Rotax 125 MAX DD2 - Page 4

Repair Manual 125 MAX DD2
Page 4 Issue 01/2006
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