Day 8: The Top End

The main reason this Montesa Cota did not run for years was rings. They are very difficult to find. I have gotten a stock set and each one has broken without the slightest hesitation. I don't know if it is from sitting on a shelf for 30 some odd years or if some other factor is involved. They were handled with the up most care.

I wanted something better for the old girl. I did some extensive research and found that I could use a pair of 1985 Honda CR125 rings. I specifically used Wiseco (part#: 2126CS) because I have always had good results and it is a solid product.

Another purchase I made at the same time was a ring installation tool. Probably the last one I will ever have to buy unless I am working on a V8 or larger. I have no information on the product at all except for the sticker on the package. That reads as follows: WPS 39-1005 Ring Installer. I would have to assume, which I do not enjoy doing, that the WPS is for White Power Systems, a well known motorcycle supplier. The tool performed very well and it was extremely simple to use.

All of these parts I got from the Vancouver Pro-Caliber Motorcycle. I have only two things to say about them. There is nothing that is even remotely close to being "Pro-Caliber" about that company and they will never get another dime of my money. Save yourself the nightmare people and shop somewhere else! You have been warned!

The next step was getting new nuts for the studs holding the head on and the top end together. Not so easy folks! The holes for the nuts to attach the studs are not big enough to get a tool on. A bit more research is needed. I do get all my nuts and bolts from Vancouver Bolt. They have taken care of myself and many friends for years! I think, at this point, I will just take the whole engine down there so they can find me a good solution to this problem. Sadly; Vancouver Bolt could not supply me with actual parts, but that is not to say that they didn't help. After consulting with their knowledgeable and friendly staff, I know exactly what I need. The actual nuts are 8mm @ 1.25 thread pitch, Allen nuts with enough room for 1/2 inch stud. It is the only thing that will fit down the very narrow 3 inch deep access hole and still be able to get a tool on it.

Folks, if you don't know what the heck you need and are starting a project, I highly recommend starting at Vancouver Bolt.

Day 7: Rolling Chassis

Once the frame was back and the prep work done, the build can begin! Above is a picture of the little lady in her current state. The swing arm and forks now move superbly after cleaning and repacking of the bearings. It is not really clear in the manual about which side of the forks some parts go on so we are trying to figure it out. Of special note, the small tab on the speedometer broke off when trying to reassemble. Karl welded on another tab and it works marvelous! Superb save Karl! In the picture below it is the tab sticking up. The day before that critical tab did not exist.

Day 6: Fresh Paint

Oh the joy and happiness that comes with a freshly painted frame and swing arm! It is not just paint folks! This parts are heated to about 480 degrees and powder coated. Then the whole menagerie is covered with three layers of clear! It looks flawless and beautiful! The swing arm is too wide now to fit so some of the powder coating must be sanded. During the time I was waiting for the frame, I took all the remaining parts and started grinding the rust off of them. A very tedious task, but important still. More good news is that I just heard from Speed and Sport and they are sending the ordered parts. I will have the rings and other various parts, listed previously, very soon. She will ride again!

Day 5: The Quest for Clean

Well today I decided to give the old girl a bath and see if anything could come clean. The rims were especially bad. Soap and water did not even put a dent in the rims. So far steel wool and a huge amount of elbow grease is my only friend there. The extensive paint chipping will be left until the frame can be sandblasted and powder coated. The grease on the front forks was a real tough one. Soap and water: No. Scrub brush: I wish! Looks like it is going to be rags and thinner. I started to break down the frame for painting. Here is what I have left now. Not surprising is the moss growing in some parts. It looks like it was just starting to get a foothold.

Day 4b: Needed Parts

Parts, parts, parts! This is the real challenge. Getting parts for a 40+ year old motorcycle. If anyone has a line on any of the parts below, drop me a line and I will be happy to purchase them or put your logo on this blog and give you credit, mention and links if you donate them. Thanks:) Montesa Cota 123 28M1448 Missing Parts (of course I will be adding to this list so check back regularly): Piston Rings, pt#: 2860.022/1s & 2860.022/2s Piston clips, pt#: D6021 (x2) Engine to head gasket, pt#: 2860.024 Carb to head gasket, pt#: 3462.108 (x2) Carb top cover, pt#: 2862.304 Throttle cable, pt#: 2862.053 Foam air filter, pt#: 2162.067 Plastic ring for air filter, pt#: 2462.057 Carb gasket, part#'s: AMAL 622/073 & AMAL 622/101

Day 4a: The Verification and Cleaning of the Carb

Before even thinking in the long term of happily puttering around at about 2.5 mph, scaling boulders, climbing overhangs and riding over the occasional car in traffic; the carburetor must be fully cleaned and all parts must be in perfect working order. This is a foundation piece to a motorcycle project like this. Everything else can be in perfect working order, but if the carb is not adjusted properly and in perfect working order, the motorcycle just won't start, no-how, no-way!

Upon breaking down the carb a few things become clear.

First, the motorcycle has not been run in a long time and the carb has not been stored with gas in it. No build up, all parts move smoothly and everything is clean.

Second, it looks like there are two parts missing. One is part# AMAL 622/101 which is the carb gasket that mates the carb to the head. The other is the gasket that mates the bowl to the body, part# AMAL 622/073.

I may just get a sheet of gasket material and start fabricating my own gaskets for this motorcycle. Making templates as I go so future gasket needs can be easily fabricated.

Day 3: The Search for Rings

Well folks, this is proving to be quite the task. I started by going to: Metacrawler and doing a search for the Montesa dealership page. That brought me to US Montesa. Two entries came up, Beaverton Honda and Apex Sports. The number for Beaverton Honda was disonnected so I tried Apex Sports. I was then informed that Lewis Sport, in California, now handled all trials bike parts. Mandy at Lewis Sports said I needed to call Matt at Speed and Sport (530-878-0700) and he could probably set me up with a set that would work. After talking to him he recommended getting the actual measurements, 53.60mm for the cylinder/piston and 52.40mm for the notch the rings fit in, and call back. He could probably get a pair together. Still I am unable to date the bike to the correct year of manufacture. Matt did give me a clue though. The M number on the frame and engine puts it in a bracket of dates. Tomorrow will tell. If anyone can direct me to someone who has parts for the Montesa Cota 123, pre 1975, especially rings, let me know! Thanks;)

Day 2: Clean-up

Cleaning up the years of misery attached to something so precious can be a daunting task. For example here is a picture of the air filter after preparing it for cleaning. There isn't much left. The screens will be salvaged, new foam purchased and a new filter fabricated to the specs of the original. The next picture is of the parts that have been cleaned so far. The metal screens are what is left of the air filter. The fender and some carburetor parts not small enough to get lost in the dishwasher. Yes folks, man's best friend; the dishwasher. You wouldn't believe what you can run through there. Just try to avoid the really greasy items.

Day 1: Reception and History

...And this is how it begins. A Montesa Cota 123 (so far dated at between 1965-1971, this will get pinned down later) last seen by myself when I was in high school and the frame had just been painted. The things 25 years under a tree will do to a freshly painted frame. The cylinder was bored out and sleeved to the original specs and the only thing the "package" is missing are the rings and the kick starter.