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Table of Contents

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FRAME&ELECTRONIC COMPONENT

1.1 Electrical device component-1……………………………………………………………………………………………………………………………………………………………………………………… 7

Main harness, dump switch, relay, flasher

1.2 Electrical device component-2……………………………………………………………………………………………………………………………………………………………………………………… 8

Flameout switch, horn,ignition coil

1.3 Electrical device component-3……………………………………………………………………………………………………………………………………………………………………………………… 9

ECU

、

relay

1.4 Electrical device component-4……………………………………………………………………………………………………………………………………………………………………………………… 10

rectifier

、

Buzzer

1.5 Frame plastic parts…………………………………………………………………………………………………………………………………………………………………………………………………

Line clamp, side cover round glue, fuel tank liner limit glue

1.6 Directional column component……………………………………………………………………………………………………………………………………………………………………………………

Lower plate component

1.7 Frame, side bracket………………………………………………………………………………………………………………………………………………………………………………………………… 13

FRAME & ENGINE COMBINATION

2.1 U Frame & engine combination…………………………………………………………………………………………………………………………………………………………………………………… 14

Lower shroud bracket

、

engine

2.2 U1 Frame & engine combination 1………………………………………………………………………………………………………………………………………………………………………………… 15

Disassemble guard bar assembly

2.3 U1 Frame & engine combination 2………………………………………………………………………………………………………………………………………………………………………………… 16

Lower shroud bracket

、

engine

INTAKE SYSTEM COMPONENT

3.1 Intake system component…………………………………………………………………………………………………………………………………………………………………………………………… 17

Air filter filter,Carbon canister

3.2 Throttle valve body component……………………………………………………………………………………………………………………………………………………………………………………

Disassemble throttle valve body component

3.3 Replace air filter element…………………………………………………………………………………………………………………………………………………………………………………………… 19

Contents

Table of Contents

Содержание ZT125-G1 2020

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

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

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

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

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

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

Страница 7: ...this manual are compiled according to the latest products However there may be some inconsistencies between your motorcycle and this manual due to the continuousimprovement of the product and other ch...

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

Страница 9: ...7 ZT310 EFI ignition coil with high voltage line 1 Fig 2 FRAME ELECTRONIC COMPONENT Electronic parts COMPONENT 2 PROCEDURE Horn Take off the plug of horn take the horn by one hand use 8 sleeve remove...

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

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

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

Страница 13: ...n of the lower connected plate After replacement it must be to check the parallelism of the column and the damping hole the vertical degree of the vertical column and the lower connected plate 1 the d...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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