Rotax 125 MAX DD2 - Table of Contents

Repair Manual 125 MAX DD2
Page 3 Issue 01/2006
Table of contents
Foreword .....................................................................................................................................................2
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