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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

Flasher

、

Buzzer

1.5 Frame plastic parts……………………………………………………………………………………………………………………………………………………………………………………………… 11

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

1.6 Directional column component………………………………………………………………………………………………………………………………………………………………………………… 12

Lower plate component

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

Frame, side bracket

FRAME & ENGINE COMBINATION

2.1 Frame & engine combination 1………………………………………………………………………………………………………………………………………………………………………………… 14

Disassemble guard bar assembly

2.2 Frame & engine combination 2………………………………………………………………………………………………………………………………………………………………………………… 15

Lower shroud bracket

、

engine

INTAKE SYSTEM COMPONENT

3.1 Intake system component……………………………………………………………………………………………………………………………………………………………………………………… 16

Air filter filter,Carbon canister

3.2 Throttle valve body component………………………………………………………………………………………………………………………………………………………………………………… 17

Disassemble throttle valve body component

3.3 Replace air filter element……………………………………………………………………………………………………………………………………………………………………………………… 18

REAR WHELL COMPONENT

4.1 Rear mud board………………………………………………………………………………………………………………………………………………………………………………………………… 19

Contents

Table of Contents

Содержание ZT125-GK

Страница 1: ...2022 5 25 ZT125 155 GK EURO V Service manual...

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

Страница 3: ...brake pedal height adjustment 5 2 Right footrest component 1 27 Disassemble the right foot support component 5 3 Right footrest component 2 28 Decomposition brake pedal component 5 4 Right footrest c...

Страница 4: ...t mud board wheel speed sensor component 1 47 Front disc brake guard component Front mud board component 7 11 Head and headlights component 1 48 Disassemble head and headlights component speedometerde...

Страница 5: ...nt 61 Upper surrounding assembly 8 3 Lower part component 62 Surrounding components 8 4 The middle cover component 63 Surrounding components 8 5 Lower part sectionalization 64 USB charging cable Front...

Страница 6: ...11 5 Rear mud board component 1 75 Demolition of the mud board component 11 6 Rear mud board component 2 76 Disassembled mud board component 11 7 Battery component colliod battery 77 Disassemble batt...

Страница 7: ...d other changesFor colors or upgrades please refer to the part codes on the official website This manual will not be listed in detail If the part names in this manual are inconsistent with the officia...

Страница 8: ...s to use a word screwdriver forceps scissors andother tools to assist The binding or can be picked out by using scissors Flasher and dump switch Remove the flasher remove the rubber sleeve that connec...

Страница 9: ...pedal with thread 1 8 1274100 017000 ZT250 S line buckle 2 Fig 2FRAME ELECTRO NIC COMPONENT Electronic parts COMPONENT 2 PROCEDURE Horn Take off the plug of horn take the horn by one hand use 8 sleev...

Страница 10: ...gative connectors and screw the nut back onto the relay stud to preventloss Take off plug of the start relay and main hamess ECU After pressing the anti release buckle rotate the ECU cable plug counte...

Страница 11: ...E 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 Engin...

Страница 12: ...ic parts PROCEDURE Fuel 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 cov...

Страница 13: ...too tight to prevent the rubber pad from deformation too larg 2 1251300 046093 Direction column adjusting screw nut M24X1 environmental color zinc 2 Fig 6FRAME ELECTRO NIC COMPONENT Directional colum...

Страница 14: ...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...

Страница 15: ...and then tighten the fasteners Assemble the inner crash bar bracket and the lower guard bar bracket first and then assemble the surrounding When reassembling the guard bar install the guard bar prote...

Страница 16: ...operation is strictly prohibited All standard parts must meet the standard torque value during reassembly and re add the oil according to the instructions Fig 2 FRAME ENGINE COMBINATION Frame engine...

Страница 17: ...the air filter inlet air temperature sensor Remove the side cover seat cushion rear shock absorber rear tail skirt etc to facilitate subsequent disassembly of the air filter and throttle body Remove...

Страница 18: ...OCEDURE High pressure oil pipe Press the anti trip buckle on the high pressure fuel pipe and then connect the oil pan to contain the remaining fuel Be careful not to let the fuel drip onto the bike bo...

Страница 19: ...erience 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 A...

Страница 20: ...T Rear mud board 6 1251700 059093 Flanging bushing 6 4 9 8 18 2 environmental color 1 PROCEDURE Rear inner mudguard First of all pull out the braking oil tube and wheel speed sensor cable which are on...

Страница 21: ...e on the right 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 perso...

Страница 22: ...nd avoid it to be lifted higher than disc brake oil cup Hold the rear wheel assembly Punch rear wheel axle with rubber hammer Take off right chain adjuster rear tire and rim assembly left chain adjust...

Страница 23: ...high pressure in summer might have possibility of tire bursting It needs running in for about 300km after changing new arresters During this period leave enough braking distance while riging The tire...

Страница 24: ...embly Person 1 fastensthe head of the 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...

Страница 25: ...e 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 5 inner hexagon socket tool Tighten...

Страница 26: ...s 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 arres...

Страница 27: ...ing position take off bolt 1 and 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 he...

Страница 28: ...component Using a plier to disassemble the pin Then take off the washer and pin Using 6 inner hexagon socket remove pcs bolt and Using 4 inner hexagon socket remove bolt then take away the oil cup CAU...

Страница 29: ...on socket remove bolts Rear disc brake oil cup can never be lower than oil tube Brake pedal assembly Using 8 inner hexagon socket remove the bolt pull out the brake pedal take off the brake pedal spri...

Страница 30: ...00 006051 ZT350 GK R front pedal dark gray matte 1 16 4064300 008051 ZT350 GK R rear pedal dark gray matte 1 PROCEDURE R front pedal Disassemble circlip Take off foot pedal pin axle Then disassemble R...

Страница 31: ...ttle bit the spline rockerarm while pulling it out from gear shift axle of engine Using 6 inner hexagon socket remove 3pcs bolts and Take off left foot pedal holder assembly Gear shift rod assembly Us...

Страница 32: ...18 1274100 042000 Miniature rod end ball bearing SAJK6C 1 19 1251100 061093 M6 22 Hex flang bolt thread level 8 8 color zinc 2 20 1271200 163000 ZT250 S shift lever spline rocker arm dark gray 1 PROC...

Страница 33: ...ing pad 1 10 4064300 007051 ZT350 GK rear left pedal 1 11 1274300 093000 ZT350 Gk footrest gum cover fixed plate 10mm longer 1 12 1244300 013000 ZT310 T footrest gum cover 1 PROCEDURE L rear foot peda...

Страница 34: ...eal ring PROCEDURE Drain the engine oil Park the motorcycle with side stand on flat ground Place holder to collect wasted engine oil under the oil drain bolt Using 14 sleeve ratchet wrench remove the...

Страница 35: ...ing 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 h...

Страница 36: ...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 t...

Страница 37: ...s 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 wa...

Страница 38: ...4021200 024000 KD150 U radiator bracket 1 PROCEDURE Water tank component Remove pipe clamp then remove water tank water inlet Pull out the water pipe Water tank bracket Using 8 sleeve remove 2pcs bolt...

Страница 39: ...into the hole near the lower link plate of the car the arrows are inserted backwards as shown in Figure A and B aligns the adjusting bolt rotates clockwise to increase and counterclockwise to decrease...

Страница 40: ...e 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...

Страница 41: ...r and lower parts of the switch Pay atten tion to the wiring when re installing and can not press on any cables Remove the throttle cable from the right hand and remove the rubber sleeve from the core...

Страница 42: ...anner remove the spacer 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...

Страница 43: ...iew mirror then take off the rubber sleeve Generation right hand switch Find and press the snap indicated by arrow then take off the plug of the generation right hand switch Hold the front disc brake...

Страница 44: ...e 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 f...

Страница 45: ...flathead screwdriver to lock the nut Repeatedly holding the brake handle until braking force is restored Front brake caliper mounting plate Remove the mounting plate from the caliper Be careful not to...

Страница 46: ...n and bending Brake disc After replacing the brake disc the new brake disc should be operated for about 300 kilometers to fully run in order to achieve the best braking effect Be careful to leave enou...

Страница 47: ...wheel speed sensor then remove 3 pcs clamp Cut off the belting Using 4 inner hexagon socket remove bolt take off the bolt Front disc brake caliper Using 8 sleeve remove bolt and using 4 inner hexagon...

Страница 48: ...olt and using 4 sleeve remove bolts remove the bushing and cushion rubber take off the front disc brake disc cover installation plate and front disc brake guard Front mud board component Remove the fr...

Страница 49: ...tive cover Left and right turn signal components Remove the 2 bolts in Figure C with 4 inner hexagon take off the flange bushing the cushion rubber Use 5 hex socket to remove self tapping bolt then re...

Страница 50: ...Anti hot plate sleeve muffler 1 19 1224200 008000 ZT310 R cable plastic staple 2 Fig 12 FRONT FORK COMPONENT PROCEDURE Left and right turn signal components Use a Phillips screwdriver to remove the sc...

Страница 51: ...1171200 059000 KD150 G1 headlight 1 6 KD150 GK headlight decoration cover 1 PROCEDURE Headlight components Remove the two bolts take off the flange bushing the cushion rubber separate the headlight an...

Страница 52: ...bolts and remove the instrument assembly Instrument Stand After fixing the instrument use a 10 sleeve to the nut and the gasket Separate the instrument bracket assembly from the instrument Remov the...

Страница 53: ...ch by referring to the steps in Right Handle Assembly and Add Brake Fluid Adjusting Rocker Arm Using 5 inner hexagon socket remover 2pcs bolts take off the generation Left handlebar switch and the lef...

Страница 54: ...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 protecti...

Страница 55: ...lot 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 sh...

Страница 56: ...pped with cotton or other soft materials to prevent scratching the paint surface Remove the bolt with a 14 sleeve and remove the gasket cushion rubber and bushing Remove the upper plate The spacer the...

Страница 57: ...ve 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...

Страница 58: ...uidcome 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 F...

Страница 59: ...remove 2pcs bolts then take 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...

Страница 60: ...or 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...

Страница 61: ...ight front grille 4 Fig 1 SURROUNDING COMPONENT Front grille component PROCEDURE Remove the 4 expansion nails Fuel tank front grille component Fuel tank left front grille component Use 4 inner hexagon...

Страница 62: ...s the upper part component PROCEDURE First refer to Frame Engine Combination 2 to remove the crash bar Upper surrounding assembly Right Upper surrounding assembly use 4 inner hexagon to remove 1 bolt...

Страница 63: ...tardant tie black 3 6 295 1 SURROUNDING COMPONENT Fig 3 SURROUNDING COMPONENT Lower part component PROCEDURE Surrounding components Remove the right side cover by referring to the Side cover component...

Страница 64: ...l 4 6 4041201 371021 KD150 GK right lower part 1 7 1244100 002000 ZT250 S Side cover round rubber 4 8 1221200 076000 KD150 GK the middle cover 1 Fig 4 SURROUNDING COMPONENT The middle cover component...

Страница 65: ...left lower part 1 PROCEDURE USB charging cable Rotate the knob indicated by the arrow in the figure counterclockwise for a few turns then take out the knob and take out the USB charging cable from th...

Страница 66: ...kle at the joint of the high pressure oil pipe and the injector and then pull it out Lift the rear part of the fuel tank assembly and pull out the fuel pump plug Note that the buckle of this plug is o...

Страница 67: ...DURE Fuel tank decorative cover Use 4 inner hexagon to remove 2 bolts take off the fuel tank right decorative cover then remove Plywood on the fuel tank right decorative cover Remove the left decorati...

Страница 68: ...ft tail up slightly after 4buckles loosens shake and push until the bickle is out of the slot but don t remove the fuel tank middle cover Remove the cables on the clip Put the fuel tank cap back into...

Страница 69: ...1 PROCEDURE Fuel tank cover assembly Remove the retaining spring attached to the rotating shaft and slowly pull out the rotating shaft Remove the torsion spring first Remove the swivel bracket assemb...

Страница 70: ...p the lower edge of the left side cover and pull it out Grasp both ends of the left side cover and pull it out and remove the left side cover Remove the right side cover in the same way There are 4 pi...

Страница 71: ...ils First grasp the position with your left hand and then grasp the position with your right hand and slightly lift the position and rotate it counterclockwise about a quarter turn to remove the rear...

Страница 72: ...then remove the expansion nail and finally unplug the mushroom button at Find the plugs of the plug at the arrow indications and unplug them take off the left rear tail cover remove the PKE external...

Страница 73: ...gure A remove the flanging bush and the cushion rubber and then take out the bottom cover plate of the rear mud plate Use 4 inner hexagon to remove bolt in Figure B Unplug the tail light plug at Use 4...

Страница 74: ...the plugs of the rear lights turn signals and license plate lights at left rear tail cover and unplug them Use a 4 inner hexagon to remove the 3 bolts in Figure B remove the flange bushing and cushion...

Страница 75: ...ve the 2 nuts that come with the turn signal take out the spring washer and gasket and remove the left and right turn signal License light assembly Remove the 3 self tapping screws that come with the...

Страница 76: ...to fix it pull off the black protective cap to remove the negative pole then pull off the red protective cap to remove the positive pole remove the battery When reinstalling connect the positive pole...

Страница 77: ...ut all the PKE plugs Remove bolt and nut with 4 inner hexagon and 10 torx wrench Remove the rear cover installation cover use 6 hexagon socket to remove 4 bolt take off the flange bushing cushion rubb...

Страница 78: ...ging bushing 8 5 14 1 2 7 1184200 137000 ZT310 PKE new version band version 1 Fig 8 REAR COVER COMPONENT Electrical device box component PROCEDURE PKE coponent Using 10 sleeve to respectively remove t...

Страница 79: ...seat cushion and pull it diagonally upwards At the same time remove the cushion by moving the rear part of the cushion from side to side Assembly cushion When assembling the cushion check whether all...

Страница 80: ...ve fix the head of the bolt using 13 ring spanner remove 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 w...

Страница 81: ...f 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...

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