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Montesa COTA 300RR 2018, Owner'S Manual

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Montesa COTA 300RR 2018 Owner'S Manual Download Page 174

6-17

6-17

Electrical servicing

Wiring diagram (2ED)

GND
BAT

3

2

5

4

1

3

2

5

4

1

5

TURN SIGNAL
INDICATOR LIGHT
12V 1,2 W

HIGH BEAM
INDICATOR LIGHT
12V 1,2 W

METER
INDICATOR LIGHT
12V 1,2 W

DIGITAL METER
12V

OBD LED

RIGHT FRONT TURN 
SIGNAL LIGHT
12V 10 W

POSITION LIGHT
12V 4 W

HEADLIGHT
12V 35/35W

LEFT FRONT TURN 
SIGNAL LIGHT
12V 10W

FRONT BRAKE 
LIGHT SWITCH

BRAKE LIGHT SWITCH

TURN SIGNAL SWITCH

LIGHTING SWITCH

HORN SWITCH

STOP SWITCH

HORN

WATER 

TEMP 

SENSOR

IGNITION COIL

PULSER

ALTERNATOR

REGULATOR/

RECTIFIER

CONDENSER

(10000uF)

BANK ANGLE

SENSOR

FAN RELAY

POWER

RELAY

WINKER

RELAY

0

2 

SENSOR 

F1 - ECU

SPEED 

SENSOR

FAN 

MOTOR

FUEL 

PUMP

SERVICE 

CHECK

CONNECTOR

RIGHT REAR 

TURN SIGNAL LIGHT

12V 10W

LEFT REAR 

TURN SIGNAL LIGHT

12V 10W

REAR BRAKE

LIGHT SWITCH

BRAKE, TAILLIGHT,

LICENSE PLATE PLATE LIGHT

12V 21/5W

POWER

INJECTOR

B BLACK
Y YELLOW
L BLUE
G GREEN
R RED
W WHITE
V VIOLET

BR BROWN
O ORANGE
SB LIGHT 

BLUE

LG LIGHT 

GREEN

P PINK
GR GREY

Summary of Contents for COTA 300RR 2018

Page 1: ...PGM FI RacingTrial Owner s Manual 2018...

Page 2: ...or others Each safety message is preceded by a safety alert symbol and one of three words DANGER WARNING or CAUTION These signal words mean DANGER You WILL be KILLED or SERIOUSLY HURT if you don t fo...

Page 3: ...versions of the COTA 300RR model All information in this publication is based on the latest product information available at the time of approval for printing MONTESA HONDA S A U reserves the right t...

Page 4: ...ion Number VIN is stamped on the right side of the steering head The serial number of the engine is stamped on the lower right side of the crankcase MODEL TYPE FRAME No ENGINE No MRT 300 J 2ED VTDND15...

Page 5: ...Tire information 2ED Cold tire pressure driver only Front 100kpa Rear 100kpa 2 Keep chain adjusted and lubricated 25 35 Mm 1 0 1 4 In Read owners manual 3 95 MKF D40 Caution label For your protection...

Page 6: ...Labels 2ED 4 2 1 6 3...

Page 7: ...Labels 4ED 4 2 6 5 3...

Page 8: ...king any modifications or adding an accessory be sure to read the following information WARNING Improper accessories or modifications can cause a crash in which you can be seriously hurt or killed Fol...

Page 9: ...Throttle Body 4 13 Water Seal And Bearing Replacement 4 15 Radiator Removal Installation 4 17 Engine Removal Installation 4 18 Cylinder Compression 4 20 Cylinder Head Removal 4 23 Cylinder Head Disas...

Page 10: ...ts well ahead of the season page 3 2 To The New Owner By selecting a MONTESA COTA 300RR as your new machine you have placed yourself in a distinguished family of owners and riders The COTA is a high p...

Page 11: ...Memo Memo...

Page 12: ...structions Operation component locations 2ED shift lever kickstarter rear brake pedal clutch lever front brake lever throttle grip magnetic stop switch rearview mirror rearview mirror light control tu...

Page 13: ...Operating instructions 1 2 1 2 Operation component locations 4ED clutch lever front brake lever throttle grip shift lever kickstarter rear brake pedal mapping switch magnetic stop switch...

Page 14: ...of Coolant and Distilled Water WARNING Removing the radiator cap while the engine is hot will allow the coolant to spray out seriously scalding you Always let the engine and radiator cool down before...

Page 15: ...ate the motorcycle 20 minutes observing the same cautions as for a new motorcycle When the piston piston ring gears etc are replaced they must be broken in observing the first 30 minutes using not mor...

Page 16: ...r Shows riding speed This shows your speed in kilometers per hour km h Odometer Shows accumulated mileage High beam indicator blue Lights when the headlight is on high beam Turn signal indicator green...

Page 17: ...e steering perform the locking sequence in the reverse order 3 Changing from Trip 1 to Trip 2 display 1 With the motorcycle running and set to Trip 1 Press the M Mode button and the display will chang...

Page 18: ...to close the throttle and pull the clutch lever in completely before shifting NOTICE Improper shifting may damage the engine transmission and drive train Learning when to shift gears comes with experi...

Page 19: ...not adjust the end of the adjuster and the clutch mas ter cylinder piston below 0 5 mm 0 019 in Clutch Lever Free Play Standard cluth lever free play should be between 0 5 15 mm 0 019 0 60 in NOTICE...

Page 20: ...ip free play is approximately 3 mm 0 12 in of grip rotation Adjustment is made with the integral throttle cable adjuster Slide the dust cover off from the integral cable adjuster Turning the adjuster...

Page 21: ...ED PGM FI electronic in jection system has two operational maps which can be selected depending on the conditions Switch in Mode 1 Standard Switch in Mode 2 Powered 1 MAPPING SWITCH 2 MODE 1 3 MODE 2...

Page 22: ...ee play can be adjusted by turning the adjuster Free play must be adjusted to provide 0 5 1 5 mm 0 019 0 060 in clearance between the end of the ad juster and the front brake master cylinder piston To...

Page 23: ...cut off just a small amou nt at a time from both side equally It is obviously much easier to make the handlebar narrower than it is to add material NOTICE Chamfer the edges to remove burrs and other...

Page 24: ...Single cylinder 3 5 inclined from vertical Bore and stroke 80 0 x 57 2 mm Displacement 288 cm3 Compression ratio 10 4 1 Valve timing Intake valve opens Intake valve closes Exhaust valve opens Exhaust...

Page 25: ...stilled water Radiator cap relief pressure 108 kPa 1 1 kgf cm2 Presi n de alivio tap n del radiador 108 kPa 1 1 kgf cm2 Unit mm in Item Standard Service limit Cylinder Head Valves Cylinder compression...

Page 26: ...0 652 17 06 0 672 16 97 0 668 Unit mm in Unit mm in Item Standard Service limit Crankshaft Transmission Crankshaft runout Right Left 0 03 0 001 0 05 0 002 Connecting rod big end Side clearance Radial...

Page 27: ...Fork oil capacity Right Left 260 cm3 285 cm3 Unit mm in Item Standard Service Limit Rear Suspension SHOWA Shock absorber spring pre load 126 5 4 98 Spring free length 133 5 2 130 3 5 13 Nitrogen gas p...

Page 28: ...7 12 1 2 9 Clutch oil bleeder screw 1 8 6 0 6 4 3 Clutch spring bolt 6 6 12 1 2 9 Clutch center lock nut 1 18 69 7 0 51 Note 1 Drive sprocket UBS bolt 1 8 31 3 2 23 Shift drum center special bolt 1 8...

Page 29: ...Front axle 1 17 69 7 0 51 Note 1 Rear axle nut 1 17 69 7 0 51 Note 1 Final driven sprocket nut 4 8 32 5 3 3 23 9 Shock absorber Upper mounting bolt nut Lower mounting bolt nut 1 1 10 10 39 4 0 29 39 4...

Page 30: ...agnosis system Description Tool number Applicability Spoke nipple wrench 07701 0020300 Front spoke nipple Gear holder 07724 0010100 Primary drive gear bolt Bearing remover head 07746 0050600 Wheel bea...

Page 31: ...ngine oil Repsol 4T stroke engine oil 10W 30 or equivalent 600 cm3 Item Material Remarks Connecting rod small end I D Molybdenum oil solution A 50 50 mixture of molybdenum disulfide grease and engine...

Page 32: ...thium based multipurpose grease Each oil seal lips Water seal lips Right crankcase and cylinder head cover water hose joint thread Sealant Cylinder head cover mating surface Three Bond 1207B or equiva...

Page 33: ...in tensioner roller bearings Clutch lever pivot sliding surface Front and rear wheel axle thread Step joint pin surface Throttle pipe sliding surface and throttle wire drum 4 stroke engine oil Brake h...

Page 34: ...Service data 2 11 2 11 Cable Harness Routing 2ED 1 FRONT BRAKE HOSE 2 THROTTLE CABLE 3 CLUTCH HOSE 4 MAGNETIC STOP SWITCH CONNECTOR 45 2 1 4 3 FRONT FRONT...

Page 35: ...Service data 2 12 2 12 Cable Harness Routing 4ED 1 FRONT BRAKE HOSE 2 THROTTLE CABLE 3 CLUTCH HOSE 4 MAGNETIC STOP SWITCH CONNECTOR 5 MAPPING SWITCH FRONT FRONT 15 mm 5 90 2 1 3 4...

Page 36: ...ONNECTOR SUB INSTALLATION 8 6P CONNECTOR SPEEDOMETER 9 3P CONNECTOR SPEED SENSOR 10 2P CONNECTOR MIL 11 FRONT STOP SWITCH CONNECTOR 12 2P CONNECTOR INACTIVE 13 9P CONNECTOR LIGHTING SWITCH 14 INDICATO...

Page 37: ...THER HOSE 4 AIR FILTER BOX BREATHER HOSE 5 STORAGE TANK 6 ENGINE STOP SWITCH WIRE 7 FAN MOTOR WIRE 8 FUEL CAP BREATHER HOSE 9 SPARK PLUG WIRE 10 WIRE HARNESS TO IGNITION COIL 11 ECT SENSOR 12 FUEL TAN...

Page 38: ...TCH HOSE 4 CONNECTORS BOOT FAN MOTOR 2P BLACK CONNECTOR POWER MAPPING CONNECTOR 5 UPPER RADIATOR HOSE 6 SPARK PLUG WIRE 7 FAN MOTOR WIRE 8 FILTER BOX BREATHER HOSE 9 CYLINDER HEAD BREATHER HOSE 10 SPE...

Page 39: ...Service data 2 16 2 16 1 THROTTLE CABLE 2 CLUTCH HOSE 3 FUEL TANK BREATHER HOSE 1 2 3 3 4 1 45 FR FR UPPER UPPER FR RH RH RH RH RH...

Page 40: ...OSE 3 FILTER BOX BREATHER HOSE 4 ALTERNATOR WIRE 5 CONDENSER 2P BLACK CONNECTOR 6 REGULATOR RECTIFIER 5P BLACK CONNECTOR 7 BANK ANGLE SENSOR 8 FAN MOTOR RELAY 4ED 9 REAR BRAKE RESERVOIR TANK 10 SPEED...

Page 41: ...AIR FILTER BOX BREATHER HOSE 5 TRANSMISSION BREAHTER HOSE 6 WIRE HARNESS 7 FUEL FEED HOSE 8 REGULATOR RECTIFIER 5P BLACK CONNECTOR 9 CONDENSOR 10 CONDENSOR 2P BLACK CONNECTOR 11 BANK ANGLE SENSOR 12 F...

Page 42: ...Service data 2 19 2 19 1 REAR BRAKE HOSE 2 REAR BRAKE RESERVOIR HOSE 3 SPEED SENSOR 2ED 90 UPPER UPPER RH FR FR FR RH FR RH 1 2 3...

Page 43: ...Service data 2 20 2 20 1 FUEL FEED HOSE 2 TRANSMISSION BREATHER HOSE 1 2...

Page 44: ...ar Loose bolts screws and other fasteners 3 Service and maintenance Maintenance schedule Perform pre ride Inspection at each scheduled maintenance period I Inspect and clean Adjust Lubricate or Replac...

Page 45: ...ve sprocket Wear or damage Frame Front rear tire Wear Brake pad Wear Chain slider Wear Driven sprocket Wear or damage Drive chain Elongation or wear Warming up Inspection When warming up the engine ch...

Page 46: ...cleaner element A fire or explosion could result Soak the element in engine oil and squeeze out the excess NOTICE Do not twist the element to squeeze out the excess Failure to follow this precaution c...

Page 47: ...plug and the cap Spark Plug Cap Remove the spark plug cap from the spark plug Clean the inside of the plug cap with electrical contact cleaner to prevent misfire 1 INSULATOR Spark Plug Using a spark p...

Page 48: ...alve stem and measure the intake and exhaust valve clearances Valve clearance Intake 0 12 0 03 mm 0 005 0 001 in Exhaust 0 30 0 03 mm 0 012 0 001 in Adjust by loosening the lock nut and turning the ad...

Page 49: ...oil filler hole Specified engine oil Repsol 4 stroke motorcycle oil SAE 10W 30 or equivalent Capacity 0 41 liter 0 43 US qt 0 36 Imp qt after draining 0 44 liter 0 46 US qt 0 39 Imp qt after oil filt...

Page 50: ...he oil filter cover into the left crankcase while aligning the cover flange with the oil filter groove Make sure that the oil filter cover seats properly in the crankcase Install the retaining plate a...

Page 51: ...level surface 2 Remove the oil filler cap from the clutch cover 3 Place an oil drain pan under the engine to catch the oil then remove the drain bolt and sealing washer from the left crankcase 4 After...

Page 52: ...is damaged Replace the water seal or the oil seal page 4 15 Coolant Replacement WARNING Removing the radiator cap while the engine is hot will allow the coolant to spray out seriously scalding you Al...

Page 53: ...s not disengaged properly or the lever feels soft or spongy bleed the air from the system 2 Remove the reservoir cover and diaphragm check the clutch fluid level If the level is low inspect the clutch...

Page 54: ...the drive chain slack and free wheel rotation After adjustment tighten the axle nut to the specified torque Torque 69 N m 7 0 kgf m 51 lbf ft Lubricate the drive chain Hook the drive chain tensioner...

Page 55: ...slack page 3 11 1 BOLTS NUT 2 DRIVEN SPROCKET Install the drive sprocket onto the countershaft as shown Install the spring washer and bolt then tighten the bolt to the specified torque Torque 31 N m...

Page 56: ...ty Brake fluid DOT 4 only 1 COVER 2 MIN LEVEL Check that the brake hose do not bind or kink in all steering position and is not pulled when the suspension is extended Replace the brake fluid every 6 m...

Page 57: ...o wobble right and left 1 BRAKE DISC 2 DISC BOLT 3 COLLAR Brake System Refer to page 1 11 for Brake Lever Adjustment Refer to page 1 11 for Brake Pedal Height Adjustment Brake Discs Measure the rear b...

Page 58: ...ft Rear 2 3 N m 0 2 0 3 kgf m 1 5 2 2 lbf ft Rim lock nut 13 N m 1 3 kgf m 9 lbf ft 1 SPOKE NIPPLE 2 RIM LOCK Steering Head Bearings Support the motorcycle using the maintenance stand with its front w...

Page 59: ...ht and track conditions by using one or more of the following methods Basically there are two adjustments you can make to the front suspension Rebound damping right fork Turning the rebound damping ad...

Page 60: ...y adjustments Make all rebound damping adjustment in one click increments Adjusting two or more clicks at a time may cause you to pass over the best adjustment Test ride after each adjustment If you b...

Page 61: ...headlight bulb The bulb for the front headlight gets very hot when it is on and remains hot for a while after the front headlight has been turned off Ensure that you leave it to cool before carrying...

Page 62: ...fue ling Stop engine and keep heat sparks and flame away Drain or refuel only outdoors Wipe up spills immediately 3 Remove the coolant drain bolt at the water pump cover to drain coolant Drain coolant...

Page 63: ...3 20 3 20 Memo...

Page 64: ...VALVE 2 SNAP RING Check the relief valve operation by pushing the relief valve piston Installation Apply oil to a new O ring and install it onto the relief valve groove Install the relief valve into t...

Page 65: ...WAY REED VALVE Inspection Check the oil pump driven gear for wear or damage Check the oil pump shaft for wear or damage Check the one way reed valve for damage replace if necessary Check the oil pump...

Page 66: ...everse order of removal 1 OIL PUMP SHAFT 2 INNER ROTOR 3 FLAT SURFACES 4 OUTER ROTOR Assembly Apply clean engine oil to the oil pump rotors and shaft Install the oil pump shaft into the right crankcas...

Page 67: ...irty and clean if ne cessary Cover the fast connector with a cloth 3 Hold fast connector with one hand and tighten the two pins of the pawl with the other hand while pulling the connector backwards Di...

Page 68: ...nd flame away Refuel only outdoors Wipe up spills immediately NOTICE Before disconnecting the fuel hoses release the fuel pressure by loosening the fuel feed hose banjo bolt at the injector holder Alw...

Page 69: ...to the fuel pump 2P connector terminals check amount of fuel flow for 10 seconds Amount of flow 0 749 l min 125 cm3 minumun 10 seg If the fuel flow is less than specified inspect the following Pinched...

Page 70: ...ct the fuel tank breather hose Remove the fuel tank mounting bolts Pull up the fuel tank and disconnect the fuel pump 2P connector Remove the fuel tank and injector as an assembly being careful not to...

Page 71: ...removed Clean any oil off from the mating surface of the fuel pump base and fuel tank Install a new packing onto the fuel pump base Install the fuel pump assembly into the fuel tank as pictures shows...

Page 72: ...t to pinch the throttle cable Install and tighten the fuel tank mounting bolts Connect the fuel tank breather hose to the hose clip 1 FUEL TANK 2 BOLT 3 BREATHER HOSE 1 2P CONNECTOR Always replace the...

Page 73: ...engine filter system from the pump body 1 PAWL 2 PUMP BODY 3 PUMP 1 FUEL PUMP Remove the fuel tank Remove the bolts from the fuel pump base and remove the base Take the fuel pump out of the fuel tank...

Page 74: ...earing is properly positioned and sup ported in the fuel tank 1 PUMP 3 PAWLS 2 BODY 4 CONNECTING PIPE 1 BEARINGS 2 PUMP 3 ENGINE CABLES 4 MOTOR 5 BODY Replace the bearings with new ones every time the...

Page 75: ...s position as shown Tighten the pump mounting bolts in alphabetical order as shown in the image Torque 7 9 N m 0 7 0 9 kgf m 5 1 6 6 lbf ft Mount the tank on the chassis Connect the breather hose to t...

Page 76: ...from the housing joint 1 BOLTS NUTS 2 AIR CLEANER HOUSING Removal Installation Do not remove the injector from the injector holder Replace the injector and holder as an assembly Always replace the O...

Page 77: ...le end from the throttle drum Loosen the insulator clamp screw then remove the insulator from the throttle body Installation Install the insulator onto the throttle body while aligning its slit with t...

Page 78: ...eplacement Drain the transmission oil page 3 8 Remove the following Water pump cover bolt cover dowel pins O ring Right crankcase cover and washer page 4 40 Hold the water pump gear teeth using a suit...

Page 79: ...into the right crankcase cover Hold the water pump gear using a suitable tool and tighten the impeller to the specified torque Torque 12 N m 1 2 kgf m 9 lbf ft Install the washer and right crankcase c...

Page 80: ...the ground eyelet bolt Remove the ignition coil mounting bolt Remove the spark plug wire wire harness breather hose clamp Disconnect the ECT sensor 3P Gray connector 1 GROUND EYELET 2 BOLTS 3 IGNITION...

Page 81: ...gine removal for servicing Crankshaft Oil pump Shift forks and shift drum Transmission Cylinder piston 1 IGNITION COIL 2 BOLTS 3 GROUND EYELET 4 WIRE CLAMP Installation is in the reverse order of remo...

Page 82: ...VERSIONS 4ED 1 24 N m 2 4 kgf m 17 8 lbf ft 24 N m 2 4 kgf m 17 8 lbf ft 26 N m 2 6 kgf m 19 2 lbf ft 26 N m 2 6 kgf m 19 2 lbf ft 69 N m 6 9 kgf m 50 9 lbf ft 39 N m 4 0 kgf m 28 7 lbf ft 50 N m 5 1...

Page 83: ...stopper tool This tool can be easily be made from a thin 1 mm thick piece of steel as shown 1 SEALING BOLT WASHER 2 STOPPER TOOL 1 CYLINDER COMPRESSION GAUGE Cylinder Compression Warm up the engine to...

Page 84: ...ylinder head side cap Remove the camshaft bearing retainer from the cylinder head cover 1 BOLTS SEALING WASHERS 2 SH BOLTS 3 SEALING WASHERS 4 CYLINDER HEAD COVER 1 BOLTS 2 TAPPET ADJUSTING HOLE COVER...

Page 85: ...wear or damage If any components are faulty replace the camshaft assembly 1 BEARINGS 2 CAMSHAFT 1 INTAKE ROCKER ARM SHAFT 2 EXHAUST ROCKER ARM SHAFT 3 INTAKE ROCKER ARM 4 EXHAUST ROCKER ARM Disassembl...

Page 86: ...ttern in two or three steps Remove the nuts washers and cylinder head 1 BOLTS 2 NUTS WASHERS 3 CYLINDER HEAD Cylinder Head Removal Remove the following Exhaust pipe Throttle body insulator Cylinder he...

Page 87: ...T COLLAR 3 CAM CHAIN TENSIONER 4 PIVOT BOLT 5 APPLY LOCKING AGENT Inspection Inspect the cam chain tensioner and cam chain guide for excessive wear or damage replace if necessary 1 CAM CHAIN TENSIONER...

Page 88: ...not compress the valve springs more than necessary to remove the cotters Tools Valve spring compressor 07757 0010000 Compressor attachment 07959 KM30101 1 VALVE SPRING COMPRESSOR 2 ATTACHMENT 3 COTTER...

Page 89: ...the free length of the intake and exhaust valve springs Service limits Inner 24 9 mm 0 98 in Outer 27 6 mm 1 09 in 1 OUTER VALVE SPRING 2 INNER VALVE SPRING Cylinder Head Inspection Cylinder Head Rem...

Page 90: ...ide I D using a ball gauge or inside micrometer Service limit IN EX 4 552 mm 0 1792 in Subtract each valve stem O D from the corresponding guide I D to obtain the stem to guide clearance Standard IN 0...

Page 91: ...H Check that the valve guides are at the proper depth using a slide caliper adjust the height if necessary Specified depth IN 8 0 8 3 mm 0 31 0 33 in EX 8 2 8 5 mm 0 32 0 33 in Let the cylinder head c...

Page 92: ...terior cutter Valve Seat Refacing Valve seat cutters grinders or equivalent valve seat refacing equipment are recommended to correct worn valve seat Follow the refacing manufacturer s instructions Con...

Page 93: ...the existing valve seat material Tools Flat cutter 25 mm 07780 0012000 Flat cutter 21 5 mm 07780 0012800 Cutter holder 4 5 mm 07781 0010600 or equivalent commercially available Use a 45 cutter remove...

Page 94: ...while turning it slowly to avoid damage to the stem seal Using a 45 seat cutter cut the seat to proper width Make sure all pitting and irregularities are removed Refinish if necessary After refacing w...

Page 95: ...pring compressor 07757 0010000 Compressor attachment 07959 KM30101 To prevent loss of tension do not compress the valve springs more than necessary Tap the valve stems gently with two plastic hammers...

Page 96: ...kcase Remove the piston pin clips with pliers Press the piston pin out of the piston and remove the piston Spread the piston rings and remove them by lifting up at a point just opposite the gap Piston...

Page 97: ...mit Taper 0 05 mm 0 002 in Out of round 0 05 mm 0 002 in Inspect the top of the cylinder for warpage Service limit 0 05 mm 0 002 in Piston Piston Ring Remove the carbon deposits from the piston head o...

Page 98: ...piston pin O D Service limit 15 98 mm 0 629 in Replace the piston pin if necessary Calculate the piston pin to piston clearance Service limit 0 04 mm 0 002 in Insert each piston ring into the cylinder...

Page 99: ...ed When it is turned clockwise with a screwdriver the tensioner shaft should be pulled into the body The shaft should spring out of the body as soon as the screwdriver is released Piston Installation...

Page 100: ...in 2 3 steps to the specified torque Torque 39 N m 4 0 kgf m 29 lbf ft 1 DOWEL PINS 2 NEW GASKET Apply locking agent to the cylinder mounting sealing bolt threads Install the cylinder mounting sealing...

Page 101: ...e hanger bolt tighten the nut to the specified torque Torque 24 N m 2 4 kgf m 17 lbf ft Connect the radiator hose to the water joint tighten the clamp screw securely Install the following Camshaft Cyl...

Page 102: ...rocker arm shaft groove Place the intake rocker and exhaust rocker arm into the cylinder head cover The intake rocker arm is identified with groove on the end of the shaft Install the intake and exhau...

Page 103: ...T ADJUSTING HOLE CAP 3 BOLTS Check the valve clearance page 3 4 Install new O rings into the tappet adjusting hole cover grooves Install the tappet adjusting hole cap with their UP marks facing up Ins...

Page 104: ...oss pattern in 2 3 steps Install the kickstarter pedal and tighten the bolt to the specified torque Torque 37 N m 3 8 kgf m 27 4 lbf ft Connect the lower radiator hose Fill the crankcase with recommen...

Page 105: ...brake fluid Apply silicone grease to the O rings Install 23 x 2 1 mm O ring Black into the spring side groove Install 21 8 x 2 4 mm O ring Green into the lifter plate side groove Do not interchange t...

Page 106: ...HOLDER 1 CLUTCH CENTER 2 CLUTCH DISCS 3 CLUTCH PLATE 4 PRESSURE PLATE 5 PAPER DISCS 1 LOCK WASHER 2 PLAIN WASHER 3 SPRING BASE WASHER Hold the clutch assembly with the clutch center holder and remove...

Page 107: ...te for wear or damage Mainshaft O D at clutch outer guide 1 LIFTER PIECE ASSEMBLY 1 OUTER GUIDE 2 NEEDLE BEARING 1 CIRCLIP 2 THRUST WASHER 3 THRUST NEEDLE BEARING 4 LIFTER PIECE Check the lifter piece...

Page 108: ...clutch plates with clean transmission oil Install the clutch discs and plates alternately onto the clutch center starting with the clutch disc Install the clutch pressure plate onto the clutch center...

Page 109: ...D Idle gear I D and bushing O D and I D Countershaft O D at the idle gear bushing 1 RATCHET SPRING 2 STARTER RATCHET 3 PINION GEAR 4 SPINDLE 5 RETURN SPRING 6 COLLAR 1 RETURN SPRING 2 COLLAR 3 WASHER...

Page 110: ...rshaft Note the direction of the idle gear as shown in the illustration Gearshift Linkage Removal Remove the gearshift pedal Pull out the gearshift spindle from the crankcase Remove the guide plate bo...

Page 111: ...EL PIN 6 CUT OUT Install the return spring plain washer and stopper arm and tighten the stopper arm bolt to the specified torque Torque 12 N m 1 2 kgf m 9 lbf ft Install the dowel pin into the shift d...

Page 112: ...Left Crankcase Cover Removal Remove the skid plate and drain engine oil Disconnect the alternator 3P Natural connector and ignition pulse generator 2P Natural connectors Remove the gearshift pedal 1...

Page 113: ...edle bearing using the special tools Tools Bearing remover shaft 15 mm 07936 KC10100 Bearing remover head 15 mm 07936 KC10200 Remover weight 07741 0010201 1 SNAP RING 2 WASHER 3 OIL SEAL 4 NEEDLE BEAR...

Page 114: ...hreads Install the alternator wire clamp Install the stator and ignition pulse generator mounting bolts Tighten the stator mounting bolts to the specified torque Torque 5 4 N m 0 55 kgf m 4 0 lbf ft T...

Page 115: ...evel Install the slid plate 1 3P NATURAL CONNECTOR 2 2P NATURAL CONNECTOR Install the left crankcase cover being careful not to damage the oil filter cover O ring NOTICE The left crankcase cover stato...

Page 116: ...se cover page 4 50 Install the flywheel onto the crankshaft Apply oil to the flywheel nut threads and seating surface Install the washer and flywheel nut 1 WASHER 2 FLYWHEEL NUT 3 APPLY OIL 1 WOODRUFF...

Page 117: ...r 1 OIL PUMP DRIVEN GEAR 2 DRIVE PIN Remove the countershaft collar and O ring Remove the oil pump driven gear and drive pin 1 COUNTERSHAFT COLLAR 2 O RING 1 DRIVE SPROCKET 2 UNIVERSAL HOLDER 3 BOLT 4...

Page 118: ...Place the right crankcase facing down and remove the left crankcase from the right crankcase Remove the gasket and dowel pins Remove the one way reed valve Remove the oil pump shaft oil pump inner and...

Page 119: ...DRUM Inspect each part for wear or damage Check the following items specifications page 2 1 Spinning gear I D Bushing I D and O D Mainshaft and countershaft O D Shift fork I D and claw thickness Shif...

Page 120: ...LEFT CRANKSHAFT OIL SEAL 6 LEFT CRANKSHAFT BEARING 7 RIGHT CRANKSHAFT BEARING 8 RIGHT CRANKSHAFT OIL SEAL 9 RIGHT MAINSHAFT BEARING 10 RIGHT COUNTERSHAFT BEARING 11 RIGHT SHIFT DRUM BEARING A 1 mm B 0...

Page 121: ...4 58 4 58 Engine servicing Transmission Assembly 1 M2 13T 2 M4 28T 3 M3 15T 4 M5 22T 5 MAINSHAFT M1 15T 6 C2 31T 7 C4 28T 8 C3 30T 9 C5 22T 10 C1 42T 11 COUNTERSHAFT 11 10 9 8 7 6 4 3 2 1 5...

Page 122: ...into the right crankcase Install the mainshaft and countershaft as an assembly into the right crankcase Install the center shift fork with its identification mark facing in Install the right and left...

Page 123: ...IVE GEAR 2 WASHER 3 SPECIAL BOLT Install the primary drive gear collar onto the crankshaft Install the primary drive gear with its groove side facing out Apply oil to the primary drive gear special bo...

Page 124: ...r tighten the special bolt to the specified torque Torque 31 N m 3 2 kgf m 23 lbf ft Install the removed parts in the reverse order of removal 1 NEW O RING 2 COUNTERSHAFT COLLAR Install the drive pin...

Page 125: ...4 62 4 62 Memo...

Page 126: ...ated disc with a high quality brake degreasing agent 1 BRAKE DISC 2 COLLAR 3 DISC BOLT 4 LEFT WHEEL BEARING 5 DISTANCE COLLAR 6 RIGHT WHEEL BEARING a 27 25 1 mm 1 07 0 0394 in 5 Frame servicing Spokes...

Page 127: ...through the wheel Tighten the axle to the specified torque Torque 69 N m 7 0 kgf m 51 lbf ft Install the brake caliper flange collars and disc cover Apply a locking agent to the threads and tighten t...

Page 128: ...ork tube down and out 1 FORK BOLT 2 FORK LEG 1 LOCK NUT 2 FORK BOLT Right Fork Disassembly Before disassembling the fork clean the entire sliding sur face and the bottom of the fork slider Be careful...

Page 129: ...with a piece of woods or soft jaws to avoid damage Do not overtighten Loosen the right fork center bolt Remove the center bolt and sealing washer 1 FORK DAMPER 2 RIGHT FORK CENTER BOLT Remove the dust...

Page 130: ...wear or scratches Remove any metal powder inside the slider and guide bushings with a nylon brush and fork fluid If copper appears on the entire surface replace the bushing Replace the back up ring if...

Page 131: ...y Install the following to the fork tube Fork tube bushing Guide bushing Back up ring Coat the guide and fork tube bushings with recommended fork fluid Install the fork tube assembly into the slider U...

Page 132: ...he fork leg Specified fork fluid OJ Racing Special Fork Oil Type 01 SAE 5W or equivalent Bleed the air as follows 1 Extend the fork without bringing to its maximum exten sion Cover the top of the fork...

Page 133: ...ce and the bottom of the fork slider Be careful not to scratch the fork tube A scratched fork tube will damage the seal causing an oil leak The fork bolt under spring pressure Before removing the fork...

Page 134: ...ng from the cilinder assy NOTICE Be careful not to damage the tapared bushing Remove the cilinder assy from the fork tube Remove the following items using the same procedure as the right fork disassem...

Page 135: ...page 5 6 Fork tube bushing Guide bushing Back up ring Using the special tool drive the guide bushing and back up ring until the stop ring groove is fully stuck in the fork slider base Install the oil...

Page 136: ...then screw the fork bolt into the fork tube Torque 13 N m 1 3 kgf m 9 3 lbf ft Tighten the bottom bridge pinch bolts to the specified torque Torque 21 N m 2 1 kgf m 14 lbf ft Overtightening the pinch...

Page 137: ...1 STEM 2 LOWER BEARING 3 DUST SEAL 1 DUST SEAL 2 UPPER BEARING 3 STEERING STEM Remove the stem bearing adjusting nut Remove the following Dust seal Upper bearing Steering stem lower bearing 1 ADJUSTIN...

Page 138: ...RIVER Install new dust seal onto the steering stem Install the new lower bearing into the steering stem using a hydraulic press and driver Tool Steering stem driver Generic tool 1 STEM 2 UPPER BEARING...

Page 139: ...to the specified torque Torque 21 N m 2 1 kgf m 15 4 lbf ft Tighten the stem nut to the specified torque Torque 99 N m 10 kgf m 65 lbf ft Recheck the steering stem adjustment before installing the rem...

Page 140: ...e drive chain adjuster and rear wheel Do not depress the brake pedal after the rear wheel is removed The caliper pistons will move and make reassembly difficult Disassembly Assembly WARNING A contamin...

Page 141: ...caliper slide rail Apply thin layer of grease to the axle Place the rear wheel between the swingarm being careful not to damage the disc Insert the rear axle into the left chain adjuster side collar a...

Page 142: ...Nitrogen Releasing Procedure Remove the air valve cap and press the valve stem and release the nitrogen from the damper until pressure is released Before disposal of the shock absorber release the nit...

Page 143: ...n the reverse order of disassembly Installation Set the shock absorber into the frame and install the upper mounting bolt from the left side Install the nut 1 UPPER MOUNTING BOLT NUT Adjust the spring...

Page 144: ...e specified torque Torque Upper mounting bolt 39 N m 4 0 kgf m 29 lbf ft Lower mounting bolt 39 N m 4 0 kgf m 29 lbf ft 1 LOWER MOUNTING BOLT NUT 1 PIVOT COLLAR A 2 PIVOT COLLAR B 3 DUST SEALS 4 NEEDL...

Page 145: ...ushion link to frame socket bolt nut Cushion arm plates Cushion arm plates to swingarm bolt nut Cushion arm plate to cushion link bolt nut Rear cushion lower mounting bolt nut Tighten the cushion arm...

Page 146: ...g Bolts and drive chain cover Bolts and driven sprocket guard Screws and drive chain slider Chain tensioner Dust seal caps Dust seals Pivot collars Thrust bushings Replace them if they have score mark...

Page 147: ...n tensioner pivot Install the chain tensioner into the swingarm Install a new O ring and tighten the pivot bolt 1 DUST SEAL 2 PIVOT COLLAR 3 DUST SEAL 4 DUST SEAL CAP 5 NEEDLE BEARING Install the pivo...

Page 148: ...tighten the screws 1 PIVOT BOLT NUT 2 HOSE CLAMPS 1 DRIVE CHAIN GUARD 2 SCREWS Install the drive chain sliders onto the swingarm Apply a locking agent to the drive chain slider screw threads and tigh...

Page 149: ...o seat the caliper pistons against the pads Push the pistons all the way in to allow installation of new brake pads Check the brake fluid level in the reservoir as this operation causes the level to r...

Page 150: ...level to rise 1 BOLT 2 SPEED SENSOR 3 SPEED SENSOR BRACKET Rear Brake Pad Replacement Clean the brake disc with a high quality degreasing agent if they are contaminated with oil or grease Replace the...

Page 151: ...under the caliper Remove the following Brake hose oil bolt Sealing washers Brake hose eyelet Caliper mounting bolts Disc cover Flange collars Brake caliper Spring pin for the pads Brake pads page 5 24...

Page 152: ...system is serviced Drain the brake system Place a clean container under the caliper Remove the following Brake hose oil bolt Sealing washers Brake hose eyelet Rear wheel page 5 15 Brake caliper bracke...

Page 153: ...nspection Check the following items page 2 4 Master cylinder and piston for scoring scratches or other damage Master piston O D and master cylinder I D Installation Installation is in the reverse orde...

Page 154: ...t Drain the brake fluid from the hydraulic system into a suitable container Remove the air cleaner housing Remove the exhaust muffler Remove the reservoir tank from the bracket Remove the brake hose o...

Page 155: ...wing Clutch lever Clutch hose bolt Master cylinder holder bolt and holder Master cylinder Installation Install the brake pedal and collars Install and tighten the pivot nut and bolt Apply sealant to t...

Page 156: ...e the snap ring and disassemble the master cylinder Inspection Check the following items page 2 3 Master cylinder and piston for scoring scratches or other damage Master piston O D and master cylinder...

Page 157: ...Memo 5 32 5 32 Memo...

Page 158: ...ctor and measure the resistance between the yellow terminals of the alternator side connector If the measured resistance at regulator rectifier 6P Black connector is incorrect and the alternator 3P Na...

Page 159: ...n pulse generator 2P Natural connector Remove the fan motor relay from the bracket 1 BOLT 2 BRAKE RESERVOIR Disconnect the condenser 2P Black and regulator rectifier 6P Black connectors Remove the rea...

Page 160: ...of the terminals and measure the ignition primary coil resistance between the primary terminals Standard 2 6 3 2 20 C 68 F Measure the secondary coil resistance Standard With plug cap 17 3 22 8 k 20 C...

Page 161: ...tion pulse generator stator assembly page 4 52 1 2P NATURAL CONNECTOR Ignition Pulse Generator Inspection Check the resistance of the pulse generator power in the 32P Black connector page 6 5 Connecti...

Page 162: ...top switch B W Ground Continuity exist only when switch is pushed ECT Engine Coolant Temperature sensor P W G O 2 3 2 6 k 20 C 68 F Sensor ground G1 Ground Continuity Power ground G1 Ground Continuity...

Page 163: ...MIL and stores a DTC in its erasable memory Fail safe function The PGM FI system is provided with a fail safe function to secure a minimum running capability even when there is trouble in the system...

Page 164: ...2P BLACK CONNECTOR FRONT 1 POWER SWITCH 2 MIL 3 WARN RESET SWITCH Self diagnosis Reset Procedure Connect the PGM FI warning unit assembly to the wire harness and 12 V battery same procedure as Self di...

Page 165: ...ngine operates normally 1 Blink Open or short circuit in MAP sensor line in the ECM Faulty MAP sensor Poor idle 7 Blinks Loose or poor contact on ECT sensor Open or short circuit in ECT sensor wire Fa...

Page 166: ...ngle sensor approximately 65 degrees to the left or right make sure that the engine stops after few seconds If the engine stops the bank angle sensor is normal If the engine does not stop replace the...

Page 167: ...spection Remove the fuel tank Disconnect the fan motor 2P Natural connector Directly connect the 12 V battery to the fan motor 2P Natural connector terminals of the fan motor side The fan motor is cor...

Page 168: ...there is no continuity repair or replace the wire harness Chapter lights instruments switches 2ED System location Front stop switch connector 2P connector inactive Speedometer Winker relay Left rear...

Page 169: ...ound Standard 12V approximately If there is no voltage check the following Open circuit in the black wire between the ignition relay and the connector 9P white on the handlebar If there is voltage dis...

Page 170: ...ing correctly and carry out the checks again If the indicator lights are not working check to see if there is an open circuit in Yellow green wire left side Blue red wire right side Green wires for th...

Page 171: ...s With the connector 6P of the speedometer connected check the following in the connector on the harness side 1 SPEEDOMETER 1 HOUSING FOR THE UPPER HEADLIGHT 2 BOLTS 3 SPEEDOMETER 4 CONNECTOR 6P 5 CON...

Page 172: ...hould be received If there is no voltage check the existence of an open circuit in the White Red wire Ground line Measure the continuity between the connector 6P of the speedometer and the ground Conn...

Page 173: ...e 12 V battery to the horn s terminals The horn is working properly when it makes a noise when the 12 V battery is connected to its terminals Horn 2ED Checks If the engine starts but the horn does not...

Page 174: ...SWITCH TURN SIGNAL SWITCH LIGHTING SWITCH HORN SWITCH STOP SWITCH HORN WATER TEMP SENSOR IGNITION COIL PULSER ALTERNATOR REGULATOR RECTIFIER CONDENSER 10000uF BANK ANGLE SENSOR FAN RELAY POWER RELAY...

Page 175: ...ER TEMP SENSOR IGNITION COIL FUN RELAY PULSER ALTERNADOR REGULATOR RECTIFIER CONDENSER 10000uF BANK ANGLE SENSOR FAN MOTOR FUEL PUMP ENGINE STOP SWITCH MAPPING SWITCH B BLACK Y YELLOW L BLUE G GREEN R...

Page 176: ...Printed in Spain...

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