Zontes ZT350T-D Maintenance Manual Download

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7. Distribution map of cooling system accessories

1-Main water tank 2- Water tank filling port 3- Secondary water tank 4- Main water tank water inlet pipe 5- Main water

tank water outlet pipe 6- Water and oil shared sensor 7- Thermostat 8- Water pump cover assembly

8. Electrical device layout

Summary of Contents for ZT350T-D

Page 1: ...1 152 ZT350T D Maintenance Manual 2022 11 24...

Page 2: ...ed in detail if the part names in this manual are inconsistent with the official website of Zontes please refer to the official website of Zontes Individual parts of different displacements that diffe...

Page 3: ...and rubber parts reducing the service life Non woven fabrics should be used for wiping with no residue Ordinary rags may leave cloth scraps or wool etc which may affect the assembly or cause other ad...

Page 4: ...efore Service 27 D350 Maintenance schedule 28 D350 Air filter filter element air inlet filter element 29 1 Support the vehicle firmly 29 2 Remove the left engine cover 29 3 Remove the air inlet cover...

Page 5: ...switch 52 2 2 Replace the brake switch 52 3 Lubricate the movable parts of the brake handle 52 3 1 Lubricate the front brake handle 52 3 2 After lubricating the brake handle 52 3 3 Replacing the brak...

Page 6: ...d switch 72 4 6 Light 73 4 7 Windshield failure 73 3 EFI system 74 Know Before Service 74 Error code 75 1 M310 Read the fault code through the meter 75 2 Read the fault code through the diagnostic too...

Page 7: ...motor 97 Examination 98 Starter motor front cover 98 Motor back cover 98 Denki 98 Check the starting relay 99 1 Operation check 99 2 Check the relay coil 99 2 1 Input line 99 2 2 Ground wire 99 3 Che...

Page 8: ...or 113 Release brake fluid 113 FMC HU and RMC HU 114 FC HU and wheel speed sensor front wheel 114 RC HU and wheel speed sensor rear wheel 114 ABS system layout 115 ABS hydraulic control unit 116 Disas...

Page 9: ...11 Disassemble the engine of the vehicle 135 1 Disassemble the storage box 135 2 Remove the cover 135 3 Put the coolant and pull out the connection plug 136 4 Disassemble the engine 138 5 Install the...

Page 10: ...led and handed over to qualified institutions for disposal it is forbidden to dump them at will to pollute the environment or water sources 7 Swallowing or inhaling coolant brake fluid etc will cause...

Page 11: ...d the VIN code is engraved on the cross tube at the rear of the frame The muffler code is on the inner side above the muffler The nameplate is above the radiator The engine identification code is engr...

Page 12: ...open temperature 95 203F Thermostat opening stroke 3 5mm 0 13 in Coolant type Ethylene glycol distilled water Front wheel steering system Item Standard Limit Tread depth 1 6mm 0 063 in Normal tempera...

Page 13: ...1 times the battery capacity Charging time 5 8 hours Charging current charging time must be controlled within the current range of 0 5 to 0 8 times the battery capacity Lamp Speedometer switch descrip...

Page 14: ...king torque Tightening torque range Standard value Breaking torque M4 1 2 1 4 1 5 3 2 5 M5 2 4 2 9 4 5 3 6 4 5 8 M6 4 7 4 9 10 8 12 10 14 5 M8 10 16 12 2 20 18 28 22 34 M10 22 25 24 5 45 40 60 44 76 M...

Page 15: ...position 3 High and low beam position 2 Side reflector 3 Right handlebar auxiliary switch 4 Right handlebar switch 5 Right rear turn light 4 Position light brake light position 5 Rear turn light posit...

Page 16: ...16 152 2 Throttle cable 1 Oil return line 2 Fuel line 3 Brake upper pump and brake hose 1 Front disc brake main pump 2 FMC HU brake hose 3 RMC HU brake hose 4 rear disc brake main pump...

Page 17: ...disc front 2 front whell ABS induction ring gear 3 wheel speed sensor front wheel 4 front disc brake caliper 5 FC HU brake hose 6 rear whell ABS induction ring gear 7 brake disc rear 8 rear disc brak...

Page 18: ...ont wheel 2 FC HU brake hose 3 RC HU brake hose 4 wheel speed sensor rear wheel 5 rear disc brake main pump 6 rear brake lever 7 rear brake switch 8 RMC HU brake hose 9 FMC HU brake hose 10 front brak...

Page 19: ...take pipe 11 solenoid valve outlet pipe 12 throttle valve body assembly Fuel evaporation Oil and gas oil and gas separator inside the oil tank adsorption vent pipe solenoid valve intake pipe solenoid...

Page 20: ...cessories 1 Main water tank 2 Water tank filling port 3 Secondary water tank 4 Main water tank water inlet pipe 5 Main water tank water outlet pipe 6 Water and oil shared sensor 7 Thermostat 8 Water p...

Page 21: ...d Motor Controller 14 Flash 15 Induction antenna 16 GPS antenna 17 USB charging cable 18 Front storage compartment lock 19 Electronic tank lock 20 carbon can solenoid valve 21 start relay 22 battery 2...

Page 22: ...c tank lock 9 Ignition coil body 10 EFI high voltage line 11 Side bracket flameout switch 12 Buzzer 9 Intake and exhaust system 1 Cylinder head 2 Cylinder head exhaust pipe 3 Air filter intake inlet 4...

Page 23: ...r Cylinder head exhaust gas control system red arrow indicates Exhaust gas cylinder head cover cylinder head exhaust pipe air filter air filter outlet pipe throttle valve body intake manifold cylinder...

Page 24: ...piece tool set Torque wrench On board tools Claw hammer Pull code Rubber hammer Dynamic Balancing Machine Tire raking machine Oil pan Measuring cup Funnel Taps dies Micrometer Depth gauge Vernier cali...

Page 25: ...dometer 16PIN 17 Inner hexagon Hoop clamp Internal Circlip Pliers External circlip pliers Clamp multimeter Multimeter Dust blow gun 14 sided 65mm cap filter wrench Some of the above pictures are from...

Page 26: ...he outer ring with two fingers and push the center cylinder up to the initial position Pinch the center cylinder with two fingers to install the swell nails to the installation position The outer ring...

Page 27: ...cal advice or consultation in time Keep away from children and pets 8 If you need to clean or wash the body parts of the vehicle you should use neutral car wash fluid or tap water diesel kerosene etc...

Page 28: ...shock absorber I Rear shock absorber I Bolts and nuts for body and engine installation T T M12 65 5 6 6 0 5 M16 80 5 8 2 0 5 Coolant I I I 3 years or 30 000 kilometers 18641 mile Gearbox oil R R Valv...

Page 29: ...hibited to avoid environmental pollution The items listed in the needle are used in regular environments If they are often used in harsh environments the frequency of maintenance should be increased S...

Page 30: ...a Use a Phillips screwdriver to remove the 6 screws that fix the filter element that comes with the air filter b Remove the old air filter element Blow the dust inside the air inlet pipe with a dust...

Page 31: ...every 4000km 2485 miles or 15 months whichever comes first The air filter element and the engine air inlet element should be cleaned regularly in accordance with the provisions of the regular maintena...

Page 32: ...ll metal surfaces of the muffler while the engine is running or after riding to prevent burns The vehicle must be parked on a flat and stable ground or a lifting platform If you need to replace the ne...

Page 33: ...6 Press the center cylindrical pin of the expansion nail on the left side of the tank cover plate with 4 Allen and remove the expansion nail Finally remove the left part of the fuel tank cover e Start...

Page 34: ...ay the dust and debris near the spark plug o Pull out the ignition coil high voltage cap p Remove the spark plug by turning it counterclockwise with the vehicle mounted tool or special 14 spark plug s...

Page 35: ...parked on a flat and stable ground or a lifting platform The operation can only be performed after the engine has cooled down completely Do not pull or knock the center electrode If the replacement o...

Page 36: ...nut it is necessary to prevent foreign matter from falling into the engine 1 Drain the oil a Start the vehicle and turn off the engine for 3 5 minutes after idling for 3 5 minutes b Use the main brac...

Page 37: ...clockwise c Remove the oil drain bolt and the copper pad d After the gear box oil is completely drained wipe the surface of the drain port with a non woven cloth e Replace with a new copper pad check...

Page 38: ...ery compartment Buckle the 2 decorative bolt buckles 3 first Remove the 4 M6 16 bolts 2 of the rear compartment with 4 Allen Press the center cylindrical pin of the 2 expansion nails with 4 Allen and...

Page 39: ...direction of the axis g Use throttle valve body cleaning agent to clean the carbon deposits on the intake manifold and throttle valve body outlet respectively It is forbidden to directly soak the thr...

Page 40: ...ems According to idle speed determine idle speed adjustment bolt position and fix replace recoil spring or cleaning throttle valve body disc Throttle body sensor performance check Fault lights are alw...

Page 41: ...ue 3 8 N m 0 4 kgf m 2 8 lbf ft b If the above adjustment fails to achieve the desired effect please refer to the description in Remove the throttle valve body assembly to clean up carbon deposits to...

Page 42: ...The limit screw on the valve body is not allowed to be adjusted privately Check idle speed Check the idling speed of the engine when the engine is warm D350 the idle speed range of the engine should...

Page 43: ...d gas separator inside the oil tank adsorption vent pipe solenoid valve intake pipe solenoid valve outlet pipe throttle valve body assembly intake manifold cylinder The fuel evaporative pollutant cont...

Page 44: ...splash should be wiped off with a clean soft cloth immediately 1 D350 check the coolant a Straighten the vehicle through the right rear gap and use a flashlight to check that the coolant level is betw...

Page 45: ...ant c Wipe all the joint surfaces clean with a non woven cloth Check whether the bolt joint surfaces are scratched if any replace them with new ones The O ring needs to be replaced every time it is di...

Page 46: ...k 4 Main water tank water inlet pipe 5 Main water tank water outlet pipe 6 Water and oil shared sensor 7 Thermostat 8 Water pump cover assembly 1 Water inlet pipe 2 Secondary water tank connection pip...

Page 47: ...tle valve body first remove the cushion and storage box components and remove them as shown in the figure below b Remove a total of 4 pcs swell nails indicated by the arrow For instructions on disasse...

Page 48: ...hicle let the engine run at idle speed and measure the fuel pressure D350 the standard pressure is 350 10kPa 3 75 0 1Kgf cm2 50 8 1 45 psi Check valve performance hold the pressure for 1 minute the pr...

Page 49: ...in the driver s manual or the throttle valve body chapter of this manual Braking System Caution For the layout of the brake hose on the vehicle please refer to the brake system accessories distributi...

Page 50: ...50 152 D350 Braking system component diagram...

Page 51: ...front wheel Observe from the front whether the brake disc swings when turning the front wheel if there is any swing please remove it according to the steps of dismantling the brake disc and place it o...

Page 52: ...ce with a new switch pay attention to align the switch boss and the limit hole of the brake main pump The replacement procedure of the front brake switch is the same as that of the rear brake switch T...

Page 53: ...embled correctly Do not operate the brake handle after removing the brake pads 5 1 Replace the front brake pads a Remove both circlips by clamping the circlip with pointed nose pliers b Remove the two...

Page 54: ...d and insert the pin with your right hand being careful not to insert it to the end Install the inner brake pad in place then insert the pin to the end and use the 5 inner hexagonal lock pin Be carefu...

Page 55: ...e handle must be operated repeatedly until the brakes restore the braking effect Contaminated disc brake discs and disc brake pads will reduce the braking effect Please replace with new disc brake dis...

Page 56: ...d at the position 2 indicated by the arrows with the other hand Separate the rear inner mud plate from the staples on the air filter and lift it up to facilitate subsequent removal of the rear rocker...

Page 57: ...n and pets The vehicle must be parked on a flat and stable ground or a lifting platform 1 Add brake fluid to the main pumps of the front and rear disc brakes a Adding brake fluid to the main pump of a...

Page 58: ...orce 2 2 Replace the rear brake fluid Refer to the steps for replacing the front brake brake fluid to replace the rear one 3 Brake system exhaust If the hand feel soft when the brake handle is squeeze...

Page 59: ...e pressure when the tire is cold and add or deflate to the standard pressure b The height of the wear mark on the tread protrusion is 1 6mm 0 06 in The triangle T W I mark on the sidewall indicates th...

Page 60: ...bf ft e The front wheel is hung in the air to straighten the direction handle and gently push and pull the direction handle by hand to feel whether the steering mechanism is smooth and free of jams Wh...

Page 61: ...or sludge mixture remove the dust seal and wipe clean the front fork tube and oil seal surface first compress the front shock absorber and then wipe clean and then press repeat the above operation 10...

Page 62: ...shock absorber has a lot of mud and sand it should be cleaned in time to prevent soft and big stones from scratching the chromed parts and causing rust Non professionals should not disassemble the re...

Page 63: ...to remove one M6 14 shoulder bolt 3 at the connection between the middle of the tail skirt and the rear armrest Grasp the rear armrest anywhere with both hands lift the rear armrest up in the directi...

Page 64: ...arts Check whether the front disc brake caliper bolts front shock absorber bottom cylinder bolts lower link plate bolts rear rocker arm and engine connecting bolts rear wheel spline shaft nuts rear di...

Page 65: ...brake handle After starting the vehicle put down the side brackets and the flame should be automatically turned off otherwise it is necessary to troubleshoot the flameout switch or brake switch failu...

Page 66: ...main support shaft 3 from right to left Pay attention to the protection measures at the spring of the main support to prevent the spring of the main support from suddenly loosening and flying out and...

Page 67: ...e is prohibited MOD key Select the next item Operate this button when driving a vehicle is prohibited Windshield switch Press the windshield glass to complete from retracting to opening or from openin...

Page 68: ...Caution The height of the headlights is too high or too low which will affect safe driving The light height should be adjusted reasonably according to the presence or absence of the occupant and the w...

Page 69: ...box After opening the fuse box cover check whether the fuse is normal No Name Function Specification Main insurance Protect all circuits 25A ECM Protect ECM ECM relay oil pump relay and other electric...

Page 70: ...is judged as a switch failure Otherwise check for cable or headlight failures c The E S mode cannot be switched by pressing the ECO button Disconnect the switch and short the ECO button switch line I...

Page 71: ...on There should be more than 5 seconds interval when adjusting or checking the horn Continuous sounding may cause ablation of the internal coil of the horn The horn is a riveted structure which is dif...

Page 72: ...see if the turn signal is on Light failure Y Check whether the meter is on Y Press the double flash button is it on There is also a problem with the double flash button The chances are small The near...

Page 73: ...rocess of lamp troubleshooting After power on turn on the left right hand switch and the lamp does not light up Check whether the lighting terminal is plugged in N Reconnect the terminals Y Unplug the...

Page 74: ...ull the engine speed above 3000 rpm d After releasing the throttle turn off the flameout switch and lock the car e After waiting for 5 seconds unlock the vehicle again to complete the reset of the EFI...

Page 75: ...code according to the number of flashes For example P0201 flashes in the following way continuous flashing 10 times intermittent 1 second continuous flashing 2 times intermittent 1 second continuous f...

Page 76: ...amp driver stage circuit failure P0262 The 1 cylinder injector control circuit is shorted to the power supply P0444 Canister solenoid valve open P0322 No speed sensor pulse signal open circuit or shor...

Page 77: ...EFI parts Caution Once the EFI components are disassembled the EFI system needs to be reset For details see the service information in this chapter Fuel pumps three in one sensors stepping motors ECUs...

Page 78: ...ot be connected in reverse It is forbidden to disassemble the fuel inlet filter which may cause foreign matter to enter the fuel pump or block the fuel injector The disassembly of the fuel pump or hig...

Page 79: ...Green red Black white Red green Oil pump White black Red bl ack White black Green y ellow Main relay Red White black Black white Orange black 6 Fuel injector When the engine is unstable and weak and t...

Page 80: ...Spark plug Removing the spark plug Put away the side brackets use the main bracket to park the vehicle firmly and unlock the vehicle turn the flameout switch to hold the brake handle and place the spa...

Page 81: ...of the throttle valve body position sensor and the external intake pressure sensor see the throttle valve body section above Air filter intake air temperature sensor Remove the temperature sensor fro...

Page 82: ...it is white it means that the silicon poisoning has been damaged and needs to be replaced if it is black it means that there is carbon deposits that can be cleaned up and continue to use if it is bro...

Page 83: ...ed intermittently it is necessary to check whether the crankshaft position sensor is normal The crankshaft position sensor is installed on the right crankcase cover and integrated with the magneto sta...

Page 84: ...the start button is pressed the starter motor can drive the engine to run normally When there are signs of a car but cannot start you can refer to the following diagnosis process to troubleshoot the...

Page 85: ...vent pipe and other hoses High idling speed of hot car When a cold car occurs it can run at a normal fast idling speed After a hot car the idling speed does not fall back to 1500 1700 rpm You can refe...

Page 86: ...c field should be installed as far away as possible from the relay wiring harness and electrical device box or not installed Y Check whether the black and white wire and red wire of the ECM main relay...

Page 87: ...The EFI parts are damaged Y After checking the route judge according to the process There has been a power outage in the whole vehicle Reset the EFI system Y High idle speed The throttle body has a la...

Page 88: ...88 152 Electrical schematic diagram of EFI system...

Page 89: ...battery has sufficient power If the power is insufficient it may result in a slow start speed or weak spark intensity of the spark plug or no spark Tool Multimeter 7 The driving conditions and mainte...

Page 90: ...guide Check whether the gap is normal If it is abnormal replace the corresponding parts The accumulated gasoline may be caused by the mixture being too thick when the cold engine is started and it ca...

Page 91: ...the main wiring harness and there are 3 in total For detailed illustrations please refer to the EFI relay section in the Electronic Injection System chapter of this manual The magneto stator and crank...

Page 92: ...f the right crankcase cover and cylinder head cover of the engine are removed to check the timing the crankcase cover gasket must be replaced it is recommended that the cylinder head cover gasket is a...

Page 93: ...lified b Tighten the timing chain check again and align the line immediately after the T mark on the flywheel with the triangle mark on the box c Rotate the camshaft to align the dots with the camshaf...

Page 94: ...ged and in good condition Check whether the main fuse 25A and ECM fuse 15A are blown If the fuse is replaced with a new one and it is blown out you need to troubleshoot the line first The starting mot...

Page 95: ...lowly Check whether the battery power is insufficient Check whether the battery cable connector is in poor contact Check whether the starter motor cable is in poor contact Check whether the starter mo...

Page 96: ...mm 0 98in and a wire diameter of 3mm 0 12in 1 Remove the starter motor a Refer to the steps of removing the rear storage box to remove the rear storage box For the removal steps refer to the stepping...

Page 97: ...r fixing the starter motor 12 1 5 N m 1 2 0 2 kgf m 9 1 lbf ft And mark with a marker 2 Disassemble the starter motor Caution If the magnet tile pulls the electric pole towards the motor housing the c...

Page 98: ...s worn and damaged Also check whether the outer ring fits tightly with the front cover Motor back cover Check whether the bushing of the back cover is worn or damaged Check whether the brush is damage...

Page 99: ...etween the yellow red wire and the ground wire should be the battery voltage 2 2 Ground wire The vehicle is powered off and locked Set the multimeter to the buzzer position connect one test lead to th...

Page 100: ...hrottle opening and closing and idle speed control 9 Cannot use carburetor cleaning agent 10 Throttle valve body parts not specified in this manual shall not be disassembled After reinstalling the bat...

Page 101: ...val of the fuel tank assembly Hold up the fuel tank assembly and turn it clockwise as shown in Figure 1 while turning let the seam welding on the right side of the fuel tank go down to the bottom of t...

Page 102: ...ery rubber pad 3 is pasted on the shell of the fuel tank which is difficult to remove If you need to remove it you can use a heat gun to heat it and tear it off or use a cleaning agent that removes th...

Page 103: ...d the small water tank When the engine is not completely cooled opening the water tank cover may cause the coolant to spray out and cause burns The water tank cover must be opened after the water tank...

Page 104: ...k 5 Water outlet pipe of main water tank 6 Water oil shared sensor 7 Thermostat 8 Water pump cover assembly Coolant flow diagram 1 Water inlet pipe 2 Water outlet pipe of main water tank 3 Water inlet...

Page 105: ...component after the bolt Place an oil pan under it and clamp it with hoop pliers 10 5 Remove the hoop 2 about 40mm 1 6 in in the direction of the arrow wear waterproof gloves with both hands pull out...

Page 106: ...utlet pipe 9 Water pump cover assembly Caution The bolt 3 at the thermostat is an exhaust bolt and the bolt at the water pump cover is a bolt for cooling liquid There are O rings of 5 6 1 at both loca...

Page 107: ...fins Except the gas pressure is specified when doing the air tightness test the compressed air of 160kPa 1 63 Kgf cm2 23 2 psi shall be introduced and the parts shall be immersed in water and left fo...

Page 108: ...ee of bubbles When the compressed air is raised to 110kPa 1 12Kgf cm2 16 psi bubbles should appear 3 Auxiliary water tank First check whether the rubber cover is aging and cracked if any replace it If...

Page 109: ...does not meet the specified value it should be replaced Or use a thermometer water heater and container to test The initial opening temperature of the thermostat is 80 84 176 183 F and the core moving...

Page 110: ...pads or brake discs have oil stains the braking force will be reduced The contaminated brake pads should be replaced and the oil stains on the brake discs can be removed with a good quality degreasing...

Page 111: ...not within the scope of the three guarantees Operate in a dry dust less or dust free environment Disassemble the front disc brake main pump a Remove the cover according to the steps in the removal dir...

Page 112: ...ng the brake pads d Front disc brake caliper disassembly A dust blow gun can be used to blow in compressed air from the oil pipe bolts to blow out the piston Pay attention to placing towels or other s...

Page 113: ...nsor installed on the front disc brake caliper mounting plate is deformed and the rear wheel is to check whether the mounting position on the rear rocker arm is deformed and whether the rear wheel nut...

Page 114: ...hod of FC HU and wheel speed sensor caliper please refer to the section Removing the front disc brake caliper c Remove the 3 wire ties and remove the wheel speed sensor wire Check whether the cable is...

Page 115: ...to remove the bolt that fixes the clamp f Check whether the surface of the removed hose is aging cracked damaged abraded etc Wipe up the remaining brake fluid with a non woven cloth and then wrap the...

Page 116: ...draulic control unit apply a small amount of brake fluid to the thread After replacing the new hydraulic control unit you need to refill the brake fluid and exhaust the air to ensure that the brakes a...

Page 117: ...icator light is always on and the ABS function is invalid When the vehicle is powered on the ABS indicator on the meter flashes continuously for 30 seconds the indicator light is always on Press the A...

Page 118: ...he throttle turn off the flameout switch and lock the car e After waiting for 5 seconds unlock the vehicle again to complete the reset of the EFI system 4 The vehicle should be powered off before disa...

Page 119: ...tifier failure N Faucet lock failure or short circuit Measure the battery voltage first then measure the charging voltage after starting the engine Battery voltage charging voltage 14 5 14 9 V N Check...

Page 120: ...152 Charging system layout diagram 1 Charging port PKE 2 Main fuse 25A 3 Battery 4 Magnetic motor 5 Rectifier Electrical schematic diagram Letter G R Y Chinese green Red yellow English Green Red Yell...

Page 121: ...chapter Inspection of sound light and electrical devices in the chapter Maintenance or the instructions delivered with the car Charging system check 1 Leakage test a Turn off the vehicle and cut off t...

Page 122: ...he right side of the frame and unplug the two connectors of the rectifier b Refer to the steps of Remove the rear armrest and rear apron Use 4 hex socket to remove the two M6 s connecting the rear inn...

Page 123: ...te the environment or water sources 7 Swallowing or inhaling coolant brake fluid etc will cause certain harm to the human body Any exposed skin such as hands and face should be cleaned thoroughly afte...

Page 124: ...124 152 Exploded view of front fork components Directional exploded view...

Page 125: ...125 152 Front fork exploded view...

Page 126: ...126 152 Exploded view of lower link board...

Page 127: ...the direction grasp the direction near the side of the seat cushion and remove the upper cover in the direction of the arrow The direction of the upper cover 2 Remove the components a Use 5 inner hex...

Page 128: ...t handlebar switches it is necessary to align the bolts 5c and 6c with the positioning holes on the handlebar and then tighten them with a cross screwdriver Use the 5 hexagonal socket to tighten the b...

Page 129: ...the disc brake oil cup and then separate it 2 brake pads b Put the front wheel in the middle of the front shock absorber shake the front wheel left and right to make the disc brake disc snap into the...

Page 130: ...heel in the air observe from the front that the disc brake disc swings when the front wheel rotates and the disc brake disc deformation is detected c Touch the surface of the disc brake disc with your...

Page 131: ...n and use a tyre raking machine to take out the tires c Use a lifter to assemble new rims or new tires And the front tire pressure is charged to the standard value D350 front tire pressure 240kPa 34 8...

Page 132: ...ith 6 hexagonal socket Torque 25N m 2 6 kgf m 18 lbf ft c Use the same method to install another shock absorber d Pick up the front wheel and install the bushing align the mounting holes between the t...

Page 133: ...oper position nearby 3 Removing the direction pad a Refer to Removing the cover to remove the head cover as shown in the figure b Untie the binding band and then take out the handle switch harness and...

Page 134: ...w in the second steering column adjusting nut 5 screw the second steering column adjusting nut 5 to align with the gap of the first steering column adjusting nut 5 and finally put in the snap washer 4...

Page 135: ...ve electrode wire and then use a cross screwdriver to screw back the bolts on the battery c Take out all the fuse boxes beside the battery d Take out the decorative buckle 2 on the bolt and use the 4...

Page 136: ...t in the direction of the arrow Note Pull out carefully to avoid scratching the cover and tail lamp h Remove the left pedal by referring to Removing the Spark plig i Remove the right paedal and surrou...

Page 137: ...the muffler and the other end is connected to the main cable do not unplug the wrong plug f Locate and pull out the plug of the magneto stator charging cable at the left frame Caution One end of the...

Page 138: ...3 30N m 3 1 kgf m 22 lbf ft d The two people hold the left and right handlebars and frames respectively push the whole motorcycle forward push it to a flat and wide place pull down the side bracket a...

Page 139: ...hexagon to tighten Finally install all the pipes connecting the brake calipers and the wheel speed sensor into the corresponding clamps and arrange the lines d One person uses 21 socket to extend into...

Page 140: ...buckle from breaking 1 Windshield 2 Front headlight 3 Front right storage box 4 Front right panel 5 Srrounding the right 6 Fuel tank cover right part 7 Right pedal 8 Right side cover 9 Seat 10 Tail sk...

Page 141: ...e 3 Front right pedal pad 4 Rear right pedal pad 5 Rear right pedal pad presser 6 Fuel tank cover 7 Middle part of the fuel tank cover 8 Front left pedal pad pressure plate 9 Front left pedal rubber p...

Page 142: ...hexagon to loosen the 4 M6 14 bolts on the left and right decorative covers of the windshield c Take out the left and right decorative covers of the windshield the windshield and the rubber pads of th...

Page 143: ...n for 2 seconds to shut down the vehicle b Hold the seat cushion with one hand remove the 3 M6 nuts fixed on the seat cushion bracket by 10 double offset ring spanner or 10 sleeve grasp the seat cushi...

Page 144: ...e the same method to remove the left part of the fuel tank cover plate Removal of the front left and right panels a Remove M6 12 bolts 1 from the front left and right panels with 4 hexagonal socket an...

Page 145: ...el and lift it in the direction of the big arrow and pull it outward to take out the speedometer panel Removal of front left and right panel bottom lining a Use the 4 hexagonal socket to remove one M6...

Page 146: ...the windshield motor bushing and buffer rubber b Remove the two M6 16 on the hydraulic control unit bracket with 8 socket Remove the hydraulic control unit with bolts Remove M8 from horn bracket with...

Page 147: ...connector from the left side of the fuel tank and sort out the harness of the fuel tank lock d Remove the oil tank cover Press the cushion bracket with one hand and take out the middle of the tank cov...

Page 148: ...e the battery to connect the positive and negative poles of the main harness to turn on the motorcycle Press the switch next to the front right storage box switch to open the front left storage box 3...

Page 149: ...atching charging port rubber sleeve g Remove 2 M6 16 with 5 hexagonal socket Separate the right storage box lock bracket from the right storage box lock h Use a Phillips screwdriver to remove three M4...

Page 150: ...art in the same way Disassembly of the surrounding bottom a Grasp the rear part of the around the bottom plate by hand and pull it back in the direction of arrow until the bottom plate is taken out Re...

Page 151: ...he tail skirt remove one bushing 2 and one buffer rubber 3 Take off the left part of the tail skirt e Remove the right part of the tail skirt in the same way f Remove two M6 with 4 socket head 14 Shou...

Page 152: ...out the rectifier connectors one by one Take out the rectifier f One person lifts the rear or both sides of the frame in the direction of the big arrow until the gap between the frame and the rear sh...

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