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TAYO Zontes ZT368T-G 2024 Maintenance Manual
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TAYO Zontes ZT368T-G 2024 Maintenance Manual

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ZT368T-G
Maintenance Manual
2024-12-02

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Summary of Contents for TAYO Zontes ZT368T-G 2024

  • Page 1 ZT368T-G Maintenance Manual 2024-12-02...
  • Page 2 Manual" that comes with the vehicle. The latest version of the driving manual can be downloaded in PDF format in the corresponding model introduction on the ZONTES official website. © Guangdong Tayo Motorcycle Technology Co., Ltd. all rights reserved User Notice...
  • Page 3 This manual is compiled by Guangdong Tayo Motorcycle Technology Co., Ltd. for the guidance of dealers or service personnel . This manual cannot provide more detailed knowledge about motorcycles and is only used as a maintenance reference. If you do not have the corresponding knowledge such as electrician and mechanic, improper assembly or maintenance failure may occur during repair .
  • Page 4 Table of contents Table of contents ....................................4 1. Vehicle Information ..................................9 Notice before service .................................. 9 Car body stickers ..................................10 368G Technical Parameters ............................... 11 Front wheel/steering system ............................. 11 Rear wheel/suspension system ............................11 Braking system .................................. 12 Battery/Charging System ................................
  • Page 5 Fuel Evaporative Pollutant Control System ..........................36 Heat sink ....................................37 1. Check the coolant ................................37 2. Add coolant (antifreeze) to the auxiliary water tank..................... 37 3. Add coolant to the main water tank ..........................37 4. Release coolant ................................38 5.
  • Page 6 4. Water and oil shared sensor ............................58 5. Injector ..................................58 6. Oxygen sensor ................................59 6.1 Detection ................................59 7. Ignition coil ..................................59 8. Carbon canister solenoid valve ............................. 59 9. Fuel pump ..................................59 10. OBD interface ................................60 11.
  • Page 7 4. Remove the external parts of the fuel tank assembly....................79 Examine ..................................... 80 1. Fuel pressure test ................................80 2. Fuel pump inspection ..............................80 3. Oil level sensor ................................80 7. Cooling system ....................................81 Notice before service ................................81 Troubleshooting ..................................
  • Page 8 Front fork exploded view ..............................101 Lower connection board exploded view ......................... 102 Replace the steering wheel ..............................103 1. Disassemble the handlebar assembly ......................... 103 2. Install the direction handle assembly.......................... 103 Replace the front wheel ................................104 1. Disassemble the front wheel assembly ........................104 2.
  • Page 9 1. Vehicle Information Notice before service 1、 You need to use good quality tools, or special tools and fixtures designed by our company. Using inferior tools may cause damage to parts, coating shedding, inadequate assembly, etc. 2、 O-rings, paper gaskets , copper gaskets, component sealing rings, etc. used for sealing must be replaced before assembly . 3、...
  • Page 10 Car body stickers ① Vehicle Identification Number VIN Located on the rear fender, near the rectifier, in the VIN style cover, the VIN code is engraved on the rear cross tube of the frame ② The storage box warning label is affixed to the rear of the storage box ③...
  • Page 11 368G Technical Parameters project parameter Front tire 110/70－17 Rear tire 150/70－14 Front rim specifications MT: 3.0 × 17 Rear rim specifications MT: 4.2 5 × 14 Brake fluid DOT4 0.25L ( 0.07 US gal,0.06 lmp gal) Complete vehicle Replace the fine filter: 1.75L（0.46 US gal,0.39 lmp gal ）...
  • Page 12 Braking system project standard Limit value Brake fluid DOT4 Brake pad usage limit Bottom of the tank Front disc brake Brake disc thickness ≥ 5.0mm (0.197 in) ＜4.5mm (0.177 in) Brake fluid DOT4 Brake pad usage limit Bottom of the tank Rear disc brake Brake disc thickness ≥4.5mm (0.177in)
  • Page 13 Tightening torque Bolt tightening torque for general fastening parts 4.8-6.8 grade (bolt head marked " 4 ") 8.8 grade (bolt head marked " 7 " or " 8.8 ") Bolt Tightening torque Standard Breaking Tightening torque Breaking Standard value diameter range value torque...
  • Page 14 Cable/pipeline/electrical components distribution diagram 1. Lighting distribution map 1- Headlight (①- Position light / daytime running light position ②- Low beam position ③- High beam position ) 2- Front turn signal 3- Front fog light 4- Side reflector 5- Left handlebar switch 6- Left handlebar auxiliary switch 7- Right handlebar auxiliary switch 8- Right handlebar switch 9- Heated handlebar switch 10- Rear taillight 1 1- Rear turn signal 1 2- Rear license plate light 1 3- Rear reflector 2.
  • Page 15 3. Brake pump and brake oil pipe 1-Front disc brake master cylinder 2-FMC-HU brake hose 3-RMC-HU brake hose 4-Rear disc brake master cylinder 4. Calipers, brake hoses and wheel speed sensors 1 - Front brake disc 2 - Wheel speed sensor 3 -FC-HU brake hose 4 - Front disc brake calipers 5 - Rear brake disc 6 - Rear disc brake caliper 7 - RC-HU brake hose 15/ 117...
  • Page 16 5. Braking system parts distribution diagram 1- Wheel speed sensor ( rear wheel ) 2-FC-HU brake hose 3-RC-HU brake hose 4-Wheel speed sensor ( front wheel ) 5- Rear disc brake master cylinder 6 -Rear brake handle 7 -Rear brake switch 8-RMC-HU brake hose 9-FMC-HU brake hose 10 -Front brake switch 1 1 -Front disc brake master cylinder 12 -Front brake handle 13 - Hydraulic control unit 16/ 117...
  • Page 17 6. Oil supply system 6.1 Fuel evaporation 1 - Fuel level sensor 2 - Fuel tank 3 - Fuel pump 4 - Fuel tank cap 5 - Adsorption /vent pipe 6 - High pressure oil pipe 7 - Carbon canister 8 - Carbon canister solenoid valve 9 - Solenoid valve inlet pipe 10 - Solenoid valve outlet pipe 11 - Throttle valve body assembly Fuel evaporation: Oil and gas →...
  • Page 18 6.2 Fuel supply Oil supply system: → Carbon canister → Adsorption /vent pipe Fuel → fuel pump filter → fuel pump → high pressure fuel pipe → fuel injector → cylinder 18/ 117...
  • Page 19 7. Cooling system accessories distribution diagram 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 water outlet pipe 8 - Engine water inlet pipe 9 - Water and oil common sensor 10- Thermostat 11- Water pump cover assembly 8.
  • Page 20 1-GPS antenna 2- PKE external antenna 3-Faucet lock 4-Dual-port universal USB charging cable 5-Dump switch 6-Electric injection rela 1 - Fog lamp drive box 2 - Ignition coil body 3 - Carbon canister solenoid valve 20/ 117...
  • Page 21 9. Intake and exhaust system 1 - cylinder head 2 - cylinder head exhaust pipe 3 - air filter inlet 4- Gearbox exhaust pipe 5- Air filter outlet pipe 6 - Throttle body assembly 7 - Intake manifold 8 - Cylinder 9 - Muffler Intake system (indicated by green arrow ) : Air →...
  • Page 22 Tool 125 piece tool set Torque wrench Vehicle Tools Claw hammer Pull code Rubber hammer Dynamic balancing machine Tire Changing Machine Oil pan Measuring cup funnel Taps and dies Micrometer Depth gauge Vernier caliper Feeler gauge PT300 EFI diagnostic Tire pressure gauge Magnetic seat + dial indicator 17# Hexagon socket instrument (16PIN)
  • Page 23 Clamp pliers Internal circlip pliers External circlip pliers Clamp Multimeter 14-sided 65mm cap filter T45/50 plum socket with ( for replacing the multimeter Blow gun wrench hole fine filter of M350 ) T25/ 45/50 plum wrench with hole Some of the above pictures are from the Internet, and the copyright belongs to the original author. Please do not use them for other purposes.
  • Page 24 Expansion nail description ① Use a 4# hexagon socket or other tools to press the center cylinder. You can hear a sound or the center cylinder moves 2mm axially. ② Use a blade, fingernail or carving knife to pry open the gap and remove it. If space permits, you can reach out to the back and push it out.
  • Page 25 2. Maintenance Notice before service 1. Use high-quality tools or special tools and fixtures designed by our company. Using inferior tools may cause damage to parts, coating shedding, inadequate assembly , etc. 2. O-rings , paper gaskets , copper gaskets, component sealing rings, etc. used for sealing must be replaced before assembly . 3.
  • Page 26 Maintenance cycle table : Check ( clean, lubricate, adjust or replace if necessary ) : Replacement : Tightening :annotation Frequency* 1 Regular replacement (inspection) drive Inspection items inspection × 1000 km × 1000 mile 1 year or 10,000 km Cradle cushion rubber ( 6214 miles ) Check once Air filter (filter element) Replace every 6,000 km...
  • Page 27 ● Initial maintenance should be performed strictly according to the above table, otherwise it may cause vehicle damage or other unpredictable failures. ● To keep your vehicle running normally, it is recommended that you have it serviced by a dealer or a qualified repair unit . Improper maintenance or care may cause vehicle damage or other unforeseen failures.
  • Page 28 c. Replace the filter element and sealing strip with a new one . b . Remove the sponge and replace the new filter element, with the black side facing the engine and the white 6. Check the air filter waste oil pipe side facing outwards .
  • Page 29 ● The vehicle must be parked on a flat, stable ground or a lift. ● If you need to replace the exhaust port gasket with a new one, you must wait until the muffler is completely cooled ●If the air filter is clogged with dust, the intake resistance will before starting the operation.
  • Page 30 Engine oil ● The vehicle must be parked on a flat, stable ground or a lift. ● Wait until the engine and muffler have cooled down before operating. When adding engine oil, prevent the oil from dripping onto the surface of the muffler. ●...
  • Page 31 engine by rotating them clockwise by hand. 4. Replace gearbox oil a. Rotate the oil filler nut ⑴ counterclockwise and remove the nut ⑴ and O-ring ⑵. The specification of the O-ring used for the oil filler nut is: 13.8×2.5. Place the nut ⑴ on the oil filler port without removing it to prevent foreign matter from falling into the engine.
  • Page 32 standard. d. Use throttle cleaning agent to clean the carbon deposits on the head of the stepper motor. Spray a small amount of cleaning agent into the valve body hole. Do not soak the stepper motor with any liquid. Throttle body Notice: ●The throttle valve body sensor and stepper motor cannot be immersed in any liquid.
  • Page 33 then pull out the desorption tube. deposits on the intake manifold and throttle body outlet. Do not soak the throttle body assembly and intake manifold assembly directly with any liquid. h. After cleaning the insulation pad, replace two new O- rings ⑽...
  • Page 34 see if the pressure parameters are consistent with the local a. Unlock the vehicle and raise the main stand; atmospheric pressure. b. Press the brake and start the vehicle; d. If you need to remove the intake pressure sensor, c. Increase the engine speed to over 3000rpm; hold the bushing (2) firmly and remove the bolt (1) with an 8# d.
  • Page 35 effect, refer to the description in " Removing the throttle body assembly to clean carbon deposits" to remove the throttle body assembly. Use a 10# open-end wrench to loosen the two nuts on the bracket to adjust. Torque: 3.0 Nm ( 0.3 kgf.m, 2.2 lbf.ft ).
  • Page 36 Fuel Evaporative Pollutant Control System 1 - Fuel level sensor 2 - Fuel tank 3 - Fuel pump 4 - Fuel tank cap 5 - Adsorption /vent pipe 6 - High pressure oil pipe 7 - Carbon canister 8 - Carbon canister solenoid valve 9 - Solenoid valve inlet pipe 10 - Solenoid valve outlet pipe 11 - Throttle valve body assembly Fuel evaporation: Oil and gas →...
  • Page 37 Heat sink 2. Add coolant (antifreeze) to the auxiliary water tank If the water level in the auxiliary water tank is lower than the "L" line, you need to add an appropriate amount of ● The vehicle must be parked on a flat, stable ground or a lift. coolant .
  • Page 38 5. Check whether the fins of the radiator tank are d. Wear waterproof gloves and use an extended funnel to add coolant to the main water tank water inlet. Wait until deformed or the air duct is blocked the thermostat bleed bolt position is stable and the coolant a.
  • Page 39 6. Check all water pipes for leakage and aging 1 - Main water tank filling port 2 - Main water tank 3 - Auxiliary water tank 4 - Main water tank outlet pipe 5 - Aluminum water pipe 6 - Engine water pipe 7 - Water pump cover water inlet pipe 8 - Water pump cover assembly 9- Thermostat assembly 10- Thermostat water outlet pipe 11- Main water tank water inlet pipe 1- Main water tank outlet pipe 2- Aluminum water pipe 3- Engine water pipe 4 - Thermostat...
  • Page 40 Brake hose Notice: ●This inspection should be completed by a qualified maintenance unit . ● Inspect the brake hose regularly according to the maintenance period table . ●It is recommended to replace the brake hose every 4 years . Refer to steps 1 and 2 of inspecting brake accessories in the brake system.
  • Page 41 previous page to remove the upper cover of the front brake ● During operation, pay close attention to the fluid level in master cylinder. the main pump and replenish it in time to prevent air from e. Use your right hand to rotate the 8 # plum wrench entering the brake hose.
  • Page 42 the air holes of the tire pressure monitoring sensor, causing affects the driving experience. difficulty in inflation or tire pressure monitoring failure. 1. Check the tires a. Park the vehicle on a flat and stable ground or a lifting platform and lower the main bracket. b.
  • Page 43 1. Check the appearance 2. Check shock absorption performance a. After parking the vehicle firmly, let the front wheel Hold the front brake handle and press down the hang in the air, turn the handlebar to check if there is leakage direction handle firmly.
  • Page 44 5. Troubleshooting a. If there is a noticeable knocking sound when driving on an uneven road or during emergency braking , the following items need to be checked: Whether the shock absorber spring is broken or the elastic force is reduced ; Whether the hydraulic oil is insufficient or air has entered ;...
  • Page 45 1. Inspection e. Use a 14 # sleeve to secure the bolts on the inside and a 14 # sleeve to remove the nuts on the outside. 1. Main bracket 2. Buffer rubber 3. Main bracket spring 4. Main bracket reset spring column a.
  • Page 46 3. Install the main bracket 1. Front brake handle 2. Right handle switch 3. Right auxiliary switch 4. Instrument 5. Left auxiliary switch 6. Left handle First align the main bracket with the mounting hole, and switch 7. Rear brake handle then insert the main bracket shaft from the left side .
  • Page 47 is clear and loud. power source. If the battery is damaged by using a low- ⑥ Steering switch: Push it all the way to the right to check quality charger, it is not covered by the warranty. whether the right front and right rear turn signals are flashing normally ;...
  • Page 48 3. Fuse box Notice: ●If the fuse blows, it must be replaced with a fuse of the same specification . It is prohibited to use wires such as copper or iron wire for direct connection . ●If the fuse blows again after replacement, you need to check the entire vehicle cable fault before replacing it. ●This vehicle uses a small fuse , about 11mm (0.43in) wide , 17mm ( 0.67in ) long, and 4mm (0.16in) thick .
  • Page 49 4. Troubleshooting If the button cannot be pressed, it can be directly judged that there is a problem with the switch. If there is no response when pressing, it is necessary to judge whether there is a problem with the switch, circuit or electrical component itself . 4.1 Right-hand switch a.
  • Page 50 4.3 Left handlebar switch 4.4 Speakers Notice: ● When adjusting or checking the horn , the interval should be more than 5 seconds . Continuous sounding may cause the internal coil of the horn to burn out . ●The speaker is riveted and difficult to restore after being disassembled . ●The bracket nut ③...
  • Page 51 4.5 Left handle switch The left-hand switch controls the turn signal, horn, high and low beam lights , hazard warning lights , and overtaking lights. There are many lines, making it difficult to check . 51/ 117...
  • Page 52 4.6 Lamps Notice: ● When using wires to test lamps, be careful to distinguish between positive and negative poles. For detailed wire colors, please refer to the electrical schematic diagram in the driver's manual that comes with the vehicle . The troubleshooting method for lamps is basically the same.
  • Page 53 3. Electronic fuel injection system Notice before service 1. The structure and working principle of the EFI system are relatively complex. Before checking and troubleshooting, you need to have a certain understanding of the working principle and structural characteristics of each EFI system . The content of this chapter requires certain maintenance experience .
  • Page 54 Fault Codes Notice: ●Unlock the vehicle and turn on the ignition switch. It is normal for the EFI fault light to be on when it is not started. If it is not on , the vehicle cannot be started. ● If the fault light comes on after starting the vehicle, indicating an EFI fault, it means there is something wrong with the EFI system.
  • Page 55 3. Clear fault codes After troubleshooting the EFI fault, it needs to be cleared manually or through a diagnostic instrument . 3.1 Manual Removal historical Manually clear faults and reset the ECU : Power on the vehicle and turn the ignition switch on and off for more than five times (on - off counts as one time).
  • Page 56 EFI parts layout Crankshaft Position Water and oil EFI relay Throttle body Fuel Injector Oxygen Sensor Sensor common sensor OBD diagnostic Carbon canister Ignition coil Fuel Pump interface (main Dump switch solenoid valve cable ) * The throttle valve assembly includes (sensor, idle speed control valve, stepper motor) . The crankshaft position sensor is integrated with the magneto stator.
  • Page 57 Fault diagnosis and troubleshooting of EFI otherwise it should be replaced. parts Notice: ● Once the EFI parts are removed, the EFI system needs to be reset. For detailed methods, refer to the service information in this chapter. ●Fuel pump, three-in-one sensor, stepper motor, ECU, etc. are precision parts.
  • Page 58 3.3 Troubleshooting process 4. Water and oil shared can be determined by the following methods : a. After parking the vehicle firmly, start the engine and sensor let it run at idle speed. Use a stethoscope or a stethoscope to When the engine is listen to the working sound of the cylinder.
  • Page 59 6. Oxygen sensor spark plug installation screw hole ) for about 6 mm (0.24 in), press the start button, if blue sparks are found at the spark plug electrode, the ignition system is normal, otherwise it should be repaired by a qualified maintenance unit. ●Be sure to wait until the engine and muffler are completely If you want to replace the ignition coil, follow these cooled before removing the oxygen sensor.
  • Page 60 ●The fuel pump is prohibited from running in dry state or in Be careful not to press the oil outlet pipe circled in red . water , otherwise its service life will be shortened, and in Once damaged, the entire fuel pump assembly can only be serious cases, it will be directly damaged.
  • Page 61 Examine Remove the dump switch without disconnecting the plug. Use OBD diagnostic instrument to detect whether the dump switch is faulty. If there is no diagnostic instrument, use a multimeter to detect the output voltage to determine whether there is a fault.
  • Page 62 Engine cannot start and there is no sign of starting fault diagnosis process When the starter motor can drive the engine to run normally when the start button is pressed , but the engine cannot work normally and there is no sign of starting, refer to the following diagnostic process to identify the cause of the fault. No spark or weak Check the ignition strength...
  • Page 63 Acceleration failure The engine speed cannot be increased immediately by turning the right-hand handle, and there is hysteresis and slow acceleration. Please refer to the following diagnostic process to find out the cause of the fault. Check Check if the air Poor Check the Check the three-...
  • Page 64 Unstable idling speed, easy to stall The engine idle speed is unstable and easy to stall, but it can return to normal after warming up. Please refer to the following diagnostic process to find out the cause of the fault. Unsteady idling / flameout Check the oil circuit Whether it returns to...
  • Page 65 EFI fault indicator light always on analysis flow chart If the EFI fault indicator light " " is always on, you should first check whether the wire plugs of each EFI sensor are loose . The fault light is always on during driving Read fault code Idle speed fault...
  • Page 66 4. Ignition system Notice before service 1. The content of this chapter requires certain maintenance experience . It is recommended to go to a qualified maintenance unit for inspection or maintenance. 2. After power is turned on , do not remove components connected to the 12V power supply at will to avoid the coil in the electrical appliance generating self-inductance and causing instantaneous voltage to damage the ECU or sensor.
  • Page 67 Troubleshooting Check the following items before diagnosing the ignition system a. Check whether the spark plug is abnormal ; b. Check whether the high-voltage cap or plug of the ignition coil is loose ; c. Check whether the high pressure cap has water in it; d.
  • Page 68 Ignition system layout 1- Right Handlebar Auxiliary Switch 2-Engine controller (ECU ) 3- Relay 4-Battery 5-Side stand flameout switch 6- Ignition coil body 7-Crankshaft position sensor 8- Spark plug 9- High voltage wire 10-Dump switch 11-Start relay 12-PKE 13- Steering lock 14- Right handlebar switch Remark: ●...
  • Page 69 Ignition system inspection Notice: ●If there is no spark from the spark plug, first check whether all cable connectors are loose or in poor contact before inspecting the ignition system. ●Use a high-precision digital multimeter. ignition coil testing methods, please refer to the ignition coil section in the "Electronic Fuel Injection Parts Fault Diagnosis and Troubleshooting "...
  • Page 70 5. Starting system Notice before service 1. If current flows through the starter motor when the engine is not started , it can be determined that the starter motor is damaged and needs to be replaced. 2. Before repairing the starter motor, the engine shutdown switch must be turned to " "...
  • Page 71 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 72 Starting system electrical schematics Starter motor Notice: ●If the starter motor is removed for maintenance, replace the new O-ring and apply an appropriate amount of engine oil. ●Our company only sells the starter motor assembly , and does not sell O-rings and motor parts separately. The inner diameter of the O-ring is φ25 mm (0.98 in) and the wire diameter is 3 mm (0.12 in) .
  • Page 73 will cause leakage. The torque of the two bolts that fix the starter motor is: 12±1.5 Nm (1.2±0.2 kgf.m, 9±1 lbf.ft) . And mark it with a marker. When reassembling, be careful not to miss the O-ring that comes with the starter motor , and align it with the teeth of the electric starter reduction gear.
  • Page 74 1-M 6 × 90 bolt × 2 2-O ring × 2 3-O ring 4-Starter motor front cover 5-gasket 6-rectangular seal 7-Starter motor outer shell 8- rectangular seal 9-electrode 10- screw × 2 11- Negative brush × 2 12-Coil spring × 4 13-Positive brush × 2 14-Brush rack 15-Brush rack insulation gasket 16-Starter motor rear cover 17-Insulation pad 18-Nut ×...
  • Page 75 Check the starter relay 1. Operational inspection a. Remove the hood. For detailed disassembly and assembly methods, see the " ZT368T-G Hood Disassembly and Assembly Video Tutorial ". b. Unlock the vehicle, turn the engine off switch to " ", retract the side stand, hold the brake handle and press the start button.
  • Page 76 4. Disassembly and assembly of the starting relay Open the white protective cover of the starter relay and use an 8# socket to remove the M6 bolt that comes with it. After taking out the wire, screw it back into the bolt to prevent it from being lost. Remove the other end in the same way. Pull out the relay connector.
  • Page 77 6. Fuel supply system Notice before service 1. Bending or twisting the control cable will affect smooth operation and may cause a short circuit or open circuit , resulting in loss of vehicle control. 2. Work should be carried out in an open and ventilated place. Smoking , using mobile phones and other behaviors that may cause sparks are prohibited at the work site .
  • Page 78 Fuel tank removal d. Use a 17 # spanner to fix the nut ⑴, and use a 14 # sleeve to loosen the bolt ⑵. Remove the four nuts ⑴ one Notice: by one, and do not remove the bolt ⑵ for the time being . ●...
  • Page 79 2. Remove the fuel pump Turn the fuel tank assembly over so that the fuel pump is facing upwards and placed firmly . You can use a small wooden chair to turn it over so that the chair surface is grounded and place the fuel tank assembly on it.
  • Page 80 Examine 1. Fuel pressure test test methods, refer to the fuel pump section in the Maintenance chapter . 2. Fuel pump inspection Unlock the vehicle and turn the engine ignition switch to " " . You should be able to hear the sound of the fuel pump running .
  • Page 81 7. Cooling system Notice before service 1. For the corresponding precautions regarding coolant (antifreeze), please refer to the radiator section in the " Maintenance " chapter of this manual . 2. Check the cooling water pipes ; check the coolant level. Adding and draining coolant are described in detail in the radiator section of the "...
  • Page 82 Coolant system distribution diagram 1 - Main water tank filling port 2 - Main water tank 3 - Auxiliary water tank 4 - Main water tank outlet pipe 5 - Aluminum water pipe 6 - Engine water pipe 7 - Water pump cover water inlet pipe 8 - Water pump cover assembly 9- Thermostat assembly 10- Thermostat water outlet pipe 11- Main water tank water inlet pipe Coolant flow diagram 1- Main water tank outlet pipe 2- Aluminum water pipe 3- Engine water pipe 4 - Thermostat 5 - Water pump cover water...
  • Page 83 Cooling system disassembly Notice: ● Before disassembly, refer to the coolant draining steps in the radiator section of the Maintenance chapter to drain all the coolant . ●During the disassembly process, you should wear protective measures such as waterproof gloves and protective glasses , and avoid coolant contact with the skin .
  • Page 84 Thermostat assembly and small loop 1-Thermostat assembly 2-M6× 12 bolt* 2 3 - M6×22 bolt * 2 4 - Water pipe clamp (φ 26) * 3 5 - Water pump cover water inlet pipe 6 - Water pipe clamp (φ 24) 7 - Water pump cover assembly 8 - Water pump cover outlet pipe joint 9 - Water pump cover outlet pipe Note: Bolt ⑵...
  • Page 85 Cooling system accessories Notice: Specialized ventilation tooling ( gas pressure reducing valve , air gun, sealing tube) is required for testing. ● After the soaking inspection is completed, the water stains should be wiped clean in time , or blown dry with a dust gun. If you use a dust gun to blow dry the main water tank and the small water tank, be careful not to use too much wind pressure and keep away from the cooling fins to avoid damage or deformation of the cooling fins .
  • Page 86 2. Water tank filling port Notice: Specialized ventilation tooling ( gas pressure reducing valve , air gun, sealing tube) is required for testing. ● After the water soaking inspection is completed, the water stains should be wiped clean in time. 2.1 Overall sealing inspection Seal the small tube and ventilate the large tube to check the air tightness.
  • Page 87 5.3 Disassembly How to check the thermostat assembly : Block the two ports and introduce 181 kPa ( 1.85 Kgf/cm , 26.3 psi) of compressed air , put it into water and let it stand to observe whether there are bubbles. If there are bubbles, it means it is leaking. 1-M6 ×22 bolts*2 2-M6 ×12 bolts 3-φ...
  • Page 88 8. Braking system Notice before service 1. The content of this chapter requires certain maintenance experience . It is recommended to go to a qualified maintenance unit for inspection or maintenance. 2. Frequent inhalation of dust produced by brake pads , regardless of its composition, may have a certain impact on health. Inhalation of dust particles should be avoided .
  • Page 89 Troubleshooting Brake handle soft a. Air enters the brake system oil circuit b. Brake fluid leakage c. The brake pad or brake disc is oily d. Brake caliper or disc main pump piston seal is worn e. Brake pad or brake disc wear f.
  • Page 90 Disassembling the front disc brake caliper a. First, use 14 # to loosen the oil pipe bolts until there is no leakage. Then use 8# hexagon socket to remove the two M10 ×1.5×60 bolts (red circles). The standard torque of the bolts is 45 ～50N.m ( 4.6 ～5.1 kgf.m, 33 ～37 lbf.ft ).
  • Page 91 Check the piston and caliper cylinder for scratches, damage , caliper piston in the previous chapter to disassemble the rear pits, etc. Check the pin for deformation. disc brake caliper piston. Check the piston and caliper Notice: cylinder for scratches, damage , pits, etc. Check the pin for silicone grease to the two pin surfaces indicated by arrows .
  • Page 92 rear wheel 92/ 117...
  • Page 93 9. Battery /Charging System Notice before service 1. Discarded batteries must be properly disposed of and should not cause environmental pollution. It is recommended that the discarded batteries be handed over to professional recycling agencies for recycling . 2. It is prohibited to use untested chargers to charge batteries . 3.
  • Page 94 Troubleshooting Battery damage or degradation 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 95 Charging system layout 1-Battery 2-Main fuse ( 25A ) 3-Charging port ( PKE ) 4 - Magneto 5 – Rectifier Electrical Schematic letter Chinese green yellow English Green Yellow 95/ 117...
  • Page 96 Battery disassembly and assembly 1. Disassembly Notice: ●The entire vehicle must be powered off before removing the battery . ●The negative pole must be removed first , then the positive pole. The opposite is true during installation . ●The positive and negative electrode protection caps must be properly covered when reinstalling .
  • Page 97 b. Check whether the plug is loose or corroded. DC Voltage file c. Use the resistance range of a multimeter to measure of multimeter the resistance of any two wires of the black 3P plug . The standard resistance is 0.55~0.85 Ω (25℃/77°F). Red pen Black pen Main cable cathode...
  • Page 98 10. Front fork assembly Notice before service 1. Use high-quality tools or special tools and fixtures designed by our company. Using inferior tools may cause damage to parts, coating shedding, inadequate assembly , etc. 2. O-rings , paper gaskets , copper gaskets, component sealing rings, etc. used for sealing must be replaced before assembly . 3.
  • Page 99 Exploded view of the front fork assembly : Exploded view of the steering wheel 99/ 117...
  • Page 100 100/ 117...
  • Page 101 Front fork exploded view 101/ 117...
  • Page 102 Lower connection board exploded view 102/ 117...
  • Page 103 Replace the steering wheel Notice: ● When removing the disc brake oil cup , be sure to point it vertically upwards to prevent air from entering the brake line. ● When disassembling or assembling the handle switch , pay attention to adjusting the internal wiring harness of the switch to avoid the wire sheath being damaged by the housing or bolt column.
  • Page 104 ● Be careful not to damage the ABS coil during disassembly . bolts ⑶, align the hole position of the heating switch ⑷ wheel is removed, do not press the brake handle . with the positioning holes ② on the handlebar switch and ●...
  • Page 105 ● After the front wheel is installed , press the brake handle ●Every time you replace the front wheel , you must go to a repeatedly until the brakes regain their braking effect. professional organization for a dynamic balance test. ●Contaminated disc brake discs and disc brake pads will ●...
  • Page 106 Front wheel assembly inspection and 2.2 How to replace the front wheel oil seal and bearing a. Refer to " Replacing the Front Wheel" to remove the maintenance : front wheel assembly . Note: ●This inspection should be completed by a qualified b.
  • Page 107 dynamic balancing. beads on the wheels can ensure that the wheels rotate more smoothly , reduce vibration and shaking, improve the stability and comfort of the vehicle, and facilitate safe driving. a. Every time you replace the front and rear wheels, please go to a professional qualified institution to check the dynamic balance.
  • Page 108 absorber . brake line. b. Use a flat-blade screwdriver to pry open a gap on the ● After disassembly, make sure all parts are reinstalled upper connecting plate , insert the corresponding shock correctly. absorber, and make sure that the upper end of the shock ●...
  • Page 109 4. Install the lower connecting plate assembly nut only needs to be tightened and aligned with the first nut. Apply a proper amount of lubricating oil to the new lower connecting plate assembly and install it from the bottom of the frame . b.
  • Page 110 11. Disassembly and assembly of vehicle covering parts 1. Windshield 2. Hood 3. Headlight 4. Upper head decoration 5. Right side head panel 6. Right pedal front decoration cover 7. Right side cover 8. Right side cover lining 9. Right rear footrest decoration cover 10. Right part of lower air deflector 11. Right part of fuel tank cover 12.
  • Page 111 1. Front left pedal rubber pad pressure plate 2. Front left pedal rubber pad 3. Rear left pedal rubber pad pressure plate 4. Rear left pedal rubber pad 5. Fuel tank movable cover 6. Fuel tank cover middle 7. Rear right pedal rubber pad pressure plate 8. Rear right pedal rubber pad 9.
  • Page 112 Notice: ● Please pay attention to the amount of force when b. Lift the windshield assembly and unplug the disassembling to avoid breaking the buckle. instrument connector. ●When removing the covers , please remove them strictly in order and do not forcefully remove the covers to avoid irreparable damage to the corresponding covers .
  • Page 113 Removal of the head decoration a. Use a crochet hook to pry open the edge of the right decorative cover on the head and remove the right decorative cover. Use the same method to remove the left decorative cover. Removal of windshield lining a .
  • Page 114 d . Find the plug of the turn signal and unplug the connector of the right turn signal. b. Use a hook to remove the 4 expansion screws shown in the picture. e . Remove the right side panel of the head. The removal c .
  • Page 115 when removing the storage box alone. b . Use a T25 hexagonal wrench to remove the eight M6 bolts securing the rear storage box . e. Use a T2 5 -inch box end wrench to remove the two middle bolts as shown in the figure. c .
  • Page 116 Rear cover assembly removal a . Use a T25 hexagon wrench to remove the three M6 bolts (1), then unplug the tire pressure main unit connector (5), remove the right rear cover (2), pay attention to the buckle of the rear cover when removing, then remove the two M6 bolts (3) and three clamps (4) fixed on the tire pressure main unit .
  • Page 117 the shock absorber (2). Remove the lower part of the tail cover lining (3). Removal of rear fender assembly a. Refer to "Removal of Tail Light Assembly" to remove c. Use a hook to remove an expansion nail ⑴, use a T25 the tail light.
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