Tao Motor 150 G Owner'S Manual Download

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The adjustable speed limiter screw must be installed for operation. Failure to install a speed limiter
screw may result in water or dirt ingestion and potential damage to the vehicle.

NOTICE

SPEED LIMITER

ADJUSTMENT

1. Locknut

2. Adjustment

Screw

3. Adjustment

Range

Adults should always limit maximum restricted

speed within the ability and capacity of the

operator

to operate the ATV safely. Never allow

children

to adjust the speed limiter screw.

To increase top speed

SPEED LIMITER

The

150 G

ATV is equipped with a vehicle speed limiter adjusting screw. Beginning riders should start with

slowest setting to learn how to control this vehicle. Once the operator has demonstrated mastery of the ATV,

the supervising adult can adjust speed limiter screw to increase the top speed . The vehicle speed limiter keeps

the throttle from fully opening, even when the throttle lever is pushed to the maximum. The adjusting

screw may be gradually turned out as the beginner becomes more familiar with operating this ATV.

Loosen locknut (#1).

To decrease the top speed of the ATV turn the adjustment screw clockwise. (#2).

Tighten the locknut to set adjustment screw in desired position

(#1).

Loosen locknut (#1).

To increase the top speed of the ATV turn the adjustment screw

counter clockwise (#2).

Tighten the locknut to set adjustment screw in desired position

(#1).

To decrease top speed

FRONT BRAKE LEVER

The front brake lever is located on the right handlebar. To apply the front brake, pull the brake lever toward the handlebar grip.

REAR

HAND

BRAKE LEVER

The rear brake lever is located on the

right foot rest

To apply the rear brake,

push

the brake lever

down

towards

the ground.

Summary of Contents for 150 G

Page 1: ...READ THIS MANUAL CAREFULLY It contains important safety and service information 150 G Owner s Manual ...

Page 2: ...Dealer or professional motorcycle mechanic You should never try or attempt assembly of this vehicle it should be done by professionals Death or serious injury could result from failure to follow these warnings and instructions Please read carefully before operating this vehicle ...

Page 3: ...res including an adjustable speed limiter We recommend that all beginners start with the slowest setting first The speed adjusting screw may be gradually adjusted as beginner becomes more familiar with operating this ATV INTRODUCTION Thank you for purchasing the 150 G This ATV is designed for years of reliable use and family fun This manual will provide you with a good basic understanding of the f...

Page 4: ...cates special precautions that must be taken to avoid damage to the vehicle or other property A TIP provides key information to make procedures easier or clearer A WARNING indicates a hazardous situation which if not avoided could result in death or serious injury TIP NOTICE NOTICE The 150 G ATV is designed and manufactured for off road use only It is illegal and unsafe to operate this ATV on any ...

Page 5: ... of the labels on your 150 G These labels contain important information for safe and proper operation Never remove any labels from your ATV If a label becomes difficult to read or comes off request a new replacement label from your local Tao Motor dealer ...

Page 6: ...ble Adjustment 22 Engine Idle Adjustment 27 Specification Chart 41 Engine Oil 48 49 Cleaning Air Filter Element 51 52 Spark Plug 53 Drive Chain Adjustment 54 56 Cleaning Spark Arrester 61 Electrical Wiring Diagram 65 Transporting 1 Description 2 Hydraulic Brake System 24 26 Commonly Asked Questions 66 Instrument Cluster 5 Gear Selector Lever 21 Electrical Connector Wiring Diagram 64 TABLE OF CONTE...

Page 7: ... covered in this manual SAFETY INFORMATION THE 150 G ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV NEVER OPERATE THIS ATV WITHOUT PROPER TRAINING OR INSTRUCTION ADULTS MAY NOT BE ABLE TO OPERATE THIS VEHICLE SAFELY DUE TO PHYSICAL OR MENTAL LIMITATION ...

Page 8: ...g this ATV Never operate the ATV on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting larger hills Never modify an ATV through improper installation or use of accessories Never attempt wheelies jumps or other stunts Always conduct a pre ride inspection and follow the proper maintenance schedule and procedures as shown in this manual Always keep both hand...

Page 9: ... for storage over 48hrs The fuel tank and carburetor should be drained for any long periods of storage and for winter storage of the vehicle Caution others near the vehicle not to get close to or touch any moving parts or any heated areas such as the engine and exhaust pipe Never let your child operate this ATV SAFETY INFORMATION continued ...

Page 10: ...xide can linger for hours or days in enclosed or poorly ventilated areas If you experience any symptoms of carbon monoxide poisoning leave the area immediately get fresh air and SEEK MEDICAL TREATMENT Do not run engine indoors Even if you try to ventilate engine exhaust with fans or open windows and doors carbon monoxide can rapidly reach dangerous levels Drain gasoline from the fuel tank and carb...

Page 11: ...use 10 Amp Tail Light Dip Stick Foot Rest Spark Plug Front Shock Fuel Cap Rear Cargo Rack Muffler Rear Shock Front Bumper LEFT SIDE Battery Under The Seat Instrument Cluster Engine Oil Gear Shift Lever Under The Seat Fuel On Off Valve 2 ...

Page 12: ...h Start Button CONTROLS FUNCTIONS IGNITION SWITCH The positions of the ignition switch are as follows Ignition ON All electrical systems are supplied with power and the engine can be started The key cannot be removed Ignition OFF All electrical systems are off The key can be removed Instrument Cluster Speed Limiter 3 ...

Page 13: ...eturn to the start position If throttle lever is not smooth in operation or will not return to start position do not start engine MAIN SWITCH Engine Start Stop Switch START BUTTON Push start button to crank the engine with starter See the starting instructions on page 18 before starting the engine HEADLIGHTS This 150 G ATV is equipped with High Low headlight features When ignition key is set to th...

Page 14: ...V Instrument cluster icons Gear indicator D N R When D is displayed on the instrument panel the forward gear in engaged When R is displayed on the instrument panel the reverse gear in engaged When N is displayed on the instrument panel the neutral gear in engaged NOTICE The ignition switch must be set to the ON position for the instrument cluster to display any icons 5 ...

Page 15: ... speed limiter screw to increase the top speed The vehicle speed limiter keeps the throttle from fully opening even when the throttle lever is pushed to the maximum The adjusting screw may be gradually turned out as the beginner becomes more familiar with operating this ATV 1 Loosen locknut 1 2 To decrease the top speed of the ATV turn the adjustment screw clockwise 2 3 Tighten the locknut to set ...

Page 16: ...nt brake lever to release the parking brake The spring loaded parking brake button will return to off position Always set the parking brake before starting the engine The ATV could start moving unexpectedly if the parking brake is not applied This could cause loss of control or a collision Always be sure you have released the parking brake before you begin riding The brakes could overheat if you r...

Page 17: ...ngine and be sure that no one is sitting on the vehicle Never refuel while smoking or while in the vicinity of sparks open flame or other sources of ignition such as the pilot light of water heaters and clothes dryers 2 Do not overfill the fuel tank When refueling be sure to insert the pump nozzle into the fuel tank filler hole Stop filling when the fuel reaches the bottom of the filler tub Becaus...

Page 18: ...leaded gasoline with a pump octane number of 91 or higher Using Ethanol added fuel may lead to carburetor clogging due to the fuel s sulfuric content reacting with brass and aluminum components in the fuel system Tao Motor always recommends using a fuel stabilizer to help mitigate damaging corrosion Visit your dealer to purchase recommended stabilizers and lubricants FUEL TANK CAP 9 ...

Page 19: ... carburetor Always turn the fuel valve to the OFF position and allow the engine to idle until it burns remaining fuel in the line when the ATV is being stored Once the fuel in the line has been cleared drain the carburetor bowls Following this procedure will help reduce corrosion and carburetor damage FUEL ON Arrow mark positioned over ON position Fuel is on and fuel will flow to the carburetor ST...

Page 20: ...backward and then pull up the seat The seat lock is located under the seat in the back of the ATV To Install Seat Insert tab 3 on the front of the seat into the seat holder 2 and push down on the seat at the rear Make sure that the seat is securely installed in place and will not move during operation 11 ...

Page 21: ...get medical attention EYES Rush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes or other sources of ignition away Ventilate when charging or using in an enclosed space KEEP OUT OF REACH OF CHILDREN Battery 9 Amp 1 Make sure the ignition switch is set to the OFF position 2 Remove seat 3 Disconnect the negative cable from the ...

Page 22: ...idate your vehicle s warranty Main Fuse Location under seat in front of battery 1 Main Fuse 10 Amp 2 Fuse Holder 3 Spare Fuse DO NOT charge battery with more than 2 Amp trickle charger DO NOT charge the battery any longer than 8 hours If you notice battery is swelling or bubbling disconnect battery charger immediately DO NOT continue to charge battery or attempt to recharge DO NOT jump start this ...

Page 23: ...e procedures described in this manual have the vehicle inspected by a Tao Motor dealer ITEM ROUTINE PAGE Fuel 8 10 91 octane min Check fuel level in fuel tank and add recommended fuel if necessary Add Fuel Stabilizer if using ethanol fuel Check fuel line for leakage Correct if necessary Engine Oil 48 49 Check oil level in engine and add recommended oil to specified level if necessary Check ATV for...

Page 24: ...ted and lubricated Refer to the Owner s Manual for instructions and recommended lubricants For more information on service and maintenance go to www taomotor com ITEM ROUTINE PAGE Throttle Lever Make sure that operation is smooth Lubricate cable and 22 lever housing if necessary Check lever free play and adjust if necessary Control Cables Make sure that operation is smooth Lubricate if necessary 2...

Page 25: ... of the throttle lever It must open smoothly and spring back to the idle position when released If throttle is not operating properly DO NOT START ENGINE Have a Tao Motor dealer correct the issue before operating this ATV SWITCHES Check to ensure all switches are working properly before starting the engine DRIVE CHAIN Check the condition of the drive chain and check the drive chain slack Lubricate...

Page 26: ...increasing your risk of an accident or death CHASSIS FASTENERS Make sure that all nuts bolts and screws are properly tightened before starting engine TIRES Check tire pressure with tire gauge to make sure that both front tires and rear tires are equally inflated and meet the recommended PSI specifications All Tao Motor ATVs are installed with tubeless low pressure ATV tires 17 ...

Page 27: ...the engine 7 Release the parking brake STARTING ENGINE WARM 1 Set the parking brake The engine can be started only when the front rear brake lever is applied 2 Turn the fuel valve lever to the ON position 3 Turn the ignition key to the ON position 4 Set RUN position on main switch 5 Set gear box to neutral position The neutral position light will illuminate on instrument cluster 6 Press and hold t...

Page 28: ...performed after every 20 hours of operation HOT MUFFLER ENGINE The muffler and other engine parts become extremely hot during operation and remain hot after the engine has stopped To reduce the risk of fire during operation or after leaving the ATV do not let brush grass and other materials collect under the vehicle near the muffler or exhaust pipe or next to other hot parts Check under the vehicl...

Page 29: ...ance limit suspension travel steering travel or control operation Use caution when adding any electrical accessories or change the normal operation of the vehicle If electrical accessories exceed the capacity of the ATV s electrical system could results in a dangerous situation and possible loss of power or damage the engine Installing aftermarket parts and or accessories could void your Tao Motor...

Page 30: ...k to lock lever in reverse position NOTICE Always look behind the vehicle prior to shifting in reverse to be clear of any obstacles animals or people Remain seated all times do not stand up When D is displayed on the instrument panel the forward gear in engaged When R is displayed on the instrument panel the reverse gear in engaged When N is displayed on the instrument panel the neutral gear in en...

Page 31: ...mm 0 197 In to 0 394 To adjust throttle cable 1 Pull rubber dust covers back to inspect and adjust throttle cable 2 Loosen lock nut 3 Turn throttle cable adjuster to make proper adjustments of throttle cable 4 Tighten locking nut and reinstall rubber dust cable covers Measure throttle free play at the tip of the lever Check proper throttle cable adjustment by turning handlebars completely to the l...

Page 32: ... 1 Loosen the locknut s 2 2 Adjusting bolt s 1 3 Adjusting bolt s 1 in direction a to increase the lever freeplay and in direction b to decrease it 4 Tighten the locknut s 2 5 While applying the front brake the upper and lower cable lengths should be equal 6 The cable joint 4 will become vertical How to adjust front brake lever free play The front brake lever freeplay must be checked and if necess...

Page 33: ...IC REAR BRAKE NOTICE New brakes will not perform to their maximum efficiency until after their initial brake in is complete Use extra caution Brake fluid replacement or brake system maintenance and repairs should be performed by an authorized Tao Motor dealer The brakes can be very hot after prolong use of the vehicle and can cause burns Wait for the brakes to cool down The rear brake system is a ...

Page 34: ...s follows Brake fluid reservoir is located on the frame under the seat right side With the ATV on a level surface check brake fluid in reservoir for proper level The fluid level should be above the LOWER mark Add fluid as required but never overfill and clean filler cap before removing it NOTICE The Reservoir is full when the fluid reaches the top of the window A low fluid level may indicate leaks...

Page 35: ...ove clevis clip pin 4 4 Move clevis clip away from brake lever 3 5 Turn clevis clip 3 clockwise to raise brake lever or counter clockwise to lower the lever 6 Move clevis clip into position and realign with brake lever 7 Reinstall clevis clip pin 4 and cotter pin 8 Tighten lock nut 2 The rear brake lever s reach should be checked and then adjusted at the intervals specified in the periodic mainten...

Page 36: ...s reached Turning the idle screw in clockwise to raise RPM Turning the screw out counterclockwise will lower RPM 4 The standard idle RPM is 1700 150 ENGINE IDLE ADJUSTMENT If it is necessary to adjust the carburetor idle screw due to changed outside environmental conditions to adjust carburetor idle screw as follows Idle Screw 27 ...

Page 37: ...o collect used fuel 5 Turn the carburetor fuel drain screw counterclockwise until fuel start to drain out form the carburetor drain hose Do not take out the drain screw from the carburetor drain valve 6 Allow all the fuel from the fuel tank and carburetor too completely to drain out 7 Pour all the unused fuel in a sealed fuel container for later use 8 Set fuel valve to OFF position 9 Tighten turn ...

Page 38: ...e stiffest 5 or decrease softest 1 the spring preload Increased spring tension will stiffen the ride Decreasing spring tension will soften the ride The suspension was pre set at the factory but can be adjusted with a special suspension adjustment tool available for purchase at your Tao Motor dealer NOTICE 1 Spring Preload Adjustment Ring 2 Position Indicator NOTICE Never turn the adjusting mechani...

Page 39: ...GETTING TO KNOW YOUR ATV 30 ...

Page 40: ...ructions which are appropriate for most types of riding Riding your ATV requires special skills acquired through practice over a period of time Take the time to learn the basic techniques well before attempting more difficult maneuvers It is essential to familiarize yourself with the operation of the ATV to achieve the skill necessary to enjoy riding safely Before you begin to ride be sure you hav...

Page 41: ... or protective eye wear Over the ankle boots gloves long sleeved shirt or jacket and long pants An approved helmet and other personal protective equipment can reduce the severity of injuries in an accident Operating without an approved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident Wear eye protection when operating your ATV to reduce the risk...

Page 42: ... Consuming alcohol or drugs could seriously affect your judgment cause you to react more slowly and affect your balance and perception Never consume alcohol or drugs before or while driving this ATV You increase your chance of an accident 1 Protective clothing 2 Protective Goggles 3 Protective Gloves 4 Protective Boots 5 Protective Helmet 33 ...

Page 43: ...pting wheelies jumps and other stunts increases the chance of an accident including an overturn Never attempt stunts such as wheelies or jumps Don t try to show off BE CAREFUL WHERE YOU RIDE This ATV is designed for off road use only Paved surfaces may seriously affect handling and control of the ATV and may cause the ATV to go out of control Always avoid paved surfaces including sidewalks drivewa...

Page 44: ...to react to hidden rocks bumps or holes Go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV Do not operate on rough slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain Always be especially cautious on these kinds of terrain Failure to use extra ca...

Page 45: ...ore difficult terrain Set the parking brake and follow the instruction on page 7 18 to start the engine Once it has warmed up you are ready to begin riding your ATV Remember that the engine and exhaust pipe will be hot when riding and afterwards do not allow skin or clothing to come in contact with these components ACCELERATING YOUR ATV With the engine idling release the parking brake Apply the th...

Page 46: ...n slip slightly allowing the ATV to make the turn properly This procedure should be practiced at slow speed many times in a large off road area with no obstacles If an incorrect technique is used your ATV may continue to go straight If the ATV doesn t turn come to a stop and then practice the procedure again If the riding surface is slippery or loose it may help to position more of your weight ove...

Page 47: ...erson an obstacle or a sharp drop off Use common sense and remember that some hills are too steep for you to climb or descend If you are climbing a hill and you find that you have not properly judged your ability to make it to the top you should turn the ATV around while you still have forward motion provided you have the room to do so and go down the hill If your ATV has stalled or stopped and yo...

Page 48: ...V to tip or roll over Carefully choose your path and ride no faster than you will be able to react to obstacles which may appear RIDING SLOPING SURFACE Traversing a sloping surface on your ATV requires you to properly position your weight to maintain proper balance Be sure that you have learned the basic riding skills on flat ground before attempting to cross a sloping surface Avoid slopes with sl...

Page 49: ... Riding over rough terrain should be done with caution Look out for obstacles which could cause damage to the ATV or could lead to an accident Be sure to keep your feet firmly mounted on the foot boards at all times Avoid jumping the ATV and always ride within your abilities SLIDING AND SKIDDING Skidding or sliding improperly may cause you to lose control of this ATV You may also regain traction u...

Page 50: ...verall Length 64 9 in 1 648mm Overall Width 44 1 in 1 120mm Overall Height 45 7 in 1 160mm Seat Height 29 5 in 749mm ENGINE Type Single Cylinder Four Stroke Air Cooled Automatic Centrifugal Clutch Displacement 150CC Bore X Stroke 57 4 mm x 57 8 mm Idle Speed 1700 150 RPM Start Mode Electric start Ignition Method CDI Spark Plug Gap 0 06 0 08mm Transfer Method Chain Drive Compression Ratio 9 5 1 Val...

Page 51: ...on Inspection adjustment and lubrication intervals of important components are explained in the following chart on the following pages Maintenance intervals are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use such as operation in wet or dusty areas should be inspected and serviced more frequently Inspect clean lu...

Page 52: ...correctly PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM CHECK OR MAINTENANCE JOB WHICHEVER COMES FIRST INITIAL EVERY Month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 No ITEM Hours 20 80 160 160 320 1 Fuel Filter Check or replace if necessary 2 Fuel Line Check fuel hoses for cracks or other damage and replace if necessary 3 Spark Plug Check condition and clean rega...

Page 53: ...to the limit 3 Rear Brake Check operation and correct if necessary Check brake pedal free play and adjust if necessary Check fluid and ATV for fluid leaks age and correct if necessary Replace brake pads Whenever worn to the limit 4 Brake Hoses Check for cracks or other damage and replace if necessary Replace Every 2 years 5 Rear Brake Hose Protectors Check for wear cracks or other damage and repla...

Page 54: ...essary Check for oil leakage and replace if necessary 11 Stabilizer Bushings Check for cracks or other damage and replace if necessary 12 Rear Knuckle Pivots Lubricate with lithium soap based grease 13 Steering Shaft Lubricate with lithium soap based grease 14 Steering System Check operation and repair or replace if damaged Check toe in and adjust if necessary 15 Engine Mount Check for cracks or o...

Page 55: ...just headlight beams GENERAL MAINTENANCE AND LUBRICATION CHART CONTINUED 21 Drive Chain Lubrication Lubricate CARBURETOR Tao Motor recommends using a fuel stabilizer at all times to prevent the buildup of residue from stale or deteriorated fuel If the vehicle is not in operation for 20 days or more fuel residue can form in jets and passages causing the vehicle not to start BATTERY The battery shou...

Page 56: ...PERIODIC MAINTENANCE RECORD MAINTENANCE INTERVAL PERFORMED SERVICING DATE SERVICING DEALER OR PERSON REMARK 47 ...

Page 57: ... damage may result 6 Check the 0 ring for damage and replace it if necessary on dipstick 7 Insert the dipstick into the oil filler hole and tighten 1 Minimum Oil Level Mark 2 Maximum Oil Level Mark TIP To check the engine oil level NOTE Your new vehicles engine comes with shipping oil shipping oil must be changed before the engine is started for the first time Please see specification chart for re...

Page 58: ... Remove engine oil filler cap dipstick 4 Remove engine oil drain plug to drain oil from the crankcase NOTE When removing oil drain plug be sure not to drop retainer spring and oil filter screen 4 Clean oil filter screen and retainer spring with parts cleaner and let air dry 5 Reinstall drain plug spring and screen to the specified torque 14 Nm 10 ft lbs 6 Refill engine with specified amount of the...

Page 59: ...is performed TIP Always replace exhaust gasket when removing exhaust pipe Never reuse exhaust gasket 1 Place ATV on level surface and set parking brake 2 Remove left side foot rest 3 Place an oil pan under the gear box oil drain plug to collect used oil 4 Remove the gear box oil filler plug 10mm and its washer from the gear box 2 5 Remove the gear box oil drain plug 10mm and its washer 1 6 Reinsta...

Page 60: ...nts or gasoline to clean the air filter element because the engine could catch fire or explode Make sure that the air filter element is properly seated in the air filter case Never operate the engine with the air filter element removed This will allow unfiltered air to enter the engine causing rapid engine wear and possible engine damage Additionally operation without the air filter element will a...

Page 61: ...isconnect gear box vent tube and clamp from air filter box 3 6 Remove the two air filter box mounting hardware 7 Remove air filter box from ATV 8 Remove air filter lid by removing the four Phillips screws 5 9 Remove the air filter element and clean surrounding area 10 Clean Air filter element with foam air filter cleaning solution 11 Check the air filter element and replace it if damaged 12 Apply ...

Page 62: ...ccordance with the periodic maintenance and lubrication chart To remove the spark plug 1 Spark Plug 1 Clean the surface of the spark plug gasket and its mating surface and then wipe off any grime from the spark plug threads 2 Install the spark plug with the spark plug wrench by turning it clockwise to the specified torque 3 Re install the spark plug cap OEM manufacturer specified spark plug is eit...

Page 63: ...d before each ride How to check for drive chain slack 1 Drive Chain Slack Drive chain slack 5 0 10 0 mm 0 19 0 39 in TIP Improper drive chain slack will overload the engine as well as other parts of the ATV To prevent this from occurring keep the drive chain slack within the specified limits When checking and adjusting drive chain slack always check without any weight on vehicle and all tires are ...

Page 64: ...k 1 Loosen axle carrier housing bolts 2 For all Tao Motor models equipped with chain tensioner always do the following lift and hold the chain tension off the chain to release chain tension until the chain adjustment is completed Carrier Housing Bolts 55 ...

Page 65: ...er nuts 2 3 Drive chain slack 6 0 12 0 mm 0 24 0 47 in Tightening Torques 14 Nm 10 ft lbs Chain Adjuster Nuts 1 2 3 45 Nm 33 ft lbs Carrier Housing Bolts 1 Remove all dirt and mud from the drive chain with a brush or cloth 2 Spray chain lubricant on the entire chain making sure that all side plates and rollers have been sufficiently oiled NOTICE The drive chain must be lubricated after washing the...

Page 66: ... contact your local Tao Motor dealer DIRECTIONAL TIRES The 150 G is equipped with directional tires directional tread pattern is designed to roll only in one direction Lateral grooves on both sides of the tire point toward the center creating a V shape The V shape must be pointing forward on each tire NOTICE When installing tires on your ATV correct tread direction is critical safety and driving p...

Page 67: ... alignment Your ATV should steer straight and not drift or pull to one side How to check Wheel Toe in 8 Calculate the toe in Toe in B A 9 If toe in is incorrect adjustment is needed 1 Mark both tie rods ends This measurement will be needed during adjustment 2 Loosen the locknuts on tie rod ends 1 3 The same number of turns should be given to both the right and left tie rod 2 until the specified to...

Page 68: ...e belt Failure to remove ALL debris when replacing the belt could result in vehicle damage loss of control and severe injury or death TIP When removing variator fan pulley hold variator housing pulley in place If variator housing pulley is moved variator weights may fall out of place TIP Due to use variator weights are needed to be inspected Result of normal wear or aging 8 Remove worn or damage C...

Page 69: ...Re install left foot rest assembly and mounting hardware 1 CVT Belt Cover Gasket 2 CVT Bet Cover 3 CVT Belt Cover Mounting Bolts 8mm 4 CVT Clutch Assembly 5 CVT Belt 6 Variator Fan Pulley 7 Variator Fan Pulley Spacer 8 Variator Fan Pulley Nut 9 Crank Shaft Always use a certified Tao Motor parts CVT belt 743 20 30 V Belt TIP 60 ...

Page 70: ... and then rinse and dry the spark arrestor 5 Check the spark arrestor for damage and replace it if necessary 6 Install the 3 Phillips screws 5 and tighten them to the specified torque 7 Install the 3 4mm allen bolts 4 securing the muffler end cap to the muffler and tighten them to the specified torque Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester Tightening Torqu...

Page 71: ...al detergent such as dish washing liquid or a product made especially for washing motorcycles or automobiles 3 Wash your motorcycle with a sponge or a soft towel As you wash check for heavy grime If necessary use a mild cleaner degreaser to remove the grime 4 After washing rinse your ATV thoroughly with plenty of clean water to remove any residue 5 Dry your ATV with a soft towel 6 Lubricate the dr...

Page 72: ... the vehicle behind the front bumper engraved on the frame The engine number can be found on the left side bottom of crank case VEHICLE IDENIFICATION LOACTION The vehicle identification number is used to identify your ATV and may require when ordering replacement parts 63 ...

Page 73: ...64 ...

Page 74: ...65 ...

Page 75: ...for starting instructions Why won t the engine stay running Try adjusting idle screw See page 27 for engine idle adjustment Where do I buy replacement parts You can connect your local Tao Motor dealer or www PartsKit com What is the spark plug gap The gap is 0 06 0 080mm See page 53 Why is my brake light not coming on Try applying both brakes with ignition key in the ON position My ATV cranks but ...

Page 76: ...ts such as the carburetor or fuel injection system the ignition system catalytic converter and engine computer if it is equipped Also included may be hoses belts connectors and other emission related assemblies Where a warrantable condition exists Tao Motor will repair your vehicle at no cost to you including diagnosis parts and labor If an emission related part on your vehicle is defective the pa...

Page 77: ...ources Board for the periods specified above I Coverage Warranty defects shall be remedied during customary business hours at any authorized Tao Motor s dealer located within the United States of America in compliance with the Clean Air Act and applicable regulations of the United States Environmental Protection Agency and the California Air Resources Board Any part or parts replaced under this wa...

Page 78: ...ent as a result of 1 accident 2 misuse 3 repairs improperly performed or replacements improperly installed 4 use of replacement parts or accessories not conforming to Tao Motor s specifictions which adversely affect performance and or use in competitive racing or related events B Inspections replacement of parts and other services and adjustments required for required maintenance C Any vehicle equ...

Page 79: ...tem Warranty IV Legal Rights This warranty gives you specific legal rights and you may also have other rights which vary from state to state V This emission control system warranty is in addition to the standard limited warranty for all vehicles VI Additional Information Any replacement part that is equivalent in performance and durability may be used in the performance of any maintenance or repai...

Page 80: ...Find important product information and how to videos on our website www taomotor com ...

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