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Streeting a Montessa Trials bike.

PostPosted: Sat Dec 04, 2021 12:09 pm
by JimVonBaden
Helped @NoVa Rider streetify his Montessa Trials bike. Since the bike comes with no lights or horn from the manufacturer in the US, he went to Austrailia (on the web) and picked up a take-off set of street parts and harness. It was nearly a bolt on exercise, with no instructions and a little bit of trial and error involved. The error being trying to troubleshoot the tail light not working without actually verifying there was a bulb in it! :baldy

Parts laid out, includes the headlight and speedo harness, front turn signals, rear plate holder and light brace, new seat and mount, and misc parts.
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Bike when we started:
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Plastics removed and the rear brace worked to install it. We had to drill the four mount holes first, then bolt it on.
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Next the headlight. The front turn signals hold the headlight in place. They were installed by dropping the fork tubes and sliding on the lights and mounts.
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Popped off the grip so we could install the switchgear.
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Tank had to come out to access the wiring. This is a minor PITA as access it tight. We took an hour just figuring out how to run the wires and where to connect them. Remember, no instructions.
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Took a while to figure out the brake switch wiring and switch location. Turns out the front was missing the T off the master cylinder, and routing the rear was a pain due to access.
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Finally got all the parts back in and the plastics on. Looks really nice, and works well. Fun to ride too!
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All in all, about 5 hours work, and it was a lot of fun surprisingly. He still needs to mount a mirror and the T for the front brake, but a very fun project.