Vortex ROK DVS J Owner's Manual
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Vortex ROK DVS J Owner's Manual

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ROK DVS J
OWNER'S
MANUAL

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  • Page 1 ROK DVS J OWNER’S MANUAL...
  • Page 2 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 supremekarts@xtra.co.nz...

  • Page 3: Table Of Contents

    INDEX 1. GENERAL INFORMATION 1.1. Symbols 1.2. Safety information 1.3. Technical Specifications 1.4. Special Technical Specifications for Homologated Engine 1.5. Packaging 2. ENGINE ASSEMBLING 2.1. Tools 2.2. Engine Assembling Procedure 3. STARTING AND BRAKE-IN 4. SERVICING YOUR ENGINE 4.1 Maintenance Schedule and Adjustments 4.2 Torque Chart 4.3 Maintenance 4.4 General Tolerances...

  • Page 4: Symbols

    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.

  • Page 5: Technical Specifications

    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...

  • Page 6: 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.

  • Page 7: Tools

    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...

  • Page 8: Engine Assembling Procedure

    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.

  • Page 9: Engine Assembling

    ENGINE ASSEMBLING 6mm Allen Wrench Caution: Engine is supplied WITHOUT oil. DO NOT start engine before oil have been added. 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.
  • Page 10 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.
  • Page 11 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.
  • Page 12 ENGINE ASSEMBLING 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.
  • Page 13 ENGINE ASSEMBLING 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) 10mm Fixed Wrench Part II Insert the fuel pump into the silent blocks and tighten it.
  • Page 14 ENGINE ASSEMBLING 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) DVS-Junior...
  • Page 15 ENGINE ASSEMBLING Fuel Pump Bracket Option 2 DVS-Junior...
  • Page 16 ENGINE ASSEMBLING 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.
  • Page 17 ENGINE ASSEMBLING 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.

  • Page 18: Engine Installation

    ENGINE INSTALLATION 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 intake silencer to carburettor by using the specific metal...
  • Page 19 ENGINE INSTALLATION 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.
  • Page 20 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.

  • Page 21: Torque Chart

    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.

  • Page 22: General Tolerances

    MAINTENANCE 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...

  • Page 23: Maintenance Detail

    MAINTENANCE 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.

  • Page 24: Changing Jets

    MAINTENANCE 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.

  • Page 25: Spark Plug Cleaning And Replacement

    MAINTENANCE 4.6.3 SPARK PLUG CLEANING AND REPLACEMENT Spark Plug Wrench Metal Brush Risk of burning: Perform this task ONLY when engine is cool. Oils produce carbon deposits or residues that make necessary 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.

  • Page 26: Cylinder Head Cleaning

    MAINTENANCE 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.
  • Page 27 MAINTENANCE 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.
  • Page 28 MAINTENANCE 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.
  • Page 29 PARITSTS DVS-Junior...
  • Page 30 PARTS W003 Candela NGK b10 eg Spark plug NGK b10 eg W511/10 Vite TBCE M6x10 Roundhead screw M6x10 W10662 Guarnizione rame 6x10x1,5 Copper gasket 6x10x1,5 W530/10FL Dado M8 chiave 10 flangiato Nut M8x10 W560/17 Rondella 8,4x17x1,6 ZNB Washer 8,4x17x1,6 ZNB W10010/DVSJ Testa motore DVS JUNIOR Engine head DVS JUNIOR...
  • Page 31 PARTS SEGMENTO DALLA SELEZIONE ALLA SELEZIONE PISTON RING FROM SElECTION SELECTION SA 10 54.00 SA 12 54.01 54.02 SA 15 54.03 54.07 SA 20 54.08 54.11 54.12 54.15 SA 25 DVS-Junior...
  • Page 32 PARTS W10140/RKF Pistone completo A.P. RKF 54.00 Complete piston A.P. RKF 54.00 W10141/RKF Pistone completo A.P. RKF 54.01 Complete piston A.P. RKF 54.01 W10142/RKF Pistone completo A.P. RKF 54.02 Complete piston A.P. RKF 54.02 W10143/RKF Pistone completo A.P. RKF 54.03 Complete piston A.P.
  • Page 33 PARTS...
  • Page 34 DVS-Junior...
  • Page 35 PARTS W2004/KF Ingranaggio contralbero su albero Balancer shaft gear on shaft W1767/1ROK Molla a tazza 20,4x32,5x1,5 Belleville washer 20,4x32,5x1,5 W1765/KF Dado M20x1 SP.5 Nut M20x1 TH.5 W2000/DVS Distanziale pompa acqua DVS Water pump spacer DVS W502/16T Vite TSCE M8x16 tornita Flathed screw M8x16 turned W124 Chiavetta 4x4x10...
  • Page 36 PARTS...
  • Page 37 PARTS W511/10 Vite TBCE M6x10 Roundhead screw M6x10 W570/12 Rondella piana 6x12x1.5 ZNB Flat washer 6x12x1.5 ZNB W10662 Guarnizione rame 6x10x1,5 Copper gasket 6x10x1,5 V.TCE6X40 Vite brugola M6x40 Socket-head screw M6x40 106A V.TCE6X45 Vite brugola M6x45 Socket-head screw M6x45 W310 Paraolio FPJ 20x35x7 doppio labbro Oilseal FPJ 20x35x7 doubble lips W530/10FL...
  • Page 38 PARTS / 145A 146 {jGi nc:::::a l.ll 1.TT...
  • Page 39 •...
  • Page 40 PARTS W075/1 Bussola carter 10x10,5x6,5 Crankcase dowel 10x10,5x6,5 W066/KF Guarnizione coperchio ingranaggi Gears cover gasket W065/DDSP Coperchio ingranaggi completo PVL Gear cover PVL complete V.TCE6X25 Vite brugola M6x25 Socket-head screw M6x25 W440 Silent-block fissaggio bobina Coil fixing silent-block W430/1 Cavetto massa in treccia Ground stranded cable 145A W430...
  • Page 41 PARTS ·I t::::@...
  • Page 42 DVS-Junior...
  • Page 43 PARTS W849/ACADEMY Flangia carburatore academy Academy carburettor flange W531/06 Dado esagonale M6x1 Hexagonal nut M6x1 W570/12 Rondella piana 6x12x1.5 ZNB Flat washer 6x12x1.5 ZNB W440 Silent-block fissaggio bobina Coil fixing silent-block W11023 Pompa depressione Dell'orto Vacuum pump Dell'orto W10052/RVX Supporto pompa benzina Vacuum support pump W10925/DDS Molla scarico DDJ...
  • Page 44 PARTS 2811 298--0 299--1 DVS-Junior...
  • Page 45 PARTS W10810/ACADEMY Carburatore Dell'orto WHST 24 BS Dell'orto carburettor WHST 24 BS W7022800000900 Kit tubetto Tube kit W7022800001000 Kit coperchio camera miscela Chamber mixture cover kit W7022800001100 Molla richiamo valvola gas Gas valve spring W14416 Fondello guida molla Spring bottom W16663-04 Nipplo valvola gas Nipple gas valve...

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