Vortex MINI ROK Owner's manual

Vortex
Brand
Vortex
Model
MINI ROK
Category
Motor vehicle accessories & components
Type
Owner's manual
MINI!ROK!
OWNER’S!
MANUAL!
INDEX!
1. GENERAL!INFORMATION!3
-C-C!>+J*(%K<J#(+ E!
-C0C!'LMN(B;!!! E!
-CEC!'$O&JL!>+O(*M$J#(+!! ! E!
-CGC!?&<P+#<$B!')&<#O#<$J#(+;!! ! G!
-C1C!')&<#$B!?&<P+#<$B!')&<#O#<$J#(+;!O(*!Q(M(B(R$J&%!6+R#+&! G!
-C.C!4$<S$R#+R!! G!
2. ENGINE!ASSEMBLING 1!
3. ENGINE/CHASSIS!ASSEMBLY -G!
4. STARTING!AND!BRAKE=IN 02!
5. SERVICING!YOUR!ENGIN
E 0-!
1C-C!T$#+J&+$+<&!'<P&%KB&!$+%!7%UK;JM&+J;! 0-!
1C0C!?(*VK&!WP$*J!!! 0-!
1CEC!'#X&;!$+%!T&$;K*&;!!! 00
1CGC!WP$#+!! ! 00
1C1C?P*(JJB&!W$NB&!!! 0E!
1C.C!W$*NK*&JJ(*!! ! 00
1CYC!')$*S!4BKR!! ! 0E
1C3C!6IP$K;J!! 0E
1CFC!WBKJ<P!$+%!'J$*J&*!Z&$*!! ! 0G!
1C-2C!4#+#(+!!! 0.!
1C--CWLB#+%&*!Q&$%! 0.
1C-0CWLB#+%&*!!! 0Y
1C-EC4#;J(+!!! 0Y
1C-GCW(++&<J#+R!5(%!! ! 0F
1C-1C:(JJ(M!6+%!! ! 0F!
6. ENGINE!EXPLODED!VIEW!AND!PARTS!LIST E2!
7. CONTACT
S
42!
1.1. INTROD UCTION!
?P$+S!L(K!O(*!L(K*!)K*<P$;#+R!(O!$!"(*J&I!&+R#+&C!?P#;!M$+K$B!<(+J$#+;!#+O(*M$J#(+!(+!P([!J(!
P&B)!L(K![#JP!R&JJ#+R!JP&!N&;J!*&;KBJ;!O*(M!L(K*!+&[!&+R#+&C!HK*JP&*M(*&,!#J![#BB!&I)B$#+!L(K!P([!
J(!()&*$J&!L(K*!"(*J&I!&+R#+&!;$O&BL!$+%!#+!$!)*()&*!M$++&*C!
"(*J&I!K)%$J&!JP#;!M$+K$B!<(+;J$+JBLC!7BB!JP&!#+O(*M$J#(+!#+!JP#;!M$+K$B!#;!N$;&%!(+!JP&!B$J&;J!
&I)&*#&+<&!$+%!)*(%K<J!#+O(*M$J#(+!$\$#B$NB&!$J!JP&!J#M&!(O![*#J#+RC!!
"(*J&I!*&;&*\&!JP&!*#RPJ!J(!M$S&!$+L!S#+%!(O!<P$+R&;!J(!JP#;!M$+K$B!$J!$+LJ#M&![#JP(KJ!+(J#<&!$+%!
[#JP(KJ!#+<K**#+R!#+!$+L!(NB#R$J#(+C!
?P#;!M$+K$B!;P$BB!N&!<(+;#%&*&%!)$*J!(O!JP&!"(*J&I!&+R#+&!$+%!;P(KB%!*&M$#+![#JP!JP&!&+R#+&!#J;&BO!
#O!*&;(B%C!
1.2. SYMBOLS!
Personal injury Mechanical Danger Caution
4$L!$JJ&+J#(+!J(!JP&!;LMN(B;!(O!JP#;!M$+K$BC!?P&L!$B&*J!L(K!(O!%$+R&*(K;!;#JK$J#(+;!O(*!L(K!(*!O(*!
L(K*!&+R#+&C!
1.3. SAFETY!INFORMATION!
A](!+(J!;J$*J!JP&!&+R#+&!#+%((*!$;!R$*$R&;,!J*$#B&*;,!&J<C!'J$*J!JP&!&+R#+&!#+!$![&BBA\&+J#B$J&%!$*&$!
(+BLC!6IP$K;J!&M#;;#(+;!$*&!P$X$*%(K;!O(*!L(K*!P&$BJPC!
A7B[$L;![&$*!RB(\&;!$+%!)*()&*!<B(JP#+R![P&+![(*S#+R!(+!L(K*!&+R#+&C!
A^;&!<$KJ#(+![P&+!P$+%B#+R!OK&BC!Z$;(B#+&!#;!OB$MM$NB&!$+%!&I)B(;#\&C!_P&+![(*S#+R![#JP!OK&B,!%(!
+(J!;M(S&!(*!K;&!#J!+&$*!O#*&!(*!OB$M&;C!7\(#%!$+L!;S#+!<(+J$<J!$+%!#+P$B#+R!OK&B!\$)(*;C!
A`&\&*!J(K<P!M(\#+R!)$*J;![P&+!JP&!&+R#+&!#;!*K++#+RC!!
A]K*#+R!()&*$J#(+!N(JP!&+R#+&!$+%!MKOOB&*,!N&<(M&!\&*L!P(JC!](!+(J!J(K<P!JP&M!$+%!%(!+(J!)B$<&!
$+LJP#+R!(+!JP&M!$OJ&*!()&*$J#(+C!!
A](!+(J!J(K<P!JP&!;)$*S!)BKR!(*!<$NB&C!>J!M$L!)*(\(S&!&B&<J*#<$B!;P(<S;C!
A^+%&*;J$+%!JP&!()&*$J#(+!(O!$BB!<(+J*(B;!$+%!B&$*+!P([!J(!;J()!JP&!&+R#+&!VK#<SBL!#+!<$;&!(O!
&M&*R&+<LC!
A](!+(J!K;&!JP&!&+R#+&![#JP(KJ!<BKJ<P!<(\&*!$+%!<P$#+!)*(J&<J#(+C!
1.4. TECHNICAL!SPECIFICATIONS!
WLB#+%&*!]#;)B$<&M&+J!9M$I=!
.2<<C!
WLB#+%&*!:(*&!9M$I=!
G0,-2!MMC!
4#;J(+!'J*(S&!
GE,22!MMC!
7%M#;;#(+!;L;J&M!
4#;J(+!4(*J!
W((B#+R!'L;J&M!
H*&&!$#*!
W$*NK*&J(*!
]&BBab*J(!4Q:Z!-3!:'!
>R+#J#(+!'L;J&M!
'&B&JJ*$!
>R+#J#(+!?L)&!
7+$B(R#<!
>R+#J#(+!?#M#+R!
E!MMC!
')$*S!4BKR!Z$)!
2,3!MMC!
HK&B!T#IJK*&!
Ec!
6+R#+&!_&#RPJ!9W(M)B&J&=!
-Y!SRC!
A7BB!;#X&;!$+%!M&$;K*&M&+J;!#+!JP#;!M$+K$B!$*&!&I)*&;;&%!#+!M&J*#<;C!
A7B[$L;!K;&!(*#R#+$B!"(*J&I!)$*J;!$+%!)*()&*!J((B;![P&+![(*S#+R!(+!L(K*!&+R#+&C!
A4*()&*!OK&B!M#I!#;!+&<&;;$*L!O(*!()J#MKM!&+R#+&!B#O&!$+%!)&*O(*M$+<&C!!
1.5. SPECIAL!TECHNICAL!SPECIFICATIONS!FOR!HOMOLOGATED!ENGINE!
"(*J&I!T#+#!5(S!6+R#+&!#;!)*(%K<&%!#+!(+&!\&*;#(+!(+BLC!Q([&\&*,!*&O&*!J(!L(K*!<(K+J*L!
P(M(B(R$J#(+!O#B&!O(*!&\&+JK$B!;)&<#O#<!*KB&;!$+%d(*!;#X&;C!
1.6. PACKAGING!
@(K*!&+R#+&![#BB!N&!)$<S&%!#+!$!;&$B&%!N(I![#JP!JP&!"(*J&I!B(R(!)*#+J&%!(+!$+%!$!;J#<S&*![#JP!
M(%&B!$+%!;&*#$B!+KMN&*!$JJ$<P&%C!>J![#BB!N&!$!;&<(+%!N(I!<(M)B&J&![#JP!$<<&;;(*#&;!$;!
<$*NK*&JJ(*,!MKOOB&*,!OK&B!)KM),!$#*!N(I,!&J<C!
7BB!^'7!&+R#+&;!MK;J!P$\&!$+!;)&<#O#<!647!;J#<S&*C!
2. ENGINE!ASSEMBLING
!!In!order!to!per fo rm!this!job,!you!will!n e e d !th e !f ollo wing!tools:!
Compressed!air!
Allen!Wrench!
3!=!4!=!5!!=!6!=!8!mm!
Fixed!Wrench!
5!=!7!=!8!!=!10!–!14!=!17!mm!
Flat!Pliers!
Socket!Spanner!
11!mm!
Hooker!
Straight!Ruler!
Cross!Screwdriver!
Flat!Screwdriver!
Torque!Wrench!
1!
!Compressed!air!
^+)$<S!JP&!&+R#+&!$+%!*&M(\&!$+L!)$<S$R#+R!
M$J&*#$B!(+!#JC!
2!
!6mm!Allen!Wrench!
8$L!JP&!&+R#+&!(+!#J;!;#%&!$+%!$JJ$<P!JP&!&+R#+&!
M(K+J!J(!JP&!&+R#+&!N$;&![#JP!O(K*!3!MM!7BB&+!
;<*&[;C!
3!
6+R#+&!_P&&BN$;&!T&$;K*&M&+J;!#+!<$;&!L(K!
+&&%!J(!%*#BB!L(K*!&+R#+&!M(K+JC!
4!
!10mm!Fixed!Wrench!
Use 2 silent blocks screwing into engine
(without loctite), mount metal-chromed
bracket on short threads protruding from
engine, use no washers and loctite these 2 x
6mm nuts.!
5!
!10mm!Fixed!Wrench!
Insert air box bracket use 1 silent block . Then
fit coil onto silent blocks installed in step 4.
Tighten with washer and 6 mm nut to 6Nm. Fit
last silent block also mounting coil earth wire.
6!
!10mm!Fixed!Wrench!
Fit fuel pump onto silent blocks, Tighten with
washers and 6mm nuts to 8Nm. *Note 2 thick
spacers and 2 thin washers not used in this
updated procedure for Aus.
7!
>+;&*J!!e;J()f!<$NB&!&+%!<(M#+R!O*(M!JP&!
#R+#J#(+!#+J(!JP&!<(#B!)BKRC!
8!
Flat!Screwdriver!
5&M(\&!JP&!)B$;J#<!<$)!O*(M!JP&!P&$%C!
!Spark!Plug!Wrench!
?#RPJ&+!JP&!;)$*S!)BKR!#+!JP&!&+R#+&!P&$%C!
?#RPJ&+!$+%!B((;&+!JP&!;)$*S!)BKR!0dE!J#M&;!J(!
$BB([!JP&!R$;S&J!J(!;&$JC!?P&+!J#RPJ&+!JP&!;)$*S!
)BKR!;&<K*&BLC!
9!
!>+;&*J!JP&!<(#B!<$NB&!#+J(!JP&!*KNN&*!)BKR!<K)!;(!
#J!#;!J#RPJC!
>J!#;!*&<(MM&+%&%!J(!;&<K*&!JP&!<(#B!<$NB&!NL!
K;#+R!$!)B$;J#<!J#&C!
4B$<&!JP&!)BKR!<$)!(+!J(!JP&!;)$*S!)BKR!$+%!
)K;P!JP&!)BKR!<$)!%([+!O#*MBLC!
10!
Flat!Screwdriver!
aC 5&M(\&!JP&!)B$;J#<!<$)!O*(M!#+B&J!M$+#O(B%C
bC 5&M(\&!<$*NK*&JJ(*!O*(M!#J;!N(IC
cC H#J!JP&!<B$M)!)*(\#%&%!J(R&JP&*![#JP!JP&
<$*NK*&JJ(*!(\&*!JP&!#+B&J!*KNN&*!M$+#O(B%C!
dC >+;&*J!JP&!<$*NK*&JJ(*!#+J(!JP&!#+B&J!*KNN&*
M$+#O(B%C!
11!
Flat!Screwdriver!
6+;K*&!JP&!<$*NK*&JJ(*!#;!<(**&<JBL!;&$J&%,!JP&+!
J#RPJ&+!JP&!<$*NK*&J(*!J(!JP&!#+B&J!M$+#O(B%!NL!
K;#+R!JP&!;)&<#O#<!<B$M)C!!
12!
'<*&[!JP&!$#*!N(I!M( K+ J!J( !JP& !<$*N K*& JJ(*!
M$+K$BBLC!](!+(J!K;&!$+L!J((BC
13!
Cross!Screwdriver!
5&M(\&!JP&!J()!(O!JP&!<$*NK*&JJ(*!NL!
K+;<*&[#+R!JP&!J[(!;<*&[;C!!
14!
>+;&*J!JP&!JP*(JJB&!<$NB&!#+J(!JP&!&BN([!(+!J()!
(O!JP&!<$*NK*&JJ(*![#JP!JP&!B&$%!+KJ!#+C!
15!
!8!mm!Fixed!Wrench!
?#RPJ&+!JP&!<$*NK*&JJ(*!JP*(JJB&!<$NB&!*&R#;J&*!
&BN([C!
16!
4$;;!JP&!JP*(JJB&!<$NB&!JP*(KRP!JP&!;)*#+R!$+%!
#+J(!JP&!<KJ!#+!JP&!;#%&!(O!JP&!)B$;J#<!;B#%&!<(\&*C!
17!
?$S&!JP&!;B#%&!(KJ!(O!JP&!<$*NK*&JJ(*C!
18!
>+;&*J!JP&!B&$%!$J!JP&!&+%!(O!JP&!JP*(JJB&!<$NB&!
#+J(!JP&!P(B&!#+!JP&!<&+J&*!(O!JP&!;B#%&C!
19!
Q((S!JP&!B&$%!+KJ!#+!JP&!;B#%&!NL!M(\#+R!#J!
$;#%&!(O!JP&!<&+J&*C!
20!
4B$<&!JP&!;B#%&,!)B$;J#<!;B#%&!<(\&*!$+%!;)*#+R!
#+J(!JP&!<$*NK*&JJ(*C!
21!
Cross!Screwdriver!
H#I!JP&!J()!(O!JP&!<$*NK*&JJ(*!J(!JP&!
<$*NK*&JJ(*!NL!K;#+R!JP&!0!;<*&[;!K+;<*&[&%!
N&O(*&!#+!4(#+J!13!
22!
!Flat!Pliers!
:L!K;#+R!OB$J!)B#&*;,!\&*L!<$*&OKBBL,!JK*+!JP&!J[(!
<$*NK*&J(*! (\&*OB([! &BN([;! (+! JP&!
<$*NK*&JJ(*!J(!)(#+J!K)[$*%;C!
*NOTE: Check any KA rule update for
breather tubes.
Optional addition as per KA Homologation
for return line to tank with fixed restrictor
inserted inside line.
*Note: Fuel tank requires professional
fitment of a bottom fuel feed fitting to
facilitate this option of return line to top of
tank.
27!
>+;&*J!JP&!$#*!JKN&!#+J(!JP&!#+J$S&!;#B&+<&*!$+%!
JP&+!)B$<&!JP&!)B$;J#<!;J(+&!RK$*%!(+!J()!(O!JP&!
$#*!JKN&C!
28!
>+;&*J!JP& "Vortex AU" debris filter!#+J(!JP&!
#+J$S&!;#B&+<&*C!?P&*&!#;!$!;B(J!#+!JP&!*KNN&*!
M$+#O(B%!JP$J!;P(KB%!N&!)*()&*BL!#+;&*J&%!
#+!JP&!#+J$S&!;#B&+<&*C!
29!
WP&<S!JP&!*KNN&*!M$+#O(B%!#;!)*()&*BL!O#I&%!#+!
#+J$S&!;#B&+<&*C!_*(+R!$;;&MNBL![#BB!<$K;&!JP&!
B(;;!(O!JP&!O($M!O#BJ&*!$+%!#+J$S&!;#B&+<&*C!
30!
4!mm!Allen!Wrench!+!10!mm!Fixed!
Wrench!!
^;&!JP&!;)&<#O#<!e'f!N&+%&%!N*$<S&J!$;;&MNB&%!
#+!4(#+J!5!J(!<(++&<J!JP&!#+J$S&!;#B&+<&*C!'&<K*&!
JP&!
#+J$S&!;#B&+<&*!NL!K;#+R!(+&!.I01!;<*&[!
[$;P&*!$+%!+KJC
31!
Flat!Screwdriver!
7JJ$<P!JP&!$;;&MNB&%!#+J$S&!;#B&+<&*!J(!JP&!
$%$)J(*!$+%!O#I!#J!NL!K;#+R!JP&!;)&<#O#<!<B$M)!
)*(\#%&%C
32!
!3!mm!and!5!mm!Fixed!Wrench!
a. 7JJ$<P!JP&!*&%!<$NB&!J(!JP&!&B&<J*#<!;J$*J&*
K;#+R!JP&!;<*&[!JP&*&!#;!#+!#JC!
b. ^+;<*&[!JP&!1!MM!7BB&+!;<*&[C!>+;&*J!JP&
&$*JP!<$NB&!9NB$<S=!)BKR!#+J(!JP&!;<*&[!$+%!
;<*&[!O#*MBLC!
33!
W(\&*!N(JP!<$NB&;!&+%;![#JP!JP&!)B$;J#<!<(\&*;!
#+;&*J&%!#+!JP&!<$NB&;C!
34!
@(K*!&+R#+&!#;!+([!*&$%L!J(!N&!#+;J$BB&%!J(!JP&!
<P$;;#;C!
3. ENGINE/CHASSIS!ASSEMBLY
1!
!5!mm!Allen!Wrench!+!10!mm!Fixed!
Wrench!!
4B$<&!JP&!;)*(<S&J!#+!JP&!;)*(<S&J!<$**#&*!$+%!
J#RPJ&+![#JP![$;P&*!$+%!+KJC!
2!
8mm!Allen!Wrench!
`([!)B$<&!JP&!&+R#+&!(+!JP&!<P$;;#;C!?#RPJ&+!
JP&!&+R#+&!M(K+J!<B$M);!J(!JP&!&+R#+&!M(K+J!
B#RPJBL!&+(KRP!J(!P(B%!JP&!&+R#+&!#+!)(;#J#(+C!
](!+(J!J#RPJ&+!<(M)B&J&BL!
3!
!Straight!Ruler!
7B#R+!JP&!*&$*!;)*(<S&J!9#+!JP&!$IB&=![#JP!JP&!
O*(+J!;)*(<S&J!9#+!JP&!<BKJ<P!N&BB=C!?P&+!#+;J$BB!
JP&!<P$#+!(O!)*()&*!B&+RJPC!WP$#+!B&+RJP!\$*#&;!
[#JP!R&$*!;#X&;C!
4!
?(!$%UK;J!<P$#+!J&+;#(+,!M(\&!JP&!&+R#+&!$P&$%!
K+J#B!JP&!)*()&*!J&+;#(+!#;!*&$<P&%C!4*()&*!
J&+;#(+!#;!$*(K+%!-!<MC!(O!O*&&!K)!$+%!%([+!
M(\&M&+J;C!
5!
!17!mm!Fixed!Wrench!
b+<&!<P$#+!J&+;#(+!#;!<(**&<J,!J#RPJ&+!M(K+J!
<B$M);!<(M)B&J&BL!$+%!*&A<P&<S!JP&!<P$#+!
J&+;#(+!$R$#+C!?P&+!;&J!JP&!&+R#+&!;J()!J(!UK;J!
<(+J$<J!JP&!&+R#+&!M(K+J,!9#O!)*(\#%&%!NL!JP&!
<P$;;#;!M$+KO$<JK*&*C=
6!
!5!mm!Allen!Wrench!
7JJ$<P!JP&!)B$;J#<!RK$*%!N&BB!<(\&*!J(!JP&!
&+R#+&!NL!K;#+R!JP*&&!.I02!MM!7BB&+!;<*&[;C!
7!
>+;&*J!+([!JP&!JP*(JJB&!<$NB&!#+J(!JP&!(KJ&*C!
8!
>+;&*J!JP&!O*&&!&+%!(O!JP&!JP*(JJB&!<$NB&!#+J(!JP&!
*&R#;J&*!$JJ$<P&%!J(!JP&!M$#+!*$#B!(O!JP&!<P$;;#;C!
9!
!3mm!Allen!Wrench!
>+;&*J!$!<B$M)!#+J(!JP&!JP*(JJB&!<$NB&!$+%!)$;;!
JP&!O*&&!&+%!JP*(KRP!JP&![&B%&%!*#+R!(+!JP&!
JP*(JJB&!)&%$BC!?P&+!B(()!#J!$*(K+%!$+%!#+;&*J!
JP&!O*&&!&+%!(O!JP&!<$NB&!#+J(!JP&!J(!JP&!<B$M)!
$R$#+!$+%!J#RPJ&+!#JC!WB$M)!+(J!;K))B#&%C
10!
Flat!Screwdriver!
?$S&!JP&!#+J$S&!;#B&+<&*!(OO!JP&!<$*NK*&JJ(*!NL!
K+;<*&[#+R!JP&!<B$M)C!>J!#;!not!+&<&;;$*L!J(!
K+;<*&[!JP&!N*$<S&JC!?P&!#+J$S&!;#B&+<&*![#BB!
JK*+!%([+!&$;#BLC!
11!
!8!mm!Fixed!Wrench!
7%UK;J!JP&!JP*(JJB&!<$NB&!NL!;&JJ#+R!JP&!)&%$B!
;J()!(+!JP&!<P$;;#;!#+!(*%&*!J(!R&J!JP&!)&%$B!J(!
;J()!$J!JP&!)(#+J![P&*&!JP&!;B#%&!#+!JP&!
<$*NK*&JJ(*!#;!OKBBL!()&+C!
12!
5!mm!Fixed!Wrench
7JJ$<P!+([!JP&!N$JJ&*L!<*$%B&!J(!JP&!<P$;;#;!
M$#+!*$#B!+&IJ!J(!JP&!;&$J!K;#+R!JP&!;)&<#O#<!
)B$;J#<!<B$M)!)*(\#%&%C!!
7!N$JJ&*L!M(K+J#+R!;)$<&*!)B$J&!M$L!N&!
*&VK#*&%!J(!<B&$*!JP&!N*$S&!<$NB&C
13!
!4!mm!Allen!Wrench!+!10!mm!Fixed!
Wrench!!
5&M(\&!*&B$L!O*(M!;(<S&J!#+!JP&![#*#+R!B((MC!
'&<K*&!JP&![#*#+R!B((M!J(!JP&!N$JJ&*L!<*$%B&!
K;#+R!$!.I01!MM!7BB&+!;<*&[,!N#!<(+#<$B![$;P&*,!
0!)B$;J#<!;)$<&*,![$;P&*!$+%!G!MM!+KJC!!
14!
>+;&*J!M$+K$BBL!JP&!*&B$L!#+J(!JP&!O&M$B&!)BKR!
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Vortex MINI ROK Owner's manual

Vortex
Brand
Vortex
Model
MINI ROK
Category
Motor vehicle accessories & components
Type
Owner's manual
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