Honda Montesa Cota 300RR (2018) Handleiding

Honda Motor Montesa Cota 300RR (2018)

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Contents

1. Operating instructions

Operation component locations ...................... 1-1

Fuel ............................................................ 1-2

Coolant ....................................................... 1-2

Basic Operation ............................................ 1-2

Shifting gears .............................................. 1-4

Braking ....................................................... 1-4

Parking ........................................................ 1-4

Controls ...................................................... 1-5

2. Service data

Specifications .............................................. 2-1

Service data ................................................. 2-2

Torque, Values ............................................. 2-5

Tools, Special .............................................. 2-7

Tools, Common ............................................ 2-7

Lubrication & Seal Points ............................... 2-8

Cable & Harness Routing ............................... 2-11

3. Service and maintenance

Maintenance schedule ................................... 3-1

Pre-ride Inspection ........................................ 3-1

Warming-up Inspection .................................. 3-2

Ride Inspection ............................................. 3-2

After Ride Inspection .................................... 3-2

Replacement Parts ........................................ 3-2

Fuel Line ..................................................... 3-3

Air Cleaner .................................................. 3-3

Spark Plug ................................................... 3-4

Valve Clearance ........................................... 3-4

Engine Oil/Oil Filter ....................................... 3-6

Engine Idle Speed ......................................... 3-8

Transmission Oil ........................................... 3-8

Coolant ....................................................... 3-9

Clutch System ............................................. 3-10

Exhaust Pipe And Muffler .............................. 3-10

Drive Chain .................................................. 3-11

Drive Chain Slider ......................................... 3-11

Drive/Driven Sprockets .................................. 3-12

Brake Fluid .................................................. 3-13

Brake Pad Wear ............................................ 3-14

Brake System ............................................... 3-14

Handlebar And Steering Head Bearings ............ 3-15

Wheels And Tires ......................................... 3-15

Front Suspension .......................................... 3-16

Fork ........................................................... 3-16

Rear Suspension ........................................... 3-17

Cleaning ......................................................

3-18

Storage .......................................................

3-18

4. Engine servicing

Oil Pressure Relief Valve ................................ 4-1

Oil Pump ..................................................... 4-1

Fuel Feed Hose ........................................... 4-4

Fuel Line Inspection ...................................... 4-5

Connect the fuel pump 2P connector. ............. 4-6

Fuel Tank/Fuel Pump ..................................... 4-7

Removal ...................................................... 4-7

Remove the rear fender. ................................ 4-7

Disconnect the fuel injector 2P connector. ....... 4-7

Remove the fuel injector socket bolts. ............. 4-7

Injector ....................................................... 4-13

Throttle Body ............................................... 4-13

Water Seal And Bearing Replacement .............. 4-15

Radiator Removal/Installation ......................... 4-17

Engine Removal/Installation ............................ 4-18

Cylinder Compression ................................... 4-20

Cylinder Head Removal ................................. 4-23

Cylinder Head Disassembly ............................ 4-25

Cylinder Head Inspection ............................... 4-26

Valve Guide Replacement .............................. 4-27

Valve Seat Inspection/Refacing ...................... 4-28

Cylinder Head Assembly ................................ 4-31

Cylinder/Piston ............................................. 4-32

Cylinder Head Installation .............................. 4-37

Camshaft/Cylinder Head Cover Installation ....... 4-38

Right Crankcase Cover .................................. 4-40

Clutch Slave Cylinder .................................... 4-41

Clutch ......................................................... 4-43

Kickstarter ................................................... 4-46

Gearshift Linkage .......................................... 4-47

Left Crankcase Cover .................................... 4-49

Flywheel ..................................................... 4-52

Crankcase Separation/Disassembly ................. 4-54

Crankshaft/Transmission Inspection ................ 4-56

Crankcase Bearing Replacement ..................... 4-56

Transmission Assembly ................................. 4-58

Crankcase Combination ................................. 4-59

5. Frame servicing

Front Wheel ................................................. 5-1

Fork ............................................................ 5-3

Steering stem .............................................. 5-12

Rear Wheel .................................................. 5-15

Shock Absorber ............................................ 5-16

Shock Linkage .............................................. 5-19

Swingarm ....................................................

5-20

Front Brake Pad Replacement

......................... 5-24

Rear Brake Pad Replacement ......................... 5-25

Front brake caliper ........................................ 5-25

Rear brake caliper ......................................... 5-26

Front master cylinder .................................... 5-27

Rear master cylinder ..................................... 5-28

Brake pedal .................................................. 5-28

Clutch master cylinder .................................. 5-29

6. Electrical servicing

Charging system inspection ........................... 6-1

Ignition system inspection ............................. 6-3

PGM-FI System inspection ............................. 6-5

PGM-FI ........................................................ 6-6

PGM-FI Self-diagnosis malfunction

indicator lamp (MIL) failure codes ................... 6-7

Bank angle sensor inspection ......................... 6-8

Engine stop switch inspection ........................ 6-9

Cooling fan system inspection ........................ 6-9

Wiring diagram ............................................. 6-10

Cota 300RR (MRT300RR)

U2NN4UMH

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. This vehicle is sold “as is” with no warranties.

FOR EXPERIENCED RIDERS, NO PASSENGERS

This motorcycle is designed as an operator-only vehicle and is for use by experienced riders only. The motorcycle load limit and seating configuration do not

safely permit the carrying of a passenger.

Read this manual carefully.

This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when resold.

Safety Messages

Your safety and the safety of others is very important. We have provided

important safety messages in this manual and on the COTA 300RR. Please read

these messages carefully.

A safety message alerts you to potential hazards that could hurt you or others.

Each safety message is preceded by a safety alert symbol and one of three

words, DANGER, WARNING, or CAUTION.

These signal words mean:

DANGER