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Summary of Contents for Zontes Z2
- Page 2 This manual summarizes the right repair and maintenance methods of motorcycle. As long as in accordance with the provisions to do, your motorcycle will be durable. ZONTES distribution unit has trained technical personnel, with the complete tools and equipment, to provide you with high quality and service at any time.
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Page 3: Table Of Contents
Content Content............... . .1 Spark plug............21 User instruction............2 Engine oil............22 Special Warning............2 Engine oil filter...........24 Code position..............3 Clutch controller free stoke......25 Maintenance of muffler..........3 Throttle cable clearance........26 Installation of location parts........4 Idling..............26 combination lock............5 Fuel evaporative pollutants control system...26 Instrument..............6 Cooling liquid.............26 Left/Right handle control system......9... -
Page 4: User Instruction
User instruction There are all kinds of accessories on the market can be assembled on your motorcycle, and we cannot directly control the market quality and applicability of attachment. The inapplicable attachments will endanger the safety of the riding personnel. The selection of accessories and installation, therefore, must be especially careful. -
Page 5: Code Position
Code positing Vehicle identification code and engine number is for the registration of motorcycles, when ordering parts or entrust the special service, this number can make distribution unit provide a better service for you. ① Identity code will be carved on the turning vertical pipe,② 3C nameplate card will be fixed in the bottom of the frame,③... -
Page 6: Installation Of Location Parts
Installtion of component parts ⑤Switch on right handle ①Clutch handle ③Meter ⑥Accelerator control handle ②Switch on left handle ④Front brake liquid cylinder ⑧ ⑨ ⑩ Front disk brake Side stand Rear disk brake Rear brake pedal Ignition coil Gearshift pole Muffler W W W . -
Page 7: Combination Lock
Combination lock The motorcycle is equipped with two keys, one of which should be kept for future use. There is a small number plate with the key. Please record the number on the number plate for future reference. key code The combination lock guard has two positions Closed position: Seal the keyhole, the key cannot be inserted into the lock cylinder, and the combination lock cannot be opened. -
Page 8: Instrument
Instrument 1 left turn lights, 2 emergency light; 3 ABS anti-lock braking system light; 4 idling gear indication light, 5 distance light lamp; 6 right turn signals light; 7 engine speed record; 8 speedometer; 9 kilometer/miles identification; 10 battery fuel gauge of low voltage prompt lable; 11 fuel oil level gage; 12 clock;... - Page 9 Instrument 8 Speedometer & Voltmeter Speedometer shows the speed is how many kilometers per hour (/miles). Voltmeter: Press the MODE button to turn on the speedometer, it enters the diagnosis mode, and displays the 3-digit voltage at the speedometer. For example: “129" is 12.9V Restart, speedometer returns to normal mode.
- Page 10 Instrument 13 ODO Long distance odometer & 14 TRIP short distance odometer The LCD screen display area has two functions: ODO meter long and short TRIP odometer. ODO long distance odometer records the motorcycle the total road mileage from start to now, it cannot be reset;...
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Page 11: Left/Right Handle Control System
Left/Right handle control system 1.Clutch controller When starting the engine or shifting gears, hold the handle to separate the clutch discs to cut off the power transmission 2.Overtaking warning lights switch When speeding up, press the button warning the cars vehicles in front or behind. 3.Dimmer switch High &low beam operation When the dimmer switch on... - Page 12 Left/Right handle control system 9.Front brake controller When braking the front wheel, hold the brake handle on the right. Due to the hydraulic disc brake, please control the grip force appropriately. When the front brake lever is gripped, the brake light will automatically illuminate.
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Page 13: Fuel Tank
Fuel tank ③ ④ The fuel tank is located in front of the seat cushion. To open the fuel tank, first open the cover ①, insert the key into the fuel tank lock hole ②, and turn the fuel tank cover ③ clockwise. When installing the cover, push down the fuel tank lock to lock it, and remove the key. -
Page 14: N Otes For Fuel, Engine Oil And Cooling Liquid
Engine oil Use high quality SN or above level four-stroke engine oil can prolong engine life. Please choose ZONTES API SN level or higher level of "four stroke motorcycle engine oil", It is on sale in all ZONTES shops. The unleaded gasoline, poor quality fuel oil and engine oil can damage the system components, and it will shorten the service life of catalyst in spark plugs and muffler. -
Page 15: Running-In Of New Motorcycle
Running-in of new motorcycle The correct new running-in can prolong the service life of the motorcycle, it can also give full play to the performance of the new motorcycle. Below is a list of running in right way. recommended maximum engine speed First 500 kilometers below 5500 turns/minute Up to 1500 kilometers... -
Page 16: Inspection Before Driving
Inspection before driving If it's not well check before driving the motorcycle, and there is no proper maintenance, it will increases the risk of accidents and the risk of motorcycle damage. Always check the motorcycle during daily usage, make sure it is safe to run. Refer to the instruction manual inspection and maintenance of the chapters. -
Page 17: Driving Essentials
Driving essentials As you drive the motorcycle for the first time, we suggest you had better look for practice on the un-public road, until you are familiar with this motorcycle control method. Driving with only one hand is the most dangerous, we should driving in both hands firmly in the grip and both feet on the foot. -
Page 18: Driving
Driving Pack up the main stand, hold the clutch handle, just wait a moment, hit the hang first gear shift lever: step on the gas and slowly release the clutch handle gently, the motorcycle will start. It you want to get to the next higher gear, speed up first, and then close the throttle, hold the clutch handle at the same time, the shift lever stepped down, hanging in the second gear. -
Page 19: Inspection And Maintenance
Inspection and maintenance Maintenance schedule The table below is the inspection for each regular maintenance should be done, the interval period should be used in months or mileage depending on which one reached first. Each check should be carried out in accordance with the project in the table below. I f your motorcycle has been used in harsh conditions, namely the continuous driving in large throttle or worked in wind sand, it should have special maintenance to keep the reliability of the motorcycle after driving. -
Page 20: Toolkit
Inspection and maintenance According to the project inspection table, if necessary, to further cleaning, lubrication, adjustment or replacement operations. In poor road conditions and high power conditions for a long time, you should increase the inspection frequency. Toolkit Open the seat lock, the tool bag is placed under the seat cushion, right rear end, the position is as shown. -
Page 21: Storage Battery
Please purchase and use our special charger to ensure the extension of the service life of the battery. There are lead-acid battery chargers for sale in Zontes shop. Users who need them can go to Zontes shop to purchase the corresponding chargers according to the batteries equipped with the model. -
Page 22: Air Filter
Air filter The air filter is located below the seat. If the air filter is dirt jam, it can make the air intake resistance increases, the output power down, and fuel consumption increases. If driving in dusty conditions, you should increase air cleaner filter cleaning or replacement frequency. Complete the following steps to check clean air filter. -
Page 23: Spark Plug
Spark plug 0.7~0.9mm Disassembly the spark plug Follow the steps below: 1.Disassembly the spark plug cap ,be careful not to use strong force, or you may break the spark plug. 2.To remove the spark plug with the spark plug wrench. 3.Check the spark plug. -
Page 24: Engine Oil
Engine Oil Top oil level line Lowest oil level line Whether the engine can be durable, it is very important to select the high quality oil and regular replacement of new oil. Check the oil level and oil change on a regular basis is two important tasks of maintenance project. - Page 25 6. Add 1000 ml from the right crankcase filler port of the engine (if the oil filter is replaced, add 1050 ml). The viscosity is SAE5W-40/10W-40/10W-50. The new API SM grade or higher "ZONTES" motorcycle four-stroke engine Oil, and then tighten the oil dipstick.
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Page 26: Engine Oil Filter
Engine oil filter Please properly recycle and handle the used oil and oil filter. 1.Place the oil unloading tray under the right crankcase cover. 2.Remove 3 cap nuts on the oil filter cover with the special tool. Loosen the oil filter cover by the rotating softly from left and right, and disassemble the oil filter cover. -
Page 27: Clutch Controller Free Stoke
clutch controller free stroke The clutch controller free stroke Measuring the clutch controller end free stroke, it should be between 10~15mm. If free stroke is not correct, accord with the following method to adjust. 10-15mm Micro adjustment 1.Loose clutch digging line nut ①. 2.Rotate clutch digging line adjustor ②... -
Page 28: Throttle Cable Clearance
Throttle cable clearance Adjustment progress： (1) Loose lock nut ①. (2) Turn the adjusting screw ② to adjust the clearance lasso, within the range of 2.0~4.0mm. (3) After completion of clearance adjustment, tighten the lock nut. After completing the clearance adjusting throttle cable, ensure the throttle hand turn automatically back to the closed position, do not make the engine idle speed by adjusting cable. -
Page 29: Fuel Pipe
Fuel pipe Fuel pipe Check the fuel pipe for damage or leakage. If there is a problem, it is necessary to replace the fuel pipe. Don't rise the fuel pipe by your means. Transmission chain Transmission chain This model is equipped with a circulation transmission chain made of special materials. When it is necessary to replace the transmission chain, please submit this work to our maintenance department. - Page 30 Transmission chain Some chain lubricant containing might damage the sealing ring of solvents and additives, so please use the special chain oil. If there is no chain oil for the seal chain, you can use high viscosity gear oil SAE90 instead. Adjustment of transmission chain Adjust the drive chain sags to the appropriate range.
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Page 31: Brake System
Braking system This motorcycle front and rear wheel assembly of the disc brake. The right brake operation is very important for safe driving. Remember to regularly check the braking system, and the inspection qualified maintenance unit to complete. Brake is highly significant components of personal safety; you should regularly check and adjust the brake, and regular cleaning the sediment on the brake caliper, etc. - Page 32 Braking system If fail to brake piece inspection and maintenance, don't change in time or in the recommended replacement, it will increase the risk of accidents. If brake piece need to be replaced, please let the designated company service units to complete the job. It must accord with the method recommended by brake piece inspection maintenance. If driving after the maintenance of the brake system or replace the motorcycle brake, operate only a few with the brake lever or brake pedal, braking effect will be worse, and the accident will happen.
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Page 33: Tires
Tires Do not pay attention to the following matters may be accident caused by the failure of the tire. Tires connect the motorcycle and ground, so it is very important. Observe the following rule: Check the tires and tire pressure condition, adjust the tire pressure before each use. Avoid the motorcycle overload. -
Page 34: Disassembly Of Tires
Disassembly of tires ① ② ③ Front axle tightening torque: 65N.m Front axle lock bolt tightening torque：23N.m Brake pliers before installation bolt tightening torque：26N.m 1.Use special support frame to support the motorcycle 2.Loosen the connected front brake caliper two bolts ① on the shock absorber remove the front brake pliers. - Page 35 Disassembly of tires Rear wheel nut tightening torque：110N.m 1.Use special support frame to support the motorcycle. 2.Remove the rear wheel nut ①. 3.Loosen the adjusting nut of left and right sides of the transmission chain ②. 4.Taking wheel. 5.Taking front moving rear wheel, remove drive chain sprocket from the rear sprocket. 6.Remove the rear wheel from behind.
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Page 36: Illumination And Signal
Illumination and signal Please refer to the instruction of the front part "check before driving" for the illumination and signal inspection. Front brake switch The front brake switch, housed in a former brake controller. When you slightly feel pressure before holding brake controller, the brake light is up. -
Page 37: Trouble Shooting
Trouble shooting The content of the troubleshooting can help you to find the cause of the general issues. Improper maintenance and adjustment can damage the motorcycle and cannot determine the cause of the problem. We can't guarantee such damage. If you are not sure how to correct operation, consult the designated company service units. -
Page 38: Engine Short Of Power
Trouble shooting Don't make the fuel flow everywhere, the container should be income. Don't let the fuel close to high temperature of the engine and the muffler. When doing the inspection, it should be far away from the fireworks, also don't close to fire and heat source. Engine short of power When engine power significantly decreased or a larger decline on original top speed, it may be the blocking of the engine fuel system make the work of engine is not normal, please immediately go... -
Page 39: Fuel Injection Attention
Fuel injection attention Fuel injection attention: 1.Before the installation of battery for new motorcycle, we should inspect that whether the connection for the fuel injection spare parts is fixed and reliable including the installation of oxygen sensor. Moreover, make sure to fill in the gas. 2.When you install the battery, you should use tools to fix the positive and negative anodes according to the positive and negative anodes of battery. - Page 40 Fuel injection attention Description Description Code Code Intake temperature sensor signal Signal of the upstream 1 cylinder P0112 P0131 voltage is too low oxygen sensor is too low Intake temperature sensor signal Signal circuit voltage of the upstream P0113 P0132 voltage is too high 1 cylinder oxygen sensor is too high Upstream 1 cylinder oxygen sensor...
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Page 41: Usb Port
USB Port Charge USB port data: Input voltage:12V-24V; output voltage: 5V; output voltage: 2A. Characteristic: 1.Waterproof cover can prevent water and dust from getting inside to extend the usage life of the charger. 2.Intelligent IC design. It will automatically adjust the charging speed according to the battery volume and type. -
Page 42: Storage Method
Storage methods Storage method If you are not using motorcycle for a while, the motorcycle needs special maintenance, this requires some special materials, equipment and technology. For this reason, it is recommended that you choose the company service units to complete the maintenance work. If you want to complete the work, please click the following method: Motorcycle Thoroughly clean the motorcycle. -
Page 43: Motorcycle Cleaning
Motorcycle cleaning Clean the motorcycle Clean the motorcycle accord with the following: 1.Use cold water to wash away dirt and mud on the surface of the motorcycle. You can use the soft sponge or soft brush to clean. You could scratch appearance parts with hard materials to clean. 2.Use neutral detergent or a car wash soap, thoroughly clean sponge or soft cloth motorcycle. -
Page 44: The Use Instruction Of Storage Battery
The use instruction of storage battery 1 The start of the new storage battery Storage battery installation a. Connect first positive (+) polar (red wire), followed by the negative (-), note: don’t connect the reverse way, Otherwise it will damage voltage rectifier electric parts, etc. b. -
Page 45: Specification Table
125 Displacement Specification table Length............................2068mm Width............................791mm Height............................1112mm Wheel base ..........................1373mm Ground clearness ........................206mm Seat height...........................790mm Net weight............................150kg Full load weight..........................160kg Engine Type ............. Single cylinder ,upright, four-strokes, wind and oil cooling Cylinder number ..........................1 Cylinder bore ..........................52.0mm Stroke ............................58.7mm Displacement .......................... - Page 46 155 Displacement Specification table Length............................2068mm Width............................791mm Height............................1112mm Wheel base ..........................1373mm Ground clearness ........................206mm Seat height...........................790mm Net weight............................150kg Full load weight..........................160kg Engine Type ............. Single cylinder ,upright, four-strokes, wind and oil cooling Cylinder number ..........................1 Cylinder bore ..........................58.0mm Stroke ............................58.7mm Displacement ..........................
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