ASSEMBLY/PRE-RIDE INSPECTION INSTRUCTIONS CT200U-A 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. For questions about these Assembly Instructions, call Coleman Powersports toll free 888-405-8725 ! WARNING Never attempt to start this Mini Bike without reading and understanding the Owner’s/Operator’s manual.
REMOVAL FROM CRATE 10mm Steering Bolt 10mm Small Washer Owner’s/Operator’s Manual 10mm Lock Nut 10mm Large Washers Tool Kit Front Fork Assembly Hardware Zip Ties Clutch Cove Cotter Hairpins Front Fender 8mm x 20mm Bolts 8mm Nuts 8mm Large Washers Front Rack and Fender Assembly Front wheel 14mm Axle Bolt 14mm Washers 14mm Lock Nut Wheel Assembly 1
FRONT FORK INSTALLATION 10mm Steering Bolt 10mm Large Washers 10mm Small Washer 10mm Lock Nut Small Washer 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 Steering Bolt Top Bracket 1. Tighten Lock nut snug, Steering Neck Note: Do not over tighten Lock nut. Over tightening will cause the steering to bind .
FRONT FENDER INSTALLATION 8mm x 20mm Bolts Large 8mm Washers 8mm Nuts 8mm x 20mm Bolts ColemanLogo 2. Attach front fender with 8mm x 20mm bolts, large 8mm washers and 8mm nuts.
FRONT WHEEL INSTALLATION 14mm Axle bolt 1ea. 14mm washers 2ea. 14mm lock nut 1ea. Arrow faces forward 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 4. Tighten Lock nut snug, 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. Zip Ties 2. Secure wires and cables to frame using the Zip ties provided. 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 4.
OIL AND FUEL Engine Oil Mini bike DOES NOT have oil in crankcase when shipped from the factory. NEVER ATTEMPT to start the engine without engine oil. Filling with Oil 1. Remove the oil fill plug (1) 1 2. fill with SAE 10W-30 motor oil. This mini bike takes .63qt. (.6L) of engine oil. Oil should be up to the brim of the fill hole. 3. Re- install fill cap, Start engine and allow to run for a few minutes, Re-check oil level and fill accordingly.
Tires TIRE PRESSURE 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 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 1/2 - 3/4 in. (15-20mm) 1. Loosen bolt (2) on the rear axle assembly. 1 2.
BRAKE ADJUSTMENT Brakes 2.0 - 4.0mm (0.08 - 0.16 in) Brake Lever Adjustment The front left brake lever (1) should have 2.0 - 4.0mm (0.08 - 0.16) of free play. 1 23 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) Brake Adjustment To adjust brakes, loosen the rear axle bolt (4) Locate the adjustment nut (5) located on the rear brake drum assembly.
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.
PRE-RIDE INSPECTION 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. ! WARNING Failing to inspect and maintain the Mini Bike could be hazardous.
STARTING ENGINE STARTING ENGINE 2 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. 3 5. Once engine has warmed up for a few minutes, place the choke lever (2) back to the “OFF” (right) position.
! 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 PHONE: Toll Free 888-405-8725 colemanpowered.
