Montesa COTA 4RT RACE REPLICA Owner's Manual page 21

Item
Cylinder/Piston
Cylinder I.D
Taper
Out-of- round
Warpage
Piston O.D.
Measurement point
Pin bore I.D.
Piston pin O.D.
Piston ring
End gap
Top
Second
Oil (side rail)
Ring-to-groove clearance
Top
Second
Cylinder-to-piston clearance
Piston-to-piston pin clearance
Connecting rod small end I.D.
Clutch/Gearshift Linkage
Recommended clutch fluid
Clutch spring free length
Clutch disc thickness
Clutch plate warpage
Clutch slave cylinder I.D.
Clutch slave piston O.D.
Kickstarter
Spindle O.D.
Pinion gear I.D.
Idle gear I.D.
Countershaft O.D.
at kickstarter idle gear
Standard
78,000 – 78,015 (3,0709 - 3,0715)
–
–
–
77,970 – 77,980 (3,0696 - 3,07008)
5 (0,2) from bottom of skirt
16,002 – 16,008 (0,6300 – 0,6302)
15,994 – 16,000 (0,6297 – 0,6299)
0,15 – 0,25 (0,008 - 0,0098425)
0,30 – 0,45 (0,012 - 0,0018)
0,20 – 0,70 (0,008 – 0,028)
0,065 – 0,100 (0,0026 – 0,0039)
0,015 – 0,050 (0,0006 – 0,0020)
0,020 – 0,045 (0,0008 – 0,0018)
0,002 – 0,014 (0,0001 – 0,0006)
16,016 – 16,034 (0,6305 – 0,6313)
DOT 4 brake fluid
27,6 (1,09)
3,22 – 3,38 (0,127 – 0,133)
–
27,000 – 27,021 (1,0630 – 1,0638)
26,940 – 26,960 (1,0606 – 1,0614)
16,466 – 16,484 (0,6483 – 0,6490)
16,516 – 16,534 (0,6502 – 0,6509)
17,016 – 17,034 (0,6699 – 0,6706)
16,983 – 16,994 (0,6686 – 0,6691)
Unit: mm (in)
Service limit Item
Crankshaft/Transmission
78,04 (3,0724) Crankshaft runout
0,05 (0,002)
0,05 (0,002)
Connecting rod big end
0,05 (0,002)
Side clearance
77,89 (3,0665)
Radial clearance
–
Transmission gear I.D.
16,03 (0,631)
15,98 (0,629)
0,39 (0,01535)
Gear bushing D.I.
0,59 (0,02323)
0,90 (0,035)
0,115 (0,0045)
O.D.
0,065 (0,0026)
0,18 (0,007)
0,04 (0,002)
16,04 (0,631)
Countershaft O.D.
–
at C1 bushing
26,8 (1,06)
at C2/C3 bushing
3,15 (0,124)
at kickstarter idle gear
0,10 (0,004)
Shift fork I.D.
–
–
Shift fork claw thickness
16,46 (0,648)
Shift fork shaft O.D.
16,55 (0,652)
17,06 (0,672)
Oil pump
16,97 (0,668)
Tip clearance
Body clearance
Side clearance
Standard
Right –
Left –
0,30 – 0,75 (0,012 – 0,030)
0,06 – 0,18 (0,002 – 0,007)
M4 23,020 – 23,041 (0,9063 – 0,9071)
M5 23,020 – 23,041 (0,9063 – 0,9071)
C1 20,020 – 20,041 (0,7882 – 0,7890)
C2 25,020 – 25,041 (0,9850 – 0,9859)
C3 25,020 – 25,041 (0,9850 – 0,9859)
M5 20,000 – 20,021 (0,7866 – 0,7882)
C1 17,000 – 17,018 (0,6693 – 0,6700)
C2 22,000 – 22,021 (0,8661 – 0,8670)
C3 22,000 – 22,021 (0,8661 – 0,8670)
M4 22,979 – 23,000 (0,9047 – 0,9055)
M5 22,979 – 23,000 (0,9047 – 0,9055)
C1 19,979 – 20,000 (0,7866 – 0,7874)
C2 24,979 – 25,000 (0,9834 – 0,9843)
C3 24,979 – 25,000 (0,9834 – 0,9843)
16,983 – 16,994 (0,6686 – 0,6691)
21,959 – 21,980 (0,8645 – 0,8654)
16,983 – 16,994 (0,6686 – 0,6691)
C 11,003 – 11,024 (0,4332 – 0,4330)
R, L 12,035 – 12,056 (0,4738 – 0,4746)
C 4,93 – 5,00 (0,194 – 0,197)
R, L 4,93 – 5,00 (0,194 – 0,197)
C 10,983 – 10,994 (0,4324 – 0,4328)
R, L 11,966 – 11,984 (0,4711 – 0,4718)
–
0,15 – 0,20 (0,006 – 0,008)
0,05 – 0,12 (0,002 – 0,004)
Service data
Unit: mm (in)
Service limit
0,03 (0,001)
0,05 (0,002)
0,8 (0,03)
0,05 (0,002)
23,07 (0,908)
23,07 (0,908)
20,06 (0,790)
25,06 (0,987)
25,06 (0,987)
20,05 (0,789)
17,04 (0,671)
22,04 (0,868)
22,04 (0,868)
22,96 (0,904)
22,96 (0,904)
19,95 (0,785)
24,95 (0,982)
24,95 (0,982)
16,97 (0,668)
21,94 (0,864)
16,97 (0,668)
11,04 (0,435)
12,07 (0,475)
4,8 (0,19)
4,8 (0,19)
10,97 (0,432)
11,95 (0,470)
0,20 (0,008)
–
–
2-3 2-3