Zontes ZT310T 2022 User manual

ZT310T-M
Engine maintenance Manual
2022-02-11

Preface
All the materials, illustrations, photos, etc. collected in this manual are compiled according to the latest products
of ZT310-M National IV. However, due to the continuous improvement of the product and other changes, there may be
some inconsistencies between your motorcycle and this manual. 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.
If part of the content of this manual is insufficient, please refer to the "Driver's Manual" included with the bike. The
latest version of the driver's manual can be downloaded as a PDF in the model introduction corresponding to the
official website of ZONTES.
©GUANG DONG TAYO MOTORCYCLE TECHNOLOGY Co.Ltd
All rights reserved

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.
If you need to clean or wash the body parts of the vehicle, you should use neutral car wash fluid or tap water,
diesel, kerosene, etc. Acidic or alkaline car wash liquid will cause irreversible corrosion of the surface paint,
electroplating surface, and anodized surface of the parts; gasoline will cause premature aging or hardening of
sealants, gaskets, and rubber parts, reducing the service life. Non-woven fabrics should be used for wiping with no
residue. Ordinary rags may leave cloth scraps or wool, etc., which may affect the assembly or cause other adverse
effects.
Our company will update this manual as soon as possible after the product changes.
The following is the meaning of the icons marked in this manual：
Failure to observe will cause personal injury or death of the driver or
maintenance personnel; or cause serious damage to parts and shorten the
service life, etc.
Failure to comply may result in personal injury or death of the driver or
maintenance personnel; or damage to parts, abnormalities, etc.
Failure to observe the warning will cause personal injury to the driver or
maintenance personnel; or matters requiring special attention during
disassembly and assembly
Indicates that there is a requirement for torque there
Indicates that the piece needs to be replaced after disassembly
Indicates that a measurement is required at this location

ZT310T-M Engine maintenance Manual
Lubrication system ....................................................................................................................................6
One. Lubrication system diagram ..........................................................................................................6
Two, Maintenance information...............................................................................................................8
Three, Common fault phenomena/troubleshooting ................................................................................9
Four, oil pump .......................................................................................................................................9
Cylinder head cover, cylinder head .........................................................................................................13
One, System components ...................................................................................................................13
Two, Maintenance information.............................................................................................................14
Three, Failure phenomenon / failure analysis ......................................................................................16
Four, Cylinder compression test ..........................................................................................................17
Five, Cylinder head cover ....................................................................................................................17
Six, Cylinder head ...............................................................................................................................18
Seven, Guide bar.................................................................................................................................27
Eight, Tension bar ...............................................................................................................................28
Nine, tensioner ....................................................................................................................................29
Cylinder, piston .......................................................................................................................................31
One, System components ...................................................................................................................31
Two, Maintenance information.............................................................................................................33
Three, troubleshooting.........................................................................................................................34
Four, The cylinder................................................................................................................................35
Five, The piston...................................................................................................................................39
Left crankcase cover, continuously variable clutch subassembly ............................................................44
One, System components ...................................................................................................................44
Two, Maintenance information.............................................................................................................45
Three, Common fault phenomena / troubleshooting ............................................................................46
Four, Left crankcase cover ..................................................................................................................46
Five, Stepless speed change clutch subassembly ...............................................................................49
Six. Inspection of parts and limit values for use ...................................................................................54
Right crankcase cover, magneto.............................................................................................................56
One, System components ...................................................................................................................56
Two. Maintenance information.............................................................................................................58
Three. Right crankcase cover/magneto stator Disassemble ................................................................59
Four - Magneto rotor............................................................................................................................64
Water pump ............................................................................................................................................66

Dismantling..........................................................................................................................................66
Inspection............................................................................................................................................67
Installation ...........................................................................................................................................67
Gearbox..................................................................................................................................................70
One - System Components .................................................................................................................70
Two- Maintenance information.............................................................................................................71
Three - Failure phenomenon / failure analysis .....................................................................................72
Four - Gearbox disassembly and decomposition .................................................................................72
Five. Gear box gear, bearing examination ...........................................................................................73
Six, Gearbox assembly........................................................................................................................74
Crankcase...............................................................................................................................................76
One, system components ....................................................................................................................76
Two, Repair information.......................................................................................................................78
Three, Common faults / troubleshooting ..............................................................................................79
Four, The decomposition of the crankcase ..........................................................................................79
Five. Assembly of the crankcase .........................................................................................................83
Left and Right Crankcase Upper Fixed Point Disassembly and Inspection..............................................86
Upper Hanging Piece Inspection .........................................................................................................86
Upper Hanging Piece Disassembly .....................................................................................................86
Upper Hanging Piece Installation.........................................................................................................86
Fine Filter................................................................................................................................................88
Dismantling..........................................................................................................................................88
Inspection............................................................................................................................................88
Installation ...........................................................................................................................................88

Lubrication system
One. Lubrication system diagram

Two, Maintenance information
General information
1. This chapter introduces the structure 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 disassembling the engine
separately.
3. The maintenance steps in this chapter can only be carried out after the oil is drained.
4. In the process of 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 limit value, the entire oil pump assembly should be
replaced.
Specification
Item Standard Maintenance
Engine oil capacity
Drain the oil for normal
maintenance (replace the filter
element)
1.75L（1.85US qt,1.54 lmp qt）-
Drain the oil during normal
maintenance (without
changing the filter element)
1.7L（1.8US qt,1.49 lmp qt）-
Drain the oil for normal
maintenance and remove the
right cover (replace the filter
element)
1.8L（1.9US qt,1.58 lmp qt）-
Drain the oil for normal
maintenance and remove the
right cover (do not replace the
filter element)
1.75L（1.85US qt,1.54 lmp qt）-
The whole machine is
disassembled and
reassembled
2.0L（2.1US qt,1.76 lmp qt）-
Recommended engine oil API SN grade or higher grade
motorcycle special motor oil
-
Oil pump rotor
End gap 0.15 mm （0.006 in）0.20 mm（0.008 in）
Pump body clearance 0.15-0.21 mm （0.006-0.008 in）0.35 mm（0.014 in）
End face clearance 0.05-0.10 mm （0.002-0.004 in）0.12 mm（0.005 in）
Torque value
Bolt type Assembly position Quantity
M6×60 Hexagon Flange Bolt Oil Pump Locking Bolt 2 11±1.5N.m -
Tools
1. Torque wrench +8# sleeve;
2. 8#-T-shaped socket wrench;

Three, Common fault phenomena/troubleshooting
1. The engine oil level is too low.
• Engine oil is leaking.
• The piston ring is worn or improperly installed.
• Cylinder wear.
• The seals such as valve guide and valve stem diameter oil seal are worn out.
2. The engine oil is dirty.
• The oil is not changed regularly.
• The gasoline is of poor quality.
• The piston ring is worn.
• Oil is oxidized.
Four, oil pump
Disassemble
Before disassembling the oil pump, perform the following operations:
• Remove the muffler. (Refer to ZT310T-M Maintenance Manual-2. Maintenance-Bolts and Nuts of Muffler for dis
assembly and assembly)
• Remove the right crankcase cover of the engine. (Refer to ZT310T-M engine maintenance manual for dis
assembly and assembly-Right crankcase cover, magneto-Right crankcase cover, magneto stator)
• Remove the magneto rotor. (Refer to ZT310T-M engine maintenance manual for disassembly and assembly-
Right crankcase cover, magneto-Magneto rotor)
•Remove the 5×5.7×16 half-circle key and electric start gear. (Refer to ZT310T-M Engine Maintenance Manual-
Magneto Rotor for disassembly and assembly)
①Use 8#-T type socket wrench to remove 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.

Installation
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,
and align the oil pump shaft with the oil pump
mounting hole on the box body and the oil pump
positioning pin with the box body. Install the oil
pump to the box body and press it in place by using
the upper positioning pin hole (Note: oil should be
sprayed on the chain, the inner and outer rotors of
the oil pump); then install 2 oil pump bolts, use a
torque wrench (or a wind screw) and 8 #The sleeve tightens the bolts, and the bolt tightening torque is 11±1.5N.
• Install 5×5.7×16 half-circle key and electric start gear. (For installation, refer to ZT310T-M Engine Maintenance
Manual- Right crankcase cover, magneto -Magneto Rotor)
•Install the magneto rotor. (Refer to ZT310T-M engine maintenance manual for installation-Right crankcase
cover, magneto-Magneto rotor)
•Install the right crankcase cover of the engine. (Refer to ZT310T-M engine maintenance manual for
installation-Right crankcase cover, magneto-Right crankcase cover, magneto stator)
• Install a muffler. (Refer to ZT310T-M Maintenance Manual-2. Maintenance-Bolts and Nuts of Muffler for dis
assembly and assembly)
Disassembly/Installation
Disassemble in the following order:
• M6×40 cross recessed pan head screws
•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 case
•ZT1P72MN oil pump shaft assembly
Oil pump chain

Please assemble in the reverse order of disassembly
(Note: When assembling, oil should be applied to the inner and outer rotors to make the inner cavity of the
oil pump fully lubricated)
Bolt: M6×40 Phillips pan head screw (tighten with a Phillips screwdriver or a wind screw + Phillips screw)
Torque: 5～7N.m
Examination
Install the inner rotor JBZ-29-11 and the outer rotor JBZ-29-11 into the upper casing of the oil pump. Install the
inner rotor JBZ-29-18 and the outer rotor JBZ-29-18 into the upper casing of the oil pump. (Before measuring the gap,
install the oil pump shaft assembly into the corresponding inner rotor respectively)
End gap a
Measure several points and compare the maximum reading with the maintenance limit value.
Use a feeler gauge to measure the gap between the inner rotor and the outer rotor.
Serial
Name
Number
1 ZT1P72 oil pump assembly 1
2 ZT1P72 oil pump upper case 1
3 Outer rotor JBZ-29-11 1
4 Inner rotor JBZ-29-11 1
5 2.5X12 cylindrical pin 1
6
3X12 cylindrical pin
2
7 ZT1P72MN oil pump lower case 4
8 8.6X11.5X1 thrust piece 1
9 Outer rotor JBZ-29-18 1
10 Inner rotor JBZ-29-18 1
11 ZT1P72MN oil pump cover 1
12 M6X40 cross recessed pan head screws 1

Maintenance limit value: 0.2mm (0.008in)
Pump body clearance b
Use a feeler gauge to measure the gap between the outer rotor of the oil pump and the oil pump body.
Maintenance limit value: 0.35mm (0.014in)
End face clearance
Use a straight edge gauge and a plug gauge to measure the end face gap.
Maintenance limit value: 0.12mm (0.005in)
Check the oil pump chain
If the chain breaks or there are cracks on the surface of the chain, the chain should be replaced.

Cylinder head cover, cylinder head
One, System components
9
8
7
6
5
4
3
2 1
26
20
19
13
16
17
18
12
10
11
34 35
33
32
31
30
29
36
27
Refer to the diagram for valve
disassembly and assembly, and
the intake and exhaust valves
have the same disassembly and
assembly structure.
14
15
25
24
23
22
21
28
37

The part information
Serial
Name
Number
Serial
Name
Number
1 6.3×12×1.6 copper gasket 1 20 9×2 EPDM O-ring 1
2 M6×16 hexagon flange bolts 1 21 Water and oil shared sensor 1
3 M6×10 top pin bolt 1 22 ZTIP72MN valve in2,ou2
4 ZT1P72MN Cylinder head
wire clamp bracket 1 23 ZT1P72MN valve spring base 4
5 LMAR8A-9 spark plug 1 24 φ5.0 valve stem diameter oil
seal 4
6 ZT1P72MN cylinder head 1 25 ZT1P72MN intake and
exhaust valve springs 4
7 AYM8－M8×38 double head
10.9 grade stud 2 26 ZT1P72MN valve spring retainer 4
8 ZT1P72MN exhaust rocker
arm sub-components 1 27 ZT1P58MJ valve lock clip 8
9 ZT1P72MN cylinder head
pressure plate 1 28 Φ8.85 valve clearance adjustment pad 4
10 M6×10 top pin bolt 4 29 ZT1P72MN cylinder head
cover air balance pipe 1
11 M5×15－5# Hexagon socket
screw 2 30 M6×30 Hexagon Flange Bolt 6
12 ZT1P72MN rocker arm limit
block 2 31 M6×10 top pin bolt 1
13 ZT1P72MN intake rocker
arm sub-components 1 32 ZT1P72MN Cylinder Head Cover Oil Pipe Clamp 1
14 ZT1P72MN intake and
exhaust rocker arm shaft 2 33 ZT1P72MN cylinder head cover 1
15 ZT1P72MN camshaft bearing
pressure plate 1 34 ZT1P72MN cylinder head cover labyrinth cover gasket 1
16 M6×10 top pin bolt 1 35 ZT1P72MN Cylinder Head
Cover Labyrinth Cover 1
17 ZT1P72MN decompression
camshaft sub-components 1 36 ZT1P72MN cylinder head cover rubber gasket 1
18 φ11.8×φ1.9 fluorine rubber
O-ring 1 37 M6×10 top pin bolt 4
19 GB276－6002-RS/P5C3
deep groove ball bearing 1 38
Two, Maintenance information
General information
1. The engine must be removed from the frame for maintenance of the cylinder head cover and cylinder head.
(Remove the engine from the whole vehicle, refer to ZT310T-M Maintenance Manual-11.Remove the engine
from the whole vehicle)
2. Remove the cylinder head cover and the cylinder head. The engine oil does not need to be drained. The rear wheel
and the main bracket can be used to stand the engine firmly.

3. Before disassembling, remove the foreign matter and dust on the cylinder head cover and the joint surface of the
cylinder head.
4. After disassembling the cylinder head cover, before disassembling the cylinder head, check the timing first and turn
the piston to the top dead center.
5. When disassembling, the disassembled parts should be installed in a clean box and marked to prevent wrong
installation during assembly.
6. When disassembling the cylinder head, first remove the two M8×110 hexagon flange bolts on the side, and finally
remove the 4 M10×1.25 hexagon flange nuts on the cylinder head.
7. When disassembling the cylinder head, it is forbidden to bump or scratch the joint surface of the cylinder head.
8. When disassembling the cylinder head, the cylinder block and cylinder head gasket cannot be reused to prevent
blow-by and air leakage.
Bolt torque value
Bolt type Assembly position Quantity Torque
(N•m)
Remarks
M6×30 Hexagon Flange Bolt - 8 12±1.5 -
M8×110 Hexagon Flange Bolt Cylinder head bolt 2 21±2 -
M10×1.25 Hexagon Flange Nut Cylinder head nut 4 52±5 -
M6×10 top pin bolt - 12 10±1 -
M6×22 Hexagon Flange Full Thread Bolt Thermostat locking bolt 2 12±1.5 -
M6×16 hexagon flange bolts - 3 12±1.5 -
M5×15－5# Hexagon socket screw Rocker arm limit block
locking bolt 2 7±1
Need to
apply thread
glue
LMAR8A-9 spark plug - 1 14±1 -
Specification
Project
Standard value
Maintenance limit value
Intake and exhaust rocker
shaft
Diameter 11.973-11.988 mm（0.4714-
0.4720 in）
11.942 mm（0.4702 in）
Intake rocker arm sub-
components
The inside
diameter of
12-12.018 mm（0.4724-0.4731
in）
12.033 mm（0.4737 in）
Exhaust rocker arm sub-
components
The inside
diameter of
12-12.018 mm（0.4724-0.4731
in）
12.033 mm（0.4737 in）
Matching clearance
between intake and
exhaust rocker arm and
intake and exhaust rocker
arm shaft
Fit clearance
0.012-0.045 mm（0.0005-0.0018
in）0.08 mm （0.0032 in）
Intake and exhaust valve
springs
Free length 35.5-36.5 mm （1.3976-1.4370
in）
33.7 mm （1.3268 in）
Camshaft tip height Inlet tip height 39.996-40.116 mm （1.5746-
1.5794 in）
39.896 mm （1.5707 in）
Exhaust tip height 39.946-40.066 mm （1.5727-39.846 mm （1.5687 in）

1.5774 in）
Camshaft Camshaft runout - 0.03mm （0.0012 in）
Matching clearance
between valve stem
diameter and valve guide
Intake 0.01-0.037 mm （0.0004-0.0015
in）
0.08 mm （0.0032 in）
Exhaust 0.025-0.052 mm （0.0010-
0.0020 in）
0.1 mm （0.0039 in）
Valve stem diameter Beat - 0.01 mm （0.0004 in）
Tools
1. Pliers.
2. T-sleeve -8#.
3. T-type sleeve -10# / torque wrench +10# sleeve.
4. T-type sleeve-14# / torque wrench +14# sleeve.
5. 5# Inner hexagon.
6. 6# inner hexagon.
7. 10# inner hexagon.
8. The valve spring is placed on top of the clamp.
9. 22# open-end wrench.
10. 17# Torx wrench.
11. Spark plug sleeve.
Three, Failure phenomenon / failure analysis
When the engine cylinder head fails, it will affect the performance of the engine, and at the worst, it will be difficult to
start the engine. The fault can be eliminated by detecting cylinder pressure, endoscope and other methods.
1. When the engine starts, the idle speed is unstable or difficult to start.
• The valve clearance is incorrect.
• Wrong timing, wrong teeth.
• The valve spring is broken.
• The valve is not closed tightly and leaks air.
• The spark plug has serious carbon deposits and insufficient ignition energy.
• The spark plug is loose and leaking.
• Blow-by of cylinder block and cylinder head gasket.
2. There is abnormal noise after the engine is running.
• The valve clearance is incorrect.
• The valve spring is broken.
• Worn valve seat.
• The camshaft slinger is broken.
• The camshaft bearing is worn or damaged.
• The tensioner is damaged.
• Worn or damaged intake and exhaust valve rocker arm bearings.
• The rocker arm limit block is broken.
• Excessive carbon deposits in the engine and deflagration.
3. After the engine warms up, the exhaust gas is abnormal.
• The valve stem diameter oil seal is worn or damaged.
• The valve guide is worn or damaged.

• The cylinder head gasket is damaged.
4. The engine is electrically started, and the crankshaft rotates without cylinder pressure or
the cylinder pressure is very small.
• The valve spring is broken.
• Broken valve.
• Blow-by of cylinder block and cylinder head gasket.
• The spark plug is loose and leaking.
• Excessive carbon deposits on the valve.Causes valves to close poorly.
Four, Cylinder compression test
1. Warm up the engine to normal operating temperature, stop the machine and pull out the spark plug cap and remove
the spark plug (Refer to ZT310T-M maintenance manual-2.Maintenance-Spark plug for disassembly and
assembly).
2. Install the cylinder pressure gauge connector into the spark plug hole.
3. Fully open the throttle opening, press the start switch, and use the starter motor to drive the crankshaft and piston
to run until the cylinder pressure gauge stops rising (Starter motor running time ≤ 15s).
Engine speed: 480-525r/min
Compression pressure: 750-1050 KPa (7.65- 10.71 Kgf/cm2, 108.8-152.3 psi)
①If the measured cylinder pressure is higher than the normal value, it indicates that there is carbon deposit on the
top of the piston or on the cylinder wall.
②If the measured cylinder pressure is lower than the normal value, pour a small amount of clean oil from the spark
plug, rotate the crankshaft a few times, make the piston ring and cylinder wall evenly covered with oil film, and retest
the cylinder pressure. If the cylinder pressure measured after the oil is poured is greater than the last cylinder
pressure value, please disassemble the machine and check the piston and piston ring.
Failure analysis:
a. The piston ring is worn.
b. Cylinder wear.
③If the cylinder pressure measured by pouring oil is the same as the last time (The cylinder pressure is too small),
First measure the valve clearance of the intake and exhaust valves for any abnormalities, then dismantle the machine
to check the intake and exhaust valves for leaks and the cylinder head gasket coating for damage to the blowby gas.
Five, Cylinder head cover
Cylinder head cover removal
1. As shown in the figure, use scissors to cut off the separator fixing tie, use clamp pliers to remove the separator tube
clamp, and remove the separator.

2. As shown in the figure, use T-rod-8# to remove the cylinder head cover locking bolts, and remove the separator
bracket, cylinder head cover, and cylinder head cover sealing ring.
Cylinder head cover installation
1. As shown in the figure, after removing the flat sealant, oil stains and dust on the joint surface of the cylinder head
and the cylinder head cover, apply an appropriate amount of flat sealant to the position shown in the figure. Check the
cylinder head cover sealing ring on the cylinder head cover. After confirming that it is installed in place, install the
cylinder head cover assembly to the corresponding position of the cylinder head. Use M6×30 bolts to pre-tighten the
separator bracket and the cylinder head cover and tighten them with a fixed twist. 12±1.5 N•m.
2. As shown in the figure, insert the separator tube into the air balance tube of the cylinder head cover, and use clamp
pliers to move the clamp to the proper position to clamp the tube. Fix the separator to the separator bracket with a
cable tie.
Six, Cylinder head
Cylinder head removal
1. As shown in the figure, use T-sleeve-8# to remove the thermostat bolts and remove the thermostat, respectively use
5# and 10# Allen wrenches to remove the M14×1.5 screw plug on the right crankcase cover, M30×1.5 aluminum
screw plug, and remove the O-ring.

2. Insert the 14#-T socket wrench from the M30×1.5 aluminum screw plug hole and set it on the magneto rotor locking
bolt, and then turn the crankshaft clockwise to align the T point engraved line on the flywheel with the M14×1.5 screw.
The plug hole marks the gap. At the same time, the top dead center engraved line on the timing driven sprocket
should also be aligned with the raised mark line on the cylinder head.
Note: Once the T-point engraved line turns over the marked line when rotating the flywheel, it cannot be
reversely rotated back to the right point. The crankshaft must be turned clockwise twice again to re-align the
points ! ! !
3. As shown in the figure, use T-bar-8# to remove the tensioner, timing driven sprocket fixing bolts, and timing driven
sprocket (Refer to ZT310T-M Engine Maintenance Manual-Cylinder Head Cover, Cylinder-Head-tensioner).
4. As shown in the figure, first remove the two M8×110 hexagonal flange bolts on the side of the cylinder head with T
rod-10#, and remove the four M10×1.25 lock nuts on the cylinder head diagonally with wrench -14#.
5. As shown in the figure, remove the cylinder head, cylinder block and cylinder head gasket and positioning pins.
Align
Align

Cylinder head decomposition
1. As shown in the figure below, use 6#-inner hexagon to remove the high-pressure oil pipe bracket, intake manifold
sub-assembly and heat insulation pad (The heat insulation pad O-ring cannot be damaged or broken).
2. As shown in the figure below, use a 22# open-end wrench to remove the oxygen sensor, and T rod-8# to remove
the cylinder head clamp bracket. Use the spark plug sleeve to remove the spark plug. Use a 17# torx wrench to
remove the water and 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.
4. As shown in the figure below, use a 5# inner hexagon to remove the rocker arm limit block bolts, and remove the
rocker arm limit block, rocker shaft, intake and exhaust rocker arm, and valve adjustment gaskets.