NATIONAL HOMOLOGATION FORM - ENGINE

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NATIONAL HOMOLOGATION FORM - ENGINE Homologation N Manufacturer VORTEX Make MINI ROK Model 60CC Validity of the homologation 6 years Number of pages 32

homologation. The height of the complete engine on all photographs must be as a minimum 7 cm.

1 NATIONAL HOMOLOGATION FORM - ENGINE Homologation N Manufacturer VORTEX Make MINI ROK Model 60CC Validity of the homologation 6 years Number of pages 32 This Homologation Form reproduces descriptions, illustrations and dimensions of the engine at the time that Karting Australia conducted the homologation. The height of the complete engine on all photographs must be as a minimum 7 cm. PHOTO OF DRIVE SIDE OF ENGINE PHOTO OF OPPOSITE SIDE OF ENGINE Signature and stamp of Karting Australia Les Allen National Technical Commissioner 17 December 2014 Copyright 2014 Karting Australia. All rights reserved. 1

Homologation N PHOTO OF THE REAR OF THE COMPLETE ENGINE

Homologation N PHOTO OF THE FRONT OF THE COMPLETE ENGINE

Homologation N PHOTO OF THE COMPLETE ENGINE TAKEN FROM

Homologation N UNIQUE AU SERIAL NUMBER SAMPLE FOR COMPLIANCE WITH KA HOMOLOGATION No deviation from the manufacturers Australian "AU" spec engine is allowed.

8 Homologation N UNIQUE AU SERIAL NUMBER SAMPLE FOR COMPLIANCE WITH KA HOMOLOGATION No deviation from the manufacturers Australian "AU" spec engine is allowed. All components must remain OEM and therefore only engines stamped with the "AU" as the second and third identifier in the engine serial number for example 4AU0001 will comply with Australian Homologation. Attention : ALL THE ENGINE PARTS MUST BE ORIGINAL BY VORTEX ROK. Neither engines nor accessories can be modified. By this we mean any shape, content or function changes which may differ from what previously conceived. Furthermore this includes any addition and /or removal of material and /or parts from the engine set-up package unless provided by this regulation. No ceramic bearings or component coatings. Copyright 2014 Karting Australia. All rights reserved. 8

9 Homologation N TECHNICAL INFORMATION A CHARACTERISTICS The number of decimal places must be 2 or comply with the relevant tolerance. Max displacement Max allowed bore Cylinder 60 cc mm Tolerances & remarks Stroke mm Admission system in the cylinder Cooling system Carburettor: Piston Port Air cooling CARBURETTOR DELL ORTO PHBG 18 BS Number of transfers 2 Shape of exhaust transfer At 4 angles Cylinder head Volume with Vortex CC check tool WA cc Minimum Crankshaft Number of bearings 2 -- Diameter of bearings 47mm 0.05mm Weight of crankshaft with Conrod 1311g 10.0g Crankpin (Big End) Diameter 18mm 0.05mm Length 40.6mm 0.05mm I.D. 6mm 0.05mm Weight of crankpin 71g 1.0g Connecting rod Connecting rod centreline 90mm 0.20mm Diameter of big end 24.02mm 0.05mm Diameter of small end 16mm 0.05mm Weight of the connecting rod 94g 10.0g Copyright 2014 Karting Australia. All rights reserved. 9

10 Homologation N Piston Number of piston rings 1 Weight of the piston 63g 5.0g Squish minimum measurement (use 1.6mm solder) 0.8mm Minimum Gudgeon pin Diameter 12mm 0.01mm Length 34mm -0.20mm Minimum weight 15g Minimum I.D. 8mm 0.10mm Clutch Minimum weight 815g 15.0g Engine Sprockets Option Only Z10-Z11 B OPENING ANGLES Of the inlet Of the transfer ports Of the exhaust C Cylinder head Cylinder Cylinder wall Sump Crankshaft Connecting rod Piston MATERIAL AL-SI AL-SI/ CI CI AL/SI ACIER NI-CR-MO ACIER NI-CR-MO AL/SI No deviation from the manufacturers Australian "AU" spec engine is allowed. All components must remain OEM and therefore only engines stamped with the "AU" as the second and third identifier in the engine number for example 4AU0001 will comply with Australian Homologation. Opening Angles adjustable via base gasket thickness only. Attention : ALL THE ENGINE PARTS MUST BE ORIGINAL BY VORTEX ROK. Neither engines nor accessories can be modified. By this we mean any shape, content or function changes which may differ from what previously conceived. Furthermore this includes any addition and /or removal of material and /or parts from the engine set-up package unless provided by this regulation. Copyright 2014 Karting Australia. All rights reserved. 10

11 Homologation N D PHOTOS, DRAWINGS & GRAPHS D.1 CYLINDER UNIT MINIMUM DISTANCE OF THE CARBURETTOR SUPPORTING PLATE FROM THE CYLINDER AXLE DRAWING OF THE CYLINDER DEVELOPMENT Copyright 2014 Karting Australia. All rights reserved. 11

12 Homologation N... Section D.1 Indicate on the drawing: A1/A2 = maximum inlet width measured at the chord. E1/E2 = minimum thickness of the exhaust rib (if existing). C1/C2/C = maximum exhaust width measured at the chord. DRAWING OF THE CYLINDER BASE with dimensions Copyright 2014 Karting Australia. All rights reserved. 12

PHOTO OF THE CYLINDER BASE Copyright 2014

14 ... Section D.1 DRAWING OF THE CYLINDER HEAD AND OF THE COMBUSTION CHAMBER with dimensions PHOTO OF THE CYLINDER HEAD PHOTO OF THE COMBUSTION CHAMBER IN THE CYLINDER HEAD Copyright 2014 Karting Australia. All rights reserved. 14

Homologation N... Section D.1 PROCEDURE USED TO MEASURE the Transfer and Exhaust Port Durations a. The measuring will be done with a gauge as per the drawing under Opening Angles in this document b.

It must be inserted at 45 degrees on the wall, you should be able to move it forward and backward during this operation, it must not give the sensation that it is somehow blocked.

15 Homologation N... Section D.1 PROCEDURE USED TO MEASURE the Transfer and Exhaust Port Durations a. The measuring will be done with a gauge as per the drawing under Opening Angles in this document b. When placing the gauge into the port the gauge is not to be bent and must be held as per photograph c. It must be inserted at 45 degrees on the wall, you should be able to move it forward and backward during this operation, it must not give the sensation that it is somehow blocked. Once the piston has made contact, no pressure must be applied to the crankshaft to block the forward and backward movement of the gauge. The feeling should be the same as when setting a tappet on a four stroke engine. Not on any account the wedge to be placed in a horizontal or vertical position. d. With the inlet manifold fitted to the engine, check the inlet port opening angle from the outside of the cylinder only. PHOTO OF THE CYLINDER FROM ABOVE CYLINDER HEIGHT Copyright 2014 Karting Australia. All rights reserved. 15

16 Homologation N... Section D.1 OPENING ANGLES measured with a thickness gauge of 0,20 mm having width of 5 mm and degrees wheel with 200 mm diameter. The exhaust angular reading must be measured with a 0,20 mm thick and 5mm wide wedge. (VORTEX Tool WD016) (see drawing beside). PROCEDURE USED TO MEASURE THE VOLUME OF THE COMBUSTION CHAMBER Disassemble the engine from the chassis Wait until the temperature is ambient temperature Verify Squish Minimum measurement (0.8mm) using 1.6mm solder. Disassemble the cylinder head in order to verify the projection of the spark plug inside the combustion chamber. Remove the spark plug ( verify the height of 18,5mm) Screw the Vortex tool (WA050) at the place of the spark plug (The tool fitted on the cylinder head must not overpass the superior part of the combustion chamber. It has to be fixed on the cylinder head in the same way the spark plug of 18,5mm was fixed) Make it air tight and water tight with grease the upper part of the piston and the cylinder wall Raise up the piston and stop the crankshaft, locking at Top Dead Centre Dry up the excess of grease Be sure that the engine is on a flat surface Refit the cylinder head and torque head nuts in X pattern to (16-18 Nm). Fill up the combustion chamber (with a mixture composed by 50% of ATF oil used to make the mixture and the 50% of the Deisel fuel) using a graduated burette (25cc or 50cc class A or B ) (mechanical or electrical) until the upper border of the insert tool. The measured volume must show a value which is complying with the minimum combustion chamber volume of 6.8cc as per the engine Technical Information herein. Copyright 2014 Karting Australia. All rights reserved. 16

17 Homologation N... Section D.1 THE EXHAUST MUFFLER AND MANIFOLD/S DIMENSION OF COLLECTOR INCLUDING WELDING Cadet 9 (Restricted) FRONT VIEW DRAWING with dimensions Cadet 12- KA12 (Open) EXHAUST GASKET 1,5 +/- 0,5 EXHAUST GASKET 1,5 +/- 0,5 Attention : ALL THE ENGINE PARTS MUST BE ORIGINAL BY VORTEX ROK. Neither engines nor accessories can be modified. By this we mean any shape, content or function changes which may differ from what previously conceived. Furthermore this includes any addition and /or removal of material and /or parts from the engine set-up package unless provided by this regulation. Copyright 2014 Karting Australia. All rights reserved. 17

18 Homologation N D.2 CRANKCASE EXPLODED DRAWING OF THE CRANKCASES UNIT Attention: ALL THE ENGINE PARTS MUST BE ORIGINAL BY VORTEX ROK. Neither engines nor accessories can be modified. By this we mean any shape, content or function changes which may differ from what previously conceived. Furthermore this includes any addition and /or removal of material and /or parts from the engine set-up package unless provided by this regulation. Copyright 2014 Karting Australia. All rights reserved. 18

19 Homologation N PHOTO OF THE CRANKSHAFT PHOTO OF THE CONROD RIGHT SIDE LEFT SIDE DRAWING OF THE CRANKSHAFT (MAIN DIMENSIONS incl. tolerances) CRANKSHAFT WEIGHT WITH CONROD 1311 gr.± 10gr Copyright 2014 Karting Australia. All rights reserved. 19

21 Homologation N BIG END CRANK PIN DIMENSIONS PISTON PIN DIMENSIONS WEIGHT OF CRANKSHAFT CRANKPIN 71gr. +/- 1gr PISTON PIN WEIGHT 15 gr Min PISTON DIMENSIONS Mandatory to have the brand VORTEX cast piston as shown in the picture WEIGHT OF PISTON 63 gr +/- 5 gr Homologation N Copyright 2014 Karting Australia. All rights reserved. 21

22 D.3 COMPLETE CLUTCH ROTOR WITH STARTING GEAR WEIGHT OF COMPL. CLUTCH ROTOR WITH STARTING GEAR: 815g +/- 15g ENGAGEMENT SPEED (MAXIMUM) CAN BE VERIFIED IN EVERY MOMENT OF THE EVENT 4000 RPM WEIGHT OF CLUTCH ROTOR 345g +/- 15g WEIGHT OF CLUTCH HOUSING 178g +/-10g INSIDE DIAMENSION OF CLUTCH HOUSING 84.5mm+/- 0.1 mm TOTAL WEIGHT OF CLUTCH ROTOR AND HOUSING 512g - 15g Copyright 2014 Karting Australia. All rights reserved. 22

23 Homologation N...Section D.3 PHOTO OF SELETTRA IGNITION Cod. PVL Part W420/2 NOTE THAT THE ONLY SPARK PLUG CAP PERMITTED IS AS PER ABOVE SPARK PLUG: Only NGK B9EG or B10EG are permitted. Spark plug must be standard and have the original washer fitted. Shank length 18.5mm maximum. No machining permitted. Vortex OEM wiring loom, connectors and start/stop buttons must be used. No Head or Exhaust temp sensors permitted. No wiring loom repairs permitted, except: The HT lead may be shorted as a repair. HT lead must not have a join. The loom wire connectors to the coil may be replaced/repaired with like for like components. Stator mounting ring must be Vortex OEM. All mounting bolts must be in original condition. Selettra Coil Part W410/MR. The Coil must be mounted on the Vortex OEM mounting bracket. Copyright 2014 Karting Australia. All rights reserved. 23

Homologation N Ignition Timing VORTEX MINI ROK IGNITION TIMING

Insert dial gauge into spark plug thread and screw in tightly.

Slowly rotate engine until the dial gauge reads 3mm +/- 0.1mm.

24 Homologation N Ignition Timing VORTEX MINI ROK IGNITION TIMING Remove spark plug. Insert dial gauge into spark plug thread and screw in tightly. Rotate engine past TDC and set gauge to read 0 at TDC. Slowly rotate engine until the dial gauge reads 3mm +/- 0.1mm. Using a straight edge check that the timing marks line up correctly. WIRING LOOM Copyright 2014 Karting Australia. All rights reserved. 24

25 Homologation N... Section D.4 BATTERY CRADLE BATTERY: Battery can be either the factory supplied lead acid type, or an alternative lightweight Lithium Ion battery and must be mounted within the Vortex OEM battery cradle, on the left side of the chassis, within easy reach of the driver. (start/stop buttons bracket end facing towards front of kart). Extra padding material is permitted. Additional holes are permitted in the base of the battery cradle to enable a second chassis mount to be fitted. Engines shall be mandatory swiched on and off by means of onboard starting system. Technical Inspectors may check the on-off onboard system anytime. Copyright 2014 Karting Australia. All rights reserved. 25

26 Homologation N D.5 EXHAUST SYSTEM (Exploded view) DIAMENSIONS OF THE EXHAUST MANIFOLD (RESTRICTED TYPE) Cadet 9 DIAMENSIONS OF THE EXHAUST MANIFOLD (OPEN TYPE) Copyright 2014 Karting Australia. All rights reserved. 26

27 Homologation N... Section D.5 TECHNICAL DESCRIPTIONS OF THE EXHAUST Weight in g 1372 g +/- 5% TECHNICAL DRAWING It must include all the information necessary to build this exhaust. Copyright 2014 Karting Australia. All rights reserved. 27

28 Homologation N CARBURETTOR DELL ORTO PHBG 18 BS AND COMPONENTS LIST COMPONENTS 1- GAS VALVE 40X64 (4.0) 2- CONICAL NEEDLE W23 3- SPRAY NOZZLE AN JET MAIN. Range JET PILOT STARTING JET FLOAT 4 gr. 8- TUBE 90 KIT 9- CHAMBER MIXTURE COVER KIT 10- CHAMBER MIXTURE COVER GASKET 11- GAS VALVE SPRING 12- CONICAL NEEDLE FASTENER FIX PLATE 13- CONICAL NEEDLE FASTENER 14- STARTING DEVICE 15- ADJUSTMENT MINIMUM SCREW KIT 16- ADJUSTMENT MINIMUM SCREW GASKET 17- ADJUSTMENT GAS VALVE SCREW KIT 18- SURGE PLATE (Compulsory) 19- GAS NEEDLE CLOSING 20- FLOAT PEG 21- FLOAT CHAMBER GASKET 22- FLOAT CHAMBER 23- FLOAT CHAMBER FIXING SCREW The aim of the exploded drawings is to identify the principles, the functioning and the whole mechanical unit Copyright 2014 Karting Australia. All rights reserved. 28

Homologation N FUEL PUMP FUEL PUMP, PULSE LINE, FUEL LINES, FUEL FILTER and CATCH BOTTLE: OEM DellOrto fuel pump and components as supplied by Vortex only. Only one fuel pump permitted.

29 Homologation N FUEL PUMP FUEL PUMP, PULSE LINE, FUEL LINES, FUEL FILTER and CATCH BOTTLE: OEM DellOrto fuel pump and components as supplied by Vortex only. Only one fuel pump permitted. The fuel pump must be mounted On the Vortex OEM mounting bracket. Length of pulse line 100mm maximum. All fuel lines must be continuous (one piece without restriction, spigots, junctions, taps and similar devices) apart from the fuel tank pick up, the fuel filter and the fuel pump. Exception: It is optional to fit a T junction in the fuel line between the Fuel Pump and the Carburettor and to run a return fuel line from this T junction back to the fuel tank fitted with appropriate barbed fitting. A fixed size restrictor may be inserted into the return fuel line only. This fixed size restrictor must not be adjustable when the engine is running. Between tank, pump it is allowed to mount only 1 (one) fuel filter. Suitable 100ml catch bottle must be used for carburettor overflow tubes Copyright 2014 Karting Australia. All rights reserved. 29

Homologation N INLET SILENCER OEM VORTEX MARKED CONNECTOR FIXING -CARBURETOR IN

Vortex OEM intake silencer with ADDITIONAL (mandatory) Vortex AU foam filter

Foam filter must be free of damage/tears/modification.

30 Homologation N INLET SILENCER OEM VORTEX MARKED CONNECTOR FIXING -CARBURETOR IN PLASTIC MATERIAL-FILTER (Sample only) black foam 30ppi (Final Marking) VORTEX AU Vortex OEM intake silencer with ADDITIONAL (mandatory) Vortex AU foam filter which must be fitted in all events. (See pictures). Foam filter must be free of damage/tears/modification. The fitting of the Vortex OEM mesh stone guard is optional. All dimensions as per diagram. The only allowable modification is the drilling of an 8mm (maximum) drain hole positioned at the front centre line of lowest point of the intake silencer box. Copyright 2014 Karting Australia. All rights reserved. 30

Homologation N CRANKCASE SEALS Seals must be original Vortex OEM (see pictures) and fitted in the original Vortex factory location/direction and maintaining the seal spring.

0 Needle: W23 Starter Jet: #60 Inner pilot: #50 Emulsion tube: 266AN Floats: 4gm Maximum venturi size (go/no go): 18mm +/-0.

31 Homologation N CRANKCASE SEALS Seals must be original Vortex OEM (see pictures) and fitted in the original Vortex factory location/direction and maintaining the seal spring. Main bearings must be original Vortex OEM SNR or KOYO used. Carburetor: Dell Orto PHBG 18mm Slide: #4.0 Needle: W23 Starter Jet: #60 Inner pilot: #50 Emulsion tube: 266AN Floats: 4gm Maximum venturi size (go/no go): 18mm +/-0.05mm The ONLY allowed changes to the carburetor are Main Jet changes in size range and Needle Clip Position. Air screw adjustment. Any other change or modification is not permitted. Attention : ALL THE ENGINE PARTS MUST BE ORIGINAL BY VORTEX ROK. Neither engines nor accessories can be modified. By this we mean any shape, content or function changes which may differ from what previously conceived. Furthermore this includes any addition and /or removal of material and /or parts from the engine set-up package unless provided by this regulation. Copyright 2014 Karting Australia. All rights reserved. 31

Homologation N FRONT SPROCKET / CLUTCH COVER Clutch cover may be modified only on the under side, in a manner not to breach the first vent slot as pictured.

32 Homologation N FRONT SPROCKET / CLUTCH COVER Clutch cover may be modified only on the under side, in a manner not to breach the first vent slot as pictured. Top and Side view must remain unmodified in its shape. Rationale : Improved chain clearance when using a larger rear axle sprockets. Attention: ALL THE ENGINE PARTS MUST BE ORIGINAL BY VORTEX ROK. Neither engines nor accessories can be modified. By this we mean any shape, content or function changes which may differ from what previously conceived. Furthermore this includes any addition and /or removal of material and /or parts from the engine set-up package unless provided by this regulation. Copyright 2014 Karting Australia. All rights reserved. 32

NATIONAL HOMOLOGATION FORM - ENGINE

NATIONAL HOMOLOGATION FORM - ENGINE Homologation N Manufacturer VORTEX Make DVS JNR Model 125CC Validity of the homologation 10 years Number of pages 30 This Homologation Form reproduces descriptions,