Coleman CT100U Installation instructions

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.

ASSEMBLY/PRE-RIDE INSPECTION

INSTRUCTIONS

CAUTION

This mini bike was

shipped without engine

oil. Always fill with with

the correct amount and

grade of engine oil as

listed in the owner's

manual.

CT100U

051816

For questions about these Assembly Instructions, call Coleman

Powersports toll free 888-405-8725

REMOVAL FROM CRATE

Owner’s/Operator’s Manual

Tool Kit

Zip Ties

Front Fender

Assembly

Front Fork

Assembly

Hardware

10mm Large Washers

10mm Lock Nut

10mm Small

Washer

10mm Steering Bolt

8mm Large Washers

8mm Nuts

8mm x 20mm Bolts

Wheel Assembly

Front wheel

Clutch Cover

12mm Washers 12mm Lock Nut

Front Fender

12mm Axle Bolt

8mm x 20mm Bolts

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

Large Washer

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

2. Tighten nut

Torque nut to 20 ft .lbs. ( 27Nm)

Note: Small portion of fender faces

foreward

Large 8mm Washers

8mm Nuts

8mm x 20mm Bolts

8mm x 20mm Bolts Large 8mm

Washers

8mm Nuts

FRONT FENDER INSTALLATION

1. Attach front fender with 8mm x

20mm bolts, large 8mm washers

and 8mm nuts.

FRONT WHEEL INSTALLATION

1. Orient the front tire so the arrow

on the tire faces forward.

Arrow faces forward

Large 8mm Washers

12mm Lock Nut

12mm Washer 12mm Axle Bolt

12mm lock nut 1ea.

12mm washers 2ea.

12mm Axle bolt 1ea.

2. Insert Axle bolt with the 12mm

washers between the forks and

wheel assembly on each side.

3. Install 12mm lock nut

and tighten.

Torque Front Lock Nut 20 ft.lbs

(27Nm)

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.

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.

OIL AND FUEL

Engine Oil

1. Remove the oil ll plug (1)

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.

Caution: Do not over or under ll

with Motor Oil

Fill level

2. 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 ll hole.

3. Re- install ll cap, Start engine and

allow to run for a few minutes, Re-check

oil level and ll accordingly.

Filling with Oil

Mini bike DOES NOT have oil in

crankcase when shipped from

the factory.

NEVER ATTEMPT to start the

engine without engine oil.

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

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

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)

2.0 - 4.0mm

(0.08 - 0.16 in)

Brakes

BRAKE ADJUSTMENT

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

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.

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).

.078 - .24 in

(2-6 mm)

It is important that the throttle grip have a

certain amount of free play .

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