Mash XY400B Quick start guide

XY400B
OPERATIONAL INSTRUCTION

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 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.
Caution
——Any ignorance of the mentioned-below information may cause the damage of motorcycle with sidecar 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、Technical Data of Main Performance…….……………………1-3
II、Safe drive……………………………………………………………4
Important safety information………….……………….………....…4
Wear protective……………………………………………………...4
Do not ride while under the influence……………………..…..…4
Safe riding principles……………………………………...………5
Being seen……………………....……………………………....….5
How to keep your motorcycle safe………………………………...6
Loading& Carrying passengers………………………………...….6
Gasoline and exhaust fumes………………….…….……..…..…..7
Modifications……………………….….......................…..…..…..7
Flue-Saving tips………………………………….….……..…..….8
III、Parts’ position……………...............................…………...…9-10
Meter reading & usage……………………………………...…11-12
IV、Switch operation…………………….....................…......…….13
Switch instruction………………………………………..….…….13
Switches on right handlebar……………………..…..………14
Switches on left handlebar...................................................14-15
Fuel filling………………………….…………………..…......15
Gear Shift …………………………...……………………….……..16
Blind spot mirrors……………………………………….….....…...16
Clutch lever…………………………………...…………….….......17
Throttle……………………………………………..……........17
Brake usage…………………………………….…………………..17
Parking lever……………………………………………………..18
Seat belt………………………………………….……………..18
Oil output tank………………………………………….…………..19
V、Basic operation and riding………………………….…………..20
Engine startin…………………………………………..…………..20
Run-in of engine……………………………………….….… 20-22
Operation………………………………………………………22-24
VI、Inspection and adjustment…………………………..……..…25
Maintenance period table………………………….……....…25
Check-up of spark plug………………………………….……..…27
Timing phase……………………………………………...……..…27
Machine oil checking……………………………….………...28-29
Valve clearance……………………………..…………………..…30
Check-up, cleaning of air filter…………………………….....…31
Idle speed……………………………..……..……………….……32
Throttle control…………………………………….………………33
Brake system……………………………………………..……34-36
Running system…………………………………………….………37
Clutch control line………………………………..............……37-38
Driving chain…………………………………………..………38-39
Battery checking……………….....................................……40-41
Replacement of Fuse……………………………….……………41
Brake lamp adjustment………………………………………..…42
Illumination signal system…………………………………..…42-43
Bolts, nuts and fasteners……………………………….………43
Vehicle washing………………………………………………43-44
Maintenance in non-use time…………………………….……44
Resumption of Service……………………………………………45
Special notice………………………………………………………45
Driving…………………………………………………………….…45
VII、Engine management system…………………….…….…46
OBD Service $01………………………………………………….50
OBD Service $02………………………………………………….51
OBD Service $03………………………………………………52-53
OBD Service $04…………………………………………………54
OBD Service $07………………………………………………….55
Service $09 (Request Vehicle Information) -PIDs supported…55
Standard torque values…………………………………………...56
VII、Electrical system diagram……….…….………………………58

1
I、Technical Data of Main Performance
Item
Data
Dimension & Weight
Length
Width
Height
Wheelbase
Wheelbase sidecar
Min. ground clearance
Complete vehicle weight
2160mm
1610mm
1125mm
1420mm
1170mm
160mm
Non-loaded weight: 260kg,
Max loading weight: 485kg,
Vehicle body
Frame type
Rake angle
Front suspension device
Rear suspension device
Front wheel type
Rear wheel type
Side wheel type
Front brake
Rear brake
Side brake
Fuel tank volume
Fuel grade
Cradle type
28°
spring & hydraulic composite damping
spring & hydraulic composite damping
100/90-19/ 280 kPa
130/80-18/ 280 kPa
100/90-19/ 280 kPa
Single disc type ModelΦ276
Single disc type ModelΦ160
Single disc type ModelΦ276
13L
93#

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Engine
Mode
Cylinder bore × Stroke
Cylinder displacement
Compression ratio
Max. power
Max. torque
Valve clearance (cold)
Valve driving gear
Air filter
Cooling method
Lubrication method
Engine oil charge volume
Engine oil filter element
Electric motor starting
Idle speed
Single-cylinder Oil –cooling 4-stroke engine
85.0mm ×70.0mm
397cc
8.8±0.2:1
20.4kw/6500rpm
30.6N.m/5000rpm
IN: 0.07-0.10；EX: 0.08-0.12
Chain drive
Oilpaper filter
Oil-cooling
Please apply Shell 15W/40-SF engine oil in summer and 10W/30-SF in winter
2.2L
Oilpaper filter
Electric
1600±100r/min
Driving system
Clutch
Clutch operating system
Variable speed gear
Primary reduction ratio
Transmission gear ratio
Final reduction ratio
Gear shifting mode
Wet clutch, coil clutch, paper friction wafer
Manual mechanical
5-speed constant mesh +1- reverse
2.666
R：2.428；Ⅰ：2.727 ；Ⅱ： 1.789；Ⅲ ：1.363 ：Ⅳ： 1.080；V ：0.925
3.000
Left foot operated to and back type；
Sequence: R－I－N－Ⅱ－Ⅲ－Ⅳ-V

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Electrical system
Electric generator
Accumulator capacity
Power supply system
Fusible cutout
Spark plug
Spark plug gap
Ignition coil type
Fuel supply mode
Ignition mode
Ignition advance angle
Ignition timing
Front lamp
Turn lamp
Taillight/Brake signal light
Position indicator
permanent magnet DC magneto
12V9A.h
DC power supply, and the electric generator is only used to recharge the
accumulator
15A/10A
DPR8Z
0.6-0.7mm
Open magnetic circuit
Electronically injection, ECU control
EMS
EMS
EMS
12V/55W/60W
Front: 12V10W Rear: 12V10W
12V21W/5W
Front: 12V5W Rear: 12V5W Sidecar: 12V5W

4
II、Safe drive
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
Riding a motorcycle leaves the rider exposed. Therefore,
wearing appropriate protective wear can prevent or diminish injuries
from accidents.
• Helmet – The majority of serious motorcycle injuries and
deaths are direct result of a head injury. Therefore, 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
·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.
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 per ride inspection.
• Start the engine in a well-ventilated area.
The exhaust emits toxic and poisonous carbon monoxide.

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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. 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 go faster than you are able to control.
Always travel at a peed 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.
• Limit the travel distance to avoid 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.
Being seen
Many motorcycle accidents are caused by car drivers who do
not see motorcycle riders on the road. Therefore you need to
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 it off after you have made your turn.
• 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.

6
How to keep your motorcycle safe
Get training if you are inexperienced.
Beginners should get training from a certified instructor.
Become familiar with this motorcycle at slow speeds first. Even
if you are an experienced operator, do not attempt to operate at
maximum performance until you are totally
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 change the design and concept of the
motorcycle. Doing so could alter the safety of your motorcycle.
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 anything to handlebars, steering, headlight or front
forks.
• Strap everything properly.
• Inflate tires properly.
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.
• 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 bystander. 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

7
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 with a passenger safely, you must:
• 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.
Gasoline and exhaust fumes
Gasoline is highly flammable and exhaust fumes are
poisonous:
• Turn off engine before refueling.
• Do not spill any gasoline on the engine, exhaust system or
the plastic parts.
• Do not refuel while smoking or near any open flame.
• Do not operate your motorcycle in a closed area as the
exhaust fumes may cause loss of consciousness or death within a
short time.
• Do not park the motorcycle near a flame source.
• If you swallow gasoline, inhale gasoline vapor or spill
gasoline in your eyes, see a doctor immediately or go to the nearest
hospital.
• If you spill gasoline on your clothes, change and wash the
affected area immediately with soap.
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.
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 dealer is familiar with all recommended accessories for
your motorcycle, and should be consulted before installing any
accessories. The owner of the motorcycle is responsible for the
safety, installation and usage of any accessories not approved by
us. 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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Flue-Saving tips
The way you drive your motorcycle will have a direct impact on
your fuel consumption.
•Driving at appropriate speed and avoiding sudden
acceleration or braking, is not only important for your safety and fuel
economy, but also to extend the usable life of your motorcycle and to
achieve a smoother operation.
•Driving within allowed limits inside the city will yield
surprising fuel economy.
•Always maintain tires at recommended pressure. Check
pressure weekly.
•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 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, this failure can be worked out through
warranty

9
III、Parts Position
Left rear view mirror
Meter
Ignition & Steer switch
Right rear view mirror
Left handlebar
Clutch lever
Switches on left handlebar
Throttle twist grip
Front brake lever
Switches on right handlebar
Fuel tank lock

10
Rear shock absorber
Seat assy
Front wheel
Front shock absorber
Gearshift pedal
Front turn light
Rear turn light
Muffler
Pedal, rear brake

11
Speedometer
Odometer
Trip mileage meter
Tachometer
EFI Indicator
Meter reading and usage
Fuel gauge
High beam indicator
Neutral indicator
Turn indicator

12
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、Low fuel indication
To refuel in nearest fuel station once indicator turn on.
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、EFI Indicator
Indicating EFI system situation

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IV、Switch operation
1. 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 maincircuits)
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 ）。
Key
The same key will operate the ignition switch, steering lock, fuel
cap.

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2. Switches on right handlebar
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 .
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.
3. Switches on left handlebar
Light changing 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
Directional switch
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.
Electric Start Button
Emergency Cut-off Switch

15
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.
4. 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 .
Horn
Butto
n
Light changing switch
Overtaking lamp switch
Directional Switch
Fuel tank cover

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5. Gear shift
①When you ride on the motorcycle and the engine is idling,
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
to ensure a natural riding start.
③When the motorcycle reaches a balanced state of
running, return back the throttle twist grip and disengage the
clutch again, and then push up the shifting pedal to change
the gear to the 2nd position.
④The gear can be shifted up to 3rd-5th gear position in the
same way.
⑤If you push down the shifting pedal instead of push up,
you can change down the gear position.
Gear down operation
If you want to speed up drastically, for example, when
passing another motorcycle, gearing down can provide faster
acceleration, but if the speed gets too high, damage for the
engine may be caused by over-speed.
6. Blind spot mirrors
Blind spot collisions are one of the principal causes of accidents
in high density traffic. To help broaden visibility,
Fashionable designed mirrors with built-in blind spot windows.
They provide extra range so riders can change lanes with confidence.
5
4
3
2
N
1
R
Shifting forward
Shifting backward
Blind spot collisions

17
7. Clutch lever
The clutch lever located on the left side is used to
disengage the transmission when vehicle is not moving, and for
shifting gears. Pull lever in completely before shifting. Once gear
has been engaged, slowly release the lever.
8. Throttle
The throttle controls engine rpm (speed). To increase
engine rpm, rotate the grip toward you. To reduce engine rpm,
rotate the grip away from you. The throttle will automatically
return to the closed position (engine idle) when you remove your
hand.
9. Brake usage
·Use front and rear brake simultaneously。
·Avoid unnecessary sudden brake。
Caution
If You only use the front or rear brake, the motorcycle may
slide down 。
When riding in rainy day or on wet road, when brake
suddenly, accidents will occur, so please speed down and use
the brake properly 。
Avoid repeat brakes and overheat the brake, which will
cause the brake lose effect.
Front brake lever
The front brake lever located on the right hand side is used to
slow down or stop the vehicle.
Rear brake pedal
The rear brake pedal is used to slow down or stop the vehicle.
Clutch lever
Throttle
Front brake lever