KARTSPORT NEW ZEALAND MANUAL SECTION N SPECIFICATIONS RULE N10 - VORTEX KIWI MINI ROK. Issue published and effective

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1 KARTSPORT NEW ZEALAND MANUAL SECTION N SPECIFICATIONS RULE N10 - VORTEX KIWI MINI ROK Issue published and effective Rule N10 VORTEX KIWI MINI ROK N10.1 GENERAL SPECIFICATIONS These engine specifications are under the control of KartSport New Zealand Executive in conjunction with Vortex/OTK Group. The KartSport New Zealand Executive reserves the right to alter the engine specifications and respective class rules, to ensure fairness of competition and safety, at any time. Only written submissions will be accepted for changes, with the Executive acting on them if considered necessary Unless otherwise specified the Vortex Mini Rok engine used in KartSport New Zealand events must be as per original manufacturer s specifications in regard to construction and surface finish of all components. Any engine which does not comply with these rules is deemed illegal and the competitor will be excluded from the results of any and all competition in which the engine has been used. Further penalties may also apply (Ref C9.4.6) Glass blasting, shot peening, sand blasting, chemical or any other surface treatment in any way shape or form is not acceptable as original manufacture All gaskets must be in situ and be original OEM Vortex or DellOrto items. The only chemical gaskets/sealants permitted are those on the mating surfaces of the crankcase halves and on the exhaust manifold/exhaust pipe slip joint Filing, grinding, polishing, surface treating, machining or removing/adding of material to any component is expressly forbidden All measurements in these specifications are for manufacturing tolerance and/or technical reference only The use of ceramic / ceramic hybrid bearings or bearings containing any ceramic component, is not permitted. Micro polishing of bearings is not permitted Fitting of helicoil type thread repair inserts to repair damaged threads is permitted, providing such repairs are not used to derive any benefit other than rectification of damage The engine is to be used with its intake silencer, carburettor, fuel pump, wiring loom, ignition system, clutch, clutch guard, respective RPM limiter and respective exhaust system as supplied by the manufacturer. N10.2 EXCHANGE and CLAIMING Exchange: Following a decision of the Stewards the Technical Officer(s) may be authorized to require the exchange of one or more of competitor(s) owned RPM limiter(s), carburettor(s), exhaust manifold(s) and/or exhaust pipe(s) with a substitute item owned by KartSport New Zealand. The substitute item(s) must be the same make and model as the item(s) previously fitted to the competitor s engine and must be returned to KartSport New Zealand when requested by the Stewards. Should an earlier return time not be nominated by the Stewards, the item(s) must be returned to their original owners no later than the end of Technical Inspection for the event. 1

2 Claiming: Following a decision of the Stewards, KartSport New Zealand reserves the right to claim an engine at its discretion. The claimed engine must have cleared Technical Inspection for the event. The complete claimed engine and all ancillaries, less engine mount, will be delivered to the Chief Steward at the end of the event. Failure to deliver the claimed engine will result in forfeiture of all awards and exclusion from the event and/or series and possible further penalties (ref C9.3.29). KartSport New Zealand will replace the engine with a new one within 5 working days, in the same configuration, less engine mount. N10.3 ENGINE NUMBER The crankcase must have an NZ engine number sequence. Eligible engine numbers will be posted from time to time on N10.4 EXHAUST PIPE: Must be as manufactured and cannot be modified No repairs are permitted. Maximum accident damage permitted, as presented to the dummy grid: In the 150mm cone section; a maximum of two points of damage, each of which must be contained within a 30mm diameter circle and have depression of no more than 3mm. In the 260mm can section; a maximum of four points of damage, each of which must be contained within a 50mm diameter circle and have a depression of no more than 5mm. Note: no damage is permitted to the curved header section. Impact damage sustained during a time trial or race will not be considered illegal in the pit shute at the end of that respective a time trial or race. The application of any coating/plating or painting is not permitted. (Note Rule L6.12 applies). The fitting of exhaust temperature or other sensors is prohibited. Exhaust Weight /- 69 grams External slip joint length from weld: mm. N10.5 EXHAUST MANIFOLD: Manifold and Exhaust Gasket as per drawings below. Carbon deposits can be removed by the Technical Officer before measurement. Only one Exhaust Gasket is permitted and this must be in place. 2

3 N Mini Rok Exhaust Manifold N Cadet Rok Exhaust Manifold Chamfer 0.5mm maximum Chamfer 0.5mm maximum N Exhaust Manifold Gasket N10.6 INTAKE SILENCER: Vortex OEM intake silencer with Vortex OEM foam filter which must be fitted. (See pictures). Foam filter must be free of damage/tears. 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 in the position indicated by the arrow. Retaining hose clamp is a non tech item. No decals/self adhesive additions or coatings permitted. The only approved addition to the Intake Silencer is a KSI/RLV style wet cover (including optional spacer) fitted with the wet cover intake opening to the rear. (see picture) 3

4 Stone Guard Foam Filter (either blue or red) Wet cover. 4

5 N10.7 INTAKE SILENCER ADAPTOR: DellOrto OEM as per photo. Must retain its original shape and form and must be fully seated on to the carburettor. N10.8 CARBURETTOR: DellOrto PHBG 18mm BS and components only. All parts used in or on the carburettor must be original parts as manufactured by DellOrto. No polishing, surface treating, sand blasting or machining permitted. All components must be in place, seated and tight in their correct position. Maximum venturi size: mm NO GO. Float height setting is free. The right angle overflow nipples must be oriented to vent upwards. Some carburettors have a brass insert fitted inside the overflow nipples (Supplied from DellOrto) on the inside of the carburettor. This is to prevent break through of internal channels and is permitted. Only the following options are permitted: Slide (Gas Valve) : #40 Conical Needle: W23. Clip position free. Outer Pilot (Starting Jet): #60 Inner Pilot (Jet Min.): #50 Emulsion Tube (Spray Nozzle): 266AN Float: 4gm Main Jet (Jet Max.): #92, #93, #94, #95, #96 or #97 Component List (ref diagram) 1 Gas Valve 2 Conical needle 3 Spray Nozzle 4 Jet Max. 5 Jet Min. 6 Starting Jet 7 Float 8 Tube 90 Degree 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 (Choke) 15 Adjustment Minimum Screw Kit 16 Adjustment Minimum Screw Gasket 17 Adjustment Gas Valve Screw Kit 18 Bottom 19 Gas Needle Closing 20 Float Peg 21 Float Chamber Gasket 22 Float Chamber 23 Float Chamber Fixing Screw 5

6 N Gas Valve (Throttle Slide) (#40) 1.1 Length of Throttle Valve Slide Spec: 27.50mm ± 0.15mm 1.2 Length of Cut Away to the top of the Throttle Valve Slide (outside) Length of Throttle Valve Slide Spec: 23mm ± 0.25mm 1.3 Length of Cut Away to the top of the Throttle Valve Slide (inside) Length of Throttle Valve Slide Spec: 23.4mm ± 0.15mm 6

7 Surface Finish: Cast N Conical Needle (#W 23) 2.1 Table of Needle Specifications as per Supplier Chart (Dellorto) (Also as per Master Sample W23 needle from the Vortex Rok Importer) L Type Characteristic expressed in millimeters ØA ØB C ØD L W ± ±0.05 (26 ±0.5) 2.5 ± ±0.2 Measured right Reference at the tip Dimension 7

8 2.2 The Technical Officer may also compare the needle to a master sample supplied by the Vortex Rok Importer. 2.3 There must be 1 mixture needle stop (Circlip, #13 on page 2) fitted to the needle. 2.4 No Washer is permitted to be fitted either above or below the circlip. 2.5 Note: The marking W23 on the needle does wear off after a period time. It is the responsibility of the competitor to ensure that if the marking wears off, that the needle is replaced with a new one. 2.6 Should the Technical Officer inspect a needle that the marking is worn off; the needle will be checked with reference to the specification above and / or a master sample. The needle will then be impounded by the Technical Officer and the competitor will be required to fit a new needle. 2.7 Wear marks towards the tip of the needle, where the needle goes through the emulsion tube are common. The needle should be replaced if wear is excessive. N Spray Nozzle Emulsion Tube (#266AN) 3.1 Length of Emulsion Tube Spec: 36.00mm ± 0.20mm 3.2 Internal Diameter from side 3.2 GO Spec: 2.66mm (GO) NO GO Spec: 2.69mm (NO GO) 3.3 Internal Diameter from side 3.3 GO Spec: 3.00mm (GO) NO GO Spec: 3.10mm (NO GO) x Rows of 4 holes GO Spec: 0.80mm (GO) NO GO Spec: 0.85mm (NO GO) x rows of 3 holes GO Spec: 0.80mm (GO) NO GO Spec: 0.85mm (NO GO) 3.6 Length of Nozzle tip to seating face Spec: 27.00mm ± 0.20mm Seating Face 3.3 8

9 Insert 3.7 Length of Insert Spec: 12.00mm ± 0.20mm 3.8 Thickness of Flange Spec: 1.00mm ± 0.20mm 3.9 Hole Diameter Spec: 4.90mm ± 0.30mm N Inner Pilot (Jet Min.) (#50) 4.1 Length of Inner Pilot Spec: 9.50mm ± 0.20mm 4.2 Internal Diameter of smallest hole inside the Inner Pilot GO Spec: 0.5 mm (GO) NO GO Spec: 0.55 mm (NO GO) N Outer Pilot (Starting Jet) (#60) 5.1 Length of Outer Pilot Spec: 27.00mm ± 0.25mm 5.2 Internal Diameter of hole inside the Outer Pilot GO Spec: 0.60 mm (GO) NO GO Spec: 0.65 mm (NO GO) holes, 90 apart GO Spec: 1.00 mm (GO) NO GO Spec: 1.10 mm (NO GO)

10 N Main Jet (Jet Max.) (#92, #93, #94, #95, #96 or #97) The anti surge plate fitted between the emulsion tube and the main jet must NOT be removed. 6.1 Length of High Speed Jet / Main Jet Spec: 8.0mm ± 0.3mm 6.1 N Needle Valve 7.1 Internal diameter of hole inside the Needle Valve GO Spec: 1.45 mm (GO) NO GO Spec: 1.55 mm (NO GO) 7.1 N Float 8.1 Weight of Float Spec: 4.0grams (As marked on the bottom of the float) 8.2 Float height setting is free. 10

11 N Adjustment Minimum Screw (Air Screw) 9.1 Diameter of Air Screw Orifice. GO Spec: 1.10 mm (GO) NO GO Spec: 1.3 mm (NO GO) Diameter of tip end: 0.9mm ±0.05mm 9.3 Diameter of tip: 1.2mm ±0.05mm The Air Screw must be fitted with O-ring, washer and spring as illustrated. 11

12 N Other Dimensions 10.1 Diameter of Throat. The throat diameter must be checked from both sides of the carburettor. Spec: 18.0mm ± 0.05mm GO Spec: mm (GO) NO GO Spec: mm (NO GO) when measured with a plug gauge NO GO Spec: mm (NO GO) when measured with a snap gauge Technical Officer to determine which gauge will be used. If both used, the carburettor must comply with both measurements Diameter of hole 10.2 as illustrated GO Spec: 1.00 mm (GO) NO GO Spec: 1.10 mm (NO GO) 10.3 Diameter of hole 10.3 as illustrated GO Spec: 2.50 mm (GO) NO GO Spec: 2.60 mm (NO GO)

13 10.4 Diameter of hole 10.4 as illustrated GO Spec: 1.10 mm (GO) NO GO Spec: 1.30 mm (NO GO) Diameter of hole 10.5 as illustrated GO Spec: 1.0 mm (GO) NO GO Spec: 1.1 mm (NO GO 10.5 N Starting Device (Choke) Choke base height: 7mm plus/minus 0.05 mm 13

14 N10.9 FUEL PUMP, PULSE LINE, FUEL LINES and FUEL FILTER: 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 (old or new version permitted). Length of pulse line 140mm maximum. Only one in-line fuel filter is permitted and this must be positioned in the fuel line between the fuel tank and the fuel pump. 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 permitted 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. 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. 14

15 N10.10 INLET MANIFOLD: As per Vortex OEM only. Intake tract length must comply with Vortex measuring tool. MINIMUM DISTANCE OF THE CARBURETTOR SUPPORTING PLATE FROM THE CYLINDER CENTRE LINE N10.11 SPARK PLUG: Only NGK B9EG or B10EG are permitted. Spark plug must be standard and have the original washer fitted. Shank length 20mm maximum. No machining permitted. N10.12 STROKE: 43.00mm mm N10.13 IGNITION SYSTEM and WIRING LOOM: Vortex OEM wiring loom, connectors and start/stop buttons must be used. No repairs permitted except: The HT lead may be shortened as a repair. The loom wire connectors to the coil may be replaced/repaired with like for like components. The green start and red stop buttons may be replaced with Vortex OEM buttons. HT lead must not have a join. Stator mounting ring must be Vortex OEM. All mounting bolts must be in original condition. Selettra Coil Part The Vortex factory applied KSNZ fern logo must be present. The Coil must be mounted on the Vortex OEM mounting bracket (old or new version permitted). Stator must have CSAI 01/ACZ/14 homologation mark. Plug Cap PVL Ignition timing must be 3mm + 0.1mm before TDC. (see M11) Respective RPM Limiter must be connected: Cadet Rok RPM, blue CSAI 01/ACZ/14/ The Vortex factory applied KSNZ fern logo must be present. Vortex Mini Rok RPM, green CSAI 01/ACZ/14/ The Vortex factory applied KSNZ fern logo must be present. The RPM Limiter must be mounted on the back of the seat with the KSNZ fern logo facing towards the rear of the kart. Foam padding must be used to line the interior of the RPM Limiter mounting bracket. The temperature of the RPM limiter must be at ambient (as determined by the Judge of Fact). KartSport New Zealand may use various test methods/equipment to determine the conformity of the ignition system. 15

16 16

17 N10.14 CYLINDER HEAD: The Vortex factory applied KSNZ fern logo must be present (see picture). Head temperature sensors are not permitted. Combustion chamber must conform to the KartSport New Zealand tech gauge. Carbon deposits can be removed before using the gauge. Spark plug thread repair permitted with helicoil only. Head to cylinder sealing with Vortex OEM O-Ring only. SQUISH GAP: 0.81 mm minimum. Measure as per Procedure Rule M12. N Head Gasket(s) OPTIONAL - either 0.1mm or 0.2mm. A maximum of two head gaskets permitted with a maximum combined measurement of 0.2mm. 17

18 N10.15 CYLINDER: The Vortex factory applied KSNZ fern logo must be present (see picture). All dimensions as per diagrams. Port Dimensions Drawing of Cylinder Base. 18

19 Cylinder Section N10.16 OPENING ANGLES: Measured in accordance with the method described in Technical Procedure M7. Transfers degrees + 1 degree Intake 142 degrees + 2 degrees Exhaust 154 degrees + 2 degrees 19

20 N10.17 PISTON: Vortex OEM brand cast piston with Vortex branding only (see picture). Piston must conform to KartSport New Zealand Tech gauge. Carbon deposits can be removed before using the gauge. No machining permitted. All dimensions and weight as per diagram. PISTON WEIGHT 63 gr. +/- 5 gr. N10.18 PISTON RING: The dykes section piston ring must be Vortex OEM. N10.19 GUDGEON PIN: Vortex OEM gudgeon pin only. It must be magnetic (Ref M9). All dimensions and weight as per diagram. GUDGEON PIN WEIGHT 15 gr. Min 20

21 N10.20 DISPLACEMENT and BORE: Displacement: 60cc maximum (Ref M6) Bore: 42.13mm maximum, (includes 0.03mm tolerance Ref M10) N10.21 CYLINDER BASE GASKETS: Genuine Vortex OEM gaskets only. N10.22 CRANKCASE: The two Vortex factory applied KSNZ fern logos must be present on both crankcase halves (see pictures). All dimensions as per diagrams. CRANKCASE INTERIOR OF THE CRANKCASE SIDE 1 21

22 INTERIOR OF THE CRANKCASE SIDE 2 INTERIOR VIEW OF THE CRANKCASE 22

23 N10.23 CRANKCASE SEALS: Seals must be original Vortex OEM (see pictures) and fitted in the original Vortex factory location. N10.24 CRANKSHAFT BEARINGS: SNR (Type 6204G15C4) or KOYO (Type 6204MGC4 or 6204SGC4) or KOYO bearings marked C4 on one side of the bearing and 6204 on the other side are the only bearing allowed. Bearing markings must be able to be read CRANK SHAFT ASSEMBLY: All components must be Vortex OEM. Repairs not permitted. All dimensions and weight as per diagrams. Only Vortex OEM big end and little end bearings permitted. 23

24 WEIGHT OF CRANKSHAFT WITH CONROD 1311 gr.± 10gr A = 15mm wide. Diameter in this section = 20.00mm mm to allow for wear. 24

25 10.26 CONNECTING ROD and CRANKSHAFT PIN: Vortex OEM only. All dimensions and weight as per diagram. Branding as per pictures. WEIGHT OF CONROD 94gr. +/- 10gr PICTURE OF COROD RH 25

26 PICTURE OF CONROD - LH WEIGHT OF CRANKSHAFT CRANKPIN 71gr. +/- 1gr CLUTCH: Vortex OEM clutch only. All dimensions and weights as per diagram. Clutch rotor and drum may not contain significant amounts of any oil or grease. Saturated friction surfaces are grounds for exclusion. 26

27 WEIGHT OF COMPLETE. CLUTCH ROTOR WITH STARTING GEAR & NUT: WEIGHT OF CLUTCH ROTOR: WEIGHT OF CLUTCH HOUSING: TOTAL WEIGHT OF CLUTCH ROTOR AND HOUSING: Drive Sprocket: Only Vortex OEM: 10T, 11T or 12T permitted. Vortex OEM Clutch Guard must be fitted. 815g +/- 15g 345 gr +/- 15gr 178 +/-10gr 512 gr +/- 15gr STARTER MOTOR: Vortex OEM starter motor and bendix only BATTERY: Battery can be either the factory supplied lead acid type, or an alternative lightweight battery and must be mounted within the Vortex OEM battery cradle. 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. (Ref K1.37). 27