Zontes ZT310T-M Motorcycle Manuals

Manuals and User Guides for Zontes ZT310T-M Motorcycle. We have 1 Zontes ZT310T-M Motorcycle manual available for free PDF download: Maintenance Manual

Zontes ZT310T-M Maintenance Manual (184 pages)

Brand: Zontes | Category: Motorcycle | Size: 38 MB

Table of Contents
4
Content
4
Vehicle Information
13
Know before Service
13
Body Label
14
Technical Specification
15
Front Wheel/Steering System
16
Rear Wheel/Suspension System
16
Brake System
16
Battery/Charging System
17
Lamp/Speedometer/Switch Description
17
Tightening Torque
18
Bolt Tightening Torque of General Tightening Part
18
Cable/Cable/Pipe/Electrical Device Distribution Map
19
Distribution Map of Lamps and Lanterns
19
Throttle Cable
19
Brake Upper Pump and Brake Hose
20
Calipers, Brake Hoses and Wheel Speed Sensors
20
Distribution Map of Brake System Accessories
21
Oil Supply System
22
Fuel Evaporation
22
Fuel Supply
23
Distribution Map of Cooling System Accessories
23
Electrical Device Layout
24
Intake and Exhaust System
26
Tool
27
Expansion Nail Description
29
Maintenance
30
Know before Service
30
Maintenance Schedule
31
Air Filter (Filter Element), Air Inlet Filter Element
32
Support the Vehicle Firmly
32
Remove the Left Engine Cover
32
Remove the Air Inlet Cover
32
Replace the Air Inlet Filter
33
Remove the Air Filter Housing
33
Replace Air Filter Element
33
Inspection Air Filter Waste Oil Pipe
34
Reinstall
34
Bolts and Nuts of Muffler
35
Spark Plug
36
Disassemble the Spark Plug
36
Check the Spark Plug
37
Refer to the Steps to Remove the Spark Plug to Restore All Parts
37
Engine Oil
38
Drain the Oil
38
Replace Fine Filter
38
Add Oil
39
Change Gear Box Oil
39
Confirm the Oil Level
39
Throttle Valve Body
40
Do Not Dismantle the Throttle Body to Clean up Carbon Deposits
40
Remove the Stepper Motor and Clean up Carbon Deposits
40
Remove the Throttle Valve Body Assembly to Clean up Carbon Deposits
42
Disassemble the Three-In-One Sensor
43
Throttle Valve Body Troubleshooting Process
43
Throttle Cable
44
Inspection
44
Adjust the Throttle Cable Clearance
44
Lube Door Cable
44
Idle Speed
45
Check Idle Speed
45
Fuel Evaporative Pollutant Control System
46
Radiator
47
Check the Coolant
47
Add Coolant (Antifreeze) to the Coolant Expansion Tank
47
Add Coolant to the Radiator
48
Put Coolant
48
Check Whether the Fins of the Radiator Water Tank Are Deformed or the Air Duct Is Blocked
48
Check All Water Pipes for Leaks; Aging
49
Fuel Pipe
51
Check the Fuel Pipe for Leaks with the Help of an Endoscope with LED Light
51
Replace High Pressure Oil Pipe
51
Fuel Pump
52
Use Oil Pressure Gauge to Measure Fuel Pressure
52
Simple Test of Fuel Pump
52
Treatment of Abnormal Fuel Pressure
53
Belt
54
System Components
54
Maintenance
55
Remove the Belt
55
Disassemble the Continuously Variable Transmission Components
55
Inspection
57
Assembly
58
Common Fault Phenomena/Troubleshooting
60
The Engine Can be Started, but the Rear Wheel Does Not Rotate
60
Engine Stall or Lack of Power
60
Insufficient High-Speed Power
60
When the Engine Is at Normal Idling Speed, the Rear Wheel Rotates Rapidly
60
Braking System
61
Check the Brake Components
62
Check the Front and Rear Brake Switches
63
Check the Brake Switch
63
Replace the Brake Switch
63
Lubricate the Movable Parts of the Brake Handle
63
Lubricate the Front Brake Handle
63
After Lubricating the Brake Handle
64
Replacing the Brake Handle
64
Adjust the Brake Handle
64
Replace the Brake Pads
64
Update the Front Brake Pads
64
Replace the Brake Pads after Replacement
65
Abnormal Sound of Brake Pads
65
Replace the Brake Disc
66
Replacing the Front Brake Disc
66
Replacing the Rear Brake Disc
66
Brake Hose
67
Brake Fluid
67
Add Brake Fluid to the Main Pumps of the Front and Rear Disc Brakes
67
Replace the Brake Fluid
68
Replace the Front Brake Brake Fluid
68
Replace the Rear Brake Fluid
69
Brake System Exhaust
69
Tire
69
Check the Tires
70
Steering Mechanism
70
Check the Steering Mechanism
71
Maintain Steering Bearings
71
Malfunction
72
Front Fork
72
Check the Appearance
72
Check the Shock Absorption Performance
73
Remove the Front Shock Absorption
73
Correct the Front Fork Tube
73
Troubleshooting
73
Rear Shock Absorption
73
Check
74
Adjust the Preload
74
Adjust the Right Rear Shock Absorption
74
Adjust the Left Rear Shock Absorption
74
Replace the Shock Absorption
75
Bolts and Nuts for Body and Engine Installation
76
Check the Heavy Parts Fasteners
76
Check Engine Fasteners
76
Valve Clearance Adjustment
77
Maintenance Information
77
General Information
77
Assemble Torque Value
77
Tools, Measuring Tools, Accessories
77
Operation Steps
77
Side Bracket
81
Check
81
Lubrication
81
Main Bracket
82
Check
82
Lubrication
82
Install the Main Bracket
82
Replace the Return Spring Post of the Main Support
82
Sound, Light, and Electrical Device Inspection
83
Check
83
Headlight Height Adjustment
84
Fuse Box
85
Troubleshooting
86
Right Hand Switch
86
Right Hand Handle Vice Switch
86
Left Hand Handle Auxiliary Switch
87
Horn
87
Left Hand Switch
89
Light
90
Windshield Failure
90
EFI System
91
Know before Service
91
Error Code
93
Read the Fault Code through the Meter
93
Read the Fault Code through the Diagnostic Tool
93
Clear Fault Code
94
Manually Clear
94
Use the Diagnostic Tool to Clear
94
EFI Parts Layout
95
Fault Diagnosis and Elimination of EFI Parts
96
Dump Switch
96
OBD Port
96
Fuel Pump
96
Carbon Canister Solenoid Valve
97
EFI Relay
97
Fuel Injector
98
Ignition Coils
98
Throttle Valve Body
100
Common Failure Phenomena
100
Disassembly
100
Troubleshooting Process
100
Three-In-One Sensor
100
Water and Oil Shared Sensor
100
Oxygen Sensor
101
Check
101
Replace
101
Ecu
101
Crankshaft Position Sensor
101
The Engine Cannot Start and There Is no Sign of Fault Diagnosis Process
102
The Engine Cannot be Started and There Is a Car Symptom Fault Diagnosis Process
103
Poor Acceleration
103
High Idling Speed of Hot Car
104
Unsteady Idle Speed of Cooling Car
104
Unsteady Idling, Easy to Cutoff
105
Analysis Flow Chart of EFI Failure Indicator Light Always on
106
Electrical Schematic Diagram of EFI System
107
Ignition System
108
Know before Service
108
Troubleshooting
109
Ignition System Layout
110
Electrical Schematic Diagram of Ignition System
110
Ignition System Inspection
111
Ignition Timing
111
Check
111
Installation
112
Ignition Coils
112
Starting System
113
Know before Service
113
Troubleshooting
113
Starting Relay
113
Starter Motor
114
The Starter Motor Runs Slowly
114
The Starter Motor Is Working Normally, but the Engine Cannot be Started
114
Ignition System Layout
114
Starting System Electrical Schematic Diagram
115
Starter Motor
115
Remove the Starter Motor
115
Disassemble the Starter Motor
116
Examination
117
Starter Motor Front Cover
117
Motor Back Cover
117
Denki
117
Check the Starting Relay
118
Operation Check
118
Check the Relay Coil
118
Input Line
118
Ground Wire
118
Disassembly and Assembly of the Starting Relay
118
Fuel Supply System
119
Know before Service
119
Fuel Tank Removal
119
Disassemble the Fuel Tank Assembly
119
Disassemble the Fuel Pump
121
Remove the External Parts of the Fuel Tank Assembly
121
Examination
121
Fuel Pressure Test
121
Fuel Pump Inspection
121
Oil Level Sensor
122
Cooling System
123
Know before Service
123
Troubleshooting
123
The Engine Temperature Is too High
123
The Engine Temperature Is too Low
123
Coolant Leakage
123
Coolant System Distribution Map
124
Coolant Flow Diagram
125
Cooling System Disassembly
126
Remove the Radiator Assembly
126
Coolant System Hoop/Clamp Distribution Map
128
Thermostat Assembly and Small Loop
128
Cooling System Accessories
129
Main Water Tank
129
Attention to the Water Tank Filling Port
130
Overall Leak Check
130
Check of Pressure Relief Valve
130
Auxiliary Water Tank
130
Aluminum Inlet Pipe and Aluminum Outlet Pipe
130
Small Water Tank
130
Water and Oil Shared Sensor
131
Thermostat
131
Inspection
131
Failure Phenomenon
131
Disassembly
132
Thermostat Core Inspection
132
Water Pipe
132
Check the Water Pump Cover Assembly
132
Braking System
133
Know before Service
133
Trouble Shooting
134
Soft Feeling from Brake Lever
134
Hard Feeling from Brake Lever
134
Disassemble the Disc Brake Main Pump and Calipers
134
Disassemble the Front Disc Brake Main Pump
134
Disassemble the Rear Disc Brake Main Pump
135
Disassemble the Front Disc Brake Caliper
135
Disassemble the Rear Disc Brake Caliper
136
Brake Hose and Wheel Speed Sensor
137
Check the Gap between the Wheel Speed Sensor and the Induction Ring Gear
137
Remove the Brake Hose and Wheel Speed Sensor
137
Release Brake Fluid
137
FMC-HU and RMC-HU
138
FC-HU and Wheel Speed Sensor (Front Wheel)
138
RC-HU and Wheel Speed Sensor (Rear Wheel)
138
ABS System Layout
140
ABS Hydraulic Control Unit
140
Disassemble
140
ABS Troubleshooting
142
Troubleshooting Process with Portable ABS Diagnostic Scanner
143
Battery/Charging System
144
Know before Service
144
Troubleshooting
145
Charging System Layout Diagram
146
Electrical Schematic Diagram
146
Battery Disassembly
147
Disassembly
147
Check
147
Charging
147
Charging System Check
147
Leakage Test
147
Check the Charging Voltage
147
Inspection of Magneto Stator Charging Coil
147
Remove the Rectifier
148
Front Fork Assembly
149
Know before Service
149
Exploded View of Front Fork Components
150
Directional Exploded View
150
Front Fork Exploded View
151
Exploded View of Lower Link Board
152
Change the Direction of the Handle
153
Remove the Direction of the Handle
153
Remove the Components
153
Installation of the Direction Component
154
Installation of the Direction Handle Cover
154
Replace the Front Wheel
155
Remove the Front Wheel Assembly
155
Install the Front Wheel Assembly
155
Front Wheel Assembly Exploded View
156
Inspection and Maintenance of Front Wheel Assembly
156
Disc Brake
156
The Service Life of the Disc Brake Disc
156
Disc Brake Replacement Method
156
Front Wheel Oil Seals and Bearings
157
Service Life of Front Wheel Oil Seals and Bearings
157
Replacement Method of Front Wheel Oil Seal and Bearing
157
Front Wheel Rims and Tires
157
The Service Life of the Front Wheel Rim and Tire
157
How to Replace the Front Wheel Rim and Tire
157
Dynamic Balance
157
Replacement of the Front Shock Absorber
158
Disassemble the Front Wheel and Front Fender Assembly
158
Remove the Left and Right Front Shock Absorbers
158
Reinstall the Shock Absorber, Front Fender, Front Wheel and Other Components
158
Replace the Lower Link Board
159
Disassemble Parts Ahead of Time
159
Remove the Faucet Lock
159
Removing the Direction Pad
160
Remove the Lower Link Board Assembly
160
Install the Lower Link Board Assembly
160
Install Other Disassembly Components
161
Disassemble the Engine of the Vehicle
162
Disassemble the Storage Box
162
Remove the Cover
163
Put the Coolant and Pull out the Connection Plug
164
Disassemble the Engine
165
Install the Engine
166
The Installation of the Corresponding Cover
167
Install the Surrounding Floor
167
Install Pedal and Pedal Decorative Cover
167
Install the Rear Skirt
168
Installing the Side Cover
169
Armrest after Installation
169
Install the Device Box
169
Disassembly and Assembly of Vehicle Covering Parts
171
Disassembly and Assembly of Vehicle Panel
173
Windshield Removal
173
Removal of the Front Sun Visor
173
Removal of the Front Cover
173
Removal of the Front Panel
174
Disassembly of Headlights
174
Removal of Front Turn Signal
175
Disassembly of the of the Speedometer Panel
175
Removal of the Front Left and Right Panels
176
Removal of the Front Part of Vent
176
Removal of the Left and Right Decorative Covers of the Front Storage Box
176
Disassembly of the Left &Right Side Cover
177
Disassembly of the Foot Pedals and Trim Cover
178
Removal of the Surrounding Middle Part
178
Disassembly of the Surrounding Bottom
179
Disassembly of the Cushion
179
Disassembly of the Storage Box
179
Disassembly of the Rear Hand Rest
180
Disassembly of the Left and Right Tail Cover
180
Disassembly of Tail Light
180
Disassembly of Rear Fender
181
Disassembly of the Left, Right Fuel Tank Cover
182
Disassembly the Middle Cover of the Fuel Tank
182
Disassembly the Left and Right Storage Boxes
183
Disassembly the Front Storage Box Panel
184

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Zontes ZT310T-M Maintenance Manual (184 pages)

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