Zontes ZT250-R Service Manual Download Page 1

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ZT250-R

（

EURO/IV

）

2021/

Service manual

Summary of Contents for ZT250-R

Page 1: ...ZT250 R EURO IV 2021 03 01 Service manual...

Page 2: ...ne oil 10 Side support Frame drain bolt assembly 1 6 Rear pedal component 11 Rear pedal component 2 FRAME ENGINE COMPONENT 2 1 Frame engine component 12 Hanging piece Bracket Sprocket cover 3 INDUCTIO...

Page 3: ...nent 4 10 Replace the rear brake pads 25 4 11 Rear brake main pump adds brake fluid 26 5 PEDAL COMPONENT 5 1 Pedal height adjustment 27 Shift lever brake pedal height adjustment 5 2 Right pedal suppor...

Page 4: ...eed sensor component 7 10 Head parts component 1 45 Dismantled head parts component 7 11 Head parts component 2 46 Dismantled the front turning light and head light rear cover 7 12 Head cover upper pa...

Page 5: ...Fuel tank middle cover Fuel tank cover Fuel tank lock 8 4 Fuel tank left and right cover assembly 60 Dismantled Fuel tank left and right cover assembly 8 5 Inner fuel tank 61 Dismantled inner fuel ta...

Page 6: ...ffler flange 12 2 Dismanted mulffer 2 72 Dismanted muffler component 12 3 Mulffer component 73 Dismanted muffler component 13 LOWER WIND DEFLECTOR COMPONENT 13 1 Lower wind deflector component 1 74 Di...

Page 7: ...ng bracket on the frame and remove the dump switch with the same method then separate the dump switch Relay head light diode Pull out the electric injection relay large lamp diode and the side stand r...

Page 8: ...GB70 1 Hexagon socket screw M8 16 color zinc 2 FIG 2 FRAME ELECTRONIC PARTS COMPONENT Electronic parts COMPONENT 2 PROCEDURE Horn and support Remove the bolts with the inner hexagon tool and remove t...

Page 9: ...from the collection clip then use the straight screwdriver to pick up the middle part of the cable clip Then take cable collection clip off Inner fuel tank ficx glue cushion Use both hands to hold th...

Page 10: ...ill shake slightly too tight can lead to inflexibility resulting in safety hazards If you have the ability and the right tool you can change the shaft ring and the dustproof cover During the replaceme...

Page 11: ...The oil cooling joint must be tightened well when re assembling which meets the standard torque value Realease the frame tube enging oil Put the oil pan at the bottom use the appropriate tool to remov...

Page 12: ...edal pin shaft out with tools Pull the pedal or outward Assemble rear pedal Place one side with two holes of pedal horizontally and put the pedal spring in the pedal or in the small hole Put the steel...

Page 13: ...to cover the head of the bolt and remove the nut with the sleeve Can not remove the bolt and the hanging piece Engine middle part frame and rear forklift component Use the sleeve to cover the head of...

Page 14: ...rd ring near the injector fixator to unplug the high pressure oil pipe as picture shown smoking and lighting fires are strictly forbidden during disassembly Air filter Remove the bolts with the inner...

Page 15: ...ve the bolts with the inner hex tool Remove thecarbon tank from the left side of the frame and remove the plywood nut Desorption tubing Clamp the pipe clamp on both ends of the desorption tubing and t...

Page 16: ...t off the filter core by blowing dust gun in the filter element If the blowback causes the dust to be unable to clean up the engine will be damaged or the induction resistance will become larger and a...

Page 17: ...ull straight the clip Remove bolt take off the clip and disc brake oil pipe clamp Use plum blossom wrench to tightent the nut and disassemble bolt which is close to ZONTES mark with a sleeve And remov...

Page 18: ...iron support front section 1 PROCEDURE Retaining plate Remove the bolts and remove the flange bushing the rubber pad and finally remove the retaining plate Aluminum alloy bracket Remove the 2 pcs of...

Page 19: ...cushion rubber Flip to the back remove the nut that comes with the rear reflector remove the clamp and the back reflector Remove the plate cushion rubber and remove the 2 plywood nuts on the back of t...

Page 20: ...service PROCEDURE Rear license light Grip the rear turning light bracket then disassemble three bolts d on the license light Rear turning signal Disassemble bolts three b and one d on the diagram left...

Page 21: ...ORKLIFT COMPONENT Rear inner mudguard 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...

Page 22: ...f the bolts and respectively and one person removes the nut with a sleeve Person 1 shakes the rear wheel up and down slightly Person 2 drags out bolt Person 1 holds the motorcyclefirmly Person 2 lifts...

Page 23: ...Take off 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...

Page 24: ...ntainence Tire Check regularly the tire on cracks and air pressure If the tire is ware to the marker change the tire with same specification See details in user manual Ingradiant of tire include semi...

Page 25: ...off the disc brake oil pipe and wheel speed sensor from the disc brake oil pipe clamp 4 loosen the bolt 3 and take off the disc brake oil pipe clamp The rear disc brake caliper is placed well and can...

Page 26: ...ad After all you should recover in time Replace the new disc brake disc the brake disc must be stuck to the card slot as shown in the lower right corner Lock the pin shaft with the inner hexagon tool...

Page 27: ...ER and LOWER If the liquid level is below LOWER check the brake disc wear condition and the brake system leakage first If swallowed brake fluid the poison control center or hospital should be contacte...

Page 28: ...he appropriate height then lock nut 1 nut 4 If above method suitable position once the nut bolt and can be removed use a screwdriver to spline radial the middle slot open slightly pull out at the same...

Page 29: ...ways be kept higher than the line a parallel to the ground to prevent gas from entering the oil circuit and causing brake failure Use pliers to remove the opening pin and remove the washer and pin Rem...

Page 30: ...al support component 2 PROCEDURE Front right pedal assembly Use the tool to remove the circlip remove the pedal pin and then remove the front right pedal assembly and the pedal torsion spring brake pe...

Page 31: ...rt component 1 PROCEDURE Left foot pedal support compenent Remove the nut by using the spanner wrench remove the bolt and insert a screwdriver into the slot to push the spline rocker slightly apart an...

Page 32: ...ring pad 1 GB6170M6 LH environmental color zinc PROCEDURE Front left foot pedal Remove the tool to remove the card spring the foot pin shaft will be removed then the front left foot step foot twist sp...

Page 33: ...ove the remaining oil in the engine Remove the oil bolts and the sealing gasket to remove the oil from the frame tube Clean all the material with a clean non woven cloth Refer to the instructions for...

Page 34: ...3 near the muffler elbow upward side with a sleeve If you do not need to remove the heat dissipation assembly do not remove the bolt CAUTION It is forbidden to disassemble the heat dissipation system...

Page 35: ...e connector of the oil cooler inlet pipe 5 outward in the axial direction Heat dissipation assembly Remove the bolt 4 near the bottom of the heat dissipation with a sleeve then remove the bolt 4 on th...

Page 36: ...cover 4 and the right trim cover 8 Push the bushing 2 out of the buffer 3 and remove the buffer from the trim cover Oil cooler inlet pipe Remove the bolt 5 with the hexagonal tool separate the oil in...

Page 37: ...rocker seat slot should be staggered position to prevent the cable from coming out Big adjustment If fine adjustment cannot be achieved loosen bolt with open end wrench rotate adjustment bolt and fina...

Page 38: ...Remove the clutch line Remove the protective sleeve from the clutch cable Install the clutch Put protective rubber sleeve into clutch elbow After inserting the clutch cable joint into the rocker arm...

Page 39: ...e 5 from the core turntable and remove it from the cable hole in the lower part of the switch Install the throttle line First pass the throttle line into the line hole in the lower part of the switch...

Page 40: ...on assembly wrapped with a clean cloth and then placed to prevent scratches Remove the lock washer 4 remove the top adjusting nut 5 with a special four jaw shank or hook wrench and remove the pad 6 If...

Page 41: ...ER 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 42: ...Lock the pin with a hexagonal tool 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...

Page 43: ...sufficient If it is not enough it needs to be added as soon as possible if it has been driven to a certain mileage it needs to be replaced as soon as possible ODO long odometer TRIP short odometer Lon...

Page 44: ...air pressure etc If the tread wear indicator has been worn out the tire of the same specification type must be replaced Refer to the relevant content of the manual for details The tires are semi hot...

Page 45: ...off the belting 1 then remove 3 pcs clamp 2 Pull out the sensor cable from the clip 6 and remove the bolts 3 abd bolts 5 on the bottom remove the sensor 7 Front disc brake caliper Remove the bolts 3 a...

Page 46: ...Use your hand to hold the head assembly and remove the two bolts 1 on both sides of the upper plate bottom with the hexagonal tool remove the flanged bushing 2 Move the head assembly forward with your...

Page 47: ...Head cover rear shell Remove the three bolts 1 at the bottom at the bottom of the left figure with the hexagonal tool Use a flat blade screwdriver to pick up the upper buckle indicated by and then ap...

Page 48: ...olt with the hexagonal tool 1 Press the buckle slightly in the direction of the arrow to separate the headlight upper assembly lower headlamp assembly Remove the bolt 7 with the hexagonal tool and rem...

Page 49: ...her person uses a cross screwdriver to insert the left or right side of the motorcycle into the zigzag position indicated by the arrows on the left Rotate the light level adjustment bolt clockwise or...

Page 50: ...then remove the left mounting ear and the right mounting ear of the instrument bracket CAUTION When removing the instrument assembly take care to protect the case and prevent scratches When the assemb...

Page 51: ...Left hand rubber sleeve and balance block assembly Can be soaked in hot water for about 10 minutes before use a dust blower to blow the left hand grip between the rubber sleeve and move the rubber sle...

Page 52: ...lance 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 b...

Page 53: ...left pad block 6 and finally remove the handle 4 Uplink board assembly Locate the faucet lock plug and remove it remove the nut and remove the shims Remove the upper plate bolts Front left and right s...

Page 54: ...tion should be wrapped with cotton or other soft materials to prevent scratching the paint surface Remove the nut and remove the gasket cushion rubber and bushing Remove the upper plate The direction...

Page 55: ...he front mud plate and remove the wire clamp When putting brake fluid prevent it from touching the skin or dripping onto the ground or other parts of the vehicle For the precautions of brake fluid ple...

Page 56: ...ove the bolts at the joint between the ABS control unit and the frame and cut the tie Press the limit tab on the cable connector and push the lever in the direction of the arrow to pull out the cable...

Page 57: ...djuster 1 17 1184200 045000 DF30 wheel speed sensor 1 18 1251100 101000 Non standard bolt M6 12 304 stainless steel 1 PROCEDURE Front disc brake main pump assembly Referring to the steps of Right Hand...

Page 58: ...ug the electronic PKE external antenna cable connector near the front of the left side cover picture B Pull the main line limit card into the outside and pull out the plug Find the limit card ring on...

Page 59: ...t surface Remove the swell nail Remove the bolt 2 with the hexagonal tool and be careful not to pull the Fuel tank cover nylon rope Pull back the middle cover assembly and remove it CAUTION Make sure...

Page 60: ...ed screwdriver to carefully open the two ends of the middle cover as shown in Figure b remove the Fuel tank lock 2 pay attention to prevent damage to the buckle Fuel tank cover assembly Hold the clamp...

Page 61: ...1 1 9 1 6 PROCEDURE Fuel tank left and right cover assembly Remove the bolt 1 bushing 2 buffer rubber 3 and plywood 4 with the hexagonal tool Remove the fuel tank left and right cover assembly Disass...

Page 62: ...pe Fuel tank cap After removing the antenna fixing block from the inner container assembly clean up the remaining glue CAUTION When disassembling the tank assembly it is recommended that the fuel be p...

Page 63: ...20036 ZT250 S right side cover decorative cover electroplated bright gray highlight special black 4044100 014036 ZT250 S right side cover electroplated bright gray highlight 4044100 014021 ZT250 S rig...

Page 64: ...ck 1 FIG 1 REAR COVER COMPONENT Rear handrail Cushion lock bracket PROCEDURE Rear handrail Remove the bolt 2 with the sleeve and remove the rear handrail 1 Rear cover left limit bracket Remove the bol...

Page 65: ...4044100 003036 Rear left side cover electroplated bright gray highlights 1 2 4044100 003021 ZT250 S rear left cover special black 1 special black Sticker The trim cover of rear cover already contains...

Page 66: ...ent of a power failure it is strictly forbidden to bridge or directly connect to the power supply Relay Pull out the starting relay upwards open the protective cap and loosen the nut to remove the rel...

Page 67: ...mponent box and the lower cover of the ZT310 electrical component box Pull down in the direction of the arrow to remove the back glue of the electrical device box Remove the bolts on the left and righ...

Page 68: ...front part and pull down with the other hand Unplug the cable connectors and of PKE and remove the electrical device box assembly CAUTION Do not pull the cable directly when unplugging it If you need...

Page 69: ...ox component Remove 7 pieces of plywood nuts from the electrical component box Remove the battery pad left glue and right glue Fuses Unplug the fuse and check if it is blown If it has blown replace th...

Page 70: ...After connecting the wires check that the wires are fixed and short press the unlock button to turn on the PKE system Disable pressing the ignition button at this time CAUTION The wire must be connect...

Page 71: ...ile remove the cushion from left and right swing cushion Install cushion When assembling the cushion first check whether all the cushion glue is complete insert the front of the cushion first and then...

Page 72: ...sensor fixing buckle Use pliers to clamp the rear radiator bracket slightly and pull out the cable clip 5 in the direction shown in Separate the oxygen sensor connector from the main harness Then use...

Page 73: ...hands then remove the bolt from the engine while holding the muffler COMPONENT Remove the muffler from the motorcycle Gasket Remove the gasket from the exhaust port of the engine CAUTION In the proces...

Page 74: ...00 028000 ZT250 S Muffler anti hot plate 1 6 1224100 029000 ZT250 S Muffler tail cover 1 7 1050953 008000 OSM planar oxygen sensor 1 PROCEDURE Oxygen sensor Remove the oxygen sensor with the open span...

Page 75: ...OR COMPONE Lower air guide sleeve component 1 PROCEDURE Lower air guide sleeve component Lift the motorcycle with tools and remove the bolt and flanged bushing with an inner hexagonal tool CAUTION In...

Page 76: ...ted bright gray highlight 4044100 009021 ZT250 S lower guide cover left special black special black FIG 2 LOWER WIND DEFLECTOR COMPONE Lower air guide sleeve component 2 2 1 8 1 PROCEDURE Lower fairin...

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