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7、FRONT FORK COMPONENT

78

CHK

ADJ

NO.

PART NO.

PART NAME

QTY

CAUTION

1

1251100-112000 Disc brake tubing bolt M10×1

－

22

1

32N.m

2

1251513-013000

Brake brake tubing copper washer φ15×φ10.2×1.5

2

3

1224100-037000 0 grade flame retardant cable tie (black 3.6×295)

3

Fig.19FRONT FORK

COMPONENT

PROCEDURE:

●

Front disc brake main pump

Cut three straps 

⑶

Place the oil pan under the hydraulic control unit

。

In the previous step of the parameter, remove the hydraulic control unit cover and the brake fluid step to

connect the FMC-HU tubing to the hydraulic control unit.

After wearing the waterproof gloves, remove the bolts 

⑴

 with a 12# sleeve; remove the copper washers

⑵

.Remove the FMC-HU tubing. It is recommended to replace the two copper washers 

⑵

 at the same time when

replacing the tubing. The bolts 

⑴

 can be replaced if they are not damaged.

Wipe the end faces of the bolt 

⑴

 and the front disc brake main pump before replacing the FMC-HU tubing.

After installing the tubing, add DOT4 brake fluid and vent the brake system. Detailed steps can be found in

Adding Brake Fluid.

CAUTION:

●

Be sure to disassemble the muffler and engine after they have cooled down completely. The horizontal support

of the vehicle should be fixed before disassembly and assembly work.

●

The precautions for brake fluid are described in the previous section.

●

The torque standard of the four tubing nut joints at the pilot unit is 18N.m

ABS brake system

－

2

Содержание ZT310-V

Страница 1: ...ZT310 V EURO IV V Service manual 2020 11 27...

Страница 2: ...e Combination 2 14 Hanging piece bracket component Lower shroud bracket 3 Intake system components 3 1 Intake system components Delphi EFI 15 Throttle valve body component air filter oil pipe Intake s...

Страница 3: ...Remove the rear rim component sprocket seat sprocket 4 8 Rear wheel component 2 34 Decomposed rear rim component 4 9 Rear fork component 35 Decomposed flat fork component 4 10 Replace the rear brake p...

Страница 4: ...ine clutch cable free travel 7 2 Light height adjustment 61 7 3 Replacement clutch cable 62 7 4 Replace the throttle line 63 7 5 Steering adjustment 64 Adjustment steering device 7 6 Add brake fluid r...

Страница 5: ...mble the disc brake main pump and tubing 7 22 ABS brake system 5 81 Disassemble rear disc brake calipers and tubing wheel speed sensor 8 Fuel tank cover component 8 1 Fuel tank cover component 82 Disa...

Страница 6: ...and right decorative cover decorative cover bracket 11 5 Tail skirt taillight component 3 100 Disassemble the rear aluminum alloy bracket 11 6 Tail skirt taillight component 4 101 Rear skirt taillight...

Страница 7: ...on illustrations and photographs collected in this manual are compiled according to the latest products However there may be some inconsistencies between your motorcycle and this manual due to the con...

Страница 8: ...g bracket on the frame and remove the dump switch with the same method then separate the dump switch Locate the main harness rubber sleeve on the right side of the frame pull out the rubber sleeve pul...

Страница 9: ...ENT Electronic parts COMPONENT 2 PROCEDURE Horn Take off the plug of horn take the horn by one hand use tool rotate the screw by another hand remove the holder then take off the horn Flameout switch F...

Страница 10: ...ELECTRONIC PARTS COMPONENT PROCEDURE Inner fuel tank ficx glue cushion Use both hands to hold the two ends cylinder parts of the inner fuel tank limited glue cushion and should push it out Side cover...

Страница 11: ...ustproof cover is required to about 14N m so as to be able to rotate out of nimbleness The top adjusting nut only needs to rotate to the bottom of the nut groove alignment not too tight to prevent the...

Страница 12: ...ed 4014200 023000 ZT310 V frame after sales assembly Euro IV including fix loop nameplate Domestic Fig 5 FRAME ELECTRONIC PARTS COMPONENT Frame Side support the operation of releasing engine oil PROCE...

Страница 13: ...ng Unplug the fuse turn on the dustproof glue of the PKE charging port and plug the charger into the charging port for charging If the charger indicator shows red it means charging and green means ful...

Страница 14: ...ver assembly Disassemble 3 bolts and take out the right trim cover components Remove the bushing buffer rubber from the right trim cover components Disassemble the bolts and take out the bracket Use a...

Страница 15: ...ll be unified into 3 as shown in FIG e 1 was produced from January to mid april 2019 as shown inf FIG c and d From the middle of April to August 15 2019 the hanging pieces with 4 holes 2 Since August...

Страница 16: ...op assembly against the end of the air filter clamp the hoop on the exhaust pipe with pliers and unplug the exhaust pipe connected to the exhaust port of the engine and then use the rubber plug suppli...

Страница 17: ...s loosen the hose clamp assembly on the side of the air filter clamp the clamp on the exhaust pipe with pliers and pull out the exhaust pipe connected to the exhaust port of the engine and then use th...

Страница 18: ...n tank remove 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 re...

Страница 19: ...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 t...

Страница 20: ...d right covers Left rear shock absorption Remove the nut with the sleeve then remove the flat mat Back inner mud board Remove the bolts and on the left side remove the bushings and and then remove the...

Страница 21: ...s Left side Hold down the arrow at the bottom of the ECU s plug and pull the plug out at the same time and then tidy up the cable Pull the fuse box up and out the cable Air filter Clamp the hoop with...

Страница 22: ...nduction system component 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 Remove...

Страница 23: ...referring 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...

Страница 24: ...eve then remove the flat mat Back inner mud board Remove the bolts and on the left side remove the bushings and and then remove the cushion rubber Remove the wheel speed sensor wire and the rear brake...

Страница 25: ...disc brake oil cup to the side to ensure that the oil cup cover faces upward Remove the two bolts of the right PKE mainframe bracket and arrange the cables Air filter Clamp the hoop with pliers and r...

Страница 26: ...air filter element Bosch 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 Remov...

Страница 27: ...ing 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 dama...

Страница 28: ...he shown three plugs Cut or use a tool to pick up the strap head stop Remove bolt remove support After fixing the nut with the plum wrench then remove the bolt with the sleeve remove the cushion the f...

Страница 29: ...4024200 035000 Front section of ZT310 V rear mud plate iron support 1 Fig 2 Rear wheel swinging arm assembly PROCEDURE Retaining plate Remove the bolts and remove the flange bushing the rubber pad and...

Страница 30: ...rubber Flip to the back 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...

Страница 31: ...ht 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 turn...

Страница 32: ...1M6 environmental color 2 PROCEDURE Rear inner mudguard First refer to the steps in the previous Intake System Assembly Replace the air filter element 1 to remove the rear inner assembly Using the inn...

Страница 33: ...and rear inner mudguard Use suitable tool to support the motorcycle Avoid accidents caused by falling motorcycle Single person manipulation is prohibited All the standard parts need to reach standard...

Страница 34: ...s motorcycle front direction and take off the chain from sprocket Hold the rear wheel assembly Punch rear wheel axle with rubber hammer Take off right chain adjuster right axle sleeve rear tire and ri...

Страница 35: ...ble bolt Then take down the ABS gear ring and the disc brake plate EURO IV Tire and rim assembly Disassemble tire valve cap Deflate the tire with tools Then disassemble the rear tire with professional...

Страница 36: ...wheel speed sensor from the disc brake oil pipe clamp loosen the bolt and take off the disc brake oil pipe clamp The rear disc brake caliper is placed well always keep the rear brake clamp facing up O...

Страница 37: ...the cross bolt on rear disc brake main pump oil cup Take 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...

Страница 38: ...nstantly 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 UPP...

Страница 39: ...il the height becomes suitable Then tighten the nuts If the above mentioned method can not adjust the gear shift rod to a satisfying position take off bolt and adjust gear shift rod spline of rocker a...

Страница 40: ...d component Lower shroud component 1 Remove the the bolts under the radiator cover component take off the bushing buffer rubber Grab the anti scalding plate and remove the 2 bolts to remove it Fix the...

Страница 41: ...e gasket and the split pin with the other hand the cotter pin needs to bend the two legs to both sides Confirm the position and lock the nut If it is not suitable to adjust the height of the brake ped...

Страница 42: ...forward to one mounting hole for the front left pedal assembly Re assemble the pedal assembly after applying a proper amount of threaded fastening to the head of the bolt Use the open end wrench to i...

Страница 43: ...nt right pedal assembly 4064200 006051 ZY310 V Front right pedal assembly dark gray matte 6 Fig 5 FOOT PEDAL COMPONENT 4 1 ZT310 V The second generation brake pedal dark gray 1274200 293000 1 PROCEDUR...

Страница 44: ...pedal dark gray 5 1244200 063000 ZT310 V Front pedal plastic sleeve 1 3 PROCEDURE Front right pedal after sale parts Remove 4 pieces bolts and take off 4 bushings Take off the pedal pressure block Tak...

Страница 45: ...od 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 wrenc...

Страница 46: ...ront left pedal bracket component Refer to to steps above remove the pedal bracket component Use the seelve to remove the blot take off the bearing gasket shift lever and front left pedal assembly by...

Страница 47: ...003000 ZT310 V Front left pedal 1274200 294000 ZT310 V Front left pedal dark gray 5 1244200 063000 ZT310 V Front pedal rubber seelve 1 PROCEDURE Front left pedal after sale parts Remove 4 pieces bolts...

Страница 48: ...te 4064200 008051 1 3 4064200 017051 ZT310 V Rear left pedal bracket assembly dark gray matte PROCEDURE Rear left pedal bracket assembly Remove 3 pieces bolts on the left side take off the left pedal...

Страница 49: ...ear right pedal rubber seelve 1 1274200 166000 ZT310 V Rear right pedal 4064200 015051 ZT310 V Rear right pedal dark gray matte 15 1274200 267021 ZT310 V rear footrest top plate hinge pin 1 PROCEDURE...

Страница 50: ...0 V rear footrest top plate hinge pin 1 Reassembly is to tighten the bolt first then pre tighten the bolt The bolt head should be coated with a proper amount of thread fastening glue After tightening...

Страница 51: ...eek 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 engi...

Страница 52: ...il filter Place holder to collect wasted engine oil under right crankcase cover Disassemble nut with tool Rotate slightly engine oil refined filter cover and take it off when it is loosen Take off sea...

Страница 53: ...ed 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...

Страница 54: ...et 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 Remove 3 bolts take off the bushing and...

Страница 55: ...1 Fig 5 COOLING SYSTEM COMPONENT PROCEDURE Radiator decorative cover assembly Remove the self tapping screws and pry the four snaps in the direction indicated by the arrow to separate the right rear p...

Страница 56: ...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...

Страница 57: ...il outlet tube Disassemble oil passing bolt Remove 2seal gasket with socket sleeve pictured B Disassemble oil passing bolt seal gasket with socket sleeve pictured C Disassemble bolt with socket sleeve...

Страница 58: ...s Sub tank assembly 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 waterproo...

Страница 59: ...aps Use the pliers to clamp the hoop and move the anti slip boss up to release the hoop Remove the bolt Pull out the water pipe after wearing the waterproof gloves Remove the hoop Use the pliers to re...

Страница 60: ...erproof 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 hoo...

Страница 61: ...uld be staggered to prevent the cable from coming out Big adjustment If fine adjustment cannot be achieved loosen the nuts with an open end wrench rotate the adjustment screw and finally tighten the n...

Страница 62: ...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 b...

Страница 63: ...move the clutch 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 ar...

Страница 64: ...irst pass the throttle cable into the cable hole in the lower part of the switch Fit the cylindrical connector of the throttle cable into the turntable on the right hand gripper Return the oil return...

Страница 65: ...nut with a spanner remove the spacer and remove the bolt with the Allen tool The direction of the upper board assembly wrapped with a clean cloth and then placed to prevent scratches Remove the lock w...

Страница 66: ...nector 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 s...

Страница 67: ...ad 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...

Страница 68: ...be replaced Refer to the relevant content of the manual for details Rim Check the rim for any deformation cracks etc Rotate the rim horizontally to check for stuck oscillating etc Axle Use a dial indi...

Страница 69: ...ke to fail Front mudguard Remove the 6 bolts with the hexagonal tool by hand and remove the bushing and cushion rubber Flip to the back remove the two bolts and remove the bushing and cushion rubber S...

Страница 70: ...a 6 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 storag...

Страница 71: ...ssembly Turn the headlight assembly forward to expose the bolt at the bottom of the storage box remove the bolt and remove the bushing and cushion rubber Turn the headlight up and remove the two bolts...

Страница 72: ...ENT Headlights assembly 3 Storage box Remove all the cables and remove the cable box Turn signal assembly Turn the turn signal assembly to the back use the open end wrench to remove the nut that comes...

Страница 73: ...ump CAUTION The motorcycle should be fixed after horizontal support Periodically check that the fluid level of the brake fluid is between 3 4 of the observation window Do not flush the cup directly wi...

Страница 74: ...arm First unplug the clutch switch then remove the bolt with a Phillips screwdriver and remove the clutch switch The rotation adjustment nut can adjust the distance between the rocker arm and the lef...

Страница 75: ...e hand and remove the bolt with a hexagonal tool in one hand remove the clamp and finally remove the direction handle Instrumentation components Flip theInstrumentation component remove the nut by tur...

Страница 76: ...hock 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 th...

Страница 77: ...ed with cotton or other soft materials to prevent scratching the paint surface Remove the nut and remove the gasket cushion rubber and bushing Remove the upper plate The spacer the upper clamp and the...

Страница 78: ...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...

Страница 79: ...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 t...

Страница 80: ...the front disc brake caliper from the front shock absorber First remove the wheel speed sensor from the clamp then remove the two bolts and remove the wheel speed sensor and the clamp from the front d...

Страница 81: ...mp Remove the bolt with a Phillips screwdriver after wear waterproof gloves Remove the oil cup cover and seal the rubber pad Pour out the brake fluid from the oil cup Use the open end wrench to remove...

Страница 82: ...luid Connect the RC HU oil pipe to the hydraulic control unit Remove the bolt find the clamp on the back of the right foot and remove it Pull the RC HU oil pipe out of the 4 disc brake tubing clamps A...

Страница 83: ...ll out at the 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 fr...

Страница 84: ...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 and...

Страница 85: ...ER 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 Remove the torsion spring first Remov...

Страница 86: ...ed 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...

Страница 87: ...el 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...

Страница 88: ...t decorative cover lower part dark gray matte PROCEDURE Left fuel tank decoration cover lower assembly Remove the two bolts and remove the bushing and cushion rubber Remove the two bolts Remove the lo...

Страница 89: ...COMPONET Fuel tank trim cover assembly 1 PROCEDURE Fuel tank decoration cover assembly Remove the 4 plywood nuts Remove the two expansion pins Remove the two bolts As shown in the lower left corner fi...

Страница 90: ...VER COMPONET Fuel tank trim cover assembly 2 PROCEDURE Fuel tank decoration cover assembly Remove the cleat nut from the left decroation cover or the right decoration cover respectively CAUTION The pa...

Страница 91: ...te Red stickers V310 red 4044201 302051 ZT310 V Left side cover Dark gray matte Yellow stickers V310 yellow 4044201 296051 ZT310 V Left side cover Dark gray matte Black stickers V310 black 4044201 304...

Страница 92: ...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 remove the two bolts and rem...

Страница 93: ...embly 1 In the gap between the left radiator and the deflector insert a 14 wrench into the nut and remove the bolt on the right side 2 Remove the bolt on the right side and the bumper connecting tube...

Страница 94: ...ve wire 1144200 039000 ZT310 V Right bumper assembly 4114200 002051 ZT310 V Right bumper assembly dark gray matte PROCEDURE Left bumper assembly 1 Remove the water stopper the bolt and the protection...

Страница 95: ...gray matte yellow yellow 4044201 248051 Engine decorative cover right front Dark gray matte black 4044201 338051 Engine decorative cover right front Dark gray matte white white 4044201 346051 Engine d...

Страница 96: ...ectrode No parallel battery charging or ignition Remove the PKE cover and pull the charging connector out Unplug the charger and plug it into a dedicated lithium battery charger for manual charging Pa...

Страница 97: ...st and then remove the negative wire then the battery 2 can be removed Battery bottom cover Remove the four bolts 3 remove the four flanging bushings and the four flanging bushing cushion rubbers then...

Страница 98: ...small cover of the rear decoration cover 4 without backrest 6 1 7 8 9 Old backrest New backrest Old backrest rubber New backrest rubber PROCEDURE Backrest assembly componen Remove the bottom two bolts...

Страница 99: ...ll 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 double topping and clea...

Страница 100: ...ticker yellow 4044201 287052 Rear cover right trim cover dark grey with goldden sticker black 4044201 295052 Rear cover right trim cover dark grey with white sticker white 4044201 289052 Rear cover ri...

Страница 101: ...0 Buffer rubber of flanging bushing 8 5 14 1 6 PROCEDURE Rear aluminum alloy bracket Remove the bolt and bolt take off the bracket Rear cover trim cover Remove PKE small cover after pressing down Remo...

Страница 102: ...ear 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...

Страница 103: ...bolt under the front of the electrical box and remove the bushing and cushion rubber Remove the bolts under the rear of the electrical box and remove the bushing and cushion rubber Hold the electrica...

Страница 104: ...with sufficient power and connect the previously made wire to the positive side of the battery Find one end of the wire attached to the frame the bolt is directly connected to the frame and the other...

Страница 105: ...hion 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 cush...

Страница 106: ...1 remove the radiator decorative cover component first Cut the tie belt Use pointed tongs to penetrate the gap of the engine decorative cover slightly clamp the limit protrusion on the buckle of the...

Страница 107: ...scalding board and remove two bolts Fix the head of the bolt with sleeve remove the nut and remove the anti scalding board The gap between the left radiator and the left pedal bracket extends into th...

Страница 108: ...ccording to the step of removing the side cover Remove three bolts and remove the right rear pedal bracket assembly Muffler assembly Put the plum wrench into the gap and fix the nut hold the muffler a...

Страница 109: ...r 1 8 1251300 063093 plywood M6 11 15 color zinc 1 5 1 PROCEDURE Decorative cover Remove the bolt at the back of the decorative cover and remove the bushing Remove the two bolts 1 of the side cover an...

Страница 110: ...m of the motorcycle and remove the plate brake pump after the bolt take off the lining Remove the bottom left and right side of the bolt remove the liner After supporting the cowl assembly remove the...

Страница 111: ...t support of lower wind deflector grey matt black 4044201 276051 Right support of lower wind deflector bright red red 4044201 270051 Right support of lower wind deflector bright yellow yellow 4044201...

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