Vortex MINI ROK Owner's Manual

Page 1
VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200
OTK KART GROUP srl
Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. +39 030 6804601 – Fax +39 030 6804698
OWNER’S
MANUAL
Page 2
VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200
OTK KART GROUP srl
Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. +39 030 6804601 – Fax +39 030 6804698
INDICE
1. GENERAL INFORMATION 3
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. ENGINE/CHASSIS ASSEMBLY 15
4. STARTING AND BRAKE-IN 22
5. SERVICING YOUR ENGINE 23
5.1. Maintenance Schedule and Adjustments 23
5.2. Torque Chart 23
5.3. Sizes and Measures 24
5.4. Chain 24
5.5.Throttle Cable 24
5.6. Carburettor 24
5.7. Spark Plug 25
5.8. Exhaust 26
5.9. Clutch and Starter Gear 26
5.10. Pinion 28
5.11.Cylinder Head 29
5.12.Cylinder 30
5.13.Piston 31
5.14.Connecting Rod 32
5.15.Bottom End 32
6. ENGINE EXPLODED VIEW AND PARTS LIST 33
7. CONTACTS 41
Page 3
VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200
OTK KART GROUP srl
Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. +39 030 6804601 – Fax +39 030 6804698
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.
Page 4
VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200
OTK KART GROUP srl
Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. +39 030 6804601 – Fax +39 030 6804698
1.4. TECHNICAL SPECIFICATIONS
Cylinder Displacement (max)
60cc.
Cylinder Bore (max)
42,10 mm.
Piston Stroke
43,00 mm.
Admission system
Piston Port
Cooling System
Free air
Carburetor
Dell’Orto PHBG 18 BS
Ignition System
Selettra
Ignition Type
Digital
Ignition Timing
3 mm.
Spark Plug Gap
0,8 mm.
Fuel Mixture
3%
Engine Weight
-All sizes and measurements in this manual are expressed in metrics.
-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 Mini Rok Engine is produced in one version only. 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.
Page 5
VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200
OTK KART GROUP srl
Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. +39 030 6804601 – Fax +39 030 6804698
2. ENGINE ASSEMBLING
In order to perform this job, you will need the following tools:
Compressed air
Allen Wrench
3 - 4 - 5 - 6 - 8 mm
Fixed Wrench
5 - 7 - 8 - 10 – 14 - 17 mm
Flat Pliers
Socket Spanner
11 mm
Hooker
Straight Ruler
Cross Screwdriver
Flat Screwdriver
Torque Wrench
1
Compressed air
Unpack the engine and remove any packaging material on it.
2
6mm Allen Wrench
Lay the engine on its side and attach the engine mount to the engine base with four 8 mm Allen screws.
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VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200
OTK KART GROUP srl
Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. +39 030 6804601 – Fax +39 030 6804698
3
Engine Wheelbase Measurements in case you need to drill your engine mount.
4
10mm Fixed Wrench
Attach the specific metal-chromed bracket provided to the engine by using 2 of the 4 silent blocks provided. Pass them through the support in the engine and tighten with washer and 6 mm nut. Sometimes thread on the silent block could be short. Use any threadlocker then.
5
10mm Fixed Wrench
Attach 1 of the remaining 2 silent blocks to the front end of the bracket. Tighten with washer and 6 mm nut. Sometimes thread on the silent block could be short. Use any threadlocker then.
6
10mm Fixed Wrench
Insert the silent block through the upper hole on the specific metal-chromed bracket. Then attach the brown cable (earth) coming from the ignition, a flat washer and 6 mm nut. Tighten everything. Sometimes thread on the silent block could be short. Use any threadlocker then.
Page 7
VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200
OTK KART GROUP srl
Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. +39 030 6804601 – Fax +39 030 6804698
7
3 mm Allen Wrench + 7 mm Fixed
Wrench
Insert the two 4x30 mm screws into the plastic electric plug. Attach the electric plug to the short bracket provided. Secure it with washer and 4 mm nut. Sometimes the holes in the plastic electric plug need to be widened with a 4 mm drill.
8
10 mm Fixed Wrench
Insert the short bracket with the electric plug attached into the two free ends of the silent blocks previously attached to the engine in
Point 4. Tighten with washer and 6 mm nut.
9
3 mm Allen Wrench + 7 mm Fixed
Wrench
Insert the 4x30 screw into the coil. Attach the coil in the specific bracket located on top the main bracket and secure it with washer and 4 mm nut.
10
The stop cable end from the ignition is “male”. The stop cable end from the battery is “male” too. We provide a “female-female” extension to link both end.
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VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200
OTK KART GROUP srl
Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. +39 030 6804601 – Fax +39 030 6804698
11
Plug the two ends from the ignition to the coil. Green cable goes in green plug.
12
3 mm and 5 mm Fixed Wrench
a. Attach the red cable to the electric starter
using the screw there is in it. b. Unscrew the 5 mm Allen screw. Insert the earth cable (black) plug into the screw and screw firmly.
13
Cover both cables ends with the plastic covers inserted in the cables.
14
10 mm Fixed Wrench
Attach the fuel pump to the free end of the same silent block where the ground cable has
been attached in point 6. Secure it with 6 mm. nut and washer provided.
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VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200
OTK KART GROUP srl
Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. +39 030 6804601 – Fax +39 030 6804698
15
Flat Screwdriver
a. Remove the plastic cap from the depression
plug.
b. Insert the fuel line from the side of the fuel pump into the depression plug in the crankcase
16
Flat Screwdriver
a. Remove the plastic cap from inlet manifold.
b. Remove carburettor from its box.
c. Fit the clamp provided together with the
carburettor over the inlet rubber manifold.
d. Insert the carburettor into the inlet rubber manifold.
17
Flat Screwdriver
Ensure the carburettor is correctly seated, then tighten the carburetor to the inlet manifold by using the specific clamp.
18
Screw the air box mount to the carburettor
manually. Do not use any tool.
Page 10
VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200
OTK KART GROUP srl
Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. +39 030 6804601 – Fax +39 030 6804698
19
Cross Screwdriver
Remove the top of the carburettor by unscrewing the two screws.
20
Insert the throttle cable into the elbow on top of the carburettor with the lead nut in.
21
8 mm Fixed Wrench
Tighten the carburettor throttle cable register elbow.
22
Pass the throttle cable through the spring and into the cut in the side of the plastic slide cover.
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VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200
OTK KART GROUP srl
Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. +39 030 6804601 – Fax +39 030 6804698
23
Take the slide out of the carburettor.
24
Insert the lead at the end of the throttle cable into the hole in the center of the slide.
25
Hook the lead nut in the slide by moving it aside of the center.
26
Place the slide, plastic slide cover and spring into the carburettor.
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VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200
OTK KART GROUP srl
Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. +39 030 6804601 – Fax +39 030 6804698
27
Cross Screwdriver
Fix the top of the carburettor to the carburettor by using the 2 screws unscrewed before in Point 19
28
Insert the fuel line from the outlet on the bottom of the fuel pump to the inlet on top carburetor.
29
Insert the air tube into the intake silencer and then place the plastic stone guard on top of the air tube.
30
Insert the foam filter into the intake silencer. There is a slot in the rubber manifold that should be inserted in the intake silencer.
Page 13
VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200
OTK KART GROUP srl
Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. +39 030 6804601 – Fax +39 030 6804698
31
Check the foam filter is properly fixed in intake silencer. Wrong assembly will cause the loss of the foam filter and intake silencer.
32
Flat Screwdriver
Attach the assembled intake silencer to the adaptor and fix it by using the specific clamp provided.
33
4 mm Allen Wrench + 10 mm Fixed
Wrench
Use the specific “S” bended bracket to connect the intake silencer to the main bracket where fuel pump is attached. Secure the intake silencer
by using one 6x25 screw (to the intake silencer) and one 6x20 (to the bracket) screw, washer,
plastic spacer and nut.
34
Flat Screwdriver
Remove the plastic cap from the head.
Spark Plug Wrench Tighten the spark plug in the engine head. Tighten and loosen the spark plug 2/3 times to allow the gasket to seat. Then tighten the spark plug securely.
Page 14
VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200
OTK KART GROUP srl
Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. +39 030 6804601 – Fax +39 030 6804698
35
Insert the coil cable into the rubber plug cup so it is tight. It is recommended to secure the coil cable by using a cable tie. Place the plug cap on to the spark plug and push the plug cap down firmly.
36
Your engine is now ready to be installed to the chassis.
Page 15
VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200
OTK KART GROUP srl
Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. +39 030 6804601 – Fax +39 030 6804698
3. ENGINE/CHASSIS ASSEMBLY
1
5 mm Allen Wrench + 10 mm Fixed Wrench
Place the sprocket in the sprocket carrier and tighten with washer and nut.
2
8mm Allen Wrench
Now place the engine on the chassis. Tighten the engine mount clamps to the engine mount lightly enough to hold the engine in position. Do not tighten completely
3
Straight Ruler
Align the rear sprocket (in the axle) with the front sprocket (in the clutch bell). Then install the chain of proper length. Chain length varies with gear sizes.
4
To adjust chain tension, move the engine ahead until the proper tension is reached. Proper tension is around 1 cm. of free up and down movements.
Page 16
VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200
OTK KART GROUP srl
Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. +39 030 6804601 – Fax +39 030 6804698
5
17 mm Fixed Wrench
Once chain tension is correct, tighten mount clamps completely and re-check the chain tension again. Then set the engine stop to just contact the engine mount, (if provided by the
chassis manufacturer.)
6
5 mm Allen Wrench
Attach the plastic guard bell cover to the engine by using three 6x20 mm Allen screws.
7
Flat Pliers
By using flat pliers, very carefully, turn the two carburetor overflow elbows on the carburettor to point upwards.
8
Insert the plastic tube provided on to each one of the carburettor overflow elbows. The tube may be provided in one piece only. In that case, cut the tube in half. The length of each tube should be 40 cm. approx.
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VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200
OTK KART GROUP srl
Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. +39 030 6804601 – Fax +39 030 6804698
9
Place a recovery tank under the carburettor and secure it to the chassis by using cable ties. Make two holes on top of the cap and insert the free ends of the tubes coming from the overflow elbows. This container must be able to vent to atmosphere.
10
Insert now the throttle cable into the outer.
11
Insert the free end of the throttle cable into the register attached to the main rail of the chassis.
12
3mm Allen Wrench
Insert a clamp into the throttle cable and pass the free end through the welded ring on the throttle pedal. Then loop it around and insert the free end of the cable into the to the clamp
again and tighten it. Clamp not supplied.
Page 18
VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200
OTK KART GROUP srl
Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. +39 030 6804601 – Fax +39 030 6804698
13
Flat Screwdriver
Take the intake silencer off the carburettor by unscrewing the clamp. It is not necessary to unscrew the bracket. The intake silencer will turn easily.
14
8 mm Fixed Wrench
Adjust the throttle cable by setting the pedal stop on the chassis in order to get the pedal to stop at the point where the slide in the carburettor is fully open.
15
5 mm Fixed Wrench
Attach now the battery cradle to the chassis main rail next to the seat using the specific plastic clamp provided. A battery mounting spacer plate may be
required to clear the brake cable.
16
4 mm Allen Wrench + 10 mm Fixed Wrench
Remove relay from socket in the wiring loom. Secure the wiring loom to the battery cradle using a 6x25 mm Allen screw, bi conical washer, 2 plastic spacer, washer and 4 mm nut.
Page 19
VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200
OTK KART GROUP srl
Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. +39 030 6804601 – Fax +39 030 6804698
17
Insert manually the relay into the female plug in the wiring loom. Do not use any tool.
18
14 mm Fixed Wrench
Place the start bottom (Green) and the stop bottom (Red) in the two slots located in the front of the battery cradle. Secure them with the specific nut attached in the cables.
19
Place the battery in the battery cradle. Insert the battery cables in the battery plugs. Red cable in red plug, black cable in black plug. Secure the battery using the two rubber O.R. provided.
20
Secure the relay with the specific spring provided.
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VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200
OTK KART GROUP srl
Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. +39 030 6804601 – Fax +39 030 6804698
21
Pass the main wire loom under the seat and secure it to the chassis by using plastic cable ties. Make sure there is no loose wiring that
may drag on the track.
22
Plug in the electric plug coming from the battery to the other half located aside the engine.
23
a. Cover the inside of the RPM limiter box
cradle with the specific foam tape provided. Fit a small piece of fuel line to the O.R as illustrated in the picture and secure the RPM
limiter box to the cradle with the O.R.
b. Attach the cradle to the seat or the chassis.
c. Insert the female plug coming from the
ignition on the male plug in the RPM limiter box.
24
Hook the two springs provided into the exhaust manifold.
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VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200
OTK KART GROUP srl
Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. +39 030 6804601 – Fax +39 030 6804698
25
11 mm Socket Wrench
Before fitting the exhaust manifold remove the exhaust gasket and the exhaust port cover. Refit the exhaust gasket to the cylinder, then fit the exhaust manifold by using the brass spacer
and the nuts. Tighten each nut alternatively.
26
Hook
Insert the muffler into the exhaust manifold. Fix the muffler by hooking the free ends of the spring into the rings welded to the muffler by pulling them.
27
Hook
Place the muffler in the exhaust cradle that is assembled on the chassis and pull the two springs provided to fasten it.
28
Insert the fuel line from the fuel tank into the fuel pump
Page 22
VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200
OTK KART GROUP srl
Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. +39 030 6804601 – Fax +39 030 6804698
4. 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 (pistons, rings, cylinder or crankshaft).
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 3% (i.e. 30cc of oil every 1.000 cc. of fuel).
2 Use a high quality 2-stroke oil specifically made for kart engines. We recommend Petronas Rok
Lube, however many others oils with the same features may be used. Check any requirements of your ASN regarding the use of specific brand/type
3 Shake 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.
4 Buttons: to start the engine press the green button. To stop the engine press the kill switch red
button.
5 To start a cold engine pull the choke lever up.
6 Press the start button (green) in order to allow the fuel pump-to-pump fuel to the carburetor.
7 Once the engine starts push the choke lever down.
8 Run the engine by accelerating intermittently to higher RPMs. Do not accelerate to full throttle.
9 Once the engine is warmed up, proceed to the track. By accelerating very carefully, the clutch
will engage and the kart will start moving forward.
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 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
Page 23
VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200
OTK KART GROUP srl
Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. +39 030 6804601 – Fax +39 030 6804698
5. SERVICING YOUR ENGINE
Good maintenance is essential for safe, economical and trouble-free operation. Here you will find a maintenance schedule, routine inspection procedures and very simple maintenance procedures 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.
5.1. Maintenance Schedule 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
Clutch
Check and cleaning Change
Every 10 hours After 30 hours
Piston
Change
After 30 hours
Chain
Change
After 10 hours
Cylinder
Honing
After 30 hours
Connecting Rod
Change
After 90 hours
Bottom End
Re-built
After 90 hours
5.2. Torque Chart
Cylinder Head Ø 8 mm Nut
kgm 1,8
Exhaust Manifold Ø 7 mm Nut
kgm 1,5
Crankcase Ø 6 mm Screws
kgm 1,2
Bendix cover Screws
kgm 0,8
Starter Gear Nut
kgm 6 (Use threadlocker)
Pinion Bell Ø 5 mm Screws
kgm 0,8
Ignition Nut
kgm 2,8
Pinion Bell Nut
kgm 2,8
Ignition Ø 5 mm Screws
kgm 0,8
Nylon crankshaft stuffer
kgm 0,8 (Use threadlocker)
Page 24
VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200
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Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. +39 030 6804601 – Fax +39 030 6804698
5.3. Sizes and Measures
Tolerance Cylinder/piston
10,5
Timming
3mm
Piston Sizes
W240/MR01A
41,88
W240/MR03A
41,91
W240/MR06A
41,93
W240/MR09A
41,95
W240/MR11A
41,98
5.4. Chain
Lube the chain 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.
5.5. 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.
5.6. Carburettor
Cleaning:
Fuel and oil may contain some kind of rubbish, impurities, and/or residues.
1.Take the intake silencer off the carburettor by unscrewing the clamp. It is not necessary to unscrew the bracket. The intake silencer will turn easily.
2.Disconnect the throttle cable from the carburetor together with its spring and slide it.
3.Took the carburetor off the engine and open the float chamber (22) by unscrewing the four screws (23). Clean the parts, openings and passages with compressed air. Check the float chamber gasket (21) and eventually change it if damaged.
4. Close the float chamber by screwing the four screws (23) and re-place the carburettor in the engine.
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VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200
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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.
Changing main jet:
1.Take the intake silencer off the carburettor by
unscrewing the clamp. It is not necessary to unscrew the bracket. The intake silencer will turn easily.
2.Disconnect the throttle cable from the carburetor together with its spring and slide it.
3.Took the carburetor off the engine and open the float chamber (22) by unscrewing the four screws (23). Clean the parts, openings and passages with compressed air.
4.Unscrew the main jet (4) by using a cross screwdriver. Place a new one. Be careful, washer (18) has only one position. Wrong assembling will cause totally black out of carburettor.
5.Check the float chamber gasket (21) and eventually change it if damaged.
6.Close the float chamber by screwing the four screws (23) and re-place the carburettor in the engine.
7.Clean the inside of the intake silencer.
8. Attach the intake silencer assembly to the
adaptor.
9.Tighten it with the specific clamp. Wrong assembly will cause the loss of the intake silencer.
5.7. Spark Plug
Cleaning:
Oils produce carbon deposits or residues that
Unplug the spark plug and clean it by using a metal brush.
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VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200
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Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. +39 030 6804601 – Fax +39 030 6804698
make necessary the spark plug to be checked and cleaned, at least every 5 hours.
Setting Plug Gap:
Use a specific spark plug gap gauge to set up correct gap. Correct gap: 0,8 mm.
5.8. Exhaust
Cleaning:
Oils produce carbon deposits or residues that make necessary the spark plug to be checked and cleaned, at least every 10 hours.
1.Remove the muffler from the engine by removing the 2 springs in the cradle and the 2 springs in the exhaust manifold.
2.Unscrew the 3 bolts in the exhaust terminal.
3.Warm up the pipe with a heat source and
remove any carbon deposits by means of a metal brush.
5.9. Clutch and Starter Gear
Cleaning and/or replacing clutch:
1.Disassemble the clutch cover.
2. Take away the Bendix cover
3.Stop the clutch drum by using the special tool
designed by Vortex for this specific task.
4.Unscrew anticlockwise the nut on the clutch drum (92). Remove the washer (91), clutch drum (87) and roller bearing (90).
5. Unscrew the three 6x14mm Allen screws (79) on the clutch.
Page 27
VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200
OTK KART GROUP srl
Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. +39 030 6804601 – Fax +39 030 6804698
6.Unscrew clockwise the central nut (84) by using a 24mm fixed wrench to remove it. Stop the starter gear with the specific tool manufactured by Vortex.
7.Take away the clutch (82) by using the appropriate extractor.
8.Before assembling the new clutch, we recommend to clean the clutch area and the pinion bell with a solvent.
ASSEMBLING
9.Install the new clutch (82) on the crankshaft
by pushing lightly with your fingers and secure it with the three 6x14mm Allen screws (79). Use thread locker to secure them.
10.Put together again the elastic washer (83) and the central nut (84) and tighten. Use
thread locker to secure the central nut.
11.After screwing the central nut place the washer (85).
12.Grease the needle bearing (90) totally and insert it on the crankshaft.
13.Place the clutch bell (87), the spacer (91) and screw the nut (92). Use thread locker to secure it.
14.Re-place Bendix cover.
15.Re-place the clutch cover.
Replacing Starter Gear
1.Disassemble the clutch cover.
2. Take away the Bendix cover
3.Stop the clutch drum by using the special tool
designed by Vortex for this specific task.
4.Unscrew anticlockwise the nut on the clutch drum (92). Remove the washer (91), clutch drum (87) and roller bearing (90).
5. Unscrew clockwise the central nut (84) by using a 24mm fixed wrench to remove it. Stop the starter gear with the specific tool manufactured by Vortex.
6.Take away the clutch (82) together with the starter gear (80) by using the appropriate extractor.
7. Unscrew the three 6x14mm Allen screws (79)
Page 28
VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200
OTK KART GROUP srl
Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. +39 030 6804601 – Fax +39 030 6804698
on the clutch.
8.Before re-assembling, we recommend to clean the area with a solvent.
ASSEMBLING
9.Screw the new starter gear (80) to the clutch
(82) by using three 6x14mm Allen screws (79). Use thread locker to secure them.
10.Insert the starter gear and clutch on the crankshaft by pushing lightly with your fingers.
11.Put together again the elastic washer (83) and the central nut (84) and tighten. Use
thread locker to secure the central nut.
12.After screwing the central nut place the washer (85).
13.Grease the needle bearing (90) totally and insert it on the crankshaft.
14.Place the clutch bell (87), the spacer (91) and screw the nut (92). Use thread locker to secure it.
15.Re-place Bendix cover.
16.Re-place the clutch cover.
5.10. Pinion
KSNZ allows the use of Z11 or Z10 pinions. Standard assembling is Z11.
1.Disassemble the clutch cover.
2.Stop the clutch drum by using the special tool
designed by Vortex for this specific task.
3.Unscrew anticlockwise the nut on the clutch drum (92). Remove the washer (91), clutch drum (87) and roller bearing (90).
4.Unscrew the four bolts inside the drum.
5.Place the new pinion on the bell and secure it
with the 4 bolts. Use thread locker to secure them.
Be aware if you are placing a Z10 pinion, a specific spacer is needed.
6.Install roller bearing and the spacer. Grease
the roller bearing properly.
6.Re-place the clutch drum, the washer and the nut. Tighten the nut by turning it to the left. Use thread locker to secure it.
7.Re-place the clutch cover.
Page 29
VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200
OTK KART GROUP srl
Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. +39 030 6804601 – Fax +39 030 6804698
5.11. Cylinder Head
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.
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 (4).
2.Unscrew the 4 nuts on top of the head (3).
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 copper gasket on top of cylinder (5).
This gasket may provoke changes in the combustion chamber volume.
6.Re-place cylinder head carefully in the four studs (10).
7.Insert brass washers (2) and nuts (3).
8.Tighten cylinder head with the proper tool
and torque.
Page 30
VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200
OTK KART GROUP srl
Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. +39 030 6804601 – Fax +39 030 6804698
5.12. 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 2 springs in the cradle and the 2 springs in the exhaust manifold.
2.Remove the carburettor from the engine by unscrewing the specific clamp.
3.Unscrew the 4 nuts on top of head (3).
3.Remove the head by pulling it up carefully.
4.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 (9).
ASSEMBLING Check the tolerance between piston and cylinder. Wrong tolerance may cause serious damage.
5.Place a new gasket (9) into the four studs
(10).
6.Insert cylinder into the four studs carefully.
7.Check the rubber O.R. (6) and brass gasket (5)
and eventually re-place them with new ones. Brass gasket may provoke changes in the combustion chamber volume.
8.Re-place the cylinder head carefully in the four studs.
9.Insert brass washers (2) and nuts (3).
10.Tighten cylinder head with the proper tool
and torque.
Important: After honing the cylinder and eventually changing the piston, the engine must go through another break-in period. See "Starting and Break-in".
Page 31
VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200
OTK KART GROUP srl
Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. +39 030 6804601 – Fax +39 030 6804698
5.13. 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 in the cradle and the 2 springs in the exhaust manifold.
2.Remove the carburettor from the engine by unscrewing the specific clamp.
3.Unscrew the 4 nuts on top of head (3).
3.Remove the head by pulling it up carefully.
4.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.
5.Remove the 2 piston pin circlips (65) by
squeezing the ends together with the needle­nose
6.Hook the connecting rod each side with two fingers.
7.Push the piston pin (66) off the piston by using a proper tool.
8.In order to avoid damages pull the piston up with one hand while holding the connecting rod with the other.
9.Take the roller bearing (70) off the connecting rod.
ASSEMBLING Check the tolerance between piston and cylinder. Assemble ONLY a new piston with the right tolerance. Wrong tolerance may cause serious damage.
10.Grease and place a new roller bearing (70),
if needed, on the connecting rod.
11.Insert a new piston in the connecting rod. The arrow marked on top of it, must face the exhaust port.
12.Insert the piston pin into the piston.
13.Insert piston pin circlips on each side of the piston. Be aware, wrong assembly of piston
Page 32
VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200
OTK KART GROUP srl
Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. +39 030 6804601 – Fax +39 030 6804698
pin circlips may cause important damage.
14.Place the piston ring in the piston and check
both ends close properly against the brass pin inserted in the piston.
15.Place a new gasket (9) into the four studs (10).
16.Insert the cylinder into the four studs carefully.
17.Check the rubber O.R. (6) and the copper gasket (5) and eventually re place them with new ones. Brass gasket may provoke changes in the combustion chamber volume.
18.Re-place the cylinder head carefully in the four studs.
19.Insert brass washers (2) and nuts (3).
20.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".
5.14. Connecting Rod
Every 60 hours the roller cage must be changed. During this operation is good use to check, and eventually replace the connecting rod, too.
Due to special tools required, this operation must be performed by the Vortex technicians or qualified mechanics only.
5.15. Bottom End
Bearings must be checked, 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.
Page 33
VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200
OTK KART GROUP srl
Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. +39 030 6804601 – Fax +39 030 6804698
6. ENGINE EXPLODED VIEW AND PARTS LIST
.
Page 34
VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200
OTK KART GROUP srl
Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. +39 030 6804601 – Fax +39 030 6804698
Page 35
VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200
OTK KART GROUP srl
Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. +39 030 6804601 – Fax +39 030 6804698
Page 36
VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200
OTK KART GROUP srl
Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. +39 030 6804601 – Fax +39 030 6804698
Page 37
VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200
OTK KART GROUP srl
Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. +39 030 6804601 – Fax +39 030 6804698
Page 38
VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200
OTK KART GROUP srl
Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. +39 030 6804601 – Fax +39 030 6804698
Dell’Orto Carburettor
Page 39
VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200
OTK KART GROUP srl
Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. +39 030 6804601 – Fax +39 030 6804698
Parts List
1
W010/MR
Air head 60cc
2
W560
Head washers 8,5 x 15 x 8
3
W530/12
Head-nut high-set m8
4
W003
Spark plug ngk b10 eg
5
W631/01MR
Copper head gasket 42,2 x 62,4 x 0,1
5
W631/02MR
Copper head gasket 42,2 x 62,4 x 0,2
6
W620/MR
O-ring head viton
7
W020/1MRC
Cylinder 60cc complete
8
W470
Exhaust stud bolt m7 x 32
9
W610/1MRC02
Cylinder basis gasket 0,2
9
W610/1MRC03
Cylinder basis gasket 0,3
9
W610/1MRC04
Cylinder basis gasket 0,4
9
W610/1MRC05
Cylinder basis gasket 0,5
10
W461/1VLC
Cylinder stud bolt m8 x 142
11
W2050/MR
Inlet manifold phbg 18
11
W2050/BR
Inlet manifold phbn 14
12
W825/1MR
Carburettor clamp d.23-35mm
13
V.TCE6X16
Socket-head screw m6 x 16
14
W820/BR
Dellorto carburettor phbn 14ms
14
W820/MR
Dellorto carburettor phbg 18b
15
W981400
Connector
16
W540/RVA
Exhaust fix. High set nut
17
W565
Exhaust washer d.8 x 12 x 1,5
18
W750/1MR
Exhaust manifold mr/t 60cc
19
W670/MR
Exhaust gasket
20
WA063
Head control template mini rok
21
WA064
Carburettor gap control template
32A
W050/MRC
Complete crankcase 60cc with bearing
33
V.TCE6X40
Socket head screw m6 x 40
34
V.TCE6X45
Socket-head screw m6 x 45
35
W075/1
Crankcase dowel 10 x 10,5 x 6,5
36
W10267
Copper gasket d. 8 x 12 x 1
37
W800
Depression pipe fitting m8 hexagonal
38
W300/MR
Insert 6204 c4
39
W310
Oil seal fpj 20 x 35 x 7 double lip
40
W940/ROK
Starter 50589
41
W019
Cylindrical pin 6x18
42
W924
Roller case bk0808
43
W916/ROK
Starter driving gear 50589
44
W910/ROK
Starter driving gear cover
45
V.TCE6X20
Socket-head screw m6 x 20
46
W960/RKT
Transmission starter support
47
V.TCE6X30
Socket-head screw m6 x 30
48
V.TCE6X65
Socket head screw m6 x 65
49
W972/MR
O.r.4200 starter support
50
W970/MR
Starter support d.50
51
W975/MR
Starter support spacer
64
W240/MR01A
Complete piston 41,88
64
W240/MR03A
Complete piston 41,91
64
W240/MR06A
Complete piston 41,93
64
W240/MR09A
Complete piston 41,95
64
W240/MR11A
Complete piston 41,98
65
W280/MR
Circlip d.12,00
66
W270/MRA
Piston pin mini rok
67
W140/MR
Magn.s.h. Crankshaft 60cc
68
W122
Ignition key 2,5 x 3,7 x 10
69
W220
Silver-plated cage d.18 x 24 x 15
70
W290/MR
Piston cage 12 x 16 x 15,5
71
W200/1MR
Crankshaft crankpin d.18 x 40,6
72
W230/MR
Conrod engine 60cc
73
W522/10
Flathead screw m5 x 10
74
W160/MR
Nylon crankshaft stuffer
75
W121
Dragging sprocket key 3 x 3,7 x 10
76
W150/MR
H.crankshaft sprocket side 60cc
77B
W190/MR
Complete conrod 60cc
78C
W130/1MR
Complete crankshaft mini rok
79
W510/14
Socket-head screw m6 x 14
80
W1753/MR
Starting driven gear z 62
81
W1766/1ROK
Cylindrical pin 6 x 10
82
W1751/1KFC
Clutch rotor kf with pin
83
W1708
Belleville washer d.16,3 x 31,5 x 1,5
84
W1727
Clutch body fix nut m16 x 1 thr.
85
W1726/1
Washer 2,0 mm mini-kf
86
W523/08
Flathead screw m5 x 8
87
W1773/MR2
Bare clutch housing mini
88
W1766/ROK
Roll d.5 x 5
89
W690/MR11
Mini rok sprocket z11
90
W1715
Clutch cage k12 x 15 x 15
91
W1777/1ROK
Clutch washer d.10,1 x 18,8 x 2
92
W696/MR
Sprocket nut 60cc
Page 40
VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200
OTK KART GROUP srl
Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. +39 030 6804601 – Fax +39 030 6804698
93D
W1750/1MR
Compl.clutch rotor with gear
94E
W1763/MR11
Compl.clutch housing w/sprocket z11
94E
W1763/MR10
Compl.clutch housing w/sprocket z10
105
W410/MR
Selettra coil mini rok
106
W531/06
Hexagonal nut m6 x 1
107
W570/12
Flat washer d.6 x1 2 x 1,5
108
W2052/MR
Fuel pump support plate
109
W440
Coil fix. Silent - block
110
W11023
Vacuum pump
111
W420/2
Spark cap
112
W529/0108
Hexagonal nut m10 x 1
113
W1777/MR
Ignition washer d.10,4 x 18 x 2
114
V.TCE5X20
Socket-head screw m5 x 20
115
W580/10
Washer d.10 x 5,5 x 0,3
116
W407/MR
Bare ignition mini rok
117
W524/14
T.c.e.i. Screw m5 x 14
118
W068/MR
Ignition support
119
0074.C0
Fuel tube 6 x 9
121
W780/1MR
Engine 60cc exhaust
122
W10925
Muffler springs
133
W2111/ROK
Relay deviator
134
W2110/ROK
Starting relay 12v - 70a
135
W2116/ROK
Red starter button on-off
136
W2115/ROK
Green starter button
137
W2113/ROK
Fixing button plate
138
W521/14
Roundhead screw m5 x14
139
W435/MR
Mini rok wiring adapter
140F
W2125/ROK
Complete starting support
141
W2130/ROK
Accumulator charger italy
141
W2131/ROK
Accumulator charger japan-u.s.a.
142
WA052/KF
Clutch puller
143
WA061
Clutch nut fix key
144
WA062
Sprocket disassembling tool sr/mr
145
W991
Accumulator fg 20722
146
0096.00
Belt or 4437
147
W2121/ROK
Accumulator support rubber
148
W2122/ROK
Accumulator support
151
W856/MR
Mini rok filter support
152G
W2122/ROKC
Complete accumulator support
153
W850/1MR
Intake filter 60cc engine
161V
W820/MR
Dellorto carburettor phbg 18b
162H
W53036-78
Tube 90° kit
163I
W53031-78
Chamber mixture cover kit
164
W9597-61
Gas valve spring
165
W14958-21
Conical needle fastener fix plate
166
W9596211
Conical needle fastener
167
W959523
Conical needle w23 x 08
168
W947540
Gas valve 40 x 64
169
W148850
Jet min. 50
170
W950160
Jet 60
171
W52526-77
Gaskets kit
172
W9450-80
Float
173
W11836-36
Float chamber fixing screw
174
W9444-96
Float chamber
175
W9506-22
Float peg
176
W283805
Gas needle closing
177
W148697
Jet max. 97
178
W9779-52
Bottom
179
W9511266
Spray nozzle an 266
180L
W53027-78
Needle gas valve kit
181M
W53024-78
Adjustment minimum screw kit
182
W9538-64
Starting device
192Z
W820/BR
Dellorto carburettor phbn 14ms
193
W7526-36
Cover fixing screw
194
W14166-53
Chamber mixture cover
195
W15058-61
Gas valve spring
196
W13687-21
Conical needle retainer
197
W1536240
Gas valve 40
198
W13681-21
Conical needle fastener
199
W1625011
Conical needle
200N
W53004-78
Starter kit
201
W14056-37
Adjustment minimum air screw
202
W1411-61
Spring adjustment min. Air screw
203P
W53086-78
Adjustment gas valve screw kit
204
W14671212
Spray nozzle ga 212
205
W641375
Jet max. 75
206
W621750
Starting device 50
207
W1160038
Jet min. 38
208
W52620-77
Gaskets kit
209O
W53053-78
Float kit
210
W13678-96
Float chamber
211
W13709-36
Float chamber fixing screw
Page 41
VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200
OTK KART GROUP srl
Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. +39 030 6804601 – Fax +39 030 6804698
7. CONTACTS
Manufacturer
Vortex Factory Via E. Fermi 5 27040 – Capospinoso Italy Tel: +39 0385 765200
support@vortex-engines.com
New Zealand Importer
Supreme Kart Supplies 78 Hurlstone Drive 1146485 NEW PLYMOUTH Tel: 06 7588891
m.j.frost@xtra.co.nz
ASN
Kart Sport New Zealand 45 Mt Wellington Highway Auckland 1060 Tel: 09 570 1392
www.kartsport.org.nz
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