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Montesa COTA 4RT RACE REPLICA, Owner'S Manual

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Montesa COTA 4RT RACE REPLICA Owner'S Manual Download Page 6

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Summary of Contents for COTA 4RT RACE REPLICA

Page 1: ...uld hurt you or others Each safety message is preceded by a safety alert symbol and one of three words DANGER WARNING or CAUTION Significan DANGER You WILL be KILLED or SERIOUSLY HURT if you don t fol...

Page 2: ...on 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 incurring any obligation No part of this publication may...

Page 3: ...n 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 F ED 2E VTDMT04...

Page 4: ...abel The meanings of each symbol and label are as follows 1 Tire information ED 2E Cold tire pressure driver only Front 100kpa Rear 100kpa 2 Keep chain adjusted and lubricated 25 35 Mm 1 0 1 4 In Read...

Page 5: ...Labels ED 2E 4 3 2 1 6...

Page 6: ...Labels 3E 4E 4 2 6 5 3...

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: ...le Body 4 10 Water Seal And Bearing Replacement 4 12 Radiator Removal Installation 4 14 Cylinder Compression 4 17 Cylinder Head Removal 4 20 Cylinder Head Disassembly 4 22 Cylinder Head Inspection 4 2...

Page 9: ...parts well ahead of the season see 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...

Page 10: ...Memo...

Page 11: ...instructions Operation component locations front brake lever throttle grip engine stop button rearview mirror rearview mirror shift lever kickstarter Rear brake pedal light control turn signal horn s...

Page 12: ...g 3 9 Coolant 50 50 Mixture 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 an...

Page 13: ...ars etc are replaced they must be broken in observing the first 30 minutes using not more than half throttle and shifting gears so that the engine does not lug When you shift the transmission into gea...

Page 14: ...on and remove the key To unlock the steering perform the locking sequence in the reverse order Shifting gears Your Cota has five forward gears in a one down four up shift pattern To start riding after...

Page 15: ...ll be reduced All of your actions should be smooth under these condi tions Rapid acceleration braking or turning may cause loss of control For your safety exercise extreme caution when braking acceler...

Page 16: ...adjuster and the clutch master cylinder piston To increase free play turn the adjuster clockwise then tighten the lock nut securely If the clutch lever free play exceeds 30 mm 1 2 in even though the...

Page 17: ...er switch to to select high beam or to to select low beam Turn signal switch Move to to signal a left turn to signal a right turn Press to turn signal off Horn button Press the button to sound the hor...

Page 18: ...HT Brake pedal height The brake pedal height can be adjusted to the rider s pre ference To adjust the rear brake pedal height 1 Loosen the push rod lock nut and brake pedal adjusting bolt lock nut The...

Page 19: ...io Valve timing Intake valve opens Intake valve closes Exhaust valve opens Exhaust valve closes Lubrication system Starting system Liquid cooled 4 stroke engine Single cylinder 3 5 inclined from verti...

Page 20: ...e coolant and distilled water Radiator cap relief pressure 108 kPa 1 1 kgf cm2 Item Standard Service limit Cylinder Head Valves Cylinder compression 460 kPa 4 7 kgf cm2 Cylinder head warpage 0 05 0 00...

Page 21: ...kickstarter idle gear 16 983 16 994 0 6686 0 6691 16 97 0 668 Item Standard Service limit Crankshaft Transmission Crankshaft runout Right 0 03 0 001 Left 0 05 0 002 Connecting rod big end Side cleara...

Page 22: ...Pre load adjuster setting 5 0 5 turns out from full soft Damping adjuster setting Tension adjuster 20 2 clicks from full hard Fork oil level Right 50 1 96 Left 100 3 93 Fork oil capacity Right 400 cm...

Page 23: ...nt Brake disc thickness 3 5 0 14 3 0 0 12 Brake disc runout 0 15 0 006 Rear Brake disc thickness 2 5 0 10 2 0 0 08 Brake disc runout 0 15 0 006 Unit mm in Item Standard Service Limit Electrical Spark...

Page 24: ...1 18 18 1 8 13 Note 2 Vacuum port joint 1 5 2 5 0 25 1 8 Primary drive gear special bolt 1 12 108 11 0 80 Note 1 Flywheel nut 1 18 167 17 0 123 Note 1 Cam chain tensioner bolt 1 6 12 1 2 9 Note 4 Val...

Page 25: ...ks Handlebar holder bolt 4 8 22 2 2 16 Note 1 Front axle 1 17 69 7 0 51 Note 1 Rear axle 1 17 69 7 0 51 Note 1 Final driven sprocket nut ED 2E 4 8 24 30 2 4 3 0 17 7 22 1 Note 3 Final driven sprocket...

Page 26: ...y Spoke nipple wrench 07701 0020300 Front spoke nipple Gear holder 07724 0010100 Primary drive gear bolt Bearing remover head 07746 0050600 Wheel bearing Bearing remover shaft 07746 0050100 Wheel bear...

Page 27: ...ol 4T stroke engine oil 10W 30 600 cm3 Item Material Remarks Connecting rod small end I D Molybdenum oil solution Connecting rod big end A 50 50 mixture of Camshaft outer surface molybdenum disulfide...

Page 28: ...ed multipurpose grease Right crankcase cover water hose joint threads Cylinder head water hose joint threads Sealant Cylinder head cover mating surface Three Bond 1215B Wheel Item Material Remarks Rea...

Page 29: ...earing spinning area Wheel axle threads Step joint pin surface Multi purpose grease Throttle pipe sliding surface and throttle wire drum 4 stroke engine oil Throttle housing screw threads Molybdenum d...

Page 30: ...Service data 2 12 2 12 Cable Harness Routing 1 FRONT BRAKE HOSE 2 THROTTLE CABLE 3 CLUTCH HOSE 4 ENGINE STOP SWITCH CONNECTOR 90 FRONT FRONT FRONT FRONT 2E 4E ED 3E 2 4 1 3...

Page 31: ...RN SIGNAL CONNECTORS 6 LEFT FRONT TURN SIGNAL CONNECTORS 7 CONNECTOR 9P 8 CONNECTOR 6P 9 CONNECTOR 3P 10 INDICATOR LIGHT INSTALLATION 11 INDICATOR LIGHT INSTALLATION CONNECTOR 12 RIGHT REAR TURN SIGNA...

Page 32: ...WIRE 3 CYLINDER HEAD BREATHER HOSE 4 CRANKCASE BREATHER JOINT HOSE 5 STRAGE TANK 6 ENGINE STOP SWITCH WIRE UPPER RH 20 30 7 FAN MOTOR WIRE 8 FUEL CAP BREATHER HOSE 9 SPARK PLUG WIRE 10 WIRE HARNESS T...

Page 33: ...CONNECTOR BOOT FAN MOTOR 2P BLACK CONNECTOR POWER CONNECTOR LIGHT RELAY CONNECTOR ED 2E 5 UPPER RADIATOR HOSE 6 SPARK PLUG WIRE 7 FAN MOTOR WIRE 8 FILTER BOX BREATHER HOSE 9 CYLINDER HEAD BREATHER HOS...

Page 34: ...Service data 2 16 2 16 1 INTAKE VACUUM HOSE 2 THROTTLE CABLE 3 CLUTCH HOSE 4 FUEL TANK BREATHER HOSE 1 2 2 3 3 4 2 45 FR FR UPPER UPPER FR RH RH RH RH RH...

Page 35: ...TER BOX BREATHER HOSE 4 ALTERNATOR WIRE 5 CONDENSER 2P BLACK CONNECTOR 6 REGULATOR RECTIFIER 5P BLACK CONNECTOR 7 ENGINE STOP RELAY 8 FAN MOTOR RELAY Only for 3E 4E version 9 REAR BRAKE RESERVOIR TANK...

Page 36: ...E BREATHER JOINT HOSE 5 TRANSMISSION BREAHTER HOSE 6 WIRE HARNESS 7 FUEL RETURN HOSE 8 FUEL FEED HOSE 9 REGULATOR RECTIFIER 5P BLACK CONNECTOR 10 CONDENSOR 11 CONDENSOR 2P BLACK CONNECTOR 12 BANK ANGL...

Page 37: ...Service data 2 19 2 19 1 REAR BRAKE HOSE 2 REAR BRAKE RESERVOIR HOSE 3 SPEED SENSOR ED 2E 90 UPPER UPPER RH FR FR RH 1 2 3...

Page 38: ...Service data 2 20 2 20 1 FUEL FEED HOSE 2 INTAKE VACUUM HOSE 3 TRANSMISSION BREATHER HOSE 1 2 3...

Page 39: ...e chain slider and roller for damage or wear Loose bolts screws and other fasteners 3 Service and maintenance Maintenance schedule Perform pre ride Inspection at each scheduled maintenance period I In...

Page 40: ...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 41: ...on 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 can result in a damaged element In...

Page 42: ...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...

Page 43: ...e rocker arm and valve 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...

Page 44: ...owly through the oil filler hole Specified engine oil Repsol 4 stroke motorcycle oil SAE 10W 30 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 fi...

Page 45: ...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 46: ...le in an upright 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 fr...

Page 47: ...is damaged Replace the water seal or the oil seal page 4 12 Coolant Replacement WARNING Removing the radiator cap while the engine is hot will allow the coolant to spray out seriously scalding you Al...

Page 48: ...is 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 clutc...

Page 49: ...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 50: ...3 5 kgf m 22 1 25 8 lbf ft Adjust the drive chain 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 tight...

Page 51: ...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 52: ...eft 1 BRAKE DISC 2 DISC BOLT 3 COLLAR Brake System Refer to page 1 3 for Brake Lever Adjustment Refer to page 1 4 for Brake Pedal Height Adjustment Brake Discs Measure the rear brake disc runout with...

Page 53: ...t 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 wh...

Page 54: ...he rider s weight 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 reb...

Page 55: ...he spring initial pre load length Fork fluid volume The effects of higher or lower fork fluid level are only felt during final fork travel Replace the fork fluid every 6 months See page 5 8 5 11 for o...

Page 56: ...justments 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 becom...

Page 57: ...he front 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 c...

Page 58: ...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 59: ...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 60: ...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 61: ...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 62: ...ssure Inspection WARNING Gasoline is highly flammable and is explosive You can be burned or seriously injured Stop engine and keep heat sparks and flame away Refuel only outdoors Wipe up spills immedi...

Page 63: ...d fuel return hose Pressure regulator Fuel pump page 4 6 If the fuel pressure is lower than specified inspect the following Fuel line leaking Clogged fuel filter Pressure regulator Fuel pump page 4 6...

Page 64: ...rminals check amount of fuel flow for 10 seconds Amount of flow 0 833 l min 139 cm3 10 seg If the fuel flow is less than specified inspect the following Pinched or clogged fuel hose and fuel return ho...

Page 65: ...e fuel pump 2P Black connector Remove the fuel tank and injector as an assembly being careful not to damage the injector especially tip of the injector After removing the fuel tank injector assembly p...

Page 66: ...ANJO BOLT Install the fuel pump mounting bolts Tighten the fuel tank mounting bolts in the alphabetical order shown in the illustration Torque 6 8 N m 0 6 0 8 kgf m 4 4 5 9 lbf ft 1 FUEL PUMP 2 BOLTS...

Page 67: ...the specified torque Torque 8 12 N m 0 8 1 2 kgf m 5 9 8 8 lbf ft Connect the fuel injector 2P Black connector Install the rear fender 1 SOCKET BOLTS 2 2P BLACK CONNECTOR 1 VACUUM HOSE 2 PRESSURE REGU...

Page 68: ...injector as an assembly page 4 6 Loosen the connecting tube band screw Remove the silencer mounting bolt Remove the air cleaner housing mounting nuts and bolt Pull the air cleaner housing backward bei...

Page 69: ...stall the throttle cable to the throttle body Adjust the throttle grip free play Install the throttle drum cover and tighten the screws 1 THROTTLE CABLE END 2 THROTTLE DRUM 3 THROTTLE CABLE 4 LOCK NUT...

Page 70: ...e following Water pump cover bolt cover dowel pins O ring Right crankcase cover and washer page 4 37 Hold the water pump gear teeth using a suitable tool then remove the impeller copper washer and wat...

Page 71: ...he 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 cover p...

Page 72: ...hose clamp Disconnect the ECT sensor 3P Gray connector 1 GROUND EYELET 2 BOLTS 3 IGNITION COIL 4 WIRE CLAMP 1 TIE WRAP 1 2P NATURAL CONNECTOR Radiator Removal Installation Remove the following Exhaust...

Page 73: ...nents require engine removal for servicing Crankshaft Oil pump Shift forks and shift drum Transmission 1 IGNITION COIL 2 BOLTS 3 GROUND EYELET 4 WIRE CLAMP Installation is in the reverse order of remo...

Page 74: ...allation Illustration 1 ONLY VERSIONS 3E 4E 1 2 2 2 6 N m 0 22 0 26 kgf m 1 6 1 9 lbf ft 60 80 N m 6 8 kgf m 44 59 lbf ft 2 5 2 7 N m 0 25 0 27 kgf m 1 8 2 lbf ft 4 7 5 3 N m 0 47 0 53 kgf m 3 4 3 9 l...

Page 75: ...e 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...

Page 76: ...cylinder 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 COVE...

Page 77: ...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 78: ...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 79: ...OT 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 TENSIONE...

Page 80: ...do 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 1 CAM...

Page 81: ...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 82: ...uide 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...

Page 83: ...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 84: ...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 85: ...of the existing valve seat material Tools Flat cutter 33 mm 07780 0012900 Flat cutter 28 mm 07780 0012100 Cutter holder 5 0 mm 07781 0010400 or equivalent commercially available Use a 45 cutter remove...

Page 86: ...le 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 wash...

Page 87: ...g 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 as s...

Page 88: ...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 89: ...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 90: ...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 91: ...ckwise 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 Place a shop towel over...

Page 92: ...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 93: ...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 94: ...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 95: ...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 96: ...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 97: ...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 98: ...ngs 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 t...

Page 99: ...e plate 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...

Page 100: ...n 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 mark o...

Page 101: ...indle O 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...

Page 102: ...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 103: ...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 104: ...ER Left Crankcase Cover Removal Remove the skid plate and drain engine oil Disconnect the alternator 3P White connector and ignition pulse generator 2P Natural connectors Remove the gearshift pedal 1...

Page 105: ...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 106: ...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 107: ...evel Install the slid plate 1 3P WHITE 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 stator...

Page 108: ...e cover page 4 48 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 109: ...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 110: ...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 111: ...FT DRUM Inspect each part 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 Sh...

Page 112: ...5 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...

Page 113: ...4 55 4 55 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 114: ...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 115: ...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 116: ...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 117: ...c 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 ED 3E 27 25 1 mm 2E 4E 5 Frame servicing Spokes Ch...

Page 118: ...he 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 mounting bolts to the spe...

Page 119: ...K BOLT 1 DAMPER ADJUSTER CASE 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 to scratch the fork tub...

Page 120: ...en Hold the fork damper using the special tool then loosen the right fork center bolt Tool Fork damper holder 89515 NN3 821 1 FORK DAMPER HOLDER 2 RIGHT FORK CENTER BOLT ED 3E ED 3E Remove the dust se...

Page 121: ...ear or scratches Remove any metal powder 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 th...

Page 122: ...l the following Fork tube bushing Guide bushing Back up ring New oil seal Coat the guide and fork tube bushings with recommended fork fluid Install the fork tube assembly into the fork slider 1 GUIDE...

Page 123: ...OJ01 SAE 5 2E 4E versions Above 5 C 41 F Showa SS05 Below 5 C 41 F Belray 5 or BP 10 Bleed the air as follows 1 Extend the fork Cover the top of the fork tube with your hand and compress the fork slow...

Page 124: ...case until it seats Hold the damper adjuster case and tighten the fork cap bolt to the specified torque Torque ED 3E 14 7 N m 1 49 kgf m 2E 4E 34 N m 3 5 kgf m Apply recommended fork fluid to the O r...

Page 125: ...e the seat pipe assembly 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 Slider bushing 1 FORK TUBE 2...

Page 126: ...lt threads Install the center bolt with a new sealing washer Hold the seat pipe using the special tool then tighten the center bolt to the specified torque Tool Fork damper holder 07930 KA50100 Torque...

Page 127: ...BOLT Install the fork spring spring seat and distance collar Apply recommended fork fluid to the new O ring then screw the fork bolt into the fork tube Pour half the required amount of recommended fo...

Page 128: ...ge 1 STEM NUT 2 TOP BRIDGE 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...

Page 129: ...UST SEAL 3 BEARING 4 STEERING STEM DRIVER 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...

Page 130: ...ts to the specified torque 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 re...

Page 131: ...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 contaminated brake dis...

Page 132: ...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 133: ...h 07702 0020001 Move the spring up next to the fastener plate Remove the Seeger fastener ring and remove the spring plate and the spring from the damper body 1 DAMPER UNIT 2 SPRING 3 DAMPER 4 SPRING P...

Page 134: ...achment Tools Shock absorber compressor 07GME 0010100 Compressor attachment 07959 MB10000 Remove the stopper ring spring seat and spring Inspection Check the following items specification page 2 3 Upp...

Page 135: ...s and dust seals Check the spherical bearing for smooth rotation or damage Remove the stop ring 2E 4E Press the spherical bearing out using the special tool Tool Spherical bearing driver 07HMF KS60100...

Page 136: ...nut Cushion arm plates Cushion 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 u...

Page 137: ...he specified torque Torque 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 SEA...

Page 138: ...ust bushings and the dust 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 driv...

Page 139: ...of a new dust seals Install 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...

Page 140: ...ghten 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 tighten...

Page 141: ...rake 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...

Page 142: ...he caliper pistons against the pads 1 NEW PADS 2 PAD PIN 3 PAD SPRING PIN Push the pistons all the way in to allow installation of new brake pads Check the brake fluid level in the reservoir as this o...

Page 143: ...ake fluid level in the reservoir as this operation causes the level to rise Remove the pad pin and brake pads Clean the brake caliper inside especially around the caliper pistons 1 BOLT 2 SPEED SENSOR...

Page 144: ...OSS 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 Operate the brake peda...

Page 145: ...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 Brake pa...

Page 146: ...and holder Master cylinder Inspection Check the following items specifications page 2 4 Master cylinder and piston for scoring scratches or other damage Master piston O D and master cylinder I D Inst...

Page 147: ...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 oil bolt and...

Page 148: ...a suitable container Remove the following Clutch lever Clutch hose bolt Master cylinder holder bolts and holder Master cylinder Installation Install the brake pedal and collars Install and tighten the...

Page 149: ...in the groove Remove the snap ring and disassemble the master cylinder Inspection Check the following items specifications page 2 4 Master cylinder and piston for scoring scratches or other damage Ma...

Page 150: ...Memo...

Page 151: ...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 152: ...ural connector and ignition 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...

Page 153: ...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 Without plug cap 13 5 16 5...

Page 154: ...e ignition pulse generator stator assembly page 4 46 1 2P NATURAL CONNECTOR Ignition Pulse Generator Inspection Check the ignition coil resistance at the ECM 32P Black connector page 6 5 Connection Wh...

Page 155: ...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 156: ...ing side as shown Turn the power switch ON check that the MIL If the ECM has no self diagnosis memory data the MIL will illuminate when you turn the power switch ON If the ECM has self diagnosis memor...

Page 157: ...ce check connector Faulty ECM PGM FI warning indicator output Engine 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 co...

Page 158: ...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 arrow UP mar...

Page 159: ...pection 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...

Page 160: ...connector and ECM 32P Black connector There should be continuity If there is no continuity repair or replace the wire harness Chapter lights instruments switches ED 2E System location speedometer win...

Page 161: ...check the voltage between the following terminals of the connector 9P white on the harness side Connection Black Ground Standard 12V approximately If there is no voltage check the following Open circ...

Page 162: ...wire Yellow green wire left side Blue red wire right side Green wires for the indicators If the indictor lights come on replace the indicator relay with one that you know is working correctly and car...

Page 163: ...ks 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 CO...

Page 164: ...ion of the speedometer system Do not disconnect the connectors 6P and 3P of the speedometer during the checks Shift the transmission into neutral Start the engine with the connectors 6P and 3P of the...

Page 165: ...and check the voltage between the following terminals of the connector 9P white on the harness side Connection Black Ground Standard 12V approximately 1 HORN 2 CONNECTORS 1 HOUSING FOR THE UPPER HEAD...

Page 166: ...NI 9P NATURAL POWER HORN WATER TEMP SENSOR IGNITION COIL FAN RELAY PULSER ALTERNATOR REGULATOR RECTIFIER CONDENSER 10000uF BANK ANGLE SENSOR REAR BRAKE LIGHT SWITCH SERVICE CHECK CONNECTOR RIGHT REAR...

Page 167: ...EU G VERT IR ROUGE W BLANC Br MARRON O ORANGE Sb BLEU CLAIR Lg VERT CLAIR P ROSE Gr GRIS SERVICE CHECK CONNECTOR POWER WATER TEMP SENSOR IGNITION COIL FUN RELAY PULSER ALTERNADOR REGULATOR RECTIFIER C...

Page 168: ...Memo...

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