Main technical specifications

Items Specifications
Model ZS177MM
Single cylinder, water cooling, 4 stroke,
Type, number of cylinder SOHC
Bore×Stroke φ77×53.6mm
Cylinder displacement 249.6ml
Compression ratio （11.1～12）：1
Type of carburetor Vacuum diaphragm type
Engine Air cleaner Dry sponge
Lubrication system Pressure + Splash
Starting system Electric start + kick start
Max. power/Corresponding RPM 18.5(1±5%)kW/9000(1±5%)rpm
Max. torque/ Corresponding RPM 22(1±5%)N.m/7000(1±5%)rpm

Idling 1500±100 r /min

Clutch Manual wet multi-plate

Normally engaged two-stage
Transmission
6-speed transmission
Reciprocating manoeuvre with left
Shifting system
foot
Primary ratio 2.91
Transmission st
1 gear 2.58
system nd
2 gear 1.8
rd
3 gear 1.33
Gearing
4th gear 1.1
th
5 gear 0.96
th
6 gear 0.88
Mode of ignition C.D.I (contactless ignition)
Equivalent to Champion RG6YC
Ignition
Spark plug and spark plug with flat seating in
system
function
Spark plug gap 0.7mm-0.8mm
Grade of fuel ≥RQ93
Specification SJ 5W/40
Fuel
Oil Capacity
1.5L
C

共 31 页 第1页
 汽缸头和气门

Cylinder head and valve

维修须知 汽缸头的检查
Maintenance instructions Inspection of cylinder head
故障排除 测量气门座接触面的宽度
Troubleshooting Measuring width of mating face at valve
汽缸头盖的拆卸 seat
Removal of cylinder head cover 汽缸头的组装
摇臂检查 Assembly of cylinder head
Inspection of rocker arm 汽缸头盖的组装
汽缸头的拆卸 Assembly of cylinder head cover
Removal of cylinder head 凸轮轴的组装
汽缸头的分解 Assembly of camshaft
Disassembly of cylinder head 汽缸头的安装
气门和气门弹簧的检查 Installation of cylinder head
Inspection of valve and vale spring 汽缸头盖的安装
气门座的检查、研磨 Installation of cylinder head cover
Inspection and grinding of valve seat

维修须知
Maintenance instructions

注意事项：
Cautions:
● 凸轮轴润滑由缸头上油道经摇臂轴油孔而润滑的，缸头上的油道绝对不能有异物
进入，并保持畅通。
● Keep foreign matters from going into oil gallery through the cylinder head and
oil gallery unobstructed in case camshaft is lubricated by allowing oil to go into
oil gallery through the cylinder head and via oil port on rocker arm shaft.
● 在安装汽缸头之前，缸头定位销一定要装配好。
● Cylinder head locating stud shall be installed in place before installing cylinder
head.
● 凸轮轴不能有划伤痕迹，装配时先打上机油。
● Camshaft shall be free of any scratch and apply oil onto it before installation

共 31 页 第2页
 项目 Item 标准值 mm 维修极限值 mm
Normal value mm Maintenance limit value
mm
摇臂与缸头盖摇臂开档的轴向间隙 0.05～0.3 0.5
Axial clearance between rocker arm and
cylinder head rocker arm opening
摇臂与摇臂轴的径向间隙 0.016～0.045 0.08
Rocker arm –to- rocker arm shaft radial
clearance
气门弹簧自由长度 48.35 47.5
Free length of valve spring
气门间隙 0.04～0.06 ------
Valve clearance
凸轮轴基圆跳动 0.02 0.04
Camshaft basic circle runout

项目 Item 标准值 mm 维修极限值 mm

Normal value mm Maintenance
limit value mm
气门杆外径 进气 φ4.972～φ4.987 φ4.96
气门 Valve stem outer diameter Intake
Valve 排气 φ4.96～φ4.975 φ4.94
Exhaust
气门导管内径 进气 φ5～φ5.012 φ5.035
Valve stem inner diameter Intake
排气 φ5～φ5.012 φ5.035
Exhaust
气门杆与导管间隙 进气 0.013～0.04 0.07
Valve stem -to- guide Intake
clearance 排气 0.25～0.052 0.08
Exhaust
气门密封带宽度 1.5 ----
Valve sealing strip width
平面度 0.04 0.05
汽缸头 Surface flatness
Cylinder head
气门座工作面宽度 0.8 ----
Valve seat work face width
各部件维修参数
Maintenance specifications for all components

共 31 页 第3页
 故障排除

Troubleshooting

缸内气压低： 排气有黑烟
Lower pressure inside the cylinder 1、 气门导管磨损
1、 气门 2、 挡油罩渗漏或损坏
----------气门间隙调整不正确 3、 汽缸头垫渗漏
----------气门密封不严 4、 活塞环间隙过大
----------配气正时不对
----------气门弹簧断裂 Black smoke mixed with exhaust gas
1. Valve 1. Worn valve guide
----------Improper adjustment of valve 2. Oil-proofing cover with leakage or
clearance damaged oil-proofing cover
---------- Poor valve tightness 3. Cylinder head gasket with leakage
---------- Improper valve timing 4. Excessive piston ring clearance
---------- Broken valve spring
噪音过大或异响
2、 汽缸头 Cylinder head 1、 气门调整不正确
----------火花塞与汽缸头连接不紧密 2、 气门卡住或气门弹簧断裂
----------汽缸头垫损坏 3、 上摇臂过度磨损
----------汽缸头有裂纹或砂眼 4、 配气正时不准
2. Cylinder head 5、 凸轮轴磨损
----------Poor connection between spark plug Excessive noise or S&R
and cylinder head 1. Improper adjustment of valve
---------- Damaged cylinder head 2. Stuck valve or broken valve spring
----------Cracked or blistered cylinder head 3. Overly worn upper rocker arm
4. Improper valve timing
3、 缸体、活塞、活塞环 5. Worn camshaft
----------活塞环间隙过大或断裂
----------活塞有裂纹或过度磨损
----------缸体内径过大或砂眼
3. Cylinder block, piston, piston ring
----------Excessive piston ring clearance or
broken piston ring
----------Cracked or overly worn piston
----------Excessive cylinder block bore or
blistered cylinder block bore

共 31 页 第4页
共 31 页 第5页
 汽缸头盖的拆卸
Removal of cylinder head cover

1.拆下汽缸头盖进气、排气两侧气门室盖的 4 颗
GB/T16674 小盘 M6×20 的紧固螺栓；
2.拆下气缸头进气、排气两侧的气门室盖；
1. Remove the 4 GB/T16674 pan head M6×20tightening
bolts from both valve the valve covers on both intake side
and exhaust side on the cylinder head ;
2. Remove valve covers on both intake side
and exhaust side from the cylinder head;

3.拆下紧固缸头盖的 2 颗 GB/T16674 小盘螺栓

M6×60、2 颗 GB/T16674 小盘螺栓 M6×35、4 颗
GB/T16674 小盘螺栓 M6×30，取下 2 颗 A88 进气
管垫圈并将其装到 M6×60 的螺栓上；
3.Remove 2 GB/T16674 pan head bolts M6×60, 2
GB/T16674 pan head bolts M6×35, 4 GB/T16674
pan head bolts M6×30 and 2 A88 intake gaskets
from the cylinder head cover and install such 2 A88 intake
gaskets on the bolts M6×60;

4.拆下缸头盖；
Remove the cylinder head cover

汽缸头的拆卸
Removal of cylinder head
1 拆下 NC250 缸头密封胶套，NC250 凸轮轴档板；
2.拆下 GB/T16674 小盘螺栓 M6×16 及 ZS500 定
位板垫圈 6.5×1.5×18；
1. Remove NC250 cylinder head sealing rubber
sheath and NC250 camshaft baffle;
2. Remove GB/T16674 pan head bolts M6×16 and
ZS500 locating plate washer 6.5×1.5×18;

共 31 页 第6页
 3.拆下 2 颗紧固张紧器的 GB/T16674 小盘螺栓
M6×20，然后在拆下张紧器螺栓、张紧器组合、张紧
紧器密封垫；
4.拆下套在正时从动链轮上的正时链条；
5.拆下凸轮轴组合；
3. Remove 2 GB/T16674 pan head bolts M6×20 from
tensioner and remove the tensioner bolt, tensioner
assembly,
tensioner gasket;
4.Remove the timing chain from the timing driven chain
wheel;
5.Remove the camshaft assembly;

6.拆下连接缸头、缸体的 GB/T16674 小盘 M6×25

螺栓；
6.Remove the GB/T16674 pan head bolt M6×25 that
attaches cylinder head to cylinder block;

7.拆下 4 颗 ZS500A、B 栓螺母 M10×1.25，然后

拆下 4 颗 ZS500A、B 栓螺母垫圈 10.5×2×20；
8. 拆下气缸头；
7.Remove 4 ZS500A and B nuts M10×1.25 and
remove 4 ZS500A and B nut washers 10.5×2×20

8.Remove the cylinder head;

汽缸头盖的分解
Disassembly of cylinder head cover
1. 拆下缸头盖上 2 颗 NC250 摇臂轴定位板螺栓
M14×1，
1. Remove 2 NC250 rocker arm shaft locating
plate
Bolts M14×1 on the cylinder head
2.取下进、排气摇臂轴，进、排气摇臂；
2. Remove intake and exhaust rocker arm shafts
and their rocker arms.

共 31 页 第7页
 气缸头的分解
Disassembly of cylinder head
用气门拆卸器将气门弹簧压下，拆下气门锁
夹；然后放松气门拆卸器，取下气门弹簧座，气门弹
簧和气门。

注意：
1.为了防止气门弹簧产生永久变形，不能过
份的压缩气门弹簧，只需能拆下气门锁夹即
可；
2.拆下的全部零件均应作好标记，确保在装
配时达到原来的装配位置。
Depress valve spring using valve remover and
remove
valve collet; and release valve remover before
removing valve spring seat, valve spring and valve.

Note：

1. To prevent permanent distortion of valve spring, keep valve

spring being depressed to an extent that allows for removal of

valve collet.

2. Mark all removed components and make sure all can be

installed where they were.

气门和气门弹簧的检查
Inspection of valve and valve spring
检查气门是否弯曲、烧伤或气门杆有不正常的磨
损，测量气门杆外径。维修极限值：
Inspect valve for distortion, burnt surface or
unusually worn valve stem. Measure valve stem
outer diameter.
Maintenance limit value:
进气：φ4.96mm
排气：φ4.94mm
Intake: φ4.96mm
Exhaust: φ4.94mm

接触面的宽度维修极限值：1.5mm

注意：
如果气门接触面很粗糙，磨蚀不均匀或与气
门座接触不正常，不能保证密封性能，均应更

共 31 页 第8页
 换气门。

Maintenance limit value for width of mating face:

1.5mm

Note:

Install new valve in case mating face on the valve is found to

be very rough, to have such uneven wear or unusual valve seat

mating face that required tightness can not be met.

测量气门弹簧的自由长度：48.35mm
维修极限值（进气和排气）
弹簧： 47.5 mm
Measure free length of valve spring: 48.35mm
Maintenance limit value (intake and exhaust)
Spring: 47.5 mm

摇臂及摇臂轴的检查
Inspection of rocker arm and rocker arm shaft

检查摇臂是否有磨损、毁坏、摇臂滚轮的轴向
间隙，如磨损、毁坏现象严重或摇臂滚轮的轴向间
隙偏大则均需更换新的摇臂。
Inspect rocker arm for wear, damage and improper
axial clearance of rocker arm roller. Install new rocker arm
in case of wear, severe damage or excessive axial
clearance of rocker arm roller.

检查摇臂轴是否有磨损现象，如果磨损现象严
重则需更换新的摇臂轴。
Inspect rocker arm shaft for wear. In case of severe
wear, install new rocker arm.

共 31 页 第9页
 凸轮轴部件的检查
Inspection of camshaft components
1.检查凸轮轴表面是否有磨损、毁坏现象及凸轮
轴两端的轴承转动是否灵活，如磨损现象严重或
轴承转动有发卡的现象，则应更换新的凸轮轴部
件；
1.Inspect camshaft surface for wear, damage and
sticky rotation of bearings at both ends of camshaft.
In case of severe wear or sticky rotation of bearing,
install new components.
2.检查 NC250 凸轮轴减压阀甩块组合是否有裂纹
、破裂等现象及减压阀离心甩块与减压阀芯轴是否
有松动的现象，如果有则需更换减压阀甩块组合。
2.Inspect NC250 camshaft pressure relief valve flail
block for crack, fracture and other damages as well as
for loose centrifugal flail block of pressure relief valve
and loose pressure relief valve spindle. In case of loose
components, install a new pressure relief valve flail
block assembly.

汽缸头的检查
Inspection of cylinder head
1. 检查汽缸头的密封性是否良好，如果缸头的密
封性较差，则应更换新的气缸头或气门 ；
1. Inspect the cylinder head for poor air
tightness. In case of poor air tightness, install a
new cylinder head or valve(s);
2.检查火花塞孔及气门座是否有裂纹；
2. Inspect spark plug and valve seat for crack;
3.检查汽缸头是否变形，并用刀口尺和塞尺检查
汽缸头的平面度。
3. Inspect the cylinder head for distortion and
check the surface flatness of cylinder head with
knife straight edge and filler gauge.

气门座的检查、研磨
Inspection and grinding of valve seat
将燃烧室内的积碳完全清除干净，在气门座上均
匀涂抹一层薄薄的红印油，将气门放在气门座上轻
轻敲击气门勿旋转，然后抽出气门，若气门工作面
上的接触痕迹有间断，则应对气门座进行研磨修
理。
Clear carbon deposit inside the combustion
chamber and apply an even and thin layer of red
stamp-pad ink to the valve seat, and then place
valve onto the seat and tap it for loose
connection, and then pull it out to check it for
interruptive contact trace. If there is any
interruptive contact trace, valve seat shall be
共 31 页 第10页
ground.
首先，清除进、排气门座上的积碳，再在气门座
上涂上研磨剂，然后用橡胶头的研磨工具吸上气
门，对气门座进行研磨。
At first, clear carbon deposit on intake and
exhaust valve seats and apply abrasive to the
valve seat, and then absorb the valve using an
abrasive tool with a rubber end and grind the
valve seat.

气门导管的检查
Inspection of valve guide
用百分表测量每一根气门导管的内径，并作好
记录。
Measure each valve guide inner diameter with
dial gage and make a record.
维修极限值：
进气：φ5.035 mm
排气：φ5.035 mm
Maintenance limit value:
Intake: φ5.035 mm
Exhaust: φ5.035 mm
注意：
测量气门导管的内径前，应先将导管内的积
碳完全清除干净。

Note:
Clear carbon deposit inside the guide
before measuring valve guide inner
diameter.

如果需要更换气门导管，则气门座应重新进行
表面研磨处理，并将各气门插入导管内，观察其运
动情况，最后算出气门杆与气门导管之间的间隙。
In case a new valve guide is installed, the valve
seat shall be ground again and insert each valve
into the guide and observe the operation of valve.
At last, measure valve stem –to-valve guide
clearance.

维修极限间隙：进气：0.07 mm
排气：0.08mm
Maintenance limit value:
Intake: 0.07 mm
Exhaust: 0.08mm

共 31 页 第11页
 气门导管的更换
Replacement of valve guide
将汽缸头放在恒温箱里加热至 100～150 摄氏度
后，取出并支起汽缸头（注意不要烫伤），用气门
拆装工具将气门导管朝摇臂室一侧打出。
Heat the cylinder heat in the constant
temperature oven to a temperature ranging from
100 to 150 degrees Celsius, and take it out of the
constant temperature oven and set it up (to keep
away from scald) and hit valve guide toward
rocker arm compartment to get it out of the
cylinder head using a valve remover.

注意：拆卸气门导管时，不要损坏汽缸头。

Note: Do not damage cylinder head when

removing valve guide

将新的气门导管压装好，待汽缸头冷却后对新安
装的气门导管进行扩孔。
Press and fit new valve guides and ream such
new valve guides when cylinder head has cooled
down.
注意：
扩孔时，须在铰刀上涂上切削油，装入或取
出铰刀时，都应进行转动。

Note:

Apply cutting fluid onto the reamer during reaming, and keep rotating

the reamer when inserting it into or taking it out of valve guides.

最后，用清洗剂对汽缸头进行清洗，并用压缩
空气清除积存在汽缸头上的金属切屑
At last, clean the cylinder head with cleaning
agent and clear metal filings deposited on the
cylinder head with compressed air.

共 31 页 第12页
 测量气门座接触面的宽度
Measuring width of mating face at valve seat

维修极限值：1.5 mm
Maintenance limit value: 1.5 mm

如查气门座太宽、太窄或有凹痕，则应研磨气门座，使之
达到正确的密封程度。
In case valve seat is found to be excessively wide, narrow or
to have dents, such valve seat shall be ground to an extent
that will meet tightness requirements.
研磨气门时，使用电动枪套上橡胶管（采用紧配合），然后
将气门杆套在橡胶管上，将研磨用的石墨膏涂少许在气门密封
带上，然后贴合在气门座密封线上，开动电枪，转动气门，进
行气门与座圈配合研磨。
Mount the valve stem on the rubber tube which is mounted
on the electric grinding tool (tight fit is used), and apply a
slight amount of abrasive graphite coating grease onto the
valve sealing strip and stick the valve sealing strip onto the
sealing line on the valve seat before turning on the electric
grinding tool and rotating the valve for grinding mating face
between valve and valve seat.
研磨后要检查气门与座圈的密封线是否已研磨出来，否则
应重新研磨。如实在研磨不到位应更换气门或缸头。
Inspect if the sealing line has appeared by grinding.
Otherwise, grinding shall continue. Install new valve or
cylinder head if continued grinding does not work.

汽缸头的组装
Assembly of cylinder head

1.将气门弹簧下座、挡油罩装到气门导管上；
2.将进、排气门杆涂上润滑油后，装入气门导管，装好气门
弹簧、气门弹簧上座及气门锁夹；
3.再用气门拆卸器压下气门弹簧，然后将气门锁夹装入气门
弹簧座内；
1. Install the valve spring lower seat and oil-proofing cover
on the valve guides.
2. Apply lubricating oil to the intake and exhaust valve
stems before fitting in valve guides and install valve spring,
valve spring higher seat and valve collet as well;
3. Depress valve spring using a valve remover and fit the
valve collet into the valve spring seat;
注意：
为防止气门弹簧产生永久变形，不能过分地压缩 此边为摇臂轴切边，在装配摇臂轴时，此边应
弹簧，以能装入气门锁夹即可。 朝缸头盖上悬挂孔
The sides that arrows point toward are scrap
edges of rocker arm shaft. When installing
rocker arm shaft, such scrap edges shall face
共 31 页 第13页 toward higher suspension ports on the cylinder
head cover.
 Note:
To prevent permanent distortion of valve

spring, keep valve spring being depressed to an

extent that allows for removal of valve collet.

4.检查气门锁夹装配是否到位；
5.对组装好的汽缸头组合进行气密性检测，若汽缸头组合无泄
露则可进行下一步操作。
4. Inspect valve collet for improper installation;
5. Inspect cylinder head assembly for air leakage. In case
there is no air leakage, proceed with the next step.

气缸头盖的组装
Assembly of cylinder head cover
先将进、排气摇臂放到缸头盖内，在分别将进、排气摇臂轴
穿过缸头盖和进气排气摇臂轴孔装配到位，最后将 NC250 摇臂
轴定位板螺栓装到缸头盖上相应的孔中并紧固。
Place intake and exhaust rocker arms inside the cylinder
head cover first and move intake and exhaust rocker arm
shaft through cylinder head cover respectively and then
through hole on the rocker arm shaft before installing them in
place. At last, fit NC250 rocker arm locating plate bolts on the NC250 左前盖大视孔盖
proper holes on the cylinder head cover and fasten them. NC250 access hole cover on left and
注意： front cover
1.装摇臂轴时，摇臂轴有切边的面应朝缸头盖上
悬挂孔，
2.缸头盖部装好后，转动摇臂，摇臂应转动灵活，
无卡滞现象，
3. 摇臂轴定位板螺栓紧固扭矩：16～20N·m。

Note:
1. The surface with scrap edge on rocker
arm shaft shall face higher suspension
hole of cylinder head cover.
2. Rotate rocker arm to inspect rocker arm
for sticky rotation after cylinder head
cover has been installed. There should be
no sticky rotation.
3. Tightening torque for bolts on rocker arm NC250 摇臂轴定位板螺栓
shaft locating plate: 16～20N·m. NC250 rocker arm locating plate
bolts

汽缸头的安装
Installation of cylinder head
1.拆下旧的汽缸头密封垫，装上新汽缸头密封垫，再装上定
共 31 页 第14页
位销；
2.将缸头装到 A、B 栓上，再将 ZS500A、B 栓螺母垫圈放到
A、B 栓上，然后将 ZS500A、B 栓螺母装到 A、B 拴上并紧固；
1. Remove the used cylinder head gasket and install a new
one before installing the locating pin;
2. Install the cylinder head on bolt A and B before placing
ZS500 nut A and B washer onto bolt A and B. Secure ZS500
nut A and B on bolt A and B before tightening them.

注意：
1.不能让尘土和渣滓进入汽缸内；
2. A、B 栓螺母紧固扭矩：55～60N.m。

NC250 磁电机转子正时标记 NC250 左前盖正时标记

Note:
1. Keep dust and shred from going into NC250 timing marker on magneto NC250 timing marker on left front
cylinder rotor cover
2. Tighten torque for nut A and B: 55～
60N.m.

3. 将缸头缸体连接螺 GB/T16674 小盘螺栓 M6×25 装到缸头

缸体的连接孔内并紧固，紧固扭矩：11～13N.m。
3.Install GB/T16674 pan head M6×25 connecting bolts
onto connecting holes for attaching cylinder head onto
cylinder block and tighten them. The tightening torque:
11～13N.m.

4. 将凸轮轴装到缸头上，再将正时链条装到凸轮轴上的正时
从动链轮上，然后检查发动机是否处在正时位置，若不在
正时位置需重新调整发动机的正时位置，
5. Install the camshaft on the cylinder head and install the
timing chain on the timing driven chain wheel on the
camshaft before checking if the engine is located at the
timing position. If not, realign the engine’s location. 正时从动链轮正时标记

Timing marker on timing driven chain wheel

NC250 发动机正时调整的方法：
（1）拆下左前盖的大视孔盖及 NC250 摇臂轴定位
板螺栓；
（2）用专用工具旋转 NC250 磁电机锁紧螺母，同
时通过左前盖上的摇臂轴定位板螺栓孔观察磁电机
转子上的正时刻度线“一”与左前盖上的正时标记是
否对正；
（3）上述正时标记对正后注意观察正时从动链轮上
的正时标记是否与合盖面在同一平面上；
只有同时满足（2）（3）发动机才处于正确的正时
位置。

共 31 页 第15页
 The method of timing adjustment for NC250
engine：
(1)Remove the access hole cover on the left
and front cover and the bolt for NC250 rocker
arm locating plate;

(2) Rotate the locking nut for NC250

magneto with a special tool while observing
if timing scale mark “一” on the magneto
rotor aligns with the timing marker on the left
and front cover through the hole on the bolt
for the rocker arm shaft locating plate on the
left and front cover;
(3)Observe if the timing marker on the
timing driven chain wheel is in the same
plane with mating face.

Engine is located at the correction timing

position only when item (2) and (3) are met.

调整好正时位置后将大视孔盖和摇臂轴定位板螺栓装配到左
前盖上；
Install the access hole cover and the bolt for the rocker arm
locating plate on the left and front cover after completion of
timing adjustment;
5.将张紧器装到缸体上对应的孔中，并用 2 颗 GB/T16674 小
盘螺栓 M6×20 紧固，最后将张紧器弹簧、密封圈、螺栓装配到
位；
5. Install the tensioner on the proper hole on the cylinder
block and tighten it with 2 GB/T16674 pan head bolts M6×20
before installing the tensioner spring, sealing ring and bolts in
place;
6.将 ZS500 定位板垫圈套到 GB/T16674 小盘螺栓 M6×16 上，
将螺栓紧固到凸轮轴上，在将 NC250 凸轮轴挡板装到缸头的挡
板槽中，最后将 NC250 缸头密封胶套装到缸头的密封胶套槽
中。
6. Put ZS500 locating plate washer on the GB/T16674 pan
head bolt M6×16 and fasten the bolt on the camshaft before
installing the NC250 camshaft baffle on the baffle groove on
the cylinder head and installing the sealing rubber sheath for
the NC250 cylinder head into the sealing rubber sheath
groove on the cylinder head.
气缸头盖的安装
Installation of cylinder head cover
1.在气缸头盖接合面均匀涂抹一层硅橡胶平面密封剂；
1. Apply an even layer of silicone rubber plane sealant to
the mating face of cylinder head cover;
2.将部装好的缸头盖装到缸头上；
2. Install the assembled cylinder head cover on the cylinder
head;
3.将 2 颗 A88 进气管垫圈套到 GB/T16674 小盘螺栓
M6×60，将其装到缸头盖油道孔内，再将 2 颗 GB/T16674 小盘
共 31 页 第16页
螺栓 M6×35 及 4 颗 GB/T16674 小盘螺栓 M6×30 穿过缸头盖
对应的孔并紧固，紧固扭矩：11～13N.m。
3. Put 2 A88 intake pipe washers onto the GB/T16674
pan head bolt M6×60 and fit the bolt inside the oil passage
hole on the cylinder head cover before moving 2 GB/T16674
pan head bolts M6×35and 4 GB/T16674 pan head bolts
M6×30 through the proper holes on the cylinder head cover
and fasten them. The tightening torque: 11～13N.m.
4.调节进、排气门的间隙，气门的间隙值：0.04～0.06mm
4. Adjust intake and exhaust valve clearance which shall be
0.04～0.06mm
5. 将 气 门 室 盖 装 到 缸 头 盖 上 并 用 GB/T16674 小 盘 螺 栓
M6×20 紧固，紧固扭矩：11～13N.m。
5. Install the valve cover on the cylinder head cover and
fasten it with a GB/T16674 pan head bolt M6×20. The
tightening torque: 11～13N.m.

共 31 页 第17页
 汽缸及活塞

Cylinder and piston

维修须知 活塞的拆卸
故障排除 活塞和活塞环的检查
汽缸的拆卸 活塞环的安装
气门的检查 活塞的安装
汽缸的安装

Maintenance instructions Removal of piston

Troubleshooting Inspection of piston and
piston ring
Removal of cylinder Installation of piston ring
Inspection of valve Installation of piston
Installation of cylinder

维修须知

Maintenance instruction

总则
注意事项：
● 缸头润滑油是经由发动机左体 AB 栓旁边的小油孔到汽缸头的，在安装汽缸之前，
应确保左体 AB 栓旁边的小油孔畅通。
● 不能使灰尘或尘埃渗入曲轴箱内。
General rules:
Cautions:
● Since the lubricating oil goes into the cylinder head via the small oil hole
adjacent to bolt A and B on the engine on the right hand side, it is necessary to
keep the small oil hole unobstructed before installation of the cylinder.
● Keep dust or dirt going into crankcase.

共 31 页 第18页
各部规格
Specifications of all components
项 目 Item 标准值 mm 维修极限值 mm
Normal value mm Maintenance limit
value mm
汽缸内径 Cylinder bore φ77～φ77.01 φ77.018

失圆度 Out-of-Round 0.05 0.01

汽缸 缸面平面度 Surface flatness 0.03 0.05

Cylinder
活塞外径 Piston outer diameter φ76.96～φ76.97 φ76.94

活塞销孔内径 φ16.001～φ16.006 φ16.015

Piston pin hole inner diameter
活塞销与活塞销孔间隙 0.001～0.012 0.025
Piston pin-to-piston pin hole fit
活塞环闭合间隙 顶环/第二环 0.2～0.35 0.5
Piston ring closing Top
活塞 gap ring/second
活塞环 ring
活塞销 油环 0.2～0.7 1.4
Piston Oil ring
Piston ring 活塞环与活塞环槽间 顶环 0.03～0.07 0.08
Piston pin 隙 Top ring
Piston ring-to-piston 第二环 0.02～0.06 0.08
ring groove fit Second ring
clearance
汽缸与活塞间隙 0.035～0.045 0.07
Cylinder wall –to- piston fit clearance
活塞销外径 φ15.994～φ16 φ15.99
Piston pin outer diameter
内径 φ16.015～φ16.025 φ16.04
连杆小端 Inner diameter
Connecting 连杆小端与活塞销间隙 0.015～0.03 0.05
rod end Piston pin-to-connecting rod
(piston pin)
clearance

故障排除

Troubleshooting
压缩力低或不稳定 过热
汽缸或活塞环有磨损。 活塞积碳过多
排出过量的黑烟 有爆震或不正常的噪音
汽缸、活塞或活塞环有磨损 活塞或汽缸有磨损
活塞环的安装不正确 活塞积碳过多

共 31 页 第19页
 活塞或汽缸壁有刮痕或刮伤
Lower or unsteady compressing force Overheating
Worn cylinder or piston ring Excessive piston carbon
deposit
Excessive black smoke Engine knocking or unusual
noise
Worn cylinder, piston or piston ring Worn piston or cylinder
Improper installation of piston ring Excessive carbon deposit
Scratched or scuffed piston or cylinder wall

共 31 页 第20页
 汽缸的拆卸
Removal of cylinder
取下链条导向板，拆下汽缸体。
Take the chain guide plate off and remove the
cylinder block.

将汽缸表面余留的垫片用刮刀刮干净。
Scrap the residue shim on the cylinder surface
using a scraper.
注意：
如将垫片浸入汽油中，则很容易拆开。进行
此项作业时，避免将汽缸接触面损坏。

Note:
It is very easy to scrap the shim off the
surface if it is sunk into the gasoline. Do not
damage mating face of the cylinder during
operation.

缸体的检查
Inspection of cylinder block
检查缸体是否有磨损或毁坏。
Inspect the cylinder block for any wear or
damage.
测量汽缸内径，应量取三个位置，即活塞行程的
顶部、中部和底部，测量时应对互成直角的两个方
向进行测量。
Measure the cylinder bore at three separate
positions, namely at top, middle and bottom of
piston travel respectively. Measure cylinder bore
at each position in two directions which are
perpendicular to each other.
维修极限值：φ77.018mm
Maintenance limit value: φ77.018mm

共 31 页 第21页
 活塞的拆卸
Removal of piston
用尖嘴钳拆下活塞销挡圈，取下活塞销及活塞。
Remove the piston pin circlip using a needle nose
plier and then remove piston pin and piston.
注意：
拆活塞销挡圈时不能将挡圈坠入曲轴箱内

Note:
Prevent circlip from falling into the crankcase
when removing the piston pin circlip.

活塞、活塞环的检查
Inspection of piston and piston ring
拆下活塞环；
Remove the piston ring:

注意：在拆卸时，不要损坏活塞环。

Note: do not damage the piston ring when

removing it.

测量活塞环与活塞环凹槽之间的间隙，维修极限
值：第一环： 0.08mm
第二环：0.08 mm
油环：0.08 mm
检查活塞是否有磨损或裂痕，活塞环凹槽是否有
磨损。
Measure piston ring –to-piston ring groove fit
clearance
Maintenance limit value:
First ring: 0.08mm
Second ring: 0.08 mm
Oil ring: 0.08 mm
Inspect the piston for wear or crack and inspect
the piston ring groove for wear.

将活塞环插入汽缸内，然后量取端隙。
维修极限值：
第一环：0.5mm
第二环：0.5mm
油环：1.4 mm

共 31 页 第22页
Install the piston ring inside the cylinder and
measure the end play.
Maintenance limit value:
First ring: 0.5mm
Second ring: 0.5mm
Oil ring: 1.4 mm

测量活塞销孔内径。
维修极限值：φ16.015 mm
Measure piston pin hole inner diameter.
Maintenance limit value: φ16.015 mm

共 31 页 第23页
 测量位于距活塞裙部 7 mm 高处的外
径
维修极限值：φ76.94 mm
算出汽缸与活塞之间的间隙。
维修极限值：0.1mm
Measure outer diameter of the piston
at a level which is 7 mm away from the
piston skirt
Maintenance limit value: φ76.94 mm
Work out cylinder wall –to-piston
clearance
Maintenance limit value: 0.1mm

量取活塞销外径
维修极限值：15.99 mm
算出活塞与活塞销之间的间隙
维修极限值：0.025 mm
Measure piston pin outer diameter
Maintenance limit value: 15.99 mm
Work out piston –to- piston pin fit
clearance
Maintenance limit value: 0.025 mm

活塞环的安装
Installation of piston ring

1.将活塞环凹槽彻底清洗干净；
2.装上活塞环；
1. Clean piston ring groove;
2.Install piston ring;

注意：
1、 在安装时，应防止活塞和活塞
环受到毁损；
2、 安装活塞环时，不能将一环、
二环装错，
一环、二环有记号的一面朝向活塞顶
部；
3、 装好后，活塞环应转动灵活。

共 31 页 第24页
 Notes:
1. Prevent piston and piston
ring from damage during
installation;
2. Do not mistake first ring for
second ring
3. Keep piston ring free from
sticky rotation after
completion of installation.

3.油环中各环之间的间隙，应该与隔
环的间隙相配合始可；安装油环时，应
先安装隔环，然后再安装边导轨。
3. Keep a proper clearance among
oil ring, spacing ring and other rings;
install spacing ring before installing oil
ring and then side guide rail.

共 31 页 第25页
 活塞的安装
Installation of piston

将活塞、活塞销及新活塞销挡圈装好。
Install piston, piston pin and new
piston pin circlip.

注意：

1.安装活塞时，印有“ ”记号一
侧应朝发动机的排气侧；
2.活塞销挡圈端隙的开口应朝下；
3.活塞销挡圈如变形严重必须更
换新的挡圈；
4.不能让活塞销挡圈坠入曲轴箱
内。

Note:
1. Install the piston with its side
在装配活塞时，印有“ ”记号一侧应朝发
marked with “ ”pointing
toward the exhaust side; 动机排气侧 Install the piston with its side

2. The opening of piston pin

circlip shall face downwards; marked with “ ”pointing toward the
3. Install a new circlip in case of exhaust side
severe distortion of it;
4. Prevent the piston pin circlip
from falling into the
crankcase.

气缸体的安装
Installation of cylinder block
1.装缸体定位销、新的气缸体密封垫；
2.在汽缸体、活塞及活塞环表面均匀
的涂抹一层机油；
3.先将活塞环之间的开口相互错开
120°后，再轻轻的把气缸体装配到位；
4.将链条导向板装配到位。
1. Install cylinder block locating
pin, new cylinder block gaskets;
2. Apply an even layer of oil onto
the surface of cylinder block, piston
and piston ring;
3. Misalign the openings of all
piston rings by 120°among each other
and install gently the cylinder block in
place;
共 31 页 第26页
 4. Install the chain guide plate in
place.

注意：安装气缸体时，要避免毁坏活
塞环。

Note: To keep piston ring in good

condition when installing cylinder
block.

共 31 页 第27页
 离合器、主动齿、超越离合器、油泵、换档机构

Clutch, driving tooth, freewheeling clutch, oil pump and

gearshift

维修须知 水泵叶轮的检查
故障排除 右曲轴箱盖的检查
水泵盖的拆卸 离合器的检查
右曲轴箱盖的拆卸 主动齿的检查
离合器的拆卸 超离及启动大齿轮的检查
主动齿的拆卸 右体机油泵的检查
超离及启动大齿轮的拆卸 换档机构的检查
右体油泵的拆卸 双联齿轮及启动电机的检查
换档机构的拆卸
双联齿轮及启动电机的拆卸

Maintenance instructions Inspection of water pump impeller

Troubleshooting Inspection of crankcase cover on right hand side
Removal of water pump cover Inspection of clutch
Removal of right crankcase cover Inspection of driving tooth
Removal of clutch Inspection of overrunning and starter gear
Removal of driving tooth Inspection of oil pump on the engine on the right
hand side
Removal of overrunning and starter gear Inspection of gearshift
Removal of oil pump oil pump on the engine on the right hand side Inspection of dual gear and starting motor
Removal of gearshift
Removal of dual gear and starting motor

维修须知
Maintenance instruction
说明：
在拆下右曲轴箱盖后，有关离合器、油泵和换档机构的拆卸、安装和维修工作无需拆下
发动机也可以进行
Explanation:
The removal, installation and maintenance of clutch, oil pump and gearshift can be
performed without disassembling the engine only when crankcase cover on the right
hand side has been detached.

共 31 页 第28页
技术规格
Technical specifications
项 目 标准值 mm 维修极限值 mm
Item Normal value Maintenance
mm limit value mm
离合器 弹簧自由长度 32.3～33.3 32.3
Clutch Free length of spring
摩擦主动片自由厚度 2.95～3.05 2.85
Free thickness of driving friction
plate
离合器从动片平面度 0.1 0.14
Flatness of clutch driven plate
离合器外罩与摩擦片间隙 0.1～0.3 0.6
Clutch housing –to- friction plate
clearance
油泵 外转子与内转子的径向间隙 0.06～0.15 ----
Oil pump Outer rotor –to- inner rotor radial
play
转子组合与盖板的端面间隙 0.04～0.1 ----
Rotor assembly –to- cover plate
end play

故障排除

Troubleshooting
离合器
离合器的操作，若发生故障，通常可借调整离合器手把自由行程而得到较好的校正。
Calibrating clutch can be performed by adjusting free travel of clutch handle in case
trouble occurs during operation of clutch.

加速时离合器打滑 放开离合器后，车辆会慢慢驶动
1、自由行程不够 1、自由行程太大
2、圆盘有磨损 2、离合器片弯曲
3、离合器片弯曲

Clutch slipping during acceleration Launching slowly after releasing the clutch
1. Poor free travel 1. Excessive free travel
2. Worn disk 2. Bent clutch plate
3. Bent clutch plate

共 31 页 第29页
 离合器操作困难
手把压力过大 1、离合器外罩滑槽有毛刺
Difficult operation of clutch
Excessive pressure to operate handle 1. Burry sliding slot in housing
of clutch
1、离合器索缆粘结，毁损或不洁 换档困难
2、提升机构损坏 1、止动板弯曲或磨损
2、离合器调整不正确
1. Sticky, damaged or polluted clutch cable Difficult gear shifting
2. Inoperative lifting gear 1. Bent or worn stop plate
2. Improper adjustment of
clutch
油压太低
1、油泵有故障 换档齿轮跳档
2、油泵驱动齿轮破裂 1、止动臂弹簧断裂或弹力不够
Lower oil pressure
1. Faulty oil pump groove-skipping
2. Oil pump with broken driving gear 1. Broken or poorly-elastic stop arm
spring
换档踏板不能回弹 缸温过高
1、 回动弹簧断裂 1.水泵叶轮有故障
2、 变速轴与曲轴箱盖相干扰 电启动困难
1.启动电机有故障
Gearshift pedal unable to rebound Excess temperature inside the
cylinder
1.Broken return spring 1. Faulty water pump
impeller
2. Gear shifting axle intervening with crankcase cover Difficult electric start
1. Faulty starting motor

共 31 页 第30页
 水泵叶轮拆卸
拆下水泵盖的放水螺栓，从放水螺栓处放掉
发动机中的冷却水，待放水螺栓处不在有水流
出时在拆下水泵盖及叶轮。
Removal of water pump impeller
Remove the drain bolt from the water pump
cover and drain the cooling water from the
engine and remove the water pump cover
and impeller when water stops flowing out of
the engine.

水泵放水螺栓 Drain bolt

右曲轴箱盖拆卸
Removal of crankcase cover on the right
hand side
1.先将机油放干（拆下左右两侧的机油滤网
盖，取出箱体里的机油滤网组合，等待箱体里
的机油流完为止）；
1. Drain the oil completely (detach the oil
strainer covers on both left and right and
take oil strainer assembly off the crankcase
and wait until oil flows out of the crankcase
completely.
2.拆下右盖连接螺钉，取下右曲轴箱盖。
2. Remove the connecting screw from the
right cover and detach the crankcase cover
on the right hand side.

水泵轴、水封组件、油封拆卸
Removal of water pump shaft, water
sealing components and oil seal
1.先拆下水泵轴孔挡圈槽中的 GB/T893.1
挡圈 22，取下水泵轴；
2.取下水泵轴孔中的水封组件、油封。
1. Remove the GB/T893.1 circlip 22 from
the circlip groove of water pump shaft hole
and detach the water pump shaft;
2. Detach the water sealing components
and oil seal from the water pump shaft hole.

离合器拆卸
Removal of clutch
1. 拆下离合器压板弹簧及螺栓，注意在扭松
离合器压盘螺栓时，应分二次或三次成
交叉方式扭松；
2.取下离合器压盘、离合器拉杆、摩擦片；
3.拆下离合器锁紧螺母及垫片；
4.拆下离合器中心套、外罩、离合器轴套、
共 31 页 第31页
垫片；
5.取出主轴中心孔中的离合器推杆。
1. Detach the clutch pressing plate spring
and bolts. Screw off the bolt for clutch
compressing disc in two or three stages at
points opposite to each other;
2. Detach the clutch compressing disc,
clutch pull rod, friction plate;
3. Detach the clutch locking nut and
shims;
4. Detach the clutch central sleeve,
housing and clutch shaft sleeve and shims;
5. Detach the clutch push rod from the
central hole of the main shaft.

主动齿、超离、启动大齿轮的拆卸
Removal of driving tooth, overrunning
and starter gear
1. 取下主动齿轮锁紧螺母及锁紧螺母垫圈；
2. 取下超离及启动大齿轮。
1. Remove the driving gear locking
nut and locking nut washer;
2. Remove the overrunning and
starter gear.

注意：
拆启动大齿轮组合时，要将启动大齿轮
垫圈与启动大齿轮一起拆下，并将垫圈妥
善保管。

Notes:
Remove the starter gear
washers altogether with the starter
gear when removing the starter
gear and keep the washers with
care.

右体泵的拆卸
Removal of oil pump on the right hand
side
1. 拆下机油泵过桥齿轮及机油泵齿轮组合
的挡圈；
2.拆下机油泵过桥齿垫圈，机油泵过桥齿，
机油泵齿轮组合；
3.拆下右机油泵盖板的 3 颗 GB/T16674 小
盘螺栓 M5×18，取下机油泵盖板组合及机油
泵内外转子组合。
1. Remove the intermediate gear of the oil
共 31 页 第32页
pump and the circlip of the oil pump gear
assembly;
2. Remove the washer for the
intermediate gear of the oil pump,
intermediate gear and oil pump gear
assembly;
3. Remove 3 GB/T16674 pan head bolts
M5×18 from the cover plate of the oil pump
on the right hand side and detach the oil
pump cover plate assembly and the
assembly of oil pump inner and outer rotor.

注意：
机油泵过桥齿上、下各有 1 个机油泵过
桥齿垫圈，拆下的挡圈、垫圈及机油泵销
子应妥善保管，以免丢失。

Note:
There is a washer at both the top
and bottom of the intermediate gear
respectively. Keep the detached
circlip, washer and pin with care.

双联齿轮的拆卸
Removal of dual gear
先拆下双联齿轮轴卡圈槽上的 GB/T894.4
挡圈 15，在取下双联齿轮垫圈，最后拆下双
联齿轮。
Remove the GB/T894.4 circlip 15 from the
retainer ring groove of dual gear before
detaching the washer and dual gear.

启动电机的拆卸
Removal of starting motor
拆下启动电机紧固螺钉，取下启动电机。
Remove the tightening screws for the
starting motor and detach the starting motor.

变档机构的拆卸
Removal of gearshift
1.拆下五星板紧固螺钉 GB/T70.1 M6×35，
取下五星板
2.拆下换挡臂部件；

共 31 页 第33页
 3.拆下定位板组合紧固螺钉，拆下定位板垫
圈及定位板组合。

1. Remove the GB/T70.1 screw M6×35 for

the stopping plate and remove the
stopping plate
2. Remove the components of the gear
shifting arm;
3. Remove the tightening screws for the
locating plate assembly and remove the
locating plate washer and locating plate
assembly.

右曲轴箱盖的检查
Inspection of crankcase cover on the
right hand side
1.检查右曲轴箱盖曲轴油封是否有破损情
况，如果发现油封破裂则需更换新的油封；
更换曲轴油封时注意两点：
1.确认油封的状态是否正确，NC250 曲
轴油封的端面应有“TCV”标记；
2.装配时有标记的面应朝外。
2. 检查启动轴油封是否有破损情况，如果发
现油封破裂则需更换新的油封。
1.Inspect the crankcase cover on the
right hand side for damaged crankshaft
oil seal. In case of damaged oil seal,
install a new oil seal.

Notes for replacement of crankshaft

oil seal:
1. Confirm the status of oil seal
and there should be a marker,
“TCV”, on the end face of NC250
crankshaft oil seal;
2. Install the oil seal with the side
with the marker facing outboard.

2.Inspect the starting shaft oil seal for

damage. In case of any damage, install
a new one.

水泵轴、水泵叶轮、水封组件、油封的检查
Inspection of water pump shaft,
impeller, seal assembly and oil seal
1.检查水泵叶轮是否有裂纹、水泵叶轮的嵌 超越离合器外罩

Housing of freewheeling clutch

共 31 页 第34页
件是否松动，如有上述现象需更换新的水泵叶
超越离合器楔块
轮；
Freewheeling clutch wedge
2.检查水封组件、油封是否破裂，检查水泵
轴磨损现象是否异常、是否有弯曲现象，如有
则需更换新的水封组件、油封及新的水泵轴，；
1. Inspect the impeller for any crack, loose
inserts of the impeller. In case of such
circumstance, install a new one.
2. Inspect the water sealing assembly and
oil seal for any crack. Inspect the water
pump shaft for unusual wearing and
distortion. In case of such circumstance,
install new ones.
右体机油泵盖板 Cover plate of oil pump on the right hand side

更换水封组件、油封、水泵轴时应注意：
1.在 NC250 水泵轴孔内涂抹适量机油，
用专用工装将 NC250 水泵轴油封压装到
位，油封端面标记朝外；
2.用专用工装将 NC250 水泵轴水封压装
到位，低于端面 0.5mm,,装配水封时水封
端面标记朝里；
3.在水封主唇口涂抹适量的润滑脂（润
滑脂型号：MYSTIK JT-6） ；
4.将新的水泵轴用专用工装压装到位；
5.将 GB/T893.1 挡圈 22 装到水泵轴孔
的挡圈槽中，装配好的水泵轴应转动灵活。

Notes for replacement of water 右体机油泵内外转子组合

sealing assembly, oil seal and water Assembly of inner and outer

pump shaft: rotor of oil pump on right hand

1. Apply a moderate amount of oil side
into NC250 water pump shaft
hole, and press and fit NC250
water pump shaft oil seal in place
with a special fixture while
keeping the marker on the end
face of oil seal facing outboard;
2. Press and fit NC250 water pump
shaft water seal in place with a
special fixture while keeping it
lower than end face by 0.5mm.
Keep the marker on the end face
of water seal facing inboard;
3. Apply a moderate amount of
lubricant grease (model: MYSTIK
JT-6) to the main lip of water seal;
4. Press and fit a new water pump
shaft in place with a special
fixture;
5. Install the GB/T893.1 circlip 22
inside the circlip groove of the

共 31 页 第35页
 shaft hole and keep free rotation
of assembled water pump shaft.

启动轴的检查
Inspection of starting shaft
检查启动轴的齿轮是否有磨损情况，若发动
机只有电启动则无此步。
Inspect the starting shaft for worn gear. In
case of electric starting available only, there
is no need to perform the inspection.

离合器弹簧的检查
Inspection of clutch spring

测量离合器弹簧自由长度
维修极限值：32.3mm
Measure free length of clutch spring
Maintenance limit value: 32.3mm

离合器摩擦片的检查
Inspection of clutch friction plate
如离合器摩擦片出现擦伤或褪色的痕迹，则
应更换。测量每片离合器摩擦片厚度。
维修极限值：2.85mm
In case clutch friction plate is found to have
scratches or to fade in color, install a new
one. Measure the thickness of each clutch
friction plate.
Maintenance limit value: 2.85mm

检查离合器从动片表面是否有扭曲，检查时

共 31 页 第36页
要用测隙规进行。
维修极限值：0.14 mm
Inspect the clutch for distorted surface of
driven plate. Feeler gauge shall be used for
inspection.
Maintenance limit value: 0.14 mm

检查离合器外罩与摩擦片的间隙。
维修极限值：0.6 mm
Inspect clutch housing –to-friction plate
clearance
Maintenance limit value: 0.6 mm

离合器外罩的检查
Inspection of clutch housing
检查外罩鼓型上的齿槽是否因离合器盘摩
擦而产生缺口、伤痕，如严重则需更换外罩。
Inspect the tooth socket on the drum of the
housing for any nick and scratch as a result
of friction by clutch. In case of any severe
nick and scratch, install a new housing.

主动齿的检查
Inspection of driving tooth
检查主动齿是否有磨损及损坏，如磨损和损
坏的现象比较严重，则需更换新的主动齿。
Inspect the driving tooth for wear and
damage. In case of severe wear and
damage, install a new driving tooth.

超越离合器的检查
Inspection of freewheeling clutch
取下超越离合器端面的卡圈，检查超越离合
器的楔块是否有磨损及损坏的现象
Detach the retainer ring from the end face of
the freewheeling clutch. Inspect the wedge
for wear or damage.

启动大齿轮的检查
Inspection of starter gear
检查启动大齿轮是否磨损或损坏。
Inspect the starter gear for wear or
damage.
共 31 页 第37页
 右体机油泵的检查
Inspection of oil pump on the right hand
side
1.检查机油泵内外转子是否有磨损和损坏
的现象，若磨损和损坏的现象严重则需更换新
的机油泵转子组件；
2.检查机油泵过桥齿轮和机油泵齿轮组合
是否有破裂现象，有则需要更换新的机油泵过
桥齿轮和机油泵齿轮组合
3.检查右机油泵盖板是否有磨损和损坏的
现象，若有则需更换新的右机油泵盖板。

1. Inspect inner and outer rotor of oil pump

for wear and damage. In case of severe
wear and damage, install a new set of
oil pump rotor assembly;
2. Inspect the oil pump intermediate gear
and gear assembly for any crack. In
case of such circumstance, install a new
intermediate gear and a new set of gear
assembly
3. Inspect the cover plate of the oil pump
on the right hand side for wear and
damage. In case of such circumstance,
install a new one.

启动电机及双联齿轮的检查
Inspection of starting motor and dual
gear
检查启动电机的齿槽是否有破坏的现象，
检查双联齿轮是否有磨损和破坏的现象。
Inspect the starting motor for damaged tooth
socket and the dual gear for wear and
damage.

变档机构的检查
Inspection of gearshift
检查定位板滚轮是否有磨损及滚轮转动是
否灵活。
Inspect the locating plate roller for damage
and sticky rotation of roller.

启动轴的装配
Assembly of starting shaft
将启动轴装到右体相应的启动轴孔中，如只

共 31 页 第38页
有电启动则无此步。
Install the starting shaft into the proper hole
on the right hand side. There is no need to
perform the installation in case of electric
starting available only.

双联齿轮的装配
Assembly of dual gear
1.将双联齿轮装到右体的双联齿轮轴上，
2.将双联齿轮垫圈装到双联齿轮端面
3.将 GB/T894.1 挡圈 15 装到双联齿轮轴上
的卡圈槽上。
1. Install the dual gear on the dual gear
shaft on the right hand side
2. Install the dual gear washer on the end
face of the dual gear
3. Install GB/T894.1 circlip 15 on the
retainer groove of the dual gear shaft
换档机构的装配
Assembly of gearshift
1.将定位板组合装到右体上并紧固；
2.将五星板装入变速鼓上，注意缺口对准变
速鼓销子，装上紧固螺钉并紧固；
3.装上变档臂，变档臂装配后先检测变档是
否正确，变档无误后再继续装机。
1. Install the locating plate assembly on
the engine on right hand side and fasten it;
2. Install the stopping plate into the
transmission drum. Note: the opening shall
align with the transmission drum pin, and fit
and fasten the screw;
3. Install the gear shifting arm and test
the installed gear shifting arm for improper
operation. Proceed to the next step when
gear shifting works as normal.

右体机油泵的装配
Assembly of oil pump on the right hand
side
1.先将机油泵销子装到机油泵轴上的销孔
中；
2.将转子组件装到右箱体的孔中；用 3 颗
GB/T16674 小盘螺钉 M5×18 将机油泵盖板组
合紧固到机油泵转子上；
1. Install the oil pump pin into the pin hole
on the oil pump shaft;
2. Install the rotor assembly into the hole
on the crankcase on the right hand side;
fasten oil pump cover plate assembly on the
rotor with 3 GB/T16674 pan head bolts
共 31 页 第39页
M5×18;

注意：
1.装机油泵转子时，内外转子有标记的
面应朝同一方向；
2.机油泵盖板螺栓紧固扭矩：7～9 N.m；
3.盖板装配后，要确保机油泵轴转动灵
活。

Note:
1. Install the oil pump rotor with
inner and outer rotor’s face with
marker pointing toward the same
direction;
2. Tightening torque for cover plate
bolts: 7～9 N.m；
3. Make sure free rotation of oil
pump shaft after completion of
installation.

3.将机油泵齿轮组合装到机油泵轴上并将
GB/T894.1 挡圈 10 装到机油泵轴上的卡圈槽
中；
4.将机油泵过桥齿轮垫圈装到机油泵过桥
齿轮轴上，在将机油泵过桥齿轮装到机油泵过
桥齿轮轴上，然后将机油泵过桥齿轮垫圈装机
油泵过桥齿轮上，最后将 GB/T894.1 挡圈 10
装到机油泵过桥齿轮轴的卡圈槽上。
3.Install the oil pump gear assembly on the
pump shaft and install the GB/T894.1 circlip
10 into the retainer groove on the pump
shaft;
4. Install the intermediate gear washer on
the intermediate gear shaft and then install
the intermediate gear on the intermediate
gear shaft before installing the washer on
the intermediate gear and installing the
GB/T894.1 circlip 10 onto the retainer ring
groove on the intermediate gear shaft.

超越离合器的组装
Assembly of freewheeling clutch
将楔块装到超越离合器的外罩上，装配时注
意：不要将楔块装反。
Install the wedge on the housing of the
freewheeling clutch. Notes during
installation: Keep the wedge in a proper
position.

启动大齿轮及超越离合器的安装
Installation of starter gear and
共 31 页 第40页
 freewheeling clutch
1.将启动大齿轮垫圈装到右曲柄上，
2.将启动大齿轮、超越离合器装到右曲柄
上。
1. Install the starter gear on the crank on
the right hand side,
2. Install the starter gear and freewheeling
clutch on the crank on the right hand side.

注意：
装启动大齿轮前，先在启动大齿轮内孔
上均匀的涂抹一层润滑脂。

Note:
Apply an even layer of lubricant
grease into the inner hole of the
starter gear before installing the
starter gear.

主动齿的安装
Installation of driving tooth
1.将主动齿装到右曲柄上，
2.将主动齿锁紧螺母垫圈装到主动齿上，3.
在主动齿锁紧螺母上涂抹 3～4 牙螺纹紧
固胶，将其装到右曲柄上并紧固。
1. Install the driving tooth on the crank
on the right hand side
2. Install the driving tooth locking nut
washer on the driving tooth,
3. Apply 3 to 4 drops of pitch thread
tightening glue onto the locking nut
before installing it on the crank on
the right hand side
注意：
主动齿锁紧螺母紧固扭矩：150～
160N·m

Note:
Tightening torque for driving tooth
locking nut: 150～160N·m
离合器的安装
Installation of clutch
1.将离合器外罩垫圈、离合器轴套、离合器
外罩和离合器中心套垫圈装到主轴上；
1. Install the clutch housing washer, clutch
shaft sleeve, clutch housing and clutch
central sleeve washer onto the main shaft;

共 31 页 第41页
 注意：离合器轴套内圈均匀涂抹润滑脂。

Note: Apply an even layer of

lubricant grease onto the inner ring
of the clutch shaft sleeve.

2.先将离合器中心套、离合器锁紧螺母垫圈
装到主轴上，在离合器锁紧螺母涂 3～4 牙螺
纹紧固胶将其装到主轴上并紧固；
2. Install the clutch central sleeve and clutch
locking nut washer on the main shaft and
apply 3 to 4 drops of pitch thread tightening
glue onto the locking nut before installing it
on the main shaft;

注意：
离合器锁紧螺母紧固扭矩：80～90N·m

Note:
Tightening torque for clutch locking
nut: 80～90N·m

3.先将离合器摩擦片装入离合器中心套及
离合器外罩上，再将离合器推杆装到主轴的中
心孔中，然后将离合器拉杆装到主轴的中心孔
内，再将推力轴承、拉杆垫圈装到拉杆上，
3. Install the clutch friction plate into the
clutch central sleeve and onto the clutch
housing and then install the clutch push rod
into the central hole on the main shaft
before installing the thrust bearing and pull
rod washer on the pull rod,
4.装上离合器压盘、离合器压盘弹簧、压盘
螺钉，用扭力扳手将压盘螺钉紧固，紧固扭矩：
8～10N·m
4.Install the clutch compressing disc, clutch
compressing disc spring and screw before
fastening the screw using a torque wrench,
tightening torque: 8～10N·m

启动电机的装配
Assembly of starting motor
在启动电机的齿槽端均匀的涂抹机油后将
启动电机装配到位，并用 2 颗 GB/T16674 小
盘螺栓 M6×25 紧固，紧固扭矩 11～13N·m。
Apply an even layer of oil into the tooth
socket ends of the starting motor before
installing the starting motor in place and
共 31 页 第42页
fasten it with 2 GB/T16674 pan head bolts
M6×25, tightening torque 11～13N·m.

右曲轴箱盖的安装
Installation of crankcase cover on
the right hand side
1.拆下旧的右曲轴箱密封垫，装上新的密封
垫，将右曲轴箱盖装配到位并用 10 颗
GB/T16674 小盘螺栓 M6×30 紧固，紧固扭矩：
11～13N·m
2.将水泵叶轮装到水泵轴轴上并紧固，紧固扭
矩：2～4N·m；
3.装上水泵盖密封垫后将水泵盖装配到位并
用 3 颗 GB/T16674 小盘螺栓 M6×35 和 1 颗
GB/T16674 小盘螺栓 M6×20 紧固。
1. Remove the used gasket before installing
a new one and install the crankcase cover
on the right hand side in place before
fastening it with 10 GB/T16674 pan head
bolts M6×30, tightening torque: 11～
13N·m
2. Install the water pump impeller onto the
water pump shaft and fasten it, tightening
torque: 2～4N·m;
3. After installation of water pump cover
gasket, install the cover in place and fasten
it with 3 GB/T16674 pan head bolts M6×35
and 1 GB/T16674 pan head bolt M6×20.

磁电机及平衡主、从动齿

Magneto, balance driving tooth and balance driven tooth

共 31 页 第43页
 维修须知 平衡主、从动齿的拆卸及检查
左曲轴箱盖的拆卸 平衡主、从动齿的安装
磁电机定子、转子的拆卸 磁电机定子、转子的安装
磁电机定子、转子的检查 左曲轴箱的安装

Maintenance instructions Removal and inspection of balance driving tooth and balance

driven tooth

Removal of crankcase cover on the left hand side Installation of balance driving tooth and balance driven tooth

Removal of magneto stator and rotor Installation of magneto stator and rotor

Inspection of magneto stator and rotor Installation of crankcase cover on the left hand side

维修须知
本节所介绍磁电机和平衡主、从动齿的拆卸和安装，只要拆下左曲轴箱盖，无需拆下发
动机即可完成。
关于磁电机的检查可参阅蓄电池充电系统章节的方法。
Maintenance instructions
This section is to specify removal and installation of magneto, balance driving tooth and
balance driven tooth. The removal and installation of them need removal of crankcase
cover on the left hand side only.

左曲轴箱盖的拆卸
Removal of crankcase cover on the left hand
side

拆下左前盖紧固螺栓，取下左曲轴箱盖；
Detach the tightening bolt for the left and
front cover and detach the crankcase
cover on the left hand side;

磁电机定子的拆卸
Removal of magneto stator
1.拆下传感的 2 颗 GB/T818 螺钉 M5×10

共 31 页 第44页
（彩锌）ML35-HIPER 紧固螺钉；
2.拆下定子线圈的 2 颗 GB/T70.1 螺钉
M5×30 紧固螺钉，然后从左曲轴箱盖上拆下
磁电机定子组合。
1. Remove 2 GB/T818 ML35-HIPER
tightening screws (colored zinc) M5×10 for
the sensor;
2. Remove 2 GB/T70.1 tightening
screws M5×30 for stator coil before
removing the magneto stator assembly
from the cover.

磁电机转子的拆卸
Removal of magneto rotor
拆下磁电机转子锁紧螺母，用专用工具拆
下磁电机转子。
Remove the locking nut from the
magneto rotor and the magneto rotor with
a special tool.
注意：
1.磁电机转子拆卸时只能用专用工具
拆卸，不允许敲击磁电机转子；
2.磁电机转子在拆卸及装配过程中受
到意外冲击，如磁电机转子摔落着地或受
到异物敲击，则应更换新的磁电机转子。

Note:
1. A special tool shall be used only
for removal of magneto rotor
without knocking onto the rotor;
2. Install a new magneto rotor in
case the rotor falls onto the floor
or is impacted by an object during
the removal and assembly.

平衡主、从动齿的拆卸
Removal of balance driving tooth and
balance driven tooth

1.取下正时链条，拆下链条张紧板，然后
分别拆下平衡主动齿锁紧螺母及主动齿锁紧
螺母垫圈；
2.拆下曲轴正时主动链轮和平衡主动齿
轮；
3.拆下平衡从动齿锁紧螺母和 CB125 离

共 31 页 第45页
合器碟形垫圈；
4.拆下平衡齿从动轮、NC250 曲轴轴套、
平衡轴平键。
1. Detach the timing chain and the chain
tension plate before detaching the balance
driving tooth locking nut and driving tooth
locking nut washer;
2. Remove the timing driving chain
wheel and balance driving gear of
crankshaft;
3. Remove the balance driven tooth
locking nut and CB 125 clutch disc-shaped
washer;
左体机油泵转子组合
4. Remove the balance tooth of the 左体机油泵盖板
Assembly of rotor on left
driven wheel, NC250 crankshaft sleeve Oil pump cover plate
and balance shaft flat key; hand side
on left hand side

左体机油泵的拆卸
Removal of oil pump on engine on left
hand side
1.拆下紧固左机油泵盖板的 3 颗
GB/T16674 小盘螺栓 M5×1 0；
2.拆下机油泵盖板，拆下左机油泵转子组
件，机油泵销子应妥善保管以免丢失。
1. Remove the 3 GB/T16674 pan head
bolts M5×1 0 for fastening the cover plate
of the oil pump on the left hand side;
2. Remove the cover plate and the rotor
assembly. Keep the oil pump pin with care.
左曲轴箱盖的检查
Inspection of crankcase cover on
the left hand side

检查左曲轴箱盖的平衡轴油封是否有损坏
的现象，如有则必须更换平衡轴油封。
Inspect the crankcase cover on the left
hand side for damaged balance shaft oil
seal. In case of damage, install a new oil
seal.

磁电机定子、转子的检查
Inspection of magneto stator and rotor
1.检查磁电机定子的磁瓦是否有裂纹或破
损情况如有则需更换新的磁电机转子。
2.检查磁电机转子是否磨损或损坏，如有
则需更换新的磁电机转子。
1. Inspect the magnetic shoe of motor
stator for any crack and damage. In case
of crack and damage, install a new stator.
2. Inspect the magneto rotor for wear or
共 31 页 第46页
damage. In case of wear or damage,
install a new rotor.

平衡主、从动齿轮的检查
Inspection of balance driving gear and
driven gear
检查平衡主、从动齿轮是否磨损或损坏。
Inspect the balance driving gear and
driven gear for wear or damage.

左体机油泵的检查
Inspection of oil pump on engine on left
hand side
1.检查左体机油泵转子组件是否有磨损和
损坏；
2.检查左体机油泵盖板是否有磨损和损
坏。
1. Inspect the rotor assembly of the oil
pump on the left hand side for wear and
damage;
2. Inspect the cover plate of the oil pump
for wear and damage.

左体机油泵的安装
Installation of oil pump on engine
on left hand side
1.将左体机油泵装到左体的相应孔中；

2.用 3 颗 GB/T16674 小盘螺栓 M5×1 0 将

机油泵左盖板紧固。
1. Install the oil pump into the proper
hole on the engine on the left hand side;
2. Fasten the cover plate with 3
GB/T16674 bolts M5×1 0.
注意：
1.装机油泵转子时，内外转子有标记的
面应朝同一方向；
2.左机油泵盖板螺栓紧固扭矩：7～
9N·m；
3.紧固后检查机油泵轴是否转动灵活。

Note:
1. Install the oil pump rotor with
inner and outer rotor’s face with
marker pointing toward the
same direction;
2. Tightening torque for the cover
plate bolts: 7～9N·m；
3. Inspect the oil pump shaft for

共 31 页 第47页
 any sticky rotation.

平衡主、从动齿轮的安装
Installation of balance driving gear and
driven gear
1.先将 NC250 曲轴轴套装到平衡轴上，在
将 NC250 平衡轴平键 4×4×13 装到平衡轴的
键槽内，最后将平衡轴从动齿轮装到平衡轴
上；
2.先将平衡主动齿装到左曲柄上，再将
NC250 曲轴正时链轮装到左曲柄上；
1. Install NC250 crankshaft sleeve onto
the balance shaft before installing NC250
balance shaft flat key 4×4×13 into the key
slot of the balance shaft. At last, install the
balance driven gear on the balance shaft;
2. Install the balance driving gear on the
crank on the left hand side before installing
NC250 crankshaft timing chain wheel on
the crank on the left side;

注意：
装平衡主、从动齿时要对正平衡主、从
动齿的正时标记，即平衡主、从动齿有正
时标记的齿要相互啮合。

Note:
Keep balance driving tooth and
driven tooth with timing markers
being engaged mutually.
3.分别将平衡主动齿螺母锁紧垫圈和
CB125 离合器碟形垫圈放到曲轴正时主动
链轮和平衡轴从动齿轮上，在平衡轴锁紧螺
母 M24×1 离合器锁紧螺母 M16×1 涂抹 3～4
牙螺纹紧固胶后将其装到曲轴和平衡轴上并
紧固，
3. Put the locking washer for the nut of
the balance driving tooth and CB125 clutch
disc-shaped washer on the crankshaft
timing driving chain wheel and balance
shaft driven gear respectively. Apply 3 to 4
drops of pitch thread tightening glue to the
balance shaft M24×1 locking nut and
clutch locking nut M16×1 before installing
them on the crankshaft and balance shaft
共 31 页 第48页
and tightening them.

注意：
平衡主、从动齿锁紧螺母紧固扭矩：
80～90N·m。

Note:
Tightening torque for locking nut of
balance driving tooth and driven
tooth: 80～90N·m.

磁电机转子的安装
Installation of magneto rotor
先将磁电机转子装到左曲柄上，然后在
IB175-FC 磁电机螺母上涂抹 3～4 牙螺纹紧
固胶后将其装到左曲柄上并紧固。
Install the magneto rotor on the crank on
the left side and then apply 3 to 4 drops of
pitch thread tightening glue to the nut of
IB175-FC magneto before install the nut
on the crank on the left hand side.
注意：
磁电机转子锁紧螺母紧固扭矩：85～
90N·m。

Note:
Tightening torque for locking nut of
magneto rotor: 85～90N·m.

磁电机定子的安装
Installation of magneto stator
将磁电机定子组件用 2 颗 GB/T818
M5×10 和 2 颗 GB/T70.1 螺钉 M5×30 紧固
到左曲轴箱盖上，紧固扭矩：7～9N·m。
Install the magneto stator assembly on the
crankcase cover on the left hand side with
2 GB/T818 screws M5×10 and 2 GB/T70.1
screws M5×30, tightening torque: 7～
9N·m.
左曲轴箱盖的安装
Installation of crankcase cover on left
hand side
1.拆下旧的密封垫，装上新的密封垫 ；
2.将左曲轴箱盖装配到位并用 8 颗
GB/T16674 小盘螺栓 M6×35 紧固，紧固扭
共 31 页 第49页
 矩：11～13 N·m。
1. Remove the used gasket and install
a new one;
2. Install the crankcase cover on the
left hand side in place and fasten it with
8 GB/T16674 pan head bolts M6×35,
tightening torque: 11～13 N·m.

曲轴箱、曲轴、变速传动、平衡轴

Crankcase, crankshaft, variable transmission and balance

shaft

维修须知 脚踏起动装置的拆卸
故障排除 起动轴传动小齿轮的检查
曲轴箱分解 起动轴的检查
曲轴的拆卸 起动轴的安装
曲轴的检查 装好起动轴
变速器的分解 变速鼓及齿轮的安装
换档拨叉/换档拨叉轴/变速鼓的检查 曲轴箱的安装

Maintenance instructions Removal of kick start mechanism

Troubleshooting Inspection of drive pinion on starting
shaft
Disassembly of crankcase Inspection of starting shaft
Removal of crankshaft Installation of starting shaft
Inspection of crankshaft Installing starting shaft in place
Disassembly of transmission Installation of variable speed drum
and gear
Inspection of shift fork, shift fork Installation of crankcase
shaft and variable speed drum
维修须知
Maintenance instructions
本节介绍变速器、曲轴、平衡机构的安装、检测，进行上述工作时，应将曲轴箱先进行
分离，关于发动机的其他部件的拆卸应在曲轴箱分离之前进行。
This section is to specify installation and testing of transmission, crankshaft and
balancing mechanism. Disassembly of crankcase occurs prior to installation and testing.
The removal of other components of engine shall occur prior to disassembly of
crankcase.

共 31 页 第50页
曲轴箱分离之前的工作
Operation prior to disassembly of crankcase
汽缸头的拆卸
汽缸/活塞的拆卸
离合器、油泵、换档机构、平衡齿的拆卸
磁电机的拆卸
Removal of cylinder head
Removal of cylinder/piston
Removal of clutch, oil pump, shifting mechanism and balance tooth
Removal of magneto

规格
Specification
项 目 Item 标准值 mm 维修极限值 mm
Normal value mm Maintenance
limit value mm
副轴右拨叉内径／副轴左拨叉内径 φ14.016～φ14.043 φ14.045
换档拨叉 Inner diameter of right fork on
Shift fork countershaft /inner diameter of left
fork on countershaft
主轴拨叉内径 φ12.016～φ12.043 φ12.045
Inner diameter of fork on main
shaft
卡爪厚度 4.8～4.9 4.8
Thickness of pawl latch
主轴拨叉轴外径 φ11.973～φ12 φ11.95
换档拨叉轴 Outer diameter of fork on main
Shift fork shaft
shaft 副轴拨叉轴外径 φ13.973～φ14 φ13.95
Outer diameter of fork on
countershaft
圆柱度 0.006 ----
Cylindricity
连杆小头内径 φ16.015～φ16.025 φ16.04
Inner diameter of connection rod
曲轴 (smaller end)
Crankshaft 轴向 0.15～0.4 0.6
连杆大端侧间隙 Axial
Connecting rod side 径向 0.008～0.016 0.02
clearance (larger end) Radial
平衡轴 轴径 φ19.98～φ19.993 φ19.96
Balance Shaft diameter
shaft

故障排除
共 31 页 第51页
 Troubleshooting

换档困难 曲轴有噪音
1、换档拨叉弯曲 1、连杆大端轴承有磨损
2、换档拨叉轴弯曲 2、连杆弯曲
3、曲轴轴承有磨损
Difficult gear shifting Crankshaft with noise
1. Bent shift fork 1. Worn bearing on connecting
rod
2. Bent shift fork shaft 2.Bent connecting rod
3.Worn bearing on crankshaft
变速器跳档
1、换档齿轮棘爪有磨损 换档齿轮有噪音
2、换档拨叉弯曲或磨损 1、换档齿轮有磨损
3、换档拨叉轴弯曲 2、花键轴有磨损
Transmission groove-skipping
1.Worn ratchetting latch of shift gear 1. Worn shift gear
2. Bent or worn shift fork 2. Worn spline shaft
3.Bent shift fork shaft

共 31 页 第52页
 曲轴箱的分解
Disassembly of crankcase

1.将发动机左曲轴箱朝上放置；
2.拆下 8 颗 GB/T16674 小盘螺栓 M6×65
和 5 颗 GB/T16674 小盘螺栓 M6×45 紧固螺
钉，将左曲轴箱与右曲轴箱分开，取下 2 颗
定位销。
1. Place the crankcase on the left
hand side with it facing upwards;
2. Remove 8 GB/T16674 pan bolts
M6×65 and 5 GB/T16674 pan head bolts
M6×45 tightening screws before detaching
the crankcase on the left hand side from
that one on the right hand side and
removing 2 locating pins.

曲轴/平衡轴/主副轴的拆卸
Removal of crankshaft/balance
shaft/Main shaft and
countershaft
从箱体内取出曲轴组件、平衡轴、拨叉轴、
拨叉、变速鼓、主副轴组件。
Take crankshaft assembly, balance
shaft, fork shaft, fork, variable speed drum
and assembly of main shaft and
countershaft away from the crankcase.

注意：
在取主副轴组件时要确保不能有零部
件遗落。

Note:
Do not miss any part from
assembly of main shaft and
countershaft.

曲轴的检查
Inspection of crankshaft
将曲轴放在 V 型铁上。
用百分表测量曲轴轴径的径向间隙。
曲轴的实际径向间隙为总读数值（TIR）的
1/2
维修极限值：0.1 mm
共 31 页 第53页
 Put the crankshaft on V-shaped iron
Measure the crankshaft radial clearance
using a dial gage.
Half of TIR is the practical radial
clearance.
Maintenance limit value: 0.1mm

测量连杆大头 X 和 Y 方向的两个点的径向
间隙。
维修极限值：0.02 mm
Measure connecting rod (larger end)
–to- two points radial clearance in
direction of X and Y
Maintenance limit value: 0.02 mm

用厚薄规测量连杆大头侧隙。
维修极限值：0.7 mm
Measure connecting rod side clearance
using a feeler gauge.
Maintenance limit value: 0.7 mm

左、右箱体轴承的检查
Inspection of bearing on crankcase on
both left and right hand sides
1.检查左、右箱体的所有轴承转动是否灵
活；若转动不灵活或有发卡的现象则应更换
相同型号的轴承；
2.取下左、右箱体的曲轴轴承检查其径跳
和端跳，如果发现有噪音或径跳和端跳过大，
则应更换新的曲轴轴承。
1. Inspect bearings on both left and right
hand sides for sticky rotation; in case of
sticky rotation, install new bearings of the
same type;
2. Detach crankshaft bearings on both left
and right hand sides to check radial runout
and axial runout. In case of unexpected
noise or excessive runout, install new
crankshaft bearing.

换档拨叉/换档拨叉轴/变速鼓的检查
Inspection of shift fork, shift fork shaft
and variable speed drum

检查各换档拨叉是否有磨损、弯曲或其他
任何故障，测量换档拨叉内径。
共 31 页 第54页
 主轴拨叉维修极限值：φ12.45 mm
副轴拨叉维修极限值：φ14.45 mm
Inspect all shift forks for wear, bending or
other failures, measure inner diameter of
shift fork.
Maintenance limit value for main shaft fork:
φ12.45 mm
Maintenance limit value for countershaft
fork:
φ14.45 mm

检查主轴、副轴拨叉轴是否有磨损、毁坏
或弯曲，测量外径。
主轴拨叉轴维修极限值：φ11.95 mm
副轴拨叉轴维修极限值：φ13.95 mm
Inspect fork shaft on both main shaft and
countershaft for wear, damage or bending,
measure outer diameter.
Maintenance limit value for main shaft fork:
φ11.95 mm
Maintenance limit value for countershaft
fork:
φ13.95 mm

共 31 页 第55页
 测量叉爪的厚度。
维修极限值：4.7 mm
Measure thickness of fork claw
Maintenance limit value: 4.7 mm

检查变速鼓表面和槽是否有磨损或损坏
Inspect surface and groove of variable
speed drum for wear or damage

主副轴组件的检查
Inspection of assembly of main
shaft and countershaft
检查主副轴组件各齿轮是否有过量或不正
常的磨损,检查齿轮之间的各卡圈是否有变
形、脱落现象。
Inspect assembly of all gears of main
shaft and countershaft for excessive or
unexpected wear and inspect all the
retainer rings among the gears for
distortion and falling-off.

机油滤清器部件、机油滤网的检查
Inspection of oil filter components and
strainer
1.检查机油滤清器部件、机油滤网的清洁
度；对清洁度差的机油滤清器部件、机油滤
网要用干净的汽油冲洗干净；
2. 检查机油滤清器部件、机油滤网是否有

共 31 页 第56页
损坏的现象；若有损坏的现象需更换新的机
油滤清器部件、机油滤网。
1. Inspect the oil filter components and
strainer for any foreign matters; Flush and
clean contaminated oil filter components
and strainer with clean gasoline;
2. Inspect the oil filter components and
strainer for damage; in case of damage,
install new oil filter components and
strainer.

共 31 页 第57页
 变速器/曲轴/平衡轴的装配
Assembly of
transmission/crankshaft/balance shaft
1.把曲轴、平衡轴装到左体相应的孔中，
2.把主、副轴组件装到左体相应的孔中，
再将拨叉装配到相应的位置，
1. Install the crankshaft and balance
shaft into the hole on the engine on the left
hand side,
2. Install the assembly of main shaft and
countershaft into the hole on the engine on
the left hand side and install the fork in
place accordingly,

注意：
1.标记为--R 的拨叉装入副轴靠右体一
侧；
2.标记为--L 的拨叉装入副轴靠左体一
侧；
3.标记为--C 的拨叉装入主轴。

Note:
1. Install the fork marked with R into
the countershaft on the right hand side;
2. Install the fork marked with L into the
countershaft on the left hand side; 此端为机油精滤器封闭端
3. Install the fork marked with C into
It is the closing end of oil filter
the main shaft ;
3. 把变速鼓装到左体相应的孔中，然后将
拨叉另一端装配变速鼓相应的槽中，最
后再将拨叉轴装到相应的拨叉中。
3. Install variable speed drum in the proper
hole on the engine on the left body and
install the other end of fork into the proper
groove of the variable speed drum. At last,
install the fork shaft into the fork
accordingly.

注意：
长拨叉轴穿过标记为—R、标记为—L
的拨叉，短拨叉轴穿过标记为—C 的拨
叉。 此端为机油精滤器的开口端，在装配时应朝向左箱体。

It is the opening end of oil filter. Keep the opening pointing toward
Note: the longer fork shaft moves
the case on the left hand side
through the forks marked with R and L.
The shorter fork shaft moves through
the fork marked with C.

共 31 页 第58页
 合箱及机油滤网的装配
Combination of cases and
assembly of oil filter
1.在右箱体合箱面上均匀的涂抹一层密封
胶，将定位销装到左箱体相应的孔中，然后
将右箱体合在左箱体上，将 5 颗 GB/T16674
小盘螺栓 M6×45、8 颗 GB/T16674 小盘螺
栓 M6×65 穿过左体相应的螺栓孔并将其紧
固；紧固扭矩：11～13 N·m。
1.Apply an even layer of sealant onto the
surface of case on the right hand side and
install the locating pin into the hole on the
case on the left hand before combining
cases on both right and left hand sides.
Move 5 GB/T16674 pan head bolts M6×45
and 8 GB/T16674 pan head bolts M6×65
through the holes on the case on the left
hand side before tightening them:
tightening torque: 11～13 N·m.

1.将机油精滤器部件装到箱体相应的孔中，

1.Install the components of oil filter into the

proper holes on the case,

注意：
装机油精滤器时，开口端应朝向左箱体

Note:
Install the oil filter with its opening
pointing toward the case on the left
hand side

然后再将机油精滤器盖装到双头螺栓上，
再用 2 颗 GB/T6177.1 螺母 M5 紧固，紧固
扭矩：7～9 N·m。

3.将机油滤网组合装到左、右箱体相应的
孔中，然后用机油滤网盖紧固，紧固扭矩：
11～13 N·m。

Install the oil filter cover onto the stud bolts

and tighten them with 2 GB/T6177.1 M5
nuts,
Tightening torque: 7～9 N·m.

4.Install the combined oil filter strainer on

the case on both left and right hand sides

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and tighten it with the cover, tightening
torque: 11～13 N·m.

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