Dismantling The Engine And Gearbox; Dismantling The Exhaust System; Dismantling The Ignition Unit - Rotax 125 MAX DD2 Repair Manual

DISMANTLING THE ENGINE AND GEARBOX

◆ Note:
Adhere to the operating and installation instructions of the Kart
manufacturer. The following basics apply: First allow the engine to cool
adequately and switch off all electrical power to the Kart.
◆ Note:
Remove the leads from the battery terminals.
▲ Warning:
When disconnecting the battery leads proceed as follows - first free the
negative pole, then the positive pole. Remember, that the ignition unit is
under a high voltage (25KV) during operation, therefore removal of the
spark plug connector during operation is not permissible.

Dismantling the exhaust system

➩ Free the exhaust system attachments in
accordance with the instructions of the Kart
manufacturer. See also Fig. 104 and the
installation manual.
➩ Detach the exhaust springs, loosen the nuts on
the shock mountings and remove the exhaust
system.

Dismantling the ignition unit

➩ Pull the spark plug connector (Item 1) from the
spark plug.
➩ Detach the plug connections on the ignition
transformer (Item 4), on the spark generator (Item
3) and on the electric starter (Item 2) by pressing
the respective catch on the wiring harness.
■ Attention: Always pull on the connector, not on
the cable.
➩ Free the ground cable for the spark generator (Item
7) on 2 nuts (Item 15).
➩ Free the starter ground cable fixing (Item 12) from
the nut (Item 14) and washer (Item 13).
➩ Loosen and remove the ignition transformer (Item
6) on the nut (Item 14), washer (Item 13) and 2
rubber mountings (Item 9).
➩ Free the guard plate (Item 8) on the spark
generator (Item 7) at the 2 screws (Item 10).
➩ Loosen and remove the starter motor (Item 5) on
the 2 screws (Item 11).
Page 13
Repair Manual 125 MAX DD2
Fig. 4
Fig. 5
Issue 01/2006