BRP ROTAX 125 MAX DD2 evo Installation Instructions And Operators Manual Download Page 1

Page: 1 / 72

for ROTAX®-engines type

125 MAX DD2 evo

Part no.: 297 733

Edition: 0

/2016

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

Installation instructions and

Operator‘s Manual

Summary of Contents for ROTAX 125 MAX DD2 evo

Page 1: ...125 MAX DD2 evo Part no 297 733 Edition 09 2016 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 Installation instructions...

Page 2: ...Page 1 70 Edition 09 2016 General information BRP Rotax recommends products of the following companies...

Page 3: ...otax 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 we exclude any liability We reserve all rights includin...

Page 4: ...nd follow all instructions p Warning This engine performs better than comparable products Repeating symbols p Warning Identifies an instruction which if not followed may cause injury or endanger the l...

Page 5: ...Page 4 70 Edition 09 2016 INSTALLATION INSTRUCTIONS FOR ROTAX ENGINE TYPE 125 MAX DD2 evo...

Page 6: ...Check of oil level in gear box 17 9 Installation of overload clutch and engine with rear axle 19 10 Engine attachment to chassis 20 10 1 Engine attachment with engine brackets 20 10 2 Direct attachmen...

Page 7: ...of the respective chassis manufacturer Note The registration document and engine identity card must be provided to the final consumer upon delivery by the authorized service center with handover date...

Page 8: ...pre assembled See Fig 1 Fig 1 Install the retaining plate with the fuel pump pos 1 on the gearbox cover by using 2 screws M6x30 pos 3 and washers pos 2 Fig 2 TIP Facilitate the assembly of the fuel h...

Page 9: ...Pay attention to the arrow s direction on the fuel filter This must point towards the fuel pump Attention Route the fuel line from the fuel tank to the fuel filter so that it does not touch any movin...

Page 10: ...2016 3 Installation and connection of the carburetor See Fig 5 Fit the carburetor pos 1 into the carburetor socket and secure with a hose clamp pos 2 in vertical position Connect the outlet hose of t...

Page 11: ...rom carburetor piston pos 2 Engage nipple of Bowden wire pos 9 in nipple screw pos 5 Fit nipple screw in carburetor piston and hand tighten with A F 10 wrench Insert carburetor piston pos 2 into carb...

Page 12: ...st not be kinked or restricted as the carburetor piston might get stuck in full throttle position Set and secure the adjustment screw for Bowden cable on chassis so that the carburetor piston will rem...

Page 13: ...re already pre assembled Install whole bracket kit with Allen screw M8x50 pos 2 and distance sleeve 8 2 12 25 5 pos 3 onto the engine Attention Slot pos 1 of retaining plate has to be installed in the...

Page 14: ...plug from the cylinder head Check electrode gap of spark plug Adjust as required Note The electrode gap of the spark plug should be 0 7 mm 0 027 in to 0 8 mm wide 0 032 in for NGK spark plugs Only sli...

Page 15: ...mm pressure line pos 7 using an Allen key SW4 Pay attention to the mounting direction It also works without an impulse nozzle this only serves to choke the opening of the exhaust valve Note In order t...

Page 16: ...end with T piece to the fuel pump Fig 12 Attach the fuel line of the hose package pos 1 to the impulse nipple on the engine housing Note Check that valve is not the lowest point of the impulse circuit...

Page 17: ...ention Do not tighten cable ties too tight because consricted lines can lead to loss of function Attach an additional cable tie pos 3 as shown in Fig 15 Fig 15 Attach the 220 mm pressure line pos 1 to...

Page 18: ...tal surface take care not to damage the crankcase sensor which is mounted on the bottom of the crank case The oil level can be checked on the inspection glass pos 1 It should reach approximately to on...

Page 19: ...e gear case remove the magnetic oil drain plug pos 1 and sealing ring pos 2 Clean the oil drain plug before installation Always use a new sealing ring Fig 34 Note Tighten magnetic oil drain plug pos 1...

Page 20: ...tl and is not transferring the peak load from the rear axle to the engine The bushings pos 2 are inside the overload clutch pos 1 Fig 35 Slide the clamp ring pos 1 Fig 36 the thrust washer pos 2 Fig 3...

Page 21: ...between front and rear axle After engine alignment tighten the 4 Allen screws M8 x 25 to fix the upper engine bracket to the engine with 28 Nm 248 lbf in Fix and tighten the lower engine bracket to th...

Page 22: ...tween the two brackets with 4 bolts Note Thread length in crankcase should be between16 24 mm 0 6 0 95 in Note Secure bolts with bolt adhesive e g LOCTITE 243 Mount engine directly on the brackets Not...

Page 23: ...llation at the engine side to work without tension on the wiring harness Attention Strain relief of the plug connections must be ensured Note Compensate excessive length of wiring harness by routing c...

Page 24: ...te Do not tighten the tie wrap yet in order to be able to change its position later on Fasten the cable lug to the shift contact assy using the Plastite screw M6x25 pos 3 Pay attention to correct sequ...

Page 25: ...ions 125 MAX DD2 evo Page 24 70 Edition 09 2016 Fig 21 Connect pick up connector to pick up sensor pos 1 Pay attention to the engagement of the connector See also section 10 2 for pick up sensor orien...

Page 26: ...ignition cables to the wiring harness See Fig 23 Fig 23 1 Connector pick up sensor 2 Connector starter 3 Connector battery 4 Connector RAVE only applicable 125 MAX evo 5 Connector ECU 6 Connector ign...

Page 27: ...unit into the respective rubber pad TIP Align at the triangular bottom of the control unit It only fits the rubber pad in one position Place the upper rubber pad pos 1 onto the control unit Fig 25 In...

Page 28: ...125 MAX DD2 evo Page 27 70 Edition 09 2016 Fig 26 Attention Make sure that the connection cable pos 2 has been installed between the two pads pos 1 The connection of the ECU is on the rear side again...

Page 29: ...fixture pos 5 with the two pipe clamps pos 1 4 to the left side frame rail beside the driver s seat Note The clamps pos 2 3 are designed for chassis tubes of 30 32 mm 1 18 1 26 in in diameter Attenti...

Page 30: ...unit See Fig 29 Fig 29 Connect the positive terminal red of the battery Connect the negative terminal black of the battery Fig 30 Install the battery cover onto the battery holder Note Make sure that...

Page 31: ...3 Assembly of paddle shift system Install spacer pos 1 into the appropriate bore pos 2 of the engine housing Fig 40 Install washer pos 1 on one of the two Bowden cables pos 2 Fig 41 Mount Bowden cable...

Page 32: ...ng plate pos 2 Fig 43 Mount Allen screw pos 1 lock washer pos 2 and spacer pos 3 together with the shift contact guidance pos 4 onto the engine housing Tightening torque 22 Nm Fig 44 The alignment bet...

Page 33: ...e pos 1 onto the retaining plate pos 2 Fig 46 Mount second Bowden cable pos 1 through shift contact guidance and sleeve onto the retaining plate pos 2 No washer is necessary on this Bowden cable Fig 4...

Page 34: ...M6 Allen screws pos 3 and washers pos 4 Pay attention to the correct installation of the control whip Note The oblique millings pos 5 of the control whip serve to guide the cables The cable ends must...

Page 35: ...also be attached to the back depending on how it is more ergonomic for the driver Install spacer pos 1 with washer pos 2 onto the bottom side of the control whip 3 Note The bottom side is where the s...

Page 36: ...ut handlebar The setting of the shifting is carried out in neutral gear which means that the control whip must be in horizontal position Tighten the screw pos 2 of the cable abutment pos 1 and the scr...

Page 37: ...hose clamps pos 10 on the coolant hoses Push the upper coolant water hose pos 2 onto the upper socket of the radiator as well as onto the water socket of the cylinder head cover Push the lower coolant...

Page 38: ...K00399 Fig 56 Establish a connection between the overflow socket on the radiator filling socket and the overflow bottle with an appropriate piece of hose Attention To warrant the best possible engine...

Page 39: ...uretor Install the filter element pos 3 with the holder pos 4 Assemble filter box and filter insert as shown in the following figure Make sure that the locking is interlocked properly Apply Air filter...

Page 40: ...9 to the support lug on the underside of the exhaust Arrange the chassis specific supports so that the exhaust system follows the straightest possible course from the exhaust socket on the cylinder t...

Page 41: ...Installation Instructions 125 MAX DD2 evo Page 40 70 Edition 09 2016 K00365 Fig 58...

Page 42: ...r to Operator s Manual section 3 1 for limits of operation regarding coolant temperature 17 1 Venting of the gear box Remove cap from the venting screw Establish a connection between the venting screw...

Page 43: ...Operators Manual 125 MAX DD2 evo Page 42 70 Edition 09 2016 OPERATOR S MANUAL FOR ROTAX ENGINE TYPE 125 MAX DD2 evo...

Page 44: ...11 Fuel pump 45 2 12 Carburetor 46 2 13 Centrifugal clutch 46 2 14 Overload clutch 46 3 Media for engine operation 47 3 1 Coolant 47 3 2 Battery and battery charging unit 47 3 3 Fuel 49 4 Engine tuni...

Page 45: ...mped from the radiator to the water pump which is driven by the clutch shaft The water pump conveys the coolant through the cylinder and the cylinder head back to the radiator The cooling circuit is e...

Page 46: ...of several layers and has been optimized in the area of air passage and filter efficiency If soiled or during engine maintenance work clean the filter with biodegradable products 2 8 Exhaust system Th...

Page 47: ...he main jet size must be adjusted to the actual conditions according to this manual 2 13 Centrifugal clutch The engine is equipped with a centrifugal clutch operating in an oil bath This clutch separa...

Page 48: ...re charge the battery before and after any operation of the kart Note It is recommended to always carry a charged spare battery The installed battery should be replaced wizh a fully charged battery b...

Page 49: ...xtinguishing red control lamp even after 24 hours of charging indicates that the charging capacity of the battery is diminishing Note A red green blinking of the charging control lamp indicates transi...

Page 50: ...o not smoke or allow naked flames Gasoline is highly flammable and explosive under certain conditions p Warning Never perform mixing and fuelling in closed rooms handle fuel in well ventilated areas o...

Page 51: ...s 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 rotational speed in revolutions per...

Page 52: ...gned to assist users with setting up the recommended main jet based on the ambient conditions and the type of engine The perfect set up can be calculated in two ways either automatically which require...

Page 53: ...ther data needs to be clicked The app will automatically show all potential Max evo engines from which one can be selected by clicking on a certain engine type 3 After all the necessary information ha...

Page 54: ...g up the carburetor like float height position of the jet needle or the air adjustment screw can be found By clicking the small red X underneath the info button you can return to the home screen For f...

Page 55: ...125 MAX DD2 evo Page 54 70 Edition 09 2016 For better understanding and as help for carburetor adjustment the following figure describes the effect of the various adjustments depending on the throttl...

Page 56: ...and ex plosion Attention Do not spill any fuel If fuel is spilled apply drying agent and dispose ecologically Drain the fuel in the float chamber into a suitable clean tray by removing the plug screw...

Page 57: ...d By turning in the adjustment screw pos 31 the air fuel mixture will become richer at idling and by turning out the screw pos 31 the air fuel mixture will become leaner at idling The default setting...

Page 58: ...d gear If these gear ratios are still not sufficient try the next shorter or next longer gear ratio Note When using short gear ratios it may happen that the response behaviour of the engine in 1st gea...

Page 59: ...rry a clutch drum with a primary drive gear and the respective secondary gear for each gear ratio Note To allow easier matching of primary and secondary gears please note that the sum of the last digi...

Page 60: ...changing from 1st to 2nd gear interrupts the ignition relieving the load from the gearbox and thereby makes gear shifting easier and faster Note Gear shifting might not be possible when the engine is...

Page 61: ...allowing gears to engage Check whether the shift paddle aligns with the steering wheel when in NEUTRAL If this is not the case correct the Bowden cable accordingly Note For adjustment of gear shiftin...

Page 62: ...covering the radiator with adhesive tape p Warning The maximum operating temperature of the engine must not be exceeded If the temperature is too high it may result in piston seizure Note Dirt must b...

Page 63: ...g contact with moving components of the kart p Warning Comply with the safety advice of the kart manufacturer p Warning Inspect any part prone to wear tyres bearings etc before each kart event for goo...

Page 64: ...gher P Use two sizes bigger main jet size based on altitude and temperature see section 4 1 P For the first 10 liters of fuel use a mixing ratio of 1 33 3 or 0 3 liter oil per 10 liters fuel P Make su...

Page 65: ...s 1 must be continuously connected This is important for the general function of the engine Variant 1 Additional cable on battery ground A See Fig 9 The additional cable is NOT attached to the ground...

Page 66: ...timing is activated at 9100 rpm Note Isolate the additional cable with an electrical insulating tape to the ground wire so that a possible contact with the engine ground does not affect the function...

Page 67: ...g components and replace if requested piston piston pin and piston pin bearing conrod and conrod bearing main bearings of crankshaft Clean airfilter apply oil replace in case of visible damage X after...

Page 68: ...pment For longer periods out of operation winter time make sure that the engine will be properly preserved Detach carburetor drain fuel from carburetor and close carburetor openings to ensure that no...

Page 69: ...________________ _____________________________________________________________________________ _____________________________________________________________________________ ___________________________...

Page 70: ...____________________________________________________ _____________________________________________________________________________ _____________________________________________________________________...

Page 71: ...eaded fuel of minimum octane level of 95 ROZ resp 91 MOZ 2 STROKE OIL Fully synthetic XPS Kart Tec OIL IN FUEL MIXING RATIO During break in 1 33 3 oil During normal use 1 50 2 oil COOLING SYSTEM 0 90...

Page 72: ...GmbH Co KG Rotaxstrasse 1 4623 Gunskirchen Austria T 43 7246 601 0 F 43 7246 637 0 www rotax com www rotax kart com R and TM are trademarks of BRP Rotax GmbH Co KG 2016 BRP Rotax GmbH Co KG All rights...

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