woodbutcher

SAMMY MILLER

YUP , GOT ONE FOR A COTA 309 + 310 , BOTH SAME . YOU SHOULD HAVE - GREY , BLACK , BLUE , BLUE (2X BLUES) GOING INTO CDI UNIT FROM STATOR . GREEN FROM CDI INTO HT COIL WITH PLUG LEAD (MAKE SURE COIL BRKT IS BOLTED TO NICE CLEAN METAL ON FRAME). WHITE FROM CDI IS NOT NEEDED JUST TO RUN BIKE (POSS JUST FOR HORN)SO TAPE UP . YELLOW GOES TO RECTIFIER ONLY NEEDED FOR LIGHTS SO TAPE UP . GREEN/YELLOW IS GROUND , BOLT TO NICE CLEAN METAL ON FRAME

you`ve paid them for a job to service + fix the problem . take forks back to get re-done by dealer properly this time for free . you will damage fork internals riding like this

HAS FOLLOWING THAT REBUILD SEQUENCE GOT YOUR CLUTCH TO DISENGAGE ? ALSO MAKE SURE THE SMALL CLUTCH CENTRE THAT SITS OVER THE THREE LONG PINS ON SHAFT WILL MOVE EASILY INSIDE THE CLUTCH PLATE CENTRE HUB

LOOK IN CLASSIC TRIALS FORUM , PAGE 2 , NOV. 9TH MONTESA 242 CLUTCH , READ SCRATT

YOU CAN PULL COMPLETE CLUTCH UNIT OFF WITH A 3 LEGGED PULLER AFTER REMOVING CENTRE NUT . WATCH OUT FOR 2 X SHIMS WHICH MIGHT STICK TO UNDERSIDE OF CLUTCH ,REMOVE THEM + PUT STRAIGHT BACK ONTOP OF CLUTCH DRIVE GEAR . THE THREE LONG LOCATING PINS THAT FIT BETWEEN THE SHAFT + CLUTCH CENTRE WILL OFTEN PULL OUT AT SAME TIME + SLIGHTLY DAMAGE THE THREADS . WHEN REFITTING MAKE SURE THE CLUTCH DRIVE GEAR WITH FOUR PROTRUSIONS HAS THE 2X SHIMS ON TOP AND THE FOUR PROTRUSIONS FIT INSIDE THE CLUTCH BASKET . FIT LOCK WASHER + CENTRE NUT+ TIGHTEN , WITH A LONG SCREWDRIVER MAKE SURE THE FOUR PRONGED DRIVE GEAR UNDER BASKET HAS SMALL AMOUNT OF MOVEMENT BACK + FORTH ALONG THE SHAFT ( APPROX 1MM )THIS IS NECCESSARY FOR CLUTCH TO DISSENGAGE . DONT NOT FORGET TO FIT + BEND OVER THE LOCKING WASHER ON CENTRE NUT

IF ENGINE IS NOT IN FRAME , IGNITION COIL HAS TO BE GROUNDED , TRY BOLTING IT TO CYLINDER HEAD STEADY BOLT HOLE AND TRY AGAIN FOR SPARK

yep thats what i had to do

try WWW.ORO2U.COM part no. 18-615 m16x1.0