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

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10.2
Guard bar assembly 2………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
92
Disassemble left and right guard components
10.3
guard bar assembly 3………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
93
Disassemble the left and right guard bar components
10.4
Engine decorative cover components………………………………………………………………………………………………………………………………………………………………………………………………………………………
94
Disassemble the engine decorative cover
11 REAR COVER COMPONENT
11.1
Electric device box cover component ………………………………………………………………………………………………………………………………………………………………………………………………………………………
95
Disassemble the electric device box cover,battery,Charging port and charging precautions
Electrical device box component (colloid battery)…………………………………………………………………………………………………………………………………………………………………………………………………………
96
11.2
Backrest assembly component………………………………………………………………………………………………………………………………………………………………………………………………………………………………
97
Disassemble the backrest,Backrest rubber
11.3
Tail skirt taillight component 1……………………………………………………………………………………………………………………………………………………………………………………………………………………………
98
Disassemble PKE single antenna, buzzer
11.4
Tail skirt taillight component 2……………………………………………………………………………………………………………………………………………………………………………………………………………………………
99
Disassemble the tail skrit left 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 component
11.7
Electrical device box component……………………………………………………………………………………………………………………………………………………………………………………………………………………………
102
Disassembled device box component,PKE controller
11.8
External battery to start PKE system………………………………………………………………………………………………………………………………………………………………………………………………………………………
103
Emergency method to turn on PKE after battery power is exhausted
12 Cushion component
12.1
cushion………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
104
Discomponent and component cushion; seat cushion rubber separately purchased parts
13 Muffler component
13.1
Muffler component 1………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
105
Disassemble the muffler peripheral components
13.2
Muffler component 2………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
106
Disassemble the front left pedal bracket components,Muffler components left side mounting position
13.3
Muffler component 3………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
107
Disassemble the muffler components, oxygen sensor
13.4
Muffler component 4………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
108
Disassemble the muffler decorative cover
14 Lower shroud component

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14.1
Lower shroud component-1…………………………………………………………………………………………………………………………………………………………………………………………………………………………………
109
Remove the shroud component, shroud bracket
14.2
Lower shroud component-2…………………………………………………………………………………………………………………………………………………………………………………………………………………………………
110
Decompose the lower shroud component
©Guangdong Tayo Motorcycle Technolog Co.
Ltd All rights reserve
All the information, illustrations andphotographs collected inthis manual are compiled according tothe 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.For 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.

1、FRAME COMPONENT 7
CHK
ADJ
NO. PART NO. PART NAME QTY CAUTION
1184200-082000 ZT310-V harness components
1184200-169000 ZT310-V wiring harness assembly (Bosch)
2 1224100-030000 Plug cable tie (black 4.8×130) 2
3 1224100-037000 0 level antiflaming binding（black 3.6×295）9
4 1184100-017000 ZT250－S Electronic fuel injection relay 3 KH-1A4T
5 1184200-024000 ZT310－R side stand relay 1G8HN-1C4T-RJ
6 1244100-082000 ZT250－S Dump switch rabber 1
7 1184100-002000 ZT250－S Dump switch 1
8 1184200-039000 ZT310－R Flasher 1
9 1251100-101000 Non-standard bolt M6×12（304 stainless steel）5
10 1274100-058000 ZT310 seat lock 1
11 1251100-102000 Non-standard bolt M6×16（304 stainless steel）3
12 1050954-019000 MT05.2 engine controller size ZT310-RC4 1ECU
13 1184100-010000 ZT250－S starting relay 1
14 1274200-171000 ZT310-V relay bracket 1
15 1274200-162000 ZT310－V fuse box bracket 1
16 1251300-085093 Non-standard cap nut M6 (environmental color) 2
17 1050954-037000 MSE6.0 Controller-ZT180MN (Euro 5) 1
18 1274200-268000 ZT310－VX Bosch ECU bracket 1
Fig.1 FRAME&ELECTRONIC
PARTS COMPONENT Electronic parts COMPONENT-1
1 1
Bosch EFI
PROCEDURE:
●Flasher and dump switch
Remove the rubber sleeve ⑻that connects the flasher ⑹to the mounting bracket on the frame, and
remove the dump switch with the same method, then separate the dump switch ⑺.
Locate the main harness rubber sleeve on the right side of the frame, pull out the rubber sleeve , pull out
the side bracket relay ⑸and the EFI relay ⑷. Locate the starter relay ⒀above the air filter to remove the
sheath of the harness and remove the self-contained nut to remove the relay from the relay bracket ⒁.
Disassemble the bracket⒁after removing the bolt⑾. Remove the bolt ⑾after removing the engine
controller plug ⑿on the left side.
●Seat lock
Take off the plug of the seat lock , and cut off binding ⑶. Remove bolts ⑼,then remove the seat lock
⑽.
●Main harness
Find the fuse box on the right side of the right air filter pull it up from the fuse box bracket⒂,then
remove the bolt⑼,take off the fuse box bracket⒂.Different plug-in methods are different, please unplug
all the electrical components connected to the main thread according to the actual operation. It needs to
use a word screwdriver, forceps, scissors and other tools to assist. The binding ⑶can be picked out by
using scissors.
The plug strap ⑵is a non-detachable structure and it is not recommended to cut it directly. It is difficult
to remove the broken portion of the buckle that is forcibly removed from the frame triangular reinforcing
plate.
CAUTION：
●Please notice the limit of the bracket when dismantling flasher and dump switch sleeve, beware of
hurting your fingers.

1、FRAME COMPONENT 8
CHK
ADJ
NO. PART NO. PART NAME QTY CAUTION
1 1251100-061093 M6×22 Screw bolt 1
2 1274200-033000 ZT310－R No.2 holder of front disc oil pipe 1
3 1184200-004000 ZT310 Horn 1
4 1274100-017000 ZT250－S Cable clip 2
5 1224100-037000 0 level antiflaming binding（black 3.6×295）2
6 1274100-095000 ZT250－S Holder of flameout switch cable 1
7 1184100-012000 ZT250－S Flameout switch 1
8 1250205-040095 GB70.1M8×16 Screw 2
9 1251112-001093 M6×16 Hexagon flange bolts (color zinc) 1
10 1274200-183000 ZT310-V outlet pipe bracket 1
1184200-033000 ZT310－R Rectifier（Lithium）
1184200-133000 ZT310 Rectifier（230W） 【1】
1184200-174000 ZT310 rectifier (five wire)
12 1274200-141000 ZT310-V high voltage package bracket 1
13 1251100-101000 Non-standard bolt M6×12（304 stainless steel）1
1184200-108000 ZT310 EFI ignition coil
1184200-104007 ZT310 EFI ignition coil (with high voltage line)
1184200-177000 ZT310 EFI ignition coil (with high-voltage wire/with
damping wire) New
15 1250201-032093 GB818M5×16 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 horn①take the horn ⑶by one hand use tool rotate the screw ⑴by another hand
remove the holder⑵then take off the horn.
●Flameout switch
⑷⑹ ⑸
.
Find and take off the plug of the flameout swich press and take off the cable clip cut ribbon
Using the inner hexagon tool, remove the bolts ⑻、the holder ⑹and the flameout switch ⑺.
●Rectifier
Find and remove the rectifier plug, remove the bolt ⑽, remove the outlet pipe bracket ⑾; remove the
bolt ⑼and remove the rectifier ⑿. Note that the rectifier is not universal.
●Ignition coil
First remove the oxygen sensor cable tie from the high pressure package bracket ⒀. Then pull out the
metal shield cap of the ignition coil ⒂from the spark plug ⒄on the engine, and then remove the bolt ⒃
with a Phillips screwdriver to remove the coil ⒂. Remove the bolt ⒁and remove the high pressure
package bracket ⒀.
CAUTION：
●The ignition coil needs to distinguish whether it has a high voltage line. If your vehicle uses an ignition coil
without a high-voltage line, you must replace the main wiring harness with an ignition coil with a high-voltage
line.
● 【1】The back of rectifier printed "ZT310(230W)" for the large magnetic motor version.
14 1
Old
111
ZT310(230W)
ZT310 EFI ignition coil
ZT310 EFI ignition
coil (with high
voltage line)

1、FRAME COMPONENT 9
CHK
ADJ
NO. PART NO. PART NAME QTY CAUTION
1 1224100-030000 Plug strap (black 4.8×130) 2
2 1244100-019000 ZT250－S Inner fuel tank fix glue cushion 1
3 1244100-002000 ZT250－S side cover cushion 6
4 1240300-007000 HJ125－6 battery cushion 1
5 1244100-061000 ZT250 Frame water proof rubber plug 2
6 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1
7 1224200-205000 ZT310 electronic cushion lock guide block 1
Frame plastic parts
Fig.3 FRAME&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 ⑵and should
push it out.
●Side cover cushion
Remove the side cover cushion ⑶with your hand directly.
●Battery cushion
Put off the battery cushion ⑷directly by hand.
●Frame waterproof rubber plug
Remove the frame waterproof rubber plug ⑸with your hand directly.
CAUTION：
●It must be dismantled them first, such as the cushion, fuel tank cover, inner fuel tank, sider cover, tail dress
and so on.
●All parts should be correctly assembled.
●From October 22, 2020,one guide block⑺have been added to the electronic cushion lock.

1、FRAME COMPONENT 10
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
1 1134100-007000
ZT250
－
S Rating nut lock washer 1
2
1251300-046093 ZT250
－
S Steering column rating nut (color zinc) 2
3 1244100-015000
ZT250
－
S Rating nut glue cushion 1
4
1224100-005000 ZT250
－
S Steering column upper dustproof cover 1
5
1130900-024000 ZT250
－
S Blowout patch 1
6
1130900-022000 ZT250
－
S One-piece steel ball 2
8
1224100-006000 ZT250
－
S Steering column down dustproof cover 1
【1】
Steering rack component
Fig.4 FRAME&ELECTRONIC
PARTS COMPONENT
17 1134100-015000 ZT250－S Down connected plate (selfmade/with
blowout patch) component
●Dissembly
Remove the lock washer ⑴.
Remove the top adjusting nut ⑵by using a special four-jaw or hook wrench tools.
Remove the rubber pad ⑶.
With one hand to hold down the down connected plate assembly ⑺, the other hand use a special four-
jaw set or hook wrench to remove the adjusting nut ⑵.
Remove the upper dustproof cover ⑷.Remove the down connected plate component ⑺.
Remove the axletee ring ⑸of the upper riser and the steel ball ⑹.
Remove the down connected plate component ⑺.
Remove the steel ball of the down connected plate component ⑺.
●Assemble
When reassembling, the conjoined steel beads should be painted lubricating grease,attention to the
dosage.
The torque of rating nut which closes to upper dustproof 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 rubber pad ⑶from deformation too larg.
CAUTION：
●Remove the head part component, handlebarcomponent and front shock absorber component first.
●Please pay attentin to fix the awaiting repair motorcycles during disassembly,prevent dumping by accident.
●
Please check whether the steel beads of the conjoined body have abnormal phenomena such as partial abrasion
and rust.If YES, please buy the regular accessories on ZONTES official website, if not, please be sure to grease
the old grease and repaint the lubricating grease on it.
●It must be to check whether the steel ball is available during reassembly.
●It must be reasonable to adjust the steering, too loose will cause the locomotive to brake slightly, and the
locomotive will shake slightly, too tight can lead to inflexibility, resulting in safety hazards.
●If you have the ability and the right tool, you can change the shaft ring ⑸and the dustproof cover ⑻.During
the replacement process, pay attention to the protection of the lower connected plate. After replacement, it must
be to check the parallelism of the column and the damping hole, the vertical degree of the vertical column and the
lower connected plate.
●【1】the down connected plate (selfmade/with blowout patch) component ⑺, has been contains the Steering
column down dustproof cover ⑻.
PROCEDURE:

1、FRAME COMPONENT 11
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
4014200-028000
ZT310-V2 frame assembly (for after-sale) (including
seat ring/nameplate/Euro V)
2
1130900-026000 ZT250
－
S Fix loop 2
after-sale
3
1274100-006000 ZT250
－
S Frame engine oil filter screen 1
4
1051453-003000 27.4×2.65 Acrylate O gule cushion loop 1
5
1274100-024000 ZT250
－
S Oil cooling joint 1 50±4N.m
6
1244100-033000 Sealing gasketφ12×φ20×2 1
7
1251100-066093 M12×1.5×15 Ablassschraube
（
color zinc
）
1 24±4N.m
8
1251300-057093 Non-standard bolt M10×1.5
（
dacromet
）
1 45±5N.m
9
1251700-025091 ZT250
－
S Side support bush 1
1274200-200000
ZT310
－
T side support(short)
1271200-165000 ZT310-T side bracket (short/dark gray)
11
1251100-088094 Non-standard bol M10×1.5×43
（
dacromet
）
1
12
1264100-001000 ZT250
－
S Side support spring 1
CAUTION：
●Remove the wind deflector component, handle bar component, steering column component first.
●Paint the lubricating grease on the cushion ring to decrease the rotary resistance of front forklift.
●The waste oil needs to be collected and returned to qualified institutions. It is forbidden to dump and
pollute the environment and the source of water.
●Pay attention to safety when mounting side support spring.
●All parts should be correctly assembled.
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
PROCEDURE:
●Checking the cushion loop
Checking whether the cushion loop ⑵is frayed, if as it, please replace it on ZONTES website, 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 appropriate tools to remove the oil cold joint ⑸, O ring ⑷, and oil
filter screen ⑶. When replacing the oil filter screen ⑶, the O-ring ⑷must be replaced at the same time. The oil
cooling joint ⑸must be tightened well when re-assembling which meets the standard torque value.
●Realease the frame tube enging oil
Put the oil pan at the bottom, use the appropriate tool to remove the oil bolts ⑺and the sealing gasket ⑹, and
remove the oil from the frame tube. Refer to the instructions for detailed steps to replace the oil. It is
recommended that the engine oil should be replaced with oil bolts ⑺and sealing gasket⑹to prevent oil leakage.
●Sider support
Use the cross screwdriver to remove the side support spring, and guard against the personal injury caused by
spring contraction, remove the nuts ⑻and bolts ⑾with the appropriate tools. Remove the side support ⑽and
bush ⑼, paint the lubricating grease on the bush⑼when re-assembling ,then put it into the frame ⑴.
1 1
10 1

1、FRAME COMPONENT 12
CHK
ADJ
NO. PART NO. PART NAME QTY CAUTION
1 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 4
2 1184200-137000 ZT310 PKE Controller（bracelet edition) 1
3 1274200-271000 ZT310－V1 PKE holder 1
4 1244200-132000 ZT310PKE rubber sleeve 1
PROCEDURE:
●PKE Controller
Unplug the PKE plug, use a No. 4 allen wrench to remove the two bolts ⑴to remove the PKE assembly ⑵
and ZT310PKE rubber sleeve⑷;
●PKE bracket
Use a No. 4 allen wrench to remove two bolts (1) to remove the PKE bracket (3);
●Fuse
Remove the fuse ①、②, check whether it is blown, if it is blown, replace the fuse of the same specification.
The band version of the PKE assembly uses 2 small 15A fuses.
●Charging
Unplug the fuse①, turn on the dustproof glue ③of 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 fully charged.
CAUTION：
●When inserting and pulling out the fuse, please pay attention to the vertical alignment before disassembly, and
it is strictly prohibited to bend. A qualified fuse should be used.
●PKE cables need to be protected. Non-professionals are strictly prohibited to disassemble the PKE system
components, otherwise it may cause permanent damage.
●Please refer to the driver's manual for PKE operating instructions.
●Be careful not to overcharge the charging time. Please refer to the manual for details on battery usage and
maintenance.
●The button battery model used in the band version: CR1225.
Fig.6 FRAME&ELECTRONIC
PARTS COMPONENT PKE component（Bosch/colloid battery）

2、FRAME & ENGINE COMPONENT 13
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
11251100-102000 Non-standard bolt M6×16 (304 stainless steel) 3
21274100-018000
ZT250
－
S muffler anti-scald plate bushing 3
31244100-017000
ZT250
－
S muffler anti-scald plate rubber 3
41224200-157000
ZT310
－
V Trim cover of right engine cover 1
51251112-005093 M6×75 hexagon flange bolt ( color zinc) 3 10N.m
61274200-221000
ZT310
－
V Mount bracket of engine right trim cover 1
71251112-003093 M6×45 hexagon flange face 9.8 bolt (color zinc) 3 10N.m
81251112-006093 M6×90 hexagon flange bolt (color zinc) 1 10N.m
91274200-220000 Front mount bracket of engine right trim cover 1
10 1274200-041000
ZT310 pipe clamp
（
φ26
）
1
11 1244200-068000
ZT310
－
V Engine water inlet pipe 1
4044201-022051
ZT310
－
R Rear left cover of engine
4050854-002051 ZT310-R engine left rear cover (dark gray)
13 4024200-058035 ZT310-V Muffler Left Anti-scalding Plate (Titanium) 1
14 1251100-135000
Non-standard bolt M10×1.5×95
（
dacromet
）
1
15 1251300-057093
Non-standard nut M10×1.5
（
dacromet
）
1 65±5N.m
PIC.1 FRAME&ENGINE ENGINE TRIM COVER ASSY
PROCEDURE:
●Engine right trim cover assembly
Disassemble 3 bolts ⑴and take out the right trim cover components.Remove the bushing ⑵、buffer rubber ⑶
from the right trim cover components. Disassemble the bolts ⑺、⑻and take out the bracket ⑼.Use a
screwdriver to loosen clamp ⑽, unplug the water inlet pipe ⑾
●Engine left rear cover
Remove the bolt ⑺disassemble the rear cover ⑿.
●Anti-scald left muffler plate
Remove the lower shroud assembly first. Secure the head of the bolt ⒁with a sleeve and remove the nut ⒂.
Grab the anti-scalding plate ⒀and remove the 2 bolts ⑸to remove it.
CAUTION：
●Engine right trim cover is only suitable for sliding clutch engine.
●The coolant should be drained before disassembly.
●Swallowing or inhaling the coolant can be harmful to the human body.Please thoroughly clean any exposed
skin such as hands, face, etc. after each addition of coolant.Contact poison control center or hospital immediately
if swallowed.If inhaled, please go to a ventilated environment immediately.In case of accidental splash into eyes,
please immediately flush eyes with plenty of running water and seek medical treatment in time.Be sure to stay
away from children and pets.
●The total amount of coolant（ZT310-V）is 1.69 liters.More details in Product Manual.
●Early production of the motorcycle does not include a left muffler anti-hot plate, may install your own.
12 1

2、FRAME & ENGINE COMPONENT 14
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
1 1251300-057093 Non-standard nut M10×1.5 8 65±5N.m
2 1020242-185000
ZT310
－
R Left hanging piece 1
3 1020242-186000
ZT310
－
R Right hanging piece 1
4 1251100-132003 Non-standard bolt M10×1.5×80 5
5 4024200-043000
ZT310
－
V bracket 1
6 1274200-092000
ZT310
－
V front bracket of left footrest 1
7 1274200-093000
ZT310
－
V front bracket of right footrest 1
8 1251100-137000 Non-standard bolt M10×1.5×100 2
9 1251112-003093 M6×45 hexagon flange face 9.8 bolt 1 12±1.5N.m
10 1274200-131000
ZT310
－
V right support of upper wind fairing 1
11 1251112-005093 M6×75 hexagon flange bolt 1 12±1.5N.m
12 1274200-130000
ZT310
－
V left support of lower wind fairing 1
13 1251300-059093 125 rear fork screw M14×1.5 1 110±5N.m
14 1252200-032000
ZT310
－
VRear forklift axle 1
15 1251100-086093 Non-standard bolt M10×1.5×112 1
16 1020241-225000
ZT250
－
R upper hanging piece
【
2
】
17 1020242-385000
ZT310
－
V Upper hanging piece
【
3
】
CAUTION：
●It is necessary to remove the seat cushion, fuel tank, side cover, pedal support, wind deflector, shift
lever, muffler, radiator and pipe, cable, air filter joint, chain, engine negative pole, etc.
●There are four versions of hanging pieces which can be universal to each other.【2】there are two
versions of 4-hole as shown in FIG. a and 5-hole as shown in FIG. b.4 holes have no stock, 5 holes are
depleting stock;when all stock are sold, it will 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 15, the five-hole hanging piecs have been
consumed【2】.
PROCEDURE:
●Front footrest bracket,wind fairing bracket
Fix the heads of the bolts ⑻with the sleeves, and disassemble the two nuts⑴on the left side
respectively.Remove the front left footrest bracket ⑹, then hold the front right footrest bracket ⑺, disassemble
the bolts ⑻and take out the right footrest bracket. Disassemble the bolt ⑾, the left bracket ⑿, the bolt⑼, and
the right bracket ⑽.
●The middle part of the engine is connected with the frame and the rear fork
Fix the head of the bolt ⒂at the lower part of the engine and the frame, and disassemble the nut ⑴. Only
disassemble the nut and other parts cannot be disassembled.
First fix the bolt ⑷head at the hanging piece with a sleeve, then remove the nut ⑴. The bolts, the upper right
hanging piece and the upper left hanging piece cannot be removed.
●Disassemble the engine
First fix the head of the rear fork shaft ⒁with a sleeve, and disassemble the nut ⒀.One person shakes the rear
fork assembly slightly and one pulls the rear fork shaft⒁.Both of them hold the engine left and right crankcase
at the same time; one person disassembles the bolts⑷, hanging pieces⑵, ⑶or take out the hanging piece
⒃.Disassemble the bolts and brackets⑸above the front bracket. Hold the engine to move to one side and pay
attention to safety during the movement. Place the engine smoothly on the ground.
【1】
Fig.2 FRAME&ENGINE FRAME&ENGINE
abc d e
2

3、INTAKE SYSTEM COMPONENT 15
CHK
ADJ
NO. PART NO. PART NAME QTY CAUTION
1 1050954-007000
39
－
N008 Fuel injector 1
2 1050954-008000
39
－
N008 Fuel injector fixator 1
3 1251112-001093
M6×16 Hexagon flange bolt
（
color zinc
）
1
4 1251300-063093
Plywood M6×11×15
（
Environmental protection
）
8
5 1251100-102000
Non-standard bolt M6×16
（
304stainless steel
）
1
6 1251100-101000
Non-standard bolt M6×12
（
304stainless steel
）
2
7 1224200-129000 ZT310-V air filter 1
8 1051354-004000
Φ56×10 Hoop assembly 2
9 1050954-005000
TB39 Throttle body part 1
10
1251100-061093 M6×22 Hexagon flange bolt
（
color zinc
）
2
11 1050954-012000
TB39 Intake pipe assembly 1
12 1051453-007000
45×2.1 Fluorine rubber O-ring 1
PROCEDURE:
●Air filter
Remove bolt ⑸、⑹; loosen the pipe hoop assembly ⑻against 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 supplied with the car to prevent foreign bodies from entering the engine. Remove the empty filter
assembly, splint nut ⑸.
●Throttle assembly
Use the plum blossom wrench to loosen the bolt ⑽,and remove the throttle assembly.Loosen the hoop⑻
between the intake pipe assembly ⑾and throttle assembly ⑼, and then remove them separately.Remove the O-
ring ⑿from the intake oipe assembly.Loosen the bolt ⑵on the injector holder ⑶with a sleeve. Remove the
holder and remove the injector ⑴.
CAUTION:
●
First it need to remove the cushion,side cover,oil tank outside cover and liner,rear shock absorber and electrical
device box etc.
●Before reassembly, check the O-ring ⑿for damage and replace it if any.
FIG.1 INTAKE SYSTEM
COMPONENT
Intake system component(Delphi EFI)

3、INTAKE SYSTEM COMPONENT 16
CHK
ADJ
NO. PART NO. PART NAME QTY CAUTION
1 1251100-101000
Non-standard bolt M6×12 (304 stainless steel) 2
2 1251100-102000
Non-standard bolt M6×16 (304 stainless steel) 1
3 1251300-063093
Clamp plate M6×11×15 (environmental color) 8
4 1224200-170000
ZT310-V1 Air filter (Bosch) 1
5 1051354-004000
Φ56×10 pipe clamp assembly 2
6 1050954-038000
ZT40 three-in-one valve body sub-assembly
manufacturing parts
1
7 1251100-061093
M6×22 Hexagon flange bolts (Class
8.8/Environmental Protection Color Zinc)
2
81250105-138093 GB5789M6×20 (environmental color) 1
9 1050968-002000
ZT1P58MJ injector retainer 1
10 1050954-023000
EV14 injector G48 1
11 1050954-034000
ZT180MN intake pipe assembly (Bosch) 1
12 1051454-016000
45×2.5 fluorine rubber O-ring 1
PROCEDURE:
●Air filter
Remove the bolts ⑴, ⑵,⑷; loosen the hose clamp assembly ⑸on 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 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 wrench toremove the bolt ⑺and remove the throttle valve assembly. Loosen the pipe clamp ⑸between
the intake pipe assembly ⑾and the throttle valve component ⑹, and remove them respectively. Remove the O-
ring ⑿from the intake pipe assembly. Remove the bolt ⑻that fixes the injector holder ⑼to remove the holder,
and remove the injector ⑽.
CAUTION:
●
First it need to remove the cushion,side cover,oil tank outside cover and liner,rear shock absorber and electrical
device box etc.
●Before reassembly, check the O-ring ⑿for damage and replace it if any.
FIG.2 INTAKE SYSTEM
COMPONENT
Intake system components (Bosch EFI)

3、INTAKE SYSTEM COMPONENT 17
CHK
ADJ
NO. PART NO. PART NAME QTY CAUTION
1 1050954-009000 YH Carbon tank electromagnetic valve 1
2 1250303-010093 GB6177.1M6（color zinc）2
3 1224100-012000
ZT250
－
S Carbon tank 1
4 1274200-088000
ZT310 water pipe clamp
（
φ10.5
）
5
5 1274200-079000
ZT310 water pipe clamp
（
φ9
）
1
Fig.3 INDUCTION
SYSTEM COMPONENT
6
7 1244200-095000
8 1244200-097000
PROCEDURE:
●Carbon tank
Clamp the hoop ⑷at the outlet of the oil and gas separator at the bottom of the tank with pliers, unplug the
adsorption tube ⑺, and remove the hoop (shown in the upper right corner). Also remove the outlet pipe ⑻and
hoop ⑸above the throttle valve body assembly (shown in the lower right corner). And the hoop ⑷on the left
side of the carbon tank ⑶, remove the adsorption tube ⑺, and pull out the intake pipe ⑹near one end of the
carbon tank. Pull the carbon tank down in the direction indicated by arrow②.
●Carbon tank electromangnetic valve
First remove the connector ①of the carbon tank solenoid valve⑴, then remove the nut ⑵with the sleeve;
remove the solenoid valve assembly. Loosen the hoop ⑷and pull out the intake pipe ⑹and the outlet pipe ⑻.
CAUTION:
●It needs to remove the seat cushion, side cover, oil tank cover, bladdar and so on.
●Regularly check whether the filter element of the carbon tank and air filter is not ventilated, otherwise it may
cause the oil supply to affect the driving experience.
●It should be no crimp, entanglement and other phenomena.
1244200-096000
Induction system component
ZT310-V carbon canister solenoid valve intake
manifold (Φ5×Φ11/Φ7×Φ13) 1
ZT310-V carbon Tank adsorption Tube (Φ 5 × Φ 11) 1
ZT310-V carbon Tank Solenoid Valve exhaust
Manifold (Φ 4 × Φ 10 / Φ 5 × Φ 11) 1

3、INTAKE SYSTEM COMPONENT 18
CHK
ADJ
NO. PART NO. PART NAME QTY CAUTION
1 1224100-010000
ZT250
－
S swell nail 1
2 1244100-061000 ZT250 anti-water rubber of frame 1
3 1250105-018091
GB5789 M8×70
（
white zinc
）
1
4 4044201-256051 ZT310-v fender ball (dark grey matte) 1
Fig.4 INDUCTION
SYSTEM COMPONENT
PROCEDURE:
●Side cover
First remove the cushion, and then remove the expansion nail⑴at the connection between the right cover and
the tail skirt. Remove waterproof plug ⑵and loosen bolt ⑶with T12 sleeve without complete removal. Pull the
decorative ball⑷out and rotate clockwise, staggering the grooves on the right cover. Pull out the right cover in
the order of①-②-③-④.
●Maintenance
The vehicle should be pushed to a dust-free or dust-free place before the rubber plug⑤of 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 device to extend the catheter into
and absorb the dirt.
CAUTION:
●In the dusty environment, the frequency of cleaning or replacing the filter element needs to be increased.
●Air filter is blocked by dust, which will increase the intake resistance, resulting in insufficient engine intake
and fuel consumption or engine damage.
●The filter element or maintenance should be replaced every 10000km under normal conditions. After each
rapid maintenance, you can continue to ride or repair the filter after 4000km.
Maintain the filter element of the air filter

3、INTAKE SYSTEM COMPONENT 19
CHK
ADJ
NO. PART NO. PART NAME QTY CAUTION
1 1250306-006097
GB923 M10×1.25×18
（
Chroming
）
1
2 1251500-007091
Non-standard flat mat φ10.5×φ24×2
（
White zinc
）
1
3 1251100-101000
Non-standard bolt M6×12
（
304stainless steel
）
1
4 1274100-057095
flanging bushing φ6.2×φ8.5×3.5
＋
φ14×1.5 2
5 1244100-052000 buffer rubber of flanging bushing （φ8.5×φ14×1）3
7 1251100-102000
Non-standard bolt M6×16
（
304stainless steel
）
3
8 1224200-110000 ZT310-V rear inner mud plate 1
A B
C D
Fig.5 INDUCTION
SYSTEM COMPONENT Replace the air filter element 1
PROCEDURE:
●Side cover
Refer to the method of removing the right cover on the previous page, remove the left and right covers.
●Left rear shock absorption
Remove the nut ⑴with the sleeve，then remove the flat mat⑵.
●Back inner mud board
Remove the bolts ⑶and ⑺on the left side, remove the bushings ⑷and ⑹, and then remove the cushion
rubber ⑸.
Remove the wheel speed sensor wire and the rear brake caliper tubing from the tubing clamp and remove the
two bolts ⑺shown.
Remove the bolt ⑺on the inside of the front and remove the bushing ⑷before removing the cushion rubber ⑸.
Pull the left rear shock absorbing head outward and remove the rear inner mud plate ⑻.
CAUTION:
●Do not pull out the stud end face completely when pulling the rear shock absorber head.
●Pay attention to the force when pulling out the wheel speed sensor line and the oil pipe.
●The bolt in the middle of the front right side (Figure C) cannot be removed.
6 1251700-059093 flanging bushingφ6.4×φ9×8＋φ18×2（environmental
color）1