Zontes ZT163ML Service Manual
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Zontes ZT163ML Service Manual

Engine euro v
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ZT163MLEngine Euro V
Service manual
2023/4/25

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Summary of Contents for Zontes ZT163ML

  • Page 1 ZT163MLEngine Euro V Service manual 2023/4/25...

  • Page 2: Table Of Contents

    目录 Table of Contents Pages Table of Contents…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… Drain engine oil and coolant procedure 1.1 Drain engine oil and coolant procedure……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… CYLINDER HEAD ASSEMBLY 2.1 Disassembly of cylinder head-1…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 2.2 Adjustment of valve clearance……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 5 2.3 Disassembly of the cylinder head-2 ……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 6 2.4 Disassembly of cylinder head sub-components……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………...
  • Page 3 目录 Table of Contents Pages CRANKCASE REMOBAL 7.1 Crankcase disassembly-1……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 23 7.2 Crankcase disassembly-2 ……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 24 7.3 Crankcase disassembly-3 ……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 25 7.4 Countershaft………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 26 7.5 Drive shaft…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… CRANKCASE BEARING AND OIL SEAL 8.1 Right crankcase parts…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 28 8.2 Parts of left crankcase…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 29 This manual is suitable for ZT125 series engines.

  • Page 4: Drain Engine Oil And Coolant Procedure

    1-Drain engine oil and coolant procedure PIG1 Drain engine oil and Drain engine oil and coolant procedure coolant procedure PART NO. PART NAME CAUTION 1251100-067093 M6×10 top pin bolt (color Zinc) 12±1.5N.m 1251513-001019 6.3×12×1.6 copper gasket 1251100-066093 M12×1.5×15 ablassschraube 30±3N.m 1244100-033000 Combined sealing gasket 12×φ20×2 PROCEDURE: ●Draining of engine oil and coolant...

  • Page 5: Cylinder Head Assembly

    12±1.5N.m 1051453-009000 O-ring， 13×2.8 1251100-061093 M6×22 Hex flang bolt thread 12±1.5N.m 1040957-001000 ZT163ML cylinder head side cover 1051457-001000 φ84.5×2.5 Acrylic O-ring PROCEDURE: ●Removal of cylinder head-1 Use a 10# inner hexagon to remove the screw plug ⑴ on the left cover of the engine, and remove the O-ring ⑵;...

  • Page 6: Adjustment Of Valve Clearance

    PART NAME CAUTION 1251300-096000 Non-standard cover type 9 degree nut M6×13 10±1.5N.m 1040957-002000 ZT163ML valve cover 1051457-002000 φ50×2 Acrylic O-ring PROCEDURE: ●Adjustment of valve clearance Use a 10 # sleeve to remove 4 nuts ⑴, and take out the valve chamber cover ⑵.

  • Page 7: Disassembly Of The Cylinder Head-2

    1251513-001019 6.3×12×1.6 copper gasket 1051270-004000 ZT1P72MN tensioner sub-assembly 1051253-004000 30×38 Washer, tensioner 1251100-340094 M6×10 Hexagon flange bolts 10±1.5N.m 1050157-012000 ZT163ML timing driven sprocket 1251100-061093 M6×22 Hex flang bolt thread 12±1.5N.m 1271200-199000 KD200-U thermostat 1051468-010000 16.5×1.95 EPDM 1251300-093000 Non-standard cap nut M8×18 25±3N.m...

  • Page 8: Disassembly Of Cylinder Head Sub-Components

    1050954-003000 communal sensor of water and oil 13±1.5N.m 1051454-009000 φ9×φ2 EPDM O-ring 1251112-001093 GB16674 M6×16 Hexagon flange bolts 12±1.5N.m 1051357-005000 ZT163ML camshaft bearing pressure plate 1050157-013000 ZT163ML rocker shaft 1050157-002000 ZT163ML intake rocker arm sub-assembly 1050157-001000 ZT163ML exhaust rocker arm sub-assembly 1050157-009000 ZT163ML Camshaft Parts 1051468-001000 8.8×1.9 fluorine rubber O-ring...

  • Page 9: Disassembly Of The Press-Fitted Assembly On The Cylinder Head

    PART NAME CAUTION 1050154-017000 ZT180MN Valve lock clamp 1050154-016000 ZT180MN Valve spring ring 1050157-007000 ZT163ML intake valve outer spring 1050158-001000 ZT184MP valve inner spring 1051553-001000 Φ5.0 valve stem diameter oil seal 1050153-015000 16.5×23.5×1 valve spring seat 1050157-004000 ZT163ML exhaust valve 1050157-003000 ZT163ML intake valve 1251111-011000 AYM8-M8×38 double head 10.9 studs bolts...

  • Page 10: Cylinder Block Disassembly And Decomposition

    1051657-001000 ZT163ML cylinder head gasket 1051657-002000 ZT163ML Cylinder block box gasket 1251401-003000 φ10×14 dowel pin 1250105-136093 GB5789M6×12 (environmental color) 10±1.5N.m 1051957-008000 ZT163ML cylinder inlet pipe joint (pier system) 1051457-006000 16×2.5 EPDM O-ring 4050557-001000 ZT163ML cylinder block PROCEDURE: ●Cylinder block disassembly and decomposition Take the guide bar ⑴...

  • Page 11: Disassembly And Decomposition Ofpiston Components

    PART NO. PART NAME CAUTION 1050457-004000 18.1×1 piston pin retaining ring 1050457-003000 16×41×9 Piston Pin 1050457-001000 ZT163ML piston 1050457-005000 63.5×0.8×2.1 first air ring 1050457-006000 63.5×0.8×2.1 second air ring 1050457-007000 63.5×1.5×2.2 oil ring combination PROCEDURE: ●Disassembly and decomposition ofpiston components Use needle-nose pliers to take out one end of the piston pin retaining ring ⑴...

  • Page 12: Right Crankcase Cover Assembly

    PART NO. PART NAME CAUTION 1251112-003093 GB16674 M6×45 Hex flange flange bolt 12±1.5N.m 1050757-004000 ZT163ML clutch cable bracket 1051656-004000 ZT158MJ right crankcase cover gasket 1251401-001000 φ8×14 hollow locating pin PROCEDURE: ●Remove the right crankcase cover assembly Use an 8# sleeve to remove the 12 bolts ⑴ on the right cover assembly, and remove the bracket ⑵.

  • Page 13: Decompose The Right Crankcase Cover Assembly-1

    1251100-067093 M6×10 top pin bolt (color Zinc) 12±1.5N.m 1251112-002093 GB16674 M6×30 Hexagon flange bolts 12±1.5N.m 1251513-001019 6.3×12×1.6 copper gasket 4050457-031051 ZT163ML water pump cover (dark gray) 4050457-030051 ZT163ML water pump cover (titanium) 1051454-006000 ZT180MN Water pump sealing ring ∅ 1051968-010000 ZT1P58MJ water pump blade 20±1.5N.m...

  • Page 14: Decompose The Right Crankcase Cover Assembly-2

    1050357-004000 ZT163ML water pump gear 1251512-007000 Thrust washer,12.2×20×1 1250511-002000 GB896 opening retaining ring φ6×1 1251512-003000 8.2×14×0.5 thrust washer 1050756-014000 ZT158MJ clutch rod shaft 1051957-005000 ZT163ML inlet and outlet water pipe joints 20±1.5N.m 1051457-003000 13×1.8 EPDM O-ring 4050457-021051 Right crankcase cover press-fit assembly (dark gray）...

  • Page 15: Decompose The Press-Fit Assembly Of The Right Crankcase Cover

    4-Right crankcase cover assembly PIG4 Right crankcase Decompose the press-fit assembly of the right cover assembly crankcase cover PART NO. PART NAME CAUTION 1250700-012000 GB/T 893 φ26 circlip for hole 1050857-007000 Φ 25 hydrogenated nitrile rubber engine oil window 1051354-013000 type hole circlip φ24×1 1051553-002000 FB14×22×5 Hydrogenated nitrile oil seal 1250602-033000 HK1412 needle roller bearing 1250602-022000 GB290-HK1010 needle roller bearing...

  • Page 16: Removal Of The Clutch Assembly

    4-Right crankcase cover assembly PIG5 Right crankcase Removal of the clutch assembly cover assembly PART NO. PART NAME CAUTION 1050756-015000 ZT158MJ clutch toothed rod 1251311-001094 Nut, M16×1 95±10N.m 1251514-002000 Lock washer, 16.2×28×2.4×2 1251512-039000 Φ16.2×φ28×1.5 thrust washer 1251602-001000 263124 duplex needle bearing 1251700-148000 ZT158MJ clutch bush 1251512-038000 Φ20.2×φ37×2 thrust washer PROCEDURE:...

  • Page 17: Clutch Parts Assembly

    PART NO. PART NAME CAUTION 1251500-084000 ZT158MJ clutch spline washer 1050757-002000 ZT163ML clutch active hub sub-assembly 1050757-003000 ZT163ML clutch driven hub sub-assembly PROCEDURE: ●Clutch parts assembly Take the friction plate assembly ①, driven disc ② and spline washer ⑴ out of the driving hub subassembly.

  • Page 18: Left Crankcase Cover Assembly

    12±1.5N.m 1251201-002094 internal hexagonal screw 12±1.5N.m 1051056-001000 ZT158MJ magnetic motor stator sub-assembly 4050357-004051 ZT163ML left crankcase cover (dark gray) 4050357-005051 ZT163ML left crankcase cover (titanium) PROCEDURE: ●Removing and disassembling the left cover assembly Use an 8# socket to remove 7 bolts ⑴, take out the left cover assembly, and then take out the gasket ⑵...

  • Page 19: Magneto Assembly Removal

    PIG2 Left crankcase Magneto Assembly Removal cover assembly PART NO. PART NAME CAUTION 1051057-004000 ZT163ML electric starter reduction gear shaft 1051057-006000 ZT163ML electric starter reduction gear 1251100-341094 M10×1.25×45 hex flange bolt 60±5N.m 1251500-041000 10.3×20×2 gasket 1051057-003000 ZT163ML magneto rotor clutch parts 1251802-003000 4×4.6×25×14 woodruff key...

  • Page 20: Crankcase Parts

    1050868-004000 Outer diameter φ22×21 hat-shaped strainer 1251100-066093 M12×1.5×15 ablassschraube 30±3N.m 1244100-033000 Combined sealing gasket 12×φ20×2 1251100-165000 M6×16-13.8×8.7 pivot bolt 12±1.5N.m 1051257-002000 ZT163ML tensioner 1250106-112000 GB9074.13 bolt M5×20 5±1N.m 1050656-010000 ZT158MJ gear display module 1051454-011000 22.5×2.5 fluoro rubber o-ring PROCEDURE: ●Removal of crankcase parts-1 Use a 5 # inner hexagon to remove 2 bolts ⑴, and remove the sensor ⑵...

  • Page 21: Removal Of Crankcase Parts-2

    1251500-107000 ZT163ML sprocket lock washer 1050357-005000 ZT163ML secondary shaft output sprocket 1050257-011000 ZT163ML output sprocket bushing subassembly 1251100-119093 Non-standard bolt M6×12 1051357-006000 ZT163ML auxiliary shaft oil seal cover 1251100-067093 M6×10 top pin bolt (color Zinc) 12±1.5N.m 1051256-003000 ZT158MJ tensioning guide pressure plate 1251112-002093 GB16674 M6×30 Hexagon flange bolts...

  • Page 22: Removal Of Crankcase Parts-3

    1260100-246000 ZT158MJ limit stop wheel return spring 1251100-321093 Big head hexagon socket head cap bolt M6×25 12±1.5N.m 1050657-002000 ZT163ML shift star cam sub-component PROCEDURE: ●Removal of crankcase parts-3 Use a pick to pick out the retaining ring ① on the oil pump assembly ⑴, and take out the gear ②...

  • Page 23: Removal Of Crankcase Parts-4

    1251112-005093 GB16674 M6×75 Hexagon flange bolts 12±1.5N.m 1051957-007000 ZT163ML right box intake mouth plate 1051657-004000 ZT163ML right box air inlet paper pad PROCEDURE: ●Removal of crankcase parts Use a suitable tool to hold the balance shaft drive tooth ⑷, and then use 19# sleeve and 24# sleeve to remove the bolt ⑴...

  • Page 24: Crankcase Remobal

    7-Crankcase removal PIG1 Crankcase removal Crankcase removal-1 PART NO. PART NAME CAUTION 1251112-002093 GB16674 M6×30 Hexagon flange bolts 12±1.5N.m 1251112-005093 GB16674 M6×75 Hexagon flange bolts 12±1.5N.m 1251112-003093 GB16674 M6×45 Hex flange flange bolt 12±1.5N.m 1251112-004093 GB16674 M6×60 Hexagon flange bolts 12±1.5N.m PROCEDURE: ●Crankcase removal-1...

  • Page 25: Crankcase Disassembly-2

    PIG2 Crankcase removal Crankcase removal-2 PART NO. PART NAME CAUTION 1251401-001000 φ8×14 hollow locating pin 1051657-003000 ZT163ML crankcase gasket 1050656-011000 ZT158MJ shift fork shaft 1050651-006000 ZT154FMI shifting spindle fork shaft 1050656-002000 ZT158MJ shifting auxiliary shaft fork 1050656-001000 ZT158MJ shifting spindle fork...

  • Page 26: Crankcase Disassembly-3

    CAUTION 1050257-002000 Transmission countershaft sub-components 1050257-001000 ZT163ML drive spindle sub-components 1050557-001000 ZT163ML balance shaft 1050457-002000 ZT163ML crankshaft connecting rod parts 4050157-003000 ZT163ML left crankcase press-fit assembly PROCEDURE: ●Crankcase removal-3 Take out the auxiliary shaft ⑴ and the main shaft ⑵ from the left box at the same time.

  • Page 27: Countershaft

    7-Crankcase removal PIG4 Crankcase removal Countershaft PART NO. PART NAME CAUTION 1050257-002000 Transmission countershaft sub-components PROCEDURE: ●Countershaft The spare parts of the transmission countershaft are not sold separately and disassembly without permission is strictly prohibited. This figure only shows the approximate assembly sequence of the transmission countershaft.

  • Page 28: Drive Shaft

    PIG5 Crankcase removal Drive shaft PART NO. PART NAME CAUTION 1050257-001000 ZT163ML drive spindle sub-components PROCEDURE: ●Drive shaft The spare parts of the drive shaft are not sold separately and disassembly without permission is strictly prohibited. This figure only shows the approximate assembly sequence of the drive shaft.

  • Page 29: Crankcase Bearing And Oil Seal

    1251112-001093 GB16674 M6×16 Hexagon flange bolts 12±1.5N.m 1051356-006000 ZT158MJ spindle bearing pressure plate 1051356-013000 Bearing press plate of the right box balance shaft 4050257-003000 ZT163ML right crankcase press-fit assembly 1250602-047000 NJ303E/C3 Cylindrical Roller Bearings 1250601-043000 GB276-6204/P6 deep groove ball bearing 1250601-134000 6805 Bearing (P6) 1250601-039000 GB276-6203/P6 deep groove ball bearing 1251900-053000 YM8×1.25-M8×1.25×213 studs...

  • Page 30: Parts Of Left Crankcase

    1250601-036000 GB276-6202RS/P6 deep groove ball bearing 1250601-097000 GB276-62/22RS/P6 deep groove ball bearing 1250602-020000 HK222910 needle roller bearing 4050157-001000 ZT163ML left crankcase (machined) 1051353-014000 ZT184MP Rear lifting hole bushing 1051554-002000 FB30×42×7 hydrogenated nitrile oil seal 1051553-005000 FB14×28×7 Fluorine rubber oil seal PROCEDURE: ●Left crankcase parts...

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