Zontes ZT350-R 2022 User manual

ZT350-R/R1 (EURO Ⅴ)
Service manual
2022/5/3

Page 1 ，Total 107 pages
Page
0Table of Contents 1
1Frame component
1.1
Electrical device component-1……………………………………………………………………………………………………………………………………………………………………………………………………………
8
Main harness, dump switch, relay, flasher, rectifier, ignition coil
1.2
Electrical device component-2……………………………………………………………………………………………………………………………………………………………………………………………………………
9
Flameout switch, horn, wake-up switch
1.3
Frame plastic parts………………………………………………………………………………………………………………………………………………………………………………………………………………………
10
Line clamp, side cover round glue, fuel tank liner limit glue
1.4
Directional column component……………………………………………………………………………………………………………………………………………………………………………………………………………
11
Lower plate component
1.5
Frame, side bracket, ………………………………………………………………………………………………………………………………………………………………………………………………………………………
12
Side bracket
2Frame & engine combination
2.1
Frame & engine combination……………………………………………………………………………………………………………………………………………………………………………………………………………
13
Engine left rear cover ,disassemble the engine
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 wheel and rear fork component
4.1
Rear auxiliary mud board component 1…………………………………………………………………………………………………………………………………………………………………………………………………
18
Disassembled rear mud board component
4.2
Rear auxiliary mud plate component 2……………………………………………………………………………………………………………………………………………………………………………………………………
19
Sub-mud holder component after discomponent
4.3
Rear auxiliary mud plate component3……………………………………………………………………………………………………………………………………………………………………………………………………
20
Contents
Table of Contents

Page 2，Total 107 pages
Page
Contents
Table of Contents
Sub-mud component after discomponent
4.4
Rear turn signal after sale parts…………………………………………………………………………………………………………………………………………………………………………………………………………
21
Rear left and right turn signals and rear license plate lights for sale
4.5
Rear mud board…………………………………………………………………………………………………………………………………………………………………………………………………………………………
22
4.6
Rear shock absorption……………………………………………………………………………………………………………………………………………………………………………………………………………………
23
Demolition after shock absorption, rear shock absorption adjustment
4.7
Rear wheel component 1…………………………………………………………………………………………………………………………………………………………………………………………………………………
24
Remove the rear rim component, sprocket seat, sprocket
4.8
Rear wheel component 2…………………………………………………………………………………………………………………………………………………………………………………………………………………
25
Decomposed rear rim component
4.9
Rear wheel component 3…………………………………………………………………………………………………………………………………………………………………………………………………………………
26
Decomposed rear rim component
4.10
Rear fork component……………………………………………………………………………………………………………………………………………………………………………………………………………………
27
Decomposed flat fork component
4.11
Replace the rear brake pads………………………………………………………………………………………………………………………………………………………………………………………………………………
28
4.12
Rear brake main pump adds brake fluid…………………………………………………………………………………………………………………………………………………………………………………………………
29
5Rear wheel and rear fork component
5.1
Adjustment chain…………………………………………………………………………………………………………………………………………………………………………………………………………………………
30
5.2
sprocket guard……………………………………………………………………………………………………………………………………………………………………………………………………………………………
31
Removing the sprocket guard
5.3
Sprocket assembly 1………………………………………………………………………………………………………………………………………………………………………………………………………………………
32
5.4
Sprocket assembly 2………………………………………………………………………………………………………………………………………………………………………………………………………………………
33
Disassemble the sprocket assembly
5.5
Rear wheel component 1…………………………………………………………………………………………………………………………………………………………………………………………………………………
34
Decomposed rear rim component
5.6
Rear wheel component 2…………………………………………………………………………………………………………………………………………………………………………………………………………………
35
Demolition of rear wheel bearing, rear disc brake disc, rear sub-mud assembly
5.7
Rear sub-slab assembly 1…………………………………………………………………………………………………………………………………………………………………………………………………………………
36
Disassembled rear mud plate bracket assembly
5.8
Rear auxiliary mud plate assembly 2……………………………………………………………………………………………………………………………………………………………………………………………………
37
Disassembled rear mud plate bracket assembly
5.9
Rear turn signal after sale parts…………………………………………………………………………………………………………………………………………………………………………………………………………
38
Rear left and right turn signals and rear license plate lights for sale
5.10
Chain adjuster assembly…………………………………………………………………………………………………………………………………………………………………………………………………………………
39

Page 3 ，Total 107 pages
Page
Contents
Table of Contents
Disassemble chain adjuster and maintain
5.11
Rear mud board…………………………………………………………………………………………………………………………………………………………………………………………………………………………
40
5.12
Rear shock absorption……………………………………………………………………………………………………………………………………………………………………………………………………………………
41
Demolition after shock absorption, rear shock absorption adjustment
5.13
Rear fork component……………………………………………………………………………………………………………………………………………………………………………………………………………………
42
Decomposed flat fork component
5.14
Replace the rear brake pads………………………………………………………………………………………………………………………………………………………………………………………………………………
43
5.15
Rear brake main pump adds brake fluid…………………………………………………………………………………………………………………………………………………………………………………………………
44
6Pedal component
6.1
Shift lever adjustment……………………………………………………………………………………………………………………………………………………………………………………………………………………
45
Adjust the height of gear shift rod/shift lever position adjustment
6.2
Right footrest component 1………………………………………………………………………………………………………………………………………………………………………………………………………………
46
6.3
Right footrest component 2………………………………………………………………………………………………………………………………………………………………………………………………………………
47
Remove the rear brake main pump heat shield/rear disc brake main pump component
6.4
Right footrest component 3………………………………………………………………………………………………………………………………………………………………………………………………………………
48
Remove the brake pedal component/muffler anti-scalding
6.5
Right footrest component 4………………………………………………………………………………………………………………………………………………………………………………………………………………
49
Remove the R, front pedal/R,rear pedal/after sales parts for pedal component
6.6
Left footrest component 1………………………………………………………………………………………………………………………………………………………………………………………………………………
50
Remove the L, foot pedal holder component/gear shift rod component/rectifier/support of disc brake lock;Rectifier fault detection
6.7
Left footrest component 2………………………………………………………………………………………………………………………………………………………………………………………………………………
51
Remove the gear shift rod component
6.8
Left footrest component 3………………………………………………………………………………………………………………………………………………………………………………………………………………
52
Remove the rear left pedal/L, rear foot pedal/after sales parts for pedal component
7Cooling system component
7.1
Change engine oil…………………………………………………………………………………………………………………………………………………………………………………………………………………………
53
7.2
Change engine oil filter…………………………………………………………………………………………………………………………………………………………………………………………………………………
54
7.3
Add coolant ……………………………………………………………………………………………………………………………………………………………………………………………………………………………
55
7.4
Draining cooling liquid……………………………………………………………………………………………………………………………………………………………………………………………………………………
56
7.5
Water tank component-1…………………………………………………………………………………………………………………………………………………………………………………………………………………
57
7.6
Water tank component-2…………………………………………………………………………………………………………………………………………………………………………………………………………………
58

Page 4 ，Total 107 pages
Page
Contents
Table of Contents
7.7
Water tank component-3…………………………………………………………………………………………………………………………………………………………………………………………………………………
59
Remove the auxiliary water tank/auxiliary water tank support
7.8
Oil cooler component 1…………………………………………………………………………………………………………………………………………………………………………………………………………………
60
Remove the oil cooler
7.9
Oil cooler component 2…………………………………………………………………………………………………………………………………………………………………………………………………………………
61
Remove the oil cooler bracket
8Front fork component
8.1
Throttle/clutch cable clearance adjustment………………………………………………………………………………………………………………………………………………………………………………………………
62
Adjust the throttle line, clutch cable free travel
8.2
Replace the throttle line, light height adjustment…………………………………………………………………………………………………………………………………………………………………………………………
63
8.3
Steering adjustment………………………………………………………………………………………………………………………………………………………………………………………………………………………
64
Adjustment steering device
8.4
Right hand component……………………………………………………………………………………………………………………………………………………………………………………………………………………
65
Remove right rear view mirror, right hand rubber sleeve, balance block
8.5
Add brake fluid, rocker adjustment………………………………………………………………………………………………………………………………………………………………………………………………………
66
Add brake fluid, brake rocker adjustment
8.6
Replace the front brake pads……………………………………………………………………………………………………………………………………………………………………………………………………………
67
8.7
Front wheel component…………………………………………………………………………………………………………………………………………………………………………………………………………………
68
Disassemble the front wheel, front disc brake disc, front axle component
8.8
Front mud board & wheel speed sensor component………………………………………………………………………………………………………………………………………………………………………………………
69
Decompose front wheel speed sensor component, front mud plate component
8.9
Head component…………………………………………………………………………………………………………………………………………………………………………………………………………………………
70
Remove the headlight component and disassemble the storage box
8.10
Headgear headlight component 1…………………………………………………………………………………………………………………………………………………………………………………………………………
71
Demolition headlight cover, headlight bracket
8.11
Headgear headlight component 2…………………………………………………………………………………………………………………………………………………………………………………………………………
72
Dismantle the headlights, hood, hood cover
8.12
Left hand component……………………………………………………………………………………………………………………………………………………………………………………………………………………
73
Remove left rear view mirror, left hand rubber sleeve, balance weight, left switch
8.13
Direction handle&Instrument……………………………………………………………………………………………………………………………………………………………………………………………………………
74
Demolition handle, clamp, instrument component
8.14
Direction handle&TFT Instrument………………………………………………………………………………………………………………………………………………………………………………………………………
75
Demolition handle, clamp, TFT instrument component
8.15
Front shock absorber, upper plate component……………………………………………………………………………………………………………………………………………………………………………………………
76

Page 5 ，Total 107 pages
Page
Contents
Table of Contents
Front shock absorber, headlight bracket, faucet lock, upper plate component
8.16
Uplink plate, direction handle block component…………………………………………………………………………………………………………………………………………………………………………………………
77
Disassemble the direction of the block, the upper plate
8.17
ABS Brake System-1……………………………………………………………………………………………………………………………………………………………………………………………………………………
78
Brake brake fluid
、
disassemble the front disc brake main pump and the tubing
、
ABS control unit
7.18
ABS Brake System-2……………………………………………………………………………………………………………………………………………………………………………………………………………………
79
Disassemble the front disc brake caliper and the FC-HU tubing
7.19
ABS Brake System-3……………………………………………………………………………………………………………………………………………………………………………………………………………………
80
Disassemble the rear disc brake main pump and the tubing
7.20
DOUBLE ABS Brake System……………………………………………………………………………………………………………………………………………………………………………………………………………
81
Disassemble the rear disc brake caliper and the FC-HU tubing
7.21
SINGLE ABS Brake System……………………………………………………………………………………………………………………………………………………………………………………………………………
82
Disassemble the rear disc brake caliper and the FC-HU tubing
9Fuel tank cover component
9.1
Tank middle cover component……………………………………………………………………………………………………………………………………………………………………………………………………………
83
Demolition tank cover component
9.2
Fuel tank cover, fuel tank cover, fuel tank lock…………………………………………………………………………………………………………………………………………………………………………………………
84
Decompose the tank cover component
9.3
Fuel tank trim cover component…………………………………………………………………………………………………………………………………………………………………………………………………………
85
Remove left and right fuel tank trim cover
9.4
Fuel tank trim cover rear shell component-1……………………………………………………………………………………………………………………………………………………………………………………………
86
Demolition tank trim cover rear case
9.5
Fuel tank trim cover rear shell component-2……………………………………………………………………………………………………………………………………………………………………………………………
87
USB charging cable, front turn signal
9.6
Fuel tank cover component 1……………………………………………………………………………………………………………………………………………………………………………………………………………
88
Remove the left and right tank cover assemblies
9.7
Fuel tank cover component 2……………………………………………………………………………………………………………………………………………………………………………………………………………
89
Decompose the left and right tank cover assemblies
10 Tank liner component
10.1
Tank liner component……………………………………………………………………………………………………………………………………………………………………………………………………………………
90
Demolition tank liner component, seat cushion fixing block
10.2
Tank liner…………………………………………………………………………………………………………………………………………………………………………………………………………………………………
91
Demolition tank liner, fuel pump, fuel tank cover bracket, fuel tank cap

Page 6 ，Total 107 pages
Page
Contents
Table of Contents
11 Side cover component
11.1
Side cover component(old applique)……………………………………………………………………………………………………………………………………………………………………………………………………
92
Decomposition side cover component
12 Skirt, rear mud board, electrical component box component
12.1
Skirt trim cover component………………………………………………………………………………………………………………………………………………………………………………………………………………
93
Remove the tail skirt left and right trim cover component
12.2
Skirt trim cover component………………………………………………………………………………………………………………………………………………………………………………………………………………
94
Remove the tail skirt interior left and right trim cover component
12.3
Tail skirt taillight component 1……………………………………………………………………………………………………………………………………………………………………………………………………………
95
Rear skirt taillight component
12.4
Tail skirt taillight component 2……………………………………………………………………………………………………………………………………………………………………………………………………………
96
Disassemble the skirt, rear position mounting plate and taillight component
12.5
Tail light component………………………………………………………………………………………………………………………………………………………………………………………………………………………
97
Disassemble the taillight component
12.6
Electrical device box component…………………………………………………………………………………………………………………………………………………………………………………………………………
98
Disassemble electrical device box cover
、
ECU
、
Realay and fuse box
12.7
Battery component………………………………………………………………………………………………………………………………………………………………………………………………………………………
99
Disassemble battery
、
Wake-up switch and charging precautions
12.8
Electrical device box component-1………………………………………………………………………………………………………………………………………………………………………………………………………
100
Disassemble electrical device box component
、
lower cover of electrical device box
12.9
Electrical device box component-2………………………………………………………………………………………………………………………………………………………………………………………………………
101
Disassemble PKE
、
Electrical device box
13 Cushion component
13.1
cushion……………………………………………………………………………………………………………………………………………………………………………………………………………………………………
102
Discomponent and component cushion; seat cushion rubber separately purchased parts
14 Muffler component
14.1
Muffler rear section………………………………………………………………………………………………………………………………………………………………………………………………………………………
103
Disassemble the rear section of the muffler, anti-scalding plate, muffler clamp
14.2
Muffler front section 1……………………………………………………………………………………………………………………………………………………………………………………………………………………
104
Remove the front part of the muffler
14.3
Muffler front section 2……………………………………………………………………………………………………………………………………………………………………………………………………………………
105

Page 7 ，Total 107 pages
Page
Contents
Table of Contents
Decompose the front section of the muffler, oxygen sensor, muffler flange
15 Lower shroud component
14.1
Lower shroud component-1………………………………………………………………………………………………………………………………………………………………………………………………………………
106
Remove the shroud component, shroud bracket
14.2
Lower shroud component-2………………………………………………………………………………………………………………………………………………………………………………………………………………
107
Decompose the lower shroud component
©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
1 1184300-033000 ZT350-R wiring harness assembly-A 1
2 1270300-273000 φ8 clip(L=73) 1
3 1244100-052000 Buffer rubber of flanging bushing (φ8.5×φ14×1) 2
4 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 2
5 1184300-024100
2.5 Generation PKE Assembly (including induction key
1
6 1274100-057095 Flanging bushing φ6.2×φ8.4×3.5
＋
φ14×1.5 2
7 1274200-017000 ZT310-R support of tail light 1
8 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 3
9 1224200-205000 ZT310 electronic cushion lock block 1
10 1274100-058000 ZT310 Electric seat lock 1
11 1184200-016000 ZT310 PKE Buzzer 1
12 1180300-101000 HJ150-3 square flasher (LED) 1
13 1050958-006000 ZT350 lgnition oil body 1
14 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color Zinc) 2
15 1050958-007000 ZT350 EFI high voltage line 1
16 1224100-030000 Pin tie (Black 4.8×130) 1
17 1224300-110000 Reverse buckle Velcro strap (20×200mm) 7
18 1224100-037000 Grade 0 flame retardant tie (black 3.6×295) 3
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 binding⑶can be picked out by using scissors.
●Flasher and dump switch
Remove the rubber sleeve that connects the flasher⑿to the mounting bracket on the frame.
●PKE
Using 4# inner hexagon socket remove the 2bolts⑷,remove the bushing⑹ and buffer rubber⑶ and PKE⑸ and
clip⑵.
●Ignition coil
Remove the bolts⒁ with 8# sleeve and remove the ignition coil⒀ .
●Rear light holder、seat lock
Find and take off the plug of the seat lock , and cut off binding⒅. Remove bolts ⑻,then remove the rear light
holder⑺,seat lock guide block⑼ and seat lock⑽.
●PKE buzzer
Remove the PKE buzzer ⑾. Clean up the remaining offset.
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.
Fig.1 FRAME PARTS
COMPONENT Electronic parts COMPONENT-1

1、FRAME COMPONENT 9
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
1 1250105-138093 GB5789M6×20 (environmental color) 1
2 1274300-065000 ZT350-VX front oil outlet pipe bracket 1
3 1100100-814000 ZT350-R brake hose FC-HU segment 1
4 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color Zinc) 1
5 1184200-004000 ZT310 horn 1
6 1274100-017000 ZT250-S cable buckle 2
7 1224100-037000 Grade 0 flame retardant tie (black 3.6×295) 1
8 1274100-095000 ZT250-S Flameout switch wire fixing bracket 1
9 1184100-012000 ZT250-S shut down switch 1
10
1250205-040095 GB70.1 inner hex bolt M8×16(color Zinc) 2
PROCEDURE:
●Horn
Take off the plug of horn ,Remove the bolt ⑴ with 10# seelve and removebrake hose.Hold the horn⑸ with one
hand,remove the bolt⑶ with 8#sleeve with the other hand ,remove the bracket⑵ and horn⑸.
●Flameout switch
Find and take off the plug of the flameout swich⑼; press and take off the clip⑹ cut ribbon ⑺.Using the inner
hexagon tool remove the bolts⑽ , remove the bracket⑻ and the flameout switch⑼.
CAUTION：
●When Take off the plug①、②can't drag any cable.
●Attention the the strength and direction of force when removing cable clip.
●Can't overcharge the charging time. Please refer to the manual for details about tthe battery.
Fig.2 FRAME PARTS
COMPONENT Electronic parts COMPONENT-2