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Zontes ZT350-EURO V 2022, Service Manual

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Zontes ZT350-EURO V 2022 Service Manual Download Page 102

12-SIDE COVER COMPONENT

101

CHK

ADJ

NO.

PART NO.

PART NAME

QTY

CAUTION

1

1224100-010000 ZT250-S swell nail

1

2

1184300-005000 ZT350 antenna

1

Fig.4 SIDE COVER

COMPONENT

The upper component on the right side 1

PROCEDURE:

●

The upper component on the right side

The upper part of the right cover is pressed down with a small cross screw knife expansion nail in the center of

the nail, and the expansion nails are removed.

First pull out the positioning of the arrow 

①

, and then pull out the mushrooms at the arrow 

②

, 

③

, 

④

, and 

⑤

in turn. Plug down and remove the left cover component.

CAUTION:

●

Remove the cushion, the outer cover component of the fuel tank, and the encirclement panel component in

advance.

●

When assembly, first assemble the buckle of the upper part of the left side, and then deduct the mushroom

buckle at 

⑤

, 

④

, 

③

, and 

②

 at the time of the positioning to insert the positioning; finally the expansion nail.

Summary of Contents for ZT350-EURO V 2022

Page 1: ...ZT350 X EURO V Service manual 2022 5 3...

Page 2: ...check the temperature sensor 3 2 Empty filter components 15 Remove the air filter and throttle valve component Check whether the external intake pressure sensor is damaged 3 3 Throttle valve body comp...

Page 3: ...board 34 5 10 Rear shock absorber 35 Rear shock absorber Adjust the rear absorber 5 11 Rear wheel assembly 36 Rear swinging arm assembly Abrasionproof block of rear swinging arm Rear fork after sale...

Page 4: ...fork component 8 1 The throttle clutching gap adjustment 55 Adjust the throttle line clutch rosor free itinerary light adjustment 8 2 Replace the clutch cable 56 8 3 Replace the throttle line 57 Remo...

Page 5: ...sassemble the left rearview mirror left switch rocker arm left hand holding rubber sleeve balance block assembly replace the rocker and clutch switch 8 24 Left handle component new model 78 Disassembl...

Page 6: ...cover of the fuel tank the fuel tank lock 93 Locking of the fuel tank the outer cover of the fuel tank 10 3 Oil tank decorative hood components 94 Disassembling left fuel tank decorative cover right...

Page 7: ...cense plate lights rear turning lights 14 7 Tail lights tail skirt components 110 After removing taillights cushion locks 14 8 Electric component box lid components 1 111 Package stent electrical comp...

Page 8: ...o 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...

Page 9: ...sors and other tools may be needed to assist There are 2 tales at the point of the driving head and the tie at the left cover should be cut and the entire body has 11 tie and a tie ECU Find the ECU pl...

Page 10: ...y 1 14 1244200 139000 ZT310 rubber buckle 120mm 1 Fig 2 FRAME ELECTRONIC COMPONENT Electricity assembly 2 PROCEDURE Horn Unplug the horn plug remove the bolt with 10 sleeve pull out the brake hose rem...

Page 11: ...our waterproof rubber plugs of the frame directly by hand Battery cushion Directly remove 8 pieces of side cover glue on both sides by hand Side cover cushion After heating with a hot air gun tear off...

Page 12: ...of the vehicle to be repaired during disassembly to prevent accidents from dumping Piece 8 has been included 1251300 046093 ZT250 S direction column adjusting screw nut M24 1 environmental color Zinc...

Page 13: ...whether the steel bowl and is frayed if as it please replace it Fix the cushion loop well and paint the lubricating grease on it with appropriate tool Sider support Using the cross screwdriver to remo...

Page 14: ...t with 14 sleeve Only remove other nuts of the nut cannot be removed Use 14 sleeve to fix the bolts and bolts at the head at the head of the bracket and then remove the nut at the 17 sleeve Use 14 sle...

Page 15: ...remove the electromagnetic valve and bracket Carbon tank Pull the oil pipe connecting the fuel tank on the carbon canister out of the fuel tank Using 4 inner hexagon socket remove the bolts remove the...

Page 16: ...ipe connecting the exhaust port of the engine then wrap it with plastic bag and cover it with rubber band to prevent foreign matters from entering and damaging the engine Remove bolt with 4 socket hea...

Page 17: ...ake pressure sensor is damaged Loosen the connector and check whether the pin is skewed or broken The vehicle is connected to the diagnostic instrument without ignition Check the engine parameters to...

Page 18: ...ount of engine oil on the upper and lower sides of the rubber strip shown in cyan as shown in the figure to reduce assembly resistance Oil pipe and water pipe Avoid water into the air filter when wash...

Page 19: ...and wheel speed sensor cable which are on the right side of rear inner mudguard from the rear disc brake pipe clamp Remove the two sensor clamps On the right side using 4 inner hexagon socket remove...

Page 20: ...er suitable status Please adjust in a reasonable range Riding experience would be influenced either the absorber is too soft or too hard Check One person will straighten and stablilize the vehicle and...

Page 21: ...y Punch rear wheel axle with rubber hammer Expose the left axle head pull the axle head outward with the left hand and shake the tire left and right to complete the disassembly of the rear axle CAUTIO...

Page 22: ...h in a small range in the circumferential direction of the rear axle axis it is normal If it can rotate back and forth in a large range check the buffer rubber and bearing clearance If it can swing le...

Page 23: ...ance Not enough tire pressure can cause abnormal wear and tare Too high pressure in summer might have possibility of tire bursting It needs running in for about 300km after changing new arresters Duri...

Page 24: ...of the rear fork shaft person 2 remove the nut with a 30 sleeve Person 1 holds the rear fork assembly and the other person removes the rear fork shaft with suitable tool and then remove the rear fork...

Page 25: ...e the cross bolt on rear disc brake main pump oil cup Take off the top cover and sealing gasket Remember to rebound the pister afterwards The new arrester must fit tightly the slot See photo right bel...

Page 26: ...cycle 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 MAX and MIN If liquid surface is...

Page 27: ...the rear sub mud assembly properly taking care not to pull the cable Sprocket assembly Use a 21 sleeve to loosen the bolt Use a special hook wrench to turn the eccentric chain adjuster at the arrow in...

Page 28: ...2000 Buffer rubber of flanging bushing 8 5 14 1 1 4 ZT310 R1 sprocket baffle 1 Fig 2 REAR WHELL COMPONENT Sprocket baffle PROCEDURE Sprocket baffle Remove the bolt with 4 hexagon socket remove the fla...

Page 29: ...bly with one hand remove the upper bolt and remove the elastic pad and flat pad Place the rear sub mud assembly properly taking care not to pull the cable Sprocket assembly Loosen the bolt with 21 sle...

Page 30: ...e PROCEDURE Sprocket assembly Remove the bushing to separate the inside and outside of the sprocket seat Remove the bushing When reassembling pay attention to the bushing The larger chamfered end face...

Page 31: ...he marker change 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...

Page 32: ...mounting plate and remove the rear axle assembly If the rear flat fork needs to be replaced continue the following steps Remove the bolt with 4 hexagon socket and remove the wheel speed sensor from th...

Page 33: ...ly improved 1 4024200 102000 9 ZT310 R1 rear sub mud aluminum alloy bracket homemade 1 1020242 265021 4 Fig 7 REAR WHELL COMPONENT Rear sub mud assembly ZT310 V rear auxiliary clay plate and iron brac...

Page 34: ...al 4024200 046000 8 1 ZT350 single rocker arm rear disc brake adapter plate self made dark gray matte 4024300 010000 4 1 PROCEDURE Disc brake mounting plate First remove the retaining ring with the re...

Page 35: ...er rubber Remove the bolt on the right side with 4 hexagon socket and remove the bushing and buffer rubber Use 8 sleeve to remove the bolt at the front of the left inner side and remove the bushing an...

Page 36: ...ly shakes it up and down and the other person pulls out the bolt One person holds the vehicle well and one person lifts the rear shock absorber slightly in the direction of the arrow and then pulls ou...

Page 37: ...disassemble nut with socket sleeve Person 1 hold the rear swinging arm assembly Person 2 take off rear swinging arm after disassembling rear swinging arm axle with suitable tool Remove the bushing the...

Page 38: ...oil cup Take off the top cover and sealing gasket Remember to rebound the pister afterwards The new arrester must fit tightly the slot See photo right below Lock the pin shaft with 5 hexagon socket Lo...

Page 39: ...the screw with an 8 open ended wrench to adjust the shift lever to a suitable height and then lock the nut and nut If the above mentioned method can not adjust the gear shift rod to a satisfying posi...

Page 40: ...o disassemble the pin Then take off the washer and pin Using 4 inner hexagon socket remove bolt then take away the oil cup Then 6 remove the bolt fixing the rear section of the muffler with the inner...

Page 41: ...ear disc brake main pump assembly 1 Right footrest component 2 PROCEDURE Rear brake main pump heat shield Using 4 hexagon socket remove 3 bolts remove flanging bushing and buffer rubber and remove rea...

Page 42: ...hexagon socket remove bolt take off pedal bearing cover and brake spring Put out the brake pedal component remove the Side cover round rubber Use 8 sleeve remove 3 bolts The brake pedal and the pedal...

Page 43: ...right footrest dark gray matte 1 PROCEDURE R front pedal Disassemble circlip Take off buffer rubbe and foot pedal pin axle Then disassemble R front pedal R foot pedal spring R rear pedal Disassemble...

Page 44: ...pulling it out from gear shift axle of engine Using 6 inner hexagon socket remove 3pcs bolts and Pull open the protective rubber sleeve of rectifier and pull out two plugs and remove the left foot ped...

Page 45: ...ental color 1 14 1250301 033000 GB6172 1 M8 color Zinc 1 Fig 7 FOOT PEDAL COMPONENT Left footrest component 2 PROCEDURE Gear shift rod component Fix bolt with 8 sleeve and remove nuts at both ends wit...

Page 46: ...otrest dark gray matte 1 17 4064300 007051 ZT350 GK rear left footrest dark gray matte 1 Fig 8 FOOT PEDAL COMPONENT Left footrest component 3 After sales PROCEDURE Rear left pedal Disassemble circlip...

Page 47: ...f 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 tighten the oil filler plug Start the engine and test it under different rotation spee...

Page 48: ...reassembling pleas check carefully if the spring seal ring are well installed Engine oil filter can not be turned over when assembling as shown in the left figure face the fine filter cover face the e...

Page 49: ...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 b...

Page 50: ...er the right side of the vehicle tilt the vehicle to the right After wearing waterproof gloves with both hands remove the bolt with a 8 sleeve and remove the combination seal Drain the coolant with a...

Page 51: ...the water tank and separate the left and right water tank connecting pipes from the right water tank assembly Separate the small circulating water pipe from the water tank assembly in the same way Rig...

Page 52: ...0 009000 ZT350 R water inlet connection water pipe 1 PROCEDURE Filler assembly Open the hoop 4 with pliers take down the connecting water pipe 6 of the water inlet first remove the bolt 3 fixing the w...

Page 53: ...ssembly Hold the auxiliary water tank assembly remove two bolts with 8 sleeves and remove the auxiliary water tank assembly Then remove the hoop and hoop from the auxiliary water tank and remove the c...

Page 54: ...en remove the bolt on the oil inlet pipe and drain the oil in the oil cooler Then remove the remaining 1 bolt and 1 bolt fixing the oil pipe and remove the oil inlet pipe oil outlet pipe and O ring Re...

Page 55: ...00 ZT350 R lower bracket of oil cooler 1 PROCEDURE Oil cooler bracket Using 8 sleeve remove three bolts and remove the upper bracket and lower bracket of the oil cooler from the frame CAUTION Disassem...

Page 56: ...t the vehicle to find the other person to find the lighting knob under the head to adjust the light to the right height The counterclockwise to lower the height of the light CAUTION During the disasse...

Page 57: ...t up and down Remove the clutch wire Remove the protective rubber cover 2 from the clutch line 2 Install the clutch line Put the protective rubber sleeve 3 into the clutch line elbow After putting the...

Page 58: ...ht hand to remove the core turntable of the glue cover and finally remove it from the lava hole in the lower part of the switch Install the throttle line Put the accelerator line into the cable hole i...

Page 59: ...tools Put the direction and the upper plate component with a clean cloth and place them Remove the anti pine cushion rot remove the top adjustable nut salamander with a dedicated four claw sleeve or...

Page 60: ...mp Hand guard Right hand holds the rubber sleeve and balance block with 5 inner hexagonal to twist the bolt on the balance block to the state in the figure then out of the balance block and then remov...

Page 61: ...guard Rightly remove the bolt of the rubber sleeve and balance block with a 5 hexagonal and then remove the balance block and right hand Right hand handle auxiliary switch Fix the main pump of the fro...

Page 62: ...up to prevent parts such as dripping to the cover parts or muffler After replacement you must continue the handle of the handle Lightly shoot the main pump of the disc brake at the same time to elimi...

Page 63: ...ur hand to hold the body pointed at the arrow in the direction of the arrow and use the sales axis to insert the hole to fix the brake tablet Tighten the axis on the T25 hexagonal plum wrench Put the...

Page 64: ...re and rotor components are removed with two bolts on the left front shock absorbing bottom b with 6 inner hexagonal First hold the front wheels and then remove the hollow shaft with 17 inner hexagona...

Page 65: ...eed sensor Locate the wheel speed sensor on the bracket and remove the sensor from the gap behind the bracket Find the wheel speed sensor plug n on the wheel speed sensor plug holder Press the buckle...

Page 66: ...mental color 2 7 ZT350 R Front Fender 1 PROCEDURE Front fender assembly Hold the front fender assembly by hand then remove the bolt with a 4 hexagon socket and take off the front oil outlet line clip...

Page 67: ...ss component The windshield components remove the two bolts on the left and remove the bushing and the buffer glue on the windshield upper left pressure block Follow the above steps off the windshield...

Page 68: ...er rocker extension spring 2 PROCEDURE Wind disassembly shield The windshield decorative board removes 5 expansion nails pulls the windshield to the direction of the arrow slightly and push it on the...

Page 69: ...hing Use a small cross screw knife to press down the center of the expansion nail and remove the two expansion nails Grasp the two sharp corners near the expansion nails and gently shake the cover pan...

Page 70: ...stainless steel 3 8 1250501 010000 GB93 6 spring pad 3 9 1274200 137000 ZT310 T motor pressure plate 1 PROCEDURE Windshield motor housing Remove four bolts bushing and buffer rubber respectively Remo...

Page 71: ...2 buffer gum Grasp the lower right rocker remove 2 screws with a cross screw knife then remove it remove the rocker arm block and 2 buffer gum CAUTION It is forbidden to directly pull the cable Pay at...

Page 72: ...ZT310 X1 speedometer TFT bracket 1 8 1274200 203000 ZT310 X1 windshield base 1 9 1244100 004000 ZT250 S Flanging bushing buffer 4 Fig 17 FRONT FORK COMPONENT Windshore base component 3 PROCEDURE Instr...

Page 73: ...rs of the motor controller remove the two bolts and remove the controller after removing the flanging sleeve Remove the bushing buffer from the controller Wiring clamp the right cover Remove the bolt...

Page 74: ...he left surrounding hand in one hand and siege the left side of the interior to the left side of the back to the back of the body slightly Similarly remove the right side Separate the front surround i...

Page 75: ...ife and the expansion nails are removed Grasp your head in one hand grab the middle of the middle of the arrow and remove the left component of the hood Remove the side cover round rubber from the lef...

Page 76: ...RE Big light component The headlight component holds the bottom of the headlight first remove the two bolts on one side and then remove the other side Remove the headlights If you only disassemble the...

Page 77: ...FRONT FORK COMPONENT Big light component 2 PROCEDURE Big light component The headlight component takes 2 side covering glue and 5 pieces of splints from the headlight protective shell Open the fixed s...

Page 78: ...ly The left hand holds the glue sleeve and the balance block assembly with 5 inner hexagon to twist the bolt on the balance block to the state in the figure and out the balance block Press the dust gu...

Page 79: ...d handle rubber sleeve and balance weight assembly Put the bolt of bolts in the left hand to remove the glue sleeve and balance block assembly with 5 hexagonal and take out the balance block Press the...

Page 80: ...f the shock absorber with one hand and insert a flat blade screwdriver into the slots of the upper and lower connecting plates to slightly expand the slot gap and remove the left shock absorber and th...

Page 81: ...uffer glue CD and the band Shanglian board faucet lock wiring bracket The upper board faucet lock and wiring bracket remove the bolt with 6 inner hexagonal and remove the bracket and bracket Remove th...

Page 82: ...OCEDURE Hydraulic control unit components Press the buckle indicated by arrow then push the push rod in the direction indicated by arrow and pull off the plug Using 8 sleeve remove 2 bolts remove the...

Page 83: ...unit and wipe off the oil stain Be careful not to let the brake fluid contact the cable connector to prevent poor contact due to corrosion RC HU is connected to the hydraulic control unit and rear bra...

Page 84: ...brake caliper from the front shock absorber First take out the wheel speed sensor from the cable clip untie the Velcro strap then remove the bolt with a 4 hexagon socket and remove the wheel speed sen...

Page 85: ...ended wrench Remove the copper gasket and rmc hu oil pipe Wheel speed sensor First refer to the steps of removing the muffler to remove the rear section of the muffler find the cable connector of whee...

Page 86: ...pilot unit After wearing the waterproof gloves remove the bolts with a 12 sleeve remove the copper washers Remove the 4 bolts and remove the 4 pieces of tubing bracket Rear disc brake caliper Using14...

Page 87: ...NTS Siege in central components PROCEDURE Surrounding the middle cover Press the buckle inwards in the direction of the arrow and then remove the cover plate 1 Bounding components Use a small Phillips...

Page 88: ...rround panel components The left encirclement panel component is pulled out of 4 from the bottom to the arrow Right surround panel components The right encirclement panel component indicates from the...

Page 89: ...ge panel sign The signs of the left surround panel are pushed out of the signs from the back of the left surrounding panel component to clean the remaining stagnation The left turn light component Rem...

Page 90: ...the sign from the back of the right surround panel component and clean up the remnant rubber print Right turn signal component Remove 4 self attack screws in the right steering light component and re...

Page 91: ...ing component with one hand and remove the two bolts on the left side with one hand and remove the band Lower right shroud assembly The bottom right right streaming component continues to hold the bot...

Page 92: ...r Zinc 2 5 1224300 010000 Right part of ZT350 X lower shroud 1 PROCEDURE Left lower shroud assembly Remove the buffer rubber the side cover round rubber and the splint from the lower left air shroud R...

Page 93: ...nt from the rear to gradually pull out the buckle At this time the lock locking of the fuel tank has not been removed Lifting the middle cover component in one hand remove the bolt with one hand and r...

Page 94: ...ock and pay attention to prevent damage to the buckle The outer cover of the fuel tank The outer lid components of the fuel tank are clamped with a pointed mouth pliers to clamp the buckle of the rota...

Page 95: ...decorative cover from the limited glue and pull out the order of pull out the left cover component of the fuel tank Take the lower and lower buffer of the left cover of the fuel tank right fuel tank...

Page 96: ...the connector on the left side of the body Insert a word screwdriver into the antenna fixed seat to pry the limited card open then remove the cable from the fixed seat then remove the PKE antenna You...

Page 97: ...nt Continue to raise the bile component in the oil tank clamp the tube on the ventlee in the direction of the arrow and pull out the ventilation Put the tank inner bile component slightly left and rig...

Page 98: ...sleeve to remove the bolt When removing the fuel pump do not bend or bend the connecting rod of the float to avoid inaccurate display of the fuel quantity After removing the fuel pump it is recommend...

Page 99: ...buckle from the lower part of the left cover in the order of Note that there is a buckle in the middle of the mushroom buckle and the mushroom buckle must be pulled out and you need to ensure that the...

Page 100: ...rrow and then pull out the mushrooms at the arrow and in turn and finally pull out the buckle backwards remove the left cover component CAUTION Remove the cushion the outer cover component of the fuel...

Page 101: ...0 063093 Plywood M6 11 15 color Zinc 2 PROCEDURE The upper component of the left side Turn it over to the back remove the 2 bolts with a 4 hexagon socket and take off the bushing and buffer glue Remov...

Page 102: ...nsion nail in the center of the nail and the expansion nails are removed First pull out the positioning of the arrow and then pull out the mushrooms at the arrow and in turn Plug down and remove the l...

Page 103: ...he upper part of the upper part of the right side Turn the upper component of the right cover over to the back remove the 2 bolts and take off the bushing and buffer glue Remove the side cover round g...

Page 104: ...hand of the bumper assembly uses a 14 ring wrench to fix the bolt and the other hand uses a 14 sleeve to remove the nut After pulling out the two bolts 2 remove the upper left guard bar Re insert the...

Page 105: ...COVER COMPONENT Rear hand armrest component PROCEDURE Rear armrest assembly The rear handrail components remove 2 bolts with 8 sleeves and remove the band hoe eloguary glue Remove 5 bolts with 12 slee...

Page 106: ...cap is covered after the nut is tightened and the electrical component box is inserted See the figure below for the starting process of launching relay failure Battery The battery will bind a strap Th...

Page 107: ...leeve Press down the central part of the expansion nail with a small Phillips screwdriver and remove the four expansion nails Remove 6 bolts with 4 hexagon socket and take down the flanging bushing an...

Page 108: ...advance Be careful not to force the cable for the disassembly process When re assembling check whether there is a pressed wire to prevent short circuit when tightening the bolt The lamp outer cover ne...

Page 109: ...nmental color 2 Fig 5 REAR COVER COMPONENT Rear Mud component 2 PROCEDURE Rear turn signal lamp Remove 2 bolts and remove the bushing and buffer rubber Remove the rear turn signal lamp Do not pull the...

Page 110: ...license light Rear turning signal Disassemble bolts three b and one d on the diagram left side and then remove left press line plank of e and press line plank c Remove the left turn signal follow the...

Page 111: ...block 1 9 1274100 058000 ZT310 Electric seat lock 1 Fig 7 REAR COVER COMPONENT Tail lights tail skirt components CAUTION It is strictly forbidden to pull the cable directly During the disassembly pro...

Page 112: ...ponent box lid component 1 Fig 8 REAR COVER COMPONENT CAUTION It is strictly forbidden to pull the cable directly During the disassembly process the material should be protected to prevent scratching...

Page 113: ...e cable directly Pay attention when removing the buckle to prevent damage to the buckle PROCEDURE Dump switch The dumping switch is pulled out of the bracket Take the dumping switch from the glue cove...

Page 114: ...ery charger ZONTES provide for you CAUTION Be careful not to overcharge the charging time About the use and maintenance of the battery see the instructions Attention should be paid to the discomponent...

Page 115: ...d pull it diagonally upwards At the same time remove 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 rub...

Page 116: ...arrow B Muffer rear assembly Remove the bolt wiht 6 inner hexagon socket and remove clamp After support the muffer rear assembly then remove the bolt wiht 6 inner hexagon socket take off the bushing...

Page 117: ...mbly Using 4 inner hexagon socket remove 3 pcs bolts take off spring pads then take off the decorative cover form the rear muffe Remove the silicone pad Muffer front assembly Using 6 inner hexagon soc...

Page 118: ...plug of the oxygen sensor near the top of the right body guard bar and pull it off Use a multimeter to measure the resistance of the heating element of two white wires to 9 2k or the measured current...

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