260 Repsol need advice on simplifying hoses and wiring

[mexmex]

Just bought 2021 4RT 260 which is somehow messy and I start servicing it and got shocked 🤣

Im used to simple 2 stroke, and I couldn't believe all the hoses and wires running under the tank! what a mess!

On the wiring side, I want to leave the bare minimum. I dont need lights and horn. I just want kiill switch and what ever the engine need (ECU, Fuel pump, fan). Any advice here?

On the hoses side, that double fuel tank vent left me confused. What the lower one is good for? Can I remove/block it or it will have some unwanted effects doing so?

The head vent goes into big catch tank. Is it ok to remove it and just route the hose into the ground?

 

Thanks for your help!

 

 

 

[lemur]

My Montesa came with an addendum to the owners manual detailing how to prep the bike for competition, it was in the crate right from the manufacturer, so I would ask your dealer if they scooped it or if they can provide that information.

... as for is it OK to remove the fuel tank vapour pollution control measures, that is likely a personal choice, the engine won't notice any difference.  I owned another 4RT that was stripped of parts almost beyond reason by a previous owner and it worked just fine.

[mexmex]

1 minute ago, lemur said:

My Montesa came with an addendum to the owners manual detailing how to prep the bike for competition, it was in the crate right from the manufacturer, so I would ask your dealer if they scooped it or if they can provide that information.

... as for is it OK to remove the fuel tank vapour pollution control measures, that is likely a personal choice, the engine won't notice any difference.  I owned another 4RT that was stripped of parts almost beyond reason by a previous owner and it worked just fine.

Thank you!!

[jrsunt]

Take it all off, it’s just stuff for homologation purposes. All the vapours and fluids end back in the air box, not what a competition engine needs. (The bike will empty the contents of the crankcase back into the air box when upside down) Remove at the air box and bung the hole. 

Firstly start with the petrol cap breather, cut it to about 6” and tuck it into where the throttle cable goes. The cylinder head breather can be shortened and tucked in down the left side of the radiator/frame legs as can the ht coil wiring. (Loosening the bolts and front engine mount helps get them in) The fuel pump breather down the right side of the radiator. The crankcase breather runs on to the sump guard at the rear.

The electrics on top of the crank cases can be made much neater, do away with the bank angle sensor nearest the shock. Unplug it from the rubber boot and put a link wire connecting the outside terminals together ( i think there’s a yellow, white and green in there). 
The relay wiring comes down from under the headstock and sits under the exhaust. Now that you’ve got room under the tank from removing the junk, the relay wire can be shortened and attached under the headstock using the fluid catch can bracket. I have the Mitani condenser, it’s very small which allows it to go into the rubber boot. I’ve removed the bank angle sensor connector which makes more space in there.
The only thing I have left is the rectifier and rear brake reservoir so I made my own carbon fibre bracket to hold them rather than the hefty steel one. Hope this helps

Edited 2 hours ago by jrsunt