Name: Zontes ZT310T-M
Brand: Zontes
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ZT310T-M

Maintenance Manual

2022-01-22

Table of Contents4
Content4
Vehicle Information13
Know before Service13
Body Label14
Technical Specification15
Front Wheel/Steering System16
Rear Wheel/Suspension System16
Brake System16
Battery/Charging System17
Lamp/Speedometer/Switch Description17
Tightening Torque18
Bolt Tightening Torque of General Tightening Part18
Cable/Cable/Pipe/Electrical Device Distribution Map19
Distribution Map of Lamps and Lanterns19
Throttle Cable19
Brake Upper Pump and Brake Hose20
Calipers, Brake Hoses and Wheel Speed Sensors20
Distribution Map of Brake System Accessories21
Oil Supply System22
Fuel Evaporation22
Fuel Supply23
Distribution Map of Cooling System Accessories23
Electrical Device Layout24
Intake and Exhaust System26
Tool27
Expansion Nail Description29
Maintenance30
Know before Service30
Maintenance Schedule31
Air Filter (Filter Element), Air Inlet Filter Element32
Support the Vehicle Firmly32
Remove the Left Engine Cover32
Remove the Air Inlet Cover32
Replace the Air Inlet Filter33
Remove the Air Filter Housing33
Replace Air Filter Element33
Inspection Air Filter Waste Oil Pipe34
Reinstall34
Bolts and Nuts of Muffler35
Spark Plug36
Disassemble the Spark Plug36
Check the Spark Plug37
Refer to the Steps to Remove the Spark Plug to Restore All Parts37
Engine Oil38
Drain the Oil38
Replace Fine Filter38
Add Oil39
Change Gear Box Oil39
Confirm the Oil Level39
Throttle Valve Body40
Do Not Dismantle the Throttle Body to Clean up Carbon Deposits40
Remove the Stepper Motor and Clean up Carbon Deposits40
Remove the Throttle Valve Body Assembly to Clean up Carbon Deposits42
Disassemble the Three-In-One Sensor43
Throttle Valve Body Troubleshooting Process43
Throttle Cable44
Inspection44
Adjust the Throttle Cable Clearance44
Lube Door Cable44
Idle Speed45
Check Idle Speed45
Fuel Evaporative Pollutant Control System46
Radiator47
Check the Coolant47
Add Coolant (Antifreeze) to the Coolant Expansion Tank47
Add Coolant to the Radiator48
Put Coolant48
Check Whether the Fins of the Radiator Water Tank Are Deformed or the Air Duct Is Blocked48
Check All Water Pipes for Leaks; Aging49
Fuel Pipe51
Check the Fuel Pipe for Leaks with the Help of an Endoscope with LED Light51
Replace High Pressure Oil Pipe51
Fuel Pump52
Use Oil Pressure Gauge to Measure Fuel Pressure52
Simple Test of Fuel Pump52
Treatment of Abnormal Fuel Pressure53
Belt54
System Components54
Maintenance55
Remove the Belt55
Disassemble the Continuously Variable Transmission Components55
Inspection57
Assembly58
Common Fault Phenomena/Troubleshooting60
The Engine Can be Started, but the Rear Wheel Does Not Rotate60
Engine Stall or Lack of Power60
Insufficient High-Speed Power60
When the Engine Is at Normal Idling Speed, the Rear Wheel Rotates Rapidly60
Braking System61
Check the Brake Components62
Check the Front and Rear Brake Switches63
Check the Brake Switch63
Replace the Brake Switch63
Lubricate the Movable Parts of the Brake Handle63
Lubricate the Front Brake Handle63
After Lubricating the Brake Handle64
Replacing the Brake Handle64
Adjust the Brake Handle64
Replace the Brake Pads64
Update the Front Brake Pads64
Replace the Brake Pads after Replacement65
Abnormal Sound of Brake Pads65
Replace the Brake Disc66
Replacing the Front Brake Disc66
Replacing the Rear Brake Disc66
Brake Hose67
Brake Fluid67
Add Brake Fluid to the Main Pumps of the Front and Rear Disc Brakes67
Replace the Brake Fluid68
Replace the Front Brake Brake Fluid68
Replace the Rear Brake Fluid69
Brake System Exhaust69
Tire69
Check the Tires70
Steering Mechanism70
Check the Steering Mechanism71
Maintain Steering Bearings71
Malfunction72
Front Fork72
Check the Appearance72
Check the Shock Absorption Performance73
Remove the Front Shock Absorption73
Correct the Front Fork Tube73
Troubleshooting73
Rear Shock Absorption73
Check74
Adjust the Preload74
Adjust the Right Rear Shock Absorption74
Adjust the Left Rear Shock Absorption74
Replace the Shock Absorption75
Bolts and Nuts for Body and Engine Installation76
Check the Heavy Parts Fasteners76
Check Engine Fasteners76
Valve Clearance Adjustment77
Maintenance Information77
General Information77
Assemble Torque Value77
Tools, Measuring Tools, Accessories77
Operation Steps77
Side Bracket81
Check81
Lubrication81
Main Bracket82
Check82
Lubrication82
Install the Main Bracket82
Replace the Return Spring Post of the Main Support82
Sound, Light, and Electrical Device Inspection83
Check83
Headlight Height Adjustment84
Fuse Box85
Troubleshooting86
Right Hand Switch86
Right Hand Handle Vice Switch86
Left Hand Handle Auxiliary Switch87
Horn87
Left Hand Switch89
Light90
Windshield Failure90
EFI System91
Know before Service91
Error Code93
Read the Fault Code through the Meter93
Read the Fault Code through the Diagnostic Tool93
Clear Fault Code94
Manually Clear94
Use the Diagnostic Tool to Clear94
EFI Parts Layout95
Fault Diagnosis and Elimination of EFI Parts96
Dump Switch96
OBD Port96
Fuel Pump96
Carbon Canister Solenoid Valve97
EFI Relay97
Fuel Injector98
Ignition Coils98
Throttle Valve Body100
Common Failure Phenomena100
Disassembly100
Troubleshooting Process100
Three-In-One Sensor100
Water and Oil Shared Sensor100
Oxygen Sensor101
Check101
Replace101
Ecu101
Crankshaft Position Sensor101
The Engine Cannot Start and There Is no Sign of Fault Diagnosis Process102
The Engine Cannot be Started and There Is a Car Symptom Fault Diagnosis Process103
Poor Acceleration103
High Idling Speed of Hot Car104
Unsteady Idle Speed of Cooling Car104
Unsteady Idling, Easy to Cutoff105
Analysis Flow Chart of EFI Failure Indicator Light Always on106
Electrical Schematic Diagram of EFI System107
Ignition System108
Know before Service108
Troubleshooting109
Ignition System Layout110
Electrical Schematic Diagram of Ignition System110
Ignition System Inspection111
Ignition Timing111
Check111
Installation112
Ignition Coils112
Starting System113
Know before Service113
Troubleshooting113
Starting Relay113
Starter Motor114
The Starter Motor Runs Slowly114
The Starter Motor Is Working Normally, but the Engine Cannot be Started114
Ignition System Layout114
Starting System Electrical Schematic Diagram115
Starter Motor115
Remove the Starter Motor115
Disassemble the Starter Motor116
Examination117
Starter Motor Front Cover117
Motor Back Cover117
Denki117
Check the Starting Relay118
Operation Check118
Check the Relay Coil118
Input Line118
Ground Wire118
Disassembly and Assembly of the Starting Relay118
Fuel Supply System119
Know before Service119
Fuel Tank Removal119
Disassemble the Fuel Tank Assembly119
Disassemble the Fuel Pump121
Remove the External Parts of the Fuel Tank Assembly121
Examination121
Fuel Pressure Test121
Fuel Pump Inspection121
Oil Level Sensor122
Cooling System123
Know before Service123
Troubleshooting123
The Engine Temperature Is too High123
The Engine Temperature Is too Low123
Coolant Leakage123
Coolant System Distribution Map124
Coolant Flow Diagram125
Cooling System Disassembly126
Remove the Radiator Assembly126
Coolant System Hoop/Clamp Distribution Map128
Thermostat Assembly and Small Loop128
Cooling System Accessories129
Main Water Tank129
Attention to the Water Tank Filling Port130
Overall Leak Check130
Check of Pressure Relief Valve130
Auxiliary Water Tank130
Aluminum Inlet Pipe and Aluminum Outlet Pipe130
Small Water Tank130
Water and Oil Shared Sensor131
Thermostat131
Inspection131
Failure Phenomenon131
Disassembly132
Thermostat Core Inspection132
Water Pipe132
Check the Water Pump Cover Assembly132
Braking System133
Know before Service133
Trouble Shooting134
Soft Feeling from Brake Lever134
Hard Feeling from Brake Lever134
Disassemble the Disc Brake Main Pump and Calipers134
Disassemble the Front Disc Brake Main Pump134
Disassemble the Rear Disc Brake Main Pump135
Disassemble the Front Disc Brake Caliper135
Disassemble the Rear Disc Brake Caliper136
Brake Hose and Wheel Speed Sensor137
Check the Gap between the Wheel Speed Sensor and the Induction Ring Gear137
Remove the Brake Hose and Wheel Speed Sensor137
Release Brake Fluid137
FMC-HU and RMC-HU138
FC-HU and Wheel Speed Sensor (Front Wheel)138
RC-HU and Wheel Speed Sensor (Rear Wheel)138
ABS System Layout140
ABS Hydraulic Control Unit140
Disassemble140
ABS Troubleshooting142
Troubleshooting Process with Portable ABS Diagnostic Scanner143
Battery/Charging System144
Know before Service144
Troubleshooting145
Charging System Layout Diagram146
Electrical Schematic Diagram146
Battery Disassembly147
Disassembly147
Check147
Charging147
Charging System Check147
Leakage Test147
Check the Charging Voltage147
Inspection of Magneto Stator Charging Coil147
Remove the Rectifier148
Front Fork Assembly149
Know before Service149
Exploded View of Front Fork Components150
Directional Exploded View150
Front Fork Exploded View151
Exploded View of Lower Link Board152
Change the Direction of the Handle153
Remove the Direction of the Handle153
Remove the Components153
Installation of the Direction Component154
Installation of the Direction Handle Cover154
Replace the Front Wheel155
Remove the Front Wheel Assembly155
Install the Front Wheel Assembly155
Front Wheel Assembly Exploded View156
Inspection and Maintenance of Front Wheel Assembly156
Disc Brake156
The Service Life of the Disc Brake Disc156
Disc Brake Replacement Method156
Front Wheel Oil Seals and Bearings157
Service Life of Front Wheel Oil Seals and Bearings157
Replacement Method of Front Wheel Oil Seal and Bearing157
Front Wheel Rims and Tires157
The Service Life of the Front Wheel Rim and Tire157
How to Replace the Front Wheel Rim and Tire157
Dynamic Balance157
Replacement of the Front Shock Absorber158
Disassemble the Front Wheel and Front Fender Assembly158
Remove the Left and Right Front Shock Absorbers158
Reinstall the Shock Absorber, Front Fender, Front Wheel and Other Components158
Replace the Lower Link Board159
Disassemble Parts Ahead of Time159
Remove the Faucet Lock159
Removing the Direction Pad160
Remove the Lower Link Board Assembly160
Install the Lower Link Board Assembly160
Install Other Disassembly Components161
Disassemble the Engine of the Vehicle162
Disassemble the Storage Box162
Remove the Cover163
Put the Coolant and Pull out the Connection Plug164
Disassemble the Engine165
Install the Engine166
The Installation of the Corresponding Cover167
Install the Surrounding Floor167
Install Pedal and Pedal Decorative Cover167
Install the Rear Skirt168
Installing the Side Cover169
Armrest after Installation169
Install the Device Box169
Disassembly and Assembly of Vehicle Covering Parts171
Disassembly and Assembly of Vehicle Panel173
Windshield Removal173
Removal of the Front Sun Visor173
Removal of the Front Cover173
Removal of the Front Panel174
Disassembly of Headlights174
Removal of Front Turn Signal175
Disassembly of the of the Speedometer Panel175
Removal of the Front Left and Right Panels176
Removal of the Front Part of Vent176
Removal of the Left and Right Decorative Covers of the Front Storage Box176
Disassembly of the Left &Right Side Cover177
Disassembly of the Foot Pedals and Trim Cover178
Removal of the Surrounding Middle Part178
Disassembly of the Surrounding Bottom179
Disassembly of the Cushion179
Disassembly of the Storage Box179
Disassembly of the Rear Hand Rest180
Disassembly of the Left and Right Tail Cover180
Disassembly of Tail Light180
Disassembly of Rear Fender181
Disassembly of the Left, Right Fuel Tank Cover182
Disassembly the Middle Cover of the Fuel Tank182
Disassembly the Left and Right Storage Boxes183
Disassembly the Front Storage Box Panel184

Brand	Zontes
Model	ZT310T-M
Category	Motorcycle
Language	English

Zontes ZT310T-M User Manual

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