Rotax 125 Max Operation and maintenance manual

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

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

DK00080.fm

BRP-Powertrain recommends products of following brands:

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

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

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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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02 01 2014

rear page

Chapter Page Date

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

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

DK00082.fm

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

DK00082.fm

NOTES

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

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

DK00083.fm

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

Effectivity: 125 MAX/Junior MAX/Mini MAX/Micro MAX page 1-2

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

DK00083.fm

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

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