Rotax 125 MAX DD2 evo Installation Instructions And Operators Manual
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Rotax 125 MAX DD2 evo Installation Instructions And Operators Manual

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Installation instructions and
Operator's Manual
for ROTAX®-engines type
125 MAX DD2 evo
Part no.: 297733
Edition: 10/2019
BRP-Rotax GmbH & Co KG | Rotaxstrasse 1 | 4623 Gunskirchen, Austria | T: +43 7246 601 0 | F: +43 7246 6370
www.rotax.com | www.rotax-kart.com

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Summary of Contents for Rotax 125 MAX DD2 evo

  • Page 1 Operator‘s Manual for ROTAX®-engines type 125 MAX DD2 evo Part no.: 297733 Edition: 10/2019 BRP-Rotax GmbH & Co KG | Rotaxstrasse 1 | 4623 Gunskirchen, Austria | T: +43 7246 601 0 | F: +43 7246 6370 www.rotax.com | www.rotax-kart.com...
  • Page 2 General information BRP-Rotax recommends products of the following companies:...
  • Page 3 For information regarding the repair of the engine 125 MAX DD2 evo contact an authorized service center or consult the workshop manual (available on the internet at www.rotax-kart.com). We ask to hand over this manual, the engine identity card and the product and service registration document to the new owner in case of a change of ownership.

  • Page 4: Table Of Contents

    2 – Fuel system Chapter 3 – Electric system Chapter 4 – Cooling system Chapter 5 – Exhaust system Chapter 6 – Installation of the accessories Chapter 7 – Finishing work Effectivity: 125 MAX DD2 evo Content Page 1 Edition: September 01 2019...
  • Page 5 BRP-Rotax INSTALLATION MANUAL NOTES Notes Effectivity: 125 MAX DD2 evo Edition /Rev. 0 Page 2 Edition: September 01 2019...

  • Page 6: Chapter Intro

    This document and all technical data and procedures therein are property of BRP-Rotax GmbH & Co KG and based on the state of knowledge at the time of publication The Manual has been drawn up to the best of our knowledge. However, excluding any liability.
  • Page 7 NOTE Indicates supplementary information which may be needed to fully complete or understand an instruction. ✔ Denotes a checking operation This information gives you additional advice and tips INTRO Effectivity: 125 MAX DD2 evo Page 2 Edition: September 01 2019...
  • Page 8 Introduction Congratulations on choosing the ROTAX engine Type 125 MAX DD2 evo. The ROTAX® engine Type 125 MAX DD2 evo has been developed exclusively for use in Go-karts, which must only be run on specified tracks. This product has numerous technical innovations.
  • Page 9 BRP-Rotax INSTALLATION MANUAL UNBOXING AND PURCHASED PARTS PACKAGE By buying a ROTAX Engine, you will receive two boxes. The engine box and the accessory box. Figure 1.1: Unboxing Engine box The engine box contains the pre-assembled engine with the secure sticker, which de- scribes the run-in procedure.
  • Page 10 BRP-Rotax INSTALLATION MANUAL Effectivity: 125 MAX DD2 evo INTRO Page 5 Edition: September 01 2019...
  • Page 11 Fuel pump with fuel hose Exhaust system Manuals and engine identity card Several small parts (spark plug, screws,...) Hose package for RAVE control unit Carburetor Paddle shift system INTRO Effectivity: 125 MAX DD2 evo Page 6 Edition: September 01 2019...

  • Page 12: Engine Information

    BRP-Rotax INSTALLATION MANUAL ENGINE INFORMATION Engine serial number The engine serial number is stamped on the clutch side housing-half. Figure 1.3: Serial number of the engine, TYPICAL Effectivity: 125 MAX DD2 evo INTRO Page 7 Edition: September 01 2019...
  • Page 13 Figure 1.4: Information sticker Gear oil and fuel specifications See the latest Operators Manual. Equipment and modifications Modifications to engine and/or equipment are not allowed. INTRO Effectivity: 125 MAX DD2 evo Page 8 Edition: September 01 2019...

  • Page 14: Engine Installation

    ENGINE INSTALLATION TOPICS IN THIS CHAPTER Installation of overload clutch and engine with rear axle .................2 Engine installation with engine brackets ....................3 Direct attachment of the engine to chassis....................5 Effectivity: 125 MAX DD2 evo Page 1 Edition: September 01 2019...
  • Page 15 NOTE The rear axle of the kart must have a smooth surface (no grooves for keys) in the area of the 4 plain bearings of the overload clutch. Effectivity: 125 MAX DD2 evo Page 2 Edition: September 01 2019...
  • Page 16 WARNING Non-compliance can result in serious injuries or death! For engine attachment to the chassis, please fol- low the instruction of the chassis manufacturer. Effectivity: 125 MAX DD2 evo Page 3 Edition: September 01 2019...
  • Page 17 BRP-Rotax INSTALLATION MANUAL Figure 2.4: Tightening sequence Allen screws Effectivity: 125 MAX DD2 evo Page 4 Edition: September 01 2019...
  • Page 18 ENGINE TO CHASSIS If the frame of the chassis is specially prepared for in- stallation of the ROTAX® 125 MAX DD2 evo, then 2 sheet metal brackets with holes are welded onto the two frame tubes. The engine is clamped between the two brackets with 4 bolts.
  • Page 19 BRP-Rotax INSTALLATION MANUAL NOTES Notes Effectivity: 125 MAX DD2 evo Edition /Rev. 0 Page 6 Edition: September 01 2019...

  • Page 20: Fuel System

    Chapter: 2 FUEL SYSTEM TOPICS IN THIS CHAPTER Installation and connection of the fuel pump...................2 Installation of the Bowden cable for carburetor control................4 Installation and connection of the carburetor ..................6 Effectivity: 125 MAX DD2 evo Page 1 Edition: September 01 2019...
  • Page 21 (pos. 1) on the gearbox cover by of circlip pliers. using 2 screws M6x30 (pos. 3) and washers (pos. 2). ATTENTION Fuel hose can be damaged! Avoid excessive widening of the fuel hose. Effectivity: 125 MAX DD2 evo Page 2 Edition: September 01 2019...
  • Page 22 ATTENTION The flow in the impulse hose and fuel lines must not be restricted by the use of cable ties. Effectivity: 125 MAX DD2 evo Page 3 Edition: September 01 2019...
  • Page 23 (throttle pedal). tach with the cable ties supplied. Make sure that the Bowden cable does not Connect Bowden cable to throttle touch any moving parts or the track. pedal. Effectivity: 125 MAX DD2 evo Page 4 Edition: September 01 2019...
  • Page 24 The Bowden cable must not be under full tension when the throttle is in fully open position. Effectivity: 125 MAX DD2 evo Page 5 Edition: September 01 2019...

  • Page 25: Installation And Connection Of The Carburetor

    (pos. 2) in vertical position. Connect the outlet hose of the fuel pump with fuel inlet (pos. 3) on the carburetor. Figure 3.6 Hose clamp Carburetor Fuel inlet Effectivity: 125 MAX DD2 evo Page 6 Edition: September 01 2019...

  • Page 26: Electric System

    ELECTRIC SYSTEM TOPICS IN THIS CHAPTER Electric system overview.........................2 Installation ECU into the battery clamp assy....................3 Installation of the battery clamp assy......................5 Installation of the wiring harness ......................7 Effectivity: 125 MAX DD2 evo Page 1 Edition: September 01 2019...

  • Page 27: Electric System Overview

    Figure 4.1 Connector pickup sensor Connector starter Connector battery Connector RAVE (only applicable 125 MAX evo) Connector ignition coil Connector ECU Tie wrap 250x4.8 Connector shift contact Tie wrap 142x3.2 Effectivity: 125 MAX DD2 evo Page 2 Edition: September 01 2019...

  • Page 28: Installation Ecu Into The Battery Clamp Assy

    It fits only in one position to the rubber Make sure that the connection cable has been pad. installed between the two pads. The connection of the ECU is on the rear side (against the driving direction). Effectivity: 125 MAX DD2 evo Page 3 Edition: September 01 2019...
  • Page 29 BRP-Rotax INSTALLATION MANUAL Figure 4.4 Rubber pad Connection cable ECU connector Effectivity: 125 MAX DD2 evo Page 4 Edition: September 01 2019...

  • Page 30: Installation Of The Battery Clamp Assy

    11 Multiple function switch Allen screw with rounded flange head (pos. 9). The battery fixture (pos. 5) can be fixed with one screw on one side of the clamp (pos. 3). Effectivity: 125 MAX DD2 evo Page 5 Edition: September 01 2019...
  • Page 31 Figure 4.7 Battery terminals Step Procedure Connect the positive terminal (red) of the battery. Connect the negative terminal (black) of the battery. Figure 4.9 Retaining lugs Flange head screw Effectivity: 125 MAX DD2 evo Page 6 Edition: September 01 2019...

  • Page 32: Installation Of The Wiring Harness

    Fasten cables with cable ties on the mounting plate. m WARNING Non-compliance can result in serious injuries or death! The wiring harness must not touch moving parts of the track. Effectivity: 125 MAX DD2 evo Page 7 Edition: September 01 2019...
  • Page 33 Do not tighten tie wrap yet in order to be able to change its position later on. Fasten the wire of the shift contact assy. with a tie wrap (pos. 1) on the bottom of the engine. Effectivity: 125 MAX DD2 evo Page 8 Edition: September 01 2019...
  • Page 34 If it's not possible to plug in the connector of the pick-up sensor, unscrew the pick-up sensor and change the angle or direction. See also section: Direct attachment of the engine to chassis. Effectivity: 125 MAX DD2 evo Page 9 Edition: September 01 2019...
  • Page 35 BRP-Rotax INSTALLATION MANUAL NOTES Notes Effectivity: 125 MAX DD2 evo Edition /Rev. 0 Page 10 Edition: September 01 2019...

  • Page 36: Cooling System

    Chapter: 4 COOLING SYSTEM TOPICS IN THIS CHAPTER Cooling system overview ........................2 Installation of the radiator ........................3 Intake silencer ............................4 Installation of the intake silencer with integrated airfilter ................5 Effectivity: 125 MAX DD2 evo Page 1 Edition: September 01 2019...
  • Page 37 COOLING SYSTEM OVERVIEW Figure 5.1 Upper coolant water hose Radiator Clamp 16–25 Lower coolant water hose Rubber puffer Rubber puffer Washer Lock nut Allen screw — rounded flange head Hose clamps Effectivity: 125 MAX DD2 evo Page 2 Edition: September 01 2019...

  • Page 38: Installation Of The Radiator

    Ensure that the air stream covers the complete ra- diator area. Push the lower coolant water hose (pos. 3) onto the lower socket of the radiator as well onto the water socket of the water pump housing. Effectivity: 125 MAX DD2 evo Page 3 Edition: September 01 2019...
  • Page 39 Figure 5.2: Overview Intake silencer case Intake silencer cover Filter element Holder for filter element O-ring Intake silencer tube Clamp 50–70 Carburetor socket Allen screww. rounded flange head Lock nut M6 Effectivity: 125 MAX DD2 evo Page 4 Edition: September 01 2019...
  • Page 40 Procedure Step Attach the intake silencer on the chas- sis using the M6 Allen screw with rounded flange head (pos. 10). Effectivity: 125 MAX DD2 evo Page 5 Edition: September 01 2019...
  • Page 41 BRP-Rotax INSTALLATION MANUAL NOTES Notes Effectivity: 125 MAX DD2 evo Edition /Rev. 0 Page 6 Edition: September 01 2019...

  • Page 42: Exhaust System

    BRP-Rotax INSTALLATION MANUAL Chapter: 5 EXHAUST SYSTEM TOPICS IN THIS CHAPTER Exhaust system overview........................2 Installation of the exhaust system ......................3 Effectivity: 125 MAX DD2 evo Page 1 Edition: September 01 2019...
  • Page 43 Exhaust system Silencer assy. Tension spring Spring stainless Exhaust gasket Retaining plate Spring stainless Rubber buffer Rubber buffer Washer 8.4 Exhaust socket assy. Lock nut M8 Exhaust gasket Spring stainless Effectivity: 125 MAX DD2 evo Page 2 Edition: September 01 2019...
  • Page 44 Additional heat-resistant LOC- TITE is not necessary anymore. Step Procedure Secure the exhaust system on the ex- haust socket using the two supplied exhaust springs (pos. 14). Effectivity: 125 MAX DD2 evo Page 3 Edition: September 01 2019...
  • Page 45 BRP-Rotax INSTALLATION MANUAL NOTES Notes Effectivity: 125 MAX DD2 evo Edition /Rev. 0 Page 4 Edition: September 01 2019...

  • Page 46: Installation Of The Accessories

    INSTALLATION OF THE ACCESSORIES TOPICS IN THIS CHAPTER Installation of mounting plate ........................2 Fitting of the spark plug...........................3 Installation and connection of the RAVE control unit ................4 Assembly of paddle shift system......................7 Effectivity: 125 MAX DD2 evo Page 1 Edition: September 01 2019...

  • Page 47: Installation Of Mounting Plate

    NOTE Distance sleeve (pos. 3) has to be install be- tween engine housing and retaining plate. Dis- tance sleeve can be replaced by fitting of an additional seat stay. Effectivity: 125 MAX DD2 evo Page 2 Edition: September 01 2019...

  • Page 48: Fitting Of The Spark Plug

    Fit supplied spark plug (pos. 1) and tighten 25 Nm (221 lbf in) to 27 Nm (239 lbf in). Install the spark plug connector (pos. 2), ensure correct engagement. Effectivity: 125 MAX DD2 evo Page 3 Edition: September 01 2019...

  • Page 49: Installation And Connection Of The Rave Control Unit

    Do not tie up the pressure line completely! Figure 7.4 Hose package Metal connector Step Procedure Attach the other end of the hose pack- age (pos. 1) (short end with T-piece) to the fuel pump. Effectivity: 125 MAX DD2 evo Page 4 Edition: September 01 2019...
  • Page 50 Do not tighten cable ties too tight, because constricted lines can lead to loss of function. Step Procedure Attach an additional cable tie (pos. 3) as shown in figure. Figure 7.6 Hose package Effectivity: 125 MAX DD2 evo Page 5 Edition: September 01 2019...
  • Page 51 (pos. 4). Attach the other end of the pressure line to the exhaust valve (pos. 2). Figure 7.9 Pressure line Exhaust valve Magnetic valve Cable tie Effectivity: 125 MAX DD2 evo Page 6 Edition: September 01 2019...

  • Page 52: Assembly Of Paddle Shift System

    Install washer (pos. 1) on one of the two Bowden cables (pos. 2). Washer Bowden cable Shift contact guidance Step Procedure Mount Bowden cable with shift contact guidance (pos. 1) to the retaining plate (pos. 2). Effectivity: 125 MAX DD2 evo Page 7 Edition: September 01 2019...
  • Page 53 -2- must be given. Otherwise it sleeve onto the retaining plate (pos. can cause increased friction, which has a negative impact on shifting No washer is necessary on this Bow- behavior. den cable. Effectivity: 125 MAX DD2 evo Page 8 Edition: September 01 2019...
  • Page 54 Thread both ends of the Bowden ca- bles (pos. 1) through the cable support (pos. 2). Install the set screw (pos. 3) onto the cable support – just pre-as- semble it, do not tighten yet. Effectivity: 125 MAX DD2 evo Page 9 Edition: September 01 2019...
  • Page 55 (pos. 2) onto the top of the control whip (pos. 3). NOTE Figure 7.21 Top is the opposite side, where the screws of Allen screw Control lever the Bowden cables are attached. Control whip Washer Effectivity: 125 MAX DD2 evo Page 10 Edition: September 01 2019...
  • Page 56 Step Procedure Finally, the length of the Bowden ca- bles can be adjusted so that they do not disturb the driver when shifting. Effectivity: 125 MAX DD2 evo Page 11 Edition: September 01 2019...
  • Page 57 BRP-Rotax INSTALLATION MANUAL Figure 7.25 Cable abutment Screw Control whip Effectivity: 125 MAX DD2 evo Page 12 Edition: September 01 2019...

  • Page 58: Finishing Work

    To warrant engine operation within temperature limits of the coolant, a temperature sensor for observation of the coolant temperature is required. NOTE Refer to Operators Manual for operating limits. Effectivity: 125 MAX DD2 evo Page 1 Edition: September 01 2019...
  • Page 59 Hand-tighten air vent screw (pos. 1). oil as described in the following steps. NOTE For gearbox oil specifications and oil capacity (total) see the latest Operators Manual. Figure 8.2 Air vent screw Effectivity: 125 MAX DD2 evo Page 2 Edition: September 01 2019...
  • Page 60 Tighten magnetic oil drain plug (pos. 1) to 20 Nm (177 lbf.in.). m WARNING Non-compliance can result in serious injuries or death! Do not run the engine without gear oil. This will lead to engine failure. Effectivity: 125 MAX DD2 evo Page 3 Edition: September 01 2019...
  • Page 61 The venting hose must not reach all the way to the bottom of the collecting reservoir. ATTENTION Do not attach the venting hose on the bottom of the collecting reservoir, if only one reservoir is in use. Effectivity: 125 MAX DD2 evo Page 4 Edition: September 01 2019...

  • Page 62: Cooling System Overview

    Wiring harness, installation ........7 Finishing work............1 Fuel pump, connection ..........2 Fuel pump, installation...........2 Fuel system, installation ........1 Intake silencer ............4 Intake silencer, installation ........5 INTRO ..............1 Mounting plate, installation........2 Index Effectivity: 125 MAX DD2 evo Page 5 Edition: September 01 2019...
  • Page 63 Operator‘s Manual...
  • Page 64 Chapter 1 – Technical Description Chapter 2 – Operating fluids and battery Chapter 3 – Engine calibration Chapter 4 – Engine operation Chapter 5 – Preservation and transport Effectivity: 125 MAX DD2 evo Content Page 1 Edition: September 01 2019...
  • Page 65 BRP-Rotax Operators Manual NOTES Page 2 Effectivity: 125 MAX DD2 evo Edition: September 01 2019...

  • Page 66: Chapter: Intro General Information

    BRP-Rotax GmbH & Co KG. BRP-Rotax GmbH & Co KG reserves the right at any time to discontinue or change specifications, prices, designs, features, models or equipment without incurring obligation.
  • Page 67 BRP-Rotax Operators Manual NOTES Page 2 Effectivity: 125 MAX DD2 evo Edition: September 01 2019...

  • Page 68: Technical Description

    BRP-Rotax Operators Manual Chapter: 1 TECHNICAL DESCRIPTION TOPICS IN THIS CHAPTER Design of the ROTAX engine 125 MAX DD2 evo..................2 General ..............................2 Cooling circuit ............................2 Balance gear............................3 Ignition unit ............................3 Electric starter ............................3 Electro pneumatically exhaust timing control ...................3 Intake silencer............................3 Exhaust system.............................4...

  • Page 69: Design Of The Rotax Engine 125 Max Dd2 Evo

    DESIGN OF THE ROTAX ENGINE 125 MAX DD2 EVO Figure 1.1 GENERAL The Rotax 125 MAX DD2 evo engine is a single cylinder two stroke engine with reed valve controlled inlet and 125 cm displacement. Mixture lubrication is achieved by adding oil to the gasoline in a specified mixing ratio.

  • Page 70: Balance Gear

    ________________________________________________________________ ELECTRO PNEUMATICALLY EXHAUST TIMING CONTROL The engine type 125 MAX DD2 evo is equipped with an electro-pneumatic exhaust con- trol. The E-RAVE (Electronic ROTAX Adjustable Variable Exhaust) system is controlled by an electro-pneumatic valve via the ECU. The vacuum required is provided by the engine crankcase.

  • Page 71: Exhaust System

    For extreme operating conditions, the main jet size must be adjusted to the actual conditions according to this manual. ________________________________________________________________ Effectivity: 125 MAX DD2 evo Page 4 Edition: September 01 2019...

  • Page 72: Centrifugal Clutch

    The engine has a mechanical overload clutch, which is installed on the rear axle. It is to protect the crankshaft from hard shocks from the drive components which are not usual during normal operation (e.g. the blocking of the rear axle). Effectivity: 125 MAX DD2 evo Page 5 Edition: September 01 2019...
  • Page 73 BRP-Rotax Operators Manual NOTES Page 6 Effectivity: 125 MAX DD2 evo Edition: September 01 2019...

  • Page 74: Operating Fluids And Battery

    BRP-Rotax Operators Manual Chapter: 2 OPERATING FLUIDS AND BATTERY TOPICS IN THIS CHAPTER Coolant..............................2 Battery..............................3 Battery charging unit..........................4 Fuel .................................6 See also table “important information (summary)” in Chapter 5. Effectivity: 125 MAX DD2 evo Page 1 Edition: September 01 2019...

  • Page 75: Coolant

    Storage below the freezing temperature of water could lead to a damage of the cooling system and the engine. ATTENTION Exceeding the engine temperature could lead to serious engine failure. The engine temperature should not exceed 85 °C / 185 °F. ______________________________________________________ Effectivity: 125 MAX DD2 evo Page 2 Edition: September 01 2019...

  • Page 76: Battery

    NOTE To charge a battery, the delivered battery charging unit specified by ROTAX® should be utilized (battery charger part no. 265148). When using the lithium bat- tery available as spare part, the battery charger Optimate Lithium (part no.

  • Page 77: Battery Charging Unit

    NOTE A red/green blinking of the charging control lamp indicates transition from main charging to additional charging and does not signal a faulty battery charger. Effectivity: 125 MAX DD2 evo Page 4 Edition: September 01 2019...
  • Page 78 (part no. 266022). If needed, contact your authorized distributor or one of their ROTAX® Service Centers. The charging condition of the battery can be estimated by using a commercially available measuring instrument. ______________________________________________________ Effectivity: 125 MAX DD2 evo Page 5 Edition: September 01 2019...

  • Page 79: Fuel

    Pay attention to the safety advice of the kart manufacturer. ATTENTION Possible engine trouble! Too much oil in the fuel mixture (more than 2%) could lead to engine trouble (e.g. coking of the exhaust valve, piston ring sticking). Effectivity: 125 MAX DD2 evo Page 6 Edition: September 01 2019...
  • Page 80 Store only the quantity of fuel in a container which will be needed in the near future. ENVIRONMENTAL NOTE Don’t spill fuel. Absorb spilled fuel with appropriate drying agent and ensure ecological disposal. ______________________________________________________ Effectivity: 125 MAX DD2 evo Page 7 Edition: September 01 2019...
  • Page 81 BRP-Rotax Operators Manual NOTES Page 8 Effectivity: 125 MAX DD2 evo Edition: September 01 2019...

  • Page 82: Engine Calibration

    Change of the carburetor main jet ......................11 Choose of gear ratio ..........................14 Exchange of gear reduction ratio ......................16 Operation of the gear box........................18 Adjustment of gear shifting ........................19 Effectivity: 125 MAX DD2 evo Page 1 Edition: September 01 2019...

  • Page 83: Engine Calibration

    In this diagram, the different performance characteristics of the MAX engines are shown. The vertical Y-axis shows the power in kilowatts (kW). The horizontal X-axis shows the ro- tational speed in revolutions per minute (rpm). For more information, please check the performance data sheets on www.rotax-kart.com. Figure 3.1: Performance graphs ______________________________________________________...

  • Page 84: Carburetor Calibration

    The following application for smartphones shows the individual setting of your ROTAX® 125 Max DD2 evo engine: The ROTAX® Max Jetting Guide is an App for Android™ and iOS devices, designed to as- sist users with setting up the recommended main jet based on the ambient conditions and the type of engine.

  • Page 85: Automatic-Set-Up

    The app will automatically show all potential Max evo engines, from which one can be selected by clicking on a certain engine type. Effectivity: 125 MAX DD2 evo Page 4 Edition: September 01 2019...
  • Page 86 Procedure After all the necessary information has been provided and selected, you on- ly need to click the circular red button saying “CALCULATE” at the bottom of the screen. Effectivity: 125 MAX DD2 evo Page 5 Edition: September 01 2019...
  • Page 87 Now the recommended main jet value will be provided. In case a second calculation needs to be made, you can start over by simply pressing the button saying “RESET” next to the calculated value. Effectivity: 125 MAX DD2 evo Page 6 Edition: September 01 2019...

  • Page 88: Manual Set-Up

    Now the recommended main jet value will be provided. In case a second calculation needs to be made, you can start over by simply pressing the button saying “RESET” next to the calculated value. Effectivity: 125 MAX DD2 evo Page 7 Edition: September 01 2019...
  • Page 89 By clicking the small red X underneath the info button, you can return to the home screen. Effectivity: 125 MAX DD2 evo Page 8 Edition: September 01 2019...
  • Page 90 Figure 3.10: QR- code, iOS device For better understanding and as help for carburetor adjustment, the following figure de- scribes the effect of the various adjustments, depending on the throttle position. Effectivity: 125 MAX DD2 evo Page 9 Edition: September 01 2019...
  • Page 91 BRP-Rotax Operators Manual Figure 3.11: Various adjustments ______________________________________________________ Effectivity: 125 MAX DD2 evo Page 10 Edition: September 01 2019...

  • Page 92: Change Of The Carburetor Main Jet

    Remove the main jet (pos. 15) and the main jet cup (pos. 14). NOTE The size of the jet is imprinted on the face of the main jet. Effectivity: 125 MAX DD2 evo Page 11 Edition: September 01 2019...
  • Page 93 Operators Manual Step Procedure Select the appropriate size of main jet, refer to ROTAX® Max Jetting Guide. Install the main jet cup (pos. 14) in position and fit the corresponding main jet (see ROTAX® Max Jetting Guide). Fit and hand-tighten the plug screw (pos. 27) and gasket ring (pos. 26).
  • Page 94 (pos. 31), the air-fuel mixture will become leaner at idling. The default setting of the adjustment screw are two full turns and one quarter of a turn (2 ¼) from inside to outside. ______________________________________________________ Effectivity: 125 MAX DD2 evo Page 13 Edition: September 01 2019...

  • Page 95: Choose Of Gear Ratio

    BRP-Rotax Operators Manual CHOOSE OF GEAR RATIO In spite of its 2 gears, the 125 MAX DD2 evo engine offers a broad performance band. Therefore, the frequent changing of the primary gear ratio is not necessary. NOTE It is not possible to change the 1 and 2 gear individually.
  • Page 96 6.52 14 to 91 100 / 62 6.23 14 to 87 105 / 65 5.95 14 to 83 110 / 68 5.69 14 to 79 115 / 72 Effectivity: 125 MAX DD2 evo Page 15 Edition: September 01 2019...

  • Page 97: Exchange Of Gear Reduction Ratio

    2 Allen screws M6x40 (pos. 3). Remove the gear cover. NOTE If the gear cover is difficult to remove, it can be levered off at the sep- arating lugs. Effectivity: 125 MAX DD2 evo Page 16 Edition: September 01 2019...
  • Page 98 At re-assembly, proceed in reverse sequence. Tighten the screws to the following torque settings: M6: 10 Nm (88 lbf. in.) / M8: 22 Nm (195 lbf. in.) Figure 3.14: Gear ratio Effectivity: 125 MAX DD2 evo Page 17 Edition: September 01 2019...

  • Page 99: Operation Of The Gear Box

    Operators Manual OPERATION OF THE GEAR BOX The ROTAX® 125 MAX DD2 evo is fitted with a 2-speed gearbox that is changed man- ually via a shifting device. The engine also has an electronic ignition cut-off which when changing from 1...

  • Page 100: Adjustment Of Gear Shifting

    If changing the gear becomes difficult after some operating hours, check , whether the retaining plate is bent, replace it with a new one or try to bend the support back into the correct position. Effectivity: 125 MAX DD2 evo Page 19 Edition: September 01 2019...
  • Page 101 BRP-Rotax Operators Manual Figure 3.15: Adjusted Effectivity: 125 MAX DD2 evo Page 20 Edition: September 01 2019...
  • Page 102 Engine start ............................2 Stopping the engine..........................4 Running – in procedure for the engine.....................5 Setting of the exhaust valve timing ......................6 Maintenance schedule for engine components ..................9 Operating Limits ..........................11 Effectivity: 125 MAX DD2 evo Page 1 Edition: September 01 2019...

  • Page 103: Engine Operating

    Press the button again until the engine starts. See Fig. “Power button” NOTE If the engine does not start, repeat the operation after a few seconds in the same manner. Effectivity: 125 MAX DD2 evo Page 2 Edition: September 01 2019...
  • Page 104 Non-compliance can result in serious injuries or death! Inspect any part prone to wear (tyres, bearings etc.) before each kart event for good condition, in accordance with the directives of the kart manufacturer. Effectivity: 125 MAX DD2 evo Page 3 Edition: September 01 2019...

  • Page 105: Stopping The Engine

    If electric starter is activated, the ignition system will consume current. This can cause a deep discharge and damage to the battery. Figure 4.3: Power button Power button ______________________________________________________ Effectivity: 125 MAX DD2 evo Page 4 Edition: September 01 2019...

  • Page 106: Running - In Procedure For The Engine

    After this running-in procedure, the full power of the engine may be used. ATTENTION Use only fully synthetic 2–stroke oil. BRP-Rotax recommends the use of XPS Kart Tec oil. ATTENTION The engine may never be operated without load. Is it operated without load (i.e. on the trolley) rpm. over 13.800 1/min are possible, which shortens the life time of components (con rod, big end bearing etc).

  • Page 107: Setting Of The Exhaust Valve Timing

    Ground wire The additional cable is attached to the ground wire. The control of the exhaust valve timing is activated at 8800 rpm. Effectivity: 125 MAX DD2 evo Page 6 Edition: September 01 2019...
  • Page 108 Cable on starter relay. The additional cable is attached to the ground wire. The control of the exhaust valve timing is activated at 8800 rpm. Effectivity: 125 MAX DD2 evo Page 7 Edition: September 01 2019...
  • Page 109 BRP-Rotax Operators Manual Figure 4.5: Cable on starter relay NOTE Either variant 1 or variant 2 has been installed in your engine. ______________________________________________________ Effectivity: 125 MAX DD2 evo Page 8 Edition: September 01 2019...

  • Page 110: Maintenance Schedule For Engine Components

    Visually inspect fuel filter regarding dirt, replace if needed Replace fuel filter Effectivity: 125 MAX DD2 evo Page 9 Edition: September 01 2019...

  • Page 111: Engine Operation

    Replace spark plug as requested Dirt catching groove on secondary gear Overload clutch inspection RAVE Clean hoses with com- pressed air. Effectivity: 125 MAX DD2 evo Page 10 Edition: September 01 2019...

  • Page 112: Operating Limits

    NOTE Dirt must be cleared from the lamination of the radiator at regular intervals to achieve the best cooling performance. ______________________________________________________ Effectivity: 125 MAX DD2 evo Page 11 Edition: September 01 2019...
  • Page 113 BRP-Rotax Operators Manual NOTES Page 12 Effectivity: 125 MAX DD2 evo Edition: September 01 2019...

  • Page 114: Preservation And Transport

    Operators Manual Chapter: 5 PRESERVATION AND TRANSPORT TOPICS IN THIS CHAPTER Preservation and transport........................2 Preservation of engine and equipment ....................2 Transport of the kart..........................2 IMPORTANT INFORMATION (SUMMARY).....................3 Notes ..............................4 Effectivity: 125 MAX DD2 evo Page 1 Edition: September 01 2019...
  • Page 115 Step Procedure Remove drain screw on float chamber of carburetor and collect the fuel in a suitable container. Clean drain screw and refit. ______________________________________________________ Effectivity: 125 MAX DD2 evo Page 2 Edition: September 01 2019...
  • Page 116 Pure water resp. antifreeze if kart is stored SYSTEM at temperatures below 0 °C/ 32 °F GEARBOX OIL 0.150 0.039 Engine oil SAE 15W-40 XPS Kart-Tec SPARK PLUG see IPC Effectivity: 125 MAX DD2 evo Page 3 Edition: September 01 2019...
  • Page 117 ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ Effectivity: 125 MAX DD2 evo Page 4 Edition: September 01 2019...
  • Page 118 Coolant ..............2 Cooling circuit ............2 Operating limits........... 11 Operation of the gear box ........18 Overload clutch.............5 Design of the ROTAX engine 125 MAX DD2 evo ..2 Performance graphs..........2 Electric starter............3 Preservation and transport........2 Electro pneumatically exhaust timing control ...3 Preservation of engine and equipment ....2 Electronic Shifting Assistant (ESA) ......4...
  • Page 120 BRP-Rotax GmbH & Co KG | Rotaxstraße 1 | 4623 Gunskirchen, Austria | T: +43 7246 601 0 | F: +43 7246 6370 www.rotax.com | www.rotax-kart.com R and TM are trademarks of BRP-Rotax GmbH & Co KG. © 2019 BRP-Rotax GmbH & Co KG. All rights reserved.

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