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

Page2,Toatal 75 pages
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CONTENTS
Table of Contents
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

Page3,Toatal 75 pages
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CONTENTS
Table of Contents
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

Page4,Toatal 75 pages
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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.

1-FRAME&ELECTRONIC COMPONENT 10
CHK
ADJ
NO. PART NO.
PART NAME QTY CAUTION
4014100-011000 ZT250
－
R frame II after
－
sales assembly (ABS
version / including seat / nameplate / national IV)
Inland
4014100-012000
ZT250－R frame II after－sale assembly (ABS
version / including seat / nameplate / Euro IV)
Export
2
1130900-026000 ZT250
－
S Fix loop 2For after-sale
3
1274100-006000 ZT250
－
S Frame engine oil filter screen 1
4
1051453-003000 27.4×2.65 Acrylate O gule cushion loop 1
5 1274100-024000 ZT250－S Oil cooling joint 1
6
1244100-033000 combined sealing gasket12×φ20×2 1
7
1251100-066093 M12×1.5×15 Ablassschraube
（
color zinc
）
1 24±4N.m
8 1251300-057093 Non-standard bolt M10×1.5（dacromet）1
9 1251700-025091 ZT250－S Side support bush 1
10 4024100-001000 ZT250－S Side support 1
11 1251100-088094
Non-standard bol M10×1.5×43
（
dacromet
）
1
12 1264100-001000
ZT250
－
S Side support spring 1
PROCEDURE:
●Checking the cushion loop
Checking whether the cushion loop ⑵is frayed, if as it, please replace it on ZONTES website, fix the
cushion loop well and paint the lubricating grease on it with appropriate tool.
●Replacing the engine oil filter screen
Put the oil pan on the bottom and use the appropriate tools to remove the oil cold joint ⑸, O ring ⑷,
and oil filter screen⑶. When replacing the oil filter screen ⑶, the O-ring⑷must be replaced at the same
time. The oil cooling joint⑸
must be tightened well when re-assembling which meets the standard torque
value.
●Realease the frame tube enging oil
Put the oil pan at the bottom, use the appropriate tool to remove the oil bolts⑺and the sealing gasket⑹,
and remove the oil from the frame tube. Refer to the instructions for detailed steps to replace the oil. It is
recommended that the engine oil should be replaced with oil bolts ⑺and sealing gasket⑹to prevent oil
leakage.
●Sider support
Use the cross screwdriver to remove the side support spring ⑿, and guard against the personal injury
caused by spring contraction, remove the nuts ⑻and bolts ⑾with the appropriate tools. Remove the side
support ⑽and bush⑿, paint the lubricating grease on the bush when re-assembling ,then put it into the
frame⑴
1 1
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.
●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.
●Pay attention to safety when mounting side support spring.
●All parts should be correctly assembled.
●The Chinese frame after-sales assembly includes 3C nameplate, seat ring and packaging carton. The export
frame after-sales assembly includes Euro IV nameplate, seat ring, and carton not included.
FIG.5 FRAME&ELECTRONIC
PARTS COMPONENT
Frame, Side support, the operation of releasing engine
oil

1-FRAME&ELECTRONIC COMPONENT 11
CHK
ADJ
NO. PART NO. PART NAME QTY CAUTION
1 1274100-012000 ZT250－S Pedal axis pin 2
2
1274200-061000 ZT310－X rear right footrest 1
3 1264100-005000 ZT250－S Pedal Steel ball spring 2
4 1264100-006000 ZT250－S Pedal clamp spring 2
5 1274100-010000 ZT250－S Rear pedal steel ball 2
6 1274100-052000 ZT250－S Rear pedal locating plate 2
7
1274200-062000 ZT310－X rear left footrest 1
8 1251100-101000
Non－standard bolt M6×12 (304 stainless steel) 2
9 1274100-100000
ZT250－R disc brake lock bracket 1
【
1
】
10 1250303-010093
GB6177.1M6(color zinc ) 2
11 1244200-024000
ZT310－X footrest gum cover 2
12 1274200-051000
ZT310－X footrest gum cover fixed plate 2
13 1250205-038000
GB70.2M5×12(stainless steel) 2
14 1032142-040000
ZT310－X rear left pedal 1
15 1032142-039000
ZT310－X rear right pedal 1
16 1250501-010000
GB93φ6 spring pad 2
PROCEDURE:
●Dissembly rear pedal
Pry open the clamp spring ⑷, then push the pedal pin shaft⑴out with tools.Pull the pedal ⑵or ⑺outward.
●Assemble rear pedal
Place one side with two holes of pedal horizontally and put the pedal spring ⑶in the pedal ⑵or ⑺in the small hole.
Put the steel ball ⑸inside,compress the steel ball and spring with the positioning plate⑹.
Assemble the pedal on the frame and distinguish the right, left pedal.
The axis pin ⑴is inserted after the pedal hole is aligned with the pedal support mounting hole.
Insert the clamp spring⑷into the pin shaft slot.
●Disc brake lock bracket
Fix the bolt ⑻with a hexagonal tool and remove the nut ⑽with a sleeve, and finally remove the disc brake lock bracket
⑼from the frame.
●Foot aftersales service parts
Grasp the left rear pedal ⒁or right rear pedal ⒂, remove the bolt ⒀with an allen tool, and remove the spring washer ⒃.
Remove the rubber sleeve ⑾and the fixing piece ⑿.
CAUTION：
●Take care of the material when removing the pedal.
●【1】Only suitable for TOP DOG disc brake lock RE008 and TOP DOG disc brake lock RE0081, other models are not
adapted.
●【2】Only for after-sales replacement of worn-out pedal parts.
【2】
Rear pedal component
FIG.6 FRAME&ELECTRONIC
PARTS COMPONENT

2-FRAME&ENGINE COMPONENT 12
CHK
ADJ
NO. PART NO. PART NAME QTY CAUTION
1 1251300-057093
Non-standard nut M10×1.5
（
dacromet
）
9
1020241-225000
ZT250
－
R Upper hanging piece out of stock
1020242-385000
ZT310
－
V Upper hanging piece
3 1251112-003093
M6×45 Hexagonal flange face 9.8 level bolt. 3
4 1274100-033000
ZT250
－
S Right support of down wind deflector 1
5 1251300-059093
125 Spindle nut of rear forklift M14×1.5
（
dacromet
）
1
6 1274100-009000
ZT250
－
S The axle sleeve of rear forklift 2
7 4024100-024000
ZT250 aluminum rear fork assembly(bearing/oil sealing
1
8 1252200-016093
250 Rear forklift axle 14×310
（
dacromet
）
1
9 1251100-086093
Non-standard bolts M10×1.5×112
（
dacromet
）
1
10 4044100-022051 ZT173YMM Output chain wheel cover 1
11 1274100-034000
ZT250
－
S Lower wind deflector left support 1
12 1251112-005093 M6×75 Hexagonal flange face 9.8 level bol 1
13 1251100-132003
Non-standard bolts M10×1.5×80
（
dacromet
）
8
14 4024100-031000
ZT250
－
R Bracket 1
PROCEDURE:
●Chain wheel cover
Dismantle the left side bolt ⑶of the engine with the sleeve and remove the chain wheel cover ⑽.
●Bracket engine hanging
Use the sleeve to cover the head of the bolt ⒀then dismantle the nut ⑴with the sleeve. Remove the
bolt then dismantle the bracket ⒁.
Use the sleeve to cover the head of the bolt ⑼, remove the nut ⑴with the sleeve, then emove the bolts.
●Hanging piece
Use the sleeve to cover the head of the bolt ⒀and remove the nut ⑴with the sleeve. Can not remove
the bolt ⒀and the hanging piece ⑵.
●Engine middle part,frame and rear forklift component
Use the sleeve to cover the head of the bolt ⑻and remove the nut ⑸with the sleeve. Other parts
cannot be removed.
●Engine
Both persons hold the left and right boxes of the engine. One person takes the bolt ⒀and hanging
piece ⑵off. Remove the rear flat fork ASSY ⑺. Support the engine to shift to one side, and pay
attention to safety during the movement. Put the engine flat on the ground.
●Wind deflector support, rear forklift sleeve
Remove the bolts ⑶with the sleeve then remove the left support ⑾and right support ⑷of the wind
deflector.
ZT250
－
R Upper hanging piece ZT310
－
V Upper hanging piece
FIG.1FRAME&ENGINE Frame&Engine
2 2
CAUTION:
●It is necessary to remove the seat cushion, fuel tank, side cover, pedal support, wind deflector, shift lever,
muffler, radiator and pipe, cable, air filter joint, chain, engine negative pole, etc.
●Use appropriate tools to support the motorcycle to prevent motorcycle dumping during disassembly. Single
operation is forbidden.
●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.
●It must be operated the engine with more than one people at the same time when removing the engine.
●All standard parts must meet the standard torque value when reassembling, and refill the engine oil according
to the operation instruction.

3-INDUCTION SYSTEM COMPONENT 13
CHK
ADJ
NO. PART NO. PART NAME QTY CAUTION
1 1050954-007000
39－N008 gasline injector 1
2 1050954-008000
39
－
N008 Fuel injector 1
3 1251112-001093
M6×16 Hexagon flange bolts (color zinc) 1
4 1050954-006000
ZT180MN high press fuel pipe of EFI 1
5 1251300-063093
Plywood M6×11×15(color zinc) 5
6 1251100-101000
Non－standard bolt M6×12 (304 stainless steel) 5
7 1274100-076000
ZT250－R rear disc brake pipe clamp (steel) 1
8 1224200-058000
ZT310
－
R second generation air filter 1
9 1051354-004000
Φ56×10 clamp components 2
10 1050953-021000
TB35 throttle body parts 1
11 1050953-022000
TB35 intake manifold assembly 1
12 1051453-007000
45×2.1 Fluoroelastomer O-ring 1
13 1244100-083000
ZT310
－
R Air filter small air inlet 1
14 1251100-061093
M6×22 Hexagon flange bolt
（
color zinc
）
2
FIG.1 INDUCTION
SYSTEM COMPONENT
Intake system component
PROCEDURE:
●High pressure oil pipe
Press anti-loose ring on the joint of the fuel pump joint which is close to high pressure oil pipe ⑷, then
pull it out directly, the balance fuel in the tube needs to be connected to the oil pot. Please prevent fuel
dripping onto any part of the vehicle. Press the anti-loose card ring near the injector fixator⑵to unplug
the high-pressure oil pipe, as picture shown, smoking and lighting fires are strictly forbidden during
disassembly.
●Air filter
Remove the bolts ⑹with the inner hex sockets tool, pull the the tubing clip⑺out from the disc brake
pipe and take it out. Loosen the pipe hoop assembly on the air filter ⑼, clamp on the exhaust pipe and
unplug the exhaust pipe from the exhaust outlet of the engine. Then use the rubber plug to prevent the
foreign body from entering the damaged engine. Remove the air filter ⑻and plywood nut ⑸.Remove the
small air inlet⒀from air filter⑻.
●Throttle valve component
Remove the bolts ⒁
with the club wrench and remove the throttle valve assembly. Loosen and remove
the pipe band ⑼between the induction manifold assembly ⑾and the throttle part ⑴,Remove the O ring
⑿from the induction pipe assembly.Remove the screw ⑶of the fuel injector fixator ⑵with the sleeve
and remove the fixer and the fuel injector ⑴.
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. Prevent accidental ignition of fuel and cause fire.
●Fireworks, answering or dialing should be strictly prohibited near the car-breaking site to prevent accidents.

3-INDUCTION SYSTEM COMPONENT 14
CHK
ADJ
NO. PART NO. PART NAME QTY CAUTION
1 1050954-009000 YH Carbon tank electromagnetic valve 1
2 1251100-101000
Non-standard bolts M6×12
（
304 stainless steel
）
2
3 1250303-010093 GB6177.1M6（color zinc）1
4 1251300-063093
Plywoord M6×11×15
（
color zinc
）
2
5 1224200-158000
ZT310
－
R Carbon tank II (with fuel pipe) 1
6 1244200-004000 TB41 Throttle valve desorption rubber tubing 1
PROCEDURE:
●Carbon tank
Clamp the pipe clamp on the exit of the oil and gas separator at the bottom of the tank with pliers and pull out
the tubing. Unplug carbon tank solenoid valve ⑴with the same method. Remove the bolts with the inner hex
tool ⑵. Remove thecarbon tank ⑸from the left side of the frame and remove the plywood nut ⑷.
●Desorption tubing
Clamp the pipe clamp on both ends of the desorption tubing,and take the it ⑹out.
●Carbon tank electromangnetic valve
Remove the plug of the solenoid valve ⑴, then remove the nut ⑶with the sleeve and remove the
electromagnetic valve.
CAUTION:
●It needs to remove the seat cushion, side cover, oil tank cover, bladdar and so on.
●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.
●It should be no crimp, entanglement and other phenomena.
●Add a fuel pipe on March 13,2019 to prevent fuel dropping onto the muffler surface.
FIG.2 INDUCTION
SYSTEM COMPONENT Carbon Tank component

3-INDUCTION SYSTEM COMPONENT 15
CHK
ADJ
NO. PART NO. PART NAME QTY CAUTION
1 1224100-024000
ZT250
－
S Plastic connector block 1
24134200-002000 ZT310－Rair filter element (with carton packaging)
1After sale
PROCEDURE:
●Filter element
If you need to maintain the filter element of the air filter,remove the plastic connection piece ⑴.Press the a-
end of the right side cover to pull out forcibly, then pull out the b-end, remove the right cover assembly; Similarly
remove the left cover assembly.Take the two standard parts①out of air filter with the tool, dismantle the box
cover②, then extract the filter element⑵. Blow the dust off the filter core by blowing dust gun in the filter
element. 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. If there is any damage, please log on the official
website and purchase another parts.
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.
●
When assembling the side cover assembly, you should install end b first, then end a, and finally press c to snap
the decorative cover to the frame tube.
FIG.3 INDUCTION
SYSTEM COMPONENT Replace the air filter element

4-REAR FORKLIFT COMPONENT 16
CHK
ADJ
NO. PART NO. PART NAME QTY CAUTION
1 1224100-037000
Grade 0 flame retardant tie (black 3.6×295) 3
2 1251100-101000
Non－standard bolt M6×12 (304 stainless steel) 2
3 1270300-273000
φ8 clip(L=73) 1
4 1184100-114000
ZT250－R auxiliary fender extension cable 1
5 1224200-003000
ZT310－Z Rear disc brake pipe clamp 1
6 1250105-143093
GB5789M8×35 (environmental color) 1
7 1250501-007093
GB93φ8(color zinc) 3
8 1250503-021093
GB97.1φ8 (environmental color) 3
9 1250105-149093
GB5789M8×30 (environmental color) 2
10 1250303-011093
GB6177.1M8(color zinc) 1
PROCEDURE:
●Rear vice fender assembly
Find interface a and unplug three plugs.
Cut off or use a tool to untie the cable tie⑴.
Pull straight the clip⑶.Remove bolt⑵, take off the clip⑶and disc brake oil pipe clamp⑸.
Use plum blossom wrench to tightent the nut⑽and disassemble bolt⑹which is close to "ZONTES" mark
with a sleeve.And remove the spring pad⑺,flat pad(8)and nut⑽.
Hold the Rear vice fender assembly and disassemble bolt⑹and bolt⑼with a sleeve. Take off spring pad⑺
and flat pad⑻.
Take off the Rear vice fender connecting cable⑷and rear vice fender assembly.
CAUTION:
●The seat cushion, left side cover, etc. must be removed in advance.
●Do not pull the cable hard when removing the vice fender connecting cable.
●
When reassembling, make sure that the torque of the three M8 bolts reaches 35N.m, and you need to apply the
thread fastening glue first. Before tightening the bolts, check that there is any pressure on the wires to prevent
short circuits when tightening the bolts.
FIG.1 REAR FORKLIFT
COMPONENT Rear sub mudguard component 1

4-REAR FORKLIFT COMPONENT 17
CHK
ADJ
NO. PART NO. PART NAME QTY CAUTION
1 1020242-263021 ZT310 rear auxiliary fender aluminum alloy bracket
(home made)
1
2 1251100-102000
Non
－
standard bolt M6×16(304 stainless steel) 5
3
1224200-090000 ZT310 rear auxiliary fender retaining plate 1
4 1250105-137093
GB5789M6×16(color zinc) 4
5 1250501-007093
GB93φ8(color zinc) 5
6 1274100-057095
Flanging bushing φ6.2×φ8.5×3.5＋φ14×1.5 5
7 1244100-052000
Buffer rubber of flanging bushing (φ8.5×φ14×1) 5
8
1251100-101000 Non－standard bolt M6×12 (304 stainless steel) 8
9 1270300-039000
HJ125－6 rear license light bracket 1
10 1250303-010093
GB6177.1M6(color zinc ) 2
11 4024200-102000
ZT310
－
R rear sub
－
plate iron bracket assembly (improved) 1
12 1184100-114000
ZT250
－
R auxiliary fender extension cable 1
13
4024200-036000 ZT310-V rear auxiliary fender iron support rear section 1
14
4024200-101000 ZT310 rear auxiliary fender iron support front section 1
PROCEDURE:
●Retaining plate
Remove the bolts⑵and ⑷, remove the flange bushing ⑹the rubber pad⑺, and finally remove the retaining
plate⑶.
●Aluminum alloy bracket
Remove the 2 pcs of bolt⑻and 3 pcs of ⑷，then remove 5 pcs of spring washer⑸.Separate the aluminum
bracket from the rear auxiliary fender assembly.
●Back license plate bracket assembly
Remove the bolt⑻and nut⑽at the license bracket⑼and remove the license bracket⑼.
●Rear auxiliary mud plate iron bracket
Hold the rear turn signal assembly, remove the bolt⑵, and remove the flange bushing⑹and rubber pad⑺.
Remove the rear sub-mud iron bracket⑾and rear turn signal assembly.
The old one-piece iron bracket has been discontinued, and the integrated iron bracket assembly ⑾needs to be
replaced. The assembly already contains the front section ⒁, the rear section ⒀and 4 bolts ⑻.
CAUTION:
●Do not pull the cable hard when removing the sub-mud switch.
●
When reassembling, first check if there is any pressure on the wire to prevent short circuit when tightening the
bolt.
After sales
FIG.2 REAR FORKLIFT
COMPONENT Rear sub mudguard component 2

4-REAR FORKLIFT COMPONENT 18
CHK
ADJ
NO. PART NO. PART NAME QTY CAUTION
1 1251300-063093
Plywood M6×11×15(color zinc) 6
2 1244100-006000
ZT250－S rear liceness rubber buffer 1
3 1224200-091000
ZT310－R rear mudguard fender 1
4 1270300-273000
φ8 clip(L=73) 1
5 1174200-035000
ZT310 rear turn signal (including license plate light) 1
6 1174100-002000
ZT250－S rear reflector 1
7 1251100-102000
Non－standard bolt M6×16(304 stainless steel) 4
8 1274100-057095
Flanging bushing φ6.2×φ8.5×3.5
＋
φ14×1.5 2
9 1244100-052000
Buffer rubber of flanging bushing (φ8.5×φ14×1) 4
10 1250502-010093
GB96.1φ6(color zinc) 2
11 1274100-018000
ZT250
－
S anti
－
hot plate sleeve, muffler 2
12 1184100-114000
ZT250
－
R auxiliary fender extension cable 1
13 1244200-082000
ZT310 Rear sub fender wire rubber plug 1
【1】
FIG.3 REAR FORKLIFT
COMPONENT Rear sub mudguard component 3
PROCEDURE:
●Back reflector, license plate cushion rubber
Flip to the back, remove the nut①that comes with the rear reflector⑹, remove the clamp⑷and the back
reflector. Remove the plate cushion rubber⑵and remove the 2 plywood nuts⑴on the back of the rear mudguard
fender⑶.
●Steering lights, fender sub-assemblies
Remove the bolts⑺on the left and right sides, and remove the flange bushing ⑻, cushion rubber⑼, anti-
scalding bushing ⑾and gasket⑽. Disassemble the turn signal and fender subassembly. Note that the sub-mud
switch cable⑿cannot be forcibly pulled.
●fender sub-assembly
Remove the 2 plywood nuts⑴and retaining rubber plug⒀from the fender subassembly⑶.
●turn signal subassembly
Remove the 2 plywood nuts⑴from the turn signal⑸. Remove the 3 joints of②and remove the sub-mud
switch cable⑿.
CAUTION:
●Do not pull the cable hard when removing the sub-mud switch.
●When reassembling, check if there is any pressure on the wire to prevent it from tightening.
Short circuit caused by bolts. Pay attention to the lamp connector, do not insert the wrong, turn left
Green + orange; right turn signal is green + blue; license plate light is green + pink.

4-REAR FORKLIFT COMPONENT 19
CHK
ADJ
NO. PART NO. PART NAME QTY CAUTION
1 1224200-120000
ZT310 rear turn signal bracket 1
2 1174200-019000
ZT310－X Rear left turning light 1
3 1174200-020000
ZT310－X Rear right turning light 1
4 1174200-021000
ZT310－X Liensed lights 1
【1】 【2】
FIG.4 REAR FORKLIFT
COMPONENT Rear turning light parts for after sales service
PROCEDURE:
●Rear license light
Grip the rear turning light bracket⑴then disassemble three bolts "d" on the license light⑷.
●Rear turning signal
Disassemble bolts three "b" and one"d" on the diagram left side, and then remove left press line plank of "e"
and press line plank "c",Remove the left turn signal⑵;follow the steps above to remove right press line plank of
"a" and press line plank "c". and remove the right turn signal⑶.
CAUTION:
●while reassembling,check there is any pressure on the cable,in case of causing short circuit when tighten the
bolt.