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Rotax 125 JUNIOR MAX evo, Installation Manual

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Rotax 125 JUNIOR MAX evo Installation Manual Download Page 43

BRP-Rotax

INSTALLATION INSTRUCTION

FITTING OF THE SPARK PLUG

The engine will be supplied with a spark plug.

Tools required:

• Feeler gauge

• Socket 21 mm

• Torque wrench

Step

Procedure

1

Remove the transport plug from the
cylinder head.

2

Check electrode gap of spark plug. Ad-
just as required.

NOTE

Check technical regulations to assure conform-
ity when setting the electrode gap.

Step

Procedure

3

Fit supplied spark plug (pos. 1) and
tighten 25 Nm (221 lbf in) to 27 Nm
(239 lbf in).

4

Install the spark plug connector (pos.
2), ensure correct engagement.

Figure 7.5

1

Spark plug

2

Spark plug connector

Effectivity: 125 MAX evo, Junior MAX
evo, Mini MAX evo, Micro MAX evo

6

Page 3

Edition: March 01 2021

Summary of Contents for 125 JUNIOR MAX evo

Page 1: ...INSTALLATION MANUAL 125 SENIOR MAX EVO 125 JUNIOR MAX EVO 125 MINI MAX EVO 125 MICRO MAX EVO KART ED 03 2021 PART NO 297732 ROTAX KART COM ...

Page 2: ...Follow us BRP Rotax GmbH Co KG Rotaxstraße 1 4623 Gunskirchen Austria T 43 7246 601 0 F 43 7246 6370 www rotax kart com GENERAL INFORMATION BRP ROTAX RECOMMENDS PRODUCTS OF THE FOLLOWING COMPANIES ...

Page 3: ...Edition March 01 2021 Table of Content Chapter INTRO Chapter 1 Engine installation Chapter 2 Fuel system Chapter 3 Electric system Chapter 4 Cooling system Chapter 5 Exhaust system Chapter 6 Installation of the accessories Chapter 7 Finishing work BRP Rotax INSTALLATION INSTRUCTION ...

Page 4: ...Notes Page 2 Edition March 01 2021 Effectivity 125 MAX evo Junior MAX evo Mini MAX evo Micro MAX evo Edition October 01 2019 Rev 0 NOTES BRP Rotax INSTALLATION INSTRUCTION ...

Page 5: ...t of our knowledge However excluding any liability We reserve all rights including technical modification and possibility of errors Reprinting translation or copies in whole or in part are authorized only after written permission by BRP Rotax GmbH Co KG BRP Rotax GmbH Co KG reserves the right at any time to discontinue or change specifications prices designs features models or equipment without in...

Page 6: ...potential hazard if not avoided could result in serious injury or death m CAUTION Indicates a hazard situation which if not avoided could result in minor or moderate injury ATTENTION Indicates an instruction which if not followed could severely damage vehicle components or other property ENVIRONMENTAL NOTE Environmental notes give you tips on environmental protection NOTE Indicates supplementary i...

Page 7: ...engine specific installation advice also take note of information from the respective chassis manufacturer Introduction Congratulations on choosing the ROTAX engine Type 125 MAX The ROTAX engine Type 125 MAX has been developed exclusively for use in Go karts which must only be run on specified tracks This product has numerous technical innovations m WARNING Non compliance can result in serious inj...

Page 8: ...oxes Figure 1 2 Unboxing Engine box The engine box contains the assembled block engine pre filled with gearbox oil Accessory box The accessory box contains all required parts for running the engine Check integrity of the accessory kit using the table below INTRO Page 4 Edition March 01 2021 Effectivity 125 MAX evo Junior MAX evo Mini MAX evo Micro MAX evo ...

Page 9: ...k plug cap O 3 Battery box and wiring harness O 4 Battery charger O 5 Intake silencer O 6 Fuel pump with fuel hose O 7 Exhaust system O 8 Manuals and engine identity card O 9 Several small parts spark plug screws O 10 Hose package for RAVE control unit O 11 ECU O 12 Carburetor O Effectivity 125 MAX evo Junior MAX evo Mini MAX evo Micro MAX evo INTRO Page 5 Edition March 01 2021 ...

Page 10: ...lutch side housing half Figure 1 4 Serial number of the engine TYPICAL Gear oil and fuel specifications See the latest Operators Manual Equipment and modifications Modifications to engine and or equipment are not allowed INTRO Page 6 Edition March 01 2021 Effectivity 125 MAX evo Junior MAX evo Mini MAX evo Micro MAX evo ...

Page 11: ...TRUCTION Chapter 1 ENGINE INSTALLATION TOPICS IN THIS CHAPTER Engine installation to the chassis 2 Attachment via engine pedestal 3 Effectivity 125 MAX evo Junior MAX evo Mini MAX evo Micro MAX evo 1 Page 1 Edition March 01 2021 ...

Page 12: ... to the engine 1 Make sure not to tighten them up now so that the en gine is still movable onto the frame 4 Put the engine back as far as possible 5 Put the chain around the rear axle and fit the chain to the front sprocket first 6 Fit the chain also to the rear sprocket 7 Move the engine forward to tighten the chain 8 If you adjusted the correct chain ten sion use the stopper to keep the en gine ...

Page 13: ...uitable for the chassis ATTENTION Non compliance can result in serious injuries When drilling the holes in the pedestal pay atten tion to the advice of the chassis manufacturer Step Procedure 2 Connect pedestal with engine crank case with 4 screws M8 min strength grade 8 8 Tighten screws to 24 Nm 212 in lb ATTENTION Pay attention to chain alignment as advised by chassis manufacturer NOTE Do not fa...

Page 14: ...Notes Page 4 Edition March 01 2021 Effectivity 125 MAX evo Junior MAX evo Mini MAX evo Micro MAX evo Edition October 01 2019 Rev 0 NOTES BRP Rotax INSTALLATION INSTRUCTION ...

Page 15: ...IN THIS CHAPTER Installation and connection of the fuel pump 2 Installation of the Bowden cable for carburetor control 5 Installation and connection of the carburetor 7 Effectivity 125 MAX evo Junior MAX evo Mini MAX evo Micro MAX evo 2 Page 1 Edition March 01 2021 ...

Page 16: ...bf in Figure 3 2 1 Support bracket 2 Screws M6x30 TIP Facilitate the assembly of fuel hose by slightly widening the hose end with a pair of circlip pliers ATTENTION Fuel hose can be damaged Avoid excessive widening of the fuel hose Figure 3 3 Step Procedure 3 The fuel hose with 230 mm length will be connected later to the carburetor see carburetor installation in section 3 4 The larger fuel hose p...

Page 17: ...ng a tie wrap pos 1 Figure 3 5 Concerns all engines Step Procedure 7 Install the connection between the fuel tank and the fuel filter the length of this line may vary from chassis to chassis ATTENTION Pay attention to the direction of the arrow on the fuel filter This must point towards the fuel pump m WARNING Non compliance can result in serious injuries or death Route the fuel line from the fuel...

Page 18: ...nes must not be restricted by the use of cable ties ATTENTION The use of an extra fuel filter must not cause further flow resistance in the fuel line between the fuel tank and the fuel pump 2 Page 4 Edition March 01 2021 Effectivity 125 MAX evo Junior MAX evo Mini MAX evo Micro MAX evo ...

Page 19: ...ton to wards intake silencer 6 Pass Bowden wire through compres sion spring pos 6 and through cover with rubber ring pos 7 8 of carburetor 7 Fit carb cover pos 7 on carburetor 8 Pass Bowden wire through Bowden conduit and through adjustment screw on chassis throttle pedal 9 Connect Bowden cable to throttle pedal Figure 3 6 1 Carburetor 2 Carburetor piston 3 Jet needle K57 4 Clip 5 Nipple screw 6 C...

Page 20: ...nt screw for Bowden cable on chassis so that the carburetor piston will remain in closed position when throttle pedal is not activated 12 Set and secure the stop screw for throttle pedal so that with pedal com pletely pressed down the carburetor piston will be in the full open position The Bowden cable must not be under full tension when the throttle is in fully open position 2 Page 6 Edition Marc...

Page 21: ...er Step Procedure 1 Fit carburetor pos 1 into carburetor socket and secure with hose clamp pos 2 in vertical position 2 Connect the outlet hose of the fuel pump with fuel inlet pos 3 on the carburetor Figure 3 7 1 Carburetor 2 Hose clamp 3 Fuel inlet Effectivity 125 MAX evo Junior MAX evo Mini MAX evo Micro MAX evo 2 Page 7 Edition March 01 2021 ...

Page 22: ...Notes Page 8 Edition March 01 2021 Effectivity 125 MAX evo Junior MAX evo Mini MAX evo Micro MAX evo Edition October 01 2019 Rev 0 NOTES BRP Rotax INSTALLATION INSTRUCTION ...

Page 23: ...CS IN THIS CHAPTER Installation of the wiring harness 2 Wiring harness overview 4 Installation ECU into the battery clamp assy 5 Installation of the battery clamp assy 7 Effectivity 125 MAX evo Junior MAX evo Mini MAX evo Micro MAX evo 3 Page 1 Edition March 01 2021 ...

Page 24: ... harness ATTENTION Strain relief of the plug connections must be ensured NOTE Compensate excessive length of wiring harness by routing cables in loops m WARNING Non compliance can result in serious injuries or death The wiring harness must not touch moving parts of the track NOTE When unplugging connections on ignition pick up and ignition coil press the integrated catch first NOTE Disconnect any ...

Page 25: ...The shift contact cable must be isolated be cause there is no use on non gear engines For engines without exhaust slide only In the following figure you see the laying of the wiring harness on engines without exhaust slide Also you see a dummy plug part no 666900 as an option which is not included in the scope of delivery It can be secured using tie wraps instead of the solenoid valve Figure 4 5 S...

Page 26: ...nnector pickup sensor 2 Connector starter 3 Connector battery 4 Connector RAVE only applicable 125 MAX evo 5 Connector ECU 6 Connector ignition coil 7 Tie wrap 250x4 8 8 Tie wrap 142x3 2 3 Page 4 Edition March 01 2021 Effectivity 125 MAX evo Junior MAX evo Mini MAX evo Micro MAX evo ...

Page 27: ...in one position to the rubber pad Figure 4 8 1 Rubber pad Step Procedure 3 Insert the complete unit into the battery clamp assy NOTE If difficulties at insertion occur the inside of the battery clamp assy can be easily bent inward so that the distance increases slightly ATTENTION Make sure that the connection cable has been installed between the two pads The connection of the ECU is on the rear si...

Page 28: ...BRP Rotax INSTALLATION INSTRUCTION Figure 4 9 1 Rubber pad 2 Connection cable 3 ECU connector 3 Page 6 Edition March 01 2021 Effectivity 125 MAX evo Junior MAX evo Mini MAX evo Micro MAX evo ...

Page 29: ... mm 1 18 1 26 in diameter ATTENTION Risk of clamp fracture Do not over tighten the screw of the pipe clamps Step Procedure 2 Install rubber pad pos 6 with battery pos 7 into the battery holder pos 5 3 Put the battery pos 7 into the fixture and install the cover pos 8 using the Allen screw with rounded flange head pos 9 Fix the wiring harness in the P clamp 12 uswing Allen screw 13 TIP The battery ...

Page 30: ...t the negative terminal black of the battery Figure 4 13 Step Procedure 6 Install the battery cover onto the bat tery holder NOTE Make sure that the two retaining lugs pos 1 are in the notches of the battery cover Step Procedure 7 Tighten flange head screw pos 2 of the battery cover Figure 4 14 1 Retaining lugs 2 Flange head screw 3 Page 8 Edition March 01 2021 Effectivity 125 MAX evo Junior MAX e...

Page 31: ...M TOPICS IN THIS CHAPTER Cooling system overview 2 Installation of the radiator 3 Intake silencer 5 Installation of the intake silencer with integrated airfilter 6 Effectivity 125 MAX evo Junior MAX evo Mini MAX evo Micro MAX evo 4 Page 1 Edition March 01 2021 ...

Page 32: ...3 Lower coolant water hose 4 Clamp 16 25 5 Radiator bracket 6 Washer 7 Allen screw with rounded flange head 8 Lock washer 9 Allen screw 10 Small radiator 125 Micro MAX evo only 11 Radiator bracket 125 Micro MAX evo only 4 Page 2 Edition March 01 2021 Effectivity 125 MAX evo Junior MAX evo Mini MAX evo Micro MAX evo ...

Page 33: ...s a filling capacity about 0 5 l and fits to engine types 125 Mini Max evo and 125 Micro MAX evo The installation of both radiators is similar Figure 5 2 Step Procedure 2 Attach the pre assembled radiator to the engine with Allen screw M8x75 pos 1 and washer pos 2 Figure 5 3 1 Allen screw M8x75 2 Washer Step Procedure 3 Attach the pre assembled upper cool ant hose to the engine using 1 hose clamp ...

Page 34: ...e upper and bottom hose is sup posed to be different but equal at delivery Therefore cut the bottom hose using scissors or a knife Figure 5 5 4 Hose clamp 16 25 4 Page 4 Edition March 01 2021 Effectivity 125 MAX evo Junior MAX evo Mini MAX evo Micro MAX evo ...

Page 35: ...ntake silencer case bottom 3 Filter element 4 Holder for filter element 5 Intake silencer tube 6 Carburetor socket 7 Lock nut M6 8 Support bracket 9 Washer 6 4 10 Allen screww M6x20 11 Clamp 50 70 Effectivity 125 MAX evo Junior MAX evo Mini MAX evo Micro MAX evo 4 Page 5 Edition March 01 2021 ...

Page 36: ...o the bottom half of intake silencer pos 2 4 Assemble bottom half of intake si lencer case pos 2 with top half pos 1 as shown in the following figure Make sure that the locking is inter locked properly 5 Attach the intake silencer with the sup plied hose clamp pos 11 to the carburetor NOTE The carburetor socket pos 6 is asymmetrical and can be turned so that the best possible po sition between car...

Page 37: ...ax INSTALLATION INSTRUCTION Chapter 5 EXHAUST SYSTEM TOPICS IN THIS CHAPTER Installation of the exhaust system 4 Effectivity 125 MAX evo Junior MAX evo Mini MAX evo Micro MAX evo 5 Page 1 Edition March 01 2021 ...

Page 38: ...Junior MAX evo 125 MINI MAX evo 2 Silencer assy 3 Tension spring 4 Spring stainless 5 Exhaust gasket 6 Retaining plate 7 Rubber buffer 8 Spring stainless 9 Rubber buffer 10 Washer 8 4 5 Page 2 Edition March 01 2021 Effectivity 125 MAX evo Junior MAX evo Mini MAX evo Micro MAX evo ...

Page 39: ...gasket 14 Spring stainless 15 Exhaust socket assy 125 Mini MAX evo 16 Exhaust socket assy 125 Micro MAX evo 17 Exhaust system 125 Micro MAX evo 18 Exhaust system 125 Mini MAX evo similar to Micro MAX evo but not the same Effectivity 125 MAX evo Junior MAX evo Mini MAX evo Micro MAX evo 5 Page 3 Edition March 01 2021 ...

Page 40: ...et on the cylinder to the muffler 3 The gasket pos 13 is the only seal ing between engine and the exhaust system Additional heat resistant LOC TITE is not necessary anymore NOTE All engine types have the same gaskets NOTE A leakage in the exhaust system may lead to performance loss Step Procedure 4 Secure the exhaust system on the ball joint using the two supplied exhaust springs pos 14 NOTE For e...

Page 41: ...ON OF THE ACCESSORIES TOPICS IN THIS CHAPTER Installation of mounting plate 2 Fitting of the spark plug 3 Installation and connection of the RAVE control unit 4 Effectivity 125 MAX evo Junior MAX evo Mini MAX evo Micro MAX evo 6 Page 1 Edition March 01 2021 ...

Page 42: ...gines with exhaust slide Step Procedure 1 Install mounting plate to crankshaft housing pos 4 using 2 Allen screws M6x20 pos 1 washers pos 2 and lock nuts M6 pos 3 Figure 7 3 1 Allen screws M6x20 2 Washer 6 4 3 Lock nut M6 4 Crankshaft housing NOTE The position of the mounting plate may vary de pending on the engine type and position of the seat stay Figure 7 4 Position of the mounting plate 6 Page...

Page 43: ...lectrode gap of spark plug Ad just as required NOTE Check technical regulations to assure conform ity when setting the electrode gap Step Procedure 3 Fit supplied spark plug pos 1 and tighten 25 Nm 221 lbf in to 27 Nm 239 lbf in 4 Install the spark plug connector pos 2 ensure correct engagement Figure 7 5 1 Spark plug 2 Spark plug connector Effectivity 125 MAX evo Junior MAX evo Mini MAX evo Micro...

Page 44: ...nly serves to choke the opening of the exhaust valve Figure 7 6 6 Impulse nozzle 7 Pressure line 8 Tie wrap small NOTE In order to prevent the displacement of the im pulse nozzle pos 6 a small cable tie pos 8 should be attached directly afterwards to the pressure line Do not tie up the pressure line completely Figure 7 7 4 Check valve 6 Impulse nozzle 7 Pressure line 8 Tie wrap small Step Procedur...

Page 45: ...10 1 Hose package 2 Metal connector Step Procedure 5 Fix another tie wrap pos 1 at the fix ing point bore on the engine housing Secure both lines with tie wrap pos 3 ensuring that the black hose pos 2 is on top Figure 7 11 1 Tie wrap 2 Black hose 3 Tie wrap Step Procedure 6 Attach the 280 mm pressure line pos 1 to the exhaust valve pos 2 and to the magnetic valve pos 3 Secure the pressure line on ...

Page 46: ...RP Rotax INSTALLATION INSTRUCTION Figure 7 12 1 Pressure line 2 Exhaust valve 3 Magnetic valve 4 Tie wrap 6 Page 6 Edition March 01 2021 Effectivity 125 MAX evo Junior MAX evo Mini MAX evo Micro MAX evo ...

Page 47: ...g of the gear compartment 4 Run in procedure 5 NOTE NOTE To warrant engine operation within temperature limits of the coolant a temperature sensor for observation of the coolant temperature is required NOTE Refer to Operators Manual for operating limits Effectivity 125 MAX evo Junior MAX evo Mini MAX evo Micro MAX evo 7 Page 1 Edition March 01 2021 ...

Page 48: ...ocedure 2 Loosen Allen screw pos 1 with gas ket ring pos 2 and absorb the leaking oil in a measuring cup If necessary remove the air vent screw pos 3 to ensure a better oil drain 3 Determine the gear oil using the meas uring cup NOTE Oil capacity at new filling is 100 cc 0 026 gal NOTE Specification of gear oil engine oil SAE 15W 40 Step Procedure 4 Tighten the Allen screw pos 1 with new gasket ri...

Page 49: ...rocket adapter along rear axle ATTENTION Pay attention to chain alignment as advised by chassis manufacturer Step Procedure 4 Establish required chain tension Sag 5 mm 0 20 in by shifting the engine NOTE Use the engine stop screw to ten sion the chain 5 Fasten engine on the chassis m WARNING Non compliance can result in serious injuries or death Besides the engine specific installation advice al s...

Page 50: ...ting reser voir using a piece of the supplied fuel hose of an appropriate length NOTE The venting hose must not reach all the way to the bottom of the collecting reservoir ATTENTION Do not attach the venting hose on the bottom of the collecting reservoir if only one reservoir is in use 7 Page 4 Edition March 01 2021 Effectivity 125 MAX evo Junior MAX evo Mini MAX evo Micro MAX evo ...

Page 51: ...uel use a mixing ratio of 1 33 3 or 0 3 liter oil per 10 liters of fuel NOTE BRP Rotax recommends to use XPS Kart Tec oil Step Procedure 1 15 min up to 10 000 rpm 15 min up to 12 000 rpm 15 min full load 2 Reduce the main jet size step by step e g 172 170 168 NOTE Make sure that the coolant temperature reaches a minimum of 55 C 130 F At cold ambient temperature radiator needs to get partly covered...

Page 52: ...Notes Page 6 Edition March 01 2021 Effectivity 125 MAX evo Junior MAX evo Mini MAX evo Micro MAX evo Edition October 01 2019 Rev 0 NOTES BRP Rotax INSTALLATION INSTRUCTION ...

Page 53: ... installation to the chassis 2 Engine attachment 3 Exhaust system 1 Exhaust system installation 4 F Finishing work 1 Fuel pump installation 2 Fuel system installation 1 I Intake silencer 5 Intake silencer installation 6 INTRO 1 M Mounting plate installation 2 O Oil level check in gear box 2 R Radiator installation 3 RAVE control unit installation 4 Running in procedure Run in procedure 5 S Spark p...

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