Zontes ZT125-G1 2020 Service Manual Download Page 1

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ZT125/155-U/U1

（

EURO

Ⅴ）

Service manual

202

Summary of Contents for ZT125-G1 2020

Page 1: ...ZT125 155 U U1 EURO Service manual 2021 01 21...

Page 2: ...round glue fuel tank liner limit glue 1 6 Directional column component 12 Lower plate component 1 7 Frame side bracket 13 2 FRAME ENGINE COMBINATION 2 1 U Frame engine combination 14 Lower shroud brac...

Page 3: ...ar turn sinagl 4 6 Rear mud board 25 4 7 Rear shock absorption 26 Demolition after shock absorption rear shock absorption adjustment 4 8 Rear wheel component 1 27 Disassemble the rear rim component sp...

Page 4: ...ttle clutch cable clearance adjustment light height adjustment 44 Adjust the throttle cable clutch cable free travel adjust the headlights light height 7 2 Replacement clutch cable 45 7 3 Replace the...

Page 5: ...eft hand component 61 Disassemble left rear view mirror left hand rubber sleeve left switch 7 19 Directional lever component 62 Disassemble directional lever 7 20 Front shock absorber upper plate comp...

Page 6: ...semble surrounding component 9 2 U surrounding component 76 Decompose U surrounding component 9 3 U1 surrounding component 77 Decompose U1 surrounding component 9 4 Surrounding bracket 78 10 SIDE COVE...

Page 7: ...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 ch...

Page 8: ...her and dump switch Remove the flasher remove the rubber sleeve that connects to the mounting bracket on the frame and remove the dump switch Relay Pull out 5pcs electric injection relay directly Seat...

Page 9: ...7 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 by one hand use 8 sleeve remove...

Page 10: ...se and unplug it Remove the bolt at the bottom of the frame with a 5 hexagon socket and then remove the ECU assembly Using 5 inner hexagon socket remove 2pcs bolts then take off the ECU from the ECU b...

Page 11: ...KD150 U engine left rear cover 1 Fig 4 FRAME ELECTRONIC COMPONENT Electronic parts COMPONENT 4 PROCEDURE PKE buzzer Find and take off the PKE buzzer plug Remove the PKE buzzer by heating it back and f...

Page 12: ...uel tank liner limit glue Push out the fuel tank liner limit glues then take off Battery cushion Put off the battery cushion directly by hand Side cover cushion Remove the side cover cushion with your...

Page 13: ...n 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 1 the d...

Page 14: ...support Using the cross screwdriver to remove the side support spring and guard against the personal injury caused by spring contraction use 14 sleeve or plum blossom wrench remove the nuts and then...

Page 15: ...s bolts then take off the bracket remove 2pcs bolts then take off the bracket Reassemble the bolts to the engine after removing the bracket to prevent oil leakage Hanging piece First use a 12 sleeve t...

Page 16: ...h bar protective glue first and then clip it into the groove of the lower guard bar bracket and then assemble it to the inner crash bar bracket finally assemble the guard bar pressure plate Fig 2 FRAM...

Page 17: ...et Using 8 sleeve remove 2pcs bolts then take off the bracket remove 2pcs bolts then take off the bracket Reassemble the bolts to the engine after removing the bracket to prevent oil leakage Hanging p...

Page 18: ...the solenoid valve to the throttle body respectively Remove the side cover seat cushion rear shock absorber rear tail skirt etc to facilitate subsequent disassembly of the air filter and throttle body...

Page 19: ...nector of the throttle valve body remove the throttle cable and use an 8 wrench to remove the 2 bolts 1 Remove the throttle valve body assembly Remove the O ring check carefully for damage before rein...

Page 20: ...l become larger and affect the driving experience When assembling apply a small amount of engine oil on the upper and lower sides of the rubber strip shown in cyan as shown in the figure to reduce ass...

Page 21: ...ly and disassemble bolt and bolt with a sleeve Take off spring washer and washer Take off the sub mudguard connecting cable and rear sub mudguard assembly From the bottom take out the auxiliary fender...

Page 22: ...the bolt with a 10 sleeve remove the flange bushing the rubber pad and finally remove the retaining plate Rear auxiliary mud board component Hold the rear auxiliary mud board component use 10 sleeve r...

Page 23: ...t and right sides take off the flanging bushing and the buffer rubber Disassemble the turn signal component and fender subassembly Note that the sub mud switch cable cannot be forcibly pulled Steering...

Page 24: ...nd remove the bushing 2 and the cushion rubber 3 Pull the bottom of the rear cover down for a certain distance and then pull out the adapter cable Remove the rear fender assembly from the bike and put...

Page 25: ...e turn signal decorative cover kit to separate the front and rear covers Turn signal light assembly Unplug all the connectors of the turn signal and the license plate light and remove the auxiliary fe...

Page 26: ...ENT PROCEDURE Rear inner mudguard First of all pull out the braking oil tube and wheel speed sensor cable which are on the right side of rear inner mudguard from the rear disc brake pipe clamp Using 4...

Page 27: ...ht to loosen the bolt counterclockwise and remove the nut Person 1 shake slightly the rear wheel up and down Person 2 drag out bolt Person 1 fix the head of the bolt with a 14 sleeve person 2 remove t...

Page 28: ...embly left axle sleeve left chain adjuster Tie firmly the rear disc brake clamp and avoid it to be lifed higher than disc brake oil cup Disassemble the rear wheel axle at last Sprocket bracket assembl...

Page 29: ...endent valve vent the air before removing the rear tire Use a 12 torx wrench to remove the nut remove the washer and then remove the valve Maintenance Tire Check regularly the tire on cracks and air p...

Page 30: ...fork shaft person 2 remove the nut with a 30 sleeve Person 1 holds the rear fork assembly and the other person removes the rear fork shaft 1 with suitable tool and then remove the rear fork assembly...

Page 31: ...ss bolt on rear disc brake main pump oil cup Take off the top cover and sealing gasket Remember to rebound the pister afterwards The new arrester must fit tightly the slot See photo right below Tighte...

Page 32: ...he ground Add DOT4 braking liquid Ensure the liquid level is between UPPER and LOWER While reassemble pay attention install sealing gasket in correct position and direction Step gently on the pedal co...

Page 33: ...nd adjust gear shift rod spline of rocker arm 2 with a straight screwdriver by shoving a little bit the groove in the middle while dragging it out Reassemble after the height is suitable Pay attention...

Page 34: ...isassemble the pin Then take off the washer and pin Using 6 inner hexagon socket remove 3pcs bolts Using 4 inner hexagon socket remove bolt then take away the oil cup CAUTION While overturning the foo...

Page 35: ...ear disc brake oil cup can never be lower than oil tube interface of main pump Brake pedal assembly Using 8 inner hexagon socket remove the bolt pull out the brake pedal take off the brake pedal sprin...

Page 36: ...pedal 1 16 ZT310 X R rear pedal 1 Right footrest component 3 Fig 4 FOOT PEDAL COMPONENT PROCEDURE R front pedal Disassemble circlip Take off foot pedal pin axle Then disassemble R front pedal foot ped...

Page 37: ...rockerarm while pulling it out from gear shift axle of engine Using 6 inner hexagon socket remove 3pcs bolts Take off left foot pedal holder assembly Gear shift rod assembly Using a 14 sleeve remove...

Page 38: ...12 stainless steel 1 18 1250501 010000 GB93 6 spring pad 1 19 1251100 167000 Non standard ball head boltsM6 8 1 20 ZT310 X L front pedal 1 PROCEDURE L Foot pedal component Disassemble circlip Take of...

Page 39: ...1032142 040000 ZT310 X rear left pedal 1 11 1274200 051000 ZT310 X footrest gum cover fixed plate 1 12 1244200 024000 ZT310 X footrest gum cover 1 Fig 7 FOOT PEDAL COMPONENT Left footrest component 3...

Page 40: ...flat ground Place holder to collect wasted engine oil under the oil drain bolt Using 14 sleeve ratchet wrench remove the oil drain bolt and the combined sealing gasket Unscrew the oil filler nut on t...

Page 41: ...rs is suggested Swallowing or inhaling cooling liquid would harm human body Clean thoroughly the hands face or explosing skin every time after adding cooling liquid If cooling liquid is swalled by acc...

Page 42: ...ins to drain into the container and the body is turned to the right tilt to drain the coolant Wipe the remaining coolant on the surface of all parts with a clean cloth and then replace the drain bolts...

Page 43: ...ts that fix the auxiliary water tank and then remove the auxiliary water pipe from the bike and pull out the leaking pipe from the auxiliary water tank Water pipe Remove the hoop at both ends of the w...

Page 44: ...4021200 024000 KD150 U radiator bracket 1 PROCEDURE Water tank component Remove pipe clam then remove water tank water inlet Pull out the water pipe Water tank bracket Using 8 sleeve remove 2pcs bolts...

Page 45: ...6mm in diameter into the hole in the right side of the storage box aligns the gear shape of the adjusting bolt turns clockwise to low beam the height and rotates counterclockwise increase the height...

Page 46: ...seat Remove the clutch cable Remove the protective sleeve from the clutch cable Install the clutch cable Put protective rubber sleeve into clutch elbow After inserting the clutch cable joint into the...

Page 47: ...he rubber sleeve from the core turntable and then remove it from the cable hole in the lower part of the switch Install the throttle cable First pass the throttle cable into the cable hole in the lowe...

Page 48: ...r hexagon socket The direction of the upper board assembly wrapped with a clean cloth and then placed to prevent scratches Remove the lock washer 4 remove the upper adjustment nut 5 with a hook wrench...

Page 49: ...art of the sheath fix the stud with a 12 wrench and then remove the nut with a 10 torx wrench Grasp the shield assembly with the right hand and use the 4 inner hexagon to remove the bolt and remove th...

Page 50: ...d and remove the bolt with a 5 inner hexagon socket Refer to the steps of removing the headlight assembly first rotate the headlamp assembly forward and find the line plug connector of the auxiliary s...

Page 51: ...the bolt Then use a 10 sleeve or ring spanner to remove the nut Remove the bolt and remove the rocker arm Add brake fluid Before driving the motorcycle check whether the brake fluid level is above th...

Page 52: ...ard slot as shown on the left Lock the pin with a 5 inner hexagon socket Use a flathead screwdriver to lock the nut Repeatedly holding the brake handle until braking force is restored CAUTION The moto...

Page 53: ...e same specification type must be replaced Refer to the relevant content of the manual for details Rim Check the rim for any deformation cracks etc Rotate the rim horizontally to check for sticking sw...

Page 54: ...bolt Front disc brake caliper Using 8 sleeve remove bolt and using 14 sleeve remove bolts so that the caliper will hang down naturally It is forbidden to invert the caliper toprevent the air from ente...

Page 55: ...on to remove the bolts on both sides and remove the bushing and cushion rubber Use a 10 wrench to remove the nut and remove the gasket Slightly open both sides of the bottom of the decorative cover an...

Page 56: ...hexagon socket remove 6pcs bolts then take off the bush and cushion rubber take off the front fender lower component The inside of the front mudguard can be protected with reticle or double sided tape...

Page 57: ...sembly forward Unplug the headlights position lights and turn signals Use 5 hex socket to remove bolt for U model and 8 sleeve for U1 model to remove bolt After confirming that all the plugs are unplu...

Page 58: ...river to remove the screws on the turn signal decorative cover 3 and then remove it Headlight bracket Locate the notch of the circlip push the circlip from the pin and then remove the circlip and pin...

Page 59: ...Right head cover decorative cover assembly Remove the 2 screws at the right position light with 6 inner hexagon and take off the right position light Remove the nail at the right decorative cover with...

Page 60: ...ort of headlight 1 PROCEDURE Storage box Unplug the left hand switch stearing lock and right hand switch and arrange the wiring harness Using 4 inner hexagon socket remove 2pcs bolts take off the bush...

Page 61: ...of the instrument Instrument assembly After finding the plug of the instrument unplug it with 6 inner hexagon to remove the 2 bolts 3 and remove the instrument assembly Instrument bracket After fixing...

Page 62: ...the steps in Right Handle Assembly and Add Brake Fluid Adjusting Rocker Arm Using 6 inner hexagon socket remover 2pcs bolts take off the half cover and the left hand arm assembly Left hand rubber slee...

Page 63: ...pick up the decorative buckles hold the direction handle in one hand and remove the bolt with a hexagonal tool in one hand remove the clamp and finally remove the direction handle Instrument bracket U...

Page 64: ...slightly enlarge the slot clearance and disassemble the left shockabsorber and the right shock absorber under Remove the upper plate assembly Reflecting film Reflective sheets are sold separately for...

Page 65: ...ton or other soft materials to prevent scratching the paint surface Remove the nut with a 14 sleeve and remove the gasket cushion rubber and bushing Remove the upper plate The spacer the upper clamp a...

Page 66: ...see this step U1 model see the next step U model needs to use 4 inner hexagon to remove bolt remove bushing and cushion rubber then remove protective cover The protective cover is pasted with sponge r...

Page 67: ...pes Afterthe brake fluid is discharged remove the hydraulic control unit and wipe off the oil Be careful not to let the brake fluidcome into contact with the cable connector to prevent poor contact du...

Page 68: ...liper from the shock absorber First remove the wheel speed sensor 4 from the clamp 3 then remove the two bolts 2 and remove the wheelspeed sensor 4 and the clamp 3 from the front disc brake caliper Or...

Page 69: ...e sensor cable out of the 2 pcs wheel speed sensor clamps Remove the sensor wire after removing the 2 pcs disc brake tubing clamps Using 4 inner hexagon socket remove the bolt remove the exhaust rubbe...

Page 70: ...y b Unplug the fuel tank lock plug and USB plug Place an oil pan on the left side of the throttle valve body press down the buckle at the joint of the high pressure oil pipe and the injector and then...

Page 71: ...cover as shown by the arrow in Figure 1 Remove the fuel tank cover assembly from the bike be careful not to pull the cable of the fuel tank lock Reinstall the fuel tank cap to prevent foreign objects...

Page 72: ...ing 5 inner hexagon socket remove the bot if your motocycle had been improved Using 4 inner hexagon socket remove the bot then take off the PKE component USB component Refer to the steps above to remo...

Page 73: ...ection of the arrow to snap the lower cover Fuel tank left cover bottom plate component Remove the nut that comes wit the USB cahrging cable then take off the USB charging cable from the left cover bo...

Page 74: ...f the right cover and the lower part of the right cover Remove the plywood from the fuel tank right cover lower Remove the screw fixing the right vent with a 5 inner hexagon and take off the right ven...

Page 75: ...p is removed the float connecting rod cannot be bent or bent to avoid inaccurate oildisplay Counterclockwise rotating the fuel tank cap and then take off it be careful not to pull the nylon cord hard...

Page 76: ...r assembly and the surrounding assembly in the direction of the arrow Split the upper back of the enclosure assembly at a to both sides and remove the enclosure assembly forward U1 surrounding compone...

Page 77: ...t sides take off the bushing and the cushion rubber Separate the left surrounding component right surrounding component middle surrounding U left surrounding component Using 5 inner hexagon socket rem...

Page 78: ...ail 7 5 1221200 104000 KD150 U upgraded version surrounding middle part 1 Fig 3 SURROUNDING COMPONENT U1 surrounding component PROCEDURE U1 surrounding component Take off 7 pcs swell nail Separate the...

Page 79: ...1 PROCEDURE Surrounding upper bracket Using 8 sleeve remove bolt then take off the right upper bracket and the left upper bracket CAUTION The parts should be protected during the disassembly process T...

Page 80: ...remove the right side cover Remove the left side cover in the same way There are 4 pieces of side cover round rubber 2 assembled on the frame and 2 pieces on the rear cover CAUTION When assembling in...

Page 81: ...ove 4pcs swell nail fix the water blocking cover then take it off Using 4 inner hexagon socket remove 2pcs bolts on both sides of the front take off the bushing and the cushion rubber Using 6 inner he...

Page 82: ...left 1 7 KD150 U tail skirt middle 1 8 KD150 U tail skirt right 1 Fig 2 REAR COVER COMPONENT Rear cover component 2 PROCEDURE Rear cover component Using 4 inner hexagon socket remove 2pcs bolts take o...

Page 83: ...late lights at the arrow indications and unplug them Remove the 2 expansion nails 2 and remove the upper cover 1 U model Remove the lower cover remove the bolt with a 12 sleeve and remove the bushing...

Page 84: ...start relay and fuse box have been unplugged from the bottom of the rear cover and then pull down the components to remove Take off 4pcs round rubber the electric device box rubber left rubber and rig...

Page 85: ...cushion Assembly rear cushion When assembling the cushion check whether all the cushion rubbers are complete the seat lock is open First insert the front of the cushion into the limit hole of the cush...

Page 86: ...the front cushion bracket componet Take off 2pcs cushion rubber from the front cushion bracket Remove tool kit rubber bar then take off the driver s tool The driver s tool has been contain 4 5 6 inner...

Page 87: ...ffer sleeve Take off the right surrounding component U1 model Refer the steps remove the guard bar and the surrounding componet take off the right guard bar and the surrounding componen and the left g...

Page 88: ...omponent 2 PROCEDURE Muffler componet Take off the bushing and bushing Take off 2pcs cushion rubbe from the muffler Using 4 inner hexagon socket 2pcs bolts fix the muffler tail cover rear take off the...

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Zontes ZT125-G1 2020, Service Manual

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