Zontes ZT310-X Service Manual
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Zontes ZT310-X Service Manual

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ZT310-X/X GP
Service manual
2020/11/11

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  • Page 1 ZT310-X/X GP Service manual 2020/11/11...
  • Page 2 Contents Table of Contents Page Table of Contents ………………………………………………………………………………………………………………………………………………………………………………………………… FRAME&ELECTRONIC PARTS COMPONENT 1.1 Electrical Device component-1 ……………………………………………………………………………………………………………………………………………………………………………………… 9 Main harness, dump switch, relay, flasher, rectifier, ignition coil 1.2 Electrical Device component-2 ……………………………………………………………………………………………………………………………………………………………………………………… 10 Flameout switch, horn, wake-up switch 1.3 Frame plastic parts…………………………………………………………………………………………………………………………………………………………………………………………………… 11 Set clamp, side cover round glue, fuel tank liner limit glue 1.4 Directional Column component………………………………………………………………………………………………………………………………………………………………………………………...
  • Page 3 Contents Table of Contents Page 4.2 Rear shock absorption……………………………………………………………………………………………………………………………………………………………………………………………… Demolition after shock absorption, rear shock absorption adjustment 4.3 Rear wheel component 1…………………………………………………………………………………………………………………………………………………………………………………………… Remove the rear rim component, sprocket seat, sprocket 4.4 Rear wheel component 2…………………………………………………………………………………………………………………………………………………………………………………………… Decomposed rear rim component 4.5 Rear fork component………………………………………………………………………………………………………………………………………………………………………………………………… 25 Decomposed flat fork component 4.6 Replace the rear brake pads…………………………………………………………………………………………………………………………………………………………………………………………...
  • Page 4 Contents Table of Contents Page Remove the shroud component and release the coolant 6.6 Right tank component……………………………………………………………………………………………………………………………………………………………………………………………… Disassemble the right tank component and the right water pipe component 6.7 Left tank component 1……………………………………………………………………………………………………………………………………………………………………………………………… Disassemble the left tank component, the left water pipe component, and the auxiliary water tank component 6.8 Left tank component 2………………………………………………………………………………………………………………………………………………………………………………………………...
  • Page 5 Contents Table of Contents Page 8.8 Front wheel component……………………………………………………………………………………………………………………………………………………………………………………………… 56 Disassemble the front wheel, front disc brake disc, front axle component 8.9 Front mud board & wheel speed sensor component………………………………………………………………………………………………………………………………………………………………… 57 Decompose front wheel speed sensor component, front mud plate component 8.10 Windshield componen(Electronic Instrument)t………………………………………………………………………………………………………………………………………………………………………...
  • Page 6 Contents Table of Contents Page 8.25 Left and right hood(TFT Instrument) ……………………………………………………………………………………………………………………………………………………………………………… Remove left and right hoods 8.26 Headlight component(TFT Instrument) 1…………………………………………………………………………………………………………………………………………………………………………… 74 Remove headlight 8.27 Headlight component………………………………………………………………………………………………………………………………………………………………………………………………… 75 Headlights and headlights for sale 8.28 Left hand component………………………………………………………………………………………………………………………………………………………………………………………………… 76 Remove left rear view mirror, left hand rubber sleeve, balance weight, left switch 8.29 Directional lever, upper plate, front shock absorbing component……………………………………………………………………………………………………………………………………………………...
  • Page 7 Contents Table of Contents Page TANK LINER COMPONENT 10.1 Fuel Tank Box component（Small fuel tank）……………………………………………………………………………………………………………………………………………………………………… 89 Demolition tank box, PKE antenna 10.2 Tank liner component（Small fuel tank）………………………………………………………………………………………………………………………………………………………………………… Demolition tank liner component, seat cushion fixing block 10.3 Tank liner（Small fuel tank）……………………………………………………………………………………………………………………………………………………………………………………… 91 Demolition tank liner, fuel pump, fuel tank cover bracket, fuel tank cap 10.4 Fuel Tank Box component（Big fuel tank）………………………………………………………………………………………………………………………………………………………………………...
  • Page 8 Contents Table of Contents Page After the disassembly, the skirt assembly, PKE buzzer, PKE antenna (short) 12.7 Rear mud board component 2……………………………………………………………………………………………………………………………………………………………………………………… After the disassembly, the middle of the skirt, the taillights and the left and right skirt components 12.8 Left rear skirt component…………………………………………………………………………………………………………………………………………………………………………………………… 105 Disassemble the left rear skirt component 12.9 Right rear skirt component……………………………………………………………………………………………………………………………………………………………………………………………...
  • Page 9 Contents Table of Contents Page Decompose the front section of the muffler, oxygen sensor, muffler flange 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 10 1、FRAME COMPONENT Fig.1 FRAME&ELECTRONIC Electronic parts COMPONENT-1 PARTS COMPONENT PART NO. PART NAME CAUTION 1184200-079000 ZT310-X1 wire harness assembly Delphi EFI 1184200-168000 ZT310－X1 Wire Harness component (Bosch) Bosch EFI 1251100-102000 Non-standard bolt M6×16（304 stainless steel） 1224100-037000 0 level antiflaming binding（black 3.6×295） 1184200-039000 ZT250－S Flasher 1244100-082000 ZT250－S Dump switch rabber 1184100-002000 ZT250－S Dump switch...
  • Page 11 1、FRAME COMPONENT Fig.2 FRAME&ELECTRONIC Electronic parts COMPONENT-2 PARTS COMPONENT PART NO. PART NAME CAUTION 1251100-061093 M6×22 Screw bolt 1274200-033000 ZT310－R No.2 holder of front disc oil pipe 1184200-004000 ZT310 Horn 1274100-017000 ZT250－S Cable clip 1224100-037000 frane retartant ribbon 1274100-095000 ZT250－S Holder of flameout switch cable 1184100-012000 ZT250－S Flameout switch 1250205-040095 GB70.1M8×16 Screw PROCEDURE:...
  • Page 12 1、FRAME COMPONENT Fig.3 FRAME&ELECTRONIC Frame plastic parts PARTS COMPONENT PART NO. PART NAME CAUTION 1244100-019000 ZT250－S Inner fuel tank fix glue cushion 1240300-007000 HJ125－6 battery cushion 1244100-002000 ZT250－S side cover cushion 1244100-061000 ZT250 Frame water proof rubber plug 1224200-016000 ZT250－R Cable collection clip 1274100-007000 ZT250-S flanging sleeve（φ6.4×φ9×6＋φ20×2）...
  • Page 13 With one hand to hold down the down connected plate assembly ⑺, the other hand use a special four- and rust.If YES, please buy the regular accessories on ZONTES official website, if not, please be sure to grease jaw set or hook wrench to remove the adjusting nut⑵.
  • Page 14 ●Checking the cushion loop CAUTION： Checking whether the cushion loop ⑵ is frayed, if as it, please replace it on ZONTES website, fix the ●Remove the wind deflector component, handle bar component, steering column component first. cushion loop well and paint the lubricating grease on it with appropriate tool.
  • Page 15 1244200-054000 ZT310-X protection bar protection glue 1251100-082093 Non-standard bolt M10×1.5×20 (Dacro) 1244100-061000 ZT250 frame waterproof rubber stopper 1251300-057093 Non-standard nut M10×1.5 (Dacro) 1274200-026000 ZT310-X lower shroud front right bracket 1144200-007000 ZT310-X lower right guard bar M6×45 hexagonal flange surface 9.8 bolt 1251112-003093...
  • Page 16 2、FRAME&ENGINE Fig.2 FRAME&ENGINE FRAME&ENGINE 2 PART NO. PART NAME CAUTION 1251300-057093 Non-standard nut M10×1.5 (Dacro) 1020242-186000 ZT310-R upper right hanging piece 1020242-185000 ZT310-R top left hanging piece ZT180MN engine ∅ 1251300-059093 125 rear fork shaft nut M14×1.5 (Dacro) 110±5N.m 1251100-086093 Non-standard bolt M10×1.5×112 (Dacro) 1252200-016093 250 rear fork shaft 14×310 (Dacro) 4024200-005000 ZT310-R bracket...
  • Page 17 3、INDUCTION SYSTEM COMPONENT FIG.1 INTAKE SYSTEM Intake system component (Delphi EFI) COMPONENT PART NO. PART NAME CAUTION 1050954-007000 39－N008 Fuel injector 1050954-008000 39－N008 Fuel injector fixator 1251112-001093 M6×16 Hexagon flange bolt（color zinc） 1050954-006000 ZT250-R Fuel injector high pressure oil pipe unit 1251300-063093 Plywood M6×11×15（Environmental protection）...
  • Page 18 3、INDUCTION SYSTEM COMPONENT FIG.2 INTAKE SYSTEM Intake system component (Bosch EFI) COMPONENT PART NO. PART NAME CAUTION 1244200-017000 ZT310－R Air filter large air inlet 1224200-171000 ZT310-T1 Air Filter (Bosch) 1251100-101000 Non-standard bolt M6×12（304stainless steel） 1251300-063093 Plywood M6×11×15（Environmental protection） 1051354-004000 Φ56×10 Hoop assembly 1050954-035000 ZT310-R Fuel injector high pressure oil pipe unit 1274200-034000 ZT310－R Rear disc brake tubing clamp (steel) PROCEDURE:...
  • Page 19 3、INDUCTION SYSTEM COMPONENT FIG.3 INTAKE SYSTEM Intake system component (Bosch EFI) COMPONENT PART NO. PART NAME CAUTION 1251100-061093 M6×22 Hexagon flange bolt（color zinc） 1244200-117000 ZT40 Throttle valve desorption rubber tubing 1050954-035000 ZT310-R Fuel injector high pressure oil pipe unit 1051454-016000 45×2.5 Fluorine rubber O-ring 1050954-034000 ZT180MN Intake pipe assembly (Bosch) 1050954-023000 EV14 Fuel injector G48 1050968-002000 ZT1P58MJ Fuel injector fixator...
  • Page 20 3、INDUCTION SYSTEM COMPONENT Fig.4 INDUCTION Induction system component SYSTEM COMPONENT PART NO. PART NAME CAUTION 1050954-009000 YH Carbon tank electromagnetic valve 1251100-101000 Non-standard bolts M6×12（304 stainless steel） 1250303-010093 GB6177.1M6（color zinc） 1251300-063093 Plywoord M6×11×15（color zinc） 1224200-158000 ZT310－R Carbon tank II (with fuel pipe) 1244200-004000 TB41 Throttle valve desorption rubber tubing Delphi EFI 1244200-117000 ZT40 Throttle valve desorption rubber tubing...
  • Page 21 3、INDUCTION SYSTEM COMPONENT Fig.5 INDUCTION Induction system component SYSTEM COMPONENT PART NO. PART NAME CAUTION ZT310 Air filter sponge filter element（with 1224200-065000 packaging） PROCEDURE: ●Filter element If you need to maintain the filter element of the air filter, remove the seat cushion, the right side cover Take the two standard parts ①...
  • Page 22 4、REAR WHELL COMPONENT Fig.1 REAR WHELL Rear inner mudguard COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non-standard Bolt M6×16（SS） 1274100-057095 Bush φ6.2×φ8.4×3.5＋φ14×1.5 1244100-052000 Gum cushion, bush（φ8.5×φ14×1） 1224200-003000 ZT310－Z rear disc brake oil tube cleat 1224200-094000 ZT310－rear inner mudguard 1251700-059093 Bush φ6.4×φ9×8＋φ18×2（environmental color-zinc） 1251112-001093 M6×16 Hexagon flange bolts (color zinc) PROCEDURE: ●Rear inner mudguard...
  • Page 23 4、REAR WHELL COMPONENT Fig.2 REAR WHELL Rear shock absorber COMPONENT PART NO. PART NAME CAUTION 1251100-085093 Non standard bolt M10×1.5×75（DACROMET） 1251100-060000 Non standard bolt M10×1.5×90（DACROMET） 1114200-033000 ZT310－R Rear shock absorber (improved) 1251300-057093 Non standard nut M10×1.5（DACROMET） PROCEDURE: ●Rear shock absorber Put down side stand.
  • Page 24 4、REAR WHELL COMPONENT Fig.3 REAR WHELL Rear wheel component 1 COMPONENT PART NO. PART NAME CAUTION 1251100-105000 ZT310－Z Chain adjusting bolt M10×70 1251300-050000 ZT310－Z Chain adjuster nut M10 1032142-073035 ZT310 R, chain adjuster(Titanium) 1032142-075051 ZT310 R, chain adjuster(dark gray) 1251300-067000 ZT250－R rear wheel axle nut 110N.m 1032142-072035 ZT310 L, chain adjuster(Titanium) 1032142-074051 ZT310 L, chain adjuster(dark gray)
  • Page 25 4、REAR WHELL COMPONENT Fig.4 REAR WHELL Rear wheel assembly 2 COMPONENT PART NO. PART NAME REMARKS 160/ 60R17 (CM638R) environmentally friendly 1230100-480000 vacuum rear tire 1094200-020000 ZT310－T black rear rim（4.5×17） 1100100-419000 ZT310－R1 rear disc brake plate（230×4.5） 1274200-168021 ABS gear ring(40T) 1274200-058000 ABS gear ring(60T) 1251100-117093 Non standard hex socket bolt M8×25 1230200-006000 HJ100－D tire valve cap...
  • Page 26 4、REAR WHELL COMPONENT Fig.5 REAR WHELL ∅ Rear swinging arm component COMPONENT PART NO. PART NAME CAUTION 1252200-016093 250Rear fork shaft 14×310（Dacro） 1251300-059093 125Rear fork shaft nutM14×1.5（Dacro） 1251100-102000 Non-standard bolt M6×16（stainless steel） 1224200-003000 ZT310－ZRear disc brake pipe clamp 1080200-032000 ZT250－R 114 Chain（CHOHO520HX） 1080200-055000 ZT250－R 114 Chain（CHOHO520HX/ open type）...
  • Page 27 4、REAR WHELL COMPONENT Fig.6 REAR WHELL Change rear brake arresters COMPONENT PART NO. PART NAME CAUTION 1100100-092000 ZT250－S rear disc brake arrester(HS10) PROCEDURE: ●Disassemble disc brake arrester Use strait screwdriver to disassemble nut①. Disassemble pin axle② with hex socket tool. Disassemble rolling axle③...
  • Page 28 4、REAR WHELL COMPONENT Fig.7 REAR WHELL Rear disc brake main pump adding braking liquid COMPONENT PART NO. PART NAME CAUTION 1224100-010000 ZT250－S Expanding bolt 1224200-055000 ZT310－R rear disc brake oil cup holder PROCEDURE: ●Add disc brake liquid Press down the middle part of expanding nail⑴ with a small cross screwdriver. Take off the expanding nail. Pull out the oil cup④;...
  • Page 29 5、FOOT PEDAL COMPONENT Fig.1 FOOT PEDAL Adjust the hight of foot pedal COMPONENT PART NO. PART NAME CAUTION 1251100-061093 M6×22 Hexagon flange bolt 8.8 degree 1274100-039000 ZT250－S Gear swift rod spline of Rocker arm 1271200-163000 ZT250－S Gear swift rod spline of Rocker arm (dark gray) 1250301-020093 GB6170M6（environmental color-zinc）...
  • Page 30 5、FOOT PEDAL COMPONENT Fig.2 FOOT PEDAL Right foot pedal holder assmebly-1 COMPONENT PART NO. PART NAME CAUTION 1250205-034093 GB70.1 Hex socket bolt M8×30 1250205-023000 GB70.1 Hex socket bolt M8×35 1274100-068095 ZT310 Muffler bush 1224100-010000 ZT250－S Expanding bolt 1244100-064000 ZT310 Muffler gum cushion PROCEDURE: ●Right Foot pedal component Use a plier to disassemble the pin①.
  • Page 31 5、FOOT PEDAL COMPONENT Fig.3 FOOT PEDAL Right foot pedal holder assmebly-2 COMPONENT PART NO. PART NAME CAUTION 1251100-121093 Non standard bolt M6×25（environmental color-zinc） 1251100-131000 Non standard bolt M10×1.5×36 1274200-010000 ZT310－R brake pedal 1274200-300051 ZT310－R brake pedal (dark gray) 1260100-119093 ZT310－R brake pedal spring 1251500-060095 Non standard washer φ10.5×φ26×1 1251100-101000 Non-standard bolt M6×12（304 stainless steel）...
  • Page 32 5、FOOT PEDAL COMPONENT Fig.4 FOOT PEDAL Right foot pedal holder assmebly-3 COMPONENT PART NO. PART NAME CAUTION 1244100-002000 ZT250－S side cover round gum cushion 1274200-049000 ZT310－R R, foot pedal holder 4064200-007051 ZT310－R R, foot pedal holder (matte dark gray) 1274100-012000 ZT250－S foot pedal pin axle 1264100-006000 ZT250－S foot pedal spring 1264100-004000 ZT250－S R, front pedal spring 1274200-185000 ZT310－X R, front pedal component（Improved）...
  • Page 33 5、FOOT PEDAL COMPONENT Fig.5 FOOT PEDAL L, foot pedal holder component-1 COMPONENT PART NO. PART NAME CAUTION 1250205-034093 GB70.1 Hex socket M8×30（environmental color-zinc） 1250205-023000 GB70.1 Hex socket M8×35（environmental color-zinc） 1251100-061093 M6×22Hexagon flange bolt 8.8 degree 1274200-037000 ZT310－R disc brake lock holder 1251100-101000 Non-standard boltM6×12（304 stanless steel）...
  • Page 34 5、FOOT PEDAL COMPONENT Fig.6 FOOT PEDAL L, foot pedal holder component-2 COMPONENT PART NO. PART NAME CAUTION 1274200-193000 ZT310－X L, front pedal component（improved) 1271200-158000 ZT310－X L, front pedal component (matte dark gray) 1264100-003000 ZT250－S L, front pedal spring 1274100-012000 ZT250－S Pedal axis pin 1274100-035000 ZT250－S Foot pedal holder 1271200-161000 ZT250－S Foot pedal holder (dark grak) 1264100-006000 ZT250－S Foot pedal circlip...
  • Page 35 5、FOOT PEDAL COMPONENT Fig.7 FOOT PEDAL L, foot pedal holder component-3 COMPONENT PART NO. PART NAME CAUTION 1274200-062000 L, rear foot pedal component 1271200-160000 L, rear foot pedal component (matte dark gray) 1264100-005000 ZT250－S foot pedal steel ball spring 1274100-010000 ZT250－S rear foot pedal steel ball 1270300-272000 KD250－F rear foot pedal positioning plate 1274100-012000 ZT250－S Foot pedal pin axle 1264100-006000 ZT250－S Foot pedal circlip...
  • Page 36 6、COOLING SYSTEM COMPONENT Fig.1 COOLING SYSTEM Change engine oil COMPONENT PART NO. PART NAME CAUTION 1050854-002000 ZT180MN Engine oil level gauge 1224200-048000 ZT310－X The middle cover of surrounded parts 1244100-033000 12×φ20×2 Sealing gasket 1251100-066093 M12×1.5×15 Oil draining bolt (color zinc) 24±4N.m PROCEDURE: ●Drain off the engine oil...
  • Page 37 6、COOLING SYSTEM COMPONENT Fig.2 COOLING SYSTEM Change engine oil filter COMPONENT PART NO. PART NAME CAUTION 1251300-056093 M6 Cover type 9 degree nut 12±1.5N.m 4050954-002000 ZT180MN Engine oil refined filter cover（Titanium） 4050954-001000 ZT180MN fine filter cover A (titanium) Sliding llutch engine 4050454-014051 ZT180MN fine filter cover A (dark gray) 1051454-004000 55×2.5 O-ring...
  • Page 38 6、COOLING SYSTEM COMPONENT Fig.3 COOLING SYSTEM Radiator tubing component COMPONENT PART NO. PART NAME CAUTION 1051454-014000 9.8×2.5 O-ring 1244200-016000 ZT310－R Chassis connected oil tube M6×22 Hex flange bolt（8.8 degree/environmental 1251100-061093 color zinc） Oil passing bolt M14×1.50×32（environmental color 1251100-089094 zinc） 1244100-034000 Seal gasketφ14×φ20×2 1244200-014000 ZT310－R Engine oil outlet tube 1244200-015000 ZT310－R Engine oil intake tube PROCEDURE:...
  • Page 39 6、COOLING SYSTEM COMPONENT Fig.4 COOLING SYSTEM Add coolant COMPONENT PART NO. PART NAME CAUTION 1224200-006000 ZT310－R sub cooling liquid tank PROCEDURE: ●Add coolant When the engine is completely cooled, the vehicle can be straightened to accurately check the liquid level. If it is lower than the L line, the coolant should be replenished in time.
  • Page 40 6、COOLING SYSTEM COMPONENT Fig.5 COOLING SYSTEM Draining cooling liquid COMPONENT PART NO. PART NAME CAUTION 1251112-001093 M6×16 Hex flange bolt（environmental color zinc） 1051654-002000 Seal gasketφ6×13×1.8 PROCEDURE: ●Drain the cooling liquid Open the sub cooling liquid tank cover. Put a holder under it. Wear waterproof gloves and disassemble bolt (1) with socket sleeve.
  • Page 41 6、COOLING SYSTEM COMPONENT Fig.6 COOLING SYSTEM Right tank component COMPONENT PART NO. PART NAME CAUTION 1274200-079000 ZT310 Hoop of cooling liquid tube（φ9） 1244200-013000 Connecting tube of sub cooling liquid tank 1274200-090000 ZT310 Hoop of cooling liquid tube（φ26） 1244200-011000 Connecting tube of L & R cooling liquid tank 1251100-061093 M6×22 Hex flange bolt 1244200-012000 ZT310－R Engine cooling liquid passing tube 1274200-041000 ZT310 Cooling liquid tube clamp（φ26）...
  • Page 42 6、COOLING SYSTEM COMPONENT Fig.7 COOLING SYSTEM Left cooling liquid tank component COMPONENT PART NO. PART NAME CAUTION 1224200-006000 ZT310－R sub cooling liquid tank 1274100-007000 ZT250-S flanging sleeve（φ6.4×φ9×6＋φ20×2） 1250105-236093 GB5789M6×55（environmental color zinc） 1274200-091000 ZT310 Hoop of cooling liquid tube（φ27） 1244200-001000 ZT310－R Engine cooling liquid outlet tube 1274200-090000 ZT310 Hoop of cooling liquid tube（φ26）...
  • Page 43 ●⑴The standard left water tank for Bosch EFI. ⑵, ⑶ is the Delphi electric spray water tank. ●(2) There is only one connector, ⑶ has two connector, ⑶ must be used with the ZT310-X right water tank (with fan). Please confirm the status of your vehicle before placing an order.
  • Page 44 Surrounding middle component COMPONENT PART NO. PART NAME CAUTION 1224200-048000 ZT310-X surrounds the middle cover 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1274100-057095 Flanging bushing φ6.2×φ8.4×3.5+φ14×1.5 1244100-052000 Cuff bushing cushioning rubber (φ8.5×φ14×1) 1224100-010000 ZT250-S expansion nail 1224200-047000 ZT310-X surrounds the middle PROCEDURE：...
  • Page 45 7、SURROUNDING COMPONENT Fig.2 SURROUNDING Envelope panel assembly COMPONENT PART NO. PART NAME CAUTION 1224100-010000 ZT250-S expansion nail PROCEDURE： ●Bound panel components Use a small Phillips screwdriver to push down the center of the expansion pin and remove the 2 expansion pins (1).
  • Page 46 CAUTION 1174200-009000 ZT310-X front left turn signal 4044201-007064 ZT310-X bright blue surround left panel blue 4044201-055001 ZT310-X pearl white surrounded by left panel white 4044201-045021 ZT310-X special black surround left panel black 4044201-045051 ZT310-X dark gray borders the left panel...
  • Page 47 Right enclosure panel assembly COMPONENT PART NO. PART NAME CAUTION 1174200-010000 ZT310-X front right turn signal 4044201-008064 ZT310-X bright blue surrounds the right panel blue 4044201-056001 ZT310-X pearl white surround right panel white 4044201-046021 ZT310-X special black surround right panel black...
  • Page 48 7、SURROUNDING COMPONENT Fig.5 SURROUNDING Lower shroud assembly 1 COMPONENT PART NO. PART NAME CAUTION 1251100-061093 M6×22 hex flange face full thread bolt 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1274100-007000 ZT250-S flanging sleeve（φ6.4×φ9×6＋φ20×2） 1250502-010093 GB96.1φ6 (environmental color) PROCEDURE： ●Bottom lower shroud assembly Remove the bolt (1) and remove the bushing (3).
  • Page 49 4044201-222000 ZT310-X2 lower shroud left（bright siver GP) 1244100-004000 ZT250-S Flanging Bushing Buffer 1244100-002000 ZT250-S side cover round glue 1251300-063093 Splint M6×11×15 (environmental color) 1020442-026000 ZT310-X lower right side of the shroud 【1】 1224200-155000 ZT310-X1 lower right side of the shroud 【2】...
  • Page 50 PART NO. PART NAME CAUTION 1154200-003000 ZT310-X Throttle refueling line Delphi EFI 1154200-018000 ZT310-X Throttle refueling line (bosch ) Bosch EFI 1154200-004000 ZT310-X Throttle return line Delphi EFI 1154200-017000 ZT310-X Throttle return line (bosch ) Bosch EFI 1154200-012000 ZT310-X1 Clutch line (sliding clutch)
  • Page 51 8、FRONT FORK COMPONENT Fig.2 FRONT FORK clutch cable replacement COMPONENT PART NO. PART NAME CAUTION 1154200-012000 ZT310－X1 Clutch cable sliding clutch 1154200-002000 ZT310－X Clutch cable light clutch 1244200-046000 ZT310－V protective rubber sleeve light clutch PROCEDURE: ●Remove the cluch line Use an open-end wrench to loosen the nuts ② and ③; fix the adjusting screw ①, rotate the nut ② up to the top of the thread of the adjusting screw, and screw the nut ③...
  • Page 52 8、FRONT FORK COMPONENT Fig.3 FRONT FORK Replace the throttle line COMPONENT PART NO. PART NAME CAUTION 1154200-005000 ZT310-R Throttle refueling line Delphi EFI 1154200-016000 ZT310-R Throttle refueling line (bosch) Bosch EFI 1154200-006000 ZT310-R Throttle return line Delphi EFI 1154200-015000 ZT310-R Throttle return line (bosch) Bosch EFI 1224200-016000 ZT310-R Line clamp 1224100-051000 0 Flame retardant tie (black 2.5×100)
  • Page 53 8、FRONT FORK COMPONENT Fig.4 FRONT FORK Turn adjustment COMPONENT PART NO. PART NAME CAUTION 1251300-045000 ZT250-S Upper connection plate decorative nut 1251500-050000 Upper connection plate gasket φ18.5×φ39×1 1250205-023000 GB70.1 Hexagon M8×35 (color zinc) 1134100-007000 ZT250-S Adjusting nut lock washer 1251300-046093 ZT250-S Direction column adjusting nut M24X1 1244100-015000 ZT250-S Adjusting nut pad 1224100-005000 ZT250-S Direction column dust cover 1130900-024000 ZT250-S Shaft ring...
  • Page 54 1100300-044000 (without handle) 1134100-032000 ZT250-R Right Hand Rocker (Machine) 1134200-023000 ZT250-R balance block 1244100-042000 ZT250-R Right hand rubber sleeve 1184200-086000 ZT310-X right hand switch(TFT) Stop selling 1184200-145000 Second Generation Right Handlebar Switch (TFT) 1184200-023000 ZT310-X right hand switch Stop selling...
  • Page 55 8、FRONT FORK COMPONENT Fig.6 FRONT FORK Add brake fluid, rocker adjustment COMPONENT PART NO. PART NAME CAUTION 1134100-032000 ZT250-R Right Hand Rocker (Machine) 1100300-044000 Front brake main pump component (without handle) 1251513-013000 Disc brake copper washer φ15×φ10.2×1.5 1251100-112000 Disc brake oil pipe bolt M10×1-22 CAUTION: PROCEDURE: ●The motorcycle should be fixed after horizontal support and check.
  • Page 56 8、FRONT FORK COMPONENT Fig. 7 FRONT FORK Replace the front brake pads COMPONENT PART NO. PART NAME CAUTION 1100100-091000 ZT250-S front disc brake pads (H10) After-sales 1100100-570000 ZT310-T front brake caliper mounting plate PROCEDURE: ●Replace the front brake pads Use a flat-blade screwdriver to remove the nut ①. Remove the pin ②...
  • Page 57 8、FRONT FORK COMPONENT Fig.8 FRONT FORK Front wheel component COMPONENT PART NO. PART NAME CAUTION 1250205-023000 GB70.1 Hexagon M8×35 (color zinc) 20N.m 1094100-033000 ZT250-R Front wheel hollow shaft 1094100-008000 ZT250-R Front wheel left sleeve 1100100-418000 ZT310-R1 Front brake disc (300×4.5) 1251100-117093 Non-standard internal hexagon bolt M8×25 1274200-168021 ABS gear ring(40T) 1274200-058000 ABS gear ring(60T)
  • Page 58 GP 4044201-392051 deep bright gray front mud board component（GP） gray GP 1274200-038000 ZT310-X Front mudguard front oil pipe fixing seat 1250402-001091 GB12615φ3×10 CAUTION: ●Disassemble the oil pipe clamp and the sensor wire clamp should pay attention to the strength.
  • Page 59 【1】 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1224200-050000 Left pressing block on ZT310-X windshield 1244200-028000 ZT310-X windshield on the left press block rubber after-sales 1224200-051000 Right pressing block on ZT310-X windshield 1244200-029000 Right pressure block rubber on ZT310-X windshield...
  • Page 60 PART NO. PART NAME CAUTION 1164200-001000 ZT310-X electronic instrument 1274200-053000 ZT310-X windshield base bracket PROCEDURE: ●Meter First remove the two nuts ② on the front of the meter "a" with a wrench and remove the spacer③. Remove the rubber caps① and pull out the meter cable connector by pressing the buckle indicated by the arrow.
  • Page 61 PART NO. PART NAME CAUTION 1251112-001093 M6×16 hex flange bolt (environmental color zinc) 4044201-001064 ZT310-X bright blue hood panel 4044201-050001 ZT310-X pearl white hood panel 4044201-040021 ZT310-X special black hood panel 4044201-066051 ZT310-X Xuanwu lime hood panel 4044201-096015 ZT310-X gemstone red hood panel...
  • Page 62 PART NAME CAUTION 1251112-001093 M6×16 hex flange bolt (environmental color zinc) 1274200-053000 ZT310-X windshield base bracket 1274200-029000 ZT310-X windshield rocker bracket rotation axis 1274200-054000 ZT310-X windshield rear rocker bracket 1250201-038000 GB818 cross recessed pan head screw M4×10 1251700-114000 φ4×φ6×5.5 copper sleeve 【1】...
  • Page 63 CAUTION 1224100-010000 ZT250-S expansion nail 1184200-100000 ZT310 dual-port universal USB charging cable dual-port 1224200-046000 ZT310-X head surrounds the front interior 1251112-001093 M6×16 hex flange bolt (environmental color zinc) 1274100-007000 ZT250-S flanging sleeve（φ6.4×φ9×6＋φ20×2） 1244100-015000 ZT250-S adjustment nut pad 1244100-004000 ZT250-S Flanging Bushing Buffer...
  • Page 64 PART NAME CAUTION 1224100-010000 ZT250-S expansion nail 1224200-024000 ZT310-X hood left 1224200-025000 ZT310-X hood right side 1244100-002000 ZT250-S side cover round glue PROCEDURE: ●Left hood assembly Use a small Phillips screwdriver to push down the center of the expansion pin and remove the expansion pin⑴.
  • Page 65 PART NO. PART NAME CAUTION 1224100-037000 0 grade flame retardant cable tie (black 3.6×295) 1274200-039000 ZT310-X head line plug fixing bracket 1224200-008000 ZT310-R line card nail 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1274100-007000 ZT250-S flanging sleeve（φ6.4×φ9×6＋φ20×2） 1244100-004000 ZT250-S Flanging Bushing Buffer 1184200-013000 ZT310-X windshield motor controller 1251100-061093 M6×22 hex flange face full thread bolt...
  • Page 66 8、FRONT FORK COMPONENT Fig.17 FRONT FORK Windshield assembly(TFT Instrument) 1 COMPONENT PART NO. PART NAME CAUTION 1224200-139000 ZT310-X1 windshield 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1274100-057095 Bush φ6.2×φ8.4×3.5＋φ14×1.5 1244100-052000 Gum cushion, bush（φ8.5×φ14×1） 1224200-132000 ZT310-X1 windshield upper left pressure block 1224200-133000 ZT310-X1 windshield upper right pressure block 1244200-080000 ZT310-X1 windshield lower pressure block pad 1264100-006000 ZT250-S pedal circlip...
  • Page 67 8、FRONT FORK COMPONENT Fig.18 FRONT FORK Windshield assembly(TFT Instrument) 2 COMPONENT PART NO. PART NAME CAUTION 1224100-010000 ZT250-S swell nail 1224200-131000 ZT310-X1 windshield trim 1224200-093000 ZT310-T head cover on rocker arm decorative block 1274200-136000 ZT310-T head cover upper rocker gasket 1250601-093000 6802 deep groove ball bearing 1274200-114000 ZT310-T windshield rocker arm 4024200-078051 ZT310-T windshield rocker arm (matte dark gray)
  • Page 68 PART NO. PART NAME CAUTION 1251112-001093 M6×16 hex flange bolt (environmental color zinc) 4044201-001064 ZT310-X bright blue hood panel 4044201-050001 ZT310-X pearl white hood panel 4044201-040021 ZT310-X special black hood panel 4044201-096015 ZT310-X gemstone red hood panel 4044201-040051 ZT310-X deep gray hood...
  • Page 69 8、FRONT FORK COMPONENT Fig.20 FRONT FORK Windshield base assembly(TFT Instrument) 1 COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1274100-057095 Bush φ6.2×φ8.4×3.5＋φ14×1.5 1244100-052000 Gum cushion, bush（φ8.5×φ14×1） 1224200-130000 ZT310-X1 windshield motor cover 1274100-007000 ZT250-S flanging sleeve（φ6.4×φ9×6＋φ20×2） 1251112-001093 M6×16 hex flange bolt (environmental color zinc) 1250501-010000 GB93φ6 spring pad 1251100-101000 Non-standard bolt M6×12 (304 stainless steel)
  • Page 70 8、FRONT FORK COMPONENT Fig.21 FRONT FORK Windshield base assembly(TFT Instrument) 2 COMPONENT PART NO. PART NAME CAUTION 1244200-074000 ZT310-T windshield motor sheath 1274200-118000 ZT310-T lower rocker clamp 4024200-081051 ZT310-T lower rocker clamp (matte dark gray) GB818 cross recessed pan head screw M4×16 1250201-046000 (environmental color) 1244200-075000 ZT310-T windshield front rocker buffer rubber...
  • Page 71 8、FRONT FORK COMPONENT Fig.22 FRONT FORK Windshield base assembly(TFT Instrument) 3 COMPONENT PART NO. PART NAME CAUTION 1250301-020093 GB6170M6 (environmental color) 1250502-010093 GB96.1φ6(environmental color) 1244200-092000 ZT310TFT instrument buffer pad ZT310 universal TFT instrument (big fuel tank / 60 1164200-012000 【1】 teeth) 1164200-009000 ZT310 universal TFT instrument (big fuel tank) 【2】...
  • Page 72 8、FRONT FORK COMPONENT Fig.23 FRONT FORK Wire clamp(TFT Instrument) COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1274100-007000 ZT250-S flanging sleeve（φ6.4×φ9×6＋φ20×2） 1244100-004000 ZT250-S Flanging Bushing Buffer 1251300-063093 Splint M6×11×15 (environmental color) 1224200-137000 ZT310-X1 wire clamp right cover 1184200-073000 ZT310-T windshield motor controller 1224200-134000 ZT310－X1 Wire clamp 1224200-136000 ZT310－X1 wire clamp left cover...
  • Page 73 1251112-001093 M6×16 hex flange bolt (environmental color zinc) 1274100-007000 ZT250-S flanging sleeve（φ6.4×φ9×6＋φ20×2） 1244100-004000 ZT250-S Flanging Bushing Buffer 1224200-026000 ZT310-X head surrounded by rear interior PROCEDURE: ●Front enclosure interior components Use a small Phillips screwdriver to push down the center of the swell nail and remove the 2 swell nails⑴.
  • Page 74 PART NAME CAUTION 1224100-010000 ZT250-S swell nail 1224200-024000 ZT310-X hood left 1224200-025000 ZT310-X hood right side 1244100-002000 ZT250-S side cover round glue PROCEDURE: ●Left hood assembly Use a small Phillips screwdriver to push down the center of the swell nail and remove the swell nail⑴.
  • Page 75 8、FRONT FORK COMPONENT Fig.26 FRONT FORK Headlight assembly(TFT Instrument) 1 COMPONENT PART NO. PART NAME CAUTION 1251100-061093 M6×22 hex flange face full thread bolt 1274100-007000 ZT250-S flanging sleeve（φ6.4×φ9×6＋φ20×2） 1244100-004000 ZT250-S Flanging Bushing Buffer PROCEDURE: ●Headlight assembly Unplug all the wires slot from the light. Hold the bottom of the headlights, first remove the 2 bolts on one side⑴, then remove the other side.
  • Page 76 1184200-052000 ZT310-X headlight harness 1174200-024000 ZT310-X headlight spotlight driver 1174200-025000 ZT310-X headlight regulater assembly 1174200-017000 ZT310-X headlight position light 1174200-015000 ZT310-X headlight left daytime running light 1174200-018000 ZT310-X headlight spotlight 1174200-016000 ZT310-X headlight right daytime running light PROCEDURE: ●Headlight assembly Remove 2 pieces of side cover round glue and 5 pieces of splint ⑶...
  • Page 77 1184200-150000 Second Generation Left Handlebar Switch (Liquid crystal) 1250205-031091 GB70.1 M6×30 (stainless steel) 1184200-141000 ZT310-X left hand switch(TFT) 1184200-066000 ZT310-X left hand switch (clutch line length 100) Stop selling 1244100-041000 ZT250-R left hand rubber sleeve 1134200-023000 ZT250－R balance block 1134200-010000 ZT310-V left hand rocker arm (machine plus) 1244200-046000 ZT310-V clutch line sheath 1251100-198000 Non-standard hexagon socket bolt M6×13-φ8×20...
  • Page 78 1134200-005000 ZT310-R direction press block (homemade) 1134200-003000 ZT310-R direction 1251300-045000 ZT250-S upper plate decorative nut (chrome plated) 1251500-050000 upper plate gasket φ18.5×φ39×1 (chrome plated) ZT310-X front left shock absorption (improved 1114200-023000 version) contain reflector ZT310-X front right shock absorption (improved...
  • Page 79 1251700-065000 ZT310-R bushing φ10×φ12×41 1134200-004000 ZT310-R uplink board (homemade) ZT310 faucet lock (electromagnetic/line length 450) 1184200-138000 assembly 1184200-035000 ZT310-X electronic faucet lock (DC) Stop selling 1250501-007093 GB93φ8 (environmental color) 1251100-121093 Non-standard bolt M6×25 (environmental color) 1251300-057093 Non-standard nut M10×1.5 (Dacro) PROCEDURE: ●Faucet lock...
  • Page 80 8、FRONT FORK COMPONENT Fig. 31 FRONT FORK ABS brake system-1 COMPONENT PART NO. PART NAME CAUTION 1250105-137093 GB5789 M6×16(environmental color) 1250501-010000 GB93 φ6 (environmental color) 1251513-013000 Brake brake tubing copper washer φ15×φ10.2×1.5 1251100-112000 Disc brake tubing bolt M10×1－22 1224100-037000 0 grade flame retardant cable tie (black 3.6×295) 1224200-016000 ZT310－R Clamp 4024200-006000 ZT310-R ABS mounting bracket 1274100-007000 ZT250-S flanging sleeve（φ6.4×φ9×6＋φ20×2）...
  • Page 81 8、FRONT FORK COMPONENT Fig. 32 FRONT FORK ABS brake system-2 COMPONENT PART NO. PART NAME CAUTION 1251100-080094 Non-standard bolt M8×37 (environmental color zinc) 1251100-101000 Non－standard bolt M6×12 (304 stainless steel) 1224200-127000 ZT310-T front wheel WSS wire clip 1184200-045000 DF30 system wheel speed sensor 1251100-112000 Disc brake oil pipe bolt M10×1-22 1251513-013000 Disc brake copper washer φ15×φ10.2×1.5 1251100-061093 M6×22 Hex flange face full thread bolt...
  • Page 82 8、FRONT FORK COMPONENT Fig.33 FRONT FORK ABS brake system-3 COMPONENT PART NO. PART NAME CAUTION 1224100-037000 0 grade flame retardant cable tie (black 3.6×295) 1250205-034093 GB70.1 Hexagonal M8×30 (environmental color zinc) 1224100-010000 ZT250-S expansion nail 1250205-023000 GB70.1 Hexagonal M8×35 (environmental color zinc) 1274100-068095 ZT310 Muffler bush 1251100-121093 Non-standard bolt M6×25 (environmental color) 1251513-013000 Brake brake tubing copper washer φ15×φ10.2×1.5...
  • Page 83 8、FRONT FORK COMPONENT Fig.34 FRONT FORK ABS brake system-4 COMPONENT PART NO. PART NAME CAUTION 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1274200-034000 ZT310－R oil pipe clamp of rear disc brake 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1224200-003000 ZT310－Z rear disc brake oil tube cleat 1224100-044000 Wheel speed sensor clamp 1184200-045000 DF30 wheel speed sensor 1251100-112000 Disc brake tubing bolt M10×1-22...
  • Page 84 9、FUEL TANK COVER COMPONENT Fig.1 FUEL TANK Tank housing assembly 1（Small fuel tank） COVER COMPONENT PART NO. PART NAME REMARKS 1224100-010000 ZT250－S swell nail 1251100-102000 Non-standard bolt M6×16（304stainless） 1274100-007000 ZT250-S flanging sleeve（φ6.4×φ9×6＋φ20×2） (Small fuel tank) PROCEDURE： ●Middle cover components Some of the X1 models produced in the early stage were in a small fuel tank state (Fig. A). The fuel tank cap was far from the upper surface of the tank cover and the tank box was visible.
  • Page 85 9、FUEL TANK COVER COMPONENT Fig.2 FUEL TANK Tank cover, tank cover, tank lock（Small fuel tank） COVER COMPONENT PART NO. PART NAME REMARKS 4044201-006064 ZT310－X Bright fuel tank middle cover 4044201-054001 ZT310－X Pearl white fuel tank middle cover Regular version 4044201-044021 ZT310－X black fuel tank middle cover 4044201-044151 ZT310－X bright gray fuel tank middle cover 4044201-100015 ZT310－X red fuel tank middle cover 4044201-211002 ZT310-X2 pearl white tank cover (red GP version)
  • Page 86 9、FUEL TANK COVER COMPONENT Fig.3 FUEL TANK Fuel tank trim kit（Small fuel tank） COVER COMPONENT PART NO. PART NAME REMARKS 1251100-102000 Non-standard M6×16（304 stainless） 1274100-007000 ZT250-S flanging sleeve（φ6.4×φ9×6＋φ20×2） 1244100-004000 ZT250－S Flanging bushing buffer 4044201-004064 ZT310－X Bright blue tank left cover 4044201-052001 ZT310－X Pearl white tank left cover 4044201-042021 ZT310－X Black tank left cover Regular version...
  • Page 87 9、FUEL TANK COVER COMPONENT Fig.4 FUEL TANK Tank housing assembly 1（Big fuel tank） COVER COMPONENT PART NO. PART NAME REMARKS 1224100-010000 ZT250－S swell nail 1224100-033000 ZT250－S thread cap of the fuel tank 1251100-102000 Non-standard bolt M6×16（304stainless） 1274100-007000 ZT250-S flanging sleeve（φ6.4×φ9×6＋φ20×2） (Big fuel tank) PROCEDURE：...
  • Page 88 9、FUEL TANK COVER COMPONENT Fig.5 FUEL TANK Tank cover, tank cover, tank lock（Big fuel tank） COVER COMPONENT PART NO. PART NAME REMARKS 4044201-260064 ZT310-X1 bright blue fuel tank cover 4044201-260002 ZT310-X1 pearl white fuel tank cover Regular version 4044201-260021 ZT310-X1 special black fuel tank cover 4044201-260051 ZT310-X1 deep bright gray fuel tank cover 4044201-260015 ZT310-X1 ruby red fuel tank cover 4044201-318002 ZT310-X1 pearl white fuel tank cover (red GP)
  • Page 89 9、FUEL TANK COVER COMPONENT Fig.6 FUEL TANK Fuel tank trim kit（Big fuel tank） COVER COMPONENT PART NO. PART NAME REMARKS 1251100-102000 Non-standard M6×16（304 stainless） 1274100-007000 ZT250-S flanging sleeve（φ6.4×φ9×6＋φ20×2） 1244100-004000 ZT250－S Flanging bushing buffer 4044201-233064 ZT310-X1 bright blue fuel tank left cover 4044201-233002 ZT310-X1 pearl white fuel tank left cover 4044201-233021 ZT310-X1 special black fuel tank left cover Regular version...
  • Page 90 10、TANK LINER COMPONENT Fig.1 TANK LINER Tank box assembly（Small fuel tank） COMPONENT PART NO. PART NAME REMARKS 1224100-010000 ZT250－S swell nail 1224200-027000 ZT310－XTank box 1251300-063093 splint M6×11×15(environmental color) 1251100-102000 Non-standard bolt M6×16（304stainless） 1274100-007000 ZT250-S flanging sleeve（φ6.4×φ9×6＋φ20×2） 1184200-053000 ZT310PKE external single antenna 1244100-004000 ZT250－S Flanging bushing buffer 1244100-002000 ZT250－S Side cover round rubber PROCEDURE:...
  • Page 91 10、TANK LINER COMPONENT Fig.2 TANK LINER Tank liner component（Small fuel tank） COMPONENT PART NO. PART NAME CAUTION 1250205-043093 GB70.1M8×55 (environmental color) 1251900-028093 ZT250-R fuel tank flat pad φ9×φ37.5×2 1244100-020000 ZT250-S fuel tank pressure 1244100-053000 ZT250-S second generation fuel tank gasket 1274100-080000 ZT250-R cushion fixing block 1224200-066000 ZT310PKE external antenna mount 1050954-006000 ZT250-R EFI High Pressure Tubing Sub-assembly...
  • Page 92 10、TANK LINER COMPONENT Fig.3 TANK LINER Tank liner（Small fuel tank） COMPONENT PART NO. PART NAME CAUTION 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1274200-014000 ZT310-R fuel tank cover rear mounting bracket 1224100-033000 ZT250-S threaded fuel tank cap 4034200-001000 ZT310-R fuel tank liner 1274200-013000 ZT310-R fuel tank cover front mounting bracket 1244100-002000 ZT250-S side cover round glue 1240300-021000 HJ125-6 shroud glass strip (1.5m)
  • Page 93 10、TANK LINER COMPONENT Fig.4 TANK LINER Tank box assembly（Big fuel tank） COMPONENT PART NO. PART NAME REMARKS 1224100-010000 ZT250－S swell nail 1224200-141000 ZT310－X1 Tank box 1251300-063093 splint M6×11×15(environmental color) 1251100-102000 Non-standard bolt M6×16（304stainless） 1274100-007000 ZT250-S flanging sleeve（φ6.4×φ9×6＋φ20×2） 1184200-053000 ZT310PKE external single antenna 1244100-004000 ZT250－S Flanging bushing buffer 1244100-002000 ZT250－S Side cover round rubber 1244200-084000 ZT310-X1 fuel tank cover limit glue...
  • Page 94 10、TANK LINER COMPONENT Fig. 5 Tank liner component Tank liner component（Big fuel tank） PART NO. PART NAME CAUTION 1250205-043093 GB70.1 M8×55 (environmental color) ZT250-R fuel tank flat pad φ9×φ37.5×2 1251900-028093 (environmental color) 1244100-020000 ZT250-S fuel tank pressure 1244100-053000 ZT250-S second generation fuel tank gasket 1274100-080000 ZT250-R cushion fixing block 1244200-084000 ZT310-X1 fuel tank cover limit glue 1224200-066000 ZT310PKE external antenna mount...
  • Page 95 10、TANK LINER COMPONENT Fig. 6 Tank liner component Tank liner component（Big fuel tank） PART NO. PART NAME CAUTION 1224100-033000 ZT250-S threaded fuel tank cap 4034200-009000 ZT310-T fuel tank liner 1244100-002000 ZT250-S side cover round glue 1240300-021000 HJ125-6 shroud glass strip (1.5m) 0.17 1250105-137093 GB5789M6×16 (environmental color) 1050954-031000 T02 built-in fuel pump－ZT310T...
  • Page 96 11、SIDE COVER COMPONENT Fig.1 SIDE COVER Side cover the lower part COMPONENT PART NO. PART NAME REMARKS 1224100-010000 ZT250－S bolts 1224200-029000 ZT310－X Lower left cover 1224200-031000 ZT310－X Lower left cover PROCEDURE： ●Side cover components Press the center of the expansion screw with a small cross screwdriver，Remove the swelling nail⑴。 Put your hand in the slot and pull it out.First pull out the card nail from the bottom up in the order of ①~④...
  • Page 97 11、SIDE COVER COMPONENT Fig.2 SIDE COVER Left side cover upper component COMPONENT PART NO. PART NAME REMARKS 1224100-010000 ZT250－S swell nail 4044201-011052 ZT310－X Iron nail grey upper left side cover 4044201-193051 ZT310-X2 iron grey upper left cover (red GP version) ZT310-X2 iron grey ash left cover upper part (gem red 4044201-192051 GP version)
  • Page 98 11、SIDE COVER COMPONENT Fig.3 SIDE COVER Right side cover upper component COMPONENT PART NO. PART NAME REMARKS 1224100-010000 ZT250－S swell nail 4044201-012052 ZT310－X The upper right side cover of iron nail ash ZT310-X2 iron gray ash right upper cover (red GP 4044201-196051 version) ZT310-X2 Iron Grix Right Side Cover Upper Part...
  • Page 99 COMPONENT PART NO. PART NAME REMARKS 1274200-044000 ZT310-X rear armrest 4114200-003051 ZT310-X rear armrest (matte dark gray) 1250105-142093 GB5789M8×20 (environmental color) 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1274100-057095 Flanging bushing φ6.2×φ8.4×3.5+φ14×1.5 1244100-052000 Cuff bushing cushioning rubber (φ8.5×φ14×1) 1244200-020000 ZT310-X rear armrest right pad rubber 1244200-019000 ZT310-X rear armrest left pad rubber PROCEDURE：...
  • Page 100 1274100-057095 Flanging bushing φ6.2×φ8.4×3.5+φ14×1.5 1244100-052000 Cuff bushing cushioning rubber (φ8.5×φ14×1) 1274200-045000 ZT310-X rear fender bracket 4024200-071051 ZT310-X rear fender bracket (matte dark gray) 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1224200-033000 ZT310-X rear mud plate bracket cover 1250502-010093 GB96.1φ6（environmental color）...
  • Page 101 1244100-052000 Cuff bushing cushioning rubber (φ8.5×φ14×1) 1174100-002000 ZT250-S rear reflector 1270300-039000 HJ125-6 rear license plate bracket 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1224200-032000 ZT310-X rear mud board 1244100-006000 ZT250-S rear license plate cushioning rubber 1250303-010093 GB6177.1M6 (environmental color) PROCEDURE：...
  • Page 102 COMPONENT PART NO. PART NAME REMARKS 1224200-120000 ZT310 rear turn signal bracket 1174200-019000 ZT310-X rear left turn signal 1174200-020000 Right turn signal after ZT310-X 1174200-021000 ZT310-X license plate light 1184200-032000 ZT310-R rear turn signal cable (L=600) PROCEDURE： ●Back license plate light After grasping the turn signal bracket ⑴, remove the three screws d on the rear license plate light⑷and remove...
  • Page 103 PART NO. PART NAME REMARKS 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1274100-007000 ZT250-S flanged bushing 1184200-016000 ZT310 PKE buzzer 1224200-044000 ZT310-X tail skirt middle cover 1240300-071000 Cuff bushing cushioning rubber（φ11×φ16×1） Flanging bushing φ8.2×φ11×4.5＋φ16× 1251700-058093 1.5(environmental color) 1251100-122093 Non-standard boltM8×16(environmental color) PROCEDURE：...
  • Page 104 PART NO. PART NAME REMARKS 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1274100-007000 ZT250-S flanged bushing 1184200-016000 ZT310 PKE buzzer 1224200-044000 ZT310-X tail skirt middle cover 1240300-071000 Cuff bushing cushioning rubber（φ11×φ16×1） Flanging bushing φ8.2×φ11×4.5＋φ16× 1251700-058093 1.5(environmental color) 1251100-122093 Non-standard boltM8×16(environmental color) PROCEDURE：...
  • Page 105 1274100-057095 Flanging bushing φ6.2×φ8.4×3.5+φ14×1.5 1244100-052000 Cuff bushing cushioning rubber (φ8.5×φ14×1) 1251300-063093 Splint M6×11×15 (environmental color) 1224200-043000 ZT310-X tail skirt middle lithium battery 1224200-165000 ZT310-X tail skirt middle (colloid battery) colloid battery 1174200-008000 ZT310-X tail light PROCEDURE： ●Back skirt assembly Flip to the back of the rear skirt assembly and use a small Phillips screwdriver to expand the center of the nail and remove the expansion pin ⑴.
  • Page 106 1251300-063093 Splint M6×11×15 (environmental color) 1244100-004000 ZT250-S Flanging Bushing Buffer 1224200-041000 ZT310-X tail skirt left lithium battery 1224200-163000 ZT310-X tail skirt left(colloid battery) colloid battery PROCEDURE： ●Left rear skirt component Remove the side cover round rubber ⑶, the cleat ⑸ and the cushion rubber ⑹ from the left tail skirt trim cover ⑴.
  • Page 107 1251300-063093 Splint M6×11×15 (environmental color) 1244100-004000 ZT250-S Flanging Bushing Buffer 1224200-042000 ZT310-X tail skirt right lithium battery 1224200-164000 ZT310-X tail skirt right(colloid battery) colloid battery PROCEDURE： ●Right rear skirt component Remove the side cover round rubber ⑶, the cleat ⑸ and the cushion rubber ⑹ from the right tail skirt trim cover ⑴.
  • Page 108 12、REAR COVER COMPONENT Fig.10 REAR COVER Electrical device cover assembly(lithium battery) COMPONENT PART NO. PART NAME REMARKS 1224200-039000 ZT310 electric device box cover 1184200-024000 ZT310-R side bracket relay G8HN-1C4T-RJ 1184100-017000 ZT250-S EFI Relay KH-1A4T 1050954-019000 MT05.2 engine controller - ZT310-RC4 type 1184100-010000 ZT250-S start relay 1244100-072000 ZT250－R Battery straps 1184100-116000 ZT250 Lithium battery...
  • Page 109 1251513-001019 6.3 x 12 x 1.6 copper gasket 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1224200-040000 ZT310 Electrical device box cover 1244200-047000 ZT310-X Electric device box back glue PROCEDURE: ●Electrical device box component Remove the bolts⑴ on the left side of the front of the electrical component box remove the four washers⑵.
  • Page 110 12、REAR COVER COMPONENT Fig.12 REAR COVER Electrical device box component 2(lithium battery) COMPONENT PART NO. PART NAME CAUTION 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1184200-054000 ZT310 PKE Controller（single antenna ） out of stock 1184200-137000 ZT310 PKE Controller（bracelet edition) 1251300-063093 Plywood M6×11×15 (environmental color) 1184100-080000 ZT250-S Fuse (15A) For after-sale 1224200-038000 ZT310 Electrical Device Box...
  • Page 111 12、REAR COVER COMPONENT Fig. 13 REAR COVER Electrical component (colloid battery) COMPONENT PART NO. PART NAME CAUTION 1224200-176000 Colloid battery electric device box upper cover 1184200-024000 ZT310－R Side bracket relay G8HN-1C4T-RJ 1184100-017000 ZT250－S EFI relay KH-1A4T 1050954-019000 MT05.2 Engine Controller - Model ZT310-RC4 Delphi EFI 1050954-037000 MSE6.0 Controller-ZT180MN Bosch EFI...
  • Page 112 For reinstallation, connect the positive electrode first, then connect the negative electrode. No parallel battery charging or ignition.Just use the battery charger''ZONTES'' provide for you. The bracelet version of the PKE assembly integrates a charging interface ●Battery anode protection glue...
  • Page 113 12、REAR COVER COMPONENT Fig. 15 REAR COVER Electrical device box component 1 (colloid battery) COMPONENT PART NO. PART NAME CAUTION 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1250303-010093 GB6177.1M6 (environmental color zinc) 1251513-001019 6.3 x 12 x 1.6 copper gasket 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1224200-040000 ZT310 Electrical device box cover 1274200-238000 ZT310-R battery holder (gel battery)
  • Page 114 12、REAR COVER COMPONENT Fig. 16 REAR COVER Electrical device box component 2 (colloid battery) COMPONENT PART NO. PART NAME CAUTION 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1184200-137000 ZT310 PKE Controller（bracelet edition) 1224200-161000 ZT310-R Electrical Device Box (colloid battery) 1244200-111000 ZT310 gel battery strap 1251300-063093 Plywood M6×11×15 (environmental color) 1240300-007000 HJ125-6 Battery Pad 1184200-128000 ZT310 Universal Fuse（15A small）...
  • Page 115 12、REAR COVER COMPONENT Fig.17 REAR COVER External battery start PKE system COMPONENT PROCEDURE: ●Emergency handling method after the battery is destroyed or the battery is exhausted for too long: Find a 15A fuse and wind a wire around any one of the fuses as shown in the left side. Remove the lower cover of the electrical device box;...
  • Page 116 After the assembly is in place, shoot the rear part of the cushion firmly. When you hear the "click" sound, it indicates that the cushion lock has been assembled. ●Cushion rubber purchased separately If the cushion rubber aging can be purchased on the Zontes official website. The corresponding installation position is shown in the lower left figure. CAUTION: ●The motorcycle should be fixed before operation.
  • Page 117 14、MUFFLER COMPONENT FIG.1 MUFFLER Muffler rear assembly COMPONENT PART NO. PART NAME REMARKS 1250205-023000 GB70.1 Hexagon M8×35 (environmental color zinc) 1274100-074000 ZT310-R Muffler clamp 4024200-003035 ZT310-R Titanium rear muffler 4084200-001051 ZT310-R Dark gray rear muffler 4024200-004035 ZT310-R Titanium anti-hot plate 4084200-002051 ZT310-R Dark gray anti-hot plate 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1250501-010000 GB93φ6 Spring washer...
  • Page 118 14、MUFFLER COMPONENT Fig.2MUFFLER Muffler front assembly 1 COMPONENT PART NO. PART NAME REMARKS 1224100-013000 ZT250-S Oxygen sensor fixing buckle 1250205-023000 GB70.1 Hexagon M8×35 (environmental color zinc) 1274100-068095 ZT310 Muffler flange bushing 1250303-011093 GB6177.1 M8 (environmental color) 1251300-058093 Hexagon nut M8 (environmental color zinc) 1020241-094000 ZT250-S Muffler flange 1070100-133000 ZT250-S Engine exhaust seal gesket PROCEDURE:...
  • Page 119 14、MUFFLER COMPONENT FIG.3 MUFFLER Muffler front assembly 2 COMPONENT PART NO. PART NAME REMARKS Delphi EFI 1050953-008000 OSM planar oxygen sensor 25322728 Delphi EFI 1050954-026000 LSF oxygen sensor Bosch EFI 1224100-013000 ZT250-S Oxygen sensor fixing buckle Delphi EFI 1224200-008000 ZT310-R line card nail Bosch EFI 1244100-064000 ZT310 Muffler cushion rubber 1274100-068095 ZT310 Muffler Flange Bushing...

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