Zontes ZT1P77MP Maintenance Manual
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Zontes ZT1P77MP Maintenance Manual

Zontes ZT1P77MP Maintenance Manual

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ZT1P77MP
Engine Maintenance
Manual
2023-2-15
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Summary of Contents for Zontes ZT1P77MP

  • Page 1 ·1 ZT1P77MP Engine Maintenance Manual 2023-2-15 1/ 63...
  • Page 2 For parts upgrades, please refer to the part codes on the official website of Zontes, which will not be listed in detail in this manual; if the names of parts in this manual are inconsistent with the official website of Zontes, the official website of Zontes shall prevail.
  • Page 3 Notice to users This manual is compiled by Guangdong Tayo Motorcycle Technology Co., Ltd. and is used to guide dealers or service personnel. This manual cannot provide more detailed knowledge about motorcycles, and is only for reference for maintenance. If you do not have the corresponding knowledge such as electrician, machine repair, etc., improper assembly or maintenance failure may occur during repair.

  • Page 4: Table Of Contents

    Table of contents Table of contents ..................4 Lubrication system ..................6 1.Diagram of lubrication system ..............6 2. Maintenance information ................. 8 3. Common failure phenomenon/troubleshooting ............8 4. Oil pump ..................9 Cylinder head cover, cylinder head ..............11 1.
  • Page 5 3. Common failure phenomenon/troubleshooting ............56 Fourth, the decomposition of the crankcase ............57 5. Assembly of the crankcase ..............60 Sixth, left and right crankcase suspension disassembly, inspection ........62 Seven, fine filter .................. 62 5/ 63...

  • Page 6: Lubrication System

    Lubrication system 1. Diagram of lubrication system 6/ 63...
  • Page 7 7/ 63...

  • Page 8: Maintenance Information

    2. Maintenance information General information 1. This chapter introduces the structural composition of the lubrication system and the maintenance of related parts. 2. The maintenance of the oil pump can be carried out on the whole vehicle without dismantling the engine separately. 3.

  • Page 9: Oil Pump

    · Remove the muffler. (Refer to the ZT350T-D maintenance manual for disassembly and assembly-- 2. Maintenance-air filter (filter element)-bolts and nuts of the muffler) · Remove the right crankcase cover of the engine. (Refer to ZT1P77MP engine maintenance manual for disassembly and assembly--right crankcase cover, magneto-right crankcase cover, magneto stator) ·...
  • Page 10 ·Install the magneto rotor. (Refer to ZT1P77MP engine maintenance manual for installation - right crankcase cover, magneto - magneto rotor) ·Install the right crankcase cover of the engine. (Refer to ZT1P77MP engine maintenance manual for installation - right crankcase cover, magneto - right crankcase cover, magneto stator) ·Install the muffler.

  • Page 11: Cylinder Head Cover, Cylinder Head

    Name Quantity ZT1P72MN oil pump shaft assembly ZT1P72MN oil pump upper housing External rotor JBZ-29-11 Internal rotor JBZ-29-11 2.5x12 cylindrical pin 3x12 cylindrical pin ZT1P72MN oil pump lower housing 86x11.5x1 thrust spacer External rotor JBZ-29-18 Internal rotor JBZ-29-18 ZT1P72MN Oil Pump Cap Cylinder head cover, cylinder head 1.
  • Page 12 ZT1P77MP cylinder head φ17.2×φ25×1 valve spring base clamp bracket φ5.0 valve rod diameter oil seal LMAR8A－9 spark plug AYM8－M8×38 double head ZT1P77MP valve outer spring 10.9 grade stud ZT1P77MP cylinder head ZT1P77MP valve inner spring ZT1P72MN cylinder head ZT1P77MP valve spring bearing...

  • Page 13: Maintenance Information

    M6×30 hexagonal flange bolts ZT1P77MP rocker limit block (environmental protection color zinc) M6×10 top pin bolt M5×15－5# hexagon socket (environmental protection color head screw (oxidized black) zinc) ZT1P77MP high-pressure fuel Water and oil shared sensor pipe bracket (short wheelbase) ZT1P77MP cylinder head cover...

  • Page 14: Fault Phenomenon/Fault Analysis

    M6×22 hexagon flange full thread Thermostat lock bolt 1 2 ± 1 .5 bolts M6×16 hex flange bolts 1 2 ± 1 .5 LMAR8A－9 spark plug 1 4 ± 1 tool 1. Pliers. 2. T-shaped sleeve -8#. 3. T-shaped socket-10# / torque wrench+10# socket. 4.

  • Page 15: Cylinder Compression Test

    1. Preheat the engine to the normal operating temperature, stop the engine, pull out the spark plug cap and remove the spark plug (refer to ZT1P77MP maintenance manual for disassembly - 2. Maintenance - spark plug). 2. Install the cylinder pressure gauge connector into the spark plug hole.

  • Page 16: Cylinder Head

    Cylinder head cover installation 1. As shown in the figure, after removing the plane sealant, oil stains and dust on the joint surface of the cylinder head and the cylinder head cover, apply an appropriate amount of plane sealant on the position shown in the figure. Check the cylinder head cover sealing ring and wire harness bracket on the cylinder head cover.
  • Page 17 3. As shown in the picture, use T bar -8# to remove the tensioner, timing driven sprocket fixing bolts, and timing driven sprocket (refer to ZT1P77MP engine maintenance manual for disassembly and assembly - cylinder head cover, cylinder head - tensioner) .
  • Page 18 (short-wheelbase model does not have an oxygen sensor installed). Remove the spark plug with a spark plug socket. Use a 17# plum wrench to remove the water oil temperature sensor. 3. As shown in the figure below, loosen the cylinder head pressure plate and camshaft pressure plate bolts, and remove the cylinder head pressure plate and camshaft pressure plate.
  • Page 19 5. As shown in the picture, screw two M6 bolts into the threaded holes of the camshaft, keep the camshaft angle consistent with the T point of the alignment timing or slightly rotate counterclockwise to an appropriate angle, and remove the camshaft.
  • Page 20 The intake and exhaust rocker rollers rotate smoothly without abnormal noise. Intake rocker arm label Exhaust rocker arm logo ZT1P77MP inner valve spring ZT1P77MP valve outer spring 3. Intake and exhaust valve springs a. The intake and exhaust springs have no cracks and abnormal wear.
  • Page 21 6. Cylinder head bearing a. Check the cylinder head bearing. The inner ring of the bearing should rotate smoothly without stagnation. If the inner ring of the bearing is stuck, please replace the cylinder head bearing. Cylinder head 1. As shown in the figure, use an air gun to blow the oil passage of the cylinder head to ensure that the oil passage of the cylinder head is unblocked.
  • Page 22 3. As shown in the figure, install the camshaft (O-rings need to be installed), the intake rocker arm sub-assembly, the exhaust rocker arm sub-assembly, and the intake and exhaust rocker arm shaft in sequence. (Note: O-rings cannot be missed on the camshaft. When the camshaft is installed, the normal T-point position needs to be inserted at an appropriate angle in the counterclockwise direction to install it in place.
  • Page 23 (Note: cylinder head gaskets cannot be reused. After dismantling the cylinder head, the gasket of the cylinder body box needs to be replaced, and the joint surface needs to be sealed with flat sealant. For the installation of the cylinder piston, refer to the ZT1P77MP Engine Maintenance Manual--Cylinder, Piston) . Positioning pin 12×20 Cylinder head gasket 2.

  • Page 24: Guide Bar

    M6×16 bolts, and tighten the timing sprocket with a fixed torque (torque is 12 ± 1.5 N•m ). After confirming that it is in place, install the tensioner. (For tensioner installation, refer to ZT1P77MP Engine Maintenance Manual - Cylinder Head Cover, Cylinder Head - Tensioner).

  • Page 25: Tension Strip

    ·Tensioner. (Refer to ZT1P77MP engine maintenance manual for disassembly and assembly--cylinder head cover, cylinder head-tensioner) ·Cylinder head cover parts. (Refer to ZT1P77MP engine maintenance manual for disassembly and assembly-- cylinder head cover, cylinder head-cylinder head cover) ·Cylinder head sub-assembly. (Refer to ZT1P77MP engine maintenance manual for disassembly and assembly-- cylinder head cover, cylinder head-cylinder head) ·Cylinder piston sub-assembly.
  • Page 26 ·Electric starter big gear. (Refer to ZT1P77MP engine maintenance manual for disassembly and assembly - right crankcase cover, magneto - magneto rotor) Tension strip removal 1. As shown in the picture, use a 5# inner hexagon to remove the fixing bolt of the tensioner, and remove the tensioning strip.

  • Page 27: Tensioner

    9. Tensioner Tensioner Removal 1. As shown in the picture, use T bar -8# to remove the top bolts and copper pads of the tensioner, then loosen the tensioner fixing bolts evenly diagonally, and remove the tensioner and tensioner gasket. Examine 1.

  • Page 28: Cylinder, Piston

    Serial Part Name Quantity number number 19×2.65 EPDM O-ring φ 12×20 hollow positioning pin ZT1P77MP cylinder water inlet pipe 18×44×11 piston pin joint GB5789M6×12 (environmental ZT1P77MP oil ring combination protection color) 20.4×1.2 piston pin retaining ring ZT1P77MP second gas ring...

  • Page 29: Maintenance Information

    ·This chapter introduces the maintenance of cylinder and piston. ·The maintenance of cylinder and piston needs to remove the engine from the whole vehicle. .Remove the cylinder head cover. (Refer to ZT1P77MP engine maintenance manual for disassembly and assembly--cylinder head cover, cylinder head-cylinder head cover) ·Remove the tensioner.

  • Page 30: Piston

    Remarks: ① Turn the piston to the top dead center before disassembly, and fix the crankshaft when pulling out the cylinder. ② Do not drop the timing chain into the crankcase. ③ When the cylinder is pulled out of the piston, fix the piston and connecting rod by hand or other auxiliary tools to avoid collision with the box and cause damage.
  • Page 31 2. Pull off each piston ring and remove it by lifting it to a position directly above the gap, use an old piston ring that has been used or other suitable objects to remove the carbon deposits on the piston ring groove. Piston ring groove Piston ring Examine...
  • Page 32 PVD2/D marked side DLC1/DY marked side 2. Insert the piston pin into the piston and install it on the connecting rod, and install the piston pin retaining ring into the ring groove with needle-nose pliers. Remarks: ① Apply an appropriate amount of engine oil to the piston pin hole and the small end hole of the connecting rod.

  • Page 33: Left Crankcase Cover, Continuously Variable Clutch Sub-Assembly

    Left crankcase cover, continuously variable clutch sub-assembly 1. System components 33/ 63...
  • Page 34 M18×1 hexagon flange nut (grade ZT1P77MP clutch jacket 10/environmental protection color zinc) φ 18.5×φ30×19.1 Drive wheel bushing ZT1P77MP driven wheel shoe assembly φ 26×φ2 fluorine rubber O-ring ZT1P77MP driven wheel sliding plate ZT1P77MP main fixed disk ZT1P77MP driven wheel fixed...

  • Page 35: Maintenance Information

    M14×1 hexagon flange nut (grade φ 10×14 hollow positioning pin 10/environmental protection color zinc) φ 21.2×φ1.8 fluorine rubber O-ring ZT1P77MP left crankcase cover A φ 14.5×φ25×16 driven wheel bushing 2. Maintenance information General information 1. This chapter introduces the repair and maintenance of driving wheel and driven wheel.

  • Page 36: Left Crankcase Cover

    4. When the engine is idling normally, the rear wheels rotate rapidly. · Centrifugal roller stuck in return position. ·The small spring of the driven wheel shoe block is damaged. ·The driven wheel bearing is damaged and the bearing is stuck. 4.

  • Page 37: Cvt Clutch Sub-Assembly

    4. Take off the M18×1 hexagon flange nut and φ 18.5×φ30×19.1 driving wheel bushing , and then remove the M14×1 hexagon flange nut and φ 14.5×φ25×16 driven wheel bushing . 5. Remove the positioning fixture of the driving and driven wheels, and remove the ZT1P77MP main fixed plate from the crankshaft.
  • Page 38 3. Check whether the inner circular surface of the driven wheel clutch casing and the driven wheel clutch shoe are worn or damaged, and they need to be replaced if they appear. ( Note: It is not recommended to grind the clutch shoes, which will increase the wear of the inner ring of the clutch casing and the clutch shoes, and may also cause riding vibration.) assembly...
  • Page 39 7. Put the ZT1P77MP driving wheel bushing equipped with two φ26×φ2 fluorine rubber O-rings and grease on the crankshaft, and take an M18×1 hexagonal flange nut and screw it into the crankshaft manually .

  • Page 40: Right Crankcase Cover, Magneto

    M6×45 hexagonal flange surface M5×15－5# hexagon socket head 9.8 grade bolts (environmental screw (oxidized black) protection color zinc) ZT1P72MN right crankcase ZT1P77MP magneto stator parts cover (dark gray) ZT1P77MP right crankcase cover trigger gasket ZT1P77MP water pump blade 18×3×3.5 Acrylic O-rings...

  • Page 41: Right Crankcase Cover / Magneto Stator

    M6×30 hexagonal flange bolts ZT1P72MN electric starter (environmental protection color reduction gear assembly zinc) 5×5.7×16 half round keys GB5789M6×12 (environmental protection color) ZT1P7 7 MN magneto rotor φ5.6×φ1 EPDM O-ring subassembly φ10.3×φ28×4 washer φ8×14 hollow positioning pin M10×1.25×45 hex flange bolts ZT1P72MN water pump cover O- (grade 10.9/oxidized black) ring...
  • Page 42 Install 1. Put the sub-components of the magneto stator on the corresponding position of the right crankcase cover, and install three GB70.1M6×25 (environmentally friendly colored zinc) bolts and three M5×15-5# inner hexagon cylindrical screws (oxidized black) Apply an appropriate amount of thread glue on the thread of the thread, screw it into the corresponding threaded hole with a torque wrench and the inner hexagonal gun head -5# and tighten it.

  • Page 43: Magneto Rotor

    3. Apply an appropriate amount of flat sealant on the waterproof rubber sleeve of the right crankcase cover and press it tightly, install the right crankcase cover, use a torque wrench and an extended outer hexagon socket -8# to insert 14 M6×45 hexagonal flange surface 9.8 grade bolts (environmental protection color zinc) tighten, 13 bolts torque is 12±1.5 N·m , one bolt plus 6.3×12×1.6 copper pad, fixed torque is 10±1 N·m.
  • Page 44 Half round key Thrust washer Electric starter gear Electric starter reduction gear shaft Electric starter reduction gear assembly wheel Install 1. After checking that the electric starter large gear, 25.2×37×1.6 thrust washer , electric starter reduction gear assembly , and electric starter reduction gear shaft are all installed correctly, use a copper rod to knock the half-round key into the crankshaft.

  • Page 45: Water Pump

    Special fixture Timing line φ10.3×φ28×4 washer M10×1.25×45 hex flange bolts (grade 12.9/oxidized black) 3. Install the right crankcase cover after the flywheel is installed. 4. Water pump to disassemble The combined parts of the water pump are detailed in the system components and parts information table. 1.
  • Page 46 Use a flathead screwdriver to pry out the two oil seals, and then knock out the bearings to complete the disassembly of (Note: When the water pump is running normally without failure, it is not recommended to the water pump. disassemble the water pump, internal bearings, oil seals, and water seals.
  • Page 47 3. Take a new water seal, check to make sure that the surface of the water seal is clean and free of debris, apply 962T bowl-shaped plug sealant on the hole where the water seal is installed, and press the water seal in place with the special pressure head for installing the water seal.
  • Page 48 6. Limit the water pump shaft with a flat-head screwdriver, take a water pump blade, use a 12# wrench to turn left to tighten the water pump blade to the water pump shaft, and tighten it with a 12# sleeve and torque wrench. Torque standard: 20N·m±...

  • Page 49: Gearbox

    Serial Serial Name Quantity Name Quantity number number GB16674M8×40 (environmental ZT1P77MP double gear assembly protection color zinc) FB25×42×6 fluorine rubber oil ZT1P77MP output shaft seal FB38×56×7 hydrogenated nitrile ZT1P77MP gearbox cover oil seal ZT1P72MN gearbox cover gasket GB893.1 circlip φ55 for holes GB276-6006-2RS/P5C3 deep φ10×14 hollow positioning pin...

  • Page 50: Maintenance Information

    ZT1P77MP drive shaft bearing M14×1.5 oil filler nut pressure plate GB5789M6×12 (environmental ZT1P58MJ cylinder head cover protection color) air balance tube ZT1P77MP drive shaft 8.3×16×1.5 copper gasket GB276-6204/P5C3 deep groove Non-standard bolt M8×25 ball bearings (nitrogenation) (environmental protection color) GB276-6204/P5C3 deep groove GB276 －...

  • Page 51: Disassembly And Decomposition Of The Gearbox

    ·Left crankcase cover ( Refer to ZT1P77MP engine maintenance manual -- left crankcase cover, continuously variable clutch subassembly -- left crankcase cover ) ·CVT assembly ( Refer to ZT1P77MP engine maintenance manual -- left crankcase cover, CVT clutch sub- assembly -- CVT clutch sub-assembly ) ·Rear brake oil pipe, rear rocker arm assembly ( Refer to ZT350T-D maintenance manual -- 2.

  • Page 52: Five, Gearbox Gear, Bearing Inspection

    GB276-6204/P5C3 deep groove ball bearings (nitrogenation) GB276－63/22P5C3 deep groove ball bearings (nitrogenation) ZT1P77MP drive shaft Drive shaft oil seal GB276－6205/C3H-F deep groove ball bearings Inspection of left crankcase bearing and oil seal 1. As shown in the figure, turn the inner ring of the bearing by hand, and the bearing will rotate smoothly and silently. If the bearing rotates stuck, please replace the bearing.

  • Page 53: Gear Box Assembly

    Drive shaft helical gear ZT1P77MP output gear ZT1P77MP double gear assembly 6. Gear box assembly Before the gear case cover is installed, remove oil stains and residual paper pads on the joint surface of the gear case cover, and check the joint surface of the gear case cover to ensure that there are no scratches or bumps.

  • Page 54: Crankcase

    Parts information Name Quantity Serial Name Quantity Serial number number ZT1P77MP right crankcase B GB276-6304P5C3 deep groove ball bearings (nitridation) ZT1P77MP lower hanging bush ZT1P77MP balance shaft press assembly assembly Locating pin 12×20 Φ 8×14 hollow positioning pin YM10×1.25－M10×1.25×190 stud...

  • Page 55: Maintenance Information

    (Note: For the ZT1P77MP model, the upper hanging material and the lower hanging material box of the left and right boxes are the same. The pressing position of the hanging hanger is related to the vehicle model. When disassembling and assembling, select the corresponding material assembly drawing for reference according to the actual situation.)

  • Page 56: Common Failure Phenomenon/Troubleshooting

    ·Left crankcase cover (refer to the ZT1P77MP engine maintenance manual for disassembly and assembly of the left crankcase cover--left crankcase cover, continuously variable clutch sub-assembly) CVT clutch (refer to ZT1P77MP engine maintenance manual for disassembly and assembly of CVT clutch - left crankcase cover, CVT clutch sub-assembly) ·Right crankcase cover (Refer to ZT1P77MP engine maintenance manual for disassembly and assembly of the...

  • Page 57: Fourth, The Decomposition Of The Crankcase

    2. Remove the tension strip Refer to the ZT1P77MP engine maintenance manual for disassembly and assembly of the tension strip - cylinder head cover, cylinder head - tension strip. 3. Disassembly and assembly of the guide bar pressure plate ①...
  • Page 58 5. Disassemble the crankcase ① As shown in the figure below, use tool 1 or tool 2 to remove the starter motor. ② Use tool 1 or tool 2 to evenly remove the crankcase locking bolts diagonally, first remove the 8 M6× 75 hexagonal flange surface bolts on the left side , and then rotate the box to remove the 5 M6×...
  • Page 59 Crankshaft journal Oil pump drive gear Timing driving gear ●Connecting rod big end backlash inspection Insert a feeler gauge between the crankshaft and the big end face of the connecting rod to measure the clearance. Maintenance limit value: 0.40mm (0.016in) Connecting rod big end backlash Check the fit clearance between crankshaft main journal and bearing bush...

  • Page 60: Assembly Of The Crankcase

    Service Threshold: 0.03 mm (0.0012 in) 5. Assembly of the crankcase Before assembly, clean the interior of the crankcase and all mating surfaces, and check for cracks or other damage. ① Apply an appropriate amount of engine oil to the inner ring of the left crankcase bearing, the cage, the inner diameter of the bearing bush, and the lip of the oil seal.
  • Page 61 Positioning pin Mesh to point ④ As shown in the figure, apply a layer of flat sealant on the joint surface of the right crankcase, and apply an appropriate amount of engine oil on the inner ring of the bearing, the cage, and the inner diameter of the bearing bush. Apply oil Flat sealant ⑤...

  • Page 62: Sixth, Left And Right Crankcase Suspension Disassembly, Inspection

    Sixth, left and right crankcase suspension disassembly, inspection Hanging inspection 1. As shown in the picture, hold the two ends of the φ 12.2×φ20×35.3 upper suspension bush or the φ 16.3×φ25×45.5 lower suspension bush by hand , and turn it back and forth. If it can rotate, it is qualified. (Note: If the hanging bush is stuck and cannot be rotated, it needs to be disassembled and added an appropriate amount of high temperature resistant and high load resistant grease.) φ12.2×φ20×35.3 upper hanging bushing...
  • Page 63 with a fixed torque: 20-25N.m (Note: the fine filter There is no scratch or damage on the O ring, and no bump or scratch on the installation joint surface of the fine filter of the left box) . Note: Please refer to the ZT350D maintenance manual for normal maintenance of the fine filter of the engine -- 2.

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