Mash TT40 Cafe Racer User manual

MAN
User Manual
English

Congratulations!
You are the happy new owner of a MASH which embodies a new spirit, a new
trend: a motorcycle with a look and a philosophy
"Vintage", synonymous with freedom.
Please read this manual thoroughly before using your MASH.
Enjoy the ride!

Important Cautions
About running-in of a motorcycle
The first 1000 km operation is very important in the entire service life of a
motorcycle. A correct running-in can guarantee both the longest service life and
the best performance of the vehicle. Running-in can polish machined surfaces and
form smooth engagement.
Careful and patient running-in can make the motorcycle stable in driving and
give a full play to its excellent performance. It is important not to do any
operation that may cause overheat to engine components.
For specific running-in method, please refer to "Running-in of a new vehicle".
Please carefully read the manual and strictly observe all instructions or
descriptions.
Special attention shall be paid to the contents emphasized with the terms of
"warning" "caution" and "note", etc.
Warning……It concerns with personal safety. Ignoring it may result in accident.
Precaution……It refers to operational methods that must be followed or
measures that should be taken, so as to prevent damage.
Note……It refers to special explanations to make maintenance or important
descriptions more explicit.
The operation manual shall be deemed as a permanent document of the
motorcycle. When transfer the vehicle to others, the instruction manual shall
also be transferred to the new owner
There are some differences among various models. For any unconformity
between your vehicle and the instruction manual, the real vehicle shall prevail.

MASH TT 40 400cc

Frame N°
Engine N°
Distributor :
Foreword
Thank you for your choosing our motorcycle. In design, development and
manufacture of the series motorcycle, our company applies the latest advanced
technology and equipment to provide you with a motorcycle that is reliable in
performance, novel in design and elegant in appearance. Motorcycle driving is
one of the most exciting sports. The motorcycle is an ideal means of transport.
It can give you infinite driving pleasure. Before driving your motorcycle, please
be familiar with all stipulations and requirements mentioned in the instruction
manual.
The instruction manual deals in the correct use, maintenance and maintenance
of the motorcycle. Observing the following stipulations will provide a guarantee
to your motorcycle for a long time use without trouble. The distributor has
skillful and well trained technical professionals to provide the best maintenance
and service to your motorcycle.

Index
IMain technical Data.................................................................... 10-11
II Operation Instruction
Protective Wear .............................................................................................12
Préparation before Operation ......................................................................13
Operation......................................................................................................16
Modification of the vehicle...........................................................................14
Loading of goods...........................................................................................14
Accessory ......................................................................................................14
Muffler ..........................................................................................................14
III Parts’ position..............................................................................15
Meter reading & usage .................................................................................16
IV Switch operation.............................................................................18
Headlight、Position Indicator ......................................................................19
Far and Near Light Lamp Instruction.............................................................20
Direction Indicator ........................................................................................20
Horn Button ..................................................................................................20
Overtaking lamp switch ................................................................................20
Electric Start Button......................................................................................20
Emergency Cut-off Switch.............................................................................20
Fuel................................................................................................................21
Checking fuel level ........................................................................................21
VCorrect driving ...................................................................................23
Engine starting ..............................................................................................21
In the start fails .............................................................................................23
Run-in of engine............................................................................................23
Maintenance of the engine...........................................................................24
Checking Before Operations ................................................................... 24-25
Gear Shift ......................................................................................................26
Gear down operation....................................................................................26
Operation......................................................................................................27

Brake system and ABS system………………………………………………………………28-29
Park…………………………………………………………………………………………………………..30
Rearview mirror…………………………………………………………………………………………31
VI Inspection and adjustment ..........................................................31
Maintenance Period Table………………………………………………………………………….32
Spark Plug…………………………………………………………………………………………………..32
Timing phase………………………………………………………………………………………………32
Lubricating oil………………………………………………………………………………………..32-33
Cylinder pressure…………………………………………………………………………………..33-34
Check-up, cleaning of Air Filter…………………………………………………………………..35
Idle speed…………………………………………………………………………………………………..36
Throttle control………………………………………………………………………………………….37
Brake system……………………………………………………………………………………38-39-40
Tires…………………………………………………………………………………………………………..41
Range…………………………………………………………………………………………………………42
Clutch control line……………………………………………………………………………………..42
Adjusting methods...................................................................................42-43
Driving chain............................................................................................ 43-44
Checking of accumulator...............................................................................45
Installation of accumulator............................................................................45
Replacement of Fuse.................................................................................... 46
Brake lamp adjustment.................................................................................46
Headlamp dimming.......................................................................................47
Position lamp bulb…......................................................................................47
Tail light and light bulb..................................................................................47
Front light and bulb.......................................................................................48
Sidestand.......................................................................................................48
Bolts, nuts and fasteners.............................................................................. 48
Vehicle washing….…..……………………………………………………………………………….. 48
Storage………………………………………………………………………………………………………49
Resumption to service……………………………………………………………………………….49
Special notice.......……………………………………………………………………………………..49
Driving....…………………………………………………………………………………………………..49
Operation turning…….……………………………………………………………………………….50

9
Turning method .... .......................................................................................50
Turning reminder ..........................................................................................50
Dead angle of sight........................................................................................50
Speed effect.... ..............................................................................................50
Postulate of brake (friction) ..........................................................................50
Limitation of braking force............................................................................ 50
Brake method... .............................................................................................50
Impact of crash ..............................................................................................50

10
I Main Technical Data
Mash Five Hundred 400cc
Motor type
Single cylinder 4T, Air cooling
Displacement
397,2 cc
Compression ratio
8.8:1
Idle Speed
1500±100RPM
Max power
20.4kw/6500 tr/min
Max torque
30.0N.m/5500 tr/min
Bore * Stroke
85.0x70.0
Ignition
CDI
Spark plug type
DPR8Z
Valve gap
Valve Intake : 0.07-0.10mm
Valve Exhaust : 0.08-0.12mm
Overcurrent protection
15A/10A
Battery
12V9Ah
Headlight
12V55W
Taillight/Brake signal light
12V 5W/21W
Position indicator
12v 5W
Turning signal light
12V 10Wx4
Turning instruction light
12V 1.7W
Meter light
12V 3W
Far-reaching light instruction
12V 1.7W
Front Tyre
100/90-19
Rear Tyre
130/70-18
Oil motor
SAE10W-30

11
Quantity oil motor
2200 mL
Length /Width /Height
2130×740×1130mm
Wheelbase
1420mm
Ground clearance
160 mm
Weight
160kg
Weight max
155kg
Fuel
SP95 or SP98 (SP95 E10 not recommended)
Capacity fuel tank
13L
Speed I
2.615
Speed II
1.789
Speed III
1.350
Speed IV
1.120
Speed V
0.892
End level transmission ratio
2.533
Initial level transmission
ratio
2.667
This list is information only. Changes can be made by the manufacturer without
warning to customers.
This manual can display photos showing vehicles equipped with accessories

12
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.
1. Protective clothing
2. Goggles
3. Gloves
4. High boots
5. Helmet

13
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 .
.
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
may be 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 .

14
Modification of the vehicle
Caution
Any unauthorized modification of the vehicle or replacement of the original
parts cannot 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 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 .

15
III Parts Position
Seat assy
Rear wheel
Muffler
Front wheel
Pedal, rear brake
Engine
starter
switches
Right rear view
mirror
Left rear view mirroir
Account
round
Meter
ABS switch
Turn signal
switch
Clutch
lever
Front
brake
level
Throttle
twist
grip
Left handlebar
Horn
switches
Ignition
Emergency
stop switch

16
Meter reading and usage
1. Speedometer
Indicate motorcycle speed (Km/h). Do not exceed legal rate-limiting to
assure safe riding.
2. ABS indicator : When the ABS system is activated, the LED is off. It
can be switched off (see procedure on page 28). This indicator will
remain on permanently in the event of an anomaly).
3. Turn indicator
（R) right turn, activate when turn to right (Green).
（L) left turn, activate 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
Rear shock
absorber
Rear turn
light
Exhaust silencer
Side
stand
e
Gear
selector
Front shock
absorber
Front turn
light

17
Warning
If the EFI indicator light comes on, contact your local dealer for inspection.
If the ABS warning light illuminates, please contact your local dealer for inspection
Tachymètre
Compteur
kilométrique total ou
journalier
Turn
indicator
Zero knob
Fuel gauge
High beam
indicator
Neutral indicator
Indicator EFI (ectronic
injection)
ABS indicator
Speedometer

18
IV Switch instruction
Main Switch used to Start or switch off the Engine .
Position
Function
For starting or driving the vehicle(making
all the main circuits)
To stop the vehicle (switching off all
circuits)
To lock the steering handle
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 ） .

19
Headlight, Position Indicator
Turn the main switch key to “ ” position, switch on the headlight。
Headlight Switch
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
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 .

20
Horn Button
When you press horn button, it will make a sound
Electric Start Button
Push this button, make the engine start
situation d’urgence
Pendant la conduite, tourner l’interrupteur de
à est dangereux et endommagera le moteur.
Avant d’·utiliser l’interrupteur d’arrêt d’urgence pour
arrêter le moteur, assurez-vous que l’interrupteur
principal soit en position , s’il est en position;
position et que le moteur est coupé, la batterie
se déchargera.
Si l’interrupteur est en position , vous ne pourrez
pas démarrer le moteur.
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 .
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.