How To Change The Gearing On Your Rotax DD2 Engine - POWER REPUBLIC

In this week's video we show you how to gearing on your Rotax DD2 engine, the easy way.
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[@p.c.h.6721]

Thank you , I just bought a DD2 and I was wondering how to do that!!

[@PowerRepublic]

Silvana H. Santos no problems my friend. What gears are in your engine ? I think they come standard here in Australia with 35’s

[@p.c.h.6721]

Power Republic Sorry I just realized that you wrote back to me. I bought my DD2 from the world championships in Brasil (DD2 with Birel Art chassis) and it came with a 35 gear. It drives really well, I love it! Thanks for all the great videos.

[@antoniomerinoblanco4817]

Rotax says that recommended torque for screw are 22Nm for M8 screws and and 10Nm for M6 screws. Kept uploading videos I learn a lot.

[@PowerRepublic]

Hey Antonio, thanks for the great feedback.

[@samrichardson3128]

Could you tell me if the bearing in the clutch drum needs some lubricating grease like the other Rotax engines or is the oil doing the job? Thanks for all the amazing vids Sam

[@alvarobenaventec.7154]

Great video, as always!

[@PowerRepublic]

Thanks for the positive vibes!

[@distinguishedgentleman01]

Hi guys great work with the Channel:) I was wondering if you guys can make a video About what to do when the clutch/gears starts to slip

[@PowerRepublic]

Hi Laz, are we taking DD2 or regular max?

[@distinguishedgentleman01]

I am so sorry :). Rotax DD2 I have a pre evo, does it differ in the gearbox?

[@distinguishedgentleman01]

To be quite honest, when I pick the kart up, the tiers spin with the axel, but as soon as I put her down and put her in 1st she won’t move, and when she does move it’s hardly a inch

[@PowerRepublic]

laz163 I think that might be terminal my friend. First up check the clutch shoes. They are under the drive Sprocket that should just slide off once you remove the gearbox cover. Then you will need to check you input shaft of crank drive nut for damage or failure. This one might be a job for your local pro go kart mechanics. Let me know how you go.

[@michaelbarrett3258]

Hi mate awesome channel I’ve learnt so much from the videos What gear set are you running at Ipswich ? And main jet pre evo DD2 Cheers

[@Jmasta7]

Hi Power Republic!! Thanks so much for the awesome video, helped me a lot since I just bought a DD2 engine myself. Was wondering what type of fluid to use for these DD2 EVO gears? I am in the USA and having an extremely hard time getting my hands on a bottle of the official XPS DD2 gear oil -- would likely cost me around $100 USD with international shipping just for 1 liter of it! Any known good alternatives? I know 15W-40 engine oil works for the senior max motors but wasn't sure for the DD2.

[@PowerRepublic]

not sure as we use the XPS but I think Maxima Kart Gearbox oil should do the trick, I think that is from the USA.

[@Jmasta7]

@@PowerRepublic Looks like exactly what I need, never heard of it surprisingly! Thanks so much for the tip, you guys are legends.

[@PowerRepublic]

@@Jmasta7 👍

[@Jmasta7]

@@PowerRepublic You know just one more question about this, so according to the video (3:48) the gear sets apparently are 36-61, 37-60, etc... is it as simple as a 1 tooth increase in the front sprocket translates to 1 tooth less on the rear sprocket? Is there any kind of chart that denominates what each gear should be paired with? Seems that it is important to marry these front sprockets up with the matching gear to make the set so I would like to get it right. Thanks!

[@PowerRepublic]

@@Jmasta7 yeah they have to match as a set or they won't mesh. and yeah to gears last numbers have to add up to 7

[@zachgordon4981]

Hi, i compete in rotax max light division at the moment I have been for about 1 year I am wondering if I should keep competing in the rotax Max more or upgrade to the dd2 will the dd2 let me progress with my racing a lot more in terms of hopefully making it a career one day ?

[@PowerRepublic]

Hi Zach, the DD2 are an awesome piece or kit. As for your career, they are more like some race cars as they have the front brakes, gears to select and they have more power. I say go for it for a at least 1 season and report back with what you find!

[@charliepedersen1900]

Hi I know this isn't the right video to ask this question, but I could not fint a video about jetting in the rotax dd2 evo. I sometimes find it hard to chose the right jetting. I know that I have to think of humidity, temperatur and air presure. Do you know if there's a chart that I can use? I haven't been able to fine one online. I'm a big fan of your video btw - always very helpful.

[@PowerRepublic]

Hey Charlie, awesome, glad you like them. I don't use the App my self. The modern EVO engine series jet within one or two sizes for almost all conditions IMO. have you watched our dellorto set up videos??

[@charliepedersen1900]

Thanks for the respons. I'll definitely have a look at the dellorto videos as well.

[@Jmasta7]

Hey man I have a DD2 and I bought a 7 dollar app on the play store it tells you all good settings based on GPS location. App is called Jetting for Rotax max EVO. but in general a 135 main jet is ok for 70-80 Fahrenheit I also live in NY for elevation reference. Needle position 4 is ok as well.

[@p.c.h.6721]

Hi! 2 questions please ,1) I need to remove my DD2 engine from the chassis, any advice, is that difficult to do? 2) Have you ever tried the 140cc cylinder on a DD2, does it improve the power considerably, or there’s not much difference with the standard 125cc cylinder, my son is driving me crazy about the 140cc cylinder. Thanks in advance.

[@PowerRepublic]

its not really that hard, other than the first time. I have one to do in the next few weeks and will video the install for you. 2) I havent used the 140cc kit, I only just heard about it the other day. I imagine it would be as awesome as going from 100cc to 125cc!!!!

[@p.c.h.6721]

Power Republic Thank you so much, I look forward to the video. I did buy the 140cc cylinder two days ago, haven’t tried it yet, I’ll let you know how it goes. Cheers!

[@PowerRepublic]

Oh yeah, that sounds like fun. Maybe go up a couple of main jets to run it in and practise with?

[@p.c.h.6721]

Power Republic Yes, that’s what I was told, to go up a couple of jets when I use the 140cc cylinder, the last thing I need is to seize the engine , that would be terrible. Thank you so much! We’ll see how it goes.

[@Mdgaming_01-i6l]

question, do i have to replace the gasket when i change the gears? or is this gasket reusable

[@PowerRepublic]

reusable unless you damage it when removing the gear case.

[@mrpoopybutthole6314]

Hey man I’m currently racing in KA3 and I’m a single race meet away from getting my B grade license. I’m stuck between DD2 and KZ3 (KZ2) class which is the 6 speed class. What do you think? As far as retrofitting a DD2 would be easier no? Because I don’t have to fit (and weld tabs) for the shifter linkages. Thanks for your advice

[@PowerRepublic]

The DD2 chassis and KZ cassis are different cause the DD2 doesn't have any bearing hangers on the engine side of the kart. so you will have to choose either DD2 or KZ2 and stick with it until you want to change class again. I reckon I would step into the DD2 first for 12 -18 months. Then once you have mastered the front brakes and extra power, step up in the KZ.

[@impulse4104]

Do you know where I can find the water pump seals for the dd2?

[@PowerRepublic]

they are behind the black water pump cover on the brake side of the engine

[@honeybadger3741]

Hey. Me and my dad bought a go kart DD2 and the go kart has been in the championships before and one thing I didn’t realise at the start when I first drove it was if the go kart maxed out on 13000 rpm and would only go up to 111 kph we only realise in the garage that the go kart had something wrong with it and wouldn’t go faster than 111 kph and capped at 13000 rpm. Can you maybe help us out because we tried looking for a problem but couldn’t find it anywhere. Do you maybe know what could be wrong ?

[@PowerRepublic]

Have you changed the gear set to 35 or 36’s? Also check the main jet isn’t too rich. Maybe check and get back to me

[@Alexandros27]

i dont understand english. from brazil. what is the original set ( gear number of teets) for this engine ?

[@PowerRepublic]

35 gears come standard

[@larsborgmann7797]

Do I lift when i shift in a dd2

[@PowerRepublic]

You can if the shift cut isn't adjusted properly. But you should be able to flat shift