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

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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

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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

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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.

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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 .

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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

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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 .

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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

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Fuel gauge
High beam indicator
Neutral indicator
Zero Knob
Turn indicator
Speedometer
Odometer
Trip mileage meter
Tachometer
FAI EFI Indicator

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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。

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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

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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

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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

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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

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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.