Rotax’s Electric Revolution in Powersports
From ICE Heritage to Next-Gen EV Architecture
Rotax, a subsidiary of BRP and a century-old leader in internal combustion engine design, is accelerating its shift to electrification. After decades supplying 100 kW two-stroke and four-stroke motors to BMW, Aprilia and others, the Gunskirchen factory in Austria now houses an end-to-end electric powertrain line. Following the Ski-Doo electric snowmobile and the Can-Am Pulse and Origin e-motorcycles, Rotax will announce its third electrified adventure vehicle in August, powered by the new REV Gen5 platform. Engineering teams have repurposed existing chassis architectures to accommodate an 800 V electric bus, a 6.8 kWh liquid-cooled battery pack and a 140 kW peak inverter, yielding 140 Nm of torque off the line.
In-House Integration of the REV Gen5 Platform
Rotax’s strategy hinges on vertically integrated development. The REV Gen5 architecture combines a high-efficiency permanent-magnet synchronous motor (PMSM), SiC MOSFET inverter and modular cell packs—all designed, tested and assembled under one roof. Continuous power output reaches 80 kW, with regenerative braking capable of recapturing up to 15 kW. Key specifications:
- Battery chemistry: NMC 811 cells in potted modules, volume energy density of 260 Wh/L
- Cooling system: dual-loop liquid cooling for motor and pack, maintaining junction temperature below 95 °C
- Control electronics: redundant automotive-grade microcontrollers, ISO 26262 ASIL B functional safety
- Charging: 20 kW onboard charger, 0–80 % state-of-charge in 45 minutes via CCS2
This level of integration—motor, inverter, BMS and charger all stamped Rotax—offers tight thermal margins, low parasitic losses (<2 %), and simplifies service procedures for dealers worldwide.
Advanced Thermal Management and Safety
Thermal management in a motorcycle or kart is mission-critical; any powertrain fade can risk rider safety. Rotax engineers have implemented a multi-layer liquid cooling jacket around the stator and cell modules, paired with a gas-reverse heat exchanger for ambient conditions down to −20 °C. Silicon carbide power stages operate at junction temperatures up to 175 °C, while an array of 12 NTC thermistors provides real-time BMS feedback. A fail-safe high-pressure cutoff valve and dual busbar isolation monitoring ensure compliance with UNECE R100 regulations.
Supply Chain, Tariffs and Geopolitical Challenges
Rotax’s global sourcing team navigates a shifting tariff landscape—particularly U.S. Section 301 duties on Austrian-made inverters—and the EU’s CBAM carbon border adjustment mechanism. Mario Gebetshuber, VP of Global Sourcing and Operations Powertrain, notes that dual-sourcing silicon carbide wafers and near-shoring cell assembly in Poland have reduced lead times by 30 %. The company also secured strategic partnerships for cobalt-free cathode materials to future-proof battery supply against ESG restrictions.
Future Roadmap: UTVs, Quads and Electric Karts
August’s reveal will likely be an electric side-by-side utility vehicle (UTV) or sport quad, leveraging the same REV Gen5 platform. These power sports are ideal EV candidates thanks to modular battery trays and ample chassis space. Meanwhile, Rotax’s indoor karting center in Linz showcases a fleet of GTX-powered electric karts, each sporting a 40 kW hub motor, torque vectoring and remote telemetry for pro-level lap analysis. Though these karts are currently for demonstration only, Rotax plans a pilot lease program in select European tracks by 2026.
Expert Insights and Industry Response
“Rotax’s move to an 800 V bus and SiC inverter technology is a milestone in EV powersports,” says Dr. Petra Müller, eMobility professor at TU Graz. “They demonstrate that high-performance electric drivetrains can match or exceed ICE benchmarks in power density and reliability.”
Competitors are indeed watching. OEMs such as KTM and Yamaha have signaled their own EV programs in response to Rotax’s rapid deployment, underscoring a broader industry pivot toward electrified off-road and on-road vehicles.
Conclusion: Ready for the Electric Era
Rotax’s shift from two-stroke engines to full electric architectures exemplifies how legacy powertrain experts can lead in the EV transition. By controlling every stage—from cell chemistry to chassis integration—Rotax is poised to set new performance and reliability standards in powersports. Riders can look forward to August’s announcement, which promises another step toward cleaner, quieter and quicker machines that still deliver that signature off-road thrill.