TAYO ZT1P52MI Manual de usuario

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ZT1P52MI

Engine maintenance manual

2023-04-01

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Foreword

All the materials, illustrations, photos, etc. Collected in this manual are compiled according to the latest product

of ZT1P52MI Euro IV. 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

motorcycle. 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.

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User Notice

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 repai r.

If you need to clean or wash the body parts of this motorcycle, you should use neutral car wash liquid or tap water or diesel

oil, kerosene, etc. Acidic or alkaline car 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 to 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 requiring 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

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Table of contents

Table of contents ....................................................................................... 4

Spark plug ............................................................................................. 6

System components ................................................................................. 6

Cylinder compression test ............................................................................ 6

Water pump ........................................................................................... 7

System components ................................................................................. 7

Cylinder head cover, cylinder head.......................................................................... 9

System components ................................................................................. 9

Cylinder head cover ................................................................................ 11

Cylinder head ..................................................................................... 12

Camshaft ......................................................................................... 13

Guide bar ........................................................................................ 16

Tensioner ........................................................................................ 17

Cylinder, piston ........................................................................................ 18

System components ................................................................................ 18

Cylinder, piston .................................................................................... 19

Electric starter box cover, starter mechanism, timing chain ..................................................... 21

System components ................................................................................ 21

Electric starter box cover ............................................................................ 22

Start agency ...................................................................................... 23

Timing chain ...................................................................................... 23

Oil pump - right crankcase cover .......................................................................... 24

System components ................................................................................ 24

Right crankcase cover ............................................................................... 25

Oil pump ......................................................................................... 25

Oil filter .............................................................................................. 26

System components ................................................................................ 26

Oil filter .......................................................................................... 27

Magneto stator, rotor................................................................................... 27

System components ................................................................................ 27

Magneto rotor .................................................................................... 28

Magneto stator .................................................................................... 29

Left crankcase cover, continuously variable clutch sub-assembly ................................................. 30

System components ................................................................................ 30

Left crankcase cover ................................................................................ 30

Continuously variable clutch sub-assembly .............................................................. 31

Gearbox.............................................................................................. 33

System components ................................................................................ 33

Gear case cover.................................................................................... 35

Thermostat, radiator , fan case cover....................................................................... 38

System components ................................................................................ 38

Thermostat, radiator, fan case cover ................................................................... 39

Crankcase ............................................................................................ 40

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System components ................................................................................ 40

Crankcase ........................................................................................ 40

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Spark plug

System components

Remove the spark plug

1. Use the special spark plug socket -16# or the extended socket head -16# to remove the spark plug counterclockwise.

Check spark plugs

1. Check the thread of the spark plug and the center electrode. If there is any damage or deformation, replace the spark plug.

2. Use a feeler gauge to measure the gap a of the spark plug, if it exceeds the range, replace the spark plug.

Note: the standard value of spark plug gap is 0.7-0.9mm.

Install spark plugs

1. Screw the spark plug into the cylinder head, put on the spark plug special sleeve -16# or the extended sleeve head -16#, and

pre-tighten it with a torque wrench to fix the torque, the torque is 14±1 N.m.

Cylinder compression test

1. Start the engine, warm up the engine to normal operating temperature, and then turn off the engine.

2. Remove the dust near the spark plug and remove the spark plug.

3. Install the cylinder pressure gauge.

4. Fully open the throttle, press the start switch, and use the starter motor to drive the crankshaft and piston to run until the

cylinder pressure gauge reading stops rising (starter motor running time ≤ 15s).

Engine speed: 420-510r/min

Compression pressure: 440-550kpa (4.49-5.61 kgf/cm 2 , 63.8-79.8 psi)

① if the measured cylinder pressure is larger than the normal value, it means that there is carbon deposit on the top of the

piston or the wall of the cylinder.

spark plug

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②if the measured cylinder pressure is lower than the normal value, pour a small amount of clean engine oil from the spark plug,

turn the crankshaft a few times, so that the piston ring and cylinder wall are evenly covered with oil film, and retest the cylinder

pressure. If the cylinder pressure measured after pouring oil is greater than the last cylinder pressure value, please dismantle the

machine and check the piston and piston ring.

5. Use the spark plug tool to install the spark plug in place and tighten it with a fixed torque (fixed torque: 14±1 N.m).

Water pump

System components

No. Part name Quantity No. Part name Quantity

1 Gb894.1 shaft retaining ring φ10 (oxidized

black)

1 11 M6×22 hexagon flange fully threaded

bolts (grade 8.8/zinc)

2 Φ8×14 hollow positioning pin 4 12 ZT1P58MJ water pump cover 1

3 Φ36×1.9 acrylic O-ring 1 13 ZT1P58MJ

water pump cover sealing

ring

4 ZT1P58MJ water pump housing 1 14 Water seal moving ring rubber 1

5 Water seal static ring 1 15 M6×30 hex flange bolts 3

6 ZT1P58MJ water pump shaft 1 16 Fb12×20×5 fluorine rubber oil seal 1

7 Water seal moving ring ceramics 1 17 ∅16.5×7.5 water plug 1

8 ZT1P58MJ water pump blade 1 18 18.2×2.4 EPDM rubber O-ring 1

9 M6×10 top pin bolt (zinc)1 19 Gb/t 276-6000-p5c3 deep groove ball

bearings

10 6.3×12×1.6 copper gasket 2

Assembly

1. Remove 3 m6×30 hexagonal flange bolts counterclockwise with a torque wrench (or air batch) and an extended outer hexagon

socket -8#, remove the water pump from the engine, and then remove the φ36×1.9 acrylic o-type ring, 18.2×2.4 EPDM O-ring

and two φ8×14 hollow positioning pins.

2. Use a torque wrench (or air batch) and an extended outer hexagon socket -8# Assembly 4 m6×22 hexagonal flange

full-threaded bolts and 1 m6×10 top pin bolt (zinc) on the water pump cover counterclockwise. Zinc), remove the water pump

cover, water pump cover sealing ring, 2 copper gaskets and 2 φ8×14 hollow positioning pins.

3. Use a 12# wrench to rotate counterclockwise to loosen and remove the water pump blade, and take out the water seal moving

ring ceramic and water seal moving ring rubber.

Take out the water pump shaft, use a flat-blade screwdriver to extend from the bearing hole until it contacts the water seal, and

then tap it slowly to knock out the water seal.

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Use a flathead screwdriver to pry out the oil seal, and then knock out the bearing to complete the disassembly of the water

pump. (note: when the water pump is running normally without failure, it is not recommended Assembly the water pump,

internal bearings, oil seals, and water seals.)

Inspection

1. Check the water pump cover ring and 18.2×2.4 O-ring on the water pump cover . If there are any defects such as wear and

edge trimming, replace the O-ring with a new one to prevent water leakage due to poor sealing .

2. Check whether the threads of the water pump blades and the water pump shaft are slippery.

3. Check the water pump shaft and blades for cracks, damage, wear, etc. If they are defective, replace them with new ones.

Install

1. Take a new fb12×20×5 fluorine rubber oil seal and press it to the position shown in the figure below. After installation,

measure the depth to confirm whether it is installed in place.

Remarks: ① apply engine oil to the oil seal installation hole and install the oil seal.

②fb12×20×5 fluorine rubber oil seal pressing depth: the distance from the end face of the oil seal to the joint surface of the

pump cover is 23.4 (-0.2,0) mm or the end face is even.

2. Check whether the bearing rotates smoothly. If the bearing rotates stuck, replace it with a new one. After oiling the bearing

hole, use a special pressure head to press the bearing into place.

Note: bearing model: gb276－6000/p5c3 deep groove ball bearing.

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.

M6×30 hex flange bolts

Apply 962T sealant

anointed with oil

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4. Put the water-sealed moving ring rubber into the inner hole of the water pump blade; put the water-sealed moving ring into

the inner ring of the water-sealed moving ring rubber (the crossed side faces inward, and the smooth side faces outward), and

apply an appropriate amount of silicone oil on the smooth surface of the moving ring;

Screw the water pump impeller assembly into the water pump shaft (apply thread glue), lock it with a 12# sleeve, and correct

the torque with a torque wrench , torque: 20±1.5 N.m.

5. Apply a small amount of engine oil to the water pump shaft and put it into the water pump casing, install it in place and install

the retaining ring for the shaft. (note: apply a proper amount of water-soluble silicone oil on the static ring and moving ring of

the water seal)

6. Take two φ8×14 hollow positioning pins and put them into the corresponding holes, put the water pump cover sealing ring on

the water pump cover groove (if the O-ring is trimmed or worn, replace it with a new one), and finally take 4 m6× 22

full-threaded bolts on the hexagonal flange surface (grade 8.8/zinc) , one of which is inserted into a 6.3×12×1.6 copper gasket,

and tightened clockwise with a torque wrench (or air batch) and an extended outer hexagonal sleeve -8# bolt. Torque standard:

12±1.5N·m.

7. Take a m6×10 top pin bolt (zinc), insert a 6.3×12×1.6 copper gasket, screw the bolt into the threaded hole at the

corresponding position, torque wrench (or wind batch) and extend the outer hexagonal sleeve cylinder-8# tighten the bolts

clockwise. Torque standard: 10±1 N·m. (note: the copper gasket is a one-time consumable, and a new gasket is required for

installation)

8. Install the φ36×1.9 acrylate O-ring and the 18.2×2.4 EPDM O-ring into the corresponding positions.

Cylinder head cover, cylinder head

System components

15 13

Refer to the figure for disassembly and

assembly of the valve, the disassembly

structure of the intake valve and exhaust valve

is the same.

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Parts information

No. Name Quantity Name

1 Aym8－m8×38 double-headed 10.9 grade stud

(zinc )2 Tool: stud socket m8fixed torque: 20±2 N.m

Thread fastening glue

2 Water and oil shared sensor 1 Tools: 17# socket and fixed torque wrench fixed

torque: 14±1N.m

3 9×2 EPDM rubber O-ring 1

4 Cr8ei spark plug (protruding type) 1 Tool: 16# spark plug socket fixed torque: 14 ± 1

N.m

5 6.3×12×1.6 copper gasket 1

6 M6×10 top pin bolt (zinc)1 Tool: t-sleeve-8# fixed torque: 10±1 N.m

ZT1P58MJ intake rocker arm subassembly－b

8 ZT1P58MJ camshaft bearing pressure plate 1

9 M5×15-5# hexagon socket head screw 2 Apply thread glue, tool: 5# inner hexagon fixed

torque: 7±1 N.m

10 M6×10 top pin bolt (zinc)1

Apply thread glue, tool: t-sleeve-8# fixed torque:

10±1 N.m

11 ZT1P58MJ exhaust rocker arm subassembly－b 1

12 ZT1P58MJ intake and exhaust rocker shaft 2

13 ZT1P58MJ camshaft sub-component-b 1

14 8.8×1.9 fluorine rubber O-ring 1

15 Gb276-6001/p5c3 deep groove ball bearings

(nitrided) 1

30 31

24 23

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