Coleman Powersports CT200U Instrucciones de instalación
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
Large 8mm Washers
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 pres-
sure 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)
12
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 .
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