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125 MAX evo
Rotax 125 MAX evo Repair Manual
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BRP-Rotax
REP
AIR
MANUAL
SYSTEM
DESCRIPTION
Overview
Position
on
the
engine
Figure
4.1:
MAX
evo
engine
shown
in
figure
1
Cylinder
2
Cylinder
head
cover
3
Intake
socket
4
E-Rave
cover
5
Exhaust
socket
assy
.
Chapter
4
Page
2
Effectivity:
125
MAX
evo,
Junior
MAX
evo,
Mini
MAX
evo,
Micro
MAX
evo
Edition
-
February
01
2018
/Rev
.
0
34
36
Table of Contents
Table of Contents
4
General Note
4
Position of the Engine Serial Number
5
Abbreviations and Terms Used in this Manual
6
Safety Information
7
Safety Notice
7
Instruction
8
Technical Documentation
9
Use for Intended Purpose
9
Technical Data
10
Maintenance
12
Handling of Fluids
15
Disassembly Advice
15
Ignition "OFF"
15
Process Advice
15
Cleaning of Parts
16
Removed Parts
16
Measurements
16
Re-Assembly Advice
16
Consumable Materials
17
Special Tools
19
Inspection and Servicing Intervals of the Engine Components
21
Engine
24
System Description
25
Engine Components View
25
Preparation for Removal
26
Removal of the Ignition System
26
Battery
27
Ignition System
28
Removal of the Exhaust System
29
Removal of Radiator with Cap Assy
29
Removal of the Fuel Line
30
Fuel Components View
30
Removal of the Bowden Cable
31
Removal of the Engine from Kart Chassis
31
Engine Clamp View
32
Positioning the Engine on the Threstle Mounting Plate
32
Cylinder Components
34
Cylinder Components View
35
Cylinder Removal
36
Removal of the Spark Plug
37
Removal of the Cylinder Head Cover
37
Cylinder View
37
Removal of the Thermostat
38
Cylinder Head Cover View
38
Removal of the Combustion Chamber Insert
39
Thermostat View
39
Combustion Chamber Insert View
40
Removal of the Exhaust Socket
40
Removal of the Intake Socket and Reed Valve
41
Removal of the Exhaust Valve
41
Exhaust Valve (RAVE) View
42
Removal of the Piston
43
Cylinder Components Inspection
44
Inspection of Piston and Piston Ring
45
Inspection of the Piston Diameter
46
Inspection of the Piston and Cylinder Sizing
47
Inspection of the Piston Pin, Circlip
48
Inspection of the Spark Plug
49
Inspection of the Cylinder Head Cover
50
Inspection of the Combustion Chamber Insert
50
Inspection of the Exhaust Socket
51
Inspection of the Carburetor Flange and Reed Valve
52
Inspection of the Exhaust Valve
53
Cylinder Components Installation
54
Installation of Exhaust Valve
54
Installation of Exhaust Valve, Gasket, Valve Rod Housing
55
Installation of the Exhaust Valve Piston
55
Installation of Piston
57
Installation of the Cylinder
58
Installation of the Exhaust Socket
59
Installation of the Carburetor Flange and Reed Valve
60
Installation of Combustion Chamber Insert
62
Installation of Cylinder Head Cover
62
Inspection and Adjustment of Squish Gap
64
Installation of Spark Plug
66
Crankcase
68
Crankcase View
69
Components of Crankcase View
70
Removal of the Crankcase
72
Remove Water Pump and Compensating Wheels
73
Gearbox Cover View
74
Water Pump and Balance Shaft View
75
Disassembling the Crankcase
76
Balance Shaft View
77
Removing Bearing and Oil Seal for Shaft
78
Ignition Side Crankcase View
81
Installation of the Crankshaft Repair Kit
82
Disassembling of the Crankshaft
82
Crankshaft Repair Jig View
83
Con Rod Parts View
84
Inspection of the Crankshaft
86
Aligning the Crankshaft
88
Crankshaft Not in Specification
88
Crankshaft Assembly
89
Crank Case Inspection
93
Inspection of Water Pump Drive
93
Inspection of Water Pump Shaft
94
Inspection of Balance Shaft Drive
94
Inspection of Balance Shaft
95
Inspection of the Housing Halves
96
Crank Case Assembly
97
Installation of Oil Seal, Ball Bearing and Needle Bushing
97
Installation of Ball Bearing and Oil Seal for Crankcase
99
Assembly of Crankshaft, Water Pump Shaft and Balance Shaft
102
Assembly of the Crankcase
103
Installation of Crankcase Assy
104
Installation of Balance and Water-Pump Shaft Drive
104
Idle Gear View
106
Carburetor and Intake Silencer
108
Carburetor and Intake Silencer Overview
109
Removal of the Carburetor and Intake Silencer
110
Removal of the Fuel Pump
111
Disassembly of the Carburetor
112
Carburetor View
113
Disassembly of the Intake Silencer
114
Carburetor and Intake Silencer - Inspection of Components
115
Inspection of Carburetor
115
Inspection of the Fuel Pump
116
Inspection of the Intake Silencer
116
Intake Silencer View
117
Installing the Carburetor and Intake Silencer
118
Assembly of Carburetor
118
Assembly of Float Housing
118
Float Chamber View
118
Assembly of Intake Silencer
119
Installation of Fuel Pump, Carburetor
120
Carburetor and Intake Silencer View
121
Centrifugal Clutch, Primary and Balance Drive
122
Centrifugal Clutch, Primary and Balance Drive Overview
123
Components of Clutch and Starter Assy. View
124
Removal of the Clutch and Starter Gear Assy
125
Removal of the Centrifugal Clutch Assy
125
Removal of the Electric Starter
125
Removal of the Clutch Drum
126
Removal of the Sprocket
128
Removal of the Starter Gear Assy.
129
Inspection of the Starter Reduction Gear Assy.
132
Inspectoin of Clutch and Starter Gear Assy.
132
Inspection of the Needle Cage and Sprocket
132
Inspection of the Clutch Drum
132
Inspection of the Electric Starter
133
Inspection of the Clutch and Starter Gear Assy
134
Electric Starter Repair Kit
135
Disassembling of Electric Starter
135
Assembling of Electric Starter
136
Installation of Clutch and Starter Gear Assy.
138
Installation of the Starter Reduction Gear Assy.
138
Installation of the Sprocket
140
Assembly of the Clutch Drum
140
Installation of Bearing Sleeve for Sprockets with 11 Teeth Only
141
Installation of the Clutch Drum
142
Installation of the Electric Starter
144
Filling Gearbox with Oil
146
Cooling System
148
Cooling System Overview
149
Radiator View
149
Water Pump View
150
Removal of Radiator
151
Removal of the Cooling Water Hose
151
Inspection of Cooling System
153
Radiator - Inspection of Components
153
Installing the Radiator
154
Installation of the Cooling Water Hoses
154
Installation of the Radiator on Engine
155
Final Tasks
157
Exhaust System
158
Exhaust System Overview
159
Checking the Exhaust System
162
Disassembling the Exhaust System
162
Assembling the Exhaust System
162
Installation of the Exhaust System
163
Exhaust System View
163
Removing the Engine from the Trestle Mounting Plate
164
Installation of the Engine on Kart Chassis
164
Installation of the Fuel Line
164
Installation of the Bowden Cable
165
Installation of the Ignition System
165
Ignition Unit View
166
Index
168
Consumable Materials
168
Special Tools
169
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100 pages
4
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Rotax 125 MAX evo Specifications
General
Brand
Rotax
Model
125 MAX evo
Category
Engine
Language
English
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