Rotax 125 MAX

Adjustable
Variable
Exhaust
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.
Without commitment to advise modifications.
BRP-Powertrain
2010.04.09
Presentation Rotax exhaust valve only for internal use 3
Without commitment to advise modifications
Installation
n 1.
Clean the cylinder with brake cleaner and check impulse bore for cleanliness. (visual)
Presentation Rotax exhaust valve only for internal use 4
Without commitment to advise modifications
Installation
n 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 5
Without commitment to advise modifications
Installation
n 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 6
Without commitment to advise modifications
Installation
n 4.
not correct gasket interferes contact between valve and
cylinder
Apply the gasket on the cylinder and assure metallic contact between exhaust valve and cylinder.
correct metallic contact between valve and cylinder
Presentation Rotax exhaust valve only for internal use 7
Without commitment to advise modifications
Installation
n 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 8
Without commitment to advise modifications
Installation
n 6.
Apply the o-ring to the stud screw.
Presentation Rotax exhaust valve only for internal use 9
Without commitment to advise modifications
Installation
n 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 10
Without commitment to advise modifications
Installation
n 8.
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.
10 NM
Presentation Rotax exhaust valve only for internal use 11
Without commitment to advise modifications
Installation
n 9.
Apply the hose spring with Rotax special tool 276070 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 12
Without commitment to advise modifications
Installation
n 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 13
Without commitment to advise modifications
Troubleshooting
R.A.V.E (ROTAX ADJUSTABLE VARIABLE EXHAUST)
Presentation Rotax exhaust valve only for internal use 14
Without commitment to advise modifications
Engine concept Rotax engine 125 MAX
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[
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125 Max 100cc
5-8% oil
2% oil
n Rotax 125 MAX versus typical 100cc kart engines
Presentation Rotax exhaust valve only for internal use 15
Without commitment to advise modifications
Engine concept Rotax engine 125 MAX
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engine speed [rpm]
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[
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Exhaust valve closed
till 7.500 rpm
Tuned exhaust pipe in
combination with ignition timing
7.500 rpm 12.500 rpm
Ignition
timing
12.500
14.000
rpm
n Performance characteristic of Rotax engine 125 MAX
Presentation Rotax exhaust valve only for internal use 16
Without commitment to advise modifications
1) Exhaust valve
At 7.500 rpm:
Exhaust valve opens through raising
pressure in the exhaust system
Till 7.500 rpm:
Exhaust valve closes by
compression spring (adjustable)
Low exhaust port timing
= longer use of
combustion energy
exhaust valve closed exhaust valve opened
High exhaust port
timing = shorter use
of combustion energy
Presentation Rotax exhaust valve only for internal use 17
Without commitment to advise modifications
1) Exhaust valve
The raising pressure in the exhaust system causing the exhaust
valve to open.
n Pressure in the exhaust system (schematic diagram)
1 2 3 4 5 6 7 8 9 10 11 12
engine speed (rpm)
p
r
e
s
s
u
r
e
exhaust valve closed exhaust valve open
Presentation Rotax exhaust valve only for internal use 18
Without commitment to advise modifications
Leistungskurven mit geschlossenem und offenem Auslaschieber
performance graphs with closed and open exhaust valve
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Motordrehzahl [1/min.], speed [rpm]
Motorleistung [kW],
performance of engine [kW]
Leistungskurve 2,
performance graph 2
Leistungskurve 1,
performance graph 1
1) Exhaust valve
Optimal opening
timing 7.500 rpm
Opening timing
too late
Opening timing
too early
n Correct opening timing of the exhaust valve
Presentation Rotax exhaust valve only for internal use 19
Without commitment to advise modifications
1) Exhaust valve
n Standard setting of the exhaust valve
5 mm = approx. 2 inch
n Adjustment of the exhaust valve
at the race track
engine must have operation temperature
accelerate from 5.000 rpm at full throttle
as soon as exhaust valve opens, noise is
changing significantly.
exhaust valve has to be adjusted to open at 7.500 rpm
n Adjustable rpm range for exhaust valve opening
Approximately +/- 300 rpm
Presentation Rotax exhaust valve only for internal use 20
Without commitment to advise modifications
1) Exhaust valve
Re-adjustment of the exhaust valve
is just necessary if the
cylinder or the height of the cylinder (base gasket) has been
changed
condition of the isolating mat in exhaust muffler has changed
(worn).
Presentation Rotax exhaust valve only for internal use 21
Without commitment to advise modifications
1) Exhaust valve
Troubleshooting
n Problem: Missing performance till
7.500 rpm (bottom end
performance)
n Possible reason: Exhaust valve
does not completely close.
n 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 does not
close completely
wrong
Short use of combustion
energy = high exhaust
port timing
correct
Exhaust valve
completely closed
Long use of combustion
energy = low exhaust
port timing
Presentation Rotax exhaust valve only for internal use 22
Without commitment to advise modifications
1) Exhaust valve - Troubleshooting
n Problem: Delayed throttle
response out of the curve.
n To the curve: Engine revs
12.500 rpm, exhaust valve is
open.
n Middle of the curve: Engine
revs drop to 9.000 rpm,
carburettor slide is closed,
exhaust pressure drops
exhaust valve closes.
n Out of the curve: Engine
revs 9.000 rpm, carburettor
slide open delayed response
of the engine
Track sector:
1
2
3
Presentation Rotax exhaust valve only for internal use 23
Without commitment to advise modifications
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