Montesa COTA 301RR 2023 User manual

PGM-FI Racing Trial Owner’s Manual
2023

Important
This motorcycle is designed and constructed as an operator-only model. The motorcycle load limit and seating configuration do not safety permit the carrying
of a passenger.
Read this manual carefully.
This manual should be considered as 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
V02

MONTESA COTA 301RR
Owner’s Manual
The following diagram shows the 4 different versions of the COTA 301RR model:
(ED) Street version, COTA 301RR (2ED) Street version, COTA 301RR RACE REPLICA
(3ED) Racing version, COTA 301RR (4ED) Racing version, COTA 301RR RACE REPLICA.
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.

(1) FRAME NUMBER (1) ENGINE NUMBER
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 ED/2ED VTDND15B?PE000001 NN4E7100001
MRT 300 P 3ED VTDNE05C?PE000001 NN4E7100001
MRT 300 P 4ED VTDNE053?PE000001 NN4E7100001
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 Tire information (ED/2ED)
Cold tire pressure (driver only)
Front: 100kpa
Rear: 100kpa
Keep chain adjusted and lubricated (ED)
25-35 Mm (1.0 -1.4 In)
Read owners manual
Keep chain adjusted and lubricated (3ED/4ED)
25-35 Mm (1.0 -1.4 In)
Read owners 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) 7% 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 1.1 Kgf/cm2.
4 Safety label (3ED/4ED)
(*) Depending on the final destination of the motorcycle
5 CE / UK CA label (3ED/4ED)
6EU Authorised Representative:
Honda Motor Europe Ltd.
- Aalst Office
Wijngaardveld 1 (Noord V)
9300 Aalst- Belgium
MADE IN SPAIN
Authorised Representative label (ED/2ED)
7UK Importer:
Honda Motor Europe Ltd.
Cain Road
Bracknell, RG12 1HL
United Kingdom
UK Importer label (3ED/4ED)

Labels (ED/2ED)
3
2
1
6

Labels (3ED/4ED)
42
1
7
3
5

7
7
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, and 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, Orings, and 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 (ED/2ED)......... 1-1
Operation component locations (3ED/4ED)....... 1-2
Fuel ............................................................ 1-3
Coolant ....................................................... 1-3
Basic Operation ............................................ 1-3
Odometer/Speedometer (ED/2ED) ................... 1-5
Steering lock (ED/2ED) .................................. 1-7
Shifting gears .............................................. 1-7
Parking........................................................ 1-8
Braking ....................................................... 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 (ED/2ED) ................. 2-11
Cable & Harness Routing (3ED/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 .................................................. 5-14
Shock Absorber............................................ 5-16
Shock Linkage.............................................. 5-19
Swingarm.................................................... 5-20
Front Brake Pad Replacement......................... 5-23
Front brake caliper ........................................ 5-25
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. ......................................... 6-9
Bank angle sensor inspection ......................... 6-10
Magnetic engine stop switch inspection .......... 6-11
Cooling fan system inspection........................ 6-11
Chapter lights / instruments / switches
(ED/2ED) ..................................................... 6-12
Speed sensor (ED/2ED) ................................. 6-16
Horn (ED/2ED) ............................................. 6-17
Wiring diagram (ED/2ED) ............................... 6-18
Wiring diagram (3ED/4ED) ............................. 6-19
7. Manufacturer and authorized representative
for the European and UK markets
Manufacturer ............................................... 7-1
Authorized Representative European market (ED) 7-1
Authorized Representative United Kingdom ...... 7-1
CE Declaration of conformity ......................... 7-3
UK CA Declaration of conformity.................... 7-5

How To Use This Manual
The purpose of this Owner’s 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 in 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.
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).
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 Manual is to help ensure that you
obtain the greatest possible satisfaction from your new
COTA trialer.
Start-up recommendations
Adjusting the idle
If using your motorcycle at different heights, 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 1-3).