IDENTIFICATION SHEET This Identification Sheet reproduces descriptions, illustrations and dimensions of the MINI ROK engine to be used in the MINI ROK CUP recognised by Motorsport South Africa PICTURE ENGINE UPPER SIDE PICTURE ENGINE LOWER SIDE - pag. 1 - www.vortex-rok.com
CYLINDER BASE CYLINDERHEAD AND COMBUSTION CHAMBER PICTURE OF THE CRANKCASE INTERIOR PICTURE OF THE CRANKCASE - pag. 2 - www.vortex-rok.com
TECHNICAL INFORMATION AND CHARACTERTICS EVERY MATERIAL ADDING OR REMOVAL (machining, burnishing, etc.) FROM ORIGINAL COMPONENTS IS FORBIDDEN Max displacement Max allowed bore 60 cc. 42,10 mm Stroke 43,00 mm. +/- 0,10 mm. Admission system in the cylinder Cooling system Spark Plug Piston Port Ad aria libera Free Air The ONLY Spark Plug permitted is an NGK B10EG Carburettor : CARBURETTOR DELL ORTO PHBG 18 BS See description pag.16 Number of transfers 2 Shape of exhaust transfer A 4 angoli At 4 angles Widht of exhaust transfer 28,00 mm. +/- 0,10 mm. Widht of admission transfer 26,00 mm. +/- 0,10 mm. Total height of piston 49 mm. +/- 0,8 mm. Weight of piston 63 gr. +/- 5 gr. Shape of combustion chamber Spherical, verifiable with gauge supplied by the Manufacturer PINION Rear Sprocket Bearings Crnakshaft Z10, Z11 Free 20/14/47 Volume of combustion chamber 6,80 cc. Min, measured with insert. See pg. 6 Clutch (Centrifugal, dry, without any possibility of external adjustment). Weight: 815 +/- 15 g. Diameter internal of the clutch housing:84.5 +/-0.1 mm - pag. 3 - www.vortex-rok.com
B OPENING ANGLES measured through 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 5 mm wide wedge. (see drawing beside). Tolorance Transfers 116,5 +/- 1 Inlet 142 +/- 2 Exhaust 154 +/- 2 - pag. 4 - www.vortex-rok.com
CYLINDER DEVELOPEMENT DRAWING OF CYLINDER BASE CYLINDER SECTION - pag. 5 - www.vortex-rok.com
DRAWING OFCYLINDERHEAD AND COMBUSTION CHAMBER CRANKSHAFT WIGHT OF CRANKSHAFT WITH CONROD 1311 gr.± 10gr - pag. 6 - www.vortex-rok.com
PROCEDURE USED TO MEASURE THE VOLUME OF THE COMBUSTION CHAMBER Disassemble the engine from the chassis Wait until the temperature is ambient temperature Disassemble the cylinder head in order to verify the projection of the sparking plug inside the combustion chamber. Disassemble the sparking plug ( verify the height of 18,5mm) Screw the INSERT at the place of the sparking plug (The insert on the cylinder head has not to overpass the superior part of the combustion chamber. It has to be fixed on the cylinder head in the same way the sparking plug of 18,5mm was fixed) Make it air tight and water tight with grease the upper part of the piston and the cylinder device Raise up the piston and stop the crankshaft Dry up the excess of grease Refit the cylinder head and torque to 20NM Be sure that the engine is on a flat surface Move up the cylinder head and tighten it to clamping forces defined by the manufacturer. Fill up the combustion chamber (with a mixture composed by 50% of the oil used to make the mixture and the 50% of the fuel) using a graduated burette (mechanical or electrical) until the upper border of the insert. The measured volume must show a value which is complying with the minimum combustion chamber volume set on the engine identification sheet concerned. PROCEDURE USED TO MEASURE the Port Durations a. The measuring will be done with a gauge as per the drawing under cylinder specifications 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 below c. It must be inserted and rest against the cylinder wall opposite the port being measured as per picture above, 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 bottomed out no pressure must be applied to the crankshaft to obtain the forward and backward movement of the gauge. The feeling should be the same as when setting a tappet on a four stroke engine - pag. 7 - www.vortex-rok.com
PISTON PISTON PIN WEIGHT OF PISTON 63 gr +/- 5 gr 15 gr Min - pag. 8 - www.vortex-rok.com
CONROD WEIGHT OF CONROD 94gr. +/- 10gr WEIGHT OF CRANKSHAFT CRANKPIN 71gr. +/- 1gr PICTURE OF COROD Rigth Side PICTURE OF CONROD Left Side - pag. 9 - www.vortex-rok.com
PICTURE OF CRANKSHAFT WITH THE BALANCER - pag. 10 - www.vortex-rok.com
MINIMUM DISTANCE OF THE CARBURETTOR SUPPORTING PLATE FROM THE CYLINDER AXLE - pag. 11 - www.vortex-rok.com
INTERIOR VIEW OF THE CRANKCASE - pag. 12 - www.vortex-rok.com
EXHAUST MUFFLER Exhaust Weight 1.372 g. +/- 5% EXHAUST MANIFOLD EXHAUST GASKET - pag. 13 - www.vortex-rok.com
IMPORTANTE IMPORTANT ALL THE ENGINE PARTS MUST BE ORIGINAL BY VORTEX. PICTURES OF SELETTRA IGNITION Cod. PVL 401 222 1. AS PER ART.2, PAR. 16.7 OF THE CIK/FIA TECHNICAL REGULATIONS, ON DECISION OF THE Clerk of the Course, IT WILL BE AUTHORISED TO INTERCHANGE ENTRANTS IGNITION SYSTEMS FOR THE SYSTEMS SUPPLIED BY THE ORGANISERS (SAME HOMOLOGATED MODELS) 2. WIRING HARNESSES ARE FREE 3. THE BATTERY USED TO START THE ENGINE CAN BE FIXED ON THE SEAT OR ON THE CHASSIS TOO. 4. THE SIZE OF BATTERY IS FREE 5. NOTE THAT THE ONLY SPARK PLUG CAP PERMITTED IS AS PER ABOVE - pag. 14 - www.vortex-rok.com
COMPL. CLUTCH ROTOR WITH STARTING GEAR WEIGHT OF COMPL. CLUTCH ROTOR WITH STARTING GEAR: 815g +/- 15g ENGAGEMENT SPEED (MAXIMUM) CAN BE VERIFIED AT ANY TIME DURING THE EVENT AND MAYNOT BE MORE THAN 4000 RPM HOUSING AND ROTOR CLUTCH MUST HAVE VORTEX OR PERFORMANCE MASTERS MARKINGS : WEIGHT OF CLUTCH ROTOR 345 gr +/- 15gr WEIGHT OF CLUTCH HOUSING 178 +/-10gr TOTAL WEIGHT OF CLUTCH ROTOR AND HOUSING 512 gr +/- 15gr - pag. 15 - www.vortex-rok.com
Mini Rok PHBG 18BS CARBURETOR SPECIFICATIONS: Note: Please note that there have been NO changes to the carburetor specifications. This document is used to clarify the Standard homologated carburetor and jets. No machining or drilling of jets is allowed on the carburetor and its internal parts. The carburetor must remain standard as supplied by the Vortex Rok Importer. The importer / Technical Consultant also has the right to supplier competitors with new jets should it be required. This is a working document and will be updated as and when required. The responsibility is on the competitor to check that the carb meets the required specification. Carburetor Specifications for all South African 60cc Mini Rok classe for 2014 until further notice. CARBURETTOR DELL ORTO PHBG 18 BS 1. Throttle Valve Slide = 40 2. Mixture Needle = W23 3. Atomiser / Emulsion Tube (Mini Rok) = 266 AN 4. Atomiser / Emulsion Tube (Maxterino) = 262 AU 5. Idle Diffuser = 50 6. Starter Jet = 60 7. Main Jet = Free 8. Needle Valve Diameter 9. Float = 4g 10. Air Screw 18. Surge Plate (Pg 2) = Compulsory A. Other Dimensions B. Other Dimensions C. Emulsion Tube / Insert Height dimensions (MINI ROK) D. General Measuring of components: Some components will be measured with aid of a vernier. Measurement of Diameters applicable to the entire document: Diameters of jets / holes will be measured using GO / NO GO gauges. Special Tools / Drill bits will be used to measure some holes and used as GO / NO GO gauges. These gauges can be verified with use of a 0-25mm micrometer. GO Gauge will be required to slide into the required hole. NO GO Gauges must not be able to slide into the required hole. Should a part be found to be out of spec, it will be impounded for further measurement if required. - pag. 16 - www.vortex-rok.com
Illustration Only 0 - pag. 17 - www.vortex-rok.com
1. Throttle Valve 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 Length of Throttle Valve Slide Spec: 23mm ± 0.25mm 1.3 Length of Cut Away to the top of the Throttle Valve Slide Length of Throttle Valve Slide Spec: 23.4mm ± 0.15mm Surface Finish: Cast 1.1 1.3 1.2 2. Mixture Needle Mini Rok (W 23) L 2.1 Table of Needle Specifications as per Supplier Chart (Dellorto) (Also as per Master Sample W23 needle from the Vortex Rok Importer) Type Value X Characteristic expressed in millimeters ØA ØB C ØD E F L W23 23 2.5 ±0.03 0.6 ±0.05 (26 ±0.5) 2.5 ±0.03 - - 45 ±0.2 Measured right at the tip Reference Dimension 2.2 The Technical Consultant may also compare the needle to a master sample supplied by the Vortex Rok Importer. 2.2 There must be 1 mixture needle stop (Circlip, #13 on page 2) fitted to the needle. 2.3 No Washer is permitted to be fitted either above or below the circlip. 2.4 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. - pag. 18 - www.vortex-rok.com
2.5 Should the technical consultant 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 TC and the competitor will be required to fit a new needle. 2.6 Wear marks towards the tip of the needle, where the needle goes through the emulsion tube is common. The needle should be replaced if wear is excessive. 3. Atomiser / Emulsion Tube (Mini Rok) (266 AN) 3.1 Length of Emulsion Tube Spec: 36.00mm ± 0.20mm 3.2 Internal Diameter from side 3.2 GO Spec: 2.66mm (GO) 3.3 Internal Diameter from side 3.3 GO Spec: 3.00mm (GO) 3.4 2 x Rows of 4 holes GO Spec: 0.80mm (GO) NO GO Spec: 0.85mm (NO GO) 3.5 2 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 3.2 3.4 3.1 3.5 3.6 Seating Face 3.3 - pag. 19 - www.vortex-rok.com
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 3. 8 3. 9 3. 7 4. Idle Diffuser (50) 4.1 Length of Idle Diffuser Spec: 9.50mm ± 0.20mm 4.2 Internal Diameter of Smallest hole inside the Idle Diffuser GO Spec: 0.5 mm (GO) NO GO Spec: 0.55 mm (NO GO) 5.1 5.2 - pag. 20 - www.vortex-rok.com
5. Starter Jet (60) 6.1 Length of Idle Jet Spec: 27.00mm ± 0.25mm 6.2 Internal Diameter of hole inside the Start Jet GO Spec: 0.60 mm (GO) NO GO Spec: 0.65 mm (NO GO) 6.3 4 holes, 90 apart GO Spec: 1.00 mm (GO) NO GO Spec: 1.10 mm (NO GO) 6.2 6.1 6.3 - pag. 21 - www.vortex-rok.com
7. High Speed Jet / Main Jet The anti surge plate fitted between the emulsion tube and the main jet may NOT be removed. 7.1 Length of High Speed Jet / Main Jet Spec: 8.0mm ± 0.3mm 7.2 Internal diameter of main jet. Spec: Free 7.2 7.1 8. Needle Valve 8.1 Internal Diameter of hole inside the Needle Valve GO Spec: 1.45 mm (GO) NO GO Spec: 1.55 mm (NO GO) The Only Needle permitted is the solid needle with no spring 8.1 9. Float 9.1 Weight of Float Spec: 4.0grams (As marked on the bottom of the float) - pag. 22 - www.vortex-rok.com
10. Air Screw 10.1 Diameter of Air Screw Orifice. GO Spec: 1.10 mm (GO) NO GO Spec: 1.3 mm (NO GO) 10. 1 9.2: Diameter of tip end: 0.9mm ±0.05mm 9.3: Diameter of tip: 1.2mm ±0.05mm 10. 2 10. 3 9.4: The Air Screw must be fitted with O-ring, washer and spring as illustrated. - pag. 23 - www.vortex-rok.com
A Other Dimensions A.1 Diameter of Throat. The throat diameter must be checked from both sides of the carburetor. Spec: 18.0mm ± 0.05mm GO Spec: 17.95 mm (GO) NO GO Spec: 18.05 mm (NO GO) A.2 Diameter of hole A2 as illustrated GO Spec: 1.00 mm (GO) NO GO Spec: 1.10 mm (NO GO) A.3 Diameter of hole A2 as illustrated GO Spec: 2.50 mm (GO) NO GO Spec: 2.60 mm (NO GO) A.1 A.1 A.2 A.3 A.2 A.3 - pag. 24 - www.vortex-rok.com
B.1 Diameter of hole B1 as illustrated GO Spec: 1.10 mm (GO) NO GO Spec: 1.30 mm (NO GO) B.1 B.2 Diameter of hole B2 as illustrated GO Spec: 1.0 mm (GO) NO GO Spec: 1.1 mm (NO GO) B.2 B.2 - pag. 25 - www.vortex-rok.com
ITEM C IS ONLY FOR REFERENCE UNTIL FURTHER NOTICE C Emulsion Tube and Insert Protrusion (MINI ROK) Special Tool XXX will be required to measure dimensions. Dimensions are from the centre line of the 18.00mm Bore. C1 Spec: 7.2 ± 0.5mm C2 Spec: 9.5 ± 0.5mm E General The over flow nipples may be turned in any direction An overflow pipe may be fitted Some carbs have a brass insert fitted inside the overflow tubes (Supplied from Dellorto) on the inside of the carb. This is to prevent Break through of internal channels and is permitted List of tools required Vernier Special Tool #XXX (Still to be confirmed) 17.95mm GO Gauge 18.05 NO GO Gauge Drill Bits, "GO / NO GO" Gauges Required (mm) 0.5 0.55 0.6 0.65 0.8 0.85 1 1.1 1.2 1.3 1.45 1.55 2.5 2.6 2.66 2.69 2.75 3 3.1 Please Note: C.2 This is a working document and will be updated as and when required. Should any discrepancies / queries regarding the document arise; the technical working group will investigate and take the required action. C.1 - pag. 26 - www.vortex-rok.com
INLET SILENCER Filtration :- Sock with spring maybe used. MODEL TYPE MINI CONNECTOR FIXING FILTER-CARBURETOR IN PLASTIC MATERIAL - pag. 27 - www.vortex-rok.com