Mash Dirt Track 650 Owner's Manual
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Mash Dirt Track 650 Owner's Manual

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Dirt Track 650
Owners Manual

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  • Page 1 Dirt Track 650 Owners Manual...
  • Page 2 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 3: Table Of Contents

    Index IV. Controls…………………......………..……...16 I、Technical Data of Main Performance………………………1-3 Ignition Switch……………………………….…….………..….…….16 II. User Instructions…………..………….………......…4 Switches on right handlebar…….……….……..…….……………17 Safety & Protective Gear…………………...……..…………….…...4 Switches on left handlebar………………………..………………18 Do not ride while under the influence……………..………….…..…5 Adding Fuel…………………….………………..……………………19 Safe riding principles………………………..………..…..……...……5 Gear Shift Lever …………………………….…….…………….…...19 Being seen……………………..………………….……..………….6 Mirrors……………………………………….…………...…………20 Know your Motorcycle…………..…………….……….……………...6...
  • Page 4 Fuse Replacement..………..…………………..……….……………49 Engine Break-Maintenance…………….…………………..……24 Turn signals………………………………………….………….…49 Pre-Ride Inspection…………………………………..…….………. 25 Vehicle Operation…………………………………….…………..26-28 Side stand….………………..………………………..………….…49 Bolts, nuts and fasteners…………………..………………..…50 VI Inspection and adjustment…………………...……………..…29 Maintenance Schedule……..………………………….…..…30-31 Vehicle Washing………………………….....…..…50 Spark Plug ………….…..…………………..……………………32 Storage………………..………………..…………..…………….…51 Engine Oil………..…..…………..…………..………..………..32-34 Special Torque Values..……………….......……..…51 Valve Clearance & Adjustment……..……..…….…………..…35 Standard Torque Values…..……………………….……………52 Air Filter……….………..………………........…36 VII.

  • Page 5: I、Technical Data Of Main Performance

    Technical Data of Main Performance Item Data Length*Width*Height 2080mm*890mm*1170mm Wheelbase 1420mm Minimum ground clearance 180mm Complete vehicle weight Non-loaded weight: 169kg Dry weight: 180kg, Curb weight: 150kg, Front suspension device Spring & hydraulic composite damping Rear suspension device Spring & hydraulic composite damping Front Tire size 120/80-18 Rear Tire size...
  • Page 6 Single-cylinder Oil –cooling 4-stroke engine Mode Cylinder bore 100.0mm Cylinder stroke 82.0mm Displacement 643.7cc Compression ratio 8.3:1 Max. power 29.5 kw / 6000 rpm Max. torque 49.8 N.m/4500rpm Intake: 0.07-0.10 mm ；Exhaust: 0.08-0.12 mm Valve clearance (cold) Air Filter Oilpaper filte Cooling method Oil-cooling Lubrication method...
  • Page 7 Clutch Wet clutch, coil clutch, paper friction wafer Clutch operating system Manual mechanical Primary reduction ratio 2.029 Ⅰ 2.667；Ⅱ 1.250 Ⅳ Transmission gear ratio 1.647；Ⅲ 1.000；V .0.840； Final reduction ratio 3.000 Gear shifting mode Left foot operated to and back type Sequence: I－N－Ⅱ－Ⅲ－Ⅳ－V Accumulator capacity 12V11.2A.h...

  • Page 8: User Instructions

    Wear protective gear User Instructions Wearing appropriate protective wear can prevent or reduce injuries Important safety information from accidents. Your safety is very important. Your motorcycle can provide many • Helmet – The majority of serious motorcycle injuries and years of service and pleasure, if you take responsibility for your deaths are the direct result of a head injury.

  • Page 9: Do Not Ride While Under The Influence

    Do not ride while under the influence • Always inspect your motorcycle each time you use it to Before getting on your bike, make sure: make sure it is in safe operating condition. • You have not consumed alcohol or taken drugs. •...

  • Page 10: Being Seen

    Being seen Know Your Motorcycle • Get training if you are inexperienced. Many motorcycle accidents are caused by car drivers who do not • Beginners should get training from a certified instructor. see motorcycle riders on the road. To reduce the chance of an •...

  • Page 11: Loading & Carrying Passengers

    loads. Be aware that improper loading of goods will adversely Loading & Carrying passengers affect the performance and stability of the vehicle. You should avoid carrying passengers or large loads until you have Keep the load low and distribute the load evenly. An uneven load can gained sufficient experience riding alone.

  • Page 12: Gasoline And Exhaust Fumes

    Gasoline and exhaust fumes Modifications • Gasoline is highly flammable and exhaust fumes are Any modifications to this motorcycle, removal of original equipment poisonous: or use of unapproved accessories, may cause it to be unsafe for use • Turn off engine before refueling. and may trigger severe accidents.

  • Page 13: Fuel-Saving Tips

    Fuel-Saving tips this instruction book carefully. ·The pictures and illustrations in this book may be different from the The way you drive your motorcycle will have a direct impact on your actual vehicle, due to cosmetic differences between models. fuel consumption. ·The vehicle is specifically designed for a maximum of two people •...

  • Page 14: Vehicle Layout

    Ill. Vehicle Layout Meter Left-hand rear-view mirror Ignition/steering lock block Right-hand rear-view mirror Throttle twist grip Clutch control lever Front brake control Left handlebar lever Switches on right handlebar Switches on left handlebar Fuel tank lock...
  • Page 15 Front shock absorber Rear shock absorber Saddle ABS rear sensor ring Front wheel Muffler Pedal, rear brake...
  • Page 16 Rear turn light Front turn light ABS front sensor ring Gearshift pedal Rear wheel...

  • Page 17: Instrument Gauges

    Instrument Gauges Turn indicator Neutral indicator RPM indicator High beam indicator Fuel level indicator Speed indicator ABS indicator Odometer Engine failure light...

  • Page 18: Gauge Check

    RPM indicator Gauge Check The instrument RPM instructions with stepper motor indicator. The Speed indicator indicated span 0-12000RPM The meter speed display with digital display, display range (0 - Turn the ignition switch to the "on" position. The tachometer will 199Km/h).When the speed is higher than 199Km/h, speed display sweep to the Redline and back indicating that the tachometer needle value is 199Km/h.
  • Page 19 indicator bulb. Once the engine has been started, the light will turn off unless the ECU has detected a fault. If the light remains illuminated or flashes when the engine is running, a fault condition exists. Contact an authorized genuine dealer for service. If the indicator light does not come on at all, check the indicator bulb and replace if necessary.

  • Page 20: Controls

    IV. CONTROLS Ignition Switch Main Switch used to Start or switch off the engine. Position Function Remarks To stop the vehicle (switching off all circuits) For starting or driving the vehicle(making all the main Can not circuits) To lock the steering handle Caution Do not change the ignition key position when riding.

  • Page 21: Switches On Right Handlebar

    Switches on right handlebar Emergency kill Switch The right-hand switch features the following controls  Electric start button With key on and motorcycle in neutral, push this button to turn the engine on.  Emergency Kill Switch The emergency kill switch is used to turn off the motorcycle if an emergency occurs while riding or if the vehicle falls over with the engine running.

  • Page 22: Switches On Left Handlebar

     Switches on Left Handlebar Overtaking lamp switch Pull the yellow button inward to light both headlights indicating to The left-hand switch features the following controls: the vehicle in front of you, your intent to overtake.  Hi and Low beam Operation ...

  • Page 23: Adding Fuel

    Fuel filling Gear Shift Lever To fuel the motorcycle, place the motorcycle on the side-stand. Gears are selected using the shift lever. This motorcycle is Open the fuel tank lock cover and using the key, turn the fuel cap equipped with a sequential transmission. and remove the fuel cap from the fuel tank.

  • Page 24: Mirrors

    Mirrors Clutch lever The clutch lever located on the left side is used to disengage the Blind spot collisions are one of the principal causes of accidents transmission when vehicle is not moving, and for shifting gears. Pull in high density traffic. Always adjust your mirrors prior to each lever in completely before shifting.

  • Page 25: Brakes

    Brake usage ·Use front and rear brake simultaneously. Rear brake pedal ·Avoid unnecessary sudden brake. Caution -When riding in wet conditions, avoid braking suddenly as accidents are more likely to occur. -Avoid repeat use or dragging of the brakes. Brakes can overheat which will cause the brake to lose effect.

  • Page 26: Side Stand

    11. Side stand 12. Helmet holder The helmet holder is located on the left-hand side of the motorcycle. The side stand is used to support your motorcycle when parked. To hook on the helmet, insert the ignition key and turn it so that the To operate the side stand, use your foot to lower the stand until it...

  • Page 27: Proper Operation

    and keep the engine running at a slightly higher speed by Proper Operation lightly applying throttle until engine warm-up is complete. Do not rev the engine during the warm up phase as this can Engine Start Conditions damage the Oxygen sensor. The engine can only be started when both the ignition switch and Engine Stop: the kill switch are in the run "...

  • Page 28: Engine Break-Maintenance

    Engine break-in period Engine Maintenance The initial break-in period of the engine is very important. Failure When the engine has been run-in for 500 miles, a mandatory first to follow the break-in procedure (or other improper operation) service and inspection is required to be performed by an will cause vehicle malfunction or damage.

  • Page 29: Pre-Ride Inspection

    pad/shoe wear and brake lines/cables prior to operating Pre-ride Inspection the vehicle. If the level of the brake fluid is lower than the In order to ensure safety, the motorcycle must be checked minimum level line, inspect brake lines for leaks or cracks. before each ride and properly maintained.

  • Page 30: Vehicle Operation

    • Caution In order to maximize fuel consumption and to ensure engine longevity, please do not accelerate or decelerate drastically. Make sure you are familiar with and follow the safety rules and Launch and Shifting Gears comply with all laws. 1) While sitting on the motorcycle with the engine running at idle in The exhaust contains harmful gas, like CO, so please make neutral, raise the side-stand and place both feet firmly on the...
  • Page 31 Brake Usage Up-Shift Use the front and rear brake simultaneously for maximum braking power. Avoid unnecessary sudden braking. Caution ·If you only use the front or rear brake, the motorcycle may become upset and a crash could result. Down-Shift ·When riding in rain or on wet road avoid sudden braking. Accidents can occur, slow down and brake cautiously.
  • Page 32 Engine Brake Park with side stand The engine can work as a brake as you decelerate using the Place the motorcycle on horizontal ground, lower the side stand, and throttle. Additionally, downshifting can further slow the motorcycle. move the handle bar to the left. If the motorcycle is placed on Be careful not to over- rev the engine during downshifts.

  • Page 33: Inspection And Adjustment

    VI. Inspection and adjustment This section introduces the technical requirements for proper inspection, maintenance and adjustment of various parts of the G400C motorcycle. Unless stated or indicated in the maintenance period table, you should check and adjust all parts of the G400C motorcycle prior to use. Periodic maintenance is a combination of verification and service operations performed through the Genuine Motorcycles dealer network.

  • Page 34: Maintenance Schedule

    Maintenance Period Table Maintenance period Odometer in Miles (see note 2 on next page) 3000 13,000 User Inspect Daily 5500 8000 10,500 Items * Engine Oil * Spark Plug ** Valve Gap * Idle Speed * Engine Bolts * Oil Filter * Air Filter * Fuel Filter * Air Cleaner Body...
  • Page 35 Maintenance Period Table continued Maintenance period Odometer in Miles (see note 2 below) 3000 13,000 User Inspect Daily 5500 8000 10,500 Items Throttle Operation Brake Shoes / Pad Wear * Brake System Brake Light Switch * Brake Fluid ** Clutch Suspension Nuts, Bolts, Fasteners Wheel / Tire / Tire Pressure...

  • Page 36: Spark Plug

    Spark Plug Engine Oil Remove the spark plug cap, then remove the spark plug with a Use SJ 15W40 in the summer or 10W30 in the winter in order to socket wrench. Visually check whether there is damage to the spark ensure maximum engine performance.
  • Page 37 Caution Engine oil replacement When the engine is at an operating temperature, the engine oil may Drain the oil while the engine is warm. A warm engine will ensure quick be very hot, so be careful not to burn yourself. and complete discharge of the engine oil inside the crankcase.
  • Page 38 Oil level check Cleaning the Oil Filter Run the engine for 2-3 minutes. Check whether or not the engine oil Remove the engine oil filter cover and remove the engine oil filter level is in the middle of the range on the engine oil dipstick. Add oil if element.

  • Page 39: Valve Clearance & Adjustment

    Valve clearance Valve Adjustment The valve clearance should be inspected and adjusted on a cold Specified valve clearance: engine by the following procedures: Intake: 0.07-0.10mm Exhaust: 0.08-0.12mm Remove the caps of the central port and the ignition timing If valve clearance adjustment is needed, loosen the locking nut on observation port on the left crankcase cover.

  • Page 40: Air Filter

    Cleaning and replacement of air filter Caution Remove the air filter and check for contamination. The air filter must be installed or the engine will ingest dust and Open the right side cover. Remove the 4 right side filter cover screws dirt, and an unbalanced air / fuel ratio resulting in a shorter ①and, open the right cover②...

  • Page 41: Idle Speed

    Idle speed Caution Do not adjust idle speed without consulting your genuine dealer. Adjusting screw The XY650-A idle speed is controlled by the ECU. The idle screw speed has been properly adjusted upon delivery. Do not adjust the idle speed. In the event the idle speed is unsteady, zero or too high, bring the vehicle to a qualified genuine dealer to determine the possible causes via troubleshooting the EMS Maintaining...

  • Page 42: Throttle

    Throttle Adjusting methods: Inspect the throttle cable for deformed, twisted or damaged locations along the cable length. Measure the throttle free-play. Tum the throttle against one side of the free stroke, and draw a straight line between the bar and the balance Retaining nut B weight.

  • Page 43: Brake System

    Brake system Rear Brake The front brake and the rear brake is hydraulic disk type, Inspect the Push the brake pedal downward by hand, check the brake pedal brake system prior to each ride. Properly functioning brake systems are free-play. The rear brake pedal free-play should be at least 18mm but vitally important to your personal safety.
  • Page 44 Caution Caution ·Brake fluid is flammable. Avoid contact with skin and eyes. If you come Brake pedal free-play is important. If the brake pedal free- play is too in contact with brake fluid, immediately run under water and contact a little or zero, the brakes may drag leading to brake failure.
  • Page 45 Caution Brake Pads Brake fluid cannot exceed the upper limit. If the brake pad wear indicator gaps touch the side of the brake disc, When adding brake fluid, use special care. Do not allow dust, water or the brake pads need replacement. other foreign material to contaminate the master cylinder.

  • Page 46: Wheels/Tires

    Wheels/Tires Clutch Check the clutch lever free-play. Check the condition of the tires; they may not have any cracks, Clutch lever free- play: 10-20mm grazes, etc. Also check the state of wear of the tread by means of the indicators on the tire. Check the tire pressure with a tire pressure gauge to which should be 10-20mm as indicated under TECHNICAL DATA.

  • Page 47: Drive Chain

    Coarse adjustment: 10. Drive Chain Adjusting Nut Drive Chain Tension Park the motorcycle on level ground with the main stand and shift the transmission to the neutral position. Check the driving chain tension. Press the chain by hand both up and down to check the range of Retaining nut movement of the lower chain.
  • Page 48 Chain/pinion/crown wear check Check the condition of the chain; there may not be any damaged rollers, loosened pins or missing O-rings. - Check the condition of the pinion and crown teeth; if the teeth are as shown in Figure A, they are in good condition, while if they are as shown in Figure B, they are to be replaced Loosen axle nut Tighten...

  • Page 49: Fork Functionality Check

    11. Fork functionality check Removing the front wheel To check proper functioning of the front fork, operate as follows: Position the motorcycle in such a way that the front wheel is lifted from - get on the motorcycle; the ground. - pull the front brake lever and forcefully push the handlebar downwards - Loosen the bolts ①...
  • Page 50 Removing the rear wheel Position the motorcycle in such a way that the rear wheel is lifted from the ground. Unscrew the nut (1) of the wheel pin (2) and remove the latter. Extract the complete rear wheel, keeping the spacers located at the hub sides.

  • Page 51: Battery

    12. Brake System The sealed battery does not require any maintenance. When electrolyte leaks, or other failure of the electrical system is detected, apply to the Genuine Motorcycles dealer for service. If the vehicle remains unused for long periods, it is recommended to disconnect the battery from the electrical system and store it in a dry place.
  • Page 52 Charge the battery as soon as possible. Your battery will be damaged if it remains unchanged for a long period of time. Using a battery charger with a constant voltage, first connect the RED positive cable to the battery positive terminal then the BLACK negative cable to the battery negative terminal.

  • Page 53: Fuse Replacement

    13. Replacement of fuse 14. Turn signal light Remove the lamp lampshade Turn the ignition switch to the “OFF” position. The main fuse is a Lightly press bulb, rotate in counter-clockwise. 15A tube type fuse, and the fuel injection nozzle is a 10A tube type Install new bulb in opposite order as below.

  • Page 54: Bolts, Nuts And Fasteners

    16. Bolts, nuts and fasteners When washing, block the muffler to avoid water getting into the muffler and engine. Bolts, nuts and fasteners should be checked periodically and 18. Maintenance Prior to Storage tightened to torque specifications outlined later in this manual. Check If the motorcycle will be stored for a long period of time, pay attention to all cotter pins, straps, ties, locks, etc the prevention of moisture, sunshine and rain in order to protect it from...

  • Page 55: Special Torque Values

    Special Torque Values Item Quantity Thread diameter (mm) Torque value (ft-lb) Cylinder head nut M10×1.25 21-24 Magneto flywheel fastening nut M10×1.25 27-33 Spark Plug M12×1.25 13-15 Front wheel axle 30-37 44-66 Real wheel axle nut Swing arm shaft nut 44-52 Engine hanging bolt 29-36 Engine cover bolt...

  • Page 56: Standard Torque Values

    Standard Torque Values Name and dimensions Torque value (ft-lb) 3.5 - 4.5 5mm bolt & nut 6mm bolt & nut 13 - 18 8mm bolt & nut 22 - 30 10mm bolt & nut 37 - 44 12mm bolt & nut 2.5 - 3.5 5mm Screw 6mm Screw...

  • Page 57: Engine Management System

    VII. Engine Management System The Engine Management System (EMS) is comprised of the following components: 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, etc. The EMS uses sensors to collect parameters such as air flow, temperature of inlet air, cylinder head temperature, atmospheric pressure and the operational state of engine (rpm, load, acceleration and deceleration).

  • Page 58: Major Components Of Efi System

    Major Components of EFI system Cylinder Head Temperature Sensor Throttle body Fuel Injecto Idle speed control valve Throttle sensor Intake air pressure sensor...
  • Page 59 Electronic Control Unit ( ECU) Oxygen sensor...

  • Page 60: Circuit Schematic Drawing

    Circuit schematic drawing...

  • Page 61: Definition Ecu Pins

    Definition ECU pins ITEM PIN No. DESCRIBE ITEM PIN No. DESCRIBE J1-1 IACAHi J2-1 COILA J1-2 MAGNETO CUT RELAY J2-2 J1-3 J2-3 KW2000 J1-4 J2-4 CRANK HI J1-5 J2-5 INJA J1-6 TACH J2-6 J1-7 CANLo J2-7 O2AHTR J1-8 CANHi J2-8 IAT_MAT J1-9 J2-9...

  • Page 62: Ems Failure Diagnosis Code List

    EMS failure diagnosis code list 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...
  • Page 63 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 Powertrain controller...
  • Page 64 OBD Service $03 System or DTC Number DTC Description Related Calibration Component P0107 MAP Circuit Low Voltage or Open KsDGDM_MAP_ShortLow #N/A Manifold Absolute Pressure Sensor (MAP) P0108 MAP Circuit High Voltage KsDGDM_MAP_ShortHigh #N/A P0112 IAT Circuit Low Voltage KsDGDM_IAT_ShortLow #N/A Intake Air Temperature Sensor (IAT) P0113...
  • Page 65 P0562 System Voltage Low KsDGDM_SysVoltLow #N/A System Voltage P0563 System Voltage High KsDGDM_SysVoltHigh #N/A P0650 MIL Circuit Malfunction KsDGDM_MIL_Circuit #N/A P1693 Tachometer Circuit Low Voltage KsDGDM_TAC_Circuit_Low 1693 #N/A Tachometer P1694 Tachometer Circuit High Voltage KsDGDM_TAC_Circuit_High 1694 #N/A P0137 O2S 2 Circuit Low Voltage KsDGDM_O2_2_ShortLow #N/A Oxygen Sensor 2...
  • Page 66 OBD Service $04 Functional description The purpose of this service is to provide a means for the external test equipment to 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 67 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 68: Engine Management Troubleshooting

    Engine Management System Troubleshooting EFI systems are complex. As such, there are many possible causes when a running issue is encountered. At times it can be confusing if an issue is caused by a mechanical problem or the EFI components. Always contact your genuine dealer if you are having trouble with your vehicle's Engine Management System.

  • Page 69: Electrical System Diagram

    VIII. Electrical system diagram...

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