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Rotax 125 MAX DD2 evo User Manual

Rotax 125 MAX DD2 evo
120 pages
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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
Installation instructions and
Operator‘s Manual

Table of Contents

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Rotax 125 MAX DD2 evo Specifications

General IconGeneral
Bore54 mm
Stroke54.5 mm
Intake SystemReed valve
Displacement124.8 cc
Max Power34 hp (25 kW) at 11, 500 rpm
Cooling SystemLiquid-cooled
IgnitionDigital CDI
Starting SystemElectric

Summary

Engine Installation

Engine Installation with Engine Brackets

Steps for mounting the engine using engine brackets and specific torque settings.

Direct Attachment of the Engine to Chassis

Instructions for directly mounting the engine to specially prepared chassis.

Fuel System Installation

Installation of the Bowden Cable for Carburetor Control

Procedure for installing and adjusting the Bowden cable for throttle control.

Electric System Installation

Installation of the Wiring Harness

Guidance on routing and connecting the vehicle's wiring harness.

Cooling System Installation

Installation of the Radiator

Detailed steps for mounting the radiator to the chassis with proper alignment.

Installation of the Intake Silencer with Integrated Airfilter

Procedure for assembling and attaching the intake silencer and air filter.

Exhaust System Installation

Installation of the Exhaust System

Steps for mounting the exhaust system to the engine and chassis securely.

Accessories Installation

Installation and Connection of the RAVE Control Unit

Procedure for connecting the RAVE control unit's hose package.

Assembly of Paddle Shift System

Instructions for assembling the paddle shift system components.

Finishing Work

Check Oil Level in Gearbox

Procedure for checking and topping up the gearbox oil level.

Operating Fluids and Battery

Fuel Specifications and Mixture Ratio

Required fuel type, octane level, and correct two-stroke oil mixture ratio.

Engine Calibration

Carburetor Calibration Guide

Procedure for setting the carburetor based on ambient conditions and altitude.

Change of Carburetor Main Jet

Steps for changing the carburetor's main jet to optimize performance.

Operation of the Gear Box

How to operate the 2-speed gearbox, including shifting techniques.

Adjustment of Gear Shifting

Correct adjustment of the gear shifting mechanism for optimal performance.

Engine Operation

Engine Start Procedure

Steps for starting the engine, including choke and power button operation.

Running-in Procedure for the Engine

Essential steps for the engine's break-in period to ensure longevity.

Maintenance Schedule for Engine Components

Recommended maintenance intervals and tasks for engine components.

Operating Limits

Specified coolant temperature ranges and operational limits for engine performance.

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