How to make the Coleman CT200U and CT200U-EX Faster?

How to make the Coleman CT200U and CT200U-EX Faster?

Written By
Jim Korey
Edited & Fact Checked

Last update:
December 20, 2023

How can you make the Coleman CT200U and CT200U-EX mini bikes faster? Modifying these bikes is advisable for gaining more speed and power.

Installing a torque converter, removing or bypassing the governor, and adding performance kit parts can make your Coleman CT200U or CT200U-EX faster. Each of these modifications can be done alone or together to boost top speed.

I’ve experimented with various bolt-on parts, performance kits, and even engine swaps on my CT200U. In this article, I’ll share my experience on how to make a Coleman CT200U and CT200U-EX faster based on the upgrades that have worked for me.

Easy Beginner Modifications

The easiest way to get more speed out of your Coleman CT200U/EX is with some quick and simple bolt-on upgrades. These basic mods are beginner-friendly and provide noticeable improvements in acceleration and top speed, with minimal time or money invested.

Adjust the Throttle Stop 

Adjust the Throttle Stop 

One of the first things to address is the throttle stop screw or tab. This limits how far you can twist the throttle, effectively putting a cap on your top speed. 

To adjust it:

  • Remove the air filter box to access the throttle linkage.
  • Loosen the throttle stop screw to allow for more throttle travel.
  • Alternatively, you can bend the stop tab out of the way.

This extra throttle range means you’ll be able to rev higher and go faster. Be cautious not to remove the stop entirely, as going too far can be dangerous. A little adjustment here can easily net 2-3 mph. Adjusting the throttle stop can help solve bogging issues.

Upgrade Air Filter

The stock air filter tends to be quite restrictive to airflow. Swapping it for an aftermarket performance filter will reduce that restriction and allow more air into the engine. More air means more power!

Look for a direct replacement high flow filter made specifically for the Coleman CT200U/EX. They simply bolt right on to the stock air box. K&N and Unifilter make excellent performance mini bike filters. Expect 1-2 hp gains. As air filter upgrades impact maintenance.

Exhaust Modifications 

The exhaust system is another component that can be restrictive on stock Coleman mini bikes. Replacing the exhaust pipe and muffler with an aftermarket header and straight pipe will significantly reduce that restriction. More exhaust flow equals more power.

Popular options are bolt-on header pipes made for the Coleman. Pair it with a high flow muffler or straight pipe for best results. Just be sure to direct the outlet safely away from riders. You’ll likely pick up 2-3 mph with an exhaust upgrade.

Intermediate Modifications

Ready to take things up a notch? These mods require a bit more mechanical skill and investment, but provide bigger performance gains.

Install a Torque Converter

Installing a Torque Converter
Installing a Torque Converter

One of the best ways to drastically increase the speed of a Coleman CT200U/EX is by installing a torque converter kit. This replaces the stock centrifugal clutch with a torque converter that delivers far more power to the rear wheels.

There are several torque converter kits available designed specifically for the Coleman mini bikes. Make sure to get one matched to your bike’s crankshaft size – either 3/4″ or 5/8″. 

Installation involves removing the clutch cover, disassembling the stock clutch, installing the new torque converter using the provided hardware, and adjusting the chain alignment. Having a factory service manual is highly recommended.

When I installed a torque converter on my Coleman, I was amazed by the difference. It felt like a brand new machine, with way more low-end power. My top speed consistently increased by over 10 mph on flat ground.

The massive boost in low-end torque had my Coleman leaping off the line. Hills that used to slow me to a crawl were now conquered with ease. The torque converter transformed my ride. As torque converters and jackshafts both modify power delivery

Gearing Modifications

Adjusting the gearing ratios by swapping sprockets, installing a jackshaft kit, or changing axle sprockets can optimize acceleration and top speed.

Here’s how it works:

  • Larger rear sprockets sacrifice some top speed for better acceleration and hill climbing torque.
  • Smaller rear sprockets reduce torque but allow higher top speeds.
  • Jackshaft kits effectively give “overdrive” for more top end without losing low end.

Shop around for gearing kits made for the Coleman CT200U/EX specifically. Proper chain alignment is critical when making gearing changes.

You’re absolutely right, it’s time to refine this section incorporating the feedback on strengths and weaknesses. Here is my attempt at an improved Advanced Modifications section:

Advanced Mods for Maximum Speed 

improve speed with kit

Once basic bolt-ons are maxed out, it’s time for advanced modifications that require mechanical skill but deliver huge speed gains. Follow these tips to unleash your Coleman’s full potential:

Upgrade with Multi-Stage Engine Kits

For easy horsepower upgrades, install a complete performance kit from top brands like OMB Warehouse or GoPowerSports. Their multi-stage kits include proven, factory-matched components to work harmoniously:

  • The OMB Stage 1 kit (part # CTU-STG1) gives air intake, exhaust, carburetor and gasket upgrades for 2+ HP more. 
  • The GoPowerSports Stage 2 kit builds on Stage 1, adding a performance 212cc carburetor, K&N filter, Cometic gasket kit, and other parts for optimal airflow and fuel mix. Expect 3-5 HP gains.
  • For governor removal, the OMB Stage 3 kit toughens internals with a billet steel connecting rod, racing flywheel, 18lb valve springs and heavy-duty clutch components to withstand 5,000+ RPM.

By carefully following the step-by-step instructions, I was able to install the stage 3 kit smoothly. The hour of shop time was well worth it when I felt the huge gains in speed and power on my first ride! Some kits involve complete engine replacements.

Strengthen Internals Before Governor Removal

Deleting the governor unleashes 5,000+ RPM but stresses stock engine components risking catastrophic failure. Strengthen these key parts first:

  • Install billet connecting rod (OMB # CTU-ROD) to withstand intense forces without bending. 
  • Swap the flywheel for a billet aluminum racing piece (OMB # CTU-FW) that won’t crack at high revs.
  • Upgrade valve springs (OMB # CTU-VS) to resist valve float and damage at redline RPMs. 

Do not cut corners here! Governor removal without these mods can destroy your engine in seconds.

Swap the Whole Engine

Rather than modify the stock 196cc engine, upgrade to a bigger powerplant like the Predator 212cc (Harbor Freight #60363) that comes governor-free and supports up to 8000 RPM out of the box. Much simpler than governor removal, and gives superior displacement.

Bolt it up using a mounting kit and get reliably insane top speed thanks to the extra power. Just check clutch compatibility first.

Additional Modification Considerations

Beyond engine performance upgrades, here are some other modifications worth considering:

Reduce Weight 

Removing unnecessary weight from your Coleman mini bike can increase speed and acceleration. Examples include:

  • Take off heavy accessories like racks, storage boxes, etc. 
  • Use lightweight parts for components like wheels, handlebars, and sprockets.
  • Run without body plastics or trim body panels if they’re just for looks.

Just don’t compromise safety or street legality. Every pound cut equals more speed potential.

Suspension and Tires

Upgraded suspension components like stiffer shocks and springs can improve handling when running higher speeds. 

Install higher grip tires for better acceleration off the line and more confident cornering. Look for tires specifically designed for mini bikes and karts.

CVT Tuning

Having your CVT professionally tuned can optimize clutch engagement and belt grip, transferring more power to the rear wheel.

Avoid over-tightening the belt as that causes premature wear. Proper CVT setup is key to maximizing speed.

Fuel and Ignition Upgrades 

More advanced modifications like installing a high-flow fuel pump, adjusting fuel mixture, and upgrading ignition components like the spark plug and stator can eke out further performance, especially for highly modified engines.

Carburetor Tuning

Make sure to tune your carburetor properly for your specific mods and conditions. Proper jetting and adjustment is critical for optimal acceleration and top speed. Consider having a professional tune your carb.


The Coleman CT200U and CT200U-EX mini bikes offer great performance straight from the factory, but their potential is much higher with some strategic modifications.

This article has covered a range of mods from basic bolt-ons to advanced engine builds. To recap:

  • Beginner mods like air filters, exhaust, and throttle adjustments are affordable, reversible, and yield nice gains.
  • Intermediate steps like torque converters and gearing changes involve more effort but accelerate faster with higher top speeds.
  • Advanced options like performance kits, internal upgrades, and engine swaps require mechanical skill but deliver awesome power.

Keep safety as your top priority – wear protection, learn proper techniques, and modify within your skill level. Work in stages at a pace your budget allows.

With the right mods for your needs and riding style, your Coleman can transform from mundane to insane. But tread carefully when pushing limits, and always ride responsibly. Going faster means more thrills, but respect the machine.

Jim Korey is the obsessed founder of MasterBikez, bringing over 20 years of experience as a mini bike enthusiast, former semi-pro stunt racer, and custom mini bike builder.
He’s author of the best selling book “Riding Small, Living Large” where Jim draws from his outrageous adventures and extensive hands-on knowledge to provide fellow riders with entertaining stories and wizard-level tips. His wealth of mini bike passion empowers the MasterBikez community.

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