Zontes Euro V ZT152 Service Manual
  1. Manuals
  2. Brands
  3. Zontes Manuals
  4. Engine
  5. Euro V ZT152
  6. Service manual
Zontes Euro V ZT152 Service Manual

Zontes Euro V ZT152 Service Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

ZT152 Engine Euro V
Service manual
2020/12/11

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Euro V ZT152 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Zontes Euro V ZT152

Summary of Contents for Zontes Euro V ZT152

  • Page 1 ZT152 Engine Euro V Service manual 2020/12/11...

  • Page 2: Table Of Contents

    Contents Table of Contents Pages Table of Contents………………………………………………………………………………………………………………………………………………………………………………………………… STEPS TO DRAIN ANTIFREEZE 1.1 Steps for discharging antifreeze………………………………………………………………………………………………………………………………… ………………………………………………… CYLINDER HEAD ASSEMBLY 2.1 Water pump assembly-1………………………………………………………………………………………………………………………………… ………………………………………………………… 5 2.2 Water pump assembly-2…………………………………………………………………………………………………………………………………………………………………………………………… 2.3 Outer parts of cylinder head………………………………………………………………………………………………………………………………………………………………………………………… 7 2.4 Cylinder head cover assembly……………………………………………………………………………………………………………………………………………………………………………………… 8 2.5 Cylinder head assembly-1…………………………………………………………………………………………………………………………………………………………………………………………...
  • Page 3 Contents Table of Contents Pages RIGHT CRANKCASE COVER ASSEMBL 6.1 Left crankcase cover assembly-1……………………………………………………………………………………………… ………………………………………………………………………………… 6.2 Left crankcase cover assembly-2………………………………………………………………………………………… ……………………………………………………………………………………… LEFT CRANKSHAFT BOX ASSEMBLY 7.1 ZT158MJ magneto rotor, crankshaft position sensor……………………………………………………………………………………………… ……………………………………………………………… 27 7.2 ZT158MJ electric starter assembly -1…………………………………………………………………………………… ………………………………………………………………………………………… 28 7.3 ZT158MJ electric starter assembly-2…………………………………………………………………………………………...
  • Page 4 Contents Table of Contents Pages This manual is suitable for ZT125 series engines. All the materials, illustrations, photos, etc. collected in this manual are compiled according to the latest products. However, due to continuous product improvement and other changes, there may be some inconsistencies between your engine and this manual.For colors or upgrades, please refer to the part codes on the official website. This manual will not be listed in detail;...

  • Page 5: Steps To Drain Antifreeze

    1- STEPS TO DRAIN ANTIFREEZE Fig.1 STEPS TO DRAIN Steps to drain antifreeze ANTIFREEZE PART NO. PART NAME CAUTION 1251100-067093 M6×10 top pin bolt (color zinc) 12±1.5N.m 1251513-001019 6.3×12×1.6 copper gasket PROCEDURE: ●As shown in the figure, find the bolt ⑴ on the right side of the engine, use an 8#T sleeve to unscrew and remove the copper gasket ⑵, place a container under the drain hole, and prepare to receive antifreeze.

  • Page 6: Cylinder Head Assembly

    2-CYLINDER HEAD ASSEMBLY Fig.1 CYLINDER HEAD Water pump assembly-1 ASSEMBLY PART NO. PART NAME CAUTION 1251112-002093 M6×30 Hexagon flange bolts (color zinc) 12±1.5N.m 1251401-001000 φ8×14 hollow positioning pin 1051656-002000 ZT158MJ water pump sealant 1051468-011000 18.2×2.4 EPDM O-ring 1051956-002000 ZT158MJ water pump leaking pipe PROCEDURE: ●Use 8#T rod sleeve to remove the three bolts ⑴, remove the water pump, positioning pin ⑵, sealant ⑶...

  • Page 7: Water Pump Assembly-2

    2-CYLINDER HEAD ASSEMBLY Fig.2 CYLINDER HEAD Water pump assembly-2 ASSEMBLY PART NO. PART NAME CAUTION 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color zinc) 12±1.5N.m 1251100-067093 M6×10 top pin bolt (color zinc) 1251513-001019 6.3×12×1.6 copper gasket 4050968-001000 ZT1P58MJ water pump cover 1251401-001000 φ8×14 hollow positioning pin 1051468-013000 ZT1P58 water pump cover sealing ring 1051154-003000 GB894.1 Circlip for shaft φ10 (Dacromet plated)

  • Page 8: Outer Parts Of Cylinder Head

    2-CYLINDER HEAD ASSEMBLY Fig.3 CYLINDER HEAD Cylinder head outer parts ASSEMBLY PART NO. PART NAME CAUTION 1050954-026000 LSF oxygen sensor 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color zinc) 12±1.5N.m 1051956-001000 ZT158MJ thermostat sub-assembly 1051468-010000 16.5×1.95 EPDM O-ring PROCEDURE: ●Use 22# open-end wrench to remove the oxygen sensor ⑴.

  • Page 9: Cylinder Head Cover Assembly

    2-CYLINDER HEAD ASSEMBLY Fig.4 CYLINDER HEAD Cylinder head cover assembly ASSEMBLY PART NO. PART NAME CAUTION 1250101-076093 GB16674 M8×45 (environmental protection color zinc) 25±3N.m 1051656-001000 ZT158MJ cylinder head cover gasket 1251401-001000 φ8×14 hollow positioning pin 1251300-056093 M6 cap type 9 grade nut (color zinc) 10±1.5N.m 4050956-002000 ZT158MJ valve cover 1051468-009000 37×1.9 Acrylic O-ring...

  • Page 10: Cylinder Head Assembly-1

    2-CYLINDER HEAD ASSEMBLY Fig.5 CYLINDER HEAD Cylinder head cover assembly-1 ASSEMBLY PART NO. PART NAME CAUTION 1251300-080094 black) 25±3N.m 1251500-079000 φ8.3×φ17×2 iron gasket 1251112-007093 M6×105 Hexagon flange bolts (color zinc) 12±1.5N.m 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color zinc) 12±1.5N.m 1051268-003000 ZT1P58MJ tensioner sub-components 1051668-006000 ZT1P58MJ Tensioner Gasket...

  • Page 11: Cylinder Head Assembly-2

    2-CYLINDER HEAD ASSEMBLY Fig.6 CYLINDER HEAD Cylinder head cover assembly-2 ASSEMBLY PART NO. PART NAME CAUTION 1050953-004000 CR8EI-8 spark plug (with nut) 14±1.5N.m 1050954-003000 Water and oil shared sensor 13±1.5N.m 1051454-009000 9×2 EPDM rubber O-ring 1251112-001093 M6×16 Hexagon flange bolts (color zinc) 12±1.5N.m 1251513-001019 6.3×12×1.6 copper gasket 1251100-067093 M6×10 top pin bolt (color zinc)

  • Page 12: Cylinder Head Assembly-3

    2-CYLINDER HEAD ASSEMBLY Fig.7 CYLINDER HEAD Cylinder head cover assembly-3 ASSEMBLY PART NO. PART NAME CAUTION 1050168-007000 ZT1P58MJ intake and exhaust rocker arm shaft 1050168-033000 ZT1P58MJ intake rocker arm sub-assembly-B 1050168-034000 ZT1P58MJ Exhaust Rocker Arm Sub-assembly-B 1251100-225000 M5×0.5 valve clearance adjusting nut 9±1N.m 1251100-222000 M5×0.5×SR12 valve clearance adjustment screw PROCEDURE:...

  • Page 13: Cylinder Head Assembly-4

    2-CYLINDER HEAD ASSEMBLY Fig.8 CYLINDER HEAD Cylinder head cover assembly-4 ASSEMBLY PART NO. PART NAME CAUTION 1050168-007000 ZT1P58MJ intake and exhaust rocker arm shaft 1050168-033000 ZT1P58MJ intake rocker arm sub-assembly-B 1050168-034000 ZT1P58MJ Exhaust Rocker Arm Sub-assembly-B PROCEDURE: ●Just pull out the camshaft sub-part ⑴ directly. CAUTION: ●When assembling the camshaft, it is necessary to spray a proper amount of oil for lubrication, and check the O-ring to avoid omissions.

  • Page 14: Cylinder Head Assembly-5

    2-CYLINDER HEAD ASSEMBLY Fig.9 CYLINDER HEAD Cylinder head cover assembly-5 ASSEMBLY PART NO. PART NAME CAUTION 1050168-016000 ZT1P58MJ valve lock clip 1050168-015000 ZT1P58MJ valve spring retainer 1050168-014000 ZT1P58MJ exhaust valve spring 1051553-001000 φ5.0 valve stem diameter oil seal 1050168-018000 ZT1P58MJ valve spring base 1050168-011000 ZT1P58MJ intake valve 1050168-012000 ZT1P58MJ exhaust valve PROCEDURE:...

  • Page 15: Cylinder Block Assembly

    3-CYLINDER BLOCK ASSEMBLY Fig.1 CYLINDER BLOCK Cylinder assembly-1 ASSEMBLY PART NO. PART NAME CAUTION 1051256-002000 ZT158MJ guide strip 1251401-001000 φ10×14 hollow positioning pin 1051668-003000 ZT1P58MJ cylinder block box gasket 1051655-001000 ZT1P52MI cylinder block cylinder head gasket 1251100-067093 M6×10 top pin bolt (color zinc) 1251513-001019 6.3×12×1.6 copper gasket 4050555-001000 ZT152MI cylinder block PROCEDURE:...

  • Page 16: Oil Drainine

    4-OIL DRAINING STEPS Fig.1 OIL DRAINING Oil Draining STEPS PART NO. PART NAME CAUTION 1251100-066093 M12×1.5×15 oil drain bolt (color zinc) 30±3N.m 1244100-033000 Combination gasket 12×φ20×2 1251300-054000 M20×1.5 Fuel filler nut 1051456-003000 φ19×φ2.65 Nitrile O-ring PROCEDURE: ●Find the oil drain bolt ⑴ under the left crankcase body, place a container underneath to contain the oil, use a 14# torx wrench to remove the oil drain bolt ⑴, and remove the combined sealing gasket ⑵.

  • Page 17: Zt158Mj Right Crankcase Cover Assembly-1

    5-RIGHT CRANKCASE COVER ASS Fig.1 RIGHT CRANKCASE ZT158MJ right crankcase cover assembly-1 COVER ASSEMBLY PART NO. PART NAME CAUTION 1251300-056093 M6 cap type 9 grade nut (color zinc) 10±1.5N.m ZT158MJ oil filter cover 【1】 1050868-002000 φ18.5×13×1.6 fine filter spring 1050856-004000 ZT150-U fine filter sealing assembly (with packaging) 1251300-054000 M20×1.5 Fuel filler nut 1051456-003000 φ19×φ2.65 Nitrile O-ring ZT158MJ right crankcase cover...

  • Page 18: Zt158Mj Right Crankcase Cover Assembly-2

    5-RIGHT CRANKCASE COVER ASS Fig.2 RIGHT CRANKCASE ZT158MJ right crankcase cover assembly-2 COVER ASSEMBLY PART NO. PART NAME CAUTION 1251112-002093 M6×30 Hexagon flange bolts (color zinc) 12±1.5N.m 1251112-003093 M6×45 Hex flange surface 9.8 bolt (color zinc) 1051356-009000 ZT158MJ clutch cable bracket PROCEDURE: ●Use a 14# open-end wrench to loosen the nuts marked by ①...

  • Page 19: Zt158Mj Right Crankcase Cover Assembly-3

    5-RIGHT CRANKCASE COVER ASS Fig.3 RIGHT CRANKCASE ZT158MJ right crankcase cover assembly-3 COVER ASSEMBLY PART NO. PART NAME CAUTION 1050756-015000 ZT158MJ clutch toothed rod 1050756-014000 ZT158MJ clutch lever shaft 1251700-141000 ZT158MJ toothed tie rod bushing 1051656-004000 ZT158MJ right crankcase cover gasket 1251401-001000 φ8×14 hollow positioning pin 1050853-020000 φ8×7.5 oil plug PROCEDURE:...

  • Page 20: Zt158Mj Right Crankcase Cover Assembly-4

    5-RIGHT CRANKCASE COVER ASS Fig.4 RIGHT CRANKCASE ZT158MJ right crankcase cover assembly-4 COVER ASSEMBLY PART NO. PART NAME CAUTION 1051154-003000 GB894.1 Circlip for shaft φ10 (Dacromet plated) 1050756-013000 ZT158MJ clutch lever rocker arm assembly 1050756-012000 ZT158MJ clutch handle torsion spring 1251512-043000 φ14.2×φ24×0.5 thrust washer (galvanized) 1250511-002000 GB896 open retaining ring φ6 1251512-003000 8.2×14×0.5 thrust washer...

  • Page 21: Zt158Mj Right Crankcase Cover Assembly-5

    5-RIGHT CRANKCASE COVER ASS Fig.5 RIGHT CRANKCASE ZT158MJ right crankcase cover assembly-5 COVER ASSEMBLY PART NO. PART NAME CAUTION 1050756-014000 ZT158MJ clutch lever shaft 1051553-002000 FB14×22×5 Hydrogenated Nitrile Rubber Oil Seal 1250602-033000 GB290－HK1412 Needle Roller Bearing 1250602-022000 GB290－HK1010 Needle Roller Bearing 1251700-141000 ZT158MJ toothed tie rod bushing 1051354-013000 Circlips for non-standard holes φ24×1 1051551-004000 φ25 oil window sub-assembly...

  • Page 22: Clutch Assembly-1

    5-RIGHT CRANKCASE COVER ASS Fig.6 RIGHT CRANKCASE Clutch assembly-1 COVER ASSEMBLY PART NO. PART NAME CAUTION 1251112-002093 M6×30 Hexagon flange bolts (color zinc) 12±1.5N.m 1251311-001094 M16×1 Hexagon Thin Nut (oxidized black) 95±10N.m 1251514-002000 φ16.2×φ28×2.4×2 lock washers 1251512-039000 φ16.2×φ28×1 thrust washer PROCEDURE: ●Use 8#T rod sleeve to remove three bolts ⑴, then the whole set of pressure plate ①...

  • Page 23: Clutch Assembly-2

    5-RIGHT CRANKCASE COVER ASS Fig.7 RIGHT CRANKCASE Clutch assembly-2 COVER ASSEMBLY PART NO. PART NAME CAUTION 1251112-002093 M6×30 Hexagon flange bolts (color zinc) 12±1.5N.m 1051356-007000 ZT158MJ clutch cover 1050756-011000 ZT158MJ clutch cushion rubber 1050756-004000 ZT158MJ clutch spring 1050756-015000 ZT158MJ clutch toothed rod 1050756-018000 ZT158MJ clutch driven disc PROCEDURE: ●Use an 8#T sleeve to remove the three bolts ⑴, remove the cover ⑵, cushion rubber ⑶, spring ⑷.

  • Page 24: Clutch Assembly-3

    5-RIGHT CRANKCASE COVER ASS Fig.8 RIGHT CRANKCASE Clutch assembly-3 COVER ASSEMBLY PART NO. PART NAME CAUTION 1251500-085000 ZT158MJ clutch spring washer 1250601-096000 GB/T 276 61901 Deep groove ball bearing 1050756-019000 ZT158MJ clutch pressure plate 1050756-023000 φ96×φ114.2×3 clutch friction plate (rubber base) 1050756-002000 φ87×φ115×2 clutch disc 1050756-001000 φ96×φ114.2×3 clutch friction plate (paper base) PROCEDURE:...

  • Page 25: Clutch Assembly-4

    5-RIGHT CRANKCASE COVER ASS Fig.9 RIGHT CRANKCASE Clutch assembly-4 COVER ASSEMBLY PART NO. PART NAME CAUTION 1251311-001094 M16×1 Hexagon Thin Nut (oxidized black) 95±10N.m 1251514-002000 φ16.2×φ28×2.4×2 lock washers 1251512-039000 φ16.2×φ28×1 thrust washer 1050756-018000 ZT158MJ clutch driven disc 1251500-084000 ZT158MJ Clutch Spline Washer 1050756-008000 ZT158MJ clutch active hub subassembly 1251602-001000 263124 double row needle roller bearings 1251700-148000 ZT158MJ clutch bushing...

  • Page 26: Left Crankcase Cover Assembly-1

    6-LEFT CRANKCASE COVER ASSEMBLY Fig.1 LEFT CRANKCASE Left crankcase cover assembly-1 COVER ASSEMBLY PART NO. PART NAME CAUTION 1251112-003093 M6×45 Hex flange surface 9.8 bolt (color zinc) 12±1.5N.m ZT158MJ left crankcase cover 1051656-005000 ZT158MJ left crankcase cover gasket 1251401-001000 φ8×14 hollow positioning pin PROCEDURE: ●Use 8#T rod sleeve to remove 7 bolts ⑴, pull out the left crankcase cover ⑵, remove the gasket ⑶...

  • Page 27: Left Crankcase Cover Assembly-2

    6-LEFT CRANKCASE COVER ASSEMBLY Fig.2 LEFT CRANKCASE Left crankcase cover assembly-2 COVER ASSEMBLY PART NO. PART NAME CAUTION 1251201-002094 M6×35 hexagon socket screw (oxidized black) 12±1.5N.m 1051056-001000 ZT158MJ magneto stator sub-components 1251201-001094 M5×15-5# Hexagon socket screw (oxidized black) 5±1.5N.m 1051356-008000 ZT158MJ stator wire pressure plate M30×1.5 aluminum screw plug 16±1.5N.m 1051453-003000 27.4×2.65 Acrylic O-ring...

  • Page 28: Zt158Mj Magneto Rotor, Crankshaft Position Sensor

    7- LEFT CRANKCASE ASSEMBLY Fig.1 LEFT CRANKCASE ZT158MJ magneto rotor, crankshaft position sensor ASSEMBLY PART NO. PART NAME CAUTION M10×1.25×45 hex flange bolt(10.9 grade / black 1251100-064094 60±5N.m oxide) 1251500-041000 10.3×20×2 gasket 1051056-002000 ZT158MJ magneto rotor clutch parts 1251201-001094 M5×15－5# Hexagon socket screw(oxidized black) 5±1.5N.m 1050956-001000 ZT158MJ crankshaft position sensor PROCEDURE:...

  • Page 29: Zt158Mj Electric Starter Assembly -1

    7- LEFT CRANKCASE ASSEMBLY Fig.2 LEFT CRANKCASE ZT158MJ electric starter assembly -1 ASSEMBLY PART NO. PART NAME CAUTION 1051068-012000 ZT1P58MJ electric starter reduction gear shaft 1051056-004000 ZT158MJ electric start reduction gear assembly 1251512-025000 22.2×40×1 Thrust Washer 1051056-007000 ZT158MJ electric start gear 1251602-002000 K22×28×23 needle roller bearing PROCEDURE: ●Remove the reduction gear shaft ⑴...

  • Page 30: Zt158Mj Electric Starter Assembly-2

    7- LEFT CRANKCASE ASSEMBLY Fig.3 LEFT CRANKCASE ZT158MJ electric starter assembly-2 ASSEMBLY PART NO. PART NAME CAUTION 1251112-002093 M6×30 Hexagon flange bolts(color zinc) 12±1.5N.m 1051056-005000 ZT158MJ starting motor parts PROCEDURE: ●Use 8#T rod sleeve to remove the two bolts ⑴. ●Push the starting motor ⑵...
  • Page 31 7- LEFT CRANKCASE ASSEMBLY Fig.4 LEFT CRANKCASE ZT158MJ Left crankshaft box assembly-1 ASSEMBLY PART NO. PART NAME CAUTION 1251300-033094 GN sprocket nut M16×1.5-6h(color zinc) 95±5N.m 1251500-088000 ZT158MJ sprocket lock gasket 1050356-002000 ZT158MJ countershaft output sprocket 1251500-089000 19Z×1M×37.5×3×φ28 involute spline washer 1251100-067093 M6×10 top pin bolt(color zinc) 12±1.5N.m 1051256-003000 ZT158MJ Tension Guide Plate...

  • Page 32: Zt158Mj Left Crankcase Assembly-2

    7- LEFT CRANKCASE ASSEMBLY Fig.5 LEFT CRANKCASE ZT158MJ Left crankshaft box assembly-2 ASSEMBLY PART NO. PART NAME CAUTION 1251100-165000 M6×16－13.8×8.7 pivot bolt 12±1.5N.m 1051256-001000 ZT158MJ Tension Strip 1050156-005000 ZT158MJ timing chain 96 links SCZ-0404SV 1250201-034093 GB818M5×20(environmental protection color) 1050656-010000 ZT158MJ file display component 1051454-011000 22.5×2.5 fluorine rubber O-ring 1050654-007000 ZT180MN gear display contact assembly PROCEDURE:...

  • Page 33: Zt158Mj Left Crankcase Assembly-3

    7- LEFT CRANKCASE ASSEMBLY Fig.6 LEFT CRANKCASE ZT158MJ Left crankshaft box assembly-3 ASSEMBLY PART NO. PART NAME CAUTION 1251112-002093 M6×30 Hexagon flange bolts(color zinc) 1251112-005093 M6×75 hexagon flange bolts(color zinc) 12±1.5N.m 1251112-003093 M6×45 Hex flange surface 9.8 bolt(color zinc) 1251112-004093 M6×60 Hexagon flange bolts(color zinc) 1251401-001000 φ8×14 hollow positioning pin 1051656-003000 ZT158MJ crankcase gasket 1050656-012000 ZT158MJ transmission mechanism sub-components...

  • Page 34: Zt158Mj Left Crankcase Assembly-4

    7- LEFT CRANKCASE ASSEMBLY Fig.7 LEFT CRANKCASE ZT158MJ Left crankshaft box assembly-4 ASSEMBLY PART NO. PART NAME CAUTION 1251112-002093 M6×30 Hexagon flange bolts(color zinc) 1251112-005093 M6×75 hexagon flange bolts(color zinc) 12±1.5N.m 1251112-003093 M6×45 Hex flange surface 9.8 bolt(color zinc) 1251112-004093 M6×60 Hexagon flange bolts(color zinc) 1251401-001000 φ8×14 hollow positioning pin 1051656-003000 ZT158MJ crankcase gasket 1050656-012000 ZT158MJ transmission mechanism sub-components...

  • Page 35: Zt158Mj Left Crankcase Assembly-5

    7- LEFT CRANKCASE ASSEMBLY Fig.8 LEFT CRANKCASE ZT158MJ Left crankshaft box assembly-5 ASSEMBLY PART NO. PART NAME CAUTION 1251112-002093 M6×30 Hexagon flange bolts(color zinc) 1251112-005093 M6×75 hexagon flange bolts(color zinc) 12±1.5N.m 1251112-003093 M6×45 Hex flange surface 9.8 bolt(color zinc) 1251112-004093 M6×60 Hexagon flange bolts(color zinc) 1251401-001000 φ8×14 hollow positioning pin 1051656-003000 ZT158MJ crankcase gasket PROCEDURE:...

  • Page 36: Zt158Mj Left Crankcase Assembly-6

    7- LEFT CRANKCASE ASSEMBLY Fig.9 LEFT CRANKCASE ZT158MJ Left crankshaft box assembly-6 ASSEMBLY PART NO. PART NAME CAUTION 1250601-097000 GB276－62/22RS/P6 deep groove ball bearing 1250601-036000 GB276－6202RS/P6 deep groove ball bearing(nitride) 1250602-020000 HK222910 needle roller bearings 1250601-060000 GB276-6207/P5C3 deep groove ball bearing 1251601-001000 63/13/P5 deep groove ball bearing(6301/13 nitriding) CAUTION: ●Bearings are all press-fit, disassembly is not recommended.

  • Page 37: Zt158Mj Oil Pump Assembly

    8-RIGHT CRANKCASE ASSEMBLY Fig.1 RIGHT CRANKCASE ZT158MJ oil pump assembly ASSEMBLY PART NO. PART NAME CAUTION Φ6 open retaining ring Not for sale 1050356-001000 ZT158MJ oil pump driven gear 8.2×14×0.5 thrust washer Not for sale Needle roller 12×2.5 1251112-001093 M6×16 hexagon flange bolts(color zinc) 12±1.5N.m ZT158MJ oil pump cover Not for sale...

  • Page 38: Zt158Mj Balance Shaft Assembly-1

    8-RIGHT CRANKCASE ASSEMBLY Fig.2 RIGHT CRANKCASE ZT158MJ balance shaft assembly-1 ASSEMBLY PART NO. PART NAME CAUTION 1251311-004094 M14×1 Hexagon Thin Lock Nut(oxidized black) 70±10N.m 1251514-001000 14.2×27×2.1×1.5 lock washers 1050556-001000 ZT158MJ balance shaft gear cover 1251311-001094 M16×1 Hexagon Thin Nut(oxidized black) 95±10N.m 1251514-002000 16.2×28×2.4×2 lock washers 1050356-014000 ZT158MJ primary drive gear...

  • Page 39: Zt158Mj Balance Shaft Assembly-2

    8-RIGHT CRANKCASE ASSEMBLY Fig.3 RIGHT CRANKCASE ZT158MJ balance shaft assembly-2 ASSEMBLY PART NO. PART NAME CAUTION 1050356-013000 ZT158MJ balance shaft drive gear 1251802-004000 5×5.5×26×9 half-round key 1050556-004000 ZT158MJ balance shaft gear assembly assembly PROCEDURE: ●Pull out the balance shaft drive gear ⑴ from the crankshaft, and remove the half-circle key ⑵. ●Remove the balance shaft gear(3) from the balance shaft, and remove the half-circle key(2).

  • Page 40: Zt158Mj Balance Shaft Gear Assembly -1

    8-RIGHT CRANKCASE ASSEMBLY Fig.4 RIGHT CRANKCASE ZT158MJ balance shaft gear assembly -1 ASSEMBLY PART NO. PART NAME CAUTION ZT154FMI balance shaft tooth buffer spring column Not for sale ZT158MJ balance shaft buffer spring ZT158MJ balance shaft gear ZT158MJ balance shaft tooth skeleton After sales assembly 1050556-004000 ZT158MJ balance shaft gear assembly assembly...

  • Page 41: Zt158Mj Shift Mechanism Assembly-1

    8-RIGHT CRANKCASE ASSEMBLY Fig.5 RIGHT CRANKCASE ZT158MJ shift mechanism assembly-1 ASSEMBLY PART NO. PART NAME CAUTION 1050656-004000 ZT158MJ shift shaft sub-assembly 1251512-009000 φ15.2×φ25×1 thrust washer 1050656-005000 ZT158MJ shift lever limit spring column M6×30 hexagon flange bolts(environmental protection 1251112-002093 12±1.5N.m color zinc) 1050651-003000 ZT154FMI shift star cam subassembly 1250404-004000 GB119.2φ4×10 cylindrical pin PROCEDURE:...

  • Page 42: Zt158Mj Shift Mechanism Assembly-2

    8-RIGHT CRANKCASE ASSEMBLY Fig.6 RIGHT CRANKCASE ZT158MJ shift mechanism assembly-2 ASSEMBLY PART NO. PART NAME CAUTION 1251100-068093 M6×14-9×2.6 pivot bolt(color zinc) 12±1.5N.m 1050656-014000 ZT158MJ stopper(NMB R-1450ZZ bearing) 1251500-091000 φ6.3×φ12×1 thrust washer 1260100-246000 ZT158MJ limit stop wheel torsion spring PROCEDURE: ●Use 10#T rod sleeve to remove bolt ⑴, remove stopper ⑵, washer ⑶, torsion spring ⑷. CAUTION: ●...

  • Page 43: Zt158Mj Right Crankcase Assembly-1

    8-RIGHT CRANKCASE ASSEMBLY Fig.7 RIGHT CRANKCASE ZT158MJ Right crankshaft box assembly-1 ASSEMBLY PART NO. PART NAME CAUTION 1251112-001093 M6×16 hexagon flange bolts(color zinc) 12±1.5N.m 1051356-013000 ZT158MJ right box balance shaft bearing pressure plate 1051356-006000 ZT158MJ spindle bearing pressure plate 1051353-014000 ZT173YMM rear hoisting hole bushing(single rocker arm) 1051754-001000 1.0×5.5×6 oil pin 1251111-008000 YM8×1.25－M8×1.25×166 double-ended stud...

  • Page 44: Zt158Mj Right Crankcase Assembly-2

    8-RIGHT CRANKCASE ASSEMBLY Fig.8 RIGHT CRANKCASE ZT158MJ Right crankshaft box assembly-2 ASSEMBLY PART NO. PART NAME CAUTION 1250601-098000 GB276-6202/P5 deep groove ball bearing(nitriding) 1250601-099000 6705 thin wall bearing(P6) 1250601-043000 GB276-6204/P6 deep groove ball bearing 1250601-039000 GB276－6203/P6 deep groove ball bearing CAUTION: ●Bearings are all press-fit, disassembly is not recommended.

  • Page 45: Gear Shifting And Transmission Mechanism Components 9.1 Gear Shifting And Transmission Mechanism Components-1

    9-TRANSMISSION ASSEMBLY Fig.1 TRANSMISSION Gear shifting and transmission mechanism ASSEMBLY components-1 PART NO. PART NAME CAUTION ZT158MJ transmission mechanism sub-components 1050256-003000 ZT158MJ drive spindle sub-components 1050256-004000 ZT158MJ transmission countershaft sub-components 1050656-001000 ZT158MJ variable speed spindle fork 1050651-006000 ZT154FMI variable speed spindle fork shaft 1050656-003000 ZT158MJ shift drum 1050656-002000 ZT158MJ shift fork 1050656-011000 ZT158MJ shift fork shaft...

  • Page 46: Gear Shifting And Transmission Mechanism Components-2

    9-TRANSMISSION ASSEMBLY Fig.2 TRANSMISSION Gear shifting and transmission mechanism ASSEMBLY components-2 PART NO. PART NAME CAUTION 1050656-003000 ZT158MJ shift drum 1050656-011000 ZT158MJ shift fork shaft 1050656-002000 ZT158MJ shift fork 1050651-006000 ZT154FMI variable speed spindle fork shaft 1050656-001000 ZT158MJ variable speed spindle fork 1050256-003000 ZT158MJ drive spindle sub-components 1050256-004000 ZT158MJ transmission countershaft sub-components PROCEDURE:...

  • Page 47: Gear Shifting And Transmission Mechanism Components-3

    9-TRANSMISSION ASSEMBLY Fig3 TRANSMISSION Gear shifting and transmission mechanism ASSEMBLY components-3 PART NO. PART NAME CAUTION ZT158MJ drive spindle 15.2×25×1.0 Thrust Washer ZT158MJ main shaft second gear 20.2×27×1.5 Thrust Washer Not for sale ZT158MJ main shaft six-speed gear 6×17×20×5×1.5×24 rectangular spline washer GB894.1 Circlip for shaft φ20×1.2 ZT158MJ main shaft third and fourth gear ZT158MJ main shaft five-speed gear...

  • Page 48: Gear Shifting And Transmission Mechanism Components-4

    9-TRANSMISSION ASSEMBLY Fig4 TRANSMISSION Gear shifting and transmission mechanism ASSEMBLY components-4 PART NO. PART NAME CAUTION ZT158MJ transmission countershaft φ22.2×φ28.5×1 thrust washer ZT158MJ secondary shaft second gear ZT158MJ secondary shaft second gear sleeve ZT158MJ counter shaft six-speed gear 17.2×27×1 Thrust Washer ZT158MJ counter shaft first gear Not for sale ZT158MJ counter shaft first gear sleeve...

  • Page 49: Gear Shifting And Transmission Mechanism Components-5

    9-TRANSMISSION ASSEMBLY Fig5 TRANSMISSION Gear shifting and transmission mechanism ASSEMBLY components-5 PART NO. PART NAME CAUTION 1050555-001000 ZT152MI balance shaft 1251802-003000 4×4.6×25×14 half-round key GB/T 276 63/28/P5 deep groove ball bearing Contained in ⑷ 1050469-001000 ZT158MJ crankshaft connecting rod parts PROCEDURE: ●Remove the balance shaft ⑴...

  • Page 50: Gear Shifting And Transmission Mechanism Components-6

    9-TRANSMISSION ASSEMBLY Fig6 TRANSMISSION Gear shifting and transmission mechanism ASSEMBLY components-6 PART NO. PART NAME CAUTION 1050468-001000 16×1 piston pin retaining ring 1050455-005000 ZT152MI Piston 1050468-002000 14×37×8.5 Piston pin 1050455-002000 52×0.8×2.05 first air ring 1050455-003000 52×0.8×2.1 second air ring 1050455-004000 52×1.5×1.9 oil ring combination PROCEDURE: ●Use needle-nose pliers or other sharp tools to pick out the piston pin retaining ring ⑴, pull out the piston pin ⑶, and remove the piston ⑵...

Table of Contents

Save PDF