Zontes ZT350-S 2022 Service Manual
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Zontes ZT350-S 2022 Service Manual

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ZT350-S (EURO V)
Service manual
2022/11/29

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Summary of Contents for Zontes ZT350-S 2022

  • Page 1 ZT350-S (EURO V) Service manual 2022/11/29...

  • Page 2: Table Of Contents

    Contents Table of Contents Page Table of Contents …………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… Swell nail description ……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 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 Contents Table of Contents Page Rear wheel and rear fork component 4.1 Adjustment chain………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 23 4.2 sprocket guard……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 24 Removing the sprocket guard 4.3 Sprocket assembly 1…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 4.4 Sprocket assembly 2…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… Disassemble the sprocket assembly 4.5 Rear wheel component………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 27 Decomposed rear rim component 4.6 Rear wheel axle component…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………...
  • Page 4 Contents Table of Contents Page Shift lever, brake pedal height adjustment 5.2 Front right pedal mounting position adjustment………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 5.3 Front left pedal mounting position adjustment…………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 44 5.4 Front right footrest component…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 45 Decompose the Front right pedal component 5.5 Front left footrest component……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 46 Decompose the Front left pedal component 5.6 Shift lever assembly………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………...
  • Page 5 Contents Table of Contents Page 7.3 Replacement clutch cable…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 7.4 Replace the throttle line……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 7.5 Steering adjustment…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… Adjustment steering device 7.6 Add brake fluid, rocker adjustment……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 66 Add brake fluid, brake rocker adjustment 7.7 Replace the front brake pads,front brake caliper mounting plate………………………………………………………………………………………………………………………………………………………………………………………………………… 67 7.8 Front wheel component………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………...
  • Page 6 Contents Table of Contents Page Disassemble the disc brake caliper and tubing,rear wheel speed sensor Fuel tank component 8.1 Fuel tank component 1……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 82 Disassemble the fuel tank component 8.2 Fuel tank component 2………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 83 Disassemble the fuel tank oil pump Guard bar sembly 9.1 Guard bar assembly 1……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………...
  • Page 7 Contents Table of Contents Page Muffler component 12.1 Muffler component 1…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 95 Diassemble muffler external parts 12.2 Muffler component 2…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 96 Diassemble muffler component 12.3 Muffler component 2…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 97 Discomponent muffler component Lower shroud component 13.1 Lower shroud component-1………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………… 98 Remove the shroud component, shroud bracket 13.2 Lower shroud component-2…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………...

  • Page 8: Swell Nail Description

    Contents Table of Contents Page Swell nail description ①Press down the center cylinder with 4# inner hexagon or other tools, you can hear a sound or the center cylinder moves axially by 2mm; ②Pry open the gap with a blade, nail or carving knife, etc. and remove it; if space permits, you can reach it Push out from the back; ③Pinch the outer ring with two fingers, and push the center cylinder up to the initial position;...

  • Page 9: Frame Component 1.1 Electrical Device Component-1

    1、FRAME COMPONENT Fig.1 FRAME&ELECTRONIC PARTS Electronic parts COMPONENT-1 COMPONENT PART NO. PART NAME CAUTION 1184300-025000 ZT350-S wiring harness assembly-A 1224100-030000 Pin tie (Black 4.8×130) 1224100-037000 Grade 0 flame retardant tie (black 3.6×295) 1244200-103000 ZT310 relay rubber sleeve 1244100-082000 ZT250-R dump switch sleeve 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: Main Harness, Dump Switch, Relay, Flasher, Rectifier, Ignition Coil 1.2 Electrical Device Component-2

    1、FRAME COMPONENT Fig.2 FRAME&ELECTRONIC PARTS Electronic parts COMPONENT-2 COMPONENT PART NO. PART NAME CAUTION 1251112-001093 M6×16 Hexagon flange bolts (color zinc) 1274300-065000 ZT350-VX front oil pipe bracket 1184200-004000 ZT310 horn 1274100-017000 ZT250-S cable buckle 1224100-037000 Grade 0 flame retardant tie (black 3.6×295) 1274100-095000 ZT250-S Flameout switch wire fixing bracket 1184100-012000 ZT250-S shut down switch 1250205-040095 GB70.1 inner hex bolt M8×16(color Zinc)

  • Page 11: Frame Plastic Parts

    1、FRAME COMPONENT Fig.3 FRAME&ELECTRONIC PARTS Frame plastic parts COMPONENT PART NO. PART NAME CAUTION 1224200-008000 ZT310-R cable plastic staple 1224100-030000 Pin tie (Black 4.8×130) 1241200-044000 KD150-U fuel tank liner limit glue 1240300-007000 HJ125-6 Battery rubber gasket 1224300-122000 ZT350-S key insert assembly 1251100-328000 Hexagon socket head screw M6×14+8.5×3 SUS302 1244100-002000 ZT250-S Side cover round rubber 1250205-038000 GB70.2M5×12 (stainless steel)

  • Page 12: Set Clamp, Side Cover Round Glue, Fuel Tank Liner Limit Glue 1.4 Directional Column Component

    1、FRAME COMPONENT Fig.4 FRAME&ELECTRONIC PARTS Steering rack component COMPONENT PART NO. PART NAME CAUTION 1134100-007000 ZT250-S Adjusting nut locking washer 1251300-046093 ZT250-S direction column adjusting screw nut M24X1 ( 1244100-015000 ZT250-S Adjusting nut rubber pad 1244300-014000 ZT350-R upper dust cover 1130900-024000 ZT250-S shaft ring 1130900-022000 ZT250-S conjoined steel ball 1134300-002000 ZT350-R conjoined steel ball...

  • Page 13: Frame, Side Bracket

    1、FRAME COMPONENT Fig.5 FRAME&ELECTRONIC PARTS Frame, Side support COMPONENT PART NO. PART NAME CAUTION ZT350-S frame after-sales assembly(including 4014300-022000 seat/310M nameplate) 1130900-026000 ZT250-S upper steel bowl 1134300-001000 ZT350-R lower seat ring 1264100-001000 ZT250-S side stand spring 1274200-289000 ZT310-T side bracket (dark gray) 1251100-088094 Non-standard bolt M10×1.5×43(Dacromet) 1251700-025091 ZT250-S side stand sleeve 1251300-057093 Non-standard nut M10×1.5(Dacromet)

  • Page 14: Pke Component

    1、FRAME COMPONENT Fig.6 FRAME&ELECTRONIC PARTS PKE component COMPONENT PART NO. PART NAME CAUTION 1224300-110000 Reverse buckle Velcro strap (20×200mm) 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) 2.5 Generation PKE Assembly (including induction 1184300-024100 key) PROCEDURE:...

  • Page 15: Frame & Engine Combination 2.1 Engine Decorative Cover Components

    2、FRAME & ENGINE COMPONENT Fig.1 FRAME&ENGINE Engine decorative cover components 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 1224200-157000 ZT310-V engine right cover trim cover 1251112-005093 M6×75 Hexagon flange bolts (9.8 gradecolor Zinc) 10N.m 1274200-221000 Engine right cover decorative cover mounting bracket...

  • Page 16: Frame & Engine Combination1

    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×φ8.4×3.5＋φ14×1.5 1244100-052000 Buffer rubber of flanging bushing (φ8.5×φ14×1) 1224300-021000 ZT350-VX rear shock absorber link baffle 1251112-001093 M6×16 Hexagon flange bolts (color Zinc) 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color Zinc) PROCEDURE: ●Preparation steps...

  • Page 17: Frame & Engine Combination 2

    2、FRAME & ENGINE COMPONENT Fig.3 FRAME&ENGINE FRAME&ENGINE 2 PART NO. PART NAME CAUTION 1251112-002093 M6×30 Hexagon flange bolts (color Zinc) 1251112-001093 M6×16 Hexagon flange bolts (color Zinc) 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color Zinc) 1250305-009091 GB6187.1 M12×1.25(White Zinc) GB5187 non-standard bolt M12×1.25×153(10.9 1251112-020000 garde/dacromet)

  • Page 18: Frame & Engine Combination 3

    2、FRAME & ENGINE COMPONENT Fig.4 FRAME&ENGINE FRAME&ENGINE 3 PART NO. PART NAME CAUTION 1251100-291000 Non-standard bolt M10×1.5×55(Dacromet) 1251300-057093 Non-standard nut M10×1.5(Dacromet) 65±5N.m 1251112-020000 GB5187 non-standard bolt M12×1.25×153 1250305-009091 GB6187.1 M12×1.25(White Zinc) 1251100-132003 Non-standard bolt M10×1.5×80 (Dacromet) 1274300-082000 ZT350-R engine hanger 1251112-019000 GB5187 non-standard bolt M12×1.25×85 PROCEDURE: ●Rear shock absorber reinforcement plate assembly...

  • Page 19: Frame & Engine Combination 4

    2、FRAME & ENGINE COMPONENT Fig.5 FRAME&ENGINE FRAME&ENGINE 4 PART NO. PART NAME CAUTION 1251112-002093 M6×30 Hexagon flange bolts (color Zinc) 1251112-003093 M6×45 Hex flange surface 9.8 bolt (color Zinc) 1251300-067000 ZT250-R rear wheel hollow shaft nut 1094200-009000 ZT310-V rear wheel hollow shaft Φ20×345 PROCEDURE: ●Water tank component Loosen the bolts⑴...

  • Page 20: Intake System Components 3.1 Air Filter Components 1

    3、INTAKE SYSTEM COMPONENT Fig.1 INTAKE SYSTEM Air filter components 1 COMPONENT PART NO. PART NAME CAUTION 1051371-002000 Φ59×9 pipe clamp assembly PROCEDURE: ●Air filter assembly First, remove the fuel tank, side cover, cushion, PKE, ECU, battery and battery bracket according to the steps of the corresponding parts to facilitate the next step of disassembly, which will not be repeated here.

  • Page 21: Disassemble Air Filter Components 3.2 Air Filter Components 2

    3、INTAKE SYSTEM COMPONENT Fig.2 INTAKE SYSTEM Air filter components 2 COMPONENT PART NO. PART NAME CAUTION 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1050961-004000 Air filter intake air temperature sensor ZT350T-D carbon canister adsorption tube (φ5×φ9× 1246400-012000 450) 1051371-002000 Φ59×9 pipe clamp assembly 1274200-088000 ZT310 water pipe clamp(φ10.5) ZT310-V canister solenoid valve vent manifold (Φ4×Φ...

  • Page 22: Throttle Body Parts

    3、INTAKE SYSTEM COMPONENT Fig.3 INTAKE SYSTEM Intake system component COMPONENT PART NO. PART NAME CAUTION GB9074.13 Hexagon cross groove spring,flat cushion 1250106-112000 combination bolt M5×20 1050961-003000 External intake pressure sensor MAP01 (18590H7U300) 1050958-009000 ZT350 fixed bracket of external intake pressure sensor 1050970-002000 ZT1P72MN injector holder 1050954-023000 EV14 injector G48 1050958-008000 Air intake pressure sensor connection hose...

  • Page 23: Replace The Air Filter Element

    3、INTAKE SYSTEM COMPONENT Fig.4 INDUCTION SYSTEM Replace the air filter element 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) 1251100-328000 Hexagon socket head screw M6×14+8.5×3 SUS302 PROCEDURE: ●Electrical device box bottom cover Remove 2 bolts⑴...

  • 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: Sprocket Guard

    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: Sprocket Assembly 1

    4、REAR WHELL COMPONENT Fig.3 Rear wheel, swinging Sprocket assembly 1 arm assembly PART NO. PART NAME CAUTION 1251100-117093 Non-standard inner hex bolt M8×25 (color Zinc) 1250501-004091 GB93φ10(white Zinc) 1250503-006091 GB97.1 φ10(white Zinc) 1251100-204000 Non-standard bolt M16×1.5×50 (environmental color) 100N.m 1094100-062000 M35 nut locking spring 1251300-070000 Non-standard nut M35×1.5 (environmental color) 200N.m 1080200-055000 114 section chain (520 oil seal chain/open type)

  • Page 27: Sprocket Assembly 2

    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 rocker sprocket buffer rubber 1094200-013000 ZT310 single rocker sprocket seat inner shell 1244200-088000 O-ring (Φ52.4×2.6) 1274200-120000 ZT310 single rocker arm 520-42T sprocket 1251100-190000 Non-standard bolt M10×1.5×30(environmental color) 1251300-057093 Non-standard nut M10×1.5(Dacromet)

  • Page 28: Disassemble The Sprocket Assembly 4.5 Rear Wheel Component

    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 (chrome plated) 110N.m 1230100-565000 180/55ZR17 CM-S3(73W) TL E4 ZT350-V1 single rocker arm rear wheel (MT5.5× 1094300-009000 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 29: Decomposed Rear Rim Component 4.6 Rear Wheel Axle Component

    4、REAR WHELL COMPONENT Fig.6 Rear wheel, swinging Rear axle assembly arm component PART NO. PART NAME REMARKS 1181200-118000 Wheel speed sensor(A) 1251100-102000 Non-standard bolt M6×16 (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 1276200-043000 φ6 wire clamp (L=57) 1224300-110000 Reverse buckle Velcro strap (20×200mm) Non-standard inner hex bolt M8×25 (environmental...

  • Page 30: Demolition Of Rear Wheel Bearing, Rear Disc Brake Disc, Rear Sub-Mud Assembly 4.7 Rear Sub-Slab Assembly 1

    4、REAR WHELL COMPONENT Fig.7 Rear wheel, swinging Rear auxiliary mud plate component 1 arm assembly PART NO. PART NAME CAUTION 1224300-110000 Reverse buckle Velcro strap (20×200mm) 1276200-043000 φ6 wire clamp (L=57) PROCEDURE: ●Rear auxiliary mud board assembly Untie the strap⑴.Open the protective sleeve indicated by the large arrow and unplug the 3 plugs at the transfer plug.

  • Page 31: Rear Auxiliary Mud Plate Assembly 2

    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 adapter cable of vice fender(L=2000) 1251100-328000 Hexagon socket head screw M6×14+8.5×3 SUS302 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: Rear Auxiliary Mud Plate Assembly 3

    4、REAR WHELL COMPONENT Fig.9 Rear wheel, swinging Rear auxiliary mud plate component 3 arm assembly PART NO. PART NAME CAUTION 1244100-006000 ZT250-S rear liceness rubber buffer 1224300-116000 ZT350-S rear sub-fender fender 1270300-273000 φ8 clip(L=73) 1174200-035000 ZT310 rear turn signal (including license plate light) 1174100-002000 ZT250-S rear reflector 1251100-328000 Hexagon socket head screw M6×14+8.5×3 SUS302 1251100-102000 Non-standard bolt M6×16 (304 stainless steel)

  • Page 33: Rear Turn Signal After Sale Parts

    4、REAR WHELL COMPONENT Fig.10 Rear wheel, swinging Rear turning light parts for after sales service 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, 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 plate 4024300-010000 (self-made/dark gray matte)

  • Page 35: Rear Mud Board

    4、REAR WHELL COMPONENT Fig.12 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 Buffer rubber of flanging bushing (φ8.5×φ14×1) 1224300-108000 ZT350-VX rear mud board 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) PROCEDURE: ●Rear mud board Use 8# sleeve to remove bolt ⑴...

  • Page 36: Rear Shock Absorption

    4、REAR WHELL COMPONENT Fig.13 Rear wheel, swinging Rear shock absorber arm component PART NO. PART NAME CAUTION GB5187 non-standard bolt M12×1.25×153(10.9 1251112-020000 garde/dacromet) 1250305-009091 GB6187.1 M12×1.25(White Zinc) 1114300-004000 ZT350-VX Rear shock absorber GB5187 non-standard bolt M12×1.25×85(10.9 1251112-019000 garde/dacromet) PROCEDURE: ●Rear shock absorption Tilt the vehicle to the left with the side support as the fulcrum, and support the muffler back pressure bag with a firm stool to keep the rear wheel off the ground.

  • Page 37: Rear Shock Absorption 1

    4、REAR WHELL COMPONENT Fig.14 Rear wheel, swinging Rear shock absorption 1 arm component PART NO. PART NAME CAUTION 1250305-009091 GB6187.1 M12×1.25(White Zinc) GB5187 non-standard bolt M12×1.25×153(10.9 1251112-020000 garde/dacromet) 1251100-132003 Non-standard bolt M10×1.5×80 (Dacromet) 1251300-057093 Non-standard nut M10×1.5(Dacromet) PROCEDURE: ●Rear shock absorber rod assembly After supporting the vehicle firmly, remove the shroud, muffler and rear inner fender first.

  • Page 38: Rear Shock Absorption 2

    4、REAR WHELL COMPONENT Fig.15 Rear wheel, swinging Rear shock absorption 2 arm component PART NO. PART NAME CAUTION 1274300-069094 ZT350-VX Muffler Front Mounting Stud 1251300-057093 Non-standard nut M10×1.5(Dacromet) 1250104-006097 GB16674M6×12 (chromed/HH) ZT310-V engine right cover decorative cover 1274200-221000 mounting bracket GB5187 non-standard bolt M12×1.25×153(10.9 1251112-020000 garde/dacromet)

  • Page 39: Rear Shock Absorption 3

    4、REAR WHELL COMPONENT Fig.16 Rear wheel, swinging Rear shock absorption 3 arm component PART NO. PART NAME CAUTION ZT310 rear shock-absorbing needle roller bearing 1274200-306000 bushing ZT350-VX rear flat fork connecting rod assembly 4024300-030000 (including bearing/oil seal) 1244200-130000 ZT310 rear shock absorber KRH oil seal after-sale 1250602-038000 ZT310 rear shock absorber KRH needle roller bearing 1274200-282041 ZT310-VX rear shock linkage rear bushing...

  • Page 40: Rear Fork Component

    4、REAR WHELL COMPONENT Fig.17 Rear wheel, swinging Rear fork component arm component PART NO. PART NAME CAUTION 1251100-061093 M6×22 Hex flang bolt thread (8.8 garde/environmenta 1276200-043000 φ6 wire clamp (L=57) 1094200-009000 ZT310-V rear wheel hollow shaft Φ20×345 110±5N.m 1251300-067000 ZT250-R rear wheel hollow shaft nut 1020242-414000 ZT310-VX rear fork shaft left bushing 1020242-415000 ZT310-VXrear axis right bushing 1244200-086000 ZT310 single rocker arm aluminum alloy flat fork left d...

  • Page 41: Decomposed Flat Fork Component 4.18 Replace The Rear Brake Pads

    4、REAR WHELL COMPONENT Fig.18 Rear wheel, swinging Change rear brake arresters arm assembly PART NO. PART NAME CAUTION 1100100-092000 ZT250-S rear disc brake arrester(HS10) PROCEDURE: ●Disassemble disc brake arrester Loosen the upper slide shaft① with a 14 mm sleeve. Loosen the lower slide shaft② with a 12mm wrench. Remove the slide shaft and remove the rear brake caliper.

  • Page 42: Rear Brake Main Pump Adds Brake Fluid

    4、REAR WHELL COMPONENT Fig.19 Rear wheel, swinging Rear brake main pump adds brake fluid arm assembly PART NO. PART NAME CAUTION 1251100-102000 Non-standard Bolt M6×16 PROCEDURE: ●Add disc brake liquid Disassemble bolt① with cross screwdriver. Take off oil cup cap②, sealing gasket③. Keep the top of oil cup④...

  • Page 43: Pedal Component 5.1 Pedal Height Adjustment

    5、FOOT PEDAL COMPONENT Fig.1 FOOT PEDAL Adjust the hight of foot pedal COMPONENT PART NO. PART NAME CAUTION 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color Zinc) 1271200-163000 ZT250-S shift lever spline rocker arm (dark gray) 1250301-020093 GB6170M6 (environmental color) ZT250-S shift lever adjusting screw φ10×150(Black 1274100-041000 Zinc)

  • Page 44: Front Right Pedal Mounting Position Adjustment

    5、FOOT PEDAL COMPONENT Fig.2 FOOT PEDAL Front right pedal mounting position adjustment COMPONENT PART NO. PART NAME CAUTION ZT350-V1 rear brake main pump piston push rod 1100100-858000 extension rod GB5789 M10×1.25×25 (10.9 grade environmental 1250105-278093 protection color) PROCEDURE: ●Front right foot position adjustment Fix the screw ①...

  • Page 45: Front Left Pedal Mounting Position Adjustment

    5、FOOT PEDAL COMPONENT Fig.3 FOOT PEDAL Front left pedal mounting position adjustment COMPONENT PART NO. PART NAME CAUTION 1251100-061093 M6×22 Hexagon flange bolts (color Zinc) GB5789 M10×1.25×25 (10.9 grade environmental 1250105-278093 protection color) 1250301-020093 GB6170M6 (environmental color) 1274200-035194 ZT310 front fender liner(Black Zinc) ZT250-S shift lever adjusting screw φ10×150(Black 1274100-041000 Zinc)

  • Page 46: Front Right Footrest Component

    5、FOOT PEDAL COMPONENT Fig.4 FOOT PEDAL Front right footrest component COMPONENT PART NO. PART NAME CAUTION GB5789 M10×1.25×25 (10.9 grade environmental 1250105-278093 protection color) 1274300-101052 ZT350-S brake pedal ZT310-VX brake pedal spring(environmental color 1260100-294000 Zinc) 1264100-006000 ZT250-S Pedal circlip 1274100-012000 ZT250-S Pedal pin 1264100-004000 ZT250-S front right foot pedal torsional spring 1274300-068000 ZT350-VX front foot support (dark gray) 1244200-115000 ZT310-VX rear right foot pedal rubber mat...

  • Page 47: Decompose The Front Right Pedal Component 5.5 Front Left Footrest Component

    5、FOOT PEDAL COMPONENT Fig.5 FOOT PEDAL Front left footrest component COMPONENT PART NO. PART NAME CAUTION GB5789 M10×1.25×25 (10.9 grade environmental 1250105-278093 protection color) 1274300-102052 ZT350-S shift lever pedal rocker arm 1264100-006000 ZT250-S Pedal circlip 1274100-012000 ZT250-S Pedal pin 1264100-003000 ZT250-S front left foot pedal torsional spring 1274300-068000 ZT350-VX front foot support (dark gray) 1244200-114000 ZT310-VX front left foot pedal rubber mat PROCEDURE:...

  • Page 48: Decompose The Front Left Pedal Component 5.6 Shift Lever Assembly

    5、FOOT PEDAL COMPONENT Fig.6 FOOT PEDAL Shift lever assembly COMPONENT PART NO. PART NAME CAUTION 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color Zinc) 1271200-163000 ZT250-S shift lever spline rocker arm (dark gray) 1274100-042000 Miniature rod end ball bearing SAJK6C 1250303-010093 GB6177.1M6 (environmental color) 1250301-020093 GB6170M6 (environmental color) 1274200-035194 ZT310 front fender liner(Black Zinc)

  • Page 49: Front Footrest Bracket

    5、FOOT PEDAL COMPONENT Fig.7 FOOT PEDAL Front footrest bracket COMPONENT PART NO. PART NAME CAUTION 1251112-001093 M6×16 Hexagon flange bolts (color Zinc) GB5187 non-standard bolt M12×1.25×153(10.9 1251112-020000 garde/dacromet) 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color Zinc) 1250305-009091 GB6187.1 M12×1.25(White Zinc) 4064300-027000 ZT350-VX front foot tread bracket PROCEDURE: ●Front footrest bracket...

  • Page 50: Rear Pedal Assembly

    5、FOOT PEDAL COMPONENT Fig.8 FOOT PEDAL Rear pedal assembly COMPONENT PART NO. PART NAME CAUTION 1250205-034093 GB70.1 Hexagonal Socket M8×30 (color Zinc) 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) PROCEDURE: ●Rear left pedal bracket assembly Using 6# inner hexagon socket remove 3 pieces bolts ⑴ on the left side, take off the left pedal bracket assembly.

  • Page 51: Rear Right Pedal Bracket Components

    5、FOOT PEDAL COMPONENT Fig.9 FOOT PEDAL Rear right pedal bracket components COMPONENT PART NO. PART NAME CAUTION 1244100-002000 ZT250-S Side cover round rubber 4064300-033051 ZT350-S rear right pedal bracket (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 1250205-038000 GB70.2M5×12 (stainless steel) 1251700-117000 Bushing Φ...

  • Page 52: Rear Left Pedal Bracket Components

    5、FOOT PEDAL COMPONENT Fig.10 FOOT PEDAL Rear left pedal bracket components COMPONENT PART NO. PART NAME CAUTION 1244100-002000 ZT250-S Side cover round rubber 4064300-032051 ZT350-S rear left pedal bracket (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 1250205-038000 GB70.2M5×12 (stainless steel) 1251700-117000 Bushing Φ...

  • Page 53: Change The Oil

    6、COOLING SYSTEM COMPONENT Fig.1 COOLING SYSTEM Change engine oil COMPONENT PART NO. PART NAME CAUTION 1051161-012000 M24×2 oil filler plug 1051461-007000 25×3.1 Hydrogenated nitrile rubber O-ring 1251100-066093 M12×1.5×15 ablassschraube (9.8 grade/environmenta 24±4N.m 1244100-033000 Combined sealing gasket 12×φ20×2 1244300-050000 ZT350-V1 oil change fairing PROCEDURE: ●Drain oil Park the motorcycle with side stand on flat ground.Place holder to collect wasted engine oil under the oil...

  • Page 54: Replace The Oil Filter

    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 Non-standard cover type 9 degree nut M6×13 1251300-096000 (environmental color Zinc) 4050454-014051 ZT180MN fine filter cover A (dark gray) 1051454-020000 55×2.5 Hydrogenated nitrile rubber O-ring after-sale...

  • Page 55: Add Coolant

    6、COOLING SYSTEM COMPONENT Fig.3 COOLING SYSTEM Add coolant COMPONENT PART NO. PART NAME CAUTION 1224300-030000 ZT350-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" line, the coolant should be replenished in time. If the auxiliary tank has no or only a small amount of coolant, check the cooling system first, and remove the leak before adding it.

  • Page 56: Water Tank Decoration Cover Component

    6、COOLING SYSTEM COMPONENT Fig.4 COOLING SYSTEM Water tank decoration cover component COMPONENT PART NO. PART NAME CAUTION 1251100-328000 Hexagon socket head screw M6×14+8.5×3 SUS302 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1251300-063093 Plywood M6×11×15(color Zinc) ZT350-S water tank right decorative cover 【1】...

  • Page 57: Vice Water Tank Components

    6、COOLING SYSTEM COMPONENT Fig.5 COOLING SYSTEM Vice water tank components COMPONENT PART NO. PART NAME CAUTION GB16674 M6×30 Hexagon flange bolts (9.8 1251112-002093 grade/environmental 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) GB16674 M6×45 Hex flange flange bolt (9.8 1251112-003093 grade/environmental color Zinc) 1274200-079000 ZT310 water pipe clamp(φ9)

  • Page 58: Draining Coolant

    6、COOLING SYSTEM COMPONENT Fig6 COOLING SYSTEM Draining coolant 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 previous “Sub tank assembly” procedure to vent the coolant in the sub tank. After placing the oil pan or other container under the right side of the vehicle, tilt the vehicle to the right.

  • Page 59: Main Tank Component 1

    6、COOLING SYSTEM COMPONENT Fig.7 COOLING SYSTEM Main water tank assembly 1 COMPONENT PART NO. PART NAME CAUTION 1274200-090000 ZT310 water pipe clamp(φ26) 1244300-052000 ZT350-S engine outlet pipe 3 1244200-113000 ZT310-V small circulation water pipe (right ackwater) 1251112-002093 M6×30 Hexagon flange bolts (9.8 rade/color Zinc) 1244100-002000 ZT250-S Side cover round rubber 1274200-091000 ZT310 water pipe clamp(φ27) 1274200-089000 ZT310 water pipe clamp(φ22)

  • Page 60: Main Tank Component 2

    6、COOLING SYSTEM COMPONENT Fig.8 COOLING SYSTEM Main water tank assembly 2 COMPONENT PART NO. PART NAME CAUTION 1250104-006097 GB16674M6×12 (chromed/HH) 1274300-043000 ZT350-VX radiator lower bracket PROCEDURE: ●Main water tank bracket Remove 2 pieces bolts⑴ with 8# sleeve then take off the bracket⑵. ●Main water tank ①Thermostat Check the opening temperature, full opening temperature and lift of the main valve in the thermostatic...

  • Page 61: Oil Cooler Component

    6、COOLING SYSTEM COMPONENT Fig.9 COOLING SYSTEM Oil cooler component COMPONENT PART NO. PART NAME CAUTION 1251100-061093 M6×22 Hex flang bolt thread (8.8 garde/ color Zinc) 1251112-001093 M6×16 Hexagon flange bolts (9.8 grade/color Zinc) 1274300-045000 ZT350－VX oil cooler upper bracket 1274300-046000 ZT350－VX oil cooler lower bracket 1251112-002093 M6×30 Hexagon flange bolts (9.8 grade/color Zinc) 1274300-125000 ZT350-R oil cooler（collector tubes）...

  • Page 62: Throttle/Clutch Cable Clearance Adjustment

    7、FRONT FORK COMPONENT Fig.1 FRONT FORK Throttle/clutch cable clearance adjustment COMPONENT PART NO. PART NAME CAUTION 1154300-004000 ZT350-X throttle refueling cable 1154300-005000 ZT350-X throttle return cable 1154300-013000 ZT350－S clutch line 1244300-051000 ZT350-GK clutch wire 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 63: Light Height Adjustment

    7、FRONT FORK COMPONENT Fig.2 FRONT FORK Light height adjustment COMPONENT PROCEDURE: ●Light height adjustment The rider sits in the bike and straightens the bike. Another person inserts a PH2 type Phillips screwdriver (diameter 6mm) into the hole near the lower link plate of the car, aligns the adjusting bolt, rotates clockwise to increase, and counterclockwise to decrease the beam height.

  • Page 64: Replacement Clutch Cable

    7、FRONT FORK COMPONENT Fig.3 FRONT FORK Replacement clutch cable COMPONENT PART NO. PART NAME CAUTION 1154300-013000 ZT350－S clutch line 1244300-051000 ZT350-GK clutch wire sheath 1244300-023000 ZT310 rubber buckle (50mm) 1244300-042000 ZT350 Rubber Wire Buckle (Double Buckle Type) 1224300-111000 Reverse buckle Velcro strap (20×300mm) PROCEDURE: ●Remove the cluch line Use an 14# open-end wrench to loosen the nuts ②...

  • Page 65: Replace The Throttle Line

    7、FRONT FORK COMPONENT Fig.4 FRONT FORK Replace the throttle line COMPONENT PART NO. PART NAME CAUTION 1154300-004000 ZT350-X throttle refueling cable 1154300-005000 ZT350-X throttle return cable 1244300-023000 ZT310 rubber buckle (50mm) 1244300-042000 ZT350 Rubber Wire Buckle (Double Buckle Type) 1224100-030000 Pin tie (Black 4.8×130) 1224300-111000 Reverse buckle Velcro strap (20×300mm) 1244100-042000 ZT250-R right handle bar rubber sleeve 1184200-185000 ZT310-V1 Right handle switch...

  • Page 66: Steering Adjustment

    7、FRONT FORK COMPONENT Fig.5 FRONT FORK Steering adjustment COMPONENT PART NO. PART NAME CAUTION 1251300-088000 ZT350-R upper connection decoration nut M22×1 100N.m 1251500-100000 φ22.5×φ39×1 gasket (chrome plated) 1250205-023000 GB70.1 inner hexagonal M8×35 (color Zinc) 25N.m 1134100-007000 ZT250-S Adjusting nut locking washer 1251300-046093 ZT250-S adjusting screw nut M24X1 color Zinc) 1244100-015000 ZT250-S Adjusting nut rubber pad 1244300-014000 ZT350-R upper dust cover...

  • Page 67: Add Brake Fluid, Rocker Adjustment

    7、FRONT FORK COMPONENT Fig.6 FRONT FORK Add brake fluid, rocker adjustment COMPONENT PART NO. PART NAME CAUTION 1100100-833000 ZT350-GK front brake lever (machine addition) 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 ZT350T-K front disc brake main pump assembly (φ...

  • Page 68: Replace The Front Brake Pads,Front Brake Caliper Mounting Plate

    7、FRONT FORK COMPONENT Fig.7 FRONT FORK Replace the front brake pads COMPONENT PART NO. PART NAME CAUTION ZT350-GK front radial caliper brake pads (SBS-SI- 1100100-827000 After-sales 104HH) 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 69: Front Wheel Component

    7、FRONT FORK COMPONENT Fig.8 FRONT FORK Front wheel component COMPONENT PART NO. PART NAME CAUTION 1250205-023000 GB70.1 inner hexagonal M8×35 (color Zinc) 20N·m 1094100-063000 ZT650 front wheel hollow shaft Φ20×243 1274300-008000 ZT350-GK front wheel bushing 1274300-007000 ZT350-GK ABS induction ring gear (60 teeth) 1251100-117093 Non-standard inner hex bolt M8×25 (color Zinc) 22～24N·m 1100100-783000 ZT350-GK front brake disc (320×5.0)

  • Page 70: Disassemble The Front Wheel, Front Disc Brake Disc, Front Axle Component 7.9 Front Mud Board & Wheel Speed Sensor Component

    7、FRONT FORK COMPONENT Fig.9 FRONT FORK Front mudguard & wheel speed sensor component COMPONENT PART NO. PART NAME CAUTION 1224300-121000 ZT350-S radiator fan plug holder 1224100-044000 Wheel speed sensor clamp 1181200-118000 Wheel speed sensor(A) 1274300-109000 ZT350-R Front oil outlet pipe clamp 1251100-121093 Non-standard bolt M6×25 (environmental color) 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) GB70.1 Hexagon socket head bolt M10×1.5×60 (grade...

  • Page 71: Decompose Front Wheel Speed Sensor Component, Front Mud Plate Component 7.10 Headlights Assembly 1

    7、FRONT FORK COMPONENT Fig.10 FRONT FORK Headlights assembly 1 COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1224100-037000 Grade 0 flame retardant tie (black 3.6×295) 1274300-088000 ZT350-S headlight upper bracket 1251100-328000 Hexagon socket head screw M6×14+8.5×3 SUS302 1250205-040095 GB70.1 inner hex bolt M8×16(color Zinc) 1224300-113000 ZT350-S headlight storage box 1224300-060000 ZT350 Universal connector holder (φ12×7)
  • Page 72 7、FRONT FORK COMPONENT Fig.11 FRONT FORK Headlights assembly 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) 1274300-089000 ZT350-S headlight lower bracket 1251300-063093 Plywood M6×11×15(color Zinc) 1224100-010000 ZT250-S swell nail 1171200-059000 KD150-G1 headlight 1250105-138093 GB5789M6×20 (environmental color)

  • Page 73: Headlights Assembly 3

    7、FRONT FORK COMPONENT Fig.12 FRONT FORK Headlights assembly 3 COMPONENT PART NO. PART NAME CAUTION Non-standard cross tapping screws ST3.9×12 (Black 1251200-050094 Zinc) 1224300-095000 ZT350-S hood turn signal lower part 1251300-063093 Plywood M6×11×15(color Zinc) 1174300-008000 ZT350-S-C1 hood right turn signal 4044302-222021 ZT350-S hood turn signal middle (extra black light) 1224300-094000 ZT350-S hood turn signal upper part 1174300-007000 ZT350-S-C1 hood left turn signal...

  • Page 74: Right Hand Component

    7、FRONT FORK COMPONENT Fig.13 FRONT FORK Right handlebar component COMPONENT PART NO. PART NAME CAUTION 1190100-409051 ZT310-VX right rearview mirror (dark gray) 1100300-121051 Front disc brake main pump assembly (φ14) 1100100-833000 ZT350-GK front brake handle (CNC) 1134300-018000 ZT350-R balance block (aggravated) 1244100-042000 ZT250-R right handle bar rubber sleeve 1184300-041000 ZT350-S right handlebar switch (dark gray TFT-500) 1250205-031091 GB70.1M6×30(stainless steel)

  • Page 75: Remove Right Rear View Mirror, Right Hand Rubber Sleeve, Balance Block，Replace The Front Brake Switch 7.14 Left Hand Component

    7、FRONT FORK COMPONENT Fig.14 FRONT FORK Left hand component COMPONENT PART NO. PART NAME CAUTION 1190100-408051 ZT310-VX left rearview mirror (dark gray) 1134300-013051 ZT350-GK left hand handle rocker arm seat assembly 1184300-019000 ZT350-R left counter handle switch(dark gray TFT-500) 1250205-031091 GB70.1M6×30(stainless steel) 10N.m 1184200-184000 ZT310-V1 Left handle switch 1244100-041000 ZT250-R left hand rubber sleeve...

  • Page 76: Directional Lever、Tft Instrument

    7、FRONT FORK COMPONENT Fig.15 FRONT FORK Direction handle&TFT Instrument 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) 1134300-012000 ZT310-R1 direction handle pressure block 1134300-024051 ZT350-S direction handle (dark gray matte) 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 77: Demolition Handle, Clamp, Tft Instrument Component 7.16 Front Shock Absorber, Upper Plate Component

    7、FRONT FORK COMPONENT Fig.16 FRONT FORK Front shock absorber, upper plate component COMPONENT PART NO. PART NAME CAUTION 1251300-088000 ZT350-R Upper connecting plate decorative nut M22×1 1251500-100000 φ22.5×φ39×1 gasket (chrome plated) 1250205-023000 GB70.1 inner hexagonal M8×35 (color Zinc) 25N.m 1114300-001000 ZT350-R front left shock absorber 1114300-002000 ZT350-R front right shock absorber 1174300-013000 Reflection light(KM-106) 1251100-121093 Non-standard bolt M6×25 (environmental color)

  • Page 78: Front Shock Absorber, Faucet Lock, Upper Plate Component 7.17 Uplink Plate, Direction Handle Block Component

    7、FRONT FORK COMPONENT Fig.17 FRONT FORK Uplink plate, direction handle block component COMPONENT PART NO. PART NAME CAUTION ZT310-R direction handle block M10×1.25 (dark gray 4094200-005051 matte/spray paint) 1274200-018000 ZT310-R gasket of upper connecting board 1246400-049000 ZT350T-D upper plate buffer glue 4094300-005051 ZT350-X upper connection board (dark gray matte) 1251700-168000 ZT350T-D bushing φ10×φ13×41 1250105-280000 GB5789 M10×1.25×60 (level 10.9 dacromet)

  • Page 79: Disassemble The Block, The Upper Plate 7.18 Abs Brake System-1

    7、FRONT FORK COMPONENT Fig.18 FRONT FORK ABS brake system-1 COMPONENT PART NO. PART NAME CAUTION 1251100-328000 Hexagon socket head screw M6×14+8.5×3 SUS302 1224300-028000 ZT350-VX hydraulic control unit protective cover 1241200-062000 3M sponge rubber pad (50×15×2) 1251112-001093 M6×16 Hexagon flange bolts (9.8 grade/color Zinc) 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...

  • Page 80: Remove The Control Unit Protection Cover, Releasing Brake Fluid, Hydraulic Control Unit 7.19 Abs Brake System-2

    7、FRONT FORK COMPONENT Fig.19FRONT FORK ABS brake system-2 COMPONENT PART NO. PART NAME CAUTION 1010407-002000 Double hole clamp (Φ8.5 with Φ17.5) 1224100-044000 Wheel speed sensor clamp 1250105-138093 GB5789M6×20 (environmental color) GB70.1 Hexagon socket head bolt M10×1.5×60 (grade 1251100-303093 12.9 / environmental protection color zinc) 1100100-936000 Caliper bleeder screw rubber cap 1100100-895000 Disc brake bleeder screw M6 Disc brake oil pipe bolts M10×1×22 (with exhaust...

  • Page 81: Abs Brake System-3

    7、FRONT FORK COMPONENT Fig.20FRONT FORK ABS brake system-3 COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1274300-063000 ZT350-V1 lower docorative cover right bracket 1250104-019097 GB16674M6×40 (chrome/HH) 1224300-110000 Reverse buckle Velcro strap (20×200mm) ZT350-V1 rear brake main pump piston push rod 1100100-858000 extension rod 1251513-013000 Disc brake pipe copper washer φ...

  • Page 82: Abs Brake System-4

    7、FRONT FORK COMPONENT Fig.21FRONT FORK ABS brake system-4 COMPONENT PART NO. PART NAME CAUTION 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1224200-003000 ZT310-R Rear disc brake pipe clamp 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color Zinc) 1276200-043000 φ6 wire clamp (L=57) 1251100-123093 Non-standard bolt M8×25 (color Zinc) 1181200-118000 Wheel speed sensor(A) 1251100-102000 Non-standard bolt M6×16 (304 stainless steel)
  • Page 83 8、FUEL TANK COVER COMPONET Fig. 1 FUEL TANK COVER Fuel tank assembly COMPONET PART NO. PART NAME CAUTION 1050956-006000 KD150-U EFI High Pressure Tubing Sub-assembly ZT350T-D carbon canister adsorption tube (φ5×φ9× 1246400-012000 450) 1250205-043093 GB70.1M8×55(environmental color) ZT250-R fuel tank flat pad φ9×φ37.5×2 1251900-028093 (environmental color) 1244100-020000 ZT250-S tank pressure glue...
  • Page 84 8、FUEL TANK COVER COMPONET Fig. 2 FUEL TANK COVER Fuel Tank middle cover assembly COMPONET PART NO. PART NAME CAUTION 1274300-113000 ZT350-S fuel tank lock 1240300-021000 HJ125-6 pod glass strip (1.5m) Fuel tank 1250105-137093 GB5789M6×16 (environmental color) 1050958-012000 T02 built-in fuel pump (ZT350-V) PROCEDURE: ●Fuel tank After the flip plate of the oil tank cover is turned up, insert the key and turn it clockwise, and open the oil...
  • Page 85 9、GUARD BAR COMPONENT Fig.1 GUARD BAR Guard bar assembly 1 COMPONENT PART NO. PART NAME CAUTION 1224300-121000 ZT350-S radiator fan plug holder 1251100-328000 Hexagon socket head screw M6×14+8.5×3 SUS302 1224300-110000 Reverse buckle Velcro strap (20×200mm) 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1224200-003000 ZT310-R Rear disc brake pipe clamp 1251100-061093 M6×22 Hex flang bolt thread (8.8 garde/color Zinc)
  • Page 86 9、GUARD BAR COMPONENT Fig.2 GUARD BAR Guard bar assembly 2 COMPONENT PART NO. PART NAME CAUTION 1251300-057093 Non-standard nut M10×1.5(Dacromet) 1274300-116000 ZT350-S cable fixing bracket 1251100-132003 Non-standard bolt M10×1.5×80 (Dacromet) 1250305-009091 GB6187.1 M12×1.25(White Zinc) GB5787 non-standard bolt M12×1.25×105(10.9 1251112-018000 garde/dacromet) 1251100-082093 Non-standard bolts M10×1.5×20(Dacromet) 1251112-002093 M6×30 Hexagon flange bolts (9.8 grade/color Zinc) 1274300-067000 ZT350-V water outlet pipe anti-wear bracket...
  • Page 87 9、GUARD BAR COMPONENT Fig.3 GUARD BAR Guard bar assembly 3 COMPONENT PART NO. PART NAME CAUTION 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1274300-092000 ZT350-S ignition coil bracket 1224100-010000 ZT250-S swell nail 4114300-010051 ZT350-S Left bumper (dark gray matte) 1274300-076094 ZT350－S Left Bumper Decorative Cover Lower Bracke 1244300-026000 ZT350-R guard bar anti-drop glue 1251100-083094 Non-standard bolt M10×1.5×50 (Dacromet) 1244300-027000 ZT350-R guard bar waterproof rubber stopper...
  • Page 88 9、GUARD BAR COMPONENT Fig.4 GUARD BAR Engine decorative cover components COMPONENT PART NO. PART NAME CAUTION 1244300-027000 ZT350-R guard bar waterproof rubber stopper 1251100-083094 Non-standard bolt M10×1.5×50 (Dacromet) 1244300-026000 ZT350-R guard bar anti-drop glue 4114300-009051 ZT350-S right bumper (dark gray matte) ZT350-S right bumper decorative cover 1251300-063093 Plywood M6×11×15(color Zinc) 1240300-007000 HJ125-6 Battery rubber gasket...
  • Page 89 10、REAR COVER COMPONENT Fig.1 REAR COVER Battery component COMPONENT PART NO. PART NAME CAUTION 1244200-111000 ZT310 gel battery strap 1184200-099000 ZT310 colloid battery (6-FM-10/10Ah) 1224300-110000 Reverse buckle Velcro strap (20×200mm) 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) 1224200-040000 ZT310 Electric parts box lower cover 1224300-114000 ZT350-S charging port bottom cover...
  • Page 90 Remove the side cover round glue⑼from the left cover outer trim panel⑾ and the right cover outer trim panel⑽. CAUTION: ●There are detailed disassembly videos on the official website of Zontes. You can search the "ZT350-S Panel Disassembly Video Tutorial" in the assembly video.
  • Page 91 10、REAR COVER COMPONENT Fig.3 REAR COVER Tail skirt component 2 COMPONENT PART NO. PART NAME CAUTION 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1274300-111000 ZT350－S rear tail skirt bracket 1250205-040095 GB70.1 inner hex bolt M8×16(color Zinc) Flanging bushing φ8.2×φ11×4.5＋φ16× 1251700-058093 1.5(environmental color) 1240300-071000 Flanging bushing rubber (φ11×φ16×1) 1274100-057095 Flanging bushing φ6.2×φ8.4×3.5＋φ14×1.5...
  • Page 92 10、REAR COVER COMPONENT Fig.4 REAR COVER Tail skirt component 3 COMPONENT PART NO. PART NAME CAUTION 1251100-328000 Hexagon socket head screw M6×14+8.5×3 SUS302 1224300-100000 ZT350-S left cover Non-standard cross tapping screws ST3.9×12 (Black 1251200-050094 Zinc) 1251300-063093 Plywood M6×11×15(color Zinc) 1224300-101000 ZT350-S right side cover 1184300-005000 ZT350 antenna 1184200-053000 ZT310PKE external single antenna PROCEDURE:...
  • Page 93 10、REAR COVER COMPONENT Fig.5 REAR COVER Tail skirt component 4 COMPONENT PART NO. PART NAME CAUTION 1251300-063093 Plywood M6×11×15(color Zinc) ZT350-S left tail skirt 1251100-328000 Hexagon socket head screw M6×14+8.5×3 SUS302 Non-standard cross tapping screws ST3.9×12 (Black 1251200-050094 Zinc) 1174300-014000 ZT350-S-B1 tail light ZT350-S right tail skirt PROCEDURE: ●Tail skirt tail lamp assembly...
  • Page 94 10、REAR COVER COMPONENT Fig.6 REAR COVER Battery bracket COMPONENT PART NO. PART NAME CAUTION 1251112-001093 M6×16 Hexagon flange bolts (9.8 grade/color Zinc) 1274300-084000 ZT350-VX battery bracket 1240300-007000 HJ125-6 Battery rubber gasket PROCEDURE: ●Battery bracket Remove 4 bolts⑴with 8 # socket; Remove the battery bracket assembly. Use a hot air gun to heat the rubber pad⑶...
  • Page 95 ●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 96 12、MUFFLER COMPONENT Fig.1 MUFFLER Muffler component 1 COMPONENT PART NO. PART NAME CAUTION 1224300-088000 ZT350-V1 EFI relay holder 1250205-023000 GB70.1 inner hexagonal M8×35 (color Zinc) 1251112-002093 M6×30 Hexagon flange bolts (color zinc) 1251112-003093 M6×45 Hex flange surface 9.8 bolt (color zinc) 1251300-058093 Inner hexagonal nut M8 (color zinc) 1020243-098000 ZT350 muffler gasket (φ8.3×φ33×1.5) ZT350-GK-H1 muffler suspension hollow cushioning...
  • Page 97 12、MUFFLER COMPONENT Fig.2MUFFLER Muffler component 2 COMPONENT PART NO. PART NAME CAUTION 1250205-023000 GB70.1 inner hexagonal M8×35 (color Zinc) 1250205-093093 GB70.1M8×40 (environmental color Zinc) 1020243-098000 ZT350 muffler gasket (φ8.3×φ33×1.5) ZT350-GK-H1 muffler suspension hollow cushioning 1244300-022000 rubber ZT350 muffler flanging bushing (φ8.3×φ11.5×20.5×φ 1020243-097000 8.4×φ33×1.5) 1250303-011093 GB6177.1M8(color Zinc)
  • Page 98 12、MUFFLER COMPONENT Fig.3MUFFLER Muffler component 3 COMPONENT PART NO. PART NAME CAUTION 1070100-499000 ZT350-GK engine exhaust outlet seal 4084300-013000 ZT350-V1-J2 Muffler (Europe Ⅴ/Bosch EFI version) 1050970-011000 LSF oxygen sensor(L=635mm) ZT350-GK-H1 muffler suspension hollow cushioning 1244300-022000 rubber 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 4044302-039051 ZT350-V1 muffler decorative cover (dark gray matte)
  • Page 99 13、LOWER SHROUD COMPONENT Fig.1 LOWER SHROUD Lower shroud component-1 COMPONENT PART NO. PART NAME CAUTION 1251112-001093 M6×16 Hexagon flange bolts (color zinc) 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 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1274100-057095 Flanging bushing φ6.2×φ8.4×3.5＋φ14×1.5...
  • Page 100 13、LOWER SHROUD COMPONENT Fig.2 LOWER SHROUD Lower shroud component 2 COMPONENT PART NO. PART NAME CAUTION ZT310-V left lower shroud 1224300-052000 ZT350-V1 lower middle shroud ZT310-VX right lower shroud 1251300-063093 Plywood M6×11×15(color zinc) 1250104-019097 GB16674M6×40 (chrome/HH) 1274300-063000 ZT350-V1 lower docorative cover right bracket 1251112-005093 M6×75 Hexagon flange bolts (color zinc) 1274300-062000 ZT350-V1 lower docorative cover left bracket PROCEDURE:...

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