Installation Of The Cylinder - Rotax 125 MAX DD2 Repair Manual

➩ Rotate the installation tool and push the mounting
sleeve further until the piston pinretaining ring
engages in the groove in the mounting sleeve.
➩ Push the Installation tool with the opening of the
piston pin retainer ring downwards onto the
piston.
➩ Support the piston with one hand, see Fig. 83,
and push the piston pin retainer ring into the
piston.
◆ Note:
The installation tool centers itself in
the piston.
✔ Inspect the piston pin retainer rings for correct
seating in the piston grooves.

Installation of the cylinder

◆ Note:
Coat the stud bolts on the longer threaded end with Loctite 221 securing medium.
◆ Note:
Screw the longer threaded portion of the stud bolts into the crank and gearbox housing and
torque tighten to 5 Nm.
➩ Fit new cylinder base gasket.
➩ Lubricate the cylinder wall and piston with engine
oil.
➩ Using two fingers, push the piston ring into the
piston.
➩ Position the cylinder over the piston.
➩ Secure the cylinder with the 4 flanged nuts to
the crank and gearbox housing, with crosswise
tightening to the prescribed tightening torque of
24 Nm.
◆ Warning:
Use exclusively the piston/cylinder pairings in accordance with the table on page 34. All
other combinations may lead to engine damage.
Page 50
Repair Manual 125 MAX DD2
Fig. 86
Fig. 87
Issue 01/2006