Zontes ZT310-V1 EURO V Service Manual Download

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2021/1/13

Service manual

ZT310-V

(EURO V)

Summary of Contents for ZT310-V1 EURO V

Page 1: ...2021 1 13 Service manual ZT310 V1 EURO V ...

Page 2: ...loid battery 13 2 Frame engine combination 2 1 Engine decorative cover components 14 Engine left rear cover right cover decorative 2 2 Frame Engine Combination1 15 Disassemble the rear shock absorber rod plate and pipeline 2 3 Frame Engine Combination 2 16 Hanging piece bracket component Lower shroud bracket 3 Intake system components 3 1 Intake system components Delphi EFI 17 Throttle valve body ...

Page 3: ... assembly 1 30 Vice fender extension cable 4 8 Rear auxiliary mud plate assembly 2 31 Disassembled rear mud plate bracket assembly 4 9 Rear auxiliary mud plate assembly 3 32 Disassembled rear mud plate bracket assembly 4 10 Rear turn signal after sale parts 33 Rear left and right turn signals and rear license plate lights for sale 4 11 Chain adjuster assembly 34 Disassemble chain adjuster and main...

Page 4: ... 5 6 Shift lever assembly 47 5 7 Front left footrest component 3 48 Decompose the front left footrest component 5 8 Rear pedal assembly 49 5 9 Rear right pedal bracket components 50 5 10 Rear left pedal bracket components 51 6 Cooling system component 6 1 Change the oil 52 6 2 Replace the oil filter 53 6 3 Add coolant 54 6 4 Radiator covercomponent 1 55 Disassemble the radiator covercomponent 6 5 ...

Page 5: ...wheel speed sensor component front mud plate component 7 10 Headlights assembly 1 71 Headlights assembly cable plug 7 11 Headlights assembly 2 72 Remove headlights 7 12 Headlights assembly 3 73 Remove headlights upper bracket front turning signal 7 13 Right hand component 74 Remove right rear view mirror right hand rubber sleeve balance block Replace the front brake switch 7 14 Left hand component...

Page 6: ...fuel tank cover fuel tank cover fuel tank lock 8 3 Fuel tank outer cover components 86 Disassemble the fuel tank outer cover rotating bracket 8 4 Fuel pump 87 Disassemble the fuel pump fuel tank buffer rubber 8 5 Fuel tank front decorative cover 88 Disassemble the fuel tank front decorative cover USB charging cable 8 6 Fuel tank decorative cover lower part 89 8 7 Fuel tank decorative cover compone...

Page 7: ... decorative cover decorative cover bracket 11 5 Tail skirt taillight component 3 101 Disassemble the rear aluminum alloy bracket 11 6 Tail skirt taillight component 4 102 Rear skirt taillight component 12 Cushion component 12 1 Cushion 103 Discomponent and component cushion seat cushion rubber separately purchased parts 13 Muffler component 13 1 Oxygen sensor 104 13 1 Muffler component 1 105 Disas...

Page 8: ...vement of the product and other changesFor colors or upgrades please refer to the part codes on the official website This manual will not be listed in detail If the part names in this manual are inconsistent with the official website the official website shall prevail This manual is compiled on the basis of the chinese version of ZT310 V1 version The export version is different from the chinese ve...

Page 9: ...he disassembly and assembly process This description will not be added if there is such a situation later in this manual PROCEDURE 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 Relay and ECU Locate the main harness rubber sleeve on the right side of the fr...

Page 10: ...5 16 bolt 2 16 1050954 017000 LDK8RTIP 0 8 sparking plug 1 Fig 2 FRAME ELECTRONIC PARTS COMPONENT Electronic parts COMPONENT 2 PROCEDURE Horn Take off the plug of horn take the horn by one hand using 8 plum wrench rotate the screw by another hand remove the holder then take off the horn Flameout switch Find and take off the plug of the flameout swich press and take off the cable clip cut ribbon Us...

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 with your hand directly Wear block Use a Phillips screwdriver to remove the 2 bolts and then remove the wear block CAUTION It must be dismantled them first such as the cushion fuel tank cover inner fue...

Page 12: ... nimbleness The top adjusting nut only needs to rotate to the bottom of the nut groove alignment not too tight to prevent the rubber pad from deformation too larg ZT250 S Down connected plate selfmade with blowout patch component CAUTION Remove the head part component handlebarcomponent and front shock absorber component first Please pay attentin to fix the awaiting repair motorcycles during disas...

Page 13: ...EDURE Checking the cushion loop Checking whether the cushion loop is frayed If there is one it needs to be replaceds fix the cushion loop well and paint the lubricating grease on it with appropriate tool Replacing the engine oil filter screen Put the oil pan on the bottom and use the 21 sleeve to remove the oil cold joint O ring and oil filter screen When replacing the oil filter screen the O ring...

Page 14: ...ould be installed last 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 Use a 4 allen wrench to remove two bolts to remove the PKE bracket Fuse The band version of the PKE assembly uses 2 small 15A fuses Charging the charging DC interface the charging fuse the PKE fuse which must be unplugged when char...

Page 15: ...and take out the right trim cover components Remove the bushing buffer rubber from the right trim cover components Using 8 sleeve disassemble the bolts and take out the bracket Using 8 sleevedisassemble the bolts and take out the bracket Use a screwdriver to loosen clamp unplug the water inlet pipe Engine left rear cover Using 8 sleeve remove the bolt disassemble the rear cover Anti scald left muf...

Page 16: ...et pipe and then insert the water pipe back Use an 8 sleeve to remove the 2 bolts remove the rear brake main pump assembly and then reinstall the bolt Refer to the detachment procedure to remove the end of the clutch line connected to the engine After loosening the pipe clamp pull out the throttle valve body assembly backward to separate it from the intake manifold Use an 8 sleeve to remove the le...

Page 17: ...by the dumping of the vehicle during the disassembly process single operation is strictly prohibited All standard parts must meet the standard torque value during reassembly and re add the oil according to the instructions PROCEDURE Front footrest bracket wind fairing bracket Fix the heads of bolts and with a 14 sleeve and remove the 2 nuts on the left with a 14 sleeve Remove the front left foot s...

Page 18: ...e exhaust port of the engine and then use the rubber plug that was delivered with the bike Plug it well to prevent foreign matter from entering and damaging the engine Remove the air filter assembly and splint nut 3 Throttle valve assembly Use a 8 wrench to remove the bolt and remove the throttle valve assembly Using 4 inner hexagon socket loosen the pipe clamp between the intake pipe assembly and...

Page 19: ... the adsorption tube and pull out the intake pipe near one end of the carbon tank Pull the carbon tank down in the direction indicated by arrow Carbon tank electromangnetic valve First remove the connector of the carbon tank solenoid valve Then remove the nut with the 10 sleeve remove the solenoid valve assembly Loosen the hoop and pull out the intake pipe and the outlet pipe CAUTION It needs to r...

Page 20: ... right cover in the order of Maintenance The vehicle should be pushed to a dust free or dust free place before the rubber plug of the air filter is removed and the filter core should be continuously blown into the air filter with a high pressure air gun for 10 to 15 minutes and then the plug should be covered back Blow the dirt out of the air inlet with a high pressure air gun or use a cleaning de...

Page 21: ...ment 1 PROCEDURE Side cover Refer to the method of removing the side cover to remove the left and right side covers Connecting rod plate Remove the connecting rod plate first by referring to the steps of the shock absorbing connecting rod plate after removal Support the whole motorcycle Tilt the body to the left with the side bracket as the fulcrum and then use a firm stool to support the muffler ...

Page 22: ...ver is facing up Remove the two bolts of the right fuse box and pull out the fuse box and arrange the cables Air filter Clamp the hoop with pliers and remove the boss on the canister Pull out the suction tube and pull out the intake pipe Place a rag under the air filter and use a needle nose pliers to pull out the waste tubing at the bottom CAUTION Always keep the disc brake oil cup cover facing u...

Page 23: ...place the air filter element 3 PROCEDURE Air filter Locate the lock pins at the four corners of the air filter Open the card and remove the four bolts with a Phillips screwdriver Electric device box Using 4 inner hexagon socket remove the bolt from the bottom remove the bush and the cushion rubber Pull down the bottom of the rear cover slightly and remove the battery bottom cover Air filter bottom...

Page 24: ...eferring to the removal procedure CAUTION The sealing ring must be assembled in place Leakage or assembly may not cause dust to enter the engine In severe cases the internal parts of the engine may be damaged Note that the torque should not be too large when locking the Phillips bolt to prevent damage to the parts When flushing the vehicle be careful not to allow water to enter the air filter If a...

Page 25: ...d 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 adjuster at the arrow indication The counterclockwise direction is to tighten the chain and the clockwise b direction is loose The chain sag is 18 25mm If it is too large it will cause the chain to be ac...

Page 26: ... rubber of flanging bushing φ8 5 φ14 1 1 4 ZT310 R1 sprocket baffle 1 PROCEDURE Sprocket baffle Using 4 inner hexagon socket remove bolt remove the flange bushing cushion rubber finally remove the sprocket baffle CAUTION When reassembling pay attention to the limit boss on the sprocket baffle to be inserted into the limit hole of the rear fork Fig 2 Rear wheel swinging arm assembly Sprocket baffle...

Page 27: ...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 pull it out in the axial direction remove the locking spring in the direction indicated by the arrow b One person stepped on the brake pedal to prevent the rear wheel from rotating One person removed the nut wit...

Page 28: ...e 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 Remove 5 pieces of sprocket cushion rubber from the outer casing assembly Remove the O ring from the inner casing The outer casing assembly already contains an oil seal and a bearing which are attached to the outer casing fo...

Page 29: ... the tire pressure sensor 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 is ware to the marker change the tire with same specification See details in user manual Ingradiant of tire include semi hot melt rubber Area with too high temperature is not suit...

Page 30: ...s 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 the tubing bracket 5 Cut the 4 straps 6 at the arrow indications and find the inside of the left rear skirt and remove the joint of the rear slab adapter cable Locate the wheel speed sensor connector near the right air f...

Page 31: ... the 2 cable ties on the right side of the canister and 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 motorcycle from the vicinity of the battery and remove it to the rear auxiliary mudboard assembly then roll up the adapter cable and tie it with a rope CAUTION The s...

Page 32: ...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 flange bushing the rubber pad and finally remove the retaining plate Aluminum alloy bracket Use a 10 sleeve to remove 3 bolts and bolts and use a 4 inner hexagon to remove 2 bolts then remove 5 pcs of spring washer Separate t...

Page 33: ...icense plate cushion rubber 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 back of the rear mudguard fender Steering lights fender sub assemblies Using 4 inner hexagon socket remove the bolts on the left and right sides and remove the flange bushing cushi...

Page 34: ...t 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 turning light follow the steps above dismantle right press line plank of a and press line plank c CAUTION Avoid fasterning the bolt on the cable while reassembling in case of shrt circuit Rear turning ligh...

Page 35: ...er limit block and remove the seal ring Chain adjuster assembly After removing the bushing remove the chain adjuster assembly from the rear fork If you have difficulty removing it you can use a flat blade screwdriver to insert the slot at the arrow indication and you can open it with a little force Chain adjuster assembly bearing maintenance It is recommended to inspect maintain and clean the bear...

Page 36: ...on 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 remove the bolt 1 at the rear left side and remove the bushing 2 and cushion rubber 3 Hold the rear inner mud plate use an 8 sleeve to remove the bolt on the upper middle of the left side and remove the bush and the cushion rubber The chain decal can be h...

Page 37: ...orcycle before proceeding to the next step One person uses 14 sleeve to hold the head of bolt or and one person uses 14 sleeve to remove nut Remove the rear shock absorber 3 from the motorcycle Adjust the rear absorber Use hook wrench to loosen adjustable nut and rotate adjustable nut If the nut is rotated towards the arrow direction the spring becomes harder Conversly the absorber is softer Tight...

Page 38: ...leeve to remove the bolt 1 Grasp the rear flat fork connecting rod assembly pull out the bolts and and then remove the connecting rod assembly Remove the 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 no malfunction it is not recommended to disassemble it by yourself Rear shock absorber connecti...

Page 39: ...94100 001000 ZT250 S needle bearing HK2016 2 17 1244200 130000 ZT310 rear shock absorber KRH oil seal 2 18 1250602 038000 ZT310 rear shock absorber KRH needle roller bearings 1 Fig 15 Rear wheel swinging arm component Rear shock absorber rod assembly 2 Rear shock absorber connecting rod assembly After sales parts PROCEDURE Rear shock absorber connecting rod assembly Remove the front bushing Use 6 ...

Page 40: ... with the 24 socket sleeve Person 2 disassemble nut with the 30 socket sleeve Person 1 hold the rear swinging arm assembly Person 2 take off rear swinging arm after disassembling rear swinging arm axle with suitable tool Remove the bushing and the left dust proof rubber plug and the dust proof rubber plug from the rear fork assembly Abrasionproof block of rear swinging arm Remove the five bolts an...

Page 41: ...ake 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 nut with strait screwdriver Tighten the pin axle with 14mm hex socket tool Torque is 34N m Use a 12mm wrench to lock the lower slide shaft Step on braking pedal several times until braking force is ...

Page 42: ...n Step gently on the pedal constantly Do not ride the motorcycle until the braking force is recovered CAUTION Support the motorcycle well on flat ground before checking Check regularly if the braking liquid surface is between UPPER and LOWER If liquid surface is below LOWER check the arrester status and confirm if the braking system is leaking If the braking liquid is accidently swallowed contact ...

Page 43: ...hod 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 little bit the groove in the middle while dragging it out Reassemble after the height is suitable Pay attention to the aligning of the groove in the middle Adjust the height of brake pedal Use an 10 open end wrench to loosen the nut Sp...

Page 44: ... right pedal mounting position adjustment 1 PROCEDURE Front pedal bracket Refer to the step of remove thte shroud component No need to remove the shroud component in the Lower shroud component Lower shroud component 1 Using 6 inner hexagon socket remove the the bolts under the radiator cover component take off the bushing buffer rubber Grasp the anti scalding plate and use an 8 sleeve to remove th...

Page 45: ...x wrench to remove the nut 3 and the fixing piece 4 on the inner side of the front right foot support Install the front right foot pedal assembly component forward with a hole align the fixing piece and then tighten the nut pay attention to the assembly direction of the fixing piece Use a 10 open end wrench to fix the screw and use a 14 open end wrench to loosen the lock nut Adjust the brake pedal...

Page 46: ...o remove the nut and the fixing piece on the inner side of the front left pedal bracket move forward to one mounting hole for the front left pedal assembly After the fixing piece is aligned tighten the nut and then reassemble the pedal assembly Pay attention to the assembly direction of the fixing piece Use the 10 open end wrench to install the bushing to the adjustment screw use 1 piece bushing f...

Page 47: ...ber pad 1 PROCEDURE Front right pedal bracket component Refer to the steps above of removing the pedal bracket component Use a 13 sleeve to remove the nut remove the fixing plate and then remove the support spacer brake pedal brake pedal torsion spring and the front right pedal assembly in sequence Front right pedal component Remove the circlip remove the pin and separate the foot support torsion ...

Page 48: ...ONENT PROCEDURE Gear shift rod assembly Use the 10 open end wrench to loosen the nut and nut use the 8 open end wrench to rotate the groove of adjustment screw and take it off Take off the nut and nut Using the 10 open end wrench to fix the nut then using the 8 sleeve remove the bolts take off the bearing Using the 8 sleeve remove the bolts at the shift lever step rocker take off the bearing Using...

Page 49: ...eft pedal rubber pad 1 PROCEDURE Front left pedal bracket component Refer to to steps above remove the pedal bracket component Use a 13 sleeve to remove the nut remove the fixing piece and then remove the support gasket the shift lever and the front left pedal assembly in sequence Front left pedal component Remove the circlip remove the pin and separate the pedal support torsion spring non standar...

Page 50: ...edal bracket assembly Using 6 inner hexagon socket remove 3 pieces bolts on the left side take off the left pedal bracket assembly Using 6 inner hexagon socket remove 3 pieces bolts on the right side take off the right pedal bracket assembly CAUTION The rear left and right foot pedal brackets are always equipped with the whole set including the side cover round glue pedal bracket pedal etc Fig 8 F...

Page 51: ...FOOT PEDAL COMPONENT PROCEDURE Rear right pedal bracket assembly Take off 3 pieces side cover round glue from the right pedal bracket Use 8 sleeve to remove bolt use 6 inner hexagon to remove bolt take off the cover plate Remove the bolt and take off the cover Take off the pedal torsion and bushing Take off the rear pedal component Take off the pedal top film and footrest top plate hinge pin Take ...

Page 52: ... PEDAL COMPONENT Rear left pedal bracket components PROCEDURE Rear left pedal bracket 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 and bushing Take off the rear pedal component Take off the pedal top film and footrest top plate hinge pin Take off...

Page 53: ...read Too week will cause leakage of 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 reassemble the engine oil gauge Start the engine and test it under different rotation speed for 2 minuts Check if the engine oil leaks Run the engine at idling speed for 5 minuts than shut down the engine for ...

Page 54: ...e oil filter Place holder to collect wasted engine oil under right crankcase cover Disassemble nut with 10 sleeve Rotate slightly engine oil refined filter cover and take it off when it is loosen Take off seal ring Change engine oil filter Check if seal ring is broken Change the seal ring along with engine oil filter is suggested When reassembling pleas check carefully if the spring seal ring are ...

Page 55: ...ted Swallowing or inhaling cooling 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 hosipital If it s inhaled please move to open air If it s spilt to the eye clean it with big quantity of clean water and see doctor in time Be sure the cooling liquid is ...

Page 56: ...racket take off bushing and buffer rubber Remove the expansion pin after pressing the intermediate part of the expansion screw Turn the front of the car to the left Using 4 inner hexagon socket remove 3 bolts take off the bushing and buffer rubber Grab the right side of the trim cover and pull it out as indicated by the green arrow at the arrow Grab the same part of the left side of the trim cover...

Page 57: ...0 V radiator trim cover front left dark grey 1 Fig 5 COOLING SYSTEM COMPONENT Radiator covercomponent 2 PROCEDURE Radiator decorative cover assembly Using cross screwdriver Remove the self tapping screws and pry the four snaps in the direction indicated by the arrow to separate the right rear part and the right front part Remove the 3 plywood nuts from the right front Remove the expansion pin afte...

Page 58: ...e 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 tank and remove the hoop Vent the coolant in the secondary tank Clamp the clamp on the leak pipe with pliers and pull it out Subsequent production of motocycles will reduce the clamps for leak pipe Clamp the hoop with pliers and pull the water pipe out of the sub ta...

Page 59: ... O ring Engine oil outlet tube Disassemble oil passing bolt Remove 2seal gasket with a 8 sleeve pictured B Disassemble oil passing bolt seal gasket with a 14 sleeve pictured C Disassemble bolt with a 8 sleeve Take off engine oil outlet tube engine oil intake tube pictured D The oil outlet pipe and the oil inlet pipe Remove 2 o ring CAUTION Disassembling the cooling system while the motorcycle is h...

Page 60: ...bly procedure to vent the coolant in the sub tank After placing the oil pan or other container 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 with a funnel or other device open the cooling liquid tank cover to accelerate the draining of cooling liqui...

Page 61: ...Using 8 sleeve remove the bolt Pull out the water pipe after wearing the waterproof gloves Remove the hoop Use the pliers to remove the hoop on the right side and pull out the engine inlet pipe Close the radiator end and remove the hoop Use a flat blade screwdriver to loosen the three clamps and remove the boss indicated by the arrow Remove the inlet pipe and the water pipe and then remove the cla...

Page 62: ...NT Main water tank assembly 2 PROCEDURE Main tank assembly Remove 4 pieces of side cover round glue from the main water tank After wearing the waterproof gloves clamp the hoop with pliers and remove the hoop after removing the anti slip boss Remove the small circulation water pipe or and take off the two hoops Remove the outlet pipe and the hoop as previously described CAUTION Cooling liquid is to...

Page 63: ...ent the cable from coming out Big adjustment If fine adjustment cannot be achieved loosen the nuts with an 14 open end wrench rotate the adjustment screw and finally tighten the nuts CAUTION The motorcycle support should be fixed during disassembly to prevent accidents caused by incline Throttle line adjustment should be noted as follows After adjustment ensure that the throttle can be reset autom...

Page 64: ...olts at a Rotate the two turn signal assemblies up to expose the head of the bolt The driver rides the motorcycle and the motorcycle is upright The other person inserts a6 the inner hexagon will loosen the bolts on both sides and adjust the light to the proper position to lock Note that tick marks aligned on both sides CAUTION Light height adjustment should be noted as follows High or too high lig...

Page 65: ...ctive 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 nut and the adjusting screw to the groove on the rocker arm Assemble the clutch cable into place according to the original alignment Rotate the nut up to the top of the thread of the adjusting screw and screw the nut to the b...

Page 66: ... and and then remove bolt that comes with the switch Switch the upper and lower parts of the switch Remove the throttle cable from the right hand and remove 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 line First pass the throttle cable into the cable hole in the lower part of the switch Fit the cylindrical co...

Page 67: ... the spacer and remove the bolt with the 6 Allen tool The direction of the upper board assembly wrapped with a clean cloth and then placed to prevent scratches Remove the lock washer remove the upper adjustment nut with a special four jaw shank or hook wrench and remove the pad If the steering resistance is too large turn the lower adjustment nut counterclockwise If the brake is slightly swaying o...

Page 68: ...nnector 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 replacement be sure to continuously hold the swing arm and tap the disc brake main pump to remove a small amount of gas entering the brake oil circuit and confirm that the brake is returned to normal Rocker Rotating...

Page 69: ...athead screwdriver to lock the nut Repeatedly holding the brake handle until braking force is restored Front brake caliper mounting plate Remove the mounting plate from the caliper Be careful not to lose the shrapnel of the front brake caliper CAUTION The motorcycle support should be fixed before operation Check the brake discs and brake discs regularly for wear Regularly check if the brake fluid ...

Page 70: ... the right sleeve and front wheel assembly Finally remove the right fixing sleeve and use the hexagonal tool to remove the 2 bolts of the right front shock absorber Brake disc ABS ring gear Using 6 inner hexagon socket remove the bolt and then remove the ABS ring gear and the brake disc Tire pressure wireless built in sensor Remove the valve cap that comes with the tire pressure wireless built in ...

Page 71: ...n remove the clamp Use 4 inner hexagon to remove bolt and remove sensor Front disc brake caliper Use a 8 sleeve to remove the bolt use a 14 sleeve to remove the bolt let the caliper sag naturally and it is strictly forbidden to invert the caliper It is forbidden to invert the caliper to prevent the air from entering and causing the brake to fail Front mudguard Remove the 6 bolts with the 4 hexagon...

Page 72: ...hexagon socket and remove the spring washer Turn the headlight assembly in the direction of the arrow expose all cable connectors Cut two tie straps Pull the wire clip from the back of the storage box with a pointed tip and pull it out of the storage box First pull out the turn signal line head Then separate all the plugs from the main cable and arrange all the cables Remove the line plug from the...

Page 73: ...Turn the headlight assembly forward to expose the bolt at the bottom of the storage box Using 4 inner hexagon socket remove the bolt and remove the bushing and cushion rubber Turn the headlight upside down and remove the two bolts at the bottom of the lower link plate with a 4 inner hexagon Remove the headlight assembly Remove the two pin shanks and remove the two pins Separate the headlights from...

Page 74: ...les and remove the cable box Turn signal assembly Turn the turn signal assembly to the back use the 17 open end wrench to remove the nut that comes with the turn signal and remove the spring pad and the gasket Separate the turn signal from the bracket Headlight bracket Remove 2 pieces of cushion rubber Grasp the left bracket or the right bracket and then remove the bolt with 6 inner hexagon CAUTIO...

Page 75: ... 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 Unplug the brake switch Remove the bolt attached to the front brake main pump and replace the front brake switch Note that the boss on the brake switch is aligned with the limit hole at the arrow indication of t...

Page 76: ...ing Rocker Arm Left hand rubber sleeve and balance block assembly Use a blow gun to blow the left hand grip between the rubber 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 on the balance block and pull out the balance block assembly Use a blow gu...

Page 77: ...e 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 hand remove the clamp and finally remove the direction handle Instrumentation components Turn the meter and the pressure block assembly to the back and use a 10 sleeve to remove the nut remove the gasket and remove the meter Take care to protect the meter screen R...

Page 78: ... 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 plates to slightly enlarge the slot clearance and disassemble the left shock absorber and the right shock absorber under Remove the upper plate assembly Reflecting film Reflective sheets are sold separately for sale no replacement shock absorption The ...

Page 79: ...terials to prevent scratching the paint surface Remove nut with a 14 sleeve remove the gasket cushion rubber and bushing Remove the upper plate The spacer the upper clamp and the direction handle are disassembled CAUTION Protect protective measures to prevent scratching the appearance of parts When reassembling it is necessary to use the direction to ensure that the center and direction of the spa...

Page 80: ...t remove the two bolts and remove the bushing Brake fluid Refer to the previous step of adding brake fluid to remove the upper cover cover and sealing gasket of the front and rear disc brake main oil cups Place the oil pan underneath After wearing the waterproof gloves pull out the hydraulic control unit and tilt it to the right side Use an open end wrench to loosen the nut joints of the four oil ...

Page 81: ...oof gloves remove the bolts with a 12 sleeve remove the copper washers Remove the FMC HU tubing It is recommended to replace the two copper washers at the same time when replacing the tubing The bolts can be replaced if they are not damaged Wipe the end faces of the bolt and the front disc brake main pump before replacing the FMC HU tubing After installing the tubing add DOT4 brake fluid and vent ...

Page 82: ... and remove the front disc brake caliper from the front shock absorber First remove the wheel speed sensor from the clamp Then use 4 inner hexagon to remove the two bolts remove the wheel speed sensor and the clamp from the front disc brake caliper Organize the wheel speed sensor line neatly Using 8 sleeve remove the two bolts on the right side Cut the straps and remove the 3 clips Then remove the...

Page 83: ...e the oil cup cover and seal the rubber pad Pour out the brake fluid from the oil cup Use the 14 open end wrench to remove the rear brake switch nut remove the copper washer The RMC HU oil pipe the rear disc brake main pump body and the rear brake switch wire are split Restore the rear disc brake oil cup Using 8 sleeve remove the two bolts and remove the bracket CAUTION Be sure to disassemble the ...

Page 84: ...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 the cable tie After wearing the waterproof gloves remove the bolts with a 12 sleeve remove the copper washers If you need to replace the RC HU tubing it is recommended to replace the two copper washers at the same time the bolts can be replaced if they are not damag...

Page 85: ...rear of the car Use 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 hexagon socket remove the bolts remove the flat pads and and press the glue Pull the fuel tank assembly slightly behind the rear and lift the rear of the fuel tank assembly up Do not ...

Page 86: ... 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 and foreign matter from falling into the tank Fuel tank lock Flip to the back and use a flat blade screwdriver to carefully open the middle cover to buckle at both ends remove the fuel tank lock pay attention to ...

Page 87: ...the rotating shaft and slowly pull out the rotating shaft Remove the torsion spring first Remove the swivel bracket assembly Remove the rotary shaft from the tank cover Remove the damper from the swivel bracket CAUTION The parts should be protected during the disassembly process to prevent damage to the paint surface Pay attention to the force when removing the buckle to prevent damage to the buck...

Page 88: ...removing the fuel pump it is recommended to temporarily seal the oil pump port to prevent something falling into the 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 process CAUTION Before disassembling the fuel tank assembly it is recommended to use the oil pump to pull out the fuel or ...

Page 89: ...placed against the fuel tank assembly and pulled the middle part of the middle of the decorative cover with another hand follow the direction of the arrow Pull out the bottom and then pull out the right middle b the left lower c and the left middle d Remove the dicoration cover assembly Flip to the back to remove the nut 1 from the usb charging cable and remove the usb charging cable from the deco...

Page 90: ...4 inner hexagon socket remove the two bolts and remove the bushing and cushion rubber Using 4 inner hexagon socket remove the two bolts Remove the lower part of the left decoration cover from the fuel tank assembly Remove the 3 piece splint nuts from the lower part of the left decoration cover Right tank trim cover lower assembly Refer to the above steps to remove the right decoration cover lower ...

Page 91: ...nner hexagon socket remove the two bolts As shown in the lower left corner first push the upper part of the decorative cover upwards with the left thumb and tap the right hand diagonally upwards to remove the left decorative cover assembly from the fuel tank Remove the right decoration cover assembly in the same way Remove the strips on the left and right sides CAUTION The parts should be protecte...

Page 92: ... 4 3 ZT310 V fuel tank right decorative cover 1 Fig 8 FUEL TANK COVER COMPONET PROCEDURE Fuel tank decoration cover assembly Remove the cleat nut from the left decroation cover or the right decoration cover respectively CAUTION The parts should be protected during the disassembly process to prevent damage to the paint surface Fuel tank trim cover assembly 2 ...

Page 93: ...ion and then remove the expansion screw at the joint between the right side cover and the tail cover Remove the water stopper and loosen the bolt with the T12 socket without completely removing it Pull the decorative ball out and turn it clockwise stagger the groove on the right side cover Pull out the right side cover in the order of Remove the left side cover using the same steps as above CAUTIO...

Page 94: ...move the left and right side covers and the fuel tank assembly by referring to the steps of removing the side cover and the fuel tank assembly Pull out the two cable plugs of the rectifier Cut the two straps Using cross screwdriver remove the two bolts and remove the ignition coil to expose the bolts Using 4 inner hexagon socket remove the bolt and move the ignition coil bracket and the oxygen sen...

Page 95: ...he right side Using 14 sleeve remove the bolt on the right side and the bumper connecting tube Using 14 sleeve fix the head of the bolt with a 14 socket and remove the nut on the right side After holding the left and right bumper remove the bolt on the right side and remove the right bumper assembly Hold the left bumpe assembly and pull out the bolts s Make sure that the cable ties cables etc on t...

Page 96: ...Fig 3 GUARD BAR COMPONENT Guard bar assembly 3 PROCEDURE Left bumper assembly Remove the water stopper Use 6 inner hexagon to remove the bolt 3 and then take off the anti drop glue 2 Using 4 inner hexagon socket remove the bolt and the disc brake lock bracket Using 8 sleeve remove the bolt and the outlet pipe bracket Hold the rectifier and remove the bolt then remove it Using 4 inner hexagon socke...

Page 97: ...tive 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 decorative the right front decorative cover and the right back decorative cover CAUTION Protect the engine decorative cover paint to prevent scratches Before replacing the engine decorative cover check wh...

Page 98: ... battery 2 can be removed Battery bottom cover Using 4 inner hexagon socket remove the four bolts 3 remove the four flanging bushings and the four flanging bushing cushion rubbers then the battery bottom cover can be removed Battery holder Use a 8 sleeve to remove the four bolts and then take off the battery holder CAUTION Remove side covers and seat cushions in advance The material should be prot...

Page 99: ...ion cover 4 without backrest Fig 2 REAR COVER COMPONENT Backrest assembly componen 7 9 8 PROCEDURE Backrest assembly componen Using 4 inner hexagon 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 with the 4 inner hexagon socket Divided the backrest...

Page 100: ...ith the double topping and the double topping on the rear cover Heat it slightly with a hot air gun then tear off the double topping and clean up the residue The end of the antenna connected to the main beam can be removed from the gap between the frame and the rear decoration cover The tail light plug it is not necessary to pull out the cushion lock plug if the cushion lock is not removed is the ...

Page 101: ...OMPONENT Tail skirt taillight component 2 PROCEDURE Rear 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 and remove the bushing and cushion rubber Using 4 inner hexagon socket remove the bolt and bolt on the trim cover holder and remove the bushing a...

Page 102: ...n to remove 2 bolts open the left and right taillights slightly 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 remove the bushing and cushion rubber Using 4 inner hexagon socket remove the bolt on the front right trim cover remove the bushing and cus...

Page 103: ...ht 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 lamp and remove it Remove the bolt on both sides of the left rear lamp remove bushing 2 and cushion rubber Pull back the left rear tail light Remove the right rear tail lamp as shown above Remove from the rear...

Page 104: ...shion 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 cushion rubbers are complete Insert the front part of the cushion first After the assembly is in place shoot the rear part of the cushion firmly When you hear the click sound it indicates that the cushio...

Page 105: ...ug on the back of the left engine trim cover and pull it out Press the buckle of the main cable end indicated by arrow a with one hand and unplug the oxygen sensor connector with the other hand Straighten out the oxygen sensor cable Use 14 torx wrench to fix the bolt 3 and then use 14 wrench to remove the nut Remove the bolt with an 8 sleeve and take off the left anti scalding plate Install the 2 ...

Page 106: ...ative cover component first using a 14 torx wrench remove the bolt on the back of the shifter pedal rocker arm Remove bolt with an 8 sleeve on the right side Use 14 torx wrench to fix the bolt on the right side and use 14 torx wrench to remove the nut on the left Use a 14 sleeve to fix the bolt on the left side and use a 14 torx wrench to remove the nut on the right side Remove bolt and bolt and r...

Page 107: ...067000 9 1 PROCEDURE Muffler assembly Push the radiator assembly forward to reveal 2 pieces of nuts 1 and remove them with 6 inner hexagon remove the muffler flange 2 Fix the nut with a 13 torx wrench on the back and remove the bolt with a 6 inner hexagon on the outside After holding the front elbow and rear section of the muffler assembly remove the middle bolt 5 with a 12 sleeve Remove the muffl...

Page 108: ...os mat 6 20 1 6 3 5 ZT310 VX muffler decorative cover 1 6 ZT310 V1 muffler 1 PROCEDURE Decorative cover After holding the decorative cover firmly use 4 inner hexagon to remove 3 bolts and remove asbestos pad Remove the decorative cover assembly Remove the bushing and the cushion rubber from the decorative cover CAUTION Prevent foreign matter from entering the muffler or engine interior Be careful ...

Page 109: ...ly use 4 inner hexagon to remove 3 bolts 1 and remove the bushing 2 After removing the lower air deflector assembly remove the 3 pieces of buffer After placing the lower air deflector assembly remove the bolt on the right with a 4 inner hexagon and remove the bushing and cushion rubber Remove bolt with 4 inner hexagon and remove bushing and cushion rubber Separate the right part of the lower air d...

Page 110: ...0 V Right support of lower wind deflector 1 9 1251300 063093 Plywood M6 11 15 environmental color 6 PROCEDURE Lower shroud assembly Remove the splint nut from the left part middle part and right part respectively CAUTION The shroud should be well protected during disassembly to prevent breakage or paint scratches caused by uneven force Fig 2 LOWER SHROUD COMPONENT Lower shroud component 2 ...

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Zontes ZT310-V1 EURO V, Service Manual

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