Sign In
Upload
Manuals
Brands
Rotax Manuals
Engine
125 MAX evo
Rotax 125 MAX evo Manuals
Manuals and User Guides for Rotax 125 MAX evo. We have
5
Rotax 125 MAX evo manuals available for free PDF download: Repair Manual, Installation Instructions And Operators Manual, Installation Instructions And Operation Manual
Rotax 125 MAX evo Repair Manual (171 pages)
Brand:
Rotax
| Category:
Engine
| Size: 7 MB
Table of Contents
Table of Contents
4
General Note
4
Position of the Engine Serial Number
5
Abbreviations and Terms Used in this Manual
6
Safety Information
7
Safety Notice
7
Instruction
8
Technical Documentation
9
Use for Intended Purpose
9
Technical Data
10
Maintenance
12
Handling of Fluids
15
Disassembly Advice
15
Ignition "OFF"
15
Process Advice
15
Cleaning of Parts
16
Removed Parts
16
Measurements
16
Re-Assembly Advice
16
Consumable Materials
17
Special Tools
19
Inspection and Servicing Intervals of the Engine Components
21
Engine
24
System Description
25
Engine Components View
25
Preparation for Removal
26
Removal of the Ignition System
26
Battery
27
Ignition System
28
Removal of the Exhaust System
29
Removal of Radiator with Cap Assy
29
Removal of the Fuel Line
30
Fuel Components View
30
Removal of the Bowden Cable
31
Removal of the Engine from Kart Chassis
31
Engine Clamp View
32
Positioning the Engine on the Threstle Mounting Plate
32
Cylinder Components
34
Cylinder Components View
35
Cylinder Removal
36
Removal of the Spark Plug
37
Removal of the Cylinder Head Cover
37
Cylinder View
37
Removal of the Thermostat
38
Cylinder Head Cover View
38
Removal of the Combustion Chamber Insert
39
Thermostat View
39
Combustion Chamber Insert View
40
Removal of the Exhaust Socket
40
Removal of the Intake Socket and Reed Valve
41
Removal of the Exhaust Valve
41
Exhaust Valve (RAVE) View
42
Removal of the Piston
43
Cylinder Components Inspection
44
Inspection of Piston and Piston Ring
45
Inspection of the Piston Diameter
46
Inspection of the Piston and Cylinder Sizing
47
Inspection of the Piston Pin, Circlip
48
Inspection of the Spark Plug
49
Inspection of the Cylinder Head Cover
50
Inspection of the Combustion Chamber Insert
50
Inspection of the Exhaust Socket
51
Inspection of the Carburetor Flange and Reed Valve
52
Inspection of the Exhaust Valve
53
Cylinder Components Installation
54
Installation of Exhaust Valve
54
Installation of Exhaust Valve, Gasket, Valve Rod Housing
55
Installation of the Exhaust Valve Piston
55
Installation of Piston
57
Installation of the Cylinder
58
Installation of the Exhaust Socket
59
Installation of the Carburetor Flange and Reed Valve
60
Installation of Combustion Chamber Insert
62
Installation of Cylinder Head Cover
62
Inspection and Adjustment of Squish Gap
64
Installation of Spark Plug
66
Crankcase
68
Crankcase View
69
Components of Crankcase View
70
Removal of the Crankcase
72
Remove Water Pump and Compensating Wheels
73
Gearbox Cover View
74
Water Pump and Balance Shaft View
75
Disassembling the Crankcase
76
Balance Shaft View
77
Removing Bearing and Oil Seal for Shaft
78
Ignition Side Crankcase View
81
Installation of the Crankshaft Repair Kit
82
Disassembling of the Crankshaft
82
Crankshaft Repair Jig View
83
Con Rod Parts View
84
Inspection of the Crankshaft
86
Aligning the Crankshaft
88
Crankshaft Not in Specification
88
Crankshaft Assembly
89
Crank Case Inspection
93
Inspection of Water Pump Drive
93
Inspection of Water Pump Shaft
94
Inspection of Balance Shaft Drive
94
Inspection of Balance Shaft
95
Inspection of the Housing Halves
96
Crank Case Assembly
97
Installation of Oil Seal, Ball Bearing and Needle Bushing
97
Installation of Ball Bearing and Oil Seal for Crankcase
99
Assembly of Crankshaft, Water Pump Shaft and Balance Shaft
102
Assembly of the Crankcase
103
Installation of Crankcase Assy
104
Installation of Balance and Water-Pump Shaft Drive
104
Idle Gear View
106
Carburetor and Intake Silencer
108
Carburetor and Intake Silencer Overview
109
Removal of the Carburetor and Intake Silencer
110
Removal of the Fuel Pump
111
Disassembly of the Carburetor
112
Carburetor View
113
Disassembly of the Intake Silencer
114
Carburetor and Intake Silencer - Inspection of Components
115
Inspection of Carburetor
115
Inspection of the Fuel Pump
116
Inspection of the Intake Silencer
116
Intake Silencer View
117
Installing the Carburetor and Intake Silencer
118
Assembly of Carburetor
118
Assembly of Float Housing
118
Float Chamber View
118
Assembly of Intake Silencer
119
Installation of Fuel Pump, Carburetor
120
Carburetor and Intake Silencer View
121
Centrifugal Clutch, Primary and Balance Drive
122
Centrifugal Clutch, Primary and Balance Drive Overview
123
Components of Clutch and Starter Assy. View
124
Removal of the Clutch and Starter Gear Assy
125
Removal of the Centrifugal Clutch Assy
125
Removal of the Electric Starter
125
Removal of the Clutch Drum
126
Removal of the Sprocket
128
Removal of the Starter Gear Assy.
129
Inspection of the Starter Reduction Gear Assy.
132
Inspectoin of Clutch and Starter Gear Assy.
132
Inspection of the Needle Cage and Sprocket
132
Inspection of the Clutch Drum
132
Inspection of the Electric Starter
133
Inspection of the Clutch and Starter Gear Assy
134
Electric Starter Repair Kit
135
Disassembling of Electric Starter
135
Assembling of Electric Starter
136
Installation of Clutch and Starter Gear Assy.
138
Installation of the Starter Reduction Gear Assy.
138
Installation of the Sprocket
140
Assembly of the Clutch Drum
140
Installation of Bearing Sleeve for Sprockets with 11 Teeth Only
141
Installation of the Clutch Drum
142
Installation of the Electric Starter
144
Filling Gearbox with Oil
146
Cooling System
148
Cooling System Overview
149
Radiator View
149
Water Pump View
150
Removal of Radiator
151
Removal of the Cooling Water Hose
151
Inspection of Cooling System
153
Radiator - Inspection of Components
153
Installing the Radiator
154
Installation of the Cooling Water Hoses
154
Installation of the Radiator on Engine
155
Final Tasks
157
Exhaust System
158
Exhaust System Overview
159
Checking the Exhaust System
162
Disassembling the Exhaust System
162
Assembling the Exhaust System
162
Installation of the Exhaust System
163
Exhaust System View
163
Removing the Engine from the Trestle Mounting Plate
164
Installation of the Engine on Kart Chassis
164
Installation of the Fuel Line
164
Installation of the Bowden Cable
165
Installation of the Ignition System
165
Ignition Unit View
166
Index
168
Consumable Materials
168
Special Tools
169
Advertisement
Rotax 125 MAX evo 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
System Description
38
Preparation
40
Dismantling the Exhaust System
40
Dismantling the Ignition Unit
41
Removal of the Fuel Line
43
Removal of the Engine from the Kart Chassis
45
Positioning the Engine on the Trestle Mounting Plate
46
Preparation
48
Remove the Engine from the Trestle Mounting Plate
48
Installation of the Engine in the Kart Chassis
48
Installation of the Fuel Line
49
Installation of the Ignition System
50
Installation of the Exhaust System
51
Starting the Engine
51
Chapter: 4 Cylinder Components
52
System Description
54
Cylinder Removal
56
Removal of Cylinder
56
Dismantling Cylinder
57
Removal of Spark Plug
57
Removal of Cylinder Head Cover
57
Removal of Combustion Chamber Insert
57
Removal of Exhaust Socket
59
Removal of Exhaust Valve (125 MAX Only)
61
Removal of Piston
62
Inspection of Cylinder Parts
64
Inspection of Cylinder
64
Inspection of Piston and Piston Ring
65
Inspection of Spark Plug
68
Inspection of Cylinder Head Cover
69
Inspection of Combustion Chamber Insert
69
Inspection of Exhaust Socket
70
Inspection of Carburetor Flange and Reed Valve
71
Inspection of Exhaust Valve (125 MAX Only)
72
Cylinder Assembly
74
Installation of Exhaust Valve (125 MAX Only)
74
Installation of Piston Pin
78
Cylinder Installation
80
Installation of Exhaust Socket
81
Installation of Combustion Chamber Insert
84
Installation of Cylinder Head Cover
84
Inspection and Adjustment of "Squich Gap
86
Installation of the Spark Plug
88
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
Checking the Clutch Drum
162
Checking the Needle Cage and Sprocket
162
Checking the Starter Reduction Gear Assembly
163
Checking the Electric Starter
164
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
Rotax 125 MAX evo Installation Instructions And Operation Manual (100 pages)
Brand:
Rotax
| Category:
Engine
| Size: 8 MB
Table of Contents
German
6
Table of Contents
6
Allgemein
11
Komplettieren des Motors
11
Montage und Anschluss der Elektrik- und Elektronikkomponenten
11
Montage der Zündspule
11
Montage der Zündkerze
12
Montage und Anschluss der RAVE Steuerung (nur 125 MAX)
13
Montage der ECU
13
Kontrolle Bzw. Ergänzung des Ölstandes IM Getrieberaum
14
Befestigung des Motors am Rahmen
15
Befestigungsweise Mittels Motorsockel
15
Direkte Verschraubung des Motors am Rahmen
15
Einhängen der Antriebskette
16
Montage der Batterie und Verlegung des Kabelstranges
17
Verlegung des Kabelstranges
17
Montage und Anschluss der Kraftstoffkomponenten
20
Montage und Anschluss der Kraftstoffpumpe
20
Montage und Anschluss des Vergasers
22
Montage des Gasseilzuges
23
Montage des Kühlers
24
Montage des Ansauggeräuschdämpfers mit Integriertem Luftfilter
27
Montage der Auspuffanlage
28
Abschließende Arbeiten
30
Entlüftung des Getrieberaumes
30
Bauart der ROTAX Motortype 125 MAX Evo, Junior MAX Evo, Mini MAX Evo und Micro MAX Evo
32
Technische Beschreibung der ROTAX Motortype 125 MAX Evo, 125 Junior MAX Evo
32
Funktionsprinzip des Motors
32
Kühlkreislauf
32
Ausgleichswelle
32
Zündanlage
32
Pneumatische Auslasssteuerung (nur 125 MAX Evo)
33
Kraftstoffpumpe
33
Vergaser
33
Ansauggeräuschdämpfer
33
Auspuffanlage
33
Betriebsmittel für den Motor
34
Kühlflüssigkeit
34
Batterie und Batterieladegerät
34
Kraftstoff
36
Motorabstimmungen
37
Vergaserabstimmung
37
Abstimmung des Übersetzungsverhältnisses
40
Wechseln der Kupplungstrommel mit dem Kettenritzel
42
Wechseln oder Erneuern des Kettenrads auf der Kupplungstrommel
43
Betriebsgrenzwerte
44
Korrekter Gebrauch des Motors
45
Starten des Motors und Fahrbetrieb
45
Abstellen des Motors
46
Einlaufverfahren für den Motor
47
Einstellung des Öffnungszeitpunktes des Auslassschiebers (nur 125 MAX Evo)
47
Kontroll- und Serviceintervalle der Motorbauteile
49
Transport des Fahrzeuges
50
Konservierung des Motors und des Zubehörs
50
English
52
General
52
Finalizing of Engine Assembly
52
Installation and Connection of the Electric and Electronic Components
52
Installation of the Ignition Coil
52
Fitting of the Spark Plug
53
Installation and Connection of the RAVE Control Unit (125 MAX Only)
54
Installation of the ECU
54
Verification or Replenishing of Oil Level in Gear Compartment
55
Engine Attachment on Chassis
56
Attachment Via Engine Pedestal
56
Direct Attachment of the Engine on Chassis
56
Fitting of the Drive Chain
57
Installation of the Battery and the Wiring Harness
58
Installation of the Wiring Harness
58
Installation and Connection of the Fuel System
61
Installation and Connection of the Fuel Pump
61
Installation and Connection of the Carburetor
63
Installation of the Bowden Cable for Carburetor Control
64
Installation of the Radiator
65
Installation of the Intake Silencer with Integrated Airfilter
67
Installation of the Exhaust System
68
Finishing Work
70
Venting of the Gear Compartment
70
Design of the ROTAX Engine Types 125 MAX Evo, Junior MAX Evo, Mini MAX Evo and Micro MAX Evo
72
Technical Description of the ROTAX Engine Types 125 MAX Evo, Junior MAX Evo, Mini MAX Evo and Micro MAX Evo
72
Type of Engine
72
Cooling Circuit
72
Balance Shaft
72
Ignition Unit
72
Electric Starter
73
Exhaust Timing Control (125 MAX Only)
73
Fuel Pump
73
Carburetor
73
Intake Silencer
73
Exhaust System
73
Media for Engine Operation
74
Coolant
74
Battery and Battery Charging Unit
74
Fuel
76
Engine Tuning
77
Carburetor Calibration
77
Selection of the Transmission Ratio
80
Exchange of the Clutch Drum with Chain Sprocket Fitted
82
Changing or Renewal of the Chain Sprocket on the Clutch Drum
83
Operating Limits
84
Engine Start and Operation
85
Stopping the Engine
86
Running-In Procedure for the Engine
87
Setting of the Exhaust Valve Timing (125 MAX Evo Only)
87
Maintenance Schedule for Engine Components
89
Transport of the Kart
90
Preservation of Engine and Equipment
90
Advertisement
Rotax 125 MAX evo Installation Instructions And Operators Manual (112 pages)
Brand:
Rotax
| Category:
Engine
| Size: 4 MB
Table of Contents
Table of Contents
5
Chapter INTRO
7
Engine Information
12
Chapter 1 Engine Installation
15
Attachment Via Engine Pedestal
17
Chapter 2 Fuel System
19
Installation and Connection of the Carburetor
24
Chapter: 3 Electric System
25
Chapter 3 Electric System
25
Installation of the Wiring Harness
26
Wiring Harness - Overview
28
Installation ECU into the Battery Clamp Assy
29
Installation of the Battery Clamp Assy
31
Chapter: 4 Cooling System
33
Chapter 4 Cooling System
33
Cooling System - Overview
34
Installation of the Radiator
35
Intake Silencer
37
Installation of the Intake Silencer with Integrated Airfilter
38
Chapter 5 Exhaust System
39
Chapter
39
Chapter 6 Installation of the Accessories
43
Fitting of the Spark Plug
45
Chapter 7 Finishing Work
49
Fitting of the Drive Chain
51
Chapter
58
Chapter: INTRO GENERAL INFORMATION
60
Chapter: 1 Technical Description
62
Technical Description
62
Design of the ROTAX Engine Types 125 MAX Evo, Junior MAX Evo, Mini MAX Evo and Micro MAX Evo
63
General
63
Cooling Circuit
63
Balance Shaft
63
Ignition Unit
63
Electric Starter
63
Electro Pneumatically Exhaust Timing Control (125 MAX Only)
64
Intake Silencer
64
Exhaust System
64
Fuel Pump
64
Carburetor
64
Centrifugal Clutch
65
Engine
66
Chapter: 3 Engine Calibration
74
Engine Calibration
74
Engine Calibration
75
Performance Graphs
75
Carburetor Calibration
76
Automatic-Set-Up
77
Manual Set-Up
80
Change of the Carburetor Main Jet
84
Selection of the Transmission Ratio
87
Exchange of the Clutch Drum with Chain Sprocket Fitted
89
Changing or Renewal of the Chain Sprocket on the Clutch Drum
91
Chapter: 4 Engine Operation
94
Engine Operating
95
Engine Start
95
Stopping the Engine
97
Running - in Procedure for the Engine
98
Setting of the Exhaust Valve Timing (125 MAX Evo Only)
99
Engine Operation
102
Maintenance Schedule for Engine Components
102
Operating Limits
104
Preservation and Transport
106
Preservation and Transport
107
Preservation of Engine and Equipment
107
Transport of the Kart
107
Important Information (Summary)
108
Notes
109
Rotax 125 MAX evo Installation Instructions And Operators Manual (108 pages)
Brand:
Rotax
| Category:
Engine
| Size: 15 MB
Table of Contents
Allgemein
7
Montage und Anschluss des Vergasers
10
Montage des Kühlers
12
Komplettieren der Trägerplatte
14
Montage des Kabelbaumes auf die Trägerplatte
16
Montage der Batterie und Verlegung des Kabelstranges
20
V Erlegung des K Abelstranges
21
M Ontage der Z Ündkerze
22
Bild
24
Bild
25
Kontrolle Bzw. Ergänzung des Ölstandes IM Getrieberaum
26
Befestigung des Motors am Rahmen
27
Montage des Ansauggeräuschdämpfers mit Integriertem Luftfilter
28
Montage der Auspuffanlage
29
E Ntlüftung des G Etrieberaumes
31
Maintenance Schedule for Engine Components
102
Advertisement
Related Products
Rotax 125 Max
Rotax 125 Mini Max
Rotax 125 Micro MAX
Rotax 125 JUNIOR MAX evo
Rotax 125 senior MAX evo
Rotax 125 DD2 MAX EVO
Rotax 122
Rotax Leonardo 120
Rotax Leonardo 154 Scarabeo 120S
Rotax Scarabeo 177S
Rotax Categories
Engine
Lubrication systems
Outboard Motor
Offroad Vehicle
Boat
More Rotax Manuals
Login
Sign In
OR
Sign in with Facebook
Sign in with Google
Upload manual
Upload from disk
Upload from URL