Zontes ZT180MN User manual

ZT180MN Engine EuroIV_V
Maintenance Manual
2021/4/19

Page 1 ，Toatal 54 Pages
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0
Table of Contents……………………………………………………………………………………………………………………………………………………………………………………………
1
11- The steps of draining oil and antifreeze before disassembling the engine
1.1
Draining oil-1……………………………………………………………………………………………… ………………………………………………………………………………………… ……
5
1.2
Draining oil-2……………………………………………………………………………………………… ………………………………………………………………………………………… ……
6
1.3
Drain antifreeze……………………………………………………………………………………………… ………………………………………………………………………………………… …
7
22-Cylinder head assembly
2.1
Cylinder head cover assembly……………………………………………………………………………………………… ………………………………………………………………………………
8
Cylinder head cover assembly
2.2
Disassembling the camshaft-1…………………………………………………………………………………………………… …………………………………………………………………………
9
Tensioner assembly, sealing cap assembly
2.3
Disassembly of 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
33-cylinder block assembly
3.1
Disassembling the guide bar……………………………………………………………………………………………… …………………………………………………………………………………
18
Guide bar
3.2
Cylinder block assembly……………………………………………………………………………………………… ……………………………………………………………………………………
19
Cylinder assembly
3.3
Disassemble the piston……………………………………………………………………………………………… ………………………………………………………………………………………
20
Piston assembly
Table of Contents
Contents

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Contents
3.4
Description of after-sales parts………………………………………………………………………………………………………… ……………………………………………………………………
21
44-right crankcase cover assembly
4.1
ZT180MN right crankcase cover assembly-1……………………………………………………………………………… ………………………………………………………………………………
22
Remove the right crankcase cover
4.2
ZT180MN right crankcase cover assembly-2……………………………………………………………………………………… ………………………………………………………………………
23
Fine filter assembly, oil dipstick
4.3
Disassembling the water pump assembly-1…………………………………………………………………………………………………… ……………………………………………………………
24
Outlet pipe joint, water pump cover assembly
4.4
Disassembling the water pump assembly-2……………………………………………………………………………………………… …………………………………………………………………
25
Water pump components
4.5
Disassembling the water pump assembly-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
Friction plate assembly
4.12
Clutch assembly-3……………………………………………………………………………………………… …………………………………………………………………………………………
33
Clutch master and driven disc assembly
55-Left crankcase cover assembly
5.1
Disassembling the reduction gear……………………………………………………………………………………………… ……………………………………………………………………………
34
Reduction gear assembly
5.2
Disassembling the starter motor……………………………………………………………………………………………… ……………………………………………………………………………
35
Starter motor components
5.3
Remove left crankcase cover assembly…………………………………………………………………………………………………… …………………………………………………………………
36

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Remove the left cover assembly
5.4
Disassembling the magneto stator……………………………………………………………………………………………… ……………………………………………………………………………
37
Magneto stator assembly
5.5
Left cover parts……………………………………………………………………………………………… ………………………………………………………………………………………… ……
38
Screw plug assembly
66-Right crankshaft body case assembly (1)
6.1
Oil pump assembly……………………………………………………………………………………………… …………………………………………………………………………………………
39
Disassemble the oil pump assembly
6.2
Right box assembly-1………………………………………………………………………………………………………… ……………………………………………………………………………
40
Remove the driving sprocket, remove the shifting star wheel
77-Left crankcase assembly (1)
7.1
Disassemble the bridge teeth and the magneto rotor……………………………………………………………………………………………… …………………………………………………………
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
88-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
99-Right crankshaft case assembly (2)
9.1
Right cabinet assembly-2………………………………………………………………………………………………………… …………………………………………………………………………
48
Tensioner assembly, stop wheel assembly, coarse filter, oil and gas baffle
9.2
Right box assembly-3…………………………………………………………………………………………………… …………………………………………………………………………………
49
Spindle bearing baffle, bearing spare parts and after-sales parts
10 10-Left crankcase assembly (2)
10.1
Left crankcase parts……………………………………………………………………………………………… …………………………………………………………………………………………
50

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10.2
After-sales spare parts for left crankcase………………………………………………………………………………………… …………………………………………………………………………
51
11 11- Gearshift and transmission mechanism components
11.1
The position relationship of the components of the speed change and transmission mechanism…………………………………………………………………………………… ………………………
52
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 some inconsistencies between your engine and this manual.

1-PREPARATION STEPS
5
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
1 1251100-066093 M12×1.5×15 oil drain bolt (color zinc) 2 25±4N.m
2 1244100-033000 Combined sealing gasket12×φ20×2 2
3 1050854-002000 ZT180MN oil level gauge 1
4 1051454-003000 15×3.1 acrylate adhesive O
－
ring 1
Fig.1 PREPARATION
STEPS Draining oil-1
PROCEDURE:
●Drain oil
Place a larger container under the engine, use 14 sleeve + ratchet wrench to remove the 2 oil drain bolts at the
bracket and the left 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 ⑵It 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 ⑴, check whether the magnet on the bolt has adsorbed iron filings. If there
are many foreign objects or parts adsorbed, check the inside of the engine. If there is only a small amount of
metal chips, don't worry, just clean it up.
●Draining oil and antifreeze can only be done when the machine is cold to prevent burns.

1-PREPARATION STEPS
6
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
1Oil outlet pipe of engine 1
2Oil inlet pipe of engine 1
3 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color zinc) 2 12±1.5N.m
4 1051454-014000 9.8×2.5 acrylic o
－
ring 2
Fig.2 PREPARATION
STEPS Draining oil-2
【1】
PROCEDURE:
●Drain oil
Use an 8# sleeve to remove the 2 bolts ⑶ on the engine oil outlet pipe ⑴ and the engine oil inlet pipe ⑵, and
remove the O-ring ⑷.
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 recommended to be replaced after disassembly to avoid oil leakage and oil leakage due to improper
seals caused by damage during disassembly.

1-PREPARATION STEPS
7
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
1 1251112-001093 M6×16 Hexagon flange bolts (color zinc) 1 12±1.5N.m
2 1251513-001019 6.3×12×1.6 copper gasket 1
PROCEDURE:
●Put antifreeze
Place a container under the drain hole, ready to receive antifreeze, use an 8# sleeve to remove the bolt (1), and
remove the copper pad (2).
Locate the water filler cap at the lower link plate on the right side of the vehicle, press down the water filler cap
and turn it counterclockwise before removing it, and wait for the antifreeze to drain.
CAUTION:
●Gasket ⑵After 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 antifreeze, immediately
rinse with clean water. If the antifreeze is splashed into the eyes, immediately rinse with plenty of water and
observe to decide whether to seek medical attention.
●The engine can be removed from the vehicle after draining the antifreeze and engine oil.
Fig.3 PREPARATION
STEPS Drain antifreeze

2-CYLINDER HEAD ASSEMBLY
8
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
1 1251112-003093 M6×45 Hex flange surface 9.8 bolt (color zinc) 2 12±1.5N.m
2 1251112-002093 M6×30 Hexagon flange bolts (color zinc) 8 12±1.5N.m
3 1250205-023000 GB70.1 inner hexagonal M8X35 (environmental color) 1 21±1.5N.m
4 1051654-001000 ZT180MN Cylinder head cover gasket 1
5 1251401-001000 φ8×14 hollow locating pin 2
6 1051454-001000 7.5×1.5 Fluorine O
－
ring 1
7 1251401-003000 Φ10×14 hollow positioning pin 1
8 1251100-067093 M6×10 top pin bolt (color zinc) 1 12±1.5N.m
9 1251513-001019 6.3×12×1.6 copper gasket 1
10 1050154-034000 ZT180MN timing chain plate 1
11 1040754-001000 ZT180MN Cylinder head cover 1
Cylinder head cover assembly
PROCEDURE:
●Cylinder head cover assembly
Use an 8# sleeve to remove 2 bolts ⑴ and 8 bolts ⑵, and remove 1 bolt ⑶ for 6# inner hexagon, then the
cylinder head cover assembly can be removed.
Take out the gasket ⑷, remove one large positioning pin ⑺ and two small positioning pins ⑸. Note: One of
the small positioning pins ⑸ has an O-ring ⑹. Clean up the remaining sealant on the joint surface.
Remove the bolt ⑻ with an 8# sleeve, and remove the copper pad ⑼.
Remove the chain guard ⑽ from the inside of the cylinder head cover ⑽, and install the chain guard ⑽ on the
boss shown in the circle in the figure.
CAUTION：
●
When installing a new gasket, apply a proper amount of sealant on the assembly plane of the cylinder head and
the upper surface of the gasket.
●The cylinder head cover bolts must be evenly loosened or tightened diagonally when removing and installing.
●Gasket ⑷ is for one-time use, and must be replaced after disassembly, otherwise the seal will not be in place
and problems such as engine oil leakage will occur.
●When cleaning residual sealant and other impurities, avoid foreign matter from entering the engine.
Fig.1 CYLINDER HEAD
ASSEMBLY

2-CYLINDER HEAD ASSEMBLY
9
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
1 1251100-067093 M6×10 top pin bolt (color zinc) 1 12±1.5N.m
2 1251513-001019 6.3×12×1.6 copper gasket 1
3 1251112-002093 M6×30 Hexagon flange bolts (color zinc) 2 12±1.5N.m
4 1051253-003000 30×38 tensioner parts 1
5 1051253-004000 30×38 Washer, tensioner 1
6 1050153-005000 Cylinder head sealing cap parts 2
Disassembling the camshaft-1
PROCEDURE:
●Tensioner assembly
Use an 8# sleeve to remove the bolt ⑴, and take out the copper pad ⑵.
Use an 8# sleeve to remove the 2 bolts (3), and use the tensioner disassembly tool to remove the tensioner ⑷
and gasket ⑸.
●Sealing cap assembly
When installing the sealing cap ⑹, a proper amount of sealant should be applied at ① to prevent oil leakage.
CAUTION：
●Gasket ⑸ is for one-time use, and must be replaced after disassembly, otherwise the seal will not be in place
and problems such as engine oil leakage will occur.
●When removing the tensioner, it is necessary to use the tensioner removal tool. Disassembly tooling is included
when purchasing the tensioner assembly. The tooling is as follows:
Fig.2 CYLINDER HEAD
ASSEMBLY