Mash Five Hundred 400 User Manual
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Mash Five Hundred 400 User Manual

Mash Five Hundred 400 User Manual

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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：

Important Information

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  • Page 1: Important Information

    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.

  • Page 2: Table Of Contents

    Index Main Technical Data……………………………... …1 I、 Emergency Cut-off Switch………………….……..15 II、 Fuel ……………………………………………………..16 Operation Instruction…………………………..…2 Protective Wear…………………………… ………...2 Checking fuel level…………………………………….. 17 Preparation before Operation…………………..…..…3 V、 Correct driving………………………...………… ..18 Operation…………………………………………...….…4 Engine startin……………………………..………….…..18 If the start fails……………………………..….….… …18 Modification of the vehicle……………………..…..….4 Run-in of engine……………………………..….….…...
  • Page 3 Lubricating oil……………………………….…………...29 Taillight、Taillight bulb……………………………………51 Cylinder pressure………………………………………...31 Front and rear lamp bulb………………………………52 Valve clearance……………………………..……….…32 Side stand……………………………………………52 Check-up, cleaning of Air Filter……………………...…34 Bolts, nuts and fasteners………………………………52 Idle speed………………………………………….……35 Vehicle washing…………………………………………52 Throttle control…………………………………………36 Maintenance in Non-use Time………………………53 Brake system……………………………………………37 Resumption of Service………………………………53 Front Brake……………………………………………37 Special notice…………………………………………54 Rear Brake………………………………………………40 Driving……………………………………………………54...

  • Page 4: I、Main Technical Data

    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...

  • Page 5: Ii、Operation Instruction

    II、Operation Instruction of polluted oil or petrol, these failure can be worked out through warranty This instruction book illustrates the notes for the Protective Wear standard and safe operation method, and basic maintenance. [1]、 Protective wear such as helmet with To ensure your comfortable and safe riding protective mask, dust proof glasses and gloves experience, please read this instruction book carefully.

  • Page 6: Preparation 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.

  • Page 7: Operation

    driver should reduce the speed a half as normal Caution speed , and relax shoulder & waist , clench the ·Do not take on the helmet which is easily increase handgrip . hurt or death probability when accident. · When driving , clench the handgrip without one ·Make sure passenger always wear helmet to hand or two hands , even lift up the front wheel , that protect eyes, and dress protecting clothes when driving.

  • Page 8: Muffler

    · Hay or rattan plant will arouse fire if too closed ·To avoid wearing out battery, do not attach any to the muffler . 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 .

  • Page 9: Iii、Parts Position

    III、Parts Position Ignition & Steer switch Right rear view mirror Left rear view mirror Meter Front brake lever Clutch lever Throttle twist grip Left handlebar Engine starter switches Horn switches Fuel tank lock...
  • Page 10 Seat assy Front wheel Rear wheel Muffler Pedal, rear brake...
  • Page 11 Front turn light Rear turn light Front shock absorber Gearshift pedal Side stand Real shock absorber...

  • Page 12: Meter Reading & Usage

    Meter reading and usage 1、Speedometer Indicate distance from Zero, by rotating Zero Knob Indicate motorcycle speed (Km/h). Do not exceed to the Direction of Arrow can return it to Zero. legal rate-limiting to assure safe riding. 10、FAI EFI Indicator 2、Odometer Indicating EFI system situation Indicate riding distance (Km).
  • Page 13 Speedometer Odometer Trip mileage meter Tachometer FAI EFI Indicator Zero Knob Turn indicator High beam indicator Neutral indicator Fuel gauge...

  • Page 14: Iv、开关操作

    IV、开关操作 Caution Switch instruction ·Do not move the Key position when Riding, if the key Main Switch used to Start or switch off the is on position during riding, all electric system Engine . will out of Action; So during riding do not move the Position Function Remarks...

  • Page 15: Far And Near Light Lamp Instruction

    Switch position Switch position Far and Near Light position indicator and taillight ON Lamp Instruction  Headlight switch off Direction Indicator Use indication switch when turning Left and right. If put main Switch on position, the indicator will wrinkle. Headlight Switch Slide Direction indicator can stop the turning signal Operation.

  • Page 16: Horn Button

    Caution ·when finished turning , the direction indicator switch will not be back to original position automatically , Overtaking lamp switch please switch it manually . ·Driving with light on will obstruct traffic . Horn Button Electric Start Button When the main switch at “ ”, press horn button , it Push this button, make the engine start.

  • Page 17: Fuel

    Fuel Caution  Fuel filling ·Emergency cut-off switch only used under urgent The capacity of the fuel tank is 13L. Lead free situation. gasoline of No.93III(RON 93) or above is required for ·During riding, turn the switch from will the motorcycle. To fuel the vehicle, support it by the cause dangers, and damage the engine.

  • Page 18: Correct Driving

    Correct driving V、 Engine starting Caution Set the key of the ignition switch to “ ”position. Set the emergency stop switch to “ ” position. The engine can only be started when the gear is in neutral position or clutch is OFF. Otherwise accident Ascertain the gear is in neutral position by checking may happen.

  • Page 19: Run-In Of Engine

    2). The adjustment of the valve clearance inside performance. cylinder head is allowed (carried out by MASH service B. The well run-in engine: the initial wear-out of the stuffs) parts is well renewed, which eases the damage to the B.

  • Page 20: Checking Before Operations

    To avoid the utter incompetence of the 2、Fuel level checking, tighten up the fuel tank cap, brake system. Please go to MASH’s technician for and check if the fuel pipe is twisted. professional inspection and suggestions, we will also 3、Transmission chain checking, loosen chain will fall...

  • Page 21: Gear Shift

    9、 Lights and horn checking, please kindly check if the ·Before you repair or mend, the engine should be illumination and the horn are working normally. switched off and the key should be pulled out. 10、Rear view mirror checking, sit on the vehicle and ·If the problems still exist after calibration , please keep your body vertical to the ground, see if you get a immediately...

  • Page 22: Gear Down Operation

    Operation position. ④The gear can be shifted up to 3rd-5th gear •Before starting the engine, please make sure the position in the same way. side stand is at the right position。 •If the side stand can’t be moved smoothly, please ⑤...

  • Page 23: Brake Usage

    Brake Usage Caution ·Use front and rear brake simultaneously。 When the motorcycle running over speed, do not ·Avoid unnecessary sudden brake。 switch to the lower gear, in case to reduce the speed Caution suddenly and cause damage to the engine and transmission system;...

  • Page 24: Rearview Mirror

    Before driving, must adjust the rearview mirror angle. ＜Park with side stand＞ Warning Place the motorcycle on horizontal ground, activate the side stand, and move the steering bar to the left Don't put anything on the back seat to avoid interfere side.

  • Page 25: Vi、Inspection And Adjustment

    VI、Inspection and adjustment Maintenance Period Table Maintenance times Period Maintenance Items 1000 4,000 7,000 10,000 Remarks *Fuel system, fuel filter *Throttle cable, clutch cable *Throttle valve body Air filter element Remark 1 Replace every 3,000km driving Spark Plug Replace every 3,000km driving Engine lubricant oil inspection : 1000km then change it every 3000km riding Oil filter...
  • Page 26 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.

  • Page 27: Spark Plug

    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.

  • Page 28: Lubricating Oil

    Lubricating oil temperature. Unscrew the draining nut when the engine is hot and Using high quality engine oil designed for four stroke then drain the old engine oil. engine will extend the life length of the engine. Please Clean the filter and then install. Fill with 2.1L new engine select the SE, SF or SG type high quality engine oil oil.
  • Page 29 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. Caution: When the engine is at a operating temperature, the engine oil might be very hot, so do not make yourself burnt.

  • Page 30: Valve Clearance

    Therefore, the valve clearance must be checked periodically. The valve clearance should be inspected and adjusted by a Mash Dealer.

  • Page 31: Check-Up, Cleaning Of Air Filter

    Check-up, cleaning of Air Filter other agent of a low ignition point. 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.

  • Page 32: Idle Speed

    Idle speed more than 1800 r/min. Only under the above two cases, unscrew the retaining nut and adjust the idle speed Caution: adjusting screw to let the intake flow reach the specified flow. Check and adjust the idle speed after all other items of Idle speed 1500 r/min ±...

  • Page 33: Throttle Control

    Throttle control Adjusting methods: First, check whether the throttle control line is deformed, Retaining nut B 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;...

  • Page 34: Brake System

    satisfying, separate the throttle control line with throttle level and brake shoe abrasion are the two most valve body and unscrew the retaining nut B to make important factors, that needs to be checked on time. adjust the free stroke in a larger range. Screw up the The brake system should be checked frequently, to retaining but B after the adjustment.

  • Page 35: Brake Fluid Level

    tautness . Warning Additionally , if the vehicle shakes from left to right as ·brake fluid will arouse inflammation , should avoid vibrating when driving , the one should check whether being touched with skin &eyes . once touched , should the hole or pipe cover touched with other parts .
  • Page 36 automatic system. Caution • avoid chemical reaction, the brake fluid is not available from different manufacturers. The brake fluid shall be DOT 4 non-petroleum base Do not allow the brake fluid contact vehicle parts, so as brake fluid. The brake fluid can’t be mixed with other impurities; not to damage the painted parts.

  • Page 37: Rear Brake

    touch to the side of the brake disc. It shows that the Brake pedal free stroke：18-25mm brake shoe has touched the wear limit. 18-25m Cotouts Rear Brake Pushing the brake pedal by hand, checking the resistance, to confirm the move of the brake pedal whether is good.

  • Page 38: Running System

    ·Please change the brake shoe in time if it has been ＜The brake piece checking ＞ touched the wear limit. Otherwise it would cause （1）Pulling the front & rear brake, checking the wear accidents by the lack of strength. and tear of the brake shoe. If the mark "△" on the drum brake cover and also on the brake cam alignment, Running system shows the brake shoe has been touched the wear limit.

  • Page 39: Spoke

    Front tire Rear tire 110/90-19 130/70-18 Normally loaded Fully loaded Front tire Rear tire Front tire Rear tire 180kPa 200kPa 200kPa 230kPa Rear wheel tire pressure tire pressure can’t reach specified requirements, check the tire for cuts, embedded iron nail Caution or other sharp articles.

  • Page 40: Clutch Control Line

    possible. 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. Adjusting Nut Coarse adjustment: Spoke nut fastening tool Retaining nut Clutch control line...

  • Page 41: Driving Chain

    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 Remove the clutch control line on the handle end, and lower chain.
  • Page 42 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. Adjustment 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.

  • Page 43: Battery Checking

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

  • Page 44: Installation Of Accumulator

    accumulator’s life span. lower mark lines If it is below the lower one distilled water shall be added to the battery. After filling in dismantle battery ,disconnect distilled water, measure the voltage of the negative pole negative(-)electrode before the positive(+)one, with a voltmeter;...

  • Page 45: Replacement Of Fuse

    Caution Lower electrolyte Upper electrolyte Do not use any fuse over 15A Level line Level line Be sure not to wash the battery when washing the Foreign matter should be prevented from entering vehicle. into battery during dismounting installation. The breathing pipe must be kept unblocked. Replacement of Fuse Set the ignition switch to “OFF”...

  • Page 46: Headlamp Dimming

    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 Adjusting nut braked.  Headlamp dimming The braking light should be lit up on time as soon as the rear wheel is braked.

  • Page 47: Position Lamp Bulb

    Screw Headlamp UNIT  Loose the screw to disassemble the headlight. Position lamp bulb  Rotating , directly unplugging  Unplugging the sidelight seat  Rotating and disassemble the bulb.  Unplugging the sidelight bulb  Install the new bulb in reverse order Headlight bulb 12V55W Screw Socket...

  • Page 48: Taillight、Taillight Bulb

     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. Bulb Screw Taillight bulb：12V21/5W Lamp lampshade Bulb Side stand Shore up the main stand , the motorcycle in proper position.

  • Page 49: Bolts, Nuts And Fasteners

    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 Bolts, nuts and fasteners clean.

  • Page 50: Maintenance In Non-Use Time

    electronic system, please protect your electronic charged once a month to preventing it from over system. discharged and out of function. ④Clean the vehicle and apply antirust oil to the part When washing the motorcycle, please remove the air cleaner cover and filter core and using foam or cotton vulnerable to rust.

  • Page 51: Special Notice

    ② Turn on turning light, release brake, make sure the ④Prior to driving, test the vehicle at low speed in a safe safe situation and then drive. place. Warning Special notice Put side stander in original position, if not it will cause Keep safe distance accident.

  • Page 52: Turning Method

    Turning method Use the friction between tire and road surface. Brake distance: Because of the friction reduce, at wet ①Turning throttle grip to original position, using front road should increase 1.5 times, at ice road should and rear brakes. increase 2 times. ②...

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