Tao Motor G 200 Owner's Manual
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Tao Motor G 200 Owner's Manual

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G 200 Owner' s Manual
READ THIS MANUAL CAREFULLY! It
This ATV should not be operated by anyone under 16 years of age.
contains important safety and service
information.

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Summary of Contents for Tao Motor G 200

  • Page 1 G 200 Owner’ s Manual READ THIS MANUAL CAREFULLY! It This ATV should not be operated by anyone under 16 years of age. 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 G 200. 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 G 200 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 G 200. 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...

  • Page 7: 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 8 SAFETY INFORMATION THE G 200 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 9 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 10 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 11: 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 12: 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 Rear Foot Spark Plug Fuel On/Off Valve...

  • Page 13: Control Layout

    CONTROL LAYOUT Main Switch Speed Limiter Engine Start / Stop Switch Instrument Cluster Front Brake Lever Throttle Lever Start Button Ignition ON Ignition OFF 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.

  • Page 14: Main Switch

    HEADLIGHTS This G 200 ATV is equipped with High, Low, Strobe 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 15: 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. Headlight "ON" when shown. 2. Fuel level Inductor. 3.

  • Page 16: Speed Limiter

    SPEED LIMITER The G 200 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 17: 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 axle parking brake. To set parking brake: Apply front brake lever and then slide parking brake lever towers the handlebar, release front brake lever. To release parking brake: Apply front brake lever, the spring loaded parking brake lever will return to off position, release front brake lever.

  • Page 18: 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 19: 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 20: 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 21: 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 22: Battery

    Positive (+) cable is red in color. Negative(-) Cable is in black in color. This G 200 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 23: Battery Charging & Changing Fuse

    1. Main Fuse (10 Amp) 4. Reinstall seat. 2. Fuse Holder If a fuse continues to blow, contact your local Tao Motor dealer to check for 3. Spare Fuse 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 24: 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 25 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 26: Front & Rear Brakes

    BRAKE LEVER Check for too much free play in brake levers. If there is too much free play or if the brake levers require adjusting, have your Tao Motor dealer check the brake levers and brakes and have the brakes adjusted to the driver.

  • Page 27: Tire Wear Limits And Chassis Fasteners

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

  • Page 28: 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 29: 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 30: 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 31: 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 32: Throttle Cable & Throttle Cable Adjustment

    THROTTL CABLE Throttle cable inspection Inspect throttle cable for excessive wear, kinking or fraying . Ensure cable moves freely. NOTE The throttle cable must be replaced if any signs of wear , fraying or other damages found. THROTTLLE CABLE ADJUSTMENT Check throttle lever free-play, adjust if necessary.

  • Page 33: Hydraulic Brake System

    Use extra caution. Brake fluid replacement or brake system maintenance and repairs should be performed by an authorized Tao Motor dealer. NOTICE The brakes can be very hot after prolong use of the vehicle and can cause burns. Wait for the brakes to cool down.
  • Page 34 Have your local Tao Motor dealer inspect brakes system for wear or damage. NOTICE Always contact your local Tao Motor Dealer if you have any concerns after inspecting your brake system for wear or damage. Brake Fluid Level Rear Brake Always check for the proper brake fluid reservoir level as follows;...

  • Page 35: Rear Foot Brake Lever Hight Adjustment

    REAR FOOT BRAKE LEVER HEIGHT ADJUSTMENT It is recommended that brake service is conducted by a certified Tao Motor technician. See your Tao Motor Dealer for details. Operating the vehicle with improperly adjusted brakes can lead to a loss in braking stopping ability and can cause an accident.

  • Page 36: 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 37: 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 38: Adjusting Suspension Spring Preload

    ADJUSTING SUSPENSION SPRING PRELOAD The G 200 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 39: Getting To Know Your Atv

    GETTING TO KNOW YOUR ATV...
  • Page 40 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 41 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 42 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 43 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 44 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 45 Do not ride in areas posted “no trespassing. ” Do not ride on private property without getting permission. OPERATING YOUR G 200 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 46 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 47 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 fl t 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 48 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 49 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 50: 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 51: 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 52 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 53 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 54 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 55  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 56 PERIODIC MAINTENANCE RECORD MAINTENANCE SERVICING DATE SERVICING DEALER OR PERSON REMARK INTERVAL PERFORMED...

  • Page 57: 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 58 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 59: 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 60: 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 61 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. Air filter replacement 1.

  • Page 62: 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 63: 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 64 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 65 NOTICE The drive chain slack is adjusted by the rota-tion 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 66: Lubricating Pivoting Joints

    Pivot joints must be lubricated at intervals specified in the periodic maintenance and lubrication chart. Hight quality heavy duty grease must be used for long life of components. Extreme pressure and water resistant grease is recommended. This G 200 ATV has multipliable grease nipples located in front and rear of the ATV. List of grease points :...

  • Page 67: Checking Wheel Hub Bearings

    Tao Motor dealer. DIRECTIONAL TIRES The G 200 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 " W " shape. The " W " shape must be pointing forward on each tire.

  • Page 68: 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 69: 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 70 2. CVT Bet Cover 3. CVT Belt Cover Mounting Bolts (8mm) 4. CVT Clutch Assembly 5. CVT Clutch Shaft O-Ring Always use a certified Tao Motor parts. 6. CVT Belt CVT belt # 743-20-30 V-Belt 7. Variator Fan Pulley 8. Variator Fan Pulley Spacer 9.

  • Page 71: Cleaning Spark Arrester

    CLEANING SPARK ARRESTER Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. 1. Unscrew the three (4mm) allen bolts (#4) securing the muffler end cap to muffler by using a 4mm allen wrench. 2. Remove muffler end cap(#3) and spacer plate (#2) from muffler assembly. 3.
  • Page 72 WASHING VEHICLE We recommend the use of a garden hose to wash your G 200. 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 73: Vehicle Identification Location

    VEHICLE IDENIFICATION LOCATION The vehicle identification number is used to identify your ATV and may required 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 top left center of crank case .

  • Page 76: 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 77: 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 78 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 79 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 80 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 81 Find important product information and how-to videos on our website www.taomotor.com...

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