Coleman Powersports AT125EX User manual

AT125EX
ASSEMBLY INSTRUCTIONS
PLEASE NOTE THAT THIS IS NOT THE OWNER’S MANUAL BUT THE
ASSEMBLY INSTRUCTIONS ONLY.
BEFORE OPERATING THIS ATV, MAKE SURE THE OPERATOR HAS
READ AND UNDERSTANDS THE OWNER’S MANUAL, WARNING
LABELS AND IS FAMILIAR WITH ALL OF THE ATV CONTROLS.
FOR QUESTIONS REGARDING THEASSEMBLY OF THISATV PLEASE
CALL COLEMAN POWERSPORTS 888-405-8725
POWERSPORTS
031218

PARTS
Tool Kit
Owner’s
Manual
1
Battery Changer
Battery Strap (2)
Battery (1)
Battery Assembly
Rear Carrier
Rear Carrier Assembly
Front Bumper M8 x 20 Bolts M8 Lock nuts
Front Bumper Assembly
M10 Castle nuts M3 cotter pins M10 Lock Washers
Tie Rod Assembly
Fuel Vent
tube
M8x25 Socket head bolts

PARTS
Handlebar
Protectors
Handlebar clamp brackets
2
Rim Covers (4)
Front tire (2) Back tire (2)
Hub Caps M8 Lock Nut (8)
M4 Cotter pins M16 Castle nuts
Large M16 Washers
Tire Assembly
Top Console Bracket
M10 x 30 bolts
M10 Washers
M10 Lock Washers
M10 Lock nuts
Handlebar Assembly
Hand protector
mounting supports
M16 Lock Washer
M6x15 Allen head cap bolts (12)
M6 Lock Nuts (12)
M6x16
(2)
M8x16 Bolts (10)
M8 nuts
(10)

HANDLEBAR ASSEMBLY
1. Attach bottom
clamp brackets to
steering assembly
bracket using M10
x 30 bolts, M10
lock washers and
M10 lock nuts
3
Top Console
Bracket
Handlebar clamp
bracket
Steering
assembly
bracket
Handlebar clamp brackets Top Console Bracket
M10 x 30 bolts M10 Washers
M10 Lock Washers
M10 Lock nuts
Handlebar Top Console
Bracket
M10 x 30
bolt
M6x16 (2)

4
ODOMETER ASSEMBLY
1. Install the odometer
assembly with 2 M6x16
bolts on the top console
bracket
Speed-odometer
Console
M6x16 bolt
Top Console Bracket

5
HANDLEBAR ASSEMBLY
Right/Left Brake Lever Install
2. Install the right
and left brake
assembles using the
M6x20 bolts
M6x20
bolts
Black
and
green
wires
1. Plug the black
and green wires
into the right
and left brake
assembles

6
HAND PROTECTOR ASSEMBLY
Hand
protector
mounting
support
M8x16
Bolt
Hand protector mounting supports Handlebar Protectors
M8x16 Bolts (10)
M8x16
Bolt
Hand
protector
mounting
support
M8 nuts
(10)
1. Attach hand protectors by
placing the mounting
supports around the
handlebar as shown in the
last photo. Secure with
M8x16 bolt and nut five
times per handle bar
Handlebar
Hand
protector

7
TIE ROD INSTALLATION
M10 Castle nuts M3 cotter pins
M10 Washers
1. Attach tie rod to
front spindle
assembly on both
sides of ATV
2. Secure tie rod
using M10 washer
and M10 castle nut.
Tighten snug
3. Insert cotter pin
then bend over
ends pin will not
back out
Front spindle
assembly
Tie Rod
M10 Washer
Castle
Nut
Cotter
Pin

8
RIM INSTALL
M6x15 Allen head cap
bolts (12)
M6 Lock Nuts (12)
Front tire (2)
Back tire (2)
Rim Covers (4)
1. Place rim cover on tire,
matching up the holes
of the rim to the holes
of the tire
2. Screw in allen head cap
bolt through every fourth
hole.
Three nuts and bolt per tire.
M6 Lock Nuts
M6x15 Allen head
cap bolt

9
REAR WHEEL INSTALL
M16 Castle nuts
M4 Cotter pins
Large M16 Washers
1. Slide rear wheels on
rear axle assembly. Make
sure valve stem on tire
faces out.
2. Attach wheel with large
M16 Washer and M16 Lock
Washer
3. Attach Castle nut.
Tighten snug
Hub caps
NOTE: Fill tires with 4 PSI of air before
assembly.
Back tires
Rim Covers (2)
M16 Lock Washer
M16
Washer
M16 Lock
Washer
M16
Castle nuts

10
4. Install cotter pin and bend
over ends.
5. Install hub caps
REAR WHEEL INSTALL

11
FRONT WHEEL INSTALL
M8 Lock nuts
NOTE: Fill tires with 4 PSI of air before assembly.
Hub caps
Front tires
1. Install front
wheels. Make sure
valve stem faces
out.
2. Attach wheel
with M8 washer,
followed by M8 lock
nut. Repeat this
four times for each
front wheel.
Torque nuts
20 ft.lbs.(27 Nm)
M8
washer
M8
lock
nut
M8 Washer
3. Install hub cap

12
M8x20 bolts
M8 x 20 Bolts
M8 Lock nuts
Front Bumper
FRONT BUMPER INSTALL
1. Install front
bumper with
M8 x 20 bolts
and M8 lock
nuts.
M8x20 bolt
M8x20 bolts

13
REAR CARRIER INSTALL
Rear Carrier
Rear of the Unit
M8x25 socket
Rear Carrier
Carrier bracket
M8x25 bolt
1. Fix the rear carrier on
the carrier bracket with
bolt M8x25 and lock nut
M8
head bolts

14
BATTERY INSTALLATION
!WARNING
Battery preparation
12
4
3
3
Step 1
Step 2
Step 3
Step 4
Battery electrolyte (sulfuric acid) is poisonous, electrolyte can cause
severe burns if contacts skin. Avoid contact with skin, eyes or clothing.
If sulfuric acid is swallowed or splashed in the eyes, treat immediately.
Sulfuric acid in the eyes can cause blindness. Serious internal injuries or
death can result if swallowed.
ANTIDOTES: For acid on the skin, flush with water.
If acid is swallowed, drink large quantities of milk or water, followed by
milk of magnesia, vegetable oil or beaten eggs. Do not induce vomiting.
Call a poison control center or doctor immediately. For acid in the eyes,
flush for several minutes with water and seek immediate medical
attention.
Make sure work area is well ventilated.
Always wear goggles or face shield when working with the battery.
Always wear protective plastic gloves to protect hands.
Always wear a protective smock to protect clothing.
1. Remove battery (1) and electrolyte
bottle (2) from the box. Remove
battery cap strip (3) from electrolyte
bottle
2. Pull tape strip (4) off top of battery
and discard.
3. Turn electrolyte bottle over and place
on top of battery pushing firmly until
the battery nozzle tips puncture the
film over the spouts. Allow all
electrolyte to flow into the battery.
Note: Dispose of electrolyte bottle
properly
4. Install battery cap strip (3). Let battery
sit for 1/2 hour before charging.
Note: The battery is a sealed type
battery once the cap is in place. There
is no maintenance to fluid level. Never
re-open once caps are in place.

15
Charging the battery
Note: Do not turn the charger on
before attaching the charger clips to
the battery terminals.
The standard charging rate is 0.7A x
5 -10 hours. Maximum charging rate
is 3A x 1hour
1. Attach the Charger to the battery
terminals. Red clip to the POS +
side of the battery. Black clip to the
NEG - side of the battery.
2. Plug in the charger and turn on
making sure it is set at the correct
settings.
3. Once battery is charged, unplug
the charger before disconnecting the
POS + and NEG- clips
!WARNING
Installing the battery
1. Install battery in battery bracket
located underneath the seat of the
ATV.
2. Attach the red wire to the POS +
side of the battery with screws pro-
vided. Attach the black wire to the
NEG - side of the battery with screws
provided. Make sure the connections
are tight.
3. Install the rubber straps to hold
the battery in place.
CAUTION
Reversing the battery lead wires
can damage the charging
system and the battery.
The red lead (clip) must go to
the POS (+) side of the battery.
The black lead (clip) must go to
the NEG (-) side of the battery.
Rubber strap
Wire attachment points
If not performed the correct way,
charging the battery could be
hazardous.
While charging battery, keep away
from sparks and open flames. The
battery gives off explosive gases.
Always connect the charger to the
battery before turning the charger on,
this prevent sparks when attaching
the terminal clips to the battery.
Always unplug the charger before
disconnecting the battery from the
charger, this will prevent sparks when
removing the terminal clips
Battery
Changer

! WARNING
THIS IS NOT THE OWNER’S MANUAL, THIS IS THE
ASSEMBLY INSTRUCTIONS ONLY.
THE OWNER’S MANUAL, INCLUDED WITH THIS ATV,
HAS ALL INFORMATION REQUIRED FOR SAFETY,
ENGINE PREPARATION, PRE-RIDE INSPECTION AND
STARTING INSTRUCTIONS.
NEVER START THE ENGINE WITHOUT READING AND
FULLY UNDERSTANDING THE OWNER’S MANUAL AND
ALL WARNINGS.
IF YOU DID NOT GET AN OWNER’S MANUAL WITH THIS
ATV, PLEASE CALL COLEMAN POWERSPORTS
AT 888-405-8725.