Zontes ZT350-V1 Service Manual Download Page 1

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2022/0

Service manual

ZT350-VX (EURO V)

Summary of Contents for ZT350-V1

Page 1: ...2022 08 02 Service manual ZT350 VX EURO V...

Page 2: ...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 Combination1 15 Disassemble the...

Page 3: ...mbly 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 signals and rear license plate lights fo...

Page 4: ...mponents 51 6 Cooling system component 6 1 Change the oil 52 6 3 Replace the oil filter 53 6 2 Add coolant 54 6 4 Radiator decorative cover grille 55 6 5 Vice water tank components 56 6 6 Draining coo...

Page 5: ...light assembly 3 74 Remove the link fender 7 15 Headlight assembly 4 75 Remove the link fender 7 16 Headlight assembly 5 76 Disassemble the headlight sub assembly 7 17 Headlight assembly 6 77 Remove h...

Page 6: ...tubing 8 Fuel tank cover component 8 1 Tank middle cover component 93 Decompose the fuel tank cover fuel tank cover fuel tank lock 8 2 Remove the front interior of the front surrounding 94 8 3 Fuel ta...

Page 7: ...er 11 REAR COVER COMPONENT 11 1 Battery component 109 11 2 Backrest assembly component 110 Disassemble the backrest Backrest rubber 11 3 Tail skirt taillight component 1 111 Disassemble PKE single ant...

Page 8: ...inconsistencies between your motorcycle and this manual due to the continuousimprovement of the product and other changesFor colors or upgrades please refer to the part codes on the official website T...

Page 9: ...frame and remove the dump switch with the same method then separate the dump switch sleeve Relay and ECU Pull out the rubber sleeve 4 on the right side of the frame and then pull out the EFI relay 12...

Page 10: ...erse buckle Velcro strap 20 200mm 1 CAUTION Do not pull the cable hard when removing the sub mud switch The replacement of the spark plug and the matters needing attention are described in the instruc...

Page 11: ...cover cushion 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 w...

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: ...priate 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 steel wire cannot be loosened or scattered during the pulli...

Page 14: ...component PKE Controller Unplug the PKE plug use a 4 allen wrench to remove the two bolts to remove the PKE assembly and ZT310PKE rubber sleeve PKE bracket Remove the bolt 7 at the oil cup with 4 hex...

Page 15: ...ng water and seek medical treatment in time Be sure to stay away from children and pets Fig 1 FRAME ENGINE Engine decorative cover components PROCEDURE Engine right trim cover assembly Using 4 inner h...

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: ...olt fixing the hydraulic control unit support Radiator middle trim cover Remove the bolt at the bottom of the middle trim cover with 8 sleeve and remove the gasket and buffer glue Front pedal support...

Page 18: ...n and one person pulls out the bolt 1 After holding the rear shock absorber assembly pull out the bolts 3 at a b and c and then remove the rear shock absorber assembly Insert the bolts at the 3 places...

Page 19: ...side and use a 30 sleeve to remove the nut on the right side One person supports the engine one person stabilizes the rear flat fork assembly of the rear wheel and the other uses a rubber hammer to kn...

Page 20: ...ee the section Electrical Components 1 in the Frame Assembly of this manual Electrical device box bottom cover After holding the bottom cover assembly of the electrical device box remove 2 bolts with...

Page 21: ...ke out Remove 7 pieces of clamp nuts The oil accumulation pipe and the water accumulation pipe should be checked and cleaned regularly Carbon Tank Assembly Use hoop pliers to remove the carbon caniste...

Page 22: ...the 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...

Page 23: ...ewdriver to pry out the middle 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 g...

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: ...ng oil seal 1 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 chamfe...

Page 28: ...t washer and then remove the tire pressure sensor Maintenance Tire Check regularly the tire on cracks and air pressure If the tire is ware to the marker change the tire with same specification See det...

Page 29: ...th the following steps Using 4 inner hexagon socket remove the bolt 2 and remove the wheel speed sensor 1 from the rear disc brake caliper mounting plate Using 8 sleeve remove the 4 bolts 4 and remove...

Page 30: ...unplug the shown three plugs Untie the strap Cut off the cable tie on the upper right side of the rear flat fork Remove the 4 tubing brackets according to the steps on the previous page Carefully pul...

Page 31: ...mental color 2 Fig 8 Rear wheel swinging arm assembly Rear auxiliary mud plate component 2 PROCEDURE Retaining plate Use 4 inner hexagon to remove bolt and use 10 sleeve to remove bolt remove the flan...

Page 32: ...ubber Flip to the back Using 10 sleeve remove the nut that comes with the rear reflector remove the clamp and the back reflector Remove the plate cushion rubber and remove the 2 plywood nuts on the ba...

Page 33: ...rning light license lamp included Grip the rear turning light 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...

Page 34: ...hain adjuster assembly bearing maintenance It is recommended to inspect maintain and clean the bearings every 6 000 km After removing the chain adjuster assembly according to the previous steps clean...

Page 35: ...h 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 the bushing 2 and the cushion rubber 3 Using 8 sleeve re...

Page 36: ...om running forward Support the whole vehicle firmly before proceeding to the next step One person uses 14 sleeve to hold the head of bolt or respectively and one person uses 17 sleeve to remove nut Re...

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: ...Torx wrench to remove the stud 1 Use a 14 sleeve to fix the head of the bolt remove the nut 2 with a 14 sleeve and then remove the bolt after grasping the rear flat fork connecting rod assembly Use a...

Page 39: ...ork connecting rod assembly are all press fitted by interference pressure If there is no malfunction it is not recommended to disassemble it by yourself Rear flat fork connectiong rod assembly already...

Page 40: ...ssembly including bearing oil seal 1 Rear fork assembly after sale PROCEDURE Rear swinging arm assembly Remove the bolt with 8 sleeve Person 1 hold the head of rear swinging arm axle with the 24 socke...

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: ...king liquid surface is between MAX and MIN If liquid surface is below MIN check the arrester status and confirm if the braking system is leaking If the braking liquid is accidently swallowed contact i...

Page 43: ...ft rod to a satisfying position take off bolt and adjust gear shift rod spline of rocker arm with a straight screwdriver by shoving a little bit the groove in the middle while dragging it out Reassemb...

Page 44: ...nstall 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 to t...

Page 45: ...ove according to the steps of removing the shroud 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 f...

Page 46: ...nstallation position of the front right foot pedal Remove the brake pedal 2 torsion spring 3 and pedal assembly Right foot pedal assembly Remove the circlip 4 remove the pin 5 and separate the foot su...

Page 47: ...DURE Front left foot pedal assembly Remove the bolt bushing and bolt 1 at the end of the shift lever according to the previous steps of adjustment of the installation position of the front left foot p...

Page 48: ...ing 6 4 9 8 18 2 environmental color 1 1 7 1274100 041000 ZT250 S shift lever adjusting screw 10 150 Black Zinc PROCEDURE Gear shift rod assembly Loosen nut and nut respectively with 10 open ended wre...

Page 49: ...ps to remove the left and right pedal assemblies to remove Remove it as shown in Figures 1 and 2 Use an 8 sleeve to remove the bolts above the right hydraulic control unit bracket Tilt the vehicle to...

Page 50: ...edal bracket assembly Using 6 inner hexagon socket remove 2 pieces bolts on the right side take off the right pedal bracket assembly CAUTION The rear left and right foot pedal brackets are always equi...

Page 51: ...9 FOOT PEDAL COMPONENT PROCEDURE Rear right pedal bracket assembly Take off 2 pieces side cover round glue from the right pedal bracket Use 8 sleeve to remove bolt use 6 inner hexagon to remove bolt...

Page 52: ...assembly Take off 3 pieces side cover round glues from the right pedal bracket Use 8 sleeve to remove bolt Use 6 inner hexagon to remove bolt and take off the cover Take off the pedal torsion spring a...

Page 53: ...changed new engine oil of SAE 10W 50 10W 40 with API SM degree or higher Then tighten the oil filler plug pay attention to check the O ring is damaged or aging and do not leak Start the engine and tes...

Page 54: ...ilter 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 the seal ring along with engine oil filter assembly When reassembling...

Page 55: ...d 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...

Page 56: ...ner hexagon and remove the bushing 2 and the cushion rubber 3 Grasp the lower part of the fender remove the 4 expansion nails and remove the lower part of the fender Radiator grille Remove 8 expansion...

Page 57: ...earing the waterproof rubber gloves put the sub tank assembly upside down the sub water tank cover down into a plastic container After clamping the hoop with pliers pull the water pipe out of the main...

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: ...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 Loosen the clamp 9 at the water pump cover with a slotted s...

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: ...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 cooler assembly Pour the oil in...

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

Page 63: ...bolt turns clockwise for lowering and counterclockwise for higher beam height CAUTION Light height adjustment should be noted as follows Too High or too low light levels can affect safe driving The he...

Page 64: ...tch 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...

Page 65: ...the throttle cable from the handle core rotary table of the right hand rubber sleeve 5 and finally from the cable hole at the lower part of the switch Install throttle cable First thread the throttle...

Page 66: ...DURE 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 at room temperature 280 kPa If it is lower th...

Page 67: ...ng connector at a high level to prevent air from entering the tubing and cause brake failure Also clean oil should be removed to prevent dripping onto parts such as covers or mufflers After replacemen...

Page 68: ...te 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 with T25 inner hexagon socket ring wrench Install the...

Page 69: ...left front shock absorber bottom b with the 6 Allen tool Hold the front wheel first and then remove the hollow shaft with the 17 internal hexagon tool emove the left sleeve and move the front wheel as...

Page 70: ...NT 2 PROCEDURE Wheel speed sensor Remove the wire clips wire clips and rubber wire buckles Hold the fixed seat with one hand and pull out the plug of the wheel speed sensor in the direction of the arr...

Page 71: ...ove the 2 bolts on the left respectively take off the bushing and the rubber pad and the upper left pressure block of the windshield Remove the upper right pressure block of the windshield according t...

Page 72: ...emove the rocker arm decorative block with a 4 inner hexagon and then remove the gasket pull the upper rocker arm assembly out and remove the tension spring Use the same method to remove the right par...

Page 73: ...CEDURE Headlight assembly Remove the 7 expansion nails 1 shown in Figure 1 and the 2 expansion nails 1 at the bottom of the headlight cover shown in Figure 2 Press the openings of the storage boxes on...

Page 74: ...of lower link plate Remove the 3 bolts shown in Figure 1 with a 4 inner hexagon and remove the bush and cushion rubber Grasp the lower part of the fender remove the 4 expansion nails and remove the lo...

Page 75: ...l outwards with both hands After releasing the buckle pull the heads on both sides and bypass the boss on the windshield motor support as shown in Figure 3 Shown Grasp both sides of the headlight asse...

Page 76: ...2 bolts take off the bush and cushion rubber Remove the expansion nails on both sides Open the mushroom hasp between the headlight covers on both sides and the headlight bracket and then remove the he...

Page 77: ...25mm 25mm T3 5mm 4 Headlight assembly 5 PROCEDURE Headlight cover sub assembly Remove the 6 pieces of splint nuts and 5 pieces of head cover cushion rubber from the head cover Remove the 5 bolts with...

Page 78: ...ed with double sided tape Remove 2pcs cable plastic staples from the headlight bracket Remove the cushion rubber from the left and right brackets of the headlight cover Grasp the left bracket of the h...

Page 79: ...R V universal TFT instrument 1 14 4024200 097051 ZT310 VX adjustable instrument upper bracket 1 PROCEDURE Windshield motor cover Use 4 inner hexagon to remove 4 bolts remove bushing and cushion rubbe...

Page 80: ...ewdriver and remove Remove the rocker arm clamp Grab the lower right rocker arm Remove the 2 screws with a Phillips screwdriver and remove Remove the rocker arm clamp CAUTION Do not pull the cable dir...

Page 81: ...3000 ZT310 X1 windshield base 1 1 PROCEDURE Electrical devices First unplug the motor controller Remove the 2 bolts at a with an 8 sleeve remove the bushing and remove the controller Remove the cushio...

Page 82: ...and use an 8 sleeve to remove the bolts remove the bush and then remove the rear interior components from the bike Unscrew the USB charging cable comes with the nut and remove it Remove 4 pieces of sp...

Page 83: ...0 VX storage box return spring 2 11 1224200 186000 ZT310 VX right storage box cover 1 12 1224200 183000 Right storage box cover limit mounting support 1 Fig 22FRONT FORK COMPONENT Storage box rear sur...

Page 84: ...1300 063093 Plywood M6 11 15 color Zinc 2 10 1274200 269000 ZT310 VX storage box switch pin 2 11 1260100 215000 ZT310 T storage box cover rotating shaft limit circlip 2 12 1260100 270000 ZT310 VX stor...

Page 85: ...Hold the front disc brake main pump with one hand and remove the bolt with the 5 hexagon socket tool Remove the wire plug connector of the sub switch and pull it out Front brake switch replacement Unp...

Page 86: ...sleeve and the direction handle tube while moving the rubber sleeve inward until the balance block positioning hole is exposed Use the tool to press the convex part at both ends of the elastic piece o...

Page 87: ...Direction handle TFT Instrument PROCEDURE Directional components Use a blade to pick up the decorative buckle hold the direction handle in one hand and remove the bolt with a 6 hexagonal tool in one...

Page 88: ...sorption Using 4 inner hexagon socket remove the bolts of the lower plate and hold the shock absorber in the middle with one hand Insert a slotted screwdriver into the slot of the upper and lower plat...

Page 89: ...ushing Remove the upper plate If you 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...

Page 90: ...ocket 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 pan to collect wasted brake fluid un...

Page 91: ...racket If you need to remove the oil pipe bracket use 8 sleeve remove the bolt then take it off CAUTION Be sure to disassemble the muffler and engine after they have cooled down completely The horizon...

Page 92: ...crewdriver Remove 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 o...

Page 93: ...ove 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 cut off...

Page 94: ...the sides of the middle cover and lift it up and pull the fuel tank lock cable from the hole in the middle of the cover Put the fuel tank cap back into the fuel tank to prevent fuel volatilization an...

Page 95: ...front interior Remove the 4 expansion nails on both sides of the head 1 Grab the lower side of the left interior with the left hand and press the upper right hand to loosen the inner button and remove...

Page 96: ...tating shaft 1 Fig 3 FUEL TANK COVER COMPONET Change engine oil PROCEDURE Fuel tank cover assembly Remove the retaining spring attached to the rotating shaft and slowly pull out the rotating shaft Rem...

Page 97: ...corative cover and cannot be pulled out directly Remove the lower left decorative cover according to the above steps CAUTION The parts should be protected during the disassembly process to prevent dam...

Page 98: ...assembly a and b and pull out the staples c and d and then push in the direction indicated by the arrow Be careful not to apply too much force to avoid scratching the paint Pull the left fuel tank de...

Page 99: ...oration cover right rear shell 1 PROCEDURE Fuel tank decoration cover bottom shell Remove the 6 bolts with a 4 inner hexagon and remove the bushing and cushion rubber remove the bolt at the upper righ...

Page 100: ...se a 4 inner hexagon to remove the bolt at a and remove the bush and the cushion rubber Loosen the bolt with a 4 inner hexagon socket b and remove the 2 self tapping screws with a cross screwdriver Re...

Page 101: ...ght fuel tank decoration cover 1 Fuel tank trim cover assembly 5 Fig 8 FUEL TANK COVER COMPONET PROCEDURE Fuel tank decoration cover Use 4 inner hexagon to remove 5 bolts remove bushing and cushion ru...

Page 102: ...a pair of pliers to clamp the hoop slightly at the bottom of the right tank and move it down about 30mm leaving the boss on the tank snorkel Adsorption tube Remove from the fuel tank Using 4 inner he...

Page 103: ...remove the decorative cover bracket Use a 10 open end wrench to fix the nut at the bottom installation point of the left decorative cover bracket and then remove the bolts with a 4 hexagon socket afte...

Page 104: ...rubber Fuel pump Using 10 sleeve remove 8 bolts When the fuel pump is removed the float connecting rod cannot be bent to avoid inaccurate oil display After removing the fuel pump it is recommended to...

Page 105: ...irst and then remove the expansion nails at the connection between the right side cover and the rear cover Remove the waterproof rubber plug after holding the nut with 13 plug wrench then using a 12 s...

Page 106: ...pieces of relay and rubber cover from the holder Remove the oxygen sensor plug wheel speed sensor plug and cooling fan plug Use a 4 hexagon socket to remove the bolt remove the bushing and the buffer...

Page 107: ...emove the cable tie and unplug the two plugs of the rectifier Pull out the rubber cap of the high voltage wire Use a 14 sleeve to fix the head of the bolt on the left side and remove the nut with a 14...

Page 108: ...51 ZT310 V1 right crash bar dark gray matte 1 PROCEDURE Left bumper assembly Remove the water stopper using 6 inner hexagon socket remove the bolt and remove the anti drop glue Remove 2 bolts then tak...

Page 109: ...ive cover components PROCEDURE Left engine decorative cover assembly 1 Remove the two nuts from the left front decorative cover of the engine 2 The same method remove the nuts from the left back decor...

Page 110: ...irst and then remove the positive wire then the battery 2 can be removed Using 4 inner hexagon socket remove the 2 bolts remove the 2 flanging bushings and the flanging bushing cushion rubbers remove...

Page 111: ...socket remove the bottom two bolts Hold the backrest assembly and remove the two upper bolts 1 with 6 inner hexagon Remove the backrest assembly from the vehicle Flip to the back and remove the bolts...

Page 112: ...right rear cover pull it out and arrange the cable The PKE antenna is pasted with the double topping and the double topping on the rear cover Heat it slightly with a hot air gun then tear off the doub...

Page 113: ...r cover trim cover Using 4 inner hexagon socket remove the bolt on the bottom left side and remove the bushing and cushion rubber Using 4 inner hexagon socket remove the bolt on the bottom right side...

Page 114: ...tly outwards and pull them diagonally to the rear to remove the bracket 3 Rear cover trim cover Remove PKE small cover after pressing down Use 6 inner hexagon to remove the two bolts at the bottom and...

Page 115: ...ar light First pull out the plug of the left rear tail lamp and the right rear tail lamp Remove two bolts of the brake lamp take off the bushing and cushion rubber Pull up the outlet side of brake lam...

Page 116: ...on and 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 cushio...

Page 117: ...in the chapter on cooling system components Refer to the fuel tank assembly to remove the fuel tank trim cover assembly Loosen the bolts and on both sides of the main water tank with an 8 sleeve push...

Page 118: ...ear 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 shall be 2 1A Otherwise it...

Page 119: ...nner 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 midd...

Page 120: ...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-V1, Service Manual

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