Zontes ZT350-GK 2022 Service Manual Download Page 1

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ZT350-GK

Service manual

2022/

Summary of Contents for ZT350-GK 2022

Page 1: ...ZT350 GK Service manual 2022 02 16...

Page 2: ...the air filter intake air temperature sensor carbon tank electromagnetic valve carbon tank Check whether the temperature sensor is damaged 3 2 The air filter assembly 15 Remove the air filter throttl...

Page 3: ...footrest component 2 28 Remove the rear brake main pump heat shield rear disc brake main pump component 5 4 Right footrest component 3 29 Remove the brake pedal component muffler anti scalding 5 5 Ri...

Page 4: ...le clearance adjustmen 47 Adjust the free travel of throttle wire and clutch zipper 7 2 Light height adjustment replacement clutch cable 48 7 3 Replace the throttle cable 49 Remove the throttle cable...

Page 5: ...ont shock absorber upper plate component 64 Remove the uplink board component front left and right shock absorption reflector faucet lock 7 19 Uplink plate direction handle block component 65 7 20 ABS...

Page 6: ...Remove battery relay and lasher 11 3 Rear armrest component 82 Remove rear armrest taillight holder OBD diagnosis interface position buzzer 11 4 PKE 83 Remove PKE antenna 11 5 Electric device box comp...

Page 7: ...ompose the rear section of the muffle muffler component mounting points on both sides 13 3 Muffler component 3 91 Decompose the front section of the muffler 14 Lower shroud component 14 1 Lower shroud...

Page 8: ...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 man...

Page 9: ...eve that connects to the mounting bracket on the frame and remove the dump switch ECU Locate and losen the rubber buckle and Pin tie Take off the ECU plug After pressing the anti release buckle rotate...

Page 10: ...2 3 4024300 023051 ZT350 GK Water tank upper bracket dark gray matte 1 PROCEDURE Horn Take off the plug of horn hold the horn by one hand use 8 sleeve remove bolts by another hand then take off the ho...

Page 11: ...the side cover cushion with your hand directly Frame waterproof rubber plug Remove the 6pcs frame waterproof rubber plugs with your hand directly Buckle Remove the bolt with 4 hexagon socket remove m...

Page 12: ...ight tool you can change the shaft ring and the dustproof cover During the replacement process pay attention to the protection of the lower connected plate After replacement it must be to check the pa...

Page 13: ...51100 066093 M12 1 5 15 Ablassschraube color zinc 1 24 4N m PROCEDURE Checking the steel bowl Checking whether the steel bowl and is frayed if as it please replace it Fix the cushion loop well and pai...

Page 14: ...cannot be disassembled First Using 14 sleeve fix the head of the bolt at the bracket then using 17 plum wrench remove the nut Using 14 sleeve fix the head of the bolt at the lower part of the engine...

Page 15: ...on socket remove the bolts remove the carbon tank Check whether the temperature sensor is damaged Remove the temperature sensor from the air filter and place it in the ambient temperature 20 30 and us...

Page 16: ...the bike Plug it well to prevent foreign matter from entering and damaging the engine Using 4 inner hexagon socket remove the bolt Air filter and splint nut 3 Throttle valve assembly Find and remove...

Page 17: ...ensor Use 5 inner hexagon to remove the bolt take off the sensor and bracket then remove the connection pipe Check whether the stepping motor is damaged After turning off the power take out the steppi...

Page 18: ...When assembling apply a small amount 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 wat...

Page 19: ...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 2pcs...

Page 20: ...ht side muffler back pressure bag of the bike to support the whole bike and let the rear wheel slightly off the ground After supporting the whole bike uses a 14 sleeve on the right to loosen the bolt...

Page 21: ...n disc brake oil cup Hold the rear wheel assembly 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...

Page 22: ...lt from sprockeseat Pull the sprocket buffer glue out of the rim Fault detection of sprocket seat The sprocket seat and the rim are connected by buffer glue If the sprocket seat assembly can rotate ba...

Page 23: ...anging the tire check air proof performace and dynamic balance Not enough tire pressure can cause abnormal wear and tare Too high pressure in summer might have possibility of tire bursting It needs ru...

Page 24: ...rson removes the rear fork shaft with suitable tool and then remove the rear fork assembly Rear fork rear resistant block Remove the bolts flanging bushing with a 4 inner hexagon socket then turn off...

Page 25: ...e top 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 5 inner hexagon socket tool Tighten...

Page 26: ...orcycle well on flat ground before checking Check regularly if the braking liquid surface is between MAX and MIN If liquid surface is below MIN check the arrester status and confirm if the braking sys...

Page 27: ...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 posit...

Page 28: ...e oil cup Then 6 remove the bolt fixing the rear section of the muffler with the hexagon socket and remove the bushing and buffer rubber Remove the bolts and with 6 Allen wrench to remove the right pe...

Page 29: ...ar disc brake main pump assembly 1 PROCEDURE Rear brake main pump heat shield Using 4 hexagon socket remove 3 bolts remove flanging bushing and buffer rubber and remove rear brake main pump insulation...

Page 30: ...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 rocker arm can be separated The brake pedal can be adju...

Page 31: ...K front right footrest dark gray matte 1 17 4064300 008051 ZT350 GK rear right footrest dark gray matte 1 Fig 5 FOOT PEDAL COMPONENT PROCEDURE R front pedal Disassemble circlip Take off buffer rubbe a...

Page 32: ...ing 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 pedal support component Gear shift rod component Re...

Page 33: ...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 with 10...

Page 34: ...ZT310 GK L front pedal 1 17 4064300 007051 ZT350 GK rear left pedal 1 Fig 8 FOOT PEDAL COMPONENT Left footrest component 3 PROCEDURE Rear left pedal Disassemble circlip Take off buffer rubbe and foot...

Page 35: ...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 36: ...efully 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 engine When assembling first...

Page 37: ...s 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 s...

Page 38: ...ative cover panel gradually pull out all the clips fixed on the decorative base plate pull open the mushroom buckle and finally pull out the decorative panel in the direction shown by the arrow in the...

Page 39: ...e cover assembly to pull out the bottom plate of the right trim cover of the water tank and remove the splint on the middle trim panel of the water tank During reassembly it shall be noted that on the...

Page 40: ...corative cover component 3 PROCEDURE Middle trim panel of water tank Remove the left and right trim cover panel components and the left and right trim cover base plate components in advance Using 8 sl...

Page 41: ...y water tank Remove the clamping plate on the auxiliary water tank After wearing waterproof rubber gloves put the auxiliary water tank assembly upside down the auxiliary water tank cover faces down in...

Page 42: ...der 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 43: ...e the hoop and remove one bolt 9 fixing the water tank on the left with 8 sleeve Remove the right holding hoop with pliers pull out the small circulating water pipe and remove the holding hoop Loosen...

Page 44: ...water pipe Loosen the hoop after the hoop moves out of the anti dropping boss Unplug the engine water outlet pipe According to the previous steps remove the small circulating water pipe and the engin...

Page 45: ...U A 1 Fig 11 COOLING SYSTEM COMPONENT Water tank bracket PROCEDURE Lower bracket compnent of water tank Using 4 sleeve remove the bolt Remove the lower bracket of water tank from the frame Upper brack...

Page 46: ...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 47: ...unit componentls in advance Disassembling the cooling system while the motorcycle is hot is prohibited Wait until the engine and muffler cool down thoroughly for the manipulation Wasted engine oil sho...

Page 48: ...the adjustment screw and the groove of the rocker seat should be staggered to prevent the cable from coming out Big adjustment If fine adjustment cannot be achieved using 14 open spanner loosen the n...

Page 49: ...ve on the rocker arm and remove the cable from the rocker arm seat Remove the clutch cable Remove the protective sleeve from the clutch cable Install the clutch line Put protective rubber sleeve into...

Page 50: ...emove 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 cable First pass the throttle cable into the cable hole in t...

Page 51: ...er remove the gasket and remove the bolt with 6 inner hexagon socket The direction of the upper board assembly wrapped with a clean cloth and then placed to prevent scratches Remove the lock washer re...

Page 52: ...ve the counterweight remove the bolts take off the hand guard rubber block rearview mirror then take out the rubber sleeve Remove the threaded sleeve with 6 inner hexagon socket Screw the bolt into th...

Page 53: ...on socket tool and then remove the nut with 10 sleeve or double offset ring spanner Remove the bolt and then remove the handle Add brake fluid Before driving the motorcycle check whether the brake flu...

Page 54: ...r hexagon socket ring wrench Press and hold the plate body indicated by arrow inward in the direction of the arrow and insert the pin shaft into the hole to fix the brake pad Tighten the pin shaft wit...

Page 55: ...ve bolt with 2 5 inner hexagon socket remove tire pressure sensor remove nut with 12 sleeve and then remove air nozzle CAUTION Use a suitable tool to support the motorcycle to prevent accidents caused...

Page 56: ...g box remove the tie and wire buckle New type pull out the plug of wheel speed sensor Then remove the wire clamp Remove the bolt with 4 hexagon socket and remove the sensor Old model pull out the plug...

Page 57: ...matte 1 3 1274300 054000 ZT350 GK front disc brake disc protective cover mounting plate support 1 PROCEDURE Front disc brake guard component Remove 3 bolts with 4 inner hexagon socket remove bushing a...

Page 58: ...lug Headlight components Remove 2 bolts 3 with 4 hexagon socket and remove flanging bushing 4 and buffer rubber 5 Remove the expansion nail 6 Remove 2 bolts 8 with 8 sleeve 1 bolt 7 with 4 socket and...

Page 59: ...headlights component 2 7 1251700 059093 Flanging bushing 6 4 9 8 18 2 environmental color 2 PROCEDURE Headlight bracket Remove the 4 bolts in figure A with 4 inner hexagon socket take off the flange b...

Page 60: ...k gray matte 1 Fig 13 FRONT FORK COMPONENT Head and headlights component 3 PROCEDURE left and right head cover components and headlamp mask Remove 3 bolts and 1 screw with 4 inner hexagon socket and r...

Page 61: ...steel 2 Fig 14 FRONT FORK COMPONENT Head and headlights component 4 PROCEDURE Left and right turn signal components Using a Phillips screwdriver to remove the screws on the turn signal decorative cov...

Page 62: ...ocket and remove flanging bushing and buffer rubber Remove 2 bolts with 6 inner hexagon socket and then remove the instrument bracket Junction box assembly Push the right handle switch plug the faucet...

Page 63: ...vibration absorbing rod with 5 inner hexagon socket grasp the head of the bolt pull it out and remove the vibration absorbing rod and buffer rubber Remove the bolt with 5 inner hexagon socket tool an...

Page 64: ...matte after sales assembly 1 4 PROCEDURE Directional components Using a blade to pick up the decorative buckles hold the direction handle in one hand and remove the bolt with a hexagonal tool in one h...

Page 65: ...t Front left and right shock absorption Remove the bolts of the lower plate with 6 inner hexagon socket and hold the shock absorber in the middle with one hand Insert a slottedscrewdriver into the slo...

Page 66: ...urface Remove the bolt with a 14 sleeve and remove the gasket cushion rubber and bushing Remove the upper plate The spacer the upper clamp and the direction handle are disassembled CAUTION Protect pro...

Page 67: ...ic control unit components Remove 2 bolts with 4 inner hexagon socket remove the bushing and then remove the hydraulic control unit Press the buckle indicated by arrow then push the push rod in the di...

Page 68: ...ning the brake fluid remove the hydraulic control 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 co...

Page 69: ...he front disc brake caliper First uncover the screw rubber cap wear waterproof gloves then remove the bolt with 8 ring wrench remove the bolt with 14 ring wrench and remove the copper washer Remove tw...

Page 70: ...plug it Remove the two wheel speed sensor clamps Pull out the sensor wire from the two disc brake oil pipe clamps Remove one bolt at the caliper with 4 inner hexagon socket pull off the exhaust rubber...

Page 71: ...he rubber 3 Clamp the circlip of the carbon canister adsorption tube with pliers and pull it out Unplug the fuel tank lock plugs Place an oil pan on the left side of the throttle valve body press down...

Page 72: ...lift tail up slightly after 4 buckles loosens shake and push until the buckle is out of the slot but don t remove the fuel tank middle cover Remove the cables on the clip Put the fuel tank cap back in...

Page 73: ...00 ZT250 S torsion spring of tank outer cover rotating shaft 1 PROCEDURE Fuel tank cover assembly Remove the retaining spring attached to the rotating shaft and slowly pull out the rotating shaft Remo...

Page 74: ...p Remove the glass strip from the fuel tank Fuel tank cap Flip to the front of the tank assembly turn the tank cap counterclockwise and remove Be careful not to pull the nylon cord during the removal...

Page 75: ...hroom buttons at the position of the side cover assembly After pulling out remove the left cover assembly Remove the right side assembly in the same way Remove 4 self tapping screws with a cross screw...

Page 76: ...at Remove the cable from the slot clip When the battery is dead remove the PKE fuse uncover the rubber plug and charge it with the charger delivered with the vehicle When charging insert the charging...

Page 77: ...t of the left cover with 4 hexagon socket remove the turn over bushing and buffer rubber pull out two Mushroom buckles on the side cover remove the upper part of the left cover turn it over to the oth...

Page 78: ...cm PROCEDURE upper part of right side cover During reassembly install mushroom buckles and in place and insert the buckle at onto the oil tank upper part of left side cover Replace the left cover acco...

Page 79: ...in MUFFLER COMPONENT First untie the two rubber wire buckles 9 of the right guard bar Press the position indicated by the arrow a and pull out wheel speed sensor connector Press the position indicated...

Page 80: ...95 Flanging bushing 6 2 8 4 3 5 14 1 5 1 9 1244100 052000 Flanging bushing rubber 8 5 14 1 1 10 1224300 058000 ZT350 GK Fan plug holder 1 Fig 2 GUARD BAR COMPONENT Guard bar component 2 PROCEDURE Left...

Page 81: ...the bushing and cushion rubber Grap the electric box uppper cover and lift it up then move it backward Note that the cable of the PKE antenna is not unplugged As shown in the picture press the white p...

Page 82: ...the vehicle and pull out the Yellow red and green red wires Pull up the start relay to remove it During reinstallation the Yellow red and green red lines of the relay correspond to the color of the m...

Page 83: ...ove the bolt 2 at the plug holder 8 with 4 inner hexagon and remove the bushing 6 and buffer rubber 7 Remove the left rear armrest 5 according to the steps of removing the right armrest Taillight plug...

Page 84: ...arge when pulling out Pay attention not to shake up and down to prevent damage to the main engine shell but slightly shake left and right Remove the two bolts 1 with 4 hexagon socket and pull out the...

Page 85: ...t remove bushing and buffer rubber and remove cover plate Note that there are two buckles near the rear tail skirt installation cover of the cover plate As shown in Fig 2 remove 2 bolts with 4 hexagon...

Page 86: ...necting bracket After grasping the connecting bracket 6 remove the bolt 1 with 4 hexagon socket and remove the bushing 2 and buffer rubber 3 Remove the connecting bracket 6 Battery support Grasp the b...

Page 87: ...1 and then pull it out Pull out the rear license lamp plug cushion lock plug and rear steering lamp plug at the left taillight plug clamp Remove the rear mud board assembly from the vehicle Be careful...

Page 88: ...nd buffer rubber 7 and remove rear license plate support 4 from rear mud plate support 1 Pull out the buffer 8 from the license plate support 5 Rear reflector Use a 10 ring wrench to remove the nut an...

Page 89: ...urning point and tail of the cushion as shown in Figure 3 and align the head of the cushion with the edge of the middle cover of the oil tank as shown in Figure 4 Press and hold the turning point at t...

Page 90: ...t the right guard bar Locate the plug for the oxgen sensor in the upper right guard bar press the indicated by arrow a with one hand and pull the plug in the direction of arrow b with the other hand M...

Page 91: ...bly 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 sock...

Page 92: ...it off Use a multimeter to measure the resistance of the heating element of two white wires to 9 2k or the measured current shall be 2 1A Otherwise it can be judged as oxygen sensor fault The ceramic...

Page 93: ...and the pad Remove the bolt with 8 sleeve then take off the bush and the pad After supporting the lower shroud assembly then remove the bolt and on the left hand side with 8 sleeve Take off the lower...

Page 94: ...n remove 2 pcs bolts take off the bush and pad Take off the bracket Lower shroud left part Using 4 inner hexagon socket remove 3 pcs bolts on the left side take off the bush and pad Separate the lower...

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Zontes ZT350-GK 2022, Service Manual

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Summary of Contents for ZT350-GK 2022

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