Coleman CT200U-EX V 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
THIS MINI BIKE WAS SHIPPED
WITHOUT ENGINE OIL. ALWAYS
FILL MINI BIKE WITH THE
CORRECT AMOUNT AND GRADE
OF ENGINE OIL AS LISTED IN
THE OWNER'S MANUAL.
080620
CT200U-EX V

REMOVAL FROM CRATE
Tool Kit
Zip Ties
8mm Large Washers
Front Fork
Assembly
Front Fork
Suspension
Front wheel
M14 Axle Bolt
Assembly
M10 Large Washers
M10 Small
Washers
M10 Lock Nut
M10 Steering Bolt
M14 Washers M14 Lock Nut
Rear Fender
Clamps M8 x 32 bolts
Rear Fender
M8 x 15 Bolts
M8 x 20 BoltsM8 Nuts
Front Fender
with light Bracket
Owner’s/Operator’s Manual Handle Bar Hardware
Grommets Front Wheel Assembly
Front Fender
Assembly
Light Assembly
M8Rubber
M8Nuts
Light
M8 x 50 Bolts
1

FRONT FORK INSTALLATION
Large Washer
Steering
Bolt
Top
Bracket
Small
Washer
Large Washer
Lock Nut Tighten
Bolt
1. Install front Fork Assembly by
inserting the M10 steering bolt
through the assembly in the
following order: Large washer,
Top bracket, Small Washer,
Steering Neck, Small washer,
Bottom bracket, Large Large
Washer, Lock Nut
M10 Steering Bolt
M10 Large
Washers
M10 Small
Washers
M10 Lock Nut
Steering Neck
Bottom Bracket
2. Tighten Lock nut
2

M8bolts
1. Attach front fender with the 2
M8 x 15mm bolts
Torque bolts 15 ft/lbs.
FRONT FENDER INSTALLATION
M8 x15 Bolts
Fork Bolts
3. Tighten fork bolts on both
sides of assembly
Torque for bolts 15 Ft/Lbs.
3

Bottom View
M8 Nuts
M8 x 20mm Bolts
Large M8 Washers
M8 Nuts
Large M8
Washers
Torquebolts 15ft/lbs.
REAR FENDER INSTALLATION
M8 x 20 Bolts
1. Attach Rear fender with M8 x
20 bolts, large M8 washers and
M8 nuts.
4

HANDLEBAR ASSEMBLY
1. Lift up handle bars and center
on fork assembly.
While installing handlebars make sure
brake cables, throttle cable and on/off
switch wire are not kinked or pinched.
CAUTION:
2. Attach handlebars using clamps
and M8 x 32 Bolts
Clamps M8 x 32 bolts
Handlebar Hardware
Torque bolts 15 ft/lbs.
M8 x 32 Bolts Clamps
5

1. Orient the front tire so the arrow
on the tire faces forward.
Arrow faces forward
Large 8mm Washers
M14 Axle Bolt
M14 Lock Nut
M14 Washer
M14 Axle bolt 1ea.
M14 washers 2ea.
M14 lock nut 1ea.
3. Install M14 lock nut
and tighten.
2. Insert Axle bolt with the M14
washers between the forks and wheel
on each side.
FRONT WHEEL INSTALLATION
6

M8Nuts
M8Rubber
Grommets
LIGHT INSTALLATION
1. Install front light onto bracket
using M8 X 50 bolts, M8 rubber
grommets and M8 nuts.
Rubber Grommets
between light
and light bracket
Torque Bolts 12ft/lbs
Note: The rubber gromets fit
between the light and the light
bracket
M8 Nuts
M8 x 50 Bolts
2. Plug light wires into wires
from engine assembly
M8 x 50 Bolts
7

TO IDLE WHEN RELEASED.
FREE MOVEMENT AND SNAP BACK
THROTTLE CABLE SHOULD HAVE
BEFORE STARTING ENGINE, THE
ALWAYS CHECK THROTTLE CABLE
! WARNING
SECURE WIRES AND CABLES
INSTALL CLUTCH COVER
2. Secure wires and cables to frame
using the Zip ties provided.
Zip Ties
Zip Ties
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.
!WARNING
8

OIL AND FUEL
Engine Oil
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.
Fill level
Mini bike is shipped without
engine oil, fill with
SAE 10W-30 Motor Oil.
Refer to owner's manual for
correct amount and grade of
engine oil.
Caution: Do not over or under ll
with engine oil
9

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
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.
1/2 - 3/4 in.
(15-20mm) 1
2
3
10

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
4
5
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.
11

THROTTLE ADJUSTMENT
Idle speed adjustment
The idle speed should be set at 1700 ±
150 RPMs
Note: A service center can perform this
adjustment . A diagnostic tachometer is
required for this adjustment.
To adjust the idle speed:
1. Locate the idle adjustment screw (1)
located on the carburetor.
2. Allow the engine to warm up
approximately 10 minutes
3. With the engine running, turn the idle
adjustment screw in or out at small
increments until the correct idle is
achieved.
1
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 .
12

THROTTLE ADJUSTMENT
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
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
• All nuts and bolts tight
• No rattles from engine
or frame while running
Brakes • Proper brake lever
play
13

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
14

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. University Dr.Tempe,
AZ. 85281
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