TAYO ZONTES ZT125 2022 Maintenance Manual Download

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ZT125/310T-M

Maintenance Manual

2022-09-14

Summary of Contents for ZONTES ZT125 2022

Page 1: ...1 188 ZT125 310T M Maintenance Manual 2022 09 14...

Page 2: ...his manual are inconsistent with the official website of Zontes please refer to the official website of Zontes Individual parts of different displacements that differ in shape or size but are disassem...

Page 3: ...and rubber parts reducing the service life Non woven fabrics should be used for wiping with no residue Ordinary rags may leave cloth scraps or wool etc which may affect the assembly or cause other ad...

Page 4: ...l supply system 22 6 1 M310 Fuel evaporation 22 6 2 M125 Fuel evaporation 23 6 3 M310 Fuel supply 23 6 4 M125 Fuel supply 24 7 Distribution map of cooling system accessories 24 7 1 M310 24 7 2 M125 25...

Page 5: ...eposits 49 3 Remove the throttle valve body assembly to clean up carbon deposits 51 4 Disassemble the three in one sensor 52 5 Throttle valve body troubleshooting process 53 M125 Throttle valve body 5...

Page 6: ...2 2 Replace the brake switch 75 3 Lubricate the movable parts of the brake handle 75 3 1 Lubricate the front brake handle 75 3 2 After lubricating the brake handle 75 3 3 Replacing the brake handle 7...

Page 7: ...eadlight height adjustment 95 3 Fuse box 96 4 Troubleshooting 97 4 1 Right hand switch 97 4 2 Right hand handle vice switch 97 4 3Left hand handle auxiliary switch 98 4 4 Horn 98 4 5 Left hand switch...

Page 8: ...Before Service 121 Troubleshooting 121 1 Starting relay 121 2 Starter motor 122 3 The starter motor runs slowly 122 4 The starter motor is working normally but the engine cannot be started 122 Igniti...

Page 9: ...water pump cover assembly M310 139 8 Braking system 140 Know Before Service 140 Trouble shooting 141 Soft feeling from brake lever 141 Hard feeling from brake lever 141 Disassemble the disc brake main...

Page 10: ...wheel rims and tires 163 3 1 The service life of the front wheel rim and tire 163 3 2 How to replace the front wheel rim and tire 164 3 3 Dynamic balance 164 Replacement of the front shock absorber 16...

Page 11: ...Disassembly of the surrounding bottom 181 Removal of the cooling fan air guide plate 181 Disassembly of the cushion 181 Disassembly of the storage box 182 Disassembly of the rear hand rest 182 Disasse...

Page 12: ...r to qualified institutions for disposal it is forbidden to dump them at will to pollute the environment or water sources 7 Swallowing or inhaling coolant brake fluid etc will cause certain harm to th...

Page 13: ...e the muffler The nameplate is above the radiator PKE OBD interface and water tank filling port position are pasted on the right storage box cover The engine identification code is engraved on the lef...

Page 14: ...at fully open temperature 95 203F Thermostat opening stroke 3 5mm 0 13 in Coolant type Ethylene glycol distilled water Front wheel steering system Item Standard Limit Tread depth 1 6mm 0 063 in Normal...

Page 15: ...specification 120 70 14 CM577 61P Front rim specification MT 2 5 14 Rear rim specification MT 3 5 14 Brake fluid DOT4 0 23L 0 06 US gal 0 05 lmp gal Oil consumption Replace fine filter 0 95L 0 25 US g...

Page 16: ...ake fluid DOT4 Brake pad use limit Trough bottom Brake disc thickness 4 0mm 0 16 in 4 0mm 0 16 in Battery charging system Item Standard Battery Type 6 FM 7L Capacity 7Ah Battery self discharge current...

Page 17: ...0 K Tightening torque Bolt tightening torque of general tightening part Intensity level Grade 4 8 6 8 mark 4 on the head of the bolt Grade 8 8 mark 7 or 8 8 on the head of the bolt Bolt diameter Tigh...

Page 18: ...sition light 5 Right daytime running light 6 Headlight 7 Right front turn signal 8 Right hand handle auxiliary switch 9 Right hand handle switch 10 Rear tail light system Moving lamp 11 Rear right tur...

Page 19: ...main pump 4 Calipers brake hoses and wheel speed sensors 1 brake disc front 2 front whell ABS induction ring gear 3 wheel speed sensor front wheel 4 front disc brake caliper 5 FC HU brake hose 6 rear...

Page 20: ...ont wheel 2 FC HU brake hose 3 RC HU brake hose 4 wheel speed sensor rear wheel 5 rear brake lever 6 rear brake switch 7 RMC HU brake hose 8 rear disc brake main pump 9 FMC HU brake hose 10 front brak...

Page 21: ...hose 3 RC HU brake hose 4 wheel speed sensor rear wheel 5 rear brake lever 6 rear brake switch 7 RMC HU brake hose 8 rear disc brake main pump 9 FMC HU brake hose 10 front brake switch 11 front disc b...

Page 22: ...vent pipe 6 a solenoid valve intake pipe 10 a solenoid valve outlet pipe 11 and a vent leakage pipe 13 The carbon canister components are sold as a complete set and are sold separately without being d...

Page 23: ...11 solenoid valve outlet pipe 12 throttle valve body assembly Fuel evaporation Oil and gas oil and gas separator inside the oil tank adsorption vent pipe solenoid valve intake pipe solenoid valve outl...

Page 24: ...ter screen Fuel pump High pressure fuel pipe Fuel injector Cylinder 7 Distribution map of cooling system accessories 7 1 M310 1 Main water tank 2 Water tank filling port 3 Secondary water tank 4 Alumi...

Page 25: ...econdary water tank link pipe 3 Engine inlet pipe 4 Thermostat outlet pipe 5 Thermostat 6 Water tank inlet pipe 7 Water and oil shared sensor 8 Water tank outlet pipe 9 Water tank filling port 10 Radi...

Page 26: ...cet lock 5 PKE 6 main cable 7 ignition coil 8 side bracket flameout switch 9 engine controller ECU 10 buzzer 11 cushion lock 12 Dump switch 13 Windshield motor controller 14 USB charging cable 15 Fron...

Page 27: ...PKE 4 faucet lock 5 front storage box lock 6 speaker 7 USB charging cable 8 dump switch 1 Cushion Lock 2 Rectifier 3 Buzzer 4 Engine Controller ECU 5 Battery 6 Fuse Box 1 7 Electronic Fuel Tank Lock...

Page 28: ...filter intake pipe Air filter element Air filter outlet pipe Throttle valve assembly body Intake manifold Cylinder Muffler Cylinder head exhaust gas control system red arrow indicates Exhaust gas cyl...

Page 29: ...Air filter element Air filter outlet pipe Throttle valve assembly body Intake manifold Cylinder Muffler Cylinder head exhaust gas control system red arrow indicates Exhaust gas cylinder head cover cyl...

Page 30: ...piece tool set Torque wrench On board tools Claw hammer Pull code Rubber hammer Dynamic Balancing Machine Tire raking machine Oil pan Measuring cup Funnel Taps dies Micrometer Depth gauge Vernier cali...

Page 31: ...diagnostic Speedometer 16PIN 17 Inner hexagon Hoop clamp Internal Circlip Pliers External circlip pliers Clamp multimeter Multimeter Dust blow gun Some of the above pictures are from the Internet and...

Page 32: ...he outer ring with two fingers and push the center cylinder up to the initial position Pinch the center cylinder with two fingers to install the swell nails to the installation position The outer ring...

Page 33: ...cal advice or consultation in time Keep away from children and pets 8 If you need to clean or wash the body parts of the vehicle you should use neutral car wash fluid or tap water diesel kerosene etc...

Page 34: ...mile Braking System I I Brake hose I Every 4 years Brake fluid I Every 2 years Tire I Steering mechanism bolts and nuts T T First adjust nut 15 2 1 5 0 2 the second adjust nut align the first nut Stee...

Page 35: ...g bearing in Steering mechanism Every 4000km 2485mile inspection or clean or lubricate Front shock absorber I Rear shock absorber I Bolts and nuts for body and engine installation T T M12 65 5 6 6 0 5...

Page 36: ...should be increased Steering system braking system electronic fuel injection system shock absorber and wheels are all key components and it is recommended to be carried out by a qualified maintenance...

Page 37: ...on shown 5 Remove the air filter housing a Use a Phillips screwdriver to remove the 9 screws that fix the housing of the air filter b Remove the air filter housing 6 Replace Air filter element a Use a...

Page 38: ...the other 4 M6 14 bolts Replace the decorative buckle The vehicle must be parked on a flat and stable ground or a lifting platform The operation can only be performed after the engine has cooled down...

Page 39: ...xagon to remove the M6 14 bolt as shown in the figure The bolt here cannot be removed temporarily just loosen it completely b Use 4 inner hexagon to press down the center cylindrical pins of the 2 swe...

Page 40: ...ipe clean the surface of the waste oil pipe and visually check for liquid If so use pliers to remove the waste oil pipe clamp clean the waste oil pipe and then reinstall it Pay attention to increase t...

Page 41: ...gun to blow air from the clean side of the filter element to blow away the dust on the surface of the filter element Do not let water enter the air filter when washing the vehicle Bolts and nuts of m...

Page 42: ...he 4 inner hexagon to remove the M6 14 bolts b Pull out in sequence in the direction of the arrow from the rear wheel to the front wheel Note that there are 5 staples at the red circle and a circle of...

Page 43: ...cracked or damaged whether the center electrode is abraded fouled corroded excessively carbonized or discolored the color of the ceramic insulator around the middle electrode of the spark plug should...

Page 44: ...s at the red circle and a circle of buckles around It takes a lot of force to pull out c Use your fingers or a plastic crowbar to insert the arrow indication point first pry the arrow indication point...

Page 45: ...or steel needle to remove the attached carbon deposits c Use a feeler gauge to inspect the gap between the center electrode and the side electrode d If necessary the gap can be adjusted by bending th...

Page 46: ...dipstick and O ring to accelerate the oil flow d After placing an oil pan under the oil drain bolt use a 14 sleeve to remove the oil drain bolt and the combined seal gasket e Wipe clean the joint surf...

Page 47: ...p with 0 2L of oil or gearbox special oil 0 21US qt 0 18 lmp qt 0 05 US gal 0 04 lmp gal g Check whether the O ring is damaged or aging wipe it clean if not and replace it if there is any h Wipe clean...

Page 48: ...c Remove the fine filter cover and O ring 3a Remove the spring the fine filter oil filter element 3b and the gasket 3c in sequence d Replace the new fine filter oil filter element and gasket The fine...

Page 49: ...tions are leaking and if there is any leakage it needs to be checked b After the engine has been idling for 5 minutes and then turned off for 3 minutes check whether the oil level meets the standard I...

Page 50: ...7 2022 follow this step and for vehicles produced after that skip directly to step h e Pull up the 3 fuse boxes and pull out the cables When re installing you need to insert the fuse box back to the...

Page 51: ...d obliquely paying attention to the cables in the battery compartment Pull up to see the left side of the glove box atmosphere lamp thread unplug the thread and remove the glove box assembly l Unplug...

Page 52: ...et respectively It is forbidden to directly soak the throttle valve body assembly and intake manifold assembly with any liquid h After cleaning the heat insulation pad replace 2 new O rings and assemb...

Page 53: ...are disassembled do not miss the sealing ring and make sure that the sealing ring is assembled in place without cutting edges Do not use carburetor cleaner or compressed air to clean the throttle valv...

Page 54: ...wdriver to remove the 2 GB9074 4 M4 12bolts and the anti off card that come with the throttle valve body assembly and then remove the stepping motor g Use throttle cleaner to clean the carbon deposits...

Page 55: ...ithout ignition turn the throttle handle from the initial position to fully open and check whether the throttle position signal changes from 0 to 100 e Check whether the external intake pressure senso...

Page 56: ...e or the rubber sleeve of the right handle d After starting the engine turn the steering handle left and right to ensure that the idling speed does not change during the steering process and then turn...

Page 57: ...ght should not light up The status of the spark plug has been checked The air filter element and the air inlet element have been inspected or replaced Check the throttle clearance The limit screw on t...

Page 58: ...intake pipe 11 solenoid valve outlet pipe 12 throttle valve body assembly Remarks The carbon canister assembly includes carbon canister 8 adsorption vent pipe 6 solenoid valve inlet pipe 10 and soleno...

Page 59: ...running water and seek medical advice or consultation in time Keep away from children and pets The engine coolant must be a model suitable for aluminum radiators based on ethylene glycol Use a coolant...

Page 60: ...a small container is required to receive the coolant overflowing from the exhaust bolt Do not allow the coolant to drip directly onto the surface of the part d Put on waterproof gloves and add coolan...

Page 61: ...ve dirt sand insects and other dirt on the surface of the radiator When using compressed air be careful not to get too close to the fins It is forbidden to flush the radiator directly with a high pres...

Page 62: ...6 Water and oil shared sensor 7 thermostat 8 water pump assembly 1 Main water tank inlet pipe 2 Leakage pipe 3 Small radiator outlet pipe 4 Water inlet pipe 5 Secondary water tank connection pipe 6 M...

Page 63: ...ondary water tank link pipe 3 Engine inlet pipe 4 Thermostat outlet pipe 5 Thermostat 6 Water tank inlet pipe 7 Water and oil shared sensor 8 Water tank outlet pipe 9 Water tank filling port 10 Radiat...

Page 64: ...cushion and storage box components and remove them as shown in the figure below b Remove a total of 4 pcs swell nails indicated by the arrow For instructions on disassembly and assembly of swell nail...

Page 65: ...l pipe of the original car to the pressure gauge and find another high pressure oil pipe to connect the pressure gauge and the fuel injector Start the vehicle let the engine run at idle speed and meas...

Page 66: ...ition site The fuel pump is a precision component that needs to be assembled in a dust free workshop and requires strict testing so it is forbidden to disassemble it by yourself The EFI system needs t...

Page 67: ...clutch cover 1 6 Driving wheel sliding plate 1 15 Driven wheel clutch shoe 1 7 Pulizhu 8 16 Sliding plate of driven wheel 1 8 Boot block 1 17 Driven wheel fixed disk 1 9 Ramp board 4 2 Maintenance Cau...

Page 68: ...over and the left crankcase cover gasket The left crankcase cover gasket 4 must be replaced when reinstalling and the hollow positioning pin 3 must not be omitted 2 2 Disassemble the continuously vari...

Page 69: ...riable clutch sub assembly 2 3 Inspection Caution Every 3 years or driving 20000 kilometers 12427 mile the continuously variable clutch sub assembly needs to be inspected maintained or repaired a Insp...

Page 70: ...ed shaft of the driven wheel are worn or damaged If they are worn loose and loose frames they need to be replaced Note that the bearings don t need to be geased to prevent the grease from slipping on...

Page 71: ...uickly extend your finger near the side of the V shaped drive belt to slide the V shaped drive belt into the belt groove between the moving plate of the driven wheel and the fixed plate Finally clamp...

Page 72: ...oubleshooting 3 1 The engine can be started but the rear wheel does not rotate a The V shaped transmission belt is severely worn or broken b The clutch shoe is worn or damaged c The large spring of th...

Page 73: ...oses disc brake calipers disc brake main pumps and hydraulic control units must be reviewed by our company before they can be purchased Domestic customers can fill in the frame code and engine on the...

Page 74: ...ep scratches grooves etc Replace it if necessary Feel with your hands whether there is a noticeable sound of grinding the brake disc when turning the front wheel Observe from the front whether the bra...

Page 75: ...ut distinguishing the positive and negative poles b Use a Phillips screwdriver to remove the bolt to remove the rear brake switch c Replace with a new switch pay attention to align the switch boss and...

Page 76: ...nd in the direction of the arrow with the help of a tool If the resistance is high you can refer to the method of adding brake fluid to the front brake main pump to remove the upper cover and then pus...

Page 77: ...s follows a The brake pad is worn to the limit If it is a new brake pad check whether there is any foreign matter caught between the brake disc and the brake pad It can return to normal after replacin...

Page 78: ...M6 14 bolt on the right middle of the rear inner mudguard use 4 hex socket to remove the front M6 12 bolt and the rear M6 16 bolt Remove the two M6 12 bolts at the bottom of the rear rocker arm and re...

Page 79: ...brake fluid and it is forbidden to mix it with other brake fluids Wear protective gloves protective clothing protective goggles protective masks Brake fluid must be used in time after opening seal and...

Page 80: ...nd of the hose into the oil pot d Remove the upper cover of the front brake main pump referring to the previous step of adding brake fluid e Rotate the 8 torx wrench with the right hand counterclockwi...

Page 81: ...sidewall is bumped punctured scratched or if the tread is damaged and the hole is large it should be replaced directly Rebalance should be done after Tyre repair Check the tire pressure regularly M31...

Page 82: ...ntenance table Park the vehicle on a flat and stable ground or a lifting platform and put down the main support Too small steering mechanism clearance will cause inflexible steering and accelerate bea...

Page 83: ...07 US oz 7 7 0 07 lmp oz 13 4 0 1 cu in After traveling on dusty or muddy roads you should clean up the foreign matter on the front fork tube exposed chrome plated cylinder in time to avoid scratchin...

Page 84: ...lowly and slightly straighten the pressure and small stroke several times and measure while straightening The radial run out after correction should be less than 0 05mm 0 002 in If the original bendin...

Page 85: ...ear shock absorption 2 2 1 M310 a Refer to the previous steps to replace the air inlet filter element and remove the left cover Disassemble it as shown in the figure below b Use an 8 sleeve to remove...

Page 86: ...on the outside and remove the nut Be careful not to remove the bolt first Remove the nut by the same operation on the other side One person supports the rear wheel assembly and one person removes the...

Page 87: ...fixed engine as shown in the figure are loose The nut on the right front part a in the figure needs to be pulled out or pulled out of the high pressure oil pipe and cable connector to facilitate tigh...

Page 88: ...s b Feeler gauge c Thread fastening glue and sealing silica gel 2 Operation steps a Use an 8 T shaped socket wrench or a wind batch to remove the 6 M6 30 hexagonal flange bolts of the cylinder head co...

Page 89: ...You need to increase the clearance of 0 04 0 08mm 0 002 0 003 in The thickness specification of the original adjusting gasket on the engine is 2 36mm 0 093in you need to replace the adjusting shim wi...

Page 90: ...int surface of the cylinder head and the seal ring of the cylinder head with a clean rag and reapply a proper amount of sealing silicone on the corners of the joint surface of the cylinder head Then i...

Page 91: ...91 188 l So far the adjustment operation of the valve clearance is completed...

Page 92: ...brake handle After starting the vehicle put down the side brackets and the flame should be automatically turned off otherwise it is necessary to troubleshoot the flameout switch or brake switch failu...

Page 93: ...main support shaft 3 from right to left Pay attention to the protection measures at the spring of the main support to prevent the spring of the main support from suddenly loosening and flying out and...

Page 94: ...o test whether it is normal SET key Short press SET to enter the main menu confirm selection Long press to return to the main interface Operate this button when driving a vehicle is prohibited MOD key...

Page 95: ...charger is the TEST button which function is same as the unlock button on the auxiliary switch 2 Headlight height adjustment Caution The height of the headlights is too high or too low which will affe...

Page 96: ...ox After opening the fuse box cover check whether the fuse is normal No Name Function Specification Main insurance Protect all circuits 25A ECM Protect ECM ECM relay oil pump relay and other electrica...

Page 97: ...is judged as a switch failure Otherwise check for cable or headlight failures c The E S mode cannot be switched by pressing the ECO button Disconnect the switch and short the ECO button switch line I...

Page 98: ...on There should be more than 5 seconds interval when adjusting or checking the horn Continuous sounding may cause ablation of the internal coil of the horn The horn is a riveted structure which is dif...

Page 99: ...see if the turn signal is on Light failure Y Check whether the meter is on Y Press the double flash button is it on There is also a problem with the double flash button The chances are small The near...

Page 100: ...rocess of lamp troubleshooting After power on turn on the left right hand switch and the lamp does not light up Check whether the lighting terminal is plugged in N Reconnect the terminals Y Unplug the...

Page 101: ...the flameout switch and lock the car e After waiting for 5 seconds unlock the vehicle again to complete the reset of the EFI system 7 Pay attention to the following when checking or troubleshooting EF...

Page 102: ...ntinuous flashing 10 times intermittent 1 second continuous flashing 2 times intermittent 1 second continuous flashing 10 times intermittent 1 second Flashes once in a row c If there is more than one...

Page 103: ...trol circuit is shorted to the power supply P0444 Canister solenoid valve open P0322 No speed sensor pulse signal open circuit or short circuit P0459 Canister solenoid valve is shorted to the power su...

Page 104: ...Ignition coils M310 Throttle valve body M310 Water and oil shared sensor Oxygen Sensor M310 MSE6 0 ECU M310 Crankshaft position sensor M310 13 14 15 16 17 18 Oxygen Sensor M125 Fuel injector M125 Igni...

Page 105: ...of the vehicle please be sure to go to a regular gas station to refuel It is forbidden to run the fuel pump in dry state or in water otherwise its service life will be shortened and it will be directl...

Page 106: ...function is the same Cable end wire color Wire no Relay 1 2 3 5 light Red Blue w hite Black and white White Start assist green Green red Black white Red green Oil pump White black Red bl ack White bla...

Page 107: ...rackets use the main bracket to park the vehicle firmly and unlock the vehicle turn the flameout switch to hold the brake handle and place the spark plug close to the engine cylinder head cover or box...

Page 108: ...nce of the two terminals T and G can be measured to determine whether it is abnormal The resistance value at 25 C 77F is 1940 2040 M125 sensor For the disassembly assembly and inspection of the M125 t...

Page 109: ...or of the top part of the head which is normally light gray If it is white it means that the silicon poisoning has been damaged and needs to be replaced if it is black it means that there is carbon de...

Page 110: ...rear storage box rear armrest and rear right rear skirt Pull out the ECU plug after pressing the buckle indicated by the arrow Remove 2 M6 12 bolts with 4 hexagon socket to remove the ECU 12 Cranksha...

Page 111: ...n the start button is pressed the starter motor can drive the engine to run normally When there are signs of a car but cannot start you can refer to the following diagnosis process to troubleshoot the...

Page 112: ...vent pipe and other hoses High idling speed of hot car When a cold car occurs it can run at a normal fast idling speed After a hot car the idling speed does not fall back to 1500 1700 rpm You can ref...

Page 113: ...c field should be installed as far away as possible from the relay wiring harness and electrical device box or not installed Y Check whether the black and white wire and red wire of the ECM main relay...

Page 114: ...The EFI parts are damaged Y After checking the route judge according to the process There has been a power outage in the whole vehicle Reset the EFI system Y High idle speed The throttle body has a l...

Page 115: ...115 188 Electrical schematic diagram of EFI system...

Page 116: ...battery has sufficient power If the power is insufficient it may result in a slow start speed or weak spark intensity of the spark plug or no spark Tool Multimeter 7 The driving conditions and mainte...

Page 117: ...and the cylinder wall and valve guide Check whether the gap is normal If it is abnormal replace the corresponding parts The accumulated gasoline may be caused by the mixture being too thick when the...

Page 118: ...comes with the main wiring harness and there are 3 in total For detailed illustrations please refer to the EFI relay section in the Electronic Injection System chapter of this manual The magneto stato...

Page 119: ...ght crankcase cover and cylinder head cover of the engine are removed to check the timing the crankcase cover gasket must be replaced it is recommended that the cylinder head cover gasket is also repl...

Page 120: ...the line immediately after the T mark on the flywheel with the triangle mark on the box c Rotate the camshaft to align the dots with the camshaft pressing plate bolts insert the timing driven sprocke...

Page 121: ...rged and in good condition Check whether the main fuse 25A and ECM fuse 15A are blown If the fuse is replaced with a new one and it is blown out you need to troubleshoot the line first The starting mo...

Page 122: ...y Check whether the battery power is insufficient Check whether the battery cable connector is in poor contact Check whether the starter motor cable is in poor contact Check whether the starter motor...

Page 123: ...M125 steps are similar to the M310 taking the M310 as an example 1 Remove the starter motor a Refer to the steps of removing the rear storage box to remove the rear storage box For the removal steps r...

Page 124: ...or fixing the starter motor 12 1 5 N m 1 2 0 2 kgf m 9 1 lbf ft And mark with a marker 2 Disassemble the starter motor Caution If the magnet tile pulls the electric pole towards the motor housing the...

Page 125: ...h the front cover Motor back cover Check whether the bushing of the back cover is worn or damaged Check whether the brush is damaged measure the length of the brush and use the limit11 5mm 0 45in Chec...

Page 126: ...wire The vehicle is powered off and locked Set the multimeter to the buzzer position connect one test lead to the green red wire and one to any bolt connected to the frame It should be conductive when...

Page 127: ...rmal throttle opening and closing and idle speed control 9 Cannot use carburetor cleaning agent 10 Throttle valve body parts not specified in this manual shall not be disassembled After reinstalling t...

Page 128: ...val of the fuel tank assembly Hold up the fuel tank assembly and turn it clockwise as shown in Figure 1 while turning let the seam welding on the right side of the fuel tank go down to the bottom of t...

Page 129: ...ery rubber pad 3 is pasted on the shell of the fuel tank which is difficult to remove If you need to remove it you can use a heat gun to heat it and tear it off or use a cleaning agent that removes th...

Page 130: ...d the small water tank When the engine is not completely cooled opening the water tank cover may cause the coolant to spray out and cause burns The water tank cover must be opened after the water tank...

Page 131: ...5 Aluminum water outlet pipe 6 Small water tank 7 Water and oil shared sensor 8 Thermostat 9 Water pump cover assembly 1 Main water tank 2 Water tank filling port 3 Secondary water tank 4 Aluminum wa...

Page 132: ...dary water tank link pipe 3 Engine inlet pipe 4 Thermostat outlet pipe 5 Thermostat 6 Water tank inlet pipe 7 Water and oil shared sensor 8 Water tank outlet pipe 9 Water tank filling port 10 Radiator...

Page 133: ...culation outlet pipe water pump cover inlet pipe Big loop indicated by the green arrow Water pump cylinder inlet pipe cylinder thermostat small water tank inlet pipe small water tank small water tank...

Page 134: ...first Wear protective measures such as waterproof gloves and protective glasses during disassembly and prevent the coolant from contacting the skin The disassembly operation must be performed after t...

Page 135: ...with the oil pan Coolant Use the same method to remove the 10 5 hoop and then pull out the water pipe Cut the cable tie and use an 8 sleeve to remove the 2 M6 22 bolts that fix the auxiliary water tan...

Page 136: ...o be replaced once they are disassembled a Use the hoop pliers to remove the hoop and hoop and separate the water pipes and and the three way pipe Remove the hoop from the water pipe b Use an 8 sleeve...

Page 137: ...e 2 1 Overall leak check Seal the small tube and ventilate the large tube for air tightness inspection 2 2 Check of pressure relief valve Pass 120kPa 1 22 Kgf cm2 17 4 psi compressed air into the big...

Page 138: ...mostat works normally If the water temperature has been rising rapidly when the internal pressure reaches a certain level the sudden overflow of boiling water indicates that the valve is stuck If it i...

Page 139: ...e fully opened Until all closed The joint surface should be cleaned before rematching and no O ring should be installed 8 Water pipe Check whether there are cracks bulges and other defects on the surf...

Page 140: ...pads or brake discs have oil stains the braking force will be reduced The contaminated brake pads should be replaced and the oil stains on the brake discs can be removed with a good quality degreasing...

Page 141: ...in pump a Remove the cover according to the steps in the removal direction in the Front Fork Assembly of this manual b Use a 12 sleeve to loosen the disc brake oil pipe bolt pay attention to loosen it...

Page 142: ...ump to speed up the discharge of brake fluid c Remove the brake pads according to the steps of removing the brake pads d Front disc brake caliper disassembly A dust blow gun can be used to blow in com...

Page 143: ...5 7 lbf ft The open end of the piston should face the caliper mounting plate and do not install it backwards If there is slight rust on the surface of the piston it can be polished off with 2000 mesh...

Page 144: ...control unit counterclockwise The nut torque 18N m 1 8 kgf m 13 lbf ft Wipe up the remaining brake fluid with a clean non woven fabric Take care to take protective measures and prevent dripping onto t...

Page 145: ...e 3 pieces of wire clamp and then pull out the wheel speed sensor and the RC HU hose from the 4 pieces of oil pipe clamp If you need to remove the tubing clamp 3 you can use 4 inner hexagon to remove...

Page 146: ...e pulled out forcibly After removing the hose prevent foreign matter from entering Before reassembling the hose connector at the hydraulic control unit apply a small amount of brake fluid to the threa...

Page 147: ...control unit and bracket assembly from the car e After holding the hydraulic control unit firmly use 4 inner hexagon to remove the M6 16 bolts then the hydraulic control unit can be removed If you ne...

Page 148: ...icator light is always on and the ABS function is invalid When the vehicle is powered on the ABS indicator on the meter flashes continuously for 30 seconds the indicator light is always on Press the A...

Page 149: ...is loose No rear wheel speed Check whether the rear wheel sensor is damaged or the connector is loose Unplug the diagnostic device restart the power supply of the vehicle ride normally and use the br...

Page 150: ...he throttle turn off the flameout switch and lock the car e After waiting for 5 seconds unlock the vehicle again to complete the reset of the EFI system 4 The vehicle should be powered off before disa...

Page 151: ...tifier failure N Faucet lock failure or short circuit Measure the battery voltage first then measure the charging voltage after starting the engine Battery voltage charging voltage 14 5 14 9 V N Check...

Page 152: ...nese green Red yellow English Green Red Yellow Battery disassembly 1 Disassembly Refer to the steps a to d in the section Removing the stepper motor and cleaning the carbon deposit in the section Thro...

Page 153: ...ed with the car Charging system check 1 Leakage test a Turn off the vehicle and cut off the power supply and remove the negative wire of the battery b Adjust the multimeter to the current position Con...

Page 154: ...sides with 5 inner hexagon respectively and remove the bush and the rubber pad After that remove the M6 14 bolts with 4 inner hexagon After that remove the M6 14 with 4 inner hexagon c Vehicles manuf...

Page 155: ...te the environment or water sources 7 Swallowing or inhaling coolant brake fluid etc will cause certain harm to the human body Any exposed skin such as hands and face should be cleaned thoroughly afte...

Page 156: ...156 188 Exploded view of front fork components M125 310 Directional exploded view...

Page 157: ...157 188 Front fork exploded view The M125 are similar to the M310 taking the M310 as an example...

Page 158: ...158 188 Exploded view of lower link board The M125 are similar to the M310 taking the M310 as an example...

Page 159: ...bolts and remove the left auxiliary handle switch the rear disc brake main pump the right auxiliary handle switch and the front disc brake main pump b Use 4 inner hexagon to remove the M6 14 bolt the...

Page 160: ...rake with the triangle mark on the handle switch and then tighten the 4 M6 30 bolts with a 5 inner hexagon d Snap the upper brackets and into the lower part of the direction control cover buckle the p...

Page 161: ...e upper cover of the disc brake oil cup and then separate it 2 brake pads b Put the front wheel in the middle of the front shock absorber shake the front wheel left and right to make the disc brake di...

Page 162: ...sensor 1 5 ABS sensor gear 55T 1 6 Non standard bolt M8 25 10 25 N m 2 5 kgf m 18 lbf ft 7 265 4 5 brake disc 1 M125 NO Part name QTY Caution 1 Oil seal TC 28 42 7 2 2 GB276 bearing 6004 2RS C3 2 20...

Page 163: ...need to be inspected according to the actual conditions of the vehicle s driving conditions and the size of the load Into the oil seal and bearing the fine dust in the water will accelerate the wear b...

Page 164: ...onally qualified organization to test the dynamic balance after each replacement of the front and rear wheels b The balance weight must be attached to the designated plane red area of the rim Replacem...

Page 165: ...dle of the shock absorber and install it to the corresponding position use the 4 inner hexagon to reinstall the 2 M6 12 bolts 3 do not miss the installation of the lining Set and cushion rubber Then u...

Page 166: ...justment nut and the adjustment nut rubber gasket Then use a four jaw sleeve to remove the lowermost direction column adjusting nut Refer to the exploded view of the lower link board b One person supp...

Page 167: ...rque 100N m 10 2 kgf m 74 bf ft 6 Install other disassembly components a Refer to Replace the front shock absorber to replace the front shock absorber b Refer to Replace the front wheel to reinstall t...

Page 168: ...rewdriver to remove the negative bolt of the battery Then lift off the red protective cover of the positive pole of the battery use a Phillips screwdriver to remove the positive pole of the battery ta...

Page 169: ...the tail skirt with one hand and pull up until the front part of the tail skirt is separated from the middle cover blue of the fuel tank hold the rear part of the tail skirt green mark with the last...

Page 170: ...in front of the muffler and the other end is connected to the main cable do not unplug the wrong plug f Locate and pull out the plug of the magneto stator charging cable at the left frame Caution One...

Page 171: ...the frame c One person uses 14 torx wrench to extend from under the tail skirt and fix the 1 M10 1 5 55 bolt on the top of the left rear shock absorber and one person uses 14 socket ratchet wrench to...

Page 172: ...ding clamps and arrange the lines d Insert the high voltage package at the front of the engine back and install one M12 nut back on the cradle to fix the engine use 17 torx wrench to fix M12 nut anoth...

Page 173: ...173 188...

Page 174: ...xample 1 Windshield 2 Right front turn light 3 Right cover front storage box 4 Front right panel 5 Front storage box panel right decorative cover 6 Right pedal decorative cover 7 Right fuel tank cover...

Page 175: ...ethod Do not forcibly unplug the plug to prevent damage to the plug resulting in poor contact of harness connector and affecting the function of various parts When installing the harness plug please c...

Page 176: ...the buckles grasp the mark on the front cover green rectangle with your hand and pull it down in the direction of the arrow until the front cover is removed Removal of the front panel a Use 4 inner he...

Page 177: ...el with one hand and lift it up in the direction of the big arrow With the other hand press the front storage box panel at the junction of the front storage box panel and the Speedometer panel Until t...

Page 178: ...nner hexagon to remove 4 M6 14 bolts on the front vent Remove the front vents and the position lights installed on the vents and other parts Caution When removing the last bolt you must hold the front...

Page 179: ...he position pointed by the small arrow using a single character batch and then pull out the front left pedal rubber pad and the front left pedal aluminum pad upwards in the direction of the big arrow...

Page 180: ...drivers Pull the rear pedal rubber pad and rear pedal rubber pad pressure plate upward in the direction of the big arrow until the rear pedal rubber pad and rear pedal rubber pad pressure plate are re...

Page 181: ...st press the power button of the vehicle then press the seat lock switch of the vehicle to open the seat lock and then long press the power button for 2 seconds to shut down the vehicle b Hold the sea...

Page 182: ...r a Remove the 4 swell nails from the apron by 4 socket b Use a 4 inner hexagon to remove the two M6 14 bolts which fix the front of the tail skirt c Grasp the mark of the fuel tank middle cover by ha...

Page 183: ...r thumb in the direction of the arrow Push the buckle on the other side away in the same way After pushing the buckles on both sides open hold the tail light with one hand and push the middle of the g...

Page 184: ...l arrow then take it out Caution When removing the rear inner fender the rear shock absorber will fall forward In order to prevent scratches on the paint or damage to the parts the rear inner fender s...

Page 185: ...area The middle cover is gray and the right part of the fuel tank cover is red of the 4 buckle positions separated b Grasp the mark green rectangle of the right cover part of the fuel tank and pull i...

Page 186: ...ttention to the position of the torsion spring when installing g After removing the ST4 2 12 self tapping screws with a 5 inner hexagon separate the outer cover and the outer cover bracket Note that t...

Page 187: ...move the front left storage box Follow the steps for the right storage box cover to disassemble the left storage box cover Disassembly the front storage box panel a Remove the two M6x14 bolts from the...

Page 188: ...e use and malfunction of PKE please refer to the driver s manual delivered with the vehicle h Use 5 hexagon socket to remove 2 M6 16 bolts and then separate the right storage box lock bracket and the...

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TAYO ZONTES ZT125 2022, Maintenance Manual

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Summary of Contents for ZONTES ZT125 2022

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