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Motorcycle safety

made in C.E.

WARNING! don’t touch

Gas at high pressure.

Nº XXXXXX

REAR DAMPER LABEL

PETROL REFUELING
Do not open.
Do not heat.

DUNLOP D803FGP
MICHELIN TRIAL COMPETITION

DUNLOP D803GP
MICHELIN TRIAL COMPETITION X11

80/100-21 M/C 51M, 2.75-21 M/C 45L

120/100R18 M/C 68M, 4.00 R18 M/C 64L

NN4-L10

TYRE INFORMATION LABEL

Cold tyre pressure (only for road use):
[Rider only]

Front

100 kPa (1,02 kgf/cm

)

Rear

100 kPa (1,02 kgf/cm

)

Tyre size (Dunlop):

Front

D803FGP

80/100-21 M/C 51M

Rear

D803GP

120/100R18 M/C 68M

Tyre size (Michelin):

Front

TRIAL COMPETITION

2.75-21 M/C 45L

Rear

TRIAL COMPETITION X11

4.00 R18 M/C 64L

Pictograms

Содержание 4ride

Страница 1: ......

Страница 2: ...ormation available at the time of printing Montesa Honda S A U reserves the right to make changes at any time with no advance notice or accepting any sort of responsibility No part of this publication may be reproduced without the pertinent prior written permission The vehicle illustrated in this Owner s Manual may not match your own vehicle 2017 Montesa Honda S A U ...

Страница 3: ......

Страница 4: ...ducts To ensure your safety and enjoyment Read this owner s manual carefully Follow all the recommendations and procedures included in it Pay careful attention to the safety messages included in the manual and on the motorcycle itself The following codes in this manual indicate each country The illustrations included in this publication correspond to the ED model Country codes Code Country ED Euro...

Страница 5: ...you must use common sense You will ﬁnd important safety information in several forms including Safety labels on the motorcycle Safety Messages preceded by a safety alert symbol and one of three safety words DANGER WARNING or CAUTION These safety messages mean 2 DANGER You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions 2 WARNING You MAY be KILLED or SERIOUSLY HURT if you don t fo...

Страница 6: ...Index Motorcycle safety P 2 Operating guide P 19 Maintenance P 35 Locating malfunctions P 79 Information P 91 Speciﬁcations P 102 INDEX P 106 ...

Страница 7: ... the safe operation of your motorcycle Read this section to ensure your safety Motorcycle safety Safety guidelines P 3 Pictograms P 6 Safety precautions P 10 Precautions while riding P 11 Accessories modiﬁcations P 15 Off road safety P 16 Loads P 17 ...

Страница 8: ...of the body So always wear an approved motorcycle helmet and protective equipment 2 P 10 Before riding Make sure that you are physically and mentally capable and that you have not consumed alcohol or drugs Check that you are using a duly approved motorcycle helmet and protective gear NOTICE This motorcycle is not designed to transport a passenger Take the time you need to learn and practise Even i...

Страница 9: ... than conditions warrant Fatigue and lack of attention can reduce your ability to act with good judgement and ride safely Don t drink and ride Alcohol is not compatible with riding One single drink can reduce your ability to respond to continuously changing conditions and your response time worsens with each additional drink Therefore if you drink don t ride and don t let your friends drink and ri...

Страница 10: ...rs controls brakes and wheels Ride slowly and cautiously The motorcycle may have suffered damage that is not immediately noticeable Have your motorcycle carefully inspected at a qualiﬁed garage as soon as possible Hazard of carbon monoxide poisoning The exhaust contains carbon monoxide a poisonous gas that is both colourless and odourless Breathing carbon monoxide can cause the loss of consciousne...

Страница 11: ...s a speciﬁc symbol These symbols mean the following Read the instructions in the Owner s manual carefully Read the instructions in the Shop manual carefully For your safety only take your motorcycle to dealerships afﬁliated with your distributor for service and maintenance DANGER with a RED background You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions WARNING with an ORANGE back...

Страница 12: ...tability and handling of this motorcycle can be affected by the addition of accessories and luggage Read the instructions in this owner s manual and the installation guide carefully before installing any accessory The total weight of the accessories and luggage added to the rider s own weight must not exceed 111 kg which is the maximum weight capacity The addition of large fairings mounted on the ...

Страница 13: ...L COMPETITION X11 80 100 21 M C 51M 2 75 21 M C 45L 120 100R18 M C 68M 4 00 R18 M C 64L NN4 L10 TYRE INFORMATION LABEL Cold tyre pressure only for road use Rider only Front 100 kPa 1 02 kgf cm2 Rear 100 kPa 1 02 kgf cm2 Tyre size Dunlop Front D803FGP 80 100 21 M C 51M Rear D803GP 120 100R18 M C 68M Tyre size Michelin Front TRIAL COMPETITION 2 75 21 M C 45L Rear TRIAL COMPETITION X11 4 00 R18 M C 6...

Страница 14: ...own protection always wear a helmet and protective gear FUEL LABEL Only unleaded petrol ONLY ONE RIDER LABEL This motorcycle is not designed to transport a passenger DRIVE CHAIN LABEL Keep the chain well adjusted and lubricated 25 to 35 mm of free play Pictograms ...

Страница 15: ...s and the road Helmet Approved highly visible and the appropriate size for your head It should ﬁt comfortably but securely with the chin strap fastened Visor with a clear ﬁeld of vision or other approved form of eye protection 2 WARNING Not wearing a helmet increases the chance of suffering serious injuries or even death in the case of a collision Make sure that you always wear an approved helmet ...

Страница 16: ...ill need speciﬁc gear for this purpose In addition to a helmet and eye protection you are recommended to wear boots and gloves for off road riding riding pants with hip and knee pads and a jumper with padded elbows and chest and shoulder protection Precautions while riding Running in For the ﬁrst 500 km follow these guidelines to ensure the reliability and future performance of your motorcycle Avo...

Страница 17: ...steep slopes can signiﬁcantly overheat the brakes which reduces their effectiveness To reduce speed use the engine brake and intermittently apply the brakes Engine brake The engine brake helps reduce the speed of the motorcycle when the throttle is released Downshift for more pronounced speed reduction Use the engine brake and intermittently apply the brakes to reduce speed when descending long st...

Страница 18: ...atures until they have cooled To reduce the probability of theft always lock the handlebars and remove the key when leaving the motorcycle The use of an anti theft system is also recommended Parking with the side stand 1 Turn off the engine 2 Lower the side stand 3 Lean the motorcycle slowly to the right until its weight rests on the side stand 4 Turn the handlebars all the way to the left 5 Inser...

Страница 19: ...ol It must be 91 octane RON or higher If you use lower octane petrol engine performance will be reduced Do not use fuels containing alcohol 2 P 93 Do not use expired or dirty petrol or oil petrol mixtures Avoid getting dirt or water in the fuel tank NOTICE The fuel level in the motorcycle must be sufﬁcient for the trip that is planned Safety precautions ...

Страница 20: ...gal to use on public streets and thoroughfares Before deciding to install accessories on the motorcycle make sure that the modiﬁcation is safe and legal 2 WARNING Inappropriate accessories or modiﬁcations may cause an accident in which you could be seriously injured or killed Follow all instructions in this owner s manual regarding accessories and modiﬁcations Do not pull a trailer or connect a si...

Страница 21: ...ycle rider so that you can help each other if necessary It is very important to be familiar with the motorcycle in case a mishap occurs far from help Never ride beyond your personal ability and experience or faster than conditions warrant Ride carefully if you are unfamiliar with the terrain Hidden rocks pits and ditches can cause serious accidents Almost all off road areas require the use of a si...

Страница 22: ...of the motorcycle Do not place objects near the lights or silencer Never transport a passenger Keep the load small and light when riding Make sure that the luggage does not brush against other objects or interfere with your movements when changing position to maintain balance and stability It is totally prohibited to transport cargo on the rear fender The motorcycle has not been designed for this ...

Страница 23: ...18 Motorcycle safety ...

Страница 24: ...erating guide Location of the parts P 20 Instruments P 22 Indicators P 25 Switches P 26 Steering lock P 27 Starting the engine P 28 Gear shift P 29 Refuelling P 30 Suspensions P 32 Storage equipment P 34 ...

Страница 25: ...cation of the parts Throttle grip P75 Right side cover P53 Coolant level and expansion cap P62 Front brake lever Right front cover P52 Kickstarter pedal P28 Rear brake pedal P64 Side stand P66 Front brake ﬂuid reservoir P64 ...

Страница 26: ...21 Operating guide Gearshift pedal P29 Clutch lever P73 Fuel ﬁller cap P30 Left side cover P53 Left front cover P52 Drive chain P67 Engine oil ﬁlter P57 ...

Страница 27: ...ruments M Mode button S Set button Checking the display screen When the motorcycle is started the display screen odometer total distance travelled and either km h or mp h segments light up depending on the prior conﬁguration ...

Страница 28: ... Mode button toggles between the total odometer and tripmeter in normal view Total odometer Odo Total distance travelled Tripmeter Trip 1 Trip 2 Distance travelled since the tripmeter was reset to zero by pressing and holding the S Set button to reset the value on the tripmeter screen to 0 0 km miles ...

Страница 29: ... 2 Changing from Odo to Trip 1 display Start the motorcycle Press the M Mode button and the Odo display will change to Trip 1 Instruments continued Press the S Set button u Keep it pressed for several seconds and Trip 1 will change to 0 0 km h mph 3 Changing from Trip 1 to Trip 2 display With the motorcycle running and set to Trip 1 u Press the M Mode button and the display will change to Trip 2 P...

Страница 30: ...25 Operating guide Indicators Right left turn signal indicator High beam indicator Malfunction indicator lamp MIL P81 ...

Страница 31: ...26 Operating guide Switches Engine stop button Keep pressed to stop the engine Headlight dimmer switch High beam Low beam Horn button Right left turn indicator switch ...

Страница 32: ...e lower bridge of the front suspension Locking Turn the handlebars all the way to the left Insert the key in the steering lock and turn it as far as it will go to the left Then press the lock all the way in and turn the key back to the original position u Move the handlebars a little if it is difﬁcult to lock Remove the key Unlocking To unlock the steering perform the locking sequence in the rever...

Страница 33: ...e door open run the engine only long enough to move your 4Ride out of the garage Cold engine starting Shift the transmission into neutral With the throttle fully closed operate the kickstarter Starting from the top of the kickstarter stroke kick through to the bottom with a rapid continuous motion After the engine starts run it for a few minutes blipping the throttle until it warms up enough to id...

Страница 34: ...29 Operating guide Gear shift The transmission of your motorcycle has ﬁve gears arranged so that ﬁrst gear is below and the other four are above ...

Страница 35: ...e the ﬁller neck Type of fuel Only unleaded petrol Octane number Your motorcycle has been designed to use fuel with an octane number RON of at least 91 Tank capacity 4 4 litres 1 16 US gal 0 97 Imp gal Fuel ﬁller cap Filler neck Fuel ﬁlling opening Breather hose ...

Страница 36: ...the fuel ﬁller cap Install the fuel ﬁller cap by turning it clockwise Connect the breather hose to the fuel ﬁller cap 2 WARNING Petrol is highly ﬂammable and is explosive You can be burned or seriously injured when refuelling Stop engine and keep heat sparks and ﬂames away Refuel only outdoors Wipe up spills immediately NOTICE Always refuel enough petrol for the trip planned Refuelling continued ...

Страница 37: ...ad length STD 4 turns out from full soft Suspensions Front suspension settings NOTICE The motorcycle is shipped with a light coating of grease on the forks This is not an indication of a leak The fork should always be adjusted for the 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 da...

Страница 38: ...u ride After break in is completed test ride your Cota with the rear suspension at the standard setting before attempting any adjustments Make all rebound damping adjustment in one click increments Adjusting two or more clicks at a time may cause you to pass over the best adjustment Test ride after each adjustment If you become confused about adjustment settings return to the standard position and...

Страница 39: ...34 Operating guide Storage equipment Document bag The document bag is located in the storage box under the seat Remove the seat P51 4Ride Document bag ...

Страница 40: ...l P 55 Transmission Oil P 60 Coolant P 62 Brakes P 64 Side stand P 66 Drive chain P 67 Wheels P 72 Clutch P 73 Throttle P 75 Crankcase breather P 77 Headlight P 78 Read the Importance of maintenance and Basic maintenance sections before carrying out any maintenance task Consult Speciﬁcations to obtain service data Maintenance ...

Страница 41: ...follow the inspection and maintenance recommendations and the schedules indicated in this owner s manual Maintenance safety Always read all the maintenance instructions before beginning work and make sure that you have the proper tools and parts as well as the necessary technical skills It is impossible to warn about all the conceivable hazards that might arise when carrying out maintenance proced...

Страница 42: ...ments Keep a maintenance record to ensure that the motorcycle receives proper maintenance Make sure whoever performs the maintenance completes this record Any scheduled maintenance is considered to be a normal operating cost for the owner who will be charged for it by the dealer Save all receipts If you sell your motorcycle these receipts must be provided to the new owner together with the motorcy...

Страница 43: ...ation 75 Engine oil 43 Engine oil ﬁlter 55 Transmission Oil 60 Drive Chain Check the item after riding in adverse conditions and dusty areas 67 Brake Fluid 64 Brake Pad Wear 65 Clutch system 73 Wheels tyres 46 72 Side stand Check the item after riding in adverse conditions and dusty areas 66 Lights horn Engine stop switch Fuel Line Fuel ﬁlter Clean under the front suspension fender Air cleaner Che...

Страница 44: ...r screen 57 Engine idle speed Radiator coolant 62 Cooling system Drive chain slider tensioner Check the item after riding in adverse conditions and dusty areas 71 Drive driven sprocket 44 Drive chain slider Brake system Clutch ﬂuid 104 Rear suspension Check the items more often when riding in adverse conditions and dusty areas Damper linkage rods Fork oil Steering pipe bearing Wheel bearings Nuts ...

Страница 45: ...y have your motorcycle serviced by your dealer Maintenance legend Inspect clean adjust lubricate or replace if necessary Replace Clean Notes 1 At higher odometer readings repeat the maintenance work at the frequency intervals established here 2 Service more frequently when riding in wet or dusty areas 3 Service more frequently when riding in rain or with the throttle fully open 4 Perform maintenan...

Страница 46: ...in all steering positions 2 P 75 Engine oil level u Add oil to the engine if necessary Check for leaks 2 P 55 Coolant level u Add coolant if necessary Check for leaks 2 P 62 Drive chain u Check the condition and the slack adjusting and lubricating it if necessary 2 P 67 Front brake u Check the operation of the front and rear brakes check the brake ﬂuid level and the wear of the brake pads 2 P 64 6...

Страница 47: ...of the ordinary Use a key to check that all the accessible nuts bolts and fasteners are tight Part replacement Always use original Montesa parts or their equivalents to ensure the reliability and safety of the vehicle 2 WARNING The installation of parts other than Montesa parts may render you motorcycle unsafe and cause an accident in which you may be seriously injured or even killed Always use or...

Страница 48: ... label to ensure that the oil meets all the following standards Standard JASO T 903 1 MA Standard SAE 2 10W 30 API Classiﬁcation 3 SG or better 1 Standard JASO T 903 is a reference for 4 speed motorcycle engine oils There are two classes MA and MB For example the following label indicates the classiﬁcation MA 2 Standard SAE classiﬁes oils according to their viscosity 3 The API classiﬁcation speciﬁ...

Страница 49: ... worn Brake Fluid Do not add or replace brake ﬂuid except for in the case of an emergency Only use new brake ﬂuid from a sealed container If you add ﬂuid have your dealer inspect the brake system as soon as possible NOTICE Brake ﬂuid can damage plastic and painted surfaces Clean any spills immediately and carefully wash the affected area Recommended brake ﬂuid DOT 4 brake ﬂuid Drive chain The driv...

Страница 50: ...ain lubricant speciﬁcally designed for chains Avoid contact between the lubricant and brakes or tyres Avoid applying an excessive amount of chain lubricant to prevent it from splashing it on your clothes or the motorcycle itself Recommended coolant The motorcycle engine is water cooled In order to provide adequate cooling it is essential for the radiator be ﬁlled with coolant up the proper level 2...

Страница 51: ...protection in cold climates NOTICE The use of coolants not speciﬁed for aluminium engines or tap water can cause corrosion Tyres inspection replacement Checking the tyre pressure Visually inspect the tyres and use a pressure gauge to check the air pressure before riding off road and every time you return to the asphalt after off road riding If you only ride on asphalted surfaces check the pressure...

Страница 52: ...ld be replaced when the tread reaches a minimum depth of 3 0 mm 2 WARNING Riding with tyres that are excessively worn or incorrectly inﬂated may cause an accident in which you could suffer serious injuries or even be killed Follow all instructions in this owner s manual regarding tyre inﬂation and maintenance Minimum depth 3 0 mm ...

Страница 53: ...ivalents of the same size construction speed rating and load capacity Remember to replace the inner tube whenever you replace a tyre An old inner tube will probably have stretched and could fail if installed in a new tyre 2 WARNING The installation of unsuitable tyres on your motorcycle can affect riding and stability which could result in an accident resulting in serious injuries or even death Al...

Страница 54: ... air cleaner housing Remove the mesh device from the air cleaner element u Check the mesh device for damage and replace it if necessary u Thoroughly wash the air cleaner element in clean non ﬂammable cleaning solvent then wash in a solution of hot water and liquid dish washing soap Apply special air cleaner oil or engine oil to the element and remove the excess oil u Clean the inside of the air cl...

Страница 55: ... cleaner element A ﬁre or explosion could result Soak the element in a special air cleaner or engine oil and drain out the excess NOTICE Do not twist the element to squeeze out the excess oil Failure to follow this precaution can result in a damaged element Installation is in the reverse order of removal ...

Страница 56: ...ide pin located on the fuel tank Lift the seat Installation 1 Align the anchor on the inner front part of the seat with the guide pin located on top of the fuel tank 2 Pressing on the front of the seat slide it forward while at the same time pressing on the rear over the lock 3 Make sure that the seat is ﬁrmly locked in the correct position Guide pin Seat lock Seat anchor Seat continued Seat lock ...

Страница 57: ...e the bolt from the inside of the top front part fuel tank Remove the bolt from the inside of the lower front part frame support Remove the bolt from the top Remove the rear screws of the front covers inside the seat box Remove the front cover Installation Install the parts in the reverse order of removal ...

Страница 58: ...ide the housing 3 Remove the lower centre pivot bolt on the fastening ring 4 Remove the side cover detaching the front and rear tabs Installation 1 Insert the front tab in its slot followed by the rear tab 2 Press the centre safety pivot bolt until it clicks in place 3 Insert the bolt through the inside of the housing Bolt Centre pivot bolt ...

Страница 59: ...ear screws of the front covers inside the seat box Remove the front relay support bolts Remove the rear bolts washers and bearings fastening the seat box onto the ﬁlter box supports Remove the screw on the right lower side cover Take off the front covers and gently lift out the seat box rear fender assy u Disconnect the electrical installation Remove the seat box rear fender assy Connector ...

Страница 60: ...ght position on level surface 4 Remove the oil ﬁller cap dipstick and wipe the oil with a clean cloth 5 Insert the dipstick without screwing it in remove it and check the oil level If the oil level is below or near the lower level line on the dipstick add the recommended engine oil to the upper level line through the oil ﬁller hole 2 P 56 Engine oil MAX MIN Dipstick ﬁller cap ...

Страница 61: ...face when checking the oil level u Do not ﬁll above the upper level mark u Make sure no foreign bodies enter the oil ﬁller opening u Clean up any spills immediately 2 Firmly replace the oil ﬁller cap NOTICE Excessive or insufﬁcient amounts of oil can damage the engine Do not mix different brands or weights of oil They could affect engine lubrication To ﬁnd out the recommended oil and indications f...

Страница 62: ... on a ﬁrm level surface and lower the side stand 3 Remove the bolts and engine skid plate 4 Remove the oil ﬁller cap dipstick 5 Place a drainage container under the drain bolt 6 Remove the drain bolt and sealing washer to drain the oil 7 Remove the left crankcase cover and the cover seal 8 Dispose of the oil and oil ﬁlter at an approved recycling centre 9 Remove the bolt the mounting plate and the...

Страница 63: ...re engine damage 14 Install new O rings in the oil ﬁlter cover grooves 15 Install the oil ﬁlter cover in the left crankcase aligning the centre of the cover with the hole in the oil ﬁlter Make sure that the oil ﬁlter cover seats properly in the crankcase 16 Install the retaining plate and tighten the bolt securely Engine oil Spring Oil ﬁlter O ring Filter cover ...

Страница 64: ...ngine crankcase and fasten it with its corresponding bolts Engine oil 20 Install a new sealing washer on the drain bolt Tighten the drain bolt Torque 22 N m 2 2 kgf m 21 Fill the engine crankcase with the recommended oil 2 P 43 and replace the oil ﬁller cap 22 Check the oil level 2 P 55 23 Start the motorcycle and make sure there are no oil leaks 24 Install the engine cover plate Sieve ﬁlter ...

Страница 65: ...ete and rapid draining u Remove the bolts and crankcase skid plate 2 Support the motorcycle in an upright position on level surface 3 Remove the oil ﬁller cap from the clutch cover 4 Place an oil drain pan under the engine to catch the oil then remove the drain bolt and sealing washer from the left crankcase Drain bolt ...

Страница 66: ...olt to the speciﬁed torque Torque 22 N m 2 2 kgf m 6 Pour speciﬁed transmission oil Speciﬁed transmission oil ELF HTX 740 75W Capacity after draining 0 50 litre 0 53 US qt 0 44 Imp qt after disassembly 0 57 litre 0 60 US qt 0 50 Imp qt Check the O ring is in good condition install the oil ﬁller cap Transmission Oil Filler cap O ring ...

Страница 67: ...rcycle on a ﬁrm level surface 2 Remove the upper radiator mounting bolt 3 Move the upper part of the radiator forward and remove the radiator cap 4 Check that the coolant level reaches the neck of the ﬁller hole If the coolant level drops noticeably it is likely that there is a serious leak Have your dealer inspect the motorcycle Coolant Filling level ...

Страница 68: ...the radiator cap u Fill until the level reaches the neck of the ﬁller hole u Make sure no foreign bodies enter the radiator during the ﬁlling procedure 2 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 cap Changing the coolant Unless you have the proper too...

Страница 69: ...voir is in a horizontal position and that the ﬂuid level is between the MIN and MAX level marks If the brake ﬂuid level in the brake ﬂuid reservoirs is below the MIN level mark or there is too much free play of the brake lever or pedal inspect the brake pads for wear If they are not worn a leak is likely Have your dealer inspect the motorcycle Recommended brake ﬂuid DOT 4 Brakes Front Rear Front b...

Страница 70: ...ickness of 0 5 mm on the front brake and 1 0 mm on the rear brake 1 Front Inspect the brake pads from the top of the brake caliper 2 Rear Inspect the brake pads from the rear right side of the motorcycle If necessary have your dealer replace the brake pads Always replace the left and right brake pads at the same time Front Rear Brakes Brake pads Disc Disc Wear Wear Brake pads ...

Страница 71: ... motorcycle is lifted the stand will no longer touch the ground and will spring back up 1 Check the stand springs for damage or loss of tension 2 Make sure that the stand assembly moves freely If the stand is stiff or squeaks clean the area around the pivot and lubricate the pivot bolt with grease or oil lubricant NOTICE Do not start the motorcycle while supported on the side stand which could be ...

Страница 72: ...d on level ground 2 Turn off the engine Shift the transmission into neutral 3 Check the tension on the lower half of the drive chain halfway between the engine sprocket and the rear wheel sprocket Drive chain slack 25 to 35 mm u Do not ride the motorcycle if the slack is greater than 50 mm 4 Move the motorcycle forward and check that the chain moves smoothly 5 Inspect the engine and rear wheel spr...

Страница 73: ...n 1 Place the motorcycle on its side stand on level ground 2 Turn off the engine Shift the transmission into neutral 3 Remove the protective covers from the axle u Loosen the rear axle nut just enough to move the rear wheel back 4 Turn the eccentric chain adjuster equally on both sides until the correct drive chain tension is obtained Drive chain Eccentric chain adjuster Loosen Stopper Tighten ...

Страница 74: ...ith the eccentric chain adjusters so that it is parallel with the centre line of the frame u Check that the stopper is between the teeth of the eccentric chain adjuster 6 Recheck the drive chain tension and free wheel rotation 7 After adjustment tighten the axle nut to the speciﬁed torque Torque 69 N m 7 0 kgf m 8 Lubricate the drive chain 9 Install the protective covers on the axle Drive chain ...

Страница 75: ...rent positions on the swingarm When it is necessary to set the eccentric chain adjuster to the maximum adjustment point position 15 of the second position of the swingarm in order to tighten the chain this means that the chain is excessively worn and must be replaced Chain REGINA 520 If necessary have your dealer replace the drive chain 1 2 ...

Страница 76: ...heck the drive chain slider for wear or damage u If the wear is 2 0 mm 0 08 in or more replace the slider 2 Check the drive chain tensioner slider for wear or damage u If the wear is 2 0 mm 0 08 in or more replace the slider Wear Wear Chain slider Chain tensioner ...

Страница 77: ... in high speed instability and possible loss of control It is not necessary to remove the wheels to carry out the service recommended in the Maintenance schedule However information about removing the wheel is included for the case of an emergency 2 P 83 1 Inspect the rims and wheel spokes for any damage 2 Tighten any loose spokes 3 Turn the wheel slowly to see if it seems to wobble If it does the...

Страница 78: ... Checking the free play of the clutch lever Check the free play of the clutch lever Free play of the clutch lever 10 to 15 mm Check the clutch cable for kinks or signs of wear If necessary have your dealer replace it Clutch Free play Clutch lever ...

Страница 79: ...d by turning the adjuster To reduce free play turn the adjuster clockwise then tighten the lock nut securely To increase free play turn the adjuster counterclockwise then tighten the lock nut securely NOTICE Do not adjust the free play of the lever to less than 10 mm Clutch lever adjuster Lock nut Free play ...

Страница 80: ...smoothly from a completely closed position to a completely open position in all steering positions and that the throttle free play is correct If the throttle does not move smoothly does not automatically close or if the cable is damaged have your dealer inspect the motorcycle Throttle grip free play 2 to 4 mm Free play ...

Страница 81: ... cable adjuster 2 Loosen the lock nut 3 Turn the adjuster u Turn the adjuster towards A to reduce the free play u Turn the adjuster towards B to increase the free play 4 Tighten the lock nut after adjustment Operate the throttle grip to ensure that it functions smoothly and returns completely in all steering positions Adjuster Lock nut Dust protector ...

Страница 82: ...ain or at full throttle Service if the accumulated deposits can be seen in the transparent section of the breather 1 Remove the breather tube from the crankcase 2 Drain the reservoirs into an appropriate container 3 Install the crankcase breather tube Crankcase breather Crankcase breather ...

Страница 83: ...d to obtain the proper alignment Bear in mind local laws and regulations 1 Remove the three bolts fastening the headlight housing 2 Adjust the alignment by moving the lower support of the headlight housing back and forth 3 Tighten the lower bolt 4 Tighten the two side bolts Headlight Bolt Bolt Bolt ...

Страница 84: ...Locating malfunctions Engine does not start P 80 Warning indicators on P 81 Flat tyres P 82 Electrical problems P 87 ...

Страница 85: ...ns Engine does not start Check the following points Check the correct engine starting sequence 2 P 28 Check that there is petrol in the fuel tank Make sure engine stop button is not pushed Keep the throttle completely closed ...

Страница 86: ...Malfunction indicator lamp MIL If the indicator comes on while riding you may have a serious problem with the PGM FI system Reduce speed and have your motorcycle inspected by your dealer as soon as possible Warning indicators on Malfunction indicator lamp MIL ...

Страница 87: ...ay fail while you are riding If you need to make a temporary repair by patching a tube or using an aerosol sealant ride cautiously at reduced speed and replace the tube before you ride again The tyre must be carefully inspected as described every time the tube is replaced 2 WARNING It can be hazardous to ride the motorcycle with a temporary repair of the tyre or inner tube If the temporary repair ...

Страница 88: ... Loosen the axle pinch bolt 3 Loosen the front axle 4 While ﬁrmly supporting the motorcycle lift the front wheel off the ground using a safety stand or lifting device 5 Remove the front axle and the wheel u Avoid getting grease oil or dirt on the surfaces of the discs or pads u Do not press the brake lever while the front wheel is off the motorcycle Flat tyres Bolt Front axle ...

Страница 89: ...Lower the front wheel to the ground 4 Press the brake lever several times Then press on the fork several times 5 Tighten the axle pinch bolt Torque 21 N m 2 1 kgf m 6 Lift the front wheel off the ground again and check that it turns without difﬁculty once the brake is released 7 Lower the front wheel to the ground again If a torque wrench was not used for installation see your dealer as soon as po...

Страница 90: ...play of the drive chain 4 Remove the rear axle nut 5 Remove the drive chain from the sprocket of the rear wheel by pressing the wheel forward 6 Remove the rear axle and the eccentric chain adjusters 7 Remove the brake caliper support the rear wheel and the side bearings u Support the brake caliper assembly so that the brake hose does not hang down Do not twist the brake hose u Avoid getting grease...

Страница 91: ...er is positioned in the swingarm anchor 3 Adjust the drive chain 2 P 68 4 Insert and tighten the rear axle nut Torque 70 N m 7 0 kgf m 5 After installing the wheel apply the brake pedal several times and then recheck the wheel making sure it can rotate freely Recheck the wheels if the brake drags or if the wheels does not rotate freely If a torque wrench was not used for installation see your deal...

Страница 92: ...own before replacing it Use only the speciﬁed bulbs Check that the bulb works properly before riding the motorcycle See the Speciﬁcations section to ﬁnd out the correct wattage of the bulb 2 P 105 Headlight bulb 1 Remove the 3 bolts 2 Remove the front headlight assembly 3 Disconnect the terminals from the bulb Electrical problems Bolt Bolt Bolt ...

Страница 93: ...bulb without turning it 6 Install a new bulb and the rest of the parts in the reverse order of removal Do not touch the glass surface with your ﬁngers If you touch the bulb with your bare hands clean it with a cloth moistened with alcohol Electrical problems Dust protector Bulb Connector Pin ...

Страница 94: ...d the socket in the reverse order of removal Front rear turn signal bulb 1 Remove the bolt 2 Remove the turn signal lens 3 Remove the amber cover 4 Slightly press the bulb and turn it counterclockwise 5 Install a new bulb and the rest of the parts in the reverse order of removal Electrical problems Bulb Sockets Bolt Bulb Turn signal lens Amber cover ...

Страница 95: ...alfunctions Registration plate light bulb 1 Remove the socket without turning 2 Pull out the bulb without turning 3 Install a new bulb and the socket in the reverse order of removal Electrical problems Bulb Sockets ...

Страница 96: ...rols and other features P 92 Fuels containing alcohol P 93 Catalytic converter P 94 Caring for your motorcycle P 95 Storing your motorcycle P 98 Transporting your motorcycle P 99 You and the Environment P 100 Serial numbers P 101 ...

Страница 97: ...re reset to 0 0 once the reading exceeds 999 9 Document bag The owner s manual as well as registration and insurance information can be kept in the plastic document bag located under the seat 2 P 34 Ignition cut off system An angle sensor bank angle stops the engine and fuel pump after a few seconds in the event that the motorcycle tips over Instruments controls and other features ...

Страница 98: ...rmation Fuels containing alcohol In some countries conventional fuels mixed with alcohol are available This motorcycle is designed only to be used with unleaded petrol with a RON of 91 or higher Fuels containing alcohol ...

Страница 99: ...tive catalytic converter contributes to air pollution and can impair your engine s performance A replacement unit must be an original Montesa part or its equivalent Follow these recommendations to protect your motorcycle s catalytic converter Always use unleaded petrol Petrol containing lead will damage the catalytic converter Keep the engine in good operating condition If you observe that your mo...

Страница 100: ...le thoroughly with a hose to remove loose dirt 2 If necessary use a sponge or soft cloth to remove road dirt u Clean the front headlight lenses panels and other plastic parts carefully to avoid scratching them Avoid applying water directly to the air cleaner the silencer or electrical parts 3 Rinse the motorcycle with plenty of water and dry it with a clean soft cloth 4 After drying the motorcycle...

Страница 101: ...ﬂer can prevent the motorcycle form starting and cause the silencer itself to rust Dry the brakes u Water impairs braking effectiveness After washing intermittently apply the brakes at a slow speed to help dry them Do not aim water under the seat u If water enters the compartment under the seat it could damage documents and other belongings Do not aim water at the air cleaner u If water enters the...

Страница 102: ...arefully with a soft sponge and plenty of water Use diluted soap to remove tough stains and rinse with plenty of water Prevent petrol brake ﬂuid and detergent from contacting instruments panels or the front headlight Aluminium components Exhaust pipe and silencer Do not use abrasive commercial cooktop cleaners to clean the exhaust pipe or silencer Use a neutral detergent to clean the painted surfa...

Страница 103: ...w these instructions Wash your motorcycle and wax all painted surfaces except matte painted surfaces Apply rust preventing oil to all chrome parts Lubricate the drive chain 2 P 45 Place the motorcycle on a maintenance stand and on blocks so that both tyres are off the ground After taking the motorcycle out of storage carry out all maintenance tasks included in the Maintenance schedule Storing your...

Страница 104: ...nsport your motorcycle do so on a motorcycle trailer or in a lorry or on a ﬂatbed trailer with a loading ramp or platform lift and use appropriate fastening straps Never attempt to tow a motorcycle with one or both wheels on the ground NOTICE Towing the motorcycle can seriously damage the transmission ...

Страница 105: ...re s protective ozone layer Recycle waste Put oil and other toxic waste in approved containers and take them to a recycling centre Call your town council or environmental service to ﬁnd out the location of your closest recycling centre and for instructions on how to dispose of waste that cannot be recycled Do not deposit used engine oil in household rubbish or pour it down the drain or on the grou...

Страница 106: ...motorcycle and are required to register it They may also be necessary to order replacement parts The frame number is stamped on the right side of the steering column The engine number is stamped on the right side of the crankcase You should make note of these numbers and keep them in a safe place Engine number Frame number ...

Страница 107: ...Major components P 103 Service Data P 104 Bulbs P 105 Torque speciﬁcations P 105 Speciﬁcations ...

Страница 108: ...weight 87 kg 191 8 lbs Maximum load 1 180 kg 396 8 lbs Maximum luggage capacity compartment 2 5 kg 5 5 lbs Passenger capacity Rider single 1 Including the rider all the luggage and accessories Displacement 259 cm3 Bore and stroke 78 0 x 54 2 mm 3 07 x 2 13 in Compression ratio 10 5 1 Fuel Unleaded petrol Recommended RON 91 or higher Fuel Capacity 4 4 litres 1 16 US gal 0 97 Imp gal Speed ratio 1st...

Страница 109: ...CR6EH 9 NGK Spark plug gap not adjustable 0 80 a 0 90 mm Idle Speed 1800 100 r p m Recommended engine oil Motorcycle oil 4 stroke Repsol 4T SAE 10W30 or equivalent Speciﬁed transmission oil ELF HTX 740 75W Engine oil capacity After draining 0 41 litres 0 86 US gal 0 72 Imp gal After draining and ﬁlter replacement 0 44 litres 0 93 US gal 0 77 Imp gal After disassembly 0 60 litres 1 26 US gal 1 05 I...

Страница 110: ... teeth Bulbs Front headlight 12V 35 35W Brake light rear lamp LED Front turn signals 12V 10W 2 Rear turn signals 12V 10W 2 Position light 12V 5W License light 12V 5W Torque speciﬁcations Engine oil drain bolt 22 N m 2 2 kgf m Transmission oil drain bolt 22 N m 2 2 kgf m Air cleaner cover bolts 10 N m 1 0 kgf m Front wheel axle 69 N m 7 0 kgf m Front wheel axle bolt 21 N m 2 1 kgf m Rear wheel axle...

Страница 111: ...ion oil 60 Engine drowned 28 Engine number 101 Environment 100 Equipment Document bag 34 92 A Accessories 15 Adjusting the headlight 78 B Brakes Brake pads wear 65 Fluid 64 Braking 12 Bulb Headlight 87 Position light 89 Registration plate 90 Turn signal 89 C Caring for your motorcycle 95 Catalytic converter 94 Clutch 73 Clutch system 73 Component removal installation Front right left cover 52 Righ...

Страница 112: ... 26 I Ignition cut off system Angle sensor 92 Indicators High beam 25 Turn signal 25 Instruments 22 L Labels 6 Load guidlines 17 Load limit 17 103 Locating malfunctions 79 Location of the parts 20 M Maintenance Basic 41 Importance 36 Safety 36 Schedule 37 Maximum weight limit 17 103 Modiﬁcations 15 O Oil Engine 55 Transmission 60 P Parking 13 ...

Страница 113: ...Storing your motorcycle 98 Suspensions settings Front 32 Rear 33 Switches Headlight dimmer 26 Turn indicator 26 T Throttle 75 Tips Coolant 45 Engine oil 43 Fuel 30 Transmission oil 60 Total odometer 23 92 Transporting your motorcycle 99 Tripmeter 23 92 Tyres Flat tyres 82 Pressure 46 Replacement 46 82 W Washing your motorcycle 95 Weight limit 17 103 Wheels Removing the front wheels 83 Removing the...

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