Rotax 125 MAX DD2 Repair Manual page 4

Repair Manual 125 MAX DD2
DISASSEMBLY , INSPECTION AND ASSEMBLY OF SPECIFIC COMPONENTS .................... 26
Carburetor ................................................................................................................................................. 26
Crank and gearbox housing ...................................................................................................................... 27
Shaft seal, water pump ............................................................................................................................. 27
Other shaft seals ....................................................................................................................................... 28
Needle and ball bearings ...........................................................................................................................28
Gear box .................................................................................................................................................... 29
Crankshaft ................................................................................................................................................. 31
Conrod set - Repair set ............................................................................................................................. 32
Piston and piston ring ................................................................................................................................ 33
Piston pin, needle bearing and retaining rings ........................................................................................... 34
Cylinder ..................................................................................................................................................... 35
Piston and cylinder sizing .......................................................................................................................... 35
Centrifugal clutch and starter crown wheel ...............................................................................................36
Clutch drum with drive gear ...................................................................................................................... 37
Gear transmission .....................................................................................................................................38
Electric starter ........................................................................................................................................... 38
Radiator ..................................................................................................................................................... 40
Overload clutch ......................................................................................................................................... 41
ASSEMBLY OF GEARBOX AND ENGINE ................................................................................ 42
Installation of the crankshaft and gearbox housing .................................................................................... 42
Overview of crank and gearbox housing components ..............................................................................43
Installation of the water pump shaft ........................................................................................................... 45
Installation of the clutch, primary and balance drive .................................................................................. 46
Overview of clutch components ................................................................................................................ 46
Installation of the piston and piston pin ...................................................................................................... 49
Installation of the cylinder .......................................................................................................................... 50
Installation of the combustion chamber insert and cylinder head cover .................................................... 51
Installation of the spark plug ...................................................................................................................... 52
Installation of the outlet slider .................................................................................................................... 52
Installation of the exhaust gas port ............................................................................................................ 54
Installation of the valve fitting and carburetor socket ................................................................................. 54
Installation of the overload clutch............................................................................................................... 55
Installation of the carburetor ...................................................................................................................... 55
Installation of the ignition box ..................................................................................................................... 55
Installation of the engine on the chassis .................................................................................................... 56
Installation of the fuel pump ....................................................................................................................... 56
Installation of the intake silencer ................................................................................................................ 57
Installation of the gear shift ........................................................................................................................ 57
Installation of the exhaust system ............................................................................................................. 58
Installation of the radiator ...........................................................................................................................59
Installation of the radiator hoses ................................................................................................................ 60
Page 4 Issue 01/2006