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
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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

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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
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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
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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
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Contents
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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

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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

1、FRAME COMPONENT 10
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
1 1244100-019000 ZT250-S fuel tank spacing glue 1
2 1240300-007000 HJ125-6 Battery rubber gasket 1
3 1244100-002000 ZT250-S Side cover round rubber 8
4 1244100-061000 ZT250 anti-water rubber of frame 4
5 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1
6 1274100-057095 Flanging bushing φ6.2×φ8.4×3.5
＋
φ14×1.5 1
7 1244100-052000 Buffer rubber of flanging bushing (φ8.5×φ14×1) 1
8 1224300-086000 ZT350-R right wire harness holder 1
PROCEDURE:
●Inner fuel tank ficx glue cushion
Use both hands to hold the two ends cylinder parts of the inner fuel tank limited glue cushion⑴and should
push it out.
●Side cover cushion
Remove the side cover cushion⑶with your hand directly.
●Frame waterproof rubber plug
Remove the frame waterproof rubber plug ⑷with your hand directly.
●Battery cushion
Put off the battery cushion ⑵ directly by hand.
●Right wire harness holder
Using 4# inner hexagon socket remove the bolt⑸,remove the bushing⑹ and buffer rubber⑺ and harness
holder⑻.
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.
Fig.3 FRAME PARTS
COMPONENT Frame plastic parts

1、FRAME COMPONENT 11
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
1 1134100-007000 ZT250-S Adjusting nut locking washer 1
3 1244100-015000 ZT250-S Adjusting nut rubber pad 1
4 1244300-014000 ZT350-R upper dust cover 1
5
1130900-024000 ZT250-S shaft ring 1
6
1130900-022000 ZT250-S conjoined steel ball 2
7 4094300-002051 ZT350-R lower connection Board (with bead top) 1
8
1224100-006000 ZT250-S steering stem dust cap(down) 1
【
1
】
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 ⑸ and 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) component⑺, has been contains the
Steering column down dustproof cover⑻.
2 1251300-046093
ZT250-S direction column adjusting screw nut M24X1
(environmental color Zinc) 2
PROCEDURE:
●Dissembly
Remove the lock washer⑴.
Remove the top adjusting nut ⑵ by 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 nut⑵.
Remove the down connected plate component⑺.
Remove the upper dustproof cover⑷.
Remove the axletee ring ⑸ of the upper riser and the steel ball⑹.
Remove the steel ball of the down connected plate component⑺.
●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 ⑶ from deformation too large.
Fig.4 FRAME PARTS
COMPONENT
Steering rack component

1、FRAME COMPONENT 12
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
1 4014300-002000
ZT350-R frame after-sales assembly(including seat/310
1
2
1130900-026000 ZT250-S upper steel bowl 1
3 1134300-001000
ZT350-R lower seat ring 1
4 1251300-057093 Non-standard nut M10×1.5(Dacromet) 1
5 1264100-001000 ZT250-S side stand spring 1
6 1251100-088094
Non-standard bolt M10×1.5×43(Dacromet) 1
7 1271200-165000
ZT310-T side bracket (short/dark gray) 1
8 1251700-025091 ZT250-S side stand sleeve 1
PROCEDURE:
●Checking the cushion loop
Checking whether the cushion loop ⑵and ⑶ is 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.
●Sider support
Use the cross screwdriver to remove the side support spring⑸, and guard against the personal injury caused by
spring contraction, remove the nuts⑷ and bolts⑹ with the appropriate tools. Remove the side support⑺ and
bush⑻, paint the lubricating grease on the bush⑻ when re-assembling ,then put it into the frame⑴.
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.
●【1】the frame after-sales component contains fix loop and nameplate.
【1】
Frame, Side support, the operation of releasing engine
oil
Fig.5 FRAME PARTS
COMPONENT

2-FRAME & ENGINE COMBINATION 13
CHK
ADJ
NO. PART NO. PART NAME QTY CAUTION
1 1251112-003093 M6×45 hexagon flange face 9.8 bolt (color zinc) 2 10N.m
2 4050854-002051 ZT310-R engine left rear cover (dark gray) 1
3 1251300-057093 Non-standard nut M10×1.5
（
dacromet
）
4 65±5N.m
4 1274300-082000 ZT350
－
R Upper hanging piece (outside association) 2
5 1251100-060000 Non-standard bolt M10×1.5×90 4
6 1251112-019000 Non-standard boltM12×85(10.9
级
/dacromet) 4
7 1250305-009091 GB6187.1 M12×1.25
（
White zinc
）
5
8 4024300-001000 ZT350
－
GK bracket 1
9 1251300-067000 ZT250
－
R Rear wheel hollow shaft nut 1
10 1252200-040000 ZT310-R Lrear flat fork hollow shaft Φ20×315 1
11 1251100-262000 Non-standard bolt M12×1.25×127
（
dacromet
）
1
Fig.1 FRAME & ENGINE
COMBINATION Engine combination
PROCEDURE:
●Engine left rear cover
Using 8# sleeve remove the bolt ⑴ disassemble the rear cover⑵.
●The middle part of the engine is connected with the frame and the rear fork
Using 14# sleeve fix the head of the bolt ⑸ at the upper hanging piece, and using 14# plum wrench remove
the nut ⑶. Only disassemble the nut and other parts cannot be disassembled.First Using 14# sleeve fix the head
of the bolt ⑹ at the bracket⑻, then using 17# plum wrench remove the nut⑺.Using 14# sleeve fix the head of
the bolt ⑾ at the lower part of the engine , and using 17# plum wrench remove the nut⑺. Don't remove the
bolts⑸ 、⑹、⑾、Upper hanging piece ⑷.
●Disassemble the engine
First using 24# open ended spanner fix the head of the rear fork shaft ⑽, and using 30# plum wrench remove
the nut⑼.One person shakes the rear fork assembly slightly and one pulls the rear fork shaft⑽ to "A" .Both of
them hold the engine left and right crankcase at the same time; one person disassembles the bolts⑸ , take out
the hanging piece⑷.Disassemble the bolts ⑹ and brackets⑻ above the front bracket.Finally remove the bolt⑾
at the lower part of the engine. Hold the engine to move to one side and pay attention to safety during the
movement. Place the engine smoothly on the ground.
CAUTION：
●It is necessary to remove the seat cushion, fuel tank, side cover, pedal support, wind deflector,lower shroud
component,shift lever, muffler, radiator and pipe, cable, air filter joint, chain, engine positive pole, etc.
●The coolant should be drained before disassembly.
●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.
●All standard parts must meet the standard torque value when reassembling, and refill the engine oil according
to the operation instruction.

3-INTAKE SYSTEM COMPONENT 14
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
1 1250303-010093 GB6177.1M6（color zinc）
3
2 1274300-038000
ZT350
－
R electromagnetic valve bracket 1
3 1050954-009000 YH Carbon tank electromagnetic valve
1
5 1251100-101000
Non-standard bolt M6×12 (304 stainless steel) 2
6
1224300-069000 ZT350
－
R Carbon tank(with fuel conduit) 1
7 1224300-002000
ZT350
－
T Air filter 1
8 1050961-004000
Air filter intake air temperature sensor 1
Fig.1 INDUCTION
SYSTEM COMPONENT Maintain the filter element of the air filter
41050958-015000 ZT44 Throttle Valve Decoupling Rubber Tube
(Φ6×Φ10×420+Φ9clip×2) 1
PROCEDURE:
●Air filter intake air temperature sensor
Remove the Air filter intake air temperature sensor⑻ on the air filter⑺.If the sealant③ falls off when pull out the
sensor⑺,plug it back to the original position
●Carbon tank electromagnetic valve
Find and remove the Carbon tank electromagnetic valve plug.
Loosen the hoop and pull out the pipe ① and ⑷,remove the pipe⑷.Then use 10# sleeve remove the nut,remove
the electromagnetic valve⑶ and bracket⑵.
●Carbon tank
Pull the oil pipe② connecting the fuel tank on the carbon canister out of the fuel tank.
Using 4# inner hexagon socket remove the bolts⑸,remove the carbon tank⑹.
●Check whether the temperature sensor is damaged
Remove the temperature sensor from the air filter and place it in the ambient temperature (20 ～ 30 ℃), and use
a multimeter to check whether the resistance of the two pins is between 2726 ～ 1770 Ω.
●check the carbon canister solenoid valve
In case of poor engine performance; Poor idle speed; If the air-fuel ratio is incorrect, check the carbon canister
solenoid valve.
Use a multimeter to measure the resistance between the two inserts of the carbon canister solenoid valve plug,
which should be 35 ± 2 Ω, otherwise the solenoid valve fault can be judged.
CAUTION:
●First it need to remove the cushion,side cover,rear shock absorber and electrical device box etc.
●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.
●The two oil pipes of the carbon canister solenoid valve must not be connected incorrectly.

3-INTAKE SYSTEM COMPONENT 15
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
1 1224300-002000
ZT350
－
T Air filter 1
2 1251100-101000
Non-standard bolt M6×12 (304 stainless steel) 4
3 1251300-063093
Plywood M6×11×15
（
Environmental protection
）
4
4
1251100-061093 M6×22 Hexagon flange bolt
（
color zinc
）
2
5
1051371-002000 Φ59×9 clamp components 1
6 1224300-110000 Reverse buckle Velcro strap (20×200mm) 1
PROCEDURE:
Press the snap pointed by the arrow "a","b","d" and pull out the plugs of External intake air pressure sensor、
Fuel injector.Press the snap pointed by the arrow "c" and pull out the stepper motor connector.Press "e" the
clip pointed by the arrow and pull it out,use the same method at the other side.Remove the high pressure
tubing. Remove the strap⑹.
●Air filter
Loosen the hose clamp assembly ⑸ come with the air filter, clamp the clamp come with 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.
Using 4# inner hexagon socket remove the bolt⑵, Air filter⑴ and splint nut (3).
●Throttle valve assembly
Find and remove the Throttle valve assembly plug.Remove the throttle line.
Using 8# sleeve to remove the bolt ⑷ and remove the throttle valve assembly.
●Check whether the external intake pressure sensor is damaged
Loosen the connector and check whether the pin is skewed or broken. The vehicle is connected to the diagnostic
instrument without ignition. Check the engine parameters to see whether the pressure parameters are consistent
with the local atmospheric pressure.
CAUTION:
●First it need to remove the cushion,side cover,oil tank component,rear shock absorber and electrical device box etc.
●Pay attenion to force when removing clamp.
●Fireworks, answering or dialing should be strictly prohibited near the car-breaking site to prevent accidents.
●When removing the high pressure oil pipe,It is sure to operate until the engine and muffler are completely cooled.
Fig.2 INDUCTION
SYSTEM COMPONENT The air filter assembly

3-INTAKE SYSTEM COMPONENT 16
CHK
ADJ
NO. PART NO. PART NAME QTY CAUTION
1 1051454-016000 45×2.5 Fluorine rubber O-ring 1
2 1050958-003000 ZT184 MP Intake pipe assembly 1
3 1051354-004000 Φ56×10 Hoop assembly 1
4 1050958-001000 ZT44 Throttle body part component (position sensor) 1
5 1050954-023000 EV14 Fuel injectorG48 1
6 1050970-002000 ZT1P72MN injector holder 1
7 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color Zinc) 1
9 1050961-003000 External intake air pressure sensorMAP0 1
10 1050958-009000 ZT350Fixed bracket for external intake pressure sensor 1
1
8 1250106-112000 GB9074.13 Hexagon cross groove spring,flat cushion
combination bolt M5×20 1
●Check whether the throttle position sensor ③ is damaged
Connect the diagnostic instrument to the whole vehicle, press the flameout switch (without ignition),
turn the throttle handle from the initial position to fully open, and check whether the throttle position
signal changes from 0 to 100.
●Check whether the fuel injector is damaged
Remove the manifold without loosening the plug of electrical parts. Press the ignition button to check
whether the two beams of oil mist emitted by the fuel injector are uniform.
CAUTION:
●Pay attenion to force when removing clamp.
●Before reassembly, check the o-ring ⑴ for damage and replace it if any.
●When reinstalling the sensor, be careful to align the square holes; there must be no foreign objects; the
sealing rubber gasket cannot be missing or misplaced. Do not touch the sensor head.
Fig.3 INDUCTION
SYSTEM COMPONENT Throttle valve body component
PROCEDURE:
●Throttle valve body assembly
Remove the O-ring ⑴ from the intake oipe assembly.
Remove the connection pipe⑾ at the A-end.
Use 8# sleeve to remove the bolt ⑺,take off the External intake air pressure sensor component,injector holder⑹
and injector ⑸.
After loosening the clamp ⑶, remove the throttle valve body assembly ⑷and intake manifold assembly⑵ , and
then remove the clamp ⑶.
●External intake air pressure sensor
Use screwdriver for cruciform head to remove the bolt ⑻,take off the sensor⑼and bracket⑽,then remove the
connection pipe⑾.
●check whether the external intake pressure sensor is damaged⑼
Loosen the connector and check whether the pin is skewed or broken. The vehicle is connected to the diagnostic
instrument without ignition. Check the engine parameters to see whether the pressure parameters are consistent
with the local atmospheric pressure.
●Check whether the stepping motor② is damaged
After turning off the power, take out the stepping motor, do not loosen the cable plug, press the flameout switch
at startup without ignition, check whether the motor plug can shrink back and forth, and finally turn off the
flameout switch to check whether the plug returns to its original position.
11 1050958-008000 Intake pressure sensor connection hose(φ3.5×φ7.5×
L38.5)

3-INTAKE SYSTEM COMPONENT 17
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
1 4134300-003000
ZT350
－
Tair filter core (with carton packaging) 1
ROCEDURE:
●Filter element
If you need to maintain the filter element of the air filter, remove the seat cushion, the right side cover Take the
standard part ① out of air filter with the tool,pull out in direction of arrow a, dismantle the box cover② Grasp
the rubber strips on the filter (both sides shown in yellow) and pull the filter element ⑴ out. Blow the dust off
the filter core by blowing dust gun in the filter element. If the filter paper is damaged, it should be replaced in
time.If the blowback causes the dust to be unable to clean up, the engine will be damaged or the induction
resistance will become larger and affect the driving experience.When assembling, apply a small amount of
engine oil on the upper and lower sides of the rubber strip (shown in cyan as shown in the figure) to reduce
assembly resistance.
●Oil pipe and water pipe
Avoid water into the air filter when washing the motorcycle. Can pulled out the oil pipe③ and water pipe④ to
release if into small water.keep no water inside before staring the engine.
CAUTION:
●First remove the side cover and remove the cable.
●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.
●When blowing dust, pay attention to maintain a certain distance to avoid excessive damage to the filter
element.
●The filter element should be checked every 5000 kilometers or 15 months; it should be replaced every 10,000
kilometers or 30 months.
●If the oil pipe③ is easy to be full when driving hundreds of kilometers normally,please fill in the quality
feedback form (parts:cylinder head).There are corrresponding engineers to follow up and solve.
Fig.4 INDUCTION
SYSTEM COMPONENT Replace air filter element

4、DOUBLE ROCKER COMPONENT 18
CHK
ADJ
NO. PART NO. PART NAME QTY CAUTION
1 1250105-149093 GB5789M8×30 (environmental color) 2
2 1250105-143093 GB5789M8×35 (environmental color) 1
3 1250501-007093 GB93 φ8 (environmental color) 3
4 1250503-021093 GB97.1φ8 (environmental color) 3
5 1250303-011093 GB6177.1M8(color Zinc) 1
6 4024300-002021
350-R rear auxiliary mud plate aluminum alloy bracket 1
7
1184200-030000 ZT310-R adapter cable of vice fender(L=2000) 1
8
1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1
9 1274100-095000
ZT250-S Flameout switch wire fixing bracket 1
Rear sub-mud assembly 1
PROCEDURE:
●Rear auxiliary mud board assembly
Locate the 3 plugs shown in the plug-in plug A.
After fixing the nut ⑸ with 13# plum wrench, remove the bolt⑵ at the arrow indication with 12# sleeve, and
remove the spring washer⑶ and the flat washer⑷ and the nut⑸.
After holding the rear sub-slab assembly, remove the 2 bolts⑴ with 12# sleeve and remove the spring washer⑶
and the flat washer⑷, respectively.
Using 4# inner hexagon socket remove the bolts⑻,remove the fixed support ⑼.
Remove the sub-mud switch cable⑺ and the rear sub-mud assembly.
CAUTION:
●The seat cushion, left side cover, etc. must be removed in advance.
●Do not pull the cable hard when removing the sub-mud switch.
●
When reassembling, make sure that the torque of the three M8 bolts reaches 35N.m, and you need to apply the
thread fastening glue first. Before tightening the bolts, check that there is any pressure on the wires to prevent
short circuits when tightening the bolts.
Fig.1 REAR WHELL
COMPONENT

4、DOUBLE ROCKER COMPONENT 19
CHK
ADJ
NO. PART NO. PART NAME QTY CAUTION
1
1224200-091000 ZT310-R rear mudguard fender 1
2 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 7
3 1224300-007000
ZT350-R rear auxiliary fender fender 1
4 1250105-137093 GB5789M6×16 (environmental color) 4
5 1250501-007093 GB93φ8 (environmental color) 5
6 1274100-057095 Flanging bushing φ6.2×φ8.4×3.5+φ14×1.5 5
7 1244100-052000 Cuff bushing cushioning rubber (φ8.5×φ14×1) 5
8
1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 6
9 1270300-039000 HJ125-6 rear license plate bracket 1
10 1250503-021093 GB97.1φ8 (environmental color) 2
11 1250303-010093 GB6177.1M6 (environmental color) 2
12 4024200-102000 ZT310-R rear sub-plate iron bracket (Improvement) 1
13 1184200-030000 ZT310-R sub-mud board adapter cable (L=2000) 1
14 4024200-036000
ZT310-V rear auxiliary fender iron support rear section 1
15 4024200-101000
ZT310 rear auxiliary fender iron support front section 1
Rear sub-mud assembly 2
Fig.2 REAR WHELL
COMPONENT
PROCEDURE:
●Retaining plate
Using 4# inner hexagon socket and 10# sleeve remove the bolts⑵and ⑷, remove the flange bushing ⑹ the
rubber pad⑺, and finally remove the retaining plate⑶.
●Aluminum alloy bracket
Using 4# inner hexagon socket and 10# sleeve remove the 2 pcs of bolt⑵ and 3 pcs of ⑷ ，then remove 5 pcs
of spring washer⑸.
●Back license plate bracket assembly
Using 4# inner hexagon socket and 10# sleeve remove the bolt⑻ and nut⑾ at the license bracket⑼ and
remove the license bracket⑼and gasket⑽.
●Rear auxiliary mud plate iron bracket
Hold the rear turn signal assembly,using 4# inner hexagon socket remove the bolt⑵, and remove the flange
bushing⑹ and rubber pad⑺. Remove the rear sub-mud iron bracket⑿and rear turn signal assembly.
CAUTION:
●Do not pull the cable hard when removing the sub-mud switch.
●
When reassembling, first check if there is any pressure on the wire to prevent short circuit when tightening the
bolt.
after-sale