Table of Contents
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Table of Contents
Related Manuals for Mash TT40 Cafe Racer
Summary of Contents for Mash TT40 Cafe Racer
- Page 1 User Manual English...
- Page 2 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!
- Page 3 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.
- Page 4 MASH TT 40 400cc...
- Page 5 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.
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Page 6: Table Of Contents
Index I Main 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 Parts’ position ................ - Page 7 Brake system and ABS system………………………………………………………………28-29 Park…………………………………………………………………………………………………………..30 Rearview mirror…………………………………………………………………………………………31 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....................
- Page 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...
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Page 10: I Main Technical Data
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 Spark plug type DPR8Z Valve Intake : 0.07-0.10mm... - Page 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 recommended) Capacity fuel tank Speed I 2.615 Speed II 1.789 Speed III 1.350 Speed IV 1.120 Speed V 0.892...
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Page 12: Operation Instruction
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. -
Page 13: Préparation Before Operation
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 . •... -
Page 14: Modification Of The Vehicle
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 . -
Page 15: Iii Parts Position
III Parts Position Meter Account round Emergency stop switch Left rear view mirroir Right rear view mirror Clutch ABS switch lever Front Left handlebar brake Engine level Ignition Turn signal Horn starter switch switches switches Throttle twist grip Seat assy Rear wheel Muffler Pedal, rear brake... -
Page 16: Meter Reading & Usage
Front shock Rear turn absorber light Rear shock absorber Side Gear Exhaust silencer Front turn stand selector light Meter reading and usage Speedometer Indicate motorcycle speed (Km/h). Do not exceed legal rate-limiting to assure safe riding. ABS indicator : When the ABS system is activated, the LED is off. It can be switched off (see procedure on page 28). - Page 17 Compteur kilométrique total ou journalier Tachymètre Speedometer Fuel gauge Zero knob Turn indicator Indicator EFI (ectronic injection) ABS indicator Neutral indicator High beam indicator 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...
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Page 18: Switch Operation
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;... -
Page 19: Headlight, Position Indicator
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 （... -
Page 20: Horn Button
Horn Button When you press horn button, it will make a sound 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 situation d’urgence Caution... -
Page 21: Fuel
Fuel Fuel filling The capacity of the fuel tank is 13L. Lead free gasoline SP98 and SP95 are 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. - Page 22 speed so as to warm up the engine for about 10 seconds or more. Caution Make sure the engine is turned off and away from any heat sources before filling your fuel tank. The Fuel will overflow if it rises above the level mark...
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Page 23: Correct Driving
V Correct driving 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 “... -
Page 24: Maintenance Of The Engine
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. - Page 25 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. 9、Lights and horn checking, please kindly check if the illumination and the horn are working normally.
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Page 26: Gear Shift
Changing the gears Gear Shift 1. When 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. 2. -
Page 27: Operation
Operation •Before starting the engine, please make sure the side stand is at the right position. •If the side stand can’t be moved smoothly, please check the lubrication of the side stand joint. •Shift the gear properly according to the motor speed, •In order to keep the fuel consumption at a lower state, and also to ensure the longevity, please do not accelerate or decelerate too drastically。... -
Page 28: Brake System And Abs System
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 。... - Page 29 Engine Brake The engine can work as a brake if you rotate the throttle grip in as reversed direction, And if you need stronger braking power, lowering the gear to IV or III is suggested, meanwhile, if you need the motorcycle roll march in a lasting decelerating state, or decelerates quickly, you may use the vehicle brake and use the engine brake at the same time.
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Page 30: Park
Park with side stand Place the motorcycle on horizontal ground, activate the side stand, and move the steering bar to the left side. If the motorcycle is placed on the terrains below, the motorcycle may possibly fall down. ·If the steering bar is moved to the right side, or the motorcycle is side stand on slopes, sandy, rough or soft ground, the vehicle is prone to fall down. -
Page 31: Vi Inspection And Adjustment
I: Carry out inspection, cleaning, tightening, adjustment, lubrication or replacement. C: Cleaning. R: Replacement. A: Adjustment. L: Lubrication. *This item is subject to maintenance by persons from MASH Service Station. If the user has special service tools, maintenance accessories or maintenance ability, it can repair it by itself. -
Page 32: Maintenance Period Table
To ensure safety, the adjustment of timing chain and valve clearance shall only be carried out by persons from MASH Service Station. Maintenance Caution This section introduces the inspection and adjustment of various parts of the FIVE HUNDRED motorcycle . -
Page 33: Cylinder Pressure
Substitution of the engine oil The engine oil plays an important role in the normal operation of the engine and for this reason it is necessary to check the engine oil periodically and to renew it after the first 1000 km and then every 5000 km according to the procedures The following. Note: When draining, clean the dipstick and replace the oil filter. - Page 34 Caution: When the engine is at a operating temperature, the engine oil might be very hot, so do not make yourself burnt. Place the motorcycle flatly, take off the plug, then fill the engine oil in the container. Clean the plug thoroughly. Oil ruler must be mounted properly, or the oil ruler will fail to function and strengthen wear-out of the engine Cleaning the sump...
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Page 35: Check-Up, Cleaning Of Air Filter
The valve clearance should be inspected and adjusted by a Mash Cylinder Dealer. Access to head The specified valve clearance is : tumblers 0.07-0.10mm for intake valve and 0.08-0.12mm for exhaust valve respectively. Top dead If clearance adjustment is needed, center mark please contact your Mash Dealer. -
Page 36: Idle Speed
The effectiveness of the air filter partly conditioning the longevity of the engine, so it is essential to make sure of its good condition. Idle speed Warring The engine of your Mash is equipped with a gasoline injection system. It’sn’t possible to adjust the idle speed of this engine. -
Page 37: Throttle Control
Throttle control First, check whether the throttle control line is deformed, twisted or damaged Then, measure the throttle bar free Free stroke 2-6mm. stroke. Turn the bar to lean it against one side of the free stroke, and draw a straight line between the bar and the balance weight with a mark pen, and then turn the bar to lean it against the... -
Page 38: Brake System
Brake system The front brake is disk type, and the rear brake is drum type, due to the abrasion of the brake shoes, the brake fluid will be getting less as time goes by. The performance can’t be adjusted, but the brake fluid level and brake shoe abrasion are the two most important factors, that needs to be checked on time. - Page 39 Caution The brake fluid is strongly corrosive, never splash it Upper level onto the surfaces of spray painted or plastic pieces; in case it splashes into the eyes or on the skin, immediately flush with large amounts of fresh water and see a doctor. Lower level Make up the brake fluid ·Turn the handle bar and make the pump cylinder be horizontal with the ground.
- Page 40 Degrease the rear brake disc at regular intervals to ensure optimum braking performance at all times. In the event of a brake fluid leak, contact your MASH dealer. Maxi In the event of a braking problem, Mini contact your MASH dealer.
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Page 41: Tires
Tire specifications and tire pressure Check the tire pressure with a tire pressure gauge to see whether the pressure conforms to the recommended value Tire spécifications and recommended tire pressure : Front tire Rear tire Tire 3/25/18 130/80-18 Normally loaded Fully loaded Cold tire air Front tire... -
Page 42: Range
Spoke adjust tool Clutch control line Check the clutch operating handle free stroke. Clutch operating handle free stroke: 10-20mm. 10-20mm Adjusting methods: Fine adjustment: Pull open the rubber lagging, unscrew the retaining nut, and turn the adjusting nut to adjust to a satisfied free stroke. And then screw up the retaining nut and mount the protective rubber lagging. -
Page 43: Adjusting Methods
Retaining nut Retaining nut Remove the clutch control line on the handle end, and then remove the clutch operating arm on the engine end; turn the clutch operating arm by a proper angle and remount it, and then mount the clutch control line, finally adjust it to a satisfied free stroke according to the fine adjustment. - Page 44 Caution The scale lines of the chain adjuster on both sides must be consistent with each other. Warning The rear wheel spindle nut must be firmly screwed up to the tightening torque of 60-90N.m Clean and inspection of chain First, remove the chain by detaching the spring locking pieces and the removable chain plate.
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Page 45: Checking Of Accumulator
Négatif(-) connector Upper level Lower level Battery control Positif(+) Open the left side cover. connector Remove dust and corrosion from the surface of the battery. Remove the negative pole and then the positive from the battery; unscrew and remove the battery retaining strap. Place the vehicle in an upright position to determine if the battery electrolyte level is between the top and bottom marking lines. -
Page 46: Replacement Of Fuse
Replacement of fuse Set the ignition switch to “OFF” position. The specified fuse tube of 15A should be used for main fuse replacement, and a 10A fuse tube for FAI injection nozzle. Open the left side cover, remove the fuse holder on the side of the battery and replace the fuse tube. -
Page 47: Headlamp Dimming
Bulb Socket Head light Rear light The rear light of your MASH is a led light. The service life is thus extended compared to a conventional bulb. If necessary, in case of failure it is necessary to replace the complete fire. -
Page 48: Front Light And Bulb
Ampoule clignotant avant et arrière : Remove screws and remove optics. Lightly press the bulb and turn it counter clockwise. Install the new bulb by following the steps in reverse order as follows. screw glass bulb Side stand Shore up the main stand, the motorcycle in proper position. Check the whether the spring have scratch problem or not, the connector is lubricating. -
Page 49: Storage
Maintenance in Non-use Time For the motorcycle to be stored for a long period of time, attention should be paid to the prevention of moisture, sunshine and rain attack in order to protect it from unnecessary damage. Special check-ups should be carried out on those important parts and subassemblies before storage. -
Page 50: Operation Turning
Riding Before start, look around to avoid accident • Take back the stander, ride on motorcycle • Turn on turning light, release brake, make sure it’s safe and then ride. Warning Put side stander in original position, if not it will cause accident. Only ride on vehicle road, if ride on footpath will lead accident. - Page 51 The copyrights attached to this manual and its ultimate interpretation belong to us. Under no circumstances may this document or any of its parts be reproduced or cited without our prior written permission. All information, descriptions, illustrations and specifications contained therein reflect the state of our knowledge at the time of publication.
- Page 52 Votre revendeur mash-motors.fr...
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