Coleman CT100U Installation instructions

WARNING
Never attempt to start this Mini Bike without reading and
understanding the Owner’s/Operator’s manual. The Owner’s/
Operator’s manual provides information on safety, parts,
functions, pre-ride inspection, starting and maintenance.
!
ASSEMBLY/PRE-RIDE INSPECTION
INSTRUCTIONS
CAUTION
This mini bike was
shipped without engine
oil. Always fill with with
the correct amount and
grade of engine oil as
listed in the owner's
manual.
CT100U
For questions about these Assembly Instructions, call Coleman
Powersports toll free 888-405-8725
020218

REMOVAL FROM CRATE
1
Owner’s/Operator’s Manual
Tool Kit
Zip Ties
Front Fender
Assembly
Front Fork
Assembly
Hardware
10mm Large Washers
10mm Lock Nut
10mm Small
Washer
10mm Steering Bolt
8mm Large Washers
8mm Nuts
8mm x 20mm Bolts
Wheel Assembly
Front wheel
Clutch Cover
12mm Washers 12mm Lock Nut
Front Fender
12mm Axle Bolt
8mm x 20mm Bolts

1. Install front Fork Assembly by
inserting the 10mm steering bolt
through the assembly in the
following order:
Top bracket, Small 10mm
Washer, Steering Neck, Large
10mm Washer, Bottom Bracket,
Large 10mm Washer, Lock Nut
FRONT FORK INSTALLATION
2
Large Washer
Small Washer Steering Bolt
Large Washer
Lock Nut
10mm Steering Bolt
10mm Large Washers 10mm Small Washer
10mm Lock Nut
Top Bracket
Steering Neck
Bottom Bracket
2. Tighten nut

3
Note: Small portion of fender faces
foreward
Large 8mm Washers
8mm Nuts
8mm x 20mm Bolts
8mm x 20mm Bolts Large 8mm
Washers
8mm Nuts
FRONT FENDER INSTALLATION
1. Attach front fender with 8mm x
20mm bolts, large 8mm washers
and 8mm nuts.

4
FRONT WHEEL INSTALLATION
1. Orient the front tire so the arrow
on the tire faces forward.
Arrow faces forward
Large 8mm Washers
12mm Lock Nut
12mm Washer 12mm Axle Bolt
12mm lock nut 1ea.
12mm washers 2ea.
12mm Axle bolt 1ea.
2. Insert Axle bolt with the 12mm
washers between the forks and
wheel assembly on each side.
3. Install 12mm lock nut
and tighten.

SECURE WIRES AND CABLES
INSTALL CLUTCH COVER
1. Make sure the On/Off Switch
wire, Throttle cable and Brake
cable are not kinked and have free
movement when the handle bars
are turned from left to right.
2. Secure wires and cables to frame
using the Zip ties provided.
5
Zip Ties
Zip Ties
Clutch Cover
3. Install clutch cover over the 4
bracket tabs provided on the clutch
assembly. Make sure the clutch
cover is attached securely.

OIL AND FUEL
Engine Oil
1
1. Remove the oil ll plug (1)
Fuel level
Filler neck
FUEL
Never use leaded gasoline in this product.
It could affect the engine’s emissions and
damage the engine.
Mini Bike requires clean unleaded regular
gasoline with a minimum octane rating of
86 or higher.
Fill with gasoline up to the bottom of the
ller neck.
6
Caution: Do not over or under ll
with Motor Oil
Fill level
2. fill with SAE 10W-30 motor oil. This
mini bike takes .63qt. (.6L) of engine oil.
Oil should be up to the brim of the ll hole.
3. Re- install ll cap, Start engine and
allow to run for a few minutes, Re-check
oil level and ll accordingly.
Filling with Oil
Mini bike DOES NOT have oil in
crankcase when shipped from
the factory.
NEVER ATTEMPT to start the
engine without engine oil.

Tires
1. Check tire pressure. Incorrect tire
pressure can affect the handling,
rider comfort, steering, tire life and
traction. Always check the tire pres-
sure before each ride.
TIRE PRESSURE
7
Tire pressure
Front tires: 5psi
Rear tires: 5psi
Chain tension
Check the tension of the chain , The
chain (1) tension should be
1/2 - 3/4 in. (15-20mm)
Chain tension (slack)
adjustment
1. Loosen bolt on chain tensioner
(2).
2. Move Tensioner right to tighten
chain or left to loosen chain.
3. If chain needs more tightening
after adjustment, loosen the 4 bolts
on the bottom of the engine plate
and move engine forward .
Note: Make sure chain is in line
with sprockets after adjustment
4. Re-check chain tension.
1/2 - 3/4 in.
(15-20mm)
1
2
3

8
Brake Lever Adjustment
The front left brake lever (1) should
have 2.0 - 4.0mm (0.08 - 0.16) of
free play.
To adjust brake lever free play:
1. Loosen the jam nut (2) on the
brake cable.
2. Turn the adjuster nut (3) until the
correct amount of free-play is
achieved.
3. Re tighten jam nut (2)
12
2.0 - 4.0mm
(0.08 - 0.16 in)
Brakes
3
BRAKE ADJUSTMENT
Brake Adjustment
The brake adjustment (4) is located
on the rear brake caliper assembly.
To adjust brakes, loosen nut (4) .
Increase or decrease the tension
of the brake cable by pulling cable
tighter or by allowing more slack.
4
5

THROTTLE ADJUSTMENT
9
Throttle Cable adjustment
The hand grip throttle free play (2) should
be .078 - .24 in (2-6 mm)
To adjust freeplay
1. Loosen jam nut (3)
2. Turn adjusting nut (4) to proper setting
3. Once throttle grip is at the proper
freeplay, re-tighten the jam nut (3).
2
3
4
.078 - .24 in
(2-6 mm)
It is important that the throttle grip have a
certain amount of free play .

THROTTLE ADJUSTMENT
10
Performing maintenance and
checks while the engine is running
could be hazardous.
You could be severely injured by
moving parts or hot surfaces.
Never perform maintenance or
check procedures while the engine
is running with the exception of
checking the engine stop switch or
throttle.
!WARNING
Failing to inspect and maintain the
Mini Bike could be hazardous.
Not following the pre-ride
inspection procedures could result
in loosing control of the Mini Bike
resulting in an accident or damage
to the Mini Bike
Always perform a Pre-ride inspec-
tion before each ride.
PRE-RIDE INSPECTION
!WARNING
Inspecting and checking the
condition of the Mini Bike before
each ride is important. Following
the pre-ride check list will help
insure there are no problems which
could result in injury or becoming
stranded. Make sure the Mini
Bike is in good operating condition
before each ride.
WHAT TO
CHECK
CHECK FOR
Steering • Smoothness
• No restriction of
movement
Brakes • Proper brake lever
play
Tires • Proper tire pressure
Fuel Tank • Enough fuel for the ride
• Fuel cap secure
• Hoses have no signs of
cracks or leaks
Throttle
grip
• Throttle grip snaps
back to idle when
released
• Operates freely
• Has correct free play
Engine
Stop
Switch
• Switch shuts off engine
when activated.
Engine
Oil
• Correct oil level
Drive
Chain
• Proper tension
• Lubricated
General
Condition
or frame while running
• Axle nuts tight
• All nuts and bolts tight
• No rattles from engine

11
STARTING ENGINE
STARTING ENGINE
To start the engine
1. Place the fuel valve (1) in the
“ON” (vertical) position.
2.. If engine is cold, place the choke
lever (2) in the “ON” (right position.
3. Place the ON/OFF switch (3),
located on the handlebars, in the
(on)position.
4. Pull the starter recoil cord (4) to
start the engine.
5. Once engine has warmed up for a
few minutes, place the choke lever
(2) back to the “OFF” (left) position.
1
2
Starting or running the Mini
Bike in an enclosed area such
as a garage or shed where
there is no ventilation is
hazardous
Inhaling exhaust fumes from
the Mini Bike can cause se-
vere injury or death
Never start or run the Mini
Bike in an inclosed
environment where there is
no ventilation. Always start
and run outdoors.
!WARNING
3
4

WARNING
Never attempt to start this Mini Bike without reading and
understanding the Owner’s/Operator’s manual. The Owner’s/
Operator’s manual provides information on safety, parts,
functions, pre-ride inspection, starting and maintenance.
!
1775 E. University Dr.
Tempe, AZ. 85281
PHONE: Toll Free 888-405-8725
colemanpowered.com