manuale shf ing - rok cup usa oil 280gr w10/40 jaso ma-2 o api sl engine weight 19kg -all sizes ......

_____________________________________________________INTRODUCTION_____________________________________________________

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ThankyouforpurchasingVortexengines.Thismanualcontainsinformationonhowtohelpyouwithgettingthebestresultsfromyournewengine.Furthermore,itwillexplainyouhowtooperateyourVortexenginesafelyandinapropermanner.Alltheinformationinthismanualisbasedonthelatestexperienceandproductinformationavailableatthetimeofwriting.Vortexreservestherighttomakeanykindofchangestothismanualatanytimewithoutnoticeandwithoutincurringinanyobligation.ThismanualshallbeconsideredpartoftheVortexengineandshouldremainwiththeengineitselfifresold.

OTKKARTGROUPs.r.l.ViadeiSoprini16

25080Prevalle(Brescia)IT

VortexFactoryViaE.Fermi5

27040Campospinoso(Pavia)IT

[email protected]

_____________________________________________________TABLEOFCONTENTS_____________________________________________________

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1. GENERALINFORMATION 1.1. Symbols 31.2. SafetyInformation 31.3. TechnicalSpecifications 41.4. SpecialTechnicalSpecificationsforHomologatedEngine 51.5. Packaging 52. ENGINEASSEMBLY 6 3. ENGINERUNNINGIN 15 4. MAINTENEANCE 164.1. MaintenanceScheduleGuideandAdjustments 164.2. TorqueChart 164.3. GeneralTolerances 164.4. PistonandPistonRings 174.5. MaintenanceDetailedChart 174.5.1 CarburettorCleaning 174.5.2 ChangingJets 184.5.3 SparkPlugCleaningandReplacement 194.5.4 ExhaustCleaning 194.5.5 CylinderHeadCleaning 204.5.6 CylinderCheckandMaintenance 214.5.7 PistonCheckandMaintenance 224.5.8 ClutchDiscReplacement 24 5. ENGINEEXPLODEDVIEWANDPARTSLIST 25

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1.1. SYMBOLSPayattentiontothesymbolsofthismanual.Theyalertyouofdangeroussituationsforyouorforyourengine.

Personal Injury Mechanical Danger Caution

In order to perform a job, special tools are requested. 1.2. SAFETYINFORMATION

-Donotstarttheengineindoorsgarages,trailersetc.Starttheengineinawell---ventilatedareaonly.Exhaustemissionarehazardoustoyourhealth.-Alwayswearglovesandproperclothingwhenworkingonyourengine.-Usecautionwhenhandlingfuel,asfuelisveryflammableandexplosive.Whenworkingwithfuel,donotsmokeoruseitnearfireorflames.Avoidanyskincontactandinhalingfuelvapors.-Nevertouchmovingpartswhentheengineisrunning.-Duringoperation,bothengineandmuffler,becomeveryhot.Donottouchthemanddonotplaceanythingonthemafteroperation.-Donottouchthesparkplugorcable.Itmayprovokeelectricalshocks.-Understandtheoperationofallcontrolsandlearnhowtostoptheenginequicklyincaseofemergency.-Donotusetheenginewithoutclutchcoverandchainprotection.


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1.3. TECHNICALSPECIFICATIONS

Motore Max MinDisplacement 124.36cc 126.00cc Bore 54.00mm +0.2mm Stroke 53.90mm 54.08mm Squish 1.15mm/Min.CombustionChamber 13cc.

IntakeSystem Inlet ReedValveatcrankcaseCarburetor Dell’OrtoWHSH30MainJet AsperHomologationFileMixtureNeedle AsperHomologationFileSprayNozzle AsperHomologationFileJetmin. AsperHomologationFileIdleDiffuser AsperHomologationFile

Ignition PVL AnalogicTiming 3mmGapsparkplug 0.8mm

General Type Mix 4% GearOil 280grW10/40 JASOMA-2oAPISL EngineWeight 19Kg -Allsizesandmeasurementsinthismanualareexpressedinmetrics.-AlwaysuseoriginalVortexpartsandpropertoolswhenworkingonyourengine.-Properfuelmixisnecessaryforoptimumenginelifeandperformance.


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1.4. SPECIALTECHNICALSPECIFICATIONSFORHOMOLOGATEDENGINES

VortexRokShifterisproducedinonlyoneversion.However,refertoyourcountryhomologationfileforspecificrulesand/orsizes.

1.5. PACKAGINGYourenginewillbepackedinasealedboxwiththeVortexlogoprintedonandastickerwithmodelandserialnumberattached.Itwillbeasecondboxcompletewithaccessoriesascarburettor,muffler,fuelpump,airbox,etc.

_____________________________________________________ENGINEASSEMBLING_____________________________________________________

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2.ENGINEASEMBLINGInordertoperformthisjob,youwillneedthefollowingtools:

Type SizeCompressedair AllenT-wrench 3AllenT-wrench 4AllenT-wrench 5AllenT-wrench 6AllenT-wrench 8Fixedwrench 5mmFixedwrench 7mmFixedwrench 8mmFixedwrench 10mmFixedwrench 13mmFixedwrench 14mmFixedwrench 17mmFixedwrench 22mmCrossheadScrewdriver SparkPlugWrench Plier TorqueWrench

Compressedair

Unpacktheengineandremoveanypackagingmaterialonit.Inlet,exhaustandoilbreatherareprotectedwithPVCcups.Takethemoffonlyaftercompressedaircleaning.


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6mmAllenT-Wrench

Laytheengineonitssideandattachtheenginemounttotheenginebasewithfour8mmAllenscrews.Enginemountandscrewscomewiththeengine.

10mmAllenT-Wrench

Warning: Engine comes with NO oil.Donotstarttheenginebeforefillingit

withoil.Remove the oil filler cap with 10mm Allen T-Wrench and fill with 280gr of engine oil,viscosityW10/40 (type JASOMA-2 or API SL).Replacetheoilcap.


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10mmFixedwrench4mmTFixedwrench

Assemblecoilsupportandcoilasperinstructions.Allneededpartscomewiththeengine.

Assemblethetwosilentblocksonthecoilssupportplateintheenginebyinsertingbetweentheplateandthesilentblockthegroundcable.

Insertcoilinthetwosilentblocks.


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Insertgroundcablefromthecoilandtheother end of the ground cable in thesilentblock.

FixgroundcablesandthecoiltothesilentblockbyusingM6nutandwashersprovided.

Becarefulwhenassemblingground

cable,theendmustbeincontactwiththecoilmetalsupport,theotheroneincontactwithenginecrankcase.Wrongassemblingwillresultincoilfailureand/ortheenginewillnotstart.Connectthecoilconnecterwiththestatorconnecter.


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SparkPlugWrench

RemovethePVCcapfromthecylinderhead.Manuallytightenthesparkplugintothecylinderhead.Lockandunlockwiththesparkplugwrench2/3timestoallowthegaskettoseatproperly.Nowyoucantightenthesparkplugproperly.Insertthecablecoilinthesparkplugcapandtightenit.Forsafety,werecommendyoutosecurethecablecoiltothesparkplugcapwithaplasticstrap.Placethesparkplugcaponthesparkplugandpressthecapfully.

10mmFixedWrench

5mmFixedWrench

Placethefuelpumpinthespecificfuelpumpbracketasperscheme.Allmaterialneededcomeswiththeengine.

10mm.FixedWrench4mm.TWrench

Whenthefuelpumpisplacedontheengineinsertthepulselineatpictured(redarrow).Lateron,theothertwolineswillbeassembled.


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ScrewdriverFlatPlier8mmFixedWrench

a.Removetheplasticcapfromtheintakemanifold.b.Removethecarburetorfromthebox.c.Putthemetalretainingclampprovidedwiththecarburetor,ontherubberintakemanifoldboot.d.Pushthecarburetorfirmlyintointakemanifoldboot.

Makingsurethatthecarburetorisinthemanifoldinthecorrectposition,secureitwiththemetalretainingclampprovided.


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Removetheupperpartofthecarburetorbyunscrewingthecap.Securethethrottlecablescrewontopofthecarburetorcover.Feedthethrottlecableinsidetheregisterandthecarburetorcovermakingsuretoleavethecableinside.Feedthethrottlecablethroughcarburetorslidespring.Pulltheslidefromthecarburetor.Placetheballattheendofthethrottlecablethroughtheholeinthecenteroftheslide.Lockthethrottlecableinsidetheslidebymovingthecabletothesidetothecenter.Placetheslideandthespringinthecarburetor.Replacethecapofthecarburetortothecarburetoritself,screwingmanually.

Verycarefully,byusingthepliers,turnthetwocarburettorventssothattheyarefacingup.


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Placetheventlinesuppliedoneachofthetwovents.Cuthalfofthelineinthecenter,tocreateaventhole.

Insertfuellinefromfuelpumptocarburetor.Securefuellinewithaplasticziptie.


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10mmFixedWrench

Place theclutchcable register. Lateron,whenenginewill beplaced in the chassis,will servetogetapropertensionedclutchcable.

5mmFixedWrench

Assemblegear leverbeforeplacing theengineinthechassis.InstalltheleverontheshaftandtightenitwiththeAllenscrew.

Place and tighten the Allen screwAFTERplacingtheleverintheshaft.

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Onlyaproperbreak-inwillinsurethebestperformanceoutofyourengineinthefutureandguaranteeitslongandtrouble-freelife.Break-inisrequiredwhenanengineisneworhasundergoneamajorserviceoftheengine’smainparts(piston,cylinder,connectingrod,etc.).Preparefuel.Vortexengineworkswithcommercialgasoline,leadedorunleaded,aswellasracingfuel,withminimum95Octane.MixOiland fuelat4% (i.e.40ccofoilevery1.000ccoffuel).Usehigh-qualitysyntheticoilspecificallymadeforkartengines.VortexsuggestsPetronasRokLube,howeverotherbrandswiththesamecompositionmightbesuitable.Shakethecanthoroughlytomixthefuelandtheoilproperly.Thenfillthegastankinyourkart.

Amistakeinmeasurementscouldresultinenginedamage.

Tostartacoldengine,raisethestarterleverpositionedonthecarburettor.Oncetheenginestartspushthechokeleverdown.WarmuptheenginebyacceleratingupanddowntheengineRPMalternatelybetweenRPM’s.Bringthewatertemperaturearound48-50°Cbeforestoppingtheengine.

Donotacceleratefullybutonlypartially.

Checkthatthecoolingsystemwarmsupevenly;incaseitwarmsunevenlyproceedagainwiththebleedingofthecoolingsystem.Oncetheengineiswarmedupandthecoolingsystemworksproperly,proceedtothetrack.RuntheenginebyalternatingRPM’safewsecondsonandoffthethrottleat¾maximumthrottle.Donotholdthethrottleataconstantspeed.Continuethiswayfor5/6lapsandreturntopits.Checkeverythingonthekartistighteningproperly.

Becareful,bothengineandmufflerarehot.ReturntothetrackandslowlyincreasetheRPManddurationoftheaccelerationphasefor10/15minmore.Intermittentlyopenthethrottlefullyandthenreleaseit.

After10/15minutesofbrake-in,yourengineisreadyforcompetition.Duringthebreak-in,nutsandboltstendtoloosen.Oncetheengineiscold,checkthetorqueoftheexhaust,head,etc.

3.ENGINEBREAKIN

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4.MAINTENANCE

Goodmaintenanceisessentialforsafe,economicalandtrouble-freeoperation.Hereyouwill find a maintenance schedule for your engine. Routine inspection procedures arevery simple by using basic tools. Some service tasks that are more difficult or needs

specialtoolsmustbeperformedbyVortextechniciansorqualifiedmechanics.Timingscheduleperiodsareonlyindicative.Extremecarburationsetupshighlymodifytimingscheduleperiods.4.1.MAINTENANCESCHEDULEGUIDEANDADJUSTEMENTS

Part Frequency OperationCarburetor EveryRace CleaningAcceleratorCable EveryRace CheckSparkPlug EveryRace CheckExhaust 20liters InternalCleaningPistonPin 60liters SubstitutionPistonPinRollerCage 60liters SubstitutionConnectingRod 400liters SubstitutionCrankShaftPin 200liters SubstitutionSilverWashers 200liters SubstitutionCrankShaftRollerCage 200liters SubstitutionOilSeals 200/oreverycrankcaseopening SubstitutionCrankShaftBearings 800liters Substitution

4.2.TORQUECHART

Part TorqueinNm NotesCylinderheadNuts 1.6 Cylinder/crankcaseNuts 2.0 CrankcaseØ6mmScrews 1.0/1.1 ClutchDiscsHolders 0.8 IgnitionRotorNut 1.8 ExhaustmanifoldNuts 1.0/1.1 ClutchNut 4.5 Position121

4.3.GENERALTOLERANCES

Part Type Measure OperationCylinder Ovalization 0.02 HoningPiston/Cylinder Clearance 0.09 --

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4.4.PISTONANDPISTONRINGS

PartNumber PistonSize PistonRingPart PistonRingW10126/SHF 53.86 W260/ROK95 53.95W10131/SHF 53.91 W260/ROK00 54.00W10136/SHF 53.96 W260/ROK00 54.00W10138/SHF 53.98 W260/ROK05 54.054.5.MAINTENEANCEDETAILCHARTIn the following section, you will find a detailed most important maintenance jobs to beperformed.4.5.1.CarburetorCleaning

FlatScrewdriver

1.Taketheintakesilenceroffthecarburetorbyunscrewingtheclamp.2.Disconnectthethrottlecablefromthecarburetortogetherwiththespringandtheguillotineslide.3.Takethecarburetorofftheengineandopenthefloatingchamberbyunscrewingthespecialcapinthemiddleofthechamber.Cleantheparts,openingsandpassageswithcompressedair.4.Unscrewthemainjetbymeansofaflatscrewdriver.Replaceitwithanothercalibrateddifferently.Becareful,thewashermustbeinstalledinonepositiononly.Awrongassemblymaycausethecarburetorcompletemalfunction.5.Checkthepluggasketofthefloatingchamberisstillintactandifdamaged,replaceit.6.Closethefloatingchamberbysecuringthespecialcapandmountthecarburetorontheengine.7.Cleantheinsideoftheintakesilencer.8.Mounttheintakesilenceronthecarburetorflange.9.Tightenitwiththespecificclamp.

Wrongassemblywillcausethelossoftheintakesilencer.

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4.5.2.ChangingJetsFlatScrewdriver22mmFixedWrench

Wrongcarburationsetupcouldcauseseverenginedamage.

1.Taketheintakesilenceroffthecarburetorbyunscrewingtheclamp.2.Disconnectthethrottlecablefromthecarburetortogetherwiththespringandtheguillotineslide.3.Takethecarburettorofftheengineandopenthefloatingchamberbyunscrewingthespecialcapinthemiddleofthechamber.Cleantheparts,openingsandpassageswithcompressedair.4.Unscrewthemainjetbymeansofaflatplier.Replaceitwithanothercalibrateddifferently.Becareful,thewashermustbeinstalledinonepositiononly.Awrongassemblymaycausethecarburettorcompletemalfunction.5.Checkthepluggasketofthefloatingchamberisstillintactandifdamaged,replaceit.6.Closethefloatingchamberbysecuringthespecialcapandmountthecarburettorontheengine.7.Cleantheinsideoftheintakesilencer.8.Mounttheintakesilenceronthecarburettorflange.9.Tightenitwiththespecificclamp.

Wrongassemblywillcausethelossoftheintakesilencer.Wrongcarburetorassemblingmaycauseenginemalfunctionanddamage.

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4.5.3.SparkPlugCleaningandReplacementSparkPlugWrenchMetalBrushRiskofburning:PerformthistaskONLYwhenengineiscool.

Oilsproducecarbondepositsorresiduesthatmakenecessarythesparkplugtobecheckedandcleaned,atleastevery5hours.Removethesparkplugandcleanitbyusingabrassmetalbrush.Useaspecificsparkpluggapgaugetosetupcorrectgap.Correctgap:0,8mm.Every 30 hours is highly recommended to changesparkplug. 4.5.4.ExhaustCleaning

MetalBrushHeater

Oils produce carbon deposits or residues thatmake necessary the exhaust to be checked andcleaned,atleastevery10hours.Disassemble the exhaust from the engine by removing the two springs and check the exhaustcarefully.Heattheexhaustwithaheaterandremoveallcarbondepositswithametalbrush.

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4.5.5.CylinderHeadCleaning10mmTubeWrenchDynamometricWrench

SparkPlugWrenchOils produce carbon deposits and/or residues thatmakenecessary cylinder head to be checked and cleaned, atleasteveryrace.

Be aware, cylinder head combustion chambervolume may vary during the race. Carbon

depositsmaycausevariationsincylinderheadvolume.Removesparkplug.Removethesixheadnutsandrelativewashers.Removecylinderheadbypullingitupcarefully.

Userubbergloves.

After cleaning the combustion chamber with fuel,reassemblecylinderhead.Pleasecheckcooperwasher,incaseitispresent,islocatedintherightposition.

Thisspecificwasher,assembledwrongly,willchangethecombustionchambervolume.Insertcarefullytheheadontothestudsandcheckallo-ringsarefittedintherightplace.Ifanyisdamage,changeit.Insertwashers andnuts in the studs and tight themmanually.Now, by using a dynamometricwrenchtightenthemalternativelyat16Nm.

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4.5.6.CylinderCheckandMaintenance

10mmTubeWrenchDynamometricWrench

Toavoidenginedamage,aVortexqualifiedmechanicmustperforminspectionandhoning.Removeexhaust.Remove spark plug. Remove the six head nuts and

relativewashers.Removecylinderheadbypullingitupcarefully.Removethecylinderfromthecrankcaseslowly.Oncecylinderisseparatefromcrankcase,holdtheconnectingrodwiththeother hand and pull the cylinder out totally by pulling it upcarefully.Every time cylinder is removed we recommend changingcylindergasket.

Cylinder must be honed when cylinder/pistonclearance ismore than0.12mmorwhenovalizationismorethan0.02mm.

Changepiston(see4.5.7)Newpistoncylinder/pistonclearancemustbe0.09mm.REASEMBLINGInsertanewgasketontothestudscarefullyandplaceitinthecrankcasesurfaceflat.Insert now the cylinder in the studs very carefully.With theotherhandclosepistonringandinsetthepistonintothe cylinder. Ifpistonring isnotclosedtotally, riskofcylinderandpistonring isveryhighPushthecylinderdownfirmly.Tightfourcylindernutswithdynamometricwrenchat20Nm.Insertcooperwasher.Pleasecheckcooperwasherislocatedintherightposition.Thisspecificwasher,assembledwrongly,willchangethecombustionchambervolume.Install,carefully,theheadontothestudsandcheckallo-ringsarefittedintherightplace.Ifanyisdamaged,changeit.Installwashersandnutsontothestudsandtightthemmanually.Now,byusingadynamometricwrenchtightenthemalternativelyat16Nm.

Everytimecylinderishonedorpistonchanged,theenginebreak-inproceduremustbeperformed.

_____________________________________________________MAINTENANCE_____________________________________________________

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4.5.7.PistonCheckandMaintenance10mmTubeWrenchDynamometricWrench

Toavoidenginedamage,aVortexqualifiedmechanicmustperforminspectionandhoning.Removeexhaust.Remove spark plug. Remove the six head nuts andrelativewashers.

Removecylinderheadbypullingitupcarefully.Oncecylinderisseparatefromcrankcase,holdtheconnectingrodwiththeotherhandandpullthecylinderouttotallybypullingitupcarefully.Every time cylinder is removed we recommend changingcylindergasket.Remove thecirclips from thepistonpin.Push thepinoutofthepiston.

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Beforeassemblinganewpistoncheckdimensionalsizes.Correctcylinder/pistonclearanceis0.09mm.ASSEMBLING

Oilandinserttherollercageintheconnectingrod.Install thenewpiston in theconnecting rodbyplacing thearrowstampedintheheadofthepistonfacingtheexhaustport. Insertnowthepistonpinandsecureitwiththecirclips.

Attention, wrong circlips assembling may causeseriousdamage.

Insert the piston ring in the piston carefully. Check bothends of the piston ringwhen totally closed have a gap of0,30/0,35mm.Nowyouarereadytoassemblecylinderandcylinderhead.

Engine needs a brake-in in session when a newpistonhasbeenplaced.

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4.5.8.CHNGINGCLUTCHDISCS

4mmFixedWrenchDynamometricWrench

Clutchiscomposedofdiscandspacerstotransmitthemovementtothepinion.Evenwhentheuseofclutchisminimumdiscsufferwear.

Removetheclutchprotectioncover.Disassemblethescrewsthatholdthediscandsprings.Takescrews,springsandspacersoff.2,3,4.Nowyoucandisassemblethecoverandtakethediscandspacerofftheclutchbell.Exchangetheolddiscwithnewones.

Be careful, first and lastdisc (A)of the seriesaredifferentthantheotherones(B).

Followtheschemetoassemblediscsandspacers.Proceedbackwardstoreassemble.Screwsmustbetightened0.8Nm

manuale shf ing - rok cup usa oil 280gr w10/40 jaso ma-2 o api sl engine weight 19kg -all sizes ......

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