Zontes ZT184MN User manual

Maintenance Manual
ZT184MN Engine EuroV
2022/7/7

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Table of Contents………………………………………………………………………………………………………………………………………………………………………………………………………………………………
1
11- The steps of draining oil
1.1
Draining oil…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
5
Discharge the oil
22-Cylinder head assembly
2.1
Remove the cylinder head cover assembly 1………………………………………………………………………………………………………………………………………………………………………………………
6
Remove the cylinder head cover assembly
2.2
Remove the cylinder head cover assembly 2………………………………………………………………………………………………………………………………………………………………………………………
7
Remove the cylinder head cover assembly
2.3
Align the timing chain…………………………………………………………………………………………………………………………………………………………………………………………………………………………
8
Align the timing chain
2.4
Adjust valve clearance………………………………………………………………………………………………………………………………………………………………………………………………………………………
9
Adjust valve clearance
2.5
Remove camshaft 1……………………………………………………………………………………………………………………………………………………………………………………………………………………………
10
sealing cap
tensioner assembly
2.6
Remove camshaft 2……………………………………………………………………………………………………………………………………………………………………………………………………………………………
11
Camshaft assembly
2.7
Remove the cylinder head 1………………………………………………………………………………………………………………………………………………………………………………………………………………
12
Remove the cylinder head
2.8
Remove the cylinder head 2………………………………………………………………………………………………………………………………………………………………………………………………………………
13
Remove the cylinder head
2.9
Remove the cylinder head 3………………………………………………………………………………………………………………………………………………………………………………………………………………
14
Disassemble the cylinder head assembly
2.10
valve assembly……………………………………………………………………………………………………………………………………………………………………………………………………………………………………
15
Check valve tightness
Remove valve assembly
2.11
After-sales parts description………………………………………………………………………………………………………………………………………………………………………………………………………………
16
Cylinder head sub-assembly
Cylinder head valve cam sub-assemblies
Cylinder head valve sub-assembly
Table of Contents
CONTENTS

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Table of Contents
Cylinder head exhaust pipe stud sub-assembly
33-Cylinder block assembly
3.1
Remove the guide bar………………………………………………………………………………………………………………………………………………………………………………………………………………………
17
guide bar
3.2
Cylinder block assembly……………………………………………………………………………………………………………………………………………………………………………………………………………………
18
Cylinder assembly
3.3
Cylinder block assembly……………………………………………………………………………………………………………………………………………………………………………………………………………………
19
Disassemble the cylinder, match the cylinder, piston
3.4
Piston assembly1………………………………………………………………………………………………………………………………………………………………………………………………………………………………
20
Disassemble the piston assembly
3.5
After-sales parts description………………………………………………………………………………………………………………………………………………………………………………………………………………
21
Disassemble the piston assembly
44-Right crankcase cover assembly
4.1
Remove Right Crankcase Cover Assembly 1………………………………………………………………………………………………………………………………………………………………………………………
22
Remove the right crankcase cover
4.2
Remove Right Crankcase Cover Assembly 2………………………………………………………………………………………………………………………………………………………………………………………
23
Remove the fine filter assembly, oil plug
4.3
Remove Right Crankcase Cover Assembly 3………………………………………………………………………………………………………………………………………………………………………………………
24
Remove the water pump cover assembly, remove the joint assembly
4.4
Remove Right Crankcase Cover Assembly 4………………………………………………………………………………………………………………………………………………………………………………………
25
right crankcase cover
4.5
Remove Right Crankcase Cover Assembly 5………………………………………………………………………………………………………………………………………………………………………………………
26
Remove Right Crankcase Cover Assembly
4.6
Remove Right Crankcase Cover Assembly 6………………………………………………………………………………………………………………………………………………………………………………………
27
Remove Right Crankcase Cover Assembly
4.7
Remove the clutch1……………………………………………………………………………………………………………………………………………………………………………………………………………………………
28
clutch pack
4.8
Clutch assembly-1………………………………………………………………………………………………………………………………………………………………………………………………………………………………
29
Friction Plate Assembly
4.9
Clutch assembly-2………………………………………………………………………………………………………………………………………………………………………………………………………………………………
30
clutch pack

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4.8
Clutch assembly-3………………………………………………………………………………………………………………………………………………………………………………………………………………………………
31
Friction Plate Assembly
55- Left crankcase cover assembly
5.1
Remove left crankcase cover 1…………………………………………………………………………………………………………………………………………………………………………………………………………
32
Remove the reduction gear
5.2
Remove left crankcase cover 2…………………………………………………………………………………………………………………………………………………………………………………………………………
33
Remove the starter motor
5.3
Remove left crankcase cover 3…………………………………………………………………………………………………………………………………………………………………………………………………………
34
Remove left crankcase cover
5.4
Remove left crankcase cover 4…………………………………………………………………………………………………………………………………………………………………………………………………………
35
Magneto Stator Assembly
66-Preparation before the box is split
6.1
Preparation before the box is split 1…………………………………………………………………………………………………………………………………………………………………………………………………
36
Disassemble the oil pump assembly
6.2
Preparation before the box is split 2…………………………………………………………………………………………………………………………………………………………………………………………………
37
Remove primary drive gear, remove shift star wheel assembly
6.3
Preparation before the box is split 3…………………………………………………………………………………………………………………………………………………………………………………………………
38
Remove the electric starter bridge teeth, remove the magneto rotor
6.4
Preparation before the box is split 4…………………………………………………………………………………………………………………………………………………………………………………………………
39
Remove the electric starter gear assembly, remove the output sprocket assembly
6.5
Preparation before the box is split 5…………………………………………………………………………………………………………………………………………………………………………………………………
40
Disassemble the gear display assembly
77-Crankcase split
7.1
Crankcase Split 1………………………………………………………………………………………………………………………………………………………………………………………………………………………………
41
Box split
7.2
Crankcase Split 2………………………………………………………………………………………………………………………………………………………………………………………………………………………………
42
Box split
7.3
Crankcase Split 3………………………………………………………………………………………………………………………………………………………………………………………………………………………………
43
Box split

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Table of Contents
7.4
Crankcase Split 4………………………………………………………………………………………………………………………………………………………………………………………………………………………………
44
Box split
88-Right crankshaft case assembly
8.1
Right crankcase disassembly 1……………………………………………………………………………………………………………………………………………………………………………………………………………
45
Disassemble the right crankcase parts
8.2
Right crankcase disassembly 2……………………………………………………………………………………………………………………………………………………………………………………………………………
46
Disassemble the right crankcase parts
8.3
After-sales parts description………………………………………………………………………………………………………………………………………………………………………………………………………………
47
Right crankcase sub-assembly, right crankcase assembly
99- Left crankcase assembly
9.1
Left crankcase disassembly 1………………………………………………………………………………………………………………………………………………………………………………………………………………
48
Disassemble left crankcase body parts
9.2
Left crankcase disassembly 2………………………………………………………………………………………………………………………………………………………………………………………………………………
49
Disassemble left crankcase body parts
9.3
After-sales parts description………………………………………………………………………………………………………………………………………………………………………………………………………………
50
Left crankcase sub-assembly, left crankcase assembly
10 10- Speed change, transmission mechanism components
10.1
Positional relationship of speed change and transmission mechanism components…………………………………………………………………………………………………………………………
51
Positional relationship of speed change and transmission mechanism components
10.2
Spindle assembly relationship……………………………………………………………………………………………………………………………………………………………………………………………………………
52
Spindle assembly relationship
10.3
Countershaft assembly relationship……………………………………………………………………………………………………………………………………………………………………………………………………
53
Countershaft assembly relationship
©Guangdong Daye Motorcycle Technology Co., Ltd.
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

1- The steps of draining oil
5
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
21244100-033000 Combined sealing gasket 12×φ20×2 2
31251100-066093 M12×1.5×15 ablassschraube (color Zinc) 224±4N.m
Fig.1 PREPARATION
STEPS
Draining oil
PROCEDURE:
●Discharge the oil
Park the vehicle on a level surface with the side stand.
Unscrew the oil plug ⑴by turning it counterclockwise.
It is recommended to remove the lower shroud before draining the oil. If it is not
removed, it is recommended to use a tool to guide the flow, so as to prevent the oil from
contaminating the cover.
Place the oil pan under the engine oil drain bolt as shown in the middle left picture.
Use a 14# sleeve to remove the oil drain bolt (3) of the engine, remove the gasket (2), and
empty the old oil.
CAUTION：
●Combined gasket ⑵It is recommended to replace it after disassembly to avoid oil leakage
and oil leakage due to damage caused during disassembly.
●The lower shroud needs to be removed first.
●Waste engine oil should be uniformly recycled and then handed over to qualified
institutions for disposal; it is forbidden to dump polluting the environment or water sources
at will.
●It is recommended to replace the oil drain bolt and combined gasket every time the oil is
changed.
11051161-012000 M24×2 oil filler plug 1

2-CYLINDER HEAD ASSEMBLY
6
CHK
ADJ
NO. PART NO. PART NAME QTY CAUTION
11251112-002093 M6×30 Hexagon flange bolts (color zinc) 812±1.5N.m
21251112-003093
M6×45 Hex flange surface 9.8 bolt (color
212±1.5N.m
41051658-002000 ZT184MN Cylinder head cover gasket 1
51251401-001000 φ8×14 hollow locating pin 1
Fig.1 CYLINDER HEAD
ASSEMBLY
Remove the cylinder head cover assembly 1
31250205-023000
GB70.1 inner hexagonal M8X35
(environmental color)
112±1.5N.m
PROCEDURE:
●Cylinder head cover assembly
Use an 8# sleeve to remove 2 bolts ⑴and 8 bolts ⑵, and remove 1 bolt ⑶for 6# inner
hexagon, then the cylinder head cover assembly can be removed.
Take out the gasket ⑷,
Take out the hollow positioning pin ⑸.
Notice:
●The cylinder head cover bolts must be evenly loosened or tightened diagonally when
removing and installing.
●Gasket ⑷is 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.
●Before installing new gaskets, it is necessary to clean the sealant on the assembly plane
on the cylinder head and the cylinder head cover to prevent problems such as oil leakage
from the engine caused by uneven assembly planes, and foreign matter should be avoided
when cleaning impurities such as residual sealant. into the engine.
●When installing a new gasket, it is necessary to apply an appropriate amount of sealant
on the assembly plane of the cylinder head and the upper surface of the gasket.

2-CYLINDER HEAD ASSEMBLY
7
CHK
ADJ
NO. PART NO. PART NAME QTY CAUTION
14050758-001000 ZT184MP Cylinder head cover 1
21251513-001019 6.3×12×1.6 copper gasket 1
31251100-067093 M6×10 top pin bolt (color zinc) 112±1.5N.m
41050154-034000 ZT180MN timing chain plate 1
Fig.2 CYLINDER HEAD
ASSEMBLY
Remove the cylinder head cover assembly 2
PROCEDURE:
●Disassemble the cylinder head cover assembly
Use the 8# sleeve to remove the bolt (3), and remove the copper pad (2);
Take out the timing chain guard ⑷from under the cylinder head cover ⑴.
Notice:
●The bolts (3) are used to check whether the oil is on the cylinder. Generally, it is not
necessary to disassemble.

2-CYLINDER HEAD ASSEMBLY
8
CHK
ADJ
NO. PART NO. PART NAME QTY CAUTION
14050956-003051 M30×1.5 aluminum screw plug (dark gray) 112±1.5N.m
21051454-023000
27.4×2.65 Hydrogenated nitrile rubber O-
1
31040953-002093
M14×1.5 plug screw (environmental color
112±1.5N.m
41051454-024000 13×2.8 Hydrogenated nitrile rubber O-ring 1
Align the timing chain
Fig.3 CYLINDER HEAD
ASSEMBLY
PROCEDURE:
●Remove the camshaft
Use 10# hexagon socket to remove the screw plug ⑴, and remove the O-ring ⑵.
Use 5# 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 ⑶, 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.
Notice:
●When the "T" dashed line coincides with the marked line, the ends of the intake and
exhaust camshafts all face outward.
●The timing is before the tensioner is retracted and after the tensioner is placed.

2-CYLINDER HEAD ASSEMBLY
9
CHK
ADJ
NO. PART NO. PART NAME QTY CAUTION
14051758-008000 ZT184MP intake camshaft sub-assembly 1
21050158-009000 3×27×19 slide tappet 4
34051758-009000 ZT184MP exhaust camshaft sub-assembly 1
Fig.4 CYLINDER HEAD
ASSEMBLY
Adjust valve clearance
PROCEDURE:
●Adjust the valve clearance
Rotate the intake and exhaust camshafts so that the base circle of the intake and exhaust
camshafts is directly on the tappet, and the camshaft can rotate flexibly.
Use a feeler gauge to measure the valve clearance.
Standard interval of intake valve clearance: 0.13-0.19mm
Standard interval of exhaust valve clearance: 0.24-0.30mm
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 replace the valve
clearance adjustment pad.
Notice:
●When measuring the clearance of the right exhaust valve, you need to rotate the
pressure reducing mechanism by hand until it is fully opened before measuring.
●The adjusting pad needs to be placed in place, and the cylinder head cannot be tilted or
dumped after adjusting the valve clearance; Camshaft lock can be used to prevent the
adjustment pad from dislocation.