Vortex MINI ROK Owner's Manual

VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. [phone]

OTK KART GROUP srl

Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. [phone] – Fax [phone]

MINI ROK

OWNER’S

MANUAL

VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. [phone]

OTK KART GROUP srl

Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. [phone] – Fax [phone]

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

VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. [phone]

OTK KART GROUP srl

Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. [phone] – Fax [phone]

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.

VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. [phone]

OTK KART GROUP srl

Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. [phone] – Fax [phone]

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.

VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. [phone]

OTK KART GROUP srl

Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. [phone] – Fax [phone]

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.

VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. [phone]

OTK KART GROUP srl

Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. [phone] – Fax [phone]

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.

VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. [phone]

OTK KART GROUP srl

Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. [phone] – Fax [phone]

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.

VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. [phone]

OTK KART GROUP srl

Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. [phone] – Fax [phone]

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.

VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. [phone]

OTK KART GROUP srl

Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. [phone] – Fax [phone]

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.

VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. [phone]

OTK KART GROUP srl

Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. [phone] – Fax [phone]

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.

VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. [phone]

OTK KART GROUP srl

Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. [phone] – Fax [phone]

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.

VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. [phone]

OTK KART GROUP srl

Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. [phone] – Fax [phone]

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.

VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. [phone]

OTK KART GROUP srl

Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. [phone] – Fax [phone]

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.