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Crankshaft runout inspection

Place the crankshaft on the V-shaped block or bracket and measure the corresponding point beating value with a
percent watch.

Note: When the crankshaft beats exceeds the maintenance limit, the new crankshaft needs to be replaced.

Maintenance limit value: 0.03 mm (0.0012 in)

Five. Assembly of the crankcase

Clean the inside of the crankcase before assembly, check whether there is crack or other damage.

①

Apparatus oil is applied at the 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 trapezoidal rougheners are not missing before installation

)

②

Apply a suitable amount of oil to the left and right main journals of the crankshaft, as shown below, the crankshaft

is loaded into the left crankcase (Note: The crankshaft semicircular keyway is upwards, do not scratch the left
crankcase bearing pad and crankshaft oil seal when putting in the crankshaft.).

Semi-tank

groove

Oil crankshaft

journal

Apply oil

Pressure valve
unit

Trapezoidal rough filter

Содержание ZT310M 2022

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 6: ...Lubrication system One Lubrication system diagram...

Страница 7: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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