Vortex ROK DVS JUNIOR Owner'S Manual Download Page 6 | Manualshive

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4

10

mm

Fixed Wrench

Attach the

braided earth wire end between

engine and silent block and tighten 10mm

locknut.

5

10mm Fixed Wrench

Assemble the second silent block on the

engine. Insert braided wire between the

small and large washers.

6

Place the coil support plate of the

ignition coil in the two silent blocks, and

secure black coil earth in same manner

as above.

WWW.PATRIZICORSE.COM

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Summary of Contents for ROK DVS JUNIOR

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

Page 2: ...5 3 STARTING AND BRAKE IN 11 4 SERVICING YOUR ENGINE 12 4 1 Maintenance Schedule and Adjustments 12 4 2 Torque Chart 12 4 3 Sizes and Measures 12 4 4 Chain 13 4 5 Throttle Cable 13 4 6 Carburettor 13...

Page 3: ...symbols of this manual They alert you of dangerous situations for you or for your engine 1 3 SAFETY INFORMATION Do not start the engine indoor as garages trailers etc Start the engine in a well venti...

Page 4: ...r engine Proper fuel mix is necessary for optimum engine life and performance 1 5 SPECIAL TECHNICAL SPECIFICATIONS FOR HOMOLOGATED ENGINE Vortex Rok DVS is produced in two versions Senior and Junior l...

Page 5: ...l on it 2 6mm Allen T Wrench Lay the engine on its side and attach the engine mount to the engine base with four 8 mm Allen screws 3 6mm Allen T Wrench Remove the oil filler cap white arrow and fill w...

Page 6: ...ighten 10mm locknut 5 10mm Fixed Wrench Assemble the second silent block on the engine Insert braided wire between the small and large washers 6 Place the coil support plate of the ignition coil in th...

Page 7: ...coil Jnr 14 000 9 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 Lock it with the key to loosening it th...

Page 8: ...om the intake manifold b Remove the carburettor from the box c Making sure that the gasket is in the correct position insert the carburettor on the studs of the intake manifold d Secure the carburetto...

Page 9: ...necessary to fix properly the rubber boot to the plastic silencer 15 Check that the rubber boot is fixed properly to the intake silencer Incorrect installation may cause a loss of the intake silencer...

Page 10: ...s tank in your kart A mistake in measurements could result in engine damage 4 Before making the first start you must fill the carburettor with fuel To do this you need to remove the spark plug and spi...

Page 11: ...arms unevenly proceed again with the bleeding of the cooling system as described in paragraphs 6 7 9 Once the engine is warmed up and the cooling system works properly proceed to the track 10 Run the...

Page 12: ...nge Every Race After 30 hours Exhaust Internal cleaning Every 10 hours Piston Change Up to 30 hours Chain Change After 10 hours Cylinder Honing Up to 30 hours Connecting Rod Change After 60 hours Bott...

Page 13: ...throttle cable from the carburettor 3 Take the carburettor off the engine and open the float chamber by unscrewing the five screws Clean the parts openings and passages with compressed air Check the...

Page 14: ...ce carbon deposits or residues that make necessary the cylinder head to be checked and cleaned at least every race Be aware cylinder head volume may be changed after the race carbon deposits may cause...

Page 15: ...ever you disassemble the cylinder we recommend replacing the cylinder gasket 27 ASSEMBLING Check the tolerance between piston and cylinder Wrong tolerance may cause serious damage 6 Place a new gasket...

Page 16: ...nder we recommend replacing the cylinder gasket 27 6 Remove the 2 piston pin circlips 32 by squeezing the ends together with the needle nose 7 Hook the connecting rod each side with two fingers 8 Push...

Page 17: ...her break in period 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 Vorte...

Page 18: ...WWW PATRIZICORSE COM...

Page 19: ...2 WWW PATRIZICORSE COM...

Page 20: ...12 W10104 KF5 Cylinder basis gasket 0 5 1 13 W670 RKF Exhaust gasket engine kf 1 14 W10930 RKF2 Exhaust manifold RKF2 DVS 1 15 VTCE6X16 Socket head screw m6 x 16 4 16C W10140 RKF Complete piston RKF 5...

Page 21: ...4 WWW PATRIZICORSE COM...

Page 22: ...23 7 x 0 4 1 69 W1768 KF Balancer shaft nut m14 x 1 left 1 70 W150 DVS Drive shaft nut m14 x 1 left 1 72 W160 KF Crankshaft stuffer 1 73 W230 KF2 Bare conrod engine 1 74 W10085 B4 Small end needle cag...

Page 23: ...6 WWW PATRIZICORSE COM...

Page 24: ...m5 x 14 3 119 W2017 KF Balancer shaft cover 1 120 W300 A4 Insert crankcase 6205 c4 1 121 W10267 Complete oil plug tcem1m 12 x 1 5 1 122 W800 Depression pipe fitting m8 hex 1 123 W10267 Copper gasket d...

Page 25: ...WWW PATRIZICORSE COM...

Page 26: ...157 R P 6X12 Flat washer 6 x 12 x 1 5 4 158 W531 06 Hexagonal nut m6 x 1 4 160 W695 1ROK Hexagonal nut m12x1 1 161 V TCE6X20 Socket head screw m6 x 20 1 162 W2036 ROK Oil level tla2 m16 x 1 5 1 163 V...

Page 27: ...10 WWW PATRIZICORSE COM...

Page 28: ...10X40 Socket head screw 10 x 40 1 197 0039 A30A AL rear engine mount bracket 1 screw 92x30mm 1 198 0039 A30 AL engine mount bracket 1 screw 92x30mm 1 199 0038 DOAF Flat MG DVS engine mount 92x30mm 6 2...

Page 29: ...12 WWW PATRIZICORSE COM...

Page 30: ...SITION PART NUMBER DESCRIPTION NUMBER 219 W10901 DVSJ Exhaust pipe Jnr 1 220 W10925 Exhaust springs Jnr 2 221 0225 GLB29 Air box 1 222 WDVS 1AF Air filter DVS 1 223 WA071 Ignition Puller PVL 1 13 WWW...

Page 31: ...14 WWW PATRIZICORSE COM...

Page 32: ...YEL 1 237 W810 362 Centre fixing screw 1 238 W810 363 Idle mixture screw low speed 1 239 W810 364 Idle mixture screw springs 1 240 W810 365 Plastic washer 1 241 W810 366 O ring square cut 1 242 W810 3...

Page 33: ...16 WWW PATRIZICORSE COM...

Page 34: ...6x100 1 K R P 6X18 Washer d 6x18x1mm 1 L 0093 T5 Bush for radiator support 1 M V TPCSEI6X25 TPSCEI screw 6 x 25 1 N 0033 00 Biconical AL washer d 6mm 1 O D M6A B A B nit M6 1 P 0031 00 Rubber d 6x20mm...

Page 35: ...18 WWW PATRIZICORSE COM...

Page 36: ...X16 TB screw 6x16 4 H R P6X12 Washer d 6 3x12 5x1mm 4 I 0094 E1A Upper radiator support rod OTK 470x265x43 1 L D M5AB A B nut M5 4 M 0093 02 Anti vibration rubber 1 N 0033 00 Biconical AL washer d 6mm...

Page 37: ...18 WWW PATRIZICORSE COM...

Page 38: ...for water pump shaft 1 I 0259 E28KIT Complete water pump clamp d 28mm 1 I 0259 E30KIT Complete water pump clamp d 30mm 1 I 0259 E32KIT Complete water pump clam d 32mm 1 J 0098 B0 Water pump pulley d...

Page 39: ...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 12 Macquarie Avenue PENRITH...

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