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DVS-Junior

INDEX

1. GENERAL INFORMATION

1.1. Symbols

1.2. Safety information

1.3. Technical Specifications

1.4. Special Technical Specifications for Homologated Engine

1.5. Packaging

2. ENGINE ASSEMBLING

2.1. Tools

2.2. Engine Assembling Procedure

3. STARTING AND BRAKE-IN

4. SERVICING YOUR ENGINE

4.1 Maintenance Schedule and Adjustments

4.2 Torque Chart

4.3 Maintenance

4.4 General Tolerances

4.5 Piston and Piston Rings

4.6 Maintenance Detail

4.6.1 Carburettor Cleaning

4.6.2 Changing Jets

4.6.3 Spark Plug Cleaning and Replacement

4.6.4 Exhaust Cleaning

4.6.5 Cylinder Head Cleaning

4.6.6 Cylinder Check and Maintenance

4.6.7 Piston Check and Maintenance

5. ENGINE EXPLODED VIEW AND PARTS LIST

Содержание ROK DVS J

Страница 1: ...ROK DVS J OWNER S MANUAL...

Страница 2: ...fely and in a proper manner All the information in this manual is based on the latest experience and product information available at the time of writing Vortex reserves the right to make any kind of...

Страница 3: ...KE IN 17 4 SERVICING YOUR ENGINE 4 1 Maintenance Schedule and Adjustments 18 4 2 Torque Chart 18 4 3 Maintenance 18 4 4 General Tolerances 19 4 5 Piston and Piston Rings 19 4 6 Maintenance Detail 20 4...

Страница 4: ...ust emissions are hazardous to your health Always wear gloves and proper clothing when working on your engine Use caution when handling fuel Gasoline is flammable and explosive Avoid any skin contact...

Страница 5: ...pray Needle AQ270 Minimum Jet U43 Maximum Jet 100 Ignition PVL Digital Timing 3mm Spark Plug Gap 0 7 0 8 mm General Specifications Fuel Mixture Crank Case Oil Engine Weight 5 30gr W80 90 10 2Kg API GL...

Страница 6: ...r country homologation file for eventual specific rules and or sizes 1 5 PACKAGING Your engine will be packed in a sealed box with the Vortex logo printed on and a sticker with model and serial number...

Страница 7: ...rform assembling or maintenance jobs you will need the following tools Tipo Misura Allen Wrench 2 5 mm Allen Wrench 5 mm Allen Wrench 6 mm Fixed Wrench 10 mm Dynamometric Wrench Phillips Screwdriver F...

Страница 8: ...on it Use compressed air to eliminate any further packaging material Remove all plastic covers AFTER cleaning the engine Allen Wrench 6mm Lay the engine on its side and attach the engine mount to the...

Страница 9: ...ngine before oil have been Remove the oil filler cap with a 6 mm Allen Wrench Fill the engine with 30gr of W80 90 viscosity oil International Specification API GL 5 Re fit the oil filler cap 10mm Alle...

Страница 10: ...to the crankcase Caution Wrong assembling will cause coil failure Insert now the coil in the two silent blocks Insert the ground cable from the coil into the upper silent block as per photo Insert a...

Страница 11: ...n the bottom silent block as per photo Tighten with washer and nut Caution One side of the ground cables may touch the crank case The other ends may touch coil support Please check photo to correct co...

Страница 12: ...eat properly Now you can tighten the spark plug properly Insert the high tension lead into the spark plug cap and tighten it For safety we recommend you secure the high tension lead to the spark plug...

Страница 13: ...t Option 1 5 mm Allen Wrench Part I Insert and tighten the silent blocks in the designed bracket Attachthe bracketto the engine with 6 mm screws provided Red arrow Part II 10mm Fixed Wrench Insert the...

Страница 14: ...ENGINE ASSEMBLING DVS Junior 13 Part III Insert now the vacuum tube into both engine and fuel pump as per red arrows Later we will insert the other 2 tubes in the fuel pump Page 15...

Страница 15: ...ENGINE ASSEMBLING DVS Junior 14 Fuel Pump Bracket Option 2...

Страница 16: ...already to run your engine Assemble aluminium air box adapter to the carburettor Fit the hose clip to the rubber manifold Insert the carburettor in the rubber manifold and tighten the hose clamp tight...

Страница 17: ...ws Get cover spring and slide off Insert the inner throttle cable into and through the elbow on top of the carburettor Insert the spring and then the slide Fit the nipple on the end of the cable into...

Страница 18: ...pump to the carburettor as per red arrows Check carefully with the attached diagram Secure the tube to the fuel pump and the carburettor by using plastic ties Phillips Screwdriver Fasten the intake si...

Страница 19: ...ion proceed as follows Fill the radiator with water and raising the kart from the radiator side make the excess air come out Now top up with more water Spin the rear axle for a few seconds to release...

Страница 20: ...by accelerating up and down the engine RPM alternately between RPM s Bring the water temperature around 48 50 C before stopping the engine Do not accelerate fully but only partially Check that the coo...

Страница 21: ...Operation Carburettor Every Race Cleaning Accelerator Cable Every Race Check Spark Plug Every Race Check Muffler 10 hours Internal Cleaning Cylinder Every piston change Check 4 2 TORQUE CHART Part Tor...

Страница 22: ...KF 54 10 W260 SA20 54 20 W10151 RKF 54 11 W260 SA20 54 20 W10152 RKF 54 12 W260 SA25 54 25 W10153 RKF 54 13 W260 SA25 54 25 W10154 RKF 54 14 W260 SA25 54 25 W10155 RKF 54 15 W260 SA25 54 25 W10140 RKF...

Страница 23: ...of the chamber Clean the parts openings and passages with compressed air 4 Unscrew the main jet by means of a flat screw driver Replace it with another calibrated differently Be careful the washer mus...

Страница 24: ...compressed air 4 Unscrew the main jet by means of a flat plier Replace it with another calibrated differently Be careful the washer must be installed in one position only A wrong assembly may cause th...

Страница 25: ...it by using a brass metal brush Use a specific spark plug gap gauge to set up correct gap Correct gap 0 8 mm Every 30 hours is highly recommended to change spark plug 4 6 4 EXHAUST CLEANING Metal Bru...

Страница 26: ...spark plug Remove the six head nuts and relative washers Remove cylinder head by pulling it up carefully Use rubber gloves After cleaning the combustion chamber with fuel reassemble cylinder head Ins...

Страница 27: ...re than 0 02 mm Change piston see 4 6 7 New piston cylinder piston clearance must be 0 12mm REASEMBLING Insert a new gasket on to the studs carefully and place it on the crankcase surface flat Insert...

Страница 28: ...circlips from the piston pin Push the pin out of the piston 4 Before assembling a new piston check dimensional sizes Correct cylinder piston clearance is 0 12mm ASSEMBLING Oil and insert the roller c...

Страница 29: ...PARITSTS _ DVS Junior 7 8 108...

Страница 30: ...9 W627 O ring prigionieri 2031 O ring stud bolt 2031 10 10B W10021 KF3C Cilindromotore DVS J con prigionieri Complete cylinder DVS J with studbolt 1 11 W10043 RVZ Prigionieritesta cilindroM8x56 Cylind...

Страница 31: ...160 SEGMENTO DALLA SELEZIONE ALLA SELEZIONE PISTON RING FROM SElECTION TO SELECTION SA 10 54 00 SA 12 54 01 54 02 SA 15 54 03 54 07 SA 20 54 08 54 11 SA 25 54 12 54 15 PARTS DVS Junior 18 16C...

Страница 32: ...tone completo V P RKF 54 01 Complete piston V P RKF 54 01 1 16C W10142 RKFVP Pistone completo V P RKF 54 02 Complete piston V P RKF 54 02 1 16C W10143 RKFVP Pistone completo V P RKF 54 03 Complete pis...

Страница 33: ...PARTS 54 63 62 64 65 66 67 69 68 72 73 75 77 820 83E...

Страница 34: ...DVS Junior...

Страница 35: ...DS DDJ DVS Driveside half crankshaft DDS DDJ DVS 1 72 W160 KF Guancetta nylon Nylon crankshaft stuffer 1 73 W230 RKF Biella nuda DVS DVSJ DDJ Bare conrod DVS DVSJ DDJ 1 74 W10085 Gabbia piede biella 1...

Страница 36: ...PARTS 128...

Страница 37: ...to banco 6205 c4 Insert crankcase 6205 c4 1 121 W10252 Tappo olio TCEM1M12x1 5completo Complete oil plug TCEM1M12x1 5 1 122 W800 Raccordo depressioneM8 esagonale Depression pipe fitting M8 hexagonal 1...

Страница 38: ...1 TT151 PARTS 141 158 I 140 142 144 145 145A146 j jGi nc a l ll 150 154 157 155 156...

Страница 39: ......

Страница 40: ...do esagonale M6x1 Hexagonal nut M6x1 10 149 V TCE6X20 Vite brugola M6x20 Socket head screw M6x20 10 150 W2036 ROK Livello olio TLA2 M16x1 5 Oil level TLA2 M16x1 5 1 151 V TCE6X25 Vite brugola M6x25 So...

Страница 41: ...261 PARTS fj 269 I t 265 263 264...

Страница 42: ...DVS Junior...

Страница 43: ...washer 6x12x1 5 ZNB 10 263 W440 Silent block fissaggiobobina Coil fixing silent block 1 264 W11023 Pompa depressioneDell orto Vacuum pump Dell orto 1 265 W10052 RVX Supporto pompa benzina Vacuum supp...

Страница 44: ...DVS Junior I PARTS 271 2811 292 297 298 0 299 1...

Страница 45: ...vice fixing screw 1 281 W7022800001300 Dispositivo avviamento Starting device 1 283 W7022800001400 Kit vite regolazione miscela minimo Adjustment minimum screw kit 1 284 W7022800001500 Kit vite regola...

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