Zontes ZT250-R Service Manual

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ZT250-R（EURO/IV）

Service manual

2021/03/01

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MOHAMMAD ALI ALDAAS

January 25, 2025

هل يمكن تركيب روؤس ترس محرك r310لمحرك zontes s250

Summary of Contents for Zontes ZT250-R

Page 1 ZT250-R（EURO/IV） Service manual 2021/03/01...
Page 2 CONTENTS Table of Contents Page Table of Contents ……………………………………………………………………………………………………………………………………………………………………………………………… FRAME&ELECTRONIC COMPONENT 1.1 Electronic parts component-1…………………………………………………………………………………………………………………………………………………………………………………… Main wire harnessk,Dump switch,Relay,Flasher,Rectifier,Ignition coil 1.2 Electronic parts component-2…………………………………………………………………………………………………………………………………………………………………………………… Shut-off switch,Horn 1.3 Frame plastic parts………………………………………………………………………………………………………………………………………………………………………………………………… Tuck loop,side cover circle rubber cushion,inner fuel tank fix rubber cushion 1.4 Steering rack component…………………………………………………………………………………………………………………………………………………………………………………………...
Page 3 CONTENTS Table of Contents Page Sub-mud component after discomponent 4.4 Rear turn signal after sale parts…………………………………………………………………………………………………………………………………………………………………………………… Rear left and right turn signals and rear license plate lights for sale 4.5 Rear mud board…………………………………………………………………………………………………………………………………………………………………………………………………… 4.6 Rear shock absorption…………………………………………………………………………………………………………………………………………………………………………………………… Demolition after shock absorption, rear shock absorption adjustment 4.7 Rear wheel component 1…………………………………………………………………………………………………………………………………………………………………………………………...
Page 4 CONTENTS Table of Contents Page Decomposition of the radiaor component FRONT FORK COMPONENT 7.1 Throttle/clutch cable clearance adjustment……………………………………………………………………………………………………………………………………………………………………… Adjust the throttle line, clutch cable free travel 7.2 Replacement clutch cable………………………………………………………………………………………………………………………………………………………………………………………… 7.3 Replace the throttle line…………………………………………………………………………………………………………………………………………………………………………………………… 7.4 Steering adjustment……………………………………………………………………………………………………………………………………………………………………………………………… Adiust steering device 7.5 Add brake fluid,adjust the swing arm……………………………………………………………………………………………………………………………………………………………………………...
Page 5 CONTENTS Table of Contents Page Dismantled the front brake calipers and ABS protection cover 7.20 ABS brake system-2……………………………………………………………………………………………………………………………………………………………………………………………… Dismantled the ABS control system component and the main pumb of disc brake 7.21 ABS brake system-3……………………………………………………………………………………………………………………………………………………………………………………………… Dismantled the rear brake calipers and discomposed the ABS control system component 8、FUEL TANK COMPONENT 8.1 Inner fuel tank component…………………………………………………………………………………………………………………………………………………………………………………………...
Page 6 CONTENTS Table of Contents Page Disassembled device box component, electric device box lower cover 10.6 Electrical component box component 2…………………………………………………………………………………………………………………………………………………………………………… 68 Remove PKE, electrical box 10.7 External battery to start PKE system……………………………………………………………………………………………………………………………………………………………………………… Emergency method to turn on PKE after battery power is exhausted CUSHION COMPONENT 11.1 Cushion……………………………………………………………………………………………………………………………………………………………………………………………………………...
Page 7 ●Flasher and dump switch ZT250-R ignition coil is matched with spark plug without screw cap. The ZT310 ignition coil is matched with a spark plug with a screw cap.
Page 8 1-FRAME&ELECTRONIC COMPONENT FIG.2 FRAME&ELECTRONIC Electronic parts COMPONENT-2 PARTS COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non-standard bolt M6×16（304 stainless steel） 1274100-086000 ZT250－R Horn intalling support 1270300-201000 Stainless steel asbestos pad 6×20×1.6 1251100-101000 Non-standard bolt M6×16（304 stainless steel） 1184200-004000 ZT310 Horn 1274100-017000 ZT250－S Cable clip 1274100-095000 ZT250－S Flameout switch wire fixing bracket 1184100-012000 ZT250－S Flameout switch...
Page 9 1-FRAME&ELECTRONIC COMPONENT FIG.3 FRAME&ELECTRONIC Frame plastic parts PARTS COMPONENT PART NO. PART NAME CAUTION 1274100-002000 ZT250－S Cable clamp 1224100-049000 ZT250－R Cable collection clip 1244100-019000 ZT250－S Inner fuel tank fix glue cushion 1244100-002000 ZT250－S Side cover round glue cushion 1244100-061000 ZT250 Frame water proof rubber plug 1240100-023000 Battery positive protection glue.
Page 10 With one hand to hold down the down connected plate assembly ⑺, the other hand use a special four- and rust.If YES, please buy the regular accessories on ZONTES official website, if not, please be sure to grease jaw set or hook wrench to remove the adjusting nut⑵.
Page 11 ●Remove the wind deflector component, handle bar component, steering column component first. Checking whether the cushion loop ⑵ is frayed, if as it, please replace it on ZONTES website, fix the ●Paint the lubricating grease on the cushion ring to decrease the rotary resistance of front forklift.
Page 12 1-FRAME&ELECTRONIC COMPONENT FIG.6 FRAME&ELECTRONIC Rear pedal component PARTS COMPONENT PART NO. PART NAME CAUTION 1274100-012000 ZT250－S Pedal axis pin 1274200-061000 ZT310－X rear right footrest 1264100-005000 ZT250－S Pedal Steel ball spring 1264100-006000 ZT250－S Pedal clamp spring 1274100-010000 ZT250－S Rear pedal steel ball 1274100-052000 ZT250－S Rear pedal locating plate 1274200-062000 ZT310－X rear left footrest 1251100-101000 Non－standard bolt M6×12 (304 stainless steel)
Page 13 2-FRAME&ENGINE COMPONENT FIG.1FRAME&ENGINE Frame&Engine PART NO. PART NAME CAUTION 1251300-057093 Non-standard nut M10×1.5（dacromet） 1020241-225000 ZT250－R Upper hanging piece out of stock 1020242-385000 ZT310－V Upper hanging piece 1251112-003093 M6×45 Hexagonal flange face 9.8 level bolt. 1274100-033000 ZT250－S Right support of down wind deflector 1251300-059093 125 Spindle nut of rear forklift M14×1.5（dacromet）...
Page 14 3-INDUCTION SYSTEM COMPONENT FIG.1 INDUCTION Intake system component SYSTEM COMPONENT PART NO. PART NAME CAUTION 1050954-007000 39－N008 gasline injector 1050954-008000 39－N008 Fuel injector 1251112-001093 M6×16 Hexagon flange bolts (color zinc) 1050954-006000 ZT180MN high press fuel pipe of EFI 1251300-063093 Plywood M6×11×15(color zinc) 1251100-101000 Non－standard bolt M6×12 (304 stainless steel) 1274100-076000 ZT250－R rear disc brake pipe clamp (steel) 1224200-058000 ZT310－R second generation air filter...
Page 15 3-INDUCTION SYSTEM COMPONENT FIG.2 INDUCTION Carbon Tank component SYSTEM COMPONENT PART NO. PART NAME CAUTION 1050954-009000 YH Carbon tank electromagnetic valve 1251100-101000 Non-standard bolts M6×12（304 stainless steel） 1250303-010093 GB6177.1M6（color zinc） 1251300-063093 Plywoord M6×11×15（color zinc） 1224200-158000 ZT310－R Carbon tank II (with fuel pipe) 1244200-004000 TB41 Throttle valve desorption rubber tubing PROCEDURE: ●Carbon tank...
Page 16 3-INDUCTION SYSTEM COMPONENT FIG.3 INDUCTION Replace the air filter element SYSTEM COMPONENT PART NO. PART NAME CAUTION 1224100-024000 ZT250－S Plastic connector block 4134200-002000 ZT310－R air filter element (with carton packaging) After sale PROCEDURE: ●Filter element If you need to maintain the filter element of the air filter,remove the plastic connection piece ⑴.Press the a- end of the right side cover to pull out forcibly, then pull out the b-end, remove the right cover assembly;...
Page 17 Pull straight the clip⑶.Remove bolt⑵, take off the clip⑶ and disc brake oil pipe clamp⑸. Use plum blossom wrench to tightent the nut⑽ and disassemble bolt⑹ which is close to "ZONTES" mark with a sleeve.And remove the spring pad⑺,flat pad(8)and nut⑽.
Page 18 4-REAR FORKLIFT COMPONENT FIG.2 REAR FORKLIFT Rear sub mudguard component 2 COMPONENT PART NO. PART NAME CAUTION ZT310 rear auxiliary fender aluminum alloy bracket 1020242-263021 (home made) 1251100-102000 Non－standard bolt M6×16(304 stainless steel) 1224200-090000 ZT310 rear auxiliary fender retaining plate 1250105-137093 GB5789M6×16(color zinc) 1250501-007093 GB93φ8(color zinc) 1274100-057095 Flanging bushing φ6.2×φ8.5×3.5＋φ14×1.5...
Page 19 4-REAR FORKLIFT COMPONENT FIG.3 REAR FORKLIFT Rear sub mudguard component 3 COMPONENT PART NO. PART NAME CAUTION 1251300-063093 Plywood M6×11×15(color zinc) 1244100-006000 ZT250－S rear liceness rubber buffer 1224200-091000 ZT310－R rear mudguard fender 1270300-273000 φ8 clip(L=73) 1174200-035000 ZT310 rear turn signal (including license plate light) 1174100-002000 ZT250－S rear reflector 1251100-102000 Non－standard bolt M6×16(304 stainless steel) 1274100-057095 Flanging bushing φ6.2×φ8.5×3.5＋φ14×1.5...
Page 20 4-REAR FORKLIFT COMPONENT FIG.4 REAR FORKLIFT Rear turning light parts for after sales service COMPONENT PART NO. PART NAME CAUTION 1224200-120000 ZT310 rear turn signal bracket 1174200-019000 ZT310－X Rear left turning light 1174200-020000 ZT310－X Rear right turning light 1174200-021000 ZT310－X Liensed lights PROCEDURE: ●Rear license light Grip the rear turning light bracket⑴...
Page 21 4-REAR FORKLIFT COMPONENT FIG.5 REAR FORKLIFT Rear inner mudguard COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non-standard bolts M6X16 (stainless steel) ZT250－R rear disc brake oil pipe clamp (steel parts/ 1274100-088000 rubber pad) 1274100-057095 Reverse bush φ6.2×φ8.4×3.5＋φ14×1.5 1244100-052000 Reverse bush buffering rubber (φ8.5×φ14×0) 1224200-003000 ZT310-Z Rear disk brake oil pipe clamp 1251700-059093 Reverse bush φ6.4×φ9×8＋φ18×2 (color) 1251112-001093 M6×16 Hexagon flange bolts (color zinc)
Page 22 4-REAR FORKLIFT COMPONENT FIG.6 REAR FORKLIFT Rear shock absorber COMPONENT PART NO. PART NAME CAUTION 1251100-085093 Non－standard bolt M10×1.5×75(dacromet) 1251100-060000 Non-standard bolts M10×1.5×90 1114200-020000 ZT310－X rear shock absorption (improved version) 1251300-057093 Non-standard bolts M10X1.5 PROCEDURE: ●Rear shock absorber After the side bracket is lowered, one person's left hand will kill the direction to the left while the right hand grips and the foot pedals to tilt the vehicle to the left;...
Page 23 1032142-073035 ZT310 Right Chain adjuster (titantium Gold ) 1251300-067000 Right adjuster(Titanium) 110N.m 1032142-072035 Left adjuster (Titanium) 1094100-032000 ZT250-R Rear wheel hollow shaft 1274200-002000 Rear wheel right shaft sleeve φ20×φ28×φ38×18.5 1244200-050000 ZT310－T cushion gum 1094200-011000 ZT310－R sprocket 1080100-068000 ZT310 － T, 520－42 T sprocket 1251300-057093 Non-standard bolts M10X1.5...
Page 24 4-REAR FORKLIFT COMPONENT FIG.8 REAR FORKLIFT Rear wheel component 2 COMPONENT PART NO. PART NAME CAUTION 1230100-207000 250kPa 150/60R17TL environmental protection vacuum tire (CM609) orange/ gray 1094200-020000 ZT310－T black rear wheel rim(4.5×17) /special black 1094200-042063 ZT310－R blue rear wheel 4.5 (4.5×17) black 1100100-419000 ZT310－R1 rear brake disc (230×4.5) 1274200-058000 ABS induction ring (60 teeth)
Page 25 4-REAR FORKLIFT COMPONENT FIG.9 REAR FORKLIFT Rear forklift component COMPONENT PART NO. PART NAME CAUTION 1252200-016093 250 rear fork shaft φ14×310 (color zinc) 1251300-059093 Rear fork shaft nut M14×1.5 (color zinc) 1251100-102000 Non－standard bolt M6×16(304 stainless steel) 1224200-003000 ZT310－Z Rear disc brake pipe clamp 1080200-032000 ZT250－S chain(CHOHO520HX) 1080200-055000 ZT250－R 114 section chain (CHOHO520HX/open type)
Page 26 4-REAR FORKLIFT COMPONENT FIG.10 REAR FORKLIFT Change rear brake arresters COMPONENT PART NO. PART NAME CAUTION 1100100-092000 Rear disk brake shoe (HS10) After sales PROCEDURE: ●Get rid of brake shoe Remove the nut with a screwdriver ①. Remove the pin shaft ② with the inner hexagon tool. Use the sleeve to remove the sliding shaft ③.
Page 27 4-REAR FORKLIFT COMPONENT FIG.11 REAR FORKLIFT Add the brake oil to the main pump or rear brake COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non-standard bolts M6c×16 (304 stainless steel) 3070100-008600 Fully synthetic brake oil DOT4 (1L bottle) 【1】 PROCEDURE: ●Add the brake liquid Remove the bolts with the inner hex tool⑴.
Page 28 5-PEDAL COMPONENT FIG.1 PEDAL Pedal height adjustment COMPONENT PART NO. PART NAME CAUTION 1250301-018093 GB6170M6－LH (environmental color) 1274100-096000 ZT250－R shift lever adjustment screw 1274200-160000 ZT310－T shift lever step rocker 1250301-020093 GB6170M6 (environmental color) 1250104-016093 GB16674M6×28 (chroming) 1274100-039000 ZT250－S shift lever spline rocker arm 1250303-010093 GB6177.1M6 (environmental color) 1274100-094000 ZT250－R brake pedal 1274200-059000 ZT310－X front right footrest...
Page 29 5-PEDAL COMPONENT FIG.2 PEDAL Right pedal support component-1 COMPONENT PART NO. PART NAME CAUTION 1250205-023000 GB70.1 inner hexagonal M8X35 (environmental color) 1251100-102000 Non－standard bolt M6×16(304 stainless steel) 1251100-121093 Non-standard bolts M6X25 (environmental color) PROCEDURE: ●Right foot pedal support component Remove the bolt ⑵, the oil cup should always be kept higher than the line a parallel to the ground to prevent gas from entering the oil circuit and causing brake failure.
Page 30 5-PEDAL COMPONENT FIG.3 PEDAL Right pedal support component-2 COMPONENT PART NO. PART NAME CAUTION 1251100-123093 Non-standard bolts M8X25 (environmental color) 1274100-091000 ZT250－R right foot pedal 1251500-048000 ZT250－S Pedal support gasket 1274100-094000 ZT250－R brake pedal 1260100-092000 ZT250－S rrake pedal torsional spring 1274100-035000 ZT250－S Foot pedestal 1274100-012000 ZT250－S Pedal pin 1264100-006000 ZT250－S Pedal circlip...
Page 31 5-PEDAL COMPONENT FIG.4 PEDAL Left pedal support component-1 COMPONENT PART NO. PART NAME CAUTION 1250205-023000 GB70.1 inner hexagonal M8X35 (environmental color) 1250303-010093 GB6177.1M6 (environmental color) 1274100-039000 ZT250－S shift lever spline rocker arm 1250104-016093 GB16674M6×28 (chroming) PROCEDURE: ●Left foot pedal support compenent Remove the nut ⑵...
Page 32 5-PEDAL COMPONENT FIG.5 PEDAL Left pedal support component-2 COMPONENT PART NO. PART NAME CAUTION 1251100-123093 Non-standard bolts M8X25(environemntal color) 1274100-092000 ZT250－R left foot pedal 1251500-048000 ZT250－S Pedal support gasket 1251100-061093 Hexagonal flange bolts (environmental color zinc) 1274100-043000 Miniature rod end ball bearing SALJK6C 1274200-160000 ZT310－T shift lever step rocker 1250303-010093 GB6177.1M6（environmental color) 1274100-012000 ZT250－S Pedal pin...
Page 33 6- RADIATOR SYSTEM COMPONENT FIG.1 RADIATOR Release the engine oil SYSTEM COMPONENT PART NO. PART NAME CAUTION 1244100-033000 Combined sealing gasket12×φ20×2 1251100-066093 M12×1.5×15 oil drain bolt (color zinc) 24±4N.m 1251100-089094 Oil bolt M14×1.50×32(color zinc) 1244100-034000 Conbination sealing gasket φ14×φ20×2 1244100-070000 Engine oil intake pipe 1251100-102000 Non-standard bolts M6×16 (304 stainless steel) 1274100-007000 ZT250-S Flanged Bushing (φ6.4×φ9×6＋φ20×2) 1051453-001000 9.8×2.2 Acrylate rubber o－rings...
Page 34 6- RADIATOR SYSTEM COMPONENT FIG.2 RADIATOR The oil pipe near the frame SYSTEM COMPONENT PART NO. PART NAME CAUTION 1051453-001000 9.8×2.2 Acrylate rubber o－rings 1244100-071000 ZT250－R Frame bypass oil pipe 1251100-061093 M6×22 Hex flang thread bolt 1251100-089094 Oil bolt M14×1.50×32（environmental zinc） 1244100-034000 Combination seal gasketφ14×φ20×2 PROCEDURE: ●Frame bypass oil pipe...
Page 35 6- RADIATOR SYSTEM COMPONENT FIG.3 RADIATOR Radiator component-1 SYSTEM COMPONENT PART NO. PART NAME CAUTION 1244100-034000 Combination seal gasket φ14×φ20×2 1244100-069000 ZT250－R Oil cooler outlet pipe 1251100-089094 Oil bolt M14×1.50×32（environmental color zinc） 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color zinc) 1244100-068000 ZT250－R Oil cooler inlet pipe 1274100-079000 ZT250－R Front disc brake tube bracket 2 PROCEDURE:...
Page 36 4044101-004036 ZT250－R oil cooler left decorative cover (dark gray) 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1051453-001000 9.8×2.2 Acrylate rubber O-shape ring 1244100-068000 ZT250-R Oil cooler inlet pipe 4044101-005036 ZT250－R oil cooler right decorative cover (dark gray) 1244100-069000 ZT250-R Oil cooler outlet pipe...
Page 37 7-FRONT FORK COMPONENT FIG.1 FRONT FORK Throttle/clutch cable clearance adjustment, light height COMPONENT adjustment PART NO. PART NAME CAUTION 1154100-013000 ZT250－R throttle accelerating cable (II) 1154100-014000 ZT250－R return line (II) 1154100-012000 ZT250－R clutch line (II) PROCEDURE: ●Throttle line Use an open-end wrench to loosen the lock nut① on the throttle refueling line(1) or the return line(2), and turn the adjustment bolt②...
Page 38 7-FRONT FORK COMPONENT FIG.2 FRONT FORK Replace the clutch line COMPONENT PART NO. PART NAME CAUTION 1154100-012000 ZT250－R clutch line (II) PROCEDURE: ●Disassemble the cluch line Use an open-end wrench to loosen the bolt② and bolt③; fix the adjusting screw①, rotate the bolt② up to the top of the thread of the adjusting screw, and screw the bolt③...
Page 39 1224100-049000 ZT250-R Line clamp 1184200-022000 ZT310－X Right handle bar switch Stop selling 1184200-140000 ZT310－X1 Right Handle Switch 1244100-042000 ZT250-R Right hand rubber sleeve 1224100-051000 Grade 0 flame retardant tie (black 2.5×100) PROCEDURE: ●Disassemble the throttle line Use an open-end wrench to turn the nut② of the throttle refueling line (1) or the oil return line (2) upside down, turn the nut④...
Page 40 . At the same time, check whether the seat ring(10) in the front frame of the motorcycle frame is abnormally worn or rusted. If you need to, you need to purchase replacement parts on Zontes official website. Newly-applied conjoined steel balls need to be evenly greased, paying attention to the amount of grease.
Page 41 Add brake fluid, rocker adjustment COMPONENT PART NO. PART NAME CAUTION 1134100-032000 ZT250-R Right handle rocker arm (Machine) 1100300-044000 ZT125T front disc brake main pump assembly (without handle) 1251513-013000 Disc brake copper washer φ15×φ10.2×1.5 1251100-112000 Disc brake oil pipe bolt M10×1-22 3070100-008600 Fully synthetic brake oil DOT4 (1L bottle) 【1】...
Page 42 7-FRONT FORK COMPONENT FIG.6 FRONT FORK Replace the front brake pads COMPONENT PART NO. PART NAME CAUTION 1100100-091000 ZT250-S Front Disc brake shoe (H10) After-sales PROCEDURE: ●Replace the front brake shoe Use a screwdriver to remove the nut①. Remove pin② with hexagonal tool. Remove the brake shoe (1).
Page 43 7-FRONT FORK COMPONENT FIG.7 FRONT FORK Instrument function description COMPONENT Instrument function: ①EFI failure signal light; ②ABS anti-lock braking system signal; ③MODE key; ④0D0 long odometer;TRIP short odometer; ⑤ total mileage; ⑥SET key;⑦Engine rev instrument；⑧ km mark; ⑨ECO indicator light; ⑩ battery low voltage prompt symbol;...
Page 44 1251100-117093 Non-standard hexagonal bolt M8×25 1274200-058000 ABS induction ring (60 teeth) 1094100-036000 ZT250-R Front wheel right axle sleeve 1094100-037000 ZT250-R Front wheel right fixed axle sleeve 1230100-077000 ZT250-S110/70R17(CM609)Tires 1094200-026000 ZT310－R black front rim (3.0×17) 1094200-034000 ZT310－R bright blue front wheel 3.0 (3.0×17)
Page 45 7-FRONT FORK COMPONENT FIG.9 FRONT FORK Front mud board & wheel speed sensor component COMPONENT PART NO. PART NAME CAUTION 1224100-037000 Grade 0 flame retardant tie (black 3.6×295) 1224100-044000 Wheel speed sensor clamp 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color zinc) 1251100-080094 Non-standard bolt M8×37 (environmental color zinc) 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1224200-127000 ZT310－T front wheel WSS wire clip...
Page 46 7-FRONT FORK COMPONENT FIG.10 FRONT FORK Head assembly 1 COMPONENT PART NO. PART NAME CAUTION 1251100-121093 Non-standard bolt M6×25 (environmental color) 1274100-007000 ZT250-S Flanged Bushing (φ6.4×φ9×6＋φ20×2) PROCEDURE: ●Head assembly Use your hand to hold the head assembly and remove the two bolts⑴ on the bottom of the lower plate with the hexagonal tool.
Page 47 7-FRONT FORK COMPONENT FIG.11 FRONT FORK Head assembly 2 COMPONENT PART NO. PART NAME CAUTION 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1174100-006000 ZT250-S Front right turn signal light 1224100-026000 ZT250-S Head cover rear shell 1244100-004000 ZT250-S Flange Bushing Buffer 1174100-005000 ZT250-S Front left turn signal light PROCEDURE: ●Turn signal light...
Page 48 7-FRONT FORK COMPONENT FIG.12 FRONT FORK Head cover upper part assembly COMPONENT PART NO. PART NAME CAUTION 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1224100-001000 ZT250-S Windshield 1251300-063093 Plywood M6×11×15(green color) 1224100-027000 ZT250-S Head cover sandwich 4044100-006033 ZT250-S Head cover upper part(bright orange) orange 4044100-006064 ZT250-S Head cover upper part(bright blue) blue...
Page 49 7-FRONT FORK COMPONENT FIG.13 FRONT FORK Front light assembly COMPONENT PART NO. PART NAME CAUTION 1174100-009000 ZT250－S LED Front light 1251300-063093 Plywood M6×11×15（environmental color） 1251200-033093 Non－standard self－tapping bolt ST4.2×12(color zinc ) ZT250－S head cover lower part (electroplated bright 4044100-007036 gray highlight) 4044100-007021 ZT250－S head cover lower part (special black) black PROCEDURE:...
Page 50 7-FRONT FORK COMPONENT FIG.14 FRONT FORK Instrument assembly COMPONENT PART NO. PART NAME CAUTION 1164100-005000 ZT250－R digital instrument (with gear display) 1274100-097000 ZT250－R instrument bracket 1244100-004000 ZT250－S Flanging bushing buffer 1274100-098000 ZT250－R instrument bracket left mounting ear 1274100-099000 ZT250－R instrument bracket right mounting ear 1250205-040095 GB70.1 inner hex bolt M8×16(color Zinc) PROCEDURE: ●Instrument...
Page 51 1184200-152000 ZT310－R Second Generation Left Handlebar Switch (LCD) 1250205-031091 GB70.1M6×30(stainless steel) 1184200-141000 ZT310－X1 Left Handle Switch 1244100-041000 ZT250-R Left hand rubber sleeve 1134200-023000 ZT250-R Balancing block 1134100-031000 ZT250-R Left handle rocker (Machine) 1244100-096000 ZT250－R protective rubber sleeve 1251100-198000 Non-standard bolt M6×13－φ8×20...
Page 52 PART NAME CAUTION 1194100-002000 ZT250-S Right rearview mirror 1100300-044000 Front disc brake main pump assembly(without handle) 1134100-032000 ZT250-R Right handle rocker arm (Machine) 1134200-023000 ZT250-R Balancing block 1244100-042000 ZT250-R Right handle rubber sleeve 1184100-105000 ZT310－R vice switch of right handle bar...
Page 53 7-FRONT FORK COMPONENT FIG.17 FRONT FORK Direction handle, upper plate assembly COMPONENT PART NO. PART NAME CAUTION 1224100-025000 ZT250-SM8 Bolt decoration buckle 1250205-023000 GB70.1 Hexagon M8×35 (environmental color zinc) 1134200-005000 ZT310－R press block of handle bar(home－made) 1134200-003000 ZT310－R handle bar 1251300-045000 ZT250-S Upper plate decorative nut (chrome) 1251500-050000 ZT250-S Upper plate gasket φ18.5×φ39×1 (chrome) 1114200-027000 ZT310－R front left shock absorber(improved)
Page 54 7-FRONT FORK COMPONENT Fig. 18 FRONT FORK Uplink plate, handle bar component COMPONENT PART NO. PART NAME CAUTION 1134200-012000 ZT310－R direction pad assembly 1274200-018000 ZT310－R gasket of upper connecting board 1244200-008000 ZT310－R buffer rubber of upper connecting board 1134200-004000 ZT310－R upper connecting board(home－made) 1251700-065000 ZT310－R bushing φ10×φ12×41 1251300-057093 Non－standard nut M10×1.5(dacromet) PROCEDURE:...
Page 55 1251100-112000 Disc brake pipe bolt M10×1－22 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color zinc) 1224100-044000 Wheel speed sensor clamp 1274100-079000 ZT250-R Front disc brake tube bracket No.2 1244100-069000 ZT250－R oil cooler outlet pipe 1224100-010000 ZT250-S Expansion nail 1224100-047000 ZT250-R ABS hydraulic control init cover 1244100-052000 Flanged bushing buffer (φ8.5×φ14×1)
Page 56 1251513-013000 Disc brake pipe copper washer φ 15× φ 10.2 × 1.5 1251112-001093 M6×16 Hexagon flange bolts (color zinc) 1274100-088000 ZT250-R Rear disc brake oil pipe clamp (steel / rubber pad) PROCEDURE: ●Foot support assembly Cut the cable tie ⑴; remove the split pin ①, gasket ②, and pin ③ at the connection between the rear brake main pump and the brake pedal.
Page 57 PART NAME CAUTION 1194100-002000 ZT250-S Right rearview mirror 1100300-044000 ZT125T front disc main pump assembly(without rocker arm) 1134100-032000 ZT250-R Right handle rocker arm (Machine) 1184100-105000 ZT310－R vice switch of right handle bar Stop selling 1184200-153000 ZT310－R Second Generation Right Handlebar Switch (LCD) 1250205-031091 GB70.1M6×30(stainless steel)
Page 58 8-FUEL TANK COMPONENT FIG.1 FUEL TANK INNER Fuel tank inner tank component COVER PART NO. PART NAME CAUTION 1250205-043093 GB70.1M8×55 (environmental color) 1251900-028093 Fuel tank flat gasket (environmental color) 1244100-020000 Fuel tank press rubber 1244100-053000 Fuel tank gasket rubber 1274100-080000 Seat fixed block 1050954-006000 Fuel injection high pressure subcomponent PROCEDURE: ●Fuel tank inner tank component...
Page 59 8-FUEL TANK COMPONENT FIG.2 FUEL TANK Fuel tank middle cover assembly COVER PART NO. PART NAME CAUTION 1251200-033093 Non-standard nut (environmental color) 1251100-102000 Non-standard bolts M6×16 (304 stainless steel) 1224100-010000 Expansion nail PROCEDURE: ●Fuel tank middle cover assembly Turn the Fuel tank cover and Fuel tank liner assembly upside down and remove the bolt (1).Be careful not to close the Fuel tank cover and take care to protect the paint surface.
Page 60 8-FUEL TANK COMPONENT FIG.3 FUEL TANK Fuel tank middle cover、Fuel tank cover、Fuel tank COVER lock PART NO. PART NAME CAUTION 4044101-003033 ZT250－R Fuel tank middle cover（bright orange） orange 4044101-003064 ZT250－R Fuel tank middle cover（bright blue） blue 4044101-003021 ZT250－R fuel tank middle cover (special black) gray 4044100-010051 ZT250－S fuel tank cover (titanium) special black...
Page 61 8-FUEL TANK COMPONENT FIG.4 FUEL TANK Fuel tank left and right cover assembly COVER PART NO. PART NAME CAUTION 1251100-102000 Non-standard bolt M6×16（stainless steel） 1274100-007000 ZT250-S Flanged Bushing (φ6.4×φ9×6＋φ20×2) 1244100-004000 ZT250－S Flanged bushing buffer 1251300-063093 Plywood M6×11×15（environmental color） 1210141-001000 ZT250－S Fuel tank sticker for after-sale ZT250－R right tank cover (electroplated bright gray 4044101-002036...
Page 62 8-FUEL TANK COMPONENT FIG.5 FUEL TANK INNER Fuel tank inner tank COVER PART NO. PART NAME CAUTION 1250105-137093 GB5789M6×16 (environmental color) 1050953-020000 T02 built-in fuel pump 4034100-006000 Fuel tank inner tank 1244100-002000 Side cover round rubber 1240300-021000 Plastic piece 0.17 1224100-033000 Fuel tank cap 1224200-066000 ZT310PKE External antenna mount 1164100-006000 T02 oil level sensor...
Page 63 9-SIDE COVER COMPONENT FIG.1 SIDE COVER Side cover assembly COMPONENT PART NO. PART NAME CAUTION 1224100-024000 ZT250－S Plastic connection piece 4044100-016036 ZT250－S left side cover (electroplated bright gray highlight) 4044100-016021 ZT250－S left side cover (special black) special black 4044100-021033 Left side cover decorative cover (bright orange) orange 4044100-021064 Left side cover decorative cover (light blue) blue...
Page 64 10-REAR COVER COMPONENT FIG.1 REAR COVER Rear handrail、Cushion lock bracket COMPONENT PART NO. PART NAME CAUTION 1144100-001000 ZT250－S Rear handrail 1251100-123093 Non-standard bolt M8×25（environmental color） 1244100-065000 ZT250-S rear cover left limit rubber 1250205-040095 GB70.1 inner hex bolt M8×16(color Zinc) 1274100-075000 ZT250－S Rear cover left limit bracket 1251100-101000 Non－standard bolt M6×12 (304 stainless steel) 1224100-051000 Grade 0 flame retardant tie (black 2.5×100) 1020241-229000 ZT250－R seat cushion lock bracket...
Page 65 Locate and unplug the cable connector of the rear taillight, grasp the rear taillight ⑽ and push the left tail skirt another one on Zontes official website. assembly back and take it off. Similarly, remove the right tail skirt assembly and remove the rear taillight ⑽.
Page 66 10-REAR COVER COMPONENT FIG.3 REAR COVER Battery、Electrical device box cover、ECU COMPONENT PART NO. PART NAME CAUTION 1224100-052000 ZT250－R Electrical device box cover 1244100-072000 ZT250－R Battery straps 1224100-051000 Grade 0 flame retardant tie (black 2.5×100) 1184100-116000 ZT250 lithium battery 1240100-023000 Battery anode protection glue 1274200-078000 ZT310－R bike tools 1251100-102000 Non－standard bolt M6×16(304 stainless steel) 1184200-024000 ZT310－R relay of side support...
Page 67 PROCEDURE： ●Electrical component box assembly Push the buckle in the direction of the arrow to remove the lower cover of the ZT250-R electrical component box ⑴ and the lower cover of the ZT310 electrical component box ⑶. Pull down in the direction of the arrow to remove the back glue of the electrical device box ⑵.
Page 68 10-REAR COVER COMPONENT FIG.5 REAR COVER Electrical device box component 1 COMPONENT PART NO. PART NAME CAUTION 1250205-040095 GB70.1 inner hex bolt M8×16(color Zinc) 1274100-101021 ZT250－R electric component box mounting board 1184200-053000 ZT310PKE external single antenna PROCEDURE: ●Electrical device box component Locate the PKE external antenna ⑶...
Page 69 10-REAR COVER COMPONENT FIG.6 REAR COVER Electrical device box component 2 COMPONENT PART NO. PART NAME CAUTION 1224200-092053 ZT250－R Electrical Device Box (PKE) 1244100-079000 ZT250－R left electric device box rubber 1251100-102000 Non－standard bolt M6×16(304 stainless steel) 1184200-054000 ZT310 PKE controller (single antenna) Stop selling 1184200-137000 ZT310 PKE new version (band version ) bracelet edition...
Page 70 10-REAR COVER COMPONENT FIG.7 REAR COVER External battery start PKE system COMPONENT PROCEDURE: ●Emergency handling method after the battery is destroyed or the battery is exhausted for too long: Find a 15A fuse and wind a wire around any one of the fuses as shown in the left side. Remove the lower cover of the electrical device box;...
Page 71 COMPONENT PART NO. PART NAME CAUTION 1204100-006000 ZT250-R Cushion one set 1244100-024000 ZT250-R Cushion front rubber for after-sale 1244100-022000 ZT250-R Cushion rubber 1244100-025000 ZT250-R Cushion circle rubber PROCEDURE: ●Seperate cushion Insert the key in the "OFF" position ,counterclockwise until the sound indicates that the cushion lock is open.
Page 72 12-MUFFLER COMPONENT FIG.1 MUFFLER Remove muffler 1 COMPONENT PART NO. PART NAME CAUTION 1251300-057093 Non-standard bolt M10×1.5 1251100-084093 Non-standard bolt M10×1.5×66 1020241-094000 ZT250－S Flange of muffler 1251300-058093 Hexagon nut M8（color zinc） 1224100-013000 ZT250－S Oxygen sensor fixing buckle PROCEDURE： ●Muffler parts Fix the motorcycle,use the sleeve to fix the head of the bolt ⑵...
Page 73 12-MUFFLER COMPONENT FIG.2 MUFFLER Remove muffler 2 COMPONENT PART NO. PART NAME CAUTION 1251100-082093 Non-standard bolt M10×1.5×20 1251100-084093 Non-standard bolt M10×1.5×66 1070100-133000 ZT250－S Engine exhaust port gasket PROCEDURE： ●Muffler component Fix the motorcycle, use the sleeve to remove the bolt ⑴ by holding the muffler tail part with hands, then remove the bolt ⑵...
Page 74 12-MUFFLER COMPONENT FIG.3 MUFFLER Muffler component COMPONENT PART NO. PART NAME CAUTION 1124100-018000 ZT250－R muffler (homemade / national IV) Inland 1124100-015000 ZT250－R Muffler(Europe IV) Export 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1274100-018000 ZT250－S Muffler anti-hot plate bushing 1244100-017000 ZT250－S Muffler anti-hot plate rubber buffer 1224100-028000 ZT250－S Muffler anti-hot plate 1224100-029000 ZT250－S Muffler tail cover 1050953-008000 OSM planar oxygen sensor...
Page 75 13-LOWER WIND DEFLECTOR COMPONE FIG.1 LOWER WIND Lower air guide sleeve component-1 DEFLECTOR COMPONE PART NO. PART NAME CAUTION 1251100-102000 Non-standard bolt M6×16 (304 stainless steel) 1274100-007000 ZT250-S Flanged Bushing (φ6.4×φ9×6＋φ20×2) PROCEDURE: ●Lower air guide sleeve component Lift the motorcycle with tools and remove the bolt ⑴ and flanged bushing ⑵ with an inner hexagonal tool. CAUTION: ●In the process of disassembly, the motorcycle should be properly supported to prevent accident caused by incline.
Page 76 13-LOWER WIND DEFLECTOR COMPONE FIG.2 LOWER WIND Lower air guide sleeve component-2 DEFLECTOR COMPONE PART NO. PART NAME CAUTION 1251300-063093 Plywood M6×11×15(environmental color) ZT250－S lower right guide guide cover (electroplated 4044100-008036 bright gray highlight) 4044100-008021 ZT250－S lower guide cover right (special black) special black 1244100-004000 ZT250－S Flanged bushing buffer 1251100-102000 Non-standard bolt M6×16 (304 stainless steel)

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Zt250-r euro/iv 2019