Zontes ZT163ML User manual

ZT163MLEngine Euro V
Service manual
2023/4/25

Page 1 ,Toatal 29 Pages
Pages
0
Table of Contents……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
1
1
Drain engine oil and coolant procedure
1.1
Drain engine oil and coolant procedure………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
3
2
CYLINDER HEAD ASSEMBLY
2.1
Disassembly of cylinder head-1……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
4
2.2
Adjustment of valve clearance………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
5
2.3
Disassembly of the cylinder head-2 ………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
6
2.4
Disassembly of cylinder head sub-components……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
7
2.5
Disassembly of the press-fitted assembly on the cylinder head……………………………………………………………………………………………………………………………………………………………………………………………………………………
8
3
CYLINDER BLOCK ASSEMBLY
3.1
Cylinder block disassembly and decomposition……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
9
3.2
Disassembly and decomposition ofpiston components…………………………………………………………………………………………………………………………………………………………………………………………………………………………………
10
4
RIGHT CRANKCASE COVER ASSEMBLY
4.1
Remove the right crankcase cover assembly…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
11
4.2
Decompose the right crankcase cover assembly-1………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
12
4.3
Decompose the right crankcase cover assembly-2 ………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
13
4.4
Decompose the press-fit assembly of the right crankcase cover…………………………………………………………………………………………………………………………………………………………………………………………………………………
14
4.5
Removal of the clutch assembly……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
15
4.6
Clutch parts assembly……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
16
5
LEFT CRANKCASE COVER ASSEMBLY
5.1
Removing and disassembling the left cover assembly…………………………………………………………………………………………………………………………………………………………………………………………………………………………………
17
5.2
Magneto Assembly Removal…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
18
6
CRANKCASE PARTS
6.1
Removal of crankcase parts-1………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
19
6.2
Removal of crankcase parts-2………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
20
6.3
Removal of crankcase parts-3………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
21
6.4
Removal of crankcase parts-4………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
22
目录
Table of Contents

Page 2 ,Toatal 29 Pages
Pages
目录
Table of Contents
7
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……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
27
8
CRANKCASE BEARING AND OIL SEAL
8.1
Right crankcase parts……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
28
8.2
Parts of left crankcase……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
29
©Guangdong Tayo Motorcycle Technology Co., Ltd.
property in copyright
This manual is suitable for ZT125 series engines. All the materials, illustrations, photos, etc. collected in this manual are compiled according to the latest products. However, due
to continuous product improvement and other changes, there may be some inconsistencies between your engine and this manual.For colors or upgrades, please refer to the part
codes on the official website. This manual will not be listed in detail; If the part names in this manual are inconsistent with the official website, the official website shall prevail.

1-Drain engine oil and coolant procedure
3
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
11251100-067093 M6×10 top pin bolt (color Zinc) 1 12±1.5N.m
2 1251513-001019 6.3×12×1.6 copper gasket 1
31251100-066093 M12×1.5×15 ablassschraube 1 30±3N.m
4 1244100-033000 Combined sealing gasket 12×φ20×2 1
PIG1 Drain engine oil and
coolant procedure Drain engine oil and coolant procedure
PROCEDURE:
●Draining of engine oil and coolant
Place a suitable water filling tool under the drain bolt, use an 8# sleeve to remove the 2 drain
bolts ⑴on the water pump cover on the right cover, and take out the copper pad ⑵; unscrew the
water tank filler cap on the vehicle. Wait for the coolant drain to complete.
Place a suitable oil loading tool under the oil drain bolt, use a 14# sleeve to remove the oil drain
bolt ⑶, and take out the gasket ⑷. Wait for the oil drain to complete.
Wait until the engine oil and coolant are completely drained before removing the engine from
the vehicle.
CAUTION:
●The discharge of engine oil and coolant must be carried out when the machine is cold to prevent
burns.
●Antifreeze is corrosive to a certain extent, so be careful not to contaminate the engine and other
parts, body, clothing, etc. when discharging the antifreeze. If parts are accidentally contaminated
with antifreeze, immediately wipe them with a clean lint-free cloth. If clothing or skin is stained
with antifreeze, immediately rinse with clean water. If the antifreeze is splashed into the eyes,
immediately rinse with plenty of water and observe to decide whether to seek medical attention.

2-Cylinder head assembly
4
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
4050956-003051 M30×1.5 aluminum screw plug (dark gray)
4050953-006051 M30×1.5 aluminum screw plug (titanium gold)
2 1051453-003000 27.4×2.65 Acrylate rubber o-rings
1
3 1040953-002093 M14×1.5 plug screw
1 12±1.5N.m
4 1051453-009000 O-ring，13×2.8
1
5 1251100-061093 M6×22 Hex flang bolt thread
3 12±1.5N.m
6 1040957-001000 ZT163ML cylinder head side cover
1
7 1051457-001000 φ84.5×2.5 Acrylic O-ring
1
PIG1 Cylinder head
assembly Removal of cylinder head-1
PROCEDURE:
●Removal of cylinder head-1
Use a 10# inner hexagon to remove the screw plug ⑴on the left cover of the engine, and
remove the O-ring ⑵;
Use the 4# inner hexagon to remove the screw plug ⑶on the left cover of the engine, and
remove the O-ring ⑷.
Use an 8# sleeve to remove the 3 bolts ⑸on the cylinder head side cover ⑹, and take out the
cylinder head side cover ⑹and O-ring ⑺.
Use a 14# sleeve to rotate the bolts in the red circle until the notch on the flywheel aligns with
the notch on the left engine cover, and the timing mark on the timing sprocket aligns with the
upper bolt hole.
CAUTION:
●When installing the O-ring, care should be taken not to cut the edge, and the edge must be
replaced if there is a cut edge.
●Do not let foreign objects fall into the engine during disassembly and installation.
●The torque standard of screw plug (1) is: 16±1.5Nm.
11

2-Cylinder head assembly
5
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
1 1251300-096000 Non-standard cover type 9 degree nut M6×13
4 10±1.5N.m
2 1040957-002000 ZT163ML valve cover
2
3 1051457-002000 φ50×2 Acrylic O-ring
2
PIG2 Cylinder head
assembly Adjustment of valve clearance
PROCEDURE:
●Adjustment of valve clearance
Use a 10 # sleeve to remove 4 nuts ⑴, and take out the valve chamber cover ⑵.
Use an 8 # plum wrench to loosen the nut ①on the intake rocker arm or exhaust rocker arm,
and then use a 3# inner hexagon to adjust the stud ②on the intake rocker arm or exhaust rocker
arm. Plug into the gap between the rocker arm and the valve, and check whether the valve
clearance is within the standard clearance.
Intake valve clearance: 0. 06 mm~ 0.1 0 mm
Exhaust valve clearance: 0.1 0 mm~ 0.1 4 mm
CAUTION:
●When adjusting the valve clearance, the notch on the flywheel must be aligned with the notch on
the left cover, and the timing mark on the timing sprocket must be aligned with the upper bolt hole.
●The gap between the two intake valves of the same cylinder head is less than 0.02mm (the
requirements for the two exhaust valves are also the same).
●After the valve clearance is adjusted, use a torque wrench to correct the torque of the nut ①,
and the torque standard is: 9±1N.m.

2-Cylinder head assembly
6
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
1 1251112-002093 GB16674 M6×30 Hexagon flange bolts
2 12±1.5N.m
2 1251100-067093 M6×10 top pin bolt (color Zinc)
3 10±1.5N.m
3 1251513-001019 6.3×12×1.6 copper gasket
3
4 1051270-004000 ZT1P72MN tensioner sub-assembly
1
5 1051253-004000 30×38 Washer, tensioner
1
6 1251100-340094 M6×10 Hexagon flange bolts
2 10±1.5N.m
7 1050157-012000 ZT163ML timing driven sprocket
1
8 1251100-061093 M6×22 Hex flang bolt thread
2 12±1.5N.m
9 1271200-199000 KD200-U thermostat
1
10 1051468-010000 16.5×1.95 EPDM
1
11 1251300-093000 Non-standard cap nut M8×18
4 25±3N.m
12 1051661-001000 Combined gasket φ9×φ18×2 (Dacromet)
4
13 1251112-007093 GB16674 M6×1055 Hexagon flange bolts
2 12±1.5N.m
14 1251401-003000 φ10×14 dowel pin
2
15 4050657-006000 ZT163ML cylinder head sub-assembly
1
PIG3 Cylinder head
assembly Removal of cylinder head-2
PROCEDURE:
●Removal of cylinder head-2
Use an 8# sleeve to pre-loosen the bolts ⑵, then remove the 2 bolts ⑴, and take out the tensioner ⑷and
gasket ⑸.
Use an 8# sleeve to remove the 2 bolts ⑹on the timing driven sprocket ⑺, and take out the timing driven
sprocket ⑺.
Use an 8# sleeve to remove 2 bolts⑻, and remove the thermostat ⑼and O-ring ⑽.
Use an 8# socket to remove 2 bolts ⒀, and take out 2 gaskets ⑶.
Use a 14# sleeve to remove 4 nuts ⑾, and take out 4 gaskets ⑿.
Grasp the cylinder head ⒂and remove it from the engine.
Note: 2 locating pins ⒁Be careful not to lose or drop them inside the engine.
During installation, it is necessary to use an 8# sleeve to remove the bolts ⑵and gaskets ⑶on the
tensioner ⑷, and then use tooling to retract the tensioner strut and put the tensioner ⑷back.
CAUTION:
●Do not let foreign objects fall into the engine during disassembly and installation.
●When installing the bolts at the timing sprocket ⑹, apply an appropriate amount of thread fastening glue
to the threads.
●The nut ⑾needs to be tightened diagonally to the appropriate torque standard during installation.

2-Cylinder head assembly
7
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
1 1050970-004000 LMAR8A-9 spark plug
1 14±1N.m
2 1251100-067093 M6×10 top pin bolt (color Zinc)
1 12±1.5N.m
3 1251513-001019 6.3×12×1.6 copper gasket
1
4 1050954-003000 communal sensor of water and oil
1 13±1.5N.m
5
1051454-009000
φ9×φ2 EPDM O-ring
1
6
1251112-001093
GB16674 M6×16 Hexagon flange bolts
1 12±1.5N.m
7 1051357-005000 ZT163ML camshaft bearing pressure plate
1
8 1050157-013000 ZT163ML rocker shaft
2
9 1050157-002000 ZT163ML intake rocker arm sub-assembly
1
10 1050157-001000 ZT163ML exhaust rocker arm sub-assembly
1
11 1050157-009000 ZT163ML Camshaft Parts
1
12
1051468-001000
8.8×1.9 fluorine rubber O-ring
1
13 4050657-004000 ZT163ML cylinder head press-fit assembly
1
PIG4 Cylinder head
assembly Disassembly of cylinder head sub-components
PROCEDURE:
●Disassembly of cylinder head sub-components
Use a 14# sleeve to remove the spark plug ⑴;
Use an 8# sleeve to remove the bolt ⑵, and remove the copper pad ⑶.
Use a 17# sleeve to remove the sensor ⑷, and take out the O-ring ⑸.
Use an 8# sleeve to remove the bolt ⑹, take out the bearing pressure plate ⑺and 2 rocker arm
shafts ⑻, and then take out the intake rocker arm ⑼and exhaust rocker arm ⑽from the gap in
the valve chamber cover. Finally, take out the camshaft ⑾and O-ring ⑿from the notch on the side
cover of the cylinder head.
CAUTION:
●The O-ring (5) is for one-time use and must be replaced after disassembly.
●When installing bolts⑹, apply an appropriate amount of thread fastening glue to the thread.

2-Cylinder head assembly
8
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
1 1050154-017000 ZT180MN Valve lock clamp
8
2 1050154-016000 ZT180MN Valve spring ring
4
3 1050157-007000 ZT163ML intake valve outer spring
4
4 1050158-001000 ZT184MP valve inner spring
4
5 1051553-001000 Φ5.0 valve stem diameter oil seal
4
6 1050153-015000 16.5×23.5×1 valve spring seat
4
7 1050157-004000 ZT163ML exhaust valve
2
8 1050157-003000 ZT163ML intake valve
2
9 1251111-011000 AYM8-M8×38 double head 10.9 studs bolts
2
10 1251111-010000
Non-standard M6×23.5 double-head 9.8 studs bolts
4
11 1250601-143000
GB276
－
6001RS/P5C3 deep groove ball bearings 1
12 4050657-001000 ZT163ML cylinder head
1
PIG5 Cylinder head
assembly
Disassembly of the press-fitted assembly on the
cylinder head
PROCEDURE:
●Disassembly of the press-fitted assembly on the cylinder head
Use the corresponding tool to press down the valve spring upper ring ⑵, take out the lock clip
⑴, outer spring ⑶, inner spring ⑷, valve oil seal ⑸, washer ⑹, and take out the exhaust valve ⑺
from the bottom of the cylinder head. The removal method of the intake valve ⑻is the same as
that of the exhaust valve ⑻.
Note: When installing, press the oil seal to the boss on the cylinder head ⑿(at the rectangular
mark).
Use the stud removal tool to remove the studs ⑼, ⑽.
The bearing ⑾is generally not damaged, if it needs to be replaced, please go to a professional
organization or a qualified maintenance organization for replacement.
CAUTION:
●The oil seal (5) is for one-time use and must be replaced after disassembly.
●Do not disassemble the valve assembly unless necessary. If it must be replaced, please go to a
professional organization or a qualified maintenance organization for replacement.
●When installing double-ended studs ⑼and ⑽, an appropriate amount of thread fastening glue
should be applied to the threads.

3-Cylinder block assembly
9
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
1 1051257-001000 ZT163ML guide strip
1
2 1051657-001000 ZT163ML cylinder head gasket
1
3 1051657-002000 ZT163ML Cylinder block box gasket
1
4 1251401-003000 φ10×14 dowel pin
2
5 1250105-136093 GB5789M6×12 (environmental color)
2 10±1.5N.m
6 1051957-008000 ZT163ML cylinder inlet pipe joint (pier system)
1
7 1051457-006000 16×2.5 EPDM O-ring
1
8 4050557-001000 ZT163ML cylinder block
1
PIG1 Cylinder block
assembly Cylinder block disassembly and decomposition
PROCEDURE:
●Cylinder block disassembly and decomposition
Take the guide bar ⑴and spacer ⑵out of the engine directly.
Grasp the cylinder block assembly and shake it slightly to take out the cylinder block assembly,
and then take out the gasket ⑶and positioning pin ⑷.
Note: 2 positioning pins (4) Be careful not to lose or drop them into the engine.
Use an 8# sleeve to remove the 2 bolts ⑸on the cylinder block ⑻, and remove the water pipe
joint ⑹and O-ring ⑺.
CAUTION:
●Gasket ⑵, gasket ⑶and O-ring (7) are for one-time use and need to be replaced every time they
are disassembled.
●O-ring (⑺) Be careful not to trim the edge when installing, and it must be replaced if the edge is
trimmed.
●Do not let foreign objects fall into the engine during disassembly and installation.

3-Cylinder block assembly
10
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
1 1050457-004000 18.1×1 piston pin retaining ring
2
2 1050457-003000 16×41×9 Piston Pin
1
3 1050457-001000 ZT163ML piston
1
4 1050457-005000 63.5×0.8×2.1 first air ring
1
5 1050457-006000 63.5×0.8×2.1 second air ring
1
6 1050457-007000 63.5×1.5×2.2 oil ring combination
1
PIG2 Cylinder block
assembly
Disassembly and decomposition ofpiston
components
PROCEDURE:
●Disassembly and decomposition ofpiston components
Use needle-nose pliers to take out one end of the piston pin retaining ring ⑴on the piston ⑶,
then push out the piston pin ⑵, and remove the piston ⑶from the crankshaft.
Hold the gas ring ⑷with your hands and stretch it out slightly, then take out the gas ring ⑸and
oil ring ⑹in the same way.
Note: When installing, the gaps of each air ring and oil ring should be staggered by 90°, and the
gaps cannot be overlapped, otherwise there will be oil burning.
CAUTION:
●The retaining ring ⑴will be deformed every time it is disassembled, and it is recommended to
replace it after each disassembly.
●When the oil ring and air ring are installed on the piston, apply a proper amount of engine oil for
lubrication to prevent scratching the outer wall of the piston.
●When the piston assembly is installed to the cylinder, it is necessary to apply an appropriate
amount of engine oil on the outer wall of the piston and the inside of the cylinder block for
lubrication to prevent scratches on the inner wall of the cylinder and cause serious damage to the
engine.

4-Right crankcase cover assembly
11
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
1 1251112-003093 GB16674 M6×45 Hex flange flange bolt
12 12±1.5N.m
2 1050757-004000 ZT163ML clutch cable bracket
1
3 1051656-004000 ZT158MJ right crankcase cover gasket
1
4 1251401-001000 φ8×14 hollow locating pin
2
PIG1 Right crankcase
cover assembly Remove the right crankcase cover assembly
PROCEDURE:
●Remove the right crankcase cover assembly
Use an 8# sleeve to remove the 12 bolts ⑴on the right cover assembly, and remove the bracket
⑵.
Grasp the two sides of the right cover assembly with both hands and shake slightly, then remove
the right cover assembly, and take out the gasket ⑶and 2 positioning pins ⑷.
CAUTION:
●Gasket ⑶is for one-time use and needs to be replaced every time it is disassembled.

4-Right crankcase cover assembly
12
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
1 1251300-096000 Non-standard cover type 9 degree nut M6×13 3 10±1.5N.m
4050456-008051 ZT158MJ oil filter cover (dark gray)
4050456-006000 ZT158MJ oil filter cover (titanium)
3 4131200-003000 ZT163ML fine filter sealing assembly 1【
1
】
4 1050868-002000 Φ18.5×13×1.6 fine filter spring 1
5 1251300-054000 M20×1.5 fuel filler cap 1
6 1051456-003000 Φ19×φ2.65 nitrile rubber O-ring 1
7 1251100-067093 M6×10 top pin bolt (color Zinc) 1 12±1.5N.m
8 1251112-002093 GB16674 M6×30 Hexagon flange bolts 3 12±1.5N.m
9 1251513-001019 6.3×12×1.6 copper gasket 1
4050457-031051 ZT163ML water pump cover (dark gray)
4050457-030051 ZT163ML water pump cover (titanium)
11 1051454-006000 1
12 1051968-010000 1 20±1.5N.m
13 1051154-003000 GB894.1 shaft retaining ring
ZT180MN Water pump sealing ring
ZT1P58MJ water pump blade
10 1
14 1050756-013000 ZT158MJ clutch rod rocker arm assembly 1
15 1050756-012000 ZT158MJ clutch handle torsion spring 1
16 1251512-043000 φ14.2×φ24×0.5 1
PIG2 Right crankcase
cover assembly
Decompose the right crankcase cover assembly-
1
2
10 1
1
PROCEDURE:
●Decompose the right crankcase cover assembly
Use a 10# sleeve to remove 3 nuts ⑴, and take out the fine filter cover ⑵, O-ring ①, spring ⑷, fine filter
②, and sealing ring ③in sequence.
Unscrew the oil filler cap ⑸and take out the O-ring ⑹.
Use an 8# sleeve to remove 1 bolt ⑺and 3 bolts ⑻, and take out 1 copper gasket ⑼, water pump cover
⑽, sealing ring ⑾and water pump blade ⑿.
Use snap ring pliers to remove retaining ring ⒀, and take out rocker arm ⒁, torsion spring ⒂and spacer
⒃in sequence.
CAUTION:
●O-ring (6), copper gasket (9) and sealing ring (11) need to be replaced after disassembly. When installing
the O-ring, care should be taken not to cut the edge, and the edge must be replaced if there is a cut edge.
●The retaining ring ⒀will be deformed every time it is disassembled, and it is recommended to replace it
after each disassembly.
●【1】：The sealing assembly includes an O-ring ①a fine filter ②and a sealing ring ③
∅

4-Right crankcase cover assembly
13
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
1 1251112-001093 GB16674 M6×16 Hexagon flange bolts 3
2 1051957-003000 ZT163ML water pump shaft pressure plate 1
3 1051357-004000 φ8×8 hollow locating pin 2
4 1251512-044000 φ8.2×φ16×1 Thrust washer 1
5 1051957-001000 ZT163ML water pump shaft 1
6 1250404-006000 GB119.2φ5×16 cylindrical pin 1
7 1050357-004000 ZT163ML water pump gear 1
8 1251512-007000 Thrust washer,12.2×20×1 1
9 1250511-002000 GB896 opening retaining ring φ6×1 1
10 1251512-003000 8.2×14×0.5 thrust washer 1
11 1050756-014000 ZT158MJ clutch rod shaft 1
12 1051957-005000 ZT163ML inlet and outlet water pipe joints 120±1.5N.m
13 1051457-003000 13×1.8 EPDM O-ring 1
4050457-021051 Right crankcase cover press-fit assembly (dark gray）
4050457-029051 Right crankcase cover press assembly (titanium)
15 1050853-020000 Φ8×7.5 oil plug 1
16 1051970-009000 ZT1P72MN Right Crankcase Cover Leakage Pipe-A 1
17 1251111-013000
Non-standard M6×25.5 double-head 9.8 studs bolts
3
PROCEDURE:
●Decompose the right crankcase cover assembly
Use an 8# sleeve to remove 3 bolts ⑴, take out the pressure plate ⑵, positioning pin ⑶, washer ⑷, water
pump shaft ⑸, gear ⑺and washer ⑻in sequence, pull out the straight pin⑹from the water pump shaft ⑸.
Use a 17# plum wrench to remove the water pipe joint ⑿, and take out the O-ring ⒀.
Use needle-nose pliers to pick out the retaining ring ⑼, take out the washer ⑽, and then pull out the
clutch rod shaft ⑾from the right cover pressing assembly ⒁.
Use the removal stud socket to remove the stud ⒄.
The oil plug ⒂and the leaking pipe ⒃are generally not damaged. If they need to be replaced, please go to
a professional organization or a qualified maintenance organization for replacement.
CAUTION:
●When installing bolts ⑴and double-ended studs ⒄, apply a proper amount of thread fastening glue to the
threads.
●The O-ring ⒀needs to be replaced after it is disassembled. When installing the O-ring, be careful not to
trim the edge. If there is a trimmed edge, it must be replaced .
●The retaining ring ⑼will be deformed every time it is disassembled, and it is recommended to replace it
after each disassembly.
14 1
PIG3 Right crankcase
cover assembly
Decompose the right crankcase cover assembly-
2

4-Right crankcase cover assembly
14
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
1 1250700-012000 GB/T 893 φ26 circlip for hole 1
2 1050857-007000 Φ 25 hydrogenated nitrile rubber engine oil window 1
3 1051354-013000 type hole circlip φ24×1 1
4 1051553-002000 FB14×22×5 Hydrogenated nitrile oil seal 2
5 1250602-033000 HK1412 needle roller bearing 1
6 1250602-022000 GB290-HK1010 needle roller bearing 1
7 1251700-141000 ZT158MJ right crankcase side cover bushing 1
8 1250601-128000 GB276-6001/P5C3 deep groove ball bearing 1
9 1051554-001000 FB12×24×5 HNBR oil seal 1
10 1051570-007000 FB12×24×5 hydrogenated nitrile rubber seal 1
11 1051954-006000 ZT180MN Water seal subassembly 1【
1
】
4050457-015051 Right crankcase cover (dark grey/machined)
4050457-023051 Right crankcase cover (titanium/machined)
PROCEDURE:
●Decompose the press-fit assembly of the right crankcase cover
Oil sight window ⑵, oil seal ⑷, oil seal ⑼, oil seal ⑽need to be replaced only if there is oil
leakage or oil leakage. If replacement is necessary, please go to a professional organization or a
qualified maintenance organization for replacement.
Bearings ⑸, bearings ⑹, bearings ⑻, and bushings ⑺will not be damaged in general. If they
need to be replaced, please go to a professional organization or a qualified maintenance
organization for replacement.
CAUTION:
●The retaining ring ⑴or ⑶will be deformed every time it is disassembled, and it is recommended
to replace it after each disassembly.
●【1】：Water seal subassembly ⑾includes water seal static ring ①and water seal dynamic ring
②. The water seal static ring ①needs to be press-fitted on the right cover.
●The oil seal must be replaced every time it is disassembled.
12 1
PIG4 Right crankcase
cover assembly
Decompose the press-fit assembly of the right
crankcase cover

4-Right crankcase cover assembly
15
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
1 1050756-015000 ZT158MJ clutch toothed rod 1
2 1251311-001094 Nut, M16×1 195±10N.m
3 1251514-002000 Lock washer, 16.2×28×2.4×2 1
4 1251512-039000 Φ16.2×φ28×1.5 thrust washer 1
5 1251602-001000 263124 duplex needle bearing 1
6 1251700-148000 ZT158MJ clutch bush 1
7 1251512-038000 Φ20.2×φ37×2 thrust washer 1
PIG5 Right crankcase
cover assembly Removal of the clutch assembly
PROCEDURE:
●Removal of the clutch assembly
Use a tool to lock the gear of the clutch assembly, and then use a 10# sleeve to remove 3 bolts
①, and take out the cover plate ②, spring ③, pressure plate ④and toothed tie rod ⑴in sequence.
Use a 24# sleeve to remove the nut ⑵, take out the washer ⑶, washer ⑷, clutch assembly ⑤in
sequence, and then take out the washer ⑺, bush ⑹and bearing ⑸from the clutch assembly ⑤.
Note: When installing, it is also necessary to use a suitable tool to clamp the gear of the clutch
assembly for installation.
CAUTION:
●⑵ After the nut is tightened to the torque, it is necessary to use a flat batch to insert the
protrusion on the nut into the groove on the engine shaft for further fixing.
●The side of the gasket ③with the letter "OUT" should be installed facing outward.
●If the normal serial number or code is not marked in the figure, it means that the part cannot be
purchased separately or only shows the disassembly structure.
●The bolt ①torque standard is: 12±1.5Nm.

4-Right crankcase cover assembly
16
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
1 1251500-084000 ZT158MJ clutch spline washer 1
2 1050757-002000 ZT163ML clutch active hub sub-assembly 1
3 1050757-003000 ZT163ML clutch driven hub sub-assembly 1
PROCEDURE:
●Clutch parts assembly
Take the friction plate assembly ①, driven disc ②and spline washer ⑴out of the driving hub
subassembly.
The installation method of friction plate assembly ①is washer ③-butterfly washer ④-friction
plate ⑤-follower plate-friction plate ⑤-…-friction plate ⑤. Do not reverse or confuse the order
when installing.
CAUTION:
●If you need to replace the friction plate assembly, please purchase the parts directly⑶: 1050757-
003000 ZT163ML clutch driven hub subassembly.
PIG6 Right crankcase
cover assembly Clutch parts assembly

5-Left crankcase cover assembly
17
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
1 1251112-003093 GB16674 M6×45 Hex flange flange bolt 7
12±1.5N.m
2 1051657-005000 ZT163ML left crankcase cover gasket 1
3 1251401-001000 φ8×14 hollow locating pin 2
4 1251201-001094 internal hexagonal round screw 2
12±1.5N.m
5 1251201-002094 internal hexagonal screw 3
12±1.5N.m
6 1051056-001000 ZT158MJ magnetic motor stator sub-assembly 1
4050357-004051 ZT163ML left crankcase cover (dark gray)
4050357-005051 ZT163ML left crankcase cover (titanium)
PIG1 Left crankcase
cover assembly
Removing and disassembling the left cover
assembly
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 ⑵and positioning pin ⑶on the engine case.
Use a 5# inner hexagon to remove 2 bolts ⑷and 3 bolts ⑸on the left cover ⑺, and take out the
magneto stator ⑹.
Note: The magneto stator is subject to the actual object. In the figure, the magneto stator has no
wire harness, but the real object has a wire harness.
CAUTION:
●Gasket ⑵is for one-time use and needs to be replaced every time it is disassembled.
●When installing bolt ⑷and bolt ⑸, it is necessary to apply an appropriate amount of thread
fastening glue on the thread.
●The waterproof rubber sleeve on the output line of the magneto stator needs to be assembled
after applying sealant on the installation joint surface.
7 1

5-Left crankcase cover assembly
18
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
1 1051057-004000 ZT163ML electric starter reduction gear shaft 1
2 1051057-006000 ZT163ML electric starter reduction gear 1
3 1251100-341094 M10×1.25×45 hex flange bolt 1
60±5N.m
4 1251500-041000 10.3×20×2 gasket 1
5 1051057-003000 ZT163ML magneto rotor clutch parts 1
6 1251802-003000 4×4.6×25×14 woodruff key 1
7 1051057-001000 ZT163ML electric starter gear 1
8 1250602-052000 KT25×31×20 needle roller bearing 1
9 1251512-050000 φ25×φ40×2.9 thrust washer 1
10 1050157-015000 6.35×7×98 toothed chain 1
PROCEDURE:
●Magneto Assembly Removal
Take out the reduction gear shaft ⑴and the reduction gear ⑵.
Use a suitable tool to lock the large starter tooth, and then use a 14# sleeve to remove the bolt
⑶and take out the gasket ⑷.
Use a suitable puller to eject the magneto rotor ⑸, and then take out the half-round key ⑹, the
electric starter tooth ⑺, the bearing ⑻, the washer ⑼and the chain ⑽.
CAUTION:
●The reduction gear shaft ⑴and the reduction gear ⑵shall be installed with proper amount of
engine oil.
●When installing the bearing ⑻and the large starting gear ⑺, an appropriate amount of engine
oil should be applied.
●The half-round key ⑹needs to be inlaid on the crankshaft during installation, and the magneto
rotor ⑸needs to be installed with the groove aligned with the half-round key ⑹.
PIG2 Left crankcase
cover assembly Magneto Assembly Removal

6-Crankcase parts
19
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
1 1251201-001094 internal hexagonal round screw 2
12±1.5N.m
2 1050956-001000 ZT158MJ crankshaft position sensor 1
3 4050968-003000 ZT1P58MJ Coarse filter cover (ceramic) 1
32±3N.m
4 1051468-003000 34.5×3.5 acrylate adhesive O-ring 1
5 1050868-003000 Φ25.8×34.2×1.8 strainer spring 1
6 1050868-004000 Outer diameter φ22×21 hat-shaped strainer 1
7 1251100-066093 M12×1.5×15 ablassschraube 1
30±3N.m
8 1244100-033000 Combined sealing gasket 12×φ20×2 1
9 1251100-165000 M6×16-13.8×8.7 pivot bolt 1
12±1.5N.m
10 1051257-002000 ZT163ML tensioner 1
11 1250106-112000 GB9074.13 bolt M5×20 2
5±1N.m
12 1050656-010000 ZT158MJ gear display module 1
13 1051454-011000 22.5×2.5 fluoro rubber o-ring 1
PIG1 Crankcase parts Removal of crankcase parts-1
PROCEDURE:
●Removal of crankcase parts-1
Use a 5 # inner hexagon to remove 2 bolts ⑴, and remove the sensor ⑵(the actual sensor shall
prevail).
Use a 24 # sleeve to remove the strainer cover ⑶, and take out the O-ring ⑷, spring ⑸, and
strainer ⑹in sequence.
Use a 14# sleeve to remove the oil drain bolt ⑺, and take out the gasket ⑻.
Use the 5# inner hexagon to remove the bolt ⑼and take out the tensioner ⑽.
Use a Phillips screwdriver to remove 2 bolts ⑾, and take out the shift display assembly ⑿, O-ring
⒀and shift display contact assembly ⒁.
CAUTION:
●O-rings ⑷and ⒀are for one-time use and must be replaced after disassembly; care should be
taken not to cut edges during installation, and must be replaced if there is a cut edge.
●Gasket ⑻is for one-time use and must be replaced after disassembly.
●When bolt ⑼is installed, an appropriate amount of thread fastening glue should be applied to
the thread.
●When installing the gear display assembly ⑿, spray an appropriate amount of engine oil on the
gear display contact assembly ⒁.