Zontes ZT125-GK Service Manual
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Zontes ZT125-GK Service Manual

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ZT125/155-GK（EURO V）
Service manual
2022/5/25

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i need a wartungsplan about zontes GK 125

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Summary of Contents for Zontes ZT125-GK

  • Page 1 ZT125/155-GK（EURO V） Service manual 2022/5/25...
  • Page 2 Contents Table of Contents Pages Table of Contents……………………………………………………………………………………………………………………………………………………………………………………………… 1 FRAME&ELECTRONIC COMPONENT 1.1 Electrical device component-1………………………………………………………………………………………………………………………………………………………………………………… Main harness, dump switch, relay, flasher 1.2 Electrical device component-2………………………………………………………………………………………………………………………………………………………………………………… Flameout switch, horn,ignition coil 1.3 Electrical device component-3………………………………………………………………………………………………………………………………………………………………………………… ECU、relay 1.4 Electrical device component-4………………………………………………………………………………………………………………………………………………………………………………… 10 Flasher、Buzzer 1.5 Frame plastic parts………………………………………………………………………………………………………………………………………………………………………………………………...
  • Page 3 Contents Table of Contents Pages Rear mud board 4.2 Rear shock absorption………………………………………………………………………………………………………………………………………………………………………………………… Demolition after shock absorption, rear shock absorption adjustment 4.3 Rear wheel component 1……………………………………………………………………………………………………………………………………………………………………………………… Disassemble the rear rim component, sprocket seat, sprocket 4.4 Rear wheel component 2……………………………………………………………………………………………………………………………………………………………………………………… Disassembled rear rim component 4.5 Rear fork component……………………………………………………………………………………………………………………………………………………………………………………………...
  • Page 4 Contents Table of Contents Pages 6.5 Water tank component 2……………………………………………………………………………………………………………………………………………………………………………………… Disassemble water tank component,water tank bracket FRONT FORK COMPONENT 7.1 Throttle/clutch cable clearance adjustment, light height adjustment…………………………………………………………………………………………………………………………………………… 38 7.2 Replacement clutch cable……………………………………………………………………………………………………………………………………………………………………………………… 39 7.3 Replace the throttle line………………………………………………………………………………………………………………………………………………………………………………………… 40 7.4 Steering adjustment…………………………………………………………………………………………………………………………………………………………………………………………… 7.5 Right hand component…………………………………………………………………………………………………………………………………………………………………………………………...
  • Page 5 Contents Table of Contents Pages 7.19 ABS brake system-A 1………………………………………………………………………………………………………………………………………………………………………………………… 56 Disassemble the hydraulic control unit and bracket 7.20 ABS brake system-A 2………………………………………………………………………………………………………………………………………………………………………………………… 57 Releasing brake fluid,FMC tubing 7.21 ABS brake system-A 3………………………………………………………………………………………………………………………………………………………………………………………… 58 Disassemble FC tubing ABS brake system-A 4………………………………………………………………………………………………………………………………………………………………………………………… 59 7.22 Disassemble RMC tubing,RC tubing SURROUNDING COMPONENT 8.1 Front grille component…………………………………………………………………………………………………………………………………………………………………………………………...
  • Page 6 Contents Table of Contents Pages 10.1 Side cover component………………………………………………………………………………………………………………………………………………………………………………………… Decompose side cover component REAR COVER COMPONENT 11.1 Rear Armrest component……………………………………………………………………………………………………………………………………………………………………………………… 71 Remove the armrest 11.2 Left rear skirt component……………………………………………………………………………………………………………………………………………………………………………………… 72 Disassemble the left rear skirt component 11.3 Right rear skirt component…………………………………………………………………………………………………………………………………………………………………………………… Disassemble the right rear skirt component 11.4 Tail light component……………………………………………………………………………………………………………………………………………………………………………………………...
  • Page 7 Contents Table of Contents Pages All the information, illustrations and photographs collected in this manual are compiled according to the latest products. However, there may be some inconsistencies between your motorcycle and this manual due to the continuousimprovement of the product and other 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 official website, the official website shall prevail.
  • Page 8 1-FRAME&ELECTRONIC COMPONENT Fig.1FRAME&ELECTRO Electronic parts COMPONENT 1 NIC COMPONENT PART NO. PART NAME CAUTION 1181200-130000 KD150-GK harness assembly(MSE8.0) 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 1180300-101000 HJ150-3 square flasher (LED) 1224100-037000 Grade 0 flame retardant tie (black 3.6×295) 1251100-101000 Non-standard bolt M6×12 (304 stainless steel)
  • Page 9 1-FRAME&ELECTRONIC COMPONENT Fig.2FRAME&ELECTRO Electronic parts COMPONENT 2 NIC 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) 1186200-014000 ZT310T－M EFI ignition coil (pedal with thread) 1274100-017000 ZT250－S line buckle...
  • Page 10 1-FRAME&ELECTRONIC COMPONENT Fig.3FRAME&ELECTRO Electronic parts COMPONENT 3 NIC COMPONENT PART NO. PART NAME CAUTION 1184300-002000 ZT350 starting relay 1251100-119093 Non-standard bolt M6×12 (environmental color) 1251100-120093 Non-standard bolts M6×16 (environmental color) MSE8.0 controller-ZT152MI (Euro 5) 1271200-204000 KD150 MSE8.0 Controller 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...
  • Page 11 1-FRAME&ELECTRONIC COMPONENT Fig.4FRAME&ELECTRO Electronic parts COMPONENT 4 NIC COMPONENT PART NO. PART NAME CAUTION 1180300-101000 HJ150-3 square flasher (LED) 1184200-016000 ZT310 PKE Buzzer 1224100-037000 Grade 0 flame retardant tie (black 3.6×295) 1251112-003093 M6×45 Hex flange surface 9.8 bolt (color zinc) 4041201-119051 KD150-U dark gray rectifier shield Bushing Φ12 ×...
  • Page 12 1-FRAME&ELECTRONIC COMPONENT Fig.5FRAME&ELECTRO NICPARTS Frame plastic 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 13 ●Please check whether the steel beads of the conjoined body have abnormal phenomena such as partial abrasion Remove the top adjusting nut ⑵ by using a special four-jaw or hook wrench tools. and rust.If YES, please buy the regular accessories on ZONTES official website, if not, please be sure to grease Remove the rubber pad ⑶.
  • Page 14 1-FRAME&ELECTRONIC COMPONENT Fig.7FRAME&ELECTRO Frame, side bracket NIC COMPONENT PART NO. PART NAME CAUTION KD150－GK frame after-sales component 【1】 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 1271200-165000 ZT310－T side bracket (short / dark gray) 1251100-088094 Non-standard nut M10×1.5×43（dacromet）...
  • Page 15 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 1244300-026000 ZT350-R guard bar anti-drop glue 1244300-028000 O-ring φ11.8×2.65（inner diameter×wire diameter）...
  • Page 16 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) 1271200-073000 KD150-U left lower bracket，surrounds cover 1271200-071000 KD150-U surrounding right lower bracket 1251112-002093 M6×30 Hexagon flange bolts (color zinc) 1250105-017091 GB5789 M8×65(zinc) 4021200-053021 KD150－G1 frame left hanging piece...
  • Page 17 3-INTAKE SYSTEM COMPONENT Fig.1 INDUCTION The air filter assembly 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 ） 1221200-130000 KD125-U air filter ( temperature sensor rubber stopper ) 1224100-037000 Grade 0 flame retardant tie (black 3.6×295) 1221200-055000 KD150-U carbon canister (EFI) 1050961-004000 Air filter intake air temperature sensor...
  • Page 18 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 ZT158M Intake pipe assembly (with intake pressure sensor) 1051356-010000 Φ45×10 pipe clamp assembly 1050956-021000 ZT29 Throttle body assembly...
  • Page 19 3-INTAKE SYSTEM COMPONENT Fig.3 INDUCTION Replace air filter element SYSTEM COMPONENT PART NO. PART NAME CAUTION 4131200-001000 KD125－U air filter element (carton packaging) 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 20 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 1181200-118000 Wheel speed sensor(A) 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 21 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) 1111200-041000 KD150-GK 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 22 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) 1032142-075051 ZT310 R, chain adjuster(dark gray matte) 1251300-067000 ZT250－R rear wheel hollow shaft nut 110N·m 1032142-074051 ZT310 L, chain adjuster(dark gray matte) 1091200-025000 KD150－U rear wheel hollow shaft...
  • Page 23 4-REAR WHELL COMPONENT Fig.4 REAR WHELL Rear wheel component 2 COMPONENT PART NO. PART NAME CAUTION 1230100-455000 130/70－17(CMAD01) vacuum tire KD150-U black rear vacuum spoke wheel (3.5×17/ 1091200-034000 11.5/ without valve mouth) 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 24 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 1080100-116000 KD150 -U 520-44 Tsprocket 1251300-050000 ZT310-Z chain adjuster nut M10(304 stainless steel) 1251100-105000 ZT310-Z chain adjuster bolt M10×70 (304 stainless stee ZT125 aluminum alloy rear flat fork (dark gray matte) 4021200-037000...
  • Page 25 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 26 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 27 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) 1271200-163000 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) 1271200-162000 ZT310－T rocker arm, gear shift rod...
  • Page 28 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) 1250205-040095 GB70.1 inner hexagonal M8X16(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 pcs bolt⑴and ⑵.
  • Page 29 5-PEDAL COMPONENT Fig.3 FOOT PEDAL Right footrest component-2 COMPONENT PART NO. PART NAME CAUTION 1251100-121093 Non－standard bolt M6×25 (environmental color zinc) 1251100-131000 Non－standard shaft position bolt M10×1.5×36(zine) 1271200-164000 KD150－U brake pedal(dark gray) 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...
  • Page 30 5-PEDAL COMPONENT Fig.4 FOOT PEDAL Right footrest component-3 COMPONENT PART NO. PART NAME CAUTION 4061200-004051 KD150－GK right pedal support 1274300-033000 ZT350－R Pedal pin 1264100-006000 ZT250－S Pedal circlip 1264100-004000 ZT250－S front right foot pedal torsional spring 4064300-010051 ZT350－GK R, front pedal component (dark gray matte 4064300-012051 ZT350－GK R, rear pedal component (dark gray matte) 1274300-032000 ZT350－R rear pedal locating plate 1274300-031000 ZT350－R rear pedal steel ball(6.35)
  • Page 31 5-PEDAL COMPONENT Fig.5FOOT PEDAL Left footrest component-1 COMPONENT PART NO. PART NAME CAUTION 1250205-040095 GB70.1 inner hexagonal M8X16(color zinc) 1250205-023000 GB70.1 inner hexagonal M8X35(color zinc) 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color zinc) GB5789 M10×1.25×25 (10.9 grade environmental 1250105-278093 protection color) 1274200-334000 ZT310-R pedal support gasket (notched)
  • Page 32 5-PEDAL COMPONENT Fig.6 FOOT PEDAL Left footrest component-2 COMPONENT PART NO. PART NAME CAUTION ZT350－GK L, front pedal component(dark gray 4064300-009051 matte) 1264100-003000 ZT250－S front left foot pedal torsional spring 1274300-033000 ZT250－R Pedal pin 1271200-195000 KD150－GK Foot pedestal (dark gray) 1264100-006000 ZT250－S Pedal circlip 1244300-013000 ZT310－T footrest gum cover 1274300-093000 ZT350-Gk footrest gum cover fixed plate(10mm longer)
  • Page 33 5-PEDAL COMPONENT Fig.7 FOOT PEDAL Left footrest component-3 COMPONENT PART NO. PART NAME CAUTION 4064300-011051 ZT350－GK L, rear foot pedal component 1260100-301000 ZT350－R foot pedal steel ball spring 1274300-031000 ZT350－R rear pedal steel ball(6.35) 1274300-032000 ZT350－R rear pedal locating plate 1274300-033000 ZT350－R Pedal pin 1264100-006000 ZT250－S Pedal circlip 4061200-003051 KD150－GK left pedal support...
  • Page 34 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 4050968-003000 ZT1P58MJ coarse filter cover (pottery) 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 35 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 36 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 37 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 38 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 39 7-FRONT FORK COMPONENT Fig.1 FRONT FORK Throttle/clutch cable clearance adjustment, light height COMPONENT adjustment PART NO. PART NAME CAUTION 1151200-048000 KD150－G1 throttle return line（elbow） 1151200-049000 KD150－G1 throttle refueling line（elbow） 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 40 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 41 7-FRONT FORK COMPONENT Fig.3 FRONT FORK Replace the throttle cable COMPONENT PART NO. PART NAME CAUTION 1151200-048000 KD150－G1 throttle return line（elbow） 1151200-049000 KD150－G1 throttle refueling line（elbow） 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 42 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 43 7-FRONT FORK COMPONENT Fig.5 FRONT FORK Right hand component COMPONENT PART NO. PART NAME CAUTION 1250205-085000 GB70.1M6×70 (stainless steel) 1131200-027000 KD150－G1 right hand guard 1190100-427000 KD150－G1 right rearview mirror (enlarged version) 1244100-042000 ZT250－R right handle bar rubber sleeve 1134200-028051 ZT250-R right hand rocker(dark gray matte) 1244100-095000 ZT250－S Rearview mirror mounting hole rubber plug ZT310T-M front disc brake main pump assembly 1100300-088000...
  • Page 44 7-FRONT FORK COMPONENT Fig.6 FRONT FORK Add brake fluid, rocker adjustment COMPONENT PART NO. PART NAME CAUTION 1134200-028051 ZT250-R right hand rocker(dark gray matte) 1100300-088000 Front disc brake main pump assembly(without handle) 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 45 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 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 46 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 47 7-FRONT FORK COMPONENT Fig.9 FRONT FORK Front mud board & wheel speed sensor component-1 COMPONENT PART NO. PART NAME CAUTION 1251100-061093 M6×22 Hex flang bolt thread level 8.8 (color zinc) 1251100-080094 Non-standard bolt M8×37 1181200-118000 Wheel speed sensor（A） 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1224100-037000 Grade 0 flame retardant tie (black 3.6×295) 1224100-044000 Wheel speed sensor clamp 1251100-102000 Non-standard bolt M6×16（304 stainless steel）...
  • Page 48 7-FRONT FORK COMPONENT Fig.10 FRONT FORK Front mud board & wheel speed sensor component-2 COMPONENT PART NO. PART NAME CAUTION KD150－G1front disc brake disc cover installation 4021200-050021 plate（matte black ） 1221200-086000 KD150－G1 front disc brake guard 1244100-052000 Buffer rubber of flanging bushing （φ8.5×φ14×1） 1274100-057095 Flanging bushing φ6.2×φ8.4×3.5＋φ14×1.5 1251100-102000 Non-standard bolt M6×16（304 stainless steel）...
  • Page 49 7-FRONT FORK COMPONENT Fig.11 FRONT FORK Head and headlights component 1 COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non-standard bolt M6×16（304 stainless steel） 1274100-057095 Flanging bushing φ6.2×φ8.4×3.5＋φ14×1.5 1244100-052000 Buffer rubber of flanging bushing （φ8.5×φ14×1） 1251200-033093 Non-standard self-tapping bolt ST4.2×12(color zinc ) 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1224100-010000 ZT250－S swell nail 1251300-063093 Plywood M6×11×15（color zinc）...
  • Page 50 7-FRONT FORK COMPONENT Fig.12 FRONT FORK Head and headlights component 2 COMPONENT PART NO. PART NAME CAUTION 1221200-115000 KD150-G1 turn light decorative cover (set) 4041201-384051 KD150-GK right head cover(dark gray matte) KD150-G1 matte black headlight badge 1170300-064000 HJ125－K front right turn signal light 1221200-122000 KD150－GK Right turn signal bracket 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1274100-057095 Flanging bushing φ6.2×φ8.4×3.5＋φ14×1.5...
  • Page 51 7-FRONT FORK COMPONENT Fig.13 FRONT FORK Head and headlights component 3 COMPONENT PART NO. PART NAME CAUTION 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1274100-057095 Flanging bushing φ6.2×φ8.4×3.5＋φ14×1.5 1244100-052000 Buffer rubber of flanging bushing （φ8.5×φ14×1） 1251300-063093 Plywood M6×11×15（color zinc） 1171200-059000 KD150－G1 headlight KD150－GK headlight decoration cover PROCEDURE: ●Headlight components...
  • Page 52 7-FRONT FORK COMPONENT Fig.14 FRONT FORK Speedometer component COMPONENT PART NO. PART NAME CAUTION 1250205-040095 GB70.1 inner hex bolt M8×16(color Zinc) 1164200-011000 ZT310-T electronic instrument 1271200-184000 KD150－GK speedometer Bracket 1250301-020093 GB6170M6 (environmental color) 1250502-010093 GB96.1φ6(environmental color) 1244200-092000 ZT310TFT gauge rubber cushion 1241200-062000 3M sponge rubber pad (50×15×2) PROCEDURE: ●Speedometer component...
  • Page 53 7-FRONT FORK COMPONENT Fig.15 FRONT FORK Left hand component COMPONENT PART NO. PART NAME CAUTION 1250205-031091 GB70.1M6×30(stainless steel) 1184300-019000 Second Generation Left Handlebar Switch(TFT-500) 1244100-095000 ZT250－S Rearview mirror mounting hole rubber plug 1184200-184000 ZT310－V1 left handlebar switch 1244100-041000 ZT250－R left hand rubber sleeve 1190100-426000 KD150－G1 left rearview mirror (enlarged version) 1131200-026000 KD150－G1 Left Hand Guard 1250205-085000 GB70.1M6×70 (stainless steel)
  • Page 54 7-FRONT FORK COMPONENT Fig.16 FRONT FORK Directional lever component COMPONENT PART NO. PART NAME CAUTION 4044102-002051 ZT250－S M8 bolt decorative buckle 1250205-023000 GB70.1 inner hexagonal M8X35 (environmental color) 1134200-031051 ZT310－R press block of handle bar(home－made) 1134200-022000 ZT310－T handle bar(dark gray) PROCEDURE: ●Directional components Using a blade to pick up the decorative buckles⑴, hold the direction handle⑷...
  • Page 55 7-FRONT FORK COMPONENT Fig.17 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 Upper connection gasket φ18.5×φ39×1 (chroming) 1250205-023000 GB70.1 inner hexagonal M8X35 (environmental color) 25N·m 1111200-039000 Front left shock absorber(dark gray matte) Includedereflect ive sheet 1111200-040000 Front right shock absorber(dark gray matte)
  • Page 56 7-FRONT FORK COMPONENT Fig.18 FRONT FORK Uplink plate, direction handle block component COMPONENT PART NO. PART NAME CAUTION 1134300-004051 ZT310－R direction pad M10×1.25(dark gray matte) 1274200-018000 ZT310－R gasket of upper connecting board 1244200-008000 ZT310－R buffer rubber of upper connecting board 1134200-030051 ZT310－R upper connecting board(dark gray matte) 1251700-065000 ZT310－R bushing φ10×φ12×41 1250105-280000 GB5789 M10×1.25×60 (level 10.9 dacromet)
  • Page 57 7-FRONT FORK COMPONENT Fig.19 FRONT FORK ABS brake system-A 1 COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non－standard bolt M6×16(304 stainless steel) 1274100-057095 Flanging bushingφ6.2×φ8.4×3.5＋φ14×1.5(color zinc) 1244100-052000 Buffer rubber of flanging bushing (φ8.5×φ14×1) 1020412-093000 ABS hydraulic control unit protective cover (A) 1241200-062000 3M sponge pad (50×15×2) 1251112-001093 M6×16 Hexagon flange bolts (color zinc) 1271200-193021 ABS hydraulic control unit bracket（A)
  • Page 58 7-FRONT FORK COMPONENT Fig.20 FRONT FORK ABS brake system-A 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 KD150－G2 hydraulic control unit（A）...
  • Page 59 7-FRONT FORK COMPONENT Fig.21 FRONT FORK ABS brake system-A 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 1181200-118000 Wheel speed sensor(A) 1251100-112000 Disc brake pipe bolt M10×1－22 1251513-013000 Disc brake pipe copper washer φ...
  • Page 60 7-FRONT FORK COMPONENT Fig.22 FRONT FORK ABS brake system-A 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 61 8-SURROUNDING COMPONENT Fig.1 SURROUNDING Front grille component COMPONENT PART NO. PART NAME CAUTION 1224100-010000 ZT250－S swell nail 1251100-102000 Non-standard bolt M6×16（304 stainless steel） 1274100-057095 Flanging bushing φ6.2×φ8.4×3.5＋φ14×1.5 1244100-052000 Buffer rubber of flanging bushing （φ8.5×φ14×1） 1251300-063093 Plywood M6×11×15（color zinc） 1221200-129000 KD150－GK fuel tank left front grille 1221200-128000 KD150－GK fuel tank right front grille PROCEDURE: Remove the 4 expansion nails⑴.
  • Page 62 8-SURROUNDING COMPONENT Fig.2 SURROUNDING Decorative cover s the upper part component COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non-standard bolt M6×16（304 stainless steel） 1274100-057095 Flanging bushing φ6.2×φ8.4×3.5＋φ14×1.5 1244100-052000 Buffer rubber of flanging bushing （φ8.5×φ14×1） 1251300-063093 Plywood M6×11×15（color zinc） 1224100-008000 ZT250－S snap joint 4041201-375022 KD150－GK right decorative cover s the upper part 4041201-376022 KD150-GK left decorative cover the upper part PROCEDURE:...
  • Page 63 8-SURROUNDING COMPONENT Fig.3 SURROUNDING Lower part component COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non-standard bolt M6×16（304 stainless steel） 1274100-057095 Flanging bushing φ6.2×φ8.4×3.5＋φ14×1.5 1244100-052000 Buffer rubber of flanging bushing （φ8.5×φ14×1） 1250502-010093 GB96.1φ6（color zinc） 1274100-018000 ZT250－S Anti-hot plate sleeve, muffler 1224100-037000 Grade 0 flame retardant tie (black 3.6×295) PROCEDURE: ●Surrounding components Remove the right side cover by referring to the "Side cover component"...
  • Page 64 8-SURROUNDING COMPONENT Fig.4 SURROUNDING The middle cover component COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non-standard bolt M6×16（304 stainless steel） 1274100-057095 Flanging bushing φ6.2×φ8.4×3.5＋φ14×1.5 1244100-052000 Buffer rubber of flanging bushing （φ8.5×φ14×1） 4041201-372021 KD150-GK left lower part 1224100-010000 ZT250－S swell nail 4041201-371021 KD150－GK right lower part 1244100-002000 ZT250－S Side cover round rubber 1221200-076000 KD150-GK the middle cover...
  • Page 65 8-SURROUNDING COMPONENT Fig.5 SURROUNDING Lower part sectionalization COMPONENT PART NO. PART NAME CAUTION 1184200-100000 ZT310 dual USB charging cable 4041201-371021 KD150－GK right lower part 1251300-063093 Plywood M6×11×15（color zinc） 4041201-372021 KD150-GK left lower part 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 cable⑴...
  • Page 66 9-FUEL TANK COMPONENT Fig.1 FUEL TANK Fuel tank component COMPONENT PART NO. PART NAME CAUTION 1250205-043093 GB70.1M8×55（color zinc） 1251900-028093 Fuel tank flat pad φ9×φ37.5×2 (environmental color) 1244100-020000 ZT250－S tank pressure glue KD150-GK fuel tank assembly KD150-GK fuel tank sticker 1224200-066000 ZT310PKE External antenna mount 1241200-044000 KD150-U fuel tank liner limit glue 1244100-053000 ZT250－S fuel tank gasket 1274100-080000 ZT250－R fixed cushion block...
  • Page 67 9-FUEL TANK COMPONENT Fig.2 FUEL TANK Fuel tank cover component COMPONENT PART NO. PART NAME CAUTION 1251100-101000 Non-standard bolt M6×12（304 stainless steel） KD150－GK fuel tank right decorative cover KD150－GK fuel tank left decorative cover 1251300-063093 Plywood M6×11×15（color zinc） PROCEDURE: ●Fuel tank decorative cover: Use 4# inner hexagon to remove 2 bolts ⑴,take off the fuel tank right decorative cover⑵,then remove Plywood ⑷...
  • Page 68 9-FUEL TANK COMPONENT Fig.3 FUEL TANK Fuel Tank middle cover assembly COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non-standard bolt M6×16（304 stainless steel） 1274100-057095 Flanging bushing φ6.2×φ8.4×3.5＋φ14×1.5 1244100-052000 Buffer rubber of flanging bushing （φ8.5×φ14×1） 1184200-002000 ZT310 electronic fuel tank lock 1224100-033000 ZT250－S threaded fuel tank cap 4041201-381051 KD150－GK fuel tank middle cover 4041201-382051 KD150－GK fuel tank outer cover...
  • Page 69 9-FUEL TANK COMPONENT Fig.4 FUEL TANK Oil tank outer cover assembly COMPONENT PART NO. PART NAME CAUTION 1274100-090000 ZT250－S fuel tank cover rotating shaft 1224100-014000 ZT250－S fuel tank cover rotary damping 1274100-021000 ZT250－S fuel tank cover rotating bracket ZT250－S torsion spring of tank outer cover rotating 1260100-255000 shaft 1260100-215000...
  • Page 70 10-SIDE COVER COMPONENT Fig.1 SIDE COVER Side cover component COMPONENT PART NO. PART NAME CAUTION Left side cover 1244100-002000 ZT250－S Side cover round rubber Right side cover PROCEDURE: ●Side cover assembly Grasp the lower edge① , ③ of the left side cover ⑴ and pull it out. Grasp both ends②...
  • Page 71 11-REAR COVER COMPONENT Fig.1 REAR COVER Rear armrest assembly COMPONENT PART NO. PART NAME CAUTION 4021200-036021 KD150-G1 right rear rack (matte black ) 4021200-035021 KD150-G1 left rear rack (matte black ) 1251100-101000 Non-standard bolt M6×16（304 stainless steel） 1251100-123093 Non-standard bolt M8×25 (color zinc) 1224100-010000 ZT250－S swell nail PROCEDURE: ●Rear armrest assembly...
  • Page 72 11-REAR COVER COMPONENT Fig.2 REAR COVER The rear cover component COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non-standard bolt M6×12 (304 stainless steel) 1274100-057095 Flanging bushing φ6.2×φ8.4×3.5＋φ14×1.5 1244100-052000 Buffer rubber of flanging bushing （φ8.5×φ14×1） 1224100-010000 ZT250-S swell nail 1244100-002000 ZT250-S Side cover round rubber 1251300-063093 Plywood M6×11×15 KD150-G1 left rear tail cover KD150-G1 right rear cover...
  • Page 73 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×φ8.4×3.5＋φ14×1.5 1244100-052000 Buffer rubber of flanging bushing （φ8.5×φ14×1） 1221200-074000 KD150－G1 Rear mud plate bottom cover 1251300-063093 Plywood M6×11×15（color zinc） 1171200-060000 KD150－G1 Rear Taillight PROCEDURE: ●Taillight assembly...
  • Page 74 11-REAR COVER COMPONENT Fig.4 REAR COVER Rear mud board assembly 1 COMPONENT PART NO. PART NAME CAUTION 1251100-102000 Non-standard bolt M6×16（304 stainless steel） 1274100-057095 Flanging bushing φ6.2×φ8.4×3.5＋φ14×1.5 1244100-052000 Buffer rubber of flanging bushing （φ8.5×φ14×1） 1224100-010000 ZT250－S swell nail 1251100-101000 Non-standard bolt M6×12（304 stainless steel） 1244100-006000 ZT250－S rear liceness rubber buffer 1221200-068000 KD150－G1 rear license plate bracket 1271200-177000 KD150－G1 rear mud board bracket (integrated)
  • Page 75 11-REAR COVER COMPONENT Fig.5 REAR COVER Rear mud board assembly 2 COMPONENT PART NO. PART NAME CAUTION 1221200-115000 KD150-G1 turn light decorative cover (set) 1170300-065000 HJ125－K rear left turn signal light 1170300-066000 HJ125－K rear right turn signal light 1174200-021000 ZT310－X Liensed lights 1221200-073000 KD150－G1 rear mud board PROCEDURE: ●Turn signal light decorative cover...
  • Page 76 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×φ8.4×3.5＋φ14×1.5 1244100-052000 Buffer rubber of flanging bushing （φ8.5×φ14×1） 1224100-010000 ZT250－S swell nail 1221200-113000 KD150－G1 electric device box upper cover 1184100-010000 ZT250－S starting relay 1244200-111000 ZT310 gel battery strap 1184200-099000 ZT310 colloid battery (6-FM-10/10Ah)
  • Page 77 11-REAR COVER COMPONENT Fig.7 REAR COVER Electrical device box component COMPONENT PART NO. PART NAME CAUTION 1250303-010093 GB6177.1M6（color zinc ） 1251100-102000 Non-standard bolt M6×16（304 stainless steel） 1221200-072000 KD150－G1 rear skirt mounting cover 1251100-122093 Non-standard bolt M8×16 (environmental color) 1251700-058093 Flanging bushing φ8.2×φ11×4.5＋φ16×1.5 1240300-071000 Flanging bushing rubber （φ11×φ16×1）...
  • Page 78 11-REAR COVER COMPONENT Fig.8 REAR COVER Electrical device box component COMPONENT PART NO. PART NAME CAUTION 1250303-011093 GB6177.1M8（color zinc） 1271200-185000 KD150－GK PKE bracket 1271200-144000 KD150－G1 battery holder (gel battery) 1251100-102000 Non-standard bolt M6×16(304 stainless steel) 1274100-057095 Flanging bushing φ6.2×φ8.4×3.5＋φ14×1.5 1244100-052000 Buffer rubber of flanging bushing （φ8.5×φ14×1） 1184200-137000 ZT310 PKE new version （band version ）...
  • Page 79 12-CUSHION COMPONENT Fig.1 CUSHION Cushion component COMPONENT PART NO. PART NAME REMARKS 4120100-003000 150-GK 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 Press the unlock button shortly.After the power-on self test is completed, press the "SEAT" button briefly to open the electronic cushion lock.
  • Page 80 13-MUFFLER COMPONENT Fig.1 MUFFLER Muffler component 1 COMPONENT PART NO. PART NAME CAUTION 1250105-021091 GB5789 M8×90（White zinc） 1250303-011093 GB6177.1 M8 (environmental color) 1070100-202000 KD150-U engine exhaust seal pad 1251300-058093 Inner hexagonal nut M8 (color zinc) PROCEDURE: ●Remove the muffler componet First remove the crash bar and front grille component.
  • Page 81 13-MUFFLER COMPONENT Fig.2 MUFFLER Muffler component 2 COMPONENT PART NO. PART NAME CAUTION 1020243-098000 ZT350 Muffler gasket（ φ8.3×φ33×1.5） ZT350－GK－H1 Muffler suspension cushioning 1244300-024000 rubber 1020243-097000 ZT350 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(dark gray) 1032112-022051 KD150－U muffler anti－scalding 1251100-101000 Non-standard bolt M6×12 (304 stainless steel)

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