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Montesa COTA 4RT 260 2020, Owner'S Manual

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Montesa COTA 4RT 260 2020 Owner'S Manual Download Page 32

(1)  MAIN WIRE HARNESS

(2)  TRANSMISSION BREATHER HOSE

(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 

(9)  REAR BRAKE RESERVOIR TANK

RH

FR

RH

RH

UPPER

UPPER

UPPER

Service data

2-15

2-15

1

2

3

4

5

6

7

8

9

Summary of Contents for COTA 4RT 260 2020

Page 1: ......

Page 2: ...important We have provided important safety messages in this manual and on the COTA 4RT Please read these messages carefully A safety message alerts you to potential hazards that could hurt you or ot...

Page 3: ...publication is based on the latest product information available at the time of approval for printing MONTESA HONDA S A U reserves the right to make changes at any time without notice and without incu...

Page 4: ...he Vehicle Identification 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...

Page 5: ...number VTDNE04C LE000150 Tire information Cold tire pressure driver only Front 100kpa Rear 100kpa Keep chain adjusted and lubricated 25 35 Mm 1 0 1 4 In Read owners manual above chassis number VTDNE0...

Page 6: ...4 3 2 1 5...

Page 7: ...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 8: ...fuel injector socket bolts 4 7 Injector 4 13 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 C...

Page 9: ...ll ahead of the season page 3 2 To The New Owner By selecting a MONTESA COTA 4RT as your new machine you have placed yourself in a distinguished family of owners and riders The COTA is a high performa...

Page 10: ...Operation component locations 1 1 1 1 1 Operating instructions FRONT BRAKE LEVER THROTTLE GRIP SHIFT LEVER KICKSTARTER REAR BRAKE PEDAL CLUTCH LEVER ENGINE STOP BUTTON MODE SWITCH...

Page 11: ...le the engine is hot will allow the coolant to spray out seriously scalding you Always let the engine and radiator cool down before removing the radiator cap NOTICE When filling the coolant system be...

Page 12: ...than half throttle and shifting gears so that the engine does not lug When you shift the transmission into gear apply front brake to prevent the motorcycle from moving forward Stopping The Engine 1 Sh...

Page 13: ...controls Applying the brakes too hard may cause the wheels to lock and slide reducing control of your Cota If this hap pens release the brake controls steer straight ahead until you regain control th...

Page 14: ...mm 0 019 0 060 in clearance between the end of the adjuster and the clutch master cylinder piston To reduce free play turn the adjuster clockwise then tighten the lock nut securely To increase free pl...

Page 15: ...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 reduce free...

Page 16: ...the pedal or in direction B to lower it 2 Tighten the lock nuts at the desired pedal height 3 After adjustment check the brake pedal free play at the top of the pedal Make sure that the clearance betw...

Page 17: ...cut off just a small amount at a time from both sides equally NOTICE Chamfer the edges to remove burrs and other irregulari ties or roughness after shaping An alternate handlebar shape through varying...

Page 18: ...inclined from vertical Bore and stroke 78 0 x 54 2 mm Displacement 259 cm3 Compression ratio 10 5 1 Valve timing Intake valve opens Intake valve closes Exhaust valve opens Exhaust valve closes 9 BTDC...

Page 19: ...oolant and distilled water Radiator cap relief pressure 108 kPa 1 1 kgf cm2 Presi n de alivio tap n del radiador Unit mm in Item Standard Service limit Cylinder Head Valves Cylinder compression 1 300...

Page 20: ...0 648 16 55 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 clea...

Page 21: ...Right Left 400 cm3 410 cm3 Rear Suspension R16V Shock absorber spring pre load 126 4 96 Spring free length 130 5 1 Nitrogen gas pressure 1 35 Mpa 13 76 kgf cm2 Tension adjuster setting 12 2 clicks fro...

Page 22: ...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 22 2 2 16 Note 4 Shif...

Page 23: ...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 24: ...leshooting Test probe 07ZAJ RDJA110 PGM FI Self diagnosis system Description Tool number Applicability Spoke nipple wrench 07701 0020300 Front spoke nipple Gear holder 2 5 07724 001A100 Primary drive...

Page 25: ...troke 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 oil Connecting rod bi...

Page 26: ...Right crankcase and cylinder head cover water hose joint thread Sealant Cylinder head cover mating surface Three Bond 1207B o equivalent Wheel Item Material Remarks Rear wheel nipple Locking agent 3ED...

Page 27: ...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 hydraulic system inside Pro Honda DO...

Page 28: ...Cable Harness Routing 1 FRONT BRAKE HOSE 2 THROTTLE CABLE 3 CLUTCH HOSE 4 ENGINE STOP BUBTTON CONNECTOR 5 MODE SWITCH FRONT FRONT 15 mm 45 2 5 4 1 3 Service data 2 11 2 11...

Page 29: ...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 TANK BREATHER...

Page 30: ...HOSE 4 CONNECTORS BOOT FAN MOTOR 2P CONNECTOR POWER MAPS CONNECTOR 5 UPPER RADIATOR HOSE 6 SPARK PLUG WIRE 7 FAN MOTOR WIRE 8 FILTER BOX BREATHER HOSE 9 CYLINDER HEAD BREATHER HOSE Service data 2 13 2...

Page 31: ...1 THROTTLE CABLE 2 CLUTCH HOSE 3 FUEL TANK BREATHER HOSE Service data 2 14 2 14 1 2 3 2 3 1 45 FR FR UPPER UPPER FR RH RH RH RH RH...

Page 32: ...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 9 REAR BRAKE RESERVOIR TANK RH FR RH RH UPPER U...

Page 33: ...SE BREATHER JOINT 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 FAN MOT...

Page 34: ...1 REAR BRAKE HOSE 2 REAR BRAKE RESERVOIR HOSE Service data 2 17 2 17 2 1...

Page 35: ...1 FUEL FEED HOSE 2 TRANSMISSION BREATHER HOSE Service data 2 18 2 18 1 2...

Page 36: ...mage or wear Loose bolts screws and other fasteners Maintenance schedule Perform pre ride Inspection at each scheduled maintenance period I Inspect and clean Adjust Lubricate or Replacement if necessa...

Page 37: ...me 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 check for the following Do not r...

Page 38: ...fire or explosion could result in serious injury or death NOTICE Do not twist the element to squeeze out the excess Failure to follow this precaution can result in a damaged element Installation is i...

Page 39: ...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 plug with the wrong heat range ca...

Page 40: ...re 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 adjusting screw until...

Page 41: ...fied engine oil Repsol 4T motorcycle oil 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 filter change 0 60 liter 0 63 US qt...

Page 42: ...ft 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 and tighten the bolt securely 1...

Page 43: ...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 the oil has drained completely insta...

Page 44: ...al 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 Always let the engine and radiator...

Page 45: ...s 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 hose and fittings for damage deterioration...

Page 46: ...eel 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 spring 1 AXLE NUT 2 ADJUSTER Drive...

Page 47: ...EN 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 3 2 kgf m 23 lbf ft Put the transmi...

Page 48: ...MIN LEVEL Check that the brake hose does not bind or kink in any steering position and is not pulled when the suspension is extended Replace the brake fluid every 6 months Replace the brake hose ever...

Page 49: ...Brake System Refer to page 1 6 for Brake Lever Adjustment Refer to page 1 7 for Brake Pedal Height Adjustment Brake Discs Measure the rear brake disc runout with a dial gauge Service limit 0 15 mm 0...

Page 50: ...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 wheel off the ground Turn the handl...

Page 51: ...ing one or more of the following methods There are two adjustments you can make to the front suspension Rebound damping right fork Turning the rebound damping adjuster adjusts how quickly the fork ext...

Page 52: ...g 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 become confused about adjustment setti...

Page 53: ...astic bag over the end of the muffler to prevent moisture from entering 9 Cover your COTA and store in a place which is free of humidity and dust Removal from Storage 1 Uncover and clean your COTA Cha...

Page 54: ...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 the left...

Page 55: ...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 56: ...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 57: ...connector must be changed every time the fuel feed hose is disconnected Disassembly of fuel pump side Turn off the engine Remove the rear fender Pull up the fuel tank Disconnect the fuel pump s 5P con...

Page 58: ...lt is removed or loosened Remove the rear fender Cover the fuel feed hose banjo bolt with a rag or shop towel Slowly loosen the banjo bolt and catch the remaining fuel using an approved gasoline conta...

Page 59: ...ery to the fuel pump 2P Black connector terminals check amount of fuel flow for 10 seconds Amount of flow 125cm2 4 32 US oz minimum 10 seconds at 12 V If the fuel flow is less than specified inspect t...

Page 60: ...ve the fuel tank and injector as an assembly being careful not to damage the injector escpecially the tip of the injector After removing the fuel tank and injector protect the tip of the injector from...

Page 61: ...Always replace the packing with a new one when the fuel pump is 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 Ins...

Page 62: ...able 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 injector O ring with a n...

Page 63: ...ilter system from the pump body 1 PAWL 2 PUMP BODY 3 PUMP Remove the fule tank Remove the bolts from the fuel pump base and remove the fuel pump assembly taking care not to damge the pump or pump wire...

Page 64: ...erminals Install a new o ring in the fuel hose Install the pump motor in the pump body being careful not to damage the wires 1 O RING 2 PUMP ASSEMBLY Assembly Insert the pump body in the pump Make sur...

Page 65: ...BREATHER HOSE Insert the mounting bolts in the pump Place the pump base in the position as shown Tighten the pump mounting bolts in alphabetical order as show Torque 7 9 N m 0 7 0 9 kgf m 5 1 6 6 lbf...

Page 66: ...injector from the injector holder Replace the fuel injetor and holder as an assembly Alway replace the O ring when the fuel injector assembly is removed from the cylinder head Throttle Body Removal R...

Page 67: ...insulator clamp screw and remove the insulator from the throttle body Installation Install the insulator onto the throttle body while aligning the slit with the lug on the throttle body as shown 1 LOC...

Page 68: ...ner housing mounting nuts and bolt securely Install the washer and silencer mounting bolt then tighten the bolt securely Adjust the angle of the connector tube clamp and tighten the screw firmly Insta...

Page 69: ...e water seal into the right crankcase cover in the direction shown in the illustration above Tool Mechanical seal installer 07965 415000A Install a new oil seal in the direction shown in the illustrat...

Page 70: ...e 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 COIL 4 WIRE CLAMP 1 2P NATU...

Page 71: ...l 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 removal NOTICE At ignition coil installation...

Page 72: ...ing 24 N m 2 4 kgf m 17 8 lbf ft 24 N m 2 4 kgf m 17 8 lbf ft 25 N m 2 5 kgf m 18 4 lbf ft 25 N m 2 5 kgf m 18 4 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 kgf m 36 8...

Page 73: ...n 1 mm thick piece of steel as shown Tool Tensioner holder 07AMG 001A100 1 SEALING BOLT WASHER 2 STOPPER TOOL 1 CYLINDER COMPRESSION GAUGE Cylinder Compression Warm up the engine to normal operating t...

Page 74: ...e 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 Remove the bolts and tappe...

Page 75: ...nents 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 Disassembly Pull out the rocker arm s...

Page 76: ...s 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 head cover camshaft Spark pl...

Page 77: ...ONER 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 2 CAM CHAIN GUIDE 1 BOLT...

Page 78: ...ings more than necessary to remove the cotters Tools Valve spring compressor 07757 0010000 Compressor attachment 07959 KM30101 1 VALVE SPRING COMPRESSOR 2 ATTACHMENT 3 COTTERS 1 CAM CHAIN GUIDE PLATE...

Page 79: ...ake 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 Remove the carbon deposits fro...

Page 80: ...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 0 010 0 037 mm 0 0004 0 001...

Page 81: ...es 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 cool to room temperature Rea...

Page 82: ...facing Valve seat cutters grinders or equivalent valve seat refacing equipment are recommended to correct worn valve seat Follow the refacing manufacturer s instructions Contact area too high or too l...

Page 83: ...erial 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 any roughness or irregulari...

Page 84: ...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 wash the cylinder head and...

Page 85: ...10000 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 as shown to seat the cott...

Page 86: ...n 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 rings are easily broken t...

Page 87: ...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 or piston ring grooves using old p...

Page 88: ...5 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 and measure the ring end gap...

Page 89: ...ng surfaces of the crankcase Apply molybdenum oil solution to the connecting rod small end Place a shop towel around the piston skirt and in the crankcase to prevent the piston pin clips from falling...

Page 90: ...d 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 bolt with a new sealing was...

Page 91: ...lt 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 Cylinder head cover Throttle b...

Page 92: ...ace 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 exhaust rocker arm shafts with...

Page 93: ...NDER HEAD COVER 2 NEW SEALING WASHERS 6 MM BOLTS 3 NEW SEALING WASHERS 4 SH BOLTS Install the cylinder head cover Install new sealing washers and 6 mm bolts Install the two new sealing washers and cyl...

Page 94: ...stall 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 recommended transmission oil page 3...

Page 95: ...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 the O rings Install the retu...

Page 96: ...LUTCH DISCS 3 CLUTCH PLATE 4 PRESSURE PLATE 5 PAPER DISCS 1 LOCK WASHER 2 PLAIN WASHER Hold the clutch assembly with the clutch center holder and remove the clutch center nut Tool Clutch holder plate...

Page 97: ...shaft 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 needle bearing by turning...

Page 98: ...scs and plates alternately onto the clutch center starting with the clutch disc Install the clutch pressure plate onto the clutch center aligning the dot mark on the pressure plate with the dot marks...

Page 99: ...g 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 Install the return spring...

Page 100: ...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 bolts and guide plate as an...

Page 101: ...e 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 drum Install the drum center...

Page 102: ...l 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 3P NATURAL CONNECTOR 2 2P NA...

Page 103: ...e bearing using the special tools Tools Bearing remover 15 mm 07936 KC10500 Remover weight 07936 371020A 1 SNAP RING 2 WASHER 3 OIL SEAL 4 NEEDLE BEARING 1 OIL PRESSURE RELIEF VALVE Disassembly Assemb...

Page 104: ...or 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 Tighten the ignition pulse g...

Page 105: ...e 1 3P NATURAL CONNECTOR 2 2P NATURAL CONNECTOR Install the left crankcase cover being careful not to damage the oil filter cover O ring NOTE The left crankcase cover stator is magnetically attached t...

Page 106: ...pply oil to the flywheel nut threads and seating surface Install the washer and flywheel nut 1 WOODRUFF KEY 1 THREAD PROTECTOR 2 FLYWHEEL 3 FLYWHEEL PULLER Install the thread protector which is includ...

Page 107: ...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 SPRING WASHER Crankcase Separation Disassem...

Page 108: ...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 outer rotors 1 GASKET 2 D...

Page 109: ...t for wear or damage Check the following items specifications page 2 3 Spinning gear I D Bushing I D and O D Mainshaft and countershaft O D Shift fork I D and claw thickness Shift fork shaft O D Shift...

Page 110: ...GHT MAINSHAFT BEARING 10 RIGHT COUNTERSHAFT BEARING 11 RIGHT SHIFT DRUM BEARING A 1 mm oil seal tolerance B 0 0 5 mm oil seal tolerance C 58 60 58 88 mm bearing height D 58 30 58 52 mm bearing height...

Page 111: ...R 17 2 mm B SPLINED WASHER 20 mm SET RING 20 mm C SET RING 20 mm SPLINED WASHER 20 mm D THRUST WASHER 20 X 30 X 1 5 mm E THRUST WASHER 20 X 30 X 1 0 mm F THRUST WASHER 20 X 30 X 1 0 mm G THRUST WASHER...

Page 112: ...stall 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 shift forks with their iden...

Page 113: ...L 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 bolt threads and seating sur...

Page 114: ...orque Torque 31 N m 3 2 kgf m 23 lbf ft Install the removed parts in the reverse order of removal Tool Universal holder 07725 0030000 1 NEW O RING 2 COUNTERSHAFT COLLAR Install the drive pin into the...

Page 115: ......

Page 116: ...ads and clean a contaminated 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 25 1 mm Spokes Check spoke...

Page 117: ...ollar 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 the mou nting...

Page 118: ...k 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 surface and the bottom of the fork slider Be careful not...

Page 119: ...mper using the special tool then loosen the right fork center bolt Remove the center bolt and sealing washer Tools Holder handle 07TMB 001010A Damping Rod Holder Att 4 pin 07AMB NN4A200 1 FORK DAMPER...

Page 120: ...r from 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 there is any distortion at the points sho...

Page 121: ...ollowing 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 fork slider 1 GUIDE BUS...

Page 122: ...d the air as follows 1 Extend the fork without bringing to its maximum exten sion Cover the top of the fork tube with your hand and compress the fork slowly several times NOTICE Totally extending fork...

Page 123: ...Screw the fork bolt on the damper adjuster case until it seats Hold the damper adjuster case and tighten the fork cap bolt to the specified torque Torque 15 N m 1 5 kgf m Apply recommended fork fluid...

Page 124: ...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 disassembly page 5 3 Oil seal Back up ring Guide bushing...

Page 125: ...ece of wood or soft jaws to avoid damage Do not overtighten the vise Clean and apply a locking agent to the center bolt threads 2ED 4ED Install the center bolt with a new sealing washer Hold the cylin...

Page 126: ...ED 3ED Apply recommended fork fluid to the new O ring then screw the fork bolt into the fork tube Torque ED 3ED 13 0 N m 1 3 kgf m 2ED 4ED 20 0 N m 2 0 kgf m Pour half the required amount of recommend...

Page 127: ...RIDGE Tighten the bottom bridge pinch bolts to the specified torque Torque 21 N m 2 1 kgf m 14 lbf ft Overtightening the pinch bolts can deform the outer tube Deformed outer tube must be replaced Tigh...

Page 128: ...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 07946 MB00000 Steering stem driver attach 07946 K...

Page 129: ...Torque 21 N m 2 1 kg m 15 4 lbf ft Tighten the stem nut to the specified torque Torque 99 N m 10 kg m 65 lbf ft Recheck the steering stem adjustment before installing the removed parts 1 TOP BRIDGE 2...

Page 130: ...not depress the brake pedal after the rear wheel is removed The caliper pistons will move and make reassembly difficult Disassembly Assembly WARNING A contaminated brake disc or pad reduces stopping...

Page 131: ...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 and wheel 1 AXLE 2 ADJUSTE...

Page 132: ...702 0020001 Move the spring up next to the fastener plate Remove the stopper ring and remove the spring plate and the spring from the damper body 1 DAMPER UNIT 2 SPRING 3 DAMPER 4 SPRING PLATE STOPPER...

Page 133: ...tallation Driver attachment 07946 GC4000A Driver 07749 0010000 Attachment 22 x 24 mm 07746 001A800 Press a new spherical bearing into the shock absorber pivot until its seats using same tool Apply gre...

Page 134: ...ushion link to frame socket bolt nut Cushion link Move the swingarm aligning the lower mount then install the lower mounting bolt from the right side Install and tighten the upper and lower mounting n...

Page 135: ...39 N m 4 0 kgf m 29 lbf ft Tighten the rear cushion lower mounting nut to the specified torque Torque 39 N m 4 0 kgf m 29 lbf ft 1 PIVOT COLLAR A 2 PIVOT COLLAR B 3 DUST SEALS 4 NEEDLE BEARINGS Needl...

Page 136: ...seal 1 NEEDLE BEARING 2 DUST SEAL 3 BUSHING 1 DUST SEAL CAP 2 DUST SEAL 3 PIVOT COLLAR 4 DUST SEAL Disassembly Remove the following Bolts and drive chain cover Bolts and driven sprocket guard Screws a...

Page 137: ...the pivot collars dust seals and dust seal caps Note the direction of the dust seal 1 DUST SEAL 2 PIVOT COLLAR 3 DUST SEAL 4 DUST SEAL CAP 1 PIVOT COLLAR A 2 PIVOT COLLAR B 3 DUST SEALS 4 NEEDLE BEAR...

Page 138: ...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 tighten the screw Install the dr...

Page 139: ...fluid level in the reservoir as this operation causes the level to rise Remove the pad pins and brake pad Clean the brake caliper inside especially around the caliper pistons 1 NEW PADS 2 PAD PIN 3 PA...

Page 140: ...5 1 CALIPER BRACKET 2 BOSS SLIT Install the new pads and secure them with the pad pin Install the brake caliper bracket aligning its slit with the boss on the swingarm Install the rear wheel page 5 16...

Page 141: ...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 bracket Spring pin for the pads...

Page 142: ...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 order of removal Torque Brake hose oil bolt...

Page 143: ...om 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 oil bolt and disconnect the...

Page 144: ...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 Torque 29 N m 3 0 kgf m 22 lbf...

Page 145: ...ylinder Tool Snap ring pliers 07914 SA50001 Inspection 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 Ins...

Page 146: ...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 Natura...

Page 147: ...ctor and ignition pulse generator 2P Natural connector 1 BOLT 2 BRAKE RESERVOIR Disconnect the condenser 2P Black and regulator rectifier 6P Black connectors Remove the rear brake reservoir tank mount...

Page 148: ...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 68 F W...

Page 149: ...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 Connection White yellow Green yellow Standard 85 1...

Page 150: ...ity 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 1 32P BLACK CONNECTOR Conden...

Page 151: ...ops the engine to protect it from damage MIL Check When the engine is started the MIL will stay on for 5 seconds and then go off If the MIL does not come off troubleshoot DTC code If the MIL does not...

Page 152: ...N If the ECM has self diagnosis memory data the MIL will start blinking when you turn the power switch ON Note how many times the MIL blinks and determine the cause of the problem See page 6 8 1 POWER...

Page 153: ...sensor line in the ECM Faulty MAP sensor Poor idle 7 Blinks P0116 Loose or poor contact on ECT sensor Open or short circuit in ECT sensor wire Faulty ECT sensor Hard starting at a low temperature Sim...

Page 154: ...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 bank angle sensor With the ar...

Page 155: ...n Remove the fuel tank Disconnect the fan motor 2P Natural connector Directly connect a 12 V battery to the fan motor 2P Natural connector terminals of the fan motor side The fan motor is correct if t...

Page 156: ...TEMP SENSOR IGNITION COIL FUN RELAY PULSER ALTERNADOR REGULATOR RECTIFIER CONDENSER 10000uF BANK ANGLE SENSOR FAN MOTOR FUEL PUMP MAPPING SWITCH B BLACK Y YELLOW L BLUE G GREEN R RED W WHITE V VIOLET...

Page 157: ...ates and lead which are known 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 nece...

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