Table of Contents
Advertisement
Advertisement
Table of Contents
Subscribe to Our Youtube Channel
Related Manuals for Mash XY400B
Summary of Contents for Mash XY400B
- Page 1 XY400B OPERATIONAL INSTRUCTION...
-
Page 2: 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 with sidecar. 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 3: Table Of Contents
Index Maintenance period table………………………….……..…25 I、 Technical Data of Main Performance…….……………………1-3 Check-up of spark plug………………………………….……..…27 II、Safe drive……………………………………………………………4 Timing phase……………………………………………...……..…27 Important safety information………….……………….………..…4 Machine oil checking……………………………….………...28-29 Wear protective……………………………………………………...4 Valve clearance……………………………..…………………..…30 Do not ride while under the influence……………………..…..…4 Check-up, cleaning of air filter……………………………..…31 Safe riding principles……………………………………...………5 Idle speed……………………………..……..……………….……32 Being seen……………………..……………………………..….5... -
Page 4: I、 Technical Data Of Main Performance
I、 Technical Data of Main Performance Item Data Length 2160mm Width 1610mm Height 1125mm Wheelbase 1420mm Wheelbase sidecar 1170mm Min. ground clearance 160mm Complete vehicle weight Non-loaded weight: 260kg, Max loading weight: 485kg, Frame type Cradle type Rake angle 28° Front suspension device spring &... - Page 5 Single-cylinder Oil –cooling Mode 4-stroke engine 85.0mm × 70.0mm Cylinder bore × Stroke Cylinder displacement 397cc Compression ratio 8.8±0.2:1 Max. power 20.4kw/6500rpm Max. torque 30.6N.m/5000rpm Valve clearance (cold) IN: 0.07-0.10；EX: 0.08-0.12 Valve driving gear Chain drive Air filter Oilpaper filter Cooling method Oil-cooling Lubrication method...
- Page 6 Electric generator permanent magnet DC magneto Accumulator capacity 12V9A.h Power supply system DC power supply, and the electric generator is only used to recharge the accumulator Fusible cutout 15A/10A Spark plug DPR8Z Spark plug gap 0.6-0.7mm Ignition coil type Open magnetic circuit Fuel supply mode Electronically injection, ECU control Ignition mode...
-
Page 7: Safe Drive
、Safe drive passengers should always wear a helmet to prevent or reduce the Important safety information chance of head injury. • Eye and Face Protection – A plastic face shield can help Your safety is very important. Your motorcycle can provide many years of service and pleasure, if you take responsibility for prevent accidents by guarding the face and eyes from debris, your own safety and understand the challenges while riding. -
Page 8: Safe Riding Principles
Caution motorcycle. Operating this motorcycle after consuming alcohol or drugs. • Limit the travel distance to avoid fatigue that can affect could seriously affect your judgment. could cause you to react performance and awareness. more slowly. Could affect your balance and perception. Could •... -
Page 9: How To Keep Your Motorcycle Safe
• Put the load as close as possible to the center of the How to keep your motorcycle safe Get training if you are inexperienced. motorcycle. • Put only light load on rear rack, if installed. Beginners should get training from a certified instructor. •... -
Page 10: Gasoline And Exhaust Fumes
motorcycle is stopped. hospital. • Keep legs away from hot and moving parts. • If you spill gasoline on your clothes, change and wash the • Stay directly behind you, leaning as you lean. affected area immediately with soap. Caution •... -
Page 11: Flue-Saving Tips
Flue-Saving tips from the actual vehicle, due to the difference of model. The way you drive your motorcycle will have a direct impact on ·The vehicle is specifically designed for two people (Including your fuel consumption. the rider himself) Caution •... -
Page 12: Parts Position
III、Parts Position Left rear view mirror Ignition & Steer switch Right rear view mirror Meter Front brake lever Throttle twist grip Clutch lever Left handlebar Fuel tank lock Switches on left handlebar Switches on right handlebar... - Page 13 Front turn light Seat assy Front shock absorber Rear turn light Rear shock absorber Muffler Gearshift pedal Front wheel Pedal, rear brake...
-
Page 14: Meter Reading & Usage
Meter reading and usage Speedometer Odometer Trip mileage meter Tachometer Fuel gauge Turn indicator High beam indicator Neutral indicator EFI Indicator... - Page 15 1、Speedometer 10、EFI Indicator Indicate motorcycle speed (Km/h). Do not exceed legal Indicating EFI system situation 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.
-
Page 16: Switch Operation
Caution IV、Switch operation Do not move the Key position when riding, if the key is on Switch instruction position during riding, all electric system will out of Action; Main Switch used to Start or switch off the engine . So during riding do not move the main switch Key in case of Position Function Remarks... -
Page 17: Switches On Right Handlebar
Switches on right handlebar Switches on left handlebar Electric start button Light changing switch Push this button, make the engine start. ·Position indicator shows its position to the nearby Vehicles; and Emergency Cut-off Switch reminding other vehicles when wait at crossroad, to avoid Confusion. Emergency cut-off switch used to Switch off the motorcycle Far and Near Light Lamp Instruction by hand;... -
Page 18: Fuel Filling
Fuel filling Horn button The capacity of the fuel tank is 13L. Lead free gasoline of When the main switch at “ ”, press horn button , it will No.93III(RON 93) or above is required for the motorcycle. To fuel the make a sound. -
Page 19: Gear Shift
Gear shift ①When you ride on the motorcycle and the engine is idling, Shifting forward 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... -
Page 20: Clutch Lever
Clutch lever Brake usage The clutch lever located on the left side is used to ·Use front and rear brake simultaneously。 disengage the transmission when vehicle is not moving, and for ·Avoid unnecessary sudden brake。 Caution shifting gears. Pull lever in completely before shifting. Once gear If You only use the front or rear brake, the motorcycle may has been engaged, slowly release the lever. -
Page 21: Parking Lever
11. Seat belt Rear brake pedal ＊ Always fasten seat belt while operating the motorcycle. ＊ Check the seat belt for any damage. Replace the damaged seat belt immediately. ＊ Do not use the seat belt if the motorcycle does not have the safety frame. -
Page 22: Oil Output Tank
12. Oil output tank 1、Oil pot total volume 2.2L, intermediate position oil dipstick oil pot on the line for 1.8L。 2、Pot plus external pipe and radiator total volume loading was 2.3 ± 0.05L。 Filling volume for 2.2L。 Oil radiator shall be installed in the face of location of the wind。... -
Page 23: Basic Operation And Riding
V、Basic operation and riding seasons, and keep the engine running at a higher speed so as to warm up the engine for about 10 seconds or more. Before riding your motorcycle, please revise the safety Caution messages given in the first pages of this manual. The engine can only be started when the gear is in neutral In this section, we will describe important notes and techniques position or clutch is OFF. - Page 24 A. Engine without run-in and the one have been run in have the carbon deposit. big difference in their power and torque performance. 2). Replace the engine oil B. The well run-in engine: the initial wear-out of the parts is 3).
-
Page 25: Operation
5、Brake system checking, to see if the brake system is the steering bar is at the best position for your safe and comfortable working normally. Brake fluid amount and the state of the brake operation, also without the tangle of cables.. Caution shoe should be checked. - Page 26 Running in tipping over backward. ＊ Do not drive near the edge of a gully or steep embankment. Make 1000km running in at the speed of 6000rpm, this can provide better longevity Avoid holes, ditches, etc. which may cause the motorcycle to tip over, Caution especially on hillsides or steep slopes.
- Page 27 both of your arms. Keep the motorcycle in balance and apply the Watch the speed of water current and its depth if riding through rear brake to slow down your speed. water is necessary. If water flows very fast or is deep, the Unless otherwise necessary, do not press the accelerator performance of the motorcycle will be affected, which may cause lever.
-
Page 28: Inspection And Adjustment
VI、Inspection and adjustment Maintenance Period Table Maintenance times Odometer km (Remark 2) Period 2000 4,000 8,000 12,000 Remarks Maintenance Items Fuel system passage Fuel precision filter Replace for every 15000km driving Throttle operating system Throttle valve body Air filter element Remark 1 Replace every 8,000km driving Oil catcher... -
Page 29: Operation
Maintenance shall be carried out to the motorcycle in a specified period. The meanings of various symbols in the list are as follows: Carry out inspection, cleaning, adjustment, lubrication or replacement. Cleaning. R: Replacement. Adjustment. Lubrication. Caution It is mandatory to replace parts and lubricants according to the maintenance table. Periodic maintenance is a combination of verification and service operations performed through Approved Service Center network, to properly maintain your motorcycle. -
Page 30: Check-Up Of Spark Plug
Check-up of spark plug Timing phase ①Remove the spark plug cap. Remove the spark plug with a It shall be carried out when the vehicle is new or there is any socket wrench. Visually check whether there is any damage with question about the timing phase. -
Page 31: Machine Oil Checking
Machine oil checking Check oil level weekly. Always keep oil level between the HI Upper scale line and LO mark. Add oil when necessary. To check oil level: • Make sure engine is has been turned off for more than 3 Lower scale line minutes, otherwise level may not be accurate. - Page 32 new one as required. Caution Check for damage of the engine oil filter cover and its Application of engine oil of poor quality will have an O-shaped sealing ring; replace with a new one as required. impact on the functional performance and life span of the Mount the engine oil filter cover and screw up the bolt to the motorcycle engine.
-
Page 33: Valve Clearance
Valve clearance The specified valve clearance is : 0.07-0.10mm for intake Noise will stem from too big valve clearance. However if valve and 0.08-0.12mm for exhaust valve respectively. there is too small gap or even no gap at all, closing of the valve If clearance adjustment is needed, loosen the locking nut on will be hindered, which will cause many problems such as engine the rock arm, turn the adjusting nut till a slight resistance is felt on... -
Page 34: Check-Up, Cleaning Of Air Filter
Check-up, cleaning of air filter Take out the air filter and check if it is contaminated. Dismounting: Open and remove the right side cover, Remove 4 screws, remove Air filter cover Air cleaner element Cleaning: Wash the filter in clean washing oil and wipe it dry with dry cloth. -
Page 35: Idle Speed
Idle speed Adjusting screw Caution screw 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. -
Page 36: Throttle Control
Throttle control Fine adjustment: First, check whether the throttle control line is deformed, Pull open the rubber lagging, unscrew the retaining nut A, and twisted or damaged. turn the adjusting solenoid to adjust to a satisfied free stroke. And Then, measure the throttle bar free stroke. Turn the bar to then screw up the retaining nut A and mount the protective rubber lean it against one side of the free stroke, and draw a straight line lagging. -
Page 37: Brake System
Brake system Warning brake fluid will arouse inflammation , should avoid being The front brake and the rear brake and the side brake is disk touched with skin & eyes. Once touched, should clean clearly type, due to the abrasion of the brake shoes, the brake fluid will be with water, furthermore, if touched with eyes, must go to getting less as time goes by. - Page 38 Brake fluid vacuum filling method: Warning This method is only applicable to refilling brake fluid for new Brake fluid will arouse inflammation , should avoid being vehicles or when the brake fluid in the cylinder is drained. touched with skin & eyes . Once touched, should clean clearly Open the cover of brake cylinder cover and refill brake fluid.
- Page 39 Brake piece checking Adjustment nut. Operating brake, if the wears limit line of the brake shoe touch to the side of the brake disc. It shows that the brake shoe has touched the wear limit. The rear brake caliper interlocks with the side brake rear caliper (controlled by rear brake pedal) Warning When it is replaced with a new brake strip or brake disc,...
-
Page 40: Running System
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: If the tire pressure can’t reach the specified requirements, check the tire for cuts, embedded iron nail or other sharp articles. -
Page 41: Driving Chain
clutch control line, finally adjust it to a satisfied free stroke according Adjusting Nut to the fine adjustment. Caution Coarse adjustment: 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. - Page 42 on the chain adjuster until the specified tension is achieved, and and mud, and then air dry it; check the chain for abrasion or then fasten the rear wheel spindle nut, and check the flexibility for cracking, and replace it in case of damage. free rotation of the rear wheel and the consistency of the front and Remount the chain and coat it with chain-specific lubricant;...
-
Page 43: Battery Checking
12. Battery checking Installation of accumulator Open the left side cover. Installation is in the reverse order of removal. While connecting the Clean away dust and corrosive from the surface of the battery. poles, connect the positive pole first. Remove the negative, then the positive pole of the Charging the battery accumulator;... -
Page 44: Replacement Of Fuse
13. Replacement of fuse accumulator’s life span. Set the ignition switch to “OFF” position. The specified fuse To dismantle battery ,disconnect the tube of 15A should be used for main fuse replacement, and a 10A negative(-)electrode before the positive(+)one, and vice fuse tube for FAI injection nozzle. -
Page 45: Brake Lamp Adjustment
14. Brake lamp adjustment 15. Illumination signal system If the rear brakes lamps abnormally light up and go out, adjust Head lamp it by turning the adjusting nut. If the rear brake lamp switch is Before driving, check the brightness, direction, etc. of the broken, replace it immediately. -
Page 46: Bolts, Nuts And Fasteners
Turn signal light Loosen the screws, remove the lamp lampshade Lightly press bulb, rotate in counter-clockwise. Install new bulb in opposite order as below. Turn lamp bulb specifications:12V10W Combined rear position lamp Loosen the screws, remove the taillight lampshade ... -
Page 47: Maintenance In Non-Use Time
18. Maintenance in Non-use Time Attention: If you use high-press water to wash the motorcycle, please do not point the squirt gun at the electrical parts, plug, For the motorcycle to be stored for a long period of time, attention cables, bearings and ECU, etc. -
Page 48: Resumption Of Service
19. Resumption of service 21. Driving ①Remove the covering and clean the vehicle. Change the Before start, look around to avoid accident lubricating oil if the vehicle has been off service for over 4 months. Take back the stander, ride on motorcycle ②Charge the battery and remount it. -
Page 49: Engine Management System
VII、 Engine management system The Engine Management System(EMS) comprises electronic control unit(ECU), throttle body, Idle speed control valve, fuel pump, fuel injector, ignition coil, O2 sensor, throttle position sensor, T-MAP sensor, cylinder head temperature sensor and so on. Based on the air flow and engine speed, the fuel injector and ignition coil are controlled by ECU to get the optimal combustible mixture of fuel and air and Ignition timing which meet all engine operating conditions. - Page 50 • High-tension cord • Spark plug (ignition) • Throttle, Idle speed control valve (air intake) Electronic control unit • ECU Major parts and components Cylinder Head Temperature Sensor Fuel Injecto Throttle body Idle speed control valve Throttle sensor Intake air pressure sensor...
- Page 51 Electronic control unit( ECU) Oxygen sensor Maintenance of Engine management system Because of the EFI, there are many possibilities for the engine issues. In other word, one issue may be caused by the mechanical problem or the EFI components. And the diagnostic tools cannot 100% indicate the root cause. So this manual shows the way to dig out the root cause with the help of the diagnostic tools.
- Page 52 5) When disassmeble the fuel pump from the pump, make sure the power is off. Or it may casue the fire. 6) The fuel pump cannot work in air or water, it will shorten the service life. And the positive and negative connecters cannot be exchanged. 7) The ignition system check only could be delivered when it is nessasary.
-
Page 53: Obd Service $01
OBD Service $01 Description Description Request supported PIDs from PID 0x01-0x20 Ignition Timing Advance for #1 Cylinder 01 Monitor status since DTCs cleared Intake air temperature Fuel system status Absolute throttle position sensor Calculated Load Value Location of oxygen sensors Engine coolant temperature OBD requirements to which vehicle or engine is certified Short Term Fuel Trim Bank1... -
Page 54: Obd Service $02
OBD Service $02 Description Request supported PIDs from PID 0x01-0x20 DTC that caused required freeze frame data storage Fuel system status Calculated Load Value Engine Coolant Temperature Long term Fuel Trim-bank1 Long term Fuel Trim-bank2 Intake manifold absolute pressure Engine RPM Vehicle speed Throttle position PIDs $21 to $40 which are supported by the Powertain controller... -
Page 55: Obd Service $03
OBD Service $03 System or Component DTC Description Related Calibration Number P0107 MAP Circuit Low Voltage or Open #N/A Manifold Absolute KsDGDM_MAP_ShortLow Pressure Sensor (MAP) P0108 MAP Circuit High Voltage #N/A KsDGDM_MAP_ShortHigh P0112 IAT Circuit Low Voltage #N/A Intake Air Temperature KsDGDM_IAT_ShortLow Sensor (IAT) P0113... - Page 56 Idle Control System P0505 Idle Speed Control Error #N/A KsDGDM_IdleControl P0562 System Voltage Low #N/A KsDGDM_SysVoltLow System Voltage P0563 System Voltage High #N/A KsDGDM_SysVoltHigh P0650 MIL Circuit Malfunction #N/A KsDGDM_MIL_Circuit P1693 Tachometer Circuit Low Voltage 1693 #N/A KsDGDM_TAC_Circuit_Low Tachometer P1694 Tachometer Circuit High Voltage 1694 #N/A...
-
Page 57: Obd Service $04
OBD Service $04 Functional description The purpose of this service is to provide a means for the external test equipmentto command ECUs to clear all emission-related diagnostic information This includes: • MIL and number of diagnostic trouble codes (can be read with Service $01, PID $01) •... -
Page 58: Obd Service $07
OBD Service $07 Functional description for ISO 15765-4 or SAE J1979 May 2007 The purpose of this service is to enable the external test equipment to obtain“pending” diagnostic trouble codes detected during current or last completed driving cycle for emission-related components / systems that are tested or continuously monitored during normal driving conditions. -
Page 59: Standard Torque Values
Standard Torque Values ENGINE Name and dimensions Torque value (N.m) Name and dimensions Torque value (N.m) Cylinder head connecting nut 8～12 40～50 Cylinder bolt 8～12 Valve adjusting screw nut 8～12 Timing driven sprocket bolt 8～12 24～28 Rocker-arm shaft cover Magneto flywheel fastening nut 38～45 38～45 Clutch fastening nut... - Page 60 Name and dimensions Torque value (N.m) Name and dimensions Torque value (N.m) Front wheel spindle 100～120 Front vibration damper plate 30～40 Real wheel spindle nut 60～90 Rear fork shaft nut 50～60 Engine hanging bolt 30～40 20～30 Steering handle set bolt 20～30 Front fork vertical pipe cap nut 60～90...
-
Page 61: Electrical System Diagram
VIII、 Electrical system diagram...
Need help?
Do you have a question about the XY400B and is the answer not in the manual?
Questions and answers
I can’t find the main fuse on my 2015 Mash 400
The main fuse on a 2015 Mash 400 is located on the side of the battery. To access it, open the left side cover and remove the fuse holder.
This answer is automatically generated
My bike has 60000km on it. The engine warning light is on. what should I check?