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Troubleshooting
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Summary of Contents for Zontes ZT350E
- Page 1 ZT350E Maintenance Manual 2023-04-11 1 / 108...
- 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.
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Page 4: Table Of Contents
Content Content ....................................... 4 1. Motorcycle information .................................. 9 Know Before Service ................................9 Body label ....................................10 E350 Technical specification ..............................11 Front wheel/steering system ............................11 Rear wheel/suspension system ............................11 Brake system ..................................11 Battery/charging system ..............................12 0Lamp/Speedometer/switch description .......................... - Page 5 6. Check all water pipes for leaks; aging........................... 38 Brake hose ....................................39 Brake fluid ....................................39 1. Add brake fluid to the main pumps of the front and rear disc brakes ................39 2. Replace the brake fluid ..............................39 2.1 Replace the front brake brake fluid ........................
- Page 6 Troubleshooting ..................................60 Ignition system layout ................................61 Electrical schematic diagram of ignition system ........................62 Ignition system inspection ................................ 63 Ignition timing ................................... 63 Check： ..................................... 63 Installation: ..................................64 Ignition coils ....................................64 5. Starting system ..................................... 65 Know Before Service .................................
- Page 7 6. Water pipe ..................................77 7. Check the water pump cover assembly ........................78 8. Braking system ....................................79 Know Before Service ................................. 79 Trouble shooting ..................................79 Soft feeling from brake lever ............................79 Hard feeling from brake lever ............................79 Disassemble the disc brake main pump and calipers .......................
- Page 8 Head side panel removal ..............................101 Removal of the headlight assembly ..........................102 Seat removal ................................... 102 Removal of the glove box ..............................103 Removal of left and right rear armrests .......................... 103 Removal of rear skirt assembly ............................103 Removal of tail light rear fender assembly ........................
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Page 9: Motorcycle Information
1. Motorcycle 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 10: Body Label
Body label ①The motorcycle identification code VIN can be seen after opening the seat Seat , and the VIN code is engraved on the cross tube at the rear of the frame. ②The muffler code is on the inner side above the muffler. ③The nameplate is above the radiator. -
Page 11: E350 Technical Specification
E350 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 Motorcycle 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 12: 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 13: 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 14: 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 turning light position (2)-Low beam position (3)-High beam position (4)-Position light/daytime running light position) 2-Side reflector 3-Right handle sub-switch 4-Right handbar switch 5-Heated handle bar switch 6-Right tail light (right turning light / brake light / position light) 7- Rear reflector 8- License plate light 9 - Left rear turning light (left turning light / brake light / position light) 10 - Left handle switch 11 –... -
Page 15: Brake Upper Pump And Brake Hose
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 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 15 / 109... -
Page 16: Distribution Map Of Brake System Accessories
5. Distribution map of brake system accessories 5.1 E350 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 pump6- rear brake lever 7- rear brake switch 8- RMC -HU brake hose9-FMC-HU brake hose 10-front brake switch 11-front disc brake main pump 12-front brake handle 13-hydraulic control unit 16 / 109... -
Page 17: Oil Supply System
6. Oil supply system 6.1 E350 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 18: E350 Fuel Supply
6.2 E350 Fuel supply Fuel supply system: Air→Carbon canister→Adsorption/vent pipe→Oil separator (inside the oil tank) Fuel → Fuel pump filter screen → Fuel pump → High pressure fuel pipe → Fuel injector → Cylinder 18 / 109... -
Page 19: Distribution Map Of Cooling System Accessories
7. Distribution map of cooling system accessories 1-Main water tank 2-Water tank filling port 3-Auxiliary water tank 4-Main water tank inlet pipe 5-Main water tank outlet pipe 6-Aluminum water pipe 7-Thermostat outlet pipe 8-Engine inlet pipe 9-Water and oil common sensor 10-Thermostat 11-Water pump cover assembly 8. - Page 20 1-TFT Meter 2-Front Left Storage Box Lock 3-Windshield Motor Controller 4-Main lock 5- Double Buckle USB Charging Cable 6-Single Port Fast Charging Assembly 7-EFI Relay 8 - Starting relay 9 - Charging port holder 10 - Tank electronic lock 1 - Seat lock 2 - Rectifier 3 - Engine controller (ECU) 4 - Buzzer 5 - Ignition coil body 6 - Carbon canister solenoid valve 20 / 109...
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Page 21: Intake And Exhaust System
9. Intake and exhaust system 1- Cylinder head 2-Cylinder head exhaust pipe3- Air filter intake inlet 4-Crankshaft Box exhaust pipe5-Air filter outlet pipe6- Throttle valve body assembly 7-Intake manifold8- Cylinder 9- Muffler 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 →... -
Page 22: 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 22 / 109... - Page 23 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.
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Page 24: 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 25: 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 26: E350 Maintenance Schedule
E350 Maintenance schedule : inspection（Inspect and clean,adjust,lubricate or replace if necessary） :replace ：Tighten★:Comment Initial Every Every Inspectio 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 27: E350 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 motorcycle or other unpredictable failures. -
Page 28: Replace The Air Inlet Filter
6. Replace Air filter element a. Use a Phillips screwdriver to remove the 6 screws that fix the filter element that comes with the air filter. 4. Replace the air inlet filter a. Remove the sponge and replace it with a new filter element. -
Page 29: Reinstall
8. Reinstall a. Refer to the steps of removing the filter housing to install the housing back. b. Clip M6×14 bolts to the inner step hole of the engine left ●The motorcycle must be parked on a flat and stable ground cover, and then use a 4# inner hexagon to penetrate from or a lifting platform. -
Page 30: Bolts And Nuts Of Muffler
●If you need to replace the new exhaust port gasket, you must wait for the muffler to cool down completely before Bolts and nuts of muffler starting operation. 1. Check for air leaks at the engine exhaust. ●Do not blast the throttle for a long time on the spot. ●Large load and long-term low-speed driving will damage the engine and muffler. -
Page 31: Engine Oil
Engine oil ●The motorcycle must be parked on a flat and stable ground or a lifting platform. ●Once the engine and muffler have cooled down, the e. Wipe clean the joint surface with a non-woven fabric. operation can be performed. Inspect the oil drain bolt⑶... -
Page 32: 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 33: Throttle Cable
Throttle cable counterclockwise. Rotate the adjustment solenoid② clockwise to reduce the free stroke, counterclockwise to 1. Inspection expand; adjust the gap to the specified value. After adjusting a. Check whether the rubber sleeve of the right hand the gap, tighten the nut①. handle and the throttle cable are damaged. -
Page 34: Check Idle Speed
Check idle speed: Check the idling speed of the engine when the engine is warm. E350 the idle speed range of the engine should be 1500-1700 rpm. If the idling speed is not within the standard range or the idling speed is stalled, it should be checked and handled by professional service personnel at the designated maintenance point of Shengshi or a qualified maintenance organization. - Page 35 Fuel evaporation: Oil and gas → oil and gas separator (inside the oil tank) → adsorption/vent pipe → solenoid valve intake pipe → solenoid valve outlet pipe → throttle valve body assembly → intake manifold → cylinder The fuel evaporative pollutant control system can only be checked after the cover is removed. Check the carbon canister for cracks or damage.
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Page 36: Radiator
2. E350 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 motorcycle must be parked on a flat and stable ground added. -
Page 37: Put Coolant
d. Tighten the filler cap of the Radiator. Tighten the b. Remove the filler cap of the Radiator to accelerate the flow of coolant. exhaust bolt; torque: 8～10N.m (0.8～1 kgf.m, 6～7 lbf.ft). c. Wipe all the joint surfaces clean with a non-woven cloth. Check whether the bolt⑶... -
Page 38: 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- Main tank outlet pipe 2-Main tank inlet pipe 3-Water pump cover outlet pipe 4-Water pump cover inlet pipe 5-Thermostat 6-Thermostat outlet pipe 38 / 109... -
Page 39: 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 40: Replace The Front Brake Brake Fluid
2.1 Replace the front brake brake fluid i. Repeatedly pinch and hold the brake handle to check whether the brake returns to normal hydraulic resistance. a. Wrap around the front brake main pump with oil- resistant plastic film, as shown in the previous section. b. -
Page 41: Check The Tires
should be made to the maintenance organization as soon as possible. If the sidewall is bumped, punctured, scratched, or if the Rebalance should be done after Tyre repair. tread is damaged and the hole is large, it should be replaced directly. ●Check the tire pressure regularly. -
Page 42: Check The Appearance
●After traveling on dusty or muddy roads, you should clean ●The motorcycle should be parked in a ventilated and dry up the foreign matter on the front fork tube (exposed environment without driving for a long time. A dark and chrome-plated cylinder) in time to avoid scratching the dust humid environment can easily cause the front fork tube to seal or oil seal and causing leakage;... -
Page 43: Troubleshooting
For slight deformation of less than 0.2mm (0.008 in), the 5. Troubleshooting front fork tube can be supported by a V-shaped iron block, a. There is obvious impact noise when driving on uneven and soft rubber, rubber, copper, etc. should be placed on the roads or emergency braking. -
Page 44: Side Bracket
Side bracket 2. Lubrication 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 45: Main Bracket
b. Remove the spring from the main support. c. Apply a proper amount of grease to the end face, inner hole of the engine box bushing and the surface of the main support shaft. Main bracket Caution: ●Park the vehicle on a flat and stable ground or a lifting platform, and put down the side brackets. -
Page 46: 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 47: Error Code
Error code Caution: ●Unlock the motorcycle 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 motorcycle cannot be started. ●After starting the motorcycle, 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 motorcycle may cause damage. -
Page 48: Clear Fault Code
4. Clear fault code After troubleshooting the EFI, it needs to be cleared manually or through a diagnostic tool. 4.1 Manually clear a. Unlock the motorcycle b. Turn off the flame switch to " "; c. Start the motorcycle, refuel in neutral gear to more than 4000 rpm and hold for 10 seconds; d. -
Page 49: 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 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 50: Dump Switch
●After disassembling the throttle valve body, apply lint-free cloth or textured paper to seal the air filter outlet and intake manifold to prevent foreign matter from entering. 1. . Dump switch Can ride Replace the normally dump switch Short-circuit the black-brown, white- Fuel cut off yellow wires... -
Page 51: Carbon Canister Solenoid Valve
compression of the seal rubber ring of the fuel pump may Need to remove the cushion and storage box first. cause leakage and cause safety hazards. 4. . Carbon canister solenoid valve When the engine performance is poor; the idle speed is poor;... -
Page 52: Throttle Valve Body
7. Throttle valve body 7.1 Common failure phenomena 1. The engine is easy to stall when the motorcycle 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 53: Oxygen Sensor
9. Oxygen Sensor white, it means that the silicon poisoning has been damaged and needs to be replaced, if it is black, it means that there is carbon deposits that can be cleaned up and continue to use; if it is brown, it means that the silicon ●The oxygen sensor must be removed after the engine and poisoning needs to be replaced. -
Page 54: 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 55: 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 56: 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 57: 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 58: Electrical Schematic Diagram Of Efi System
Electrical schematic diagram of EFI system 58 / 109... -
Page 59: 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 60: 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 motorcycle to test whether there is spark;... -
Page 61: Ignition System Layout
Ignition system layout 1 - Dump switch 2 - PKE 3 – relay 4 - main lock 5 - right handle bar auxiliary switch 6 - right handle bar 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 62: Electrical Schematic Diagram Of Ignition System
Electrical schematic diagram of ignition system 62 / 109... -
Page 63: 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 64: Installation
Installation: 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 65: 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 66: 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 67: Starting System Electrical Schematic Diagram
Starting system electrical schematic diagram 67 / 109... -
Page 68: Starter Motor
d. Pull the air outlet pipe to the right side of the Starter motor motorcycle to expose the two M6×30 bolts that fix the Caution: starter motor, and remove them with an 8# sleeve. After ●If the starter motor is removed for maintenance, replace removing the bolts, remove the starter motor from the the O-ring with a new one and apply a proper amount of engine in the direction indicated by the big arrow. -
Page 69: 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 70: Check The Starting Relay
Check the starting relay 2.2 Ground wire The motorcycle is powered off and locked. Set the 1. Operation check multimeter to the buzzer position, connect one test lead to a. Remove the seat and rear storage box first, find the the green/red wire, and one to any bolt connected to the starting relay connector on the right inner side of the frame, frame. -
Page 71: 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 motorcycle 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 72: 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 73: 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 74: 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 75: Cooling System Accessories
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（φ 24) 7-Water pipe hoop（φ 26) * 2 8-Water pump cover outlet pipe 9-Water pump cover assembly Caution: The bolt (3) at the thermostat is an exhaust bolt, and the bolt at the water pump cover is a bolt for cooling liquid. -
Page 76: Main Water Tank
●The heat dissipation fins are allowed to have a small amount of lodging deformation. If the lodging area is too large, it will affect the heat dissipation effect, and it is recommended to replace it. A small amount of deformation can be corrected with a small flat-blade screwdriver. -
Page 77: Failure Phenomenon
When the temperature reaches 80°C (176 F), the heating rate slows down, and the thermostat works normally. If the water temperature has been rising rapidly, when the internal pressure reaches a certain level, the sudden overflow of boiling water indicates that the valve is stuck. If it is stuck or closed loosely, it can be removed and cleaned or repaired first, otherwise it should be replaced. -
Page 78: Check The Water Pump Cover Assembly
7. Check the water pump cover assembly Check the two points indicated by the arrows for leakage. The bolts are for cooling liquid bolts. If there is leakage, remove the bolts and replace the O-ring. If there is leakage at the leaking pipe of the right crankcase cover, you can try to remove the leaking pipe (because the sealant is applied before press-fitting, it is difficult to pull out), clean it up, reapply the sealant and reinstall it;... -
Page 79: 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 80: Disassemble The Rear Disc Brake Main Pump
loosen this bolt later. Grasp the mirror rod of the right rear view mirror, use a 13# sleeve to remove the nut④, remove the small washer③, spring②, and large washer①, and take off the rear view mirror. When reassembling, make sure that the small washer③ is aligned with the side plane of the mirror rod bolt. -
Page 81: Disassemble The Rear Disc Brake Caliper
●Apply thread fastening glue to the thread of the caliper pin, torque: 22N.m (2.2kgf.m, 16 lbf.ft). ●The torque of the air release nozzle: 7～9N.m (0.7～ 0.9kgf.m, 5～7 lbf.ft). ●The open end of the piston should face the caliper mounting plate, and do not install it backwards. ●If there is slight rust on the surface of the piston, it can be polished off with 2000 mesh fine sandpaper. -
Page 82: Brake Hose And Wheel Speed Sensor
Front wheel 1- caliper mounting plate pin 2- bushing 3- rubber cap 4- caliper pin 5- vent nozzle 6-vent nozzle rubber cap 7-oil seal 8-dust seal 9-piston 10-caliper pin rubber cap 11- Caliper mounting plate 12- Brake pad spring 13- Caliper housing Rear wheel Caution: ●Apply silicone grease to the surface of the pin and bush... -
Page 83: Abs Troubleshooting
ABS troubleshooting 83 / 109... -
Page 84: 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 85: Troubleshooting
Troubleshooting Battery damage or attenuation troubleshooting process Battery failure Use a Measure the multimeter to battery voltage Battery Remove the battery and check whether 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 86: 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 绿 红 黄 English Green Yellow 86 / 109... -
Page 87: Battery Disassembly
Battery disassembly Charging system check 1. Disassembly 1. Leakage test Caution: a. Turn off the motorcycle and cut off the power supply, ●The whole motorcycle must be powered off before and remove the negative wire of the battery. disassembling the battery. b. -
Page 88: 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 89: Exploded View Of Front Fork Components
Exploded view of front fork components: Directional exploded view 89 / 109... -
Page 90: Front Fork Exploded View
Front fork exploded view 90 / 109... -
Page 91: Exploded View Of Lower Link Board
Exploded view of lower link board 91 / 109... -
Page 92: 1、Change The Direction Of The Handle
1、Change the direction of the handle Caution: ●When removing the disc brake oil cup, it must be vertically upward to prevent air from entering the brake pipeline. ●When disassembling and assembling the handle switch, pay attention to adjusting the internal wiring harness of the switch to avoid damage to the wire skin caused by the shell or bolt column. -
Page 93: 3、Installation Handle Bar To Put The Component
parts of the right handle bar switch. Remove the right handle mark on the handle bar switch, and then use 5# hexagon to bar (8) and the right heated handle bar (9) separately. tighten 4 M6×30 bolts. 4、Install the handle bar cover a. -
Page 94: 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 95: 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 Tire pressure sensor Bend toward the left. ABSsensor 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) 95 / 109... -
Page 96: Inspection And Maintenance Of Front Wheel Assembly
2.2 Replacement method of front wheel oil seal Inspection and maintenance of front wheel assembly： and bearing Caution: ●This inspection should be completed by a qualified a. Remove the front wheel assembly by referring to maintenance organization. "Replace the front wheel". ●Do not press the brake handle after the front wheel is b. -
Page 97: Change The Front Shock Absorber
counterweight method to make the wheel correct the b. The balance weight must be attached to the designated balance of each edge part, this correction process Is what we plane (red area) of the rim. call dynamic balance. The dynamic balance particles of the wheels can ensure that the wheels are more stable when rotating, reduce vibration and shaking, improve the stability and comfort of the motorcycle, and are conducive to safe driving. -
Page 98: 2．Remove The Left And Right Front Shock Absorbers
b. Use a batch to pry open a gap on the upper plate, put in 2．Remove the left and right front shock the corresponding shock absorber, install the shock absorbers absorption in place, and remove the next word batch. Screw a. -
Page 99: 十一、Disassembly And Assembly Of Coverings
十一、Disassembly and assembly of coverings 1. Windshield 2. Headlights 3. Lower part of the hood 4. Right panel of the hood 5. Front right panel 6. Right side cover 7. Right pedal decorative cover 8. Lower deflector right 9. Seat 10. Right rear armrest 11. Right part of tail skirt 12. Rear tail light 13. - Page 100 1. Instrument panel 2. Front left pedal rubber pad pressure plate 3. Front left pedal rubber pad 4. Rear left pedal rubber pad pressure plate 5. Rear left pedal rubber pad 6. Fuel tank decorative cover 7. Fuel tank cover 8. Front right pedal rubber pad pressure plate 9.
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Page 101: Removal Of The Windshield
Removal of the upper part of the hood and the Notice: ●When disassembling, please pay attention to controlling the windshield liner size of the force, so as not to break the buckle. a. Use a 4# inner hexagon to press down the central ●When removing the covers, please remove them in strict cylindrical pins of the two expansion nails, then remove the order, and do not disassemble the covers forcibly, so as to... -
Page 102: Removal Of The Headlight Assembly
d. Unplug the cable connector at the head cable cover, but c. Gently pat the left head side panel forward with your not the handle switch connector. hand to remove it, and use the same method to remove the right side panel. e. -
Page 103: Removal Of The Glove Box
hands and pull out the seat obliquely upwards according to c. Slightly lift the back of the glove box until the harness the angle of the studs. Note: When the angle is wrong and connector on the left side of the glove box is exposed, unplug the seat cannot be pulled out, do not use brute force to the ambient light plug on the left side of the glove box, forcibly pull the seat out to prevent damage to the thread on... -
Page 104: Removal Of Tail Light Rear Fender Assembly
b. Gently tap the tail skirt back with your hand to remove d. Buckle down the two expansion nails as shown in the the right rear tail skirt assembly. Pay attention to the buckle picture, use a 10# sleeve to remove the two M6×16 bolts on in the circle as shown in the picture when installing. -
Page 105: Removal Of Front Left And Right Storage Box Covers
Removal of front left and right storage box covers a. Press the power button to turn it on, press the lock button of the storage box, open the left storage box cover, and the right storage box cover can be opened directly by pressing the lock button of the storage box. -
Page 106: Removal Of Front Storage Box Panel
e. Remove 3 M6×16 bolts ⑵ with 5# inner hexagon, remove 1 M6×14 bolt ⑶ on the rear side with 4# inner b. Use a 4# inner hexagon to remove 2 bolts on the left hexagon, and remove 1 expansion nail at the front and rear and right sides, pull off the lining plate of the right decorative cover and the water tank filling port, and remove the lining plate on the left side. - Page 107 c. Use 6# inner hexagon to remove the left and right g. Use the 4# inner hexagon to remove the bolts on the left handles and switch components. and right storage box brackets. h. Unplug all the wire harnesses on the PKE and tidy up the d.
- Page 108 k. Remove the 4 expansion nails on the left and right sides m. Unplug the charging port connector that fix the panels of the front storage box. n. Pass the handle assembly through the front storage box panel, and remove the front storage box panel assembly. l.
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Questions and answers
Wie kann ich bei leerer batterie die Sitzbank öffnen?
To open the seat of a Zontes ZT350E with a dead battery, follow these steps:
1. Open the buckle and remove the OBD diagnostic connector.
2. Remove 3 bolts with a 6 mm inner hexagon and take off the spring washers and flat washers.
3. Use a 4 mm inner hexagon to remove 2 M6×14 bolts and a 6 mm inner hexagon to remove 2 M6×25 bolts to detach the main lock.
4. Pull out the main lock connector.
This process allows manual access to the seat lock mechanism when the battery is dead.
This answer is automatically generated
Need to reset maintenance sign