Rotax Kart Engine Fr 125 Max, Fr 125 Junior Max Fr 125 Mini Max Service Manual on 2040-parts.com

INSTALLATION INSTRUCTIONS FOR ROTAX ENGINE
Service Repair Maintenance Manuals

This Auction is for 2 PDF Format Manuals in 2 Languages On CD

MULTILINGUAL, ENGLISH AND GERMAN/ Deutsch SEE SAMPLES FOR DETAILS

This is The Best Service Repair Maintenance Manual
This Manual Covering Construction Function and
Servicing Procedures of your Engines
There is lots of Information for Service And Repair
The Manuals Are in PDF File Format

 

There Are 2 PDF Format in 2 Languages English and

Said (EINBAUHINWEISE) I Think it is in German
FOR YOUR ROTAX KART ENGINES
Engines Type
FR 125 MAX, FR 125 Junior MAX FR 125 Mini MAX
 EINBAUHINWEISE

und

BETRIEBSANLEITUNG

INSTALLATION INSTRUCTIONS

and

OPERATORS MANUAL

ROTAX-Motoren Type

for ROTAX-engines type

FR 125 MAX

FR 125 Junior MAX

FR 125 Mini MAX

Teile-Nr./Part no.: 297 150

Ausgabe/Edition: 09 2003
Engines Type
FR 125 MAX, FR 125 Junior MAX FR 125 Mini MAX

Version: Configuration no:
FR 125 MAX (21kW)
37.125.1301

Version: Configuration no:

FR 125 Junior MAX (15kW)
300125.130
Edition 11 2000

Manual Contain the Following information
IMPORTANT INFORMATION
Repeating Symbols
General Precautions & Safety Information TECHNICAL DATA
Check and Service Intervals of Engine Compounds
Special Tools, Securing and Sealing Agents
Location of the Engines Serial Numbers
Engine Removal from the Chassis
Engine Removal
Setting UP the Engine on the Trestle
ENGINE DISASSEMBLY
Removal of the radiator
Removal of the Intake Silencer and of the Carburetor Socket

Removal of Electric Starter
Removal of the Centrifugal Clutch
Removal of Cylinder head cover and combustion chamber insert
Cylinder Removal
Piston Removal
Disassembly of the Drive for the balance Shaft & the Water Pump Shaft
Separation of the Crank case Halves
Crank shaft Removal  
Individual Component Maintenance
Crank case
Removal and refitting of bearings and oil Seals
Crank shaft
Replacement of the Crank shaft repair set
Balance shaft
Drive of the Balance shaft
Drive of the water Pump
Water Pump shaft
Centrifugal Clutch
Bearing of the Clutch Drum Assembly
Clutch Drum with Chain Sprocket Assembly
Cylinder Assembly
Exhaust Valve Assembly (only on engine Version FR 125 MAX)
Disassembly of the Exhaust Valve (only on engine Version FR 125 MAX)
Instillation of the Exhaust Valve (only on engine Version FR 125 MAX)
Exhaust Socket
Reed Valve Assembly and Carburetor flange
Cylinder
Piston and Piston Ring
Piston Pin, Needle Cage, Piston Circlips
Combustion chamber insert
Cylinder Head Cover
Ignition Unit
Spark Plug
Starter Reduction Gear Assembly
Electric starter
Radiator
Intake Silencer
Carburetor
Fuel Pump
Exhaust System
Engine Reassembly
Crank Case Assembly
Instillation of the Balance Shaft and the water Pump Drive
Piston Instillation
Cylinder Instillation
Instillation of the combustion chamber Insert & Cylinder
Head Cover
Checking Adjustment of the Squish Gap between Piston and combustion chamber Insert
Starter Reduction Gear Instillation
Centrifugal Clutch Instillation
Pick- UP coil for Ignition unit- Instillation
Spark Plug- Fitting
Electric Starter- Instillation
Radiator and intake silencer- Instillation
Fuel Pump- Instillation
Carburetor Instillation
Filling of Gear Compartment with Oil

INSTALLATION INSTRUCTIONS FOR ROTAX ENGINE TYPE

FR 125 MAX, FR 125 Junior MAX, FR 125 MINI MAX

1 General precaution and safety information for engine installation

2. Engine removal from the crate

3. Verification or replenishing of oil level in gear compartment

4. Engine suspension on chassis

4.1. Attachment via engine pedestal

4.2. Direct attachment of the engine on chassis

5. Fitting of the drive chain

6. Fitting of the start button and of ON/OFF circuit breaker

7. Installation of the battery

8. Connecting and routing of the cable harness

9. Fitting of the spark plug

10. Installation of the radiator

11. Installation and connection of the fuel pump

12. Installation and connection of the carburetor

13. Installation of the Bowden cable for carburetor control

14. Installation of the intake silencer with integrated airfilter

15. Venting of the gear compartment

16. Flooding of the carburetor

17. Installation of the exhaust system

18. Connection of the battery

19. Observation of engine speed and coolant temperature

Warning: Before engine operation, read the Operator's Manual.

OPERATING INSTRUCTIONS FOR ROTAX ENGINE TYPE

FR 125 MAX, FR 125 JUNIOR MAX, FR 125 MINI MAX

 

1. Design of the ROTAX engine FR 125 MAX, FR 125 Junior MAX and FR 125 Mini

MAX

Single cylinder two cycle engine, reed valve controlled, 125 cm3 displacement

Liquid cooled, forced flow by integrated water pump

Balance shaft

Integrated thermostat

Digital battery ignition

Integrated electric starter

Pneumatic controlled exhaust timing

Crankcase impulse operated fuel pump

Piston carburetor Dellorto VHSB 34

Intake silencer with integrated air filter

Tuned exhaust with after-muffler

2. Technical description of the ROTAX engine, Type FR 125 MAX, FR 125 Junior

MAX and FR 125 Mini MAX

2.1. Type of engine

2.2. Cooling circuit

2.3. Balance shaft

2.4. Ignition unit

2.5. Electric starter

2.6. Exhaust timing control

2.7. Fuel pump

2.8. Carburetor

2.9. Intake silencer

2.10. Exhaust system

3. Media for engine operation

3.1. Coolant

3.2. Battery and battery charging unit

3.3. Fuel

4. Engine tuning

4.1. Carburetor calibration

4.2. Selection of the transmission ratio (FR 125 MAX)

4.3. Selection of the transmission ratio (FR 125 Junior MAX)

4.4. Selection of the transmission ratio (FR 125 Mini MAX)

4.5. Exchange of the clutch drum with chain sprocket fitted

4.6. Changing or renewal of the chain sprocket on the clutch drum

6. Engine start and operation

7. Stopping the engine

8. Running-in procedure for the engine

11. Transport of the kart

12. Preservation of engine and equipment

WICHTIGE INFORMATIONEN (ZUSAMMENFASSUNG)

IMPORTANT INFORMATION (SUMMARY) and Much More
Engine Instillation on chassis and Lot Lot Lot Lot More