Zontes ZT250-R User manual

ZT250-R（EURO/IV）
2021/03/01
Service manual

Page1,Toatal 75 pages
Page
0
Table of Contents ………………………………………………………………………………………………………………………………………………………………………………………………
1
1FRAME&ELECTRONIC COMPONENT
1.1
Electronic parts component-1……………………………………………………………………………………………………………………………………………………………………………………
6
Main wire harnessk,Dump switch,Relay,Flasher,Rectifier,Ignition coil
1.2
Electronic parts component-2……………………………………………………………………………………………………………………………………………………………………………………
7
Shut-off switch,Horn
1.3
Frame plastic parts…………………………………………………………………………………………………………………………………………………………………………………………………
8
Tuck loop,side cover circle rubber cushion,inner fuel tank fix rubber cushion
1.4
Steering rack component…………………………………………………………………………………………………………………………………………………………………………………………
9
Down connected plate
1.5
Frame,Side support,the operation of releasing engine oil…………………………………………………………………………………………………………………………………………………………
10
Side support,Frame drain bolt assembly
1.6
Rear pedal component……………………………………………………………………………………………………………………………………………………………………………………………
11
Rear pedal component
2FRAME&ENGINE COMPONENT
2.1
Frame&engine component…………………………………………………………………………………………………………………………………………………………………………………………
12
Hanging piece,Bracket,Sprocket cover
3INDUCTION SYSTEM COMPONENT
3.1
Induction system component………………………………………………………………………………………………………………………………………………………………………………………
13
Throttle body module,Air filter,Oil pipe
3.2
Carbon Tank component…………………………………………………………………………………………………………………………………………………………………………………………
14
Carbon Tank ,Carbon Tank solenoid valve
3.3
Replace the air filter element………………………………………………………………………………………………………………………………………………………………………………………
15
4REAR FORKLIFT COMPONENT
4.1
Rear sub mudguard component 1…………………………………………………………………………………………………………………………………………………………………………………
16
Dismantled rear sub mudguard component
4.2
Rear sub mudguard component 2…………………………………………………………………………………………………………………………………………………………………………………
17
Sub-mud holder component after discomponent
4.3
Rear sub mudguard component 3…………………………………………………………………………………………………………………………………………………………………………………
18
CONTENTS
Table of Contents

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Sub-mud component after discomponent
4.4
Rear turn signal after sale parts……………………………………………………………………………………………………………………………………………………………………………………
19
Rear left and right turn signals and rear license plate lights for sale
4.5
Rear mud board……………………………………………………………………………………………………………………………………………………………………………………………………
20
4.6
Rear shock absorption……………………………………………………………………………………………………………………………………………………………………………………………
21
Demolition after shock absorption, rear shock absorption adjustment
4.7
Rear wheel component 1…………………………………………………………………………………………………………………………………………………………………………………………
22
Remove the rear rim component, sprocket seat, sprocket
4.8
Rear wheel component 2…………………………………………………………………………………………………………………………………………………………………………………………
23
Decomposed rear rim component
4.9
Rear fork component………………………………………………………………………………………………………………………………………………………………………………………………
24
Decomposed flat fork component
4.10
Replace the rear brake pads………………………………………………………………………………………………………………………………………………………………………………………
25
4.11
Rear brake main pump adds brake fluid…………………………………………………………………………………………………………………………………………………………………………
26
5PEDAL COMPONENT
5.1
Pedal height adjustment……………………………………………………………………………………………………………………………………………………………………………………………
27
Shift lever, brake pedal height adjustment
5.2
Right pedal support component-1…………………………………………………………………………………………………………………………………………………………………………………
28
Dismantled right pedel support componet
5.3
Right pedal support component-2…………………………………………………………………………………………………………………………………………………………………………………
29
Dismantled the right pedel support componet
5.4
Left pedal support component-1…………………………………………………………………………………………………………………………………………………………………………………
30
Dismantled left pedel support componet
5.5
Left pedal support component-2…………………………………………………………………………………………………………………………………………………………………………………
31
Dismantled the left pedel support componet
6RADIATOR SYSTEM COMPONENT
6.1
Release the engine oil……………………………………………………………………………………………………………………………………………………………………………………………
32
6.2
The oil pipe near the frame………………………………………………………………………………………………………………………………………………………………………………………
33
Dismantled the oil pipe near the frame
6.3
Radiator component-1……………………………………………………………………………………………………………………………………………………………………………………………
34
Dismantled the radiaor component
6.4
Radiator component-2……………………………………………………………………………………………………………………………………………………………………………………………
35

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Decomposition of the radiaor component
7FRONT FORK COMPONENT
7.1
Throttle/clutch cable clearance adjustment………………………………………………………………………………………………………………………………………………………………………
36
Adjust the throttle line, clutch cable free travel
7.2
Replacement clutch cable…………………………………………………………………………………………………………………………………………………………………………………………
37
7.3
Replace the throttle line……………………………………………………………………………………………………………………………………………………………………………………………
38
7.4
Steering adjustment………………………………………………………………………………………………………………………………………………………………………………………………
39
Adiust steering device
7.5
Add brake fluid,adjust the swing arm……………………………………………………………………………………………………………………………………………………………………………
40
Add brake fluid,adjust the brake swing arm
7.6
Replace front brake block…………………………………………………………………………………………………………………………………………………………………………………………
41
7.7 Meter function description………………………………………………………………………………………………………………………………… 42
7.8
Front tire component………………………………………………………………………………………………………………………………………………………………………………………………
43
Dismantled the front tire component
7.9
Front tire wheel speed sensor component…………………………………………………………………………………………………………………………………………………………………………
44
Dismantled the front tire wheel speed sensor component
7.10
Head parts component-1…………………………………………………………………………………………………………………………………………………………………………………………
45
Dismantled head parts component
7.11
Head parts component-2…………………………………………………………………………………………………………………………………………………………………………………………
46
Dismantled the front turning light and head light rear cover
7.12
Head cover upper parts component………………………………………………………………………………………………………………………………………………………………………………
47
7.13 Head light component ………………………………………………………………………………………………………………………………… 48
7.14
Meter component…………………………………………………………………………………………………………………………………………………………………………………………………
49
Remove the instrument and instrument support
7.15
Left handle component……………………………………………………………………………………………………………………………………………………………………………………………
50
Remove rear left view mirror
、
Left hand rubber sleeve
、
Left hand rocker
、
Left switch
7.16
Right hand component……………………………………………………………………………………………………………………………………………………………………………………………
51
Remove right rear view mirror, right hand rubber sleeve, balance block
7.17
Handle bar ,upper connected plate component……………………………………………………………………………………………………………………………………………………………………
52
Decomposition direction handle, pressure block, upper link plate, combination lock, front left and right shock absorption
7.18
Uplink plate, direction handle block component…………………………………………………………………………………………………………………………………………………………………
53
Disassemble the direction of the block, the upper plate
7.19
ABS brake system-1………………………………………………………………………………………………………………………………………………………………………………………………
54

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Dismantled the front brake calipers and ABS protection cover
7.20
ABS brake system-2………………………………………………………………………………………………………………………………………………………………………………………………
55
Dismantled the ABS control system component and the main pumb of disc brake
7.21
ABS brake system-3………………………………………………………………………………………………………………………………………………………………………………………………
56
Dismantled the rear brake calipers and discomposed the ABS control system component
8
8、FUEL TANK COMPONENT
8.1
Inner fuel tank component…………………………………………………………………………………………………………………………………………………………………………………………
57
Dismantled inner fuel tank component and cushion fixed block
8.2
Fuel tank middle cover assembly…………………………………………………………………………………………………………………………………………………………………………………
58
Dismantled Fuel tank middle cover assembly
8.3
Fuel tank middle cover
、
Fuel tank cover
、
Fuel tank lock………………………………………………………………………………………………………………………………………………………
59
Dismantled Fuel tank middle cover、Fuel tank cover、Fuel tank lock
8.4
Fuel tank left and right cover assembly……………………………………………………………………………………………………………………………………………………………………………
60
Dismantled Fuel tank left and right cover assembly
8.5
Inner fuel tank……………………………………………………………………………………………………………………………………………………………………………………………………
61
Dismantled inner fuel tank and fuel pump
9SIDE COVER COMPONENT
9.1
SIDE COVER COMPONENT…………………………………………………………………………………………………………………………………………………………………………………
62
Dismantled SIDE COVER COMPONENT
10 REAR COVER
、
REAR MUDGUARD
、
ELECTRICAL DEVICE BOX COMPONENT
10.1
Rear handrail
、
Cushion lock bracket……………………………………………………………………………………………………………………………………………………………………………
63
Dismantled Rear handrail
、
Cushion lock bracket
、
Rear cover left limit bracket
10.2
Rear cover
、
Tail light assembly…………………………………………………………………………………………………………………………………………………………………………………
64
Dismantled Rear cover
、
Tail light assembly
10.3
Battery
、
Electrical device box cover
、
ECU……………………………………………………………………………………………………………………………………………………………………
65
Dismantled Battery
、
Electrical device box cover
、
ECU
、
Motorcycle tool
10.4
Electrical device box assembly……………………………………………………………………………………………………………………………………………………………………………………
66
Dismantled Electrical device box assembly
10.5
Electrical component box component 1……………………………………………………………………………………………………………………………………………………………………………
67

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Disassembled device box component, electric device box lower cover
10.6
Electrical component box component 2……………………………………………………………………………………………………………………………………………………………………………
68
Remove PKE, electrical box
10.7
External battery to start PKE system………………………………………………………………………………………………………………………………………………………………………………
69
Emergency method to turn on PKE after battery power is exhausted
11 CUSHION COMPONENT
11.1
Cushion……………………………………………………………………………………………………………………………………………………………………………………………………………
70
Dismantled cushion and cushion rubber (Buy by separated)
12 MUFFLER COMPONENT
12.1
Dismanted mulffer1………………………………………………………………………………………………………………………………………………………………………………………………
71
Dismanted muffler flange
12.2
Dismanted mulffer 2………………………………………………………………………………………………………………………………………………………………………………………………
72
Dismanted muffler component
12.3
Mulffer component………………………………………………………………………………………………………………………………………………………………………………………………
73
Dismanted muffler component
13 LOWER WIND DEFLECTOR COMPONENT
13.1
Lower wind deflector component-1………………………………………………………………………………………………………………………………………………………………………………
74
Dismanted lower wind deflector component
13.2
Lower wind deflector component-2………………………………………………………………………………………………………………………………………………………………………………
75
Dismantled lower wind deflector component
©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 continuous improvement of the product and other changes.

1-FRAME&ELECTRONIC COMPONENT 6
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
1 1184100-115000
ZT250－R wire harness assembly (PKE) 1
2 1224100-030000 Pin tie (Black 4.8×130) 1
3 1251100-102000 Non-standard bolt M6×16
（
304 stainless steel
）
3
4 1224100-037000 0 level antiflaming binding
（
black 3.6×295
）
8
5 1184200-039000 ZT310
－
R Flasher 1
6 1184100-002000 ZT250
－
S Dump switch 1
7 1244100-082000 ZT250
－
S Dump switch gum cover 1
8 1184100-017000 ZT250
－
S Electronic fuel injection relay 2
9 1250201-032093 GB818M5×16 z (color zinc) 2
1050954-013000 ZT250
－
R Ignition coil, ignition cable component without nut
1184200-108000 ZT310 EFI Ignition coil
1184200-104007 ZT310 EFI Ignition coil(with high voltage line)
11 1274100-085000 ZT250
－
R Ignition coil installing support 1
12 1184100-101000 ZT250
－
R Head light diode 1
13 1184100-015000 ZT250
－
S Rectifier 1
14 1270300-201000
Stainless steel asbestos pad 6×20×1.6
2
15 1184200-024000 ZT310
－
R relay of side support 1
PROCEDURE:
●Main harness
Different plug-in methods are different, please unplug all the electrical components connected to the
main thread according to the actual operation. It needs to use a word screwdriver, forceps, scissors and
other tools to assist. The binding ⑵、⑷ can be picked out by using scissors. It is recommended to cut
the strap directly with scissors and replace the material with the same specifications on the official
website.
●Flasher and dump switch
Remove the rubber sleeve ⑺that connects the flasher ⑸to the mounting bracket on the frame, and
remove the dump switch with the same method, then separate the dump switch ⑹.
●Relay&head light diode
Pull out the electric injection relay⑻, large lamp diode⑿and the side stand relay⒂。
●Ignition coil &support
Remove the crosshead bolts ⑼with a cross screwdriver and remove the ignition coil. Remove the bolt
⑶with 10# sleeve and remove the ignition coil support ⑾.
●Rectifier
Remove the bolts ⑶with the inner hexagon tool and remove the rectifier ⒀,then remove the asbestos
pad⒁
FIG.1 FRAME&ELECTRONIC
PARTS COMPONENT Electronic parts COMPONENT-1
CAUTION:
●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 flasher and dump switch sleeve, beware of hurting your fingers.
●EFI relay ⑻model: KH-1A4T. Side bracket relay ⒂model: G8HN-1C4T-RJ.
●The EFI ignition coil and the ignition coil with high-voltage wire cannot be used in common. Please check whether the
ignition coil of the original bike is equipped with high-voltage wire before purchasing. For vehicles without high-voltage
lines or spark plugs without screw caps, the main cable needs to be purchased with an ignition coil with high-voltage lines.
ZT250-R ignition coil is matched with spark plug without screw cap. The ZT310 ignition coil is matched with a spark plug
with a screw cap.
10 1 sparking plug
(with nut )
ZT250－R Ignition coil
ZT310 EFI Ignition coil
Sparking plug (without
nut )
ZT310 EFI Ignition coil(with
high voltage line)
Sparking plug (with nut )

1-FRAME&ELECTRONIC COMPONENT 7
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
1
1251100-102000 Non-standard bolt M6×16
（
304 stainless steel
）
2
2
1274100-086000 ZT250
－
R Horn intalling support 1
3
1270300-201000 Stainless steel asbestos pad 6×20×1.6 2
4
1251100-101000 Non-standard bolt M6×16
（
304 stainless steel
）
1
5
1184200-004000 ZT310 Horn 1
6
1274100-017000 ZT250
－
S Cable clip 1
7
1274100-095000 ZT250－S Flameout switch wire fixing bracket 1
8
1184100-012000 ZT250
－
S Flameout switch 1
9
1250205-040095 GB70.1 Hexagon socket screw M8×16(color zinc) 2
FIG.2 FRAME&ELECTRONIC
PARTS COMPONENT Electronic parts COMPONENT-2
PROCEDURE:
●Horn and support
Remove the bolts with the inner hexagon tool ⑷and remove the horn ⑸. Remove the bolt ⑴, the horn support
⑵and the asbestos pad ⑶.
●Flameout switch
Use pliers (as above picture shown) to hold the line in the direction of the arrow with a slightly clamping hand
to remove the cable clip ⑹.Remove the bolts⑼with the inner hexagon tool, Remove the bolts ⑻with the inner
hexagon tool and remove the flameout switch ⑺.
CAUTION：
●Please pay attention to the strength when removing the cable clip.
●An asbestos pad is needed to insulate the heat transfer between horn support and frame.

1-FRAME&ELECTRONIC COMPONENT 8
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
1
1274100-002000 ZT250
－
S Cable clamp 2
2
1224100-049000 ZT250
－
R Cable collection clip 1
3
1244100-019000 ZT250
－
S Inner fuel tank fix glue cushion 1
4
1244100-002000 ZT250
－
S Side cover round glue cushion 8
5
1244100-061000 ZT250 Frame water proof rubber plug 2
6
1240100-023000 Battery positive protection glue. 1
FIG.3 FRAME&ELECTRONIC
PARTS COMPONENT Frame plastic parts
PROCEDURE:
●Cable collection clip
First, take the cable and the main thread out from the collection clip, then use the straight screwdriver to pick up
the middle part of the cable clip⑴. Then take cable collection clip ⑵off.
●Inner fuel tank ficx glue cushion
Use both hands to hold the two ends cylinder parts of the inner fuel tank limited glue cushion ⑶and should
push it out.
●Side cover cushion
Remove the side cover cushion ⑷with your hand directly.
●Frame waterproof rubber plug
Remove the frame waterproof rubber plug ⑸with your hand directly.
●Positive pole protection glue
Find out the slot parts position,open and take it out with tools.⑹
CAUTION：
●It must be dismantled them first, such as the cushion, fuel tank cover, inner fuel tank, sider cover, tail dress
and so on.
●All parts should be correctly assembled.

1-FRAME&ELECTRONIC COMPONENT 9
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
1 1134100-007000
ZT250
－
S Rating nut lock washer 1
2
1251300-046093 ZT250
－
S Steering column rating nut (color zinc) 2
3 1244100-015000
ZT250
－
S Rating nut glue cushion 1
4
1224100-005000 ZT250
－
S Steering column upper dustproof cover 1
5
1130900-024000 ZT250
－
S Blowout patch 1
6
1130900-022000 ZT250
－
S One-piece steel ball 2
7
1134100-015000
S lower connection borad(self made/with ball head) assembly
1
8
1224100-006000 ZT250－S steering stem dust cap(down) 1
【1】
CAUTION：
●Remove the head part component, handlebar component and front shock absorber component first .
●Please pay attentin to fix the awaiting repair motorcycles well 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 ZONTES 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 ⑸and 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.
FIG.4 FRAME&ELECTRONIC
PARTS COMPONENT
Steering rack component
PROCEDURE:
●Dissembly
Remove the lock washer⑴.
Remove the top adjusting nut ⑵by 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 ⑸of 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 cover⑷is 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.