Tao Motor TBR7, Owner'S Manual

Page 1: ...service information TBR7 Owner s Manual THIS IS AN UNAUTHORIZED EDIT OF THE ORIGINAL MANUAL IT HAS BEEN EDITED FOR SPELLING AND CLARITY AND IS IN NO WAY ENDORSED OR ACKNOWLEDGED BY TAO MOTOR THE EDIT IS INTENDED TO ENHANCE THE ORIGINAL MANUAL AND NOT REPLACE IT ...

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: ...his manual covers the main data basic structure and main procedures of operation adjustment maintenance and troubleshooting of this motorcycle Products are always subject to further improvement which will cause some difference between the vehicle and this manual ...

Page 4: ...NGE 18 SPARK PLUG 19 AIR FILTER ELEMENT 20 THROTTLE CABLE 21 ENGINE IDLE ADJUSTMENT 22 CLUTCH LEVER ADJUSMENT 23 HYDRAULIC FRONT BRAKE 24 REAR BRAKE 25 SIDE STAND SPROCKET 26 DRIVE CHAIN 27 CHAIN ADJUSMENT 28 DRIVE CHAIN LUBRICATION 29 BATTERY 30 BATTERY CHARGING 31 WASHING VEHICLE 32 MAINTENANCE SCHEDULE 33 GENERAL MAINTENANCE AND LUBRICATION CHART 34 36 PERIODIC MAINTENANCE RECORD 37 ELECTRICAL ...

Page 5: ... inexperienced or untrained riders we urge all riders to take a certified course approved safety learning class Developing off road riding skills is a gradual step by step process Start by practicing at low speeds in a safe area and slowly build your skills On Road Riding The most frequent motorcycle collision happens when a car turns left in front of a motorcycle Another common situation is a car...

Page 6: ... keep your motorcycle properly maintained and in safe riding condition Having a breakdown can be difficult especially if you are stranded off road far from help To help avoid problems inspect your motorcycle before every ride and perform all recommended maintenance Never exceed load limits Modification Modifying your motorcycle or using non OEM parts or accessories can make your motorcycle unsafe ...

Page 7: ...l comfortable with its size and weight SAFETY INFORMATION Helmets and Eye Protection A helmet is your most important piece of riding gear because it offers the best protection against head injuries A helmet should fit your head comfortably and securely A bright colored helmet and reflective strips can make you more noticeable in traffic An open face helmet offers some protection but a full face he...

Page 8: ...he labels on your TBR7 These labels contain important information for safe and proper operation Never remove any labels from your motorcycle If a label becomes difficult to read or comes off request a new replacement label from your local Tao Motor dealer 4 4 ...

Page 9: ...x RPM 11kW 6500 RPM Wheelbase 1345mm Maximum Torque RPM 17 5N m 5500 RPM Dry Weight 130 kg Idle RPM 1500 RPM 150 Max Load 150kg including the driver Front Wheel 90 90 19 Spark Plug D8EA Rear Wheel 110 90 17 Spark Plug Gap 0 6mm 0 8mm Maxiumum Speed 90km h Valve Clearance Intake Valve 0 04mm 0 06mm Braking Distance 7m 30km h Exhaust Valve 0 04mm 0 06mm Max Incline 20 Continued 5 5 ...

Page 10: ...TIONS Volume of Lubricating Oil 1 1L Fuse 10A Fuel Tank Capacity 12 5L Battery 12V9Ah Transmission Gear Ratios Ignition Type C D I 1st gear 2 909 2nd gear 1 867 3rd gear 1 389 4th gear 1 150 5th gear 0 9545 6 6 ...

Page 11: ...DESCRIPTION Left Rear View Mirror Speedometer Ignition Key Switch Right Rear View Mirror Front Brake Lever Throttle Engine Start Switch Clutch Lever Horn Button 7 7 ...

Page 12: ...The VIN is on the right side of the frame Fuel Cock Fuel Valve Gear Shifter Side Stand Rear Wheel DESCRIPTION 8 ...

Page 13: ...Kick Start Lever Rear Brake Lever Front Shock Absorber Front Wheel Exhaust Muffler Seat Cushion Rear View Mirror Front Turn Signals DESCRIPTION 9 ...

Page 14: ...am Indicator Lit when high beam is on 4 Gear Position Display Shows currently selected gear 5 Neutral Indicator Comes on when the transmission is Neutral 6 Fuel Level Display Indicates fuel level 7 Odometer Total distance ridden 1 1 8 4 5 7 8 Trip Odometer Reset Knob Turn the knob to reset the trip odometer 3 INSTRUMENT CLUSTER 10 ...

Page 15: ...ehicle engine Turns off the electrical system The key can be removed ON For starting or riding the vehicle Turns on the electrical system The key cannot be removed LOCK Locks the steering The key can be removed LOCK OFF ON IGNITION SWITCH 11 11 ...

Page 16: ...the vehicle by the main stand unlock fuel cap with ignition key and fill with fuel Close fuel tank cap and remove key FUEL COCK FUEL VALVE The fuel cock valve supplies fuel from the tank to the carburetor The fuel cock valve lever positions are explained as follows and shown in the illustrations FUEL OFF Arrow mark positioned over OFF position Fuel is off and fuel will not flow to the carburetor A...

Page 17: ...be in the off position all the way down in order to operate the vehicle STARTING ENGINE COLD 1 Turn the fuel valve lever to ON position 2 Turn the ignition key to the ON position 3 Set RUN position on main switch 4 Set Gear box to Neutral position N will be displayed on instrument cluster 5 Set the choke lever to the warm start position all the way down 6 Press and hold start button until the engi...

Page 18: ...revious page before starting the engine Engine Stop Kill Switch Engine Run Switch Engine Start Button 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 14 ...

Page 19: ...ree positions OFF Running Light Headlight ON It s always recommended you ride with the headlight ON all the time 2 Headlight High Low beam switch High beam Low beam 3 Turn signal switch Move Switch to left or right to activate the turn signal 4 Horn button Press and hold to sound the horn 15 ...

Page 20: ... Your motorcycle transmission has 5 forward gears in one down four up shift pattern Start the engine and let it warm up at idle speed Apply the clutch lever and select 1st gear slowly releasing the clutch lever A small amount of throttle may be needed to move forward 16 ...

Page 21: ...imum Oil Level Mark 2 Maximum Oil Level Mark TIP If the engine was started before checking the oil level be sure to warm up the engine sufficiently and then wait at least ten minutes until the oil settles for an accurate reading The engine oil dip stick is located on the right side of the vehicle next to kick starter lever TIP Only add engine oil into the dipstick filler hole Never pour engine oil...

Page 22: ...Nm 10 ft lbs 6 Refill engine with specified amount of the recommended engine oil Recommended engine oil is SF 15W40 and oil capacity is 1 1L 7 Start the engine and then it let it idle for a few minutes 8 Turn off engine and check engine dip stick for correct engine oil level NOTICE When removing the engine oil drain bolt the O ring may fall out Take care not to lose these parts NOTICE Before insta...

Page 23: ...lectrode of the spark 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 Spark Plug Gap 0 6 0 8 mm 1 Clean the surface of the spark plug gasket and its mating surface and then wi...

Page 24: ...r filter element should be cleaned every 20 40 hours It should be cleaned and lubricated more often if the vehicle 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 catch fire or explode Make s...

Page 25: ...6mm 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 left and right If ...

Page 26: ...s reached Turning the idle screw in clockwise to raise RPM Turning the screw out counterclockwise will lower RPM 3 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 22 22 ...

Page 27: ...er CLUTCH LEVER ADJUSTMENT Checking the clutch lever free play Free play at the clutch lever Check the clutch cable for kinks or signs of wear If necessary have it replaced by your Tao Motor dealer Lubricate the clutch cable with a commercially available cable lubricant to prevent premature wear and corrosion NOTE Improper free play adjustment can cause premature clutch wear Adjusting the clutch l...

Page 28: ...he fluid reaches the top of the window A low fluid level may indicate leaks or worn brake pads 1 2 Maximum Fluid Level Minimum Fluid Level HYDRAULIC FRONT BRAKE New brakes will not perform to their maximum efficiency until after their initial break in is complete Use extra caution Brake fluid replacement or brake system maintenance and repairs should be performed by an authorized Tao Motor dealer ...

Page 29: ...rake release it and then spin the wheel and check that it rotates freely Repeat this procedure several times 3 Check the free play If you can t adjust the free play properly see your Tao Motor dealer 2 Rear Brake Adjusting Nut 3 Brake Arm Pin counterclockwise Increase Free Play clockwise Decrease Free Play Inspections Lubrication Check that the rear pedal assembly is positioned properly and the se...

Page 30: ...mage and loss of tension 2 Check the side stand assembly for freedom of movement Worn Sprocket Teeth Damaged Sprocket Teeth REPLACE Normal Sprocket Teeth GOOD REPLACE NOTICE Use of a new chain with worn sprockets will cause chain wear Inspect the front and rear sprocket teeth for excessive wear or damage If necessary have your Tao Motor dealer replace a worn sprocket Sprocket 26 ...

Page 31: ...essive when the rear axle is moved to the farthest limit of adjustment Excessive slack indicates the chain is worn beyond its service limit 1 1 Drive Chain Slack DRIVE CHAIN The service life of the chain depends on proper lubrication and adjustment Poor maintenance can cause premature wear or damage to the drive chain or sprockets Under severe usage or when the motorcycle is ridden in unusually du...

Page 32: ...t 2 2 Turn both the right and left chain adjusters clockwise or counterclockwise 3 equally to increase or decrease chain slack 3 After adjusting be sure the chain adjusters are equal in length on both sides of the swing arm 4 4 Tighten the rear axle nut 5 Recheck drive chain slack Check rear brake pedal free play and adjust if necessary CHAIN ADJUSMENT 28 ...

Page 33: ...aler When the drive chain becomes extremely dirty it should be cleaned prior to lubrication 1 Clean the side surfaces of the chain with a dry cloth Do not brush Brushing will damage the O ring chain Use of a solvent may also damage the O rings 2 Inspect the drive chain for possible wear or damage Replace the drive chain if it has damaged rollers loose fitting links or otherwise appears unserviceab...

Page 34: ...einstall rear left side cover NOTICE Positive cable is red in color Battery electrolyte is poisonous and dangerous and 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 and get medical attention EYES Flush with water for 15 minutes and get p...

Page 35: ...e specified amperage 3 Set ignition key to the ON position to check if all the devices are operating 4 Reinstall rear left cover 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 electr...

Page 36: ...nty of clean water to remove any residue 5 Dry your motorcycle with a soft towel Lubricate the drive chain to prevent rusting 6 Start the engine and let it idle for several minutes The engine heat will help dry moist areas As a precaution ride at a slow speed and apply the brakes several times This will help dry the brakes and restore normal braking performance We recommend the use of a garden hos...

Page 37: ...on Oil Replace every 6000kms or 6 Months Braking System Inspect Inspect Inspect Inspect Inspect Throttle operation Inspect Inspect Inspect Throttle control system Inspect Inspect Inspect Headlight Adjustment Inspect Tighten all Nuts Screws Inspect Inspect Inspect MAINTENANCE SCHEDULE For vehicles equipped with an odometer or an hour meter follow the km mi or hours maintenance intervals However kee...

Page 38: ...ay and adjust if necessary Check fluid and motorcycle 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 replace if necessary 6 Wheels Check runout for damage Replace if necessary 7 Tires Check t...

Page 39: ...operation and correct if necessary 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...

Page 40: ...ary Adjust headlight beams GENERAL MAINTENANCE AND LUBRICATION CHART CONTINUED 20 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 batter...

Page 41: ...PERIODIC MAINTENANCE RECORD MAINTENANCE INTERVAL PERFORMED SERVICING DATE SERVICING DEALER OR PERSON REMARKS 37 ...

Page 42: ...ELECTRICAL DIAGRAM 38 ...

Page 43: ...luding diagnosis parts and labor MANUFACTURER S WARRANTY COVERAGE The 2019 and later model year highway motorcycle are warranted for 18 000 km or for 5 years whichever comes first If any emission related part on your vehicle is defective the part will be repaired or replaced by Tao Motor This is your emission control system DEFECTS WARRANTY OWNER S WARRANTY RESPONSIBILITIES As the vehicle owner yo...

Page 44: ...or the duration of the warranty period Warranty repairs will be made without charge for diagnosis parts or labor All defective parts replaced under this warranty become the property of Tao Motor A list of warranted parts is included in this warranty statement Normal maintenance items such as spark plugs and filters that are on the warranted parts list are warranted up to their required replacement...

Page 45: ...Tao Motor dealer or service shop who is authorized by Tao Motor to sell or service that Tao Motor product during his normal business hours Claims for repair or adjustment found to be caused solely by defects in material or workmanship will not be denied because the vehicle was not properly maintained and used To find a local dealer or a service shop in your area please call our toll free number 88...

Page 46: ...ntrol system warranty implied by law including any warranty of merchantability or fitness for a particular purpose is limited to the express emission control system warranty terms stated in this warranty The foregoing statements of warranty are exclusive and in line of all other remedies Some states do not allow limitations on how long an implied warranty lasts so the above limitations may not app...

Page 47: ...Find important product information and how to videos on our website www taomotor com ...