Zontes ZT350-S 2022 User manual

2022/11/29
Service manual
ZT350-S (EURO V)

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Total 99 pages
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0
Table of Contents ……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
1
Swell nail description ………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
7
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
Set 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
1.6
PKE component……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
13
2Frame & engine combination
2.1
Engine decorative cover components…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
14
Engine left rear cover,right cover decorative,drain the coolant
2.2
Frame & Engine Combination1……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
15
Disassemble the rear shock absorber rod plate
2.3
Frame & Engine Combination 2.……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
16
2.4
Frame & Engine Combination 3……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
17
2.5
Frame & Engine Combination 4……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
18
3Intake system components
3.1
Air filter components 1…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
19
Disassemble air filter components
3.2
Air filter components 2.………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
20
Disassemble carbon canister, air filter
3.3
Throttle body parts ………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
21
3.4
Replace the air filter element ………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
22
Contents
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4Rear wheel and rear fork component
4.1
Adjustment chain…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
23
4.2
sprocket guard………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
24
Removing the sprocket guard
4.3
Sprocket assembly 1……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
25
4.4
Sprocket assembly 2……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
26
Disassemble the sprocket assembly
4.5
Rear wheel component…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
27
Decomposed rear rim component
4.6
Rear wheel axle component…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
28
Demolition of rear wheel bearing, rear disc brake disc, rear sub-mud assembly
4.7
Rear sub-slab assembly 1………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
29
Vice fender extension cable
4.8
Rear auxiliary mud plate assembly 2……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
30
Disassembled rear mud plate bracket assembly
4.9
Rear auxiliary mud plate assembly 3……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
31
Disassembled rear mud plate bracket assembly
4.10
Rear turn signal after sale parts……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
32
Rear left and right turn signals and rear license plate lights for sale
4.11
Chain adjuster assembly………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
33
Disassemble chain adjuster and maintain
4.12
Rear mud board……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
34
4.13
Rear shock absorption…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
35
Demolition after shock absorption, rear shock absorption adjustment
4.14
Rear shock absorption 1………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
36
4.15
Rear shock absorption 2………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
37
4.16
Rear shock absorption 3………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
38
4.17
Rear fork component……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
39
Decomposed flat fork component
4.18
Replace the rear brake pads…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
40
4.19
Rear brake main pump adds brake fluid………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
41
5Pedal component
5.1
Pedal height adjustment………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
42

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Shift lever, brake pedal height adjustment
5.2
Front right pedal mounting position adjustment…………………………………………………………………………………………………………………………………………………………………………………………………………………………………
43
5.3
Front left pedal mounting position adjustment……………………………………………………………………………………………………………………………………………………………………………………………………………………………………
44
5.4
Front right footrest component……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
45
Decompose the Front right pedal component
5.5
Front left footrest component………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
46
Decompose the Front left pedal component
5.6
Shift lever assembly………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
47
Decompose the shift lever assembly
5.7
Front footrest bracket…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
48
5.8
Rear pedal assembly……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
49
5.9
Rear right pedal bracket components…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
50
Decompose the rear right pedal componts
5.10
Rear left pedal bracket components……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
51
Decompose the rear left pedal componts
6Cooling system component
6.1
Change the oil………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
52
6.3
Replace the oil filter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
53
6.2
Add coolant…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
54
6.4
Water tank decoration cover component……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
55
Disassemble the water tank decoration cover component
6.5
Vice water tank components………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
56
6.6
Draining coolant……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
57
6.7
Main tank component 1………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
58
Disassemble water pipe water tank
6.8
Main tank component 2………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
59
Water tank maintenance,check the thermostat
6.9
Oil cooler component……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
60
7Front fork component
7.1
Throttle/clutch cable clearance adjustment…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
61
Adjust the throttle line, clutch cable free travel
7.2
Light height adjustment………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
62

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7.3
Replacement clutch cable……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
63
7.4
Replace the throttle line………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
64
7.5
Steering adjustment……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
65
Adjustment steering device
7.6
Add brake fluid, rocker adjustment………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
66
Add brake fluid, brake rocker adjustment
7.7
Replace the front brake pads,front brake caliper mounting plate…………………………………………………………………………………………………………………………………………………………………………………………………………
67
7.8
Front wheel component………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
68
Disassemble the front wheel, front disc brake disc, front axle component
7.9
Front mud board & wheel speed sensor component……………………………………………………………………………………………………………………………………………………………………………………………………………………………
69
Decompose front wheel speed sensor component, front mud plate component
7.10
Headlights assembly 1…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
70
Headlights assembly, cable plug
7.11
Headlights assembly 2…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
71
Remove headlights
7.12
Headlights assembly 3…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
72
Remove headlights upper bracket, front turning signal
7.13
Right hand component…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
73
Remove right rear view mirror, right hand rubber sleeve, balance block
，
Replace the front brake switch
7.14
Left hand component……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
74
Demolition handle, clamp, instrument component
7.15
Directional lever
、
TFT Instrument………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
75
Demolition handle, clamp, TFT instrument component
7.16
Front shock absorber, upper plate component……………………………………………………………………………………………………………………………………………………………………………………………………………………………………
76
Front shock absorber, faucet lock, upper plate component
7.17
Uplink plate, direction handle block component…………………………………………………………………………………………………………………………………………………………………………………………………………………………………
77
Disassemble the block, the upper plate
7.18
ABS brake system-1………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
78
Remove the control unit protection cover, releasing brake fluid, hydraulic control unit
7.19
ABS brake system-2………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
79
Remove the front disc brake main pump and oil pipe
7.20
ABS brake system-3………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
80
Remove the rear disc brake main pump and tubing
7.21
ABS brake system-4………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
81

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Disassemble the disc brake caliper and tubing,rear wheel speed sensor
8Fuel tank component
8.1
Fuel tank component 1………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
82
Disassemble the fuel tank component
8.2
Fuel tank component 2…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
83
Disassemble the fuel tank oil pump
9Guard bar sembly
9.1
Guard bar assembly 1……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
84
Disassemble the guard bar outer parts
9.2
Guard bar assembly 2……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
85
Disassemble left and right guard components
9.3
Guard bar assembly 3……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
86
Disassemble the left and right guard bar components
9.4
Engine decorative cover components…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
87
Disassemble the engine decorative cover
10 REAR COVER COMPONENT
10.1
Battery component………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
88
Diassemble the charging port holder and the battery
10.2
Tail skirt component 1…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
89
Diassemble the side cover exterior trim panel
10.3
Tail skirt component 2…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
90
Diassemble the electric device box
10.4
Tail skirt component 3…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
91
Diassemble the side cover
10.5
Rear skirt taillight component………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
92
Diassemble the rear skirt and the taillight
10.6
Battery bracket……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
93
11 Cushion component
11.1
Cushion…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..……
94
Discomponent and component cushion; seat cushion rubber separately purchased parts

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12 Muffler component
12.1
Muffler component 1……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
95
Diassemble muffler external parts
12.2
Muffler component 2……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
96
Diassemble muffler component
12.3
Muffler component 2……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
97
Discomponent muffler component
13 Lower shroud component
13.1
Lower shroud component-1…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
98
Remove the shroud component, shroud bracket
13.2
Lower shroud component-2…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
99
Decompose the lower shroud component

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Swell nail description
©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 continuousimprovement of the product and other changesFor colors or upgrades, please refer to the part codes on the official website. This manual
will not be listed in detail; If the part names in this manual are inconsistent with the official website, the official website shall prevail. This manual is compiled on the basis of the chinese
version of ZT350-S version. The export version is different from the chinese version with only a few parts, such as decals, ECU version, muffler catalyst, etc. Although the status of such parts
are different, the disassembly method is same, so refer to the chinese manual.
①Press down the center cylinder with 4# inner hexagon or other tools, you can hear a sound or the center cylinder moves axially by 2mm;
②Pry open the gap with a blade, nail or carving knife, etc. and remove it; if space permits, you can reach it Push out from the back;
③Pinch the outer ring with two fingers, and push the center cylinder up to the initial position;
④Pinch the center cylinder with two fingers to install the swell nails to the installation position;
⑤The outer ring is attached to the connected parts; if not attached Check whether it is misaligned;
⑥Press the center cylinder with your fingers or other tools, and you can hear a sound or the top of the center cylinder is almost flush with the top surface of the outer ring, indicating that
the assembly is in place.

1
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FRAME COMPONENT
8
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
11184300-025000 ZT350-S wiring harness assembly-A 1
21224100-030000 Pin tie (Black 4.8×130) 1
31224100-037000 Grade 0 flame retardant tie (black 3.6×295) 3
41244200-103000 ZT310 relay rubber sleeve 5
51244100-082000 ZT250-R dump switch sleeve 1
61184100-002000 ZT250-S dump switch 1
71180300-101000 HJ150-3 square flasher (LED) 1
81251100-101000 Non-standard bolt M6×12 (304 stainless steel) 5
91224200-205000 ZT310 electronic cushion lock block 1
10 1274100-058000 ZT310 Electric seat lock 1
11 1274300-111000 ZT350－S rear tail skirt bracket 1
12 1184100-017000 ZT250-S fuel-injection relay 5KH-1A4T
13 1224300-110000 Reverse buckle Velcro strap (20×200mm) 8
14 1224300-111000 Reverse buckle Velcro strap (20×300mm) 4
15 1184300-002000 ZT350 starting relay 1
16 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1
17 1274200-171000 ZT310-V relay bracket 1
18 1251300-085093 Non-standard cap nut M6 2
20 1274200-268000 ZT310-VX Bosch ECU bracket 1
Fig.1 FRAME&ELECTRONIC PARTS
COMPONENT Electronic parts COMPONENT-1
19 1050958-014000 MSE6.0 controller - ZT184MP (matching split sensor /
Euro V) 1
PROCEDURE:
●Flasher and dump switch
Remove the rubber sleeve that connects the flasher ⑺to the mounting bracket on the frame, and remove
the dump switch with the same method, then separate the dump switch sleeve ⑸.
●Relay and ECU
Pull out the rubber sleeve⑷on the right side of the frame and upper the air filter,and then pull out the EFI
relay⑿. Find the starting relay⒂above the air filter, pull off the sheath of the harness, remove the self-
contained nut and remove the relay from the relay support⒄. Remove the bolt ⒃with 4# hexagon socket
and remove the bracket⒄. Unplug the plug of the engine controller ⒆on the left and remove the nut ⒅with
a 10# sleeve. Remove 2 bolts ⑻with 4# socket head and then remove ECU bracket⒇.
●Seat lock
Take off the plug of the seat lock , and cut off binding ⑶. Use a 4# inner hexagon to remove the front bolt
⑻, and remove the guide block ⑼; remove the 2 rear bolts and remove the electronic cushion lock ⑽ankd
the rear tail skirt bracket⑾.
●
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 screwdriver, forceps, scissors and
other tools to assist.The binding ⑶can be picked out by using scissors.Take off straps⒀and ⒁.
CAUTION：
●Please notice the limit of the bracket when dismantling flasher and dump switch sleeve, beware of
hurting your fingers.

1
、
FRAME COMPONENT
9
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
11251112-001093 M6×16 Hexagon flange bolts (color zinc) 1
21274300-065000 ZT350-VX front oil pipe bracket 1
31184200-004000 ZT310 horn 1
41274100-017000 ZT250-S cable buckle 2
51224100-037000 Grade 0 flame retardant tie (black 3.6×295) 2
61274100-095000 ZT250-S Flameout switch wire fixing bracket 1
71184100-012000 ZT250-S shut down switch 1
81250205-040095 GB70.1 inner hex bolt M8×16(color Zinc) 2
91224300-110000 Reverse buckle Velcro strap (20×200mm) 3
10 1251100-061093 M6×22 Hex flang bolt thread (8.8 garde/color Zinc) 1
11 1251112-002093 M6×30 Hexagon flange bolts (9.8 grade/color Zinc) 1
12 1274300-067000 ZT350-V water outlet pipe anti-wear bracket 1
13 1186200-013000 ZT310 Rectifier (350W) 1
14 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1
15 1274300-092000 ZT350-S ignition coil bracket 1
16 1050958-006000 ZT350 ignition coil body 2
17 1050958-007000 ZT350 EFI high voltage line 1
Fig.2 FRAME&ELECTRONIC PARTS
COMPONENT Electronic parts COMPONENT-2
CAUTION：
●Do not pull the cable hard when removing the sub-mud switch.
●The replacement of the spark plug and the matters needing attention are described in the
instruction manual.
PROCEDURE:
●Horn
Take off the plug of horn take the horn ⑶by one hand, using 8# plum wrench rotate the screw ⑴by
another hand remove the holder ⑵then take off the horn.
●Flameout switch
Find and take off the plug of the flameout swich ⑹press and take off the cable clip ⑷cut ribbon ⑸,take off
2 pcs strap⑼.Using the 6# inner hexagon tool, remove the bolts ⑻、the holder ⑹and the flameout switch
⑺.
●Rectifier
After unfastening the tie strap ⑼then find and remove the rectifier plug, Using 8# sleeve remove the bolt
⑾, remove the outlet pipe bracket⑿；Using 8#sleeve remove the bolt ⑽and remove the rectifier ⒀.
●Ignition coil
Pull out the high-voltage wire ⒄then end of the spark plug, pull out the end of the ignition coil body and
remove it. Remove the bolt ⑽with 8# sleeve and remove the ignition coil body ⒃. Then using 4# hexagon
socket remove the bolt ⒁and remove the high-pressure package support⒂.