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Zontes ZT125T-D User Manual

Zontes ZT125T-D
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ZT125/350T-D
Maintenance Manual
2023-04-14

Table of Contents

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Zontes ZT125T-D Specifications

General IconGeneral
Displacement124.6 cc
Front SuspensionTelescopic Fork
Front BrakeDisc
Rear BrakeDisc
Engine TypeSingle Cylinder, 4-Stroke
TransmissionCVT
Fuel SystemEFI
CoolingAir Cooled
Rear SuspensionDual shock absorbers

Summary

Introduction

User notice

Vehicle Information

Know Before Service

Essential guidelines and precautions before performing maintenance or disassembly.

Body Label Identification

Identifies key labels and their locations on the vehicle body.

D350 Technical Specifications

Detailed technical specifications for the D350 model.

Battery and Charging System Details

Specifications and details for the battery and charging system.

Lamp, Speedometer, and Switch Descriptions

Description of lamps, speedometer, and switches.

Tightening Torque Standards

Table of standard tightening torques for various bolts and nuts.

Cable and Electrical Device Layouts

Diagrams showing the routing of cables, pipes, and electrical devices.

Throttle Cable Routing

Diagram and description of the throttle cable routing.

Brake System Hose and Pump Layout

Diagram showing brake pump and hose routing.

Brake Calipers, Hoses, and Speed Sensors

Diagrams illustrating brake calipers, hoses, and speed sensors for D350 and D125.

Brake System Component Distribution Map

Diagram showing the layout of brake system components for D350.

Oil Supply System: Fuel Evaporation

Details on the fuel evaporation system for D350 and D125.

Cooling System Component Layouts

Diagrams showing cooling system components for D350 and D125.

Electrical Device Layout (D350)

Diagram showing the electrical device layout for D350.

Intake and Exhaust System Diagrams

Diagrams of the intake and exhaust systems for D350.

Maintenance Tools

Illustrations of various tools used for maintenance and repair.

Swell Nail Description

Step-by-step guide for swelling nail disassembly and assembly.

Maintenance Procedures

Maintenance Know Before Service

Essential guidelines and precautions before performing maintenance or disassembly.

D350 Maintenance Schedule

Maintenance schedule with intervals and actions for D350.

D125 Maintenance Schedule

Maintenance schedule with intervals and actions for D125.

D350 Air Filter Replacement

Procedure for replacing the air filter element and air inlet filter for D350.

D125 Air Filter Replacement

Procedure for replacing the air filter element and air inlet filter for D125.

Muffler Bolts and Nuts Check

Instructions for checking muffler bolts and nuts for leaks.

D350 Spark Plug Service

Steps for disassembling and removing the spark plug for the D350 model.

D125 Spark Plug Service

Steps for checking and verifying the spark plug for the D125 model.

D350 Engine Oil Service

Procedures for draining, replacing filter, and adding engine oil for D350.

D125 Engine Oil Service

Procedures for draining, replacing filter, and adding engine oil for D125.

D350 Throttle Valve Body Cleaning

Instructions for cleaning carbon deposits on the D350 throttle body.

D125 Throttle Valve Body Cleaning

Instructions for cleaning carbon deposits on the D125 throttle body.

Throttle Cable Inspection and Adjustment

Inspection and adjustment procedures for the throttle cable.

Engine Idle Speed Checks

Procedures for checking engine idle speed for D350 and D125.

Fuel Evaporative Pollutant Control System

Details on the fuel evaporative pollutant control system for D350.

Radiator Coolant Service

Procedures for checking and adding coolant to the radiator and expansion tank.

Cooling System Water Pipe Checks

Instructions for checking coolant water pipes for leaks and aging for D350.

Fuel Pipe Checks and Replacement

Procedures for checking fuel pipes for leaks and replacing high-pressure oil pipes.

Fuel Pump Pressure Measurement

Steps for measuring fuel pressure using an oil pressure gauge for D350 and D125.

Abnormal Fuel Pressure Troubleshooting

Troubleshooting steps for abnormal fuel pressure issues.

Braking System Overview

General information and cautions regarding the braking system.

Brake Component Checks

Procedures for checking brake components, discs, and pads.

Brake Switch Checks and Replacement

How to check and replace front and rear brake switches.

Brake Handle Lubrication

Steps for lubricating movable parts of the brake handle.

Brake Handle Replacement and Adjustment

Procedure for replacing the brake handle and adjusting it.

Front Brake Pad Replacement (D350)

Safety precautions and steps for replacing front brake pads for D350.

Front Brake Pad Replacement (D125)

Steps for replacing front brake pads for D125.

Rear Brake Pad Replacement

Procedure for replacing rear brake pads.

Brake Pad Noise Troubleshooting

Common reasons for abnormal noise from brake pads.

Brake Disc Replacement

Safety precautions and recommendations before replacing brake discs.

Front Brake Disc Replacement

Reference to front fork assembly for front brake disc replacement.

Rear Brake Disc Replacement

Steps for replacing the rear brake disc for D350 and D125.

Brake Hose Inspection and Replacement

Inspection and replacement recommendations for brake hoses.

Brake Fluid Service

Cautions and procedures for adding and replacing brake fluid.

Front Brake Fluid Replacement

Detailed steps for replacing front brake fluid.

Rear Brake Fluid Replacement

Steps for replacing rear brake fluid.

Brake System Air Bleeding

Procedure for bleeding air from the brake system.

Tire Checks and Maintenance

Precautions and checks for tire condition and pressure before driving.

Tire Inspection

Instructions for checking tire wear, damage, and pressure.

Tire Replacement Procedures

Procedures for replacing front and rear tires.

Steering Mechanism Checks

Maintenance checks and precautions for the steering mechanism.

D350 Steering Mechanism Adjustment

Steps for adjusting steering mechanism clearance for D350.

D125 Steering Mechanism Adjustment

Steps for adjusting steering mechanism clearance for D125.

Steering Bearing Maintenance

Procedures for maintaining steering bearings if clearance adjustment fails.

Steering Mechanism Malfunctions

Troubleshooting common steering mechanism malfunctions.

Front Fork System Cautions

Cautions and checks for front fork condition and performance.

Front Shock Absorber Performance Check

How to check front shock absorber performance and identify issues.

Front Shock Absorber Removal

Reference to front fork assembly for removing front shock absorbers.

Front Fork Tube Correction

Steps for correcting front fork tube deformation.

Shock Absorber Troubleshooting

Troubleshooting steps for shock absorber issues.

Rear Shock Absorber Cautions

Cautions and checks for rear shock absorbers.

Rear Shock Absorber Check

Procedures for checking the condition and function of rear shock absorbers.

Rear Shock Absorber Preload Adjustment

Instructions for adjusting rear shock absorber preload.

Shock Absorber Replacement

Steps for disassembling and replacing shock absorbers for D125 and D350.

Body and Engine Fastener Checks

Checks for critical fasteners on the body and engine.

Engine Fastener Checks

Specific torque values for engine cradle nuts for D350 and D125.

Side Bracket Checks

Cautions and checks for the side bracket and its spring.

Side Bracket Lubrication

Steps for lubricating the side bracket.

Main Bracket Checks

Cautions and checks for the main bracket, its spring, and components.

Main Bracket Lubrication and Installation

Procedures for lubricating and installing the main bracket.

Sound, Light, and Electrical Device Checks

Checks for normal operation of lights, horn, and electrical switches.

Headlight Height Adjustment

Procedures for adjusting headlight height for safe driving.

Fuse Box Identification

Identification and function of fuses in the fuse box.

Switch Troubleshooting (Right Hand)

Flowcharts for diagnosing issues with right-hand switches.

Horn Troubleshooting

Procedures for checking and troubleshooting the horn.

Left Hand Switch Troubleshooting

Troubleshooting flow chart for left-hand switch functions.

Lighting System Troubleshooting

General troubleshooting process for vehicle lights.

Windshield Failure Diagnosis

Troubleshooting abnormal windshield lifting and falling.

EFI System Service

EFI System Know Before Service

Essential knowledge and precautions for working with the EFI system.

EFI Error Code Reading

Methods for reading fault codes through the meter or diagnostic tool.

EFI Parts Layout Diagrams

Diagrams showing the layout of EFI system components for D350 and D125.

EFI Parts Fault Diagnosis

Troubleshooting procedures for EFI components, starting with the dump switch.

OBD Port Functionality

Information on the OBD port for diagnostic tool connection.

Fuel Pump Checks

Cautions and checks for abnormal fuel pump performance.

Carbon Canister Solenoid Valve Check

Procedure for checking the carbon canister solenoid valve.

EFI Relay Identification and Testing

Identification and testing of EFI relays.

Fuel Injector Checks and Testing

Procedures for checking and testing the fuel injector.

Ignition Coil Diagnosis

Diagnosis and checks for ignition coil faults.

Throttle Valve Body Service

Common failure phenomena and troubleshooting process for the throttle valve body.

Sensor Checks and Replacement

Procedures for checking throttle position and air temperature sensors.

Water and Oil Shared Sensor Service

Checks and replacement for the water and oil shared sensor.

Oxygen Sensor Service

Procedures for checking and replacing the oxygen sensor.

ECU Verification

Method for checking ECU normality by replacement.

Crankshaft Position Sensor Checks

Checks for the crankshaft position sensor and magneto stator.

Engine Start Diagnosis (No Fault Signs)

Diagnostic flow chart for engine start issues without fault indicators.

Engine Start Diagnosis (With Symptoms)

Diagnostic flow chart for engine start issues with symptoms.

Poor Acceleration Troubleshooting

Diagnostic flow chart for poor acceleration issues.

High Idle Speed (Hot Engine) Troubleshooting

Diagnostic flow chart for high idling speed on a hot engine.

Unsteady Idle Speed (Cold Engine) Troubleshooting

Diagnostic flow chart for unsteady idle speed on a cold engine.

Unsteady Idle/Stalling Troubleshooting

Diagnostic flow chart for unstable idling and stalling.

EFI Failure Light Flow Chart

Flow chart for troubleshooting when the EFI failure light is always on.

EFI System Schematic Diagram

Wiring diagram for the EFI system.

Ignition System Service

Ignition System Know Before Service

Essential knowledge and precautions for working with the ignition system.

Ignition System Troubleshooting

Steps for diagnosing ignition system issues, focusing on spark plug problems.

Ignition System Layout Diagrams

Diagrams showing the layout of ignition system components.

Ignition System Schematic Diagram

Wiring diagram for the ignition system.

Ignition System Inspection

Procedures for inspecting the ignition system, including spark plugs and coils.

Ignition Timing Information

Information on ignition timing, noting it's preset and requires factory adjustment.

Starting System Service

Starting System Know Before Service

Essential knowledge and precautions for working with the starting system.

Starting System Troubleshooting

Troubleshooting flow chart for starter motor issues.

Starter Motor Service

Troubleshooting steps for starter motor operation.

Ignition System Layout

Diagram showing the layout of ignition system components.

Starting System Schematic Diagram

Wiring diagram for the starting system.

Starter Motor Removal and Disassembly

Cautions and procedures for removing and disassembling the starter motor.

Starter Motor Disassembly Steps

Detailed steps for disassembling the starter motor assembly.

Starter Motor Component Examination

Inspection of starter motor components like front cover and back cover.

Starting Relay Checks

Procedures for checking the operation, coil, and ground wire of the starting relay.

Starting Relay Disassembly and Assembly

Steps for disassembling and assembling the starting relay.

Fuel Supply System Service

Fuel Supply Know Before Service

Essential knowledge and precautions for working with the fuel supply system.

Fuel Tank Removal Procedures

Cautions and steps for removing the fuel tank assembly.

Fuel Tank Assembly Disassembly

Procedures for disassembling the fuel tank assembly.

Fuel Pump Removal and Disassembly

Steps for removing and disassembling the fuel pump.

Oil Level Sensor Removal

Procedure for removing and inspecting the oil level sensor.

External Fuel Tank Parts Removal

Steps for removing external parts of the fuel tank assembly.

Fuel Pump Inspection Methods

Methods for inspecting the fuel pump and its relay.

Oil Level Sensor Checks

Procedure for checking the oil level sensor resistance and float.

Cooling System Service

Cooling System Know Before Service

Essential knowledge and precautions for working with the cooling system.

Cooling System Troubleshooting

Common issues related to engine temperature and coolant leakage.

Coolant System Distribution Maps

Diagrams illustrating coolant system layouts for D350 and D125.

Coolant Flow Diagrams

Diagrams showing the coolant flow paths for D350.

Cooling System Disassembly Cautions

Cautions and procedures for disassembling the cooling system.

D125 Radiator Assembly Removal

Steps for removing the radiator assembly for the D125 model.

D350 Radiator Assembly Removal

Steps for removing the radiator assembly for the D350 model.

D350 Coolant Pipe and Clamp Layout

Diagram showing the routing of coolant pipes and clamps for D350.

D350 Thermostat Assembly and Small Loop

Diagram and steps for removing the thermostat assembly and small loop for D350.

Cooling System Accessories Testing

Testing and inspection procedures for cooling system accessories.

D350 Main Water Tank Checks

Checks and procedures related to the D350 main water tank.

D350 Water Tank Filling Port Precautions

Specific precautions for inspecting the water tank filling port for D350.

Auxiliary Water Tank Inspection

Checks for the auxiliary water tank's air tightness and appearance.

Water and Oil Shared Sensor Reference

Reference to EFI system diagnosis for the water and oil shared sensor.

Thermostat Inspection

Procedures for inspecting the thermostat's appearance, damage, and operation.

Thermostat Failure Phenomena

Common failure phenomena related to the thermostat and engine temperature.

Thermostat Assembly Check

Method for checking the thermostat assembly's seal and components.

Thermostat Core Inspection

Detailed inspection of the thermostat core's opening temperature and movement.

Water Pipe Inspection

Inspection procedures for water pipes, checking for damage and leaks.

Water Pump Cover Assembly Check

Inspection for leaks at the water pump cover assembly.

Braking System Service

Braking System Know Before Service

Essential knowledge and precautions for working with the braking system.

Brake System Troubleshooting

Common issues related to brake lever feel and troubleshooting steps.

Brake Pump and Caliper Disassembly

Cautions and recommendations before disassembling brake pumps and calipers.

Front Disc Brake Main Pump Disassembly

Steps for disassembling the front disc brake main pump.

Rear Disc Brake Main Pump Disassembly

Procedure for disassembling the rear disc brake main pump.

Front Disc Brake Caliper Disassembly (D350)

Steps for disassembling the front disc brake caliper for D350.

Front Disc Brake Caliper Disassembly (D125)

Steps for disassembling the front disc brake caliper for D125.

Rear Disc Brake Caliper Disassembly

Procedure for disassembling the rear disc brake caliper.

Brake Hose and Speed Sensor Gap Check

Checking the gap between the wheel speed sensor and ABS ring gear.

Brake Hose and Speed Sensor Removal

Cautions and steps for removing brake hoses and speed sensors.

Brake Fluid Release Procedure

Procedures for releasing brake fluid from the system.

FC-HU Hose and Front Wheel Speed Sensor

Procedures for removing and inspecting FC-HU hose and front wheel speed sensor.

RC-HU Hose and Rear Wheel Speed Sensor

Procedures for removing and inspecting RC-HU hose and rear wheel speed sensor.

ABS System Layout

Diagram showing the ABS system components and layout.

ABS Hydraulic Control Unit Disassembly

Cautions and steps for disassembling the ABS hydraulic control unit.

ABS Troubleshooting Process

Diagnostic flow charts for troubleshooting ABS system faults.

Battery and Charging System Service

Battery/Charging System Know Before Service

Essential knowledge and precautions for working with the battery and charging system.

Battery Damage or Attenuation Troubleshooting

Troubleshooting process for battery damage or attenuation issues.

Charging System Layout Diagram

Diagram illustrating the charging system components.

Charging System Electrical Schematic

Wiring diagram for the charging system.

Battery Disassembly and Checks

Steps for disassembling and checking the battery.

Charging System Checks

Procedures for testing leakage and charging voltage.

Magneto Stator Charging Coil Inspection

Steps for inspecting the magneto stator charging coil.

Front Fork Assembly Service

Front Fork Assembly Know Before Service

Essential knowledge and precautions for front fork assembly and disassembly.

D350 Front Fork Components Exploded View

Exploded view of front fork components for D350.

D125 Front Fork Components Exploded View

Exploded view of front fork components for D125.

D350 Front Fork Exploded View with Torques

Exploded view of D350 front fork components with torque values.

D125 Front Fork Exploded View with Torques

Exploded view of D125 front fork components with torque values.

D350 Lower Link Board Exploded View

Exploded view of the lower link board assembly for D350.

D125 Lower Link Board Exploded View

Exploded view of the lower link board assembly for D125.

Handlebar Direction Control Service

Handle Direction Removal Precautions

Handle removal precautions regarding brake fluid and wiring.

Handle Direction Component Removal

Steps for removing the handle and associated components.

Component Removal Steps

Procedures for removing handle switches and brake system components.

Direction Component Installation

Steps for installing the direction component and handle switches.

Direction Handle Cover Installation

Procedures for installing the direction handle cover.

Front Wheel Replacement Service

Front Wheel Assembly Removal

Steps for removing the front wheel assembly.

Front Wheel Assembly Installation

Steps for installing the front wheel assembly.

Front Wheel Assembly Exploded View

Exploded view of the front wheel assembly for D350 and D125.

Front Wheel Assembly Inspection

Inspection and maintenance of disc brakes, oil seals, bearings, rims, and tires.

Front Shock Absorber Replacement

D350 Front Wheel and Fender Disassembly

Steps for disassembling the front wheel and fender assembly for D350.

Left and Right Front Shock Absorber Removal

Procedures for removing the front shock absorbers.

Shock Absorber, Fender, Wheel Reinstallation

Steps for reinstalling shock absorbers, fender, and front wheel.

D125 Front Shock Absorber Replacement

Steps for disassembling the front wheel and fender for D125.

D125 Left and Right Front Shock Absorber Removal

Procedures for removing front shock absorbers for D125.

Lower Link Board Service

Lower Link Board Parts Disassembly

Preliminary steps for disassembling parts related to the lower link board.

Faucet Lock Removal

Steps for removing the faucet lock.

Direction Pad Removal (D350)

Procedures for removing the direction pad for D350.

Lower Link Board Assembly Removal

Steps for removing the lower link board assembly.

Lower Link Board Assembly Installation (D350)

Procedures for installing the lower link board assembly for D350.

Lower Link Board Assembly Installation (D125)

Procedures for installing the lower link board assembly for D125.

Other Disassembly Component Installation

Instructions for installing other disassembled components.

Engine Disassembly and Installation

Vehicle Engine Disassembly Precautions

General cautions for engine disassembly and related parts.

Storage Box Disassembly

Steps for disassembling the storage box.

Vehicle Cover Removal

Procedures for removing vehicle covers, including tail skirt and rear armrest.

Coolant Drain and Plug Removal

Steps for draining coolant and removing connection plugs.

Engine Electrical Connector Unplugging

Procedures for unplugging various electrical connectors on the engine.

Throttle Valve Motor and Sensor Plug Removal

Steps for removing stepper motor and sensor plugs on the throttle valve body.

Fuel Pipe and Injector Connector Unplugging

Procedures for unplugging fuel pipe and injector connectors.

Crankshaft Sensor and Oxygen Sensor Plug Removal

Steps for unplugging crankshaft position and oxygen sensor connectors.

Magneto Stator Charging Cable Plug Removal

Procedure for unplugging the magneto stator charging cable.

Starter Motor Bolt and Wire Removal

Removing the starter motor and its negative wire.

Muffler Removal Reference

Reference to muffler removal steps.

D350 Engine Disassembly

Procedures for disassembling the engine for D350.

D125 Engine Disassembly

Procedures for disassembling the engine for D125.

D350 Engine Installation

Steps for installing the engine for the D350 model.

D125 Engine Installation

Steps for installing the engine for the D125 model.

Vehicle Covering Parts Disassembly and Assembly

Vehicle Covering Parts Disassembly Cautions

General cautions for panel disassembly and assembly.

Windshield Removal Steps

Steps for removing the windshield and its decorative covers.

Front Sun Visor Removal

Steps for removing the front sun visor.

Front Cover and Panel Removal

Procedures for removing the front cover and front panel.

Left and Right Side Cover Disassembly

Steps for disassembling left and right side covers.

Seat Cushion Disassembly

Steps for disassembling the seat cushion.

Storage Box Disassembly Steps

Steps for disassembling the storage box.

Fuel Tank Cover Disassembly

Procedures for disassembling fuel tank covers.

Front Left and Right Panel Removal

Steps for removing front left and right panels.

Speedometer Panel Disassembly

Steps for disassembling the speedometer panel.

Front Panel Bottom Lining Removal

Steps for removing the bottom lining of front panels.

Headlight Disassembly

Steps for disassembling headlights.

Windshield Base Removal

Steps for removing the windshield base assembly.

Middle Fuel Tank Cover Disassembly

Procedures for disassembling the middle fuel tank cover.

Pedal and Surrounding Parts Removal

Steps for removing pedals and surrounding parts.

Surrounding Bottom Panel Disassembly

Steps for disassembling the surrounding bottom panel.

Surrounding Middle Part Removal

Steps for removing the surrounding middle part.

Radiator Deflector Removal

Steps for removing the radiator deflector.

Rear Hand Rest Disassembly

Steps for disassembling the rear hand rest.

Tail Skirt and Tail Lamp Removal

Steps for removing the tail skirt and tail lamp.

Rear Mud Flap Removal

Steps for removing the rear mud flap.

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