Table Of Contents - Rotax 125 MAX DD2 Repair Manual

Table of Contents

Repair Manual 125 MAX DD2

Foreword .....................................................................................................................................................2

IMPORTANT INFORMATION .........................................................................................................5

Attention captions ........................................................................................................................................5

General preAttentionary and safety measures ...........................................................................................5

Technical data .............................................................................................................................................8

Visual inspection and servicing intervals of the engine components ...........................................................9

SPECIAL TOOLS, LUBRICATION AND SECURING DEVICES ................................................. 10

Overview of the special tools required ......................................................................................................10

Overview of the lubricants and securing devices ...................................................................................... 11

Location of the engine number ..................................................................................................................12

DISMANTLING THE ENGINE AND GEARBOX .......................................................................... 13

Dismantling the exhaust system ............................................................................................................... 13

Dismantling the ignition unit ....................................................................................................................... 13

Removal of the gear shift ..........................................................................................................................14

Removal of the radiator hoses ..................................................................................................................14

Removal of carburetor and intake silencer ................................................................................................15

Removal of slipper clutch ..........................................................................................................................15

Removal of the engine from the Kart chassis ........................................................................................... 16

Oil draining ................................................................................................................................................ 16

Removal of the electric starter ..................................................................................................................16

Positioning the engine on the trestle mounting plate ................................................................................. 16

Exhaust outlet slider function .................................................................................................................... 17

Disassembly of the exhaust outlet slider ................................................................................................... 17

Removal of the exhaust gas flange ........................................................................................................... 18

Removal of the carburetor socket and valve fitting ....................................................................................18

Removal of spark plug............................................................................................................................... 19

Removal of cylinder head cover and combustion chamber insert ............................................................ 19

Removal of cylinder head cover ................................................................................................................19

Removal of combustion chamber insert ................................................................................................... 19

Removal of coolant thermostat .................................................................................................................20

Removal of cylinder ...................................................................................................................................20

Removal of the piston and piston ring .......................................................................................................20

Removal of the water pump shaft ............................................................................................................. 21

Removal of the gear shift mechanism ......................................................................................................21

Disassembly of the clutch, primary and balance drive ..............................................................................22

Overview of clutch components ................................................................................................................22

Disassembly of the crank and gearbox housing .......................................................................................24

Overview of the crank and gearbox housing components ........................................................................ 24

Page 3

Issue 01/2006