Rotax 125 MAX Adjustable Variable Exhaust

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1 Rotax 125 MAX Adjustable Variable Exhaust

2 Introduction: This information is in addition to the valid repair manual. Safety requirement has to be taken from the valid repair manual. This information is only for internal usage.. BRP-Powertrain

3 Installation 1. Clean the cylinder with brake cleaner and check impulse bore for cleanliness. (visual) Presentation Rotax exhaust valve only for internal use 3

4 Installation 2. Clean the Exhaust valve with brake cleaner and scotch brite and check the total length of the exhaust valve. ( 72 +/- 0,3) ATTENTION: Stud screw has to be locked with LOCTITE 648 Presentation Rotax exhaust valve only for internal use 4

5 Installation 3. Insert the exhaust valve as shown on the picture and assure free movement of the exhaust valve. Presentation Rotax exhaust valve only for internal use 5

interferes contact between valve and cylinder Apply the gasket on the

6 Installation 4. correct metallic contact between valve and cylinder not correct gasket interferes contact between valve and cylinder Apply the gasket on the cylinder and assure metallic contact between exhaust valve and cylinder. Presentation Rotax exhaust valve only for internal use 6

7 Installation 5. Apply the valve rod housing to the cylinder and check the exhaust valve for free movement. In case the exhaust valve piston get caught, check the position of the valve rod housing. Presentation Rotax exhaust valve only for internal use 7

8 Installation 6. Apply the o-ring to the stud screw. Presentation Rotax exhaust valve only for internal use 8

9 Installation 7. Apply the bellow on the valve housing and check the sealing surface for proper sealing. The small hose spring at the bottom of the bellow has to be installed correctly to the groove of the bellow. Presentation Rotax exhaust valve only for internal use 9

10 Installation NM Hand tighten the exhaust valve piston to the stud screw and adjust a total length of 73,5 +/- 0,3 mm Torque the exhaust valve with 10 Nm to the cylinder. Presentation Rotax exhaust valve only for internal use 10

11 Installation 9. Apply the hose spring with Rotax special tool to the bellow. Assure free movement of the exhaust valve and make a visual check for the correct installation of the hose spring to the groove. Presentation Rotax exhaust valve only for internal use 11

12 Installation 10. Apply the compression spring to the Exhaust Valve and mount the Valve Cover by means of the spring clip to the housing. Presentation Rotax exhaust valve only for internal use 12

13 Troubleshooting R.A.V.E (ROTAX ADJUSTABLE VARIABLE EXHAUST) Presentation Rotax exhaust valve only for internal use 13

14 Engine concept Rotax engine 125 MAX Rotax 125 MAX versus typical 100cc kart engines Max 100cc 20 engine performance [kw] % oil % oil engine speed [rpm] Presentation Rotax exhaust valve only for internal use 14

15 Engine concept Rotax engine 125 MAX Performance characteristic of Rotax engine 125 MAX 22 performance of engine [kw] Exhaust valve closed till rpm Tuned exhaust pipe in combination with ignition timing rpm rpm Ignition timing rpm engine speed [rpm] Presentation Rotax exhaust valve only for internal use 15

16 1) Exhaust valve exhaust valve closed exhaust valve opened Low exhaust port timing = longer use of combustion energy High exhaust port timing = shorter use of combustion energy Till rpm: Exhaust valve closes by compression spring (adjustable) At rpm: Exhaust valve opens through raising pressure in the exhaust system Presentation Rotax exhaust valve only for internal use 16

17 1) Exhaust valve Pressure in the exhaust system (schematic diagram) exhaust valve closed exhaust valve open pressure engine speed (rpm) The raising pressure in the exhaust system causing the exhaust valve to open. Presentation Rotax exhaust valve only for internal use 17

18 1) Exhaust valve Correct opening timing of the exhaust valve Motorleistung [kw], performance of engine [kw] 22 Leistungskurven mit geschlossenem und offenem Auslaßschieber performance graphs with closed and open exhaust valve Opening timing too early Optimal opening timing rpm Opening timing too late Leistungskurve 2, performance graph Leistungskurve 1, performance graph Motordrehzahl [1/min.], speed [rpm] Presentation Rotax exhaust valve only for internal use 18

1) Exhaust valve Standard setting of the exhaust valve 5 mm = approx. 2 inch Adjustment of the exhaust valve Ë at the race track Ë engine must have operation temperature Ë accelerate from 5.

19 1) Exhaust valve Standard setting of the exhaust valve 5 mm = approx. 2 inch Adjustment of the exhaust valve Ë at the race track Ë engine must have operation temperature Ë accelerate from rpm at full throttle as soon as exhaust valve opens, noise is changing significantly. Ë exhaust valve has to be adjusted to open at rpm Adjustable rpm range for exhaust valve opening Approximately +/- 300 rpm Presentation Rotax exhaust valve only for internal use 19

20 1) Exhaust valve Re-adjustment of the exhaust valve is just necessary if the Ë cylinder or the height of the cylinder (base gasket) has been changed Ë condition of the isolating mat in exhaust muffler has changed (worn). Presentation Rotax exhaust valve only for internal use 20

1) Exhaust valve Troubleshooting Problem: Missing performance till 7.

21 1) Exhaust valve Troubleshooting Problem: Missing performance till rpm ( bottom end performance ) Exhaust valve does not close completely wrong Short use of combustion energy = high exhaust port timing Possible reason: Exhaust valve does not completely close. Solution: Check assembly of exhaust valve. Exhaust valve has to touch the cylinder surface in closed position. Metallic noise at closing has to be noticeable. Exhaust valve completely closed correct Long use of combustion energy = low exhaust port timing Presentation Rotax exhaust valve only for internal use 21

22 1) Exhaust valve - Troubleshooting Problem: Delayed throttle response out of the curve. Track sector: Å To the curve: Engine revs rpm, exhaust valve is open. Ç Middle of the curve: Engine revs drop to rpm, carburettor slide is closed, exhaust pressure drops exhaust valve closes. 2 3 É Out of the curve: Engine revs rpm, carburettor slide open delayed response of the engine 1 Presentation Rotax exhaust valve only for internal use 22

2006 Bombardier Recreational Products Inc.

23 Ski-Doo Lynx Sea-Doo Evinrude Johnson Rotax Can-Am Presentation Rotax exhaust valve only for internal use Bombardier Recreational Products Inc. All rights reserved. Trademark of Bombardier Recreational Products Inc. or its affiliates.

HOMOLOGATION OF KART ENGINE

HOMOLOGATION OF KART ENGINE Category ROTAX SENIOR MAX Manufacturer Bombardier Rotax Model FR125 UK Agent JAG Engineering Valid From 1 st June 2011 Number of pages 21 This Homologation Form reproduces descriptions,