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    • TM15 TrailMaster Complete Assembly Manual

    Posted by Jason Merrell on 18th Jul 2025

    Person working on a TM15 dirt bike in a workshop.

    TM15 Trail Master Complete Assembly Manual

    A Step-by-Step Build Guide by GoPowerSports

    Pre-Assembly Preparation

    Tools Required:

    • Sockets: 8mm, 10mm, 13mm (deep), 14mm, 17mm
    • Allen Keys: 4mm, 5mm, 6mm, 8mm
    • Wrenches: 10mm, 14mm
    • Screwdrivers: Phillips head
    • Optional: Impact driver (for faster assembly)
    • Pliers: Needle-nose recommended

    What's Included in Your Hardware Box:

    • Kickstarter
    • Handlebar pad
    • Lower and upper handlebar mounts
    • Tank vent cap
    • Cable holder (front end)
    • Gear shifter
    • Both foot pegs (left and right)
    • Owner's manual
    • Various bolts, washers, and hardware

    Step 1: Initial Frame Preparation

    1.1 Remove Shipping Materials

    1. Cut all zip ties securing protective materials to the frame
    2. Remove all plastic coverings from frame components
    3. Remove foam padding and any remaining zip-tied protective materials
    4. Keep hardware organized - don't lose small parts during removal

    1.2 Release Bike from Shipping Frame

    1. Locate the front axle securing the bike to shipping frame
    2. Using 17mm socket and 14mm wrench, remove front axle bolt and nut
    3. Push bolt from one side, pull from the other to remove completely
    4. Save front axle spacers - note their positions for reassembly
    5. Carefully lift bike onto work stand - bike is now free from shipping frame

    Step 2: Front End Assembly

    2.1 Prepare Handlebars

    1. Cut zip ties securing handlebars to frame
    2. Remove plastic protective covering from handlebars
    3. Position handlebars on top of triple tree (let them hang temporarily)
    4. Remove zip tie from number plate and set aside

    2.2 Install Front Fender

    Hardware Needed: 3 x M6 bolts, 3 x washers (pre-installed on bike)

    1. Locate hardware - bolts and washers already installed in mounting points
    2. Position front fender against mounting points
    3. Install one washer and bolt per hole (3 total)
    4. Start all bolts by hand first - prevent cross-threading
    5. Tighten with 8mm socket - snug but don't over-tighten

    2.3 Install Number Plate

    Hardware Needed: Pre-installed bolts, 10mm wrench, 8mm socket

    1. Locate mounting hardware already installed in designated position
    2. Connect electrical plugs - number plate has 2 male plugs, fender has 2 female plugs
    3. Thread brake line through number plate opening
    4. Start bolts by hand (can be difficult - use deep socket if needed)
    5. Tighten with 10mm wrench and 8mm socket - moderate torque

    Step 3: Front Wheel Installation

    3.1 Prepare Brake Caliper

    1. Remove zip tie from brake caliper
    2. Remove protective plugs from inside brake caliper
    3. Use provided wedge tools to gently open brake caliper
      • CAUTION: Be gentle to avoid damaging brake pads
      • Only open enough to provide clearance for brake disc

    3.2 Install Front Wheel

    Hardware Needed: Front axle, 2 spacers (different sizes), axle bolt

    Important: The longer spacer goes on the brake side (right side)

    1. Remove both spacers from axle temporarily
    2. Install shorter spacer first (left side)
    3. Position wheel with brake disc on right side
    4. Align brake disc between brake pads - watch carefully during installation
    5. Insert axle through:
      • First spacer
      • Wheel hub
      • Second spacer (longer one on brake side)
    6. Thread axle bolt by hand to start
    7. Tighten with 17mm socket and 14mm wrench

    3.3 Test Front Brake System

    1. Check wheel spin - should rotate freely
    2. Pump brake lever several times to seat brake pads
    3. Verify brake function - wheel should stop when brake is applied

    Step 4: Cable Management and Handlebar Installation

    4.1 Install Cable Holder

    Hardware Needed: Cable holder, 6mm Allen key

    1. Loosen cable holder with 6mm Allen key
    2. Create slack in brake cable for proper routing
    3. Insert brake cable into cable holder
    4. Position for proper cable routing - no sharp bends
    5. Tighten cable holder to secure cable

    4.2 Install Lower Handlebar Mounts

    Hardware Needed: Lower handlebar clamps, 5mm Allen key

    1. Choose mounting holes - use foremost holes for comfort and clearance
    2. Position clamps evenly - they are asymmetrical but should match
    3. Start bolts by hand with 5mm Allen key
    4. Partially tighten - keep adjustable for handlebar installation
    5. Ensure clamps are parallel before final tightening

    4.3 Install Handlebars

    Hardware Needed: Upper handlebar clamps, 6mm and 8mm Allen keys

    1. Remove remaining plastic from handlebars
    2. Position handlebars in lower clamps
      • Note: Cables will resist - they are strong
    3. Install upper clamps - center them on handlebars
    4. Adjust handlebar angle to preference (slightly forward recommended)
    5. Ensure even positioning of upper clamps
    6. Tighten alternately with 6mm and 8mm Allen keys
      • Alternate between bolts for even pressure
      • IMPORTANT: Once tightened, position cannot be adjusted

    4.4 Adjust Controls

    1. Brake lever position: Use 4mm Allen key to adjust angle
    2. Throttle position: Check tightness and adjust if needed
    3. Verify all controls move freely and are secure

    Step 5: Battery Installation and Electrical

    5.1 Remove Seat

    Hardware Needed: 13mm deep socket

    1. Remove seat bolt with 13mm deep socket
    2. Keep washer with bolt for reassembly
    3. Lift seat off - note hook positions underneath

    5.2 Connect Battery

    Hardware Needed: Phillips head screwdriver, terminal hardware (taped to battery)

    Battery is pre-installed but not connected

    1. Locate terminal hardware taped to battery
    2. Install positive terminal:
      • Slide terminal connector onto positive post
      • Insert Phillips head bolt
      • Tighten until terminal nut rises
      • Ensure terminal is fully covered
    3. Install negative terminal using same process
    4. Cover both terminals with protective caps

    5.3 Test Electrical System

    1. Turn key to ON position
    2. Test starter - should engage properly
    3. Check all electrical functions
    4. Turn off before continuing

    5.4 Reinstall Seat

    1. Position seat over mounting points
    2. Hook front tabs under frame hooks
    3. Hook rear tab under bolt location
    4. Press down and slide to ensure proper seating
    5. Install seat bolt with washer using 13mm socket
    6. Verify secure mounting

    Step 6: Foot Controls Installation

    6.1 Install Foot Pegs (Both Sides)

    Hardware Needed: Cotter pins, springs, mounting pins

    Process is identical for both left and right foot pegs

    1. Remove cotter pin from mounting assembly
    2. Remove mounting pin and spring - keep track of orientation
    3. Note spring tab positions:
      • One tab rests against foot peg
      • Other tab rests against frame pipe
    4. Install foot peg on mounting point
    5. Position spring with tabs in correct locations
    6. Align all components and press together
    7. Reinstall mounting pin through all components
    8. Secure with cotter pin
    9. Test retraction - foot peg should fold up and return

    6.2 Install Kick Starter (Left Side)

    Hardware Needed: 10mm wrench

    1. Remove 10mm nut completely from kick starter shaft
    2. Position kick starter at proper angle
      • Recommended: Slight upward angle
      • Avoid: Contact with exhaust pipe
    3. Slide kick starter onto splined shaft
    4. Reinstall 10mm nut and tighten securely
    5. Test operation - should kick smoothly

    6.3 Install Gear Shifter (Right Side)

    Hardware Needed: 10mm wrench

    1. Remove 10mm bolt completely from shifter shaft
    2. Position gear shifter at preferred angle
      • Note: This is personal preference
      • Recommended: Slight downward angle for comfort
      • Remember: TM15 is all-upshift (no down gears)
    3. Align shifter groove with shaft groove
    4. Insert 10mm bolt through aligned grooves
    5. Tighten securely with 10mm wrench
    6. Test shifting action

    Step 7: Crankcase Ventilation System

    7.1 Connect Ventilation Hose

    Reference the yellow instruction card included with bike

    Components:

    • Crankcase ventilation nipple (on engine)
    • Ventilation hose with filter
    • Hose clamp
    1. Locate ventilation nipple on engine case
    2. Remove vacuum cap from nipple
    3. Remove zip tie from ventilation hose
    4. Connect hose to nipple - use needle-nose pliers if needed
    5. Position hose clamp over connection
    6. Tighten hose clamp securely
    7. Route hose to avoid kinks - proper breathing is essential

    Step 8: Rear Suspension Installation

    8.1 Install Rear Shock

    Hardware Needed: 14mm socket, 14mm open-end wrench

    Shock comes uninstalled for shipping

    1. Locate shock mounting points on swing arm and frame
    2. Position shock between mounting points
    3. Use legs to hold components in alignment
    4. Insert mounting bolt through swing arm and shock
    5. Start nut by hand on opposite side
    6. Tighten with 14mm socket and wrench - moderate torque
    7. Check upper mounting point - ensure it's secure
    8. Test suspension action

    Step 9: Final Assembly and Accessories

    9.1 Install Handlebar Pad

    Hardware Needed: Handlebar pad with velcro straps

    1. Position pad on top of handlebars
    2. Wrap velcro straps around handlebars
    3. Secure underneath handlebar for safety
    4. Ensure pad won't slip during riding

    9.2 Install Tank Vent

    Hardware Needed: Tank vent cap

    1. Locate vent nipple on fuel cap
    2. Slide tank vent over nipple
    3. Ensure secure fit - should not come off easily

    9.3 Optional Cable Management

    Hardware Needed: Additional cable holder (if needed)

    1. Inspect cable routing throughout bike
    2. Install additional cable holder if cables need securing
    3. Recommended location: Front area for brake cable management

    Step 10: Pre-Ride Inspection and Testing

    10.1 Fluid Level Checks

    1. Check engine oil level - bikes come pre-filled but verify
    2. Add fuel to tank for test ride
    3. Check brake fluid if equipped with hydraulic brakes

    10.2 Final Safety Check

    • All bolts properly tightened
    • Wheels spin freely
    • Brakes function properly
    • Throttle operates smoothly
    • All electrical connections secure
    • No loose cables or hoses
    • Foot pegs retract and return properly
    • Gear shifter operates correctly
    • Kick starter functions smoothly

    10.3 Test Ride

    1. Start engine and let warm up briefly
    2. Test all controls while stationary
    3. Take short test ride in safe area
    4. Verify all systems work properly
    5. Check for any unusual noises or vibrations

    Troubleshooting Common Issues

    Front Wheel Won't Install Properly

    • Check spacer orientation - longer spacer goes on brake side
    • Ensure brake disc is properly seated between brake pads
    • Verify axle is fully inserted through all components

    Handlebars Feel Loose

    • Check lower clamp tightness - must be secure before installing handlebars
    • Verify upper clamps are evenly tightened
    • Ensure proper torque on all handlebar bolts

    Electrical Issues

    • Verify battery connections are tight and clean
    • Check terminal covers are properly installed
    • Ensure all plugs are fully connected

    Poor Shifting

    • Check gear shifter alignment - groove must align with shaft groove
    • Verify proper angle - too high or low affects operation
    • Ensure bolt is fully tightened

    Maintenance Reminders

    Break-In Period

    • First 5 hours: Check all bolts for tightness
    • First oil change: Follow manufacturer's recommendations
    • Regular inspections: Check cable routing and connections

    Ongoing Maintenance

    • Regular cleaning of air filter
    • Periodic oil changes per manual specifications
    • Chain maintenance if equipped
    • Brake inspection and adjustment as needed

    Contact Information

    For additional support:

    • Website: www.gopowersports.com
    • Parts and manuals available in parts breakdown section
    • Technical support available through website

    Congratulations on completing your TM15 Trail Master assembly!

    This manual covers the complete assembly process as demonstrated in the GoPowerSports video. Always refer to the official owner's manual for specific torque specifications and maintenance schedules.