Vortex ROK DVS JUNIOR User manual

ROK DVS JUNIOR
OWNER’S
MANUAL
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TABLE OF CONTENTS
1. GENERAL INFORMATION
1.1. Introduction 3
1.2. Symbols 3
1.3. Safety information 3
1.4. Technical Specifications 4
1.5. Special Technical Specifications for Homologated Engine 4
1.6. Packaging 4
2. ENGINE ASSEMBLING 5
3.STARTING AND BRAKE-IN 11
4.SERVICING YOUR ENGINE 12
4.1. Maintenance Schedule and Adjustments 12
4.2. Torque Chart 12
4.3. Sizes and Measures 12
4.4. Chain 13
4.5. Throttle Cable 13
4.6. Carburettor 13
4.7. Spark plug 13
4.8. Exhaust 14
4.9. Pinion 14
4.10. Cylinder head 15
4.11.Cylinder 16
4.12. Piston 16
4.13.Connecting rod 17
4.14.Bottom end bearings 17
5.ENGINE EXPLODED VIEW AND PARTS LIST 18
6.CONTACTS 39
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1.1. INTRODUCTION
Thank you for your purchasing of a Vortex engine. This manual contains information on how to
help you with getting the best results from your new engine. Furthermore, it will explain you how
to operate your Vortex engine safely and in a proper manner.
Vortex update this manual constantly. All the information in this manual is based on the latest
experience and product information available at the time of writing.
Vortex reserve the right to make any kind of changes to this manual at anytime without notice and
without incurring in any obligation.
This manual shall be considered part of the Vortex engine and should remain with the engine itself
if resold.
1.2. SYMBOLS
Personal injury Mechanical Danger Caution
Pay attention to the symbols of this manual. They alert you of dangerous situations for you or for
your engine.
1.3. SAFETY INFORMATION
- Do not start the engine indoor as garages, trailers, etc. Start the engine in a well-ventilated area
only. Exhaust emissions are hazardous to your health.
- Always wear gloves and proper clothing when working on your engine.
- Use caution when handling fuel. Gasoline is flammable and explosive. When working with fuel,
do not smoke or use it near fire or flames. Avoid any skin contact and inhaling fuel vapors.
- Never touch moving parts when the engine is running.
- During operation both engine and muffler, become very hot. Do not touch them and do not place
anything on them after operation.
- Do not touch the spark plug or cable. It may provoke electrical shocks.
- Understand the operation of all controls and learn how to stop the engine quickly in case of
emergency.
- Do not use the engine without clutch cover and chain protection.
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1.4. TECHNICAL SPECIFICATIONS
Cylinder Displacement (max) 125cc
Cylinder Bore JNR (max) 54.28 mm
Piston Stroke 54.00 mm
Admission system Crankcase reed
Cooling System Liquid
Carburetor Ibea ROK DVS
Ignition System PVL
Ignition Type Digital
Ignition Timing Snr 2.5 mm
Ignition Timing Jnr 3.0 mm
Spark Plug Gap 0.8 mm
Fuel Mixture 5%
Engine Weight 13 kg
-All sizes and measurements in this manual are expressed in metric.
-Always use original Vortex parts and proper tools when working on your engine.
-Proper fuel mix is necessary for optimum engine life and performance.
1.5. SPECIAL TECHNICAL SPECIFICATIONS FOR HOMOLOGATED ENGINE
Vortex Rok DVS is produced in two versions: “Senior” and “Junior” lower powered version.
However, refer to your country homologation file for eventual specific rules and/or sizes.
1.6. PACKAGING
Your engine will be packed in a sealed box with the Vortex logo printed on and a sticker with
model and serial number attached. It will be a second box complete with accessories as
carburettor, muffler, fuel pump, air box, etc.
2. ENGINE ASSEMBLING
In order to perform this job, you will need the following tools:
Cylinder Bore SNR (max) 54.32 mm
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VORTEX FACTORY: Via E. Fermi, 5 –27040 Campospinoso (PV)–ITALY –Tel. [phone]
Compressed air
Allen T-wrench
4 - 5 - 6 mm
Fixed wrench
8 - 10 mm
Flat plier
Hollowed T-wrench
10 mm
1
Compressed air
Unpack the engine and remove any packaging
material on it.
2
6mm Allen T-Wrench
Lay the engine on its side and attach the engine
mount to the engine base with four 8 mm Allen
screws.
3
6mm Allen T-Wrench
Remove the oil filler cap (white arrow) and fill
with 30 cc of engine oil viscosity 40W90
Replace the oil cap and check that the indicator
lamp (yellow arrow) is completely covered with
oil. If it is not, add more engine oil, until
complete coverage of the indicator lamp.
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4
10 mm Fixed Wrench
Attach the braided earth wire end between
engine and silent block and tighten 10mm
locknut.
5
10mm Fixed Wrench
Assemble the second silent block on the
engine. Insert braided wire between the
small and large washers.
6
Place the coil support plate of the
ignition coil in the two silent blocks, and
secure black coil earth in same manner
as above.
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7
Connect a kill switch to steering wheel
(not supplied) to female bullet connector
(pink wire)
8
The coil incorporates RPM control.
(Green coil Snr 16,000) (Blue coil Jnr
14,000)
9
Flat Plier
Remove the plastic cap from the head of the
cylinder.
Spark Plug Wrench
Manually tighten the spark plug at the head of
the cylinder.
Lock it with the key to loosening it then
retighten 2/3 consecutive times; so as to allow
the gasket to enter into seat properly. Now you
can tighten the spark plug properly.
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10
Insert the cable coil in the spark plug and
tighten it.
For safety, we recommend you to secure the
cable coil to the spark plug cap with a plastic
strap.
Place the spark plug cap on the spark plug and
press down the cap fully.
11
Flat Plier
5 mm Allen T-Wrench
a.Remove the plastic cap from the intake
manifold.
b.Remove the carburettor from the box.
c.Making sure that the gasket is in the correct
position insert the carburettor on the studs of
the intake manifold.
d.Secure the carburettor tightening with the
appropriate column nuts supplied.
12
Plug the throttle cable inside the carburettor
throttle control making sure to leave the pawl
of the cable in the special seat on the
carburettor and pass the throttle cable in the
adjuster on the carburettor
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13
Place intake cylinders inside the intake silencer.
14
Pre-drill drain hole no larger than 8mm in the
centreline underneath location as pictured.
Place the DVS air filter connector to the
carburettor inside the intake muffler. You will
find a groove in the sleeve, necessary to fix
properly the rubber boot to the plastic silencer.
15
Check that the rubber boot is fixed properly to
the intake silencer. Incorrect installation may
cause a loss of the intake silencer itself.
16
Flat Plier
Fasten the intake silencer previously assembled
to the carburettor by using the specific metal
clamp supplied.
Secure intake silencer from rotating with zip
ties linked to the chassis or by adapting a
bracket. (not supplied)
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17
Your Vortex engine is now ready to be installed
on the chassis.
3. STARTING AND BRAKE-IN
Only a proper break-in will insure the best performance out of your engine in the future and
guarantee its long and trouble-free life.
Break-in is required when an engine is new or has undergone a major service of the engine's main
parts (piston, cylinder, connecting rod, etc.).
1 Prepare fuel. Vortex engine works with commercial gasoline, leaded or unleaded, as well as
racing fuel, with minimum 95 ROM.
Mix oil and gasoline at 5% (i.e. 50cc of oil every 1.000 cc. of fuel) 20:1
2Use a high-quality synthetic oil specifically made for kart engines. Check any requirements of
your ASN regarding the use of specific brand/type.
3Shake the can thoroughly to mix the fuel and the oil properly. Then fill the gas tank in your kart.
A mistake in measurements could result in engine damage.
4Before making the first start you must fill the carburettor with fuel.
To do this you need to remove the spark plug and spin the rear tires for a few seconds.
Once the fuel line will be completely full, you can reinstall the spark plug and proceed to first
start.
5
To start the engine on the stand wrap a tough belt around the rear tire, press down
decompression button on head, ask helper to apply small throttle opening and pull belt quickly.
Adjust idle stop screw to absolute minimum idle speed if at all.
To stop the engine, press the brake pedal.
6 For proper operation of the cooling system it
is necessary to bleed the circuit by each air
bubble.
To adequately perform this operation proceed
as follows:
Fill the radiator with water and raising the kart
from the radiator side make the excess air
come out. Now top up with more water. Spin
the rear axle for a few seconds to release air
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from the external water pump. If necessary top
up the radiator again. Do not close the radiator
cap.
7
4 mm Allen T-Wrench
Now bleed the cylinder head circuit. Loosen the
screw on the head (yellow arrow) and keep it
open until it comes out only water. Now
tighten the screw and refill the radiator with
water.
At this point you can close the radiator cap.
8Warm up the engine accelerating driving up the motor speed and then let it down again
alternately. Bring the water temperature around 48 -50 ° C before stopping the engine. Do not
accelerate fully but only partially.
Check that the cooling system warms up evenly, in case it warms unevenly proceed again with
the bleeding of the cooling system as described in paragraphs 6-7.
9Once the engine is warmed up and the cooling system works properly, proceed to the track.
10 Run the engine by alternating a few seconds on and off the throttle at ¾ of the opening.
Do not hold the throttle at a constant speed.
Continue this way for 5/6 laps.
11 Check everything on the kart is tighten properly. Be careful, engine and muffler are hot.
12 Return to the track and slowly increase the RPM and duration of the acceleration phase for
10/15min more. Intermittently open the throttle fully and then release it.
13 After 10/15 minutes of brake-in, your engine is ready for competition. During the break-in,
nuts and bolts tend to loosen. Once the engine is cold, check the torque of the exhaust, head,
etc.
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4.SERVICING YOUR ENGINE
Good maintenance is essential for safe, economical and trouble-free operation. Here you will find
a maintenance schedule for your engine. Routine inspection procedures are very simple by using
basic tools. Some service tasks that are more difficult or needs special tools must be performed by
Vortex technicians or qualified mechanics.
Timing schedule periods are only indicative.
4.1. Maintenance Schedule Guide and Adjustments
Carburettor
Cleaning
After every race/heat
Throttle Cable
Check
Every race
Spark Plug
Check
Change
Every Race
After 30 hours
Exhaust
Internal cleaning
Every 10 hours
Piston
Change
Up to 30 hours
Chain
Change
After 10 hours
Cylinder
Honing
Up to 30 hours
Connecting Rod
Change
After 60 hours
Bottom End bearings
Check/Change
After 30/60 hours
4.2. Torque Chart
Cylinder Head Ø 8 mm Nut
18 Nm
Exhaust Manifold Ø 6 mm Bolts
12 Nm (Use threadlocker)
Crankcase Ø 6 mm Bolts
12 Nm
Ignition Nut
28 Nm
Ignition Ø 5 mm Bolts
8 Nm
Nylon crankshaft stuffer
8 Nm (Use threadlocker)
4.3. Sizes and Measures
Tolerance Cylinder/Piston JNR 0.12mm
Timing Snr DVS 2.5 mm
Timing Jnr DVS 3.0 mm
Piston Sizes
W10140/DVS 54.00
W10143/DVS 54.03
W10146/DVS 54.06
W10149/DVS 54.09
W10152/DVS 54.12
W10155/DVS 54.15
Tolerance Cylinder/Piston SNR 0.13mm
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4.4. Chain
Lube the chain every race by spraying chain lube on
the chain while manually rotating the rear wheel.
To replace the chain, loosen the engine and slide it
back to release the old chain from the sprocket.
Reverse the procedure after installing a new chain.
4.5. Throttle Cable
Lubricate the throttle cable each time the engine is
run. Also check, and adjust the cable as needed, to
assure the correct throttle and that the throttle
returns properly and opens full size.
If the cable frays, it must be replaced.
4.6. Carburettor
Cleaning:
Fuel and oil may contain impurities,
and/or residues.
1. Take the intake silencer off the carburettor by
unscrewing the clamp.
2. Disconnect the throttle cable from the carburettor.
3. Take the carburettor off the engine and open the
float chamber by unscrewing the five screws. Clean
the parts, openings and passages with compressed air.
Check the float chamber gaskets and eventually
change them if damaged.
4. Close the float chamber by screwing the five screws
and replace the carburettor in the engine.
5. Clean the inside of the intake silencer.
6. Attach the intake silencer assembly to the adaptor.
7. Tighten it with the specific clamp. Wrong assembly
will cause the loss of the intake silencer.
4.7. Spark Plug
Cleaning:
Oils produce carbon deposits or
residues that make necessary the spark
plug to be checked and cleaned, at
least every 5 hours.
Unplug the spark plug and clean it by using a brass
metal brush.
Setting Plug Gap:
Use a specific spark plug gap gauge to set up correct
gap. Correct gap: 0.8 mm.
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4.8. Exhaust
Cleaning:
Oils produce carbon deposits or
residues that make necessary the
exhaust to be checked and cleaned, at
least every 10 hours.
1. Remove the muffler from the engine by removing the
springs in the cradle between exhaust and manifold.
2. Unscrew the 3 bolts in the exhaust end cap.
3. Warm up the pipe with a heat source and remove
any carbon deposits by means of a metal brush.
4.9. Pinion
Some ASNs allow the use of Z11, Z12
pinions.
Standard pinion supplied by Vortex is
Z12.
1.By the special tool, remove the snap ring of the
pinion.
2.Remove the pinion by pulling the pinion towards the
outside.
3. Place the new pinion on the crankshaft and secure it
by using the appropriate snap ring.
4.10. Cylinder Head
Oils produce carbon deposits or
residues that make necessary the
cylinder head to be checked and
cleaned, at least every race.
Be aware, cylinder head volume may
be changed after the race, carbon
deposits may cause variations on the
cylinder head volume.
In order to perform this job, we highly recommend
taking the engine off the chassis. However, you may do
the job even with the engine mounted.
1. Unscrew the spark plug (16).
2. Unscrew the 6 nuts on top of the head (19) and the 6
washers (20).
3. Remove the head by pulling it up carefully.
4. Clean the combustion chamber using a rag
moistened with gasoline or solvent.
ASSEMBLING
5. Check O-RINGS on top of cylinder.
6. Re-place cylinder head carefully in the 6 studbolts and
check that o-rings (22 –23 –24) are properly fitted in
place.
7. Insert brass washers (20) and manually screw nuts (19).
8. Tighten cylinder head nuts with the proper tool and
torque, respecting the tightening torque.
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4.11. Cylinder
Every 30 hours cylinder must be
honed.
In order to perform this job, we highly recommend
taking the engine off the chassis. However, you may do
the job even with the engine mounted.
1. Take away the muffler from the engine by removing the
springs fixing it to the exhaust manifold.
2. Unscrew and remove the spark plug (16).
3.Unscrew and remove the 6 nuts on top of head (19)
and the 6 washers (20).
4.Remove the head by pulling it up carefully.
5. Unscrew the 4 nuts on top of head.
6. Remove the cylinder with one hand by pulling it up. To
avoid contact with the crankcase, use the other hand to
hold the connecting rod.
Whenever you disassemble the cylinder, we recommend
replacing the cylinder gasket (27).
ASSEMBLING
Check the tolerance between piston and cylinder. Wrong
tolerance may cause serious damage.
6. Place a new gasket (27) into the four studbolts.
7. Insert cylinder into the four studs carefully and tighten
the nuts paying attention to the tightening torque.
8. Check the rubber o-ring (22 –23 - 24) and eventually
re-place them with new ones.
9. Re-place the cylinder head carefully in the six studbolts
(26).
10. Insert brass washers (20) and manually screw the nuts
(19).
11. Tighten cylinder head with the proper tool and
torque.
12. Place a new ex gasket (28) loctite 4 bolts,
torque - 12Nm.
Important: After honing the cylinder and eventually
changing the piston, the engine must go through another
break-in period. See "Starting and Break-in".
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4.12. Piston
Oils produce carbon deposits or
residues that make necessary the spark
plug to be checked and cleaned, at
least every race.
Be aware, cylinder head volume may
be changed after the race, carbon
deposits may cause variations on the
cylinder head volume.
Every 30 hours piston must be
replaced.
In order to perform this job, we highly recommend
taking the engine off the chassis. However, you may do
the job even with the engine mounted.
1. Take away the muffler from the engine by removing
the 2 springs fixing it to the exhaust manifold.
2. Unscrew and remove the spark plug (16).
3. Unscrew and remove the 6 nuts on top of head (19)
and the 6 washers (20).
4. Remove the head by pulling it up carefully.
5. Unscrew the 4 nuts on top of head.
6. Remove the cylinder with one hand by pulling it up. To
avoid contact with the crankcase, use the other hand to
hold the connecting rod.
Whenever you disassemble the cylinder, we
recommend replacing the cylinder gasket (27).
6. Remove the 2 piston pin circlips (32) by squeezing the
ends together with the needle-nose.
7. Hook the connecting rod each side with two fingers.
8. Push the piston pin (33) off the piston by using a
proper tool.
9. In order to avoid damages pull the piston up with one
hand while holding the connecting rod with the other.
10.Take the roller bearing off the connecting rod.
ASSEMBLING
Check the tolerance between piston and cylinder.
Wrong tolerance may cause serious damage.
11.Lubricate and replace a new roller bearing, if needed,
on the connecting rod.
12.Insert a new piston in the connecting rod. The arrow
marked on top of it, must face the exhaust port.
13.Insert the piston pin into the piston.
14.Insert piston pin circlips on each side of the piston.
Be aware, wrong assembly of piston pin circlips may
cause important damage.
15.Fit the piston ring and check both ends close properly
against the brass pin inserted in the piston.
16. Place a new gasket (27) into the 4 studbolts.
17. Insert the cylinder into the 4 studbolts carefully and
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tighten the nuts paying attention to the tightening
torque.
18. Check the rubber O.R. (22-23-24) and eventually
replace them with new ones.
19. Re-place the cylinder head carefully in the 6
studbolts (26).
20. Insert brass washers (19) and nuts manually (20).
21. Tighten cylinder head with proper tool and torque.
Important: After changing the piston, the engine must
go through another break-in
period. See "Starting and Break-in".
4.13. Connecting Rod
Every 60 hours the con-rod and roller cage must be changed.
Due to special tools required, this operation must be performed by the Vortex technicians or
qualified mechanics only.
4.14. Bottom End bearings
Bearings must be checked at 30hrs, and eventually replaced, after 60 hours of use.
Bearings must be assembled or reassembled, with name and type facing each others..
Due to special tools required, this operation must be performed by the Vortex technicians or
qualified mechanics only.
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2
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ROK DVS JUNIOR
POSITION PART NUMBER DESCRIPTION NUMBER
1 W003 Spark plug ngk b10 eg 1
2 W511/10 Roundhead screw m6 x 10 2
3 W10662 Copper gasket 6 x 10 x 1.5 2
4 W530/10FL Nut m8 x 10 6
4 W012/DVS Head sealing nuts 2
5 W560/17 Washer m8.2 x 17 x 1.5 6
6 W10010/DVSJ Engine head DVS Junior 1
7 W629 O-ring cylinder/head 3400 1
8 W620 O-ring head 2237 viton 1
9 W627 O-ring stud bolt or 2031 1
10B W10021/KF3C Complete cylinder engine RAD KF3 1
11 W10043/RVZ Cylinder head studbolt m8 x 56 1
12 W10104/KF2 Cylinder basis gasket 0.2 1
12 W10104/KF3 Cylinder basis gasket 0.3 1
12 W10104/KF4 Cylinder basis gasket 0.4 1
12 W10104/KF5 Cylinder basis gasket 0.5 1
13 W670/RKF Exhaust gasket engine kf 1
14 W10930/RKF2 Exhaust manifold RKF2-DVS 1
15 VTCE6X16 Socket-head screw m6 x 16 4
16C W10140/RKF Complete piston RKF 54.00 1
16C W10143/RKF Complete piston RKF 54.03 1
16C W10146/RKF Complete piston RKF 54.06 1
16C W10149/RKF Complete piston RKF 54.09 1
16C W10152/RKF Complete piston RKF 54.12 1
16C W10155/RKF Complete piston RKF 54.15 1
16D W260/SA10 ‘L’ Piston ring 54.10x1.5 1
16D W260/SA15 ‘L’ Piston ring 54.15x1.5 1
16D W260/SA20 ‘L’ Piston ring 54.20x1.5 1
16D W260/SA25 ‘L’ Piston ring 54.25x1.5 1
17 W10081 Piston pin circlip 1
18 W10082 Piston pin d.15 1
19 W10012/DVS Decompression valve 1
20 WA063/DVS Head control template DVS 1
21 W630/005KF Brass head GKT 0.05mm 1
21W630/10KF Copper head GKT 0.10mm 1
3
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