Coleman POWERSPORTS BK160 User manual

OWNER’S MANUAL
No one under the age of 16 should operate this go kart.
Always wear a helmet it could save your life!
READ THIS MANUAL CAREFULLY! Model:BK150
Provincial / Municipal governments have different regulations
pertaining to owning and operating an off-road vehicle,
learn the regulations in your area.
POWERSPORTS

To the Owner
Congratulations on your purchase of a Coleman Powersports Go Kart. This
Owner’s/Operator’s manual will provide you information regarding safe
operation, operational instructions, maintenance and care. Fully
understanding this manual and following all of the instructions herein will
provide the knowledge needed to have safe and enjoyable Go Kart
operation.
For questions regarding operation and maintenance of this Go Kart, please
call Coleman Powersports toll free 888-405-8725
Safety - Notice to parents
No one under the age of 16 should operate this Go Kart . Not all
children have the strength, size, skill, and judgment needed to
operate this vehicle safely.
THIS Go Kart IS NOT A TOY AND COULD BE HAZARDOUS TO
OPERATE. A Go Kart handles differently from other vehicles
including motorcycles and cars. A collision or rollover can occur
quickly, even during routine maneuvers such as turning, driving on
hills and over obstacles.
I
Reading the Owner’s/ Operator’s Manual
It is important this manual is read from cover to cover carefully by the Go
Kart owner and all operators. Parents should review the manual carefully
with their children. Never allow anyone to operate the Go Kart without first
reading and understanding the
Owner’s/Operator’s manual.
This Owner’s/ Operator’s manual should be a permanent part of the Go
Kart and should remain with the vehicle at all times. The manual should
also remain with the vehicle if sold.

To emphasize special important information in the manual, please note the following :
This is the alert symbol. The symbol means ATTENTION!, BECOME ALERT!,
YOUR SAFETY IS INVOLVED.
To emphasize important safety information, the word WARNING, with the alert symbol, has
special meaning.:
Indicates a potential hazard that could result in
SEVERE INJURY or DEATH to the operator, bystander
or person inspecting or repairing the Go Kart.
To emphasize important information, the word CAUTION has special meaning.:
Indicates special precautions that must be taken to
avoid damage to the Go Kart.
To emphasize important information, the word NOTE has special meaning.:
Indicates key information to make procedures easier
or clearer to understand.
Coleman Powersports is concerned about the environment and believes in conserving
and protecting all natural resources. For this reason , owners should recycle, trade in, or
dispose as appropriate, batteries, oil and tires.
!WARNING or CAUTION
The first part will identify a POTENTIAL HAZARD.
The second part will describe WHAT COULD HAPPEN if the warning or caution is
ignored.
!
!
WARNING
CAUTION:
NOTE:
This manual is based on the latest product information available at the time
of publication. Coleman Powersports has a policy of continually improving its products.
Due to improvements, or other changes, there may be some discrepancies. We reserve
the right to make product changes at any time, without notice and without incurring any
obligation to make the same or similar changes to vehicles previously built or sold.
II

Operating, servicing and
maintaining a passenger vehicle or
o-road vehicle can expose you to
chemicals including engine
exhaust , carbon monoxide,
phthalates, and lead, which are
known to the state of California to
cause cancer and birth defects or
other reproductive harm. To
minimize exposure, avoid
breathing exhaust, do not idle the
engine except as necessary, service
your vehicle in a well-ventilated
area and wear gloves or wash your
hands frequently when servicing
your vehicle. For more information
go to www.P65Warnings.ca.gov/-
passenger-vehicle
!WARNING
III

TABLE OF CONTENTS
COLEMAN POWERSPORTS WARRANTY..2
IMPORTANT SAFETY LABELS................4
LOCATION......................................4
LABELS. ........................................5
SAFETY..............................................7
DESCRIPTION AND PART LOCATIONS... 8
DESCRIPTION AND PART FUNCTIONS.. 9
IGNITION SWITCH/IGNITION KEY ..... 9
BRAKE PEDAL. ...............................9
GAS PEDAL. ...................................9
PARKING BRAKE LEVER. .................9
FORWARD AND REVERSE LEVER. .....9
HORN. ............................................. 9
LIGHT SWITCH/HIGH LOWBEAM.......9
FUEL TANK CAP ..............................10
OIL FILL PLUG/DIPSTICK.................10
SEAT ADJUSTMENT.........................11
FUEL AND OIL. ................................... 12
FUEL. ............................................12
ENGINE OIL. .................................. 12
BREAK IN .......................................... 13
PRE RIDE INSPECTION........................14
OPERATING THE GO KART ...................15
WARNINGS....................................15
HELMET, EYE PROTECTION AND
PROTECTIVE CLOTHING. ..................16
SEAT BELTS. .................................. 17
STARTING THE ENGINE....................18
STARTING OFF ................................19
OPERATING ON HILLS......................20
CLIMBING A HILL. ................20
DESCENDING A HILL. ...........20
TRAVERSING A HILL..............20
SKIDDING OR SLIDING. ...................21
OPERATING THROUGHWATER. .........22
OPERATING IN COLD WEATHER. .......23
LOAD GUIDELINES. .........................24
AFTER MARKET PARTS.....................24
MAINTENANCE. ..................................25
MAINTENANCE CHART.....................26
BATTERY INSTALLATION ...................27
AIR FILTER......................................29
SPARK PLUG. .................................30
ENGINE OIL.................................... 31
CHECKING. .........................31
CHANGING..........................31
CLEANING OIL FILTER...........32
TRANSMISSION OIL........................32
IDLE SPEED ADJUSTMENT ...............33
SHOCK ABSORBER ADJUSTMENT ....33
FUEL HOSE INSPECTION .................34
BRAKES. .......................................34
BRAKE FLUID INSPECTION....34

VALVE CLEARANCE. ........................35
FUSE REPLACEMENT ......................35
CHAIN ...........................................36
INSPECTION ...........................36
TENSION AND ADJUSTMENT.....36
CLEANING AND
LUBRICATION...36 TIRES. .............. 37
REPLACING. ...........................37
STORAGE.......................................38
RETURNING TO SERVICE. ................38
WASHING THE GO KART ..................39
TRANSPORTING. ................................39
TROUBLE SHOOTING. .........................40
TORQUE SPECIFICATIONS...................41
SPECIFICATIONS................................42
VEHICLE AND ENGINE NUMBER
LOCATION ........................................
43
EMISSION CONTROL SYSTEM
WARRANTY ...................................... 44

COLEMAN POWERSPORTS LIMITED WARRANTY
This Warranty is NOT the Emissions Control Warranty
Please note this is a general Limited Warranty for this product. It IS NOT an Emissions Control
Warranty. Please see the Emissions Control Warranty in this manual for warranties covering
Emission components. The Emissions Control Warranty can be found on page 46.
The Warranty
Coleman Powersports offers the following warranty to the initial purchaser of this new
Coleman Powersports product. The initial purchaser is defined as the first person to
purchase a new Coleman Powersports product from an Authorized Retailer of Coleman
Powersports products.
The limited warranty period for this product is 90 days from the date of purchase shown
on the original sales receipt.
What is a Defect?
The Product is warranted to be free from manufacturing defects in material and work-
manship for a period of 90 days from the date of purchase shown on the sales receipt.
During this period of time Coleman Powersports will, at its option, either repair or replace
any original Coleman Powersports part which is covered by this warranty and is proven to
be defective in workmanship or material.
To qualify for this warranty the part:
1. Must have been purchase from Coleman Powersports or from an authorized Coleman
Powersports Retailer.
2. This warranty does not apply to any vehicle which is used in competition or used in a
manner not consistent with the normal and proper intended use for the vehicle. This
vehicle is not intended for rental or commercial use.
Who Can Perform Repairs Under this Warranty?
2
Repairs under this warranty should be performed by an authorized Coleman Powersports
retailer or comparable servicing dealer.
How to get service under this warranty
To get warranty service call Coleman Powersports at 888-405-8725 for the location of
your local servicing retailer / dealer. Please do not return the product to the retailer
where the product was purchased unless instructed to do so by Coleman Powersports.
The retailer of this product does not make any warranty of its own and has no authority
to implement this warranty on behalf of Coleman Powersports without the approval of
Coleman Powersports. A COPY OF YOUR SALES RECEIPT IS REQUIRED FOR WARRANTY
SERVICE.

3
What this Warranty Does Not Cover
This warranty does not cover the following
1. Damage due to lack or improper maintenance as described in this manual.
2. Damage which is caused by normal use and not caused by a defect in materials or
workmanship.
3. Use of the product which is not consistent with the intended use as described in the
operating instructions.
4. Any expendable maintenance item which need replacement or service as part of
normal maintenance, unless such items have defects in material or workmanship which
cause failure or premature wear.
5. Any product which has been altered or modified in a manner not consistent with the
original design of the product or in a manner not approved by Coleman Powersports.
6. Tires
7. Damage or failures due to abuse, neglect, or misuse of the product.
Limitations of this Warranty
This warranty does not cover and Coleman Powersports disclaims any responsibility for:
1. Loss of time or loss of use of the product.
2. Transportation costs to and from the authorized center.
3. Other loss or damage to other equipment or personal items.
Length of Implied Warranties
Any implied warranties are limited to the duration set forth in this warranty. Coleman
Powersports does not make any claim as to the merchantability or fitness for a particular
purpose which would extend longer than the duration of this written warranty.
Check you State Laws as some State Laws do not allow limitations as to the duration of
an implied warranty. Some States may also not allow limitation or exclusions based on
incidental or consequential damages.

4
IMPORTANT LABELS
5
9
7
8
6
4
3
2
1

5
11 12

6
WARNING LABELS
1
4
2
!WARNING
6
5
7
8
3
9
ALWAYS WEAR SEAT BELTS WHILE OPERATING OR
RIDING AS A PASSENGER IN THIS VEHICLE. KEEP HANDS,
ARMS, FEET AND LEGS IN THE VEHICLE AT ALL TIMES.
THIS VEHICLE IS FOR OFF ROAD USE
ONLY. DO NOT OPERATE ON PUBLIC
STREETS ROADS OR HIGHWAYS
FAILING TO TIE UP
LONG HAIR COULD
RESULT IN HAIR
GETTING CAUGHT IN
MOVING PARTS
RESULTING IN SEVERE
INJURY OR DEATH
ALL HAIR MUST BE TIED UP ABOVE
SHOULDER LENGTH. ALL LOOSE
CLOTHING MUST BE SECURED. ALL
NECKLACES AND SCARVES MUST BE
SECURED
FAILURE TO FOLLOW THESE WARNINGS COULD
RESULT IN SEVERE INJURY OR DEATH
NEVER OPERATE without first reading and
understanding the owner’s/operator’s manual
at speeds too fast for your skills or the
conditions on public roads - a collision can
occur with another vehicle with more than one
passenger - More than one passenger will
affect balance and control
ALWAYS:
•be cautious while operating to avoid vehicle
overturns on hills, rough terrain and in turns
•avoid paved surfaces - pavement may
seriously affect handling and control
•wear seat belts and keep hands, arms and feet
in kart at all times
LOCATE AND READ OWNER’S MANUAL.
FOLLOW ALL INSTRUCTIONS AND WARNINGS
ALWAYS USE
AN APROVED
HELMET AND
PROTECTIVE
GEAR
NEVER USE
ON PUBLIC
ROADS
NEVER CARRY
MORE THAN ONE
PASSENGER.
PASSENGER
MUST BE SEATED
NEVER USE
WITH DRUGS
OR ALCOHOL
Improper tire pressure or overloading can
cause loss of control.
Loss of control can result in severe injury
or death.
•Cold tire pressure:
Front: 10 ± .5psi (69 ± 3.5kpa) Rear: 10
± .5psi (69 ± 3.5kpa)
•Maximum weight capacity is 320 lbs.
(145.2 kg)
WARNING
NEVER operate this vehicle if you are
under age 16 or without a valid
driver’s license.
Operating this vehicle if you are
under the age of 16 increases your
chance of severe injury or death.

7
10
11
12
!WARNING

8
SAFETY
1. Always read and understand the
Owner’s/Operator’s manual and
warnings before starting the Go Kart
for the first time
2. This Go-Kart should only be
assembled by someone who has the
knowledge, ability and skills to read
and understand mechanical
instructions.
3. Use caution when providing
maintenance on this Go-Kart. Make
sure engine is turned off and all
components are cool. Never attempt
to make any adjustments while engine
is running.
4. Do not modify this Go-Kart in any
way, modifications could make the
Go-Kart unsafe and/or in violation of
Federal and State laws.
5. Never allow anyone under the age
of 16 to operate this Go Kart.
6. Always wear a certified DOT
certified motorcycle type helmet that
fits properly, over the ankle boots, eye
protection, gloves, long sleeve shirt
and long pants while operating this Go
Kart.
7. This Go Kart is designed for one
operator and one passenger. Never
allow more than one operator and one
passenger.
8. Always wear seat belts provided.
Make sure seat belts fit properly for
both operator and passenger before
starting the Go Kart.
9. Never operate this Go Kart on paved
surfaces and/or public roads.
Pavement may cause the Go Kart to
be- come unstable.
10. The brush guard surrounding the
driver and passenger is not intended to
provide rollover protection. Before
each use, make sure all tubes are
securely in place and bolts are tight.
11. . Never operate Go Kart with long
hair, loose jewelry or loose clothing
that could get caught in moving parts.
12. Always go slow on unfamiliar
terrain. Be alert to changing terrain
conditions when operating the Go Kart.
13. Never take drugs or alcohol before
or during operation of this Go Kart.
14. Never attempt jumps or any other
type of stunts while operating this Go
Kart.
15. Always follow the pre-ride
inspection procedures and
maintenance procedures located in
this manual before use
16. Always go slow on terrain that is
not familiar, be alert, an obstacle could
come up unexpectedly.
17. Always keep hands, arms, legs and
feet inside the Go Kart at all times.
18. Never operate Go Kart in water that
is deeper than 4 inches. Do not
operate in fast flowing water. Water
can affect braking performance of the
Go Kart. Check braking performance
after exposure to water, it may be
necessary to apply the brakes allowing
friction to dry out the pads.
19. Do not attempt to fill the Go-Kart
with gasoline while the engine is
running or the engine is hot.

9
DESCRIPTION AND PART FUNCTIONS
4
3
Ignition key (1): When the ignition
switch is placed in the (ON) position the
engine can start when the ignition key is
turned to the right. When the ignition
switch is placed in the (OFF) position the
engine will not start, or will turn off, if
running.
Note: Always make sure the ignition
switch (1) is placed in the (OFF) position
after operation. Leaving the switch (ON)
will drain the battery.
Light switch/High and Low beam(2)
Brake Pedal (3): Depressing the brake
pedal will stop the Go Kart.
Note: Always check brakes before
operation
Gas Pedal (4): Depressing gas pedal will
increase engine RPMs causing Go Kart to
move.
Parking Brake Lever (5):Lever pulled to
back position will set the parking brake.
Always use parking brake when engine is
not running or while engine is running and
is in a stopped position for an extended
period of time.
Forward and Reverse lever (6): Lever
placed in forward position will allow the
kart to move forward. Lever pulled to back
position places kart in reverse.
Note: Never try to shift Go Kart in Forward
or reverse while the Go Kart is
moving. Before shifting, make sure kart is
stopped and engine is at low idle.
2
1
5
6

10
DESCRIPTION AND PART FUNCTIONS
Fuel Cap 7
Fuel Tank Cap (7):
To open fuel tank cap, Turn cap counter
clockwise to remove. Tore-install cap,
turn cap clockwise until snug. Make sure
cap is seated properly .
8
Oil Fill plug/Dipstick (8)
To open Oil fill plug/Dipstick, turn cap
counter clockwise to remove. To re-install
cap, turn cap clockwise until snug. Make
sure cap is seated properly

11
DESCRIPTION AND PART FUNCTIONS
SEAT ADJUSTMENT
Seat Latch (9)
The seat latch is located under the
driver side seat. To access, look
under the front of the driver side
seat. . Pull the seat latch up to
move the seat forward or
backward . Before operating the
Go Kart make sure the seats are
bolted in properly and that the
seat latch is locked in place in
desired position.
!
WARNING
Failure to have the seat locked in
position could be hazardous
The seat coming loose could
cause the operator to loose
control.
Never operate the Go Kart
without the seat locked in place.
9

12
FUEL AND OIL
FUEL
Never use leaded gasoline in this product.
It could affect the engine’s emissions and
damage the engine.
Go Kart requires clean unleaded regular
gasoline with a minimum octane rating of
90 or higher.
Gasoline/ Ethanol blends
A blend of unleaded gasoline with Ethanol,
also known as GASOHOL, at or below 10%
(E10 ) can be used in your Go Kart.
Ethanol greater than 10% can damage
your engine and will void your warranty.
Gasoline/Methanol Blends
A blend of gasoline with Methanol of 5% or
less can be used in your Go Kart. Do not
use gasoline, under any circumstances,
containing more than 5% Methanol, doing
so will damage your engine and will void
the warranty
Fuel Filling
ENGINE OIL
The recommended oil for this Go Kart is
SAE10W-40 motor oil, if this oil is not
available, any of the oils on the chart
below will work. Note the temperature
requirements for each of the oils.
!WARNING
Fuel and fuel vapor are highly
flammable and toxic. You can be
burned or poisoned while
refueling.
Before refueling make sure to fol-
low the procedures listed:
1. Shut off engine, Make sure
there are no flames, sparks
or heat sources close by.
2. Make sure engine has
cooled
3. Refuel only outdoors in a
well ventilated area.
4. Do not smoke while
refueling.
5 Wipe up any spills immediately.
Quantity of oil - 1qt. (1L).

13
!
WARNING
Overfilling the fuel tank can
cause the fuel to expand which
can cause overflow due to the
heat from the engine or sun.
Spilled fuel can catch fire.
Never fill the fuel tank above
the bottom edge of the filler
neck.

14
BREAK - IN
Observe your initial and most
critical maintenance service
The initial service( break in maintenance )
is the most important service for your Go
Kart. During the break-in time frame, all
of the engine components will have mated
together and seated. Maintenance
required as part of the initial service
includes correction of all adjustments,
tightening of all fasteners and replace-
ment of dirty oil. Timely performance of
this maintenance will help make sure your
Go Kart will have the best service life and
perf ormance of the engine.
BREAK IN PERIOD
The initial 20 hours of operation is most
important in the life of your Go Kart.
Proper operation during this break in
period will help assure maximum life of
your Go Kart engine.
The following guidelines will explain the
proper break in procedures.
1. During the first 10 hours of
operation, do not apply more than
1/2 throttle for long periods of
time.
Vary the engine speed
Make sure to vary the engine speed
during the break in period, this allows the
engine to load and unload which helps
the parts to seat properly. It is essential
to place some stress on the engine during
the break in process, however, too much
stress could cause damage to the engine
components. Be careful not to load the
engine too much.
Allow oil to circulate before
operating.
Always allow the Go Kart engine to warm
up before operating. This allows the oil
to circulate throughout the engine which
lubricates the components.

15
PRE-RIDE INSPECTION
Inspecting and checking the condition of
the Go Kart before each ride is important.
Following the pre-ride check list will help
insure the you do not have mechanical
problems which could result in injury or
becoming stranded. Make sure the Go
Kart is in good operating condition before
each use.
!
WARNING
Failing to inspect and maintain
your Go Kart could be hazardous.
Not following the pre-ride inspec-
tion procedures could result in
loosing control of the Go Kart
resulting in an accident or
damage to the Go Kart
Always perform a Pre-ride inspec-
tion before each operate.
!
WARNING
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
ignition switch or throttle.
WHAT TO
CHECK
CHECK FOR
Steering
•Smoothness
•No restriction of
movement
Brakes
•Correct fluid level
•Inspect hoses for leaks
•Inspect brake pads for
wear.
wear.
Tires
•Proper tire pressure
•Proper tread depth
•Rubber has no cracks
Fuel Tank
•Enough fuel for the ride
•Fuel cap secure
•Hoses have no signs of
cracks or leaks
cracks or leaks
Throttle
Pedal
•Pedal snaps back to
idle when released
•Operates freely
Lighting
•Proper operation of
Head lights and Tail
lights.
Engine
Ignition
switch
•Switch shuts off engine
when activated.
Engine Oil
•Correct oil level
Forward/
reverse
lever
•No damage
•Operates as intended
Drive
Chain
•Proper tension
•Lubricated
•No excessive wear or
damage
damage
General
Condition
•All nuts and bolts tight
•No rattles from engine
or frame while running