Rotax 125 MAX evo Installation Instructions And Operators Manual
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Rotax 125 MAX evo Installation Instructions And Operators Manual

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Installation instructions and
Operator's Manual
for ROTAX®-engines type
125 MAX evo
125 JUNIOR MAX evo
125 MINI MAX evo
125 MICRO MAX evo
Part no.: 297732
Edition: 10/2019
BRP-Rotax 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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Summary of Contents for Rotax 125 MAX evo

  • Page 1 125 JUNIOR MAX evo 125 MINI MAX evo 125 MICRO MAX evo Part no.: 297732 Edition: 10/2019 BRP-Rotax GmbH & Co KG | Rotaxstrasse 1 | 4623 Gunskirchen, Austria | T: +43 7246 601 0 | F: +43 7246 6370 www.rotax.com | www.rotax-kart.com...
  • Page 2 ROTAX 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo General information BRP-Rotax recommends products of the following companies:...
  • Page 3 Reprinting, translation or copies in whole or in part, are authorized only after written permission by BRP-Rotax GmbH & Co KG. BRP-Rotax GmbH & Co KG reserves the right at any time to discontinue or change specifications, prices, designs, features, models or equipment without incurring any obligations.

  • Page 5: Table Of Contents

    4 – Cooling system Chapter 5 – Exhaust system Chapter 6 – Installation of the accessories Chapter 7 – Finishing work Effectivity: 125 MAX evo, Junior MAX Content evo, Mini MAX evo, Micro MAX evo Page 1 Edition: October 01 2019...
  • Page 6 BRP-Rotax INSTALLATION INSTRUCTION NOTES Notes Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 2 Edition October 01 2019/Rev. 0 Edition: October 01 2019...

  • Page 7: Chapter Intro

    Contents This Installation Manual contains instructions for all the installation work on the ROTAX®- Engine Type 125 MAX evo, 125 Junior MAX evo, 125 Mini MAX evo and 125 Micro MAX evo. General This document and all technical data and procedures therein are property of BRP-Rotax GmbH &...
  • Page 8 INSTALLATION INSTRUCTION NOTE In case of participating in the ROTAX® MAX CHALLENGE (RMC) the engine must be verified for conformity with the technical regulations and sealed. The serial number of the seal must be entered in the engine identity card.
  • Page 9 Introduction Congratulations on choosing the ROTAX engine Type 125 MAX. The ROTAX® engine Type 125 MAX has been developed exclusively for use in Go-karts, which must only be run on specified tracks. This product has numerous technical innovations.
  • Page 10 BRP-Rotax INSTALLATION INSTRUCTION UNBOXING AND PURCHASED PARTS PACKAGE By buying a ROTAX Engine, you will receive two boxes. The engine box and the accessory box. Figure 1.2: Unboxing Engine box The engine box contains the pre-assembled engine with the secure sticker, which de- scribes the run-in procedure.
  • Page 11 Exhaust system Manuals and engine identity card Several small parts (spark plug, screws,...) Hose package for RAVE control unit Carburetor Effectivity: 125 MAX evo, Junior MAX INTRO evo, Mini MAX evo, Micro MAX evo Page 5 Edition: October 01 2019...

  • Page 12: Engine Information

    Engine serial number The engine serial number is stamped on the clutch side housing-half. Figure 1.4: Serial number of the engine, TYPICAL INTRO Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 6 Edition: October 01 2019...
  • Page 13 Gear oil and fuel specifications See the latest Operators Manual. Equipment and modifications Modifications to engine and/or equipment are not allowed. Effectivity: 125 MAX evo, Junior MAX INTRO evo, Mini MAX evo, Micro MAX evo Page 7 Edition: October 01 2019...
  • Page 14 BRP-Rotax INSTALLATION INSTRUCTION NOTES Notes Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 8 Edition October 01 2019/Rev. 0 Edition: October 01 2019...

  • Page 15: Engine Installation

    BRP-Rotax INSTALLATION INSTRUCTION Chapter: 1 ENGINE INSTALLATION TOPICS IN THIS CHAPTER Engine installation to the chassis......................2 Attachment via engine pedestal ......................3 Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 1 Edition: October 01 2019...
  • Page 16 If you adjusted the correct chain ten- sion, use the stopper to keep the en- gine in the correct position. Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 2 Edition: October 01 2019...

  • Page 17: Attachment Via Engine Pedestal

    BRP-Rotax INSTALLATION INSTRUCTION ATTACHMENT VIA ENGINE PEDESTAL When using an engine pedestal for the ROTAX® en- gine 125 MAX evo/Junior MAX evo/Mini MAX evo/ Micro MAX evo, the engine is inclined at 0° to 15° in the driving direction. Step Procedure Drill 4 holes (8.5 mm dia / 0.315 in.
  • Page 18 BRP-Rotax INSTALLATION INSTRUCTION NOTES Notes Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 4 Edition October 01 2019/Rev. 0 Edition: October 01 2019...

  • Page 19: Fuel System

    Installation and connection of the fuel pump...................2 Installation of the Bowden cable for carburetor control................4 Installation and connection of the carburetor ..................6 Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 1 Edition: October 01 2019...
  • Page 20 3. The larger fuel hose (pos. 1) should be connected to the fuel filter (pos. 2) and to the fuel tank. Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 2 Edition: October 01 2019...
  • Page 21 Figure 3.4 Figure 3.5 Large fuel hose Fuel filter Concerns all engines Concerns all engines except 125 MAX evo Step Procedure For engines without exhaust slide, a direct connec- Install the connection between the fuel tion (with vacuum hose’) between the gearbox and tank and the fuel filter.
  • Page 22 Make sure that the Bowden cable does not Connect Bowden cable to throttle touch any moving parts or the track. pedal. Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 4 Edition: October 01 2019...
  • Page 23 The Bowden cable must not be under full tension when the throttle is in fully open position. Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 5 Edition: October 01 2019...

  • Page 24: Installation And Connection Of The Carburetor

    Connect the outlet hose of the fuel pump with fuel inlet (pos. 3) on the carburetor. Figure 3.7 Hose clamp Carburetor Fuel inlet Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 6 Edition: October 01 2019...

  • Page 25: Electric System

    Installation of the wiring harness ......................2 Wiring harness - overview ........................4 Installation ECU into the battery clamp assy....................5 Installation of the battery clamp assy......................7 Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 1 Edition: October 01 2019...

  • Page 26: Installation Of The Wiring Harness

    The wiring harness must not touch moving parts of the track. NOTE When unplugging connections on ignition pick up and ignition coil, press the integrated catch first. Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 2 Edition: October 01 2019...
  • Page 27 Figure 4.5 mounted tie wrap (pos. 2) onto the mounting plate. Step Procedure Attach the ignition cable onto the wir- ing harness. Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 3 Edition: October 01 2019...

  • Page 28: Wiring Harness - Overview

    INSTALLATION INSTRUCTION WIRING HARNESS - OVERVIEW Figure 4.6 Connector pickup sensor Connector starter Connector battery Connector RAVE (only applicable 125 MAX evo) Connector ignition coil Connector ECU Tie wrap 250x4.8 Tie wrap 142x3.2 Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo...

  • Page 29: Installation Ecu Into The Battery Clamp Assy

    Make sure that the connection cable has been pad. installed between the two pads. The connection of the ECU is on the rear side (against the driving direction). Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 5 Edition: October 01 2019...
  • Page 30 BRP-Rotax INSTALLATION INSTRUCTION Figure 4.9 Rubber pad Connection cable ECU connector Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 6 Edition: October 01 2019...

  • Page 31: Installation Of The Battery Clamp Assy

    (pos. 9). The battery fixture (pos. 5) can be fixed with one screw on one side of the clamp (pos. 3). Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 7 Edition: October 01 2019...
  • Page 32 Connect the positive terminal (red) of the battery. Connect the negative terminal (black) of the battery. Figure 4.14 Retaining lugs Flange head screw Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 8 Edition: October 01 2019...

  • Page 33: Cooling System

    Cooling system - overview ........................2 Installation of the radiator ........................3 Intake silencer ............................5 Installation of the intake silencer with integrated airfilter ................6 Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 1 Edition: October 01 2019...

  • Page 34: Cooling System - Overview

    Allen screw with rounded flange head Lock washer Small radiator (125 Micro MAX evo only) Allen screw Radiator bracket (125 Micro MAX evo only) Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 2 Edition: October 01 2019...

  • Page 35: Installation Of The Radiator

    NOTE Figure 5.3 The large radiator (pos. 1) fits to engine types 125 MAX evo, 125 Junior MAX evo and 125 Washer Allen screw M8x75 Mini Max evo. The small radiator (pos. 2) fits to engine type...
  • Page 36 Therefore, cut the bottom hose using scissors or a knife. Figure 5.5 Hose clamp 16–25 Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 4 Edition: October 01 2019...

  • Page 37: Intake Silencer

    Holder for filter element Intake silencer tube Carburetor socket Support bracket Lock nut M6 Washer 6.4 Allen screww. M6x20 Clamp 50–70 Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 5 Edition: October 01 2019...

  • Page 38: Installation Of The Intake Silencer With Integrated Airfilter

    Attach the intake silencer on the sup- port bracket (pos. 8) using 2 Allen screws M6x20 (pos. 10) with washers (pos. 9) and nuts (pos. 7). Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 6 Edition: October 01 2019...

  • Page 39: Exhaust System

    BRP-Rotax INSTALLATION INSTRUCTION Chapter: 5 EXHAUST SYSTEM TOPICS IN THIS CHAPTER Installation of the exhaust system ......................4 Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 1 Edition: October 01 2019...
  • Page 40 BRP-Rotax INSTALLATION INSTRUCTION Figure 6.1 Exhaust system (125 MAX evo, 125 Junior MAX Silencer assy. evo, 125 MINI MAX evo) Tension spring Spring stainless Exhaust gasket Retaining plate Spring stainless Rubber buffer Rubber buffer Washer 8.4 Effectivity: 125 MAX evo, Junior MAX...
  • Page 41 BRP-Rotax INSTALLATION INSTRUCTION Exhaust socket assy. (125 MAX evo, 125 Junior Lock nut M8 MAX evo) Exhaust gasket Spring stainless Exhaust socket assy. (125 Mini MAX evo) Exhaust socket assy. (125 Micro MAX evo) Exhaust system (125 Mini MAX evo), similar to...
  • Page 42 TITE is not necessary anymore. NOTE All engine types have the same gaskets. NOTE A leakage in the exhaust system may lead to performance loss. Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 4 Edition: October 01 2019...

  • Page 43: Installation Of The Accessories

    TOPICS IN THIS CHAPTER Installation of mounting plate ........................2 Fitting of the spark plug...........................3 Installation and connection of the RAVE control unit ................4 Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 1 Edition: October 01 2019...
  • Page 44 (pos. 4) using 2 Allen screws Position of the mounting plate M6x20 (pos. 1), washers (pos. 2) and lock nuts M6 (pos. 3). Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 2 Edition: October 01 2019...

  • Page 45: Fitting Of The Spark Plug

    25 Nm (221 lbf in) to 27 Nm (239 lbf in). Install the spark plug connector (pos. 2), ensure correct engagement. Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 3 Edition: October 01 2019...
  • Page 46 (pos. 6), a small cable tie (pos. 8) should be attached directly afterwards to the pressure line. Do not tie up the pressure line completely! Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 4 Edition: October 01 2019...
  • Page 47 (pos. 3). Secure the pressure line on the magnetic valve with a tie wrap (pos. 4). Figure 7.10 Hose package Metal connector Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 5 Edition: October 01 2019...
  • Page 48 BRP-Rotax INSTALLATION INSTRUCTION Figure 7.12 Pressure line Exhaust valve Magnetic valve Tie wrap Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 6 Edition: October 01 2019...

  • Page 49: Finishing Work

    To warrant engine operation within temperature limits of the coolant, a temperature sensor for observation of the coolant temperature is required. NOTE Refer to Operators Manual for operating limits. Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 1 Edition: October 01 2019...
  • Page 50 (pos. 2) to 10 Nm. Replenish new gear oil in the air vent hole. Hand-tighten the air vent screw (pos. Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 2 Edition: October 01 2019...

  • Page 51: Fitting Of The Drive Chain

    NOTE Use the engine stop screw to ten- sion the chain. Figure 8.2: Chain tensioner Fasten engine on the chassis. Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 3 Edition: October 01 2019...
  • Page 52 BRP-Rotax INSTALLATION INSTRUCTION Figure 8.3: Engine alignment Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 4 Edition: October 01 2019...
  • Page 53 ATTENTION Do not attach the venting hose on the bottom of the collecting reservoir, if only one reservoir is in use. Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 5 Edition: October 01 2019...
  • Page 54 BRP-Rotax INSTALLATION INSTRUCTION NOTES Notes Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 6 Edition October 01 2019/Rev. 0 Edition: October 01 2019...
  • Page 55 Fuel system, installation ........1 Intake silencer ............5 Intake silencer, installation ........6 INTRO ..............1 Mounting plate, installation........2 Oil level, check in gear box ........2 Effectivity: 125 MAX evo, Junior MAX Index evo, Mini MAX evo, Micro MAX evo Page 7 Edition: October 01 2019...
  • Page 56 Operator‘s Manual...

  • Page 58: Chapter

    Chapter 2 – Engine Chapter 3 – Engine calibration Chapter 4 – Engine operation Chapter 5 – Preservation and transport Effectivity: 125 MAX evo, Junior MAX Content evo, Mini MAX evo, Micro MAX evo Page 1 Edition: October 01 2019...
  • Page 59 BRP-Rotax Operators Manual NOTES Page 2 Effectivity: 125 MAX evo, Junior MAX Edition: October 01 2019 evo, Mini MAX evo, Micro MAX evo...

  • Page 60: Chapter: Intro General Information

    Contents This Operators Manual contains instructions about how to operate the ROTAX®-Engine Type 125 MAX evo, 125 Junior MAX evo, 125 Mini MAX evo and 125 Micro MAX evo. Symbols used This Manual uses the following symbols to emphasize particular information. This information is important and must be observed.
  • Page 61 BRP-Rotax Operators Manual NOTES Page 2 Effectivity: 125 MAX evo, Junior MAX Edition: October 01 2019 evo, Mini MAX evo, Micro MAX evo...

  • Page 62: Technical Description

    BRP-Rotax Operators Manual Chapter: 1 TECHNICAL DESCRIPTION TOPICS IN THIS CHAPTER Design of the ROTAX engine types 125 MAX evo, Junior MAX evo, Mini MAX evo and Micro MAX evo ................................2 General ..............................2 Cooling circuit ............................2 Balance shaft ............................2 Ignition unit ............................2 Electric starter ............................2...

  • Page 63: Design Of The Rotax Engine Types 125 Max Evo, Junior Max Evo, Mini Max Evo And Micro Max Evo

    EVO, MINI MAX EVO AND MICRO MAX EVO GENERAL The Rotax 125 MAX evo engine is a single cylinder two stroke engine with reed valve con- trolled inlet and 125 cm displacement. Mixture lubrication is achieved by adding oil to the gasoline in a specified mixing ratio.

  • Page 64: Electro Pneumatically Exhaust Timing Control (125 Max Only)

    Operators Manual ELECTRO PNEUMATICALLY EXHAUST TIMING CONTROL (125 MAX ONLY) The engine type 125 MAX evo is equipped with an electro-pneumatic exhaust control. The E-RAVE (Electronic ROTAX Adjustable Variable Exhaust) system is controlled by an elec- tro-pneumatic valve via the ECU. The vacuum required is provided by the engine crankcase.

  • Page 65: Centrifugal Clutch

    2.500 rpm. Only at an engine speed of ap- prox. 4.000 rpm. the centrifugal clutch is completely engaged. ________________________________________________________________ Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 4...

  • Page 66: Engine

    BRP-Rotax Operators Manual Chapter: 2 ENGINE TOPICS IN THIS CHAPTER Operating fluids and battery ........................2 Coolant..............................2 Battery..............................2 Battery charging unit..........................4 Fuel..............................5 Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 1 Edition: October 01 2019...
  • Page 67 It is recommended to always carry a charged spare battery. The installed battery should be replaced with a fully charged battery before it is completely exhausted. Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 2...
  • Page 68 NOTE To charge a battery, the battery charging unit specified by ROTAX® and available as an accessory should be utilized (battery charger part no. 265148). When using the lithium battery available as spare part, the battery charger Optimate Lithium (part no.
  • Page 69 NOTE A red/green blinking of the charging control lamp indicates transition from main charging to additional charging and does not signal a faulty battery charger. Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 4...
  • Page 70 Non-compliance can result in serious injuries or death! Never perform mixing and fuelling in closed rooms, handle fuel in well ventilated areas only. Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 5 Edition: October 01 2019...
  • Page 71 ATTENTION Unleaded fuel has a limited storage life. Store only the quantity of fuel in a container which will be needed in the near future. Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 6...
  • Page 72 BRP-Rotax Operators Manual ENVIRONMENTAL NOTE Don’t spill fuel. Absorb spilled fuel with appropriate drying agent and ensure ecological disposal. ______________________________________________________ Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 7 Edition: October 01 2019...
  • Page 73 BRP-Rotax Operators Manual NOTES Page 8 Effectivity: 125 MAX evo, Junior MAX Edition: October 01 2019 evo, Mini MAX evo, Micro MAX evo...

  • Page 74: Engine Calibration

    Selection of the transmission ratio ......................14 Exchange of the clutch drum with chain sprocket fitted ................16 Changing or renewal of the chain sprocket on the clutch drum ..............18 Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 1...

  • Page 75: Engine Calibration

    In this diagram, the different performance characteristics of the MAX engines are shown. The vertical Y-axis shows the power in kilowatts (kW). The horizontal X-axis shows the ro- tational speed in revolutions per minute (rpm). For more information, please check the performance data sheets on www.rotax-kart.com. Figure 3.1: Performance graphs ______________________________________________________...

  • Page 76: Carburetor Calibration

    The following application for smartphones shows the individual setting of your ROTAX® 125 Max evo engine: The ROTAX® Max Jetting Guide is an App for Android™ and iOS devices, designed to as- sist users with setting up the recommended main jet based on the ambient conditions and the type of engine.

  • Page 77: Automatic-Set-Up

    The app will automatically show all potential Max evo engines, from which one can be selected by clicking on a certain engine type. Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 4...
  • Page 78 After all the necessary information has been provided and selected, you on- ly need to click the circular red button saying “CALCULATE” at the bottom of the screen. Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 5...
  • Page 79 Now the recommended main jet value will be provided. In case a second calculation needs to be made, you can start over by simply pressing the button saying “RESET” next to the calculated value. Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 6...

  • Page 80: Manual Set-Up

    Now the recommended main jet value will be provided. In case a second calculation needs to be made, you can start over by simply pressing the button saying “RESET” next to the calculated value. Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 7...
  • Page 81 By clicking the small red X underneath the info button, you can return to the home screen. Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo...
  • Page 82 For better understanding and as help for carburetor adjustment, the following figure de- scribes the effect of the various adjustments, depending on the throttle position. Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 9...
  • Page 83 BRP-Rotax Operators Manual Figure 3.11: Various adjustments ______________________________________________________ Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 10 Edition: October 01 2019...

  • Page 84: Change Of The Carburetor Main Jet

    Remove the main jet (pos. 15) and the main jet cup (pos. 14). NOTE The size of the jet is imprinted on the face of the main jet. Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 11...
  • Page 85 Operators Manual Step Procedure Select the appropriate size of main jet, refer to ROTAX® Max Jetting Guide. Install the main jet cup (pos. 14) in position and fit the corresponding main jet (see ROTAX® Max Jetting Guide). Fit and hand-tighten the plug screw (pos. 27) and gasket ring (pos. 26).
  • Page 86 The default setting of the adjustment screw are two full turns and one quarter of a turn (2 ¼) from inside to outside. ______________________________________________________ Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 13...

  • Page 87: Selection Of The Transmission Ratio

    The following chart (125 MAX evo) shows that the difference between the engine perform- ance and the driving resistance constantly increases at a speed range from 5000 to 9000 rpm, remains the same at a speed range from 9000 to 11500 rpm and decreases again at a speed about 11500 rpm onwards.
  • Page 88 BRP-Rotax Operators Manual engine performance [kW] 125 MAX evo - engine performance/driving resistance 110,5 km/h Difference between engine performance and driving resistance at 10.000 rpm 125 MAX evo 109,8 km/h Driving Resistance 12/78 Driving resistance 12/72 engine speed [rpm] Figure 3.13...

  • Page 89: Exchange Of The Clutch Drum With Chain Sprocket Fitted

    Hex. nut M28x1 15x17x17.6 Needle cage K O-ring 12x2.5 Thrust washer 15.2/25/1 15x19x7 Thrust washer 10/19/ Fixation tool assy. Hex. nut M10x1 Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 16 Edition: October 01 2019...
  • Page 90 BRP-Rotax Operators Manual NOTE Only sprockets with the ROTAX® logo are GENUINE ROTAX® parts! NOTE For the chain sprocket with 11 teeth, use the plain bearing (pos. 9) instead of the needle cage (pos. 10). The plain bearing has to be pressed flush into the bore of the chain sprocket with chamfered end leading.

  • Page 91: Changing Or Renewal Of The Chain Sprocket On The Clutch Drum

    Place the clutch drum with chain sprocket on the respective centering pin so that the clutch drum is secured by the fixation pin. Remove the hex. nut (pos. 5) from the chain sprocket. Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 18...
  • Page 92 Attach the chain sprocket with the hex. nut (pos. 5) to the clutch drum. Tightening torque 120 Nm / 89 lb ft. ______________________________________________________ Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 19 Edition: October 01 2019...
  • Page 93 BRP-Rotax Operators Manual NOTES Page 20 Effectivity: 125 MAX evo, Junior MAX Edition: October 01 2019 evo, Mini MAX evo, Micro MAX evo...
  • Page 94 Engine start ............................2 Stopping the engine..........................4 Running – in procedure for the engine.....................5 Setting of the exhaust valve timing (125 MAX evo only) ................6 Maintenance schedule for engine components ..................9 Operating Limits ..........................11 Effectivity: 125 MAX evo, Junior MAX...

  • Page 95: Engine Operating

    Press the button again until the engine starts. See Fig. “Power button” NOTE If the engine does not start, repeat the operation after a few seconds in the same manner. Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 2 Edition: October 01 2019...
  • Page 96 Inspect any part prone to wear (tyres, bearings etc.) before each kart event for good condition, in accordance with the directives of the kart manufacturer. Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 3...

  • Page 97: Stopping The Engine

    If electric starter is activated, the ignition system will consume current. This can cause a deep discharge and damage to the battery. Figure 4.3: Power button Power button ______________________________________________________ Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 4 Edition: October 01 2019...

  • Page 98: Running - In Procedure For The Engine

    After this running-in procedure, the full power of the engine may be used. ATTENTION Use only fully synthetic 2–stroke oil. BRP-Rotax recommends the use of XPS Kart Tec oil. ______________________________________________________ Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo...

  • Page 99: Setting Of The Exhaust Valve Timing (125 Max Evo Only)

    BRP-Rotax Operators Manual SETTING OF THE EXHAUST VALVE TIMING (125 MAX EVO ONLY) Tools required: • Allen key 4 mm or Socket wrench 8 mm Due to the principle of equal parts, the harness for all MAX engines is identical. For en- gines without E-RAVE, the auxiliary cable (pos.
  • Page 100 The additional cable is attached to the ground wire. The control of the exhaust valve timing is activated at 7600 rpm. Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 7 Edition: October 01 2019...
  • Page 101 Operators Manual Figure 4.5: Cable on starter relay NOTE Either variant 1 or variant 2 has been installed in your engine. ______________________________________________________ Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 8 Edition: October 01 2019...

  • Page 102: Engine Operation

    Re-tighten or re- new as required. Oil level in the Check oil level, gear replenish as compartment required. Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 9 Edition: October 01 2019...
  • Page 103 RAVE Clean hoses with compressed air. ______________________________________________________ Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 10 Edition: October 01 2019...

  • Page 104: Operating Limits

    NOTE Dirt must be cleared from the lamination of the radiator at regular intervals to achieve the best cooling performance. ______________________________________________________ Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 11 Edition: October 01 2019...
  • Page 105 BRP-Rotax Operators Manual NOTES Page 12 Effectivity: 125 MAX evo, Junior MAX Edition: October 01 2019 evo, Mini MAX evo, Micro MAX evo...

  • Page 106: Preservation And Transport

    TOPICS IN THIS CHAPTER Preservation and transport........................2 Preservation of engine and equipment ....................2 Transport of the kart..........................2 IMPORTANT INFORMATION (SUMMARY).....................3 Notes ..............................4 Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 1 Edition: October 01 2019...

  • Page 107: Preservation And Transport

    Remove drain screw on float chamber of carburetor and collect the fuel in a suitable container. Clean drain screw and refit. ______________________________________________________ Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 2 Edition: October 01 2019...

  • Page 108: Important Information (Summary)

    0 °C/ 32 °F: drain the system) 0.10 BALANCE DRIVE Engine oil SAE 15W-40 XPS Kart-Tec GEARBOX OIL (100 cc) SPARK PLUG see IPC Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 3 Edition: October 01 2019...

  • Page 109: Notes

    ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 4 Edition: October 01 2019...
  • Page 110 Coolant ..............2 Operating fluids and battery ........2 Cooling circuit ............2 Operating limits........... 11 Design of the ROTAX engine, Type 125 MAX ..2 Performance graphs..........2 Preservation and transport........2 Preservation of engine and equipment ....2 Electric starter............2 Electro pneumatically exhaust timing control ...3 Engine calibration ..........2...
  • Page 112 BRP-Rotax GmbH & Co KG | Rotaxstraße 1 | 4623 Gunskirchen, Austria | T: +43 7246 601 0 | F: +43 7246 6370 www.rotax.com | www.rotax-kart.com R and TM are trademarks of BRP-Rotax GmbH & Co KG. © 2019 BRP-Rotax GmbH & Co KG. All rights reserved.

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