Overload Clutch - Rotax 125 MAX DD2 Repair Manual

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. The overload clutch absorbs the forces and thus prevents the overloading of the
engine and drive components.
➩ Loosen the wheel-side clamping ring (Item 1, Fig.
97).
➩ Loosen equally the 4 Allen screws (Item 2) of
the overload clutch.
➩ Loosen the front clamping ring (Item 7) - 9 screws
(Item 4) - and remove the residue of the securing
medium.
✔ Inspect all plastic bearings (Item 1) for wear and
replace if necessary.
✔ Check the thrust washers (Items 5+6) for wear
and replace if necessary.
➩ Oil the 4 plastic bearings in the overload clutch
before assembly (Use engine oil).
➩ Tighten the clamping ring (Item 7) with the thrust washer (Item 5) with the 9 screws, to a tightening
torque of 15 Nm in a crosswise sequence.
◆ Note:
The screws used to attach the clamping ring are to be secured with Loctite 648.
➩ Slide the clamping ring (Item 1, Fig. 97, page 55) and wheel-side thrust washer (Item 6) onto the rear
axle.
➩ Slide the overload clutch with the 4 plastic bearings onto the hollow shaft.
◆ Note:
Under no circumstances must the overload clutch be mounted on the rear axle by means of
a slot or keyway, since this leads to increased wear of the bearing bushing. Lightly oil the
bearing sleeves in the hollow shaft in the engine (Engine oil SAE 15W-40) and carefully slide
the engine onto the rear axle.
◆ Note:
Do not yet secure the installation of the overload clutch and stop sleeve (See page 55,
overload clutch).
Page 41
Repair Manual 125 MAX DD2
Fig. 66
Issue 01/2006