Coleman CT200U-CL User manual

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.
!
For questions about these Assembly Instructions, call Coleman
Powersports toll free 888-405-8725
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.
CT200U-CL
060718

REMOVAL FROM CRATE
1
Owner’s/Operator’s Manual
Tool Kit
Zip Ties
Front Fender
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
14mm Lock Nut
14mm Washers
14mm Axle Bolt
Clutch Cover
M8Rubber
M8Nuts
M8 x 50 Bolts Light
GrommetsLight
Headlight
Front fender and headlight
bracket
Headlight bracket

FRONT FORK INSTALLATION
2
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
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
1. Tighten Lock nut snug,
Note: Do not over
tighten Lock nut. Over
tightening will cause
the steering to bind .

27
HEADLIGHT BRACKET ASSEMBLY
M8Rubber
M8Nuts
M8 x 50 Bolts Light
GrommetsLight
Headlight
Rubber Grommets
between light
and light bracket
M8 Nuts
Note: The rubber gromets fit
between the light and the light
bracket Rubber Grommets
1. Install front light onto bracket
using M8 X 50 bolts, M8 rubber
grommets and M8 nuts.

3
Note: Small portion of fender faces
foreward
8mm x 20mm Bolts Large 8mm
Washers
8mm Nuts
8mm x 20mm Bolts
2. Attach front fender and bottom
of light bracket with 8mm x 20mm
bolts, large M8 washers and M8
nuts.
Large M8 Washers
M8 Nuts
8mm x 20mm Bolts
and M8 Nuts
1. Attach top of light bracket and
to top Steering Column Assembly
using 8mm x 20mm bolts, and M8
nuts
2. Plug light wires into wires
from engine assembly
FRONT HEADLIGHT AND FENDER INSTALLATION

4
FRONT WHEEL INSTALLATION
1. Orient the front tire so the arrow
on the tire faces forward.
2. Insert Axle bolt with the 14mm
washers between the forks and
wheel assembly on each side.
14mm Axle Bolt
14mm Washer
14mm Lock Nut
Arrow faces forward
Large 8mm Washers
14mm Axle bolt 1ea.
14mm washers 2ea.
14mm lock nut 1ea.
3. Install 14mm lock nut
4. TightenLocknutsnug,
Note: Do not over
tighten Lock nut. Over
tightening can damage
wheel bearings.

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
3. Install clutch cover over the 4
bracket tabs provided on the clutch
assembly. Make sure the clutch
cover is attached securely.
Clutch Cover
Bracket Tabs

OIL AND FUEL
Engine Oil
Mini bike may have oil in it when
shipped from the factory.
However, it is a good idea to
drain this oil and replace with
new SAE 10W-30 Motor Oil.
1
Changing the engine oil
1. Remove the oil ll plug (1)
2. Remove the drain bolt (2) located on
the bottom of the engine.
3. Allow the oil to drain in an appropriate
container. Note: Dispose of oil at an oil
recycle center.
4. Install the drain plug and ll 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.
5. Re- install ll cap, Start engine and
allow to run for a few minutes, Re-check
oil level and ll accordingly.
1
2
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

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
Front tires: 10psi
Rear tires: 10psi
TIRE PRESSURE
7
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 (2) on the rear axle
assembly.
2. Adjust chain tension by turning the
tension nuts (3) (Note: Tension nuts are
located on both sides of the mini bike.)
Clockwise will tighten the chain. Counter
clockwise will loosen the chain.
3. Once the chain is at the correct tension
re-tighten axle bolt (2).
4. Re-check chain tension.
2
3
1/2 - 3/4 in.
(15-20mm) 1

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
To adjust brakes, loosen the rear
axle bolt (4)
Locate the adjustment nut (5)
located on the rear brake drum
assembly.
To adjust brakes, turn the
adjusting nut (5) clockwise to
increase braking, counter clockwise
to decrease braking.
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
• Cotter Pins on axle
• All nuts and bolts tight
• No rattles from engine
or frame while running

11
STARTING ENGINE
STARTING ENGINE
To start the engine
1. Place the fuel valve (1) to the “ON”
(right) position
2.. If engine is cold, place the choke lever
(2) to the “ON” (left) position.
3. Place the ON/OFF switch (3), located on
the handlebars, to the (on)position.
4. Pull the starter recoil cord to start the
engine.
5. Once engine has warmed up for a few
minutes, place the choke lever (2)
back to the “OFF” (right) 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 severe 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

PHONE: Toll Free 888-405-8725
colemanpowered.com
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. Universtiy Dr.
Tempe, AZ. 85281