Coleman CT200U-EX V Assembly Instructions Manual
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Coleman CT200U-EX V Assembly Instructions Manual

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ASSEMBLY/PRE-RIDE INSPECTION
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.
INSTRUCTIONS
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.
CT200U -EX V
080620

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Summary of Contents for Coleman CT200U-EX V

  • Page 1 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.

  • Page 2: Removal From Crate

    REMOVAL FROM CRATE Clamps M8 x 32 bolts Owner’s/Operator’s Manual Handle Bar Hardware Front Fender Tool Kit with light Bracket Zip Ties M8 x 15 Bolts Front Fender Assembly Rear Fender M8 Nuts Front Fork M8 x 20 Bolts Suspension 8mm Large Washers M10 Steering Bolt Rear Fender...

  • Page 3: Front Fork Installation

    FRONT FORK INSTALLATION M10 Steering Bolt M10 Large M10 Small Washers Washer s M10 Lock Nut Steering Bolt Large Washer 1. Install front Fork Assembly by inserting the M10 steering bolt Bracket through the assembly in the following order: Large washer, Top bracket, Small Washer, Steering Neck, Small washer, Small...

  • Page 4: Front Fender Installation

    3. Tighten fork bolts on both sides of assembly Fork Bolts Torque for bolts 15 Ft/Lbs. FRONT FENDER INSTALLATION M8 x15 Bolts 1 . Attach front fender with the 2 M8 x 15mm bolts Torque bolts 15 ft/lbs. M8 bolts...

  • Page 5: Rear Fender Installation

    REAR FENDER INSTALLATION M8 x 20 Bolts Large M8 Washers M8 Nuts M8 x 20mm Bolts 1. Attach Rear fender with M8 x 20 bolts, large M8 washers and M8 nuts. Torque bolts 15 ft/lbs. Large M8 Washers M8 Nuts Bottom View...

  • Page 6: Handlebar Assembly

    HANDLEBAR ASSEMBLY Clamps M8 x 32 bolts Handlebar Hardware 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. M8 x 32 Bolts Clamps 2.

  • Page 7: Front Wheel Installation

    FRONT WHEEL INSTALLATION M14 Axle bolt 1ea. M14 washers 2ea. M14 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 M14 washers between the forks and wheel on each side.

  • Page 8: Light Installation

    LIGHT INSTALLATION M 8 x 50 Bolts M 8 R ubber G rommets M 8 N uts 1. Install front l ight 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 R ubber Grommets...
  • Page 9 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.

  • Page 10: Oil And Fuel

    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 Fill level FUEL Never use leaded gasoline in this product.

  • Page 11: Tire Pressure

    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 pres- sure 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.

  • Page 12: Brake Adjustment

    BRAKE ADJUSTMENT Brakes 2.0 - 4.0mm Brake Lever Adjustment (0.08 - 0.16 in) 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.

  • Page 13: Throttle Adjustment

    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.

  • Page 14: Pre-Ride Inspection

    PRE-RIDE INSPECTION Inspecting and checking the condition of the Mini Bike before each ride is important. Following WHAT TO CHECK FOR the pre-ride check list will help CHECK insure there are no problems which Steering • Smoothness could result in injury or becoming •...

  • Page 15: Starting Engine

    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.
  • Page 16 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.com...

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