ASSEMBLY/PRE-RIDE INSPECTION
INSTRUCTIONS
CT200U
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 first time.
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.
11132012
REMOVAL FROM CRATE
10mm Steering Bolt
10mm Small 10mm Lock Nut Owner’s/Operator’s Manual
Washer
10mm Large Washers
Tool Kit
Front Fork
Assembly
Hardware
Zip Ties
Clutch Cover
Front Rack
Front Fender
Front wheel
8mm Nuts 14mm Axle Bolt
8mm x 20mm Bolts
8mm Large Washers 14mm Washers 14mm Lock Nut
Front Rack
and Fender Wheel Assembly
Assembly
1
FRONT FORK INSTALLATION
10mm Steering Bolt
10mm Large Washers 10mm Small Washer
10mm Lock Nut
Small Washer Steering Bolt
1. Install front Fork Assembly by
inserting the 10mm steering bolt
through the assembly in the Top Bracket
following order:
Top bracket, Small 10mm
Washer, Steering Neck, Large
10mm Washer, Bottom Bracket,
Large 10mm Washer, Lock Nut
Steering Neck
Large Washer
Bottom Bracket
2. Tighten nut
Torque nut to 30 ft .lbs. ( 41Nm)
Large Washer
Lock Nut
2
FRONT RACK AND FENDER INSTALLATION
8mm x 20mm Bolts Large 8mm
Washers
8mm Nuts
8mm x 20mm Bolts
8mm Nuts
1. Attach the Front Rack to the
Steering Column Assembly using
8mm x 20mm bolts, and 8mm nuts
8mm x 20mm Bolts
2. Attach front fender with 8mm x
20mm bolts, large 8mm washers
and 8mm nuts.
Note: Small portion of fender faces
foreward
Large 8mm Washers
8mm Nuts
3
FRONT WHEEL INSTALLATION
14mm Axle bolt 1ea.
14mm washers 2ea.
14mm 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 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 Washer 14mm Axle Bolt
14mm Lock Nut
4
SECURE WIRES AND CABLES
INSTALL CLUTCH COVER
1. Make sure the On/Off Switch
wire, Throttle cable and Brake Zip Ties
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.
Zip Ties
Clutch Cover
3. Install clutch cover over the 4
bracket tabs provided on the clutch
assembly. Make sure the clutch
cover is attached securely.
Bracket Tabs
5
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.
Changing the engine oil
1. Remove the oil fill plug (1)
2. Remove the drain bolt (2) located on
the bottom of the engine.
1
3. Allow the oil to drain in an appropriate
container. Note: Dispose of oil at an oil
recycle center.
Fill level
4. Install the drain plug and fill with SAE
10W-30 motor oil. This mini bike takes
.63qt. (.6L) of engine oil. Oil should be up
to the brim of the fill hole. 1
5. Re- install fill cap, Start engine and
allow to run for a few minutes, Re-check
oil level and fill accordingly.
Caution: Do not over or under fill
with Motor Oil
2
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
Filler neck
86 or higher. Fuel level
Fill with gasoline up to the bottom of the
filler neck.
6
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. (15-20mm)
Chain tension (slack)
adjustment
1. Loosen bolt (2) on the rear axle 1/2 - 3/4 in.
assembly. (15-20mm) 1
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.
2
3
7
BRAKE ADJUSTMENT
Brakes
Brake Lever Adjustment 2.0 - 4.0mm
(0.08 - 0.16 in)
The front left brake lever (1) should 23
1
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)
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 4
to decrease braking. 5
8
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.
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 1
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
4 3
.078 - .24 in
be .078 - .24 in (2-6 mm)
(2-6 mm)
To adjust freeplay
1. Loosen jam nut (3)
2. Turn adjusting nut (4) to proper setting 2
3. Once throttle grip is at the proper
freeplay, re-tighten the jam nut (3).
9
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 WHAT TO CHECK FOR
CHECK
insure there are no problems which
Steering • Smoothness
could result in injury or becoming
• No restriction of
stranded. Make sure the Mini movement
Bike is in good operating condition Brakes • Proper brake lever
before each ride. play
Tires • Proper tire pressure
Fuel Tank • Enough fuel for the ride
! WARNING • Fuel cap secure
• Hoses have no signs of
Failing to inspect and maintain the cracks or leaks
Mini Bike could be hazardous.
Throttle • Throttle grip snaps
Not following the pre-ride grip back to idle when
released
inspection procedures could result
• Operates freely
in loosing control of the Mini Bike • Has correct free play
resulting in an accident or damage Engine • Switch shuts off engine
to the Mini Bike Stop when activated.
Switch
Always perform a Pre-ride inspec-
Engine • Correct oil level
tion before each ride. Oil
Drive • Proper tension
Chain • Lubricated
! WARNING General • Cotter Pins on axle
Condition • All nuts and bolts tight
Performing maintenance and • No rattles from engine
checks while the engine is running or frame while 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.
10
STARTING ENGINE
STARTING ENGINE
To start the engine 2
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.
4. Pull the starter recoil cord to start the
engine.
3 1
5. 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.
11
! 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.
PHONE: Toll Free 888-405-8725
colemanpowersportsusa.com
