Rotax 125 Max Operation and maintenance manual

for ROTAX®-engines type
125 MAX
125 JUNIOR MAX
125 MINI MAX/125 MICRO MAX
Part no.: 297731 Edition: 02 2014
BRP-Powertrain GmbH & Co KG | Rotaxstraße 1 | 4623 Gunskirchen, Austria | T: [phone] | F: [phone]
www.rotax.com | www.rotax-kart.com
Installation Instructions and Operators Manual

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Introduction
Foreword All data and procedures are based on the state of knowledge at
the time of publication and the Manual has been drawn up to the
best of our knowledge, however, excluding any liability.
These instructions are only valid for engines and parts, which
were supplied by BRP-Powertrain. This Operators Manual con-
tains important information about safe operation of the engine, to-
gether with descriptions of the system and its layout, technical
data, operating media and the operational limits of the engine.
If any passages of the Manual are not clearly understood or if you
have questions, please contact an authorized Distributor or Ser-
vice Center for ROTAX-Kart engines.
Introduction Congratulations on choosing the ROTAX engine Type 125 MAX,
125 Junior MAX, 125 Mini MAX or 125 Micro MAX.
This ROTAX engine has been developed exclusively for use in
Go-Karts, which must only be run on specified tracks. This prod-
uct has many technical innovations that have been filed for patent.
In case of change of the ownership, hand over this Manual, the
Engine Identity Card and the product- and service registration
document to the new owner.
NOTE: Technical information contained in this docu-
ment may be different to the RMC technical reg-
ulations.
Chapter structure The Installation- and Operators Manual is subdivided into the fol-
lowing chapters:
Subject Chapter
Introduction Chapter INTRO
List of effective pages Chapter LEP)
Table of amendments Chapter TOA)
Installation instructions Chapter 1)
Operators Manual Chapter 2)

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BRP-Powertrain recommends products of following brands:

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LEP) List of effective pages
Chapter Page Date
cover page
INTRO INTRO-1
INTRO-2
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02 01 2014
LEP LEP-1
LEP-2
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TOA TOA-1
TOA-2
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Chapter Page Date

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NOTES

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TOA) Summary of amendments
Content Summary of the relevant amendments in this context, but without
any claim to completeness.
Current
No.
Manual
section
Chapter Page Date of
change
Comments
0Installation
instructions
1 - 14 all 02 01 2014 -
0Operators
Manual
1 - 10 all 02 01 2014 -

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NOTES

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1) Installation instructions
Inhalt This chapter describes the installation of engine types ROTAX
125 MAX/Junior MAX/Mini MAX and Micro MAX. The description
is divided into subsections.
Topic Page
General precaution and safety information for engine in-
stallation
Unpacking of engine and accessories
Verification or replenishing of oil level in gear
compartment
page 1-2
page 1-2
page 1-6
Engine suspension on chassis
Fitting of the drive chain
page 1-7
page 1-7
Electrical components, Installation of:
Start button and ON/OFF switch
Wiring harness
Spark plug
Battery
page 1-9
page 1-9
page 1-10
page 1-12
page 1-13
Installation of the radiator
Installation of the fuel pump
Connection of the fuel pump
Installation of the carburetor
Installation of the Bowden cable
Installation of the intake silencer with integrated airfilter
Venting of the gear compartment
page 1-15
page 1-16
page 1-17
page 1-19
page 1-20
page 1-21
page 1-23
Installatiion of the exhaust system
Connection of the battery
Observation of engine speed and coolant temperature
page 1-23
page 1-24
page 1-26

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1) General precaution and safety information for engine installation
Safety information
2) Unpacking of engine and accessories
General
These parts are available at the authorized distributor or one of it‘s
Service Centers.
These parts change the characteristics of the engine, details to
follow in next chapters.
NOTE: To be able to use the battery charger in your
homecountry, contact your nearest ROTAX
Service Center for an adapter plug and/or an
adapter cable.
Engine type
125 MAX
The engine package (equipment package) of the 125 MAX con-
tains the following parts:
WARNU
WARNING
Non-compliance can result in serious injuries
or death!
Modifications on engine or equipment are not
allowed.
WARNUNG
NOTICE
For the best possible engine operation,
compliance with the following advice regar-
ding installation of engine and equipment is
required.
WARNUNG
NOTICE
Engine operation is permitted only with
equipment supplied by ROTAX.
WARNUNG
NOTICE
Besides the engine-specific installation
advice, also take note of information from the
respective chassis manufacturer.
ENVIRONMENT NOTE
All packing material is recyclable and should be disposed of ac-
cordingly
WARNUNG
NOTICE
If the engine should be placed on a flat
surface, take care not to damage the elec-
trical connection of the starter.
Qty Part no. Description Application
PARTS SET SMALL