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Ice Bear PST300-20, Manual

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48

As shown in Figure1, the Electronic Control Unit (ECU) controls the engine in injection and ignition process
after calculating on all kinds signals from sensors. Fuel quantity and ignition timing are always controlled in
optimized state, so the engine will have good performance at fuel consumption, power and emission

Part 1. Main Fault Instant Checking Table

Fault

Type

Fault Cause

Fault Performance

Fault Mechanism

Hard
to
start

Flame
out

Powerless

Others
Performance

Summary of Contents for PST300-20

Page 1: ...PST300C PST300R PST300 20 PST300 21 MANUAL HUZHOU DAIXI ZHENHUA TECHNOLOGY TRADE CO Ltd PACIFIC RIM INT L WEST INC USA ...

Page 2: ...ll offer you more convenience to your work and bring more pleasure to your life The manual contains the right and simple way to use and maintain the motorcycles Please read carefully before using it It is very helpful for your using and maintenance In order to make your motorcycle work in good condition please use the initial fitting of ZHENGHUA factory If you have any question and difficulty in t...

Page 3: ...NGINE OIL RECOMMENDATION FUEL 15 BREAK IN FOR A NEW MOTORCYCLE 16 INSPECTION BEFROE RIDING 18 RIDING ESSENTIALS 19 STOPPING AND PARKING 21 INSPECTION AND MAINTENANCE 22 INTENANCE CHART 23 TOOL 24 SPARK PLUG 27 DRIVE CHAIN 31 BRAKES 33 TYRES 36 RENEWAL OF LIGHT 38 FUSE 39 ENGINE IMPETUS IS NOT SUFFICIENT 42 CLEANING 42 STORAGE GUIDE 44 SPECIFICATIONS 47 EFI System Maintenance Instructions 48 TABLE ...

Page 4: ...e engine parts to excessive heat such as running at very high speed for a long time Please refer to break in section for specific break in recommendation WARNING CAUTION NOTE Please read this manual and follow its instruction carefully To emphasize special informa tion the words WARNING CAUTION and NOTE carry special meaning and should be carefully reviewed NOTE This provides special information t...

Page 5: ...sories should be carefully checked in unfastened equipment will cause the diversion from the center of the gravity and inviting unnecessary trouble 2 Checking the off ground height of accessory and the angle the improper adding will make the two aspects unsafe also the accessory adding should not hinder parking diverting and other manipulating 3 To avoid the unbalance problems the accessory should...

Page 6: ...otorcycle riding also requires that some extra precautions be taken to ensure the safety of the rider The driver should comply with the following rules WEAR A HELMET Motorcycle safety equipment starts with a good quality helmet One of the most serious injuries that can happen is a head injury ALWAYS wear a properly approved helmet You should also wear suitable eye protection DRESS The slack and cu...

Page 7: ... keep a sufficient brake distance Take extreme caution at railway crossings and on metal gratings and bridges Whenever in doubt about road conditions slow down PRECAUTIONS ABOUT THE RIDING ACCI DENT Many motorcycle accidents happen during motorcycle turning or other vehicle turning in front of motorcycle therefore it is best to wear bright or reflective clothing and take care while turning You sho...

Page 8: ... to register the motorcycle it is also useful for the Zhenhua maintenance station The frame number is stamped on the steering head tube The engine number is reverted on the surface of steering head tube Please write down the numbers here for reference Frame NO Engine NO ...

Page 9: ...6 PARTS LOCATION PST300C PST300R ...

Page 10: ...7 PST300C ...

Page 11: ...8 PST300C ...

Page 12: ...position When all the electricity was cut off and the engine could not be opened up the key can be pulled out ON position There are two positions OFF position When all the electricity was cut off and the engine could not be opened up the key can be pulled out IGNITION position When all the electricity working you may ignite at any time the key can not be pulled out PST300C PST300R ...

Page 13: ...ey into the hole on the cap and turn on clockwise the cap can be opened The fuel tank capacity is 11 L in which the reserve capacity is 1 6 L WARNING Do not overfill the fuel tank to prevent the fire caused by fuel overflowing to hot engine Never refuel near an open fire PST300C PST300R ...

Page 14: ...meter is used to show how many kilometers per hour the running speed is Water temperature indicator The odometer is used to show how many kilometers the motorcycle has driven Neutral indicator FEED WATER POSITION PST300C PST300R PST300C PST300R ...

Page 15: ... up If these lights are unnecessary push the button of right light on position LEFT RIGHT TURNING SIGNAL BUTTON Turn the button left the left signal can be lighted up Turn the button right the right signal can be lighted up The indicator on the dashboard can also be lighted up If you want to turn down the signal press the button down HORN BUTTON Press down the button the horn blares WARNING SENT T...

Page 16: ...oward yourself to increase the engine speed Turn it away from yourself to decrease the engine speed Turn it away from yourself to decrease the engine speed LIGHT BUTTON in this position the headlights backlights parking lights and dashboard lights are lighted up in this position the backlights parking lights and dashboard lights are lighted up in this position the headlights backlights parking lig...

Page 17: ... OF OPERATING YOU SHOULD CHECK THE FUELING SYSTEM AND STARTING CIRCUIT REAR SHOCK ABSORBER There is shock absorber in the front the rear wheel it is designed according to rider s requirements loading road condition and other factors It is factory set and no adjustment is needed REVERSING GEAR DEVICE Pull from A to B for reversing gear PST300C PST300R ...

Page 18: ... engine oil used in this motorcycle conforms to Chinese National Standards GB11121 95 and American National Standards SAEJ183E80 Please use good quality 10W 40 engine oil Zhenhua special engine oil band four strobe 15w 40 engine oil is strongly recommended to use Mixed oil with different brand is unallowable Choose the different engine oil according to the various area and climate The following it...

Page 19: ...is aids the mating process of the parts It is essential that some stress be placed on the engine components during bread in to ensure this mating process Do not though apply excessive load on the engine AVOID CONSTANT LOW SPEED Operating the engine at constant low speed light load for a long time can cause parts to graze and not fit close to each other Allow the engine to accelerate freely through...

Page 20: ...o each other sufficiently All adjustments will be restored all fasteners will be tightened and the dirty oil will be replaced Timely service during the 1000km service will ensure optimum service life and the best performance of the engine WARNING Maintenance for 1000km should be according to the maintenance planning in the specification Pay more attention to the NOTE WARNING ...

Page 21: ...limit 2 Brake shoes to be within the wear limit 3 No dragging sponge status Tires 1 proper pressure 2 Adequate tread depth 3 No cracks or cuts on the tire surface Fuel reservation Enough fuel for the planned distance of operation light Operating all the lights front light rear light brake light light of dashboard turning light indicator Horn button The function is in normal Engine oil proper oil l...

Page 22: ...ation is not allowed when turning 4 You should ride the motorcycle slowly and keep a sufficient brake distance in rainy and smooth road 5 Observe the traffic regulation and limit the speed STARTING THE ENGINE WARNING Never start the engine in the narrow position to avoiding danger When the engine is COLD the procedure is as follow 1 Turn the fuel cock to ON position 2 Insert the key into the lock ...

Page 23: ...chine closed down the chock valve open the throttle then press the starting lever for several times to make the engine easy to start WARNING Do not try to start the engine in the staff room for the poisonous of carbon monoxide long time running may cause suffocation death stop the engine while there is no person watching it RIDING NOTES Preview the related riding knowledge before riding NOTES Do n...

Page 24: ... you and vehicles The drivers with no experience are used to brake by the rear brake this will increase the abrasion of the rear brake system It is dangerous to stop your motorcycle by only using the front or rear brake this method will make your motorcycle out of control for the skidding Take more care and use the brake system slightly in the rainy and smooth road To brake sharply in the rugged a...

Page 25: ...nt rear brakes suspension and wheel components are key items and require very special and careful servicing For maximum safety we suggest that you have these items inspected and serviced by your authorized dealer or qualified service mechanic WARNING The periodic checking and maintenance to your motorcycle is very necessary and important to ensure your safety and prolong your motorcycle service li...

Page 26: ...I I R I Engine Bolt I I I I Gear Oil R R R R Air Cleaner C C C C Drive Chain I L I L I L I L EFI Comp I I I I Throttle Operation I I I I Brake shoes Pad Wear I I I I Brake System I I I I Brake Light Switch I I I I Brake Liquid I I I I Suspension I I I I Nuts Bolts Fasteners I I I I Wheel Tire I I I I I Inspect A Adjust C Clean R Replace T Tighten ...

Page 27: ...accumulator can be seeing NOTES The voltage of accumulator is 12v without liquid inspection and watering NOTES 1 In order to avoid dangerous do not open the sealed cap at any time 2 The condition of electrification can be inspected by the voltmeter The normal voltage is more than 12 8v PST300C PST300R ...

Page 28: ...ol clean it with water or go to doctor as soon as possible THE METHOD OF CHARGING WITH SEALED ACCUMULATOR FOR YOUR MOTORCYCLE 1 To energize after half a year s storage 2 To energize as the following method Constant voltage charging by current limiting the charging voltage is between 13 8v and 14 5v the current limiting is between 1 5A and 2 5A the charging time is between 9 and 12 hours NOTES The ...

Page 29: ...ue to richer mixture Clean the air cleaner filter periodically CAUTION If driving under dusty conditions the filter must be cleaned and replaced more frequently CAUTION Never operate the engine without the air cleaner in position Operating the engine without the air cleaner will increase engine wear Always be sure that the air cleaner is in excellent operational condition at all times The life of ...

Page 30: ...ug gap to 0 6 0 7 mm by using a spark plug gap thickness gauge if it is necessary The spark plug should be replaced periodically The procedure of installing spark plug is opposite to take down it please make sure that the washer is connecting to the spark plug NOTES 1 Do not make the spark plug too fastened for fear of destroying the screw thread Never make the impurities come into the engine thro...

Page 31: ...quality engine oil and periodical replacement of engine oil will extend your engine s life Check engine oil level daily and replace engine oil periodically are two most important tasks to be carried out for maintenance items CHECKING ENGINE OIL LEVEL Checking the oil level after the engine stopped working for several minutes the motorcycle should be placed on the plain ground Insert the dipstick u...

Page 32: ...arm when replacing the engine oil support your motorcycle with side stand to facilitate draining the oil fully The procedure is as follow shown 1 Stand your motorcycle with side stand Put a drain pan under the engine 2 Unscrew and remove the oil drain bolt under the engine to drain the dirt oil ...

Page 33: ... the engine let it run at idle speed for 2 3 minutes shut off the engine and wait for a minute check whether the oil is at upper level mark If the oil level is below the upper level mark add the oil until it reaches the upper level mark NOTES 1 Check oil filler and oil drain bolt carefully to avoid dripping Check the water cooler system for leakage for the water cooling engine 2 Engine oil should ...

Page 34: ...forming the periodical check the following state of drive chain should be checked 1 Loose pins 2 Dry or rusty chain links or twisted or bonded links 3 Damaged sprocket 4 twisted or bonded links 5 excessive damage 6 incorrect adjusting chain If the above troubles found the sprocket may be considered to cause the damage of the chain Therefore the following check of the sprocket is necessary 1 Excess...

Page 35: ...e adjusted irregularly as per the riding condition to maintain it in normal status WARNING Excessive chain slack could cause the chain to come off the sprockets and result in an accident or serious engine damage Please check and adjust the drive chain constantly WARNING The hot silencer may hurt you it will hot enough to hurt you even the engine was closed In order to avoid scald please inspect yo...

Page 36: ...as hydraulic disc front and rear brake Brakes are items of personal safety and should be properly adjusted We suggest that you should entrust Zhenhua dealer with this check FRONT BRAKE BRAKE FLUID and BRAKE PAD WARNING The brake fluid is poisonous if swallowed forced to spit it Avoid contact with skin or eyes In case of contact flush thoroughly with water and call ...

Page 37: ...upwards the HIGHER mark CAUTION Do not use the remained brake fluid from a unsealed container and the brake fluid remained in the last repairing because the used brake fluid may absorb the water from the air influencing the performance of brake Only DOT3 brake fluid can be used Never make the brake fluid splash on the surface of painting and rubber NOTE Checking whether the pipe is in poor conditi...

Page 38: ...ion CAUTION The high pressure brake is used by disc brake system To ensure the safety the replacement interval should not be more than that stipulated in MAINTENANCE SCHEDULE of this manual When performing the periodical check the following state of brake system should be checked 1 Dripping or not 2 Crack tube or not 3 Keep the certain recovery 4 Wore brake pads WARNING When the new brake pads beg...

Page 39: ...e riding safety before riding and when performing the periodic inspection NOTE This motorcycle is traffic motorcycle Riding on the hill road desert rugged road and rainy road will invite troubles Disobeying the stipulation will cause serious dangerous TIRE PRESSURE Improper tire pressure may not only hastens tire wear but also serious affects the stability of the motorcycle over inflation may resu...

Page 40: ... are cold Cold inflation tire pressure Front tire Rear tire tire pressure 225KPa 241KPa Tire Specifications 130 60 13 M C 190 50 12 Check your tire for both wear and inflation pressure to ensure the riding safety make sure that there are no mark cut nail and other sharp material inserting in your tire If there is any wear status please the Zhenhua dealer THREAD OF TIRES ...

Page 41: ...se danger so we strongly recommend you choose the tire from Zhenhua dealer Tire inflation pressure and the general tire condition are extremely important to the proper performance and a safety of the vehicle Check your tires frequently for both wear and inflation pressure Replace the tire as per following stipulation RENEWAL OF LIGHT When changing a burned bulb the same power bulb should be meetin...

Page 42: ...hen changing the bulb Check in again after finishing the bulb changing to make sure the new bulb can work well FUSE There is a fuse box beside the storage cell The entire electrical appliance is protected by a fuse Please check the fuse first when your motorcycle is dead If the fuse has burned out that may suggest the electrical appliance is overloaded or short circuit Please trust Zhenhua dealer ...

Page 43: ...ws steps 1 There is not enough fuel in the tank 2 Whether the fuel has flows into carburetor from fuel system 3 If the last step has been verified please check the igniting system WARNING Do not make the fuel flow all ground it should be put into containers Keep the fuel off the hot engine and exhausting pipe Keep away from fire or fire source or hot source while performing the test 1 Remove the s...

Page 44: ...tation WARNING Don t let the spark plug to be near spark plug to be near spark plug opening aperture in cylinder head because the fuel vapor in cylinder can ignite causing fire For reducing the possibility of electronic breakdown Metal parts of spark plug should be close to the metal parts of frame without paint For preventing from the possibility of electronic breakdown People should avoid proces...

Page 45: ...ct Zhenghua authorized service center If your motorcycle is valid in guarantee period servicing by yourself may affect your advantage of guarantee CLEANING To protect the surface of painting you should clean your motorcycle periodically Check for the wear parts and the lacking of engine oil NOTE High pressure current may damage the parts of your motorcycle To avoid spraying the follows parts with ...

Page 46: ... make it run for several minutes after drying the motorcycle 3 Before start the engine again try the brakes several times until the normal function can be shown WARNING You d better consider the distance for braking to avoid danger after cleaning 4 Add the lubricating oil to the drive chain after cleaning and drying ALUMINUM TIRE MAINTENANCE The corrosion is caused when the aluminum tire gets to r...

Page 47: ...le is removed from storage STORAGE 1 change engine oil 2 drain the fuel tank and carburetor into a petrol container Spray the inside of the fuel tank with aerosol rest inhibiting oil Reinstall the fuel filling cap CAUTION If storage will last more than half month carburetor draining is very important to assure proper performance after storage WARNING Petrol is extremely flammable and is explosive ...

Page 48: ... oil Reinstall the spark plug and spark plug cover 4 discharge the storage cell and putting in the place without freezing and direct sunlight Charge it one time per half year 5 wash and dry the motorcycle Wax all painted surfaces 6 lubricate the drive chain 7 inflate the tires to their recommended pressure Place the motorcycle on blocks to raise both tires off the ground Park the motorcycle stable...

Page 49: ...pty before use Fill the fuel tank with fresh petrol 4 perform all pre ride inspection checks refer to related contents Before restoring the normal riding test ride the motorcycle in a safe riding area from traffic if no trouble found you can restore the normal riding ...

Page 50: ...rburetor piston type Air cleaner polyurethane foam filter Starter system pull and electricity Lubrication system pressure and splash combined Max speed 90km h Max oil consumption 3 0L 100km Max power 13kw 6500r min Standard power and rotation 14kw 6500r min Max torque 21N m 5500r min Idling 1500r min EFI System Maintenance Instructions P1 P2 ...

Page 51: ...l kinds signals from sensors Fuel quantity and ignition timing are always controlled in optimized state so the engine will have good performance at fuel consumption power and emission Part 1 Main Fault Instant Checking Table Fault Type Fault Cause Fault Performance Fault Mechanism Hard to start Flame out Powerless Others Performance ...

Page 52: ... Leakage of exhaust pipe or O2 sensor joint Fuel consumption increases Air comes into exhaust pipe oxygen sensor signal is disturbed fuel mixture is revised too rich Fuel Fuel pump fault Lack of fuel poor atomization Negative pressure driving pump fault Suddenly powerless and hard to start again Poor cooling effect on fuel pump Gas block in the fuel pipe ...

Page 53: ...ion Idem Idem Injector dripping or continuous injection Fuel mixture is too rich Injector or fuel filter jams Can t reach high speed Fuel mixture is too lean Spark Igniter or ignition coil fault No spark or weak spark Spark plug fault Idem ...

Page 54: ...Ω Electric Bad contact of kill switch Suddenly flameout when running Spark disable Bad contact of key switch of battery wire ends Idem Voltage instability Loose contact of other plug Idem Signal can t be received and send Rectifier fault Can t reach high speed Huge voltage fluctuation breaks ECU or low voltage causes low battery ...

Page 55: ...nd high fuel consumption Wrong close loop correction fuel injection is not suitable ECU Self learn error See attachment 1 to restore factory settings Software or hardware error ECU software or hardware failure because the low system of spark plug or spark plug cap or rectifier fault Machine Too small valve gap Low cylinder pressure ...

Page 56: ...le after high speed Then hard to restart Idem Too big gap of the crankshaft position The signal of the crankshaft position is too low Too small gap of the crankshaft position Trembling when accelerating Noise in the crank angle signal when high speed ...

Page 57: ... Light Flash after engine works Always off meaning no driver of oil pump Check injector driver connections and wires 3 Igniter Signal Light Flash after engine works Always off Check first the crankshaft position sensor and its connections and wires 4 Oxygen Sensor Signal Light Alternating light and dark 1 3 times a second during closed loop oxygen adjustment Always off meaning does not enter close...

Page 58: ...on or light after the engine running Check ECU connections cylinder temperature sensor and wires Unstable light and dark during engine operation ECU is likely to get interfered Measure whether the resistance of spark plug or its cap is in the range of 3 9KΩ Check if the rectifier is fault ...

Page 59: ...56 ...

Page 60: ... about 10 seconds or hear the fuel pump stops working then release the throttle 3 Turn off the key now the self learning parameters have set back to factory settings Step II It is best to have a self learning process later select a road with good condition pull throttle slowly from small to large openness then from large to small openness The essential is to make the throttle change as slow as pos...

Page 61: ...58 Attachment 2 Pin assignment diagram of ECU socket viewed in a direction facing the socket ...

Page 62: ...f 3KΩ 9KΩ If the rectifier is damaged 4 Crankshaft position sensor Open circuit or the crankshaft position sensor signal is abnormal Check the plug adjust the gap of the crankshaft position sensor to a range of 0 5 0 8mm 5 Battery voltage Voltage is too high Check if the rectifier damages 6 Oxygen Sensor Oxygen heating circuit is open or shorted the slow response to the oxygen concentration signal...

Page 63: ...the pump if it is between 1 2 1 7 Ω if not replace the pump 10 Igniter Open circuit Check the plug or replace the igniter 11 Throttle position sensor Throttle calibration error or an open or short circuit Re calibration or replacing ECU 12 ECU Software or hardware damage Replace ECU 13 Intake air temperature Open or short circuit or high temperature Check the plug or replace ECU Remark When the tr...

Page 64: ...manual You should become thoroughly familiar with the information presented in this operation manual before riding your motorcycle All information instructions photographs and specifications contained in this manual are based on the latest product information available at the time of publication Due to improvements or other changes there may be some discrepancies in this manual The change will not...

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