Zontes ZT310-T EURO IV Service Manual
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Zontes ZT310-T EURO IV Service Manual

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ZT310-T (EURO IV/V)
Service manual
2021/1/4

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ANTONIO DIOGENES MELGAREJO
February 17, 2025

El circuito eléctrico de la moto ZONTES T 310 no esta en el manual.

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Summary of Contents for Zontes ZT310-T EURO IV

  • Page 1 ZT310-T (EURO IV/V) Service manual 2021/1/4...
  • Page 2 Contents Table of Contents Page Table of Contents Frame component 1.1 Electrical device component-1 …………………………………………………………………………………………………………………………………………………………………………………… 8 Main harness、Dump switch、Relay、Flasher、Rectifier、Ignition coil 1.2 Electrical device component-2…………………………………………………………………………………………………………………………………………………………………………………… 9 Side bracket flameout switch、Horn、Wake-up switch 1.3 Frame plastic parts…………………………………………………………………………………………………………………………………………………………………………………………………10 Line clamp、Side cover round glue、Fuel tank liner limit glue 1.4 Directional column component……………………………………………………………………………………………………………………………………………………………………………………...
  • Page 3 Contents Table of Contents Page 4.4 Rear turn signal after sale parts…………………………………………………………………………………………………………………………………………………………………………………… 22 Rear left and right turn signals and rear license plate lights after sale parts 4.5 Rear mud board…………………………………………………………………………………………………………………………………………………………………………………………………… 23 4.6 Rear shock absorption…………………………………………………………………………………………………………………………………………………………………………………………… 24 Demolition after shock absorption, rear shock absorption adjustment 4.7 Rear wheel component-1…………………………………………………………………………………………………………………………………………………………………………………………...
  • Page 4 Contents Table of Contents Page Disassemble the radiator tubing component 6.4 Add the coolant…………………………………………………………………………………………………………………………………………………………………………………………………… 40 6.5 Release coolant…………………………………………………………………………………………………………………………………………………………………………………………………… 41 Release coolant 6.6 Right water tank component……………………………………………………………………………………………………………………………………………………………………………………… 42 Disassemble the right water tank component and right side water pipe component 6.7 Left water tank component……………………………………………………………………………………………………………………………………………………………………………………… 43 Disassemble left water tank component、Left water pipe component and auxiliary water tank component Front fork component 7.1 Accelerator/Clutch cable gap adjustment、Light height adjustment……………………………………………………………………………………………………………………………………………...
  • Page 5 Contents Table of Contents Page Disassemble the upper part of front mud guard component-1 7.15 Upper part of the front mud guard component-2………………………………………………………………………………………………………………………………………………………………… 58 Disassemble the upper part of front fender component-2 7.16 Ftont headlight component-1……………………………………………………………………………………………………………………………………………………………………………………… 59 Dismantle the headlight component、Mounting bracket on the guard bar 7.17 Front headlight component-2………………………………………………………………………………………………………………………………………………………………………………………...
  • Page 6 Contents Table of Contents Page 8.1 Fuel tank middle cover component……………………………………………………………………………………………………………………………………………………………………………… 74 Demolition fuel tank middle cover component 8.2 Fuel tank middle cover、Fuel tank outside cover、Fuel tank lock……………………………………………………………………………………………………………………………………………… 75 Decompose the tank niddle cover component 8.3 Decorative cover grill…………………………………………………………………………………………………………………………………………………………………………………………… 76 Demolition cover grill 8.4 Fuel tank trim cover component…………………………………………………………………………………………………………………………………………………………………………………...
  • Page 7 Contents Table of Contents Page 10.3 Tail skirt component-2…………………………………………………………………………………………………………………………………………………………………………………………… 89 Disassemble tail skirt、Fender mounting cover Rear mud board assembly 1……………………………………………………………………………………………………………………………………………………………………………………… 90 Rear mud board assembly 2……………………………………………………………………………………………………………………………………………………………………………………… 91 Rear turn signal after sale parts…………………………………………………………………………………………………………………………………………………………………………………… 92 10.4 Electrical device box component(TFT Instrument)……………………………………………………………………………………………………………………………………………………………… 93 Disassemble electrical device box cover、ECU、Realay and fuse box 10.5 Electrical device box component(electrical Instrument)…………………………………………………………………………………………………………………………………………………………...
  • Page 8 Contents Table of Contents Page Decompose the front section of muffler、Oxygen Sensor、Muffler flangle Lower shroud component 13.1 Lower shroud component-1……………………………………………………………………………………………………………………………………………………………………………………… 106 Remove lower shroud component、Shroud bracket 13.2 Sliding clutch version lower shroud component………………………………………………………………………………………………………………………………………………………………… 107 Decompose lower shroud component 13.3 Light-clutch version lower shroud component…………………………………………………………………………………………………………………………………………………………………… 108 Decompose lower shroud component All the information, illustrations and photographs collected in this manual are compiled according to the latest products.
  • Page 9 1、FRAME COMPONENT FIG.1 FRAME&ELECTRONIC Electrical device component-1 PARTS COMPONENT PART NO. PART NAME CAUTION 1184200-098007 ZT310－T1 Harness assembly TFT Instrument 1184200-046000 ZT310－T Harness assembly 1184200-164000 ZT310-T1 wiring harness assembly (Bosch ECU) 1224100-037000 0 grade flame retardant cable tie (black 3.6×295) 1184200-108000 ZT310 EFI ignition coil ZT310(230W) 1184200-104007 ZT310 EFI ignition coil (with high voltage line)
  • Page 10 1、FRAME COMPONENT FIG.2 FRAME&ELECTRONIC Electrical device component-2 PARTS COMPONENT PART NO. PART NAME CAUTION 1251100-061093 M6×22Hex flange face full thread bolt 1274200-033000 ZT310－R Front disc brake tubing bracket No. 2 1184200-004000 ZT310 Horn 1274100-017000 ZT250－SLine buckle 1224100-037000 0 grade flame retardant cable tie (black 3.6×295) 1274100-095000 Side bracket flameout switch wire fixing bracket 1184100-012000 Side bracket flameout switch wire fixing bracket 1250205-040095 GB70.1Hexagon socket bolt M8×16...
  • Page 11 1、FRAME COMPONENT FIG.3 FRAME&ELECTRONIC Frame plastic component PARTS COMPONENT PART NO. PART NAME CAUTION 1244100-019000 ZT250－S Tank liner limit glue 1240300-007000 HJ125－6 Battery pad 1244100-002000 ZT250－S Side cover round glue 1244100-061000 ZT250 Frame waterproof rubber stopper 1224200-016000 ZT310－R Clamp 1274100-007000 ZT250－S Flanging bushing(φ6.4×φ9×6＋φ20×2) 1250105-236093 GB5789 M6×55（Environmental color）...
  • Page 12 1、FRAME COMPONENT FIG.4 FRAME&ELECTRONIC Steering rack component PARTS COMPONENT PART NO. PART NAME CAUTION 1134100-007000 ZT250－S Adjust nut lock washer 1251300-046093 ZT250－S Directional column adjustment nut M24X1 1244100-015000 ZT250－S Adjusting nut pad 1224100-005000 ZT250－S Dust cover to the column 1130900-024000 ZT250－S Shaft ring 1130900-022000 ZT250－S Siamese steel ball ZT250－S Lower joint plate (homemade / with bead 1134100-015000...
  • Page 13 Place the oil plate underneath and remove the oil-cooled joint(5), O-ring (4), and oil filter(3) with “X”, “T40”. For example, ZT1908T40: "ZT" stands for ZONTES, "1908" stands for August 2019, and "T40" is appropriate tools. When replacing the oil filter (3), the O-ring (4) must be replaced at the same time.
  • Page 14 2、FRAME&ENGINE FRAME&ENGINE Frame&Engine PART NO. PART NAME CAUTION 1251300-057093 Non-standard nut M10×1.5（Dacro） 65±5N.m 1020242-186000 ZT310－R Right hanging piece 1020242-185000 ZT310－R Left hanging piece M6×45 Hexagonal flange face 9.8 level bolt.（color 1251112-003093 12±1.5N.m zinc） 1274200-066000 ZT310－T Lower shroud right bracket 1251300-059093 125 Rear fork shaft nut M14×1.5（Dacro） 110±5N.m ZT250 Aluminum alloy rear fork assembly (including 4024100-024000...
  • Page 15 3、INTAKE SYSTEM COMPONENT FIG.1 INTAKE SYSTEM Intake system component 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） 1251100-101000 Non-standard bolt M6×12（304stainless steel）...
  • Page 16 3、INTAKE SYSTEM COMPONENT FIG.2 INTAKE SYSTEM Intake system component(Bosch) 1 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） Frame 1051354-004000 Φ56×10 Hoop assembly 1050954-035000 ZT310-R Fuel injector high pressure oil pipe unit Frame CAUTION:...
  • Page 17 3、INTAKE SYSTEM COMPONENT FIG.3 INTAKE SYSTEM Intake system component (Bosch EFI) 2 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...
  • Page 18 3、INTAKE SYSTEM COMPONENT Fig.2 INTAKE SYSTEM Canister assembly COMPONENT PART NO. PART NAME CAUTION 1050954-009000 YH canister solenoid valve 1251100-101000 Non-standard bolt M6×12（304stainless steel） 1250303-010093 GB6177.1M6（environmental color） 1251300-063093 Plywood M6×11×15（environmental color） 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 Bosch EFI...
  • Page 19 3、INTAKE SYSTEM COMPONENT Fig.3 INTAKE SYSTEM Replace air filter element COMPONENT PART NO. PART NAME CAUTION 4134200-002000 ZT310－R Air filter element（carton packaging） PROCEDURE: ●Air filter element If you need to maintain the air filter element, first remove the cushion, right side cover and so on. Remove two standard parts①...
  • Page 20 Pull straight the clip⑶.Remove bolt⑵, take off the clip⑶ and disc brake oil pipe clamp⑸. Use plum blossom wrench to tightent the nut⑽ and disassemble bolt⑹ which is close to "ZONTES" mark with a sleeve.And remove the spring pad⑺,flat pad(8)and nut⑽.
  • Page 21 4、REAR WHEEL COMPONENT Fig.2 REAR WHEEL Rear sub mudguard component 2 COMPONENT PART NO. PART NAME CAUTION 1020242-263021 Rear auxiliary mud plate aluminum alloy bracket 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1224200-090000 Rear auxiliary mud board retaining plate 1250105-137093 GB5789M6×16 (environmental color) 1250501-007093 GB93φ8 (environmental color) 1274100-057095 Flanging bushing φ6.2×φ8.4×3.5+φ14×1.5 1244100-052000 Cuff bushing cushioning rubber (φ8.5×φ14×1)
  • Page 22 4、REAR WHEEL COMPONENT Fig.3 REAR WHEEL New rear sub-mud component 3 COMPONENT PART NO. PART NAME CAUTION 1251300-063093 Plywood M6×11×15（environment color） 1244100-006000 ZT250－SRear license plate buffer rubber ZT310－RRear auxiliary mudguard fender（250R、 1224200-091000 310R/X/T） 1270300-273000 φ8 Clip（L=73) 1174200-035000 ZT310Rear turn signal (including license plate light） 1174100-002000 ZT250－S Back reflector 1251100-102000 Non-standard boltM6×16（304stainless steel）...
  • Page 23 4、REAR WHEEL COMPONENT Fig.4 REAR WHEEL Rear turning light parts for after sales service COMPONENT PART NO. PART NAME CAUTION 1224200-120000 ZT310 Rear turn signal bracket 1174200-019000 ZT310－X Rear left turn signal 1174200-020000 ZT310－X Rear right turn signal 1174200-021000 ZT310－X License Plate Light PROCEDURE: ●Rear license light Grip the rear turning light bracket⑴...
  • Page 24 4、REAR WHEEL COMPONENT Fig.5 REAR WHEEL Rear inner mudguard COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non-standard bolt M6×16（stainless steel） 1274100-057095 Flanging bushingφ6.2×φ8.4×3.5＋φ14×1.5 1244100-052000 Flanging bushing buffer rubber (φ8.5×φ14×1) 1224200-003000 ZT310－ZRear disc brake pipe clamp 1224200-094000 ZT310－R Rear inner fender 1251700-059093 Bush φ6.4×φ9×8＋φ18×2（environmental color-zinc）...
  • Page 25 4、REAR WHEEL COMPONENT Fig.6 REAR WHEEL Rear shock absorber COMPONENT PART NO. PART NAME CAUTION 1251100-085093 Non-standard bolt M10×1.5×75（Dacro） 1251100-060000 Non-standard bolt M10×1.5×90（Dacro） 1114200-020000 ZT310－X Rear shock absorber (improved) 1114200-019000 ZT310－T Rear shock absorber (improved) 1251300-057093 Non-standard bolt M10×1.5（Dacro） 45±5N.m PROCEDURE: ●Rear shock absorber After the side bracket is lowered, one person's left hand will kill the direction to the left while the right hand...
  • Page 26 4、REAR WHEEL COMPONENT Fig.7 REAR WHEEL Rear wheel component 1 COMPONENT PART NO. PART NAME CAUTION 1251100-105000 Chain adjuster bolt M10×70（304stainless steel） 1251300-050000 Chain adjuster nut M10（304stainless steel） 1251300-067000 ZT250－RRear wheel hollow shaft nut 110N.m 1032142-073035 ZT310 Right chain adjuster(Titanium) 1032142-075051 ZT310 Right chain adjuster(dark gray matte) 1032142-072035 ZT310 Left chain adjuster (Titanium) 1032142-074051 ZT310 Left chain adjuster (dark gray matte)
  • Page 27 4、REAR WHEEL COMPONENT Fig.8 REAR WHEEL Rear wheel component 2 COMPONENT PART NO. PART NAME CAUTION 1230100-385000 ZT310－T 160/60R17(CM509P) tyre 1230100-232000 ZT310－T 160/60R17(CM509) tyre 1094200-020000 ZT310－T black rear rim（4.5×17） 1100100-419000 ZT310－R1 rear disc brake plate（230×4.5） 1274200-058000 ABS induction ring gear (60 teeth) 1274200-168021 ABS induction ring gear (40 teeth) 1251100-117093 Non standard hex socket bolt M8×25 22～24N.m...
  • Page 28 4、REAR WHEEL COMPONENT Fig.9 REAR WHEEL ∅ 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） 110±5N.m 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 29 4、REAR WHEEL COMPONENT Fig.10 REAR WHEEL Change rear brake arresters COMPONENT PART NO. PART NAME CAUTION 1100100-092000 ZT250－S rear disc brake arrester(HS10) PROCEDURE: ●Disassemble disc brake pad Use slotted screwdriver to disassemble nut①. Disassemble pin axle② with inner hex socket tool. Disassemble rolling axle③...
  • Page 30 4、REAR WHEEL COMPONENT Fig.11 REAR WHEEL Rear disc brake main pump adding braking liquid COMPONENT PART NO. PART NAME CAUTION 1224100-010000 ZT250-S Expansion nail 1224200-055000 ZT310－R rear disc brake oil cup bracket 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 31 5、FOOT PEDAL COMPONENT Fig. 1 FOOT PEDAL Pedal adjustment COMPONENT PART NO. PART NAME CAUTION 1251100-061093 M6×22 Hexagon flange face bolt full thread 8.8 1274100-039000 ZT250-S shift lever spline rocker arm 1250301-020093 GB6170 M6 (environmental color) 1274200-003000 ZT310-R shift lever adjustment screw φ10×130 1250301-018093 GB6170 M6-LH (environmental color zinc) 1274200-160000 ZT310-T shift lever pedal rocker 1274200-010000 ZT310-R brake pedal...
  • Page 32 5、FOOT PEDAL COMPONENT Fig. 2 FOOT PEDAL Right footrest component-1 COMPONENT PART NO. PART NAME CAUTION 1250205-034093 GB70.1 Inner hexagon M8×30 (environmental color 1250205-023000 GB70.1 Inner hexagon M8×35 (environmental color 1274100-068095 ZT310 Muffler flanged bushing 1224100-010000 ZT250-S Expansion nail 1244100-064000 ZT310 Muffler buffer rubber PROCEDURE: ●Right footrest assembly Use the pliers to straighten the split pin ①...
  • Page 33 5、FOOT PEDAL COMPONENT Fig. 3 FOOT PEDAL Right footrest component-2 COMPONENT PART NO. PART NAME CAUTION 1251100-121093 Non-standard bolt M6×25 (environmental color) 1251100-131000 Non-standard shaft 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 torsion spring 1251500-060095 Non-standard flat pad φ10.5×φ26×1 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1274100-057095 Flanging bushing...
  • Page 34 5、FOOT PEDAL COMPONENT Fig. 4 FOOT PEDAL Right footrest component-3 COMPONENT PART NO. PART NAME CAUTION 1244100-002000 ZT250-S side cover round glue 1274200-049000 ZT310-R right pedal stand 4064200-007051 ZT310-R right pedal stand(dark gray matte) 1274100-012000 ZT250-S pedal pin 1264100-006000 ZT250-S pedal circlip 1264100-004000 ZT250-S front right pedal torsion spring 1274200-194000 ZT310-T front right pedal assembly (improved) ZT310-T front right pedal assembly (improved/gray...
  • Page 35 5、FOOT PEDAL COMPONENT Fig. 5 FOOT PEDAL Left footrest component-1 COMPONENT PART NO. PART NAME CAUTION 1250205-034093 GB70.1 Hexagon M8×30 (environmental color zinc) 1250205-023000 GB70.1 Hexagon M8×35 (environmental color zinc) 1251100-061093 M6×22 hex flange bolt full thread 8.8 1274200-037000 ZT310-R disc brake lock bracket 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1251500-048000 ZT250-S foot support gasket 1251100-123093 Non-standard bolt M8×25 (environmental color)
  • Page 36 5、FOOT PEDAL COMPONENT Fig. 6 FOOT PEDAL Left footrest component-2 COMPONENT PART NO. PART NAME CAUTION 1274200-195000 ZT310-T front left pedal component(improved) improved 1274200-071000 ZT310-T front left pedal component old models ZT310-T front left pedal component(improved/dark 4064200-014051 gray matte) 1264100-003000 ZT250-S front left foot torsion spring 1274100-012000 ZT250-S foot pin 1274100-035000 ZT250-S foot support 1271200-161000 ZT250-S foot support(Dark gray)
  • Page 37 5、FOOT PEDAL COMPONENT Fig. 7 FOOT PEDAL Left footrest componet-3 COMPONENT PART NO. PART NAME CAUTION 1274200-073000 ZT310-T rear left pedal assembly 4064200-022051 ZT310-T rear left pedal assembly(dark gray matte) 1264100-005000 ZT250-S pedal steel ball spring 1274100-010000 ZT250-S rear pedal steel ball 1270300-272000 KD250-F rear pedal positioning piece 1274100-012000 ZT250-S foot pin 1264100-006000 ZT250-S pedal circlip...
  • Page 38 ●Changing the draining bolt and sealing gasket every time when changing the engine oil is suggested. ●It is recommended to buy genuine "ZONTES" special oil on the official website. ●Since the crankshaft connecting rod of the engine is bushing structure, at least 1 liter of oil should be added to start the engine before replacing the oil.Otherwise, the bearing bush may be scrapped or the crankshaft may get...
  • Page 39 6、COOLING SYSTEM COMPONENT Fig.2 COOLING SYSTEM Replace the 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） 1051454-004000 55×2.5 O-ring after-sale 1051454-005000 ZT180MN Engine oil refined filter seal ring 4134200-003000 ZT180 refined filter seal component 【1】...
  • Page 40 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 1251100-061093 M6×22 Hex flange bolt 1251100-089094 Oil passing bolt M14×1.50×32 30±2N.m 1244100-034000 Seal gasketφ14×φ20×2 1244200-014000 ZT310－R Engine oil outlet tube 1244200-015000 ZT310－R Engine oil intake tube PROCEDURE: ●Chassis connected oil tube...
  • Page 41 6、COOLING SYSTEM COMPONENT Fig.4 COOLING SYSTEM Add coolant COMPONENT PART NO. PART NAME CAUTION 1224200-006000 ZT310－R sub water 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 42 6、COOLING SYSTEM COMPONENT Fig.5 COOLING SYSTEM Draining cooling liquid COMPONENT PART NO. PART NAME CAUTION 1251112-001093 M6×16 Hex flange bolt（ 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 43 6、COOLING SYSTEM COMPONENT Fig.6 COOLING SYSTEM Right water tank component COMPONENT PART NO. PART NAME CAUTION 1274200-079000 ZT310 Hoop of water tube（φ9） 1244200-013000 ZT310－R Connecting tube of sub water tank 1274200-090000 ZT310 Hoop of water tube（φ26） 1244200-011000 ZT310－R Connecting tube of L & R water tank 1251100-061093 M6×22 Hex flange bolt(level 8 ,color zinc) 1244200-012000 ZT310－R Engine cooling liquid passing tube 1274200-041000 ZT310 water tank tube clamp（φ26）...
  • Page 44 6、COOLING SYSTEM COMPONENT Fig.7 COOLING SYSTEM Left water tank component COMPONENT PART NO. PART NAME CAUTION 1224200-006000 ZT310－R Sub water tank 1274100-007000 ZT250－S Flanging bushing(φ6.4×φ9×6＋φ20×2) 1250105-236093 GB5789M6×55（color zinc） 1274200-091000 ZT310 Hoop of water tube（φ27） 1244200-001000 ZT310－R Engine water intake tube 1274200-090000 ZT310 Hoop of water tube（φ26）...
  • Page 45 7、FRONT FORK COMPONENT Fig. 1 FRONT FORK Throttle/clutch cable clearance adjustment, light height COMPONENT adjustment PART NO. PART NAME CAUTION 1154200-003000 ZT310-X throttle oil line 1154200-018000 ZT310-X throttle oil line(Bosch) 1154200-004000 ZT310-X throttle oil return line ZT310-T1 clutch line 1154200-017000 ZT310-X throttle oil return line(Bosch) 1154200-013000 ZT310-T1 clutch line 1244200-046000 ZT310-V clutch line sheath PROCEDURE:...
  • Page 46 7、FRONT FORK COMPONENT Fig. 2 FRONT FORK Replacement clutch cable COMPONENT PART NO. PART NAME CAUTION 1154200-013000 ZT310-T1 clutch line sliding clutch 1154200-007000 ZT310-T clutch line lihgt clutch 1244200-046000 ZT310-V clutch line protecting bush PROCEDURE: ●take down the clutch cable Use an open-end wrench to loosen the nuts ②, ③;...
  • Page 47 7、FRONT FORK COMPONENT Fig. 3 FRONT FORK Replace the throttle line COMPONENT PART NO. PART NAME CAUTION 1154200-003000 ZT310-X throttle oil line 1154200-018000 ZT310-X throttle oil line(Bosch) 1154200-004000 ZT310-X throttle oil return line 1154200-017000 ZT310-X throttle oil return line(Bosch) 1224200-016000 ZT310-R hub clamp 1224100-051000 0 grade flame retardant cable tie (black 2.5×100) 1244100-042000 ZT250-R right hand rubber sleeve 1184200-022000 ZT310-X right hand switch...
  • Page 48 7、FRONT FORK COMPONENT Fig. 4 FRONT FORK Steering adjustment COMPONENT PART NO. PART NAME CAUTION 1251300-045000 ZT250-S upper plate decorative nut (chrome plated) 100N·m 1251500-050000 ZT250-S upper plate gasket φ18.5×φ39×1 1250205-023000 GB70.1 Hexagonal M8×35 (environmental color zinc) 22～24N.m 1134100-007000 ZT250-S adjusting nut lock washer 1251300-046093 ZT250-S direction column adjustment nut M24X1 1244100-015000 ZT250-S adjustment nut pad 1224100-005000 Dust cover on ZT250-S direction column...
  • Page 49 7、FRONT FORK COMPONENT Fig.5 FRONT FORK Add brake fluid, rocker adjustment COMPONENT PART NO. PART NAME CAUTION 1134100-032000 ZT250-R right hand rocker arm (machine plus) 1100300-044000 ZT125T front disc brake main pump assembly 1251513-013000 Brake brake tubing copper washer φ15×φ10.2×1.5 1251100-112000 Disc brake tubing bolt M10×1-22 32N.m PROCEDURE:...
  • Page 50 7、FRONT FORK COMPONENT Fig. 6 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 51 7、FRONT FORK COMPONENT Fig. 7 FRONT FORK Guard bar component COMPONENT PART NO. PART NAME CAUTION 1251100-137000 Non-standard bolt M10×1.5×100 (Dacro) 65±5N.m 1251100-082093 Non-standard bolt M10×1.5×20 (Dacro) 65±5N.m 1251300-057093 Non-standard nut M10×1.5 (Dacro) 65±5N.m 1251112-001093 M6×16 Hex flang bolt thread(color zinc) 4024200-027000 ZT310-T frame protection bar pressure plate 1144200-034000 ZT310-T left guard 1144200-030000 ZT310-T retaining bar rubber sleeve...
  • Page 52 7、FRONT FORK COMPONENT Fig. 8 FRONT FORK Windshield component COMPONENT PART NO. PART NAME CAUTION 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1224200-072000 ZT310-T windshield left decorative cover 1224200-073000 ZT310-T windshield right decorative cover 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) 1224200-071000 ZT310-T windshield...
  • Page 53 7、FRONT FORK COMPONENT Fig. 9 FRONT FORK Windshield bracket component COMPONENT (Electronic Instrument) PART NO. PART NAME CAUTION 1264100-006000 ZT250-S pedal circlip 1274200-030000 ZT310-X windshield lower pressing block rotating shaft 1274200-112000 ZT310-T windshield left bracket 1274200-113000 ZT310-T windshield right bracket 1224100-010000 ZT250-S expansion nail 1224200-076000 ZT310-T hood middle decorative cover PROCEDURE:...
  • Page 54 7、FRONT FORK COMPONENT Fig. 10 FRONT FORK Windshield bracket component(TFT Instrument) COMPONENT PART NO. PART NAME CAUTION 1264100-006000 ZT250-S pedal circlip 1244200-089000 ZT310-T windshield right buffer rubber 1274200-030000 ZT310-X windshield lower pressing block rotating shaft 1244200-048000 ZT310-T windshield left buffer rubber 1274200-112000 ZT310-T windshield left bracket 4024200-076051 ZT310-T windshield left bracket(dark gray matte) 1274200-113000 ZT310-T windshield right bracket...
  • Page 55 7、FRONT FORK COMPONENT Fig. 11 FRONT FORK Windshield motor component COMPONENT PART NO. PART NAME CAUTION 1244200-073000 ZT310-T windshield controller rubber sleeve 1184200-073000 ZT310-T windshield motor controller 1260100-218000 ZT310-T rocker extension spring 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1250501-010000 GB93φ6 spring pad 1274200-137000 ZT310-T motor pressure plate 1244200-074000 ZT310-T windshield motor sheath 1184200-074000 ZT310-T windshield motor...
  • Page 56 7、FRONT FORK COMPONENT Fig. 12 FRONT FORK Head cover aluminum bracket, instrument COMPONENT component(Electronic Instrument) PART NO. PART NAME CAUTION 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1251112-001093 M6×16 hex flange bolt (environmental color zinc) 1224200-093000 ZT310-T upper rocker decorative block 1274200-136000 ZT310-T hood upper rocker gasket 1250601-093000 6802 deep groove ball bearing 1274200-114000 ZT310-T windshield rocker arm...
  • Page 57 7、FRONT FORK COMPONENT Fig. 13 FRONT FORK Head cover aluminum bracket, instrument COMPONENT component(TFT Instrument) PART NO. PART NAME CAUTION 1250301-020093 GB6170M6(environmental color) 1250502-010093 GB96.1φ6(environmental color) 1164200-009000 ZT310 universal TFT instrument (large fuel tank) ZT310 universal TFT instrument (large fuel tank / 60 1164200-012000 teeth) 1164200-028000 ZT310 TFT meter (17 inch deep gear tire / Bosch)
  • Page 58 7、FRONT FORK COMPONENT Fig. 14 FRONT FORK Front fender upper component 1 COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1224100-010000 ZT250-S expansion nail PROCEDURE: ●Front fender upper component Remove two bolts (1) at the joint between the front mud plate and the rear cover of the fuel tank trim cover. Remove three expansion screws (2) on the back of the front mud plate and remove the 2 bolts (1).
  • Page 59 7、FRONT FORK COMPONENT Fig. 13 FRONT FORK Front fender upper component 2 COMPONENT PART NO. PART NAME CAUTION Non-standard self-tapping screws ST4.2×12 1251200-033093 (environmental color) ZT310-T front mud board right decorative cover 1224200-081000 bottom plate ZT310-T front mud board left decorative cover 1224200-080000 bottom plate ZT310-T front mud plate (bright black / applique...
  • Page 60 7、FRONT FORK COMPONENT Fig. 16 FRONT FORK Headlight component 1 COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1270300-273000 Φ8 line clamp (L=73) 1274100-007000 ZT250－S Flanging bushing(φ6.4×φ9×6＋φ20×2) 1244100-004000 ZT250-S Flanging Bushing Buffer 1251100-084093 Non-standard bolt M10×1.5×66 (Dacro) 1251500-007091 Non-standard flat pad φ10.5×φ24×2 (white zinc) 4024200-028000 ZT310-T guard bar mounting bracket 1251300-057093 Non-standard nut M10×1.5 (Dacro)
  • Page 61 7、FRONT FORK COMPONENT Fig. 17 FRONT FORK Headlight component 2 COMPONENT PART NO. PART NAME CAUTION 1224100-010000 ZT250-S expansion nail 1251300-063093 Splint M6×11×15 (environmental color) 1020442-048000 ZT310-T headlight front trim cover 1244100-002000 ZT250-S side cover round glue 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1224200-075000 ZT310-T hood right decorative cover 1224200-074000 ZT310-T hood left decorative cover PROCEDURE:...
  • Page 62 First push the rotating shaft (2) to the left side of the vehicle and then remove the circlip (1) with pliers. Remove the rotary shaft (2). Remove the glove compartment cover (3) from both sides of the end of the glove compartment cover "ZONTES" and remove it.
  • Page 63 7、FRONT FORK COMPONENT Fig. 17 FRONT FORK Front wheel component COMPONENT PART NO. PART NAME CAUTION 1250205-023000 GB70.1 Hexagonal 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 (300×5.0) Non-standard hexagon socket bolt M8×25 1251100-117093 25N.m...
  • Page 64 7、FRONT FORK COMPONENT Fig. 20 FRONT FORK Front mud board & wheel speed sensor component COMPONENT PART NO. PART NAME CAUTION 1224100-051000 0 level fire-retardant belting （black2.5×100） 1224100-044000 Wheel speed sensor clamp 1251100-061093 M6×22 hex flange face full thread bolt 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...
  • Page 65 7、FRONT FORK COMPONENT Fig. 21 FRONT FORK Hand guard component COMPONENT PART NO. PART NAME CAUTION 1244200-059021 ZT310-T left hand windshield hand gel 1250205-085000 GB70.1M6×70 (stainless steel) 1244200-077000 ZT310-T left hand protection decorative rubber strip 1244200-060021 ZT310-T right hand windshield hand gel 1244200-078000 ZT310-T right hand protection decorative rubber strip 1134200-009000 ZT310-T aluminum alloy left hand 1251100-101000 Non-standard bolt M6×12 (304 stainless steel)
  • Page 66 7、FRONT FORK COMPONENT Fig. 22 FRONT FORK Hand guard component(Bosch) COMPONENT PART NO. PART NAME CAUTION 1244200-059021 ZT310-T left hand windshield hand gel 1250205-085000 GB70.1M6×70 (stainless steel) 1244200-077000 ZT310-T left hand protection decorative rubber strip 1244200-060021 ZT310-T right hand windshield hand gel 1244200-078000 ZT310-T right hand protection decorative rubber strip 1134200-024051 ZT310-T Aluminum alloy left handguard (2021) 1251100-101000 Non-standard bolt M6×12 (304 stainless steel)
  • Page 67 7、FRONT FORK COMPONENT Fig.23 FRONT FORK Left hand component COMPONENT PART NO. PART NAME CAUTION 1194100-001000 ZT250－S left rear view mirror 1134200-011000 ZT310－V left hand rocker arm component 1184200-085000 ZT310-X left hand switch(TFT) Stop selling 1184200-144000 Second Generation Left Handlebar Switch TFT) 1184100-106000 ZT310-X left hand switch Stop selling 1184200-131000 ZT310-X left hand switch(without ABS button)
  • Page 68 Locate and unplug the cable of the right handle switch (5) and sub switch (6). First remove the bolt (7) and remove the sub-switch (6). Pay attention to keeping the side of the “ZONTES” on the front disc brake main pump (2) horizontally to prevent the air from entering the brake hose and causing the brake to fail.
  • Page 69 “X”, “T40G”. excessive force to avoid damage. For example, ZT2003T40G: "ZT" stands for ZONTES, "2003" ●The damping state can be distinguished by the lettering inside the front shock absorber bottom tube. The shock stands for March 2003, and "T40G"...
  • Page 70 7、FRONT FORK COMPONENT Fig. 26 FRONT FORK Uplink plate, handle bar component COMPONENT PART NO. PART NAME CAUTION 1134200-013000 ZT310-X hamdle bar block component 1274200-018000 ZT310-R upper plate gasket 1244200-008000 ZT310-R upper plate buffer rubber Stop selling 1251700-065000 ZT310-R bushing φ10×φ12×41 1134200-004000 ZT310-R uplink board (homemade) 1251300-057093 Non-standard nut M10×1.5 (Dacro) 40N.m...
  • Page 71 7、FRONT FORK COMPONENT Fig. 27 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 32N.m 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 bushing(φ6.4×φ9×6＋φ20×2)
  • Page 72 7、FRONT FORK COMPONENT Fig. 28 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 32N.m 1251513-013000 Disc brake copper washer φ15×φ10.2×1.5...
  • Page 73 7、FRONT FORK COMPONENT Fig. 29 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 74 7、FRONT FORK COMPONENT Fig. 30 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 75 8、FUEL TANK COMPONENT Fig. 1 FUEL TANK Fuel tank middle cover component COMPONENT PART NO. PART NAME CAUTION 1224100-010000 ZT250-S expansion nail 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) PROCEDURE: ●Middle cover component Use a small Phillips screwdriver to push down the center of the expansion pin and remove the expansion pin (1) at the rear of the middle cover component (Figure A).
  • Page 76 8、FUEL TANK COMPONENT Fig. 2 FUEL TANK Fuel tank cover, fuel tank cover, fuel tank lock COMPONENT PART NO. PART NAME CAUTION 4044201-325035 ZT310-T fuel tank cover (titanium matte) 【2】 4044201-329064 ZT310-T fuel tank cover (bright blue) 【3】 4044201-331033 ZT310-T fuel tank cover (bright orange) 【4】...
  • Page 77 8、FUEL TANK COMPONENT Fig. 3 FUEL TANK Decorative cover grill COMPONENT PART NO. PART NAME CAUTION 1224100-010000 ZT250-S expansion nail 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1224200-053000 ZT310-R decorative cover grill PROCEDURE: ●Furniture cover grille Remove the expansion screw (1) and the bolt (2). Remove the decorative cover grille in one hand, and grasp the bottom of the fuel tank trim cover with one hand and pull it out slightly, and remove the trim cover grille (3).
  • Page 78 8、FUEL TANK COMPONENT Fig. 4 FUEL TANK Fuel tank cover component COMPONENT PART NO. PART NAME CAUTION 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) 1251300-063093 Splint M6×11×15 (environmental color) ZT310-R fuel tank left decorative cover (bright black / Special 4044201-145021 decal titanium gold / ADV)
  • Page 79 8、FUEL TANK COMPONENT Fig. 5 FUEL TANK Fuel tank trim cover rear shell component COMPONENT PART NO. PART NAME CAUTION 1224200-013000 ZT310-R fuel tank left decorative cover back shell 1244100-052000 Cuff bushing cushioning rubber (φ8.5×φ14×1) 1274100-057095 Flanging bushing φ6.2×φ8.4×3.5＋φ14×1.5 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1251300-063093 Splint M6×11×15 (environmental color) 1174200-004000 ZT310-R front left turn signal 1184200-100000 ZT310 dual-port USB charging cable...
  • Page 80 8、FUEL TANK COMPONENT Fig. 6 FUEL TANK Large fuel tank versiong fuel tank component 1 COMPONENT PART NO. PART NAME CAUTION 1244100-004000 ZT250-S Flanging Bushing Buffer 1274100-007000 ZT250－S Flanging bushing(φ6.4×φ9×6＋φ20×2) 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1251300-063093 Splint M6×11×15 (environmental color) 1244100-002000 ZT250-S side cover round glue 1224200-066000 ZT310PKE external antenna mount PROCEDURE:...
  • Page 81 8、FUEL TANK COMPONENT Fig. 7 FUEL TANK Small fuel tank versiong fuel tank component 1 COMPONENT PART NO. PART NAME CAUTION 1244100-004000 ZT250-S Flanging Bushing Buffer 1274100-007000 ZT250－S Flanging bushing(φ6.4×φ9×6＋φ20×2) 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1251300-063093 Splint M6×11×15 (environmental color) 1244100-002000 ZT250-S side cover round glue 1224200-066000 ZT310PKE external antenna mount PROCEDURE:...
  • Page 82 ●The fuel tank cover upper part has been swithched form decal to soft sticker form mid-March 2020 . ZT310-T fuel tank right cover upper part (bright We suggest buy a "1210342-475000 ZONTES soft sticker" together when changing the old fuel tank 4044201-466021...
  • Page 83 ZT310-R fuel tank left cover lower part (bright orange) Bright orange ZT310-R fuel tank right cover upper part (bright black 4044201-147021 Special black / applique dark gray / ZONTES) 4044201-034051 ZT310-R fuel tank right cover upper part (dark gray) 【2】 4044201-017051...
  • Page 84 8、FUEL TANK COMPONENT Fig. 10 FUEL TANK Fuel tank liner component COMPONENT PART NO. PART NAME CAUTION 1250205-043093 GB70.1 M8×55 (environmental color) 22～24N.m 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 1224200-066000 ZT310PKE external antenna mount 1050954-006000 ZT250-R EFI High Pressure Tubing Sub-assembly...
  • Page 85 8、FUEL TANK COMPONENT Fig. 11 FUEL TANK Large fuel tank liner component COMPONENT 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) 1050954-018000 T02 built-in fuel pump -300...
  • Page 86 8、FUEL TANK COMPONENT Fig. 12 FUEL TANK Small fuel tank liner component 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 87 9、SIDE COVER COMPONENT Fig. 1 Side cover Side cover component component PART NO. PART NAME CAUTION 1224100-010000 ZT250-S Expansion nail Right side cover (Dark gray matte/applique 4044201-149051 【1】 black/T310) 4044201-142052 Right side cover (dark gray light/applique black/T310) 【2】 Right side cover (Dark gray matte/applique 4044201-462051 【3】...
  • Page 88 10、REAR COVER COMPONENT Fig.1 REAR COVER Rear rack COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non-standard bolt M6×16 (stainless steel) 1274100-057095 Flange bushing φ6.2×φ8.4×3.5＋φ14×1.5 1244100-052000 Flange bushing buffer rubber（φ8.5×φ14×1） 1274200-103000 ZT310－T Rear Aluminum alloy rack 1251100-123093 Non-standard bolt M8×25 (environmental color) 1250105-137093 GB5789M6×16(environmental color) PROCEDURE: ●REAR RACK...
  • Page 89 10、REAR COVER COMPONENT Fig. 2 REAR COVER Rear cover component 1 COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non-standard boltM6×16(304 stainless steel) 1274100-057095 Flange bushing φ6.2×φ8.4×3.5＋φ14×1.5 1244100-052000 Flange bushing buffer rubber（φ8.5×φ14×1） 1174200-023000 ZT310－T taillight 1251300-063093 Plywood M6×11×15(environmental color) 1250105-137093 GB5789M6×16(environmental color) PROCEDURE: ●Taillight Take off all the connectors at the location①,do not touch the cables.
  • Page 90 10、REAR COVER COMPONENT Fig. 3 REAR COVER Rear cover component 2 COMPONENT PART NO. PART NAME CAUTION 4044201-108021 ZT310－T fender cap of rear cover（black） black 4044201-108052 －T fender cap of rear cover（gray） blue/orange ZT310 1251100-122093 Non-standard bolt M8×16 (environmental color) 1251700-058093 Flange bushing φ8.2×φ11×4.5+φ16×1.5 1240300-071000 Flange bushing buffer (φ11×φ16×1) 4044201-107021 ZT310－T rear cover（black）...
  • Page 91 10、REAR COVER COMPONENT Fig. 4 REAR COVER Rear mud board assembly 1 COMPONENT PART NO. PART NAME CAUTION 1251100-123093 Non-standard bolt M8×25(environmental color) 1251100-102000 Non-standard bolt M6×116 (304 stainless steel) 1274100-057095 Flanging bush φ6.2×φ8.4×3.5＋φ14×1.5 1244100-052000 Flanging bushing cushion rubber (φ8.5×φ14×1) 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...
  • Page 92 10、REAR COVER COMPONENT Fig. 5 REAR COVER Rear mud board assembly 2 COMPONENT PART NO. PART NAME CAUTION 1174200-035000 ZT310 rear turn signal (including license plate light) 1251300-063093 Splint M6×11×15 (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) 1174100-002000 ZT250-S rear reflector 1270300-039000 HJ125-6 rear license plate bracket...
  • Page 93 10、REAR COVER COMPONENT Fig. 6 REAR COVER Rear turn signal after sale parts COMPONENT PART NO. PART NAME CAUTION 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：...
  • Page 94 10、REAR COVER COMPONENT Fig 7 REAR COVER Electrical component box component (TFT Instrument) COMPONENT PART NO. PART NAME CAUTION 1224200-086000 ZT310－T Electrical 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 - Model ZT310-RC4 1184100-010000 ZT250-S Start relay 1184200-016000 ZT310 PKE buzzer PROCEDURE:...
  • Page 95 10、REAR COVER COMPONENT Electrical component box component (electrical Fig 8 REAR COVER COMPONENT Instrument) PART NO. PART NAME CAUTION 1224200-086000 ZT310－T Electrical 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 - Model ZT310-RC4 1184100-010000 ZT250-S Start relay 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1184200-016000 ZT310 PKE buzzer...
  • Page 96 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.PKE insurance must be removed before charging; the bracelet version cannot be unplugged. The bracelet version of the PKE assembly integrates a charging interface, and some models may also have a charging interface for the main harness.
  • Page 97 10、REAR COVER COMPONENT Fig. 10 REAR COVER Electrical device box component 1 COMPONENT PART NO. PART NAME CAUTION 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 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:...
  • Page 98 10、REAR COVER COMPONENT Fig.11 REAR COVER Electrical device box component 2 COMPONENT PART NO. PART NAME CAUTION 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1184200-054000 ZT310 PKE Controller（single antenna ） stop selling 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 99 10、REAR COVER COMPONENT Fig. 12 REAR COVER Electrical component (colloid battery) COMPONENT PART NO. PART NAME CAUTION 1184200-024000 ZT310－R Side bracket relay G8HN-1C4T-RJ 1184100-017000 ZT250－S EFI relay KH-1A4T 1224200-175000 ZT310-T colloid battery electric device box upper cover 1050954-019000 MT05.2 Engine Controller - Model ZT310-RC4 Delphi 1050954-037000 MSE6.0 Controller-ZT180MN (Euro 5) Bosch...
  • Page 100 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 101 10、REAR COVER COMPONENT Fig. 14 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 102 10、REAR COVER COMPONENT Fig. 15 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) 1224200-162000 ZT310 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 103 11、CUSHION COMPONENT Fig.1 CUSHION Cushion component COMPONENT PART NO. PART NAME CAUTION 2021 model 1200100-462000 ZT310－T cushion(2021 model) one set 1244100-024000 ZT250－S Cushion front rubber only for after-sale 1244100-022000 ZT250－S Cushion rubber service 1244100-025000 ZT250－S Cushion round rubber PROCEDURE： ●Remove seat cushion Press the unlock button"...
  • Page 104 12、MUFFLER COMPONENT Fig.1 Muffler component Muffler rear component PART NO. PART NAME CAUTION 1250205-023000 GB70.1 inner hexagonal M8X35 (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 board 4084200-002051 ZT310-R dark gray anti-scalding board 1251100-101000 non-standard bolt M6×12（304 stainless steel）...
  • Page 105 12、MUFFLER COMPONENT Fig.2 Muffler component Muffler front component 1 Part No. Part Name CAUTION 1224100-013000 ZT250－S oxygen sensor fixed buckle 1250205-023000 GB70.1 inner hexagonal M8X35 ( color Zinc) 1274100-068095 ZT310 Muffler flanging bushing 1250303-011093 GB6177.1M8（color Zinc） 1251300-058093 inner hexagonal nut M8 ( color Zinc) 1020241-094000 ZT250－S muffler flange 1070100-133000 ZT250－S engine exhaust port seal gasket PROCEDURE：...
  • Page 106 12、MUFFLER COMPONENT Fig.3 Muffler component Muffler front component 1 Part No. Part Name CAUTION 1050953-008000 OSM planar oxygen sensor 25322728 Delphi EFI 1050954-026000 LSF oxygen sensor Bosch EFI 1224100-013000 ZT250-S Oxygen sensor fixing buckle 1224200-008000 ZT310-R cable clip 1244100-064000 ZT310 Muffler cushion rubber 1274100-068095 ZT310 Muffler Flange Bushing 1124200-002000 ZT310-R Front muffler (homemade/Euro IV) Delphi EFI...
  • Page 107 13、LOWER SHROUD COMPONET Fig.1 LOWER SHROUD Lower shroud component 1 COMPONENT PART NO. PART NAME CAUTION 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color zinc) 1250502-010093 GB96.1φ6（color zinc） 1251112-005093 M6×75 Hex flange bolts (color zinc) 12±1.5N.m 1274200-065000 ZT310-R Lower shroud left bracket 1274200-066000 ZT310-R Lower shroud right bracket...
  • Page 108 13、LOWER SHROUD COMPONET Fig.2 LOWER SHROUD Sliding clutch version lower shroud component COMPONENT PART NO. PART NAME CAUTION 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color zinc) 1250502-010093 GB96.1φ6（color zinc） 1244100-004000 ZT250 －S Flanging bushing buffer 1274100-007000 ZT250－S Flanging bushing(φ6.4×φ9×6＋φ20×2) 1274200-067000 ZT310－T front bracket of lower shroud 1224200-101000 ZT310－T lower shroud PROCEDURE:...
  • Page 109 13、LOWER SHROUD COMPONET Fig.3 LOWER SHROUD Light-clutch version lower shroud component COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1274100-007000 ZT250－S Flanging bushing(φ6.4×φ9×6＋φ20×2) 1244100-004000 ZT250 －S Flanging bushing buffer 1274200-067000 ZT310－T front bracket of lower shroud 1224200-101000 ZT310－T lower shroud PROCEDURE: ●Front bracket of lower shroud...

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