Zontes ZT125-U User manual

ZT125/155-U/U1（EUROⅤ）
Service manual
2021/01/21

Page 1 ，Total 87 pages
Pages
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
rectifier
、
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
2FRAME & ENGINE COMBINATION
2.1
U Frame & engine combination……………………………………………………………………………………………………………………………………………………………………………………
14
Lower shroud bracket
、
engine
2.2
U1 Frame & engine combination 1…………………………………………………………………………………………………………………………………………………………………………………
15
Disassemble guard bar assembly
2.3
U1 Frame & engine combination 2…………………………………………………………………………………………………………………………………………………………………………………
16
Lower shroud bracket
、
engine
3INTAKE SYSTEM COMPONENT
3.1
Intake system component……………………………………………………………………………………………………………………………………………………………………………………………
17
Air filter filter,Carbon canister
3.2
Throttle valve body component……………………………………………………………………………………………………………………………………………………………………………………
18
Disassemble throttle valve body component
3.3
Replace air filter element……………………………………………………………………………………………………………………………………………………………………………………………
19
Contents
Table of Contents

Page 2 ，Total 87 pages
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Contents
Table of Contents
4REAR WHELL COMPONENT
4.1
U rear auxiliary mud board component 1…………………………………………………………………………………………………………………………………………………………………………
20
Disassemble rear auxiliary mud board component
4.2
U rear auxiliary mud board component 2…………………………………………………………………………………………………………………………………………………………………………
21
Disassemble rear auxiliary mud board component
4.3
U rear auxiliary mud board component 3…………………………………………………………………………………………………………………………………………………………………………
22
Disassemble rear auxiliary mud board,rear turn sinagl component
4.4
U1 rear mud board component 1……………………………………………………………………………………………………………………………………………………………………………………
23
Disassemble U1 rear fender component,rear fender bracket cover,rear fender bracket
4.5
U1 rear mud board component 2……………………………………………………………………………………………………………………………………………………………………………………
24
Disassemble rear mud board component,rear turn sinagl
4.6
Rear mud board……………………………………………………………………………………………………………………………………………………………………………………………………
25
4.7
Rear shock absorption………………………………………………………………………………………………………………………………………………………………………………………………
26
Demolition after shock absorption, rear shock absorption adjustment
4.8
Rear wheel component 1……………………………………………………………………………………………………………………………………………………………………………………………
27
Disassemble the rear rim component, sprocket seat, sprocket
4.9
Rear wheel component 2……………………………………………………………………………………………………………………………………………………………………………………………
28
Disassembled rear rim component
4.10
Rear fork component………………………………………………………………………………………………………………………………………………………………………………………………
29
Disassembled rear fork component
4.11
Replace the rear brake pads…………………………………………………………………………………………………………………………………………………………………………………………
30
4.12
Rear brake main pump adds brake fluid……………………………………………………………………………………………………………………………………………………………………………
31
5PEDAL COMPONENT
5.1
Pedal height adjustment……………………………………………………………………………………………………………………………………………………………………………………………
32
Shift lever, brake pedal height adjustment
5.2
Right footrest component-1…………………………………………………………………………………………………………………………………………………………………………………………
33
Disassemble the right foot support component
5.3
Right footrest component-2…………………………………………………………………………………………………………………………………………………………………………………………
34
Decomposition brake pedal component
5.4
Right footrest component-3…………………………………………………………………………………………………………………………………………………………………………………………
35
Disassemble the right pedal component
5.5
Left footrest component-1…………………………………………………………………………………………………………………………………………………………………………………………
36

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Table of Contents
Disassemble the left foot support component and the shift lever component
5.6
Left footrest component-2…………………………………………………………………………………………………………………………………………………………………………………………
37
Decomposition shift lever component, front left pedal component
5.7
Left footrest component-3…………………………………………………………………………………………………………………………………………………………………………………………
38
Disassemble the left footrest component
6COOLING SYSTEM COMPONENT
6.1
Change the oil and the oil filter……………………………………………………………………………………………………………………………………………………………………………………
39
6.2
Add coolant…………………………………………………………………………………………………………………………………………………………………………………………………………
40
6.3
Change coolant……………………………………………………………………………………………………………………………………………………………………………………………………
41
6.4
Water tank component 1……………………………………………………………………………………………………………………………………………………………………………………………
42
Disassemble the auxiliary water tank component,water pipe
6.5
Water tank component 2……………………………………………………………………………………………………………………………………………………………………………………………
43
Disassemble water tank component,water tank bracket
7FRONT FORK COMPONENT
7.1
Throttle/clutch cable clearance adjustment, light height adjustment………………………………………………………………………………………………………………………………………………
44
Adjust the throttle cable, clutch cable free travel; adjust the headlights light height
7.2
Replacement clutch cable……………………………………………………………………………………………………………………………………………………………………………………………
45
7.3
Replace the throttle cable……………………………………………………………………………………………………………………………………………………………………………………………
46
7.4
Steering adjustment…………………………………………………………………………………………………………………………………………………………………………………………………
47
Adjustment steering device
7.5
U1 hand guard cover component……………………………………………………………………………………………………………………………………………………………………………………
48
Disassemble U1 hand guard cover
7.6
Right hand component………………………………………………………………………………………………………………………………………………………………………………………………
49
Disassemble right hand component, right handle sub switch
7.7
Add brake fluid, rocker adjustment…………………………………………………………………………………………………………………………………………………………………………………
50
Add brake fluid, brake rocker adjustment
7.8
Replace the front brake pads………………………………………………………………………………………………………………………………………………………………………………………
51
7.9
Front wheel component……………………………………………………………………………………………………………………………………………………………………………………………
52
Disassemble the front wheel, front disc brake disc, front axle component
7.10
U front mud board & wheel speed sensor component………………………………………………………………………………………………………………………………………………………………
53
Disassemble front wheel speed sensor component, front mud plate component
7.11
U hood lower decorative cover……………………………………………………………………………………………………………………………………………………………………………………
54

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7.12
U1 front mud board & wheel speed sensor component……………………………………………………………………………………………………………………………………………………………
55
Disassemble front mud plate component
7.13
Head and headlights component……………………………………………………………………………………………………………………………………………………………………………………
56
Disassemble head and headlights component
7.14
Head and headlights component 1…………………………………………………………………………………………………………………………………………………………………………………
57
Disassemble front turn singal,headlights low bracket,windshield
7.15
Head and headlights component 2…………………………………………………………………………………………………………………………………………………………………………………
58
Disassemble headlights and position light
、
hood decorative cover
7.16
Headlights storage box component…………………………………………………………………………………………………………………………………………………………………………………
59
Disassemble the headlights storage box
、
the headlights upper bracket
7.17
Speedometer component……………………………………………………………………………………………………………………………………………………………………………………………
60
Disassemble speedometer and bracket
7.18
Left hand component………………………………………………………………………………………………………………………………………………………………………………………………
61
Disassemble left rear view mirror, left hand rubber sleeve, left switch
7.19
Directional lever component………………………………………………………………………………………………………………………………………………………………………………………
62
Disassemble directional lever
7.20
Front shock absorber, upper plate component………………………………………………………………………………………………………………………………………………………………………
63
Disassemble front shock absorber, headlight bracket, faucet lock, upper plate component
7.21
Uplink plate, direction handle block component……………………………………………………………………………………………………………………………………………………………………
64
Disassemble the direction of the block, the upper plate
7.22
ABS brake system-1………………………………………………………………………………………………………………………………………………………………………………………………
65
Disassemble the hydraulic control unit and bracket
7.23
ABS brake system-2………………………………………………………………………………………………………………………………………………………………………………………………
66
Releasing brake fluid,FMC tubing
7.24
ABS brake system-3………………………………………………………………………………………………………………………………………………………………………………………………
67
Disassemble FC tubing
7.25
ABS brake system-4………………………………………………………………………………………………………………………………………………………………………………………………
68
Disassemble RMC tubing,RC tubing
8FUEL TANK COMPONENT
8.1
Fuel tank component………………………………………………………………………………………………………………………………………………………………………………………………
69
Disassemble Fuel tank component
8.2
Tank middle cover component,fuel tank lock………………………………………………………………………………………………………………………………………………………………………
70
Decompose tank middle cover component

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8.3
Fuel tank cover component…………………………………………………………………………………………………………………………………………………………………………………………
71
Disassemble fuel tank cover component
8.4
Fuel tank decorative cover bottom plate component………………………………………………………………………………………………………………………………………………………………
72
Disassemble PKE
、
USB
8.5
Fuel tank cover component…………………………………………………………………………………………………………………………………………………………………………………………
73
Decompose fuel tank cover component
8.6
Fuel tank component………………………………………………………………………………………………………………………………………………………………………………………………
74
Disassemble fuel tank and fuel pump
9SURROUNDING COMPONENT
9.1
Surrounding component……………………………………………………………………………………………………………………………………………………………………………………………
75
Disassemble surrounding component
9.2
U surrounding component…………………………………………………………………………………………………………………………………………………………………………………………
76
Decompose U surrounding component
9.3
U1 surrounding component…………………………………………………………………………………………………………………………………………………………………………………………
77
Decompose U1 surrounding component
9.4
Surrounding bracket…………………………………………………………………………………………………………………………………………………………………………………………………
78
10 SIDE COVER COMPONENT
10.1
Side cover component………………………………………………………………………………………………………………………………………………………………………………………………
79
Decompose side cover component
11 REAR COVER COMPONENT
11.1
Rear cover component 1……………………………………………………………………………………………………………………………………………………………………………………………
80
Disassemble Rear cover component
11.2
Rear cover component 2……………………………………………………………………………………………………………………………………………………………………………………………
81
Disassemble rear cover
11.3
Skirt bottom part component 1……………………………………………………………………………………………………………………………………………………………………………………
82
Disassemble battery
、
tail skirt upper cover
11.4
Skirt bottom part component 2……………………………………………………………………………………………………………………………………………………………………………………
83
Disassemble battery bracket,tail light
12 CUSHION COMPONENT

Page 6 ，Total 87 pages
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Contents
Table of Contents
12.1
Rear cushion component……………………………………………………………………………………………………………………………………………………………………………………………
84
Discomponent and component rear cushion; seat cushion rubber separately purchased parts
12.2
Front cushion component……………………………………………………………………………………………………………………………………………………………………………………………
85
Discomponent and component front cushion; seat cushion rubber separately purchased parts
、
seat bracket
13 MUFFLER COMPONENT
13.1
Muffler component 1………………………………………………………………………………………………………………………………………………………………………………………………
86
Disassemble muffler component
13.2
Muffler component 2………………………………………………………………………………………………………………………………………………………………………………………………
87
Disassemble muffler decorative cover
©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 changes.For 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-U and KD150-U1 high-
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 1184200-103007
KD150-U (electrospray version) harness assembly 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 5 KH-1A4T
7 1184200-039000
ZT310-R flasher 1
8 1224100-037000 Grade 0 flame retardant tie (black 3.6×295)
10
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
Fig.1 FRAME&ELECTRONIC
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 binding⑻ or ⑾can be picked out by using scissors.
●Flasher and dump switch
Remove the flasher⑺,remove the rubber sleeve⑷ that 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.
●Additional buide block for motorcycles manufactrued after 21 October 2020.Early-produced motorcycles
can be purchased and installed on their own.
12 1224200-205000 ZT310 Electric seat lock guide block 1

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
5 1184100-012000 ZT250
－
S shut down switch 1
6 1250201-032093 GB818M5×16 (environmental color) 2
7 1184200-104007 ZT310 EFI ignition coil (with high voltage line) 1
Fig.2 FRAME&ELECTRONIC
COMPONENT Electronic parts COMPONENT-2
PROCEDURE：
●Horn
Take off the plug of horn, take the horn(⑴ by one hand use 8# sleeve remove bolts ⑵ by another hand,then
take off the horn⑴.
●Shut down switch
Find and take off the plug of the shut down switch⑸ , cut ribbon ⑶.Using 6# inner hexagon socket remove
2pcs bolts⑷ then take off shut down switch⑸.
●Ignition coil
Take off the plug of the ignition coil.Remove the crosshead bolts⑹ with 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 1184100-010000 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
4MSE6.0 controller 1
【
1
】
5 1271200-080000 KD150-U Bosch ECU bracket 1
1Main fuse 7ABS ECU
2ECM 8lights fuse
3ACC 9Resrve
4ABS motor 10 Resrve
5Resrve 11 Resrve
6Resrve 12 Resrve
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
Turn the ECU cable plug clockwise and unplug it. Remove the bolt ⑵ at the bottom of the frame with a 5#
hexagon socket, and then remove the ECU assembly.
Using 5# inner hexagon socket remove 2pcs bolts⑶ then take off the ECU⑷ from the ECU bracket⑸.
CAUTION：
●When Take off the plug can't drag any cable.
●【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.
●Please refer to the driver's manual for details about the related content of the 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.3 FRAME&ELECTRONIC
COMPONENT Electronic parts COMPONENT-3
Start ABS Aided Other

1-FRAME&ELECTRONIC COMPONENT 10
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
1 1184200-016000 ZT310 PKE Buzzer 1
2 1251112-003093 M6×45 Hex flange surface 9.8 bolt (color zinc) 2
3KD150-U rectifier shroud 1
4 1251700-146000 Bushing Φ12 × Φ6 × 26.5 (environmental color) 2
5 1181200-085000 KD150-U rectifier 1
6 1251112-002093 M6×30 Hexagon flange bolts (color zinc) 2
7KD150
－
U engine left rear cover 1
Fig.4 FRAME&ELECTRONIC
COMPONENT Electronic parts COMPONENT-4
PROCEDURE：
●PKE buzzer
Find and take off the PKE buzzer plug.Remove the PKE buzzer⑴ by heating it back and forth with a heat gun.
Clean up the remaining offset.
●Rectifier
Using 8#sleeve remove 2pcs bolts⑵,then take off the rectifier shroud⑶and bushing⑷.
Find and take off the rectifier plug,then take off the rectifier⑸.
●Engine left rear cover
Using 8#sleeve remove 2pcs bolts⑹,then take off the engine left rear cover⑺.
CAUTION：
●When Take off the plug can't drag any cable.

1-FRAME&ELECTRONIC COMPONENT 11
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
1 1241200-044000 KD150-U fuel tank liner limit glue 2
2
1240300-007000 HJ125－6 Battery rubber gasket 1
3
1244100-002000 ZT250－S Side cover round rubber 4
4 1240100-023000 Battery anode protection glue 1
5 1244100-061000 ZT250 anti-water rubber of frame 6
6
1251112-001093 M6×16 Hexagon flange bolts (color zinc)
1
7 1221200-058000 KD150-U clamp 1
Fig.5FRAME&ELECTRONIC
PARTS COMPONENT Frame plastic parts
PROCEDURE：
●Fuel tank liner limit glue
Push out the fuel tank liner limit glues⑴ then take off.
●Battery cushion
Put off the battery cushion ⑵directly by hand.
●Side cover cushion
Remove the side cover cushion⑶with your hand directly.
●Battery anode protection glue
Put off the battery anode protection glue ⑷directly by hand.
●Frame waterproof rubber plug
Remove the 6pcs frame waterproof rubber plugs ⑸with your hand directly.
●Clamp
First,take the throttle line off the clamp; hold the clamp by one hand,use 8# sleeve remove bolt⑹ by another
hand，take off clamp⑺.
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.

1-FRAME&ELECTRONIC COMPONENT 12
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
1 1134100-007000 ZT250－S Adjusting nut locking washer 1
3 1244100-015000 ZT250－S Adjusting nut rubber pad 1
4
1224100-005000 Steering stem dust cap (Up) 1
5
1130900-024000 Upper bead top 1
6
1130900-022000 Upper connect iron ball 2
8
1224100-006000 steering stem dust cap(down) 1
【
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 on official website, 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 ⑸ and the dustproof cover ⑻.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.
●【1】the down connected plate (selfmade/with blowout patch) component⑺, has been contains the Steering
column down dustproof cover⑻.
2
PROCEDURE:
●Dissembly
Remove the lock washer⑴.
Remove the top adjusting nut ⑵ by using a hook wrench tools.
Remove the rubber pad ⑶.
With one hand to hold down the down connected plate assembly ⑺, the other hand use a special four-
jaw set or hook wrench to remove the adjusting nut⑵.
Remove the upper dustproof cover⑷.
Remove the down connected plate component⑺.
Remove the axletee ring ⑸ of the upper riser and the steel ball⑹.
Remove the down connected plate component⑺.
Remove the steel ball of the down connected plate component⑺.
●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 ⑶ from deformation too larg.
1
2
Fig.6 FRAME&ELECTRONIC
COMPONENT Directional column component
7 1134100-015000 ZT250－S lower connection borad(self made/with ball
head) assembly
1251300-046093 Direction column adjusting screw nut M24X1
(environmental color zinc)

1-FRAME&ELECTRONIC COMPONENT 13
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
2
1130900-026000 ZT250
－
S upper steel bowl 2after sales
3 1251300-057093
Non-standard nut M10×1.5
（
dacromet
）
1
4 1251700-025091
ZT250
－
S side stand sleeve 1
5Side support 1
6 1251100-088094
Non-standard nut M10×1.5×43
（
dacromet
）
1
7 1264100-001000
ZT250
－
S side stand spring 1
PROCEDURE：
●Checking the cushion loop
Checking whether the cushion loop ⑵ is frayed, if as it, please replace it. Fix the cushion loop well and paint
the lubricating grease on it with appropriate tool.
●Sider support
Using the cross screwdriver to remove the side support spring⑺, and guard against the personal injury caused
by spring contraction, use 14#sleeve or plum blossom wrench remove the nuts ⑶ and then remove bolts ⑸ .
Remove the side support ⑸ and bush⑷, paint the lubricating grease on the bush⑷ when 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.
Fig.7 FRAME&ELECTRONIC
COMPONENT Frame, side bracket
11 Frame after-sales component(contains fix loop and
nameplate)

2-FRAME & ENGINE COMBINATION 14
CHK
ADJ
NO. PART NO. PART NAME QTY CAUTION
1 1251112-003093 M6×45 Hex flange surface 9.8 bolt (color zinc) 2
2 1271200-073000 KD150-U left lower bracket，surrounds cover 1
3 1271200-071000 KD150-U surrounding right lower bracket 1
4 1251112-002093 M6×30 Hexagon flange bolts (color zinc) 2
5 1250105-017091 GB5789 M8×65(zinc) 3
6 4021200-030000 KD150－U frame left hanging piece 1
7 4021200-031000 KD150－U frame right hanging piece 1
8 1250305-002091 GB6187.1 M8（White zinc）3
9 4021200-029000 KD150－U frame bracket 1
10 1251100-085093 Non-standard bolt M10×1.5×75（dacromet）4
11 1252200-068000 KD150－U rear flat fork hollow shaft 1
12 1251300-057093 Non-standard nut M10×1.5（dacromet）5
13 1251100-086093 Non-standard bolt M10×1.5×112 1
14 1251300-067000 ZT250－R rear wheel hollow shaft nut 1
Fig.1 FRAME & ENGINE
COMBINATION U Frame & engine combination
The engine hang has not been removed
The engine hang has been remove
After removeing the upper suspension
hole of the enging,the corresponding left
and right hangning piece switch to a new
state and reduce 1 pcs bolt⑸ and nut⑻.
PROCEDURE:
●Shroud bracket
Using 8# sleeve remove 2pcs bolts⑴ then take off the bracket⑵,remove 2pcs bolts⑷ then take off the bracket
⑶Reassemble the bolts to the engine after removing the bracket to prevent oil leakage.
●Hanging piece
First use a 12# sleeve to cover the head of the bolt ⑸, then use a 12# sleeve to remove the nut ⑻, the bolt ⑸,
the upper right hanging piece ⑺ and the upper left hanging piece ⑹.
●Bracket, Engine hanger
First use a 14# sleeve to cover the head of the bolt ⑽ at the bracket, and then use a 14# sleeve to remove the
nut ⑿ without removing the boltt ⑽ and bracket ⑼.
Use a 14# sleeve to cover the head of the bolt ⒀ at the bottom of the engine, and then use a 14# sleeve to
remove the nut ⑿ without removing the bolt ⒀.
Fix the head of the rear fork shaft ⑾ with a tool, and then use a 30# sleeve to remove the nut ⒁, take off the
rear fork shaft ⑾ and then remove the rear flat fork shaft ⑾ and press down the rear fork assembly away from
the engine.
Two people hold the left and right boxes of the engine at the same time; one person removes the 4 bolts ⑽
and the bottom bolt ⒀, and the bracket ⑼.
Support the engine to shift to one side, and pay attention to safety during the movement. Put the engine flat on
the ground.
CAUTION:
●The waste oil needs to be collected and returned to qualified institutions. It is forbidden to dump and
pollute the environment and the source of water.Please pay attention to safety to prevent accident.

2-FRAME & ENGINE COMBINATION 15
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
1
1244100-061000 ZT250 anti-water rubber of frame 2
2
1251100-142000 Non-standard hexagon socket bolt M10 × 1.5 × 130 2
3
1244100-089000 ZT250-R guard bar anti-drop glue 2
4
KD150
－
U left Guard Bar 1
5
1251112-001093 M6×16 Hexagon flange bolts (color zinc) 4
6
1241200-056000 KD150
－
U upgraded version of protective rubber 2
7
4024200-027000 ZT310-T frame protection bar pressure plate 1
8
KD150
－
U Right Guard Bar 1
9
KD150
－
U Guard bar left inside bracket 1
10
1251100-060000 Non-standard bolts M10X1.5X90
（
dacromet
）
2
11
1251300-057093 Non-standard nut M10×1.5
（
dacromet
）
3 65±5N.m
12
4021200-021000 KD150
－
U guard bar lower bracket 1
13
1251100-132003 Non-standard bolt M10×1.5×80
（
dacromet
）
1
14
KD150
－
U Guard bar right inside bracket 1
15
1250305-002091 GB6187.1 M8
（
White zinc
）
2
16
1250105-042091 GB5789M8 × 75 (level 10.9 / white zinc) 2
CAUTION:
●When reinstalling, please press down
the lower bracket of the crash bar to the
end and then tighten the fasteners.
Assemble the inner crash bar bracket and
the lower crash bar bracket first, and then
assemble the surrounding.
●When reassembling the crash bar,
install the crash bar protective glue first
and then clip it into the groove of the
lower guard bar bracket and then
assemble it to the inner crash bar bracket;
finally, assemble the guard bar pressure
plate.
Fig.2 FRAME & ENGINE
COMBINATION U1 Frame & engine combination 1
PROCEDURE:
●Frame protection bar pressure plate
Using 8# sleeve remove 4pcs bolts⑸,take off the frame protection bar pressure plate⑺.
●Guard bar component
Take off rubber⑴.
Grasp the left crash bar assembly firmly, and use 8# inner hexagon to remove the hexagon socket bolt (2); take
off the left crash bar assembly and the glue (3).
Remove the protective rubber ⑹ from the left crash bar ⑷.
Refer to the above steps to remove the right crash bar ⑻.
●Lower bracket
First remove the seat cushion, fuel tank assembly, surrounding assembly and side cover, and then use the 14#
sleeve to fix the head of the bolt ⒀, then use the 14# sleeve to remove the nut ⑾, grasp the lower bracket of the
guard ⑿ and then remove the bolt ⒀after, remove the lower bracket of the guard bar ⑿.
●Crash car assembly
One person grasps the left crash bar inner bracket ⑼ and fixes the 2 bolts ⑽ at the bracket with a 14# sleeve and
fixes the bolt ⒃ head on the upper part of the crash bar with a 12# sleeve, and the other holds the right crash bar.
After support ⒁, use 14# sleeve to remove nut ⑾ and 12# sleeve to remove nut ⒂. After removing bolts ⑽ and
⒃, remove the inner support of the guard bar and place it.

2-FRAME & ENGINE COMBINATION 16
CHK
ADJ
NO. PART NO. PART NAME QTY CAUTION
1 1251112-003093 M6×45 Hex flange surface 9.8 bolt (color zinc) 2
2 1271200-073000 KD150-U left lower bracket，surrounds cover 1
3 1271200-071000 KD150-U surrounding right lower bracket 1
4 1251112-002093 M6×30 Hexagon flange bolts (color zinc) 2
5 1250105-017091 GB5789 M8×65(zinc) 3
6 4021200-030000 KD150－U frame left hanging piece 1
7 4021200-031000 KD150－U frame right hanging piece 1
8 1250305-002091 GB6187.1 M8（White zinc）3
9 4021200-029000 KD150－U frame bracket 1
10 1251100-085093 Non-standard bolt M10×1.5×75（dacromet）2
11 1252200-068000 KD150－U rear flat fork hollow shaft 1
12 1251300-057093 Non-standard nut M10×1.5（dacromet）3 65±5N.m
13 1251100-086093 Non-standard bolt M10×1.5×112（dacromet）1
14 1251300-067000 ZT250－R rear wheel hollow shaft nut 1
The engine hang has been remove
After removeing the upper suspension
hole of the enging,the corresponding left
and right hangning piece switch to a new
state and reduce 1 pcs bolt⑸ and nut⑻.
The engine hang has not been removed
Fig.3 FRAME & ENGINE
COMBINATION U1 Frame & engine combination 2
PROCEDURE:
●Shroud bracket
Using 8# sleeve remove 2pcs bolts⑴ then take off the bracket⑵,remove 2pcs bolts⑷ then take off the bracket
⑶Reassemble the bolts to the engine after removing the bracket to prevent oil leakage.
●Hanging piece
First use a 12# sleeve to cover the head of the bolt ⑸, then use a 12# sleeve to remove the nut ⑻, remove the
bolt ⑸, the upper right hanging piece ⑺ and the upper left hanging piece ⑹.
●Bracket, Engine hanger
First use a 14# sleeve to cover the head of the bolt ⑽ at the bracket, and then use a 14# sleeve to remove the nut
⑿without removing the bolt and bracket ⑼.
Use a 14# sleeve to cover the head of the bolt ⒀ at the bottom of the engine, and then use a 14# sleeve to remove
the nut ⑿ without removing the bolt ⒀.
Fix the head of the rear fork shaft ⑾ with a tool, and then use a 30# sleeve to remove the nut ⒁, take off the
rear fork shaft ⑾ and then remove the rear flat fork shaft ⑾ and press down the rear fork assembly away from
the engine.
Two people hold the left and right boxes of the engine at the same time; one person removes the 3 bolts ⑸ ,the
right hanging piece⑺,the left hanging piece⑹, and the bottom bolt ⒀.
Support the engine to shift to one side, and pay attention to safety during the movement. Put the engine flat on
the ground.
CAUTION:
●Using appropriate tools to support the motorcycle to prevent motorcycle dumping during disassembly.
Single operation is forbidden.

3-INTAKE SYSTEM COMPONENT 17
CHK
ADJ
NO. PART NO. PART NAME QTY CAUTION
1 1051356-012000 φ42 × 10 pipe hoop assembly 1
2 1050954-009000 YH canister solenoid valve 1
3 1250303-010093 GB6177.1M6（color zinc ）1
4 1221200-055000 KD150-U carbon canister (EFI) 1
5 1221200-033000 KD125-U air filter 1
6 1246200-041000 KD150-U oil and gas separator intake pipe 1
8 1246200-042000 KD150-U oil and gas separator outlet pipe 1
9 1224100-037000 Grade 0 flame retardant tie (black 3.6×295) 1
10 1251100-101000 Non-standard bolt M6×12 (304 stainless steel) 3
11 1251300-063093 Plywood M6×11×15（color zinc）3
12 1051754-001000 1.0 × 5.5 × 6 over－oil pin 1
Fig.1 INDUCTION
SYSTEM COMPONENT Intake system component
1221200-124000 KD150-U external oil and gas separator (no filter
element) assembly 17
PROCEDURE:
●Air filter
First pull out the oil pipe ③ connecting the carbon canister to the fuel tank from the oil tank, and unplug the oil
pipe ① connecting the carbon canister to the solenoid valve and the oil pipe ② connecting the solenoid valve to
the throttle body respectively.
Remove the side cover, seat cushion, rear shock absorber, rear tail skirt, etc. to facilitate subsequent
disassembly of the air filter and throttle body.
First use 4# inner hexagon to remove the 3 bolts ⑽ on both sides of the frame.
Loosen the hose clamp assembly ⑴ at 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 clamp on the exhaust pipe ④ and unplug the exhaust pipe connected to the exhaust port
of the engine, 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 3pcs plywood⑾ from the air filter⑸,remove the carbon canister⑷ from the air filter⑸.
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.
●The 2 oil pipes of the canister solenoid valve cannot be connected wrongly.
●Attention when disassembling the clamp.
●It should be no crimp, entanglement and other phenomena.
Increase in mid-
november 2020

3-INTAKE SYSTEM COMPONENT 18
CHK
ADJ
NO. PART NO. PART NAME QTY CAUTION
1 1251112-001093 M6×16 Hexagon flange bolts (color zinc) 2
2 1050956-006000 KD150-U EFI High Pressure Tubing Sub-assembly 1
3 1051468-007000 31.8×2 fluorine rubber O-ring 1
4Intake manifold assembly 1
5 1051356-010000 Φ45×10 pipe clamp assembly 1
6Throttle body assembly 1
7 1050968-003000 EV14 injector G06 1
8 1050968-002000 ZT1P58MJ injector holder 1
9 1250105-138093 GB5789M6×20 (environmental color) 1
10 1050956-005000 DLA-mini stepless motor 5mm 1
11 1050954-024000 CTS three-in-one sensor 1
PROCEDURE:
●High-pressure oil pipe
Press the anti-trip buckle on the high-pressure fuel pipe ⑵ and then connect the oil pan to contain the remaining
fuel. Be careful not to let the fuel drip onto the bike body.Pay attention to protect the oil pump outlet pipe at the
arrow point
●Throttle valve body assembly
Unplug the connector of the throttle valve body, remove the throttle cable and use an 8# wrench to remove the
2 bolts (1) Remove the throttle valve body assembly.
Remove the O-ring ⑶, check carefully for damage before reinstalling.
Use a 10# sleeve to remove the bolt ⑼ and then remove the retainer ⑻, and remove the fuel injector ⑺.
After loosening the clamp ⑸, remove the throttle valve body assembly ⑹, and then remove the clamp ⑸.
●Throttle valve body after-sales parts
Throttle valve body assembly already contains stepper motor ⑽ and sensor ⑾. Remove the 2 bolts and then
remove the clip, and then remove the stepping motor ⑽; then remove the 2 bolts that fix the sensor to remove the
sensor ⑾.
CAUTION:
●First it need to remove the cushion,side cover,oil tank outside cover and liner,rear shock absorber and
electrical device box etc.
●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.
after-sales
Fig.2 INDUCTION
SYSTEM COMPONENT Throttle valve body component

3-INTAKE SYSTEM COMPONENT 19
CHK
ADJ
NO. PART NO. PART NAME QTY CAUTION
1KD125－U air filter element
1
Fig.3 INDUCTION
SYSTEM COMPONENT Replace air filter element
ROCEDURE:
●Filter element
If you need to maintain the filter element of the air filter, remove the seat cushion, the right side cover Take the
two standard parts ① out of air filter with the tool, dismantle the box cover ②.Grasp the rubber strips on the
filter (both sides shown in yellow) and pull the filter element ⑴ 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 pipe③ and water pipe④ 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.