Montesa Cota 349 Service Manual
Installation To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. (00251a) 1 WARNING 1 WARNING ® Kit Numbers 41279-04, 41282-04, 41463-05, 41467-05, 41633-05, 41634-05, 41640-05, and 41639-05 1 of 3 Figure 1.
Motorcycle, Vintage, Mailorder, Montesa, Spanish. Number Produced. Aug 9, 2009 - montesa 315r parts manual - wordpress - montesa 315r parts manual. Wordpress - montesa 348 parts manual montesa cota 349 workshop.
Rear Wheel Removal i02495 1. Axle (keep) 2.
Axle adjuster (keep) 3. Axle nut (keep) 4.
Montesa Cota 348 Service Manual
“E”-clip (keep) 5. Spacer (3) (keep) 6.
Torx screw (5) (replace) 7. Brake disc (keep) 8.
Wheel assembly (replace) 9. Valve cap (keep) 10. Compensator bowl (keep) 11. Compensator cushion (keep) 12.12 pt screw (5) (keep) 13. Lockwasher (5) (keep) 14. Sprocket assembly (keep) 1. Refer to the Service Manual and follow the MAXI-FUSE instructions to remove the right-side cover and maxi- fuse.
Proceed to Step 2 for the wheel being replaced. Rear Wheel 2. See Figure 1. Remove the rear wheel per the REAR WHEEL, REMOVAL instructions in the Service Manual. Disassemble, clean and inspect all parts to be re-used per Service Manual instructions. Re-assemble all saved components to the new chrome rear wheel assembly.
See REAR WHEEL, ASSEMBLY in the Service Manual. Do not re-use brake disc screws. Re-using disc screws can result in torque loss and damage to rotor and/or brake assembly. Fasten the brake disc to the valve stem side of the wheel using the Torx®screws from the kit.
Install the compensator bowl with the 12-point screws and lockwashers saved earlier. Install the new wheel to the rear fork. Refer to REAR WHEEL, INSTALLATION in the Service Manual. Proceed to Step 7. Front Wheel 2.
See Figure 2. Remove the front wheel per the FRONT WHEEL, REMOVAL instructions in the Service Manual. Disassemble, clean and inspect all parts to be re-used per Service Manual instructions. Mark the left and right brake discs so they can be re-installed to the same location.
Re-assemble all saved components to the new chrome front wheel assembly. See FRONT WHEEL, ASSEMBLY in the Service Manual.
Do not re-use brake disc screws. Re-using disc screws can result in torque loss and damage to rotor and/or brake assembly. Using the Torx ® shoulder bolts from the kit, and the saved spring washers fasten the brake discs to the same side of the wheel from which they were removed.
Install the new wheel to the front forks per the FRONT WHEEL, INSTALLATION instructions in the Service Manual. Proceed to Step 7. Front and Rear Wheels 7. Refer to the Service Manual and follow the MAXI-FUSE instructions to replace the maxi-fuse and right-side cover. After servicing brakes and before moving motorcycle, pump brakes to build brake system pressure. Insufficient pressure can adversely affect brake performance, which could result in death or serious injury. (00279a) After servicing the brake system, test brakes at low speed.
If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or serious injury. (00289a) Maintenance and Cleaning Chrome parts must be maintained regularly to ensure that they keep their original shine and luster. Clean heavily-soiled wheel surfaces using Harley Wheel and Tire Cleaner, part number 94658-98, applied with Harley Wheel and Spoke Brush, part number 43078-99. Thoroughly clean chrome with a good quality chrome cleaner, such as Harley Bright Chrome Cleaner, part number 94683-99. After cleaning and polishing, seal the finish with a good quality sealer such as Harley Glaze Polish and Sealant, part number 99701-84 Incoming search terms:.
Additional Parts Required This kit includes the custom wheel only. Once you have found al1 the identification nurnbers, record thern for reference when nbuying parts. Since the rnanufacturers change specifications, parts and vendors (cornpanies that rnanufacture various cornponents on the rnachine), providing the ID nurnbers is the only av to be reasonablv sure that vou are buvina Model, c d e and production year CBR400RR-J (1988) CBR400RR-K (1 989) CBR400RR-L (t990 and 91) CBR400RR-N (1992 and 93) CBR400RR-R (1 994-on), the correct parts. Whenever possible, take the worn pari to the dealer so direct cornparison with the new cornponent can be rnade.
Along the trail frorn the rnanufacturer to the parts shelf, there are nurnerous places that the part can end up with the wrong nurnber or be listed incorrectly. The two places to purchase new parts for your rnotorcycle – the accessory shop and the rnotorcycle dealer – differ in the type of parts they carry.
While dealers can obtain virtually every part for your rnotorcycle, the accessory shop is usually lirnited to norrnal high wear iterns such as shock absorbers, tune-up parts, various engine gaskets, cables, chains, brake parts, etc. Rarely will an accessory outlet have rnajor suspension cornponents, cylinders, transrnission gears, or cases. Used parts can be obtained for roughly half the price of new ones, but you can’t always be sure of what you’re getting. Once again, take your worn part to the breaker for direct cornparison. Whetherhung new, used or rebuilt parts, the best course is to dea1 directly with sorneone who specialises in parts for your particular rnake.
Frame nwnber NC t0 1036454 NC23 t090001 t0 10981 16 NC to 101 0598 NC on NC29-l t00001 on Unofficial (grey) imports All CBR400RR rnodels in the LIK are unofficial (grey) irnports frorn Japan. The rnajority are second-hand rnachines and are allocated age-related licence plates for UK use (the licence plate letter reflects the production year in Japan), although new CBRs are allocated current year UK registration letter plates.
Cornrnon changes rnade prior to sale in the UK are the disabling of the rev-lirniter device (or more correctly ‘speed-lirniter’ device), which is fitted to cornply with Japanese rnarket regulations. The device is located inthe speedorneter head and is linked to th Incoming search terms:. CHROME 1.25 INCH (31.75 MM) DIAMETER HANDLEBAR KIT GENERAL Kit Number 56032-08 Models For model fitment information, see the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only). This kit does not fit models equipped with a hydraulic clutch, handlebar mounted gauges or the Road Tech® Radio. Additional Parts or Accessories Required Separate purchase of additional parts or accessories is required for proper installation of this Handlebar Kit on this model motorcycle. Please see the P&A retail catalog or the Parts and Accessories section of for a list of required parts or accessories for this model.
For Australia, Brazil, England, Europe and Japan, two special screws (Part Number 2935A) will also be required. Tools and Supplies Required Loctite® 271 Threadlocker and Sealant – Red (H-D Part Number 99671-97) is required for the proper installation of this kit. Fresh, uncontaminated DOT 4 brake fluid from a sealed container will also be needed. Replace brake line gaskets. Re-using original gaskets can cause brake failure and loss of vehicle control, which could result in death or serious injury. (00318a) For models that retain the original brake line, the two brake- line gaskets found at each banjo fitting must be replaced.
Refer to the appropriate parts catalog or see a Harley-Davidson dealer for the correct part numbers. Motorcycles equipped with a glued left-side hand grip will also require a new grip, sold separately. Refer to the parts catalog for replacement stock hand grips. Ask a Harley-Davidson dealer about the selection of Genuine Motor Accessory hand grips that are available. The rider’s safety depends upon the correct installation of this kit. Use the appropriate service manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation.
Improper installation of this kit could result in death or serious injury. (00333a) NOTE This instruction sheet references service manual information. A service manual for this year and model motorcycle is required for this installation and is available from a Harley-Davidson dealer. Kit Contents See Figure 6 and Table 1.
INSTALLATION Preparation To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. Refer to the service manual and follow the instructions given to remove the seat and disconnect the battery cables, negative cable first.
Retain all seat mounting hardware. Direct contact of D.O.T. 4 brake fluid with eyes can cause irritation.
Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 4 brake fluid can cause digestive discomfort.
If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN.
(00240a) D.O.T. 4 brake fluid will damage painted and body panel surfaces it comes in contact with.
Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage. (00239b) NOTE Immediately wipe up any brake fluid spillage with a clean, dry, soft cloth. Follow up by thoroughly wiping affected area with a clean, damp, soft cloth (small spills) or washing with a large quantity of soapy water (large spills) Incoming search terms:.
INSTALLATION 1. Remove existing front wheel assembly. Save axle, axle nut, brake disc, and wheel spacers for kit installation. Refer to FRONT WHEEL in service manual.
For FLSTC and FLSTN models: Discard moon-style hub cap. Do not re-use brake disc screws. Re-using disc screws can result in torque loss and damage to rotor and/or brake assembly. See Figure 1. Install valve stem assembly (D) on wheel. Refer to TIRES in service manual.
Assemble wheel installation kit components and brake disc(s) to wheel, using the appropriate service parts table. Refer to FRONT WHEEL in service manual. NOTES Install the primary bearing first with the WHEEL BEARING REMOVER/INSTALLER, following the service manual instructions. The machined grooves in the hub face indicate the primary bearing side. The front wheel should be installed so that the valve stem is on the right side of the motorcycle.
Install wheel assembly parts from the appropriate service parts table for your fitment and stock brake disc(s). Discard parts from the installation kit that are not required. Refer to FRONT WHEEL in service manual. For FLSTC and FLSTN Models: Install wheel kit and right side wheel spacer provided in kit installation. All other models: Install wheel spacers previously removed.
Install front wheel (1), stock axle and stock axle nut. Refer to FRONT WHEEL in service manual. For 2009-Later TLE/U Sidecars: Assemble the sidecar brake disc and hub cap (purchased separately) to the wheel.
The brake disc is to be installed on the side of the wheel opposite the valve stem. Install wheel according to the sidecar service manual. REMOVAL Prepare for Service 1. Position motorcycle on a suitable lift. NOTE If vehicle is equipped with Harley-Davidson Smart Security System, see owner’s manual for instructions to disarm the system. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding.
Disconnect battery cables, negative (-) battery cable first. Remove seat according to the instructions in the service manual. Refer to service manual to remove left saddlebag and side cover. When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury.
Remove fuel tank according to the instructions in the service manual. Remove Engine Components 1. Remove existing air cleaner assembly.
Discard backplate but save remaining parts. Refer to AIR CLEANER REMOVAL in service manual. Remove existing exhaust system. Refer to EXHAUST SYSTEM REMOVAL in service manual. Remove engine from chassis following the instructions in the service manual.
Disassemble engine top end and bottom end. Refer to appropriate ENGINE sections in service manual. Remove existing clutch diaphragm spring. Refer to CLUTCH REMOVAL in service manual. The procedures in this instruction sheet should be performed by one experienced in precision measuring techniques.
Failure to meet tolerances called for in this instruction sheet can result in engine damage. (00511b) -J04793 1 2 is03517 1. O-ring counterbore 2. Spigot bore Figure 1. Spigot Bore and O-Ring Counterbore Dimensions Table 1.
Spigot Bore and O-Ring Counterbore Dimensions Depth Bore Description 1.625 +/- 0.010 in. (41.3 +/- 0.25 mm) 4.205 +/- 0.010 in.
(107 +/- 0.25 mm) Spigot Bore 0.085 +/- 0.003 in. (2.16 +/- 0.08 mm) 4.415 +/- 0.002 in.
(112 +/- 0.05 mm) O-Ring Counter- bore is03456 Figure 2. Cylinder Wall MACHINE CRANKCASE Crankcase Boring Preparation NOTE During final assembly of the engine, Harley-Davidson recommends replacing the OE cylinder studs with Screamin’ Eagle High Tensile Studs (16505-01). Remove cylinder studs from the engine crankcase. Mask off all bearings and oil holes to prevent debris and contaminants from entering those areas.
Inspect and clean engine case mating surfaces. See Figure 6. Reassemble engine case with OE screws, except the top center screw between the cylinders, and tighten to specifications listed in service manual. NOTE To prevent damage to crankcase boring tool, it is important to replace the top center screw with a modified top center screw (1093). This screw is included in the Crankcase Boring Tool Kit (94419-06) and can be purchased separately from a Harley- Davidson dealer. Install modified top center screw (1093) between the cylinders and tighten to 50-90 in-lbs (5.6-10.2 Nm).
See Figure 1 and Table 1. Machine crankcase cylinder spigot bore and O-ring counterbore to the dimensions shown. Modify Crankcase Incoming search terms:. Cover the throttle bodies to prevent anything from dropping into the engine. Remove the front seat and disconnect the battery. (Refer to Service Manual, Page 8-8) 2.
Lift up the fuel tank. (Refer to Service Manual, Page 5-3) 3. Remove the air cleaner box. (Refer to Service Manual, Page 5-14) 4. Remove and replace the ISC valve.
(Refer to Service Manual, Page 5-25) NOTE: Since the ECM is also being replaced there is no need to perform the ISC valve preset operation. Install the air cleaner box in reverse order of removal.
(Refer to Service Manual, Page 5-14) 6. Lower the fuel tank. (Refer to Service Manual, Page 5-3) 7. Remove the upper seat rail plate. Disconnect and remove the ECM.
(Figure 1) @ ISC Valve Mounting Screw Torque: 2.1± ±0.6 N.m (1.5± ±0.4 lb-ft)! Carefully insert the ISC valve straight into the throttle body hole to prevent damaging the o-ring. Turn the ISC valve slightly to confirm that the o-ring has not twisted. Using the new screw provided in the replacement parts kit, make sure the screw is completely seated on the plate after the screw has been tightened to the specified torque. Remove and replace the ISC valve. (Refer to Service Manual, Page 5-25) NOTE: Since the ECM is also being replaced there is no need to perform the ISC valve preset operation.! Cover the throttle bodies to prevent anything from dropping into the engine.
Remove the front seat and disconnect the battery. (Refer to Service Manual, Page 8-8) 2.
Lift up the fuel tank. (Refer to Service Manual, Page 5-3) 3. Remove the air cleaner box. (Refer to Service Manual, Page 5-14) REPLACEMENT PROCEDURE: 8.
Install the new ECM in reverse order of removal. Apply thread lock to the upper plate mounting bolts when reinstalling the upper seat rail plate. Incoming search terms:. Installation of any parts should be performed by a qualified, trained mechanic. All parts included in the Rocker Boards™Conversion Kit are intended to be used as sold. Modification of any part will void all warranties. Installation should be performed on a motorcycle that is completely cool to avoid burns or other injuries.
Refer to a specific authorized Harley-Davidson service manual for correct disassembly and reassembly procedures for any parts that need to be removed to facilitate installation. Motorcycle exhaust fumes are toxic and poisonous and must not be inhaled. Always run motorcycle in a well-ventilated area.
Do not perform any installation steps under the influence of alcohol, drugs, or if feeling fatigued. Warranty Briggs Made Cycle Parts, Inc. Rocker Boards™and all parts included in the conversion kit are warranted to the original purchaser to be free of manufacturing defects in materials and workmanship for a period of one (1) year from the original date of purchase. Any part that fails to conform to these conditions, will be repaired or replaced at the discretion of Briggs Made Cycle Parts, Inc. Upon receipt of the defective part within the one year warranty period. In the event a part has been rendered defective, Briggs Made Cycle Parts, Inc. Must be notified prior to the return of the defective part.
Briggs Made Cycle Parts, Inc. Will not be liable for any consequential or incidental damages resulting from the failure of any part, the breach of any warranties, the failure to deliver, delay in delivery or any other breach of duty between Briggs Made Cycle Parts, Inc. And a customer. Remove existing front wheel assembly. Save axle, axle nut, brake disc, and wheel spacers for kit installation. Refer to FRONT WHEEL in service manual.
For FLSTC and FLSTN Models: Discard moon-style hub cap.J04065 1 of 8 For FXSTD Models: Discard the tapered r ight side wheel spacer. Do not re-use brake disc/rotor screws. Re-using these screws can result in torque loss and damage to brake components. (00319c) NOTE. For Kits 43573-08, 43575-08, 43703-08, 43978-07, 43771- 07, 43609-07, 44323-07, 44282-07, 44322-07, 43975-07, 43602-07 and 43773-07 install short valve stem (43157- 83A) included in the installation kit. For Kits 40943-09, 40966-09 and 40996-09 install long valve stem (43206-01) included in the installation kit.
See Figure 2. Install valve stem assembly (L, M or N) on wheel. Refer to TIRES in service manual. Assemble wheel installation kit components and brake disc(s) to wheel, using the appropriate service parts table. Refer to FRONT WHEEL in Service Manual. NOTES Install the primary bearing first using appropriate service manual and WHEEL BEARING REMOVER/INSTALLER.
For Kits 43573-08, 43575-08, 43703-08, 43978-07, 43771-07, 43609-07, 40943-09, 40966-09 and 40996-09:. The left side of the wheel has a machined groove (item 5, Figure 2) in the hub face and/or DOT markings to identify it as the brake disc and primary bearing side. Install the wheel so that the valve stem is on the right side of the motorcycle. For Kits 44323-07, 44322-07 and 44282-07:. Install the wheel so that the hub markings are on the left side of the motorcycle.
The left side of the wheel has a machined groove (item 5, Figure 2) in the hub face and hub markings to identify it as the primary bearing side. These kits include one or two hub plates (43985-00) to install between the brake disc and the wheel and a chrome hub cap (43986-00) to install on the wheel opposite the brake disc side. Hub covers must be installed to prevent water intrusion, which could cause an imbalance condition. Dual brake disc models: Install one stainless steel hub plate (3) between each brake disc and wheel hub. Discard chrome hub cap (2). Install brake discs according to service manual procedures.
Single brake disc models: Install one stainless steel hub plate (3) between the brake disc and wheel hub. Install the brake disc according to service manual procedures. Install the chrome hub cap (2) on the side opposite the brake disc. Discard extra stainless steel hub plate (3). The gross axle weight ratings is unaffected by the installation of this wheel on a vehicle equipped with a 21-inch wheel.
For Kits 43975-07, 43773-07, and 43602-07:. The wheel has a machined groove (item 5, Figure 2) in the hub face to identify the right side. For 2007 and later FX Softail Models and 2008 and later FXDWG: The left side of the wheel is the primary bearing side. For all other models the right side of the wheel is the primary bearing side. For Kit 43602-07: An arrow is engraved into the right side hub to indicate the direction of rotation. For Kits 43975-07 and 43773-07: An arrow is cast between the spokes on the right side to indicate the direction of rotation.
These kits include one or two hub plates (43985-00) to install between the brake disc and the wheel and a chrome hub cap (43986-00) to install on the wheel opposite the brake-disc side. Hub covers must be installed to prevent water intrusion, which could cause an imbalance condition. Dual brake disc models: Install one stainless steel hub plate (3) between each brake disc and wheel hub. Discard chrome hub cap (2). Install brake discs according to service manual procedures. Single brake disc models: Install one stainless steel hub plate (3) between the brake disc and wheel hub.
Install the brake disc according to service manual procedures. Install the chrome hub cap (2) on the side opposite the brake disc. Discard extra stainless steel hub plate (3).
Montesa Cota 349 Workshop Manual
Install wheel assembly parts from the appropriate Service Parts table for this fitment and stock brake disc. Discard parts from the installation kit that are not required. Refer to FRONT WHEEL in Service Manual. For FLSTC and FLSTN Models: Install wheel kit and right side wheel spacer provided in installation kit. For FXSTD Models: Install wheel kit, stock left wheel spacer and right side wheel spacer from installation kit in place of the tapered right side wheel spacer discarded in Step 1. Refer to FRONT WHEEL in service manual. For FXSTS Models: Install the left side wheel spacer provided in the kit between the stock left wheel spacer and the left fork.
All other models: Install wheel spacers previously removed. Install front wheel (1), stock axle and stock axle nut. Refer to FRONT WHEEL in service manual Incoming search terms:. This instruction sheet references service manual information. A service manual for your model motorcycle is required for this installation and is available from a Harley-Davidson dealer. Kit Contents See Figure 1 and Service Parts Tables.
INSTALLATION 1. Remove existing rear wheel assembly. Save axle, axle nut, brake disc and wheel spacers for kit installation. Refer to the service manual. NOTES Prior to removing or installing the wheel, the rear brake caliper must be removed. The cotter pin or spring clip for the axle nut must be replaced. They are available for purchase from you dealer.
See your dealer for the correct part number for your model motorcycle. Do not re-use brake disc screws. Re-using disc screws can result in torque loss and damage to rotor and/or brake assembly. (00319b) Do not re-use sprocket mounting screws.
Re-using sprocket mounting screws can result in torque loss and damage to the sprocket and/or belt assembly. See Figure 1. Install valve stem assembly (E) on wheel. Refer to the service manual. Assemble wheel installation kit components, stock brake disc, and sprocket to wheel using the appropriate service parts table. Refer to the service manual. NOTES Install the primary bearing first using appropriate service manual and WHEEL BEARING REMOVER/INSTALLER.
Montesa Cota Parts
The machined grooves in the hub face indicate the primary bearing side. Install rear wheel (1), stock axle and stock spacers to motorcycle.
Refer to the service manual. MAINTENANCE AND CLEANING Chrome parts must be maintained regularly to keep their original shine and luster. Clean heavily-soiled wheel surfaces using Harley-Davidson Wheel and Tire Cleaner, applied with Harley Wheel and Spoke Brush. Thoroughly clean chrome with a good quality chrome cleaner, such as Harley Bright Chrome Cleaner. After cleaning and polishing, seal the finish with a good quality sealer, such as Harley Glaze Polish and Sealant Incoming search terms:.
Model Year C.C.