Replica KIT 2020 - The images contained in this document may not correspond to the current model. They are given only to facilitate the ...
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The images contained in this
document may not correspond
to the current model. They
are given only to facilitate the
understanding of the explained
procedure.
Replica KIT 2020
E 2020
PROCEDURE FOR 2020 OPTIONAL PARTS INSTALLATION
AND ELECTRICAL COMPONENTS DISASSEMBLY
! ATTENTION
Part List Catalogue available at
http://motos.honda.es/montesa/manuales-eng.php
(see Part Llist blocks F-25, F-26 Optional parts)
- Remove the rear fender.
Remove the top and side screws and the
fastening screws of the metal support of
the rear light (depending on version).
- Remove the fuel tank.
Remove the upper screw.
Do not lift the tank.
- Remove the fuel injector holder.
2 2008 Montesa Honda, S.A.
E 2020
- Disconnect the injector by pressing the
clips on the sides.
! WARNING
Carefully lift the petrol tank, being careful
not to pull abruptly as the fuel hoses are
connected and could be damaged.
- Remove the engine breather hose from the
cylinder head cover.
- Remove the fuel breather tube from the
lower front of the fuel tank.
- Disconnect the fuel pump black connector
(2P).
- Remove the fuel tank.
2008 Montesa Honda, S.A. 3
E 2020
- Remove the connectors from the protective
cable cover.
- Disconnect the 4P connector (a) from lights
installation.
a
- Disconnect the connector from the taillights c
wire harness (b).
- Remove the license plate holder or the
lower support of the rear fender of the filter b
box (c) (depending on version).
- Loosen the filter casing intake flange.
- Remove and extract the filter casing.
4 2008 Montesa Honda, S.A.
E 2020
- Remove the breather hose from the filter
casing.
- Disconnect the black connector (a) from
the front headlight installation. a b
- Disconnect the white connector (b) from
the headlight switch installation.
- Disconnect the connector (c) from the
speedometer (rear wheel speed sensor).
- Disconnect the malfunction indicator lamp
(MIL) connector.
c
- Disconnect the front brake light cable (d).
- Remove the front brake light switch (e).
d
e
- Cut the cable tie (a).
- Remove the handlebar light switch.
a
2008 Montesa Honda, S.A. 5
E 2020
- Disconnect the front turn signal connectors.
- Remove the two side screws from the
headlight housing.
- Remove the bottom screw from the
headlight housing.
! ATTENTION
Save the screw; it will be used on the new
housing.
- Remove the steering block cylinder
(optional).
- Remove the brake hose from the flange on
the headlight housing.
- Remove the headlight housing.
6 2008 Montesa Honda, S.A.
E 2020
- Loosen the two screws on the upper bridge
and the four screws on the lower bridge of
the fork.
- Move the fork bars down and remove the
headlight housing supports.
- Tech ED/3ED: ED / 3E 2E / 4E
Position the fork sliders (a) on the upper
b d
steering stem (b) so that they are at the level
of the upper bridge.
- Showa 2ED/4ED:
Place the forks legs (c) in the bottom bridge
(d) at the first slot a c
FRONT FRONT
- Tighten the six screws on the fork bridges.
Torque: 21 N•m (2.1 kgf•m)
2008 Montesa Honda, S.A. 7
E 2020 - Remove the gas cable from the gas grip. - Replace the gas cable between the fork bridges. - Reassemble the gas cable in the throttle housing. Replace the cover on the throttle housing. - Remove the clutch lever assembly. 8 2008 Montesa Honda, S.A.
E 2020
- Replace the clutch hose between the fork
bridges, between the gas cable and the
brake hose as shown.
- Reassemble the clutch lever assembly on
the handlebar.
Torque: 5 N•m (0.5 kgf•m)
! WARNING
This set part is not approved to use in public
street roads.
- Attach the metal bracket (61315-REP-J00)
on the bottom of the housing using the
screw (90113-NN4-L80).
- Insert the LED bulb / headlight wire harness
(32101-REP-L30) in the new headlight
housing compartment (61310-REP-P10ZC).
Press down on the bulb until you hear a
click.
- Assemble the Headlight Kit on the COTA.
Use the same screw removed from the
housing.
2008 Montesa Honda, S.A. 9
E 2020
- Attach the headlight housing on the top
using the two cable ties (61312-NN4-D10).
- Fix LED lamp installation with the flange on
the left side (do not stress the installation
between the flange and the lamp).
- Connect the new headlight wire harness to
the connector on the main harness.
- For models with Map Switch, connect the
(a) connector of headlight wire harness to
map switch connector.
- On models that DO NOT mount the Map
a
Switch, connect the plug (32606-GEV-
761)
- Fasten the wire harness on the headlight,
the stop cable and the map cable
(depending on the version) with a cable
tie (61312-NN4-D10) on the left side of the
frame.
10 2008 Montesa Honda, S.A.E 2020
- Disconnect the connectors from the horn
cable.
- Remove the horn.
Tighten the crankcase screw (a) once
again.
Torque: 24 - 30 N • m (2.4 - 3.0 kgf • m)
a
- Disconnect the cable from the rear brake
switch.
- Remove the rear brake switch.
- Remove the speed sensor from the bracket.
- Loosen the flanges on the swingarm and
remove the sensor wire.
- Tighten the flanges, holding the rear brake
hose once again.
- Remove the speed sensor support from
the rear brake caliper.
- Remove the section of the wire harness
that is no longer being used.
- Disconnect the injector connector from the
sub-installation connector.
2008 Montesa Honda, S.A. 11E 2020
- Fit the filter casing.
Torque: 10 - 14 N•m (1,0 - 1,4 kgf•m)
- Connect the breather tube in the filter
casing.
- Tighten the filter casing intake flange.
- Fit the fuel tank.
When fitting the tank, be sure to place
tubes and cables in the right places.
- Connect the fuel pump black connector
2P.
- Fit the engine breather hose to the cylinder
head cover.
- Fit the engine breather hose to the front
lower part of the fuel tank (depending of
the version).
- Position the wires and tubes correctly.
12 2008 Montesa Honda, S.A.E 2020
- Fit the fuel holder (a).
b
Torque: 8 - 12 N•m (0,8 - 1,2 kgf•m)
! ATTENTION
Ensure that the injector O-ring is in the
correct position.
- Fit the injector connector (b).
a
- Fit the rear fender.
Torque: 8 - 12 N•m (0,8 - 1,2 kgf•m)
Front brake hose installation.
- Remove the front brake hose holder.
- Cut the fixation knob (c)
- Drill a hole (using a 3,5 mm drill) at the base
of the holder to fix it with a tie-band.
c
- Place the front brake hose inside the holder
(d) and fix it to left fork with the tie-band
(61312-NN4-D10).
d
2008 Montesa Honda, S.A. 13E 2020
Replica optional parts installation.
a
Exhaust pipe protector installation.
- Replace the exhaust pipe protector with
the new protector (a) (18328-REP-R00).
Torque: 10-12 N•m (1.0-1.2 kgf•m)
Clutch cover protector installation.
- Replace the clutch cover protector with
the new protector (b) (11330-REP-SOL).
Torque: 10-12 N•m (1.0-1.2 kgf•m)
b
Front fork protector installation.
- Install the carbon front fork protector
(53211-REP-SOL) using light pressure.
! ATTENTION
Ensure that the carbon front fork protector
is in the correct side.
The images contained in this document may not correspond to the current model. They are
given only to facilitate the understanding of the explained procedure.
14 2008 Montesa Honda, S.A.You can also read
