Nigelpugh

Thanks for the comments bud. Looks like I forgot to update the current status. It’s pretty much complete now. Let me dig out the latest pictures.

Here’s the 75th Anniversary book. Montesa Art Dont think that Link works! Seems I have run out of space for posting pictures!

There’s some more here too! 75th Anniversary

I’ve got the big book they made for the 2020 75th Anniversary, there’s lots of history relating to the first Cota bike there. Heres some of it. Montesa History

I bought a new genuine Honda side stand kit for my 2021 4RT. These were the springs with the Honda part numbers on them. Not sure if that helps, but may at least give a steer relating to the part numbers.

I also fitted the new rear secondary mud guards too. Almost threw the old one away before removing the little alloy ring inserts first!

Cheers Bud! I did mostly finish all the jobs yesterday, just need to fit the new rear tyre next. Seems to be running very sweetly now to. I suspect that the throttle cable was not that good for quite some time before the fire too.

I’ve made a start on it today. As you said much easier with the throttle body off the bike. Found lots of dirt in hidden areas so decided to clean the throttle body and air box fully whilst off the bike.

Thanks for this guide, I’m fitting a new cable today and your instructions really helped. Had the cable throttle body off and gave it a good clean whilst it was off the bike.

Thanks for that info bud, really helpful. I didn’t get time to do any work on it at the weekend, might try later today. Thanks again for the tips.

My new parts arrived yesterday, so I will make a start on fitting them today. I still think the hardest part to install will be the throttle cable. I have still not managed to remove the old damaged one, as it looks like I will either have to twist or remove the whole of the EFI throttle body to remove and refit the new cable, Any tips on removing and replacing the throttle cable guys?

Update and thanks for the response to others too. It was indeed the melted cables on the jitsie magnetic cut out, it looked like one of them was shorting to the handlebar hence making the ignition cut out. Disconnected it and removed it completely and when we put the plug back in it fired up straight away. We will get the cable ordered now and start on the rest of the mostly cosmetic damage to get it back to normal. Thanks again. So I’ve ordered a new rear tyre, a rear mudguard, a new kill switch and a new throttle cable, they should be delivered Friday, so I can fit most bits at the weekend. I will post some pictures of rhe work as I do each section.

The bank angle thingy? Nope that was one of the first things I looked at, and it seems fine. Anyway as posted it was indeed the kill switch , and it’s running again now!

Update and thanks for the response to others too. It was indeed the melted cables on the jitsie magnetic cut out, it looked like one of them was shorting to the handlebar hence making the ignition cut out. Disconnected it and removed it completely and when we put the plug back in it fired up straight away. We will get the cable ordered now and start on the rest of the mostly cosmetic damage to get it back to normal. Thanks again.

Thanks I will have a good luck at the other wires on the rest of the loom today. It looks like we are still getting power, because when we kick the engine over the front LED lights up for a brief amount of time. I assume it more common for the low voltage cables to have issues rather than the high voltage output side of the coil pack?

Hi guys, Sadly we has a fire at our house last week and my Montesa 4RT suffered some fire, smoke and water damage. It’s not insured regrettably so I have to see if I can get it up and running again. The heat and fire damage seems to have affected a few plastics like the rear mudguard and also killed the rear tyre too. However at this point I also can’t get it to start at all, so I’ve been trying to work out what’s wrong in a step by step fault finding basis. The first thing we noticed was that the throttle cable was stiff and stuck and not returning to its home position. We have now removed that and will order a new one. The bike is still not starting though, so we pulled the plug out and it’s not sparking at all on kick over. We did notice that the jitsie magnetic kill pull looked like the cables might have melted., so tried unplugging that and shorting the ignition feed. Still no spark. So what’s the best next steps to fault find why we don’t have a spark. Thanks for any tips or pointers!

You are welcome chap! Let me know if you need any help with fitment once you get it, it’s lot exactly straight forward!

Yep that was my thinking too, if they get damaged then as you say they a pretty much disposable!

The other parts of my frame also had some battle scars on them, so found these graphics for £12.00 for both sides and the air box graphic too. They look pretty good for not a lot of cash!

I thought I posted a thread and pictures about fitting it, but perhaps I didn’t! here’s some pics as I fitted it.