Mash Dirt Track 650 User manual

Dirt Track 650
Owners Manual

1
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：

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Index
I、Technical Data of Main Performance………………………1-3
II. User Instructions…………..………….………......................…4
Safety & Protective Gear…………………...……..…………….…...4
Do not ride while under the influence……………..………….…..…5
Safe riding principles………………………..………..…..……...……5
Being seen……………………....………………….……..………….6
Know your Motorcycle…………..…………….……….……………...6
Loading & Carrying Passengers………………………………..…….7
Gasoline and exhaust fumes………………………….….….…...….8
Modifications……………………..................... .……......……...….8
Fuel-Saving tips……………………….……...….……...….……...9
III. Vehicle Layout….........................….…..……...........…..10-12
Instrument Gauges……………………………….……..…...….13
Gauge Check…………….………………...…………………..…14-15
IV. Controls………………….........................………......……...16
Ignition Switch……………………………….…….………..….…….16
Switches on right handlebar…….……….……....…….……………17
Switches on left handlebar………………………..………………18
Adding Fuel…………………….………………..……………………19
Gear Shift Lever …………………………….…….…………….…...19
Mirrors……………………………………….…………...…………20
Clutch lever…………………………...…………………....…….......20
Throttle………………………………………….......…………..…….20
Brakes……………………………………………...…..……………..21
Anti-Lock Braking System………………………..…...……………..21
Side stand………………………………………………..….………...22
Helmet holder……………………………………………….………...22
V. Proper Operation…………………..………. ….…. …………..23
Engine Start /Stop………………………………………. ….……..23

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Engine Break-Maintenance…………….…………………..……24
Pre-Ride Inspection…………………………………..…….………. 25
Vehicle Operation…………………………………….…………..26-28
VI Inspection and adjustment…………………...……………..…29
Maintenance Schedule……..………………………….…....…30-31
Spark Plug ………….…..………………….....……………………32
Engine Oil……….....…..…………..…………..………..………..32-34
Valve Clearance & Adjustment……..……..…….…………..…35
Air Filter……….………..………………......................................…36
Idle Speed…...….………..…..………..…………………..………... 37
Thrott le …… …………………… ………… ….. .…. …… …….… 38
Brake System….………………..………………………..……39-41
Wheels/Tires…..…………………………………………......…42
Clutch………………………………….....................…..….......42-43
Drive Chain………………..………………..…………..………43-44
Fork functionality check…..………………..…………..………45-47
Battery….…..……………….........................................……47-48
Fuse Replacement..………..…………………..……….……………49
Turn signals………………………………………….………….…49
Side stand….………………..………………………..………….…49
Bolts, nuts and fasteners…………………..………………......…50
Vehicle Washing………………………….....................….......…50
Storage………………..………………..…………..…………….…51
Special Torque Values..……………….......................……..…51
Standard Torque Values…..……………………….……………52
VII. Engine Management System…..……………….……..…53
EFI System Composition…………………………………….………53
Major Components of EFI System……………………………...54-55
Circuit schematic drawing…………………………………………...56
Definition ECU pins……………………………………...…………...57
EMS failure diagnosis code list………………….…...……...58-63
Engine Management Troubleshooting………………………..64
VIII. Electrical system diagram……..…………..…….……..…..65

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I. Technical Data of Main Performance
Item
Data
Dimension &
Weight
Length*Width*Height
Wheelbase
Minimum ground clearance
Complete vehicle weight
2080mm*890mm*1170mm
1420mm
180mm
Non-loaded weight: 169kg Dry weight: 180kg, Curb weight: 150kg,
Vehiclebody
Front suspension device
Rear suspension device
Front Tire size
Rear Tire size
Front wheel pressure
Rear wheel pressure
Front brake
Rear brake
Fuel tank volume
Spring & hydraulic composite damping
Spring & hydraulic composite damping
120/80-18
130/80-18
Normally loaded: 225 kPa,
Normally loaded: 225 kPa,
Single disc type Diameter Φ320mm
Single disc type Diameter Φ240mm
13.0L

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Engine
Mode
Cylinder bore
Cylinder stroke
Displacement
Compression ratio
Max. power
Max. torque
Valve clearance (cold)
Air Filter
Cooling method
Lubrication method
Engine oil grade
Engine oil charge volume
Engine oil filter element
Electric motor starting
Idle speed
Single-cylinder Oil –cooling 4-stroke engine
100.0mm
82.0mm
643.7cc
8.3:1
29.5 kw / 6000 rpm
49.8 N.m/4500rpm
Intake: 0.07-0.10 mm ；Exhaust: 0.08-0.12 mm
Oilpaper filte
Oil-cooling
Pressure / Splash
SJ15W/40 / MA2 engine oil in warm weather and SJ10W/30 / MA2 in cold weather
climates
2.2L
Oil paper filter
Electric
1500±150r/min

3
Driving system
Clutch
Clutch operating system
Primary reduction ratio
Transmission gear ratio
Final reduction ratio
Gear shifting mode
Wet clutch, coil clutch, paper friction wafer
Manual mechanical
2.029
Ⅰ2.667；Ⅱ 1.647；Ⅲ 1.250 Ⅳ1.000；V .0.840；
3.000
Left foot operated to and back type
Sequence: I－N－Ⅱ－Ⅲ－Ⅳ－V
Electrical system
Accumulator capacity
Power supply system
Fusible cutout
Spark plug
Spark plug gap
Ignition coil type
Fuel supply mode
Ignition mode
Front lamp/ Front -position lamp
Turn lamp
Stop / Rear-position lamp
12V11.2A.h
DC power supply, and the electric generator is only used to recharge the accumulator
15A /10A
DPR8EA-9
0.6～0.7mm
Open magnetic circuit
Electronically injection, ECU control
EMS
12V55W/5W
4×12V10W
12V1.5W/0.5W

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II. User Instructions
Important safety information
Your safety is very important. Your motorcycle can provide many
years of service and pleasure, if you take responsibility for your
own safety and understand the challenges while riding. There is
much you can do to protect yourself when you ride.
Please read through the following instructions before riding your
bike the first time.
• Be sure you read this owner ’ s manual completely and
understand all operating features.
• Take sufficient time training with safe and proper riding
technique.
• Practice until you are knowledgeable and comfortable with
your motorcycle, and knowledgeable with all road signs.
• Failure to follow any safety instructions could cause severe
injury or even death to the motorcycle operator, passenger or
bystander.
Before riding each time, make sure of the following:
Wear protective gear
Wearing appropriate protective wear can prevent or reduce injuries
from accidents.
• Helmet – The majority of serious motorcycle injuries and
deaths are the direct result of a head injury. Drivers and
passengers should always wear a helmet to prevent or reduce
the chance of head injury.
• Eye and Face Protection – A plastic face shield can help
prevent accidents by guarding the face and eyes from debris,
allowing the rider to devote full attention to the road. Goggles or
glasses can protect the eyes in the same manner.
• Clothing – Bright clothing should be worn by the driver so
as to be seen easily by other motorists. Avoid loose clothing that
could catch on the levers, chain or wheels which could result in
an accident. Gloves give you a better grip and help protect your
hands from the elements.
Caution
· Failure to wear a helmet will significantly increase the likelihood
of injury or death if an accident occurs.
· Make sure passengers always wear a helmet to protect eyes, and
wear protective clothing.

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Do not ride while under the influence
Before getting on your bike, make sure:
• You have not consumed alcohol or taken drugs.
• You are in good physical and mental condition.
• You have done the recommended pre-ride inspection.
• Start the engine in a well-ventilated area.
• The exhaust emits toxic and poisonous carbon monoxide.
Caution
Operating this motorcycle after consuming alcohol or drugs could
seriously affect your judgment, could cause you to react more slowly,
could affect your balance and perception and could result in an
accident.
Safe riding principles
• Keep enough distance with the other vehicles around you
as this gives you time to react.
• Always observe the rules of the road. Observe the posted
speed limit, and signal your turns well in advance.
• Know your limits. Do not travel faster than you are able to
safely control the vehicle. Always travel at a speed that is proper
for the operating conditions, your ability and experience.
• Always inspect your motorcycle each time you use it to
make sure it is in safe operating condition.
• Always follow the inspection and scheduled maintenance
procedures described in this manual.
• Test your brakes after operating in wet conditions.
• Never attempt wheelies, jumps and other stunts, as these
could cause damage to the motorcycle and cause loss of control.
• Always keep both hands on the handlebar and feet on the
foot pegs during operation.
• Never consume alcohol or drugs before or while riding your
motorcycle.
• Be aware that long travel distances can cause fatigue that
can affect performance and awareness.
• Do not touch the engine or exhaust after riding as they will
be extremely hot right after the engine has been turned off.
• Park the motorcycle away from fuel or flammable
materials.

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Being seen
Many motorcycle accidents are caused by car drivers who do not
see motorcycle riders on the road. To reduce the chance of an
accident, follow these guidelines:
• Wear bright clothing to increase visibility. Bright orange,
yellow or green jackets or vests and a brightly colored helmet
can help others see you.
• Always use turn signals when you are planning to turn or
merge to main roads, and turn off signal after completing turns.
• Flash brake lights whenever you are going to slow down
quickly or where others may not expect you are going to slow
down.
• Stay out of blind spots of other motorists.
• When you come to an intersection, move to the portion of
your lane that will bring you into another driver ’ s field of sight at
the earliest possible moment.
Know Your Motorcycle
• Get training if you are inexperienced.
• Beginners should get training from a certified instructor.
• Become familiar with the motorcycle at slow speeds first.
Even if you are an experienced rider, do not attempt to operate at
maximum performance until you are very familiar with the
vehicle.
• The equilibrium and stability of your motorcycle are
affected by the manner in which you load it. It is very important
that you do not install accessories that compromise the design
and concept of the motorcycle. Doing so could alter the safety of
your motorcycle.

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Loading & Carrying passengers
You should avoid carrying passengers or large loads until you have
gained sufficient experience riding alone. Extra weight changes
handling, stability, braking performance, turns,
Acceleration and deceleration. The load you carry on the motorcycle
has an important effect on your safety, as well as the life of the
motorcycle; therefore, apart from driver and passenger, it is advised
to keep load to a minimum. If you decide to carry any load, take the
following into account:
• Make sure the load is as light and as small as possible.
• Make sure the load does not interfere with any moving
parts.
• Make sure the load does not interfere with your ability to
move around in order to maintain proper equilibrium.
• Put the load as close as possible to the center of the
motorcycle.
• Put only light load on rear rack, if installed.
• Do not attach load to handlebars, headlight or front forks.
• Properly secure all items.
• Inflate tires properly.
Caution
The design of the motorcycle requires even distribution of all
loads. Be aware that improper loading of goods will adversely
affect the performance and stability of the vehicle.
Keep the load low and distribute the load evenly. An uneven load can
cause the motorcycle to drift to one side. Carrying excess load on
your motorcycle can cause an accident or crash resulting in severe
injury or even death to the motorcycle operator, passenger or
bystanders. To carry passengers safely, you must instruct the
passenger before you start to:
• Wear a helmet.
• Get on the motorcycle after you have started the engine.
• Sit as far forward as possible without crowding the driver.
• Hold firmly to your waist, hips, belt or passenger handles.
• Keep both feet on the pegs at all time, even when the
motorcycle is stopped.
• Keep legs away from hot and moving parts.
• Stay directly behind you, leaning as you lean.
• Avoid any unnecessary motion.
To drive witha passengersafely, youmust:
• Go slower.
• Start slowing earlier as you approach a stop.
• Maintain a larger cushion of space ahead and to the sides.
• Wait for larger gaps when you want to cross, enter or
merge into traffic.

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Gasoline and exhaust fumes
• Gasoline is highly flammable and exhaust fumes are
poisonous:
• Turn off engine before refueling.
• Do not overfill fuel tank!! Fill fuel level to 1/2 inch below the
neck of the fuel tank fill opening.
• Do not spill any gasoline on the engine, exhaust system or
plastic parts.
• Do not refuel while smoking or near any open flame.
• If you swallow gasoline, inhale gasoline vapor or spill
gasoline in your eyes, seek medical help immediately.
• If you spill gasoline on your clothes, change and wash the
affected area immediately with soap.
• Do not operate your motorcycle in a closed area as the
exhaust fumes may cause loss of consciousness or death within
a short time.
Caution
To avoid scalding by muffler, do not park the vehicle near
walkways.
Passenger should pay special attention to avoid exhaust burns.
Hay or other flammable items will create fire if too close to the
exhaust system.
Modifications
Any modifications to this motorcycle, removal of original equipment
or use of unapproved accessories, may cause it to be unsafe for use
and may trigger severe accidents. Some modifications may also
make your motorcycle illegal to use on public roadways, and will void
all warranty coverage.
Your genuine dealer is familiar with all recommended accessories for
your motorcycle, and should be your primary source for purchasing
and installing any accessories. The owner of the motorcycle is
responsible for the safety, installation and usage of any accessories
not approved by Genuine.
Before installing new accessories, make sure they do not interfere
with moving parts, reduce ground clearance, and do not interfere
with the operating controls.

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Fuel-Saving tips
The way you drive your motorcycle will have a direct impact on your
fuel consumption.
• Drive at appropriate speed and avoiding sudden
acceleration or braking. Fluent motorcycle operation is not only
important for your safety and fuel economy, but also extends the
usable life of your motorcycle.
• Driving within allowed speed limits will yield optimum fuel
economy.
• Always maintain tires at recommended pressure. Check
pressure prior to each ride.
• Have your motorcycle inspected and serviced according to
the periodic service and maintenance table.
• Check that brakes are not dragging and preventing the
wheels from turning freely. Avoid riding with the rear brake pedal
pressed.
• Turn off the engine if waiting for more than a few minutes.
• Do not fill up fuel tank above cap neck.
This instruction book illustrates the notes for the standard and safe
operation method, and basic maintenance.
To ensure a 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 cosmetic differences between models.
· The vehicle is specifically designed for a maximum of two people
(Including the rider himself)
Caution
Do not use contaminated fuel ；
Using contaminated fuel may possibly cause rust inside the fuel
tank, which in turn can block fuel lines causing failure to the EFI
system, or even cause severe damage to the engine.
Do not use sub-standard or polluted engine oil
Always use the specified grade of engine oil, so the engine ’ s
performance and longevity can be ensured.
Any failures as a result of the use of inappropriate fluids are not
covered under warranty.

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Ill. Vehicle Layout
Left-hand rear-view mirror
Meter
Ignition/steering lock block
Right-hand rear-view mirror
Left handlebar
Clutch control lever
Switches on left handlebar
Throttle twist grip
Front brake control
lever
Switches on right handlebar
Fuel tank lock

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Rear shock absorber
Saddle
Front wheel
Front shock absorber
Muffler
Pedal, rear brake
ABS rear sensor ring

12
Gearshift pedal
Front turn light
Rear turn light
Rear wheel
ABS front sensor ring

13
Instrument Gauges
High beam indicator
Neutral indicator
Turn indicator
Speed indicator
Odometer
RPM indicator
Engine failure light
ABS indicator
Fuel level indicator
A
B

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Gauge Check
1) Speed indicator
The meter speed display with digital display, display range (0 -
199Km/h).When the speed is higher than 199Km/h, speed display
value is 199Km/h.
2) Single mileage and total mileage display
This instrument is single mileage and total mileage display with
digital display. Single mileage range 0 - 999.9Km, total mileage
range 0 - 999.9Km 0 — 9999.9Km 。 When the mileage value exceeds
the value, the amount will automatically reset and save Single
mileage and the total mileage of precise 0.1Km 。
3) Turning indicator light (green light)
The light fl ashes when activating the left- or right hand turning
indicator using the control lever on the left-hand switch 。
4) High-beam light（blue light）
The light comes on when activating the high-beam light using the
control on the left-hand switch.
5) Neutral warning light .
Using the shift lever, shift the motorcycle into neutral. The green "N"
indicator light will illuminate. If light does not illuminate, check the
neutral switch or indicator bulb for malfunctions.
6) RPM indicator
The instrument RPM instructions with stepper motor indicator. The
indicated span 0-12000RPM
Turn the ignition switch to the "on" position. The tachometer will
sweep to the Redline and back indicating that the tachometer needle
is functioning properly.
7) Fuel quantity display
The instrument of oil quantity display using bar code display, the
display range 1-6 lattice, When the fuel level indicator pointer is close
to the last scale, (low oil level indicator and the first oil quantity
indicator is blinking) ， there is less fuel left in the tank. Replenish
unleaded gasoline.
Turn the ignition switch to the "on" position. The yellow "low fuel"
indicator will illuminate for 1 second and then turn off. If the fuel light
remains on, check the fuel level. If light does not illuminate, or
remains illuminated when tank is full, check the fuel sender or
indicator bulb for malfunctions.
8) Engine failure light
When the ignition switch is in the "on" position, and all other start
conditions have been satisfied (see "Start Conditions" for more
information), the Diagnostic Trouble Code light (red "check engine"
light) will illuminate and stay lit until the engine has been started.
This is a "Lamp Test" to allow you to check the function of the

15
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.
9) ABS Lamp
After ignition, ABS warning lamp is lit up, and then goes out after a
short period of time. If the ABS lamp is always on after the ignition, or
suddenly light up in the process of driving, these mean that there are
faults in the ABS, the ABS is disabled. But the braking system itself is
still working, only the ABS control system is failed.
Instrument button operation instructions
Press the left build "A" ：
Switching between big and small mileage 。
Press the right build "B" ：
Press the right button before power up. Switching between metric
and British system 。
Under the TRIP display interface, long press right and left to build the
trip odometer to zero 。

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IV. CONTROLS
1. Ignition Switch
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 change the ignition key position when riding.
If the key is moved to the position during riding, all electrical
systems will be off. While riding, do not remove the main switch key
in order to avoid an accident. If necessary, stop the motorcycle
prior to removing the key.
Before removing the key, make sure the handle bar is locked.
If the engine is not started after turning the key to the position,
the battery will discharge over time.
Do not use sharp metal keys or key fobs to avoid scratching the
upper triple clamp. Use a cloth or leather key fob.