Mash Five Hundred 400 User Manual

Important Information

Please read the user’s manual carefully before going on the first riding. This manual contains a large amount of

information of operation and cautions, which will help you to handle and control of the motorcycle. For your safety,
please pay a great importance to the cautions as follows:

Warning

——Any ignorance of the mentioned-below information may lead to safety problems.

Caution

——Any ignorance of the mentioned-below information may cause the damage of motorcycle parts or it may

compromise the driving safety of the motorcycle itself.

Please fill in the blank with the serial Nos. of the motorcycle,

Frame No.：

Engine No.：

Distributor：

Index

I、Main Technical Data……………………………... …1

II、Operation Instruction…………………………....…2

Protective Wear…………………………… ………...2
Preparation before Operation…………………..…..…3
Operation…………………………………………...….…4

Modification of the vehicle……………………....…..….4

Loading of goods………………………………....…..….4

Accessories…………………………………………..….5
Muffler……………………………………….………..…..5

III、Parts’ position………………………………….…….6

Meter reading & usage……………………………...…….9
IV、开关操作………………………………………...…….13

Switch operation………………………………..……….13
Headlight、Position Indicator…………………..………13
Far and Near Light Lamp Instruction …………….…….14

Direction Indicator………………………….………......14

Horn Button…………………………...………….……..15

Overtaking lamp switch…………………….….....…...15

Electric Start Button…………………………….….......15

Emergency Cut-off Switch………………….……........15

Fuel ……………………………………………………..16
Checking fuel level…………………………………….. 17

V、Correct driving………………………...………… ..18

Engine startin……………………………..………….…..18
If the start fails……………………………..….….… …18
Run-in of engine……………………………..….….… …19

Maintenance of the engine……………………….19
Checking Before Operations………………………….20
Gear Shift……………………………………………….21
Gear down operation………………………………..…22
Operation……………………………………………..…22
Brake Usage…………………………………………..…23
Park…………………………………………………..…23
Rearview mirror………………………………………..…24
Oil cooler installation………………………………..…24

VI、Inspection and adjustment………………..…26

Maintenance Period Table…………………………..…26
Spark Plug……………………………………………..…28
Timing phase…………………………………………..…29

1

Lubricating oil……………………………….…………...29
Cylinder pressure………………………………………...31
Valve clearance……………………………..……….…32
Check-up, cleaning of Air Filter……………………...…34
Idle speed………………………………………….……35
Throttle control…………………………………………36
Brake system……………………………………………37
Front Brake……………………………………………37
Rear Brake………………………………………………40
Running system…………………………………………41
Spoke………… … ………………… … …… …………42
Clutch control line………………………………………43
Adjusting methods………………………………………43
Driving chain……………………………………………44
Battery Checking………………………………………46
Installation of accumulator………………………………47
Replacement of Fuse……………………………………48
Brake lamp adjustment…………………………………48
Headlamp dimming……………………………………49
Position lamp bulb………………………………………50

Taillight、Taillight bulb……………………………………51
Front and rear lamp bulb………………………………52
Side stand……………………………………………52
Bolts, nuts and fasteners………………………………52
Vehicle washing…………………………………………52
Maintenance in Non-use Time………………………53
Resumption of Service………………………………53
Special notice…………………………………………54
Driving……………………………………………………54
Operation turning………………………………………54
Turning method…………………………………………54
Turning reminder…………………………………………55
Dead angle of sight………………………………………55
Speed effect………………………………………………55
Postulate of brake (friction) ……………………………55
Restrict of Brake effort …………………………………55
Brake method……………………………………………55
Impact of crash…………………………………………55
Standard Torque Values…………………………………56

VII、Electrical system diagram……………………58

1

I、Main Technical Data

Length

2130mm

Bore * Stroke

85.0×70.0

Width

740mm

Compression ratio

8.8:1

Height

1130mm

Max power

19.5Kw/7000R/min

Wheelbase

1420mm

Max torque

30.0N.m/5500r/min

Gross weight

160kg

Idle Speed

1500±150r/min

Max loading weight

151kg

Displacement

397.2cc

Front wheel type

100/90-19/280

Spark plug type

DPR8Z

Rear wheel type

130/70-18/290

Spark plug gap

0.6mm-0.7mm

Lubricant volume

2.2L

Valve gap
Intake valve: 0.07-0.10 mm

Fuel tank volume

13L

Exhaust valve: 0.08～0.12mm

End level transmission ratio

2.533

Overcurrent protection

15A/10A

Initial level transmission ratio

2.667

Battery

12V 9Ah

Headlight

12V55W

Taillight/Brake signal light

12V 5W/21W

Position indicator

12V 5W

Turning signal light

12V 10W×4

Turning instruction light

12V 1.7W

Meter light

12V 3W

Far-reaching light instruction

12V 1.7W

Minimum ground clearance

160mm

2

II、Operation Instruction

This instruction book illustrates the notes for the
standard and safe operation method, and basic
maintenance.

To ensure your comfortable and safe riding
experience, please read this instruction book carefully.

·The pictures and illustrations in this book may
be different from the actual vehicle, due to the
difference of model.

·The vehicle is specifically designed for two people
(Including the rider himself)

Caution

Do not use polluted fuel；

Using polluted fuel may possibly cause stain inside
the fuel tank, which in turn block the fuel line, and
occurs failure when the engine starts, or even cause
severe damage to the engine.

Do not use sub-standard or polluted engine oil

Always use decent engine oil, so the engine’s

performance and longevity can be ensured.

If any failure occurs under the inappropriate usage

of polluted oil or petrol, these failure can be worked
out through warranty

Protective Wear

[1]、 Protective wear such as helmet with
protective mask, dust proof glasses and gloves
should be worn during drive for the sake of personal
safety.

[2]、 The passenger should wear high boots or
long clothes to protect legs from hurt by the heated
exhaust silencer during ride.

[3]、 Loose clothes are not suitable for
motorcycle drive or ride as they may get caught on
the operating lever, kick lever, footrest or wheel,
resulting in danger.

·always wear helmet

·wear goggles

·drive safely

·Pay attention to the muffler which may be

on fire because of heat during riding.

3

1. Protective clothing 2. goggles 3. gloves

4.high boots 5. helmet

Preparation before Operation

·read the operating instruction carefully

·maintaining & checking before operation.

·keep the engine switched off and away from

fire.

·There exist harmful substance such as co in the

waste gas , please start engine at the draughty area .

Proper Dress

·Always wear helmet , gloves and safety

goggles throughout

·Do not suggest wearing the uniform which can

easily affect operation, it’s very dangerous if uniform

was hitched by brake beam or driving chain.

·To avoid affecting brake or gearing , do not

suggest to wear the slipper during riding.

·Many automobile and motor accident happened

is because the drivers ignore riders.

Make yourself conspicuous to avoid accident
which is not caused by you.

_Dress flashy or reflective clothes.

_Do not ride at the other driver’s blindness

area .

4

Caution

·Do not take on the helmet which is easily increase

hurt or death probability when accident.

·Make sure passenger always wear helmet to

protect eyes, and dress protecting clothes when driving.

Operation

· The driver should make himself orientate naturally,

keep driving favoring .

· Please check yourself whether are unnatural,

anxious or excited

· Rider’s gesture is very effective to safe operating.

Please always keep sitting in the middle of the saddle,
particularly do not sit in backseat , in case lightening the
weight in front and trembling of handle.

· Passenger should stay on the vehicle, or hold on

the driver , with putting feet on the rear footrest.

· When making a turn, make your body tend to the

way you turn , if not , there maybe dangerous .

· When driving on the circuitous & uneven road, it

is not safe if you do not follow safety caution.

· To drive safely on this circuitous & uneven road ,

driver should reduce the speed a half as normal
speed , and relax shoulder & waist , clench the
handgrip .

· When driving , clench the handgrip without one
hand or two hands , even lift up the front wheel , that
is easily to rollover , and arouse serious accident .

Modification of the vehicle

Caution

Any unauthorized modification of the vehicle or
replacement of the original parts can not ensure
driving safety and is illicit. The user must observe the
regulations of the traffic control authorities. We are
not responsible for any vehicle unauthorized
modification.

Loading of goods

Caution

The design of the motorcycle requires
distribution of the carried goods in certain extent of
equilibrium and improper arrangement of goods will
adversely affect the performance and stability of the

5

vehicle. The manufacturer shall not take any
responsibility due to the reason mentioned above.

Accessory

·To avoid wearing out battery, do not attach any
other lighting equipment except MASH’s original
accessory.

·Check the accessories carefully, insure they will
not block your sight , lower ground clearance and slant
angle , limit moving of suspension, diversion, or control
function .

·Do not add electric equipment , in case that would
exceed capacity of vehicle electric system , lower light
luminance and engine power .

·The vehicle is designed without side-car or trailer ,
because it will affect loading capacity seriously .

Muffler

·Passenger should especially pay attention to
avoid scalding by the muffler when driving .

Caution

· To avoid scalding by muffler , do not park the

vehicle at the walkway .

· Passenger should attention that avoid scalded

by the muffler

· Hay or rattan plant will arouse fire if too closed

to the muffler .

6

III、Parts Position

Left rear view mirror

Meter

Ignition & Steer switch

Right rear view mirror

Left handlebar

Clutch lever

Horn switches

Throttle twist grip

Front brake lever

Engine starter switches

Fuel tank lock

7

Seat assy

Front wheel

Rear wheel

Muffler

Pedal, rear brake

8

Real shock absorber

Front shock absorber

Side stand

Gearshift pedal

Front turn light

Rear turn light

9

Meter reading and usage

1、Speedometer

Indicate motorcycle speed (Km/h). Do not exceed

legal rate-limiting to assure safe riding.

2、Odometer

Indicate riding distance (Km).

3、Turn indicator

（R）right turn，twinkle when turn to right(Green).
 （L）left turn，twinkle when turn to left(Green).

4、High beam indicator

light on when Far light is switched on.

5、Neutral indicator

It is lit up when in the neutral position.

6、Tachometer

It shows the speed(rpm) of the engine.

7、Fuel gauge

Display tank fuel oil

8、Trip mileage meter

It shows the mileage of trip in kilometers.

9、Zero Knob

Indicate distance from Zero, by rotating Zero Knob

to the Direction of Arrow can return it to Zero.

10、FAI EFI Indicator

Indicating EFI system situation

10

Fuel gauge
High beam indicator

Neutral indicator

Zero Knob

Turn indicator
Speedometer

Odometer

Trip mileage meter

Tachometer

FAI EFI Indicator

11

IV、开关操作
Switch instruction

Main Switch used to Start or switch off the

Engine .

Position

Function

Remarks

To stop the vehicle
(switching off all
circuits)

Can

For starting or driving
the vehicle(making all
the main circuits)

Can not

To lock the steering
handle

Can

Caution

·Do not move the Key position when Riding, if the key
is on position during riding, all electric system
will out of Action; So during riding do not move the

main switch Key in case of accident. If it’s necessary,

rider should stop the motorcycle before taking out the
key.

·Before take out from motorcycle, make sure the
handle bar is knocked.

·If the engine is not started when the key is put on
position, the battery will discharge.

·Do not use the key with other sharp Metal keys or key
box，in case of scratching the upper board or leads to
other kind of lost（suggest to use cloth or leather made
key box）。

Headlight、Position Indicator

Turn the main switch key to “ ” position，switch on
the headlight。

12

Switch position

Switch position

position indicator and taillight ON



Headlight switch off

·Position indicator shows its position to the nearby
Vehicles; and reminding other vehicles when wait at
crossroad, to avoid Confusion.
Far and Near Light Lamp Instruction
Press the button, the use of far and near light switch
can control the distance light

（ ）headlight on full beam
（ ）headlight on lower beam

Direction Indicator
Use indication switch when turning Left and right.

If put main Switch on position, the indicator will
wrinkle.
Slide Direction indicator can stop the turning signal
Operation.

（R）Turn Right
 （L）Turn Left

Headlight Switch

Far and Near Light
Lamp Instruction

Direction Indicator

13

Caution

·when finished turning , the direction indicator switch
will not be back to original position automatically ,
please switch it manually .

·Driving with light on will obstruct traffic .

Horn Button
When the main switch at “ ”, press horn button , it

will make a sound

Overtaking lamp switch

According to Ultra Lights, headlights flashing, to
indicate the vehicle in front to overtake

Electric Start Button
Push this button, make the engine start.

Emergency Cut-off Switch
Emergency cut-off switch used to Switch off the

motorcycle by hand; under normal situation, assure it
used when position on , but not .

Horn Button

Electric Start Button
Overtaking lamp switch

14

Caution

·Emergency cut-off switch only used under urgent
situation.

·During riding, turn the switch from to

will

cause dangers, and damage the engine.

·Use Emergency cut-off switch to stop the engine
should make sure that the Main Switch on
position; if on

position and engine powered off , the

battery discharged.

·If put the Switch on

position, the engine cannot be

started.

Fuel

 Fuel filling
The capacity of the fuel tank is 13L. Lead free
gasoline of No.93III(RON 93) or above is required for
the motorcycle. To fuel the vehicle, support it by the
main stand, open the lock cover of the fuel tank by the
key and fill fuel through the opening, and then close
the tank by the cover and take out the key.

Caution

·To ensure the engine is stopped and far away from
fire before adding fuel .

·Fuel will spill if the fuel is up to the underline of level
card .

Emergency
Cut-off Switch

Fuel tank cover

15

V、Correct driving
Engine starting

Set the key of the ignition switch to “ ”position.
Set the emergency stop switch to “ ” position.
Ascertain the gear is in neutral position by checking
the neutral position lamp is lighted.
Ascertain the fuel level in the tank.

To start engine :

Start the engine by the electric cell motor. Each time
you push down the start button, it is recommended
that you stop pushing when firing sound of the engine
combustion is heard and the engine is fired and
running. If the engine is not firing, please stop pushing
down the start button in 5 seconds, and wait for more
than 5 seconds before next start.
Slightly turn the throttle twist grip by about 1/8 turn but
never over 1/4 turn to increase intake air and restart
the engine again if the engine started but stalled
during idling in cold seasons, and keep the engine
running at a higher speed so as to warm up the
engine for about 10 seconds or more.

Caution

The engine can only be started when the gear is in
neutral position or clutch is OFF. Otherwise accident
may happen.
Unnecessary long time idle running (especially at a
high speed ) may be harmful to the engine.

To stop engine running:

you can also stop the engine running by turn the
ignition key to “ ” position to cut off all electrical
power.

If the start fails

If the engine can’t be started, or the motorcycle is not

moving, the points below should be checked：

·If there is fuel in the tank

·If the motorcycle is properly operated according to
the instruction book shows

·If the fuse is melted

·If the engine start button is working properly

·If the battery is finished with power which cause the

16

engine start button not working, please try the kick
start

Run-in of engine

Run-in of the engine is very important. Any operation
without run-in (or improper operation) will cause
serious damages or failures of function
A. Engine without run-in and the one has been run in
have big difference in their power and torque
performance.
B. The well run-in engine: the initial wear-out of the
parts is well renewed, which eases the damage to the
parts in fierce movements, and extend the service life
of the engine.
C. Requirements

1). Never fully open the throttle when the new
motorcycle has not been ridden for more than 350km.

2). When riding in each gear, the speed should less
than 80% of its allowed speed (the opening of the
throttle should be less than 80%), and shift the gear in
time.

3). Do not let your engine bear too much load in the
first 350km.

Maintenance of the engine:

A. When the engine has run in for 800-1000km, a duly
check should be taken.

1). Replace the engine oil (the capacity of the engine
oil is 1.8L)

2). The adjustment of the valve clearance inside
cylinder head is allowed (carried out by MASH service
stuffs)
B. After finishing 800-1000km run-in, please activate
ordinary maintenance.

1). Check the spark plug, adjust the clearance and
clean up the carbon deposit.

2). Replace the engine oil

3). Tighten each fastener

4). Clean the air cleaner

17

Checking Before Operations

In order to ensure safety, vehicles must be checked
and maintained on time.
Please make sure thorough inspection for the vehicle
is finished each time before you ride.
1、Engine oil level checking: Insufficient engine oil will
cause earlier abrasion, and damages.
2、Fuel level checking, tighten up the fuel tank cap,
and check if the fuel pipe is twisted.
3、Transmission chain checking, loosen chain will fall
out of the sprocket, severely worn out chain may
break, insufficient lubrication may cause the abrasion
to the chain and sprocket, and if the chain is getting
too tight, then the transmission system will be
suffering extra burden, which in turn abase the chain
or break the transmission.
4、Check the tire, to see if the tire is under abrasion,
tire with scratch or grooves abnormal should be

replaced, the tire tread’s depth should meets the legal

regulation, moreover, tire pressure inspection is also
crucial. Both factors mentioned above is key to the

motorcycle performance and safety.
5、Brake system checking, to see if the brake system
is working normally. Brake fluid amount and the state
of the brake shoe should be checked. The brake fluid
checking should be done before the engine started, if
the level of the fluid is lower than the minimum level
line, the cause maybe leaking or the abrasion of the
brake shoe. To avoid the utter incompetence of the
brake system. Please go to MASH’s technician for
professional inspection and suggestions, we will also
help you to check the condition of the brake pipe, disk
and brake shoe, also the distance of the brake lever
and pedal.
6、Cable checking, Please check if all the cable for
control is correctly installed, and moves smoothly.
7、Throttle checking, check the throttle grip, throttle
cable to see if there is enough gap, and if the
acceleration process is smooth, and turning off
process is fast and clear.
8、Clutch checking, the cable should have enough gap
to move, and can move smoothly.

18

9、Lights and horn checking, please kindly check if the
illumination and the horn are working normally.
10、Rear view mirror checking, sit on the vehicle and
keep your body vertical to the ground, see if you get a
clear view of the world behind you from the rear view
mirror.
11、Steering bar adjusting, sit vertically on the seat,
check if the steering bar is at the best position for your
safe and comfortable operation, also without the
tangle of cables..

Caution

When you check, please make sure your conformity to
the safety rules and law.

·The exhaustion contains harmful gas, like CO, so
please make sure when you make the checking with
the engine started, keep it in ventilated place.

·The checking should be launched in flat and hard
ground, with stable support.

·Watch our for fire when the engine is just switched off,
because the engine and muffler are still quite hot then.

·Before you repair or mend, the engine should be
switched off and the key should be pulled out.

·If the problems still exist after calibration , please
immediately get contact with our authorized
workshops , dealers or appointed repair shops .

Gear Shift

①When you ride on the motorcycle and the
engine is idling, disengage the clutch and push the
gear shifting pedal down by left foot fingers to
change the gear from neutral to 1st gear position.

②Gradually turn the throttle twist grip to increase
the speed of the engine to about 3000 r/min, and
slowly release the clutch lever until the motorcycle
start to move, with a good coordination between the
two operations of throttle and clutch to ensure a
natural riding start.

③When the motorcycle reaches a balanced state
of running, return back the throttle twist grip and
disengage the clutch again, and then push up the
shifting pedal to change the gear to the 2nd

19

position.

④The gear can be shifted up to 3rd-5th gear

position in the same way.

⑤If you push down the shifting pedal instead of

push up, you can change down the gear position.

Gear down operation

If you want to speed up drastically, for example, when
passing another motorcycle, gearing down can
provide faster acceleration, but if the speed gets too
high, damage for the engine may be caused by
over-speed.

Operation

•Before starting the engine, please make sure the
side stand is at the right position。

•If the side stand can’t be moved smoothly, please

check the lubrication of the side stand joint.

•Shift the gear properly according to the motor speed,

•In order to keep the fuel consumption at a lower state,

and also to ensure the longevity, please do not
accelerate or decelerate too drastically。

＜Running in＞

Make 1000km running in at the speed of 6000rpm,
this can provide better longevity

Caution

·Always start the vehicle from gear I, and make the
starting process as slow and carefully as possible.

·During the riding, if there is any abnormal noise,
please contact the authorized distributors for
inspection, and take necessary step.

·Keep the speed under the legal limit.

5
4
3
2
N
1

Shifting forward

Shifting backward

20

Brake Usage

·Use front and rear brake simultaneously。

·Avoid unnecessary sudden brake。

Caution

·If You only use the front or rear brake, the motorcycle
may slide down。

·When riding in rainy day or on wet road, when brake
suddenly, accidents will occur, so please speed down
and use the brake properly。

·Avoid repeat brakes and overheat the brake, which
will cause the brake lose effect.

＜Engine Brake＞

The engine can work as a brake if you rotate the
throttle grip in as reversed direction, And if you need
stronger braking power, lowering the gear to IV or III is
suggested, meanwhile, if you need the motorcycle roll
march in a lasting decelerating state, or decelerates
quickly, you may use the vehicle brake and use the
engine brake at the same time.

Caution

When the motorcycle running over speed, do not
switch to the lower gear, in case to reduce the speed
suddenly and cause damage to the engine and
transmission system; and even cause shaking of rear
section of the vehicle.

Park

·Shift the gear to neutral, and switch off the
motorcycle.

·Turn off the throttle.

·Please use the main stand to keep the motorcycle
steady, and keep the motorcycle on the horizontal
ground, or else, the vehicle will fall down.

Caution

·Park the motorcycle in safe and traffic free place.

·The muffler could be severely hot, please pull off the
motorcycle away from the place of easy access.

21

＜Park with side stand＞

Place the motorcycle on horizontal ground, activate
the side stand, and move the steering bar to the left
side.
If the motorcycle is placed on the terrains below, the
motorcycle may possibly fall down.

·If the steering bar is moved to the right side, or the
motorcycle is side stand on slopes, sandy, rough or
soft ground, the vehicle is prone to fall down.

·In unavoidable situations, necessary steps must be
taken to ensure the stability.

Rearview mirror

Before driving, must adjust the rearview mirror angle.

Warning

Don't put anything on the back seat to avoid interfere
with vision mirror .
Don't adjust mirror while you are riding.

Caution

To use soft paper or similar material to clean mirror,
you can use detergent, but please don't spray
detergent on the mirror directly.

22

VI、Inspection and adjustment

Maintenance Period Table

Maintenance times

Maintenance Items

Period

1000

4,000

7,000

10,000

Remarks

*Fuel system, fuel filter

I I

I

*Throttle cable, clutch cable

I I I

I

*Throttle valve body

I I I

I

Air filter element

Remark 1

C R R

Replace every 3,000km driving

Spark Plug I I I

Replace every 3,000km driving

Engine lubricant oil

1st inspection : 1000km then change it every 3000km riding

Oil filter R

Replace every 3000km driving

*Tensioned (timing)

Remark 3 I I I I

both intake and exhaust (valve clearance)

Remark 3

I

Check every 7,000km driving

Clutch I I I

I

*Driving chain

Proceed with I and L for every 500km driving

**Front and rear brake system

I I I I

** Brake Pad

I I I

I

** Brake fluid

Change every 2 years

*Front and rear brake lamp switch

I I I

I

23

*Accumulator

o

I I I

I

*Suspension system

I I I

I

*Nut and bolt fastening

I I I

I

**Wheel & tire

I I I

I

**Steering column bearing

I I I

I

Maintenance shall be carried out to the motorcycle in a specified period. The meanings of various symbols in the list
are as follows:

I: Carry out inspection, cleaning, tightening, adjustment, lubrication or replacement.
C: Cleaning. R: Replacement.
A: Adjustment.
L: Lubrication.

* This item is subject to maintenance by persons from MASH Service Station. If the user has special service tools,
maintenance accessories or maintenance ability, it can repair it by itself.
** To ensure safety, this item is only subject to maintenance by persons from MASH Dealer.

Remarks:

①

While driving in a dusty area, it shall be cleaned more often.

②

When the odometer reads more than the given maximum value, its maintenance period shall still repeat as per

the mile interval as stipulated in the table.

③

To ensure safety, the adjustment of timing chain and valve clearance shall only be carried out by persons from

MASH Service Station.

Maintenance Caution

24

This section introduces the inspection and adjustment of various parts of the FIVE HUNDRED motorcycle . It also
introduces the technical requirements for the inspection and adjustment.

Explanation:

Unless expressly stated or indicated in the maintenance period table, check and adjust all parts of the FIVE
HUNDRED motorcycle according to the contents hereof before using it.

Spark Plug

Remove the spark plug cap. Remove the spark plug
with a socket wrench. Visually check whether there is
any damage with the spark plug insulator and ablation
with the electrodes. If yes, replace them.
Check the spark plug electrode gap with a plug gauge.
Spark plug electrode gap 0.6 -0.7mm. Carefully adjust
the electrode gap. Then clear away the accumulated
carbon and contaminants with a spark plug cleaner or
string wire. Check that the spark plug sealing gasket is
in good condition.
To mount the spark plug, manually screw up the spark
plug first, and then tighten it with a socket wrench. Put
on the spark plug cap.

Gap: 0.6 -0.7mm

Check for gap, deposit
and electrode

Check for the gasket
sealing property

25

.Lubricating oil

Using high quality engine oil designed for four stroke
engine will extend the life length of the engine. Please
select the SE, SF or SG type high quality engine oil
classified in API
Please apply Shell 15W/40-SF engine oil in summer and
10W/30-SF in winter

Caution

The insufficiency or poor quality of the engine oil will
lead to the premature wear-out of the engine.

Substitution of the engine oil

Engine oil plays a very important role in the normal
operation of the engine and for that reason, it is
necessary to check the motorcycle for Engine oil
periodically and renew the oil once every 800-1000 km
of drive by the following procedures.
Note: When replacing the engine oil, please clean the
short and long oil rulers and to replace with both oil
filters. The engine oil should be replaced at an operating

temperature.
Unscrew the draining nut when the engine is hot and
then drain the old engine oil.
Clean the filter and then install. Fill with 2.1L new engine
oil. Start the engine for idle running with 2-3 minutes.
Check whether or not the engine oil level is among the
lowest and highest level of the oil ruler.

Machine oil gauge

Screw plug for oil
draining

26

Caution:

When the engine is at a operating temperature, the
engine oil might be very hot, so do not make yourself
burnt.
Place the motorcycle flatly, take off the plug, then fill the
engine oil in the container. Clean the plug thoroughly.
Since all the oil has been used up, clean the gasket and
tighten the gasket and plug together to 20－30N.m
Oil ruler must be mounted properly, or the oil ruler will
fail to function and strengthen wear-out of the engine.

Cleaning the sump

 Drain off the engine oil thoroughly.
 Disassemble each parts

 Clean each part respectively.
 Fuel with the appointed engine oil.
 This work only can be done by professional stuff,

please have your sump cleaned at the
authorized service station.

Cleaning oil filter

The oil drain plug (filtering net cover) remove
Out the filter net
The filtering net is dross clean
According to the original machine assembly reduction

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Valve clearance

Noise will stem from too big valve clearance. However
if there is too small gap or even no gap at all, closing of
the valve will be hindered, which will cause many
problems such as engine stall, power loss, etc.
Therefore, the valve clearance must be checked
periodically.
The valve clearance should be inspected and adjusted
by a Mash Dealer.

The specified valve clearance is : 0.07-0.10mm for
intake valve and 0.08-0.12mm for exhaust valve
respectively.
If clearance adjustment is needed, please contact your
Mash Dealer.

Valve cap

Turn the key clockwise

Throttle bar fully opened

Press engine’s start button

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Check-up, cleaning of Air Filter

Take out the air filter and check if it is contaminated.

Dismounting:
Open the right side cover. Remove the right side cover
screw of the filter, open the right cover and disassemble
the air filter.
Cleaning:
Wash the filter in clean washing oil and wipe it dry with
dry cloth.

Caution:

The air filter element for use must be intact or the
engine will suck in dust and dirt, resulting a shorter
service life of the engine.
Water should be prevented from entering into the filter
in washing the vehicle.
The filter shall never be cleaned with gasoline or any

other agent of a low ignition point.

Air cleaner cover

Air cleaner element

29

Idle speed

Caution:

Check and adjust the idle speed after all other items of
the engine have been adjusted to the specified ranges.

For this model, the idle speed is controlled by an ECU.
Since the intake flow at idle speed has been properly
adjusted upon delivery, do not adjust the idle speed
adjusting screw as desired. In case the idle speed is
unsteady, zero or too high, find out the possible causes
with the troubleshooting method for the EMS system
and eliminate the trouble.
Under the monitoring of the maintaining and diagnostic
instrument, check whether the ignition advance angle is
between 0°-15°. If the ignition advance angle is more
than 15°, it indicates the throttle valve’s intake flow at
idle speed is insufficient, and at this point, the idle speed
is unstable or null; if the ignition advance angle is less
than 0°, it indicates the intake flow at idle speed is too
big, and at this point, the idle speed is often as high as

more than 1800 r/min. Only under the above two cases,
unscrew the retaining nut and adjust the idle speed
adjusting screw to let the intake flow reach the specified
flow.
Idle speed 1500 r/min ± 150 r/min.
After adjusting toe-in, remember to screw up the
retaining nut.

Idling speed adjusting

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Throttle control

First, check whether the throttle control line is deformed,
twisted or damaged.
Then, measure the throttle bar free stroke. Turn the bar
to lean it against one side of the free stroke, and draw a
straight line between the bar and the balance weight
with a mark pen, and then turn the bar to lean it against
the other side of the free stroke; measure the distance
the straight line staggers, i.e. the throttle bar free stroke.
Free stroke 2-6mm.

If the free stroke is insufficient or too big, make
adjustment.

Adjusting methods:

Fine adjustment:

Pull open the rubber lagging, unscrew the retaining nut
A, and turn the adjusting solenoid to adjust to a satisfied
free stroke. And then screw up the retaining nut A and
mount the protective rubber lagging.
Coarse adjustment: If the fine adjustment is not

Retaining nut A

Retaining nut B

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satisfying, separate the throttle control line with throttle
valve body and unscrew the retaining nut B to make
adjust the free stroke in a larger range. Screw up the
retaining but B after the adjustment.
Check whether the throttle can turn smoothly from full
open to full close at any position. If there is clogging,
adjust or replace it.

Warning

use not full throttle to the free stroke motorcycle is a
dangerous operation, rotating the handle, not full throttle
to the free stroke can make the engine speed increases
suddenly.

Brake system

The front brake is disk type, and the rear brake is drum
type, due to the abrasion of the brake shoes, the brake
fluid will be getting less as time goes by.

The performance can’t be adjusted, but the brake fluid

level and brake shoe abrasion are the two most
important factors, that needs to be checked on time.
The brake system should be checked frequently, to
ensure there is no leaking.

Front Brake

＜brake handle idling＞

Pull brake handle lightly till to when you feel the tension ,
then check the free stroke , if brake handle has no free
stroke or too loose , that is the sign of brake system
fault .

free stroke of brake handle ：10 – 20mm

10 – 20mm

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Warning

·brake fluid will arouse inflammation , should avoid
being touched with skin &eyes . once touched , should
clean clearly with water , furthermore , if touched with
eyes , must go to hospital .

·storing in the area where child cannot touch .

＜brake fluid level＞

The motorcycle is supported on the flat ground, operate
steel wheel and check brake fluid when cylinder cover is
at the level position .
Check fluid level, whether it is below the lower position .
If the brake fluid level tend to low , that means weeping
exists in brake system , check the leaking situation or
brake system , if this situation happens , the one should
check the leaking source , or the damage situation of

system , as well as checking the link point and holder’s

tautness .
Additionally , if the vehicle shakes from left to right as
vibrating when driving , the one should check whether
the hole or pipe cover touched with other parts .

Caution

• brake fluid supplement can not exceed the upper, so

that the liquid outflow.

• supplementary brake fluid due to special care, don't let
the dust or water into the cylinder.
If the brake fluid is obviously reduced, is a sign of failure

Lower level

Upper level

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automatic system.

• avoid chemical reaction, the brake fluid is not available

from different manufacturers.
Do not allow the brake fluid contact vehicle parts, so as
not to damage the painted parts.

＜make up the brake fluid＞

·Turn the handle bar and make the pump cylinder be
horizontal with the ground.

·wipe out the dust and foreign matters from pump
cylinder.

·Loosen the screw of cover, then take out the
diaphragm.
Add the recommended brake fluid into the upper
position of cylinder, then tighten the cover with special
attention for diaphragm to avoid no foreign matters in.

Caution

1 The brake fluid shall be DOT 4 non-petroleum base

brake fluid.

2 The brake fluid can’t be mixed with other impurities;

otherwise the braking performance shall be
reduced due to chemical change.

Caution

The brake fluid is strongly corrosive, never splash it
onto the surfaces of spray painted or plastic pieces; in
case it splashes into the eyes or on the skin,
immediately flush with large amounts of fresh water and
see a doctor.

＜Brake piece checking＞

Operating brake, if the wears limit line of the brake shoe

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touch to the side of the brake disc. It shows that the
brake shoe has touched the wear limit.

Rear Brake

Pushing the brake pedal by hand, checking the
resistance, to confirm the move of the brake pedal
whether is good. If not, it could be adjusted by adjusting
the rear brake adjustment nut. Twirling the nut to adjust
the pedal stroke. Pushing the brake pedal by hand till
feeling resistance . Validation the pedal free stroke
whether is in the scope of regulations.

Brake pedal free stroke：18-25mm

18-25mm

Cotouts

Adjustment nut.

35

＜The brake piece checking ＞

（1）Pulling the front & rear brake, checking the wear

and tear of the brake shoe. If the mark "△" on the
drum brake cover and also on the brake cam alignment,
shows the brake shoe has been touched the wear limit.
Please change it.
（ 2） If it needs to be changed. Please go to the
designated special maintenance station. And it is better
to use the parts from our company.

Caution

·Please change the brake shoe in time if it has been
touched the wear limit. Otherwise it would cause
accidents by the lack of strength.

Running system

Tire specifications and tire pressure

Check the tire pressure with a tire pressure gauge to
see whether the pressure conforms to the
recommended value.

Tire specifications and recommended tire pressure:

△

△

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Tire

specs

.

Front tire

Rear tire

110/90-19

130/70-18

Cold tire air

pressure

Normally loaded

Fully loaded

Front tire

Rear tire

Front tire

Rear tire

180kPa

200kPa

200kPa

230kPa

If the tire pressure can’t reach the specified

requirements, check the tire for cuts, embedded iron nail
or other sharp articles.

Caution

The tire pressure measured when the tire is cooled
down shall be the correct tire pressure.

Spoke

Check the wheel for loosened or broken spokes.
Screw the loosened spokes to the specified torque with

a spoke nut fastening tool .The spoke nut torque:

2.45-4.9N.m.
If any spoke is broken or cracked, replace it as soon as

Rear wheel tire pressure

Front wheel tire pressure

37

possible.

Clutch control line

Check the clutch operating handle free stroke. Clutch
operating handle free stroke: 10-20mm.

Adjusting methods:

Fine adjustment: Pull open the rubber lagging, unscrew
the retaining nut, and turn the adjusting nut to adjust to a
satisfied free stroke. And then screw up the retaining nut
and mount the protective rubber lagging.

Coarse adjustment:

If a satisfactory free stroke can't be achieved by fine
adjustment, remove the clutch control line on the handle
end to adjust the engine end.

Spoke nut fastening tool

10-20mm

Adjusting Nut

Retaining nut

Adjusting Nut

Retaining nut

Retaining nut

38

Remove the clutch control line on the handle end, and
then remove the clutch operating arm on the engine end;
turn the clutch operating arm by a proper angle and
remount it, and then mount the clutch control line, finally
adjust it to a satisfied free stroke according to the fine
adjustment.

Caution:

Always ensure the clutch operating handle has the
proper free stroke! Being too loose will cause a failure of
the clutch detachment, while being too tight will cause
poor clutch engagement thus damaging the clutch.

Driving chain

Driving chain tension inspection

Park the motorcycle on level ground with main stand,

and shift the transmission to the neutral position. Check
the driving chain tension. Press the chain with a finger
up and down to check the amount of movement of the
lower chain.
Driving chain tension: 20-30mm.

If the chain is too loose or too tight, make adjustment.
Adjusting methods:
Unscrew the rear wheel spindle nut and turn the
adjusting bolt on the chain adjuster until the specified
tension is achieved, and then fasten the rear wheel
spindle nut, and check the flexibility for free rotation of
the rear wheel and the consistency of the front and rear
wheels.

39

Caution:

The scale lines of the chain adjuster on both sides must
be consistent with each other.

Warning:

The rear wheel spindle nut must be firmly screwed up to

the tightening torque of 60-90N.m.
Clean and inspection of chain

First, remove the chain by detaching the spring locking
pieces and the removable chain plate.
Use cleaning liquid to wash the driving chain and
remove dust and mud, and then air dry it; check the
chain for abrasion or cracking, and replace it in case of
damage.
Remount the chain and coat it with chain-specific
lubricant; while mounting the chain, the spring locking
pieces shall be in the opposite direction with the chain
movement, the left and right scale lines of the chain
adjuster shall be consistent and the chain swag (tension)
shall be 20-30mm.
Inspect the abrasion of major / minor sprocket. In case
of serious tooth abrasion, teeth missing or broken teeth,
replace it.

Unscrew the rear wheel

Adjustment

40

Caution

This model uses the oil seal chain, so the selected
washing oil shall be in corrosive to the oil seal; while
assembling the chain, the locking piece coupling spindle
shall be coated with appropriate amount of
chain-specific lubricating oil.

Warning:

While mounting the spring locking pieces, its opening
end shall be in the opposite direction with the normal
movement of the driving chain.

Battery Checking

Open the left side cover.
Clean away dust and corrosive from the surface of the
battery.
Remove the negative, then the positive pole of the
accumulator; unscrew and remove the loosen battery
strap
Set the vehicle in a vertical position to see whether the
level of the battery electrolyte is between the upper and

Cleaning and coating oil

Movement direction

Spring locking piece

41

lower mark lines If it is below the lower one distilled
water shall be added to the battery. After filling in
distilled water, measure the voltage of the negative pole
with a voltmeter; if it is less than 12V, recharge it with a
charge power supply.
Seriously corroded conductor connectors of the battery
shall be replaced.

Installation of accumulator

Installation is in the reverse order of removal. While
connecting the poles, connect the positive pole first.

Caution

1 In this model, both the startup and EMS system

are completely powered with accumulator.
Therefore, it is quite important to ensure sufficient
electric quantity of accumulator, otherwise, startup
is impossible.

2 Never fill in tap water, because this will shorten the

accumulator’s life span.

3 To dismantle battery ,disconnect the

negative(-)electrode before the positive(+)one,
and vice versa in installation .Ensure against any
contact of the positive(+)electrode with the vehicle
body.

4 Never have the electrolyte level come over the

upper mark line when adding distilled
water .Otherwise overflow and corrosion will occur.

5 The electrolyte contains sulfuric acid and will

cause serious hurt to skin and eyes by contact. In
case of contact with it, wash it off for 5 minutes and
see a doctor immediately.

Negative (-) Connector
Positive (+Connector

42

6 Foreign matter should be prevented from entering

into the battery during dismounting and
installation.

7 The breathing pipe must be kept unblocked.

Replacement of Fuse

Set the ignition switch to “OFF” position. The
specified fuse tube of 15A should be used for main fuse
replacement, and a 10A fuse tube for FAI injection
nozzle.
Open the left side cover, remove the fuse holder on
the side of the battery and replace the fuse tube.
If the new fuse tube is broken again as soon as it is
fitted on, it means that somewhere of the electric parts is
shorted unexpectedly.

Caution

Do not use any fuse over 15A
Be sure not to wash the battery when washing the
vehicle.

Brake lamp adjustment

If the rear brake lamps abnormally light up and go out,
adjust it by turning the adjusting nut. If the rear brake
lamp switch is broken, replace it immediately.

Lower electrolyte
Level line

Upper electrolyte
Level line

Fuse

Rear brake

switch

43

 The braking light should be lit up on time as soon

as the rear wheel is braked. If not, adjustment shall
be made by turning the adjusting nut.

 With the braking light switch in “ON” position, the

braking light should be lit up. If not, check should
be carried out to see whether the braking lamp,
circuit and switch work normally, Make
replacement if needed.

Caution

For the adjustment of the braking light switch, the brake
needs to be first checked to make sure that the free
operating stroke is ensured within the specified range.
If the braking light switch does not work well, the

designed safety system BOS (Brake Override System)
may not work well, causing problems such as no power
when accelerating the throttle, or still powered even
braked.

Headlamp dimming

Before driving, check the brightness, direction, etc. of
the headlamp.
The adjustment can be made to the headlamp in the left
/ right and vertical directions.

Adjusting nut

Adjusting bolt

44

 Loose the screw to disassemble the headlight.
 Rotating , directly unplugging
 Rotating and disassemble the bulb.
 Install the new bulb in reverse order

Headlight bulb 12V55W

Position lamp bulb

 Unplugging the sidelight seat
 Unplugging the sidelight bulb

Taillight、Taillight bulb

 Loosen the screws, remove the taillight lampshade

Screw

Socket

Bulb

Wier

Screw

Headlamp UNIT

Socket

Bulb

45

Lamp lampshade

 Lightly rotate taillight seat, take out the seat and

bulb.

 Lightly press bulb, rotate in counter-clockwise.
 Install new bulb in opposite order as below.

Taillight bulb：12V21/5W

Front and rear lamp bulb

 Loosen the screws, remove the lamp lampshade
 Lightly press bulb, rotate in counter-clockwise.
 Install new bulb in opposite order as below.

Front and rear lamp bulb12V10W

Side stand

Shore up the main stand , the motorcycle in proper
position.
Check the whether the spring have scratch problem or
not, the connector is lubricating or not

Screw

Taillight lampshade

Bulb

Screw

Bulb

46

Bolts, nuts and fasteners

All the bolts, nuts and fasteners shall be screwed up as
per the maintenance period table. And check all the
cotter pins, safety gripping gears, locks, etc.

Vehicle washing

Cleaning the motorcycle
To keep a good looking of the covers, please wash your
motorcycle often.
The best way to clean your motorcycle is to use warm
water combining with detergent to mop up the dirt before
using water to clean up.
Attention: If you use high-press water to wash the

motorcycle, please do not point the squirt gun at the
electrical parts, plug, cables, bearings and ECU, etc.
The high press would let the water get into the parts and
lead to the failure of function and premature aging.

-Please use ordinary detergent brands to clean your
motorcycle, for the dirtiest places, please use brush to
clean.

-Plug up the muffler before cleaning with water to
prevent water getting into the inside muffler.

-After cleaning with water, please mop up the
motorcycle with clothing or just dry off. Ride for a
distance until the engine has reached a working
temperature; meanwhile apply brake to evaporate the
water left inside the parts.

- Since the motorcycle cools down, please grease all the
sliding parts and bearings with lubricating oil and butter,
meanwhile grease the oil plug with lubricating oil.

- In order to avoid any sundries getting into the

47

electronic system, please protect your electronic
system.
When washing the motorcycle, please remove the air
cleaner cover and filter core and using foam or cotton
yarn to protect the intake channel.
When washing, please block up the muffler to avoid the
water getting into the muffler and engine.

Maintenance in Non-use Time

For the motorcycle to be stored for a long period of time,
attention should be paid to the prevention of moisture,
sunshine and rain attack in order to protect it from
unnecessary damage. Special check-ups should be
carried out on those important parts and subassemblies
before storage.

①Change lubricating oil.
②Grease the chain.
③Dismantle the battery and put it in a shady, cool and

well-ventilated place. It is suggested that the battery be

charged once a month to preventing it from over
discharged and out of function.
④Clean the vehicle and apply antirust oil to the part
vulnerable to rust.
⑤Inflate the tyre as required and support the vehicle up
with the main stand.
⑥Take out the ignition key and keep it in your well
planned place for easy resumption of service.
⑦Put the covering over the motorcycle.

Resumption of Service

①Remove the covering and clean the vehicle. Change
the lubricating oil if the vehicle has been off service for
over 4 months.

②Charge the battery and remount it.
③Filling new fuel to the required level, or replace in-tank

deteriorated fuel with new fuel if the motorcycle has not
been used for more than 4 months and the engine can
not be started.

48

④Prior to driving, test the vehicle at low speed in a safe
place.

Special notice

Keep safe distance

Don’t obstruct the traffic.
Don’t drive on footpath.

Overtake from the left side lane.
Make sure brake at anytime
Stop for while should in braking situation
Don’t drive too much long distance.
If find abnormal, should stop for checking
Wait 2 to 3 minutes after crash, and then restart the
motorcycle.
Turn on headlight when drive at night.

Driving

Before start, look around to avoid accident

① Take back the stander, ride on motorcycle

② Turn on turning light, release brake, make sure the

safe situation and then drive.

Warning

Put side stander in original position, if not it will cause
accident.
Only drive on vehicle road, if drive on footpath will lead
accident.
Drive on uneven road in high speed, will lead rollover
and hurt.
Don’t drive on grit road, if grit enters in engine or tire, will
cause rollover and hurt.

If possible, don’t drive near seaside or Calcium chloride

road, muffler, some other outside parts, and jointing
position are easily rust.

Operation turning

Turning basic principle is combine the centrifugal force
and gravitation well to get balance result.

49

Turning method

①Turning throttle grip to original position, using front
and rear brakes.
② Lean towards the inner side, keep constant speed
driving.
③ Speed up gradually.

Turning reminder

Don’t drive at the inner side of huge vehicle turning area.

Dead angle of sight

Dead angle of sight is the sight area which the rider
can’t distinguish immediately.
Turning distance of front and rear wheels
Turning distance is the front and rear wheels turning
distance
It is related with the length of motorcycle.

Speed effect

Centrifugal force increase, one reason is turning radius
increase, another reason is speed. So when turning,
keep low speed and close inner side.

Postulate of brake (friction)

Use the friction between tire and road surface.
Brake distance: Because of the friction reduce, at wet
road should increase 1.5 times, at ice road should
increase 2 times.

Restrict of Brake effort

After brake, motorcycle can’t stop as once due to the

inertia.

Brake method

Turning throttle grip to original position, use engine
brake.
Let motorcycle vertical.
Use front and rear brake.

Impact of crash

Impact force is rising as direct proportion with speed
and weight. The force of crash in 50km/h to wall is the
same as fall from 10 meters.

50