Zontes ZT310-V User manual

ZT310-V (EURO IV/V)
Service manual
2020/11/27

Page 1 ，Total 110 pages
Page
0
Table of Contents …………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
1
1Frame component
1.1
Electrical Device component-1 ……………………………………………………………………………………………………………………………………………………………………………………………………………………………
7
Main harness, dump switch, relay, flasher, rectifier, ignition coil
1.2
Electrical Device component-2 ……………………………………………………………………………………………………………………………………………………………………………………………………………………………
8
Flameout switch, horn, wake-up switch
1.3
Frame plastic parts…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
9
Set clamp, side cover round glue, fuel tank liner limit glue
1.4
Directional Column component……………………………………………………………………………………………………………………………………………………………………………………………………………………………
10
Lower plate component
1.5
Frame, side bracket, put on the oil operation………………………………………………………………………………………………………………………………………………………………………………………………………………
11
Side bracket, frame oil drain bolt component
1.6
PKEcomponent
（
Bosch/colloid battery）…………………………………………………………………………………………………………………………………………………………………………………………………………………
12
2Frame & engine combination
2.1
Engine decorative cover components………………………………………………………………………………………………………………………………………………………………………………………………………………………
13
Engine left rear cover,right cover decorative
2.2
Frame & Engine Combination 2.……………………………………………………………………………………………………………………………………………………………………………………………………………………………
14
Hanging piece, bracket component
，
Lower shroud bracket
3Intake system components
3.1
Intake system components (Delphi EFI)……………………………………………………………………………………………………………………………………………………………………………………………………………………
15
Throttle valve body component, air filter, oil pipe
Intake system components (Bosch EFI)……………………………………………………………………………………………………………………………………………………………………………………………………………………
16
3.2
Carbon canister component.…………………………………………………………………………………………………………………………………………………………………………………………………………………………………
17
Carbon canister, canister solenoid valve
3.3
Air filter filter maintenance …………………………………………………………………………………………………………………………………………………………………………………………………………………………………
18
3.4
Replace the air filter element 1……………………………………………………………………………………………………………………………………………………………………………………………………………………………
19
Remove the rear inner board
3.5
Replace the air filter element 2……………………………………………………………………………………………………………………………………………………………………………………………………………………………
20
Demolition filter external related parts
3.6
Replace the air filter element 3……………………………………………………………………………………………………………………………………………………………………………………………………………………………
21
Remove filter bottom case
3.7
Replace air filter element 4…………………………………………………………………………………………………………………………………………………………………………………………………………………………………
22
Replace the air filter
3.8
Replace the air filter element (Bosch) 1……………………………………………………………………………………………………………………………………………………………………………………………………………………
23
Remove the rear inner board
3.9
Replace the air filter element (Bosch) 2……………………………………………………………………………………………………………………………………………………………………………………………………………………
24
Demolition filter external related parts
3.10
Replace the air filter element (Bosch) 3……………………………………………………………………………………………………………………………………………………………………………………………………………………
25
Contents
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Remove filter bottom case
3.11
Replace air filter element (Bosch) 4…………………………………………………………………………………………………………………………………………………………………………………………………………………………
26
Replace the air filter
4Rear wheel and rear fork component
4.1
Rear auxiliary mud board component 1……………………………………………………………………………………………………………………………………………………………………………………………………………………
27
Disassembled rear mud board component
4.2
Rear auxiliary mud plate component 2………………………………………………………………………………………………………………………………………………………………………………………………………………………
28
Sub-mud holder component after discomponent
4.3
Rear auxiliary mud plate component3………………………………………………………………………………………………………………………………………………………………………………………………………………………
29
Sub-mud component after discomponent
4.4
Rear turn signal after sale parts……………………………………………………………………………………………………………………………………………………………………………………………………………………………
30
Rear left and right turn signals and rear license plate lights for sale
4.5
Rear mud board……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
31
4.6
Rear shock absorption………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
32
Demolition after shock absorption, rear shock absorption adjustment
4.7
Rear wheel component 1……………………………………………………………………………………………………………………………………………………………………………………………………………………………………
33
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 pads…………………………………………………………………………………………………………………………………………………………………………………………………………………………………
36
4.11
Rear brake main pump adds brake fluid……………………………………………………………………………………………………………………………………………………………………………………………………………………
37
5Pedal component
5.1
Pedal height adjustment……………………………………………………………………………………………………………………………………………………………………………………………………………………………………
38
Shift lever, brake pedal height adjustment
5.2
Front right pedal mounting position adjustment 1…………………………………………………………………………………………………………………………………………………………………………………………………………
39
5.3
Front right pedal mounting position adjustment 3…………………………………………………………………………………………………………………………………………………………………………………………………………
40
5.4
Front left pedal mounting position adjustment………………………………………………………………………………………………………………………………………………………………………………………………………………
41
5.5
Front right footrest component-3……………………………………………………………………………………………………………………………………………………………………………………………………………………………
42
Decompose the Front right pedal component
5.6
Front right pedal after sale parts……………………………………………………………………………………………………………………………………………………………………………………………………………………………
43
5.7
Shift lever assembly…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
44
5.8
Front left footrest component-3……………………………………………………………………………………………………………………………………………………………………………………………………………………………
45
Decompose the front left footrest component
5.9
Front left pedal after sale parts………………………………………………………………………………………………………………………………………………………………………………………………………………………………
46
Decompose the left footrest component
5.10
Rear pedal assembly…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
47
5.11
Rear right pedal bracket components………………………………………………………………………………………………………………………………………………………………………………………………………………………
48

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5.12
Rear left pedal bracket components…………………………………………………………………………………………………………………………………………………………………………………………………………………………
49
6Cooling system component
6.1
Change the oil………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
50
6.2
Replace the oil filter…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
51
6.3
Add coolant…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
52
6.4
Radiator covercomponent 1…………………………………………………………………………………………………………………………………………………………………………………………………………………………………
53
Disassemble the radiator covercomponent
6.5
Radiator covercomponent 2…………………………………………………………………………………………………………………………………………………………………………………………………………………………………
54
6.6 Vice water tank components……………………………………………………………………………………………………………………………………………………………………………………………………………………………… 55
6.7
Radiator tubing component…………………………………………………………………………………………………………………………………………………………………………………………………………………………………
56
Disassemble the radiator tubing component
6.8
Cooling liquid………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
57
Remove the shroud component and release the coolant
6.9
Main tank component 1……………………………………………………………………………………………………………………………………………………………………………………………………………………………………
58
6.10
Main tank component 2……………………………………………………………………………………………………………………………………………………………………………………………………………………………………
59
Disassemble the main tank component
7Front fork component
7.1
Throttle/clutch cable clearance adjustment…………………………………………………………………………………………………………………………………………………………………………………………………………………
60
Adjust the throttle line, 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, rocker adjustment…………………………………………………………………………………………………………………………………………………………………………………………………………………………
65
Add brake fluid, brake rocker adjustment
7.7
Replace the front brake pads,front brake caliper mounting plate…………………………………………………………………………………………………………………………………………………………………………………………
66
7.8
Front wheel component……………………………………………………………………………………………………………………………………………………………………………………………………………………………………
67
Disassemble the front wheel, front disc brake disc, front axle component
7.9
Front mud board & wheel speed sensor component…………………………………………………………………………………………………………………………………………………………………………………………………………
68
Decompose front wheel speed sensor component, front mud plate component
7.10
Headlights assembly 1………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
69
Headlights assembly, cable plug
7.11
Headlights assembly 2………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
70
Remove headlights
7.12
Headlights assembly 3………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
71
Remove headlights upper bracket, front turning signal
7.13
Right hand component………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
72
Remove right rear view mirror, right hand rubber sleeve, balance block
，
Replace the front brake switch

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7.14
Left hand component………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
73
Demolition handle, clamp, instrument component
7.15
Directional lever
、
TFT Instrument…………………………………………………………………………………………………………………………………………………………………………………………………………………………
74
Demolition handle, clamp, TFT instrument component
7.16
Front shock absorber, upper plate component………………………………………………………………………………………………………………………………………………………………………………………………………………
75
Front shock absorber, faucet lock, upper plate component
7.17
Uplink plate, direction handle block component……………………………………………………………………………………………………………………………………………………………………………………………………………
76
Disassemble the block, the upper plate
7.18
ABS brake system-1…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
77
Remove the control unit protection cover, releasing brake fluid, hydraulic control unit
7.19
ABS brake system-2…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
78
Remove the front disc brake main pump and oil pipe
7.20
ABS brake system-3…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
79
Remove the front disc brake caliper and tubing
7.21
ABS brake system-4…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
80
Disassemble the disc brake main pump and tubing
7.22
ABS brake system-5…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
81
Disassemble rear disc brake calipers and tubing, wheel speed sensor
8Fuel tank cover component
8.1
Fuel tank cover component…………………………………………………………………………………………………………………………………………………………………………………………………………………………………
82
Disassemble the fuel tank cover component
8.2
Tank middle cover component………………………………………………………………………………………………………………………………………………………………………………………………………………………………
83
Decompose the fuel tank cover, fuel tank cover, fuel tank lock
8.3
Fuel tank outer cover components…………………………………………………………………………………………………………………………………………………………………………………………………………………………
84
Disassemble the fuel tank outer cover ,rotating bracket
8.4
fuel pump……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
85
Disassemble the fuel pump, fuel tank buffer rubber
8.5
Fuel tank front decorative cover……………………………………………………………………………………………………………………………………………………………………………………………………………………………
86
Disassemble the fuel tank front decorative cover,USB charging cable
8.6
fuel tank decorative cover lower part………………………………………………………………………………………………………………………………………………………………………………………………………………………
87
8.7
Fuel tank decorative cover components 1…………………………………………………………………………………………………………………………………………………………………………………………………………………
88
8.8
fuel tank decorative cover components 2……………………………………………………………………………………………………………………………………………………………………………………………………………………
89
9Side cover component
9.1
Side cover component………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
90
Decomposition side cover component
10 guard bar sembly
10.1
Guard bar assembly 1………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
91
Disassemble the guard bar outer parts