Zontes ZT125-M 2022 Manuals

Manuals and User Guides for Zontes ZT125-M 2022. We have 1 Zontes ZT125-M 2022 manual available for free PDF download: Maintenance Manual

Zontes ZT125-M 2022 Maintenance Manual (218 pages)

Brand: Zontes | Category: Motorcycle | Size: 41 MB

Table of Contents
4
Content
4
Vehicle Information
13
Know before Service
13
Body Label
14
M310 Technical Specification
15
Front Wheel/Steering System
15
Rear Wheel/Suspension System
15
Brake System
15
Battery/Charging System
16
M125 Technical Specification
16
Front Wheel/Steering System
16
Rear Wheel/Suspension System
17
Brake System
17
Battery/Charging System
17
M350 Technical Specification
18
Front Wheel/Steering System
18
Rear Wheel/Suspension System
18
Brake System
18
Battery/Charging System
19
Lamp/Speedometer/Switch Description
19
Tightening Torque
20
Bolt Tightening Torque of General Tightening Part
20
Cable/ Pipe/Electrical Device Distribution Map
21
Distribution Map of Lamps and Lanterns
21
Throttle Cable
21
Brake Upper Pump and Brake Hose
22
Calipers, Brake Hoses and Wheel Speed Sensors
22
Distribution Map of Brake System Accessories
23
M310
23
M125
24
M350
25
Oil Supply System
26
M310 Fuel Evaporation
26
M125 Fuel Evaporation
27
M350 Fuel Evaporation
27
M310 Fuel Supply
28
M125 Fuel Supply
28
M350 Fuel Supply
29
Distribution Map of Cooling System Accessories
29
M310
29
M125
31
M350
31
Electrical Device Layout
31
M310
34
Intake and Exhaust System
37
M310
37
M125
38
M350
39
Tool
40
Swell Nail Description
41
Maintenance
42
Know before Service
42
M310 Maintenance Schedule
43
M125 Maintenance Schedule
44
M350 Maintenance Schedule
45
M310 Air Filter (Filter Element), Air Inlet Filter Element
46
Support the Vehicle Firmly
46
Remove the Left Engine Cover
46
Remove the Air Inlet Cover
47
Replace the Air Inlet Filter
47
Remove the Air Filter Housing
47
Replace Air Filter Element
47
Inspection Air Filter Waste Oil Pipe
48
Reinstall
48
M125 Air Filter (Filter Element), Air Inlet Filter Element
49
Support the Vehicle Firmly
49
Remove the Left Engine Cover
49
Replace the Air Inlet Filter
49
Remove the Air Filter Housing
50
Replace Air Filter Element
50
Inspection Air Filter Waste Oil Pipe
50
Reinstall
50
M350 Air Filter (Filter Element), Air Inlet Filter Element
51
Support the Vehicle Firmly
51
Remove the Left Engine Cover
51
Replace the Air Inlet Filter Element
52
Remove the Air Filter Shell
52
Replace the Filter Element of the Air Filter
52
Check the Waste Oil Pipe of Air Filter
52
Reassembly
53
Bolts and Nuts of Muffler
53
Check for Air Leaks at the Engine Exhaust
53
Check for Nut and Bolts at the Muffler
54
M310/350 Spark Plug
54
Disassemble the Spark Plug
54
Check the Spark Plug
56
Refer to the Steps to Remove the Spark Plug to Restore All Parts
56
M125 Spark Plug
56
Disassemble the Spark Plug
56
Check the Spark Plug
58
Refer to the Steps to Remove the Spark Plug to Restore All Parts
58
Engine Oil
58
M310
58
Drain the Oil
58
Replace Fine Filter
59
Add Oil
59
Change Gear Box Oil
59
Confirm the Oil Level
60
M125
60
Drain the Oil
60
Replace Fine Filter
60
Add Oil
61
Change Gear Box Oil
61
Confirm the Oil Level
61
M350
62
Drain the Oil
62
Replace the New Combination Gasket (4) and Install the Oil Drain Bolt (3) and Combination Gasket (4) Back on the Engine Box with the 14# Sleeve. Torque: 25 N.M(2.6 Kgf.M,18 Lbf.ft)
62
Wipe the Oil Gauge Clean, and Install the Oil Gauge (1) and O Ring (2) Back to the Right Crankcase Cover of the Engine by Clockwise Rotation by Hand
63
Replace the Gearbox Oil
63
Then Rotate It Clockwise Back to the Gear Box Refueling Mouth by Hand
63
M310/350 Throttle Valve Body
64
Do Not Dismantle the Throttle Body to Clean up Carbon Deposits
64
Remove the Stepper Motor and Clean up Carbon Deposits
64
Remove the Throttle Valve Body Assembly to Clean up Carbon Deposits
66
M310 Disassemble the Three-In-One Sensor
67
Remove Sensor from M350 Throttle Body
67
Throttle Valve Body Troubleshooting Process
68
M125 Throttle Valve Body
69
Do Not Dismantle the Throttle Body to Clean up Carbon Deposits
69
Remove the Stepper Motor and Clean up Carbon Deposits
69
Remove the Throttle Valve Body Assembly to Clean up Carbon Deposits
70
Disassemble the Sensor
70
Throttle Valve Body Troubleshooting Process
71
Throttle Cable
71
Inspection
71
Adjust the Throttle Cable Clearance
71
Lube Door Cable
72
Idle Speed
72
Check Idle Speed
73
Fuel Evaporative Pollutant Control System
73
M310 Fuel Evaporation
73
M125 Fuel Evaporation
74
M350 Fuel Evaporation
75
Radiator
76
Check the Coolant
76
M125/310
76
M350
76
Add Coolant (Antifreeze) to the Coolant Expansion Tank
76
M350
77
Add Coolant to the Radiator
77
M125/310
77
M350
78
Put Coolant
78
M310
78
M125
78
Check Whether the Fins of the Radiator Water Tank Are Deformed or the Air Duct Is Blocked
78
M350
79
Check All Water Pipes for Leaks; Aging
80
M310
80
M125
80
M350
82
Fuel Pipe
82
Check the Fuel Pipe for Leaks with the Help of an Endoscope with LED Light
82
Replace High Pressure Oil Pipe
82
Fuel Pump
83
Use Oil Pressure Gauge to Measure Fuel Pressure
83
Simple Test of Fuel Pump
83
Treatment of Abnormal Fuel Pressure
84
M310 V Belt
85
System Components
85
Maintenance
85
Remove the Belt
85
Disassemble the Continuously Variable Transmission Components
86
Inspection
87
Assembly
88
Common Fault Phenomena/Troubleshooting
90
The Engine Can be Started, but the Rear Wheel Does Not Rotate
90
Engine Stall or Lack of Power
90
Insufficient High-Speed Power
90
When the Engine Is at Normal Idling Speed, the Rear Wheel Rotates Rapidly
90
Braking System
91
M310 Braking System Component Diagram
91
M125 Braking System Component Diagram
91
M350 Braking System Component Diagram
92
Check the Brake Components
92
Check the Front and Rear Brake Switches
94
Check the Brake Switch
94
Replace the Brake Switch
94
Lubricate the Movable Parts of the Brake Handle
94
Lubricate the Front Brake Handle
94
Lubricating the Rear Brake Handle
94
Replacing the Brake Handle
94
Adjust the Brake Handle
94
Replace the Brake Pads
94
Replace the Front Brake Pads
95
M125/310
95
M350
95
Replace the Rear Brake Pads
96
Abnormal Sound of Brake Pads
97
Replace the Brake Disc
97
Replacing the Front Brake Disc
97
Replacing the Rear Brake Disc
97
Brake Hose
98
Brake Fluid
99
Add Brake Fluid to the Main Pumps of the Front and Rear Disc Brakes
99
Replace the Brake Fluid
99
Replace the Front Brake Brake Fluid
99
Replace the Rear Brake Fluid
100
Brake System Exhaust
100
Tire
100
Check the Tires
101
Replace Tires
101
Steering Mechanism
101
Check the Steering Mechanism
101
Adjust the Steering Mechanism
102
M125/310
102
M350
102
Maintain Steering Bearings
102
Malfunction
102
Front Fork
103
Check the Appearance
103
Check the Shock Absorption Performance
103
Remove the Front Shock Absorption
104
Correct the Front Fork Tube
104
Troubleshooting
104
Rear Shock Absorption
104
Check
104
Adjust the Preload
104
Adjust the Right Rear Shock Absorption
105
M125/310
105
M350
105
Adjust the Left Rear Shock Absorption
105
M310
105
M125
105
Replace the Shock Absorption
105
Bolts and Nuts for Body and Engine Installation
106
Check the Fasteners for the Critical Parts
106
Check Engine Fasteners
106
Valve Clearance Adjustment (M310)
108
Maintenance Information
108
General Information
108
Assemble Torque Value
108
Tools, Measuring Tools, Accessories
108
Operation Steps
108
Side Bracket
112
Check
112
Lubrication
112
Main Bracket
113
Check
113
Lubrication
113
Install the Main Bracket
113
Replace the Return Spring Post of the Main Support
113
Sound, Light, and Electrical Device Inspection
114
Check
114
M125/310 Charging
115
M350 Charging
115
Headlight Height Adjustment
115
Fuse Box
116
Troubleshooting
117
Right Hand Switch
117
Right Hand Handle Vice Switch
117
Left Hand Handle Auxiliary Switch
118
Horn
119
Left Hand Switch
119
Light
121
Windshield Failure
121
EFI System
122
Know before Service
122
Error Code
123
M310 Read the Fault Code through the Meter
123
Read the Fault Code through the Diagnostic Tool
123
M125/310
123
M350
123
Error Code
124
Clear Fault Code
124
M310 Manually Clear
124
Use the Diagnostic Tool to Clear
125
EFI Parts Layout
125
Fault Diagnosis and Elimination of EFI Parts
126
Dump Switch
126
OBD Port
126
Fuel Pump
127
Carbon Canister Solenoid Valve
127
EFI Relay
127
Fuel Injector
128
Ignition Coils
128
M125/310
129
M350
129
Throttle Valve Body
130
Common Failure Phenomena
130
Disassembly
130
Troubleshooting Process
130
Sensor
130
M310 Three-In-One Sensor
130
M125 Sensor
130
M1350 Sensor
130
Water and Oil Shared Sensor
130
Oxygen Sensor
131
Check
131
Replace
131
M310
131
M125
131
M350
132
Ecu
132
M310/350
132
M125
133
Crankshaft Position Sensor
133
The Engine Cannot Start and There Is no Sign of Fault Diagnosis Process
134
The Engine Cannot be Started and There Is a Car Symptom Fault Diagnosis Process
134
Poor Acceleration
135
High Idling Speed of Hot Car
135
Unsteady Idle Speed of Cooling Car
135
Unsteady Idling, Easy to Cutoff
136
Analysis Flow Chart of EFI Failure Indicator Light Always on
137
Electrical Schematic Diagram of EFI System
138
Ignition System
139
Know before Service
139
Troubleshooting
140
Ignition System Layout
141
Electrical Schematic Diagram of Ignition System
141
Ignition System Inspection
142
Ignition Timing
142
Check
142
Installation
142
Ignition Coils
143
Starting System
144
Know before Service
144
Troubleshooting
144
Starting Relay
144
Starter Motor
145
The Starter Motor Runs Slowly
145
The Starter Motor Is Working Normally, but the Engine Cannot be Started
145
Ignition System Layout
145
Starting System Electrical Schematic Diagram
146
Starter Motor
146
Remove the Starter Motor
146
Disassemble the Starter Motor
147
Examination
148
Starter Motor Front Cover
148
Motor Back Cover
148
Denki
148
Check the Starting Relay
148
Operation Check
148
Check the Relay Coil
149
Input Line
149
Ground Wire
149
Check the Starting Relay
149
Disassembly and Assembly of the Starting Relay
149
Fuel Supply System
150
Know before Service
150
Fuel Tank Removal
150
Disassemble the Fuel Tank Assembly
150
Disassemble the Fuel Pump
151
Remove the External Parts of the Fuel Tank Assembly
152
Examination
152
Fuel Pressure Test
152
Fuel Pump Inspection
152
Oil Level Sensor
152
Cooling System
153
Know before Service
153
Troubleshooting
153
The Engine Temperature Is too High
153
The Engine Temperature Is too Low
153
Coolant Leakage
153
Coolant System Distribution Map
154
M310
154
M125
154
M350
155
Coolant Flow Diagram
156
M310
156
M125
157
M350
157
Cooling System Disassembly
158
M310 Remove the Radiator Assembly
158
M310 Coolant System Hoop/Clamp Distribution Map
159
M310 Thermostat Assembly and Small Loop
159
M125 Remove the Radiator Assembly
160
M350 Remove the Radiator Assembly
160
M350 Coolant System Hoop/Clamp Distribution Map
161
M350 Thermostat Assembly and Small Loop
161
Cooling System Accessories
162
Main Water Tank
162
M310
162
M350
162
Attention to the Water Tank Filling Port
162
Overall Leak Check
162
Check of Pressure Relief Valve
163
M350
163
Auxiliary Water Tank
163
Aluminum Inlet Pipe and Aluminum Outlet Pipe(M310)
163
Small Water Tank(M310)
163
Water and Oil Shared Sensor
163
Thermostat
164
Inspection
164
Failure Phenomenon
164
Disassembly
164
Thermostat Core Inspection
164
Water Pipe
164
Check the Water Pump Cover Assembly(M310)
165
Braking System
166
Know before Service
166
Trouble Shooting
167
Soft Feeling from Brake Lever
167
Hard Feeling from Brake Lever
167
Disassemble the Disc Brake Main Pump and Calipers
167
Disassemble the Front Disc Brake Main Pump
167
Disassemble the Rear Disc Brake Main Pump
168
Disassemble the Front Disc Brake Caliper
168
M125/310
168
M350
168
Disassemble the Rear Disc Brake Caliper
169
Brake Hose and Wheel Speed Sensor
169
Check the Gap between the Wheel Speed Sensor and the Induction Ring Gear
169
Remove the Brake Hose and Wheel Speed Sensor
170
Release Brake Fluid
170
FMC-HU and RMC-HU
170
FC-HU and Wheel Speed Sensor (Front Wheel)
171
RC-HU and Wheel Speed Sensor (Rear Wheel)
171
ABS System Layout
172
ABS Hydraulic Control Unit
172
Disassemble
172
ABS Troubleshooting
174
M310 Troubleshooting Process with Portable ABS Diagnostic Scanner
175
Battery/Charging System
176
Know before Service
176
Troubleshooting
177
Charging System Layout Diagram
178
Electrical Schematic Diagram
178
Battery Disassembly
178
Disassembly
178
Check
179
Charging
179
Charging System Check
179
Leakage Test
179
Check the Charging Voltage
179
Inspection of Magneto Stator Charging Coil
179
Remove the Rectifier
180
Front Fork Assembly
181
Know before Service
181
Exploded View of Front Fork Components
182
M125/310 Directional Exploded View
182
M350 Directional Exploded View
183
Front Fork Exploded View
184
M125/310
184
M350
185
Exploded View of Lower Link Board
186
M125/310
186
M350
187
Change the Direction of the Handle
188
Remove the Direction of the Handle
188
Remove the Components
188
Installation of the Direction Component
189
Installation of the Direction Handle Cover
189
Replace the Front Wheel
190
Remove the Front Wheel Assembly
190
Install the Front Wheel Assembly
190
Front Wheel Assembly Exploded View
191
M310
191
M125
191
M350
192
Inspection and Maintenance of Front Wheel Assembly
192
Disc Brake
192
The Service Life of the Disc Brake Disc
192
Disc Brake Replacement Method
192
Front Wheel Oil Seals and Bearings
192
Service Life of Front Wheel Oil Seals and Bearings
192
Replacement Method of Front Wheel Oil Seal and Bearing
193
Front Wheel Rims and Tires
193
The Service Life of the Front Wheel Rim and Tire
193
How to Replace the Front Wheel Rim and Tire
193
Dynamic Balance
193
M125/310 Replacement of the Front Shock Absorber
193
Disassemble the Front Wheel and Front Fender Assembly
193
Remove the Left and Right Front Shock Absorbers
194
Reinstall the Shock Absorber, Front Fender, Front Wheel and Other Components
194
M350 Replacement of the Front Shock Absorber
194
Disassemble the Front Wheel and Front Fender Assembly
194
Remove the Left and Right Front Shock Absorbers
195
Reinstall the Shock Absorber, Front Fender, Front Wheel and Other Components
195
M125/310 Replace the Lower Link Board
196
Disassemble Parts Ahead of Time
196
Remove the Faucet Lock
196
Removing the Direction Pad
196
Remove the Lower Link Board Assembly
197
Install the Lower Link Board Assembly
197
Install Other Disassembly Components
197
M350 Replace the Lower Link Board
197
Disassemble the Engine of the Vehicle
199
Disassemble the Storage Box
199
Remove the Cover
199
Put the Coolant and Pull out the Connection Plug
200
Disassemble the Engine
202
Install the Engine
202
Disassembly and Assembly of Vehicle Covering Parts
204
Disassembly and Assembly of Vehicle Panel
205
Windshield Removal
205
Removal of the Front Sun Visor
205
Removal of the Front Cover
206
Removal of the Front Panel
206
Disassembly of Headlights
206
Removal of Front Turn Signal
207
Disassembly of the of the Speedometer Panel
207
Removal of the Front Left and Right Panels
207
Removal of the Front Part of Vent
208
Removal of the Windshield Base
208
Removal of the Left and Right Decorative Covers of the Front Storage Box
209
Disassembly of the Left &Right Side Cover
210
Disassembly of the Foot Pedals and Trim Cover
210
Removal of the Surrounding Middle Part
211
Disassembly of the Surrounding Bottom
211
Removal of the Cooling Fan Air Guide Plate
211
Disassembly of the Cushion
211
Disassembly of the Storage Box
212
Disassembly of the Rear Hand Rest
212
Disassembly of the Left and Right Tail Cover
212
Disassembly of Tail Light
213
Disassembly of Rear Fender
213
Disassembly of the Left, Right Fuel Tank Cover
215
Disassembly the Middle Cover of the Fuel Tank
215
Disassembly the Left and Right Storage Boxes
216
Disassembly the Front Storage Box Panel
217

Zontes Categories

Motorcycle Scooter Engine Bicycle Racks & Stands

More Zontes Manuals

Zontes ZT125-M 2022 Manuals

Zontes ZT125-M 2022 Maintenance Manual (218 pages)

Table of Contents

Related Products

Zontes Categories