ZT152 Engine Euro V
Service manual
2020/1
2
/
11
Page 1: ...ZT152 Engine Euro V Service manual 2020 12 11 ...
Page 2: ...assembly 4 12 2 9 Cylinder head assembly 5 13 3 CYLINDER BLOCK ASSEMBLY 3 1 Cylinder block assembly 1 14 4 Steps of draining oil before removing side cover and box body Oil drainine 15 5 RIGHT CRANKCASE COVER ASSEMBL 5 1 ZT158MJ right crankcase cover assembly 1 16 5 2 ZT158MJ right crankcase cover assembly 2 17 5 3 ZT158MJ right crankcase cover assembly 3 18 5 4 ZT158MJ right crankcase cover assem...
Page 3: ...6 35 8 RIGHT CRANKSHAFT BOX ASSEMBLY 8 1 ZT158MJ oil pump assembly 36 8 2 ZT158MJ balance shaft assembly 1 37 8 3 ZT158MJ balance shaft assembly 2 38 8 4 ZT158MJ balance shaft gear assembly 1 39 8 5 ZT158MJ shift mechanism assembly 1 40 8 6 ZT158MJ shift mechanism assembly 2 41 8 7 ZT158MJ right crankcase assembly 1 42 8 8 ZT158MJ right crankcase assembly 2 43 9 Gear shifting and transmission mech...
Page 4: ... 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 If the part names in this manual are inconsistent with the official website the offic...
Page 5: ...t 2 is removed it is best to replace it with a new one to avoid water leakage The tightening torque of bolt is 12 1 5N m Antifreeze is corrosive to a certain extent so be careful not to contaminate the engine and other parts body clothing etc when discharging the antifreeze If parts are accidentally contaminated with antifreeze immediately wipe them with a clean lint free cloth If clothing or skin...
Page 6: ...ng pipe can be removed by turning counterclockwise Clean up the remaining sealant on the bonding surface CAUTION There is still a part of antifreeze in the water pump When disassembling place a rag under the water pump to prevent the antifreeze from directly contaminating the surface of the engine When cleaning the remaining sealant be careful not to allow foreign matter to enter the engine The ma...
Page 7: ...ts and then take off the water pump cover positioning pin and sealing ring Use 8 T rod sleeve to remove the drain bolt and remove the gasket Use circlip pliers to remove the opening retaining ring fix the water pump shaft and rotate the water pump blade counterclockwise to remove the blade CAUTION Open retaining ring is for one time use and must be replaced after disassembly so as to avoid plastic...
Page 8: ... thermostat sub assembly 1 4 1051468 010000 16 5 1 95 EPDM O ring 1 Fig 3 CYLINDER HEAD ASSEMBLY Cylinder head outer parts PROCEDURE Use 22 open end wrench to remove the oxygen sensor Use 8 T rod sleeve to remove the two bolts and remove the thermostat and the sealing ring CAUTION The sealing ring is for one time use It is recommended to replace it after disassembly to avoid leakage due to imprope...
Page 9: ...3 Clean up the remaining sealant on the joint surface and be careful not to drop foreign matter into the engine Use a 10 T rod sleeve to disassemble the cover nut and remove the valve chamber cover and the sealing ring Use 8 T rod sleeve to remove two bolts and remove two washers CAUTION The cylinder head cover gasket is a one time use and must be replaced after disassembly otherwise it will cause...
Page 10: ...emove the two bolts on the cylinder block and remove the tensioner and gasket to loosen the toothed chain Use a 12 T rod sleeve to remove the bolt remove the sprocket and the decompression component and put the toothed chain back into the engine Pull up the cylinder head and remove the sub components of the cylinder head CAUTION To disassemble the cylinder head you must first disassemble the bolt ...
Page 11: ...PROCEDURE Use a 16 spark plug socket wrench to disassemble the spark plug be careful not to drop the gasket on the spark plug Use 17 T rod sleeve to remove the water and oil shared sensor and remove the sealing ring Use 8 T rod sleeve to remove bolt and remove gasket Use 8 T rod sleeve to remove bolt use 5 Allen wrench to remove two bolts then bearing pressure plate can be removed CAUTION Spark pl...
Page 12: ...oosen the nut then use 3 open end wrench to adjust the screw use a feeler gauge to measure the valve clearance after adjusting to the corresponding clearance range 3 open end wrench to fix the screw 8 torx wrench lock Tighten the nut tighten the torque to 9 1N m and finally measure the gap again Intake valve clearance 0 12 0 02mm two intake valve clearance difference 0 02mm exhaust valve clearance...
Page 13: ...34000 ZT1P58MJ Exhaust Rocker Arm Sub assembly B 1 PROCEDURE Just pull out the camshaft sub part 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 Bearing 3 is an interference fit Generally it is not recommended to disassemble if there is no fault Fig 8 CYLINDER HEAD ASSEMBLY Cylinder head cover ass...
Page 14: ...op Pay attention to distinguish the intake and exhaust Place the cylinder head on a clean lint free soft cloth to prevent the installation joint surface from being scratched and the seal is not in place to leak oil Put the four valve spring bases into the four valve rods respectively to make them fall to the bottom Put the four new oil seals on the four valve stems respectively and use an 8 sleeve...
Page 15: ...embly 1 PROCEDURE Pull the guide bar upwards Pull the cylinder block directly upward and remove the cylinder block hollow positioning pin and gasket from the crankcase Remove the positioning pin and gasket from the cylinder block respectively Use 8 torx wrench to remove bolt and remove washer CAUTION Gasket and gasket are both disposable and must be replaced after disassembly Guide bar must be rem...
Page 16: ... and remove the combined sealing gasket Unscrew the oil filler nut 3 and the seal ring 4 on the right crankcase cover and wait for the oil to drain from the oil drain CAUTION Combined gasket It is recommended to replace it after disassembly to avoid oil leakage and oil leakage due to damage caused by the disassembly process After removing the oil drain bolt 1 check whether the magnet on the bolt h...
Page 17: ...e sealing ring on the fine filter cover Take out the spring and the fine filter sealing assembly Unscrew the filler nut and remove the sealing ring CAUTION The fine filter seal assembly is for one time use please replace it after disassembly When assembling the fine filter make sure that the sealing ring is not installed reversely The direction is as shown in position in the figure and the side wi...
Page 18: ...2 RIGHT CRANKCASE COVER ASSEMBLY ZT158MJ right crankcase cover assembly 2 12 1 5N m PROCEDURE Use a 14 open end wrench to loosen the nuts marked by and on the clutch line in the direction of the arrow pull the clutch line down in the direction of arrow then take it out in the direction of arrow and remove the clutch line from the right crankcase Remove the cover Use 8 T rod sleeve to remove 9 bolt...
Page 19: ...The assembly relationship between the right crankcase cover and the clutch toothed lever is shown in the figure Turn the clutch lever shaft counterclockwise and directly remove the right crankcase cover from the crankcase body Remove the two positioning pins remove the gasket and clean the remaining sealant on the joint surface CAUTION The oil plug is an interference fit with the right crankcase c...
Page 20: ...58MJ right crankcase cover assembly 4 PROCEDURE Use circlip pliers to remove the retaining ring and then take off the clutch lever rocker torsion spring and washer Use needle nose pliers or other sharp tools to pick out the retaining ring in the direction of and then remove the washer CAUTION Retaining ring and retaining ring are prone to plastic deformation during disassembly It is recommended to...
Page 21: ...e the retaining ring then the oil seal can be removed It is not recommended to remove the oil seal if it is not a malfunction CAUTION The relative position and assembly relationship of the clutch lever shaft and each bearing bushing and oil seal are shown in the figure Bearings are all interference fits and have press fitting accuracy requirements Under normal circumstances disassembly is not reco...
Page 22: ... RIGHT CRANKCASE COVER ASSEMBLY Clutch assembly 1 PROCEDURE Use 8 T rod sleeve to remove three bolts then the whole set of pressure plate can be removed 24 sleeve remove the nut remove the lock washer and washer you can take off the entire clutch assembly CAUTION When disassembling the bolts you should loosen them one by one try to keep the bolts from having too much height difference otherwise th...
Page 23: ...ghtly clockwise and lift it up to remove the clutch pressure plate assembly and remove the pull down lever If you only need to replace the friction plate assembly take out the friction plate assembly and replace it For the assembly sequence refer to the content on the next page CAUTION When disassembling the bolts you should loosen them one by one try to keep the bolts from having too much height ...
Page 24: ...ROCEDURE The washer can be directly picked out with needle nose pliers Bearing can be ejected from a cylinder with an outer diameter of about 15mm CAUTION Washer This part does not normally need to be disassembled if it is not malfunctioning The bearing is an interference fit disassembly may cause damage to the joint surface Generally disassembly is not required for non faulty There is a rubber ba...
Page 25: ...12 038000 φ20 2 φ37 3 thrust washer 1 PROCEDURE Use a 24 sleeve to remove the nut and remove the lock washer and washer Pull out the driven disk from the driving hub sub assembly and remove the spline washer Unplug the clutch driving hub subassembly from the main shaft and take out the bearing bushing and washer CAUTION The driving disc and gear of the driving hub subassembly are fixed by rivets P...
Page 26: ...158MJ left crankcase cover gasket 1 4 1251401 001000 φ8 14 hollow positioning pin 2 Fig 1 LEFT CRANKCASE COVER ASSEMBLY Left crankcase cover assembly 1 PROCEDURE Use 8 T rod sleeve to remove 7 bolts pull out the left crankcase cover remove the gasket and positioning pin Clean up the remaining sealant on the bonding surface CAUTION The gasket 3 is for one time use and must be replaced after disasse...
Page 27: ...move the screw plug and remove the sealing ring Use a 5 Allen wrench to remove the screw plug and remove the sealing ring CAUTION When installing bolt and bolt evenly apply thread fastening glue on the threads The waterproof rubber sleeve on the output wire of the magneto stator should be assembled after applying sealant on the mounting joint surface When installing the crimping plate pay attentio...
Page 28: ...length to pull out the magneto rotor Use a 5 Allen key to remove the two bolts and remove the waterproof rubber sleeve on the crankshaft position sensor line from the box and then the crankshaft position sensor can be removed Clean up the remaining sealant on the joint surface CAUTION When installing the bolt apply thread fastening glue evenly on the thread The waterproof rubber sleeve on the cran...
Page 29: ...ust Washer 2 4 1051056 007000 ZT158MJ electric start gear 1 5 1251602 002000 K22 28 23 needle roller bearing 1 Fig 2 LEFT CRANKCASE ASSEMBLY ZT158MJ electric starter assembly 1 PROCEDURE Remove the reduction gear shaft from the box body and remove the reduction gear Remove the washer 3 and then remove the large starting gear 4 and the other washer 3 from the crankshaft CAUTION Subsequent old state...
Page 30: ...NKCASE ASSEMBLY ZT158MJ electric starter assembly 2 PROCEDURE Use 8 T rod sleeve to remove the two bolts Push the starting motor in the direction of arrow to remove it CAUTION The starter motor comes with a sealing ring whether the NoteInspection is missing before installation Before installing the starter motor apply a proper amount of engine oil to the seal ring to make the installation smoother...
Page 31: ...late 1 Fig 4 LEFT CRANKCASE ASSEMBLY ZT158MJ Left crankshaft box assembly 1 PROCEDURE Before disassembling the nut first align the part of the washer bent over the nut then use a 27 sleeve to disassemble the nut remove the washer output sprocket and spline washer Use 8 T rod sleeve to remove the two bolts and remove the pressure plate CAUTION The output sprocket 3 is best to be disassembled on the...
Page 32: ...hed chain in the direction of arrow to remove it Use a cross batch to remove the two bolts and remove the gear display assembly sealing ring and gear display contact assembly CAUTION When installing the bolts apply a proper amount of thread fastening glue on the threads The toothed chain 3 should mesh with the drive gear of the crankshaft during installation Gear display contact assembly When inst...
Page 33: ... upwards fix the left box body use a rubber hammer to gently knock the right box body loose then put the crankcase body on a clean non woven fabric the left crankshaft The box is on the bottom and the right crankcase is on the top Remove the right crankcase Remove the two positioning pins and gasket to remove the remaining sealant on the joint surface Unplug the two fork shafts of the transmission...
Page 34: ...ts 1 12 1 5N m PROCEDURE Use a 24 sleeve to disassemble the coarse filter cover and remove the sealing ring spring and coarse filter Use a 17 sleeve to remove the oil drain bolt and remove the combined sealing gasket Use 8 T rod sleeve to remove the two bolts and remove the oil seal cover CAUTION It is recommended to replace the sealing ring and the combined sealing gasket after disassembly to avo...
Page 35: ... it needs to be disassembled use a small hammer to slowly loosen it and then pull it out Use a single type batch to directly eject the lifting hole bushing at the other end The oil seal and oil seal can be removed directly CAUTION Double ended studs 1 One end with boss faces the box as shown in in the figure Double headed stud After driving into the box the height of the top relative to the joint ...
Page 36: ...ings 1 4 1250601 060000 GB276 6207 P5C3 deep groove ball bearing 1 5 1251601 001000 63 13 P5 deep groove ball bearing 6301 13 nitriding 1 CAUTION Bearings are all press fit disassembly is not recommended The depth of the bearing compared to the joint surface of the box is shown in the figure and the data below unit mm 57 9 0 0 1 58 1 0 0 1 47 5 0 0 1 27 25 0 0 1 32 25 0 0 1 Fig 9 LEFT CRANKCASE AS...
Page 37: ... assembly 1 After sales ZT158MJ oil pump assembly Not for sale PROCEDURE Use needle nose pliers to clamp out the retaining ring and remove the oil pump driven gear washer and needle Use 8 T rod sleeve to remove three bolts take off the oil pump cover plate and two cylindrical pins Remove the oil pump shaft and outer rotor from the box remove the inner rotor from the oil pump shaft and pull out the...
Page 38: ...28 2 4 2 lock washers 1 6 1050356 014000 ZT158MJ primary drive gear 1 ZT158MJ balance shaft assembly 1 PROCEDURE Use a 19 sleeve to disassemble the nut 1 and remove the lock washer 2 and the cover 3 Use a 24 sleeve to disassemble the nut remove the lock washer and the primary drive gear CAUTION The lock washer is literally facing the nut Note The meshing of the balance shaft drive gear and the bal...
Page 39: ...5 5 5 26 9 half round key 1 3 1050556 004000 ZT158MJ balance shaft gear assembly assembly 1 PROCEDURE Pull out the balance shaft drive gear from the crankshaft and remove the half circle key Remove the balance shaft gear 3 from the balance shaft and remove the half circle key 2 ZT158MJ balance shaft assembly 2 Fig 3 RIGHT CRANKCASE ASSEMBLY ...
Page 40: ...shaft tooth skeleton 1 5 1050556 004000 ZT158MJ balance shaft gear assembly assembly 1 PROCEDURE Take off the frame directly you can remove all the buffer spring posts and buffer spring CAUTION A total of six springs three buffer spring posts every other spring install a buffer spring post as shown in the figure After sales assembly Not for sale ZT158MJ balance shaft gear assembly 1 Fig 4 RIGHT CR...
Page 41: ...subassembly 1 6 1250404 004000 GB119 2φ4 10 cylindrical pin 2 ZT158MJ shift mechanism assembly 1 4 1251112 002093 M6 30 hexagon flange bolts environmental protection color zinc 2 12 1 5N m PROCEDURE Pull out the shift shaft sub assembly directly and remove the washer and the spring post Use 8 T rod sleeve to remove bolt remove the shift star cam sub assembly and cylindrical pin CAUTION Cylinder pi...
Page 42: ...stopper NMB R 1450ZZ bearing 1 3 1251500 091000 φ6 3 φ12 1 thrust washer 1 4 1260100 246000 ZT158MJ limit stop wheel torsion spring 1 ZT158MJ shift mechanism assembly 2 PROCEDURE Use 10 T rod sleeve to remove bolt remove stopper washer torsion spring CAUTION Bolt When installing apply thread fastening glue evenly on the threads Fig 6 RIGHT CRANKCASE ASSEMBLY ...
Page 43: ...h to directly eject the lifting hole bushing at the other end The oil pin is generally not disassembled If it needs to be disassembled use a drill to destroy it and then take it out Double headed stud is generally not disassembled If it needs to be disassembled weld an M8 nut on the exposed end and then unscrew it with a sleeve CAUTION Three bolts 1 When installing apply thread fastening glue even...
Page 44: ...00 GB276 6204 P6 deep groove ball bearing 1 4 1250601 039000 GB276 6203 P6 deep groove ball bearing 1 ZT158MJ Right crankshaft box assembly 2 CAUTION Bearings are all press fit disassembly is not recommended The depth of the bearing compared to the joint surface of the box is shown in the figure and the data below unit mm 32 45 0 0 1 28 5 0 0 1 44 7 0 0 1 44 7 0 0 1 Fig 8 RIGHT CRANKCASE ASSEMBLY ...
Page 45: ...nter shaft shifting shaft of the transmission mechanism sub component remove the main shaft shifting fork and the two counter shaft shifting forks then the transmission mechanism can be divided into components main shaft sub components The secondary shaft sub component 3 remove from the left box CAUTION When installing the shift fork the side with letters on the shift fork faces the right crankcas...
Page 46: ...158MJ transmission countershaft sub components 1 Gear shifting and transmission mechanism components 2 PROCEDURE Pull out the countershaft fork shaft and remove the countershaft fork Pull out the spindle and remove the spindle Remove the variable speed drum from the box CAUTION When assembling the shift fork first assemble the spindle shift fork then assemble the gear shift drum and then insert th...
Page 47: ...shown in the picture remove the washer gear washer gear washer in sequence use circlip pliers to remove the retaining ring remove the gear and again use circlip pliers to remove the other retaining ring remove washer gear and washer CAUTION Do not install the gear in the reverse direction the specific direction is shown in Picture The opening retaining ring must be stuck in the card slot as shown ...
Page 48: ... 5 thrust washer 3 14 ZT158MJ counter shaft third gear 1 Not for sale PROCEDURE As shown in the figure starting from the output sprocket end remove the washer gear bushing washer gear in sequence Remove washer gear shaft sleeve washer gear retaining ring washer gear washer gear washer CAUTION Do not install the gear in the reverse direction the specific direction is shown in Picture The gear sleev...
Page 49: ...e left crankcase body is required to be 26 85 0 0 25 mm When measuring take three different points to measure and they can only be used if they are qualified The crankshaft connecting rod component and the GB276 6207 P53 deep groove ball bearing on the left crankcase body are interference fit so disassembly is not recommended The bearing 3 is included in the crankshaft connecting rod part which is...
Page 50: ...ring in the oil ring assembly and take them out after finding the gaps CAUTION Piston pin retaining ring must be replaced after disassembly because piston pin retaining ring may undergo plastic deformation during disassembly If the piston pin retaining ring falls off in the engine it may cause cylinder pulling in severe cases Piston pin 3 crankshaft and piston 2 are in clearance fit and they can m...
