Coleman Powersports BK200-K Assembly and Pre-Ride Inspection Instructions

Removal from Crate

1. Remove metal crate from around Go-Kart.
2. Locate and remove Owner's/Operator's manual, setup instructions, and all documentation.

   Note: Read Owner's / Operator's manual thoroughly before starting Go-Kart for the first time.

3. Locate and remove all parts and hardware from crate and set aside.

   Note: Some hardware may already be mounted at part locations on the Go-Kart. This hardware will need to be removed then re-attached during assembly.

Hardware Pack Contents (Visual Description): Includes Front Tires, Oil Cooler, Middle Protecting Pole, Seats, Front Bumper, Front Protecting Pole, Rear Guide Bar.

Front Shock Assembly

Hardware:

• M10 X 45 bolts - 4 pieces (1)
• M10 Lock Nuts - 4 pieces (2)

Note: The center of the Go-kart will need to be lifted to install shocks, spindles, and wheels. This can be done with a floor jack.

1. Attach shocks on each side of the front assembly to the top shock mounts with M10 bolts (1) and Lock Nuts (2).

Diagram Description: Shows the front assembly with labels indicating shock mount locations for installation using bolts (1) and nuts (2).

Wheel Installation (Front and Rear)

Hardware:

• M10 Lug Nuts - 8 pieces (1)

1. Install front tires with valve stems facing out. Ensure the tread pattern is facing forward (2).
2. Secure each front tire onto each front hub (3) using 4 M10 Lug Nuts (1).
3. Install rear tires on the rear hubs (3). Secure tires with the M10 Lock Nuts (1) provided.
4. Tighten all Lug Nuts to 29 ft.lbs (40Nm).
5. Inspect hubs, ensure they are tight and that Cotter Pin (5) is installed.
6. Snap Rubber Hub Caps (6) onto hubs.

Diagram Description: Illustrates M10 Lug Nuts (1), front tire (2), front hub (3), rear hub, Cotter Pin (5), and Rubber Hub Caps (6) with arrows showing installation.

Seat Installation

Seat Hardware:

• M8 X 50mm bolts - 2 pieces (5)
• M8 Large Flat washers - 6 pieces (6)
• M8 lock washers - 6 pieces (7)
• M8 Nuts - 6 pieces (8)

1. Install driver side seat by sliding the seat into place using the front hook connector on the seat brackets, then bolt into place using bolts (5), Flat Washers (6), lock washers (7), and nuts (8).
2. Install passenger seat by inserting the 4 M8 bolts located on the bottom of the seat into the holes located on the frame. Attach seat with flat washers (6), lock washers (7), and nuts (8).

Diagram Description: Shows seat hardware (5-8), seat brackets with "hook connectors", the driver's seat, and the passenger seat being attached to the frame.

Brush Guard Installation

Hardware:

• M8 X 60 bolts - 5 pieces (1)
• M8 X 55 bolts - 6 pieces (2)
• M8 Lock Nuts - 6 pieces (3)
• M8 Concave Spacers - 17 pieces (4)

1. Attach Middle protecting pole (5) with M8 X55 bolts (2), Concave Spacers (4), and Lock Nuts (3).
2. Attach Front protecting pole (6) with M8X60 bolts (1), M8X55 bolts (2), Concave Spacers (4), and Lock Nuts (3).
3. Attach Rear guide bar (6) with M8X60 bolts (1), Concave Spacers (4).

Note: Tighten all bolts on rack and Brush Guard assembly. Do not tighten bolts at this time; keep bolts loose until the brush guard is completely assembled.

Diagram Description: Illustrates the attachment points for the middle protecting pole, front protecting pole, and rear guide bar using specified hardware.

Front Bumper Installation

Hardware:

• M8 X 60 bolts - 2 pieces (1)
• M8 X 55 bolts - 2 pieces (2)
• M8 Lock Nuts - 4 pieces (3)
• M8 Concave Spacers - 4 pieces (4)

1. Attach Front Bumper (5) to Frame with M8X 60 bolts (1), M8 X 55 bolts (2), Concave Spacers (4), and Lock Nuts (3).

Diagram Description: Shows the front bumper (5) being attached to the frame using bolts (1, 2), spacers (4), and nuts (3) at indicated locations.

Oil Cooler Installation (Optional on 200cc)

Hardware:

• M6 X 20 bolts - 2 pieces (1)
• M6 X 30 bolts - 2 pieces (2)
• M6 Lock Nuts - 4 pieces (3)

1. Attach Oil Cooler (4) to Frame and Rear guide bar with M6 X 20 bolts (1), M6 X 30 bolts (2), and Lock Nuts (3).

Diagram Description: Illustrates the oil cooler (4) being attached to the frame and rear guide bar using bolts (1, 2) and nuts (3).