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FULL POWER VERSIONONLY FOR COMPETITION PURPOUSE
2014
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22
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2008 Montesa Honda, S.A.
Air cleaner cover replacement.
- Remove the rear fender.Remove the top and side screws.
- Remove the air cleaner cover.
DESCRIPTION QUANTITY SPARE PARTS P/N
KIT FULL POWER, COMPLET 1 01840-NN4-405
• CAP AIR/C CASE 1 17212-NN4-000
• PROTECTOR EXH PIPE 1 18323-NN4-000
• RIVET BLIND 4.0 5 18326-NN4-G10
• PIPE COMP EXH 1 18330-NN4-G10
• CAP COMP END 1 18338-NN4-G30
• CHAIN DRIVE 1 40530-NN2-000
• SPROCKET 41T FINAL DRIVEN 1 41202-NN4-J30
KIT FULL POWER SPARE PARTS
SUBSTITUTION PROCESS
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2008 Montesa Honda, S.A.
- Replace the air cleaner cover with the new cover (17212-NN4-000) supplied in the kit.
- Fasten the cover with the same screws.
Modifying the power curve
- Remove the fuel tank.Remove the front screw.Do not lift the tank.
- Remove the fuel injector holder.
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2008 Montesa Honda, S.A.
- Disconnect the fuel pump black connector (2P).
Carefully lift the petrol tank, being careful not to pull abruptly as the fuel hoses are connected and could be damaged.
- Disconnect the suction hose from the cylinder head.
- Disconnect the injector by pressing the clips on the sides.
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55
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2008 Montesa Honda, S.A.
- Remove the fuel tank.
- Remove the connectors from the protective cable cover.
- Disconnect the lights connector
- Disconnect the WHITE / GREEN cable from the clamp.
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2008 Montesa Honda, S.A.
- Remove the wire by pressing on the inside of the connector using a wire remover.
- Completely remove the cable from the clamp and protect it with insulating tape (a).
- Reconnect the lights connector (b).
- Cover the connectors with the cable guard.
Muffl er terminal replacement.
- Remove the protective cover from the muffl er.
a
b
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2008 Montesa Honda, S.A.
- Remove the exhaust pipe clamp.
- Remove the silencer attachment bolt (a).
- Remove the muffl er.
- Remove the fi ve rivets on the muffl er terminal.Use a drill to remove the rivets.
- Insert the new muffl er terminal (18338-NN4-G30) supplied in the kit.
a
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2008 Montesa Honda, S.A.
- Rivet the new muffl er terminal with the fi ve rivets (18326-NN4-G10) supplied in the kit.
Removal of the exhaust pipe and O2 sensor
- Remove the upper clamp on the O2 sensor from the left hand side of the engine.
- Remove the coil to take off the O2 sensor cable
- Remove the cable from the O2 sensor
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2008 Montesa Honda, S.A.
- Refi t the coil.
- Loosen the screw on the horn and move it to one side.Leave it in a vertical position.
- Remove the nuts attaching the exhaust pipe to the cylinder head.
- Remove the manifold from the exhaust pipe together with the O2 sensor
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1010
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2008 Montesa Honda, S.A.
Removal of the fuel restriction washer
- Disconnect the taillights connector
- Loosen the fi lter casing intake fl ange.
- Remove and extract the fi lter casing
- Remove the breather hose from the fi lter casing.
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2008 Montesa Honda, S.A.
- Disconnect the ECU connector wires.
- Remove the insulator. Loosen the screws on the fastening fl ange and remove the insulator by carefully moving the injector casing.
- Remove the lock washer located on the insulator on the part connected to the injector casing.
- Fit the insulator.
- Fit the ECU casing
- Connect the ECU connector.
- Fit the fi lter casing. - Connect the breather tube in the fi lter
casing.
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1212
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2008 Montesa Honda, S.A.
- Tighten the fi lter casing intake fl ange.
- Adjust the engine idle speed.Turn the idle screw by approximately ¾ of a turn to the right.The engine must be warm for an accurate idle inspection and adjustment.
Idle speed: 1,800 ± 100 min-1 (rpm)
- Fit the fuel tank. When fi tting the tank, be sure to place tubes
and cables in the right places.
- Ensure the injection pump/tank suction hose passes properly under the gas wire.
- Connect the fuel pump black connector 2P.
- Fit the fuel holder.
Torque: 20 - 24 N•m (2 – 2.4 kgf•m)
Ensure that the injector O-ring is in the correct position.
- Fit the injector connector.
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2008 Montesa Honda, S.A.
- Position the wires and tubes correctly.
- Connect the suction hose to the cylinder head.
Exhaust pipe and exhaust protector assembly.
- Replace the exhaust pipe manifold (a) with the new manifold (b) (18330-NN4-G10) supplied in the kit.
- Fit the manifold.
Torque: 10 - 14 N•m (1 - 1,4 kgf•m)
- Fit the exhaust pipe manifold guard (18323-NN4-000) supplied in the kit.
a
b
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2008 Montesa Honda, S.A.
- Place the horn in position (horizontal) and tighten the screw.
- Fit the exhaust muffl er.
- Fit the mounting bolt (a).
- Tighten the exhaust pipe bracket bolt (b).
- Remove the protective cover from the muffl er.
- Fit the rear fender.
a
b
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1515
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2008 Montesa Honda, S.A.
- Change the position of the chain tensioner stopper.Initial position (a)
- Move the stopper to the middle hole.Final position (b)
ATTENTIONChange the stopper position on both swing arm sides.
- Remove the drive chain pin.
- Replace the drive chain with the new chain (40530-NN2-000) supplied in the kit.
Replacement of the sprocket and drive chain.
- Remove the rear wheel.
- Replace the rear wheel sprocket with the new sprocket (41202-NN4-J30) supplied in the kit.
a
b
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2008 Montesa Honda, S.A.
- Fit the rear wheel.
- Tighten the drive chain by placing the two eccentrics (a) (on the right and left of the swing arm) in the same position.
- Tighten the rear wheel axle nut.
Torque: 69 N•m (7,0 kgf•m)
a
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