Coleman GK200 User manual

ASSEMBLY MANUAL
GK200 196cc
GAS
POWERED
GO-KART
4120 E. Scyene Road, Mesquite, Texas 78710
powgrp.com
@colemanpowersportsusa @colemanpowersports_usa Coleman Powersports
WARNING
NEVER ATTEMPT TO START THIS GO-KART 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
CAUTION
This Go-Kart was shipped without
engine oil. Always fill with the correct
amount and grade of engine oil as
listed in the owner’s manual.
Provincial/Municipal governments have dierent regulations
pertaining to owning and operating an o-road vehicle, learn
the regulations in your area.
4120 E. Scyene Road, Mesquite, Texas 78710
powgrp.com

1
REMOVAL FROM CRATE
1. Remove the metal crate
from the Go-Kart.
2. Locate and Remove
Owner’s/Operator’s manual,
set up instructions and all
documentation.
Note: Read Owner’s /
Operator’s manual
thoroughly before starting
Go-Kart for the first time.
3. Locate and remove all
parts and hardware from
crate and set aside.
Note: Some hardware may
already be mounted on the
Go-Kart. This will have to be
removed and then re-
attached during assembly.
St eering Wheel
S t ee r i n g W h ee l
S teer ing W heel C ap
Wheel Parts
Rear Tires
Front Tires
Rubber Hub Caps
Rear Rack

2
Brush Guard Parts
Brush Guard Side Support
Main Brush Guard
Brush Guard Cross Braces
Safety Net
Safety Belt
Seat

3
Hardware:
REAR WHEEL ASSEMBLY
12
M20 Washer 2ea. (1)
4
M20 Castle nuts 2ea. (2)
3
Cotter pins 2ea. (3)
M20 Large
Washer
2ea. (4)
1.Lift the Kart with a jack.
Note: Make sure tire tread faces forward
and Air valve stem is on the outside of the
tire when installing.
3.Install Hub Caps (5) by snapping on hub.
4
1
2
3
Failing t o install co tt er pins
could
be hazardous.
Failing
t o install co tt er pins
could cause
the castle nuts
t o fall off resulting in an
accident.
Nev er operat e Go Kar t
without co tt er pins installed .
5
2. Install rear tire assembly in the
following order:
1. Wheel
2. M20 Large washer (4)
3. M20 Washer (1)
4. M20 Castle nut (2)
5. Colter pin (3)
!W
ARNING
Make sure
the trend
faces
forward

4
FRONT WHEEL ASSEMBLY
12
4
Hardware:
M14 Washer 2ea. (1)
M14 Castle nuts 2ea. (2) 3
Cotter pins 2ea. (3)
M14 Large
Washer
2ea. (4)
1. Lift the Kart with a jack.
Make sure
tread faces
forward
3. Install Hub Caps (5) by snapping on hub.
1.
2. Install the front wheel assembly in the
following order.
2.
Wheel
3.
M14 Large washer (1)
4.
M14 Washer (4)
5.
M14 Castle nut (2)
Colter pin (3)
Failing t o install co tt er pins
could be hazardous. Failing
t o install co tt er pins could
cause the castle nuts t o fall
off resulting in an accident.
Nev er operat e Go Kar t
without co tt er pins installed .
123
!W
ARNING
4
5

5
STEERING WHEEL INSTALLATION
Hardware:
M6X16 Bolts 3ea.(1)
M6 Nuts 3ea.(2)
1. Attach steering wheel using
M6 bolts (1) and M6 nuts (2).
2. Attach steering wheel cap by
snapping into place on
center of steering wheel.
1
2
2
1
Steeling Wheel
Cap

6
SEAT INSTALLATION
Hardware:
M8 x 35 bolts 2 ea. (1)
M8 Nuts 2 ea. (2)
1. To install the seat, attach
the barb, located on the
bottom of the seat, to the
bracket on the Go Kart
before attaching the bolt.
2. Install the seat with M8x35
bolts (1) and M8 Nuts (2)
SAFETY BELT INSTALLATION
1. Install the self belt on the frame with bolt, washer, nut & gasket.
2
1
1
2
Place bottom portion
of the belt through the
seat.
barb
bracket

7
BRUSH GUARD INSTALLATION
4 ea. (1)
Hardware:
M8 X 50 bolts
M8 X 20 bolts 12ea. (2)
M8 Concave Washers 4 ea. (3)
1.Attach Main Brush Guard
withM8x20 bolts.
Note:Do not tighten bolts at
this time,keep bolts loose
until the brush guard is
completely assembled.
2.Attach Center and side
Supports with M8 Concave
Washers (3 )and Bolt M8x50.
Tighten all bolts on rack and brush
guard assembly.
321
31
2

8
REAR SAFETY NET
1.Attach safety net on brushguard.

REAR RACK INSTALLATION
Hardware:
M8x16 bolts 4 ea.(1)
M8 nuts 4 ea. (2)
Assemble the rear rack
to the roll mounting
point with Flange bolt
M8x16(1)and nut M8.
2
1
9

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 ride.
!W
ARNING
Failing t o inspect and
maintain your Go Kar t could be
hazardous.
No t following the pre-ride inspection
procedures could result in loosing
control of the Go Kar t resulting in an
accident or damage t o the Go
Kar t
Always perform a Pre-ride
inspection bef ore each ride.
!W
ARNING
P erforming maintenance and
c hecks while the engine is running
could be hazardous.
Y ou could be sev erely injured by
moving par ts or ho t surfaces.
Nev er perform maintenance or
c heck procedures while the
engine is running with the ex ception
of c hec king the ignition switch or
thro ttle.
WHAT T O
CHECK
CHECK FOR
St eering
• Smoothness
• No restriction of
mo vement
Brak es
• Correct fluid level
• Inspect hoses for
leaks
• Inspect brak e pads
for wear.
Tires
• Proper tire pressure
• Proper tread depth
• Rubber has no
crac ks
Fuel T ank
• Enough fuel for the
ride
• Fuel cap secure
• Hoses ha ve no
signs of crac ks or
leaks
Thro ttle
P edal
• P edal snaps bac k
t o idle when
released
• Operat es freely
Engine
Ignition
switch
• Switch shuts off
engine when
• activated.
Engine
Oil
• Correct oil level
T orque
Con v er t er
Guard
• No damage
• Securely attached
Driv e
Chain
• Proper t ension
• Lubricated
• No excessive wear
or damage
General
Condition
• All nuts and bolts
tight
• No rattles from
engine or frame
while running
10