Coleman CT200U User Manual

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

Coleman CT200U Specifications

General

Engine	196cc
Horsepower	6.5 hp
Starting System	Recoil Start
Frame	Steel
Weight Capacity	200 lbs
Transmission	Automatic centrifugal clutch
Tires	19x7-8

Summary

Assembly and Pre-Ride Inspection Instructions

Important Safety Warning

Read and understand the Owner's/Operator's manual before operating the Mini Bike.

Removal from Crate

Owner's/Operator's Manual

Key document for understanding safety, parts, functions, and maintenance.

Tool Kit and Zip Ties

Essential tools and fasteners provided for assembly.

Front Rack Assembly

Component for carrying items, to be installed on the front.

Front Fender

Protective component for the front wheel.

Front Fork Assembly Hardware

Hardware required for installing the front fork.

Clutch Cover

Protective casing for the clutch mechanism.

Front Wheel Assembly

Includes wheel, axle, washers, and lock nut for the front.

Front Fork Installation

Installing the Front Fork Assembly

Step-by-step guide for inserting the steering bolt through the assembly.

Torque Specification

Tighten the front fork nut to 30 ft.lbs. (41Nm).

Front Rack and Fender Installation

Attaching the Front Rack

Secure the front rack to the steering column using bolts and nuts.

Attaching the Front Fender

Install the front fender with bolts, washers, and nuts.

Front Wheel Installation

Tire Orientation

Ensure the arrow on the front tire faces forward.

Axle Bolt Installation

Insert axle bolt with washers between forks and wheel.

Lock Nut Tightening

Install and tighten the 14mm lock nut to 30 ft.lbs. (41Nm).

Secure Wires and Install Clutch Cover

Wire and Cable Management

Ensure wires are not kinked and secure them with zip ties.

Clutch Cover Installation

Attach the clutch cover securely over the bracket tabs.

Engine Oil and Fuel

Engine Oil Change Procedure

Drain and replace engine oil with SAE 10W-30 motor oil.

Fuel Requirements

Use clean unleaded regular gasoline with an octane rating of 86 or higher.

Tire Pressure and Chain Tension

Tire Pressure Check

Maintain front and rear tire pressure at 10psi.

Chain Tension Adjustment

Adjust chain slack to 1/2 - 3/4 in. (15-20mm).

Brake Adjustment

Brake Lever Free Play

Adjust front brake lever free play to 2.0 - 4.0mm (0.08 - 0.16 in).

Rear Brake Adjustment

Adjust rear brake by turning the adjustment nut clockwise or counter-clockwise.

Throttle Adjustment

Idle Speed Adjustment

Set idle speed to 1700 ± 150 RPMs using the adjustment screw.

Throttle Cable Free Play

Adjust throttle grip free play to 0.078 - 0.24 in (2-6 mm).

Pre-Ride Inspection Checklist

Steering and Brake Checks

Ensure smooth steering and proper brake lever play.

Tire and Fuel System Checks

Verify tire pressure, fuel level, cap security, and hose condition.

Throttle, Switch, and Oil Checks

Confirm throttle operation, stop switch function, and correct oil level.

Drive Chain and General Condition

Check chain tension, lubrication, and overall bolt tightness.

Starting the Engine

Engine Starting Procedure

Follow steps for fuel valve, choke, ignition, and starter recoil.

WARNING: Ventilation Required

Always start and run the Mini Bike outdoors or in a well-ventilated area.