Zontes ZT350-R 2022 Service Manual
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Zontes ZT350-R 2022 Service Manual

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ZT350-R/R1 (EURO Ⅴ)
Service manual
2022/5/3

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Summary of Contents for Zontes ZT350-R 2022

  • Page 1 ZT350-R/R1 (EURO Ⅴ) Service manual 2022/5/3...
  • Page 2 Contents Table of Contents Page Table of Contents Frame component 1.1 Electrical device component-1…………………………………………………………………………………………………………………………………………………………………………………………………………… 8 Main harness, dump switch, relay, flasher, rectifier, ignition coil 1.2 Electrical device component-2…………………………………………………………………………………………………………………………………………………………………………………………………………… 9 Flameout switch, horn, wake-up switch 1.3 Frame plastic parts……………………………………………………………………………………………………………………………………………………………………………………………………………………… 10 Line clamp, side cover round glue, fuel tank liner limit glue 1.4 Directional column component……………………………………………………………………………………………………………………………………………………………………………………………………………...

  • Page 3: Table Of Contents

    Contents Table of Contents Page Sub-mud component after discomponent 4.4 Rear turn signal after sale parts………………………………………………………………………………………………………………………………………………………………………………………………………… Rear left and right turn signals and rear license plate lights for sale 4.5 Rear mud board………………………………………………………………………………………………………………………………………………………………………………………………………………………… 4.6 Rear shock absorption…………………………………………………………………………………………………………………………………………………………………………………………………………………… 23 Demolition after shock absorption, rear shock absorption adjustment 4.7 Rear wheel component 1…………………………………………………………………………………………………………………………………………………………………………………………………………………...

  • Page 4: Demolition After Shock Absorption, Rear Shock Absorption Adjustment

    Contents Table of Contents Page Disassemble chain adjuster and maintain 5.11 Rear mud board………………………………………………………………………………………………………………………………………………………………………………………………………………………… 5.12 Rear shock absorption…………………………………………………………………………………………………………………………………………………………………………………………………………………… 41 Demolition after shock absorption, rear shock absorption adjustment 5.13 Rear fork component…………………………………………………………………………………………………………………………………………………………………………………………………………………… Decomposed flat fork component 5.14 Replace the rear brake pads……………………………………………………………………………………………………………………………………………………………………………………………………………… 43 5.15 Rear brake main pump adds brake fluid…………………………………………………………………………………………………………………………………………………………………………………………………...
  • Page 5 Contents Table of Contents Page 7.7 Water tank component-3………………………………………………………………………………………………………………………………………………………………………………………………………………… 59 Remove the auxiliary water tank/auxiliary water tank support 7.8 Oil cooler component 1………………………………………………………………………………………………………………………………………………………………………………………………………………… Remove the oil cooler 7.9 Oil cooler component 2………………………………………………………………………………………………………………………………………………………………………………………………………………… Remove the oil cooler bracket Front fork component 8.1 Throttle/clutch cable clearance adjustment………………………………………………………………………………………………………………………………………………………………………………………………...
  • Page 6 Contents Table of Contents Page Front shock absorber, headlight bracket, faucet lock, upper plate component 8.16 Uplink plate, direction handle block component………………………………………………………………………………………………………………………………………………………………………………………… 77 Disassemble the direction of the block, the upper plate 8.17 ABS Brake System-1…………………………………………………………………………………………………………………………………………………………………………………………………………………… 78 Brake brake fluid、disassemble the front disc brake main pump and the tubing、ABS control unit 7.18 ABS Brake System-2……………………………………………………………………………………………………………………………………………………………………………………………………………………...
  • Page 7 Contents Table of Contents Page Side cover component 11.1 Side cover component(old applique)…………………………………………………………………………………………………………………………………………………………………………………………………… Decomposition side cover component Skirt, rear mud board, electrical component box component 12.1 Skirt trim cover component……………………………………………………………………………………………………………………………………………………………………………………………………………… 93 Remove the tail skirt left and right trim cover component 12.2 Skirt trim cover component………………………………………………………………………………………………………………………………………………………………………………………………………………...
  • Page 8 Contents Table of Contents Page Decompose the front section of the muffler, oxygen sensor, muffler flange Lower shroud component 14.1 Lower shroud component-1……………………………………………………………………………………………………………………………………………………………………………………………………………… 106 Remove the shroud component, shroud bracket 14.2 Lower shroud component-2……………………………………………………………………………………………………………………………………………………………………………………………………………… 107 Decompose the lower shroud component All the information, illustrations and photographs collected in this manual are compiled according to the latest products.
  • Page 9 1、FRAME COMPONENT Fig.1 FRAME PARTS Electronic parts COMPONENT-1 COMPONENT PART NO. PART NAME CAUTION 1184300-033000 ZT350-R wiring harness assembly-A 1270300-273000 φ8 clip(L=73) 1244100-052000 Buffer rubber of flanging bushing (φ8.5×φ14×1) 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1184300-024100 2.5 Generation PKE Assembly (including induction key 1274100-057095 Flanging bushing φ6.2×φ8.4×3.5＋φ14×1.5 1274200-017000 ZT310-R support of tail light 1251100-101000 Non-standard bolt M6×12 (304 stainless steel)
  • Page 10 1、FRAME COMPONENT Fig.2 FRAME PARTS Electronic parts COMPONENT-2 COMPONENT PART NO. PART NAME CAUTION 1250105-138093 GB5789M6×20 (environmental color) 1274300-065000 ZT350-VX front oil outlet pipe bracket 1100100-814000 ZT350-R brake hose FC-HU segment 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color Zinc) 1184200-004000 ZT310 horn 1274100-017000 ZT250-S cable buckle 1224100-037000 Grade 0 flame retardant tie (black 3.6×295)
  • Page 11 1、FRAME COMPONENT Fig.3 FRAME PARTS Frame plastic parts COMPONENT PART NO. PART NAME CAUTION 1244100-019000 ZT250-S fuel tank spacing glue 1240300-007000 HJ125-6 Battery rubber gasket 1244100-002000 ZT250-S Side cover round rubber 1244100-061000 ZT250 anti-water rubber of frame 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1274100-057095 Flanging bushing φ6.2×φ8.4×3.5＋φ14×1.5 1244100-052000 Buffer rubber of flanging bushing (φ8.5×φ14×1) 1224300-086000 ZT350-R right wire harness holder...
  • Page 12 ●Please check whether the steel beads of the conjoined body have abnormal phenomena such as partial Remove the axletee ring ⑸ of the upper riser and the steel ball⑹. abrasion and rust.If YES, please buy the regular accessories on ZONTES official website, if not, please Remove the steel ball of the down connected plate component⑺.
  • Page 13 PROCEDURE: ●Checking the cushion loop Checking whether the cushion loop ⑵and ⑶ is frayed, if as it, please replace it on ZONTES website, fix the cushion loop well and paint the lubricating grease on it with appropriate tool. ●Sider support Use the cross screwdriver to remove the side support spring⑸, and guard against the personal injury caused by...
  • Page 14 2-FRAME & ENGINE COMBINATION Fig.1 FRAME & ENGINE Engine combination COMBINATION PART NO. PART NAME CAUTION 1251112-003093 M6×45 hexagon flange face 9.8 bolt (color zinc) 10N.m 4050854-002051 ZT310-R engine left rear cover (dark gray) 1251300-057093 Non-standard nut M10×1.5（dacromet） 65±5N.m 1274300-082000 ZT350－R Upper hanging piece (outside association) 1251100-060000 Non-standard bolt M10×1.5×90 1251112-019000 Non-standard boltM12×85(10.9级/dacromet) 1250305-009091 GB6187.1 M12×1.25（White zinc）...
  • Page 15 3-INTAKE SYSTEM COMPONENT Fig.1 INDUCTION Maintain the filter element of the air filter SYSTEM COMPONENT PART NO. PART NAME CAUTION 1250303-010093 GB6177.1M6（color zinc） 1274300-038000 ZT350－R electromagnetic valve bracket 1050954-009000 YH Carbon tank electromagnetic valve ZT44 Throttle Valve Decoupling Rubber Tube 1050958-015000 (Φ6×Φ10×420+Φ9clip×2) 1251100-101000 Non-standard bolt M6×12 (304 stainless steel)
  • Page 16 3-INTAKE SYSTEM COMPONENT Fig.2 INDUCTION The air filter assembly SYSTEM COMPONENT PART NO. PART NAME CAUTION 1224300-002000 ZT350－T Air filter 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1251300-063093 Plywood M6×11×15（Environmental protection） 1251100-061093 M6×22 Hexagon flange bolt（color zinc） 1051371-002000 Φ59×9 clamp components 1224300-110000 Reverse buckle Velcro strap (20×200mm) PROCEDURE: Press the snap pointed by the arrow "a","b","d"...
  • Page 17 3-INTAKE SYSTEM COMPONENT Fig.3 INDUCTION Throttle valve body component SYSTEM COMPONENT PART NO. PART NAME CAUTION 1051454-016000 45×2.5 Fluorine rubber O-ring 1050958-003000 ZT184 MP Intake pipe assembly 1051354-004000 Φ56×10 Hoop assembly 1050958-001000 ZT44 Throttle body part component (position sensor) 1050954-023000 EV14 Fuel injectorG48 1050970-002000 ZT1P72MN injector holder 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color Zinc) GB9074.13 Hexagon cross groove spring,flat cushion...
  • Page 18 3-INTAKE SYSTEM COMPONENT Fig.4 INDUCTION Replace air filter element SYSTEM COMPONENT PART NO. PART NAME CAUTION 4134300-003000 ZT350－Tair filter core (with carton packaging) ROCEDURE: ●Filter element If you need to maintain the filter element of the air filter, remove the seat cushion, the right side cover Take the standard part ①...
  • Page 19 4、DOUBLE ROCKER COMPONENT Fig.1 REAR WHELL Rear sub-mud assembly 1 COMPONENT PART NO. PART NAME CAUTION 1250105-149093 GB5789M8×30 (environmental color) 1250105-143093 GB5789M8×35 (environmental color) 1250501-007093 GB93 φ8 (environmental color) 1250503-021093 GB97.1φ8 (environmental color) 1250303-011093 GB6177.1M8(color Zinc) 4024300-002021 350-R rear auxiliary mud plate aluminum alloy bracket 1184200-030000 ZT310-R adapter cable of vice fender(L=2000) 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1274100-095000 ZT250-S Flameout switch wire fixing bracket...
  • Page 20 4、DOUBLE ROCKER COMPONENT Fig.2 REAR WHELL Rear sub-mud assembly 2 COMPONENT PART NO. PART NAME CAUTION 1224200-091000 ZT310-R rear mudguard fender 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1224300-007000 ZT350-R rear auxiliary fender fender 1250105-137093 GB5789M6×16 (environmental color) 1250501-007093 GB93φ8 (environmental color) 1274100-057095 Flanging bushing φ6.2×φ8.4×3.5+φ14×1.5 1244100-052000 Cuff bushing cushioning rubber (φ8.5×φ14×1) 1251100-101000 Non-standard bolt M6×12 (304 stainless steel)
  • Page 21 4、DOUBLE ROCKER COMPONENT Fig.3 REAR WHELL Rear sub-mud assembly 3 COMPONENT PART NO. PART NAME CAUTION 1251300-063093 Splint M6×11×15 (environmental color) 1244100-006000 ZT250-S rear license plate cushioning rubber 1224200-091000 ZT310-R rear Associate fender 1270300-273000 Φ8 line clamp (L = 73) 1174200-035000 ZT310 rear turn light (including license plate light) 1174100-002000 ZT250-S rear reflector 1251100-102000 Non-standard bolt M6×16 (304 stainless steel)
  • Page 22 4、DOUBLE ROCKER COMPONENT Fig.4 REAR WHELL Rear turning light parts for after sales service COMPONENT 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 23: Rear Mud Board

    4、DOUBLE ROCKER COMPONENT Fig.5 REAR WHELL Rear inner mudguard COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non-standard Bolt M6×16（SS） 1274100-057095 Bush φ6.2×φ8.4×3.5＋φ14×1.5 1244100-052000 Gum cushion, bush（φ8.5×φ14×1） 1224200-003000 ZT310－Z rear disc brake oil tube cleat 1224300-048000 ZT350-R rear inner mud plate 1251700-059093 Bush φ6.4×φ9×8＋φ18×2（environmental color-zinc）...
  • Page 24 4、DOUBLE ROCKER COMPONENT Fig.6 REAR WHELL Rear shock absorber COMPONENT PART NO. PART NAME CAUTION 1251112-019000 GB5187 non-standard bolt M12×1.25×85 1250305-009091 GB6187.1 M12×1.25(White Zinc) 1251112-017000 GB5187 non-standard bolt M12×105 1250501-016000 GB93φ12 spring pad 1251500-001097 Non-standard flat pad φ12×φ20×2 (chrome plated) 1114300-008000 ZT350-GK rear shock absorber PROCEDURE: ●Rear shock absorber...
  • Page 25 4、DOUBLE ROCKER COMPONENT Fig.7 REAR WHELL Rear wheel component 1 COMPONENT PART NO. PART NAME CAUTION 1251100-105000 ZT310-R chain adjuster bolt M10×70 1251300-050000 ZT310-R chain adjuster bolt M10 (304 stainless steel) 1251300-087000 ZT350 rear wheel hollow shaft nut(M25) 110N.m 1274300-015051 ZT350 right chain adjuster (dark gray) 1250401-019091 GB91 Split pin Φ4×40 1094300-010000 ZT350 rear wheel hollow shaft Φ25×278 1274300-014051 ZT350 Left Chain Adjuster (Dark Gray)
  • Page 26 4、DOUBLE ROCKER COMPONENT Fig.8 REAR WHELL Rear wheel component 2 COMPONENT PART NO. PART NAME CAUTION ZT350－GK rear wheel right sleeve(φ25×φ30× 1274300-011000 15.5/shoulder φ38) 1244300-002000 ZT350－GK rear sprocket buffer adhesive 1250305-002091 GB6187.1 M8(White zinc) 24N.m 1094300-015000 ZT350－GK rear sprocket seat 1080100-121000 ZT350－GK 520－44T Sprocket 1251100-117093 Non-standard inner hex bolt M8×25 24N.m...
  • Page 27 4、DOUBLE ROCKER COMPONENT Fig.9 REAR WHELL Rear wheel component 3 COMPONENT PART NO. PART NAME CAUTION 1230100-564000 160/60ZR17 CM－S3 69W TL E4 1094300-006000 ZT350-GK rear aluminum wheel (MT4.5×17\black) 1100100-784000 ZT350－GK rear brake disc (265×4.5) 1274200-058000 ABS induction ring (60 teeth) 1251100-117093 Non-standard inner hex bolt M8×25 22～24N.m 1184300-034000 ZT350 tire pressure sensor (M8 straight head)

  • Page 28: Rear Fork Component

    4、DOUBLE ROCKER COMPONENT Fig.10 REAR WHELL Rear fork component COMPONENT PART NO. PART NAME CAUTION 1252200-040000 ZT310-R1 rear flat fork hollow shaft Φ20×315 1251300-067000 ZT250－R rear wheel hollow shaft nut 110±5N.m 1080200-106000 ZT350－GK 112 pitch chain (520 oil seal chain) 1251300-050000 ZT310－R chain adjuster bolt M10(304 stainless steel) 1251100-105000 ZT310-R chain adjuster bolt M10×70 ZT350 aluminum alloy rear flat fork (dark gray matte)

  • Page 29: Replace The Rear Brake Pads

    4、DOUBLE ROCKER COMPONENT Fig.11 REAR WHELL Replace the rear brake pads COMPONENT PART NO. PART NAME CAUTION 1100100-092000 ZT250-S rear disk brake pads (HS10) After-sales PROCEDURE: ●Disassemble disc brake arrester Using strait screwdriver to disassemble nut①. Disassemble pin axle② with a 5# inner hexagon socket. Disassemble rolling axle③...

  • Page 30: Rear Brake Main Pump Adds Brake Fluid

    4、DOUBLE ROCKER COMPONENT Fig.12 REAR WHELL Rear brake main pump adds brake fluid COMPONENT PART NO. PART NAME CAUTION 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) PROCEDURE: ●Add disc brake liquid Cover the right pedal bracket and muffler with a waterproof plastic bag to prevent the brake fluid from dripping onto the paint and causing corrosion.

  • Page 31: Adjustment Chain

    5、 SINGLE ROCKER COMPONENT Fig.1 Rear wheel, swinging Adjustment chain arm assembly PART NO. PART NAME CAUTION 1251100-117093 Non standard hex socket bolt M8×25 1250501-004091 GB93φ10（white zinc） 1250503-006091 GB97.1φ10（white zinc） 1251100-204000 Non-standard Bolt M16×1.5×50（color zinc） 100N.m PROCEDURE: ●Rear auxiliary mud plate assembly Remove the bolt (1) at the bottom of the rear sub-slab assembly and remove the spring washer (2) and flat washer (3).

  • Page 32: Sprocket Guard

    5、 SINGLE ROCKER COMPONENT Fig.2 Rear wheel, swinging Sprocket baffle arm assembly PART NO. PART NAME CAUTION 1251100-101000 Non-standard Bolt M6×12（304 stainless steel） 1274100-057095 Bush φ6.2×φ8.4×3.5＋φ14×1.5 1244100-052000 Gum cushion, bush（φ8.5×φ14×1） ZT310-R1 sprocket baffle PROCEDURE: ●Sprocket baffle Remove the bolt⑴, remove the flange bushing ⑵, cushion rubber⑶; finally remove the sprocket baffle⑷. CAUTION: ●When reassembling, pay attention to the limit boss on the sprocket baffle to be inserted into the limit hole of the rear fork.

  • Page 33: Sprocket Assembly 1

    5、 SINGLE ROCKER COMPONENT Fig.3 Rear wheel, swinging Sprocket assembly 1 arm assembly PART NO. PART NAME CAUTION 1251100-117093 Non standard hex socket bolt M8×25 1250501-004091 GB93φ10（white zinc） 1250503-006091 GB97.1φ10（white zinc） 1251100-204000 Non standard bolt M16×1.5×50(color zinc) 100N.m 1094100-062000 M35 nut locking spring 1251300-070000 Non standard nut M35×1.5(environmental color zinc) 200N.m 1080200-055000 ZT250－R 114 chain（CHOHO520HX/Open type）...

  • Page 34: Sprocket Assembly 2

    5、 SINGLE ROCKER COMPONENT Fig.4 Rear wheel, swinging Sprocket assembly 2 arm component PART NO. PART NAME REMARKS 1274100-108000 Bushing Φ45×Φ35×5.5+Φ54×Φ35×2 1274100-105000 Bushing Φ46×Φ35×7.3 1244100-087000 ZT310-R1 single rear fork sprocket buffer rubber 1094200-013000 ZT310 single rear fork sprocket seat inner shell 1244200-088000 O-ring (Φ52.4×2.6) 1080100-112000 ZT250-T1 single rear fork arm 520-43T sprocket 1251100-190000 Non standard bolt M10×1.5×30（color zinc）...

  • Page 35: Rear Wheel Component 1

    5、 SINGLE ROCKER COMPONENT Fig.5 Rear wheel, swinging Rear wheel component arm component PART NO. PART NAME REMARKS 1251300-071000 Non standard nut M12×1.5（chromed） 110N.m 1230100-564000 160/60ZR17 CM－S3 69W TL E4 280kPa ZT350-GK1 single rocker arm rear aluminum wheel 1094300-008000 (MT4.5×17/black) 1260100-238000 ZT310-R1 rear wheel rim sign spring 1210142-000100 ZT310-R1 single rocker black rim sign 1184300-034000 ZT350 tire pressure sensor (M8 straight head)

  • Page 36: Rear Wheel Component 2

    5、 SINGLE ROCKER COMPONENT Fig.6 Rear wheel, swinging Rear axle assembly arm component PART NO. PART NAME REMARKS 1181200-118000 Wheel speed sensor(A) 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1251100-123093 Non standard M8×25(color zinc) 1250104-006097 GB16674M6×12（chromed/HH） 1274200-119000 Single rocker rear flat fork tubing bracket 1251100-117093 Non standard hex socket bolt M8×25 1274200-058000 ABS gear ring(60T) 1100100-784000 ZT350-GK rear brake disc (265×4.5)

  • Page 37: Rear Sub-Slab Assembly 1

    5、 SINGLE ROCKER COMPONENT Fig.7 Rear wheel, swinging Rear sub-mud assembly 1 arm assembly PART NO. PART NAME CAUTION 1184200-030000 ZT310－R vice fender extension cable(L=2000) 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1274100-057095 Flanging bushing φ6.2×φ8.4×3.5+φ14×1.5 1244100-052000 Cuff bushing cushioning rubber (φ8.5×φ14×1) ZT310-R1 rear sub-mud aluminum alloy bracket 1020242-265021 (homemade)

  • Page 38: Rear Auxiliary Mud Plate Assembly 2

    5、 SINGLE ROCKER COMPONENT Fig.8 Rear wheel, swinging New rear sub-mud component 3 arm component PART NO. PART NAME CAUTION 1251300-063093 Plywood M6×11×15（environment color） 1244100-006000 ZT250－SRear license plate buffer rubber ZT310－RRear auxiliary mudguard fender（250R、 1224200-091000 310R/X/T） 1270300-273000 φ8 Clip（L=73) 1174200-035000 ZT310Rear turn signal (including license plate light） 1174100-002000 ZT250－S Back reflector 1251100-102000 Non-standard boltM6×16（304stainless steel）...

  • Page 39: Rear Turn Signal After Sale Parts

    5、 SINGLE ROCKER COMPONENT Fig.9 Rear wheel, swinging Rear turning light parts for after sales service arm component PART NO. PART NAME CAUTION 1224200-120000 ZT310 Rear turn signal bracket 1174200-019000 ZT310－X Rear left turn signal 1174200-020000 ZT310－X Rear right turn signal 1174200-021000 ZT310－X License Plate Light PROCEDURE: ●Rear license light...

  • Page 40: Chain Adjuster Assembly

    5、 SINGLE ROCKER COMPONENT Fig.10 Rear wheel, Chain adjuster assembly swinging 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) 1251100-204000 Non-standard bolt M16×1.5×50 (environmental color)
  • Page 41 5、 SINGLE ROCKER COMPONENT Fig.11 Rear wheel, Rear mud board swinging arm component PART NO. PART NAME CAUTION 1250104-006097 GB16674M6×12（chromed/HH） 1274100-057095 Flanging bushing φ6.2×φ8.4×3.5＋φ14×1.5 1244100-052000 Cuff bushing cushioning rubber (φ8.5×φ14×1) 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1210342-424000 ZT310 rear mud board decal (RACING) 1224300-087000 ZT350-R1 rear mud board 1210343-056000 ZT350-GK chain decal PROCEDURE:...
  • Page 42 5、 SINGLE ROCKER COMPONENT Fig.12 Rear wheel, Rear shock absorber swinging arm component PART NO. PART NAME CAUTION 1251112-019000 GB5187 non-standard bolt M12×1.25×85(10.9 garde/da 1250305-009091 GB6187.1 M12×1.25(White Zinc) 1114300-007000 ZT350-R1 rear shock absorber 1251100-132003 Non-standard bolt M10×1.5×80 (Dacromet) 1251300-057093 Non-standard bolt M10×1.5（Dacro） PROCEDURE: ●Rear shock absorber After the side bracket is lowered, one person's left hand will kill the direction to the left while the right hand...
  • Page 43 5、 SINGLE ROCKER COMPONENT Fig.13 Rear wheel, Rear wheel assembly swinging arm component PART NO. PART NAME CAUTION 1252200-040000 ZT310-R1 rear flat fork hollow shaft 1251300-067000 ZT250－R rear wheel axle nut 110±5N.m ZT310 single rocker arm aluminum alloy flat fork right 1244200-085000 dustproof rubber plug ZT310 single rocker arm aluminum alloy flat fork left...
  • Page 44 5、 SINGLE ROCKER COMPONENT Fig.14 Rear wheel, Change rear brake arresters swinging arm assembly PART NO. PART NAME CAUTION 1100100-092000 ZT250－S rear disc brake arrester(HS10) after sale PROCEDURE: ●Disassemble disc brake arrester Loosen the upper slide shaft① with a 14# sleeve. Loosen the lower slide shaft②...
  • Page 45 5、 SINGLE ROCKER COMPONENT Fig.15 Rear wheel, Rear disc brake main pump adding braking liquid swinging arm assembly PART NO. PART NAME CAUTION 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) PROCEDURE: ●Add disc brake liquid Cover the right pedal bracket and muffler with a waterproof plastic bag to prevent the brake fluid from dripping onto the paint and causing corrosion.

  • Page 46: Pedal Component

    6-PEDAL COMPONENT Fig.1 FOOT PEDAL Shift lever adjustment COMPONENT PART NO. PART NAME CAUTION 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color zinc) 1271200-163000 ZT250－S Gear swift rod spline of Rocker arm 1250301-020093 GB6170M6 (environmental color) 1274300-026000 ZT350-R shift lever adjusting screw (Φ10×82.3) 1250301-018093 GB6170 M6-LH (army green) 4024300-029000 ZT350－R shift lever rocker arm (lucluding bearings) PROCEDURE:...
  • Page 47 6-PEDAL COMPONENT Fig.2 FOOT PEDAL Right footrest component 1 COMPONENT PART NO. PART NAME CAUTION 1250205-023000 GB70.1 inner hexagonal M8×35 (color zinc) 1250205-034093 GB70.1 inner hexagonal M8×30 (color zinc) 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) ZT350-GK-H1 muffler suspension hollow cushioning 1244300-022000 rubber ZT350 muffer flanging bushing(φ8.3×φ11.5×20.5×φ...
  • Page 48 6-PEDAL COMPONENT Fig.3 FOOT PEDAL Right footrest component 2 COMPONENT PART NO. PART NAME CAUTION 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1274100-057095 Flanging bushing φ6.2×φ8.4×3.5＋φ14×1.5 1244100-052000 Buffer rubber of flanging bushing (φ8.5×φ14×1) 1224300-023000 ZT350 rear brake main pump heat shield 1244300-039000 ZT350－R rear muffer silicone pad 1251112-001093 M6×16 Hexagon flange bolts (color zinc) 1100100-787000 ZT350－GK rear disc brake main pump assembly...
  • Page 49 6-PEDAL COMPONENT Fig.4 FOOT PEDAL Right footrest component 3 COMPONENT PART NO. PART NAME CAUTION GB70.3 M8×30 (10.9 grade environmental protection 1250205-124000 color) 1274300-027000 ZT350 pedal bearing cover 4024300-028000 ZT350－R pedal rocker arm(lncluding bearings) 1260100-303000 ZT350－R brake return spring 1274300-019000 ZT350 brake adjusting pedal 1251112-001093 M6×16 Hexagon flange bolts (color zinc) 1244100-002000 ZT250－S Side cover round rubber 1020443-011000 ZT350－R muffler anti－scalding...
  • Page 50 6-PEDAL COMPONENT Fig.5 FOOT PEDAL Right footrest component 4 COMPONENT PART NO. PART NAME CAUTION 4064300-021051 ZT350 right pedal support (HT/ dark gray matte) 1274300-033000 ZT350-R Pedal pin 1244100-052000 Buffer rubber of flanging bushing (φ8.5×φ14×1) 1264100-006000 ZT250－S Pedal circlip 1264100-004000 ZT250－S front right foot pedal torsional spring 4064300-010051 ZT350－GK R, front pedal component (dark gray matte 4064300-012051 ZT350－GK R, rear pedal component (dark gray matte) 1260100-301000 ZT350－R foot pedal steel ball spring...
  • Page 51 6-PEDAL COMPONENT Fig.6 FOOT PEDAL Left footrest component 1 COMPONENT PART NO. PART NAME CAUTION 1250205-034093 GB70.1 inner hexagonal M8×30(color zinc) 1250205-023000 GB70.1 inner hexagonal M8×35(color zinc) 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color zinc) 1184300-013000 ZT350 rectifier (350W) 1250205-124000 GB70.3 M8×30 (color zinc) 1274300-027000 ZT350 pedal bearing cover 4024300-029000 ZT350-R shift lever rocker arm (lucluding bearings)
  • Page 52 6-PEDAL COMPONENT Fig.7 FOOT PEDAL Left footrest component 2 COMPONENT PART NO. PART NAME CAUTION 1250303-010093 GB6177.1M6 (environmental protection color) 1271200-163000 ZT250－S shift lever spline rocker arm(dark gray) 1274100-042000 Miniature rod end ball bearing SAJK6C 1250301-020093 GB6170M6 (army green) 1274300-026000 ZT350 adjusting screw of gear shift lever 1250301-018093 GB6170 M6－LH (army green) 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color zinc) 1274100-043000 Miniature rod end ball bearing SALJK6C...
  • Page 53 6-PEDAL COMPONENT Fig.8 FOOT PEDAL Left footrest component 3 COMPONENT PART NO. PART NAME CAUTION 4064300-022051 ZT350 left pedal support (dark gray matte) 1274300-033000 ZT350-R Pedal pin 1244100-052000 Buffer rubber of flanging bushing (φ8.5×φ14×1) 1264100-006000 ZT250－S Pedal circlip 1264100-003000 ZT250－S front left foot pedal torsional spring 4064300-009051 ZT350-GK front left pedal assembly (dark gray matte) 4064300-011051 ZT350-GK rear left foot pedal assembly 1260100-301000 ZT350－R foot pedal steel ball spring...
  • Page 54 7、COOLING SYSTEM COMPONENT Fig.1 COOLING SYSTEM Change engine oil COMPONENT PART NO. PART NAME CAUTION 1050854-002000 ZT180MN Engine oil level gauge 1244100-033000 Sealing gasket 12×φ20×2 1251100-066093 M12×1.5×15 Oil draining bolt 24±4N.m 1224300-112000 ZT350－X wheel speed sensor plug holder 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color zinc) 1276200-043000 φ6 wire clamp (L=57) PROCEDURE: ●wire clamp...

  • Page 55: Change Engine Oil Filter

    7、COOLING SYSTEM COMPONENT Fig.2 COOLING SYSTEM Change engine oil filter COMPONENT PART NO. PART NAME CAUTION 1251300-096000 Non-standard cover type 9 degree nut M6×13 4050454-014051 ZT180MN fine filter cover A (dark gray) 1051454-020000 55×2.5 acrylate adhesive O shape circle after-sale 1051454-005000 ZT180MN Engine oil refined filter seal ring 4134300-001000 ZT184 refined filter seal component 【1】...

  • Page 56: Add Coolant

    7、COOLING SYSTEM COMPONENT Fig.3 COOLING SYSTEM Change engine oil COMPONENT PART NO. PART NAME CAUTION 1224200-006000 ZT310－R sub cooling liquid tank 1051954-016000 TOTAL antifreeze liquid (-35 ° C, 4L) 1.44L PROCEDURE: ●Add coolant When the engine is completely cooled, the vehicle can be straightened to accurately check the liquid level. If it is lower than the "L"...

  • Page 57: Draining Cooling Liquid

    7、COOLING SYSTEM COMPONENT Fig.4 COOLING SYSTEM Draining cooling liquid COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non standard bolt M6×16（304 stainless steel） 1274100-007000 ZT250-S flanging sleeve（φ6.4×φ9×6＋φ20×2） 1251112-001093 M6×16 Hex flange bolt（environmental color zinc） 1051654-002000 Seal gasketφ6×13×1.8 PROCEDURE: ●Engine fairing assembly Lift the motorcycle with platform.
  • Page 58 7、COOLING SYSTEM COMPONENT Fig.5 COOLING SYSTEM Right cooling liquid tank component-1 COMPONENT PART NO. PART NAME CAUTION 1274300-024000 ZT350-R right water tank 1244100-002000 ZT250－S Side cover round gum cushion 1251100-061093 M6×22 Hex flange bolt 1274200-089000 ZT310 water pipe clamp（φ22） 1244300-010000 ZT350-R auxiliary water tank connecting water pipe 1274200-079000 ZT310 water pipe clamp（φ9）...
  • Page 59 7、COOLING SYSTEM COMPONENT Fig.6 COOLING SYSTEM Right cooling liquid tank component-2 COMPONENT PART NO. PART NAME CAUTION 1274300-025000 ZT350-R water tank water inlet fixing bracket 1224300-020000 ZT350-R water tank filling port 1250104-006097 GB16674M6×12 (chromed/HH) 1274200-089000 ZT310 water pipe clamp（φ22） 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1244300-009000 ZT350－R water inlet connection water pipe PROCEDURE: ●...
  • Page 60 7、COOLING SYSTEM COMPONENT Fig.7 COOLING SYSTEM Left cooling liquid tank component COMPONENT PART NO. PART NAME CAUTION 1274300-023000 ZT350-R left water tank 1244100-002000 ZT250－S Side cover round rubber 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color zinc) 1274200-090000 ZT310 water pipe clamp（φ26） 1244200-010000 ZT310－R water inlet pipe of left water tank 1244200-001000 ZT310－R water outlet pipe of engine 1274200-091000 ZT310 water pipe clamp（φ27）...
  • Page 61 7、COOLING SYSTEM COMPONENT Fig.8 COOLING SYSTEM Oil cooler component 1 COMPONENT PART NO. PART NAME CAUTION 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color zinc) 1251112-001093 M6×16 Hexagon flange bolts (color zinc) 1244300-007000 ZT350－GK oil outlet pipe of engine 1244300-008000 ZT350－GK oil inlet pipe of engine 1051454-025000 9.8×2.
  • Page 62 7、COOLING SYSTEM COMPONENT Fig.9 COOLING SYSTEM Oil cooler component 2 COMPONENT PART NO. PART NAME CAUTION 1251112-001093 M6×16 Hex flange bolt(environmental color zinc) 1274300-036000 ZT350－R upper bracket of oil cooler 1274300-037000 ZT350－R lower bracket of oil cooler PROCEDURE: ●Oil cooler bracket Using 8# sleeves remove three bolts⑴, and remove the upper bracket⑵...
  • Page 63 8-FRONT FORK COMPONENT Fig.1 FRONT FORK Throttle/clutch cable clearance adjustmen COMPONENT PART NO. PART NAME CAUTION 1154300-004000 ZT350-X throttle refueling line 1154300-005000 ZT350-X throttle return line 1154300-001000 ZT350-R clutch cable 1244200-046000 ZT310-V clutch line sheath PROCEDURE: ●Throttle cable Fix the adjusting screw ② with 8# open-ended wrench, and then loosen the lock nut ① on the accelerator oil filling line ⑴...
  • Page 64 8-FRONT FORK COMPONENT Fig.2 FRONT FORK light height adjustment,Replacement clutch cable COMPONENT PART NO. PART NAME CAUTION 1244300-023000 ZT310 rubber buckle (50mm) 1154300-001000 ZT350-R clutch cable 1244200-046000 ZT310-V clutch line sheath PROCEDURE: ●Light height adjustment The rider sits on 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,the arrows are inserted backwards as shown in Figure "A"...
  • Page 65 8-FRONT FORK COMPONENT Fig.3 FRONT FORK Replace the throttle cable COMPONENT PART NO. PART NAME CAUTION 1244300-042000 ZT310 rubber buckle (double buckle type) 1154300-004000 ZT350-X throttle refueling line 1154300-005000 ZT350-X throttle return line 1274300-025000 ZT350-R water tank water inlet fixing bracket 1244100-042000 ZT250-R right handle bar rubber sleeve 1184200-185000 ZT310-V1 right handlebar switch 1251100-219000 Cross ball screw M5×30...
  • Page 66 8-FRONT FORK COMPONENT Fig.4 FRONT FORK Steering adjustment COMPONENT PART NO. PART NAME CAUTION 1251300-088000 ZT350-R upper connection decoration nut M22×1 100N.m 1274200-018000 ZT310－R gasket of upper connecting board 1250205-023000 GB70.1 inner hexagonal M8×35 (color zinc) 25N.m 1134100-007000 ZT250－S Adjusting nut locking washer ZT250－S direction column adjusting screw nut 1251300-046093 M24X1 (environmental color zinc)
  • Page 67 8-FRONT FORK COMPONENT Fig.5 FRONT FORK Right hand component COMPONENT PART NO. PART NAME CAUTION 1190100-409051 ZT310-VX right rearview mirror (dark gray) ZT350－GK front disc brake main pump assembly (φ 1100100-831000 1100100-833000 ZT350－GK front brake handle (CNC) 1134200-023000 ZT250-R balance block 1244100-042000 ZT250－R right handle bar rubber sleeve 1250205-031091 GB70.1M6×30（stainless steel）...
  • Page 68 8-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) 1100100-831000 ZT350-GK front disc main pump assembly（φ14） 1251513-013000 Disc brake pipe copper washer φ 15× φ 10.2 × 1.5 1251100-112000 Disc brake pipe bolt M10×1-22 32N·m PROCEDURE:...
  • Page 69 8-FRONT FORK COMPONENT Fig.7 FRONT FORK Replace the front brake pads COMPONENT PART NO. PART NAME CAUTION 1100100-827000 ZT350-GK front radial caliper brake pad After-sales PROCEDURE: ●Replace the front brake pad Clamp the circlip ① with pointed nose pliers, pull it out and remove the two circlips. Remove the upper pin shaft ②...
  • Page 70 8-FRONT FORK COMPONENT Fig.8 FRONT FORK Front wheel component COMPONENT PART NO. PART NAME CAUTION 1250205-023000 GB70.1 inner hexagonal M8×35 (environmental color) 20N·m 1094100-063000 ZT310T-M front wheel hollow shaft Φ20×243 1274300-008000 ZT350-GK front tire shaft sleeve 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 plate(320×5.0)
  • Page 71 8-FRONT FORK COMPONENT Fig.9 FRONT FORK Front mud board & wheel speed sensor component COMPONENT PART NO. PART NAME CAUTION 1224100-044000 Wheel speed sensor clamp 1181200-118000 Wheel speed sensor(A) 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) Gb70.1 Inner hexagon bolt M10 × one point five × 60 1251100-303093 (grade 10.9 / environmental color zinc) 1274300-109000 ZT350-R Front oil outlet pipe clamp...
  • Page 72 8-FRONT FORK COMPONENT Fig.10 FRONT FORK Head component COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1274100-057095 Flanging bushing φ6.2×φ8.4×3.5+φ14×1.5 1244100-052000 Cuff bushing cushioning rubber (φ8.5×φ14×1) 1224200-007000 ZT310-R storage box 1224300-085000 ZT350-R cable plastic staple PROCEDURE: ●Head assembly After holding the head assembly, turn the left and right directions to the bottom respectively.
  • Page 73 8-FRONT FORK COMPONENT Fig.11 FRONT FORK Headgear headlight component 1 COMPONENT PART NO. PART NAME CAUTION 1264100-006000 ZT250-S pedal circlip 1274200-024000 ZT310-R headlight rotating pin 1274200-007000 ZT310-R headlight lower bracket 1240400-007000 HJ125-3 battery bracket cushion rubber ring 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1274100-057095 Flanging bushing φ6.2×φ8.4×3.5+φ14×1.5 1244100-052000 Cuff bushing cushioning rubber (φ8.5×φ14×1) ZT310-R headlights on the decorative cover...
  • Page 74 8-FRONT FORK COMPONENT Fig.12 FRONT FORK Headgear headlight component 2 COMPONENT PART NO. PART NAME CAUTION 1174300-001000 ZT310-R front combination headlights ZT310-R hood ZT310-R hood right decorative cover ZT310-R hood left decorative cover 1251300-063093 Splint M6×11×15 (environmental color) 1244200-005000 ZT310-R hood cushion rubber PROCEDURE: ●Head cover assembly Use a small flat-blade screwdriver to insert the hood and the headlight gap (as indicated by the arrow on the...
  • Page 75 8-FRONT FORK COMPONENT Fig.13 FRONT FORK Left hand component COMPONENT PART NO. PART NAME CAUTION 1190100-408051 ZT310-VX left rearview mirror (dark gray) 1134200-029051 ZT310-V left hand handle rocker arm seat assembly 1184300-019000 ZT350-R second generation left counter handle switch 1250205-031091 GB70.1M6×30(stainless steel) 1184200-184000 ZT310-V1 Left handle switch 1244100-041000 ZT250-R left hand rubber sleeve 1134200-023000 ZT250-R balance block...
  • Page 76 8-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 Hexagonal M8×35 1134300-012000 ZT310-R1 direction handle pressure block (dark gray m 1134200-038051 ZT310-R handle bar(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 Cuff bushing cushioning rubber (φ8.5×φ14×1)
  • Page 77 8-FRONT FORK COMPONENT Fig.16 FRONT FORK Front shock absorber, upper plate component COMPONENT PART NO. PART NAME CAUTION 1251300-045000 ZT250-S upper plate decorative nut (chrome plated) 100N·m 1251500-050000 ZT250-S upper plate gasket φ18.5×φ39×1 1250205-023000 GB70.1 Hexagonal M8×35 (environmental color zinc) 25N.m 1114300-005000 ZT350-GK front left shock absorber 1274200-006000 ZT310-R left upper support of headlight...
  • Page 78 8-FRONT FORK COMPONENT Fig.19 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 1244200-008000 ZT310-R buffer rubber of upper connecting board 4094300-001051 ZT350-R upper connection board (dark gray matte) 1251700-065000 ZT310-R bushing φ10×φ12×41 1250105-280000 GB5789 M10×1.25×60(10.9 level/dacromet)
  • Page 79 8-FRONT FORK COMPONENT Fig.20 FRONT FORK ABS brake system-1 COMPONENT PART NO. PART NAME CAUTION 1251112-001093 M6×16 Hexagon flange bolts (color Zinc) 1250501-010000 GB93φ6 spring pad ZT250-S Flanging bushing buffer 1244100-004000 1274100-007000 ZT250-S flanging sleeve(φ6.4×φ9×6＋φ20×2) Non-standard bolt M6×16 (304 stainless steel) 1251100-102000 1274300-071094 ZT350-R hydraulic control unit bracket PROCEDURE:...
  • Page 80 8-FRONT FORK COMPONENT Fig.21 FRONT FORK ABS brake system-2 COMPONENT PART NO. PART NAME CAUTION 1251100-112000 Disc brake pipe bolt M10×1-22 1251513-013000 Disc brake pipe copper washer φ 15× φ 10.2 × 1.5 1100100-831000 ZT350-GK front disc main pump assembly（φ14） PROCEDURE: ●Release brake fluid Referring to the previous steps of adding brake fluid, remove the upper cover, cover plate and sealant pad of the...
  • Page 81 8-FRONT FORK COMPONENT Fig.22 FRONT FORK ABS brake system-3 COMPONENT PART NO. PART NAME CAUTION 1244300-019000 Caliper bleed screw rubber cap 1251100-308000 Disc brake exhaust screw M6 1251100-307000 Disc brake oil pipe bolts M10×1×22 (with exhaust threa 1251513-013000 Disc brake pipe copper washer φ 15× φ 10.2 × 1.5 GB70.1 Hexagon socket head bolt M10×1.5×60 (grade 1251100-303093 12.9 / environmental protection color Zinc)
  • Page 82 8-FRONT FORK COMPONENT Fig.23 FRONT FORK (Double rocker arm rear fork) ABS brake system COMPONENT PART NO. PART NAME CAUTION 1251513-013000 Disc brake pipe copper washer φ 15× φ 10.2 × 1.5 1251100-112000 Disc brake pipe bolt M10×1-22 1251112-001093 M6×16 Hexagon flange bolts (color Zinc) 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1224200-003000 ZT310-R Rear disc brake pipe clamp 1251100-102000 Non-standard bolt M6×16 (304 stainless steel)
  • Page 83 8-FRONT FORK COMPONENT Fig. 20 FRONT FORK (Single rocker rear fork)ABS brake system COMPONENT PART NO. PART NAME CAUTION 1251100-123093 non-standard bolt M8×25 (color zinc) 1251513-013000 Brake brake tubing copper washer φ15×φ10.2×1.5 1251100-112000 Disc brake tubing bolt M10×1-22 1250104-006097 GB16674M6×12 (chromed/HH) 1274200-119000 Single rocker rear flat fork tubing bracket PROCEDURE: ●RC-HU tubing...
  • Page 84 9、FUEL TANK COVER COMPONENT Fig.1 FUEL TANK Fuel tank middle cover component COVER COMPONENT PART NO. PART NAME CAUTION 1224100-010000 ZT250-S expansion nail 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) PROCEDURE: ●Middle cover assembly Use a small Phillips screwdriver to push down the center of the expansion pin and remove the expansion pin⑴ from the rear of the middle cover assembly (Figure A).
  • Page 85 9、FUEL TANK COVER COMPONENT Fig.2 FUEL TANK Fuel tank cover, fuel tank cover, fuel tank lock COVER COMPONENT PART NO. PART NAME CAUTION ZT310-R fuel tank middle cover 1184200-002000 ZT310 electronic fuel tank lock ZT310-R fuel tank cover 1224100-014000 ZT250-S fuel tank cover rotary damping 1274100-021000 ZT250-S fuel tank cover rotating bracket 1274100-090000 ZT250-S fuel tank cover rotating shaft 1260100-215000 ZT310－T circlip...
  • Page 86 9、FUEL TANK COVER COMPONENT Fig.3 FUEL TANK Fuel tank trim cover component COVER COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1274100-057095 Flanging bushing φ6.2×φ8.4×3.5＋φ14×1.5 1244100-052000 Cuff bushing cushioning rubber (φ8.5×φ14×1) 1251300-063093 Splint M6×11×15 (environmental color) 1224300-090000 ZT350-R fuel tank left decorative cover 1224300-091000 ZT350-R fuel tank right decorative cover Non-standard flat mat φ13×φ8.2×1.5(environmental...
  • Page 87 9、FUEL TANK COVER COMPONENT Fig.4 FUEL TANK Fuel tank trim cover rear shell component-1 COVER COMPONENT PART NO. PART NAME CAUTION ZT350－R rear cover of left decorative cover of fuel 1224300-090000 tank 1224300-084000 ZT350－R Left front harness holder 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1244100-052000 Buffer rubber of flanging bushing (φ8.5×φ14×1) 1274100-057095 Flanging bushing φ6.2×φ8.4×3.5＋φ14×1.5 1274100-018000 Anti-hot plate sleeve, muffler...
  • Page 88 9、FUEL TANK COVER COMPONENT Fig.5 FUEL TANK Fuel tank trim cover rear shell component-2 COVER COMPONENT PART NO. PART NAME CAUTION 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (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) 1250303-010093 GB6177.1M6 (environmental color) 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) ZT350－R rear cover of left decorative cover of fuel...
  • Page 89 9、FUEL TANK COVER COMPONENT Fig.6 FUEL TANK Fuel tank cover component1 COVER COMPONENT PART NO. PART NAME CAUTION 1244100-004000 ZT250-S Flanging bushing buffer 1274100-007000 ZT250-S flanging sleeve（φ6.4×φ9×6＋φ20×2） 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1251300-063093 Splint M6×11×15 (environmental color) 1244100-002000 ZT250-S side cover round glue PROCEDURE: ●Fuel tank cover assembly Using 4# inner hexagon socket remove the 4 bolts⑶...
  • Page 90 9、FUEL TANK COVER COMPONENT Fig.7 FUEL TANK Fuel tank cover component2 COVER COMPONENT PART NO. PART NAME CAUTION ZT310－R fuel tank left cover upper part 1244100-004000 ZT250-S Flanging Bushing Buffer 1184200-053000 ZT310PKE external single antenna 1251300-063093 Splint M6×11×15 (environmental color) 1244100-052000 Flanging bushing cushioning rubber (φ8.5×φ14×1) 1274100-057095 Flanging bushing φ6.2×φ8.4×3.5＋φ14×1.5 1251100-102000 Non-standard bolt M6×16 (304 stainless steel)
  • Page 91 10、TANK LINER COMPONENT Fig.1 TANK LINER Tank liner component COMPONENT PART NO. PART NAME CAUTION 1250205-043093 GB70.1M8×55 (environmental color) 1251900-028093 ZT250-R fuel tank flat pad φ9×φ37.5×2 1244100-020000 ZT250-S fuel tank pressure 1244100-053000 ZT250-S second generation fuel tank gasket 1274100-080000 ZT250-R cushion fixing block 1224200-066000 ZT310PKE external antenna mount 1050954-035000 ZT310-R EFI High Pressure Tubing Sub-assembly 1240300-021000 HJ125－6 pod glass strip （1.5m）...
  • Page 92 10、TANK LINER COMPONENT Fig.2 TANK LINER Tank liner COMPONENT PART NO. PART NAME CAUTION 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1274200-014000 ZT310-R fuel tank cover rear mounting bracket 1224100-033000 ZT250-S threaded fuel tank cap 4034200-001000 ZT310-R fuel tank liner 1274200-013000 ZT310-R fuel tank cover front mounting bracket 1244100-002000 ZT250-S side cover round glue 1240300-021000 HJ125-6 shroud glass strip (1.5m)
  • Page 93 11、SIDE COVER COMPONENT Fig.1 SIDE COVER SIDE COVER COMPONENT(Old applique) COMPONENT PART NO. PART NAME CAUTION 1224100-010000 ZT250-S Expansion nail ZT310-R Right side cover (iron grey) ZT310-R Left side cover (iron grey) 1184300-005000 ZT350 antenna PROCEDURE: ●Side cover assembly Use a small Phillips screwdriver to press down on the center of the expansion screw and remove the expansion screw⑴.
  • Page 94 12、REAR COVER COMPONENT Fig.1 REAR COVER Rear cover trim cover component COMPONENT PART NO. PART NAME CAUTION ZT310-R Rear cover right trim cover (bright blue) 1244100-052000 Flange bushing buffer (φ8.5×φ14×1) 1274100-057095 Flanged bush φ6.2×φ8.4×3.5＋φ14×1.5 1251100-101000 Non-standard bolt M6×12 (stainless steel) ZT310-R Rear cover left trim cover (bright blue) 1250105-142093 GB5789M8×20 (environmental color) 1251700-058093 Flange bushing φ8.2×φ11×4.5+φ16×1.5...
  • Page 95 12、REAR COVER COMPONENT Fig.2 REAR COVER Rear cover interior trim cover component COMPONENT PART NO. PART NAME CAUTION 1224100-010000 ZT250-S Expansion nail 1251100-102000 Non-standard bolt M6×16 (stainless steel) 1274100-057095 Flanged bush φ6.2×φ8.4×3.5＋φ14×1.5 1244100-052000 Flange bushing buffer (φ8.5×φ14×1) 1224200-095000 ZT310-R Rear cover interior left trim cover 1251200-033093 Non-standard self-tapping screws ST4.2×12 1224200-096000 ZT310-R Rear cover internal right trim cover 1251100-101000 Non-standard bolt M6×12 (304 stainless steel)
  • Page 96 12、REAR COVER COMPONENT Fig.3 REAR COVER Rear cover tail light component 1 COMPONENT PART NO. PART NAME CAUTION ZT310-R Rear cover fender cover 1251100-122093 Non-standard bolt M8×16 (environmental color) 1251700-058093 Flange bushing φ8.2×φ11×4.5+φ16×1.5 1240300-071000 Flange bushing buffer (φ11×φ16×1) 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1274100-057095 Flanged bush φ6.2×φ8.4×3.5＋φ14×1.5 1244100-052000 Flange bushing buffer (φ8.5×φ14×1) PROCEDURE:...
  • Page 97 12、REAR COVER COMPONENT Fig.4 REAR COVER Rear cover taillight component 2 COMPONENT PART NO. PART NAME CAUTION 1244100-002000 ZT250-S Side cover round rubber 1251300-063093 plywood M6×11×15 (environmental color) ZT310-R Rear cover 1224100-010000 ZT250-S Expansion nail 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1224200-054000 ZT310-R Taillight left mounting plate 1224200-056000 ZT310-R Taillight right mounting plate PROCEDURE:...
  • Page 98 12、REAR COVER COMPONENT Fig.5 REAR COVER Taillight component COMPONENT PART NO. PART NAME CAUTION 1174200-012000 ZT310-R left rear position lamp 1174200-014000 ZT310-R stop lamp 1174200-013000 ZT310-R right rear position lamp PROCEDURE: ●Taillamp component Remove the left bolt① and hold the stop lamp(2). Pull the left rear position lamp⑴ out in the direction of the arrow.
  • Page 99 12、REAR COVER COMPONENT Fig. 6 REAR COVER Electrical component COMPONENT PART NO. PART NAME CAUTION 1224200-176000 Colloid battery electric device box upper cover 1184100-017000 ZT250－S fuel-injection relay MSE6.0 controller - ZT184MP (matching split sensor / 1050958-014000 Euro V) 1184100-010000 ZT250－S starting relay 1240300-007000 HJ125－6 Battery rubber gasket PROCEDURE: ●Relay...
  • Page 100 Unscrew the black protective cap ② to remove the negative pole; then remove the red protective cap ① and remove the positive pole; remove the battery. For reinstallation, connect the positive electrode first, then connect the negative electrode. No parallel battery charging or ignition.Just use the battery charger''ZONTES'' provide for you. CAUTION: ●Be careful not to overcharge the charging time.
  • Page 101 12、REAR COVER COMPONENT Fig. 8 REAR COVER Electrical device box component 1 COMPONENT PART NO. PART NAME CAUTION 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1250303-010093 GB6177.1M6 (environmental color zinc) 1251513-001019 6.3 x 12 x 1.6 copper gasket 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1224200-040000 ZT310 Electrical device box cover 1274200-238000 ZT310-R battery holder (gel battery) 1274100-057095 Flanging bushing φ6.2×φ8.5×3.5＋φ14×1.5...
  • Page 102 12、REAR COVER COMPONENT Fig. 9 REAR COVER Electrical device box component 2 COMPONENT PART NO. PART NAME CAUTION 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1244200-111000 ZT310 gel battery strap 1224200-161000 ZT310-R Electrical Device Box (colloid battery) 1240300-007000 HJ125-6 Battery Pad 1251300-063093 Plywood M6×11×15 (environmental color) Non-standard cross tapping screws ST3.9×12 (Black 1251200-050094...
  • Page 103 ●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 104 14-MUFFLER COMPONENT Fig.1 MUFFLER Muffler component 1 COMPONENT PART NO. PART NAME CAUTION 1276200-043000 φ6 wire clamp (L=57) 1224300-085000 ZT350-R cable plastic staple 1250205-023000 GB70.1 inner hexagonal M8×35 (color Zinc) 1274100-074000 ZT310-R Muffler stainless steel bar clasp 1250205-125000 GB70.2 M8×35(12.9 garde,darco) ZT350 muffler flanging bushing (φ8.3×φ11.5×20.5×φ...
  • Page 105 14-MUFFLER COMPONENT Fig.2 MUFFLER Muffler component 2 COMPONENT PART NO. PART NAME CAUTION 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1250501-010000 GB93φ6 spring pad 4084300-010051 350－GK rear muffe decorative cover (dark gray matte) 4084300-011051 ZT350－GK rear muffer(dark gray matte) 1250205-125000 GB70.2 M8×35（12.9 grade,darco） 1020243-098000 ZT350 muffer gasket（...
  • Page 106 14-MUFFLER COMPONENT Fig.3 MUFFLER Muffler component 3 COMPONENT PART NO. PART NAME CAUTION 1251300-058093 Inner hexagonal nut M8 (color zinc) 1070100-499000 ZT350-GK engine exhaust outlet seal ZT350-GK-H2 front muffler (self-made/Europe Ⅴ 4084300-012000 /Bosch EFI version) 1050970-011000 LSF oxygen sensor(L=635mm） ZT350 muffer flanging bushing（φ8.3×φ11.5×20.5×φ 1020243-097000 8.4×φ33×1.5）...
  • Page 107 15、LOWER SHROUD COMPONENT FIG.1 LOWER SHROUD Lower shroud component 1 COMPONENT PART NO. PART NAME REMARKS 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 1251112-005093 M6×75 Hexagonal flange bolt (color zinc) 1274300-005000 ZT310-R Lower shroud left bracket 1274300-006000 ZT310-R Lower shroud right bracket 1251112-003093 M6×45 Hex flange surface 9.8 bolts (color zinc) PROCEDURE:...
  • Page 108 15、LOWER SHROUD COMPONENT FIG.2 LOWER SHROUD Lower shroud component 2 COMPONENT PART NO. PART NAME REMARKS 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1274100-057095 Flanged bush φ6.2×φ8.4×3.5＋φ14×1.5 1244100-052000 Flange bushing buffer (φ8.5×φ14×1) 1251300-063093 Plywood M6×11×15 (environmental color) 1244100-004000 ZT250－S Flanging bushing buffer Lower shroud left part 1224300-006000 ZT350－R Lower shroud middle part Lower shroud right part...

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Zt350-r1 2022

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