Vortex MINI ROK Owner'S Manual Download Page 1

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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

Rev. 30/09/15

MINI ROK

OWNER’S

MANUAL

Summary of Contents for MINI ROK

Page 1: ...o PV ITALY Tel 39 0385 765200 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 0...

Page 2: ...Specifications 4 1 5 Special Technical Specifications for Homologated Engine 4 1 6 Packaging 4 2 ENGINE ASSEMBLING 5 3 ENGINE CHASSIS ASSEMBLY 15 4 STARTING AND BRAKE IN 22 5 SERVICING YOUR ENGINE 23...

Page 3: ...of the Vortex engine and should remain with the engine itself if resold 1 2 SYMBOLS Personal injury Mechanical Danger Caution Pay attention to the symbols of this manual They alert you of dangerous si...

Page 4: ...on Timing 3 mm Spark Plug Gap 0 8 mm Fuel Mixture 3 Engine Weight All sizes and measurements in this manual are expressed in metrics Always use original Vortex parts and proper tools when working on y...

Page 5: ...0 09 15 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 14 17 mm Flat Pliers Socket Spanner 11 mm Hook...

Page 6: ...Fax 39 030 6804698 Rev 30 09 15 3 Engine Wheelbase Measurements in case you need to drill your engine mount 4 Prepare the three silent blocks washers and nuts provided as per photo 5 10mm Fixed Wrench...

Page 7: ...ate with 6mm nuts and washers supplied photo1 The fixing of the silent block on the opposite side is made with the only 6mm nuts photo 2 Again pay attention to the assembly of the silent block that su...

Page 8: ...one 5mm and one 10mm spacer Fix airbox bracket also by using one 5mm and one 10mm spacer and 6mm screw washer and self locking nut 10 Flat Screwdriver Remove the plastic cap from the head Spark Plug...

Page 9: ...09 15 12 Flat Screwdriver a Remove the plastic cap from inlet manifold b Remove carburettor from its box c Fit the clamp provided together with the carburettor over the inlet rubber manifold d Insert...

Page 10: ...ia ITALY Tel 39 030 6804601 Fax 39 030 6804698 Rev 30 09 15 15 Cross Screwdriver Remove the top of the carburettor by unscrewing the two screws 16 Insert the throttle cable into the elbow on top of th...

Page 11: ...Via dei Soprini 16 25080 PREVALLE Brescia ITALY Tel 39 030 6804601 Fax 39 030 6804698 Rev 30 09 15 19 Take the slide out of the carburettor 20 Insert the lead at the end of the throttle cable into th...

Page 12: ...the top of the carburettor to the carburettor by using the 2 screws unscrewed before in Point 15 24 Flat Pliers By using flat pliers very carefully turn the two carburetor overflow elbows on the carbu...

Page 13: ...ne guard on top of the air tube 28 Insert the foam filter into the intake silencer There is a slot in the rubber manifold that should be inserted in the intake silencer 29 Check the foam filter is pro...

Page 14: ...30 6804601 Fax 39 030 6804698 Rev 30 09 15 31 Flat Screwdriver Attach the assembled intake silencer to the adaptor and fix it by using the specific clamp provided 32 10mm Fixed Wrench 3mm Allen Wrench...

Page 15: ...dei Soprini 16 25080 PREVALLE Brescia ITALY Tel 39 030 6804601 Fax 39 030 6804698 Rev 30 09 15 33 Cover both cables ends with the plastic covers inserted in the cables 34 The stop cable end from the...

Page 16: ...PV ITALY Tel 39 0385 765200 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 03...

Page 17: ...cket carrier and tighten with washer and nut 2 8mm Allen Wrench Now place the engine on the chassis Tighten the engine mount clamps to the engine mount lightly enough to hold the engine in position Do...

Page 18: ...ntact the engine mount if provided by the chassis manufacturer 6 5 mm Allen Wrench Attach the plastic guard bell cover to the engine by using three 6x20 mm Allen screws 8 Insert the plastic tube provi...

Page 19: ...4601 Fax 39 030 6804698 Rev 30 09 15 10 Insert now the throttle cable into the outer 11 Insert the free end of the throttle cable into the register attached to the main rail of the chassis 12 3mm Alle...

Page 20: ...l stop on the chassis in order to get the pedal to stop at the point where the slide in the carburettor is fully open 15 5 mm Fixed Wrench Attach now the battery cradle to the chassis main rail next t...

Page 21: ...17 Insert manually the relay into the female plug in the wiring loom Do not use any tool 18 14 mm Fixed Wrench Place the start bottom Green and the stop bottom Red in the two slots located in the fron...

Page 22: ...cal washer red plastic 6mm washer and 6mm self locking nut supplied b Fix the self adhesive supplied on each plug and on the aluminum support as showed 22 Plug in the two plugs together and then fix t...

Page 23: ...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 spac...

Page 24: ...5 765200 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 Rev 30 09...

Page 25: ...properly Then fill the gas tank in your kart A mistake in measurements could result in engine damage 4 Buttons to start the engine press the green button To stop the engine press the kill switch red...

Page 26: ...icative 5 1 Maintenance Schedule and Adjustments Carburettor Cleaning After every race heat Throttle Cable Check Every race Spark Plug Check Change Every Race After 30 hours Exhaust Internal cleaning...

Page 27: ...correct throttle and that the throttle returns properly and opens full size If the cable frays it must be replaced 5 6 Carburettor Cleaning Fuel and oil may contain some kind of rubbish impurities an...

Page 28: ...the parts openings and passages with compressed air 4 Unscrew the main jet 4 by using a cross screwdriver Place a new one Be careful washer 18 has only one position Wrong assembling will cause totally...

Page 29: ...aust manifold 2 Unscrew the 3 bolts in the exhaust terminal 3 Warm up the pipe with a heat source and remove any carbon deposits by means of a metal brush 5 9 Clutch and Starter Gear Cleaning and or r...

Page 30: ...wing the central nut place the washer 85 12 Grease the needle bearing 90 totally and insert it on the crankshaft 13 Place the clutch bell 87 the spacer 91 and screw the nut 92 Use thread locker to sec...

Page 31: ...t it on the crankshaft 14 Place the clutch bell 87 the spacer 91 and screw the nut 92 Use thread locker to secure it 15 Re place Bendix cover 16 Re place the clutch cover 5 10 Pinion KSNZ allows the u...

Page 32: ...n chamber using a rag moistened with gasoline or solvent ASSEMBLING 5 Check copper gasket on top of cylinder 5 This gasket may provoke changes in the combustion chamber volume 6 Re place cylinder head...

Page 33: ...and eventually changing the piston the engine must go through another break in period See Starting and Break in 5 13 Piston Oils produce carbon deposits or residues that make necessary the spark plug...

Page 34: ...Y a new piston with the right tolerance Wrong tolerance may cause serious damage 10 Grease and place a new roller bearing 70 if needed on the connecting rod 11 Insert a new piston in the connecting ro...

Page 35: ...ing and Break in 5 14 Connecting Rod Every 60 hours the roller cage must be changed During this operation is good use to check and eventually replace the connecting rod too Due to special tools requir...

Page 36: ...ALY Tel 39 0385 765200 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 6804...

Page 37: ...Campospinoso PV ITALY Tel 39 0385 765200 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 6804...

Page 38: ...Campospinoso PV ITALY Tel 39 0385 765200 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 6804...

Page 39: ...Campospinoso PV ITALY Tel 39 0385 765200 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 6804...

Page 40: ...Campospinoso PV ITALY Tel 39 0385 765200 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 6804...

Page 41: ...so PV ITALY Tel 39 0385 765200 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...

Page 42: ...1 37 W800 Depression pipe fitting m8 hexagonal 38 W300 MR Insert 6204 c4 39 W310 Oil seal fpj 20 x 35 x 7 double lip 40 W940 ROK Starter 50589 41 W019 Cylindrical pin 6x18 42 W924 Roller case bk0808 4...

Page 43: ...W2130 ROK Accumulator charger italy 141 W2131 ROK Accumulator charger japan u s a 142 WA052 KF Clutch puller 143 WA061 Clutch nut fix key 144 WA062 Sprocket disassembling tool sr mr 145 W991 Accumulat...

Page 44: ...038 Jet min 38 208 W52620 77 Gaskets kit 209O W53053 78 Float kit 210 W13678 96 Float chamber 211 W13709 36 Float chamber fixing screw 7 CONTACTS Manufacturer Vortex Factory Via E Fermi 5 27040 Caposp...

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