Name: Zontes ZT350T-M 2022
Brand: Zontes
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ZT125/310/350T-M

Maintenance Manual

2022-11-25

Table of Contents4
Content4
Vehicle Information13
Know before Service13
Body Label14
M310 Technical Specification15
Front Wheel/Steering System15
Rear Wheel/Suspension System15
Brake System15
Battery/Charging System16
M125 Technical Specification16
Front Wheel/Steering System16
Rear Wheel/Suspension System17
Brake System17
Battery/Charging System17
M350 Technical Specification18
Front Wheel/Steering System18
Rear Wheel/Suspension System18
Brake System18
Battery/Charging System19
Lamp/Speedometer/Switch Description19
Tightening Torque20
Bolt Tightening Torque of General Tightening Part20
Cable/ Pipe/Electrical Device Distribution Map21
Distribution Map of Lamps and Lanterns21
Throttle Cable21
Brake Upper Pump and Brake Hose22
Calipers, Brake Hoses and Wheel Speed Sensors22
Distribution Map of Brake System Accessories23
M31023
M12524
M35025
Oil Supply System26
M310 Fuel Evaporation26
M125 Fuel Evaporation27
M350 Fuel Evaporation27
M310 Fuel Supply28
M125 Fuel Supply28
M350 Fuel Supply29
Distribution Map of Cooling System Accessories29
M31029
M12531
M35031
Electrical Device Layout31
M31034
Intake and Exhaust System37
M31037
M12538
M35039
Tool40
Swell Nail Description41
Maintenance42
Know before Service42
M310 Maintenance Schedule43
M125 Maintenance Schedule44
M350 Maintenance Schedule45
M310 Air Filter (Filter Element), Air Inlet Filter Element46
Support the Vehicle Firmly46
Remove the Left Engine Cover46
Remove the Air Inlet Cover47
Replace the Air Inlet Filter47
Remove the Air Filter Housing47
Replace Air Filter Element47
Inspection Air Filter Waste Oil Pipe48
Reinstall48
M125 Air Filter (Filter Element), Air Inlet Filter Element49
Support the Vehicle Firmly49
Remove the Left Engine Cover49
Replace the Air Inlet Filter49
Remove the Air Filter Housing50
Replace Air Filter Element50
Inspection Air Filter Waste Oil Pipe50
Reinstall50
M350 Air Filter (Filter Element), Air Inlet Filter Element51
Support the Vehicle Firmly51
Remove the Left Engine Cover51
Replace the Air Inlet Filter Element52
Remove the Air Filter Shell52
Replace the Filter Element of the Air Filter52
Check the Waste Oil Pipe of Air Filter52
Reassembly53
Bolts and Nuts of Muffler53
Check for Air Leaks at the Engine Exhaust53
Check for Nut and Bolts at the Muffler54
M310/350 Spark Plug54
Disassemble the Spark Plug54
Check the Spark Plug56
Refer to the Steps to Remove the Spark Plug to Restore All Parts56
M125 Spark Plug56
Disassemble the Spark Plug56
Check the Spark Plug58
Refer to the Steps to Remove the Spark Plug to Restore All Parts58
Engine Oil58
M31058
Drain the Oil58
Replace Fine Filter59
Add Oil59
Change Gear Box Oil59
Confirm the Oil Level60
M12560
Drain the Oil60
Replace Fine Filter60
Add Oil61
Change Gear Box Oil61
Confirm the Oil Level61
M35062
Drain the Oil62
Replace the New Combination Gasket (4) and Install the Oil Drain Bolt (3) and Combination Gasket (4) Back on the Engine Box with the 14# Sleeve. Torque: 25 N.M(2.6 Kgf.M,18 Lbf.ft)62
Wipe the Oil Gauge Clean, and Install the Oil Gauge (1) and O Ring (2) Back to the Right Crankcase Cover of the Engine by Clockwise Rotation by Hand63
Replace the Gearbox Oil63
Then Rotate It Clockwise Back to the Gear Box Refueling Mouth by Hand63
M310/350 Throttle Valve Body64
Do Not Dismantle the Throttle Body to Clean up Carbon Deposits64
Remove the Stepper Motor and Clean up Carbon Deposits64
Remove the Throttle Valve Body Assembly to Clean up Carbon Deposits66
M310 Disassemble the Three-In-One Sensor67
Remove Sensor from M350 Throttle Body67
Throttle Valve Body Troubleshooting Process68
M125 Throttle Valve Body69
Do Not Dismantle the Throttle Body to Clean up Carbon Deposits69
Remove the Stepper Motor and Clean up Carbon Deposits69
Remove the Throttle Valve Body Assembly to Clean up Carbon Deposits70
Disassemble the Sensor70
Throttle Valve Body Troubleshooting Process71
Throttle Cable71
Inspection71
Adjust the Throttle Cable Clearance71
Lube Door Cable72
Idle Speed72
Check Idle Speed73
Fuel Evaporative Pollutant Control System73
M310 Fuel Evaporation73
M125 Fuel Evaporation74
M350 Fuel Evaporation75
Radiator76
Check the Coolant76
M125/31076
M35076
Add Coolant (Antifreeze) to the Coolant Expansion Tank76
M35077
Add Coolant to the Radiator77
M125/31077
M35078
Put Coolant78
M31078
M12578
Check Whether the Fins of the Radiator Water Tank Are Deformed or the Air Duct Is Blocked78
M35079
Check All Water Pipes for Leaks; Aging80
M31080
M12580
M35082
Fuel Pipe82
Check the Fuel Pipe for Leaks with the Help of an Endoscope with LED Light82
Replace High Pressure Oil Pipe82
Fuel Pump83
Use Oil Pressure Gauge to Measure Fuel Pressure83
Simple Test of Fuel Pump83
Treatment of Abnormal Fuel Pressure84
M310 V Belt85
System Components85
Maintenance85
Remove the Belt85
Disassemble the Continuously Variable Transmission Components86
Inspection87
Assembly88
Common Fault Phenomena/Troubleshooting90
The Engine Can be Started, but the Rear Wheel Does Not Rotate90
Engine Stall or Lack of Power90
Insufficient High-Speed Power90
When the Engine Is at Normal Idling Speed, the Rear Wheel Rotates Rapidly90
Braking System91
M310 Braking System Component Diagram91
M125 Braking System Component Diagram91
M350 Braking System Component Diagram92
Check the Brake Components92
Check the Front and Rear Brake Switches94
Check the Brake Switch94
Replace the Brake Switch94
Lubricate the Movable Parts of the Brake Handle94
Lubricate the Front Brake Handle94
Lubricating the Rear Brake Handle94
Replacing the Brake Handle94
Adjust the Brake Handle94
Replace the Brake Pads94
Replace the Front Brake Pads95
M125/31095
M35095
Replace the Rear Brake Pads96
Abnormal Sound of Brake Pads97
Replace the Brake Disc97
Replacing the Front Brake Disc97
Replacing the Rear Brake Disc97
Brake Hose98
Brake Fluid99
Add Brake Fluid to the Main Pumps of the Front and Rear Disc Brakes99
Replace the Brake Fluid99
Replace the Front Brake Brake Fluid99
Replace the Rear Brake Fluid100
Brake System Exhaust100
Tire100
Check the Tires101
Replace Tires101
Steering Mechanism101
Check the Steering Mechanism101
Adjust the Steering Mechanism102
M125/310102
M350102
Maintain Steering Bearings102
Malfunction102
Front Fork103
Check the Appearance103
Check the Shock Absorption Performance103
Remove the Front Shock Absorption104
Correct the Front Fork Tube104
Troubleshooting104
Rear Shock Absorption104
Check104
Adjust the Preload104
Adjust the Right Rear Shock Absorption105
M125/310105
M350105
Adjust the Left Rear Shock Absorption105
M310105
M125105
Replace the Shock Absorption105
Bolts and Nuts for Body and Engine Installation106
Check the Fasteners for the Critical Parts106
Check Engine Fasteners106
Valve Clearance Adjustment (M310)108
Maintenance Information108
General Information108
Assemble Torque Value108
Tools, Measuring Tools, Accessories108
Operation Steps108
Side Bracket112
Check112
Lubrication112
Main Bracket113
Check113
Lubrication113
Install the Main Bracket113
Replace the Return Spring Post of the Main Support113
Sound, Light, and Electrical Device Inspection114
Check114
M125/310 Charging115
M350 Charging115
Headlight Height Adjustment115
Fuse Box116
Troubleshooting117
Right Hand Switch117
Right Hand Handle Vice Switch117
Left Hand Handle Auxiliary Switch118
Horn119
Left Hand Switch119
Light121
Windshield Failure121
EFI System122
Know before Service122
Error Code123
M310 Read the Fault Code through the Meter123
Read the Fault Code through the Diagnostic Tool123
M125/310123
M350123
Error Code124
Clear Fault Code124
M310 Manually Clear124
Use the Diagnostic Tool to Clear125
EFI Parts Layout125
Fault Diagnosis and Elimination of EFI Parts126
Dump Switch126
OBD Port126
Fuel Pump127
Carbon Canister Solenoid Valve127
EFI Relay127
Fuel Injector128
Ignition Coils128
M125/310129
M350129
Throttle Valve Body130
Common Failure Phenomena130
Disassembly130
Troubleshooting Process130
Sensor130
M310 Three-In-One Sensor130
M125 Sensor130
M1350 Sensor130
Water and Oil Shared Sensor130
Oxygen Sensor131
Check131
Replace131
M310131
M125131
M350132
Ecu132
M310/350132
M125133
Crankshaft Position Sensor133
The Engine Cannot Start and There Is no Sign of Fault Diagnosis Process134
The Engine Cannot be Started and There Is a Car Symptom Fault Diagnosis Process134
Poor Acceleration135
High Idling Speed of Hot Car135
Unsteady Idle Speed of Cooling Car135
Unsteady Idling, Easy to Cutoff136
Analysis Flow Chart of EFI Failure Indicator Light Always on137
Electrical Schematic Diagram of EFI System138
Ignition System139
Know before Service139
Troubleshooting140
Ignition System Layout141
Electrical Schematic Diagram of Ignition System141
Ignition System Inspection142
Ignition Timing142
Check142
Installation142
Ignition Coils143
Starting System144
Know before Service144
Troubleshooting144
Starting Relay144
Starter Motor145
The Starter Motor Runs Slowly145
The Starter Motor Is Working Normally, but the Engine Cannot be Started145
Ignition System Layout145
Starting System Electrical Schematic Diagram146
Starter Motor146
Remove the Starter Motor146
Disassemble the Starter Motor147
Examination148
Starter Motor Front Cover148
Motor Back Cover148
Denki148
Check the Starting Relay148
Operation Check148
Check the Relay Coil149
Input Line149
Ground Wire149
Check the Starting Relay149
Disassembly and Assembly of the Starting Relay149
Fuel Supply System150
Know before Service150
Fuel Tank Removal150
Disassemble the Fuel Tank Assembly150
Disassemble the Fuel Pump151
Remove the External Parts of the Fuel Tank Assembly152
Examination152
Fuel Pressure Test152
Fuel Pump Inspection152
Oil Level Sensor152
Cooling System153
Know before Service153
Troubleshooting153
The Engine Temperature Is too High153
The Engine Temperature Is too Low153
Coolant Leakage153
Coolant System Distribution Map154
M310154
M125154
M350155
Coolant Flow Diagram156
M310156
M125157
M350157
Cooling System Disassembly158
M310 Remove the Radiator Assembly158
M310 Coolant System Hoop/Clamp Distribution Map159
M310 Thermostat Assembly and Small Loop159
M125 Remove the Radiator Assembly160
M350 Remove the Radiator Assembly160
M350 Coolant System Hoop/Clamp Distribution Map161
M350 Thermostat Assembly and Small Loop161
Cooling System Accessories162
Main Water Tank162
M310162
M350162
Attention to the Water Tank Filling Port162
Overall Leak Check162
Check of Pressure Relief Valve163
M350163
Auxiliary Water Tank163
Aluminum Inlet Pipe and Aluminum Outlet Pipe(M310)163
Small Water Tank(M310)163
Water and Oil Shared Sensor163
Thermostat164
Inspection164
Failure Phenomenon164
Disassembly164
Thermostat Core Inspection164
Water Pipe164
Check the Water Pump Cover Assembly(M310)165
Braking System166
Know before Service166
Trouble Shooting167
Soft Feeling from Brake Lever167
Hard Feeling from Brake Lever167
Disassemble the Disc Brake Main Pump and Calipers167
Disassemble the Front Disc Brake Main Pump167
Disassemble the Rear Disc Brake Main Pump168
Disassemble the Front Disc Brake Caliper168
M125/310168
M350168
Disassemble the Rear Disc Brake Caliper169
Brake Hose and Wheel Speed Sensor169
Check the Gap between the Wheel Speed Sensor and the Induction Ring Gear169
Remove the Brake Hose and Wheel Speed Sensor170
Release Brake Fluid170
FMC-HU and RMC-HU170
FC-HU and Wheel Speed Sensor (Front Wheel)171
RC-HU and Wheel Speed Sensor (Rear Wheel)171
ABS System Layout172
ABS Hydraulic Control Unit172
Disassemble172
ABS Troubleshooting174
M310 Troubleshooting Process with Portable ABS Diagnostic Scanner175
Battery/Charging System176
Know before Service176
Troubleshooting177
Charging System Layout Diagram178
Electrical Schematic Diagram178
Battery Disassembly178
Disassembly178
Check179
Charging179
Charging System Check179
Leakage Test179
Check the Charging Voltage179
Inspection of Magneto Stator Charging Coil179
Remove the Rectifier180
Front Fork Assembly181
Know before Service181
Exploded View of Front Fork Components182
M125/310 Directional Exploded View182
M350 Directional Exploded View183
Front Fork Exploded View184
M125/310184
M350185
Exploded View of Lower Link Board186
M125/310186
M350187
Change the Direction of the Handle188
Remove the Direction of the Handle188
Remove the Components188
Installation of the Direction Component189
Installation of the Direction Handle Cover189
Replace the Front Wheel190
Remove the Front Wheel Assembly190
Install the Front Wheel Assembly190
Front Wheel Assembly Exploded View191
M310191
M125191
M350192
Inspection and Maintenance of Front Wheel Assembly192
Disc Brake192
The Service Life of the Disc Brake Disc192
Disc Brake Replacement Method192
Front Wheel Oil Seals and Bearings192
Service Life of Front Wheel Oil Seals and Bearings192
Replacement Method of Front Wheel Oil Seal and Bearing193
Front Wheel Rims and Tires193
The Service Life of the Front Wheel Rim and Tire193
How to Replace the Front Wheel Rim and Tire193
Dynamic Balance193
M125/310 Replacement of the Front Shock Absorber193
Disassemble the Front Wheel and Front Fender Assembly193
Remove the Left and Right Front Shock Absorbers194
Reinstall the Shock Absorber, Front Fender, Front Wheel and Other Components194
M350 Replacement of the Front Shock Absorber194
Disassemble the Front Wheel and Front Fender Assembly194
Remove the Left and Right Front Shock Absorbers195
Reinstall the Shock Absorber, Front Fender, Front Wheel and Other Components195
M125/310 Replace the Lower Link Board196
Disassemble Parts Ahead of Time196
Remove the Faucet Lock196
Removing the Direction Pad196
Remove the Lower Link Board Assembly197
Install the Lower Link Board Assembly197
Install Other Disassembly Components197
M350 Replace the Lower Link Board197
Disassemble the Engine of the Vehicle199
Disassemble the Storage Box199
Remove the Cover199
Put the Coolant and Pull out the Connection Plug200
Disassemble the Engine202
Install the Engine202
Disassembly and Assembly of Vehicle Covering Parts204
Disassembly and Assembly of Vehicle Panel205
Windshield Removal205
Removal of the Front Sun Visor205
Removal of the Front Cover206
Removal of the Front Panel206
Disassembly of Headlights206
Removal of Front Turn Signal207
Disassembly of the of the Speedometer Panel207
Removal of the Front Left and Right Panels207
Removal of the Front Part of Vent208
Removal of the Windshield Base208
Removal of the Left and Right Decorative Covers of the Front Storage Box209
Disassembly of the Left &Right Side Cover210
Disassembly of the Foot Pedals and Trim Cover210
Removal of the Surrounding Middle Part211
Disassembly of the Surrounding Bottom211
Removal of the Cooling Fan Air Guide Plate211
Disassembly of the Cushion211
Disassembly of the Storage Box212
Disassembly of the Rear Hand Rest212
Disassembly of the Left and Right Tail Cover212
Disassembly of Tail Light213
Disassembly of Rear Fender213
Disassembly of the Left, Right Fuel Tank Cover215
Disassembly the Middle Cover of the Fuel Tank215
Disassembly the Left and Right Storage Boxes216
Disassembly the Front Storage Box Panel217

Brand	Zontes
Model	ZT350T-M 2022
Category	Motorcycle
Language	English

Zontes ZT350T-M 2022 User Manual

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