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
Table of Contents
Page 1,Total 114 pages

Page 2,Total 114 pages
Pages
Contents
Table of Contents
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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Table of Contents
©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

1-FRAME&ELECTRONIC COMPONENT 10
CHK
ADJ
NO. PART NO. PART NAME QTY CAUTION
1 1250105-138093 GB5789M6×20 (environmental color) 1
2 1100100-820000 ZT350-R brake hose RC-HU section
（
A
）
1
1184200-004000 ZT310 horn
1184300-038000 ZT350-T speaker (19-inch dedicated)
4 1274300-065000 ZT350-VX front oil outlet pipe bracket 1
5 1251112-001093 M6×16 Hexagon flange bolts (color Zinc) 1
6 1250205-040095 GB70.1 inner hex bolt M8×16(color Zinc) 2
7 1184100-012000 ZT250-S shut down switch 1
8 1274100-095000 ZT250-S Flameout switch wire fixing bracket 1
9 1274100-017000 ZT250-S cable buckle 2
10 1224100-037000 Grade 0 flame retardant tie (black 3.6×295) 1
11 1050958-007000 ZT350 EFI high voltage line 1
12 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color Zinc) 2
13 1050958-006000 ZT350 lgnition oil body 1
14 1244200-139000 ZT310 rubber buckle (120mm) 1
Electronic parts component 2
3
PROCEDURE:
●Horn
Unplug the horn plug, remove the bolt ⑴ with 10# sleeve, pull out the brake hose ⑵, remove the bolt ⑸ with
8# sleeve, and remove the horn ⑸ and oil outlet pipe support ⑷.
●Shut down switch
Find the plug of the flameout switch ⑺ and pull it off; ⑷ press the thread buckle inward in the direction of the
arrow shown in the figure and pull it out with force; Cut the tie ⑸. Remove the bolt ⑻ with 6# hexagon socket,
remove the bracket ⑹ and the flameout switch ⑺.
●Ignition coil
Find and pull out the plug of ignition coil ⒀, untie the wire buckle ⒁, pull out the EFI high-voltage wire in the
direction indicated by the arrow in the figure, and remove the EFI high-voltage wire ⑾; Use 8# sleeve to remove
two bolts ⑾ and remove ignition coil ⒀.
CAUTION：
●When take off the plug can't drag any cable.
●Pay attention to the force when removing the buckle to prevent damage to the buckle.
1
Fig.2 FRAME&ELECTRONIC
COMPONENT

1-FRAME&ELECTRONIC COMPONENT 11
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 10
4 1244100-061000 ZT250 anti-water rubber of frame 4
5 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1
6 1274300-025000 ZT350-R water tank water inlet fixing bracket 1
7 1224300-086000 ZT350-R right wire harness holder 1
8 1244100-052000 Buffer rubber of flanging bushing (φ8.5×φ14×1) 1
9 1274100-057095 Flanging bushing φ6.2×φ8.4×3.5
＋
φ14×1.5 1
10 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1
PROCEDURE:
●Fuel tank liner limit glue
Push out the fuel tank liner limit glues⑴ then take off.
●Battery cushion
Directly remove 10 pieces of side cover glue ⑶ on both sides by hand.
●Side cover cushion
After heating with a hot-air gun, tear off the battery rubber pad ⑵ directly by hand and clean up the residual
glue.
●Frame waterproof rubber plug
Remove the four waterproof rubber plugs ⑷ of the frame directly by hand.
●Buckle
Remove one bolt ⑸ with 4# socket head and remove the bracket ⑹.
Remove the bolt ⑽ with 4# hexagon socket, remove the bushing ⑼ and buffer rubber ⑻, and then remove the
fixed seat ⑺.
CAUTION:
●
It must be dismantled them first, such as the cushion, fuel tank component, sider cover,water tank outer cover,
upper hanging piece,engine stail dressand so on.
●All parts should be correctly assembled.
●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.
Frame plastic parts
Fig.3 FRAME&ELECTRONIC
COMPONENT

1-FRAME&ELECTRONIC COMPONENT 12
CHK
ADJ
NO. PART NO. PART NAME QTY CAUTION
1 1134100-007000 ZT250
－
S Rating nut lock washer 1
2 1251300-046093 ZT250
－
S Steering column rating nut (color zinc) 2
3 1244100-015000 ZT250
－
S Rating nut glue cushion 1
4 1244300-014000 ZT350
－
R Steering stem dust cap (Up) 1
5 1130900-024000 ZT250
－
S shaft ring 1
6 1130900-022000 ZT250
－
S conjoined steel ball 1
7 1134300-002000 ZT350
－
R conjoined steel ball 1
9 1134300-003000 ZT350
－
R lower shaft ring 1
10 1244300-015000 ZT350
－
R steering stem dust cap(down) 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 ⑼ and the dustproof
cover⑽.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.
Directional column component
8 4094300-002051 ZT350－RLower connection board (dark gray
matte/including shaft ring) 1
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 ⑻, the other hand use a special four-jaw set or
hook wrench to remove the adjusting nut⑵.
Remove the down connected plate component⑻.
Remove the upper dustproof cover⑷.
Remove the shaft ring ⑸ and the steel ball⑹.
Remove the steel ball⑺ of the down connected plate component⑻.
●Assemble
When reassembling, the conjoined steel ball 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 upper adjustment nut only needs to be screwed to the bottom nut groove, and should not be too tight to
prevent the rubber pad ⑶ from being deformed too much.
Fig.4 FRAME&ELECTRONIC
COMPONENT

1-FRAME&ELECTRONIC COMPONENT 13
CHK
ADJ
NO. PART NO. PART NAME QTY CAUTION
2 1130900-026000 ZT250
－
S upper steel bowl 1After-sales
3 1134300-001000 ZT350-R lower seat ring 1After-sales
4 1264100-001000 ZT250
－
S side stand spring 1
5 1271200-165000 ZT310
－
T side bracket (short / dark gray) 1
6 1251100-088094 Non-standard bolt M10×1.5×43(dacromet) 1
7 1251300-057093 Non-standard nut M10×1.5(dacromet) 1 45±5N.m
8 1251700-025091 ZT250
－
S side stand sleeve 1
PROCEDURE：
●Checking the steel bowl
Checking whether the steel bowl ⑵and⑶ is frayed, if as it, please replace it. Fix the cushion loop well and
paint the lubricating grease on it with appropriate tool.
●Sider support
Using the cross screwdriver to remove the side support spring⑷, using 14#sleeve or plum blossom wrench
remove the nut ⑺ and then remove bolt ⑹ . Remove the side support ⑸ and bush⑻, paint the lubricating grease
on the bush⑻ when re-assembling ,then put it into the frame⑴.
CAUTION:
●Remove the steering handle assembly and the steering column assembly first.
●All parts shall be correctly assembled in place. Pay attention to safety when disassembling and assembling the
side support spring. The seat ring needs to be coated with grease to reduce the rotation resistance of the front
fork.
1 4014300-013000 ZT350-T frame aftermarket assembly (including seat
ring/310M nameplate) 1
Frame, Side support
Fig.5 FRAME&ELECTRONIC
COMPONENT

2-FRAME & ENGINE COMPONENT 14
CHK
ADJ
NO. PART NO. PART NAME QTY CAUTION
1 1251112-003093 M6×45 Hex flange surface 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) 3
65±5N.m
4 1274300-082000
ZT350-R engine hanger 2
5 1251100-060000
Non-standard bolts M10X1.5X90 (Dacromet) 3
7 4024300-003021
ZT350-R bracket 1
8 1250305-009091
GB6187.1 M12×1.25(White Zinc) 3
9
1251300-067000 ZT250-R rear wheel hollow shaft nut 1
10
1252200-040000 ZT310-R1 rear flat fork hollow shaft Φ20×315 1
11 1251100-262000
Non-standard bolt M12×1.25×127(Dacromet) 1
Fig.1 FRAME & ENGINE
COMPONENT Engine combination
PROCEDURE：
●Engine left rear cover
Using 8# sleeve remove the bolt ⑴ disassemble the rear cover⑵.
●Remove the engine
Remove the guard bar assembly according to the steps of "guard bar assembly". Fix the head of bolt⑸ at the
connection between the upper part of the engine and the frame with 14# sleeve, remove three nuts (3) and bolts ⑸
with 14# sleeve, and remove the hanger ⑷. Fix the head of the bolt ⑹ at the bracket with a 14# sleeve, and then
remove the two nuts⑻ with 17# sleeve. Pull out two bolts ⑹ and remove the bracket⑺. Fix the bolt⑾ at the lower
hanging part of the engine with 14# sleeve, and then remove the nut⑻ with sleeve without pulling out the bolt ⑾.
Fix the head of the rear flat fork shaft ⑽ with 24# open-ended wrench and remove the nut ⑼ with 30# sleeve.
One person lifts the engine slightly, and the other person pulls out the rear flat fork shaft to the left shaft sleeve of
the rear flat fork, as shown in the left figure. Two people hold the left and right boxes of the engine at the same time.
One person pulls out the bolt ⑾ hanging under the engine and holds the engine out to the right side of the vehicle.
Pay attention to safety during movement. Place the engine on a level surface.
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, positive wire of the motor, 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.
6GB5187 non-standard bolt M12×1.25×85(10.9
garde/dacromet)
1251112-019000 2

3-INTAKE SYSTEM COMPONENT 15
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 1050958-015000 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
PROCEDURE:
●Air filter intake air temperature sensor
Remove the Air filter intake air temperature sensor⑺on the air filter⑻.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
⑴,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.
Fig.1 INDUCTION
SYSTEM COMPONENT Maintain the filter element of the air filter
4 1244200-117000 ZT44 Throttle Valve Decoupling Rubber Tube
(Φ6×Φ10×L420+Φ9 pipe clamp ×2) 1

3-INTAKE SYSTEM COMPONENT 16
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 pipe clamp assembly 1
6 1224300-110000
Reverse buckle Velcro strap (20×200mm) 1
Fig.2 INDUCTION
SYSTEM COMPONENT The air filter assembly
PROCEDURE:
Press the clip pointed by arrow A, B and D, pull out the connectors of external intake pressure sensor and
fuel injector, pull out the clip pointed by arrow C, and pull out the connector of stepping motor. Press the snap
pointed by the e arrow and pull out the interface. In the same way at the other end, remove the high-pressure
oil pipe. Untie the reverse buckle tie ⑹.
●Air filter
Loosen the pipe clamp assembly ⑸ near the end of the air filter, clamp the clamp on the waste gas pipe with
pliers and pull out the waste gas pipe ① connecting the exhaust port of the engine, then wrap it with plastic bag
and cover it with rubber band to prevent foreign matters from entering and damaging the engine.
Remove bolt ⑵ with 4# socket head; Remove the air filter ⑴ and clamp plate nut ⑶.
●Throttle valve body assembly
Unplug the connector of throttle valve body assembly, remove the throttle cable, and then use 8# ring wrench to
remove 2 bolts ⑷ to remove the throttle valve body 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.

3-INTAKE SYSTEM COMPONENT 17
PROCEDURE:
●Throttle valve body assembly
Remove the O-ring ⑴ from the intake oipe assembly.
Remove the connection pipe⑾ at the A-end.
Use 10# sleeve to remove the bolt ⑺,take off the External intake air pressure sensor component,injector holder
⑹and 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 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 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.
●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.
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
Fig.3 INDUCTION
SYSTEM COMPONENT Throttle valve body component
11 1050958-008000 Intake pressure sensor connection hose(φ3.5×φ7.5×
L38.5)

3-INTAKE SYSTEM COMPONENT 18
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
1 4134300-003000
ZT350
－
Tair filter core (with carton packaging) 1
2 1224300-110000 Reverse buckle Velcro strap (20×200mm) 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-SINGLE ROCKER COMPONENT 19
CHK
ADJ
NO. PART NO. PART NAME QTY CAUTION
1 1251100-117093 Non standard hex socket bolt M8×25 2
2 1250501-004091 GB93φ10
（
white zinc
）
2
3 1250503-006091 GB97.1φ10
（
white zinc
）
2
4 1251100-204000 Non-standard Bolt M16×1.5×50
（
color zinc
）
1 100N.m
Fig.1 Rear wheel, swinging
arm assembly Adjustment chain
PROCEDURE：
●Rear auxiliary mud plate assembly
Remove the bolt ⑴
at the bottom of the rear auxiliary mud plate assembly with 6# socket head, and remove the
spring washer ⑵ and flat washer ⑶.
After holding the rear sub-mud assembly in one hand, remove the upper bolt ⑴ and remove the spring pad ⑵
and flat pad ⑶. Place the rear sub-mud assembly properly, taking care not to pull the cable.
●Sprocket assembly
Use a #21 sleeve to loosen the bolt ⑷.
Use a special hook wrench to turn the eccentric chain adjuster at the arrow indication. The counterclockwise
direction is to tighten the chain, and the clockwise b direction is loose.
The chain sag is 18~25mm. If it is too large, it will cause the chain to be accidental or damage the engine. If it
is too small, it will aggravate the wear of the chain and sprocket.
After adjusting the chain, restore it and pay attention to the torque of the bolt ⑷.
CAUTION:
●The upper bolt can only be removed after holding the rear mud plate assembly; Do not pull the cable
●The torque of the bolt ⑷ is 100N.m.
●The chain must be checked regularly for excessive wear; the chain should be cleaned and properly lubricated
regularly.