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

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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

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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

BRP-Rotax

INSTALLATION MANUAL

Effectivity: 125 MAX DD2 evo INTRO

Page 5

Edition: September 01 2019

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