Zontes ZT350-GK 2022 User manual

ZT350-GK
Service manual
2022/02/16

Pages
0
Table of Contents……………………………………………………………………………………………………………………………………………………………………………………………………
1
1FRAME&ELECTRONIC COMPONENT
1.1
Electronic parts component 2…………………………………………………………………………………………………………………………………………………………………………………………
8
Remove the dump switch/ECU
1.2
Electronic parts component 2…………………………………………………………………………………………………………………………………………………………………………………………
9
Horn/Shut down switch/Ignition coil
1.3
Frame plastic parts……………………………………………………………………………………………………………………………………………………………………………………………………
10
Remove the Fuel tank liner limit glue/Battery cushion/Side cover cushion/Buckle
1.4
Directional column component………………………………………………………………………………………………………………………………………………………………………………………
11
Dissembly/Assemble
1.5
Frame, Side support, the operation of releasing engine oil…………………………………………………………………………………………………………………………………………………………
12
Remove realease the oil cooler enging oil/oil cooler/sider support;Checking the steel bowl
2FRAME & ENGINE COMBINATION
2.1
Engine component …………………………………………………………………………………………………………………………………………………………………………………………………
13
Remove the engine/Engine left rear cover
3INTAKE SYSTEM COMPONENT
3.1
Carbon tank component ……………………………………………………………………………………………………………………………………………………………………………………………
14
Remove the air filter intake air temperature sensor/carbon tank electromagnetic valve/carbon tank;Check whether the temperature sensor is damaged
3.2
The air filter assembly ………………………………………………………………………………………………………………………………………………………………………………………………
15
Remove the air filter/throttle valve component;Check whether the external intake pressure sensor is damaged/whether the fuel injector is damaged
3.3
Throttle valve body component………………………………………………………………………………………………………………………………………………………………………………………
16
Remove the throttle valve body component/external intake air pressure sensor/check whether the stepping motor is damaged /check whether the throttle position sensor 500ccw is damaged
3.4
Replace air filter element……………………………………………………………………………………………………………………………………………………………………………………………
17
Remove the filter element;Clean the Oil pipe and water pipe
4REAR WHELL COMPONENT
4.1
Rear mud board………………………………………………………………………………………………………………………………………………………………………………………………………
18
4.2
Rear shock absorption………………………………………………………………………………………………………………………………………………………………………………………………
19
Remove the rear shock absorber/adjust the rear absorber/check/troubleshooting
4.3
Rear wheel component 1……………………………………………………………………………………………………………………………………………………………………………………………
20
Contents
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Remove the rear wheel component
4.4
Rear wheel component 2……………………………………………………………………………………………………………………………………………………………………………………………
21
Remove the sprocket seat component/fault detection of sprocket seat
4.5
Rear wheel component 3……………………………………………………………………………………………………………………………………………………………………………………………
22
Remove the disc brake plate&ABS gear ring/tire and wheel component
4.6
Rear fork component…………………………………………………………………………………………………………………………………………………………………………………………………
23
Remove the rear fork component/rear fork rear-resistant block
4.7
Replace the rear brake pads…………………………………………………………………………………………………………………………………………………………………………………………
24
Disassemble disc brake arrester/change rear disc brake arrester
4.8
Rear brake main pump adds brake fluid……………………………………………………………………………………………………………………………………………………………………………
25
5PEDAL COMPONENT
5.1
Shift lever adjustment………………………………………………………………………………………………………………………………………………………………………………………………
26
Adjust the height of gear shift rod/shift lever position adjustment
5.2
Right footrest component 1…………………………………………………………………………………………………………………………………………………………………………………………
27
5.3
Right footrest component 2…………………………………………………………………………………………………………………………………………………………………………………………
28
Remove the rear brake main pump heat shield/rear disc brake main pump component
5.4
Right footrest component 3…………………………………………………………………………………………………………………………………………………………………………………………
29
Remove the brake pedal component/muffler anti-scalding
5.5
Right footrest component 4…………………………………………………………………………………………………………………………………………………………………………………………
30
Remove the R, front pedal/R,rear pedal/after sales parts for pedal component
5.6
Left footrest component 1……………………………………………………………………………………………………………………………………………………………………………………………
31
Remove the L, foot pedal holder component/gear shift rod component/rectifier/support of disc brake lock;Rectifier fault detection
5.7
Left footrest component 2……………………………………………………………………………………………………………………………………………………………………………………………
32
Remove the gear shift rod component
5.8
Left footrest component 3……………………………………………………………………………………………………………………………………………………………………………………………
33
Remove the rear left pedal/L, rear foot pedal/after sales parts for pedal component
6COOLING SYSTEM COMPONENT
6.1
Change engine oil……………………………………………………………………………………………………………………………………………………………………………………………………
34
Drain oil/change engine oil
6.2
Change engine oil filter………………………………………………………………………………………………………………………………………………………………………………………………
35
6.3
Add coolant …………………………………………………………………………………………………………………………………………………………………………………………………………
36
6.4
Water tank decorative cover component 1……………………………………………………………………………………………………………………………………………………………………………
37
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Remove the right water tank trim cover component/left water tank trim cover component
6.5
Water tank decorative cover rcomponent 2…………………………………………………………………………………………………………………………………………………………………………
38
Remove the bottom plate of right decorative cover of water tank/bottom plate of left decorative cover of water tank
6.6
Water tank decorative cover component 3……………………………………………………………………………………………………………………………………………………………………………
39
Remove the middle trim panel of water tank
6.7
Auxiliary water tank component……………………………………………………………………………………………………………………………………………………………………………………
40
Remove the auxiliary water tank/auxiliary water tank support
6.8
Draining cooling liquid………………………………………………………………………………………………………………………………………………………………………………………………
41
6.9
Main water tank component 1………………………………………………………………………………………………………………………………………………………………………………………
42
6.10
Main water tank component 2………………………………………………………………………………………………………………………………………………………………………………………
43
6.11
Water tank bracket……………………………………………………………………………………………………………………………………………………………………………………………………
44
6.12
Oil cooler component 1………………………………………………………………………………………………………………………………………………………………………………………………
45
6.13
Oil cooler component 2………………………………………………………………………………………………………………………………………………………………………………………………
46
Remove the oil cooler bracket
77-FRONT FORK COMPONENT
7.1
Throttle/clutch cable clearance adjustmen……………………………………………………………………………………………………………………………………………………………………………
47
Adjust the free travel of throttle wire and clutch zipper
7.2
Light height adjustment,replacement clutch cable……………………………………………………………………………………………………………………………………………………………………
48
7.3
Replace the throttle cable……………………………………………………………………………………………………………………………………………………………………………………………
49
Remove the throttle cable/install the throttle cable/right handlebar switch
7.4
Steering adjustment…………………………………………………………………………………………………………………………………………………………………………………………………
50
Check steering device
7.5
Right hand component………………………………………………………………………………………………………………………………………………………………………………………………
51
Remove the right rearview mirror/hand guard/generation right hand switch
7.6
Add brake fluid, rocker adjustment…………………………………………………………………………………………………………………………………………………………………………………
52
7.7
Replace the front brake pads…………………………………………………………………………………………………………………………………………………………………………………………
53
7.8
Front wheel component………………………………………………………………………………………………………………………………………………………………………………………………
54
Remove the tire and wheel component/brake disc, ABS ring gear/tire and wheel component
7.9
Front mud board & wheel speed sensor component…………………………………………………………………………………………………………………………………………………………………
55
Remove the wheel speed sensor/front disc brake caliper/front mud board component
7.10
Front mud board & Front disc brake disc pritective cover component ……………………………………………………………………………………………………………………………………………
56
Remove the front disc brake guard component/decompose front mud board component
7.11
Head and headlights component 1……………………………………………………………………………………………………………………………………………………………………………………
57
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Disassemble speedometer component/headlight components
7.12
Head and headlights component 2……………………………………………………………………………………………………………………………………………………………………………………
58
Remove the eadlight bracket/eadlamp and headlamp bracket
7.13
Head and headlights component 3……………………………………………………………………………………………………………………………………………………………………………………
59
Remove the left and right head cover components and headlamp mask
7.14
Head and headlights component 4……………………………………………………………………………………………………………………………………………………………………………………
60
Remove the left and right turn signal components/speedometer component
7.15
Head and headlights component 5……………………………………………………………………………………………………………………………………………………………………………………
61
Remove the headlamp bracket/junction box component/USB charging cable
7.16
Left hand component…………………………………………………………………………………………………………………………………………………………………………………………………
62
Remove the left mirror,left switch,hand guard/left handlebar rubber sleeve/replace the left-hand handle rocker arm and clutch switch
7.17
Directional lever component…………………………………………………………………………………………………………………………………………………………………………………………
63
7.18
Front shock absorber, upper plate component………………………………………………………………………………………………………………………………………………………………………
64
Remove the uplink board component/front left and right shock absorption/reflector/faucet lock
7.19
Uplink plate, direction handle block component……………………………………………………………………………………………………………………………………………………………………
65
7.20
ABS brake system-A 1………………………………………………………………………………………………………………………………………………………………………………………………
66
Remove the hydraulic control unit component
7.21
ABS brake system-A 2………………………………………………………………………………………………………………………………………………………………………………………………
67
Release brake fluid/remove FMC-HU
7.22
ABS brake system-A 3………………………………………………………………………………………………………………………………………………………………………………………………
68
Release brake fluid/remove the front disc crake caliper and oil pipe
7.23
ABS brake system-A 4………………………………………………………………………………………………………………………………………………………………………………………………
69
RMC-HU/wheel speed sensor/rear disc brake caliper/RC-HU
88-SURROUNDING COMPONENT
8.1
Fuel tank component…………………………………………………………………………………………………………………………………………………………………………………………………
70
8.2
Fuel Tank middle cover component…………………………………………………………………………………………………………………………………………………………………………………
71
Remove the fuel tank middle cover component/fuel tank lock/fuel tank cover compnent
8.3
Oil tank outer cover component………………………………………………………………………………………………………………………………………………………………………………………
72
Remove the fuel tank cover/swivel bracket
8.4
Oil pump……………………………………………………………………………………………………………………………………………………………………………………………………………
73
Remove the oil pump component/shroud glass strip/fuel tank cap/heat insulation cotton
99-FUEL TANK COMPONENT
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9.1
Side cover component 1………………………………………………………………………………………………………………………………………………………………………………………………
74
9.2
Side cover component 2………………………………………………………………………………………………………………………………………………………………………………………………
75
Remove the charging port base
9.3
Side cover component 3………………………………………………………………………………………………………………………………………………………………………………………………
76
9.4
Side cover component 4………………………………………………………………………………………………………………………………………………………………………………………………
77
10 GUARD BAR COMPONENT
10.1
Guard bar component 1………………………………………………………………………………………………………………………………………………………………………………………………
78
Guard bar
10.2
Guard bar component 2………………………………………………………………………………………………………………………………………………………………………………………………
79
Left guard bar/Right guard bar
11 Rear cover component
11.1
Electric device box cover component ………………………………………………………………………………………………………………………………………………………………………………
80
Remove electric device box cover component
11.2
Colloid battery………………………………………………………………………………………………………………………………………………………………………………………………………
81
Remove battery,relay and lasher
11.3
Rear armrest component……………………………………………………………………………………………………………………………………………………………………………………………
82
Remove rear armrest/taillight holder/OBD diagnosis interface position/buzzer
11.4
PKE…………………………………………………………………………………………………………………………………………………………………………………………………………………
83
Remove PKE/antenna
11.5
Electric device box component 1……………………………………………………………………………………………………………………………………………………………………………………
84
Remove electric device box component
11.6
Electric device box component 2……………………………………………………………………………………………………………………………………………………………………………………
85
Remover battery bracket
11.7
Rear mud board component 1………………………………………………………………………………………………………………………………………………………………………………………
86
Remover cushion lock/rear mud board component/taillight
11.8
Rear mud board component 2………………………………………………………………………………………………………………………………………………………………………………………
87
Decompose rear mud board/license plate light/turn singal light
12 CUSHION COMPONENT
12.1
Cushion………………………………………………………………………………………………………………………………………………………………………………………………………………
88
Discomponent and component cushion; seat cushion rubber separately purchased parts
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13 Muffler component
13.1
Muffler component 1…………………………………………………………………………………………………………………………………………………………………………………………………
89
Remove the rear section of the muffler
13.2
Muffler component 2…………………………………………………………………………………………………………………………………………………………………………………………………
90
Decompose the rear section of the muffle,muffler component mounting points on both sides
13.3
Muffler component 3…………………………………………………………………………………………………………………………………………………………………………………………………
91
Decompose the front section of the muffler
14 Lower shroud component
14.1
Lower shroud component 1…………………………………………………………………………………………………………………………………………………………………………………………
92
Remove the shroud component, shroud bracket
14.2
Lower shroud component 2…………………………………………………………………………………………………………………………………………………………………………………………
93
Decompose the lower shroud component
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©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.
Page 7 ，Toatal 93 Pages

1-FRAME&ELECTRONIC COMPONENT 8
CHK
ADJ
NO. PART NO. PART NAME QTY CAUTION
1 1184300-027000 ZT350-GK Harness components-A 1
2 1244200-139000 ZT310 Rubber buckle(120mm) 2
3 1251100-101000 Non-standard bolt M6×12（304 stainless steel）4
4 1224200-205000 ZT310 electronic cushion lock guide block 1
5 1244100-082000 ZT250－S Dump switch rabber 1
6 1184100-002000 ZT250－S Dump switch 1
7 1250104-006097 GB16674M6×12 (chromed/HH) 2
8 1050958-014000 MSE6.0 controller-ZT184MP (Euro 5) 1Bosch EFI
9 1274100-058000 ZT310 Seat lock 1
10 1224100-030000 Pin tie (Black 4.8×130）2
11 1274300-034000 ZT350-GK dump switch support 1
PROCEDURE:
●Dump switch
Remove the rubber sleeve⑸ that connects to the mounting bracket on the frame, and remove the dump switch
⑹.
●ECU
Locate and losen the rubber buckle⑵ and Pin tie⑽.
Take off the ECU plug,After pressing the anti release buckle,rotate the ECU cable plug clockwise and pull it
out.
Remove the bolt⑺ on the frame with a 8# sleeve, and then remove the ECU⑻ .
CAUTION：
●It must be dismantled them first, such as the cushion, fuel tank component,sider cover, tail dress and so on.
●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.
●Please notice the limit of the bracket when dismantling dump switch sleeve, beware of hurting your fingers.
Fig.1FRAME&ELECTRO
NIC COMPONENT Electronic parts COMPONENT 1

1-FRAME&ELECTRONIC COMPONENT 9
CHK
ADJ
NO. PART NO. PART NAME QTY CAUTION
1 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1
2 1184200-004000 ZT310 Horn 1
4 1274100-017000 ZT250
－
S Cable clip 2
5 1244200-139000 ZT310 rubber buckle (120mm) 1
6 1274100-095000 ZT250
－
S Holder of flameout switch cable 1
7 1184100-012000 ZT250
－
S Flameout switch 1
8 1250205-040095 GB70.1 inner hex bolt M8×16
（
color Zinc
）
2
9 1050958-006000 ZT350 Ignition coil 1
10 1050958-007000 ZT350 EFI high voltage line 1
11 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color zinc) 2
12 1224100-037000 0 level antiflaming binding
（
black 3.6×295
）
1
Fig.2FRAME&ELECTRO
NIC COMPONENT Electronic parts COMPONENT 2
3 4024300-023051 ZT350－GK Water tank upper bracket (dark gray
matte) 1
PROCEDURE:
●Horn
Take off the plug of horn, hold the horn⑵ by one hand use 8# sleeve remove bolts ⑴ by another hand,then take
off the horn⑵.
●Shut down switch
Find and take off the plug of the shut down switch⑺;press the Cable clip⑷ inward in the reverse direction of
the arrow in the figure and pull it out;Cut the tie⑿.Using 6# inner hexagon socket remove 2pcs bolts⑻ then take
off shut down switch⑺ and bracket⑹.
●Ignition coil
Find and remove the ignition coil⑼.Take off the rubber buckle⑸
, plug,pull out the EFI high voltage line in the
direction indicated by the arrow "a" "b" ,remove the EFI high voltage line⑽; after holding the ignition coil then
using 8#sleeve remove bolts ⑾,remove the ignition coil⑼.
CAUTION:
●When take off the plug can't drag any cable.
●Pay attention to the force when removing the buckle to prevent damage to the buckle.