Zontes ZT310M 2022 Maintenance Manual Download Page 36

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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

Installation

1. Apply appropriate amount of sealant to the corresponding position of the cylinder block and box joint surface, install
a new cylinder block gasket, and two 12×20 positioning pins.

Clean
residual
sealant

Flat sealant

Cylinder block
box gasket

12×20 positioning pin

Cylinder block box gasket

Summary of Contents for ZT310M 2022

Page 1: ...ZT310T M Engine maintenance Manual 2022 02 11...

Page 2: ...art 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...

Page 3: ...ervice life Non woven fabrics should be used for wiping with no residue Ordinary rags may leave cloth scraps or wool etc which may affect the assembly or cause other adverse effects Our company will u...

Page 4: ...8 Nine tensioner 29 Cylinder piston 31 One System components 31 Two Maintenance information 33 Three troubleshooting 34 Four The cylinder 35 Five The piston 39 Left crankcase cover continuously variab...

Page 5: ...3 Six Gearbox assembly 74 Crankcase 76 One system components 76 Two Repair information 78 Three Common faults troubleshooting 79 Four The decomposition of the crankcase 79 Five Assembly of the crankca...

Page 6: ...Lubrication system One Lubrication system diagram...

Page 7: ......

Page 8: ...the filter element 1 75L 1 85US qt 1 54 lmp qt Drain the oil during normal maintenance without changing the filter element 1 7L 1 8US qt 1 49 lmp qt Drain the oil for normal maintenance and remove th...

Page 9: ...ntenance Bolts and Nuts of Muffler for dis assembly and assembly Remove the right crankcase cover of the engine Refer to ZT310T M engine maintenance manual for dis assembly and assembly Right crankcas...

Page 10: ...ngine Maintenance Manual Right crankcase cover magneto Magneto Rotor Install the magneto rotor Refer to ZT310T M engine maintenance manual for installation Right crankcase cover magneto Magneto rotor...

Page 11: ...upper casing of the oil pump Before measuring the gap install the oil pump shaft assembly into the corresponding inner rotor respectively End gap a Measure several points and compare the maximum readi...

Page 12: ...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 0 005...

Page 13: ...ponents 9 8 7 6 5 4 3 2 1 26 20 19 13 16 17 18 12 10 11 34 35 33 32 31 30 29 36 27 Refer to the diagram for valve disassembly and assembly and the intake and exhaust valves have the same disassembly a...

Page 14: ...ck 2 31 M6 10 top pin bolt 1 13 ZT1P72MN intake rocker arm sub components 1 32 ZT1P72MN Cylinder Head Cover Oil Pipe Clamp 1 14 ZT1P72MN intake and exhaust rocker arm shaft 2 33 ZT1P72MN cylinder head...

Page 15: ...5 M8 110 Hexagon Flange Bolt Cylinder head bolt 2 21 2 M10 1 25 Hexagon Flange Nut Cylinder head nut 4 52 5 M6 10 top pin bolt 12 10 1 M6 22 Hexagon Flange Full Thread Bolt Thermostat locking bolt 2...

Page 16: ...ted by detecting cylinder pressure endoscope and other methods 1 When the engine starts the idle speed is unstable or difficult to start The valve clearance is incorrect Wrong timing wrong teeth The v...

Page 17: ...he measured cylinder pressure is higher than the normal value it indicates that there is carbon deposit on the top of the piston or on the cylinder wall If the measured cylinder pressure is lower than...

Page 18: ...nstall the cylinder head cover assembly to the corresponding position of the cylinder head Use M6 30 bolts to pre tighten the separator bracket and the cylinder head cover and tighten them with a fixe...

Page 19: ...the flywheel it cannot be reversely rotated back to the right point The crankshaft must be turned clockwise twice again to re align the points 3 As shown in the figure use T bar 8 to remove the tensi...

Page 20: ...ove the cylinder head clamp bracket Use the spark plug sleeve to remove the spark plug Use a 17 torx wrench to remove the water and oil temperature sensor 3 As shown in the figure below loosen the cyl...

Page 21: ...ing overhead pliers to remove the valve lock clamp do not over compress the valve spring After removing the valve lock clip remove the valve spring retainer valve spring valve stem diameter oil seal T...

Page 22: ...rm sub components inside diameter b 12 12 018 mm 0 4724 0 4731 in 12 033 mm 0 4737 in Matching clearance between intake and exhaust rocker arm and intake and exhaust rocker arm shaft Fit clearance 0 0...

Page 23: ...ce of the cylinder head and there is no abnormal wear or ablation Item Standard value Repair limit value Matching clearance between valve stem diameter and valve guide Intake 0 01 0 037 mm 0 0004 0 00...

Page 24: ...p Install with valve installation tools Note When installing the valve spring the sparse ring faces upwards and the dense ring faces downwards 3 As shown in the figure install the camshaft Need to ins...

Page 25: ...e after adjusting the valve clearance install the rocker arm limit block and the limit block locking bolt the bolt needs to be coated with thread glue the torque is 7 1 N m Install the pressure plate...

Page 26: ...coated with a flat sealant For the installation of the cylinder piston refer to the ZT310T M Engine Maintenance Manual Cylinder Piston 2 As shown in the figure check whether the timing chain has falle...

Page 27: ...linder head cover cylinder head Tensioner Note After confirming that the timing chain has not fallen off from the timing driving gear tighten the timing sprocket with a fixed twist After installing th...

Page 28: ...to ZT310T M Engine Maintenance Manual Cylinder Head Cover Cylinder Head Cylinder Head Cover Cylinder head sub assembly Refer to ZT310T M Engine Maintenance Manual Cylinder Head Cover Cylinder Head Cy...

Page 29: ...the figure the fixing bolts of the tensioning strip are coated with thread glue and installed to the corresponding position of the box body and the bolts are tightened with a fixed torque The torque i...

Page 30: ...ensioner with your hand When the highest point is received tighten it forcefully The ejector rod can be automatically locked Put the tensioner gasket into the tensioner and put it into the correspondi...

Page 31: ...Cylinder piston One System components 6 7 5 8 9 10 3 2 1 4 11 12 13...

Page 32: ...hexagon flange bolts environmental protection color zinc 1 4 Cylinder block box gasket 1 5 piston 1 6 17 42 10 Piston pin 1 7 20 1 2 piston pin retaining ring 2 8 Oil ring combination 1 9 Second air r...

Page 33: ...p the carbon deposits and dirt on the top and be careful not to drop it into the box Clean the disassembled parts and blow them dry and then carry out the inspection work Specification Unit mm in Item...

Page 34: ...of the engine is too high during compression and it will make a knocking sound during operation Excessive carbon deposits on the top of the piston or in the combustion chamber 3 Abnormal engine noise...

Page 35: ...block 2 Remove the cylinder Remarks Piston turned to upper stop before disassembly and fix the crankshaft when pulling out the cylinder Do not drop the timing chain into the crankcase Fix the piston a...

Page 36: ...joint surface to avoid scratches on the joint surface Installation 1 Apply appropriate amount of sealant to the corresponding position of the cylinder block and box joint surface install a new cylind...

Page 37: ...n of piston ring Remarks Before installing the cylinder block apply a proper amount of engine oil evenly on the inner wall of the cylinder block Apply proper amount of engine oil to the piston skirt a...

Page 38: ...ylinder Maintenance limit value Flatness 0 05 mm 0 002 in Outer roundness 0 05 mm 0 002 in Note If the cylinder block exceeds the maintenance limit value a new cylinder block must be replaced If a new...

Page 39: ...etaining ring Block the opening of the crankshaft case with cloth or other objects to prevent the piston pin retaining ring from falling into the case during disassembly 2 Remove the piston rings by p...

Page 40: ...xial direction of the piston pin the second ring gap b is on the right side of the EX mark and the angle with a is 180 lower side The gap e of the oil ring wiper is at 45 between EX and b the angle be...

Page 41: ...stall it backwards Inspection 1 Rotate the piston ring and check the rotation of the piston ring The piston ring should be able to rotate freely in the groove without feeling stuck Press the piston ri...

Page 42: ...75 mm 0 6683 in Calculate the clearance between the inner diameter of the piston pin hole and the outer diameter of the piston pin Standard value 0 002 0 014 mm Note when the fit clearance between the...

Page 43: ...7 06 mm 0 6717 in Calculate the fit clearance between the small end of connecting rod and piston pin Standard value 0 01 0 023 mm 0 0004 0 0009 in Maintenance limit value 0 06 mm 0 0024 in Note the fi...

Page 44: ...Left crankcase cover continuously variable clutch subassembly One System components 1 2 3 4 5 6 7 9 10 11 12 14 15 16 13 17 8 18 19 20 21 22 24 23...

Page 45: ...left crankcase cover 1 12 21 8 1 8 acrylate rubber O ring 2 24 M6 30 hexagon flange bolt 12 Two Maintenance information General information 1 This section describes the repair and maintenance of the...

Page 46: ...When the engine idles normally the rear wheels rotate rapidly Centrifugal roller return stall Small spring of driven wheel shoe block is damaged The driven wheel bearing is damaged and the bearing is...

Page 47: ...he air filter outward with one hand and press the rear inner mud plate inward with the other hand Separate the air filter from the rear inner mud plate Use T shaped socket 8 to remove 12 M6 bolts of l...

Page 48: ...ant torque of 12 1 5 N M Note The left crankcase cover gasket may be broken or fractured during disassembly and will need to be replaced with a new gasket for assembly As shown in the figure below ins...

Page 49: ...serted seperatively into the two locating holes on the outer blade of the main fixing disc and the two symmetrical heat sink holes on the clutch housing of the driven wheel Prevent the driving wheel a...

Page 50: ...om the crankshaft Remove the driven wheel clutch housing from the drive shaft Pinch the middle part of the V drive belt and remove the belt together with the driven wheel sub part Pinch the main slidi...

Page 51: ...d to the main sliding wheel sub part with the corresponding guide pillar Figure 3 below Note When placing the centrifugal roller the covered end of the inner bore of the centrifugal roller points in t...

Page 52: ...tep requires greater hand strength and certain operating experience to complete Insufficient hand strength or no operating experience may cause injury to fingers caught by the driven pulley pulley Pic...

Page 53: ...g disc and the clutch housing of the driven wheel are clamped with special clamps so that they cannot rotate freely Tighten the M12 1 25 35 hexagon flange bolts clockwise with a torque wrench or wind...

Page 54: ...sure the outer diameter of the distance cylinder with a vernier caliper or an outer micrometer It needs to be replaced when the outer diameter is less than or equal to 34 9mm Check whether the centrif...

Page 55: ...n or damaged Use a vernier caliper to measure the diameter of the hoof block If the diameter is less than or equal to 146mm it needs to be replaced Note Grinding the clutch shoes is not recommended it...

Page 56: ...Right crankcase cover magneto One System components Part information...

Page 57: ...ing plate 1 9 21 1 5 EPDM O ring 1 30 M5 15 5 Hexagon socket cylinder screw oxidized black 3 10 M6 30 Hexagon Flange Bolt Environmental Protection Color Zinc 4 31 Trigger 1 11 GB5789M6 12 environmenta...

Page 58: ...int 1 20 2 5 M6 30 Hexagon Flange Bolt Environmental Protection Color Zinc Water pump cover locking bolt 4 12 1 5 GB5789M6 12 environmental protection color Water pump cover drain bolt 1 10 1 M30 1 5...

Page 59: ...y the gasket of the right crankcase cover is replaced there is no need to put the coolant and the water pipe does not need to be pulled out Unscrew the oil bolt to drain the engine oil Refer to ZT310T...

Page 60: ...2 10 14 hollow positioning pin and right crankcase cover gasket 5 After the right crankcase cover is removed from the engine the magneto stator sub component is on the right crankcase cover Use a torq...

Page 61: ...ized 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 The torque stand...

Page 62: ...in The gasket of the right crankcase cover must not show creases or cracks The removed right crankcase cover gasket cannot be reused because there is a risk of oil leakage it needs to be replaced with...

Page 63: ...Connect the trigger wire and rectifier wire and install the toilet in place Refer to ZT310T M Maintenance Manual 11 Complete vehicle engine disassembly 5 Install engine 6 Installation of the correspon...

Page 64: ...e half round key in the crankshaft groove with a copper rod and take out the 25 2 37 1 6 thrust washer electric starter gear electric starter reduction gear assembly electric starter reduction gear sh...

Page 65: ...g the flywheel so that it does not turn freely use a torque wrench and sleeve 14 to tighten the M10 1 25 45 hexagonal flange bolts grade 10 9 oxidized black the torque standard is 75 7 N m Remarks App...

Page 66: ...out the water seal dynamic ring and rubber Press the water pump shaft out use a screwdriver to reach through the bearing hole to contact the water seal then slowly tap the water seal out Use a screwd...

Page 67: ...5 FKM oil seal is 0 3 0 5mm shorter than the bearing limit surface and the distance between FB12 24 5 nitrile oil seal PTFE and pump cover combination surface is 17 6 0 0 1 mm 2 Check that the bearin...

Page 68: ...ce the ceramic scribe line is facing inward and the smooth surface is facing out Apply an appropriate amount of water soluble silicone oil to the static ring and dynamic ring of the water seal 6 Use a...

Page 69: ...ith a torque spanner or Air Screw and a lengthened hexagonal socket 8 Torque standard 12 1 5 N m 11 5 1 8 EPDM O Rings Water pump cover O rings M6 30 Hexagonal flange bolts 8 14 Hollow locating Water...

Page 70: ...Gearbox One System Components 12 1 3 2 4 6 9 10 5 7 8 13 14 15 16 17 19 18 11 20...

Page 71: ...ball bearing 1 9 ZT1P72MN drive shaft 1 19 GB276 62 22 P5 Deep groove ball bearing 1 10 GB276 6304 P5C3 deep groove ball bearing 1 20 GB276 6303 P5C3 Deep groove ball bearings nitriding 1 Two Mainten...

Page 72: ...he gearbox oil needs to be drained and the following parts must be disassembled Drain the gear box oil Refer to ZT310T M Maintenance Manual Engine Oil Change Gear Box Oil The parts to be disassembled...

Page 73: ...heck the drive shaft oil seal oil seal is not scratched abnormal wear such as scratches and replacement of abnormal grinding Left curved box bearings oil seal check 1 as shown rotate the bearing inner...

Page 74: ...ins on the joint surface of the gearbox cover and inspect the joint surface of the gearbox cover and require no scratches bumps 1 As shown apply oil to the bearing surface of the left crankcase gear h...

Page 75: ...n 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 a...

Page 76: ...Crankcase One system components 1 5 4 2 3 6 8 7 16 15 18 17 20 19 48 21 24 22 28 26 25 23 27 30 29 34 9 13 10 11 12 14 35 36 38 37 39 40 41 42 43 44 31 45 46 47 51 49 50 31 32 33...

Page 77: ...acrylate glue O ring 1 24 M14 1 5 fuel port nut 1 25 8 20 19 shock absorber hanging hole bushing 1 26 GB276 60 28 2RK deep groove ball bearings 1 27 GB893 1 hole with elastic retaining ring 52 1 28 F...

Page 78: ...bly refer to ZT310T M engine repair manual Cylinder head cover cylinder head Cylinder piston Cylinder piston disassembly reference ZT310T M engine repair manual Cylinder piston Left curved box cover L...

Page 79: ...leeve wrench 3 Spring clamp for shafts Three Common faults troubleshooting 1 Abnormal sound Crankcase shaft watts are wear The end shaft watt watt in the link The tabtop is abnormal Balance axis beari...

Page 80: ...position bolt applied to the threaded glue screw into the pressed bolt hole and tighten the tool 1 and the tightening torque is 10 1 N m 4 Disassemble the trapezoidal thick filter Disassembly Remove...

Page 81: ...crankcase If the crankcase is found to have functional damage such as cracks or combined surface the corresponding crankcase should be replaced Rotate the left and right box balance axis bearing inner...

Page 82: ...and the diameter of the right shaft is reduced by the diameter of the crankshaft body and the mating gap between the left and right spindle necks and the shaft tiles can be calculated Maintenance limi...

Page 83: ...left crank tank bearing inner ring and the cage the inner diameter and the oil seal lip Note Check that the left crankcase pressure relief valve sub assembly 9 8 x 2 4 hydrogenated nitrile O ring and...

Page 84: ...kshaft balance axis drive teeth must correctly engage the point Install two 8 14 hollow locating pins into the left crankcase locating pin holes As shown in the figure apply a layer of flat sealed rub...

Page 85: ...bonding surfaces First load 5 M6 75 hex flange bolts from the right side uniformly pretextile from the positioning pin position torsion torsion of 12 1 5 nm rotate the casing 8 M6 75 hex flange bolts...

Page 86: ...the diagram remove the circlip for shaft with tool 3 spring clamp for shafts and take out 18 1 26 1 washer 17 6 2 4 NBR O ring and 12 4 19 35 3 upper hanging piece bushing Upper Hanging Piece Install...

Page 87: ...al the grease then install the 18 1 26 1 Gasket and circlip for shaft Note Use high temperature and high load resistant grease Diagram of the Finished Assembly 12 4 19 35 3 Upper Hanging Piece Bushing...

Page 88: ...l filter change intervals 2 Maintenance Maintenance intervals table Installation 1 Place the cylindrical fine filter including gasket 18 5 13 1 6 fine filter spring and fine filter cover O ring presse...

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