Summary of Contents for GPX ZS194MQ
- Page 1 GPX 450 FSE Engine manual ZS194MQ (NC450) send move machine dimension build handbook Chongqing Zongshen Engine Manufacturing Co., Ltd. Prepare: Proofread: Review: Approve: Repair of cylinder head assembly Page 131...
- Page 2 1. Troubleshooting 9. Assembly of cylinder head 2. Maintenance Instructions 10. Installation of cylinder head 3. Removal of the cylinder head cover 11. Installation of cylinder head cover 4. Disassembly of the cylinder head 5. Decomposition of the cylinder head 6.
- Page 3 Disassembly and maintenance of cylinder head assembly 1. Cylinder head assembly drawing . For this drawing please see the bottom of this document For a key to these diagrams please visit the bottom of this document. For the key to these diagrams see the end of this document Page 331...
- Page 4 Removal of cylinder head cover 1. Remove the 2 NC450 cylinder head covers from the cylinder head cover and fix them Bolts (special-shaped M6×29.7), 2 NC450 cylinder head covers are fixed Bolts (special-shaped M6× 50.7 ); 4. Remove the cylinder head cover; boltM6 ×...
- Page 5 wheel, remove the timing chain set on the timing driven sprocket ; 5. Remove the M6×40 bolts connecting the cylinder head and the cylinder block; 6. Remove 4 NC450 cylinder stud bolts AB (M 10×152), then remove 4 flat washers; NC250Rocker shaft 7.
- Page 6 Notice: 1. In order to prevent the permanent deformation of the valve spring, the valve spring cannot be compressed excessively, and only the valve lock clip can be removed; 2. All the removed parts should be marked to ensure that the original assembly position is reached during assembly.
- Page 7 1. Check whether the surface of the camshaft is worn or damaged And whether the camshaft bearing rotates flexibly, such as serious wear Or the bearing rotates with the phenomenon of hairpin, then the cam should be replaced with a new one. shaft parts;...
- Page 8 Assembly of the cylinder head 1. Install the valve spring lower seat (3) and the oil shield (4) to the valve guide; 2. After applying a small amount of lubricating oil to the intake valve rod (1) and exhaust valve rod (2), install the valve guide, install the valve outer spring (5), the valve inner spring (6), and the valve spring upper seat ( 7) and valve...
- Page 9 hole; 8. Take the exhaust rocker arm and valve rocker arm shaft respectively, and assemble them at the position of the cylinder head exhaust rocker arm shaft hole; 9. Use a flat-blade screwdriver to turn the rocker arm shaft of the intake and exhaust rocker arm to align the threaded hole of the rocker arm shaft with the position of the smooth hole of the...
- Page 10 (6 ) to the cylinder head , in the connecting hole of the cylinder body and fasten it; Notice: 1. The cylinder head gasket must be replaced with a new one; 2. Tightening torque of bolts A and B: 55～60N.m. 3.
- Page 11 of the NC250 rocker shaft positioning plate to the left front cover; 6. Take 2 pieces of bolts M6 × 10, and fasten the NC450 timing driven sprocket on the camshaft; take 1 piece of the camshaft pressure reducing valve throwing block combination and the pressure reducing valve return...
- Page 12 Installation of the cylinder head cover 1. Take the NC450 cylinder head cover sealing ring (1) and the Derbi125 head cover bolt buffer washer (3), and assemble them on the designated position of the NC450 cylinder head cover (2). 2. Take 2 pieces of NC450 cylinder head cover fixing bolts (4) and 2 pieces of NC450 cylinder head cover fixing bolts (5), assemble the NC450 cylinder head cover (2) on the cylinder...
- Page 13 Cylinder block and piston repair 1. Maintenance Instructions 2. Disassembly of the cylinder 3. Cylinder inspection 4. Disassembly of the piston 5. Inspection of piston and piston ring 6. Installation of piston ring 7. Installation of piston 8. Installation of the cylinder Maintenance notice Notes : ●...
- Page 14 Assembly drawing 1. NC450 piston 2. NC450 piston pin retaining ring 3. NC450 piston ring assembly 4. NC450 piston pin 5. NC450 cylinder block parts 6. NC450 cylinder block gasket 7. Cylindrical pin φ6×12 8. NC450 chain guide plate combination NC450 timing chain...
- Page 15 chain guide Disassembly of the cylinder Remove the chain guide plate, remove the two cylinder blocks and the box connecting bolts M6 × remove the cylinder block. 25, and boltM6×25 Use a scraper to scrape off the remaining gasket on the cylinder surface. Cylinder block inspection 1.
- Page 16 Disassembly of the piston Use needle-nose pliers to remove the piston pin retaining ring and remove the piston pin and piston. Notice: When removing the piston pin retaining ring, do not drop the retaining ring into the crankcase Inspection of pistons and piston rings 1.
- Page 17 Page 1731...
- Page 18 5. Measure the outer diameter at a height of 7 mm from the piston skirt Maintenance limit: φφ94.43 mm 6. Calculate the gap between the cylinder and the piston. Maintenance limit: 0.1mm 7. Measure the outer diameter of the piston pin Maintenance limit: φ19.99 mm 8.
- Page 19 installed first, and then the side guide rails should be installed. Page 1931...
- Page 20 Piston installation Install the piston, piston pin and new piston pin retainer. Notice: When installing the piston, the side marked with " " should face the exhaust side of the engine 2. The opening of the end clearance of the piston pin retaining ring should face downward;...
- Page 21 Clutch, driving gear, overrunning clutch, oil pump, shifting mechanism 1. Maintenance Instructions 13. Inspection of super separation and starting gear 2. Removal of the water pump cover 14. Inspection of the right oil pump 3. Removal of right crankcase cover 15. Inspection of shifting mechanism 4.
- Page 22 Water pump cover removal Remove the drain bolt of the water pump cover, drain the cooling water in the engine from the drain bolt, and remove the water pump cover when no water flows out from the Water pump cover drain bolt drain bolt.
- Page 23 1. Remove the water pump impeller (8) and the water pump shaft (9); 2. Remove the water seal assembly (10) and oil seal (11) in the shaft hole of the water pump. Needle Roller Bearings 垫片 clutch removal 1. Remove the clutch pressure plate spring Drive tooth lock nut and bolts, pay attention to loosening the clutch...
- Page 24 the oil pump gear combination; 2. Remove the oil pump bridge tooth washer, the oil pump bridge tooth, and the oil Bolt M6×25 pump gear combination; 3. Remove the 3 bolts M5×18 on the cover plate of the right oil pump, and remove Bol tM6×35 the combination of the oil pump cover plate shift...
- Page 25 Inspection of Right Crankcase Cover 1. Check whether the crankshaft oil seal of the right crankcase cover is damaged If the oil seal is found to be broken, it needs to be replaced with a new oil seal When replacing the crankshaft oil seal, pay attention to two points: 1.
- Page 26 2. Use special tooling to press-fit the NC450 water pump shaft water seal in place, 0.5mm lower than the end face, and the end face mark of the water seal faces outward when assembling the water seal 3. Apply an appropriate amount of lubricating oil to the main lip of the water seal;...
- Page 27 Inspection of clutch cover Check whether the tooth grooves on the drum shape of the outer cover are notched or scratched due to friction of the clutch disc . If it is serious, the outer cover needs to be replaced. Inspection of the overrunning clutch Remove the collar on the end face of the...
- Page 28 new right oil pump cover. Assembly of the gearshift mechanism 1. Install the positioning plate combination (1) and the flat washer (2), snap the positioning plate spring (3) into the corresponding position of the positioning plate, and fasten with M6×20 bolts (4); 2.
- Page 29 corresponding oil pump hole on the right body (the marked surface of the oil pump rotor assembly should face the same direction), 3. Install the oil pump cover plate assembly (4) on the oil pump, and fasten it with 3 M5×18 bolts (5). 4.
- Page 30 2. Install the large starting gear (13), needle bearing (14) and overrunning clutch (15) on the right crank. Notice: Before installing the starter gear, evenly apply oil on the inner hole of the starter gear Installation of driving gear 1. Install the driving tooth (16) on the right crank, 2.
- Page 31 into the center hole of the main shaft, then install the clutch push rod (27) into the center hole of the main shaft, and then install the thrust bearing (28) and the push rod washer (29) to the top. on the rod, 4.
- Page 32 Magnetic motor and balanced main and driven gear 1. Maintenance instructions 7. Inspection of magneto stator and rotor 2. Removal of left crankcase cover 8. Inspection of balanced main and driven gears 3. Disassembly of magneto stator and rotor 9. Inspection of left body oil pump 4.
- Page 33 Notice: 1. When disassembling the magneto rotor, it can only be disassembled with special tools, and it is not allowed to knock the magneto rotor 2. The magneto rotor is accidentally impacted during disassembly and assembly. If the magneto rotor falls to the ground or is struck by foreign objects, the magneto rotor should be replaced with a new one.
- Page 34 1. Check whether the magnetic tile of the magneto rotor is cracked or damaged , and if so, replace it with a new magneto rotor. 2. Check whether the magneto stator coil is black, if so, replace it with a new magneto stator. Check the balance of the main and driven gears 1.
- Page 35 gear assembly (7) on the balance shaft ; 2. First install the balance driving gear (8) on the left crank, then install the NC250 balance shaft flat key (6) into the keyway of the crankshaft, and then install the NC450 crankshaft timing sprocket (9) on the left crank;...
- Page 36 Installation of magneto stator Fasten the magneto stator assembly (18) to the left crankcase cover with 2 screws M5×10 (19) and 2 screws M5×40 (20) . Tightening torque: 7～9N·m . Installation of the left crankcase cover 1. Remove the old gasket (21) and install a new gasket;...
- Page 37 Crankcase, crankshaft, transmission, balance shaft repair 1. Maintenance instructions 9. Inspection of oil filter parts and oil filter 2. Crankcase decomposition 10. Assembly of transmission/crankshaft/balance shaft 3. Removal of crankshaft 11. Box closing 4. Inspection of crankshaft 12. Assembly of oil filter 5.
- Page 38 Disassembly of the crankcase 1. Place the left crankcase of the engine upwards; 2. Remove the fastening screws of 3 bolts M6 × 70, 3 bolts M6 × 65 and 6 bolts M6 × 45, separate the left crankcase from the right crankcase, and remove the 2 positioning pins.
- Page 39 Measure the thickness of the prongs. Service limit: 4.7 mm Inspect gear drum surfaces and grooves for wear or damage Inspection of main and countershaft components Check whether the gears of the main and countershaft assemblies have excessive or abnormal wear , and check whether the collars between the gears are deformed or fallen off.
- Page 40 Assembly of transmission/crankshaft/balance shaft 1. Install the balance shaft (1) and crankshaft (2) into the corresponding holes of the left body, 2. Install the main and auxiliary shaft assemblies (3) into the corresponding holes of the left body, and then assemble the forks (4), (5), (7) to the corresponding positions, Notice: 1.
- Page 41 (14) , apply 3 to 4 thread glues to the bolts, and first fit the tension plate bushing to the tension plate In the corresponding hole, tighten the tension plate in the corresponding hole of the left body with screws; 4.
- Page 42 oil into the inner hole of the oil filter cover (3), and fasten it on the box body; Tightening torque: 11 to 13 N·m. b. Take the NC250 oil filter part (4) and install it into the corresponding hole in the right case body c.
- Page 43 (14)NC450 pressure reducing valve return torsion spring (15) NC450 camshaft pressure reducing valve block combination (16) Flat washer (17) Bolt M6×16 Page 4331...
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