Rotax 122 User Manual

Explains warning, attention, and note symbols used for important information.

General safety instructions for using the ROTAX engine 122 and manufacturer's liability.

Offers conversion factors for length, area, weight, temperature, volume, and torque.

Lists possible causes and remedies for engine starting issues.

Provides troubleshooting steps for poor engine idling performance.

Addresses issues related to reduced engine power at lower RPMs.

Addresses issues related to reduced engine power at higher RPMs.

Discusses causes and solutions for engine knocking or detonation.

Outlines potential causes and corrections for excessive engine vibration.

Identifies reasons for engine overheating and how to resolve them.

Addresses issues related to the engine operating at temperatures that are too low.

Details causes and remedies for a slipping clutch.

Explains how to fix a clutch that does not disengage properly.

Describes how to securely mount the removed engine onto a workbench trestle.

Steps for removing the electric starter from the engine.

Procedure for removing the cylinder head cover and combustion chamber insert.

Instructions for removing the cylinder from the engine assembly.

Steps for removing the piston from the cylinder.

Procedures for disassembling the engine's ignition system components.

Steps for removing the chain sprocket from the engine.

Instructions for removing the engine's oil pump.

Steps for removing the engine's clutch assembly.

Procedures for removing the balance gear and primary drive components.

Instructions specific to removing the kickstarter on RX models.

Steps for removing the engine's water pump.

Instructions on how to separate the crankcase halves.

Procedures for removing the gear shift mechanism and gearbox assembly.

Steps for removing the engine's crankshaft.

Procedures for cleaning, inspecting, and checking the crankcase for wear and damage.

Detailed steps for removing and refitting ball bearings and oil seals on the magneto side crankcase half.

Detailed steps for removing and refitting ball bearings and oil seals on the clutch side crankcase half.

Methods for checking crankshaft for wear, including runout and clearance.

Procedure for measuring and adjusting the crankshaft's axial clearance using shims.

Procedures for removing, cleaning, and checking the exhaust valve and its related parts.

Method for measuring piston-to-wall clearance and checking ring end gap.

Steps for checking the carburetor flange for cracks and porosity.

Detailed steps for venting the oil pump and lines after maintenance or oil replacement.

An exploded view and list of individual components of the ignition unit.

Provides the wiring diagram for the engine's ignition system.

Troubleshooting guide for ignition system malfunctions, including resistance checks.

Procedures for checking the starter gear for wear and proper engagement.

Instructions for checking the chain sprocket for wear and ensuring proper chain and sprocket replacement.

Steps for fitting the crankshaft into the engine, including checking axial clearance.

Detailed instructions for installing the crankshaft using specialized tools.

Procedures for assembling the gearbox components onto the shafts.

Steps for installing the gear shift mechanism, including forks and shift drum.

Instructions for installing the balance shaft into its bearings.

Steps for assembling the crankcase halves with a new gasket.

Instructions for installing the kickstarter mechanism, specific to RX models.

Steps for installing the engine's water pump assembly.

Procedures for installing the balance shaft drive, primary drive, and clutch assembly.

Instructions for mounting the clutch cover, including alignment of the oil pump shaft.

Procedures for adjusting the clutch release lever and checking free travel.

Steps for fitting the reed valve assembly and carburetor flange.

Instructions for fitting the chain sprocket onto the mainshaft.

Steps for installing the electric starter motor onto the engine.