Montesa COTA 4RT 260R 2022 Owner's Manual
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Montesa COTA 4RT 260R 2022 Owner's Manual

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2022
PGM-FI Racing Trial
Owner's Manual

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Summary of Contents for Montesa COTA 4RT 260R 2022

  • Page 1 2022 PGM-FI Racing Trial Owner’s Manual...
  • Page 2 2022 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 N *VTDNE04C?NE000001* 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 Fork ............5-3 1. Operating instructions Fork ............3-16 Steering stem ..........5-12 Operation component locations ...... 1-1 Fuel ............
  • 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 Cylinder Head/Valves Lubrication 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) Left – 0.05 (0.002) Taper – 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 Rear Suspension SHOWA Axle runout 0.20 (0.008) Shock absorber spring pre-load 126.5 (4.98) – Tire air pressure Spring free length 133 (5.2) 130.3 (5.13) 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 Perform pre-ride Inspection at each scheduled maintenance period. For your safety, it is very important to take a few I: Inspect and clean, Adjust, Lubricate or Replacement if necessary. C: Clean, R: Replace, L: Lubricate. moments before each ride to walk around your COTA 4RT and check its condition.

  • Page 37: Warming-Up Inspection

    Service and maintenance Warming-up Inspection Replacement Parts Parts Requiring Periodic Replacement When warming-up the engine, check for the following: Do not rev the engine more than necessary or engine damage may result. Item Replacement Interval Cause Check for fuel, oil, and water leaks Warm up the engine for a few minutes until it is heated Engine to the operating temperature until the engine responds...

  • 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 Inspect and adjust the idle speed after all other engine Oil Change 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 Replace the fork fluid every 6 months. See page 5-8, 5-10 for oil level adjustment after changing the fork fluid. Inspection The motorcycle is shipped with a light coating of grease Use specified fork fluid which additives to assure maxi- on the forks.

  • Page 52: Rear Suspension

    Service and maintenance (1) COMPRESSION ADJUSTER (1) PRE-LOAD ADJUSTER (1) REBOUND ADJUSTER Rear Suspension Periodically check and clean all front suspension parts When your Cota is new, your suspension will break-in to assure top performance. Check the dust seals for as you ride.

  • Page 53: Cleaning

    Service and maintenance Cleaning Storage Clean your COTA regularly to protect the surface finishes Extended storage, such as for winter, requires that you and inspect for damage, wear, or oil leaks. take certain steps to reduce the effects of non-use. In When washing your COTA, always use water and a mild addition, it is useful to do the necessary repairs BEFORE detergent (such as dishwashing liquid) to avoid discolo-...
  • Page 54 Service and maintenance Removal from Storage 1. Uncover and clean your COTA. Change the engine and transmission oil if more than 4 months have passed since the start of storage. 2. Uncover the end of the muffler and remove the rag from the muffler outlet.
  • Page 55 Memo...

  • Page 56: Engine Servicing

    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 57 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 58 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 59: 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 60: 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 61: 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 62: 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 63 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 64 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 65 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 66 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 67 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 68: 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 69 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 70: 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 71 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 72: 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 73: 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 74 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 75: 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 76 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 77 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 78: 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 79 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 80: 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 81: 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 82: 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 83: 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 84 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 85 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 86: 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 87: 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 88 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 89 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 90 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 91 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 92: 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 93: 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 94 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 95: 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 96: 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 97 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 98: 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 99 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 100 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 101: 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 102: 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 103 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 104: 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 105 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 106 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 107: 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 108 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 109: 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 110 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 111: 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 112 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 113: 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 114: 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 115 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 116 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 117 Memo...

  • Page 118: 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 (3) SIDE COLLAR Drive...
  • Page 119 Frame servicing (1) SIDE COLLAR (1) BRAKE CALIPER (1) AXLE PINCH BOLTS (2) AXLE (2) DISC COVER (3) BOLTS Installation Install the brake caliper, flange collars and disc cover. While keeping the fork parallel, tighten the axle pinch bolt Apply a locking agent to the threads and tighten the mou- to the specified torque.

  • Page 120: 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 121 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 122 Frame servicing (1) FORK TUBE BUSHING (4) OIL SEAL (1) BUSHING (1) FORK DAMPER (3) FORK TUBE (2) GUIDE BUSHING (5) FORK SLIDER (2) BACK-UP RING (2) DAMPER ROD (4) CENTERING PLATE (3) BACK-UP RING (3) INSPECTION POINT Check that the fork tube moves smoothly in the slider. Fork Damper If it does not, check the fork tube bending or damage, and Check the fork damper assembly for damage or...
  • Page 123 Frame servicing (1) FORK TUBE BUSHING (4) OIL SEAL (1) FORK SEAL DRIVER (1) FORK DAMPER ASSEMBLY (2) GUIDE BUSHING (5) FORK SLIDER (2) CENTERING PLATE (3) BACK-UP RING (3) FORK TUBE Install the stop ring into the slider groove securely. Right Fork Assembly Install the dust seal.
  • Page 124 Frame servicing (1) FORK DAMPER (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 125 Frame servicing (1) FORK BOLT (1) CILINDER ASSY (2) DISTANCE COLLAR (2) CENTER BOLT (3) SPRING SEAT (4) FORK SPRING Hold the axle holder in a vise protected with a piece of (5) TAPERED BUSHING wood or soft jaws to avoid damage. (6) FORK TUBE Do not overtighten.
  • Page 126 Frame servicing (1) FORK TUBE (1) CILINDER ASSY (1) FORK TUBE (2) CILINDER ASSY (2) PISTON RING (2) CILINDER ASSY (3) OIL BLOCKER (3) REBOUND SPRING (3) OIL BLOCKER (4) FORK SLIDER (4) OIL BLOCKER (4) FORK SLIDER Remove the oil blocker from the fork piston. Left Fork Inspection Left Fork Assembly Check the following items (service data;...
  • Page 127 Frame servicing (1) CILINDER ASSY (1) GUIDE BUSHING (2) CENTER BOLT (2) BACK-UP RING (3) OIL SEAL Hold the axle holder in a vise protected with a piece of (4) STOP RING Pour half the required amount of recommended fork fluid wood or soft jaws to avoid damage.
  • Page 128 Frame servicing FORWARD (1) FORK SPRING (1) FORK TUBE (1) BOTTOM BRIDGE PINCH BOLTS (2) SPRING SEAT (2) TOP BRIDGE (2) FORK BOLT (3) DISTANCE COLLAR (3) TOP BRIDGE PINCH BOLTS (4) O-RING Installation Tighten the bottom bridge pinch bolts to the specified (5) FORK BOLT torque.

  • Page 129: Steering Stem

    Frame servicing (1) STEM NUT (1) ADJUSTING NUT (1) STEM (2) TOP BRIDGE (2) LOWER BEARING (3) DUST SEAL Steering stem Disassembly Remove the following: – Handlebar – Front wheel (page 5-1) – Front fender Remove the steering stem nut and washer. Remove the fork legs (page 5-3).
  • Page 130 Frame servicing (1) STEM (1) DRIVER (1) ADJUSTING NUT (2) DUST SEAL (2) ATTACHMENT (3) BEARING (4) STEERING STEM DRIVER Screw the stem bearing adjusting nut all the way with your fingers. Install new dust seal onto the steering stem. Install the new lower bearing into the steering stem using a hydraulic press and driver.

  • Page 131: Rear Wheel

    Frame servicing (1) TOP BRIDGE (1) ADJUSTER (2) STEM NUT (2) AXLE Rear Wheel Turn the steering stem lock-to-lock 5 times to seat the Apply grease to the stem nut thread and seating surfaces. bearings and retighten the adjusting nut to the specified Install the top bridge, washer and stem nut.
  • Page 132 Frame servicing Spokes: Check spoke tension frequently between the first few rides. As the spokes, spoke nuts and rim contact 32 N•m (3.2 kgf•m) (4E) points seat-in, the spokes may need to be retightened. Once past this initial seating-in period, the spokes should hold their tension.

  • Page 133: Shock Absorber

    Frame servicing (1) AXLE NUT (1) LOWER MOUNTING BOLT/NUT (1) SPRING COMPRESSOR (2) ATTACHMENT (3) SPRING SEAT STOPPER Apply grease to the axle nut threads and seating surface. Disassembly Install the right chain adjuster and axle nut. Loosen the spring lock nut and adjuster. Install the drive chain.
  • Page 134 Frame servicing (1) VALVE CAP (1) DUST SEALS (1) SPRING (2) STOP RING (2ED/4ED) (2) SPRING SEAT (3) SPHERICAL BEARING (3) STOPPER RING (4) COMPRESSOR Nitrogen Releasing Procedure Spherical Bearing Replacement Remove the air valve cap and press the valve stem and Assembly release the nitrogen from the damper until pressure is re- Remove the collars and dust seals.
  • Page 135 Frame servicing (1) PRE-LOAD LENGTH (1) UPPER MOUNTING BOLT/NUT (1) LOWER MOUNTING BOLT/NUT (2) ADJUSTER (3) LOCK NUT Installation Move the swingarm aligning the lower mount, then install Adjust the spring pre-load length (page 2-4). the lower mounting bolt from the right side. Hold the spring adjuster and tighten the lock nut to the Set the shock absorber into the frame and install the specified torque.

  • Page 136: Shock Linkage

    Frame servicing 3 mm (0.12 in) (1) LOWER MOUNTING BOLT/NUT (1) PIVOT COLLAR A (1) CUSHION LINK (2) BOLTS/NUTS (2) PIVOT COLLAR B (2) CUSHION ARM PLATES (3) CUSHION ARM PLATES (3) DUST SEALS (3) BOLTS/NUTS (4) CUSHION LINK (4) NEEDLE BEARINGS (4) LOWER MOUNTING BOLT/NUT Shock Linkage Needle Bearing Replacement...

  • Page 137: Swingarm

    Frame servicing (1) SHOCK ABSORBER LOWER MOUNTING BOLT/NUT (1) BRAKE HOSE CLAMPS (1) DUST SEAL CAP (2) SHOCK ARM PLATES-TO-SWINGARM BOLT/NUT (2) SWINGARM PIVOT BOLT/NUT (2) DUST SEAL (3) PIVOT COLLAR (4) DUST SEAL Remove the following: Swingarm – Brake hose clamps screws Disassembly –...
  • Page 138 Frame servicing 3.0 mm (0.12 in) 5.5 mm (0.22 in) (1) NEEDLE BEARING (1) PIVOT COLLAR A (1) DUST SEAL (2) DUST SEAL (2) PIVOT COLLAR B (2) PIVOT COLLAR (3) BUSHING (3) DUST SEALS (3) DUST SEAL (4) NEEDLE BEARING (4) DUST SEAL CAP Pivot Bearing Replacement Link Bearing Replacement...
  • Page 139 Frame servicing (1) CHAIN TENSIONER (1) DRIVE CHAIN SLIDER (1) PIVOT BOLT/NUT (2) BUSHINGS (2) SCREWS (2) HOSE CLAMPS (3) O-RINGS (4) PIVOT BOLT Installation Apply grease to the pivot chain tensioner, bushings and Apply thin coat of grease to the swingarm pivot bolt O-rings.

  • Page 140: Front Brake Pad Replacement

    Frame servicing (1) SHOCK ARM PLATES-TO-SWINGARM BOLT/NUT (1) CALIPER (2) SHOCK ABSORBER LOWER MOUNTING BOLT/NUT (2) BOLTS (3) DISC COVER (4) PAD SPRING PIN Install the following: (5) PAD PIN – Shock arm plates-to-swingarm bolt/nut – Rear cushion lower mounting bolt/nut Brake pad replacement Tighten the shock arm plate bolt.

  • Page 141: Rear Brake Pad Replacement

    Frame servicing (1) NEW PADS (1) BOLT (2) PAD PIN (2) SPEED SENSOR (3) PAD SPRING PIN (3) SPEED SENSOR BRACKET Install the new pads and secure with the pin and the Rear Brake Pad Replacement spring pin for the pads. NOTICE Install the caliper to the fork so the disc is positioned between the pads, being careful not to damage the pads.

  • Page 142: Front Brake Caliper

    Frame servicing (1) BRAKE PADS (1) CALIPER BRACKET (1) BRAKE HOSE OIL BOLT (2) PAD PIN (2) BOSS/SLIT (2) MOUNTING BOLTS (3) DISC COVER (4) BRAKE CALIPER Remove the pad pin and brake pads. Install the brake caliper bracket aligning its slit with the Clean the brake caliper inside especially around the caliper boss on the swingarm.

  • Page 143: 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 144: 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 145: 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 146: 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 147 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 148: 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 149 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 150: 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 151 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 152: 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 153 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 154 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 155: 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 156: 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 157: 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. Fan motor inspection Disconnect the engine stop switch connectors. Connect an ohmmeter to the fan motor relay connector Check the engine stop switch for continuity.

  • Page 158: Wiring Diagram

    Electrical servicing Wiring diagram FUEL MAPPING 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 159 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.
  • Page 160 Printed in Spain U2NN4SUMH U2NN4SUMH...

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