Author Topic: 81 Montesa Cota 200 Repair and Restoration  (Read 7395 times)

Offline vexedofverwood

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81 Montesa Cota 200 Repair and Restoration
« on: January 24, 2012, 12:01:11 PM »
Hello everyone i'm new to the site as me and my father are repairing and eventually restoring my 81 Cota 200 and i'm probably going to need some of your wisdom!

I've had the bike for about 4 years now, and it was running fine until one day, it randomly wouldn't fire up (there's no longer a spark), and also the gears are messed up....

It's difficult for me to explain what the gears are doing and i'll give it my best at describing the problem but chances are i'll have to take it to a specialist! :( right the gear lever/selector wil click up and down but i think it's going into other gears all in one click. i.e if i go up from neutral (when i can get it into neutral that is) it will select the next gear, then the lever won't spring back into the middle but will allow me to carry on going up into the next gear, and possibly the next gear after that! and it's the same when i shift back down again.

Also the kickstarter doesn't spring back to it's starting position (but i think i can fix that one).

I've got lots of pictures and i've got the bike in pieces now, i've taken the case off the side of the crankcase, so the clutch and cogs etc are all out in the open....

Please help as i have little knowledge on this engine because i've never needed to take it to work on it before.

There's also a small key slot in the stem in the side of the frame, just under the handlebars/yolkes does anyone know anything about this? I think it's some sort of steering lock which i don't have a key for.

Thankyou Luke

(I'll be copying and pasting this on other forums)

Offline esometisse

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Re: 81 Montesa Cota 200 Repair and Restoration
« Reply #1 on: January 24, 2012, 05:08:06 PM »
Your gearbox problem seems to be related to the ratchet and spring mechanism in the selector. But as I have never peeked inside a Montesa engine I cannot give any specific advice. I would carefully dismantle everything step by step and look for anything that seems to be wrong i.e. broken springs, worn cogs, nuts having worked loose etc.
A repair manual would be of great assistance, of course. There is a Clymer publication on the Spanish offroaders of the seventies, but I don't know if it covers your model. Look up their website.


Cheers
Andy
« Last Edit: January 24, 2012, 05:10:12 PM by esometisse »

Offline vexedofverwood

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Re: 81 Montesa Cota 200 Repair and Restoration
« Reply #2 on: January 24, 2012, 08:48:11 PM »
yeah i'm scared to take the crank case to bits in case i f*ck it up! lol. i've got a manual somewhere.... think i better dig it out, and as for the clymer publication, i imagine it wouldn't be featured in there, as it's an 81'. anyway if i do rip it to pieces i'll put all the photo's on here of course! :D