Wondering how to assemble your TaoTao TBR7? You’ve found the right place. As this is the most frequented page and sometimes the only page visited, I’ll make an effort to continue updating as I get feedback from those using it to assemble their bikes. These assembly steps also apply to the TBR7-D as the only real difference is the headlight, but it mounts the same way.
It’s really not that bad, let me know if I missed anything. Also, if this is your first TBR7, go ahead and get the Starter Package so you are good to go out of the gate instead of riding the bike when it’s dying for more fuel.
Tools needed (I’ll probably miss something):
Blade of some type (just for unpacking and zipties)
Wrenches (8mm, 10mm, 12mm, 13mm, 14mm, 17mm, 19mm)
Socket wrench (with same measurements as above, maybe not the 19mm).
Preferable but not mandatory – 1 3/16″ or 30mm socket to tighten steering nut and 18mm(or 11/16″) deep well for swapping spark plug
Long extension for socket wrench (will save your knuckles)
Allen key for fairing bolts (?size – 5mm?)
Phillips head screw driver
Blade screwdriver (small)
Optional: Hacksaw/dremel (for jetting carb)
Optional: Spring puller (I always just use a screw driver)
Bike lift / milk crate / floor jack / strong friend – I suggest the bike stand from JFG on Amazon
Needle nose pliers to bend cotter pins
Nice to have: Torque wrench and reference the torque specs over on the Riders Manual
Or you can just pick up a nice tool set and grab only the things not included.. but this should get you through almost everything:
If you really wanna do this right, aside from basically assembling the bike, you’ll need to:
- Change the oil (Not an option, it does not ship with anything that will lubricate the engine properly) – ( Upgrades – Starter Package )
- Adjust the forks down ( https://youtu.be/EB-DMOqmnmE )
- Change the spark plug ( Upgrades – Electrical)
- Change the fork oil ( Upgrades – Suspension )
- Adjust the valves ( Upgrades – Engine )
- Tension the chain properly ( https://www.youtube.com/watch?v=WwPo3v0h-qo )
- Adjust your clutch, rear brake, front brakes ( https://www.youtube.com/watch?v=8MW4h1Rk9AA )
- -Why do the work when someone else has, here’s some great Rear Brake install documentation!
- Top off the battery with a proper battery charger
Parts:
1. Mirrors
2. Zip ties for front brake & Speedometer
3.Straps for cables to forks
4. Trash
5. Hand Guard hardware (Guide for these comes with bike)
6. Reflectors (Also trash)
7. Handlebar pad
8. Rear luggage rack
9. Rear brake sensor spring
10. Rear brake spring
11. Kick stand spring
12. Front turn signals (and headlight mount attached)
13. Shifter
14. Rear brake
15. Front wheel spacer (opposite side of speedo when installing front wheel, but comes packaged on rear axle)
16. Rear axle
17. Risers for handlebars (bolts installed)
18. Kick stand
19. Fairing spreader
20. Bolt for fairing spreader (also use #23)
21. Rear luggage rack bolts (8mm) (use with #27)
22. Front wheel cover bolts (10mm)
23. Rubber grommet for fairing spreader (works with #20)
24. Bar end bolts (for handguard installation)
25. Nuts for instrument cluster mounting (use with 30)
26. Grommets for fairings
27. Grommets for Rear luggage rack (use with #21)
28. Exhaust crush gasket (flat side towards engine)
29. Acorn nuts for Exhaust
30. Washers for headlight install and instrument cluster install
31. Fender washers (mixed opinions on proper use of these)
32. Allen head bolts for headlight / fairing spreader
33. Fender washers (mixed opinions on proper use of these)
34. Washers for under the luggage rack
35. Allen head bolts for tank fairings (shorter so they don’t pierce the tank)
36. Washer for rear brake lever install
37. Cotter pin for rear brake lever install
38. Cap for trip tree hole
Below are photos for guidance. This will be a living document and I will continue to add as people find anything that is missing!
When Unpacking, Don’t forget to check your bike for damage. This bike had a hole but no damage to the actual bike (other than a missing rear brake clevis. If you have the same issue, check here)
This bike was missing the rear brake clevis, assuming yours shows up, follow this great walk through:
Rear Brake install documentation!
If you are also missing your rear brake clevis, pick up Connor’s upgraded clevis Here
