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10-GEARSHIFT AND TRANSMISSION

CHK

ADJ

NO.

PART NO.

PART NAME

QTY

CAUTION

4051758-010000

ZT184MP Transmission main shaft parts

4051758-012000 Transmission auxiliary shaft sub-assembly

Ordinary

4051758-014000 Transmission auxiliary shaft sub-assembly

（

）

Lengthened

1050658-002000

ZT184MP Shift speed changer subassembly

1050653-007000

ZT173YMM Shift fork shaft

1050654-003000

variable speed countershaftright fork

1050654-004000

ZT180MN shifting spindle in the fork

1050654-002000

shifting auxiliary shaft left shift fork

Fig.1 GEARSHIFT AND
TRANSMISSION

Positional relationship of speed change and

transmission mechanism components

PROCEDURE:

●

Assembly position relation of speed change and transmission mechanism

The positions of the main shaft (1), secondary shaft (2), speed change drum (3), shift fork

(5),

⑹

⑺

, and shift fork shaft (4) are shown on the left.

When disassembling, first take out the fork shaft

⑷

, take down the fork

⑸

⑹

⑺

, take

out the speed change drum

⑶

, and finally take off the main shaft

⑴

and countershaft

⑵

the same time.

Notice:

●

When installing the shift fork, the side with letters on the shift fork faces the right

crankcase.

●

Place one end of the spindle shift fork into the slot of the third and fourth gears of the

spindle, and one end into the groove of the transmission drum profile.

●

The right shift fork

⑸

near the right crankcase is placed in the fifth gear slot of the

counter shaft, and the left shift fork

⑺

near the left crankcase is placed in the sixth gear slot

of the counter shaft.

Содержание ZT184MN

Страница 1: ...Maintenance Manual ZT184MN Engine EuroV 2022 7 7...

Страница 2: ...4 Adjust valve clearance 9 Adjust valve clearance 2 5 Remove camshaft 1 10 sealing cap tensioner assembly 2 6 Remove camshaft 2 11 Camshaft assembly 2 7 Remove the cylinder head 1 12 Remove the cylind...

Страница 3: ...4 1 Remove Right Crankcase Cover Assembly 1 22 Remove the right crankcase cover 4 2 Remove Right Crankcase Cover Assembly 2 23 Remove the fine filter assembly oil plug 4 3 Remove Right Crankcase Cove...

Страница 4: ...reparation before the box is split 1 36 Disassemble the oil pump assembly 6 2 Preparation before the box is split 2 37 Remove primary drive gear remove shift star wheel assembly 6 3 Preparation before...

Страница 5: ...Left crankcase sub assembly left crankcase assembly 10 10 Speed change transmission mechanism components 10 1 Positional relationship of speed change and transmission mechanism components 51 Position...

Страница 6: ...contaminating the cover Place the oil pan under the engine oil drain bolt as shown in the middle left picture Use a 14 sleeve to remove the oil drain bolt 3 of the engine remove the gasket 2 and empt...

Страница 7: ...d Take out the gasket Take out the hollow positioning pin Notice The cylinder head cover bolts must be evenly loosened or tightened diagonally when removing and installing Gasket is for one time use a...

Страница 8: ...1050154 034000 ZT180MN timing chain plate 1 Fig 2 CYLINDER HEAD ASSEMBLY Remove the cylinder head cover assembly 2 PROCEDURE Disassemble the cylinder head cover assembly Use the 8 sleeve to remove the...

Страница 9: ...camshaft Use 10 hexagon socket to remove the screw plug and remove the O ring Use 5 internal hexagon to remove the aluminum screw plug 3 and remove the O ring 4 Use a 17 sleeve to extend from the alum...

Страница 10: ...andard interval of exhaust valve clearance 0 24 0 30mm If it does not meet the standard remove the intake and exhaust camshafts take out the tappet and replace the valve clearance adjustment pad under...

Страница 11: ...l sealant on the assembly plane of the cylinder head Apply an appropriate amount of sealant to the place on the new sealing cap 1 and then install it to the appropriate place on the cylinder head Remo...

Страница 12: ...it back inside the engine Be careful when you put it inside you can t turn to the crankshaft anymore Notice When installing it is necessary to apply an appropriate amount of oil on the positioning pi...

Страница 13: ...14 sleeve to remove the 4 nuts 3 in the cylinder head and remove the gasket 4 Notice The bolt is for one time use and must be replaced every time it is disassembled Failure to replace it may cause pr...

Страница 14: ...2 PROCEDURE Remove the cylinder head Take out the cylinder head assembly vertically upwards and remove the positioning pin 1 and gasket 2 Notice The gasket is for one time use and must be replaced af...

Страница 15: ...remove the sensor and remove the O ring Use the spark plug special sleeve to remove the spark plug The double ended stud does not need to be disassembled under normal circumstances If there are specia...

Страница 16: ...ced If the engine burns oil it is necessary to disassemble and replace the valve oil seal otherwise it is not necessary to disassemble Check air tightness Close the intake valve and exhaust valve and...

Страница 17: ...e sub assembly 3 includes the cylinder head exhaust pipe stud sub assembly intake valve exhaust valve and other components Cylinder head exhaust pipe double ended stud sub assembly The cylinder head e...

Страница 18: ...LINDER BLOCK ASSEMBLY Remove the guide bar PROCEDURE Guide Strip Pull out the guide bar in the direction of the arrow Notice When installing the guide bar the guide bar needs to be clamped to the posi...

Страница 19: ...wise there will be oil leakage and water leakage Check the inner wall of the cylinder If there are obvious scratches or damages on the inner wall of the cylinder it must be replaced Before installing...

Страница 20: ...he manufacture of cylinders and pistons our company divides the corresponding tolerances into 3 groups namely A B and C Which group the cylinder of group A can only buy the piston of group A if the pu...

Страница 21: ...nd oil rings Notice Remove the carbon deposits on the piston ring groove and piston ring and apply appropriate amount of engine oil to the piston ring groove It is necessary to prevent the piston pin...

Страница 22: ...to your own needs When installing the piston make sure that the side with the IN mark on the piston head is not on the side in the direction of the tensioner mounting surface Pistons and cylinders are...

Страница 23: ...crankcase cover foaming rubber 1 PROCEDURE Remove the right crankcase cover Fix the engine use an 8 sleeve to remove 3 bolts 1 with a copper washer 2 6 bolts 3 1 bolt 4 and 1 bolt 5 take out the Clutc...

Страница 24: ...emove the fine filter cover O ring sealing ring fine filter spring Oil plug Hold the oil plug by hand and turn it counterclockwise to take out the O ring Notice When replacing the fine filter the O ri...

Страница 25: ...let pipe connector 1 12 1051761 005000 3 5 23 copper overflow pipe joint 1 PROCEDURE Remove the water pump cover assembly Use an 8 sleeve to remove 3 bolts 1 and 1 ejector bolt 2 remove the copper gas...

Страница 26: ...ve to counterclockwise remove the water pump 1 Pull out the water pump shaft 2 from the reverse side and remove the cylindrical pin 4 gear 5 and washer 6 on the water pump shaft 2 Right crankcase cove...

Страница 27: ...4 22 5 Hydrogenated nitrile oil seal 1 15 1250602 033000 HK1412 needle roller bearing 1 16 1250602 022000 GB290 HK1010 needle roller bearing 1 PROCEDURE Removing the right crankcase cover assembly Use...

Страница 28: ...antling is to weld an M6 nut at the exposed thread and then remove it with an 8 sleeve When installing the stud screw in an M6 cap nut on the longer thread apply sealant on one end of the shorter thre...

Страница 29: ...buffer rubber the pressure plate and take off the separation rod Take out the friction plate sub assembly lock washer thrust washer The edge of the lock washer is chamfered Notice When installing the...

Страница 30: ...ner hole friction disc with large inner hole There are 7 friction plates and 6 driven plates including 3 friction plates with large inner holes and 1 driven plate with large inner holes Notice The dir...

Страница 31: ...late with small inner hole follower of small inner hole Disc friction disc with small inner hole follower disc with small inner hole friction disc with large inner hole There are 8 friction plates and...

Страница 32: ...eedle Roller Bearings 1 8 1050753 022000 ZT173YMM Clutch bushing home made 1 9 1050753 010000 ZT173YMM clutch bushing thrust pad 1 Fig 10 RIGHT CRANKCASE COVER Clutch assembly 3 PROCEDURE Clutch maste...

Страница 33: ...4MP Reduction gear cover components dark grey 1 PROCEDURE Reduction gear assembly Use an 8 sleeve to remove 3 bolts 1 and remove the reduction gear cover assembly 2 and O ring 3 Bearing is installed i...

Страница 34: ...RE 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 Notice When installing and removing p...

Страница 35: ...ng pin Notice Gasket must be replaced once removed Otherwise oil leakage may occur Before installing the left cover make sure that the assembly plane of the box body and the left cover is smooth and f...

Страница 36: ...y Use 5 inner hexagon to remove 3 bolts take out the crimping plate Use 5 inner hexagon to remove 3 bolts 3 and take out the entire magneto stator sub component 4 Notice 2 Bearings and are included in...

Страница 37: ...the two positioning pins 4 under the oil pump assembly to prevent loss Note Oil pump sub assembly does not include gear and thrust washer please confirm the status you need before placing an order Not...

Страница 38: ...to prevent the crankshaft from rotating when the nut 1 is removed Use a 24 sleeve to remove the nut 1 take out the lock washer 2 the primary drive tooth 3 the flat key 4 the water pump gear 5 the spr...

Страница 39: ...sher 1 at the front and back of the bridge tooth 2 and do not miss it Remove the magneto rotor Grasp the magneto rotor with one hand use the stun gun 17 sleeve to remove the bolt 3 with the other hand...

Страница 40: ...st washer 1 and the thrust washer 4 from the crankshaft in sequence When installing pay attention to the start of the large tooth 2 the thrust washers 1 must be installed on both sides and cannot be o...

Страница 41: ...ve the gear display assembly Use an 8 sleeve to remove 2 bolts 1 and take out the pressure plate 2 Use a cross batch to remove 2 bolts 3 remove the gear display switch 4 the picture here is different...

Страница 42: ...0 Hexagon flange bolts color Zinc 3 Fig 1 CRANKCASE Crankcase Split 1 12 1 5N m PROCEDURE Cabinet split Use an 8 sleeve to remove 1 bolt on the right crankcase body Use an 8 sleeve to remove 1 bolt 3...

Страница 43: ...n take out the shift shaft Notice Most parts of the box body are installed on the left crankcase When disassembling the left crankcase must be down otherwise the parts will fall off The gasket is for...

Страница 44: ...with a rubber hammer with the other hand to take out the crankshaft assembly and balance shaft 3 Notice When taking out the main shaft 2 and the secondary shaft 1 pay attention to the fact that there...

Страница 45: ...e other hand to take out the crankshaft assembly and balance shaft 3 Notice When taking out the main shaft 2 and the secondary shaft 1 pay attention to the fact that there is a gasket near the left ca...

Страница 46: ...068093 M6 14 9 2 6 pivot bolt environmental protection colored zinc 1 12 1 5N m PROCEDURE Disassemble the right crankcase parts Use10 inner hexagon to remove bolt take out the tension bar and thrust w...

Страница 47: ...shaft bearing pressure plate 4 respectively Bearings are all fitted on the box by interference pressure and do not need to be replaced under normal conditions Stud stud does not need to be disassembl...

Страница 48: ...e right case exhaust gas chamber inlet cover the tension strip the sealing ring the torque Spring washer limit stop wheel sub assemblies Right crankcase assembly The right crankcase assembly includes...

Страница 49: ...ove the copper pad Use a 14 sleeve to remove the oil drain bolt and take out the gasket Bearings oil seals and do not need to be replaced under normal circumstances but must be replaced if the oil sea...

Страница 50: ...d stud 2 After sale 5 After sale PROCEDURE Disassemble the left crankcase parts Use an 8 sleeve to remove 2 bolts 1 and take out 2 limit pieces 2 Take out the oil pin and O ring Bearings are installed...

Страница 51: ...in bolt return spring column copper pad countershaft oil seal cover ejector bolt bearing limit piece and left crankcase assembly components Left crankcase assembly The left crankcase assembly includes...

Страница 52: ...ts PROCEDURE Assembly position relation of speed change and transmission mechanism The positions of the main shaft 1 secondary shaft 2 speed change drum 3 shift fork 5 and shift fork shaft 4 are shown...

Страница 53: ...0 15 2 25 1 0 thrust washer 1 Fig 2 GEARSHIFT AND TRANSMISSION Spindle assembly relationship PROCEDURE Spindle assembly relationship The assembly relationship of the gears on the main shaft is shown o...

Страница 54: ...cylindrical pin 1 12 ZT180MN Countershaft four gear 1 13 transmission auxiliary shaft subassembly 1 14 ZT180MN Countershaft six gear 1 15 25 2 31 1 0 thrust gasket 1 16 ZT180MN countershaftsecond gea...

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