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BRP ROTAX 125 MAXevo Repair Manual
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BRP ROTAX 125 MAXevo Repair Manual

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REPAIR MANUAL 修護手冊
for ROTAX®-engines type
125 MAX evo
125 JUNIOR MAX evo
125 MINI MAX evo
125 MICRO MAX evo
BRP-Rotax GmbH & Co KG | Rotaxstraße 1 | 4623 Gunskirchen, Austria | T: +43 7246 601 0 |
0
www.rotax.com | www.rotax-kart.com
F: +43 7246 637
Part no. 298061

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Summary of Contents for BRP ROTAX 125 MAXevo

  • Page 1 125 JUNIOR MAX evo 125 MINI MAX evo 125 MICRO MAX evo Part no. 298061 BRP-Rotax GmbH & Co KG | Rotaxstraße 1 | 4623 Gunskirchen, Austria | T: +43 7246 601 0 | F: +43 7246 637 www.rotax.com | www.rotax-kart.com...
  • Page 2 BRP-Rotax REPAIR MANUAL 修護手冊 Chapter章節: INTRO GENERAL INFORMATION基本訊息 Preface前言 Before carrying out repair work on the engine, read the Repair Manual carefully. If any passages of the Manual are not clearly understood or if you have questions, please contact an authorized Distribution or Service Center for ROTAX®-kart engines.
  • Page 3 BRP-Rotax REPAIR MANUAL 修護手冊 NOTES 筆記 Notes Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 2 Edition - February 01 2018 /Rev. 0...

  • Page 5: Table Of Contents

    BRP-Rotax REPAIR MANUAL 修復手冊 Chapter: Chapter 1 GENERAL NOTE 第一章 一般注意事項 TOPICS IN THIS CHAPTER 本章節主題 Abbreviations and terms used in this Manual 手冊中的縮寫與術語 ............... 3 Safety 安全相關事宜 ............................4 Safety notice 安全須知 ............................ 4 Instruction 指引 ............................... 6 Technical documentation 技術文檔......................... 8 Use for intended purpose 使用目的...
  • Page 6 BRP-Rotax REPAIR MANUAL 修復手冊 Purpose This Repair Manual is based on information and the state-of-knowledge of BRP-Rotax of the product current at the date of issue. 目的 本維修手冊基於發布之日當前產品的 BRP-Rotax 信息和知識狀態。 Documentation For additional information on engines, maintenance or parts, you can also contact your nearest authorized ROTAX®-Engine distributor.

  • Page 7: Abbreviations And Terms Used In This Manual 手冊中的縮寫與術語

    BRP-Rotax REPAIR MANUAL 修復手冊 ABBREVIATIONS AND TERMS USED IN THIS MANUAL 本手冊中使用的縮寫和術語 Description Abbreviations 詳述 縮寫 °C Degree Celsius (Centigrade) 攝氏度 °F Degree Fahrenheit 華氏度 Revolutions per minute 每分鐘轉速 125 MAX evo see Manual (Type designation) 型號名稱-細節需查閱手冊 125 Junior MAX evo see Manual (Type designation) 型號名稱-細節需查閱手冊...

  • Page 8: Safety 安全相關事宜

    Always take care by conducting manual work and use safety equipment. The information and components-/system descriptions con- tained in this Manual are correct at the time of publication. BRP-Rotax, however, main- tains a policy of continuous improvement of its products without imposing upon itself any obligation to install them on its products previously manufactured.
  • Page 9 It is, however, important to understand that these warnings and cautions are carefully checked. BRP-Rotax can not evaluate and advise the user of all conceivable ways in which service might be done or of the possible hazardous consequences that may occur.

  • Page 10: Instruction 指引

    BRP-Rotax from its warranty obligations. 對於發動機和相關部件的未經准許的改裝， BRP-Rotax將不進行保修義務。 Accessories 配件 This engine must only be operated with accessories supplied, recommended and re- leased by BRP-Rotax. Modifications are only allowed after the exceptional advice or ap- proval by the engine manufacturer. 本發動機只能使用 BRP-Rotax 提供、推薦和發布的 配件來施作。 只有在獲得發動機製造商的特殊建議或准許後，才可進行改裝。...
  • Page 11 GENUINE ROTAX® spare parts and/or accessories (see IPC) or suitable equivalent in the manufacturer‘ s opinion. Otherwise, any limited warranty by BRP-Rotax is null and void (see latest Warranty Conditions). Spare parts are available at the authorized ROTAX® Distribution- and Service Center. Any warranty by BRP-Rotax becomes null and void if spare parts and or accessories other than GEN- UINE ROTAX®...

  • Page 12: Technical Documentation 技術文檔

    The current edition of the Manual is shown at the bottom of the pages or on the front cover. 本手冊當前的版本顯示在頁面底部或封面上。 Reference 參考 Any reference to a document refers to the latest edition issued by BRP-Rotax, if not stated otherwise. 除非另作言明，對文件的任何參考均以 BRP-Rotax 發布的最新版本為主。 Illustrations 插圖...

  • Page 13: Use For Intended Purpose 使用目的

    Non-compliance can result in serious injuries or death! 不遵守可能會導致重傷或死亡！ Use 用途 The ROTAX Engine Type 125 MAX has been designed and developed exclusively for use in a Kart. Any other use renders the BRP-Rotax factory limited warranty null and void. ROTAX 125 MAX型發動機是專為卡丁車而設計和開發。 任何其他用途都會導致 BRP- Rotax 工廠有限的保修失效。...

  • Page 14: Technical Data 技術規格

    BRP-Rotax REPAIR MANUAL 修復手冊 TECHNICAL DATA 技術規格 125 MAX evo / 125 Junior MAX evo / 125 Mini Engine Type 引擎型式 MAX evo / 125 Micro MAX evo 54.00 mm / 54.5 mm Bore/stroke 內徑/行程 125.0 cc Displacement 排氣量 Nominal power (max.) 最大功率...
  • Page 15 BRP-Rotax REPAIR MANUAL 修復手冊 水泵流量 11000 rpm狀態下，大約22公升 100 % Water (distilled). Drain water after operation in Coolant mixture cold condition to prevent freezing. 冷卻液 混合量 使用100% 蒸餾水 發動機冷機狀態下，把水漏掉、以避免結凍 Coolant capacity 0.6 liter 冷卻液容量 0.6 公升 Oil-in-gasoline lubrication, synthetic 2 Stroke oil Engine lubrication 發動機潤滑油...
  • Page 16 BRP-Rotax REPAIR MANUAL 修復手冊 125 MAX evo / 125 Junior MAX evo / 125 Mini Engine Type MAX evo / 125 Micro MAX evo SAE Engine oil 15W-40 Lubrication of the differential drive 差速驅動潤滑 50 ml (for plastic balance gears) Engine oil capacity 發動機機油容量...
  • Page 17 BRP-Rotax REPAIR MANUAL 修復手冊 Chapter: Chapter 2 MAINTENANCE TOPICS IN THIS CHAPTER 本章節主題 General note 一般注意事項 ..........................2 Authorized personnel 授權人員 ........................3 Process advice 建議的工序 ..........................4 Consumable materials 耗材 ..........................7 Special tools 特殊工具 ............................. 10 Inspection and servicing intervals of the engine components 發動機部件的檢查和維修間隔期 ....12 Contents 內容...

  • Page 18: General Note 一般注意事項

    We particularly emphasize that parts and accessories not supplied as genuine BRP-Rotax accessories parts are not verified for suitability by BRP-Rotax and thus are not authorized for use. In- stallation and/or use of such products may possibly change or negatively influence the 部件和配件...

  • Page 19: Authorized Personnel授權人員

    ROTAX® 維修手冊中概述的適當工具和固定裝置。 • Reasonable maintenance practices are utilized. 實施合理的維護。 Information 信息 Maintenance organizations and individuals are encouraged to contact BRP-Rotax through its worldwide distribution network for information and guidance on any of the tasks out- lined herein. 在此鼓勵各個團隊或個人通過其全球經銷網絡聯繫 BRP-Rotax，以獲取有關 本冊所述的所有任務的信息和指導。...

  • Page 20: Process Advice 建議的工序

    BRP-Rotax REPAIR MANUAL 修復手冊 PROCESS ADVICE 建議的工序 Safety note 安全注意事項 m WARNING 警告 Non-compliance can result in serious injuries or death! 不遵守可能會導致重傷或死亡！ When carrying out maintenance and service work, respect without fail the safety regulations. 在進行維護 和服務工作時，請務必遵守安全規定。 Ignition “OFF” 熄火...
  • Page 21 BRP-Rotax REPAIR MANUAL 修復手冊 Tool 工具 ATTENTION 注意 In order to avoid mechanical damages, never loosen or tighten screws and nuts with pli- ers but only with the specified tools.只可使用指定的工具擰鬆或鎖固螺栓和螺帽。切勿使用鉗子以避免機械損壞 Safety wiring 安全的接線 （保安部品的更換） ATTENTION 注意 If during diassembling/reassembling the removal of a safety item (e.g. safety wiring, self-locking fastener, etc.) should be necessary, it must be always replaced by a new one.
  • Page 22 BRP-Rotax REPAIR MANUAL 修復手冊 Cleaning of parts 部件的清潔 ATTENTION 注意 All metal and synthetic parts are generally washed with suitable cleaning agents. Be- fore using new and unknown cleaning agents check the compatibility of materials. 所有金屬和合成部件都要採用合適的清潔劑 作清洗。 在使用新的或是未知的清潔劑之前，請先檢查材料的兼容性。 Removed parts 關於拆下的部件...

  • Page 23: Consumable Materials 耗材

    一般注意事項 ATTENTION 注意 Use only the specified or technically equivalent materials from BRP-Rotax for all maintenance work. When handling chemicals, comply with all the customary regula- tions and specifications of the producer, including the expiry date and instruction. 所有維護工作只可採用 BRP-Rotax 指定的或等效技術規格的材料來進行。 處理化學品...
  • Page 24 BRP-Rotax 897161 MOLYKOTE 111 100 g (0.22 lb) REPAIR MANUAL 修復手冊 long-term lubricant for shaft seal 軸封用的長效潤滑劑 897330 Lithium-based grease or Dow 250 g (0.55 lb) Corning to prevent leakage current 鋰基潤滑脂或Dow Corning(硅膠) 防止漏電流 25473 XPS Kart TEC DD2 Kart Gear oil 1000 ml (0.26 US...
  • Page 25 BRP-Rotax REPAIR MANUAL 修復手冊 ATTENTION 注意 Use only approved cleaning agents (e.g. kerosine, varsol, etc.) for cleaning all metal parts. 清潔所有金屬部件 只可使用經認定的清潔劑（例如煤油、varsol 等） Do not use lye-based cold cleaner or degreasing agents. Do not clean coolant or oil ho- ses with aggressive solutions.

  • Page 26: Special Tools 特殊工具

    BRP-Rotax REPAIR MANUAL 修復手冊 SPECIAL TOOLS 特殊工具 Figure 圖 2.2 Chapter 2 Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 10 Edition - February 01 2018 /Rev. 0...
  • Page 27 BRP-Rotax REPAIR MANUAL 修復手冊 Part no. Description 編號 料號 說明 277381 Fixation tool for crankshaft 曲柄軸固定工具 276016 Puller assy.拉拔器總成 676010 Insertion sleeve 插入襯套 676021 Insertion jig 插入冶具 676030 Insertion jig插入冶具 676040 Insertion tool 插入工具 676035 Insertion tool 插入工具 877930 Trestle support 支撐架...
  • Page 28 BRP-Rotax REPAIR MANUAL 修復手冊 INSPECTION AND SERVICING INTERVALS OF THE ENGINE COMPONENTS 發動機部件的檢查及維修週期 Safety note 安全注意事項 m WARNING 警告 Non-compliance can result in serious injuries or death! 不遵守可能會導致重傷或死亡！ All repair and maintenance work must only be carried out by a qualified technician.
  • Page 29 BRP-Rotax REPAIR MANUAL 修復手冊 Inspect the radiator hoses and hose Inspect before every clamps on the engine and radiator for operation of vehicle tightness and sealing. 車輛運轉之前都要檢查 檢查發動機和水箱的軟管與軟管夾是 否有鎖緊且密封。 3) Carburetor and intake silencer 化油器以及進氣消音器 Inspect the carburetor connections to...
  • Page 30 BRP-Rotax REPAIR MANUAL 修復手冊 Points of inspection Interval Chapter Operating hours Reference 檢查重點 作業間隔時間 參考章節 Inspection, remedial action as indicated 檢查,補救措施 以下所示 4) Fuel system 燃油系統 Inspect fuel filter for dirt, replace if Inspect before every required. operation of vehicle 檢查燃油濾清器，髒了就換掉...
  • Page 31 BRP-Rotax REPAIR MANUAL 修復手冊 (依實際使用狀況來斟酌) 9) Clutch 離合器 Inspect clutch drum needle bearing for Every 10 hours of wear, replace if necessary. operation 檢查離合器鼓、滾針軸承是否磨耗 每運轉10小時進行一次 如有必要就更換 Every 10 hours of Clean the sealing groove in the starter gear assy. operation 清潔啟動齒輪內的密封油脂...
  • Page 32 BRP-Rotax REPAIR MANUAL修復手冊 NOTES 筆記 Chapter 3 Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 1 Edition - February 01 2018 /Rev. 0...
  • Page 33 BRP-Rotax REPAIR MANUAL 修復手冊 Chapter 3: 第三章 ENGINE 發動機 TOPICS IN THIS CHAPTER 本章節主題 System description 系統說明 ........................... 2 Preparation for removal 拆卸前的準備 ......................3 Removal of the ignition system 點火系統的拆卸 ..................... 3 Removal of the exhaust system 排氣系統的拆卸 .................... 6 Removal of radiator with cap assy 水箱與水箱蓋的拆卸...

  • Page 34: System Description 系統說明

    BRP-Rotax REPAIR MANUAL 修復手冊 SYSTEM DESCRIPTION 系統說明 Overview 概述 Engine 發動機 Figure 3.1: Engine components 發動機組件 發動機 1 Engine 化油器 Carburetor 排氣系統 進氣消音器 3 Exhaust system Intake silencer 燃油泵 6 Radiator 冷卻水箱 5 Fuel pump 7 Battery mounting + ECU 電瓶支架...

  • Page 35: Preparation For Removal 拆卸前的準備

    BRP-Rotax REPAIR MANUAL 修復手冊 PREPARATION FOR REMOVAL 拆卸前的準備 Safety instructions 安全指引 m WARNING 警告 Danger of severe burns and scalds! Always allow the engine to cool down to am- bient temperature before starting any work.在開始任何工作之前，一定要讓發動機冷卻至環境溫度。否則會有嚴重燒傷和燙傷的危險！ REMOVAL OF THE IGNITION SYSTEM 點火系統的拆卸...
  • Page 36 BRP-Rotax REPAIR MANUAL 修復手冊 Figure 3.2: Battery 電瓶 電瓶蓋板 Ｏ型環 1 Battery cover O-ring 3 Allen screw with rounded flange head Positive battery terminal 電瓶正極端子 附盤型法蘭的內六角螺栓 5 Negative battery terminal 電瓶負極端子 Instruction 指引 See system. 點火系統 Figure圖: Ignition 4. Pull the spark plug connector (1) off the spark plug. Minimum removal force 30 N.
  • Page 37 BRP-Rotax REPAIR MANUAL 修復手冊 Figure 圖 3.3: Ignition system 點火系統 火花塞接頭 點火線圈 1 Spark plug connector 2. Ignition coil 曲軸角度傳感器 3 Crankshaft positioning sensor (CPS) 啟動電機 Electric starter 點火線圈接頭 電磁閥 Connector ignition coil 5 Solenoid valve 電磁閥接頭 內六角螺栓 7 Solenoid connector...

  • Page 38: Removal Of The Exhaust System 排氣系統的拆卸

    BRP-Rotax REPAIR MANUAL 修復手冊 REMOVAL OF THE EXHAUST SYSTEM 排氣系統的拆卸 General 概要 Proceeds follows to dismantle the exhaust system: 排氣系統的拆卸步驟如下： Step 步驟 Procedure 程序 Removal of the exhaust system. See Chapter 9. 拆卸排氣系統，參考第9章節 REMOVAL OF RADIATOR WITH CAP ASSY. 水箱與水箱蓋總成的拆卸...

  • Page 39: Removal Of The Fuel Line 燃油管路的拆卸

    BRP-Rotax REPAIR MANUAL 修復手冊 REMOVAL OF THE FUEL LINE 燃油管路的拆卸 Safety 安全 instructions 指引 m WARNING 警告 Danger of explosion and ignition! 具有爆炸和燃燒的危險！ Overflowing and spoilt gasoline must be absorbed immediately with a binding agent and correctly disposed. Do not work with open flames and sources of ignition. Fuel must not come into contact with hot engine parts or components.
  • Page 40 BRP-Rotax REPAIR MANUAL 修復手冊 REMOVAL OF THE BOWDEN CABLE 化油器（油門）拉索的拆卸 Instruction 指引 Proceed as follows to remove the Bowden cable: 依照以下的程序來拆解化油器（油門）拉索 1. Remove the carburetor cover (1).移除化油器上蓋(1號件) 2. Release the nipple screw from the slide. 由滑蓋鬆開此細長螺紋接頭 3. Disconnect the Bowden cable (2) from the nipple screw (3). 由此細長螺紋接頭(3號件)來拆除化油器拉...
  • Page 41 BRP-Rotax REPAIR MANUAL 修復手冊 • Centrifugal clutch 離心離合器 • Cylinder with combustion chamber insert and cylinder head cover 汽缸、燃燒室、缸頭、缸頭蓋 • Exhaust valve 排氣閥 • Reed valve 舌簧閥 • Piston 活塞 • Starter 啟動電機 • Oil Service 換機油 Chapter 3 Effectivity: 125 MAX evo, Junior MAX...
  • Page 42 BRP-Rotax REPAIR MANUAL 修復手冊 Figure圖 3.6: Engine clamp 發動機夾塊 (Illustration similar此為近似圖) 發動機夾塊 1 Engine clamp POSITIONING THE ENGINE ON THE TRESTLE MOUNTING PLATE 發動機放上支架安裝板（拆解台） General 概要 ATTENTION 注意 Do not use flammable liquids and aggressive cleaning agents to clean the engine. 請勿使用易燃液體和腐蝕性清...
  • Page 43 BRP-Rotax REPAIR MANUAL 修復手冊 Special tools 特殊工具 The following special tools and equipment are required: 需要以下的特殊工具或設備 下列是必要的特殊工具 Part no. 料號 Description 說明 Field of application 運用的部位 877390 Engine 發動機 Trestle mounting plate (trestle support) 支撐架 676052 Fixing plate for engine 發動機維修板...
  • Page 44 BRP-Rotax REPAIR MANUAL 修復手冊 Chapter: Chapter 4 章節4 CYLINDER COMPONENTS 汽缸組成 TOPICS IN THIS CHAPTER 本章節主題 System description 系統說明 ..........................2 Cylinder removal 汽缸的拆卸 ..........................3 Removal of the spark plug 火花塞的拆卸 ......................4 Removal of the cylinder head cover 缸頭蓋的拆卸 ..................4 Removal of the thermostat 節溫器的拆卸...
  • Page 45 BRP-Rotax REPAIR MANUAL修復手冊 Installation of the exhaust socket 排氣管座的安裝 ..................30 Installation of the carburetor flange and reed valve 化油器接口與舌簧閥的安裝 .......... 31 Installation of combustion chamber insert 內燃燒室的安裝 ................33 Installation of cylinder head cover 缸頭蓋的安裝 ..................34 Inspection and adjustment of squish gap 擠壓間隙的檢查與調整 ..............36 Installation of spark plug 火花塞的安裝...
  • Page 46 BRP-Rotax REPAIR MANUAL 修復手冊 SYSTEM DESCRIPTION 系統說明 Position on the engine 各部件在發動機上的位置 Overview概述 Figure 圖 4.1: MAX evo engine shown in figure 此圖示乃MAX evo 發動機 汽缸 1 Cylinder Cylinder head cover 缸頭蓋 E-Rave cover 進氣管座 3 Intake socket 電子排氣閥蓋 排氣管座總成...

  • Page 47: Cylinder Removal 汽缸的拆卸

    BRP-Rotax REPAIR MANUAL修復手冊 CYLINDER REMOVAL 汽缸的拆卸 General概要 m WARNING 警告 Danger of severe burns and scalds! Always allow the engine to cool down to am- bient temperature before starting any work.在開始任何工作之前，一定要讓發動機冷卻至環境溫度。否則會有嚴重燒傷和燙傷的危險！ NOTE 注意事項 If only the components in the crankcase are to be replaced or inspected, then the 如果要更換...

  • Page 48: Removal Of The Spark Plug 火花塞的拆卸

    BRP-Rotax REPAIR MANUAL 修復手冊 Instruction 指引 Figure 圖 : Cylinder. 汽缸 Proceed as follows to remove the cylinder: 依以下順序來拆解汽缸 1. Remove the cylinder with the socket set by unscrewing the four M8 collar nuts from the crankcase. 鬆開四個帶緣的M8螺帽，由曲軸箱拆下汽缸 2. Remove the cylinder (1) from the crankcase. 由曲軸箱上拆下汽缸...

  • Page 49: Removal Of The Thermostat 節溫器的拆卸

    BRP-Rotax REPAIR MANUAL修復手冊 Figure圖 4.3: Cylinder head cover 缸頭蓋 缸頭蓋 型環 1 Cylinder head cover O-ring O 105x2.5 內六角螺栓 內六角螺栓 3 Allen screw M6x25 Allen screw M6x16 REMOVAL OF THE THERMOSTAT 節溫器的拆卸 Instruction 指引 Figure圖: Thermostat.節溫器 1. Remove the coolant thermostat from the cylinder head cover (1) by removing the 2 TAPTITE screws M4x8 (6) on the thermostat retaining bracket (5).

  • Page 50: Removal Of The Combustion Chamber Insert 內燃燒室的拆卸

    BRP-Rotax REPAIR MANUAL 修復手冊 Figure圖 4.4: Thermostat 節溫器 Thermostat, 45 Degree celcius 缸頭蓋 1 Cylinder head cover 節溫器 , 規格：45攝氏度 壓縮彈簧 節溫器保持器 Compression spring 3 Thermostat holder 節溫器支架 三角柱 5 Thermostat retaining bracket TAPTITE screw M4x8 型自攻螺栓 Ｍ4x8 REMOVAL OF THE COMBUSTION CHAMBER INSERT 內燃燒室的拆卸...

  • Page 51: Removal Of The Exhaust Socket 排氣管座的拆卸

    BRP-Rotax REPAIR MANUAL修復手冊 Figure圖 4.5: Combustion chamber insert 內燃燒室 1 Combustion chamber insert O-ring 64x2 內燃燒室 型環 64x2 3 O-ring 23.3x2.4 Hex. screw M8x30 外六角螺栓 M8x30 型環 23.3 x 2.4 5 Lock washer A8 防鬆墊圈 A8 REMOVAL OF THE EXHAUST SOCKET 排氣管座的拆卸...

  • Page 52: Removal Of The Intake Socket And Reed Valve 進氣管座與舌簧閥的拆卸

    BRP-Rotax REPAIR MANUAL 修復手冊 REMOVAL OF THE INTAKE SOCKET AND REED VALVE 進氣管座與舌簧閥的拆卸 Instruction 指引 1. Remove support bracket (3) and intake socket (4) by loosing the 5 Allen screws M6x25 (1) (2). 鬆開 5 個內六角螺栓 M6x25 (1、2號件)，卸下支撐架 (3號件) 和進氣管座 (4號件)。...

  • Page 53: Removal Of The Exhaust Valve (125 Max Only) 排氣閥的拆卸 （僅限125 Max機種

    BRP-Rotax REPAIR MANUAL修復手冊 REMOVAL OF THE EXHAUST VALVE (125 MAX ONLY) 排氣閥的拆卸 （僅限125 MAX 機種） General 概要 The engine has an electronically controlled magnet valve which is opening and closing at a certain rpm defined by the ECU. The opening rpm can be set to following: 此發動機有一個...
  • Page 54 BRP-Rotax REPAIR MANUAL 修復手冊 Figure 4.8: Exhaust valve (RAVE) 電子排氣閥 調節栓 Ｏ型環 1 Adjustment screw O-ring 15.9–2.3 三角自攻螺栓 閥蓋 3 TAPTITE screw M5x25 Valve cover 5 Compression spring 48.5/0.8 mm 外管彈簧 Hose spring 134–3.0–0.65 134–3.0–0.65 壓縮彈簧 48.5/0.8 mm 排氣閥活塞 波紋管...

  • Page 55: Removal Of The Piston 活塞的拆卸

    BRP-Rotax REPAIR MANUAL修復手冊 REMOVAL OF THE PISTON 活塞的拆卸 概要 活塞. General Figure圖: piston ATTENTION 注意 In order to protect the piston pin circlip from unintentional loss, a suitable clean cloth should be used to cover the open cylinder bore in the crankcase.
  • Page 56 BRP-Rotax REPAIR MANUAL 修復手冊 Figure圖 4.9: Piston 活塞 活塞銷卡環拉出器 活塞銷卡環 1 Circlip puller Circlip 活塞銷 3 Special tool part no. 676035 Piston pin 特殊工具 料號：676035 Chapter 4 Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 12 Edition - February 01 2018 /Rev.

  • Page 57: Cylinder Components Inspection 汽缸組件的檢查

    BRP-Rotax REPAIR MANUAL修復手冊 CYLINDER COMPONENTS INSPECTION 汽缸組件的檢查 General概要 ATTENTION 注意 Components, which have reached or exceeded their wear limits, must be replaced. Components, which are found to be defective in the context of the visual inspection and might influence the engine's performance, must also be replaced.

  • Page 58: Inspection Of Piston And Piston Ring 活塞與活塞環的檢查

    BRP-Rotax REPAIR MANUAL 修復手冊 INSPECTION OF PISTON AND PISTON RING 活塞與活塞環的檢查 Instructions指引 Figure圖: Piston and piston ring.活塞與活塞環 1. Inspect the piston for cracks and signs of piston seizure. 檢查活塞是否有裂痕或活塞卡死跡象。 2. Inspect the bore of the piston pin for damage and wear. 檢查活塞銷孔是否損壞或磨損。...

  • Page 59: Inspection Of The Piston Diameter 活塞外徑的檢查

    BRP-Rotax REPAIR MANUAL修復手冊 INSPECTION OF THE PISTON DIAMETER 活塞外徑的檢測 Instructions 指引 1. Measure the piston diameter with a micrometer (1). Conditions of measurement: room tem- perature = 20 °C, measuring point 20 mm from the lower edge of the piston, perpendicular to the piston pin axis.

  • Page 60: Inspection Of The Piston And Cylinder Sizing 活塞與汽缸內徑尺寸的檢查

    BRP-Rotax REPAIR MANUAL 修復手冊 INSPECTION OF THE PISTON AND CYLINDER SIZING 活塞與汽缸(內徑)尺寸的檢查 General 概要 NOTE 注意事項 Every new piston has the size classification and a production letter printed on the top of the piston (piston crown). 每個新活塞都有尺寸分類和生產字母，都印在活塞頂部（活塞頂）。 NOTE 注意事項 Every new cylinder has the size classification stamped on the upper sealing surface.

  • Page 61: Inspection Of The Piston Pin, Circlip 活塞銷與卡環的檢查

    BRP-Rotax REPAIR MANUAL修復手冊 Piston classification “h” h類型活塞 Piston labeling Minimum dimen- Maximum dimen- Tolerance field (mm) sion (mm) sion (mm) 活塞分級標記 公差範圍 最小尺寸 最大尺寸 53.925 53.955 “h” 53.94 +0.015 / -0.015 mm “h” 53.95 +0.015 / -0.015 mm 53.935 53.965 “h”...

  • Page 62: Inspection Of The Spark Plug 火花塞的檢查

    BRP-Rotax REPAIR MANUAL 修復手冊 INSPECTION OF THE SPARK PLUG 火花塞的檢查 Instructions 指引 Figure 圖 : Spark plug 火花塞. 1. Inspect spark plug connector for cracks, burn-off, dampness and fouling. 檢查火花塞接頭是否有裂痕、 燒損、潮濕或積垢。 2. Visual inspection of the spark plug for carbonization, oil fouling and discoloration of the electrode.

  • Page 63: Inspection Of The Cylinder Head Cover 缸頭蓋的檢查

    BRP-Rotax REPAIR MANUAL修復手冊 INSPECTION OF THE CYLINDER HEAD COVER 缸頭蓋的檢查 Instructions 指引 See Figure圖: Cylinder head cover. 缸頭蓋 (汽缸頭上蓋) 1. Inspect cylinder head cover for cracks (visual inspection). 檢查汽缸頭上蓋是否有裂痕（目視檢查） 2. Inspect the contact surfaces of the two O-rings (1 and 2) for good condition (max. depth of wear 0.05 mm).

  • Page 64: Inspection Of The Exhaust Socket 排氣管座的檢查

    BRP-Rotax REPAIR MANUAL 修復手冊 Figure 圖 4.16: Combustion chamber insert 內燃燒室 燃燒室 外部區域 1 Combustion chamber 2 Outside area 火花塞螺牙 3 Spark plug thread INSPECTION OF THE EXHAUST SOCKET 排氣管座的檢查 Instructions指引 See Figure圖: Exhaust socket.排氣管座 1. Inspect the exhaust socket for damage or deformation.

  • Page 65: Inspection Of The Carburetor Flange And Reed Valve 化油器接口與舌簧閥的檢查

    BRP-Rotax REPAIR MANUAL修復手冊 INSPECTION OF THE CARBURETOR FLANGE AND REED VALVE 化油器接口與舌簧閥的檢查 General 概況 Instructions 指引 See Figure圖 : Carburetor port and valve guide. 化油器接合口和導閥 1. Inspect rubber lining of reed valves (1) for perishing (if applicable replace complete reed valve).

  • Page 66: Inspection Of The Exhaust Valve (125 Max Only) 排氣閥的檢查 （僅限125 Max機種

    BRP-Rotax REPAIR MANUAL 修復手冊 INSPECTION OF THE EXHAUST VALVE (125 MAX ONLY) 排氣閥的檢查 （僅限125 MAX機種） Instructions 指引 See following figure.參見下圖 Preparation 準備 The following preparation is required before removal. 拆卸前須先進行以下的準備 1. Clean oil or oil deposits from all parts with a suitable cleaning agent. 用合適的清潔劑清潔所有零件上的油或油漬物。...

  • Page 67: Cylinder Components Installation 安裝汽缸組件

    BRP-Rotax REPAIR MANUAL修復手冊 CYLINDER COMPONENTS INSTALLATION 安裝汽缸組件 INSTALLATION OF EXHAUST VALVE (125 MAX ONLY) 安裝排氣閥 （本篇限於125 MAX） NOTE 注意事項 確保組件安裝在正確的位置。 Make sure that the components are installed in their correct position. Special tools特殊工具 The following special tools and equipment are required:需要以下的特殊工具與設備...
  • Page 68 BRP-Rotax REPAIR MANUAL 修復手冊 INSTALLATION OF EXHAUST VALVE, GASKET, VALVE ROD HOUSING 排氣閥、墊片、閥殼的安裝 Instructions 指引 valve. gasket, valve rod housing 排氣閥，墊片，閥桿殼 Figure: Exhaust 1. Insert exhaust valve into the slot in the cylinder head (1). Pay attention on the installation di- rection and make sure that the valve is not ranging into the exhaust port! 將排氣閥插入缸頭(1號件) 的溝槽中。...

  • Page 69: Installation Of The Exhaust Valve Piston 排氣閥活塞的安裝

    BRP-Rotax REPAIR MANUAL修復手冊 INSTALLATION OF THE EXHAUST VALVE PISTON 排氣閥活塞的安裝 General概況 In order to protect the piston pin circlip from unintentional loss in the crankcase, a suitable clean cloth should be used to cover the open cylinder bore. 為防止活塞銷卡環在曲軸箱中 遺失的意外，應使用合適的乾淨布蓋住打開的汽缸口。...

  • Page 70: Installation Of Piston 活塞的安裝

    BRP-Rotax REPAIR MANUAL 修復手冊 INSTALLATION OF PISTON 活塞的安裝 Special tools 特殊工具 The following special tools and equipment are required: 需要以下的特殊工具或設備 Part no. 料號 Description 說明 Field of application 運用的部位 676035 Installation tool 安裝工具 Piston 活塞 n.a. Engine oil 發動機機油 Piston pin 活塞銷...
  • Page 71 BRP-Rotax REPAIR MANUAL修復手冊 5. Push the mounting sleeve (5) with the circlip over it. 把卡環推到安裝套筒 (5) 的上端面。 6. Push the circlip deeper into the mounting sleeve with the tapered side of the installation tool (6). 使用安裝工具 (6號件) 的錐形側將卡環更深地推入安裝套筒（5號件）。 7. Rotate the installation tool and continue to push the mounting sleeve until the circlip locks in- to the mounting sleeve groove.

  • Page 72: Installation Of The Cylinder 汽缸的安裝

    BRP-Rotax REPAIR MANUAL 修復手冊 INSTALLATION OF THE CYLINDER 汽缸的安裝 General 概況 ATTENTION 注意 Use only the piston/cylinder pairings specified by the table in Chapter 4 Section 3.2. All other combinations may lead to engine damage. 一定要採用第 4 章第 3.2 節中的表格指定的規格來配對活塞/氣缸。...
  • Page 73 BRP-Rotax REPAIR MANUAL修復手冊 Figure 4.24: Cylinder head 缸頭 螺樁 活塞 Stud bolts 2 Piston 汽缸 墊片 3 Cylinder 4 Gasket Chapter 4 Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 29 Edition - February 01 2018 /Rev. 0...

  • Page 74: Installation Of The Exhaust Socket 排氣管座的安裝

    BRP-Rotax REPAIR MANUAL 修復手冊 INSTALLATION OF THE EXHAUST SOCKET 排氣管座的安裝 Special tools特殊工具 The following special tools and equipment are required:需要以下的特殊工具或設備 Part no. 料號 Description 說明 Field of application 運用的部位 297386 SILASTIC 732 Gasket 墊片 排氣管座. Instructions指引 Figure圖: Exhaust socket Proceed as follows to install the exhaust socket: 依照以下程序安裝排氣管座...
  • Page 75 BRP-Rotax REPAIR MANUAL修復手冊 INSTALLATION OF THE CARBURETOR FLANGE AND REED VALVE 化油器接口及蛇簧閥的安裝 Special tools 特殊工具 Part no. 料號 Desc ription 說明 Field of application 運用的部位 899788 LOCTITE 648 Screw locking 螺栓的緊固 Figure: Carburetor flange and reed valve 化油器接口以及舌簧閥 Instructions指引 Proceed as follows to install the exhaust socket: 依照以下程序安裝排氣管座...
  • Page 76 BRP-Rotax REPAIR MANUAL 修復手冊 Figure圖 4.26: Carburetor flange and reed valve 化油器接口與舌簧閥 舌簧片 Reed petal 簧片閥體 1 Reed valve 檔片 凹頭螺栓 3 Valve detent Recessed head screw M3x6 化油器接口 墊片 Gasket 6 Carburetor flange Allen screw M6x25, with hole for sealing 支撐架...

  • Page 77: Installation Of Combustion Chamber Insert 內燃燒室的安裝

    BRP-Rotax REPAIR MANUAL修復手冊 INSTALLATION OF COMBUSTION CHAMBER INSERT 內燃燒室的安裝 General 概況 NOTE 注意事項 Note the installation position of the combustion chamber insert ( ) - “Made in Aus- 注意：內燃燒室 的安裝 tria” points to the exhaust port. - “Made in Austria ”這個...

  • Page 78: Installation Of Cylinder Head Cover 缸頭蓋的安裝

    BRP-Rotax REPAIR MANUAL 修復手冊 INSTALLATION OF CYLINDER HEAD COVER 缸頭蓋的安裝 Special tools 特殊工具 The following special tools and equipment are required: 需要以下的特殊工具或設備 Part no. 料號 Description 說明 Field of application 運用的部位 897651 LOCTITE 243 Screw locking 螺栓防鬆用 Preparation 準備 The following preparation is required before installation: 安裝前需先進行以下的準備...
  • Page 79 BRP-Rotax REPAIR MANUAL修復手冊 insert. 內燃燒室 Instructions指引 See Figure: Combustion chamber Proceed as follows to install the combustion chamber insert: 請依照以下步驟安裝內燃燒室 2. Position O-ring (1) on the combustion chamber insert. 將(1號件)Ｏ型環放置在內燃燒室頂 3. Grease the O-ring (2) lightly to ensure that it adheres better to the groove of the cylinder head cover, otherwise fix it with sealant (Silastic).

  • Page 80: Inspection And Adjustment Of Squish Gap 擠壓間隙的檢查與調整

    BRP-Rotax REPAIR MANUAL 修復手冊 Figure圖 4.29: Combustion chamber insert 內燃燒室 Ｏ型環 Ｏ型環 1 O-ring 23.3x2.4 O-ring 64x2 缸頭蓋 3 Cylinder head cover red Allen screw M6x25 （紅色） 內六角螺栓 INSPECTION AND ADJUSTMENT OF SQUISH GAP 擠壓間隙的檢查與調整 General 概況 NOTE 注意事項 The gap between the piston (at the TDC of the piston) and the combustion cham- ber insert (= “squish gap”) is partly responsible for the power characteristics of the...
  • Page 81 BRP-Rotax REPAIR MANUAL修復手冊 Special tools 特殊工具 The following special tools and equipment are required: 需要以下的特殊工具或設備 Part no. 料號 Description 內容 Use 施作 580130 Combustion chamber Solder銲錫線 2 mm 燃燒室 580132 Combustion chamber Solder銲錫線 3 mm 燃燒室 n.a. Vernier caliper 游標卡尺...
  • Page 82 BRP-Rotax REPAIR MANUAL 修復手冊 You find the latest valid reglement on: 可以在以下位址找到最新的設定： http://www.rotax-kart.com/de/Max-Challenge/MAX-Challenge/Regulations. NOTE 注意事項 We recommend setting a squish gap in the upper tolerance range of the relevant model. 我們建議採用公差上限值來設置擠壓間隙。（各機種的設定不同） NOTE 注意事項 The squish gap can be set to a different thickness with cylinder base gaskets.

  • Page 83: Installation Of Spark Plug 火花塞的安裝

    BRP-Rotax REPAIR MANUAL修復手冊 Figure圖 4.30: Squish gap measurement 擠壓間隙量測 銲錫線 游標卡尺 2 Vernier caliper Solder INSTALLATION OF SPARK PLUG 火花塞的安裝 Proceed as follows to install the spark plug: 請依以下步驟安裝火花塞 Instructions指引 1. Screw in spark plug hand-tight and use tightening torque to tighten it with 27 Nm (20 ft.lb).
  • Page 84 BRP-Rotax REPAIR MANUAL 修復手冊 NOTES 筆記 Chapter 5 Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 1 Edition - February 01 2018 /Rev. 0...
  • Page 85 BRP-Rotax REPAIR MANUAL 修復手冊 Chapter: Chapter 5 CRANKCASE 曲軸箱 TOPICS IN THIS CHAPTER 本章節主題 System description 系統說明 ........................... 2 Removal of the crankcase 曲軸箱的拆卸 ......................5 Drain oil 洩放機油 ............................5 Remove water pump and compensating wheels 拆下水泵與平衡輪 ............6 Disassembling the crankcase 拆解曲軸箱...

  • Page 86: System Description 系統說明

    BRP-Rotax REPAIR MANUAL 修復手冊 SYSTEM DESCRIPTION 系統說明 Overview 概況 Figure 圖 5.1: Position on the engine 發動機上的所在位置 Chapter 5 Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 2 Edition - February 01 2018 /Rev. 0...
  • Page 87 BRP-Rotax REPAIR MANUAL 修復手冊 Overview 概況 Components of crankcase 曲軸箱的組成 Figure 5.2 密封環 Sealing ring A 6x10 內六角螺栓 1 Allen screw M6x25 內六角螺栓 齒輪箱蓋 3 Allen screw M6x30 Gearbox cover 凸耳固定環 墊片 Retaining ring with lug 2 0x1.2 5 Gasket 水泵齒輪...
  • Page 88 BRP-Rotax REPAIR MANUAL 修復手冊 沉頭螺栓 止推墊圈 15 Countersunk screw M5x12 Thrust washer Ｏ型環 曲軸箱總成. 黑 17 O-ring 18x3.5 Crank case assy. Black 曲軸箱總成 墊片 19 Crank case assy. Gasket 內六角螺栓 內六角螺栓 21 Allen screw M6x45 Allen screw M6x60 滾針襯套 油封...

  • Page 89: Removal Of The Crankcase 曲軸箱的拆卸

    BRP-Rotax REPAIR MANUAL 修復手冊 REMOVAL OF THE CRANKCASE 曲軸箱的拆卸 Safety information 安全訊息 The following preparation is required before removal: 拆卸前需先進行以下的準備 Preparation準備 m WARNING 警告 Danger of severe burns and scalds! Always allow the engine to cool down to am- bient temperature before starting any work.在開始任何工作之前，一定要讓發動機冷卻至環境溫度。否則會有嚴重燒傷和燙傷的危險！...

  • Page 90: Remove Water Pump And Compensating Wheels 拆下水泵與平衡輪

    BRP-Rotax REPAIR MANUAL 修復手冊 Figure圖 5.3: Drain oil 洩放機油 密封圈 齒輪箱蓋 2 Sealing ring A6x10 Gearbox cover 內六角螺栓 3 Allen screw M6x25 REMOVE WATER PUMP AND COMPENSATING WHEELS 拆下水泵與平衡輪 Special tools 特殊工具 The following special tools and equipment are required: 需要以下的特殊工具或設備...
  • Page 91 BRP-Rotax REPAIR MANUAL 修復手冊 Figure圖 5.4: Gearbox cover 齒輪箱蓋 Sealing ring A 6x10 內六角螺栓 1 Allen screws 密封圈 齒輪蓋 墊片 3 Gear cover Gasket Figure 圖: Water pump and balance shaft. 水泵與平衡軸 Instruction指引 3. Remove water-pump pinion (2) and idle gear (1).拆下水泵齒輪(2號件)以及惰齒輪(1號件) 4.
  • Page 92 BRP-Rotax REPAIR MANUAL 修復手冊 Figure 圖 5.5: Water pump and balance shaft 水泵與平衡軸組 惰齒輪 水泵齒輪 1 Idle gear 28/13 T Water pump pinion 16T 針銷 止推墊圈 3 Needle pin 4x15.8 Thrust washer 凸耳固定環 Water pump 驅動齒輪 5 Retaining ring with lug 20x1.2...

  • Page 93: Disassembling The Crankcase 拆解曲軸箱

    BRP-Rotax REPAIR MANUAL 修復手冊 DISASSEMBLING THE CRANKCASE 拆解曲軸箱 Special tools 特殊工具 The following special tools and equipment are required: 需要以下的特殊工具或設備 Part no. 料號 Description 說明 Field of application 運用的部位 276016 Puller assembly 拉拔器總成 Case halves 曲軸半箱 n.a. Plastic hammer 塑料錘...
  • Page 94 BRP-Rotax REPAIR MANUAL 修復手冊 Instruction 指引 See Figure圖: Balance shaft.平衡軸 4. Remove gasket (2) from the case half (1). 從曲軸半箱 (1號件) 上拆下墊圈 (2號件)。 5. Remove water-pump shaft (4). 拆下水泵軸(4號件) 6. Remove balance shaft (3) from the case. 從曲軸半箱上拆下平衡軸(4號件) Figure 圖 5.7: Balance shaft 平衡軸...

  • Page 95: Removing Bearing And Oil Seal For Shaft 拆卸軸上的軸承以及油封

    BRP-Rotax REPAIR MANUAL 修復手冊 Figure 圖 5.8: Crankcase 曲軸箱 曲軸 曲軸半箱 1 Crankshaft 2 Crankcase half 塑料錘 3 Plastic hammer REMOVING BEARING AND OIL SEAL FOR SHAFT 拆卸軸上的軸承以及油封 Special tools 特殊工具 The following special tools and equipment are required: 需要以下的特殊工具或設備...
  • Page 96 BRP-Rotax REPAIR MANUAL 修復手冊 4. Remove air vent screw (6).拆下排氣螺栓(6號件)。 5. Remove countersunk screw (7) and thrust washer (8). 拆下沉頭螺栓 (7號) 和止推墊圈 (8號件)。 6. Heat the two halves of the case to approx. 150 °C in the convection oven until the bearing can be tapped gently out.
  • Page 97 BRP-Rotax REPAIR MANUAL 修復手冊 m WARNING 警告 Danger of severe burns and scalds! 有嚴重燒傷和燙傷的危險！ Wear heat-resistant gloves during this process! 在此過程中戴上耐熱手套！ Clutch end case half 離合器側的曲軸半箱 離合器側的曲軸半箱 Instruction 指引 Figure: Clutch end case half. 7. Remove case half (1) from the convention oven and drop onto a flat wood board. This re- leases the ball bearing (2) of the crankshaft and the ball bearing (3) from the case.
  • Page 98 BRP-Rotax REPAIR MANUAL 修復手冊 Figure 圖 5.10: Clutch end case half 離合器側的曲軸半箱 曲軸箱總成 滾珠軸承 1 Crank case assy. Ball bearing 6206 滾珠軸承 安裝工具 3 Ball bearing 6302 Installation tool part no. 676030 滾針軸套 管子 5 Needle bushing 8x12x8 Tube Ignition end case half 點火系統側的曲軸半箱...
  • Page 99 BRP-Rotax REPAIR MANUAL 修復手冊 9. Remove case half (3) from the convection oven and drop onto a flat wood board with the case split pane. This removes the ball bearing (4,5) from the crankshaft and the balance shaft. 從烤箱中取出曲軸半箱 (3) 並放在平坦的木板上。 可以將曲軸和平衡軸的滾珠軸...

  • Page 100: Installation Of The Crankshaft Repair Kit 曲軸維修套件包的安裝

    BRP-Rotax REPAIR MANUAL 修復手冊 INSTALLATION OF THE CRANKSHAFT REPAIR KIT 曲軸維修套件包的安裝 DISASSEMBLING OF THE CRANKSHAFT 拆解曲軸 Safety instructions 安全指示 m WARNING 警告 Non-compliance can result in serious injuries or death! 不遵守可能會導致重傷或死亡！ Be particularly careful when working with a tool such as a hydraulic press, and follow the instructions of the manufacturer.All repair and maintenance work must only be car- ried out by a...
  • Page 101 BRP-Rotax REPAIR MANUAL 修復手冊 Figure圖 5.12: Crankshaft repair jig 曲軸維修冶具 Part Part no. 料號 Function 功能 Bottom section of the repair jig 曲軸拆解冶具底座-襯底 Top section of the repair jig 頂部的維修夾具 Thrust plate 推板 276051 Sleeve 襯套 Thrust ring 止推環 Crowbar 撬棒...
  • Page 102 BRP-Rotax REPAIR MANUAL 修復手冊 Part 部件 Part no. 料號 Description 描述 685011 Crankshaft repair kit (1x) 曲軸修復包 consisting of: 組成 217431 Con rod (1x) 連桿 221162 Con rod pin (1x) 連桿銷 232884 Needle bearing (1x) 滾針軸承 227731 Thrust washers (2x) 止推墊圈...
  • Page 103 BRP-Rotax REPAIR MANUAL 修復手冊 2. Position the crankshaft on the thrust plate (3) on bottom section of the tool (4) and make sure that the crankshaft matches the bore in the bottom section at the crankshaft repair jig (4). 將...
  • Page 104 BRP-Rotax REPAIR MANUAL 修復手冊 NOTE 注意事項 Take an available con rod pin (6) and push the old con rod (7) with needle bearing and thrust washer onto the con rod pin. Note the installation instructions. 取一個 堪用的連桿銷 (6號件) 並將帶有滾針軸承和止推墊圈的舊連桿 (7號件) 推到連桿銷...

  • Page 105: Inspection Of The Crankshaft 檢查曲軸

    之一，則必須更換整個曲軸。 be replaced. CS01 CS02 NOTE 注意事項 If one of the wear limits CS03, CS04 or CS05 is reached, BRP-Rotax recom- 如 mends use of the applicable repair kit. See also Chapter 5 Figure: Con rod parts. 果達到磨損極限 、 或...
  • Page 106 BRP-Rotax REPAIR MANUAL 修復手冊 Figure 5.15 Code New dimension Wear limit Description 描述 代碼( 上圖) 新尺寸 磨耗極限 Main bearing seat CS01 29.980 mm - 29.94 mm 29.995 mm 主軸承座 Clutch bearing seat CS02 14.98 mm - 15.003 14.95 mm 離合器軸承座...
  • Page 107 BRP-Rotax REPAIR MANUAL 修復手冊 Description 描述 Code代碼( 上圖) New dimension 新尺寸 Wear limit 磨耗極限 Distance of crank webs CS07 48.95 mm - 49.05mm 49.05 mm 曲軸配重塊的跨距 Thrust washer thinkness CS08 1.0 mm 0.85 mm 止推墊圈厚度 HAFT NOT IN SPECIFICATION 曲軸超標的處理方法...
  • Page 108 BRP-Rotax REPAIR MANUAL 修復手冊 曲軸半邊 台鉗 1 Crankshaft half 2 Vise 撬棒 3 Crowbar 3. The crankshaft can be aligned to the external diameter of the crankshaft webs with target strokes of an aluminum hammer. 可以使用鋁錘來校正曲軸的行程以及配重塊的外徑。 Figure圖 5.17: Aluminum hammer 鋁錘...

  • Page 109: Crankshaft - Assembly 組裝曲軸

    BRP-Rotax REPAIR MANUAL 修復手冊 CRANKSHAFT – ASSEMBLY 組裝曲軸 General 概況 NOTE 注意事項 Clean the bore for the connecting rod pins of the gearbox-side crankshaft half with 使用清潔劑清洗（去脂）曲軸半箱齒輪箱側的連 a cleaning agent (grease-free). 桿銷孔。 Special tools 特殊工具 The following special tools and equipment are required: 需要以下的特殊工具或設備...
  • Page 110 BRP-Rotax REPAIR MANUAL 修復手冊 NOTE 注意事項 Transfer the new con rod from the old con rod pin to the pressed–in (new) con rod pin in the crankshaft repair jig. (note the installation position). 使用曲軸維修冶具， 使用舊的連桿銷來壓入（新）的連桿銷。 （注意安裝位置）。 4. Position the drive end crankshaft half (3) on the thrust plate (2) and press the new con rod pin (5) into the crankshaft until the con rod pin stops moving, then remove the sleeve (6).
  • Page 111 BRP-Rotax REPAIR MANUAL 修復手冊 Figure 圖5.18: Crankshaft assembly 組裝曲軸 止推板 Thrust plate 油壓機 1 Press 曲軸驅動半端 3 Drive end crankshaft half Bottom section of the repair jig 襯底的維修冶具 連桿銷 套管 Con rod pin 6 Sleeve 曲軸 Crankshaft Instructions 指引 See Figure 圖: Crankshaft...
  • Page 112 BRP-Rotax REPAIR MANUAL 修復手冊 NOTE 注意事項 Remove excess LOCTITE, otherwise the con rod may be damaged. 施作後，去除多餘的 LOCTITE膠，否則可能會損壞連桿。 Figure 5.19 曲軸半端 1 Crankshaft half (engine end) Bottom section of the repair jig 襯底的維修冶具 （發動機側） 連桿銷 連桿 3 Con rod pin Con rod 9.
  • Page 113 BRP-Rotax REPAIR MANUAL 修復手冊 Figure 圖 5.20: Crankshaft assembly 組裝曲軸 1 Press stamp Bottom section of the repair jig 襯底的維修冶具 油壓機 3 Top section of the repair jig Thrust ring 頂部的維修冶具 止推環 Chapter 5 Effectivity: 125 MAX evo, Junior MAX...

  • Page 114: Crank Case Inspection 檢查曲軸箱

    BRP-Rotax REPAIR MANUAL 修復手冊 CRANK CASE INSPECTION 檢查曲軸箱 INSPECTION OF WATER PUMP DRIVE 水泵驅動系統的檢查 NOTE 注意事項 General 概況 If the edges of the idle gear teeth (1) or the water pump pinion (2) show signs of 如果惰輪齒 號件 或水泵小齒輪 號件...

  • Page 115: Inspection Of Water Pump Shaft 水泵軸的檢查

    BRP-Rotax REPAIR MANUAL 修復手冊 INSPECTION OF WATER PUMP SHAFT 水泵軸的檢查 Instruction 指引 Figure 圖 : Water pump shaft. 水泵軸 1. Check the water pump shaft in the areas around the two shaft seal rings; if it is excessively worn it must be replaced. 檢查水泵軸的兩端密封圈附近區域； 如果過度磨損，則必須更...
  • Page 116 BRP-Rotax REPAIR MANUAL 修復手冊 齒輪在花鍵處的齒隙。 3. Check outer teeth of the two balance gears for signs of wear. If the teeth of one of the bal- ance gears shows signs of wear, both balance gears must be replaced. 檢查兩個平衡齒 輪的外齒是否有磨損跡象。 如果其中一個平衡齒輪的齒形出現磨損跡象，則兩個平衡齒...

  • Page 117: Inspection Of Balance Shaft 平衡軸的檢查

    BRP-Rotax REPAIR MANUAL 修復手冊 Figure 圖 5.23: Balance shaft drive 平衡軸驅動（系統） 平衡軸齒輪 1 Balance gear 50 T O-ring 18x3.5 Ｏ型環 平衡軸 3 Balance shaft Crankshaft assy. 曲軸總成 INSPECTION OF BALANCE SHAFT 平衡軸的檢查 General 概況 NOTE 注意事項 If one of the wear limits BS10 or BS11 is reached, the balance shaft must be 如果達到磨損極限...
  • Page 118 BRP-Rotax REPAIR MANUAL 修復手冊 Figure 圖 5.24: Balance shaft 平衡軸 INSPECTION OF THE HOUSING HALVES 曲軸箱半箱的檢查 Instructions 指引 Figure 圖: Crankcase.曲軸箱 1. Clean both case halves with commercial detergents. 使用清潔劑清潔兩個曲軸半箱。 2. Check both halves (1) for cracks and damage (visual inspection). 目視檢查兩個曲軸半箱 (1號件) 是否有...

  • Page 119: Crank Case - Assembly 組裝曲軸箱

    BRP-Rotax REPAIR MANUAL 修復手冊 CRANK CASE – ASSEMBLY 組裝曲軸箱 General 概況 NOTE 注意事項 Always replace old gaskets, circlips, O-rings and oil seals with new ones after disassembling. 每次拆解後，一定都要把舊的墊片、卡環、Ｏ型環、墊片更換掉 Special tools 特殊工具 The following special tools and equipment are required: 需要以下的特殊工具或設備...
  • Page 120 BRP-Rotax REPAIR MANUAL 修復手冊 NOTE 注意事項 The oil seal for shaft can also be installed from outside to inside if the crankshaft is installed . 如果已安裝了曲軸，也可以從外到內來安裝軸油封。 Figure 圖 5.26: Oil seal installation 油封的安裝冶具 組裝工具 油封 2 Mounting tool part no. 676010...
  • Page 121 BRP-Rotax REPAIR MANUAL 修復手冊 Figure 圖 5.27: Ball bearing 滾珠軸承 滾珠軸承 滾珠軸承 Ball bearing 6206 2 Ball bearing 6302 Chapter 5 Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 37 Edition - February 01 2018 /Rev. 0...
  • Page 122 BRP-Rotax REPAIR MANUAL 修復手冊 Instruction 指引 See Figure 圖 : Needle bushing. 滾針襯套 1. Press in the needle bushing 8x12x8 (1) to the limit stop with the installation tool (2) (part no. 676030) so the label on the needle bearing is facing outwards. 使用安裝工具 (2號件)（料...
  • Page 123 BRP-Rotax REPAIR MANUAL 修復手冊 4. Coat the oil seal (4) for the ignition end crankcase half with oil in the area between the seal- ing lip and dust lip. 針對曲軸箱半部的點火端面的油封(4號件)，密封唇和防塵唇之間的區域 塗上油（發動機機油）。 5. Press in the oil seal (4) to the limit stop with the insertion sleeve (5) (part no. 676010) so the open end of the oil seal for shaft is directed to the balance drive.
  • Page 124 BRP-Rotax REPAIR MANUAL 修復手冊 NOTE 注意事項 The oil seal for shaft can also be installed from outside to inside if the crankshaft 。 如果已安裝了曲軸，也可以從外到內安裝曲軸油封 is installed. Figure 圖 5.29: Ball bearing, oil seal 滾珠軸承、油封 滾珠軸承 止推墊圈 Ball bearing 6005 2 Thrust washer 沉頭螺栓...
  • Page 125 BRP-Rotax REPAIR MANUAL 修復手冊 軸油封。 11. Press in the second oil seal for shaft to the limit stop with the installation tool (8) (part no. 676021) so the open end of the oil seal (4) for shaft is visible. 使用安裝工具 (8號件，料...
  • Page 126 BRP-Rotax REPAIR MANUAL 修復手冊 ASSEMBLY OF CRANKSHAFT, WATER PUMP SHAFT AND BALANCE SHAFT 曲軸、水泵軸以及平衡軸的組裝 Special tools 特殊工具 The following special tools and equipment are required: 需要以下的特殊工具或設備 Part no. Description Field of application 料號 說明 運用的部位 n.a. Convection oven 烤箱 Case half 半曲軸箱...
  • Page 127 BRP-Rotax REPAIR MANUAL 修復手冊 Figure 圖 5.31: Crankshaft, Balance shaft, Water pump shaft 曲軸，平衡軸，水泵軸 曲軸總成 平衡軸 Crankshaft assy. 2 Balance shaft 水泵軸 墊片 Water pump shaft 4 Gasket Chapter 5 Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 43 Edition - February 01 2018 /Rev.

  • Page 128: Assembly Of The Crankcase 曲軸箱的組裝

    BRP-Rotax REPAIR MANUAL 修復手冊 ASSEMBLY OF THE CRANKCASE 曲軸箱的組裝 NOTE 注意事項 General 概況 When using new studs for the assembly of the cylinder, first screw the long side of the threaded studs into the housing and secure them with LOCTITE 243. 使用新螺...
  • Page 129 BRP-Rotax REPAIR MANUAL 修復手冊 Figure 圖 5.32: Mounting plan 安裝圖1-10 內六角螺栓 內六角螺栓 Allen screw M6x45 2 Allen screw M6x60 5. Cut off the protruding section of the crankcase gasket with a sharp knife at the cylinder base surface. 用鋒利的刀片切掉曲軸箱密封墊片凸出汽缸基面的部分。 Chapter 5...

  • Page 130: Installation Of Crankcase Assy 曲軸箱總成的安裝

    BRP-Rotax REPAIR MANUAL 修復手冊 INSTALLATION OF CRANKCASE ASSY.曲軸箱總成的安裝 Final tasks 最終任務 1. Install cylinder assy. See Chapter 4). 安裝氣缸總成。 見第 4 章）。 2. Install balance drive and centrifugal clutch. See Chapter 7). 安裝平衡傳動和離心離合器。 見第 7 章）。 3. Take the engine off the assembly stand. See Chapter 3). 從組裝架上取下發動機。 見第3章）。...
  • Page 131 BRP-Rotax REPAIR MANUAL 修復手冊 Figure 圖 5.33: Crankcase 曲軸箱 Ｏ型環 1 O-ring 18x3.5 曲軸 Crankshaft 平衡軸 平衡軸齒輪 3 Balance shaft Balance gear 平衡軸齒輪 定位記號 5 Balance shaft gear Positioning marking 的位置記號 7 TDC position marking TDC Instruction 指引 See Figure 圖 : Idle gear.
  • Page 132 BRP-Rotax REPAIR MANUAL 修復手冊 8. Check the seating of the needle pin (4) in the cutout in the water pump pinion. 確認針銷 (4號件) 在水 泵小齒輪切口中的位置。 9. Install the idle gear (7) on the cylindrical pin in the case. 將惰齒輪 (7號件) 安裝在曲軸箱的圓柱銷上。...
  • Page 133 BRP-Rotax REPAIR MANUAL 修復手冊 Figure 5.34: Idle gear 惰齒輪 水泵齒輪 凸耳固 1 Water pump gear 19 T Retaining ring with lug 定環 20x1.2 針銷 止推墊圈 Needle pin 4x15.8 3 Thrust washer 10.1/17/1 水泵小齒輪 cylindrical pin 圓柱銷 5 Water pump pinion 16 T 惰齒輪...
  • Page 134 BRP-Rotax REPAIR MANUAL 修復手冊 Figure 圖 5.35 墊片 齒輪箱蓋 Gasket 2 Gearbox cover 密封圈 內六角螺栓 Sealing ring A 6x10 4 Allen screw M6x25 內六角螺栓 Allen screw M6x30 Chapter 5 Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 50 Edition - February 01 2018 /Rev.
  • Page 135 BRP-Rotax REPAIR MANUAL 修復手冊 Chapter章節: Chapter 6 化油器 及 進氣消音器 CARBURETOR AND INTAKE SILENCE TOPICS IN THIS CHAPTER 本章節主題 System description 系統說明 ..........................1 Removal of the carburetor and intake silencer 化油器與進氣消音器的拆卸 ..........3 Removal of the carburetor and intake silencer 化油器與進氣消音器的拆卸 ............ 3 Removal of the fuel pump 燃油泵的拆卸...

  • Page 136: System Description 系統說明

    BRP-Rotax REPAIR MANUAL SYSTEM DESCRIPTION 系統說明 Overview 概述 Position on engine 在發動機上的位置 Figure圖 6.1: Position on engine, TYPICAL (Figure shows 125 MAX evo engine) 在發動機上的位置 （圖示的是125 MAX evo 發動機） 進氣消音器 化油器 Intake silencer 2 Carburetor 燃油泵 3 Fuel pump Chapter 6...
  • Page 137 BRP-Rotax REPAIR MANUAL 修復手冊 REMOVAL OF THE CARBURETOR AND INTAKE SILENCER 化油器與進氣消音器的拆卸 Safety Instructions 安全指引 m WARNING 警告 Danger of severe burns and scalds! 有嚴重燒傷和燙傷的危險！ Always allow the engine to cool down to ambient temperature before starting any work. 在開始任何工作之前，...

  • Page 138: Removal Of The Carburetor And Intake Silencer 化油器與進氣消音器的拆卸

    BRP-Rotax REPAIR MANUAL 修護手冊 REMOVAL OF THE CARBURETOR AND INTAKE SILENCER 化油器與進氣消音器的拆卸 Instruction 指引 Figure 圖: Carburetor and intake silencer. 化油器 與 進氣消音器 ATTENTION 注意 拆卸化油器時，燃油可能會溢出 Fuel may spill out when removing the carburetor. ENVIRONMENTAL NOTE 環境注意事項 Protect the environment! 保護環境！...

  • Page 139: Removal Of The Fuel Pump 燃油泵的拆卸

    BRP-Rotax REPAIR MANUAL 修復手冊 Figure 圖 6.2: Carburetor and intake silencer 化油器 與 進氣消音器 Impulse line 連到化油 1 Fuel line to the carburetor 導壓管 器的燃油管 Fuel pump 化油器 3 Carburetor 燃油泵 Support bracket 內六角螺栓 5 Allen screw M6x25 支撐架 管夾...

  • Page 140: Disassembly Of The Carburetor 化油器的拆解

    BRP-Rotax REPAIR MANUAL 修護手冊 Figure 圖 6.3: Fuel pump 燃油泵 燃油泵 支撐架 1 Fuel pump Support bracket 防鬆螺帽 墊圈 3 Lock nut Washer 內六角螺栓 5 Allen screw M6x20 DISASSEMBLY OF THE CARBURETOR 化油器的拆解 1. Disassembly of the carburetor to the parts shown in...
  • Page 141 BRP-Rotax REPAIR MANUAL 修復手冊 Figure 圖 6.4: Carburetor 化油器 Chapter 6 Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 7 Edition - February 01 2018 /Rev. 0...

  • Page 142: Disassembly Of The Intake Silencer 進氣消音器的拆解

    BRP-Rotax REPAIR MANUAL 修護手冊 DISASSEMBLY OF THE INTAKE SILENCER 進氣消音器的拆解 Figure 圖: Intake Intake silencer進氣消音器 silencer.進氣消音器 1. Disassemble the intake silencer to the parts shown in following Figure. 進氣消音器分解如下圖 所示的零件。 Figure 圖 6.5: Intake silencer 進氣消音器 1 Intake silencer case Intake silencer cover 進氣消音器外殼...

  • Page 143: Inspection Of The Carburetor 化油器的檢查

    BRP-Rotax REPAIR MANUAL 修復手冊 CARBURETOR AND INTAKE SILENCER – INSPECTION OF COMPONENTS 化油器和進氣消音器 – 分件檢查 In the case of problems with the fuel supply the carburetor should be checked: First the components should be cleaned and then inspected. 如果燃油供應出現 問題，就該檢查化油器：首先應清潔部件，然後再檢查部件狀態。...
  • Page 144 BRP-Rotax REPAIR MANUAL 修護手冊 化油器外殼 Carburetor housing 燃油濾芯 Fuel filter 啟動油針 怠速與啟動油嘴 Needle jet DP 267 Idling and starter jets 主油嘴 主油嘴蓋 Main jet Main jet cup 針閥 Needle valve 150 (standard 扣環 8 Clip 標準件 選配件 ) 200 (optional 主油針...

  • Page 145: Inspection Of The Fuel Pump 燃油泵的檢查

    BRP-Rotax REPAIR MANUAL 修復手冊 INSPECTION OF THE FUEL PUMP 燃油泵的檢查 NOTE 注意事項 General概況 燃 Only the complete membrane and gasket set of the fuel pump can be replaced. 油泵的完整隔膜和墊圈組只能更換新品。 Fuel pump gasket set: Part no. 296165 燃油泵墊片組：料號 296165 Instruction 指引...
  • Page 146 BRP-Rotax REPAIR MANUAL 修護手冊 Instruction 指引 Figure 圖 : Intake silencer. 進氣消音器 1. Inspect the silencer case (1) and silencer cover (2) for cracks.檢查消音器外殼(1號件)和消音器 上蓋 (2號件) 是否有裂痕。 2. Inspect the intake silencer tube (3) and carburetor socket (10) for cracks or porosity. 檢查進氣...
  • Page 147 BRP-Rotax REPAIR MANUAL 修復手冊 Figure 圖 6.8: Intake silencer 進氣消音器 進氣消音器外殼 進氣消音器上蓋 1 Intake silencer case Intake silencer cover 濾芯支架/保持器 進氣消音管 Filter element support/holder 3 Intake silencer tube 支撐架 濾芯支架 Support bracket 5 Filter element 墊圈 內 六角螺栓 7 Washer...

  • Page 148: Assembly Of Carburetor 化油器的組裝

    BRP-Rotax REPAIR MANUAL 修護手冊 INSTALLING THE CARBURETOR AND INTAKE SILENCER 安裝化油器與進氣消音器 ASSEMBLY OF CARBURETOR 化油器的組裝 Instruction 指引 NOTE 注意事項 使用 原廠墊圈套件, 料號： 。 Use ROTAX® gasket set, part no. 293834. ROTAX 293834 1. Assemble the components in the opposite succession as you disassembled them. See also Chapter 6) section: Disassembly of the carburetor 按照拆解組件的相反的順序來進行組裝。...
  • Page 149 BRP-Rotax REPAIR MANUAL 修復手冊 Figure圖 6.9: Float chamber 浮筒艙 浮筒配件 浮筒 4.p 1 Float attachment 2 Float 4.0 調整螺栓 混合比調整螺栓 Adjustment screw 4 Adjustment screw kit Chapter 6 Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 15 Edition - February 01 2018 /Rev.

  • Page 150: Assembly Of Intake Silencer 進氣消音器的組裝

    BRP-Rotax REPAIR MANUAL 修護手冊 ASSEMBLY OF INTAKE SILENCER 進氣消音器的組裝 NOTE 注意事項 General 概況 Before assembly, first immerse the filter element in filter oil. Squeeze out excess 組裝前，先將濾芯浸入濾油中。 然後將多餘的油擠出。 oil. Instruction 指引 The following steps are required to install the intake silencer: 用以下步驟安裝進氣消音器：...

  • Page 151: Installation Of Fuel Pump, Carburetor 安裝 燃油泵及化油器

    BRP-Rotax REPAIR MANUAL 修復手冊 INSTALLATION OF FUEL PUMP, CARBURETOR 安裝燃油泵 及 化油器 Safety instructions 安全指引 m WARNING 警告 Danger of explosion and ignition! 具有爆炸和燃燒的危險！ Overflowing and spoilt gasoline must be absorbed immediately with a binding agent and correctly disposed. Do not work with open flames and sources of ignition. Fuel must not come into contact with hot parts such as engine or exhaust since this may cause a fire!.
  • Page 152 BRP-Rotax REPAIR MANUAL 修護手冊 Figure圖 6.10: Fuel pump 燃油泵 燃油泵 支撐架 1 Fuel pump Support bracket 防鬆螺帽 墊圈 3 Lock nut Washer 內六角螺栓 內六角螺栓 5 Allen screw M6x20 Allen screw M6x25 Chapter 6 Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 18 Edition - February 01 2018 /Rev.
  • Page 153 BRP-Rotax REPAIR MANUAL 修復手冊 Instruction 指引 To install the carburetor and intake silencer the following steps are required: 用以下步驟安裝化油器與 進氣消音器 silencer. 化油器與進氣消音器 Figure圖: Carburetor and intake 1. Pull the hose clamp (3) over the carburetor flange. 將管夾 (3) 拉到化油器接口上。 2. Push the carburetor (1) onto the carburetor flange (2) and fasten the hose clamp (3). 將化油器 (1號件) 推到化油器接口...
  • Page 154 BRP-Rotax REPAIR MANUAL 修復手冊 Chapter章節: Chapter 7 CENTRIFUGAL CLUTCH, PRIMARY AND BALANCE DRIVE 離心式離合器, 主傳動與平衡驅動 TOPICS IN THIS CHAPTER 本章節主題 System description 系統說明 ..........................2 Removal of the clutch and starter gear assy 拆卸離合器及啟動齒輪總成 ............4 Removal of the centrifugal clutch assy 離心式離合器總成的拆卸 ..............4 Removal of the electric starter 啟動電機的拆卸...

  • Page 155: System Description 系統說明

    BRP-Rotax REPAIR MANUAL SYSTEM DESCRIPTION 系統說明 Overview 概況 Position on engine 發動機上的位置 Figure 圖 7.1: Clutch and starter gear assy. 離合器與啟動電機總成 啟動電機總成 離合器鼓 1 Starter gear assy. 2 Clutch drum 鏈輪 3 Sprocket Chapter 7 Effectivity: 125 MAX evo, Junior MAX...
  • Page 157 BRP-Rotax REPAIR MANUAL 修復手冊 Overview 概況 Components of clutch and starter assy. 離合器與啟動電機總成 Figure 圖 7.2 鏈條保護蓋 Chain protection 內六角螺栓 1 Allen screw M6x25 六角螺帽 止推墊圈 3 Hex. nut M10x1 Thrust washer 離合器鼓 鏈輪 5 Clutch drum Sprocket 滑動軸承 /...

  • Page 158: Removal Of The Electric Starter 啟動電機的拆卸

    BRP-Rotax REPAIR MANUAL 修復手冊 REMOVAL OF THE CLUTCH AND STARTER GEAR ASSY.離合器與啟動電機的拆卸 REMOVAL OF THE CENTRIFUGAL CLUTCH ASSY.離心離合器總成的拆卸 Safety instructions 安全指引 m WARNING 警告 Danger of severe burns and scalds! Always allow the engine to cool down to am- bient temperature before starting any work.在開始任何工作之前，一定要讓發動機冷卻至環境溫度。否則會有嚴重燒傷和燙傷的危險！...

  • Page 159: Removal Of The Clutch Drum 離合器鼓的拆卸

    BRP-Rotax REPAIR MANUAL 修復手冊 REMOVAL OF THE CLUTCH DRUM 離合器鼓的拆卸 Special tools 特殊工具 The following special tools and equipment are required: 需要以下的特殊工具或設備 Part no. 料號 Description 內容 Use 施作 277381 Locking tool Spark plug thread 卡位工具 火花塞螺牙 676205 Fixation tool assy.
  • Page 160 BRP-Rotax REPAIR MANUAL 修復手冊 Figure 圖 7.5 固定工具總成 曲軸固定工具 2 Fixation tool assy. Fixation tool for crankshaft 4. Unscrew and remove hex nut (1). 拆鬆並移除六角螺帽(1號件) 5. Remove thrust washer (2), clutch drum with sprocket (3), needle cage (4) O-ring (5) and thrust washer 15.2 (6).

  • Page 161: Removal Of The Sprocket 鏈輪的拆卸

    BRP-Rotax REPAIR MANUAL 修復手冊 Figure 圖 7.6 六角螺帽 止推墊圈 Hex. nut M10x1 2 Thrust washer 滾針軸承 滑動軸承 離合器 4 Needle cage / Plain bearing 3 Clutch drum Ｏ型環 止推墊圈 O-ring 6 Thrust washer 15.2 REMOVAL OF THE SPROCKET 鏈輪的拆卸 Instruction 指引...

  • Page 162: Removal Of The Starter Gear Assy 啟動齒輪總成的拆卸

    BRP-Rotax REPAIR MANUAL 修復手冊 Figure 圖 7.7: Fixation tool 固定工具 鏈輪 固定工具 2 Sprocket Fixation tool 針銷 離合器鼓 Needle pin 4 Clutch drum 六角螺帽 5 Hex. Nut REMOVAL OF THE STARTER GEAR ASSY. 啟動齒輪總成的拆卸 Special tools 特殊工具 The following special tools and equipment are required: 需要以下的特殊工具或設備...
  • Page 163 BRP-Rotax REPAIR MANUAL 修復手冊 Figure 圖 7.8: Fixation tool 固定工具 曲軸固定工具 啟動電機固定工具 Fixation tool (crankshaft) 2 Fixation tool (starter gear) 3. Remove the clutch (3).拆下離合器(3號件) 4. Unscrew hex. nut M20 (4).拆下M20 六角螺帽 (4號件) Figure 圖 7.9: Clutch 離合器 離合器 內六角螺栓...
  • Page 164 BRP-Rotax REPAIR MANUAL 修復手冊 5. Fasten the puller assy. (1) to the starter gear assembly with 3 Allen screws M6x60 (2). 採用 3 個內六角螺栓 M6x60 (2號件) 將拉拔器總成(1號件)鎖緊到啟動齒輪總成上。 NOTE 注意事項 確保螺栓不 Make sure the screws do not touch the housing. Do not screw them in too far.

  • Page 165: Inspection Of The Clutch Drum 離合器鼓的檢查

    BRP-Rotax REPAIR MANUAL 修復手冊 INSPECTION OF CLUTCH AND STARTER GEAR ASSY.離合器鼓以及啟動電機的檢查 INSPECTION OF THE CLUTCH DRUM 離合器鼓的檢查 General 概況 If the clutch drum starts to tumble when the engine is idling with a sprocket with 11 teeth, this indicates a worn out bearing. Please replace the bearing immediately. 鏈輪齒數為11 的設定狀態下，如果在發動機怠速運轉時，離合器鼓就開始轉動，就表示軸承已磨損。...
  • Page 166 BRP-Rotax REPAIR MANUAL 修復手冊 Figure 圖 7.11: Clutch drum, plain bearing / needle cage, sprocket 離合器鼓, 滑動軸承 / 滾針軸承,鏈輪 離合器鼓 止推墊圈 1 Clutch drum Thrust washer Plain bearing / needle cage 止推墊圈 3 Thrust washer 15.2 滑動軸承 / 滾針軸承 鏈輪...

  • Page 167: Inspection Of The Electric Starter 啟動電機的檢查

    BRP-Rotax REPAIR MANUAL 修復手冊 Instructions 指引 Figure: Starter reduction gear assy. 啟動減速齒輪總成 1. Clean starter reduction gear assy. (1). 清潔啟動減速齒輪總成(1號件)。 2. Inspect the gear wheels (2) for wear. 檢查輪齒 (2號件) 是否磨損。 3. Inspect the operation of the starter reduction gear assy. 檢查啟動減速齒輪總成的運轉情況。...
  • Page 168 BRP-Rotax REPAIR MANUAL 修復手冊 Figure 圖 7.13: Electric starter 啟動電機 啟動電機電纜線 電機的齒輪 Starter cable 2 Teeth INSPECTION OF THE CLUTCH AND STARTER GEAR ASSY. 離合器與啟動齒輪的檢查 Figure 圖 : Clutch and starter gear assy. 離合器與啟動齒輪總成 Instructions指引 1. Check the hole (1) in the clutch (2). 檢查離合器(2號件)上的孔 (1)。...
  • Page 169 BRP-Rotax REPAIR MANUAL 修復手冊 ELECTRIC STARTER REPAIR KIT 啟動電機維修套件包 Special tools 特殊工具 The following special tools and equipment are required: 需要以下的特殊工具或設備 Part no. 料號 Description 內容 Use 施作 281262 Electric starter repair kit Electric starter 啟動電機 啟動電機維修套件包 Instructions 指引 Figure 圖 : Electric starter 啟動電機...

  • Page 170: Disassembling Of Electric Starter 啟動電機的拆解

    BRP-Rotax REPAIR MANUAL 修復手冊 DISASSEMBLING OF ELECTRIC STARTER 啟動電機的拆解 Instructions 指引 Figure: Electric starter disassembly 拆解啟動電機 NOTE 注意事項 注意不要鬆開有預載彈簧的滑動觸點。 Take care not to loose the spring-loaded sliding contacts. 1. Secure the rotor shaft with a suitable tool. 使用合適的工具來固定轉子軸。 2. Pull out solenoid housing. 拉出電磁閥外殼。...

  • Page 171: Assembling Of Electric Starter 啟動電機的組裝

    BRP-Rotax REPAIR MANUAL 修復手冊 ASSEMBLING OF ELECTRIC STARTER 啟動電機的組裝 NOTE 注意事項 Instructions 指引 碳刷必須正確接觸滑轉環。 The brushes must contact the slip ring correctly. 1. Inspect the carbon brushes and replace if necessary with new parts (ROTAX® part no. 281262). 檢查碳刷，必要時更換新零件（ROTAX® 料號 281262）。...

  • Page 172: Installation Of Clutch And Starter Gear Assy 安裝離合器及啟動齒輪總成

    BRP-Rotax REPAIR MANUAL 修復手冊 INSTALLATION OF CLUTCH AND STARTER GEAR ASSY. 安裝離合器及啟動齒輪總成 General 概要 Follow the sequence exactly. The starter reduction gear assy. cannot be installed after in- sertion of the starter gear assy. 嚴格按照順序。插入啟動齒輪總成後，將無法安裝啟動電機減速齒輪總成。 INSTALLATION OF THE STARTER REDUCTION GEAR ASSY. 啟動機減速齒輪總成的安裝...
  • Page 173 BRP-Rotax REPAIR MANUAL 修復手冊 INSTALLATION OF THE STARTER GEAR ASSY. 啟動電機齒輪總成的安裝 Special tools 特殊工具 The following special tools and equipment are required: 需要以下的特殊工具或設備 Part no. Description Field of application 料號 說明 運用的部位 277381 Locking tool Spark plug thread火花塞螺牙 (crankshaft) 曲軸卡位工具...
  • Page 174 BRP-Rotax REPAIR MANUAL 修復手冊 Instructions 1. Preferred version 1: screw in fixation tool for crankshaft (1) into the spark plug thread till the 指引 end stop. 首選方法一：將曲軸固定工具(1號件)旋入火花塞孔內，鎖到底為止 。 Figure 圖 7.18: Fixation tools 固定工具 曲軸固定工具 啟動齒輪固定工具 Fixation tool (crankshaft) 2 Fixation tool (starter gear) 2.

  • Page 175: Installation Of The Sprocket 鏈輪的安裝

    BRP-Rotax REPAIR MANUAL 修復手冊 Figure 圖 7.19: Starter gear assy. 啟動齒輪總成 啟動齒輪總成 六角螺帽 Starter gear assy. 2 Hex. nut M28x1 啟動齒輪固定工具 離合器 Fixation tool (starter gear) 4 Clutch 內六角螺栓 Allen screw M6x12 ASSEMBLY OF THE CLUTCH DRUM 組裝離合器鼓 INSTALLATION OF THE SPROCKET 鏈輪的安裝...
  • Page 176 BRP-Rotax REPAIR MANUAL 修復手冊 Figure 圖7.20: Fixation tool 固定工具 鏈輪 固定工具 2 Sprocket Fixation tool 針銷 離合器鼓 Needle pin 4 Clutch drum 六角螺帽 5 Hex. nut. INSTALLATION OF BEARING SLEEVE (FOR SPROCKETS WITH 11 TEETH ONLY) 軸承襯套的安裝(僅適用於11齒的鏈輪) Special tools 特殊工具 The following special tools and equipment are required: 需要以下的特殊工具或設備...

  • Page 177: Installation Of The Clutch Drum 離合器鼓的安裝

    BRP-Rotax REPAIR MANUAL 修復手冊 Figure 圖7.21: Installation of bearing sleeve 軸承襯套的安裝 軸承襯套 斜緣 Bearing sleeve 2 Beveled edge 離合器鼓 3 Clutch drum INSTALLATION OF THE CLUTCH DRUM 離合器鼓的安裝 Safety 安全 m WARNING Risk of fatal injury ! 有致命傷害的危險 The engine must not be started without a clutch drum. 發動機不可在沒有離合器鼓的狀態下啟動...
  • Page 178 BRP-Rotax REPAIR MANUAL 修復手冊 1. Lubricate crankshaft with lithium based grease in the running area of the needle cage (4). Instruction 在曲軸滾針軸承(4號件)的工作範圍內，塗覆鋰基潤滑脂潤滑。 指引 2. Position thrust washer 15.2 (6) and O-ring (5) on the crankshaft. 將止推墊圈 15.2 (6號件) 和 O型環 (5號件)裝上曲軸。...
  • Page 179 BRP-Rotax REPAIR MANUAL 修復手冊 8. Lubricate starter reduction gear assy. in the area shown in the following figure.依圖 所示的區域潤滑啟動電機減速齒輪總成。 9. Install chain protection with 3 Allen screws M6x25. Tightening torque 5 Nm (44 in. lb). 使用3個 M6x25 內六角螺栓安裝鏈條護蓋。 鎖固扭力 5 Nm (44 in. lb)。...
  • Page 180 BRP-Rotax REPAIR MANUAL 修復手冊 Figure圖 7.23: Chain protection 鏈條護蓋 鏈條護蓋 內六角螺栓 1 Chain protection 2 Allen screw M6x25 INSTALLATION OF THE ELECTRIC STARTER 啟動電機的安裝 Instructions 指引 1. Lubricate O-ring (2) on the center of the electric starter (1). 潤滑啟動電機(1號件) 中心的O型環 (2號件)。...
  • Page 181 BRP-Rotax REPAIR MANUAL 修復手冊 NOTE 注意事項 Push the electric starter (1) into the centering of the housing (3) by rotating it back and forth until the teeth of the electric starter are meshed with the teeth of the starter reduction gear assy. 將啟動電機 (1號件) 前後旋推，直到啟動電機的齒與啟...

  • Page 182: Filling Gearbox With Oil 注入齒輪油

    BRP-Rotax REPAIR MANUAL 修復手冊 FILLING GEARBOX WITH OIL 注入齒輪油 General 概況 NOTE 注意事項 Take a measuring cup and fill with 100 ml of XPS® KART TEC GEAR OIL取一個量杯，裝入 100 毫升 XPS® KART TEC 齒輪油 Special tools 特殊工具 The following special tools/equipment are required: 需要以下特殊工具/設備：...
  • Page 183 BRP-Rotax REPAIR MANUAL NOTES 筆記 Notes Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 26 Edition - February 01 2018 /Rev. 0...
  • Page 184 BRP-Rotax REPAIR MANUAL Chapter: Chapter 8 COOLING SYSTEM 冷卻系統 TOPICS IN THIS CHAPTER 本章節主題 System description 系統說明 ..........................2 Removal of radiator 拆卸水箱 ........................... 4 Removal of the cooling water hose 冷卻水管的拆卸 ..................4 Inspection of cooling system 檢查冷卻系統 ....................6 Radiator –...
  • Page 186 BRP-Rotax REPAIR MANUAL 修復手冊 SYSTEM DESCRIPTION 系統說明 Overview 概述 Figure 圖 8.1: Radiator 水箱 冷卻水管 水箱 2 Cooling water hose 1 Radiator 水管夾 3 Hose clamp. Chapter 8 Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 2 Edition - February 01 2018 /Rev.
  • Page 187 BRP-Rotax REPAIR MANUAL 修復手冊 Overview 概述 Figure 圖 8.2: Radiator 水箱 水箱蓋含墊片 水箱 Radiator (Max evo, Junior evo, 2 Radiator cap with gasket Mini evo) 內六角螺栓 Allen screw M6x16 with 遮風板 Windshield (Max evo, Junior 包含圓墊圈 rounded flange head evo, Mini evo) 墊圈...
  • Page 188 BRP-Rotax REPAIR MANUAL 修復手冊 REMOVAL OF RADIATOR 拆卸水箱 Safety instructions安全指引 m WARNING 警告 Danger of severe burns and scalds! Always allow the engine to cool down to am- bient temperature before starting any work.在開始任何工作之前，一定要讓發動機冷卻至環境溫度。否則會有嚴重燒傷和燙傷的危險！ Preparation 準備 The following preparations should be carried out before removing the components: 拆卸組件前應進...
  • Page 189 BRP-Rotax REPAIR MANUAL 修復手冊 Figure圖 8.3: Cooling water hoses 冷卻水管 水 Hose clamps 水管 1 Hoses 管夾 內六角螺栓 防 3 Allen screw M8x75 Lock washer 鬆螺栓 Chapter 8 Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 5 Edition - February 01 2018 /Rev.
  • Page 190 BRP-Rotax REPAIR MANUAL 修復手冊 INSPECTION OF COOLING SYSTEM 檢查冷卻系統 RADIATOR – INSPECTION OF COMPONENTS 水箱 – 各分件的檢查 Radiator. 水箱（散熱器） Instruction指引 Figure圖: NOTE 注意事項 如果有些 If some of the cooling fins are slightly bent, they may be gently bent back into shape.
  • Page 191 BRP-Rotax REPAIR MANUAL 修復手冊 INSTALLING THE RADIATOR 安裝水箱 INSTALLATION OF THE COOLING WATER HOSES 水箱的安裝 Preparation 準備 1. Mount radiator bracket (5) on radiator through the holes with rubber grommets and tighten with Allen srew M6x20 and washer 6.2. 將水箱支架(5號件)穿過帶有橡膠墊圈的孔，安裝...
  • Page 192 BRP-Rotax REPAIR MANUAL 修復手冊 Figure 圖 8.6: Installation of cooling water hoses 冷卻水管的安裝 冷卻水管 水箱連接頭 Cooling water hoses 2 Radiator connection 水管夾 水箱蓋 Hose clamps 4 Radiator cap Chapter 8 Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 8 Edition - February 01 2018 /Rev.
  • Page 193 BRP-Rotax REPAIR MANUAL 修復手冊 INSTALLATION OF THE RADIATOR ON ENGINE 將水箱安裝上發動機 Instructions 指引 Figure 圖: Installation of the radiator on engine 水箱安裝上發動機 1. Install radiator with pre-mounted radiator bracket (3) on engine an tighten with Allen screw M8x75 (2) and Lock washer A8 (1). Tightening torque 24 Nm (18 ft. lb). 將已預裝水箱支架...
  • Page 194 BRP-Rotax REPAIR MANUAL 修復手冊 FINAL TASKS 最終任務 Instructions 指引 1. Using a funnel, pour the specified amount of coolant into the filling opening of the radiator. 使用漏斗， 依指定用量將冷卻液倒入水箱加注口。 2. Close the radiator cap. 關上水箱蓋。 3. Check that the cooling system is leak-free by warming up the engine. 採取預熱發動機的方式，確認冷...
  • Page 195 BRP-Rotax REPAIR MANUAL Chapter: Chapter 9 EXHAUST SYSTEM 排氣系統 TOPICS IN THIS CHAPTER 本章節主題 System description 系統說明 ..........................2 Removal of the exhaust system 拆卸排氣系統 ....................4 Checking the exhaust system 點檢排氣系統 ....................5 Disassembling the exhaust system 拆解排氣系統 ..................5 Assembling the exhaust system 組裝排氣系統...

  • Page 196: System Description 系統說明

    BRP-Rotax REPAIR MANUAL 修復手冊 SYSTEM DESCRIPTION 系統說明 Position on the engine 在發動機上的位置 Overview概述 Figure 圖 9.1 排氣消音器總成 消音器總成 Exhaust muffler assy. 2 Silencer assy. 排氣口總成 3 Exhaust socket assy. Chapter 9 Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 1 Edition - February 01 2018 /Rev.
  • Page 197 BRP-Rotax REPAIR MANUAL 修復手冊 Overview 概述 Exhaust system 排氣系統 Figure圖 9.2 排氣口總成 排氣墊片 不鏽鋼彈簧 1 Exhaust socket assy. 2 Exhaust gasket 3 Spring stainless 排氣消音器總成 消音器總成 隔音墊 4 Exhaust muffler assy. 5 Silencer assy. 6 Isolating mat 打孔管總成 排氣墊片 不鏽鋼彈簧...

  • Page 198: Removal Of The Exhaust System 拆卸排氣系統

    BRP-Rotax REPAIR MANUAL 修復手冊 REMOVAL OF THE EXHAUST SYSTEM 拆卸排氣系統 Safety instructions 安全指引 m WARNING 警告 Danger of severe burns and scalds! Always allow the engine to cool down to am- bient temperature before starting any work.在開始任何工作之前，一定要讓發動機冷卻至環境溫度。否則會有嚴重燒傷和燙傷的危險！ Special tools 特殊工具 The following special tools and equipment are required: 需要以下的特殊工具或設備...

  • Page 199: Checking The Exhaust System 點檢排氣系統

    BRP-Rotax REPAIR MANUAL 修復手冊 CHECKING THE EXHAUST SYSTEM 點檢排氣系統 ATTENTION 注意 A worn isolating mat has a major engine damage as result! 破損的隔音墊會導致嚴重的發動機損壞！ Instructions 指引 See Figure 圖 1. Check exhaust system for cracks, bending or other damages. Replace if necessary. 檢查排氣系統是否有裂...

  • Page 200: Assembling The Exhaust System 組裝排氣系統

    BRP-Rotax REPAIR MANUAL 修復手冊 ASSEMBLING THE EXHAUST SYSTEM 組裝排氣系統 Figure 圖 : Exhaust Instructions指引 system.排氣系統 1. Roll up new isolating mat (3) on the inside silencer assy. (2). 使用新的隔音墊(3號件)，捲起放 進消音器總成(2號件)的內部。 2. Put both into the exhaust system. 將兩者都一起放入排氣系統。 使 用內六角螺絲 M4x12 (6 3.
  • Page 201 BRP-Rotax REPAIR MANUAL 修復手冊 Figure圖 9.4: Exhaust system 排氣系統 排氣消音器總成 消音器總成 1 Exhaust muffler assy. Silencer assy. 隔音墊 尾管總成 3 Isolating mat Perforated tube assy ㄘ 防鬆螺帽 內六角螺栓 5 Lock nut Allen screw M4x12 排氣墊圈 不鏽鋼彈簧 7 Exhaust gasket Spring stainless 張力彈簧...

  • Page 202: Preparation For Installation 安裝前的準備

    BRP-Rotax REPAIR MANUAL 修復手冊 PREPARATION FOR INSTALLATION 安裝前的準備 Safety instructions安全指引 ATTENTION 注意 Clean and inspect disassembled parts and assemble them in accordance with the in- structions. All screws and nuts must always be clean. Inspect surfaces and threads for damage. In case of doubt use new screws and nuts.
  • Page 203 BRP-Rotax REPAIR MANUAL 修復手冊 m WARNING 警告 Risk of fire and explosion! 有火災和爆炸危險！ Make sure that fuel will not splash onto hot engine components or equipment. 需確保燃油不會濺到發動機熱的部件或設備上。 Chapter 9 Effectivity: 125 MAX evo, Junior MAX evo, Mini MAX evo, Micro MAX evo Page 9 Edition - February 01 2018 /Rev.

  • Page 204: Installation Of The Bowden Cable 安裝油門拉索

    BRP-Rotax REPAIR MANUAL 修復手冊 Instructions 指引 Proceed as follows to install the fuel line: 按照以下步驟安裝燃油管路： 1. The installation of the fuel line is identical to the removal, but in reverse order. 燃油管路的安裝與拆卸相同，但順序相反。 Removal of the fuel line 另見燃油管路的拆卸] 章節 See also INSTALLATION OF THE BOWDEN CABLE 安裝油門拉索...

  • Page 205: Installation Of The Exhaust System 安裝排氣系統

    BRP-Rotax REPAIR MANUAL 修復手冊 Figure 圖 9.5: Ignition unit 點火裝置 火花塞接頭 點火線圈 1 Spark plug connector 2 Ignition coil 曲軸角度傳感器 4 Electric starter 啟動電機 3 Crankshaft positioning sensor (CPS) 6 Connector ignition coil 點火線圈接頭 電磁閥 5 Solenoid valve 8 Allen screw 電磁閥接頭...
  • Page 206 BRP-Rotax REPAIR MANUAL 修復手冊 NOTES 筆記 evo, Mini MAX evo, Micro MAX evo Page 1 Edition - February 01 2018 /Rev. 0...
  • Page 207 BRP-Rotax REPAIR MANUAL 修復手冊 Index Abbreviations ............3 Filling gearbox with oil ..........25 Assembling of electric starter ......... 15 Final tasks .............. 10 Assembling the exhaust system ....... 5 Assembly of carburetor .......... 11 Assembly of crankshaft, water pump shaft and balance shaft ............
  • Page 208 BRP-Rotax REPAIR MANUAL 修復手冊 Installation of spark plug ......... 33 Removal of the clutch and starter gear assy ..... 4 Installation of the bowden cable....... 8 Removal of the clutch drum ........5 Installation of the carburetor flange and reed Removal of the combustion chamber insert ....
  • Page 209 BRP-Rotax REPAIR MANUAL 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. © 2018 BRP-Rotax GmbH & Co KG. All rights reserved.

This manual is also suitable for:

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