Zontes ZT125-Z2 Service Manual Download Page 55

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7-FRONT FORK COMPONENT

CHK

ADJ

NO.

PART NO.

PART NAME

QTY

CAUTION

1251100-102000 Non

－

standard bolt M6×16(304 stainless steel)

1251700-059093 Flanging bushingφ6.4×φ9×8

＋

φ18×2(color zinc)

1244100-052000 Buffer rubber of flanging bushing (φ8.5×φ14×1)

1221200-097000 ABS hydraulic control unit protective cover

1241200-062000 3M sponge pad (50×15×2)

1244100-081000 Black foam single side tape

0.12

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

1274100-007000 ZT250

－

S flanging sleeve(φ6.4×φ9×6

＋

φ20×2)

4021200-027000 KD150

－

U hydraulic control unit bracket (two

－

stage)

1244100-004000 ZT250

－

S Flanging bushing buffer

Fig.18 FRONT FORK

COMPONENT

ABS brake system 1

PROCEDURE:

●

Hydraulic control unit components

First use a 14# sleeve to loosen the bolts of the 4 disc brake oil pipes and then tighten them slightly to prevent

oil leakage.
Use 4# inner hexagon to remove bolt

⑴

, remove bushing

⑵

and cushion rubber

⑶

, then remove protective

cover

⑷

. The protective cover

⑷

is pasted with sponge rubber pad

⑸

and tape

⑹

.The length of the tape

⑹

is 1

meter. Here you need to cut 2 sections of 60mm in length and paste it to the position shown in the figure

Push the cable connector push rod away and unplug the connector.

Use a 8# sleeve to remove the 3 bolts

⑺

at the bracket, and pull out the hydraulic control unit assembly.

Use a 4# inner hexagon to remove the 2 bolts

⑴

fixing the hydraulic control unit, and remove the bush

⑻

and

bracket

⑼

. Remove the cushion rubber

⑽

from the support

⑼

CAUTION:

●

The seat cushion, fuel tank component, side cover and right surrounding component must be removed in

advance.

●

Be sure to disassemble the muffler and engine after they have cooled down completely. The horizontal support

of thevehicle should be fixed before disassembly and assembly work.

●

The precautions for brake fluid are described in the previous section.

Summary of Contents for ZT125-Z2

Page 1: ...2021 1 6 ZT125 155 Z2 EURO V Service manual ...

Page 2: ...ver round glue fuel tank liner limit glue 1 6 Directional column component 11 Lower plate component 1 7 Frame side bracket 12 2 FRAME ENGINE COMBINATION 2 1 Frame engine combination 1 13 Disassemble guard bar assembly 2 2 Frame engine combination 2 14 Lower shroud bracket engine 3 INTAKE SYSTEM COMPONENT 3 1 Intake system component 15 Air filter filter Carbon canister 3 2 Throttle valve body compo...

Page 3: ...ment 5 2 Right footrest component 1 26 Disassemble the right foot support component 5 3 Right footrest component 2 27 Decomposition brake pedal component 5 4 Right footrest component 3 28 Disassemble the right pedal component 5 5 Left footrest component 1 29 Disassemble the left foot support component and the shift lever component 5 6 Left footrest component 2 30 Decomposition shift lever componen...

Page 4: ...eed sensor component front mud plate component 7 10 Head and headlights component 1 46 Remove the headlight 7 11 Head and headlights component 2 47 Disassemble headlight component 7 12 Head and headlights component 3 48 Disassemble headlight bracket head cover rear shell 7 13 Speedometer component 49 Disassemble speedometer and bracket 7 14 Left hand component 50 Disassemble left rear view mirror ...

Page 5: ...uel tank cover component 8 4 Fuel tank cover component 3 61 Disassemble fuel tank cover component 8 5 Fuel tank component 62 Disassemble fuel tank and fuel pump 9 SURROUNDING COMPONENT 9 1 Surrounding component 63 Disassemble surrounding component 10 SIDE COVER COMPONENT 10 1 Side cover component 1 64 Decompose side cover component 10 2 Side cover component 2 65 Decompose side cover component 11 R...

Page 6: ...uffler decorative cover Guangdong Tayo Motorcycle Technolog Co Ltd All rights reserve All the information illustrations and photographs collected in this manual are compiled according to the latest products However there may be some inconsistencies between your motorcycle and this manual due to the continuousimprovement of the product and other changesFor colors or upgrades please refer to the par...

Page 7: ...ove 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 lock Find and take off the plug of the seat lock and cut off binding Using 4 inner hexagon remove 3pcs bolts then take off seat lock Canister solenoid valve First unplug the two oil pipes connecting the carbon canister to the solenoid valve ...

Page 8: ...07 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 bolts by another hand then take off the horn Shut down switch Find and take off the plug of the shut down switch cut ribbon Using 6 inner hexagon socket remove 2pcs bolts then take off shut down swit...

Page 9: ...start relay and main hamess ECU Turn the ECU cable plug clockwise 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 bracket CAUTION When Take off the plug can t drag any cable 1 If the part code is empty it indicates that the part has multiple states or ...

Page 10: ...ngine left rear cover 1 PROCEDURE Flasher Find and take off the flasher Rectifier Using 8 sleeve remove 2pcs bolts then take off the rectifier shroud and bushing Find and take off the rectifier plug then take off the rectifier Engine left rear cover Using 8 sleeve remove 2pcs bolts then take off the engine left rear cover CAUTION When Take off the plug can t drag any cable Fig 4 FRAME ELECTRONIC C...

Page 11: ...e 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 hand directly Frame waterproof rubber plug Remove the 6pcs frame waterproof rubber plugs with your hand directly Clamp First take the throttle line off the clamp hold the clamp by one hand use 8 sleeve remove bolt by another hand take o...

Page 12: ...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 down connected plate selfmade with blowout patch component has been contains the Steering column down dustproof cover PROCEDURE Dissembly Remove the lock washer Remove the top adjusting nut by using a speci...

Page 13: ... 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 remove bolts Remove the side support and bush paint the lubricating grease on the bush when re assembling then put it into the frame CAUTION Remove the wind deflector component handle bar component st...

Page 14: ...rocess single operation is strictly prohibited All standard parts must meet the standard torque value during reassembly PROCEDURE Guard bar component First remove the lower fairing assembly Take off rubber Grasp the right crash bar assembly firmly and use 8 inner hexagon to remove the hexagon socket bolt remove the protecting rubber and install the shaft sleeve Refer to the above steps to remove t...

Page 15: ...lts 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 to cover the head of the bolt then use a 12 sleeve to remove the nut remove the bolt the upper right hanging piece and the upper left hanging piece Bracket Engine hanger First use a 14 sleeve to cover the ...

Page 16: ...ar shock absorber rear tail skirt etc to facilitate subsequent disassembly of the air filter and throttle body First use 4 inner hexagon to remove the 3 bolts on both sides of the frame Loosen the hose clamp assembly at the end of the air filter and move the clamp out toward the air filter and pull out the air filter outlet pipe from the throttle valve body Use pliers to clamp the hoop on the gas ...

Page 17: ...le 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 reinstalling Use a 10 sleeve to remove the bolt and then remove the retainer and remove the fuel injector After loosening the clamp remove the throttle valve body assembly and then remove the clamp Throttle valve body after ...

Page 18: ...ll 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 assembly resistance Oil pipe and water pipe Avoid water into the air filter when washing the motorcycle Can pulled out the oil pipe and water pipe to release if into small water keep no water inside bef...

Page 19: ...ONENT Rear mud board 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 inner hexagon socket remove 2pcs bolts take off the brake pipe clamp Using 4 inner hexagon socket remove 2pcs bolts on the left of the rear mud board take off the flanging bushing bu...

Page 20: ...e 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 the nut with a 14 sleeve Lift the rear shock absorber towards the arrow direction and drag out bolt Take off the rear absorber at last Adjust the rear absorber Using hook spanner to loosen adjustive nut Rotate adjustive nut If the nut is rotated tow...

Page 21: ... right chain adjuster right axle sleeve rear tire and rim assembly 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 assembly Put down the rear wheel assemble horizontally Take off nut with 14 sleeve Take off sprocket sprocket bracket Pull out the sprocket gum cu...

Page 22: ...clude semi hot melt rubber Area with too high temperature is not suitable If temparature of outdoor is too low storing the motorcycle in warm place or indoor is suggested in order to avoid frost crack Normal temperaturestandard 250kPa Rim Check if the rim has deformation or crack Support the rim horizontally and check if it can rotate smoothly Specification of oil seal on rear rim is φ47 φ28 7 Bea...

Page 23: ...rear 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 with suitable tool and then remove the rear fork assembly Rear fork rear resistant block Remove the bolts flanging bushing with a 4 inner hexagon socket then turn off the rear fork assembly using 4 inner hexagon socket remove 2pcs bolts take off the bracke...

Page 24: ...oss 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 Tighten the pin axle with inner hexagon socket tool Tighten rolling axle with socket sleeve Tighten nut with strait screwdriver Step on braking pedal several times until braking force is recovered CAUTION ...

Page 25: ...een UPPER and LOWER While reassemble pay attention install sealing gasket in correct position and direction Step gently on the pedal constantly Do not ride the motorcycle until the braking force is recovered CAUTION Support the motorcycle well on flat ground before checking Check regularly if the braking liquid surface is between UPPER and LOWER If liquid surface is below LOWER check the arrester ...

Page 26: ... and adjust gear shift rod spline of rocker arm 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 to the aligning of the groove in the middle Adjust the height of brake pedal Follow the direction of arrow and loosen Nut with a 14 open spanner Spin the adjustment rod bolt with a 10 open spannerand...

Page 27: ...disassemble 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 foot pedal holder keep the components nearby well protected in case they are scratched Mind the disc brake oil tube while overturning the holder Support the motorcycle properly while disassembling in ca...

Page 28: ...sc 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 spring and the washer Rear disc brake oil cup holder Using 4 inner hexagon socket romove the bolt take off the oil cup bracket CAUTION Applying lubrification on inner surface of brake pedal bush can reduce resis...

Page 29: ... pedal 1 16 ZT310 X R rear pedal 1 After sales PROCEDURE R front pedal Disassemble circlip Take off foot pedal pin axle Then disassemble R front pedal foot pedal spring R rear pedal Disassemble circlip Take off foot pedal pin axle Then pull out R rear pedal Take down positioning plate steel ball spring After sales parts for pedal component Hold tightly the R front pedal Disassemble bolt with a 10 ...

Page 30: ...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 bolt Separate left foot pedal component and gear shift rod assembly from left foot pedalholder assembly Take off foot pedal holder washer CAUTION Support the motorcycle properly while disassembling in case it falls down Pay a...

Page 31: ...B70 2M5 12 stainless steel 1 18 1250501 010000 GB93φ6 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 off foot pedal pin axle Take off L foot pedal foot pedal spring from foot pedal holder Gear shift rod assembly Disassemble on both sides nut wit a 10 sleeve and bolt with a 8 open spanner Disasse...

Page 32: ...0 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 PROCEDURE L rear foot pedal Disassmble circlip with a tool Take off foot pedal pin axle Then pull out L rear foot pedal Take off positioning plate steel ball spring After sales parts of foor pedal with rubber Hold the L rear foot pedal tightly using 3...

Page 33: ...n 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 the right side to speed up the oil outflow Using 24 sleeve ratchet wrench remove the coarse filter cover component take off the spring and the strainer Take off the O ring from the coarse filter cover...

Page 34: ...ling 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 accident please contact toxication center or hosipital If it s inhaled please move to open air If it s spilt to the eye clean it with big quantity of clean water and see doctor in time Be sure the cooling liquid is far away from children or pets...

Page 35: ...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 and copper pads It is recommended to replace them with new bolts and copper pads Add cooling liquid Slowly pour new coolant into the filling port of the water tank filling port and do not cover the c...

Page 36: ...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 water inlet pipe at the bottom left of the water tank and pull it out remove the two hoop Move the bolts of the hoop on the small circulating water pipe on the upper left side of the water tank out of the raised part of the water pipe joint pull out the ...

Page 37: ...7 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 take off the water tank cover bracket and the radiator bracket CAUTION Cooling liquid is toxic Avoid strictly eye or skin contact For more details see Attention of previous page Do not disassemble ...

Page 38: ...be achieved using 14 open spanner loosen the nuts and rotate the adjustment screw and finally tighten the nuts and Light height adjustment Insert a PH2 type Phillips screwdriver diameter 6mm into the dimming hole on the right rear side of the wire storage box from the small hole under the headlamp bracket align the adjusting bolt turn clockwise to increase and counterclockwise to decrease the beam...

Page 39: ...arm seat Remove the clutch cable Remove the protective sleeve from the clutch cable Install the clutch line Put protective rubber sleeve into clutch elbow After inserting the clutch line joint into the rocker arm screw the nut and the adjusting screw to the groove on the rocker arm Assemble the clutch cable into place according to the original alignment Rotate the nut up to the top of the thread o...

Page 40: ...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 lower part of the switch Fit the cylindrical connector of the throttle cable into the turntable on the right hand gripper Return the oil return line card to the limit slot provided on the fuel line Use a 5 inner hexagon socket lock the bolt to a torque of 8 to ...

Page 41: ...pacer and remove the bolt with 6 inner hexagon socket The direction of the upper board assembly wrapped with a clean cloth and then placed to prevent scratches Remove the lock washer remove the upper adjustment nut with a hook wrench and remove the pad If the steering resistance is too large turn the lower adjustment nut counterclockwise If the brake is slightly swaying or swings rotate clockwise ...

Page 42: ...use the tool to press the convex parts at both ends of the elastic block on the balance block and pull out the balance block assembly and then put the right handle Remove the rubber sleeve Right handlebar half cover Hold the front disc brake main pump with one hand and remove the bolt with a 6 inner hexagon socket remove the half cover of right handle bar CAUTION The motorcycle should be fixed aft...

Page 43: ...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 the LOWER marking If not check the brake disc or brake disc for wear and whether there is any oil leakage or oil leakage in the brake system Abnormal needs to add brake fluid The brake fluid can only be adde...

Page 44: ... 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 motorcycle support should be fixed before operation Check the brake discs and brake discs regularly for wear Regularly check if the brake fluid level in the observation window of the front disc brake master pump is 3 4 It is strictly...

Page 45: ... disc Tire and rim component Disassemble tire valve cap Deflate the tire with tools Then disassemble the rear tire with professional tire changing machine Disassemble the tire valve with suitable tool CAUTION Use a suitable tool to support the motorcycle to prevent accidents caused by dumping during disassembly Take care when disassembling tires and rims to prevent damage to the material After rep...

Page 46: ...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 entering and causing the brake to fail Front mud board component Hold the front mud board componet with your hand and then remove the 4 bolts with a 4 inner hexagon socket and remove the bushing and cushion rubber R...

Page 47: ...olts 1 in Figure A Turn the stearing to the far right and remove the 2 bolts 1 in Figure B Use scissors to cut off the tie in Figure C Unplug all the plugs in Figure D and remove the headlights CAUTION Pay attention to the force when removing the cable and unplugging the plug and the cable to avoid damage The head unit should be supported during the disassembly process and protective measures shou...

Page 48: ...0300 066000 KD250 J head cover pad 1 PROCEDURE Left and right head cover Remove the 6 bolts with a 4 inner hexagon take out the bushing cushion rubber and remove the left head cover and right head cover Windshield Use 4 inner hexagon to remove 3 bolts 1 take out bushing 2 cushion rubber 3 and take off windshield 5 The rubber pad on the upper part of the headlight rear shell needs to be cut into tw...

Page 49: ...After removing the headlights and arranging the wiring harness you can directly remove the hood rear shell from the motorcycle and remove the two wire insertion clips from the hood rear shell Headlight bracket Use 4 inner hexagon to remove 2 bolts 3 then use 10 torx wrench to remove the 2 bolts at the lower link plate remove the bushing you can take out the headlight bracket and finally remove the...

Page 50: ...tand After fixing the instrument use a 10 sleeve to respectively remove the nut and the gasket that come with the instrument Separate the instrument bracket assembly from the instrument Remov the side cover round rubber from the instrument support CAUTION Protective measures must be taken to prevent scratches on the instrument and decorative cover Refer to the manual for details about the function...

Page 51: ... and balance block assembly Use a blow gun to blow the left hand grip between the rubber sleeve and the direction handle tube while moving the rubber sleeve inward until the balance block positioning hole is exposed Use the tool to press the convex part at both ends of the elastic piece on the balance block and pull out the balance block assembly Use a blow gun to blow the left hand grip and the d...

Page 52: ...OCEDURE Directional components Using a blade to 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 CAUTION Protect protective measures to prevent scratching the appearance of the instrument case and the decorative cover When assembling the clamping block first tighten th...

Page 53: ...crewdriver into the slot of the upper and lower plates to 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 sale no replacement shock absorption The heat reflecting sheet can be movedback and forth by a hot air blower to reduce the viscosity of the d...

Page 54: ...otton 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 and the direction handle are disassembled CAUTION Protect protective measures to prevent scratching the appearance of parts When reassembling it is necessary to use the direction to ensure that the c...

Page 55: ...n tighten them slightly to prevent oil leakage Use 4 inner hexagon to remove bolt remove bushing and cushion rubber then remove protective cover The protective cover is pasted with sponge rubber pad and tape The length of the tape is 1 meter Here you need to cut 2 sections of 60mm in length and paste it to the position shown in the figure Push the cable connector push rod away and unplug the conne...

Page 56: ...e 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 due to corrosion RC HU is connected to the hydraulic control unit and rear brake caliper RMC HU is the rear disc brake main pump FC HU is the front disc brake caliper FMC HU is the front disc brake main pump FMC HU The oil pipe front disc brake m...

Page 57: ...ake the front disc brake caliper from the shock absorber First remove the wheel speed sensor from the clamp then remove the two bolts and remove the wheelspeed sensor and the clamp from the front disc brake caliper Organize the wheel speed sensor line neatly Using 8 sleeve remove the bolt at the front mud board Removing 2 pcs bolts on the bottom of the left water tank take off the oil pipe bracket...

Page 58: ...sensor cable connector and pull it out Pull the 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 rubber cap then take off the wheel speed sensor cable Rear disc brake caliper Refer to the steps of removing the rear wheel assembly in the front remove the re...

Page 59: ...the right side of the bike Notice that the buckle of the fuel pump plug is on the inside and cannot be removed forcibly Unplug the fuel pipe connected to the dump valve of the carbon canister on the left side of the bike Grab the head of the fuel tank assembly with one hand and pull it back and with the other hand grab the rear part and lift it up and shake it left and right Remove the fuel tank a...

Page 60: ...ative cover and right decorative cover to the direction of the arrow and take it out with sharp objects such as a word batch The buckles here are all inverted buckles please remove them carefully Do not use excessive force to damage the buckles Use 4 inner hexagon to remove 6 bolts 3 and remove left inner plate and right inner plate Remove the self tapping nail fixed on the left bottom plate with ...

Page 61: ...10 dual USB charging cable 1 11 1220300 146000 SK150 Z fuel tank left decorative cover bottom plate 1 PROCEDURE Fuel tank decoration cover assembly Use 4 inner hexagon to remove 2 bolts take off the bushing cushion rubber Then use 4 inner hexagon to remove 2 bolts remove gasket cushion rubber bushing Remove the left decorative bottom plate and the right decorative bottom plate and remove the 6 spl...

Page 62: ... 150000 SK150 Z fuel tank right bottom plate 1 9 1220300 149000 SK150 Z fuel tank left bottom plate 1 PROCEDURE Side cover front assembly Take the front part of the left side cover and the front part of the right side cover out in the direction of the arrow and remove the 2 splints and 4 buckles Remove the 4 bolts fixing the left bottom plate and the right bottom plate with a 4 inner hexagon and r...

Page 63: ...k sub assembly Remove the rubber strip from the fuel tank head cover pad Use the key to remove the fuel tank cover lock 3 The direction indicated by the arrow is the front of the bike Do not install the fuel tank lock backwards otherwise the fuel tank will be damaged Turn the fuel tank over remove the dump valve at the bottom in the direction of the arrow and then remove the fuel pipe connecting t...

Page 64: ...OCEDURE Surrounding components Use 4 inner hexagon to remove the 4 bolts that surround the component remove the bushing cushion rubber then the surrounding component can be removed Use a 4 inner hexagon to remove the 2 bolts on the middle part of the air deflector remove the bushing cushion rubber take out 4 expansion nails and remove the middle part of the air deflector Remove 2 pieces of splints...

Page 65: ...g φ8 5 φ14 1 4 4 1224100 010000 ZT250 S swell nail 2 Fig 1 SIDE COVER COMPONENT Side cover component 1 PROCEDURE Side cover assembly Use 4 inner hexagon to remove 4 bolts 1 take off the bushing 2 and cushion rubber 3 Remove the 2 expansion nails at the back of the side cover assembly CAUTION The parts should be protected during the disassembly process When removing the buckle pay attention to the ...

Page 66: ...Z2 right cover bottom plate 1 PROCEDURE Side cover assembly Pull out the rear part of the left side cover and the rear part of the right side cover from the frame and remove the 2 buckles on the rear of the side cover Then pull out the left side cover bottom plate and the right side cover bottom plate from the frame CAUTION The parts should be protected during the disassembly process When removing...

Page 67: ...0 Z2 rear cover right 1 6 KD150 Z2 rear cover left 1 Fig 1 REAR COVER COMPONENT Rear cover components PROCEDURE Rear cover components Remove the 6 bolts 1 with 4 inner hexagon and take out the bushing 2 and the cushion rubber 3 Remove the left part of the rear cover the right part of the rear cover from the motorcycle and then remove the 2 pieces of clip from the rear cover CAUTION The cushion sid...

Page 68: ...00 002051 SK150 Z rack dark gray matte 1 Fig 2 REAR COVER COMPONENT Rear armrests and shelf components PROCEDURE Rear armrests and shelf components Remove one bolt with 4 inner hexagon Use a 12 sleeve to remove 5 bolts 2 Remove the rear armrest and the shelf from the motorcycle and remove the 4 bolts with 6 inner hexagon CAUTION The cushion side cover assembly rear cover components need to be remo...

Page 69: ... Z2 tail light 1 PROCEDURE Taillight assembly Use 4 inner hexagon to remove 2 bolts take off the bushing cushion rubber Locate and unplug the tail light connector at the position indicated by the arrow remove the tail light in the direction of the arrow and remove the splint on the tail light CAUTION The side cover seat cushion rear armrest and other components need to be removed in advance The ma...

Page 70: ... sleeve to remove the 4 bolts 1 and remove the bushing 2 and the cushion rubber 3 Pull down the bottom of the rear cover for a certain distance and then pull the plug of the adapter cable out of the small hole pointed by the arrow Remove the rear fender assembly from the bike and put it away Cover Use 4 inner hexagon to remove 2 bolts then remove the bushing and cushion rubber and then remove the ...

Page 71: ...nplug all the connectors of the turn signal and the license plate light and remove the auxiliary fender adapter cable Remove the 2 pieces of nuts from the turn signal bracket Remove the 3 screws that come with the license plate light and then remove the license plate light Grasp the left right turn signal and use a 17 open end wrench to remove the nut that comes with the turn signal remove the spr...

Page 72: ...d take out the upper cover of the electrical device box 4 Gel battery assembly First take out the end of the battery strap close to the positive electrode then pull up the gel battery and fix it pull off the black protective cap to remove the negative electrode then pull off the red protective cap to remove the positive electrode remove the battery finally tie the battery Take off When reinstallin...

Page 73: ...m assembly Remove bolt and nut with 4 inner hexagon and 10 torx wrench Pull out the fuse box and the starting relay from the bottom of the rear cover without removing it the ECU plug does not need to be pulled out you can pull down the entire rear cover and remove the entire rear skirt Take out the battery holder from the rear cover The battery rubber pad is a double sided tape pasted on the batte...

Page 74: ...f the cushion when you hear a click Assembly cushion When assembling the cushion check whether all the cushion rubbers are complete Insert the front part of the cushion first After the assembly is in place shoot the rear part of the cushion firmly When you hear the click sound it indicates that the cushion lock has been assembled Cushion rubber purchased separately The corresponding installation p...

Page 75: ... remove the nut then take off the bolt Hold the buffer component then use 6 inner hexagon socket or 12 sleeve remover the nut Hold the bottom of the fender return pressure package with one hand and grab the flange at the exhauster to remove it Wrap the flange with a rubber band or rope to prevent the flange from moving back and forth on the front elbow and causing scratches Take off the exhaust se...

Page 76: ...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 spring pad then remove the muffler tail cover rear On the back of the muffler anti scalding using 4 inner hexagon socket remove the bolt fix the muffler tail cover front take off the spring pad Grasp the muffler tail cover then using 4 inner ...

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