Vortex ROK DVS J Owner's Manual

ROK DVS J

OWNER’S

MANUAL

FOREWORD

DVS-Junior

1

Thank you for purchasing Vortex engines. This
manual contains information on how to help
you with getting the best results from your new
engine. Furthermore, it will explain to you how
to operate your Vortex engine safely and in a
proper manner. All the information in this
manual is based on the latest experience and
product information available at the time of
writing. Vortex reserves the right to make any
kind of changes to this manual at any time
without notice and without incurring in any
obligation.

This manual shall be considered part of the Vortex engine.

Supreme Kart Supplies

79 Hurlstone Drive

New Plymouth

06 7588891

[e-mail]

DVS-Junior

2

INDEX

1. GENERAL INFORMATION

1.1. Symbols

3

1.2. Safety information

3

1.3. Technical Specifications

4

1.4. Special Technical Specifications for Homologated Engine

5

1.5. Packaging

5

2. ENGINE ASSEMBLING

2.1. Tools

6

2.2. Engine Assembling Procedure

7

3. STARTING AND BRAKE-IN

17

4. SERVICING YOUR ENGINE

4.1 Maintenance Schedule and Adjustments 18

4.2 Torque Chart 18

4.3 Maintenance 18

4.4 General Tolerances 19

4.5 Piston and Piston Rings 19

4.6 Maintenance Detail 20

4.6.1 Carburettor Cleaning 20

4.6.2 Changing Jets 21

4.6.3 Spark Plug Cleaning and Replacement 22

4.6.4 Exhaust Cleaning 22

4.6.5 Cylinder Head Cleaning 23

4.6.6 Cylinder Check and Maintenance 24

4.6.7 Piston Check and Maintenance 25

5. ENGINE EXPLODED VIEW AND PARTS LIST

26

DVS-Junior

3

GENERAL INFORMATION

1.1. SYMBOLS

Pay attention to the symbols of this manual. They alert you of dangerous situations for you or for
your engine.

Personal Injury Mechanical Danger Caution

Special tools needed to perfom operation.

1.2. SAFETY INFORMATION

- Do not start the engine indoors eg, 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.
Avoid any skin contact and inhaling fuel vapors.

- 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 chain protection.

DVS-Junior

4

GENERAL INFORMATION

1.3 TECHNICAL SPECIFICATIONS

Engine

Original

Max

Min

Displacement

124.130cc

124.957cc

Stroke

54.00mm +0.2mm

-0.2mm

Connecting Rod

102.00mm +0.2mm

-0.2mm

Bore 54.10mm 54.28mm

Squish

0.8mm

Combustion Chamber

11cc

Intake

Intake Reed Valve
Carburettor Dell’orto 24mm Type: WHST 24 BS
Gas Valve 50
Conic Needle D55
Spray Needle AQ270
Minimum Jet U43
Maximum Jet 100

Ignition

PVL Digital
Timing 3mm
Spark Plug Gap 0.7/0.8 mm

General Specifications

Fuel Mixture

Crank Case Oil

Engine Weight

5%

30gr W80/90

10.2Kg

API GL5

All sizes and measurements in this manual are expressed in metrics and may change at any
time.
For Racing purposes, ONLY the National Homologation File is to be considered the official

document.
Always use original Vortex parts and proper tools when working on your engine.
Proper fuel mix is necessary for optimum engine life and performance.

DVS-Junior

5

GENERAL INFORMATION

1.4 SPECIAL TECHNICAL SPECIFICATIONS FOR HOMOLOGATED ENGINE

Refer to your country homologation file for eventual specific rules and/or sizes.

1.5 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. There will be a second box complete with accessories,
carburetor, muffler, fuel pump, air box, etc.

DVS-Junior

6

ENGINE ASSEMBLING

2.1. TOOLS

In order to perform assembling or maintenance jobs, you will need the following tools:

Tipo Misura

Allen Wrench 2.5 mm.
Allen Wrench 5 mm.
Allen Wrench 6 mm.
Fixed Wrench 10 mm.
Dynamometric Wrench
Phillips Screwdriver
Flat Screwdriver
Spark Plug Wrench
Compressed Air
Heater

DVS-Junior

7

ENGINE ASSEMBLING

2.2. ENGINE ASSEMBLING PROCEDURE

Compressed Air

Unpack the engine and remove any packaging material
on it.
Use compressed air to eliminate any further packaging
material.
Remove all plastic covers AFTER cleaning the engine.

Allen Wrench 6mm

Lay the engine on its side and attach the engine
mount to the engine base with four 8x35 mm.
Allen screws.

Attention: Engine Mount and screws are
not with the engine. May vary according
to chassis.

DVS-Junior

8

ENGINE ASSEMBLING

added.

6mm Allen Wrench

Caution: Engine is supplied WITHOUT oil.
DO NOT start engine before oil have been

Remove the oil filler cap with a 6 mm. Allen
Wrench. Fill the engine with 30gr of W80/90
viscosity oil (International Specification: API GL 5).
Re fit the oil filler cap.

10mm Allen Wrench

Assemble coil as per diagram.
All material needed to perform this task is provided with the engine.

DVS-Junior

9

ENGINE ASSEMBLING

Fix ground cables to the engine by assembling
the two silent blocks in the crankcase as per
photo. Tighten both silent blocks to the
crankcase.

Caution: Wrong assembling will cause coil
failure.

Insert now the coil in the two silent blocks.

Insert the ground cable from the coil into the
upper silent block as per photo.
Insert a washer.

Insert now the ground cable previously attached
to the crank case with the upper silent block and
tighten with washer and nut provided as per
photo.

DVS-Junior

10

ENGINE ASSEMBLING

Insert now the ground cable previously
attached to the crank case in the bottom silent
block as per photo.
Tighten with washer and nut.

Caution: One side of the ground

cables may touch the crank case.
The other ends may touch coil support.
Please check photo to correct coil assembling.

Wrongly ground cables assembling
will result in failure and coil
irreversible damage.

ENGINE ASSEMBLING

DVS-Junior

11

Spark Plug Wrench

Remove the plastic cap from the head of the cylinder.
Manually tighten the spark plug into the cylinder
head.
Lock it with the spark plug wrench. Loosen it then
retighten 2/3 consecutive times; so as to allow the spark
plug washer to seat properly. Now you can tighten the
spark plug properly. Insert the high tension lead into the
spark plug cap and tighten it. For safety, we recommend
you secure the high tension lead to the spark plug cap
with a cable tie.
Place the spark plug cap on the spark plug and press
the cap down fully.

10mm Fixed Wrench

5mm Allen Wrenc

h

Diagram to assemble fuel pump and bracket option 1. Proceed as explained in
next page. All material needed to perform this task is provided with the engine.

ENGINE ASSEMBLING

DVS-Junior

12

Fuel Pump Bracket Option 1

5 mm. Allen Wrench
Part I

Insert and tighten the silent blocks in the designed
bracket.
Attach

the bracket to the engine with 6 mm screws

provided. (Red arrow)

Part II

10mm Fixed Wrench

Insert the fuel pump into the silent blocks and
tighten it.

ENGINE ASSEMBLING

DVS-Junior

13

Part III
Insert now the vacuum tube into both, engine and fuel pump as per red
arrows. Later we will insert the other 2 tubes in the fuel pump. (Page.15)

ENGINE ASSEMBLING

DVS-Junior

14

Fuel Pump Bracket Option 2

ENGINE ASSEMBLING

DVS-Junior

15

2.5mm Allen Wrench

Flat Screwdriver

Now assemble the carburettor. All parts
needed are in the accessory box.
The standard set up in the carburettor is already to run
your engine.

Assemble aluminium air box adapter to the carburettor.

Fit the hose clip to the rubber manifold. Insert
the carburettor in the rubber manifold and
tighten the hose clamp tight with the flat
screwdriver.

Standard Carburettor Set Up

Type specifics

Carburettor Dell’orto 24mm WHST 24BS
Gas Valve 50
Conic Needle D55
Spray AQ270
Minimum Jet U43
Maximum Jet 110

ENGINE ASSEMBLING

DVS-Junior

16

Phillips

Screwdriver

Remove the top of the carburettor by
unscrewing the two screws.

Get cover, spring and slide off.

Insert the inner throttle cable into and
through the elbow on top of the
carburettor.

Insert the spring and then the slide.
Fit the nipple on the end of the cable into the hole at
centre of the slide.

Re insert the slide into the carburettor and tighten
the two screws on top of it.

ENGINE INSTALLATION

DVS-Junior

17

Insert now the tube from the fuel pump to the carburettor as per red arrows. Check carefully with
the attached diagram.

Secure the tube to the fuel pump and the carburettor
by using plastic ties.

Phillips

Screwdriver

Fasten the intake silencer to the
carburettor by using the specific metal
clamp supplied.

ENGINE INSTALLATION

DVS-Junior

18

The airbox needs supporting at the front. Drill a 6mm hole through the support tab at the front of the airbox

and fit a bracket, as per photo, to support the airbox.

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
from the external water pump. If necessary top
up the radiator again. Do not close the radiator
cap.

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.

ENGINE INSTALLATION

DVS-Junior

19

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.).

Prepare fuel. Vortex engine works with commercial gasoline, leaded or unleaded, as well as racing
fuel, with minimum 95 Octane.
Mix Oil and fuel at 5% (i.e. 50cc of oil every 1.000cc of fuel).

This engine is only to be run Motul GP engine oil.

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.

To start a cold engine, raise the choke lever positioned on the
carburettor.
Once the engine starts push the choke lever down.
Warm up the engine by accelerating up and down the engine RPM alternately between RPM’s.
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.
Once the engine is warmed up and the cooling system works properly, proceed to the track.
Run the engine by alternating RPM’s a few seconds on and off the throttle at 3⁄4 maximum
throttle.
Do not hold the throttle at a constant speed. Continue this way for 10/15 minutes and return to
pits. Check everything on the kart is tightening properly.

Be careful, both engine and muffler are hot.
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.

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.

DVS-Junior

20

MAINTENANCE

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 need special tools must be performed by Vortex technicians or
qualified mechanics.
Timing schedule periods are only indicative. Extreme carburation set ups highly modify timing schedule periods.

4.1 MAINTENANCE SCHEDULE GUIDE AND ADJUSTEMENTS

Part

Frequency

Operation

Carburettor

Every Race

Cleaning

Accelerator Cable

Every Race

Check

Spark Plug Every Race

Check

Muffler 10 hours

Internal Cleaning

Cylinder Every piston change

Check

4.2 TORQUE CHART

Part

Torque in Kgm

Notes

Cylinder/head Nuts

1.6

Cylinder/crankcase Nuts

2.0

Crankcase Ø 6 mm Screws

1.0/1.1

Ignition Rotor Nut

2.0

Exhaust manifold Nuts

1.0/1.1

4.3 MAINTENANCE

Part Hours Operation

Piston

20

Check/Replace

Spark Plug

30

Replace

Piston Pin

20

Check/Replace

Piston Pin Roller Cage

20

Check/Replace

Connecting Rod

100

Substitution

Crank Shaft Pin

50

Check/Replace

Silver Washers

50

Check/Replace

Crank Shaft Roller Cage

50

Check/Replace

Oil Seals 50 / or every crank case opening

Check/Replace

Bearings When needed

Substitution

MAINTENANCE

DVS-Junior

19

4.4 GENERAL TOLERANCES

Part

Type

Measure

Operation

Cylinder

Ovalization

0.02

Honing

Piston/cylinder

-- 0.

12

--

4.5 PISTON AND PISTON RINGS

Part Number

Piston Size

Piston Ring

Piston Ring Size

W10140/RKF

54.00

W260/SA10

54.10

W10141/RKF

54.01 W260/SA12

54.12

W10142/RKF

54.02 W260/SA12

54.12

W10143/RKF

54.03 W260/SA15

54.15

W10144/RKF

54.04 W260/SA15

54.15

W10145/RKF

54.05 W260/SA15

54.15

W10146/RKF

54.06 W260/SA15

54.15

W10147/RKF

54.07 W260/SA15

54.15

W10148/RKF

54.08 W260/SA20

54.20

W10149/RKF

54.09 W260/SA20

54.20

W10150/RKF

54.10 W260/SA20

54.20

W10151/RKF

54.11 W260/SA20

54.20

W10152/RKF

54.12 W260/SA25

54.25

W10153/RKF

54.13 W260/SA25

54.25

W10154/RKF

54.14 W260/SA25

54.25

W10155/RKF

54.15 W260/SA25

54.25

W10140/RKFVP

54.00

W260/SA10

54.10

W10141/RKFVP

54.01 W260/SA12

54.12

W10142/RKFVP

54.02 W260/SA12

54.12

W10143/RKFVP

54.03 W260/SA15

54.15

W10144/RKFVP

54.04 W260/SA15

54.15

W10145/RKFVP

54.05 W260/SA15

54.15

W10146/RKFVP

54.06 W260/SA15

54.15

W10147/RKFVP

54.07 W260/SA15

54.15

W10148/RKFVP

54.08 W260/SA20

54.20

W10149/RKFVP

54.09 W260/SA20

54.20

W10150/RKFVP

54.10 W260/SA20

54.20

W10151/RKFVP

54.11 W260/SA20

54.20

W10152/RKFVP

54.12 W260/SA25

54.25

W10153/RKFVP

54.13 W260/SA25

54.25

W10154/RKFVP

54.14 W260/SA25

54.25

W10155/RKFVP

54.15 W260/SA25

54.25

MAINTENANCE

DVS-Junior

20

4.6 MAINTENANCE DETAIL

In the following section, you will find a detailed most important maintenance jobs to be
performed.

4.6.1 CARBURATTOR CLEANING

Flat Screwdriver

1.Take the intake silencer off the carburettor by unscrewing the clamp.

2. Disconnect the throttle cable from the carburettor together with the
spring and the guillotine slide.

3. Take the carburettor off the engine and open the floating
chamber by unscrewing the special cap in the middle of the
chamber. Clean the parts, openings and passages with
compressed air.

4. Unscrew the main jet by means of a flat screw driver. Replace
it with another calibrated differently. Be careful, the washer
must be installed in one position only. A wrong assembly may
cause the carburettor complete malfunction.

5. Check the plug gasket of the floating chamber is still intact
and if damaged, replace it.

6. Close the floating chamber by securing the special cap and
mount the carburettor on the engine.

7. Clean the inside of the intake silencer.

8. Mount the intake silencer on the carburettor flange.

9. Tighten it with the specific clamp.

Wrong assembly will cause the loss of the intake silencer.

MAINTENANCE

DVS-Junior

21

4.6.2 CHANGING JETS

Flat Screwdriver

22mm Fixed Wrench

Wrong carburation set up could cause sever engine

damage.

1. Take the intake silencer off the carburettor by unscrewing the
clamp.

2. Disconnect the throttle cable from the carburettor together
with the spring and the guillotine slide.

3. Take the carburettor off the engine and open the floating
chamber by unscrewing the special cap in the middle of the
chamber. Clean the parts, openings and passages with
compressed air.

4. Unscrew the main jet by means of a flat plier. Replace it with
another calibrated differently. Be careful, the washer must be
installed in one position only. A wrong assembly may cause the
carburettor complete malfunction.

5. Check the plug gasket of the floating chamber is still intact and if damaged, replace it.

6. Close the floating chamber by securing the special cap and mount the carburettor on the

engine.

7. Clean the inside of the intake silencer.

8. Mount the intake silencer on the carburettor flange.

9. Tighten it with the specific clamp.

Wrong carburettor assembling may cause engine malfunction and damage.

Wrong assembly will cause the loss of the intake silencer.

MAINTENANCE

DVS-Junior

22

4.6.3 SPARK PLUG CLEANING AND REPLACEMENT

Spark Plug Wrench

Metal Br

ush

Risk of burning: Perform this task ONLY when engine is cool.

Oils produce carbon deposits or residues that make n

ece

ssa

ry
the spark plug to be checked and cleaned, at least every 5 hours.
Remove the spark plug and clean it by using a brass metal brush.

Use a specific spark plug gap gauge to set up correct gap.
Correct gap: 0,8 mm.
Every 30 hours is highly recommended to change spark plug.

4.6.4 EXHAUST CLEANING

Metal Brush

Heater

Oils produce carbon deposits or residues that make necessary the exhaust to be checked and
cleaned, at least every 10 hours.
Disassemble the exhaust from the engine by removing the two springs and check the exhaust
carefully.

Heat the exhaust with a heater and remove all carbon deposits with a metal brush.

MAINTENANCE

DVS-Junior

23

4.6.5 CYLINDER HEAD CLEANING

10mm Tube Wrench

Torque Wrench

Spark Plug Wrench

Be aware, cylinder head combustion chamber

volume may vary during the race. Carbon deposits may
cause variations in cylinder head volume.
Remove spark plug. Remove the six head nuts and relative
washers.
Remove cylinder head by pulling it up carefully.

Use rubber gloves.

After cleaning the combustion chamber with fuel, reassemble
cylinder head.

Insert carefully the head on to the studs and check all o-rings are fitted in the right place. If any is
damage, change it.
Insert washers and nuts in the studs and tight them manually. Now, by using a torque wrench
tighten them alternatively at 1,2 Kgm.

MAINTENANCE

DVS-Junior

24

4.6.6 CYLINDER CHECK AND MAINTENEANCE

10mm Tube Wrench

Torque Wrench

To avoid engine damage, a Vortex qualified mechanic

must perform inspection and honing.

Remove exhaust.

Remove spark plug. Remove the six head nuts and
relative washers.
Remove cylinder head by pulling it up carefully.
Remove the cylinder from the crankcase slowly. Once cylinder
is separate from crankcase, hold the connecting rod with the
other hand and pull the cylinder out totally by pulling it up
carefully.
Every time cylinder is removed we recommend changing
cylinder gasket.

Cylinder must be honed when cylinder/piston

clearance is more than 0.12mm or when ovalization is

more than 0.02 mm.
Change piston (see 4.6.7)
New piston cylinder/piston clearance must be 0.12mm.

REASEMBLING
Insert a new gasket on to the studs carefully and place it on the
crankcase surface flat.
Insert now the cylinder in the studs very carefully. With the
other hand close piston ring and inset the piston into the
cylinder. If piston ring is not closed totally, risk of damaging the cylinder and piston ring is very
high. Push the cylinder down firmly. Tight four cylinder nuts with torque wrench at 20Nm.
Insert cooper washer.
Install, carefully, the head onto the studs and check all o-rings are fitted in the right place. If any is
damaged, change it.
Install washers and nuts onto the studs and tight them manually. Now, by using a torque wrench
tighten them alternatively at 1,6 kgm.

Every time cylinder is honed or piston changed, the engine break-in procedure must be

performed.

MAINTENANCE

DVS-Junior

25

4.6.7 PISTON CHECK AND MAINTENEANCE

10mm Tube Wrench

Torque Wrench

To avoid engine damage, a Vortex qualified mechanic

must perform inspection and honing.

Remove exhaust.

Remove spark plug. Remove the six head nuts and
relative washers.
Remove cylinder head by pulling it up carefully.
Once cylinder is separate from crankcase, hold the connecting
rod with the other hand and pull the cylinder out totally by
pulling it up carefully.
Every time cylinder is removed we recommend changing
cylinder gasket. (3)

Remove the circlips from
the piston pin. Push the pin
out of the piston. (4)

Before
assembling a new
piston check

dimensional sizes. Correct
cylinder/piston clearance is 0.12mm.
ASSEMBLING
Oil and insert the roller cage in the connecting rod.
Install the new piston in the connecting rod by placing the
arrow stamped in the head of the piston facing the exhaust
port.
Insert now the piston pin and secure it with the circlips.

Attention, wrong circlips assembling may cause serious
damage.

Insert the piston ring in the piston carefully. Check both ends of the piston ring when totally closed
have a gap of 0,30/0,35 mm.
Now you are ready to assemble cylinder and cylinder head as per 4.6.6

Engine needs a brake-in session when a new piston has been placed.

PARITSTS

_

DVS-Junior

7

8

108

PARTS

DVS-Junior

27

1

W003 Candela NGK b10 eg Spark plug NGK b10 eg 1

2

W511/10 Vite TBCE M6x10 Roundhead screw M6 x10 10

3

W10662

Guarnizione

rame 6x10x1,5 Copper gasket 6x10x1,5 10

4

W530/10FL Dado M8 chiave 10 flangiato Nut M8x10 10

5

W560/17 Rondella 8,4x17x1,6 ZNB Washer 8,4x17x1,6 ZNB 10

6

W10010/DVSJ Testa motore DVS JUNIOR Engine head DVS JUNIOR 1

--

W630/005KF

Guarnizione

testa ottone crudo 0,05 Brass head gasket 0,05 1

--

W630/10KF

Guarnizione

testa ottone crudo 0,10 Brass head gasket 0,10 1

--

W630/20KF

Guarnizione

testa ottone crudo 0,20 Brass head gasket 0,20 1

--

W630/30KF

Guarnizione

testa ottone crudo 0,30 Brass head gasket 0,30 1

7

W629 O-ring 3400 testa/cilindro NBR O-ring

cylinder/head

3400 NBR 1

8

W620 O-ring testa 2237 viton O-ring head 2237 viton 1

9

W627 O-ring prigionieri 2031 O-ring stud bolt 2031 10

10B W10021/KF3C Cilindro motore DVS J con prigionieri Complete cylinder DVS J with studbolt 1

11

W10043/RVZ Prigionieri testa/cilindro M8x56 Cylinder head studbolt M8x56 1

12

W10104/KF1 Guarnizione base cilindro spessore 0.1 Cylinder basis gasket 0,1 1

12

W10104/KF2 Guarnizione base cilindro spessore 0.2 Cylinder basis gasket 0,2 1

12

W10104/KF3 Guarnizione base cilindro spessore 0.3 Cylinder basis gasket 0,3 1

12

W10104/KF4 Guarnizione base cilindro spessore 0.4 Cylinder basis gasket 0,4 1

12

W10104/KF5 Guarnizione base cilindro spessore 0.5 Cylinder basis gasket 0,5 1

13

W670/RKF

Guarnizione

scarico Exhaust gasket engine 1

14

W10930/DDJ Collettore scarico Exhaust manifold 1

15

W510/14 Vite brugola M6x14 8.8

Socket-head

screw M6x14 8,8 10

19

W10012/DVS Valvola decompressione

Decompression

valve 1

22

W10928/DDS

Orecchietta

attacco molla collettore di scarico Ear connector for the spring exhaust manifold 1

160

SEGMENTO

DALLA

SELEZIONE ALLA SELEZIONE

PISTON

RING

FROM

SElECTION TO SELECTION

SA 10

54.00

SA 12

54.01 54.02

SA 15 54.03

54.07

SA 20 54.08

54.11

SA 25

54.12 54.15

PARTS

DVS-Junior

18

16C

/

29

PARTS

16C W10140/RKF Pistone completo A.P. RKF 54.00 Complete piston A.P. RKF 54.00 1

16C W10141/RKF Pistone completo A.P. RKF 54.01 Complete piston A.P. RKF 54.01 1

16C W10142/RKF Pistone completo A.P. RKF 54.02 Complete piston A.P. RKF 54.02 1

16C W10143/RKF Pistone completo A.P. RKF 54.03 Complete piston A.P. RKF 54.03 1

16C W10144/RKF Pistone completo A.P. RKF 54.04 Complete piston A.P. RKF 54.04 1

16C W10145/RKF Pistone completo A.P. RKF 54.05 Complete piston A.P. RKF 54.05 1

16C W10146/RKF Pistone completo A.P. RKF 54.06 Complete piston A.P. RKF 54.06 1

16C W10147/RKF Pistone completo A.P. RKF 54.07 Complete piston A.P. RKF 54.07 1

16C W10148/RKF Pistone completo A.P. RKF 54.08 Complete piston A.P. RKF 54.08 1

16C W10149/RKF Pistone completo A.P. RKF 54.09 Complete piston A.P. RKF 54.09 1

16C W10150/RKF Pistone completo A.P. RKF 54.10 Complete piston A.P. RKF 54.10 1

16C W10151/RKF Pistone completo A.P. RKF 54.11 Complete piston A.P. RKF 54.11 1

16C W10152/RKF Pistone completo A.P. RKF 54.12 Complete piston A.P. RKF 54.12 1

16C W10153/RKF Pistone completo A.P. RKF 54.13 Complete piston A.P. RKF 54.13 1

16C W10154/RKF Pistone completo A.P. RKF 54.14 Complete piston A.P. RKF 54.14 1

16C W10155/RKF Pistone completo A.P. RKF 54.15 Complete piston A.P. RKF 54.15 1

16C W10140/RKFVP Pistone completo V.P. RKF 54.00 Complete piston V.P. RKF 54.00 1

16C W10141/RKFVP Pistone completo V.P . RKF 54 .01 Complete piston V.P. RKF 54.01 1

16C W10142/RKFVP Pistone completo V.P. RKF 54.02 Compl ete piston V.P. RKF 54.02 1

16C W10143/RKFVP Pistone completo V.P. RKF 54.03 Compl ete piston V.P. RKF 54.03 1

16C W10144/RKFVP Pistone completo V.P. RKF 54.04 Compl ete piston V.P. RKF 54.04 1

16C W10145/RKFVP Pistone completo V.P. RKF 54.05 Compl ete piston V.P. RKF 54.05 1

16C W10146/RKFVP Pistone completo V.P. RKF 54.06 Compl ete piston V.P. RKF 54.06 1

16C W10147/RKFVP Pistone completo V.P. RKF 54.07 Compl ete piston V.P. RKF 54.07 1

16C W10148/RKFVP Pistone completo V.P. RKF 54.08 Compl ete piston V.P. RKF 54.08 1

16C W10149/RKFVP Pistone completo V.P. RKF 54.09 Compl ete piston V.P. RKF 54.09 1

16C W10150/RKFVP Pistone completo V.P. RKF 54.10 Compl ete piston V.P. RKF 54.10 1

16C W10151/RKFVP Pistone completo V.P. RKF 54.11 Compl ete piston V.P. RKF 54.11 1

16C W10152/RKFVP Pistone completo V.P. RKF 54.12 Compl ete piston V.P. RKF 54.12 1

16C W10153/RKFVP Pistone completo V.P. RKF 54.13 Compl ete piston V.P. RKF 54.13 1

16C W10154/RKFVP Pistone completo V.P. RKF 54.14 Compl ete piston V.P. RKF 54.14 1

16C W10155/RKFVP Pistone completo V.P. RKF 54.15 Compl ete piston V.P. RKF 54.15 1

16D W260/SA10 Fascia elastica 54,10x1,5 Piston ring 54,10x1,5 1

16D W260/SA15 Fascia elastica 54,15 x1,5 Piston ring 54,15x1,5 1

16D W260/SA20 Fascia elastica 54,20x1,5 Piston ring 54,20x1,5 1

16D W260/SA25 Fascia elastica 54,25x1,5 Piston ring 54,15x1,5 1

17

W10081 Anellino fermo spinotto d.15 Piston circlip d.15 10

18

W10082 Spinotto pistone d.15 Piston pin d.15 1

DVS-Junior

PARTS

54

63

62

64

65

66

67

69

68

72

73

75

77

820

83E

DVS-Junior

31

PARTS

54

W2004/KF Ingranaggio

contralbero

su albero Balancer shaft gear on shaft 1

55

W1767/1ROK Molla a tazza 20,4x32,5x1,5

Belleville

washer 20,4x32,5x1,5 1

56

W1765/KF Dado M20x1 SP.5 Nut M20x1 TH.5 1

57

W2000/DVS Distanziale pompa acqua DVS Water pump spacer DVS 1

58

W502/16T Vite TSCE M8x16 tornita Flathed screw M8x16 turned 1

59

W124 Chiavetta 4x4x10 Key 4x4x10 1

60

W126 Chiavetta 4x4x20 Key 4x4x20 1

61

W2016/KF Ralla massetta contralbero Counterweight washer balancer shaft 1

62

W2014/KF Massetta lato trasmissione contralbero Counterweight drive side balancer shaft 1

63

W302/KF Cuscinetto a rrulli nu203 ECPC3 Insert nu203 ECPC3 1

64

W2012/KF Albero contralbero Shaft balancer shaft 1

65

W301/ROK Cuscinetto 6302 tn9 c4 Insert 6302 tn9 c4 1

66

W2013/KF Massetta

contralbero

lato accensione Counterweight balancer shaft ignition side 1

67

W2003/KF Ingranaggio

contralbero

su contralbero Balancer shaft gear on balancer shaft 1

68

W1764/KF Ralla a tazza 14,3x23,7x0,4 Washer 14,3x23,7x0,4 10

69

W1768/KF Dado contralbero M14x1 filetto sx Balancer shaft nut M14x1 left 1

70

W150/DVS Semialbero lato trazione DDS/DDJ/DVS Drive side half crankshaft DDS/DDJ/DVS 1

72

W160/KF Guancetta nylon Nylon crankshaft stuffer 1

73

W230/RKF Biella nuda DVS/DVSJ/DDJ Bare conrod DVS/DVSJ/DDJ 1

74

W10085 Gabbia piede biella 15x19x20 B2 Small end needle cage 15x19x20 B2 1

74

W10085/B4 Gabbia piede biella 15x19x20 B4 Small end needle cage 15x19x20 B4 1

75

W10320 Gabbia argentata iko 20x26x15 B2 Silver plated cage iko 20x26x15 B2 1

75

W10320/B4 Gabbia argentata iko 20x26x15 B4 Silver plated cage iko 20x26x15 B4 1

75

W10320/B6 Gabbia argentata iko 20x26x15 B6 Silver - plated cage iko 20x2x15 B6 1

76

W200/KF Asse accoppiamento albero Crankshaft crankpin 1

77

W10310/KF Ralla argentata d.20.1 a stella Silver-plated s him d.20,1 1

78

W522/12 Vite TSCE M5x12 Flathead screw M5x12 10

79

W124 Chiavetta 4x4x10 Key 4x4x10 1

80

W140/KF Semialbero lato accensione DDS/DDJ/DVS PVL Magneto side half crankshaft DDS/DDJ/DVS PVL 1

81

W122 Chiavetta lato

accensione

2,5x3,7x10 Key 2,5x3,7x10 1

82

W690/3VLR Pignone z-10 Sprocket z-10 1

82

W690/3VLR11 Pignone z-11 Sprocket z-11 1

82

W690/3VLR12 Pignone z-12 Sprocket z-12 1

82

W690/3VLR13 Pignone z-13 Sprocket z-13 1

83

W693/VLR Seeg er pignone Sprocket circlip 10

82D W190/RKF Biella completa DDJ/DVS Complete conrod DDJ/DVS 1

83E W130/DDJ Albero motore completo DDJ/DVS PVL Complete crankshaft DDJ/DVS PVL 1

DVS-Junior

PARTS

128

PARTS

103 W511/10 Vite TBCE M6x10 Roundhead screw M6x10 10

104 W570/12 Rondella piana 6 x12x1.5 ZNB Flat washer 6x12x1.5 ZNB 10

105 W10662

Guarnizione

rame 6x10x1,5 Copper gasket 6x10x1,5 10

106 V.TCE6X40 Vite brugola M6x40

Socket-head

screw M6x40 10

106A V.TCE6X45 Vite brugola M6x45

Socket-head

screw M6x45 10

107 W310 Paraolio FPJ 20 x35x7 doppio labbro Oilseal FPJ 20x35x7 doubble lips 1

108 W530/10FL Dado m8 chiave 10 flangiato Nut m8x10 10

109 W10042/1

Prigioniero

base cilindro M8x55 Cylinder studbolt M8x55 1

109A W10042/KF

Prigioniero

base cilindro M8x49 Cylinder studbolt M8x49 1

110 W10552 Paraolio pignone 25x40x7 Sprocket seal 25x40x7 1

111 W075/1 Bussola carter 10x10,5x6,5 Crankcase dowel 10x10,5 x6,5 1

112 W015 Raccordo acqua testa/cilindro Water head pipe fitting 1

113 W1766/1ROK Spina cilindrica 6x12 Cylindrical pin 6x12 1

114 W10662

Guarnizione

rame 6x10x1,5 Copper gasket 6x10x1,5 10

115 W800/ROK Raccordo presa depressione Depression pipe fitting 1

118 W512/14 Vite TSCE M5x14 Flathead screw M5x14 10

119 W2017/DDS Coperchio contralbero DDS/DDJ DDS/DDJ Balancer shaft cover 1

120 W300/A4 Cuscinetto banco 6205 c4 Insert

crankcase

6205 c4 1

121 W10252 Tappo olio TCEM1M12x1.5 completo Complete oil plug TCEM1M12x1,5 1

122 W800 Raccordo depressione M8 esagonale Depression pipe fitting M8 hexagonal 1

123 W10267

Guarnizione

rame 8x12x1 Copper gasket 8x12x1 10

124 V.TCE6X50 Vite brugola M6x50

Socket-head

screw M6x50 10

125 V.TCE6X16 Vite brugola M6x16

Socket-head

screw M6x16 10

126 W10277 Fascetta carburatore Carburettor clamp 1

127 V.TCE6X20 Vite brugola M6x20

Socket-head

screw M6x20 10

127 W510/14 Vite brugola M6x14 8.8

Socket-head

screw M6x14 8,8 10

128 W350/ACADEMY Convogliatore pacco lamellare DDJ academy Reed valve piramid conveyor academy 1

129 W740/MR Coperchio carter frizione Clutch guard cover 1

130 W351/RKF

Guarnizione

convogliatore pacco la mellare Conveyor reed valve pyramid gasket 1

131 W362/DVS Pacco lamellare DDS/DDJ/DVS con balestrini Reed pyram. DDS/DDJ/DVS with stiffener 1

132 W393/1KF30 Petalo carbonio spessore 0,30 Carbon petal thickness 0,30 1

132A W399/KF Balestrino carbonio 9/12 Carbon Flow deviat.9/12 1

133 W389 Piastrina lunga pacco maggiorato Enlarged pyramid long plate 1

134 W380 Viti fissaggio lamelle M3x5 Reeds fixing screws M3 x5 10

135 W501/18 Vite TBCE M8x18 10.9 Roundhead screw M8x18 10.9 10

136 W2050/DDJ24 Collettore carburatore 24mm Inlet manifold 24mm 12

DVS-Junior

33

1

.TT

15

1

PARTS

141

158

I

140

142

144

145

/145A

146

/

@ @

@@@

(j

{jGi

nc:::::a

l.ll

(@)

150

1

54

157

155

156

•

35

PARTS

140 W075/1 Bussola carter 10x10,5x6,5 Crankcase dowel 10x10,5x6,5 1

141 W066/KF

Guarnizione

coperchio ingranaggi Gears cover gasket 1

142 W065/DDSP Coperchio ingranaggi completo PVL Gear cover PVL complete 1

143 V.TCE6X25 Vite brugola M6x25

Socket-head

screw M6x25 10

144 W440 Silent-block fissaggio bobina Coil fixing silent-block 1

145 W430/1 Cavetto massa in treccia Ground stra nded cable 1

145A W430 Cavetto massa Ground cable 1

146 R.P.6X18 Rondella piana 6x18x1 Flat washer 6x18x1 10

147 R.P.6X12 Rondella piana 6.3x12,5x1 Plain washer 6.3x12,5x1 10

148 W531/06 Dado esagonale M6x1 Hexagonal nut M6x1 10

149 V.TCE6X20 Vite brugola M6x20

Socket-head

screw M6x20 10

150 W2036/ROK Livello olio TLA2- M16x1,5 Oil level TLA2 M16x1,5 1

151 V.TCE6X25 Vite brugola M6x25

Socket-head

screw M6x25 10

152 W524/14 Vite brugola ribassata M5x14

Socket-head

screw M5x14 10

153 W320/1 Paraolio FPJ 17x28x7 doppio labbro Oil seal FPJ 17x28x7 double lip 1

154 W7002203000100 Accensione completa Bare Ignition 1

155 W580/11 Rondella piana 11,5 x5,3x1 Flat washer 11,5x5,3x1 10

156 V.TCE5X18 Vite brugola M5x18

Socket-head

screw M5x18 10

157 W695/1ROK Dado accensione M12x1 ZNB Ignition nut M12x1 ZNB 1

158 W420/2 Pipetta candela per accensione digitale Spark cap for digital ignition 1

159 W7002244000200 Bobina accensione DVS JUNIOR Coil DVS JUNIOR 1

DVS-Junior

261

PARTS

'\'

fj

269

·

I

t::::@

265

263

264

DVS-Junior

DVS-Junior

37

PARTS

260 W849/ACADEMY Flangia carburatore academy Academy carburettor flange 1

261 W531/06 Dado esagonale M6x1 Hexagonal nut M6x1 10

262 W570/12 Rondella piana 6x12x1.5 ZNB Flat washer 6x12x1.5 ZNB 10

263 W440 Silent-block fissaggio bobina Coil fixing silent-block 1

264 W11023 Pompa depressione Dell'orto Vacuum pump Dell'orto 1

265 W10052/RVX Supporto pompa benzina Vacuum support pump 1

267 W10925/DDS Molla scarico DDJ Muffler spring DDJ 1

268 W10901/DDJ Marmitta DDJ Muffler DDJ 1

270 W10810/ACADEMY Carburatore Dell'orto WHST 24 BS Dell'orto carburettor WHST 24 BS 1

DVS-Junior

I

PARTS

271

2811

292

297

298--0
299--1

DVS-Junior

39

PARTS

270 W10810/ACADEMY Carburatore Dell'orto WHST 24 BS Dell'orto carburettor WHST 24 BS 1

271 W7022800000900 Kit tubetto Tube kit 1

272 W7022800001000 Kit coperchio camera miscela Chamber mixture cover kit 1

273 W7022800001100 Molla richiamo valvola gas Gas valve spring 1

274 W14416 Fondello guida molla Spring bottom 1

275 W16663-04 Nipplo valvola gas Nipple gas valve 1

276 W9596211 Fermaglio spillo Needle fastener 1

277 W10825231 Rondella piana Flat washer 1

278 W702280000020A Spillo conico Conical needle 1

279 W702280000010A Valvola gas Gas valve 1

280 W7022800001200 Vite fissaggio dispositivo avviamento Starting device fixing scr ew 1

281 W7022800001300 Dispositivo avviamento Starting device 1

283 W7022800001400 Kit vite regolazione miscela minimo Adjustment minimum screw kit 1

284 W7022800001500 Kit vite regolazione valvola gas Adjustment gas valve screw kit 1

285 W702280000070A Getto avviamento Starting jet 1

286 W702280002100A Getto emulsionatore minimo Diffuser jet jet min. 1

288 W702280000030A Polverizzatore Spray nozzle 1

291 W702280000040A Valvola a spillo Needle valve 1

292 W7022800001600 Busta g uarnizioni car buratore Carburettor gaskets kit 1

293 W7022800001700 Bilanciere galleggiante Float balancer 1

294 W7022800001800 Perno galleggiante Float peg 1

295 W1576003

Galleggiante

gr. 4 Float gr.4 1

297 W7028000001900 Vaschetta Float chamber 1

298 W6413110 Getto massimo Jet max. 1

300 W7022800002000 Tappo vaschetta Float chamber plug 1