Set-UD instru

2006 Montesa Honda, S A

9 9 M t W 6 - December 2005

FOR YOUR CUS I OMI-R'S SAI-t I Y

P r o ~ e set-UD and re-deliverv service are essential t o rider safetv and the rebabilitv of the machine. r

Improper set-up or pre-delivery service can

FOR YOUR SAFETY

precautions in this

several ~ o t e n t i a lhazards:

ss the instruction tells y o u t o do so.

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2006 Montesa Honda, S.A.

How l o Use l h ~ s Manual

Modifications and Accessories

or for personal injuries resulting from the modification of said Honda product. Throughout this manual, the following ab

2005 Montesa Honda, S.A.

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SET-UP AND PRE-DELIVERY SERVICE

p i G i q
Take every precaution when removing the Some parts may differ in shape from those illustrated according to market differences.

that it is functioning properly.

uence number ([I I [21...). Install or remove the loose parts

l any all loose parts w i t h the Parts List in the manual.

: Work sequence number : Size of bolt, screw or nut, and torque value : These numbers represent FINGER TIGHT sequence.

ground represent

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2006 Montesa Honda, S.A.

STANDARD
FASTENERS TYPE 5 mm hex bolt and nut 6 mm hex bolt and nut 8 mm hex bolt and nut 10 mm hex bolt and nut 12 mm hex bolt and nut 5 mm screw 6 rnm screw T

torque values listed above.

NOTE:
1. 2.
Apply sealant t o the threads. Apply a locking agent t o the threads.

To: Honda Dealerships

I for the tasks that are not described in this manual.

ore
ing the Motorcycle

Place the cardboard packaging on a flat surface where there is no risk of it slipping.

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2006 Montesa Honda, S.A.

Description

Qty. 1 2

Reference 30432-MBWD20 53105-MCSG00

n
4 d

I
1 1 1 1 1 1 1 1 1 1 1 4 4 4 4 2

64121-MEW920 64122-MEW920 64131-MEW920 64132-MEW920 64502-MEW920 64503-MEW920 64504-M EWWO 64505-MEW920 83642-MBLD60 88110-MEW921 88120-MEW921 90116-MEW920 90117-MEW920 90130-MEE000 90148-SA0000 90191-MEW920

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Place the motorcycle box on a level surface.

Cut the straps and remove the staples from the top cover. Open the box upwards.

Remove the staples from the lower sides that attach the box to the wooden base.

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2006 Montesa Honda, S.A.

Cut the attachment strap from the front wheel and remove the wheel from the housing.

Remove the two pinch bolts from the handlebars. Remove the rear wooden bridge. Take all necessary precautions to avoid damaging any part of the motorbike during this process.

The bolts are in the accessory box.

Torque: 27 N-m (2.7 kgf-m, 25 Ibf-ft)

Hold the motorbike in place, passing the strap below the handlebars, between both steering brackets.

Hold the motorbike in place, passing the strap below the left and right rider foot steps.

Remove the rear attachment straps. Remove the support straps for the right and base.

We recommend that two people lift the motorcycle off the wooden base. Work with care whilst holding the motorcycle to avoid possible damage.

Remove the rear attachment straps. Remove the support straps for the right and left front parts of the stirrups from the wooden base.

Remove the two pinch bolts from the rear wooden bridge. Remove the rear wooden bridge. Take all necessary precautions to avoid damaging any part of the motorbike during this process. Install the two original bolts and caps in the seat cowl. The bolts are in the accessory box.

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2006 Montesa Honda, S.A.

Carefully lift the motorbike using a hoist.

Remove the right and left brake callipers.

Loosen the bolts at the bottom of the fork.

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Remove the cardboard protectors from inside the brake pads.

Fit the short side collar to the right side of the wheel hub (depending on light position.)

Fit the long side collar to the left side of the wheel hubjdepending on light position.)

Apply a thin layer of grease to the front axle.

Install the brake callipers (right and left) in the brake disks. Torque: 31 N-m (3.1 kgf-m, 25 Ibf-fi)

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Install and tighten the front axle to the specified torque.

Torque: 59 N-m (5.9 kgf-m, 25 Ibf-ft)

With the front brake applied, pump the front UD sus~ension and down several times to seat the axle and check the front brake operation.

Tighten the axle bolts to the specified torque.

Torque: 22 N-m (2.2 kgf-m, 25 Ibf-ft)

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Lift the motorcycle from the wooden base. RoU the motorcycle forward gently.

Before taking the motorcycle off the base, check that there are no objects on the floor that might obstruct the operation. Make sure the bike is not in gear.

NOTE: Prepare the battery only if the motorbike has been sold or is going to be used of demonstration purposes. I f necessary, charge the battery according to specifications. WARNING The battery gives off explosive gases; keep sparks, flames, and cigarettes away from the battery. Provide suitable ventilation when charging or using the battery in a suitable place.

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2006 Montesa Honda, S.A.

List of parts for windshield attachment. 1.2.3.4.5.6.7.8.9.a

Windscreen Cover R windscreen Cover L windscreen Cover R screen stay Cover L screen stay St R S C ~ Stay L screen Spacer R screen Spacer L screen 1U.- Bolt S C bX6 p 11.- Bolt screen stay 12.- Washer Bpr Bolt

-"

Fit the four bolts (90117-MEW920) and the four washers (90148-SA0000) to the left and right (do not tighten).

ASSEMBLING THE WINDSHIELD IN THE STANDARD POSITION

Attach stay (64502-MEW902) to the right and stay (64503-MEW920) to the left (depending on liqht position). Tighten the bolts to the specified torque.

ASSEMBLING THE WINDSHIELD IN T RAISED POSITION

on light position). Tighten the four bolts to the specified torqu

Attach the bolts correctly.

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2006 Montesa Honda, S.A.

Fit the windshield (64110-MEW920) matchin up the holes on the shield with those on t stays.

Attach spacer (64504-MEW920) to the right and spacer (64505-MEW920) to the left. Tighten the four bolts (90116-MEW920) to the specified torque.

Fit cove? (64171-MFWWO) to the

cover (64122-MEW920) to the left. Press the cover gently into position.

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Attach the right (88110-MEW921) and left (88120-MEW921) rear view mirrors, holding them in place with the four bolts (90130MEE000).

Attach the license plate to the back of the motorbike. Make three holes in the protruding parts of the mudguard. Fit the two collars (84706-4150000) on the top holes and the collar (90556m . The three license plate holding bolts are not supplied in the kit.

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2006 Montesa Honda, S.A.

NOTE:

Idle speed: Smoothness, throttle response, return t o ~ d l e speed. Check the idle speed again 10 minutes after stopping and ride around again.

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