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: +43 7246 6010 | F: +43 7246 6370

www.rotax.com | www.rotax-kart.com

Installation Instructions and Operators Manual

Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page INTRO-1

Edition 1/Rev. 0 BRP-Powertrain February 01/2014

DK00080.fm

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)

Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page INTRO-2

OM Edition 1/Rev. 0 BRP-Powertrain February 01/2014

DK00080.fm

BRP-Powertrain recommends products of following brands:

Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page LEP-1

Edition 1/Rev. 0 BRP-Powertrain February 01/2014

DK00081.fm

LEP) List of effective pages

Chapter Page Date

cover page

INTRO INTRO-1

INTRO-2

02 01 2014

LEP LEP-1

LEP-2

02 01 2014

TOA TOA-1

TOA-2

02 01 2014

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02 01 2014

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02 01 2014

rear page

Chapter Page Date

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Edition 1/Rev. 0 BRP-Powertrain February 01/2014

DK00081.fm

NOTES

Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page TOA-1

Edition 1/Rev. 0 BRP-Powertrain February 01/2014

DK00082.fm

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 -

Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page TOA-2

Edition 1/Rev. 0 BRP-Powertrain February 01/2014

DK00082.fm

NOTES

Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page 1-1

Edition 1/Rev. 0 BRP-Powertrain February 01/2014

DK00083.fm

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 1-6

Engine suspension on chassis

Fitting of the drive chain

page 1-7

Electrical components, Installation of:

Start button and ON/OFF switch

Wiring harness

Spark plug

Battery

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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DK00083.fm

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

Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page 1-3

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DK00083.fm

2 222746 Cooling water hose -

1 827307 Washer 6,2/18/0,5 -

2 938795 Spring 66 MM -

1 440751 Allen screw with round-

ed flange head M6x16

2 840880 Allen screw M6x30 -

6 241930 Allen screw M8x20 -

1 841831 Allen screw M8x75 -

4 942030 Lock nut M8 -

4 242141 Nut M6 -

4 242211 Hex. nut M6 -

8 842040 Lock nut M6 -

12 244211 Washer 6,4 -

1 945752 Lock washer A8 -

4 250313 Washer 8,4 -

1 251720 Support bracket -

1 651690 Radiator bracket -

2 951791 Clamp 50 - 70 -

4 951870 Clamp 16 - 25 -

2 260657 Rubber buffer

25x20xM6

1 660767 Rubber pad -

2 660920 Rubber buffer

30x30xM8

1 265580 Start button -

1 265592 ON-OFF pull switch -

1 266125 Wiring harness -

11 866710 Cable tie 142x2,5 -

1 274161 Fuel filter -

1 994483 Mikuni fuel pump -

1 297838 Spark plug 14 IW 27 -

PARTS SET LARGE

NOTE: Contains parts set small.

1 281453 Parts set small -

1 225015 Intake silencer case,

bottom

1 225025 Intake silencer case,

top

Qty Part no. Description Application

Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page 1-4

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DK00083.fm

Engine type

125 Junior MAX

This engine type is identical to the 125 MAX, except for the follow-

ing main parts:

NOTE: The engines 125 Junior MAX, Mini MAX and

Micro MAX have cylinders without exhaust

valve.

Engine type

125 Mini MAX

This engine type is identical to the 125 Junior MAX, except for the

following main parts.

1 225031 Carburetor socket -

1 225041 Intake silencer tube -

1 225051 Filter element -

2 225061 Holder for filter element -

1 251123 Battery clamp -

1 251254 Pipe clamp set 32 -

1 260772 Reduction gear cover -

1 660221 Battery cover -

1 265148 Battery charger -

1 265515 Battery 12 V - 6,5Ah

1 265579 Ignition coil assy. -

1 273076 Exhaust system assy. -

1 974529 Tube A5x8/2500 mm -

1 295928 Radiator assy. -

1 295998 Carburetor -

1 297122 Throttle bowden cable

assy.

1 297461 ROTAX XPS full synth.

2-stroke oil

Qty Part no. Description Application

1 223994 Cylinder NI SI C plated -

as req. 281376 Upgrade kit from Junior

to Max

Includes all required

parts to update the en-

gine 125 Junior Max to

configuration 125 Max.

Qty Part no. Description Application

1 273972 Exhaust socket -

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DK00083.fm

Engine type

125 Micro MAX

This engine type is identical to the 125 Mini MAX, except for the

following main parts.

Engine Identity

Card

NOTE: An Engine Identity Card stating date of delivery

and company has to be issued by the autho-

rized Service Center for the customer.

NOTE: The data entered in the Engine Identity Card is

required for verification of a warranty claim.

Without a completely filled-in Engine Identity

Card no warranty claim will be granted.

NOTE: In case of participating in the ROTAX MAX

CHALLENGE (RMC) the engine must be veri-

fied for conformity with the technical regulations

and sealed. The serial number of the seal must

be entered in the Engine Identity Card.

Qty Part no. Description Application

1 276530 Intake restrictor -

1 276535 Intake restrictor -

1 273130 Exhaust system assy. -

1 295923 Radiator assy. -

Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page 1-6

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DK00083.fm

3) Verification or replenishing of oil level in gear compartment

General The gear compartment has already been filled with the appropri-

ate amount of oil by the engine manufacturer. However, before

engine installation into the frame (chassis), the oil level must be

verified and replenished if necessary.

NOTE: The filling capacity is 6.10 cu in. (0.0265 US

gal).

Oil specification

Procedures See Fig. 1.

NOTE: By removing the Allen screw (2) the oil can be

drained from the gear compartment.

Graphic Oil level check

Fig. 1 K00233_b

Part no. Description Application

n.a. Gear oil specification

SAE30

gearbox

Step Procedure

1 Remove venting screw (1).

2 Remove drain plug (2).

3 Drain gear oil completely.

4 Install drain plug (2) with new sealing.

5 Fill in gear oil as specifed (6.10 cu in. (0.0265 US gal)).

6 Tighten venting screw (1) by hand.

1. Venting screw 2. Drain plug

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DK00083.fm

4) Engine suspension on chassis

General Using an engine pedestral for the ROTAX engine 125 MAX/Junior

MAX/Mini MAX, the engine is inclined at 0° to 15° in the driving di-

rection.

NOTE: Engaged thread length in crankcase to be be-

tween 16 mm (5/8“) - 24 mm (1 in.).

4.1) Fitting of the drive chain

Safety information

General The required length of the drive chain depends on chassis and

transmission ratio and therefore the chain is not included in the

supply volume of the engine.

Special tools/

products/parts

Recommended by ROTAX:

WARNUNG

NOTICE

Do not fasten engine on chassis until chain is

in position and properly aligned and tensi-

oned.

Step Procedure

1 Connect pedestral with engine crankcase by 4 screws M8

(minimum strengh grade 8.8).

Tightening torque for the connection between pedestral and

engine crankcase = 24 Nm (212 in lb.).

WARNU

WARNING

Non-compliance can result in serious injuries

or death!

Install a chain cover!

WARNU

WARNING

Non-compliance can result in serious injuries

or death!

Pay attention to instructions of the chassis

manufacturer regarding the drive chain align-

ment.

Part no. Description Application

582458 Kart chain links 219/94 Engine

582459 Kart chain links 219/96 Engine

582460 Kart chain links 219/98 Engine

582470 Kart chain o-ring 219/98 Engine

582461 Kart chain links 219/100 Engine

582471 Kart chain o-ring 219/100 Engine

582462 Kart chain links 219/102 Engine

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DK00083.fm

Procedures Following steps are necessary:

582472 Kart chain o-ring 219/102 Engine

582463 Kart chain links 219/104 Engine

582473 Kart chain o-ring 219/104 Engine

582464 Kart chain links 219/106 Engine

582474 Kart chain o-ring 219/106 Engine

582465 Kart chain links 219/108 Engine

582475 Kart chain o-ring 219/108 Engine

582466 Kart chain links 219/110 Engine

582476 Kart chain o-ring 219/110 Engine

582467 Kart chain links 219/112 Engine

582477 Kart chain o-ring 219/112 Engine

582468 Kart chain links 219/114 Engine

582478 Kart chain o-ring 219/114 Engine

582469 Kart chain links 219/116 Engine

582479 Kart chain o-ring 219/116 Engine

Part no. Description Application

Step Procedure

1 Place the chain on the sprockets of the clutch and the rear

axle.

2 Verify chain alignment between front and back chain

sprocket with a straight edge. Correct as required by shifting

sprocket adapter along rear axle.

3 Establish required chain tension (Sag = +/- 5 mm (0.20 in.))

by shifting the engine.

WARNU

WARNING

Non-compliance can result in serious injuries

or death!

Take note of advice of the chassis manufac-

turer regarding engine suspension on

chassis.

Step Procedure

4 Fasten engine on the chassis.

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DK00083.fm

5) Electrical components

5.1) Installation of the start button and ON/OFF switch

General Both items have to be fitted into top section (left or right) of the

front shield.

NOTE: Hand-tighten the attachment nut of starter but-

ton and ON/OFF switch.

Procedures See Fig. 2.

Graphic Start button and ON/OFF switch

Fig. 2 K00252

Step Procedure

1 Drill a ø22 mm (1/8“) bore for the starter button (2) into either

left or right side of the front shield.

2 Approx. 40 mm (1.5“) below drill a ø12 mm (0.5“) bore for

the ON/OFF switch (1).

3 Attach start button furnished with rubber cap by hex. nut on

front shield.

4 Attach ON/OFF switch on the front shield with the 2 nuts

supplied.

1. Start button 2. ON/OFF switch

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DK00083.fm

5.2) Installation of the wiring harness

General

Establish connections in accordance with Fig. 3.

Disconnect any electrical plug connection only by pulling on the

plugs.

NOTE: Compensate excessive length of wiring har-

ness by routing cables in loops.

Graphic Wiring harness

Fig. 3 K00030

WARNU

WARNING

Non-compliance can result in serious injuries

or death!

The wiring harness must not touch moving

parts or the track.

WARNUNG

NOTICE

The battery should only be connected just

before starting the engine.

1. Start button 2. ON/OFF switch

3. Cable 6 mm2/S.W.G. 11 4. Cable 2 mm2/S.W.G. 16

5. Ignition coil 6. Rubber mount

7. Washer 6,4 8. Lock nut M6

9. Masseleitung 10. Trigger coil

11. Electric Starter 12. Spark plug

11 12

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DK00083.fm

Start button and

ON/OFF switch

NOTE: Polarity of the cable for start button and ON/

OFF switch is optional.

Procedures See Fig. 3.

Ignition coil NOTE: Attach the wiring harness with the supplied ca-

ble ties to top side of chassis tubes and in the

area of the ignition coil support. Make sure that

plug connectors on the ignition pick-up and igni-

tion coil are free of stress.

NOTE: The location of the ignition coil is adjustable

within the ablong holes in gear cover and igni-

tion coil yoke. Position ignition coil as far as

possible from the exhaust.

Procedures See Fig. 3.

Step Procedure

1 Connect the two 6 mm2/ S.W.G. 11 cables (3) with start but-

ton (1).

2 Connect the two 2 mm2/ S.W.G. 16 cables (4) with ON/OFF

switch (2).

WARNUNG

NOTICE

The ignition coil must be attached flexibly on

the gear cover, exclusively via the two rubber

mounts. Under any circumstances the igni-

tion coil may not touch any rigid parts of the

frame (e.g. seat strut).

Step Procedure

1 Attach ignition coil on the reduction cover, utilizing the sup-

plied attachment elements 2 pcs. rubber mount (6), 4 pcs.

Washer 6,4 (7) and 4 pcs. lock nut M6 (8).

2 On the top of the attachment screw of ignition coil connect

also the grounding cable (9).

WARNUNG

NOTICE

Pay special attention to proper ground

connection on gear compartment cover. An

interrupted grounding can ruin the ignition

coil.

Step Procedure

3 Connect the wiring harness to the ignition coil (5).

4 Connect the wiring harness to the trigger coil (10).

5 Connect the wiring harness to the electric starter (11).

Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page 1-12

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DK00083.fm

5.3) Installation of the spark plug

General NOTE: Following spark plugs are declassified by BRP-

Powertrain:

DENSO IW 24-31, as standard a

DENSO IW 27 is installed.

Procedures See Fig. 3.

NOTE: The electrode gap should be between 0,4 mm

(0.016 in.) and 0,6 mm (0.024 in.) (for DENSO

spark plugs).

Only slight bending of the ground electrode is

permitted.

Step Procedure

1 Remove the transport plug from spark plug tapping.

2 Inspect electrode gap of spark plug (12), adjust if necessary.

Step Procedure

3 Fit spark plug by hand and tighten to 27 Nm (239 in.lb).

4 Install spark plug connector on spark plug.

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