Rotax 125 MAX DD2 evo Bedienungs- und Wartungshandbuch
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
General information
BRP-Rotax recommends products of the following companies:
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.
Preface
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, we exclude any liability.
We reserve all rights including technical modification and possibility of errors.
Reprinting, translation or copies in whole or in part, are authorized only after written permission by
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 any obligations.
Engine performance may vary depending on, among other things, general conditions, ambient
temperature and altitude.
Effectivity: 125 MAX DD2 evo Content
Page 1
Edition: September 01 2019
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 – Finishing work
BRP-Rotax
INSTALLATION MANUAL
Notes
Page 2
Edition: September 01 2019
Effectivity: 125 MAX DD2 evo
Edition /Rev. 0
NOTES
BRP-Rotax
INSTALLATION MANUAL
BRP-Rotax
INSTALLATION MANUAL
Chapter: INTRO
Preface
For information regarding repair of the engine 125 MAX DD2 evo contact an authorized
service center or consult the workshop manual
(available on internet under 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.
Contents
This Installation Manual contains instructions for all the installation work on the ROTAX®-
Engine Type 125 MAX DD2 evo.
General
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.
We reserve all rights including technical modification and possibility of errors. Reprinting,
translation or copies in whole or in part, are authorized only after written permission by
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.
Engine performance may vary depending on, among other things, general conditions,
ambient temperature and altitude.
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 and
company stamp.
NOTE
The data entered in the registration document and/or engine identity card is
required for the verification of a warranty claim. Without a completely filled-in
engine identity card, no warranty claim will be granted.
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.
Effectivity: 125 MAX DD2 evo INTRO
Page 1
Edition: September 01 2019
BRP-Rotax
INSTALLATION MANUAL
Symbols used
This Manual uses the following symbols to emphasize particular information. This
information is important and must be observed.
mWARNING
Identifies an instruction, which if not followed may cause injury or endanger the
life of the driver, mechanic or third party.
ATTENTION
Identifies an instruction which, if not followed may cause injury or endanger the
life of the driver, mechanic or third party.
ENVIRONMENTAL NOTE
Environmental notes give you tips on environmental protection.
NOTE
Indicates supplementary information which may be needed to fully complete or
understand an instruction.
✔Denotes a checking operation
TIP This information gives you additional advice and tips
INTRO
Page 2
Edition: September 01 2019
Effectivity: 125 MAX DD2 evo
BRP-Rotax
INSTALLATION MANUAL
Safety information
mWARNING
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.
mWARNING
Non-compliance can result in serious injuries or death!
Engine operation is permitted only with equipment supplied by ROTAX®
mWARNING
Non-compliance can result in serious injuries or death!
Besides the engine-specific installation advice, also take note of information from the
respective chassis manufacturer.
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.
mWARNING
Non-compliance can result in serious injuries or death!
Before starting with installation and operation of the engine, observe the installation
instructions and Operator’s Manual and follow all instructions.
mWARNING
Non-compliance can result in serious injuries or death!
This engine performs better as comparable products
Effectivity: 125 MAX DD2 evo INTRO
Page 3
Edition: September 01 2019
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. Take the engine out of the box.
Accessory box
The accessory box contains all required parts for running the engine. Lay down all parts,
so you have a good overview of the parts. Check, if all parts of the following table are
delivered.
INTRO
Page 4
Edition: September 01 2019
Effectivity: 125 MAX DD2 evo
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