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Related Manuals for Rotax 125 MAX DD2
Summary of Contents for Rotax 125 MAX DD2
- Page 1 Repair Manual 125 MAX DD2 Repair Manual 125 MAX DD2 for ROTAX Engine Type ® Engine version number 360.125.200 Issued: 01 2006 BRP-ROTAX GmbH & Co. KG A-4623 GUNSKIRCHEN - Austria www.rotax.com www.kart-rotax.com Page 1 Issue 01/2006...
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Page 2: Foreword
® Rotax Engine Type 125 MAX DD2. A special feature of the engine is the chainless and maintenance-free direct drive, which is coupled to a straight-toothed, two-speed gear box. This Repair Manual is based on information and the state-of-knowledge of BRP-Rotax of the product current at the date of issue. -
Page 3: Table Of Contents
Repair Manual 125 MAX DD2 Table of contents Foreword ..............................2 IMPORTANT INFORMATION ......................5 Attention captions ............................5 General preAttentionary and safety measures ...................5 Technical data .............................8 Visual inspection and servicing intervals of the engine components ............9 SPECIAL TOOLS, LUBRICATION AND SECURING DEVICES ..........10 Overview of the special tools required ......................10... - Page 4 Repair Manual 125 MAX DD2 DISASSEMBLY , INSPECTION AND ASSEMBLY OF SPECIFIC COMPONENTS ....26 Carburetor ..............................26 Crank and gearbox housing ........................27 Shaft seal, water pump ..........................27 Other shaft seals ............................28 Needle and ball bearings ...........................28 Gear box ..............................
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Page 5: Important Information
The ROTAX Engine Type 125 MAX DD2 has been designed and developed exclusively for use in a Kart. Any other use renders the BRP-ROTAX factory limited warranty null and void. ■ Attention: The information provided in this repair manual is based on the experience of experts over many years. - Page 6 Repair Manual 125 MAX DD2 ■ Attention: Dismantled nuts, bolts and other fixing elements must be reassembled in a cleaned and rust-free condition or replaced by new parts of equivalent quality. ■ Attention: Correct observance of the prescribed maintenance interval and careful attention to the technical documentation is decisive for the life and serviceability of the engine.
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Page 8: Technical Data
Repair Manual 125 MAX DD2 Technical data (QJLQH 7\SH 0$; '' %RUHVWURNH PP PP 'LVSODFHPHQW FP 1RPLQDO SRZHU PD[ N: DW USP 7RUTXH PD[ 1P DW USP ,GOH VSHHG USP... -
Page 9: Visual Inspection And Servicing Intervals Of The Engine Components
Repair Manual 125 MAX DD2 Visual inspection and servicing intervals of the engine components &RPSRQHQW ,QVSHFWLRQ RU 6HUYLFH ,QWHUYDO ,QVSHFWLRQ 5HPHGLDO DFWLRQ *HQHUDO ,QVSHFW EHIRUH HYHU\ RSHUDWLRQ RI ,QVSHFW RYHUIORZ WDQN YHKLFOH HPSW\ LI QHFHVVDU\ ,QVSHFW RYHUORDG FOXWFK ,QVSHFW VSDUN SOXJ UHSODFH LI QHFHVVDU\... -
Page 10: Special Tools, Lubrication And Securing Devices
876 762 Trestle support assy. Engine support device for servicing and repair work 676 052 Trestle adapter for ROTAX engine FR 125 MAX DD2 251 680 Spring hook Engine 297 040 ROTAX logo with registered serial number... -
Page 11: Overview Of The Lubricants And Securing Devices
Repair Manual 125 MAX DD2 Overview of the lubricants and securing devices Fig. 2 Item ROTAX Part No. Description 297 434 Loctite Antiseize 15387 899 788 Loctite 648 Screw locking 899 785 Loctite 221 Screw locking 897 161 Molykote 111... -
Page 12: Location Of The Engine Number
Repair Manual 125 MAX DD2 Location of the engine number The engine number is stamped on the clutch side housing half, see Fig. 3. This information is required for the unambiguous ordering of spare parts and for enquiries. Fig. 3... -
Page 13: Dismantling The Engine And Gearbox
Repair Manual 125 MAX DD2 DISMANTLING THE ENGINE AND GEARBOX ◆ Note: Adhere to the operating and installation instructions of the Kart manufacturer. The following basics apply: First allow the engine to cool adequately and switch off all electrical power to the Kart. -
Page 14: Removal Of The Gear Shift
Repair Manual 125 MAX DD2 Removal of the gear shift ➩ Cut through the cable ties around the Bowden cables. ➩ Unhook the gear shift actuator Bowden cables. Fig. 6 Removal of the radiator hoses ➩ Unscrew the radiator hose for the water pump from the connector component at the clamp shown in Fig. -
Page 15: Removal Of Carburetor And Intake Silencer
Repair Manual 125 MAX DD2 Removal of carburetor and intake silencer ▲ Warning: Any spilt and overflowing gasoline must be immediately absorbed with the aid of a binding agent and correctly disposed of. Do not work with open flames or other sources of ignition. -
Page 16: Removal Of The Engine From The Kart Chassis
Repair Manual 125 MAX DD2 Removal of the engine from the Kart chassis ➩ Free the engine support following the Kart manufacturer’s instructions. ➩ Lift the engine from the Kart chassis using a suitable hoist. Oil draining ➩ Remove the oil drain screw (Item 1) with sealing (Item 2) from the crank and gearbox housing. -
Page 17: Exhaust Outlet Slider Function
Repair Manual 125 MAX DD2 Exhaust outlet slider function ◆ Note: The engine has a pneumatic exhaust outlet control to optimize the performance characteristics. Air pressure controls the slider bellows via the impulse bore. The slider piston pulls up the exhaust outlet slider and thus provides a longer outlet control time. -
Page 18: Removal Of The Exhaust Gas Flange
Repair Manual 125 MAX DD2 Removal of the exhaust gas flange ➩ Free the flange (Item 1) at the 2 Allen screws (Item 2) from the cylinder (Item 3) and remove the gasket (Item 4). ◆ Note: A leaking connection between the outlet port and the exhaust system leads to a loss of performance. -
Page 19: Removal Of Spark Plug
Repair Manual 125 MAX DD2 Removal of spark plug ➩ Unscrew the spark plug from its threaded socket with the spanner SW 16. ✔ Visual inspection of the spark plug for carbonization, oil fouling and discoloration of the electrode. Fig. 18 shows the most frequently found examples of spark plug unserviceability, leading to replacement. -
Page 20: Removal Of Coolant Thermostat
Repair Manual 125 MAX DD2 Removal of coolant thermostat ➩ Remove the coolant thermostat (Item 13) from the cylinder head cover on removing the 2 screws (Item 17) on the metal mounting bracket (Item 16). ➩ Remove the thermostat from the support plate (Item 14). -
Page 21: Removal Of The Water Pump Shaft
➩ Push the piston pin from the piston and conrod using the “Installation tool, complete“ special tool. ◆ Note: Use the Special tool - “Installation tool, complete“ - ROTAX part no. 676 035. ➩ Remove the piston together with the needle bearing. -
Page 22: Disassembly Of The Clutch, Primary And Balance Drive
Repair Manual 125 MAX DD2 Disassembly of the clutch, primary and balance drive Overview of clutch components Fig. 26 ➩ Free the gearbox casing cover (Clutch cover, Item 1) with 6 screws (Item 16), bracket (Item 3) with 4 screws (Item 15) and remove gasket (Item 2). - Page 23 Repair Manual 125 MAX DD2 ➩ Secure the locking device (A) on the starter toothed ring with a fixing bolt. ◆ Note: Use the special tool - “Locking device, complete“ - ROTAX part no. 676 200 or 676 202. ➩ Unscrew the M22x1.5 hexagon nut of the centrifugal clutch attachment (Item 8).
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Page 24: Disassembly Of The Crank And Gearbox Housing
Repair Manual 125 MAX DD2 Disassembly of the crank and gearbox housing ◆ Note: 2 M6 x 60 screws are required to push the two halves of the housing apart. Overview of the crank and gearbox housing components Fig. 30 ➩... - Page 25 Repair Manual 125 MAX DD2 ➩ Screw in 3 M8 x 70 fixing screws (Item 15, Fig. 26) from the support plate (Item.3, Fig. 26) equally, for use as leveling feet, see Fig. 31. ➩ Position the ignition side of the housing over the 3 screws on the work bench.
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Page 26: Disassembly , Inspection And Assembly Of Specific Components
Repair Manual 125 MAX DD2 DISASSEMBLY , INSPECTION AND ASSEMBLY OF SPECIFIC COMPONENTS ▲ Warning: Components, which have reached or exceeded their wear limits, must be replaced. Components, which are found to be defective in the context of the visual inspection and might influence the engine’s performance, must also be replaced. -
Page 27: Crank And Gearbox Housing
Repair Manual 125 MAX DD2 Crank and gearbox housing ✔ Inspect both housing halves for cracks and damage. ✔ Inspect the sealing surfaces for damage. ✔ Inspect all threads for cleanliness and ease of running. ◆ Note: The cylinder attachment stud bolts... -
Page 28: Other Shaft Seals
Repair Manual 125 MAX DD2 Other shaft seals ➩ Using a suitable tool, pull the shaft seals from the bearing seats of the crankshaft, hollow shaft and shift(Fork)shaft. ➩ Grease the new shaft seals in the region of the seal lip with Molycote 111. -
Page 29: Gear Box
Repair Manual 125 MAX DD2 ➩ Take one housing half from the oven with the bearings facing upwards. ➩ Turn the housing half over and swing it lightly onto a flat surface, preferably of wood. ➩ In most cases it will be sufficient to unseat the ball bearings. - Page 30 Repair Manual 125 MAX DD2 ✔ The following gearbox components must be checked for corrosion, damage and wear in the context of an engine inspection: ❇ Gear wheels, pinion shaft (Item 16), ❇ Idling gears (Items 6+7), ❇ Gear shift sleeve (Item 8), ❇...
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Page 31: Crankshaft
Repair Manual 125 MAX DD2 Crankshaft ➩ Thoroughly clean the crankshaft. ➩ Clean the residues of the securing medium from the conical starter crown wheel. ✔ Inspect the crankshaft for visible damage and traces of wear: ❇ Conical thread, ❇... -
Page 32: Conrod Set - Repair Set
Repair Manual 125 MAX DD2 Conrod set - Repair set ■ Attention: Repair of the crankshaft requires a special tool and must only be carried out by workshops with the appropriate experience and equipment. ➩ Separate the crankshaft using a suitable press device. -
Page 33: Piston And Piston Ring
Repair Manual 125 MAX DD2 Piston and piston ring ✔ Inspect the piston for pressure points, cracks and signs of scuffing. ✔ Inspect the bore of the piston pin for damage and wear. ✔ Inspect the piston pin circlips for defects. -
Page 34: Piston Pin, Needle Bearing And Retaining Rings
Repair Manual 125 MAX DD2 ✔ Check the piston ring locking pin for wear. ✔ Determine the piston diameter with a micrometer, as shown in Fig. 51. Conditions of measurement: Room temperature = 20 °C, Measuring position 20 mm from the lower edge of the piston, at right angles to the piston pin. -
Page 35: Cylinder
Repair Manual 125 MAX DD2 Cylinder ➩ Remove lime deposits from the water cooling jacket of the cylinder (Item 1). ➩ Clean the exhaust gas and slider duct of combustion residues. ➩ Clean the o-ring groove (Item 3). ✔ Inspect the threads (Item 2). -
Page 36: Centrifugal Clutch And Starter Crown Wheel
Repair Manual 125 MAX DD2 Centrifugal clutch and starter crown wheel ➩ Remove the 3 shaft circlips (Item 6) and the adjusting washers (Item 5) beneath them with a suitable pair of pliers, see Fig. 55. ➩ Pull the centrifugal weights (Item 2) from the support bolts (Item 4) with a suitable tool, see Fig. -
Page 37: Clutch Drum With Drive Gear
➩ Clamp the clutch drum in the special holding device, see Fig. 58. ◆ Note: Use special tool “Locking device“ ROTAX No. 676 190 or 676 192. ➩ Bend the lock nut tab washer straight with a suitable tool. ➩ Unscrew the lock nut SW1.5 inch with the appropriate spanner. -
Page 38: Gear Transmission
Repair Manual 125 MAX DD2 Gear transmission ➩ Dismantle the centering plate and clutch cover as described. See from page 42 for assembly. ✔ The dirt trap groove in the secondary gear wheel (Item 4, Fig. 76 on page 46) should be cleaned every 10 operating hours. - Page 39 ✔ Inspect the carbon brushes and replace if necessary with new parts ROTAX No. 281 260. ➩ Insert the plastic ring, so that it does not rotate, in the starter motor support.
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Page 40: Radiator
Repair Manual 125 MAX DD2 Radiator Fig. 65 The radiator is screwed to 3 rubber mountings (Item 5) and 3 cable clamps (Item 8) on the Kart frame. The coolant hoses are secured via 4 screw hose clamps (Item 4) on the radiator (Item 1) and secured to the engine connections. -
Page 41: Overload Clutch
Repair Manual 125 MAX DD2 Overload clutch ◆ Note: The overload clutch is the coupling between the engine and the rear axle of the Kart. If a braking action briefly locks the rear axle, the loading that occurs is not transmitted directly to the engine. -
Page 42: Assembly Of Gearbox And Engine
➩ Drive the crankshaft seal into the clutch-side housing half. ➩ Drive a hollow shaft seal into both housing halves using the ROTAX Special tool “Installation tool“ Part No. 676 022. ◆ Note: For installation of the water pump- shaft seals see page 27 ◆... -
Page 43: Overview Of Crank And Gearbox Housing Components
Repair Manual 125 MAX DD2 Overview of crank and gearbox housing components Fig. 70 Pos. ROTAX Part No. Description 684 231 Housing, complete Crank and gearbox housing, ignition side 684 231 Housing, complete Crank and gearbox housing, ignition side 630 520... - Page 44 When using new housing halves insert new dowel pins in the ignition-side housing half; when using the old housing halves unscrew the set bolts. ➩ Insert a new housing gasket ROTAX No. 630 520. ➩ Position the drive-side housing half on the shafts.
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Page 45: Installation Of The Water Pump Shaft
Repair Manual 125 MAX DD2 Installation of the water pump shaft ➩ Secure the impeller of the water pump (Item 4) by means of a dowel pin (Item 7). ➩ Screw in the water pump shaft (Item 6, Fig. 74) with rotation to the left and secure with Loctite 221 (Violet). -
Page 46: Installation Of The Clutch, Primary And Balance Drive
Repair Manual 125 MAX DD2 Installation of the clutch, primary and balance drive Overview of clutch components Fig. 76 Item ROTAX Part No.. Description Remarks 610 641 Clutch cover 630 510 Sealing, housing Sealing, housing r‡r‡Ãu‚yy‚Æuhs‡ 251 335 Bracket Secondary gear wheel... - Page 47 Repair Manual 125 MAX DD2 ➩ Insert the starter drive (Item 1) with thrust washer (Item 2) into the housing (Item 3). ◆ Note: Make sure that the correct sequence is followed - it is no longer possible to install the star ter drive after inserting the clutch drum with the drive gear.
- Page 48 Repair Manual 125 MAX DD2 ◆ Note: The shaft circlips should be installed with the chamfer facing the pressure side of the shaft. ➩ Complete the starter crown wheel, see from page 36, and position it on the crankshaft. ✔ Inspect the disc spring for wear.
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Page 49: Installation Of The Piston And Piston Pin
Repair Manual 125 MAX DD2 Installation of the piston and piston pin ◆ Note: Cover the crankcase with a clean cloth to prevent small parts from inadvertently falling into the crank and gearbox housing and causing damage. ➩ Coat the piston pin retainer with lithium-base grease, ➩... -
Page 50: Installation Of The Cylinder
Repair Manual 125 MAX DD2 ➩ Rotate the installation tool and push the mounting sleeve further until the piston pinretaining ring engages in the groove in the mounting sleeve. ➩ Push the Installation tool with the opening of the piston pin retainer ring downwards onto the piston. -
Page 51: Installation Of The Combustion Chamber Insert And Cylinder Head Cover
Repair Manual 125 MAX DD2 Installation of the combustion chamber insert and cylinder head cover ➩ Insert the new o-ring (7) in the groove. ➩ Secure the combustion chamber insert (Item 6) to the cylinder (Item 2) by crosswise tightening... -
Page 52: Installation Of The Spark Plug
On each of the components cylinder head, exhaust outlet and carburetor socket a screw with a hole in the top is used for the purpose of attaching sealing wire - ROTAX part no. 641 361. ◆ Note: Note the installed position of the thermostat, see Fig. - Page 53 Repair Manual 125 MAX DD2 ➩ Position the outlet slider gasket (Item 10), making sure that the impulse bore on the cylinder is not covered. ➩ Insert the slider guide component (Item 9) with the cutout facing the exhaust port. Screw the two screws (Item 11) with spring washers (Item 12) into the cylinder (Item 16) and tighten to 10 Nm.
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Page 54: Installation Of The Exhaust Gas Port
Repair Manual 125 MAX DD2 Installation of the exhaust gas port ➩ Secure the exhaust gas port, with a new gasket, to the cylinder, tightening the two screws to the prescribed torque of 20 Nm. ✔ Check the connection between the cylinder and the exhaust gas port for correct sealing. -
Page 55: Installation Of The Overload Clutch
Repair Manual 125 MAX DD2 Installation of the overload clutch ➩ Slide the wheel-side clamping ring (Item 1) onto the rear axle. ➩ Slide the thrust washer onto the rear axle. ➩ Slide the overload clutch with the 4 plastic bearings onto the hollow shaft, ➩... -
Page 56: Installation Of The Engine On The Chassis
Repair Manual 125 MAX DD2 Installation of the engine on the chassis ▲ Warning: Before installing the engine on the chassis the installation instructions for the engine and the installation instructions of the chassis manufacturer must be read and understood. -
Page 57: Installation Of The Intake Silencer
➩ Clean the silencer filter (Item 5). ◆ Note: Immerse the filter element in filter oil before assembly (Use Rotax No. 297 160) and then Fig. 101 expel the surplus oil. ➩ Insert the silencer filter in the housing. ➩ Fasten the cover on the housing. -
Page 58: Installation Of The Exhaust System
✔ Inspect the baffle for wear. ■ Attention: A worn out baffle can lead to major engine damage. ➩ Insert a new baffle ROTAX No. 297 980 tightly Fig. 104 into the exhaust inner pipe (Item 3). ➩ Insert the exhaust inner pipe and baffle into the exhaust system. -
Page 59: Installation Of The Radiator
Repair Manual 125 MAX DD2 Installation of the radiator Fig. 105 ➩ Fix the radiator (Item 1), complete, to the 3 rubber mountings (Item 5) on the Kart chassis. The prescribed torque is 10 Nm. ➩ Fit the radiator hoses (Item 3) on the support fittings on the radiator and align them with the engine support fittings. -
Page 60: Installation Of The Radiator Hoses
Repair Manual 125 MAX DD2 Installation of the radiator hoses ➩ First connect the radiator hose to the connection support on the cylinder head cover. Then tighten the clamp to provide water tightness with the recessed head screw, as shown in Fig. 106. - Page 61 Repair Manual 125 MAX DD2 Page 61 Issue 01/2006...
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