Rotax 125 senior MAX evo Manual de usuario

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

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:

Effectivity: 125 MAX evo, Junior MAX

evo, Mini MAX evo, Micro MAX evo Content

Page 1

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

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

BRP-Rotax

INSTALLATION INSTRUCTION

Chapter: INTRO

Preface

For information regarding repair of the engine 125 MAX contact an authorized service

center or consult the repair manual (available on internet under www.rotax-kart.com).

Also check out our YouTube-Channel:

Figure 1.1: QR code

Make sure to hand over this manual, the engine identity card and the product and

service registration document to the new owner in case of a change of ownership.

Contents

This Installation Manual contains instructions for all the installation work on the ROTAX®-

Engine Type 125 MAX evo, 125 Junior MAX evo, 125 Mini MAX evo and 125 Micro MAX

evo.

General

This document and all technical data and procedures therein are property of

BRP-Rotax GmbH & Co KG and based on the state of knowledge at the time of

publication The Manual has been drawn up to the best 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 incurring obligation.

Engine performance may vary depending on, among other things, general conditions,

ambient temperature and altitude.

NOTE

The registration document and engine identity card must be provided to the final

consumer upon delivery by the authorized service center with handover date and

company stamp.

NOTE

The data entered in the registration document and/or engine identity card is

required for the verification of a warranty claim. Without a completely filled-in

engine identity card, no warranty claim will be granted.

Effectivity: 125 MAX evo, Junior MAX

evo, Mini MAX evo, Micro MAX evo INTRO

Page 1

Edition: March 01 2021

BRP-Rotax

INSTALLATION INSTRUCTION

NOTE

In case of participating in the ROTAX® MAX CHALLENGE (RMC) the engine

must be verified for conformity with the technical regulations and sealed. The

serial number of the seal must be entered in the engine identity card.

Safety Messages

The types of safety messages, what they look like and how they are used in this guide are

explained as follows: The safety alert symbol indicates a potential injury hazard.

mWARNING

Indicates a potential hazard, if not avoided, could result in serious injury or

death.

mCAUTION

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 information which may be needed to fully complete or

understand an instruction.

✔Denotes a checking operation

TIP This information gives you additional advice and tips

INTRO

Page 2

Edition: March 01 2021

Effectivity: 125 MAX evo, Junior MAX

evo, Mini MAX evo, Micro MAX evo

BRP-Rotax

INSTALLATION INSTRUCTION

Safety information

mWARNING

Non-compliance can result in serious injuries or death!

For the best possible engine operation, compliance with the following advice regarding

installation of engine and equipment is required.

mWARNING

Non-compliance can result in serious injuries or death!

Engine operation is permitted only with equipment supplied by ROTAX®

mWARNING

Non-compliance can result in serious injuries or death!

Besides the 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.

mWARNING

Non-compliance can result in serious injuries or death!

Before starting with installation and operation of the engine, observe the installation

instructions and Operator’s Manual and follow all instructions.

Effectivity: 125 MAX evo, Junior MAX

evo, Mini MAX evo, Micro MAX evo INTRO

Page 3

Edition: March 01 2021

BRP-Rotax

INSTALLATION INSTRUCTION

UNBOXING YOUR ROTAX POWERPACK

Congratulations on choosing a ROTAX engine! Your ROTAX kart engine comes delivered

in two boxes.

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

BRP-Rotax

INSTALLATION INSTRUCTION

Figure 1.3: Accessory box

Pos. Description Check mark

1 Radiator with coolant hoses O

2 Mounting plate with ignition coil, solenoid valve and spark plug cap O

3 Battery box and wiring harness O

4 Battery charger O

5Intake silencer O

6Fuel pump with fuel hose O

7Exhaust system O

8 Manuals and engine identity card O

9Several 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

BRP-Rotax

INSTALLATION INSTRUCTION

ENGINE INFORMATION

Engine serial number

The engine serial number is stamped on the clutch 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

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