Zontes ZT125-U Manual de usuario

ZT125/155-U/U1（EUROⅤ）

Service manual

2021/01/21

Page 1 ，Total 87 pages

Pages

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

1FRAME&ELECTRONIC COMPONENT

1.1

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

Main harness, dump switch, relay, flasher

1.2

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

Flameout switch, horn,ignition coil

1.3

Electrical device component-3………………………………………………………………………………………………………………………………………………………………………………………

ECU

、

relay

1.4

Electrical device component-4………………………………………………………………………………………………………………………………………………………………………………………

rectifier

、

Buzzer

1.5

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

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

1.6

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

Lower plate component

1.7

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

2FRAME & ENGINE COMBINATION

2.1

U Frame & engine combination……………………………………………………………………………………………………………………………………………………………………………………

Lower shroud bracket

、

engine

2.2

U1 Frame & engine combination 1…………………………………………………………………………………………………………………………………………………………………………………

Disassemble guard bar assembly

2.3

U1 Frame & engine combination 2…………………………………………………………………………………………………………………………………………………………………………………

Lower shroud bracket

、

engine

3INTAKE SYSTEM COMPONENT

3.1

Intake system component……………………………………………………………………………………………………………………………………………………………………………………………

Air filter filter,Carbon canister

3.2

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

Disassemble throttle valve body component

3.3

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

Contents

Table of Contents

Page 2 ，Total 87 pages

Pages

Contents

Table of Contents

4REAR WHELL COMPONENT

4.1

U rear auxiliary mud board component 1…………………………………………………………………………………………………………………………………………………………………………

Disassemble rear auxiliary mud board component

4.2

U rear auxiliary mud board component 2…………………………………………………………………………………………………………………………………………………………………………

Disassemble rear auxiliary mud board component

4.3

U rear auxiliary mud board component 3…………………………………………………………………………………………………………………………………………………………………………

Disassemble rear auxiliary mud board,rear turn sinagl component

4.4

U1 rear mud board component 1……………………………………………………………………………………………………………………………………………………………………………………

Disassemble U1 rear fender component,rear fender bracket cover,rear fender bracket

4.5

U1 rear mud board component 2……………………………………………………………………………………………………………………………………………………………………………………

Disassemble rear mud board component,rear turn sinagl

4.6

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

4.7

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

Demolition after shock absorption, rear shock absorption adjustment

4.8

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

Disassemble the rear rim component, sprocket seat, sprocket

4.9

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

Disassembled rear rim component

4.10

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

Disassembled rear fork component

4.11

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

4.12

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

5PEDAL COMPONENT

5.1

Pedal height adjustment……………………………………………………………………………………………………………………………………………………………………………………………

Shift lever, brake pedal height adjustment

5.2

Right footrest component-1…………………………………………………………………………………………………………………………………………………………………………………………

Disassemble the right foot support component

5.3

Right footrest component-2…………………………………………………………………………………………………………………………………………………………………………………………

Decomposition brake pedal component

5.4

Right footrest component-3…………………………………………………………………………………………………………………………………………………………………………………………

Disassemble the right pedal component

5.5

Left footrest component-1…………………………………………………………………………………………………………………………………………………………………………………………

Page 3 ，Total 87 pages

Pages

Contents

Table of Contents

Disassemble the left foot support component and the shift lever component

5.6

Left footrest component-2…………………………………………………………………………………………………………………………………………………………………………………………

Decomposition shift lever component, front left pedal component

5.7

Left footrest component-3…………………………………………………………………………………………………………………………………………………………………………………………

Disassemble the left 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 1……………………………………………………………………………………………………………………………………………………………………………………………

Disassemble the auxiliary water tank component,water pipe

6.5

Water tank component 2……………………………………………………………………………………………………………………………………………………………………………………………

Disassemble water tank component,water tank bracket

7FRONT FORK COMPONENT

7.1

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

Adjust the throttle cable, clutch cable free travel; adjust the headlights light height

7.2

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

7.3

Replace the throttle cable……………………………………………………………………………………………………………………………………………………………………………………………

7.4

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

Adjustment steering device

7.5

U1 hand guard cover component……………………………………………………………………………………………………………………………………………………………………………………

Disassemble U1 hand guard cover

7.6

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

Disassemble right hand component, right handle sub switch

7.7

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

Add brake fluid, brake rocker adjustment

7.8

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

7.9

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

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

7.10

U front mud board & wheel speed sensor component………………………………………………………………………………………………………………………………………………………………

Disassemble front wheel speed sensor component, front mud plate component

7.11

U hood lower decorative cover……………………………………………………………………………………………………………………………………………………………………………………

Page 4 ，Total 87 pages

Pages

Contents

Table of Contents

7.12

U1 front mud board & wheel speed sensor component……………………………………………………………………………………………………………………………………………………………

Disassemble front mud plate component

7.13

Head and headlights component……………………………………………………………………………………………………………………………………………………………………………………

Disassemble head and headlights component

7.14

Head and headlights component 1…………………………………………………………………………………………………………………………………………………………………………………

Disassemble front turn singal,headlights low bracket,windshield

7.15

Head and headlights component 2…………………………………………………………………………………………………………………………………………………………………………………

Disassemble headlights and position light

、

hood decorative cover

7.16

Headlights storage box component…………………………………………………………………………………………………………………………………………………………………………………

Disassemble the headlights storage box

、

the headlights upper bracket

7.17

Speedometer component……………………………………………………………………………………………………………………………………………………………………………………………

Disassemble speedometer and bracket

7.18

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

Disassemble left rear view mirror, left hand rubber sleeve, left switch

7.19

Directional lever component………………………………………………………………………………………………………………………………………………………………………………………

Disassemble directional lever

7.20

Front shock absorber, upper plate component………………………………………………………………………………………………………………………………………………………………………

Disassemble front shock absorber, headlight bracket, faucet lock, upper plate component

7.21

Uplink plate, direction handle block component……………………………………………………………………………………………………………………………………………………………………

Disassemble the direction of the block, the upper plate

7.22

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

Disassemble the hydraulic control unit and bracket

7.23

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

Releasing brake fluid,FMC tubing

7.24

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

Disassemble FC tubing

7.25

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

Disassemble RMC tubing,RC tubing

8FUEL TANK COMPONENT

8.1

Fuel tank component………………………………………………………………………………………………………………………………………………………………………………………………

Disassemble Fuel tank component

8.2

Tank middle cover component,fuel tank lock………………………………………………………………………………………………………………………………………………………………………

Decompose tank middle cover component

Page 5 ，Total 87 pages

Pages

Contents

Table of Contents

8.3

Fuel tank cover component…………………………………………………………………………………………………………………………………………………………………………………………

Disassemble fuel tank cover component

8.4

Fuel tank decorative cover bottom plate component………………………………………………………………………………………………………………………………………………………………

Disassemble PKE

、

USB

8.5

Decompose fuel tank cover component

8.6

Disassemble fuel tank and fuel pump

9SURROUNDING COMPONENT

9.1

Surrounding component……………………………………………………………………………………………………………………………………………………………………………………………

Disassemble surrounding component

9.2

U surrounding component…………………………………………………………………………………………………………………………………………………………………………………………

Decompose U surrounding component

9.3

U1 surrounding component…………………………………………………………………………………………………………………………………………………………………………………………

Decompose U1 surrounding component

9.4

Surrounding bracket…………………………………………………………………………………………………………………………………………………………………………………………………

10 SIDE COVER COMPONENT

10.1

Side cover component………………………………………………………………………………………………………………………………………………………………………………………………

Decompose side cover component

11 REAR COVER COMPONENT

11.1

Rear cover component 1……………………………………………………………………………………………………………………………………………………………………………………………

Disassemble Rear cover component

11.2

Rear cover component 2……………………………………………………………………………………………………………………………………………………………………………………………

Disassemble rear cover

11.3

Skirt bottom part component 1……………………………………………………………………………………………………………………………………………………………………………………

Disassemble battery

、

tail skirt upper cover

11.4

Skirt bottom part component 2……………………………………………………………………………………………………………………………………………………………………………………

Disassemble battery bracket,tail light

12 CUSHION COMPONENT

Page 6 ，Total 87 pages

Pages

Contents

Table of Contents

12.1

Rear cushion component……………………………………………………………………………………………………………………………………………………………………………………………

Discomponent and component rear cushion; seat cushion rubber separately purchased parts

12.2

Front cushion component……………………………………………………………………………………………………………………………………………………………………………………………

Discomponent and component front cushion; seat cushion rubber separately purchased parts

、

seat bracket

13 MUFFLER COMPONENT

13.1

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

Disassemble muffler component

13.2

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

Disassemble muffler decorative cover

©Guangdong Tayo Motorcycle Technolog Co.

Ltd All rights reserve

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 changes.For 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-U and KD150-U1 high-

seat 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 7

CHK

ADJ

NO. PART NO.

PART NAME QTY CAUTION

1 1184200-103007

KD150-U (electrospray version) harness assembly 1

2 1250303-010093

GB6177.1M6

（

color zinc

）

3 1050954-009000

YH canister solenoid valve 1

4 1244100-082000

ZT250

－

R dump switch sleeve 1

5 1184100-002000

ZT250

－

S dump switch 1

6 1184100-017000

ZT250

－

S fuel-injection relay 5 KH-1A4T

7 1184200-039000

ZT310-R flasher 1

8 1224100-037000 Grade 0 flame retardant tie (black 3.6×295)

9 1251100-101000 Non-standard bolt M6×12 (304 stainless steel)

10 1274100-058000

ZT310 Electric seat lock 1

11 1224100-051000

0 level fire-retardant belting

（

black2.5×100

）

Fig.1 FRAME&ELECTRONIC

COMPONENT Electronic parts COMPONENT-1

PROCEDURE:

●Main harness

Different plug-in methods are different, please unplug all the electrical components connected to themain

thread according to the actual operation. It needs to use a word screwdriver, forceps, scissors andother tools to

assist. The binding⑻ or ⑾can be picked out by using scissors.

●Flasher and dump switch

Remove the flasher⑺,remove the rubber sleeve⑷ that connects to the mounting bracket on the frame, and

remove the dump switch⑸.

●Relay

Pull out 5pcs electric injection relay⑹directly.

●Seat lock

Find and take off the plug of the seat lock , and cut off binding⑾.Using 4# inner hexagon remove 3pcs bolts

⑼,then take off seat lock⑽.

●Canister solenoid valve

First unplug the two oil pipes connecting the carbon canister to the solenoid valve, unplug the cable connector

and then loosen the nut ⑵and remove the solenoid valve ⑶.

CAUTION：

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

●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.

●Please notice the limit of the bracket when dismantling dump switch sleeve, beware of hurting your fingers.

●Additional buide block for motorcycles manufactrued after 21 October 2020.Early-produced motorcycles

can be purchased and installed on their own.

12 1224200-205000 ZT310 Electric seat lock guide block 1

1-FRAME&ELECTRONIC COMPONENT 8

CHK

ADJ

NO. PART NO.

PART NAME QTY CAUTION

1 1184200-004000 ZT310 horn 1

2 1251112-001093 M6×16 Hexagon flange bolts (color zinc) 1

3 1224100-037000 Grade 0 flame retardant tie (black 3.6×295) 2

4 1250205-040095 GB70.1 inner hex bolt M8×16

（

color Zinc

）

5 1184100-012000 ZT250

－

S shut down switch 1

6 1250201-032093 GB818M5×16 (environmental color) 2

7 1184200-104007 ZT310 EFI ignition coil (with high voltage line) 1

Fig.2 FRAME&ELECTRONIC

COMPONENT Electronic parts COMPONENT-2

PROCEDURE：

●Horn

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

take off the horn⑴.

●Shut down switch

Find and take off the plug of the shut down switch⑸ , cut ribbon ⑶.Using 6# inner hexagon socket remove

2pcs bolts⑷ then take off shut down switch⑸.

●Ignition coil

Take off the plug of the ignition coil.Remove the crosshead bolts⑹ with a cross screwdriver and remove the

ignition coil⑺.

CAUTION：

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

1-FRAME&ELECTRONIC COMPONENT 9

CHK

ADJ

NO. PART NO.

PART NAME QTY CAUTION

1 1184100-010000 Starting relay 1

2 1251100-119093 Non-standard bolt M6×12 (environmental color) 2

3 1251100-120093 Non-standard bolts M6×16 (environmental color) 2

4MSE6.0 controller 1

【

】

5 1271200-080000 KD150-U Bosch ECU bracket 1

1Main fuse 7ABS ECU

2ECM 8lights fuse

3ACC 9Resrve

4ABS motor 10 Resrve

5Resrve 11 Resrve

6Resrve 12 Resrve

PROCEDURE：

●Relay

Turn off the positive and negative.protective rubber caps (red for the positive and black for the negative) of the

starter relay⑴.Using 10#sleeve remove nuts then remove the positive and negative connectors, and screw the

nut back onto the relay stud to preventloss.Take off plug of the start relay and main hamess.

●ECU

Turn the ECU cable plug clockwise and unplug it. Remove the bolt ⑵ at the bottom of the frame with a 5#

hexagon socket, and then remove the ECU assembly.

Using 5# inner hexagon socket remove 2pcs bolts⑶ then take off the ECU⑷ from the ECU bracket⑸.

CAUTION：

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

●【1】If the part code is empty, it indicates that the part has multiple states or colors. For specific states, please

find the corresponding state or color in the official website parts. Only the disassembly and assembly steps are

explained here, and the color and status do not affect the disassembly and assembly process. This description

will not be added if there is such a situation later in this manual.

●Please refer to the driver's manual for details about the related content of the EFI fault code. The latest electronic

version of the driver's manual can be downloaded from the corresponding model introduction page of the official

website.

Fig.3 FRAME&ELECTRONIC

COMPONENT Electronic parts COMPONENT-3

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