Zontes ZT125-GK User manual

2022/5/25
ZT125/155-GK（EURO V）
Service manual

Page 1 ，Toatal 81 Pages
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0
Table of Contents………………………………………………………………………………………………………………………………………………………………………………………………
1
1FRAME&ELECTRONIC COMPONENT
1.1
Electrical device component-1…………………………………………………………………………………………………………………………………………………………………………………
7
Main harness, dump switch, relay, flasher
1.2
Electrical device component-2…………………………………………………………………………………………………………………………………………………………………………………
8
Flameout switch, horn,ignition coil
1.3
Electrical device component-3…………………………………………………………………………………………………………………………………………………………………………………
9
ECU
、
relay
1.4
Electrical device component-4…………………………………………………………………………………………………………………………………………………………………………………
10
Flasher
、
Buzzer
1.5
Frame plastic parts………………………………………………………………………………………………………………………………………………………………………………………………
11
Line clamp, side cover round glue, fuel tank liner limit glue
1.6
Directional column component…………………………………………………………………………………………………………………………………………………………………………………
12
Lower plate component
1.7
Frame, side bracket……………………………………………………………………………………………………………………………………………………………………………………………
13
Frame, side bracket
2FRAME & ENGINE COMBINATION
2.1
Frame & engine combination 1…………………………………………………………………………………………………………………………………………………………………………………
14
Disassemble guard bar assembly
2.2
Frame & engine combination 2…………………………………………………………………………………………………………………………………………………………………………………
15
Lower shroud bracket
、
engine
3INTAKE SYSTEM COMPONENT
3.1
Intake system component………………………………………………………………………………………………………………………………………………………………………………………
16
Air filter filter,Carbon canister
3.2
Throttle valve body component…………………………………………………………………………………………………………………………………………………………………………………
17
Disassemble throttle valve body component
3.3
Replace air filter element………………………………………………………………………………………………………………………………………………………………………………………
18
4REAR WHELL COMPONENT
4.1
Rear mud board…………………………………………………………………………………………………………………………………………………………………………………………………
19
Contents
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Table of Contents
Rear mud board
4.2
Rear shock absorption…………………………………………………………………………………………………………………………………………………………………………………………
20
Demolition after shock absorption, rear shock absorption adjustment
4.3
Rear wheel component 1………………………………………………………………………………………………………………………………………………………………………………………
21
Disassemble the rear rim component, sprocket seat, sprocket
4.4
Rear wheel component 2………………………………………………………………………………………………………………………………………………………………………………………
22
Disassembled rear rim component
4.5
Rear fork component……………………………………………………………………………………………………………………………………………………………………………………………
23
Disassembled rear fork component
4.6
Replace the rear brake pads……………………………………………………………………………………………………………………………………………………………………………………
24
4.7
Rear brake main pump adds brake fluid………………………………………………………………………………………………………………………………………………………………………
25
5PEDAL COMPONENT
5.1 Adjust the hight of foot pedal 26
Shift lever, brake pedal height adjustment
5.2
Right footrest component 1……………………………………………………………………………………………………………………………………………………………………………………
27
Disassemble the right foot support component
5.3
Right footrest component 2……………………………………………………………………………………………………………………………………………………………………………………
28
Decomposition brake pedal component
5.4
Right footrest component 3……………………………………………………………………………………………………………………………………………………………………………………
29
Disassemble the right pedal component
5.5
Left footrest component 1………………………………………………………………………………………………………………………………………………………………………………………
30
Disassemble the left foot support component and the shift lever component
5.6
Left footrest component 2………………………………………………………………………………………………………………………………………………………………………………………
31
Decomposition shift lever component, front left pedal component
5.7
Left footrest component 3………………………………………………………………………………………………………………………………………………………………………………………
32
Disassemble the left footrest component
6COOLING SYSTEM COMPONENT
6.1
Change the oil and the oil filter…………………………………………………………………………………………………………………………………………………………………………………
33
6.2
Add coolant……………………………………………………………………………………………………………………………………………………………………………………………………
34
6.3
Change coolant…………………………………………………………………………………………………………………………………………………………………………………………………
35
6.4
Water tank component 1………………………………………………………………………………………………………………………………………………………………………………………
36
Disassemble the auxiliary water tank component,water pipe

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6.5
Water tank component 2………………………………………………………………………………………………………………………………………………………………………………………
37
Disassemble water tank component,water tank bracket
7FRONT FORK COMPONENT
7.1
Throttle/clutch cable clearance adjustment, light height adjustment……………………………………………………………………………………………………………………………………………
38
7.2
Replacement clutch cable………………………………………………………………………………………………………………………………………………………………………………………
39
7.3
Replace the throttle line…………………………………………………………………………………………………………………………………………………………………………………………
40
7.4
Steering adjustment……………………………………………………………………………………………………………………………………………………………………………………………
41
7.5
Right hand component…………………………………………………………………………………………………………………………………………………………………………………………
42
Disassemble right hand component
7.6
Add brake fluid, rocker adjustment……………………………………………………………………………………………………………………………………………………………………………
43
7.7
Replace the front brake pads……………………………………………………………………………………………………………………………………………………………………………………
44
7.8
Front wheel component…………………………………………………………………………………………………………………………………………………………………………………………
45
Disassemble the front wheel, front disc brake disc, front axle component
7.9
Front mud board & wheel speed sensor component 1…………………………………………………………………………………………………………………………………………………………
46
Disassemble front wheel speed sensor component, front mud plate component
7.10
Front mud board & wheel speed sensor component 1…………………………………………………………………………………………………………………………………………………………
47
Front disc brake guard component,Front mud board component
7.11
Head and headlights component 1………………………………………………………………………………………………………………………………………………………………………………
48
Disassemble head and headlights component,speedometerdecorative cover,left and right turn signal bracket assembly
7.12
Head and headlights component 2………………………………………………………………………………………………………………………………………………………………………………
49
Disassemble front turn singal,headlights low bracket,left and right turn signal bracket assembly,bracket under headlight
7.13
Head and headlights component 3………………………………………………………………………………………………………………………………………………………………………………
50
Disassemble headlights
7.14
Speedometer component………………………………………………………………………………………………………………………………………………………………………………………
51
Disassemble speedometer and bracket
7.15
Left hand component……………………………………………………………………………………………………………………………………………………………………………………………
52
Disassemble left hand component
7.16
Directional lever component……………………………………………………………………………………………………………………………………………………………………………………
53
Disassemble directional lever
7.17
Front shock absorber, upper plate component…………………………………………………………………………………………………………………………………………………………………
54
Disassemble front shock absorber, faucet lock, upper plate component
7.18
Uplink plate, direction handle block component………………………………………………………………………………………………………………………………………………………………
55
Disassemble the direction of the block, the upper plate

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7.19
ABS brake system-A 1…………………………………………………………………………………………………………………………………………………………………………………………
56
Disassemble the hydraulic control unit and bracket
7.20
ABS brake system-A 2…………………………………………………………………………………………………………………………………………………………………………………………
57
Releasing brake fluid,FMC tubing
7.21
ABS brake system-A 3…………………………………………………………………………………………………………………………………………………………………………………………
58
Disassemble FC tubing
ABS brake system-A 4…………………………………………………………………………………………………………………………………………………………………………………………
59
7.22 Disassemble RMC tubing,RC tubing
8SURROUNDING COMPONENT
8.1
Front grille component…………………………………………………………………………………………………………………………………………………………………………………………
60
Fuel tank front grille component
8.2
Decorative cover s the upper part component…………………………………………………………………………………………………………………………………………………………………
61
Upper surrounding assembly
8.3
Lower part component …………………………………………………………………………………………………………………………………………………………………………………………
62
Surrounding components
8.4
The middle cover component……………………………………………………………………………………………………………………………………………………………………………………
63
Surrounding components
8.5 Lower part sectionalization 64
USB charging cable,Front grille standard component
9FUEL TANK COMPONENT
9.1
Fuel tank component……………………………………………………………………………………………………………………………………………………………………………………………
65
Fuel tank component
9.2
Fuel tank cover component ……………………………………………………………………………………………………………………………………………………………………………………
66
Fuel tank decorative cover
9.3
Fuel Tank middle cover assembly………………………………………………………………………………………………………………………………………………………………………………
67
Fuel tank middle cover component, fuel tank lock ,fuel tank cover assembly
9.4
Change engine oil………………………………………………………………………………………………………………………………………………………………………………………………
68
Fuel tank cover assembly
9.5
Oil pump………………………………………………………………………………………………………………………………………………………………………………………………………
69
Fuel tank trim cover fixing block,Oil pump component,Shroud glass strip,fuel tank cap
10 SIDE COVER COMPONENT

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Table of Contents
10.1
Side cover component…………………………………………………………………………………………………………………………………………………………………………………………
70
Decompose side cover component
11 REAR COVER COMPONENT
11.1
Rear Armrest component………………………………………………………………………………………………………………………………………………………………………………………
71
Remove the armrest
11.2
Left rear skirt component………………………………………………………………………………………………………………………………………………………………………………………
72
Disassemble the left rear skirt component
11.3
Right rear skirt component……………………………………………………………………………………………………………………………………………………………………………………
73
Disassemble the right rear skirt component
11.4
Tail light component……………………………………………………………………………………………………………………………………………………………………………………………
74
Disassemble the taillight component
11.5
Rear mud board component 1…………………………………………………………………………………………………………………………………………………………………………………
75
Demolition of the mud board component
11.6
Rear mud board component 2…………………………………………………………………………………………………………………………………………………………………………………
76
Disassembled mud board component
11.7
Battery component(colliod battery)……………………………………………………………………………………………………………………………………………………………………………
77
Disassemble battery ,electric device box cover,battery anode protection glue
11.8
Battery component………………………………………………………………………………………………………………………………………………………………………………………………
78
Disassemble battery
、
Wake-up switch and charging precautions
12 CUSHION COMPONENT
12.1
Cushion…………………………………………………………………………………………………………………………………………………………………………………………………………
79
Discomponent and component cushion; seat cushion rubber separately purchased parts
13 MUFFLER COMPONENT
13.1
Muffler component 1……………………………………………………………………………………………………………………………………………………………………………………………
80
Disassemble muffler component
13.2
Muffler component 2……………………………………………………………………………………………………………………………………………………………………………………………
81
Disassemble muffler decorative cover

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©Guangdong Tayo Motorcycle Technolog Co.
Ltd All rights reserve
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-G1high-seat 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 7
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
1 1181200-130000 KD150-GK harness assembly(MSE8.0) 1
2 1250303-010093
GB6177.1M6
（
color zinc
）
1
3 1050954-009000
YH canister solenoid valve 1
4 1244100-082000
ZT250
－
R dump switch sleeve 1
5 1184100-002000
ZT250
－
S dump switch 1
6 1184100-017000
ZT250
－
S fuel-injection relay 6
7 1180300-101000 HJ150-3 square flasher (LED) 1
8 1224100-037000
Grade 0 flame retardant tie (black 3.6×295) 11
9 1251100-101000
Non-standard bolt M6×12 (304 stainless steel) 3
10 1274100-058000
ZT310 Electric seat lock 1
11 1224100-051000
0 level fire-retardant belting
（
black2.5×100
）
2
12 1224200-205000
ZT310 Electric seat lock guide block 1
Fig.1FRAME&ELECTRO
NIC COMPONENT Electronic parts COMPONENT 1
PROCEDURE:
●
Main harness Different plug-in methods are different, please unplug all the electrical components connected to
themain thread according to the actual operation. It needs to use a word screwdriver, forceps, scissors andother
tools to assist. The binding⑻or ⑾can be picked out by using scissors.
●Flasher and dump switch
Remove the flasher⑺,remove the rubber sleeve⑷that connects to the mounting bracket on the frame, and
remove the dump switch⑸.
●Relay
Pull out 5pcs electric injection relay⑹directly.
●Seat lock
Find and take off the plug of the seat lock , and cut off binding⑾.Using 4# inner hexagon remove 3pcs bolts
⑼,then take off seat lock⑽.
●Canister solenoid valve
First unplug the two oil pipes connecting the carbon canister to the solenoid valve, unplug the cable connector
and then loosen the nut ⑵and remove the solenoid valve ⑶.
CAUTION：
●It must be dismantled them first, such as the cushion, fuel tank component,sider cover, tail dress and so on.
●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.
●Please notice the limit of the bracket when dismantling dump switch sleeve, beware of hurting your fingers.

1-FRAME&ELECTRONIC COMPONENT 8
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
1 1184200-004000
ZT310 horn 1
2 1251112-001093
M6×16 Hexagon flange bolts (color zinc) 1
3 1224100-037000
Grade 0 flame retardant tie (black 3.6×295) 2
4 1250205-040095
GB70.1 inner hex bolt M8×16
（
color Zinc
）
2
51184100-012000
ZT250
－
S shut down switch 1
6 1250201-032093
GB818M5×16 (environmental color) 2
7 1186200-014000
ZT310T
－
M EFI ignition coil (pedal with thread) 1
8 1274100-017000
ZT250
－
S line buckle 2
Fig.2FRAME&ELECTRO
NIC COMPONENT Electronic parts COMPONENT 2
PROCEDURE:
●Horn
Take off the plug of horn, take the horn(⑴by one hand use 8# sleeve remove bolts ⑵by another hand,then
take off the horn⑴.
●Shut down switch
Find and take off the plug of the shut down switch⑸,remove line buckle⑻,cut ribbon ⑶.Using 6# inner
hexagon socket remove 2pcs bolts⑷then take off shut down switch⑸.
●Ignition coil
Take off the plug of the ignition coil.Remove the crosshead bolts⑹with a cross screwdriver and remove the
ignition coil⑺.
CAUTION:
●When Take off the plug can't drag any cable.

1-FRAME&ELECTRONIC COMPONENT 9
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
1 1184300-002000 ZT350 starting relay 1
2 1251100-119093
Non-standard bolt M6×12 (environmental color) 2
3 1251100-120093
Non-standard bolts M6×16 (environmental color) 2
4MSE8.0 controller-ZT152MI (Euro 5) 1
5 1271200-204000 KD150 MSE8.0 Controller Bracket 1
7ABS ECU
1Main fuse 8lights fuse
2ECM 9Resrve
3ACC 10 Resrve
4ABS motor 11 Resrve
5Resrve 12 Resrve
6Resrve
PROCEDURE:
●Relay
Turn off the positive and negative.protective rubber caps (red for the positive and black for the negative) of the
starter relay⑴.Using 10#sleeve remove nuts then remove the positive and negative connectors, and screw the
nut back onto the relay stud to preventloss.Take off plug of the start relay and main hamess.
●ECU
After pressing the anti release buckle,rotate the ECU cable plug counterclockwise and pull it out.
Remove the bolt ⑵at the bottom of the frame with a 5# hexagon socket, and then remove the ECU assembly.
Using 5# inner hexagon socket remove 2pcs bolts⑶then take off the ECU⑷from the ECU bracket⑸.
CAUTION:
●The cushion and rear cover should be removed in advance.
●When Take off the plug can't drag any cable.
●Please refer tothe driver's manual for details about the related content ofthe EFI fault code. The latest electronic
version of the driver's manual can be downloaded from the corresponding model introduction page of the
official website.
Fig.3FRAME&ELECTRO
NIC COMPONENT Electronic parts COMPONENT 3
Start ABS Aided Other