Zontes ZT125-Z2 Service Manual
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Zontes ZT125-Z2 Service Manual

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ZT125/155-Z2（EURO V）
Service manual
2021/1/6

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Summary of Contents for Zontes ZT125-Z2

  • Page 1 ZT125/155-Z2（EURO V） Service manual 2021/1/6...
  • Page 2 Contents Table of Contents Pages Table of Contents…………………………………………………………………………………………………………………………………………………………………………………… FRAME&ELECTRONIC COMPONENT 1.1 Electrical device component-1………………………………………………………………………………………………………………………………………………………………………… 6 Main harness, dump switch, relay, flasher 1.2 Electrical device component-2………………………………………………………………………………………………………………………………………………………………………… 7 Flameout switch, horn,ignition coil 1.3 Electrical device component-3………………………………………………………………………………………………………………………………………………………………………… 8 ECU、relay 1.4 Electrical device component-4………………………………………………………………………………………………………………………………………………………………………… 9 rectifier、Buzzer 1.5 Frame plastic parts……………………………………………………………………………………………………………………………………………………………………………………...
  • Page 3 Contents Table of Contents Pages 4.2 Rear shock absorption………………………………………………………………………………………………………………………………………………………………………………… 19 Demolition after shock absorption, rear shock absorption adjustment 4.3 Rear wheel component 1……………………………………………………………………………………………………………………………………………………………………………… 20 Disassemble the rear rim component, sprocket seat, sprocket 4.4 Rear wheel component 2……………………………………………………………………………………………………………………………………………………………………………… 21 Disassembled rear rim component 4.5 Rear fork component…………………………………………………………………………………………………………………………………………………………………………………...
  • Page 4 Contents Table of Contents Pages Disassemble water tank component,water tank bracket FRONT FORK COMPONENT 7.1 Throttle/clutch cable clearance adjustment, light height adjustment…………………………………………………………………………………………………………………………………… 37 7.2 Replacement clutch cable……………………………………………………………………………………………………………………………………………………………………………… 38 7.3 Replace the throttle cable……………………………………………………………………………………………………………………………………………………………………………… 39 7.4 Steering adjustment…………………………………………………………………………………………………………………………………………………………………………………… 40 7.5 Right hand component………………………………………………………………………………………………………………………………………………………………………………… 41 Remove right rear view mirror, right hand rubber sleeve, balance block 7.6 Add brake fluid, rocker adjustment……………………………………………………………………………………………………………………………………………………………………...
  • Page 5 Contents Table of Contents Pages Releasing brake fluid,FMC tubing 7.20 ABS brake system-3…………………………………………………………………………………………………………………………………………………………………………………… 56 Disassemble FC tubing 7.21 ABS brake system-4…………………………………………………………………………………………………………………………………………………………………………………… 57 Disassemble RMC tubing,RC tubing FUEL TANK COMPONENT 8.1 Fuel tank component…………………………………………………………………………………………………………………………………………………………………………………… 58 Disassemble Fuel tank component 8.2 Fuel tank cover component 1………………………………………………………………………………………………………………………………………………………………………… Disassemble fuel tank cover component 8.3 Fuel tank cover component 2…………………………………………………………………………………………………………………………………………………………………………...
  • Page 6 Contents Table of Contents Pages Disassemble the taillight component 11.4 Rear mud board component 1………………………………………………………………………………………………………………………………………………………………………… 69 Disassemble rear fender component,rear fender bracket cover,rear fender bracket 11.5 Rear mud board component 2………………………………………………………………………………………………………………………………………………………………………… 70 Disassemble rear mud board component,rear turn sinagl 11.6 Battery component(colliod battery)…………………………………………………………………………………………………………………………………………………………………… 71 Disassemble battery ,electric device box cover 11.7 Battery component……………………………………………………………………………………………………………………………………………………………………………………...
  • Page 7 1-FRAME&ELECTRONIC COMPONENT Fig.1 FRAME&ELECTRONIC Electronic parts COMPONENT 1 COMPONENT PART NO. PART NAME CAUTION 1181200-106000 KD150－Z2 wiring harness assembly 1250303-010093 GB6177.1M6（color zinc ） 1050954-009000 YH canister solenoid valve 1244100-082000 ZT250－R dump switch sleeve 1184100-002000 ZT250－S dump switch 1184100-017000 ZT250－S fuel-injection relay KH-1A4T 1184200-039000 ZT310-R flasher 1224100-037000 Grade 0 flame retardant tie (black 3.6×295)
  • Page 8 1-FRAME&ELECTRONIC COMPONENT Fig.2 FRAME&ELECTRONIC Electronic parts COMPONENT 2 COMPONENT PART NO. PART NAME CAUTION 1184200-004000 ZT310 horn 1251112-001093 M6×16 Hexagon flange bolts (color zinc) 1224100-037000 Grade 0 flame retardant tie (black 3.6×295) 1250205-040095 GB70.1 inner hex bolt M8×16（color Zinc） 1184100-012000 ZT250－S shut down switch 1250201-032093 GB818M5×16 (environmental color) 1184200-104007 ZT310 EFI ignition coil (with high voltage line) PROCEDURE：...
  • Page 9 1-FRAME&ELECTRONIC COMPONENT Fig.3 FRAME&ELECTRONIC Electronic parts COMPONENT 3 COMPONENT PART NO. PART NAME CAUTION 1184100-010000 Starting relay 1251100-119093 Non-standard bolt M6×12 (environmental color) 1251100-120093 Non-standard bolts M6×16 (environmental color) MSE6.0 controller 【1】 1271200-080000 KD150-U Bosch ECU bracket PROCEDURE： ●Relay Turn off the positive and negative.protective rubber caps (red for the positive and black for the negative) of the starter relay⑴.Using 10#sleeve remove nuts then remove the positive and negative connectors, and screw the nut back onto the relay stud to preventloss.Take off plug of the start relay and main hamess.
  • Page 10 1-FRAME&ELECTRONIC COMPONENT Fig.4 FRAME&ELECTRONIC Electronic parts COMPONENT 4 COMPONENT PART NO. PART NAME CAUTION 1184200-039000 ZT310-R flasher 1251112-003093 M6×45 Hex flange surface 9.8 bolt (color zinc) KD150-U rectifier shroud Bushing Φ12 × Φ6 × 26.5 (environmental protection 1251700-146000 color) 1181200-085000 KD150-U rectifier 1251112-002093 M6×30 Hexagon flange bolts (color zinc) KD150－U engine left rear cover PROCEDURE：...
  • Page 11 1-FRAME&ELECTRONIC COMPONENT Fig.5FRAME&ELECTRONIC Frame plastic parts PARTS COMPONENT PART NO. PART NAME CAUTION 1241200-044000 KD150-U fuel tank liner limit glue 1240300-007000 HJ125－6 Battery rubber gasket 1244100-002000 ZT250－S Side cover round rubber 1244100-061000 ZT250 anti-water rubber of frame 1251112-001093 M6×16 Hexagon flange bolts (color zinc) 1221200-058000 KD150-U clamp PROCEDURE：...
  • Page 12 ●Please check whether the steel beads of the conjoined body have abnormal phenomena such as partial abrasion Remove the rubber pad ⑶. and rust.If YES, please buy the regular accessories on ZONTES official website, if not, please be sure to grease the old grease and repaint the lubricating grease on it.
  • Page 13 1-FRAME&ELECTRONIC COMPONENT Fig.7 FRAME&ELECTRONIC Frame, side bracket COMPONENT PART NO. PART NAME CAUTION Frame after-sales component(contains fix loop and nameplate) 1130900-026000 ZT250－S upper steel bowl after sales 1251300-057093 Non-standard nut M10×1.5（dacromet） 1251700-025091 ZT250－S side stand sleeve Side support 1251100-088094 Non-standard nut M10×1.5×43（dacromet） 1264100-001000 ZT250－S side stand spring PROCEDURE：...
  • Page 14 2-FRAME & ENGINE COMBINATION Fig.1 FRAME & ENGINE Frame & engine combination 1 COMBINATION PART NO. PART NAME CAUTION 1244100-061000 ZT250 anti-water rubber of frame 1251100-142000 Non-standard hexagon socket bolt M10 × 1.5 × 130 1244100-089000 ZT250-R guard bar anti-drop glue KD150－Z2 crash bar rubber mounting sleeve (dark 4111200-007051 gray matte)
  • Page 15 2-FRAME & ENGINE COMBINATION Fig.2 FRAME & ENGINE Frame & engine combination 2 COMBINATION PART NO. PART NAME CAUTION 1251112-003093 M6×45 Hex flange surface 9.8 bolt (color zinc) 1271200-138000 KD150－Z2 Left bracket of lower shroud 1271200-139000 KD150－Z2 Right bracket of the lower shroud 1251112-002093 M6×30 Hexagon flange bolts (color zinc) 1250105-017091 GB5789 M8×65(zinc) 4021200-030000 KD150－U frame left hanging piece...
  • Page 16 3-INTAKE SYSTEM COMPONENT Fig.1 INDUCTION Intake system component SYSTEM COMPONENT PART NO. PART NAME CAUTION 1051356-012000 φ42 × 10 pipe hoop assembly 1050954-009000 YH canister solenoid valve 1250303-010093 GB6177.1M6（color zinc ） 1221200-125000 KD150－G1 Carbon Canister (Special for Euro V) 1221200-033000 KD125-U air filter 1246200-041000 KD150-U oil and gas separator intake pipe KD150-U external oil and gas separator (no filter 1221200-124000...
  • Page 17 3-INTAKE SYSTEM COMPONENT Fig.2 INDUCTION Throttle valve body component SYSTEM COMPONENT PART NO. PART NAME CAUTION 1251112-001093 M6×16 Hexagon flange bolts (color zinc) 1050956-010000 KD150-G1 EFI High Pressure Tubing Sub-assembly 1051468-007000 31.8×2 fluorine rubber O-ring Intake manifold assembly 1051356-010000 Φ45×10 pipe clamp assembly Throttle body assembly 1050968-003000 EV14 injector G06 1050968-002000 ZT1P58MJ injector holder...
  • Page 18 3-INTAKE SYSTEM COMPONENT Fig.3 INDUCTION Replace air filter element SYSTEM COMPONENT PART NO. PART NAME CAUTION KD125－U air filter element ROCEDURE: ●Filter element If you need to maintain the filter element of the air filter, remove the seat cushion, the right side cover Take the two standard parts ①...
  • Page 19 4-REAR WHELL COMPONENT Fig.1 REAR WHELL Rear mud board COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non－standard bolt M6×16(304 stainless steel) 1224200-003000 ZT310－Z Rear disc brake pipe clamp 1184200-045000 DF30 wheel speed sensor 1100100-564000 KD150－U brake hose RC－HU segment 1244100-052000 Buffer rubber of flanging bushing (φ8.5×φ14×1) Flanging bushingφ6.4×φ9×8＋φ18×2(environmental 1251700-059093 color)
  • Page 20 4-REAR WHELL COMPONENT Fig.2 REAR WHELL Rear shock absorption COMPONENT PART NO. PART NAME CAUTION 1251100-085093 Non－standard bolt M10×1.5×75(dacromet) 1251100-132003 Non－standard bolt M10×1.5×80(dacromet) Rear shock absorption 1251300-057093 Non－standard nut M10×1.5(dacromet) 65±2N.m PROCEDURE: ●Rear shock absorber Put down side stand. Person 1: Turn the handling bar to left end with left hand; hold tight the rear pedal with right hand and lean the motorcycle to left side.Another person used a wooden stool to put a soft rubber cushion on the right side muffler back pressure bag of the bike to support the whole bike and let the rear wheel slightly off the ground.
  • Page 21 4-REAR WHELL COMPONENT Fig.3 REAR WHELL Rear wheel component 1 COMPONENT PART NO. PART NAME CAUTION 1251100-105000 ZT310－Z chain adjuster bolt M10×70 1251300-050000 ZT310－Z chain adjuster bolt M10(304 stainless steel) ZT310 R, chain adjuster 1251300-067000 ZT250－R rear wheel hollow shaft nut 110N.m ZT310 L, chain adjuster 1091200-025000 KD150－U rear wheel hollow shaft...
  • Page 22 4-REAR WHELL COMPONENT Fig.4 REAR WHELL Rear wheel component 2 COMPONENT PART NO. PART NAME CAUTION 1230100-446000 130/70－17 (CMNK01) environmental protection vacuum tire 1091200-023000 KD150－U bright black rear rim (3.5×17) 1100100-600000 KD150－U rear brake disc (230 × 4.5 / KD) 1274200-058000 ABS induction ring (60 teeth) 1251100-117093 Non－standard inner hex bolt M8×25(color zinc) 22～24N.m...
  • Page 23 4-REAR WHELL COMPONENT Fig.5 REAR WHELL Rear fork component COMPONENT PART NO. PART NAME CAUTION 1252200-068000 KD150－U rear fork shaft 1251300-067000 ZT250－R rear wheel shaft nut 110±5N.m Link chain (KMC520HD) 1251300-050000 ZT310-Z chain adjuster nut M10(304 stainless steel) 1251100-105000 ZT310-Z chain adjuster bolt M10×70 (304 stainless steel) ZT125 aluminum alloy rear fork assembly 1251100-102000 Non－standard bolt M6×16(304 stainless steel) 1274100-057095 Flanging bushing φ6.2×φ8.5×3.5＋φ14×1.5...
  • Page 24 4-REAR WHELL COMPONENT Fig.6 REAR WHELL Replace the rear brake pads COMPONENT PART NO. PART NAME CAUTION 1100100-092000 ZT250－S rear disk brake piece (HS10) after-sales PROCEDURE: ●Disassemble disc brake arrester Using strait screwdriver to disassemble nut①. Disassemble pin axle② with a 5# inner hexagon socket. Disassemble rolling axle③...
  • Page 25 4-REAR WHELL COMPONENT Fig.7 REAR WHELL Rear brake main pump adds brake fluid COMPONENT PART NO. PART NAME CAUTION 1251100-101000 Non－standard bolt M6×12 (304 stainless steel) 1271200-087000 KD150－U rear disc brake oil cup bracket PROCEDURE: ●Add disc brake liquid Cover the right pedal bracket with a waterproof plastic bag to prevent the brake fluid from dripping onto the paint and causing corrosion.
  • Page 26 5-PEDAL COMPONENT Fig.1 FOOT PEDAL Adjust the hight of foot pedal COMPONENT PART NO. PART NAME CAUTION 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color zinc) ZT250－S Gear swift rod spline of Rocker arm 1250301-020093 GB6170M6 (environmental color) 1271200-086000 KD150－U shift lever adjusting screw φ10×72 1250301-018093 GB6170 M6－LH (army green) ZT310－T rocker arm, gear shift rod KD150－U brake pedal...
  • Page 27 5-PEDAL COMPONENT Fig.2 FOOT PEDAL Right footrest component 1 COMPONENT PART NO. PART NAME CAUTION 1250205-023000 GB70.1 inner hexagonal M8X35 (color zinc) 1251100-101000 Non－standard bolt M6×12 (304 stainless steel) PROCEDURE: ●Right Foot pedal component Using a plier to disassemble the pin①. Then take off the washer② and pin③. Using 6# inner hexagon socket remove 3pcs bolts⑴.
  • Page 28 5-PEDAL COMPONENT Fig.3 FOOT PEDAL Right footrest component 2 COMPONENT PART NO. PART NAME CAUTION 1251100-121093 Non－standard bolt M8×25 (color zinc) 1251100-131000 Non－standard shaft position bolt M10×1.5×36(zine) KD150－U brake pedal 1260100-119093 ZT310－R Brake footrest torsion spring (color zinc) 1251500-060095 Non－standard flat padφ10.5×φ26×1(zine) 1251100-101000 Non－standard bolt M6×12 (304 stainless steel) 1271200-087000 KD150－U rear disc brake oil cup bracket PROCEDURE:...
  • Page 29 5-PEDAL COMPONENT Fig.4 FOOT PEDAL Right footrest component 3 COMPONENT PART NO. PART NAME CAUTION KD150－U right pedal support 1274100-012000 ZT250－S Pedal pin 1264100-006000 ZT250－S Pedal circlip 1264100-004000 ZT250－S front right foot pedal torsional spring ZT310－X R, front pedal component ZT310－X R, rear pedal component 1270300-272000 KD250－F rear pedal locating plate 1274100-010000 ZT250－S rear pedal steel ball...
  • Page 30 5-PEDAL COMPONENT Fig.5 FOOT PEDAL Left footrest component 1 COMPONENT PART NO. PART NAME CAUTION 1250205-023000 GB70.1 inner hexagonal M8X35(color zinc) 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color zinc) 1251100-123093 Non－standard bolt M8×25 (color zinc) 1251500-048000 ZT250－S Pedal support gasket PROCEDURE: ●L, foot pedal holder assembly Remove the rectifier guard first.
  • Page 31 5-PEDAL COMPONENT Fig.6 FOOT PEDAL Left footrest component 2 COMPONENT PART NO. PART NAME CAUTION ZT310－X L, front pedal component 1264100-003000 ZT250－S front left foot pedal torsional spring 1274100-012000 ZT250－S Pedal pin 1274100-035000 ZT250－S Foot pedestal 1264100-006000 ZT250－S Pedal circlip 1250303-010093 GB6177.1M6(color zinc ) 1274200-160000 ZT310－T shift lever step rocker 1274100-043000 Miniature rod end ball bearing SALJK6C...
  • Page 32 5-PEDAL COMPONENT Fig.7 FOOT PEDAL Left footrest component 3 COMPONENT PART NO. PART NAME CAUTION ZT310－X L, rear foot pedal component 1264100-005000 ZT250－S foot pedal steel ball spring 1274100-010000 ZT250－S rear pedal steel ball 1270300-272000 KD250－F rear pedal locating plate 1274100-012000 ZT250－S Pedal pin 1264100-006000 ZT250－S Pedal circlip KD150－U left pedal support...
  • Page 33 6-COOLING SYSTEM COMPONENT Fig.1 COOLING SYSTEM Change the oil and the oil filter COMPONENT PART NO. PART NAME CAUTION 1251100-066093 M12×1.5×15 oil drain bolt (color zinc) 30±3N.m 1244100-033000 Combined sealing gasket12×φ20×2 1050868-010000 ZT1P58MJ coarse filter cover (iron gray) 32±1.5N.m 1051468-003000 34.5×3.5 acrylate adhesive O－ring 1050868-003000 Φ25.8×34.2×1.8 coarse filter spring 1050868-004000 Outer diameter φ22×21 hat－shaped coarse filter 1251300-054000 M20×1.5 fuel filler cap...
  • Page 34 6-COOLING SYSTEM COMPONENT Fig.2 COOLING SYSTEM Add coolant COMPONENT PART NO. PART NAME CAUTION 1221200-050000 KD150－U auxiliary water tank PROCEDURE: ●Add coolant When the engine is completely cooled, the vehicle can be straightened to accurately check the liquid level. If it is lower than the "L"...
  • Page 35 6-COOLING SYSTEM COMPONENT Fig.3 COOLING SYSTEM Change coolant COMPONENT PART NO. PART NAME CAUTION 1251100-067093 M6×10 top pin bolt (color zinc) 12±1.5N.m 1251513-001019 6.3×12×1.6 copper gasket 1221200-069000 KD150－U water tank water inlet 1221200-050000 KD150－U auxiliary water tank PROCEDURE: ●Drain the cooling liquid Cover the right crankcase cover and cylinder block of the engine with a waterproof cloth to prevent the coolant from dripping onto the cover and the engine.
  • Page 36 6-COOLING SYSTEM COMPONENT Fig.4 COOLING SYSTEM Water tank component 1 COMPONENT PART NO. PART NAME CAUTION 1274200-088000 ZT310 water pipe clamp(φ10.5) 1241200-051000 KD150-U auxiliary water tank connection water pipe 1274200-089000 ZT310 water pipe clamp(φ22) 1241200-054000 KD150－U engine water inlet pipe 1251112-002093 M6×30 Hexagon flange bolts (color zinc) 1241200-055000 KD150－U small circulation water pipe 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color zinc)
  • Page 37 6-COOLING SYSTEM COMPONENT Fig.5 COOLING SYSTEM Water tank component 2 COMPONENT PART NO. PART NAME CAUTION 1221200-069000 KD150－U water tank water inlet 1274200-089000 ZT310 water pipe clamp(φ22) 1241200-052000 Water tank water inlet connection water pipe 1271200-066000 KD150－U water tank 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color zinc) 1271200-081000 KD150－U water tank cover bracket 4021200-024000 KD150－U radiator bracket PROCEDURE:...
  • Page 38 7-FRONT FORK COMPONENT Fig.1 FRONT FORK Throttle/clutch cable clearance adjustment, light height COMPONENT adjustment PART NO. PART NAME CAUTION 1151200-041000 KD150－Z2 throttle return cable 1151200-046000 KD150－Z2 throttle accelerating cable 1154100-011000 ZT250 － R clutch cable 1244200-046000 ZT310－V clutch cable sheath PROCEDURE: ●Throttle cable Use an open-end wrench to loosen the lock nut ①...
  • Page 39 7-FRONT FORK COMPONENT Fig.2 FRONT FORK Replacement clutch cable COMPONENT PART NO. PART NAME CAUTION 1154100-011000 ZT250 － R clutch cable 1244200-046000 ZT310－V clutch cable sheath PROCEDURE: ●Remove the cluch cable Use an open-end wrench to loosen the nuts ② and ③; fix the adjusting screw ①, rotate the nut ② up to the top of the thread of the adjusting screw, and screw the nut ③...
  • Page 40 7-FRONT FORK COMPONENT Fig.3 FRONT FORK Replace the throttle cable COMPONENT PART NO. PART NAME CAUTION 1151200-041000 KD150－Z2 throttle return cable 1151200-046000 KD150－Z2 throttle accelerating cable 1221200-058000 KD150－U clamp 1224100-051000 Grade 0 flame retardant tie (black 2.5×100) 1244100-042000 ZT250－R right handle bar rubber sleeve 1184200-185000 ZT310－V1 right handlebar switch 1251100-219000 Cross ball screw M5×30 after-sales...
  • Page 41 7-FRONT FORK COMPONENT Fig.4 FRONT FORK Steering adjustment COMPONENT PART NO. PART NAME CAUTION 1251300-045000 ZT250－S upper connection decoration nut(chroming) 100N·m 1251500-050000 ZT250－S upper connection gasket φ18.5×φ39×1 1250205-023000 GB70.1 inner hexagonal M8X35 (environmental color) 22～24N.m 1134100-007000 ZT250－S Adjusting nut locking washer 1251300-046093 Direction column adjusting screw nut M24X1 1244100-015000 ZT250－S Adjusting nut rubber pad 1224100-005000 ZT250－S steering stem dust cap (Up)
  • Page 42 7-FRONT FORK COMPONENT Fig.5 FRONT FORK Right hand component COMPONENT PART NO. PART NAME CAUTION 1194100-002000 ZT250－S right rearview mirror ZT125T front disc main pump assembly（without 1100300-044000 rocker arm） 1134100-032000 ZT250-R Right handle rocker (Machine) 1134200-023000 ZT250－R balance block assembly 1244100-042000 ZT250－R right handle bar rubber sleeve 1134100-019000 ZT250-R right hand half cover 1251100-121093 Non-standard bolt M8×25 (color zinc)
  • Page 43 7-FRONT FORK COMPONENT Fig.6 FRONT FORK Add brake fluid, rocker adjustment COMPONENT PART NO. PART NAME CAUTION 1134100-032000 ZT250－R Right handle rocker (Machine) 1100300-044000 ZT125T front disc main pump assembly 1251513-013000 Disc brake pipe copper washer φ 15× φ 10.2 × 1.5 1251100-112000 Disc brake pipe bolt M10×1－22 32N.m PROCEDURE:...
  • Page 44 7-FRONT FORK COMPONENT Fig.7 FRONT FORK Replace the front brake pads COMPONENT PART NO. PART NAME CAUTION 1100100-704000 KD150－U front disk brake piece(SF627) after-sales 1100100-570000 ZT310－T front brake caliper mounting plate after-sales PROCEDURE: ●Replace the front brake pad Use a screwdriver to remove the nut①. Remove pin ②...
  • Page 45 7-FRONT FORK COMPONENT Fig.8 FRONT FORK Front wheel component COMPONENT PART NO. PART NAME CAUTION 1250205-023000 GB70.1 inner hexagonal M8X35 (environmental color) 20N.m 1094100-033000 ZT250－R front wheel hollow shaft 1094100-008000 ZT250－R front right sleeve 1100100-601000 KD150－U front brake disc plate(300 × 4.5 / KD) 1251100-117093 Non－standard inner hex bolt M8×25(color zinc) 22～24N.m 1274200-058000 ABS induction ring (60 teeth)
  • Page 46 7-FRONT FORK COMPONENT Fig.9 FRONT FORK Front mud board & wheel speed sensor component COMPONENT PART NO. PART NAME CAUTION 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color zinc) 1224100-044000 Wheel speed sensor clamp 1251100-080094 Non－standard bolt M8×37(color zinc) 1224100-037000 Grade 0 flame retardant tie (black 3.6×295) 1251100-101000 Non－standard bolt M6×12 (304 stainless steel) 1184200-045000 DF30 wheel speed sensor...
  • Page 47 7-FRONT FORK COMPONENT Fig.10 FRONT FORK Head and headlights component 1 COMPONENT PART NO. PART NAME CAUTION 1251100-101000 Non-standard bolt M6×12（304 stainless steel） 1224100-037000 grade 0 flame retardant tie (black 3.6×295) PROCEDURE: ●Remove the headlight Turn the stearing to the far left, and remove the 2 bolts (1) in Figure A. Turn the stearing to the far right, and remove the 2 bolts (1) in Figure B.
  • Page 48 7-FRONT FORK COMPONENT Fig.11 FRONT FORK Head and headlights component 2 COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non-standard bolt M6×16（304 stainless steel） 1274100-057095 Flanging bushing φ6.2×φ8.5×3.5＋φ14×1.5 1244100-052000 Buffer rubber of flanging bushing （φ8.5×φ14×1） 4041201-152051 KD150－Z2 dark gray head cover left part 4041201-153051 KD150－Z2 dark gray head cover right part 4041201-224000 ZT155-Z2 windshield 1251300-063093 Plywood M6×11×15（color zinc）...
  • Page 49 7-FRONT FORK COMPONENT Fig.12 FRONT FORK Head and headlights component 3 COMPONENT PART NO. PART NAME CAUTION 1221200-087000 KD150－Z2 hood rear case 1224200-008000 ZT310－R cable plastic staple 1251100-102000 Non-standard bolt M6×16（304 stainless steel） 1250105-138093 GB5789M6×20 (environmental color) 1251700-059093 Flanging bushingφ6.4×φ9×8＋φ18×2 1240400-007000 Battery holder buffer aprons 1240300-021000 HJ125－6 pod glass strip (1.5m) 38mm...
  • Page 50 7-FRONT FORK COMPONENT Fig.13 FRONT FORK Speedometer component COMPONENT PART NO. PART NAME CAUTION 1250205-040095 GB70.1 inner hex bolt M8×16(color Zinc) 1166100-001000 ZT125－U electronic instrument (electrospray version) 1271200-134000 KD150－Z2 instrument bracket PROCEDURE: ●Speedometer component After finding the plug of the instrument, unplug it with 6# inner hexagon to remove the 2 bolts ⑴, and remove the instrument assembly.
  • Page 51 7-FRONT FORK COMPONENT Fig.14 FRONT FORK Left hand component COMPONENT PART NO. PART NAME CAUTION 1194100-001000 ZT250－S left rearview mirror 1251100-121093 Non-standard bolt M8×25 (color zinc) 1134100-017000 ZT250－R half cover of left handle bar 1184200-184000 ZT310-V1 left handlebar switch 1244100-041000 ZT250-R left hand rubber sleeve 1134200-023000 ZT250－R balance block assembly 1134200-010000 ZT310－VLeft hand rocker arm (CNC) 1244200-046000 ZT310-V clutch line sheath...
  • Page 52 7-FRONT FORK COMPONENT Fig.15 FRONT FORK Directional lever component COMPONENT PART NO. PART NAME CAUTION 1224100-025000 ZT250－S M8 bolt decorative buckle 1250205-023000 GB70.1 inner hexagonal M8X35 (environmental color) 1134200-005000 ZT310－R press block of handle bar(home－made) 1134200-003000 ZT310－R handle bar PROCEDURE: ●Directional components Using a blade to pick up the decorative buckles⑴, hold the direction handle⑷...
  • Page 53 7-FRONT FORK COMPONENT Fig.16 FRONT FORK Front shock absorber, upper plate component COMPONENT PART NO. PART NAME CAUTION 1251300-045000 ZT250－S upper connection decoration nut(chroming) 100N.m 1251500-050000 ZT250－S upper connection gasket φ18.5×φ39×1 1250205-023000 GB70.1 inner hexagonal M8X35 (environmental color) 25N.m Left shock absorption Includedereflect ive sheet Right shock absorption...
  • Page 54 7-FRONT FORK COMPONENT Fig.17 FRONT FORK Uplink plate, direction handle block 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) 40N.m...
  • Page 55 7-FRONT FORK COMPONENT Fig.18 FRONT FORK ABS brake system 1 COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non－standard bolt M6×16(304 stainless steel) 1251700-059093 Flanging bushingφ6.4×φ9×8＋φ18×2(color zinc) 1244100-052000 Buffer rubber of flanging bushing (φ8.5×φ14×1) 1221200-097000 ABS hydraulic control unit protective cover 1241200-062000 3M sponge pad (50×15×2) 1244100-081000 Black foam single side tape 0.12...
  • Page 56 7-FRONT FORK COMPONENT Fig.19 FRONT FORK ABS brake system 2 COMPONENT PART NO. PART NAME CAUTION 1251100-248000 Disc brake oil pipe hexagon head bolt M10 × 1 × 20 18～20N.m 1251513-013000 Disc brake pipe copper washer φ 15× φ 10.2 × 1.5 1100100-676000 ZT310 hydraulic control unit (wet type) 1251100-112000 Disc brake pipe bolt M10×1－22 30～32N.m...
  • Page 57 7-FRONT FORK COMPONENT Fig.20 FRONT FORK ABS brake system 3 COMPONENT PART NO. PART NAME CAUTION 1251100-080094 Non－standard bolt M8×37(color zinc) 1251100-101000 Non－standard bolt M6×12 (304 stainless steel) 1224200-127000 ZT310－T front wheel WSS wire clip 1184200-045000 DF30 wheel speed sensor 1251100-112000 Disc brake pipe bolt M10×1－22 1251513-013000 Disc brake pipe copper washer φ...
  • Page 58 7-FRONT FORK COMPONENT Fig.21 FRONT FORK ABS brake system 4 COMPONENT PART NO. PART NAME CAUTION 1224100-037000 Grade 0 flame retardant tie (black 3.6×295) 1251100-121093 Non－standard bolt M6×25 (environmental color) 1251513-013000 Disc brake pipe copper washer φ 15× φ 10.2 × 1.5 1251100-101000 Non－standard bolt M6×12 (304 stainless steel) 1251100-102000 Non－standard bolt M6×16 (304 stainless steel) 1224200-003000 ZT310－Z Rear disc brake pipe clamp...
  • Page 59 8-FUEL TANK COMPONENT Fig.1 FUEL TANK Fuel tank component COMPONENT PART NO. PART NAME CAUTION 1250205-023000 GB70.1 inner hexagonal M8X35 (army green) 1244100-023000 ZT250－S fixed cushion block 1244100-020000 ZT250－S tank pressure glue 1244100-053000 ZT250-S fuel tank gasket 1224100-037000 Grade 0 flame retardant tie (black 3.6×295) PROCEDURE: ●Fuel tank component Use the key to unlock the cushion lock and remove the cushion.
  • Page 60 8-FUEL TANK COMPONENT Fig.2 FUEL TANK Fuel tank cover component 1 COMPONENT PART NO. PART NAME CAUTION ZT155－Z2 dark gray fuel tank left decorative cover ZT155－Z2 dark gray fuel tank right decorative cover 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1250204-031093 GB845St4.2×12 (environmental color) 1170300-100000 SK150-Z front left turn signal 1220300-142000 SK150-Z fuel tank left decorative cover inner panel...
  • Page 61 8-FUEL TANK COMPONENT Fig.3 FUEL TANK Fuel tank cover component 2 COMPONENT PART NO. PART NAME CAUTION 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1274100-057095 Flanging bushing φ6.2×φ8.5×3.5＋φ14×1.5 1244100-052000 Buffer rubber of flanging bushing （φ8.5×φ14×1） 1251100-102000 Non-standard bolt M6×16（304 stainless steel） 1250502-010093 GB96.1φ6（color zinc）...
  • Page 62 8-FUEL TANK COMPONENT Fig.4 FUEL TANK Fuel tank cover component 3 COMPONENT PART NO. PART NAME CAUTION 1251300-063093 Plywood M6×11×15（color zinc） 4041201-155051 KD150-Z2 dark gray front right cover (high light) 4041201-154051 KD150-Z2 dark gray front left side cover (high light) 1224100-008000 ZT250－S snap joint 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1244100-052000 Buffer rubber of flanging bushing （φ8.5×φ14×1）...
  • Page 63 8-FUEL TANK COMPONENT Fig.5 FUEL TANK Fuel tank component COMPONENT PART NO. PART NAME CAUTION 1240300-066000 KD250-J head cover pad 1181200-101000 KD150－G1 lock set 1240300-021000 HJ125－6 pod glass strip (1.5m) 0.33 500mm ZT155-Z2 fuel tank 1250105-137093 GB5789M6×16（color zinc） 1050954-031000 T02 built-in fuel pump - ZT310T PROCEDURE: ●Fuel tank sub-assembly Remove the rubber strip ⑷...
  • Page 64 9-SURROUNDING COMPONENT Fig.1 SURROUNDING Surrounding component COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non-standard bolt M6×16（304 stainless steel） 1274100-018000 ZT250－S anti-hot plate sleeve muffler 1244100-037000 φ12×φ8.5×2.5 circle buffer glue 1274100-057095 Flanging bushing φ6.2×φ8.5×3.5＋φ14×1.5 1244100-052000 Buffer rubber of flanging bushing （φ8.5×φ14×1） 1224100-010000 ZT250－S swell nail 1221200-090000 KD150－Z2 middle of the lower shroud ZT155－Z2 lower fairing left part...
  • Page 65 10-SIDE COVER COMPONENT Fig.1 SIDE COVER Side cover component 1 COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non-standard bolt M6×16（304 stainless steel） 1274100-057095 Flanging bushing φ6.2×φ8.5×3.5＋φ14×1.5 1244100-052000 Buffer rubber of flanging bushing （φ8.5×φ14×1） 1224100-010000 ZT250－S swell nail PROCEDURE: ●Side cover assembly Use 4# inner hexagon to remove 4 bolts (1), take off the bushing (2) and cushion rubber (3).
  • Page 66 10-SIDE COVER COMPONENT Fig.2 SIDE COVER Side cover component 2 COMPONENT PART NO. PART NAME CAUTION 1244100-002000 ZT250－S Side cover round rubber ZT155－Z2 dark gray left side cover rear ZT155－Z2 dark gray right side cover rear 1224100-008000 ZT250－S snap joint 1221200-091000 KD150－Z2 left cover bottom plate 1221200-092000 KD150－Z2 right cover bottom plate PROCEDURE:...
  • Page 67 11-REAR COVER COMPONENT Fig.1 REAR COVER Rear cover components COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non-standard bolt M6×16（304 stainless steel） 1274100-057095 Flanging bushing φ6.2×φ8.5×3.5＋φ14×1.5 1244100-052000 Buffer rubber of flanging bushing （φ8.5×φ14×1） 1251300-063093 Plywood M6×11×15（color zinc） KD150－Z2 rear cover right KD150－Z2 rear cover left PROCEDURE: ●Rear cover components...
  • Page 68 11-REAR COVER COMPONENT Fig.2 REAR COVER Rear armrests and shelf components COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non-standard bolt M6×16（304 stainless steel） 1250105-142093 GB5789M8×20（color zinc） 1250205-002091 GB70.1 M8×30(zinc) 4111200-012051 KD150-Z2 rear armrest (dark gray matte) 4111100-002051 SK150-Z rack (dark gray matte) PROCEDURE: ●Rear armrests and shelf components Remove one bolt ⑴...
  • Page 69 11-REAR COVER COMPONENT Fig.3 REAR COVER Taillight component COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non-standard bolt M6×16（304 stainless steel） 1274100-057095 Flanging bushing φ6.2×φ8.5×3.5＋φ14×1.5 1244100-052000 Buffer rubber of flanging bushing （φ8.5×φ14×1） 1251300-063093 Plywood M6×11×15（color zinc） 1171200-062000 KD150－Z2 tail light PROCEDURE: ●Taillight assembly Use 4# inner hexagon to remove 2 bolts ⑴, take off the bushing ⑵, cushion rubber ⑶.
  • Page 70 11-REAR COVER COMPONENT Fig.4 REAR COVER Rear mud board component 1 COMPONENT PART NO. PART NAME CAUTION 1250105-148093 GB5789M8×25(color zinc ) 1251700-058093 Flanging bushing φ8.2×φ11×4.5＋φ16×1.5(color zinc) 1240300-071000 Flanging bushing rubber (φ11×φ16×1) 1251100-101000 Non－standard bolt M6×12 (304 stainless steel) 1274100-057095 Flanging bushing φ6.2×φ8.5×3.5＋φ14×1.5 1244100-052000 Buffer rubber of flanging bushing (φ8.5×φ14×1) 1221200-052000 KD150－U rear fender bracket cover 1251100-120093 Non－standard bolts M6×16 (environmental color)
  • Page 71 11-REAR COVER COMPONENT Fig.5 REAR COVER Rear mud board component 2 COMPONENT PART NO. PART NAME CAUTION 1174100-002000 ZT250－S rear reflector 1221200-051000 KD150－U rear fender plate 1244100-006000 ZT250－S rear liceness rubber buffer 1181200-103000 KD150－U auxiliary mud plate transfer line（short） 1171200-057000 KD150－U license plate light 1251300-063093 Plywood M6×11×15(color zinc) 1170300-064000 HJ125－K front right turn signal light 1221200-053000 KD150－U rear turn signal bracket...
  • Page 72 11-REAR COVER COMPONENT Fig.6 REAR COVER Battery pack COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non-standard bolt M6×16（304 stainless steel） 1274100-057095 Flanging bushing φ6.2×φ8.5×3.5＋φ14×1.5 1244100-052000 Buffer rubber of flanging bushing （φ8.5×φ14×1） 1221200-109000 KD150－Z2 electric device box upper cover MSE6.0 controller 1184100-010000 ZT250－S starting relay 1184200-099000 ZT310 colloid battery (6-FM-10/10Ah) 1244200-111000 ZT310 gel battery strap...
  • Page 73 11-REAR COVER COMPONENT Fig.8 REAR COVER Electrical device box component COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non-standard bolt M6×16（304 stainless steel） 1250303-010093 GB6177.1M6（color zinc ） 1271200-144000 KD150－G1 battery holder (gel battery) 1240300-007000 HJ125－6 Battery rubber gasket 1251300-063093 Plywood M6×11×15（color zinc） 1244200-087000 ZT310-X tail skirt middle waterproof rubber stopper 1221200-094000 KD150－Z2 bottom of tail group PROCEDURE:...
  • Page 74 12-CUSHION COMPONENT Fig.1 CUSHION Cushion component COMPONENT PART NO. PART NAME REMARKS 4120100-001000 150-Z2 cushion 1244100-024000 ZT250－S cushion front rubber 1244100-022000 ZT250－S cushion rubber 1244100-025000 ZT250－S round cushion rubber PROCEDURE: ●Remove the cushion Insert the key, turn it counterclockwise, and take off the cushion when you hear a "click". ●Assembly cushion When assembling the cushion, check whether all the cushion rubbers are complete.
  • Page 75 13-MUFFLER COMPONENT Fig.1 MUFFLER Muffler component 1 COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non-standard bolt M6×16（304 stainless steel） 1274100-057095 Flanging bushing φ6.2×φ8.5×3.5＋φ14×1.5 1244100-052000 Buffer rubber of flanging bushing （φ8.5×φ14×1） 1070100-202000 KD150-U engine exhaust seal pad 1251300-058093 Hexagonal nut (color zinc) 1250105-021091 GB5789 M8×90（White zinc）...
  • Page 76 13-MUFFLER COMPONENT Fig.2 MUFFLER Muffler component 2 COMPONENT PART NO. PART NAME CAUTION 1251900-055093 KD150－U muffler suspension bushing 1241200-045000 KD150－U muffler suspension cushioning rubber 1274100-068095 ZT310 Muffler flanging bushing 1251100-102000 Non－standard bolt M6×16(304 stainless steel) 1250501-010000 GB93φ6 spring pad 1032112-014000 KD150－U muffler tail cover rear KD150－U muffler tail cover front KD150－U muffler anti－scalding 1251100-101000 Non-standard bolt M6×12 (304 stainless steel)

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Zt155-z2

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