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Working with Montesa parts manual

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Following a request that my friend Enrique made to me in the La Maneta forum, I decided to write a small guide to help those who do not know how the amazing “Montesa parts manuals” work, which make life easier for everyone who uses them. Above all, if we understand them as they were conceived in the factory. Even today I am amazed by the mentality of Pedro Permanyer, at a time when we were far from the rising of computer science in our lives. The system can’t be more logical.

The first thing we should know is that, from the Impala, all Montesa parts have a unique reference formed by three groups of numbers (and sometimes a fourth group). These groups were separated from each other initially with a point, but eventually ended up joining the first two groups into one (I believe that because the point that separated the model and group was not necessary because there were no confusions). These composed references are those that appear in the sections of Montesa, and it is worth understanding how they are generated. Because understanding it will help us enormously to locate parts, know what compatibilities there are between models, etc.

The first number of the three that make up each reference is given by the factory code of the model, which was also used to number each frame and engine. The list-taken in part from the old Rocky Mountain Montesa of my missed friend John Haberbosch-is as follows:


Model

Name

Displacement

3M

Impala Sport

175cc

4M

Impala

175cc

4M post 20.000

Impala 2

175cc

5M

Microscooter

60cc

6M

Comando

175cc

7M

Montesa 50 A 1

50cc

8M

Kenya

175cc

9M

Comando Impala

175cc

10M

Cota 25, 25A

50cc

11M

Trial 250

247cc

12M

Texas 175

175cc

13M

Impala Cross 175 (175 Scrambler)

175cc

13M

Impala Cross 250 (250 El Diablo)

250cc

14M

Enduro 175

175cc

15M

Sport 250

247cc

16M

Cota 74

74cc

17M

Ciclo Montesa / Indiana

50cc

18M

Cappra 125 MX

125cc

19M

Cota 172

157.3cc

20M

Cota 49

50cc

21M

Cotas 247 y 248

247cc

23M

La Cross

250cc

24M

Texas 250 (Scorpion USA)

250cc

25M

Impala Sport (USA)

250cc

26M

Enduro 75 L

74cc

27M

Mini Montesa (Moped)

50cc

28M

Cota 123, 123T

125cc

29M

Cota 200

173.7cc

30M

Scorpion 50, 50R

50cc

32M

Cota 80

80cc

33M

Cappra 250

250cc

34M

King Scorpion 250

250cc

36M

Cappra 360 GP Europe/USA

351.2cc

37M

Brío

50cc

38M

Cappra 125 VA a VF

125cc

39M

Cota 242, 304, 307 y 309

237.5cc

40M

Rapita 50, 50R

50cc

41M

Impala 2 125

125cc

42M

Crono 74

74cc

43M

Cappra 250 Five

250cc

44M

King Scorpion Automix 250

250cc

45M

Rapita Automix 250

250cc

46M

Cappra 360GP, 360DS

351.2cc

47M

Mini Mini

50cc

48M

Enduro 125 L

125cc

50M

Cota 25 C

50cc

51M

Cotas 348, 349 y 350

305.8cc

52M

Crono 125

125cc

53M

Cappra 250 GP

250cc

54M

Enduro 250 todas las versiones.

250cc

55M

Crono 350

350cc

56M

Cappra 360 GP

350cc

57M

Fura

50cc

58M

Enduro 125H

125cc

61M

Cota 330

327.8cc

62M

Enduro 75 H6 y H7

74cc

63M

Cappra 250 MX

250cc

66M

Cappra 360 VA a 414 VG

350.4cc

67M

Enduro 360 H6 y H7

350cc

68M

Enduro 125 H6 y H7

125cc

73M

Cappra 250 VR a VG

250cc


In addition to those on this list, there is a "fictitious model" (the 2M, or 02 in the parts lists) that corresponds to the original Impala monoblock engine, from which everything changed at the Montesa factory. This number is very frequent and is maintained until a very late time because even the latest engines inherited many pieces of the original Impala.

The second digit of the part number is given by the "Group" to which the part in question belongs. The list of Groups is the following:



Grupo

Número

Observaciones

Frame

20

Usually divided into two sheets (I and II) that correspond to frame and fenders and to tank and seat.

Steering and front suspension

30

Handlebar, seat, grips, throttle and steering axle.

Front suspension

35

Spares that are part of the fork, except for the triple clamps.

Rear suspension

40

Swinging arm and shock absorbers. Sometimes it includes cutting of the shock absorbers with their manufacturer's own codes.

Wheels and brakes

50

Tires, rims, hubs, rear sprockets and bearings.

Brake parts

55

Brake shoes, brake levers, rear brake levers and control cables.

Engine

60

It is usually divided into I and II which correspond respectively to thermodynamic group plus escape and to crankcases.

Flywheel

61

Flywheel, coils and spark plugs. It usually includes references of the manufacturer of the elements.

Carburetion

62

Carburetor and air filter, with references of the manufacturers of the elements.

Clutch and primary drive

63

Includes chain, control cable and sprocket.

Transmission

64

Gear sprockets and selection forks.

Kick Starter

65

Lever and internal mechanism.

Selector

66

Selector and shift lever.

Electrical system

70

Electrical wiring, headlamp and rear lamps. It usually includes cutting of the lighting elements with references from its manufacturer.

Standard accessories

80

Odometer, tools, front plates, etc.

Workshop tools

87

 

Combining these two tables we already have an idea of how the references work. We will know, for example, that an Enduro 360 frame part will always be a 67.20.XXX (6720.XXX after the loss of the first intermediate point), or that a steering part from a Cota 348 will be a 5130.XXX . We will even learn things about the evolution of the models: for example, when we see the sheet of Cota 348’s tank and see in it the piece 34.20.06201, corresponding to the tank’s badges, we will know that those badges comes from a King Scorpion since its numbers begin with a 3420.

 
Useful, right? But there is much more. Because Mr. Permanyer sent each dealer a series of ring binders containing the original sections of each of his bikes, arranged in the sequence given above for the Groups. This allowed that when the factory introduced an improvement or a change in the model, an additional sheet was added to know what changes were introduced.

 
To understand how it works, we’ll discuss the first two pages of a Cota 247 frame. The first one:

The first thing we must look at is the lower area where we are informed that it is a sheet of a Cota 247, corresponding to the Frame I Group (there is a Frame II that is a tank, seat and accessories), and that it applies to the motorcycle from 21M0001 (that is, to the first unit of Cota 247).

 
The next thing is that we will see a mixture of pieces 21.20.XXX created especially for the model, along with others from different models, such as 33.20.020 (the sidestand spring) that comes from a Cappra 250 (model 33M, as we see in the models table).

 
Finally, and to them I will refer last, we will see that there are also parts with numbers that start with 0.9X.YYY, which are special cases.

 
When we turn to the next page of the manual, we will see that we are facing the first modification, which was applied from motorcycle number 500 (21M0500).

 

 

And to make our lives easier, Montesa emphasizes the part numbers that have changed in this "Frame Group I", as it happens with the same sidestand spring, which is now a Cappra 250 Five (43M). It’s impossible to make it easier.

 
Finally, it is necessary to explain the special groups of parts, which we could call "generic". They are the following:

 
0090.XXYYY Metric screws.

Where XX marks the diameter in millimeters and YYY the length. Thus, a 0090.05022 is a hexagonal screw M5 of 22 mm in length. A “5x22” as they are commonly referred in the supply stores.

0091.XXXXX Special screws.

Where the casuistry is wide and I do not have it very clear. I believe that the denomination comes from the pieces "D91XX" that in the original Impala indicated Withworth measurements. In the last series they were used for countersunk screws (present in Dimensions from 330 and 242), Allen screws, etc. These last denominations are very long, as for example the 0091.0010502032 that indicates an Allen screw 5x20.

 
0092.XXYYY Nuts.

Where the XX is the diameter in millimeters, and can include several suffixes to indicate if it is self-blocking, standard, etc. For example, a 0092.08011 is an M8 self-locking nut and a 0092.08030 is an M8 elastic nut.

 

D92XX Withworth nuts

As far as I know, they were only used in Impala and derived for very specific things. They are the D9206 (1/4 inch) that fixed the saddle to the frame, D9210 (1/8 inch) and D9211 (5/32 inch).

 
0093.XXXXXX Washers and o-rings.

Where the casuistry is large:

0093.104 to 0093.112 indicate flat washer between M4 and M12

0093.30XXXXX are o-rings, like the 0093.3010015 that are 10x1,5 o-rings.

0093.4XXX indicate cable grommets.

0093.504 to 0093.518 indicate elastic washer between M4 and M18.

0093.7XX and 0093.8XX are spacial washers.

 
0094.XXXX Balls, bearings and bushes.

X is usually the numbering of the standard bearing model used. Sometimes it uses the suffix C3 to indicate tolerance, as in the crankshaft.

 
0095.XXYY Rivets.

X and Y are usually measured in millimeters as in 0095.0413 which are 4x13 rivets.

 
0097.XXYY Plugs and fasteners.

X and Y is usually diameter and length.

 
0098.XYY Elastic rings (Seeger type).

Being the X values 1, 2 and 3 for axis, hole or "type E", and the YY diameter in millimeters. A 098.114 is a seeger for a 14 mm sahft, a 0098.240 is the seeger for a hole of 40 mm, and a 0098.310 is a “type e” seeger for a 10 mm shaft.

 
0099.XXYY Seals.

Normally X and Y mark internal and external diameter. As a general rule, the thickness is usually 7 mm, with few exceptions that I remember now, and that go to 10.

 
Sorry for such a heavy text. But I hope it will be of help for those who love Montesas and a good starting point to make your own discoveries.

 

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Is there a parts manual which decodes the numbers into the name of the part? Could use one for the 349. 

 

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For some modern models (Cota 242, if I don't remember badly) there is a list for each page of the parts manual. I haven't seen one for the 349.

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7 hours ago, turbofurball said:

The 349MH manual does that, for what it's worth!

It’s worth it’s weight in gold!! Is there a way it can be seen somehow? It would be a great tool. 

Thank you. 

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Anyone have a parts number description for the Cota49’s engine? It would be nice to know what all the lower engine engine parts are called. 

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any know where I can get a workshop manual for montesa cota 247, I have the parts manual but need the strip down manual, having a bit of trouble selecting gears, have just got new clutch plates and springs , and selector return spring ,not fitted yet

Edited by Ciaran

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