Honda Montesa Cota RR301 (2020) Handleiding

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Contents

1.Operating instructions

Operation component locations (2ED).............. 1-1

Operation component locations (4ED).............. 1-2

Fuel ............................................................ 1-3

Coolant ....................................................... 1-3

Basic Operation ............................................ 1-3

Odometer/Speedometer (2ED) ........................ 1-5

Steering lock ................................................ 1-6

Shifting gears .............................................. 1-7

Braking ....................................................... 1-7

Parking ........................................................ 1-8

Controls ...................................................... 1-8

2.Service data

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

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

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

Tools .......................................................... 2-7

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

Cable & Harness Routing (2ED) ...................... 2-11

Cable & Harness Routing (4ED) ...................... 2-12

Cable & Harness Routing ............................... 2-14

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

Front headlight and front and rear position light. 3-18

Cleaning ...................................................... 3-19

Storage ....................................................... 3-19

4.Engine servicing

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

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

Disassembly / Installation of fuel feed hose .... 4-4

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

Fuel Tank/Fuel Pump ..................................... 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 ........................................ 5-26

Rear brake caliper ......................................... 5-27

Front master cylinder .................................... 5-28

Rear master cylinder ..................................... 5-29

Brake pedal .................................................. 5-29

Clutch master cylinder .................................. 5-30

6.Electrical servicing

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

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

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

PGM-FI Self-diagnosis malfunction indicator lamp

(MIL) failure codes ........................................ 6-8

Bank angle sensor inspection ......................... 6-9

Engine stop switch inspection ........................ 6-10

Cooling fan system inspection ........................ 6-10

Chapter lights / instruments / switches (2ED) ... 6-11

Speed sensor (2ED) ...................................... 6-15

Horn (2ED) .................................................. 6-16

Wiring diagram (2ED) .................................... 6-17

Wiring diagram (4ED) .................................... 6-18

2020 Montesa Cota RR301

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