Zontes ZT125-C Manual de usuario

2023/10/25

ZT125/155/200-C（EURO V

）

Page 1 ，Total 64 pages

Pages

Table of Contents…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

1FRAME&ELECTRONIC COMPONENT

1.1

Electrical device component-1………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

horn,ignition coil

1.2

Electrical device component-2………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

Front electrical device box, frame front decoration cover

1.3

Frame plastic parts…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

Line clamp, side cover round glue, fuel tank liner limit glue

1.4

Directional column component……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

Lower plate component

1.5

Frame, side bracket………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

Frame, side bracket,Flameout switch

2FRAME & ENGINE COMBINATION

2.1

Frame & engine combination 1……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

2.2

Frame & engine combination 2……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

3INTAKE SYSTEM COMPONENT

3.1

Air filter component………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

Disassemble air filter,ECU,Carbon canister

3.2

Throttle valve body component……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

3.3

Replace air filter element………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

4REAR WHELL COMPONENT

4.1

Rear mud board 1…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

4.2

Rear mud board 2…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

4.3

Rear shock absorption……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

4.4

Rear wheel component 1………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

Disassemble the rear rim component, sprocket seat, sprocket

4.5

Rear wheel component 2………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

Disassembled rear rim component

4.6

Rear fork component……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

Contents

Table of Contents

Page 2 ，Total 64 pages

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Contents

Table of Contents

Disassembled rear fork component

4.7

Replace the rear brake pads…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

4.8

Rear brake main pump adds brake fluid………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

5PEDAL COMPONENT

5.1 Adjust the hight of foot pedal 24

Shift lever, brake pedal height adjustment

5.2

Front right foot pedal assembly position adjustment……………………………………………………………………………………………………………………………………………………………………………………………………………………………

5.3

Front left foot pedal assembly position adjustment………………………………………………………………………………………………………………………………………………………………………………………………………………………………

5.4

Right footrest component………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

5.5

Left footrest component………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

5.6

Rear footrest component………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

6COOLING SYSTEM COMPONENT

6.1

Change the oil and the oil filter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

6.2

Add coolant……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

6.3

Change coolant………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

6.4

Water tank component(125/155CC)………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

6.5

Water tank component(200CC)……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

7FRONT FORK COMPONENT

7.1

Throttle/clutch cable clearance adjustment, light height adjustment……………………………………………………………………………………………………………………………………………………………………………………………………

7.2

Replacement clutch cable………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

7.3

Replace the throttle line………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

7.4

Steering adjustment………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

7.5

Right hand component…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

Disassemble right hand component

7.6

Add brake fluid, rocker adjustment………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

7.7

Replace the front brake pads…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

7.8

Front wheel component…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

Disassemble the front wheel, front disc brake disc, front axle component

7.9

Front mud board & wheel speed sensor component 1…………………………………………………………………………………………………………………………………………………………………………………………………………………………

Disassemble front wheel speed sensor component, front mud plate component

7.10

Left hand component……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

Page 3 ，Total 64 pages

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Contents

Table of Contents

Disassemble left hand component

7.11

Direction handle pressure block assembly……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

Direction handle assembly

7.12

Upper conncetion board Instrumentation assembly……………………………………………………………………………………………………………………………………………………………………………………………………………………………

Upper conncetion board Components

、

faucet lock

7.13

Upper conncetion board

、

direction handlebar pad assembly………………………………………………………………………………………………………………………………………………………………………………………………………………

Upper conncetion board

、

direction handlebar pad assembly

7.14

Head assembly 1……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

Headlight assembly, front shock absorber

7.15

Head assembly 2……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

Disassembling the headlight assembly

7.16

ABS brake system 1………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

Releasing brake fluid

、

tool box

7.17

ABS brake system 2………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

Disassemble the hydraulic control unit

、

FMC-HU

、

FC-HU

7.18

ABS brake system 3………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

RMC-HU

、

rear brake mame pump

7.19

ABS brake system 4………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

RC-HU

、

wheel speed sensor

、

rear disc brake caliper

8SURROUNDING COMPONENT

8.1

Decorative covers the upper part component………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

8.2

Decorative covers the lower part component………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

9FUEL TANK COMPONENT

9.1

Fuel tank component1…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

9.2

Fuel tank component2…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

10 SIDE COVER COMPONENT

10.1

Side cover componen……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

Decompose side cover component, charging port holder

11 Rear Electrical device box component

11.1

Battery component………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

Page 4 ，Total 64 pages

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Contents

Table of Contents

Disassemble battery ,battery cover,start relay

11.2

Rear Electrical device box component 1………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

Disassemble PKE,antenna

11.3

Rear Electrical device box component 2………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

Disassemble electrical device box,battery bracket

12 CUSHION COMPONENT

12.1

Cushion…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..……

13 MUFFLER COMPONENT

13.1

Muffler component 1……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

13.2

Muffler component 2……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

Page 5 ，Total 64 pages

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Contents

Table of Contents

Swell nail description

©Guangdong Tayo Motorcycle Technolog Co.

Ltd All rights reserve

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;

③Pinch the outer ring with two fingers, and push the center cylinder up to the initial position;

④Pinch the center cylinder with two fingers to install the swell nails to the installation position;

⑤The outer ring is attached to the connected parts; if not attached Check whether it is misaligned;

⑥Press the center cylinder with your fingers or other tools, and you can hear a sound or the top of the center cylinder is almost flush with the top surface of the outer ring, indicating that the

assembly is in place.

All the information, illustrations and photographs collected in this manual are compiled according to the latest products. However, there may be some inconsistencies between your

motorcycle and this manual due to the continuousimprovement of the product and other changesFor colors or upgrades, please refer to the part codes on the official website. This manual

will not be listed in detail; If the part names in this manual are inconsistent with the official website, the official website shall prevail. This manual is compiled on the basis of the chinese

version of KD150-C version. The export version is different from the chinese version with only a few parts, such as decals, ECU version, muffler catalyst, etc. Although the status of such parts

are different, the disassembly method is same, so refer to the chinese manual.

1-FRAME&ELECTRONIC COMPONENT 6

CHK

ADJ

NO. PART NO.

PART NAME QTY CAUTION

11184200-004000

ZT310 horn 1

21250104-006097

GB16674M6×12 (chromed/HH) 1

31250201-032093

GB818M5×16 (environmental color) 2

1186200-014000

ZT310T-M EFI ignition coil (pedal with thread) 125/155CC

1186500-007000

KD200 electric jet ignition coil 200CC

51251100-101000

Non-standard bolt M6×12 (304 stainless steel) 3

61224200-205000

ZT310 electronic cushion lock block 1

71274100-058000

ZT310 Electric seat lock 1

Fig.1 FRAME&ELECTRONIC

COMPONENT

PROCEDURE:

●Horn

Take off the plug of horn, take the horn(⑴ by one hand use 8# sleeve remove bolts ⑵by another hand,then

take off the horn⑴.

●Ignition coil

Take off the plug of the ignition coil.Remove the crosshead bolts⑶with a cross screwdriver and remove the

ignition coil⑷.

●Seat lock

Find and take off the plug of the seat lock .Using 4# inner hexagon remove 3pcs bolts⑸,then take off seat

lock⑺and electric seat lock guide block⑹.

●Main harness Different plug-in methods are different, please unplug all the electrical components

connected tothemain thread according to the actual operation. It needs to use a word screwdriver, forceps,

scissors andothertools to assist.

CAUTION:

●When Take off the plug can't drag any cable.

●In order to avoid the improper contact of the bending electrical parts, please pay attention to the direction

and angle of force when plugging the electrical parts, so as to avoid the improper contact of the bending

electrical parts. No violent operation.

●The location or number of ties may vary from batch to batch, so you need to disassemble them according to

the actual situation, and this manual only lists some of the tie locations.

Electronic parts COMPONENT 1

1-FRAME&ELECTRONIC COMPONENT 7

CHK

ADJ

NO. PART NO.

PART NAME QTY CAUTION

1251300-063093 Plywood M6×11×15(color Zinc) 4

21226500-004000

KD200-C front electrical device box 1

31244100-004000

ZT250-S Flanging bushing buffer 2

41224100-010000

ZT250-S swell nail 5

51251100-101000

Non-standard bolt M6×12 (304 stainless steel) 2

61240300-021000

HJ125-6 pod glass strip (1.5m) 1

71226500-020000

KD200-C left front decorative cover 1

81226500-021000

KD200-C right front decorative cover 1

Electronic parts COMPONENT 2

Fig.2 FRAME&ELECTRONIC

COMPONENT

PROCEDURE:

●Front electrical device box

It is necessary to remove the engine, fluid control unit, flasher, carbon canister, etc. first.

Remove the bottom bolts (5) with a 4# hex, and remove the 7 pieces of swell nails (4).

Remove the electronic parts component from the frame, and remove the two pieces of Flanging bushing

buffer (3) and the 4 pieces of plywood (1).

●Front decorative cover

Remove the left front and right front decorative cover components from the frame.

Remove the pod glass strip (6) from the front of the decorative cover respectively.

CAUTION:

●This manual only roughly explains the disassembly steps, and replacing the front decorative cover and front

electrical device box is difficult, so it is recommended to go to a qualified aftermarket store for repairs.

1-FRAME&ELECTRONIC COMPONENT 8

CHK

ADJ

NO. PART NO. PART NAME QTY CAUTION

11244100-002000 ZT250-S Side cover round rubber 7

21274100-017000 ZT250-S cable buckle 2

31244200-138000 ZT310 rubber buckle (80mm) 2

41246500-027000 KD200-C frame φ7 decorative buckle 2

51241200-044000 KD150-U fuel tank liner limit glue 2

71240100-023000 Battery anode protection glue 1

81244100-061000 ZT250 anti-water rubber of frame 4

91224100-030000 Pin tie (Black 4.8×130) 1

PROCEDURE:

●Fuel tank liner limit glue

Push out the fuel tank liner limit glues⑸then take off.

●Battery cushion

Put off the battery cushion ⑻directly by hand.

●Side cover cushion

Remove the side cover cushion ⑴with your hand directly.

●Rubbers

Remove the anti-water rubber of frame (8), cable buckle (2) and decorative buckle (4) directly by hand.

●Pin tie

Cut or pinch the snap on the back and push out the pin tie (9).

●Foam Tape

A 5-8cm piece of foam tape is affixed to the suspension brackets on both sides of the frame to prevent

rattling when the tool box cover and sub-tank cover are too close to the frame, required only for 125/155-C

models, not for 200-C.

CAUTION:

●It must be dismantled them first, such as the cushion, fuel tank component, sider cover, tail dressand so on.

●All parts should be correctly assembled.

60.1 only for

125/155-C

1246200-051000 P-240 foam improvement (width 6mm, length 1m,

thickness 5mm)

Frame plastic parts

Fig.3 FRAME&ELECTRONIC

COMPONENT

1-FRAME&ELECTRONIC COMPONENT 9

CHK

ADJ

NO. PART NO.

PART NAME QTY CAUTION

11134100-007000

ZT250-S Adjusting nut locking washer 1

31244100-015000

ZT250-S Adjusting nut rubber pad 1

41244300-014000

ZT350-R upper dust cover 1

51130900-024000

ZT250-S shaft ring 1

61130900-022000

ZT250-S conjoined steel ball 1

71130900-026000

ZT250-S upper steel bowl 1

81134300-001000

ZT350-R lower seat ring 1

91134300-002000

ZT350-R conjoined steel ball 1

CAUTION:

●Remove the head part component, handlebarcomponent and front shock absorber component first.

●Please pay attentin to fix the awaiting repair motorcycles during disassembly,prevent dumping by

accident.

●Please check whether the steel beads of the conjoined body have abnormal phenomena such as

partial abrasion and rust.If YES, please buy the regular accessories, if not, please be sure to grease the

old grease and repaint the lubricating grease on it.

●It must be to check whether the steel ball is available during reassembly.

●It must be reasonable to adjust the steering, too loose will cause the locomotive to brake slightly,

and the locomotive will shake slightly, too tight can lead to inflexibility, resulting in safety hazards.

●If you have the ability and the right tool, you can change the shaft ring and the dustproof cover

.During the replacement process, pay attention to the protection of the lower connected plate. After

replacement, it must be to check the parallelism of the column and the damping hole, the vertical

degree of the vertical column and the lower connected plate.

PROCEDURE:

●Dissembly

Remove the lock washer⑴.

Remove the top adjusting nut ⑵by using a special four-jaw or hook wrench tools.

Remove the rubber pad ⑶.

With one hand to hold down the down connected plate assembly, the other hand use a special four-jaw set

or hook wrench to remove the adjusting nut⑵.

Remove the down connected plate component.

Remove the upper dustproof cover⑷.

Remove the axletee ring ⑸of the upper riser and the steel ball⑹.

Remove the steel ball of the down connected plate component⑼.

●Assemble

When reassembling, the conjoined steel beads should be painted lubricating grease,attention to the dosage.

The torque of rating nut which closes to upper dustproof cover is required to about 14N·m.so as to be able to

rotate out of nimbleness.

The top adjusting nut only needs to rotate to the bottom of the nut groove alignment, not too tight to

prevent the rubber pad ⑶from deformation too larg.

Fig.4 FRAME&ELECTRONIC

COMPONENT

Directional column component

ZT250-S direction column adjusting screw nut M24×1

(environmental color Zinc)

1251300-046093

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