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Montesa COTA 4RT 260 2023, Owner'S Manual

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Montesa COTA 4RT 260 2023 Owner'S Manual Download Page 36

Service data

2-13

2-13

(1)  MAIN WIRE HARNESS

(2)  FUEL PUMP WIRE

(3)  CYLINDER HEAD BREATHER 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 TANK BREATHER HOSE (ED)

(13) HOSE CONNECTOR (ED)

UPPER

RH

20-30º

1

8

2

3

4

5

6

7

8

9

10

11

12

13

Summary of Contents for COTA 4RT 260 2023

Page 1: ...PGM FI Racing Trial 2023 Owner s Manual...

Page 2: ...u 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 f...

Page 3: ...cing version COTA 4RT 260 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 to make c...

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 260 P ED VTDNE13B...

Page 5: ...ead owners manual 2 95 Caution label This motorcycle is not designed to transport a passenger Read owner s manual carefully For yourprotection always wear your helmet while riding Ethanol ethyl alcoho...

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

Page 7: ...Labels 3ED 4 3 2 1 7 5...

Page 8: ...ing 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 Foll...

Page 9: ...Head Cover Camshaft Removal 4 20 Cylinder Head Removal 4 23 Cylinder Head Disassembly 4 25 Cylinder Head Inspection 4 26 Valve Guide Replacement 4 27 Valve Seat Inspection Refacing 4 28 Cylinder Head...

Page 10: ...rts well 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 pe...

Page 11: ...Memo...

Page 12: ...instructions Operation component locations ED kickstarter rear brake pedal clutch lever front brake lever throttle grip engine stop button rearview mirror rearview mirror shift lever light control tur...

Page 13: ...Operating instructions 1 2 1 2 Operation component locations 3ED throttle grip front brake lever clutch lever shift lever kickstarter rear brake pedal mapping switch engine stop button...

Page 14: ...ed 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 removing the radiator...

Page 15: ...rst 30 minutes using not more 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 move forward S...

Page 16: ...lity occurs in the system the ECM turns on the MIL Setting mode The main screen is used to adjust the following settings 1 Changing the speed units 1 Start the motorcycle 2 Press the SET button Press...

Page 17: ...hour digit advances fast release the button when the desired time is displayed Press the SET button to change the minutes y Press less than 2 seconds the digit will increase by one minute each time t...

Page 18: ...1 rpm speed is too high or you release the clutch lever too quickly your Cota may lurch forward 5 When you attain a moderate speed close the throttle pull the clutch lever in and raise the shift leve...

Page 19: ...ontrols steer straight ahead until you regain control then reapply the brakes more gently Generally reduce your speed or complete braking befo re beginning a turn Avoid braking or closing the throttle...

Page 20: ...crease free play Tighten the lock nut after adjustment Operate the throttle grip to ensure that it functions smoothly and returns completely in all steering position 1 DUST COVER A DECREASE 2 LOCK NUT...

Page 21: ...emergency push and hold the engine stop button 1 ENGINE STOP BUTTON 1 TURN SIGNAL SWITCH Turn signal switch Move to to signal a left turn to signal a right turn Press to turn signal off 1 HORN BUTTON...

Page 22: ...y To reduce free play turn the adjuster clockwise then tighten the lock nut securely y To increase free play turn the adjuster counterclockwi se then tighten the lock nut securely If brake lever feels...

Page 23: ...that gripping the bar and ope rating the controls is comfortable while both seated and standing while riding straight ahead and turning Handlebar width can be trimmed with a hacksaw to bet ter your pa...

Page 24: ...ngle cylinder 3 5 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 va...

Page 25: ...0 50 mixture coolant and distilled 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...

Page 26: ...4 0 6686 0 6691 16 46 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...

Page 27: ...87 3 4 Fork oil capacity Right Left 405 cm3 410 cm3 Unit mm in Item Standard Service Limit Rear Suspension SHOWA Shock absorber spring pre load 124 5 1 4 9 0 04 Spring free length 133 5 2 130 3 5 13...

Page 28: ...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 22 2 2 16 Note 4...

Page 29: ...Handlebar holder bolt 4 8 22 2 2 16 Note 1 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...

Page 30: ...diagnosis system Diagnostic tool DST Generic tool PGM FI Self diagnosis system Description Tool number Applicability Spoke nipple wrench 07701 0020300 Front spoke nipple Gear holder 07724 0010100 Prim...

Page 31: ...kcase inside engine 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 grea...

Page 32: ...seal lips 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...

Page 33: ...ensioner 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 hydra...

Page 34: ...Service data 2 11 2 11 Cable Harness Routing 1 FRONT BRAKE HOSE 2 THROTTLE CABLE 3 CLUTCH HOSE 4 ENGINE STOP BUTTON CONNECTOR 5 MAPPING SWITCH 3ED FRONT FRONT 15 mm 45 90 2 5 4 4 1 3 ED 3ED...

Page 35: ...LATION 8 6P CONNECTOR SPEEDOMETER 9 3P CONNECTOR SPEED SENSOR 10 4P CONNECTOR MIL 11 FRONT STOP SWITCH CONNECTOR 12 2P CONNECTOR INACTIVE 13 9P CONNECTOR LIGHTING SWITCH 14 INDICATOR LIGHT INSTALLATIO...

Page 36: ...R 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 TANK B...

Page 37: ...ECTORS BOOT FAN MOTOR 2P CONNECTOR POWER MAPS 4P CONNECTOR COOLANT TEMPERATURE 2P CONNECTOR ED 5 UPPER RADIATOR HOSE 6 SPARK PLUG WIRE 7 FAN MOTOR WIRE 8 FILTER BOX BREATHER HOSE 9 CYLINDER HEAD BREAT...

Page 38: ...Service data 2 15 2 15 1 THROTTLE CABLE 2 CLUTCH HOSE 3 FUEL TANK BREATHER HOSE 1 2 3 2 3 1 45 FR FR UPPER UPPER FR RH RH RH RH RH...

Page 39: ...R 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 10 SPEED S...

Page 40: ...4 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...

Page 41: ...Service data 2 18 2 18 1 REAR BRAKE HOSE 2 REAR BRAKE RESERVOIR HOSE 3 SPEED SENSOR ED 90 UPPER UPPER RH FR FR RH 1 2 3...

Page 42: ...Service data 2 19 2 19 1 FUEL FEED HOSE 2 TRANSMISSION BREATHER HOSE 1 2...

Page 43: ...Memo...

Page 44: ...ge or wear y 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...

Page 45: ...et 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 check for t...

Page 46: ...the air 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 pre...

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: ...ght position on 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 c...

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: ...ngaged 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 hose and...

Page 54: ...ck 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 tensione...

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: ...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 months Re...

Page 57: ...DISC 2 DISC BOLT 3 COLLAR Brake System Refer to page 1 11 for Brake Lever Adjustment Refer to page 1 12 for Brake Pedal Height Adjustment Brake Discs Measure the rear brake disc runout with a dial ga...

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: ...lower fork fluid level are only felt during final fork travel Standard position 2 5 0 5 turns out from full soft Replace the fork fluid every 6 months See page 5 8 5 10 for oil level adjustment after...

Page 60: ...our Cota with the rear suspension at the standard setting before attempting any adjustments y Make all rebound damping adjustment in one click increments Adjusting two or more clicks at a time may cau...

Page 61: ...break If you touch the bulb with your bare hands clean it with a cloth moistened with alcohol to prevent its early failure y Ensure that you replace the dust cover after changing the front headlight...

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: ...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: ...ame away y Refuel only outdoors y 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 Alwa...

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 pic tures 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 BOLTS 3 BREATHER HOSE 1 2P CONNECTOR Always replace th...

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: ...positioned and sup ported in the fuel tank 1 PUMP 3 PAWL 2 BODY 4 CONNECTING PIPE 1 BEARINGS 4 MOTOR 2 PUMP 5 BODY 3 ENGINE CABLES Replace the bearings with new ones every time the fuel pump is disas...

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: ...ine 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 remov...

Page 82: ...ion 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 83: ...ith the 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 e...

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: ...DTH 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...

Page 92: ...erior 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 y Co...

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: ...per 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 or pist...

Page 98: ...ton 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 an...

Page 99: ...ushed 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 Installati...

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: ...hanger bolt tighten the bolt 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 th...

Page 106: ...gs 1 CLUTCH CENTER HOLDER 1 CLUTCH CENTER 2 CLUTCH 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 th...

Page 107: ...sure plate for wear or damage y 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 li...

Page 108: ...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 aligning the dot ma...

Page 109: ...O D y Idle gear I D and bushing O D and I D y 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 W...

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

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: ...Memo...

Page 126: ...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 5 Frame servicing...

Page 127: ...ough the wheel and left side collar 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 thre...

Page 128: ...fork 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...

Page 129: ...d damage Do not overtighten Hold the fork damper using a generic tool then loosen the right fork center bolt Remove the center bolt and sealing washer Tool Fork damper holder Generic tool 1 FORK DAMPE...

Page 130: ...guide bushing back up ring and oil seal from the fork tube Right Fork Inspection Check the following items page 2 4 Fork tube for score marks scratches and excessive wear Fork tube runout Fork slider...

Page 131: ...stall 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 fork slider...

Page 132: ...ed fork fluid in the fork leg Specified fork fluid Showa SS05 SAE 5W or equivalent Bleed the air as follows 1 Extend the fork Cover the top of the fork tube with your hand and compress the fork slowly...

Page 133: ...sassembling the fork clean the entire sliding surface 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...

Page 134: ...l blocker from the fork piston NOTICE Be careful not to damage the oil blocker Remove the cilinder assy from the fork tube Remove the following items using the same procedure as the right fork disasse...

Page 135: ...til the stop ring groove is fully stuck in the fork slider base Install the oil seal with the mark facing up in the fork slider Drive the oil seal using the special tool performing a constant pressure...

Page 136: ...g then screw the fork bolt into the fork tube Torque 22 0 N m 2 2 kgf m 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 c...

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: ...tall the steering stem upper bearing and dust seal 1 DRIVER 2 ATTACHMENT 1 STEM 2 DUST SEAL 3 BEARING 4 STEERING STEM DRIVER Install new dust seal onto the steering stem Install the new lower bearing...

Page 139: ...lean a contaminated disc with a high quality brake degreasing agent 1 ADJUSTER 2 AXLE Apply grease to the stem nut thread and seating surfaces Install the top bridge washer and stem nut Temporarily in...

Page 140: ...T NUT 3 LEFT WHEEL BEARING 4 DISTANCE COLLAR 5 RIGHT WHEEL BEARING 6 DISC BOLT 7 BRAKE DISC 8 REAR WHEEL NIPPLE a 30 0 5 MM Installation Install the rear brake caliper aligning with the caliper slide...

Page 141: ...nd of the clip in the direction of wheel rotation Check and adjust the drive chain slack page 3 11 Tighten the axle nut Torque 69 N m 7 0 kgf m 51 lbf ft 1 SPRING COMPRESSOR 2 ATTACHMENT 3 SPRING SEAT...

Page 142: ...G 4 COMPRESSOR Assembly Assembly is in the reverse order of disassembly Spherical Bearing Replacement Remove the collars and dust seals Check the spherical bearing for smooth rotation or damage Remove...

Page 143: ...ing the lower mount then install the lower mounting bolt from the right side Install and tighten the upper and lower mounting nuts to the specified torque Torque Upper mounting bolt 39 N m 4 0 kgf m 2...

Page 144: ...ushion lower mounting bolt nut Tighten the cushion arm plate and cushion link nuts to the specified torque Torque 39 N m 4 0 kgf m 29 lbf ft Tighten the rear cushion lower mounting nut to the specifie...

Page 145: ...the following Brake hose clamps screws Rear brake caliper Swingarm pivot bolt nut and swingarm assembly 1 BRAKE HOSE CLAMPS 2 SWINGARM PIVOT BOLT NUT Disassembly Remove the following Bolts and drive c...

Page 146: ...CAP 5 NEEDLE BEARING 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 BEARING Link Bearing Replacement Remove the pivot collars and dust s...

Page 147: ...the swingarm into the frame Install the swingarm pivot bolt from the left side Install and tighten the swingarm pivot nut to the specified torque Torque 69 N m 7 0 kgf m 51 lbf ft Install the brake c...

Page 148: ...VER 4 PAD SPRING PIN 5 PAD PIN Brake pad replacement Clean the brake disc with a high quality degreasing agent if they are contaminated with oil or grease Replace the pads if they are contaminated Fro...

Page 149: ...caliper pistons against the pads 1 BOLT 2 SPEED SENSOR 3 SPEED SENSOR BRACKET Rear Brake Pad Replacement NOTICE Before replacing the rear brake pads remove the speed sensor The speed sensor may be da...

Page 150: ...bolt Sealing washers Brake hose eyelet Caliper mounting bolts Disc cover Flange collars Brake caliper Spring pin for the pads Brake pads page 5 23 1 CALIPER BRACKET 2 BOSS SLIT 1 BRAKE PADS 2 PAD PIN...

Page 151: ...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 14 Brake caliper brack...

Page 152: ...ion 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 order of r...

Page 153: ...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 154: ...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 the th...

Page 155: ...ove the snap ring and disassemble the master cylinder Inspection Check the following items page 2 4 Master cylinder and piston for scoring scratches or other damage Master piston O D and master cylind...

Page 156: ...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 157: ...ion 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 r...

Page 158: ...ition 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 Without plug cap 13 5 16 5 k 2...

Page 159: ...enerator 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 Connection White yel...

Page 160: ...itch B W and 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 and Ground Continuity Power ground G1 and Ground Cont...

Page 161: ...the injector the fail safe function stops 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 tro...

Page 162: ...ou turn the power switch ON 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 pr...

Page 163: ...e blue wire terminal of the wire harness side ECM 32P Black connector y If the wire is OK replace the combination meter Tool Test probe 07ZAJ RDJA110 1 4P WHITE CONNECTOR 1 PROBE Mil circuit troublesh...

Page 164: ...circuit in MAP sensor line in the ECM y Faulty MAP sensor y Poor idle 7 Blinks P0116 y Loose or poor contact on ECT sensor y Open or short circuit in ECT sensor wire y Faulty ECT sensor y Hard starti...

Page 165: ...angle 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 166: ...ection Fan motor inspection 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 T...

Page 167: ...ere is no continuity repair or replace the wire harness Chapter lights instruments switches ED System location Speedometer Winker relay Right rear turn signal connectors Lighting switch 9P connector S...

Page 168: ...nector 9P white on the harness side Connection Black and Ground Standard 12V approximately If there is no voltage check the following y Open circuit in the black wire between the ignition relay and th...

Page 169: ...correctly and carry out the checks again y 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 the...

Page 170: ...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 171: ...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 Connectio...

Page 172: ...the 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 Checks If the engine starts but the horn does not w...

Page 173: ...ITCH HORN WATER TEMP SENSOR IGNITION COIL PULSER ALTERNATOR REGULATOR RECTIFIER CONDENSER 10000uF BANK ANGLE SENSOR FAN RELAY POWER RELAY WINKER RELAY 02 SENSOR F1 ECU SPEED SENSOR FAN MOTOR FUEL PUMP...

Page 174: ...ER 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 VIOL...

Page 175: ...Memo...

Page 176: ...Barcelona Spain Authorized Representative European market ED Honda Motor Europe Ltd Aalst Office Wijngaardveld 1 Noord V 9300 Aalst Belgium Authorized Representative United Kingdom Honda Motor Europe...

Page 177: ...Z D EhD Z Kd Zd Z Z sd E W sd E W 8 5 7 21 2 21 250 7 Keep this copy always with the manual MONTESA HONDA S A U Carrer del Mar del Nord 1 Pol lnd La Torre del Rector 08130 SANTA PERPETUA DE MOGODA BA...

Page 178: ...Z D EhD Z Kd Zd Z Z sd E W sd E W 8 5 7 21 2 21 250 7 Keep this copy always with the manual MONTESA HONDA S A U Carrer del Mar del Nord 1 Pol lnd La Torre del Rector 08130 SANTA PERPETUA DE MOGODA BA...

Page 179: ...Memo...

Page 180: ...Printed in Spain 62NN4TEMH...

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