Zontes ZT125-Z2 User manual

2021/1/6
ZT125/155-Z2（EURO V）
Service manual

Page 1 ，Total 75 pages
Pages
0
Table of Contents……………………………………………………………………………………………………………………………………………………………………………………
1
1FRAME&ELECTRONIC COMPONENT
1.1
Electrical device component-1…………………………………………………………………………………………………………………………………………………………………………
6
Main harness, dump switch, relay, flasher
1.2
Electrical device component-2…………………………………………………………………………………………………………………………………………………………………………
7
Flameout switch, horn,ignition coil
1.3
Electrical device component-3…………………………………………………………………………………………………………………………………………………………………………
8
ECU
、
relay
1.4
Electrical device component-4…………………………………………………………………………………………………………………………………………………………………………
9
rectifier
、
Buzzer
1.5
Frame plastic parts……………………………………………………………………………………………………………………………………………………………………………………
10
Line clamp, side cover round glue, fuel tank liner limit glue
1.6
Directional column component…………………………………………………………………………………………………………………………………………………………………………
11
Lower plate component
1.7
Frame, side bracket……………………………………………………………………………………………………………………………………………………………………………………
12
2FRAME & ENGINE COMBINATION
2.1
Frame & engine combination 1…………………………………………………………………………………………………………………………………………………………………………
13
Disassemble guard bar assembly
2.2
Frame & engine combination 2…………………………………………………………………………………………………………………………………………………………………………
14
Lower shroud bracket
、
engine
3INTAKE SYSTEM COMPONENT
3.1
Intake system component………………………………………………………………………………………………………………………………………………………………………………
15
Air filter filter,Carbon canister
3.2
Throttle valve body component…………………………………………………………………………………………………………………………………………………………………………
16
Disassemble throttle valve body component
3.3
Replace air filter element………………………………………………………………………………………………………………………………………………………………………………
17
4REAR WHELL COMPONENT
4.1
Rear mud board………………………………………………………………………………………………………………………………………………………………………………………
18
Rear mud board
Contents
Table of Contents

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Contents
Table of Contents
4.2
Rear shock absorption…………………………………………………………………………………………………………………………………………………………………………………
19
Demolition after shock absorption, rear shock absorption adjustment
4.3
Rear wheel component 1………………………………………………………………………………………………………………………………………………………………………………
20
Disassemble the rear rim component, sprocket seat, sprocket
4.4
Rear wheel component 2………………………………………………………………………………………………………………………………………………………………………………
21
Disassembled rear rim component
4.5
Rear fork component…………………………………………………………………………………………………………………………………………………………………………………
22
Disassembled rear fork component
4.6
Replace the rear brake pads……………………………………………………………………………………………………………………………………………………………………………
23
4.7
Rear brake main pump adds brake fluid………………………………………………………………………………………………………………………………………………………………
24
5PEDAL COMPONENT
5.1
Pedal height adjustment………………………………………………………………………………………………………………………………………………………………………………
25
Shift lever, brake pedal height adjustment
5.2
Right footrest component-1……………………………………………………………………………………………………………………………………………………………………………
26
Disassemble the right foot support component
5.3
Right footrest component-2……………………………………………………………………………………………………………………………………………………………………………
27
Decomposition brake pedal component
5.4
Right footrest component-3……………………………………………………………………………………………………………………………………………………………………………
28
Disassemble the right pedal component
5.5
Left footrest component-1………………………………………………………………………………………………………………………………………………………………………………
29
Disassemble the left foot support component and the shift lever component
5.6
Left footrest component-2………………………………………………………………………………………………………………………………………………………………………………
30
Decomposition shift lever component, front left pedal component
5.7
Left footrest component-3………………………………………………………………………………………………………………………………………………………………………………
31
Disassemble the left footrest component
6COOLING SYSTEM COMPONENT
6.1
Change the oil and the oil filter…………………………………………………………………………………………………………………………………………………………………………
32
6.2
Add coolant……………………………………………………………………………………………………………………………………………………………………………………………
33
6.3
Change coolant…………………………………………………………………………………………………………………………………………………………………………………………
34
6.4
Water tank component 1………………………………………………………………………………………………………………………………………………………………………………
35
Disassemble the auxiliary water tank component,water pipe
6.5
Water tank component 2………………………………………………………………………………………………………………………………………………………………………………
36

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Contents
Table of Contents
Disassemble water tank component,water tank bracket
7FRONT FORK COMPONENT
7.1
Throttle/clutch cable clearance adjustment, light height adjustment……………………………………………………………………………………………………………………………………
37
7.2
Replacement clutch cable………………………………………………………………………………………………………………………………………………………………………………
38
7.3
Replace the throttle cable………………………………………………………………………………………………………………………………………………………………………………
39
7.4
Steering adjustment……………………………………………………………………………………………………………………………………………………………………………………
40
7.5
Right hand component…………………………………………………………………………………………………………………………………………………………………………………
41
Remove right rear view mirror, right hand rubber sleeve, balance block
7.6
Add brake fluid, rocker adjustment……………………………………………………………………………………………………………………………………………………………………
42
7.7
Replace the front brake pads……………………………………………………………………………………………………………………………………………………………………………
43
7.8
Front wheel component…………………………………………………………………………………………………………………………………………………………………………………
44
Disassemble the front wheel, front disc brake disc, front axle component
7.9
Front mud board & wheel speed sensor component……………………………………………………………………………………………………………………………………………………
45
Disassemble front wheel speed sensor component, front mud plate component
7.10
Head and headlights component 1……………………………………………………………………………………………………………………………………………………………………
46
Remove the headlight
7.11
Head and headlights component 2……………………………………………………………………………………………………………………………………………………………………
47
Disassemble headlight component
7.12
Head and headlights component 3……………………………………………………………………………………………………………………………………………………………………
48
Disassemble headlight bracket,head cover rear shell
7.13
Speedometer component………………………………………………………………………………………………………………………………………………………………………………
49
Disassemble speedometer and bracket
7.14
Left hand component…………………………………………………………………………………………………………………………………………………………………………………
50
Disassemble left rear view mirror, left hand rubber sleeve, left switch
7.15
Directional lever component……………………………………………………………………………………………………………………………………………………………………………
51
Disassemble directional lever
7.16
Front shock absorber, upper plate component…………………………………………………………………………………………………………………………………………………………
52
Disassemble front shock absorber, headlight bracket, faucet lock, upper plate component
7.17
Uplink plate, direction handle block component………………………………………………………………………………………………………………………………………………………
53
Disassemble the direction of the block, the upper plate
7.18
ABS brake system-1……………………………………………………………………………………………………………………………………………………………………………………
54
Disassemble the hydraulic control unit and bracket
7.19
ABS brake system-2……………………………………………………………………………………………………………………………………………………………………………………
55

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Releasing brake fluid,FMC tubing
7.20
ABS brake system-3……………………………………………………………………………………………………………………………………………………………………………………
56
Disassemble FC tubing
7.21
ABS brake system-4……………………………………………………………………………………………………………………………………………………………………………………
57
Disassemble RMC tubing,RC tubing
8FUEL TANK COMPONENT
8.1
Fuel tank component……………………………………………………………………………………………………………………………………………………………………………………
58
Disassemble Fuel tank component
8.2
Fuel tank cover component 1…………………………………………………………………………………………………………………………………………………………………………
59
Disassemble fuel tank cover component
8.3
Fuel tank cover component 2…………………………………………………………………………………………………………………………………………………………………………
60
Disassemble fuel tank cover component
8.4
Fuel tank cover component 3…………………………………………………………………………………………………………………………………………………………………………
61
Disassemble fuel tank cover component
8.5
Fuel tank component……………………………………………………………………………………………………………………………………………………………………………………
62
Disassemble fuel tank and fuel pump
9SURROUNDING COMPONENT
9.1
Surrounding component………………………………………………………………………………………………………………………………………………………………………………
63
Disassemble surrounding component
10 SIDE COVER COMPONENT
10.1
Side cover component 1………………………………………………………………………………………………………………………………………………………………………………
64
Decompose side cover component
10.2
Side cover component 2………………………………………………………………………………………………………………………………………………………………………………
65
Decompose side cover component
11 REAR COVER COMPONENT
11.1
Rear cover component …………………………………………………………………………………………………………………………………………………………………………………
66
Disassemble Rear cover component
11.2
Rear armrests and shelf components……………………………………………………………………………………………………………………………………………………………………
67
Disassemble rear armrests and shelf components
11.3
Tail light component……………………………………………………………………………………………………………………………………………………………………………………
68

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Table of Contents
Disassemble the taillight component
11.4
Rear mud board component 1…………………………………………………………………………………………………………………………………………………………………………
69
Disassemble rear fender component,rear fender bracket cover,rear fender bracket
11.5
Rear mud board component 2…………………………………………………………………………………………………………………………………………………………………………
70
Disassemble rear mud board component,rear turn sinagl
11.6
Battery component(colliod battery)……………………………………………………………………………………………………………………………………………………………………
71
Disassemble battery ,electric device box cover
11.7
Battery component……………………………………………………………………………………………………………………………………………………………………………………
72
Disassemble battery
、
Wake-up switch and charging precautions
12 CUSHION COMPONENT
12.1
Cushion…………………………………………………………………………………………………………………………………………………………………………………………………
73
Discomponent and component cushion; seat cushion rubber separately purchased parts
13 MUFFLER COMPONENT
13.1
Muffler component 1…………………………………………………………………………………………………………………………………………………………………………………
74
Disassemble muffler component
13.2
Muffler component 2…………………………………………………………………………………………………………………………………………………………………………………
75
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 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-Z2 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 6
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
1 1181200-106000
KD150
－
Z2 wiring 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 6 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
1224200-205000 ZT310 Electric seat lock guide block
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.
Fig.1 FRAME&ELECTRONIC
COMPONENT Electronic parts COMPONENT 1

1-FRAME&ELECTRONIC COMPONENT 7
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 8
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
Fig.3 FRAME&ELECTRONIC
COMPONENT Electronic parts COMPONENT 3
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.
Start ABS Aided Other

1-FRAME&ELECTRONIC COMPONENT 9
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
1 1184200-039000 ZT310-R flasher 1
2 1251112-003093 M6×45 Hex flange surface 9.8 bolt (color zinc) 2
3KD150-U rectifier shroud 1
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
PROCEDURE：
●Flasher
Find and take off the flasher.
●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.
Fig.4 FRAME&ELECTRONIC
COMPONENT Electronic parts COMPONENT 4
4 1251700-146000 Bushing Φ12 × Φ6 × 26.5 (environmental protection
color) 2