Page 1 ZT350E Maintenance Manual 2023-10-23 1 / 111...
Page 2 For colors or upgrades, please refer to the part codes on the official website of Zontes. This manual will not be listed in detail; if the part names in this manual are inconsistent with the official website of Zontes, please refer to the official website of Zontes.Individual parts of different displacements that differ in shape or...
Page 3 User notice This manual is compiled by Guangdong Tayo Motorcycle Technology Co., Ltd. to guide dealers or service personnel to use it. 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 repair failure may occur during repair.
Page 4 Content Content ....................................... 4 1. Motorcycle information .................................. 9 Know Before Service ................................9 Body label ....................................10 E350 Technical specification ..............................11 Front wheel/steering system ............................11 Rear wheel/suspension system ............................11 Brake system ..................................11 Battery/charging system ..............................12 0Lamp/Speedometer/switch description ..........................
Page 5 Radiator..................................... 39 1. Check the coolant................................39 2. E350 add coolant (antifreeze) to the Coolant expansion tank ..................39 3. E350 add coolant to the Radiator ..........................39 4. Put coolant ..................................40 5. Check whether the fins of the radiator water tank are deformed or the air duct is blocked ........40 6.
Page 6 Unsteady idle speed of cooling car ........................... 58 Unsteady idling, easy to cutoff............................59 Analysis flow chart of EFI failure indicator light always on ....................60 Electrical schematic diagram of EFI system ........................61 4. Ignition system ....................................62 Know Before Service ................................. 62 Troubleshooting ..................................
Page 7 5. Thermostat ..................................79 5.1 Inspection ................................79 5.2 Failure phenomenon ............................80 5.3 Disassembly ................................. 80 5.4 Thermostat core inspection ..........................80 6. Water pipe ..................................80 7. Check the water pump cover assembly ........................81 8. Braking system ....................................82 Know Before Service .................................
Page 8 2．Remove the left and right front shock absorbers ..................... 101 3. Reinstall compinents such sa shock absorbers,front mudboards,and front wheels........... 101 11.Disassembly and assembly of coverings ............................ 102 Removal of the windshield .............................. 104 Removal of the upper part of the hood and the windshield liner .................. 104 Head side panel removal ..............................
Page 9 1. Motorcycle information Know Before Service 1. Use good quality tools, or special tools and fixtures designed by our company. The use of inferior tools may cause damage to parts, peeling of plating, improper assembly, etc. 2. The O-rings, paper gaskets, copper gaskets, and component sealing rings used for sealing must be replaced before assembling. 3.
Page 10 Body label ①The motorcycle identification code VIN can be seen after opening the seat Seat , and the VIN code is engraved on the cross tube at the rear of the frame. ②The muffler code is on the inner side above the muffler. ③The nameplate is above the radiator.
Page 11 E350 Technical specification Item Specification Front tire specification 120/70－15 CM576 56S Rear tire specification 140/70－14 CM577 68S Front rim specification MT:3.5×15 Rear rim specification MT:3.75×14 Motorcycle Brake fluid DOT4 0.25L（0.07 US gal,0.06 lmp gal） Replace fine filter： 1.75L（0.46 US gal,0.39 lmp gal） Oil consumption Without replacing the fine filter：...
Page 12 Battery/charging system Item Standard Type YTX12-BS Capacity 12Ah Battery self-discharge current 1.1mA average Full 13.1～13.3V Charging voltage required for ≤12.8V Voltage unloaded bike Charging voltage required for ≤12V loading Battery Constant voltage range 14.4～14.8V Constant voltage charging Initial charging current 0.1～0.2 times the battery capacity mode Charging time...
Page 13 Tightening torque Bolt tightening torque of general tightening part Intensity Grade 4.8-6.8 (mark "4" on the head of the Grade 8.8 (mark "7" or "8.8" on the head of level bolt) the bolt) Tightening torque Standar Breaking Tightening Standard Breaking Bolt diameter range d value...
Page 14 Cable/cable/pipe/electrical device distribution map 1. Distribution map of lamps and lanterns 1- Headlights ((1)-Front turning light position (2)-Low beam position (3)-High beam position (4)-Position light/daytime running light position) 2-Side reflector 3-Right handle sub-switch 4-Right handbar switch 5-Heated handle bar switch 6-Right tail light (right turning light / brake light / position light) 7- Rear reflector 8- License plate light 9 - Left rear turning light (left turning light / brake light / position light) 10 - Left handle switch 11 –...
Page 15 3. Brake upper pump and brake hose 1-Front disc brake main pump 2-FMC-HU brake hose 3-RMC-HU brake hose 4-rear disc brake main pump 4. Calipers, brake hoses and wheel speed sensors 1-brake disc (front) 2- front whell ABS induction ring gear 3-wheel speed sensor (front wheel) 4-front disc brake caliper 5-FC-HU brake hose 6- rear whell ABS induction ring gear 7-brake disc (rear) 8-rear disc brake caliper 9-wheel speed sensor (rear wheel) 10-RC-HU brake hose 15 / 111...
Page 16 5. Distribution map of brake system accessories 5.1 E350 1-wheel speed sensor (front wheel) 2-FC-HU brake hose 3-RC-HU brake hose 4-wheel speed sensor (rear wheel) 5- rear disc brake main pump6- rear brake lever 7- rear brake switch 8- RMC -HU brake hose9-FMC-HU brake hose 10-front brake switch 11-front disc brake main pump 12-front brake handle 13-hydraulic control unit 16 / 111...
Page 17 6. Oil supply system 6.1 E350 Fuel evaporation 1- Fuel level sensor 2- Fuel tank 3- Fuel pump 4- Oil-air separator (welded inside the fuel tank) 5- Fuel tank cap 6- Adsorption/vent pipe 7-High pressure fuel pipe 8-Carbon tank 9-Carbon tank solenoid valve 10- Solenoid valve intake pipe 11-solenoid valve outlet pipe 12-throttle valve body assembly Fuel evaporation: Oil and gas →...
Page 18 6.2 E350 Fuel supply Fuel supply system: Air→Carbon canister→Adsorption/vent pipe→Oil separator (inside the oil tank) Fuel → Fuel pump filter screen → Fuel pump → High pressure fuel pipe → Fuel injector → Cylinder 18 / 111...
Page 19 7. Distribution map of cooling system accessories 1-Main water tank 2-Water tank filling port 3-Auxiliary water tank 4-Main water tank inlet pipe 5-Main water tank outlet pipe 6-Aluminum water pipe 7-Thermostat outlet pipe 8-Engine inlet pipe 9-Water and oil common sensor 10-Thermostat 11-Water pump cover assembly 8.
Page 20 1-TFT Meter 2-Front Left Storage Box Lock 3-Windshield Motor Controller 4-Main lock 5- Double Buckle USB Charging Cable 6-Single Port Fast Charging Assembly 7-EFI Relay 8 - Starting relay 9 - Charging port holder 10 - Tank electronic lock 1 - Seat lock 2 - Rectifier 3 - Engine controller (ECU) 4 - Buzzer 5 - Ignition coil body 6 - Carbon canister solenoid valve 20 / 111...
Page 21 9. Intake and exhaust system 1- Cylinder head 2-Cylinder head exhaust pipe3- Air filter intake inlet 4-Crankshaft Box exhaust pipe5-Air filter outlet pipe6- Throttle valve body assembly 7-Intake manifold8- Cylinder 9- Muffler Intake system (indicated by the green arrow): Air → Air filter intake pipe → Air filter element → Air filter outlet pipe → Throttle valve assembly body → Intake manifold → Cylinder →...
Page 22 Tool 125-piece tool set Torque wrench On-board tools Claw hammer Pull code Rubber hammer Dynamic Balancing Machine Tire raking machine Oil pan Measuring cup Funnel Taps, dies Micrometer Depth gauge Vernier caliper Feeler gauge 22 / 111...
Page 23 PT300 electronic spraying and Tire pressure gauge Magnetic base + dial indicator writing diagnostic Speedometer 17#Inner hexagon （16PIN） Hoop clamp Internal Circlip Pliers External circlip pliers Clamp multimeter Multimeter Dust blow gun 14-sided 65mm cap filter wrench Some of the above pictures are from the Internet, and the copyright belongs to the author of the original picture. Do not use it for other purposes.
Page 24 Swell nail description ①Press down the center cylinder with 4# inner hexagon or other tools, you can hear a sound or the center cylinder moves axially by 2mm; ②Pry open the gap with a blade, nail or carving knife, etc. and remove it; if space permits, you can reach it Push out from the back;...
Page 25 2. Maintenance Know Before Service 1. Use good quality tools, or special tools and fixtures designed by our company. The use of inferior tools may cause damage to parts, peeling of plating, improper assembly, etc. 2. The O-rings, paper gaskets, copper gaskets, and component seals used for sealing must be replaced before assembly. 3.
Page 26 E350 Maintenance schedule : inspection（Inspect and clean,adjust,lubricate or replace if necessary） :replace ：Tighten★:Comment Initial Every Every Inspectio Torque mile 1000/621 4000/2485 Check item n before 8000/4971 Replace regularly N.m/kgf.m driving Months Initial 3 Every 15 Every 30 Inspection every 2 years or 20,000 Cradle buffer glue kilometers (12427 mile) Air filter (filter element)
Page 27 ensure riding comfort. Transmission system: If it is found th at the driving speed has dropped significantly, it is recommended to maintain and inspect th e CVT transmission system at any time, and replace it in advance if necessary. ●The initial maintenance should be carried out strictly in accordance with the above table, otherwise it may cause damage to the motorcycle or other unpredictable failures.
Page 28 d. Remove the air filter housing. 4. Replace the air inlet filter e. Place the rubber plug and tapping screw properly to avoid loss. a. Remove the sponge and replace it with a new filter 6. Replace Air filter element element.
Page 29 ●The motorcycle must be parked on a flat and stable ground 8. Reinstall or a lifting platform. a. Refer to the steps of removing the filter housing to ●The operation can only be performed after the engine has install the housing back. cooled down completely.
Page 30 Bolts and nuts of muffler 1. Check for air leaks at the engine exhaust. ●Do not touch all metal surfaces of the muffler while the engine is running or after riding to prevent burns. ●The motorcycle must be parked on a flat and stable ground or a lifting platform.
Page 31 Engine oil ●The motorcycle must be parked on a flat and stable ground or a lifting platform. ●Once the engine and muffler have cooled down, the e. Wipe clean the joint surface with a non-woven fabric. operation can be performed. Inspect the oil drain bolt⑶...
Page 32 3. Add oil b. Use a 14# sleeve to loosen the oil drain bolt⑶ counterclockwise. a. Replace the filter element with a measuring cup with a viscosity of SAE5W-40/10W-40/10W-50. The new API SN grade or higher motorcycle special machine 1.75L (1.85US qt, 1.54 lmp qt, 0.46 US gal, 0.39 lmp gal).
Page 33 c. Slightly lift the back of the glove box until the harness Throttle valve body connector on the left side of the glove box is exposed, unplug Caution: the ambient light plug on the left side of the glove box, ●The three-in-one sensor and stepper motor cannot be unplug the plug, and take out the glove box completely.
Page 34 3. Remove the throttle valve body assembly to e. Use 5# inner hexagon to remove 2 bolts⑹ and then remove the valve body assembly from the engine. clean up carbon deposits a. Unplug the plugs of the stepping motor① and the sensor②.
Page 35 5. Throttle valve body troubleshooting process Throttle valve body troubleshooting process Idle adjustment bolt Throttle body sensor looseness,poition spring stagnation and performance check other problems The diagnostic instrument eads the data Fault lights are always stream and requires the c. Use a short Phillips screwdriver to remove the 2 According to idle on druing riding engineer to judge...
Page 36 Throttle cable counterclockwise. Rotate the adjustment solenoid② clockwise to reduce the free stroke, counterclockwise to 1. Inspection expand; adjust the gap to the specified value. After adjusting a. Check whether the rubber sleeve of the right hand the gap, tighten the nut①. handle and the throttle cable are damaged.
Page 37 Check idle speed: Check the idling speed of the engine when the engine is warm. E350 the idle speed range of the engine should be 1500-1700 rpm. If the idling speed is not within the standard range or the idling speed is stalled, it should be checked and handled by professional service personnel at the designated maintenance point of Shengshi or a qualified maintenance organization.
Page 38 Fuel evaporation: Oil and gas → oil and gas separator (inside the oil tank) → adsorption/vent pipe → solenoid valve intake pipe → solenoid valve outlet pipe → throttle valve body assembly → intake manifold → cylinder The fuel evaporative pollutant control system can only be checked after the cover is removed. Check the carbon canister for cracks or damage.
Page 39 2. E350 add coolant (antifreeze) to the Coolant Radiator expansion tank If the water level of the Coolant expansion tank is lower than the "L" line, an appropriate amount of coolant must be ●The motorcycle must be parked on a flat and stable ground added.
Page 40 d. Tighten the filler cap of the Radiator. Tighten the b. Remove the filler cap of the Radiator to accelerate the flow of coolant. exhaust bolt; torque: 8～10N.m (0.8～1 kgf.m, 6～7 lbf.ft). c. Wipe all the joint surfaces clean with a non-woven cloth. Check whether the bolt⑶...
Page 41 6. Check all water pipes for leaks; aging. 1-Main water tank 2- Water tank filling port 3- Secondary water tank 4- Main water tank water inlet pipe 5- Main water tank water outlet pipe 6- Water and oil shared sensor 7- Thermostat 8- Water pump cover assembly 1- Main tank outlet pipe 2-Main tank inlet pipe 3-Water pump cover outlet pipe 4-Water pump cover inlet pipe 5-Thermostat 6-Thermostat outlet pipe 41 / 111...
Page 42 Brake hose Caution: ●This inspection should be completed by a qualified maintenance organization. ●Check the hhose according to the maintenance schedule. ●It is recommended to replace the brake hose every 4 years. Refer to steps 1 and 2 of checking brake fittings in the brake system, you can use the endoscope with LED to easily check the oil pipe joints of the ABS hydraulic control unit and the main pump, or remove the corresponding cover for...
Page 43 2.1 Replace the front brake brake fluid i. Repeatedly pinch and hold the brake handle to check whether the brake returns to normal hydraulic resistance. a. Wrap around the front brake main pump with oil- resistant plastic film, as shown in the previous section. b.
Page 44 should be made to the maintenance organization as soon as possible. If the sidewall is bumped, punctured, scratched, or if the Rebalance should be done after Tyre repair. tread is damaged and the hole is large, it should be replaced directly. ●Check the tire pressure regularly.
Page 45 ●After traveling on dusty or muddy roads, you should clean ●The motorcycle should be parked in a ventilated and dry up the foreign matter on the front fork tube (exposed environment without driving for a long time. A dark and chrome-plated cylinder) in time to avoid scratching the dust humid environment can easily cause the front fork tube to seal or oil seal and causing leakage;...
Page 46 For slight deformation of less than 0.2mm (0.008 in), the 5. Troubleshooting front fork tube can be supported by a V-shaped iron block, a. There is obvious impact noise when driving on uneven and soft rubber, rubber, copper, etc. should be placed on the roads or emergency braking.
Page 47 Side bracket 2. Lubrication a. Put away the side bracket so that the spring is in the Caution: shortest position for easy disassembly. ●Park the vehicle on a flat and stable ground or a lifting b. The thick steel wire can be rolled into a circle and put platform, and put down the main support.
Page 48 b. Remove the spring from the main support. c. Apply a proper amount of grease to the end face, inner hole of the engine box bushing and the surface of the main support shaft. Main bracket Caution: ●Park the vehicle on a flat and stable ground or a lifting platform, and put down the side brackets.
Page 49 3. EFI system Know Before Service Caution: 1. The structure and working principle of the EFI system are relatively complicated, and it is necessary to have a certain understanding of the working principle and structural characteristics of each EFI system before checking and troubleshooting. The content of this chapter requires certain maintenance experience.
Page 50 Error code Caution: ●Unlock the motorcycle and turn on the flameout switch. When it is not started, the EFI fault light is always on as normal. If it is not on, the motorcycle cannot be started. ●After starting the motorcycle, if the fault light is on and the EFI failure is reported, it means that the EFI system is abnormal. ●When the EFI system reports a failure, continuing to drive the motorcycle may cause damage.
Page 51 4. Clear fault code After troubleshooting the EFI, it needs to be cleared manually or through a diagnostic tool. 4.1 Manually clear a. Unlock the motorcycle b. Turn off the flame switch to " "; c. Start the motorcycle, refuel in neutral gear to more than 4000 rpm and hold for 10 seconds; d.
Page 52 EFI parts layout OBD diagnostic Carbon canister Dump switch interface (main Fuel pump Ignition coil body EFI relay solenoid valve cable) Water and oil Throttle Body Crankshaft Fuel injector Oxygen Sensor shared sensor Assembly position sensor Fault diagnosis and elimination of EFI parts Caution: ●Once the EFI components are disassembled, the EFI system needs to be reset.
Page 53 ●After disassembling the throttle valve body, apply lint-free cloth or textured paper to seal the air filter outlet and intake manifold to prevent foreign matter from entering. 1. Dump switch Can ride Replace the normally dump switch Short-circuit the black-brown, white- Fuel cut off yellow wires during driving...
Page 54 compression of the seal rubber ring of the fuel pump may Need to remove the cushion and storage box first. cause leakage and cause safety hazards. 4. Carbon canister solenoid valve When the engine performance is poor; the idle speed is poor;...
Page 55 7. Throttle valve body 7.1 Common failure phenomena 1. The engine is easy to stall when the motorcycle is running, and it is difficult to start, especially cold starting. 2. Idle speed is unstable or no idle speed, and there is intermittent jitter when accelerating. 3.
Page 56 9. Oxygen Sensor white, it means that the silicon poisoning has been damaged and needs to be replaced, if it is black, it means that there is carbon deposits that can be cleaned up and continue to use; if it is brown, it means that the silicon ●The oxygen sensor must be removed after the engine and poisoning needs to be replaced.
Page 57 The engine cannot start and there is no sign of fault diagnosis process When the start button is pressed and the starter motor can drive the engine to run normally, but the engine does not work normally, and there is no sign of the car, you can refer to the following diagnosis process to troubleshoot the cause of the fault. No spark or weak Check the ignition strength...
Page 58 Poor acceleration Rotate the rubber sleeve with the right hand. The engine speed cannot increase immediately, and there is hysteresis, and the acceleration is slow; you can refer to the following diagnosis process to troubleshoot the cause of the fault. Check Check if the air Poor...
Page 59 Unsteady idling, easy to cutoff The engine is running at an unstable idling speed, easy to stall, and can return to normal after a warm car. You can refer to the following diagnosis process to troubleshoot the cause of the fault. Unsteady idling / flameout Check the oil circuit Whether it returns to...
Page 60 Analysis flow chart of EFI failure indicator light always on If the EFI failure indicator light " " is always on, you should first check whether the wires of the EFI sensors are loose. The fault light is always on during driving Read fault code Idle speed fault...
Page 61 Electrical schematic diagram of EFI system 61 / 111...
Page 62 4. Ignition system Know Before Service 1. The content of this chapter requires certain maintenance experience. It is recommended to check or repair with a qualified maintenance organization. 2. Do not disassemble the parts connected to the 12V power supply at will after power-on, to avoid the self-inductance of the coil in the electrical appliance, which may damage the ECU or sensor due to the instantaneous voltage.
Page 63 Troubleshooting Check the following items before diagnosing the ignition system a. Check whether the spark plug is abnormal; b. Check whether the ignition coil high-voltage cap or plug is loose; c. Check whether water enters the high pressure cap; d. If there is no spark, find the ignition coil of the same model to confirm that there is no fault and install it on the faulty motorcycle to test whether there is spark;...
Page 64 Ignition system layout 1 - Dump switch 2 - PKE 3 – relay 4 - main lock 5 - right handle bar auxiliary switch 6 - right handle bar switch 7 - battery 8 - fuse box 9 - start relay 10 - ignition coil 11 - side bracket flameout switch 12 - spark plug 13 - crankshaft position sensor 14 - magneto stator 15 - ECU Caution: ●The fuse box comes with the main wiring harness and there are 3 in total.
Page 65 Electrical schematic diagram of ignition system 65 / 111...
Page 66 Ignition system inspection Caution: ●If there is no spark in the spark plug, check all the cable connections for looseness or poor contact before checking the ignition system. ●Use a high-precision digital multimeter. For details of the ignition coil test method, please refer to the section "Ignition Coil" in the "Electronic Injection System" chapter of this manual.
Page 67 Installation: a. Align the keyway of the flywheel with the half-circle key and install the flywheel in place, put in φ10.3×φ28×4 washer, M10×1.25×45 hexagon flange bolts, screw in the threads manually, tighten the timing chain, and turn the flywheel clockwise , Align the line immediately after the "T"...
Page 68 5. Starting system Know Before Service 1. If current flows through the starter motor when the engine is not started, it can be judged that the starter motor is damaged and needs to be replaced. 2. Before servicing the starter motor, turn on the engine stop switch to " "...
Page 69 2. Starter motor Does the Brake switch or After the vehicle is Short circuit starter motor flameout switch energized, the flameout relay work? failure switch is hit“ ” The flameout switch of the Whether the EFI Press the start Does the starting Relay failure right handle is fault light is on...
Page 70 Starting system electrical schematic diagram 70 / 111...
Page 71 d. Pull the air outlet pipe to the right side of the Starter motor motorcycle to expose the two M6×30 bolts that fix the Caution: starter motor, and remove them with an 8# sleeve. After ●If the starter motor is removed for maintenance, replace removing the bolts, remove the starter motor from the the O-ring with a new one and apply a proper amount of engine in the direction indicated by the big arrow.
Page 72 1-M6×90 bolt×2 2-O ring×2 3-O ring 4-starter motor front cover 5-gasket 6-rectangular sealing ring 7-starter motor outer shell 8- rectangular sealing ring 9-electric pole 10-screw ×2 11-Negative brush×2 12-Volute spring×4 13-Positive brush×2 14-Brush frame 15-Brush holder insulation gasket 16-Starter motor back cover 17-Insulation gasket 18-Nut×2 19- Gasket Examination Starter motor front cover：...
Page 73 Check the starting relay 2.2 Ground wire The motorcycle is powered off and locked. Set the 1. Operation check multimeter to the buzzer position, connect one test lead to a. Remove the seat and rear storage box first, find the the green/red wire, and one to any bolt connected to the starting relay connector on the right inner side of the frame, frame.
Page 74 6. Fuel supply system Know Before Service 1. Bending or twisting the control cable will affect the smooth operation, and may cause a short circuit or open circuit, causing the motorcycle to lose control. 2. The operation should be carried out in an open and ventilated place. All activities that may cause sparks, such as smoking, calling on mobile phones, etc., are prohibited on the job site.
Page 75 7. Cooling system Know Before Service 1. Please refer to the radiator section of the "Maintenance" chapter of this manual for the corresponding precautions for the coolant (antifreeze). 2. Check the cooling water pipe; check the height of the cooling liquid, adding and discharging the cooling liquid have been described in detail in the radiator section of the "Maintenance"...
Page 76 Coolant system distribution map 1 - Main water tank 2 - Water tank filler 3 - Auxiliary water tank 4 - Water inlet pipe of main water tank 5 - Water outlet pipe of main water tank 6 - Water oil shared sensor 7 - Thermostat 8 - Water pump cover assembly Coolant flow diagram 1 - Water inlet pipe 2 - Water outlet pipe of main water tank 3 - Water inlet pipe of main water tank 4 - Connecting pipe of auxiliary water tank 5 - Water inlet pipe of cylinder 6 - Water inlet pipe of water pump cover...
Page 77 Cooling system: Small loop (indicated by the blue arrow): Water pump → cylinder inlet pipe → cylinder → thermostat → small circulation outlet pipe → water pump cover inlet pipe Big loop (indicated by the green arrow): Water pump → cylinder inlet pipe → cylinder → thermostat → small water tank inlet pipe → small water tank → small water tank outlet pipe →...
Page 78 1-Thermostat assembly 2-M6 × 22 Bolt * 2 3-M6 × 12 bolts * 2 4-water pipe hoop（φ 25) 5 - Water pump cover inlet pipe 6 - Water pipe hoop（φ 24) 7-Water pipe hoop（φ 26) * 2 8-Water pump cover outlet pipe 9-Water pump cover assembly Caution: The bolt (3) at the thermostat is an exhaust bolt, and the bolt at the water pump cover is a bolt for cooling liquid.
Page 79 ●The heat dissipation fins are allowed to have a small amount of lodging deformation. If the lodging area is too large, it will affect the heat dissipation effect, and it is recommended to replace it. A small amount of deformation can be corrected with a small flat-blade screwdriver.
Page 80 When the temperature reaches 80°C (176 F), the heating rate slows down, and the thermostat works normally. If the water temperature has been rising rapidly, when the internal pressure reaches a certain level, the sudden overflow of boiling water indicates that the valve is stuck. If it is stuck or closed loosely, it can be removed and cleaned or repaired first, otherwise it should be replaced.
Page 81 7. Check the water pump cover assembly Check the two points indicated by the arrows for leakage. The bolts are for cooling liquid bolts. If there is leakage, remove the bolts and replace the O-ring. If there is leakage at the leaking pipe of the right crankcase cover, you can try to remove the leaking pipe (because the sealant is applied before press-fitting, it is difficult to pull out), clean it up, reapply the sealant and reinstall it;...
Page 82 8. Braking system Know Before Service 1. The content of this chapter requires certain maintenance experience. It is recommended to check or repair with a qualified maintenance organization. 2. Frequent inhalation of the dust generated by the brake pads, regardless of the composition, may have a certain impact on health.
Page 83 loosen this bolt later. Grasp the mirror rod of the right rear view mirror, use a 13# sleeve to remove the nut④, remove the small washer③, spring②, and large washer①, and take off the rear view mirror. When reassembling, make sure that the small washer③ is aligned with the side plane of the mirror rod bolt.
Page 84 ●Apply thread fastening glue to the thread of the caliper pin, torque: 22N.m (2.2kgf.m, 16 lbf.ft). ●The torque of the air release nozzle: 7～9N.m (0.7～ 0.9kgf.m, 5～7 lbf.ft). ●The open end of the piston should face the caliper mounting plate, and do not install it backwards. ●If there is slight rust on the surface of the piston, it can be polished off with 2000 mesh fine sandpaper.
Page 85 Front wheel 1- caliper mounting plate pin 2- bushing 3- rubber cap 4- caliper pin 5- vent nozzle 6-vent nozzle rubber cap 7-oil seal 8-dust seal 9-piston 10-caliper pin rubber cap 11- Caliper mounting plate 12- Brake pad spring 13- Caliper housing Rear wheel Caution: ●Apply silicone grease to the surface of the pin and bush...
Page 86 ABS troubleshooting 86 / 111...
Page 87 9. Battery/charging system Know Before Service 1. It is necessary to properly dispose of discarded batteries to avoid pollution to the environment. It is recommended that waste batteries be returned to a professional recycling agency for recycling. 2. It is forbidden to use chargers that have not passed the inspection to charge the battery. 3.
Page 88 Troubleshooting Battery damage or attenuation troubleshooting process Battery failure Use a Measure the multimeter to battery voltage Remove the battery and check whether Battery first, then use a battery tester to there is leakage, Check the voltage<charging measure the check the battery the leakage charging voltage voltage<14.5～14.9...
Page 89 Charging system layout diagram 1-Charging port (PKE) 2-Main fuse (25A) 3-Battery 4-Magnetic motor 5-Rectifier Electrical schematic diagram Letter Chinese 绿红黄 English Green Yellow 89 / 111...
Page 90 Battery disassembly Charging system check 1. Disassembly 1. Leakage test Caution: a. Turn off the motorcycle and cut off the power supply, ●The whole motorcycle must be powered off before and remove the negative wire of the battery. disassembling the battery. b.
Page 91 10. Front fork assembly Know Before Service 1. Use good quality tools, or special tools and fixtures designed by our company. The use of inferior tools may cause damage to parts, peeling of plating, improper assembly, etc. 2. The O-rings, paper gaskets, copper gaskets, and component seals used for sealing must be replaced before assembly. 3.
Page 92 Exploded view of front fork components: Directional exploded view 92 / 111...
Page 93 Front fork exploded view 93 / 111...
Page 94 Exploded view of lower link board 94 / 111...
Page 95 1、Change the direction of the handle Caution: ●When removing the disc brake oil cup, it must be vertically upward to prevent air from entering the brake pipeline. ●When disassembling and assembling the handle switch, pay attention to adjusting the internal wiring harness of the switch to avoid damage to the wire skin caused by the shell or bolt column.
Page 96 parts of the right handle bar switch. Remove the right handle mark on the handle bar switch, and then use 5# hexagon to bar (8) and the right heated handle bar (9) separately. tighten 4 M6×30 bolts. 4、Install the handle bar cover a.
Page 97 Replace the front wheel b. Put the front wheel in the middle of the front shock absorber, shake the front wheel left and right to make the Caution: disc brake disc snap into the middle of the brake pad, align ●Be careful not to damage the ABS coil when disassembling.
Page 98 ： Front wheel assembly exploded view Part name Caution Oil seal TC φ28×φ42×7 GB276 bearing 6004-2RS-C3 φ20×φ42×12 Sleeve Tire pressure sensor Bend toward the left. ABSsensor gear（56T） 265×5.0front brake disc Non-standard bolt M8×25 25 N.m(2.5 kgf.m，18 lbf.ft) GB12615 φ3.2×9 rivet (stainless steel) 98 / 111...
Page 99 2.2 Replacement method of front wheel oil seal Inspection and maintenance of front wheel assembly： and bearing Caution: ●This inspection should be completed by a qualified a. Remove the front wheel assembly by referring to maintenance organization. "Replace the front wheel". ●Do not press the brake handle after the front wheel is b.
Page 100 counterweight method to make the wheel correct the b. The balance weight must be attached to the designated balance of each edge part, this correction process Is what we plane (red area) of the rim. call dynamic balance. The dynamic balance particles of the wheels can ensure that the wheels are more stable when rotating, reduce vibration and shaking, improve the stability and comfort of the motorcycle, and are conducive to safe driving.
Page 101 b. Use a batch to pry open a gap on the upper plate, put in 2．Remove the left and right front shock the corresponding shock absorber, install the shock absorbers absorption in place, and remove the next word batch. Screw a.
Page 102 11.Disassembly and assembly of coverings 1. Windshield 2. Headlights 3. Lower part of the hood 4. Right panel of the hood 5. Front right panel 6. Right side cover 7. Right pedal decorative cover 8. Lower deflector right 9. Seat 10. Right rear armrest 11. Right part of tail skirt 12. Rear tail light 13.
Page 103 1. Instrument panel 2. Front left pedal rubber pad pressure plate 3. Front left pedal rubber pad 4. Rear left pedal rubber pad pressure plate 5. Rear left pedal rubber pad 6. Fuel tank decorative cover 7. Fuel tank cover 8. Front right pedal rubber pad pressure plate 9.
Page 104 Removal of the upper part of the hood and the Notice: ●When disassembling, please pay attention to controlling the windshield liner size of the force, so as not to break the buckle. a. Use a 4# inner hexagon to press down the central ●When removing the covers, please remove them in strict cylindrical pins of the two expansion nails, then remove the order, and do not disassemble the covers forcibly, so as to...
Page 105 d. Unplug the cable connector at the head cable cover, but c. Gently pat the left head side panel forward with your not the handle switch connector. hand to remove it, and use the same method to remove the right side panel. e.
Page 106 hands and pull out the seat obliquely upwards according to c. Slightly lift the back of the glove box until the harness the angle of the studs. Note: When the angle is wrong and connector on the left side of the glove box is exposed, unplug the seat cannot be pulled out, do not use brute force to the ambient light plug on the left side of the glove box, forcibly pull the seat out to prevent damage to the thread on...
Page 107 b. Gently tap the tail skirt back with your hand to remove d. Buckle down the two expansion nails as shown in the the right rear tail skirt assembly. Pay attention to the buckle picture, use a 10# sleeve to remove the two M6×16 bolts on in the circle as shown in the picture when installing.
Page 108 Removal of front left and right storage box covers a. Press the power button to turn it on, press the lock button of the storage box, open the left storage box cover, and the right storage box cover can be opened directly by pressing the lock button of the storage box.
Page 109 e. Remove 3 M6×16 bolts ⑵ with 5# inner hexagon, remove 1 M6×14 bolt ⑶ on the rear side with 4# inner hexagon, and remove 1 expansion nail at the front and rear b. Use a 4# inner hexagon to remove 2 bolts on the left and right sides, pull off the lining plate of the right decorative cover and the water tank filling port, and remove the lining plate on the left side.
Page 110 c. Use 6# inner hexagon to remove the left and right g. Use the 4# inner hexagon to remove the bolts on the left handles and switch components. and right storage box brackets. h. Unplug all the wire harnesses on the PKE and tidy up the d.
Page 111 k. Remove the 4 expansion nails on the left and right sides m. Unplug the charging port connector that fix the panels of the front storage box. n. Pass the handle assembly through the front storage box l. Unplug the USB charging port connector and take it out panel, and remove the front storage box panel assembly.
Page 112 ·1 ZT1P77MP Engine Maintenance Manual 2023-2-15 1/ 63...
Page 113 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 114 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 115 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 116 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 117 Lubrication system 1. Diagram of lubrication system 6/ 63...
Page 118 7/ 63...
Page 119 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 120 4. Oil pump to disassemble Before disassembling the oil pump, do the following: · 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 121 ·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 122 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 123 Parts information Serial Serial Name Quantity Name Quantity number number φ11.11×φ1.78 fluorine rubber O- 6.3×12×1.6 copper gasket ring GB276－6002-RS/P5C3 deep M6×16 hex flange bolts groove ball bearings Into 2 row M6×10 top pin bolt ZTIP77MP valve ZT1P77MP cylinder head φ17.2×φ25×1 valve spring base clamp bracket φ5.0 valve rod diameter oil seal LMAR8A－9 spark plug...
Page 124 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 9 x 2 EPDM O-rings harness bracket ZT1P77MP intake and...
Page 125 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 126 4. The engine is started electrically, and the crankshaft rotates without cylinder pressure or with very little cylinder pressure ·The valve spring is broken. ·The valve is broken. ·Cylinder head gasket gas blowing. ·The spark plug is loose and leaks air. ·...
Page 127 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 128 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) . 4.
Page 129 (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 130 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 131 b. 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. 4.
Page 132 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 133 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 134 6. As shown in the figure, install the spark plug (torque 14 ± 1 N•m), water and oil temperature sensor (do not omit the O-ring, torque 14 ± 1.5 N•m), oxygen sensor, cylinder head clamp bracket (Torque 10 ± 1 N•m, the bracket is not installed on short wheelbase models).
Page 135 3. As shown in the figure, after confirming that there is no missing or wrong installation, install the cylinder head into the corresponding position of the engine. After evenly diagonally pre-tightening the cylinder head nut and the two locking bolts on the side, use a fixed torque wrench to tighten them respectively (M10×1.25 hexagonal flange nut fixed torque 55 ±...
Page 136 1. As shown in the picture, remove the guide bar. Examine 1. Check the guide bar for excessive wear or damage. Guide bar installation 1. As shown in the figure, install the guide bar. (Note: After the guide bar is installed in place, the convex point of the guide bar is lower than the joint surface of the cylinder block and cylinder head.) Guide bar pressure plate 8.
Page 137 ·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 138 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 139 Cylinder, piston 1. System components Parts information Serial Part Name Quantity 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 140 2. Maintenance information General 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 141 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 142 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 143 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 144 Left crankcase cover, continuously variable clutch sub-assembly 1. System components 33/ 63...
Page 145 Parts information Serial Part Name Quantity Serial Part Name Quantity number number 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 146 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. 2.
Page 147 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 148 5. CVT clutch sub-assembly to disassemble 1. Align the cylindrical bayonet pins of the special driving and driven wheel positioning fixtures with the two positioning holes inserted into the outer blade of the main fixed disc, and the two symmetrical cooling holes on the outer cover of the driven wheel clutch.
Page 149 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 150 5. Pick up the combined driven wheel and the V-shaped transmission belt as a whole, make the clutch outer cover of the driven wheel face the outside, align the inner hole of the center of the driven wheel with the drive shaft, and then push the driven wheel inward and install it in place (the drive shaft is used for One section of the optical shaft of the φ...
Page 151 Right crankcase cover, magneto 1. System components 21 22 19 20 16 17 23 24 Parts information Serial Part Name Quantity Serial Part Name Quantity number number 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...
Page 152 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 153 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 154 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 155 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 156 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 157 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 158 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 159 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 160 Gearbox System components Parts information 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 161 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 162 2. There is abnormal noise in the gearbox · Gears are worn, and the gear meshing surface is corroded or damaged. • Bearings are worn or damaged. 3. Gearbox oil leakage · The oil seal is worn or damaged. · The locking bolts of the gearbox are loose or the joint surface of the gearbox cover leaks oil. 4.
Page 163 3. As shown in the figure, remove the output gear, duplex gear assembly, output shaft and output shaft retaining ring in sequence. Five, gearbox gear, bearing inspection Gearbox cover bearing and oil seal inspection 1. As shown in the figure, turn the inner ring of the bearing by hand, the bearing will rotate smoothly and silently, and turn the drive shaft by hand, the bearing of the drive shaft will rotate smoothly and silently.
Page 164 Drive shaft, output shaft, duplex gear inspection 1. As shown in the figure, check the position of the drive shaft, output shaft and splines for bending deformation and abnormal wear. If so, please replace them. (Note: If the drive shaft has no obvious problems, it is not recommended to press it out from the 6205 bearing.
Page 165 Crankcase 1. System components 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 6304-C3 deep groove ball bearings (FAG)
Page 166 GB276-6204/P5C3 deep groove M6×16－13.8×8.7 pivot bolt ball bearings (nitrogenation) φ 12.2×φ20×35.3 upper hanging GB276-6006-2RS/P5C3 deep bushing groove ball bearings φ 23×φ2 nitrile rubber O-ring GB893.1 circlip φ55 for holes φ 15.3×φ2.2 nitrile rubber O-ring FB38×56×7 hydrogenated nitrile oil seal ZT1P77MP upper hanging bush GB276－62/22/P5 deep groove press assembly ball bearings (human/nitrided)
Page 167 ·Cylinder head cover (Refer to the ZT1P77MP engine maintenance manual for disassembly and assembly of the cylinder head cover--cylinder head cover, cylinder head) Tensioner (Refer to ZT1P77MP engine maintenance manual for disassembly and assembly of the tensioner-- cylinder head cover, cylinder head--tensioner) ·Cylinder head assembly (Refer to the ZT1P77MP engine maintenance manual for disassembly and assembly of the cylinder head assembly--cylinder head cover, cylinder head) ·Cylinder and piston (Refer to ZT1P77MP engine maintenance manual for disassembly and assembly of cylinder...
Page 168 2. The crankshaft does not rotate · Crankshaft bearing shell damage. ·The big end bearing shell of the connecting rod is damaged. .The small end of the connecting rod is abnormally worn. Fourth, the decomposition of the crankcase 1. Remove the timing chain ①...
Page 169 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 170 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 171 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 172 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 173 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 174 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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