TAYO Zontes National IV ZT703-F 2024

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ZT703-F

Service Manual

2024-11-25

Main Page

User Notice3
Table of Contents4
Contents4
Vehicle Information11
Pre-Service Notice11
Motorcycle Body Identification Characters12
Technical Specifications13
Front Wheel /Steering System13
Rear Wheel / Suspension System13
Braking System13
Battery/Charging System13
Lighting/Instrument/Switch Description14
Tightening Torque - Supplementary14
Bolt Tightening Torque for General Fastening Parts14
Cable/Cable/Pipeline /Electrical Components Distribution Diagram15
Lighting Distribution Map15
Throttle and Clutch Cable15
Brake Master Cylinder and Brake Oil Pipe16
Calipers, Brake Hoses and Wheel Speed Sensors17
Braking System Parts Distribution Diagram18
Oil Supply System19
Fuel Evaporation19
Fuel Supply20
Distribution of Cooling System Components21
Electrical Device Layout Diagram23
Intake and Exhaust Systems25
Intake System25
Exhaust System26
Tools27
Expansion Nail Description28
Maintenance29
Pre-Service Notice29
Maintenance of Periodic Tables30
List of Daily Vehicle Operation Inspection Items32
Air Filter Element Replacement33
Remove the Corresponding Parts33
Replace the Filter Element of the Air Filter33
Check the Waste Oil Pipe33
Reassemble the Corresponding Parts33
Muffler Overhaul and Maintenance34
Disassembly of the Engine Guard34
Check the Muffler34
Check the Muffler Installation Bolts34
Disassembly of the Muffler35
Reassembly of Muffler and Engine Guard36
Inspection and Replacement of Spark Plugs36
Disassemble the Spark Plug36
Check the Spark Plug37
Install the Spark Plugs37
Overhaul and Maintenance of Cooling Systems37
Check the Coolant38
Addition of Coolant (Antifreeze) to the Auxiliary Tank38
Addition of Coolant (Antifreeze) to the Main Water Tank38
Drain the Coolant39
Check if the Fins of the Radiator Tank Are Deformed or if the Air Ducts Are Blocked39
Overhaul and Maintenance of Oil Coolers39
Check the Water/Oil Pipes for Leakage and Aging40
Engine Oil and Filter Replacement41
Put the Oil41
Replace the Fine Filter41
Add Oil41
Confirm the Oil Level42
Brake, Clutch, Cable Clearance Adjustment43
Adjust the Clutch Handle and Clutch Line43
Check43
Adjust the Clutch Cable Clearance43
Fine Tuning43
Lubricate the Clutch Cable43
Adjust the Clutch Handle43
Replace the Clutch Handle43
Adjust the Brake Lever, Brake Pedal, Throttle Cable44
Check44
Adjust the Throttle Cable Clearance44
Cables for Lubricating the Throttle44
Adjust the Brake Lever and Brake Pedal45
Replace the Brake Lever and Brake Pedal45
Idle Speed45
Check the Idle Speed45
Fuel Evaporative Pollutant Control System45
Fuel Evaporates45
Fuel Lines45
With the Help of an Endoscope with LED Light, the Fuel Line Is Inspected for Leaks45
Replace the High-Pressure Oil Line46
Fuel Pump47
Fuel Pressure Is Measured Using an Oil Pressure Gauge47
Simple Tested Fuel Pumps47
Abnormal Fuel Pressure Disposal47
Chain, Rear Flat Fork Wear Block48
Maintenance and Inspection48
Check48
Maintenance48
Replace the Chain48
Adjust the Chain48
Replace the Rear Flat Fork Wear Block48
Braking System50
Diagram of Braking System Components50
Check the Brake Components51
Check the Front and Rear Brake Switches52
Check the Brake Switch52
Replace the Brake Switch52
Lubricate the Brake Handle and Brake Pedal Moving Parts52
Lubricate the Front Brake Handle52
Lubricate the Rear Brake Pedal52
Replace the Brake Lever and Brake Pedal52
Adjust the Brake Lever and Brake Pedal53
Replace the Brake Pads53
Replace the Front Brake Pads53
Replace the Rear Brake Pads54
Brake Pads Rattle54
Replace the Brake Disc55
Replace the Front Brake Disc55
Brake Hoses55
Brake Fluid55
Brake Fluid Is Added to the Front and Rear Disc Brake Main Cylinders55
Add Front Brake Master Cylinder Brake Fluid55
Add Rear Brake Master Cylinder Brake Fluid56
Change the Brake Fluid56
Replace the Front Brake Fluid56
Replace the Rear Brake Fluid56
Brake System Exhaust57
Rims and Tires57
Check the Tires57
Replace the Tires58
Steering Mechanism58
Check the Steering Mechanism58
Adjust the Steering Mechanism58
Maintain Steering Bearings59
Fault59
Front Shock Absorber59
Check the Appearance59
Check the Shock Absorption Performance60
Adjust the Preload60
Shock Absorber before Disassembly60
Rectify the Front Fork Tube60
Troubleshooting60
Rear Shock Absorber61
Check61
Adjust the Preload61
Replace the Rear Shock Absorber61
Bolt/Nut/Fasteners62
Side Brackets62
Check62
Lubrication63
Main Bracket64
Check64
Disassemble the Main Bracket65
Lubrication66
Replace the Main Bracket Return Spring Post67
Shift Lever Rocker Arm Height Adjustment67
Inspection of Sound, Light and Electric Devices68
Check68
Headlamp Light Height Adjustment71
Fuse Box72
Troubleshooting72
Horn72
Light74
Windshield Failure74
Left Hand Switch77
EFI System79
Pre-Service Notice79
Fault Codes80
Read the Fault Code through the Instrument80
Read the Fault Code through the Diagnostic Instrument80
Common Fault Code Information80
Clearing Fault Codes81
Manual Clear81
Clear Using Diagnostic Instrument81
EFI Parts82
EFI Parts Layout Drawing83
Fault Diagnosis and Troubleshooting of EFI Parts84
Tilt Switch84
Troubleshooting Process84
Check85
OBD Interface85
Fuel Pump85
Canister Solenoid Valve87
Relay (KH-1A4T-R)87
Injector88
Oxygen Sensor90
Detect90
Replace91
Starting Relay91
Water and Oil Share Sensors91
Ecu92
Throttle Body93
Common Fault Signs93
Disassembly93
Troubleshoot the Process93
Sensor93
Throttle Position Sensor93
Inlet Air Pressure Sensor94
Stepper Motors94
Ignition Coil95
Relays（G8Hn-1C4T-RJ96
Secondary Make-Up Valve97
Crankshaft Position Sensor97
Troubleshooting Process When the Engine Does Not Start and There Are no Signs of Landing98
Troubleshooting Process When the Engine Does Not Start and There Are Signs of Landing98
Poor Acceleration99
The Idle Speed of the Hot Car Is High99
The Cooling Car Is Unstable at Idle99
The Idle Speed Is Unstable and Easy to Stall100
EFI Fault Indicator Is Always on Analysis Flow Chart101
Ignition System102
Pre-Service Notice102
Troubleshooting103
There Are no Sparks from the Spark Plugs103
Ignition System Layout104
Ignition System Check105
Ignition Coil105
Crankshaft Position Sensor105
Disassembly105
Installation105
Detect105
Starting System106
Pre-Service Notice106
Troubleshooting106
Starter Relay106
Starter Motor107
The Starter Motor Runs Slowly107
The Starter Motor Is Working Normally, but the Engine Cannot Start107
Starting System Layout107
Electrical Schematic Diagram of the Starting System108
Starter Motor108
Remove the Starter Motor108
Disassemble the Starter Motor108
Examination109
Starter Motor Front Cover109
Starter Motor Back Cover109
Electric Pestle110
Check the Starter Relay110
Operation Inspection110
Check the Relay Coil110
Input Line110
Ground Wire110
Check the Starter Relay111
Disassemble and Assemble the Starter Relay111
Fuel Supply System112
Pre-Service Notice112
Fuel Tank Disassembly113
Disassemble the Fuel Tank Assembly113
Disassemble the Fuel Pump113
Disassemble the Oil Level Sensor114
Disassemble the External Materials and Parts of the Fuel Tank Assembly114
Examination114
Fuel Pressure Test114
Fuel Pump Inspection114
Oil Level Sensor114
Cooling System and Air Intake System115
Pre-Service Notice115
Troubleshooting115
The Engine Temperature Is too High115
The Engine Temperature Is too Low115
Coolant Leakage115
Cooling System Distribution Map116
Schematic Diagram of Coolant Flow118
Disassembly of the Cooling System119
Disassemble the Oil Cooler and Tubing Assembly119
Disassemble the Main Water Tank Assembly119
Disassemble the Water Pipe and Auxiliary Water Tank Components120
Cooling System Accessories121
The Main Water Tank121
Water Tank Filler122
Overall Tightness Inspection122
Pressure Relief Valve Inspection122
An Auxiliary Water Tank122
Oil Cooler122
Air Tightness Inspection122
Ventilation Test122
Thermostat122
Inspection of Thermostat122
Fault Phenomenon122
Air Intake System123
Disassembly of the Air Filter123
Disassembly of the Carbon Canister123
Disassembly of the Air Inlet Cavity Assembly on the Left Side of the Air Filter123
Disassembly of the Air Filter Housing123
Exploded View of Air Filter Accessories125
Air Filter System Accessories126
A Carbon Canister126
YH Secondary Air Supply Valve126
The Air Inlet Cavity Assembly on the Left Side of the Air Filter126
Connecting Pipes126
Air Filter Housing126
Braking System127
Pre-Service Notice127
Troubleshooting128
The Brake Handle Is Soft128
The Brake Handle Is Hard128
Disassemble the Disc Brake Master Cylinder and Caliper128
Disassemble the Front Disc Brake Main Pump128
Disassemble the Rear Disc Brake Main Pump128
Disassemble the Front Disc Brake Caliper129
Disassemble the Rear Disc Brake Caliper129
Brake Hose and Wheel Speed Sensor130
Wheel Speed Sensor and Inductive Ring Gear Clearance Check130
Remove the Brake Hose and Wheel Speed Sensor130
Release the Brake Fluid130
FMC-HU and FC-HU. Wheel Speed Sensor (Front Wheel)131
RC-HU and RMC-HU. Wheel Speed Sensor (Rear Wheel)132
ABS System Arrangement132
ABS Hydraulic Control Unit132
Disassembly132
Battery/Charging System134
Pre-Service Notice134
Troubleshooting135
Troubleshooting Process for Battery Damage or Attenuation135
Electrical Schematic136
Accumulator Disassembly and Assembly137
Disassembly137
Check137
Charge137
Charging System Check137
Creepage Test137
Check the Charging Voltage137
Magneto Stator Charging Coil Inspection138
Rectifier138
Dismantle the Rectifier138
Rectifier Detection138
Front Fork Assembly139
Pre-Service Notice139
Exploded View of the Front Fork Assembly140
Exploded View of the Handlebar140
Front Fork Exploded View141
Lower Connection Board Exploded View142
Replace the Handlebar143
Remove the Handlebar Guard143
Remove the Handlebar Assembly143
Install the Handlebar Assembly144
Replace Front Wheel144
Remove the Front Wheel Assembly144
Install the Front Wheel Assembly144
Exploded View of the Front Wheel Assembly145
Inspection and Maintenance of Front Wheel Components146
Disc Brake Discs146
The Service Life of the Disc Brake Disc146
How to Replace the Disc Brake Disc146
Front Wheel Oil Seals and Bearings146
The Service Life of the Front Wheel Oil Seals and Bearings146
How to Replace the Oil Seals and Bearings of the Front Wheels146
Front Rims and Tires146
The Service Life of the Front Rim and Tires146
How to Replace the Front Rim and Tires146
Replace the Front Shock Absorber147
Remove the Front Fender Assembly and Lower Fender Assembly147
Remove the Left and Right Front Shock Absorbers147
Replace Components such as Shock Absorbers, Front Fenders, and Front Wheels148
Adjust the Front Shock Absorber148
Disassemble Parts in Advance148
Remove the Faucet Lock148
Remove the Upper Plate and the Direction Handlebar Pad148
Disassemble the Lower Panel Assembly149
Install the Lower Board Component149
Install Other Disassembly Components149
Rear Fork Component150
Pre-Service Notice150
Replace the Rear Wheels151
Disassemble the Rear Wheel Assembly151
Remove the Brake Disc151
Remove the Sprocket Seat151
Install the Rear Wheel Assembly151
Exploded View of the Rear Wheel Assembly152
Rear Wheel Assembly Inspection and Maintenance152
Disc Brake Discs152
The Service Life of the Disc Brake Disc152
How to Replace the Disc Brake Disc152
Rear Wheel Oil Seals and Bearings153
Service Life of Rear Wheel Seals and Bearings153
How to Replace the Oil Seals and Bearings of the Rear Wheel153
Rear Rims and Tires153
The Service Life of the Rear Rim and Tires153
How to Replace the Rear Rim and Tires153
Balancing153
Replace the Rear Flat Fork153
Disassemble the Chain Box and Chain Guard153
Remove the Rear Flat Fork154
Replace the Rear Flat Fork154
Shock Absorption after Replacement154
Dismantle the Shock Absorber154
Put Back the Shock Absorber155
Rear Shock Adjustment and Inspection155
Disassembly and Assembly of Vehicle Covers156
Removal of the Windshield157
Disassembly of the Hood Panel157
Removal of the Windshield Lining157
Disassembly of the Windshield Lift Assembly158
Disassembly of Instrument Trim Cover Assembly158
Disassembly of Instrument Components159
Disassembly of the Head Lining Assembly159
Disassembly of the Wiring Board on the Right Side160
Disassembly of the Surrounding Lower Assembly160
Removal of the Left Cover of the Frame161
Disassembly of the Right Cover of the Frame161
Disassembly of the Guard Bar Assembly162
Disassembly of the Upper Part of the Enclosure162
Disassembly of the Head Bracket Assembly163
Removal of the Seat Cushion163
Removal of the Rear Armrest163
Removal of the Rear Position Lights164
Dismantling of the Left and Right Tail Skirts164
Removal of the Rear Fender165

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TAYO Zontes National IV ZT703-F 2024 Specifications

General

Brand	TAYO
Model	Zontes National IV ZT703-F 2024
Category	Motorcycle
Language	English

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