Coleman CT200U-EX V 196cc Mini Bike Manual

ASSEMBLY/PRE-RIDE INSPECTION
INSTRUCTIONS

CT200U-EX V

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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.

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. The Owner’s/Operator’s manual provides information on safety, parts, functions, pre-ride inspection, starting, and maintenance.

REMOVAL FROM CRATE

FRONT FORK INSTALLATION

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

2. Tighten Lock nut

3. Tighten fork bolts on both sides of assembly
Torque for bolts 15 Ft/Lbs.

FRONT FENDER INSTALLATION

1. Attach front fender with the 2 M8 x 15mm bolts
Torque bolts 15 ft/lbs.

REAR FENDER INSTALLATION

1. Attach Rear fender with M8 x 20 bolts, large M8 washers and M8 nuts.
Torque bolts 15 ft/lbs.

HANDLEBAR ASSEMBLY

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

FRONT WHEEL INSTALLATION

1. Orient the front tire so the arrow on the tire faces forward.
2. Insert Axle bolt with the M14 washers between the forks and wheel on each side.
3. Install M14 lock nut and tighten.

LIGHT INSTALLATION

1. Install front light onto bracket using M8 X 50 bolts, M8 rubber grommets and M8 nuts.
Note: The rubber gromets fit between the light and the light bracket

Torque Bolts 12ft/lbs
2. Plug light wires into wires from engine assembly

SECURE WIRES AND CABLES

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.

WARNING !
WARNING ALWAYS CHECK THROTTLE CABLE BEFORE STARTING ENGINE, THE THROTTLE CABLE SHOULD HAVE FREE MOVEMENT AND SNAP BACK TO IDLE WHEN RELEASED.

OIL AND FUEL

Engine Oil
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 fill with engine oil
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 filler neck.

TIRE PRESSURE

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

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

Loosen bolt (2) on the rear axle assembly.
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. Counterclockwise will loosen the chain.
Once the chain is at the correct tension re-tighten axle bolt (2).
Re-check chain tension.

BRAKE ADJUSTMENT

Brakes
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:

Loosen the jam nut (2) on the brake cable.
Turn the adjuster nut (3) until the correct amount of free-play is achieved.
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.
To adjust brakes, turn the adjusting nut (5) clockwise to increase braking, counter clockwise to decrease braking.

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:

Locate the idle adjustment screw (1) located on the carburetor.
Allow the engine to warm up approximately 10 minutes
With the engine running, turn the idle adjustment screw in or out at small increments until the correct idle is achieved.

Throttle Cable adjustment
It is important that the throttle grip have a certain amount of free play.
The hand grip throttle free play (2) should be .078 – .24 in (2-6 mm)
To adjust freeplay

Loosen jam nut (3)
Turn adjusting nut (4) to proper setting
Once throttle grip is at the proper freeplay, re-tighten the jam nut (3).

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. 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.

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 engine stop switch or throttle.

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	• All nuts and bolts tight • No rattles from engine or frame while running+A7:B16

STARTING ENGINE

STARTING ENGINE
To start the engine

Place the fuel valve (1) to the “ON” (right) position
If engine is cold, place the choke lever (2) to the “ON” (left) position.
Place the ON/OFF switch (3), located on the handlebars, to the (on)position.
Pull the starter recoil cord to start the engine.
Once engine has warmed up for a few minutes, place the choke lever (2) back to the “OFF” (right) position.

WARNING 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 ! 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
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