DK00026.fm
REPAIR MANUAL
BRP-Powertrain
Effectivity: 125 MAX/125 Junior MAX/125 Mini
MAX/125 Micro MAX
Edition 2 / Rev. 0
Chapter 4
Page 1
December 01/2010
Chapter: 4
CYLINDER COMPONENTS
Contents This chapter describes the disassembly and assembly of the cylinder
components of the ROTAX 125 MAX engine. The description is divided
into sections.
Subject Page
System description Page 3
Cylinder removal
Removal of cylinder
Dismantling cylinder
Removal of spark plug
Removal of cylinder head cover
Removal of coolant thermostat
Removal of combustion chamber insert
Removal of exhaust socket
Removal of the carburetor socket and reed valve
Removal of exhaust valve (125 MAX only)
Removal of piston
Page 5
Page 5
Page 6
Page 6
Page 6
Page 6
Page 6
Page 8
Page 8
Page 9
Page 11
Inspection of cylinder parts
Inspection of cylinder
Inspection of piston and piston ring
Inspection of spark plug
Inspection of cylinder head cover
Inspection of combustion chamber insert
Inspection of exhaust socket
Inspection of carburetor flange and reed valve
Inspection of exhaust valve (125 MAX only)
Page 13
Page 13
Page 14
Page 17
Page 18
Page 18
Page 19
Page 20
Page 21
Cylinder assembly
installation of exhaust valve (125 MAX only)
Installation of piston
Installation of piston pin
Cylinder installation
Installation of exhaust socket
Installation of the reed valve and carburetor socket
Installation of combustion chamber insert
Installation of cylinder head cover
Inspection and adjustment of “squich gap”
Installation of the spark plug
Page 23
Page 23
Page 27
Page 27
Page 29
Page 30
Page 31
Page 33
Page 33
Page 35
Page 37
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