xt250 cb250 es zongshen engine - …xtrememoto.com.au/docs/xt250 xb35 zongshen engine part...

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XT250 CB250 ES ZONGSHEN ENGINE

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Page 1: XT250 CB250 ES ZONGSHEN ENGINE - …xtrememoto.com.au/docs/XT250 XB35 Zongshen Engine Part (OHC)2.pdf · oil pump assy. (s5) ref.no. part no ... 29 90303-i006-0000 oil seal 20×34×7

XT250 CB250 ES ZONGSHEN ENGINE

Page 2: XT250 CB250 ES ZONGSHEN ENGINE - …xtrememoto.com.au/docs/XT250 XB35 Zongshen Engine Part (OHC)2.pdf · oil pump assy. (s5) ref.no. part no ... 29 90303-i006-0000 oil seal 20×34×7

REF.No. PART No. DESCRIPTION QTY1 91201-I006-00000X NUT M8 42 93301-80852218000 WASHER 8.5×2.2×18 43 B166740A06003570X BOLT M6×35 44 11230-I006-00000G CAP ASSEMBLY, TAPPET ADJUSTING HOLE 25 90101-20350000300 O-RING 35×3 26 81300-I006-0000 SPARK PLUG (STANDARD) 17 91521-08001400000 DOWEL PIN 8×14×6.3 28 91138-G012-00000X STUD M8×36 29 11015-I006-0000 RUBBER, CASING CAP 110 1122B-ME05-000086 CYLINDER HEAD ASSY 111 17100-MA76-0002 CARBURETOR ASSY (PZ30) 112 B061700006000090X NUT M6 213 B057830006002070X BOLT M6×20 214 15800-L044-0041 INLET PIPE (JQ-41) 115 B166740A06012570X BOLT M6×125 116 93301-3062201300B WASHER,6.2×2×13 117 91521-10002000000 DOWE PIN 10×20 218 90101-20750000265 O-RING 75×2.65 119 90202-I006-0000 GASKET,L.COVER 120 11227-I006-100186 L. COVER,CYLINDER HEAD 121 B166740A06002070X BOLT M6×20 222 9022B-ME05-0000 GASKET, CYLINDER HEAD 123 1110B-ME05-000086 CYLINDER COMP 124 90205-J025-0000 GASKET, CYLINDER BLOCK 1

CYLINDER ASSY. (S1)

Page 3: XT250 CB250 ES ZONGSHEN ENGINE - …xtrememoto.com.au/docs/XT250 XB35 Zongshen Engine Part (OHC)2.pdf · oil pump assy. (s5) ref.no. part no ... 29 90303-i006-0000 oil seal 20×34×7

REF.No. PART No. DESCRIPTION QTY1 15403-I006-0000 ADJUSTING NUT,TAPPET 22 15404-I006-0000 ADJUSTING SCREW,TAPPET 23 1540A-I006-0000 ROCKER ARM ASSEMBLY, VALVE 24 15707-I006-0000 VALVE KEEPER 45 15705-I006-0000 SPRING SEAT , VALVE 26 15710-I006-0000 INNER SPRING,VALVE 27 90211-I049-0000 GASKET 18 1572B-I008-0000 SEAL,VALVE STEM 29 15708-I008-0000 VALVE SPRING INNER SEAT 210 15706-I008-0000 VALVE SPRING OUTER SEAT 211 15702-LA74-0000 EX.VALVE 112 15402-I006-0100 SHAFT,VALVE ROCKET ARM 213 1553A-ME05-0000 GUIDE PLATE CHAIN 114 15301-L044-0000 TIMING DRIVEN SPROCKET 115 B057830006001270B BOLT M6×12 216 1532B-ME05-0000 TIMING CHAIN 117 1552A-ME05-0000 TENSION PLATE ASSY 118 93301-70851514000 WASHER 8.5×1.5×14 119 91109-I006-00000X BOLT 120 1554B-I049-000086 CHAIN TENSIONER ASSY. 121 B000700106001670X SCREW M6×16 222 90101-20090000180 O-RING 9×1.8 123 91120-I006-0000 SCREW M6×10 124 15100-ME05-0000 CAMSHAFT COMP 125 15701-LA74-0000 IN.VALVE 126 11201-I006-0000 POSITION PLATE,ROCKER SHAFT 127 B008190106001620B SCREW M6×16 128 2143B-L044-0000 BRACKET 129 B057830006001670B BOLT M6×16 1

VALVE ASSY. (S2)

Page 4: XT250 CB250 ES ZONGSHEN ENGINE - …xtrememoto.com.au/docs/XT250 XB35 Zongshen Engine Part (OHC)2.pdf · oil pump assy. (s5) ref.no. part no ... 29 90303-i006-0000 oil seal 20×34×7

REF.No. PART No. DESCRIPTION QTY1 B166740A06002570X BOLT M6×25 42 B166740A06003570X BOLT M6×35 23 B166740A06004070X BOLT M6×40 104 B166740A06005070X BOLT M6×50 15 12426-I008-0000 VIEW WINDOW,OIL LEVEL 16 90304-I006-0000 OIL SEAL 16×28×7 17 2242A-I006-07000G CLUTCH LEVER ASSY 18 90101-20087000190 OIL SEAL 8.7×1.9 29 22427-I006-0000 CLUTCH LEVER SPRING 110 B0087901030120000 PIN3×12 111 14301-I006-0000 OIL-RULER ASSY 112 90101-10180000300 O-RING 18×3 113 12421-I008-140185 CRANKCASE COVER, RH 114 91521-08001400000 DOWEL PIN 8×14×6.3 415 90206-I008-0000 GASKER, R.CRANKCASE COVER 116 B008180006001220X SCREW M6×12 417 B166740A06002070X BOLT M6×20 218 B166740A06002870X BOLT M6×28 219 90101-10630000265 O-RING 63×2.65 120 12308-I049-100085 COVER , REDUCTION GEAR 121 92102-000HK101410 BEARING (HK101410) 122 12301-I049-100085 CRANKCASE COVER, LH 123 90204-I049-0000 GASKER. L.CRANKCASE COVER 124 12303-G011-000085 CAP,SMALL SIGHT HOLE 125 90101-10132000265 O-RING 13.2×2.65 126 90101-10274000265 O-RING 27.4×2.65 127 12302-I049-070085 BACK COVER, L.CRANKCASE 128 12307-I008-10010G DECORATE COVER,L.CRANKCASE F.COVER 129 B166740A06005570X BOLT M6×55 3

CRANKCASE COVERS, LH - RH (S3)

Page 5: XT250 CB250 ES ZONGSHEN ENGINE - …xtrememoto.com.au/docs/XT250 XB35 Zongshen Engine Part (OHC)2.pdf · oil pump assy. (s5) ref.no. part no ... 29 90303-i006-0000 oil seal 20×34×7

REF.No. PART No. DESCRIPTION QTY1 22214-LA73-0000 DRIVE FRICITION PLATE,CLUTCH 72 22215-J034-0000 DRIVEN FRICITION PLATE,CLUTCH 63 22122-LA73-0000 PRESSURE PLATE,CLUTCH 14 22150-LA73-0100 CLUTCH OUTER CASE COMP 15 22403-I006-0000 ROD,CLUTCH PUSH 16 92102-00000016003 BEARING (16003) 17 22121-LA12-0000 END PLATE,CLUTCH COMP 18 91403-I008-0000 RING 20 19 91129-J034-00000B BOLT M5×20 610 22142-LA73-0000 SPRING CLUTCH 611 22105-LA73-0100 DRIVEN HUB ASSY,CLUTCH 112 22002-I006-0000 WASHER ,SPLINE 113 22000-LA73-0906 CLUTCH ASSY 1

CLUTCH ASSY. (S4)

Page 6: XT250 CB250 ES ZONGSHEN ENGINE - …xtrememoto.com.au/docs/XT250 XB35 Zongshen Engine Part (OHC)2.pdf · oil pump assy. (s5) ref.no. part no ... 29 90303-i006-0000 oil seal 20×34×7

REF.No. PART No. DESCRIPTION QTY1 14200-IA20-0100 OIL FILTER,COMP 12 23101-I006-0000 DRIVE GEAR 13 14203-IA20-0100 OIL FOLTER ROTOR BODY 14 90209-IA20-0000 GASKET,OIL FILTER CAP 15 22004-I006-0000 DISH WASHER 16.5×2×27 16 91202-I006-0000 LOCK NUT 17 14208-I006-0000 LOCK PIN 18 14207-IA20-00000W CAP, OIL FOLTER ROTOR 19 14202-I006-0000 SPRING,OIL THROUGH GUIDE 110 B008190105001220B SCREW M5×12 311 14201-I006-0000 THROUGH OIL,GUIDE 112 14100-L044-0001 OIL,PUMP ASSY 113 B008190106003020B SCREW M6×30 214 B057820005002070B BOLT M5×20 215 14113-L044-0000 COVER 116 14102-L044-0001 GEAR , OIL PUMP DRIVE 117 14107-L044-0200 AXES 118 14110-L044-0200 OIL PUMP COVER 119 14112-L044-0000 OUTER ROTOR OIL PUMP 120 14111-L044-0200 INNER ROTOR,OIL PUMP 121 B008190104001020B SCREW M4×12 222 14108-L044-0200 CAP , OIL PUMP COVER 123 90101-10094000240 O-RING 9.4×2.4 2

OIL PUMP ASSY. (S5)

Page 7: XT250 CB250 ES ZONGSHEN ENGINE - …xtrememoto.com.au/docs/XT250 XB35 Zongshen Engine Part (OHC)2.pdf · oil pump assy. (s5) ref.no. part no ... 29 90303-i006-0000 oil seal 20×34×7

REF.No. PART No. DESCRIPTION QTY1 B166740A06005570X BOLT M6×60 12 22422-IA18-01000X HOLDER,CLIUTCH CABLE 13 91102-L044-0000 STUD B 14 92102-000NK152312 BREATHER TUBE (NK152312) 15 92102-00000006006 BEARING (6006) 16 92102-000HK212810 BEARING (HK212810) 17 92102-00000006204 BEARING (6204) 18 1222B-ME05-000085 CRANKCASE COMP,R 19 91521-10001400000 PIN 10×14 410 91101-KA35-0000 STUD A 211 90208-ME05-0000 GASKET, CRANKCASE 112 1212B-IA27-000085 L.CRANKCASE COMP 113 1431B-I006-0000 STRAINER,OIL FILTER 114 14221-I006-0000 SPRING,OIL FILTER STRAINER 115 90101-20350000300 O-RING 35×3 116 11230-I006-00000W CAP, OIL STRAINER 117 90301-I006-0000 OIL SEAL 14×28×7 118 88001-I049-0500 GEARSHIFT SWITCH PLATE 119 91204-I049-0000 NUT , GEARSHIFT SWITCH PLATE M10 120 8803B-I049-050045 GEARSHIFT SWITCH COMP 121 12103-I008-0000 CLAMPER,WIRE HARNESS 122 B166740A06001270B BOLT M6×12 123 B166740A06005070X BOLT M6×50 1024 91102-L044-0100 STUD B 125 18097-I008-0000 CLIP,BREATH TUBE 226 12130-MA95-0200 BREATHER TUBE 127 12162-MA95-0000 OIL AND GAS SEPARATOR 128 12130-ME13-0101 BREATHER TUBE 129 90303-I006-0000 OIL SEAL 20×34×7 130 92102-0000TM6202Z BEARING (TM6202Z) 131 92102-000HK101410 BEARING(HK101410) 1

CRANKCASE, LH - RH (S6)

Page 8: XT250 CB250 ES ZONGSHEN ENGINE - …xtrememoto.com.au/docs/XT250 XB35 Zongshen Engine Part (OHC)2.pdf · oil pump assy. (s5) ref.no. part no ... 29 90303-i006-0000 oil seal 20×34×7

REF.No. PART No. DESCRIPTION QTY1 1310A-ME05-0000 PISTON RING COMP 12 91401-I006-0000 CIRCLIP, PISTON PIN 23 13102-LA66-0000 PISTON PIN 14 13101-ME05-0000 PISTON 15 92102-00TMSC06B42 BEARING (TM-SC06B42) 26 13220-ME05-0000 CONNECTING ROD COMP 3 17 91601-I008-0000 SEMICIRCLE KEY 25×14×4 18 13222-ME05-0000 TIMING SPROCKET 19 1320B-ME05-0000 CRANKSHAFT CONNECTING-ROD ASSY 1

CRANKSHAFT / PISTON ASSY. (S7)

Page 9: XT250 CB250 ES ZONGSHEN ENGINE - …xtrememoto.com.au/docs/XT250 XB35 Zongshen Engine Part (OHC)2.pdf · oil pump assy. (s5) ref.no. part no ... 29 90303-i006-0000 oil seal 20×34×7

REF.No. PART No. Description QTY1 93301-61521025000 WASHER 15.2×1×25 12 23222-LA73-0002 GEAR M-2 13 23222-LA73-0005 GEAR M-5 14 23223-I006-0000 SPACER 17.3(20)×1.6×26 35 91402-D002-0100 CIRCLI 36 23222-LA73-0004 GEAR M-4 17 23222-LA73-0003 GEAR M-3 18 23221-LA73-0000 TRANSMISSION MAIN SHAFT 19 93301-62020527000 WASHER 20.2×0.5×27 110 23231-I008-0000 FINAL SHAFT 111 93301-61521030000 WASHER 15.2×1×30 112 23248-I008-0000 COUNTERSHAFT STARTING GEAR 113 23203-I008-0003 BUSH 114 93301-51650524000 WASHER 16.5×0.5×24 215 23242-LA73-0001 GEAR C-1 116 23203-I006-0001 BUSH 117 23242-LA73-0003 GEAR C-3 118 23242-LA73-0004 GEAR C-4 119 23241-I008-0000 TRANSMISSION COUNTER SHAFT 120 23242-LA73-0005 GEAR C-5 121 23242-LA73-0002 GEAR C-2 122 93301-62020527000 WASHER 20.2×0.5×27 123 23401-I008-0008 DRIVE SPROCKET 124 23402-I006-0000 FIXING PLATE,DRIVE SPROCKET 125 B057830006001070B BOLT M6×10 226 93301-51211018000 WASHER 12.1×1×18 127 B0089401160000000 CIRCLIP 16 128 2112B-I008-0000 GUIDE PLATE ASS. 129 21119-I008-0000 SPRING, KICK STARTING RATCHET WHEEL 130 93301-51611024000 WASHER 16.1×1×24 131 21118-I008-0000 STARTING RATCHET 132 91402-I008-0000 CIRCLI φ18.5×1.2×φ22.4 1

TRANSMISSION / COUNTER-SHAFT / KICK START ASSY. (S8)

Page 10: XT250 CB250 ES ZONGSHEN ENGINE - …xtrememoto.com.au/docs/XT250 XB35 Zongshen Engine Part (OHC)2.pdf · oil pump assy. (s5) ref.no. part no ... 29 90303-i006-0000 oil seal 20×34×7

REF.No. PART No. Description QTY33 93301-62000527000 WASHER 20×0.5×27 134 21117-I008-0000 GEAR, KICK STARTER 135 21107-I008-0001 PIVOT, KICK STARTING SHAFT 136 21104-I008-0000 SEAT, SPRING, KICK STARTING SHAFT 137 21106-I008-0000 RETURN SPRING, KICK STARTING SHAFT 138 21111-I008-0000 COLLAPSIBLE 139 93301-51611030000 WASHER 16.1×1×30 140 21100-I008-0202 KICK STARTING SHAFT ASSEMBLY 141 23220-LA73-0000 MAIN SHAFT, TRANSMISSION 142 23240-LA73-0000 COUTERSHAFT TRANSMISSION 143 21200-I008-0009 KICK STARTER 1

TRANSMISSION / COUNTER-SHAFT / KICK START ASSY. (S8) CONT'

Page 11: XT250 CB250 ES ZONGSHEN ENGINE - …xtrememoto.com.au/docs/XT250 XB35 Zongshen Engine Part (OHC)2.pdf · oil pump assy. (s5) ref.no. part no ... 29 90303-i006-0000 oil seal 20×34×7

REF.No. PART No. Description QTY1 B057830006002070B BOLT M6×20 12 2434A-I008-0000 LOCATING PLATE ASSY 13 24304-I006-0000 SPRING ,LOCATING PLATE 14 B057830006002570B BOLT M6×25 15 B0009300060000000 WASHER 6 16 24202-I006-0500 FIVE STAR PLATE 17 B0011901040100000 PIN 4×10 18 24213-I006-0500 GEARSHIFT CAM 19 24107-I006-0000 SHAFT , GEARSHIFT FORK 110 24104-I006-0000 FORK , R.GEARSHIFT 111 24106-I006-0000 FORK , CENTER GEARSHIFT 112 24105-I006-0000 FORK , L.GEARSHIFT 113 B0089401120000000 CIRCLIP 12 114 24303-I006-0000 SPRING, GEARSHIFT PLATE 115 24319-I006-0000 GEARSHIFT PLATE 116 24301-I006-00000C SPINDLE COMP, GEARSHIFT 117 24302-I008-0000 RETURN SPRING , GEARSHIFT SHAFT 118 93301-51400520000 WASHER 14×0.5×20 219 B0089401140000000 CIRCLIP 14 120 24300-I006-00000C GEARSHIFT PLATE ASSY 121 24400-I008-0016 GEARSHIFT PEDAL COMP(BT-6) 1

GEAR SHIFT ASSY. (S9)

Page 12: XT250 CB250 ES ZONGSHEN ENGINE - …xtrememoto.com.au/docs/XT250 XB35 Zongshen Engine Part (OHC)2.pdf · oil pump assy. (s5) ref.no. part no ... 29 90303-i006-0000 oil seal 20×34×7

REF.No. PART No. Description QTY

1 82130-I049-0400 ROTOR ASSY,MAGNETO 1

2 91106-I008-0000 BOLT M8×33 13 B008230004001020B SCREW M4×10 24 B166740A06002870B BOLT M6×28 25 82120-I049-010043 STATOR ASSY,MAGNETO 1

6 B0009300040000000 WASHER 4 2

REF.No. PART No. Description QTY1 82200-ME05-030051 STARTING MOTOR ASSY 12 93301-51050518000 WASHER 10.5×0.5×18 43 21402-I049-0000 SHAFT,REDUCTION 14 2140A-L044-0000 GEAR, REDUCTION, 1 15 21401-L044-0000 GEAR, REDUCTION, 2 16 2142A-IA27-0000 STARTER GEAR ASSY 17 93301-E2203534000 WASHER 22×3.5×34 18 B166740A06002870X BOLT M6×28 29 82202-ME05-0000 WASHER 2

MAGNETO / FLYWHEEL ASSY. (S10)

STARTER ASSY. (S11)