Vortex MINI ROK Скачать руководство пользователя страница 26

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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

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. 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.

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

Every 10 hours

Clutch

Check and cleaning

Change

Every 10 hours

After 30 hours

Piston

Change

After 30 hours

Chain

Change

After 10 hours

Cylinder

Honing

After 30 hours

Connecting Rod

Change

After 90 hours

Bottom End

Re-‐built

After 90 hours

5.2. Torque Chart

Cylinder Head Ø 8 mm Nut

kgm 1,8

Exhaust Manifold Ø 7 mm Nut

kgm 1,5

Crankcase Ø 6 mm Screws

kgm 1,2

Bendix cover Screws

kgm 0,8

Starter Gear Nut

kgm 6 (Use threadlocker)

Pinion Bell Ø 5 mm Screws

kgm 0,8

Ignition Nut

kgm 2,8

Pinion Bell Nut

kgm 2,8

Ignition Ø 5 mm Screws

kgm 0,8

Nylon crankshaft stuffer

kgm 0,8 (Use threadlocker)

5.3. Sizes and Measures

Tolerance Cylinder/piston

10,5

Timming

3mm

Piston Sizes

W240/MR01A

41,88

Содержание MINI ROK

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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