Mash Two Fifty 250 cc User Manual Download

Page: 57 / 62

Table of engine troubleshooting

Problem

Cause

Remedy

•

Eng

tar

d or

sta

lls

Sparking
normal in high
voltage cable
and no
sparking in
spark plug

•

Oil stained spark

plug

•

Broken spark plug

magnetic core or

broken electrode

•

Carbon deposit in

spark plug

electrode

•

Incorrect spark
plug gap

•

Remove, clean and

dry it

•

Replace spark plug

•

Clean out carbon

deposit

•

Adjust the gap.

Normal
sparking to
spark plug,
poor cylinder
compression

•

Leaking cylinder

head gasket

•

Loose spark plug

•

Seized piston ring

•

Excessively worn

piston or broken

piston ring

•

Serious cylinder

wearing

•

Leaking intake pipe

•

Damaged

crankshaft sealing

•

Tighten screw or

replace gasket

•

Tighten spark plug

•

Clean off carbon

deposit in piston

ring and ring groove

•

Replace piston and

piston ring

•

Replace cylinder

body

•

Tighten or replace

rubber ring

•

Replace sealing

Summary of Contents for Two Fifty 250 cc

Page 1: ...User Manuel ...

Page 2: ... 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: ... 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...

Page 4: ......

Page 5: ......

Page 6: ... in appearance Motorcycle riding is one of the most exciting sports The motorcycle is an ideal means of transport It can give you infinite riding pleasure Before riding 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 sti...

Page 7: ...hapter 3 Control Part 12 Chapter 4 Instructions on fuel and engine oil 22 Chapter 5 Running in of new motorcycle 24 Chapter 6 Inspection before riding 26 Chapter 7 Essentials of riding 27 Chapter 8 Inspection and maintenance 31 Chapter 9 Measures to reduce pollution 54 Chapter 10 Troubleshooting 55 Chapter 11 Storage 59 ...

Page 8: ... h Spark plug DR8EA Battery 12V8Ah Front tire 110 80 17 Rear tire 130 70 17 Oil motor SAE10W 30 Quantity oil motor 1700 ml Length Width Height 2140x710x1050 mm Wheelbase 1370mm Ground clearance 150mm Weight 130kg Weight max 300kg Capacity fuel tank réservocarburant 14 liters Fuel SP95 or SP98 SP95 E10 not recommended This list is only information Changes can be made to Made by the manufacturer wit...

Page 9: ...mes from practice Understand what is a safe speed Riding speed depends on road surface conditions your skills and the weather Understanding the limit may prevent accident At any time accident may be prevented as long as riding in the range of your skill Wear protected motorcycle clothes Loose and fancy clothes may make you uncomfortable and unsafe in your riding Gloves boots and safety helmet will...

Page 10: ...order components or service to allow the distributor to provide you with better service Chassis number or VIN code is on the riser pipe of chassis Engine number is on the left side of crankcase Metal nameplate is on the riser pipe of chassis showing the main technical parameters manufacturer and date of production of the motorcycle Write the numbers in the spaces below for future reference Chassis...

Page 11: ...nstrument Speedometer Ignition switch Clutch grip Right handlebar switch Left handlebar switch Rearview mirror Front brake grip Accelerator Right side Battery and fuse box Rear footrests Spark plug Front Footrests Brake pedal Left side Drain plug Air filter ...

Page 12: ...e other in a safe place for future use Instrumental panel 1 Reset counter 2 Tachometer Miles km h 3 General Odometer Indicates the total distance traveled by the motorcycle since its first use 4 Turn signal indicator Lights up when turn signals are used Analogue counter 4 5 Digital counter 6 9 10 10 6 ...

Page 13: ...ge recorder Indicates the distance traveled on a day or a partial area 8 ABS indicator Illuminates when the ABS system fails 9 Injection indicator Lights up in the event of failure of the injection system 10 Minimum fuel level indicator Lights up when the fuel supply passes to the reserve Make an add on as soon as possible Warning When one of the two indicators is damaged it is possible that the i...

Page 14: ... started The key cannot be removed in this position Lock the handlebar Position In order to lock the handlebar turn the bar to the left then insert the key Rotate it clockwise to full stop for locking the handlebar Parking position To park the motorcycle turn the key to position In this position the key can be removed and the tail lamps parking lamps and front positioning lamps keep ON for parking...

Page 15: ...is turned down to low beam position the low beam is lit 3 Turn signal switch When the switch is turned to left position the left turning signal lamp is lit and the indicator lamp on instrument panel flashes When the switch is turned to right position the right turning signal lamp is lit and the indicator lamp on instrument panel flashes Before turn the key to position park the vehicle with its sid...

Page 16: ... the starter motor cannot be started Do not put the switch in this position during riding 2 Front brake grip To apply front wheel brake slowly press the brake grip on the right handlebar As the motorcycle adopts hydraulic braking do not press it abruptly or forcefully When the brake grip is pressed the brake light will be lit automatically 3 Electric start button Press button to turn on the start ...

Page 17: ...nk cap can be removed together with the key To replace the cap align the arrow on the cap and press the cap together with the key into the fuel tank cap hole until a click sound is heard Then remove the key The starter motor shall be operated not more than 5 seconds Heavy discharge may cause overheat to circuit and starter motor If starting is failed after several attempts stop to check the fuel s...

Page 18: ...ear Owing to the ratchet mechanism it cannot move two or more gears up or down in one operation To shift from 2 speed gear to low gear or from low gear to 2 speed gear it passes the neutral position but not stays there To engage to neutral gear stop it in the middle of moving from low gear to 2 speed gear Do not fill the tank excessively Never splash fuel to hot engine No fuel shall be left on the...

Page 19: ... gear during high speed riding the engagement of clutch may make a sudden increase in engine speed Before engaging a low gear slow down the motorcycle to prevent unnecessary wear of components in transmission system Rear brake pedal Press down this pedal to apply rear wheel brake and the brake indicator light is lit Side stand The vehicle is equipped with a side stand If you want to park vehicle w...

Page 20: ...the required position The first stage is the softest and the fifth stage is the hardest The second stage is as the factory setting Warning If you park the vehicle on sloped ground please let it head higher direction to prevent it from sliding down For the sake of riding safety before setting out please make sure that stands are return to upper position and they don t loose and swag The springs of ...

Page 21: ...21 Original factory setting Tool kit The tools box is right of side cover To open the box insert the ignition key and turn it clockwise and take down the box cover ...

Page 22: ...used according to local air temperature There are three viscosity levels suitable for the engine namely SAE15W 40 SAE10W 30 and SAE5W 30 Refer to the figure below Gasoline is inflammable and explosive When handling gasoline attention should be paid to prevent burnt or accident In places where gasoline is stored or handled shutdown the engine do not smoke and keep away from naked flame or spark Ref...

Page 23: ...e table please refer to Page 32 When riding in dusty area engine oil shall be replaced more frequently than the stipulations in the maintenance table Explanation During cold weather in northeast and northwest China it is advisable for user to use high quality low temperature lubricating oil SE 10W 30 or SF 5W 30 is recommended For temperature below 35 C the following use time API SG or higher clas...

Page 24: ...rantee good fitting This is every important but do not apply excessive load to the engine Avoid riding at a low speed Running at a certain low engine speed with light load can only polish the parts but cannot get a good running in So long as the upper limit of recommended throttle opening is not exceeded ride the vehicle in various gears with proper acceleration However never ride at the maximum a...

Page 25: ...nce can guarantee a long engine life and the best engine performance Precaution 1000 km maintenance shall be carried out according to the Troubleshooting in the manual Pay special attention to the precaution and warning in the section ...

Page 26: ...clearance of rear brake pedal and front brake grip 2 No spongy feeling 3 No leakage Indicators Neutral gear gear position oil level indicators or turning signal indicators Accelerator 1 Proper free play in accelerator wire 2 Free fuel flow and reliable accelerator throttle valve returning to closed position Tires 1 Correct air pressure 2 Proper tread pattern depth 3 No injury or cut Horn Correct f...

Page 27: ...vance Observe the traffic laws and speed limit Engine starting Make sure the fuel switch is in open position and the engine shutdown switch in position Insert the ignition key in ignition switch and turn it to ON position If the transmission is in neutral position the neutral indicator lamp is lit Press the electric starting button for ignition Never rotate the accelerator grip when pressing the s...

Page 28: ...g difficulty In this case do not rotate the accelerator grip but repeat starting Cold engine No choke in the injection system Warm engine Rotate accelerator grip for 1 8 1 4 turns and press electric start button to start the engine When the engine is warm it is not necessary to use carburetor enrichment system Never start the engine in a room with poor or no ventilation It is because carbon monoxi...

Page 29: ... This can prevent the engine from shutdown due to abnormal combustion Riding on a slope To shift from a high gear to a low gear control the speed in a safe speed range before gear shifting Otherwise abrupt deceleration sudden rise of engine speed may happen causing gear impacts sever parts wearing or overbalance of the vehicle it is dangerous Slope climbing When going up a steep slope the motorcyc...

Page 30: ...f control On wet highway or other dull road surface and during turning be extremely careful to apply the brake gently Hard braking on rough or dull road surface is very dangerous The motorcycle shall be parked on stable and flat ground To park your motorcycle on a gentle slope by using the side stand engage the first gear to prevent sliding off the side stand Remember to shift to neutral gear befo...

Page 31: ... the light of safety it is advisable to the inspection and maintenance done by your distributor or qualified maintenance staff Be sure to make regular maintenance thoroughly according to the instructions in the manual Precaution In regular maintenance it may be necessary to replace one or more parts For part replacement it is advisable to use genuine parts or equivalent products No matter if you a...

Page 32: ...arance R R Air filter I I I Oil hose R R R Oil filter strainer N N N Chassis bolt and nut S S S Brake I I I Front fork I I Tyres I I I Riding chain I I I Steering gear I I I Rear shock absorber I I Cylinder head nut and exhaust pipe bolt S S S Caption Inspection I Tightening S Cleaning C Replace R Note that the revision interval is 3000 km Do not forget to certify them in the warranty booklet prov...

Page 33: ...heel bearing Grease 2 Brake pedal Grease or Engine oil 1 2 Steering gear Lubricate every two years or every 10 000 km Référence IPONE 1 Spray Cables 2 Graisse multifonction 3 Spray chain Tools To help you for regular maintenance a set of tools is provided in the tool box on the rear left side of the vehicle Battery Battery is normally stored inside the guard board on the right side of the frame Th...

Page 34: ... cell checked by your distributor by using an electrolyte hydrometer Safety 1 Electrolyte contains strong acid and shall be prevented from contacting the skin During operation wear safety helmet and safety clothing Once the battery has been in use no diluted sulfuric acid shall be added If the fluid level drops below the lower limit fill distilled water to the upper limit Never use tap water Preca...

Page 35: ...te remove battery from the vehicle Check if the electrolyte conforms to specification requirements Direction for use of maintenance free battery No electrolyte filling is necessary before and after battery using To prolong the service life fully recharge it before using Note No matter what type it is the battery may discharges and power may drop after a long store time After removing from the vehi...

Page 36: ...hite or even glowing it means the spark plug was working in overheated conditions Replace it with a spark plug of higher caloric value Standard spark plug for the motorcycle is carefully selected and suitable for most operations If the color of spark plug is found different from standard spark plug it is advisable to contact your distributor before replacing with spark plug in a different heat res...

Page 37: ...37 Engine oil The longevity of the engine depends on the quality of the oil used the frequency of its replacement and the checking of the oil level ...

Page 38: ...e engine is still warm so as to thoroughly drain old oil from the engine The method is as follows 1 Park the motorcycle by using the central stand 2 Remove oil filler cap Warning Engine oil ruler shows the oil level When oil level is low never start the engine Fill oil until the oil level is just below the upper limit of oil window 1 Fil cap 2 Porthole F Level maxi L Level mini ...

Page 39: ...ck the oil level to make sure the oil quantity is correct 5 Start the engine and allow it running idle speed for several seconds 6 Stop the engine and wait about one minute before checking the fluid level with the oil dipstick The level must reach the upper mark maximum If the level is below this benchmark add oil to suit Warning Please use the engine oil recommended in Instructions on fuel and en...

Page 40: ...g action is known as free play If the front brake is a drum brake the free play of brake lever measured at lever bracket shall be 10 20mm Hydraulic brake system shall be checked every day as follows 1 Check for leakage in the front wheel brake system 2 Check for any leakage or crack in oil pressure pipe 3 The front brake lever shall have a certain back spring force 4 Check wearing conditions of fr...

Page 41: ... Never use unpacked fluid or any fluid left over in the last maintenance because moisture may get into the old fluid Only SAE J1703 brake fluid shall be used Pay attention not to splash hydraulic oil to paint or plastic surface to prevent corrosion Référence IPONE brake dot4 Warning Disc brakes are part of a high pressure system For your safety the replacement interval and hydraulic oil should not...

Page 42: ...imit mark If wearing exceeds the mark the brake lining shall be replaced with a new one Do not ride immediately after replacing a new wheel disk brake lining Press the braking grip for several times to allow the brake lining fully extended the grip spring force restored and the brake fluid is circulated smoothly ...

Page 43: ...e lamp is lit immediately when pressure is applied but before the grip is fully pressed Rear brake Adjusting the rear wheel brake The rear brake is a disc brake To adjust the rear wheel brake pedal turn the pedal to the most comfortable position by turning the clamping nut 1 Once the position is adjusted lock it with the counter nut 2 Please keep a guard between 10 and 20 mm 3 20 30 mm ...

Page 44: ...um braking performance at all times In the event of a brake fluid leak contact your MASH dealer In the event of a braking problem contact your Mash dealer Brake Fluid Type DOT4 Rear brake light switch Rear brake light switch is located at the right side of chassis Adjust rear brake light switch as follows Lift or lower the switch so that when the brake pedal is pressed the lamp is lit before feeli...

Page 45: ...rical system In case of any trouble to electrical system check the fuse first If the fuse is blown out replace it with the spare fuse 15A in the fuse box Precaution Always replace the blown fuse with a new one of the specified amperage Never use aluminum foil steel wire or other things as substitute for fuse If a new fuse is blown in a short time it means there is a major electric trouble Contact ...

Page 46: ...t is clogged by dust the output power may reduce and the intake resistance may increase The fuel consumption will also increase Therefore the air filter element shall be checked and cleaned every 3000 km as follows 1 Remove the left side guard board 2 Unscrew the air filter outer cover screw 1 and take out the air filter sleeve 2 Precaution The head light is generally reflection lamp Do not touch ...

Page 47: ...lution Never twist the filter element to avoid damaging 3 Soak the filter element in engine oil tank and squeeze oil out keeping it slightly wet Référence IPONE AIRFILTER CLEAN LIQUIDE FILTER OIL Precaution During cleaning the filter element check for any damage to the filter element and replace when necessary Never start the engine without the filter element installed or the engine wearing may be...

Page 48: ... a diagnostic Warning Before and during cleaning pay attention to check the filter element for any contamination crack or damage Replace it with a new one when necessary Reinstall the filter in reverse order Make sure the filter element is firmly fixed in correct position and reliably sealed Never start the engine without the air filter installed The air filter element must be cleaned or replaced ...

Page 49: ...nt of carburetor idle speed RPM 1 Locking nut 2 Adjuster 1 Loosen the locking nut 2 Rotate the adjuster to make the wire clearance between 0 5 1 0 mm 3 After clearance adjustment tighten the locking nut once again ...

Page 50: ...he clutch grip the wire clearance measured at clutch grip shall be 4 mm If the clutch wire clearance is found incorrect carry out adjustment as follows Warning After accelerator wire adjustment check the operation of accelerator grip Engine idle speed shall not increase due to the adjustment and the grip shall return to the closed position automatically 4 5 6 ...

Page 51: ...the lock nut 1 and the ring 5 then wrap them with the rubber sleeve 3 Adjustment of riding chain 1 Adjusting bolt 2 Locking nut 3 Mark 4 Rear wheel shaft nut To adjust 1 Park the motorcycle with central stand 2 Loosen rear wheel shaft nut 3 Loosen the locking nut 4 Rotate the adjusting bolt left and right to adjust the chain Note When a new chain is installed it is necessary to check both chain wh...

Page 52: ...ter Besides regular check make it habit to check the tire air pressure from time to time to ensure maximal safety and long life Tire pressure A low tire pressure may intensify tire wearing and badly affect the riding stability causing difficulties in turning But a too high tire pressure may reduce the contact area between tires and road surface causing wheel slip and even out of control It is nece...

Page 53: ...1 6 mm or less it is advisable to replace the cover tire When the tread pattern of rear wheel is reduced to 2 mm or less replace the tire with a new one Problems may happen if no standard tire is used You are sincerely recommended to use standard tire Correct tire inflation pressure is very important for normal vehicle performance and riding safety Check the tire wear and inflation pressure from t...

Page 54: ...s to Reduce Pollution To reduce exhaust emission and noise pollution please follow the several points below Use special purpose lubricant Use unleaded gasoline 95 or 98 Do not use fuel E10 Observe any abnormal engine noise ...

Page 55: ...ing is strictly prohibited during fuel system checking Carry out the work in a spacious place 1 Remove spark plug and connect it with the high voltage cable 2 Turn the ignition switch to ON position and the engine shutdown switch to position Place the spark plug near the engine and start the engine If the ignition system is in working order there shall be blue sparks jumping over the spark plug ga...

Page 56: ... load operation of the engine Note Before any troubleshooting it is advisable to consult with your distributor in advance If the motorcycle is still in warranty period be sure to contact your distributor before making any attempt to repair by yourself Tampering with the vehicle in warranty period may invalidate the basis of warranty Refer to the warranty book provided by the authorized MASH dealer...

Page 57: ...an and dry it Replace spark plug Clean out carbon deposit Adjust the gap Normal sparking to spark plug poor cylinder compression Leaking cylinder head gasket Loose spark plug Seized piston ring Excessively worn piston or broken piston ring Serious cylinder wearing Leaking intake pipe Damaged crankshaft sealing Tighten screw or replace gasket Tighten spark plug Clean off carbon deposit in piston ri...

Page 58: ...deposit Replace spark plug Unstable engine operation Contamination of fuel intake system Crankcase leakage Clean or replace fuel line Replace the seal Overheat engine Low gear riding over a long time Over loaded riding or long time riding with heavy load Unqualified engine oil or insufficient transmission oil Slipping clutch Too tight chain Unreleased brake Change gear position and control time Co...

Page 59: ...torcycle empty the fuel tank Gasoline used in motorcycle is highly inflammable and even explosive under certain conditions Therefore never allow the motorcycle to get close to any fire Never park the vehicle in a place storing articles subject to spontaneous combustion such as grains coal cotton etc because fire hazard may happen when the fuel in the vehicle contacts naked flame Tires Make tire in...

Page 60: ...20 hours Note that storing a low battery for a long time may cause battery damage When a battery has whitened plate electrodes low power or low fluid level below the lower limit and cannot restore the performance after a long time storage even after recharging it means the service life has been terminated Steps of returning service 1 Clean the entire motorcycle 2 Remove spark plug kick the kickbac...

Page 61: ...the latest before publishing Owing to improvement or other changes the contents of the manual may differ from actual conditions our company reserves the right of modification at any time Product specifications and parameters are subject to change without notice Product configuration and spare parts supply may vary for different countries or regions For details please consult with your local distri...

Page 62: ...www mashmotors com Votre revendeur mash motors fr ...

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Summary of Contents for Two Fifty 250 cc

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