Rotax 125 Micro MAX Manuals

Manuals and User Guides for Rotax 125 Micro MAX. We have 7 Rotax 125 Micro MAX manuals available for free PDF download: Repair Manual, Installation Instructions And Operators Manual, Installation Instructions And Operation Manual, Installation Manual

Rotax 125 Micro MAX Repair Manual

Rotax 125 Micro MAX 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

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Rotax 125 Micro MAX Repair Manual

Rotax 125 Micro 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

Rotax 125 Micro MAX Installation Instructions And Operation Manual

Rotax 125 Micro MAX Installation Instructions And Operation Manual (100 pages)

Brand: Rotax | Category: Engine | Size: 8 MB

Table of Contents

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Rotax 125 Micro MAX Installation Instructions And Operators Manual

Rotax 125 Micro MAX 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
Chapter: 4 Cooling System

33
- Chapter 4 Cooling System
  
  33
- 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
Chapter: 4 Engine Operation

94
- Engine Operating
  95
- 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 Micro MAX Installation Instructions And Operators Manual

Rotax 125 Micro 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

Rotax 125 Micro MAX Installation Instructions And Operators Manual

Rotax 125 Micro MAX Installation Instructions And Operators Manual (108 pages)

Brand: Rotax | Category: Engine | Size: 15 MB

Table of Contents

Rotax 125 Micro MAX Installation Manual

Rotax 125 Micro MAX Installation Manual (54 pages)

Brand: Rotax | Category: Engine | Size: 3 MB

Table of Contents

Brp-Rotax Table of Content

3
- Table of Contents
  3
- Chapter INTRO
  5
- Chapter 1 Engine Installation
  
  11
- Chapter 2 Fuel System
  
  15
Brp-Rotax Chapter: 3 Electric System

23
- Chapter 3 Electric System
  
  23
Brp-Rotax Chapter: 4 Cooling System

31
Chapter: 7 Finishing Work

47
- Chapter 7 Finishing Work
  
  47
  - Check Oil Level in Gear Box
    48
  - Fitting of the Drive Chain
    49
  - Venting of the Gear Compartment
    50
  - Run-In Procedure
    51

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