Page 1 ZT350T-D Maintenance Manual 2022-11-24 1 / 152...
Page 2 For colors or upgrades, please refer to the part codes on the official website of Zontes. This manual will not be listed in detail; if the part names in this manual are inconsistent with the official website of Zontes, please refer to the official website of Zontes.Individual parts of different displacements that differ in shape or...
Page 3 User notice This manual is compiled by Guangdong Tayo Motorcycle Technology Co., Ltd. to guide dealers or service personnel to use it. This manual cannot provide more detailed knowledge about motorcycles, and is only for reference for maintenance. If you do not have the corresponding knowledge such as electrician, machine repair, etc., improper assembly or repair failure may occur during repair.
Page 4: Table Of Contents
Content Content ....................................... 4 1. Vehicle information ..................................10 Know Before Service ................................. 10 Body label ....................................11 D350 Technical specification..............................12 Front wheel/steering system ............................12 Rear wheel/suspension system ............................12 Brake system ..................................12 Battery/charging system ..............................13 Lamp/Speedometer/switch description ...........................
Page 5 Throttle cable .................................... 41 1. Inspection ..................................41 2. Adjust the throttle cable clearance ..........................41 3. Lube door cable ................................41 Idle speed ....................................42 Check idle speed: ................................42 Fuel evaporative pollutant control system ..........................43 Radiator..................................... 44 1.
Page 6 1. Check ..................................... 62 2. Adjust the preload ................................. 62 2.1 Adjust the right rear shock absorption ....................... 62 2.2 Adjust the left rear shock absorption........................63 D350 ..................................63 3. Replace the shock absorption ............................63 Bolts and nuts for body and engine installation ........................64 1.
Page 7 Poor acceleration ..................................85 High idling speed of hot car ..............................85 Unsteady idle speed of cooling car ............................85 Unsteady idling, easy to cutoff ..............................86 Analysis flow chart of EFI failure indicator light always on ....................... 87 Electrical schematic diagram of EFI system ..........................88 4.
Page 8 2. Attention to the water tank filling port ........................108 2.1 Overall tightness inspection ........................108 2.2 Pressure relief valve inspection ........................ 108 3. Auxiliary water tank ..............................108 4. Water and oil shared sensor ............................108 5. Thermostat .................................. 108 5.1 Inspection ................................
Page 9 Front wheel assembly exploded view： ......................... 130 Inspection and maintenance of front wheel assembly： ....................130 1. Disc brake ..................................130 1.1 The service life of the disc brake disc ........................ 130 1.2 Disc brake Replacement method ........................130 2. Front wheel oil seals and bearings ..........................130 2.1 Service life of front wheel oil seals and bearings ....................
Page 10: Vehicle Information
1. Vehicle information Know Before Service 1. Use good quality tools, or special tools and fixtures designed by our company. The use of inferior tools may cause damage to parts, peeling of plating, improper assembly, etc. 2. The O-rings, paper gaskets, copper gaskets, and component sealing rings used for sealing must be replaced before assembling. 3.
Page 11: Body Label
Body label ① The vehicle identification code VIN can be seen after opening the seat cushion, and the VIN code is engraved on the cross tube at the rear of the frame. ② The muffler code is on the inner side above the muffler. ③...
Page 12: D350 Technical Specification
D350 Technical specification Item Specification Front tire specification 120/70－15 CM576 56S Rear tire specification 140/70－14 CM577 68S Front rim specification MT:3.5×15 Rear rim specification MT:3.75×14 Vehicle Brake fluid DOT4 0.25L（0.07 US gal,0.06 lmp gal） Replace fine filter： 1.75L（0.46 US gal,0.39 lmp gal） Oil consumption Without replacing the fine filter：...
Page 13: Battery/Charging System
Battery/charging system Item Standard Type 6－FM－12 Capacity 12Ah Battery self-discharge current 1.1mA average Full 13.1～13.3V Charging voltage required for ≤12.8V Voltage unloaded bike Charging voltage required for ≤12V loading Battery Constant voltage range 14.4～14.8V Constant voltage charging Initial charging current 0.1～0.2 times the battery capacity mode Charging time...
Page 14: Tightening Torque
Tightening torque Bolt tightening torque of general tightening part Intensity Grade 4.8-6.8 (mark "4" on the head of the Grade 8.8 (mark "7" or "8.8" on the head of level bolt) the bolt) Tightening torque Standar Breaking Tightening Standard Breaking Bolt diameter range d value...
Page 15: Cable/Cable/Pipe/Electrical Device Distribution Map
Cable/cable/pipe/electrical device distribution map 1. Distribution map of lamps and lanterns 1 - Headlights ((1) - Front turn light position (2) - Position light / daytime running light position (3) - High and low beam position) 2 - Side reflector 3 - Right handlebar auxiliary switch 4 - Right handlebar switch 5 - Right rear turn light ((4) - Position light / brake light position (5) - Rear turn light position) 6 - Rear reflector 7 - License plate light 8 - Left rear turn light ((4) - Brake light / position lamp position (5) - Rear turn light position) 9 - Left handlebar switch 10 - Left handle sub-switch.
Page 16: Throttle Cable
2. Throttle cable 1- Oil return line 2- Fuel line 3. Brake upper pump and brake hose 1-Front disc brake main pump 2-FMC-HU brake hose 3-RMC-HU brake hose 4-rear disc brake main pump 16 / 152...
Page 17: Calipers, Brake Hoses And Wheel Speed Sensors
4. Calipers, brake hoses and wheel speed sensors 1-brake disc (front) 2- front whell ABS induction ring gear 3-wheel speed sensor (front wheel) 4-front disc brake caliper 5-FC-HU brake hose 6- rear whell ABS induction ring gear 7-brake disc (rear) 8-rear disc brake caliper 9-wheel speed sensor (rear wheel) 10-RC-HU brake hose 17 / 152...
Page 18: Distribution Map Of Brake System Accessories
5. Distribution map of brake system accessories 5.1 D350 1-wheel speed sensor (front wheel) 2-FC-HU brake hose 3-RC-HU brake hose 4-wheel speed sensor (rear wheel) 5- rear disc brake main pump 6- rear brake lever 7- rear brake switch 8- RMC -HU brake hose 9-FMC-HU brake hose 10-front brake switch 11-front disc brake main pump 12-front brake handle 13-hydraulic control unit 18 / 152...
Page 19: Oil Supply System
6. Oil supply system 6.1 D350 Fuel evaporation 1- Fuel level sensor 2- Fuel tank 3- Fuel pump 4- Oil-air separator (welded inside the fuel tank) 5- Fuel tank cap 6- Adsorption/vent pipe 7-High pressure fuel pipe 8-Carbon tank 9-Carbon tank solenoid valve 10- Solenoid valve intake pipe 11-solenoid valve outlet pipe 12-throttle valve body assembly Fuel evaporation: Oil and gas →...
Page 20: Distribution Map Of Cooling System Accessories
7. Distribution map of cooling system accessories 1-Main water tank 2- Water tank filling port 3- Secondary water tank 4- Main water tank water inlet pipe 5- Main water tank water outlet pipe 6- Water and oil shared sensor 7- Thermostat 8- Water pump cover assembly 8.
Page 21 1-TFT meter 2-Speaker 3-Faucet lock 4-Charging port holder 5-PKE 6-Main cable 7-EFI high-voltage cable 8-Side bracket flameout switch 9-Engine Controller (ECU) 10-Rectifier 11-seat lock 12-Tipping switch 13-Windshield Motor Controller 14-Flash 15-Induction antenna 16- GPS antenna 17-USB charging cable 18-Front storage compartment lock 19- Electronic tank lock 20 - carbon can solenoid valve 21 - start relay 22 - battery 23 - PKE buzzer.
Page 22: Intake And Exhaust System
1-seat lock 2-Rectifier 3-Engine controller (ECU) 4-pke external antenna 5-Fuse box 6-Start relay 7-Battery 8- Electronic tank lock 9-Ignition coil body 10-EFI high-voltage line 11-Side bracket flameout switch 12-Buzzer. 9. Intake and exhaust system 1- Cylinder head 2- Cylinder head exhaust pipe 3- Air filter intake inlet 4- Crankshaft Box exhaust pipe 5- Air filter outlet pipe 6- Throttle valve body assembly 7- Intake manifold 8- Cylinder 9- Muffler 22 / 152...
Page 23 Intake system (indicated by the green arrow): Air → Air filter intake pipe → Air filter element → Air filter outlet pipe → Throttle valve assembly body → Intake manifold → Cylinder → Muffler Cylinder head exhaust gas control system (red arrow indicates): Exhaust gas →...
Page 24: Tool
Tool 125-piece tool set Torque wrench On-board tools Claw hammer Pull code Rubber hammer Dynamic Balancing Machine Tire raking machine Oil pan Measuring cup Funnel Taps, dies Micrometer Depth gauge Vernier caliper Feeler gauge 24 / 152...
Page 25 PT300 electronic spraying and Tire pressure gauge Magnetic base + dial indicator writing diagnostic Speedometer 17#Inner hexagon （16PIN） Hoop clamp Internal Circlip Pliers External circlip pliers Clamp multimeter Multimeter Dust blow gun 14-sided 65mm cap filter wrench Some of the above pictures are from the Internet, and the copyright belongs to the author of the original picture. Do not use it for other purposes.
Page 26: Swell Nail Description
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;...
Page 27: Maintenance
2. Maintenance Know Before Service 1. Use good quality tools, or special tools and fixtures designed by our company. The use of inferior tools may cause damage to parts, peeling of plating, improper assembly, etc. 2. The O-rings, paper gaskets, copper gaskets, and component seals used for sealing must be replaced before assembly. 3.
Page 28: D350 Maintenance Schedule
D350 Maintenance schedule ：Tighten ★:Comment : inspection（Inspect and clean,adjust,lubricate or replace if necessary） :replace Initial Every Inspectio Every Torque mile 1000/621 4000/2485 Check item n before 8000/4971 Replace regularly N.m/kgf.m driving Months Initial 3 Every 15 Every 30 Inspection every 2 years or 20,000 Cradle buffer glue kilometers (12427 mile) Air filter (filter element)
Page 29: D350 Air Filter (Filter Element), Air Inlet Filter Element
ensure riding comfort. Transmission system: If it is found th at the driving speed has dropped significantly, it is recommended to maintain and inspect th e CVT transmission system at any time, and replace it in advance if necessary. ●The initial maintenance should be carried out strictly in accordance with the above table, otherwise it may cause damage to the vehicle or other unpredictable failures.
Page 30: Replace The Air Inlet Filter
d. Remove the air filter housing. 4. Replace the air inlet filter e. Place the rubber plug and tapping screw properly to avoid loss. a. Remove the sponge and replace it with a new filter element. Note that the black side faces the engine and the white side faces outward.
Page 31: Reinstall
inspection appropriately when the air humidity is large. If there is excessive dirt in the hose, be sure to check the air filter element for excessive dirt or damage, and replace the ●The vehicle must be parked on a flat and stable ground or a air filter element if necessary.
Page 32: Bolts And Nuts Of Muffler
Bolts and nuts of muffler 1. Check for air leaks at the engine exhaust. ●If you need to remove the muffler for other operations, it is The models: recommended to cover the air inlet and outlet holes of the muffler with textured paper to prevent foreign objects from entering.
Page 33: D350 Spark Plug
e. Start by snapping the 4 decorative bolt buckles. Remove D350 Spark plug the 4 M6×14 shoulder bolts (1) of the windshield with 4# Caution: Allen. Remove the windshield cover, windshield pad, and sun ●Before disassembling, blow off the dust near the spark plug visor.
Page 34: Check The Spark Plug
i. Use your fingers or a plastic crowbar to insert the arrow n. Use 4# inner hexagon to remove 3 M6×14 bolts. indication point, first pry the arrow indication point open the gap and then pull up. m. Use a dust blow gun to blow away the dust and debris j.
Page 35: Refer To The Steps To Remove The Spark Plug To Restore All Parts
d. If necessary, the gap can be adjusted by bending the side electrodes, paying attention to the strength during adjustment. e. Clean the surface of the spark plug gasket and the joint surface, and wipe off the dirt on the thread. f.
Page 36: Engine Oil
Engine oil ●The vehicle must be parked on a flat and stable ground or a lifting platform. ●Once the engine and muffler have cooled down, the operation can be performed. e. Wipe clean the joint surface with a non-woven fabric. ●When adding engine oil, prevent the engine oil from Inspect the oil drain bolt⑶...
Page 37: Add Oil
3. Add oil b. Use a 14# sleeve to loosen the oil drain bolt⑶ counterclockwise. a. Replace the filter element with a measuring cup with a viscosity of SAE5W-40/10W-40/10W-50. The new API SN grade or higher motorcycle special machine 1.75L (1.85US qt, 1.54 lmp qt, 0.46 US gal, 0.39 lmp gal).
Page 38: Throttle Valve Body
Throttle valve body Caution: ●The three-in-one sensor and stepper motor cannot be immersed in any liquid. ●It is forbidden to adjust the idle speed adjustment screw on the valve body. 1. Do not dismantle the throttle body to clean up carbon deposits a.
Page 39: Disassemble The Sensor
f. Remove the heat insulation pad and O-ring assembly, and remove the O-ring⑽. Use a 4# inner hexagon to loosen the clamp⑼ and separate the intake manifold from the valve body assembly. Use 2 10# open-end wrenches to loosen the two nuts of the fuel line⑻ and then pull them out to remove them from the bracket;...
Page 40: Throttle Valve Body Troubleshooting Process
c. Use a short Phillips screwdriver to remove the 2 GB9074.4 M4×16 bolts③ that comes with the throttle valve body assembly, and then remove the the anti-off card④, ●The vehicle must be parked on a flat and stable ground or a and then take off the stepper motor.It is forbidden to soak lifting platform.
Page 41: Throttle Cable
c. If the above two adjustments are invalid, replace the Throttle cable throttle cable with a new one. 1. Inspection 3. Lube door cable a. Check whether the rubber sleeve of the right hand If the rotation resistance is large and the bending of the handle and the throttle cable are damaged.
Page 42: Idle Speed
Idle speed Caution: ●Before checking the idle speed, you should check other engine maintenance items and the condition is normal before proceeding. ●Check the following items before checking the idle speed: The maintenance indicator light " " should not light up. The status of the spark plug has been checked.
Page 43: Fuel Evaporative Pollutant Control System
Fuel evaporative pollutant control system 1- Fuel level sensor 2- Fuel tank 3- Fuel pump 4- Oil-air separator (welded inside the fuel tank) 5- Fuel tank cap 6- Adsorption/vent pipe 7-High pressure fuel pipe 8-Carbon tank 9-Carbon tank solenoid valve 10- Solenoid valve intake pipe 11- solenoid valve outlet pipe 12-throttle valve body assembly Fuel evaporation: Oil and gas →...
Page 44: Radiator
2. D350 add coolant (antifreeze) to the Coolant Radiator expansion tank If the water level of the Coolant expansion tank is lower than the "L" line, an appropriate amount of coolant must be ●The vehicle must be parked on a flat and stable ground or a added.
Page 45: Put Coolant
b. Remove the filler cap of the Radiator to accelerate the flow of coolant. c. Wipe all the joint surfaces clean with a non-woven cloth. Check whether the bolt⑶ joint surfaces are scratched, if any, replace them with new ones. The O ring⑷ needs to be replaced every time it is disassembled.
Page 46: Check All Water Pipes For Leaks; Aging
6. Check all water pipes for leaks; aging. 1- Main water tank 2- Water tank filling port 3- Secondary water tank 4- Main water tank water inlet pipe 5- Main water tank water outlet pipe 6- Water and oil shared sensor 7- Thermostat 8- Water pump cover assembly 1- Water inlet pipe 2- Secondary water tank connection pipe 3- Main water tank inlet pipe 4- Small radiator outlet pipe 5- Cylinder inlet pipe 6-Water pump cover inlet pipe 46 / 152...
Page 47: Fuel Pipe
b. Remove a total of 4 pcs swell nails indicated by the Fuel pipe arrow. For instructions on disassembly and assembly of swell Caution: nails, please refer to the pre-service instructions in this ●A small amount of fuel will flow out when the high-pressure chapter.
Page 48: Fuel Pump
f. Pull out the high-pressure oil pipe from the bracket at b. Unplug the fuel pump and start the engine to idle until the cylinder head. the engine stops. Turn the engine stop switch to " ", power off the vehicle and lock the vehicle. After putting on waterproof and oil-proof gloves, press the anti-trip lock and pull out the high-pressure oil pipe in the direction of the arrow.
Page 49: Braking System
●When pulling out the high-level oil pipe, be sure to pull it toward the axis, and do not press or push or pull The protruding part of the fuel pump and nozzle holder. ●It is forbidden to smoke, dial mobile phones and other actions that may cause a fire at the demolition site. ●The fuel pump is a precision component that needs to be assembled in a dust-free workshop and requires strict testing, so it is forbidden to disassemble it by yourself.
Page 50: D350 Braking System Component Diagram
D350 Braking system component diagram: 50 / 152...
Page 51: Check The Brake Components
Caution: place it on a standard platform, use a dial indicator to ●This inspection should be completed by a qualified measure the run out or use a feeler gauge to check the brake maintenance organization. disc and The gap of the standard platform; such as> 0.08mm ●Regularly check whether the brake fluid level is at 3/4 of the (0.003 in), you need to replace the new brake disc.
Page 52: Check The Front And Rear Brake Switches
fit together to restore normal grip and to make the brake 3. Lubricate the movable parts of the brake fluid circulate stably. handle ●The braking distance may be longer than the original 3.1 Lubricate the front brake handle. braking distance after replacing the new brake disc or brake pad.
Page 53: Replace The Brake Pads
5. Replace the brake pads ●A qualified maintenance organization should check and maintain the brake pads on a regular basis. ●Do not drive immediately after replacing the new brake pads. Be sure to hold and release the brake handle several times to allow the brake disc and brake pads to fully fit together to restore normal grip and to make the brake fluid d.
Page 54: Replace The Rear Brake Pads
h. Press the blade pointed by the arrow ⑧ inward in the d. Grasp the outer brake pad with your left hand and insert direction of the arrow with your hand, and insert the pin ② the pin② with your right hand, being careful not to insert it to the end.
Page 55: Replace The Brake Disc
6. Replace the brake disc ●The vehicle must be parked on a flat and stable ground or a lifting platform. ●After replacing the brake discs, brake pads, or reassembling the front and rear wheels, the brake handle must be operated repeatedly until the brakes restore the braking effect.
Page 56: Replacing The Front Brake Disc
6.1 Replacing the front brake disc The front brake disc can be removed by referring to the description of the steps for disassembling the front wheel assembly in the "Front Fork Assembly" of this manual. 6.2 Replacing the rear brake disc a.
Page 57: Brake Hose
Brake hose Caution: ●This inspection should be completed by a qualified maintenance organization. ●Check the hhose according to the maintenance schedule. ●It is recommended to replace the brake hose every 4 years. Refer to steps 1 and 2 of checking brake fittings in the brake system, you can use the endoscope with LED to easily check the oil pipe joints of the ABS hydraulic control unit and the main pump, or remove the corresponding cover for...
Page 58: Replace The Front Brake Brake Fluid
2.1 Replace the front brake brake fluid ●When pinching the brake handle, it must be slow and uniform to avoid air bubbles from entering the brake a. Wrap around the front brake main pump with oil- pipeline. resistant plastic film, as shown in the previous section. ●The vent nozzle must be locked in place before the brake b.
Page 59: Check The Tires
●Check the tire pressure regularly. D350 the standard is 240kPa (2.5 kgf/cm2, 35 PSI) under normal temperature conditions. The maximum tire pressure in the cold state shall not exceed 300 kPa (3.1 kgf/cm2, 44 PSI). ●When the tire pressure is found to drop, check whether the tire has nails or small holes;...
Page 60: Adjust The Steering Mechanism
b. Keep the front wheel suspended, shake the front wheel c. Screw the adjusting nut (4b) clockwise to 50N.m (5.1 assembly in multiple directions, to confirm whether the front kgf.m, 37 lbf.ft), turn the front of the car to feel tight to fork assembly is axially strung or loosened in the radial normal, loosen 1/4 turn counterclockwise, and screw direction.
Page 61: Check The Appearance
mixing different hydraulic oils.D350 measure 497±5ml accumulated during the assembly of the dust seal, and it can (16.8±0.17 US oz, 17.5±0.18 lmp oz, 3.3±0.3 cu-in). be judged that the oil seal is not leaking. If there is a small ●After traveling on dusty or muddy roads, you should clean amount of oil stains or sludge mixture, remove the dust seal up the foreign matter on the front fork tube (exposed and wipe clean the front fork tube and oil seal surface, first...
Page 62: Troubleshooting
●It should be maintained according to the regular maintenance table. 1. Check a. One person straightens the vehicle and stabilizes the vehicle, and one person presses the rear armrest behind to observe whether the rear shock absorber can recover smoothly. b.
Page 63: Adjust The Left Rear Shock Absorption
2.2 Adjust the left rear shock absorption D350 Use the 5# inner hexagon to insert into the hole of the left rear shock absorber adjuster, and rotate to the required gear in the direction of the arrow. c. Remove the two expansion nails and two bolts (5) at the connection between the left and right parts of the fuel tank cover plate and the tail group, and remove the bushing (6) and buffer glue (7).
Page 64: Bolts And Nuts For Body And Engine Installation
f. Grasp the rear right shock absorber and remove the bolt (10) with a 16 # socket or ratchet wrench, then remove the bolt (9) and replace the rear right shock absorber. When replacing the shock absorber, replace one side of the shock absorber before replacing the other side.
Page 65: Side Bracket
2. Lubrication Side bracket a. Put away the side bracket so that the spring is in the Caution: shortest position for easy disassembly. ●Park the vehicle on a flat and stable ground or a lifting b. The thick steel wire can be rolled into a circle and put platform, and put down the main support.
Page 66: Main Bracket
3. Install the main bracket Main bracket After aligning the main bracket with the mounting holes, Caution: insert the main bracket shaft from the left. After inserting the ●Park the vehicle on a flat and stable ground or a lifting gasket, Insert the split pin, then bend the split pin on both platform, and put down the side brackets.
Page 67: Sound, Light, And Electrical Device Inspection
②MOD key: Select the next item. Operate this button when Sound, light, and electrical device driving a vehicle is prohibited. Inspection ③Windshield switch: Press the windshield glass to complete Caution: from retracting to opening or from opening to retracting. ●Before driving, check whether the lights of the whole car ④Steering switch: Push it to the right to check whether the are normal, including turn signals, tail lights, brake lights, front right and rear right turn signals are flashing normally;...
Page 68: Headlight Height Adjustment
Open the protective cap①, pull out the PKE insurance③, first insert the DC output plug of the charger provided with the car into the PKE charging port; then connect the charger input AC terminal to 110-220V household AC. ① is the protective cap for the charging DC interface;② is the charging insurance;③...
Page 69: Fuse Box
3.Fuse box Caution: ●If the fuse is blown, you must replace the fuse of the same specification. It is forbidden to use wires such as copper or iron wire for direct connection. ●If it is blown after replacement, you need to troubleshoot the entire vehicle cable before replacing it. ●This vehicle uses a small fuse.
Page 70: Troubleshooting
4. Troubleshooting If the button cannot be pressed, it is directly judged as a switch problem. If there is no response when pressed, it is necessary to judge the problem of the switch, circuit, or electrical device. 4.1 Right hand switch a.No response when pressing the start button：...
Page 71: Left Hand Handle Auxiliary Switch
d. “ ” Not responding There is a detailed description of PKE functions in the driver's manual, including the method of emergency starting the vehicle when the sensor key is exhausted, and the specific meaning of the buzzer sound. Bring the Replace the battery, the Right auxiliary induction key...
Page 72: Left Hand Switch
4.5 Left hand switch The left hand switch controls the turn signal, horn and far, low beam, hazard warning light, and overtaking light. It is difficult to check if there are more lines. 72 / 152...
Page 73: Light
4.6 Light Caution: ●When using wires to detect lamps, please pay attention to distinguish the positive and negative poles. For detailed wire colors, please refer to the electrical schematic diagram in the driver's manual provided with the car. The troubleshooting methods of the lamps are basically the same. You can directly lead the wires to the battery with the battery.
Page 74: Efi System
3. EFI system Know Before Service Caution: 1. The structure and working principle of the EFI system are relatively complicated, and it is necessary to have a certain understanding of the working principle and structural characteristics of each EFI system before checking and troubleshooting. The content of this chapter requires certain maintenance experience.
Page 75: Error Code
Error code Caution: ●Unlock the vehicle and turn on the flameout switch. When it is not started, the EFI fault light is always on as normal. If it is not on, the vehicle cannot be started. ●After starting the vehicle, if the fault light is on and the EFI failure is reported, it means that the EFI system is abnormal. ●When the EFI system reports a failure, continuing to drive the vehicle may cause damage.
Page 76: Error Code
3. Error code Code Instruction Code Instruction The heating control circuit of the upstream 1 Engine coolant temperature sensor signal is P0030 PD116 cylinder oxygen sensor is open unreasonable The upstream 1 cylinder oxygen sensor Engine coolant temperature sensor circuit voltage is P0031 P0117 heating control circuit voltage is too low...
Page 77: Efi Parts Layout
EFI parts layout OBD diagnostic Carbon canister Dump switch interface (main Fuel pump Ignition coil body EFI relay solenoid valve cable) Water and oil Throttle Body Crankshaft Fuel injector Oxygen Sensor MSE6.0 ECU shared sensor Assembly position sensor Fault diagnosis and elimination of EFI parts Caution: ●Once the EFI components are disassembled, the EFI system needs to be reset.
Page 78: Dump Switch
1. Dump switch Can ride Replace the normally dump switch Short-circuit the black-brown, white- Fuel cut off yellow wires during driving connected to the dump switch Check ECU, fuel Can't ride pump, throttle normally valve body, etc. Refer to the steps of "Maintenance-Fuel Pipe- 2.
Page 79: Carbon Canister Solenoid Valve
When reassembling, you need to pre-tighten diagonally 6. Fuel injector and then tighten the 5 bolts. Otherwise, the uneven When the engine is unstable and weak, and the power compression of the seal rubber ring of the fuel pump may performance is poor, check whether the injector is normal.
Page 80: Ignition Coils
7. Ignition coils b. Remove the left cover according to the section "Maintenance - Remove Spark Plug". Unplug the high- There is no high-voltage spark; the high-voltage spark is voltage wire in the figure from the ignition coil. weak; when the engine is started without dust, check whether the ignition coil is normal.
Page 81: Throttle Valve Body
8. Throttle valve body 8.1 Common failure phenomena 1. The engine is easy to stall when the vehicle is running, and it is difficult to start, especially cold starting. 2. Idle speed is unstable or no idle speed, and there is intermittent jitter when accelerating. 3.
Page 82: Oxygen Sensor
10. Oxygen Sensor ●The oxygen sensor must be removed after the engine and muffler have cooled down completely. When there is poor engine performance, unstable idle speed, high fuel consumption, and incorrect air-fuel ratio, check the oxygen sensor. The fault code can be read through the diagnostic Speedometer to confirm whether the oxygen sensor is faulty. 10.1 Check Find and pull out the oxygen sensor connector at the front elbow of the muffler.
Page 83: Crankshaft Position Sensor
The index finger and middle finger are respectively located under the lever. While pressing the buckle with the thumb, turn the index finger and middle finger to the thumb direction to pull out the ECU plug. Use 5# inner hexagon to remove the bolt⑴ to take off the ECU⑵.
Page 84: The Engine Cannot Start And There Is No Sign Of Fault Diagnosis Process
The engine cannot start and there is no sign of fault diagnosis process When the start button is pressed and the starter motor can drive the engine to run normally, but the engine does not work normally, and there is no sign of the car, you can refer to the following diagnosis process to troubleshoot the cause of the fault. No spark or weak Check the ignition strength...
Page 85: Poor Acceleration
Poor acceleration Rotate the rubber sleeve with the right hand. The engine speed cannot increase immediately, and there is hysteresis, and the acceleration is slow; you can refer to the following diagnosis process to troubleshoot the cause of the fault. Check Check if the air Poor...
Page 86: Unsteady Idling, Easy To Cutoff
Unsteady idling, easy to cutoff The engine is running at an unstable idling speed, easy to stall, and can return to normal after a warm car. You can refer to the following diagnosis process to troubleshoot the cause of the fault. Unsteady idling / flameout Check the oil circuit Whether it returns to...
Page 87: Analysis Flow Chart Of Efi Failure Indicator Light Always On
Analysis flow chart of EFI failure indicator light always on If the EFI failure indicator light " " is always on, you should first check whether the wires of the EFI sensors are loose. The fault light is always on during driving Read fault code Idle speed fault...
Page 88: Electrical Schematic Diagram Of Efi System
Electrical schematic diagram of EFI system 88 / 152...
Page 89: Ignition System
4. Ignition system Know Before Service 1. The content of this chapter requires certain maintenance experience. It is recommended to check or repair with a qualified maintenance organization. 2. Do not disassemble the parts connected to the 12V power supply at will after power-on, to avoid the self-inductance of the coil in the electrical appliance, which may damage the ECU or sensor due to the instantaneous voltage.
Page 90: Troubleshooting
Troubleshooting Check the following items before diagnosing the ignition system a. Check whether the spark plug is abnormal; b. Check whether the ignition coil high-voltage cap or plug is loose; c. Check whether water enters the high pressure cap; d. If there is no spark, find the ignition coil of the same model to confirm that there is no fault and install it on the faulty vehicle to test whether there is spark;...
Page 91: Ignition System Layout
Ignition system layout 1 - Dump switch 2 - PKE 3 – relay 4 - main lock 5 - right handlebar auxiliary switch 6 - right handlebar switch 7 - battery 8 - fuse box 9 - start relay 10 - ignition coil 11 - side bracket flameout switch 12 - spark plug 13 - crankshaft position sensor 14 - magneto stator 15 - ECU Caution: ●The fuse box comes with the main wiring harness and there are 3 in total.
Page 92: Ignition System Inspection
Ignition system inspection Caution: ●If there is no spark in the spark plug, check all the cable connections for looseness or poor contact before checking the ignition system. ●Use a high-precision digital multimeter. For details of the ignition coil test method, please refer to the section "Ignition Coil" in the "Electronic Injection System" chapter of this manual.
Page 93: Ignition Coils
a. Align the keyway of the flywheel with the half-circle key and install the flywheel in place, put in φ10.3×φ28×4 washer, M10×1.25×45 hexagon flange bolts, screw in the threads manually, tighten the timing chain, and turn the flywheel clockwise , Align the line immediately after the "T"...
Page 94: Starting System
5. Starting system Know Before Service 1. If current flows through the starter motor when the engine is not started, it can be judged that the starter motor is damaged and needs to be replaced. 2. Before servicing the starter motor, turn on the engine stop switch to " "...
Page 95: Starter Motor
2. Starter motor Does the Brake switch or After the vehicle is Short circuit starter motor flameout switch energized, the flameout relay work? failure ” switch is hit“ The flameout switch of the Whether the EFI Press the start Does the starting Relay failure right handle is fault light is on...
Page 96: Starting System Electrical Schematic Diagram
Starting system electrical schematic diagram Starter motor Caution: ●If the starter motor is removed for maintenance, replace the O-ring with a new one and apply a proper amount of engine oil. ●Our company only sells starter motor assemblies, not O- rings and motor parts separately.
Page 97: Disassemble The Starter Motor
d. Pull the air outlet pipe to the right side of the vehicle the electric starter reduction gear. Note that the O-ring to expose the two M6×30 bolts that fix the starter motor, needs to be correctly assembled into the box, as it will and remove them with an 8# sleeve.
Page 98: Examination
1-M6×90 bolt×2 2-O ring×2 3-O ring 4-starter motor front cover 5-gasket 6-rectangular sealing ring 7-starter motor outer shell 8- rectangular sealing ring 9-electric pole 10-screw ×2 11-Negative brush×2 12-Volute spring×4 13-Positive brush×2 14-Brush frame 15-Brush holder insulation gasket 16-Starter motor back cover 17-Insulation gasket 18-Nut×2 19- Gasket Examination Starter motor front cover：...
Page 99: Check The Starting Relay
2.2 Ground wire Check the starting relay The vehicle is powered off and locked. Set the multimeter 1. Operation check to the buzzer position, connect one test lead to the a. Remove the seat and rear storage box first, find the green/red wire, and one to any bolt connected to the frame.
Page 100: Fuel Supply System
6. Fuel supply system Know Before Service 1. Bending or twisting the control cable will affect the smooth operation, and may cause a short circuit or open circuit, causing the vehicle to lose control. 2. The operation should be carried out in an open and ventilated place. All activities that may cause sparks, such as smoking, calling on mobile phones, etc., are prohibited on the job site.
Page 101: Disassemble The Fuel Pump
d. Remove the oil pump plug in the same way. Pinch the snorkel clamp and move it down, and pull out the snorkel. Press the anti-release buckle of the high-pressure oil pipe at the end of the oil pump, and pull the high-pressure oil pipe along the axis of the oil outlet of the oil pump.
Page 102: Remove The External Parts Of The Fuel Tank Assembly
When re-assembling, you need to pre-tighten the corners When reassembling, you need to pre-tighten the corners and then tighten the 5 bolts. Otherwise, the uneven and then tighten the 4 M6×16 bolts. Otherwise, the uneven compression of the sealing rubber ring of the fuel pump will compression of the sealing rubber ring of the oil level sensor easily cause leakage and cause safety hazards.
Page 103: Cooling System
7. Cooling system Know Before Service 1. Please refer to the radiator section of the "Maintenance" chapter of this manual for the corresponding precautions for the coolant (antifreeze). 2. Check the cooling water pipe; check the height of the cooling liquid, adding and discharging the cooling liquid have been described in detail in the radiator section of the "Maintenance"...
Page 104: Coolant System Distribution Map
Coolant system distribution map 1 - Main water tank 2 - Water tank filler 3 - Auxiliary water tank 4 - Water inlet pipe of main water tank 5 - Water outlet pipe of main water tank 6 - Water oil shared sensor 7 - Thermostat 8 - Water pump cover assembly Coolant flow diagram 1 - Water inlet pipe 2 - Water outlet pipe of main water tank 3 - Water inlet pipe of main water tank 4 - Connecting pipe of auxiliary water tank 5 - Water inlet pipe of cylinder 6 - Water inlet pipe of water pump cover...
Page 105: Cooling System Disassembly
Cooling system: Small loop (indicated by the blue arrow): Water pump → cylinder inlet pipe → cylinder → thermostat → small circulation outlet pipe → water pump cover inlet pipe Big loop (indicated by the green arrow): Water pump → cylinder inlet pipe → cylinder → thermostat → small water tank inlet pipe → small water tank → small water tank outlet pipe →...
Page 106: Coolant System Hoop/Clamp Distribution Map
Coolant system hoop/clamp distribution map 1- Water pipe clamp (φ9) 2-Water pipe clamp (φ26)*3 3-Water pipe clamp (φ24) *2 4-Water pipe clamp (φ26) Thermostat assembly and small loop 1-Thermostat assembly 2-M6 × 22 Bolt * 2 3-M6 × 12 bolts * 2 4-water pipe hoop（ φ 25) 5 - Water pump cover inlet pipe 6 - Water pipe hoop（...
Page 107: Cooling System Accessories
Before reassembly, the joint surface should be cleaned. Note that the O-ring cannot be missing and must be correctly assembled in place. The hoop should be clamped inside the boss to prevent loosening. Bolt⑵ Torque: 12±1.5 N.m (1.2±0.2 kgf.m, 9±1 lbf.ft). Cooling system accessories Caution: ●Special ventilation tooling (gas pressure reducing valve, air gun, sealing tube) is required for testing.
Page 108: Attention To The Water Tank Filling Port
Plug ports A and C with self-made head, and check the sealing by ventilation from port C. Inject the gas with a pressure of 160kPa (1.63Kgf/cm2, 23.2 psi) to ensure that there is no air leakage at the nozzle. Immerse the water tank in the water for 10s and observe whether there are bubbles.
Page 109: Failure Phenomenon
5.2 Failure phenomenon When the water temperature gauge indicates high, the engine temperature is overheated, but the coolant temperature in the water tank is not high, it is not hot when touching the radiator by hand, and the small water tank fan rotates normally. It indicates that the big circulation is blocked or blocked, which can be preliminarily judged as abnormal thermostat.
Page 110: Braking System
8. Braking system Know Before Service 1. The content of this chapter requires certain maintenance experience. It is recommended to check or repair with a qualified maintenance organization. 2. Frequent inhalation of the dust generated by the brake pads, regardless of the composition, may have a certain impact on health.
Page 111: Trouble Shooting
Trouble shooting Soft feeling from brake lever a. The brake system oil circuit enters the air b. Brake fluid leakage c. The brake pads or brake discs have oil stains d. Wear of brake caliper or disc drive main pump piston seal ring e.
Page 112: Disassemble The Rear Disc Brake Main Pump
The air compressor with poor drying or filtering effect may c. Remove the brake pads according to the steps of blow dust, moisture or other debris into the main pump removing the brake pads housing that has been cleaned through the blower; high d.
Page 113: Brake Hose And Wheel Speed Sensor
c. Refer to the procedure for replacing the brake pads to Remove the brake hose and wheel speed sensor remove the brake pads first. Caution: d. Disassemble the rear disc brake caliper ●Check whether the brake hose is normal according to the Refer to the previous steps to disassemble the front disc maintenance table.
Page 114: Fmc-Hu And Rmc-Hu
Use oil-resistant plastic bag or plastic film to put it around Use an 8# sleeve to remove the bolt⑷, and take off the the bottom of the hydraulic control unit, and fix it with tape FC-HU hose. to prevent the residual brake fluid from dripping on the parts If you need to remove the hose bracket⑵, you can use 4# when the oil pipe nut joint is loosened.
Page 115: Abs System Layout
c. Pull the RC-HU head out of the gap between the pke and e. Pull out the wheel speed sensor from the clamp⑷, the frame. remove the bolt⑸ with a 4# inner hexagon, and then remove the wheel speed sensor from the car. If you need to remove the clamp⑷, you can use 4# inner hexagon to remove the bolt⑸...
Page 116: Abs Hydraulic Control Unit
c. Remove the 2 bolts that were put back in the front (1) ABS hydraulic control unit Remove the hydraulic control unit and bracket assembly Caution: from the car. ●Before disassembling the hydraulic control unit, the positive and negative electrodes of the battery must be disassembled to prevent damage to electrical components caused by misoperation.
Page 117: Abs Troubleshooting
ABS troubleshooting 117 / 152...
Page 118: Battery/Charging System
9. Battery/charging system Know Before Service 1. It is necessary to properly dispose of discarded batteries to avoid pollution to the environment. It is recommended that waste batteries be returned to a professional recycling agency for recycling. 2. It is forbidden to use chargers that have not passed the inspection to charge the battery. 3.
Page 119: Troubleshooting
Troubleshooting Battery damage or attenuation troubleshooting process Battery failure Use a Measure the multimeter to battery voltage Remove the battery and check whether Battery first, then use a battery tester to there is leakage, Check the voltage<charging measure the check the battery the leakage charging voltage voltage<14.5～14.9...
Page 120: Charging System Layout Diagram
Charging system layout diagram 1-Charging port (PKE) 2-Main fuse (25A) 3-Battery 4-Magnetic motor 5-Rectifier Electrical schematic diagram Letter Chinese green yellow English Green Yellow 120 / 152...
Page 121: Battery Disassembly
attention to first adjust the current to the high gear, and Battery disassembly then gradually reduce to the appropriate gear. 1. Disassembly c. Measure whether the leakage current is below 0.3mA. If Refer to the steps “a” to “d” in the section "Removing the it exceeds the standard value, check whether the circuit has stepper motor and cleaning the carbon deposit"...
Page 122: Remove The Rectifier
d. After unplugging the yellow 3P plug, measure the red c. Remove 2 outer hexagon M6× 22 from the bottom with positive wire and green negative wire with a multimeter, and 8 # short socket, and then pull the rectifier and rear fender the battery voltage should be measured.
Page 123: Front Fork Assembly
10. Front fork assembly Know Before Service 1. Use good quality tools, or special tools and fixtures designed by our company. The use of inferior tools may cause damage to parts, peeling of plating, improper assembly, etc. 2. The O-rings, paper gaskets, copper gaskets, and component seals used for sealing must be replaced before assembly. 3.
Page 124: Exploded View Of Front Fork Components
Exploded view of front fork components: Directional exploded view 124 / 152...
Page 125: Front Fork Exploded View
Front fork exploded view 125 / 152...
Page 126: Exploded View Of Lower Link Board
Exploded view of lower link board 126 / 152...
Page 127: Change The Direction Of The Handle
Change the direction of the handle a. Use 5# inner hexagon to remove 4 M6×30 bolts⑵, and remove the left auxiliary handle switch, the rear disc brake Caution: main pump, the right auxiliary handle switch, and the front ●When removing the disc brake oil cup, it must be vertically disc brake main pump.
Page 128: Installation Of The Direction Component
e. Unscrew the M6 provided by the right balance weight c. When installing the auxiliary handle switch, align the with 5 # hexagonal socket counterclockwise × 80 bolts, be joint surface of the auxiliary handle switch and the main careful not to screw them too many times, otherwise the nut pump of the disc brake with the triangle mark on the handle of the balance weight will fall into the handle and increase switch, and then tighten the 4 M6×30 bolts with a 5# inner...
Page 129: Replace The Front Wheel
Replace the front wheel b. Put the front wheel in the middle of the front shock absorber, shake the front wheel left and right to make the Caution: disc brake disc snap into the middle of the brake pad, align ●Be careful not to damage the ABS coil when disassembling.
Page 130: Front Wheel Assembly Exploded View
： Front wheel assembly exploded view Part name Caution Oil seal TC φ28×φ42×7 GB276 bearing 6004-2RS-C3 φ20×φ42×12 Sleeve Bend toward the left. Tire pressure sensor ABS sensor gear（56T） 265×5.0front brake disc Non-standard bolt M8×25 25 N.m(2.5 kgf.m，18 lbf.ft) GB12615 φ3.2×9 rivet (stainless steel) Inspection and maintenance of front wheel assembly：...
Page 131: Replacement Method Of Front Wheel Oil Seal And Bearing
2.2 Replacement method of front wheel oil seal counterweight method to make the wheel correct the balance of each edge part, this correction process Is what we and bearing call dynamic balance. a. Remove the front wheel assembly by referring to The dynamic balance particles of the wheels can ensure "Replace the front wheel".
Page 132: Remove The Left And Right Front Shock Absorbers
d.First press the two sides of the front mud board 3. Reinstall the shock absorber, front fender, front according to the small arrow, press the protrusion on the wheel and other components front mud board arrow inward, and then move the front mud a.
Page 133: Replace The Lower Link Board
b. Untie the binding band, and then take out the handle switch harness and brake hose in the steering handle clamp from the notch of the steering handle clamp one by one until ●The vehicle must be parked on a level and stable ground or all harnesses in the steering handle clamp are removed.
Page 134: Install Other Disassembly Components
b. Put the bearing (9), shaft ring (8) and dust cover (7) c. Install the steering handle seat block and lower yoke smeared with grease on the lower yoke plate in turn, screw plate, put in the gasket (3), and finally screw in the cap nut in one adjusting nut (5) of the steering column, and tighten (2) with a torque of 100N.
Page 135: Disassemble The Engine Of The Vehicle
11. Disassemble the engine of the vehicle Caution: d. Take out the decorative buckle (2) on the bolt, and use ●The vehicle must be parked on a level and stable ground or the 4 # hexagonal socket to remove the two M6 × 16 bolts (1) on a lifting platform.
Page 136: Put The Coolant And Pull Out The Connection Plug
c. Remove the left cover in the same way. h. Remove the left pedal by referring to”Removing the Spark plig. i. Remove the right paedal and surround the right part in the same way. d. Remove two expansion nails and two bolts (5) at the connection between the left and right part of the fuel tank cover plate and the tail group respectively with 4 # socket head and 8 # sleeve, and remove the bushing (6) and buffer...
Page 137 c. Remove the plugs of the stepper motor ① and sensor g. Use an 8# sleeve to remove a bolt on the starter motor, ② on the throttle valve body according to the steps in and take out the negative wire⑧ on the bolt. Caution: The negative wire of the early production model Removing the Throttle Valve Body Assembly to Clean the is fixed on the bolt around the starter motor.
Page 138: Disassemble The Engine
k. Remove one M6 fixing the wheel speed sensor on the d. The two people hold the left and right handlebars and rear rocker arm with the 4 # hexagonal socket × Take out the frames respectively, push the whole motorcycle forward, wheel speed sensor and take it out of the fixed clamp.
Page 139 c. open the brake pads on the rear brake caliper with a flat- d. One person uses 21 # socket to extend into the front of blade or other suitable tool, then install the brake caliper on the fine filter to fix one nut (2) on the left side of the motorcycle to fix the engine, and the other person uses 24 # the rear rocker arm, and then install 2 M8×37 bolts⑹, use socket to replace one bolt (1) on the right side of the...
Page 140: Disassembly And Assembly Of Vehicle Covering Parts
12. Disassembly and assembly of vehicle covering parts Caution: ●The vehicle must be parked on a level and stable ground or on a lifting platform. ●The operation can only be performed after the engine and muffler has cooled down completely. ●Attention and sequence when removing the plastic buckle to avoid the buckle from breaking 1.Windshield 2.Front headlight 3.Front right storage box 4.Front right panel 5.
Page 141 1.Instrument panel 2.Front right pedal pad pressure plate 3.Front right pedal pad 4.Rear right pedal pad 5.Rear right pedal pad presser 6.Fuel tank cover 7.Middle part of the fuel tank cover 8.Front left pedal pad pressure plate 9.Front left pedal rubber pad 10.Rear left pedal rubber pad 11.Rear left pedal pad presser 141 / 152...
Page 142: Disassembly And Assembly Of Vehicle Panel
Disassembly and assembly of vehicle panel Removal of the front sun visor Caution: a. Use 4# inner hexagon to remove the 3 swell nails on the ●During disassembly, please pay attention to the force to front sun visor. prevent breaking the buckle. ●When removing the panels, please remove them in strict order.
Page 143: Disassembly Of The Left &Right Side Cover
c. Remove 4 M6 × 14 from the front cover plate with 4 # b. Hold the seat cushion with one hand, remove the 3 M6 socket head Shoulder bolt (1). Separate the front panel from nuts fixed on the seat cushion bracket by 10# double offset the front cover.
Page 144: Disassembly Of The Left, Right Fuel Tank Cover
Disassembly of the left, right fuel tank Removal of the front left and right panels cover a. Remove M6× 12 bolts (1) from the front left and right panels with 4 # hexagonal socket and expansion nails. a. Remove 2 expansion nails connecting the fuel tank trim cover and the tail skirt with 4 # hexagonal socket.
Page 145: Removal Of Front Left And Right Panel Bottom Lining
b. Remove the M6× 14 Shoulder bolt (1) at the left of the headlamp with the 4 # hexagonal socket. Remove the expansion nail with 4 # hexagonal socket. Remove the bolts and expansion nails on the other side in the same way. c.
Page 146: Removal Of Windshield Base
b. Unfasten the wire clamp and tidy up the harness. b. Remove the two M6× 16 on the hydraulic control unit bracket with 8 # socket. Remove the hydraulic control unit with bolts. Remove M8 from horn bracket with 6 # hexagonal socket ×...
Page 147: Disassembly The Middle Cover Of The Fuel Tank
f. Use a Phillips screwdriver to remove two M4 × 16 bolts, c. Find and unplug the fuel tank lock connector from the separate the rocker arm pressure block from the right lower left side of the fuel tank, and sort out the harness of the fuel rocker arm.
Page 148: Disassembly The Left And Right Storage Boxes
Disassembly the left and right storage boxes a. Press the switch indicated by the small arrow to open the front right storage box; Remove M6× 14 Shoulder bolt (1) with 4 # hexagonal socket. Remove the front right storage box cover and the front right storage box inner cover bracket togethe e.
Page 149: Removal Of Left And Right Pedals And Surrounding Left And Right Parts
d. Turn to the back and pull the cable out of the lock frame h. Use a Phillips screwdriver to remove three M4 × 25. in the direction of the arrow. Turn back the front and remove Remove the electronic storage box lock after the bolt. M6×...
Page 150: Disassembly Of The Surrounding Bottom
d. Use the 4 # hexagonal socket to remove the 1 M6× 14 Disassembly of the surrounding bottom Shoulder bolt ⑴ at the left of the surrounding base plate a. Grasp the rear part of the around the bottom plate by connection;...
Page 151: Removal Of Tail Skirt And Tail Lamp
e. Remove the right part of the tail skirt in the same way. Removal of tail skirt and tail lamp f. Remove two M6 with 4 # socket head × 14 Shoulder bolt a. Use the 4 # hexagonal socket to remove the 3 expansion (4).
Page 152 d. Use a ratchet wrench+8 # socket to extend under the rectifier and remove the two outer hexagon M6× 22 bolts (7) fixing the rectifier. Caution: The rectifier can not be taken out at this time, just hang it in the air e.

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