TAYO Zontes ZT125-M 2022 Maintenance Manual
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TAYO Zontes ZT125-M 2022 Maintenance Manual

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ZT125/310T-M
Maintenance Manual
2022-09-14
1 / 188

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Summary of Contents for TAYO Zontes ZT125-M 2022

  • Page 1 ZT125/310T-M Maintenance Manual 2022-09-14 1 / 188...
  • Page 2 If part of the content of this manual is insufficient, please refer to the "Driver's Manual" included with the bike. The latest version of the driver's manual can be downloaded as a PDF in the model introduction corresponding to the official website of Zontes. © GUANG DONG TAYO MOTORCYCLE TECHNOLOGY Co.,Ltd All rights reserved 2 / 188...
  • Page 3 User notice This manual is compiled by Guangdong Tayo Motorcycle Technology Co., Ltd. to guide dealers or service personnel to use it. This manual cannot provide more detailed knowledge about motorcycles, and is only for reference for maintenance. If you do not have the corresponding knowledge such as electrician, machine repair, etc., improper assembly or repair failure may occur...

  • Page 4: Table Of Contents

    Content Content ....................................... 4 1. Vehicle information ..................................12 Know Before Service ................................. 12 Body label ....................................13 M310 Technical specification ..............................14 Front wheel/steering system ............................14 Rear wheel/suspension system ............................14 Brake system ..................................14 Battery/charging system ..............................15 M125 Technical specification ..............................
  • Page 5 6. Inspection air filter waste oil pipe ..........................40 7. Reinstall ..................................40 Bolts and nuts of muffler ................................41 1. Check for air leaks at the engine exhaust........................41 2. Check for nut and bolts at the muffler .......................... 41 M310 Spark plug ..................................
  • Page 6 1. Check the fuel pipe for leaks with the help of an endoscope with LED light ..............64 2. Replace high pressure oil pipe ............................64 3. Fuel pump ..................................65 3.1 Use oil pressure gauge to measure fuel pressure ....................65 3.2 Simple test of fuel pump .............................
  • Page 7 2. Adjust the preload ................................. 85 2.1 Adjust the right rear shock absorption ....................... 85 2.2 Adjust the left rear shock absorption........................85 2.2.1 M310 ................................ 85 2.2.2 M125 ................................ 85 3. Replace the shock absorption ............................86 Bolts and nuts for body and engine installation ........................86 1.
  • Page 8 10. Oxygen Sensor ................................109 10.1 Check ................................109 10.2 Replace ................................109 11. ECU .................................... 110 M310 ..................................110 M125 ..................................110 12. Crankshaft position sensor ............................110 The engine cannot start and there is no sign of fault diagnosis process ................111 The engine cannot be started and there is a car symptom fault diagnosis process ...............
  • Page 9 1. The engine temperature is too high:........................... 130 2. The engine temperature is too low: ..........................130 3. Coolant leakage ................................130 Coolant system distribution map ............................131 M310 ....................................131 M125 ....................................131 Coolant flow diagram ................................133 M310 ....................................133 M125 ....................................
  • Page 10 Charging system check ................................153 1. Leakage test ................................153 2. Check the charging voltage ............................153 3. Inspection of magneto stator charging coil......................... 153 Remove the rectifier ................................154 10. Front fork assembly .................................. 155 Know Before Service ................................155 Exploded view of front fork components: ..........................
  • Page 11 Removal of the front part of vent ............................178 Removal of the windshield base ............................. 178 Removal of the left and right decorative covers of the front storage box ................179 Disassembly of the left &right side cover ..........................180 Disassembly of the foot pedals and trim cover ........................

  • Page 12: Vehicle Information

    1. Vehicle information Know Before Service 1. Use good quality tools, or special tools and fixtures designed by our company. The use of inferior tools may cause damage to parts, peeling of plating, improper assembly, etc. 2. The O-rings, paper gaskets, copper gaskets, and component sealing rings used for sealing must be replaced before assembling. 3.

  • Page 13: Body Label

    Body label ① The vehicle identification code VIN can be seen after opening the seat cushion, and the VIN code is engraved on the cross tube at the rear of the frame. ② The muffler code is on the inner side above the muffler. ③...

  • Page 14: M310 Technical Specification

    M310 Technical specification Item Specification Front tire specification 110/80－14 CM－SC01 59S Rear tire specification 140/70－14 CM－SC01 68S Front rim specification MT:2.5×14 Rear rim specification MT:3.75×14 Vehicle Brake fluid DOT4 0.23L（0.06 US gal,0.05 lmp gal） Replace fine filter： 1.75L（0.46 US gal,0.39 lmp gal） Oil consumption Without replacing the fine filter：...

  • Page 15: Battery/Charging System

    Battery/charging system Item Standard Type 6－FM－12 Capacity 12Ah Battery self-discharge current 1.1mA average Full 13.1～13.3V Charging voltage required for ≤12.8V Voltage unloaded bike Charging voltage required for ≤12V loading Battery Constant voltage range 14.4～14.8V Constant voltage charging Initial charging current 0.1～0.2 times the battery capacity mode Charging time...

  • Page 16: Rear Wheel/Suspension System

    Rear wheel/suspension system Item Standard Limit Tread depth ≥1.6mm (0.063 in) Normal temperature standard tire pressure 270kPa (2.75 kgf/cm PSI) Radial 1.5mm (0.006 in) Rear wheel rim runout Axial 1.5mm (0.006 in) V belt Top width 25.3mm (0.996 in) ≥24.3mm (0.957 in) Standard position of rear shock absorber and preload regulator Third gear Brake system...

  • Page 17: Lamp/Speedometer/Switch Description

    Lamp/Speedometer/switch description Item Specification High beam 12V～23W Front headlight Low beam 12V～15W Front position light 2.8W Front turn signal 1.2W Light（LED） Rear turn signal License plate light 0.5W Brake lights/tail lights 1.3/0.4W Storage box atmosphere light 0.2W Main insurance ABS hydraulic control unit motor Insurance Hydraulic control unit ECU Lights...

  • Page 18: Cable/Cable/Pipe/Electrical Device Distribution Map

    Cable/cable/pipe/electrical device distribution map 1. Distribution map of lamps and lanterns 1-Left front turn signal 2-Left daytime running light 3-Side reflector 4-Position light 5-Right daytime running light 6-Headlight 7- Right front turn signal 8-Right-hand handle auxiliary switch 9-Right-hand handle switch 10-Rear tail light/system Moving lamp 11-Rear right turn signal 12-Rear reflector 13-License plate lamp 14-Left rear turn signal 15-Left handle switch 16-Left handle assistant switch 2.

  • Page 19: Brake Upper Pump And Brake Hose

    3. Brake upper pump and brake hose 1-Front disc brake main pump 2-FMC-HU brake hose 3-RMC-HU brake hose 4-rear disc brake main pump 4. Calipers, brake hoses and wheel speed sensors 1-brake disc (front) 2- front whell ABS induction ring gear 3-wheel speed sensor (front wheel) 4-front disc brake caliper 5-FC-HU brake hose 6- rear whell ABS induction ring gear 7-brake disc (rear) 8-rear disc brake caliper 9-wheel speed sensor (rear wheel) 10-RC-HU brake hose 19 / 188...

  • Page 20: Distribution Map Of Brake System Accessories

    5. Distribution map of brake system accessories 5.1 M310 1-wheel speed sensor (front wheel) 2-FC-HU brake hose 3-RC-HU brake hose 4-wheel speed sensor (rear wheel) 5-rear brake lever 6-rear brake switch 7-RMC -HU brake hose 8-rear disc brake main pump 9-FMC-HU brake hose 10-front brake switch 11- front disc brake main pump 12-front brake handle 13-hydraulic control unit 20 / 188...

  • Page 21: M125

    5.2 M125 1-wheel speed sensor (front wheel) 2-FC-HU brake hose 3-RC-HU brake hose 4-wheel speed sensor (rear wheel) 5-rear brake lever 6-rear brake switch 7-RMC -HU brake hose 8-rear disc brake main pump 9-FMC-HU brake hose 10-front brake switch 11- front disc brake main pump 12-front brake handle 13-hydraulic control unit 21 / 188...

  • Page 22: Oil Supply System

    6. Oil supply system 6.1 M310 Fuel evaporation 1- Fuel level sensor 2- Fuel tank 3- Fuel pump 4- Oil-air separator (welded inside the fuel tank) 5- Fuel tank cap 6- Adsorption/vent pipe 7-High pressure fuel pipe 8-Carbon tank 9-Carbon tank solenoid valve 10- Solenoid valve intake pipe 11- solenoid valve outlet pipe 12-throttle valve body assembly 13-intake pipe Caution: The carbon canister assembly includes a carbon canister 8, an adsorption/vent pipe 6, a solenoid valve intake pipe 10, a solenoid...

  • Page 23: M125 Fuel Evaporation

    6.2 M125 Fuel evaporation 1- Fuel level sensor 2- Fuel tank 3- Fuel pump 4- Oil-air separator (welded inside the fuel tank) 5- Fuel tank cap 6- Adsorption/vent pipe 7-High pressure fuel pipe 8-Carbon tank 9-Carbon tank solenoid valve 10- Solenoid valve intake pipe 11- solenoid valve outlet pipe 12-throttle valve body assembly Fuel evaporation: Oil and gas →...

  • Page 24: M125 Fuel Supply

    6.4 M125 Fuel supply Fuel supply system: Air→Carbon canister→Adsorption/vent pipe→Oil separator (inside the oil tank) Fuel → Fuel pump filter screen → Fuel pump → High pressure fuel pipe → Fuel injector → Cylinder 7. Distribution map of cooling system accessories 7.1 M310 1- Main water tank 2- Water tank filling port 3- Secondary water tank 4- Aluminum water inlet pipe 5- Aluminum water outlet pipe 6- Small water tank 7- Water and oil shared sensor 8- Thermostat 9- Water pump cover assembly...

  • Page 25: M125

    7.2 M125 1- Secondary water tank 2-Secondary water tank link pipe 3-Engine inlet pipe 4- Thermostat outlet pipe 5- Thermostat 6- Water tank inlet pipe 7- Water and oil shared sensor 8- Water tank outlet pipe 9- Water tank filling port 10- Radiator assembly 11- Water pump cover assembly 25 / 188...

  • Page 26: Electrical Device Layout

    8. Electrical device layout 1-TFT Speedometer 2-Flasher 3-horn 4-faucet lock 5-PKE 6-main cable 7-ignition coil 8-side bracket flameout switch 9-engine controller (ECU) 10-buzzer 11-cushion lock 12 -Dump switch 13-Windshield motor controller 14-USB charging cable 15-Front storage box lock 16-Electronic fuel tank lock 17-Canister solenoid valve 26 / 188...
  • Page 27 18-Battery 19-Rectifier 1-TFT meter 2-Windshield motor controller 3-PKE 4-faucet lock 5-front storage box lock 6-speaker 7-USB charging cable 8-dump switch 1- Cushion Lock 2- Rectifier 3- Buzzer 4- Engine Controller (ECU) 5- Battery 6- Fuse Box 1 7- Electronic Fuel Tank Lock 8- Fuse Box 2 9- Fuse Box 3 10- Ignition Coil 11- Side Bracket flameout switch 27 / 188...

  • Page 28: Intake And Exhaust System

    9. Intake and exhaust system 9.1 M310 1- External oil and gas separator 2- Cylinder head 3- Throttle valve body assembly 4- Intake manifold 5- Cylinder head exhaust pipe 6- Air filter intake pipe 7- Air filter outlet pipe 8- Cylinder 9- Muffler 10- Crankshaft Box exhaust pipe Intake system (indicated by the green arrow): Air →...

  • Page 29: M125

    9.2 M125 1- Cylinder head 2-Cylinder head exhaust pipe 3- Air filter intake pipe 4- Crankshaft Box exhaust pipe 5-Air filter outlet pipe 6- Throttle valve body assembly 7- Intake manifold 8-Cylinder 9- Muffler Intake system (indicated by the green arrow): Air →...

  • Page 30: Tool

    Tool 125-piece tool set Torque wrench On-board tools Claw hammer Pull code Rubber hammer Dynamic Balancing Machine Tire raking machine Oil pan Measuring cup Funnel Taps, dies Micrometer Depth gauge Vernier caliper Feeler gauge 30 / 188...
  • Page 31 PT300 electronic spraying and Tire pressure gauge Magnetic base + dial indicator writing diagnostic Speedometer 17#Inner hexagon （16PIN） Hoop clamp Internal Circlip Pliers External circlip pliers Clamp multimeter Multimeter Dust blow gun Some of the above pictures are from the Internet, and the copyright belongs to the author of the original picture. Do not use it for other purposes.

  • Page 32: Swell Nail Description

    Swell nail description ①Press down the center cylinder with 4# inner hexagon or other tools, you can hear a sound or the center cylinder moves axially by 2mm; ②Pry open the gap with a blade, nail or carving knife, etc. and remove it; if space permits, you can reach it Push out from the back;...

  • Page 33: Maintenance

    2. Maintenance Know Before Service 1. Use good quality tools, or special tools and fixtures designed by our company. The use of inferior tools may cause damage to parts, peeling of plating, improper assembly, etc. 2. The O-rings, paper gaskets, copper gaskets, and component seals used for sealing must be replaced before assembly. 3.

  • Page 34: M310 Maintenance Schedule

    M310 Maintenance schedule : inspection（Inspect and clean,adjust,lubricate or replace if necessary） :replace ：Tighten Initial Every Every Inspectio Torque mile 1000/621 5000/3107 10000/6214 Replace regularly Check item n before N.m/kgf.m driving Months Initial 3 Every 15 Every 30 Inspection every 2 years or 20,000 Cradle buffer glue kilometers (12427 mile) Air filter (filter element)

  • Page 35: M125 Maintenance Schedule

    M125 Maintenance schedule : inspection（Inspect and clean,adjust,lubricate or replace if necessary） :replace ：Tighten Initial Every Every Inspectio Torque mile 1000/621 4000/2485 8000/4971 Replace regularly Check item n before N.m/kgf.m driving Months Initial 3 Every 15 Every 30 Inspection every 2 years or 20,000 Cradle buffer glue kilometers (12427 mile) Air filter (filter element)

  • Page 36: M310 Air Filter (Filter Element), Air Inlet Filter Element

    ●M310 the first maintenance is carried out for the first 1000 kilometers (621mile) or 3 months (whichever arrives first), and thereafter regular maintenance is carried out every 5000 kilometers (3107mile) or 15 months (whichever arrives first). M125 the first maintenance is carried out for the first 1000 kilometers (621mile) or 3 months (whichever arrives first), and thereafter regular maintenance is carried out every 4000 kilometers (2485mile) or 6 months (whichever arrives first).

  • Page 37: Replace The Air Inlet Filter

    b. Use 4# inner hexagon to remove the 3 M6×14 bolts as shown in the figure. b. Remove the air filter housing. c. Remove the air inlet cover and the air inlet filter element together. Remove the rubber strip on the box. 6.

  • Page 38: Reinstall

    f. Before installing other bolts, install the exposed sponge and plug it back into the left cover. 8. Reinstall a. Refer to the steps of removing the filter housing to install the housing back. b. Replace the air inlet baffle and the air inlet cover of the replaced air inlet filter element.

  • Page 39: M125 Air Filter (Filter Element), Air Inlet Filter Element

    b. Use 4# inner hexagon to press down the center cylindrical pins of the 2 swell nails, and then remove the swell nails and the engine rear decorative cover. ●If the air filter is clogged with dust, the air intake resistance will increase and the output power will decrease.

  • Page 40: Remove The Air Filter Housing

    4. Remove the air filter housing a. Use a Phillips screwdriver to remove the 9 pcs screws that fix the housing of the air filter. 7. Reinstall a. Refer to the steps of removing the filter housing to b. Remove the air filter housing. install the housing back.

  • Page 41: Bolts And Nuts Of Muffler

    f. Reinstall the engine rear decorative cover. ●The vehicle must be parked on a flat and stable ground or a lifting platform. ●The operation can only be performed after the engine has cooled down completely. ●The air filter element is checked every 4000 kilometers or 15 months (whichever comes first), and replaced every 8000 The models Ⅲ: kilometers or 30 months (whichever comes first).

  • Page 42: M310 Spark Plug

    ●If you need to remove the muffler for other operations, it is c. Use your fingers or a plastic crowbar to insert the arrow recommended to cover the air inlet and outlet holes of the indication point, first pry the arrow indication point open the muffler with textured paper to prevent foreign objects from gap and then pull up.

  • Page 43: Check The Spark Plug

    h. Use 4# inner hexagon to remove 7pcs M6×14 bolts. n. It is recommended to seal the spark plug installation hole with masking paper or other soft plastic bags to prevent foreign matter from entering the engine. 2. Check the spark plug i.

  • Page 44: M125 Spark Plug

    spark plug, you can turn it by hand until there is resistance and then rotate it 1/2 turn. For example, if you use an old spark plug, you can turn it to the standard torque as soon as possible. ●Pay attention and order when removing the plastic buckle to avoid the buckle from breaking.

  • Page 45: Check The Spark Plug

    2. Check the spark plug front part with a 4# inner hexagon. For instructions on disassembly and assembly of swell nails, please refer to the a. Check whether the insulator is cracked or damaged, pre-service instructions in this chapter. whether the center electrode is abraded, fouled, corroded, excessively carbonized or discolored (the color of the ceramic insulator around the middle electrode of the spark plug should be light brown).

  • Page 46: M310

    ●The vehicle must be parked on a flat and stable ground or a lifting platform. ●Once the engine and muffler have cooled down, the operation can be performed. ●When adding engine oil, prevent the engine oil from dripping onto the surface of the muffler. ●The engine oil should be kept away from children and pets.

  • Page 47: Change Gear Box Oil

    c. Wipe clean the fuel filler opening with a non-woven cloth. c. Remove the oil drain bolt⑶ and the copper pad⑷. d. After the gear box oil is completely drained, wipe the surface of the drain port with a non-woven cloth. e.

  • Page 48: Replace Fine Filter

    d. Replace the new fine filter (oil filter element) and gasket. The fine filter assembly already contains O ring (3a), fine filter (oil filter element) (3b) and gasket (3c). Replace in order. e. Remove the O ring on the fine filter cover and replace it with a new O ring.

  • Page 49: Change Gear Box Oil

    4. Change gear box oil positions are leaking, and if there is any leakage, it needs to be checked. a. Remove the left engine cover by referring to the steps b. After the engine has been idling for 5 minutes and then for replacing the air inlet filter element.
  • Page 50 c. Grasp the rear of the battery cover assembly, turn it up, and then pull it out toward the rear of the vehicle. Note that f. Pull out the two relay wires. there are buckles on both sides of the front. The rebate position needs to be inserted in the front when re-installing.

  • Page 51: Remove The Throttle Valve Body Assembly To Clean Up Carbon Deposits

    atmosphere lamp thread, unplug the thread and remove the glove box assembly. Remove the M6×16 bolts(3) on both sides with a 4# inner l. Unplug the plug of the stepping motor①. hexagon. m. Use a short Phillips screwdriver to remove the 2 GB9074.4 M4×12 bolts③...

  • Page 52: Disassemble The Three-In-One Sensor

    b. Place the small container under the high-pressure oil pipe, press the buckle indicated by③ and pull out the high- pressure oil pipe⑴ in the direction of the arrow at the same time. A small amount of fuel will flow out when it is pulled out, and it is forbidden to drip onto the surface of the part.

  • Page 53: Throttle Valve Body Troubleshooting Process

    b. Pinch the brake and start the vehicle; c. Pull the engine speed above 3000 rpm; d. After releasing the throttle, turn off the flameout switch and lock the car; e. After waiting for 5 seconds, unlock the vehicle again to complete the reset of the EFI system.

  • Page 54: Remove The Throttle Valve Body Assembly To Clean Up Carbon Deposits

    f. Use a short Phillips screwdriver to remove the 2 c. Remove the decorative buckle⑻ of the M6 hexagon GB9074.4 M4×12bolts③ and the anti-off card④ that come socket bolt; remove the M6×16 bolts⑶ on both sides with with the throttle valve body assembly, and then remove the 4# hex socket.

  • Page 55: Disassemble The Sensor

    b. After unplugging the desorption pipe at the bottom, pull out the air filter outlet pipe and then remove the throttle valve body assembly. Connect the diagnostic instrument to the whole vehicle, press the flameout switch (without ignition), turn the throttle handle from the initial position to fully open, and check c.

  • Page 56: Throttle Cable

    Torque: 3.8 N.m (0.4 kgf.m, 2.8 lbf.ft). ●Remove the throttle valve body to clean the carbon deposits and operate in a dust-free and dust-free environment to prevent dust from entering the inside of the engine. ●Prevent foreign matter from falling into the engine or air filter.

  • Page 57: Idle Speed

    ●After the adjustment, the engine idling speed cannot increase when turning the front of the car. ●Do not use high-viscosity oil to lubricate the cable to ●After adjusting the gap of the throttle cable, make sure that prevent excessive viscosity from affecting the free movement the throttle handle can be automatically turned back to the of the cable.

  • Page 58: Fuel Evaporative Pollutant Control System

    Fuel evaporative pollutant control system M310 fuel evaporation 1- Fuel level sensor 2- Fuel tank 3- Fuel pump 4- Oil-air separator (welded inside the fuel tank) 5- Fuel tank cap 6- Adsorption/vent pipe 7-High pressure fuel pipe 8-Carbon tank 9-Carbon tank solenoid valve 10- Solenoid valve intake pipe 11- solenoid valve outlet pipe 12-throttle valve body assembly Remarks: The carbon canister assembly includes carbon canister 8, adsorption/vent pipe 6, solenoid valve inlet pipe 10, and solenoid valve outlet pipe 11.

  • Page 59: Radiator

    1- Fuel level sensor 2- Fuel tank 3- Fuel pump 4- Oil-air separator (welded inside the fuel tank) 5- Fuel tank cap 6- Adsorption/vent pipe 7-High pressure fuel pipe 8-Carbon tank 9-Carbon tank solenoid valve 10- Solenoid valve intake pipe 11- solenoid valve outlet pipe 12-throttle valve body assembly Fuel evaporation: Oil and gas →...

  • Page 60: M310 Add Coolant To The Radiator

    a. Use 4# inner hexagon to remove the upper 2 M6×14 bolts. d. Put on waterproof gloves and add coolant to the water inlet of the Radiator with the help of an extended funnel. Until the position of the vent bolt of the thermostat is stably overflowed with coolant, the coolant level can be seen at the water filling port.

  • Page 61: Check Whether The Fins Of The Radiator Water Tank Are Deformed Or The Air Duct Is Blocked

    b. Pull the deformed fins straight with a flat engraving knife or a small flat-blade screwdriver. If the deformed fins b.将车辆用升降台长高然后用 8#套筒拆下 M6×10 螺栓 exceed 20%, a new heat sink needs to be replaced. M125 ⑴，取下 6.3×12×1.6 铜垫，将冷却液放出。拧下主水箱 参照前面步骤将水箱罩拆下后参考 M310 的步骤进行 散热器底部的螺钉⑶，将冷却液放完，注意不能遗漏...

  • Page 62: Check All Water Pipes For Leaks; Aging

    6. Check all water pipes for leaks; aging. M310 1-Radiator 2-Coolant expansion tank 3-Aluminum water inlet pipe 4-Aluminum water outlet pipe 5-Small radiator 6-Water and oil shared sensor 7-thermostat 8-water pump assembly 1- Main water tank inlet pipe 2- Leakage pipe 3- Small radiator outlet pipe 4- Water inlet pipe 5- Secondary water tank connection pipe 6 Main water tank outlet pipe 7- Engine inlet pipe 8- Small radiator inlet pipe 9- Small circulation outlet pipe 10- Water pump cover inlet pipe 11-Cylinder inlet pipe 62 / 188...
  • Page 63 M125 1-Secondary water tank 2-Secondary water tank link pipe 3-Engine inlet pipe 4- Thermostat outlet pipe 5- Thermostat 6- Water tank inlet pipe 7- Water and oil shared sensor 8- Water tank outlet pipe 9- Water tank filling port 10- Radiator assembly 11- Water pump cover assembly 63 / 188...

  • Page 64: M125

    2. Replace high pressure oil pipe Fuel pipe a. Refer to steps a to j of "Remove stepping motor and Caution: clean up carbon deposits" in the throttle valve body, first ●A small amount of fuel will flow out when the high-pressure remove the cushion and storage box components, and fuel pipe is removed.

  • Page 65: Fuel Pump

    b. Unplug the fuel pump and start the engine to idle until the engine stops. Turn the engine stop switch to " ", e. Unplug the fuel pump and start the engine at idle speed power off the vehicle and lock the vehicle. After putting on until the engine stops.
  • Page 66 The protruding part of the fuel pump and nozzle holder. ●It is forbidden to smoke, dial mobile phones and other actions that may cause a fire at the demolition site. ●The fuel pump is a precision component that needs to be assembled in a dust-free workshop and requires strict testing, so it is forbidden to disassemble it by yourself.

  • Page 67: M310 V Belt

    M310 V belt 1. System Components Parts information Serial number part name quantity serial M12×1.25×35 hexagon flange bolts (grade φ23.2×φ40×3.25 washer 10.9/environmental protection color) M14×1 Hexagon Flange Nut (Grade φ12.3×φ40×4 washer 10/Environmental Protection Color Zinc) Driving wheel drive disc φ21.8×φ1.8 Acrylic O-ring Distance tube φ14.5×φ25×16 driven wheel bushing V-shaped transmission belt...

  • Page 68: Disassemble The Continuously Variable Transmission Components

    f. Remove the left crankcase cover⑵ and the left crankcase cover gasket⑷. The left crankcase cover gasket (4) must be replaced when reinstalling, and the hollow positioning pin (3) must not be omitted. b. Use an 8# sleeve to remove the two bolts (1) shown in the figure.

  • Page 69: Inspection

    d. Remove M12×1.25×35 hexagon flange bolts and h. Pinch the sliding plate of the driving wheel and the ramp φ12.3×φ40×4 washer. Then remove the M14×1 hexagon plate inside, and remove it together with the distance tube. flange nut and φ14.5×φ25×16 driven wheel bushing. i.

  • Page 70: Assembly

    c. Check whether the Puli beads are worn out or round, and need to be replaced if they are out of round and deformed. Use a vernier caliper or an outside micrometer to measure the diameter of the outer cylindrical surface of the Puli beads.
  • Page 71 Finally, clamp the middle of the belt with an elastic clip to prevent the belt from loosening by itself. Caution: This step requires greater hand strength and certain operating experience to complete. Insufficient hand strength or no operating experience may cause injury to fingers caught by the driven pulley pulley! ! ! e.

  • Page 72: Common Fault Phenomena/Troubleshooting

    h. Point the stepped end of the φ14.5×φ25×16 driven k. At this point, the assembly of the stepless variable wheel bushing toward the driven wheel, and install it on the speed sub-assembly is completed. exposed optical axis of the drive shaft. Then screw on the 3.

  • Page 73: Braking System

    Braking System Caution: ●For the layout of the brake hose on the vehicle, please refer to the brake system accessories distribution diagram in the "Vehicle Information" chapter of this manual. Caution: In order to facilitate after-sales tracking, those who need to purchase brake hoses, disc brake calipers, disc brake main pumps, and hydraulic control units must be reviewed by our company before they can be purchased.

  • Page 74: Check The Brake Components

    Caution: c. Measure the thickness of the front and rear brake discs. ●This inspection should be completed by a qualified If it is less than 4.0mm (0.16 in), replace it. Hang the front maintenance organization. wheel in the air and turn the front wheel by hand to observe ●Regularly check whether the brake fluid level is at 3/4 of the whether there are obvious damages on the surface, such as observation window.

  • Page 75: Check The Front And Rear Brake Switches

    The replacement procedure of the front brake switch is the same as that of the rear brake switch. The throttle cable needs to be removed to facilitate the removal of the bolt①. ●A qualified maintenance organization should check and maintain the brake pads on a regular basis. ●Do not drive immediately after replacing a new brake disc or brake pad.

  • Page 76: Replace The Brake Pads

    d. Take out the new brake pad and install it back. You need to hold the bottom of the brake pad (through hole end) with your hand. Be careful not to install it backwards, the side 5. Replace the brake pads with 3 grooves faces the brake disc;...

  • Page 77: Abnormal Sound Of Brake Pads

    Inside Outside c. Push the piston to the end in the direction of the arrow e. After adjusting the position of the brake pad, reinstall with the help of a tool. If the resistance is high, you can refer the bolt③ and lock it with a 12# sleeve. Standard torque: to the method of adding brake fluid to the front brake main 24N.m (2.4 kgf.m, 18 lbf.ft).

  • Page 78: Replacing The Front Brake Disc

    6.1 Replacing the front brake disc The front brake disc can be removed by referring to the description of the steps for disassembling the front wheel assembly in the "Front Fork Assembly" of this manual. 6.2 Replacing the rear brake disc a.

  • Page 79: Brake Hose

    Brake fluid Caution: ●This inspection should be completed by a qualified maintenance organization. ●It is strictly forbidden to directly flush the main pump with high-pressure water. ●After disassembly, make sure that all parts are installed correctly. ●It is strictly forbidden to mix in water, dust, impurities and silicic acid or petroleum-based liquids, otherwise it will cause f.

  • Page 80: Replace The Brake Fluid

    c. Put the other end of the hose into the oil pot. d. Remove the upper cover of the front brake main pump e. Use the brake fluid water content tester to measure the referring to the previous step of adding brake fluid. water content, if it is more than 2%, all brake fluid needs to e.

  • Page 81: Brake System Exhaust

    3. Brake system exhaust ●When the tire pressure is found to drop, check whether the tire has nails or small holes; whether there is a collision on If the hand feel soft when the brake handle is squeezed the side of the rim that causes deformation or cracks. and the braking performance is significantly reduced, first ●Be careful to avoid the position of the valve when removing check whether the brake fluid level of the main pump is...

  • Page 82: Replace Tires

    b. Keep the front wheel suspended, shake the front wheel assembly in multiple directions, to confirm whether the front fork assembly is axially strung or loosened in the radial direction. b. The height of the wear mark on the tread protrusion is 1.6mm (0.06 in).

  • Page 83: Maintain Steering Bearings

    to touch the rubber pad (3) and align the lock washer (2) with chrome-plated cylinder) in time to avoid scratching the dust the groove of the nut (1b) and (1c). Tighten the nut (1a) to seal or oil seal and causing leakage; wipe it clean with a soft 100N.m (10.2 kgf.m, 74 lbf.ft).

  • Page 84: Check The Shock Absorption Performance

    d. Check whether there is any leakage at the bottom of the deformation part is out of round after correction, it should be bottom cylinder with the help of a mirror or mobile phone replaced. If the deformation is too large, the shock lens.

  • Page 85: Adjust The Preload

    b. Use an 8# sleeve to remove the bolts (1) at the position shown in the figure. c. Use needle-nose pliers to clamp the exhaust pipe clamp d. Check whether the weld at the bottom of the shock on the inner side of the air filter and move it upward about absorber is leaking.

  • Page 86: Replace The Shock Absorption

    3. Replace the shock absorption e. Pull down the front part of the rear mud plate, fix the nut⑺ with a 14# sleeve or a torx wrench, loosen the bolt⑹ a. After removing the muffler assembly, follow the steps completely with a 14# sleeve on the outside, and remove the “a”...

  • Page 87: Check Engine Fasteners

    2. Check engine fasteners d. Check whether the engine nut is loose. Standard torque of 5 M12 nuts of engine cradle: 65N.m (6.6 kgf.m, 48 lbf.ft). a. Refer to the steps for removing the rear storage box and tail skirt to remove it to the extent shown in the figure. b.

  • Page 88: Valve Clearance Adjustment (M310)

    Valve clearance adjustment (M310) b. Use 5# and 10# Allen wrenches to remove M14×1.5 screw plugs and M30×1.5 aluminum screw plugs, and remove ●The M125 steps are similar to the M310, taking the M310 as the O-ring. an example. 1. Maintenance information 1.1 General information a.
  • Page 89 f. Push the intake valve rocker arm and exhaust valve rocker arm to the side of the timing driven sprocket to expose the valve adjusting gasket. Then, according to the standard value of valve clearance (intake valve: 0.08～ 0.12mm (0.003～0.005 in), exhaust valve: 0.18～0.22mm (0.007～0.009 in), determine the specifications of the adjusting gasket that needs to be replaced.
  • Page 90 h. After replacing the four valve adjusting gaskets, check and confirm the four valve gaps again. If there is a deviation from the standard, repeat step⑥ and⑦ to adjust again j. Wipe off the oil and residual sealant on the joint surface until it meets the standard range.
  • Page 91 l. So far, the adjustment operation of the valve clearance is completed. 91 / 188...

  • Page 92: Side Bracket

    b. The thick steel wire can be rolled into a circle and put Side bracket into the spring⑴ pull hook. Pay attention to ensure that the Caution: steel wire cannot loose or fall apart during the pulling ●Park the vehicle on a flat and stable ground or a lifting process.

  • Page 93: Main Bracket

    Main bracket Caution: ●Park the vehicle on a flat and stable ground or a lifting platform, and put down the side brackets. ●When disassembling and installing the spring, it is necessary to prevent the spring from flying off suddenly and causing personal injury.

  • Page 94: Sound, Light, And Electrical Device Inspection

    Sound, light, and electrical device ①SET key: Short press SET to enter the main menu/confirm selection. Long press to return to the main interface. Operate Inspection this button when driving a vehicle is prohibited. Caution: ②MOD key: Select the next item. Operate this button when ●Before driving, check whether the lights of the whole car driving a vehicle is prohibited.

  • Page 95: Headlight Height Adjustment

    serration of the dimming bolt; Rotate the clockwise to turn down, and counterclockwise to turn up. If the battery power supply fails to start, it can be charged through the PKE charging port. Open the right storage box cover, insert the buckle with your fingernail or a thin flat-blade screwdriver, press inward and pull out the buckles on both sides, and then remove the right storage box cover.

  • Page 96: Fuse Box

    3.Fuse box Caution: ●If the fuse is blown, you must replace the fuse of the same specification. It is forbidden to use wires such as copper or iron wire for direct connection. ●If it is blown after replacement, you need to troubleshoot the entire vehicle cable before replacing it. ●This vehicle uses a small fuse.

  • Page 97: Troubleshooting

    4. Troubleshooting If the button cannot be pressed, it is directly judged as a switch problem. If there is no response when pressed, it is necessary to judge the problem of the switch, circuit, or electrical device. 4.1 Right hand switch a.No response when pressing the start button：...

  • Page 98: Left Hand Handle Auxiliary Switch

    d. “ ” Not responding There is a detailed description of PKE functions in the driver's manual, including the method of emergency starting the vehicle when the sensor key is exhausted, and the specific meaning of the buzzer sound. Bring the Replace the battery, the Right auxiliary induction key...

  • Page 99: Left Hand Switch

    4.5 Left hand switch The left hand switch controls the turn signal, horn and far, low beam, hazard warning light, and overtaking light. It is difficult to check if there are more lines. 99 / 188...

  • Page 100: Light

    4.6 Light Caution: ●When using wires to detect lamps, please pay attention to distinguish the positive and negative poles. For detailed wire colors, please refer to the electrical schematic diagram in the driver's manual provided with the car. The troubleshooting methods of the lamps are basically the same. You can directly lead the wires to the battery with the battery.

  • Page 101: Efi System

    3. EFI system Know Before Service Caution: 1. The structure and working principle of the EFI system are relatively complicated, and it is necessary to have a certain understanding of the working principle and structural characteristics of each EFI system before checking and troubleshooting. The content of this chapter requires certain maintenance experience.

  • Page 102: Error Code

    Error code Caution: ●Unlock the vehicle and turn on the flameout switch. When it is not started, the EFI fault light is always on as normal. If it is not on, the vehicle cannot be started. ●After starting the vehicle, if the fault light is on and the EFI failure is reported, it means that the EFI system is abnormal. ●When the EFI system reports a failure, continuing to drive the vehicle may cause damage.

  • Page 103: Error Code

    3. Error code Code Instruction Code Instruction The heating control circuit of the upstream 1 Engine coolant temperature sensor signal is P0030 PD116 cylinder oxygen sensor is open unreasonable The upstream 1 cylinder oxygen sensor Engine coolant temperature sensor circuit voltage is P0031 P0117 heating control circuit voltage is too low...

  • Page 104: Efi Parts Layout

    EFI parts layout M310 M125 OBD diagnostic Carbon canister Fuel injector Dump switch interface (main Fuel pump EFI relay solenoid valve (M310) cable) Crankshaft Ignition coils Throttle valve Water and oil Oxygen Sensor MSE6.0 ECU position sensor (M310) body (M310) shared sensor (M310) (M310)

  • Page 105: Fault Diagnosis And Elimination Of Efi Parts

    Fault diagnosis and elimination of EFI parts Caution: ●Once the EFI components are disassembled, the EFI system needs to be reset. For details, see the service information in this chapter. ●Fuel pumps, three-in-one sensors, stepping motors, ECUs, etc. are precision parts, such as unauthorized disassembly may cause damage, and it is not within the scope of the three guarantees for human reasons.

  • Page 106: Carbon Canister Solenoid Valve

    3 and 5 are normally closed contacts, which can be tested with a multimeter buzzer. 1 and 2 are normally open contacts. Otherwise, it can be judged as a relay failure. The following cable end colors are for reference and the actual vehicle shall prevail.

  • Page 107: Ignition Coils

    b. Pull out in sequence in the direction of the arrow (from the rear wheel to the front wheel). Note that there If you need to replace the fuel injector, wait until the are 5 staples at the red circle and a circle of buckles around. engine and muffler have cooled down.

  • Page 108: Throttle Valve Body

    8. Throttle valve body 8.1 Common failure phenomena 1. The engine is easy to stall when the vehicle is running, and it is difficult to start, especially cold starting. 2. Idle speed is unstable or no idle speed, and there is intermittent jitter when accelerating. 3.
  • Page 109 10. Oxygen Sensor ●The oxygen sensor must be removed after the engine and muffler have cooled down completely. When there is poor engine performance, unstable idle speed, high fuel consumption, and incorrect air-fuel ratio, check the oxygen sensor. The fault code can be read through the diagnostic Speedometer to confirm whether the oxygen sensor is faulty. M310 M125 10.1 Check...
  • Page 110 11. ECU M310 When the engine cannot be started and the performance is poor, check whether the ECU is normal. Because the ECU is more complicated and difficult to judge, the elimination method can generally be used to remove the ECU from a normal vehicle of the same model and replace it with a faulty vehicle.
  • Page 111 The engine cannot start and there is no sign of fault diagnosis process When the start button is pressed and the starter motor can drive the engine to run normally, but the engine does not work normally, and there is no sign of the car, you can refer to the following diagnosis process to troubleshoot the cause of the fault. No spark or weak Check the ignition strength...
  • Page 112 Poor acceleration Rotate the rubber sleeve with the right hand. The engine speed cannot increase immediately, and there is hysteresis, and the acceleration is slow; you can refer to the following diagnosis process to troubleshoot the cause of the fault. Check Check if the air Poor...
  • Page 113 Unsteady idling, easy to cutoff The engine is running at an unstable idling speed, easy to stall, and can return to normal after a warm car. You can refer to the following diagnosis process to troubleshoot the cause of the fault. Unsteady idling / flameout Check the oil circuit Whether it returns to...
  • Page 114 Analysis flow chart of EFI failure indicator light always on If the EFI failure indicator light " " is always on, you should first check whether the wires of the EFI sensors are loose. The fault light is always on during driving Read fault code Idle speed fault...
  • Page 115 Electrical schematic diagram of EFI system 115 / 188...
  • Page 116 4. Ignition system Know Before Service 1. The content of this chapter requires certain maintenance experience. It is recommended to check or repair with a qualified maintenance organization. 2. Do not disassemble the parts connected to the 12V power supply at will after power-on, to avoid the self-inductance of the coil in the electrical appliance, which may damage the ECU or sensor due to the instantaneous voltage.
  • Page 117 Troubleshooting Check the following items before diagnosing the ignition system a. Check whether the spark plug is abnormal; b. Check whether the ignition coil high-voltage cap or plug is loose; c. Check whether water enters the high pressure cap; d. If there is no spark, find the ignition coil of the same model to confirm that there is no fault and install it on the faulty vehicle to test whether there is spark;...
  • Page 118 Ignition system layout M310 M125 1- Dump switch 2- Side bracket flameout switch 3- Faucet 4- PKE 5- Ignition coil 6-Spark plug 7- Right-hand handle auxiliary switch 8- Right-hand handle switch 9 Fuse box 10- Relay 11-Starting relay 12-Battery 13-Magnetic Motor stator 14-Crankshaft position sensor 15-ECU Caution: ●The fuse box comes with the main wiring harness and there are 3 in total.
  • Page 119 Ignition system inspection Caution: ●If there is no spark in the spark plug, check all the cable connections for looseness or poor contact before checking the ignition system. ●Use a high-precision digital multimeter. For details of the ignition coil test method, please refer to the section "Ignition Coil" in the "Electronic Injection System" chapter of this manual.
  • Page 120 washer, M10×1.25×45 hexagon flange bolts, screw in the threads manually, tighten the timing chain, and turn the flywheel clockwise , Align the line immediately after the "T" mark on the flywheel with the triangle mark on the box body, install the flywheel limit tool, tighten the bolts with a wind gun, and correct with a fixed torsion, and mark with an oil-based pen.
  • Page 121 5. Starting system Know Before Service 1. If current flows through the starter motor when the engine is not started, it can be judged that the starter motor is damaged and needs to be replaced. 2. Before servicing the starter motor, turn on the engine stop switch to " "...
  • Page 122 2. Starter motor Does the Brake switch or After the vehicle is Short circuit starter motor flameout switch energized, the flameout relay work? failure switch is hit“ ” The flameout switch of the Whether the EFI Press the start Does the starting Relay failure right handle is fault light is on...
  • Page 123 Starting system electrical schematic diagram Starter motor Caution: ●If the starter motor is removed for maintenance, replace the O-ring with a new one and apply a proper amount of engine oil. ●Our company only sells starter motor assemblies, not O- rings and motor parts separately.
  • Page 124 outlet pipe toward the rear wheel to pull out the throttle e. When reassembling, make sure not to omit the O ring valve body. that comes with the starter motor, and align the teeth of the electric starter reduction gear. Note that the O-ring needs to be correctly assembled into the box, as it will cause leakage if cut edges occur.
  • Page 125 1-M6×90 bolt×2 2-O ring×2 3-O ring 4-starter motor front cover 5-gasket 6-rectangular sealing ring 7-starter motor outer shell 8- rectangular sealing ring 9-electric pole 10-screw ×2 11-Negative brush×2 12-Volute spring×4 13-Positive brush×2 14-Brush frame 15-Brush holder insulation gasket 16-Starter motor back cover 17-Insulation gasket 18-Nut×2 19- Gasket Examination Starter motor front cover：...
  • Page 126 green/red wire, and one to any bolt connected to the frame. It should be conductive when the start button is pressed. b. Unlock the vehicle, turn the engine shutoff switch to " ", retract the side bracket, pinch the brake handle and 3.
  • Page 127 6. Fuel supply system Know Before Service 1. Bending or twisting the control cable will affect the smooth operation, and may cause a short circuit or open circuit, causing the vehicle to lose control. 2. The operation should be carried out in an open and ventilated place. All activities that may cause sparks, such as smoking, calling on mobile phones, etc., are prohibited on the job site.
  • Page 128 d. Remove the oil pump plug in the same way. Pinch the snorkel clamp and move it down, and pull out the snorkel. Press the anti-release buckle of the high-pressure oil pipe at the end of the oil pump, and pull the high-pressure oil pipe along the axis of the oil outlet of the oil pump.
  • Page 129 When re-assembling, you need to pre-tighten the corners When reassembling, you need to pre-tighten the corners and then tighten the 5 bolts. Otherwise, the uneven and then tighten the 4 M6×16 bolts. Otherwise, the uneven compression of the sealing rubber ring of the fuel pump will compression of the sealing rubber ring of the oil level sensor easily cause leakage and cause safety hazards.
  • Page 130 7. Cooling system Know Before Service 1. Please refer to the radiator section of the "Maintenance" chapter of this manual for the corresponding precautions for the coolant (antifreeze). 2. Check the cooling water pipe; check the height of the cooling liquid, adding and discharging the cooling liquid have been described in detail in the radiator section of the "Maintenance"...
  • Page 131 Coolant system distribution map M310 1- Main water tank 2- Water tank filling port 3- Secondary water tank 4- Aluminum water inlet pipe 5- Aluminum water outlet pipe 6- Small water tank 7- Water and oil shared sensor 8- Thermostat 9- Water pump cover assembly 1- Main water tank 2- Water tank filling port 3- Secondary water tank 4- Aluminum water inlet pipe 5- Aluminum water outlet pipe 6- Small water tank 7- Water and oil shared sensor 8- Thermostat 9- Water pump cover assembly M125...
  • Page 132 1- Secondary water tank 2-Secondary water tank link pipe 3-Engine inlet pipe 4- Thermostat outlet pipe 5- Thermostat 6- Water tank inlet pipe 7- Water and oil shared sensor 8- Water tank outlet pipe 9- Water tank filling port 10- Radiator assembly 11- Water pump cover assembly 132 / 188...
  • Page 133 Coolant flow diagram M310 1- Main water tank inlet pipe 2- Leakage pipe 3- Small water tank outlet pipe 4- Water inlet pipe 5- Secondary water tank connection pipe 6 Main water tank outlet pipe 7- Engine inlet pipe 8- Small water tank inlet pipe 9- Small circulation outlet pipe 10-Water pump cover inlet pipe 11-Cylinder inlet pipe Cooling system: Small loop (indicated by the blue arrow):...
  • Page 134 M125 1- Secondary water tank 2-Secondary water tank link pipe 3-Engine inlet pipe 4- Thermostat outlet pipe 5- Thermostat 6- Water tank inlet pipe 7- Water and oil shared sensor 8- Water tank outlet pipe 9- Water tank filling port 10- Radiator assembly 11- Water pump cover assembly Cooling system: Small loop (indicated by the blue arrow):...
  • Page 135 c. Press the buckle indicated by the arrow to pull out the plug of the cooling fan of the small water tank. d. Use an 8# sleeve to remove the 3 M6×22 bolts ⑺ shown in the figure. g. Use the hoop pliers to move the φ10.5 hoop⑾ in the direction of the arrow, and then pull out the leaking pipe⒀.
  • Page 136 j. If you need to remove the water filler fixing bracket, you a. Use the hoop pliers to remove the hoop⑹ and hoop⑻, can use an 8# sleeve to remove the bolt⒄. Grasp the and separate the water pipes⑶,⑺ and⑼ and the three- bracket⒅...
  • Page 137 ●After the soaking inspection is completed, the water stains should be wiped clean in time, or use a dust blower to blow dry. If the main water tank and the small water tank are blown dry by blowing dust loose, the wind pressure should not be too large and should be far away from the radiating fins to avoid damage or deformation of the radiating fins.
  • Page 138 1-Water tank front guard bolt*4 2-Water tank front guard 3-Water tank 4-Fan nut 5-Fan 6-Fan motor 7-Fan Guard 8-Fan Guard Bolt*3 9-Fan Motor Bolt*3 6. Water and oil shared sensor For details on sensor detection and disassembly methods, please refer to the section "Electronic Injection System" chapter EFI Parts Fault Diagnosis and Elimination.
  • Page 139 1-M6×10 bolt*2 2-M6×12 bolt 3-φ5.6×φ1O ring 4-thermostat upper shell 5-thermostat core 6-thermostat lower shell 7.4 Thermostat core inspection Check the opening temperature, full opening temperature and lift of the main valve in the thermostatic heating equipment with adjustable temperature. If one of them does not meet the specified value, it should be replaced.
  • Page 140 8. Braking system Know Before Service 1. The content of this chapter requires certain maintenance experience. It is recommended to check or repair with a qualified maintenance organization. 2. Frequent inhalation of the dust generated by the brake pads, regardless of the composition, may have a certain impact on health.
  • Page 141 Trouble shooting Soft feeling from brake lever a. The brake system oil circuit enters the air b. Brake fluid leakage c. The brake pads or brake discs have oil stains d. Wear of brake caliper or disc drive main pump piston seal ring e.
  • Page 142 brake fluid, and do not apply other lubricating materials such as lubricating oil, grease or anti-rust oil. g. Apply an appropriate amount of high-vacuum silicone grease to the outer end of the handle bolt and piston assembly according to the previous requirements for lubricating the movable part of the handle.
  • Page 143 ●Apply thread fastening glue to the thread of the caliper pin, remove the copper pad⑵, and remove the RC-HU oil pipe. torque: 27N.m (2.8kgf.m, 20 lbf.ft). Refer to the steps for adding brake fluid to the main pump of ●The torque of the air release nozzle: 7～9N.m (0.7～ the rear disc brake.
  • Page 144 Release brake fluid clean non-woven fabric. Take care to take protective measures and prevent dripping onto the cover or cable a. Refer to the previous steps to remove the oil pan first, connector. place the oil pan at the front and rear calipers, remove the FMC-HU and RMC-HU disc brake oil pipe bolts and copper pads first, and drain the brake fluid into the oil pan, and then refer to the front and...
  • Page 145 d. Check whether the surface of the removed hose is aging, cracked, damaged, abraded, etc. Wipe up the d. Pull the RC-HU head out of the gap between the remaining brake fluid with a non-woven cloth, and then wrap auxiliary water tank and the frame. the ends of the hose with cling film or a plastic bag to prevent foreign matter from entering.
  • Page 146 ABS system layout 1-Front and rear wheel speed sensor 2-ABS hydraulic control unit 3-OBD diagnostic interface ABS hydraulic control unit b. Use a 8# sleeve to remove 2 bolts (1) Remove the water tank filler bracket assembly to expose the ABS hydraulic Caution: control unit.
  • Page 147 M125 d. Remove the 2 bolts that were put back in the front (1) Remove the hydraulic control unit and bracket assembly from the car. e. After holding the hydraulic control unit firmly, use 4# inner hexagon to remove the M6×16 bolts⑵, then the hydraulic control unit⑸...
  • Page 148 ABS troubleshooting 148 / 188...
  • Page 149 M310 Troubleshooting process with portable ABS diagnostic scanner No front wheel speed No rear wheel speed 149 / 188...
  • Page 150 9. Battery/charging system Know Before Service 1. It is necessary to properly dispose of discarded batteries to avoid pollution to the environment. It is recommended that waste batteries be returned to a professional recycling agency for recycling. 2. It is forbidden to use chargers that have not passed the inspection to charge the battery. 3.
  • Page 151 Troubleshooting Battery damage or attenuation troubleshooting process Battery failure Use a Measure the multimeter to battery voltage Remove the battery and check whether Battery first, then voltage<charging use a battery tester to there is leakage, Check the measure the check the battery the leakage charging voltage voltage<14.5～14.9...
  • Page 152 Charging system layout diagram 1-Charging port (PKE) 2-Main fuse (25A) 3-Battery 4-Magnetic motor 5-Rectifier Electrical schematic diagram Letter Chinese green yellow English Green Yellow Battery disassembly section "Throttle valve body" in the "Maintenance" chapter of this manual to remove the battery. 1.
  • Page 153 ●The negative pole must be removed first, and then the b. Adjust the multimeter to the current position. Connect positive pole. The opposite is true when installing. the black test lead to the negative terminal of the battery ●The positive and negative electrode protective caps must and the red test lead to the removed negative wire.
  • Page 154 d. After unplugging the yellow 3P plug, measure the red positive wire and green negative wire with a multimeter, and the battery voltage should be measured. Use the buzzer file of the multimeter to check whether the green negative wire and the ground wire (the ground wire can be found in any stud directly connected to the frame) are always conducting.
  • Page 155 10. Front fork assembly Know Before Service 1. Use good quality tools, or special tools and fixtures designed by our company. The use of inferior tools may cause damage to parts, peeling of plating, improper assembly, etc. 2. The O-rings, paper gaskets, copper gaskets, and component seals used for sealing must be replaced before assembly. 3.
  • Page 156 Exploded view of front fork components: M125/310 Directional exploded view 156 / 188...
  • Page 157 Front fork exploded view The M125 are similar to the M310, taking the M310 as an example. 157 / 188...
  • Page 158 Exploded view of lower link board The M125 are similar to the M310, taking the M310 as an example. 158 / 188...
  • Page 159 Change the direction of the handle Caution: ●When removing the disc brake oil cup, it must be vertically upward to prevent air from entering the brake pipeline. ●When disassembling and assembling the handle switch, pay attention to adjusting the internal wiring harness of the switch to avoid damage to the wire skin caused by the shell or bolt column.
  • Page 160 assembly. Grasp the balance block and pull it out while d. Snap the upper brackets⑦,⑧, and⑨ into the lower shaking it up and down, left and right. Use the same method part of the direction control cover, buckle the pressure block, to pull out the left balance weight, soak in hot water for tighten 4 M8×35 bolts with 6# inner hexagon, and use 5# about 10 minutes before using Blow the dust gun into the...
  • Page 161 Replace the front wheel Caution: ●After the front wheel is installed, please press the brake ●Be careful not to damage the ABS coil when disassembling. handle repeatedly until the brake restores the braking effect. ●After removing the front wheel, do not press the brake ●Contaminated disc brake discs and disc brake pads will handle.
  • Page 162 ： Front wheel assembly exploded view M310 Part name Caution Oil seal TC φ28×φ42×7 GB276 bearing 6004-2RS-C3 φ20×φ42×12 Sleeve Tire pressure sensor ABS sensor gear（55T） Non-standard bolt M8×25 25 N.m(2.5 kgf.m，18 lbf.ft) 265×4.5 brake disc M125 Part name Caution Oil seal TC φ28×φ42×7 GB276 bearing 6004-2RS-C3 φ20×φ42×12 Sleeve...
  • Page 163 mileage is not absolute. It needs to be determined according Inspection and maintenance of front wheel assembly ： to the owner's travel habits (whether you like sudden Caution: braking), road conditions, maintenance intervals and other ●This inspection should be completed by a qualified factors, but if the following three conditions are reached If maintenance organization.
  • Page 164 1. Disassemble the front wheel and front fender b. When the tire tread wear reaches the limit position of the design. assembly c. There are many aging cracks in the tire. a. Refer to "Replace the front wheel" to remove the front 3.2 How to replace the front wheel rim and tire wheel.
  • Page 165 ●The vehicle must be parked on a level and stable ground or on a lifting platform. ●After the front wheel is installed, please press the brake handle repeatedly until the brake restores the braking effect. Replace the lower link board Caution: ●After the front wheel is disassembled, please do not press 3.
  • Page 166 Left 4. Remove the lower link board assembly a. Use a four-jaw sleeve to remove the direction column adjustment nut on the uppermost layer of the lower link plate, take out the cassette washer, the middle direction column adjustment nut, and the adjustment nut rubber gasket.
  • Page 167 d. Install the semi-circular key in the groove of the lower 6. Install other disassembly components link plate, then align the gap between the spacer and the a. Refer to "Replace the front shock absorber" to replace base with the semi-circular key, and finally screw in the cap the front shock absorber.
  • Page 168 11. Disassemble the engine of the vehicle Caution: ●The vehicle must be parked on a level and stable ground or on a lifting platform. ●The operation can only be performed after the engine has cooled down completely. ●Do not press the brake handle after removing the rear brake caliper.
  • Page 169 last hand, Grab the front of the tail skirt with one hand and take it out in the direction of the arrow. c.Then grasp the end of the side cover with your hand, and press the arrow Pull out in the direction (from back to front) g.
  • Page 170 b. Unplug the high-voltage package plug from the engine f. Locate and pull out the plug of the magneto stator head. charging cable⑦ at the left frame. Caution: One end of the magneto stator charging cable is connected to the inside of the engine, and one end is connected to the connector on the rectifier;...
  • Page 171 j. Locate and unplug the tube connecting the throttle body remove a M12×1.25×290 bolt that fixes the engine on the to the carbon canister at the lower part of the throttle body. right side of the vehicle, pull out the bolt from the frame. k.
  • Page 172 b. One person holds the whole car and slightly lifts the rear e. Install the rear pedal on the right side of the vehicle to a part of the frame, and one person rotates the two rear shock suitable position, install two M8×25 bolts, and tighten them absorbers to the frame installation groove, and then rotates with a 14# sleeve;...
  • Page 173 173 / 188...
  • Page 174 12. Disassembly and assembly of vehicle covering parts Caution: ●The vehicle must be parked on a level and stable ground or on a lifting platform. ●The operation can only be performed after the engine and muffler has cooled down completely. ●Attention and sequence when removing the plastic buckle to avoid the buckle from breaking ●The M125 steps are similar to the M310, taking the M310 as an example.
  • Page 175 1. Instrument panel 2. Front right pedal pad pressure plate 3. Front right pedal pad 4. Rear right pedal pad 5. Rear right pedal pad presser 6. Fuel Tank Outer Cover 7. Fuel tank cover middle part 8. Front left pedal pad pressure plate 9. Front left pedal rubber pad 10.
  • Page 176 Removal of the front panel b. Hold the mark on the front sun visor (green rectangle) with your hand, pull it up in the direction of the arrow, and a. Use 4# inner hexagon to remove the two M6×12 bolts take out the front sun visor.
  • Page 177 Disassembly of the of the Speedometer b. Hold the headlight with one hand and take it out for a certain distance, pull out the 3P plug (green and white wire) panel behind the headlight with the other hand, and take out the a.
  • Page 178 Removal of the windshield base b. Grasp the mark on the front left panel (green rectangle) with both hands, and carefully pull out in the direction of the a. Use a 4# inner hexagon to remove the M6×16 bolts that big arrow.
  • Page 179 Removal of the left and right decorative and buffer glue, and remove the rocker spring. Remove the right windshield and rocker spring in the same way. covers of the front storage box a. Use 4# inner hexagon to remove one M6×14 bolt connecting the left decorative cover of the front storage box panel and the surrounding middle part;...
  • Page 180 storage box panel in the order of the small arrows. The connection of the middle and left pedal decoration cover (yellow area: 7 buckles on the front storage box panel, 3 buckles on the left pedal decoration cover; blue area: surrounds the 4 points where the middle part is connected to the front storage box panel The 10 buckles of the bayonet) and the 4 bayonets are separated, and then remove the left...
  • Page 181 f. Remove the right pedal trim cover and the right pedal sleeve to remove the 4 M6×12 bolts that fix the fuel tank, in the same way. and then remove the air deflector. Removal of the surrounding middle part Use 4# inner hexagon to remove the two M6×12 bolts connecting surround middle part and the front storage box panel and then remove the middle surround.
  • Page 182 b. Use a 4# inner hexagon to remove the two M6×14 bolts Disassembly of the storage box which fix the front of the tail skirt. Refer to the steps of "Removing the Stepper Motor and Cleaning the Carbon Deposit". Disassembly of the rear hand rest a.
  • Page 183 Disassembly of tail light taillights. Note that there is a friction button in the middle, so it takes a lot of force to break it apart. a. Remove the two M6x14 bolts on the left part of the bottom plate of the tail cover by 4# inner hexagon. Remove 1 ST4.2×12 screw on the left part of the tail skirt bottom plate by 5# inner hexagon.
  • Page 184 the frame slowly until the rear shock absorber upper part is fitted to the mounting point on the frame, then assembly the bolts upper the rear shock. d. Follow this step for vehicles produced before May 25, 2022, and then skip to step f. Use the ratchet wrench + 8# sleeve to extend under the rectifier and remove the 2 outer hexagon M6x16 bolts of the rectifier.
  • Page 185 washer. After holding the rear reflector ② firmly, use a 10# sleeve to remove the nut and washer that comes with it. c. Remove the left part of the fuel tank cover by the same method. k. If you need to replace the rear fender, you need to remove 4 pieces of plywood nuts, 1 piece of side cover rubber and 1 piece of rear license plate buffer glue.
  • Page 186 cover bracket. Note that there is a buckle on the head of the cover that is inserted into the cover bracket. d. Remove the oil tank cover; Press the cushion bracket with one hand and take out the middle of the tank cover plate with the other hand.
  • Page 187 d. There are three ways to open the front left storage box :1. Before removing the battery, press the switch next to the front right storage box switch to open it .2, Use the battery to connect the positive and negative terminals of the vehicle to make the vehicle start up, press the switch next to the front right storage box switch to open it .3.
  • Page 188 g. Use 4# hexagon socket to remove 2 M6×14 shoulder bolts and then separate the PKE bracket and PKE. For details on the use and malfunction of PKE, please refer to the driver's manual delivered with the vehicle. h. Use 5# hexagon socket to remove 2 M6×16 bolts and then separate the right storage box lock bracket and the right storage box lock.

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Zontes zt310t-m 2022

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