Installation Of The Exhaust System - Rotax 125 MAX DD2 Repair Manual

Installation of the exhaust system

✔ Inspect the exhaust system for cracks and
breakages.
✔ Inspect the exhaust gas flange for deposits and
deformation.
✔ Inspect the rivets of the exhaust inner pipe for
tightness and seating.
◆ Note:
If the exhaust system noise
increases, then the silencer baffle
mat (Item 2) should be replaced.
➩ Drill out the rivets (Item 4) with a sheet drill -
wear eye protection!
➩ Wearing gloves, pull out the exhaust inner pipe
and baffle from the exhaust system (Item 1).
✔ Inspect the baffle for wear.
■ Attention: A worn out baffle can lead to major
engine damage.
➩ Insert a new baffle ROTAX No. 297 980 tightly
into the exhaust inner pipe (Item 3).
➩ Insert the exhaust inner pipe and baffle into the
exhaust system.
➩ Secure the exhaust inner pipe in the exhaust system with new rivets, using suitable riveting tongs.
➩ Install the exhaust system on the attachments (Items 5-10) on the Kart chassis and torque tighten the
new self-locking nuts to the prescribed torque of 10 Nm.
➩ Coat the exhaust gas ball with sealant.
➩ Fit the springs (Item 5) to the exhaust gas flange of the engine with a suitable tool.
✔ Inspect the tightness of the exhaust pipe and seating on the exhaust gas ball.
Page 58
Repair Manual 125 MAX DD2
Fig. 104
Issue 01/2006