Zontes ZT350-S 2022 Service Manual Download Page 1

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2022/11/29

Service manual

ZT350-S (EURO V)

Summary of Contents for ZT350-S 2022

Page 1: ...2022 11 29 Service manual ZT350 S EURO V...

Page 2: ...side bracket 12 Side bracket 1 6 PKE component 13 2 Frame engine combination 2 1 Engine decorative cover components 14 Engine left rear cover right cover decorative drain the coolant 2 2 Frame Engine...

Page 3: ...isassembled rear mud plate bracket assembly 4 9 Rear auxiliary mud plate assembly 3 31 Disassembled rear mud plate bracket assembly 4 10 Rear turn signal after sale parts 32 Rear left and right turn s...

Page 4: ...components 50 Decompose the rear right pedal componts 5 10 Rear left pedal bracket components 51 Decompose the rear left pedal componts 6 Cooling system component 6 1 Change the oil 52 6 3 Replace th...

Page 5: ...Headlights assembly 3 72 Remove headlights upper bracket front turning signal 7 13 Right hand component 73 Remove right rear view mirror right hand rubber sleeve balance block Replace the front brake...

Page 6: ...isassemble the left and right guard bar components 9 4 Engine decorative cover components 87 Disassemble the engine decorative cover 10 REAR COVER COMPONENT 10 1 Battery component 88 Diassemble the ch...

Page 7: ...e muffler external parts 12 2 Muffler component 2 96 Diassemble muffler component 12 3 Muffler component 2 97 Discomponent muffler component 13 Lower shroud component 13 1 Lower shroud component 1 98...

Page 8: ...hinese version with only a few parts such as decals ECU version muffler catalyst etc Although the status of such parts are different the disassembly method is same so refer to the chinese manual Press...

Page 9: ...OCEDURE 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 sl...

Page 10: ...7000 ZT350 EFI high voltage line 1 Fig 2 FRAME ELECTRONIC PARTS COMPONENT Electronic parts COMPONENT 2 CAUTION Do not pull the cable hard when removing the sub mud switch The replacement of the spark...

Page 11: ...shion Remove the side cover cushion with your hand directly Battery cushion Put off the battery cushion directly by hand Frame waterproof rubber plug Remove the frame waterproof rubber plug with your...

Page 12: ...wer connected plate 1 the down connected plate component has been contains the lower shaft ring and the dust cap PROCEDURE Dissembly Remove the lock washer Remove the top adjusting nut by using a spec...

Page 13: ...ring well and paint the lubricating grease on it with appropriate tool Sider support The thick steel wire shall be rolled into a circle and put into the spring 4 hook Pay attention to ensure that the...

Page 14: ...y according to the steps in the rear tail skirt section Untie the tie and remove the cable to facilitate PKE removal Unplug the PKE plug use a 4 allen wrench to remove the two bolts to remove the PKE...

Page 15: ...olts and take out the bracket After removing the bracket scew the bols that holds the bracket back to the engine to prevent leakage Put the coolant After placing an oil pan or other container under th...

Page 16: ...muffler bumper etc need to be removed first Link baffle assembly After holding the baffle plate use an 8 sleeve to remove 3 bolts and 1 bolt respectively and remove the bushing and buffer rubber Remo...

Page 17: ...trim cover with 8 sleeve Front pedal support assembly Fix the head of bolt with 14 sleeve on the left side and remove nut with 17 sleeve on the right side After grasping the front pedal support assem...

Page 18: ...then one person gently shakes the rear wheel rear flat fork assembly up and down and one person pulls out the bolt After holding the rear shock absorber assembly pull out the bolts at a b and c and t...

Page 19: ...tabilizes the rear flat fork assembly of the rear wheel and the other uses a rubber hammer to knock the shaft to the left to leave the engine box There is no need to remove it to prevent the rear flat...

Page 20: ...ich will not be repeated here Unplug the desorption tube and exhaust tube on the left side After loosening the clamp pull out the air outlet pipe from the throttle valve body Refer to the Electrical D...

Page 21: ...5 11 7 13 1 PROCEDURE Air filter assembly Remove the air filter intake air temperature sensor from the air filter If the sealant falls off it needs to be plugged back to its original position Remove...

Page 22: ...e pressure sensor and unplug it Loosen the clamp on the intake manifold end of the hose and pull it out Use a 8 sleeve to remove the bolt remove the external intake air pressure sensor assembly the ho...

Page 23: ...le of the air filter element rubber strip grab the rubber strip with your hands and pull it out to remove the filter element Note that if the filter element card is tight grab both sides of the strip...

Page 24: ...flat pad 3 Place the rear sub mud assembly properly taking care not to pull the cable Sprocket assembly Use a 21 sleeve to loosen the bolt 4 Use a special hook wrench to turn the eccentric chain adju...

Page 25: ...rubber of flanging bushing 8 5 14 1 1 4 ZT310 R1 sprocket baffle 1 Fig 2 Rear wheel swinging arm assembly Sprocket baffle PROCEDURE Sprocket baffle Using 4 inner hexagon socket remove bolt remove the...

Page 26: ...assembly properly taking care not to pull the cable Sprocket assembly Use the No 21 sleeve to loosen the bolt without removing it Pull the locking spring a radially out of the groove on the nut and p...

Page 27: ...shing to separate the inside and outside of the sprocket seat Remove the bushing When reassembling pay attention to the bushing The larger chamfered end faces the inner shell of the sprocket seat Remo...

Page 28: ...ensor Finally use a 12 torx wrench to remove the valve nut and the flat washer and then remove the tire pressure sensor Maintenance Tire Check regularly the tire on cracks and air pressure If the tire...

Page 29: ...ing plate Remove the rear axle assembly To replace the rear fork you need to continue with the following steps Using 4 inner hexagon socket remove the bolt 2 and remove the wheel speed sensor 1 from t...

Page 30: ...the wire clamp on the upper right side of the rear flat fork Remove the 4 tubing brackets according to the steps on the previous page Carefully pull the auxiliary mudboard adapter cable out of the mo...

Page 31: ...rm assembly Rear auxiliary mud plate component 2 14 4024200 035000 Front segment of ZT310 V rear auxiliary clay plate and iron bracket 1 PROCEDURE Retaining plate Use 4 inner hexagon to remove bolt an...

Page 32: ...DURE Back reflector license plate cushion rubber Flip to the back Using 10 sleeve remove the nut and gasket that comes with the rear reflector remove the clamp and the rear reflector Remove the plate...

Page 33: ...holder then disassemble bolts d on the license lamp Disassemble bolts b and d on the diagram left side and then dismantle left press line plank of e and press line plank c dismantle the L rear turnin...

Page 34: ...unting plate First remove the retaining ring with the shaft circlip then remove the washer and O ring and finally remove the disc brake mounting plate Take the lower limit block and remove the seal ri...

Page 35: ...ion rubber 3 Remove the bolt on the lower right side with a 4 inner hexagon and remove the bush and the cushion rubber Using 8 sleeve remove the bolt 1 on the inside of the left inner side and remove...

Page 36: ...shock absorber from the vehicle Adjust the soft and hard shock absorption Loosen the adjusting nut with a hook wrench then screw the adjusting nut adjust in the direction of the arrow compress the dam...

Page 37: ...e left to remove the bolts and then remove the nuts Insert the bolt at b first Use a 17 Torx wrench to fix the 2 nuts at the a of the front pedal bracket respectively on the left side and use a 14 soc...

Page 38: ...bolt M12 1 25 85 10 9 garde dacromet 1 PROCEDURE Rear shock absorber reinforcement plate Make a mark with a marker first then hold the bracket and remove the bolt with an 8 sleeve and take off the bra...

Page 39: ...fork connectiong rod assembly Take off the front bushing The oil seal and needle roller bearing on the rear flat fork connecting rod assembly are all press fitted by interference pressure If there is...

Page 40: ...stproof rubber plug 1 Rear fork assembly after sale Rear fork component Fig 17 Rear wheel swinging arm component 8 1244200 085000 ZT310 single rocker arm aluminum alloy flat fork right dustproof rubbe...

Page 41: ...ke 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 Tighten the pin axle with 5mm hex socket tool Tighten...

Page 42: ...system is leaking If the braking liquid is accidently swallowed contact intoxication center or hospital immediately If it gets into the eye wash it away with clean water then see the doctor Keep the b...

Page 43: ...nuts If the above mentioned method can not adjust the gear shift rod to a satisfying position take off bolt and adjust gear shift rod spline of rocker arm with a straight screwdriver by shoving a litt...

Page 44: ...nch Install the foot pedal assembly back into a hole position and assemble the U joint on the adjusting screw without assembling the extension rod Assemble according to the disassembly sequence Adjust...

Page 45: ...Remove according to the steps of removing the shroud Use a 10 open end wrench to loosen the nut bushing screw and nut After grasping the shift lever firmly use an 8 Torx wrench to remove the bolt Use...

Page 46: ...disc brake according to the previous steps of adjustment of the installation position of the front right foot pedal Remove the brake pedal 2 torsion spring 3 and pedal assembly Right foot pedal assemb...

Page 47: ...ion color 1 Fig 5 FOOT PEDAL COMPONENT Front left footrest component PROCEDURE Front left foot pedal assembly Remove the bolt bushing and bolt 1 at the end of the shift lever according to the previous...

Page 48: ...ith 10 open ended wrench rotate the groove position on adjusting screw with 8 open ended wrench and loosen bushing with 10 open ended wrench Use 10 sleeve to remove bolt Remove the bearing nut nut bus...

Page 49: ...bolts above the right hydraulic control unit bracket Tilt the vehicle to the left and fix it firmly then use an 8 sleeve to remove the 2 bolts Note that a small amount of oil will leak from the oil pi...

Page 50: ...embly Using 6 inner hexagon socket remove 3 pieces bolts on the left side take off the left pedal bracket assembly Remove the bolt fixing the oil cup with the 4 hexagonal socket fix the oil cup and ma...

Page 51: ...steel ball spring 1 12 1274300 031000 ZT350 R rear pedal steel ball 6 35 1 13 1274300 032000 ZT350 R rear pedal locating plate 1 Fig 9 FOOT PEDAL COMPONENT Rear right pedal bracket components PROCEDU...

Page 52: ...oot pedal steel ball spring 1 12 1274300 031000 ZT350 R rear pedal steel ball 6 35 1 13 1274300 032000 ZT350 R rear pedal locating plate 1 PROCEDURE Rear left pedal bracket assembly Take off the side...

Page 53: ...cause leakage of oil Change engine 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 tighten th...

Page 54: ...Disassemble nut with 10 sleeve Rotate slightly engine oil refined filter cover and take it off when it is loosen Take off the O ring and the seal ring Change engine oil filter Change the O ring and th...

Page 55: ...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 hosip...

Page 56: ...embly in the same way Remove the 2 bolts 2 with the 4 hex socket and remove the right bracket 5 and the splint nut 3 After removing the tapping nail with a Phillips screwdriver the 2 expansion nails w...

Page 57: ...stic container After clamping the hoop with pliers pull the water pipe out of the main tank and remove the hoop Vent the coolant in the secondary tank Remove the leak pipe Clamp the hoop with pliers a...

Page 58: ...er under the right side of the vehicle tilt the vehicle to the right After wearing waterproof gloves with both hands remove the bolts with a 8 sleeve and remove the combination seal Drain the coolant...

Page 59: ...oss and then loosen the hoop Pull out the water pipe 2 after wearing waterproof gloves Remove the hoop 1 and hoop 6 Use the same method to remove two holding hoops 7 and pull out the water pipe 3 Loos...

Page 60: ...ethod is to put the core body into a high temperature resistant container pour it into boiling water and soak for a period of time take out the core body with pliers and observe whether the valve can...

Page 61: ...two bolts at the right engine cover with 8 sleeve and pull out the two oil pipes Keep the oil cooler in the low position grasp the two oil pipes to keep them in the high position and remove the oil co...

Page 62: ...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 14 open end wrench rotate the adjustmen...

Page 63: ...wise to increase and counterclockwise to decrease the beam height CAUTION Light height adjustment should be noted as follows Too High or too low light levels can affect safe driving The height of the...

Page 64: ...the rocker arm and remove the cable from the rocker arm seat First untie the thread buckle and strap Remove the clutch line Remove the protective sleeve from the clutch cable Install the clutch line...

Page 65: ...andle core rotary table of the right hand rubber sleeve and finally from the cable hole at the lower part of the switch Install throttle cable First thread the throttle cable into the cable hole at th...

Page 66: ...on to the amount of grease after sales PROCEDURE When the front fork is slightly swaying or when the direction handle is swung Check if the pressure of the front tire is the recommended air pressure a...

Page 67: ...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 fluid level is above the LOWER marking If not c...

Page 68: ...shaft into the hole to fix the brake pad Tighten the pin shaft with T25 inner hexagon socket ring wrench Install the two circlips back onto the pin shaft The buckle is assembled in place after it make...

Page 69: ...ofessional tire puller to remove the rear tire taking care to avoid the tire pressure sensor Finally use a 12 wrench to remove the valve nut and the flat washer and then remove the tire pressure senso...

Page 70: ...3 pcs clamps Hold the fixed seat with one hand and pull out the plug of the wheel speed sensor with the other hand Take the brake oil pipe and wheel speed sensor wire out of the wire clamp remove the...

Page 71: ...adlights assembly Remove the bolts shown in picture 1 with a 6 hexagon socket Remove 2 bolts on the bottom Hold the headlight assembly and pull it forward Remove the three plugs of the left and right...

Page 72: ...ZT350 S hood left trim 1 Headlights assembly 2 Fig 11 FRONT FORK COMPONENT PROCEDURE Headlight bracket assembly Remove the bolt in the middle of the bottom of the headlamp with 4 hex remove the bushin...

Page 73: ...wer part Hood turn signal upper part Remove the two tapping nails 1 fixing the right turn signal with a Phillips screwdriver and remove the right turn signal 4 Remove the left turn signal in the same...

Page 74: ...e 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 5 hexagon socket tool...

Page 75: ...r arm by referring to the steps in Right Handle Assembly and Add Brake Fluid Adjusting Rocker Arm Left hand rubber sleeve and balance block assembly Use a blow gun to blow the left hand grip between t...

Page 76: ...063093 Plywood M6 11 15 color Zinc 1 18 1250205 040095 GB70 1 inner hex bolt M8 16 color Zinc 1 19 1274300 103000 ZT350 S USB bracket 1 20 1186400 009000 ZT350 Dual Port Universal USB Charging Cable...

Page 77: ...plate and hold the shock absorber in the middle with one hand Insert a slotted screwdriver into the slot of the upper and lower plates to slightly enlarge the slot clearance and disassemble the left s...

Page 78: ...u need to replace the double studs separately you can lock the two M10 1 5 nuts to each other as shown in the small figure and then use the sleeve to turn clockwise to remove the studs When replacing...

Page 79: ...unit assembly Using 4 inner hexagon socket remove the two bolts and remove the bushing Take off the bracket component if needed take off 2 pcs cushion rubbers from the bracket Brake fluid Place an oil...

Page 80: ...c brake caliper from the front shock absorber 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 coppe...

Page 81: ...ve the oil cup cover and sealant pad Loosen the rear brake switch nut with 14 open ended wrench and drain the brake fluid Remove the hoop at the main pump with pliers and pull out the oil pipe Remove...

Page 82: ...emove the bolt at the right guard bar and take the front section of the oil pipe out of the wire clamp Use an 8 sleeve to remove the bolt on the upper right front part of the rear flat fork and remove...

Page 83: ...ight tank and move it down about 30mm leaving the boss on the tank snorkel Adsorption tube remove from the fuel tank Remove the cushion and side cover exterior trim panel Using 6 inner hexagon socket...

Page 84: ...to hear the sound reset the key and then pull out the key Oil gas separator pipe water leakage pipe Fuel pump Using 10 sleeve remove 8 bolts When the fuel pump is removed the float connecting rod cann...

Page 85: ...sensor plug wheel speed sensor plug and cooling fan plug Use a 4 hexagon socket to remove the bolt and remove the fixing seat Pull out the RC tubing from the tubing clamp remove the bolt with the 4 he...

Page 86: ...fix the head of the bolt on the left side and remove the nut with a 14 sleeve and move away the cable fixing bracket Use a 14 sleeve to fix the head of the bolt on the right side and remove the nut wi...

Page 87: ...er Bracket 1 PROCEDURE Left bumper assembly Remove the outer expansion nail After grasping the left guard bardecorative cover remove the 2 bolts above the inner side with 4 hex and remove the ignition...

Page 88: ...e cover 1 6 1251300 063093 Plywood M6 11 15 color Zinc 1 7 1240300 007000 HJ125 6 Battery rubber gasket 1 PROCEDURE Right bumper decorative cover assembly Remove the rubber plug remove the bolt with t...

Page 89: ...emove 2pcs bolts then the charging port bottom cover can be removed Pay attention to the four clips indicated by the arrow and the end close to the air filter should be lowered first Unplug the two pl...

Page 90: ...indicated by the arrows from the electrical box Pull out the rubber plug use a 13 box wrench to stretch in from the gap and fix the nut on the inside use a 12 socket on the outside to remove the bolt...

Page 91: ...olts on the front part first Remove the bolt at the bottom with 8 sleeve and remove the bushing and buffer rubber Pull out both sides of the rear tail skirt front part and pull them out backwards for...

Page 92: ...from the right tail skirt according to the above steps Non inductive antenna Remove two self tapping screws with a cross screwdriver and then remove the induction antenna PKE antenna The PKE antenna...

Page 93: ...from the tail lamp and pay attention to the clips Remove 3 splint nuts from the left tail skirt Remove the right tail skirt and three splint nuts in the same way Remove 4 splint nuts from the tail lam...

Page 94: ...0300 007000 HJ125 6 Battery rubber gasket 2 5 PROCEDURE Battery bracket Remove 4 bolts with 8 socket Remove the battery bracket assembly Use a hot air gun to heat the rubber pad back and forth and tea...

Page 95: ...me remove the cushion by moving the rear part of the cushion from side to side Using 4 inner hexagon socket remove 5 pcs bolts take off the bushing and buffer rubber then remover the cushion decorativ...

Page 96: ...0 5 8 4 33 1 5 2 PROCEDURE Muffler assembly Untile the strap whitch tie on the right bumper Use one hand to support the fixing seat above and inside the right guard bar pull the oxygen sensor plug up...

Page 97: ...5 8 4 33 1 5 2 Fig 2MUFFLER COMPONENT Muffler component 2 PROCEDURE Muffler assembly Use a 13 Torx wrench to fix the nut on the back and remove the bolt with a 6 hexagon socket on the outside After su...

Page 98: ...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 ceramics inside the oxygen sensor are hard and brittle It is...

Page 99: ...ner hexagon to 2 bolts on the right side and bottom of left side and remove the bushing After grasping the lower air deflector assembly then using 8 plum wrench removing the bolt and bolt at the middl...

Page 100: ...lor zinc 1 8 1274300 062000 ZT350 V1 lower docorative cover left bracket 1 PROCEDURE Lower shroud assembly Remove the splint nut from the left part middle part and right part respectively Lower shroud...

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Zontes ZT350-S 2022, Service Manual

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Summary of Contents for ZT350-S 2022

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