Zontes ZT184MN Maintenance Manual
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Zontes ZT184MN Maintenance Manual

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ZT184MN Engine EuroV
Maintenance Manual
2022/7/7

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MOHAMMAD ALI ALDAAS
January 24, 2025

هل zontes s250له نفس قطع غيار zontes310من حيث تروس ناقل الحركة

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Summary of Contents for Zontes ZT184MN

  • Page 1 ZT184MN Engine EuroV Maintenance Manual 2022/7/7...

  • Page 2: Table Of Contents

    Table of Contents CONTENTS Table of Contents……………………………………………………………………………………………………………………………………………………………………………………………………………………………… 1 1- The steps of draining oil 1.1 Draining oil………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 5 Discharge the oil 2-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…………………………………………………………………………………………………………………………………………………………………………………………………………………………...
  • Page 3 Table of Contents Cylinder head exhaust pipe stud sub-assembly 3-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………………………………………………………………………………………………………………………………………………………………………………………………………………...
  • Page 4 Table of Contents 4.8 Clutch assembly-3……………………………………………………………………………………………………………………………………………………………………………………………………………………………… 31 Friction Plate Assembly 5- 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…………………………………………………………………………………………………………………………………………………………………………………………………………...
  • Page 5 Table of Contents 7.4 Crankcase Split 4……………………………………………………………………………………………………………………………………………………………………………………………………………………………… 44 Box split 8-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 9- Left crankcase assembly 9.1 Left crankcase disassembly 1………………………………………………………………………………………………………………………………………………………………………………………………………………...

  • Page 6: 1- The Steps Of Draining Oil

    1- The steps of draining oil Fig.1 PREPARATION Draining oil STEPS PART NO. PART NAME CAUTION 1051161-012000 M24×2 oil filler plug Combined sealing gasket 12×φ20×2 1244100-033000 M12×1.5×15 ablassschraube (color Zinc) 24±4N.m 1251100-066093 PROCEDURE: ●Discharge the oil Park the vehicle on a level surface with the side stand. Unscrew the oil plug ⑴...

  • Page 7: 2-Cylinder Head Assembly

    GB70.1 inner hexagonal M8X35 12±1.5N.m 1250205-023000 (environmental color) 1051658-002000 ZT184MN Cylinder head cover gasket 1251401-001000 φ8×14 hollow locating pin 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.

  • Page 8: Remove The Cylinder Head Cover Assembly 2

    2-CYLINDER HEAD ASSEMBLY Fig.2 CYLINDER HEAD Remove the cylinder head cover assembly 2 ASSEMBLY PART NO. PART NAME CAUTION 4050758-001000 ZT184MP Cylinder head cover 1251513-001019 6.3×12×1.6 copper gasket M6×10 top pin bolt (color zinc) 12±1.5N.m 1251100-067093 ZT180MN timing chain plate 1050154-034000 PROCEDURE: ●Disassemble the cylinder head cover assembly...

  • Page 9: Align The Timing Chain

    2-CYLINDER HEAD ASSEMBLY Fig.3 CYLINDER HEAD Align the timing chain ASSEMBLY PART NO. PART NAME CAUTION 4050956-003051 M30×1.5 aluminum screw plug (dark gray) 12±1.5N.m 1051454-023000 27.4×2.65 Hydrogenated nitrile rubber O- M14×1.5 plug screw (environmental color 12±1.5N.m 1040953-002093 13×2.8 Hydrogenated nitrile rubber O-ring 1051454-024000 PROCEDURE: ●Remove the camshaft...

  • Page 10: Adjust Valve Clearance

    2-CYLINDER HEAD ASSEMBLY Fig.4 CYLINDER HEAD Adjust valve clearance ASSEMBLY PART NO. PART NAME CAUTION 4051758-008000 ZT184MP intake camshaft sub-assembly 1050158-009000 3×27×19 slide tappet ZT184MP exhaust camshaft sub-assembly 4051758-009000 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.

  • Page 11: Remove Camshaft 1

    2-CYLINDER HEAD ASSEMBLY Fig.5 CYLINDER HEAD Remove camshaft 1 ASSEMBLY PART NO. PART NAME CAUTION 1050153-005000 ZT173YMM cylinder head sealing cap parts 1251401-001000 φ8×14 hollow locating pin 12±1.5N.m 7.5×1.5 Hydrogenated nitrile rubber O-ring 1051454-027000 M6×30 Hexagon flange bolts (color Zinc) 1251112-002093 1051253-003000 30×38 tensioner parts...

  • Page 12: Remove Camshaft 2

    2-CYLINDER HEAD ASSEMBLY Fig.6 CYLINDER HEAD Remove camshaft 2 ASSEMBLY PART NO. PART NAME CAUTION M6×45 Hexagon Flange Face 9.8 Bolts 12±1.5N.m (Environmentally Friendly Color Zinc) ZT180MN intake camshaft left seat cover ZT180MN intake camshaft middle seat cover Intake and exhaust camshaft right seat cover blank 【1】...

  • Page 13: Remove The Cylinder Head 1

    2-CYLINDER HEAD ASSEMBLY Fig.7 CYLINDER HEAD Remove the cylinder head 1 ASSEMBLY PART NO. PART NAME CAUTION 1251112-002093 M6×30 Hexagon flange bolts (color Zinc) 12±1.5N.m M8×1×117 Hexagon Flange Bolts (Grade 1251112-024000 23±2N.m 10.9/Oxidized Black) M10×1.25 cap nut (12 grade / oxidized 60±5N.m 1251300-052094 1251500-041000...

  • Page 14: Remove The Cylinder Head 2

    2-CYLINDER HEAD ASSEMBLY Fig.8 CYLINDER HEAD Remove the cylinder head 2 ASSEMBLY PART NO. PART NAME CAUTION 1051301-052000 Locating pin 12×20 1051658-001000 ZT184MP cylinder head gasket components PROCEDURE: ●Remove the cylinder head Take out the cylinder head assembly vertically upwards, and remove the positioning pin (1) and gasket (2).

  • Page 15: Remove The Cylinder Head 3

    2-CYLINDER HEAD ASSEMBLY Fig.10CYLINDER HEAD Remove the cylinder head 3 ASSEMBLY PART NO. PART NAME CAUTION 1251112-001093 M6×16 Hexagon flange bolts (color Zinc) 1051954-001000 ZT180MN Outlet pipe subassembly 19×2.65 EPDM O-ring 1051454-007000 communal sensor of water and oil 1050954-003000 1051454-009000 9×2 EPDM O-ring LDK9RTIP-8 sparking plug(calorific value 8 clearance 0.8 iridium platinum)

  • Page 16: Valve Assembly

    2-CYLINDER HEAD ASSEMBLY Fig.11 CYLINDER HEAD valve assembly ASSEMBLY PART NO. PART NAME CAUTION 1050161-021000 3×27×19 sliding tappet 1050154-020000 φ 8.85 valve clearance adjusting pad ZT184MP Valve lock clamp 1050158-008000 ZT180MN Valve spring ring 1050154-016000 1050154-039000 ZT180MN valve outer spring A 1050158-001000 ZT184MP valve inner spring 16.5×23.5×1 valve spring seat...

  • Page 17: After-Sales Parts Description

    2-CYLINDER HEAD ASSEMBLY Fig.12 CYLINDER HEAD After-sales parts description ASSEMBLY PART NO. PART NAME CAUTION 4050658-004000 ZT184MP cylinder head sub-assembly ZT184MP cylinder head valve camshaft sub- 4050658-008000 After-sale assembly ZT184MP cylinder head valve sub-assembly 4050658-009000 4050658-005000 ZT184MP cylinder head assembly PROCEDURE: ●Cylinder head sub-assembly Cylinder head assembly (1) includes cylinder head assembly, valve assembly, camshaft...

  • Page 18: 3-Cylinder Block Assembly

    3-CYLINDER BLOCK ASSEMBLY Fig.1 CYLINDER BLOCK Remove the guide bar ASSEMBLY PART NO. PART NAME CAUTION ZT184MP guide strip 1050158-005000 PROCEDURE: ●Guide Strip Pull out the guide bar ⑴ in the direction of the arrow. Notice: ●When installing the guide bar, the guide bar needs to be clamped to the position shown in the lower left.

  • Page 19: Cylinder Block Assembly

    3-CYLINDER BLOCK ASSEMBLY Fig.2 CYLINDER BLOCK Cylinder block assembly ASSEMBLY PART NO. PART NAME CAUTION ZT184MP Cylinder body assembly 4050558-004000 1051658-007000 ZT184MP Cylinder body gasket (foam rubber) φ8×14 hollow locating pin 1251401-001000 GB119.2 φ9×14 cylindrical pin 1051161-003000 PROCEDURE: Take the cylinder assembly out vertically, remove the gasket ⑵, positioning pins ⑶,cylindrical pin⑷, and clean the remaining sealant on the joint surface.

  • Page 20: Cylinder Block Assembly

    3-CYLINDER BLOCK ASSEMBLY Fig.3 CYLINDER BLOCK Cylinder block assembly ASSEMBLY PART NO. PART NAME CAUTION ZT180MN Inlet and outlet pipe connector 1051954-007000 19×1.5 ethylene propylene terpolymer O 1051454-008000 shape circle ZT184MP Cylinder body 4050558-001000 PROCEDURE: ●Disassemble the cylinder Use a 24# sleeve to remove the water pipe joint and take out the O-ring. ●Match cylinder and piston Due to tolerances in the manufacture of cylinders and pistons, our company divides the corresponding tolerances into 3 groups, namely A", "B"...

  • Page 21: Piston Assembly1

    3-CYLINDER BLOCK ASSEMBLY Fig.4 CYLINDER BLOCK Piston assembly1 ASSEMBLY PART NO. PART NAME CAUTION 21×1.2 piston pin retainer 1050454-007000 After-sale 1050458-002000 ZT184MP(19×47.3×10) Piston pin 1050458-008000 ZT184MP Piston assembly Assembly ZT184MP(84.5) piston 1050458-001000 ZT184MP(84.5×1) First air ring 1050458-003000 After-sale ZT184MP(84.5×1) Second air ring 1050458-004000 1050458-005000 ZT184MP(84.5×1.5) Oil ring combination...

  • Page 22: After-Sales Parts Description

    3-CYLINDER BLOCK ASSEMBLY Fig.5 CYLINDER BLOCK After-sales parts description ASSEMBLY PART NO. PART NAME CAUTION ZT184MP cylinder piston sub-assembly 4050558-003000 After-sale 4050558-004000 ZT184MP Cylinder body assembly 1050458-008000 ZT184MP Piston assembly PROCEDURE: ●Cylinder piston sub-assembly The cylinder piston sub-assembly includes a piston assembly and a cylinder block assembly.

  • Page 23: Remove Right Crankcase Cover Assembly 1

    4-RIGHT CRANKCASE COVER ASSEMBL Fig.1 RIGHT Remove Right Crankcase Cover Assembly 1 CRANKCASE COVER PART NO. PART NAME CAUTION M6×60 Hexagon flange bolts (color Zinc) 1251112-004093 1251513-001019 6.3×12×1.6 copper gasket M6×45 Hex flange surface 9.8 bolt (color Zinc 1251112-003093 M6×90 Hexagon flange bolts (color Zinc) 1251112-006093 M6×75 Hexagon flange bolts (color Zinc) 1251112-005093...

  • Page 24: Remove Right Crankcase Cover Assembly 2

    4-RIGHT CRANKCASE COVER ASSEMBL Fig.2 RIGHT Remove Right Crankcase Cover Assembly 2 CRANKCASE COVER PART NO. PART NAME CAUTION Non-standard cover type 9 degree nut M6× 12±1.5N.m 1251300-096000 13 (environmental color Zinc) ZT180MN fine filter cover A (dark gray) 4050454-014051 55×2.5 Hydrogenated nitrile rubber O-ring 1051454-020000 ZT180MN Oil filter sealing ring...

  • Page 25: Remove Right Crankcase Cover Assembly 3

    4-RIGHT CRANKCASE COVER ASSEMBL Fig.3 RIGHT Remove Right Crankcase Cover Assembly 3 CRANKCASE COVER PART NO. PART NAME CAUTION M6×30 Hexagon flange bolts (color Zinc) 1251112-002093 1251100-067093 M6×10 top pin bolt (color Zinc) 6.3×12×1.6 copper gasket 1251513-001019 ZT180MN water pump cover A (dark gray) 4050454-015051 ZT180MN Water pump sealing ring 1051454-006000...

  • Page 26: Remove Right Crankcase Cover Assembly 4

    4-RIGHT CRANKCASE COVER ASSEMBL Fig.4 RIGHT Remove Right Crankcase Cover Assembly 4 CRANKCASE COVER PART NO. PART NAME CAUTION ZT184MP water pump 1051958-001000 1051958-002000 ZT184MP Water pump shaft ZT180MN Water seal subassembly 1051954-006000 GB119.2φ5×18 cylindrical pin 1250404-006000 ZT184MP Water pump gear 1050358-006000 1251512-007000 Thrust washer,12.2×20×1...

  • Page 27: Remove Right Crankcase Cover Assembly 5

    4-RIGHT CRANKCASE COVER ASSEMBL Fig.5 RIGHT Remove Right Crankcase Cover Assembly 5 CRANKCASE COVER PART NO. PART NAME CAUTION GB893.1 hole retaining ring φ15 1051358-006000 1051358-007000 ZT184MP pressure relief valve spring seat ZT184MP pressure relief valve spring 1050858-006000 ZT184MP pressure relief valve plunger 1050858-007000 ∅...

  • Page 28: Remove Right Crankcase Cover Assembly 6

    4-RIGHT CRANKCASE COVER ASSEMBL Fig.6 RIGHT Remove Right Crankcase Cover Assembly 6 CRANKCASE COVER PART NO. PART NAME CAUTION GB/T893.1 hole retaining ring φ30×1.2 1051361-002000 (Dacromet) φ30 hydrogenated nitrile rubber engine oil 1050861-002000 window Non-standard M6×25.5 double-head 9.8 1251111-013000 studs bolts (environmental color Zinc) ZT184MP right crankcase cover assembly 4050458-003000 (dark gray)

  • Page 29: Remove The Clutch1

    4-RIGHT CRANKCASE COVER ASSEMBL Fig.7 RIGHT Remove the clutch1 CRANKCASE COVER PART NO. PART NAME CAUTION M6×30 flange full thread bolt(graped 1251100-070093 9.8/environmental color) ZT180MN clutch spring pressure plate 1050754-007000 ZT184MP clutch spring 1050758-002000 ZT180MN sliding clutch cushion rubber 1051454-017000 ZT180MN sliding clutch pressure plate sub- 1050754-024000 assembly...

  • Page 30: Clutch Assembly-1

    4-RIGHT CRANKCASE COVER ASSEMBL Fig.8 RIGHT Clutch assembly-1 CRANKCASE COVER PART NO. PART NAME CAUTION ZT180MN sliding clutch friction plate sub- 7pieces 1050754-023000 assembly 125×1.5-26Z clutch driven plate 1050754-022000 125X1.5 clutch follower plate 1050753-012000 PROCEDURE: ●Friction plate assembly Take out 1 piece of friction plate with large inner hole → 1 piece of follower plate with large inner hole →...

  • Page 31: Clutch Assembly-2

    4-RIGHT CRANKCASE COVER ASSEMBL Fig.9 RIGHT Clutch assembly-2 CRANKCASE COVER PART NO. PART NAME CAUTION ZT184MP sliding clutch friction plate sub- 8pieces 1050758-007000 assembly 125×1.5-26Z clutch driven plate 1050754-022000 125X1.5 clutch follower plate 1050753-012000 PROCEDURE: ●Friction plate assembly Take out 1 piece of friction plate with large inner hole → 1 piece of follower plate with large inner hole →...
  • Page 32 4-RIGHT CRANKCASE COVER ASSEMBL Fig.10 RIGHT Clutch assembly-3 CRANKCASE COVER PART NO. PART NAME CAUTION 108±15N.m 1251311-001094 M16×1 Hexagon Thin Nut (Oxidized Black) 1251514-002000 16.2×28×2.4×2 Lock Washers Thrust washer,16.2×30×1 1251512-011000 ZT184MP slip clutch driven disc 4051058-004000 Thrust washer, 22.2×37×2 1251512-022000 1050758-001000 ZT184MP clutch outer comp subassembly 1250602-014000...

  • Page 33: 5-Left Crankcase Cover Assembly

    5-LEFT CRANKCASE COVER ASSEMBLY Fig.1 LEFT CRANKCASE Remove left crankcase cover 1 COVER ASSEMBLY PART NO. PART NAME CAUTION M6×30 Hexagon flange bolts (color Zinc) 12±1.5N.m 1251112-002093 ZT184MP Reduction gear cover components 4051058-001051 (dark grey) 69×3 Hydrogenated nitrile rubber O-ring 1051454-022000 GB893.1 Retaining Ring for Hole φ32×1.2 1051358-008000...

  • Page 34: Remove Left Crankcase Cover 2

    5-LEFT CRANKCASE COVER ASSEMBLY Fig.2 LEFT CRANKCASE Remove left crankcase cover 2 COVER ASSEMBLY PART NO. PART NAME CAUTION M6×30 Hexagon flange bolts (color Zinc) 12±1.5N.m 1251112-002093 1051058-004000 ZT184MP Start motor assembly PROCEDURE: ●Remove the starter motor Use an 8# socket to remove 2 bolts (1). Grasp the starter motor (2) and pull it in the direction of the arrow, and remove the starter motor (2).

  • Page 35: Remove Left Crankcase Cover 3

    5-LEFT CRANKCASE COVER ASSEMBLY Fig.3 LEFT CRANKCASE Remove left crankcase cover 3 COVER ASSEMBLY PART NO. PART NAME CAUTION M6×30 Hexagon flange bolts (color Zinc) 12±1.5N.m 1251112-002093 1251112-005093 M6×75 Hexagon flange bolts (color Zinc) 12±1.5N.m ZT184MP left crankcase cover sub-assembly 4050358-002051 (dark gray) ZT173YMM left crankcase cover cushion piece...

  • Page 36: Remove Left Crankcase Cover 4

    5-LEFT CRANKCASE COVER ASSEMBLY Fig.4 LEFT CRANKCASE Remove left crankcase cover 4 COVER ASSEMBLY PART NO. PART NAME CAUTION M5×15－5# hexagon socket head cap 1251201-001094 5±1N.m screws (oxidized black) ZT173YMM Stator pressure plate 1051353-005000 M6×35 socket head cap screws (oxidized 12±1.5N.m 1251201-002094 ZT184MP magneto stator sub-component...

  • Page 37: 6-Preparation Before The Box Is Split

    6-Preparation before the box is split Fig.1 DISASSEMBLY Preparation before the box is split 1 PREPARATION OF BOX PART NO. PART NAME CAUTION M6×30 Hexagon flange bolts (color Zinc) 1251112-002093 M6×45 Hex flange surface 9.8 bolt (color 1251112-003093 12±1.5N.m Zinc) ZT184MP Oil pump seat cushion 1051658-006000 φ8×14 hollow locating pin...

  • Page 38: Preparation Before The Box Is Split 2

    6-Preparation before the box is split Fig.2 DISASSEMBLY Preparation before the box is split 2 PREPARATION OF BOX PART NO. PART NAME CAUTION M18×1.0 Hexagon thin nut 108±15N.m 1251311-002094 1251514-003000 Lock washer, 18.2×30×2.5×2 ZT184MP primary drive gear 1050358-005000 5×5.5×19.2 general flat key 1251801-003000 ZT184MP water pump drive gear 1050358-007000...

  • Page 39: Preparation Before The Box Is Split 3

    6-Preparation before the box is split Fig.3 DISASSEMBLY Preparation before the box is split 3 PREPARATION OF BOX PART NO. PART NAME CAUTION 10.2×21×1 thrust washer 1251512-004000 1050358-001000 ZT184MP electric starting carrier gear M12X1.25X50 hexagonal flange bolts (10.9 103±15N.m 1251100-065094 level/ black) 12.3×26×3 gasket 1251500-034000...

  • Page 40: Preparation Before The Box Is Split 4

    6-Preparation before the box is split Fig.4 DISASSEMBLY Preparation before the box is split 4 PREPARATION OF BOX PART NO. PART NAME CAUTION φ28.2×φ40×1 thrust washer 1051358-005000 1051058-008000 ZT184MP electric start gear KTφ28×φ34×22 Needle roller bearing 1051058-009000 30.2×41.2×1.5 thrust washer 1051354-006000 M18×1.0 lock nut level 10 (environmental 1251300-066093...

  • Page 41: Preparation Before The Box Is Split 5

    6-Preparation before the box is split Fig.5 DISASSEMBLY Preparation before the box is split 5 PREPARATION OF BOX PART NO. PART NAME CAUTION M6×10 top pin bolt (color Zinc) 12±1.5N.m 1251100-067093 1051358-011000 ZT184MP gear sensor crimping plate GB818M5×20 (environmental color) 5±1N.m 1250201-034093 ZT180MN Gear switch...

  • Page 42: 7-Crankcase Split

    7-CRANKCASE SPLIT Fig.1 CRANKCASE Crankcase Split 1 PART NO. PART NAME CAUTION M6×30 Hexagon flange bolts (color Zinc) 1251112-002093 12±1.5N.m 1251112-005093 M6×75 Hexagon flange bolts (color Zinc) M6×90 Hexagon flange bolts (color Zinc) 1251112-006093 PROCEDURE: ●Cabinet split Use an 8# sleeve to remove 1 bolt ⑴ on the right crankcase body. Use an 8# sleeve to remove 1 bolt ⑴, 3 bolts ⑶, 7 bolts ⑵...

  • Page 43: Crankcase Split 2

    7-CRANKCASE SPLIT Fig.2 CRANKCASE Crankcase Split 2 PART NO. PART NAME CAUTION ZT184MP crankcase gasket 1051658-004000 1251401-001000 φ8×14 hollow locating pin ZT184MP gear swift comp 1050658-006000 PROCEDURE: ●Cabinet split Place the left crankcase horizontally (the closing surface is facing upward), and take out the right crankcase assembly, gasket ⑴, and positioning pin ⑵.

  • Page 44: Crankcase Split 3

    7-CRANKCASE SPLIT Fig.4 CRANKCASE Crankcase Split 4 PART NO. PART NAME CAUTION ZT184MP transmission auxiliary shaft sub- 4051758-012000 assembly ZT184MP Transmission main shaft parts 4051758-010000 ZT184MP Balance shaft assembly 4051758-006000 ZT184MP Crankshaft connecting rod 4051758-007000 assembly PROCEDURE: ●Cabinet split Take out the main shaft ⑴ and the counter shaft ⑵ at the same time, paying attention to any parts on the main shaft and the counter shaft not to be disassembled.
  • Page 45 7-CRANKCASE SPLIT Fig.4 CRANKCASE Crankcase Split 4 PART NO. PART NAME CAUTION ZT184MP transmission auxiliary shaft sub- 4051758-012000 assembly ZT184MP Transmission main shaft parts 4051758-010000 ZT184MP Balance shaft assembly 4051758-006000 ZT184MP Crankshaft connecting rod 4051758-007000 assembly PROCEDURE: ●Cabinet split Take out the main shaft ⑴ and the counter shaft ⑵ at the same time, paying attention to any parts on the main shaft and the counter shaft not to be disassembled.
  • Page 46 8-RIGHT CRANKCASE ASSEMBLY Fig.1 RIGHT Right crankcase disassembly 1 CRANKCASE PART NO. PART NAME CAUTION M6×15-10×7.8 pivot bolt(Zinc) 1251100-168093 12±1.5N.m 1050158-004000 ZT184MP tensioning strip 6.2×15×1 thrust washer 1251512-001000 M6×14-9×2.6 pivot bolt (environmental 12±1.5N.m 1251100-068093 protection colored zinc) 1050653-002000 shift limit stop wheel subassembly 1050654-008000 ZT180MN limit stop wheel torsion spring 75.7×53.2 trapezoidal strainer...
  • Page 47 8-RIGHT CRANKCASE ASSEMBLY Fig.2 RIGHT Right crankcase disassembly 2 CRANKCASE PART NO. PART NAME CAUTION M6×16 Hexagon flange bolts (color Zinc) 12±1.5N.m 1251112-001093 1051353-006000 ZT173YMM spindle bearing baffle M6×10 top pin bolt (color Zinc) 1251100-067093 GB276-16004 bearing baffle 1051371-003000 GB276-62/22/P5 deep groove ball bearing 1250601-052000 After-sale 1250601-057000...
  • Page 48 8-RIGHT CRANKCASE ASSEMBLY Fig.3 RIGHT After-sales parts description CRANKCASE PART NO. PART NAME CAUTION ZT184MP Right crankcase subassembly 4050258-002000 4050258-003000 ZT184MP Right crankcase assembly PROCEDURE: ●Right crankcase sub-assembly The right crankcase sub-assembly includes the right crankcase assembly, the pivot bolt, the shift limit sub-assembly, the main shaft bearing baffle, the trapezoidal strainer, the right case exhaust gas chamber inlet cover, the tension strip, the sealing ring, the torque Spring, washer, limit stop wheel sub-assemblies.
  • Page 49 9-LEFT CRANKCASE ASSEMBLY Fig.1 LEFT CRANKCASE Left crankcase disassembly 1 ASSEMBLY PART NO. PART NAME CAUTION M6×10 top pin bolt (color Zinc) 12±1.5N.m 1251100-067093 1051354-001000 ZT180MN countershaft oil seal cover M10× 1.25 return spring column 25±4N.m 1251400-002000 10.3×20×2 copper gasket 1251513-004019 M12×1.5×15 ablassschraube (color Zinc) 25±4N.m...
  • Page 50 9-LEFT CRANKCASE ASSEMBLY Fig.2 LEFT CRANKCASE Left crankcase disassembly 2 ASSEMBLY PART NO. PART NAME CAUTION M6×10 top pin bolt (color Zinc) 12±1.5N.m 1251100-067093 1051354-003000 63/22 deep groove ball bearing fixed pin 1.2×6×12 oil-passing pin 1050858-005000 After-sale 4.5×1 Hydrogenated Nitrile O-ring 1051461-008000 GB276-63/22/P53 deep groove ball bearing 1050558-003000...
  • Page 51 9-LEFT CRANKCASE ASSEMBLY Fig.3 LEFT CRANKCASE After-sales parts description ASSEMBLY PART NO. PART NAME CAUTION ZT184MP left crankcase subassembly 4050158-002000 4050158-003000 ZT184MP left crankcase assembly PROCEDURE: ●Left crankcase sub-assembly The left crankcase sub-assembly includes oil drain bolt, return spring column + copper pad, countershaft oil seal cover, ejector bolt + bearing limit piece, and left crankcase assembly components.
  • Page 52 10-GEARSHIFT AND TRANSMISSION Fig.1 GEARSHIFT AND Positional relationship of speed change and TRANSMISSION transmission mechanism components PART NO. PART NAME CAUTION ZT184MP Transmission main shaft parts 4051758-010000 4051758-012000 Transmission auxiliary shaft sub-assembly Ordinary Lengthened 4051758-014000 Transmission auxiliary shaft sub-assembly（L） ZT184MP Shift speed changer subassembly 1050658-002000 ZT173YMM Shift fork shaft 1050653-007000...
  • Page 53 ZT184MN Main shaft five gear 20Z×1M×37.5×1.5×26 evolvent Spline gasket Retaining ring for non-standard shaft φ21× 【2】 ZT184MN Main shaft three or four gear ZT180MN spindle six gears ZT184MP main shaft sixth gear sleeve ZT184MN spindle second gear 15.2×25×1.0 thrust washer PROCEDURE: ●Spindle assembly relationship...
  • Page 54 10-GEARSHIFT AND TRANSMISSION Fig.3 GEARSHIFT AND Countershaft assembly relationship TRANSMISSION PART NO. PART NAME CAUTION Ordinary 4051758-012000 Transmission auxiliary shaft sub-assembly 4051758-014000 Transmission auxiliary shaft sub-assembly（L） Lengthened 17.2×27×1 thrust washers ZT180MN countershaftone gear ZT173YMM countershaft gear shaft sleeve 18.2×28×1.5 thrust washer ZT180MN Countershaft five gear Retaining ring for non-standard shaft φ23×1.2 22Z×1M×37.5×1.5×27.5 involute spline...

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