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Coleman POWERSPORTS BK160, Owner'S Manual

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To the Owner

Congratulations on your purchase of a Coleman Powersports Go Kart. This 

Owner’s/Operator’s manual will provide you information regarding safe 

operation, operational instructions, maintenance and care. Fully 

understanding this manual and following all of the instructions herein will 

provide the knowledge needed to have safe and enjoyable Go Kart 

operation.

For questions regarding operation and maintenance of this Go Kart, please 

call Coleman Powersports toll free 888-405-8725

Safety - Notice to parents

 

No one under the age of 16 should operate this Go Kart . Not all 
children have the strength, size, skill, and judgment needed to 
operate this vehicle safely.

 

THIS Go Kart IS NOT A TOY AND COULD BE HAZARDOUS TO 
OPERATE.

 

A  Go Kart

 

handles differently from other vehicles 

including motorcycles and cars. A collision or rollover can occur 
quickly, even during routine maneuvers such as turning, driving on 
hills and over obstacles.

 

I

 

Reading the Owner’s/ Operator’s Manual

 

It is important this manual is read from cover to cover carefully by the Go 
Kart owner and all operators. Parents should review the manual carefully 
with their children. Never allow anyone to operate the Go Kart without first 
reading and understanding the 

Owner’s/Operator’s 

 manual.

 

This  Owner’s/  Operator’s  manual  should  be  a  permanent  part  of  the  Go 

Kart and should remain with the vehicle at all times. The manual should 
also remain with the vehicle if sold.

 

Summary of Contents for POWERSPORTS BK160

Page 1: ...this go kart Always wear a helmet it could save your life READ THIS MANUAL CAREFULLY Model BK150 Provincial Municipal governments have different regulations pertaining to owning and operating an off road vehicle learn the regulations in your area POWERSPORTS ...

Page 2: ... and judgment needed to operate this vehicle safely THIS Go Kart IS NOT A TOY AND COULD BE HAZARDOUS TO OPERATE A Go Kart handles differently from other vehicles including motorcycles and cars A collision or rollover can occur quickly even during routine maneuvers such as turning driving on hills and over obstacles I Reading the Owner s Operator s Manual It is important this manual is read from co...

Page 3: ...on to make procedures easier or clearer to understand Coleman Powersports is concerned about the environment and believes in conserving and protecting all natural resources For this reason owners should recycle trade in or dispose as appropriate batteries oil and tires WARNING or CAUTION The first part will identify a POTENTIAL HAZARD The second part will describe WHAT COULD HAPPEN if the warning ...

Page 4: ...wn to the state of California to cause cancer and birth defects or other reproductive harm To minimize exposure avoid breathing exhaust do not idle the engine except as necessary service your vehicle in a well ventilated area and wear gloves or wash your hands frequently when servicing your vehicle For more information go to www P65Warnings ca gov passenger vehicle WARNING III ...

Page 5: ...INSPECTION 14 OPERATING THE GO KART 15 WARNINGS 15 HELMET EYE PROTECTION AND PROTECTIVE CLOTHING 16 SEAT BELTS 17 STARTING THE ENGINE 18 STARTING OFF 19 OPERATING ON HILLS 20 CLIMBING A HILL 20 DESCENDING A HILL 20 TRAVERSING A HILL 20 SKIDDING OR SLIDING 21 OPERATING THROUGHWATER 22 OPERATING IN COLDWEATHER 23 LOAD GUIDELINES 24 AFTER MARKET PARTS 24 MAINTENANCE 25 MAINTENANCE CHART 26 BATTERYINS...

Page 6: ... ADJUSTMENT 36 CLEANING AND LUBRICATION 36 TIRES 37 REPLACING 37 STORAGE 38 RETURNING TO SERVICE 38 WASHING THE GO KART 39 TRANSPORTING 39 TROUBLE SHOOTING 40 TORQUE SPECIFICATIONS 41 SPECIFICATIONS 42 VEHICLE AND ENGINENUMBER LOCATION 43 EMISSION CONTROL SYSTEM WARRANTY 44 ...

Page 7: ... or replace any original Coleman Powersports 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 This warranty does not apply to any vehicle which is used in competition or used in a manner not consistent with the ...

Page 8: ...er 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 personal items Length of...

Page 9: ...4 IMPORTANT LABELS 5 9 7 8 6 4 3 2 1 ...

Page 10: ...5 11 12 ...

Page 11: ...with more than one passenger More than one passenger will affect balance and control ALWAYS be cautious while operating to avoid vehicle overturns on hills rough terrain and in turns avoid paved surfaces pavement may seriously affect handling and control wear seat belts and keep hands arms and feet in kart at all times LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS ALWAYS USE ...

Page 12: ...7 10 11 12 WARNING ...

Page 13: ... paved surfaces and or public roads Pavement may cause the Go Kart to be come unstable 10 The brush guard surrounding the driver and passenger is not intended to provide rollover protection Before each use make sure all tubes are securely in place and bolts are tight 11 Never operate Go Kart with long hair loose jewelry or loose clothing that could get caught in moving parts 12 Always go slow on u...

Page 14: ...ake pedal will stop the Go Kart Note Always check brakes before operation Gas Pedal 4 Depressing gas pedal will increase engine RPMs causing Go Kart to move Parking Brake Lever 5 Lever pulled to back position will set the parking brake Always use parking brake when engine is not running or while engine is running and is in a stopped position for an extended period of time Forward and Reverse lever...

Page 15: ... cap counter clockwise to remove To re install cap turn cap clockwise until snug Make sure cap is seated properly 8 Oil Fill plug Dipstick 8 To open Oil fill plug Dipstick turn cap counter clockwise to remove To re install cap turn cap clockwise until snug Make sure cap is seated properly ...

Page 16: ...seat latch up to move the seat forward or backward Before operating the Go Kart make sure the seats are bolted in properly and that the seat latch is locked in place in desired position WARNING Failure to have the seat locked in position could be hazardous The seat coming loose could cause the operator to loose control Never operate the Go Kart without the seat locked in place 9 ...

Page 17: ...line under any circumstances containing more than 5 Methanol doing so will damage your engine and will void the warranty Fuel Filling ENGINE OIL The recommended oil for this Go Kart is SAE10W 40 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 WARNING Fuel and fuel vapor are highly flammable and toxic You can...

Page 18: ...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 bottom edge of the filler neck ...

Page 19: ... your Go Kart Proper operation during this break in period will help assure maximum life of your Go Kart engine The following guidelines will explain the proper break in procedures 1 During the first 10hours of operation do not apply more than 1 2 throttle for long periods of time Vary the engine speed Make sure to vary the engine speed during the break in period this allows the engine to load and...

Page 20: ...g parts or hot surfaces Never perform maintenance or check procedures while the engine is running with the exception of checking the ignition switch or throttle WHAT TO CHECK CHECK FOR Steering Smoothness No restriction of movement Brakes Correct fluid level Inspect hoses for leaks Inspect brake pads for wear wear Tires Proper tire pressure Proper tread depth Rubber has no cracks Fuel Tank Enough ...

Page 21: ...idewalks driveways and streets can cause loss of control resulting in severe injury or death Go Kart tires are designed for off road use only paved surfaces adversely affect handling and control Avoid operating Go Kart on paved surfaces If you must cross a paved surface go slow and do not make sudden turns or stops WARNING Operating a Go Kart on hills could be hazardous Operating a Go Kart on a hi...

Page 22: ...as a helmet and protective operating gear should be mandatory when operating a Go Kart Wear protective clothing Long sleeve shirt 3 Gloves 4 Long pants 5 over the ankle boots 6 Operating a Go Kart exposes the operator to many hazards wearing protective clothing can help protect the operator from injury WARNING Operating a Go Kart without a helmet eye protection and protective clothing can be hazar...

Page 23: ...tighten the shoulder straps by pulling the loose ends 4 to wards the bottom of the go kart If there is no passenger in the passenger seat make sure the passenger seat belt is latched together and secure 5 WARNING Riding in this go kart without the seat belt harness worn and attached properly for both the operator and passenger could be hazardous Operating the go kart without the seat belt harness ...

Page 24: ...conds at a time doing so could damage the starter Note Do not depress the gas pedal while starting engine doing so will disengage the choke making it difficult for engine to start 5 Once engine has started allow engine to warm up 3 to 5 minutes before operating 3 WARNING Starting or running the Go Kart in an enclosed area such as a garage or shed where there is no ventilation is hazardous Inhaling...

Page 25: ...until you become fully familiar with the Go Karts handling characteristics 3 2 WARNING Operating this Go Kart at excessive speeds could be hazardous Operating at excessive speeds increases your chances of losing control of the Go Kart which could result in severe injury or death Always go at a speed that is proper for the terrain visibility operating conditions operator skill and operator experien...

Page 26: ...s not too steep the terrain is not loose or slippery and that there are no obstacles 2 Do not go down the hill on a sharp angle this could cause the Go Kart to flip over Instead go straight down the hill Apply the brakes on the way down TRAVERSING A HILL If it is determined the Go Kart cannot be backed down the hill safely 1 Apply the brakes so the Go Kart does not roll backwards 2 If you feel you...

Page 27: ... the Go Kart to slide out of control The Go Kart could turn over or slide into an object This could result in severe injury or death Apply the parking brake only after the Go Kart has come to a complete stop WARNING Skidding or sliding of the Go Kart could be hazardous Skidding or sliding could result in the Go Kart sliding into an object or overturning suddenly by regaining traction resulting in ...

Page 28: ...ater if doing so could damage the river bank or shore line Brakes need to be inspected cleaned and replaced more often if Go Kart is used in muddy wet or sandy conditions Inspect the Go Kart brakes regularly have a service center clean or replace as needed WARNING Operating this Go Kart through fast or deep water could be hazardous Deep or fast moving water could cause the Go Kart to loose tractio...

Page 29: ... Once brakes are thawed check again for proper operation if they still do not work take the Go Kart to an authorized service center Do not attempt to operate the Go Kart with brakes that do not work correctly Preventive maintenance in cold weather operating is important after operating in cold weather with snow slush water or ice dry off the Go Kart including brake and throttle linkages Apply the ...

Page 30: ...ing at higher speeds Allow plenty of distance to stop while carrying cargo The more weight on theGo Kart the longer distance it will take to stop WARNING Operating this Go Kart with modifications or adding accessories could be hazardous Modifications to the Go Kart including adding accessories could adversely affect the handling of the Go Kart causing an accident which could result in severe injur...

Page 31: ...enance and inspec tion while the engine is running could be hazardous Performing maintenance and inspections 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 injury Shut off engine when performing maintenance and inspection checks with the exception checking the ignition switch and t...

Page 32: ...creen I I Transmission oil R Drive Chain Inspect drive chain before each ride Clean and lubricate as necessary Brakes I I Brake hose I I Brake fluid Inspect brake fluid level before each ride if low check brake pads for wear and brake lines and components for leaks Replace brake fluid every 2 years Tires I Steering I I Front suspension I I Rear suspension I I Chassis nuts and bolts T I T Recommend...

Page 33: ... can damage the charging system and the battery The red lead clip must go to the POS side of the battery The black lead clip must go to the NEG side of the battery WARNING If not performed the correct way charging the battery could be hazardous While charging battery keep away from sparks and open flames The battery gives off explosive gases Always connect the charger to the battery before turning...

Page 34: ...y loosening and removing the 4 screws on the filter assembly cover 1 2 Remove paper element 2 from inside the filter housing Inspect element if torn or if element shows signs of wear replace 3 Clean paper element by gently tapping on a hard surface to remove large particles 4 Use low pressure compressed air to clean the filter Blow out particles from the inside out Note Do not apply air to the out...

Page 35: ...Use a thickness feeler to inspect the spark plug gap 2 The spark plug gap should be 0 6 0 8mm 0 024 0 031 in CAUTION Dirt can damage the engine if it enters the spark plug hole Make sure the spark plug hole is covered after removing plug NST A7RTC NGK Re install the inspected plug or a new plug until finger tight Finish tightening plug with a wrench If spark plug is a new plug tighten approximatel...

Page 36: ...ith oil this could dam age the engine 2 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 plug 1 3 Remove the drain bolt 2 located on the bottom of the engine 4 Allow the oil to drain in an appropriate container Note Dispose of oil at an oil reclaim facility 5 Install the drain plug and fill wit...

Page 37: ...t and grade of engine oil TRANSMISSION OIL Go kart is sent from the factory with the correct transmission oil type and quantity Refer to maintenance schedule for oil change intervals Checking the level of transmission oil can only be done by draining and replacing with the correct oil type and quantity 1 Locate and remove transmission oil fill plug 4 located on bottom side rear portion of engine a...

Page 38: ... ADJUSTMENT The front and rear shocks each have five adjustable positions The default position has been set by the manufacture The tension of the shock will change depending on the position of the adjustment ring 2 To increase to a stiffer suspension rotate the adjustment ring counter clockwise Todecrease to a lighter suspension turn adjustment ring clockwise Generally heavier riders will want sus...

Page 39: ...pect brakes before each use could be hazardous Inspect brakes before each use according to the Preride check list make sure to follow the maintenance schedule and procedures 3 Check the brake fluid level 2 for brakes If fluid level is below the lower mark inspect the brake hoses 3 for leaks or cracks If there are no leaks inspect the brake pads for excessive wear If brake pads are worn take to a s...

Page 40: ...formance Follow the valve gap adjustment intervals listed in the maintenance chart Proper Valve Clearance Intake 0 0012 in 0 03mm Exhaust 0 002 in 0 05mm 1 FUSE REPLACEMENT If starter motor does not turn over it may be the 15 amp fuse is bad Toaccess 15 amp fuse remove electronics cover 1 located on top of engine assembly 2 3 Locate and open fuse holder 2 Inspect fuse 3 if damaged replace ...

Page 41: ...mean the sprockets may be worn Look for the following on sprockets 1 Worn teeth broken or damaged teeth loose sprocket mounting nuts If sprockets show signs of wear contact a service center for replacement CHAIN TENSION Check tension of drive chain 2 chain tension should be 5 15mm 0 2 0 6in Chain tension slack Adjustment 1 Loosen jam nuts 3 on Chain tensioners 4 2 Adjust chain tension by turning t...

Page 42: ...d service center Service centers have the correct equipment and expertise to change tires without causing damage Punctures to tires can usually be repaired by using plug type patches Plug type patches cannot repair tires that have been cut If the tire has been cut or has a puncture in a location or size that cannot be repaired replace the tire Be prepared for flat tires always carry a plug type pa...

Page 43: ...e starter key and allow the Go Kart turn over a few times If Go Kart starts shut off immediately This is to coat the inside cylinder head with oil 6 Cover the muffler outlet and air intake with oily rags so the Go Kart will be protected from humidity in storage 7 Remove the Battery and clean battery case and terminals with soap and water Store battery in a cool dark place Charge battery at least o...

Page 44: ...eaning materials that could scratch the Go Kart Note Be careful not to allow water to enter the muffler outlet air filter intake brake cables or switches TRANSPORTING 1 Open the drain screw 1 Allow all fuel to drain from the carburetor Once fuel is drained re tighten drain screw 1 Note Make sure to drain fuel in a proper storage container 2 Transport the Go Kart in the upright position tied down s...

Page 45: ...e plug Gap the plug Attach spark plug cap Do not apply throttle while starting doing so disengages auto choke Take to a service center for repair Take to a service center for diagnostics and repair while starting doing so disengages auto choke Take to a service center for repair Take to a service center for diagnostics and repair Engine stalls or runs erratically Idle is not adjusted properly Prob...

Page 46: ...bs 8 12 nm 8mm bolts and nuts 13 18 ft lbs 18 25 nm 10mm bolts and nuts 22 29 ft lbs 30 40 nm 12 mm bolts and nuts 36 43 ft lbs 50 60 nm 4 mm screws 22 30 22 30 in lbs 2 5 3 4 nm 5mm screws 30 43 in lbs 3 5 5 nm 6 mm hex bolts 87 121 in lbs 10 14 nm 8 mm hex bolts 17 22 ft lbs 24 30 nm 10mm hex bolts 25 32 ft lbs 35 45 nm 39 52 in lbs ...

Page 47: ...ear Tire Size 18x9 5 8 Tire pressure 10psi 69kpa Dimensions and Weights Length 89in 2270mm Height 54in 1380mm Width 59 8in 1520mm Wheelbase 70 5in 1792mm Vehicle Wt 484 lbs 220kg Horse Power 7 37 hp 5 5 kw 7000 RPM Torque 9 3N m 5500rpmTop Speed 34 18mph 55km h Weight Cap 333lbs Fuel 150kg Transmission Type CVT with forward and reverse Drive System Type Chain Drive Gear Ratio Automatic Suspension ...

Page 48: ... help or when registering your Go Kart Locate the numbers and list the numbers below for your reference The 17digit Vehicle Identification Number VIN is stamped on the frame under the front spring on the passenger side ofthe Kart Vehicle Identification Number The engine number is located on the left bottom rear portion of he Go Kart Engine Engine Number ...

Page 49: ...lated assemblies Where a warrantable condition exists Tao Motor will repair your vehicle at no cost to you including diagnosis parts and labor If an emission related part on your vehicle is defective the part will be repaired or re placed by Tao Motor This is your emission control system defectswarranty NOTICE Use of any Tao Motor vehicle in any type of competitive event completelyand absolutely v...

Page 50: ...es Board for the periods specified above I Coverage Warranty defects shall be remedied during customary business hours at any authorized Tao Motor s dealer located within the United States ofAmerica in compliance with the Clean Air Act and applicable regulations of the UnitedStates Environmental Protection Agency and the California Air Resources Board Any part or parts replaced under this warranty...

Page 51: ...cular purpose is limited to the express emission control system warranty terms stated in this warranty The foregoing statements of warranty are exclusive and in line of all other remedies Some states do not allow limitations on how long an implied warranty lasts so the above limitations may not apply to you C No dealer is authorized to modify this Tao Motor Limited EmissionControl System Warranty ...

Page 52: ...47 NOTES ...

Page 53: ...POWERSPORTS 1775 E University Dr Tempe AZ 85281 PHONE Toll Free 888 405 8725 https www colemanpowered com https www facebook com colemanpowersportusa https www instagram com colemanpowersports_usa ...

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