Rotax 125 MAX evo Operating instructions
Repair Manual
BRP-Powertrain GmbH & Co KG
A-4623 Gunskirchen-Austria
www.rotax.com
www.kart-rotax.com
TNr.298061
for ROTAX Engine Type 125 MAX
125 Junior MAX
125 Mini MAX
125 Micro MAX
DK00020.fm
REPAIR MANUAL
BRP-Powertrain
Effectivity: 125 MAX/125 Junior MAX/125 Mini MAX/
125 Micro MAX
Edition 2 / Rev. 0 INTRO
Page 1
December 01/2010
Chapter: INTRO
GENERAL NOTE
Foreword Before carrying out repair work on the engine, read the Repair Manual
carefully.
If any passages of the Manual are not clearly understood or if you have
questions, please contact an authorized Distribution or Service Center for
ROTAX-kart engines.
Chapter structure The Repair Manual is subdivided into the following chapters:
Subject Chapter
Introduction Chapter INTRO
List of effective pages Chapter LEP
Table of amendments Chapter RV
General note Chapter 1
Maintenance Chapter 2
Engine and Gearbox Chapter 3
Cubic capacity parts Chapter 4
Crank housing Chapter 5
Carburetor and Intake silencer Chapter 6
Centrifugal clutch and Starter gear Chapter 7
Radiator Chapter 8
Exhaust system Chapter 9
DK00020.fm
REPAIR MANUAL
BRP-Powertrain
Effectivity: 125 MAX/125 Junior MAX/125 Mini MAX/
125 Micro MAX
Edition 2 / Rev. 0 INTRO
Page 2
December 01/2010
NOTES
Effectivity: 125 MAX/125 Junior MAX/125 Mini MAX/
125 Micro MAX
Edition 2 / Rev. 0
DK00021.fm
REPAIR MANUAL
BRP-Powertrain
LEP
Page 1
December 01/2010
Chapter: LEP
LIST OF EFFECTIVE PAGES
tchapter page date
INTRO Title page
1
212 01 2010
12 01 2010
LEP 1
2
3
4
12 01 2010
12 01 2010
12 01 2010
12 01 2010
TOA 1
212 01 2010
12 01 2010
11
2
3
4
5
6
7
8
9
10
11
12
13
14
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
21
2
3
4
5
6
7
8
9
10
11
12
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
31
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
41
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
chapter page date
Effectivity: 125 MAX/125 Junior MAX/125 Mini MAX/
125 Micro MAX
Edition 2 / Rev. 0
DK00021.fm
REPAIR MANUAL
BRP-Powertrain
LEP
Page 2
December 01/2010
429
30
31
32
33
34
35
36
37
38
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
51
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
chapter page date
39
40
41
42
12 01 2010
12 01 2010
12 01 2010
12 01 2010
61
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
71
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
chapter page date
DK00021.fm
REPAIR MANUAL
BRP-Powertrain
Effectivity: 125 MAX/125 Junior MAX/125 Mini MAX/
125 Micro MAX
Edition 2 / Rev. 0 LEP
Page 3
December 01/2010
726
27
28
29
30
31
32
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
81
2
3
4
5
6
7
8
9
10
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
91
2
3
4
5
6
7
8
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
chapter page date
DK00021.fm
REPAIR MANUAL
BRP-Powertrain
Effectivity: 125 MAX/125 Junior MAX/125 Mini MAX/
125 Micro MAX
Edition 2 / Rev. 0 LEP
Page 4
December 01/2010
NOTES
DK00022.fm
REPAIR MANUAL
BRP-Powertrain
Effectivity: 125 MAX/125 Junior MAX/125 Mini MAX/
125 Micro MAX
Edition 2 / Rev. 0 TOA
Page 1
December 01/2010
Chapter: RV
TABLE OF AMENDMENTS
no. chapter page date of
change date of issue signature
0
0
0
0
0
0
0
0
0
0
0
0
INTRO
LEP
TOA
1
2
3
4
5
6
7
8
9
all
all
all
all
all
all
all
all
all
all
all
all
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
12 01 2010
DK00022.fm
REPAIR MANUAL
BRP-Powertrain
Effectivity: 125 MAX/125 Junior MAX/125 Mini MAX/
125 Micro MAX
Edition 2 / Rev. 0 TOA
Page 2
December 01/2010
NOTES
DK00023.fm
REPAIR MANUAL
BRP-Powertrain
Effectivity: 125 MAX DD2
Edition 2 / Rev. 0 Chapter 1
Page 1
September 01/2011
Chapter: 1
GENERAL NOTE
Contents This Repair Manual contains instructions for all the necessary repair and
maintenance work on the ROTAX-Engine Type 125 MAX DD2.
Table of contents This chapter of the Repair Manual contains general and safety informa-
tion concerning the operation of the kart engines.
Subject Page
General note Page 3
Abbreviations and terms used in this Manual Page 5
Safety notice
Safety information
Instruction
Technical documentation
Use for intended purpose
Page 7
Page 8
Page 10
Page 11
Page 12
Technical data Page 13
Other manuals for 125 MAX evo
4
This manual suits for next models
3
Table of contents
Other Rotax Engine manuals
Rotax
Rotax 582 UL series User manual
Rotax
Rotax 125 MAX evo Operating instructions
Rotax
Rotax 125 MAX evo Operation and maintenance manual
Rotax
Rotax 912 Series User manual
Rotax
Rotax 125 MAX DD2 Operating instructions
Rotax
Rotax 912-UL User manual
Rotax
Rotax 912 Series User manual
Rotax
Rotax 914 series User manual
Rotax
Rotax 912 i series User manual
Rotax
Rotax OM-912 User manual
Rotax
Rotax 24-30-00 Original operating manual
Rotax
Rotax 914 series User manual
Rotax
Rotax 915 i A SERIES User manual
Rotax
Rotax 912 i series User manual
Rotax
Rotax 912 Series User manual
Rotax
Rotax 503 UL User manual
Rotax
Rotax 125 MAX evo Operation and maintenance manual
Rotax
Rotax 912 iS Sport User manual
Rotax
Rotax 377 UL Operating instructions
Rotax
Rotax 277 User manual
