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Summary of Contents for Ice Bear 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 PREFACE To my dear customers: Your coming are warmly welcomed, we’d like express our gratitude for your choosing ZHENGHUA motorcycles. ZHENGHUA motorcycles are sold overseas for its reasonable design, advanced technique and beautiful appearance. The quality of our products enjoys good reputation among new and old customers. As an ideal foot-substitute and transport tool, ZHENGHUA motorcycles will offer you more convenience to your work and bring more pleasure to your life.
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Page 3: Table Of Contents
TABLE OF CONTENTS CONSUMER INFORMATION AND BREAK-IN INSPECTION AND MAINTENANCE …………22 INFORMATION ………………………………1 INTENANCE CHART …………………………23 CONSUMER INFORMAION …………………2 TOOL ……………………………………………24 SAFE RIDING RULES…………………………3 SPARK PLUG …………………………………27 SERIAL NUMBER LOCATION ………………5 DRIVE CHAIN …………………………………31 PARTS LOCATION ……………………………6 BRAKES…………………………………………33 STEERING SYSTEM …………………………9 TYRES …………………………………………36 LEFT HANDLEBAR SYSTEM ………………12 RENEWAL OF LIGHT …………………………38... -
Page 4: Consumer Information And Break-In
CONSUMER INFORMATION AND BREAK-IN tion, the words “WARNING”, “CAUTION” and INFORMATION FOR YOUR MOTORCYCLE “NOTE” carry special meaning and should be The first 1600 km is the most important in the carefully reviewed. life of your motorcycle. Proper break-in operation WARNING! during this time will ensure maximum life and The personal safety of the rider may be... -
Page 5: Consumer Informaion
CONSUMER INFORMAION from the center of the gravity and inviting PRECAUTIONS ABOUT ADDING ACCESS- unnecessary trouble. ORIES AND PREPARATION BEFORE RIDING (2) Checking the off-ground height of accessory You may buy all kinds of accessories to add and the angle, the improper adding will make the two your Zhenhua motorcycle, but unnecessary and aspects unsafe, also the accessory adding should not unsuitable accessories would invite trouble for your... -
Page 6: Safe Riding Rules
WEAR A HELMET the accessory may be destroyed or the power may be cut off. Motorcycle safety equipment starts with a When adding the accessories, it should fasten to the good quality helmet. One of the most serious injuries body of the motorcycle; the improper adding would that can happen is a head injury. - Page 7 FAMILIARIZE YOURSELF WITH metal gratings and bridges. Whenever in doubt about MOTORCYCLE road conditions, slow down! PRECAUTIONS ABOUT THE RIDING ACCI- Your riding skill your mechanical DENT knowledge form the foundation for the safe riding practice. We suggest that you practise riding your Many motorcycle accidents...
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Page 8: Serial Number Location
SERIAL NUMBER LOCATION The frame and engine serial numbers are used to register the motorcycle; it is also useful for the Zhenhua maintenance station. The frame number ① is stamped on the steering head tube. The engine number ② reverted on the surface of steering head tube. Please write down the numbers here for reference: Frame NO.:... -
Page 9: Parts Location
PARTS LOCATION PST300C PST300R... - Page 10 PST300C...
- Page 11 PST300C...
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Page 12: Steering System
STEERING SYSTEM could not be opened up, the key can be pulled out. “ON” position there are two keys to the motorcycle. The keys can control sparking switch, steering- lock, cap lock and helmet-pole lock. SPARK SWITCH PST300R There are two positions: “OFF”... - Page 13 FUEL TANK CAP ⑴FUEL TANK CAP ⑵IGNITION KEY When you want to open the cap, insert the key 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.
- Page 14 INSTRUMENT PANEL Speedometer ① The speedometer is used to show how many kilometers per hour the running speed is Water temperature indicator ② The odometer is used to show how many kilometers the motorcycle has driven. Neutral indicator ③ FEED WATER POSITION PST300C PST300C PST300R...
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Page 15: Left Handlebar System
LEFT HANDLEBAR SYSTEM right light is on “ ” position, the high beam and the night beam can be lighted up. Put the button on “ ” position, the dipped headlight can be lighted up. If these lights are unnecessary, push the button of right light on “·”... -
Page 16: Right Steering System
RIGHT STEERING SYSTEM THROTILE GRIP③ The throttle grip is used to control the engine speed. Twist the throttle grip toward 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 BUTTON④... - Page 17 CAUTIONS There is shock absorber in the front the rear MUCH DISCHARGE WILL wheel; it is designed according to rider’s MAKE THE CIRCUIT AND MOTOR TOO requirements, loading, road condition and other HOT, POWER ON THE MOTOR FOR NO factors. It is factory set and no adjustment is MORE THAN FIVE SECOND ONCE A needed.
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Page 18: Fuel
FUEL AND ENGINE OIL RECOMMENDATI- use in sphere of application. ON FUEL Please use unleaded [GB17930-1999] petrol with a octane number of 91 or high. Using the unleaded high quality oil can prolong the life of your motorcycle and can also contribute to environmental protection. -
Page 19: Break-In For A New Motorcycle
BREAK-IN FOR A NEW MOTORCYCLE engine components during bread-in to ensure this The forward explains how important the proper mating process. Do not, though, apply excessive load running-in is to achieve maximum life and on the engine. performance of your new motorcycle. The following AVOID CONSTANT LOW SPEED guidelines explain proper running-in procedures. - Page 20 PERFORM NECESSARY PERIODIC MAINTENANCE The initial 1000 km service is the most important to your motorcycle. During break-in all of the engine components will fit close to each other sufficiently. All adjustments will be restored, all fasteners will be tightened, and the dirty oil will be replaced.
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Page 21: Inspection Befroe Riding
INSPECTION BEFROE RIDING Before riding the motorcycle, be sure to check the following items. Never ignore the importance of these checks. Perform all of them before riding the machine. WHAT TO CHECK IMPORTANT ITEMS Steering 1) Smoothness 2) No restriction of movement. 3) No play or looseness Brakes 1) the fluid level in brake fluid reservoir should be higher than the “LOWER”... -
Page 22: Riding Essentials
RIDING ESSENTIALS STARTING THE ENGINE WARNING WARNING 1: if you ride this motorcycle for the first time, Never start the engine in the narrow position we suggest that you practise riding your to avoiding danger motorcycle in a non-traffic situation without obstacles until you are thoroughly familiar with When the engine is “COLD”, the procedure is as your machine. - Page 23 make the engine easy to start. NOTES: Do not race your engine when you are not WARNING: riding. A long time race will make your engine Do not try to start the engine in the staff room too hot and destroy the interior parts. for the poisonous of carbon monoxide, long time running may cause suffocation death.
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Page 24: Stopping And Parking
STOPPING AND PARKING rainy and smooth road. To brake sharply in the 1) Twist the throttle grip away from yourself to close rugged and smooth road will make your out of the throttle completely. control. 2) Use the front and rear brakes evenly and at the same time. -
Page 25: Inspection And Maintenance
INSPECTION AND MAINTENANCE WARNING: The following chart indicated the intervals between The periodic checking and maintenance to your periodic services in kilometers and months. As the motorcycle is very necessary and important to end of each interval, be sure to inspect, check, ensure your safety and prolong your motorcycle lubricate and service as instructed. -
Page 26: Intenance Chart
INTENANCE CHART I：Inspect A：Adjust C：Clean R：Replace T：Tighten Maintenance Odometer(km) period 1000 4000 8000 12000 18000 Everyday check before riding Items **Engine Oil **Spark Plug *Engine Bolt *Gear Oil *Air Cleaner *Drive Chain *EFI Comp. Throttle Operation Brake shoes/Pad Wear Brake System Brake Light Switch Brake Liquid Suspension... -
Page 27: Tool
TOOL There is a set of tool with the motorcycle for your inspection ACCUMULATOR Open the seat, the accumulator can be seeing. PST300C PST300R 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. - Page 28 CAUTIONS: Although the accumulator is totally sealed, the improper operation will invite trouble. Please observe the following items: 1) Fasten the accumulator, never make it loosen or make the cathode and anode opposite to each other. 2) Never place it in the high-temperature or smoke and flame location. 3) If your eyes or skin is stained with vitriol, clean it with water or go to doctor as soon as possible.
- Page 29 AIR CLEANER The air cleaner filter used in this motorcycle is a polyurethane foam filter. If the filter has become clogged with dust, intake resistance will increase with a resultant decrease in power output and increase in fuel consumption due to richer mixture. Clean the air cleaner filter periodically. CAUTION: If driving under dusty conditions, the filter must be cleaned and replaced more frequently.
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Page 30: Spark Plug
SPARK PLUG We suggest you can use the qualified parts- NGK DR8EA 1) Pull out the spark cap 2) Remove the spark plug with a plug wrench and clean all the dusty on the bottom. Remove the carbon deposits from the spark plug with a small wire brush or a spark plug cleaning machine. - Page 31 selected and can meet most working. If the color of spark plug is quite different from the standard plug, you’d better contact with the Zhenhua dealer. For the improper spark plug will effect the engine’s working. 3) Use the spark plug specified on the VECI label or will invite trouble for your operating, so you’d better contact with the Zhenhua dealer before choosing it.
- Page 32 REPLACING ENGINE OIL The engine oil replacement should be carried out when the engine is warm, 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 ①...
- Page 33 WARNING To avoid unnecessary hurt when the fuel and engine oil was heated. 3) stamp the kick starter lever for several times to drain the remaining oil. 4) Replace the used oil filtering net with a new one, check whether the spring and sealing washer are well installed.
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Page 34: Drive Chain
DRIVE CHAIN We suggest that you’d better entrust Zhenghua dealer with replacement of drive chain when the chain was damaged. WARNING! To ensure the maximum safety, the inspection and adjustment of drive chain should be carried out before riding. When performing 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... - Page 35 A dirty drive chain may not only accelerate the chain wear, but also damage the sprocket. Therefore after cleaning it with clean deterging. Smear the drive chain with special chain oil or engine oil. The drive chain should be 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...
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Page 36: Brakes
silencer was cooled down. NOTE: Check the front and rear sprocket for wear when replacing the drive chain, replace the sprocket if necessary. BRAKES This motorcycle has hydraulic disc front and rear brake. Brakes are items of personal safety and should be properly adjusted. - Page 37 a doctor if your eyes were exposed. Please check the fluid lever whether it is upward the “LOWER” level mark The brake fluid should be added to the reservoir whenever the fluid level begins to reach the “LOWER” level mark please make the fluid upwards the “HIGHER” mark CAUTION: Do not use the remained brake fluid from a unsealed container, and the brake fluid remained in...
- Page 38 If the brake system or brake pads have to be repaired, we suggest that these repairs should be performed by your Zhenhua dealer. Zhenhua dealer knows your motorcycle better and is dedicated to your complete satisfaction. CAUTION: The high pressure brake is used by disc brake system.
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Page 39: Tyres
ride your motorcycle immediately after replacement. Apply the brake, release it. Repeat this procedures several times and allow the brake fluid to circulate normally. REAR BRAKE Similar method as front brake TYRES Check your tires for both wear and inflation pressure to ensure the riding safety before riding and when performing the periodic inspection. - Page 40 side slip of motorcycle and loss of the control to the vehicle. Therefore tire pressure should be within specified range. Adjust the air pressure correctly when the tires are cold. Cold inflation tire pressure: Front tire: Rear tire: tire pressure 225KPa 241KPa Tire...
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Page 41: Renewal Of Light
It is dangerous to use the wear tires; it will affect the traction, stability, steering and operating system. A new front tire should be replaced when the depth of thread is decreased below 1.6 mm. A new rear tire should be replaced when the depth of thread is decreased below 2 mm. WARNING: The standard of your tires is as follows: Front tire: 130/60-13 M/C Rear tire: 190/50-12... -
Page 42: Fuse
WARINING: When the bulb is very hot in “ON” position, this condition will last for a short time after the button was turn off. So the bulb should be cooled down before operating. NOTE: Turn the igniting on “OFF” position when changing the bulb. - Page 43 NOTE: Turn the igniting button on “OFF” position before changing or inspecting fuse. WARNING! Do not use other standard fuse, which may destroy your engine and light. TROUBLE-SHOOTING If you can’t start your engine, please check in as the follows steps 1) There is not enough fuel in the tank 2) Whether the fuel has flows into carburetor from fuel system.
- Page 44 2) Fasten the spark plug on the motorcycle. Turn the ignition switch on “ON” position and press down the button to start it. If the ignition works well, there will be sparks between spark plug play. If there is no spark please contact Zhenhua authority repair station.
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Page 45: Engine Impetus Is Not Sufficient
ENGINE IMPETUS IS NOT SUFFICIENT 1: check for fuel supply system of fuel tank. 2: check for ignition timing of ignition system. 3: check for engine idle speed. CAUTION: Before servicing, you are strongly recommended to contact Zhenghua authorized service center. If your motorcycle is valid in guarantee period, servicing by yourself may affect your advantage of guarantee. - Page 46 Ignition switch instrument carburetor drive chain entrance of silencer bottom of fuel tank switch of steering bar seat bottom 1) Spraying your motorcycle with clean water after finishing cleaning. Some remains of detergent may eroded the alloy parts. NOTE: Clean the plastics with soft cloth clean the dirty place several with clean water. 2) Start the engine and make it run for several minutes after drying the motorcycle.
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Page 47: Storage Guide
STORAGE GUIDE Extended storage, such as for winter, requires that you take certain steps to reduce the affects of deterioration from non-use of the motorcycle. In addition necessary repairs should be made before storing the motorcycle; otherwise these repairs may be forgotten by the time the motorcycle is removed from storage. STORAGE 1: change engine oil. - Page 48 flames or sparks in the area where the engine is refueled or where petrol is stored. 3: perform the following antirust procedures in cylinder inside: Remove the spark plug cover, fix it to near plastic parts with rubberize fabric or cord, let it separated from the spark plug.
- Page 49 3: In case fulfilled rust preventing oil please drain it till empty 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.
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Page 50: Specifications
SPECIFICATIONS: Type……single cylinder four stoke water cooled Bore………………………………………..72.5mm Stroke………………………………………66.8mm Piston displacement………………………...275ml Compression ratio………………………….. 10:3:1 Carburetor………………………………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... - Page 51 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.
- Page 52 Lack of Idle Idle bypass intake tube intake air jam ， rinse it with ● ● carburetor cleansing agent. Loose of inlet Fuel mixture becomes ● pipe screw too lean. Leakage Fuel consumption Air comes into exhaust exhaust pipe increases pipe, oxygen sensor...
- Page 53 Fuel Pipe Idem Idem buckling ● ● Wrong connection Injector Fuel mixture is too rich. dripping continuous injection Injector or fuel Can’t reach high Fuel mixture is too lean. ● ● filter speed jams Igniter No spark or weak spark ignition coil ●...
- Page 54 Resistance Electromagnetic spark plug or interference ● its cap is too resistance is out of the small range from 3-9K Ω Bad contact of Suddenly flameout Spark disable ● ● Electric kill switch when running Bad contact of Voltage instability ●...
- Page 55 Sensor Cylinder head Hard to start when Unable cold ● temperature the engine is cold correction sensor Oxygen sensor Smoke and high fuel Wrong close loop ● ● consumption correction, fuel injection is not suitable Self-learn error attachment ● ● ●...
- Page 56 Leakage Flameout when Idem ● ● valve release throttle after high speed. Then hard to restart Too big gap of signal ● the crankshaft crankshaft position is too position low. Too small gap Trembling when Noise in the crank angle ●...
- Page 57 Part 2. ECU Signal Lamps Instant Checking Table (Fig. 2) Number Name Normal Performance Abnormal Main measurement Performance and Notice Fuel Pump Flash after engine works Always off, meaning no Check fuel pump driver Signal driver of oil pump connections and wires Light Injector Flash after engine works...
- Page 58 Always on, or light after Check connections, Lit up for 2 seconds after the engine running. cylinder temperature sensor the ignition key is on, and wires. Fault Alarm then off Unstable light and dark Measure whether Lamp during engine operation. resistance of spark plug or its ECU is likely to get cap is in the range of 3-9KΩ.
- Page 60 Attachment 1: Reset to Factory Setting Under special circumstances, the EFI system may have self-learning errors. Engine will show issues like powerless in acceleration, exhaust pipe detonation. You can try to reset to factoring settings: Step I Step II It is best to have a self-learning process later: 1.
- Page 61 Attachment 2 Pin assignment diagram of ECU socket (viewed in a direction facing the socket)
- Page 62 Attachment 3 Fault Alarm Lamp Flash Code Table Flash Fault source Fault content Remedy frequency Idling intake Idle flow area is too low Cleaning the throttle valve and the air is too low idle bypass passage。 Interference Electromagnetic power Check spark plug cap, spark plug, Interference if their resistance is in the range of 3KΩ~9KΩ.
- Page 63 temperature temperature failure, check the plug, or change the temperature sensor Injector Open or short circuit Check the plug, measure the resistance if the injector, if it is between 12-17 Ω , if not replace Fuel pump Open or short circuit Check the plug, measure the resistance if the pump, if it is between 1.2-1.7 Ω, if not replace...
- Page 64 · This manual should be regarded as one permanent component of the motorcycle. Keep it well with the motorcycle when you resell or lend the motorcycle to other man. The proper operation maintenance information that your motorcycle requires is outlined in this manual. You should become thoroughly familiar with the information presented in this operation manual before riding your motorcycle.