OPERATOR‘S

MANUAL
125 DD2 MAX EVO

KART ED. 03/2021

PART NO. 297732
ROTAX-KART.COM
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
 BRP-Rotax
Operators Manual

Table of Content

Chapter INTRO – GENERAL INFORMATION

Chapter 1 – Technical Description
Chapter 2 – Operating fluids and battery
Chapter 3 – Engine calibration
Chapter 4 – Engine operation
Chapter 5 – Preservation and transport

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Content
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NOTES

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Chapter: INTRO
GENERAL INFORMATION
Preface Before operating the engine, read the Operators Manual carefully.
If any passages of the Manual are not clearly understood or if you have questions, please
contact an authorized Distribution or Service Center for ROTAX®-kart engines.
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.
Contents This Operators Manual contains instructions about how to operate the ROTAX®-Engine
Type 125 MAX DD2 evo.
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.

m CAUTION
Indicates a hazard situation which, if not avoided, could result in minor or
moderate injury.

ATTENTION
Indicates an instruction which, if not followed, could severely damage vehicle
components or other property.

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

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INTRO
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TIP This information gives you additional advice and tips

m WARNING
This vehicle may exceed the performance of other vehicles you may have ridden. Take
time to familiarize yourself with your new vehicle.

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INTRO
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Chapter: 1
TECHNICAL DESCRIPTION

TOPICS IN THIS CHAPTER

Design of the ROTAX engine 125 MAX DD2 evo.......................................................................................2
General ................................................................................................................................................2
Cooling circuit .......................................................................................................................................2
Balance gear.........................................................................................................................................3
Ignition unit ...........................................................................................................................................3
Electric starter .......................................................................................................................................3
Electro pneumatically exhaust timing control ...........................................................................................3
Intake silencer.......................................................................................................................................3
Exhaust system.....................................................................................................................................4
Gearbox ...............................................................................................................................................4
Electronic Shifting Assistant (ESA) .........................................................................................................4
Fuel pump ............................................................................................................................................4
Carburetor ............................................................................................................................................4
Centrifugal clutch ..................................................................................................................................5
Overload clutch .....................................................................................................................................5

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DESIGN OF THE ROTAX ENGINE 125 MAX DD2 EVO

Figure 1.1

GENERAL
The Rotax 125 MAX DD2 evo engine is a single cylinder two stroke engine with reed valve
controlled inlet and 125 cm3 displacement. Mixture lubrication is achieved by adding oil to
the gasoline in a specified mixing ratio.
The power transmission to the rear axle takes place via a manually shift able integrated 2-
speed gearbox.
________________________________________________________________

COOLING CIRCUIT
The coolant is pumped from the radiator to the water pump which is driven by the clutch
shaft. The water pump conveys the coolant through cylinder and the cylinder head back to
the radiator.
The cooling circuit is equipped with a thermostat (opening point 45 °C / 113 °F). It assures
that the engine reaches its operating temperature quickly and keeps it at a relatively con-
stant level.
The thermostat is integrated in the cylinder head cover.
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BALANCE GEAR
The balance gear is mounted on the primary shaft and rotates counter-wise to the crank-
shaft to reduce engine vibration.

________________________________________________________________

IGNITION UNIT
The control of the ignition system is exercised by the ECU (Engine Control Unit). To calcu-
late the ignition timing, an engine speed sensor is needed, which is installed on the bottom
of the engine housing. There is no manual adjustment of the ignition system necessary
and/or possible.
If the power button is pressed once, the ignition is activated and the button lights up. To
start the engine, it only needs to be pressed once again. To turn off the engine as well as
the ignition, proceed in reverse order.

________________________________________________________________

ELECTRIC STARTER
By pressing the "START" button, the circuit between the battery and the electric starter will
be closed by a relay. The electric starter drives the starter gear on the crankshaft via an in-
termediate gear with free wheeling, until the engine starts to run. An automatic switch re-
set from "START" to "ON" is integrated.

________________________________________________________________

ELECTRO PNEUMATICALLY EXHAUST TIMING CONTROL

The engine type 125 MAX DD2 evo is equipped with an electro-pneumatic exhaust con-
trol. The E-RAVE (Electronic ROTAX Adjustable Variable Exhaust) system is controlled by
an electro-pneumatic valve via the ECU. The vacuum required is provided by the engine
crankcase.
If the engine is running at idle speed or below the opening point of the E-RAVE system
(between approximately 8000-9000 rpm) the exhaust valve is closed. With the engine run-
ning, it closes or opens the electro-pneumatic valve of the exhaust depending on the
speed and, therefore it provides optimum performance characteristics.

________________________________________________________________

INTAKE SILENCER
The intake silencer incorporates an air filter to clean the intake air. The intake silencer has
been designed for optimum reduction of air intake noise level and represents a tuned sys-
tem with the engine.
The air filter consists 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 biode-
gradable products.

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EXHAUST SYSTEM
The exhaust system is designed as resonance system with an after-muffler and repre-
sents a tuned system with engine.

________________________________________________________________

GEARBOX
The power transmission to the rear axle takes place via manually shiftable integrated 2-
speed gearbox and not as usual, via a maintenance intensive chain drive. Changing the
gear activates the gear shift fork as well as a shifting sleeve, which slides on the hollow
shaft between the 1st and 2nd gear and then engages in the respective idle gear.
The gear is kept in position by an index pin, which keeps the gearshift fork in the selected
position, 1st gear, neutral or 2nd gear.
To allow shifting into 2nd gear without lifting the foot from the gas pedal, the ignition is cut
off for a moment when actuating the shifting paddle.

________________________________________________________________

ELECTRONIC SHIFTING ASSISTANT (ESA)

To optimize the shifting from 1st to 2nd gear, the ignition is interrupted for a short time. This
releases load from the gearset and, gear shifting is faster and less stressful for the
gearset.

________________________________________________________________

FUEL PUMP
The fuel pump functions due to the alternating negative pressure and overpressure in the
crankcase and sucks fuel from the fuel tank into the carburetor via the fuel pump.
In the suction side of the fuel pump (between fuel tank and fuel pump) a fuel filter is in-
stalled to prevent contamination of the fuel pump and carburetor.

________________________________________________________________

CARBURETOR
The carburetor (DELL’ORTO VHSB 34) is a slide type carburetor with float system. The
standard main jet is suitable for almost all operating conditions. For extreme operating
conditions, the main jet size must be adjusted to the actual conditions according to this
manual.
________________________________________________________________

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CENTRIFUGAL CLUTCH
The engine is equipped with a centrifugal clutch operating in an oil bath. This clutch sepa-
rates the engine from the gearbox at less than 2.500 rpm. Only at an engine speed of ap-
prox. 4.000 rpm. the centrifugal clutch is completely engaged.
________________________________________________________________

OVERLOAD CLUTCH
The engine has a mechanical overload clutch, which is installed on the rear axle. It is to
protect the crankshaft from hard shocks from the drive components which are not usual
during normal operation (e.g. the blocking of the rear axle).

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NOTES

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Chapter: 2
OPERATING FLUIDS AND BATTERY

TOPICS IN THIS CHAPTER

Coolant....................................................................................................................................................2
Battery.....................................................................................................................................................3
Battery charging unit...............................................................................................................................4
Fuel .........................................................................................................................................................6

See also table “important information (summary)” in Chapter 5.

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COOLANT
Use only distilled water as engine coolant. If the kart is stored below the freezing tempera-
ture of water, make sure to drain the water from the cooling radiator and engine
completely.

Step Procedure
1 Open radiator cap and fill the system with coolant.
Small radiator: approx. 0.52 liter / 0.137 gal for the complete cooling system
Big radiator: approx. 0.7 liter / 0.185 gal for the complete cooling system
2 Close radiator cap.

ATTENTION
Observe the storage conditions.
Storage below the freezing temperature of water could lead to a damage of the cooling
system and the engine.

ATTENTION
Exceeding the engine temperature could lead to serious engine failure.
The engine temperature should not exceed 85 °C / 185 °F.

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BATTERY
See Fig. Pos. 1: Charging connector, TYPICAL.
The power for the ignition unit and electric starter is only supplied from the battery. With a
fully charged battery of 12 V and 6.5 Ah, the engine can be started approximately one hun-
dred times and operated over a period of approximately five hours. With the battery volt-
age decreasing to approximately 11 V the point will be reached when the battery voltage
is too low to generate a spark for ignition.

ATTENTION
The lifespan of the battery will be drastically reduced by exhausting the battery
completely.
Fully 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 with a fully charged battery before it is completely exhausted.
NOTE
If the spark plug is removed, to check if the battery still generates a spark, consid-
er the following: with the spark plug removed it is easier for the electric starter to
crank the engine, which reduces current absorption of the electric starter, result-
ing in battery voltage adequate to generate a spark. If the spark plug is fitted
again, it may happen that the engine does not start.
NOTE
To charge a battery, the delivered battery charging unit specified by ROTAX®
should be utilized (battery charger part no. 265148). When using the lithium bat-
tery available as spare part, the battery charger Optimate Lithium (part no.
581325) is mandatory.
NOTE
To be able to use the battery charger in your home country, please contact your
nearest authorized ROTAX® distributor or one of their ROTAX® Service Centers
to receive an adapter plug or adapter cable, respectively.
NOTE
This battery charger will switch over automatically to maintenance charge as soon
as the target voltage is reached. Therefore overcharging with the result of ruining
the battery will be impossible.

ATTENTION
Use of any other battery charger can impair the battery life or may ruin the battery.

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BATTERY CHARGING UNIT

When charging the battery take note of the following:

Step Procedure
1 Connect battery charger to the charging connector (pos. 1).

Figure 2.1: Pos. 1: Charging connector, TYPICAL

Step Procedure
2 Connect the battery charging unit on 110-230V, 50 - 60Hz power supply.
During the charging procedure, the charge indicating lamp will light up red.
3 At completion of the charging process, the control lamp will change to
green, but the charging current will remain, thus warranting a fully charged
battery.
4 The charging time amounts to approx. 12 hours.

NOTE
The battery charger may be connected to the battery for a longer period, as the
battery takes just the current required to be fully charged.

NOTE
A non-extinguishing 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 transition from main
charging to additional charging and does not signal a faulty battery charger.

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Step Procedure
5 Unplug power supply to battery charging unit.
6 Remove output wires of the battery charger from the battery.
7 The battery is ready again for use.

ATTENTION
In addition to these directives, follow the advice of the battery charging unit
manufacturer.

NOTE
When the battery is charged while not mounted on the kart, use the connector ca-
ble (part no. 266022). If needed, contact your authorized distributor or one of their
ROTAX® Service Centers.
The charging condition of the battery can be estimated by using a commercially available
measuring instrument.
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FUEL
For engine operation, a mixture of unleaded gasoline of at least ROZ min. 95 / 91 (RON
+MON) / 2 and fully synthetic two-stroke oil, mixed at ratio 1: 50 (2% oil) has to be used.

ATTENTION
Carry out a correct running-in procedure.

See Chapter 4 section: Running-in procedure for the engine.

m WARNING
Non-compliance can result in serious injuries or death!
When mixing fuel and fuelling do not smoke or allow open fire. Gasoline is highly flam-
mable and explosive under certain conditions.

m WARNING
Non-compliance can result in serious injuries or death!
Never perform mixing and fuelling in closed rooms, handle fuel in well ventilated areas
only.

m WARNING
Non-compliance can result in serious injuries or death!
Fuel the kart only when engine is not running and the combination switch is at OFF
position.

m WARNING
Risk of fire and explosion!
Make sure that fuel will not splash onto hot engine components or equipment. Always
wipe off any fuel spillage from the vehicle.

m WARNING
Non-compliance can result in serious injuries or death!
Pay attention to the safety advice of the kart manufacturer.

ATTENTION
Possible engine trouble!
Too much oil in the fuel mixture (more than 2%) could lead to engine trouble (e.g. coking
of the exhaust valve, piston ring sticking).

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ATTENTION
Possible engine blow-up!
Insufficient amount of oil in the fuel mixture (less than 2%) could result in e.g. piston
seizure.

ATTENTION
Engine damage and damage to the intake system may occur.
Do not try any different sorts of fuel.

ATTENTION
Before each fuelling, shake fuel container well to ensure adequate mixing of the gaso-
line with the oil.

ATTENTION
Ensure that no contamination enters the fuel tank and the carburetor.

ATTENTION
Unleaded fuel has a limited storage life.
Store only the quantity of fuel in a container which will be needed in the near future.

ENVIRONMENTAL NOTE
Don’t spill fuel. Absorb spilled fuel with appropriate drying agent and ensure ecological
disposal.

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Chapter: 3
ENGINE CALIBRATION

TOPICS IN THIS CHAPTER

ENGINE CALIBRATION............................................................................................................................2
Run-in procedure ..................................................................................................................................2
Performance graphs ..............................................................................................................................2
Carburetor calibration ............................................................................................................................4
Automatic-set-up ...................................................................................................................................5
Manual set-up .......................................................................................................................................8
Change of the carburetor main jet .........................................................................................................12
Choose of gear ratio ............................................................................................................................15
Exchange of gear reduction ratio ..........................................................................................................17
Operation of the gear box.....................................................................................................................19
Adjustment of gear shifting ...................................................................................................................20

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ENGINE CALIBRATION
RUN-IN PROCEDURE

m WARNING
Non-compliance may result in serious injuries or death!
Running-in has to be done with a “long” gear ratio and a rich main jet (2 sizes bigger
than the recommended main jet based on altitude and temperature.

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
1 15 min. up to 10.000 rpm.
15 min. up to 12.000 rpm.
15 min. full load.
2 Reduce the main jet size step by step (e.g. 172 - 170 - 168 ...).

NOTE
Make sure that the coolant temperature reaches a minimum of 55 °C (130 °F).
At cold ambient temperature radiator needs to get partly covered by tape.

PERFORMANCE GRAPHS
In this 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 ro-
tational speed in revolutions per minute (rpm).
For more information, please check the performance data sheets on www.rotax-kart.com.

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Figure 3.1: Performance graphs

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CARBURETOR CALIBRATION
The standard carburetor calibration is for an ambient temperature of 25 °C / 77 °F and
400 m / 1310 ft above sea level. At operation with different temperatures and altitudes, the
main jet of the carburetor has to be changed in accordance with Table 1, to optimize en-
gine performance.

NOTE
For engine operation at an ambient temperature below 10 °C / 50 °F, make sure
not to demand full power before the coolant temperature has reached 45 °C /
113 °F.
NOTE
The warranty by BRP-Rotax will no longer apply, if the carburetor calibration is
carried out improperly and causes engine damage.
The following application for smartphones shows the individual setting of your ROTAX®
125 Max DD2 evo engine:
The ROTAX® Max Jetting Guide is an App for Android™ and iOS devices, designed to as-
sist 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 requires a GPS signal and an internet connection, or manually - which requires
certain knowledge about altitude and weather conditions.
______________________________________________________

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AUTOMATIC-SET-UP
Step Procedure
1 Click on the blue font "Update GPS weather data" button below the weather
information. After a short time the app will automatically provide all the nec-
essary information regarding weather and geographical position.

Figure 3.2

Step Procedure
2 To select your engine type for the calculation click on one of the engine
models, MICRO MAX is selected by default. You can swipe left and right to
see all engine types available.

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Figure 3.3

Step Procedure
3 Having completed all fields of the weather data and having selected the en-
gine type you can press the white "CALCULATE" button on the bottom of
your screen to find out the suitable jet for your engine type and
environment.

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Figure 3.4

Step Procedure
4 Now the recommended main jet value will be provided. In case a second
calculation needs to be made, you can start over by simply pressing the
button saying “RESET” next to the calculated value.

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Figure 3.5

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MANUAL SET-UP
Step Procedure
1 In case no GPS signal or internet connection is available, the necessary da-
ta needs to be added manually, which of course requires knowledge about
current weather conditions at the race track as well as the altitude. By click-
ing on the empty space next to “Temperature”, “Altitude”, “Atmos. Pressure”
and “Humidity”, you are able to enter the required information. In terms of
“Atmos. Pressure”, the atmospheric pressure at sea level has to be entered,
usually the barometer shows the actual level.
2 As a second step, the engine type of the kart needs to be selected. There-
fore, the button underneath the weather 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.

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3 After all the necessary information has been provided and selected, you on-
ly need to click the circular red button saying “CALCULATE” at the bottom
of the screen.
4 Now the recommended main jet value will be provided. In case a second
calculation needs to be made, you can start over by simply pressing the
button saying “RESET” next to the calculated value.

Additional Information

• In case values are being entered manually, the provided numbers will turn from white to
red if they are considered to be unrealistic.

• Depending on their preference, users can decide if they would like to use the metric or
the imperial system. You can change between Celsius and Fahrenheit by simply clicking
on the small °C or °F next to the value for temperature. The same works with feet and
meter, where you can just click on the small m or ft located next to the value for altitude
in order to change between the systems.

Figure 3.6

• In the top right corner, you can find a button called “INFO”. By clicking this button, addi-
tional information about the app as well as setting up the carburetor like float height, po-
sition 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.

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Figure 3.7

Please scan the following QR-code for a detailed instruction video:

Figure 3.8: QR- code

App Download

Please scan the following QR-code for your mobile device:

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Figure 3.9: QR- code, Android device

Figure 3.10: QR- code, iOS device

For better understanding and as help for carburetor adjustment, the following figure de-
scribes the effect of the various adjustments, depending on the throttle position.

Figure 3.11: Various adjustments

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CHANGE OF THE CARBURETOR MAIN JET

To change the carburetor main jet, proceed as follows:

Tools required:

• Open-end wrench 19 mm
• Flathead screwdriver

NOTE
The carburetor must not be removed from the engine in order to change the
jetting.

m WARNING
Non-compliance can result in serious injuries or death!
Handle fuel in well-ventilated areas only.

m WARNING
Non-compliance can result in serious injuries or death!
When handling with fuel, do not smoke or allow open flames. Gasoline and gasoline va-
por are highly flammable and explosive under certain conditions.

m WARNING
Risk of fire and explosion!
Make sure that fuel will not splash onto hot engine components or equipment. Always
wipe off any fuel spillage from the vehicle.

ENVIRONMENTAL NOTE
Don’t spill fuel. Absorb spilled fuel with appropriate drying agent and ensure ecological
disposal.

Step Procedure
1 Drain the fuel in the float chamber into a suitable clean tray by removing the
plug screw (pos. 27) and gasket ring (pos. 26).

NOTE
The fuel drained from the float chamber may be poured back into the
fuel tank.
2 Remove the main jet (pos. 15) and the main jet cup (pos. 14).

NOTE
The size of the jet is imprinted on the face of the main jet.

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Step Procedure
3 Select the appropriate size of main jet, refer to ROTAX® Max Jetting Guide.
4 Install the main jet cup (pos. 14) in position and fit the corresponding main
jet (see ROTAX® Max Jetting Guide).
5 Fit and hand-tighten the plug screw (pos. 27) and gasket ring (pos. 26).

8
9
10
7

12 11
5
4
3 Needle position

6 1
2
3
2 4
5

31
30
35
36
32
33
34
20
19 13
16
18

14
15 17
21
22
23

24

25
28

29 26
27
K00403

Figure 3.12: Components of carburetor

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NOTE
In a disassembled carburetor, the position of the jet needle (pos. 3) can be
changed. The standard position of the jet needle is ‘position 2’. If the clip (pos. 4)
is set in ‘position 1’ of the jet needle, the full mixture in part and full-load will be-
come slightly leaner. If the clip (pos. 4) is set into ‘position 5’, the fuel mixture will
become slightly richer in the part and full-load range.
NOTE
The fuel filter (pos. 32) is located below the fuel inlet on the carburetor, preventing
contamination from entering the carburetor, which could impair operation of the
carburetor.
Step Procedure
6 Remove the hex. screw (pos. 34) and gasket ring (pos. 33).
7 Pull out the fuel filter (pos. 32) and clean the filter and fuel inlet.
8 Refit the fuel filter (pos. 32), the gasket ring (pos. 33) and hex. screw (pos.
34).

NOTE
When trying to start the engine it, will take a few seconds for the fuel pump to fill
the float chamber and for the engine to start.
NOTE
With the adjustment screw (pos. 36), the idle speed of the engine can be ad-
justed. By turning in the adjustment screw (pos. 36) the idle speed increases and
by turning out the screw (pos. 36) the idle speed will be reduced.
NOTE
With the adjustment screw (pos. 31), the fuel mixture formation can be adjusted.
By turning in the adjustment screw (pos. 31), the air-fuel mixture will become rich-
er at idling and by turning out the screw (pos. 31), the air-fuel mixture will become
leaner at idling. The default setting of the adjustment screw are two full turns and
one quarter of a turn (2 ¼) from inside to outside.
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CHOOSE OF GEAR RATIO

In spite of its 2 gears, the 125 MAX DD2 evo engine offers a broad performance band.
Therefore, the frequent changing of the primary gear ratio is not necessary.

NOTE
It is not possible to change the 1st and 2nd gear individually.
On most of the Kart circuits you will be well served with the standard gear ratio (35/62
which is equivalent to 12/90 for 1st gear and 14/79 for 2nd gear).
If due to the special shape of the circuit (e.g. extremely sharp corners or long straights), it
is deemed necessary, the primary gear ratio can be changed both, a shorter or a longer
ratio.
If the rpm. range from 9.200 to 12.200 rpm. is not sufficient because of a particular track
shape (extremely long straight), the maximum engine speed of 13.600 rpm. should be
aimed for.

NOTE
A basic requirement for the full use of the speed range between 12.200 to 13.600
rpm. is optimized carburetor jetting (see chapter 4.1. Carburetor calibration).

The acceleration potential between 9.200 and 12.200 rpm. is essentially higher than be-
tween 12.200 and 13.600 rpm. Therefore, it does not always make sense to use this rpm.
range (high top speed on a straight) and to not take advantage of the acceleration poten-
tial of the lower rpm. range (out of sharp corners).
This is a suggestion. The optimum choice can only be found with the exact knowledge of
the race track.
To approach and optimize the reduction gear ratio, the following charts should be helpful.
The optimization procedure regarding the reduction gear ratio for a new race track is ex-
plained step by step by the following example:

Procedure
Start with the standard gear ratio (35/62, equivalent to 12/90 at 1st gear and 14/79 at 2nd
gear).

Based on the following criteria, you must decide, whether a shorter or longer gear ratio is
necessary.
Does the engine reach 12.500 rpm in 2nd gear at the end of the longest straight?

IF YES, proceed Procedure

as follows
Choose the next longer gear ratio (36/61 equivalent to 12/87 in 1st gear and 14/76 in 2nd
gear).

IF NO, proceed as Procedure

follows
Choose the next shorter gear ratio (34/63 equivalent to 11/87 in 1st gear and 14/83 in
2nd gear).
.

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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 behavior of the en-
gine in 1st gear is aggressive and the vehicle handling becomes difficult. For a
good lap time, often a longer gear ratio is helpful to achieve reasonable perform-
ance behavior.

NOTE
To help with the choice of adequate gear ratios, the two charts below illustrate the
traditional gear ratios and the top speeds in [kmh] that can be reached in the re-
spective gear at an engine speed of 12.500 rpm.

Gear ratio 1 st gear

Number Number of Gear ratio Traditional Theoretical max. speed

of teeth of teeth of gear ratio (in km/h / mile/h) (at
primary secondary (in sprocket 12.500 rpm and wheel
drive gear drive gear size) diameter 870 mm /34.25
in.)
32 65 8.65 10 to 87 75 / 47
33 64 8.26 11 to 91 79 / 49
34 63 7.89 11 to 87 83 / 52
35 62 7.55 12 to 90 86 / 53
36 61 7.22 12 to 87 90 / 56
37 60 6.91 12 to 83 94 / 58
38 59 6.61 12 to 80 99 / 62

gear ratio of 1st gear 4.26

(cannot be changed)

Gear ratio 2 nd gear

Number Number of Gear ratio Traditional Theoretical max. speed

of teeth of teeth of gear ratio (in km/h / mile/h) (at
primary secondary (in sprocket 12.500 rpm and wheel
drive gear drive gear size) diameter 870 mm /34.25
in.)
32 65 6.52 14 to 91 100 / 62
33 64 6.23 14 to 87 105 / 65
34 63 5.95 14 to 83 110 / 68
35 62 5.69 14 to 79 115 / 72

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Gear ratio 2 nd gear

Number Number of Gear ratio Traditional Theoretical max. speed

of teeth of teeth of gear ratio (in km/h / mile/h) (at
primary secondary (in sprocket 12.500 rpm and wheel
drive gear drive gear size) diameter 870 mm /34.25
in.)
36 61 5.44 14 to 76 120 / 75
37 60 5.21 14 to 73 125 / 78
38 59 4.98 15 to 75 131 / 81

gear ratio of 2nd gear 3.21

(cannot be changed)

NOTE
To facilitate the change of gear ratio, it is recommended to carry 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 digits of the teeth number must always be 7 or 17 (35 / 62).

EXCHANGE OF GEAR REDUCTION RATIO

Tools required:

• Torque wrench
• Allen key 5 mm
• Allen key 6 mm

At first glance, the exchange of the gear ratio seems to be more complicated than you are
used to. If, however, you follow the hints below, you will notice that the work involved is not
much different.
Step Procedure
1 Lift engine side of the kart and place the vehicle on a trolley.
2 Remove the right rear hub with wheel.
3 Unscrew 4 Allen screws M6x30 (pos. 1), 4 Allen screws M8x70 (pos. 2) and
2 Allen screws M6x40 (pos. 3). Remove the gear cover.

NOTE
If the gear cover is difficult to remove, it can be levered off at the sep-
arating lugs.

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Figure 3.13: Gear cover

Step Procedure
4 Remove the primary drive gear (pos. 4) and secondary gear (pos. 5) and fit
the gear pair of your choice.

NOTE
At re-assembly, proceed in reverse sequence. Tighten the screws to
the following torque settings:
M6: 10 Nm (88 lbf. in.) / M8: 22 Nm (195 lbf. in.)

Figure 3.14: Gear ratio

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OPERATION OF THE GEAR BOX

The ROTAX® 125 MAX DD2 evo is fitted with a 2-speed gearbox that is changed man-
ually via a shifting device. The engine also has an electronic ignition cut-off which when
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 not running as it is not as-
sured that the gear engages.
In principle, the gear shifting is very simple, only some points have to be observed:
Engagement of the 1st gear

ATTENTION
It is prohibited, to rev the engine up in idle mode in order to change engage the
1st gear. This could lead to engine failure.

Shifting from 1st to 2nd gear

• In principle, this is possible at any engine speed (rpm.). The optimum timing for shifting
is at about 12.200 1/min.
• Due to the electronic ignition cut-off, the gas pedal can stay fully activated during the
shifting operation.
Shifting from 2nd to 1st gear
• Due to the high difference in rpm. between the two gears, it is not recommended to shift
down at a speed of over 10.200 rpm.

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ADJUSTMENT OF GEAR SHIFTING

The perfect functioning of gear shifting depends to a great extent on the correct adjust-
ment of the gear shifting mechanism.

NOTE
When the engine is not running, it may not be possible to engage gears, depend-
ing on the position between shifting sleeve and idle gear of the first or second
gear. In this case, turn the rear axle until you find a position allowing gears to
engage.

Step Procedure
1 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 shifting, please follow the instruction of the
chassis manufacturer.
NOTE
If the gearshift cables are excessively tensioned, the gears are hard
to shift.
2 The distance between shift contact and screw head at the gearshift shaft
must be 1,0 – 1,5 mm / 0.04 – 0.06 in. The distance can be adjusted by
turning the Allen screw (pos.1) in or out. See Fig. “Adjusted”

NOTE
If the distance between shift contact and screw head is not correctly
adjusted, the function of the ignition cut-off is not assured. This may
cause gear shifting problems.
NOTE
If changing the gear becomes difficult after some operating hours,
check , whether the retaining plate is bent, replace it with a new one
or try to bend the support back into the correct position.

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Figure 3.15: Adjusted

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NOTES

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Chapter: 4
ENGINE OPERATION

TOPICS IN THIS CHAPTER

ENGINE OPERATING ...............................................................................................................................2
Engine start ..........................................................................................................................................2
Stopping the engine...............................................................................................................................4
Setting of the exhaust valve timing .........................................................................................................5
Maintenance schedule for engine components ........................................................................................8
Operating Limits ..................................................................................................................................10

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ENGINE OPERATING
ENGINE START
Before starting the engine, make sure you have completed all necessary tasks for running
the engine:

✔ Fuel tank full.

✔ Battery charged and connected.

✔ Battery voltage over 12 V.

✔ Carburetor Bowden cable is moving freely and carburetor piston connected in idle
position.

✔ For safety reasons, it’s recommended to put the shifting device in "Neutral" (no gear
engaged).
At engine start proceed as follows:

Step Procedure
1 On a cold engine, pull the choke lever (pos. 1, ) into a vertical position.

Figure 4.1: Choke lever

Step Procedure
2 Press the power button once, the ignition system is activated (light turns
on). Press the button again until the engine starts. See Fig. “Power button”

NOTE
If the engine does not start, repeat the operation after a few seconds
in the same manner.

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Figure 4.2: Power button

Step Procedure
3 After engine start, take choke back until engine idles smoothly without
choke.

m WARNING
Non-compliance can result in serious injuries or death!
Always wear protective clothing for kart operation (helmet, overall, gloves, shoes, neck
and rib guards).

m CAUTION
Non-compliance can result in serious injuries!
Do not touch the engine, the radiator or the exhaust system during and immediately
after kart operation. Risk of burning!

m WARNING
Non-compliance can result in serious injuries or death!
During kart operation, beware of any contact of body or clothing with moving parts of
the kart (drive chain, rear axle and wheels)..

m WARNING
Non-compliance can result in serious injuries or death!
Comply with the safety advice of the engine and kart manufacturer.

m WARNING
Non-compliance can result in serious injuries or death!
Inspect any part prone to wear (tyres, bearings etc.) before each kart event for good
condition, in accordance with the directives of the kart manufacturer.

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ATTENTION
Non-compliance can result in engine damage!
Keep to running-in procedure as directed.

ATTENTION
Operate engine only within the specified limits and intended purpose.

m WARNING
Non-compliance can result in serious injuries or death!
Only get in and out of the kart if engine is not running.

______________________________________________________

STOPPING THE ENGINE

See Fig. Power button

Step Procedure
1 Press the power button and the engine will stop.

NOTE
If electric starter is activated, the ignition system will consume current. This can
cause a deep discharge and damage to the battery.

Figure 4.3: Power button

1 Power button

______________________________________________________

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SETTING OF THE EXHAUST VALVE TIMING

Tools required:

• Allen key 4 mm or Socket wrench 8 mm

The opening time of the exhaust valve is set in the ECU and depends on the engine
speed. However, the ECU allows two different modes of the exhaust valve opening. These
can be selected by connecting an additional cable to the cylinder head cover.

ATTENTION
The ground wire must be continuously connected.
This is important for the general function of the engine.

Variant 1: Additional cable on battery ground

A:
See Ground wire
The additional cable is NOT attached to the ground wire. The control of the exhaust valve
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.

B:
See Ground wire
The additional cable is attached to the ground wire. The control of the exhaust valve timing
is activated at 8800 rpm.

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Figure 4.4: Ground wire

Variant 2: Additional cable on starter relay

A:
See Cable on starter relay.
The additional cable is NOT attached to the ground wire. The control of the exhaust valve
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.

B:
See Cable on starter relay.
The additional cable is attached to the ground wire. The control of the exhaust valve timing
is activated at 8800 rpm.

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Figure 4.5: Cable on starter relay

NOTE
Either variant 1 or variant 2 has been installed in your engine.
______________________________________________________

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MAINTENANCE SCHEDULE FOR ENGINE COMPONENTS

ATTENTION
Non-compliance with the specified maintenance schedule could result in engine
damage.

FREQUENCY NOTES
ENGINE Before After Every Every Every Every
every every 2 5 10 50
opera- opera- hours hours hours hours
tion tion of op- of op- of op- of op-
era- era- eration era-
tion tion tion
Check oil level in X
gearbox
Exchange oil in gearbox after first 5 hours of op-
eration, then inspect
the oil every 5 hours
and change it if
necessary
Clean exhaust valve and X
check if moving freely
Check overflow bottle, X
empty if needed
Tear-down inspection of X Inspect following com-
engine (must be con- ponents and replace if
ducted by an authorized requested: piston, pis-
ROTAX® Service ton pin and piston pin
Center) bearing, conrod and
conrod bearing, main
bearings of crankshaft.
Clean airfilter, apply oil, X after each rainy ses-
replace in case of visible sion, use air filter
damage cleaner kit
Visually inspect connec- X right after every
tions between engine collision
and carburetor and check
fit and tightness of intake
silencer
Visually inspect fuel filter X
regarding dirt, replace if
needed
Replace fuel filter X

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FREQUENCY NOTES
ENGINE Before After Every Every Every Every
every every 2 5 10 50
opera- opera- hours hours hours hours
tion tion of op- of op- of op- of op-
era- era- eration era-
tion tion tion
Renew damping material X
in after muffler of exhaust
system
Check fit and tightness of X
exhaust
Inspect for oil or water on X right after every
the leakage bore at the collision
crankcase
Verify a tight fit and non X right after every
leakage of radiator hoses collision
and clamps at engine
and radiator
Replace spark plug X as requested
Dirt catching groove on X
secondary gear
Overload clutch X
inspection
RAVE X Clean hoses with com-
pressed air.

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OPERATING LIMITS
Operating the engine is only permitted under following conditions:
Recommended coolant temperature rang: 45 °C – 85 °C (113 °F – 185 °F).

ATTENTION
Operating the engine at a too low temperature could result in piston seizure.
The engine is only allowed to be run at peak performance after reaching the specified
operating temperature.

NOTE
If the engine does not reach the minimum specified operating temperature due to
the low ambient temperature, then the cooling efficiency of the radiator must be
reduced by partially covering the radiator with adhesive tape.

ATTENTION
Non-compliance can result in engine damage!
The maximum operating temperature of the engine must not be exceeded. If the tem-
perature is too high, it may result in piston seizure.

NOTE
Dirt must be cleared from the lamination of the radiator at regular intervals to
achieve the best cooling performance.
______________________________________________________

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Chapter: 5
PRESERVATION AND TRANSPORT

TOPICS IN THIS CHAPTER

Preservation and transport......................................................................................................................2
Preservation of engine and equipment ....................................................................................................2
Transport of the kart...............................................................................................................................2
IMPORTANT INFORMATION (SUMMARY).............................................................................................3
Notes ...................................................................................................................................................4

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PRESERVATION AND TRANSPORT

PRESERVATION OF ENGINE AND EQUIPMENT
For longer periods out of operation (winter time), make sure that the engine will be properly
preserved.

Step Procedure
1 Detach carburetor, drain fuel from carburetor and close carburetor openings
to ensure that no dust or dirt can enter.
2 If the vehicle gets stored at temperatures below freezing, drain the entire
cooling system and clean the cooling circuit with pressure air.

ATTENTION
Not following this may lead to engine damage.

Step Procedure
3 Close intake and exhaust port of engine with adhesive tape so that they are
airtight.
4 Apply oil on exhaust system to prevent corrosion.
5 Remove battery from the fixture and charge periodically with the specified
battery charger.

______________________________________________________

TRANSPORT OF THE KART

If the carburetor is still filled with fuel, the kart is only allowed to be transported in a horizontal
position.
If the kart is to be transported in a vertical position, the fuel must be drained from the carburetor
first.

NOTE
If the kart is in a vertical position at transport, the remaining fuel in the carburetor
might flow into the crankcase with the result that the engine won’t start at next try.
Step Procedure
1 Remove drain screw on float chamber of carburetor and collect the fuel in a
suitable container.
2 Clean drain screw and refit.

______________________________________________________

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IMPORTANT INFORMATION (SUMMARY)

IMPORTANT Liter GAL. SPECIFICATION RECOMMENDED
INFORMATION BRANDS
FUEL Unleaded fuel of minimum octane level of
95 ROZ resp. 91 MOZ
2–STROKE OIL Fully synthetic XPS Kart-Tec
OIL IN FUEL MIX- During break-in: 1:33 (=3% oil)
ING RATIO During normal use: 1:50 (=2% oil)
COOLING 0.90 0.237 Pure water resp. antifreeze if kart is stored
SYSTEM at temperatures below 0 °C/ 32 °F
GEARBOX OIL 0.150 0.039 Engine oil SAE 15W-40 XPS Kart-Tec
SPARK PLUG see IPC NGK

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NOTES
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Index
A General ................................................................2
Adjustment of gear shifting...................................20
Automatic-set-up...................................................5 I
Ignition unit ...........................................................3
B IMPORTANT INFORMATION (SUMMARY).............3
Intake silencer ......................................................3
Balance gear ........................................................3
INTRO .................................................................1
Battery and battery charging unit ............................3
Battery charging unit .............................................4
M
C Maintenance schedule for engine components ........8
Manual set-up .......................................................8
Carburetor ............................................................4
Carburetor calibration ............................................4
Centrifugal clutch ..................................................5 N
Change of the carburetor main jet.........................12
Choose of gear ratio ............................................15 NOTES ................................................................4
Coolant ................................................................2
Cooling circuit .......................................................2
O
Operating limits...................................................10
D Operation of the gear box ....................................19
Design of the ROTAX engine 125 MAX DD2 evo .....2 Overload clutch.....................................................5

E P
Electric starter.......................................................3 Performance graphs..............................................2
Electro pneumatically exhaust timing control ...........3 Preservation and transport.....................................2
Electronic Shifting Assistant (ESA) .........................4 Preservation of engine and equipment ....................2
Engine calibration .................................................2
Engine operating...................................................2
Engine operation...................................................1 R
Engine start ..........................................................2 Running-in procedure, Run-in procedure ................2
Exchange of gear reduction ratio ..........................17
Exhaust system ....................................................4
S
F Setting of the exhaust valve timing..........................5
Stopping the engine ..............................................4
Fuel .....................................................................6
Fuel pump ............................................................4
T
G Technical Description ............................................1
Transport of the kart ..............................................2
Gearbox ...............................................................4

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