Zontes ZT350E User manual

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ZT350E
Maintenance Manual
2023-04-11

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Introduction
All the materials, illustrations, photos, etc. collected in this manual are compiled according to the latest products of ZT350-
D National IV. However, due to the continuous improvement of the product and other changes, there may be some
inconsistencies between your motorcycle and this manual. For colors or upgrades, please refer to the part codes on the official
website of Zontes. This manual will not be listed in detail; if the part names in this manual are inconsistent with the official
website of Zontes, please refer to the official website of Zontes.Individual parts of different displacements that differ in shape or
size but are disassembled and assembled in the same way, will not listed in this manual.
If part of the content of this manual is insufficient, please refer to the "Driver's Manual" included with the bike. The latest
version of the driver's manual can be downloaded as a PDF in the model introduction corresponding to the official website of
Zontes.
©GUANG DONG TAYO MOTORCYCLE TECHNOLOGY Co.,Ltd
All rights reserved

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User notice
This manual is compiled by Guangdong Tayo Motorcycle Technology Co., Ltd. to guide dealers or service personnel to use it. This
manual cannot provide more detailed knowledge about motorcycles, and is only for reference for maintenance. If you do not
have the corresponding knowledge such as electrician, machine repair, etc., improper assembly or repair failure may occur
during repair.
If you need to clean or wash the body parts of the motorcycle, you should use neutral car wash fluid or tap water, diesel,
kerosene, etc. Acidic or alkaline car wash liquid will cause irreversible corrosion of the surface paint, electroplating surface, and
anodized surface of the parts; gasoline will cause premature aging or hardening of sealants, gaskets, and rubber parts, reducing
the service life. Non-woven fabrics should be used for wiping with no residue. Ordinary rags may leave cloth scraps or wool, etc.,
which may affect the assembly or cause other adverse effects.
Our company will update this manual as soon as possible after the product changes.
The following is the meaning of the icons marked in this manual：
Failure to observe will cause personal injury or death of the driver or maintenance
personnel; or cause serious damage to parts and shorten the service life, etc.
Failure to comply may result in personal injury or death of the driver or maintenance
personnel; or damage to parts, abnormalities, etc.
Failure to observe the warning will cause personal injury to the driver or
maintenance personnel; or matters requiring special attention during disassembly
and assembly
Indicates that there is a requirement for torque there
Indicates that the piece needs to be replaced after disassembly

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Content
Content ............................................................................................................................................................................................... 4
1. Motorcycle information .................................................................................................................................................................. 9
Know Before Service ........................................................................................................................................................... 9
Body label ................................................................................................................................................................................. 10
E350 Technical specification ..................................................................................................................................................... 11
Front wheel/steering system ............................................................................................................................................ 11
Rear wheel/suspension system ........................................................................................................................................ 11
Brake system..................................................................................................................................................................... 11
Battery/charging system................................................................................................................................................... 12
0Lamp/Speedometer/switch description ................................................................................................................................. 12
Tightening torque ..................................................................................................................................................................... 13
Bolt tightening torque of general tightening part............................................................................................................. 13
Cable/cable/pipe/electrical device distribution map ............................................................................................................... 14
1. Distribution map of lamps and lanterns ....................................................................................................................... 14
2. Throttle cable ................................................................................................................................................................ 14
3. Brake upper pump and brake hose............................................................................................................................... 15
4. Calipers, brake hoses and wheel speed sensors ........................................................................................................... 15
5. Distribution map of brake system accessories.............................................................................................................. 16
5.1 E350..................................................................................................................................................................... 16
6. Oil supply system .......................................................................................................................................................... 17
6.1 E350 Fuel evaporation ........................................................................................................................................ 17
6.2 E350 Fuel supply ................................................................................................................................................. 18
7. Distribution map of cooling system accessories ........................................................................................................... 19
8. Electrical device layout.................................................................................................................................................. 19
9. Intake and exhaust system............................................................................................................................................ 21
Tool ........................................................................................................................................................................................... 22
Swell nail description ................................................................................................................................................................ 24
2. Maintenance ................................................................................................................................................................................. 25
Know Before Service ................................................................................................................................................................. 25
E350 Maintenance schedule..................................................................................................................................................... 26
E350 Air filter (filter element), air inlet filter element.............................................................................................................. 27
1. Support the motorcycle firmly ...................................................................................................................................... 27
2. Remove the left engine cover ....................................................................................................................................... 27
3. Remove the air inlet cover ............................................................................................................................................ 27
4. Replace the air inlet filter.............................................................................................................................................. 28
5. Remove the air filter housing........................................................................................................................................ 28
6. Replace Air filter element ............................................................................................................................................. 28
7. Inspection air filter waste oil pipe................................................................................................................................. 28
8. Reinstall......................................................................................................................................................................... 29
Bolts and nuts of muffler .......................................................................................................................................................... 30
Engine oil................................................................................................................................................................................... 31
1. Drain the oil........................................................................................................................................................... 31
2. Replace fine filter .................................................................................................................................................. 31
3. Add oil ................................................................................................................................................................... 32
4. Change gear box oil ............................................................................................................................................... 32
5. Confirm the oil level .............................................................................................................................................. 32
Throttle cable............................................................................................................................................................................ 33
1. Inspection...................................................................................................................................................................... 33
2. Adjust the throttle cable clearance............................................................................................................................... 33
Idle speed.................................................................................................................................................................................. 33
Check idle speed: .............................................................................................................................................................. 34
Fuel evaporative pollutant control system............................................................................................................................... 34
Radiator..................................................................................................................................................................................... 36
1. Check the coolant.......................................................................................................................................................... 36
2. E350 add coolant (antifreeze) to the Coolant expansion tank...................................................................................... 36
3. E350 add coolant to the Radiator ................................................................................................................................. 36
4. Put coolant .................................................................................................................................................................... 37
5. Check whether the fins of the radiator water tank are deformed or the air duct is blocked....................................... 37

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6. Check all water pipes for leaks; aging. .......................................................................................................................... 38
Brake hose ................................................................................................................................................................................ 39
Brake fluid ................................................................................................................................................................................. 39
1. Add brake fluid to the main pumps of the front and rear disc brakes.......................................................................... 39
2. Replace the brake fluid ................................................................................................................................................. 39
2.1 Replace the front brake brake fluid .................................................................................................................... 40
2.2 Replace the rear brake fluid ................................................................................................................................ 40
3. Brake system exhaust ................................................................................................................................................... 40
Tire ............................................................................................................................................................................................ 40
1. Check the tires .............................................................................................................................................................. 41
2. Replace tires.................................................................................................................................................................. 41
Front fork .................................................................................................................................................................................. 41
1. Check the appearance................................................................................................................................................... 42
2. Check the shock absorption performance .................................................................................................................... 42
3. Remove the front shock absorption.............................................................................................................................. 42
4. Correct the front fork tube ........................................................................................................................................... 42
5. Troubleshooting ............................................................................................................................................................ 43
Side bracket .............................................................................................................................................................................. 44
1. Check............................................................................................................................................................................. 44
2. Lubrication .................................................................................................................................................................... 44
Main bracket............................................................................................................................................................................. 45
1. Check............................................................................................................................................................................. 45
2. Lubrication .................................................................................................................................................................... 45
3. Install the main bracket ................................................................................................................................................ 45
4. Replace the return spring post of the main support..................................................................................................... 45
3. EFI system ..................................................................................................................................................................................... 46
Know Before Service ................................................................................................................................................................. 46
Error code ................................................................................................................................................................................. 47
1. E350 Read the fault code through the meter ............................................................................................................... 47
2. Read the fault code through the diagnostic tool .......................................................................................................... 47
3. Error code...................................................................................................................................................................... 47
4. Clear fault code ............................................................................................................................................................. 48
4.1 Manually clear..................................................................................................................................................... 48
4.2 Use the diagnostic tool to clear .......................................................................................................................... 48
EFI parts layout ......................................................................................................................................................................... 49
Fault diagnosis and elimination of EFI parts ............................................................................................................................. 49
1. Dump switch ................................................................................................................................................................. 50
2. OBD port ....................................................................................................................................................................... 50
3. Fuel pump ..................................................................................................................................................................... 50
4. Carbon canister solenoid valve ..................................................................................................................................... 51
5. EFI relay......................................................................................................................................................................... 51
6. Fuel injector .................................................................................................................................................................. 51
7. Throttle valve body ....................................................................................................................................................... 52
7.1 Common failure phenomena .............................................................................................................................. 52
7.2 Disassembly......................................................................................................................................................... 52
7.3Troubleshooting process...................................................................................................................................... 52
8. Water and oil shared sensor ......................................................................................................................................... 52
9. Oxygen Sensor............................................................................................................................................................... 53
9.1 Check................................................................................................................................................................... 53
10. ECU.............................................................................................................................................................................. 53
11. Crankshaft position sensor.......................................................................................................................................... 53
The engine cannot start and there is no sign of fault diagnosis process .......................................................................... 54
The engine cannot be started and there is a car symptom fault diagnosis process......................................................... 54
Poor acceleration .............................................................................................................................................................. 55
High idling speed of hot car .............................................................................................................................................. 55
Unsteady idle speed of cooling car ................................................................................................................................... 55
Unsteady idling, easy to cutoff.......................................................................................................................................... 56
Analysis flow chart of EFI failure indicator light always on............................................................................................... 57
Electrical schematic diagram of EFI system ...................................................................................................................... 58
4. Ignition system.............................................................................................................................................................................. 59
Know Before Service ................................................................................................................................................................. 59

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Troubleshooting........................................................................................................................................................................ 60
Ignition system layout............................................................................................................................................................... 61
Electrical schematic diagram of ignition system....................................................................................................................... 62
Ignition system inspection ........................................................................................................................................................ 63
Ignition timing........................................................................................................................................................................... 63
Check：............................................................................................................................................................................. 63
Installation: ....................................................................................................................................................................... 64
Ignition coils .............................................................................................................................................................................. 64
5. Starting system ............................................................................................................................................................................. 65
Know Before Service ................................................................................................................................................................. 65
Troubleshooting........................................................................................................................................................................ 65
1. Starting relay ................................................................................................................................................................. 65
2. Starter motor ................................................................................................................................................................ 66
3. The starter motor runs slowly....................................................................................................................................... 66
4. The starter motor is working normally, but the engine cannot be started .................................................................. 66
Ignition system layout............................................................................................................................................................... 66
Starting system electrical schematic diagram........................................................................................................................... 67
Starter motor ............................................................................................................................................................................ 68
1. Remove the starter motor ............................................................................................................................................ 68
2. Disassemble the starter motor ..................................................................................................................................... 68
Examination .............................................................................................................................................................. 69
Starter motor front cover：.............................................................................................................................. 69
Motor back cover：.......................................................................................................................................... 69
Denki：............................................................................................................................................................. 69
Check the starting relay ............................................................................................................................................................ 70
1. Operation check ............................................................................................................................................................ 70
2. Check the relay coil ....................................................................................................................................................... 70
2.1 Input line ............................................................................................................................................................. 70
2.2 Ground wire ........................................................................................................................................................ 70
3. Check the starting relay ................................................................................................................................................ 70
4. Disassembly and assembly of the starting relay ........................................................................................................... 70
6. Fuel supply system........................................................................................................................................................................ 71
Know Before Service ................................................................................................................................................................. 71
Examination .............................................................................................................................................................................. 71
1. Fuel pressure test.......................................................................................................................................................... 71
2. Fuel pump inspection.................................................................................................................................................... 71
3. Oil level sensor .............................................................................................................................................................. 71
7. Cooling system .............................................................................................................................................................................. 72
Know Before Service ................................................................................................................................................................. 72
Troubleshooting........................................................................................................................................................................ 72
1. The engine temperature is too high:............................................................................................................................. 72
2. The engine temperature is too low:.............................................................................................................................. 72
3. Coolant leakage............................................................................................................................................................. 72
Coolant system distribution map.............................................................................................................................................. 73
Coolant flow diagram................................................................................................................................................................ 73
Cooling system disassembly...................................................................................................................................................... 74
Coolant system hoop/clamp distribution map ................................................................................................................. 74
Thermostat assembly and small loop ............................................................................................................................... 74
Cooling system accessories....................................................................................................................................................... 75
1. Main water tank............................................................................................................................................................ 76
2. Attention to the water tank filling port......................................................................................................................... 76
2.1Overall tightness inspection......................................................................................................................... 76
2.2Pressure relief valve inspection ................................................................................................................... 76
3. Auxiliary water tank ...................................................................................................................................................... 76
4. Water and oil shared sensor ......................................................................................................................................... 76
5. Thermostat.................................................................................................................................................................... 76
5.1 Inspection............................................................................................................................................................ 76
5.2 Failure phenomenon........................................................................................................................................... 77
5.3 Disassembly......................................................................................................................................................... 77
5.4 Thermostat core inspection ................................................................................................................................ 77

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6. Water pipe .................................................................................................................................................................... 77
7. Check the water pump cover assembly ........................................................................................................................ 78
8. Braking system .............................................................................................................................................................................. 79
Know Before Service ................................................................................................................................................................. 79
Trouble shooting....................................................................................................................................................................... 79
Soft feeling from brake lever ............................................................................................................................................ 79
Hard feeling from brake lever ........................................................................................................................................... 79
Disassemble the disc brake main pump and calipers ............................................................................................................... 79
Disassemble the front disc brake main pump................................................................................................................... 79
Disassemble the rear disc brake main pump .................................................................................................................... 80
Disassemble the front disc brake caliper .......................................................................................................................... 80
Disassemble the rear disc brake caliper............................................................................................................................ 81
Brake hose and wheel speed sensor......................................................................................................................................... 82
Check the gap between the wheel speed sensor and the induction ring gear................................................................. 82
ABS troubleshooting ................................................................................................................................................................. 83
9. Battery/charging system............................................................................................................................................................... 84
Know Before Service ................................................................................................................................................................. 84
Troubleshooting........................................................................................................................................................................ 85
Charging system layout diagram............................................................................................................................................... 86
Electrical schematic diagram .................................................................................................................................................... 86
Battery disassembly .................................................................................................................................................................. 87
1. Disassembly................................................................................................................................................................... 87
2. Check............................................................................................................................................................................. 87
3. Charging ........................................................................................................................................................................ 87
Charging system check.............................................................................................................................................................. 87
1. Leakage test .................................................................................................................................................................. 87
2. Check the charging voltage ........................................................................................................................................... 87
3. Inspection of magneto stator charging coil................................................................................................................... 87
10. Front fork assembly .................................................................................................................................................................... 88
Know Before Service ................................................................................................................................................................. 88
Exploded view of front fork components: ................................................................................................................................ 89
Directional exploded view................................................................................................................................................. 89
Front fork exploded view .................................................................................................................................................. 90
Exploded view of lower link board.................................................................................................................................... 91
1、Change the direction of the handle .................................................................................................................................... 92
Disassemble the handle bar cover .................................................................................................................................... 92
3、Installation handle bar to put the component............................................................................................................ 93
4、Install the handle bar cover ........................................................................................................................................ 93
Replace the front wheel............................................................................................................................................................ 94
1. Remove the front wheel assembly................................................................................................................................ 94
2. Install the front wheel assembly ................................................................................................................................... 94
Front wheel assembly exploded view：........................................................................................................................... 95
Inspection and maintenance of front wheel assembly：................................................................................................. 96
1. Disc brake...................................................................................................................................................................... 96
1.1 The service life of the disc brake disc.................................................................................................................. 96
1.2 Disc brake Replacement method ........................................................................................................................ 96
2. Front wheel oil seals and bearings................................................................................................................................ 96
2.1 Service life of front wheel oil seals and bearings................................................................................................ 96
2.2 Replacement method of front wheel oil seal and bearing.................................................................................. 96
3. Front wheel rims and tires ............................................................................................................................................ 96
3.1 The service life of the front wheel rim and tire .................................................................................................. 96
3.2 How to replace the front wheel rim and tire ...................................................................................................... 96
3.3 Dynamic balance ................................................................................................................................................. 96
Change the front Shock absorber ............................................................................................................................................. 97
1. Remove the front wheel and front mudplate assembly ............................................................................................... 97
2．Remove the left and right front shock absorbers ....................................................................................................... 98
3. Reinstall compinents such sa shock absorbers,front mudboards,and front wheels..................................................... 98
十一、Disassembly and assembly of coverings ............................................................................................................................... 99
Removal of the windshield.............................................................................................................................................. 101
Removal of the upper part of the hood and the windshield liner .................................................................................. 101

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Head side panel removal................................................................................................................................................. 101
Removal of the headlight assembly ................................................................................................................................ 102
Seat removal ................................................................................................................................................................... 102
Removal of the glove box................................................................................................................................................ 103
Removal of left and right rear armrests.......................................................................................................................... 103
Removal of rear skirt assembly....................................................................................................................................... 103
Removal of tail light rear fender assembly ..................................................................................................................... 104
Removal of front left and right storage box covers ........................................................................................................ 105
Removal of fuel tank side cover ...................................................................................................................................... 105
Big pedal assembly removal............................................................................................................................................ 105
Removal of front storage box panel................................................................................................................................ 106

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1. Motorcycle information
Know Before Service
1. Use good quality tools, or special tools and fixtures designed by our company. The use of inferior tools may cause damage to
parts, peeling of plating, improper assembly, etc.
2. The O-rings, paper gaskets, copper gaskets, and component sealing rings used for sealing must be replaced before assembling.
3. Fasteners with torque requirements need to use a torque wrench to check the torque; if the torque is not required, refer to
the general torque value recommended by general fasteners.
4. Clean up before assembly; after assembly, check whether the assembly is correct and in place.
5. The motorcycle should be parked balanced and pay attention to safety during disassembly and assembly. Including but not
limited to the use of electric tools, hand tools, pneumatic tools, hydraulic tools, handling; prevent contact with skin, eyes, burns,
etc.
6. The replaced oils, liquids, batteries, etc. must be recycled and handed over to qualified institutions for disposal; it is forbidden
to dump them at will to pollute the environment or water sources.
7. Swallowing or inhaling coolant, brake fluid, etc. will cause certain harm to the human body. Any exposed skin such as hands
and face should be cleaned thoroughly after each addition. If swallowed by mistake, immediately contact the poison control
center or hospital; if inhaled, please immediately go to a ventilated environment. If it accidentally splashes into the eyes,
immediately rinse the eyes with a large amount of running water and seek medical advice or consultation in time. Keep away
from children and pets.
8.If your 350-D motorcycle is constructed of M6×16 bolts + flange bushings + flange bushing seating rubber, you can use the
M6×14 axle shoulder hexagonal bolts instead. Similar explanations will not be repeated in subsequent sections of this manual.
Only part of the basic requirements for matters needing attention, prevention of accidental injury, etc. can be listed; it is not
possible to list all situations in detail. Be vigilant during disassembly and assembly to prevent accidents.

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Body label
①The motorcycle identification code VIN can be seen after opening the seat Seat , and the VIN code is engraved on the cross
tube at the rear of the frame.
②The muffler code is on the inner side above the muffler.
③The nameplate is above the radiator.
④Right front compartment warning label,affixed to the right front compartment lid.
⑤Left front compartment warning label,affixed to the left front compartment lid.
⑥The storage box warning label is pasted on the front of the storage box.
⑦The engine identification code is engraved on the left crankcase.