Zontes ZT125-M 2022 Maintenance Manual Download Page 2

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Introduction

All the materials, illustrations, photos, etc. collected in this manual are compiled according to the latest products of ZT310-

M National IV. However, due to the continuous improvement of the product and other changes, there may be some

inconsistencies between your motorcycle and this manual. For colors or upgrades, please refer to the part codes on the official

website of Zontes. This manual will not be listed in detail; if the part names in this 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 disassembled and assembled in the same way, will not listed in this manual.

The M125/350 steps are similar to the M310, taking the M310 as an example.

If part of the content of this manual is insufficient, please refer to the "Driver's Manual" included with the bike. The latest

version of the driver's manual can be downloaded as a PDF in the model introduction corresponding to the official website of

Zontes.

GUANG DONG TAYO MOTORCYCLE TECHNOLOGY Co.,Ltd

Summary of Contents for ZT125-M 2022

Page 1: ...1 218 ZT125 310 350T M Maintenance Manual 2022 11 25...

Page 2: ...s 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 disassembl...

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: ...e pipe electrical device distribution map 21 1 Distribution map of lamps and lanterns 21 2 Throttle cable 21 3 Brake upper pump and brake hose 22 4 Calipers brake hoses and wheel speed sensors 22 5 Di...

Page 5: ...t and bolts at the muffler 54 M310 350 Spark plug 54 1 Disassemble the spark plug 54 2 Check the spark plug 56 3 Refer to the steps to remove the spark plug to restore all parts 56 M125 Spark plug 56...

Page 6: ...M350 76 2 Add coolant antifreeze to the Coolant expansion tank 76 M125 310 76 M350 77 3 Add coolant to the Radiator 77 M125 310 77 M350 78 4 Put coolant 78 M310 78 M125 78 5 Check whether the fins of...

Page 7: ...t and rear disc brakes 99 2 Replace the brake fluid 99 2 1 Replace the front brake brake fluid 99 2 2 Replace the rear brake fluid 100 3 Brake system exhaust 100 Tire 100 1 Check the tires 101 2 Repla...

Page 8: ...ht 121 4 7 Windshield failure 121 3 EFI system 122 Know Before Service 122 Error code 123 1 M310 Read the fault code through the meter 123 2 Read the fault code through the diagnostic tool 123 M125 31...

Page 9: ...arting system 144 Know Before Service 144 Troubleshooting 144 1 Starting relay 144 2 Starter motor 145 3 The starter motor runs slowly 145 4 The starter motor is working normally but the engine cannot...

Page 10: ...e relief valve 163 M350 163 3 Auxiliary water tank 163 4 Aluminum inlet pipe and aluminum outlet pipe M310 163 5 Small water tank M310 163 6 Water and oil shared sensor 163 7 Thermostat 164 7 1 Inspec...

Page 11: ...e handle 188 1 Remove the direction of the handle 188 2 Remove the components 188 3 Installation of the direction component 189 4 Installation of the direction handle cover 189 Replace the front wheel...

Page 12: ...el 205 Windshield removal 205 Removal of the front sun visor 205 Removal of the front cover 206 Removal of the front panel 206 Disassembly of headlights 206 Removal of front turn signal 207 Disassembl...

Page 13: ...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 14: ...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 15: ...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 16: ...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 17: ...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 18: ...ully 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 tem...

Page 19: ...1 times the battery capacity Charging time 5 8 hours Charging current charging time must be controlled within the current range of 0 5 to 0 8 times the battery capacity Lamp Speedometer switch descrip...

Page 20: ...king torque Tightening torque range Standard value Breaking torque M4 1 2 1 4 1 5 3 2 5 M5 2 4 2 9 4 5 3 6 4 5 8 M6 4 7 4 9 10 8 12 10 14 5 M8 10 16 12 2 20 18 28 22 34 M10 22 25 24 5 45 40 60 44 76 M...

Page 21: ...ion 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 turn s...

Page 22: ...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 23: ...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 24: ...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 25: ...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 26: ...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 27: ...noid valve intake pipe solenoid valve outlet pipe throttle valve body assembly intake manifold cylinder 6 3 M350 Fuel evaporation 1 Fuel level sensor 2 Fuel tank 3 Fuel pump 4 Oil air separator welded...

Page 28: ...side the oil tank Fuel Fuel pump filter screen Fuel pump High pressure fuel pipe Fuel injector Cylinder 6 5 M125 Fuel supply Fuel supply system Air Carbon canister Adsorption vent pipe Oil separator i...

Page 29: ...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 30: ...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 31: ...ling port 3 Secondary water tank 4 auxiliary water tank is connected with water pipe 5 main water tank inlet pipe 6 main water tank outlet pipe 7 Water and oil shared sensor 8 Thermostat 9 Water pump...

Page 32: ...e 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 Front storage box lock 16 Elec...

Page 33: ...t 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 8 Fuse Box 2...

Page 34: ...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 Front storage...

Page 35: ...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 36: ...ition coil 8 side bracket flameout switch 9 engine controller ECU 10 Rectifier 11 cushion lock 12 Dump switch 13 Windshield motor controller 14 Flasher 15 antenna 16 USB charging cable 17 Front storag...

Page 37: ...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 38: ...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 39: ...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 40: ...ubber hammer Dynamic Balancing Machine Tire raking machine Oil pan Measuring cup Funnel Taps dies Micrometer Depth gauge Vernier caliper Feeler gauge Tire pressure gauge Magnetic base dial indicator P...

Page 41: ...ll the swell nails to the installation position The outer ring is attached to the connected parts if not attached Check whether it is misaligned Press the center cylinder with your fingers or other to...

Page 42: ...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 43: ...adjust nut 15 2 1 5 0 2 the second adjust nut align the first nut Steering bearing in Steering mechanism Every5000km 3107mile inspection or clean or lubricate Front shock absorber I Rear shock absorb...

Page 44: ...adjust nut 15 2 1 5 0 2 the second adjust nut align the first nut Steering bearing in Steering mechanism Every 4000km 2485mile inspection or clean or lubricate Front shock absorber I Rear shock absor...

Page 45: ...shock absorber I Rear shock absorber I Bolts and nuts for body and engine installation T T M12 65 5 6 6 0 5 M16 80 5 8 2 0 5 Coolant I I I 3 years or 30 000 kilometers 18641 mile Gearbox oil R R Valve...

Page 46: ...avoid environmental pollution The items listed in the needle are used in regular environments If they are often used in harsh environments the frequency of maintenance should be increased Steering sys...

Page 47: ...dry with a clean non woven fabric b Replace with 2 new rubber strips one is installed in the air inlet cover the other is installed in the box Take out the new air inlet filter element and install it...

Page 48: ...oter has a shock proof sponge it needs to be placed well if not go to the next step d Clip M6 14 bolts to the inner step hole of the engine left cover and then use a 4 inner hexagon to penetrate from...

Page 49: ...r element air inlet filter element Step 1 Support the vehicle firmly Prop up the vehicle with the main bracket and put down the side brackets as shown in the figure 2 Remove the left engine cover a Us...

Page 50: ...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 51: ...ce will increase and the output power will decrease If the filter element of the engine air intake is blocked by dust the air intake resistance will increase which will reduce the heat dissipation of...

Page 52: ...air filter e Place the rubber plug and tapping nail properly to avoid loss 5 Replace the filter element of the air filter a Use a Phillips screwdriver to remove the six screws used to secure the filte...

Page 53: ...ns of the regular maintenance and lubrication table If you often ride in humid or dusty areas you should check the air filter element more frequently Be sure to inspect the waste oil pipe of the air f...

Page 54: ...ng time on the spot Large load and long term low speed driving will damage the engine and muffler It is forbidden to use leaded gasoline to avoid the loss of exhaust gas purification ability due to ca...

Page 55: ...xagon for instructions on disassembly and assembly of swell nails please refer to the pre service instructions in this chapter M310 vehicles produced before May 18 2022 have 4 expansion nails on the l...

Page 56: ...t and stable ground or a lifting platform The operation can only be performed after the engine has cooled down completely Do not pull or knock the center electrode If the replacement of inappropriate...

Page 57: ...sassembly and assembly of swell nails please refer to the pre service instructions in this chapter j Press the blue part inward at the junction of green and blue as shown in the figure pull the red an...

Page 58: ...e as soon as possible Pay attention and order when removing the plastic buckle to avoid the buckle from breaking Engine oil The vehicle must be parked on a flat and stable ground or a lifting platform...

Page 59: ...ter cover and then install it back to the engine box f Screw back the 3 nuts 1 first pre tighten the bottom 2 with a 10 sleeve and tighten the upper nut 1a with a 10 torx wrench then tighten the botto...

Page 60: ...ter idling for 3 5 minutes b Use the main bracket to park the vehicle firmly c Rotate the oil dipstick on the right side of the engine counterclockwise and remove the oil dipstick and O ring to accele...

Page 61: ...ring clockwise by hand to replace the right crankcase cover of the engine 4 Change gear box oil a Remove the left engine cover by referring to the steps for replacing the air inlet filter element b P...

Page 62: ...clean c Replace the new combination gasket 4 and install the oil drain bolt 3 and combination gasket 4 back on the engine box with the 14 sleeve Torque 25 N m 2 6 kgf m 18 lbf ft 2 Replace the fine fi...

Page 63: ...efueling port does not need to be removed to prevent foreign matter from falling into the engine a Place the oil tray under the rear of the left engine Loosen the drain bolt 3 counterclockwise with th...

Page 64: ...For vehicles produced before March 7 2022 follow this step and for vehicles produced after that skip directly to step h Use 4 inner hexagon to press down 4 swell nails center cylindrical pins and then...

Page 65: ...h sides with a 4 inner hexagon i According to this step for folding rear storage box and the monolithic rear storage box skip directly to the next step Use your fingers or a plastic crowbar to pry the...

Page 66: ...of the arrow at the same time A small amount of fuel will flow out when it is pulled out and it is forbidden to drip onto the surface of the part c Find the circlip at the bottom of the valve body 2 p...

Page 67: ...ut switch at startup without ignition check whether the motor plug can shrink back and forth and finally turn off the flameout switch to check whether the plug returns to its original position To chec...

Page 68: ...ort sleeve to remove the bolt If it is inconvenient to operate remove the battery and electrical parts box before proceeding Clamp the bottom clamp with the pliers move up to the top remove the intake...

Page 69: ...ly remove carbon deposits b Use a regular and qualified fuel cleaner to add in the amount indicated Frequent use may cause damage to the oil supply line 2 Remove the stepper motor and clean up carbon...

Page 70: ...nsor a If the idling speed is abnormal it is easy to extinguish and the spark plug and high voltage coil are eliminated the ensor needs to be removed for investigation It should not be disassembled un...

Page 71: ...perate in a dust free and dust free environment to prevent dust from entering the inside of the engine Prevent foreign matter from falling into the engine or air filter If the stepper motor sensor and...

Page 72: ...the thread core and turn the throttle while injecting c If the problem with high resistance cannot be solved after lubrication the throttle cable needs to be replaced After adjusting the gap of the th...

Page 73: ...Injection System of this manual Fuel evaporative pollutant control system M310 fuel evaporation 1 Fuel level sensor 2 Fuel tank 3 Fuel pump 4 Oil air separator welded inside the fuel tank 5 Fuel tank...

Page 74: ...7 High pressure fuel pipe 8 Carbon tank 9 Carbon tank solenoid valve 10 Solenoid valve intake pipe 11 solenoid valve outlet pipe 12 throttle valve body assembly Fuel evaporation Oil and gas oil and ga...

Page 75: ...rator inside the oil tank adsorption vent pipe solenoid valve intake pipe solenoid valve outlet pipe throttle valve body assembly intake manifold cylinder The fuel evaporative pollutant control system...

Page 76: ...nces It is necessary to select the corresponding antifreeze liquid according to the lowest possible local temperature The vehicle added to the factory is Total 35 C 31F green antifreeze M310 the total...

Page 77: ...rubber cover of the auxiliary water tank and add an appropriate amount of coolant with the aid of a funnel Hold the vehicle upright and observe whether the liquid level in the auxiliary water tank is...

Page 78: ...he tank cover firmly remove the three M6x14 bolts with the 4 hex socket and then remove them b Lift the vehicle with the lifting platform and then remove the M6x10 bolts 1 with the 8 sleeve remove the...

Page 79: ...air or low pressure water gun brush etc to remove sediment insects and other dirt on the radiator surface When using compressed air be careful not to be too close to the fins It is prohibited to dire...

Page 80: ...ll water pipes for leaks aging M310 1 Radiator 2 Coolant expansion tank 3 Aluminum water inlet pipe 4 Aluminum water outlet pipe 5 Small radiator 6 Water and oil shared sensor 7 thermostat 8 water pum...

Page 81: ...ed sensor 8 Water tank outlet pipe 9 Water tank filling port 10 Radiator assembly 11 Water pump cover assembly M350 1 Main water tank 2 Water tank filling port 3 Secondary water tank 4 Auxiliary water...

Page 82: ...r purposes 2 Replace high pressure oil pipe a Refer to steps a to j of Remove stepping motor and clean up carbon deposits in the throttle valve body first remove the cushion and storage box components...

Page 83: ...to k of Remove stepper motor and clean up carbon deposits in the throttle valve body first remove the seat cushion and storage box components and remove them as shown in the figure below b Unplug the...

Page 84: ...p filter is blocked d Whether the fuel pump is faulty e Whether the fuel is insufficient When pulling out the high level oil pipe be sure to pull it toward the axis and do not press or push or pull Th...

Page 85: ...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 86: ...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 87: ...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 88: ...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 89: ...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 90: ...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 91: ...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 92: ...sure water 1 Check the brake components a Check whether the liquid level of the front disc brake main pump and the rear disc brake main pump are above the LOWER line Check whether there is brake fluid...

Page 93: ...ate the brake handle after removing the caliper M350 Remove two M10 1 5 60 bolts with 8 hex The standard torque of the bolts is 45 50N m 4 6 5 1kgf m 33 37 lbf ft Do not operate the brake handle after...

Page 94: ...bricate the front brake handle a Use a 10 torx wrench to rotate counterclockwise to remove the nut b After grasping the handle use a 5 inner hexagon counterclockwise rotation to remove the bolt remove...

Page 95: ...er to the method of adding brake fluid to the front brake main pump to remove the upper cover and then push If the spring on the caliper falls off it needs to be reinstalled in the direction shown in...

Page 96: ...irclip is deformed it can be corrected with a hammer with appropriate force l Hold the brake handle repeatedly until the braking force is recovered 5 2 Replace the rear brake pads a Use a flat blade s...

Page 97: ...brake discs brake pads or reassembling the front and rear wheels the brake handle must be operated repeatedly until the brakes restore the braking effect Contaminated disc brake discs and disc brake p...

Page 98: ...ut affecting the rocker arm after disassembly Use a 14 sleeve to loosen the 2 bolts Then use a 12 sleeve to remove the bolt that fixes the rear shock absorber and then remove the rear shock absorber a...

Page 99: ...resistant plastic film to prevent the brake fluid from dripping onto the surface of the parts and damaging the paint layer d After wearing waterproof gloves use a Phillips screwdriver to remove the bo...

Page 100: ...ts after excluding the above two items you can try the exhaust operation The exhaust operation is similar to the previous operation of replacing the brake fluid When replacing the brake fluid a clean...

Page 101: ...to the standard pressure b The height of the wear mark on the tread protrusion is 1 6mm 0 06 in The triangle T W I mark on the sidewall indicates the location of the wear bar If the wear reaches the m...

Page 102: ...a to 100N m 10 2 kgf m 74 lbf ft f The front wheel is hung in the air to straighten the direction handle and gently push and pull the direction handle by hand to feel whether the steering mechanism is...

Page 103: ...arance a After parking the vehicle firmly let the front wheel hang in the air and turn the direction knob to observe whether the front shock absorber is leaking whether there are scratches pits rust e...

Page 104: ...ulic oil is insufficient or enters the air Whether there is too much hydraulic oil Whether the spring is axially bent and rubs against the front fork tube b The following items should be checked for e...

Page 105: ...the exhaust pipe out of the crankcase by hand d Pull the tail of the air filter outward with one hand and press the rear inner mud plate inward with the other hand Separate the air filter from the rea...

Page 106: ...oth sides lower the rear wheel assembly to the ground Nut torque standard 30N m 3 1 kgf m 22 lbf ft f Grasp the rear right shock absorber and use a 12 sleeve to remove the bolt and remove the rear rig...

Page 107: ...pulled out or pulled out of the high pressure oil pipe and cable connector to facilitate tightening with tools c Use 4 inner hexagon to remove M6 14 bolt Grasp the rear left pedal assembly and use a 1...

Page 108: ...rags 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...

Page 109: ...e 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 w...

Page 110: ...oint 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...

Page 111: ...111 218 l So far the adjustment operation of the valve clearance is completed...

Page 112: ...on without pinching the front or rear 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...

Page 113: ...and remove the gasket Knock out the 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 s...

Page 114: ...w to 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...

Page 115: ...sted with a non inductive antenna and cannot be pulled by force Unplug the PKE fuse open the rubber plug and insert it into the original standard charger DC plug Then plug the AC socket into the 110 2...

Page 116: ...n Main insurance Protect all circuits 25A ECM Protect ECM ECM relay oil pump relay and other electrical devices 15A Regular power supply Protect fans meters and anti theft device connectors 15A Hydrau...

Page 117: ...can it be started Y N Faulty right handle switch Turn to Y N Y b When the light switch is turned on the headlight does not turn on check whether the light fuse is blown if it is blown check the cable...

Page 118: ...sor key is exhausted and the specific meaning of the buzzer sound No response when unlocking The sensor key is too far away Whether the sensor key has sufficient power Y Bring the induction key close...

Page 119: ...is normal to start the engine and raise the speed but abnormal low speed can also be judged as insufficient battery power The battery needs to be charged If the power is sufficient check whether the h...

Page 120: ...uble flash button is it on There is also a problem with the double flash button The chances are small The near high beam does not light up Disassemble the handle switch and short circuit the light swi...

Page 121: ...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 122: ...Pull the engine speed above 3000 rpm d After releasing the 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 EF...

Page 123: ...fter the fault light is off during the flashing process waiting for more than 5 seconds and still no longer lights up it means that the fault code has been flashed d If you need to observe the blinkin...

Page 124: ...is open P0629 The oil pump relay control circuit is shorted to the power supply P0261 1 cylinder injector control circuit is shorted to ground P0650 MIL lamp driver stage circuit failure P0262 The 1 c...

Page 125: ...es after the engine is turned off it is a historical fault which will not affect the performance and life of the whole vehicle and will automatically disappear later EFI parts layout M310 M125 M350 1...

Page 126: ...stepping motors ECUs etc are precision parts such as unauthorized disassembly may cause damage and it is not within the scope of the three guarantees for human reasons After disassembling the throttl...

Page 127: ...el pipe Refer to the section Maintenance Fuel Pipe Fuel Pump to measure fuel pressure with a fuel pressure gauge or use a simple test method to test whether the fuel pump is normal If the fuel pump ne...

Page 128: ...ll out the plug after pressing the anti trip lock Using a multimeter to measure the static coil resistance should be 12 0 6 otherwise the injector must be replaced if it fails If you need to replace t...

Page 129: ...er pulling out the bottom Then grasp the middle of the cover press down the back of the cover and pull out the left cover at the same time d Refer to the section Maintenance Removal of Spark Plug to r...

Page 130: ...rmine 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 throttle valve body position sensor and the external inta...

Page 131: ...e oxygen sensor is hard and brittle It is forbidden to knock with hard objects or blow with strong gas otherwise it is easy to cause damage Or remove the oxygen sensor and observe the color of the top...

Page 132: ...mance is poor check whether the ECU is normal Because the ECU is more complicated and difficult to judge the elimination method can generally be used to remove the ECU from a normal vehicle of the sam...

Page 133: ...ently it is necessary to check whether the crankshaft position sensor is normal The crankshaft position sensor is installed on the right crankcase cover and integrated with the magneto stator Locate t...

Page 134: ...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 135: ...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 136: ...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 137: ...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 138: ...138 218 Electrical schematic diagram of EFI system...

Page 139: ...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 140: ...ston 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...

Page 141: ...M350 Caution The fuse box 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 thi...

Page 142: ...d 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 replaced and the sealant should be appli...

Page 143: ...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 144: ...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 145: ...heck 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 is...

Page 146: ...25 350 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...

Page 147: ...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 148: ...heck 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 Check the connectivity of the back cover...

Page 149: ...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 150: ...al 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 the...

Page 151: ...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 152: ...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 153: ...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 154: ...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 155: ...red sensor 8 Water tank outlet pipe 9 Water tank filling port 10 Radiator assembly 11 Water pump cover assembly M350 1 Main water tank 2 Water tank filling port 3 Secondary water tank 4 Auxiliary wate...

Page 156: ...irculation 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 tan...

Page 157: ...he green arrow Cylinder thermostat Thermostat outlet pipe Engine inlet pipe water pump cover M350 1 Main water tank 2 Water tank filling port 3 Secondary water tank 4 Auxiliary water tank is connected...

Page 158: ...nd move it about 40mm 1 6 in in the direction of the arrow and separate the inlet pipe of the small water tank from the thermostat Use an oil pan to receive the coolant that may remain in the pipe c P...

Page 159: ...bution diagram of each hoop is shown in the figure below M310 Coolant system hoop clamp distribution map 1 Water pipe clamp 26 2 Water pipe clamp 22 10 3 Water pipe clamp 26 4 Water pipe clamp 9 5 Wat...

Page 160: ...n the figure Pull out the plug of the cooling fan of the main water tank at the lower left side in the direction of the arrow press the anti slip snap and then pull out the plug b Remove the right par...

Page 161: ...12 bolts 2 4 Water pipe hoop 25 5 Water pump cover inlet pipe 6 Water pump cover hoop 24 7 Water pipe hoop 26 2 8 Water pump cover outlet pipe 9 Water pump cover assembly Note The bolts at the thermos...

Page 162: ...self made cap and check the tightness by ventilating from the B port Compressed air with lower air pressure can be blown from the back to the water tank from a long distance to clean up foreign object...

Page 163: ...aluminum outlet pipe M310 Check whether the weld is cracked or cracked check whether the buffer rubber is aging and cracked If the appearance is good then check the air tightness Seal one end and vent...

Page 164: ...closed for a long time and the coolant is circulated in a small circulation route regardless of the water temperature which causes the engine to overheat b The main valve is in the open state for a l...

Page 165: ...crankcase cover you can try to remove the leaking pipe because the sealant is applied before press fitting it is difficult to pull out clean it up reapply the sealant and reinstall it or directly repl...

Page 166: ...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 167: ...Disassemble the front disc brake main 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...

Page 168: ...loosen the bolt with a 12 sleeve and turn the caliper upside down so that the head of the bolt is facing down to drain the brake fluid into the oil pan Remove the bolt and the copper pad and then remo...

Page 169: ...ous description and will not be repeated here 1 caliper mounting plate pin 2 bushing 3 rubber cap 4 caliper pin 5 vent nozzle 6 vent nozzle rubber cap 7 oil seal 8 dust seal 9 piston 10 caliper pin ru...

Page 170: ...nd copper pads at the main pumps of the front and rear disc brakes Only the disassembly steps of the brake hose are explained here b Press the buckle indicated by the arrow turn the plug push rod in t...

Page 171: ...f you need to remove the hose bracket you can use 4 inner hexagon to remove the bolt and then take it off If you only remove the hose you can skip this step d Check whether the surface of the removed...

Page 172: ...2 ABS hydraulic control unit 3 OBD diagnostic interface ABS hydraulic control unit Caution Before disassembling the hydraulic control unit the positive and negative electrodes of the battery must be...

Page 173: ...brake fluid remove the 4 hose connectors and unplug the cable connectors M310 M125 M350 d Remove the 2 bolts that were put back in the front 1 Remove the hydraulic control unit and bracket assembly f...

Page 174: ...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 175: ...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 176: ...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 177: ...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 178: ...the stepper motor and cleaning the carbon deposit in the section Throttle valve body in the Maintenance chapter of this manual to remove the battery Caution The whole vehicle must be powered off befor...

Page 179: ...inal of the battery and the red test lead to the removed negative wire Pay attention to first adjust the current to the high gear and then gradually reduce to the appropriate gear c Measure whether th...

Page 180: ...th 4 inner hexagon After that remove the M6 14 with 4 inner hexagon c Vehicles manufactured before May 25 2022 Remove 2 bolts 5 from the bottom with 8 short sleeve and then pull down the rectifier and...

Page 181: ...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 182: ...182 218 Exploded view of front fork components M125 310 Directional exploded view...

Page 183: ...183 218 M350 Directional exploded view...

Page 184: ...184 218 Front fork exploded view M125 310 The M125 are similar to the M310 taking the M310 as an example...

Page 185: ...185 218 M350...

Page 186: ...186 218 Exploded view of lower link board M125 310 The M125 are similar to the M310 taking the M310 as an example...

Page 187: ...187 218 M350...

Page 188: ...30 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 t...

Page 189: ...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 190: ...the 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...

Page 191: ...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 192: ...otates and the disc brake disc deformation is detected c Touch the surface of the disc brake disc with your hands to detect obvious pits visually inspect for deep scratches and grooves 1 2 Disc brake...

Page 193: ...ce the front wheel rim and tire a Refer to Replace the front wheel to remove the front wheel assembly b Take the removed front wheel assembly to a professional organization and use a tyre raking machi...

Page 194: ...talling the front wheel use the 6 inner hexagon to tighten the two M8 35 bolts at the bottom of the right front shock absorber torque 20N m 2 0 kgf m 15 lbf ft e First use a single batch to separate t...

Page 195: ...pry open the gap on the upper connection board c Use a 6 hex to remove the four bolts of the M8x35 pry open the gaps in the lower connection plate with a flat head screwdriver and remove the left fro...

Page 196: ...ng the brake pipeline After disassembly make sure that all parts are installed correctly Appropriate amount of grease should be applied when installing the bearing The M125 steps are similar to the M3...

Page 197: ...link plate in turn and then screw in a steering column adjusting nut and tighten the steering column adjusting nut with a four jaw socket Torque 50N m 5 1 kgf m 37 lbf ft make sure that the upper link...

Page 198: ...198 218 difference is that the M350 has one less adjusting nut and one more step to remove the connecting plate...

Page 199: ...screwdriver 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...

Page 200: ...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 201: ...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 202: ...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 203: ...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 204: ...example 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 cov...

Page 205: ...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 206: ...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 207: ...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 208: ...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 209: ...hexagon to remove 1 non standard M6 14 bolt on the left decoration cover of front storage box panel use 4 inner hexagon to remove 1 swell nail on the left decoration cover of the front storage box pa...

Page 210: ...hod Disassembly of the foot pedals and trim cover a Protrude the rear pedal rubber pad and rear pedal rubber pad pressure plate from the position indicated by the small arrow with the Slot type Screwd...

Page 211: ...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 212: ...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 213: ...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 214: ...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 215: ...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 216: ...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 217: ...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 218: ...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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Zontes ZT125-M 2022, Maintenance Manual

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