Zontes Z2 User manual

Preface
Thank you for using ZONTES brand motorcycles. We use most advanced technology to design,
test and produce the type of motorcycle, to provide you with joy, fun and safe driving. When you are
fully familiar with all the essentials in this manual, you will feel riding a motorcycle is one of the most
exciting sports, at the same time, can feel the real pleasure of driving.
This manual summarizes the right repair and maintenance methods of motorcycle. As long as in
accordance with the provisions to do, your motorcycle will be durable. ZONTES distribution unit has
trained technical personnel, with the complete tools and equipment, to provide you with high quality
and service at any time.
The contents of this manual are updated quickly, and the official website shall prevail. The PDF
version of the manual can be downloaded from the official website.

Content
Content.........................................................................1
User instruction...........................................................2
Special Warning.........................................................2
Code position..............................................................3
Maintenance of muffler..............................................3
Installation of location parts.......................................4
combination lock....................................................... 5
Instrument....................................................................6
Left/Right handle control system.............................9
Fuel tank ...................................................................11
Shift lever...................................................................11
Rear brake pedal......................................................11
Rear shock absorber................................................11
Side stand..................................................................11
Notes for fuel, engine oil and cooling liquid..........12
Fuel oil.......................................................................12
Engine oil..................................................................12
Cooling liquid............................................................12
Running-in of new motorcycle................................13
Maximum recommend engine rotate speed........13
Gear position and rotate speed of engine............13
Running-in of tires....................................................13
Avoiding the rotation of fixed low speed...............13
Engine oil cycling before driving.............................13
First inspection..........................................................13
Inspection before driving.........................................14
Driving essentials.....................................................15
Starting of engine.....................................................15
Driving........................................................................16
Use the transmission system.................................16
Climbing driving........................................................16
Brake and park.........................................................16
Inspection and maintenance...................................17
Regular maintenance table......................................17
Toolkit.........................................................................18
Disassembly of fuel tank instruction......................18
Lubricating point.......................................................18
Storage battery..........................................................19
Air filter.......................................................................20
Spark plug..........................................................21
Engine oil............................................................22
Engine oil filter...................................................24
Clutch controller free stoke..............................25
Throttle cable clearance..................................26
Idling...................................................................26
Fuel evaporative pollutants control system...26
Cooling liquid.....................................................26
Fuel pipe............................................................27
Transmission chain...........................................27
Brake system.....................................................29
Tires....................................................................31
Disassembly of tires.........................................32
Illumination and signal......................................34
Accelerant..........................................................34
Trouble shooting...............................................35
Fuel system inspection ...................................35
Ignition system inspection................................35
Engine inoperation............................................35
Engine short of power......................................36
Carbon deposit cleaning..................................36
Fuel injection attention.....................................37
USB port............................................................39
Adding electrical parts......................................39
Storage method................................................40
Restart method.................................................40
Motorcycle cleaning..........................................41
Transportation....................................................41
The use instruction of storage battery............42
Specification table.............................................43
Circuit diagram...................................................45
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User instruction
There are all kinds of accessories on the market can be assembled on your motorcycle, and we
cannot directly control the market quality and applicability of attachment. The inapplicable
attachments will endanger the safety of the riding personnel. The selection of accessories and
installation, therefore, must be especially careful. Though we can't examine the applicability of
accessories for sell on the market, but your distribution unit can help you to choose high quality
accessories on the market, and can be installed correctly.
Attachment installed incorrectly or modified motorcycles will change handling of the motorcycle, this will
cause an accident. Never use inappropriate attachments, to ensure that attachments are installed correctly. All
accessories and parts should use pure part of the company.
You should be properly installed accessories and spare parts, if you have any questions, please relate this
company designated shop of distribute of engage by special arrangement or special repair shop.s company shop
of distribute of engage by special arrangement or special repair shop.
Wind deflector, chair back, saddle bags, luggage, etc., are all laid attachments, easy to cause the
instability of driving. Especially in the side wind or with large vehicles encountered. If the attachment
installed wrong or poorly designed attachments, would endanger the safety.
Additional electrical accessories can make the electrical system overload, serious overload may
damage the wiring, make the engine stalling when driving, and even destroy vehicles.
When transporting goods, they should be fixed in the low position as far as possible close to the
motorcycle. Fixed goods incorrectly can lift the center of gravity which is very dangerous. It can make
the motorcycle hard to control. The size of the goods will affect the air drag and motorcycle
maneuverability. Please balance the left sides of the motorcycle, and fixed the goods.
Modification
Motorcycle modification or removal device cannot guarantee the original motorcycle driving safety,
and it is illegal. The user will lose the rights of quality guarantee if they modify the motorcycles..
Safe driving instruction
Driving a motorcycle is a very interesting and exciting sport activity. It also requires special
precautions to ensure the safety of drivers and motorists. Preventive measures are as follows:
Examination before driving
Read carefully "before they check" section of the instruction, and check item by item according to
the instructions, we must never forget that it can guarantee the safety of drivers and train personnel.
Familiar with your motorcycle
Your driving skill and mechanical knowledge, is the foundation of safe driving. First practice at
where there are fewer cars, until you can fully familiar with the mechanical performance and
operation method of motorcycle. Remember that! Practice makes perfect.
Realize your own driving skills
At any time drive within the scope of your own skilled. Know your skills limit and not to be reluctant
so as to avoid accidents.
Rainy day traffic alert
Rainy day driving should be paid attention to, keep in mind the braking distance is twice as many
as sunny days. Drive away from the road marking paint, manhole covers, and oil on the road to avoid
slippage. When you drive on the railway crossing, bars and Bridges, you have to be careful. In the
case of a negative judgment road, you should slow down.
Speed limit
Any time don't let the speed to be too high, and don't let the noise of engine speed is too high,
from the outside.
Strategy during driving
Most of the motorcycle accident are turning cars bumped into people who driving a motorcycle in
front. Wise driving strategy is to make the other driver seeing you; even in the broad road you also
should pay attention to during the day. Wear smart clothing with safety reflective materials. Don't get
in the other driver's blind spot. Special warning
2
If the weight distribution of accessaries or goods attached on vehicle changes, the stability and operability of
the vehicle may be adversely affected. In order to eliminate the possibility of an accident caused by it, the
weight of the rear rack should be limited to be less than 10kg, and the weight of the side box should be limited
to be less than 10kg. Please do not overload and modify the rear rack without permission.
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Code positing
Please write down the number in the space below for your reference
Vehicle identification number:
Engine number:
Vehicle identification code and engine number is for the registration of motorcycles, when ordering
parts or entrust the special service, this number can make distribution unit provide a better service for
you.
This motorcycle muffler with catalyst can effectively reduce the operation process of motorcycle
emissions of harmful substances into the atmosphere. To make the device work effectively, please
refer to "maintain" the preventive maintenance in the section table.
In order to improve the service life of the muffler, and avoid faults caused by not-normal-use and
maintenance of the mufflers rust, catalytic conversion efficiency decrease, please be sure to comply
with the following items:
·Long time in high speed boom throttle is prohibited
·Long great load and low gear driving is prohibited
·Add muffler rust-proof oil or oil is prohibited
·Hot state muffler is washed with cold water directly is prohibited
·Slide when shut down is prohibited
·Use inferior oil is prohibited
·Use unleaded gasoline
·Keep clear the dirt of muffler to the rear and the surface
·Keep the engines running on good condition, regular maintenance and inspection. Avoid failure
Leads to engine combustion exhaust gas in the exhaust pipe to cause secondary combustion
catalyst sintering failure.
· Installing a muffler, be sure to properly installed muffler gasket.
·If you need to dismantle oxygen sensor, be sure to use the right tools, and be sure to stay muffler
outfit after cooling to room temperature.
Maintenance of muffler
Driving must pack up side racks, so as not to turn to when overturned vehicles, riding personnel casualties.
Rear brake system must be checked to see if it is working correctly before driving. If there is problem, please
repair immediately
Driving is not allow to tie the helmet on the helmet pothook, to avoid helmets be involved in the wheel to make
the vehicle turned over to cause casualties.
Non-professional personnel do not pull the fuel pipe to discharge fuel, to avoid meeting flame and damaged
vehicles; don't let the motorcycle muffler to touch other matter to avoid fire: motorcycle usage and storage
environment cannot have fire hazard.
Vehicle maintenance need to replacement parts, have to use the pure part of the company, the use of pure
components, electrical components in particular, it might damage the motorcycle, and even destroyed vehicles.
Please don't add attachments at your will, especially the electrical components, if improper wiring or electrical
load is too large, it could destroy vehicles.
3
① Identity code will be carved on the turning vertical pipe,② 3C nameplate card will be fixed
in the bottom of the frame,③ Engine code will be printed on the left side of the crankcase.
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4
Installtion of component parts
①Clutch handle
②Switch on left handle
⑤Switch on right handle
⑥Accelerator control handle
③Meter
④Front brake liquid cylinder
Side stand
Rear disk brake
Muffler
Rear brake pedal
Ignition coil
11 Front disk brake
Gearshift pole
12
13
9
810
⑩
⑧ ⑨
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5
Combination lock
The motorcycle is equipped with two keys, one of which should be kept for future use.
There is a small number plate with the key. Please record the number on the number plate
for future reference.
The combination lock guard has two positions
Closed position: Seal the keyhole, the key cannot be inserted into the lock cylinder, and
the combination lock cannot be opened.
Open position: The keyhole is open, and the key can be inserted at any time to operate the
combination lock.
Combination lock has five positions
“ON" position
In the "OFF" position, turn clockwise to the "ON" position, the ignition circuit is turned on,
and the ignition can be started at any time. In this position, the key cannot be removed.
"OFF" position
The ignition circuit is cut off, the engine cannot be started, and the key can be removed.
"LOCK" position
In order to lock the steering mechanism, first turn the steering wheel to the extreme left
position, press the key to the "OFF" position to the end, and turn it counterclockwise to the
"LOCK" position. All circuits are disconnected.
"SEAT" position
In the "OFF" position, turn counterclockwise to the "SEAT" position, open the cushion lock,
and the key rebounds to the "OFF" position
key code
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1 left turn lights, 2 emergency light; 3 ABS anti-lock braking system light; 4 idling gear indication light,
5 distance light lamp; 6 right turn signals light; 7 engine speed record; 8 speedometer; 9
kilometer/miles identification; 10 battery fuel gauge of low voltage prompt lable; 11 fuel oil level gage;
12 clock; 13 long tern odometer; 14 short trip odometer; 15 MODE “key”; 16 “SET" key; 17 gear
display; 18 water temperature.
When the key is pressed to the "NO" position, the motorcycle is powered on, the meter performs a
self-test, and the LCD screen displays all the content. At the same time, the engine speed scans to
the maximum scale and falls back to enter the normal operation mode.
Do not use high pressure water washing instrument directly.
Do not use dishcloth with organic solvent such as gasoline, kerosene, alcohol, brake fluid to wipe the
instrument, Otherwise, the instrument may cause local cracks or discoloration due to exposure to organic
solvents.
Instrument
1 Left turn signal light
When the turn signal switch to the left, the left turn signal light will be flashing.
2 Fuel injection error signal light
When the vehicle turns on the electric door lock switch and the ameout switch, it is normal for the
electronic injection fault signal light to be on when it is not started ,if the electronic injection signal
light is not on, please do not start the vehicle. When the engine starts successfully, if the yellow
electrojet fault signal lights up and the electrojet fault is reported, it indicates that the system is
abnormal.
When the fuel injection system is showing error, it will break the fuel injection system when you still drive the
mortorcycle. Please contact the after-sales dealership shop to check the fuel injection system.
3 ABS anti-lock braking system singal light
ABS indicator light: Used to display the working status of the ABS control system. When the key
is pressed to the "NO" position, when the motorcycle is powered on and parking is stopped, the ABS
indicator light will automatically light up in normal conditions. When the speed exceeds 5km / h, the
ABS indicator goes off automatically. Otherwise, it means that the ABS control system is faulty.
Please contact our service center for inspection.
4 Idling gear indication light
The motorcycle is using the international gear, and it will show the green idling gear light “N”.
5 Distance light lamp
When using the high beam headlights, indicator light will be lighter.
6 Right turn signal light
When press the right turn signal right to the right, it will be flashing.
7 Engine speed recorder
It shows the speed of the engine, indicating the number of revolutions per minute of engine
crankshaft. 10000-12000rpm is red alert zone for engine speed (red printing section).
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Instrument
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9. Kilometer/miles swift method
In “ODD” MODE, long press MODE key to switch between speed in MPH, km/h, and in related, odometer
unit in the mile, km switching.
10. Battery low voltage prompt
When the vehicle is not started: the voltage ≤12.1V “ ” symbol flashes. At this time, the battery
is too low, please charge it in time; when the voltage is ≥12.5V, the “ ” symbol stops flashing and
disappears.
After the vehicle starts: the voltage ≤12.9V “ ” symbol flashes. At this time, the battery is not
fullycharged. Please check if the power is too large or check the charging system. When the voltage
is≥13.1V, the “ ” symbol stops flashing and disappears.
When the motorcycle is supported by the side stand, the fuel level gauge cannot be accurately displayed. Lift
the car to the normal driving state, Open the key to the "ON" position, do not start the engine, the fuel level
indicator light can be accurately displayed for 2 minutes.
about 3 liters about 5 liters full
glint
Fuel oil
level gage
fuel tank
8 Speedometer & Voltmeter
Speedometer shows the speed is how many kilometers per hour (/miles).
Voltmeter: Press the MODE button to turn on the speedometer, it enters the diagnosis mode, and
displays the 3-digit voltage at the speedometer. For example: “129" is 12.9V Restart, speedometer
returns to normal mode.
12 Clock
The clock display in the 12 hours system.
According to the following method to adjust the clock:
ODO MODE: long press SET key, enter the time setting MODE, short press MODE key,
increasing hours upward; SET key long press is a SET, very digits flashing, increasing MODE key up
short by the hour; Long press SET key points a SET, a digit flashing, increasing MODE key up short
by the hour; SET key long press finish time setting.
If the battery is removed or battery lost electricity, it will be shown from "12:00" clock.
11 Fuel oil level gage
The fuel level gauge shows the amount of fuel remaining in the fuel tank. The fuel level gauge
shows 8 segments, indicating that the fuel tank is full. When the amount of oil drops to about 5 liters,
the fuel level gauge shows a section, and when the amount of oil drops to about 3 liters, the last
segment flashes. Please add fuel as soon as possible.
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13 ODO Long distance odometer & 14 TRIP short distance odometer
The LCD screen display area has two functions: ODO meter long and short TRIP odometer.
ODO long distance odometer records the motorcycle the total road mileage from start to now, it
cannot be reset; maximum record 99999.9; TRIP records a single or accumulated mileage traveled
for many times, it can be reset, maximum record of 999.9.
When driving a motorcycle, instrument operation is very dangerous. Leave handlebar will reduce the
performance control of the motorcycle. Always put the hand on the handlebars while driving.
15 Mode button
Mode button is used to adjust the instrument, see related section content for instrument.
16 Set button
Adjust button is used to adjust the instrument, see related section content for instrument.
(See the speed table content unit switching method)
17 Gear display
The motorcycle is using international gear, and there are six gear display which is 1,2,3,4,5,6
shown on the instrument.
18 Water temperature
When the water temperature reaches to 110 degree, it will start to flash. It might be that the
cooling liquid is too hot or cold or the surface level of liquid is too low.
It there is warning sign shown in water temperature table, please stop the motorcycle ! Shut down the engine
and check; also cool down the liquid surface. If it is necessary, please refill the cooling liquid. In order to cool
down the liquid, we should avoid idling speed yet high rotation speed for a long time.
Instrument operation instruction:
Long press is defined as press the button for over 2S, short press is defined as press the button
for less than 2S.
1.Shift to big and small mileage: under TRIP mode, short press MODE bottom, shift to ODO
mode. Short press MODE button again, switch back to TRIP mode.
2.Adjust brightness; The meter back light has five levels of brightness adjustable. When it TRIP
mode, short press the SET button to lower the brightness level and same way in turn.
3.Time setting: under ODO mode, long press SET bottom, it can head into time setting mode.
4.Change speed counter unit: under ODO mode, long press MODE bottom, change the speed
unit, at the same time the mileage unit will also be changed accordingly.
5.Clear engine oil indication light: under ODO mode, long press MODE bottom.
6.Clear single trip mileage record: under TRIP mode, long press SET bottom, single mileage
record will be cleared.
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Instrument