Montesa COTA 4RT 260R 2022 User manual

2022
PGM-FI Racing Trial Owner’s Manual

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 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 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
or
NOTE
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.
California Proposition 65 Warning
WARNING: This product contains or emits chemicals known to the State
of California to cause cancer and birth defects or other reproductive harm.
2022
V04

MONTESA COTA 4RT
Owner’s / Service Manual
This manual describes the service procedures for the MRT260 3ED.
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.
3ED shown with accessory headlight

(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 260 N 3ED *VTDNE04C?NE000001* NN4E5209001
11

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
Cold tire pressure (driver only)
Front: 100kpa
Rear: 100kpa
Keep chain adjusted and lubricated
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) 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
5
1

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
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

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.
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 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 Owner’s / Service 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 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).

Operation component locations
1-1
1-1
1. Operating instructions
FRONT BRAKE LEVER
THROTTLE GRIP
SHIFT LEVER
KICKSTARTER
REAR BRAKE PEDAL
CLUTCH LEVER
ENGINE STOP BUTTON
MODE SWITCH

(1) BREATHER HOSE
(2) FUEL TANK CAP
(1) RADIATOR CAP (1) KICKSTARTER PEDAL
Fuel
Gasoline:
Unleaded gasoline (commercially available unleaded;
pump octane number 91 or higher)
Fuel tank capacity:
0.52 US gal (2.0 ± 0.2 liter , 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.
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. Release the side stand all the way.
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.
NOTE
Always operate the kickstarter with the throttle fully closed.
1
2
1
1
Operating instructions
1-2
1-2

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.
When you shift the transmission into gear, apply front
brake to prevent the motorcycle from moving forward.
Stopping The Engine
1. Shift the transmission into neutral.
2. Push the engine stop button until the engine stops
completely.
(1) ENGINE STOP BUTTON (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 side stand springs for damage and loss of
tension.
2. Check the side stand assembly for freedom of
movement.
If the side stand is stiff or squeaky, clean the pivot area
and lubricate the pivot bolt with grease grease or oil lu-
bricant.
NOTICE
Do not start the motorcycle while supported on the side
stand, which could be bent.
Operating instructions
1-3
1-3
2
1
1

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.
Operating instructions
1-4
1-4

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
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).
Operating instructions
1-5
1-5
1
1
2
2
1

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).
1
A
B
2
3
Operating instructions
1-6
1-6
2
1
1
2

Emergency engine stop
To stop the engine in an emergency, push and hold the
engine stop button.
(1) ENGINE STOP BUTTON(1) LOCK NUT
(2) ROD
(3) ADJUSTING BOLT
(4) FREE PLAY
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 4RT260 PGM-FI electronic injec-
tion system has two operational maps (Dry and Wet),
which can be selected depending on the conditions:
Switch in Mode 1:
Dry (appropriate for dry terrain)
Switch in Mode 2:
Wet (appropriate for wet terrain)
Operating instructions
1-7
1-7
11
3
2
AA
B
B
1
1
2
3
4

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
Operating instructions
1-8
1-8
1

Specifications
Item Specification
Dimensions
Overall length 2,020 mm
Overall width 840 mm
Overall height 1,135 mm
Wheelbase 1,320 mm
Seat height 677 mm
Ground clearance 300 mm
Frame
Type Aluminium twin tube
Front suspension Telescopic
Rear suspension Swingarm PRO-LINK
Front tire DUNLOP D803FGP
(80/100-21 M/C 51M)
MICHELIN TRIAL COMPETITION
(2.75-21 M/C 45L) / (2,75-21 M/C 45M)*
Rear tire DUNLOP D803GP
(120/100R18 M/C 68M)
MICHELIN TRIAL COMPETITION X11
(4.00 R18 M/C 64L) / (4.00 R18 M/C 64M)*
Front brake, diameter Single disc, 183 mm
Rear brake, diameter Single disc, 150 mm
Fuel capacity 1.9 litres
Caster angle 24º 34’
Trail length 63 mm
Engine
Type Liquid cooled 4–stroke engine
Cylinder arrangement Single cylinder, 3.5˚inclined from vertical
Bore and stroke 78.0 x 54.2 mm
Displacement 259 cm3
Compression ratio 10.5 : 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 GQPEB
Throttle bore 29.4 mm
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”
2. Service data
2-1
2-1

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 ELF HTX740
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. GQPEB
Throttle grip free play 3 mm (0.1 in)
Engine idle speed 1,800 ± 100 (rpm)
Fuel pressure 314 - 382 kPa (3.2 - 3.9 kgf/cm2) at idle
(3.2 kgf/cm2 - 3.9 kgf/cm2, 45 psi - 55 psi) at idle
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
Unit: mm (in)
Item Standard Service limit
Cylinder Head/Valves
Cylinder compression 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
2-2
2-2

Item Standard Service limit
Cylinder/Piston
Cylinder I.D
Taper
Out-of- round
Warpage
78.000 – 78.015 (3.0709 - 3.0715)
–
–
–
78.04 (3.0724)
0.05 (0.002)
0.05 (0.002)
0.05 (0.002)
Piston O.D.
Measurement point
Pin bore I.D.
77.970 – 77.980 (3.0696 - 3.07008)
5 (0.2) from bottom of skirt
16.002 – 16.008 (0.6300 – 0.6302)
77.89 (3.0665)
–
16.03 (0.631)
Piston pin O.D. 15.994 – 16.000 (0.6297 – 0.6299) 15.98 (0.629)
Piston ring
End gap
Top
Second
Oil (side rail)
0.15 – 0.25 (0.008 - 0.0098425)
0.30 – 0.45 (0.012 - 0.0018)
0.20 – 0.70 (0.008 – 0.028)
0.39 (0.01535)
0.59 (0.02323)
0.90 (0.0354)
Ring-to-groove clearance
Top
Second
0.065 – 0.100 (0.0026 – 0.0039)
0.015 – 0.050 (0.0006 – 0.0020)
0.115 (0.0045)
0.065 (0.0026)
Cylinder-to-piston clearance 0.020 – 0.045 (0.0008 – 0.0018) 0.18 (0.007)
Piston-to-piston pin clearance 0.002 – 0.014 (0.0001 – 0.0006) 0.04 (0.002)
Connecting rod small end I.D. 16.016 – 16.034 (0.6305 – 0.6313) 16.04 (0.631)
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)
–
–
Service data
2-3
2-3