zerorev3rev4

look on richmond motor club website

thought it was funny when a young n 21 whose had motorbikes and push bikes thought a mountain bike with 3 front cogs and 7 rear had 10 gears , but then on the other hand not many folk can tell a bolt from a nut

remove tank and make sure it hasnt had an inline thermo switch fitted , if you were to join the wires up that go to this switch the fan should come on if not theres another problem , try putting 12v neg and pos to the fan to see if it works ok also see if you can find a montesa wiring diagram on the net to down load if you cant find 1 there is gas gas ones that will give you an idea but if you have no idea with electrics id get someone else to look ,but removing tank should give a better view of parts

ive had an alloy part inside the inner tube sticking ,had to sand it down , it must of swelled

jr standard time wigg 15 will renolds 14 james fry 13 olderson 12 hemingway 11 thorpe 10 challoner 9 sam conner 8 sadler 7 haslem 6 austermule 5 m brown 4 j richardson 3 r danby 2 dougy 1

dougie brown and richardson riding well

good chance you are loosing the spark under compression and then it floods replace plug and cap check ht lead ,id replace points if dont look in good nick but mostly if the condensor is still on the stator disconnect it and wire an old car type to the the coil wire under the tank as it will keep cool better

couldnt of been much more wrong with it then bit of a bummer ,, plug or throttle chopping from what i remember is done at full open throttle and then engine killed quickly to give plug colour at full throttle not ideal for a rebuilt engine ,150 main jet sounds right poss on the richer side as some recomend 140 , try putting clip at the bottom position and see if it runs spluttery and rich that way you know it can get more than enough fuel then bring it back to middle and see how it runs , use same idea with idle mixture screw air screw only half out and see if it then runs rich if not go for the bigger idle jet which was fitted, in the ideal world 1 and half turns out +- half would be good also with needle in the middle position would indicate correct main jet all this is ok as long as air filter clean and not over oiled fuel flow has no dirty filters crank seals are good and plug is good (also correct heat range plug fitted) i would get a new stat as you could burn the regulator out running constant ,, the damp cold can also make them run a bit on the richer side as engine will run cooler it is an art to know if a bike is running rich a good indication is smoking and not much power pulling up a steep hill also unburnt fuel dripping from exhaust joints , is there any modifications to take into account

if the shaft assembly does not follow the order of parts as above it could be from the kick start assembly ,if not, there should be one before the circlip on the idler cog kind of hard to say without seeing

they are both very good robust bikes question might be is which can you get parts for easiest

the large washers are the same as each other looks like you have 1 on the shaft if you find for some reason you need to use both inner washers make sure theres enough clearence with a large washer fitted when fitting casing

let us know how getting one made gets on might be worth having a few made to sell on ,i think someone else use to make these in the past

that assembly looks incorrect it should be starting from inside working out ,, 1 inner small bush 2 1x washer (poss shim) 3 cog 4 ratchet mechanism 5 light spring 6 large washer 7 shaft 8 heavy return spring 9 large washer 10 outer large bush in outer case 11 seal 12 kick start ,,,, the assembly can be kept in the engine when removing cover just by keeping it pushed in when lifting the cover ,,,, if the clip is popping off the idler gear check the groove in the shaft for wear and also remember circlips have a incorrect and correct way round and best to use a new one if its popped off

they do come up on ebay or you can get a ty175 air box to work you need to remove the lid by drilling the spot welds out to get it high enough

now we are getting somewhere

look in other cota 200 topics in montesa forum

ive used ty175 on the 200,s

is the bolt too long ,and the bolt head could be too big its difficult to find a bolt that does not catch ,the spring cant go on wrong i dont think ,but its the timing of the ratchet spur it needs to be on the correct spline to get the tension correct to return the kickstart to the stop correctly ,the engagement of when it starts to turn the engine also has to be correct , when you put the cover on the shaft should be sprung clockwise and when you fit the kickstart you need to turn the shaft anticlockwise to allow the grove in the shaft to align for the bolt to go through

nice buy off ebay ,, tensioner fits to engine under the sprocket but easily gets damaged and removed id fit a universal one pref to swing arm so it doesnt get caught underneath , kickstart has to be set up presicely to prevent smashing parts most parts available through inmotion

there is a bush in the outer and inner casing can be purchased through inmotion

you missed 311 and 314 from what i can see

no i did not mean 123 this is one here not sure if they are a made up of different bikes https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-ash3/1417_309251759178986_543900607_n.jpg

anyone know anything about these never seen one other than in a pic , clutch case looks differnt is it a 200 with a difffernt top end

good front tyre helps the fronts get miss looked at as not thought that important also lean away from the bank keeping bike upright steering up slightly