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ENGLISH

ZS125-80 Motorcycle Ser vice
Manual

First edition (April, 2017)
The copyright of this Motorcycle Service Manual is
owned by Zongshen Industrial Group. The content
and images in the Motorcycle Service Manual are

Summary of Contents for ZS125-80

Page 1: ...ZS125 80 Motorcycle Service Manual First edition April 2017 The copyright of this Motorcycle Service Manual is owned by Zongshen Industrial Group The content and images in the Motorcycle Service Manu...

Page 2: ...ENGLISH...

Page 3: ...ual is printed We have the authority to revise this manual without notice Please understand Any part of this manual is copyrighted by Zongshen Industrial Group No entities or individuals shall be allo...

Page 4: ...ENGLISH...

Page 5: ...and Exhaust System 17 Section 4 Evaporative System EVAP 21 Section 5 Rear Driveline 23 Section 6 Frame and Accessory Mechanism 27 Section 7 Steering Gear 30 Section 8 Steel Wire Rope for Control 31 S...

Page 6: ...ENGLISH...

Page 7: ...iving high strength and rigidity The brake system is configured with front and rear disc brakes which enable stable safe and reliable braking Nice and durable wheels are made of aluminum alloy 1 Front...

Page 8: ...raking system mainly functions to exert direct control on running direction driving running speed braking lighting and signals etc to ensure the safe driving of the motorcycle The steering and braking...

Page 9: ...sts mainly of a generator magneto and a storage battery and other components When the engine drives the generator to reach a certain rotate speed the generator outputs electric energy In addition that...

Page 10: ...tter pin if applicable 3 Bolts or nuts should be fastened in an order of diagonal cross and gradually tightened 2 to 3 times to reach a standard torque value as required 4 To clean parts the use of fl...

Page 11: ...n Decomposition order and method is not absolute According to different models decomposition procedures and methods can be different Refer to the subsequent methods given in respect of demolition inst...

Page 12: ...2 Measurement The measurement method is to measure dimensions and geometrical shapes of parts with gauges and instruments and compare the obtained data with the allowable limits to determine the techn...

Page 13: ...ers and conical hand reamers etc A basic hole must be drilled before reaming Drilling a basic hole is to leave a proper processing allowance for the reaming process according to the accuracy requireme...

Page 14: ...el tank assembly saddle assembly etc on this basis install the headlamp tail lamp sidelight klaxon and storage battery assembly connect all the electrical circuits and control cables install the trans...

Page 15: ...intain a free stroke of 2mm 6mm in which process the engine should not be subject to speed increase and speed loss The free stroke whether too big or too small shall be adjusted This adjustment item i...

Page 16: ...p switch Headlamp dimming Main side stand Front and rear dampers Nut bolt fastener Front and rear tyre covers Steering mechanism bearing Odometer km 1000km 4000km 8000km 12000km A I I A R I I I L I I...

Page 17: ...allation method can reduce the direct impact of vibration on the fuel pump The fuel pump installed in the fuel tank can make the oil supply system simple and hinder the fuel leakage The fuel pump is a...

Page 18: ...ration of fuel or aging install a new fuel pipe The ignition switch must be off to stop fuel pump operating and keep the fuel from flowing outwards when installing a new fuel pipe or a new fuel filter...

Page 19: ...any of these found install a new fuel pump gasket 7 Take out the fuel pump Wash away the oil residues and moisture in the fuel tank with a cleaning agent 6 Apply an allen wrench to release six M4 12...

Page 20: ...h e m o t o r c y c l e looks not good Repair or place the tank Fuel pump The oil filter screen i s t o o d i r t y o r clogged Fuel is supplied improperly T h e m o t o r c y c l e h a s d i f f i c...

Page 21: ...or structure whose sliding terminal is driven by the throttle shaft Different opening degrees of the throttle valve leads to different resistance signals transmitted by the sensor to the ECU The syste...

Page 22: ...increases thereby feeding real time engine air fuel ratio back to the ECU 2 Demolition and Maintenance of EFI System The motorcycle EFI system has been commissioned before leaving the factory If any f...

Page 23: ...nnects the throttle valve to the engine inlet and also supports the function of the throttle valve It is simple in structure Its curved shape mainly depends on The induction system of the motorcycle e...

Page 24: ...all a new element when there is too much dust Air cleaner element Air cleaner 4 Demolition and Maintenance of Exhaust System 1 Remove the lock nuts on muffler exhaust pipe and suspension bolts on the...

Page 25: ...washer Check the muffler sealing washer for any breakage A broken muffler sealing washer needs to be replaced or re welded Every time the muffler is disassembled a new seal must be installed Caution 4...

Page 26: ...cult in starting the engine is under powered the engine idling is of instability the fuel is consumed excessively the exhaust muffler exhausts black smoke Clean or replace the filter element The filte...

Page 27: ...letely combusted mixed gas flows into the hot catalytic converter it may appear a re combustion phenomenon and lead to the catalyst converter being overheated in a way to leave the catalytic converter...

Page 28: ...damage forms fault phenomena and common maintenance methods of the evaporative system Table 3 5 Maintenance of Evaporative System EVAP Component Name Damage Form Component Fault Phenomenon Motorcycle...

Page 29: ...driving gear driven gear transmission chain chain connector transmission chain set chain adjuster buffer block and other components The power is firstly output through the driving sprocket at the end...

Page 30: ...he chain connectors and the transmission chain Check the chain connectors for any abrasion Replace the chain connectors if necessary 6 Check the transmission chain for any abrasion and deformation Rep...

Page 31: ...eplace the bearing in time if seriously abraded otherwise it will affect the normal operation of the transmission system Replace the rear drive sprocket bearing if abraded otherwise it will cause the...

Page 32: ...e set of driving and driven sprockets and the transmission chain Transmission chain The chain is too dirty or poorly lubricated The transmission chain makes an abnormal sound when transmission Rinse o...

Page 33: ...ncluded the front section frame tail frame and engine cradle The main frame is used to support the motorcycle engine transmission system control system seat cushion fuel tank and brake system etc it a...

Page 34: ...cessary If the closure panel is damaged it should be replaced If the seat cushion is damaged it should be replaced Suggestion Suggestion Check the closure Seat cushion 5 Check the rubber jacket of the...

Page 35: ...rn normally The motorcycle makes a sound when driving affecting the parking of the motorcycle Replace the return spring LHS side cover It is damaged due to a crash The LHS side cover is damaged The ap...

Page 36: ...f the steering bar is the throttle twist grip which controls the fuel flow the right handle is the front brake handle The RHS and LHS bars have been installed with the left and right combination switc...

Page 37: ...10min while pulling it back and forth to wash out the debris inside the hose 2 Soak the entire set of wire rope in mixed oil prepared by 1 1 to and lubricant for 5min while pulling it back and forth t...

Page 38: ...etween the one way valve seat and the cone of the piston rod seat is getting smaller and smaller and the damping force is increased to prevent the front damper cylinder from colliding with the front d...

Page 39: ...Check the oil seal for any abrasion on its edge and if necessary replace it 5 Remove the damper column and the damper cylinder Check the damper column and the damper cylinder for any abrasion Replace...

Page 40: ...t damper and check it for any abrasion Replace it if necessary 9 To install the front damper the damper oil must be added as specified and the standard capacity of the front damper oil is 330 5 mL 1 C...

Page 41: ...front damper column The front damper cylinder is heavily abraded or broken The front damper leaks oil The front motorcycle wheel runs off tracking affecting the comfort stability and security Replace...

Page 42: ...es of various parts of the rear fork become larger and the rear fork swings too dramatically In any of the above conditions please replace or repair the rear fork timely to ensure the riding comfort a...

Page 43: ...l rim may be a die cast rim and a spoke type rim Die cast the wheel rim and wheel hub into a whole by use of aluminum alloy and then machine it consequently forming a die cast rim Such a rim is high i...

Page 44: ...ront wheel axle and take out the front wheel axle and the front wheel assembly 4 Take out the front wheel axle bushing and check it for wear In case it is severely worn install a new one 5 Take out th...

Page 45: ...ore In case of air leak from inner tube repair it or install a new inner tube 7 In case the front wheel bearing is severely worn or damaged knock the front wheel bearing out gently using a bearing ext...

Page 46: ...heck the rear wheel axle for wear If it is worn install a new one Apply lubricating grease before installation Caution Take out the rear wheel axle Check the rear wheel hub 13 Check front rear aluminu...

Page 47: ...racking and the steering bar jitters or shakes in the driving Replace the bearing Front tire The tire is abraded excessively The tire is easy to slip in the driving and is of poor side slip prevention...

Page 48: ...brake pedal brake master cylinder oil storage cylinder the oil storage cylinder and the brake master cylinder are generally made as one in the front brake brake caliper brake disc brake pipe and other...

Page 49: ...nt wheel Remove the brake friction plate Take down the front wheel 5 Take out the speedometer and check it for any abrasion on the oil seal edge If the oil seal edge of speedometer is severely worn re...

Page 50: ...of brake disc 9 Check whether the brake pedal can return to position normally and whether the free stroke of brake pedal is too large or too small Adjust the free stroke of brake pedal to 20mm 30mm 10...

Page 51: ...its performance If the brake caliper piston cannot function properly the hydraulic brake must be repaired or replaced Fitting nut Check the friction plate 14 Check the rear brake disc for any abrasio...

Page 52: ...c diagram Read the trouble code and the description using ABS fault diagnosis tester In case A sensor distortion is indicated install a new appropriate sensor a elimination process is employed if ABS...

Page 53: ...s like braking is soft or gone Cause study 1 Poor sealing of brake fluid which leads to leakage of brake fluid 2 Brake system vacuum filling fails It fails to fill brake fluid with the 2nd circuit of...

Page 54: ...ointer to rotate The higher the speed the stronger the magnetic field of the eddy current disc Thus the torsional moment and the angle of deflection increases so the pointer has an increased angle of...

Page 55: ...e Method Instrument assembly The indicator lamp filament is burnt out The indicator lamp filament is burnt out The indicator lamp does not light Replace the bulb of the indicator lamp T h e i n s t r...

Page 56: ...ance to it This resistance is called the electronic resistance denoted by R The resistance is Ohms expressed by Different materials have different resistances For example copper iron aluminum and othe...

Page 57: ...electrical system so the company generally provides electrical schematic diagrams in motorcycle maintenance manuals and service manuals Section 2 Power Supply The power supply portion generally inclu...

Page 58: ...shell is generally marked with two upper and lower lines marked H for the upper line and L for the lower indicating the upper and lower limits of the battery Meanwhile it is also marked with positive...

Page 59: ...neto stator Apply a multimeter to measure the magneto stator resistor is in short circuit or open circuit Replace the stator if the magneto stator resistor is in a short circuit or open circuit 2 Remo...

Page 60: ...rting or fails to star t the complete motorcycle is under charged the electrical equipment fails to work properly Replace the magneto rotor Magnetism fading The magneto does not output a current The e...

Page 61: ...o Now more commonly used AC regulators are electronic An AC regulator includes a transistor diode and thyristor and other components When the magneto works the lighting and signalling coils will produ...

Page 62: ...ited it is necessary to replace it 3 Check whether the starting relay is working properly If the starting relay does not work properly it is necessary to install a new starting relay of the same model...

Page 63: ...e is damaged it is necessary to bundle it timely 5 Remove the protective tube and check it for any burn out Install a new protective tube of the same model Protective tube model 12V 20A Install a new...

Page 64: ...ontact The starting dynamo does not work or runs weakly The motorcycle fails to electrically start Check the storage battery Protective tube It is damaged or burnt out No power The starting dynamo doe...

Page 65: ...m a beam with high brightness It is mostly made of stamped aluminum The glass cover is mainly used to diffuse the light beam reflected by the condenser to ensure that a large enough area in front can...

Page 66: ...whether the tail lamp is burnt out If the tail lamp is burnt it is necessary to install a new tail lamp of the same model 3 Check whether the sidelight is burnt out If the sidelight is burnt it is nec...

Page 67: ...d l a m p filament is burnt out The headlamp filament is burnt out The headlamp does not light Replace the bulb of the headlamp Tail lamp brake lamp Ta i l l a m p b r a k e lamp filament is burnt ou...

Page 68: ...idle speed after cleaning carbon deposition in bypass airway Check the throttle body idling bypass airway Check the external joints for any leakage Check the air is distributed at correct time C h e...

Page 69: ...the abrasion of piston ring and cylinder Start engine and gently turn throttle control grip inward Observe the rev change of engine The compressing pressureisnotenough The compressing pressure is norm...

Page 70: ...heck if the CDI ignition is faulty yes yes yes yes No Non contact magneto ignition system 1 Check if the ignition power supply coil is short circuited or open circuited 2 Check if the trigger coil is...

Page 71: ...lack Exhaust muffler emits black smoke when engine runs with the medium low speed The accelerating performance is bad and idle speed is unstable But it is normal when with high speed s p a r k p l u g...

Page 72: ...fuel pipe and so on for any leakage and if the tube hoop is locked Inflate sufficient gas as required Normal pressure Too low pressure Check the tire pressure Check the brake for any drag Check the wh...

Page 73: ...ffler of 4 stroke engine emits blue and white thick smoke No Yes Yes No No Yes Improve operation method Check whether the gearshift axle is distorted or whether gearshift arm is distortedorworn C h e...

Page 74: ...uncompletely Wholly replace cluth spring Check whether drive and driven hub trough are worn to be zigzag Check whether the elasticity of cluth spring is well proportioned Repair or replace them No Ye...

Page 75: ...cle cable Measure the resistance with ohmic meter and check whether the resistance between export lead of charging coil accords with the standard value Resistance value is smaller than standard value...

Page 76: ...sassemble starting motor and check as follows 1 Check whether carbon brush is worn 2 Check whether the spring of carbon brush breaks off or its elasticity is poor 3 Check whether armature comb is worn...

Page 77: ...is power export from the export lead of illuminating coil with a bulb The bulb doesn t illuminate The bulb illuminates The the illuminating coil of generator or its export lead has open circuit or sh...

Page 78: ...Short circuit or tanct is not good Normal R e c t i f i e r h a s trouble Illuminating lamplight is weak AC supply illuminating system Replace rectifier Illuminating lamplight becomes normal Illumina...

Page 79: ...batteryis low Remove the cover of turning light and check whether of turning light is burned out Turn on off turning light switch Make short circuit for two ends of flasher with a lead or a screwdrive...

Page 80: ...age with multimeter When rubbing there is spark or the voltage is normal When rubbing there is no spark or the voltage is not normal The power wire between ignition switch and electric horn has open c...

Page 81: ...it or open circuit When rubbing there is spark The lead between brake light switch and brake light has short circuit or open circuit No Yes No Yes Dismantle high voltage wire and check whether there i...

Page 82: ...76 ENGLISH Appendix Electrical Schematic Diagram B l a c k B Re d R G r e e n G O r a n g e O B l u e U Pu r p l e P Grey H Pink K Brown N Light blue Lb Light green Lg...

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