ZONGSHEN ZS125-86 User manual

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ZS125-86 Motorcycle Service Manual
First edition (April, 2017)
The copyright of this Motorcycle Service Manual is
owned by Zongshen Industrial Group. The content
and images in the Motorcycle Service Manual are
for reference only. Specifications are subject to the
physical product.

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The motorcycle service manual details the motorcycle’s basic structure, working principles,
disassembly and maintenance, fault diagnosis and exclusion, etc. At the same time, it has also introduced
the motorcycle’s technical specifications, performance parameters and maintenance and adjustment
data. The manual is informative, illustrated and practical. It is hoped that this manual can provide support
and guidance on the maintenance technology for the customers and aftersales staff.
The technical specifications, performance parameters and maintenance and adjustment data labeled in
the manual are based on the latest status. Our company’s subsequent improvements for the motorcycle
model will be done without notice. If there is any difference between the manual and the improved
product, please understand. We sincerely wish that you can tell us your ideas and suggestions about the
design, manufacture or quality of the motorcycle, so that we can make improvements in time. Thanks for
your support.
Althea information, figures, data and performance indexes shown in the manual were what they
were till the time the manual is printed. We have the authority to revise this manual without notice.
Please understand. Any part of this manual is copyrighted by Zongshen Industrial Group. No entities or
individuals shall be allowed to reproduce the manual without the permission of our company, otherwise,
investigations will be conducted for criminal liability according to law.
Taking the motorcycle model ZS125-86 as an example, the manual has detailed the disassembly,
assembly, maintenance, fault phenomena and maintenance methods of the motorcycle series. Due to the
limited level of the editor, there may be some faults or careless omissions in the manual. We are looking
forward to your criticism and corrections.
Chongqing Zongshen Automobile Industry Co., Ltd.
Address: Chaoyouchang, Ba’nan district, Chongqing
Customer Service Hotline: [phone]
For details, please click the website of our company: www.zongshenmotor.com
Foreword
Symbols given in this Motorcycle Service Manual have the following meanings:
Warning
Caution
Suggestion
It indicates a potential danger that may cause death or injury if any misoperation.
It indicates a potential danger that may cause damages to the motorcycle if any misoperation.
The most efficient service information is available for more simple maintenance and more
understandable instructions.

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Contents
Chapter 1 Overview ................................................................................................................... 1
Section 1 Overview of Complete Motorcycle .................................................................................... 1
Section 2 General Construction...................................................................................................... 2
Chapter 2 Knowledge about Maintenance..................................................................................... 4
Section 1 Cautions ....................................................................................................................... 4
Section 2 Common Sense of Maintenance ...................................................................................... 5
Chapter 3 Complete Motorcycle ................................................................................................ 11
Section 1 Fuel Supply System ..................................................................................................... 11
Section 2 Cooling System ........................................................................................................... 15
Section 3 EFI System.................................................................................................................. 17
Section 4 Air Intake and Exhaust System ...................................................................................... 19
Section 5 Evaporative System (EVAP) ........................................................................................... 23
Section 6 Rear Driveline.............................................................................................................. 25
Section 7 Frame and Accessory Mechanism .................................................................................. 29
Section 8 Steering Gear .............................................................................................................. 32
Section 9 Steel Wire Rope for Control .......................................................................................... 33
Section 10 Damper .................................................................................................................... 34
Section 11 Rear Fork.................................................................................................................. 38
Section 12 Wheels ......................................................................................................... 39
Section 13 Brake ....................................................................................................................... 44
Section 14 Instrument ................................................................................................................ 49
Chapter 4: Electrical Parts ....................................................................................................... 51
Section I Basic Knowledge .......................................................................................................... 51
Section 2 Power Supply .............................................................................................................. 52
Section 3 Control Part................................................................................................................. 56
Section 4 Power Consumption .................................................................................................... 60
Chapter 4 Motorcycle Fault Diagnostic Procedure ........................................................................ 63
Appendix: Electrical Schematic Diagram..................................................................................... 77