Zontes ZT310-VX EURO IV Service Manual
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Zontes ZT310-VX EURO IV Service Manual

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ZT310-VX (EURO IV/V)
Service manual
2021/06/04

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Summary of Contents for Zontes ZT310-VX EURO IV

  • Page 1 ZT310-VX (EURO IV/V) Service manual 2021/06/04...
  • Page 2 Contents Table of Contents Page Table of Contents ………………………………………………………………………………………………………………………………………………………………………………………… Frame component 1.1 Electrical Device component-1 …………………………………………………………………………………………………………………………………………………………………………… Main harness, dump switch, relay, flasher, rectifier, ignition coil 1.2 Electrical Device component-2 …………………………………………………………………………………………………………………………………………………………………………… Flameout switch, horn, wake-up switch 1.3 Frame plastic parts………………………………………………………………………………………………………………………………………………………………………………………… Set clamp, side cover round glue, fuel tank liner limit glue 1.4 Directional Column component……………………………………………………………………………………………………………………………………………………………………………...

  • Page 3: Table Of Contents

    Contents Table of Contents Page Remove filter bottom case 3.7 Replace air filter element 4………………………………………………………………………………………………………………………………………………………………………………… Replace the air filter Rear wheel and rear fork component 4.1 Adjustment chain…………………………………………………………………………………………………………………………………………………………………………………………… 23 4.2 Sprocket guard……………………………………………………………………………………………………………………………………………………………………………………………… Removing the sprocket guard 4.3 Sprocket assembly 1………………………………………………………………………………………………………………………………………………………………………………………… 25 4.4 Sprocket assembly 2…………………………………………………………………………………………………………………………………………………………………………………………...
  • Page 4 Contents Table of Contents Page 4.17 Replace the rear brake pads………………………………………………………………………………………………………………………………………………………………………………… 39 4.18 Rear brake main pump adds brake fluid…………………………………………………………………………………………………………………………………………………………………… 40 Pedal component 5.1 Pedal height adjustment…………………………………………………………………………………………………………………………………………………………………………………… Shift lever, brake pedal height adjustment 5.2 Front right pedal mounting position adjustment 1………………………………………………………………………………………………………………………………………………………… 5.3 Front right pedal mounting position adjustment 3…………………………………………………………………………………………………………………………………………………………...
  • Page 5 Contents Table of Contents Page Adjust the throttle line, clutch cable free travel 7.2 Light height adjustment…………………………………………………………………………………………………………………………………………………………………………………… 7.3 Replacement clutch cable…………………………………………………………………………………………………………………………………………………………………………………… 62 7.4 Replace the throttle line……………………………………………………………………………………………………………………………………………………………………………………… 63 7.5 Steering adjustment………………………………………………………………………………………………………………………………………………………………………………………… 64 Adjustment steering device 7.6 Add brake fluid, rocker adjustment………………………………………………………………………………………………………………………………………………………………………… 65 Add brake fluid, brake rocker adjustment 7.7 Replace the front brake pads,front brake caliper mounting plate……………………………………………………………………………………………………………………………………………...
  • Page 6 Contents Table of Contents Page 7.21 Storage box, rear surrounding components 1……………………………………………………………………………………………………………………………………………………………… Remove PKE charging instructions, rear surrounding components 7.22 Storage box, rear surrounding components 2……………………………………………………………………………………………………………………………………………………………… 7.23 Storage box, rear surrounding components 3……………………………………………………………………………………………………………………………………………………………… 7.24 Right hand component……………………………………………………………………………………………………………………………………………………………………………………… 83 Remove right rear view mirror, right hand rubber sleeve, balance block，Replace the front brake switch 7.25 Left hand component………………………………………………………………………………………………………………………………………………………………………………………...
  • Page 7 Contents Table of Contents Page Remove the rear shell of the fuel tank decoration cover 8.7 Fuel tank decorative cover components 4…………………………………………………………………………………………………………………………………………………………………… 99 Remove the turn signal and decorative cover grid 8.8 Fuel tank decorative cover components 5…………………………………………………………………………………………………………………………………………………………………… 100 Remove the decorative cover and bottom plate of the fuel tank 8.9 Fuel tank cover component…………………………………………………………………………………………………………………………………………………………………………………...
  • Page 8 Contents Table of Contents Page Disassemble the rear aluminum alloy bracket 11.6 Tail skirt taillight component 4……………………………………………………………………………………………………………………………………………………………………………… 114 Rear skirt taillight component Cushion component 12.1 cushion……………………………………………………………………………………………………………………………………………………………………………………………………… 115 Discomponent and component cushion; seat cushion rubber separately purchased parts Muffler component 13.1 Oxygen sensor……………………………………………………………………………………………………………………………………………………………………………………………… 116 13.1 Muffler component 1………………………………………………………………………………………………………………………………………………………………………………………...
  • Page 9 1、FRAME COMPONENT Fig.1 FRAME&ELECTRONIC Electronic parts COMPONENT-1 PARTS COMPONENT PART NO. PART NAME CAUTION 1184200-165000 ZT310－VX wiring harness assembly 1224100-030000 Plug cable tie (black 4.8×130) 1224100-037000 0 level antiflaming binding（black 3.6×295） 1184100-017000 ZT250－S Electronic fuel injection relay KH-1A4T 1244100-082000 ZT250－R Dump switch rabber 1184100-002000 ZT250－S Dump switch 1180300-101000 HJ150-3 square flasher (LED) 1251100-101000 Non-standard bolt M6×12（304 stainless steel）...
  • Page 10 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 0 level antiflaming binding（black 3.6×295） 1274100-095000 ZT250－S Holder of flameout switch cable 1184100-012000 ZT250－S Flameout switch 1250205-040095 GB70.1M8×16 Screw...
  • Page 11 1、FRAME COMPONENT Fig.3 FRAME&ELECTRONIC Frame plastic parts PARTS COMPONENT PART NO. PART NAME CAUTION 1224100-030000 Plug strap (black 4.8×130) 1244100-019000 ZT250－S Inner fuel tank fix glue cushion 1244100-002000 ZT250－S side cover cushion 1240300-007000 HJ125－6 battery cushion 1244100-061000 ZT250 Frame water proof rubber plug 1250201-030093 GB818M5×12 (color zinc) 1240300-060000 KD150－E Wear block PROCEDURE:...
  • Page 12 When reassembling, the conjoined steel beads should be painted lubricating grease,attention to the dosage. abrasion and rust.If YES, please buy the regular accessories on ZONTES official website, if not, please The torque of rating nut which closes to upper dustproof cover is required to about 14N.m.so as to be able to be sure to grease the old grease and repaint the lubricating grease on it.
  • Page 13 1、FRAME COMPONENT Frame, Side support, the operation of releasing engine Fig.5 FRAME&ELECTRONIC PARTS COMPONENT PART NO. PART NAME CAUTION ZT310－VX frame assembly 1130900-026000 ZT250－S Fix loop after-sale 1274100-006000 ZT250－S Frame engine oil filter screen 1051453-003000 27.4×2.65 Acrylate O gule cushion loop 1274100-024000 ZT250－S Oil cooling joint 50±4N.m 1244100-033000 Sealing gasketφ12×φ20×2...
  • Page 14 2、FRAME & ENGINE COMPONENT PIC.1 FRAME&ENGINE Engine trim cover assy PART NO. PART NAME CAUTION 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1274100-018000 ZT250－S muffler anti-scald plate bushing 1244100-017000 ZT250－S muffler anti-scald plate rubber 1224200-157000 ZT310－V Trim cover of right engine cover 1251112-005093 M6×75 hexagon flange bolt ( color zinc) 10N.m 1274200-221000 ZT310－V Mount bracket of engine right trim cover...
  • Page 15 2、FRAME & ENGINE COMPONENT Fig.2 FRAME&ENGINE Frame & Engine 1 PART NO. PART NAME CAUTION 1250104-006097 GB16674M6×12 (chromed/HH) 1274100-057095 Flanging bushing φ6.2×φ8.5×3.5＋φ14×1.5 1244100-052000 Buffer rubber of flanging bushing (φ8.5×φ14×1) 1224200-193000 ZT310-VX rear shock absorber connecting rod plate 1274200-041000 ZT310 Water pipe clamp (φ25) 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color zinc) 1251112-003093 M6×45 Hex flange surface 9.8 bolt (color zinc) 1154200-021000 ZT310－VX clutch cable...
  • Page 16 2、FRAME & ENGINE COMPONENT Fig.3 FRAME&ENGINE Frame & Engine 2 PART NO. PART NAME CAUTION 1251300-057093 Non-standard nut M10×1.5 65±5N.m 1020242-385000 ZT310－V Upper hanging piece 1251100-132003 Non-standard bolt M10×1.5×80 4024200-043000 ZT310－V bracket ZT310－V front bracket of left footrest ZT310－V front bracket of right footrest 1251100-137000 Non-standard bolt M10×1.5×100 1251112-003093 M6×45 hexagon flange face 9.8 bolt 12±1.5N.m...
  • Page 17 3、INTAKE SYSTEM COMPONENT Fig.1 INTAKE SYSTEM Intake system component COMPONENT PART NO. PART NAME CAUTION 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1251300-063093 Clamp plate M6×11×15 (environmental color) 1224200-170000 ZT310-V1 Air filter (Bosch) 1051354-004000 Φ56×10 pipe clamp assembly ZT40 three-in-one valve body sub-assembly 1050954-038000...
  • Page 18 3、INTAKE SYSTEM COMPONENT Fig.2 INDUCTION Induction system component SYSTEM COMPONENT PART NO. PART NAME CAUTION 1050954-009000 YH Carbon tank electromagnetic valve 1250303-010093 GB6177.1M6（color zinc） 1224100-012000 ZT250－S Carbon tank 1274200-088000 ZT310 water pipe clamp（φ10.5） 1274200-079000 ZT310 water pipe clamp（φ9） ZT310-V carbon canister solenoid valve intake 1244200-096000 manifold (Φ5×Φ11/Φ7×Φ13) 1244200-095000 ZT310-V carbon Tank adsorption Tube (Φ...
  • Page 19 3、INTAKE SYSTEM COMPONENT Fig.3 INDUCTION Maintain the filter element of the air filter SYSTEM COMPONENT PART NO. PART NAME CAUTION 1224100-010000 ZT250－S swell nail 1244100-061000 ZT250 anti-water rubber of frame 1250105-018091 GB5789 M8×70（white zinc） 4044201-256051 ZT310-v fender ball (dark grey matte) ZT310－V right side cover PROCEDURE: ●Side cover...
  • Page 20 3、INTAKE SYSTEM COMPONENT Fig.4 INDUCTION Replace the air filter element 1 SYSTEM COMPONENT PART NO. PART NAME CAUTION 1224100-010000 ZT250－S swell nail 1244100-061000 ZT250 anti－water rubber of frame 1250105-018091 GB5789 M8×70(white zinc) 4044201-256051 ZT310－V fender ball (dark grey matte) 1251100-102000 Non－standard bolt M6×16(304 stainless steel) 1274100-057095 Flanging bushing φ6.2×φ8.5×3.5＋φ14×1.5 1244100-052000 Buffer rubber of flanging bushing (φ8.5×φ14×1) 1224200-193000 ZT310-VX rear shock absorber connecting rod plate...
  • Page 21 3、INTAKE SYSTEM COMPONENT Fig.5 INDUCTION Replace the air filter element 2 SYSTEM COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non-standard bolt M6×16（304stainless steel） 1251100-101000 Non-standard bolt M6×12（304stainless steel） 1274200-162000 ZT310－V Fuse Box Bracket 1244200-095000 ZT310-V carbon Tank adsorption Tube (Φ 5 × Φ 11) Intake Manifold of Solenoid Valve for ZT310-V 1244200-096000 carbon Tank (Φ...
  • Page 22 3、INTAKE SYSTEM COMPONENT Fig.6 INDUCTION Replace the air filter element 3 SYSTEM COMPONENT PART NO. PART NAME CAUTION 1251100-101000 Non-standard bolt M6×12（304stainless steel） 1274100-057095 Flanging bush φ6.2×φ8.4×3.5＋φ14×1.5 1244100-052000 Buffer rubber of flanging bushing (φ8.5×φ14×1) 4044201-467051 ZT310-VX battery bottom cover (dark gray matte) PROCEDURE: ●Air filter Locate the lock pins at the four corners of the air filter.
  • Page 23 3、INTAKE SYSTEM COMPONENT Fig.7 INDUCTION Replace the air filter element 4 SYSTEM COMPONENT PART NO. PART NAME CAUTION 4134200-001000 ZT310-V air filter core (with carton packaging) PROCEDURE: ●Air filter element Use a Phillips screwdriver to remove the four bolts. Replace the filter element with a new one. Prepare new filter elements and seals.

  • Page 24: Adjustment Chain

    4、REAR WHELL COMPONENT Fig.1 Rear wheel, swinging Adjustment chain arm assembly PART NO. PART NAME CAUTION 1251100-117093 Non standard hex socket bolt M8×25 1250501-004091 GB93φ10（white zinc） 1250503-006091 GB97.1φ10（white zinc） 1251100-204000 Non-standard Bolt M16×1.5×50（color zinc） 100N.m PROCEDURE: ●Rear auxiliary mud plate assembly Use a 6# inner hexagon socket remove the bolt (1) at the bottom of the rear sub-slab assembly and remove the spring washer (2) and flat washer (3).
  • Page 25 4、REAR WHELL COMPONENT Fig.2 Rear wheel, swinging Sprocket baffle arm assembly PART NO. PART NAME CAUTION 1251100-101000 Non-standard Bolt M6×12（304 stainless steel） 1274100-057095 Bush φ6.2×φ8.4×3.5＋φ14×1.5 1244100-052000 Buffer rubber of flanging bushing (φ8.5×φ14×1) ZT310－R1 sprocket baffle PROCEDURE: ●Sprocket baffle Using 4# inner hexagon socket remove bolt⑴，remove the flange bushing ⑵, cushion rubber⑶; finally remove the sprocket baffle⑷.

  • Page 26: Rear Auxiliary Mud Plate Assembly

    4、REAR WHELL COMPONENT Fig.3 Rear wheel, swinging Sprocket assembly 1 arm assembly PART NO. PART NAME CAUTION 1251100-117093 Non standard hex socket bolt M8×25 1250501-004091 GB93φ10（white zinc） 1250503-006091 GB97.1φ10（white zinc） 1251100-204000 Non standard bolt M16×1.5×50(color zinc) 100N.m 1094100-062000 M35 nut locking spring 1251300-070000 Non standard nut M35×1.5(environmental color zinc) 200N.m 1080200-079000 ZT310－R1 114 chain（DID520VF/Open type）...
  • Page 27 4、REAR WHELL COMPONENT Fig.4 Rear wheel, swinging Sprocket assembly 2 arm component PART NO. PART NAME REMARKS 1274100-108000 Bushing Φ45×Φ35×5.5+Φ54×Φ35×2 1274100-105000 Bushing Φ46×Φ35×7.3 1244100-087000 ZT310-R1 single rear fork sprocket buffer rubber 1094200-013000 ZT310 single rear fork sprocket seat inner shell 1244200-088000 O-ring (Φ52.4×2.6) 1274200-120000 ZT310 single rear fork arm 520-42T sprocket 1251100-190000 Non standard bolt M10×1.5×30（color zinc）...
  • Page 28 4、REAR WHELL COMPONENT Fig.5 Rear wheel, swinging Rear wheel component arm component PART NO. PART NAME REMARKS 1251300-071000 Non standard nut M12×1.5（chromed） 110N.m 1230100-386000 180/55R17(CM638)Rear tire(environmental/TL) 1094200-047000 ZT310－VX single rocker arm bright black rear wheel 1260100-238000 ZT310-R1 rear wheel sign spring 1210142-000100 ZT310-R1 single rocker black rim sign 1184200-155000 ZT310 tire pressure wireless built-in sensor PROCEDURE:...
  • Page 29 4、REAR WHELL COMPONENT Fig.6 Rear wheel, swinging Rear axle assembly arm component PART NO. PART NAME REMARKS 1184200-045000 DF30 wheel speed sensor 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1251100-123093 Non standard M8×25(color zinc) 1250104-006097 GB16674M6×12（chromed/HH） 1274200-119000 Single rocker rear flat fork tubing bracket 1224100-037000 0 grade flame retardant cable tie (black 3.6×295) 1251100-117093 Non standard hex socket bolt M8×25 1274200-058000 ABS gear ring(60T)
  • Page 30 4、REAR WHELL COMPONENT Fig.7 Rear wheel, swinging Rear auxiliary mud plate component 1 arm assembly PART NO. PART NAME CAUTION 1184200-030000 ZT310-R sub-mud board adapter cable (L=2000) 1224100-037000 0 grade flame retardant cable tie (black 3.6×295) PROCEDURE: ●Rear auxiliary mud board assembly Find the 3 plugs at the transfer plug and unplug the shown three plugs.
  • Page 31 4、REAR WHELL COMPONENT Fig.8 Rear wheel, swinging Rear auxiliary mud plate component 2 arm assembly PART NO. PART NAME CAUTION 1184200-030000 ZT310-R sub-mud board adapter cable (L=2000) 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 Buffer rubber of flanging bushing (φ8.5×φ14×1) 1020242-265021 ZT310-R1 rear sub-mud aluminum alloy bracket 1224200-106000 ZT310-R1 rear auxiliary mud board retaining plate 1250105-137093 GB5789M6×16 (environmental color)
  • Page 32 4、REAR WHELL COMPONENT Fig.9 Rear wheel, swinging Rear auxiliary mud plate component 3 arm assembly PART NO. PART NAME CAUTION 1251300-063093 Splint M6×11×15 (environmental color) 1244100-006000 ZT250-S rear license plate cushioning rubber 1224200-109000 ZT310-V rear mud plate fende 1270300-273000 Φ8 line clamp (L = 73) 1174200-035000 ZT310 rear turn light (including license plate light) 1174100-002000 ZT250-S rear reflector 1251100-102000 Non-standard bolt M6×16 (304 stainless steel)
  • Page 33 4、REAR WHELL COMPONENT Fig.10 Rear wheel, Rear turning light parts for after sales service swinging arm assembly PART NO. PART NAME CAUTION 1224200-120000 ZT310 rear turning light holder 1174200-019000 ZT310－X L, rear turning light 1174200-020000 ZT310－X R, rear turning light 1174200-021000 ZT310－X license lamp PROCEDURE: ●Rear turning light（license lamp included）...

  • Page 34: Chain Adjuster Assembly

    4、REAR WHELL COMPONENT Fig.11 Rear wheel, Chain adjuster assembly swinging arm assembly PART NO. PART NAME CAUTION 1250700-009000 Shaft type A circlip φ75×2.5 1251500-096000 φ90×φ76×1 washer 1244200-105000 O-ring φ80×2.65 (inner diameter×wire diameter) Single rocker rear disc brake mounting plate Single rocker rear disc brake mounting plate limit block 1244200-066000 O-ring seal (φ22.2×2.4) 4024200-046000 Single rocker eccentric chain adjuster assembly 1274100-104000 Bushing Φ50×Φ40×7.5...

  • Page 35: Rear Mud Board

    4、REAR WHELL COMPONENT Fig.12 Rear wheel, Rear mud board swinging arm assembly PART NO. PART NAME CAUTION 1250104-006097 GB16674M6×12（chromed/HH） 1274100-057095 Flanging bushing φ6.2×φ8.4×3.5＋φ14×1.5 1244100-052000 Buffer rubber of flanging bushing （φ8.5×φ14×1） 1224200-201000 ZT310－VX rear mud board 1210342-449000 ZT310-X1 chain decal 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) PROCEDURE: ●Rear mud board Use 8# sleeve to remove bolt ⑴...
  • Page 36 4、REAR WHELL COMPONENT Fig.13 Rear wheel, Rear shock absorber swinging arm assembly PART NO. PART NAME CAUTION 1251100-261000 Non-standard bol M10×1.5×127（Dacro） 1251300-057093 Non-standard bolt M10×1.5（Dacro） 1114200-022000 ZT310－VX Rear shock absorber 1251100-085093 Non-standard bolt M10×1.5×75（Dacro） PROCEDURE: ●Rear shock absorber Tilt the body to the left with the side bracket as the fulcrum, and then use a firm stool to support the muffler back pressure package to keep the rear wheels off the ground.

  • Page 37: Rear Shock Absorber Rod Assembly 1

    4、REAR WHELL COMPONENT Fig.14 Rear wheel, Rear shock absorber rod assembly 1 swinging arm assembly PART NO. PART NAME CAUTION 1251100-132003 Non－standard boltsM10×1.5×80 (dacromet) 4024200-092000 ZT310-VX rear flat fork connecting rod assembly 1251300-057093 Non－standard nut M10×1.5(dacromet) 1251100-291000 Non－standard boltsM10×1.5×55(dacromet) 1244200-130000 ZT310 rear shock absorber KRH oil seal after-sale 1250602-038000 ZT310 rear shock absorber KRH needle roller bearings 1274200-306000 ZT310 rear shock absorber needle roller bearing bush...

  • Page 38: Rear Shock Absorber Rod Assembly 2

    4、REAR WHELL COMPONENT Fig.15 Rear wheel, Rear shock absorber rod assembly 2 swinging arm assembly PART NO. PART NAME CAUTION 1251100-261000 Non－standard bolts M10×1.5×127(dacromet) 1250205-040095 GB70.1 inner hex bolt M8×16(color Zinc) 1274200-315000 ZT310－VX lower connecting rod right bracket 4024200-067000 Rear shock absorber lower bracket right reinforcement plate 1250305-009091 GB6187.1M12×1.25 (White zinc) 1251300-057093 Non－standard nut M10×1.5(dacromet) 1114200-022000 ZT310－VX rear shock absorber...
  • Page 39 4、REAR WHELL COMPONENT Fig.16 Rear wheel, Rear wheel assembly swinging arm assembly PART NO. PART NAME CAUTION 1094200-009000 ZT310－V rear flat fork hollow shaft 1251300-067000 ZT250－R rear wheel axle nut 110±5N.m 1020242-414000 ZT310－VX Left bushing of rear fork shaft 1020242-415000 ZT310－VX Right bushing of rear fork shaft ZT310 single rocker arm aluminum alloy flat fork left 1244200-086000 dustproof rubber plug...
  • Page 40 4、REAR WHELL COMPONENT Fig.17 Rear wheel, Change rear brake arresters swinging arm assembly PART NO. PART NAME CAUTION 1100100-092000 ZT250－S rear disc brake arrester(HS10) after-sale PROCEDURE: ●Disassemble disc brake arrester Loosen the upper slide shaft① with a 14 mm sleeve. Loosen the lower slide shaft②...
  • Page 41 4、REAR WHELL COMPONENT Fig.18 Rear wheel, Rear disc brake main pump adding braking liquid swinging arm assembly PART NO. PART NAME CAUTION 1251100-102000 Non-standard Bolt M6×16 PROCEDURE: ●Add disc brake liquid Remove the seat cushion and the right side cover first; remove the bolt ⑴ with 4# inner hexagon. Pull out the oil cup④;...
  • Page 42 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 ZT250－S Gear swift rod spline of Rocker arm 1250301-020093 GB6170 M6（environmental color-zinc） 1274100-041000 ZT250－S shift lever adjustment screw 1250301-018093 GB6170 M6－LH（environmental color-zinc）...
  • Page 43 5、FOOT PEDAL COMPONENT Fig.2 FOOT PEDAL Front right pedal mounting position adjustment 1 COMPONENT PART NO. PART NAME CAUTION 1251100-121093 Non-standard bolt M6×25(environmental color) 1274100-057095 Flanging bushingφ6.2×φ8.4×3.5＋φ14×1.5 1244100-052000 Buffer rubber of flanging bushing （φ8.5×φ14×1） 1251112-005093 M6×75 hexagon flange bolt ( color zinc) 10N.m ZT310-V Muffler Left Anti-scalding Plate 1251300-057093 Non-standard nuts M10×1.5(Dacromet)
  • Page 44 5、FOOT PEDAL COMPONENT Fig.3 FOOT PEDAL Front right pedal mounting position adjustment 2 COMPONENT PART NO. PART NAME CAUTION 1251100-261000 Non－standard boltM10×1.5×127(dacromet) 1251300-057093 Non－standard nut M10×1.5(dacromet) 1250303-011093 GB6177.1M8(color zinc) 1274200-313000 ZT310－VX right foot support fixing piece ZT310-V rear brake main pump piston push rod 1274200-170000 extension rod PROCEDURE:...
  • Page 45 5、FOOT PEDAL COMPONENT Fig.4 FOOT PEDAL Front left pedal mounting position adjustment COMPONENT PART NO. PART NAME CAUTION 1250301-018093 GB6170 M6-LH (army green) 1274100-041000 Shift lever adjusting screw 1250301-020093 GB6170M6 (environmental color) 1250303-011093 GB6177.1M8 (color zinc) 1274200-312000 ZT310－VX left foot support fixing piece 1274200-035194 ZT310 front fender bushing (black zinc) PROCEDURE: ●Move front left pedal foeward...
  • Page 46 5、FOOT PEDAL COMPONENT Fig.5 FOOT PEDAL Front right footrest component COMPONENT PART NO. PART NAME CAUTION 1250303-011093 GB6177.1M8 (color zinc) 1274200-313000 ZT310－VX right foot support fixing piece ZT310－VX front right foot pedal support 1274200-322000 ZT310－VX Pedal support gasket ZT310－VX brake pedal 1260100-294000 ZT310－VX Brake footrest torsion spring (color zinc) 1251100-293000 ZT310－VX pedal non-standard bolt M8×70 ZT310－VX right foot support...
  • Page 47 5、FOOT PEDAL COMPONENT Fig.6 FOOT PEDAL Shift lever assembly COMPONENT PART NO. PART NAME CAUTION 1251100-061093 M6×22 Hexagone flange bolt 8.8 degree 1274100-039000 ZT250－S Gear shift rod spline rocker arm 1274100-043000 Knuckle Bearing SALJK6C 1250303-010093 GB6177.1M6（environmental color-zinc） 1250301-018093 GB6170M6－LH（environmental color-zinc） 1274100-041000 shift lever adjusting screw 1250301-020093 GB6170M6（environmental color-zinc）...
  • Page 48 5、FOOT PEDAL COMPONENT Fig.7 FOOT PEDAL Front left footrest component COMPONENT PART NO. PART NAME CAUTION 1250303-011093 GB6177.1M8(color zinc) 1274200-312000 ZT310－VX left foot support fixing piece ZT310－VX front left foot pedal support 1274200-322000 ZT310－VX Pedal support gasket ZT310－VX gear lever rocker arm 1251100-293000 ZT310－VX pedal non-standard bolt M8×70 ZT310－VX left foot support 1264100-006000 ZT250－S Foot pedal circlip...
  • Page 49 5、FOOT PEDAL COMPONENT Fig.8 FOOT PEDAL Rear pedal assembly COMPONENT PART NO. PART NAME CAUTION 1250205-023000 GB70.1 inner hexagonal M8X35 (army green) ZT310－V Rear left pedal bracket assembly ZT310－V Rear right pedal bracket assembly PROCEDURE: ●Rear left pedal bracket assembly Using 6# inner hexagon socket remove 3 pieces bolts ⑴...
  • Page 50 5、FOOT PEDAL COMPONENT Fig.9 FOOT PEDAL Rear right pedal bracket components COMPONENT PART NO. PART NAME CAUTION 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color zinc) 1250205-043093 GB70.1M8×55（environmental color-zinc） ZT310－V Rear right pedal cover 1260100-225000 ZT310－V Rear right pedal torsion spring 1251700-118000 Bushing Φ13×Φ8×18.1 1244100-002000 ZT250－S Side cover round rubber ZT310－V Rear right pedal bracket...
  • Page 51 5、FOOT PEDAL COMPONENT Fig.10 FOOT PEDAL Rear left pedal bracket components COMPONENT PART NO. PART NAME CAUTION 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color zinc) 1250205-043093 GB70.1M8×55（environmental color-zinc） ZT310－V Rear left pedal cover 1260100-224000 ZT310－V Rear left pedal torsion spring 1251700-118000 Bushing Φ13×Φ8×18.1 1244100-002000 ZT250－S Side cover round rubber ZT310－V Rear left pedal bracket...
  • Page 52 6、COOLING SYSTEM COMPONENT Fig.1 COOLING SYSTEM Change engine oil COMPONENT PART NO. PART NAME CAUTION 1050854-002000 ZT180MN Engine oil level gauge 1244100-033000 Sealing gasket 12×φ20×2 1251100-066093 M12×1.5×15 Oil draining bolt 24N.m PROCEDURE: ●Drain off the engine oil First remove the lower shroud assembly.Drain with a suitable tool to prevent oil from contaminating the cover. Park the motorcycle with side stand on flat ground.
  • Page 53 6、COOLING SYSTEM COMPONENT Fig.2 COOLING SYSTEM Change engine oil filter COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non-standard bolt M6×16（304 stainless steel） 1274100-018000 ZT250－S anti－hot plate sleeve, muffler 1251300-056093 M6 Cover type 9 degree nut 12±1.5N.m ZT180MN Engine oil refined filter cover 1051454-004000 55×2.5 O-ring after-sale 1051454-005000 ZT180MN Engine oil refined filter seal ring...
  • Page 54 6、COOLING SYSTEM COMPONENT Fig.3 COOLING SYSTEM Change engine oil COMPONENT PART NO. PART NAME CAUTION 1274200-188001 ZT310-V 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"...
  • Page 55 6、COOLING SYSTEM COMPONENT Fig.4 COOLING SYSTEM Radiator grille COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non-standard bolt M6×16（304 stainless steel） 1274100-057095 Flanging bushing φ6.2×φ8.5×3.5＋φ14×1.5 1244100-052000 Buffer rubber of flanging bushing （φ8.5×φ14×1） 1224100-010000 ZT250－S swell nail 1224200-191000 Lower part of the lower part of the mudguard 1224200-173000 ZT310－VX Radiator grille 1251100-121093 Non-standard bolt M6×25 (color zinc) PROCEDURE:...
  • Page 56 6、COOLING SYSTEM COMPONENT Fig.5 COOLING SYSTEM Vice water tank components COMPONENT PART NO. PART NAME CAUTION 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color zinc) 1251112-003093 M6×45 Hex flange surface 9.8 bolt (color zinc) 1274200-079000 ZT310 water pipe clamp（φ9） 1244200-069000 ZT310-V sub water tank leakage pipe 1274200-188001 ZT310-V sub water tank 1274200-088000 ZT310 water pipe clamp（φ10.5）...
  • Page 57 6、COOLING SYSTEM COMPONENT Fig.6 COOLING SYSTEM Change engine oil COMPONENT PART NO. PART NAME CAUTION 1051454-014000 9.8×2.5 acrylic o-ring 1274200-186000 ZT310-V Frame bypass oil pipe 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color zinc) 1251100-089094 Oil bolt M14×1.50×32 30±2N.m 1244100-034000 Combined sealing gasket φ14×φ20×2 1274200-189000 ZT310-V Engine outlet oil pipe 1244200-015000 ZT310-R Engine inlet oil pipe...
  • Page 58 6、COOLING SYSTEM COMPONENT Fig.7 COOLING SYSTEM Draining cooling liquid COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non-standard bolt M6×16(304 stainless steel) 1274100-018000 ZT250-S muffler anti-scalding bushing 1251112-001093 M6×16 Hex flange bolt（environmental color zinc） 1051654-002000 Seal gasketφ6×13×1.8 PROCEDURE: ●Engine decorative cover assembly Using 4# inner hexagon socket remove 3 bolts ⑴...
  • Page 59 6、COOLING SYSTEM COMPONENT Fig.8 COOLING SYSTEM Main water tank assembly 1 COMPONENT PART NO. PART NAME CAUTION 1224100-051000 0 grade flame retardant cable tie (black 2.5×100) 1274200-090000 ZT310 Hoop of cooling liquid tube（φ26） 1251112-002093 M6×30 Hexagon flange bolts (color zinc) 1244200-068000 ZT310-V engine inlet water pipe 1274200-041000 ZT310 Cooling liquid tube clamp（φ26）...
  • Page 60 6、COOLING SYSTEM COMPONENT Fig.9 COOLING SYSTEM Main water tank assembly 2 COMPONENT PART NO. PART NAME CAUTION 1274200-274021 ZT310－V main water tank 1244100-002000 ZT250－S Side cover round rubber 1274200-091000 ZT310 water pipe clamp（φ27） 1274200-089000 ZT310 water pipe clamp（φ22） 1244200-113000 ZT310-V small circulation water pipe 1244200-071000 ZT310-V engine outlet water pipe PROCEDURE: ●Main tank assembly...
  • Page 61 7、FRONT FORK COMPONENT Fig.1 FRONT FORK Throttle/clutch cable clearance adjustment COMPONENT PART NO. PART NAME CAUTION 1154200-023000 ZT310－VX Throttle Refueling Line 1154200-022000 ZT310－VX Throttle Return Line 1154200-021000 ZT310－VX Clutch cable 1244200-046000 ZT310－V clutch line sheath PROCEDURE: ●Throttle line Use an 10# open-end wrench to loosen the lock nut ① on the throttle refueling line ⑴ or the return line ⑵, and turn the adjustment screw ②...
  • Page 62 7、FRONT FORK COMPONENT Fig.2 FRONT FORK Light height adjustment COMPONENT PROCEDURE: ●Light height adjustment The driver sits in the bike and straightens the bike. The other person inserts the PH2 type Phillips screwdriver (diameter 6mm) into the hole at the bottom of the vehicle head, aligns it with the tooth profile of the adjusting bolt, turns clockwise for lowering, and counterclockwise for higher beam height.
  • Page 63 7、FRONT FORK COMPONENT Fig.3 FRONT FORK Replacement clutch cable COMPONENT PART NO. PART NAME CAUTION 1154200-021000 ZT310－VX Clutch line 1244200-046000 ZT310－V protective rubber sleeve PROCEDURE: ●Remove the cluch line Use an 14# 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 64 7、FRONT FORK COMPONENT Fig.4 FRONT FORK Replace the throttle line COMPONENT PART NO. PART NAME CAUTION 1154200-023000 ZT310－VX Throttle Refueling 1154200-022000 ZT310－VX Throttle Return Line 1224100-030000 Pin tie (Black 4.8×130） 1224100-051000 0 Flame retardant tie (black 2.5×100) 1244100-042000 ZT250－R Right handlebar rubber sleeve 1184200-140000 ZT310－X1 Right handlebar switch 1250205-031091 GB70.1M6×30 (stainless steel) 10N.m...
  • Page 65 7、FRONT FORK COMPONENT Fig.5 FRONT FORK Steering adjustment COMPONENT PART NO. PART NAME CAUTION 1251300-045000 ZT250－S Upper connection plate decorative nut 100N.m 1251500-050000 ZT250－S Upper connection plate gasket φ18.5×φ39×1 1250205-023000 GB70.1 Hexagon M8×35 (color zinc) 22～24N.m 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...
  • Page 66 7、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 32N.m PROCEDURE: ●...
  • Page 67 7、FRONT FORK COMPONENT Fig.7 FRONT FORK Replace the front brake pad COMPONENT PART NO. PART NAME CAUTION 1100100-091000 ZT250－S Front disc brake pad (H10) after-sales 1100100-570000 ZT310－T front brake caliper mounting plate PROCEDURE: ●Replace the front brake pad Use a screwdriver to remove the nut①. Remove pin ②...
  • Page 68 7、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 25N.m 1274200-058000 ABS gear ring(60T)
  • Page 69 7、FRONT FORK COMPONENT Fig.9 FRONT FORK Front mudguard & wheel speed sensor component COMPONENT PART NO. PART NAME CAUTION 1251100-061093 M6×22 Hex flange face full thread bolt 1224100-044000 Wheel speed sensor clamp 1184200-045000 DF30wheel speed sensor 1251100-080094 Non－standard bolt M8×37 (color zinc) 1251100-101000 Non－standard bolt M6×12 (304 stainless steel) 1251100-102000 Non－standard bolt M6×16 (304 stainless steel) 1244100-037000 φ12×φ8.5×2.5 circle buffer glue...
  • Page 70 7、FRONT FORK COMPONENT Fig.10 FRONT FORK Windshield components 1 COMPONENT PART NO. PART NAME CAUTION 1224200-188000 ZT310－VX Windshield 1251100-102000 Non－standard bolt M6×16(304 stainless steel) 1274100-057095 Flanging bushing φ6.2×φ8.5×3.5＋φ14×1.5 1244100-052000 Buffer rubber of flanging bushing （φ8.5×φ14×1） 1224200-189000 ZT310－VX windshield upper left pressure block 1224200-190000 ZT310－VX windshield upper right pressure block 1244200-116000 Windshield lower pressure block rubber pad 1264100-006000 ZT250－S Pedal circlip...
  • Page 71 7、FRONT FORK COMPONENT Fig.11 FRONT FORK Windshield components 2 COMPONENT PART NO. PART NAME CAUTION 1224200-093000 ZT310－T head cover on rocker arm decorative block 1274200-136000 ZT310－T head cover upper rocker gasket 4024200-100051 ZT310-VX windshield upper rocker arm 1260100-295000 ZT310－V1 Rocker Arm Spring 1250601-093000 6802 deep groove ball bearing PROCEDURE: ●Windshield upper rocker arm...
  • Page 72 7、FRONT FORK COMPONENT Fig.12 FRONT FORK Headlight assembly 1 COMPONENT PART NO. PART NAME CAUTION 1224100-010000 ZT250－S swell nail 1251112-001093 M6×16 Hexagon flange bolts (color zinc) 1274100-057095 Flanging bushing φ6.2×φ8.5×3.5＋φ14×1.5 1244100-052000 Buffer rubber of flanging bushing （φ8.5×φ14×1） PROCEDURE: ●Headlight assembly Remove the 7 expansion nails (1) shown in Figure 1 and the 2 expansion nails (1) at the bottom of the headlight cover shown in Figure 2.
  • Page 73 7、FRONT FORK COMPONENT Fig.13 FRONT FORK Headlight assembly 2 COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non－standard bolt M6×16(304 stainless steel) 1274100-057095 Flanging bushing φ6.2×φ8.5×3.5＋φ14×1.5 1244100-052000 Buffer rubber of flanging bushing （φ8.5×φ14×1） 1224100-010000 ZT250－S swell nail 1224200-191000 ZT310－VX lower link fender lower part 1224200-192000 ZT310－VX lower link fender upper part 1251100-101000 Non－standard bolt M6×12(304 stainless steel) 1274200-290021 Lower link board fender lower part mounting bracket...
  • Page 74 7、FRONT FORK COMPONENT Fig.14 FRONT FORK Headlight assembly 3 COMPONENT PART NO. PART NAME CAUTION 1251100-101000 Non－standard bolt M6×12(304 stainless steel) 1250205-040095 GB70.1 inner hex bolt M8×16(color Zinc) PROCEDURE: ●Headlight assembly Use 4# inner hexagon to remove the 4 bolts ⑴ on both sides from under the head; use 6# inner hexagon to remove the 4 bolts in the middle part ⑵;...
  • Page 75 7、FRONT FORK COMPONENT Fig.15 FRONT FORK Headlight assembly 4 COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non－standard bolt M6×16(304 stainless steel) 1274100-057095 Flanging bushing φ6.2×φ8.5×3.5＋φ14×1.5 1244100-052000 Buffer rubber of flanging bushing （φ8.5×φ14×1） 1251900-058000 Mushroom buckle (25mm×25mm×T3.5mm) 1224100-010000 ZT250－S swell nail PROCEDURE: ●Headlight components Remove the 6 bolts ⑴...
  • Page 76 7、FRONT FORK COMPONENT Fig.16 FRONT FORK Headlight assembly 5 COMPONENT PART NO. PART NAME CAUTION 1224200-181000 ZT310－VX Windshield Trim ZT310－VX headlight cover 1244200-005000 ZT310－R buffer rubber of head cover 1251300-063093 Plywood M6×11×15(color zinc) 1251100-101000 Non－standard bolt M6×12 (304 stainless steel) 1274100-057095 Flanging bushing φ6.2×φ8.5×3.5＋φ14×1.5 1244100-052000 Buffer rubber of flanging bushing （φ8.5×φ14×1）...
  • Page 77 7、FRONT FORK COMPONENT Fig.17 FRONT FORK Headlight assembly 6 COMPONENT PART NO. PART NAME CAUTION 1251900-058000 Mushroom buckle (25mm×25mm×T3.5mm) 1244100-002000 ZT250－S Side cover round rubber 1274200-279000 ZT310－VX headlight cover left bracket 1251100-101000 Non－standard bolt M6×12 (304 stainless steel) 1274200-280000 ZT310－VX headlight cover right bracket 1250105-138093 GB5789M6×20 (environmental color) 1251700-059093 Flanging bushingφ6.4×φ9×8＋φ18×2 1240400-007000 HJ125－3 battery holder buffer aprons...
  • Page 78 7、FRONT FORK COMPONENT Fig.18 FRONT FORK Windshield motor components COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non－standard bolt M6×16(304 stainless steel) 1274100-057095 Flanging bushing φ6.2×φ8.5×3.5＋φ14×1.5 1244100-052000 Buffer rubber of flanging bushing （φ8.5×φ14×1） 1224200-130000 ZT310－X1 windshield motor outer cover 1251100-101000 Non－standard bolt M6×12(304 stainless steel) 1250501-010000 GB93φ6 spring pad 1274200-137000 ZT310－T motor pressure plate 1250205-006091 GB70.1 M8×45(White zinc)
  • Page 79 7、FRONT FORK COMPONENT Fig.19FRONT FORK Windshield motor sub-assembly COMPONENT PART NO. PART NAME CAUTION 1244200-074000 ZT310-T windshield motor sheath 4024200-081051 ZT310-T lower rocker clamp (matte dark gray) 1250201-046000 GB818 cross recessed pan head screw M4×16 1244200-075000 ZT310-T windshield front rocker buffer rubber 1184200-074000 ZT310－Twindshield motor 4024200-079051 ZT310-T hood lower left rocker 4024200-080051 ZT310-T hood right lower rocker...
  • Page 80 7、FRONT FORK COMPONENT Fig.20FRONT FORK PKE, windshield controller COMPONENT PART NO. PART NAME CAUTION 1251112-001093 M6×16 Hexagon flange bolts (color zinc) 1274100-007000 ZT250－S flanging sleeve(φ6.4×φ9×6＋φ20×2) 1244100-004000 ZT250－S Flanging bushing buffer 1184200-073000 ZT310－T windshield motor controller 1224100-037000 Grade 0 flame retardant tie (black 3.6×295) 1184200-053000 ZT310PKE external single antenna 1250303-010093 GB6177.1M6(color zinc ) 1251100-101000 Non－standard bolt M6×12 (304 stainless steel)
  • Page 81 7、FRONT FORK COMPONENT Fig.21FRONT FORK Storage box, rear surrounding components 1 COMPONENT PART NO. PART NAME CAUTION 1251112-001093 M6×16 Hexagon flange bolts (color zinc) 1274100-007000 ZT250－S flanging sleeve(φ6.4×φ9×6＋φ20×2) 1244100-004000 ZT250－S Flanging bushing buffer 1184200-100000 ZT310 dual USB charging cable 1224100-010000 ZT250－S swell nail 1224200-204000 ZT310－VX PKE small cap 1251300-063093 Plywood M6×11×15(color zinc) PROCEDURE:...
  • Page 82 7、FRONT FORK COMPONENT Fig.22FRONT FORK Storage box, rear surrounding components 2 COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non－standard bolt M6×16(304 stainless steel) 1274100-057095 Flanging bushing φ6.2×φ8.5×3.5＋φ14×1.5 1244100-052000 Buffer rubber of flanging bushing （φ8.5×φ14×1） 1251300-063093 Plywood M6×11×15(color zinc) 1224200-182000 Left storage box cover limit mounting support 1224200-187000 ZT310－VX left storage box cover 1274100-090000 ZT250－S rotating axle of fuel tank outside cover 1260100-215000 ZT310－T storage box cover rotating shaft limit circlip...
  • Page 83 7、FRONT FORK COMPONENT Fig.23 FRONT FORK Storage box, rear surrounding components 3 COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non－standard bolt M6×16(304 stainless steel) 1274100-057095 Flanging bushing φ6.2×φ8.5×3.5＋φ14×1.5 1244100-052000 Buffer rubber of flanging bushing （φ8.5×φ14×1） 1224200-184000 ZT310－VX right storage box 4044201-607003 ZT310-VX Right storage box switch (Silver white matte 1224200-180000 ZT310-VX Front surrounding rear interior 1224200-185000 ZT310－VX left storage box...
  • Page 84 7、FRONT FORK COMPONENT Fig.24 FRONT FORK Right handlebar component COMPONENT PART NO. PART NAME CAUTION 1190100-409000 ZT310－VX Right rearview mirror 1100300-044000 Front disc brake main pump component(without handle) 1134100-032000 ZT250－R Right Hand Rocker (Machine) 1134200-023000 ZT250－R Balancing block 1244100-042000 ZT250－R Right hand rubber sleeve 1184200-145000 ZT310－X Second Generation Right Handlebar Switch 1250205-031091 GB70.1M6×30 (stainless steel) 10N.m...
  • Page 85 7、FRONT FORK COMPONENT Fig.25 FRONT FORK Left hand component COMPONENT PART NO. PART NAME CAUTION 1190100-408000 ZT310－VX left rear view mirror 1134200-011000 ZT310－V left hand rocker arm component 1184200-144000 ZT310－X Second Generation Left Handlebar Switch 1250205-031091 GB70.1M6×30 (stainless steel) 10N.m 1184200-141000 ZT310－X1 Left handlebar switch 1244100-041000 ZT250－R left hand rubber sleeve 1134200-023000 ZT250－R balance block...
  • Page 86 7、FRONT FORK COMPONENT Fig.26 FRONT FORK Direction handle&TFT Instrument COMPONENT PART NO. PART NAME CAUTION 1224100-025000 ZT250－SM8 bolt decorative buckle 1250205-023000 GB70.1 Hexagonal M8×35 1134200-005000 ZT310－R direction clamp 1134200-026000 ZT310－VX Direction 1250205-040095 GB70.1 inner hex bolt M8×16(color Zinc) 1274200-105000 ZT310－T left wiring bracket 1274200-106000 ZT310－T right wiring bracket PROCEDURE: ●Directional components...
  • Page 87 7、FRONT FORK COMPONENT Fig.27 FRONT FORK Front shock absorber, upper plate component COMPONENT PART NO. PART NAME CAUTION 1251300-045000 ZT250－S upper plate decorative nut (chrome plated) 1251500-050000 ZT250－S upper plate gasket φ18.5×φ39×1 1250205-023000 GB70.1 Hexagonal M8×35 (environmental color zinc) 25N.m ZT310－V front left shock absorption(improve) Includede reflective sheet...
  • Page 88 7、FRONT FORK COMPONENT Fig.28 FRONT FORK Uplink plate, direction handle block component COMPONENT PART NO. PART NAME CAUTION 1134200-019000 ZT310－V direction pad assembly 1274200-018000 ZT310－R upper plate gasket 1244200-008000 ZT310－R upper plate buffer rubber 1134200-004000 ZT310－R upper plate 1251700-065000 ZT310－R bushing φ10×φ12×41 1251300-057093 Non－standard nut M10×1.5 (Dacro) 40N.m PROCEDURE:...
  • Page 89 7、FRONT FORK COMPONENT Fig.29 FRONT FORK ABS brake system－1 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 Buff bushing cushioning rubber (φ8.5×φ14×1) 1224200-140000 ZT310－V hydraulic control unit protective cover 1224100-010000 ZT250－S expansion nail 1251300-063093 Plywood M6×11×15（color zinc）...
  • Page 90 7、FRONT FORK COMPONENT Fig.30 FRONT FORK ABS brake system－2 COMPONENT PART NO. PART NAME CAUTION 1251100-112000 Disc brake tubing bolt M10×1－22 32N.m 1251513-013000 Brake brake tubing copper washer φ15×φ10.2×1.5 1224100-037000 0 grade flame retardant cable tie (black 3.6×295) PROCEDURE: ●Front disc brake main pump Cut three straps ⑶...
  • Page 91 7、FRONT FORK COMPONENT Fig.31 FRONT FORK ABS brake system－3 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 wheel speed sensor 1251100-112000 Disc brake tubing bolt M10×1－22 32N.m 1251513-013000 Brake brake tubing copper washer φ15×φ10.2×1.5...
  • Page 92 7、FRONT FORK COMPONENT Fig.32 FRONT FORK ABS brake system－4 COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non－standard bolt M6×16 (304 stainless steel) 1251100-121093 Non－standard bolt M6×25 (environmental color) 1224100-037000 0 grade flame retardant cable tie (black 3.6×295) 1251513-013000 Brake brake tubing copper washer φ15×φ10.2×1.5 1251112-003093 M6×45 Hex flange surface 9.8 bolt (color zinc) 1274200-246000 ZT310－V rear disc brake main pump bracket PROCEDURE:...
  • Page 93 7、FRONT FORK COMPONENT Fig.33 FRONT FORK ABS brake system－5 COMPONENT PART NO. PART NAME CAUTION 1251100-061093 M6×22 hex flange face full thread bolt 1224100-037000 Grade 0 flame retardant tie (black 3.6×295) 1251100-123093 Non－standard bolt M8×25 (color zinc) 1251513-013000 Brake brake tubing copper washer φ15×φ10.2×1.5 1251100-112000 Disc brake tubing bolt M10×1－22 1250104-006097 GB16674M6×12 (chromed/HH) 1274200-119000 Single rocker rear flat fork tubing bracket...
  • Page 94 8、FUEL TANK COVER COMPONET Fig. 7 FUEL TANK Fuel tank trim cover assembly 4 COVER COMPONET 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 Buffer rubber of flanging bushing （φ8.5×φ14×1） 1224200-196000 ZT310－VX fuel tank decoration cover left grid 1251300-063093 Splint M6×11×15 ( color zinc) 1174200-052000 ZT310－VX front left turn signal 1251200-038093 Non－standard self－tapping screwST3.9×12(zine)
  • Page 95 8、FUEL TANK COVER COMPONET Fig. 8 FUEL TANK Fuel tank trim cover assembly 5 COVER COMPONET 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 Buffer rubber of flanging bushing （φ8.5×φ14×1） ZT310－VX left fuel tank decorative cover 1251300-063093 Splint M6×11×15 ( color zinc) 1224200-202000 Left fuel tank decorative cover bottom plate 1224200-200000 Right fuel tank decorative cover bottom plate...
  • Page 96 8、FUEL TANK COVER COMPONET Fig. 9 FUEL TANK Fuel tank assembly COVER COMPONET PART NO. PART NAME CAUTION 1250205-043093 Gb70.1m8×55 (environmental color) 1251900-028093 ZT250－R fuel tank flat pad φ9×φ37.5×2 1251500-081000 Non－Standard flat pad φ13×φ8.2×1.5 ( color zinc) 1244100-020000 ZT250－S fuel tank pressure rubber 1050954-027000 ZT310－V EFI high pressure tubing assembly 1274200-088000 ZT310 water pipe hoop (φ10.5) 1244200-095000 ZT310－V carbon canister adsorption tube (φ5×φ11)
  • Page 97 8、FUEL TANK COVER COMPONET Fig. 10 FUEL TANK Fuel tank decorative cover bracket COVER COMPONET PART NO. PART NAME CAUTION 1251100-101000 Non－Standard bolt m6×12 (304 stainless steel) 1274200-276000 ZT310－VX Fuel tank lower decorative cover bracket 1250303-010093 GB6177.1M6 ( color zinc) 4024200-095051 ZT310－VX left fuel tank decorative cover bracket 1240300-021000 HJ125－6 shroud glass strip (1.5m) 4024200-094051 ZT310-VX right fuel tank decorative cover bracket...
  • Page 98 8、FUEL TANK COVER COMPONET Fig. 11 FUEL TANK Oil pump COVER COMPONET PART NO. PART NAME CAUTION 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 Buffer rubber of flanging bushing （φ8.5×φ14×1） 1244200-083000 ZT310－V fuel tank cushion rubber 1250105-137093 Gb5789m6×16 (environmental color) 1050954-021000 T02 built－in fuel pump －ZT310v ZT310－V fuel tank...
  • Page 99 9、SIDE COVER COMPONENT Fig.1 SIDE COVER SIDE COVER COMPONENT COMPONENT PART NO. PART NAME CAUTION 1224100-010000 ZT250-S Expansion nail 1244100-061000 ZT250 anti-water rubber of frame 1250105-018091 GB5789 M8×70（white zinc） 4044201-256051 ZT310－V Bumper decorative ball（Dark gray matte） ZT310－V Right side cover ZT310－V Left side cover PROCEDURE: ●Side cover...
  • Page 100 10、GUARD BAR COMPONENT Fig.1 GUARD BAR Guard bar assembly 1 COMPONENT PART NO. PART NAME CAUTION 1244100-061000 ZT250 anti-water rubber of frame 1250105-018091 GB5789 M8×70（white zinc） 1251700-058093 Flanging bushing φ8.2×φ11×4.5＋φ16×1.5 1240300-071000 Flanging bushing rubber （φ11×φ16×1） 4044201-256051 ZT310－V Bumper decorative ball（Dark gray matte） 1224100-037000 0 grade flame retardant cable tie (black 3.6×295) 1250201-032093 GB818M5×16 (environmental color) 1184200-177000 ZT310 electric jet ignition coil...
  • Page 101 10、GUARD BAR COMPONENT Fig.2 GUARD BAR Guard bar assembly 2 COMPONENT PART NO. PART NAME CAUTION 1251300-057093 non-standard nuts M10×1.5 (color zinc) 1251100-082093 non-standard bolt M10×1.5×20 1251100-132003 non-standard bolt M10×1.5×80 1251100-137000 non-standard boltM10×1.5×100 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color zinc) 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) after 2021 1224200-003000 ZT310－R Rear disc brake pipe clamp...
  • Page 102 10、GUARD BAR COMPONENT Fig.3 GUARD BAR Guard bar assembly 3 COMPONENT PART NO. PART NAME CAUTION ZT310－V Left bumper assembly 1244100-089000 ZT250-R guard bar anti-drop glue (outside association) 1251100-083094 Non-standard bolt M10×1.5×50 (black zinc) 1244100-061000 ZT250 anti-water rubber of frame 1251100-101000 non-standard bolt M6×12 (304 stainless steel) 1274200-037000 ZT310－R support of disc brake lock 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color zinc)
  • Page 103 10、GUARD BAR COMPONENT Fig.4 GUARD BAR Engine decorative cover components COMPONENT PART NO. PART NAME CAUTION 1251300-063093 Plywood M6×11×15（color zinc） Engine decorative cover left front Engine decorative cover left back Engine decorative cover right front Engine decorative cover right back PROCEDURE: ●Left engine decorative cover assembly 1.Remove the two nuts ⑴...
  • Page 104 11、REAR COVER COMPONENT Fig.1 REAR COVER ZT310 battery assembly COMPONENT PART NO. PART NAME CAUTION 1244200-111000 ZT310 Gel Battery Bands 1184200-099000 ZT310 colloid battery (6-FM-10/10Ah) 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 12±1.5N.m 1274100-057095 Flanging bushing φ6.2×φ8.5×3.5＋φ14×1.5 1244100-052000 Buffer rubber of flanging bushing (φ8.5×φ14×1) 4044201-467051 ZT310-VX battery bottom cover (dark gray matte) 1251112-001093 M6×16 hexagon flange bolts 12±1.5N.m...
  • Page 105 11、REAR COVER COMPONENT Fig.2 REAR COVER Backrest assembly componen COMPONENT PART NO. PART NAME CAUTION 1250205-040095 GB70.1 inner hex bolt M8×16（color Zinc） 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1244200-062100 ZT310－V rear backrest rubber 1244200-005000 ZT310－R buffer rubber of head cover 1274200-146000 ZT310－V rear backrest rubber holder ZT310－V rear backrest 4044201-257051 ZT310－V rear decoration cover front cover...
  • Page 106 11、REAR COVER COMPONENT Fig.3 REAR COVER Tail skirt taillight component 1 COMPONENT PART NO. PART NAME CAUTION 1184200-016000 ZT310 PKE Buzzer 1184200-053000 ZT310PKE external single antenna PROCEDURE: ●Buzzer Find the connector of the buzzer ⑴ close to the side cover on the front left side of the rear cover, and press the card of the white plug to remove the plug.Move the buzzer after back and forth with a hot air gun or hair dryer with heat.
  • Page 107 11、REAR COVER COMPONENT Fig.4 REAR COVER Tail skirt taillight component 2 COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non-standard bolt M6×16（304 stainless steel） 1274100-057095 Flanging bushing φ6.2×φ8.5×3.5＋φ14×1.5 1244100-052000 Buffer rubber of flanging bushing （φ8.5×φ14×1） 1274200-138000 ZT310-V Rear cover trim cover holder ZT310－V Rear cover left trim cover ZT310－V Rear cover right trim cover 1250502-010093 GB96.1φ6（color zinc）...
  • Page 108 11、REAR COVER COMPONENT Fig.5 REAR COVER Tail skirt taillight component 3 COMPONENT PART NO. PART NAME CAUTION 1250105-142093 GB5789M8×20（color zinc） 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) ZT310-V rear aluminimum holder 4044201-255051 ZT310-V PKE cover (dark grey) 1250205-040095 GB70.1 inner hex bolt M8×16(color Zinc) 1251700-058093 Flanging bushing φ8.2×φ11×4.5＋φ16×1.5 1240300-071000 Flanging bushing rubber （φ11×φ16×1）...
  • Page 109 11、REAR COVER COMPONENT Fig.6 REAR COVER Tail skirt taillight component 4 COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non-standard bolt M6×16（304 stainless steel） 1274100-057095 Flanging bushing φ6.2×φ8.5×3.5＋φ14×1.5 1244100-052000 Buffer rubber of flanging bushing （φ8.5×φ14×1） 1174200-029000 ZT310-V Stop light 1174200-027000 ZT310-V rear left light 4044201-252051 ZT310-V rear cover dark grey 1174200-028000 ZT310-V rear right light 1251300-063093 Plywood M6×11×15（color zinc）...
  • Page 110 ●Cushion rubber and belt, purchased separately If the cushion rubber aging or excessive wear of the belt can be purchased on the Zontes official website. The corresponding installation position is shown in the lower left figure.
  • Page 111 13、MUFFLER COMPONENT Fig.1 MUFFLER LSF oxygen sensor COMPONENT PART NO. PART NAME CAUTION 1224100-037000 0 grade flame retardant cable tie (black 3.6×295) 1251112-005093 M6×45 Hex flange surface 9.8 bolt (color zinc) 10N.m 1251100-135000 Non－standard bolt M10×1.5×95(Dacromet) 1251300-057093 Non－standard nut M10×1.5(dacromet) 65±5N.m ZT310－V muffler left anti－hot plate 1224200-008000 ZT310－R cable plastic staple...
  • Page 112 13、MUFFLER COMPONENT Fig.2 MUFFLER Muffler component 1 COMPONENT PART NO. PART NAME CAUTION 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color zinc) 1251100-261000 Non－standard boltM10×1.5×127(Dacromet) 1251300-057093 Non－standard nut M10×1.5(dacromet) 65±5N.m 1251100-137000 Non－standard boltM10×1.5×100(Dacromet) 1251112-002093 M6×30 Hexagon flange bolts (color zinc) 1251112-003093 M6×45 Hex flange surface 9.8 bolt (color zinc) PROCEDURE: ●Muffler assembly...
  • Page 113 13、MUFFLER COMPONENT Fig.3MUFFLER Muffler component 2 COMPONENT PART NO. PART NAME CAUTION 1251300-058093 Hexagonal nut M8(color zinc) 1020241-094000 ZT250－S muffler flange 1250205-023000 GB70.1 inner hexagonal M8X35 (environmental color) GB6177.1M8(color zinc) 1250303-011093 1250105-143093 GB5789M8×35 (environmental color) 1070100-133000 ZT250－S engine exhaust outlet seal 1274100-068095 ZT310 Muffler flanging bushing 1241200-045000 KD150－U muffler suspension cushioning rubber ZT310－VX rear shock absorber lower bracket right...
  • Page 114 13、MUFFLER COMPONENT Fig.4MUFFLER Muffler component 3 COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1274100-018000 ZT250－S anti-hot plate sleeve, muffler 1244100-017000 ZT250－S muffler hot plate rubber buffer 1270300-201000 Stainless steel asbestos mat 6×20×1.6 ZT310－VX muffler decorative cover ZT310－V1 muffler PROCEDURE: ●Decorative cover...
  • Page 115 14、LOWER SHROUD COMPONENT Fig.1 LOWER SHROUD Lower shroud component-1 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 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1274100-057095 Flanged bush φ6.2×φ8.4×3.5＋φ14×1.5 1244100-052000 Buffer rubber of flanging bushing （φ8.5×φ14×1）...
  • Page 116 14、LOWER SHROUD COMPONENT Fig.2 LOWER SHROUD Lower shroud component 2 COMPONENT PART NO. PART NAME CAUTION ZT310－V Left support of lower wind deflector 1224200-108000 ZT310－V middle part of lower wind deflector ZT310－V Right support of lower wind deflector 1251300-063093 Plywood M6×11×15 (environmental color) PROCEDURE: ●Lower shroud assembly Remove the splint nut ⑷...

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Zt310-vx euro v

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