Coleman Mini Bike Manual

ASSEMBLY/PRE-RIDE INSPECTION
INSTRUCTIONS

CT200U-EX

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 Locknut

3. Tighten fork bolts on both sides of the 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 handlebars 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

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

LIGHT INSTALLATION

Install front light onto the bracket using M8 X 50 bolts, M8 rubber grommets and M8 nuts.
Note: The rubber grommets fit between the light and the light bracket
Torque Bolts 12ft/lbs
Plug light wires into wires from engine assembly

SECURE WIRES AND CABLES INSTALL CLUTCH COVER

Make sure the On/Off Switch wire, throttle cable, and brake cable are not kinked and have free movement when the handlebars are turned from left to right.
Secure wires and cables to frame using the Zip ties provided.

WARNING

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

OIL AND FUEL

Engine Oil
Minibike is shipped without engine oil, fill with SAE 10W-30 Motor Oil.
Refer to the owner’s manual for the correct amount and grade of engine oil.
Caution: Do not over or underfill 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
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 minibike.) Clockwise will tighten the chain. Counterclockwise will loosen the chain.
3. Once the chain is at the correct tension re-tighten the axle bolt (2).
4. Re-check chain tension.

BRAKE ADJUSTMENT

BrakesBrake Lever AdjustmentThe 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.
Retighten 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, counterclockwise 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 handgrip throttle free play (2) should be .078 – .24 in (2-6 mm) To adjust Free play.

Loosen jam nut (3)
Turn adjusting nut (4) to the proper setting
Once throttle grip is at the proper free play, 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 checklist will help ensure there are no problems that 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 losing control of the Mini Bike resulting in an accident or damage to the Mini Bike Always perform a Pre-ride inspection 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

STARTING ENGINE

To start the engine

Place the fuel valve (1) to the “ON” (right) position
If the 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 the 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 enclosed environment where there is no ventilation. Always start and run outdoors.