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, Special .............................................. 2-7
Tools, 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
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 diagram ............................................. 6-10
Cota 300RR (MRT300RR)
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