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125 MAX DD2
Rotax 125 MAX DD2 Manuals
Manuals and User Guides for Rotax 125 MAX DD2. We have
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Rotax 125 MAX DD2 manual available for free PDF download: Repair Manual
Rotax 125 MAX DD2 Repair Manual (62 pages)
Brand:
Rotax
| Category:
Engine
| Size: 4 MB
Table of Contents
Foreword
2
Table of Contents
3
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
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
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