Tao Motor BULL 200s Owner's Manual
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Tao Motor BULL 200s Owner's Manual

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Bull 200s Owner' s Manual
READ THIS MANUAL CAREFULLY! It
contains important safety and service
information.

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Summary of Contents for Tao Motor BULL 200s

  • Page 1 Bull 200s Owner’ s Manual READ THIS MANUAL CAREFULLY! It contains important safety and service information.
  • Page 2 Please read carefully before operating this vehicle! This vehicle should only be assembled and prepped by an authorized Tao Motor 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...
  • Page 3 INTRODUCTION Thank you for purchasing the Bull 200S. This ATV is designed for years of reliable use and family fun. This manual will provide you with a good basic understanding of the features and operation of this ATV. This manual includes important safety information. It also includes general riding techniques, maintenance and inspection procedures.
  • Page 4 Product and specifications are subject to change without notice. IMPORTANT NOTICE The Bull 200S ATV is designed and manufactured for off-road use only. It is illegal and unsafe to operate this ATV on any public street, road or highway. This ATV complies with all applicable off-road noise level and spark arrester laws and regulations.
  • Page 5 Please read and understand all of the labels on your Bull 200S. 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: Table Of Contents

    TABLE OF CONTENTS Transporting ................... 1 Engine Idle Adjustment ............26 Description ..................2 Fuel Drain ..................27 Control Layout ................3 Adjusting Suspension Spring Preload........28 Main Switch ..................4 Getting To Know Your ATV ..........29-39 Specification Chart ..............40 Instrument Cluster ................
  • Page 7 SAFETY INFORMATION THE BULL 200S 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.
  • Page 8 SAFETY INFORMATION Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, parking lots and streets. FOR OFF-ROAD USE ONLY. Never operate an ATV on any public street, road or highway, even a dirt or gravel road. This ATV is designed and manufactured for off Road use only no public roads.
  • Page 9 SAFETY INFORMATION (continued) Never permit anyone other than an adult to start the ATV. Drain gasoline from the fuel tank and carburetor prior to transporting the ATV, also 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.

  • Page 10: Transporting

    TRANSPORTING THE ATV Avoid Carbon Monoxide Poisoning! All engine exhaust contains carbon monoxide, a deadly gas. Breathing carbon monoxide can cause headaches, dizziness, drowsiness, nausea, confusion, and eventually death. Carbon Monoxide is a colorless, odorless tasteless gas which may be present even if you do not see or smell any engine exhaust.

  • Page 11: Description

    DESCRIPTION LEFT SIDE RIGHT SIDE Fuse 10 Amp Rear Cargo Rack Fuel Cap Front Shock Battery Air Filter Gear Shift Lever Front Cargo Rack (Under (Under The Seat) The Seat) Muffler CVT Belt Front Bumper Rear Shock Foot Rest Engine Oil Spark Plug Fuel On/Off Valve Spark Arrester...

  • Page 12: Control Layout

    CONTROL LAYOUT Rear Brake Lever Main Switch Assembly Instrument Cluster Front Brake Lever Throttle Lever Start Button Engine Start / Stop Switch Ignition ON Ignition OFF CONTROLS & FUNCTIONS IGNITION SWITCH The positions of the ignition switch are as follows. Ignition "ON"...

  • Page 13: Main Switch

    Push start button to crank the engine with starter. See the starting instructions on page 18 before starting the engine. HEADLIGHTS This Bull 200S ATV is equipped with High, Low, headlight features. When ignition key is set to the " On " potion press the headlight switch to turn on headlights and to toggle through modes.

  • Page 14: Instrument Cluster

    INSTRUMENT CLUSTER The Instrument cluster displays important information about the ATV. Make sure the rider is familiar with all the information displayed on Instrument cluster before riding ATV. Instrument panel icons: 1. Engine RPM (multiplied by 1000r / min), with the change in engine RPM display will also change. 2.

  • Page 15: Speed Limiter

    SPEED LIMITER The Bull 200S 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.

  • Page 16: Parking Brake

    PARKING BRAKE Use the parking brake before starting the engine or after parking the ATV, especially on a slope. This ATV is equipped with front and rear axle parking brake. To set parking brake: Apply the front brake lever, push down the lock button and release brake lever to set parking brake. To release parking brake: Apply brake lever, move parking brake holding tab towards handle bar and release brake lever.

  • Page 17: Fuel Tank Capacity

    FUEL TANK CAPACITY Gasoline and gasoline vapors are extremely flammable. To avoid fires, explosions and to reduce the risk of injury when refueling, follow these instructions. 1. Before refueling, turn off the engine 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.

  • Page 18: Fuel Tank Cap

    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...

  • Page 19: Fuel Cock/Fuel Valve

    FUEL COCK/ FUEL VALVE 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. Always turn the fuel valve to the "OFF"...

  • Page 20: Seat

    SEAT To Remove Seat To remove the seat, pull the seat lock lever (#1) 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.

  • Page 21: Battery

    NOTICE Positive (+) cable is red in color. Negative (-) Cable is in black in color. This Bull 200S ATV has two positive (+) cables red in color. Both attach to positive terminal on the battery. Battery electrolyte is poisonous and dangerous, acid contains sulfuric acid, which can cause severe burns. Avoid contact with skin, eyes or clothing.

  • Page 22: Battery Charging & Changing Fuse

    4. Reinstall seat. 3. Spare Fuse 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.

  • Page 23: Pre-Ride Safety Checks

    PRE-RIDE SAFETY CHECKS Inspect the ATV prior to each use to ensure it is in a safe operating condition. Always follow the inspections, procedures and schedules described in the Owner’s Manual. Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment failure.
  • Page 24 ITEM ROUTINE PAGE Throttle Lever • Make sure that operation is smooth. Lubricate cable and lever housing if necessary. • Check lever free play, and adjust if necessary. Control Cables • Make sure that operation is smooth. Lubricate if necessary. Drive Chain •...

  • Page 25: Front & Rear Brakes

    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.

  • Page 26: Tire Wear Limits And Chassis Fasteners

    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. TIRE WEAR LIMIT When the tire groove decreases to 3mm (0.12 in) due to wear, replace the tire.

  • Page 27: Starting Engine

    STARTING ENGINE (COLD) Set the parking brake. (The engine can be started only when the front / rear brake lever is applied) Turn the fuel valve lever to the "ON" position. Turn the ignition key to the "ON" position. Set "RUN" position on main switch. Set gear box to neutral position.

  • Page 28: Engine Break-In

    ENGINE BREAK-IN Proper engine break-in will increase the lifespan of your Tao Motor vehicle ATV. The engine break-in period is the initial 20 hours of operation. You should avoid maintaining a constant engine RPM and do not operate your ATV above 1/2 throttle during the break-in period.

  • Page 29: Parking, Accessories & Modifications, Rear Cargo Rack

    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 factory warranty. See a Tao Motor dealer for more details.

  • Page 30: Gear Selector Lever

    GEAR SELECTOR LEVER GEAR SELECTOR LEVER This ATV is equipped with a 2 gear transmission gearbox, the gear shift lever is located on the right side of the ATV. When changing the transmission position, first apply the brakes to come to a complete stop, before moving the lever to the desired position.

  • Page 31: Throttle Cable & Throttle Cable Adjustment

    THROTTLLE CABLE ADJUSTMENT Check throttle lever free-play, adjust if necessary. NOTE If cable adjustment is unattainable, see an authorized Tao Motor dealer. Normal throttle free-play is 5mm to 10mm 0.197 in to 0.394 Throttle cable lubrication Lubricate cable using silicone cable lubricant to reduce premature wear and to ensure proper movement of the cable.

  • Page 32: Hydraulic Brake System

    BRAKES Replacement of brake components requires professional knowledge. Brake service should be performed by a Tao Motor dealer. Operating with improperly adjusted brakes could lead to a loss in braking ability and an accident. The brakes can be very hot after prolong use of the vehicle and can cause burns. Wait for the brake to cool down.
  • Page 33 Have your local Tao Motor dealer inspect brakes system for wear or damage. NOTICE If any problem is found concerning the brake system connect your local Tao Motor dealer for service. Brake Fluid Always use recommended brake fluid DOT 4 or 3.

  • Page 34: Engine Hour Meter

    ENGINE HOUR METER This ATV is equipped with an engine hour meter, this meter will display total engine running time. Hour glass symbol appears and flashes on/off to indicate counting engine run time. Total engine run time can be very useful to maintain your ATV.

  • Page 35: Engine Idle Adjustment

    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; Apply parking brake. Warm up the engine by running the vehicle. Adjust the carburetor idle screw until the desired idle RPM is reached. Turning the idle screw in (clockwise) to raise RPM. Turning the screw out (counterclockwise) will lower RPM.

  • Page 36: Fuel Drain

    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 48 hrs. or more fuel residue can form in jets and passages causing the vehicle not to start. Tao Motor recommends to drain the fuel from carburetor and fuel tank system.

  • Page 37: Adjusting Suspension Spring Preload

    ADJUSTING SUSPENSION SPRING PRELOAD The Bull 200S ATV is equipped with adjustable coil springs front and rear. The spring preload can be adjusted to suit the rider’s weight and the riding conditions. Turn the spring preload adjusting ring to increase (stiffest= 5) or decrease (softest= 1) the spring preload.

  • Page 38: Getting To Know Your Atv

    GETTING TO KNOW YOUR ATV...
  • Page 39 This ATV is intended for use by operators 16 years of age and older. Adult supervision is required while a child operates any ATV. Do not operate this ATV or allow anyone else to operate it without proper Instruction. The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain.
  • Page 40 Never carry a passenger. Carrying a passenger on this ATV greatly reduces your ability to balance and control this ATV. You could have an accident, resulting in severe injury or death to you and/or your passenger. The long seat is to allow the operator to shift position as needed during operation.
  • Page 41 Protective clothing Protective Goggles Protective Gloves Protective Boots Protective Helmet Do not operate after or while consuming alcohol or drugs. The operator’s performance capability is reduced by the influence of alcohol or drugs. Consuming alcohol or drugs could seriously affect your judgment, cause you to react more slowly, and affect your balance and perception.
  • Page 42 DURING RIDING Always keep your feet on the foot boards during operation; otherwise, they may contact the rear wheels. Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV. If you remove a foot from a foot board, your foot or leg may come into contact with the rear wheels, which could injure you or cause an accident.
  • Page 43 Never operate this ATV on any public street, road or highway, even a dirt or gravel one. You could collide with another vehicle. Know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hidden hazards which may cause the ATV to upset.
  • Page 44 “no trespassing. ” Do not ride on private property without getting permission. OPERATING YOUR Bull 200S ATV: Select a large, flat off-road area to become familiar with your ATV. Make sure that this area is free of obstacles and other riders.
  • Page 45 STEERING YOUR ATV To achieve maximum traction while riding off road, the two rear wheels turn together at the same speed. Therefore, unless the wheel on the inside of the turn is allowed to slip or lose some traction, the ATV will resist turning. A special turning technique must be used to allow the ATV to make turns quickly and easily.
  • Page 46 Avoid higher speeds until you are thoroughly familiar with the operation of your ATV. Do not attempt to climb hills until you have mastered basic maneuvers on flat ground. Always check the terrain carefully before attempting any hill. In all cases avoid inclines with slippery or loose surfaces, or obstacles that might cause you to lose control.
  • Page 47 Stalling, rolling backwards or improperly dismounting while climbing a hill could result in ATV overturning. If you cannot control the ATV, dismount immediately on the uphill side. DOWNHILL RIDING When riding your ATV downhill, shift your weight as far to the rear and uphill side of the ATV as possible.
  • Page 48 WATER CROSSINGS The ATV can be used to cross slow moving, shallow water of up to a maximum of 11 cm (3 in) in depth. Before entering the water, choose your path carefully. Enter where there is no sharp drop off, and avoid rocks or other obstacles which may be slippery or upset the ATV.

  • Page 49: Specification Chart

    SPECIFICATION CHART ENGINE Fuel Tank ............... 1.3 Gal (5.0L) Type ............... Single-Cylinder Four-Stroke, Engine Oil ............SAE 15W40 ................. Air-Cooled, Automatic Gear Box Oil ............SAE 80W90 ................. Centrifugal Clutch Climbing .............. ≥20° Displacement ..........169CC Acceleration Noise Level ........ ≤82dB Bore X Stroke ..........

  • Page 50: Maintenance & Chart

    Due to the nature of the adjustments marked with a √ on the following chart, it is CAUTION recommended that service be performed by an authorized Tao Motor dealer. • Perform maintenance more often if you use your ATV under severe conditions, such as dirty or wet conditions to purge water or dirt contamination from grease fittings and other critical components.
  • Page 51 Items marked with an asterisk should be performed by a dealer as they require special tools, data and technical skills. • Off-road vehicles require regular maintenance. The following items are critical to keep your Tao Motor ATV performing correctly. WHICHEVER COMES FIRST...
  • Page 52 GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL EVERY WHICHEVER COMES FIRST Month CHECK OR km (mi) 1300 2500 2500 5000 MAINTENANCE JOB (200) (800) (1600) (1600) (3200) ITEM Hours Air Filter Element • Clean and replace if necessary. Every 20-40 hours (more often in wet or dusty areas) Front Brake* ...
  • Page 53 GENERAL MAINTENANCE AND LUBRICATION CHART CONTINUED WHICHEVER COMES FIRST INITIAL EVERY Month CHECK OR km (mi) 1300 2500 2500 5000 MAINTENANCE JOB (200) (800) (1600) (1600) (3200) ITEM Hours Wheel Hub • Check for looseness or damage, and replace if necessary. ...
  • Page 54  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.
  • Page 55 PERIODIC MAINTENANCE RECORD MAINTENANCE SERVICING DATE SERVICING DEALER OR PERSON REMARK INTERVAL PERFORMED...

  • Page 56: Engine Oil

    ENGINE OIL The engine oil level should be checked before each ride. In addition, always follow the maintenance schedule for oil changes as shown in the maintenance schedule. NOTE Your new vehicles engine comes with shipping oil, shipping oil must be changed before the engine is started for the first time.
  • Page 57 To change the engine oil SAE Viscosity Grade and Outdoor Temperature Chart 1. Place ATV on a level surface and set parking brake. 2. Place an oil pan under the engine to collect the used oil. 3. Remove engine oil filler cap (dipstick) 4.

  • Page 58: Gear Box Oil

    GEAR BOX OIL The Gear box case must be checked for oil leaks before each ride. If any leakage is found have a Tao Motor dealer perform repairs. Gear box oil must be changed at the intervals specified in the maintenance and lubrication chart.

  • Page 59: Cleaning Air Filter Element

    CLEANING AIR FILTER ELEMENT The air filter element should be serviced at the intervals specified in the periodic maintenance and lubrication chart. Clean and replace as needed. Clean and replace air filter more frequently if used in dusty or dirty areas. Never use low-flash-point solvents or gasoline to clean the air filter element because the engine could catch fire or explode.
  • Page 60 The air filter element should be replaced every 20-40 hours. It should be replaced 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. 1.

  • Page 61: Spark Plug

    SPARK PLUG Checking the spark plug The spark plug is an important engine component, which is easy to check. The spark plug should be removed and checked in accordance with the periodic maintenance and lubrication chart. To remove the spark plug 1.

  • Page 62: Drive Chain & Adjustment

    DRIVE CHAIN Checking Drive Chain Slack The drive chain slack should be checked before each ride. How to check for drive chain slack; 1. Place the ATV on a level surface. 2. Move the ATV back and forth to locate the tightest portion of the drive chain, and then measure the drive chain slack as shown. 3.
  • Page 63 2. Loosen brake caliper mounting bracket bolt (#1). 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.
  • Page 64 NOTICE The drive chain slack is adjusted by the rotation of the carrier/housing forward and rear wards. To tighten drive chain, A. Insert an appropriate sized bolt through the sprocket into axle carrier. (M10X60 Bolt found in tool kit supplied with ATV) B.

  • Page 65: Checking Wheel Hub Bearings

    Tao Motor dealer. DIRECTIONAL TIRES The Bull 200S 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.

  • Page 66: Adjusting Steering Toe-In

    4. Tighten the tie-rod end locknuts of both tie rods. 35Nm / 25.3ft/lbs. After adjusting the toe-in to specification, ride the ATV at slow speed for some distance to verify adjustments are correct. If any questions call your local Tao Motor dealer. Adjust the rod so that (C) and (D) are equal.

  • Page 67: Cvt Clutch & Belt Replacement

    CONTINUOUSLY VARIABLE TRANSMISSION SYSTEM Do not modify any component of the CVT system. The CVT system has been precision balanced any modification will cause the system to be out of balance, creating vibration and additional loads on components. The CVT system rotates at high speeds, creating large amounts of force on clutch components. As the owner, you have the following responsibilities for your own safety and the safety of others.
  • Page 68 1. CVT Belt Cover Gasket 2. CVT Bet Cover 3. CVT Belt Cover Mounting Bolts (8mm) 4. CVT Clutch Assembly Always use a certified Tao Motor parts. 5. CVT Belt CVT belt # 743-20-30 V-Belt 6. Variator Fan Pulley 7. Variator Fan Pulley Spacer 8.

  • Page 69: Cleaning Spark Arrester

    CLEANING SPARK ARRESTER Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. 1. Unscrew the three allen bolts (#6) securing the muffler end cap to muffler by using a (4mm) allen wrench. 2. Remove muffler end cap (#4) from muffler assembly. 3.
  • Page 70 WASHING VEHICLE We recommend the use of a garden hose to wash your Bull 200S. High pressure washers can damage certain parts of your ATV. If you use a high pressure washer, avoid spraying the following areas: - Muffler outlet...

  • Page 71: Vehicle Identification Location

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

  • Page 74: Commonly Asked Questions

    Why didn't I get an assembly instruction manual? This vehicle should only be assembled and prepped by authorized Tao Motor Dealer or professional motorcycle mechanic. You should never to try to attempt assembly of this vehicle, it should be done by professionals. Death or serious injury could result from failure to follow these warnings and...

  • Page 75: Emission Control System Warranty

    10,000 km or 60 months which comes firs. Tao Motor must warrant the emission control system on your vehicle for 5,000 km or for 30 months, whichever comes firs, provided that there has been no abuse, neglect or improper maintenance of your vehicle.
  • Page 76 All the repairs will be done free of charge to the customer. You must take your Tao Motor Vehicle, along with your sales receipt or other proof of original purchase date, at your expense, to any Tao Motor dealer who is authorized by Tao Motor to sell and service that Tao Motor product during his normal business hours.
  • Page 77 Tao Motor’s dealer at its place of business during customary business hours. This warranty does not cover inconvenience or loss of use of the vehicle or transportation of the vehicle to or from the Tao Motor’s dealer. Tao Motor shall not be liable for any other expenses, loss or damage, whether direct, incidental, consequential or exemplary arising in connection with the sale or use of or inability to use the vehicle for any purpose.
  • Page 78 VI. Additional Information. Any replacement part that is equivalent in performance and durability may be used in the performance of any maintenance or repairs. However, Tao Motor is not liable for these parts. The owner is responsible for the performance of all required maintenance.
  • Page 79 Find important product information and how-to videos on our website www.taomotor.com...

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