be found in the official website parts Similar situations will not be repeated in the follow up O rings are recomm...

Page 8: ...e antifreeze to drain CAUTION Gasket After disassembly new gaskets must be replaced to avoid water leakage Antifreeze is corrosive to a certain extent so be careful not to contaminate the engine other parts body clothing etc when discharging the antifreeze If parts are accidentally contaminated with antifreeze immediately wipe them with a clean lint free cloth If clothing or skin is stained with a...

Page 9: ...bolt for 6 inner hexagon then the cylinder head cover assembly can be removed Take out the gasket remove one large positioning pin and two small positioning pins Note One of the small positioning pins has an O ring Clean up the remaining sealant on the joint surface Remove the bolt with an 8 sleeve and remove the copper pad Remove the chain guard from the inside of the cylinder head cover and inst...

Page 10: ...remove the bolt and take out the copper pad Use an 8 sleeve to remove the 2 bolts 3 and use the tensioner disassembly tool to remove the tensioner and gasket Sealing cap assembly When installing the sealing cap a proper amount of sealant should be applied at to prevent oil leakage CAUTION Gasket is for one time use and must be replaced after disassembly otherwise the seal will not be in place and ...

Page 11: ...ve the camshaft Use 5 hexagon socket to remove the screw plug and remove the O ring Use 10 internal hexagon to remove the aluminum screw plug 3 and remove the O ring 4 Use a 17 sleeve to extend from the aluminum screw plug use the sleeve to turn the flywheel bolt counterclockwise so that the flywheel T dot dash line coincides with the center line of the small AC hole mark slot on the left cover CA...

Page 12: ...e standard 12 1 5N m remove camshaft pressing blocks do not take out the positioning pin Remove the intake camshaft assembly first and then remove the exhaust camshaft assembly The timing chain does not need to be taken out at this time just put it back into the engine CAUTION 1 Parts not marked with codes are included in the parts assembly and are not sold separately EX means out of air IN means ...

Page 13: ...eeve to remove the 4 nuts 3 in the cylinder head and remove the gasket 4 CAUTION The bolt is for one time use and must be replaced every time it is disassembled Failure to replace it may cause problems with the airtightness of the cylinder and the cylinder head Prevent foreign objects from falling into the engine during disassembly and installation Nuts 3 must be evenly loosened diagonally and eac...

Page 14: ... assembly 2 PROCEDURE Remove the cylinder head Take out the cylinder head assembly vertically upwards and remove the positioning pin 1 and gasket 2 The gasket is for one time use and must be replaced after disassembly CAUTION When removing and installing the cylinder head assembly pay attention to the guide bar When removing and installing the cylinder head assembly avoid foreign matter from enter...

Page 15: ...hread glue to the thread of the stud and the cylinder head The oil plug at the place cannot be disassembled Here is an interference fit If disassembled and then assembled it will cause problems with the sealing of the cylinder head The water plug at the place is also not removable Special waterproof glue is applied to the threads here Disassembly and assembly may cause water leakage CAUTION Apply ...

Page 16: ...ove the sliding tappet and valve clearance adjustment cushion Squeeze the valve spring with a valve disassembler remove the valve lock clamp 3 and remove the upper spring ring outer spring inner spring spring seat oil seal and intake valve in sequence Use the same method to remove the other valves CAUTION Oil seal is for one time use and must be replaced after disassembly oil seal needs to be pres...

Page 17: ...learance 0 10 0 19mm Standard interval of exhaust valve clearance 0 15 0 28mm If it does not meet the standard remove the intake and exhaust camshafts take out the tappet and replace the valve clearance adjustment pad under the tappet After the replacement is completed measure the valve clearance with a feeler gauge again the adjustment is successful if it is qualified otherwise continue to replac...

Page 18: ... 1 includes cylinder head assembly valve assembly camshaft assembly etc Cylinder head assembly Cylinder head assembly 2 includes cylinder head assembly valve assembly excluding camshaft and other components Cylinder head sub assembly The cylinder head sub assembly 3 only contains the cylinder head assembly CAUTION Please check the status of parts before placing an order and place an order accordin...

Page 19: ... Guide Strip Pull out the guide bar in the direction of the arrow CAUTION When installing the guide bar the guide bar needs to be clamped to the position shown in the lower left Prevent foreign objects from falling into the engine during disassembly and installation Fig 1 CYLINDER BLOCK ASSEMBLY Disassembling the guide bar ...

Page 20: ...and O ring are for one time use and must be replaced after disassembly otherwise there will be oil leakage and water leakage Check the inner wall of the cylinder If there are obvious scratches or damages on the inner wall of the cylinder it must be replaced Before installing the cylinder make sure that the box and cylinder assembly planes are smooth and flat and apply a proper amount of sealant on...

Page 21: ...thod to remove all gas and oil rings CAUTION Remove the carbon deposits on the piston ring groove and piston ring and apply appropriate amount of engine oil to the piston ring groove It is necessary to prevent the piston pin retaining ring or other foreign objects from falling into the box during installation and removal Check whether the piston skirt is scratched or damaged if any it must be repl...

Page 22: ...tlet pipe joints and O rings Cylinder block The cylinder block is just a single cylinder block CAUTION Please check the status of parts before placing an order and place an order according to your own needs When installing the piston make sure that the side with the IN mark on the piston head is not on the side of the water inlet pipe The piston ring should be inserted into the cylinder correctly ...

Page 23: ...e from falling over to prevent the gasket from falling off when the right cover is removed Use a 8 sleeve to remove 4 bolts 1 bolt 2 bolts 3 bolts 1 bolt and remove 1 copper pad Remove the right cover from the engine and take out the 2 positioning pins gasket and washer CAUTION The gasket is for one time use and must be replaced after disassembly Before installing the box body make sure that the b...

Page 24: ...e the 3 nuts remove the fine filter cover O ring sealing ring fine filter spring Dipstick Pinch the upper boss of the oil dipstick and rotate it counterclockwise take out the oil dipstick and O ring CAUTION It is strictly forbidden to lift the fine filter cover with hard objects otherwise it will cause oil leakage Check whether the O ring is damaged If it is damaged replace it immediately otherwis...

Page 25: ... water pump cover A 1 Disassembling the water pump assembly 1 PROCEDURE Outlet pipe joint Use a 24 torx wrench to remove the outlet pipe joint and take out the O ring Water pump cover assembly Use an 8 sleeve to remove the 3 bolts 3 remove the water pump cover assembly and take out the sealing ring and the positioning pin Use an 8 sleeve to remove 1 bolt from the water pump cover and remove the ga...

Page 26: ... and then use a 12 sleeve to remove the water pump The water seal moving ring belongs to the water seal assembly and is installed on the water pump Remove the water seal moving ring from the water pump Pull out the water pump shaft from the reverse side and remove the cylindrical pin gear and washer on the water pump shaft CAUTION The smooth surface of the water seal moving ring faces outwards and...

Page 27: ...the water seal stationary ring faces the indenter the bearing marked side faces the indenter and the oil seal marked side faces the indenter Bearings are all press fitted Most of the bearings are interference fit and have accuracy requirements It is not recommended to disassemble unless special circumstances If disassembly is required please go to a qualified maintenance organization for press fit...

Page 28: ...eld 1 3 1051454 015000 ZT180MN right cover noise reduction glue 1 Fig 6 RIGHT CRANKCASE COVER ASSEMBLY Remove the noise reduction component of the right cover PROCEDURE Right cover noise reduction component Use 4 inner hexagon to remove 3 bolts take off guard plate noise reduction glue CAUTION Appropriate amount of thread fastening glue should be applied to the threads of the 3 bolts during instal...

Page 29: ...etaining ring φ9 1 6 1050254 008000 ZT180MN clutch rod shaft 1 PROCEDURE Clutch lever assembly Use circlip pliers to take out the retaining ring remove the washer and pull out the lever rocker arm assembly and torsion spring Use circlip pliers to pick out the retaining ring and remove the gasket Take out the clutch lever shaft in the direction of the arrow CAUTION Retaining ring and retaining ring...

Page 30: ...ill be damaged if they are disassembled To avoid oil leakage please disassemble and replace them When installing the oil seal the oil seal should be press fitted evenly to avoid deformation and flanging of the oil seal When the oil seal is press fitted the marking surface of the oil seal should face outwards Do not install it backwards to cause oil leakage Please do not disassemble or assemble the...

Page 31: ... unless under special circumstances otherwise oil leakage will occur Stud generally does not need to be disassembled disassembly is to weld an M6 nut where the thread is exposed and then use an 8 sleeve to remove it CAUTION When installing the stud screw in an M6 cap nut on the longer thread apply sealant on one end of the shorter thread and install the stud on the right cover with an 8 sleeve Rig...

Page 32: ...Use an 8 sleeve to remove 3 bolts 1 and take out the pressure plate 2 and 3 springs 3 Pull out the pressure plate and remove the separation lever Take out the friction plate sub assembly lock washer thrust washer The edge of the lock washer is chamfered CAUTION When installing the side of the lock washer with lettering should face outward When disassembling the bolts loosen them one by one Try to ...

Page 33: ...e follower disc with small inner hole friction disc with large inner hole There are 7 friction plates and 6 driven plates including 3 friction plates with large inner holes and 1 driven plate with large inner holes CAUTION The direction of the outermost friction plate is inconsistent with the direction of other friction plates and is stuck in the groove of the driving disc Please check the frictio...

Page 34: ...e bearing 1 8 1050753 022000 ZT173YMM Clutch bushing home made 1 9 1050753 010000 ZT173YMM clutch bush thrust pad 1 PROCEDURE Clutch master and driven disc assembly Use a 24 sleeve to remove bolt remove lock washer thrust take out driven plate thrust washer Take out the driving disc needle roller bearing bush thrust pad CAUTION Install the lock washer with the OUT mark facing outward It is necessa...

Page 35: ...duction gear cover assembly 2 and O ring 3 The bearing is press fitted in the reduction gear cover and there is no need to take it out for non special circumstances Reduction gear cover assembly includes bearing and reduction gear cover Remove the washer and the reduction gear One washer at the front and rear of the deceleration tooth CAUTION It is recommended to replace the O ring after disassemb...

Page 36: ... Starter motor components Use an 8 torx wrench to remove the 2 bolts grasp the place and pull it out in the direction of the arrow and take out the starting motor CAUTION When installing and removing pay attention to whether the O ring at has fallen off Bolts 1 must be coated with appropriate amount of sealant otherwise it may leak Fig 2 LEFT CRANKCASE COVER ASSEMBLY Disassembling the starter moto...

Page 37: ...t cover assembly Use an 8 sleeve to remove 7 bolts and 1 bolt Remove the left cover assembly take out the gasket and 2 positioning pins CAUTION Gasket must be replaced once removed Otherwise oil leakage may occur Before installing the left cover make sure that the assembly plane of the box body and the left cover is smooth and flat and apply a proper amount of sealant on the assembly plane of the ...

Page 38: ...emove 3 bolts take out the crimping plate Use 5 inner hexagon to remove 3 bolts 3 and take out the entire magneto stator sub component 4 Finally take out the gasket CAUTION When installing bolts and apply proper amount of thread fastening glue to the threads Clean up the surface sealant indicated by the arrow before installation to ensure that the installation surface is flat and smooth Appropriat...

Page 39: ...t cover parts PROCEDURE Screw plug assembly Use 5 inner hexagon to remove the screw plug and remove the O ring Use 10 inner hexagon to remove the plug and remove the O ring CAUTION 1 Parts not marked with codes are included in the parts assembly and are not sold separately When disassembling the screw plug please check whether the O ring is damaged which affects its sealing performance Bearings ar...

Page 40: ...omponents Use an 8 sleeve to remove the bolts and take out the copper pad and remove the entire oil pump assembly Remove the seat cushion and the two positioning pins under the oil pump assembly to prevent loss Remove the 3 positioning pins and O ring on the oil pump assembly Note The oil pump subassembly does not include gear and thrust washer please confirm the state you need before placing an o...

Page 41: ...e speed star cam 1 10 1250404 003000 GB119 2φ3 10 cylindrical pin 1 PROCEDURE Remove the driving sprocket Use a 24 sleeve to remove the nut take out the lock washer the flat key and the primary drive tooth Pull out the driving sprocket take out the half circle key the limit retaining ring Remove the gearshift star wheel Use 8 sleeve to remove bolt take out cam and cylindrical pin CAUTION After put...

Page 42: ...start bridge gear assembly Take out the gasket and the bridge tooth Note There is a gasket before and after the bridge tooth Magnetor rotor assembly Grasp the magneto rotor with your hands and remove the bolts with the gun 17 sleeve head Use a 24 sleeve to screw the M20 1 5 bolt into the middle position of the magneto and push the magneto out CAUTION There is a semicircular key between the main sh...

Page 43: ...luoro rubber o ring 2 PROCEDURE Starting gear assembly Take out the thrust washer start gear needle bearing thrust washer Note Start the big gear 2 1 thrust washer at the front and back 1 Output sprocket assembly Before disassembly and assembly use a hammer and a flat blade to knock the locking piece flat use a 24 sleeve to remove the bolt remove the locking piece and pull out the output sprocket ...

Page 44: ...007000 ZT180MN gear Display contact parts 1 PROCEDURE Gear switch assembly Use an 8 sleeve to remove the 2 bolts and remove the crimping plate Use a cross batch to remove the 2 bolts 3 and take out the gear switch O ring and contact CAUTION Bolt Appropriate amount of thread fastening glue should be applied when installing After installing the contact spray a proper amount of engine oil on it O rin...

Page 45: ... Hexagon flange bolts color zinc 2 4 1251513 001019 6 3 12 1 6 copper gasket 1 Fig 1 CRANKCASE Crankcase disassembly 1 PROCEDURE Cabinet split Use an 8 sleeve to remove 1 bolt on the right crankcase body Use an 8 sleeve to remove 1 bolt 2 bolts 7 bolts and 1 copper pad on the left crankcase body CAUTION The bolts must be tightened or loosened diagonally when removing and installing 12 1 5N m ...

Page 46: ...hen take out the shift shaft CAUTION Most parts of the box body are installed on the left crankcase When disassembling the left crankcase must be down otherwise the parts will fall off The gasket is for one time use Once removed it must be replaced otherwise it will cause oil leakage Before assembling the shift shaft apply a proper amount of engine oil on the surface of the part Before installing ...

Page 47: ... fork Note The marks L R and C on the shift fork correspond to the left shift fork the right shift fork and the middle shift fork respectively Take out the variable speed drum CAUTION When installing the side with the mark on the fork should be installed upwards Check the fork shaft roll the fork shaft on a flat surface and find that it is bent it must be replaced Check the shift fork whether ther...

Page 48: ...haft not to be disassembled Stagger the angle between the crankshaft assembly and the balance shaft 3 hold the upper crank with one hand and tap the lower crank with a rubber hammer with the other hand to take out the crankshaft assembly and balance shaft 3 Take out the half circle key from the crankshaft CAUTION When installing and removing the crankshaft connecting rod cannot hit the box Check t...

Page 49: ...color zinc 2 12 1 5N m 8 1050853 010000 66 50 trapezoid coarse coarse filter 1 9 1051353 001000 ZT173YMM oil and gas baffle sub assembly 1 Right box assembly 2 PROCEDURE Tension bar assembly Use 5 inner hexagon to remove bolt take out the tension bar and thrust washer Stop wheel assembly Use a 12 sleeve to remove bolt take out stop wheel thrust washer and torsion spring Coarse filter Use an 8 slee...

Page 50: ...ng 1 PROCEDURE Spindle bearing baffle Use an 8 sleeve to remove the 2 bolts 1 and remove the bearing baffle 2 from the right box assembly 3 Bearing parts and after sales parts The bearings and are all press fitted on the right box and will not be damaged under normal circumstances CAUTION Bolt When installing apply proper amount of thread fastening glue on the thread ZT180MN right crankcase assemb...

Page 51: ...ankcase assembly Ordinary 4050154 008000 ZT180MN left crankcase sub assembly V Lengthened Fig 1 LEFT CRANKCASE ASSEMBLY Left crankcase parts PROCEDURE Oil seal cover assembly Use an 8 sleeve to remove the 2 bolts 1 and remove the oil seal cover 2 Return spring column Use 14 to remove the spring column and remove the copper pad Drain bolt Use a 14 sleeve to remove the oil drain bolt and take out th...

Page 52: ...er bearing 1 8 4050154 004000 ZT180MN left crankcase parts without bearing 1 PROCEDURE Left box after sales spare parts Oil seals bearings are all press fitted on the left box body CAUTION When the oil seal is press fitted the marking surface of the oil seal should face outwards Do not install it backwards to cause oil leakage It is recommended to go to a maintenance organization capable of doing ...

Page 53: ...aft counter shaft speed change drum fork and fork shaft are shown in the left figure The protruding ends of the shift forks and are assembled on the shift drum and the groove is locked on the counter shaft The protruding end of the shift fork is transferred to the transmission drum and the grooved end is locked on the main shaft When disassembling first take out the shift fork shaft remove the shi...

Page 54: ...0MN spindle six gears 1 8 ZT180MN spindle six gear sleeve 1 9 ZT180MN spindle second gear 1 10 15 2 25 1 0 thrust washer 1 Fig 2 GEARSHIFT AND TRANSMISSION Spindle assembly relationship 3 PROCEDURE Spindle assembly relationship The assembly relationship of the gears on the main shaft is shown on the left CAUTION The spindle is not allowed to be disassembled under special circumstances and only the...

Page 55: ...180MN Countershaft four gear 1 13 ZT180MN transmission auxiliary shaft subassembly 1 14 ZT180MN Countershaft six gear 1 15 25 2 31 1 0 thrust gasket 1 16 ZT180MN countershaftsecond gear shaft sleeve 1 17 ZT180MN countershaftsecond gear shaft sleeve 1 18 23 1 28 5 2 Thrust Washer 1 3 PROCEDURE Counter shaft assembly The assembly relationship of the gears on the countershaft is shown in the left fig...