Vortex MINI ROK Owner's Manual
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Vortex MINI ROK Owner's Manual

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VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200
MINI ROK
OWNER'S
MANUAL
OTK KART GROUP srl
Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. +39 030 6804601 – Fax +39 030 6804698

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  • Page 1 VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200 MINI ROK OWNER’S MANUAL OTK KART GROUP srl Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. +39 030 6804601 – Fax +39 030 6804698...

  • Page 2: Table Of Contents

    VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200 INDICE 1. GENERAL INFORMATION 3 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.

  • Page 3: General Information

    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

    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: Engine Assembling

    VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200 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 –...
  • Page 6 VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200 Engine Wheelbase Measurements in case you need to drill your engine mount. 10mm Fixed Wrench Attach the specific metal-chromed bracket provided to the engine by using 2 of the 4 silent blocks provided.
  • Page 7 VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200 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.
  • Page 8 VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200 Plug the two ends from the ignition to the coil. Green cable goes in green plug. 3 mm and 5 mm Fixed Wrench a. Attach the red cable to the electric starter using the screw there is in it.
  • Page 9 VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200 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 Flat Screwdriver a.
  • Page 10 VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200 Cross Screwdriver Remove the top of the carburettor by unscrewing the two screws. Insert the throttle cable into the elbow on top of the carburettor with the lead nut in.
  • Page 11 VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200 Take the slide out of the carburettor. Insert the lead at the end of the throttle cable into the hole in the center of the slide.
  • Page 12 VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200 Cross Screwdriver Fix the top of the carburettor to the carburettor by using the 2 screws unscrewed before in Point Insert the fuel line from the outlet on the bottom of the fuel pump to the inlet on top carburetor.
  • Page 13 VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200 Check the foam filter is properly fixed in intake silencer. Wrong assembly will cause the loss of the foam filter and intake silencer. Flat Screwdriver...
  • Page 14 VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200 Insert the coil cable into the rubber plug cup so it is tight. It is recommended to secure the coil cable by using a cable tie.

  • Page 15: Engine/Chassis Assembly

    VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200 3. ENGINE/CHASSIS ASSEMBLY 5 mm Allen Wrench + 10 mm Fixed Wrench Place the sprocket in the sprocket carrier and tighten with washer and nut.
  • Page 16 VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200 17 mm Fixed Wrench Once chain tension is correct, tighten mount clamps completely and re-check the chain tension again. Then set the engine stop to just contact the engine mount, (if provided by the chassis manufacturer.)
  • Page 17 VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200 Place a recovery tank under the carburettor and secure it to the chassis by using cable ties. Make two holes on top of the cap and insert the free ends of the tubes coming from the overflow elbows.
  • Page 18 VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200 Flat Screwdriver Take the intake silencer off the carburettor by unscrewing the clamp. It is not necessary to unscrew the bracket. The intake silencer will turn easily.
  • Page 19 VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200 Insert manually the relay into the female plug in the wiring loom. Do not use any tool. 14 mm Fixed Wrench Place the start bottom (Green) and the stop bottom (Red) in the two slots located in the front of the battery cradle.
  • Page 20 VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200 Pass the main wire loom under the seat and secure it to the chassis by using plastic cable ties. Make sure there is no loose wiring that may drag on the track.
  • Page 21 VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200 11 mm Socket Wrench Before fitting the exhaust manifold remove the exhaust gasket and the exhaust port cover. Refit the exhaust gasket to the cylinder, then fit the exhaust manifold by using the brass spacer and the nuts.

  • Page 22: Starting And Brake-In

    VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200 4. STARTING AND BRAKE-IN 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 (pistons, rings, cylinder or crankshaft).

  • Page 23: Servicing Your Engine

    VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200 5. SERVICING YOUR ENGINE Good maintenance is essential for safe, economical and trouble-free operation. Here you will find a maintenance schedule, routine inspection procedures and very simple maintenance procedures by using basic tools.

  • Page 24: Sizes And Measures

    VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200 5.3. Sizes and Measures Tolerance Cylinder/piston 10,5 Timming Piston Sizes W240/MR01A 41,88 W240/MR03A 41,91 W240/MR06A 41,93 W240/MR09A 41,95 W240/MR11A 41,98 5.4. Chain Lube the chain by spraying chain lube on the chain while manually rotating the rear wheel.

  • Page 25: Spark Plug

    VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200 5.Clean the inside of the intake silencer. 6. Attach the intake silencer assembly to the adaptor. 7.Tighten it with the specific clamp. Wrong assembly will cause the loss of the intake silencer.

  • Page 26: Exhaust

    VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200 make necessary the spark plug to be checked and cleaned, at least every 5 hours. Setting Plug Gap: Use a specific spark plug gap gauge to set up correct gap.
  • Page 27 VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200 6.Unscrew clockwise the central nut (84) by using a 24mm fixed wrench to remove it. Stop the starter gear with the specific tool manufactured by Vortex.

  • Page 28: Pinion

    VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200 on the clutch. 8.Before re-assembling, we recommend to clean the area with a solvent. ASSEMBLING 9.Screw the new starter gear (80) to the clutch (82) by using three 6x14mm Allen screws (79).

  • Page 29: Cylinder Head

    VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200 5.11. Cylinder Head Oils produce carbon deposits or residues that In order to perform this job, we highly make necessary the spark plug to be checked recommend taking the engine off the chassis.

  • Page 30: Cylinder

    VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200 5.12. Cylinder Every 30 hours cylinder must be honed. In order to perform this job, we highly recommend taking the engine off the chassis.

  • Page 31: Piston

    VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200 5.13. Piston Oils produce carbon deposits or residues that In order to perform this job, we highly make necessary the spark plug to be checked recommend taking the engine off the chassis.

  • Page 32: Connecting Rod

    VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200 pin circlips may cause important damage. 14.Place the piston ring in the piston and check both ends close properly against the brass pin inserted in the piston.

  • Page 33: Engine Exploded View And Parts List

    VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200 6. ENGINE EXPLODED VIEW AND PARTS LIST OTK KART GROUP srl Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. +39 030 6804601 – Fax +39 030 6804698...
  • Page 34 VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200 OTK KART GROUP srl Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. +39 030 6804601 – Fax +39 030 6804698...
  • Page 35 VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200 OTK KART GROUP srl Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. +39 030 6804601 – Fax +39 030 6804698...
  • Page 36 VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200 OTK KART GROUP srl Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. +39 030 6804601 – Fax +39 030 6804698...
  • Page 37 VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200 OTK KART GROUP srl Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. +39 030 6804601 – Fax +39 030 6804698...
  • Page 38 VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200 Dell’Orto Carburettor OTK KART GROUP srl Via dei Soprini, 16 – 25080 PREVALLE (Brescia) ITALY-Tel. +39 030 6804601 – Fax +39 030 6804698...

  • Page 39: Parts List

    VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200 Parts List W010/MR Air head 60cc V.TCE6X20 Socket-head screw m6 x 20 W560 Head washers 8,5 x 15 x 8 W960/RKT Transmission starter support...
  • Page 40 VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200 W1750/1MR Compl.clutch rotor with gear 162H W53036-78 Tube 90° kit W1763/MR11 Compl.clutch housing w/sprocket z11 163I W53031-78 Chamber mixture cover kit W1763/MR10 Compl.clutch housing w/sprocket z10...

  • Page 41: Contacts

    VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200 7. CONTACTS Manufacturer Vortex Factory Via E. Fermi 5 27040 – Capospinoso Italy Tel: +39 0385 765200 support@vortex-engines.com New Zealand Importer Supreme Kart Supplies...

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