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Removal of the cylinderhead cover and combustion chamber insert
Note:
If only the crankcase has to be taken to
pieces the completely assembled unit
of cylinder with reed valve, carburetor
socket, exhaust valve assy, exhaust
socket and combustion chamber insert
and cylinderhead cover, can be
removed from crankcase.
Remove 4 Allen screws M6 (1) (fig. 8)
Remove the cylinderhead cover (2)
Take off both O-rings (3) and (4)
Remove 5 Allen screws M8 (5) and lock washers
Remove the combustion chamber insert (6) and
O-ring (7)
Cylinder-removal
Remove 4 hex. nuts(8) with a A/F 11 spanner
Remove the cylinder (9) from the crankcase
Attention: Take care not to damage the piston
Remove the cylinder base gasket (10)
Piston – removal
Force out the piston pin circlips (11) with a suitable
tool
Attention: Prior to the removal of the piston pin
circlips cover the crankcase opening
with a clean rag (fig. 9) to prevent piston
pin circlips from dropping into the
crankcase.
Push out the piston pin (12) with the insertion pusher
Note:
Special tool – "insertion pusher"
ROTAX part no: 676 035
Attention: Always support the piston by hand (fig.
9) whilst pushing out the piston pin to
avoid a bending moment on the conrod.
Remove the piston (13) along with needle cage
(14)
Page 14
Repair Manual FR 125 MAX and FR 125 Junior MAX
Figure 8
Figure 9
Figure 10
Edition 11/2000
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