Coleman Powersports CT200U, Owner'S Manual

Page 1: ...nder the age of 13 to operate this Mini Bike Persons age 13 to 16 should operate this mini bike only under continual adult supervision Provincial Municipal governments have different regulations pertaining to owning and operating an off road vehicle learn the regulations in your area REV 073112 www colemanpowered com OWNER S MANUAL ...

Page 2: ...i bike safely Parents should supervise their child s use of the mini bike at all times Parents should permit continued use only if they determine that the child has the ability to operate the mini bike safely THIS MINI BIKE IS NOT A TOY AND COULD BE HAZARDOUS TO OPERATE Reading the Owner s Operator s Manual It is important this manual is read from cover to cover carefully by the owner and all oper...

Page 3: ...on to make procedures easier or clearer to understand This manual is based on the latest product information available at the time of publication Coleman Powersports has a policy of continually improving its products Due to improvements or other changes there may be some discrepancies We reserve the right to make product changes at any time without notice and without incurring any obligation to ma...

Page 4: ...The engine exhaust from this mini bike contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm California proposition 65 WARNING ...

Page 5: ... 12 STARTING THE ENGINE 13 STARTING OFF 14 LOAD GUIDELINES 15 MAINTENANCE 16 MAINTENANCE CHART 17 AIR FILTER 18 SPARK PLUG 19 ENGINE OIL 20 CHECKING 20 CHANGING 20 IDLE SPEED ADJUSTMENT 21 THROTTLE CABLE ADJUSTMENT 21 FUEL HOSE INSPECTION 21 BRAKES 22 BRAKE LEVER ADJUSTMENT 22 BRAKE ADJUSTMENT 22 VALVE CLEARANCE 22 CHAIN AND SPROCKET 23 INSPECTION 23 TENSION AND ADJUSTMENT 23 CLEANING AND LUBRICAT...

Page 6: ... part which is covered by this warranty and is proven to be defective in workmanship or material To qualify for this warranty the part 1 Must have been purchase from Coleman Powersports or from an authorized Coleman Powersports Retailer 2 Must have been used in a manner consistent with the intended use for the vehicle This warranty does not apply to any vehicle which is used in competition or used...

Page 7: ...duct or in a manner not approved by Coleman Powersports 6 Tires 7 Damage or failures due to abuse neglect or misuse of the product Limitations of this Warranty This warranty does not cover and Coleman Powersports disclaims any responsibility for 1 Loss of time or loss of use of the product 2 Transportation costs to and from the authorized center 3 Other loss or damage to other equipment or persona...

Page 8: ...IMPORTANT LABELS LOCATION 3 4 1 2 4 5 6 7 ...

Page 9: ...ate this mini bike in an unsafe manner by attempting stunts jumps or wheelies This could lead to severe injury or death Always supervise children ages 13 16 wear a DOT certified helmet eye protection gloves over the ankle boots long sleeve shirt and long pants avoid paved surfaces paved surfaces can adversely affect handling and control keep hands and feet away from all moving parts Check the thro...

Page 10: ...starting the mini bike Never allow anyone under the age of 13 to operate this mini bike Persons age 13 to 16 should operate this mini bike only under continual adult supervision Some children may not have the coordination or ability to operate the mini mike safely It is the parents responsibility to access the childs abilities before allowing the child to continue to ride Always wear a certified D...

Page 11: ...mbly 14 Rear Wheel 15 Fuel Tank and Cap 16 Chain Guard 17 Chain 18 Chain adjustment bolts 19 Muffler 20 Clutch Cover 21 Front Fork assembly 22 Left Hand Grip 23 Rear Brake Lever 24 Rear Brake Cable 25 Throttle Cable 26 ON OFF Switch Wire 27 ON OFF Switch 28 Throttle Grip 1 2 3 4 6 7 8 9 10 12 11 13 14 15 16 17 18 19 20 21 22 23 24 26 27 25 DESCRIPTIONS AND PART LOCATIONS 5 7 28 ...

Page 12: ...rning the throttle grip away from the operator Engine Stop Switch 2 Mini Bike engine can start when the Engine stop switch is placed in the on position Engine will shut off and the engine will not start when the switch is placed in the off position Left hand brake lever 3 The rear brake is applied when the left hand brake lever is pulled toward the hand grip 1 2 3 DESCRIPTION AND PART FUNCTIONS 8 ...

Page 13: ... be placed in the ON right position This allows fuel to flow to the carburetor When finished riding and while transporting place fuel valve in the OFF left position Choke Lever 1 If the engine is cold the choke can help start the engine by placing the choke lever to the ON left position Once engine has warmed up place choke lever to the OFF right position Choke operation 3 Oil Fill plug Oil Fill P...

Page 14: ...L The recommended oil for this Mini Bike is SAE10W 30 motor oil if this oil is not available any of the oils on the chart below will work Note the temperature requirements for each of the oils Quantity of oil 63qt 6L Overfilling the fuel tank can cause the fuel to expand which can cause overflow due to the heat from the engine or sun Spilled fuel can catch fire Never fill the fuel tank above the f...

Page 15: ...each ride is important Following the pre ride check list will help insure the you do not have mechanical problems which could result in injury or becoming stranded Make sure the Mini Bike is in good operating condition before each ride WHAT TO CHECK CHECK FOR Steering Smoothness No restriction of movement Brakes Brake shoe wear Proper brake lever play Tires Proper tire pressure Proper tread depth ...

Page 16: ...atory when riding a Mini Bike Wear protective clothing Long sleeve shirt 3 Gloves 4 Long pants 5 over the ankle boots 6 Riding a Mini Bike exposes the rider to many hazards wearing protective clothing can help protect the rider from injury Riding the Mini Bike without a helmet eye protection and protective clothing can be hazardous Riding a Mini Bike without a helmet increases the chance of severe...

Page 17: ... the engine 5 Once engine has warmed up for a few minutes place the choke lever 2 back to the OFF right position 1 2 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 ventilat...

Page 18: ... on the handlebars and both feet on the footrests while operating the Mini Bike WARNING STARTING OFF 1 Start and warm up the engine according to the instructions in this manual 2 Place the side kick stand in the up position 2 Apply the throttle gradually to start riding Practice riding mini bike on a flat dirt surface that has plenty of room for turning Turning the throttle grip to full throttle w...

Page 19: ...jury of death Never Modify this Mini Bike in anyway including adding accessories unless the modification is a genuine certified modification or accessory approved by the manufacture Never modify the Mini Bike with improper installation Make sure to follow all instructions recommended in the certified modification Use only genuine parts After market parts and accessories may be available from other...

Page 20: ...tenance and inspection checks with the exception of checking the engine stop switch and throttle WARNING Failing to perform the recommended maintenance on this Mini Bike could be hazardous Failing to perform proper maintenance on this Mini Bike could result in an accident Always perform the recommended maintenance for the Mini Bike as listed in this manual WARNING Failing to perform recommended ma...

Page 21: ... hrs Every 6 Mo 100 Hrs Every Year 300 hrs Engine oil check X Engine oil change X X Air filter check X Air filter clean X Air filter change X Carburetor Sediment cup clean X Spark plug clean and adjust X Spark Plug Replace X Idle speed check and adjust X Valve clearance check adjust X Fuel tank and Filter clean X Fuel tube check X Centrifugal clutch clean and lube Every 5 hours of use All nuts and...

Page 22: ...eaning frequently can plug up the air filter which can cause poor gas mileage low power and cause damage to the engine CAUTION Air filter removal inspection and cleaning instructions 1 Locate the air filter assembly 1 2 Open the Air filter assembly cover 2 by unhooking tab on underside of cover 3 Remove the air filter element 3 from the assembly 3 Clean foam element with mild soap and water Rinse ...

Page 23: ... the plug Use a thickness feeler to inspect the spark plug gap 2 The spark plug gap should be 0 6 0 8mm 0 024 0 032 in 0 6 0 8 mm 0 024 0 032 in LD F7TC Re install the inspected plug or new plug until finger tight Finish tightening plug with a wrench If the plug is a new plug tighten approximately 1 2 turn more with the wrench If plug is an old plug tighten approximately 1 8 turn more with a wrenc...

Page 24: ...ed on bottom front left front side of the engine 3 If engine oil is low add oil until oil is at edge of fill hole 2 Use the correct grade of oil as listed in this manual Do not over or under fill engine with oil this could damage the engine 1 Changing the engine oil 1 Make sure engine is warm before attempting to drain the oil A warm engine will help the oil drain quicker 2 Remove the oil fill plu...

Page 25: ... 3 Once throttle grip is at the proper freeplay re tighten the jam nut 3 2 3 4 Inadequate throttle play can be hazardous The engine speed could rise when the handlebars are turned if there is not enough throttle play This could result in loss of control Always check throttle play before each ride Turn handlebars from side to side making sure throttle does not increase when doing so WARNING MAINTEN...

Page 26: ...ce Adjusting the valves should be done by an authorized service center Proper valve gap will help Mini Bike run at peak performance Follow the valve gap adjustment intervals listed in the maintenance chart Proper Valve Clearance Intake 0 1 0 15 mm Exhaust 0 15 0 2 mm MAINTENANCE 22 Brakes Brake Adjustment The brake adjustment nut 4 is located on the rear brake drum assembly 5 located on the rear w...

Page 27: ...of the chain The chain 1 tension should be 1 2 3 4 in 15 20mm Chain tension slack adjustment 1 Loosen bolts under engine 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 ...

Page 28: ...CIRCULATION ONLY DO NOT OIL THE INSIDE OF THE CLUTCH Performing maintenance and inspection on the centrifugal clutch while the engine is running could be hazardous Performing maintenance and inspec tions on the centrifugal clutch while the engine is running could result in getting body parts or clothing caught in moving parts or could result in touching hot items which could result in severe injur...

Page 29: ... Bike with worn tires will reduce traction which could result in an accident Never operate this Mini Bike with tires that have a tread depth of less than 4mm 0 16 in WARNING Minimum tread 4mm 16 in Tire pressure Front tires 10psi 69 kpa Rear tires 10psi 69 kpa Replacing tires Always replace tires with type and size listed in this manual Always use the correct tools when replacing tires The bead an...

Page 30: ... Fuel stabilizer can be purchased at most motor cycle shops and auto parts stores 4 Remove spark plug and poor 1 tablespoon of motor oil in the spark plug hole Re install spark plug 5 Place the starter button to the off position and pull the start recoil cord a few times This is to coat the inside cylinder head with oil 6 Fill tires with correct air pressure 7 If possible store Mini Bike in a shed...

Page 31: ... Note Be careful not to allow water to enter the muffler outlet air filter intake brake cable throttle cable or switches Transporting 1 Make sure fuel valve 1 is turned to the OFF left position 2 Drain carburetor by turning fuel valve 1 to the off position and opening the drain screw 2 Allow all fuel to drain from the carburetor Once fuel is drained re tighten drain screw 2 Note Make sure to drain...

Page 32: ...he ON left position Take to a service center for repair Clean or replace air filter Take to a service center for repair Engine stalls or runs erratically Low fuel Stale or contaminated fuel Choke is left in the ON left position Spark plug is fouled or defective Spark plug gap is incorrect Spark plug cap is loose Carburetor is clogged or has water in it Idle is not adjusted properly Problem with th...

Page 33: ...32km h Transmission Drive System Type Chain Drive Gear Ratio 10 1 Centrifugal Clutch Suspension Front Type Low pressure tires Rear Type Low pressure tires Braking Rear Brakes Type Drum Tires Front Tire Size AT19x7 8 Rear Tire Size AT19x7 8 Dimensions and Weights Length 57in 1450mm Height 26 5in 680mm Width 38in 960mm Wheelbase 42in 1050mm Vehicle Wt 121lbs 55kg Weight Cap 200lbs 91kg Ground Cleara...

Page 34: ...e Locate the numbers and list the numbers below for reference The 17 digit Vehicle Identification Number VIN is located on the vertical tube on the neck of the mini bike Vehicle Identification Number The engine number is located on the left bottom front portion of he Mini Bike Engine VIN Engine Number FRAME AND ENGINE NUMBER LOCATION ENGINE 30 ...

Page 35: ...failure would increase an engines emissions including electronic controls fuel injection exhaust gas recirculation after treatment or any other system utilized in this vehicle to control emissions Replacing or repairing other components not covered by this emissions warranty or the standard warranty is the responsibility of the owner including the parts labor and other costs associated with recomm...

Page 36: ...anty excludes failures not caused by a defect in material or workmanship This limited warranty does not cover damage due to accidents abuse or improper handling maintenance or use This limited warranty does not cover any engine that has been structurally altered or any engine that has been used in racing competition This limited warranty also does not cover physical damage corrosion or defects cau...

Page 37: ...POWERSPORTS 888 405 8725 Coleman Powersports 364 S Smith Rd Tempe AZ 85281 www colemanpowered com ...