Zontes ZT310-X Service Manual Download Page 118

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14、MUFFLER COMPONENT

117

CHK

ADJ

NO.

PART NO.

PART NAME

QTY

REMARKS

1224100-013000 ZT250-S Oxygen sensor fixing buckle

1250205-023000 GB70.1 Hexagon M8×35 (environmental color zinc)

1274100-068095 ZT310 Muffler flange bushing

1250303-011093 GB6177.1 M8 (environmental color)

1251300-058093 Hexagon nut M8 (environmental color zinc)

1020241-094000 ZT250-S Muffler flange

1070100-133000 ZT250-S Engine exhaust seal gesket

Fig.2MUFFLER

COMPONENT

Muffler front assembly 1

PROCEDURE:

●

Oxygen sensor fixing buckle

Pull the cable clip

⑴

out of the radiator bracket with the pliers after slightly clamping it to the outside top (as

shown in Figure A). Separate the oxygen sensor connector from the main harness.

●

Muffler assembly

Lower the side bracket to fix the motorcycle.
Under the right nameplate of the motorcycle, after fixing the nut

⑷

with a boxer wrench, remove the bolt

⑵

and

remove the bushing

⑶

, as shown in Figure B.

Remove the nut

⑸

and remove the muffler flange

⑹

as shown in Figure C.

Hold the muffler front assembly with one hand, remove the bolt

⑵

from under the side bracket mounting plate

with one hand, and remove the bushing

⑶

as shown in Figure D.

After removing the muffler front assembly, remove the gasket

⑺

as shown in Figure E.

CAUTION:

●

The lower shroud assembly needs to be removed in advance. For the removal procedure, see "Lower shroud

assembly".

●

The muffler should be completely cooled before it is disassembled.

●

Prevent foreign matter from entering the muffler or engine interior.

●

It is recommended that new seals should be replaced each time the muffler front assembly is removed to

prevent air leakage.

Summary of Contents for ZT310-X

Page 1: ...ZT310 X X GP Service manual 2020 11 11 ...

Page 2: ...t frame oil drain bolt component 2 FRAME ENGINE 2 1 Frame Engine Combination 1 14 Detachment standard lower guard bar shroud front bracket engine left rear cover 2 2 Frame Engine Combination 2 15 Hanging piece bracket component 3 INDUCTION SYSTEM COMPONENT 3 1 Intake system components Delphi EFI 16 Throttle valve body component air filter oil pipe 3 2 Intake system components Bosch EFI 17 Air filt...

Page 3: ...ight adjustment 5 2 Right footrest component 1 29 Remove the right foot support component 5 3 Right footrest component 2 30 Decomposition brake pedal component 5 4 Right footrest component 3 31 Decompose the right pedal component 5 5 Left footrest component 1 32 Remove the left foot support component and the shift lever component 5 6 Left footrest component 2 33 Decomposition shift lever component...

Page 4: ...losure panel the left turn signal and the left enclosure trim panel 7 4 Right enclosure panel component 46 Disassemble the right surrounding panel the right turn signal and the right surrounding decorative panel 7 5 Lower shroud component 1 47 Remove the shroud component 7 6 Lower shroud component 2 48 Disassemble Lower shroud component 8 FRONT FORK COMPONEN 8 1 Throttle clutch cable clearance adj...

Page 5: ...SB charging cable 8 15 Left and right hood Electronic Instrument 63 Remove left and right hoods 8 16 Motor Controller Headlight component Electronic Instrument 64 Dismantle motor controller wire plug fixing bracket headlight component 8 17 Windshield component TFT Instrument 1 65 Remove windshield windshield clamp 8 18 Windshield component TFT Instrument 2 66 Remove the rocker arm on the windshiel...

Page 6: ...ont disc brake main pump and the tubing ABS control unit 8 32 ABS Brake System 2 80 Disassemble the front disc brake caliper and the FC HU tubing 8 33 ABS Brake System 3 81 Disassemble the rear disc brake main pump and the tubing 8 34 ABS Brake System 4 82 Disassemble the rear disc brake caliper and the FC HU tubing 9 FUEL TANK COVER COMPONENT 9 1 Tank middle cover component Small fuel tank 83 Dem...

Page 7: ...racket fuel tank cap 11 SIDE COVER COMPONENT 11 1 Side cover lower components 95 Remove the lower part of the left side cover and the lower part of the right side cover 11 2 Left side cover upper component 96 Remove the upper and middle parts of the left side cover 11 3 Right side cover upper component 97 Remove the upper and middle parts of the right side cover 12 REAR COVER COMPONENT 12 1 Rear A...

Page 8: ...box 12 13 Electrical device box component colliod battery 110 Disassemble electrical device box cover ECU Realay and fuse box 12 14 Battery component colliod battery 111 Disassemble battery Wake up switch and charging precautions 12 15 Electrical device box component 1 colliod battery 112 Disassemble electrical device box component lower cover of electrical device box 12 16 Electrical device box c...

Page 9: ...uangdong Tayo Motorcycle Technolog Co Ltd All rights reserve All the information illustrations and photographs collected in this manual are compiled according to the latest products However there may be some inconsistencies between your motorcycle and this manual due to the continuous improvement of the product and other changes ...

Page 10: ...ssors and other tools to assist The binding and can be picked out by using scissors Flasher and dump switch Remove the rubber sleeve that connects the flasher to the mounting bracket on the frame and remove the dump switch with the same method then separate the dump switch Relay head light diode Pull out the side stand relay and electric injection relay directly Ignition coil support Remove the cr...

Page 11: ... 1250205 040095 GB70 1M8 16 Screw 2 PROCEDURE Horn Take off the plug of horn take the horn 3 by one hand use tool rotate the screw 1 by another hand remove the holder then take off the horn Flameout switch Find and take off the plug of the flameout swich press and take off the cable clip cut ribbon Using the inner hexagon tool remove the bolts the holder and the flameout switch CAUTION When Take o...

Page 12: ...e cushion Use both hands to hold the two ends cylinder parts of the inner fuel tank limited glue cushion and should push it out Side cover cushion Remove the side cover cushion with your hand directly Frame waterproof rubber plug Remove the frame waterproof rubber plug with your hand directly Cable collection clip First take the cable and the main thread out from the collection clip then use the s...

Page 13: ...o upper dustproof cover is required to about 14N m so as to be able to rotate out of nimbleness The top adjusting nut only needs to rotate to the bottom of the nut groove alignment not too tight to prevent the rubber pad from deformation too larg 1 CAUTION Remove the head part component handlebarcomponent and front shock absorber component first Please pay attentin to fix the awaiting repair motor...

Page 14: ...he O ring must be replaced at the same time The oil cooling joint must be tightened well when re assembling which meets the standard torque value Realease the frame tube enging oil Put the oil pan at the bottom use the appropriate tool to remove the oil bolts and the sealing gasket and remove the oil from the frame tube Refer to the instructions for detailed steps to replace the oil It is recommen...

Page 15: ...strictly prohibited Waste engine oil should be recycled and disposed of by a qualified organization it is forbidden to dump the polluted environment or water source at will Wipe clean oil Always be vigilant throughout the process to prevent accidents When disassembling the engine be sure to operate it at the same time 9 1251112 003093 M6 45 hexagonal flange surface 9 8 bolt environmental color zin...

Page 16: ...e and then remove the nut 1 with a sleeve Remove the bracket after removing the bolt 8 First cover the head of the bolt 6 with a sleeve and then remove the nut 1 with a sleeve Then remove the bolt 6 Both of them hold the left and right boxes of the engine at the same time one person removes the bolts 7 Then remove the rear fork assembly Remove the bolt 9 and remove the upper right hanging piece 2 ...

Page 17: ...reaking site to prevent accidents PROCEDURE High pressure oil pipe First press the high pressure oil pipe 4 the anti loose snap ring close to the fuel pump connector and pull it out directly A small amount of fuel in the oil pipe needs to be caught in the oil can prevent fuel from dripping to any part of the vehicle Then press the anti loose snap ring near the injector holder 2 and remove the high...

Page 18: ...ed during the disassembly process Air filter Fisrt use the inner hexagon tool to remove the bolt 3 Pull off the brake oil pipe from the oil pipe clamp 7 and remove it Loosen the pipe clamp assembly 5 on the end of the air filter Clamp the clamp on the exhaust pipe with pliers and unplug the exhaust pipe connected to the exhaust port of the engine Then use the rubber plug that is delivered with the...

Page 19: ... stepper motor 8mm 1 12 1050954 024000 CTS three in one sensor 1 after sale Throttle assembly Use a wrench to remove the bolt 1 remove the throttle valve assembly and remove the O ring 4 from the intake pipe assembly 5 Then press the anti loose snap ring near the injector holder 7 and remove the high pressure oil pipe as shown in the lower right figure Pull out the throttle valve desorption rubber...

Page 20: ...with pliers and pull out the tubing Unplug carbon tank solenoid valve with the same method Remove the bolts with the inner hex tool Remove thecarbon tank from the left side of the frame and remove the plywood nut Desorption tubing Clamp the pipe clamp on both ends of the desorption tubing and take the it out Carbon tank electromangnetic valve Remove the plug of the solenoid valve then remove the n...

Page 21: ...lean up the engine will be damaged or the induction resistance will become larger and affect the driving experience If there is any damage please log on the official website and purchase another parts Oil pipe and water pipe Avoid water into the air filter when washing the motorcycle Can pulled out the oil pipe and water pipe to release if into small water keep no water inside before staring the e...

Page 22: ... bolts color zinc 1 Fig 1 REAR WHELL COMPONENT Rear inner mudguard PROCEDURE Rear inner mudguard First of all pull out the braking oil tube and wheel speed sensor cable which are on the right side of rear inner mudguard from the slot of rear disc brake oil tube cleat Disassemble 3bolts and bolts with hex sockets tool and open end wench disassemble bush bush gum cushion finally take off the rear in...

Page 23: ... socket sleeve Person 1 shake slightly the rear wheel up and down Person 2 drag out bolt Person 1 hold firmly the motorcycle Person 2 lift the rear shock absorber towards the arrow direction and drag out bolt Take off the rear absorber at last Adjust the rear absorber Use hook spanner to loosen adjustive nut Rotate adjustive nut If the nut is rotated towards the arrow direction the spring becomes ...

Page 24: ...ar wheel assembly Punch rear wheel axle with rubber hammer Take off right chain adjuster right axle sleeve rear tire and rim assembly left axle sleeve left chain adjuster Tie firmly the rear disc brake clamp and avoid it to be lifed higher than disc brake oil cup Disassemble the rear wheel axle at last Sprocket bracket assembly Put down the rear wheel assemble horizontally Take off nut with socket...

Page 25: ... the tire with same specification See details in user manual Ingradiant of tire include semi hot melt rubber Area with too high temperature is not suitable If temparature of outdoor is too low storing the motorcycle in warm place or indoor is suggested in order to avoid frost crack Normal temperaturestandard 250kPa Rim Check if the rim has deformation or crack Support the rim horizontally and chec...

Page 26: ...oil pipe clamp 4 loosen the bolt 3 and take off the disc brake oil pipe clamp The rear disc brake caliper is placed well and cannot be higher than the disc brake oil cup as shown in left figure One person fastens the head of the rear fork shaft with sleeve and the other person remove the nut 2 with it One person holds the rear fork assembly and the other person removes the rear fork shaft 1 with s...

Page 27: ...op cover and sealing gasket Remember to rebound the pister afterwards The new arrester must fit tightly the slot See photo right below Tighten the pin axle with hex socket tool Tighten rolling axle with socket sleeve Tighten nut with strait screwdriver Step on braking pedal several times until braking force is recovered CAUTION Check regularly the arrester and disc brake plate status To change arr...

Page 28: ...pay attention install sealing gasket in correct position and direction Step gently on the pedal constantly Do not ride the motorcycle until the braking force is recovered CAUTION Support the motorcycle well on flat ground before checking Check regularly if the braking liquid surface is between UPPER and LOWER If liquid surface is below LOWER check the arrester status and confirm if the braking sys...

Page 29: ...d adjustment bolt until the height becomes suitable Then tighten the nuts If the above mentioned method can not adjust the gear shift rod to a satisfying position take off bolt 1 and adjust gear shift rod spline of rocker arm 2 with a straight screwdriver by shoving a little bit the groove in the middle while dragging it out Reassemble after the height is suitable Pay attention to the aligning of ...

Page 30: ...sition of rear part of muffler and disassemble the bolt behind the foot pedal holder and take off the bush Take off the bolts in the front Overturn and take off the bush and gum cushion Disassmble the expanding bolt CAUTION While overturning the foot pedal holder keep the components nearby well protected in case they are scratched Mind the disc brake oil tube while overturning the holder Support t...

Page 31: ... 1 PROCEDURE Rear disc brake pump assembly Disassmble bolt Rear disc brake oil cup can never be lower than oil tube interface of main pump Brake pedal assembly Disassemble bolt pull out brake pedal take off brake pedal spring washer Rear disc brake oil cup holder Disassemble bolt take off bush gum cushion bush oil cup holder CAUTION Applying lubrification on inner surface of brake pedal bush can r...

Page 32: ...nt pedal matte dark gray 1032142 039000 ZT310 X R rear pedal 1032112 019051 ZT310 X R rear pedal matte dark gray 16 1274200 254093 BushingΦ12 Φ6 19 environmental color 1 17 1251100 224000 Non standard ball head bolt M6 26 1 18 1250501 010000 GB93φ6 spring washer 2 PROCEDURE R front pedal Disassemble circlip Take off foot pedal pin axle Then disassemble R front pedal foot pedal spring R rear pedal ...

Page 33: ...ring spanner Insert strait screwdriver into slot and open a little bit the spline rocker arm while pulling it out from gear shift axle of engine Disassemble bolt bolt with hex socket tool Take off left foot pedal holder assembly Disc brake lock holder Turn over to the back side Disassemble bolt with hex socket tool Take off disc brake lock holder Gear shift rod assembly Disassemble bolt Separate l...

Page 34: ...24000 ZT310 X Foot pedal rubber 1 16 1274200 051000 ZT310 X Foot pedal rubber positioning plate 1 17 1250205 038000 GB70 2M5 12 Stainless steel 1 1032142 041000 ZT310 X L front pedal 1032112 020051 ZT310 X L front pedal matte dark gray 19 1274200 254093 BushingΦ12 Φ6 19 environmental color 1 20 1251100 224000 Non standard ball head bolt M6 26 21 1250501 010000 GB93φ6 spring washer 1 PROCEDURE L Fo...

Page 35: ...ar foot pedal 1032112 021051 ZT310 X L rear foot pedal matte dark gray 13 1250501 010000 GB93φ6 spring washer 1 12 1 PROCEDURE L rear foot pedal Disassmble circlip with a tool Take off foot pedal pin axle Then pull out L rear foot pedal Take off positioning plate steel ball spring Foot pedal holder Disassemble side cover gum cushion After sales parts of foor pedal with rubber Hold the L rear foot ...

Page 36: ...before reassembling Torque on bolt is 24 4N m Too strong will damage the thread Too week will cause leakage of oil Add from opening on right crankcase of engine 1 6L 1 7L if oil filter is changed new engine oil of SAE 10W 50 10W 40 with API SM degree or higher Then reassemble the engine oil gauge Start the engine and test it under different rotation speed for 2 minuts Check if the engine oil leaks...

Page 37: ...oosen Take off seal ring Change engine oil filter Check if seal ring is broken Change the seal ring along with engine oil filter is suggested When reassembling pleas check carefully if the spring seal ring are well installed Engine oil filter can not be turned over when assembling Torque of cover type nut is 12 1 5N m CAUTION For the slipper clutch version please purchase the ZT180MN fine filter c...

Page 38: ...eal gasket with socket sleeve See photo middle left Engine oil intake tube Disassemble oil passing bolt seal gasket with socket sleeve See photo left lower Disassemble bolt with socket sleeve Take off engine oil outlet tube engine oil intake tube Take off O ring See photo right lower CAUTION Disassembling the cooling system while the motorcycle is hot is prohibited Wait until the engine and muffle...

Page 39: ...ested Swallowing or inhaling cooling liquid would harm human body Clean thoroughly the hands face or explosing skin every time after adding cooling liquid If cooling liquid is swalled by accident please contact toxication center or hosipital If it s inhaled please move to open air If it s spilt to the eye clean it with big quantity of clean water and see doctor in time Be sure the cooling liquid i...

Page 40: ...e Take off seal gasket 2 Cooling liquid starts draining when the cooling liquid in sub cooling liquid tank is all out open the right cooling liquid tank cover to accelerate the draining of cooling liquid in the cooling system Wipe out all of the cooling liquid on surface every component with a clean cloth CAUTION Motorcycle should be well supported Manipulation should start after the engine is com...

Page 41: ... fall off holder Drag out the anti fall off holder from the engine Take off hoop Use strait screwdriver to loosen the bolt of clamp and then move it out the interface Pull out the tube from right tank cover tube interface The models on production use clamp for the moment After the stock of tank cover is finished will use hoop As the construction is different be attention while buying after sales c...

Page 42: ...bly Disassemble bolt on the right side Take off bush See Fig A move away clamp Disassemble cooling liquid leaking tube and connecting tube Then disassemble bolt undersub cooling liquid tank Take off sub cooling liquid tank See Fig C Left cooling liquid tank assembly See Fig B Use a plier to grip as the arrow shows on the cable clip and pull it out of left cooling liquid tank holder Move hoop and t...

Page 43: ...ndard left water tank for Bosch EFI is the Delphi electric spray water tank 2 There is only one connector has two connector must be used with the ZT310 X right water tank with fan Please confirm the status of your vehicle before placing an order Fig 8 COOLING SYSTEM COMPONENT Left cooling liquid tank component 1 1274200 275000 ZT310 X left water tank without temperature control switch double conne...

Page 44: ...OMPONENT Surrounding middle component PROCEDURE Surround the middle cover Press the buckle in the direction of the arrow and then remove the middle cover 1 Bounding components Use a small Phillips screwdriver to push down the center of the expansion pin and remove the 3 expansion pins 5 Remove the 6 bolts 2 and remove the bushing 3 and cushion rubber 4 Pull the left and right surrounding component...

Page 45: ... indicated by the arrows pull out the left surrounding panel assembly and then remove the left turn signal cable connector and remove it Right enclosure panel assembly Pull out from the bottom to the top of the four directions indicated by the arrow pull out the right enclosure panel assembly remove the right turn signal cable connector and remove CAUTION The vehicle should be fixed before operati...

Page 46: ... 2 8 1251300 063093 Splint M6 11 15 environmental color 4 9 1224100 010000 ZT250 S expansion nail 2 10 1251200 033093 Non standard self tapping screws ST4 2 12 4 Fig 3 SURROUNDING COMPONENT Left surround panel assembly PROCEDURE Left bracket panel signage Lift the label 4 out from the back of the left enclosure panel assembly to clean up the remaining offset Left turn signal assembly Remove the 4 ...

Page 47: ... φ8 5 φ14 1 2 8 1251300 063093 Splint M6 11 15 environmental color 4 9 1224100 010000 ZT250 S expansion nail 2 10 1251200 033093 Non standard self tapping screws ST4 2 12 4 PROCEDURE Right enclosure panel signage Eject the label 4 from the back of the right enclosure panel assembly and clean the remaining offset Right turn signal assembly Remove the 4 self tapping screws 10 and remove the right tu...

Page 48: ...ide with one hand on the bottom of the lower shroud assembly and remove the bushing 3 lower right shroud assembly Continue to hold the bottom of the lower shroud assembly with one hand and remove the bolt 1 and remove the bushing 3 Remove the 3 bolts 2 on the right side and remove the bushing 3 Slightly open the rear of the lower right shroud and remove the shim 4 Lower shroud assembly CAUTION Pay...

Page 49: ...oud GP 3 4044201 333000 ZT310 X1 lower right side of the shroud GP 4 1 1 PROCEDURE Bottom lower shroud assembly Remove the cushion rubber 2 the side cover round rubber 3 and the splint 4 from the lower left shroud 1 lower right shroud assembly Remove the cushion rubber 2 the side cover round rubber 3 and the splint 4 from the lower right shroud 5 CAUTION Pay attention to the force when disassembli...

Page 50: ...e groove of the rocker seat should be staggered to prevent the cable from coming out Big adjustment If fine adjustment cannot be achieved loosen the nuts with an open end wrench rotate the adjustment screw and finally tighten the nuts Light height adjustment The driver sits on the motorcycle and keep it upright The other person uses the light height control knob to adjust the appropriate height an...

Page 51: ...ker arm and remove the cable from the rocker arm seat Remove the clutch line Remove the protective sleeve from the clutch cable Install the clutch line Put protective rubber sleeve into clutch elbow After inserting the clutch cable joint into the rocker arm screw the nut and the adjusting screw to the groove on the rocker arm Assemble the clutch cable into place according to the original alignment...

Page 52: ...ith your hand and remove the bolts and before removing the bolt Switch the upper and lower parts of the switch Remove the throttle cable from the right hand and remove the rubber sleeve from the core turntable and then remove it from the cable hole in the lower part of the switch Install the throttle line First pass the throttle cable into the cable hole in the lower part of the switch Fit the cyl...

Page 53: ...ith a spanner remove the spacer 2 and remove the bolt 3 with the Allen tool The direction of the upper board assembly wrapped with a clean cloth and then placed to prevent scratches Remove the lock washer 4 remove the upper adjustment nut 5 with a special four jaw shank or hook wrench and remove the pad 6 If the steering resistance is too large turn the lower adjustment nut 5 counterclockwise If t...

Page 54: ...orward to expose the upper balance block fixing hole use the tool to press the convex parts at both ends of the elastic block on the balance block and pull out the balance block assembly and then put the right handle Remove the rubber sleeve Right handlebar half cover Hold the front disc brake main pump with one hand and remove the bolt with the hexagon socket tool Remove the wire plug connector o...

Page 55: ...e the bolt and remove the rocker arm Add brake fluid Before driving the motorcycle check whether the brake fluid level is above the LOWER marking If not check the brake disc or brake disc for wear and whether there is any oil leakage or oil leakage in the brake system Abnormal needs to add brake fluid The brake fluid can only be added after the motorcycle is fixed horizontally Remove the bolt with...

Page 56: ...e nut Hold the brake handle repeatedly until the braking force is restored Front brake caliper mounting plate Remove the mounting plate 2 from the caliper Be careful not to lose the shrapnel of the front brake caliper CAUTION The vehicle support should be fixed before operation The wear of the brake pads and brake discs should be checked regularly Check whether the brake fluid in the main disc obs...

Page 57: ...ear indicator has been worn out the tire of the same specification type must be replaced Refer to the relevant content of the manual for details Rim Check the rim for any deformation cracks etc Rotate the rim horizontally to check for stuck oscillating etc Axle Use a dial indicator to check for deformation and bending Brake disc After replacing the brake disc the new brake disc should be operated ...

Page 58: ...10 X Front mudguard front oil pipe fixing seat 1 12 1250402 001091 GB12615φ3 10 1 PROCEDURE Wheel speed sensor Pull out the plug of the wheel speed sensor then remove the clamp Cut the tie 4 remove the bolt and remove the sensor Front disc brake caliper Remove the bolts and so that the caliper will hang down naturally It is forbidden to invert the caliper to prevent the air from entering and causi...

Page 59: ...ressing block rubber on the front side of the windshield are heated and softened by a heat gun and then torn off and the residual glue is cleaned Remove the clamp rubber on the back of the windshield as described above Windshield press block assembly Hold the lower left clamp and use the tool to push the circlip out then remove the rotary shaft Remove the lower left clamp Remove the right clamp as...

Page 60: ...able connector by pressing the buckle indicated by the arrow Remove the nut at the back of the meter b and remove the spacer Gently shake left and right and then lift up and lift the meter off the windshield base bracket Remove the cushion rubber from the windshield base bracket CAUTION Protect protective measures to prevent scratching the instrument lens Do not pull the cable directly when unplug...

Page 61: ...0 S expansion nail 2 2 1 GP PROCEDURE Head cover panel assembly Use a small Phillips screwdriver to push down the center of the expansion pin and remove the 2 expansion pins Remove the bolt at the bottom of the hood panel Remove the 2 bolts at the top of the hood panel and remove the bushing Grasp the two sharp corners near the expansion pin and gently remove the hood panel from side to side Remov...

Page 62: ...of the windshield motor and remove the 4 bolts and remove the windshield base assembly Remove the retaining spring with the tool and grasp the rear rocker bracket to remove the rotating shaft and the torsion spring Remove the rear rocker bracket Remove the screws and 2 screws on the right side of the motor with the phillips screwdriver and remove the limit switch Remove the remaining three screws ...

Page 63: ...e bolt and remove the bushing Hold the left envelop in one hand and gently sway back and forth from the left side of the interior to the back of the car in the first hand Separate the front enclosure interior assembly from the rear enclosure interior component Grasp the front enclosure components remove the nut 1 from the USB charging cable and remove the rubber pad and the cushion rubber Since 0c...

Page 64: ...n the center of the expansion pin and remove the expansion pin Grab the head with one hand and pull the middle of the hand in the direction of the arrow to remove the left part of the hood Remove the side cover round rubber from the left part of the hood Right hood assembly Remove the right side cover and the side cover round rubber as described above CAUTION Pay attention to the strength and dire...

Page 65: ...ressed in the direction of the arrow and pushed out from the fixing bracket If you need to remove the staples use the pliers to clamp the cylindrical part of the staples and pull them diagonally toward the umbrella boss Unplug all connectors of the motor controller and headlights Remove the bolt remove the bushing and remove the motor controlle Remove the cushion rubber from the motor controller H...

Page 66: ...amp 1 PROCEDURE Windshield assembly Remove the two bolts on the left side and remove the two parts of the bushing and the rubber pad and the left pressure block on the windshield Remove the right clamp on the windshield as described above Hold the windshield and remove the bolt under the upper clamp remove the bushing and the rubber pad and remove the windshield Remove the clamp pad Windshield pre...

Page 67: ...0 T head cover rocker extension spring 2 Fig 18 FRONT FORK COMPONENT Windshield assembly TFT Instrument 2 PROCEDURE Windshield trim Remove the 5 expansion screws 1 pull the windshield trim slightly in the direction of the arrow and push it diagonally downward in the direction of the arrow shown in the small figure Remove the windshield trim 2 Windshield rocker arm component Remove the upper rocker...

Page 68: ...ght Gray Head Cover Panel Bright Blue GP Version 4044201 227021 PROCEDURE Head cover panel assembly Remove the bolt at the bottom of the hood panel Remove the 2 bolts at the top of the hood panel and remove the bushing Use a small Phillips screwdriver to push down the center of the expansion pin and remove the 2 expansion pins Grasp the two sharp corners near the expansion pin and gently sway the ...

Page 69: ... Non standard bolt M6 12 304 stainless steel 3 9 1274200 137000 ZT310 T motor pressure plate 1 PROCEDURE Windshield motor cover Remove the four bolts remove the bushing and the cushion rubber remove the motor cover Locate and unplug the cable connector of the meter and windshield motor Windshield motor Remove the 3 bolts and remove the 3 spring washers remove the motor pressure plate Remove the wi...

Page 70: ...1 ZT310 T hood right lower rocker matte dark gray 2 1 1 7 6 Fig 21 FRONT FORK COMPONENT Windshield base assembly TFT Instrument 2 PROCEDURE Windshield motor parts Remove the motor sheath and 4 pieces of cushion rubber Grab the lower left rocker arm Remove the 2 screws with a Phillips screwdriver and remove Remove the rocker arm clamp Grab the lower right rocker arm Remove the 2 screws with a Phill...

Page 71: ...to remove the instrument bracket from the windshield base Remove 3 pieces of cushion rubber from the meter bracket Remove 4 pieces of cushion rubber from the windshield base CAUTION Protect protective measures to prevent scratching the instrument lens 1 At present all of them are in the state of 60 tooth induction ring gear of large fuel tank 2 is the 40 tooth induction ring gear of the large fuel...

Page 72: ...g the motor controller remove the two bolts remove the bushing and remove the controller Remove the cushion rubber from the controller Wire clamp right cover Remove the bolt and remove the wire clamp right cover Remove the 2 plywood nuts from the right cover Wire clamp First remove the cable connector from the wire clamp and then remove the two bolts to remove the wire clamp from the frame Remove ...

Page 73: ...ell nail and remove the 2 swell nails Locate and unplug the USB charging cable Remove the bolt and remove the bushing Hold the left envelop in one hand and gently sway back and forth from the left side of the interior to the back of the car in the first hand Separate the front enclosure interior assembly from the rear enclosure interior component Grasp the front enclosure components remove the nut...

Page 74: ...rewdriver to push down the center of the swell nail and remove the swell nail Grab the head with one hand and pull the middle of the hand in the direction of the arrow to remove the left part of the hood Remove the side cover round rubber from the left part of the hood Right hood assembly Remove the right side cover and the side cover round rubber as described above CAUTION Pay attention to the st...

Page 75: ...plug all the wires slot from the light Hold the bottom of the headlights first remove the 2 bolts on one side then remove the other side Remove the headlight assembly If only the headlights are removed the bushing and cushion rubber should not be removed from the frame CAUTION Do not pull the cable directly when pulling the plug The lamp cover should be protected during the disassembly process to ...

Page 76: ...on Fig 27 FRONT FORK COMPONENT white GP 4044201 230000 ZT310 X2 headlights protection shell ruby red GP version black GP 4044201 232000 ZT310 X2 headlights protection shell bright blue GP version gray GP PROCEDURE Headlight assembly Remove 2 pieces of side cover round glue and 5 pieces of splint from the headlights protective shell Headlights after sale parts Remove 2 self tapping screws from the ...

Page 77: ...T FORK COMPONENT Left hand component Old 5 1 3 1 PROCEDURE Left rear view mirror left switch rocker arm Remove the clutch line by referring to the Replace Clutch Line procedure Remove the left rear view mirror rocker base left sub switch bolt left switch and rocker arm by referring to the steps in Right Handle Assembly and Add Brake Fluid Adjusting Rocker Arm Left hand rubber sleeve and balance bl...

Page 78: ...r into the slot of the upper and lower plates to slightly enlarge the slot clearance and disassemble the left shock absorber and the right shock absorber under Remove the upper plate assembly Reflecting film The reflector is for replacement after sale no shock reduction The heat reflecting sheet can be moved back and forth by a hot air blower to reduce the viscosity of the double sided adhesive af...

Page 79: ...vent the block from rotating during the disassembly process The direction should be wrapped with cotton or other soft materials to prevent scratching the paint surface Remove the nut and remove the gasket cushion rubber and bushing Remove the upper plate The direction pad component the upper clamp and the direction handle are disassembled CAUTION Protect protective measures to prevent scratching t...

Page 80: ... the oil Be careful not to let the brake fluid come into contact with the cable connector to prevent poor contact due to corrosion RC HU is connected to the hydraulic control unit and rear brake caliper RMC HU is the rear disc brake main pump FC HU is the front disc brake caliper FMC HU is the front disc brake main pump FMC HU For the disassembly of the front disc brake main pump and handle see th...

Page 81: ...ake caliper from the front shock absorber First remove the wheel speed sensor 4 from the clamp 3 then remove the two bolts 2 and remove the wheel speed sensor 4 and the clamp 3 from the front disc brake caliper Organize the wheel speed sensor line neatly Remove the two bolts 7 on the right side Cut the cable ties 9 and 10 remove the 3 clips 8 Then remove the FC HU tubing If you need to replace the...

Page 82: ...ug Remove the bolts 2 and bolts 4 and remove the gasket 5 Remove the right footrest bracket assembly and the RMC HU tubing from the frame After wearing the waterproof gloves remove the brake fluid by referring to the procedure of adding the brake fluid of the rear brake master pump Use the open end wrench to loosen the brake switch nut 4 Remove the copper pad 7 and the RMC HU oil tubing The cotter...

Page 83: ...disc brake caliper Refer to the steps of removing the rear wheel assembly in the front remove the rear axle nut and the right chain adjuster and then retract the rear axle to the left to remove the rear disc brake caliper assembly Put the rear axle right chain adjuster and rear axle nut back into the rear fork RC HU tubing Place the oil pan under the rear disc brake caliper In the previous step of...

Page 84: ...1 of the rear and front parts of the hood assembly Drag up the back of the middle cover assembly As photoD show Pull out all the middle cover component buckle Lift the cover assembly with one hand Remove the bolt with other hand Remove the liner As E show Pull the right fuel tank trim out take out the fuel tank lock cable from right fuel tank cover and the gap of fuel tank inner tank Find the lock...

Page 85: ...sion 4044201 212052 ZT310 X2 deep bright gray tank cover bright blue GP version 3 1 Regular version 4044201 214002 ZT310 X2 pearl white fuel tank cover red GP version Fig 2 FUEL TANK COVER COMPONENT Tank cover tank cover tank lock Small fuel tank GP version 4044201 213021 ZT310 X2 special black fuel tank cover gem red GP version 4044201 215052 ZT310 X2 Deep Bright Gray Fuel Tank Cover Bright Blue ...

Page 86: ...er 4044201 207002 X2 pearl white fuel tank right cover red GP version 4044201 205021 special black fuel tank right cover gem red GP 4044201 209052 deep bright gray fuel tank right cover bright blue GP 5 1 Regular version GP version PROCEDURE Left tank cover Remove the bolts separately Remove the liner Pull out the left cover assembly of the fuel tank by pulling out in order Remove the buffler from...

Page 87: ... time the fuel tank lock switch cable has not been removed so the middle cover cannot be removed Lift the middle cover assembly in one hand remove the bolt with one hand and remove the bushing shown in Figure E Pull the right fuel tank trim out take out the fuel tank lock cable from right fuel tank cover and the gap of fuel tank inner tank Find the lock cable plug of the fuel tank at the back of t...

Page 88: ...l Tank Cover Bright Blue GP 4 1224100 014000 ZT250 S Tank cover rotary damping 1 5 1274100 021000 ZT250 S Tank cover swivel support 1 6 1274100 090000 ZT250 S Swivel shaft for tank cover 1 7 1260100 215000 ZT310 T circlip 1 1 Fig 5 FUEL TANK COVER COMPONENT Tank cover tank cover tank lock Big fuel tank 1 1 Regular version GP version 3 1 Regular version GP version PROCEDURE Fuel tank lock Use a fla...

Page 89: ...X1 special black fuel tank right cover gem red GP 4044201 321052 X1 dark light gray tank right cover bright blue GP Fig 6 FUEL TANK COVER COMPONENT Fuel tank trim kit Big fuel tank 4 1 Regular version GP version 5 1 Regular version GP version PROCEDURE Right fuel tank trim cover Remove the bolts separately Remove the liner Remove from the rear and pull out the tank right cover assembly Remove the ...

Page 90: ...laced the joint should be found on the left side of the car body and the nut should be spun out and removed If the PKE is a new states of the single antenna will find the connector hte liit plate down and unplug Use a hot air gun to heat up a bit remove the double sided glue from the tank box and clean the residual glue Tank box assembly Press down the center of the swell nail with a small cross s...

Page 91: ...ining glue Locate the limit retaining ring on the high pressure tubing sub assembly and pull it out while pressing hard Continue to raise the tank liner assembly clamp the tube clamp on the snorkel with pliers in the direction of the arrow and remove the vent tube Swing the tank liner assembly slightly left and right while pulling it back obliquely upwards CAUTION The seat cushion side cover fuel ...

Page 92: ...Tank liner assembly is placed upside down remove the bolts with a sleeve When the fuel pump is removed the float connecting rod cannot be bent or bent to avoid inaccurate oil display CAUTION Before removing the Tank liner assembly it is recommended to use the oil pump to pump out the fuel or dissipate the fuel before disassembling Fireworks answering or dialing should be strictly prohibited near t...

Page 93: ...need to fine the cable joint on the left of the motorcycle Insert the flat blade screwdriver into the antenna holder remove the limit card and remove the cable from the holder then remove the PKE antenna Use a hot air gun to heat up a bit remove the double sided glue from the tank box and clean the residual glue Tank box assembly Press down the center of the swell nail with a small cross screwdriv...

Page 94: ... to raise the tank liner assembly clamp the tube clamp on the snorkel with pliers in the direction of the arrow and remove the vent tube Swing the tank liner assembly slightly left and right while pulling it back obliquely upwards Remove 2 pieces of limit glue and 1 piece of antenna holder from the tank liner both of which are glued to the tank liner with double sided tape CAUTION The seat cushion...

Page 95: ...remove the bolts 5 with a sleeve When the fuel pump 6 is removed the float connecting rod cannot be bent or bent to avoid inaccurate oil display CAUTION It is recommended to use the oil pump to pump out the fuel or consume the fuel before disassembling the tank component Fireworks answering or dialing should be strictly prohibited near the car breaking site to prevent accidents Reverse the fuel ta...

Page 96: ...lot and pull it out First pull out the card nail from the bottom up in the order of Grab the center of the left side of the cover and pull back and remove Follow the above steps to remove the right side cover lowe CAUTION The seat cushion tank cover assembly and surround panel assembly should be removed in advance When assembling insert the expansion pin of the head of the side cover and fasten it...

Page 97: ...044201 194051 ZT310 X2 iron grey upper left cover bright blue GP version PROCEDURE Left side cover upper assembly Using small cross screwdriver to press down on the center of the swell nail remove the swell nail First the card buckle at the outlet is pulled out and then the card nail and the impeller are pulled out Finally the card button at the outlet at the outlet is pulled out and the upper com...

Page 98: ... Edition 4044201 197051 PROCEDURE Right side cover upper assembly Using small cross screwdriver to press down on the center of the swell nail remove the swell nail First pls pull out the snap on then take out the bolts and finally pull out and finally take out the snap on Remove the right cover upper assembly Flip it over to the back remove 2 bolts remove bush and buffer Remove bolts Separate the ...

Page 99: ...ber 1 7 1244200 019000 ZT310 X rear armrest left pad rubber 1 Fig 1 REAR COVER COMPONENT Rear armrest assembly PROCEDURE Rear armrest assembly Remove the 2 bolts and remove the bushing and cushion rubber Remove the 5 bolts and pull the rear armrests diagonally behind Rear armrest rubber assembly Turn to the back remove the bolt remove the bushing and then remove the left pad and right pad CAUTION ...

Page 100: ... hot plate bushing 2 Fig 2 REAR COVER COMPONENT Rear mud board assembly 1 PROCEDURE Rear mud board assembly Locate the cable connector on the rear mud plate assembly and unplug it The color is three joints of green orange green blue green powder Remove the 4 bolts and remove the rear mud plate assembly During the removal process be careful not to pull the cable forcibly Remove the 2 bolts and remo...

Page 101: ...or 2 PROCEDURE Rear turn signal Remove the 2 bolts and remove the bushing and cushion rubber Remove the rear turn signal If you remove the cable during the removal process you cannot force the cable Remove the splint from the rear turn signal Back license bracket Secure the head of the bolt with a hexagon socket tool and remove the nut with a sleeve on the back of the rear mud plate Remove the bol...

Page 102: ...icense plate light After grasping the turn signal bracket remove the three screws d on the rear license plate light and remove it Rear turn signal Remove the 3 screws b and 1 screw d on the left side of the above figure remove the left pressure plate e and the crimping plate c and remove the left turn signal similarly the 3 screws on the right side of the figure above remove the right pressing lin...

Page 103: ... and remove the bushing Remove the two snaps at the indication of the arrow on the middle cover and remove Remove the bolt and remove the bushing and the cushion rubber Grab the pin on the front of the left skirt and pull it out Grab the pin on the front of the right skirt and pull it out Remove the rear skirt assembly from the frame by slightly separating the front of the left and right skirts Re...

Page 104: ...nd remove the bushing Remove the two snaps at the indication of the arrow on the middle cover and remove Remove the bolt and remove the bushing and the cushion rubber Grab the pin on the front of the left skirt and pull it out Grab the pin on the front of the right skirt and pull it out Remove the rear skirt assembly from the frame by slightly separating the front of the left and right skirts Remo...

Page 105: ...to the back of the rear skirt assembly and use a small Phillips screwdriver to expand the center of the nail and remove the expansion pin Flip down to the bottom remove the 7 bolts in sequence and remove the bushing and cushion rubber The rear skirt assembly is split into left and right skirt assemblies a middle assembly and a taillight assembly Remove the splint from the middle of the skirt Remov...

Page 106: ...44201 218002 ZT310 X2 pearl white tail skirt left decorative cover red GP version 4044201 220052 ZT310 X2 Deep Bright Gray Skirt Left Decorative Cover Bright Blue GP Version GP version 4044201 216021 ZT310 X2 special black tail skirt left decorative cover gem red GP version 1 1 Regular version Fig 8 REAR COVER COMPONENT Left rear skirt component 7 1 PROCEDURE Left rear skirt component Remove the s...

Page 107: ...ONENT 1 1 Regular version 4044201 219002 ZT310 X2 pearl white tail dress right decorative cover red GP version GP version 4044201 217021 ZT310 X2 special black tail skirt right decorative cover gem red GP version 4044201 221052 ZT310 X2 dark bright gray tail skirt right decorative cover bright blue GP version Right rear skirt component PROCEDURE Right rear skirt component Remove the side cover rou...

Page 108: ...lay stud to prevent loss Locate the starter relay and the main cable connector Engine controller ECU Grasp the connector 1 of the ECU and pull it out in the direction of the arrow to separate the ECU from the main cable Fuse box There is a corresponding description on the fuse box cover Battery straps vehicle tools Remove the metal buckle of the battery strap and pull it out of the limit buckle th...

Page 109: ...evice box backing in the direction of the arrow Old state PKE Find the connectors and of the PKE antenna unscrew the nut and pull it out Connector short antenna connector long antenna New states PKE Find and unplug the connectors of the PKE antenna single Hold the electric device box component in one hand and grasp the front part downwards with one hand Unplug the PKE cable connectors and and remo...

Page 110: ... of plywood nuts from the electrical component box Remove the battery pad and clean the remaining adhesive Fuses Unplug the fuse or and check if it is blown If it has blown replace the fuse of the same specification The dual antenna and the single antenna PKE controller used medium 15A fuses The bracelet edition PKE controller used 2pcs small fuses CAUTION When inserting or removing the fuse pay a...

Page 111: ...plug the side stand relay 2 and the EFI relay 3 Turn off the positive and negative protective rubber caps red for the positive and black for the negative of the starter relay 5 Remove the positive and negative connectors by unscrewing the nut and screw the nut back onto the relay stud to prevent loss Find the starting relay and main cable connector unplugged Engine Control Unit ECU Delphi EFI Hold...

Page 112: ...at the center of the battery anode protection glue is aligned to the center of the battery positive after the battery is assembled and dose the read protective cap cover the positive Prevents the positive battery from coming into contact with the frame CAUTION Be careful not to overcharge the charging time About the use and maintenance of the battery see the instructions Attention should be paid t...

Page 113: ...Remove the bolts 1 on the right side of the front of the electrical component box Remove the bolts 4 on the bottom of the rear frame of the frame Push the card in the direction of the arrow to snap the lower cover Find and remove the connector of the PKE antenna Hold the electric device box component in one hand and grasp the front part downwards with one hand Unplug the PKE cable connectors and a...

Page 114: ...omponent Remove 6 pieces of plywood nuts from the electrical component box Remove the battery pad and clean the remaining adhesive Fuses Unplug the fuse and check if it is blown If it has blown replace the fuse of the same specification The bracelet edition PKE controller used 2pcs small fuses CAUTION When inserting or removing the fuse pay attention to the vertical alignment and then disassemble ...

Page 115: ...he other end to the negative pole of the battery After connecting the wires check that the wires are fixed and short press the unlock button to turn on the PKE system Disable pressing the ignition button at this time CAUTION The wire must be connected to the right slot in the forward direction of the finished motorcycle When connecting the battery always connect the positive electrode first and th...

Page 116: ...ve the cushion by moving the rear part of the cushion from side to side Assembly cushion When assembling the cushion check whether all the cushion rubbers are complete Insert the front part of the cushion first After the assembly is in place shoot the rear part of the cushion firmly When you hear the click sound it indicates that the cushion lock has been assembled Cushion rubber purchased separat...

Page 117: ... in one hand and use the hexagon tool to remove the bolt from the space between the frame tube and the pedal bracket Remove the clamp Remove the bolt at the pedal bracket and remove the muffler rear assembly Remove the bolt and remove the spring washer Remove the anti hot plate from the muffler rear part Graphite gasket Remove the graphite gasket and protect the nozzle If there is any deformation ...

Page 118: ...m the main harness Muffler assembly Lower the side bracket to fix the motorcycle Under the right nameplate of the motorcycle after fixing the nut with a boxer wrench remove the bolt and remove the bushing as shown in Figure B Remove the nut and remove the muffler flange as shown in Figure C Hold the muffler front assembly with one hand remove the bolt from under the side bracket mounting plate wit...

Page 119: ...mall slotted screwdriver to open the fastener and press it in the direction indicated by arrow to push it out from the oxygen sensor connector Remove the oxygen sensor with an open wrench Bosch EFI Remove the plug connected to the oxygen sensor on the main cable in the direction of the arrow and unplug the oxygen sensor Note The line card nail of Bosch EFI is placed on the connector at one end of ...

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Zontes ZT310-X, Service Manual

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