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
Table of 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.

1
、
FRAME COMPONENT
10
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
11224200-008000 ZT310-R cable plastic staple 1
21224100-030000 Pin tie (Black 4.8×130) 1
31241200-044000 KD150-U fuel tank liner limit glue 2
41240300-007000 HJ125-6 Battery rubber gasket 1
51224300-122000 ZT350-S key insert assembly 1
61251100-328000 Hexagon socket head screw M6×14+8.5×3 SUS302 2
71244100-002000 ZT250-S Side cover round rubber 6
81250205-038000 GB70.2M5×12 (stainless steel) 2
91244300-048000 ZT350-V1 chain abrasive brick 1
10 1244100-061000 ZT250 anti-water rubber of frame 6
Fig.3 FRAME&ELECTRONIC PARTS
COMPONENT Frame plastic parts
PROCEDURE:
●Inner fuel tank ficx glue cushion
Hold the inner fuel tank limited glue cushion ⑶and then push it out.
●Side cover cushion
Remove the side cover cushion ⑺with your hand directly.
●Battery cushion
Put off the battery cushion ⑷directly by hand.
●Frame waterproof rubber plug
Remove the frame waterproof rubber plug ⑽with your hand directly.
●Wear block
Use a 3# hexagon socket to remove the 2 bolts ⑻and then remove the wear block ⑼
●Cable plastic staple
Use a pair of pliers to clamp in the direction of the arrow with a little force and then push thecable plastic
staple⑴out of the frame.
●Key insert assembly
Use a 4# hexagon socket to remove the 2 bolts⑹and then take off the key insert assembly⑸.
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.
●The plug strap⑵is a non-detachable structure and it is not recommended to cut it directly. It is difficult to
remove the broken portion of the buckle that is forcibly removed from the frame triangular reinforcing plate.

1
、
FRAME COMPONENT
11
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
11134100-007000 ZT250-S Adjusting nut locking washer 1
21251300-046093
ZT250-S direction column adjusting screw nut M24X1 (
2
31244100-015000 ZT250-S Adjusting nut rubber pad 1
41244300-014000 ZT350-R upper dust cover 1
51130900-024000 ZT250-S shaft ring 1
61130900-022000 ZT250-S conjoined steel ball 1
71134300-002000 ZT350-R conjoined steel ball 1
84094300-002051 ZT350-R lower connection Board (with bead top) 1
91134300-003000 ZT350-R lower shaft ring 1
10 1244300-015000 ZT350-R dust cap(down) 1【1】
●
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 change, 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 ⑼and the dustproof cover
⑽.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 component ⑻, has been contains the lower shaft ring⑼and the
dust cap ⑽.
PROCEDURE:
●Dissembly
Remove the lock washer ⑴.
Remove the top adjusting nut ⑵by 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 nut ⑵.
Remove the down connected plate component ⑻.
Remove the upper dustproof cover ⑷.
Remove the axletee ring ⑸of the upper riser and the steel ball ⑹.
Remove the steel ball⑺on the down connected plate component .
●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 ⑶from deformation too large.
●When braking, the front fork moves slightly or the steering handle swings
First check whether the front tire pressure is the recommended pressure under normal temperature: normal
temperature: Standard 280kpa.
If it is lower than the recommended pressure, inflate the front tire pressure to 350kPa first, and then deflate
to the standard pressure for test run to check whether it is relieved. If not, support the front wheel and rotate
it to check the tread. If there is eccentric wear or deformation, replace the front tire. If not, readjust the
adjusting nut.
CAUTION：
●Remove the head part component, handlebarcomponent and front shock absorber component first.
Fig.4 FRAME&ELECTRONIC PARTS
COMPONENT Steering rack component

1
、
FRAME COMPONENT
12
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
2
1130900-026000 ZT250-S upper steel bowl 1
3
1134300-001000 ZT350-R lower seat ring 1
4
1264100-001000 ZT250-S side stand spring 1
5
1274200-289000 ZT310-T side bracket (dark gray) 1
6
1251100-088094 Non-standard bolt M10×1.5×43(Dacromet) 1
7
1251700-025091 ZT250-S side stand sleeve 1
81251300-057093
Non-standard nut M10×1.5(Dacromet) 1
Fig.5 FRAME&ELECTRONIC PARTS
COMPONENT Frame, Side support
PROCEDURE:
●Checking the cushion loop
Checking whether the seat ring ⑵and ⑶is frayed, If yes, it needs to be replaceds. Fix the seat ring well and
paint the lubricating grease on it with appropriate tool.
●Sider support
The thick steel wire shall be rolled into a circle and put into the spring (4) hook. Pay attention to ensure that
the steel wire cannot be loosened or scattered during the pulling process. And guard against the personal
injury caused by spring contraction, remove the nuts ⑻and bolts ⑹with the 14# sleeve. Remove the side
support ⑸and bush ⑺, paint the lubricating grease on the bush⑺when re-assembling ,then put it into the
frame ⑴.
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.
14014300-022000 ZT350-S frame after-sales assembly(including
seat/310M nameplate) 1

1
、
FRAME COMPONENT
13
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
11224300-110000
Reverse buckle Velcro strap (20×200mm) 2
21251100-101000
Non-standard bolt M6×12 (304 stainless steel) 2
31274100-057095
Flanging bushing φ6.2×φ8.4×3.5＋φ14×1.5 2
41244100-052000
Buffer rubber of flanging bushing (φ8.5×φ14×1) 2
PROCEDURE:
●PKE Controller
Remove the right cover exterior decorative cover and the right tail skirt side cover assembly according to the
steps in the rear tail skirt section.
Untie the tie⑴and remove the cable to facilitate PKE removal.
Unplug the PKE plug,use a 4# allen wrench to remove the two bolts ⑹to remove the PKE assembly ⑺and
ZT310PKE rubber sleeve⑼;
CAUTION：
●Non-professionals are strictly prohibited to disassemble the PKE system components, otherwise it may
cause permanent damage.
●Please refer to the driver's manual for PKE operating instructions.
●The button battery model used in the band version: CR1225.
51184300-024100 2.5 Generation PKE Assembly (including induction
key) 1
Fig.6 FRAME&ELECTRONIC PARTS
COMPONENT PKE component

2
、
FRAME & ENGINE COMPONENT
14
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
11251100-102000 Non-standard bolt M6×16 (304 stainless steel) 3
21274100-018000 ZT250-S Anti-hot plate sleeve, muffler 3
31244100-017000 ZT250-S muffler hot plate rubber buffer 3
41224200-157000 ZT310-V engine right cover trim cover 1
51251112-005093 M6×75 Hexagon flange bolts (9.8 gradecolor Zinc) 310N.m
61274200-221000 Engine right cover decorative cover mounting bracket 1
71251112-003093 M6×45 Hex flange flange bolt (9.8 grade/color Zinc) 310N.m
81251112-006093 M6×90 Hexagon flange bolts (9.8 grade/color Zinc) 110N.m
91274200-220000 Engine rightdecorative cover front mounting bracket 1
10 1251112-001093 M6×16 Hexagon flange bolts (9.8 grade/ color Zinc) 1
11 1051654-002000 Combination seal 6×13×1.8 1
12 1274200-041000 ZT310 Water pipe clamp (φ26) 1
13 1244200-068000 ZT310-V engine inlet pipe 1
14 4044302-259022 ZT310-R engine left rear cover assembly (matte black) 1
Fig.1 FRAME&ENGINE Engine decorative cover components
PROCEDURE:
●Engine right trim cover assembly
Using 4# inner hexagon socket disassemble 3 bolts ⑴and take out the right trim cover components.Remove
the bushing ⑵、buffer rubber ⑶from the right trim cover components.Using 8# sleeve disassemble the bolts
⑸and take out the bracket ⑹. Using 8# sleevedisassemble the bolts ⑺、⑻and take out the bracket ⑼.
After removing the bracket ,scew the bols that holds the bracket back to the engine to prevent leakage.
●Put the coolant
After placing an oil pan or other container under the right side of the vehicle, tilt the vehicle to the right.
After wearing waterproof gloves with both hands, remove the bolt ⑽with an 8# sleeve, and remove the
combined sealing ring ⑾.
Drain the coolant with a funnel or other device. Opening the main tank cover can speed up the entire
coolant drain of the cooling system.
Loosen the two clamps ⑿with a flat-blade screwdriver and remove the boss indicated by the arrow.
Pull out the water inlet pipe ⒀and then remove the clamp ⑸from the water pipe.
Use a clean cloth to wipe off any remaining coolant on the surfaces of all parts.
●Engine left rear cover
Using 8# sleeve remove the bolt ⑺disassemble the rear cover⒁.
CAUTION：
●The 3 M6 bolts of the engine trim cover bracket must be coated with thread fastening glue before
reassembly, with a torque of 10N.m.
●The coolant should be drained before disassembly.
●Swallowing or inhaling the coolant can be harmful to the human body.Please thoroughly clean any
exposed skin such as hands, face, etc. after each addition of coolant.Contact poison control center or
hospital immediately if swallowed.If inhaled, please go to a ventilated environment immediately.In
case of accidental splash into eyes, please immediately flush eyes with plenty of running water and
seek medical treatment in time.Be sure to stay away from children and pets.

2
、
FRAME & ENGINE COMPONENT
15
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
1
1250104-006097 GB16674M6×12 (chromed/HH) 3
21274100-057095 Flanging bushing φ6.2×φ8.4×3.5＋φ14×1.5 4
31244100-052000 Buffer rubber of flanging bushing (φ8.5×φ14×1) 4
41224300-021000 ZT350-VX rear shock absorber link baffle 1
51251112-001093 M6×16 Hexagon flange bolts (color Zinc) 1
61251100-061093 M6×22 Hex flang bolt thread level 8.8 (color Zinc) 1
PROCEDURE:
●Preparation steps
The seat cushion, fuel tank, side cover, lower fairling, muffler, bumper, etc. need to be removed first.
●Link baffle assembly
After holding the baffle plate, use an 8# sleeve to remove 3 bolts ⑴and 1 bolt ⑸respectively, and remove the bushing
⑵and buffer rubber ⑶. Remove the connecting rod stopper ⑷.
●Disassemble the main pump U-joint of the disc brake
Straighten the cotter pin ①and remove it, remove the spacer ②and then remove the pin ③.
●Shift lever spline rocker arm
Use an 8# socket or a torx wrench to remove the bolt ⑹, and pull out the rocker arm ⑹.
CAUTION：
●Use the appropriate tools to support the vehicle to prevent accidents caused by the dumping of the vehicle during the
disassembly process; single operation is strictly prohibited.
Fig.2 FRAME&ENGINE FRAME&ENGINE 1

2
、
FRAME & ENGINE COMPONENT
16
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
11251112-002093 M6×30 Hexagon flange bolts (color Zinc) 1
21251112-001093 M6×16 Hexagon flange bolts (color Zinc) 4
31251100-061093 M6×22 Hex flang bolt thread level 8.8 (color Zinc) 4
41250305-009091 GB6187.1 M12×1.25(White Zinc) 2
61274200-091000 ZT310 water pipe clamp(φ27) 1
71244300-052000 ZT350-S engine outlet pipe 1
81050958-007000 ZT350 EFI high voltage line 1
Fig.3 FRAME&ENGINE FRAME&ENGINE 2
1251112-020000 GB5187 non-standard bolt M12×1.25×153(10.9
garde/dacromet) 25
PROCEDURE:
●Oil cooler
It is recommended to cover the front pedal support with waterproof and oil-resistant plastic cloth, and then
remove the two bolts⑶on the right side with 8# sleeve and pull out the two oil pipes.
Remove the three bolts⑵above the oil cooler with 8# sleeves. Pull out the oil cooler assembly for a certain
distance and remove the bolt⑵fixing the hydraulic control unit support.
●Radiator middle trim cover
Remove the bolt⑴at the bottom of the middle trim cover with 8# sleeve.
●Front pedal support assembly
Fix the head of bolt⑷with 14# sleeve on the left side and remove nut⑸with 17# sleeve on the right side.
After grasping the front pedal support assembly, remove the bolt⑸and remove the pedal support assembly.
●Left side of engine
It is recommended to use a 8# ring wrench with a 72 tooth ratchet wheel corner to remove the bolts⑶of the
intake manifold. Or loosen the clamp at the air outlet of the air filter and the clamp between the throttle valve
body and the intake manifold; And unplug the high-pressure oil pipe, fuel injector and external pressure
sensor.
Move the hoop⑺upward by about 30mm with hoop pliers, and then pull out the engine end of the water
outlet pipe⑹.
Pull out one end of the high-voltage wire⑻spark plug.
Unplug the plugs of exhaust pipe and cylinder head water temperature sensor.
CAUTION：
●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.
●The steps of removing the engine are complicated and difficult to describe in words, so only the key steps
are briefly explained here, and the removal shall be carried out according to the actual situation.

2
、
FRAME & ENGINE COMPONENT
17
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
11251100-291000 Non-standard bolt M10×1.5×55(Dacromet) 1
21251300-057093 Non-standard nut M10×1.5(Dacromet) 565±5N.m
31251112-020000 GB5187 non-standard bolt M12×1.25×153 5
41250305-009091 GB6187.1 M12×1.25(White Zinc) 7
51251100-132003 Non-standard bolt M10×1.5×80 (Dacromet) 4
61274300-082000 ZT350-R engine hanger 2
71251112-019000 GB5187 non-standard bolt M12×1.25×85 2
Fig.4 FRAME&ENGINE FRAME&ENGINE 3
PROCEDURE:
●Rear shock absorber reinforcement plate assembly
Make sure that the vehicle is supported firmly, and the rear flat fork assembly of the rear wheel cannot be
supported because the rear shock absorber assembly needs to be removed later. Use a 14# sleeve to fix the
head of the bolt⑶on the right side, and use a 17# sleeve to remove the nuts⑷) at three places a, b, and c on
the left side. Do not remove the bolt⑶yet. Note that the other 2 places only need to loosen the nut ⑷for
about 5 turns, which is convenient for subsequent removal of the rear shock absorber assembly.
Use a 14# sleeve to fix the head of the bolt⑴on the left and left side, and then remove the nut⑵with a 14#
sleeve to ensure that the whole vehicle is stable, and then one person gently shakes the rear wheel rear flat
fork assembly up and down, and one person pulls out the bolt⑴.
After holding the rear shock absorber assembly, pull out the bolts⑶at a, b, and c, and then remove the rear
shock absorber assembly.
Insert the bolts at the 3 places indicated by the arrows in Figure 2 back.
●Hanging piece
Use a 14# sleeve on the left to fix the heads of the two bolts ⑸above the hanger, and remove the nut 2 on
the right 14# sleeve.
Use a 14# Torx wrench on the right to fix the heads of the two nuts⑵above the hanging piece, and remove
the bolts⑸on the left 14# socket.
●Bracket
Use a 14# sleeve on the left to separate the heads of the 2 bolts ⑺at the bracket, and remove the nut ⑷on
the right 17# sleeve. Do not remove bolt ⑺and bracket assembly yet.
●Starter motor
Open the protective cap indicated by the arrow in Figure 3 on the right side, remove the upper nut with a
10# sleeve, and then pull out the cable, and screw the nut back to the motor to avoid loss. Or remove the nut
on the red positive end of the starter relay on the upper right side of the air filter, and then remove the
positive wire of the motor. This method is difficult and requires re-routing the positive wire, so it is not
recommended.
After removing the protective cap at the bottom, use an 8# Torx wrench to remove the bolt, then remove the
negative wire and the ground wire of the main cable, and screw the bolt back.
●
Clutch line

2
、
FRAME & ENGINE COMPONENT
18
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
11251112-002093 M6×30 Hexagon flange bolts (color Zinc) 1
21251112-003093 M6×45 Hex flange surface 9.8 bolt (color Zinc) 1
31251300-067000 ZT250-R rear wheel hollow shaft nut 1
41094200-009000 ZT310-V rear wheel hollow shaft Φ20×345 1
PROCEDURE:
●Water tank component
Loosen the bolts⑴on the upper direction of the main water tank with an 8# sleeve on the left side, and
loosen the bolts⑵on the right side. Grasp the bottom of the water tank assembly and turn it upward at a
certain angle to facilitate subsequent unloading of the engine.
●Rear fork assembly
Loosen the chain first and remove it from the small sprocket according to the method of adjusting the chain.
Tie the chain to the rear fork.
After ensuring that the vehicle is supported firmly, be careful not to support the rear flat fork assembly on
the rear wheel. Use a 24# open-end wrench to fix the bolt head on the left side, and use a 30# sleeve to
remove the nut ⑷on the right side. One person supports the engine, one person stabilizes the rear flat fork
assembly of the rear wheel, and the other uses a rubber hammer to knock the shaft to the left to leave the
engine box. There is no need to remove it to prevent the rear flat fork assembly from falling off.
●Disassemble the engine
Check whether the cables, pipes, etc. connected to the engine have been removed.
Remove parts such as brake hoses, cables, etc. that may block removal of the engine.
After supporting the engine cylinder head, remove the 4 bolts at the bracket and remove the bracket
assembly.
Hold the engine, remove the engine rear mounting bolt indicated by the arrow, and remove the engine.pay
attention to safety during move the engine. Place the engine on a flat ground.
CAUTION：
●Use the appropriate tools to support the vehicle to prevent accidents caused by the dumping of the vehicle
during the disassembly process; single operation is strictly prohibited.
●All standard parts must meet the standard torque value during reassembly, and re-add the oil according to
the instructions.
●The steps of removing the engine are complicated and difficult to describe in words, so only the key steps
are briefly explained here, and the removal shall be carried out according to the actual situation.
Fig.5 FRAME&ENGINE FRAME&ENGINE 4

3
、
INTAKE SYSTEM COMPONENT
19
CHK
ADJ
NO. PART NO. PART NAME QTY CAUTION
11051371-002000 Φ59×9 pipe clamp assembly 1
Fig.1 INTAKE SYSTEM
COMPONENT Air filter components 1
PROCEDURE:
●Air filter assembly
First, remove the fuel tank, side cover, cushion, PKE, ECU, battery and battery bracket according to the steps
of the corresponding parts to facilitate the next step of disassembly, which will not be repeated here.
Unplug the desorption tube and exhaust tube on the left side. After loosening the clamp ⑴, pull out the air
outlet pipe from the throttle valve body.
Refer to the "Electrical Device Assembly-1" section of this manual "Frame Assembly" on the upper right side
to remove the starter relay and bracket.
Unplug the temperature sensor indicated by the arrow in Figure 3.
Unplug the canister solenoid valve indicated by the arrow in Figure 4.
CAUTION:
●Remove the side cover, seat cushion,fuel tank, etc. in advance.
●Do not pull the cable hard when unplug the connector.