Zontes ZT350-T EURO V 2022 Service Manual
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Zontes ZT350-T EURO V 2022 Service Manual

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ZT350-T(EURO V)
Service manual
2022/08/05

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Summary of Contents for Zontes ZT350-T EURO V 2022

  • Page 1 ZT350-T(EURO V) Service manual 2022/08/05...

  • Page 2: Table Of Contents

    Contents Table of Contents Pages Table of Contents……………………………………………………………………………………………………………………………………………………………………………………………… 1 1-FRAME&ELECTRONIC COMPONENT Electrical device component-1………………………………………………………………………………………………………………………………………………………………………………… Disassemlbe the main harness and ECU Electrical device component-2………………………………………………………………………………………………………………………………………………………………………………… 10 Horn,shut down switch and ignition coil Frame plastic parts……………………………………………………………………………………………………………………………………………………………………………………………… 11 Remove the Fuel tank liner limit glue,battery cushion,side cover cushion and buckle Directional column component…………………………………………………………………………………………………………………………………………………………………………………...
  • Page 3 Contents Table of Contents Pages Sprocket assembly 1…………………………………………………………………………………………………………………………………………………………………………………………… 21 Rear auxiliary mud plate assembly;Sprocket assembly;Chain Sprocket assembly 2…………………………………………………………………………………………………………………………………………………………………………………………… 22 Sprocket assembly;Sprocket Rear wheel component………………………………………………………………………………………………………………………………………………………………………………………… 23 Rear wheel assembly;Tire and rim assembly;Maintenance Rear axle assembly…………………………………………………………………………………………………………………………………………………………………………………………… Rear axle outer assembly;Rear axle assembly Rear sub-mud assembly ………………………………………………………………………………………………………………………………………………………………………………………...
  • Page 4 Contents Table of Contents Pages Replace the rear brake pads（Double rocker arm）…………………………………………………………………………………………………………………………………………………………… 39 5.10 Rear brake main pump adds brake fluid……………………………………………………………………………………………………………………………………………………………………… PEDAL COMPONENT Shift lever adjustment………………………………………………………………………………………………………………………………………………………………………………………… Adjust the height of gear shift rod and shift lever position adjustment Right footrest component 1…………………………………………………………………………………………………………………………………………………………………………………… Right footrest component 2……………………………………………………………………………………………………………………………………………………………………………………...
  • Page 5 Contents Table of Contents Pages Oil cooler component 2………………………………………………………………………………………………………………………………………………………………………………………… 57 Oil cooler bracket FRONT FORK COMPONENT Throttle/clutch cable clearance adjustmene…………………………………………………………………………………………………………………………………………………………………… Adjust the free travel of throttle wire and clutch zipper ;Light height adjustment Replacement clutch cable……………………………………………………………………………………………………………………………………………………………………………………… 59 Replace the throttle cable……………………………………………………………………………………………………………………………………………………………………………………… 60 Remove the throttle cable,install the throttle cable and right handlebar switch Steering adjustment……………………………………………………………………………………………………………………………………………………………………………………………...
  • Page 6 Contents Table of Contents Pages 8.18 Front mudboard component 1(spoke wheel)…………………………………………………………………………………………………………………………………………………………………… 75 Wheel speed sensor;Front mudboard water baffle;Oil outlet pipe support;Reflector 8.19 Front mudboard component 2(spoke wheel)）………………………………………………………………………………………………………………………………………………………………… 76 The front and left sides of the front mud plate 8.20 Front mudboard component（Aluminum）…………………………………………………………………………………………………………………………………………………………………… 77 Front wheel speed sensor;Front disc brake caliper;Front mud board component 8.21 Hand guard component…………………………………………………………………………………………………………………………………………………………………………………………...
  • Page 7 Contents Table of Contents Pages Fuel tank assembly component 1……………………………………………………………………………………………………………………………………………………………………………… Disassemble oil tank cover assembly Fuel tank assembly component 2……………………………………………………………………………………………………………………………………………………………………………… Disassemble oil tank assembly Tank liner component………………………………………………………………………………………………………………………………………………………………………………………… Fuel pump;Fuel tank cap;Adhesive strip;Side cover round glue SIDE COVER COMPONENT 10.1 Side cover component 1………………………………………………………………………………………………………………………………………………………………………………………… 96 Remove the left cover assembly 10.2 Side cover component 2…………………………………………………………………………………………………………………………………………………………………………………………...
  • Page 8 Contents Table of Contents Pages 12.9 PKE component ……………………………………………………………………………………………………………………………………………………………………………………………… 107 Remove induction antenna and PKE 12.10 Electrical device box component 1 …………………………………………………………………………………………………………………………………………………………………………… 108 Remove battery support 12.11 Electrical device box component 2…………………………………………………………………………………………………………………………………………………………………………… Electrical component box assembly;Charging port base;Charging port bracket CUSHION COMPONENT 13.1 Cushion…………………………………………………………………………………………………………………………………………………………………………………………………………...
  • Page 9 Contents Table of Contents Pages All the information, illustrations and photographs collected in this manual are compiled according to the latest products. However, there may be some inconsistencies between your motorcycle and this manual due to the continuous improvement of the product and other changes. ©Guangdong Tayo Motorcycle Technolog Co.

  • Page 10: 1-Frame&Electronic Component

    1-FRAME&ELECTRONIC COMPONENT Fig.1 FRAME&ELECTRONIC Electronic parts component 1 COMPONENT PART NO. PART NAME CAUTION 1184300-009000 ZT350-T wiring harness assembly-A 1224300-093000 Reverse buckle Velcro strap (20×150mm) 1224300-110000 Reverse buckle Velcro strap (20×200mm) 1224300-111000 Reverse buckle Velcro strap (20×300mm) 1224100-037000 Grade 0 flame retardant tie (black 3.6×295) MSE6.0 controller - ZT184MP (matching split sensor / 1050958-014000 Bosch EFI...

  • Page 11: Electrical Device Component-2

    1-FRAME&ELECTRONIC COMPONENT Fig.2 FRAME&ELECTRONIC Electronic parts component 2 COMPONENT PART NO. PART NAME CAUTION 1250105-138093 GB5789M6×20 (environmental color) 1100100-820000 ZT350-R brake hose RC-HU section（A） 1184200-004000 ZT310 horn 1184300-038000 ZT350-T speaker (19-inch dedicated) 1274300-065000 ZT350-VX front oil outlet pipe bracket 1251112-001093 M6×16 Hexagon flange bolts (color Zinc) 1250205-040095 GB70.1 inner hex bolt M8×16(color Zinc) 1184100-012000 ZT250-S shut down switch 1274100-095000 ZT250-S Flameout switch wire fixing bracket...

  • Page 12: Frame Plastic Parts

    1-FRAME&ELECTRONIC COMPONENT Fig.3 FRAME&ELECTRONIC Frame plastic parts COMPONENT PART NO. PART NAME CAUTION 1244100-019000 ZT250-S fuel tank spacing glue 1240300-007000 HJ125-6 Battery rubber gasket 1244100-002000 ZT250-S Side cover round rubber 1244100-061000 ZT250 anti-water rubber of frame 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1274300-025000 ZT350-R water tank water inlet fixing bracket 1224300-086000 ZT350-R right wire harness holder 1244100-052000 Buffer rubber of flanging bushing (φ8.5×φ14×1)

  • Page 13: Directional Column Component

    ●Please check whether the steel beads of the conjoined body have abnormal phenomena such as partial Remove the shaft ring ⑸ and the steel ball⑹. abrasion and rust.If YES, please buy the regular accessories on ZONTES official website, if not, please Remove the steel ball⑺ of the down connected plate component⑻.

  • Page 14: Frame, Side Bracket

    1-FRAME&ELECTRONIC COMPONENT Fig.5 FRAME&ELECTRONIC Frame, Side support COMPONENT PART NO. PART NAME CAUTION ZT350-T frame aftermarket assembly (including seat 4014300-013000 ring/310M nameplate) 1130900-026000 ZT250－S upper steel bowl After-sales 1134300-001000 ZT350-R lower seat ring After-sales 1264100-001000 ZT250－S side stand spring 1271200-165000 ZT310－T side bracket (short / dark gray) 1251100-088094 Non-standard bolt M10×1.5×43(dacromet) 1251300-057093 Non-standard nut M10×1.5(dacromet) 45±5N.m...

  • Page 15: Frame & Engine Combination 2.1 Engine Component

    2-FRAME & ENGINE COMPONENT Fig.1 FRAME & ENGINE Engine combination COMPONENT PART NO. PART NAME CAUTION 1251112-003093 M6×45 Hex flange surface 9.8 bolt (color Zinc) 10N.m 4050854-002051 ZT310-R engine left rear cover (dark gray) 1251300-057093 Non-standard nut M10×1.5(Dacromet) 65±5N.m 1274300-082000 ZT350-R engine hanger 1251100-060000 Non-standard bolts M10X1.5X90 (Dacromet) GB5187 non-standard bolt M12×1.25×85(10.9 1251112-019000...

  • Page 16: Carbon Tank Componen

    3-INTAKE SYSTEM COMPONENT Fig.1 INDUCTION Maintain the filter element of the air filter SYSTEM COMPONENT PART NO. PART NAME CAUTION 1250303-010093 GB6177.1M6（color zinc） 1274300-038000 ZT350－R electromagnetic valve bracket 1050954-009000 YH Carbon tank electromagnetic valve ZT44 Throttle Valve Decoupling Rubber Tube 1244200-117000 (Φ6×Φ10×L420+Φ9 pipe clamp ×2) 1050958-015000 Non-standard bolt M6×12 (304 stainless steel)

  • Page 17: The Air Filter Assembly

    3-INTAKE SYSTEM COMPONENT Fig.2 INDUCTION The air filter assembly SYSTEM COMPONENT PART NO. PART NAME CAUTION 1224300-002000 ZT350－T Air filter 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1251300-063093 Plywood M6×11×15（Environmental protection） 1251100-061093 M6×22 Hexagon flange bolt（color zinc） 1051371-002000 Φ59×9 pipe clamp assembly 1224300-110000 Reverse buckle Velcro strap (20×200mm) PROCEDURE: Press the clip pointed by arrow A, B and D, pull out the connectors of external intake pressure sensor and...

  • Page 18: Throttle Valve Body Component

    3-INTAKE SYSTEM COMPONENT Fig.3 INDUCTION Throttle valve body component SYSTEM COMPONENT PART NO. PART NAME CAUTION 1051454-016000 45×2.5 Fluorine rubber O-ring 1050958-003000 ZT184 MP Intake pipe assembly 1051354-004000 Φ56×10 Hoop assembly 1050958-001000 ZT44 Throttle body part component (position sensor) 1050954-023000 EV14 Fuel injectorG48 1050970-002000 ZT1P72MN injector holder 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color Zinc) GB9074.13 Hexagon cross groove spring,flat cushion...

  • Page 19: Replace Air Filter Element

    3-INTAKE SYSTEM COMPONENT Fig.4 INDUCTION Replace air filter element SYSTEM COMPONENT PART NO. PART NAME CAUTION 4134300-003000 ZT350－Tair filter core (with carton packaging) 1224300-110000 Reverse buckle Velcro strap (20×200mm) ROCEDURE: ●Filter element If you need to maintain the filter element of the air filter, remove the seat cushion, the right side cover Take the standard part ①...

  • Page 20: Single Rocker Component

    4-SINGLE ROCKER 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 Remove the bolt ⑴...

  • Page 21: Sprocket Baffle

    4-SINGLE ROCKER 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 Gum cushion, bush（φ8.5×φ14×1） ZT310-R1 sprocket baffle PROCEDURE： ●Sprocket baffle Remove the bolt ⑴ with 4# hexagon socket, remove the flanging bushing ⑵ and buffer rubber ⑶; Finally, remove the sprocket baffle ⑷.

  • Page 22: Sprocket Assembly 1

    4-SINGLE ROCKER 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 1080200-055000 ZT250－R 114 chain（CHOHO520HX/Open type）...

  • Page 23: Sprocket Assembly 2

    4-SINGLE ROCKER COMPONENT Fig.4 Rear wheel, swinging Sprocket assembly 2 arm component PART NO. PART NAME CAUTION 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) 1080100-112000 ZT250－T1 520－43T sprocket 1251100-190000 Non standard bolt M10×1.5×30（color zinc）...

  • Page 24: Rear Wheel Component

    4-SINGLE ROCKER COMPONENT Fig.5 Rear wheel, swinging Rear wheel component arm component PART NO. PART NAME CAUTION 1251300-071000 Non standard nut M12×1.5（chromed） 110N.m 1230100-567000 160/60ZR17 CM－A1S 69W TL E4 ZT350-GK1 single rocker arm rear aluminum wheel 1094300-008000 (MT4.5×17/black) 1260100-238000 ZT310-R1 rear wheel rim sign spring 1210142-000100 ZT310-R1 single rocker black rim sign 1184300-034000 ZT350 tire pressure sensor (M8 straight head) PROCEDURE：...

  • Page 25: Rear Axle Assembly

    4-SINGLE ROCKER COMPONENT Fig.6 Rear wheel, swinging Rear axle assembly arm component PART NO. PART NAME CAUTION 1181200-118000 Wheel speed sensor(A) 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1251100-123093 Non-standard bolt M8×25 (color Zinc) 1250104-006097 GB16674M6×12 (chromed/HH) 1274200-119000 Single rocker rear flat fork tubing bracket 1224300-110000 Reverse buckle Velcro strap (20×200mm) 1251100-117093 Non-standard inner hex bolt M8×25 (color Zinc) 1274200-058000 ABS induction ring (60 teeth)

  • Page 26: Rear Sub-Mud Assembly

    4-SINGLE ROCKER COMPONENT Fig.7 Rear wheel, swinging Rear sub-mud assembly arm component PART NO. PART NAME CAUTION 1250105-137093 GB5789M6×16 (environmental color) 1250501-007093 GB93 φ8 (environmental color) 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) ZT310-R1 rear sub-mud aluminum alloy bracket 1020242-265021 (homemade) 1274100-057095 Flanging bushing φ6.2×φ8.4×3.5＋φ14×1.5 1244100-052000 Buffer rubber of flanging bushing (φ8.5×φ14×1)

  • Page 27: Chain Adjuster Assembly

    4-SINGLE ROCKER COMPONENT Fig.8 Rear wheel, swinging Chain adjuster assembly arm component 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) ZT350 single rocker arm rear disc brake adapter 4024300-010000 plate (self-made/dark gray matte) 1251100-204000 Non-standard bolt M16×1.5×50 (environmental color)

  • Page 28: Rear Mud Board

    4-SINGLE ROCKER COMPONENT Fig.9 Rear wheel, swinging Rear mud board arm component 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 Cuff bushing cushioning rubber (φ8.5×φ14×1) 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1210342-424000 ZT310 rear mud board decal (RACING) 1224300-087000 ZT350-R1 rear inner mud plate 1210343-056000 ZT350-GK chain decal PROCEDURE：...

  • Page 29: Rear Shock Absorber

    4-SINGLE ROCKER COMPONENT Fig.10 Rear wheel, Rear shock absorber swinging arm component PART NO. PART NAME CAUTION GB5187 non-standard bolt M12×1.25×85(10.9 1251112-019000 garde/dacromet) 1250305-009091 GB6187.1 M12×1.25(White Zinc) 1114300-007000 ZT350-R1 rear shock absorber 1251100-132003 Non-standard bolt M10×1.5×80 (Dacromet) 1251300-057093 Non-standard nut M10×1.5(Dacromet) 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 30: Rear Wheel Assembly

    4-SINGLE ROCKER COMPONENT Fig.11 Rear wheel, Rear wheel assembly swinging arm component PART NO. PART NAME CAUTION 1252200-040000 ZT310-R1 rear flat fork hollow shaft Φ20×315 1251300-067000 ZT250-R rear wheel hollow shaft nut 110±5N.m ZT310 single rocker arm aluminum alloy flat fork right 1244200-085000 dustproof rubber plug ZT310 single rocker arm aluminum alloy flat fork left...

  • Page 31: Change Rear Brake Arresters

    4-SINGLE ROCKER COMPONENT Fig.12 Rear wheel, Change rear brake arresters swinging arm component PART NO. PART NAME CAUTION 1100100-092000 ZT250－S rear disc brake arrester(HS10) After-sale PROCEDURE： ●Disassemble disc brake arrester Loosen the upper sliding shaft ① with a 14# sleeve. Loosen the lower sliding shaft ②...

  • Page 32: Rear Mud Board

    5-DOUBLE ROCKER COMPONENT Fig.1 REAR WHELL Rear mud board COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non-standard bolt M6×16（304 stainless steel） 1224200-003000 ZT310-R Rear disc brake pipe clamp 1224100-044000 Wheel speed sensor clamp 1100100-820000 ZT350-R brake hose RC-HU section（A） 1181200-118000 Wheel speed sensor(A) Flanging bushing φ6.4×φ9×8＋φ18×2(environmental 1251700-059093 color)

  • Page 33: Double Rocker Component

    5-DOUBLE ROCKER COMPONENT Fig.2 REAR WHELL Rear shock absorption COMPONENT PART NO. PART NAME CAUTION GB5787 Non－standard bolt M12×1.25×105((10.9 1251112-017000 grade/dacromet/Two diameters) 1250501-016000 GB93φ12 spring pad 1251500-001097 Non-standard flat pad φ12×φ20×2 (chrome plated) 1114300-011000 ZT350-T rear shock absorber 1250305-009091 GB6187.1 M12×1.25（White zinc） GB578 Non－standard bolt M12×1.25×85((10.9 1251112-019000 grade/dacromet)

  • Page 34: Rear Wheel Component

    5-DOUBLE ROCKER COMPONENT Fig.3 REAR WHELL Rear wheel component 1 COMPONENT PART NO. PART NAME CAUTION 1251100-105000 ZT310－R chain adjuster bolt M10×70 1251300-050000 ZT310－R chain adjuster bolt M10(304 stainless steel) 1251300-087000 ZT350 rear wheel hollow shaft nut(M25) 110N.m 1274300-015051 ZT350 R, chain adjuster(dark gray) 1250401-019091 GB91 Split pin Φ4×40 1094300-010000 ZT350 rear wheel hollow shaft Φ25×278 1274300-014051 ZT350 L, chain adjuster(dark gray)

  • Page 35: Rear Wheel Component

    5-DOUBLE ROCKER COMPONENT Fig.4 REAR WHELL Rear wheel component 2(aluminum） COMPONENT PART NO. PART NAME CAUTION ZT350－GK rear wheel right sleeve(φ25×φ30× 1274300-011000 15.5/shoulder φ38) 1244300-002000 ZT350－GK rear sprocket buffer adhesive 1250305-002091 GB6187.1 M8(White zinc) 24N.m 1094300-015000 ZT350－GK rear sprocket seat 1080100-121000 ZT350－GK 520－44T Sprocket Non-standard inner hex bolt M8×25 (environmental 1251100-117093...

  • Page 36: Rear Wheel Component

    5-DOUBLE ROCKER COMPONENT Fig.5 REAR WHELL Rear wheel component 3(aluminum） COMPONENT PART NO. PART NAME CAUTION 1230100-567000 160/60ZR17 CM－A1S 69W TL E4 1094300-006000 ZT350-GK rear aluminum wheel (MT4.5×17\black) 1100100-784000 ZT350－GK rear brake disc (265×4.5) 1274200-058000 ABS induction ring (60 teeth) Non-standard inner hex bolt M8×25 (environmental 1251100-117093 22～24N.m...

  • Page 37: Rear Wheel Component 4 (Spoke Wheel)

    5-DOUBLE ROCKER COMPONENT Fig.6 REAR WHELL Rear wheel component 4 (spoke wheel) COMPONENT PART NO. PART NAME CAUTION ZT350－GK rear wheel right sleeve(φ25×φ30× 1274300-011000 15.5/shoulder φ38) 1244300-002000 ZT350－GK rear sprocket buffer adhesive 1250305-002091 GB6187.1 M8(White zinc) 24N.m 1094300-015000 ZT350－GK rear sprocket seat 1080100-121000 ZT350－GK 520－44T Sprocket 1251100-117093 Non-standard inner hex bolt M8×25 (environmental color)

  • Page 38: Rear Wheel Component 5 (Spoke Wheel)

    5-DOUBLE ROCKER COMPONENT Fig.7 REAR WHELL Rear wheel component 5 (spoke wheel) COMPONENT PART NO. PART NAME CAUTION 1230100-567000 160/60ZR17 CM－A1S 69W TL E4 ZT350－T front spoke wheel MT4.5×17 1100100-784000 ZT350－GK rear brake disc (265×4.5) 1274200-058000 ABS induction ring (60 teeth) Non-standard inner hex bolt M8×25 (environmental 1251100-117093 22～24N.m...

  • Page 39: Rear Swinging Arm Component

    5-DOUBLE ROCKER COMPONENT Fig.8 REAR WHELL Rear swinging arm component COMPONENT （Double rocker arm） PART NO. PART NAME CAUTION 1252200-040000 ZT310-R1 rear flat fork hollow shaft Φ20×315 1251300-067000 ZT250－R rear wheel hollow shaft nut 110±5N.m 1080200-106000 ZT350－GK 112 pitch chain (520 oil seal chain) 1251300-050000 ZT310－R chain adjuster bolt M10(304 stainless steel) ZT310-R chain adjuster bolt M10×70 (304 stainless 1251100-105000...
  • Page 40 5-DOUBLE ROCKER COMPONENT Fig.9 REAR WHELL Replace the rear brake pads(Double rocker arm) COMPONENT PART NO. PART NAME CAUTION 1100100-092000 ZT250-S rear disk brake pads (HS10) After-sales PROCEDURE: ●Disassemble disc brake arrester Using strait screwdriver to disassemble nut①. Disassemble pin axle② with a 5# inner hexagon socket. Disassemble rolling axle③...
  • Page 41 5-DOUBLE ROCKER COMPONENT Fig.10 REAR WHELL Rear brake main pump adds brake fluid COMPONENT PART NO. PART NAME CAUTION 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) PROCEDURE: ●Add disc brake liquid Cover the right pedal bracket and muffler with a waterproof plastic bag to prevent the brake fluid from dripping onto the paint and causing corrosion.
  • Page 42 6-PEDAL COMPONENT Fig.1 FOOT PEDAL Shift lever adjustment COMPONENT PART NO. PART NAME CAUTION 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color zinc) 1271200-163000 ZT250－S Gear swift rod spline of Rocker arm 1250301-020093 GB6170M6 (environmental color) 1274300-026000 ZT350-R shift lever adjusting screw (Φ10×82.3) 1250301-018093 GB6170 M6-LH (army green) 4024300-029000 ZT350－R shift lever rocker arm (lucluding bearings)
  • Page 43 6-PEDAL COMPONENT Fig.2 FOOT PEDAL Right footrest component 1 COMPONENT PART NO. PART NAME CAUTION 1250205-023000 GB70.1 inner hexagonal M8×35 (color zinc) 1250205-034093 GB70.1 inner hexagonal M8×30 (color zinc) 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) ZT350-GK-H1 muffler suspension hollow cushioning 1244300-022000 rubber ZT350 muffer flanging bushing(φ8.3×φ11.5×20.5×φ...
  • Page 44 6-PEDAL COMPONENT Fig.3 FOOT PEDAL Right footrest component 2 COMPONENT 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) 1224300-023000 ZT350 rear brake main pump heat shield 1244300-039000 ZT350－R rear muffer silicone pad 1251112-001093 M6×16 Hexagon flange bolts (color zinc) 1100100-787000 ZT350－GK rear disc brake main pump assembly...
  • Page 45 6-PEDAL COMPONENT Fig.4 FOOT PEDAL Right footrest component 3 COMPONENT PART NO. PART NAME CAUTION GB70.3 M8×30 (10.9 grade environmental protection 1250205-124000 color) 1274300-027000 ZT350 pedal bearing cover 4024300-028000 ZT350－R pedal rocker arm(lncluding bearings) 1260100-303000 ZT350－R brake return spring 1274300-019000 ZT350 brake adjusting pedal 1251112-001093 M6×16 Hexagon flange bolts (color zinc) 1244100-002000 ZT250－S Side cover round rubber 1020443-011000 ZT350－R muffler anti－scalding...
  • Page 46 6-PEDAL COMPONENT Fig.5 FOOT PEDAL Right footrest component 4 COMPONENT PART NO. PART NAME CAUTION 4064300-021051 ZT350 right pedal support (HT/ dark gray matte) 1274300-033000 ZT350-R Pedal pin 1244100-052000 Buffer rubber of flanging bushing (φ8.5×φ14×1) 1264100-006000 ZT250－S Pedal circlip 1264100-004000 ZT250－S front right foot pedal torsional spring 4064300-010051 ZT350－GK R, front pedal component (dark gray matte) 4064300-012051...
  • Page 47 6-PEDAL COMPONENT Fig.6 FOOT PEDAL Left footrest component 1 COMPONENT PART NO. PART NAME CAUTION 1250205-034093 GB70.1 inner hexagonal M8×30(color zinc) 1250205-023000 GB70.1 inner hexagonal M8×35(color zinc) 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color zinc) 1184300-013000 ZT350 rectifier (350W) 1250205-124000 GB70.3 M8×30 (color zinc) 1274300-027000 ZT350 pedal bearing cover 4024300-029000...
  • Page 48 6-PEDAL COMPONENT Fig.7 FOOT PEDAL Left footrest component 2 COMPONENT PART NO. PART NAME CAUTION 1250303-010093 GB6177.1M6 (environmental protection color) 1271200-163000 ZT250－S shift lever spline rocker arm(dark gray) 1274100-042000 Miniature rod end ball bearing SAJK6C 1250301-020093 GB6170M6 (army green) 1274300-026000 ZT350 adjusting screw of gear shift lever 1250301-018093 GB6170 M6－LH (army green) 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color zinc) 1274100-043000 Miniature rod end ball bearing SALJK6C...
  • Page 49 6-PEDAL COMPONENT Fig.8 FOOT PEDAL Left footrest component 3 COMPONENT PART NO. PART NAME CAUTION 4064300-022051 ZT350 left pedal support (dark gray matte) 1274300-033000 ZT350-R Pedal pin 1244100-052000 Buffer rubber of flanging bushing (φ8.5×φ14×1) 1264100-006000 ZT250－S Pedal circlip 1264100-003000 ZT250－S front left foot pedal torsional spring 4064300-009051 ZT350-GK front left pedal assembly (dark gray matte) 4064300-011051 ZT350－GK L, rear foot pedal component 1260100-301000 ZT350－R foot pedal steel ball spring...
  • Page 50 7-COOLING SYSTEM COMPONENT Fig.1 COOLING SYSTEM Change engine oil COMPONENT PART NO. PART NAME CAUTION 1051161-012000 M24×2 oil filler plug 1244100-033000 Combined sealing gasket 12×φ20×2 1251100-066093 M12×1.5×15 ablassschraube (color zinc) 24±4N.m PROCEDURE: ●Drain oil Park the motorcycle with side stand on flat ground.Place holder to collect wasted engine oil under the oil drain bolt.
  • Page 51 7-COOLING SYSTEM COMPONENT Fig.2 COOLING SYSTEM Change engine oil filter COMPONENT PART NO. PART NAME CAUTION Non-standard cover type 9 degree nut M6×13 1251300-096000 12±1.5N.m (environmental color Zinc) 4050454-014051 ZT180MN fine filter cover A (dark gray) 1051454-020000 55×2.5 Hydrogenated nitrile rubber O-ring After-sale 1051454-005000 ZT180MN Oil filter sealing ring 4134300-001000...
  • Page 52 7-COOLING SYSTEM COMPONENT Fig.3 COOLING SYSTEM Add coolant COMPONENT PART NO. PART NAME CAUTION 1224300-019000 ZT350－R sub-water tank 1051954-016000 TOTAL antifreeze liquid (-35 ° C, 4L) 1340ml 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 53 7-COOLING SYSTEM COMPONENT Fig.4 COOLING SYSTEM Draining cooling liquid COMPONENT PART NO. PART NAME CAUTION 1251100-067093 M6×10 top pin bolt (color zinc) 12±1.5N.m 1051654-002000 Combination seal 6×13×1.8 PROCEDURE: ●Drain the cooling liquid Refer to the procedure of “Auxiliary water tank component” to empty the coolant in the auxiliary water tank. After placing the oil pan or other container under the right side of the vehicle, tilt the vehicle to the right.
  • Page 54 7-COOLING SYSTEM COMPONENT Fig.5 COOLING SYSTEM Water tank assembly 1 COMPONENT PART NO. PART NAME CAUTION 1274300-024000 ZT350-R right water tank 1244100-002000 ZT250－S Side cover round rubber 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color zinc) 1274200-089000 ZT310 water pipe clamp(φ22) 1244300-010000 ZT350-R auxiliary water tank connecting water pipe 1274200-079000 ZT310 water pipe clamp(φ9) 1244300-009000 ZT350-R water inlet connection water pipe...
  • Page 55 7-COOLING SYSTEM COMPONENT Fig.6 COOLING SYSTEM Water tank assembly 2 COMPONENT PART NO. PART NAME CAUTION 1274300-025000 ZT350-R water tank water inlet fixing bracket 1224300-020000 ZT350-R water tank filling port 1250104-006097 GB16674M6×12 (chromed/HH) 1274200-089000 ZT310 water pipe clamp（φ22） 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1244300-009000 ZT350－R water inlet connection water pipe PROCEDURE：...
  • Page 56 7-COOLING SYSTEM COMPONENT Fig.7 COOLING SYSTEM Water tank assembly 3 COMPONENT PART NO. PART NAME CAUTION 1274300-023000 ZT350-R left water tank 1244100-002000 ZT250－S Side cover round rubber 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color zinc) 1274200-090000 ZT310 water pipe clamp（φ26） 1244200-010000 ZT310－R water inlet pipe of left water tank 1244200-001000 ZT310－R water outlet pipe of engine 1274200-091000 ZT310 water pipe clamp（φ27）...
  • Page 57 7-COOLING SYSTEM COMPONENT Fig.8 COOLING SYSTEM Oil cooler component 1 COMPONENT PART NO. PART NAME CAUTION 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color zinc) 1251112-001093 M6×16 Hexagon flange bolts (color zinc) 1244300-007000 ZT350－GK oil outlet pipe of engine 1244300-008000 ZT350－GK oil inlet pipe of engine 1051454-025000 9.8×2.
  • Page 58 7-COOLING SYSTEM COMPONENT Fig.9 COOLING SYSTEM Oil cooler component 2 COMPONENT PART NO. PART NAME CAUTION 1251112-001093 M6×16 Hex flange bolt(environmental color zinc) 1274300-036000 ZT350－R upper bracket of oil cooler 1274300-037000 ZT350－R lower bracket of oil cooler PROCEDURE: ●Oil cooler bracket Using 8# sleeve remove three bolts⑴, and remove the upper bracket⑵...
  • Page 59 8-FRONT FORK COMPONENT Fig.1 FRONT FORK Throttle/clutch cable clearance adjustmen, COMPONENT light height adjustment PART NO. PART NAME CAUTION 1154300-004000 ZT350-X throttle refueling cable 1154300-005000 ZT350-X throttle return cable 1154300-007000 ZT350-X clutch cable 1244200-046000 ZT310-V clutch line sheath PROCEDURE: ●Throttle cable Fix the adjusting screw ②...
  • Page 60 8-FRONT FORK COMPONENT Fig.2 FRONT FORK Replacement clutch cable COMPONENT PART NO. PART NAME CAUTION 1154300-007000 ZT350-X clutch cable 1051354-008000 ZT180MN clutch cable bracket 1244200-046000 ZT310-V clutch line sheath 1224300-093000 Reverse buckle Velcro strap (20×150mm) PROCEDURE: ●Remove the cluch cable Use 14# an open-end wrench to loosen the nuts ②...
  • Page 61 8-FRONT FORK COMPONENT Fig.3 FRONT FORK Replace the throttle cable COMPONENT PART NO. PART NAME CAUTION 1224300-110000 Reverse buckle Velcro strap (20×200mm) 1154300-004000 ZT350-X throttle refueling cable 1154300-005000 ZT350-X throttle return cable 1274300-025000 ZT350-R water tank water inlet fixing bracket 1244100-042000 ZT250－R right handle bar rubber sleeve 1184200-140000 ZT310－X1 Right Handle Switch 1251100-219000 Cross ball screw M5×30...
  • Page 62 8-FRONT FORK COMPONENT Fig.4 FRONT FORK Steering adjustment COMPONENT PART NO. PART NAME CAUTION 1251300-088000 ZT350-R Upper connecting plate decorative nut M22×1 100N.m 1274200-018000 ZT310-R gasket of upper connecting board 1250205-023000 GB70.1 inner hexagonal M8×35 (color Zinc) 25N.m 1134100-007000 ZT250-S Adjusting nut locking washer ZT250-S direction column adjusting screw nut M24×1 1251300-046093 (environmental color Zinc)
  • Page 63 8-FRONT FORK COMPONENT Fig.5 FRONT FORK Add brake fluid, rocker adjustment COMPONENT PART NO. PART NAME CAUTION 1100100-833000 ZT350-GK front brake lever (machine addition) 1100100-831000 ZT350-GK front disc main pump assembly（φ14） 1251513-013000 Disc brake pipe copper washer φ 15× φ 10.2 × 1.5 1251100-112000 Disc brake pipe bolt M10×1-22 32N·m PROCEDURE:...
  • Page 64 8-FRONT FORK COMPONENT Fig.6 FRONT FORK Replace the front brake pads COMPONENT PART NO. PART NAME CAUTION 1100100-827000 ZT350-GK front radial caliper brake pad After-sales PROCEDURE: ●Replace the front brake pad Clamp the circlip ① with pointed nose pliers, pull it out and remove the two circlips. Remove the upper pin shaft ②...
  • Page 65 8-FRONT FORK COMPONENT Fig.7 FRONT FORK Windshield component 1 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 Buffer rubber of flanging bushing (φ8.5×φ14×1) 1224200-071000 ZT310-T windshield...
  • Page 66 8-FRONT FORK COMPONENT Fig.8 FRONT FORK Windshield component 2 COMPONENT PART NO. PART NAME CAUTION 1264100-006000 ZT250-S pedal circlip 1244200-048000 ZT310-T windshield left buffer rubber ZT310-X windshield lower pressing block rotating 1274200-030000 shaft 1244200-089000 ZT310-T windshield right buffer rubber 4024200-076051 ZT310-T windshield left bracket(dark gray matte) 4024200-077051 ZT310-T windshield right bracket(dark gray matte) 1224100-010000 ZT250-S swell nail 1224200-142000 ZT310-T1 hood middle decorative cover...
  • Page 67 8-FRONT FORK COMPONENT Fig.9 FRONT FORK Windshield motor component COMPONENT PART NO. PART NAME CAUTION 1244200-073000 ZT310-T windshield controller rubber sleeve 1186200-016000 ZT310T-M windshield motor controller(limited time) 1260100-218000 ZT310-T head cover 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...
  • Page 68 8-FRONT FORK COMPONENT Fig.10 FRONT FORK Head cover aluminum bracket, instrument component COMPONENT PART NO. PART NAME CAUTION 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1251112-001093 M6×16 Hexagon flange bolts (color zinc) 1224200-093000 ZT310-T head cover on rocker arm decorative block 1274200-136000 ZT310-T head cover upper rocker gasket 1250601-093000 6802 deep groove ball bearing 4024200-078051 ZT310－T Windshield Rocker (Dark Gray Matte)
  • Page 69 8-FRONT FORK COMPONENT Fig.11 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 ⑴ on the left and right sides of the connection between the front mud plate and the rear shell of the fuel tank trim cover with 4# inner hexagon.
  • Page 70 8-FRONT FORK COMPONENT Fig.12 FRONT FORK Front fender upper component 2 COMPONENT PART NO. PART NAME CAUTION 1251200-033093 Non-standard self-Tapping bolt ST4.2×12 ZT310-T front fender right decorative cover bottom 1224200-081000 plate 1224200-080000 ZT310-T front fender left cover bottom plate ZT310-T special black front fender 4044201-109051 ZT310-T dark gray front fender left decorative cover 4044201-110051 ZT310-T dark gray front fender right decorative cover 1251100-101000 Non-standard bolt M6×12 (304 stainless steel)
  • Page 71 8-FRONT FORK COMPONENT Fig.13 FRONT FORK Headlamp assembly 1 COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1270300-273000 φ8 clip(L=73) 1274100-007000 ZT250-S flanging sleeve（φ6.4×φ9×6＋φ20×2） 1244100-004000 ZT250－S Flanging bushing buffer 1251100-084093 Non-standard bolts M10×1.5×66(dacromet) 1251500-007091 Non-standard flat mat φ10.5×φ24×2（White zinc） 4024200-028000 ZT310-T guard bar mounting bracket 1251300-057093 Non-standard nut M10×1.5(dacromet) 65±5N.m...
  • Page 72 8-FRONT FORK COMPONENT Fig.14 FRONT FORK Headlamp assembly 2 COMPONENT PART NO. PART NAME CAUTION 1224100-010000 ZT250-S swell nail 1251300-063093 Plywood M6×11×15(color Zinc) 1020442-048000 ZT310-T headlight front trim cover 1244100-002000 ZT250－S Side cover round rubber 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1224200-075000 ZT310-T head cover right decorative cover 1224200-074000 ZT310-T head cover left cover PROCEDURE：...
  • Page 73 8-FRONT FORK COMPONENT Fig.15 FRONT FORK Headlamp assembly 3 COMPONENT PART NO. PART NAME CAUTION 1260100-215000 ZT310-T storage box cover rotating shaft limit circlip 1260100-159000 ZT310-T head cover debris box cover torsion spring 1274100-090000 ZT310T-M fuel tank outer cover rotating bracket shaft 1224300-081000 ZT350-T hood glove box cover 1224300-051000 ZT350-T hood glove box bottom 1260100-307000 ZT350-T hood glove box extension spring...
  • Page 74 8-FRONT FORK COMPONENT Fig.16 FRONT FORK Front wheel component (spoke wheel) COMPONENT PART NO. PART NAME CAUTION 1250205-023000 GB70.1 inner hexagonal M8×35 (color Zinc) 20N.m 1094100-063000 ZT310 front wheel hollow shaft Φ20×243 ZT350-GK front wheel bushing (φ20×φ28× 1274300-008000 15.5/shoulder outer diameterφ34) 1274300-007000 ZT350-GK ABS induction ring gear (60 teeth) 1100100-783000 ZT350-GK front brake disc (320×5.0) 1251100-117093 Non-standard inner hex bolt M8×25 (color Zinc)
  • Page 75 8-FRONT FORK COMPONENT Fig.17 FRONT FORK Front wheel component( aluminum) COMPONENT PART NO. PART NAME CAUTION 1250205-023000 GB70.1 inner hexagonal M8×35 (color Zinc) 25N.m 1094100-063000 ZT650 front wheel hollow shaft Φ20×243 ZT350-GK front wheel bushing (φ20×φ28× 1274300-008000 15.5/shoulder outer diameterφ34) 1274300-007000 ZT350-GK ABS induction ring gear (60 teeth) 1100100-783000 ZT350-GK front brake disc (320×5.0) 1251100-117093 Non-standard inner hex bolt M8×25 (color Zinc)
  • Page 76 8-FRONT FORK COMPONENT Fig.18 FRONT FORK Front mudboard component 1(spoke wheel) COMPONENT PART NO. PART NAME CAUTION 1251112-002093 M6×30 Hexagon flange bolts (color Zinc) 1174300-013000 Reflection light(KM-106) 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1244100-052000 Buffer rubber of flanging bushing (φ8.5×φ14×1) 1274100-057095 Flanging bushing φ6.2×φ8.4×3.5＋φ14×1.5 1274300-112000 ZT350－T front mudboard 1251100-101000 Non-standard bolt M6×12 (304 stainless steel)
  • Page 77 8-FRONT FORK COMPONENT Fig.19 FRONT FORK Front mudboard component 2(spoke wheel) 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 Buffer rubber of flanging bushing (φ8.5×φ14×1) ZT350-T front fender left part 1251300-063093 Plywood M6×11×15（color zinc）...
  • Page 78 8-FRONT FORK COMPONENT Fig.20 FRONT FORK Front mudboard component（Aluminum） COMPONENT PART NO. PART NAME CAUTION 1224100-044000 Wheel speed sensor clamp 1181200-118000 Wheel speed sensor(A) 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) GB70.1 Hexagon socket head bolt M10×1.5×60 (grade 1251100-303093 12.9 / environmental protection color Zinc) 1224300-093000 Reverse buckle Velcro strap (20×150mm) 1224200-066000 ZT310PKE External antenna mount 1274300-109000 ZT350-R Front oil outlet pipe clamp...
  • Page 79 8-FRONT FORK COMPONENT Fig.21 FRONT FORK Hand guard component COMPONENT PART NO. PART NAME CAUTION 1250205-085000 GB70.1M6×70 (stainless steel) 1134200-024051 ZT310－T aluminum alloy left hand guard (2020) 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) 1224200-203021 ZT310-T left hand windshield (2020 models) 1224200-199021 ZT310-T right hand windshield (2020 models) 1134200-025051 ZT310－T aluminum alloy right hand guard (2020)
  • Page 80 8-FRONT FORK COMPONENT Fig.22 FRONT FORK Left hand component COMPONENT PART NO. PART NAME CAUTION 1190100-408051 ZT310-VX left rearview mirror (dark gray) 1251100-198000 Non-standard hexagon socket bolt M6×13-φ8×20 1244200-046000 ZT310-V clutch line sheath 1184200-170000 ZT310-V clutch switch 1251300-073000 GB/T6185 hexagonal nylon lock nut M6 (color Zinc) ZT350-X second generation left auxiliary handle 1184300-017000 switch (dark gray TFT-750)
  • Page 81 Find and unplug the cable plugs of the right-hand handle switch ⑸ and the auxiliary handle switch ⑹. First remove the bolt ⑺ and remove the auxiliary switch ⑹. Pay attention to keep the "zontes" side of the front disc brake main pump ⑵ horizontal and upward to prevent air from entering the brake oil pipe and causing brake failure.
  • Page 82 8-FRONT FORK COMPONENT Fig.24 FRONT FORK Hand bar component COMPONENT PART NO. PART NAME CAUTION 4044102-002051 ZT250-S M8 bolt decorative buckle (matte gray ) 1250205-023000 GB70.1 inner hexagonal M8×35 (color Zinc) 1134200-031051 ZT310-R direction handle block (dark gray matte) 1134200-035051 ZT350-T direction handle (dark gray matte) 1251300-088000 Z T350-R Upper connecting plate decorative nut M22×1 1274200-018000 ZT310－R gasket of upper connecting board 1114300-012000 ZT350-V front left shock absorber...
  • Page 83 8-FRONT FORK COMPONENT Fig.25 FRONT FORK Uplink plate, handle bar component COMPONENT PART NO. PART NAME CAUTION ZT310-X direction handlebar pad M10×1.25(dark gray 4094200-007051 matte/spray paint) 1274200-018000 ZT310－R gasket of upper connecting board 25N.m 1244200-008000 ZT310－R buffer rubber of upper connecting board 4094300-001051 ZT350-R upper connection board (dark gray matte) 1251700-065000 ZT310-R bushing φ10×φ12×41 1250105-280000 GB5789 M10×1.25×60 (level 10.9 dacromet)
  • Page 84 8-FRONT FORK COMPONENT Fig.26 FRONT FORK ABS brake system-A 1 COMPONENT PART NO. PART NAME CAUTION 1251112-001093 M6×16 Hexagon flange bolts (color Zinc) 1250501-010000 GB93φ6 spring pad 1244100-004000 ZT250-S Flanging bushing buffer 1274100-007000 ZT250-S flanging sleeve(φ6.4×φ9×6＋φ20×2) 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1274300-071094 ZT350-R hydraulic control unit bracket PROCEDURE: ●Hydraulic control unit components...
  • Page 85 8-FRONT FORK COMPONENT Fig.27 FRONT FORK ABS brake system-A 2 COMPONENT PART NO. PART NAME CAUTION 1251100-112000 Disc brake pipe bolt M10×1-22 1251513-013000 Disc brake pipe copper washer φ 15× φ 10.2 × 1.5 1100100-831000 ZT350-GK front disc main pump assembly（φ14） PROCEDURE: ●Release brake fluid Referring to the previous steps of adding brake fluid, remove the upper cover, cover plate and sealant pad of the...
  • Page 86 8-FRONT FORK COMPONENT Fig.28 FRONT FORK ABS brake system-A 3 COMPONENT PART NO. PART NAME CAUTION 1244300-019000 Caliper exhaust screw rubber cap 1251100-308000 Disc brake exhaust screw M6 Disc brake oil pipe bolts M10×1×22 (with exhaust 1251100-307000 threaded holes) 1251513-013000 Disc brake pipe copper washer φ 15× φ 10.2 × 1.5 GB70.1 Hexagon socket head bolt M10×1.5×60 (grade 1251100-303093 12.9 / environmental protection color Zinc)
  • Page 87 8-FRONT FORK COMPONENT Fig.29 FRONT FORK ABS brake system-A 4（Double rocker arm） COMPONENT PART NO. PART NAME CAUTION 1251513-013000 Disc brake pipe copper washer φ 15× φ 10.2 × 1.5 1251112-001093 M6×16 Hexagon flange bolts (color zinc) 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1224200-003000 ZT310-R Rear disc brake pipe clamp 1224100-044000 Wheel speed sensor clamp...
  • Page 88 8-FRONT FORK COMPONENT Fig.30 FRONT FORK ABS brake system-A 4（Single rocker arm） COMPONENT PART NO. PART NAME CAUTION 1251100-123093 Non-standard bolt M8×25 (color Zinc) 1251513-013000 Disc brake pipe copper washer φ 15× φ 10.2 × 1.5 1251100-112000 Disc brake pipe bolt M10×1-22 1250104-006097 GB16674M6×12 (chromed/HH) 1274200-119000 Single rocker rear flat fork tubing bracket PROCEDURE:...
  • Page 89 9-FUEL TANK COMPONENT Fig. 1 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) 1224100-033000 ZT250-S thread cap of the fuel tank PROCEDURE： ●Middle cover component Press down the center of the expansion screw with a small cross screwdriver and remove the expansion screw ⑴...
  • Page 90 9-FUEL TANK COMPONENT Fig. 2 FUEL TANK Fuel tank lock,fuel tank cover component COMPONENT PART NO. PART NAME CAUTION ZT310-T fuel tank middle cover 1184200-002000 ZT310 electronic fuel tank lock ZT310-T fuel tank outer cover 1224100-014000 ZT250-S tank cover spinning damping 1274100-021000 ZT250-S tank cover rotating stents 1274100-090000 ZT250-S rotating axle of fuel tank outside cover 1260100-215000 ZT310-T storage box cover rotating shaft limit circlip...
  • Page 91 9-FUEL TANK COMPONENT Fig.3 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 Buffer rubber of flanging bushing (φ8.5×φ14×1) Non-standard flat pad φ13×φ8.2×1.5 (environmental 1251500-081000 color) Fuel tank left decorative cover 1224100-010000 ZT250-S expansion nail...
  • Page 92 9-FUEL TANK COMPONENT Fig.4 FUEL TANK Fuel tank trim cover rear shell component 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 Buffer rubber of flanging bushing （φ8.5×φ14×1） 1224300-084000 ZT350-R Left front harness holder 1184200-100000 ZT310 dual USB charging cable 1174200-004000 ZT310－R front left turning light 1251300-063093 Plywood M6×11×15（color zinc）...
  • Page 93 9-FUEL TANK COMPONENT Fig.5 FUEL TANK Fuel tank trim cover rear shell component 2 COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non-standard bolt M6×16（304 stainless steel） 1274100-057095 Flanging bushing φ6.2×φ8.4×3.5＋φ14×1.5 1244100-052000 Buffer rubber of flanging bushing （φ8.5×φ14×1） 1274100-018000 Anti-hot plate sleeve, muffler 1224300-083000 ZT350-R right front wire harness holder 1224200-066000 ZT310PKE External antenna mount 1251300-063093 Plywood M6×11×15（color zinc）...
  • Page 94 9-FUEL TANK COMPONENT Fig.6 FUEL TANK Fuel tank assembly component 1 COMPONENT PART NO. PART NAME CAUTION 1244100-004000 ZT250－S Flanging bushing buffer 1274100-007000 ZT250-S flanging sleeve（φ6.4×φ9×6＋φ20×2） 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1251300-063093 Plywood M6×11×15（color zinc） 1244100-002000 ZT250－S Side cover round rubber 1224200-066000 ZT310PKE External antenna mount 1184200-053000 ZT310PKE external single antenna PROCEDURE：...
  • Page 95 9-FUEL TANK COMPONENT Fig.7 FUEL TANK Fuel tank assembly component 2 COMPONENT PART NO. PART NAME CAUTION ZT310-T fuel tank left cover upper part 1251300-063093 Plywood M6×11×15(color Zinc) 1274100-057095 Flanging bushing φ6.2×φ8.4×3.5＋φ14×1.5 1244100-052000 Buffer rubber of flanging bushing (φ8.5×φ14×1) 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) ZT310-R lower part of left cover of fuel tank ZT310-T fuel tank right cover upper part ZT350-T fuel tank right cover lower part...
  • Page 96 9-FUEL TANK COMPONENT Fig. 8 FUEL TANK Tank liner component COMPONENT PART NO. PART NAME CAUTION 1250105-137093 GB5789M6×16 (environmental color) 1050958-013000 T02 built-in fuel pump (ZT350-T) 4034200-009000 ZT310-T fuel tank liner 1240300-021000 HJ125－6 pod glass strip （1.5m） 1244100-002000 ZT250－S Side cover round rubber 1224100-033000 ZT250－S thread cap of the fuel tank PROCEDURE：...
  • Page 97 10-SIDE COVER COMPONENT Fig.1 SIDE COVER Side cover component 1 COMPONENT PART NO. PART NAME CAUTION 1224100-010000 ZT250-S expansion nail ZT310-R Left Cover ZT310-R Right Side Cover PROCEDURE： ●Side cover component Use a small cross screwdriver or 4# inner hexagon socke to press down the center of the expansion screw and remove the two expansion screws ⑴.
  • Page 98 10-SIDE COVER COMPONENT Fig.2 SIDE COVER Side cover component 2 COMPONENT PART NO. PART NAME CAUTION ZT350-T fuel tank right cover lower part ZT310-R Right Side Cover 1184300-005000 ZT350 antenna PROCEDURE： ●Side cover component Open the right cover ⑵ according to the steps of removing the "left cover", unplug the plug of the non electric induction antenna, and remove the right cover assembly.
  • Page 99 11-GUARD BAR COMPONENT Fig1 GUARD BAR Guard bar component COMPONENT PART NO. PART NAME CAUTION 1144200-030000 ZT310-T retaining bar rubber sleeve 4024200-027000 ZT310-T frame protection bar pressure plate 1251112-001093 M6×16 Hexagon flange bolts (color zinc) 1144300-001000 ZT350－T left guard bar 1251100-084093 Non-standard bolts M10×1.5×66(dacromet) 1251500-007091 Non-standard flat mat φ10.5×φ24×2（White zinc）...
  • Page 100 12-REAR COVER COMPONENT Fig.1 REAR COVER Rear rack 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 Buffer rubber of flanging bushing （φ8.5×φ14×1） 1274200-103000 ZT310-T aluminum alloy shelf 1251100-123093 Non-standard bolt M8×25 (color zinc) 1250105-137093 GB5789M6×16 (environmental color) PROCEDURE: ●Rear rack...
  • Page 101 12-REAR COVER COMPONENT Fig.2 REAR COVER Rear mud plate assembly 1 COMPONENT PART NO. PART NAME CAUTION 1251100-123093 Non-standard bolt M8×25 (color zinc) Flanging bushing φ8.2×φ11×4.5＋φ16× 1251700-058093 1.5(environmental color) 1240300-071000 Flanging bushing rubber （φ11×φ16×1） 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）...
  • Page 102 12-REAR COVER COMPONENT Fig.3 REAR COVER Rear mud plate assembly 2 COMPONENT PART NO. PART NAME CAUTION 1174200-035000 ZT310 rear turn signal (including license plate light) 1251300-063093 Plywood M6×11×15（color zinc） 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）...
  • Page 103 12-REAR COVER COMPONENT Fig.4 REAR COVER 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 104 12-REAR COVER COMPONENT Fig.5 REAR COVER Tail light and tail skirt assembly 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 Buffer rubber of flanging bushing （φ8.5×φ14×1） 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1224200-205000 ZT310 electronic cushion lock block 1274100-058000 ZT310 Electric seat lock 1251300-063093 Plywood M6×11×15（color zinc）...
  • Page 105 Unscrew the black protective cap ② to remove the negative pole; then remove the red protective cap ① and remove the positive pole; remove the battery. 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.
  • Page 106 12-REAR COVER COMPONENT Fig.7 REAR COVER Electrical component box component 1 COMPONENT PART NO. PART NAME CAUTION 1224200-175000 ZT310-T upper cover, Gel battery box 1244200-111000 ZT310 gel battery strap 1184200-099000 ZT310 colloid battery (6-FM-10/10Ah) 1184100-017000 ZT250－S fuel-injection relay 1184100-010000 ZT250－S starting relay PROCEDURE：...
  • Page 107 12-REAR COVER COMPONENT Fig.8 REAR COVER Electrical component box component 2 COMPONENT PART NO. PART NAME CAUTION 1184200-016000 ZT310 PKE Buzzer 1180300-101000 HJ150-3 square flasher (LED) PROCEDURE： ●Buzzer Find and unplug the plug on the right side of the tail skirt. The buzzer ⑴ is pasted on the frame with double- sided adhesive.
  • Page 108 12-REAR COVER COMPONENT Fig.9 REAR COVER PKE 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 Buffer rubber of flanging bushing （φ8.5×φ14×1） 1184300-024100 2.5 Generation PKE Assembly (including induction key) 1270300-273000 φ8 clip（L=73) PROCEDURE：...
  • Page 109 12-REAR COVER COMPONENT Fig.10 REAR COVER Electrical device box component 1 COMPONENT PART NO. PART NAME CAUTION 1250303-010093 GB6177.1M6 (environmental color) 1274200-238000 ZT310-R battery holder (gel battery) 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1240300-007000 HJ125－6 Battery rubber gasket 1274100-057095 Flanging bushing φ6.2×φ8.4×3.5＋φ14×1.5 1244100-052000 Buffer rubber of flanging bushing （φ8.5×φ14×1）...
  • Page 110 12-REAR COVER COMPONENT Fig.11 REAR COVER Electrical device box component 2 COMPONENT PART NO. PART NAME CAUTION 1244100-082000 ZT250-R dump switch sleeve 1184100-002000 ZT250-S dump switch 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1224300-071000 ZT350-T electrical device box 1251513-001019 6.3×12×1.6 copper gasket 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1251200-050094 Non-standard cross tapping screws ST3.9×12 1184300-003000 ZT350 charging port holder...
  • Page 111 13-CUSHION COMPONENT Fig.1 CUSHION Cushion component COMPONENT PART NO. PART NAME CAUTION 4120100-008000 ZT350－T cushion component 1244100-024000 ZT250－S cushion front rubber After-sale 1244300-033000 ZT350 cushion rubber 1244100-025000 ZT250－S round cushion rubber PROCEDURE: ●Remove seat cushion Press the unlock button " "...
  • Page 112 14-MUFFLER COMPONENT Fig.1 MUFFLER Muffler component 1 COMPONENT PART NO. PART NAME CAUTION 1276200-043000 φ6 wire clamp (L=57) 1224300-085000 ZT350-R cable plastic staple 1250205-023000 GB70.1 inner hexagonal M8×35 (color Zinc) 1274100-074000 ZT310-R Muffler stainless steel bar clasp 1250205-125000 GB70.2 M8×35(12.9 garde,darco) ZT350 muffler flanging bushing (φ8.3×φ11.5×20.5×φ...
  • Page 113 14-MUFFLER COMPONENT Fig.2 MUFFLER Muffler component 2 COMPONENT PART NO. PART NAME CAUTION 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1250501-010000 GB93φ6 spring pad 4084300-010051 ZT350－GK rear muffe decorative cover (dark gray matte) 4084300-011051 ZT350－GK rear muffer(dark gray matte) 1250205-125000 GB70.2 M8×35（12.9 grade,darco） 1020243-098000 ZT350 muffer gasket（...
  • Page 114 14-MUFFLER COMPONENT Fig.3 MUFFLER Muffler component 3 COMPONENT PART NO. PART NAME CAUTION 1251300-058093 Inner hexagonal nut M8 (color zinc) 1070100-499000 ZT350-GK engine exhaust outlet seal ZT350-GK-H2 front muffler (self-made/Europe Ⅴ 4084300-012000 /Bosch EFI version) 1050970-011000 LSF oxygen sensor(L=635mm） ZT350 muffer flanging bushing（φ8.3×φ11.5×20.5×φ 1020243-097000 8.4×φ33×1.5）...
  • Page 115 15-LOWER SHROUD COMPONENT Fig.1 LOWER SHROUD Lower shroud component 1 COMPONENT PART NO. PART NAME CAUTION 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color zinc) 1274100-007000 ZT250-S flanging sleeve（φ6.4×φ9×6＋φ20×2） 1244100-004000 ZT250－S Flanging bushing buffer 1224300-001000 ZT350－T lower decorative cover 1251112-005093 M6×75 hexagon flange bolts (environmental color) 12±1.5N.m 1274300-002000 ZT350－T lower docorative cover left bracket...

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