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.