Page 1 ZT125-250-350-368E Maintenance Manual 2025-4-25 1 / 162...
Page 2: All Rights Reserved
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
User notice This manual is compiled by Guangdong Tayo Motorcycle Technology Co., Ltd. to guide dealers or service personnel to use it. This manual cannot provide more detailed knowledge about motorcycles, and is only for reference for maintenance. If you do not have the corresponding knowledge such as electrician, machine repair, etc., improper assembly or repair failure may occur during repair.
Page 4: Table Of Contents
Content Content ...................................... 4 1. Motorcycle information................................. 10 Know Before Service ................................10 Body label ..................................11 E350 Technical specification .............................. 12 Front wheel/steering system............................12 Rear wheel/suspension system ..........................12 E125 Technical specification .............................. 13 Front wheel/steering system............................13 Rear wheel/suspension system ..........................
Page 5 Swell nail description ................................. 44 2. Maintenance ..................................45 Know Before Service ................................45 E350/368 Maintenance schedule ............................46 E125 Maintenance schedule .............................. 48 E250 Maintenance schedule .............................. 50 E350 Air filter (filter element), air inlet filter element ......................51 1.
Page 6 4. Change gear box oil ............................67 5. Confirm the oil level ............................68 E368 ..................................69 1. Drain the oil..............................69 2. Replace fine filter ............................69 3. Add oil ................................69 4. Change gear box oil ............................70 Throttle valve body................................
Page 7 2. Read the fault code through the diagnostic tool ..................... 89 3. Error code ................................90 4. Clear fault code ..............................91 4.1 Manually clear .............................. 91 4.2 Use the diagnostic tool to clear ........................91 EFI parts layout.................................. 92 E350/E368 .................................
Page 8 2. Check the relay coil .............................. 114 2.1 Input line ..............................114 2.2 Ground wire ............................... 114 3. Check the starting relay ............................114 4. Disassembly and assembly of the starting relay ....................114 6. Fuel supply system ................................115 Know Before Service ................................
Page 9 1. Leakage test ................................. 132 2. Check the charging voltage........................... 132 3. Inspection of magneto stator charging coil ......................132 10. Front fork assembly ................................133 Know Before Service ................................ 133 Exploded view of front fork components: ........................134 Directional exploded view ............................134 Front fork exploded view ............................
Page 10: 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 11: 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 12: 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 13: E125 Technical Specification
E125 Technical specification Item Specification 100/80-14 48P Front tire specification Rear tire specification 120/70-14 61P Front rim specification MT:2.50×14 Rear rim specification MT:3.50×14 Motorcycle Brake fluid DOT4 0.25L（0.07 US gal,0.06 lmp gal） Replace fine filter： 0.95L（0.25 US gal,0.21 lmp gal） Oil consumption Without replacing the fine filter：...
Page 14: E250 Technical Specification
E250 Technical specification Item Specification Front tire specification 120/70-15 M/C 56S Rear tire specification 140/70-14 M/C 68S Front rim specification MT: 3.50×15 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 15: E368 Technical Specification
E368 Technical specification Item Specification Front tire specification 120/70-15 M/C 56S Rear tire specification 140/70-14 M/C 68S Front rim specification MT: 3.50×15 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 16: Brake System
Brake system Item Standard Limit Brake fluid DOT4 Brake pad use limit Trough bottom Front brake disc Brake disc thickness ≥5.0mm(0.197 in) ＜4.5mm(0.177in) Brake fluid DOT4 Brake pad use limit Trough bottom Rear brake disc Brake disc thickness ≥4.5mm(0.177 in) ＜4.0mm(0.157 in) Battery/charging system Item...
Page 17: 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 18: 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 19: Throttle Cable
2. Throttle cable E350-E125-E250 1- Oil return line 2- Fuel line E368 Throttle cable 1- throttle cable (Integrated) 19 / 162...
Page 20: Brake Upper Pump And Brake Hose
3.Brake upper pump and brake hose E350-E125-E250 1-Front disc brake main pump 2-FMC-HU brake hose 3-RMC-HU brake hose 4-rear disc brake main pump E368 1-Front disc brake main pump 2-FMC-HU brake hose 3-RMC-HU brake hose 4-rear disc brake main pump 20 / 162...
Page 21: Calipers, Brake Hoses And Wheel Speed Sensors
4. Calipers, brake hoses and wheel speed sensors E350-E125-E250 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 E368 1-Front brake disc components 2-Wheel speed sensor（Font Wheel）...
Page 22: Distribution Map Of Brake System Accessories
5. Distribution map of brake system accessories E350-E125-E250 1-Wheel speed sensor (front wheel) 2-FC-HU brake hose 3-RC-HU brake hose 4-Wheel speed sensor (rear wheel) 5- Rear disc brake main pump 6-Rear brake lever 7-Rear brake switch 8- RMC -HU brake hose 9-FMC-HU brake hose 10-Front brake switch 11-Front disc brake main pump 12-Front brake handle 13-Hydraulic control unit 22 / 162...
Page 23: E368
E368 1-Wheel speed sensor (front wheel) 2-FC-HU brake hosepipe 3-RC-HU brake hosepipe 4-Wheel speed sensor (rear wheel) 5-Rear disc brake main pump 6-Rear brake handle 7-Rear brake switch 8-RMC-HU brake hosepipe 9-FMC-HU brake hosepipe 10-Front brake switch 11-Front disc brake main pump 12-Front brake handle 13-Hydraulic control unit 23 / 162...
Page 24: Oil Supply System
6. Oil supply system 6.1Fuel evaporation E350-E125-E250 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 25 E368 1-Oil level sensor 2-Fuel tank 3-Built-in fuel pump 4-High pressure oil pipe 5-Carbon canister solenoid valve outlet pipe 6-Throttle valve body assembly 7-Canister solenoid valve 8-Carbon tank 9-Carbon canister adsorption tube 10-External oil and gas separator 11- Fuel tank breather pipe 12- Fuel tank cover 13-Carbon canister solenoid valve intake pipe Fuel evaporation: Air→Fuel tank breather pipe→External oil and gas separator→carbon canister adsorption tube→Carbon tank→carbon canister...
Page 26: E368
6.2 Fuel supply E350-E125-E250 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 E368 Fuel supply system: Air→Carbon tank→carbon canister adsorption tube→External oil and gas separator→Fuel tank breather pipe Fuel→Fuel pump filter screen→Fuel pump→High pressure fuel pipe→Fuel injector →Cylinder 26 / 162...
Page 27: Distribution Map Of Cooling System Accessories
7. Distribution map of cooling system accessories Cooling system E250-E350 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 27 / 162...
Page 28: E125
E125 1-Main water tank 2-Water tank filling port 3- Main water tank inlet pipe 4- Thermostat 5- Thermostat outlet pipe 6-Water and oil common sensor 7- Engine inlet pipe 8-Auxiliary water tank 9-Auxiliary water tank connecting water pipe 10- Main water tank outlet pipe 11-Water pump cover assembly 28 / 162...
Page 29: E368
E368 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 29 / 162...
Page 30: Electrical Device Layout
8. Electrical device layout E350 1-TFT Meter 2-Electric Heat Handle bar Switch 3-Non-inductive antenna 4-Windshield motor controller 5-Battery 6-Main lock 7-PKE 8-Horn 9-Side bracket flame-out switch 10-Carbon canister solenoid valve 11-Engine controller (ECU) 12-Rectifier 13-Seat lock 14-Flash 15-Dump switch 16- GPS antenna 30 / 162...
Page 31 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 31 / 162...
Page 32: E250
E250 1-TFT Meter 2-Electric Heat Handle bar Switch 3-Non-inductive antenna 4-Windshield motor controller 5-Battery 6-Main lock 7-PKE 8-Horn 9-Side bracket flame-out switch 10-Carbon canister solenoid valve 11-Engine controller (ECU) 12-Rectifier 13-Seat lock 14-Flash 15-Dump switch 16- GPS antenna 32 / 162...
Page 33 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 - electric jet ignition coil 6 - Carbon canister solenoid valve 33 / 162...
Page 34: E125
E125 1-TFT Meter 2-Non-inductive antenna 3-Windshield motor controller 4-Battery 5-Main lock 6-PKE 7-Horn 8-Side bracket flame-out switch 9-Carbon canister solenoid valve 10-Engine controller (ECU) 11-Rectifier 12-Seat lock 13-Flash 14-Dump switch 15- GPS antenna 34 / 162...
Page 35: E368
E368 1-TFT instrument 2-Flasher 3-Windshield motor controller 4-Battery 5-Horn 6-Side bracket flame-out switch 7-Carbon canister solenoid valve 8-GPS antenna 9-Non-inductive antenna 10-Main lock 11-Electric Heat Handle bar Switch 12-Tire pressure receiving host 13-Engine controller (ECU) 14-Rectifier 15-Seat lock 16-PKE 17-Dump switch 35 / 162...
Page 36 1- TFT instrument 2-Windshield motor controller 3-Dual Port Universal USB Charging Cable 4-PKE 5-Starting relay 6-Charging port 7-GPS antenna 8-Electronic fuel tank lock 9-Non-inductive antenna 10-Main lock 11-Left front luggage box lock 12-Single port universal USB charging cable 13-EFI Relay 1 - Seat lock 2 - Rectifier 3 - Engine controller (ECU) 4 –...
Page 37 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 - electric jet ignition coil 6 - Carbon canister solenoid valve 37 / 162...
Page 38: Intake And Exhaust System
9. Intake and exhaust system E350 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 →...
Page 39: E125
E125 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 40: E250
E250 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 41: E368
E368 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 42: 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 42 / 162...
Page 43 PT300 electronic spraying and writing diagnostic Speedometer Tire pressure gauge Magnetic base + dial indicator 17#Inner hexagon （16PIN） Hoop clamp Internal Circlip Pliers External circlip pliers Clamp multimeter Multimeter Dust blow gun 14-sided 65mm cap filter wrench Some of the above pictures are from the Internet, and the copyright belongs to the author of the original picture. Do not use it for other purposes.
Page 44: 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 45: 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 46: E350/368 Maintenance Schedule
E350/368 Maintenance schedule ：Tighten ★:Comment : inspection（Inspect and clean,adjust,lubricate or replace if necessary） :replace 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 year or 10,000 Cradle buffer glue kilometers (6214 mile) Air filter (filter element)
Page 47 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 48: E125 Maintenance Schedule
E125 Maintenance schedule : inspection（Inspect and clean,adjust,lubricate or replace if necessary） :replace ：Tighten★:Comment Initial Every Inspectio Every Torque mile 1000/621 4000/2485 8000/4971 Replace regularly Check item n before N.m/kgf.m driving Months Initial 3 Every 15 Every 30 Inspection every 1 years or 10,000 Cradle buffer glue kilometers (6214 mile) Air filter (filter element)
Page 49 ★Note2：Active and driven wheel bushings are recommended to be maintained and lubricated every 10000km (6214 mile) with Shell brand Gadus S3 V220 C2 extreme pressure grease or high temperature resistant No.2 grease of the same viscosity to 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.
Page 50: E250 Maintenance Schedule
E250 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 1 years or 10,000 Cradle buffer glue kilometers (6214 mile) Air filter (filter element)
Page 51: 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 52: Replace The Air Inlet Filter
d. Remove the air filter housing. 4. Replace the air inlet filter a. Remove the sponge and replace it with a new filter element. Note that the black side faces the engine and the white side faces outward. e. Place the rubber plug and tapping screw properly to avoid loss.
Page 53: Reinstall
attention to increase the frequency of inspection appropriately when the air humidity is large. If there is excessive dirt in the hose, be sure to check the air filter element for excessive dirt or damage, and replace the air filter element if necessary. ●The motorcycle must be parked on a flat and stable ground or a lifting platform.
Page 54: E125 Air Filter (Filter Element), Air Inlet Filter Element
E125 Air filter (filter element), air inlet filter element Step： 1. Support the motorcycle firmly Prop up the motorcycle with the main bracket and put down the side brackets, as shown in the figure. 4. Replace the air inlet filter a.
Page 55: Reinstall
●The vehicle must be parked on a flat and stable ground or a lifting platform. ●The operation can only be performed after the engine has cooled down completely. ●The air filter element is checked every 4000 kilometers or 6 months (whichever comes first), and replaced every 6000 7.
Page 56: E250 Air Filter (Filter Element), Air Inlet Filter Element
E250 Air filter (filter element), air inlet filter element Step： 1. Support the motorcycle firmly Prop up the motorcycle with the main bracket and put down the side brackets, as shown in the figure. 3. Remove the air inlet cover a.
Page 57: Replace Air Filter Element
c.Use a Phillips screwdriver to remove the 4 screws that fix the housing of the air filter. c. Replace the new filter element and sealing strip. 7. Inspection air filter waste oil pipe After removing the rubber stopper, use a flashlight to light from directly below according to the direction of the arrow, and observe whether the waste oil drain pipe accumulates dirt or water through the rubber plug hole.
Page 58: E368 Air Filter (Filter Element), Air Inlet Filter Element
c. Pull out the 2 mushroom buckles on the air filter d. Use 4# inner hexagon to install the other 4 M6×14 bolts. decoration cover and remove the air filter decoration cover. Replace the decorative buckle. 3.Remove the air inlet cover E368 Air filter (filter element), air inlet a.
Page 59: Remove The Air Filter Housing
appropriately when the air humidity is large. If there is 4.Remove the air filter housing excessive dirt in the hose, be sure to check the air filter element for excessive dirt or damage, and replace the air a. Remove 10 self-tapping nails with a Phillips screwdriver. filter element if necessary.
Page 60 ●Ensure that the filter element is assembled in place. ●If the replacement period is not reached, the surface of the filter element is clean without damage, and you can use a dust blow gun to blow air from the clean side of the filter ●If the air filter is clogged with dust, the air intake resistance element to blow away the dust on the surface of the filter will increase and the output power will decrease.
Page 61: Bolts And Nuts Of Muffler
E368: Bolts and nuts of muffler Use the 8# hexagon to remove the 3 M10 bolts that fix the 1. Check for air leaks at the engine exhaust. muffler, and use the 6# hexagon to remove the M8 bolts on the inside, loosen the clamp, and remove the rear section of the muffler and the decorative cover.
Page 62 ●Keep the drain hole at the bottom of the muffler unblocked to prevent condensation water from accumulating in the muffler cavity. ●Do not touch all metal surfaces of the muffler while the engine is running or after riding to prevent burns. ●The motorcycle must be parked on a flat and stable ground or a lifting platform.
Page 63: Engine Oil
Engine oil d. After placing an oil pan under the oil drain bolt, use a 14# sleeve to remove the oil drain bolt⑶ and the combined seal gasket⑷. ●The motorcycle must be parked on a flat and stable ground or a lifting platform. ●Once the engine and muffler have cooled down, the operation can be performed.
Page 64: Add Oil
Note that the sealing ring cannot be omitted, and the surface of the sealing ring should be checked for damage, hardening and other defects before assembly. b. Use a 14# sleeve to loosen the oil drain bolt⑶ counterclockwise. 3. Add oil a.
Page 65: E125
E125 Drain the oil a. Start the motorcycle and turn off the engine for 3-5 minutes after idling for 3-5 minutes. b. Use the main bracket to park the motorcycle firmly. c. Rotate the oil dipstick⑴ on the right side of the engine counterclockwise, and remove the oil dipstick⑴...
Page 66: Change Gear Box Oil
d.inspection O ring⑵Whether there is damage or aging, if c. Use a 14# sleeve to loosen the oil drain bolt⑶ not, wipe it clean, if any, replace it. counterclockwise, and remove the bolt⑶ and copper pad⑷. e. Wipe clean the oil dipstick, and turn the oil dipstick⑴ and O-ring⑵...
Page 67: E250
E250 e. Remove the O ring on the fine filter cover and replace it with a new O ring. First put the O ring (3a) into the groove of Drain the oil the fine filter cover⑵, and then install it back to the engine a.
Page 68: Confirm The Oil Level
5. Confirm the oil level a. After starting the motorcycle and running at idle speed for several minutes, check whether all the disassembled positions are leaking, and if there is any leakage, it needs to be checked. b. After the engine has been idling for 5 minutes and then turned off for 3 minutes, check whether the oil level meets the standard.
Page 69: E368
E368 Drain the oil a. Start the motorcycle and turn off the engine for 3-5 minutes after idling for 3-5 minutes. b. Use the main bracket to park the motorcycle firmly. c. Rotate the oil dipstick⑴ on the right side of the engine counterclockwise, and remove the oil dipstick⑴...
Page 70: Change Gear Box Oil
d. After the gear box oil is completely drained, wipe the surface of the drain port with a non-woven cloth. e. Replace with a new copper pad⑷, check whether the joint surface of the oil drain bolt⑶ is scratched, if not, wipe it clean and install it in order.
Page 71: Throttle Valve Body
Throttle valve body c. Slightly lift the back of the glove box until the harness connector on the left side of the glove box is exposed, unplug Caution: the ambient light plug on the left side of the glove box, ●The three-in-one sensor and stepper motor cannot be unplug the plug, and take out the glove box completely.
Page 72: Remove The Throttle Valve Body Assembly To Clean Up Carbon Deposits
3. Remove the throttle valve body assembly to e. Use 5# inner hexagon to remove 2 bolts⑹ and then remove the valve body assembly from the engine. clean up carbon deposits a. Unplug the plugs of the stepping motor① and the sensor②.
Page 73: Throttle Valve Body Troubleshooting Process
5. Throttle valve body troubleshooting process Throttle valve body troubleshooting process Idle adjustment bolt Throttle body sensor looseness,poition performance check spring stagnation and other problems The diagnostic instrument eads the data c. Use a short Phillips screwdriver to remove the 2 Fault lights are always stream and requires the According to idle...
Page 74: Throttle Cable
wrench to loosen the 2 nuts on the bracket to adjust. Torque: Throttle cable 3.0 N.m (0.3 kgf.m, 2.2 lbf.ft). 1. Inspection a. Check whether the rubber sleeve of the right hand handle and the throttle cable are damaged. b. Check whether the rubber sleeve of the right hand rotates smoothly and whether it can return automatically.
Page 75: Fuel Evaporative Pollutant Control System
Fuel evaporative pollutant control system 1- Fuel level sensor 2- Fuel tank 3- Fuel pump 4- Oil-air separator (welded inside the fuel tank) 5- Fuel tank cap 6- Adsorption/vent pipe 7-High pressure fuel pipe 8-Carbon tank 9-Carbon tank solenoid valve 10- Solenoid valve intake pipe 11-solenoid valve outlet pipe 12-throttle valve body assembly Fuel evaporation: 350-125-150E:...
Page 76: Radiator
2. E125-E250-E350 add coolant (antifreeze) to the Radiator Coolant 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 77: E125
d. Tighten the filler cap of the Radiator. Tighten the exhaust bolt; torque: 8～10N.m (0.8～1 kgf.m, 6～7 lbf.ft). d. Put on waterproof gloves and add coolant to the water inlet of the Radiator with the help of an extended funnel. Until the position of the vent bolt of the thermostat is stably overflowed with coolant, the coolant level can be seen at the water filling port.
Page 78: Check Whether The Fins Of The Radiator Water Tank Are Deformed Or The Air Duct Is Blocked
b. Remove the filler cap of the Radiator to accelerate the flow of coolant. 5. Check whether the fins of the radiator water c. Wipe all the joint surfaces clean with a non-woven cloth. tank are deformed or the air duct is blocked Check whether the bolt⑶...
Page 79: Check All Water Pipes For Leaks; Aging
6. Check all water pipes for leaks; aging. 6.1 E250-E350 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 6.2 E125 1- water tank water inlet 2-main water tank inlet pipe 3-engine inlet pipe.4-Water pump cover inlet pipe 5-Secondary water tank 6- auxiliary water tank connection water pipe 7- water tank outlet pipe...
Page 80: 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 81: Replace The Front Brake Brake Fluid
braking effect to deteriorate or fail, which will affect driving ●When pinching the brake handle, it must be slow and safety. uniform to avoid air bubbles from entering the brake pipeline. 2.1 Replace the front brake brake fluid ●The vent nozzle must be locked in place before the brake a.
Page 82: Check The Tires
●Check the tire pressure regularly. ●When the tire pressure is found to drop, check whether the tire has nails or small holes; whether there is a collision on the side of the rim that causes deformation or cracks. ●Be careful to avoid the position of the valve when removing the tire with the tyre raking machine.
Page 83: Check The Appearance
accumulated during the assembly of the dust seal, and it can lmp oz, 25.07±0.12 cu-in ). E125 is 412±2ml(13.93±0.07 be judged that the oil seal is not leaking. If there is a small US oz,14.5±0.07 lmp oz, 25.13±0.1 cu-in )。 amount of oil stains or sludge mixture, remove the dust seal ●After traveling on dusty or muddy roads, you should clean and wipe clean the front fork tube and oil seal surface, first...
Page 84: Troubleshooting
5. Troubleshooting a. There is obvious impact noise when driving on uneven roads or emergency braking. The following items need to be checked: Whether the spring of the shock absorber is broken or the elasticity drops; Whether the hydraulic oil is insufficient or enters the air; Whether there is too much hydraulic oil;...
Page 85: E350 Side Bracket
E350 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 86: E368 Side Bracket
c. Check whether the flameout switch function is normal. The vehicle should not be started when the side bracket is lowered (parking position); the vehicle cannot be started E368 Side bracket when the side bracket is retracted (driving position) without Caution: pinching the front or rear brake handle;...
Page 87: Main Bracket
Main bracket Caution: ●Park the vehicle on a flat and stable ground or a lifting platform, and put down the side brackets. ●When disassembling and installing the spring, it is necessary to prevent the spring from flying off suddenly and causing personal injury.
Page 88: 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 89: 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 90: Error Code
3. Error code Code Instruction Code Instruction Oxygen Sensor Heater Control Circuit Open P0137 P0030 Oxygen Sensor Circuit Low Voltage Bank 1 Sensor 2 Bank 1 Sensor 1 Oxygen Sensor Heater Control Circuit Low Bank P0138 P0031 Oxygen Sensor Circuit High Voltage Bank 1 Sensor 2 1 Sensor 1 Oxygen Sensor Heater Control Circuit High P0032...
Page 91: 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 92: Efi Parts Layout
EFI parts layout E350/E368 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 92 / 162...
Page 93: E125/E250
E125/E250 OBD diagnostic Carbon canister Dump switch interface (main Fuel pum p 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 94: Dump Switch
1. Dump switch Can ride Replace the normally dump switch Short-circuit the black-brown, white- Fuel cut off yellow wires during driving connected to the dump switch Check ECU, fuel Can't ride pump, throttle normally valve body, etc. 2. OBD port Refer to the steps of "Maintenance-Fuel Pipe- Replacement of High-pressure Fuel Pipe"...
Page 95: Carbon Canister Solenoid Valve
4. Carbon canister solenoid valve Need to remove the cushion and storage box first. When the engine performance is poor; the idle speed is poor; the air-fuel ratio is incorrect, the carbon canister solenoid valve should be checked. Use a multimeter to measure the resistance between the two inserts of the canister solenoid valve plug should be 35±2Ω, otherwise it can be judged that the solenoid valve is faulty.
Page 96: 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 97: 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 98: 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 99: 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 100: 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 101: 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 102: Electrical Schematic Diagram Of Efi System
Electrical schematic diagram of EFI system 102 / 162...
Page 103: 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 104: 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 105: E350/E368 Ignition System Layout
E350/E368 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 –...
Page 106: E125/E250 Ignition System Layout
E125/E250 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 107: 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 108: 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 109: 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 110: 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 111: Starting System Electrical Schematic Diagram
Starting system electrical schematic diagram 111 / 162...
Page 112: 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 113: 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 114: 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 115: 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 116: 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 117: E350/E250/E368 Coolant System Distribution Map
E350/E250/E368 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 E350/E250/E368 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 118: E125 Coolant System Distribution Map
Cooling system: Small loop (indicated by the purple 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 119: Cooling System Disassembly
Cooling system disassembly Caution: ●Before disassembling, please refer to the steps of discharging the cooling liquid in the cooling system section of the "Maintenance" chapter to drain all the cooling liquid first. ●Wear protective measures such as waterproof gloves and protective glasses during disassembly, and prevent the coolant from contacting the skin.
Page 120: Cooling System Accessories
Before reassembly, the joint surface should be cleaned. Note that the O-ring cannot be missing and must be correctly assembled in place. The hoop should be clamped inside the boss to prevent loosening. Bolt⑵ Torque: 12±1.5 N.m (1.2±0.2 kgf.m, 9±1 lbf.ft). Cooling system accessories Caution: ●Special ventilation tooling (gas pressure reducing valve, air gun, sealing tube) is required for testing.
Page 121: Attention To The Water Tank Filling Port
Check whether the fan and the mesh cover are firmly assembled, and the rotating fan blades should be free of stagnation. Check whether the buffer rubber is aged and cracked. Check whether the fan cable is damaged The fan plug is positive in blue and negative in black. Find the battery with sufficient power, connect the wires according to the positive and negative poles, and check whether the fan draws air backward Compressed air with lower air pressure can be blown from the back to the water tank from a long distance to clean up foreign objects on the surface.
Page 122: Failure Phenomenon
5.2 Failure phenomenon When the water temperature gauge indicates high, the engine temperature is overheated, but the coolant temperature in the water tank is not high, it is not hot when touching the radiator by hand, and the small water tank fan rotates normally. It indicates that the big circulation is blocked or blocked, which can be preliminarily judged as abnormal thermostat.
Page 123: 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 124: E350/E125/E250 Disassemble The Rear Disc Brake Main Pump
without leakage, otherwise it will be more difficult to 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...
Page 125: E368 Disassembly Of Front Disc Brake Master Cylinder
The oil window assembly (a) should not be disassembled unless absolutely necessary; b denotes a φ0.5 oil hole; c E368 Disassembly of Front Disc Brake Master denotes a φ3 pressure relief oil hole. Cylinder a.Remove it according to the steps for removing the steering handle in this manual "Fork Assembly".
Page 126: Disassemble The Front Disc Brake Caliper
Disassemble the front disc brake caliper damage. Check the piston and caliper cylinder for scratches, damage, pits, etc. Check whether the pin is a. Use 14 # to loosen the oil pipe bolt without leakage. deformed. Remove 2 M10 pieces with 8 # hexagonal socket × one Caution: point five ×...
Page 127 c. Refer to the procedure for replacing the brake pads to Caution: remove the brake pads first. d. Disassemble the rear disc brake caliper ●The motorcycle needs to be parked on a stable lifting Refer to the previous steps to disassemble the front disc platform or on a level and level ground.
Page 128: Abs Troubleshooting
ABS troubleshooting 128 / 162...
Page 129: 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 130: Troubleshooting
Troubleshooting Battery damage or attenuation troubleshooting process Battery failure Use a Measure the multimeter to battery voltage Remove the battery and check whether Battery first, then use a battery tester to there is leakage, Check the voltage<charging measure the check the battery the leakage charging voltage voltage<14.5～14.9...
Page 131: 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 131 / 162...
Page 132: 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 133: 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 134: Exploded View Of Front Fork Components
Exploded view of front fork components: Directional exploded view 134 / 162...
Page 135: Front Fork Exploded View
Front fork exploded view 135 / 162...
Page 136: Exploded View Of Lower Link Board
Exploded view of lower link board 136 / 162...
Page 137: E368 Exploded View Of Front Fork Components
E368 Exploded view of front fork components: Directional exploded view 137 / 162...
Page 138: Front Fork Exploded View
Front fork exploded view 138 / 162...
Page 139: Exploded View Of Lower Link Board
Exploded view of lower link board 139 / 162...
Page 140: E350/E250/E250 Change The Direction Of The Handle
E350/E250/E250 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 141: Installation Handle Bar To Put The Component
right handle bar (8) and the right heated handle bar (9) b. When installing the left hand handle switch, it is separately. necessary to align the bolt (11a) with the positioning hole (1) on the directional handle, and then tighten it with a cross batch.
Page 142: E368 Change The Direction Of The Handle
f. Replace the left and right expansion nails. Use the 4# Allen to replace the 2 bolts on the left and right sides. (Check c. Pry the upper cover ⑼ with a batch of words at arrow whether the direction is crimped) A and remove it.
Page 143: Disassemble The Handle Bar Assembly
e. Use the 2.5# Allen to remove the setting screw ⑽under 2. Disassemble the handle bar assembly the left handle rubber⑼, Use the 5# Allen to remove the bolts(g) and (h)below the left hand handle switch,and then a.Remove the 2 M6×12 bolts (1) from the handguard use a cross screwdriver to remove the bilts(f).Separate the bracket using the #4# Allen.
Page 144: Install The Handle Bar Cover
c. When installing the secondary handle bar switch, it is necessary to align the joint surface of the counter-handle bar e. To prevent scratching the covering, cover the bubble switch and the main pump of the disc brake with the triangle bag to the panel of the storage box.
Page 145: 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 146: 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) c.
Page 147: Replacement Method Of Front Wheel Oil Seal And Bearing
the bearing. When the following conditions occur, the front wheel oil seals and bearings should be checked in advance 3.2 How to replace the front wheel rim and tire a. Abnormal front wheel noise when riding. a. Refer to "Replace the front wheel" to remove the front b.
Page 148: Change The Front Shock Absorber
Change the front Shock absorber Note: ● Do not press the brake lever after the front wheel is removed. ● Be careful not to damage the ABS coil when disassembling. ● When disassembling the front clay board, be careful not to scratch the shock absorber or the front clay board.
Page 149 tightened or penetrate the right shock absorber, and the shock absorber that is not installed in place will need to be removed again and installed in place. e. After installing the front wheel, use the 6# Allen to tighten the two M8×35 bolts in the lower part of the right front shock absorber, torque: 20N.m (2.0 kgf.m, 15 lbf.ft).
Page 150: Disassembly And Assembly Of Coverings
11.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 151 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.
Page 152: Removal Of The Windshield
Notice: E350 Removal of the upper part of the hood and ●When disassembling, please pay attention to controlling the 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 153: E368 Removal Of The Upper Part Of The Hood And The Windshield Liner
Head side panel removal expansion nails on the inner side, and remove the rear of the windshield liner. a. Use a 4# inner hexagon to remove one M6×14 shoulder bolt on the inner side of the left side plate. b. Start the motorcycle, open the left glove box, and use a 4# inner hexagon to remove one M6×14 shoulder bolt and E368 Removal of the upper part of the hood and one expansion nail as shown in the picture...
Page 154: Seat Removal
c. Use the 4 expansion nails on the left and right sides as shown in the figure to remove. Seat removal a. First press the power button of the motorcycle, then press the seat lock switch of the motorcycle to open the seat lock, then press and hold the power button for 2 seconds to turn off the motorcycle.
Page 155: Removal Of Left And Right Rear Armrests
⑵, and the rear two M8× 35 bolts ⑶, remove the rear armrest. b. Old model: Use 4# inner hexagon to remove the 4 shoulder bolts at the rear and the middle (1), remove the front hexagonal bolt decorative buckle (2) and then remove the bolts (1).
Page 156: Removal Of Front Left And Right Storage Box Covers
b. Use 4# inner hexagon to remove the 2 M6×14 bolts that f. Unplug the wire harness connector on the left side of the fix the rear fender assembly on the frame. rear of the motorcycle, arrange the wire harness and remove the rear fender assembly of the taillight.
Page 157: Removal Of Fuel Tank Side Cover
and use the same method to disassemble the left and right sides Removal of fuel tank side cover Removal of the decorative cover of the instrument panel panel a. Open the left and right front box covers, remove the 2 expansion nails as shown in the picture, pull out the decorative cover of the instrument panel in the direction of the arrow, pull out the PKE antenna pasted on the decorative...
Page 158: Removal Of Front Storage Box Panel
d. Lift out the pedal rubber pad and the pedal rubber pad pressure plate using a one-word batch, press and pull up the c. Press and pull out the 8 expansion nails at the bottom of pedal rubber pad and the pedal rubber pad pressure plate the fairing, and remove the bottom of the lower fairing.
Page 159 h. Unplug all the wire harnesses on the PKE and tidy up the wire harnesses e. Remove 3 bolts with 6# inner hexagon, and take off the spring washers and flat washers. i.Open the buckle and remove the OBD diagnostic connector f.
Page 160: Removal Of Front Storage Box Panel(Thailand)
Removal of front storage box panel(Thailand) a. The front storage box assembly needs to remove the head cover first. b. Use a 4# inner hexagon to remove the 2 bolts ⑴ and 2 expansion nails ⑵ of the lower cover that fix the direction. l.
Page 161 j. Use 4# inner hexagon to remove 2 M6×14 bolts ⑵, use 6# inner hexagon to remove 2 M6×25 bolts ⑴ to fix the f. Pull out the cable fixed on the steering handle. Remove the main lock, and pull out the main lock connector. steering handle.
Page 162 n. Pass the handle assembly through the front storage box panel, and remove the front storage box panel assembly. 162 / 162...

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