Repair Manual 125 MAX DD2
Page 32 Issue 01/2006
Conrod set - Repair set
■ Attention: Repair of the crankshaft requires a special tool and must only be carried out by workshops
with the appropriate experience and equipment.
➩ Separate the crankshaft using a suitable press device.
✔ Inspect the bores in the crank webs for score marks.
◆ Note: If score marks are visible the crankshaft must be replaced.
◆ Note: The repair set comprises the conrod, crank pin, needle bearing and two thrust washers.
■ Attention: The parts in the repair set are paired together and must therefore be exclusively used together.
➩ Lubricate the crank pin and both bores of the
crank webs with grease.
➩ Lay one crank web on the press device.
➩ Press in the crank pin with a guide sleeve up to
the detent in the crank web.
➩ First fit the thrust washer, needle bearing, conrod
and two thrust washers on the crank pin.
➩ Press together the two crank webs in the press
device to give the specified dimension M08 =
48.95 – 49.05 mm.
✔ Check the crankshaft for eccentricity.
◆ Note: The crank webs must be in exact
alignment. The alignment can be
adjusted using a plastic hammer.
➩ Make targeted strikes on the unclamped crank
web to achieve the desired alignment.
✔ Inspect the alignment of the crankshaft as shown in Fig. 46.
Fig. 47
M08
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