Rotax fr125 max manual

Tightening torque 10 Nm 90 in. Page Removal Of The Crankcase Remove needle pins 6 and thrust washer 7 from the water-pump shaft.

Remove circlips 8 with circlip pliers. Remove the drive gear 9 from the crankshaft. Page 95 Water-pump pinion Idle gear Needle pin Thrust washer Page Disassemble Crankcase Screw cyl. Remove gasket from the case half.

Remove water-pump shaft 2. Remove balance shaft 3 from the case. Page Remove The Crankshaft Gently tap the crankshaft with the plastic hammer 2 to remove the crankshaft from the case half. Page 99 Heat the two halves of the case to approx. Page Case half Ball bearing crankshaft Ball bearing balance shaft Installation tool part no. Press Crankshaft n. Dial gauge Part no. Page Part number Description Part no. Page Position crankshaft 3 with the thrust plate on bottom section of the tool 4 and make sure that the connecting rod pin is above the center hold of the bottom section.

Page Inspect Crankshaft If the maximum approved stroke CS06 of the crankshaft is exceeded, the crankshaft must be realigned.

Page Distance of crank webs CS07 Page - check that all needle bearings are present Slide the new con rod 7 assembly with cage from the connecting rod pin mounting device onto the pressed-in connecting rod pin 5. Slide the drive-end crankshaft half 3 into the top section of the tool 9. Page Crankcase-Inspection Of Components Inspect the water pump shaft 6 in the region of the two oil seals for shaft for increased wear and replace if applicable.

Inspect impeller 7 for damage or abnormal deformation and replace if applicable. Page Assembly Of Crankcase Press in the needle bearing 2 to the limit stop with the installation tool 3 part no. Allow the crankcase halves to cool in this position. Page Press in the first oil seal for shaft to the limit stop with the installation tool 7 part no. Page 8 part no. Page Position new gasket 4 on the ignition end crankcase half. Crankcase Part no. Page Installation Of Crankcase Screw on gearbox cover 13 with 6 cyl.

M6x25 screws 14 and 2 cyl. M6x30 screws. The descrip- tion is divided into sections. Subject Page System description Remove carburetor 3 with intake silencer 4 with support bracket 5 and fuel pump 6.

Page Remove the fuel pump 1 at the bottom of the support bracket 2 for the intake silencer. Page Disassembly Of Carburetor Disassemble the carburetor to the parts shown in Figure 4 and clean with fuel. Page Disassemble the intake silencer to the parts shown in Figure 5. Page Checking Fuel Pump 3 and in case of doubt replace. Page Checking Intake Silencer Clean the silencer filter element 5 with a gasoline-oil mixture. Check the silencer filter element 5 for cracks.

Check the support bracket 6 for cracks. Carburetor Step Procedure The assembly of the parts is identical to the disassembly in reverse order.

Page Procedure The assembly of the parts is identical to the disassembly in reverse order. Connect the fuel feed line 6 and the cable 7 to the carburetor. Connect the impulse pipe 8. It is pressed into the sprocket. Page Removal Of The Sprocket Insert clutch drum 3 with installed sprocket 4 into the corresponding toothed cutout.

Unscrew the hex nut 5 for the sprocket. Remove the sprocket from the clutch drum. Pull out starter gear assembly. Remove starter reduction gear assembly 9 with the thrust washer 10 be- low.

Check teeth 2 for deformation and wear. Page If necessary, unscrew the rubber seal and the ground pole from the starter support and clean them. Page Hold the rotor shaft with a suitable tool and secure the solenoid housing on the starter motor support. Installation of the electric starter Instructions See also Chap. Tightening torque 5 Nm Page Starter gear assembly Crankshaft Clutch Cyl. Page Assembling The Clutch Drum 11 teeth 3 and press into the stop in the sprocket with the installation tool part no.

Page Installing Sprocket Position clutch drum 6 on the sprocket. Tightening torque Nm 74 ft. Page Fixation tool for sprocket part no. Page O-ring 12x2. Page Electric Starter Connect the electrical and the ground cable to the starter. Adding oil. Subject Page System description Page 3 Removing the water radiator Unscrew the hose clamp 2 and pull the cooling water hose from the port.

Check the cooling system for leaks by running the engine until it is at operating temperature. Subject Page System description Page 3 Removal of the exhaust system Remove old silencer baffle mat 4. Install cover 6 and new rivets.

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