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Installation Instructions and Operators Manual for ROTAX®-engines type 125 MAX 125 JUNIOR MAX 125 MINI MAX/125 MICRO MAX Part no.: 297731 Edition: 02 2014 BRP-Powertrain GmbH & Co KG | Rotaxstraße 1 | 4623 Gunskirchen, Austria | T: +43 7246 6010 | F: +43 7246 6370...
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If any passages of the Manual are not clearly understood or if you have questions, please contact an authorized Distributor or Ser- vice Center for ROTAX-Kart engines. Congratulations on choosing the ROTAX engine Type 125 MAX, Introduction 125 Junior MAX, 125 Mini MAX or 125 Micro MAX.
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BRP-Powertrain recommends products of following brands: Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page INTRO-2 OM Edition 1/Rev. 0 BRP-Powertrain February 01/2014...
1) Installation instructions This chapter describes the installation of engine types ROTAX Inhalt 125 MAX/Junior MAX/Mini MAX and Micro MAX. The description is divided into subsections. Topic Page General precaution and safety information for engine in- page 1-2 stallation Unpacking of engine and accessories...
To be able to use the battery charger in your homecountry, contact your nearest ROTAX Service Center for an adapter plug and/or an adapter cable. The engine package (equipment package) of the 125 MAX con- Engine type 125 MAX tains the following parts: Part no.
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Spark plug 14 IW 27 PARTS SET LARGE NOTE: Contains parts set small. 281453 Parts set small 225015 Intake silencer case, bottom 225025 Intake silencer case, Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page 1-3 Edition 1/Rev. 0 BRP-Powertrain February 01/2014...
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Throttle bowden cable assy. 297461 ROTAX XPS full synth. 2-stroke oil This engine type is identical to the 125 MAX, except for the follow- Engine type 125 Junior MAX ing main parts: NOTE: The engines 125 Junior MAX, Mini MAX and Micro MAX have cylinders without exhaust valve.
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Without a completely filled-in Engine Identity Card no warranty claim will be granted. NOTE: In case of participating in the ROTAX MAX CHALLENGE (RMC) the engine must be veri- fied for conformity with the technical regulations and sealed. The serial number of the seal must be entered in the Engine Identity Card.
Fill in gear oil as specifed (6.10 cu in. (0.0265 US gal)). Tighten venting screw (1) by hand. Oil level check Graphic 1. Venting screw 2. Drain plug Fig. 1 K00233_b Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page 1-6 Edition 1/Rev. 0 BRP-Powertrain February 01/2014...
4) Engine suspension on chassis Using an engine pedestral for the ROTAX engine 125 MAX/Junior General MAX/Mini MAX, the engine is inclined at 0° to 15° in the driving di- rection. Do not fasten engine on chassis until chain is...
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Non-compliance can result in serious injuries WARNU WARNING or death! Take note of advice of the chassis manufac- turer regarding engine suspension on chassis. Step Procedure Fasten engine on the chassis. Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page 1-8 Edition 1/Rev. 0 BRP-Powertrain February 01/2014...
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Procedure Connect the wiring harness to the ignition coil (5). Connect the wiring harness to the trigger coil (10). Connect the wiring harness to the electric starter (11). Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page 1-11 Edition 1/Rev. 0 BRP-Powertrain...
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Only slight bending of the ground electrode is permitted. Step Procedure Fit spark plug by hand and tighten to 27 Nm (239 in.lb). Install spark plug connector on spark plug. Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page 1-12 Edition 1/Rev. 0 BRP-Powertrain February 01/2014...
Install battery (7) into battery holder, as shown in Fig. 4 tighten it (combination of screws + nuts). Connect battery to wiring harness. See section Connec- tion of the battery. Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page 1-13 Edition 1/Rev. 0 BRP-Powertrain February 01/2014...
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Battery Graphic 1-4. Pipe clamp set 5. Battery holder 6. Rubber pad 7. Battery Fig. 4 K00238 Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page 1-14 Edition 1/Rev. 0 BRP-Powertrain February 01/2014...
Accumulated oil could impair the operation of the fuel pump. Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page 1-17 Edition 1/Rev. 0 BRP-Powertrain...
Set and secure the stop screw for throttle pedal such, that with pedal completely pressed down, the carburetor piston will be in the full open position. Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page 1-20 Edition 1/Rev. 0 BRP-Powertrain...
(11) to the carburetor. NOTE: The carburetor socket (6) is asymmetrical and can be turned so that the best possible position for maximum legroom can be achieved. Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page 1-21 Edition 1/Rev. 0 BRP-Powertrain February 01/2014...
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5. Intake silencer case, top 6. Carburetor socket 7. Nut M6 8. Support bracket 9. Washer 6.4 10. Allen screw M6x20 11. Clamp 50-70 Fig. 9 K00254, K00141 Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page 1-22 Edition 1/Rev. 0 BRP-Powertrain February 01/2014...
Procedures Step Procedure Coat the exhaust socket (1) with sealant. Attach springs (2) to the engine exhaust socket (1) with suit- able tool (part no. 251680). Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page 1-23 Edition 1/Rev. 0 BRP-Powertrain February 01/2014...
Attach the exhaust system to the fasteners on the frame- work of the Kart and use new self-locking nuts. Check the exhaust (3) for secure attachment on the exhaust socket (1). Exhaust system, example of 125 MAX Grafik 1. Exhaust socket 2. Spring 3.
14) Observation of engine speed and coolant temperature NOTE: ROTAX is not offering a composite indicating in- strument (inductive rev-counter and thermosen- sor). To determine the best possible transmission ratio, the use of a Rev-counter rev-counter is required. To warrant engine operation within temperature limits of coolant...
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Service Center or consult the Repair Manual (available un- der www.kart-rotax.com). Content Topic Page Design of the ROTAX Kart engine 125 MAX / Junior page 2-2 MAX / Mini MAX / Micro MAX Operating limits page 2-2 Technical description...
1) Design of the ROTAX Kart engine 125 MAX / Junior MAX / Mini MAX / Micro MAX Single cylinder two-stroke engine, reed valve controlled, General 125 cm³ displacement Liquid cooled, forced flow by integrated water pump Balance shaft Integrated thermostat...
To stop the engine, the ON/OFF switch needs to be pushed in. This will interrupt the ignition circuit and the engine stops. Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page 2-4 Edition 1/Rev. 0 BRP-Powertrain...
2.6) Exhaust timing control (125 MAX only) The engine is equipped with a pneumatic exhaust control which optimizes the performance characteristics. Variable exhaust ti- ming depending on exhaust pressure will be achieved by a slide valve in the exhaust port.
At the engine type 125 Mini MAX and 125 Micro MAX the perfor- mance characteristic gets adapted to the age of drivers by use of an exhaust socket with integrated restrictor (Rotax part no.: 273972). Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page 2-6 Edition 1/Rev.
It is recommended to always carry a charged General Informati- spare battery. The installed battery should be replaced by a fully charged battery before it is completely discharged. Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page 2-7 Edition 1/Rev. 0 BRP-Powertrain February 01/2014...
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But if the spark plug is fitted again it may happen that the engine won’t start. NOTE: To charge a battery, the battery charging unit specified by ROTAX and available as an acces- sory should be used: Standard battery charger ROTAX part no.: 265148, 581320 Lithium battery charger ROTAX part no.:...
(2). NOTE: If the battery gets charged, while not mounted on the Kart, use the adapter cable (ROTAX part no. 266021). Plug the battery charger (3) into a 110 - 230 V / 50 – 60 Hz voltage supply. During the charging process the charging control lamp will light up red.
(e. g. piston seizure). When mixing fuel and refuelling do not smoke WARNING WARNU or use open fire. Gasoline is highly flammable and explosive under certain conditions. Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page 2-10 Edition 1/Rev. 0 BRP-Powertrain February 01/2014...
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ENVIRONMENT NOTE Don’t spill fuel! Absorb spilled fuel with appropriate drying agent and ensure ecological disposal. Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page 2-11 Edition 1/Rev. 0 BRP-Powertrain February 01/2014...
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Pour fuel into fuel tank of Kart, using a funnel. NOTE: Never fill to the brim! Close fuel tank and fuel container immediately after refuel- ling. Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page 2-12 Edition 1/Rev. 0 BRP-Powertrain February 01/2014...
At engine operation with ambient temperatures below 10 °C / 50 °F make sure not to demand full power before the coolant temperature has reached 45 °C / 113 °F. Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page 2-13 Edition 1/Rev. 0 BRP-Powertrain...
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(1) and gasket ring (2). NOTE: The fuel drained from the float chamber may be poured back into the fuel tank using a sy- ringe (or similar extruding tool). Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page 2-14 Edition 1/Rev. 0 BRP-Powertrain February 01/2014...
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By turning in the ad- justment screw, the air-fuel mixture will become richer at idling and by turning out this screw, the air-fuel mixture will become leaner at idling. Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page 2-15 Edition 1/Rev. 0 BRP-Powertrain...
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For better understanding and as an aid for the carburetor calibra- Carburetor calib- ration tion the following diagram is used to show the effectiveness of in- dividual settings, depending on the throttle position. Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page 2-16 Edition 1/Rev. 0 BRP-Powertrain February 01/2014...
2 - TYPE AND POSITION OF JET NEEDLE 3 - TYPE OF NEEDLE JET 4 - MAINJET Fig. 5 K00264 4.2) Selection of the transmission ratio - 125 MAX Never run the engine without load. By revving General CAUTION WARNUNG the engine without load, speeds above 14.000 rpm can be reached and this exces-...
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NOTE: This is just a remark making it obvious that the best possible tuning can only be achieved with an exact knowledge of the race track. Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page 2-18 Edition 1/Rev. 0 BRP-Powertrain February 01/2014...
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NOTE: To simplify changing of the transmission ratio it is recommended to carry clutch drums with a prefitted chain sprocket of various numbers of teeth. Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page 2-19 Edition 1/Rev. 0 BRP-Powertrain February 01/2014...
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Above the engine speed of 11.500 rpm the ef- fectiveness of the exhaust system decreases, resulting in a big drop of performance (see Fig. in chapter Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page 2-20 Edition 1/Rev. 0 BRP-Powertrain February 01/2014...
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Table 2 shows clearly that in order to reach the maximum engine speed of 12.000 rpm at a transmission ratio of 6,31 (between 6,20 and 6,40) and an engine speed of 11.000 rpm, the Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page 2-21 Edition 1/Rev. 0...
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Above the engine speed of 11.500 rpm the ef- fectiveness of the exhaust system decreases, resulting in a big drop of performance (see Fig. in chapter Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page 2-22 Edition 1/Rev. 0 BRP-Powertrain February 01/2014...
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Table 2 shows clearly that to reach the maximum engine speed of 11.500 rpm at a transmission ratio of 6,31 (between 6,20 and 6,40) and an engine speed of 11.000 rpm, the Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page 2-23 Edition 1/Rev. 0...
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Above the engine speed of 10.500 rpm the ef- fectiveness of the exhaust system decreases, resulting in a big drop of performance (see Fig. in chapter Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page 2-24 Edition 1/Rev. 0 BRP-Powertrain February 01/2014...
(4) and torque is transmitted by a needle pin (3). The pro- per exchange or renewal of the chain sprocket is only feasible when using the appropriate fixture ROTAX part no. 277364. NOTE: On the chain sprocket with 11 teeth, the plain...
Prior to engine start, verify the following: Preparation Fuel tank full Battery charged and connected Carburetor Bowden cable is moving freely and carburetor pis- ton connected in idle position Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page 2-31 Edition 1/Rev. 0 BRP-Powertrain February 01/2014...
A fully synthetic 2-stroke oil must be used! CAUTION WARNUNG Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page 2-32 Edition 1/Rev. 0 BRP-Powertrain February 01/2014...
(e. g. carburetor piston stuck in full throttle position). Step Procedure Push the ON/OFF switch (see Fig. 10) in, and the engine will stop. Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page 2-33 Edition 1/Rev. 0 BRP-Powertrain February 01/2014...
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ON/OFF switch on the ignition unit will consume current thus discharging the battery completely and finally leading to damage or ruin of the battery. Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page 2-34 Edition 1/Rev. 0 BRP-Powertrain February 01/2014...
Valve opening too early Leistungskurve 1 performance graph 1 Schieberöffnungs- zeitpunkt zu spät Valve opening too late Motordrehzahl [1/min.], engine revolutions [rpm] Fig. 11 K00266 Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page 2-35 Edition 1/Rev. 0 BRP-Powertrain February 01/2014...
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7.500 rpm has been reached, the opening time can be adjusted to a slightly lower speed by turning adjustment screw (16) out- wards. Graphic Fig. 12 K00243 Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page 2-36 Edition 1/Rev. 0 BRP-Powertrain February 01/2014...
Apply oil on exhaust system to prevent corrosion. Remove battery from the fixture and charge periodically with the specified battery charger. Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page 2-37 Edition 1/Rev. 0 BRP-Powertrain February 01/2014...
1x per Year Component / Fluid Procedure Fuel filter Renew Gear oil Renew Tear-down inspection of Have a tear-down inspection conducted by engine an authorized distributor. Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page 2-38 Edition 1/Rev. 0 BRP-Powertrain February 01/2014...
Insufficient fuel supply to the Check the fuel supply to the carburetor carburetor Fuel filter in carburetor clogged Clean fuel filter, see section 4.1) (step 8 to 10) Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page 2-39 Edition 1/Rev. 0 BRP-Powertrain February 01/2014...
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Fly wheel fractured Renew all fly wheels Excessive noise emission from After muffler isolating mat Replace isolating mat, see burned away latest Repair Manual exhaust system Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page 2-40 Edition 1/Rev. 0 BRP-Powertrain February 01/2014...
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BRP-Powertrain GmbH & Co KG | Rotaxstraße 1 | 4623 Gunskirchen, Austria | T: +43 7246 601 0 | F: +43 7246 6370 www.rotax.com | www.rotax-kart.com...
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