Tao Motor G125, Owner'S Manual

Page 1: ...READ THIS MANUAL CAREFULLY It contains important safety and service information G125 Owner s Manual This ATV should not be ridden by anyone under 12 years of age ...

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: ...s Manual Then be sure your child understands and will follow them Children differ in skills physical abilities and judgment Some children may not be able to operate an ATV safely Parents should supervise their child s use of the ATV at all times Parents should permit continued use only if they determine that the child has the ability to operate this ATV safely The G125 ATV has multiple safety feat...

Page 4: ...icates 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 G125 ATV is designed and manufactured for off road use only It is illegal and unsafe to operate this ATV on any ...

Page 5: ...f the labels on your G125 ATV 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: ...LOCATION OF THE WARNING AND SPECIFICATION LABELS 1 2 3 5 1 2 3 4 5 4 ...

Page 7: ...23 Throttle Cable Throttle Cable Adjustment 25 Front Brake Lever 26 Front Brake Lever Freeplay Lower adjustment 27 EngineIdle Adjustment 29 Specification Chart 43 Maintenance Chart 44 48 Engine Oil 49 50 Cleaning Air Filter Element 51 Spark Plug 52 Drive Chain Adjustment 53 55 Cleaning Spark Arrester 56 Electrical Wiring Diagram 59 Transporting 3 Description 4 TABLE OF CONTENTS Hydraulic Rear brak...

Page 8: ...UTION LABELS ON THE ATV NEVER OPERATE THIS ATV WITHOUT PROPER TRAINING OR INSTRUCTION CHILDREN MAY NOT BE ABLE TO OPERATE THIS VEHICLE SAFELY DUE TO PHYSICAL OR MENTAL LIMITATION NOTICE The ATV you purchased may differ slightly from the illustrations in this Owner s Manual Please consult your local Tao Motor dealer with any questions not covered in this manual ...

Page 9: ...consume alcohol or drugs before or while operating 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 procedu...

Page 10: ... Never let your child operate an ATV without close adult supervision a child under 10 should not operate this ATV even with adult supervision Promptly correct your child if he or she begins to ride beyond his or her abilities and if necessary intervene by pulling the cord lanyard or press Engine Stop on the wireless key fob to stop the engine If the child rides beyond his or her abilities or rides...

Page 11: ...Test the range by turning on the ATV and walk 50 feet away and press the shut off button on the wireless remote The engine should stop running if the engine continues to run you may need to get closer or make sure there are no obstructions between the ATV and you 2 Before using the wireless engine shut off switch make sure the batteries in the remote are new and have a full charge Low or dead batt...

Page 12: ...t the other end of the cord 3 As your child is riding walk behind the ATV closely watching his or her actions as well as the path ahead 4 If there is a potential hazard ahead or if your child is not riding correctly pull firmly on the cord lanyard to stop the engine Because the ATV will continue to roll for some distance allow extra time and distance to pull the cord before a potentially hazardous...

Page 13: ...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 14: ...er Fuse 10 Amp Spark Arrester Engine Oil Dip Stick Foot Rest Spark Plug Front Shock Fuel Cap Rear Cargo Rack Rear Shock Front Bumper Fuel On Off Valve LEFT SIDE Battery Under the Seat Rear Foot Brake Lever Gear Shift Lever Muffler 4 ...

Page 15: ...l 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 Ignition OFF Ignition ON Speed Limiter Front Brake Lever Throttle Lever Main Switch Start Button Lanyard Engine Start Stop switch Instrument Cluster 5 ...

Page 16: ...utton ENGINE STOP SWITCH WITH LANYARD Lanyard cap must be pushed in all the way for the engine to start MAIN SWITCH Engine Start Stop switch Use this switch to Stop the engine in an emergency situation The engine will not start when this switch is set to this position Set this switch to Run position before starting the engine START BUTTON Push start button to crank the engine with starter See the ...

Page 17: ...V 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 Instrument cluster icons Gear indicator D N R 7 ...

Page 18: ...ed limiter screw To increase top speed SPEED LIMITER The G125 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 ...

Page 19: ...queeze the front brake lever to release the parking brake 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 ride the ATV without releasing the parking brake You c...

Page 20: ...e choke lever all the way up when starting a cold engine Once the engine is warmed up return the choke lever all the way down in the running position Choke Lever NOTICE For maximum engine life never accelerate hard when the engine is cold or choke lever is in the on position 10 ...

Page 21: ... 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 Because fuel expands when it heats up outside heat can cause fuel to expand and overflow fuel tank FUEL TANK CAPA...

Page 22: ...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 12 ...

Page 23: ... 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 24: ...e 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 1 Seat Lock Lever 2 Frame 3 Seat Tab 14 ...

Page 25: ...gative cable and re screw battery terminal bolt 5 Reinstall seat NOTICE Positive cable is red in color Negative Cable is in black in color Battery electrolyte is poisonous and dangerous acid contains sulfuric acid which can cause severe burns Avoid contact with skin eyes or clothing Always shield your eyes when working near batteries EXTERNAL Flush with water INTERNAL Call a physician Immediately ...

Page 26: ... specified amperage 3 Set ignition key to the ON position to check if all the devices are operating 4 Reinstall seat If a fuse continues to blow contact your local Tao Motor dealer to check for electrical repair Always use a fuse of the specified rating Never use any substitute fuses or larger amp fuses than the original rated fuels Any improper fuse or substitute fuse can cause electrical damage ...

Page 27: ...have the vehicle inspected by a Tao Motor dealer ITEM ROUTINE PAGE Fuel 11 13 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 49 50 Check oil level in engine and add recommended oil to specified level if necessary Check ATV for oil leakage Correct if necessary Fro...

Page 28: ...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 25 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 29: ... brakes do not provide proper braking performance check the brake shoes pads for wear THROTTLE LEVER Check the operation 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...

Page 30: ...nstalled with tubeless low pressure ATV valved tires Tire Wear Limit TIRE WEAR LIMIT When the tire groove decreases to 3mm 0 12 in due to wear replace the tire Never operate an ATV with worn tires as this may cause loss of control increasing your risk of an accident or death CHASSIS FASTENERS Make sure that all nuts bolts and screws are properly tightened before starting engine 20 ...

Page 31: ...up move the choke lever down Choke lever must be in the off position all the way to the down in order to operate the ATV 9 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 ge...

Page 32: ...ould be 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 th...

Page 33: ...imit 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 facto...

Page 34: ...ction Applying the brakes quickly or accelerating when sliding out of control is not recommended until you have corrected the slide Always completely stop the ATV and apply the brakes prior to moving the transmission lever GEAR SELECTOR LEVER This ATV is equipped with a 2 gear transmission gearbox The gear shift lever is located on the left side of the ATV When changing the transmission gear posit...

Page 35: ...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 36: ... 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 37: ...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 38: ... reservoir level as follows Brake fluid reservoir is located on the frame in front of the right rear tire With the ATV on a level surface check brake fluid in reservoir for proper level The fluid should above the MIN mark Add fluid as required but never overfill and clean filler cap before removing NOTICE The Reservoir is full when the fluid reaches the top of the window A low fluid level may indi...

Page 39: ...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 1500 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 29 ...

Page 40: ...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 mechanism...

Page 41: ...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 42: ...GETTING TO KNOW YOUR ATV 32 ...

Page 43: ...quired 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 have read this manual completely and understand how to operate all of the ATV s controls Pay particul...

Page 44: ... 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 45: ... 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 35 ...

Page 46: ...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 47: ...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 48: ...ore difficult terrain Set the parking brake and follow the instruction on page 9 21 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 49: ...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 50: ...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 51: ...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 52: ...les could cause loss of control or a collision Before operating in a new area check for obstacles Never attempt to ride over large obstacles such as large rocks or fallen trees When you go over obstacles always follow proper procedures as described in the Owner s Manual Riding over rough terrain should be done with caution Look out for obstacles which could cause damage to the ATV or could lead to...

Page 53: ...IONS Overall Length 57 4 in 1 460 mm Overall Width 39 0 in 1000 mm Overall Height 36 2 in 920 mm Seat Height 35 5 in 650 mm ENGINE Type Single Cylinder Four Stroke Air Cooled Automatic Centrifugal Clutch Displacement 107CC Bore X Stroke 52 4 mm x 49 5 mm Idle Speed 1500 150 RPM Start Mode Electric start Ignition Method CDI Spark Plug Gap 0 06 0 085mm Transfer Method Chain Drive Compression Ratio 9...

Page 54: ...orrectly 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 regap...

Page 55: ...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 56: ...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 57: ...and correct if necessary Adjust 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 sta...

Page 58: ...PERIODIC MAINTENANCE RECORD MAINTENANCE INTERVAL PERFORMED SERVICING DATE SERVICING DEALER OR PERSON REMARK 48 ...

Page 59: ...se engine damage may result 6 Check the 0 ring for damage and replace it if necessary 7 Insert the dipstick into the oil filler hole and then tighten the engine oil filler cap The engine oil dip stick is located on the right side of the ATV behind the right foot rest 1 Minimum Oil Level Mark 2 Maximum Oil Level Mark TIP To check the engine oil level NOTE Your new vehicles engine comes with shippin...

Page 60: ...recommended engine oil Recommended engine oil is SAE 15W40 and oil capacity is 0 8 US qt or 0 8 liters 6 Start the engine and then it let it idle for a few minutes 7 Turn off engine and check engine dip stick for correct engine oil level NOTICE When removing the engine oil drain bolt the 0 ring may fall out Take care not to lose these parts NOTICE Before installing the engine oil drain bolt be sur...

Page 61: ...ews 10 Install the seat The air filter element should be cleaned every 20 40 hours It should be cleaned and lubricated more often if the ATV is operated In extremely dusty areas When servicing the air filter element be sure to check the air inlet of the air filter case for obstructions NOTICE Never use low flash point solvents or gasoline to clean the air filter element because the engine could ca...

Page 62: ... plug to see if it s worn out 2 Check the spark plug for electrode erosion and excessive carbon or other deposits and replace it if necessary 3 Measure the spark plug gap with a wire thickness gauge and if necessary adjust the gap to specification To install the 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 ...

Page 63: ...ed before each ride How to check for drive chain slack 1 Drive Chain Slack Drive chain slack 6 0 12 0 mm 0 24 0 47 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 54 ...

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: ... using a 8mm socket wrench 2 Unscrew the 3 Phillips screws 5 securing spark arrester to muffler 3 Carefully remove the spark arrester from the muffler assembly 4 Remove accumulated carbon on the spark arrestor screen with soap and water and remove hard to remove carbon carefully with a brass wire brush and then rinse and dry the spark arrestor 5 Check the spark arrestor for damage and replace it i...

Page 67: ...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 68: ... the vehicle behind the front bumper engraved on the frame The engine number can be found on the bottom left of the crank case VEHICLE IDENIFICATION LOCATION The vehicle identification number is used to identify your ATV and may required when ordering replacement parts 58 ...

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Page 71: ...ons Why won t the engine stay running Try adjusting idle screw See page 29 for engine idle adjustment Where do I buy replacement parts You can connect your local Tao Motor dealer or www PatsKit com What is the spark plug gap The gap is 0 06 0 085mm See page 52 Why is my brake light not coming on Try applying both brakes with ignition key in the ON position My ATV cranks but wont fire Ensure tether...

Page 72: ...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 73: ...urces 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 war...

Page 74: ...t 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 specific tions which adversely affect performance and or 5 use in competitive racing or related events B Inspections replacement of parts and other services and adjustments required for required maintenance C Any vehicle eq...

Page 75: ...ontrol System 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 maintenanc...

Page 76: ...Find important product information and how to videos on our website www taomotor com ...

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