Repair Manual 125 MAX DD2
Page 44 Issue 01/2006
◆ Note: Note the sequence for the idling gear wheels - first gear 1. Position gear (81Z) on the hollow
shaft, then idling gear 2. Gear (77Z). If the sequence is incorrect it prevents further assembly
of the gearbox and engine components.
◆ Note: When assembling the gear wheels, make sure that their flatter side faces the shifting claw. A
reverse positioning does not allow engagement of the shifting claw in the gear wheels and
so there is also no drive.
◆ Note: When using new housing halves insert new dowel pins in the ignition-side housing half;
when using the old housing halves unscrew the set bolts.
➩ Insert a new housing gasket ROTAX No. 630 520.
➩ Position the drive-side housing half on the shafts.
➩ Using a plastic hammer, complete the assembly of the drive-side housing half. Avoid striking the sealing
surfaces.
➩ Fix both hosing halves on the trestle mounting
plate.
◆ Note: Use Special tool “Trestle mounting
plate, complete“ ROTAX No. 876 762
and 676 052.
➩ Tighten the 12 screws from the inside towards
the outside in crosswise sequence to a torque
value of 10 Nm.
➩ Cut off the overlapping housing gasket in the area
of the cylinder base seal and smooth with a
grinding stone.
Fig. 72
Fig. 71
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