Name: Zontes ZT125
Brand: Zontes
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ZT125/350T-D

Maintenance Manual

2023-04-14

Table of Contents4
Content4
Vehicle Information12
Know before Service12
Body Label13
D350 Technical Specification14
Front Wheel/Steering System14
Rear Wheel/Suspension System14
Brake System14
Battery/Charging System15
Lamp/Speedometer/Switch Description15
D125 Technical Specification16
Front Wheel/Steering System16
Rear Wheel/Suspension System16
Brake System17
Battery/Charging System17
Tightening Torque17
Bolt Tightening Torque of General Tightening Part17
Cable/Cable/Pipe/Electrical Device Distribution Map18
Distribution Map of Lamps and Lanterns18
Throttle Cable19
Brake Upper Pump and Brake Hose19
Calipers, Brake Hoses and Wheel Speed Sensors20
Distribution Map of Brake System Accessories21
D35021
D12523
Oil Supply System23
D350 Fuel Evaporation23
M125 Fuel Evaporation23
D350 Fuel Supply24
M125 Fuel Supply24
Distribution Map of Cooling System Accessories25
D35025
M12525
Electrical Device Layout26
D35026
M12528
Intake and Exhaust System31
D35031
Md12532
Tool33
Swell Nail Description34
Maintenance35
Know before Service35
D350 Maintenance Schedule36
D125 Maintenance Schedule38
D350 Air Filter (Filter Element), Air Inlet Filter Element39
Support the Vehicle Firmly39
Remove the Left Engine Cover39
Remove the Air Inlet Cover39
Replace the Air Inlet Filter39
Remove the Air Filter Housing39
Replace Air Filter Element40
Inspection Air Filter Waste Oil Pipe40
Reinstall40
M125 Air Filter (Filter Element), Air Inlet Filter Element42
Support the Vehicle Firmly42
Remove the Left Engine Cover42
Replace the Air Inlet Filter42
Remove the Air Filter Housing42
Replace Air Filter Element43
Inspection Air Filter Waste Oil Pipe43
Reinstall43
Bolts and Nuts of Muffler44
Check for Air Leaks at the Engine Exhaust44
Check for Nut and Bolts at the Muffler44
D350 Spark Plug45
Disassemble the Spark Plug45
D35045
D12546
Check the Spark Plug47
D35047
D12547
Refer to the Steps to Remove the Spark Plug to Restore All Parts47
Engine Oil48
D35048
Drain the Oil48
Replace Fine Filter48
Add Oil49
Change Gear Box Oil49
Confirm the Oil Level49
M12550
Drain the Oil50
Replace Fine Filter50
Add Oil50
Change Gear Box Oil51
Confirm the Oil Level51
D350 Throttle Valve Body51
Do Not Dismantle the Throttle Body to Clean up Carbon Deposits51
Remove the Stepper Motor and Clean up Carbon Deposits51
Remove the Throttle Valve Body Assembly to Clean up Carbon Deposits52
Disassemble the Sensor53
Throttle Valve Body Troubleshooting Process54
M125 Throttle Valve Body55
Do Not Dismantle the Throttle Body to Clean up Carbon Deposits55
Remove the Stepper Motor and Clean up Carbon Deposits55
Remove the Throttle Valve Body Assembly to Clean up Carbon Deposits56
Disassemble the Sensor56
Throttle Valve Body Troubleshooting Process56
Throttle Cable57
Inspection57
Adjust the Throttle Cable Clearance57
Lube Door Cable57
Idle Speed58
Check Idle Speed58
Fuel Evaporative Pollutant Control System59
D350 Fuel Evaporation59
M125 Fuel Evaporation60
Radiator61
Check the Coolant61
Add Coolant (Antifreeze) to the Coolant Expansion Tank61
D350 Add Coolant to the Radiator61
Put Coolant62
D35062
M12562
Check Whether the Fins of the Radiator Water Tank Are Deformed or the Air Duct Is Blocked62
M12563
Check All Water Pipes for Leaks; Aging63
D35063
M12564
Fuel Pipe65
Check the Fuel Pipe for Leaks with the Help of an Endoscope with LED Light65
Replace High Pressure Oil Pipe65
Fuel Pump66
Use Oil Pressure Gauge to Measure Fuel Pressure66
Simple Test of Fuel Pump67
Treatment of Abnormal Fuel Pressure67
Braking System68
D350 Braking System Component Diagram68
D125 Braking System Component Diagram68
Check the Brake Components69
Check the Front and Rear Brake Switches70
Check the Brake Switch70
Replace the Brake Switch70
Lubricate the Movable Parts of the Brake Handle70
Lubricate the Front Brake Handle70
After Lubricating the Brake Handle70
Replacing the Brake Handle71
Adjust the Brake Handle71
Replace the Brake Pads71
Replace the Front Brake Pads71
D35071
D12572
Replace the Rear Brake Pads72
Abnormal Sound of Brake Pads73
Replace the Brake Disc73
Replacing the Front Brake Disc74
Replacing the Rear Brake Disc74
Brake Hose75
Brake Fluid75
Add Brake Fluid to the Main Pumps of the Front and Rear Disc Brakes75
Replace the Brake Fluid75
Replace the Front Brake Brake Fluid76
Replace the Rear Brake Fluid76
Brake System Exhaust76
Tire76
Check the Tires77
Replace Tires77
Steering Mechanism77
Check the Steering Mechanism78
Adjust the Steering Mechanism78
D35078
D12578
Maintain Steering Bearings79
Malfunction79
Front Fork79
Check the Appearance79
Check the Shock Absorption Performance80
Remove the Front Shock Absorption80
Correct the Front Fork Tube80
Troubleshooting80
Rear Shock Absorption80
Check81
Adjust the Preload81
Adjust the Right Rear Shock Absorption81
D12581
M35081
Adjust the Left Rear Shock Absorption81
D35081
Replace the Shock Absorption81
Bolts and Nuts for Body and Engine Installation82
Check the Fasteners for the Critical Parts82
Check Engine Fasteners82
D35082
D12583
Side Bracket83
Check83
Lubrication84
Main Bracket84
Check84
Lubrication85
Install the Main Bracket85
Replace the Return Spring Post of the Main Support85
Sound, Light, and Electrical Device Inspection86
Check86
Headlight Height Adjustment87
Fuse Box88
Troubleshooting89
Right Hand Switch89
Right Hand Handle Vice Switch89
Left Hand Handle Auxiliary Switch90
Horn90
Left Hand Switch91
Light92
Windshield Failure92
EFI System93
Know before Service93
Error Code94
D350 Read the Fault Code through the Meter94
Read the Fault Code through the Diagnostic Tool94
Error Code95
Clear Fault Code95
Manually Clear95
Use the Diagnostic Tool to Clear95
EFI Parts Layout96
Fault Diagnosis and Elimination of EFI Parts97
Dump Switch97
OBD Port98
Fuel Pump98
Carbon Canister Solenoid Valve98
EFI Relay99
Fuel Injector99
Ignition Coils99
D350100
D125100
Throttle Valve Body101
Common Failure Phenomena101
Disassembly101
Troubleshooting Process101
Sensor101
D350 Sensor101
M125 Sensor101
Water and Oil Shared Sensor101
Oxygen Sensor102
Check102
Replace102
D350102
D125103
Ecu103
D350103
D125104
Crankshaft Position Sensor104
The Engine Cannot Start and There Is no Sign of Fault Diagnosis Process105
The Engine Cannot be Started and There Is a Car Symptom Fault Diagnosis Process105
Poor Acceleration106
High Idling Speed of Hot Car106
Unsteady Idle Speed of Cooling Car106
Unsteady Idling, Easy to Cutoff107
Analysis Flow Chart of EFI Failure Indicator Light Always on108
Electrical Schematic Diagram of EFI System109
Ignition System110
Know before Service110
Troubleshooting111
Ignition System Layout112
Electrical Schematic Diagram of Ignition System112
Ignition System Inspection113
Ignition Timing113
Ignition Coils114
Starting System115
Know before Service115
Troubleshooting115
Starting Relay115
Starter Motor116
The Starter Motor Runs Slowly116
The Starter Motor Is Working Normally, but the Engine Cannot be Started116
Ignition System Layout116
Starting System Electrical Schematic Diagram117
Starter Motor117
Remove the Starter Motor117
Disassemble the Starter Motor118
Examination119
Starter Motor Front Cover119
Motor Back Cover119
Denki119
Check the Starting Relay120
Operation Check120
Check the Relay Coil120
Input Line120
Ground Wire120
Disassembly and Assembly of the Starting Relay120
Fuel Supply System121
Know before Service121
Fuel Tank Removal121
Disassemble the Fuel Tank Assembly121
Disassemble the Fuel Pump122
Remove the External Parts of the Fuel Tank Assembly123
Examination123
Fuel Pressure Test123
Fuel Pump Inspection123
Oil Level Sensor123
Cooling System124
Know before Service124
Troubleshooting124
The Engine Temperature Is too High124
The Engine Temperature Is too Low124
Coolant Leakage124
Coolant System Distribution Map125
D350125
D125125
Coolant Flow Diagram126
D350126
D125127
Cooling System Disassembly127
D125 Remove the Radiator Assembly127
D350 Remove the Radiator Assembly128
D350 Coolant System Hoop/Clamp Distribution Map129
D350 Thermostat Assembly and Small Loop129
Cooling System Accessories130
D350 Main Water Tank131
D350 Attention to the Water Tank Filling Port131
Overall Tightness Inspection131
Pressure Relief Valve Inspection131
Auxiliary Water Tank131
Water and Oil Shared Sensor131
Thermostat132
Inspection132
Failure Phenomenon132
Disassembly132
Thermostat Core Inspection133
Water Pipe133
Check the Water Pump Cover Assembly133
Braking System134
Know before Service134
Trouble Shooting135
Soft Feeling from Brake Lever135
Hard Feeling from Brake Lever135
Disassemble the Disc Brake Main Pump and Calipers135
Disassemble the Front Disc Brake Main Pump135
Disassemble the Rear Disc Brake Main Pump136
Disassemble the Front Disc Brake Caliper136
D350136
D125136
Disassemble the Rear Disc Brake Caliper137
Brake Hose and Wheel Speed Sensor138
Check the Gap between the Wheel Speed Sensor and the Induction Ring Gear138
Remove the Brake Hose and Wheel Speed Sensor138
Release Brake Fluid138
FMC-HU and RMC-HU139
FC-HU and Wheel Speed Sensor (Front Wheel)139
RC-HU and Wheel Speed Sensor (Rear Wheel)139
ABS System Layout140
ABS Hydraulic Control Unit141
Disassemble141
ABS Troubleshooting142
Battery/Charging System143
Know before Service143
Troubleshooting144
Charging System Layout Diagram145
Electrical Schematic Diagram145
Battery Disassembly146
Disassembly146
Check146
Charging146
Charging System Check146
Leakage Test146
Check the Charging Voltage146
Inspection of Magneto Stator Charging Coil146
Remove the Rectifier147
Front Fork Assembly148
Know before Service148
Exploded View of Front Fork Components149
D350 Directional Exploded View149
D125 Directional Exploded View150
Front Fork Exploded View151
D350151
D125152
Exploded View of Lower Link Board153
D350153
D125154
Change the Direction of the Handle155
Remove the Direction of the Handle155
Remove the Components155
Installation of the Direction Component156
Installation of the Direction Handle Cover156
Replace the Front Wheel157
Remove the Front Wheel Assembly157
Install the Front Wheel Assembly157
Front Wheel Assembly Exploded View158
D350158
D125158
Inspection and Maintenance of Front Wheel Assembly159
Disc Brake159
The Service Life of the Disc Brake Disc159
Disc Brake Replacement Method159
Front Wheel Oil Seals and Bearings159
Service Life of Front Wheel Oil Seals and Bearings159
Replacement Method of Front Wheel Oil Seal and Bearing159
Front Wheel Rims and Tires159
The Service Life of the Front Wheel Rim and Tire159
How to Replace the Front Wheel Rim and Tire159
Dynamic Balance160
D350 Replacement of the Front Shock Absorber160
Disassemble the Front Wheel and Front Fender Assembly160
Remove the Left and Right Front Shock Absorbers160
Reinstall the Shock Absorber, Front Fender, Front Wheel and Other Components161
D125 Replacement of the Front Shock Absorber161
Disassemble the Front Wheel and Front Fender Assembly161
Remove the Left and Right Front Shock Absorbers162
Reinstall the Shock Absorber, Front Fender, Front Wheel and Other Components162
Replace the Lower Link Board162
Disassemble Parts Ahead of Time162
Remove the Faucet Lock162
Removing the Direction Pad163
D350163
D125163
Remove the Lower Link Board Assembly163
Install the Lower Link Board Assembly163
D125164
Install Other Disassembly Components164
Disassemble the Engine of the Vehicle165
Disassemble the Storage Box165
Remove the Cover165
Put the Coolant and Pull out the Connection Plug166
Disassemble the Engine168
D350168
D125169
Install the Engine169
D350169
D125170
Disassembly and Assembly of Vehicle Covering Parts171
Disassembly and Assembly of Vehicle Panel173
Windshield Removal173
Removal of the Front Sun Visor173
Removal of the Front Cover and the Front Panel173
Disassembly of the Left &Right Side Cover174
Disassembly of the Cushion174
Disassembly of the Storage Box174
Disassembly of the Left, Right Fuel Tank Cover175
Removal of the Front Left and Right Panels175
Disassembly of the of the Speedometer Panel175
Removal of Front Left and Right Panel Bottom Lining176
Disassembly of Headlights176
Removal of Windshield Base177
Disassembly the Middle Cover of the Fuel Tank178
Disassembly the Left and Right Storage Boxes179
Removal of Front Storage Box Panel179
Removal of Left and Right Pedals and Surrounding Left and Right Parts180
Disassembly of the Surrounding Bottom181
Removal of the Surrounding Middle Part181
Radiator Deflector Removal181
Disassembly of the Rear Hand Rest181
Removal of Tail Skirt and Tail Lamp182
Removal of Rear Mud Flap182

Brand	Zontes
Model	ZT125
Category	Scooter
Language	English

Zontes ZT125 User Manual

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Zontes ZT125 Specifications

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