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 6
December 01/2010
2.2) Dismantling cylinder
General See Figure 2.
NOTES: If only the components in the crankcase are to be replaced
or inspected, then the cylinder can be removed complete
with the peripheral components. The exhaust socket, car-
buretor flange and exhaust valve remain installed.
Proceed as follows to disassemble the cylinder:
2.2.1) Removal of spark plug
Spark plug
2.2.2) Removal of cylinder head cover
Cylinder head
cover
See Figure 2.
2.2.3) Removal of the thermostat
Thermostat See Figure 2.
2.2.4) Removal of combustion chamber insert
Combustion
chamber insert
See Figure 2.
Step Procedure
1 Remove the spark plug connector (minimum removal force 30 Nm (22 ft.lb)).
2 Remove the spark plug with the spark plug socket.
Step Procedure
1 Remove the cylinder head cover (4) by removing the 4 cyl. screws (5) from the
cylinder.
2 Lift away the cylinder head cover complete with the O-ring (6).
Step Procedure
1 Remove the coolant thermostat (7) from the cylinder head cover by removing
the 2 taptite screws (8) on the thermostat retaining bracket (9).
2 Remove the thermostat from the thermost holder (10).
3 Remove the compression spring (11).
Step Procedure
1 Remove the combustion chamber insert (12) by unscrewing the 5 hex screws
(13) crosswise the lock washer (14).
2 Lift away the combustion chamber insert with lower (15) and upper O-rings
(16).
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