Zontes ZT350-X 2022 User manual

ZT350-X(EURO V)
Service manual
2022/5/3

Page, 1Total 117 Pages
Pagues
0
Table of Contents ……………………………………………………………………………………………………………………………………………………………………………… …………………
1
11-Frame & Electronic Component
1.1
Electrical device component-1 ……………………………………………………………………………………………………………………………………………………………………… ………………
8
Disassemlbe the main harness and ECU
1.2
Electrical device component-2 ………………………………………………………………………………………………………………………………………………………………………… ……………
9
Horn,shut down switch and ignition coil
1.3
Frame plastic parts …………………………………………………………………………………………………………………………………………………………………… ……………………………
10
Remove the Fuel tank liner limit glue,battery cushion,side cover cushion and buckle
1.4
Directional column component ………………………………………………………………………………………………………………………………………………………………… …………………
11
Disassembly and assembly of lower connecting plate assembly
1.5
Frame, side bracket............................................................................................................................................................................................................................................................................................
12
Remove the sider bracket;Checking the steel bowl
2FRAME & ENGINE COMBINATION
2.1
Engine component ………………………………………………………………………………………………………………………………………………………………………… ………………………
13
Remove the engine;Engine left rear cover
3Intake System Component
3.1
Carbon tank components …………………………………………………………………………………………………………………………………………………………………………… ………………
14
Disassembling temperature sensor, carbon can solenoid valve, carbon can; check the temperature sensor
3.2
Empty filter components ……………………………………………………………………………………………………………………………………………………………………… ……………………
15
Remove the air filter and throttle valve component;Check whether the external intake pressure sensor is damaged
3.3
Throttle valve body component ………………………………………………………………………………………………………………………………………………………………………………………
16
Remove the throttle valve body componen and external intake air pressure sensor.Check stepping motor and throttle position sensor
3.4
Replace air filter element ...................................................................................................................................................................................................................................................................................
17
Remove the filter element;Clean the Oil pipe and water pipe
4Double rocker component
4.1
Rear mud board .................................................................................................................................................................................................................................... …………………………………………
18
4.2
Rear shock absorption........................................................................................................................................................................................................................................................................................
19
Rear shock absorber;Adjust the rear absorber;Check
4.3
Rear wheel component 1 …………………………………………………………………………………………………………………………………………………………………… ………………………
20
Removal wheel assembly
4.4
Rear wheel component 2 …………………………………………………………………………………………………………………………………………………………………… ………………………
21
Disassembling chain wheel component, sprocket wheel failure detection
4.5
Rear wheel component 3 ……………………………………………………………………………………………………………………………………………………………………… ……………………
22
Disassembling brake plate, ABS gear, tire and rotor components
4.6
Houping fork components …………………………………………………………………………………………………………………………………………………………………………………………
23
Disassembling flat fork component, rear flat fork anti -grinding block
Contents
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4.7
Replace the rear brake pads …………………………………………………………………………………………………………………………………………………………………………… ……………
24
Disassembly brake sheet, replace the post -making film
4.8
Rear brake main pump adds brake fluid ...................................................................................................................................................................... …………………………………………………………
25
5
Single Rocker Component
5.1
Adjust the chain ……………………………………………………………………………………………………………………………………………………………………… ……………………………
26
Rear auxiliary mud plate assembly;Sprocket assembly
5.2
Sprocket baffle………………………………………………………………………………………………………………………………………………………………………… ……………………………
27
Remove sprocket baffle
5.3
Sprocket assembly 1 ………………………………………………………………………………………………………………………………………………………………………… ……………………
28
Rear auxiliary mud plate assembly;Sprocket assembly;Chain
5.4
Sprocket assembly 2 …………………………………………………………………………………………………………………………………………………………………… …………………………
29
Sprocket assembly;Sprocket
5.5
Rear wheel component…………………………………………………………………………………………………………………………………………………………………… …………………………
30
Rear wheel assembly;Tire and rim assembly;Maintenance
5.6
Rear axle assembly.............................................................................................................................................................................................................................................................................................
31
Rear axle outer assembly;Rear axle assembly
5.7
Rear sub-mud assembly ……………………………………………………………………………………………………………………………………………………………………………………………
32
5.8
Chain adjuster assembly ……………………………………………………………………………………………………………………………………………………………………………………………
33
Disc brake mounting plate;Chain adjuster assembly
5.9
Rear mud board .................................................................................................................................................................................................................................... …………………………………………
34
5.10
Rear shock absorber ..........................................................................................................................................................................................................................................................................................
35
Rear shock absorber;Adjust the rear absorber
5.11
Rear wheel assembly ………………………………………………………………………………………………………………………………………………………………………………………………
36
Rear swinging arm assembly;Abrasionproof block of rear swinging arm;Rear fork after sale
5.12
Change rear brake arresters……………………………………………………………………………………………………………………………………………………………………… …………………
37
6PEDAL Component
6.1
Shift lever adjustment........................................................................................................................................................................................................................................................................................
38
Adjust the height of gear shift rod and shift lever position adjustment
6.2
Right footrest component 1 ……………………………………………………………………………………………………………………………………………………………… …………………………
39
6.3
Right footrest component 2………………………………………………………………………………………………………………………………………………………………… ………………………
40
Remove the rear brake main pump heat shield and rear disc brake main pump component
6.4
Right footrest component 3 ………………………………………………………………………………………………………………………………………………………………… ………………………
41
Remove the brake pedal component and muffler anti-scalding
6.5
Right footrest component 4 ………………………………………………………………………………………………………………………………………………………………… ………………………
42
Remove the R, front pedal,R,rear pedal and after sales parts for pedal component
6.6
Left footrest component 1……………………………………………………………………………………………………………………………………………………………… ……………………………
43
Remove the L, foot pedal holder component,gear shift rod component,rectifier and support of disc brake lock;Rectifier fault detection
6.7
Left footrest component 2 …………………………………………………………………………………………………………………………………………………………… ……………………………
44
Remove the gear shift rod component

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6.8
Left footrest component 3 ……………………………………………………………………………………………………………………………………………………………… …………………………
45
Remove the rear left pedal,L, rear foot pedal and after sales parts for pedal component
7Cooling System Component
7.1
Change engine oil..............................................................................................................................................................................................................................................................................................
46
Drain oil and change engine oil
7.2
Change engine oil filter......................................................................................................................................................................................................................................................................................
47
7.3
Add coolant.......................................................................................................................................................................................................................................................................................................
48
7.4
Draining cooling liquid......................................................................................................................................................................................................................................................................................
49
Discharge coolant
7.5
Water tank assembly 1.......................................................................................................................................................................................................................................................................................
50
Sub water tank connecting tube,connecting water pipes of left and right water tanks,right water tank assembly and engine water pipe
7.6
Water tank assembly 2…………………………………………………………………………………………………………………………………………………………………… …………………………
51
Filler assembly
7.7
Water tank assembly 3 ……………………………………………………………………………………………………………………………………………………………………… ………………………
52
Auxiliary water tank assembly,thermostat and left water tank assembly
7.8
Oil cooler component 1……………………………………………………………………………………………………………………………………………………………………… ………………………
53
Cooler
7.9
Oil cooler component 2……………………………………………………………………………………………………………………………………………………………………… ………………………
54
Oil cooler bracket
8Front fork component
8.1
The throttle/clutching gap adjustment ………………………………………………………………………………………………………………………………………………………………………………
55
Adjust the throttle line, clutch rosor free itinerary, light adjustment
8.2
Replace the clutch cable…………………………………………………………………………………………………………………………………………………………………………… ………………
56
8.3
Replace the throttle line ……………………………………………………………………………………………………………………………………………………………………………………………
57
Remove the throttle line, install the throttle line
8.4
Steering adjustment…………………………………………………………………………………………………………………………………………………………………………………………………
58
Check the steering device and steering bearing.
8.5
Right handlebar component (old model) ……………………………………………………………………………………………………………………………………………………………………………
59
Remove the right rear-view mirror,hand guard,right hand handle auxiliary switch
8.6
Right handlebar component (new model)……………………………………………………………………………………………………………………………………………………………………………
60
Remove the right rear-view mirror,hand guard,right hand handle auxiliary switch
8.7
Add dynamic fluid and rocker arm adjustment ..................................................................................................................................................................................................................................................
61
The main pump, handle, and adding dynamic fluid of the front disc
8.8
Replace the front brake film ................................................................................................ ………………………………………………………………………………………………………………………
62
8.9
The front wheel component …………………………………………………………………………………………………………………………………………………………………… ……………………
63
Disassembling tires and rotor components, brake discs, ABS gear, tires and rotation components
8.10
Rotating sensor components …………………………………………………………………………………………………………………………………………………………………… …………………
64
Disassembling speed sensor, front disc brake calipers
8.11
The front mud plate ...........................................................................................................................................................................................................................................................................................
65

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8.12
Windshor glass components …………………………………………………………………………………………………………………………………………………………………………………………
66
Demolition wind glass component, windshield underwater block component component
8.13
Windshor glass components …………………………………………………………………………………………………………………………………………………………………………………………
67
Wind disassembly shield, windshield rocker arm
8.14
Cover panel component………………………………………………………………………………………………………………………………………………………………………………………………
68
8.15
The windshield assembly 1 …………………………………………………………………………………………………………………………………………………………………………………………
69
Remove the windshield motor cover and windshield motor.
8.16
The windshield assembly 2 …………………………………………………………………………………………………………………………………………………………………………………………
70
8.17
The windshield assembly 3 …………………………………………………………………………………………………………………………………………………………………………………………
71
Remove instrument and windshield base.
8.18
Clip …………………………………………………………………………………………………………………………………………………………………………………………………… ……………
72
Electric disassembly controller, wiring clamp the right cover, hub clip
8.19
Siege interior components ………………………………………………………………………………………………………………………………………………………………………… ………………
73
Disassembling the front interior component, surrounding the interior component
8.20
Left and right hood components ……………………………………………………………………………………………………………………………………………………………… ……………………
74
Disassemble the left -handed component, right head cover component
8.21
Big light component 1 ………………………………………………………………………………………………………………………………………………………………………………………………
75
8.22
Big light component 2 ………………………………………………………………………………………………………………………………………………………… ……………………………………
76
Disassembling headlight components, headlights,
8.23
Left handle component (old paragraph)………………………………………………………………………………………………………………………………………………………………… …………
77
Disassemble the left rearview mirror, left switch, rocker arm, left hand holding rubber sleeve, balance block assembly; replace the rocker and clutch switch
8.24
Left handle component (new model)…………………………………………………………………………………………………………………………………………………………………………………
78
Disassemble the left rearview mirror, left switch, rocker arm, left hand holding rubber sleeve, balance block assembly; replace the rocker and clutch switch
8.25
The direction handle, upper board, front shock absorption component ... …………………………………………………………………………………………………………………………………………
79
Demolition direction, component, upper board component, reflector
8.26
The upper plate and the direction of the pad component ....................................................................................................................................................................................................................................
80
Disassembling pad component, Shanglian board, faucet lock, wiring bracket
8.27
ABS brake system A-1 ……………………………………………………………………………………………………………………………… ……………………………………………………………
81
Demolition control unit component
8.28
ABS brake system A-2 ……………………………………………………………………………………………………………………………… ……………………………………………………………
82
Maker liquid, FMC-huu
8.29
ABS brake system A-3 ………………………………………………………………………………………………………………………………… …………………………………………………………
83
Liquid
8.30
Double Rock Ace ABS Brake System A-4………………………………………………………………………………………………………… ………………………………………………………………
84
Demolition of RMC-HU, wheel speed sensor, rear disc brake calibration, RC-HU oil pipe
8.31
Single rocker ABS brake system A-4………………………………………………………………………………………………………… ……………………………………………………………………
85
Demolition of RC-HU oil pipe, rear disc brake calipers
9Wraparound components
9.1
Siege in the central component …………………………………………………………………………………………………………………………………………………………………… ………………
86
Disassembling the middle cover and encirclement component of the encirclement

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9.2
Siege panel components ……………………………………………………………………………………………………………………………………………………………………… ……………………
87
Disassembling encirclement panel component, left and right surround panel components
9.3
Left surround panel component ………………………………………………………………………………………………………………………………………………………………… …………………
88
Disassemble the left siege panel sign, the left turn light component, the left panel component
9.4
Right surround panel component ………………………………………………………………………………………………………………………………………………………………… …………………
89
Disassemble the right siege panel sign, right turn signal component, right panel component
9.5
The underwritten stream component 1 ………………………………………………………………………………………………………………………………………………………………………………
90
Disassemble the left and lower right direction hood components
9.6
The underwritten stream component 2 ………………………………………………………………………………………………………………………………………………………………………………
91
Disassemble the left and lower right direction hood components
10 Fuel Tank Housing Assembly
10.1
The middle cover component of the box ……………………………………………………………………………………………………………………………………………………………………… ……
92
disassemble oil tank middle cover assembly
10.2
The cover, the outer cover of the fuel tank, the fuel tank lock ………………………………………………………………………………………………………………………………………………………
93
Locking of the fuel tank, the outer cover of the fuel tank
10.3
Oil tank decorative hood components ………………………………………………………………………………………………………………………………………………………………… ……………
94
Disassembling left fuel tank decorative cover, right fuel tank decorative cover
11 Fuel Tank Liner Assembly
11.1
Oil tank box components …………………………………………………………………………………………………………………………………………………………………… ………………………
95
Disassembling PKE antenna, fuel tank box component
11.2
Inner biliary components of the fuel tank ..........................................................................................................................................................................................................................................................
96
11.3
Inner biliary of the fuel tank ..............................................................................................................................................................................................................................................................................
97
Disassembling fuel tank cover, glue strip, side cover round glue, fuel pump
12 SIDE COVER Component
12.1
The lower part of the side cover ……………………………………………………………………………………………………………………………………………………………………… ……………
98
Disassembling component
12.2
The upper part of the left side 1 …………………………………………………………………………………………………………………………………………………………… ………………………
99
12.3
The upper part of the left side 2 ………………………………………………………………………………………………………………………………………………………… …………………………
100
12.4
The upper part of the upper part of the right side 1 …………………………………………………………………………………………………………………………………………………………… ……
101
12.5
The upper part of the upper part of the right side 2 ………………………………………………………………………………………………………………………………………………………… ………
102
13 Guard Bar Component
13.1
The barrier component ………………………………………………………………………………………………………………………………………………………………………………………………
103
14 Rear Cover Component
14.1
After the armrest component .............................................................................................................................................................................................................................................................................
104
After disassembly handrail components, rear handrail padding components

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14.2
ZT31Colloid battery assembly……………………………………………………………………………………………………………………… ………………………………………………………………
105
Disassemble the relay, battery, relay fixed seat, taillight plug card seat
14.3
Tail skirt components ………………………………………………………………………………………………………………………………………………………………………… ……………………
106
Disassembly left tail skirt, right -tail skirt, tail light plug card seat
14.4
Rear mud components 1 ………………………………………………………………………………………………………………………………………………………………… …………………………
107
14.5
Rear mud components 2 ……………………………………………………………………………………………………………………………………………………………………………………………
108
Disassembly turn the lamp, the latter license bracket, the rear reflex, the latter license plate buffer glue
14.6
Rear turning to the lamp after -sales loose parts ……………………………………………………………………………………………………………………………………………………………………
109
After disassembling license plate lights, rear turning lights
14.7
Tail lights, tail skirt components ……………………………………………………………………………………………………………………………………………………………… ……………………
110
After removing taillights, cushion locks
14.8
Electric component box lid components 1 ……………………………………………………………………………………………………………………………………………………………… …………
111
Package stent, electrical component component
14.9
Electric components 2 …………………………………………………………………………………………………………………………………………………………………… …………………………
112
Disassembling switch, electrical component component
14.10
Battery components ………………………………………………………………………………………………………………………………………………………………… ………………………………
113
Battery, battery strap
15 Cushion component
14.1
Cushion components ……………………………………………………………………………………………………………………………………………………………………… ………………………
114
Disassembling cushion, assembly cushion
16 Muffler component
16.1
Muffler component 1 ………………………………………………………………………………………………………………………………………………………………… ……………………………
115
Remove the rear section of the muffler
16.2
Muffler component 2…………………………………………………………………………………………………………………………………………………………………………………………………
116
Decompose the rear section of the muffle,muffler component mounting points on both sides
16.3
Muffler component 3 ………………………………………………………………………………………………………………………………………………………………………………………………
117
Decompose the front section of the muffler

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Guangdong Tayo Motorcycle Technology Co.,Ltd
all rights reserve
All the information, 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 continuous improvement of the product and other changes.

1-FRAME&ELECTRONIC COMPONENT 8
CHK
ADJ
NO. PART NO. PART NAME QTY CAUTION
1 1184300-008000 ZT350-X wiring harness assembly (A) 1
2 1224300-111000 Reverse buckle Velcro strap (20×300mm) 1
3 1240300-007000 HJ125-6 Battery rubber gasket 1
4 1224100-037000 Grade 0 flame retardant tie (black 3.6×295) 3
5 1224300-110000 Reverse buckle Velcro strap (20×200mm) 11
Fig.1 FRAME&ELECTRONIC
COMPONENT Electricity assembly 1
PROCEDURE:
●Main harness
Unplug all electrical components connected to the main harness. Different connector modes are different, and
the operation is based on the actual situation. A slotted screwdriver, pliers, scissors and other tools may be
needed to assist.
There are 2 tales at the point of the driving head①, and the tie⑷at the left cover should be cut, and the entire
body has 11 tie⑶and a tie⑵.
●ECU
Find the ECU plug at the rear of the frame, press the anti release buckle at ③, rotate clockwise and pull out the
plug. Tidy up the fuse box and harness and take out the ECU⑹.
CAUTION:
●You need to remove the head assembly, the direction, the assembly, the cushion, the fuel tank, etc.
●Pay attention to the restrictions of the bracket when removing the flash device and the dumping switch.
●Pay attention to the direction and angle when inserting the electrical device, so as to avoid poor contact with
bending electrical computers and prohibit violent operations.
6 1050958-014000
MSE6.0 controller - ZT184MP (matching split sensor /
Euro V) 1Bosch EFI

1-FRAME&ELECTRONIC COMPONENT 9
CHK
ADJ
NO. PART NO. PART NAME QTY CAUTION
1 1250105-138093 GB5789M6×20 (environmental color) 1
2 1100100-820000 ZT350-R brake hose RC-HU section
（
A
）
1
3 1184200-004000 ZT310 horn 1
4 1274300-065000 ZT350-VX front oil outlet pipe bracket 1
5 1251112-001093 M6×16 Hexagon flange bolts (color Zinc) 1
6 1250205-040095 GB70.1 inner hex bolt M8×16(color Zinc) 2
7 1184100-012000 ZT250-S shut down switch 1
8 1274100-095000 ZT250-S Flameout switch wire fixing bracket 1
9 1274100-017000 ZT250-S cable buckle 2
10 1224100-037000 Grade 0 flame retardant tie (black 3.6×295) 1
11 1050958-007000 ZT350 EFI high voltage line 1
12 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color Zinc) 2
13 1050958-006000 ZT350 lgnition oil body 1
14 1244200-139000 ZT310 rubber buckle (120mm) 1
Fig.2 FRAME&ELECTRONIC
COMPONENT Electricity assembly 2
PROCEDURE:
●Horn
Unplug the horn plug, remove the bolt ⑴with 10# sleeve, pull out the brake hose ⑵, remove the bolt ⑸with
8# sleeve, and remove the horn ⑸and oil outlet pipe support ⑷.
●Shut down switch
Find the plug of the flameout switch ⑺and pull it off; ⑷press the thread buckle inward in the direction of the
arrow shown in the figure and pull it out with force; Cut the tie ⑸. Remove the bolt ⑻with 6# hexagon socket,
remove the bracket ⑹and the flameout switch ⑺.
●Ignition coil
Find and pull out the plug of ignition coil ⒀, untie the wire buckle ⒁, pull out the EFI high-voltage wire in the
direction indicated by the arrow in the figure, and remove the EFI high-voltage wire ⑾; Use 8# sleeve to remove
two bolts ⑾and remove ignition coil ⒀.
CAUTION:
●When take off the plug can't drag any cable.
●Pay attention to the force when removing the buckle to prevent damage to the buckle.