Related Manuals for Rotax 125 senior MAX evo
Summary of Contents for Rotax 125 senior MAX evo
- Page 1 INSTALLATION MANUAL 125 SENIOR MAX EVO 125 JUNIOR MAX EVO 125 MINI MAX EVO 125 MICRO MAX EVO KART ED. 03/2021 PART NO. 297732 ROTAX-KART.COM...
- Page 2 GENERAL INFORMATION BRP-ROTAX RECOMMENDS PRODUCTS OF THE FOLLOWING COMPANIES: BRP-Rotax GmbH & Co KG T: + 43 7246 601 - 0 Follow us: Rotaxstraße 1 F: + 43 7246 6370 4623 Gunskirchen, Austria www.rotax-kart.com...
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Page 3: Table Of Contents
BRP-Rotax INSTALLATION INSTRUCTION Table of Content Chapter INTRO – Chapter 1 – Engine installation Chapter 2 – Fuel system Chapter 3 – Electric system Chapter 4 – Cooling system Chapter 5 – Exhaust system Chapter 6 – Installation of the accessories Chapter 7 –... - Page 4 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: March 01 2021...
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Page 5: Chapter Intro
This document and all technical data and procedures therein are property of BRP-Rotax GmbH & Co KG and based on the state of knowledge at the time of publication The Manual has been drawn up to the best of our knowledge. However, excluding any liability. - Page 6 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 7 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 8 BRP-Rotax INSTALLATION INSTRUCTION UNBOXING YOUR ROTAX POWERPACK Congratulations on choosing a ROTAX engine! Your ROTAX kart engine comes delivered in two boxes. Figure 1.2: Unboxing Engine box The engine box contains the assembled block engine pre-filled with gearbox oil. Accessory box The accessory box contains all required parts for running the engine.
- Page 9 BRP-Rotax INSTALLATION INSTRUCTION Figure 1.3: Accessory box Pos. Description Check mark Radiator with coolant hoses Mounting plate with ignition coil, solenoid valve and spark plug cap Battery box and wiring harness Battery charger Intake silencer Fuel pump with fuel hose...
- Page 10 BRP-Rotax INSTALLATION INSTRUCTION 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 Gear oil and fuel specifications See the latest Operators Manual. Equipment and modifications Modifications to engine and/or equipment are not allowed.
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Page 11: 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: March 01 2021... - Page 12 BRP-Rotax INSTALLATION INSTRUCTION ENGINE INSTALLATION TO THE Procedure Step CHASSIS Tighten the screws for the engine brackets. Tools required: Make sure that the rear sprocket and • Allen key 8mm the front sprocket align to each other, use a ruler to check it.
- Page 13 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 14 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: March 01 2021...
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Page 15: Fuel System
BRP-Rotax INSTALLATION INSTRUCTION Chapter: 2 FUEL SYSTEM TOPICS IN THIS CHAPTER Installation and connection of the fuel pump...................2 Installation of the Bowden cable for carburetor control................5 Installation and connection of the carburetor ..................7 Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo... - Page 16 BRP-Rotax INSTALLATION INSTRUCTION INSTALLATION AND CONNECTION OF THE FUEL PUMP Step Procedure The retaining plate, rubber buffers, fuel pump, fuel hose (with 230 mm and 1800 mm length) is already pre- assembled. Figure 3.2 Support bracket Screws M6x30 Facilitate the assembly of fuel hose by slightly widening the hose end with a pair of circlip pliers.
- Page 17 BRP-Rotax INSTALLATION INSTRUCTION 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 18 BRP-Rotax INSTALLATION INSTRUCTION ATTENTION The flow in the impulse hose and fuel lines must not be restricted by the use of cable ties. ATTENTION The use of an extra fuel filter must not cause further flow resistance in the fuel line between the fuel tank and the fuel pump.
- Page 19 BRP-Rotax INSTALLATION INSTRUCTION INSTALLATION OF THE BOWDEN CABLE FOR CARBURETOR CONTROL Tools required: • Open-end wrench 10 mm Step Procedure Carefully remove carburetor cover with rubber ring (pos. 7, 8). m CAUTION Reset spring of carb piston presses against carburetor cover and might eject carburetor cover at removal.
- Page 20 BRP-Rotax INSTALLATION INSTRUCTION m WARNING Non-compliance can result in serious injuries or death! The carburetor Bowden cable must not be kinked or restricted as the carburetor piston might get stuck in full throttle position. Step Procedure Set and secure the adjustment screw...
- Page 21 BRP-Rotax INSTALLATION INSTRUCTION INSTALLATION AND CONNECTION OF THE CARBURETOR Tools required: • Ratchet wrench with socket 7 mm • Phillips screwdriver Step Procedure Fit carburetor (pos. 1) into carburetor socket and secure with hose clamp (pos. 2) in vertical position.
- Page 22 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: March 01 2021...
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Page 23: Electric System
BRP-Rotax INSTALLATION INSTRUCTION Chapter: 3 ELECTRIC SYSTEM TOPICS IN THIS CHAPTER 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... -
Page 24: Installation Of The Wiring Harness
BRP-Rotax INSTALLATION INSTRUCTION INSTALLATION OF THE WIRING NOTE HARNESS Disconnect any electrical plug connection only by pulling against the plugs. The wiring harness is delivered partly pre-assembled to facilitate the installation. This means that the relay, Procedure Step the multiple function switch and the battery cover are already pre-assembled and wired. - Page 25 BRP-Rotax INSTALLATION INSTRUCTION Figure 4.4 Figure 4.2 NOTE Step Procedure The shift contact cable must be isolated, be- Connect pick-up connector to pick-up cause there is no use on non-gear engines. sensor (pos. 1). Pay attention to the engagement of the connector.
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Page 26: Wiring Harness - Overview
BRP-Rotax INSTALLATION INSTRUCTION WIRING HARNESS - OVERVIEW Figure 4.6: TYPICAL 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... -
Page 27: Installation Ecu Into The Battery Clamp Assy
BRP-Rotax INSTALLATION INSTRUCTION INSTALLATION ECU INTO THE BATTERY CLAMP ASSY. Step Procedure Prepare rubber pad (consists of two halves) (pos. 1) and the ECU (pos. 2) for installation. Figure 4.8 Rubber pad Step Procedure Insert the complete unit into the battery Figure 4.7... - Page 28 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: March 01 2021...
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Page 29: Installation Of The Battery Clamp Assy
BRP-Rotax INSTALLATION INSTRUCTION INSTALLATION OF THE BATTERY CLAMP ASSY. Tools required: • Allen key 4 mm • Ratchet wrench with socket 8 mm or Phillips screwdriver m WARNING Non-compliance can result in serious injuries or death! Make absolutely sure to avoid short-circuiting of battery terminals. - Page 30 BRP-Rotax INSTALLATION INSTRUCTION Figure 4.11 NOTE The battery terminals must point in the direction Figure 4.13 of the control unit. Step Procedure Install the battery cover onto the bat- tery holder. NOTE Make sure that the two retaining lugs (pos. 1)
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Page 31: Cooling System
BRP-Rotax INSTALLATION INSTRUCTION Chapter: 4 COOLING SYSTEM TOPICS IN THIS CHAPTER 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 32: Cooling System - Overview
BRP-Rotax INSTALLATION INSTRUCTION COOLING SYSTEM - OVERVIEW Figure 5.1 Large radiator Upper coolant water hose Clamp 16–25 Lower coolant water hose Radiator bracket Washer Allen screw with rounded flange head Lock washer Small radiator (125 Micro MAX evo only) Allen screw... -
Page 33: Installation Of The Radiator
BRP-Rotax INSTALLATION INSTRUCTION INSTALLATION OF THE RADIATOR ATTENTION Warrant the best possible engine cooling. Ensure that the air stream covers the complete ra- diator area. Step Procedure Pre-mount radiator with cooling hoses and radiator support as shown. NOTE The large radiator (pos. 1) has a filling capacity Figure 5.3... - Page 34 BRP-Rotax INSTALLATION INSTRUCTION NOTE The length of the upper and bottom hose is sup- posed to be different, but equal at delivery. Therefore, cut the bottom hose using scissors or a knife. Figure 5.5 Hose clamp 16–25 Effectivity: 125 MAX evo, Junior MAX...
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Page 35: Intake Silencer
BRP-Rotax INSTALLATION INSTRUCTION INTAKE SILENCER Figure 5.6 Intake silencer case, top Intake silencer case, bottom Filter element 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... -
Page 36: Installation Of The Intake Silencer With Integrated Airfilter
BRP-Rotax INSTALLATION INSTRUCTION INSTALLATION OF THE INTAKE SILENCER WITH INTEGRATED AIRFILTER Procedure Step Install the rubber intake pipe (pos. 5) in a vertical position into the bottom half (pos. 2) of the intake silencer so that the rounded intake openings point outwards. -
Page 37: 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: March 01 2021... - Page 38 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 39 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 40 BRP-Rotax INSTALLATION INSTRUCTION INSTALLATION OF THE EXHAUST Step Procedure SYSTEM Secure the exhaust system on the ball joint using the two supplied exhaust Tools required: springs (pos. 14). • Open-end wrench 13 mm NOTE • Spring hook For easier installation use the special tool NOTE "Spring hook"...
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Page 41: Installation Of The Accessories
BRP-Rotax INSTALLATION INSTRUCTION Chapter: 6 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 42 BRP-Rotax INSTALLATION INSTRUCTION INSTALLATION OF MOUNTING PLATE NOTE The retaining plate, the mounting plate, the sole- noid valve (except engines without exhaust slide) and the ignition coil are already pre- assembled. Figure 7.3 Allen screws M6x20 Washer 6.4 Crankshaft housing...
- Page 43 BRP-Rotax INSTALLATION INSTRUCTION FITTING OF THE SPARK PLUG The engine will be supplied with a spark plug. Tools required: • Feeler gauge • Socket 21 mm • Torque wrench Procedure Step Remove the transport plug from the cylinder head. Check electrode gap of spark plug. Ad- Figure 7.5...
- Page 44 BRP-Rotax INSTALLATION INSTRUCTION INSTALLATION AND CONNECTION OF THE RAVE CONTROL UNIT NOTE The hose package of the RAVE control is al- ready pre-assembled. NOTE The impulse restrictor is offered optionally. Step Procedure Insert impulse nozzle (pos. 6) about 25 Figure 7.7 mm into the 420 mm pressure line (pos.
- Page 45 BRP-Rotax INSTALLATION INSTRUCTION Step Procedure Step Procedure Attach the fuel line (pos. 1) to the im- Fix another tie wrap (pos. 1) at the fix- pulse nipple on the engine housing ing point (bore) on the engine housing. and secure the line with tie wrap Secure both lines with tie wrap (pos.
- Page 46 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: March 01 2021...
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Page 47: Finishing Work
BRP-Rotax INSTALLATION INSTRUCTION Chapter: 7 FINISHING WORK TOPICS IN THIS CHAPTER Check oil level in gear box........................2 Fitting of the drive chain..........................3 Venting of the gear compartment ......................4 Run-in procedure ............................5 NOTE NOTE To warrant engine operation within temperature limits of the coolant, a temperature sensor for observation of the coolant temperature is required. -
Page 48: Check Oil Level In Gear Box
BRP-Rotax INSTALLATION INSTRUCTION CHECK OIL LEVEL IN GEAR BOX The gear box is already filled with the appropriate amount of oil 100 CC (0.026 gal.) by the engine man- ufacturer. However, before the engine is installed in the frame, the oil level must be verified or replenished. -
Page 49: Fitting Of The Drive Chain
ATTENTION BRP-Rotax recommends O-ring drive chains by ROTAX Premium. Step Procedure Use a chain with the length corre- sponding to the selected transmission ratio of dimension 7.75 x 4.6 x 4.5. -
Page 50: Venting Of The Gear Compartment
BRP-Rotax INSTALLATION INSTRUCTION VENTING OF THE GEAR COMPARTMENT Step Procedure Remove cap from the venting screw. Establish a connection between the venting screw and a collecting reser- voir using a piece of the supplied fuel hose of an appropriate length. -
Page 51: Run-In Procedure
ATTENTION For the first 10 liters of fuel use a mixing ratio of 1:33 (= 3% or 0.3 liter oil per 10 liters of fuel). NOTE BRP-Rotax recommends to use XPS Kart - Tec oil. Step Procedure 15 min. up to 10.000 rpm. - Page 52 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: March 01 2021...
- Page 53 BRP-Rotax INSTALLATION INSTRUCTION Index Battery, installation ..........7 Radiator, installation ..........3 Bowden cable, installation........5 RAVE control unit, installation ........4 Running-in procedure, Run-in procedure ....5 Carburetor, connection ..........7 Carburetor, installation...........7 Spark plug, fitting ..........3 Cooling system .............1 Cooling system overview ........2 Unboxing..............1 Drive chain, fitting..........3...