BRP ROTAX 125 SENIOR MAX EVO Operator's Manual
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BRP ROTAX 125 SENIOR MAX EVO Operator's Manual

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OPERATOR'S
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

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Summary of Contents for BRP ROTAX 125 SENIOR MAX EVO

  • Page 1 OPERATOR‘S 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...

  • Page 3: Table Of Contents

    BRP-Rotax Operators Manual Table of Content Chapter INTRO – GENERAL INFORMATION Chapter 1 – Technical Description Chapter 2 – Engine Chapter 3 – Engine calibration Chapter 4 – Engine operation Chapter 5 – Preservation and transport Effectivity: 125 MAX evo, Junior MAX...
  • Page 4 BRP-Rotax Operators Manual NOTES Page 2 Effectivity: 125 MAX evo, Junior MAX Edition: March 01 2021 evo, Mini MAX evo, Micro MAX evo...

  • Page 5: Chapter: Intro General Information

    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 obligation.
  • Page 6 BRP-Rotax Operators Manual This information gives you additional advice and tips m WARNING This vehicle may exceed the performance of other vehicles you may have ridden. Take time to familiarize yourself with your new vehicle. ______________________________________________________ INTRO Effectivity: 125 MAX evo, Junior MAX...

  • Page 7: 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 8: Design Of The Rotax Engine Types 125 Max Evo, Junior Max Evo, Mini Max Evo And Micro Max Evo

    BRP-Rotax Operators Manual DESIGN OF THE ROTAX ENGINE TYPES 125 MAX EVO, JUNIOR MAX 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.

  • Page 9: Electro Pneumatically Exhaust Timing Control (125 Max Only)

    BRP-Rotax 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 10: Centrifugal Clutch

    BRP-Rotax Operators Manual CENTRIFUGAL CLUTCH The engine is equipped with a centrifugal clutch operating in an oil bath. This clutch sepa- rates the engine from the gearbox at less than 2.500 rpm. Only at an engine speed of ap- prox. 4.000 rpm. the centrifugal clutch is completely engaged.

  • Page 11: 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: March 01 2021...
  • Page 12 BRP-Rotax Operators Manual OPERATING FLUIDS AND BATTERY See also table “important information (summary)” in Chapter 5. COOLANT Use only distilled water as engine coolant. If the kart is stored below the freezing tempera- ture of water, make sure to drain the water from the cooling radiator and engine completely.
  • Page 13 BRP-Rotax Operators Manual NOTE If the spark plug is removed, to check if the battery still generates a spark, consid- er the following: with the spark plug removed it is easier for the electric starter to crank the engine, which reduces current absorption of the electric starter, result- ing in battery voltage adequate to generate a spark.
  • Page 14 BRP-Rotax Operators Manual BATTERY CHARGING UNIT When charging the battery take note of the following: Step Procedure Connect battery charger to the charging connector (pos. 1). Figure 2.1: Pos. 1: Charging connector, TYPICAL Step Procedure Connect the battery charging unit on 110-230V, 50 - 60Hz power supply.
  • Page 15 BRP-Rotax Operators Manual Step Procedure Unplug power supply to battery charging unit. Remove output wires of the battery charger from the battery. The battery is ready again for use. ATTENTION In addition to these directives, follow the advice of the battery charging unit manufacturer.
  • Page 16 BRP-Rotax Operators Manual m WARNING Non-compliance can result in serious injuries or death! Fuel the kart only when engine is not running and the combination switch is at OFF position. m WARNING Risk of fire and explosion! Make sure that fuel will not splash onto hot engine components or equipment.Always wipe off any fuel spillage from the vehicle.
  • Page 17 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: March 01 2021...
  • Page 18 BRP-Rotax Operators Manual NOTES Page 8 Effectivity: 125 MAX evo, Junior MAX Edition: March 01 2021 evo, Mini MAX evo, Micro MAX evo...

  • Page 19: Engine Calibration

    BRP-Rotax Operators Manual Chapter: 3 ENGINE CALIBRATION TOPICS IN THIS CHAPTER ENGINE CALIBRATION..........................2 Run-in procedure ..........................2 Performance graphs ..........................2 Carburetor calibration ..........................4 Automatic-set-up ...........................5 Manual set-up ............................8 Change of the carburetor main jet ......................12 Selection of the transmission ratio ......................15 Exchange of the clutch drum with chain sprocket fitted ................17...

  • Page 20: Engine Calibration

    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 21 BRP-Rotax Operators Manual Figure 3.1: Performance graphs ______________________________________________________ Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 3 Edition: March 01 2021...

  • Page 22: Carburetor Calibration

    45 °C / 113 °F. NOTE The warranty by BRP-Rotax will no longer apply, if the carburetor calibration is carried out improperly and causes engine damage. The following application for smartphones shows the individual setting of your ROTAX®...

  • Page 23: Automatic-Set-Up

    BRP-Rotax Operators Manual AUTOMATIC-SET-UP Step Procedure Click on the blue font "Update GPS weather data" button below the weather information. After a short time the app will automatically provide all the nec- essary information regarding weather and geographical position. Figure 3.2...
  • Page 24 BRP-Rotax Operators Manual Figure 3.3 Step Procedure Having completed all fields of the weather data and having selected the en- gine type you can press the white "CALCULATE" button on the bottom of your screen to find out the suitable jet for your engine type and environment.
  • Page 25 BRP-Rotax Operators Manual Figure 3.4 Step Procedure 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.

  • Page 26: Manual Set-Up

    BRP-Rotax Operators Manual Figure 3.5 ______________________________________________________ MANUAL SET-UP Step Procedure In case no GPS signal or internet connection is available, the necessary da- ta needs to be added manually, which of course requires knowledge about current weather conditions at the race track as well as the altitude. By click- ing on the empty space next to “Temperature”, “Altitude”, “Atmos.
  • Page 27 BRP-Rotax Operators Manual 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. 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”...
  • Page 28 BRP-Rotax Operators Manual Figure 3.7 Please scan the following QR-code for a detailed instruction video: Figure 3.8: QR- code App Download Please scan the following QR-code for your mobile device: Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo...
  • Page 29 BRP-Rotax Operators Manual Figure 3.9: QR- code, Android device Figure 3.10: QR- code, iOS device 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.

  • Page 30: Change Of The Carburetor Main Jet

    BRP-Rotax Operators Manual CHANGE OF THE CARBURETOR MAIN JET To change the carburetor main jet, proceed as follows: Tools required: • Open-end wrench 19 mm • Flathead screwdriver NOTE The carburetor must not be removed from the engine in order to change the jetting.
  • Page 31 BRP-Rotax 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 32 BRP-Rotax Operators Manual NOTE In a disassembled carburetor, the position of the jet needle (pos. 3) can be changed. The standard position of the jet needle is ‘position 2’. If the clip (pos. 4) is set in ‘position 1’ of the jet needle, the full mixture in part and full-load will be- come slightly leaner.

  • Page 33: Selection Of The Transmission Ratio

    BRP-Rotax Operators Manual SELECTION OF THE TRANSMISSION RATIO The transmission ratio (between chain pinion on the engine and chain sprocket on the rear axle of the kart) has an essential influence on the achievable lap time. The routing (fluent or non-fluent) and the conditions (high or low tire grip) of the track re- quire a certain transmission ratio to ensure an optimal lap time.
  • Page 34 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 35: Exchange Of The Clutch Drum With Chain Sprocket Fitted

    BRP-Rotax Operators Manual EXCHANGE OF THE CLUTCH DRUM WITH CHAIN SPROCKET FITTED Step Procedure Remove spark plug connector for safety. Use the fixation tool (pos. 15) to lock the starter gear. Remove hex. nut (pos. 14) and thrust washer (pos. 13). See Fig. Compo- nents of clutch.
  • Page 36 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 37: Changing Or Renewal Of The Chain Sprocket On The Clutch Drum

    BRP-Rotax Operators Manual CHANGING OR RENEWAL OF THE CHAIN SPROCKET ON THE CLUTCH DRUM The chain sprocket (pos. 2) is attached to the clutch drum (pos. 4) with a hex. nut (pos. 5) and torque is transmitted by a needle pin (pos. 3) (see Fig.). The proper changing or renewal of the chain sprocket is only feasible when using the appropriate fixture (pos.
  • Page 38 BRP-Rotax Operators Manual Step Procedure Clean all remains of the securing agent from the components. Degrease the chain sprocket, the clutch hub and the hex. nut. Place the new chain sprocket or the chain sprocket with required number of teeth on the respective centering pin of the fixture.
  • Page 39 BRP-Rotax Operators Manual Chapter: 4 ENGINE OPERATION TOPICS IN THIS CHAPTER ENGINE OPERATING ..........................2 Engine start ............................2 Stopping the engine..........................4 Setting of the exhaust valve timing (125 MAX evo only) ................5 Maintenance schedule for engine components ..................8 Operating Limits ..........................10...

  • Page 40: Engine Operating

    BRP-Rotax Operators Manual ENGINE OPERATING ENGINE START Before starting the engine, make sure you have completed all necessary tasks for running the engine: Fuel tank full. ✔ ✔ Battery charged and connected. ✔ ✔ Battery voltage over 12 V. ✔ ✔...
  • Page 41 BRP-Rotax Operators Manual Figure 4.2: Power button Procedure Step After engine start, take choke back until engine idles smoothly without choke. m WARNING Non-compliance can result in serious injuries or death! Always wear protective clothing for kart operation (helmet, overall, gloves, shoes, neck and rib guards).

  • Page 42: Stopping The Engine

    BRP-Rotax Operators Manual ATTENTION Non-compliance can result in engine damage! Keep to running-in procedure as directed. ATTENTION Operate engine only within the specified limits and intended purpose. m WARNING Non-compliance can result in serious injuries or death! Only get in and out of the kart if engine is not running.

  • Page 43: 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 44 BRP-Rotax Operators Manual Figure 4.4: Ground wire Variant 2: Additional cable on starter relay Cable on starter relay. The additional cable is NOT attached to the ground wire. The control of the exhaust valve timing is activated at 7900 rpm.
  • Page 45 BRP-Rotax 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 7 Edition: March 01 2021...

  • Page 46: Engine Operation

    BRP-Rotax Operators Manual MAINTENANCE SCHEDULE FOR ENGINE COMPONENTS ATTENTION Non-compliance with the specified maintenance schedule could result in engine damage. FREQUENCY NOTES ENGINE Before After Every Every Every Every every every 2 hours 5 hours 10 hours 50 hours of oper-...
  • Page 47 BRP-Rotax Operators Manual FREQUENCY NOTES ENGINE Before After Every Every Every Every every every 2 hours 5 hours 10 hours 50 hours opera- opera- of oper- of oper- of opera- of opera- tion tion ation ation tion tion Drive gears for...

  • Page 48: Operating Limits

    BRP-Rotax Operators Manual OPERATING LIMITS Operating the engine is only permitted under following conditions: Recommended coolant temperature rang: 45 °C – 85 °C (113 °F – 185 °F). ATTENTION Operating the engine at a too low temperature could result in piston seizure.

  • Page 49: Preservation And Transport

    BRP-Rotax Operators Manual Chapter: 5 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 50 BRP-Rotax Operators Manual PRESERVATION AND TRANSPORT PRESERVATION OF ENGINE AND EQUIPMENT For longer periods out of operation (winter time), make sure that the engine will be properly preserved. Step Procedure Detach carburetor, drain fuel from carburetor and close carburetor openings to ensure that no dust or dirt can enter.
  • Page 51 BRP-Rotax Operators Manual IMPORTANT INFORMATION (SUMMARY) IMPORTANT Liter GAL. SPECIFICATION RECOMMENDED INFORMATION BRANDS FUEL Unleaded fuel of minimum octane level of 95 ROZ resp. 91 MOZ Fully synthetic 2–STROKE OIL XPS Kart-Tec OIL IN FUEL MIX- During break-in: 1:33 (=3% oil)
  • Page 52 BRP-Rotax Operators Manual NOTES ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ Effectivity: 125 MAX evo, Junior MAX...
  • Page 53 BRP-Rotax Operators Manual Index Automatic-set-up...........5 Ignition unit ............2 IMPORTANT INFORMATION (SUMMARY).....3 Intake silencer ............3 INTRO ..............1 Balance shaft............2 Battery and battery charging unit ......2 Battery charging unit ..........4 Maintenance schedule for engine components ..8 Manual set-up ............8 Carburetor ............3 Carburetor calibration ..........4 Centrifugal clutch ..........4...

This manual is also suitable for:

Rotax 125 junior max evoRotax 125 mini max evoRotax 125 micro max evo

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