Montesa COTA 4RT 2005 User manual

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 4RT. 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 mean:
You WILL be KILLED or SERIOUSLY HURT if you
don’t follow instructions.
You CAN be KILLED or SERIOUSLY HURT if you
don’t follow instructions.
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:
Your COTA 4RT 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 4RT,
other property, or the environment.
NOTICE

!DANGER

!WARNING

!CAUTION

MONTESA COTA 4RT
Owner’s Manual
All information in this publication is based on the latest product information available at the time of approval for printing.
MONTESA HONDA, S.A. 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.

Contents
1. Operating Instruction
Fuel 1-1
Coolant 1-1
Basic Operation 1-1
Operating Mode 1-2
Controls 1-3
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 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 Line Inspection 4-4
Fuel Tank/Fuel Pump 4-6
Injector 4-9
Throttle Body 4-10
Water Seal And Bearing Replacement 4-12
Radiator Removal/Installation 4-14
Engine Removal/Installation 4-15
Cylinder Compression 4-17
Cylinder Head Cover/Camshaft Removal 4-17
Cylinder Head Removal 4-20
Cylinder Head Disassembly 4-22
Cylinder Head Inspection 4-23
Valve Guide Replacement 4-24
Valve Seat Inspection/Refacing 4-25
Cylinder Head Assembly 4-28
Cylinder/Piston 4-29
Cylinder Head Installation 4-34
Camshaft/Cylinder Head Cover Installation 4-35
Right Crankcase Cover 4-37
Clutch Slave Cylinder 4-38
Clutch 4-40
Kickstarter 4-43
Gearshift Linkage 4-44
Left Crankcase Cover 4-46
Flywheel 4-49
Crankcase Separation/Disassembly 4-51
Crankshaft/Transmission Inspection 4-53
Crankcase Bearing Replacement 4-54
Transmission Assembly 4-55
Crankcase Combination 4-56
5. Frame Servicing
Front Wheel 5-1
Fork 5-3
Steering Stem 5-12
Rear Wheel 5-15
Shock Absorber 5-16
Shock Linkage 5-18
Swingarm 5-19
Brake Pad Replacement 5-23
Front Brake Caliper 5-24
Rear Brake Caliper 5-25
Front Master Cylinder 5-26
Rear Master Cylinder 5-27
Brake Pedal 5-27
Clutch Master Cylinder 5-28
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 Diagrams 6-11

To The New Owner
By selecting a MONTESA COTA 4RT 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.
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
(see page 3-2).
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.

Memo

1. Operating Instructions
1-1
(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 liter (0.53 US gal, 0.44 Imp gal)
Disconnect the fuel tank breather hose clamp from the
clutch hose.
Turn the fuel tank cap counterclockwise, then remove the
cap.
Gasoline is highly flammable and is explosive.
You can be burned or seriously injured when
refueling.
•Stop engine and keep heat, sparks, and flame
away.
•Refuel only outdoors.
•Wipe up spills immediately.
Install the fuel tank cap by turning it clockwise.
Install the breather hose clamp onto the clutch hose.
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
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.
When filling the coolant system, be sure to bleed air
completely. If not, the system cannot be sufficiently filled
and will cause overheating.
(1)
Basic Operation
Starting The Engine
Your COTA exhaust contains poisonous carbon
monoxide 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. 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.
3. After the engine starts, run it for a few minutes,
“blipping” the throttle, until it warms up enough to
idle.
Do not start the engine with the transmission into gear
while squeezing the clutch lever, so the motorcycle will
move forward.
(1) KICKSTARTER PEDAL
(1)
NOTICE
NOTICE

!WARNING

!WARNING
(1)
(2)

Operating Instructions
1-2
(1) ENGINE STOP BUTTON
When you shift the transmission into gear, apply front
brake to prevent the motorcycle move forward.
Stopping The Engine
1. Shift the transmission into neutral.
2. Push the engine stop button 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
•After replacing the cylinder and crankshaft, operate
the motorcycle 20 minutes observing the same
cautions as for a new motorcycle.
•When 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)

(1) UPPER LEVEL LINE (1) ADJUSTER (2) LOCK NUT (1) DUST COVER (2) LOCK NUT (3) ADJUSTER
(A) DECREASE (B) INCREASE
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.
Clutch Lever
The clutch lever free play can be adjusted by turning the
adjuster.
Free play must be adjusted to provide 0.1 – 1.4 mm
(0.004 – 0.055 in) clearance between the end of the
adjuster and the clutch master cylinder piston.
To increase free play, turn the adjuster clockwise, then
tighten the lock nut securely.
If the clutch lever free play exceeds 30 mm (1.2 in) even
though the end of the adjuster and the clutch master
cylinder piston is adjusted to the minimum of 0.1 mm
(0.004 in), there is probably air in the clutch system and
it must be bled.
Do not adjust the end of the adjuster and the clutch
master cylinder piston below 0.1 mm (0.004 in).
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.
Operating Instructions
1-3
(1)
(2)
(1)
(1)
(3)
(2)
(A)
(B)
NOTICE

Operating Instructions
1-4
(1) LOCK NUT (2) ADJUSTING BOLT
(A) RAISE THE PEDAL HEIGHT
(B) LOWER THE PEDAL HEIGHT
(1) HANDLEBAR
Brake Pedal Height
The brake pedal height can be adjusted to the rider’s
preference.
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
adjusting bolt and frame is at least 1 mm (0.04 in).
Handlebar Position, Width And Shape
Position the handlebar so that gripping the bar and
operating 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
preference. Think this though carefully and cut off just a
small amount at a time from both side equally. It is
obviously much easier to make the handlebar narrower
than it is to add material.
Chamfer the edges to remove burrs and other
irregularities or roughness after shaping.
An alternate handlebar shape. through varying rise or
rearward 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)
(2)
(B)
(1)
Front Brake Lever
The front brake lever free play can be adjusted by
turning the adjuster.
Free play must be adjusted to provide 0.1 – 1.4 mm
(0.004 – 0.055 in) clearance between the end of the
adjuster and the front brake master cylinder piston.
To increase free play, turn the adjuster clockwise, then
tighten the lock nut securely.
If the brake lever free play exceeds 30 mm (1.2 in) even
though the end of the adjuster and the front brake
master cylinder piston is adjusted to the minimum of 0.1
mm (0.004 in), there is probably air in the brake system
and it must be bled.
Do not adjust the end of the adjuster and the front brake
master cylinder piston below 0.1 mm (0.004 in).
(1) ADJUSTER (2) LOCK NUT
(1)
(2)
(A)
(B)
(A)
(2)
(1)
NOTICE
NOTICE