Bombardier-Rotax FR 125 MAX FR 125 Junior MAX Repair Manual

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 1 Edition 11/2000EO2 REPAIR MANUALfor ROTAX-engines type FR

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 10 Edition 11/2000Location of the engine serial numberThe engin

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 11 Edition 11/2000Engine removal▲ Warning: Strictly observe rem

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 12 Edition 11/2000Setting up the engine on the trestle➩ Remove

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 13 Edition 11/2000Removal of the centrifugal clutch➩ Remove the

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 14 Edition 11/2000Removal of the cylinderhead cover and combust

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 15 Edition 11/2000Disassembly of the drive for the balance shaf

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 16 Edition 11/2000Crankshaft removal➩ Firmly hold the crankshaf

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 17 Edition 11/2000✔ check the leakage bore (1) of the sealing s

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 18 Edition 11/2000➩ take the preheated clutch side crankcase ha

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 19 Edition 11/2000➩ let the crankcase halves cool down to room

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 2 Edition 11/2000PrefaceThis Repair Manual contains essential a

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 20 Edition 11/2000➩ Take the ignition-side crankcase half from

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 21 Edition 11/2000➩ apply Molycotc 111 around the sealing lip o

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 22 Edition 11/2000Crankshaft➩ clean the crankshaft with a non-a

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 23 Edition 11/2000Replacement of the crankshaft repair set Att

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 24 Edition 11/2000Balance shaft✔ Inspect the groove (1) for the

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 25 Edition 11/2000Drive of the waterpump✔ Inspect the drive gea

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 26 Edition 11/2000Centrifugal clutch➩ Remove the 3 retaining ri

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 27 Edition 11/2000➩ Place the 3 rubber sleeves (6) on to the su

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 28 Edition 11/2000➩ Press out the bearing using the fitting pun

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 29 Edition 11/2000Cylinder assembly◆ Note: If the cylinder asse

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 3 Edition 11/2000Table of contentsPreface...

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 30 Edition 11/2000Figure 39Disassembly of the exhaust valve (on

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 31 Edition 11/2000Figure 40Figure 41112Installation of the exha

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 32 Edition 11/2000Exhaust socket✔ Verify the joint between cyli

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 33 Edition 11/2000Reed valve assembly and carburetor flange➩ Re

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 34 Edition 11/2000Cylinder➩ Remove calcareous deposits from the

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 35 Edition 11/2000Piston and piston ring✔ Inspect the piston fo

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 36 Edition 11/2000➩ Take readings of the piston dia. using a mi

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 37 Edition 11/2000Combustion chamber insert✔ Clean the combusti

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 38 Edition 11/2000Ignition unit◆ Note: Ignition timing is contr

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 39 Edition 11/2000Spark plug◆ Note: The engine from the serial

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 4 Edition 11/2000Electric starter ...

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 40 Edition 11/2000Radiator➩ Clean the cooling fins of the radia

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 41 Edition 11/2000Carburetor◆ Note: At malfunction of the engin

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 42 Edition 11/2000Fuel Pump◆ Note: Only the diaphragm and gaske

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 43 Edition 11/2000ENGINE REASSEMBLY Attention: Always renew re

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 44 Edition 11/2000▲ Warning: Always wear heat-protective glove

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 45 Edition 11/2000Installation of the balance shaft and water p

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 46 Edition 11/2000Piston installation➩ Apply engine oil to lubr

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 47 Edition 11/2000➩ Place the circlip insertion tool such on th

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 48 Edition 11/2000Installation of combustion chamber insert and

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 49 Edition 11/2000Checking and adjustment of the squish gap bet

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 5 Edition 11/2000IMPORTANT INFORMATIONRepeating symbolsPay atte

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 50 Edition 11/2000 Attention: The smaller the squish gap the h

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 51 Edition 11/2000Centrifugal clutch installation➩ Screw the fi

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 52 Edition 11/2000Pick-up coil for ignition unit - installation

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 53 Edition 11/2000Radiator and intake silencer- installation◆ N

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 54 Edition 11/2000Figure 73Filling of gear compartment with oil

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 6 Edition 11/2000 Attention: Always secure engine safely on tr

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 7 Edition 11/2000Technical dataEngine Type FR 125 MAXFR 125 Jun

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 8 Edition 11/2000Check and service intervals of engine componen

Repair Manual FR 125 MAX and FR 125 Junior MAXPage 9 Edition 11/2000Special tools, securing and sealing agentsFigu