Rotax 125 Max Manuals

Rotax 125 Max Manuals

Manuals and User Guides for Rotax 125 Max. We have 3 Rotax 125 Max manuals available for free PDF download: Repair Manual, Installation Instructions And Operators Manual, Retrofit Instruction

Rotax 125 Max Repair Manual

Rotax 125 Max Repair Manual (199 pages)

Brand: Rotax | Category: Engine | Size: 7 MB

Table of Contents

Chapter: 2 Maintenance

24
- Table of Amendments
  8
- General Note
  12
- Abbreviations and Terms Used in this Manual
  14
- Safety Notice
  17
- Table of Contents
  24
- Maintenance
  26
  - General Note
    26
  - Authorized Personnel
    27
  - Procedure Notes
    28
  - Consumable Materials
    30
  - Special Tools
    32
Chapter: 3 Engine and Gearbox

36
Chapter: 4 Cylinder Components

52
Chapter: 5 Crankcase

90
- System Description
  92
- Removal of the Crankcase
  94
- Disassemble Crankcase
  96
  - Remove the Crankshaft
    98
- Conrod Set - Repair Set
  103
  - Disassemble Crankshaft
    106
  - Inspect Crankshaft
    107
  - Crankshaft out of Round
    109
  - Assembly of Crankshaft
    111
- Crankcase-Inspection of Components
  114
  - Inspection of Water Pump Drive
    114
  - Inspection of Balance Shaft Drive
    116
  - Inspection of Balance Shaft
    116
  - Inspection of Crankcase
    118
- Assembly of Crankcase
  120
  - Installation of Bearing and Oil Seal for Shaft
    120
  - Balance Shaft
    125
  - Screw Case Halves Together
    125
- Installation of Crankcase
  128
  - Installation of Balance and Water-Pump Shaft
    128
Chapter: 6 Carburetor and Intake Silencer

132
- System Description
  134
- Removal of Carburetor and Intake Silencer
  136
  - Disassembly of Carburetor
    139
- Checking Components of Carburetor and Intake Silencer
  142
  - Checking Carburetor
    142
  - Checking Fuel Pump
    143
  - Checking Intake Silencer
    144
- Installation of Carburetor and Intake Silencer
  148
  - Assembly of Intake Silencer
    149
Chapter: 7 Clutch and Starter Gear Assembly

150
- System Description
  152
- Removal of the Clutch and Starter Gear Assembly
  154
  - Oil Draining
    154
  - Removal of the Electric Starter
    155
- Removal of the Clutch Drum
  156
  - Removal of the Sprocket
    157
- Removal of the Clutch and Starter Gear Assembly
  159
- Checking Components of Clutch and Starter Gear
  162
- Electric Starter Repair Kit
  165
  - Checking the Clutch and Starter Gear Assembly
    168
- Installation of Clutch and Starter Gear Assembly
  170
  - Installing Starter Reduction Gear Assembly
    170
  - Installing Starter Gear Assembly
    171
- Assembling the Clutch Drum
  174
  - Installing Bearing Sleeve
    174
  - Installing Sprocket
    175
- Installing Clutch Drum
  177
  - Electric Starter
    179
  - Filling Gearbox with Oil
    180
  - System Description
    184
  - Removing the Water Radiator
    186
    
    Removal of the Cooling Water Hose
    186
  - Water Radiator -Inspection of Components
    188
  - Installation of Water Radiator
    190
    
    Installation of the Cooling Water Hose
    190
    
    Installation of the Water Radiator
    191
    
    Exhaust System
    192
  - System Description
    194
  - Removal of the Exhaust System
    196
    
    Checking the Exhaust System
    196
    
    Disassembling the Exhaust System
    196
    
    Assembling the Exhaust System
    197
  - Installation of the Exhaust System
    198

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Rotax 125 Max Retrofit Instruction

Rotax 125 Max Retrofit Instruction (62 pages)

Brand: Rotax | Category: Engine | Size: 28 MB

Table of Contents

Rotax 125 Max Installation Instructions And Operators Manual

Rotax 125 Max Installation Instructions And Operators Manual (76 pages)

Brand: Rotax | Category: Engine | Size: 4 MB

Table of Contents

1) Installation Instructions

9
2) Operators Manual

35
- Design of the ROTAX Kart Engine 125 MAX / Junior
  36
  - Operating Limits
    36
- Technical Description
  38
  - Type of Engine
    38
  - Cooling Circuit
    38
  - Balance Shaft
    38
  - Ignition Unit
    38
  - Electric Starter
    39
  - Exhaust Timing Control
    39
  - Fuel Pump
    39
  - Carburetor
    39
  - Intake Silencer
    40
  - Exhaust System
    40
- Operating Fluids and Equipment
  41
  - Coolant
    41
  - Battery and Charger
    43
  - Fuel
    44
- Engine Tuning
  47
- Engine Operation
  65
  - Engine Start
    65
  - Running-In Procedure for the Engine
    66
  - Engine Stop
    67
- Setting of the Exhaust Valve Timing (125 MAX Only)
  69
- Preservation of Engine and Equipment
  71
- Transport of the Kart
  71
- Maintenance Schedule for Engine Components
  72
- Troubleshooting
  73

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