Zontes ZT310T 2022 Maintenance Manual
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Zontes ZT310T 2022 Maintenance Manual

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ZT310T-M
Engine maintenance Manual
2022-02-11

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Summary of Contents for Zontes ZT310T 2022

  • Page 1 ZT310T-M Engine maintenance Manual 2022-02-11...
  • Page 2 For colors or upgrades, please refer to the part codes on the official website of ZONTES This manual will not be listed in detail; if the part names in this manual are inconsistent with the official website of ZONTES, please refer to the official website of ZONTES.
  • Page 3 User notice This manual is compiled by Guangdong Tayo Motorcycle Technology Co., Ltd. to guide dealers or service personnel to use it. This manual cannot provide more detailed knowledge about motorcycles, and is only for reference for maintenance. If you do not have the corresponding knowledge such as electrician, machine repair, etc., improper assembly or repair failure may occur during repair.

  • Page 4: Table Of Contents

    ZT310T-M Engine maintenance Manual Lubrication system ............................ 6 One. Lubrication system diagram ......................6 Two, Maintenance information ....................... 8 Three, Common fault phenomena/troubleshooting ................9 Four, oil pump ............................9 Cylinder head cover, cylinder head ......................13 One, System components ........................13 Two, Maintenance information ......................
  • Page 5 Dismantling............................66 Inspection ............................67 Installation ............................67 Gearbox ..............................70 One - System Components ......................... 70 Two- Maintenance information......................71 Three - Failure phenomenon / failure analysis ..................72 Four - Gearbox disassembly and decomposition ................. 72 Five. Gear box gear, bearing examination ................... 73 Six, Gearbox assembly ........................

  • Page 6: Lubrication System

    Lubrication system One. Lubrication system diagram...

  • Page 8: Two, Maintenance Information

    Two, Maintenance information General information 1. This chapter introduces the structure of the lubrication system and the maintenance of related parts. 2. The maintenance of the oil pump can be carried out on the whole vehicle without disassembling the engine separately.

  • Page 9: Three, Common Fault Phenomena/Troubleshooting

    Three, Common fault phenomena/troubleshooting 1. The engine oil level is too low. • Engine oil is leaking. • The piston ring is worn or improperly installed. • Cylinder wear. • The seals such as valve guide and valve stem diameter oil seal are worn out. 2.
  • Page 10 Installation ① Put one end of the oil pump chain on the driven sprocket of the oil pump, and the other end on the driving gear of the oil pump at the crankshaft end, and align the oil pump shaft with the oil pump mounting hole on the box body and the oil pump positioning pin with the box body.
  • Page 11 Please assemble in the reverse order of disassembly (Note: When assembling, oil should be applied to the inner and outer rotors to make the inner cavity of the oil pump fully lubricated) Bolt: M6×40 Phillips pan head screw (tighten with a Phillips screwdriver or a wind screw + Phillips screw) Torque: 5～7N.m Serial Name...
  • Page 12 Maintenance limit value: 0.2mm (0.008in) Pump body clearance b Use a feeler gauge to measure the gap between the outer rotor of the oil pump and the oil pump body. Maintenance limit value: 0.35mm (0.014in) End face clearance Use a straight edge gauge and a plug gauge to measure the end face gap. Maintenance limit value: 0.12mm (0.005in) Check the oil pump chain If the chain breaks or there are cracks on the surface of the chain, the chain should be replaced.

  • Page 13: Cylinder Head Cover, Cylinder Head

    Cylinder head cover, cylinder head One, System components Refer to the diagram for valve disassembly and assembly, and the intake and exhaust valves have the same disassembly and assembly structure.

  • Page 14: Two, Maintenance Information

    The part information Serial Name Number Serial Name Number 6.3×12×1.6 copper gasket 9×2 EPDM O-ring M6×16 hexagon flange bolts Water and oil shared sensor M6×10 top pin bolt ZTIP72MN valve in2,ou2 ZT1P72MN Cylinder head ZT1P72MN valve spring wire clamp bracket base φ5.0 valve stem diameter oil LMAR8A-9 spark plug...
  • Page 15 3. Before disassembling, remove the foreign matter and dust on the cylinder head cover and the joint surface of the cylinder head. 4. After disassembling the cylinder head cover, before disassembling the cylinder head, check the timing first and turn the piston to the top dead center.

  • Page 16: Three, Failure Phenomenon / Failure Analysis

    1.5774 in） Camshaft Camshaft runout 0.03mm （0.0012 in） Matching clearance Intake 0.01-0.037 mm （0.0004-0.0015 0.08 mm （0.0032 in） between valve stem in） diameter and valve guide Exhaust 0.025-0.052 mm （0.0010- 0.1 mm （0.0039 in） 0.0020 in） Valve stem diameter Beat 0.01 mm （0.0004 in）...

  • Page 17: Four, Cylinder Compression Test

    • The cylinder head gasket is damaged. 4. The engine is electrically started, and the crankshaft rotates without cylinder pressure or the cylinder pressure is very small. • The valve spring is broken. • Broken valve. • Blow-by of cylinder block and cylinder head gasket. •...

  • Page 18: Six, Cylinder Head

    2. As shown in the figure, use T-rod-8# to remove the cylinder head cover locking bolts, and remove the separator bracket, cylinder head cover, and cylinder head cover sealing ring. Cylinder head cover installation 1. As shown in the figure, after removing the flat sealant, oil stains and dust on the joint surface of the cylinder head and the cylinder head cover, apply an appropriate amount of flat sealant to the position shown in the figure.
  • Page 19 2. Insert the 14#-T socket wrench from the M30×1.5 aluminum screw plug hole and set it on the magneto rotor locking bolt, and then turn the crankshaft clockwise to align the T point engraved line on the flywheel with the M14×1.5 screw. The plug hole marks the gap.
  • Page 20 Cylinder head decomposition 1. As shown in the figure below, use 6#-inner hexagon to remove the high-pressure oil pipe bracket, intake manifold sub-assembly and heat insulation pad (The heat insulation pad O-ring cannot be damaged or broken). 2. As shown in the figure below, use a 22# open-end wrench to remove the oxygen sensor, and T rod-8# to remove the cylinder head clamp bracket.
  • Page 21 5. As shown in the figure, screw 2 M6 bolts into the camshaft threaded hole, keep the camshaft angle consistent with the point T of the alignment time, or rotate it slightly counterclockwise to an appropriate angle, and then remove the camshaft.
  • Page 22 Cylinder head parts inspection: 1. Intake and exhaust rocker shaft a. There is no abnormal wear on the inlet and exhaust rocker arm shafts. Item Standard value Repair limit value Intake and exhaust rocker diameter 11.973-11.988 mm（0.4714-0.4720 in） 11.942 mm（0.4702 in） shaft （a）...
  • Page 23 4. Camshaft a. Check whether the return position of the camshaft pressure reducing valve is normal. b. Check the camshaft pick for abnormal wear. c. Rotate the camshaft bearing by hand, and it should rotate smoothly and without abnormal noise. Item Standard value Repair limit value...
  • Page 24 6、Cylinder head bearing a. Check the cylinder head bearing. The bearing inner ring shall rotate smoothly without jamming. If the bearing inner ring rotates sluggishly, please replace the cylinder head bearing. Cylinder head subassembly 1. As shown in the figure, blow the cylinder head oil passage with an air gun to ensure that the cylinder head oil passage is unblocked.
  • Page 25 φ11.8×φ1.9 fluorine rubber O-ring 4. As shown in the figure, Install camshaft bearing pressing plate, M6×10 bolts need to be applyed thread glue. Install the valve clearance adjustment pad to adjust the valve clearance. (Refer to ZT310T-M Maintenance Manual- 2.Maintenance -Valve Clearance Adjustment for valve clearance adjustment) 5.
  • Page 26 7. As shown in the figure, install the heat insulation pad (2 O-rings are not missing), the high-pressure oil pipe bracket and the intake manifold sub-assembly. Cylinder head installation 1、Remove the oil, water and dust on the joint surface of the cylinder and the cylinder head. After checking the cylinder and piston surfaces for foreign objects, install two φ12 positioning pins and cylinder block and cylinder head gaskets (Note: the cylinder block and cylinder head gaskets cannot be reused.After the cylinder head has been disassembled, the cylinder block box gasket also needs to be replaced, and the joint surface needs to...

  • Page 27: Seven, Guide Bar

    4、As shown in the figure, check the flywheel T point marking line, After confirming alignment with the right cover M14 x 1.5 screw plug hole scale, and turn the camshaft so that the dot is aligned with the camshaft pressing plate bolt.Put the timing driven sprocket into the timing chain and assemble it on the camshaft.

  • Page 28: Eight, Tension Bar

    1. Remove the guide bar as shown in the figure. Chenck 1. Check whether the guide bar is excessively worn or damaged. Guide bar installation 1. Install the guide bar as shown in the figure. (Note: After the guide bar is installed in place, the raised point of the guide bar is lower than the joint surface of the cylinder block and cylinder head.) Guide bar Eight, Tension bar...

  • Page 29: Nine, Tensioner

    Tension bar removal 1. As shown in the figure, remove the fixing bolt of the tensioner with a 5# inner hexagon, and remove the tensioning bar. Tension bar Check 1. Check whether the tensioning strip is excessively worn or damaged. Tension strip installation 1.
  • Page 30 Check 1. As shown in the figure, when the top rod of the tensioner is normally extended, press the fixed rod of the tensioner by hand, and the top rod is qualified if it cannot rebound. Tensioner mandrel Tensioner installation 1.

  • Page 31: Cylinder, Piston

    Cylinder, piston One, System components...
  • Page 32 The information of parts Serial Name Number cylinder 6.3×12.×1.6 copper gasket M6×16 hexagon flange bolts (environmental protection color zinc) Cylinder block box gasket piston 17×42×10 Piston pin 20×1.2 piston pin retaining ring Oil ring combination Second air ring First air ring Locating pin 12×20 pipe connector φ21×φ1.5 EPDM O-ring...

  • Page 33: Two, Maintenance Information

    Two, Maintenance information General information • This chapter introduces the maintenance of cylinders and pistons. • The work of repairing cylinders and pistons requires removing the engine from the vehicle. (Remove the engine from the whole vehicle, refer to ZT310T-M Maintenance Manual-11，Remove the engine from the whole vehicle) •...

  • Page 34: Three, Troubleshooting

    Tool 1. Clamp pliers 2. Needle-nose pliers 3. Vernier caliper 4. Plug gauge 5. Roundness meter 6. Straightedge Three, troubleshooting 1. When the engine is running at low speed, the compression pressure is too low, it is difficult to start or the performance is poor. •...

  • Page 35: Four, The Cylinder

    Four, The cylinder Disassemble 1. After the cylinder head is disassembled, Use clamp tool to remove the clamp from the pump cover outlet pipe connection, pull out the water pipe, and remove the cylinder block. Water pipe Water pipe 2. Remove the cylinder. Remarks: ①...
  • Page 36 3. Remove the gasket of the cylinder block and case, and cleaning of residual sealant from the cylinder block binding face. Remarks: ① Be careful when cleaning the joint surface to avoid scratches on the joint surface Clean residual sealant Cylinder block box gasket Installation 1.
  • Page 37 2. Install the cylinder block, and press the piston ring into the cylinder block by hand; the piston ring opening is staggered and assembled. (Refer to -ZT310T-M Engine Maintenance Manual-Cylinder, Piston-Piston for installation of piston ring) Remarks: ① Before installing the cylinder block, apply a proper amount of engine oil evenly on the inner wall of the cylinder block.
  • Page 38 Inspection 1. Check for scratches and wear on the inner wall of the cylinder. Measure and record the cylinder inner diameters of the three horizontal planes in the X and Y axis directions respectively. The largest reading is used to judge whether the cylinder is worn or not. Maintenance limit value: 72.055 mm (2.8368 in) 2.

  • Page 39: Five, The Piston

    Five, The piston Disassemble 1. After the cylinder is removed, use needle-nose pliers to remove the piston pin retaining ring, push the piston pin out of the piston and connecting rod, and then remove the piston. Remarks: ① Do not scratch the piston and piston ring when removing the piston pin retaining ring. ②...
  • Page 40 Installation 1. Apply a proper amount of engine oil to each piston ring and piston ring groove, and install the piston ring on the corresponding groove. Remarks: ① Do not use the first air ring and the second air ring interchangeably. ②...
  • Page 41 2. Put the piston pin into the piston and install it on the connecting rod, and use needle-nose pliers to install the piston pin retaining ring into the ring groove. Remarks: ① Apply a proper amount of engine oil to the piston pin hole and the small end hole of the connecting rod. ②...
  • Page 42 2. Use the piston to push the piston ring firmly into the cylinder, and use the plug gauge to measure the end clearance. Maintenance limit value: First ring: 0.50 mm (0.0197 in) Second ring: 0.85 mm (0.0335in) Plug gauge Piston ring Piston ring 3.
  • Page 43 Note: when the fit clearance between piston and cylinder block exceeds the maintenance limit value, please evaluate and replace the parts with large wear and determine whether the fit clearance is within the maintenance limit value. If yes, replace the corresponding parts;...

  • Page 44: Left Crankcase Cover, Continuously Variable Clutch Subassembly

    Left crankcase cover, continuously variable clutch subassembly One, System components...

  • Page 45: Two, Maintenance Information

    Part information Serial Name Number Serial Name Number M12 × one point two five × 35 hexagon φ 14.5 ×φ 25 × 16 driven wheel flange bolt (grade 10.9 / environmental bushing color) φ12.3 ×φ 40 × 4 washer ZT1P72MN Driven wheel clutch housing ZT1P72MN Driving wheel drive plate Driven wheel clutch shoe...

  • Page 46: Three, Common Fault Phenomena / Troubleshooting

    Three, Common fault phenomena / troubleshooting 1. The engine can be started and the rear wheel of the filler door does not rotate. • The V-belt is severely worn or broken. • The clutch shoe is worn or damaged. • The large spring of the driven wheel is damaged. •...
  • Page 47 Air filter fixing bolt ③ Clamp the exhaust pipe clamp on the inner side of the tail of the air filter with pointed nose pliers and move it upward by about 20mm (0.8 in). Then pull the exhaust pipe out of the crankcase by hand. ④...
  • Page 48 Left cover Locating pin Left crankcase Inspection for left crankcase cover ① Check the 6005 bearing of the left crankcase cover. If the inner ring of the bearing is stuck in rotation, please replace it in time. 6005 bearing Installation of left crankcase cover ①...

  • Page 49: Five, Stepless Speed Change Clutch Subassembly

    ③ After installing the air filter, install the engine air inlet filter element, engine air inlet mask, anti vibration sponge of left engine cover and left engine cover in place. (For assembly, refer to ZT310T-M maintenance manual-2, Maintenance-air filter element (filter element), air inlet filter element chapter) Five, Stepless speed change clutch subassembly Disassemble ①...
  • Page 50 ⑤ Remove the drive and driven wheel positioning jigs and remove the ZT1P72MN main fixing disc from the crankshaft. ⑥ Remove the driven wheel clutch housing from the drive shaft. ⑦ Pinch the middle part of the V-drive belt and remove the belt together with the driven wheel sub-part. ⑧...
  • Page 51 ⑨ Finally take out the φ23.2×φ40×3.25 washer to complete the disassembly of the continuously variable clutch sub- assembly. Assembly Note: 1. Before assembling, it is necessary to conduct a comprehensive inspection of all the parts of the disassembled continuously variable clutch sub-assembly, and replace the parts that reach the limit of use. 2. Before assembling, use an air gun to completely clean the dust accumulated in the belt room of the left crankcase.
  • Page 52 ④ Place the driven wheel flat on the workbench or on a clean ground then make the indicating arrow on the V- shaped transmission belt point to the counterclockwise rotation direction, place the V-shaped transmission belt on the outer ring of the driven wheel, and make a certain distance from The moving wheel is 4~5cm away. Press the driven wheel clutch housing with the palms of both hands, and the fingers of both hands buckle the moving plate of the driven wheel while pulling it upwards while rotating it clo ckwise.
  • Page 53 ⑧ Point the stepped end of the φ14.5×φ25×16 driven wheel bushing toward the driven wheel, and install it on the exposed optical axis of the drive shaft. Then screw on the M14×1 hexagon flange nut on the drive shaft thread. （Note: If there is a lack of grease in the groove of the inner ring of the driven wheel bushing, high temperature resistant grease should be added.

  • Page 54: Six. Inspection Of Parts And Limit Values For Use

    Six. Inspection of parts and limit values for use Note: Every 20,000 kilometers, the CVT clutch sub-assembly needs to be inspected, maintained or repaired ! ! ! 1. Check items and usage limits of the driving wheel ① Use a knife-edge ruler to align the tapered working surface of the driving wheel (Main fixed disc and sliding disc) in parallel, and then use a feeler gauge to check the amount of wear.
  • Page 55 ⑤ Check the inner circular surface of the driven wheel clutch housing for wear or damage. Use a vernier caliper to measure the inner diameter of the inner circle. It needs to be replaced when the hole diameter is greater than or equal to φ150.5mm.

  • Page 56: Right Crankcase Cover, Magneto

    Right crankcase cover, magneto One, System components Part information...
  • Page 57 Part information Serial Name Number Serial Name Number M6×45 hexagon flange face 9.8 GB276－6001/P5C3 deep groove ball grade bolts bearing Right crankcase cover gasket FB12×22×5 fluorine rubber oil seal φ10×14 hollow positioning pin FB12×24×5 Nitrile rubber oil seal (PTFE) Dipstick Water seal sub-component 18×3×3.5 Acrylic Glue O-ring Right crankcase cover...

  • Page 58: Two. Maintenance Information

    Two. Maintenance information General information • This chapter introduces the removal and installation of the right crankcase cover, flywheel and magneto. • These repairs can be carried out on the entire vehicle without disassembling the engine. • Drain the engine oil and coolant before disassembling. Torque value NAME Assembly location...

  • Page 59: Three. Right Crankcase Cover/Magneto Stator Disassemble

    10. Copper rod 11. Plane sealant 12. Thread fastening glue 13. Stun gun Three. Right crankcase cover/magneto stator Disassemble Disassemble Before removing the right crankcase cover: •Remove the complete toilet, and disconnect the trigger wire and magneto stator cable connector. (Refer to ZT310T-M Maintenance Manual-Disassembly and Start-Remove Storage Box) •...
  • Page 60 3. Use clamp pliers to take out the clamp on the water pipe joint and the outlet pipe of the water pump cover, and then pull out the coolant pipe. Clamp pliers Coolant pipe 4. Use a torque wrench (or wind screw) and an extended outer hexagonal sleeve-8# to remove the 11 M6×45 hexagon flange bolts on the right crankcase cover diagonally and counterclockwise, and remove the right crankcase cover, 2 φ10 ×14 hollow positioning pin and right crankcase cover gasket.
  • Page 61 GB70.1M6×25 (Environmental protection color zinc) M5×15－5# Hexagon socket screw (oxidized black) Installation 1. Place the stator sub-components of the magneto on the corresponding position of the right crankcase cover, on the three GB70.1M6×25 (environmental color zinc) bolts and three M5×15-5# hexagon socket screws (oxidized black) Apply a proper amount of thread glue on the threads, screw them into the corresponding threaded holes with a torque wrench and an inner hexagonal gun head-5# and tighten them.
  • Page 62 2. Install two φ10×14 hollow positioning pins and a new right crankcase cover gasket on the joint surface of the right crankcase and the right crankcase cover; rotate the oil pump shaft to make the straight protruding surface radially align with the oil pump convex Point mark; use a flat bolt cutter to turn the water pump shaft so that the flat groove is aligned with the raised marking point on the right crankcase cover.
  • Page 63 4. Reconnect the two water pipes to the right cover respectively, and use clamp pliers to install the clamp in place. Water pipe Clamp pliers 5. As shown in the figure, install the bottom liner of the right cover decoration cover in place, and tighten the right cover decoration cover locking bolts with a 5# inner hexagon.

  • Page 64: Four - Magneto Rotor

    Four - Magneto rotor Disassemble 1. After the right crankcase cover is removed, Special clamps for fixing the flywheel so that it does not turn freely, use a torque wrench (or electric gun) and sleeve-14# to remove the M10×1.25×45 hexagonal flange bolts, and remove the φ10 .3×φ28×4 washer;...
  • Page 65 Installation 1. After checking that the electric starter gear, 25.2×37×1.6 thrust washer, electric starter reduction gear assembly, and electric starter reduction gear shaft are all installed correctly, use a copper rod to knock the half-circle key into the crankshaft. Remarks: ① When installing the semicircular key, pad cloth to prevent the semicircular key from falling into the box. Half round key Thrust washer Copper rod...

  • Page 66: Water Pump

    Water pump Dismantling The combined parts of the water pumps are detailed in the table of system components and parts information 1. Counterclockwise dismantling of 4 x M6 x 30 hexagonal flange bolts (environmentally friendly coloured zinc) on the pump cover using a torque spanner (or Air Screw) and an extended hexagon socket - 8# and remove the pump cover O-ring, φ11.5×φ1.8 EPDM O-ring and two φ8×14 hollow locating pins.

  • Page 67: Inspection

    Inspection 1. Check the pump cover O-ring and φ11.5×φ1.8 EPDM O-ring on the pump cover. If there are bad phenomena such as wear and tear, cutting edge, etc., replace the O-ring with a new one to prevent the occurrence of poor sealing leading to water leakage.
  • Page 68 Special Pressure Head Water Seal 4. After checking that there is no abnormal wear on the water pump shaft, press it into the bearing hole and press it into place when the flange surface of the pump shaft is in contact with the inner ring of the bearing. Note:①...
  • Page 69 clockwise with a torque spanner (or Air Screw ) and a lengthened hexagonal socket - 8#. Torque standard: 12±1.5 N- φ8×14 Hollow locating Water pump blade φ11.5×φ1.8 EPDM O-Rings Water pump cover M6×30 Hexagonal O-rings flange bolts...

  • Page 70: Gearbox

    Gearbox One - System Components...

  • Page 71: Two- Maintenance Information

    The part information Serial Name Number Serial Name Number GB276 － 6303-P5C3 deep groove GB16674M8×40(environmental protection color zinc) ball bearing (nitriding) FB25×42×6 fluorine rubber oil seal ZT1P72MN output gear ZT1P72MN gear box cover ZT1P72MN Double gear assembly ZT1P72MN gear box cover gasket GB894.1 Circlip for shaft φ28×1.5 φ10×14 hollow positioning pin ZT1P72MNOutput shaft...

  • Page 72: Three - Failure Phenomenon / Failure Analysis

    Three - Failure phenomenon / failure analysis 1. The engine gas valve is operating normally, but the car does not move • Damage to the drive shaft, output shaft, double-tooth keyway or helical teeth in the gearbox causes the idling rear wheels to not move.

  • Page 73: Five. Gear Box Gear, Bearing Examination

    3. Remove the output gear, duplex gear assembly, output shaft and output shaft retainer in sequence as shown. Output shaft retaining ring Five. Gear box gear, bearing examination Gear box cover bearing, oil seal check 1. As shown in the figure, rotate the bearing inner ring with hand, the bearing is smooth, and the drive shaft is rotated, and the drive shaft bearing is smooth and silent.

  • Page 74: Six, Gearbox Assembly

    GB276-6303-P5C3 deep groove ball bearing FB35 × 54 × 7 fluorine oil seal GB276-60 / 28-2RK deep groove ball bearings GB276-62 / 22 / P5 deep groove ball bearings Drive shaft, output shaft, double gear check 1. As shown, ck drive shafts, output shafts and spline positions for bending, deformation and abnormal wear, if there is any replacement.
  • Page 75 Output shaft retaining ring 2, As shown, positioning pins and new gearbox cover paper pads are placed on the gearbox joint surface, apply the oil in the gearbox cover bearing surface, and install the gearbox cover in place, put 6 M8 × 40 bolts, from The positioning pin position is pressed against the angle and is tightened, and the torque is 20 ±...

  • Page 76: Crankcase

    Crankcase One, system components...
  • Page 77 The part information Serial Name Number YM10 × 1.25-M10 × 1.25 × 190 double head stud 53 × 50.5 trapezoidal thick filter 6.35 × 7 × 110 toothed chain φ10 × φ15 × 28.2 main support bushing ZT1P72MN directive barrier plate M6 ×...

  • Page 78: Two, Repair Information

    9.8×2.4 Hydrogenated nitrile rubber O-ring ZT1P72MN Pressure Valve Parts ZT1P72MN injector φ11 × φ1.8 fluorine glue O-ring M10 × 1.25 × 10 oil block bolt ZT1P72MN crankshaft link parts assembly Two, Repair information General information 1. This chapter introduces the separation of the crankcase and the inspection and maintenance of parts such as the crankshaft.

  • Page 79: Three, Common Faults / Troubleshooting

    Liner inner diameter 17.010-17.017 (0.6697-0.67 in) 17.06 (0.6717) Torque value: Bolt model Assembly location quantity Torque Remark M6 × 75 hex flange bolt Left and right box body Mean 12 ± 1.5n.m box bolts M6 × 10 hex flange 10 ± 1N.m M6 ×...
  • Page 80 ③ Assembly The chain surface is sprayed, and the chain end is still set on the timing chain teeth according to the above figure, and the other end is pulled out from the sprocket chamber and straightened the chain from falling off. 2, Remove the tightness (Tension tight disassembly refer to ZT310T-M engine repair manual - cylinder head cover, cylinder head - tight)
  • Page 81 side, and then rotate the box to remove the right side of 5 M6 × 75 hex flange bolts. ③ Place the left crankcase down, taking the rubber hammer symmetry, tapping the box to reinforce the hole or process boss (Note: Do not knock the crankcase binding surface or other assembly joint surface), so that the crankcase is uniformly separated, Finally remove the right crankcase, balance shaft, crankshaft and locating pin.
  • Page 82 Crank journal Oil pump drive gear Positive initiative gear ● Line small head inner diameter inspection (link small head inner diameter check Reference ZT310T-M engine repair manual - cylinder, piston - piston) ● Linear front slot check The plug is inserted between the crankshaft and the end surface of the connecting rod, and the gap is measured. Maintenance limit value: 0.40mm (0.016in) ●...

  • Page 83: Five. Assembly Of The Crankcase

    ● Crankshaft runout inspection Place the crankshaft on the V-shaped block or bracket and measure the corresponding point beating value with a percent watch. Note: When the crankshaft beats exceeds the maintenance limit, the new crankshaft needs to be replaced. Maintenance limit value: 0.03 mm (0.0012 in) Five.
  • Page 84 ③ Apply an appropriate amount of oil at the balance axis neck to load the balance axis to align the balance axis bearing hole into the left curve. (Note: Balanced axle teeth and crankshaft balance axis drive teeth must correctly engage the point!) Meshing-to-peer ④...
  • Page 85 ⑥ Combine the right crankcase to two positioning pins, and complete the box downward. (Note: When placing the right crankcase, do not scratch the right crankcase bearing pad and do not operate with violence when closing the case to avoid bumping or scratching the parts and the bonding surfaces.) ⑦...

  • Page 86: Left And Right Crankcase Upper Fixed Point Disassembly And Inspection

    Left and Right Crankcase Upper Fixed Point Disassembly and Inspection Upper Hanging Piece Inspection 1. As shown in the diagram, pinch the ends of the upper hanging piece bushings on φ12.4×φ19×35.3 by hand and turn it back and forth, if it can turn, it passes. (Note: If the upper hanging bushings do not rotate, they need to be disassembled to add the appropriate amount of high temperature and high load resistant grease.) Upper Hanging Piece Disassembly 1.
  • Page 87 side of the upper hanging piece bushing and press it into place to seal the grease, then install the φ18.1×φ26×1 Gasket and circlip for shaft. (Note: Use high temperature and high load resistant grease.) φ12.4×φ19×35.3 Upper Circlip for Shaft Hanging Piece Bushing φ18.1×φ26×1 Washer φ17.6×φ2.4Nitrile Rubber Diagram of the...

  • Page 88: Fine Filter

    Fine Filter Dismantling 1.Remove three M6 cap nuts on fine filter cover with a 10# socket (or T-socket-10#) and remove the fine filter cover, 55×2.5 polyacrylate rubber (SGA) O-ring, φ18.5×13×1.6 fine filter spring, and φ45×46 cylindrical fine filter of outside diameter (including gasket) respectively.

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