Rotax 125 Max Bedienungs- und Wartungshandbuch

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

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BRP-Powertrain recommends products of following brands:

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

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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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rear page

Chapter Page Date

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NOTES

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

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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 -

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

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

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NOTES

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

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

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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 1-6

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

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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

Andere Handbücher für 125 Max

Dieses Handbuch passt für folgende Modelle

Inhaltsverzeichnis

Andere Rotax Motor Handbücher

Rotax

Rotax 915 i A SERIES Bedienungsanleitung

Rotax

Rotax 912 i series Bedienungsanleitung

Rotax

Rotax 912 i series Betriebsanleitung

Rotax

Rotax 125 MAX evo Fehlerbehebungshandbuch

Rotax

Rotax 915 i A SERIES Bedienungsanleitung

Rotax

Rotax 914 UL Series Bedienungs- und Montageanleitung

Rotax

Rotax 125 MAX DD2 evo Bedienungs- und Wartungshandbuch

Rotax

Rotax 912-UL Bedienungsanleitung

Rotax

Rotax MMH-912 Series Bedienungsanleitung

Rotax

Rotax 125 Max Bedienungsanleitung

Rotax

Rotax 122 Betriebsanleitung

Rotax

Rotax 912 Series Bedienungs- und Montageanleitung

Rotax

Rotax 915 i A SERIES Original Betriebsanleitung

Rotax

Rotax 912 Series Bedienungsanleitung

Rotax

Rotax 914 series Bedienungsanleitung

Rotax

Rotax 912 Series Bedienungsanleitung

Rotax

Rotax 447 UL SCDI Bedienungsanleitung

Rotax

Rotax 912 Series Bedienungsanleitung

Rotax

Rotax 912 iS Sport Bedienungsanleitung

Rotax

Rotax 125 MAX evo Betriebsanleitung

Rotax

Rotax 125 MAX evo Bedienungs- und Wartungshandbuch

Rotax

Rotax 912 i series Betriebsanleitung

Rotax

Rotax 912 Series Bedienungsanleitung

Rotax

Rotax 912 Series Bedienungsanleitung

Beliebte Motor Handbücher anderer Marken

Kohler

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MTD

MTD OHV Series Bedienungsanleitung

Kohler

Kohler COMMAND CH18-745 Bedienungsanleitung

Mercury

Mercury D4.2L D-Tronic Bedienungsanleitung

Selve

Selve SE Plus-RC Series Bedienungsanleitung

Perkins

Perkins 1206E-E66TA Bedienungsanleitung

Skov

Skov DA 174 Handbuch

Rossi

Rossi TX11 Series Bedienungsanleitung

Siemens

Siemens SIMOTICS T-1FW3 Merkblatt

AL-KO

AL-KO PRO 350 Bedienungsanleitung

MTU

MTU 12 V 4000 Lx4 Bedienungsanleitung

Nanni

Nanni N3.30 Gebrauchsanweisung

Nanni

Nanni N5.160 CR2 Bedienungsanleitung

KSB

KSB SuPreme Series Montageanleitung

Hiwin

Hiwin EM1 Series Bedienungsanleitung

Siemens

Siemens SIMOTICS XP 1MB1 Bedienungsanleitung

Bosch

Bosch Rexroth 70 Series Bedienungsanleitung

Wacker Neuson

Wacker Neuson WM 130 Betriebsanleitung