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General| Engine Type | Single-cylinder, 2-stroke |
|---|---|
| Displacement | 124.8 cc |
| Bore | 54 mm |
| Stroke | 54.5 mm |
| Cooling System | Liquid-cooled |
| Starter | Electric starter |
| Intake System | Reed valve |
| Ignition | Digital |
| Exhaust System | Tuned exhaust |
| Clutch | Centrifugal clutch |
| Lubrication | Mixture lubrication |
Manual's scope, purpose, and general notes on engine operation and safety.
Glossary of abbreviations and technical terms used in the manual.
Details safety notices, warnings, cautions, and symbols used in the manual.
Guidelines for engine operation, maintenance, repair, modifications, and accessories.
Explains technical documentation standards, references, manual status, and illustration conventions.
Specifies engine's intended use and conditions for maintenance and repair.
Details bore, stroke, displacement, power, torque, and idle speed for ROTAX 125 MAX engines.
Specifies ignition system, spark plug types, electrode gap, fuel type, and minimum octane rating.
Provides details on the cooling system, engine lubrication, and clutch engagement.
Describes maintenance information applicable to skilled mechanics under normal working conditions.
Lists specific maintenance topics covered in this chapter, including personnel, procedures, and tools.
Provides general notes and safety advice regarding engine maintenance procedures and limits.
Details instructions, policies on modifications, and guidelines for parts and accessories.
Provides a comprehensive list of special tools required for maintenance procedures.
Outlines visual inspection points and servicing intervals for engine components.
Overview of the engine and gearbox module for the ROTAX 125 MAX engine.
Details preparation steps for dismantling and assembly of the engine and gearbox.
Covers the procedure and safety precautions for starting the engine after maintenance.
Illustrates and describes the engine in its installed status, identifying key components.
Outlines preparation steps and safety instructions before starting engine work.
Lists the special tools required for engine dismantling and assembly procedures.
Provides step-by-step instructions for removing the exhaust system from the engine.
Step-by-step guide for safely removing the ignition system components.
Instructions for safely disconnecting and removing the engine's fuel line.
Step-by-step guide to disconnect and remove the carburetor control cable.
Instructions for removing the engine from the kart chassis, noting parts that do not require removal.
Guide for safely positioning the engine on a trestle mounting plate for service.
Procedure for removing the engine from the trestle mounting plate in reverse order of positioning.
Safety precautions and instructions for installing the engine into the kart chassis.
Instructions for reinstalling the fuel line, referencing the removal procedure.
Procedure for reinstalling the carburetor control cable, referencing the removal steps.
Guide for correctly installing the ignition unit and its components.
Steps for mounting the exhaust system, including sealing and securing fasteners.
Safety precautions and essential reading before starting the engine after maintenance.
Overview of the cylinder components module for the ROTAX 125 MAX engine.
Details the process for removing the cylinder, including dismantling steps.
Guides on inspecting various cylinder components for wear and damage.
Step-by-step instructions for assembling the cylinder and its related parts.
Illustrates the cylinder's position on the engine, identifying key parts like cylinder head and exhaust valve.
Safety precautions and necessary preparation steps before removing the cylinder.
Lists the specific tools required for the cylinder removal process.
Step-by-step instructions for detaching the cylinder from the crankcase.
Procedures for disassembling the cylinder, including spark plug, head cover, and thermostat.
Instructions for removing the exhaust socket, carburetor flange, and reed valve.
Detailed steps for removing the exhaust valve mechanism, specific to the 125 MAX model.
Instructions and special tools for safely removing the piston from the cylinder.
Guides on inspecting cylinder, cylinder bore, and related parts for wear and damage.
Procedures for inspecting the piston and piston rings for cracks, seizure, and wear.
Instructions for measuring piston diameter and determining clearance with the cylinder bore.
Details on piston and cylinder sizing classifications and wear limits.
Guide for inspecting the piston pin, needle cage, and circlips for wear and damage.
Visual inspection of the spark plug for carbonization, fouling, and checking electrode gap.
Instructions for inspecting the cylinder head cover and its O-ring contact areas.
Guide for inspecting the combustion chamber insert for cracks, threads, and sealing surfaces.
Procedure for inspecting the exhaust socket for wear and replacing if necessary.
Details on inspecting the carburetor flange, reed valves, and petals for cracks and wear.
Instructions for inspecting the exhaust valve mechanism, bellows, and piston for damage and overheating.
Steps for installing the exhaust valve, including using LOCTITE 648 and specific tools.
Guide for installing the piston and piston pin, including using special tools and new circlips.
Steps for installing the cylinder, including stud bolts, base gasket, and piston.
Instructions for installing the exhaust socket with gasket and securing with cylinder screws.
Guide for installing the reed valve and carburetor flange, ensuring correct positioning and tightening.
Steps for installing the combustion chamber insert, including O-ring and tightening.
Instructions for installing the cylinder head cover, thermostat, and related components.
Procedure for measuring and adjusting the squish gap for optimal engine performance.
Instructions for installing the spark plug with correct tightening torque.
Overview of the crankcase module for the ROTAX 125 MAX engine.
Guides on removing the crankcase, disassembling it, and dealing with the con rod set.
Details on inspecting crankcase components like water pump drive and balance shaft.
Step-by-step instructions for assembling and installing the crankcase.
Illustrates the crankcase's position on the engine, identifying the main crankcase part.
Safety instructions and preparation steps required before removing the crankcase.
Instructions for removing the water pump and compensating wheels from the crankcase.
Step-by-step guide to separate crankcase halves, remove gasket, water-pump shaft, and balance shaft.
Procedure for removing the crankshaft from the crankcase half using a plastic hammer.
Instructions for removing oil seals and bearings from the crankcase halves using tools and heat.
Steps for removing ball and needle bearings from the clutch end case half.
Procedure for removing ball bearings from the ignition end case half.
Instructions for disassembling the conrod set and crankshaft, requiring special tools and care.
Guides on inspecting crankshaft for visible damage, wear, and measuring critical dimensions.
Procedure for re-aligning the crankshaft if its run-out exceeds tolerance.
Steps for assembling the crankshaft, including using LOCTITE 648 and special tools.
Guides on inspecting the water pump drive gears and shaft for wear and damage.
Instructions for inspecting balance shaft gears, drive, and shaft for wear and cracks.
Steps for inspecting crankcase halves, sealing surfaces, threads, and bearings for defects.
Guide for installing bearings and oil seals into the crankcase halves using special tools and heat.
Steps for assembling crankshaft, balance shaft, and water pump shaft into the ignition end crankcase half.
Procedure for fastening the crankcase halves, including screw types and torque specifications.
Steps for installing the balance shaft, water pump shaft drive, and drive gear, with timing marks.
Overview of the carburetor and intake silencer module for the ROTAX 125 MAX engine.
Guides on removing the carburetor, intake silencer, and fuel pump.
Details on checking carburetor, fuel pump, and intake silencer components.
Step-by-step instructions for installing the carburetor, float housing, and intake silencer.
Illustrates the carburetor's position on the engine, identifying key parts like carburetor, silencer, and fuel pump.
Safety precautions and preparation steps required before removing the carburetor and intake silencer.
Step-by-step instructions for removing the carburetor, intake silencer, fuel pump, and impulse pipe.
Instructions for removing the fuel pump from its mounting bracket.
Guide to disassembling the carburetor into its component parts for cleaning and inspection.
Instructions for disassembling the intake silencer into its constituent parts.
Steps for cleaning and inspecting the carburetor, including fuel filter, jets, and needle valve.
Instructions for checking the fuel pump's impulse pipe, fuel line, and overflow line for condition.
Guides on inspecting the intake silencer housing, tube, filter element, and bracket for cracks.
Instructions for assembling the carburetor, including float housing and float adjustments.
Steps for assembling the intake silencer, including immersing and squeezing the filter element.
Steps for installing the fuel pump, carburetor, intake silencer, and connecting lines.
Overview of the clutch and starter gear assembly module for the ROTAX 125 MAX engine.
Guides on removing the clutch and starter gear assembly, including oil draining and component removal.
Details on checking clutch drum, needle cage, sprocket, starter gear, and electric starter.
Step-by-step instructions for installing the clutch and starter gear assemblies.
Illustrates the position of the starter gear assembly, clutch drum, and sprocket on the engine.
Safety precautions and steps for draining the oil from the crankcase and gearbox case.
Instructions for disconnecting and removing the electric starter motor from the engine.
Steps for removing the clutch drum, including using special tools and removing nuts and washers.
Instructions for removing the sprocket from the clutch drum using special tools and hex nuts.
Steps for removing the starter drive cover, clutch, and starter gear assembly using special tools.
Procedure for checking the clutch drum for wear and signs of bearing sleeve issues.
Guide for cleaning, checking gear wheels, and verifying operation of the starter reduction gear assembly.
Instructions for checking the electric starter, including cable, parts, and teeth for wear.
Steps for using the electric starter repair kit, including disconnecting and removing the starter housing.
Guide to disassembling the electric starter, emphasizing care with spring-loaded contacts.
Steps for correctly assembling the electric starter, ensuring brushes contact the slip ring.
Procedure for checking the clutch hole, starter gear teeth, and removing LOCTITE residue.
Steps for installing the starter reduction gear assembly with grease and thrust washer.
Procedure for installing the starter gear assembly onto the crankshaft taper, using LOCTITE and securing screws.
Instructions for installing the bearing sleeve onto the sprocket using a special tool.
Steps for installing the sprocket onto the clutch drum, including degreasing and securing the hex nut.
Guide for installing the clutch drum onto the crankshaft, including greasing, O-rings, and hex nuts.
Steps for installing the electric starter motor onto the housing, including greasing and fastening.
Instructions for adding the specified volume of gear oil to the gearbox, including vent and level plugs.
Overview of the water radiator module for the ROTAX 125 MAX engine.
Guides on removing the water radiator and its cooling water hose.
Details on inspecting radiator fins, cracks, cap gasket, hoses, and retaining plate.
Step-by-step instructions for installing the water radiator and cooling water hose.
Illustrates the radiator's position on the engine, identifying key parts like radiator, hose, and clamp.
Safety precautions and preparation steps required before removing the water radiator.
Instructions for disconnecting and removing the cooling water hose from the radiator and engine.
Procedure for cleaning and inspecting the radiator, fins, cap gasket, hoses, and retaining plate for damage.
Steps for fitting the cooling water hose to the radiator and engine, tightening hose clamps.
Instructions for installing the radiator, adding coolant, and checking for leaks.
Overview of the exhaust system module for the ROTAX 125 MAX engine.
Guides on removing, checking, and disassembling the exhaust system.
Steps for assembling the exhaust system and installing it back onto the engine.
Illustrates the exhaust system's position on the engine, identifying muffler, socket, and spring.
Safety precautions and preparation steps required before removing the exhaust system.
Instructions for checking the exhaust system for cracks and disassembling it by removing rivets and baffle mat.
Steps for assembling the exhaust system, including inserting isolating mat and installing cover with rivets.
Instructions for installing the exhaust system in the reverse order of removal.
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