Fork internals Cota 348MRR

[Montesa13]

I would be grateful if anyone has a drawing / sketch / diagram /photograph of the internals of Montesa Cota 348 MRR front forks.
I find the parts manual exploded view confusing, what I need to see is which part goes where and in what order? My front suspension
seems ridiculously hard i.e. in the shed I can stand the bike upright and push with all my strength and there is hardly any travel whatsoever!!

So my guess is there's something not right in my reassembly or could too much fork oil be causing this (but I only put the recommended amount in each 190cc's)? I have the original fork caps with flat top and central screw fitted.

[Kombivan]

OK the slider is the bottom half, you put the fork tube inside it with the threaded end to the top, you have a plunger with a long tube about 13mm with a small threaded hole in the bottom you drop that inside the fork tube then screw the allen key screw in from the bottom of the slider this stops the fork tube from coming out. you can now put your spring in and slide the fork up into the tripple clamps inserting the headlight brackets if your going to use them now you can put your oil in from memory its about 200mm of 20w or could be 10w check your specs in your manual remember these were designed basicly for castrol oil as that was all they had back then that was available everywhere.when you have the oil in you can screw in the top valve caps and be prepaired to be squirted with oil when you first start riding; the exploded view in your manual has the parts in ouder of assembly there should be a thin line from part to part. Cheers. The only difference between the 247 and 348 forks is abouit 13mm in length and the internal fittings but they work the same some caps are different.

[Montesa13]

OK the slider is the bottom half, you put the fork tube inside it with the threaded end to the top, you have a plunger with a long tube about 13mm with a small threaded hole in the bottom you drop that inside the fork tube then screw the allen key screw in from the bottom of the slider this stops the fork tube from coming out. you can now put your spring in and slide the fork up into the tripple clamps inserting the headlight brackets if your going to use them now you can put your oil in from memory its about 200mm of 20w or could be 10w check your specs in your manual remember these were designed basicly for castrol oil as that was all they had back then that was available everywhere.when you have the oil in you can screw in the top valve caps and be prepaired to be squirted with oil when you first start riding; the exploded view in your manual has the parts in ouder of assembly there should be a thin line from part to part. Cheers. The only difference between the 247 and 348 forks is abouit 13mm in length and the internal fittings but they work the same some caps are different.

Thanks mate yep done all that but I think I have two springs in there a short and long one the long one protrudes from the fork tube about 100mm and has to be compressed into the fork tube to screw the cap in as I said I think I have something wrong? AND they are ridiculously stiff way too firm I should be able to compress them a bit at least while stationary shouldn't I. It may be the replacement NOS fork tubes are a bit tight!!?

[Montesa13]

OK well after dismantling the front end and mucking around a bit I finally freed up the forks however one internal plunger part is broken along the edge where it's held in place with a small circlip (0098.H6), the number of the part is 2135.023 (see highlighted on image)
If anyone can tell me where I can get this part or has a secondhand one they can part with I'd be very appreciative?

Despiece Cota 348 4 Grupo Dirección y Suspensión delantera.jpg (175.9 KiB) Viewed 12743 times

[Montesa13]

AGAIN SORTED THIS ISSUE had a mate machine a couple out of nylon for me.