Vortex ROK DVS J Manuale utente
ROK
DVS J
OWNER’S
MANUAL
FOREWORD
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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
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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
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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.
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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.
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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.
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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
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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.
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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.
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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.
Indice
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