Zontes ZT310-X1 2021 User manual

ZT310-X1/X1 GP
Service manual
2021/11/22

Page 1 ，Total 115 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
2Frame & engine combination
2.1
Frame & Engine Combination 1…………………………………………………………………………………………………………………………………………………………………………………
12
Detachment standard, lower guard bar; shroud front bracket; engine left rear cover
2.2
Frame & Engine Combination 2.………………………………………………………………………………………………………………………………………………………………………………
13
Hanging piece, bracket component
3Intake system components
3.1
Intake system components (Delphi EFI)…………………………………………………………………………………………………………………………………………………………………………
14
Throttle valve body component, air filter, oil pipe
3.2
Intake system components (Bosch EFI)…………………………………………………………………………………………………………………………………………………………………………
15
Air filter
3.3
Intake system components (Bosch EFI)…………………………………………………………………………………………………………………………………………………………………………
16
Throttle valve body component, oil pipe
3.4
Carbon canister component.……………………………………………………………………………………………………………………………………………………………………………………
17
Carbon canister, canister solenoid valve
3.5
Replace the air filter element……………………………………………………………………………………………………………………………………………………………………………………
18
4Rear wheel and rear fork component
4.1
Adjustment chain………………………………………………………………………………………………………………………………………………………………………………………………
19
Contents
Table of Contents

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4.2
sprocket guard…………………………………………………………………………………………………………………………………………………………………………………………………
20
Removing the sprocket guard
4.3
Sprocket assembly 1……………………………………………………………………………………………………………………………………………………………………………………………
22
4.4
Sprocket assembly 2……………………………………………………………………………………………………………………………………………………………………………………………
23
Disassemble the sprocket assembly
4.5
Rear wheel component 1………………………………………………………………………………………………………………………………………………………………………………………
24
Decomposed rear rim component
4.6
Rear wheel component 2………………………………………………………………………………………………………………………………………………………………………………………
25
Demolition of rear wheel bearing, rear disc brake disc, rear sub-mud assembly
4.7
Rear sub-slab assembly 1………………………………………………………………………………………………………………………………………………………………………………………
26
Disassembled rear mud plate bracket assembly
4.8
Rear auxiliary mud plate assembly 2……………………………………………………………………………………………………………………………………………………………………………
27
Disassembled rear mud plate bracket assembly
4.9
Rear turn signal after sale parts…………………………………………………………………………………………………………………………………………………………………………………
28
Rear left and right turn signals and rear license plate lights for sale
4.10
Chain adjuster assembly…………………………………………………………………………………………………………………………………………………………………………………………
29
Disassemble chain adjuster and maintain
4.11
Rear mud board…………………………………………………………………………………………………………………………………………………………………………………………………
30
4.12
Rear shock absorption…………………………………………………………………………………………………………………………………………………………………………………………
31
Demolition after shock absorption, rear shock absorption adjustment
4.13
Rear fork component……………………………………………………………………………………………………………………………………………………………………………………………
32
Decomposed flat fork component
4.14
Replace the rear brake pads……………………………………………………………………………………………………………………………………………………………………………………
33
4.15
Rear brake main pump adds brake fluid…………………………………………………………………………………………………………………………………………………………………………
34
5Pedal component
5.1
Pedal height adjustment…………………………………………………………………………………………………………………………………………………………………………………………
35
Shift lever, brake pedal height adjustment
5.2
Right footrest component-1……………………………………………………………………………………………………………………………………………………………………………………
36
Remove the right foot support component
5.3
Right footrest component-2……………………………………………………………………………………………………………………………………………………………………………………
37
Decomposition brake pedal component
5.4
Right footrest component-3……………………………………………………………………………………………………………………………………………………………………………………
38
Decompose the right pedal component

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5.5
Left footrest component-1………………………………………………………………………………………………………………………………………………………………………………………
39
Remove the left foot support component and the shift lever component
5.6
Left footrest component-2………………………………………………………………………………………………………………………………………………………………………………………
40
Decomposition shift lever component, front left pedal component
5.7
Left footrest component-3………………………………………………………………………………………………………………………………………………………………………………………
41
Decompose the left footrest component
6Cooling system component
6.1
Change the oil……………………………………………………………………………………………………………………………………………………………………………………………………
42
6.2
Replace the oil filter……………………………………………………………………………………………………………………………………………………………………………………………
43
6.3
Radiator tubing component………………………………………………………………………………………………………………………………………………………………………………………
44
Disassemble the radiator tubing component
6.4
Add coolant……………………………………………………………………………………………………………………………………………………………………………………………………
45
6.5
Cooling liquid……………………………………………………………………………………………………………………………………………………………………………………………………
46
Remove the shroud component and release the coolant
6.6
Right tank component……………………………………………………………………………………………………………………………………………………………………………………………
47
Disassemble the right tank component and the right water pipe component
6.7
Left tank component 1…………………………………………………………………………………………………………………………………………………………………………………………
48
Disassemble the left tank component, the left water pipe component, and the auxiliary water tank component
6.8
Left tank component 2…………………………………………………………………………………………………………………………………………………………………………………………
49
Left tank component
7Surrounding component
7.1
Surrounding the middle component……………………………………………………………………………………………………………………………………………………………………………
50
Unpack the middle cover and surround the middle
7.2
Envelope panel components……………………………………………………………………………………………………………………………………………………………………………………
51
Remove the left and right surrounding panel components
7.3
Left surround panel component…………………………………………………………………………………………………………………………………………………………………………………
52
Dismantle the left enclosure panel, the left turn signal, and the left enclosure trim panel
7.4
Right enclosure panel component………………………………………………………………………………………………………………………………………………………………………………
53
Disassemble the right surrounding panel, the right turn signal, and the right surrounding decorative panel
7.5
Lower shroud component 1……………………………………………………………………………………………………………………………………………………………………………………
54
Remove the shroud component
7.6
Lower shroud component 2……………………………………………………………………………………………………………………………………………………………………………………
55

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Disassemble Lower shroud component
8Front fork component
8.1
Throttle/clutch cable clearance adjustment, light height adjustment……………………………………………………………………………………………………………………………………………
56
Adjust the throttle line, clutch cable free travel; adjust the headlights light height
8.2
Replacement clutch cable………………………………………………………………………………………………………………………………………………………………………………………
57
8.3
Replace the throttle line…………………………………………………………………………………………………………………………………………………………………………………………
58
8.4
Steering adjustment……………………………………………………………………………………………………………………………………………………………………………………………
59
Adjustment steering device
8.5
Right hand component…………………………………………………………………………………………………………………………………………………………………………………………
60
Remove right rear view mirror, right hand rubber sleeve, balance block
8.6
Add brake fluid, rocker adjustment……………………………………………………………………………………………………………………………………………………………………………
61
Add brake fluid, brake rocker adjustment
8.7
Replace the front brake pads……………………………………………………………………………………………………………………………………………………………………………………
62
8.8
Front wheel component…………………………………………………………………………………………………………………………………………………………………………………………
63
Disassemble the front wheel, front disc brake disc, front axle component
8.9
Front mudguard & wheel speed sensor component……………………………………………………………………………………………………………………………………………………………
64
Decompose front wheel speed sensor component, front mud plate component
8.10
Windshield component 1………………………………………………………………………………………………………………………………………………………………………………………
65
Remove windshield, windshield clamp
8.11
Windshield component 2………………………………………………………………………………………………………………………………………………………………………………………
66
Remove the rocker arm on the windshield
8.12
Head cover panel assembly………………………………………………………………………………………………………………………………………………………………………………………
67
Disassemble the headlight cover panel
8.13
Windshield Base component 1…………………………………………………………………………………………………………………………………………………………………………………
68
Remove windshield motor assembly
8.14
Windshield Base component 2…………………………………………………………………………………………………………………………………………………………………………………
69
Disassemble the windshield motor assembly
8.15
Windshield Base component 3…………………………………………………………………………………………………………………………………………………………………………………
70
Disassemble the windshield base and instrument
8.16
Wire clamp………………………………………………………………………………………………………………………………………………………………………………………………………
71
Windshield motor controller, Wire clamp
8.17
Enclosing the interior components………………………………………………………………………………………………………………………………………………………………………………
72
Remove left and right hoods

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8.18
Left and right hood ……………………………………………………………………………………………………………………………………………………………………………………………
73
Remove left and right hoods
8.19
Headlight component 1…………………………………………………………………………………………………………………………………………………………………………………………
74
Remove headlight
8.20
Headlight component 2…………………………………………………………………………………………………………………………………………………………………………………………
75
Headlights for sale
8.21
Left hand component……………………………………………………………………………………………………………………………………………………………………………………………
76
Remove left rear view mirror, left hand rubber sleeve, balance weight, left switch
8.22
Directional lever, upper plate, front shock absorbing component………………………………………………………………………………………………………………………………………………
77
Demolition direction, upper clamp, upper plate component and front left and right shock absorption
8.23
Uplink plate, direction handle block component………………………………………………………………………………………………………………………………………………………………
78
Disassemble the block, the upper plate, the electronic faucet lock
8.24
ABS brake system-1……………………………………………………………………………………………………………………………………………………………………………………………
79
Disassembly control unit, FMC-HU brake hose
8.25
ABS brake system-2……………………………………………………………………………………………………………………………………………………………………………………………
80
Remove front disc brake caliper, FC-HU brake hose
8.26
ABS brake system-3……………………………………………………………………………………………………………………………………………………………………………………………
81
Disassemble rear disc brake main pump, RMC-HU brake hose
8.27
ABS brake system-4……………………………………………………………………………………………………………………………………………………………………………………………
82
Remove rear disc brake caliper, RC-HU brake hose
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
）
………………………………………………………………………………………………………………………………………………
87
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 (lithium battery)…………………………………………………………………………………………………………………………………………………………………
99
After the disassembly, the skirt assembly, PKE buzzer, PKE antenna (short)
12.3
Rear mud board component 1 (colloid battery)…………………………………………………………………………………………………………………………………………………………………
100
After the disassembly, the skirt assembly, PKE buzzer, PKE antenna (short)
12.4
Rear mud board component 2……………………………………………………………………………………………………………………………………………………………………………………
101
After the disassembly, the middle of the skirt, the taillights and the left and right skirt components
12.5
Left rear skirt component………………………………………………………………………………………………………………………………………………………………………………………
102
Disassemble the left rear skirt component

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12.6
Right rear skirt component………………………………………………………………………………………………………………………………………………………………………………………
103
Disassemble the right rear skirt component
12.7
Electrical Device Cover component……………………………………………………………………………………………………………………………………………………………………………
104
Disassembled device cover, ECU, relay and fuse box Battery and charging considerations
12.8
Electrical component box component 1…………………………………………………………………………………………………………………………………………………………………………
105
Disassembled device box component, electric device box lower cover
12.9
Electrical component box component 2…………………………………………………………………………………………………………………………………………………………………………
106
Remove PKE, electrical box
12.10
Electrical device box component(colliod battery)………………………………………………………………………………………………………………………………………………………………
107
Disassemble electrical device box cover
、
ECU
、
Realay and fuse box
12.11
Battery component(colliod battery)………………………………………………………………………………………………………………………………………………………………………………
108
Disassemble battery
、
Wake-up switch and charging precautions
12.12
Electrical device box component-1(colliod battery)……………………………………………………………………………………………………………………………………………………………
109
Disassemble electrical device box component
、
lower cover of electrical device box
12.13
Electrical device box component-2(colliod battery)……………………………………………………………………………………………………………………………………………………………
110
Disassemble PKE
、
Electrical device box
12.14
External battery to start PKE system……………………………………………………………………………………………………………………………………………………………………………
111
Emergency method to turn on PKE after battery power is exhausted
13 Cushion component
13.1
cushion…………………………………………………………………………………………………………………………………………………………………………………………………………
112
Discomponent and component cushion; seat cushion rubber separately purchased parts
14 Muffler component
14.1
Muffler rear section……………………………………………………………………………………………………………………………………………………………………………………………
113
Disassemble the rear section of the muffler, anti-scalding plate, muffler clamp
14.2
Muffler front section 1…………………………………………………………………………………………………………………………………………………………………………………………
114
Remove the front part of the muffler
14.3
Muffler front section 2…………………………………………………………………………………………………………………………………………………………………………………………
115
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 8
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－S Flasher 1
5 1244100-082000 ZT250－S Dump switch rabber 1
6 1184100-002000 ZT250－S Dump switch 1
7 1274100-058000 ZT310 seat lock 1
8 1251100-101000 Non-standard bolt M6×12（304 stainless steel）4
9 1184200-024000 ZT310－R side stand relay 1G8HN-1C4T-RJ
10 1184100-017000 ZT250－S Electronic 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
14 ZT310 EFI ignition coil 1
15 1274100-085000 ZT250－R Ignition 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
18 1274200-291000 ZT310-R ignition coil connection bracket 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 binding⑶ and 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 bolts⒀ with a cross screwdriver and remove the ignition coil⒁ . Remove the bolt
⑵and remove the ignition coil support⒂.
●Rectifier
Remove the nuts⑿ and remove the rectifier⑾.Note that the rectifier is not universal.The back of rectifier
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
lock⑺ and seat lock guide block⒄.
Fig.1 FRAME&ELECTRONIC
PARTS COMPONENT Electronic parts COMPONENT-1
CAUTION：
●In order to avoid the improper contact of the bending electrical parts, please pay attention to the direction and
angle of force when plugging the electrical parts, so as to avoid the improper contact of the bending electrical
parts. No violent operation.
●The type of side stand relay：G8HN-1C4T-RJ. The type of EFI Ignition coil installing：KH-1A4T.
●From the end of October 2020, a new seat lock guide block ⒄.
11
1
1
1
Delphi EFI

1、FRAME COMPONENT 9
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 frane retartant ribbon 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 1250303-010093 GB6177.1M6 (environmental color zinc) 1
10 1274200-179000 ZT310-X1 Wiring bracket 1
11 1250105-137093 GB5789M6×16 (environmental color zinc) 1
Fig.2 FRAME&ELECTRONIC
PARTS COMPONENT Electronic parts COMPONENT-2
PROCEDURE:
●Horn
Take off the plug of horn①
take the horn(3) by one hand use tool rotate the screw(1) by another hand remove the
holder⑵ then take off the horn.
●Flameout switch
Find and take off the plug of the flameout swich⑹ press and take off the cable clip⑷ cut ribbon ⑸.Using the
inner hexagon tool, remove the bolts⑻、the holder⑹ and the flameout switch⑺.
●Wiring bracket
Secure the head of the bolt (11) with a sleeve, remove the nut (9), and remove the wiring bracket (10).
Subsequent cancellation of the nut (9) to weld the nut on the frame.
CAUTION：
●When Take off the plug①、②can't drag any cable.
●Attention the the strength and direction of force when removing cable clip.