Coleman CT200U, CT100U Assembly/pre-ride Inspection 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.

!

For questions about these Assembly Instructions, call Coleman
Powersports toll free 888-405-8725

ASSEMBLY/PRE-RIDE INSPECTION
INSTRUCTIONS

11132012

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 before starting the
engine for the rst time.

CT200U

REMOVAL FROM CRATE

1

Owner’s/Operator’s Manual

Tool Kit

Zip Ties

Front Fender

Front Rack

and Fender

Assembly

Front Fork

Assembly

Hardware

10mm Large Washers

10mm Lock Nut

10mm Small
Washer

10mm Steering Bolt

Front Rack

8mm Large Washers

8mm Nuts

8mm x 20mm Bolts

Wheel Assembly

Front wheel

14mm Lock Nut

14mm Washers

14mm Axle Bolt

Clutch Cover

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

2. Tighten nut
Torque nut to 30 ft .lbs. ( 41Nm)

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

3

2. Attach front fender with 8mm x
20mm bolts, large 8mm washers
and 8mm nuts.

Note: Small portion of fender faces
foreward

FRONT RACK AND FENDER INSTALLATION

Large 8mm Washers
8mm Nuts

8mm x 20mm Bolts

8mm x 20mm Bolts

8mm x 20mm Bolts

Large 8mm
Washers

8mm Nuts

8mm Nuts

1. Attach the Front Rack to the
Steering Column Assembly using
8mm x 20mm bolts, and 8mm nuts

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.

3. Install 14mm lock nut
and tighten.
Torque Front Lock Nut 30 ft.lbs
(41Nm)

14mm Axle Bolt

14mm Washer

14mm Lock Nut

Arrow faces forward

14mm Axle bolt 1ea.

14mm washers 2ea.

14mm lock nut 1ea.

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 pres­sure 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.

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)

1

2

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.

THROTTLE ADJUSTMENT

9

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 .

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 inspec­tion 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

364 S. Smith Rd.

Tempe, AZ. 85281

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.

!