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Vortex ROK DVS JUNIOR Owner's Manual

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ROK DVS JUNIOR
OWNER'S
MANUAL
WWW.PATRIZICORSE.COM

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Summary of Contents for Vortex ROK DVS JUNIOR

  • Page 1 ROK DVS JUNIOR OWNER’S MANUAL WWW.PATRIZICORSE.COM...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS 1. GENERAL INFORMATION 1.1. Introduction 1.2. Symbols 1.3. Safety information 1.4. Technical Specifications 1.5. Special Technical Specifications for Homologated Engine 1.6. Packaging 2. ENGINE ASSEMBLING 3. STARTING AND BRAKE-IN 4. SERVICING YOUR ENGINE 4.1. Maintenance Schedule and Adjustments 4.2.

  • Page 3: Introduction

    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.

  • Page 4: Technical Specifications

    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 Compressed air Allen T-wrench 4 - 5 - 6 mm Fixed wrench 8 - 10 mm Flat plier Hollowed T-wrench 10 mm Compressed air Unpack the engine and remove any packaging material on it.
  • Page 6 10 mm Fixed Wrench Attach the braided earth wire end between engine and silent block and tighten 10mm locknut. 10mm Fixed Wrench Assemble the second silent block on the engine. Insert braided wire between the small and large washers. Place the coil support plate of the ignition coil in the two silent blocks, and secure black coil earth in same manner as above.
  • Page 7 Connect a kill switch to steering wheel (not supplied) to female bullet connector (pink wire) The coil incorporates RPM control. (Green coil Snr 16,000) (Blue coil Jnr 14,000) Flat Plier Remove the plastic cap from the head of the cylinder. Spark Plug Wrench Manually tighten the spark plug at the head of the cylinder.
  • Page 8 Insert the cable coil in the spark plug and tighten it. For safety, we recommend you to secure the cable coil to the spark plug cap with a plastic strap. Place the spark plug cap on the spark plug and press down the cap fully.
  • Page 9 Place intake cylinders inside the intake silencer. Pre-drill drain hole no larger than 8mm in the centreline underneath location as pictured. Place the DVS air filter connector to the carburettor inside the intake muffler. You will find a groove in the sleeve, necessary to fix properly the rubber boot to the plastic silencer.

  • Page 10: Starting And Brake-In

    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 ROM.
  • Page 11 from the external water pump. If necessary top up the radiator again. Do not close the radiator cap. 4 mm Allen T-Wrench 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.

  • Page 12: Servicing Your Engine

    Routine inspection procedures are very simple 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.

  • Page 13: Chain

    4.4. Chain Lube the chain every race 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. 4.5.

  • Page 14: Exhaust

    Some ASNs allow the use of Z11, Z12 1. By the special tool, remove the snap ring of the pinions. pinion. Standard pinion supplied by Vortex is 2. Remove the pinion by pulling the pinion towards the Z12. outside. 3. Place the new pinion on the crankshaft and secure it by using the appropriate snap ring.
  • Page 15 4.11. Cylinder Every 30 hours cylinder must be In order to perform this job, we highly recommend honed. 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 springs fixing it to the exhaust manifold.

  • Page 16: Cylinder

    4.12. Piston Oils produce carbon deposits or In order to perform this job, we highly recommend residues that make necessary the spark taking the engine off the chassis. However, you may do plug to be checked and cleaned, at the job even with the engine mounted. least every race.

  • Page 17: Connecting Rod

    See "Starting and Break-in". 4.13. Connecting Rod Every 60 hours the con-rod and roller cage must be changed. Due to special tools required, this operation must be performed by the Vortex technicians or qualified mechanics only. 4.14. Bottom End bearings Bearings must be checked at 30hrs, and eventually replaced, after 60 hours of use.

  • Page 18: Engine Exploded View And Parts List

    WWW.PATRIZICORSE.COM...
  • Page 19 WWW.PATRIZICORSE.COM...
  • Page 20 ROK DVS JUNIOR POSITION PART NUMBER DESCRIPTION NUMBER W003 Spark plug ngk b10 eg W511/10 Roundhead screw m6 x 10 W10662 Copper gasket 6 x 10 x 1.5 W530/10FL Nut m8 x 10 W012/DVS Head sealing nuts W560/17 Washer m8.2 x 17 x 1.5...
  • Page 21 刀 伀 䬀   䐀 嘀 匀   䨀 唀 一 䤀 伀 刀 WWW.PATRIZICORSE.COM...
  • Page 22 ROK DVS JUNIOR POSITION PART NUMBER DESCRIPTION NUMBER W2004/KF Balancer shaft gear on shaft W1767/1ROK Belleville washer 20.4 x 40 x 1.5 W1765/KF Nut m20 x 1 th. 5 W2000/DVS Water pump spacer DVS W502/16T Flathead screw m8 x 16 turned...
  • Page 23 WWW.PATRIZICORSE.COM...
  • Page 24 ROK DVS JUNIOR POSITION PART NUMBER DESCRIPTION NUMBER W511/10 Roundhead screw m6 x 10 W570/12 Head washer 6 x 12 x 1.5 W10662 Copper gasket d.6 x 10 x 1.5 V.TCE6X40 Socket-head screw m6 x 40 106A V.TCE6X45 Socket-head screw m6 x 45...
  • Page 25 WWW.PATRIZICORSE.COM...
  • Page 26 ROK DVS JUNIOR POSITION PART NUMBER DESCRIPTION NUMBER W075/1 Crankcase dowel 10 x 10.5 x 6.5 W066/KF Gears cover gasket W065/DDSP Complete gears cover DVS V.TCE6X25 Socket-head screws m6 x 25 W440 Coil fixing silent-block R.P.6X18 Flat washer 6 x 18 x 1.5 R.P.6X12...
  • Page 27 刀 伀 䬀   䐀 嘀 匀   䨀 唀 一 䤀 伀 刀 WWW.PATRIZICORSE.COM...
  • Page 28 ROK DVS JUNIOR POSITION PART NUMBER DESCRIPTION NUMBER V.TCE10X40 Socket head screw 10 x 40 0039.A30A AL rear engine mount bracket 1 screw 92x30mm 0039.A30 AL engine mount bracket 1 screw 92x30mm 0038.DOAF Flat MG DVS engine mount 92x30mm V.TCE8X35 Socket head screw 8 x 35 WWW.PATRIZICORSE.COM...
  • Page 29 WWW.PATRIZICORSE.COM...
  • Page 30 ROK DVS JUNIOR POSITION PART NUMBER DESCRIPTION NUMBER W10901/DVSJ Exhaust pipe Jnr W10925 Exhaust springs Jnr 0225.GLB29 Air box WDVS/1AF Air filter DVS WA071 Ignition Puller PVL WWW.PATRIZICORSE.COM...
  • Page 31 WWW.PATRIZICORSE.COM...
  • Page 32 ROK DVS JUNIOR POSITION PART NUMBER DESCRIPTION NUMBER W810/DVS IBEA carburetor d. 24 W810/408DVS Gasket kit DVS W810/409DVS Kit complete DVS W810/351 Lower body gasket W810/352 Black bottom membrane W810/353 Diaphragm cover W810/355 Top body gasket W810/356 Top membrane (clear)
  • Page 33 刀 伀 䬀   䐀 嘀 匀   䨀 唀 一 䤀 伀 刀 WWW.PATRIZICORSE.COM...
  • Page 34 ROK DVS JUNIOR POSITION PART NUMBER DESCRIPTION NUMBER 0093.TB OTK radiator 400x200mm complete with supports 0094.TA Support for OTK radiator 400x200mm 0093.T3 Radiator plug 0094.R0 Support for radiator 400x200mm 0094.S0 Support prop for radiator 400x200mm 0094.PA Support plate for radiator 0093.02...
  • Page 35 刀 伀 䬀   䐀 嘀 匀   䨀 唀 一 䤀 伀 刀 WWW.PATRIZICORSE.COM...
  • Page 36 ROK DVS JUNIOR POSITION PART NUMBER DESCRIPTION NUMBER Radiator kit OTK 470x265x43 complete with 0093.EOKIT supports (Air choke kit optional) 0094.ZB Air choke kit V.TB5X20 TB screw 6x16 R.P.5X11 Washer d=5x11x1 mm 0094.E1 Upper support for radiator OTK 470x265x43 0094.E1B Upper radiator support bar OTK 470x265x43 V.TB6X16...
  • Page 37 刀 伀 䬀   䐀 嘀 匀   䨀 唀 一 䤀 伀 刀 WWW.PATRIZICORSE.COM...
  • Page 38 ROK DVS JUNIOR POSITION PART NUMBER DESCRIPTION NUMBER 0097.00 Water pump 0097.02 Water pump pulley 0097.03 Water pump crankshaft 0097.04 Water pump bearing 0097.05 Water pump oil seal 0097.06 Water pump OR 0097.07 Water pump impeller 0097.08 Seeger for water pump shaft 0259.E28KIT...

  • Page 39: Contacts

    6. CONTACTS MANUFACTURER Vortex Factory Via E. Fermi 5 27040 – Campospinoso Italy Phone no.: +39 0385 765200 support@vortex-engines.com Australian Importer Patrizicorse Lot 1 John Lund Dr Hope Island, QLD, 4212 Phone: +61 7 5530 1583 info@patrizicorse.com www.patrizicorse.com AKA Australian Karting Association...

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