VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel.

+39 0385 765200

MINI ROK

OWNER’S
MANUAL

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 VORTEX FACTORY: Via E. Fermi, 5 – 27040 Campospinoso (PV)– ITALY – Tel. +39 0385 765200

INDICE

1. GENERAL INFORMATION 3
1.1. Introduction 3
1.2. Symbols 3
1.3. Safety Information 3
1.4. Technical 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

5.1. Maintenance Schedule and Adjustments 23
5.2. Torque Chart 23
5.3. Sizes and Measures 24
5.4. Chain 24
5.5.Throttle Cable 24
5.6. Carburettor 24
5.7. Spark Plug 25
5.8. Exhaust 26
5.9. Clutch and Starter Gear 26
5.10. Pinion 28
5.11.Cylinder Head 29
5.12.Cylinder 30
5.13.Piston 31
5.14.Connecting Rod 32
5.15.Bottom End 32

6. ENGINE EXPLODED VIEW AND PARTS LIST 33

7. CONTACTS 41

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1.1. INTRODUCTION
Thank you for your purchasing of a Vortex engine. This manual contains information on how to
help you with getting the best results from your new engine. Furthermore, it will explain you how
to operate your Vortex engine safely and in a proper manner.

Vortex update this manual constantly. All the information in this manual is based on the latest
experience and product information available at the time of writing.
Vortex reserve the right to make any kind of changes to this manual at anytime without notice and
without incurring in any obligation.

This manual shall be considered part 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 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-ventilated area
only. Exhaust 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. When working with fuel, do
not smoke or use it near fire or flames. Avoid any skin contact and inhaling fuel vapors.
-Never touch moving parts when the engine is running.
-During operation both engine and muffler, become very hot. Do not touch them and do not place
anything on them after operation.
-Do not touch the spark plug or cable. It may provoke electrical shocks.
-Understand the operation of all controls and learn how to stop the engine quickly in case of
emergency.
-Do not use the engine without clutch cover and chain protection.

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1.4. TECHNICAL SPECIFICATIONS

Cylinder Displacement (max) 60cc.

Cylinder Bore (max) 42,10 mm.
Piston Stroke 43,00 mm.
Admission system Piston Port
Cooling System Free air
Carburetor Dell’Orto PHBG 18 BS
Ignition System Selettra
Ignition Type Digital
Ignition 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 your engine.
-Proper fuel mix is necessary for optimum engine life and performance.

1.5. SPECIAL TECHNICAL SPECIFICATIONS FOR HOMOLOGATED ENGINE

Vortex Mini Rok Engine is produced in one version only. However, refer to your country
homologation file for eventual specific rules and/or sizes.

1.6. PACKAGING
Your engine will be packed in a sealed box with the Vortex logo printed on and a sticker with
model and serial number attached. It will be a second box complete with accessories as
carburettor, muffler, fuel pump, air box, etc.

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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
Hooker
Straight Ruler
Cross Screwdriver
Flat Screwdriver
Torque Wrench

Compressed air
Unpack the engine and remove any packaging
material on it.

6mm Allen Wrench

Lay the engine on its side and attach the engine
mount to the engine base with four 8 mm Allen
screws.

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3
Engine Wheelbase Measurements in case you
need to drill your engine mount.

10mm Fixed Wrench

Attach the specific metal-chromed bracket
provided to the engine by using 2 of the 4 silent
blocks provided. Pass them through the support
in the engine and tighten with washer and 6
mm nut. Sometimes thread on the silent block
could be short. Use any threadlocker then.

10mm Fixed Wrench

Attach 1 of the remaining 2 silent blocks to the
front end of the bracket. Tighten with washer
and 6 mm nut. Sometimes thread on the silent
block could be short. Use any threadlocker
then.

10mm Fixed Wrench

Insert the silent block through the upper hole
on the specific metal-chromed bracket. Then
attach the brown cable (earth) coming from the
ignition, a flat washer and 6 mm nut. Tighten
everything. Sometimes thread on the silent
block could be short. Use any threadlocker
then.

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3 mm Allen Wrench + 7 mm Fixed

Wrench
Insert the two 4x30 mm screws into the plastic
electric plug. Attach the electric plug to the
short bracket provided. Secure it with washer
and 4 mm nut.
Sometimes the holes in the plastic electric plug
need to be widened with a 4 mm drill.

10 mm Fixed Wrench
Insert the short bracket with the electric plug
attached into the two free ends of the silent
blocks previously attached to the engine in
Point 4. Tighten with washer and 6 mm nut.

3 mm Allen Wrench + 7 mm Fixed

Wrench
Insert the 4x30 screw into the coil. Attach the
coil in the specific bracket located on top the
main bracket and secure it with washer and 4
mm nut.

10
The stop cable end from the ignition is “male”.
The stop cable end from the battery is “male”
too.
We provide a “female-female” extension to link
both end.

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11
Plug the two ends from the ignition to the coil.
Green cable goes in green plug.

12

3 mm and 5 mm Fixed Wrench

a. Attach the red cable to the electric starter
using the screw there is in it.
b. Unscrew the 5 mm Allen screw. Insert the
earth cable (black) plug into the screw and
screw firmly.

13
Cover both cables ends with the plastic covers
inserted in the cables.

14

10 mm Fixed Wrench
Attach the fuel pump to the free end of the
same silent block where the ground cable has
been attached in point 6. Secure it with 6 mm.
nut and washer provided.

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15

Flat Screwdriver
a. Remove the plastic cap from the depression
plug.

b. Insert the fuel line from the side of the fuel

pump into the depression plug in the crankcase

16

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 the carburettor into the inlet rubber

manifold.

17

Flat Screwdriver
Ensure the carburettor is correctly seated, then
tighten the carburetor to the inlet manifold by
using the specific clamp.

18
Screw the air box mount to the carburettor
manually. Do not use any tool.

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19

Cross Screwdriver
Remove the top of the carburettor by
unscrewing the two screws.

20
Insert the throttle cable into the elbow on top
of the carburettor with the lead nut in.

21

8 mm Fixed Wrench
Tighten the carburettor throttle cable register
elbow.

22
Pass the throttle cable through the spring and
into the cut in the side of the plastic slide cover.

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23
Take the slide out of the carburettor.

24
Insert the lead at the end of the throttle cable
into the hole in the center of the slide.

25
Hook the lead nut in the slide by moving it
aside of the center.

26
Place the slide, plastic slide cover and spring
into the carburettor.

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27

Cross Screwdriver
Fix the top of the carburettor to the
carburettor by using the 2 screws unscrewed
before in Point 19

28
Insert the fuel line from the outlet on the
bottom of the fuel pump to the inlet on top
carburetor.

29
Insert the air tube into the intake silencer and
then place the plastic stone guard on top of the
air tube.

30
Insert the foam filter into the intake silencer.
There is a slot in the rubber manifold that
should be inserted in the intake silencer.

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31
Check the foam filter is properly fixed in intake
silencer. Wrong assembly will cause the loss of
the foam filter and intake silencer.

32

Flat Screwdriver
Attach the assembled intake silencer to the
adaptor and fix it by using the specific clamp
provided.

33

4 mm Allen Wrench + 10 mm Fixed

Wrench
Use the specific “S” bended bracket to connect
the intake silencer to the main bracket where
fuel pump is attached. Secure the intake silencer
by using one 6x25 screw (to the intake silencer)
and one 6x20 (to the bracket) screw, washer,
plastic spacer and nut.

34

Flat Screwdriver
Remove the plastic cap from the head.

Spark Plug Wrench

Tighten the spark plug in the engine head.
Tighten and loosen the spark plug 2/3 times to
allow the gasket to seat. Then tighten the spark
plug securely.
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35
Insert the coil cable into the rubber plug cup so
it is tight.
It is recommended to secure the coil cable by
using a cable tie.
Place the plug cap on to the spark plug and
push the plug cap down firmly.

36
Your engine is now ready to be installed to the
chassis.

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3. ENGINE/CHASSIS ASSEMBLY
1

5 mm Allen Wrench + 10 mm Fixed

Wrench

Place the sprocket in the sprocket carrier and

tighten with washer and nut.

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 not tighten completely

Straight Ruler

Align the rear sprocket (in the axle) with the

front sprocket (in the clutch bell). Then install
the chain of proper length. Chain length varies
with gear sizes.

4
To adjust chain tension, move the engine ahead
until the proper tension is reached. Proper
tension is around 1 cm. of free up and down
movements.

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17 mm Fixed Wrench

Once chain tension is correct, tighten mount

clamps completely and re-check the chain
tension again. Then set the engine stop to just
contact the engine mount, (if provided by the
chassis manufacturer.)

5 mm Allen Wrench

Attach the plastic guard bell cover to the

engine by using three 6x20 mm Allen screws.

Flat Pliers

By using flat pliers, very carefully, turn the two

carburetor overflow elbows on the carburettor
to point upwards.

8
Insert the plastic tube provided on to each one
of the carburettor overflow elbows.
The tube may be provided in one piece only. In
that case, cut the tube in half. The length of
each tube should be 40 cm. approx.

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9
Place a recovery tank under the carburettor
and secure it to the chassis by using cable ties.
Make two holes on top of the cap and insert
the free ends of the tubes coming from the
overflow elbows. This container must be able
to vent to atmosphere.

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 Allen Wrench

Insert a clamp into the throttle cable and pass

the free end through the welded ring on the
throttle pedal. Then loop it around and insert
the free end of the cable into the to the clamp
again and tighten it. Clamp not supplied.

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13

Flat Screwdriver

Take the intake silencer off the carburettor by

unscrewing the clamp. It is not necessary to
unscrew the bracket. The intake silencer will
turn easily.

14

8 mm Fixed Wrench

Adjust the throttle cable by setting the pedal

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 to the seat using the specific
plastic clamp provided.
A battery mounting spacer plate may be
required to clear the brake cable.

16

4 mm Allen Wrench + 10 mm Fixed

Wrench

Remove relay from socket in the wiring loom.

Secure the wiring loom to the battery cradle
using a 6x25 mm Allen screw, bi conical washer,
2 plastic spacer, washer and 4 mm nut.

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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
front of the battery cradle. Secure them with
the specific nut attached in the cables.

19

Place the battery in the battery cradle. Insert

the battery cables in the battery plugs. Red
cable in red plug, black cable in black plug.
Secure the battery using the two rubber O.R.
provided.

20
Secure the relay with the specific spring
provided.

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21
Pass the main wire loom under the seat and
secure it to the chassis by using plastic cable
ties. Make sure there is no loose wiring that
may drag on the track.

22
Plug in the electric plug coming from the battery to
the other half located aside the engine.

23
a. Cover the inside of the RPM limiter box
cradle with the specific foam tape provided.
Fit a small piece of fuel line to the O.R as
illustrated in the picture and secure the RPM
limiter box to the cradle with the O.R.

b. Attach the cradle to the seat or the chassis.

c. Insert the female plug coming from the

ignition on the male plug in the RPM limiter
box.

24
Hook the two springs provided into the exhaust
manifold.

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25

11 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 spacer
and the nuts. Tighten each nut alternatively.

26

Hook

Insert the muffler into the exhaust manifold. Fix

the muffler by hooking the free ends of the
spring into the rings welded to the muffler by
pulling them.

27

Hook

Place the muffler in the exhaust cradle that is

assembled on the chassis and pull the two
springs provided to fasten it.

28
Insert the fuel line from the fuel tank into the
fuel pump

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4. STARTING AND BRAKE-IN

Only a proper break-in will insure the best performance out of your engine in the future and
guarantee its long and trouble-free life.
Break-in is required when an engine is new or has undergone a major service of the engine's main
parts (pistons, rings, cylinder or crankshaft).

1 Prepare fuel. Vortex engine works with commercial gasoline, leaded or unleaded, as well as
racing fuel, with minimum 95 ROM.
Mix oil and gasoline at 3% (i.e. 30cc of oil every 1.000 cc. of fuel).

2 Use a high quality 2-stroke oil specifically made for kart engines. We recommend Petronas Rok
Lube, however many others oils with the same features may be used. Check any requirements of
your ASN regarding the use of specific brand/type

3 Shake the can thoroughly to mix the fuel and the oil 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
button.

5 To start a cold engine pull the choke lever up.

6 Press the start button (green) in order to allow the fuel pump-to-pump fuel to the carburetor.
7 Once the engine starts push the choke lever down.
8 Run the engine by accelerating intermittently to higher RPMs. Do not accelerate to full throttle.
9 Once the engine is warmed up, proceed to the track. By accelerating very carefully, the clutch
will engage and the kart will start moving forward.

10 Run the engine by alternating a few seconds on and off the throttle at ¾ of the opening.
Do not hold the throttle at a constant speed.
Continue this way for 5/6 laps.

11 Check everything on the kart is tighten properly. Be careful, engine and muffler are hot.
12 Return to the track and slowly increase the RPM and duration of the acceleration for
10/15min more. Intermittently open the throttle fully and then release it.

13 After 10/15 minutes of brake-in, your engine is ready for competition. During the break-in,
nuts and bolts tend to loosen. Once the engine is cold, check the torque of the exhaust, head, etc
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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 Every Race
Change After 30 hours
Exhaust Internal cleaning Every 10 hours
Clutch Check and cleaning Every 10 hours
Change 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)

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5.3. Sizes and Measures

Tolerance Cylinder/piston 10,5
Timming 3mm
Piston Sizes
W240/MR01A 41,88
W240/MR03A 41,91
W240/MR06A 41,93
W240/MR09A 41,95
W240/MR11A 41,98

5.4. Chain
Lube the chain by spraying chain lube on the
chain while manually rotating the rear wheel.
To replace the chain, loosen the engine and
slide it back to release the old chain from the
sprocket. Reverse the procedure after installing
a new chain.

5.5. Throttle Cable

Lubricate the throttle cable each time the
engine is run. Also check, and adjust the cable
as needed, to assure the correct throttle and
that the throttle returns properly and opens full
size.
If the cable frays, it must be replaced.

5.6. Carburettor
Cleaning: 1.Take the intake silencer off the carburettor by
Fuel and oil may contain some kind of rubbish, unscrewing the clamp. It is not necessary to
impurities, and/or residues. unscrew the bracket. The intake silencer will
turn easily.
2.Disconnect the throttle cable from the
carburetor together with its spring and slide it.
3.Took the carburetor off the engine and open
the float chamber (22) by unscrewing the four
screws (23). Clean the parts, openings and
passages with compressed air. Check the float
chamber gasket (21) and eventually change it if
damaged.
4. Close the float chamber by screwing the four
screws (23) and re-place the carburettor in the
engine.
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5.Clean the inside of the intake silencer.

6. Attach the intake silencer assembly to the
adaptor.
7.Tighten it with the specific clamp. Wrong
assembly will cause the loss of the intake
silencer.

Changing main jet: 1.Take the intake silencer off the carburettor by
unscrewing the clamp. It is not necessary to
unscrew the bracket. The intake silencer will
turn easily.
2.Disconnect the throttle cable from the
carburetor together with its spring and slide it.
3.Took the carburetor off the engine and open
the float chamber (22) by unscrewing the four
screws (23). Clean 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 black out of
carburettor.
5.Check the float chamber gasket (21) and
eventually change it if damaged.
6.Close the float chamber by screwing the four
screws (23) and re-place the carburettor in the
engine.
7.Clean the inside of the intake silencer.
8. Attach the intake silencer assembly to the
adaptor.
9.Tighten it with the specific clamp. Wrong
assembly will cause the loss of the intake
silencer.

5.7. Spark Plug

Cleaning: Unplug the spark plug and clean it by using a
Oils produce carbon deposits or residues that metal brush.
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make necessary the spark plug to be checked

and cleaned, at least every 5 hours.
Setting Plug Gap: Use a specific spark plug gap gauge to set up
correct gap. Correct gap: 0,8 mm.

5.8. Exhaust
Cleaning: 1.Remove the muffler from the engine by
Oils produce carbon deposits or residues that removing the 2 springs in the cradle and the 2
make necessary the spark plug to be checked springs in the exhaust manifold.
and cleaned, at least every 10 hours. 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 replacing clutch: 1.Disassemble the clutch cover.

2. Take away the Bendix cover
3.Stop the clutch drum by using the special tool
designed by Vortex for this specific task.
4.Unscrew anticlockwise the nut on the clutch
drum (92). Remove the washer (91), clutch
drum (87) and roller bearing (90).
5. Unscrew the three 6x14mm Allen screws (79)
on the clutch.
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6.Unscrew clockwise the central nut (84) by

using a 24mm fixed wrench to remove it. Stop
the starter gear with the specific tool
manufactured by Vortex.
7.Take away the clutch (82) by using the
appropriate extractor.

8.Before assembling the new clutch, we

recommend to clean the clutch area and the
pinion bell with a solvent.

ASSEMBLING
9.Install the new clutch (82) on the crankshaft
by pushing lightly with your fingers and secure
it with the three 6x14mm Allen screws (79).
Use thread locker to secure them.
10.Put together again the elastic washer (83)
and the central nut (84) and tighten. Use
thread locker to secure the central nut.
11.After screwing 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
secure it.
14.Re-place Bendix cover.
15.Re-place the clutch cover.

Replacing Starter Gear 1.Disassemble the clutch cover.

2. Take away the Bendix cover
3.Stop the clutch drum by using the special tool
designed by Vortex for this specific task.
4.Unscrew anticlockwise the nut on the clutch
drum (92). Remove the washer (91), clutch
drum (87) and roller bearing (90).
5. Unscrew clockwise the central nut (84) by
using a 24mm fixed wrench to remove it. Stop
the starter gear with the specific tool
manufactured by Vortex.
6.Take away the clutch (82) together with the
starter gear (80) by using the appropriate
extractor.
7. Unscrew the three 6x14mm Allen screws (79)
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on the clutch.

8.Before re-assembling, we recommend to

clean the area with a solvent.

ASSEMBLING
9.Screw the new starter gear (80) to the clutch
(82) by using three 6x14mm Allen screws (79).
Use thread locker to secure them.
10.Insert the starter gear and clutch on the
crankshaft by pushing lightly with your fingers.
11.Put together again the elastic washer (83)
and the central nut (84) and tighten. Use
thread locker to secure the central nut.
12.After screwing the central nut place the
washer (85).
13.Grease the needle bearing (90) totally and
insert 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 use of Z11 or Z10 pinions. 1.Disassemble the clutch cover.
Standard assembling is Z11. 2.Stop the clutch drum by using the special tool
designed by Vortex for this specific task.
3.Unscrew anticlockwise the nut on the clutch
drum (92). Remove the washer (91), clutch
drum (87) and roller bearing (90).
4.Unscrew the four bolts inside the drum.
5.Place the new pinion on the bell and secure it
with the 4 bolts. Use thread locker to secure
them.
Be aware if you are placing a Z10 pinion, a
specific spacer is needed.
6.Install roller bearing and the spacer. Grease
the roller bearing properly.
6.Re-place the clutch drum, the washer and the
nut. Tighten the nut by turning it to the left.
Use thread locker to secure it.
7.Re-place the clutch cover.

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5.11. Cylinder Head

Oils produce carbon deposits or residues that In order to perform this job, we highly
make necessary the spark plug to be checked recommend taking the engine off the chassis.
and cleaned, at least every race. However, you may do the job even with the
Be aware, cylinder head volume may be engine mounted.
changed after the race, Carbon deposits may
cause variations on the cylinder head volume. 1. Unscrew the spark plug (4).
2.Unscrew the 4 nuts on top of the head (3).
3.Remove the head by pulling it up carefully.
4.Clean the combustion 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 carefully in the four
studs (10).
7.Insert brass washers (2) and nuts (3).
8.Tighten cylinder head with the proper tool
and torque.

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5.12. Cylinder
Every 30 hours cylinder must be honed. In order to perform this job, we highly
recommend taking the engine off the chassis.
However, you may do the job even with the
engine mounted.

1.Take away the muffler from the engine by

removing the 2 springs in the cradle and the 2
springs in the exhaust manifold.
2.Remove the carburettor from the engine by
unscrewing the specific clamp.
3.Unscrew the 4 nuts on top of head (3).
3.Remove the head by pulling it up carefully.
4.Remove the cylinder with one hand by pulling
it up. To avoid contact with the crankcase, use
the other hand to hold the connecting rod.
Whenever you disassemble the cylinder, we
recommend replacing the cylinder gasket (9).

ASSEMBLING
Check the tolerance between piston and
cylinder. Wrong tolerance may cause serious
damage.
5.Place a new gasket (9) into the four studs
(10).
6.Insert cylinder into the four studs carefully.
7.Check the rubber O.R. (6) and brass gasket (5)
and eventually re-place them with new ones.
Brass gasket may provoke changes in the
combustion chamber volume.
8.Re-place the cylinder head carefully in the
four studs.
9.Insert brass washers (2) and nuts (3).
10.Tighten cylinder head with the proper tool
and torque.

Important: After honing the cylinder and

eventually changing the piston, the engine
must go through another break-in period. See
"Starting and Break-in".

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5.13. Piston
Oils produce carbon deposits or residues that In order to perform this job, we highly
make necessary the spark plug to be checked recommend taking the engine off the chassis.
and cleaned, at least every race. However, you may do the job even with the
Be aware, cylinder head volume may be engine mounted.
changed after the race, carbon deposits may
cause variations on the cylinder head volume. 1.Take away the muffler from the engine by
removing the 2 springs in the cradle and the 2
Every 30 hours piston must be replaced. springs in the exhaust manifold.
2.Remove the carburettor from the engine by
unscrewing the specific clamp.
3.Unscrew the 4 nuts on top of head (3).
3.Remove the head by pulling it up carefully.
4.Remove the cylinder with one hand by pulling
it up. To avoid contact with the crankcase, use
the other hand to hold the connecting rod.
Whenever you disassemble the cylinder, we
recommend replacing the cylinder gasket.
5.Remove the 2 piston pin circlips (65) by
squeezing the ends together with the needle-
nose
6.Hook the connecting rod each side with two
fingers.
7.Push the piston pin (66) off the piston by
using a proper tool.
8.In order to avoid damages pull the piston up
with one hand while holding the connecting rod
with the other.
9.Take the roller bearing (70) off the
connecting rod.

ASSEMBLING
Check the tolerance between piston and
cylinder. Assemble ONLY 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 rod.
The arrow marked on top of it, must face the
exhaust port.
12.Insert the piston pin into the piston.
13.Insert piston pin circlips on each side of the
piston. Be aware, wrong assembly of piston
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pin circlips may cause important damage.

14.Place the piston ring in the piston and check
both ends close properly against the brass pin
inserted in the piston.
15.Place a new gasket (9) into the four studs
(10).
16.Insert the cylinder into the four studs
carefully.
17.Check the rubber O.R. (6) and the copper
gasket (5) and eventually re place them with
new ones. Brass gasket may provoke changes in
the combustion chamber volume.
18.Re-place the cylinder head carefully in the
four studs.
19.Insert brass washers (2) and nuts (3).
20.Tighten cylinder head with proper tool and
torque.

Important: After changing the piston, the

engine must go through another break-in
period. See "Starting 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 required, this operation must be performed by the Vortex technicians or
qualified mechanics only.

5.15. Bottom End

Bearings must be checked, and eventually replaced, after 60 hours of use.
Bearings must be assembled or reassembled, with name and type facing each others.
Due to special tools required, this operation must be performed by the Vortex technicians or
qualified mechanics only.

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6. ENGINE EXPLODED VIEW AND PARTS LIST

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Dell’Orto Carburettor

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Parts List
1 W010/MR Air head 60cc 45 V.TCE6X20 Socket-head screw m6 x 20
2 W560 Head washers 8,5 x 15 x 8 46 W960/RKT Transmission starter support
3 W530/12 Head-nut high-set m8 47 V.TCE6X30 Socket-head screw m6 x 30
4 W003 Spark plug ngk b10 eg 48 V.TCE6X65 Socket head screw m6 x 65
5 W631/01MR Copper head gasket 42,2 x 62,4 x 0,1 49 W972/MR O.r.4200 starter support
5 W631/02MR Copper head gasket 42,2 x 62,4 x 0,2 50 W970/MR Starter support d.50
6 W620/MR O-ring head viton 51 W975/MR Starter support spacer
7 W020/1MRC Cylinder 60cc complete 64 W240/MR01A Complete piston 41,88
8 W470 Exhaust stud bolt m7 x 32 64 W240/MR03A Complete piston 41,91
9 W610/1MRC02 Cylinder basis gasket 0,2 64 W240/MR06A Complete piston 41,93
9 W610/1MRC03 Cylinder basis gasket 0,3 64 W240/MR09A Complete piston 41,95
9 W610/1MRC04 Cylinder basis gasket 0,4 64 W240/MR11A Complete piston 41,98
9 W610/1MRC05 Cylinder basis gasket 0,5 65 W280/MR Circlip d.12,00
10 W461/1VLC Cylinder stud bolt m8 x 142 66 W270/MRA Piston pin mini rok
11 W2050/MR Inlet manifold phbg 18 67 W140/MR Magn.s.h. Crankshaft 60cc
11 W2050/BR Inlet manifold phbn 14 68 W122 Ignition key 2,5 x 3,7 x 10
12 W825/1MR Carburettor clamp d.23-35mm 69 W220 Silver-plated cage d.18 x 24 x 15
13 V.TCE6X16 Socket-head screw m6 x 16 70 W290/MR Piston cage 12 x 16 x 15,5
14 W820/BR Dellorto carburettor phbn 14ms 71 W200/1MR Crankshaft crankpin d.18 x 40,6
14 W820/MR Dellorto carburettor phbg 18b 72 W230/MR Conrod engine 60cc
15 W981400 Connector 73 W522/10 Flathead screw m5 x 10
16 W540/RVA Exhaust fix. High set nut 74 W160/MR Nylon crankshaft stuffer
17 W565 Exhaust washer d.8 x 12 x 1,5 75 W121 Dragging sprocket key 3 x 3,7 x 10
18 W750/1MR Exhaust manifold mr/t 60cc 76 W150/MR H.crankshaft sprocket side 60cc
19 W670/MR Exhaust gasket 77B W190/MR Complete conrod 60cc
20 WA063 Head control template mini rok 78C W130/1MR Complete crankshaft mini rok
21 WA064 Carburettor gap control template 79 W510/14 Socket-head screw m6 x 14
32A W050/MRC Complete crankcase 60cc with bearing 80 W1753/MR Starting driven gear z 62
33 V.TCE6X40 Socket head screw m6 x 40 81 W1766/1ROK Cylindrical pin 6 x 10
34 V.TCE6X45 Socket-head screw m6 x 45 82 W1751/1KFC Clutch rotor kf with pin
35 W075/1 Crankcase dowel 10 x 10,5 x 6,5 83 W1708 Belleville washer d.16,3 x 31,5 x 1,5
36 W10267 Copper gasket d. 8 x 12 x 1 84 W1727 Clutch body fix nut m16 x 1 thr.
37 W800 Depression pipe fitting m8 hexagonal 85 W1726/1 Washer 2,0 mm mini-kf
38 W300/MR Insert 6204 c4 86 W523/08 Flathead screw m5 x 8
39 W310 Oil seal fpj 20 x 35 x 7 double lip 87 W1773/MR2 Bare clutch housing mini
40 W940/ROK Starter 50589 88 W1766/ROK Roll d.5 x 5
41 W019 Cylindrical pin 6x18 89 W690/MR11 Mini rok sprocket z11
42 W924 Roller case bk0808 90 W1715 Clutch cage k12 x 15 x 15
43 W916/ROK Starter driving gear 50589 91 W1777/1ROK Clutch washer d.10,1 x 18,8 x 2
44 W910/ROK Starter driving gear cover 92 W696/MR Sprocket nut 60cc

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93D W1750/1MR Compl.clutch rotor with gear 162H W53036-78 Tube 90° kit
94E W1763/MR11 Compl.clutch housing w/sprocket z11 163I W53031-78 Chamber mixture cover kit
94E W1763/MR10 Compl.clutch housing w/sprocket z10 164 W9597-61 Gas valve spring
105 W410/MR Selettra coil mini rok 165 W14958-21 Conical needle fastener fix plate
106 W531/06 Hexagonal nut m6 x 1 166 W9596211 Conical needle fastener
107 W570/12 Flat washer d.6 x1 2 x 1,5 167 W959523 Conical needle w23 x 08
108 W2052/MR Fuel pump support plate 168 W947540 Gas valve 40 x 64
109 W440 Coil fix. Silent - block 169 W148850 Jet min. 50
110 W11023 Vacuum pump 170 W950160 Jet 60
111 W420/2 Spark cap 171 W52526-77 Gaskets kit
112 W529/0108 Hexagonal nut m10 x 1 172 W9450-80 Float
113 W1777/MR Ignition washer d.10,4 x 18 x 2 173 W11836-36 Float chamber fixing screw
114 V.TCE5X20 Socket-head screw m5 x 20 174 W9444-96 Float chamber
115 W580/10 Washer d.10 x 5,5 x 0,3 175 W9506-22 Float peg
116 W407/MR Bare ignition mini rok 176 W283805 Gas needle closing
117 W524/14 T.c.e.i. Screw m5 x 14 177 W148697 Jet max. 97
118 W068/MR Ignition support 178 W9779-52 Bottom
119 0074.C0 Fuel tube 6 x 9 179 W9511266 Spray nozzle an 266
121 W780/1MR Engine 60cc exhaust 180L W53027-78 Needle gas valve kit
122 W10925 Muffler springs 181M W53024-78 Adjustment minimum screw kit
133 W2111/ROK Relay deviator 182 W9538-64 Starting device
134 W2110/ROK Starting relay 12v - 70a 192Z W820/BR Dellorto carburettor phbn 14ms
135 W2116/ROK Red starter button on-off 193 W7526-36 Cover fixing screw
136 W2115/ROK Green starter button 194 W14166-53 Chamber mixture cover
137 W2113/ROK Fixing button plate 195 W15058-61 Gas valve spring
138 W521/14 Roundhead screw m5 x14 196 W13687-21 Conical needle retainer
139 W435/MR Mini rok wiring adapter 197 W1536240 Gas valve 40
140F W2125/ROK Complete starting support 198 W13681-21 Conical needle fastener
141 W2130/ROK Accumulator charger italy 199 W1625011 Conical needle
141 W2131/ROK Accumulator charger japan-u.s.a. 200N W53004-78 Starter kit
142 WA052/KF Clutch puller 201 W14056-37 Adjustment minimum air screw
143 WA061 Clutch nut fix key 202 W1411-61 Spring adjustment min. Air screw
144 WA062 Sprocket disassembling tool sr/mr 203P W53086-78 Adjustment gas valve screw kit
145 W991 Accumulator fg 20722 204 W14671212 Spray nozzle ga 212
146 0096.00 Belt or 4437 205 W641375 Jet max. 75
147 W2121/ROK Accumulator support rubber 206 W621750 Starting device 50
148 W2122/ROK Accumulator support 207 W1160038 Jet min. 38
151 W856/MR Mini rok filter support 208 W52620-77 Gaskets kit
152G W2122/ROKC Complete accumulator support 209O W53053-78 Float kit
153 W850/1MR Intake filter 60cc engine 210 W13678-96 Float chamber
161V W820/MR Dellorto carburettor phbg 18b 211 W13709-36 Float chamber fixing screw

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7. CONTACTS

Manufacturer
Vortex Factory
Via E. Fermi 5
27040 – Capospinoso
Italy
Tel: +39 0385 765200
support@vortex-engines.com

New Zealand Importer

Supreme Kart Supplies
78 Hurlstone Drive
1146485 NEW PLYMOUTH
Tel: 06 7588891
m.j.frost@xtra.co.nz

ASN
Kart Sport New Zealand
45 Mt Wellington Highway
Auckland 1060
Tel: 09 570 1392
www.kartsport.org.nz

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