Zontes ZT125-C User manual

2023/10/25
ZT125/155/200-C（EURO V
）

Page 1 ，Total 64 pages
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0
Table of Contents…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
1
1FRAME&ELECTRONIC COMPONENT
1.1
Electrical device component-1………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
6
horn,ignition coil
1.2
Electrical device component-2………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
7
Front electrical device box, frame front decoration cover
1.3
Frame plastic parts…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
8
Line clamp, side cover round glue, fuel tank liner limit glue
1.4
Directional column component……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
9
Lower plate component
1.5
Frame, side bracket………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
10
Frame, side bracket,Flameout switch
2FRAME & ENGINE COMBINATION
2.1
Frame & engine combination 1……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
11
2.2
Frame & engine combination 2……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
12
3INTAKE SYSTEM COMPONENT
3.1
Air filter component………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
13
Disassemble air filter,ECU,Carbon canister
3.2
Throttle valve body component……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
14
3.3
Replace air filter element………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
15
4REAR WHELL COMPONENT
4.1
Rear mud board 1…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
16
4.2
Rear mud board 2…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
17
4.3
Rear shock absorption……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
18
4.4
Rear wheel component 1………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
19
Disassemble the rear rim component, sprocket seat, sprocket
4.5
Rear wheel component 2………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
20
Disassembled rear rim component
4.6
Rear fork component……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
21
Contents
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Disassembled rear fork component
4.7
Replace the rear brake pads…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
22
4.8
Rear brake main pump adds brake fluid………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
23
5PEDAL COMPONENT
5.1 Adjust the hight of foot pedal 24
Shift lever, brake pedal height adjustment
5.2
Front right foot pedal assembly position adjustment……………………………………………………………………………………………………………………………………………………………………………………………………………………………
25
5.3
Front left foot pedal assembly position adjustment………………………………………………………………………………………………………………………………………………………………………………………………………………………………
26
5.4
Right footrest component………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
27
5.5
Left footrest component………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
28
5.6
Rear footrest component………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
29
6COOLING SYSTEM COMPONENT
6.1
Change the oil and the oil filter………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
30
6.2
Add coolant……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
31
6.3
Change coolant………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
32
6.4
Water tank component(125/155CC)………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
33
6.5
Water tank component(200CC)……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
34
7FRONT FORK COMPONENT
7.1
Throttle/clutch cable clearance adjustment, light height adjustment……………………………………………………………………………………………………………………………………………………………………………………………………
35
7.2
Replacement clutch cable………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
36
7.3
Replace the throttle line………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
37
7.4
Steering adjustment………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
38
7.5
Right hand component…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
39
Disassemble right hand component
7.6
Add brake fluid, rocker adjustment………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
40
7.7
Replace the front brake pads…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
41
7.8
Front wheel component…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
42
Disassemble the front wheel, front disc brake disc, front axle component
7.9
Front mud board & wheel speed sensor component 1…………………………………………………………………………………………………………………………………………………………………………………………………………………………
43
Disassemble front wheel speed sensor component, front mud plate component
7.10
Left hand component……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
44

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Disassemble left hand component
7.11
Direction handle pressure block assembly……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
45
Direction handle assembly
7.12
Upper conncetion board Instrumentation assembly……………………………………………………………………………………………………………………………………………………………………………………………………………………………
46
Upper conncetion board Components
、
faucet lock
7.13
Upper conncetion board
、
direction handlebar pad assembly………………………………………………………………………………………………………………………………………………………………………………………………………………
47
Upper conncetion board
、
direction handlebar pad assembly
7.14
Head assembly 1……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
48
Headlight assembly, front shock absorber
7.15
Head assembly 2……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
49
Disassembling the headlight assembly
7.16
ABS brake system 1………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
50
Releasing brake fluid
、
tool box
7.17
ABS brake system 2………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
51
Disassemble the hydraulic control unit
、
FMC-HU
、
FC-HU
7.18
ABS brake system 3………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
52
RMC-HU
、
rear brake mame pump
7.19
ABS brake system 4………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
53
RC-HU
、
wheel speed sensor
、
rear disc brake caliper
8SURROUNDING COMPONENT
8.1
Decorative covers the upper part component………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
54
8.2
Decorative covers the lower part component………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
55
9FUEL TANK COMPONENT
9.1
Fuel tank component1…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
56
9.2
Fuel tank component2…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
57
10 SIDE COVER COMPONENT
10.1
Side cover componen……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
58
Decompose side cover component, charging port holder
11 Rear Electrical device box component
11.1
Battery component………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
59

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Disassemble battery ,battery cover,start relay
11.2
Rear Electrical device box component 1………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
60
Disassemble PKE,antenna
11.3
Rear Electrical device box component 2………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
61
Disassemble electrical device box,battery bracket
12 CUSHION COMPONENT
12.1
Cushion…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..……
62
13 MUFFLER COMPONENT
13.1
Muffler component 1……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
63
13.2
Muffler component 2……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
64

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Swell nail description
©Guangdong Tayo Motorcycle Technolog Co.
Ltd All rights reserve
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;
③Pinch the outer ring with two fingers, and push the center cylinder up to the initial position;
④Pinch the center cylinder with two fingers to install the swell nails to the installation position;
⑤The outer ring is attached to the connected parts; if not attached Check whether it is misaligned;
⑥Press the center cylinder with your fingers or other tools, and you can hear a sound or the top of the center cylinder is almost flush with the top surface of the outer ring, indicating that the
assembly is in place.
All the information, illustrations and photographs collected in this manual are compiled according to the latest products. However, there may be some inconsistencies between your
motorcycle and this manual due to the continuousimprovement of the product and other changesFor colors or upgrades, please refer to the part codes on the official website. This manual
will not be listed in detail; If the part names in this manual are inconsistent with the official website, the official website shall prevail. This manual is compiled on the basis of the chinese
version of KD150-C version. The export version is different from the chinese version with only a few parts, such as decals, ECU version, muffler catalyst, etc. Although the status of such parts
are different, the disassembly method is same, so refer to the chinese manual.

1-FRAME&ELECTRONIC COMPONENT 6
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
11184200-004000
ZT310 horn 1
21250104-006097
GB16674M6×12 (chromed/HH) 1
31250201-032093
GB818M5×16 (environmental color) 2
1186200-014000
ZT310T-M EFI ignition coil (pedal with thread) 125/155CC
1186500-007000
KD200 electric jet ignition coil 200CC
51251100-101000
Non-standard bolt M6×12 (304 stainless steel) 3
61224200-205000
ZT310 electronic cushion lock block 1
71274100-058000
ZT310 Electric seat lock 1
1
Fig.1 FRAME&ELECTRONIC
COMPONENT
PROCEDURE:
●Horn
Take off the plug of horn, take the horn(⑴ by one hand use 8# sleeve remove bolts ⑵by another hand,then
take off the horn⑴.
●Ignition coil
Take off the plug of the ignition coil.Remove the crosshead bolts⑶with a cross screwdriver and remove the
ignition coil⑷.
●Seat lock
Find and take off the plug of the seat lock .Using 4# inner hexagon remove 3pcs bolts⑸,then take off seat
lock⑺and electric seat lock guide block⑹.
●Main harness Different plug-in methods are different, please unplug all the electrical components
connected tothemain thread according to the actual operation. It needs to use a word screwdriver, forceps,
scissors andothertools to assist.
CAUTION:
●When Take off the plug can't drag any cable.
●In order to avoid the improper contact of the bending electrical parts, please pay attention to the direction
and angle of force when plugging the electrical parts, so as to avoid the improper contact of the bending
electrical parts. No violent operation.
●The location or number of ties may vary from batch to batch, so you need to disassemble them according to
the actual situation, and this manual only lists some of the tie locations.
Electronic parts COMPONENT 1
4

1-FRAME&ELECTRONIC COMPONENT 7
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
1
1251300-063093 Plywood M6×11×15(color Zinc) 4
21226500-004000
KD200-C front electrical device box 1
31244100-004000
ZT250-S Flanging bushing buffer 2
41224100-010000
ZT250-S swell nail 5
51251100-101000
Non-standard bolt M6×12 (304 stainless steel) 2
61240300-021000
HJ125-6 pod glass strip (1.5m) 1
71226500-020000
KD200-C left front decorative cover 1
81226500-021000
KD200-C right front decorative cover 1
Electronic parts COMPONENT 2
Fig.2 FRAME&ELECTRONIC
COMPONENT
PROCEDURE:
●Front electrical device box
It is necessary to remove the engine, fluid control unit, flasher, carbon canister, etc. first.
Remove the bottom bolts (5) with a 4# hex, and remove the 7 pieces of swell nails (4).
Remove the electronic parts component from the frame, and remove the two pieces of Flanging bushing
buffer (3) and the 4 pieces of plywood (1).
●Front decorative cover
Remove the left front and right front decorative cover components from the frame.
Remove the pod glass strip (6) from the front of the decorative cover respectively.
CAUTION:
●This manual only roughly explains the disassembly steps, and replacing the front decorative cover and front
electrical device box is difficult, so it is recommended to go to a qualified aftermarket store for repairs.

1-FRAME&ELECTRONIC COMPONENT 8
CHK
ADJ
NO. PART NO. PART NAME QTY CAUTION
11244100-002000 ZT250-S Side cover round rubber 7
21274100-017000 ZT250-S cable buckle 2
31244200-138000 ZT310 rubber buckle (80mm) 2
41246500-027000 KD200-C frame φ7 decorative buckle 2
51241200-044000 KD150-U fuel tank liner limit glue 2
71240100-023000 Battery anode protection glue 1
81244100-061000 ZT250 anti-water rubber of frame 4
91224100-030000 Pin tie (Black 4.8×130) 1
PROCEDURE:
●Fuel tank liner limit glue
Push out the fuel tank liner limit glues⑸then take off.
●Battery cushion
Put off the battery cushion ⑻directly by hand.
●Side cover cushion
Remove the side cover cushion ⑴with your hand directly.
●Rubbers
Remove the anti-water rubber of frame (8), cable buckle (2) and decorative buckle (4) directly by hand.
●Pin tie
Cut or pinch the snap on the back and push out the pin tie (9).
●Foam Tape
A 5-8cm piece of foam tape is affixed to the suspension brackets on both sides of the frame to prevent
rattling when the tool box cover and sub-tank cover are too close to the frame, required only for 125/155-C
models, not for 200-C.
CAUTION:
●It must be dismantled them first, such as the cushion, fuel tank component, sider cover, tail dressand so on.
●All parts should be correctly assembled.
60.1 only for
125/155-C
1246200-051000 P-240 foam improvement (width 6mm, length 1m,
thickness 5mm)
Frame plastic parts
Fig.3 FRAME&ELECTRONIC
COMPONENT

1-FRAME&ELECTRONIC COMPONENT 9
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
11134100-007000
ZT250-S Adjusting nut locking washer 1
31244100-015000
ZT250-S Adjusting nut rubber pad 1
41244300-014000
ZT350-R upper dust cover 1
51130900-024000
ZT250-S shaft ring 1
61130900-022000
ZT250-S conjoined steel ball 1
71130900-026000
ZT250-S upper steel bowl 1
81134300-001000
ZT350-R lower seat ring 1
91134300-002000
ZT350-R conjoined steel ball 1
CAUTION:
●Remove the head part component, handlebarcomponent and front shock absorber component first.
●Please pay attentin to fix the awaiting repair motorcycles during disassembly,prevent dumping by
accident.
●Please check whether the steel beads of the conjoined body have abnormal phenomena such as
partial abrasion and rust.If YES, please buy the regular accessories, if not, please be sure to grease the
old grease and repaint the lubricating grease on it.
●It must be to check whether the steel ball is available during reassembly.
●It must be reasonable to adjust the steering, too loose will cause the locomotive to brake slightly,
and the locomotive will shake slightly, too tight can lead to inflexibility, resulting in safety hazards.
●If you have the ability and the right tool, you can change the shaft ring and the dustproof cover
.During the replacement process, pay attention to the protection of the lower connected plate. After
replacement, it must be to check the parallelism of the column and the damping hole, the vertical
degree of the vertical column and the lower connected plate.
PROCEDURE:
●Dissembly
Remove the lock washer⑴.
Remove the top adjusting nut ⑵by using a special four-jaw or hook wrench tools.
Remove the rubber pad ⑶.
With one hand to hold down the down connected plate assembly, the other hand use a special four-jaw set
or hook wrench to remove the adjusting nut⑵.
Remove the down connected plate component.
Remove the upper dustproof cover⑷.
Remove the axletee ring ⑸of the upper riser and the steel ball⑹.
Remove the steel ball of the down connected plate component⑼.
●Assemble
When reassembling, the conjoined steel beads should be painted lubricating grease,attention to the dosage.
The torque of rating nut which closes to upper dustproof cover is required to about 14N·m.so as to be able to
rotate out of nimbleness.
The top adjusting nut only needs to rotate to the bottom of the nut groove alignment, not too tight to
prevent the rubber pad ⑶from deformation too larg.
Fig.4 FRAME&ELECTRONIC
COMPONENT
22
Directional column component
ZT250-S direction column adjusting screw nut M24×1
(environmental color Zinc)
1251300-046093

1-FRAME&ELECTRONIC COMPONENT 10
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
1Frame after-sales component 1【
1
】
21130900-026000 ZT250-S upper steel bowl 1
31134300-001000 ZT350-R lower seat ring 1
41251300-057093 Non-standard nut M10×1.5(dacromet) 1
54026500-001000 KD200-C side bracket 1
61251700-175091 KD200-C side stand sleeve φ10×φ17×24 1
71251100-365000 Non-standard bolt M10×1.5×45(with threaded hole) 1
81186800-006000 ZT350 side bracket flameout switch 1
91251513-001019 6.3×12×1.6 copper gasket 1
11 1264100-001000 ZT250-S side stand spring 1
PROCEDURE:
●Checking the cushion loop
Checking whether the cushion loop⑵,⑶is frayed, if as it, please replace it. Fix the cushion loop well and
paint the lubricating grease on it with appropriate tool.
●Sider support
Unplug the conecter of the flameout switch, using the cross screwdriver to remove the side support spring⑾,
and guard against the personal injury caused by spring contraction.Using 8# sleeve remove the bolt⑽,then
take off the gasket⑼,the flameout switch⑻.Using 14# sleeve fixed the bolt⑺and then remove nut⑷.
Remove the bush⑹,side support ⑸, paint the lubricating grease on the bush⑹when re-assembling ,then put
it into the frame⑴.
CAUTION:
●Remove the wind deflector component, handle bar component, steering column component first.
●Paint the lubricating grease on the cushion ring to decrease the rotary resistance of front forklift.
●Pay attention to safety when mounting side support spring.
●All parts should be correctly assembled.
●【1】If the part code is empty, it indicates that the part has multiple states or colors. For specific states,
please find the corresponding state or color in the official website parts. Only the disassembly and assembly
steps are explained here, and the color and status do not affect the disassembly and assembly process. This
description will not be added if there is such a situation later in this manual.
Fig.5 FRAME&ELECTRONIC
COMPONENT Frame, side bracket
GB16674 M6×16 Hexagon flange bolts (9.8
grade/environmental color Zinc) 110 1251112-001093

2-FRAME & ENGINE COMBINATION 11
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
11251500-116000
Non-standard aluminum washer φ20×φ10×3 6
24026500-012000
KD150-C hanging piece 2
31251100-123093 Non-standard bolt M8×25 (color Zinc) 4
41250105-144093 GB5789M10×1.25×30 (environmental color) 2
51244200-138000 ZT310 rubber buckle (80mm) 2
61276500-021000 KD200-C bracket connecting shaft φ10×280 1
71251100-085093 Non-standard bolt M10×1.5×75 (Dacromet) 2
91226500-008000
KD200-C engine left rear cover 1
10 1252200-084000
KD200-C rear fork axle φ20×320 1
11 1251300-057093
Non-standard nut M10×1.5(dacromet) 465±5N.m
12 1251100-261000
Non-standard bolt M10×1.25×127(Dacromet) 1
●The waste oil and coolant needs to be collected and returned to qualified institutions. It is forbidden
to dump and pollute the environment and the source of water.
Fig.1 FRAME & ENGINE
COMBINATION
2
Frame & engine combination 1
81251112-002093 GB16674 M6×30 Hexagon flange bolts (9.8
grade/environmental color Zinc)
PROCEDURE:
●Remove engine accessories
Firstly drain the coolant. Then remove the seat cushion, fuel tank, tool box, sub-tank, surround and bracket,
rectifier, pedal bracket, throttle body assembly, and left side cover. Locate and unplug the gear display and
magneto, unplug the water temperature sensor on the right side, unplug the ignition coil against the spark
plug side, unplug the crankcase exhaust pipe, remove the clutch cable against the engine end, and remove the
rear flat fork protective rubber sleeve and nut. Remove the motor positive wire, engine hitch wire, and
cooling water pipe.
Remove 2 pieces of rubber buckles⑸.
After removing the 2 bolts⑶and bolts⑷securing the hanging piece⑵ on the left side with a 12# socket,
remove the hanging piece and 3 pieces of aluminum washers⑴. Remove the right side hanging piece in the
same way.
Remove the left rear cover⑼by removing the bolt⑻with the 8# socket. After removing the rear flat fork
shaft, remove the chain from the small sprocket.
Secure the bolts ⑹, ⑺and ⑿ respectively with a 14# socket, and remove the 4 nuts⑾ first with a 14# socket,
taking care that the bolts⑹, ⑺and ⑿should not be removed first.
CAUTION:
●This manual only roughly explains the disassembly steps, and replacing the engine is difficult, so it is
recommended to go to a qualified aftermarket store for repairs.
●Here we take 125 engine as an example to roughly explain the disassembly steps, the steps for 155 and 200
displacement models are similar, and will not be repeated.
●Using suitable tools to support the motorcycle, in case of accidents caused by motorcycle falling down.
Single person operating is prohibited.

2-FRAME & ENGINE COMBINATION 12
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
14026500-002000 KD200-C bracket 1
24026500-009000 KD200-C bracket left-right connecting sleeve 2
31276500-021000 KD200-C bracket connecting shaft φ10×280 1
41251100-085093 Non-standard bolt M10×1.5×75 (Dacromet) 2
51251100-261000 Non-standard bolt M10×1.25×127(Dacromet) 1
PROCEDURE:
●Remove the engine
Check again that all cables, tubes, etc., connected to the engine have been removed.
Two persons hold the left and right engine cases at the same time; one person withdraws the shaft (3) and
removes the sleeve⑵. Remove the bracket⑴after removing the bolt⑷.
Confirm that the engine is supported and then pull out the bolt (5), and then remove the engine from the
vehicle, paying attention to safety during the movement. Place the engine smoothly on a flat surface.
CAUTION：
●Here we take 125 engine as an example to roughly explain the disassembly steps, the steps for 155 and 200
displacement models are similar, and will not be repeated.
●Use a suitable tool to support the motorcycle to prevent accidents caused by dumping during disassembly.
●The waste oil and coolant needs to be collected and returned to qualified institutions. It is forbidden to
dump and pollute the environment and the source of water.
●Use the appropriate tools to support the whole vehicle to prevent accidents caused by the dumping of the
vehicle during the disassembly process; single operation is strictly prohibited.
●All standard parts must meet the standard torque value during reassembly, and re-add the oil according to
the instructions.
Fig.2 FRAME & ENGINE
COMBINATION Frame & engine combination 2

3-INTAKE SYSTEM COMPONENT 13
CHK
ADJ
NO. PART NO. PART NAME QTY CAUTION
1
MSE8.0 Controller
（
ECU
）
1
21251100-101000
Non-standard bolt M6×12 (304 stainless steel) 1
31050957-016000
KD200-C EFI high pressure oil pipe assembly 1
41051356-012000 φ42×10 pipe hoop assembly 1
51251300-063093
Plywood M6×11×15(color Zinc) 4
61050961-004000
Air filter intake air temperature sensor 1
71224100-030000 Pin tie (Black 4.8×130) 1
CAUTION:
●This manual only roughly explains the disassembly procedure, replacing the air filter requires some
hands-on ability, and it is recommended to go to a qualified aftermarket shop for maintenance.
●Regularly check whether the filter element of the carbon tank and air filter is not ventilated,
otherwise it may cause the oil supply to affect the driving experience.
●The 2 oil pipes of the canister solenoid valve cannot be connected wrongly.
●
Pay attenion to force when removing clamp.
The air filter assembly
Fig.1 INDUCTION SYSTEM
COMPONENT
PROCEDURE:
●High pressure oil pipe and ECU
Remove the high-pressure oil pipe⑶by squeezing the clip on the high-pressure oil pipe with your hand
while moving it in the direction of the arrow. Be careful not to damage the injector holder. Remove the plug
from the ECU by pressing the plug release catch, and remove the ECU⑴by removing the bolt⑵with a 4#
hexagonal socket.
●Air filter
Pull out the air filter inlet air temperature sensor.
Remove the fuel tank, seat cushion, side cover, rear box of electrical parts, rear flat fork, etc. The specific
steps are detailed in the corresponding chapters and will not be repeated here. Carbon canister solenoid valve
removal is detailed in the side cover removal section.
Remove the Air filter intake air temperature sensor⑹on the air filter.If the sealant falls off when ou pull out
the sensor⑹, plug it back to the original position.
First use 4# inner hexagon to remove the 3 bolts ⑴on the frame.
Loosen the hose clamp assembly ⑷at the end of the air filter and move the clamp out toward the air filter,
and pull out the air filter outlet pipe from the throttle valve body.
Use pliers to clamp the hoop on the gas separator outlet pipe, and then plug it with the rubber plug to
prevent foreign matter from entering and damaging the engine.
Remove the air filter and carbon canister assembly.
Take off 4 pcs plywood ⑸from the air filter.
●Check sensor
Check the carbon canister solenoid valve:
In case of poor engine performance; Poor idle speed; If the air-fuel ratio is incorrect, check the carbon
canister solenoid valve.
Use a multimeter to measure the resistance between the two inserts of the carbon canister solenoid valve
Check whether the temperature sensor is damaged:
Remove the temperature sensor from the air filter and place it in the ambient temperature (20 ～30
℃
), and use a multimeter to check whether the resistance of the two pins is between 2726
～
1770 Ω.

3-INTAKE SYSTEM COMPONENT 14
CHK
ADJ
NO. PART NO. PART NAME QTY CAUTION
11251100-101000
Non-standard bolt M6×12 (304 stainless steel) 2
21050957-018000
KD200-C carbon canister EVAP tekmar-dohrmann 1
31251300-063093
Plywood M6×11×15(color Zinc) 2
41226500-003000
KD200-C carbon canister 1
51051468-007000
31.8×2 fluorine rubber O-ring 1125CC
61050955-008000 ZT152MI intake pipe assembly (with intake pressure sensor)
1125CC
81050968-003000
EV14 injector G06 1
91050968-002000
ZT1P58MJ injector holder 1
13 1251100-061093
M6×22 Hex flang bolt thread level 8.8 (color zinc) 1
14 1050955-002000
ZT26 Throttle Body Assembly (position sensor) 1125CC
15 1050954-043000
Left hole angle sensor bushing
（
RPAZ023A
－
5K
）
1
125CC,after-sale
16 1051356-010000
Φ45×10 pipe clamp assembly 1
17 1250205-036097
Gb70.1m6 ×16 (Chrome plated) 2
18 1050957-021000
Pressure sensor fixing rubber sleeve 1
●External intake air pressure sensor
Using screwdriver for cruciform head remove the bolt ⑿,take off the sensor⑾and support⑽,then
remove the connection hose⑺.Remove the rubber sleeve⒅,added from approximately Oct.24,2023.
CAUTION:
●This is an example of how to disassemble the throttle valve body assembly for the 125
displacement model. The steps for the 155 and 200 displacement models are similar, with only some
of the parts differing in appearance, so they will not be repeated.
●When removing the high pressure oil pipe,It is sure to operate until the engine and muffler are
completely cooled.
●Fireworks, answering or dialing should be strictly prohibited near the car-breaking site to prevent
accidents.
PROCEDURE:
●Carbon canister assembly
After removing the left sub-tank and right tool box, remove the carbon canister assembly from the vehicle by
removing the bottom bolt⑴ with a 4# hex. Remove 2 pcs plywood⑶. Remove the tekmar-dohrmann⑵.
●Throttle valve body assembly
Unplug the connector of the throttle valve body assembly, and remove the pipe clamp ⒃ with a 4#
hexagonal socket to remove the throttle valve body assembly. Remove the throttle cable and then take off the
throttle body⒁. Unplug the sensor⑾and injector⑻and remove the intake manifold assembly by removing 2
bolts⒄ with a 4# hexagon socket.
Remove the O-ring ⑸, check carefully for damage before reinstalling.
Remove theconnection hose⑺at the intake pipe assembly end.
Use 8# wrench to remove the bolt ⒀,take off the External intake air pressure sensor component,injector
holde⑼and injector⑻.
Fig.2 INDUCTION SYSTEM
COMPONENT
1
1
1
1
1050956-022000
1050956-025000
1050961-003000
1250106-112000
Throttle valve body component(125CC)
KD150GK intake pressure sensor connecting hose (φ
3.5×φ7.5×L38.5)
KD150 external intake pressure sensor fixing bracket
External intake pressure sensor MAP01
(18590H7U300)
GB9074.13 Hexagon cross groove spring,flat cushion
combination bolt M5×20
7
10
11
12

3-INTAKE SYSTEM COMPONENT 15
CHK
ADJ
NO. PART NO. PART NAME QTY CAUTION
11226400-174000 ZT310-R Air Filter Element (carton packaging) 1
ROCEDURE:
●Filter element
If you need to maintain the filter element of the air filter, remove the seat cushion.Lift the battery cover and
relay assembly up and out of the way, and pull the dump switch rubber sleeve out of the filter cartridge
cover.Take the two standard screws out of air filter, dismantle the box cover Grasp the rubber strips on the
filter (both sides shown in yellow) and pull the filter element out. Blow the dust off the filter core by blowing
dust gun in the filter element. If the filter paper is damaged, it should be replaced in time.If the blowback
causes the dust to be unable to clean up, the engine will be damaged or the induction resistance will become
larger and affect the driving experience.When assembling, apply a small amount of engine oil on the upper
and lower sides of the rubber strip (shown in cyan as shown in the figure) to reduce assembly resistance.
●Oil pipe and water pipe
Avoid water into the air filter when washing the motorcycle. Can pulled out the oil pipe to release if into
small water.keep no water inside before staring the engine. Inspecte the oil pipe regularly if more oil is
accumulated should be released in time.
CAUTION:
●Regularly check whether the filter element of the carbon tank and air filter is not ventilated, otherwise it
may cause the oil supply to affect the driving experience.
●When blowing dust, pay attention to maintain a certain distance to avoid excessive damage to the filter
element.
●The filter element should be checked every 5000 kilometers or 15 months; it should be replaced every
10,000 kilometers or 30 months.
Fig.3 INDUCTION SYSTEM
COMPONENT Replace air filter element

4-REAR WHELL COMPONENT 16
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
11186500-006000 KD200-C auxiliary mud plate transfer line 1
21250205-036091 GB70.1M8×50(white Zinc) 2
31244300-023000 ZT310 rubber buckle (50mm) 2
41244100-006000 ZT250-S rear liceness rubber buffer 1
51251100-328000 Hexagon socket head screw M6×14+8.5×3 SUS302 5
61250305-010093 GB6187.1M6 (environmental color) 3
74026500-003000 KD200-C rear auxiliary fender bracket 1
81226500-011000 KD200-C rear auxiliary fender 1
10 1276500-011021 KD200-C rear license plate bracket 1
11 1250105-138093 GB5789M6×20 (environmental color) 2
Fig.1 REAR WHELL
COMPONENT
PROCEDURE:
●Rear auxiliary mudguard component
Remove the left side cover assembly first and unplug the 3 plugs indicated by the arrows. Pull the adapter
wire out of the wire slot above the chain box.
Remove the rubber buckle⑶and the rear liceness rubber buffer⑷.
Remove the 2 pieces of bolts⑵ with a 6# hex and the rear sub mud board assembly.
Secure the bottom screw⑸with a 4# hex and remove the nut⑹ with a 10# socket.
Remove the top 2 screws⑸with a 4# hex.
Turn over to the back and remove the rear auxiliary fender⑻by removing the two screws⑸ with a 4# hex.
After securing the bolts⑾with a 10# socket remove the two nuts⑹securing the rear license plate bracket ⑽
with a 10# socket and remove the licence plate bracket. Remove the 2 pieces of waterproof rubber plugs ⑼.
Unplug the turn signal licence plate light from the adapter cable and remove the adapter cable.
CAUTION:
●Using side support to support the motorcycle, in case of accidents caused by motorcycle falling down.
Single person operating is prohibited.
●Stay alert during the manipulation and avoid accident.
21244200-0520009
Rear mud board-1
ZT310 univsersal side box bracket waterproof rubber
plug

4-REAR WHELL COMPONENT 17
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
11226500-009000 KD200-C licence plate mounting plate backing 1
21251300-063093 Plywood M6×11×15(color Zinc) 2
31251100-102000 Non-standard bolt M6×16 (304 stainless steel) 2
41176500-006000
KD200-C left turn signal
（
L=100mm) 1
51176500-007000
KD200-C right turn signal
（
L=100mm) 1
61270300-273000 φ8 clip(L=73) 1
71226500-010000 KD200-C plate mounting plate 1
81174200-021000 ZT310-X Liensed lights 1
91174100-002000 ZT250-S rear reflector 1
PROCEDURE:
●Rear licence plate mounting plate
Remove the bottom liner assembly by removing each of the 2 pieces of bolts⑶with a 4# hex. Remove the
plywood⑵from the backing⑴. Remove the turn signal light from the plate mounting plate⑺. Remove the
adapter wire by breaking the wire clip straight and unplugging the turn signal and licence plate light.
Remove the nut ①and spacer②supplied with the rear reflector⑼ with a 10# socket, and remove the wire
clip⑹. Remove the licence light⑻by pressing the snap at the arrow indication.
CAUTION:
●When reinstalling, pay attention to differentiate the turn signal wire colours to avoid inserting them
backwards.
Fig.2REAR WHELL
COMPONENT Rear mud board-2

4-REAR WHELL COMPONENT 18
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
11250105-147093 GB5789M8×16 (environmental color) 2
21250502-016093 GB96.1φ8 (environmental color) 2
31276600-015097 Φ30×Φ14.5×2 gasket (chromed) 2
41251100-088094 Non-standard bolt M10×1.5×43(Dacromet) 2
51116500-003000 KD200-C rear shock absorber 2
61251300-057093 Non-standard nut M10×1.5(dacromet) 2
71276400-077000 ZT350T-K rear shock absorber adjustment wrench 1gift of vehicle
Fig.3 REAR WHELL
COMPONENT
PROCEDURE:
●Rear shock absorber
Put down side stand. Person 1: Turn the handling bar to left end with left hand; hold tight the rear pedal with
right hand and lean the motorcycle to left side.Another person used a wooden stool to put a soft rubber
cushion on the right side muffler back pressure bag of the bike to support the whole bike and let the rear
wheel slightly off the ground.
After supporting the whole bike, use a 14# wrench to fix the nut ⑹at the bottom of the shock absorber.Uses
a 14# sleeve on the out side to loosen the bolt ⑷counterclockwise and remove the nut ⑹.
Remove the bolt⑴ with a 12# sleeve,take off the gasket⑵,and then take off the rear absorber at,last take off
the gasket⑶.
●Adjust the rear absorber
Use the supplied hook spanner to turn the adjusting nut clockwise to compress the damping spring and thus
stiffen the damping, and conversely to soften it. Please adjust in a reasonable range. Riding experience would
be influenced either the absorber is too soft or too hard.
CAUTION:
●Using suitable tool to support the motorcycle. Avoid accidents caused by falling motorcycle. Single person
manipulation is prohibited.
Rear shock absorption

4-REAR WHELL COMPONENT 19
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
14046502-039000 KD200-C chain cover assembly (MES) 1
21251300-063093 Plywood M6×11×15(color Zinc) 1
31251100-101000 Non-standard bolt M6×12 (304 stainless steel) 1
41251100-328000 Hexagon socket head screw M6×14+8.5×3 SUS302 2
51246500-016000 KD200-C rear wheel shaft protection rubber sleeve 1
61250305-029000 GB6187.1M16×1.5 (Dacromet) 180N.m
71276500-007000 KD200-C right chain adjuster scaleplate 1
8Chain adjuster 2
91276500-006000 KD200-C left chain adjuster scaleplate 1
10 1096500-004000 KD200-C rear wheel axle (φ17×342) 1
Fig.3 REAR WHELL
COMPONENT Rear wheel component 1
PROCEDURE:
●Chain box
To prevent damage to the chain box when removing the rear wheel assembly, remove it first. Remove the
chain box assembly from the vehicle by removing the 1 bolt ⑶and 2 screws⑷ with a 4# hex. Remove the
plywood⑵.
●Rear wheel assembly
Remove the protection rubber sleeve⑹and⑾. Loosen the nuts of the chain adjusters on both sides first with
a 13# spanner. Secure the head of the rear wheel axle⑽ with a 19# socket on the left side and remove the nut
⑹ with a 21# socket on the right side. Remove the right chain adjuster scaleplate⑺.
Tie the rear disc brake caliper to the rear flat fork with a tie or rope. Push the rear wheel assembly toward
the front of the motorcycle to the end and remove the chain from the chain disc. Tap the rear wheel axle⑽
with a rubber mallet after holding the rear wheel assembly, and remove the right side chain adjuster⑻, the
rear tyre and rim assembly, and the left side chain adjuster⑻in turn.
CAUTION:
●Use suitable tool to support the motorcycle. Avoid accidents caused by falling motorcycle. Single person
manipulation is prohibited.All the standard parts need to reach standard torque while reassembling.
●Using iron hammer to punch rear wheel axle, disc brake clamp assembly is prohibitd.
●While disassembling the rear wheel assemble, avoid the rear disc brake clamp to be lifted higher than the
disc brake oil cup. If not, air will get into the tubes and cause softness or failure on braking system. As disc
brake tubes request extreamly high vaccum degree. Make sure manipulator has maintenance ability before
disassembling the disc brake assembly.
●Check the chain regularly. Increase the frequency of adjustment of the chain according to the driving
conditions. Keep the tightness of chain to be in a suitable range. Too loose chain have possibility to separate
from sprocket or damage the engine. Too tight chain can be worn out quickly.
1246500-021021 1
KD200-C rear wheel shaft head protection rubber
sleeve
11