HOW TO: OLD ROTAX REPAIR - Get Your Old Karts Back on the Track - POWER REPUBLIC

In this week's video we're restoring an old Merlin Kart with a Rotax 125 engine and showing you how easy it is to get your old karts back on the track.
Videos Mentioned:
Carburettor - • HOW TO: The Ultimate R...
Power Valve - • How To Service The Rot...
Fuel Pump - • HOW TO: Rotax Pre Seas...
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[@AFFMotorsport]

Good work Mate, lets get more karts back on track :)

[@PowerRepublic]

yeah boi!

[@emmanuelruizleon4866]

did u know the gas for old rotax

[@falconx5744]

Mad video thanks bud. Ive got an old Azzurro with an early rotax 125, i love it, i keep it clean and well serviced and for what i use it for social use it’s perfect and still rips 👍

[@PowerRepublic]

yeah boi, the oldie and Goldie karts are still heaps fun for skids and happy laps for sure

[@1020michael1020]

Can we get a video on how to “salvage” old chassis with small cracks, if it’s possible. A vid for upcoming budget karters.

[@PowerRepublic]

yeah I reckon we could do a video on how to prep a chassis and weld it up

[@christianbuczko1481]

You can often buy cheap chassie's on ebay, ive seen unused tonykart chassies for less than £100. If your hoping to weld one up, you should look at youtube welding channels or get an expert to do it because its a skilled job if your not sure, welding isnt something anybody can do so get advice.

[@lman22]

👌 Great video

[@PowerRepublic]

Thanks for tuning in YO. The Rotax is super popular and these older karts can still be heaps of fun.

[@PurryKitchenWithTaste]

Hello, could you make a video on how to change the piston on modern rotax engines?

[@martykath4427]

I once had my old rotax running like a dog . Cutting out etc, Turned out that the breather/ overflow line ends were submerged in the contents of the overflow bottle that made it hard for the fuel pump to supply fuel to the carby consistently. Emptied overflow bottle shortened lines and it ran like magic.

[@PowerRepublic]

Boom. nice and easy and your back on the track. thanks for sharing the video

[@MS-gj6ky]

nice and clear video again for people who start with the rotax . the 2 plastic gears of the crankshaft and balance shaft are also often a faded glory after a long time😅

[@rodolfocoelho7652]

What happens if they crack?

[@PowerRepublic]

MS, great pic up. those plastic gears and the original style clutch are not awesome. definitely if you can afford the upgrade I recommend it. thanks for tuning in and liking the video!!!

[@PowerRepublic]

@@rodolfocoelho7652 they have been upgraded to steel gears since 2009

[@rodolfocoelho7652]

@@PowerRepublic o just asked because I have a iame leopard and some plastic parts in the shaft got screw up and the engine seized

[@PowerRepublic]

@@rodolfocoelho7652 yeah its a not really good when that happens

[@Dethrone47]

Thanks for the entertainment. No overflow container on the radiator?

[@PowerRepublic]

Hey Yo, thanks for tuning in and sharing the video!!! I took it off and didn't have any of mounting brackets to put it back on. the camera lady had had enough watching me fix a go kart so I had to leave the kart a little short and finish it on Monday 😉

[@marioalves7610]

would love to see a vid just like this with the older lepard motors

[@PowerRepublic]

you lie the old leopard engines? haven't seen them for a few years now

[@marioalves7610]

@@PowerRepublic I have seen a few pop up for sale and they still allowed in club racing

[@swoggles100]

Hey Des! What would you recommend to help clean up the pods and other plastics on an older second hand kart? Recently bought my first kart ( used and about 8 years old) and the plastics are pretty filthy with ingrained oil etc. Thanks, love the videos, great for newbies like myself.

[@PowerRepublic]

Hey Steve, welcome to the club and thanks for tuning in. I would use a scotch brite green scouring pad and some heavy soap 🧼 degreaser. Then wash em down and your gtg

[@EricBanner571]

Des, If I'm a weekend warrior, can I run 50/50 green coolant in the radiator and leave it there for 12 months? Someone had mentioned to me that coolant is not recommended for the rotax pre evo engine as it may coagulate. I understand that some race tracks will not allow you to run coolant but I would prefer to have some radiator and engine protection against corrosion if possible.

[@tonyhanson9235]

Ive watched alot of your videos. where is the best place to buy parts

[@gurveersinghsohanpal3259]

Hi there. Love your videos. Always great to watch and learn new tips. I have a general question, is it possible to fit a rotax max to a viper tony kart..this would be used for fun and practice sessions. The only thing I notice that is different is that there is no third bearing.

[@GlennGuest]

Yep no problem with doing that. I ran an X30 on a Viper chassis.

[@gurveersinghsohanpal3259]

@@GlennGuest thanks for that. Just been offered a rolling chassis viper. So was questioning whether it’s possible.

[@PowerRepublic]

@@gurveersinghsohanpal3259 thanks @Glenn Guest for the info. I not familiar with the TK Viper. What year frame is that?

[@Will-tb8vi]

Awsome video. Do you need to change the piston at all?

[@PowerRepublic]

Hey Will, Not on this one. But you could if you wanted too

[@vicgalea7755]

Hi, a great video and I hope very useful to me as I start my new project bringing back to life an old kart that has been stored away for about 7 years. Can you please advise if I can purchase all the bits and pieces that you recommend in this video in a simple kit? That is all the gaskets, spark plug and jets, etc. Or do I have to get them all individually? I have a 125 Rotax Senior Max. If they all available in a kit please advise where and about how much will it cost me. Much appreciate any help you can give this complete new boy into the world of karts. Regards.

[@PowerRepublic]

Hey Vic, yeah we have them in a kit we can post out to you. where do you live? maybe contact us through our website with an email inquiry and we will get on it for you?

[@colbyvillers4062]

So i have an old DD2 that was running really rich so i disassembled the Carb and cleaned it and adjusted the needle position to the highest spot to lean it out a bit but now that ive got the carb back in i cant get it to start. Its not pulling any fuel from the tank. You can see when i "key" on the fuel just stays in the line as if the fuel pump isnt working anymore. is their a specific way you have to prime these fuel systems? I figured with the fuel pump it should just prime itself.

[@tonyholding5111]

Another great video 👏👊 can you change out a wiring loom like this old girl has to a current spec loom? Or are they completely different. May be a stupid question 😵‍💫

[@PowerRepublic]

Yeah nah. If you add the new harness you would have to add the new coil and ECU. But of overkill on this old girl

[@tonyholding5111]

@@PowerRepublic refer to the last line of my post ‘maybe a stupid question’ now confirmed 🤐🤪🤣

[@PowerRepublic]

hahahah

[@philistineau]

Do you have a video on what kart to start with? My son is 19 months old so I have a few years, but not sure if I should be buying or building / welding a kit as a first kart for him?

[@PowerRepublic]

I don't Phil, but you could get a Bambino kart from Tony Kart....... www.tonykart.com/telai-micro_en.php

[@rellmoneyloveyall]

Hi can you do a video showing the wiring of the push start in the mission button

[@PowerRepublic]

do mean on a Retro style kart that you push start? they are normally standard wiring from the stator to the coil.

[@rellmoneyloveyall]

Yew

[@jeremievaliquette2734]

Wath is the seize off the main jet to start for a close tune ??

[@PowerRepublic]

160

[@miraculixhi5524]

Hi I'm currently repairing and restauring an old swiss huttless kart. But because no one i know has experience with karts, I need to get my knowledge somewhere else andreally love your vids!! But I do have some questions left. For example: there is a small bottle over the fuel tank, which is also connected to it. Whats that for? Thanks alot and greetings from Switzerland.

[@PowerRepublic]

Hey , I was just I. Switzerland this January. Loved it The small bottle is an overflow bottle for the fuel tank. Make sure it has a hole in it to atmosphere.

[@miraculixhi5524]

@@PowerRepublic Thanks alot!!

[@theautomotivegeek8621]

Are older karts like this still competitive?

[@oscarsomers8597]

not even a chance, to start off this is a very old version of the rotax max engine and so is down about 5hp, you can convert it to an evo but that's like 1500 dollars so probably not really worth it. the chassis looks to be about 15 years old if not more and considering most comp drivers use their chassis for only half a year before they get a new one, this says enough. idk where you're from but in most places in europe your chassis needs to be within the last cik homologation which is from 2015 i believe and your rotax is sometimes required to be an original evo (not a conversion so you're looking at 2018 or newer). so i wouldn't get you hopes up for racing. but these things can be great fun just to drive around with for a cheap starting price, you can always upgrade later

[@JuanGonzalez-oo6hf]

Hello Power republic I have a small issue with my Rotax max 125 I just got it to turn on after 6 months of sitting but I can’t seem to get it past 20 mph :( I have 70 tooth rear sprocket and a 12 tooth front sprocket do you have any pointers on what it could be ??

[@CharlMarais247]

Is it worth buying a second hand cart to start out racing rotax max. What should I look out for. Any tips?

[@PowerRepublic]

Yeah for sure to get started. I have some vids on second hand karts and checking for straight.

[@rellmoneyloveyall]

How to get my backstarted it won't start backup After Clunk the carburetor out

[@R.B_B]

About those clear fuel line. What material is made or brand/model? Because All the Clear fuel lines I buy degraded very quickly. Today I use Car and motorcycles black EFI lines.

[@PowerRepublic]

We use the OTK fuel line. It’s some sort of plastic. Does go off over time, especially if you leave the fuel in it.

[@MrKartman35]

Don't forget to check the brakes before you hit the track!! Don't ask how I know....

[@PowerRepublic]

Good call ☎️

[@kennkart]

I have an old swiss huttless vito chassis. Where do i find the parts now? Im just trying to get it on for teaching purpose.

[@PowerRepublic]

try here www.agskartparts.com.au

[@manueljimenez6528]

i have a rotax junior max. and the carb doesn’t seem to be getting any fuel even tho when i disconnected the fuel like that was connected to the carb i tried turning it on and fuel was pumping out? but why isn’t it going into my carb my kart only starts with starting fluid and than dies off after 30secs

[@jamiescott892]

You may need a new carb kit search you carbs name and carb kit

[@martykath4427]

You didn't oil the foam element. is that normal? I imagine the fuel spitting out of the carby would do it eventually.

[@PowerRepublic]

they come pre oiled. you can spray more oil on them to help catch the dust particle

[@MrWillowpig]

I run a old rotax pre evo, is there a standard setting on the red power valve adjuster ?

[@PowerRepublic]

Hey ADs, not really. start at 12-14 clicks open with a fresh power valve bellows. if its old bellows, I usually have to screw them into zero clicks to get the PV to close below 7500 rpm

[@MrWillowpig]

@@PowerRepublic brilliant thanks for the help👍

[@TylerDurden775]

Total beginnner here - I have purchased the incorrect fuel filter for the Kartelli fuel line on my arrow kart X5. What is a standard fuel line (and therefore fuel filter) size. Thanks,

[@PowerRepublic]

Hey Ray, all good, we all started at the beginning bro. 6mm fuel line is the standard stuff. you can open the fuel line up a bit using some circlip pliers if its tight

[@andytaylor9618]

Hi can you put a rotax max evo power valve on a none evo

[@miwadabest1isgood476]

You can convert it but you’d need the loom and everything else to go with

[@tobijaklanjscek4782]

Can you still drive on pro races or are they still compenitive to younger karts

[@PowerRepublic]

yeah the older karts are better for fun karting

[@tobijaklanjscek4782]

Yeah, but can you race in profesional races, do you have a chance to compete❤

[@ulrc_tv]

Where can I find a Go kart service centre in Ontario

[@PowerRepublic]

Google ?

[@emmanuelruizleon4866]

i wanna know the gas u use for old rotax please i got the same go kart

[@PowerRepublic]

pump fuel, I use BP or Shell 98

[@emmanuelruizleon4866]

so no need mixed nathing

[@emmanuelruizleon4866]

@@PowerRepublic wich vp please

[@christianbuczko1481]

Another midnight premier.

[@PowerRepublic]

sorry bout that Chriso, its a bank holiday here in Queensland

[@emmanuelruizleon4866]

how i know the year of my rotax 125 cc max old ingine please?

[@PowerRepublic]

Should be on the side of the cylinder near the radiator mounting hole

[@emmanuelruizleon4866]

@@PowerRepublic 220S ???

[@emmanuelruizleon4866]

@@PowerRepublic 220S Gilardoni. 1

[@emmanuelruizleon4866]

meaning

[@briangamez1098]

I need help

[@rellmoneyloveyall]

How I got one just like this one something wrong with it

[@miwadabest1isgood476]

They’re rubbish motors mate

[@PowerRepublic]

yeah new is best, but not in everyones reach. sometimes we just have to make do w with what we got

[@miwadabest1isgood476]

@@PowerRepublic what?

[@briangamez1098]

I don’t think mine is getting spark

[@PowerRepublic]

check the coil our first

[@theburrell4626]

How old is too old? Not the kart… the driver 😄

[@PowerRepublic]

hahahaha classic. we have drivers in their 60's still racing. make sure you get a rib protection first !

[@JuanGonzalez-oo6hf]

Hello Power republic I have a small issue with my Rotax max 125 I just got it to turn on after 6 months of sitting but I can’t seem to get it past 20 mph :( I have 70 tooth rear sprocket and a 12 tooth front sprocket do you have any pointers on what it could be ??