Montesa COTA 4RT 260 2020 Owner's Manual
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Montesa COTA 4RT 260 2020 Owner's Manual

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  • Page 2 2020/2021 FOR COMPETITION USE ONLY This motorcycle is designed and manufactured and sold for closed-course competition use only. It does not conform to Federal Motor Vehicle Safety Standards or U.S. EPA Noise and Emission Standards. Operation on public streets, roads, highways, or for off-road recreation is illegal. State and federal laws prohibit operation of this vehicle except in an organized competitive event on a closed course, or by permit issued by the local governmental jurisdiction.
  • Page 3 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 changes at any time without notice and without incurring any obligation. No part of this publication may be reproduced without written permission.
  • Page 4 (1) FRAME NUMBER (1) ENGINE NUMBER Serial numbers The serial number of the engine is stamped on the lower MODEL TYPE FRAME No. ENGINE No. right side of the crankcase. The Vehicle Identification Number (VIN) is stamped on the right side of the steering head. MRT 260 L *VTDNE04C?LE000001* NN4E5209001...
  • Page 5 Labels The following pages show the meanings and locations of the labels on your Cota. Others provide important safety information. Read this information carefully and don’t remove the labels. If a label comes off or becomes hard to read, contact your dealer for a replacement. There is a specific symbol on each label.
  • Page 7 Genuine accessories that have been specifically designed protection, and proper protective gear. and tested for your Cota. Because Montesa cannot test all other accessories, you must be personally responsible Take Time to Get to Know Your Cota.

  • Page 8: Table Of Contents

    Contents Contents Handlebar And Steering Head Bearings .... 3-15 5. Frame servicing Wheels And Tires ......... 3-15 Front Wheel ..........5-1 Front Suspension .......... 3-16 1. Operating instructions Fork ............5-3 Fork ............3-16 Steering stem ..........5-12 Operation component locations ...... 1-1 Rear Suspension ...........
  • Page 9 To The New Owner Importance Of Proper Preparation How To Use This Manual By selecting a MONTESA COTA 4RT as your new Proper pre-competition preparation and regular service The purpose of this Owner’s / Service Manual is to help machine, you have placed yourself in a distinguished...

  • Page 10: Operating Instructions

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

  • Page 11: Fuel

    Operating instructions (1) BREATHER HOSE (1) RADIATOR CAP (1) KICKSTARTER PEDAL (2) FUEL TANK CAP Fuel Coolant Basic Operation Starting The Engine Gasoline: The engine of COTA is a water-cooled type. In order to Unleaded gasoline (commercially available unleaded; provide adequate cooling, it is essential that the radiator WARNING pump octane number 91 or higher) be filled with coolant up the proper level (See pag.
  • Page 12 Operating instructions (1) ENGINE STOP BUTTON (1) SIDE STAND (2) SIDE STAND SPRINGS When you shift the transmission into gear, apply front Break-In Procedure Side Stand brake to prevent the motorcycle from moving forward. New Motorcycle The side stand is used to support your Cota while parked. Stopping The Engine Following proper break-in procedure helps ensure that To operate, use your foot to lower the side stand until it...

  • Page 13: Shifting Gears

    Operating instructions Braking NOTICE To slow or stop, apply the front brake lever and rear brake Improper shifting may damage the engine, transmission, pedal smoothly, while downshifting to match your speed. and drive train. Gradually increase braking as you feel the brakes slowing your speed.

  • Page 14: Controls

    Operating instructions (1) UPPER LEVEL LINE (1) ADJUSTER (1) CLUTCH LEVER (2) LOCK NUT (2) FREE PLAY Controls Clutch Lever Clutch Lever Free Play Standard cluth lever free play should be between The clutch lever free play can be adjusted by turning the 0.5 –...
  • Page 15 Operating instructions (1) DUST COVER (A) DECREASE (1) ADJUSTER (1) FRONT BRAKE LEVER (2) LOCK NUT (B) INCREASE (2) LOCK NUT (2) FREE PLAY (3) ADJUSTER Throttle Grip Front brake lever Front brake lever free play Standard front brake lever free play should be Throttle Grip Free Play The front brake lever free play can be adjusted by turning between 0.5 –...
  • Page 16 Operating instructions (1) LOCK NUT (1) ENGINE STOP BUTTON (1) MODE SWITCH (2) ROD (2) MODE 1 (3) ADJUSTING BOLT (3) MODE 2 (4) FREE PLAY Emergency engine stop Mode switch Brake pedal height To stop the engine in an emergency, push and hold the The ECU for the Cota 4RT260 PGM-FI electronic injec- engine stop button.
  • Page 17 Operating instructions (1) HANDLEBAR Handlebar position, width and shape Position the handlebar so 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 better your particular shoulder width and riding preferen- ce.

  • Page 18: Specifications

    2. Service data Specifications Item Specification Item Specification Dimensions Fuel System Overall length 2,020 mm Type PGM-FI Overall width 840 mm Identification number GQPEB Overall height 1,135 mm Throttle bore 29.4 mm Wheelbase 1,320 mm Drive Train Seat height 677 mm Clutch operating system Hydraulic operated Ground clearance...
  • Page 19 Service data Service data Unit: mm (in) Item Specification Item Standard Service limit Lubrication Cylinder Head/Valves Repsol 4T oil-stroke motorcycle oil Cylinder compression 1,300 kPa (13.2 kgf/cm – Specified engine oil SAE 10W-30 or equivalent Cylinder head warpage – 0.05 (0.002) Engine oil capacity 0.12 ±...
  • Page 20 Service data Unit: mm (in) Unit: mm (in) Item Standard Service limit Item Standard Service limit Cylinder/Piston Crankshaft/Transmission Crankshaft runout Right – 0.03 (0.001) Cylinder 78.000 – 78.015 (3.0709 - 3.0715) 78.04 (3.0724) Taper – 0.05 (0.002) Left – 0.05 (0.002) Out-of- round –...
  • Page 21 Service data Unit: mm (in) Unit: mm (in) Item Standard Service Limit Item Standard Service Limit Wheels/Tires Brakes Axle runout 0.20 (0.008) Recommended brake fluid DOT 4 brake fluid – Tire air pressure Front Brake disc thickness 3.5 (0.14) 3.0 (0.12) Front 5.6 - 6.3 psi (39 –...

  • Page 22: Torque Values

    Service data Torque Values Engine Standard Torque Thread Torque Item Item Q’ty Remarks N•m (kgf•m / Ibf•ft) Dia. (mm) N•m (kgf•m / lbf•ft) Transmission oil drain bolt 22 (2.2 / 16) Note 1 5 mm bolt and nut 5 (0.52 / 3.5) Engine oil drain bolt 22 (2.2 / 16) Note 1...
  • Page 23 Service data Frame Frame Thread Torque Thread Torque Item Q’ty Remarks Item Q’ty Remarks Dia. (mm) N•m (kgf•m / Ibf•ft) Dia. (mm) N•m (kgf•m / Ibf•ft) Handlebar holder bolt 22 (2.2 / 16) Note 1 Brake pedal pivot bolt 29 (3.0 / 22) Note 2 Steering head top thread 5 (0.5 / 3.6)

  • Page 24: Tools

    Service data Tools Tools Special Common Description Tool number Applicability Description Tool number Applicability Spoke nipple wrench 07701–0020300 Front spoke nipple Bearing remover, 12 mm 07936–166010A Water pump bearing Gear holder, 2.5 07724–001A100 Primary drive gear bolt Remover handle 07936–3710100 Bearing remover head, 20 mm 07746–0050600 Wheel bearing...

  • Page 25: Lubrication & Seal Points

    Service data Lubrication & Seal Points Engine Item Material Remarks Item Material Remarks Crankcase sealing bolt threads and seating surface Repsol 4T-stroke engine oil Connecting rod small end I.D. Molybdenum oil solution (A 50/50 mixture of Cylinder bore inner surface Connecting rod big end molybdenum disulfide Cylinder head nut threads and seating surface...
  • Page 26 Service data Cam chain tensioner bolt Left crankcase drain hole #225 Item Material Remarks Clutch slave cylinder piston/O-ring Silicone grease Application zone Application zone Left crankcase cover cap threads Lithium based multipurpose 6.5±1 mm 3 - 4 mm 2.5±1 mm 1.2±0.4 mm grease Each oil seal lips...
  • Page 27 Service data Frame Item Material Remarks Item Material Remarks Multi-purpose grease Locking agent Steering head bearing race and bearings Drive chain adjuster stopper screws threads Steering head dust seal lips Side stand bracket bolt threads Swingarm pivot needle bearing Drive chain slider mounting screw threads Swingarm pivot dust seal lips Rear brake hose clamp screw threads Shock link/shock arm needle bearings...

  • Page 28: Cable & Harness Routing

    Service data Cable & Harness Routing 15 mm 45º (1) FRONT BRAKE HOSE (2) THROTTLE CABLE (3) CLUTCH HOSE (4) ENGINE STOP BUBTTON CONNECTOR (5) MODE SWITCH 2-11 2-11...
  • Page 29 Service data UPPER 20-30º (1) MAIN WIRE HARNESS (7) FAN MOTOR WIRE (2) FUEL PUMP WIRE (8) FUEL CAP BREATHER HOSE (3) CYLINDER HEAD BREATHER HOSE (9) SPARK PLUG WIRE (4) AIR FILTER BOX BREATHER HOSE (10) WIRE HARNESS (TO IGNITION COIL) (5) STORAGE TANK (11) ECT SENSOR (6) ENGINE STOP SWITCH WIRE...
  • Page 30 Service data Clamp at white tape (1) WIRE HARNESS (5) UPPER RADIATOR HOSE (2) THROTTLE CABLE (6) SPARK PLUG WIRE (3) CLUTCH HOSE (7) FAN MOTOR WIRE (4) CONNECTORS BOOT (8) FILTER BOX BREATHER HOSE – FAN MOTOR 2P CONNECTOR (9) CYLINDER HEAD BREATHER HOSE –...
  • Page 31 Service data UPPER UPPER 45º (1) THROTTLE CABLE (2) CLUTCH HOSE (3) FUEL TANK BREATHER HOSE 2-14 2-14...
  • Page 32 Service data UPPER UPPER UPPER (1) MAIN WIRE HARNESS (6) REGULATOR/RECTIFIER 5P (BLACK) CONNECTOR (2) TRANSMISSION BREATHER HOSE (7) BANK ANGLE SENSOR (3) FILTER BOX BREATHER HOSE (8) FAN MOTOR RELAY (4) ALTERNATOR WIRE (9) REAR BRAKE RESERVOIR TANK (5) CONDENSER 2P (BLACK) CONNECTOR 2-15 2-15...
  • Page 33 Service data Clamp at white tape (1) MAIN WIRE HARNESS (TO CONNECTOR COVER) (8) REGULATOR/RECTIFIER 5P (BLACK) CONNECTOR (2) MAIN WIRE HARNESS (TO RELAY) (9) CONDENSOR (10) CONDENSOR 2P (BLACK) CONNECTOR (3) MAIN WIRE HARNESS (TO ECU) (4) CRANKCASE BREATHER JOINT HOSE (11) BANK ANGLE SENSOR (5) TRANSMISSION BREAHTER HOSE (12) FAN MOTOR RELAY...
  • Page 34 Service data (1) REAR BRAKE HOSE (2) REAR BRAKE RESERVOIR HOSE 2-17 2-17...
  • Page 35 Service data (1) FUEL FEED HOSE (2) TRANSMISSION BREATHER HOSE 2-18 2-18...

  • Page 36: Service And Maintenance

    3. Service and maintenance Pre-ride Inspection Maintenance schedule For your safety, it is very important to take a few Perform pre-ride Inspection at each scheduled maintenance period. moments before each ride to walk around your COTA 4RT I: Inspect and clean, Adjust, Lubricate or Replacement if necessary. C: Clean, R: Replace, L: Lubricate. and check its condition.

  • Page 37: Warming-Up Inspection

    Service and maintenance Warming-up Inspection Replacement Parts When warming-up the engine, check for the following: Parts Requiring Periodic Replacement  Do not rev the engine more than necessary or engine damage may result. Item Replacement Interval Cause  Check for fuel, oil, and water leaks ...

  • Page 38: Fuel Line

    Service and maintenance (1) FUEL FEED HOSE (1) BOLTS (1) FLAME TRAP (2) AIR CLEANER HOUSING COVER (2) AIR CLEANER ELEMENT Fuel Line Remove the flame trap from the air cleaner element. Check the frame trap for damage, replace if necessary. Remove the rear fender.

  • Page 39: Spark Plug

    Service and maintenance (1) SPARK PLUG CAP / SPARK PLUG (1) INSULATOR (1) BOLTS (2) TAPPET ADJUSTING HOLE COVER Spark Plug Using a spark plug with the wrong heat range can damage the engine or cause the plug to foul. Be careful to select the correct spark plug for the conditions.
  • Page 40 Service and maintenance (1) “T” MARK (1) FEELER GAUGE (1) O-RING (2) INDEX MARK (2) VALVE ADJUSTING HOLE COVER (3) “UP” MARK (4) BOLTS Operate the kickstarter pedal and align the “T” mark on Insert a feeler gauge between the rocker arm and the flywheel with the index mark on the left crankcase valve stem and measure the intake and exhaust valve cover.

  • Page 41: Engine Oil/Oil Filter

    Service and maintenance (1) OIL FILLER CAP/DIPSTICK (1) OIL FILLER CAP/DIPSTICK (1) BOLT (2) UPPER LEVEL LINE (2) DRAIN BOLT/SEALING WASHER (2) RETAINING PLATE (3) LOWER LEVEL LINE Engine Oil/Oil Filter Oil Change Change the engine oil with the engine warm. Oil Level Inspection Support the motorcycle with it side stand.
  • Page 42 Service and maintenance (1) SPRING (1) NEW O-RINGS (1) OIL STRAINER SCREEN (2) OIL FILTER (2) OIL FILTER COVER (3) APPLY GREASE Oil Strainer Screen Cleaning Remove the oil strainer screen from the left crankcase groove. Clean the strainer. Reinstall the oil strainer screen. Note the direction of the screen.

  • Page 43: Engine Idle Speed

    Service and maintenance (1) IDLE SPEED ADJUSTMENT SCREW (1) DRAIN BOLT (1) FILLER CAP (2) O-RING Engine Idle Speed Transmission Oil 5. Pour specified transmission oil. Specified transmission oil: ELF HTX 740 Oil Change Inspect and adjust the idle speed after all other engine adjustments are within specification.

  • Page 44: Coolant

    Service and maintenance (1) OVERFLOW HOSE (1) INSPECTION HOLE (1) BOLT (2) RADIATOR (2) COOLANT DRAIN BOLT/SEALING WASHER (2) RADIATOR CAP Coolant 6. Check the water pump inspection hole bottom of the 2.Remove the radiator upper mounting bolt and move water pump for leakage.

  • Page 45: Clutch System

    Service and maintenance (1) FILLER NECK (1) CLUTCH FLUID RESERVOIR (1) EXHAUST PIPE (2) LOWER LEVEL LINE (2) MUFFLER Clutch System Exhaust Pipe And Muffler 4. Fill the radiator with coolant up to the filler neck. 5. Squeeze the radiator hoses alternately. If the coolant level drops, fill the coolant again.

  • Page 46: Drive Chain

    Service and maintenance (1) DRIVE CHAIN SLACK (1) AXLE NUT (1) DRIVE CHAIN SLIDER (2) ADJUSTER (2) DRIVE CHAIN TENSIONER SLIDER Drive Chain Drive Chain Slider Drive Chain Slack Adjustment Loosen the rear axle nut just enough to move the rear Drive Chain Slack Inspection Inspection/Replacement wheel in fore-aft direction.

  • Page 47: Drive/Driven Sprockets

    Service and maintenance (1) BOLT (1) DRIVE SPROCKET (1) BOLTS/NUT (2) SPRING WASHER (2) SPRING WASHER (2) DRIVEN SPROCKET (3) DRIVE SPROCKET (3) BOLT Drive/Driven Sprockets Install the drive sprocket onto the countershaft as shown. Driven Sprocket Replacement Install the spring washer and bolt, then tighten the bolt to the specified torque.

  • Page 48: Brake Fluid

    Service and maintenance (1) “MIN” LEVEL (1) BRAKE HOSE (1) COVER (2) “MIN” LEVEL Brake Fluid Check that the brake hose does not bind or kink in any Rear Master Cylinder steering position and is not pulled when the suspension is extended.

  • Page 49: Brake Pad Wear

    Service and maintenance (1) BRAKE PAD (1) BRAKE DISC (1) BRAKE DISC (2) DISC BOLT (3) COLLAR Brake Pad Wear Brake System The front brake is floating type disc. Replace the disc and disc bolts if the play in the rotating direction exceeds 2.0 mm (0.08 in), as measured at its Measure the brake pad thickness.

  • Page 50: Handlebar And Steering Head Bearings

    Service and maintenance (1) HOLDER BOLTS (1) STEERING HEAD BEARINGS (1) SPOKE NIPPLE (2) UPPER HOLDER (2) RIM LOCK Wheels And Tires Handlebar And Steering Head Bearings Steering Head Bearings Proper air pressure will provided maximum stability and Support the motorcycle using the maintenance stand with Handlebar tire life.

  • Page 51: Front Suspension

    Service and maintenance (1) PRE-LOAD ADJUSTER (1) REBOUND ADJUSTER Front Suspension Fork Use specified fork fluid which additives to assure maximum performance of your Cota’s front suspension. Inspection The motorcycle is shipped with a light coating of grease Specified fork fluid: on the forks.

  • Page 52: Rear Suspension

    Service and maintenance (1) PRE-LOAD ADJUSTER (1) REBOUND ADJUSTER  When your Cota is new, your suspension will break-in Rear Suspension Inspection as you ride.  After break-in is completed, test ride your Cota with 1. Check for a broken or collapsed spring. The Pro-Link swingarm is controlled by a shock absorber.

  • Page 53: Cleaning

    Service and maintenance Cleaning Storage Removal from Storage 1. Uncover and clean your COTA. Clean your COTA regularly to protect the surface finishes Extended storage, such as for winter, requires that you Change the engine and transmission oil if more than 4 and inspect for damage, wear, or oil leaks.

  • Page 54: Oil Pressure Relief Valve

    4. Engine servicing (1) SNAP RING (1) RELIEF VALVE (1) DRIVEN GEAR (2) PRESSURE RELIEF VALVE (2) O-RING (2) DRIVE PIN Oil Pressure Relief Valve Oil Pump Removal/Inspection Disassembly Drain the engine oil. Remove the engine from the frame. Remove the left crankcase cover (page 4-49). Separate the crankcase halves (page 4-54).
  • Page 55 Engine servicing (1) ONE-WAY REED VALVE (1) DRIVEN GEAR (1) SNAP RING (2) GASKET (2) OIL PUMP SHAFT (2) OIL SEAL (3) DOWEL PINS (1) OUTER ROTOR (1) ONE-WAY REED VALVE (2) INNER ROTOR (3) OIL PUMP SHAFT Inspection Check the oil pump shaft oil seal in the left crankcase for Remove the one-way reed valve, gasket and dowel pins.
  • Page 56 Engine servicing (1) OIL PUMP SHAFT (1) DRIVE PIN (2) INNER ROTOR (3) FLAT SURFACES (2) DRIVEN SPROCKET (4) OUTER ROTOR Assembly Apply clean engine oil to the oil pump rotors and shaft. Install the oil pump shaft into the right crankcase. Install the inner rotor aligning the flat surface between the rotor and pump shaft.

  • Page 57: Fuel Feed Hose

    Engine servicing (1) PAWL (1) 5P CONNECTOR (1) QUICK CONNECTOR PROTECTOR (2) QUICK CONNECTOR Fuel Feed Hose Disassembly / Installation The pawl of the connector must be changed every time the fuel feed hose is disconnected. Disassembly of fuel pump side Turn off the engine.

  • Page 58: Fuel Line Inspection

    Engine servicing (1) BANJO BOLT (1) BANJO BOLT, 12 MM (1) FUEL PRESSURE GAUGE (2) SEALING WASHER (2) SEALING WASHER, 12 MM (3) SEALING WASHER (4) FUEL PRESSUE GAUGE Fuel Line Inspection Start the engine. Remove the fuel feed hose banjo bolt and attach the fuel Read the fule pressure at idle.

  • Page 59: Connect The Fuel Pump 2P Connector

    Engine servicing (1) FUEL RETURN HOSE (1) BANJO BOLT (1) 2P CONNECTOR (2) SEALING WASHER Fuel Pump Flow Inspection After inspection, install the banjo bolt into the fuel feed Connect the fuel pump 2P connector. hose using new sealing washers. Start the engine and check for fuel leaks.

  • Page 60: Fuel Tank/Fuel Pump

    Engine servicing (1) 2P CONNECTOR (1) BREATHER HOSE (1) 2P CONNECTOR (2) SOCKET BOLTS (2) BOLT (3) FUEL TANK Fuel Tank/Fuel Pump Pull up the fuel tank and disconnect the fuel pump 2P Disconnect the fuel tank breather hose. connector. Remove the fuel tank mounting bolt.
  • Page 61 Engine servicing (1) QUICK CONNECTOR (1) FUEL PUMP (1) FUEL PUMP (2) FUEL FEED HOSE (2) BOLTS (3) 5P CONNECTOR Installation NOTICE Always replace the packing with a new one when the fuel pump is removed. Clean any oil off from the mating surface of the fuel pump base and fuel tank.
  • Page 62 Engine servicing (1) O-RING (NEW) (1) FUEL TANK (1) SOCKET BOLTS (2) FUEL FEED HOSE (2) BOLT (2) 2P (BLACK) CONNECTOR (3) QUICK CONNECTOR (3) BREATHER HOSE Install the fuel tank into the frame being careful not to Install and tighten the injector holder socket bolts to the pinch the throttle cable.
  • Page 63 Engine servicing (1) 5P CONNECTOR (1) BOLTS (1) PAWL (2) FUEL PUMP BASE (2) PUMP BODY (3) PUMP (1) CABLE TERMINALS (1) QUICK CONNECTOR (1) FUEL PUMP ASSEMBLY (2) MOTOR/FILTER Remove the fule tank. Disassembly Cleaning the fuel filter Remove the bolts from the fuel pump base and remove Disconnect the 5P connector from the fuel pump Press the three pawls between the pump body and the the fuel pump assembly, taking care not to damge the...
  • Page 64 Engine servicing (1) FILTER SURFACE (1) O-RINGS (4) MOTOR/FILTER (1) PUMP (3) PAWLS (2) PUMP (5) PUMP BODY (2) PUMP BODY (4) CONNECTING PIPE (3) MOTOR WIRES Clean the surface of the filter. Replace the o-rings with new ones every time the fuel pump is disassembled.
  • Page 65 Engine servicing (1) FUEL PUMP BASE (1) FUEL TANK (1) QUICK CONNECTOR (2) BOLTS (2) CLIP (3) BREATHER HOSE Mount the fuel tank on the chassis. Connect the breather hose to the fuel tank and secure it with the clip. Insert the mounting bolts in the pump.

  • Page 66: Injector

    Engine servicing (1) FUEL INJECTOR (1) FUEL INJECTOR (1) BOLTS/NUTS (2) O-RING (2) AIR CLEANER HOUSING Injector Throttle Body Removal/Installation Do not remove the fuel injector from the injector holder. Inspection Removal Replace the fuel injetor and holder as an assembly. Remove the rear fender.
  • Page 67 Engine servicing (1) 32P (BLACK) CONNECTOR (1) LOCK NUT (2) THROTTLE CABLE (1) THROTTLE CABLE END (2) THROTTLE DRUM (2) BAND SCREW (3) THROTTLE CABLE END (4) THROTTLE DRUM (3) THROTTLE CABLE (4) LOCK NUT (3) THROTTLE BODY (1) SCREWS (1) SCREW (1) THROTTLE DRUM COVER (2) THROTTLE DRUM COVER...

  • Page 68: Water Seal And Bearing Replacement

    Engine servicing (1) THROTTLE BODY (1) AIR CLEANER HOUSING (1) BOLTS (2) BAND SCREW (2) BOLTS/NUTS (2) WATER PUMP COVER (3) 32P (BLACK) CONNECTOR Install the air cleaner housing onto the frame and connect Install the throttle body together with insulator at cylinder the crankcase breather hose.
  • Page 69 Engine servicing (1) BEARING REMOVER, 12 MM (1) MECHANICAL SEAL INSTALLER (1) WASHER (2) WATER PUMP SHAFT (3) NEW COPPER WASHER (4) IMPELLER Remove the water pump bearing from the right crankcase cover using the special tools. Install the water pump shaft, new copper washer and impeller into the right crankcase cover.

  • Page 70: Radiator Removal/Installation

    Engine servicing (1) DOWEL PINS (1) 2P (NATURAL) CONNECTOR (1) GROUND EYELET (2) BOLTS (2) NEW O-RING (3) IGNITION COIL (4) WIRE CLAMP (3) WATER PUMP COVER (1) WATER PUMP COVER (1) TIE WRAP (1) 3P (GRAY) CONNECTOR (2) BOLTS Radiator Removal/Installation Install the following: Remove the ground eyelet bolt.

  • Page 71: Engine Removal/Installation

    Engine servicing (1) RADIATOR HOSES (1) IGNITION COIL (1) RADIATOR (2) HANGER BOLT (2) BOLTS (2) EXHAUST PIPE (3) DOWN TUBE BOLTS (3) GROUND EYELET (3) MUFFLER (4) DOWN TUBE (4) WIRE CLAMP (4) SKID PLATE (5) RADIATOR MOUNTING BOLT (6) RADIATOR Engine Removal/Installation Disconnect the radiator hoses at the right crankcase cover...
  • Page 72 Engine servicing Engine Removal/Installation Illustration 24 N•m (2.4 kgf•m) (17.8 lbf•ft) 24 N•m 25 N•m (2.4 kgf•m) (2.5 kgf•m) (17.8 lbf•ft) (18.4 lbf•ft) 25 N•m (2.5 kgf•m) (18.4 lbf•ft) 69 N•m 39 N•m (6.9 kgf•m) (4.0 kgf•m) (50.9 lbf•ft) (28.7 lbf•ft) 50 N•m (5.1 kgf•m) (36.8 lbf•ft)

  • Page 73: Cylinder Compression

    Engine servicing (1) CYLINDER COMPRESSION GAUGE (1) SEALING BOLT/WASHER (1) TIMING HOLE CAP (2) STOPPER TOOL Cylinder Compression Warm up the engine to normal operating temperature. Stop the engine and remove the spark plug. Install a compression gauge. Shift the transmission into neutral. Open the throttle all the way and crank the engine with the kickstarter until the gauge reading stops rising.
  • Page 74 Engine servicing (1) BOLTS (1) BOLTS/SEALING WASHERS (2) SH BOLTS (1) CAM CHAIN (2) TAPPET ADJUSTING HOLE COVER (3) SEALING WASHERS (4) CYLINDER HEAD COVER (2) CAMSHAFT Remove the bolts and tappet adjusting hole covers. Remove the cam chain from the cam sprocket and suspend the cam chain with a piece of wire to prevent it Make sure the piston at TDC (Top Dead Center) on the from falling into the crankcase.
  • Page 75 Engine servicing (1) INTAKE ROCKER ARM SHAFT (1) BEARINGS (1) ROCKER ARM (2) EXHAUST ROCKER ARM SHAFT (2) CAMSHAFT (2) ROCKER ARM SHAFT (3) INTAKE ROCKER ARM (4) EXHAUST ROCKER ARM Check the rocker arms and shafts for wear or damage. Measure the rocker arm I.D.

  • Page 76: Cylinder Head Removal

    Engine servicing (1) RADIATOR HOSE (1) BOLTS (1) GASKET (2) HANGER BOLTS (2) NUTS/WASHERS (2) DOWEL PINS (3) CYLINDER HEAD Cylinder Head Removal Remove the cylinder head mounting bolts. Loosen the cylinder head mounting nuts in a crisscross pattern in two or three steps. Remove the following: Remove the nuts, washers and cylinder head.
  • Page 77 Engine servicing (1) BOLTS (1) CAM CHAIN TENSIONER (1) WASHER (2) PIVOT COLLAR (2) CAM CHAIN GUIDE PLATE (2) CAM CHAIN GUIDE (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.

  • Page 78: Cylinder Head Disassembly

    Engine servicing (1) CAM CHAIN GUIDE (1) VALVE SPRING COMPRESSOR (1) RETAINER (2) ALIGN (2) ATTACHMENT (2) OUTER SPRING (3) COTTERS (3) INNER SPRING (4) SPRING SEAT Cylinder Head Disassembly (5) VALVE (6) STEM SEAL Remove the cylinder head (page 4-23). (7) COTTERS Remove the valve spring cotters using the special tools.

  • Page 79: Cylinder Head Inspection

    Engine servicing (1) COMBUSTION CHAMBER (1) OUTER VALVE SPRING (1) VALVE (2) INNER VALVE SPRING Cylinder Head Inspection Valve spring Valve/Valve Guide Check the valve springs for fatigue or damage. Inspect each valve for out-of-round, burns, scratches or Cylinder Head Measure the free length of the intake and exhaust valve abnormal stem wear.

  • Page 80: Valve Guide Replacement

    Engine servicing (1) VALVE GUIDE REAMER (1) VALVE GUIDE DRIVER Valve Guide Replacement Ream the valve guide to remove any carbon build-up Measure and record the valve guide I.D. using a ball gauge before measuring the guide. or inside micrometer. Insert the reamer from the combustion chamber side of Mark new valve guides at the proper depth (see Service limit:...

  • Page 81: Valve Seat Inspection/Refacing

    Engine servicing (1) VALVE GUIDE DRIVER (1) VALVE SEAT WIDTH Valve Seat Inspection/Refacing Remove the guide from the freezer. Check that the valve guides are at the proper depth using While the cylinder head is still heated, drive new valve a slide caliper, adjust the height if necessary.
  • Page 82 Engine servicing 45º 32º 60º 32º (1) ROUGHNESS  Contact area (too high or too low) Valve Seat Refacing – Reface the valve seat. Valve seat cutters, grinders, or equivalent valve seat The valves cannot be ground, If a valve face is burned refacing equipment are recommended to correct worn or badly worn or if it contacts the seat unevenly, replace valve seat.
  • Page 83 Engine servicing 32º 45º 60º (1) SEAT WIDTH Use a 45˚ cutter, remove any roughness or irregularities Use a 32˚ flat cutter, remove 1/4 of the existing valve Use a interior cutter, remove 1/4 of the existing valve from the seat. seat material.

  • Page 84: Cylinder Head Assembly

    Engine servicing 45º (1) SPRING SEAT (2) STEM SEAL (3) VALVE (4) INNER SPRING Using a 45˚ seat cutter, cut the seat to proper width. Install the valve springs with the tightly wound coils (5) OUTER SPRING Make sure all pitting and irregularities are removed. facing the combustion chamber.

  • Page 85: Cylinder/Piston

    Engine servicing (1) VALVE SPRING COMPRESSOR (1) PLASTIC HAMMERS (1) BOLTS (2) ATTACHMENT (2) CAM CHAIN TENSIONER LIFTER (3) COTTERS (3) GASKET Cylinder/Piston Compress the valve springs with the special tools and Tap the valve stems gently with two plastic hammers as install the cotters.
  • Page 86 Engine servicing (1) SEALING BOLT/SEALING WASHER (1) PISTON PIN CLIP (2) CYLINDER (2) PISTON PIN Piston Removal Spread the piston rings and remove them by lifting up at a point just opposite the gap. Place a clean shop towel over the crankcase to prevent Piston rings are easily broken;...
  • Page 87 Engine servicing Inspection Piston/Piston Ring Temporarily install the piston rings to their proper position Remove the carbon deposits from the piston head or with the mark facing up. piston ring grooves using old piston rings. Measure the piston ring-to-ring groove clearance with the Cylinder Inspect the piston for damage and the ring grooves for rings pushed into the grooves.
  • Page 88 Engine servicing Measure the O.D. of the piston at 5 mm (0.2 in) from Insert each piston ring into the cylinder and measure the Connecting Rod bottom of skirt and 90 degrees to the piston pin hole. ring end gap. Measure the connecting rod small end I.D.
  • Page 89 Engine servicing (1) TENSIONER LIFTER (1) TOP RING (1) INDENTS (2) SECOND RING (2) PISTON PIN (3) OIL RINGS (3) NEW PISTON PIN CLIP (4) SPACER Tensioner lifter (5) INDENTS Piston Installation Check the tensioner lifter operation as follows: – The tensioner shaft should not go into the body when Piston Ring Installation it is pushed.

  • Page 90: Cylinder Head Installation

    Engine servicing (1) DOWEL PINS (1) CYLINDER (1) DOWEL PINS (2) NEW GASKET (2) NEW SEALING BOLT/SEALING WASHER (2) NEW GASKET Apply locking agent to the cylinder mounting sealing bolt threads. Install the cylinder mounting sealing bolt with a new sealing washer but do not tighten it yet.

  • Page 91: Camshaft/Cylinder Head Cover Installation

    Engine servicing (1) CYLINDER HEAD BOLTS (1) HANGER BOLT (1) “T” MARK (2) CYLINDER SEALING BOLT (2) RADIATOR HOSE (2) INDEX MARK Camshaft/Cylinder Head Cover Installation Tighten the cylinder sealing bolt and cylinder head Install the upper engine hanger bolt, tighten the bolt to mounting bolts securely.
  • Page 92 Engine servicing (1) BEARINGS (1) NEW O-RINGS (1) APPLY SEALANT (2) GROOVE (2) INTAKE ROCKER ARM SHAFT (2) BEARING RETAINER (3) INTAKE ROCKER ARM (4) EXHAUST ROCKER ARM (5) EXHAUST ROCKER ARM SHAFT Cylinder Head Cover Assembly Apply molybdenum oil solution to the rocker arm I.D. and rocker arm shaft sliding surface.

  • Page 93: Right Crankcase Cover

    Engine servicing (1) CYLINDER HEAD COVER (1) TAPPET ADJUSTING HOLE CAP (2) O-RING (1) RADIATOR HOSE (2) NEW SEALING WASHERS/6 MM BOLTS (2) KICKSTARTER PEDAL (3) NEW SEALING WASHERS (3) BOLTS (4) SH BOLTS (4) CLUTCH COVER (5) RIGHT CRANKCASE COVER Install the cylinder head cover.

  • Page 94: Clutch Slave Cylinder

    Engine servicing (1) DOWEL PINS (1) RIGHT CRANKCASE COVER (1) OIL BOLTS (2) NEW GASKET (2) CLUTCH COVER (2) SEALING WASHERS (3) WATER PUMP COVER (4) BOLTS Installation (5) RADIATOR HOSE (6) KICKSTARTER PEDAL Install two dowel pins and new gasket onto the crankcase. Install the right crankcase cover while turning the water pump impeller.
  • Page 95 Engine servicing (1) SLAVE CYLINDER PISTON (1) O-RING (1) SEALING WASHERS (2) SPRING (2) DOWEL PINS (2) OIL BOLTS (3) O-RING (BLACK) (3) CLUTCH COVER (4) O-RING (GREEN) Install the clutch hose eyelet with new sealing washers. Install and tighten the oil bolt.. Apply small squirts of air pressure to the fluid inlet to remove the piston.

  • Page 96: Clutch

    Engine servicing (1) CLUTCH LIFTER PIECE ASSEMBLY (1) CLUTCH CENTER HOLDER (1) CLUTCH CENTER (2) CLUTCH DISCS (2) LIFTER PLATE BOLTS (3) CLUTCH PLATE (4) PRESSURE PLATE (3) LIFTER PLATE (5) PAPER DISCS (4) CLUTCH SPRINGS Clutch Removal Pull the clutch lever and hold it with a suitable clamp. Remove the bolts and clutch cover without disconnecting the clutch fluid line.
  • Page 97 Engine servicing (1) CLUTCH CENTER (1) LIFTER PIECE ASSEMBLY (1) OUTER GUIDE (2) CLUTCH OUTER (2) NEEDLE BEARING (3) OUTER GUIDE (4) NEEDLE BEARING Inspection Check the following items (page 2-2).  Clutch outer for wear, cracks or indentation by the clutch discs.
  • Page 98 Engine servicing (1) PRESSURE PLATE (1) THRUST WASHER (1) CLUTCH SPRINGS (2) CLUTCH CENTER (2) LOCK WASHER (“OUTSIDE” MARK IN FRONT) (2) LIFTER PLATE (3) DOT MARKS (3) BOLTS (4) LIFTER PIECE ASSEMBLY Install the clutch springs, lifter plate and spring bolts. Tighten the spring bolts in a crisscross pattern in several steps, then tighten them to the specified torque.

  • Page 99: Kickstarter

    Engine servicing (1) IDLE GEAR/THRUST WASHER (1) RATCHET SPRING (2) STARTER RATCHET (1) RETURN SPRING (2) BOLT (3) PINION GEAR (4) SPINDLE (2) COLLAR (3) STOPPER PLATE (5) RETURN SPRING (6) COLLAR (3) WASHER (4) KICKSTARTER ASSEMBLY Install the return spring with its end into the spindle hole. Kickstarter Install the collar aligning its groove with the return spring end, then install the washer.

  • Page 100: Gearshift Linkage

    Engine servicing (1) KICKSTARTER ASSEMBLY (1) STOPPER PLATE (1) GEARSHIFT SPINDLE (2) SPRING HOOK (2) BOLT (2) BOLTS (3) GUIDE PLATE Gearshift Linkage Install the kickstarter assembly and hook the starter ratchet with the stopper. Install the return spring end into the crankcase hole as Removal shown.
  • Page 101 Engine servicing (1) DRUM SHIFTER (1) RETURN SPRING (1) SHIFT DRUM CENTER (2) SPRING (2) WASHER (2) CENTER PIN (3) PLUNGER (3) STOPPER ARM (4) RATCHET PAWL A (4) DRUM CENTER (5) RATCHET PAWL B (5) DOWEL PIN (6) GUIDE PLATE (6) CUT-OUT Inspection Install the return spring, plain washer and stopper arm...

  • Page 102: Left Crankcase Cover

    Engine servicing (1) WASHER (2) GEARSHIFT SPINDLE (1) 3P (NATURAL) CONNECTOR (1) DRAIN BOLT/SEALING WASHER (3) RETURN SPRING PIN (2) 2P (NATURAL) CONNECTOR (2) BOLTS (4) SHIFTER COLLAR (3) LEFT CRANKCASE COVER Left Crankcase Cover Remove the engine oil drain bolt and sealing washer, drain the engine oil.
  • Page 103 Engine servicing (1) BOLTS (2) IGNITION PULSE GENERATOR (1) SNAP RING (2) WASHER (1) NEEDLE BEARING (3) WIRE GUIDE (4) SOCKET BOLTS (3) OIL SEAL (4) NEEDLE BEARING (5) STATOR Press new needle bearing into the left crankcase cover using the special tools. Tools: Driver 07749–0010000...
  • Page 104 Engine servicing (1) OIL SEAL (1) STATOR (1) OIL FILTER COVER (2) WASHER (2) IGNITION PULSE GENERATOR (2) O-RING (3) SNAP RING (3) WIRE CLAMP (4) SOCKET BOLTS Apply grease to the new oil seal lip and install it into the (5) BOLTS left crankcase cover.

  • Page 105: Flywheel

    Engine servicing (1) LEFT CRANKCASE COVER (1) 3P (NATURAL) CONNECTOR (2) BOLTS (2) 2P (NATURAL) CONNECTOR (3) NEW SEALING WASHER/DRAIN BOLT Flywheel Install the left crankcase cover being careful not to Install the gearshift pedal. damage the oil filter cover O-ring. Connect the alternator 3P (Natural) connector and ignition Removal pulse generator 2P (Natural) connectors.
  • Page 106 Engine servicing (1) THREAD PROTECTOR (1) WOODRUFF KEY (2) FLYWHEEL (3) FLYWHEEL PULLER Installation Hold the flywheel with flywheel holder, tighten the Install the thread protector, which is included with the flywheel nut to the specified torque. flywheel puller, onto the crankshaft. Install the woodruff key into the crankshaft groove.

  • Page 107: Crankcase Separation/Disassembly

    Engine servicing (1) DRIVE SPROCKET (1) COUNTERSHAFT COLLAR (1) CLUTCH OUTER (2) UNIVERSAL HOLDER (2) O-RING (2) GEAR HOLDER (3) BOLT (3) PRIMARY DRIVE GEAR (4) SPRING WASHER Temporarily install the clutch outer guide, needle bearing Crankcase Separation/Disassembly and clutch outer onto the mainshaft and attach the gear holder between the primary drive and driven gears.
  • Page 108 Engine servicing (1) TRANSMISSION OIL DRAIN BOLT (1) GASKET (1) SHIFT FORK SHAFTS (2) CRANKCASE BOLTS (2) DOWEL PINS (2) SHIFT FORKS (3) ONE-WAY REED VALVE (3) MAINSHAFT (4) COUNTERSHAFT Remove the transmission oil drain bolt and sealing washer. Loosen the crankcase bolts in a crisscross pattern in 2 or Remove the following: 3 steps.

  • Page 109: Crankshaft/Transmission Inspection

    Engine servicing 8 mm 6 mm HOLD HOLD (1) RIGHT CRANKCASE Crankshaft/Transmission Inspection Measure the crankshaft runout. Support the crankshaft with V-blocks or a stand and then measure the runout at the points “C” and “D”. Service limit: 0.05 mm (0.002 in) 0.03 mm (0.001 in) Measure the connecting rod big end side clearance and big end axial/radial play (specification;...
  • Page 110 Engine servicing Crankcase Bearings/Oil Seals Location (1) LEFT SHIFT DRUM BEARING (A) 1 mm (oil seal tolerance) (2) LEFT COUNTERSHAFT BEARING (B) 0 ± 0.5 mm (oil seal tolerance) (3) LEFT COUNTERSHAFT OIL SEAL (C) 58.60 – 58.88 mm (bearing height) (4) LEFT MAINSHAFT BEARING (D) 58.30 –...

  • Page 111: Transmission Assembly

    Engine servicing Transmission Assembly (A) THRUST WASHER, 17.2 mm (B) SPLINED WASHER, 20 mm SET RING, 20 mm (C) SET RING, 20 mm SPLINED WASHER, 20 mm (D) THRUST WASHER, 20 X 30 X 1.5 mm (E) THRUST WASHER, 20 X 30 X 1.0 mm (F) THRUST WASHER, 20 X 30 X 1.0 mm (G) THRUST WASHER, 22 X 21 X 1.0 mm SET RING, 22 mm...

  • Page 112: Crankcase Combination

    Engine servicing (1) MAINSHAFT (1) OIL PUMP SHAFT (1) ONE-WAY REED VALVE (2) COUNTERSHAFT (2) INNER ROTOR (3) SHIFT FORK SHAFTS (3) OUTER ROTOR (4) LEFT SHIFT FORK (5) RIGHT SHIFT FORK (6) CENTER SHIFT FORK Crankcase Combination Clean the crankcase mating surfaces before assembling and check for wear or damage.
  • Page 113 Engine servicing (1) CRANKCASE BOLTS (1) DRIVE GEAR COLLAR (1) CLUTCH OUTER (2) NEW SEALING WASHER/OIL DRAIN BOLT (2) GEAR HOLDER Install the crankcase bolts. Temporarily install the clutch outer guide, needle bearing Tighten the crankcase bolts in a crisscross pattern in and clutch outer onto the mainshaft and attach the gear 2 –...
  • Page 114 Engine servicing (1) DRIVE PIN (1) DRIVE SPROCKET (2) OIL PUMP DRIVEN GEAR (2) UNIVERSAL HOLDER (3) SPRING WASHER (4) BOLT Install the drive sprocket. Install the spring washer and drive sprocket bolt. Hold the drive sprocket with universal holder, tighten the special bolt to the specified torque.

  • Page 116: Frame Servicing

    5. Frame servicing Disassembly/Assembly WARNING A contaminated brake disc or pad reduces stopping power, and can cause a serious injury or death. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent. (1) AXLE PINCH BOLT (2) AXLE Front Wheel Removal...
  • Page 117 Frame servicing (1) AXLE (1) BRAKE CALIPER (1) AXLE PINCH BOLT (2) DISC COVER (3) BOLTS Install the brake caliper, flange collars and disc cover. While keeping the fork parallel, tighten the axle pinch bolt Installation Apply a locking agent to the threads and tighten the mou- to the specified torque.

  • Page 118: Fork

    Frame servicing (1) FRONT FENDER (1) FORK BOLT (1) LOCK NUT (2) HEADLIGHT/NUMBER PLATE (2) FORK LEG (2) FORK BOLT (3) TOP BRIDGE (4) BOTTOM BRIDGE Right Fork Disassembly (5) FORK LEG Before disassembling the fork, clean the entire sliding Fork surface and the bottom of the fork slider.
  • Page 119 Frame servicing (1) FORK DAMPER (1) FORK DAMPER (1) DUST SEAL (2) RIGHT FORK CENTER BOLT (2) CENTERING PLATE (2) STOP RING (3) FORK TUBE (3) FORK SLIDER Hold the axle holder in a vise protected with a piece of Remove the fork damper assembly and centering plate woods or soft jaws to avoid damage.
  • Page 120 Frame servicing (1) FORK TUBE BUSHING (1) BUSHING (1) FORK DAMPER (2) GUIDE BUSHING (2) DAMPER ROD (3) BACK-UP RING (3) FORK TUBE (4) OIL SEAL Right Fork Inspection (4) CENTERING PLATE (5) FORK SLIDER Check the following items (page 2-4): Fork Damper Check that the fork tube moves smoothly in the slider.
  • Page 121 Frame servicing (1) FORK TUBE BUSHING (1) FORK SEAL DRIVER (1) FORK DAMPER ASSEMBLY (2) GUIDE BUSHING (2) CENTERING PLATE (3) BACK-UP RING (3) FORK TUBE (4) OIL SEAL Install the stop ring into the fork slider groove securely. (5) FORK SLIDER Install the dust seal.
  • Page 122 Frame servicing (1) FORK DAMPER HOLDER (1) FORK FLUID (2) RIGHT FORK CENTER BOLT (2) FORK TUBE Hold the axle holder in a vise protected with a piece of Pour recommended fork fluid in the fork leg. woods or soft jaws to avoid damage. Do not overtighten the vise.
  • Page 123 Frame servicing (1) DAMPER ADJUSTER CASE (1) FORK BOLT (2) LOCK NUT (2) DISTANCE COLLAR (3) SPRING SEAT (4) FORK SPRING If the damper adjuster case was removed from the damper (5) TAPERED BUSHING (ED/3ED) rod, reinstall the damper adjuster case as follows: (6) FORK TUBE 1.
  • Page 124 Frame servicing (1) CILINDER ASSY (1) FORK TUBE (1) CILINDER ASSY (2) CENTER BOLT (2) CILINDER ASSY (2) PISTON RING (3) TAPERED BUSHING (3) REBOUND SPRING (4) FORK SLIDER (4) TAPERED BUSHING Hold the axle holder in a vise protected with a piece of wood or soft jaws to avoid damage.
  • Page 125 Frame servicing (1) FORK TUBE (1) CILINDER ASSY (1) GUIDE BUSHING (2) CILINDER ASSY (2) CENTER BOLT (2) BACK-UP RING (3) TAPERED BUSHING (3) OIL SEAL (4) FORK SLIDER (4) STOP RING Hold the axle holder in a vise protected with a piece of (5) DUST SEAL wood or soft jaws to avoid damage.
  • Page 126 Frame servicing FORWARD (1) FORK SPRING (1) FORK TUBE (2) SPRING SEAT (2) TOP BRIDGE (3) DISTANCE COLLAR (4) O-RING Pour half the required amount of recommended fork fluid Installation (5) FORK BOLT in the fork leg. (6) TAPERED BUSHING (ED/3ED) Install the fork leg.

  • Page 127: Steering Stem

    Frame servicing (1) BOTTOM BRIDGE PINCH BOLTS (1) STEM NUT (1) ADJUSTING NUT (2) FORK BOLT (2) TOP BRIDGE (3) TOP BRIDGE PINCH BOLTS Steering stem Tighten the bottom bridge pinch bolts to the specified torque. Disassembly Torque: 21 N•m (2.1 kgf•m, 14 lbf•ft) Remove the following: –...
  • Page 128 Frame servicing (1) STEM (1) STEM (1) DRIVER (2) LOWER BEARING (2) DUST SEAL (2) ATTACHMENT (3) DUST 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.
  • Page 129 Frame servicing (1) ADJUSTING NUT (1) TOP BRIDGE (2) STEM NUT Screw the stem bearing adjusting nut all the way with Turn the steering stem lock-to-lock 5 times to seat the Apply grease to the stem nut thread and seating surfaces. your fingers.

  • Page 130: Rear Wheel

    Frame servicing Spokes: Check spoke tension frequently between the first few rides. As the spokes, spoke nuts and rim contact 27 N•m (2.7 kgf•m) (3E) points seat-in, the spokes may need to be retightened. 32 N•m (3.2 kgf•m) (4E) Once past this initial seating-in period, the spokes should hold their tension.

  • Page 131: Shock Absorber

    Frame servicing (1) AXLE (1) AXLE NUT (1) LOWER MOUNTING BOLT/NUT (2) ADJUSTERS Installation Apply grease to the axle nut threads and seating surface. Install the right chain adjuster and axle nut. Install the rear brake caliper aligning with the caliper slide Install the drive chain.
  • Page 132 Frame servicing (1) SPANNER WRENCH (1) STOPPER RING Removal Secure the damper in a bench vise Loosen the lock nut and the spring adjuster using the spanner wrench (07702-0020001). (1) DAMPER UNIT (6) LOWER DISTANCER Move the spring up next to the fastener plate. (2) SPRING (7) UPPER DISTANCER (3) DAMPER...
  • Page 133 Frame servicing (1) DISTANCE COLLAR (1) DUST SEALS (1) PRE-LOAD LENGTH (2) SPHERICAL BEARING (2) ADJUSTER (3) LOCK NUT Remove the distance collar. Adjust the spring pre-load length (page 2-4). Spherical Bearing Replacement Hold the spring adjuster and tighten the lock nut to the Remove the stopper ring, spring seat and spring.

  • Page 134: Shock Linkage

    Frame servicing (1) UPPER MOUNTING BOLT/NUT (1) LOWER MOUNTING BOLT/NUT (1) LOWER MOUNTING BOLT/NUT (2) BOLTS/NUTS (3) CUSHION ARM PLATES (4) CUSHION LINK Installation Move the swingarm aligning the lower mount, then install the lower mounting bolt from the right side. Shock Linkage Set the shock absorber into the frame and install the Install and tighten the upper and lower mounting nuts to...

  • Page 135: Swingarm

    Frame servicing 3 mm (0.12 in) (1) PIVOT COLLAR A (1) CUSHION LINK (1) SHOCK ABSORBER LOWER MOUNTING BOLT/NUT (2) PIVOT COLLAR B (2) CUSHION ARM PLATES (2) SHOCK ARM PLATES-TO-SWINGARM BOLT/NUT (3) DUST SEALS (3) BOLTS/NUTS (4) NEEDLE BEARINGS (4) LOWER MOUNTING BOLT/NUT Swingarm Needle Bearing Replacement...
  • Page 136 Frame servicing 5.5 mm (0.22 in) (1) BRAKE HOSE CLAMPS (1) DUST SEAL CAP (1) NEEDLE BEARING (2) SWINGARM PIVOT BOLT/NUT (2) DUST SEAL (2) DUST SEAL (3) PIVOT COLLAR (3) BUSHING (4) DUST SEAL Remove the following: Pivot Bearing Replacement –...
  • Page 137 Frame servicing 3.0 mm (0.12 in) (1) PIVOT COLLAR A (1) DUST SEAL (1) CHAIN TENSIONER (2) PIVOT COLLAR B (2) PIVOT COLLAR (2) BUSHINGS (3) DUST SEALS (3) DUST SEAL (3) O-RINGS (4) NEEDLE BEARING (4) DUST SEAL CAP (4) PIVOT BOLT Link Bearing Replacement Apply grease to the pivot chain tensioner, bushings and...
  • Page 138 Frame servicing (1) DRIVE CHAIN SLIDER (1) PIVOT BOLT/NUT (1) SHOCK ARM PLATES-TO-SWINGARM BOLT/NUT (2) SCREWS (2) HOSE CLAMPS (2) SHOCK ABSORBER LOWER MOUNTING BOLT/NUT Installation Install the following: – Shock arm plates-to-swingarm bolt/nut – Rear cushion lower mounting bolt/nut Apply thin coat of grease to the swingarm pivot bolt surface.

  • Page 139: Front Brake Pad Replacement

    Frame servicing (1) PAD PIN (1) NEW PADS (2) PAD SPRING PIN (2) PAD PIN (3) BOLTS (3) PAD SPRING PIN (4) DISC COVER Install the new pads and secure with the pin and the (5) CALIPER spring pin for the pads. Brake pad replacement Install the caliper to the fork so the disc is positioned between the pads, being careful not to damage the pads.

  • Page 140: Rear Brake Pad Replacement

    Frame servicing (1) BRAKE PADS (1) BRAKE HOSE OIL BOLT (2) PAD PIN (2) MOUNTING BOLTS (3) DISC COVER (4) BRAKE CALIPER Front brake caliper Removal NOTICE Avoid spilling brake fl uid on painted, plastic or rubber parts. Place a shop rag over these parts whenever the system is serviced.

  • Page 141: Rear Brake Caliper

    Frame servicing (1) OIL BOLT (1) CALIPER PISTON (2) BRAKE HOSE (3) BRAKE CALIPER Rear brake caliper Inspection Inspection Clean the inside of the caliper. Clean the inside of the caliper. Removal Check the oil leakage from the caliper cylinders. Check the oil leakage from the caliper cylinder.

  • Page 142: Front Master Cylinder

    Frame servicing (1) BOOT (2) SNAP RING (3) PISTON ASSEMBLY (4) SPRING (5) OIL SEAL (6) CIRCLIP (1) OIL BOLT (2) BRAKE HOSE (3) BOLT (4) MASTER CYLINDER Front master cylinder Removal/Installation NOTICE  Avoid spilling brake fl uid on painted, plastic or rubber parts.

  • Page 143: Rear Master Cylinder

    Frame servicing (1) OIL BOLT (1) BOLTS (1) NUT (2) BRAKE HOSE (2) MASTER CYLINDER (2) BOLT (3) MASTER CYLINDER (3) BRAKE PEDAL Rear master cylinder Brake pedal Remove the mounting bolts and master cylinder. Installation Removal/Installation Removal Installation is in the reverse order of removal. Remove the brake pedal pivot nut and bolt.

  • Page 144: Clutch Master Cylinder

    Frame servicing 3.0 mm (0.12 in) (1) BEARING (1) COLLAR B (1) OIL BOLT (2) DUST SEALS (2) PEDAL (2) CLUTCH HOSE (3) COLLAR A (3) BOLT (4) MASTER CYLINDER Installation Clutch master cylinder Install the brake pedal and collars. Install and tighten the pivot nut and bolt.
  • Page 145 Frame servicing (1) BOOT (2) SNAP RING (3) PISTON ASSEMBLY (4) SPRING (5) OIL SEAL (6) CIRCLIP Disassembly/Assembly Inspection Check the following items (page 2-4): NOTICE – Master cylinder and piston for scoring, scratches or other damage  Keep the master cylinder piston, oil seals, spring and –...

  • Page 146: Electrical Servicing

    6. Electrical servicing (1) 6P (BLACK) CONNECTOR (1) 3P (NATURAL) CONNECTOR (1) 4P (NATURAL) CONNECTOR Charging system inspection If the resistance is out of specification, disconnect the Regulated Voltage Inspection alternator 3P (Natural) connector and measure the resistance between the yellow terminals of the alternator Disconnect the power 4P (Natural) connector.
  • Page 147 Electrical servicing (1) 3P (NATURAL) CONNECTOR (1) 2P (BLACK) CONNECTOR (1) BOLTS (2) 2P (NATURAL) CONNECTOR (2) 6P (BLACK) CONNECTOR (2) ELECTRICAL COMPONENTS SUPPORT Regulator/Rectifier Removal/installation Remove the throttle body (page 4-13). Disconnect the alternator 3P (Natural) connector and ignition pulse generator 2P (Natural) connector. (1) BOLT (1) 2P (BLACK) CONNECTOR (2) BRAKE RESERVOIR...

  • Page 148: Ignition System Inspection

    Electrical servicing (1) BOLTS (1) PRIMARY TERMINALS (1) SPARK PLUG CAP (2) REGULATOR/RECTIFIER (2) TIE-WRAP Ignition system inspection Remove the bolts and regulator/rectifier from the electrical Removal/Installation components support. Remove the fuel tank/injector assembly. Ignition coil inspection Install the regulator/rectifier and condenser in the reverse order of removal.
  • Page 149 Electrical servicing (1) WIRE CLAMP (1) 32P (BLACK) CONNECTOR (1) 2P (NATURAL) CONNECTOR (2) PRIMARY WIRES (3) BOLTS (4) IGNITION COIL Ignition Pulse Generator Inspection If the resistance is out of specification, measure the resistance at the ignition pulse generator 2P (Natural) Remove the wire clamp.

  • Page 150: Pgm-Fi System Inspection

    Electrical servicing (1) CONDENSER (1) 32P (BLACK) CONNECTOR PGM-FI System inspection Condenser Inspection If the engine does not start, check for the items “engine Place the motorcycle upright position and remove the rear fender. does not start” in the PGM-FI Malfunction Indicator Lamp Disconnect the ECM 32P (Black) connector.
  • Page 151 If the MIL indicator is still on after 5 seconds, inspect the MIL Check motorcycle at your Montesa dealer as soon as possible. Connect the diagnostic tool (DST) as shown in the OBD system (diagnosis system) When the engine is started the MIL will stay on for 5 illustration and start the motorcycle.
  • Page 152 Electrical servicing (1) PGM WARNING UNIT ASSEMBLY (1) POWER SWITCH (1) POWER SWITCH (2) RED WIRE EYELET (2) MIL (2) MIL (3) GREEN WIRE EYELET (3) WARN/RESET SWITCH (3) WARN/RESET SWITCH (4) 2P (BLACK) CONNECTOR (5) 4P (RED) CONNECTOR Self-diagnosis Reset Procedure DTC readout procedure –...

  • Page 153: Mil And Dtc (Iso) Error Codes For The Pgm-Fi Injection System

    Electrical servicing MIL and DTC (ISO) error codes for the PGM-FI injection system.  The PGM-FI MIL denotes the failure codes (the number of blinks from 0 to 54). When the indicator lights for 1.3 seconds, it is equivalent to ten blinks. For example; a 1.3 second illumination and two blinks (0.5 second x 2) of the indicator equals 12 blinks.

  • Page 154: Bank Angle Sensor Inspection

    Electrical servicing (1) SCREWS (1) ARROW/UP MARK (2) BANK ANGLE SENSOR (2) BANK ANGLE SENSOR Bank angle sensor inspection Connect the bank angle sensor 3P (Natural) connector. Install the bank angle sensor in the reverse order of With the arrow mark on the bank angle sensor facing up, removal.

  • Page 155: Engine Stop Switch Inspection

    Electrical servicing (1) CONNECTORS (1) 2P (NATURAL) CONNECTOR (1) FAN MOTOR RELAY Engine stop switch inspection Cooling fan system inspection Fan motor relay inspection Remove the fan motor relay. Disconnect the engine stop switch connectors. Fan motor inspection Connect an ohmmeter to the fan motor relay connector Check the engine stop switch for continuity.

  • Page 156: Wiring Diagram

    Electrical servicing Wiring diagram MAPPING FUEL SWITCH MOTOR PUMP SERVICE CHECK CONNECTOR POWER FUN RELAY WATER REGULATOR/RECTIFIER TEMP BLACK SENSOR YELLOW BLUE CONDENSER BANK ANGLE GREEN (10000uF) SENSOR PULSER ALTERNADOR WHITE VIOLET BROWN ORANGE IGNITION COIL LIGHT BLUE LIGHT GREEN ENGINE STOP PINK...
  • Page 157 California Proposition 65 Warning WARNING Operating, servicing and maintaining a passenger vehicle or off-road vehicle can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm. To minimize exposure, avoid breathing exhaust, do not idle the engine except as necessary, service your vehicle in a wellventilated area and wear gloves or wash your hands frequently when servicing your vehicle.

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