Rotax 125 MAX DD2 Repair Manual page 25

➩ Screw in 3 M8 x 70 fixing screws (Item 15, Fig.
26) from the support plate (Item.3, Fig. 26)
equally, for use as leveling feet, see Fig. 31.
➩ Position the ignition side of the housing over the
3 screws on the work bench.
■ Attention: Increased risk of injury due to
slipping. On no account damage the
housing sealing surface with the tool.
◆ Note:
The item numbers used in the
following section relate to Fig. 30.
➩ The forcing screws indicated in Fig. 32 must be
screwed equally into the respective threads.
➩ Force the housing halves from the ball bearing
seatings by targeted striking with a plastic
hammer.
➩ Set the upper housing half (Item 2) to one side,
remove the gasket (Item 3) and remove the
components from the lower housing half (Item
1) in the following sequence.
▲ Warning:
Consider the respective weights of
the shafts - increased risk of injury
➩ Pull the first idling gear wheel (Item 6) from the
hollow shaft (Item 5).
➩ Pull the gear shift sleeve (Item 8) from the hollow shaft and shift fork (Item 11) downwards out of the
housing.
➩ Carefully pull or knock the hollow shaft from the ball bearing (Item 12). Do not damage the shaft sealing
ring (Item 13), or it will have to be replaced on assembly.
➩ Pull the second idling gear wheel (Item 7) from the hollow shaft.
➩ Remove the retainer rings (Item 10) and bearing sleeves (Item 9) of the idling gears from hollow shaft.
➩ Pull the crankshaft, complete (Item 4) from the bearings (Item 14).
➩ Pull or knock the pinion shaft (Item 16) from the ball bearings (Item 15).
✔ Inspect the shift fork shaft seal (Item 17) for damage.
✔ Inspect the crankshaft seal (Item 18) for damage.
Page 25
Repair Manual 125 MAX DD2
Fig. 31
Fig. 32
Issue 01/2006