Zontes ZT310-X User manual

ZT310-X/X GP
Service manual
2020/11/11

Page 1 ，Toatal 118 Pages
Page
0
Table of Contents …………………………………………………………………………………………………………………………………………………………………………………………………
1
1FRAME&ELECTRONIC PARTS COMPONENT
1.1
Electrical Device component-1 ………………………………………………………………………………………………………………………………………………………………………………………
9
Main harness, dump switch, relay, flasher, rectifier, ignition coil
1.2
Electrical Device component-2 ………………………………………………………………………………………………………………………………………………………………………………………
10
Flameout switch, horn, wake-up switch
1.3
Frame plastic parts……………………………………………………………………………………………………………………………………………………………………………………………………
11
Set clamp, side cover round glue, fuel tank liner limit glue
1.4
Directional Column component………………………………………………………………………………………………………………………………………………………………………………………
12
Lower plate component
1.5
Frame, side bracket, put on the oil operation…………………………………………………………………………………………………………………………………………………………………………
13
Side bracket, frame oil drain bolt component
2FRAME&ENGINE
2.1
Frame & Engine Combination 1……………………………………………………………………………………………………………………………………………………………………………………
14
Detachment standard, lower guard bar; shroud front bracket; engine left rear cover
2.2
Frame & Engine Combination 2.……………………………………………………………………………………………………………………………………………………………………………………
15
Hanging piece, bracket component
3INDUCTION SYSTEM COMPONENT
3.1
Intake system components (Delphi EFI)……………………………………………………………………………………………………………………………………………………………………………
16
Throttle valve body component, air filter, oil pipe
3.2
Intake system components (Bosch EFI)………………………………………………………………………………………………………………………………………………………………………………
17
Air filter
3.3
Intake system components (Bosch EFI)………………………………………………………………………………………………………………………………………………………………………………
18
Throttle valve body component, oil pipe
3.4
Carbon canister component.…………………………………………………………………………………………………………………………………………………………………………………………
19
Carbon canister, canister solenoid valve
3.5
Replace the air filter element…………………………………………………………………………………………………………………………………………………………………………………………
20
4REAR WHELL COMPONENT
4.1
Rear mud board………………………………………………………………………………………………………………………………………………………………………………………………………
21
Contents
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4.2
Rear shock absorption………………………………………………………………………………………………………………………………………………………………………………………………
22
Demolition after shock absorption, rear shock absorption adjustment
4.3
Rear wheel component 1……………………………………………………………………………………………………………………………………………………………………………………………
23
Remove the rear rim component, sprocket seat, sprocket
4.4
Rear wheel component 2……………………………………………………………………………………………………………………………………………………………………………………………
24
Decomposed rear rim component
4.5
Rear fork component…………………………………………………………………………………………………………………………………………………………………………………………………
25
Decomposed flat fork component
4.6
Replace the rear brake pads…………………………………………………………………………………………………………………………………………………………………………………………
26
4.7
Rear brake main pump adds brake fluid……………………………………………………………………………………………………………………………………………………………………………
27
5
5.1
Pedal height adjustment………………………………………………………………………………………………………………………………………………………………………………………………
28
Shift lever, brake pedal height adjustment
5.2
Right footrest component-1…………………………………………………………………………………………………………………………………………………………………………………………
29
Remove the right foot support component
5.3
Right footrest component-2…………………………………………………………………………………………………………………………………………………………………………………………
30
Decomposition brake pedal component
5.4
Right footrest component-3…………………………………………………………………………………………………………………………………………………………………………………………
31
Decompose the right pedal component
5.5
Left footrest component-1……………………………………………………………………………………………………………………………………………………………………………………………
32
Remove the left foot support component and the shift lever component
5.6
Left footrest component-2……………………………………………………………………………………………………………………………………………………………………………………………
33
Decomposition shift lever component, front left pedal component
5.7
Left footrest component-3……………………………………………………………………………………………………………………………………………………………………………………………
34
Decompose the left footrest component
6COOLING SYSTEM COMPONENT
6.1
Change the oil………………………………………………………………………………………………………………………………………………………………………………………………………
35
6.2
Replace the oil filter…………………………………………………………………………………………………………………………………………………………………………………………………
36
6.3
Radiator tubing component…………………………………………………………………………………………………………………………………………………………………………………………
37
Disassemble the radiator tubing component
6.4
Add coolant…………………………………………………………………………………………………………………………………………………………………………………………………………
38
6.5
Cooling liquid………………………………………………………………………………………………………………………………………………………………………………………………………
39

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Remove the shroud component and release the coolant
6.6
Right tank component………………………………………………………………………………………………………………………………………………………………………………………………
40
Disassemble the right tank component and the right water pipe component
6.7
Left tank component 1………………………………………………………………………………………………………………………………………………………………………………………………
41
Disassemble the left tank component, the left water pipe component, and the auxiliary water tank component
6.8
Left tank component 2………………………………………………………………………………………………………………………………………………………………………………………………
42
Left tank component
7SURROUNDING COMPONENT
7.1
Surrounding the middle component…………………………………………………………………………………………………………………………………………………………………………………
43
Unpack the middle cover and surround the middle
7.2
Envelope panel components…………………………………………………………………………………………………………………………………………………………………………………………
44
Remove the left and right surrounding panel components
7.3
Left surround panel component………………………………………………………………………………………………………………………………………………………………………………………
45
Dismantle the left enclosure panel, the left turn signal, and the left enclosure trim panel
7.4
Right enclosure panel component……………………………………………………………………………………………………………………………………………………………………………………
46
Disassemble the right surrounding panel, the right turn signal, and the right surrounding decorative panel
7.5
Lower shroud component 1…………………………………………………………………………………………………………………………………………………………………………………………
47
Remove the shroud component
7.6
Lower shroud component 2…………………………………………………………………………………………………………………………………………………………………………………………
48
Disassemble Lower shroud component
8
FRONT FORK COMPONEN
8.1
Throttle/clutch cable clearance adjustment, light height adjustment…………………………………………………………………………………………………………………………………………………
49
Adjust the throttle line, clutch cable free travel; adjust the headlights light height
8.2
Replacement clutch cable……………………………………………………………………………………………………………………………………………………………………………………………
50
8.3
Replace the throttle line………………………………………………………………………………………………………………………………………………………………………………………………
51
8.4
Steering adjustment…………………………………………………………………………………………………………………………………………………………………………………………………
52
Adjustment steering device
8.5
Right hand component………………………………………………………………………………………………………………………………………………………………………………………………
53
Remove right rear view mirror, right hand rubber sleeve, balance block
8.6
Add brake fluid, rocker adjustment…………………………………………………………………………………………………………………………………………………………………………………
54
Add brake fluid, brake rocker adjustment
8.7
Replace the front brake pads…………………………………………………………………………………………………………………………………………………………………………………………
55

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8.8
Front wheel component………………………………………………………………………………………………………………………………………………………………………………………………
56
Disassemble the front wheel, front disc brake disc, front axle component
8.9
Front mud board & wheel speed sensor component…………………………………………………………………………………………………………………………………………………………………
57
Decompose front wheel speed sensor component, front mud plate component
8.10
Windshield componen(Electronic Instrument)t………………………………………………………………………………………………………………………………………………………………………
58
Remove windshield, windshield clamp, windshield liner
8.11
Electronic Instrument…………………………………………………………………………………………………………………………………………………………………………………………………
59
Dismantle the instrument
8.12
Head Cover Panel Components(Electronic Instrument)……………………………………………………………………………………………………………………………………………………………
60
Demolished cover panel
8.13
Windshield Base component(Electronic Instrument)…………………………………………………………………………………………………………………………………………………………………
61
Windshield motor, windshield rocker and windshield base
8.14
Enclosing the interior components(Electronic Instrument)…………………………………………………………………………………………………………………………………………………………
62
Front and rear surround, USB charging cable
8.15
Left and right hood(Electronic Instrument) …………………………………………………………………………………………………………………………………………………………………………
63
Remove left and right hoods
8.16
Motor Controller, Headlight component(Electronic Instrument)……………………………………………………………………………………………………………………………………………………
64
Dismantle motor controller, wire plug fixing bracket, headlight component
8.17
Windshield component(TFT Instrument) 1…………………………………………………………………………………………………………………………………………………………………………
65
Remove windshield, windshield clamp
8.18
Windshield component(TFT Instrument) 2…………………………………………………………………………………………………………………………………………………………………………
66
Remove the rocker arm on the windshield
8.19
Head cover panel assembly(TFT Instrument)………………………………………………………………………………………………………………………………………………………………………
67
Disassemble the headlight cover panel
8.20
Windshield Base component(TFT Instrument) 1……………………………………………………………………………………………………………………………………………………………………
68
Remove windshield motor assembly
8.21
Windshield Base component(TFT Instrument) 2……………………………………………………………………………………………………………………………………………………………………
69
Disassemble the windshield motor assembly
8.22
Windshield Base component(TFT Instrument) 3……………………………………………………………………………………………………………………………………………………………………
70
Disassemble the windshield base and instrument
8.23
Wire clamp(TFT Instrument)…………………………………………………………………………………………………………………………………………………………………………………………
71
Windshield motor controller, Wire clamp
8.24
Enclosing the interior components(TFT Instrument)…………………………………………………………………………………………………………………………………………………………………
72
Remove left and right hoods

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8.25
Left and right hood(TFT Instrument) ………………………………………………………………………………………………………………………………………………………………………………
73
Remove left and right hoods
8.26
Headlight component(TFT Instrument) 1……………………………………………………………………………………………………………………………………………………………………………
74
Remove headlight
8.27
Headlight component…………………………………………………………………………………………………………………………………………………………………………………………………
75
Headlights and headlights for sale
8.28
Left hand component…………………………………………………………………………………………………………………………………………………………………………………………………
76
Remove left rear view mirror, left hand rubber sleeve, balance weight, left switch
8.29
Directional lever, upper plate, front shock absorbing component……………………………………………………………………………………………………………………………………………………
77
Demolition direction, upper clamp, upper plate component and front left and right shock absorption
8.30
Uplink plate, direction handle block component……………………………………………………………………………………………………………………………………………………………………
78
Disassemble the block, the upper plate, the electronic faucet lock
8.31
ABS Brake System-1…………………………………………………………………………………………………………………………………………………………………………………………………
79
Brake brake fluid
、
disassemble the front disc brake main pump and the tubing
、
ABS control unit
8.32
ABS Brake System-2…………………………………………………………………………………………………………………………………………………………………………………………………
80
Disassemble the front disc brake caliper and the FC-HU tubing
8.33
ABS Brake System-3…………………………………………………………………………………………………………………………………………………………………………………………………
81
Disassemble the rear disc brake main pump and the tubing
8.34
ABS Brake System-4…………………………………………………………………………………………………………………………………………………………………………………………………
82
Disassemble the rear disc brake caliper and the FC-HU tubing
9FUEL TANK COVER COMPONENT
9.1
Tank middle cover component
（
Small fuel tank
）
…………………………………………………………………………………………………………………………………………………………………
83
Demolition tank cover component
9.2
Fuel tank cover, fuel tank cover, fuel tank lock
（
Smalll fuel tank
）
………………………………………………………………………………………………………………………………………………
84
Decompose the tank cover component
9.3
Fuel tank trim cover component
（
Small fuel tank
）
………………………………………………………………………………………………………………………………………………………………
85
Remove left and right fuel tank trim cover
9.4
Tank middle cover component
（
Big fuel tank
）
……………………………………………………………………………………………………………………………………………………………………
86
Demolition tank cover component
9.5
Fuel tank cover, fuel tank cover, fuel tank lock
（
Big fuel tank
）
…………………………………………………………………………………………………………………………………………………
89
Decompose the tank cover component
9.5
Fuel tank trim cover component
（
Big fuel tank
）
…………………………………………………………………………………………………………………………………………………………………
88
Remove left and right fuel tank trim cover

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10 TANK LINER COMPONENT
10.1
Fuel Tank Box component
（
Small fuel tank
）
………………………………………………………………………………………………………………………………………………………………………
89
Demolition tank box, PKE antenna
10.2
Tank liner component
（
Small fuel tank
）
…………………………………………………………………………………………………………………………………………………………………………
90
Demolition tank liner component, seat cushion fixing block
10.3
Tank liner
（
Small fuel tank
）
………………………………………………………………………………………………………………………………………………………………………………………
91
Demolition tank liner, fuel pump, fuel tank cover bracket, fuel tank cap
10.4
Fuel Tank Box component
（
Big fuel tank
）
………………………………………………………………………………………………………………………………………………………………………
92
Demolition tank box, PKE antenna
10.5
Tank liner component
（
Big fuel tank
）
……………………………………………………………………………………………………………………………………………………………………………
93
Demolition tank liner component, seat cushion fixing block
10.6
Tank liner
（
Big fuel tank
）
…………………………………………………………………………………………………………………………………………………………………………………………
94
Demolition tank liner, fuel pump, fuel tank cover bracket, fuel tank cap
11 SIDE COVER COMPONENT
11.1
Side cover lower components………………………………………………………………………………………………………………………………………………………………………………………
95
Remove the lower part of the left side cover and the lower part of the right side cover
11.2
Left side cover upper component……………………………………………………………………………………………………………………………………………………………………………………
96
Remove the upper and middle parts of the left side cover
11.3
Right side cover upper component……………………………………………………………………………………………………………………………………………………………………………………
97
Remove the upper and middle parts of the right side cover
12 REAR COVER COMPONENT
12.1
Rear Armrest component……………………………………………………………………………………………………………………………………………………………………………………………
98
Remove the armrest
12.2
Rear mud board component 1………………………………………………………………………………………………………………………………………………………………………………………
99
Demolition of the mud board component and the rear mud board bracket
12.3
Rear mud board component 2………………………………………………………………………………………………………………………………………………………………………………………
100
Disassembled mud board component
12.4
Rear Turning Light After-sales Parts…………………………………………………………………………………………………………………………………………………………………………………
101
12.5
Rear mud board component 1 (lithium battery)……………………………………………………………………………………………………………………………………………………………………
102
After the disassembly, the skirt assembly, PKE buzzer, PKE antenna (short)
12.6
Rear mud board component 1 (colloid battery)……………………………………………………………………………………………………………………………………………………………………
103

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After the disassembly, the skirt assembly, PKE buzzer, PKE antenna (short)
12.7
Rear mud board component 2………………………………………………………………………………………………………………………………………………………………………………………
104
After the disassembly, the middle of the skirt, the taillights and the left and right skirt components
12.8
Left rear skirt component……………………………………………………………………………………………………………………………………………………………………………………………
105
Disassemble the left rear skirt component
12.9
Right rear skirt component……………………………………………………………………………………………………………………………………………………………………………………………
106
Disassemble the right rear skirt component
12.10
Electrical Device Cover component…………………………………………………………………………………………………………………………………………………………………………………
107
Disassembled device cover, ECU, relay and fuse box Battery and charging considerations
12.11
Electrical component box component 1………………………………………………………………………………………………………………………………………………………………………………
108
Disassembled device box component, electric device box lower cover
12.12
Electrical component box component 2………………………………………………………………………………………………………………………………………………………………………………
109
Remove PKE, electrical box
12.13
Electrical device box component(colliod battery)……………………………………………………………………………………………………………………………………………………………………
110
Disassemble electrical device box cover
、
ECU
、
Realay and fuse box
12.14
Battery component(colliod battery)…………………………………………………………………………………………………………………………………………………………………………………
111
Disassemble battery
、
Wake-up switch and charging precautions
12.15
Electrical device box component-1(colliod battery)…………………………………………………………………………………………………………………………………………………………………
112
Disassemble electrical device box component
、
lower cover of electrical device box
12.16
Electrical device box component-2(colliod battery)…………………………………………………………………………………………………………………………………………………………………
113
Disassemble PKE
、
Electrical device box
12.17
External battery to start PKE system…………………………………………………………………………………………………………………………………………………………………………………
114
Emergency method to turn on PKE after battery power is exhausted
13 CUSHION COMPONENT
13.1
cushion………………………………………………………………………………………………………………………………………………………………………………………………………………
115
Discomponent and component cushion; seat cushion rubber separately purchased parts
14 MUFFLER COMPONENT
14.1
Muffler rear section…………………………………………………………………………………………………………………………………………………………………………………………………
116
Disassemble the rear section of the muffler, anti-scalding plate, muffler clamp
14.2
Muffler front section 1………………………………………………………………………………………………………………………………………………………………………………………………
117
Remove the front part of the muffler
14.3
Muffler front section 2………………………………………………………………………………………………………………………………………………………………………………………………
118

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Decompose the front section of the muffler, oxygen sensor, muffler flange
©Guangdong Tayo Motorcycle Technolog 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 COMPONENT 9
CHK
ADJ
NO. PART NO. PART NAME QTY CAUTION
1184200-079000 ZT310-X1 wire harness assembly Delphi EFI
1184200-168000 ZT310－X1 Wire Harness component (Bosch) Bosch EFI
2 1251100-102000 Non-standard bolt M6×16（304 stainless steel）1
3 1224100-037000 0 level antiflaming binding（black 3.6×295）11
4 1184200-039000 ZT250－SFlasher 1
5 1244100-082000 ZT250－S Dump switch rabber 1
6 1184100-002000 ZT250－SDump switch 1
7 1274100-058000 ZT310 seat lock 1
8 1251100-101000 Non-standard bolt M6×12（304 stainless steel）3
9 1184200-024000 ZT310－R side stand relay 1G8HN-1C4T-RJ
10 1184100-017000 ZT250－SElectronic fuel injection relay 2 KH-1A4T
1184200-033000 ZT310-R rectifier (for lithium battery)
1184200-133000 ZT310 rectifier (230W)
1184200-174000 ZT310 rectifier (five wire) Bosch EFI
12 1250303-010093 GB6177.1 M6 2
13 1250201-032093 GB818M5×16 bolt 2
1184200-108000 ZT310 EFI ignition coil
1184200-104007 ZT310 EFI ignition coil (with high voltage line)
15 1274100-085000 ZT250－RIgnition coil installing holder 1
16 1224100-030000 Plug cable tie (black 4.8×130) 1
17 1224200-205000 ZT310 electronic seat lock guide block 1
PROCEDURE:
●Main harness
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 binding⑶and ⒃can be picked out by using scissors.
●Flasher and dump switch
Remove the rubber sleeve⑷that connects the flasher⑸to the mounting bracket on the frame, and
remove the dump switch with the same method, then separate the dump switch⑹.
●Relay&head light diode
Pull out the side stand relay⑼and electric injection relay⑽directly.
●Ignition coil &support
Remove the crosshead bolts⒀with a cross screwdriver and remove the ignition coil⒁. Remove the bolt
⑵and remove the ignition coil support⒂.
●Rectifier
Remove the nuts⑿and remove the rectifier⑾.Note that the rectifier isnot universal.The back ofrectifier
printed "ZT310(230W)" for the colloid battery,othervise for the lithium battery.The standard rectifier for
Bosch EFI is"ZT310 rectifier (five-wire)".
●Seat lock
Find and take off the plug of the seat lock , and cut off binding⑶.Remove bolts ⑻,then remove the seat
lock⑺and seat lock guide block⒄.ZT310 EFI ignition coil
14 1
Delphi EFI
Fig.1 FRAME&ELECTRONIC
PARTS COMPONENT Electronic parts COMPONENT-1
1 1
Bosch EFI
11 1 Delphi EFI
1184200-177000 ZT310 EFI ignition coil (with high-voltage wire/with
damping wire)
CAUTION
：
●The ignition coil can not be universal.If your motorcycle used " 1184200-108000 ZT310 EFI ignition coil"
when replacing the wire harness component,it will be purchased with "1184200-104007 ZT310 EFI ignition
coil (with high voltageline)"
●From the end of October 2020, a new seat lock guide block ⒄.
ZT310 EFI ignition coil
(with high voltage line)
ZT310 EFI
ignition coil
(with high-
voltage
wire/with
damping wire)