Taller - MOTOR ZONTES350

Manual taller - Servicio Motor 350
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ZT180MN Engine EuroIV_V
Maintenance Manual
2021/4/19
Table of Contents
Contents Pg.
0 Table of Contents…………………………………………………………………………………………………………………………………………………………………………………………… 1
1 1- The steps of draining oil and antifreeze before disassembling the engine
1.1 Draining oil-1……………………………………………………………………………………………… ………………………………………………………………………………………… …… 5
1.2 Draining oil-2……………………………………………………………………………………………… ………………………………………………………………………………………… …… 6
1.3 Drain antifreeze……………………………………………………………………………………………… ………………………………………………………………………………………… … 7
2 2-Cylinder head assembly

2.1 Cylinder head cover assembly……………………………………………………………………………………………… ……………………………………………………………………………… 8
Cylinder head cover assembly
2.2 Disassembling the camshaft-1…………………………………………………………………………………………………… ………………………………………………………………………… 9
Tensioner assembly, sealing cap assembly
2.3 Disassembly of camshaft-2………………………………………………………………………………………… ……………………………………………………………………………………… 10
Disassemble camshaft
2.4 Disassembling the camshaft-3……………………………………………………………………………………………… ……………………………………………………………………………… 11
Camshaft assembly
2.5 Cylinder head assembly-1…………………………………………………………………………………………………… ……………………………………………………………………………… 12
Remove the cylinder head
2.6 Cylinder head assembly-2……………………………………………………………………………………………… …………………………………………………………………………………… 13
Remove the cylinder head
2.7 Cylinder head assembly-3……………………………………………………………………………………………… …………………………………………………………………………………… 14
Cylinder head assembly
2.8 Disassembling the valve……………………………………………………………………………………………… …………………………………………………………………………………… 15
Valve assembly
2.9 Adjust the valve clearance……………………………………………………………………………………………… …………………………………………………………………………………… 16
2.10 Description of after-sales parts………………………………………………………………………………………………………… …………………………………………………………………… 17
3 3-cylinder block assembly

3.1 Disassembling the guide bar……………………………………………………………………………………………… ………………………………………………………………………………… 18
Guide bar
3.2 Cylinder block assembly……………………………………………………………………………………………… …………………………………………………………………………………… 19
Cylinder assembly
3.3 Disassemble the piston……………………………………………………………………………………………… ……………………………………………………………………………………… 20
Piston assembly
Page 1 ，Toatal 54 Pages

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Contents Pg.
3.4 Description of after-sales parts………………………………………………………………………………………………………… …………………………………………………………………… 21
4 4-right crankcase cover assembly

4.1 ZT180MN right crankcase cover assembly-1……………………………………………………………………………… ……………………………………………………………………………… 22
Remove the right crankcase cover
4.2 ZT180MN right crankcase cover assembly-2……………………………………………………………………………………… ……………………………………………………………………… 23
Fine filter assembly, oil dipstick
4.3 Disassembling the water pump assembly-1…………………………………………………………………………………………………… …………………………………………………………… 24
Outlet pipe joint, water pump cover assembly
4.4 Disassembling the water pump assembly-2……………………………………………………………………………………………… ………………………………………………………………… 25
Water pump components
4.5 Disassembling the water pump assembly-3……………………………………………………………………………………………… ………………………………………………………………… 26
Bearing and oil seal assembly
4.6 Remove the noise reduction component of the right cover…………………………………………………………………………………………………… …………………………………………… 27
Right cover noise reduction component
4.7 Disassembling the clutch lever………………………………………………………………………………………………………… …………………………………………………………………… 28
Clutch lever assembly
4.8 Right cover bearing and oil seal………………………………………………………………………………………… ………………………………………………………………………………… 29
Right cover bearing and oil seal parts
4.9 Right cover parts……………………………………………………………………………………………… ………………………………………………………………………………………… … 30
Right cover parts
4.10 Clutch assembly-1……………………………………………………………………………………………… ………………………………………………………………………………………… 31
Clutch assembly
4.11 Clutch assembly-2……………………………………………………………………………………………… ………………………………………………………………………………………… 32
Friction plate assembly
4.12 Clutch assembly-3……………………………………………………………………………………………… ………………………………………………………………………………………… 33
Clutch master and driven disc assembly
5 5-Left crankcase cover assembly

5.1 Disassembling the reduction gear……………………………………………………………………………………………… …………………………………………………………………………… 34
Reduction gear assembly
5.2 Disassembling the starter motor……………………………………………………………………………………………… …………………………………………………………………………… 35
Starter motor components
5.3 Remove left crankcase cover assembly…………………………………………………………………………………………………… ………………………………………………………………… 36

Table of Contents
Contents Pg.
Remove the left cover assembly
5.4 Disassembling the magneto stator……………………………………………………………………………………………… …………………………………………………………………………… 37
Magneto stator assembly
5.5 Left cover parts……………………………………………………………………………………………… ………………………………………………………………………………………… …… 38
Screw plug assembly
6 6-Right crankshaft body case assembly (1)

6.1 Oil pump assembly……………………………………………………………………………………………… ………………………………………………………………………………………… 39
Disassemble the oil pump assembly
6.2 Right box assembly-1………………………………………………………………………………………………………… …………………………………………………………………………… 40
Remove the driving sprocket, remove the shifting star wheel
7 7-Left crankcase assembly (1)

7.1 Disassemble the bridge teeth and the magneto rotor……………………………………………………………………………………………… ………………………………………………………… 41
Electric bridge gear assembly, magneto rotor assembly
7.2 Disassemble the large starting gear and the output sprocket……………………………………………………………………………………………… ………………………………………………… 42
Start big gear assembly, output sprocket assembly
7.3 Remove the gear switch……………………………………………………………………………………………… ……………………………………………………………………………………… 43
Gear switch assembly
8 8-Crankcase disassembly
8.1 Crankcase disassembly-1…………………………………………………………………………………………………… ……………………………………………………………………………… 44
8.2 Crankcase disassembly-2………………………………………………………………………………………………………… ………………………………………………………………………… 45
9 9-Right crankshaft case assembly (2)

9.1 Right cabinet assembly-2………………………………………………………………………………………………………… ………………………………………………………………………… 48
Tensioner assembly, stop wheel assembly, coarse filter, oil and gas baffle
9.2 Right box assembly-3…………………………………………………………………………………………………… ………………………………………………………………………………… 49
Spindle bearing baffle, bearing spare parts and after-sales parts
10 10-Left crankcase assembly (2)

10.1 Left crankcase parts……………………………………………………………………………………………… ………………………………………………………………………………………… 50

Table of Contents
Contents Pg.
10.2 After-sales spare parts for left crankcase………………………………………………………………………………………… ………………………………………………………………………… 51
11 11- Gearshift and transmission mechanism components

11.1 The position relationship of the components of the speed change and transmission mechanism…………………………………………………………………………………… ……………………… 52
11.2 Spindle assembly relationship……………………………………………………………………………………………… ……………………………………………………………………………… 53
11.3 Countershaft assembly relationship……………………………………………………………………………………………… ………………………………………………………………………… 54
This manual is suitable for ZT180MN series engines. All the materials, illustrations, photos, etc. collected in this manual are compiled according to the latest products. However, due to the
continuous improvement of the product and other changes, there may be some inconsistencies between your engine and this manual.
©Guangdong Daye Motorcycle Technology Co., Ltd.
all rights reserved

1-PREPARATION STEPS
Fig.1 PREPARATION CHK

Draining oil-1
STEPS ADJ
NO. PART NO. PART NAME QTY CAUTION
1 1251100-066093 M12×1.5×15 oil drain bolt (color zinc) 2 25±4N.m
2 1244100-033000 Combined sealing gasket12×φ20×2 2
3 1050854-002000 ZT180MN oil level gauge 1
4 1051454-003000 15×3.1 acrylate adhesive O－ring 1
PROCEDURE:
●Drain oil
Place a larger container under the engine, use 14 sleeve + ratchet wrench to remove the 2 oil drain bolts at the
bracket and the left crankcase (1), and remove the gasket (2).
Unscrew the oil dipstick (3) on the right crankcase cover, take out the sealing ring (4), and wait for the oil to
drain from the oil drain.
CAUTION：
●Combined gasket ⑵It is recommended to replace it after disassembly to avoid oil leakage and oil leakage due
to damage caused during disassembly.
●After removing the oil drain bolt ⑴, check whether the magnet on the bolt has adsorbed iron filings. If there
are many foreign objects or parts adsorbed, check the inside of the engine. If there is only a small amount of
metal chips, don't worry, just clean it up.
●Draining oil and antifreeze can only be done when the machine is cold to prevent burns.
5
1-PREPARATION STEPS

Draining oil-2
STEPS ADJ
1 Oil outlet pipe of engine 1
【1】
2 Oil inlet pipe of engine 1
3 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color zinc) 2 12±1.5N.m
4 1051454-014000 9.8×2.5 acrylic o－ring 2
PROCEDURE:
●Drain oil
Use an 8# sleeve to remove the 2 bolts ⑶ on the engine oil outlet pipe ⑴ and the engine oil inlet pipe ⑵, and
remove the O-ring ⑷.
Wait for the oil to flow out.
CAUTION：
●【1】Because there may be multiple states for different models, colors, status changes, etc., only the name is
reserved here, and the corresponding correct state can be found in the official website parts. Similar situations
will not be repeated in the follow-up.
●O-rings are recommended to be replaced after disassembly to avoid oil leakage and oil leakage due to improper
seals caused by damage during disassembly.
6
1-PREPARATION STEPS

Drain antifreeze
STEPS ADJ
1 1251112-001093 M6×16 Hexagon flange bolts (color zinc) 1 12±1.5N.m
2 1251513-001019 6.3×12×1.6 copper gasket 1
PROCEDURE:
●Put antifreeze
Place a container under the drain hole, ready to receive antifreeze, use an 8# sleeve to remove the bolt (1), and
remove the copper pad (2).
Locate the water filler cap at the lower link plate on the right side of the vehicle, press down the water filler cap
and turn it counterclockwise before removing it, and wait for the antifreeze to drain.
CAUTION:
●Gasket ⑵After disassembly, new gaskets must be replaced to avoid water leakage.
●Antifreeze is corrosive to a certain extent, so be careful not to contaminate the engine, 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 is stained with antifreeze, immediately
rinse with clean water. If the antifreeze is splashed into the eyes, immediately rinse with plenty of water and
observe to decide whether to seek medical attention.
●The engine can be removed from the vehicle after draining the antifreeze and engine oil.
7
2-CYLINDER HEAD ASSEMBLY
Fig.1 CYLINDER HEAD CHK

Cylinder head cover assembly
ASSEMBLY ADJ
1 1251112-003093 M6×45 Hex flange surface 9.8 bolt (color zinc) 2 12±1.5N.m
3 1250205-023000 GB70.1 inner hexagonal M8X35 (environmental color) 1 21±1.5N.m
4 1051654-001000 ZT180MN Cylinder head cover gasket 1
5 1251401-001000 φ8×14 hollow locating pin 2
6 1051454-001000 7.5×1.5 Fluorine O－ring 1
7 1251401-003000 Φ10×14 hollow positioning pin 1
8 1251100-067093 M6×10 top pin bolt (color zinc) 1 12±1.5N.m
9 1251513-001019 6.3×12×1.6 copper gasket 1
10 1050154-034000 ZT180MN timing chain plate 1
11 1040754-001000 ZT180MN Cylinder head cover 1
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.
Take out the gasket ⑷, remove one large positioning pin ⑺ and two small positioning pins ⑸. Note: One of
the small positioning pins ⑸ has an O-ring ⑹. Clean up the remaining sealant on the joint surface.
Remove the bolt ⑻ with an 8# sleeve, and remove the copper pad ⑼.
Remove the chain guard ⑽ from the inside of the cylinder head cover ⑽, and install the chain guard ⑽ on the
boss shown in the circle in the figure.
CAUTION：
●When installing a new gasket, apply a proper amount of sealant on the assembly plane of the cylinder head and
the upper surface of the gasket.
●The cylinder head cover bolts must be evenly loosened or tightened diagonally when removing and installing.
●Gasket ⑷ is for one-time use, and must be replaced after disassembly, otherwise the seal will not be in place
and problems such as engine oil leakage will occur.
●When cleaning residual sealant and other impurities, avoid foreign matter from entering the engine.
8

Disassembling the camshaft-1
ASSEMBLY ADJ
2 1251513-001019 6.3×12×1.6 copper gasket 1
4 1051253-003000 30×38 tensioner parts 1
5 1051253-004000 30×38 Washer, tensioner 1
6 1050153-005000 Cylinder head sealing cap parts 2
PROCEDURE:
●Tensioner assembly
Use an 8# sleeve to remove the bolt ⑴, and take out the copper pad ⑵.
Use an 8# sleeve to remove the 2 bolts (3), and use the tensioner disassembly tool to remove the tensioner ⑷
and gasket ⑸.
●Sealing cap assembly
When installing the sealing cap ⑹, a proper amount of sealant should be applied at ① to prevent oil leakage.
CAUTION：
●Gasket ⑸ is for one-time use, and must be replaced after disassembly, otherwise the seal will not be in place
and problems such as engine oil leakage will occur.
●When removing the tensioner, it is necessary to use the tensioner removal tool. Disassembly tooling is included
when purchasing the tensioner assembly. The tooling is as follows:
9

Disassembly of camshaft-2
ASSEMBLY ADJ
1 1040953-002093 M14×1.5 plug screw (environmental color zinc) 1
2 1051453-009000 O－ring 13×2.8 1
3 M30×1.5 aluminum screw plug 1
4 1051453-003000 27.4×2.65 Acrylate rubber o－rings 1
PROCEDURE:
●Remove the camshaft
Use 5# hexagon socket to remove the screw plug ⑴, and remove the O-ring ⑵.
Use 10# internal hexagon to remove the aluminum screw plug (3), and remove the O-ring (4).
Use a 17# sleeve to extend from the aluminum screw plug ⑶, use the sleeve to turn the flywheel bolt
counterclockwise, so that the flywheel "T" dot-dash line coincides with the center line of the small AC hole mark
slot on the left cover.
CAUTION：
●When the "T" dashed line coincides with the marked line, the ends of the intake and exhaust camshafts all face
outward.
10

Disassembling the camshaft-3
ASSEMBLY ADJ
1 M6×45 Hex flange surface 9.8 bolt (color zinc) 12
2 Intake and exhaust camshaft right seat cover blank 1
3 ZT180MN intake camshaft middle seat cover blank 1
4 ZT180MN intake camshaft left seat cover blank 1 【1】
5 ZT180MN exhaust camshaft middle seat cover blank 1
6 ZT180MN exhaust camshaft left seat cover blank 1
7 φ8×14 hollow locating pin 10
8 1050154-042000 ZT180MN intake camshaft sub－assembly 1
9 1050154-043000 ZT180MN exhaust camshaft sub－assembly 1
10 1050154-033000 6.35×9×130 gear chain 1
PROCEDURE:
●Camshaft assembly
Use 8# cylinder to remove 12 bolts (1), torque standard: 12±1.5N.m, remove camshaft pressing blocks ⑵, ⑶,
⑷, ⑸, ⑹, do not take out the positioning pin ⑺.
Remove the intake camshaft assembly ⑻ first, and then remove the exhaust camshaft assembly ⑼. The timing
chain does not need to be taken out at this time, just put it back into the engine.
CAUTION：
●【1】Parts not marked with codes are included in the parts assembly and are not sold separately.
●"EX" means out of air, "IN" means air in, "L" means left seat, and "M" means middle seat. Be careful not to
install it wrongly.
●The positioning pin ⑺ needs to be put back to the corresponding position of the cylinder head and cannot be
misplaced.
●When installing, apply a proper amount of oil to the corresponding position of the camshaft, install the exhaust
camshaft first, and then install the intake camshaft.
●The bolts of the camshaft seat cover must be tightened diagonally, otherwise it will damage the cylinder head,
seat cover and camshaft.
11

Cylinder head assembly-1
ASSEMBLY ADJ
2 1251112-010000 M8×110 Hexagonal flange Level 9.8 bolt(color zinc) 2 25±1.5N.m
3 1251300-052094 M10×1.25 cap nut (12 grade / oxidized black) 4 60±1.5N.m
4 1251500-041000 10.3×20×2 gasket 4
PROCEDURE:
●Remove the cylinder head
Use 8# torx wrench to remove 1 bolt (1) connecting the cylinder and the cylinder head.
Use an 8# sleeve to remove the 2 bolts in the cylinder head (2).
Use a 14# sleeve to remove the 4 nuts (3) in the cylinder head, and remove the gasket (4).
CAUTION：
●The bolt ⑵ is for one-time use, and must be replaced every time it is disassembled. Failure to replace it may
cause problems with the airtightness of the cylinder and the cylinder head.
●Prevent foreign objects from falling into the engine during disassembly and installation.
●Nuts (3) must be evenly loosened diagonally, and each nut must be loosened 1/3 at a time, and then removed
after all the nuts are completely loosened.
●Nut (3) Before installation, lubricating oil should be applied to the thread of the nut, and the installation also
needs to be evenly tightened diagonally in 3 times.
12

ASSEMBLY ADJ
1 1051301-052000 Locating pin 12×20 2
2 1051654-006000 Cylinder body and head gasket subassembly A 1
PROCEDURE:
●Remove the cylinder head
Take out the cylinder head assembly vertically upwards, and remove the positioning pin (1) and gasket (2). The
gasket ⑵ is for one-time use and must be replaced after disassembly.
CAUTION：
●When removing and installing the cylinder head assembly, pay attention to the guide bar.
●When removing and installing the cylinder head assembly, avoid foreign matter from entering the engine.
13

ASSEMBLY ADJ
2 1051954-001000 ZT180MN Outlet pipe subassembly 1
3 1051454-007000 19×2.65 EPDM O－ring 1
4 1050954-003000 Communal sensor of water and oil 1 13±1.5N.m
5 1051454-009000 9×2 EPDM O－ring 1
6 1050954-017000 LDK8RTIP－0.8 sparking plug 1 20±2N.m
7 1251111-011000 AYM8－M8×38 double head 10.9 stud bolts is deactivated 2 20±1.5N.m
PROCEDURE:
●Cylinder head assembly
Use an 8# sleeve to remove the 2 bolts (1), and remove the outlet pipe (2) and O-ring (3).
Use a 17# sleeve to remove the sensor ⑷, and remove the O-ring ⑸.
Use the spark plug special sleeve to remove the spark plug ⑹.
Use M8 double-end stud sleeve to remove the stud ⑺. When installing, apply a proper amount of thread glue to
the thread of the stud ⑺ and the cylinder head.
① The oil plug at the place cannot be disassembled. Here is an interference fit. If disassembled and then
assembled, it will cause problems with the sealing of the cylinder head.
②The water plug at the place is also not removable. Special waterproof glue is applied to the threads here.
Disassembly and assembly may cause water leakage.
CAUTION：
●Apply appropriate amount of thread glue to the thread of the bolt (1) during installation.
●O-rings (3) and (5) are for one-time use. If they are removed, they must be replaced. Failure to replace it may
cause problems such as water leakage.
●When removing and installing the cylinder head assembly, avoid foreign matter from entering the engine.
●Check the spark plug thread and center electrode. If there is damage or deformation, replace the spark plug.
●The standard value of spark plug gap a is: 0.7-0.9mm, and it must be replaced if it exceeds the range.
14

Disassembling the valve
ASSEMBLY ADJ
1 1050154-032000 3×27 slide tappet 4
2 1050154-020000 φ 8.85 valve clearance adjusting pad 4
3 1050154-017000 ZT180MN Valve lock clamp 8
4 1050154-016000 ZT180MN Valve spring ring 4
5 1050154-039000 ZT180MN valve outer spring A 4
6 1050154-040000 ZT180MN valve inner spring A 4
7 1050153-015000 16.5×23.5×1 valve spring seat 4
8 1051553-001000 Φ5.0 valve stem diameter oil seal 4
9 1050154-012000 ZT180MN Intake valve A 2
10 1050154-013000 ZT180MN Exhaust valve A 2
PROCEDURE:
●Valve assembly
Remove the sliding tappet ⑴ and valve clearance adjustment cushion ⑵.
Squeeze the valve spring with a valve disassembler, remove the valve lock clamp (3), and remove the upper
spring ring ⑷, outer spring ⑸, inner spring ⑹, spring seat ⑺, oil seal ⑻, and intake valve ⑼ in sequence.
Use the same method to remove the other valves.
CAUTION：
●Oil seal ⑻ is for one-time use and must be replaced after disassembly; oil seal ⑻ needs to be press-fitted on
the boss on the valve guide; please go to a qualified maintenance organization for replacement.
●Install the valve spring with the close-spaced end facing down.
●When disassembling the valves, the 4 groups of dismantled valves should be marked so that they can be
installed back to their original positions.
15

Adjust the valve clearance
ASSEMBLY ADJ
1 1050154-043000 ZT180MN exhaust camshaft sub－assembly 1
2 1050154-032000 3×27 slide tappet 4
3 1050154-042000 ZT180MN intake camshaft sub－assembly 1
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.
Use a feeler gauge to measure the valve clearance.
Standard interval of intake valve clearance: 0.10-0.19mm
Standard interval of exhaust valve clearance: 0.15-0.28mm
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 the tappet.
After the replacement is completed, measure the valve clearance with a feeler gauge again, the adjustment is
successful if it is qualified, otherwise continue to replace the valve clearance adjustment pad.
CAUTION：
●When measuring the clearance of the right exhaust valve, you need to rotate the pressure reducing mechanism
by hand until it is fully opened before measuring.
●When installing the camshaft, apply a proper amount of engine oil to the camshaft.
●You can watch the detailed operation in "ZT310 Valve Clearance Adjustment Video".
16

Description of after-sales parts
ASSEMBLY ADJ
1 4050654-008000 ZT180MN cylinder head sub－assembly (Bosch) 1
2 4050654-004000 ZT180MN cylinder head assembly 1 After-sale
3 4050654-001000 ZT180MN Cylinder head subassembly 1
PROCEDURE:
●Cylinder head sub-assembly
Cylinder head assembly (1) includes cylinder head assembly, valve assembly, camshaft assembly, etc.
●Cylinder head assembly
Cylinder head assembly (2) includes cylinder head assembly, valve assembly, excluding camshaft and other
components.
●Cylinder head sub-assembly
The cylinder head sub-assembly (3) only contains the cylinder head assembly.
CAUTION：
●Please check the status of parts before placing an order and place an order according to your own needs.
17
3-CYLINDER BLOCK ASSEMBLY
Fig.1 CYLINDER BLOCK CHK

Disassembling the guide bar
ASSEMBLY ADJ
1 1051254-004000 ZT180MN guide bar part B 1
PROCEDURE:
●Guide Strip
Pull out the guide bar ⑴ in the direction of the arrow.
CAUTION：
●When installing the guide bar, the guide bar needs to be clamped to the position shown in the lower left.
18

Cylinder block assembly
ASSEMBLY ADJ
1 1051654-007000 ZT180MN Cylinder body gasket A 1
2 1051301-052000 Locating pin 12×20 1
4 1051954-007000 ZT180MN Inlet and outlet pipe connector 1
5 1051454-008000 19×1.5 ethylene propylene terpolymer O shape circle 1
PROCEDURE:
●Cylinder assembly
Take the cylinder assembly out vertically, remove the gasket ⑴, positioning pins ⑵, ⑶, and clean the
remaining sealant on the joint surface.
Use 24# torx wrench to remove the outlet pipe joint ⑷, and take out the O-ring ⑸.
CAUTION：
●The gasket ⑴ and O-ring ⑸ are for one-time use and must be replaced after disassembly, otherwise 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 the cylinder, make sure that the box and cylinder assembly planes are smooth and flat and
apply a proper amount of sealant on the box assembly plane. After installing the new gasket, apply a proper
amount of sealant on the upper surface of the new gasket.
●Before installing the cylinder, apply a proper amount of engine oil to the inner wall of the cylinder as
lubrication.
19

Disassemble the piston
ASSEMBLY ADJ
1 1050454-007000 21×1.2 piston pin retainer 2
After-sale
2 1050454-003000 ZT180MN Piston pin 1
3 1050454-013000 ZT180MN Piston assembly 1 Assembly
4 1050454-002000 ZT180MN Piston 1
5 1050454-004000 ZT180MN First air ring 1
After-sale
6 1050454-005000 ZT180MN Second air ring 1
7 1050454-006000 ZT180MN Oil ring combination 1
PROCEDURE:
●Piston assembly
Turn the opening of the piston retaining ring ⑴ to the vicinity of the gap of the retaining ring groove, and
remove it with needle-nose pliers.
Push the piston pin ⑵ out of the crankshaft connecting rod, and remove the piston ⑶.
Open the gap at the end of the first air ring ⑷ by hand, and lift the other side to the top of the piston, and
remove the first air ring ⑷.
Use the same method to remove all gas and oil rings.
CAUTION：
●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 retaining ring ⑴ or other foreign objects from falling into the box
during installation and removal.
●Check whether the piston skirt is scratched or damaged, if any, it must be replaced.
●When installing the oil ring assembly, you need to install the copper liner ring first, and then install the two
wiper rings. The copper liner ring interface cannot overlap.
●When installing the air ring, the marked surface should be installed toward the top of the piston, air ring 1:
"R", air ring 2: "2R"
●When installing, the openings of each air ring and scraper ring should be staggered by 180 degrees.
●Check the piston pin retaining ring ⑴, if it is deformed and has no elasticity, it must be replaced.
20

Description of after-sales parts
ASSEMBLY ADJ
1 4050554-001000 ZT180MN Cylinder piston subassembly 1
2 4050554-002000 ZT180MN Cylinder body assembly 1 After-sale
3 1040554-001000 ZT180MN Cylinder body 1
PROCEDURE:
●Cylinder piston sub-assembly
The cylinder piston sub-assembly includes a piston assembly and a cylinder block assembly.
●Cylinder block assembly
The cylinder block assembly includes a cylinder block, water inlet and outlet pipe joints and O-rings.
●Cylinder block
The cylinder block is just a single cylinder block.
CAUTION：
●Please check the status of parts before placing an order and place an order according 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 of
the water inlet pipe.
●The piston ring should be inserted into the cylinder correctly, and it should not come out of the ring groove.
●Pistons and cylinders are divided into four groups: A, B, C, and D. The assembled piston and cylinder must be
in the same group.
21
4-RIGHT CRANKCASE COVER ASSEMBLY
Fig.1 RIGHT CRANKCASE CHK

ZT180MN right crankcase cover assembly-1
COVER ASSEMBLY ADJ
1 1251112-003093 M6×45 Hex flange surface 9.8 bolt (color zinc) 4
2 1251112-006093 M6×90 Hexagon flange bolts (color zinc) 1
6 1251513-001019 6.3×12×1.6 copper gasket 1
8 1051653-005000 Right crankcase cover cushion piece 1
9 1051354-012000 9.2 × 18 × 1 Thrust Washer 1 【1】
10 Sliding clutch right crankcase cover sub－assembly 1
PROCEDURE:
●Remove the right crankcase cover
First, prevent the engine from falling over to prevent the gasket ⑼ from falling off when the right cover ⑽ is
removed.
Use a 8# sleeve to remove 4 bolts ⑴, 1 bolt ⑵, 2 bolts ⑶, 3 bolts ⑷, 1 bolt ⑸, and remove 1 copper pad ⑹.
Remove the right cover ⑽ from the engine, and take out the 2 positioning pins ⑺, gasket ⑻, and washer ⑼.
CAUTION：
●The gasket ⑻ is for one-time use and must be replaced after disassembly.
●Before installing the box body, make sure that the box body assembly plane is smooth and flat and apply an
appropriate amount of sealant on the box body assembly plane. After installing the new gasket ⑻, it is necessary
to apply sealant again on the upper surface of the gasket ⑻.
●When installing the right cover, all bolts should be evenly tightened at the corners to ensure tightness.
●You can watch the detailed operation in the "Clutch Cover and Clutch Disassembly Video".
22

ZT180MN right crankcase cover assembly-2
COVER ASSEMBLY ADJ
1 1251300-056093 M6 cap nut(12 grade / environmental color) 3 12±1.5N.m
2 ZT180MN fine filter cover A 1
3 1051454-004000 55×2.5 acrylate adhesive O shape circle 1
After-sale
4 1051454-005000 ZT180MN Oil filter sealing ring 1
5 ZT180MN fine filter sealing assembly 1
6 1050853-009000 Φ16.4×17×1.6 filter spring 1
7 1050854-002000 ZT180MN oil level gauge 1
8 1051454-003000 15×3.1 acrylate adhesive O－ring 1
PROCEDURE:
●Fine filter assembly
Use a 10# sleeve to remove the 3 nuts ⑴, remove the fine filter cover ⑵, O-ring ⑶, sealing ring ⑷, fine filter
⑸, spring ⑹.
●Dipstick
Pinch the upper boss of the oil dipstick and rotate it counterclockwise, take out the oil dipstick ⑺ and O-ring
⑻.
CAUTION：
●It is strictly forbidden to lift the fine filter cover with hard objects, otherwise it will cause oil leakage.
●Check whether the O-ring is damaged. If it is damaged, replace it immediately, otherwise it will cause oil
leakage.
●Do not install the fine filter cover upside down. The end face of the filter element with the "OUT-SIDE" mark
faces the fine filter cover.
●You can watch the detailed operation in "ZT310 Replacing Fine Filter Video".
23

Disassembling the water pump assembly-1
COVER ASSEMBLY ADJ
1 1051954-007000 ZT180MN Inlet and outlet pipe connector 1
2 1051454-008000 19×1.5 ethylene propylene terpolymer O shape circle 1
4 1051454-006000 ZT180MN Water pump sealing ring 1
7 1051654-002000 Combination seal 6×13×1.8 1
8 ZT180MN water pump cover A 1
PROCEDURE:
●Outlet pipe joint
Use a 24# torx wrench to remove the outlet pipe joint ⑴, and take out the O-ring ⑵.
●Water pump cover assembly
Use an 8# sleeve to remove the 3 bolts (3), remove the water pump cover assembly, and take out the sealing
ring ⑷ and the positioning pin ⑸.
Use an 8# sleeve to remove 1 bolt ⑹ from the water pump cover ⑻, and remove the gasket ⑺.
CAUTION：
●The 3 bolts for fixing the water pump cover need to apply appropriate amount of sealant on the threads to
prevent water leakage.
●O-ring ⑵, sealing ring ⑷ and gasket ⑺ are for one-time use, and must be replaced after disassembly to
prevent water leakage.
24

COVER ASSEMBLY ADJ
1 1051954-015000 ZT180MN water pump 1 20±1.5N.m
2 1051954-010000 ZT180MN Water pump shaft 1
3 1250404-006000 φ5×16 cylindrical pin 1
4 1051954-004000 ZT180MN Water pump gear 1
5 1251512-007000 12.2×20×1 thrust washer 1
PROCEDURE:
●Water pump components
Use a 14# open-end wrench to fix the ① on the water pump shaft, and then use a 12# sleeve to remove the
water pump ⑴. (The water seal moving ring ② belongs to the water seal assembly and is installed on the water
pump.) Remove the water seal moving ring ② from the water pump.
Pull out the water pump shaft ⑵ from the reverse side, and remove the cylindrical pin ⑶, gear ⑷ and washer
⑸ on the water pump shaft ⑵.
CAUTION：
●The smooth surface of the water seal moving ring faces outwards and a proper amount of silicone oil should be
applied, and the sealing rubber gasket should not protrude.
●The water seal movable ring and the water seal static ring form the water seal sub-assembly.
25

COVER ASSEMBLY ADJ
1 1051954-006000 ZT180MN Water seal subassembly 1
2 1051554-001000 FB12×24×5 HNBR oil seal 2
3 1250601-077000 6201－C deep groove ball bearing(FAG) 1
4 1051354-013000 Type hole circlip φ24×1 1
5 1051554-004000 NY12×23×7 Hydrogenated nitrile rubber oil seal 2
PROCEDURE:
●Bearing and oil seal assembly
Pull out the static ring of the water seal subassembly ⑴, you can remove the 2 oil seals ⑵, knock out the
bearing ⑶.
Use circlip pliers to take out the retaining ring ⑷, then 2 oil seals ⑸ can be removed.
CAUTION：
●When press-fitting, the black resin side of the water seal stationary ring faces the indenter, the bearing marked
side faces the indenter, and the oil seal marked side faces the indenter.
●Bearings are all press-fitted. Most of the bearings are interference fit and have accuracy requirements. It is not
recommended to disassemble unless special circumstances. If disassembly is required, please go to a qualified
maintenance organization for press-fitting.
●When installing the oil seal, the oil seal should be press-fitted evenly to avoid deformation and flanging of the
oil seal.
●Oil seals will be damaged if they are disassembled. To avoid oil leakage, please disassemble and replace them.
●The retaining ring will be deformed during disassembly. It is recommended to replace it after disassembly.
26
Fig.6 RIGHT CRANKCASE Remove the noise reduction component of the right CHK
COVER ASSEMBLY cover ADJ
1 1251100-119093 Non－standard bolt M6×12 (environmental color) 3
2 1051354-010000 ZT180MN right cover noise reduction plastic shield 1
3 1051454-015000 ZT180MN right cover noise reduction glue 1
PROCEDURE:
●Right cover noise reduction component
Use 4# inner hexagon to remove 3 bolts ⑴, take off guard plate ⑵, noise reduction glue ⑶.
CAUTION：
●Appropriate amount of thread fastening glue should be applied to the threads of the 3 bolts during installation.
22

Disassembling the clutch lever
COVER ASSEMBLY ADJ
1 1051154-003000 GB894.1 shaft retaining ring 10 (plated up to.Crowe) 1
2 1051154-004000 10.2×18×1 gasket (plated up to Crowe) 2
3 1051354-009000 ZT180MN clutch lever rocker arm assembly 1
4 1050754-018000 ZT180MN sliding clutch rod torsion spring 1
5 1250511-003000 GB896 opening retaining ring φ9 1
6 1050254-008000 ZT180MN clutch rod shaft 1
PROCEDURE:
●Clutch lever assembly
Use circlip pliers to take out the retaining ring ⑴, remove the washer ⑵, and pull out the lever rocker arm
assembly ⑶ and torsion spring ⑷.
Use circlip pliers to pick out the retaining ring ⑸ and remove the gasket ⑵.
Take out the clutch lever shaft ⑹ in the direction of the arrow.
CAUTION：
●Retaining ring ⑴ and retaining ring ⑸ will be deformed during disassembly, it is recommended to replace
them after disassembly.
28

Right cover bearing and oil seal
COVER ASSEMBLY ADJ
1 1051553-002000 FB14×22×5 Hydrogenated nitrile oil seal 1
2 1250602-033000 HK1412 needle roller bearing 1 Aftre-sale
3 1250602-022000 GB290－HK1010 needle roller bearing 1
PROCEDURE:
●Right cover bearing and oil seal parts
The oil seal ⑴, bearing ⑵, and ⑶ are all press-fitted in the right cover and will not be damaged under normal
circumstances.
CAUTION：
●Oil seals will be damaged if they are disassembled. To avoid oil leakage, please disassemble and replace them.
●When installing the oil seal, the oil seal should be press-fitted evenly to avoid deformation and flanging of the
oil seal.
●When the oil seal is press-fitted, the marking surface of the oil seal should face outwards. Do not install it
backwards to cause oil leakage.
●Please do not disassemble or assemble the bearing unless special circumstances. If it is necessary to replace the
bearing, please go to a maintenance organization capable of replacing it.
29

Right cover parts
COVER ASSEMBLY ADJ
1 1251111-010000 Non－standard M6×23.5 double－head 9.8 studs bolts 3
PROCEDURE:
●Right cover assembly
The 2 oil plugs ① are interference press-fitting and cannot be disassembled unless under special circumstances,
otherwise oil leakage will occur.
Stud ⑴ generally does not need to be disassembled, disassembly is to weld an M6 nut where the thread is
exposed, and then use an 8# sleeve to remove it.
CAUTION：
●When installing the stud, screw in an M6 cap nut on the longer thread, apply sealant on one end of the shorter
thread, and install the stud on the right cover with an 8# sleeve.
30

Clutch assembly-1
COVER ASSEMBLY ADJ
1 1251100-070093 M6×30 flange full bolt 3 12±1.5N.m
2 1050754-007000 ZT180MN clutch spring pressure plate 1
3 1050754-021000 ZT180MN clutch spring A 3
4 1050754-024000 Sliding clutch pressure plate sub－assembly 1
5 1050754-006000 ZT180MN clutch release lever 1
6 1050754-023000 ZT180MN sliding clutch friction plate sub－assembly 1
7 1251514-006000 96.5×107×2.2×1 gasket 1 Flat cushion
8 1251512-031000 96.3×107×7 thrust washer 1 Butterfly gasket
9 1051454-017000 ZT180MN clutch cushion rubber 3
PROCEDURE:
●Clutch assembly
Use an 8# sleeve to remove 3 bolts (1), and take out the pressure plate (2) and 3 springs (3). Pull out the
pressure plate ⑷, and remove the separation lever ⑸.
Take out the friction plate sub-assembly ⑹, lock washer ⑺, thrust washer ⑻. The edge of the lock washer ⑺
is chamfered.
CAUTION：
●When installing, the side of the lock washer with lettering should face outward.
●When disassembling the bolts, loosen them one by one. Try to keep the bolts from having too much height
difference, otherwise the parts may bounce off under the action of the spring. The installation should also be
tightened one by one.
●Check the wear of each part of the clutch, and replace the defective parts with serious wear.
●For installation details, please refer to "ZT310 sliding clutch disassembly video".
31

Clutch assembly-2
COVER ASSEMBLY ADJ
1 1050754-023000 ZT180MN sliding clutch friction plate sub－assembly 1
2 1050754-022000 125×1.5－26Z clutch driven plate 1
3 1050753-012000 125X1.5 clutch driven piece 5
PROCEDURE:
●Friction plate assembly
Take out 1 piece of friction plate with large inner hole → 1 piece of follower plate with large inner hole → 1
piece of friction plate with large inner hole → follower plate with small inner hole → friction plate 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 7 friction plates and 6 driven plates, including 3
friction plates with large inner holes and 1 driven plate with large inner holes.
CAUTION：
●The direction of the outermost friction plate is inconsistent with the direction of other friction plates and is
stuck in the groove of the driving disc.
●Please check the friction lining during installation. If the friction lining becomes more black, you need to
replace a new set of friction lining.
●When installing, please check whether the follower is assembled evenly. If it is not, you need to replace it with
a new one.
●For installation details, please refer to "ZT310 sliding clutch disassembly video".
32

Clutch assembly-3
COVER ASSEMBLY ADJ
1 1251311-001094 M16×1 thin nut hexagonal 1 108±15N.m
2 1251514-002000 Lock washer, 16.2×28×2.4×2 1
3 1251512-011000 Thrust washer,16.2×30×1 1
4 1050754-002000 ZT180MN slip clutch driven disc 1
5 1251512-022000 Thrust washer, 22.2×37×2 1
6 1050753-004000 ZT173YMM clutch outer comp subassembly 1
7 1250602-014000 K27X32X29.3 Needle bearing 1
8 1050753-022000 ZT173YMM Clutch bushing (home－made) 1
9 1050753-010000 ZT173YMM clutch bush thrust pad 1
PROCEDURE:
●Clutch master and driven disc assembly
Use a 24# sleeve to remove bolt ⑴, remove lock washer ⑵, thrust ⑶, take out driven plate ⑷, thrust washer
⑸.
Take out the driving disc ⑹, needle roller bearing ⑺, bush ⑻, thrust pad ⑼.
CAUTION：
●Install the lock washer with the "OUT" mark facing outward.
●It is necessary to knock the edge of the nut at the notch of the spindle with a rubber hammer and a flat-head
screw during installation to further prevent loosening.
33
5-LEFT CRANKCASE COVER ASSEMBLY
Fig.1 LEFT CRANKCASE CHK

Disassembling the reduction gear
COVER ASSEMBLY ADJ
2 ZT180MN reduction gear cover sub－assembly 1
3 1051453-005000 69×3 Nitrile rubber o－rings 1
HK1208 bearing Old
4 1
1051054-028000 GB290－HK1212 Needle roller bearing New
5 ZT180MN Reduction gear cove 1
6 1251512-007000 Thrust washer,12.2×20×1 2
7 1051054-008000 ZT180MN reduction gear sub－assembly 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).
The bearing ⑸ is press-fitted in the reduction gear cover ⑸, and there is no need to take it out for non-special
circumstances. Reduction gear cover assembly ⑵ includes bearing ⑷ and reduction gear cover ⑸.
Remove the washer ⑹ and the reduction gear ⑺. One washer at the front and rear of the deceleration tooth⑹
CAUTION：
●It is recommended to replace the O-ring after disassembly to prevent oil leakage.
●Check the reduction gear, if it is damaged or worn, replace the reduction gear.
●When the reduction gear is installed, there is a washer on the front and the back, which can not be omitted.
●Please do not disassemble or assemble the bearing unless special circumstances. If it is necessary to replace the
bearing, please go to a maintenance organization capable of replacing it.
34

Disassembling the starter motor
COVER ASSEMBLY ADJ
2 1051054-014000 ZT180MN starter motor parts 1
PROCEDURE:
●Starter motor components
Use an 8# torx wrench to remove the 2 bolts ⑴, grasp the place ① and pull it out in the direction of the arrow,
and take out the starting motor ⑵.
CAUTION：
●When installing and removing, pay attention to whether the O-ring at ② has fallen off.
●Bolts (1) must be coated with appropriate amount of sealant, otherwise it may leak.
35

Remove left crankcase cover assembly
COVER ASSEMBLY ADJ
12±1.5N.m
3 1051653-004000 ZT173YMM left crankcase cover cushion piece 1
PROCEDURE:
●Remove the left cover assembly
Use an 8# sleeve to remove 7 bolts ⑵ and 1 bolt ⑴.
Remove the left cover assembly, take out the gasket ⑶ and 2 positioning pins ⑷.
CAUTION：
●Gasket ⑶ 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 flat, and apply a proper amount of sealant on the assembly plane of the box body. After installing the new
gasket (3), apply the sealant again on the upper surface of the gasket (3).
●When installing the left cover, all bolts should be evenly tightened at the corners to ensure tightness.
36

Disassembling the magneto stator
COVER ASSEMBLY ADJ
1 1251201-001094 M5×15－5# internal hexagonal round screw 1 5±1N.m
2 1051353-005000 ZT173YMM Stator pressure plate 1
3 1251201-002094 M6×35 internal hexagonal screw 3 12±1.5N.m
4 1051054-022000 ZT180MN magnetic motor stator sub－component A 1
5 1051054-024000 ZT180MN magnetic motor stator split washer A 1
PROCEDURE:
●Magnetic motor stator assembly
Use 5# inner hexagon to remove 3 bolts ⑴, take out the crimping plate ⑵.
Use 5# inner hexagon to remove 3 bolts (3), and take out the entire magneto stator sub-component (4).
Finally, take out the gasket ⑸.
CAUTION：
●When installing bolts ⑴ and ⑶, apply proper amount of thread fastening glue to the threads.
●Clean up the surface sealant indicated by the arrow before installation to ensure that the installation surface is
flat and smooth. Appropriate amount of flat sealant should be applied to the waterproof rubber sleeve according
to the arc surface.
●For installation details, please refer to "Video of Replacing Magneto Stator".
37

Left cover parts
COVER ASSEMBLY ADJ
1 1040953-002093 M14×1.5 plug screw (environmental color zinc) 1
2 1051453-009000 O－ring 13×2.8 1
3 M30×1.5 aluminum screw plug 1
4 1051453-003000 27.4×2.65 Acrylate rubber o－rings 1
5 ZT180MN left crankcase cover components 1
6 GB290－HK1210 needle rolling bearing 1
7 GB290－BK1010 Needle roller bearing 1 【1】
8 ZT180MN left crankcase cover 1
PROCEDURE:
●Screw plug assembly
Use 5# inner hexagon to remove the screw plug ⑴, and remove the O-ring ⑵.
Use 10# inner hexagon to remove the plug ⑶, and remove the O-ring ⑷.
CAUTION：
●When disassembling the screw plug, please check whether the O-ring is damaged, which affects its sealing
performance.
●Bearings are all press-fit, and cannot be disassembled under normal circumstances. Do not disassemble or
disassemble the bearings unless special circumstances. If it is necessary to replace the bearing, please go to a
maintenance organization capable of replacing it.
38
6-RIGHT CRANKCASE ASSEMBLY

Oil pump assembly
ASSEMBLY ADJ
4 1251513-001019 6.3×12×1.6 copper gasket 1
5 1050854-003000 ZT180MN Oil pump seat cushion 1
8 1051454-014000 9.8×2.5 acrylic o－ring 3
9 1050854-001000 ZT180MN Oil pump subassembly 1
10 1050854-004000 ZT180MN Oil pump driven gear 1
11 1251512-007000 12.2×20×1 thrust washer 1
PROCEDURE:
●Remove oil pump components
Use an 8# sleeve to remove the bolts ⑴, ⑵, and ⑶, take out the copper pad ⑷, and remove the entire oil
pump assembly.
Remove the seat cushion ⑸ and the two positioning pins ⑹ under the oil pump assembly to prevent loss.
Remove the 3 positioning pins ⑺ and O-ring ⑻ on the oil pump assembly.
Note: The oil pump subassembly ⑼ does not include gear ⑽ and thrust washer ⑾, please confirm the state
you need before placing an order.
CAUTION：
●Check the oil pump: shift the driven gear of the oil pump to check whether it can rotate normally. If it does not
rotate normally, the oil pump needs to be replaced.
●Check whether the oil pump seat cushion is deformed or cracked, if it is, it needs to be replaced. Check
whether the O-ring is cracked or hardened, if it is, it needs to be replaced.
●When assembling the oil pump, the parts should be sprayed with proper amount of oil.
39

Right box assembly-1
ASSEMBLY ADJ
1 1251311-002094 M18×1.0 thin nut hexagonal 1 108±15N.m
2 1251514-003000 Lock washer, 18.2×30×2.5×2 1
3 1251801-003000 5×5.5×19.2 general flat key 1
4 1050353-001000 ZT173YMM primary drive gear 1
5 1050154-041000 ZT180MN counterweight timing drive sprocket A 1
6 1251802-004000 5×5.5×26×9 woodruff key 1
7 1050454-017000 ZT180MN crankshaft right bearing limit retaining ring 1
9 1050654-001000 ZT180MN variable speed star cam 1
10 1250404-003000 GB119.2φ3×10 cylindrical pin 1
PROCEDURE:
●Remove the driving sprocket
Use a 24# sleeve to remove the nut ⑴, take out the lock washer ⑵, the flat key ⑶ and the primary drive tooth
⑷.
Pull out the driving sprocket ⑸, take out the half-circle key ⑹, the limit retaining ring ⑺.
●Remove the gearshift star wheel
Use 8# sleeve to remove bolt ⑻, take out cam ⑼ and cylindrical pin ⑽.
CAUTION：
●After putting in the retaining ring and half-circle key, spray proper amount of engine oil.
●When assembling the lock washer, the side marked with "out" faces outward.
●The timing chain can be assembled after the drive sprocket is installed, and the timing chain can be taken out
after the oil pump is disassembled.
40
7-LEFT CRANKCASE ASSEMBLY

Disassemble the bridge teeth and the magneto rotor
ASSEMBLY ADJ
1 1251512-004000 10.2×21×1 thrust washer 2
2 1051053-004000 ZT173YMM electric starting carrier gear 1
3 1251100-065094 M12X1.25X50 hexagonal flange bolts 1 103±15N.m
4 1251500-034000 12.3×26×3 gasket 1
5 1051054-027000 ZT180MN Magneto Motor Rotor Clutch Sub part A 1
PROCEDURE:
●Electric start bridge gear assembly
Take out the gasket and the bridge tooth. Note: There is a gasket before and after the bridge tooth.
●Magnetor rotor assembly
Grasp the magneto rotor with your hands, and remove the bolts with the gun +17# sleeve head. Use a 24#
sleeve to screw the M20*1.5 bolt into the middle position of the magneto and push the magneto out.
CAUTION：
● There is a semicircular key between the main shaft and the magneto, which is located in the groove on the
magneto and the main shaft. When installing, install it according to the groove.
●You can watch the detailed operation in "Replacement of Large Magnet Motor and Rectifier Teaching Video".
41
Fig.2 LEFT CRANKCASE Disassemble the large starting gear and the output CHK
ASSEMBLY sprocket ADJ
1 1251512-028000 26.2×38×1 thrust washer 2
2 1051054-012000 ZT180MN electric start large tooth A 1
3 1250602-028000 KT26×32×21.8 needle bearing 1
4 1051354-006000 30.2×41.2×1.5 thrust washer 1
5 1251300-066093 M18×1.0 lock nut level 10 (environmental color zinc) 1 95±15N.m
6 1051354-002000 ZT180MN output sprocket nut lock piece 1
7 1050354-023000 Rubber－covered output sprocket subassembly 1
1050254-001000 ZT180MN Output chain wheel shaft sleeve Ordinary
8 1
1050254-007000 ZT180MN output sprocket bushing (lengthened) Lengthened
9 1051454-011000 22.5×2.5 fluoro rubber o－ring 2
PROCEDURE:
●Starting gear assembly
Take out the thrust washer ⑴, start gear ⑵, needle bearing ⑶, thrust washer ⑷. Note: Start the big gear (2), 1
thrust washer at the front and back (1).
●Output sprocket assembly
Before disassembly and assembly, use a hammer and a flat blade to knock the locking piece ⑹ flat, use a 24#
sleeve to remove the bolt ⑸, remove the locking piece ⑹, and pull out the output sprocket ⑺ and sprocket shaft
sleeve ⑻. The O-ring ⑼ is installed in the groove inside the sprocket sleeve ⑻.
CAUTION：
●After installing the nut, knock one end of the locking piece flush with one end of the nut. Prevent bolts from
falling off.
●When installing the shaft sleeve, please check whether the two O-rings inside the shaft sleeve have fallen off.
42

Remove the gear switch
ASSEMBLY ADJ
2 1051354-005000 ZT180MN Gear switch tension disc 1
3 1250201-034093 GB818M5×20 (environmental color) 2 5±1N.m
4 1050654-005000 ZT180MN Gear switch 1
5 1051454-011000 22.5×2.5 fluoro rubber o－ring 1
6 1050654-007000 ZT180MN gear Display contact parts 1
PROCEDURE:
●Gear switch assembly
Use an 8# sleeve to remove the 2 bolts ⑴, and remove the crimping plate ⑵.
Use a cross batch to remove the 2 bolts (3), and take out the gear switch ⑷, O-ring ⑸ and contact ⑹.
CAUTION：
●Bolt ⑴Appropriate amount of thread fastening glue should be applied when installing.
●After installing the contact ⑹, spray a proper amount of engine oil on it.
●O-rings are for one-time use and must be replaced after disassembly to prevent oil leakage.
43
8-CRANKCASE
CHK
Fig.1 CRANKCASE Crankcase disassembly-1
ADJ
4 1251513-001019 6.3×12×1.6 copper gasket 1
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, 2 bolts ⑶, 7 bolts ⑵ and 1 copper pad ⑷ on the left crankcase body.
CAUTION：
●The bolts must be tightened or loosened diagonally when removing and installing.
44
8-CRANKCASE
CHK
ADJ
1 1051654-005000 ZT180MN Crankcase gasket 1
3 1050653-003000 ZT173YMM gear swift comp 1
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.
Press the shift shaft ⑶ in the direction of the arrow by hand, and then take out the shift shaft ⑶.
CAUTION：
●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 one-time use. Once removed, it must be replaced, otherwise it will cause oil leakage.
●Before assembling the shift shaft, apply a proper amount of engine oil on the surface of the part.
●Before installing the box body, make sure that the box body assembly plane is smooth and flat and apply a
proper amount of sealant on the box body assembly plane. After installing the new gasket ⑴, you need to apply
the sealant again on both sides of the gasket ⑴ according to the red line.
45
8-CRANKCASE
CHK
ADJ
1 1050653-007000 ZT173YMM fork axle, gear shift 1
2 1050654-003000 ZT180MN variable speed countershaftright fork 1
3 1050654-004000 ZT180MN shifting spindle in the fork 1
4 1050654-002000 ZT180MN shifting auxiliary shaft left shift fork 1
5 1050654-006000 ZT180MN Shift speed changer subassembly 1
PROCEDURE:
●Cabinet split
Pull out the shift fork shaft ⑴, take out the left shift fork ⑵, middle shift fork ⑶, right shift fork ⑷. Note:
The marks "L", "R" and "C" on the shift fork correspond to the left shift fork ⑵, the right shift fork ⑶, and the
middle shift fork ⑷ respectively.
Take out the variable speed drum ⑸.
CAUTION：
●When installing, the side with the mark on the fork should be installed upwards.
●Check the fork shaft, roll the fork shaft on a flat surface and find that it is bent, it must be replaced.
●Check the shift fork, whether there are any problems such as bending, damage, cracks, etc. at the shift fork
jaws. If there is, it must be replaced.
●Check the variable speed drum, whether the variable speed drum has abrasion, scratches, etc., if there is, it
must be replaced.
●When installing, apply proper amount of engine oil on the surface of the parts.
46
8-CRANKCASE
CHK
ADJ
1 1050254-012000 ZT180MN drive spindle sub－component A 1
1050254-005000 ZT180MN Transmission countershaft parts Ordinary
2 1
1050654-011000 ZT180MN transmission auxiliary shaft sub－assembly Lengthened
3 1050554-006000 ZT180MN Balance shaft assembly A 1
4 1050454-012000 ZT180MN Crankshaft connecting rod assembly 1
5 1251802-003000 4×4.6×25×14 woodruff key 1
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.
Stagger the angle between the crankshaft assembly and the balance shaft (3), hold the upper crank with one
hand, and tap the lower crank with a rubber hammer with the other hand to take out the crankshaft assembly and
balance shaft (3).
Take out the half circle key ⑸ from the crankshaft ⑷.
CAUTION：
●When installing and removing, the crankshaft connecting rod cannot hit the box.
●Check the balance shaft, if there are scratches or wear, replace the balance shaft.
●The crankshaft and balance shaft should be installed as shown in the left figure. The two marked teeth on the
crankshaft clamp the marked teeth on the balance shaft.
●Apply a proper amount of engine oil on the surface of the parts before installation.
47

ASSEMBLY ADJ
1 1251100-168093 M6×15－10×7.8 pivot bolt(Zinc) 1 12±1.5N.m
2 1051254-003000 ZT180MN tensioning strip sub－component B 1
3 1251512-001000 6.2×15×1 thrust washer 2
4 1251100-068093 M6×14－9×2.6 pivot bolt (color zinc) 1 12±1.5N.m
5 1050653-002000 ZT173YMM gear swift limit sprocket comp 1
6 1050654-008000 ZT180MN limit stop wheel torsion spring 1
8 1050853-010000 66×50 trapezoid coarse coarse filter 1
9 1051353-001000 ZT173YMM oil and gas baffle sub－assembly 1
PROCEDURE:
●Tension bar assembly
Use 5# inner hexagon to remove bolt ⑴, take out the tension bar ⑵ and thrust washer ⑶.
●Stop wheel assembly
Use a 12# sleeve to remove bolt ⑷, take out stop wheel ⑸, thrust washer ⑶ and torsion spring ⑹.
●Coarse filter
Use an 8# sleeve to remove the bolt ⑺ and remove the coarse filter ⑻.
●Oil-air baffle
Use an 8# sleeve to remove the bolt ⑺, and pull out the oil-air baffle ⑼.
CAUTION：
●When installing bolts ⑴ and ⑺, apply proper amount of thread fastening glue to the threads.
48

ASSEMBLY ADJ
2 1051353-006000 ZT173YMM spindle bearing baffle 1
4050254-003000 ZT180MN Right crankcase assembly
3 1
4050254-009000 ZT180MN right crankcase sub－assembly (V)
4 1250601-082000 6304－C3 deep groove ball bearing(FAG) 1
5 1250601-052000 GB276－62/22/P5 deep groove ball bearing (nitride) 1
6 1250601-057000 GB276－6203/P5 deep groove ball bearing (nitride) 1 After-sale
7 1250602-026000 GB290－HK2012 Needle roller bearing 1
8 4050254-005000 ZT180MN right crankcase parts(without bearing) 1
PROCEDURE:
●Spindle bearing baffle
Use an 8# sleeve to remove the 2 bolts (1), and remove the bearing baffle (2) from the right box assembly (3).
●Bearing parts and after-sales parts
The bearings ⑷, ⑸, ⑹, and ⑺ are all press-fitted on the right box ⑻ and will not be damaged under normal
circumstances.
CAUTION：
●Bolt ⑴ When installing, apply proper amount of thread fastening glue on the thread.
●"ZT180MN right crankcase assembly assembly" contains "ZT180MN right crankcase assembly assembly
(excluding bearings)" and 4 bearings. Please confirm the accessories you need before placing the order.
●Please do not disassemble or assemble the bearing unless it is special. If the bearing must be replaced, please
go to a maintenance organization capable of replacing it.
49

Left crankcase parts
ASSEMBLY ADJ
2 1051354-001000 ZT180MN countershaft oil seal cover 1
3 1251400-002000 M10×1.25 Rebound spring 1 25±4N.m
4 1251513-004019 10.3×20×2 copper gasket 1
5 1251100-066093 M12×1.5×15 oil drain bolt (color zinc) 1 25±4N.m
6 1244100-033000 Combined sealing gasket12×φ20×2 1
7 1051354-003000 63/22 deep groove ball bearing fixed pin 2
4050154-003000 ZT180MN Left crankcase assembly Ordinary
8 1
4050154-008000 ZT180MN left crankcase sub－assembly (V) Lengthened
PROCEDURE:
●Oil seal cover assembly
Use an 8# sleeve to remove the 2 bolts (1), and remove the oil seal cover (2).
●Return spring column
Use 14# to remove the spring column ⑶, and remove the copper pad ⑷.
●Drain bolt
Use a 14# sleeve to remove the oil drain bolt ⑸ and take out the gasket ⑹.
●Bearing limit piece
Use an 8# sleeve to remove the 2 bolts ⑴, and take out the 2 bearing limit pieces ⑺.
CAUTION：
●When installing bolts ⑴ and ⑶, apply proper amount of thread fastening glue to the threads.
●The gasket ⑹ is recommended to be replaced after disassembly to prevent oil leakage.
50

After-sales spare parts for left crankcase
ASSEMBLY ADJ
1 1051554-002000 FB30×42×7 hydrogenated nitrile oil seal 1
2 1051553-005000 FB14×28×7 Fluorine rubber oil seal 1
3 1250602-022000 GB290－HK1010 needle roller bearing 1
4 1250601-082000 6304－C3 deep groove ball bearing(FAG) 1
After-sale
5 1250601-036000 GB276－6202RS/P6 deep groove ball bearing (nitride) 1
6 1250601-056000 63/23RS/P5 deep groove ball bearing (nitriding) 1
7 1250602-020000 HK222910 needle roller bearing 1
8 4050154-004000 ZT180MN left crankcase parts(without bearing) 1
PROCEDURE:
●Left box after-sales spare parts
Oil seals ⑴, ⑵, bearings ⑵, ⑷, ⑸, ⑹, ⑺ are all press-fitted on the left box body.
CAUTION：
●When the oil seal is press-fitted, the marking surface of the oil seal should face outwards. Do not install it
backwards to cause oil leakage. It is recommended to go to a maintenance organization capable of doing the
replacement.
●Please do not disassemble or assemble the bearing unless it is special. If the bearing must be replaced, please
go to a maintenance organization capable of replacing it.
51
11- GEARSHIFT AND TRANSMISSION
Fig.1 GEARSHIFT AND The position relationship of the components of the CHK
TRANSMISSION speed change and transmission mechanism ADJ
ZT180MN Transmission countershaft parts Ordinary
2 1
1050654-011000 ZT180MN transmission auxiliary shaft sub－assembly Lengthened
3 1050654-006000 ZT180MN Shift speed changer subassembly 1
4 1050653-007000 ZT173YMM fork axle, gear shift 1
5 1050654-003000 ZT180MN variable speed countershaftright fork 1
6 1050654-002000 ZT180MN shifting auxiliary shaft left shift fork 1
7 1050654-004000 ZT180MN shifting spindle in the fork 1
PROCEDURE:
●Assembly position relation of speed change and transmission mechanism
The positions of main shaft ⑴, counter shaft ⑵, speed change drum ⑶, fork ⑸, ⑹, ⑺, and fork shaft ⑷ are
shown in the left figure.
The protruding ends of the shift forks ⑸ and ⑹ are assembled on the shift drum ⑶, and the groove is locked
on the counter shaft ⑵. The protruding end of the shift fork ⑺ is transferred to the transmission drum ⑶, and
the grooved end is locked on the main shaft ⑴.
When disassembling, first take out the shift fork shaft ⑷, remove the shift forks ⑸, ⑹, ⑺, take out the speed
change drum ⑶, and finally remove the main shaft ⑴ and the counter shaft ⑵ at the same time.
CAUTION：
●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 ⑹ near the left crankcase is placed in the sixth gear slot of the counter shaft.
52
Fig.2 GEARSHIFT AND CHK

Spindle assembly relationship
TRANSMISSION ADJ
2 ZT173YMM drive spindle B 1
3 ZT180MN Main shaft five gear 2
4 19Z×1M×37.5×1.5×25.5 evolvent Spline gasket 2
5 GB894.1 shaft circlip with φ20×1.2 1
6 ZT180MN Main shaft three or four gear 1 【3】
7 ZT180MN spindle six gears 1
8 ZT180MN spindle six gear sleeve 1
9 ZT180MN spindle second gear 1
10 15.2×25×1.0 thrust washer 1
PROCEDURE:
●Spindle assembly relationship
The assembly relationship of the gears on the main shaft is shown on the left.
CAUTION：
●The spindle is not allowed to be disassembled under special circumstances, and only the assembly relationship
is shown here.
53
Fig.3 GEARSHIFT AND CHK

Countershaft assembly relationship
TRANSMISSION ADJ
1 ZT180MN Transmission countershaft parts 1
2 17.2×27×1 thrust washers 1
3 ZT173YMM countershaft gear shaft sleeve 1
4 ZT180MN countershaftone gear 1
5 18.2×28×1.5 thrust washer 1
6 ZT180MN Countershaft five gear 1
7 23×1.2 shaft retaining ring 1
8 22Z×1M×37.5×1.5×27.5 involute spline washer 1
9 ZT180MN Countershaft three gear 1
10 ZT173YMM countershaftbaffles of third－forth gears 1 【3】
11 GB119.2φ2×5 cylindrical pin 1
12 ZT180MN Countershaft four gear 1
13 ZT180MN transmission auxiliary shaft subassembly 1
14 ZT180MN Countershaft six gear 1
15 25.2×31×1.0 thrust gasket 1
16 ZT180MN countershaftsecond gear shaft sleeve 1
17 ZT180MN countershaftsecond gear shaft sleeve 1
18 23.1 × 28.5 × 2 Thrust Washer 1
PROCEDURE:
●Counter shaft assembly
The assembly relationship of the gears on the countershaft is shown in the left figure.
CAUTION：
●It is forbidden to dismantle the countershaft except in special circumstances, here only the assembly relationship is
indicated.
54

Taller - MOTOR ZONTES350

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Manual taller - Servicio Motor 350

Mensajes por WhatsApp + 549 11 2640 8612

2 2-Cylinder head assembly

3 3-cylinder block assembly

Page 1 ，Toatal 54 Pages

4 4-right crankcase cover assembly

5 5-Left crankcase cover assembly

Page 2 ，Toatal 54 Pages

6 6-Right crankshaft body case assembly (1)

7 7-Left crankcase assembly (1)

9 9-Right crankshaft case assembly (2)

10 10-Left crankcase assembly (2)

Page 3 ，Toatal 54 Pages

11 11- Gearshift and transmission mechanism components

Page 4 ，Toatal 54 Pages

Fig.1 PREPARATION CHK

Fig.2 PREPARATION CHK

Fig.3 PREPARATION CHK

Fig.1 CYLINDER HEAD CHK

Fig.2 CYLINDER HEAD CHK

Fig.3 CYLINDER HEAD CHK

Fig.4 CYLINDER HEAD CHK

Fig.5 CYLINDER HEAD CHK

Fig.6 CYLINDER HEAD CHK

Fig.7 CYLINDER HEAD CHK

Fig.8 CYLINDER HEAD CHK

Fig.9 CYLINDER HEAD CHK

Fig.10 CYLINDER HEAD CHK

Fig.1 CYLINDER BLOCK CHK

Fig.2 CYLINDER BLOCK CHK

Fig.3 CYLINDER BLOCK CHK

Fig.4 CYLINDER BLOCK CHK

Fig.1 RIGHT CRANKCASE CHK

Fig.2 RIGHT CRANKCASE CHK

Fig.3 RIGHT CRANKCASE CHK

Fig.4 RIGHT CRANKCASE CHK

Fig.5 RIGHT CRANKCASE CHK

Fig.7 RIGHT CRANKCASE CHK

Fig.8 RIGHT CRANKCASE CHK

Fig.9 RIGHT CRANKCASE CHK

Fig.10 RIGHT CRANKCASE CHK

Fig.11 RIGHT CRANKCASE CHK

Fig.12 RIGHT CRANKCASE CHK

Fig.1 LEFT CRANKCASE CHK

Fig.2 LEFT CRANKCASE CHK

Fig.3 LEFT CRANKCASE CHK

Fig.4 LEFT CRANKCASE CHK

Fig.5 LEFT CRANKCASE CHK

Fig.1 RIGHT CRANKCASE CHK

Fig.2 RIGHT CRANKCASE CHK

Fig.1 LEFT CRANKCASE CHK

Fig.3 LEFT CRANKCASE CHK

Fig.1 RIGHT CRANKCASE CHK

Fig.2 RIGHT CRANKCASE CHK

Fig.1 LEFT CRANKCASE CHK

Fig.1 LEFT CRANKCASE CHK

Fig.2 GEARSHIFT AND CHK

Fig.3 GEARSHIFT AND CHK

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