HOW TO: Service Your Rotax Max Clutch - POWER REPUBLIC

[@OBPSTi]

Greatly appreciate these Rotax Max Evo videos! You do a fantastic job covering the vitals and keep it simple and fun. I've been watching them all and taking notes as I am new to the engine this year. Got a few video suggestions: Rebuilding the carb and fuel pump at their recommended intervals, inspecting and replacing the reed pedals. Thanks!

[@PowerRepublic]

OBPSTi thanks for the positive feedback. Have fun Karting. Where do you race?

[@vigiror1]

Hi mate!! Couple of comments additional to the great job that you have done: 1) Lubricate crankshaft with lithium based grease in the running area of the needle cage 2) Tighten hex. nut with thrust washer (machined side towards the clutch drum). Tighten- ing torque 35 Nm (26 ft.lb). I have done it today, as Rotax recommend to do it after 2 hours. Regards from Valencia (Spain)

[@PowerRepublic]

Hola Vig, thanks heaps for tuning in and sharing the videos. how's the karting in Spain this winter?

[@vigiror1]

@@PowerRepublic hi Derek, karting in Spain is great even during winter time, Take into account that the coldest day we get specially in Valencia is 10 degree Celsius and by noon in a sunny day we get 18C. Close to my city With less than 40 minutes drive I have 7 circuits, valencia is the city of the Motorsport, come to me in case you come over to Valencia sometimes , all the best! Vicente

[@VictorySpecification]

looking to get into karting on a really tight budget. thanks for the videos. Would like to learn to do everything myself to keep costs down

[@PowerRepublic]

Yeah the costs can bow out pretty fast. If you want to keep it as cheap as possible, consider only getting a practise license. It's the Racing that adds up the bills because its so damn fun and addictive !!!!

[@harrisonmandell3600]

Great video sir! Thank you for also explaining the way the shoes engage with the drum. Its helpful to know how these things actually work.

[@PowerRepublic]

thanks heaps for tuning in and sharing the videos

[@cmcg5011]

Brilliant videos. Really helping me get to grips with the kart mechanics

[@PowerRepublic]

Thank legend 🤛

[@dgb5820]

Another awesome video appreciate you going to the effort

[@PowerRepublic]

Glad you enjoyed it

[@jochenschlueter894]

You do a great job, keep it up. Can you make a video about the mounting and height adjustment of a DD2. Greetings from Germany.

[@PowerRepublic]

Thanks Jochen. Will add it to the list. Do you have a DD2 and race it in Germany?

[@jochenschlueter894]

Yes, I drive clubsport races and would like to change over to OTK soon.

[@eeken4946]

Could you do a video giving a complete guide going through the basics of a full complete kart going over what to look out for and what all the important parts do etc. I am new to karting and a longer "starter guide" would be great.

[@PowerRepublic]

Thanks for the great question. I can certainly add that one to the list of videos to make. If you have just started, welcome. It's a long, fun and infinite road ahead of learning the craft of kart racing.

[@pietrozucci3971]

Ich hab selbst ein Rotax, und das ist echt gut erklärt. Hauptsächlich Funktion und Sicherheit das die Sache richtig gemacht ist. Dumbs up

[@PowerRepublic]

Ja, das sind coole Motoren. Vielen Dank für die positive Stimmung und Sie sind sehr willkommen

[@jackpainter481]

Really helpful and clear video, thanks!

[@PowerRepublic]

Thanks Jack Painter

[@jnnsky9861]

Hi Derek, thank you for the helpful advice at track today! Great videos👍

[@PowerRepublic]

Hey Jnn, yeah boi, get out there. you were going pretty hard in the last session !!!

[@CFGRacing]

New to the sport, just found huge cracks on my clutch drum after hearing it grind against flywheel. Looks easy enough to change, but I never thought the drum was a wear and tear part.

[@PowerRepublic]

CFG Goes Racing the older ones cracked on the regular. The newer ones are harder to break but still do from time to time. They are a bit like tyres, when worn out, replace it

[@MarcinDylewski0680]

Great channel with lots of informative details. Maybe something about inspecting and ways of fixing frame's geometry?

[@PowerRepublic]

Thanks for the positive feedback. When you are talking about geometry are you asking about the Camber and Castor geometry or something else?

[@MarcinDylewski0680]

@@PowerRepublic Well, checking it after caster/camber is something I am not yet aware so I will definitelly like that as well. However I was rather thinking about inspecting frame for bents and how to fix that.

[@Eastendhunter9]

Derek great video again I wished you would have went alittle further taken the ring gear off (so I could've seen what puller tool you used) and how you serviced the starter Bendix , still learning a ton from your video's thanks

[@PowerRepublic]

Thank mate, okay I'll make a 2.0 version of this video for you so you can see how its done.

[@ryanpratt9746]

As a newby I’m really enjoying your videos and learning so much . Thanks . Can you do a video on a clutch upgrade to the newer style clutch and gearing ?. I’ve got the kit in a box of parts and keen to get this done . Much love

[@PowerRepublic]

Hey Ryan, you are very welcome. The vids are definitely there to help you new guys with the fundamentals. We have a video on how to remove and install the Rotax Ring gear and also the new style clutch drum. Check them out and if I’m still short, let me know and I will do a remake for ya

[@ryanpratt9746]

I’ve since had a better look through your extensive videos . Only question I had (maybe missed ) was the flywheel . Is it just a case of using the gun to whip the nut off ?. Thanks for the videos , big fan

[@IggySport1388]

Another great video Derek, since we're on rotax i was wondering if you could do a video one day on how to distinguish when a rotax piston skirt has minor, moderate and excessive wear on the skirt. I monitoring mine Everytime i pull the exhaust off but with none to compare to I'm not sure how it ought to look in the 3 scenarios i described above.

[@PowerRepublic]

Thanks Chris for the great feedback. I will definitely do that video for you

[@shift-lightneil7283]

Hi. Great videos. Learning a lot ahead of buying a kart. What strength Loctite are you using please? Also what torque did you go to for the three shoe bolts? Thanks!

[@PowerRepublic]

I use blue Nut Locker. And 16nm for the clutch shoe nuts

[@shift-lightneil7283]

Power Republic Thanks Man!

[@noeldavis929]

Thanks mate..seems simple enough...😎😎😎

[@PowerRepublic]

hey noel, it sure is. thanks heaps for tuning in and liking the videos.

[@rickyhutchings2263]

Great video thanks

[@PowerRepublic]

Thanks Ricky

[@dinocalia4668]

Wish you would have talked about the sleeve bearing vs the needle bearing and installation. Also you said tighten clutch Allen heads to 15NM this is incorrect and I snapped a bolt. After reading the FSM as I should have in the first place it is 5NM!

[@madaalexstoica6999]

Hi Power Republic, thanks for the video! it helped to do the service and change the sprocket on our engine. I have a question though: why in your video there isn't a needle cage between the engine axel and the drum assembly like is the case for our engine? Are there different engine models? Thank you very much.

[@PowerRepublic]

Yeah the 11T sprocket has a plastic bush as the bearing

[@markamendola6222]

Hello thank you for your reply, the videos are very informative. I have one question regarding my lo206. The sprocket carrier on my 50mm axle has the key way with 2 holes in it. When I mounted a new lo206 engine the clutch sprocket or driver was outboard and I had to move the rear axle sprocket / carrier further to left or brake side. The key is now only half way under the carrier. I was told to wrap the protruding side with electrical tape and it should be ok. I’m just wondering / worried this isn’t ok. Any help would be appreciated. Thanks. Mark Thank you very much.

[@PowerRepublic]

Hey Mark, yeah that should be okay, otherwise you will need to move the keyway over to be under the sprocket carrier in a Milling Machine.

[@samrichardson3128]

Hi there lovin your videos as always, i just have a quick question for you. I have a very new clutch fitted to my max engine but the drum doesnt really spin freely by hand is this normal? Its been well lubed just was thinking perhaps this is binding on the o ring or is it possible the thrust washers fitted are the wrong size, cos it spins well if you pull the drum out a but when the nut is tightened it doesnt spin so good. Any help on this is most appreciated. Thanks Sam

[@PowerRepublic]

a fresh o ring and clutch assembly can be tight. have you double checked that the sprocket has a relief in the back for the o ring to sit in?

[@samrichardson3128]

Power Republic I’ve checked the sprocket there is no relief for it to sit in, this is a 13 tooth sprocket

[@jasonleslie6366]

Another informative video, Derek. One question though. Do you clean and lubricate the needle bearing also? If so, do you use a heavy silicone grease or a lighter weight lubricant like Tri-flow?

[@IggySport1388]

In this video this engine is running the 11t sprocket which does not have the needle bearing, but rather a bush thats pressed into the sprocket. In both cases they need to be greased, Derek probably overlooked that in this demo. You need to use a heavy grease so that it wont fling off and get into the clutch and make it slip. Triflow is a definite no no, that will surely get flung everywhere inside there and your clutch is gonna slip massively. I use Bel-Ray waterproof grease it works perfectly but don't put too much, just a little dab and distribute it evenly

[@Eastendhunter9]

thanks for pointing that out , I was wondering the same thing . I use hi temp disk brake grease with no issues

[@cotrapro]

@@IggySport1388 ​ Eastendhunter9 I use for the needle bearing LITHIUM-BASE GREASE from rotax, item number 897330

[@PowerRepublic]

Thanks guys for your responses. I didn't cover there cleaning and re greasing in this video. Apologies, this engine is in for a full rebuild and I was only using it for the demo before it got pulled down, so I neglected to lube the bearing in this demo. If you have the clutch drum off for servicing, definitely clean the bearing and re-grease.

[@nicholascory4804]

Hi there could you do a video on changing from rotax old clutch to new clutch, I'm still running the old spring shoes , thank you

[@PowerRepublic]

Yes I can

[@parkitplo3575]

Hi, I'm jumping into a Rotax for the first time at my local track with the Rotax FR125 Senior package after taking the L0206 class. Should I expect the same look when I get to my clutch package? I'm fortunate that my local track has a lot of very enthusiastic bunch of gear heads. Thank you for your time,

[@PowerRepublic]

Hey Neil, awesome news and welcome to the club. the clutch on a Rotax is very simple and requires no servicing or adjustment. I haven't used a L206 here in Aus but I would assume you can adjust the weights and pick up points?

[@KP-yd7xd]

Hey Derek, great video. Yesterday I was doing a practice session at track and. I realised a very loud noise at Low RPM. I would give a bit of throttle and the kart will hesitate to move and make a loud Reving like noise. I also noticed a a bit of metallic specs/dust near the chain guard and also the engine near the clutch. Any idea what the issue is?

[@PowerRepublic]

it might be that your clutch ring gear has some loose or there is a problem with the clutch or clutch bolts. let me know how you go. D

[@TheNings400]

Hey mate sure if you still see these questions. I did not have a oring retaining that washer? When I put a oring on when I do the retaining nut on after the drum it binds. If I take it off it is fine but has around 2mm of side to side play?

[@PlusSpec]

Thanks, great video. My issue is the ring gear is loose so I can't get the nut off to remove the clutch. Do you have any pointers?

[@kaikourasunshine7205]

Me too, I see the manual mention a piston stop tool

[@TheMirza1707]

great video, how often should this be done ?

[@PowerRepublic]

if you are using 11T front sprocket then its a great idea to re grease the bearing before the race weekend. the 12t front sprocket with the needle roller bearing are much more forgiving

[@TheMirza1707]

@@PowerRepublic Thx for your quick reply. I must say the videoes are amazing, and I see you find the time to answer most of the questions, I'm really please with this level of service !

[@TheMirza1707]

or should I say amazed, thumbs up :-)

[@PowerRepublic]

@@TheMirza1707 you are very welcome, thanks for the positive vibes!

[@maddoxfrench9259]

Hey I have the same exact go cart is there any chance you can tell me where I can get another clutch for my go cart it’s the 125cc it’s starting to slip so I’m trynna replace it

[@PowerRepublic]

hello my friend, where about do you live?

[@pablin123]

Hi Derek! would you do same video for DD2 engine?

[@PowerRepublic]

Sure can, we have a vid on the DD2 gears and the the clutch is almost the same as the senior max and just behind the gear set that slides off the end of the crank shaft

[@kartaroundtheworld]

Does the 38mm nut have a correct orientation ? I heard that the 2 sides are different and there is a correct way to install it.

[@PowerRepublic]

Yeah not sure. I usually put the side with the bevel to the top

[@terrier53]

Is it necessary to put white lithium grease on the shaft before assembly? I've seen videos where this is done.

[@PowerRepublic]

hey tea, yeah some sort of grease is preferred for sure

[@thelivestreamedclassroom1540]

My ring gear is loose and because of this, when I go to take off the retaining nut to take the clutch cover off, the shaft moves with the nut as I turn it so I cannot loosen it. Have you any tips on holding the shaft still so I can take off the retaining nut? Thanks

[@PowerRepublic]

remove the spark plug and insert a piston stop. that will stop the crank shaft from rotating. otherwise buy the little ring gear locking tool from Rotax like we use in the video

[@sollysuliman2357]

What could usually causes vibration problems (on idle and also while driving)? Even though the clutch is new..

[@PowerRepublic]

Wheels out of balance ?

[@sollysuliman2357]

Power Republic actually I can see the kart moving a lot even when the it’s on top of the trolly. And it really doesn’t feel like the wheels are shaking.

[@PowerRepublic]

What sort of engine do you have

[@rcmichael6524]

Do you have a video like this for the x30 engine or is it roughly the same?

[@PowerRepublic]

Great question, the latest X30 clutch shoes and ring gear set up is very similar with the 3 screws. The shoes do fit over a spigot on the ring gear which is a tight fit, so you might need the X30 clutch puller to get the shoes off. Vortex Mini ROk is very similar to IAME by the way.

[@xenoa77]

Can you do same kinda videos for X30 too ?

[@PowerRepublic]

Sure can, anything in particular that your have issues with?

[@Kids-np7bt]

Hi, do you have to use different size retaining washer for 11T and 12T sprocket ? My clutch always breaks and spits out the clutch drums past the mounting nut.

[@PowerRepublic]

Yes you do. 11t is small , 12t is larger

[@PurryKitchenWithTaste]

Hello, I want to buy a new clutch for my old rotax. However i dont want to spendera 400 dollars on a expensive clutch, max 80 dollars. Do you have any reccomendation? Btw I live in europe.

[@PowerRepublic]

maybe eBay would be best

[@robertkamperin4382]

When the kart is sitting on the trolley, I get this small hollow twitching sound from the clutch when I turn the axle. Not continously but once per revolution. It doesn't sound like its coming from the engine so it shouldn't be the piston / piston ring (Will tear it apart and double check to be sure). Anything you've come across??

[@PowerRepublic]

nah its the clutch drum 'tinging' on the rig gear I would imagine. maybe a new clutch needle roller bearing would fix it.

[@robertkamperin4382]

@@PowerRepublic thank you very much for the input! Will get some spares ordered (might as well add a clutch drum and other candy) right away and get to work! 🙏

[@olisutton1368]

What do you torque the M6 cap head bolts holding on the clutch to?

[@PowerRepublic]

Hi Oli, 15Nm for those mate, 8:51 in the vid

[@ruhandewittdewitt7800]

Where did you buy your allenkey t bat .

[@PowerRepublic]

www.sgkarts.com/product/12142-t-bar-kit-8pc-hex-key-metric?categoryId=433

[@jasongaskin2956]

Can you do a video of getting the nut off from clutch my one keeps turning That's with the special key that goes in it There are another way of getting it off

[@markamendola6222]

Where can you buy the key and the mold? Thank you

[@PowerRepublic]

Hi Mark. Where do you live? We can post them out to you in Australia 🇦🇺 if you send me your email address and postal address?

[@albertomuniz1328]

Yo ago lo mismo pero parece que cuando pongo la torica la arandela de goma luego al apretar la campana se queda muy dura i no gira es normal??

[@PowerRepublic]

make sure the rubber has lube on it. also too the old front sprockets didn't have the recess in them for the O ring. so check that too. Then make sure you have the bearings sitting perfect.

[@albertomuniz1328]

@@PowerRepublic ok gracias , creo que este motor va sin la goma. Un saludo

[@adenawerperezsanchez897]

@@albertomuniz1328 Al final cómo debe ir colocada las arandelas ? Porque yo apreto el conjunto y se queda la campaña muy dura. Un saludo

[@SammyPProductions]

Where can I buy the lock key for the rotax max 125?

[@PowerRepublic]

the clutch lock tool? we sell them and also any Rotax engine dealer will get them for you. www.internationalkarting.com.au/shop/item/clutch-locking-tool

[@rexwhisnant9075]

I use you tube always!

[@PowerRepublic]

number 1

[@iandadd9257]

Hi mate, would a Jmax be the same set up..??

[@PowerRepublic]

Hi Ian, yes the senior max and junior max use the same parts in the entire bottom end assembly. its only the cylinder and electronics that change.

[@iandadd9257]

Cheers mate

[@BLITZKRIEG1]

when my kart is up on a stand the rear axle doesn't rotate very easily. I've been told it may be something with the clutch. Is there a way to loosen it up a bit?

[@PowerRepublic]

yeah it is probably the O ring in the clutch, its no big deal, but you could lube it up with some grease if you are really worried. are you using the 11T on the Rotax

[@ksundar6594]

Can Rotax clutch be used to replace OEM clutch of x125T motor? Also how to prolong service life of these centrifugal clutches?

[@ksundar6594]

Great video btw!

[@PowerRepublic]

Hey K, thanks mate for tuning in. the Rotax clutch only fits on the Rotax engine normally. you could try and fit it to other engines but it is not worth the trouble in my opinion . hope that helps

[@geppebba]

👍🍻

[@markamendola6222]

Hello thank you for your reply, the videos are very informative. I have one question regarding my lo206. The sprocket carrier on my 50mm axle has the key way with 2 holes in it. When I mounted a new lo206 engine the clutch sprocket or driver was outboard and I had to move the rear axle sprocket / carrier further to left or brake side. The key is now only half way under the carrier. I was told to wrap the protruding side with electrical tape and it should be ok. I’m just wondering / worried this isn’t ok. Any help would be appreciated. Thanks. Mark Thank you very much.

[@PowerRepublic]

thanks heaps for tuning in