Zontes ZT350-T EURO V 2022 User manual

ZT350-T(EURO V)
Service manual
2022/08/05

Pages
0
Table of Contents………………………………………………………………………………………………………………………………………………………………………………………………
1
11-FRAME&ELECTRONIC COMPONENT
1.1
Electrical device component-1…………………………………………………………………………………………………………………………………………………………………………………
9
Disassemlbe the main harness and ECU
1.2
Electrical device component-2…………………………………………………………………………………………………………………………………………………………………………………
10
Horn,shut down switch and ignition coil
1.3
Frame plastic parts………………………………………………………………………………………………………………………………………………………………………………………………
11
Remove the Fuel tank liner limit glue,battery cushion,side cover cushion and buckle
1.4
Directional column component…………………………………………………………………………………………………………………………………………………………………………………
12
Disassembly and assembly of lower connecting plate assembly
1.5
Frame, side bracket……………………………………………………………………………………………………………………………………………………………………………………………
13
Remove the sider bracket;Checking the steel bowl
2FRAME & ENGINE COMBINATION
2.1
Engine component………………………………………………………………………………………………………………………………………………………………………………………………
14
Remove the engine;Engine left rear cover
3INTAKE SYSTEM COMPONENT
3.1
Carbon tank componen…………………………………………………………………………………………………………………………………………………………………………………………
15
Remove the air filter intake air temperature sensor,carbon tank electromagnetic valve and carbon tank;Check whether the temperature sensor is damaged
3.2
The air filter assembly…………………………………………………………………………………………………………………………………………………………………………………………
16
Remove the air filter and throttle valve component;Check whether the external intake pressure sensor is damaged
3.3
Throttle valve body component…………………………………………………………………………………………………………………………………………………………………………………
17
Remove the throttle valve body componen and external intake air pressure sensor.Check stepping motor and throttle position sensor
3.4
Replace air filter element………………………………………………………………………………………………………………………………………………………………………………………
18
Remove the filter element;Clean the Oil pipe and water pipe
4SINGLE ROCKER COMPONENT
4.1
Adjustment chain………………………………………………………………………………………………………………………………………………………………………………………………
19
Rear auxiliary mud plate assembly;Sprocket assembly
4.2
Sprocket baffle…………………………………………………………………………………………………………………………………………………………………………………………………
20
Remove sprocket baffle
Contents
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Page 1,Total 114 pages

Page 2,Total 114 pages
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4.3 Sprocket assembly 1…………………………………………………………………………………………………………………………………………………………………………………………… 21
Rear auxiliary mud plate assembly;Sprocket assembly;Chain
4.4 Sprocket assembly 2…………………………………………………………………………………………………………………………………………………………………………………………… 22
Sprocket assembly;Sprocket
4.5 Rear wheel component………………………………………………………………………………………………………………………………………………………………………………………… 23
Rear wheel assembly;Tire and rim assembly;Maintenance
4.6 Rear axle assembly…………………………………………………………………………………………………………………………………………………………………………………………… 24
Rear axle outer assembly;Rear axle assembly
4.7 Rear sub-mud assembly ……………………………………………………………………………………………………………………………………………………………………………………… 25
4.8 Chain adjuster assembly……………………………………………………………………………………………………………………………………………………………………………………… 26
Disc brake mounting plate;Chain adjuster assembly
4.9 Rear mud board………………………………………………………………………………………………………………………………………………………………………………………………… 27
4.10 Rear shock absorber…………………………………………………………………………………………………………………………………………………………………………………………… 28
Rear shock absorber;Adjust the rear absorber
4.11 Rear wheel assembly …………………………………………………………………………………………………………………………………………………………………………………………… 29
Rear swinging arm assembly;Abrasionproof block of rear swinging arm;Rear fork after sale
4.12 Change rear brake arresters…………………………………………………………………………………………………………………………………………………………………………………… 30
5DOUBLE ROCKER COMPONENT
5.1 Rear mud board………………………………………………………………………………………………………………………………………………………………………………………………… 31
5.2 Rear shock absorption………………………………………………………………………………………………………………………………………………………………………………………… 32
Rear shock absorber;Adjust the rear absorber;Check
5.3 Rear wheel component 1……………………………………………………………………………………………………………………………………………………………………………………… 33
Remove rear wheel component
5.4 Rear wheel component 2(aluminum）………………………………………………………………………………………………………………………………………………………………………… 34
Sprocket seat component;Fault detection of sprocket seat
5.5 Rear wheel component 3(aluminum）………………………………………………………………………………………………………………………………………………………………………… 35
Disc brake plate, ABS gear ring;Tire and wheel component
5.6 Rear wheel component 4 (spoke wheel)……………………………………………………………………………………………………………………………………………………………………… 36
Sprocket seat component;Fault detection of sprocket seat
5.7 Rear wheel component 5 (spoke wheel)……………………………………………………………………………………………………………………………………………………………………… 37
Disc brake plate, ABS gear ring;Tire and wheel component
5.8 Rear swinging arm component………………………………………………………………………………………………………………………………………………………………………………… 38
Rear fork component;Rear fork rear-resistant block

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5.9
Replace the rear brake pads
（
Double rocker arm
）
……………………………………………………………………………………………………………………………………………………………
39
5.10
Rear brake main pump adds brake fluid………………………………………………………………………………………………………………………………………………………………………
40
6PEDAL COMPONENT
6.1
Shift lever adjustment…………………………………………………………………………………………………………………………………………………………………………………………
41
Adjust the height of gear shift rod and shift lever position adjustment
6.2
Right footrest component 1……………………………………………………………………………………………………………………………………………………………………………………
42
6.3
Right footrest component 2……………………………………………………………………………………………………………………………………………………………………………………
43
Remove the rear brake main pump heat shield and rear disc brake main pump component
6.4
Right footrest component 3……………………………………………………………………………………………………………………………………………………………………………………
44
Remove the brake pedal component and muffler anti-scalding
6.5
Right footrest component 4……………………………………………………………………………………………………………………………………………………………………………………
45
Remove the R, front pedal,R,rear pedal and after sales parts for pedal component
6.6
Left footrest component 1………………………………………………………………………………………………………………………………………………………………………………………
46
Remove the L, foot pedal holder component,gear shift rod component,rectifier and support of disc brake lock;Rectifier fault detection
6.7
Left footrest component 2………………………………………………………………………………………………………………………………………………………………………………………
47
Remove the gear shift rod component
6.8
Left footrest component 3………………………………………………………………………………………………………………………………………………………………………………………
48
Remove the rear left pedal,L, rear foot pedal and after sales parts for pedal component
7COOLING SYSTEM COMPONENT
7.1
Change engine oil………………………………………………………………………………………………………………………………………………………………………………………………
49
Drain oil and change engine oil
7.2
Change engine oil filter…………………………………………………………………………………………………………………………………………………………………………………………
50
7.3
Add coolant……………………………………………………………………………………………………………………………………………………………………………………………………
51
7.4
Draining cooling liquid…………………………………………………………………………………………………………………………………………………………………………………………
52
7.5
Water tank assembly 1…………………………………………………………………………………………………………………………………………………………………………………………
53
Sub water tank connecting tube,connecting water pipes of left and right water tanks,right water tank assembly and engine water pipe
7.6
Water tank assembly 2…………………………………………………………………………………………………………………………………………………………………………………………
54
Filler assembly
7.7
Water tank assembly 3…………………………………………………………………………………………………………………………………………………………………………………………
55
Auxiliary water tank assembly,thermostat and left water tank assembly
7.8
Oil cooler component 1…………………………………………………………………………………………………………………………………………………………………………………………
56
Page 3,Total 114 pages

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7.9
Oil cooler component 2…………………………………………………………………………………………………………………………………………………………………………………………
57
Oil cooler bracket
8FRONT FORK COMPONENT
8.1
Throttle/clutch cable clearance adjustmene……………………………………………………………………………………………………………………………………………………………………
58
Adjust the free travel of throttle wire and clutch zipper ;Light height adjustment
8.2
Replacement clutch cable………………………………………………………………………………………………………………………………………………………………………………………
59
8.3
Replace the throttle cable………………………………………………………………………………………………………………………………………………………………………………………
60
Remove the throttle cable,install the throttle cable and right handlebar switch
8.4
Steering adjustment……………………………………………………………………………………………………………………………………………………………………………………………
61
Check steering device
8.5
Add brake fluid, rocker adjustment……………………………………………………………………………………………………………………………………………………………………………
62
8.6
Replace the front brake pads……………………………………………………………………………………………………………………………………………………………………………………
63
8.7
Windshield component 1………………………………………………………………………………………………………………………………………………………………………………………
64
Remove left and right guard bar
8.8
Windshield component 2………………………………………………………………………………………………………………………………………………………………………………………
65
Disassemble wind sheild bracket and head cover middle trim cover
8.9
Windshield motor component…………………………………………………………………………………………………………………………………………………………………………………
66
Disassemble windsheild motor,motor controller and bracket;Rocker after the head cover
8.10
Head cover aluminum bracket
、
Instrument component………………………………………………………………………………………………………………………………………………………
67
Disassemble head cover aluminum bracket
、
Instrument
、
Instrument bracket
、
Windshield rocker
8.11
Upper part of front mud guard-1………………………………………………………………………………………………………………………………………………………………………………
68
8.12
Upper part of front mud guard-2………………………………………………………………………………………………………………………………………………………………………………
69
8.13
Ftont headlight component-1……………………………………………………………………………………………………………………………………………………………………………………
70
Dismantle the headlight component;Front fender back board;Mounting bracket on the guard bar;
8.14
Front headlight component-2……………………………………………………………………………………………………………………………………………………………………………………
71
Headlight front cover;Hood cover
8.15
Front headlight component-2……………………………………………………………………………………………………………………………………………………………………………………
72
Grocery box
8.16
Front wheel component (spoke wheel)…………………………………………………………………………………………………………………………………………………………………………
73
Tire and wheel component;Brake disc and ABS ring gear;Tire and wheel component
8.17
Front wheel component( aluminum)……………………………………………………………………………………………………………………………………………………………………………
74
Tire and wheel component;Brake disc and ABS ring gear;Tire and wheel component
Page 4,Total 114 pages

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8.18
Front mudboard component 1(spoke wheel)……………………………………………………………………………………………………………………………………………………………………
75
Wheel speed sensor;Front mudboard water baffle;Oil outlet pipe support;Reflector
8.19
Front mudboard component 2(spoke wheel)
）
…………………………………………………………………………………………………………………………………………………………………
76
The front and left sides of the front mud plate
8.20
Front mudboard component
（
Aluminum
）
……………………………………………………………………………………………………………………………………………………………………
77
Front wheel speed sensor;Front disc brake caliper;Front mud board component
8.21
Hand guard component…………………………………………………………………………………………………………………………………………………………………………………………
78
8.22
Left hand component……………………………………………………………………………………………………………………………………………………………………………………………
79
Left rearview mirror, rocker arm and clutch switch assembly;Left handlebar rubber sleeve and left handlebar switch assembly
8.23
Right hand component…………………………………………………………………………………………………………………………………………………………………………………………
80
8.24
Hand bar component……………………………………………………………………………………………………………………………………………………………………………………………
81
Directional components;Uplink board assembly;Front left and right shock absorption
8.25
Uplink plate, handle bar component……………………………………………………………………………………………………………………………………………………………………………
82
Uplink plate and spacer assembly;Faucet lock
8.26
ABS brake system-A 1…………………………………………………………………………………………………………………………………………………………………………………………
83
Hydraulic control unit components
8.27
ABS brake system-A 2…………………………………………………………………………………………………………………………………………………………………………………………
84
Release brake fluid,FMC-HU oil pipe
8.28
ABS brake system-A 3…………………………………………………………………………………………………………………………………………………………………………………………
85
Brake brake fluid,FC-HU oil pipe
8.29
ABS brake system-A 4
（
Double rocker arm
）
………………………………………………………………………………………………………………………………………………………………
86
RMC-HU oil pipe;Wheel speed sensor;Rear disc brake caliper;RC-HU oil pipe
8.30
ABS brake system-A 4
（
Single rocker arm
）
…………………………………………………………………………………………………………………………………………………………………
87
RC-HU oil pipe;Rear disc brake caliper
9FUEL TANK COMPONENT
9.1
Middle cover component………………………………………………………………………………………………………………………………………………………………………………………
88
9.2
Fuel tank lock,fuel tank cover component………………………………………………………………………………………………………………………………………………………………………
89
9.3
Fuel tank cover component……………………………………………………………………………………………………………………………………………………………………………………
90
9.4
Fuel tank trim cover rear shell component 1……………………………………………………………………………………………………………………………………………………………………
91
Left tank trim cover back shell component;Left front turn signal lamp
9.5
Fuel tank trim cover rear shell component 2……………………………………………………………………………………………………………………………………………………………………
92
Right tank trim cover back shell component;Right front turn signal lamp
Page 5,Total 114 pages

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9.6
Fuel tank assembly component 1………………………………………………………………………………………………………………………………………………………………………………
93
Disassemble oil tank cover assembly
9.7
Fuel tank assembly component 2………………………………………………………………………………………………………………………………………………………………………………
94
Disassemble oil tank assembly
9.8
Tank liner component…………………………………………………………………………………………………………………………………………………………………………………………
95
Fuel pump;Fuel tank cap;Adhesive strip;Side cover round glue
10 SIDE COVER COMPONENT
10.1
Side cover component 1…………………………………………………………………………………………………………………………………………………………………………………………
96
Remove the left cover assembly
10.2
Side cover component 2…………………………………………………………………………………………………………………………………………………………………………………………
97
Remove the right cover assembly
11 GUARD BAR COMPONENT
11.1
Guard bar component……………………………………………………………………………………………………………………………………………………………………………………………
98
Guard bar assembly;Support on guard bar
12 Rear cover component
12.1
Rear rack………………………………………………………………………………………………………………………………………………………………………………………………………
99
12.2
Rear mud plate assembly 1……………………………………………………………………………………………………………………………………………………………………………………
100
Disassemble rear mudboard assembly
12.3
Rear mud plate assembly 2……………………………………………………………………………………………………………………………………………………………………………………
101
Rear turn signal lamp;Rear license plate bracket;Rear reflector;Rear license plate buffer
12.4
Rear turning light parts for after sales service…………………………………………………………………………………………………………………………………………………………………
102
Rear license light;Rear turning signal
12.5
Tail light and tail skirt assembly………………………………………………………………………………………………………………………………………………………………………………
103
Tail light;Tail skirt;Cushion lock
12.6
Battery component………………………………………………………………………………………………………………………………………………………………………………………………
104
Battery straps;Battery
12.7
Electrical component box component 1…………………………………………………………………………………………………………………………………………………………………………
105
Upper cover of battery box;Start relay;Relay holder
12.8
Electrical component box component 2…………………………………………………………………………………………………………………………………………………………………………
106
Remove buzzer and flasher
Page 6,Total 114 pages

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12.9
PKE component ………………………………………………………………………………………………………………………………………………………………………………………………
107
Remove induction antenna and PKE
12.10
Electrical device box component 1 ……………………………………………………………………………………………………………………………………………………………………………
108
Remove battery support
12.11
Electrical device box component 2……………………………………………………………………………………………………………………………………………………………………………
109
Electrical component box assembly;Charging port base;Charging port bracket
13 CUSHION COMPONENT
13.1
Cushion…………………………………………………………………………………………………………………………………………………………………………………………………………
110
Disassembly seat cushion and rubber
14 Muffler component
14.1
Muffler component 1……………………………………………………………………………………………………………………………………………………………………………………………
111
Remove the rear section of the muffler
14.2
Muffler component 2……………………………………………………………………………………………………………………………………………………………………………………………
112
Decompose the rear section of the muffle,muffler component mounting points on both sides
14.3
Muffler component 3……………………………………………………………………………………………………………………………………………………………………………………………
113
Decompose the front section of the muffler
15 Lower shroud component
15.1
Lower shroud component-1……………………………………………………………………………………………………………………………………………………………………………………
114
Decompose the lower shroud component
Page 7,Total 114 pages

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©Guangdong Tayo Motorcycle Technolog Co.
Ltd All rights reserve
All the information, illustrations and photographs collected in this manual are compiled according to the latest products. However, there may be some inconsistencies between your motorcycle and
this manual due to the continuous improvement of the product and other changes.
Page 8,Total 114 pages

1-FRAME&ELECTRONIC COMPONENT 9
CHK
ADJ
NO. PART NO. PART NAME QTY CAUTION
1 1184300-009000 ZT350-T wiring harness assembly-A 1
2 1224300-093000 Reverse buckle Velcro strap (20×150mm) 2
3 1224300-110000 Reverse buckle Velcro strap (20×200mm) 7
4 1224300-111000 Reverse buckle Velcro strap (20×300mm) 3
5 1224100-037000 Grade 0 flame retardant tie (black 3.6×295) 1
PROCEDURE:
●Main harness
Unplug all electrical components connected to the main harness. Different connector modes are different, and the
operation is based on the actual situation. A slotted screwdriver, pliers, scissors and other tools may be needed to
assist.
It is necessary to untie three ties ⑷ at the front ① and ②, two ties ⑵ at the front ①, cut the tie ⑸ at the left
cover, and untie seven ties ⑶ at the left and right sides of the body.
●ECU
Find the ECU plug at the rear of the frame, press the anti release buckle at ③, rotate clockwise and pull out the
plug. Tidy up the fuse box and harness and take out the ECU⑹.
CAUTION：
●It must be dismantled them first, such as the cushion, fuel tank component,sider cover, tail dress and so on.
●In order to avoid the improper contact of the bending electrical parts, please pay attention to the direction and
angle of force when plugging the electrical parts, so as to avoid the improper contact of the bending electrical
parts. No violent operation.
●Please notice the limit of the bracket when dismantling dump switch sleeve, beware of hurting your fingers.
Fig.1 FRAME&ELECTRONIC
COMPONENT Electronic parts component 1
MSE6.0 controller - ZT184MP (matching split sensor /
Euro V)
1050958-0140006 1 Bosch EFI