Montesa COTA 301 2023 User manual

PGM-FI Racing Trial Owner’s Manual
2023

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 301RR. 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 You WILL be KILLED or SERIOUSLY HURT if you
don’t follow instructions.
!WARNING You CAN be KILLED or SERIOUSLY HURT if you
don’t follow instructions.
!CAUTION You CAN be HURT if you don’t follow instructions.
Each message tells you what the hazard is, what can happen and what you can
do to avoid or reduce injury.
Damage Prevention Messages
You will also see other important messages that are preceded by the word
NOTICE .
This word means:
NOTICE
Your COTA 301RR or other property can be damaged if you don’t follow
instructions.
The purpose of these messages is to help prevent damage to your COTA
301RR, other property, or the environment.
2023
V05

MONTESA COTA 301RR
Owner’s / Service Manual
This manual describes the service procedures for the COTA 301RR (4ED).
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.
(4ED) Racing version, COTA 301RR RACE REPLICA.

Serial numbers
The Vehicle Identification Number (VIN) is stamped on the
right side of the steering head.
The serial number of the engine is stamped on the lower
right side of the crankcase. MODEL TYPE FRAME No. ENGINE No.
MRT 300 P 4ED VTDNE053?PE000001 NN4E7100001
(1) FRAME NUMBER (1) ENGINE NUMBER
1
1

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. The meanings of each symbol and label are as follows.
1
30mm
Keep chain adjusted and lubricated
25-35 mm (1.0 -1.4 in)
Read Owner’s Manual.
2
95
+
Caution label
- This motorcycle is not designed to transport a passenger.
- Read owner’s manual carefully.
- For yourprotection always wear your helmet while riding.
- Ethanol (ethyl alcohol) 5% by volume.
- Ethanol (ethyl alcohol) 10% by volume.
- Use unleaded gasoline, octane number 95 (RON) or higher.
3 Radiator cap label
Danger
Never open when hot.
Hot coolant will scald you.
Relief pressure valve begins to open at 15.6 psi (1.1 Kgf/cm
2
)
4 Safety label
5 EC label

4
3
2
1
5
Labels

Important Safety Precautions
Your Cota can provide many years of pleasure if you take
responsibility for your own safety and understand the
challenges you can meet in competitive racing.
As an experienced rider, you know there is much you can
do to protect yourself when you ride.
The following are a few precautions we consider to be
most important.
Never Carry a Passenger.
Your Cota is designed for one operator only.
Carrying a passenger can cause crashes in which you and
others can be hurt.
Wear Protective Gear.
Whether you’re practicing to improve your skills, or riding
in competition, always wear an approved helmet, eye
protection, and proper protective gear.
Take Time to Get to Know Your Cota.
Because every motorcycle is unique, take time to become
thoroughly familiar with how this one operates and
responds to your commands before placing your machine,
and yourself, in competition.
Learn and Respect Your Limits.
Never ride beyond your personal abilites or faster than
conditions warrant. Remember that alcohol, drugs, illness
and fatigue can reduce your ability to perform well and
ride safely.
Don’t Drink and Ride.
Alcohol and riding don’t mix. Even one drink can reduce
your ability to respond to changing conditions, and your
reaction time gets worse with every additional drink. So
don’t drink and ride, and don’t let your friends drink and
ride either.
Keep your Montesa in Safe Condition.
Maintaining your Cota properly is critical to your safety. A
loose bolt, for example, can cause a breakdown in which
you can be seriously injured.
Accessories & Modifications
Modifying your Cota or using non-Montesa accessories
can make your Cota unsafe.
Before you consider making any modifications or adding
an accessory, be sure to read the following information.
!WARNING
Improper accessories or modifications can cause a
crash in which you can be seriously hurt or killed.
Follow all instructions in this Owner’s Manual
regarding modifications and accessories.
Accessories
We strongly recommend that you use only Montesa
Genuine accessories that have been specifically designed
and tested for your Cota. Because Montesa cannot test
all other accessories, you must be personally responsible
for proper selection, installation, and use of non-Montesa
accessories.
Check with your dealer for assistance and always follow
this guideline:
yMake sure the accessory does not reduce ground clea-
rance and lean angle, limit suspension travel or steering
travel, alter your riding position, or interfere with ope-
rating any controls.
Modifications
We strongly advise you not to remove any original
equipment or modify your Cota in any way that would
change its design or operation.
Such changes could seriously impair your Cota’s handling,
stability, or braking, making it unsafe to ride.
General Competition Maintenance
Perform maintenance on firm, level ground using the side
stand, a workstand, or equivalent support.
When tightening bolts, nuts or screws, start with the
larger diameter or inner fasteners, and tighten them to
the specified torque using a crisscross pattern.
Use Montesa Genuine Parts or their equivalent when
servicing your Cota.
Clean parts in non-flammable (high flash point) cleaning
solvent (such as kerosene) when disassembling. Lubricate
any sliding surface, O-rings, or seals before reassembling.
Grease parts by coating or filling where specified.
After any engine disassembly, always install new gaskets,
O-rings, cotter pins, piston pin clips, snap rings, etc. when
reassembling. After reassembly, check all parts for proper
installation and operation.

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 .......................................................... 2-7
Special........................................................ 2-7
Tools .......................................................... 2-7
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
MIL and DTC (ISO) error codes for
the PGM-FI injection system. ......................... 6-8
Bank angle sensor inspection ......................... 6-9
Engine stop switch inspection ........................ 6-10
Cooling fan system inspection........................ 6-10
Wiring diagram............................................. 6-11
7. Manufacturer and authorized representative for
the USA markets
Manufacturer ............................................... 7-1
Authorized Representative USA market..............7-1

How To Use This Manual
The purpose of this Owner’s / Service Manual is to help
ensure that you obtain the greatest possible satisfaction
from your new COTA trialer; satisfaction with the
performance of the motorcycle, and through success in
competition.
If you plan to do any service on your COTA, section 3
describes standard maintenance and sections 4 through
6 contain information on repair, disassembly, assembly
and special tools.
Follow the Maintenance Schedule recommendation
(page 3-1) to ensure that your COTA is always in peak
operating condition.
Start-up recommendations
Adjusting the idle
If using your motorcycle at varying elevations, bear in
mind that you must adjust the idle; otherwise, you may
have problems operating the vehicle. (See page 3-8)
Engine start
If you have problems starting your vehicle, follow the
steps below:
1. Open the throttle all the way (100%) and hold.
2. Without releasing the throttle, operate the kick-starter
once or twice.
3. Close the throttle and start your motorcycle as normal
(page 1-2).
Importance Of Proper Preparation
Proper pre-competition preparation and regular service
is essential to rider safety and the reliability of the
motorcycle. Any error or oversight made by the technician
during preparation or servicing can easily result in faulty
operation, damage to the machine, or injury to the rider.
Parts Availability
Orders for the parts tend to be concentrated during the
season, so you need to plan your parts orders carefully.
To prevent delays in shipment, place orders on regularly
replaced and fast-wearing parts well ahead of the season
(page 3-2).
Authorized Manuals
The Service Manual used by your authorized dealer is
available from your Honda dealer or Helm, Inc. (USA only,
Canada: See your dealer to order authorized manuals.)
Also available, but not necessary to service your model,
is the Honda Common Service Manual, which explains
basic service information for various systems on Honda
motorcycles, scooters, and ATV.
The Winter Storage Guide in conjunction with the Owner’s
Manual and Service Manual can help you prepare your
Honda motorcycle, scooter, ATV, and SxS for winter
storage.
These Honda manuals are written for the professional
technician. However, if you possess the propper tools,
observe the safety standards, and are mechanically
capable, you should find them easy to use. Special Honda
tools are necessary for some procedures.
yCommon Service Manual (61CSM00)
yWinter Storage Guide (S9507)
To The New Owner
By selecting a MONTESA COTA 301RR as your new
machine, you have placed yourself in a distinguished
family of owners and riders.
The COTA is a high performance trial motorcycle utilizing
the latest trial technology. This motorcycle is intended for
competition use by experienced riders only.
This new trialer was designed to be as competitive as
possible. But motorcycle trial is a physically demanding
sport that requires more than just a fine racing machine.
To do well, you must be in excellent physical condition
and be a skillful rider. For the best possible results, work
diligently on your physical conditioning and practice
frequently.
The purpose of this Owner’s / Service Manual is to help
ensure that you obtain the greatest possible satisfaction
from your new COTA trialer.

1-1
1-1
1. Operating instructions
Operation component locations
MAGNETIC STOP SWITCH
THROTTLE GRIP
FRONT BRAKE LEVERCLUTCH LEVER
SHIFT LEVER
KICKSTARTER
REAR BRAKE PEDAL
MAPPING SWITCH

Operating instructions
1-2
1-2
(1) BREATHER HOSE
(2) FUEL TANK CAP
(1) RADIATOR CAP
Fuel
Gasoline: Premium unleaded gasoline (commercially
available unleaded; pump octane number 91
or higher)
Fuel tank capacity:
2.0 ± 0.2 liter (0.52 US gal, 0.43 Imp gal)
Disconnect the breather hose from the fuel filler cap.
Turn the fuel tank cap counterclockwise, then remove
the cap.
!WARNING
Gasoline is highly flammable and is explosive.
You can be burned or seriously injured when refueling.
yStop engine and keep heat, sparks, and flame away.
yRefuel only outdoors.
yWipe up spills immediately.
Install the fuel tank cap by turning it clockwise.
Connect the breather hose to the fuel filler cap.
Coolant
The engine of COTA is a water-cooled type. In order to
provide adequate cooling, it is essential that the radiator
be filled with coolant up the proper level (See pag. 3-9).
Coolant: 50/50 Mixture of Coolant and Distilled Water
!WARNING
Removing the radiator cap while the engine is hot will
allow the coolant to spray out, seriously scalding you.
Always let the engine and radiator cool down before
removing the radiator cap.
NOTICE
When filling the coolant system, be sure to bleed air
completely. If not, the system cannot be sufficiently filled
and will cause overheating.
Oxygenated Fuels
Some conventional gasolines are being blended with al-
cohol or an ether compound. These gasolines are collec-
tively referred to as oxygenated fuels. To meet clean air
standards, some areas of the United States and Canada
use oxygenated fuels to help reduce emissions.
If you use an oxygenated fuel, be sure it is unleaded and
meets the minimum octane rating requirement.
Before using an oxygenated fuel, try to confirm the fuel’s
contents. Some states/provinces require this information
to be posted on the pump.
The following percentages of oxygenates:
ETHANOL (ethyl or grain alcohol) up to 10% by volume.
You may use gasoline containing up to 10% by volume.
Gasoline containing ethanol may be marked under the
name “Gasohol”
Do not use gasoline containing METHANOL (methyl al-
cohol).
1
21
95
+

Operating instructions
1-3
1-3
When you shift the transmission into gear, apply front
brake to prevent the motorcycle move forward.
Magnetic Stop Switch
1. Shift the transmission into neutral.
2. Pull the stop magnetic switch (red) until the engine
stops completely.
Break-In Procedure
New Motorcycle
Following proper break-in procedure helps ensure that
the most important and expensive components on your
new motorcycle will provide maximum performance and
service life. (Also follow proper break-in procedure for a
newly rebuilt engine.)
When riding a new motorcycle, operate the motorcycle
for the first 20 minutes using not more than half throttle
and shifting gears so that the engine does not lug.
Reconditioned Motorcycle
yAfter replacing the cylinder and crankshaft, operate
the motorcycle for 20 minutes observing the same
cautions as for a new motorcycle.
yWhen the piston, piston ring, gears, etc. are replaced,
they must be broken in observing the first 30 minutes
using not more than half throttle and shifting gears so
that the engine does not lug.
(1) MAGNETIC STOP SWITCH(1) KICKSTARTER PEDAL
Basic Operation
Starting The Engine
!WARNING
Your COTA exhaust contains poisonous carbon mo-
noxide gas. High levels of carbon monoxide can collect
rapidly in enclosed areas such as a garage. Do not run
the engine with the garage door closed. Even with the
door open, run the engine only long enough to move
your COTA out of the garage.
Cold Engine Starting
1. Shift the transmission into neutral.
2. Raise the side stand.
3. With the throttle fully closed, operate the kickstarter.
Starting from the top of the kickstarter stroke, kick
through to the bottom with a rapid, continuous motion.
4. After the engine starts, run it for a few minutes, “blip-
ping” the throttle, until it warms up enough to idle.
NOTICE
Always operate the kickstarter with the throttle fully closed.
(1) SIDE STAND
(2) SIDE STAND SPRINGS
Side Stand
The side stand is used to support your Cota while parked.
To operate, use your foot to lower the side stand until it
is fully extended.
Before riding, raise the side stand.
Inspection
1. Check the stand springs for damage or loss of tension.
2. Check the side stand assembly for freedom of
movement.
If the stand is stiff or squeaks, clean the area around
the pivot and lubricate the pivot bolt with grease or oil
lubricant.
NOTICE
Do not start the motorcycle while supported on the side
stand, which could be bent.
1
2
1
1

Operating instructions
1-4
1-4
Shifting gears
Your Cota has five forward gears in a one-down, four-up
shift pattern.
To start riding, after the engine has been warmed and the
side stand raised.
1. Close the throttle and pull the front brake lever in.
2. Pull the clutch lever all the way in.
3. Depress the shift lever from neutral down to first gear.
4. Release the front brake lever. Gradually open the
throttle while you slowly release the clutch lever. If the
engine (rpm) (speed) is too low when you release the
clutch lever, the engine will stall.
If the engine (rpm) (speed) is too high or you release the
clutch lever too quickly, your Cota may lurch forward.
5. When you attain a moderate speed, close the throttle,
pull the clutch lever in, and raise the shift lever. After
shifting, release the clutch lever and apply the throttle.
6. To continue shifting up to each higher gear, repeat step 5.
7. To shift down to a lower gear, close the throttle, pull
the clutch lever in, and depress the shift lever. After
shifting, release the clutch lever and apply the throttle.
Remember to close the throttle and pull the clutch lever in
completely before shifting.
Braking
To slow or stop, apply the front brake lever and rear brake
pedal smoothly, while downshifting to match your speed.
Gradually increase braking as you feel the brakes slowing
your speed. To prevent stalling the engine, pull the clutch
lever in before coming to a complete stop. For support,
put your left foot down first, then your right foot when
you are through using the rear brake pedal.
For maximum braking, close the throttle and firmly apply
the front brake lever and rear brake pedal controls.
Applying the brakes too hard may cause the wheels to
lock and slide, reducing control of your Cota. If this hap-
pens, release the brake controls, steer straight ahead until
you regain control, then reapply the brakes more gently.
Generally, reduce your speed or complete braking befo-
re beginning a turn. Avoid braking or closing the throttle
quickly while turning. Either action may cause one or both
wheels to slip. Any wheel slip will reduce your control of
your Cota.
When riding in wet or raining conditions, or on loose sur-
faces, the ability to maneuver and stop will be reduced.
All of your actions should be smooth under these condi-
tions. Rapid acceleration, braking, or turning may cause
loss of control. For your safety, exercise extreme caution
when braking, accelerating, or turning.
When descending a long, steep grade, use engine com-
pression braking by downshifting, with intermittent use
of both brakes.
When you brake to a stop, pull the clutch lever in before
stopping completely to prevent stalling the engine. For
support, put your left foot on the ground first, then your
right foot when you have finish braking.
Parking
Lower the side stand to support your Cota.
Always choose a level surface to park.
NOTICE
Improper shifting may damage the engine, transmission,
and drive train.
Learning when to shift gears comes with experience.
Upshift to a higher gear or reduce throttle before engine
(rpm) (speed) gets too high. Downshift to a lower gear
before you feel the engine laboring (lugging) at low (rpm).
NOTICE
Downshifting can help slow your motorcycle, especially
on downhills. However, downshifting when engine (rpm)
is too high can cause engine damage.
NOTICE
To prevent transmission damage, do not coast or tow the
motorcycle for long distances with the engine off.

Clutch Lever
The clutch lever free play can be adjusted by turning the
adjuster.
Free play must be adjusted to provide 0.5 – 1.5 mm
(0.019 – 0.060 in) clearance between the end of the
adjuster and the clutch master cylinder piston.
yTo reduce free play, turn the adjuster clockwise, then
tighten the lock nut securely.
yTo increase free play, turn the adjuster counterclockwi-
se, then tighten the lock nut securely.
If the clutch will not disengage or motorcycle creeps
with clutch disengaged,there is probably air in the clutch
system and it must be bled.
NOTICE
Do not adjust the end of the adjuster and the clutch mas-
ter cylinder piston below 0.5 mm (0.019 in).
(1) ADJUSTER
(2) LOCK NUT
(1) CLUTCH LEVER
(2) FREE PLAY
Clutch Lever Free Play
Standard cluth lever free play should be between
0.5 – 15 mm (0.019 – 0.60 in).
NOTICE
Do not adjust the free play of the lever to less than 5 mm
(0.196 in).
Controls
Clutch
Your COTA has a hydraulically actuated clutch. There are
no adjustments to perform but the clutch system must be
inspected periodically for fluid level and leakage.
If the control lever free play becomes excessive and the
motorcycle creeps or stalls when shifted into gear, or if
the clutch slips, causing acceleration to lag behind engine
speed, there is probably air in the clutch hydraulic system
and it must be bled out.
(1) UPPER LEVEL LINE
Operating instructions
1-5
1-5
1
1
2
2
1

Operating instructions
1-6
1-6
Throttle Grip
Throttle Grip Free Play
Standard throttle grip free play is approximately 3 mm
(0.12 in) of grip rotation.
Adjustment is made with the integral throttle cable
adjuster.
Slide the dust cover off from the integral cable adjuster.
Turning the adjuster in direction “A” will decrease free
play and turning it in direction “B” will increase free play.
Tighten the lock nut after adjustment.
Operate the throttle grip to ensure that it functions
smoothly and returns completely in all steering position.
(1) DUST COVER (A) DECREASE
(2) LOCK NUT (B) INCREASE
(3) ADJUSTER
(1) ADJUSTER
(2) LOCK NUT
Front brake lever
The front brake lever free play can be adjusted by turning
the adjuster.
Free play must be adjusted to provide 0.5 – 1.5 mm
(0.019 – 0.060 in) clearance between the end of the ad-
juster and the front brake master cylinder piston.
yTo reduce free play, turn the adjuster clockwise, then
tighten the lock nut securely.
yTo increase free play, turn the adjuster counterclockwi-
se, then tighten the lock nut securely.
If brake lever feels soft or spongy, there is probably air in
the brake system and it must be bled.
NOTICE
Do not adjust the end of the adjuster and the front brake
master cylinder piston below 0.5 mm (0.019 in).
(1) FRONT BRAKE LEVER
(2) FREE PLAY
Front brake lever free play
Standard front brake lever free play should be
between 0.5 – 15 mm (0.019 – 0.60 in).
NOTICE
Do not adjust the free play of the lever to less than 5 mm
(0.196 in).
2
1
1
2
1
A
B
2
3

Operating instructions
1-7
1-7
(1) LOCK NUT
(2) ADJUSTING BOLT
(A) RAISE THE PEDAL HEIGHT
(B) LOWER THE PEDAL HEIGHT
Brake pedal height
The brake pedal height can be adjusted to the rider’s pre-
ference.
To adjust the rear brake pedal height:
1. Loosen the push rod lock nut and brake pedal adjusting
bolt lock nut. Then turn the both adjusting bolts in
direction “A” to raise the pedal, or in direction “B” to
lower it.
2. Tighten the lock nuts at the desired pedal height.
3. After adjustment, check the brake pedal free play at
the top of the pedal.
Make sure that the clearance between the front adjus-
ting bolt and frame is at least 1 mm (0.04 in).
(1) MODE SWITCH
(2) MODE 1
(3) MODE 2
Mode switch
The ECU for the COTA 301RR PGM-FI electronic injection
system has two operational maps which can be selected
depending on the conditions:
Switch in Mode 1:
Standard
Switch in Mode 2:
Powered
Magnetic stop switch
Pull the stop magnetic switch (red) until the engine stops
completely.
(1) ENGINE STOP BUTTON
1
3
2
1
AA
B
B
1
1
2
3
4

Operating instructions
1-8
1-8
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. Think this though carefully and cut off just a small
amount at a time from both sides equally.
NOTICE
Chamfer the edges to remove burrs and other irregulari-
ties or roughness after shaping.
An alternate handlebar shape, through varying rise or re-
arward sweep dimensions, will provide further adjustment
to riding position and may better suit your particular body
size or riding style. Each of the ergonomic dimensions
of the motorcycle were determined to suit the greatest
possible number of riders based on an average size rider.
(1) HANDLEBAR
1

2. Service data
Specifications
2-1
2-1
Item Specification
Dimensions
Overall length 2,020 mm (79.52 in)
Overall width 840 mm (33.07 in)
Overall height 1,135 mm (44.68 in)
Wheelbase 1,320 mm (51.98 in)
Seat height 677 mm (26.65 in)
Ground clearance 300 mm (11.81 in)
Frame
Type Aluminium twin tube
Front suspension Telescopic
Rear suspension Swingarm PRO-LINK
Front tire MICHELIN TRIAL COMPETITION
(2.75-21 M/C 45L) / (2,75-21 M/C 45M)*
Rear tire MICHELIN TRIAL COMPETITION X11
(4.00 R18 M/C 64L) / (4.00 R18 M/C 64M)*
Front brake, diameter Single disc, 184 mm (7.24 in)
Rear brake, diameter Single disc, 150 mm (5.9 in)
Fuel capacity 2.0 ± 0.2 litres
Caster angle 24º 34’
Trail length 63 mm (2.48 in)
Engine
Type Liquid cooled 4–stroke engine
Cylinder arrangement Single cylinder, 3.5˚inclined from vertical
Bore and stroke 81.5 x 57.2 mm (3.20 x 2.25 in)
Displacement 298 cm3
Compression ratio 10.4 : 1
Valve timing
Intake valve opens
Intake valve closes
Exhaust valve opens
Exhaust valve closes
9˚BTDC
27˚ABDC
37˚BBDC
5˚ATDC
(at 1.0 mm lift)
Lubrication system Forced pressure and wet sump
Starting system Primary kickstarter
Item Specification
Fuel System
Type PGM-FI
Identification number GQPMD
Throttle bore 28 mm (1.10 in)
Drive Train
Clutch operating system Hydraulic operated
Clutch type Wet, multi-plate
Transmission 5 speed constant mesh
Primary reduction 3.167 (57/18T)
Gear ratio 1st 2.800 (42/15T)
2nd 2.385 (31/13T)
3rd 2.000 (30/15T)
4th 1.273 (28/22T)
5th 0.815 (22/27T)
Final reduction 4.100 (41/10T)
Gearshift pattern 1 – N – 2 – 3 – 4 – 5
Electrical
Alternator Triple phase output alternator
Ignition system PGM-IGN
Regulator type SCR shorted/triple phase, full wave rectification
* Minimum speed rating “L”

Service data
2-2
2-2
Service data
Item Specification
Lubrication
Specified engine oil Repsol 4T oil-stroke motorcycle oil SAE 10W-30 or
equivalent
Engine oil capacity
after draining
after oil filter change
after disassembly
0.41 liter (0.43 US qt, 0.36 Imp qt)
0.44 liter (0.46 US qt, 0.39 Imp qt)
0.60 liter (0.63 US qt, 0.53 Imp qt)
Specified transmission oil REPSOL MOTO TRANSMISSION (75W)
ELF HTX740 (75W)
Transmission oil capacity
after draining
after disassembly
0.54 liter (0.57 US qt, 0.48 Imp qt)
0.57 liter (0.60 US qt, 0.50 Imp qt)
Fuel System
Throttle body identification No. GQPMD
Throttle grip free play 3 mm (0.118 in)
Engine idle speed 1,800 ± 100 (rpm)
Fuel pressure 314 - 382 kPa (3,2 - 3,9 kgf/cm2)
Fuel pump flow at 12 V 125 cm3minimum/10 seconds
Injector resistance 11.1 – 12.3 Ω(20˚C/68˚F)
Cooling System
Recommended coolant 50/50 mixture coolant and distilled water
Radiator cap relief pressure 108 kPa (1.1 kgf/cm2)
Presióndealiviotapóndelradiador 108kPa(1,1kgf/cm2)
Unit: mm (in)
Item Standard Service limit
Cylinder Head/Valves
Cylinder compression 189 psi (1,300 kPa, 13.2 kgf/cm2)–
Cylinder head warpage – 0.05 (0.002)
Valve stem O.D. IN
EX
0.12 ± 0.03 (0.005 ± 0.001)
0.30 ± 0.03 (0.012 ± 0.001)
–
–
IX
EX
4.475 – 4.490 (0.1762 – 0.1768)
4.465 – 4.480 (0.1758 – 0.1764)
4.470 (0.1760)
4.460 (0.1756)
Valve guide I.D. IN/EX 4.500 – 4.512 (0.1772 – 0.1776) 4.552 (0.1792)
Valve stem-to-guide clearance IN
EX
0.010 – 0.037 (0.0004 – 0.0015)
0.020 – 0.047 (0.0008 – 0.0019)
–
–
Valve guide projection above
cylinder head IN
EX
8.0 – 8.3 (0.31 – 0.33)
8.2 – 8.5 (0.32 – 0.33)
–
–
Valve spring free length
Inner
Outer
25.41 (1.000)
28.32 (1.115)
24.9 (0.98)
27.6 (1.09)
Rocker arm I.D. 10.000 – 10.015 (0.3937 – 0.3943) 10.051 (0.3957)
Rocker arm shaft O.D. 9.972 – 9.987 (0.3926 – 0.3932) 9.925 (0.3907)
Rocker arm-to-shaft clearance 0.013 – 0.043 (0.0005 – 0.0017) 0.11 (0.04)
Cam lobe height AD
ES
32.011 – 33.051 (1.2603 – 1.3012)
32.855 – 32.935 (1.2935 – 1.2967)
31.871 (1.2548)
32.748 (1.2893)

Service data
2-3
2-3
Item Standard Service limit
Cylinder/Piston
Cylinder I.D
Taper
Out-of- round
Warpage
81.500 – 81.515 (3.2086 – 3.2092)
–
–
–
81.540 (3.2102)
0.05 (0.002)
0.05 (0.002)
0.05 (0.002)
Piston O.D.
Measurement point
Pin bore I.D.
81.470 – 81.480 (3.2074 – 3.2078)
3.0 (0.118) from bottom of skirt
16.006 – 16.010 (0.6301 – 0.6303)
81.440 (3.2062)
–
16,02 (0,6307)
Piston pin O.D. 15.997 – 16.000 (0.6298 – 0.6299) 15.99 (0.6295)
Piston ring
End gap
Top
Second
Oil (side rail)
0.20 – 0.30 (0.008 – 0.0118)
0.35 – 0.50 (0.0137 - 0.0197)
0.20 – 0.70 (0.008 – 0.028)
0.44 (0.0173)
0.64 (0.0251)
0.90 (0.0354)
Ring-to-groove clearance
Top
Second
0.070 – 0.110 (0.028 – 0.0043)
0.020 – 0.060 (0.008 – 0.0236)
0.115 (0.0045)
0.065 (0.0026)
Cylinder-to-piston clearance 0.020 – 0.045 (0.008 – 0.0177) 0.08 (0.003)
Piston-to-piston pin clearance 0.006 – 0.013 (0.0002 – 0.0005) 0.03 (0.0011)
Clutch/Gearshift Linkage
Recommended clutch fluid DOT 4 brake fluid –
Clutch spring free length 27.6 (1.09) 26.8 (1.06)
Clutch disc thickness 3.22 – 3.38 (0.127 – 0.133) 3.15 (0.124)
Clutch plate warpage – 0.10 (0.004)
Clutch slave cylinder I.D. 27.000 – 27.021 (1.0630 – 1.0638) –
Clutch slave piston O.D. 26.940 – 26.960 (1.0606 – 1.0614) –
Kickstarter
Spindle O.D.
Pinion gear I.D.
Idle gear I.D.
Countershaft O.D. at kickstarter idle gear
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)
16.46 (0.648)
16.55 (0.652)
17.06 (0.672)
16.97 (0.668)
Unit: mm (in) Unit: mm (in)
Item Standard Service limit
Crankshaft/Transmission
Crankshaft runout Right
Left
–
–
0.03 (0.001)
0.05 (0.002)
Connecting rod big end
Side clearance
Radial clearance
0.30 – 0.75 (0.012 – 0.030)
0.06 – 0.18 (0.002 – 0.007)
0.8 (0.03)
0.05 (0.002)
Transmission gear I.D. M4
M5
C1
C2
C3
23.020 – 23.041 (0.9063 – 0.9071)
23.020 – 23.041 (0.9063 – 0.9071)
20.020 – 20.041 (0.7882 – 0.7890)
25.020 – 25.041 (0.9850 – 0.9859)
25.020 – 25.041 (0.9850 – 0.9859)
23.07 (0.908)
23.07 (0.908)
20.06 (0.790)
25.06 (0.987)
25.06 (0.987)
Gear bushing D.I. M5
C1
C2
C3
20.000 – 20.021 (0.7866 – 0.7882)
17.000 – 17.018 (0.6693 – 0.6700)
22.000 – 22.021 (0.8661 – 0.8670)
22.000 – 22.021 (0.8661 – 0.8670)
20.05 (0.789)
17.04 (0.671)
22.04 (0.868)
22.04 (0.868)
O.D. M4
M5
C1
C2
C3
22.979 – 23.000 (0.9047 – 0.9055)
22.979 – 23.000 (0.9047 – 0.9055)
19.979 – 20.000 (0.7866 – 0.7874)
24.979 – 25.000 (0.9834 – 0.9843)
24.979 – 25.000 (0.9834 – 0.9843)
22.96 (0.904)
22.96 (0.904)
19.95 (0.785)
24.95 (0.982)
24.95 (0.982)
Countershaft O.D.
at C1 bushing
at C2/C3 bushing
at kickstarter idle gear
16.983 – 16.994 (0.6686 – 0.6691)
21.959 – 21.980 (0.8645 – 0.8654)
16.983 – 16.994 (0.6686 – 0.6691)
16.97 (0.668)
21.94 (0.864)
16.97 (0.668)
Shift fork I.D. C
R, L
11.003 – 11.024 (0.4332 – 0.4330)
12.035 – 12.056 (0.4738 – 0.4746)
11.04 (0.435)
12.07 (0.475)
Shift fork claw thickness C
R, L
4.93 – 5.00 (0.194 – 0.197)
4.93 – 5.00 (0.194 – 0.197)
4.8 (0.19)
4.8 (0.19)
Shift fork shaft O.D. C
R, L
10.983 – 10.994 (0.4324 – 0.4328)
11.966 – 11.984 (0.4711 – 0.4718)
10.97 (0.432)
11.95 (0.470)
Oil pump
Tip clearance
Body clearance
Side clearance
–
0.15 – 0.20 (0.006 – 0.008)
0.05 – 0.12 (0.002 – 0.004)
0.20 (0.008)
–
–