Zontes ZT1P77MP User manual

1/ 63
·1
ZT1P77MP
Engine Maintenance
Manual
2023-2-15

2/ 63
Foreword
All the materials, illustrations, photos, etc. collected in this manual are compiled
according to the latest product of ZT 1P77MP Euro 5 . However, due to continuous
improvement of products and changes in other aspects, there may be some
inconsistencies between your motorcycle and this manual. 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.
If some contents of this manual are insufficient, please refer to the “Driver’s
Manual" attached to the vehicle. You can download the latest version of the driver's
manual as a PDF in the corresponding model introduction on the Zontes official
website.
©Guangdong Tayo Motorcycle Technology Co., Ltd.
All rights reserved

3/ 63
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.
If you need to clean or wash the body parts of this vehicle, you should use neutral motorcycle wash liquid or tap
water or diesel oil, kerosene, etc. Acidic or alkaline motorcycle wash liquid will cause irreversible corrosion to the surface
paint, electroplated surface, anodized surface, etc. of parts; gasoline will cause premature aging or hardening of sealants,
gaskets, rubber parts, etc., reducing the service life. It should be wiped with a non-woven cloth that will not leave residues.
Ordinary rags may leave rags or wool that will affect assembly or cause other adverse effects.
Our company tries to update this manual in a timely manner after product changes.
The following are the meanings of the icons marked in this manual:
Failure to comply will result in personal injury or death of the driver or
maintenance personnel ; or serious damage to spare parts , shortened service
life, etc.
Failure t
o comply may result in personal injury or death of the driver or
maintenance personnel ; or damage to spare parts , abnormality, etc.
Failure to follow the warnings will result in personal injury to the driver or
maintenance personnel ; or matters requi
ring special attention during
disassembly.
Indicates that there is a requirement for torque
Indicates that the part needs to be replaced after disassembly
Indicates that the location needs to be measured

4/ 63
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. System components ............................................................................ 11
2. Maintenance information ........................................................................ 13
3. Fault phenomenon/fault analysis.................................................................. 14
4. Cylinder compression test ....................................................................... 15
5. Cylinder head cover............................................................................. 15
6. Cylinder head .................................................................................. 16
7. Guide bar ..................................................................................... 24
8. Tension strip ................................................................................... 25
9. Tensioner ..................................................................................... 27
Cylinder, piston....................................................................................... 28
1. System components ............................................................................ 28
2. Maintenance information ........................................................................ 29
3. Troubleshooting ................................................................................ 29
4. Cylinder ....................................................................................... 29
5. Piston......................................................................................... 30
Left crankcase cover, continuously variable clutch sub-assembly ............................................ 33
1. System components ............................................................................ 33
2. Maintenance information ........................................................................ 35
3. Common failure phenomenon/troubleshooting ...................................................... 35
4. Left crankcase cover ............................................................................ 36
5. CVT clutch sub-assembly........................................................................ 37
Right crankcase cover, magneto ........................................................................ 40
1. System components ............................................................................ 40
2. Right crankcase cover / magneto stator............................................................ 41
3. Magneto rotor .................................................................................. 43
4. Water pump ................................................................................... 45
Gearbox............................................................................................. 49
1. System components ............................................................................ 49
2.Maintenance information ......................................................................... 50
3. Fault phenomenon/fault analysis.................................................................. 50
4. Disassembly and decomposition of the gearbox..................................................... 51
Five, gearbox gear, bearing inspection............................................................... 52
6. Gear box assembly ............................................................................. 53
Crankcase ........................................................................................... 54
1. System components ............................................................................ 54
2. Maintenance information ........................................................................ 55

5/ 63
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

6/ 63
Lubrication system
1. Diagram of lubrication system

7/ 63

8/ 63
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. The maintenance steps in this chapter must be carried out only after the engine oil has been drained.
4. When disassembling and installing the oil pump, be careful not to let dust and dirt enter the engine.
5. If the wear of any part of the oil pump exceeds the maintenance threshold, the entire oil pump assembly should be
replaced.
Specification
Project
Standard
Remark
Engine Oil
Capacity
Drain the oil for normal maintenance
(replace filter element)
1.75L ( 1.85 US qt, 1.54 lmp qt )
Drain the oil for normal maintenance
(without changing the filter element)
1.55L ( 1.64 US qt, 1. 36 lmp qt )
Drain the oil and remove the right
cover for normal maintenance
(replace the filter element)
1.8L ( 1.9 US qt, 1.5 8 lmp qt )
Drain the oil and remove the right
cover for normal maintenance
(without replacing the filter element)
1.6L ( 1.69 US qt, 1.41 lmp qt )
Disassembly and reassembly of the
whole machine
2.0L (21 US qt, 1.76 lmp qt )
recommended engine oil API SN grade or higher
motorcycle special motor oil
Torque value
Bolt model
Assembly position
Quantity
Torque ( Nm )
Remark
M6×60 hex flange bolts Oil pump locking bolt 2 11 ± 1.5 Nm -
tool
1. Torque wrench + 8# sleeve;
2. 8#-T-shaped socket wrench;
3. Common failure phenomenon/troubleshooting
1. Engine oil level is too low
·Engine oil leakage
Worn or improperly installed piston rings
·Cylinder wear
Abrasion of seals such as valve guides and valve rod diameter oil seals
2. The oil is dirty
·No regular oil change
·Poor gasoline quality
·Piston ring wear
·Oil oxidation

9/ 63
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)
· Remove the magneto rotor. (Refer to ZT1P77MP engine maintenance manual for disassembly and assembly -
right crankcase cover, magneto - magneto rotor)
·Remove the 5×5.7×16 half-round key and the large electric starter gear. (Refer to ZT1P77MP engine maintenance
manual for disassembly and assembly - magneto rotor)
①Use an 8#-T socket wrench to remove the 2 oil pump locking bolts (rotate counterclockwise).
②Take out the 2 oil pump bolts , and take out the oil pump assembly and the oil pump
chain together.
Install
①Put one end of the oil pump chain on the
driven sprocket of the oil pump, and the
other end on the driving gear of the oil pump
at the crankshaft end, align the oil pump
shaft with the oil pump installation hole on
the box body, and align the oil pump
positioning pin with the box body. Install the
oil pump on the upper positioning pin hole
and press it in place ( Note : spray oil on the
chain, inner and outer rotors of the oil
pump); then install 2 oil pump bolts, use a torque wrench (or air batch) and 8 #Tighten the bolt with the sleeve, and
the bolt locking torque is 11±1.5N.
·Install 5×5.7×16 semicircle keys and large gear for electric starter. (Refer to ZT1P77MP engine maintenance manual
for installation - right crankcase cover, magneto - magneto rotor)
Oil pump chain

10/ 63
·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. (Refer to the ZT1P77MP maintenance manual for installation -- 2. Maintenance-air filter (filter
element)-bolts and nuts of the muffler)
Disassembly/installation
Disassemble in the following order
· M6×40 cross recessed pan head screw
· ZT1P72MN oil pump cover
·Inner rotor JBZ-29-18
·Outer rotor JBZ-29-18
· 2.5×12 cylindrical pin
· 8.6×11.5×1 thrust washer
· ZT1P72MN oil pump lower case
· 3×12 cylindrical pins
·Inner rotor JBZ-29-11
·Outer rotor JBZ-29-11
· 2.5×12 cylindrical pin
· ZT1P72MN oil pump upper casing
· ZT1P72MN oil pump shaft assembly
Please assemble in the reverse order of disassembly
(Note: During assembly, oil should be applied to the inner and outer rotors to fully lubricate the inner cavity of
the oil pump)
Bolt: M6×40 cross recessed pan head screw (tighten with a cross screwdriver or air batch + cross batch head)
Torque: 5～7N.m