BRP ROTAX 125 DD2 MAX EVO Installation Manual

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INSTALLATION

MANUAL

125 DD2 MAX EVO

KART ED. 03/2021

PART NO. 297732

ROTAX-KART.COM

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Summary of Contents for BRP ROTAX 125 DD2 MAX EVO

Page 1 INSTALLATION MANUAL 125 DD2 MAX EVO KART ED. 03/2021 PART NO. 297732 ROTAX-KART.COM...
Page 2 GENERAL INFORMATION BRP-ROTAX RECOMMENDS PRODUCTS OF THE FOLLOWING COMPANIES: BRP-Rotax GmbH & Co KG T: + 43 7246 601 - 0 Follow us: Rotaxstraße 1 F: + 43 7246 6370 4623 Gunskirchen, Austria www.rotax-kart.com...
Page 3: Table Of Contents
BRP-Rotax INSTALLATION MANUAL Table of Content Chapter INTRO – Chapter 1 – Engine installation Chapter 2 – Fuel system Chapter 3 – Electric system Chapter 4 – Cooling system Chapter 5 – Exhaust system Chapter 6 – Installation of the accessories Chapter 7 –...
Page 4 BRP-Rotax INSTALLATION MANUAL NOTES Notes Effectivity: 125 MAX DD2 evo Edition /Rev. 0 Page 2 Edition: March 01 2021...
Page 5: 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 6 BRP-Rotax INSTALLATION MANUAL NOTE In case of participating in the ROTAX® MAX CHALLENGE (RMC) the engine must be verified for conformity with the technical regulations and sealed. The serial number of the seal must be entered in the engine identity card.
Page 7 BRP-Rotax INSTALLATION MANUAL Safety Messages The types of safety messages, what they look like and how they are used in this guide are explained as follows: The safety alert symbol indicates a potential injury hazard. m WARNING Indicates a potential hazard, if not avoided, could result in serious injury or death.
Page 8 BRP-Rotax INSTALLATION MANUAL Safety information m WARNING Non-compliance can result in serious injuries or death! For the best possible engine operation, compliance with the following advice regarding installation of engine and equipment is required. m WARNING Non-compliance can result in serious injuries or death! Engine operation is permitted only with equipment supplied by ROTAX®...
Page 9 BRP-Rotax INSTALLATION MANUAL UNBOXING YOUR ROTAX POWERPACK Congratulations on choosing a ROTAX engine! Your ROTAX kart engine comes delivered in two boxes. Figure 1.2: Unboxing Engine box The engine box contains the assembled block engine pre-filled with gearbox oil. Accessory box The accessory box contains all required parts for running the engine.
Page 10 BRP-Rotax INSTALLATION MANUAL Figure 1.3: Accessory box Pos. Description Check mark Radiator with coolant hoses Mounting plate with ignition coil, solenoid valve and spark plug cap Battery box and wiring harness Battery charger Intake silencer Fuel pump with fuel hose...
Page 11: Engine Information
BRP-Rotax INSTALLATION MANUAL ENGINE INFORMATION Engine serial number The engine serial number is stamped on the clutch side housing-half. Figure 1.4: Serial number of the engine, TYPICAL Gear oil and fuel specifications See the latest Operators Manual. Equipment and modifications Modifications to engine and/or equipment are not allowed.
Page 12 BRP-Rotax INSTALLATION MANUAL NOTES Notes Effectivity: 125 MAX DD2 evo Edition /Rev. 0 Page 8 Edition: March 01 2021...
Page 13: Engine Installation
BRP-Rotax INSTALLATION MANUAL Chapter: 1 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...
Page 14: Installation Of Overload Clutch And Engine With Rear Axle
BRP-Rotax INSTALLATION MANUAL INSTALLATION OF OVERLOAD NOTE CLUTCH AND ENGINE WITH REAR Do not tighten the overload clutch and clamp AXLE ring yet (see section Engine attachment with en- gine brackets). NOTE The overload clutch is the link between the en- gine and the rear axle of the kart.
Page 15 BRP-Rotax INSTALLATION MANUAL ENGINE INSTALLATION WITH Step Procedure ENGINE BRACKETS Slide the engine onto the rear axle and align the rear axle and the engine by Tools required: measuring the distance between the front and the rear axle • Allen key 8mm After engine alignment, tighten the 4 •...
Page 16 BRP-Rotax INSTALLATION MANUAL Figure 2.4: Tightening sequence Allen screws Effectivity: 125 MAX DD2 evo Page 4 Edition: March 01 2021...
Page 17 BRP-Rotax INSTALLATION MANUAL DIRECT ATTACHMENT OF THE 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.
Page 18 BRP-Rotax INSTALLATION MANUAL NOTES Notes Effectivity: 125 MAX DD2 evo Edition /Rev. 0 Page 6 Edition: March 01 2021...
Page 19: Fuel System
BRP-Rotax INSTALLATION MANUAL 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...
Page 20: Installation And Connection Of The Fuel Pump
BRP-Rotax INSTALLATION MANUAL INSTALLATION AND CONNECTION OF THE FUEL PUMP Tools required: • Allen key 5 mm • Circlip pliers Step Procedure The retaining plate, rubber buffers, fuel pump, fuel hose (with 230 mm and 1800 mm length) is already pre- assembled.
Page 21 BRP-Rotax INSTALLATION MANUAL Step Procedure The fuel hose with 230 mm length will be connected later to the carburetor, see carburetor installation. The larger fuel hose (pos. 1) should be connected to the fuel filter (pos. 2) and to the fuel tank.
Page 22: Installation Of The Bowden Cable For Carburetor Control
BRP-Rotax INSTALLATION MANUAL INSTALLATION OF THE BOWDEN CABLE FOR CARBURETOR CONTROL Tools required: • Open-end wrench 10 mm Step Procedure Carefully remove carburetor cover with rubber ring (pos. 7, 8). m CAUTION Reset spring of carb piston presses against carburetor cover and might eject carburetor cover at removal.
Page 23 BRP-Rotax INSTALLATION MANUAL m WARNING Non-compliance can result in serious injuries or death! The carburetor Bowden cable must not be kinked or restricted as the carburetor piston might get stuck in full throttle position. Step Procedure Set and secure the adjustment screw...
Page 24: Installation And Connection Of The Carburetor
BRP-Rotax INSTALLATION MANUAL INSTALLATION AND CONNECTION OF THE CARBURETOR Tools required: • Ratchet wrench with socket 7 mm • Phillips screwdriver Step Procedure Fit carburetor (pos. 1) into carburetor socket and secure with hose clamp (pos. 2) in vertical position.
Page 25: Electric System
BRP-Rotax INSTALLATION MANUAL Chapter: 3 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...
Page 26: Electric System Overview
BRP-Rotax INSTALLATION MANUAL ELECTRIC SYSTEM OVERVIEW Figure 4.1: TYPICAL 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 27: Installation Ecu Into The Battery Clamp Assy
BRP-Rotax INSTALLATION MANUAL INSTALLATION ECU INTO THE BATTERY CLAMP ASSY. Step Procedure Prepare rubber pad (consists of two halves) (pos. 1) and the ECU (pos. 2) for installation. Figure 4.3 Rubber pad Step Procedure Insert the complete unit into the battery Figure 4.2...
Page 28 BRP-Rotax INSTALLATION MANUAL Figure 4.4 Rubber pad Connection cable ECU connector Effectivity: 125 MAX DD2 evo Page 4 Edition: March 01 2021...
Page 29: Installation Of The Battery Clamp Assy
BRP-Rotax INSTALLATION MANUAL INSTALLATION OF THE BATTERY CLAMP ASSY. Tools required: • Allen key 4 mm • Ratchet wrench with socket 8 mm or Phillips screwdriver m WARNING Non-compliance can result in serious injuries or death! Make absolutely sure to avoid short-circuiting of battery terminals.
Page 30 BRP-Rotax INSTALLATION MANUAL Figure 4.6 NOTE The battery terminals must point in the direction Figure 4.8 of the control unit. Step Procedure Install the battery cover onto the bat- tery holder. NOTE Make sure that the two retaining lugs (pos. 1)
Page 31: Installation Of The Wiring Harness
BRP-Rotax INSTALLATION MANUAL INSTALLATION OF THE WIRING NOTE HARNESS When unplugging connections on ignition pick up and ignition coil, press the integrated catch Tools required: first. • Torx screwdriver T30 NOTE The wiring harness is delivered partly pre-assembled Disconnect any electrical plug connection only to facilitate the installation.
Page 32 BRP-Rotax INSTALLATION MANUAL Step Procedure Fasten the cable lug (pos. 3) to the shift contact assy. using the Plastite screw M6x25 (pos. 4). Pay attention to correct sequence of the components! See following Figures. For correct adjusting of the plastite screw find the according section inside the latest Operators Manual.
Page 33 BRP-Rotax INSTALLATION MANUAL Step Procedure Attach ignition cables to the spark plug. Figure 4.14 Tie wrap Step Procedure Connect pick up connector to pick up sensor (pos. 1). Pay attention to the engagement of the connector. See al- so section: Direct attachment of the engine to chassis.
Page 34 BRP-Rotax INSTALLATION MANUAL NOTES Notes Effectivity: 125 MAX DD2 evo Edition /Rev. 0 Page 10 Edition: March 01 2021...
Page 35: Cooling System
BRP-Rotax INSTALLATION MANUAL 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: March 01 2021...
Page 36: Cooling System Overview
BRP-Rotax INSTALLATION MANUAL 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...
Page 37: Installation Of The Radiator
BRP-Rotax INSTALLATION MANUAL INSTALLATION OF THE RADIATOR Procedure Step Tools required: Secure the coolant hoses with the hose clamps (pos. 10). • Ratchet wrench with socket 7 mm or Phillips Secure the upper coolant water hose screwdriver to the driver's seat (pos. 2) using the provided cable tie.
Page 38: Intake Silencer
BRP-Rotax INSTALLATION MANUAL INTAKE SILENCER Figure 5.2: Overview Intake silencer case Intake silencer cover Filter element Holder for filter element Intake silencer tube Carburetor socket Clamp 50–70 Lock nut M6 Allen screw. rounded flange head Effectivity: 125 MAX DD2 evo...
Page 39: Installation Of The Intake Silencer With Integrated Airfilter
BRP-Rotax INSTALLATION MANUAL INSTALLATION OF THE INTAKE SILENCER WITH INTEGRATED AIRFILTER Tools required: • Allen key 4 mm • Ratchet wrench with socket 7 mm or Phillips screwdriver Step Procedure Install the rubber intake pipe (pos. 5) in a vertical position into the bottom half (pos.
Page 40 BRP-Rotax INSTALLATION MANUAL NOTES Notes Effectivity: 125 MAX DD2 evo Edition /Rev. 0 Page 6 Edition: March 01 2021...
Page 41: 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: March 01 2021...
Page 42 BRP-Rotax INSTALLATION MANUAL EXHAUST SYSTEM OVERVIEW Figure 6.1 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 43 BRP-Rotax INSTALLATION MANUAL INSTALLATION OF THE EXHAUST NOTE SYSTEM For easier installation use the special tool "Spring hook" part no. 251680. Tools required: • Open-end wrench 13 mm ATTENTION • Spring hook Do not over-stress the springs when fitting them.
Page 44 BRP-Rotax INSTALLATION MANUAL NOTES Notes Effectivity: 125 MAX DD2 evo Edition /Rev. 0 Page 4 Edition: March 01 2021...
Page 45: Installation Of The Accessories
BRP-Rotax INSTALLATION MANUAL Chapter: 6 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 46: Installation Of Mounting Plate
BRP-Rotax INSTALLATION MANUAL INSTALLATION OF MOUNTING PLATE Tools required: • Allen key 6 mm Step Procedure The holding bracket, the mounting plate, the solenoid valve and the igni- tion coil are already pre-assembled. Install whole bracket kit with Allen screw M8x50 (pos. 2) and distance sleeve 8.2/12/25.5 (pos.
Page 47: Fitting Of The Spark Plug
BRP-Rotax INSTALLATION MANUAL FITTING OF THE SPARK PLUG The engine will be supplied with a spark plug. Tools required: • Feeler gauge • Socket 21 mm • Torque wrench Procedure Step Remove the transport plug from the cylinder head. Check electrode gap of spark plug. Ad- Figure 7.2...
Page 48: Installation And Connection Of The Rave Control Unit
BRP-Rotax INSTALLATION MANUAL INSTALLATION AND CONNECTION OF THE RAVE CONTROL UNIT NOTE The hose package of the RAVE control is al- ready pre-assembled. NOTE The impulse restrictor is offered optionally. Procedure Step Insert impulse nozzle (pos. 6) about 25 Figure 7.3 mm into the 420 mm pressure line (pos.
Page 49 BRP-Rotax INSTALLATION MANUAL Step Procedure Attach cable tie with mount (pos. 1) to the housing. Figure 7.5 Hose package Step Procedure Attach the fuel line of the hose pack- age (pos. 1) to the impulse nipple on Figure 7.7 the engine housing..
Page 50 BRP-Rotax INSTALLATION MANUAL Figure 7.8: Cable tie Cable tie Black hose Cable tie Step Procedure Attach the 220 mm pressure line (pos. 1) to the magnetic valve (pos. 3). Se- cure the pressure line on the magnetic valve with a tie wrap (pos. 4). Attach the other end of the pressure line to the exhaust valve (pos.
Page 51: Assembly Of Paddle Shift System
BRP-Rotax INSTALLATION MANUAL ASSEMBLY OF PADDLE SHIFT SYSTEM Tools required: • Allen key 6 mm • Allen key 5 mm Step Procedure Install spacer (pos. 1) into the appro- priate bore (pos. 2) of the engine Figure 7.11 housing. Bowden cable...
Page 52 BRP-Rotax INSTALLATION MANUAL Figure 7.13 Figure 7.15 Shift contact Retaining plate guidance Point 1 Point 2 Procedure Step Procedure Step Mount Allen screw (pos. 1), lock wash- er (pos. 2) and spacer (pos. 3) togeth- Mount sleeve (pos. 1) onto the retain- er with the shift contact guidance (pos.
Page 53 BRP-Rotax INSTALLATION MANUAL Figure 7.17 Figure 7.19 Retaining plate Bowden cable Cable support Bowden cables Guidance Set screw Step Procedure Step Procedure Install Bowden cables (pos. 1) into the Hand-tighten both Bowden cables support on the back of the engine.
Page 54 BRP-Rotax INSTALLATION MANUAL NOTE The control lever can also be attached on the back, depending on how it is more ergonomic for the driver. Procedure Step Install spacer (pos. 1) with washer (pos. 2) onto the bottom side of the control whip (3).
Page 55 BRP-Rotax INSTALLATION MANUAL Figure 7.23 Figure 7.24 Washer Allen screw M6x60 Lock nut M6 Washer Control whip Allen screw M6x60 Step Procedure Step Procedure The setting of the shifting is carried out Place the entire shifting unit onto the in neutral gear, which means that the...
Page 56 BRP-Rotax INSTALLATION MANUAL Figure 7.25 Cable abutment Screw Control whip Effectivity: 125 MAX DD2 evo Page 12 Edition: March 01 2021...
Page 57: Finishing Work
BRP-Rotax INSTALLATION MANUAL Chapter: 7 FINISHING WORK TOPICS IN THIS CHAPTER Check oil level in gearbox........................2 Venting of the gear compartment ......................4 Run-in procedure ............................5 NOTE To determine the best possible transmission ratio, the use of a rev-counter is required for observation of the speed limits.
Page 58 BRP-Rotax INSTALLATION MANUAL CHECK OIL LEVEL IN GEARBOX The gearbox is already filled with the appropriate amount of oil by the engine manufacturer. However, before the engine is installed in the frame, the oil lev- el must be verified or replenished.
Page 59 BRP-Rotax INSTALLATION MANUAL NOTE For draining the oil from the gear case, remove the magnetic oil drain plug (pos. 1) and sealing ring (pos. 2). Clean the oil drain plug before in- stallation. Always use a new sealing ring. Figure 8.3...
Page 60: Venting Of The Gear Compartment
BRP-Rotax INSTALLATION MANUAL VENTING OF THE GEAR COMPARTMENT Step Procedure Remove cap from the venting screw. Establish a connection between the venting screw and a collecting reser- voir using a piece of the supplied fuel hose of an appropriate length.
Page 61: Run-In Procedure
ATTENTION For the first 10 liters of fuel use a mixing ratio of 1:33 (= 3% or 0.3 liter oil per 10 liters of fuel). NOTE BRP-Rotax recommends to use XPS Kart - Tec oil. Step Procedure 15 min. up to 10.000 rpm.
Page 62 BRP-Rotax INSTALLATION MANUAL NOTES Notes Effectivity: 125 MAX DD2 evo Edition /Rev. 0 Page 6 Edition: March 01 2021...
Page 63 BRP-Rotax INSTALLATION MANUAL Index Battery, installation ..........5 Oil level, check in gearbox ........2 Bowden cable, installation........4 Overload clutch, installation ........2 Carburetor, connection ..........6 Paddle shift system, assembly .......7 Carburetor, installation...........6 Cooling system .............1 Cooling system overview ........2 Radiator, installation ..........3 RAVE control unit, installation ........4...