Rotax 125 senior MAX evo Manuel utilisateur
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
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:
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
Ce manuel convient aux modèles suivants
3
Table des matières
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