Table Of Contents - Rotax 125 MAX evo Repair Manual

Table of Contents

General Note4
Table Of Contents4
Position Of The Engine Serial Number5
Abbreviations And Terms Used In This Manual6
Safety Information7
Safety Notice7
Instruction8
Technical Documentation9
Use For Intended Purpose9
Technical Data10
Maintenance12
Process Advice15
Ignition "Off"15
Handling Of Fluids15
Disassembly Advice15
Cleaning Of Parts16
Removed Parts16
Measurements16
Re-Assembly Advice16
Consumable Materials17
Special Tools19
Inspection And Servicing Intervals Of The Engine Components21
Engine24
System Description25
Engine Components View25
Preparation For Removal26
Removal Of The Ignition System26
Battery27
Ignition System28
Removal Of The Exhaust System29
Removal Of Radiator With Cap Assy29
Removal Of The Fuel Line30
Fuel Components View30
Removal Of The Bowden Cable31
Removal Of The Engine From Kart Chassis31
Positioning The Engine On The Threstle Mounting Plate32
Engine Clamp View32
Cylinder Components34
Cylinder Components View35
Cylinder Removal36
Removal Of The Spark Plug37
Removal Of The Cylinder Head Cover37
Cylinder View37
Removal Of The Thermostat38
Cylinder Head Cover View38
Removal Of The Combustion Chamber Insert39
Thermostat View39
Removal Of The Exhaust Socket40
Combustion Chamber Insert View40
Removal Of The Intake Socket And Reed Valve41
Removal Of The Exhaust Valve41
Exhaust Valve (Rave) View42
Removal Of The Piston43
Cylinder Components Inspection44
Inspection Of Piston And Piston Ring45
Inspection Of The Piston Diameter46
Inspection Of The Piston And Cylinder Sizing47
Inspection Of The Piston Pin, Circlip48
Inspection Of The Spark Plug49
Inspection Of The Cylinder Head Cover50
Inspection Of The Combustion Chamber Insert50
Inspection Of The Exhaust Socket51
Inspection Of The Carburetor Flange And Reed Valve52
Inspection Of The Exhaust Valve53
Cylinder Components Installation54
Installation Of Exhaust Valve54
Installation Of Exhaust Valve, Gasket, Valve Rod Housing55
Installation Of The Exhaust Valve Piston55
Installation Of Piston57
Installation Of The Cylinder58
Installation Of The Exhaust Socket59
Installation Of The Carburetor Flange And Reed Valve60
Installation Of Combustion Chamber Insert62
Installation Of Cylinder Head Cover62
Inspection And Adjustment Of Squish Gap64
Installation Of Spark Plug66
Crankcase68
Crankcase View69
Components Of Crankcase View70
Removal Of The Crankcase72
Remove Water Pump And Compensating Wheels73
Gearbox Cover View74
Water Pump And Balance Shaft View75
Disassembling The Crankcase76
Balance Shaft View77
Removing Bearing And Oil Seal For Shaft78
Ignition Side Crankcase View81
Installation Of The Crankshaft Repair Kit82
Disassembling Of The Crankshaft82
Crankshaft Repair Jig View83
Con Rod Parts View84
Inspection Of The Crankshaft86
Crankshaft Not In Specification88
Aligning The Crankshaft88
Crankshaft Assembly89
Crank Case Inspection93
Inspection Of Water Pump Drive93
Inspection Of Water Pump Shaft94
Inspection Of Balance Shaft Drive94
Inspection Of Balance Shaft95
Inspection Of The Housing Halves96
Crank Case Assembly97
Installation Of Oil Seal, Ball Bearing And Needle Bushing97
Installation Of Ball Bearing And Oil Seal For Crankcase99
Assembly Of Crankshaft, Water Pump Shaft And Balance Shaft102
Assembly Of The Crankcase103
Installation Of Crankcase Assy104
Installation Of Balance And Water-Pump Shaft Drive104
Idle Gear View106
Carburetor And Intake Silencer108
Carburetor And Intake Silencer Overview109
Removal Of The Carburetor And Intake Silencer110
Removal Of The Fuel Pump111
Disassembly Of The Carburetor112
Carburetor View113
Disassembly Of The Intake Silencer114
Carburetor And Intake Silencer - Inspection Of Components115
Inspection Of Carburetor115
Inspection Of The Fuel Pump116
Inspection Of The Intake Silencer116
Intake Silencer View117
Installing The Carburetor And Intake Silencer118
Assembly Of Carburetor118
Assembly Of Float Housing118
Float Chamber View118
Assembly Of Intake Silencer119
Installation Of Fuel Pump, Carburetor120
Carburetor And Intake Silencer View121
Centrifugal Clutch, Primary And Balance Drive122
Centrifugal Clutch, Primary And Balance Drive Overview123
Components Of Clutch And Starter Assy. View124
Removal Of The Clutch And Starter Gear Assy125
Removal Of The Centrifugal Clutch Assy125
Removal Of The Electric Starter125
Removal Of The Clutch Drum126
Removal Of The Sprocket128
Removal Of The Starter Gear Assy.129
Inspectoin Of Clutch And Starter Gear Assy.132
Inspection Of The Clutch Drum132
Inspection Of The Needle Cage And Sprocket132
Inspection Of The Starter Reduction Gear Assy.132
Inspection Of The Electric Starter133
Inspection Of The Clutch And Starter Gear Assy134
Electric Starter Repair Kit135
Disassembling Of Electric Starter135
Assembling Of Electric Starter136
Installation Of Clutch And Starter Gear Assy.138
Installation Of The Starter Reduction Gear Assy.138
Assembly Of The Clutch Drum140
Installation Of The Sprocket140
Installation Of Bearing Sleeve For Sprockets With 11 Teeth Only141
Installation Of The Clutch Drum142
Installation Of The Electric Starter144
Filling Gearbox With Oil146
Cooling System148
Cooling System Overview149
Radiator View149
Water Pump View150
Removal Of Radiator151
Removal Of The Cooling Water Hose151
Inspection Of Cooling System153
Radiator - Inspection Of Components153
Installing The Radiator154
Installation Of The Cooling Water Hoses154
Installation Of The Radiator On Engine155
Final Tasks157
Exhaust System158
Exhaust System Overview159
Checking The Exhaust System162
Disassembling The Exhaust System162
Assembling The Exhaust System162
Installation Of The Exhaust System163
Exhaust System View163
Removing The Engine From The Trestle Mounting Plate164
Installation Of The Engine On Kart Chassis164
Installation Of The Fuel Line164
Installation Of The Bowden Cable165
Installation Of The Ignition System165
Ignition Unit View166
Index168