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ADJUSTMENT AND MAiNTENANcE Of THE cHASSiS

1. 20 5 2 3 The go kart is hard to turn 41 3 8 1 1 Of the 20 9 2 4 The steering of the go kart is not precise 41 5 2 5 The go kart tends to go to the side 41 5 2 6 The go kart skids very much on bends 41 4 Adjustment and maintenance of the 515 1 21 T C 42 Braki g UNICI NN 22 4 4 1 Brake fl id ncc eene 22 7 Maintenance schedules 44 4 1 2 Brake 23 4 1 3 Brake fluid hoses 23 7 1 Daily maintenance 45 de PERS EEUU 24 7 2 Monthly maintenance 47 4 3 Throttle cable change 24 7 9 49 4 3 1 Clearance adjustment 25 4 3 2 Adjusting the potentiometer travel 25 MAN VOLT EN 02 USE SPARE PARTS OF SODIKART ORIGIN 12 2010 5 6 c 6 2 2 User maintenance guide SAFETY INSTRUCTIONS This user guide is updated by SODIKART to allow without delay to know the last safety i and maintenance improvements Refer to our website regularly to dowload the last version of user guide This document is a tra
2. 39 3 2 7 Start up of the 0 Lo RN MN 39 4 16 2 Notched belt 39 3 3 Checking before cessions E EEEa 39 g 14 4 16 4 Bodywork parts 39 5 4 16 5 lt os ei ee o ee 40 3 2 gt 15 446 6 Braking s tenes 40 s 3 3 To e e 16 4 16 7 Chassis cleaning 40 3 4 Engine transmission and batteries 16 8 S cs ee 16 5 Trouble shooting 41 a 3 4 2 EXIDE MAXXIMA 900DC batteries 17 5 1 Electrical fault 41 E 3 4 3 LifePo4 batteries 17 5 1 1 The go kart does not start 41 3414 17 5 1 2 The go kart goes too 41 3 5 Tyre 5 22 22 18 5 1 3 The batteries no longer hold their charge 2 _ 5 2 2 24 4 404241 41 28 Bodywork lis 5 2 1 The go kart will not 41 3 7 Bolting 19 5 2 2 The go kart brakes continually 41 3 8 Adjustable
3. 5 12 35 Battery fixing 35 Belt mti n 28 29 36 Bleeder screw 22 Bodywork fixation 19 Brake calliper 14 Brake CISC ere iod 14 Brake fluid reservoir 22 Brake fluid reservoir 23 Brake hose eer RE 14 Brake ne eee eee 14 22 24 Brake security 16 gt nl CADIE ee e 38 Cable coro rr Hen 24 CAPOT enon 22 Central 24 Charger socket o bee e eee ba odo 13 ILLI 16 32 Conical flange essen 28 Conical rear sprocket 28 Connel 21 Connector support 12 COVEN nm nest aa sde at T EA AE 38 PSS eee Direction of rotation 30 37 RS End bracket 5c rp er e reae Ron E 36 SL P H 16 Engine rmio ri iic reo dads 16 24 29 Engine sprocket holder 28 KEEP GO KART IN ORIGINAL CONFIGURATION Filler CaP RA 22 FRANC nan den tiec ved veda dew Oa 14 Front protection 31 32
4. eae 24 RP 30 37 Half Sprocket etr RR ARR 28 12 Height with roll over bar 12 Hose and CONTAINER iiic ect ott ideas 22 DIEITUR 23 RUD rate LEE 27 Indexing 24 Inflation system 30 37 Left hand battery 21 Eeft 23 EM 12 MEV Sie aves 20 Lower engine flange 16 Lower guide stem 2 23 Lower plastic column 15 Master cylinder e e tte ee aes 14 22 Mode switch 13 Mounting BOOK oot oem ertt ttes 35 Nassau panel eere eee dt ede 32 Notched 17 ON OFF DUTON i oto ed i ib eade cada 13 This document can not be reproduced or released without the Sodikart authorization MAN VOLT EN 02 12 2010 Pedal support 24 Throttle cable aaan 24 PillardOOp rtt ot ne drames 30 Throttle pedal dett ette teen 24 E 14 iue a 15 Plastic colomn 15 Tie rod nut and lock nut 26 Potentlomleter rite ve es 25 Oligue ouiexoiieenn tet
5. ZIVAN NG7 Type Weight without connecting cables Input 50 60Hz oma uve wx Connect the charger to a socket that has been correctly installed and earthed in accordance with the laws and regulations in force in your country Voltage 230 V AC we few USE SPARE PARTS OF SODIKART ORIGIN User maintenance guide GO KART RECEPTION 2 5 Delivery During the delivery check the go kart is not damaged and all documents are supplied user maintenance guide engine user s guide spare parts catalogue otherwise contact SODIKART e Make sure the go kart and the engine correspond to your order User maintenance guide 4 5 6 1900 mm 7 1275 mm Height with roll over bar 1040 mm Legend Battery connector Power harness connector Connector support Polarising device Unclip the connector 4 from the holder 6 Connect the power harness connector 5 observing the correct orientation align the wires with matching colours polarising device 7 Clip the connected connectors in the holders 6 2 5 1 Connecting LiFePo4 batteries e e The polarising devices 7 on the Go karts are delivered with the batteries disconnected 1 z AA Battery cover 2 3 Battery 4 Battery connector Remove the 2 screws 1 Remove the battery cover 2 12 KEEP GO KART IN ORIGINAL CONFIGURATION connectors prevent an
6. 12 2010 ADJUSTMENT AND MAINTENANCE OF THE CHASSIS 4 10 Bolting Change nuts and bolts if damaged gt Although the safety points listed here A must be checked daily it is obvious that other fastenings must not be ignored Indeed it is advised to check all fastenings almost daily to minimise all risks 4 10 1 Check points User maintenance guide Item Description Qty Tightening Ho EE _ forbears 6 om Secon and nuts or seat adjustable seat i O S This document can not be reproduced or released without the Sodikart authorization s Seewamimtstrpestiecoomsupot t 25Nm rag USE SPARE PARTS SODIKART ORIGIN User maintenance guide 4 11 Batteries 4 4 11 1 Battery marking It is recommended that the batteries of each go kart should be identified as a set of batteries EXIDE MAXXIMA 900DC batteries The marking can be performed as follows e Batteries contain environmentally hazardous substances They must not be disposed of with domestic waste but in accordance with the regulations in force For further information refer to the instructions for the new battery e One letter per set of batteries with the date of entry into service A01 01 2010 e All batteries on a go kart must have the same markings e Never mix batteries from different sets LifePo4 batteries The marking can be performed as follows e
7. e f pedals do not go back check the state of the springs 3 e Check the pedals 4 activate throttle and brakes 5 correctly e Check the tightening of pedals The using parts of pedal can be directly change on the pedal assembly except the central case of pedals 7 and the pedals support 8 More detail on the pedal assembly on the corresponding spare parts catalogue in order to prevent accidents e Before the go kart operates check the thumb screw 1 is inserted in the plate 6 Check that the pedals are not held up by the front spoiler when the pedalboard is in a forward position and the pedals are pushed in the maximum position e e t is essential to check the pedals every day serious or even fatal injury gt The functioning of pedalboard in a forward position may be held up by an gt A faulty pedal system may lead to a absorption system in a bad state KEEP GO KART IN ORIGINAL CONFIGURATION Legend Throttle cable Cable adjuster Upper screw Lower screw Sheath end Rest position Full throttle position Place the ON OFF button in the OFF position and set the mode switch to STOP Disconnect the charger from the go kart e Putthe pedals on back position e Loosen the superior screw 3 to release the used throttle cable e Remove the used throttle cable e Pass the new throttle cable 1 in the throttle cable sheath then in the cable tightener 2 e Check that the end of i
8. 17 Gry Da ND 7 e lt 9 Y A v AS 9 SS 78 2 Legend J O O1 R N Hose and container Bleeder screw Filler cap Brake pedal Calliper Brake fluid reservoir Master cylinder Retaining ring Banjobol Lift the front of the go kart The container must be higher than the brake calliper Use a hose and a container 1 to collect the used fluid Remove the protective cap from the bleeder screw 2 and then place the hose on the bleeder screw The other end of the hose should be placed in an empty container Gently unscrew the bleeder screw and the filler cap 3 Repeatedly press the brake pedal 4 until all the fluid has drained out When all the fluid has been drained remove the filler cap 3 and top up to the maximum level with brake fluid KEEP GO KART IN ORIGINAL CONFIGURATION Tighten the bleed screw 2 and then press the brake pedal 4 three or four times Loosen the bleeder screw 2 Brake fluid should flow out Tighten the bleeder screw repeat this procedure several times to ensure the system is completely full of fluid Remember to top up the brake fluid in the reservoir 6 as it feeds the master cylinder 7 and calliper 5 Bleed the circuit so that the brake fluid flowing out of the hose 1 contains no air bubbles Retighten the calliper bleed screw 2 remove the pipe 1 and reapply the protective cap Refill the master cylin
9. e Store the charged batteries e Recharge stored batteries once a month This document not be reproduced or released without the Sodikart authorization MAN VOLT EN 02 12 2010 ADJUSTMENT AND MAINTENANCE OF THE CHASSIS 4 11 4 Replacement EXIDE MAXXIMA 900DC batteries LifePo4 batteries User maintenance guide Ay lt a MS gt f EN Jp d M 0 5 5 Legend 5 1 Screw 8 2 Battery cover 5 2 3 Battery 5 2 Battery cover nu ew 5 Betionyinoundng ser 2 4 Battery fixing 5 Mounting hook e Remove power from the go kart switch its ON OFF 6 Battery button to OFF and disconnect the go kart from the e Remove power from the go kart switch its ON OFF charger 8 button to OFF disconnect the go kart from the e Place the go kart on a trolley E charger e Remove the 2 screws 1 3 e Place the go kart on a trolley e Remove the battery cover 2 3 e Remove the 2 screws 1 e Disconnect the connector 4 from the harness e Remove the battery cover 2 e Remove the 2 screws 5 E e Disconnect the shunt cables according to the e Remove the used battery 3 2 procedure described at the Beginning of the e Install the new battery 3 8 e Disconnect the second terminal from the batteries e Tighten the 2 screws 5 5 Remove ihe e Connect the connector 4 to the harness 3 alid Uis banery meds and the mounting e
10. flanges 6 and 7 securely to the chassis 4 This document can not be reproduced or released without the Sodikart authorization 16 KEEP GO KART IN ORIGINAL CONFIGURATION This document can not be reproduced or released without the Sodikart authorization MAN VOLT EN 02 12 2010 gt SE ESS RS 2 CA Legend 1 Battery e Check that the batteries 1 are correctly installed in the go kart e Check that the battery lugs 1 are not damaged and that they are properly tightened 3 4 3 LifePo4 batteries P am ae E a Legend 1 Battery Check that the batteries 1 are correctly installed in the go kart Check that the battery connectors 1 are not damaged and that they are properly connected 3 4 4 Drive belt Legend Notched belt Roller Check that the drive belt is tightened and in a good state It prevents mechanical damages Tighten the notched belt 1 with the roller adjuster 2 The notched belt must have 5mm allowance For tension of the notched belt Cf chap 4 7 USE SPARE PARTS OF SODIKART ORIGIN CHECKING BEFORE CESSIONS User maintenance guide User maintenance guide
11. gt Wear insulating gloves and goggles for all operations on the electrical circuit gt Never short circuit the batteries This could cause an explosion fire or a serious or even fatal accident EXIDE MAXXIMA 900DC batteries Legend 1 Terminal 1 2 Terminal 2 3 Terminal 3 4 Terminal 4 e Disconnect the shunt cable on terminal 1 of the front left battery and then the shunt cable on terminal 2 of the rear left battery Disconnect the shunt cable on terminal 3 of the front right battery and then the shunt cable on terminal 2 of the rear right battery A gt To perform this operation use insulated spanners only gt No not use tools whose insulating coating is cracked nicked or otherwise damaged LifePo4 batteries Legend 1 Battery 2 Connector 3 Left hand battery connector e Disconnect the connector 2 from the battery on the left hand side of the go kart 3 Cf chap 2 5 1 USE SPARE PARTS OF SODIKART ORIGIN User maintenance guide User maintenance guide ADJUSTMENT AND MAINTENANCE OF THE CHASSIS 4 1 Braking 4 1 1 Brake fluid a ory D QG j re
12. 02 12 2010 Legend Rim Studded tyre Direction of rotation Inflation system Grease Tyre iron OO O1 B ND Place the go kart on a trolley Remove the front wheel or rear wheel with the proper size wrench Place the wheel on a tyre remover for strip off the studded tyre available on the ITAKA catalogue When the tyre 2 is detached on both sides remove it completely using tyre irons 6 available in the ITAKA catalogue Take the new tyre and grease the tyre in order to make assembly and removal easier Replace the tyre 2 on the valve side of the wheel rim 1 ensuring the correct rotation direction Once the tyre is correctly positioned inflate with a compressed air line to a pressure of 3 5 bars so that the walls make a good seal with the wheel rim Then deflate to recommended pressures Reinstall the wheel on the go kart Check the tightening torque of the mounting nut tyre is changed fronts rears or all the set e Always place the tyres so that they rotate in the direction indicated on the tyre wall Never inflate the tyres more than 4 bars Excessive wear of tyres can be caused by bad front wheel axle unit alignment d e Always change the whole set whenever a Give worn tyres at a specialist of tyre treatment according to local environmental regulation gt Change all damaged rims A damaged rim may lead to a loss of tyre or loss of pressure and may lead to a serious or even fatal in
13. ORIGINAL CONFIGURATION Always change the whole set whenever a tyre is changed fronts rears or all the set Always place the tyres so that they rotate in the direction indicated on the tyre wall Never inflate the tyres more than 4 bars Excessive wear of tyres can be result from bad front wheel axle unit alignment Use tyres with a grip adapted to your track Give worn tyres at a specialist of tyre treatment according to local environmental regulation gt Change all damaged rims A damaged rim may lead to a loss of tyre or loss of pressure and may lead to a serious or even fatal injury gt Check the tyre wear daily Worn or damaged tyres may lead to a serious or even fatal injury gt Never run with worn or damaged tyres a burst of tyre may lead to a serious or even fatal injury gt Always blow up tyre with the pressure recommended by the manufacturer gt Cold tyres have a reduced adherence and increase the loss of control of the go kart This may lead to a serious or even fatal injury gt Too much grip reduces the stability of the go kart under impact and lead to a tendency to go on two wheels It also increases the risk of riding over gt Store tyres in an appropriate area to prevent fire hazard This document be reproduced released without the Sodikart authorization MAN VOLT EN 02 12 2010 4 9 Assembly of the bodyworks and
14. both ends of the front protection 1 with the two side protections 4 using the four screws 5 USE SPARE PARTS OF SODIKART ORIGIN m 6 m c 6 n m 6 6 4 E Step 1 Legend 1 washer 2 Axle cover 3 Support 4 Screw Place the chassis on a trolley Place the cup washers 1 on the axle cover 2 Place the axle cover 2 on these supports 3 Tighten with 4 screws 4 Legend 1 Spoiler 2 Screw 3 Front protection 4 Side protection Place the spoiler 1 against the front protection 3 and the side protections 4 Tighten the assembly using the screws 2 KEEP GO KART IN ORIGINAL CONFIGURATION Legend 1 Side pod 2 Side pod mounting flange plate 3 Screw 4 Chassis Place the side pod 1 on the chassis 4 Pass the 2 side pod mounting flange plates 2 through the hole located below the side pod 1 Tighten the assembly using the 4 screws 3 Step 4 Legend O ND Bolt Nassau panel Screw Support Shock mount Release the nassau panel 2 from the support 4 using the two screws 3 Loosen the bolts 1 Remove and replace the Nassau panel Reassemble this assembly by applying the disassembly steps in reverse order This document can not be reproduced or released without the Sodikart authorization MAN VOLT EN 02
15. e After an accident check the state of the belt serious or fatal accident A and the fixing before to let the go kart run gt Use EXXIDE MAXIMA 900 DC or LifePo4 on the track batteries only e Check that the seat belt is locked and that the driver is well maintained in the seat gt LiFePo4 batteries are paired up at the time of mounting and must never be gt Modify the seat belt system may lead to a serious or even fatal injury gt Clean the belt with chemical product may modify the efficiency of the belt and lead to a serious or even fatal injury gt A seat belt not locked may lead to a serious or even fatal injury separated If servicing is required send the complete set of batteries 4 12 Seat belt The roll over bar with the seat belt option improves the go kart safety in case of accident It is very important that safety systems is checked and maintained regularly 4 12 1 Seat belt This document can not be reproduced or released without the Sodikart authorization Legend Pillar loop Belt Retractor End bracket Tongue O ND e Check the state of the belt 2 to detect the anomalies undone stitchings chemical damages slashs worn side e Check that all fixings are well tightened and that the seat belt parts are in a good state KEEP GO KART IN ORIGINAL CONFIGURATION ide 0 This document can not be reproduced or released without the Sodikart authorization MAN VOLT EN
16. from the brake pad Do not put the go kart in operation if the guide stems and a break system is faulty or if you have a e Remove the 2 stalk of guide 5 and 6 and remove doubt both worn plaques of Drake 7 gt Faulty braking system lead to e Insert the new pads taking care to position them serious or even fatal injury correctly e Hold the two pads in position and slide the two guide stems 5 and 6 e Check that the clips 4 are in good condition and then engage them e Check that the clips 4 are properly engaged e Ifthe brake fluid is above maximum level partially bleed the system top up and replace the filler cap with its sealing ring e Testthe brake before to rent the go kart This document can not be reproduced or released without the Sodikart authorization gt Check connexions of hoses no leak gt Use brake fluid DOT 4 only 2 USE SPARE PARTS SODIKART ORIGIN User maintenance guide 4 2 Pedals Driving in an ergonomic position is safer Adjustable pedals provide better ergonomics It is very important to check the state of the pedal system daily Legend Indexing button Slide Return spring Throttle pedal Brake pedal Engine mount Central box Pedal support ONOOaRWN Lift the thumb screw 1 and slide it to different positions e Ifthe pedals do not slide or are stiff check that the slides 2 are not obstructed e Press the pedals and release them
17. not be reproduced or released without the Sodikart authorization USE SPARE PARTS SODIKART ORIGIN MAINTENANCE SCHEDULES So e Write the letter representing the check A carried out in the box for the go kart being inspected e g Write a V in the engine mount box after checking the tightness of the engine mount Write A in the engine mount tightening box if the tightness of the engine mount has been changed Maintenance schedule Surname Signature Safety stickers P X _ RES Beepdwer Pedais displacement X x tt STOPigtsate X j TT TT E Steering rods state X X P MN Tightening ofwhees x j Tightening ofsteeringwheel X X Seatbettstates X IX Rolloverbarfixing f Optional equipment Chassis Replacement gt Adjustment This document can not be reproduced or released without the Sodikart authorization a KEEP GO KART IN ORIGINAL CONFIGURATION This document can not be reproduced or released without the Sodikart authorization MAN VOLT EN 02 USE SPARE PARTS OF SODIKART ORIGIN 12 2010 MAINTENANCE SCHEDULES 7 2 Monthly maintenance e Write the letter representing the check Inspect each go kart which will be used all day The carried out in the box for the go kart
18. with a grip adapted to your track gt Change all damaged rims A damaged rim may lead to a loss of tyre or loss of pressure and may lead to a serious or even fatal injury gt Check the tyre wear daily Worn or damaged tyres may lead to a serious or even fatal injury gt Never run with worn or damaged tyres a burst of tyre may lead to a serious or even fatal injury gt Always blow tyre with the pressure recommended by the manufacturer gt Cold tyres have a reduced adherence and increase the loss of control of the go kart This may lead to a serious or even fatal injury gt Too much grip reduces the stability of the go kart under impact and lead to a tendency to go on two wheels It also increases the risk of riding over gt Store tyres an appropriate area to prevent fire hazard This document can not be reproduced or released without the Sodikart authorization MAN VOLT EN 02 12 2010 CHECKING BEFORE CESSIONS 3 6 Bodywork parts gt Arear axle cover which is badly secured 3 The bodywork parts are essential safety components or in a bad state may lead to a serious 3 They protect the driver against or even fatal injury by winding of long 97 hair or loose clothes around the rear rotating parts risk of entanglement of long axle e harana 0056 clothes gt Make sure that the rear axle cover is the e The stability under impact risk of lifting etc good v
19. 1 lll Chassis Replacement Adjustment This document can not be reproduced or released without the Sodikart authorization oe Fixed seatstate XS P 0 lg tT TT Adjustable seatstate X gans x XP Optional equipment GO KART IN ORIGINAL CONFIGURATION Millie ron This document can not be reproduced or released without the Sodikart authorization MAINTENANCE SCHEDULES 7 3 Annual maintenance Write the letter representing the check Inspect each go kart which will be used all day The carried out in the box for the go kart being inspected mechanic technician must sign the maintenance sheet the motorization amp transmission is on the recto of the after checking the tightness of the engine sheet and the chassis on the verso mount Write A in the engine mount tightening box if the tightness of the engine mount has been changed Surname Signature NT 4 Motorization amp transmission X X e 1 Use compressed air to clean via the A engine ventilation holes e 2 Use compressed air to clean the charger N gt E in E E MAN VOLT EN 02 USE SPARE PARTS OF SODIKART ORIGIN 12 2010 Maintenance schedule MAINTENANCE SCHEDULES S
20. 2 40 38 26 21 Web www sodikart com E mail sodikart sodikart com S A au capital de 1 166 235 euros Saint Nazaire B 320 922 800 Siret 320 922 800 00059
21. 6 Nylstop nuts 6 Extract the conical flange 7 Take out the half rear sprockets 8 Place the news half rear sprockets 8 in the conical sprocket hub 9 IMPORTANT match them correctly so that a full tooth or hollow is obtained when putting the two parts together If the match is not correct turn one of the half belt sprocket e Place the conical flange 7 on the stud of the conical sprocket hub 9 e Tighten the 6 nuts 6 at 20Nm e Check the alignment of the belt Bad User maintenance guide alignment reduces lifetime of the belt e A belt with irregular wear is a sign of bad alignment Check the state of the belt daily Legend 1 9 Belt e Check daily the state of engine sprocket 2 Screw and belt sprocket since a damaged 3 Sprocket transmission reduces power and exposes 4 Engine sprocket holder to a risk of damaging the engine 5 Pin e Check that the engine sprocket is centred 6 Nut on the tensioning roller The offset between 7 Conical flange the outer faces of the sprocket and the 8 Half sprocket roller must be equal on the left and the 9 Conical rear sprocket holder right e Place the go kart on a trolley e Remove the rear axle cover e Loosen the belt 1 and remove Cf chap 4 7 4 6 1 Removing the engine spocket e Loosen the two screws 2 from the sprocket 3 e Insert a screw into the 3rd hole of sprocket holder 4 e Tighten to extract the sprocket holder 4 it frees the sp
22. 7 This document can not be reproduced or released without the Sodikart authorization v Kit of 3 big safety stickers Ref AC701 128 USE SPARE PARTS SODIKART ORIGIN SAFETY INSTRUCTIONS So 1 3 2 Batteries Explanation of pictograms INSTRUCTIONS DE SECURITE No smoking e Maintenir le kart en bon tat de fonctionnement se r f rer au manuel d entretien e Faire respecter les r gles et consignes de s curit briefing obligatoire Corrosive substances e Ne pas laisser un pilote conduire gt Sans les protections ad quates gt Avec les cheveux long l ext rieur du casque gt Avec une charpe ou des v tements flottants Electrical hazard gt Sous l emprise de drogue ou d alcool User maintenance guide Warning Hazardous batteries SAFETY INSTRUCTIONS e Keep the kart in good condition refer to maintenance manual e Instruct the pilot about safety compulsory briefing e Do not let a pilot drive gt Without adequate protections Read the User Manual gt With long hair out of the helmet gt With a scarf or floating clothes gt Under the influence of drugs or alcohol Eye protection is mandatory Ref AC701 123 LIQUIDE DE FREIN DOT 4 UNIQUEMENT ASMO LiFePo4 Battery Pack 8S 40AHA 25 6V max 3C charge B RA KE FL UI D Discharge continius 3C Imp 10C Do not open Do not short circuit D T4 ON LY Read instruction carefully before use Ref AC701 124 Ref AC701 116 T
23. 8 Adjustable seat This option allows driving in an ergonomic position and improves safety The tall and small people can sit comfortably 3 8 1 Adjustment of the seat User maintenance guide Legend 1 Seat 2 Lever e Turn the locking lever 2 forward to unlock the seat 1 e Move the seat 1 to adapt its position to the length of the legs e Turn the locking lever 2 backward to lock the seat the adjustable seat daily e Check the seat is locked before the go kart 1 d e Check the tightening of screws and nuts of operates This document can not be reproduced or released without the Sodikart authorization gt A loosened adjustable seat can result in A serious bodily injury or death gt An adjustable seat system that is faulty or in bad state can result in serious or bodily injury or death gt Never adjust the seat whilst driving gt Adjustments must be made by track personnel before you start out 20 KEEP GO KART IN ORIGINAL CONFIGURATION iili ahs This document can not be reproduced or released without the Sodikart authorization MAN VOLT EN 02 12 2010 4 Adjustment and maintenance of the chassis Use the sheets included at the end of user maintenance guide to control and follow the maintenance of the go kart ADJUSTMENT AND MAINTENANCE OF THE CHASSIS A warn The batteries must be disconnected before carrying out any inspection or maintenance on the go kart A
24. A A This document can not be reproduced or released without the Sodikart authorization MAN VOLT EN 02 12 2010 protections e Check carefully that screws are tightened and do not protrude out of the protections e Check that no bodywork component rubs on the ground causing premature wear of the bodywork gt A bodywork part with dangerous sharp edges may lead to a serious or even fatal injury gt Never allow a go kart to run with broken or missing bodywork parts it may lead to a serious or even fatal injury gt Do not modify bodywork parts you might unwillingly significantly reduce it s efficiency as a safety item 4 9 1 Protections Step 1 1 Rear bumper 2 Shock mount 3 Screw e Place the chassis on a trolley e Place the rear bumper 1 on the shock mounts 2 e Tighten with 4 screws 3 Legend OONO Rear bumper Side protection Side pod Screw Screw Spoiler Screw Place the side protection 4 on the side pod 5 and the rear bumper 1 Secure the side protection 4 to the side pod 5 using the six screws 6 and the mounting flange plates Secure it to the rear bumper 1 using the two screws 7 Secure the front part of the side protection 4 to the spoiler 8 using the screws 9 Step 3 Legend N Front protection Screw Support Side protection Screw Place the front protection 1 on the support 3 using the screws 2 Tighten
25. CHECKING BEFORE CESSIONS tension increases the lifetime of the belt e e Tighten the notched belt daily Good e Replace any damaged belt to eliminate the risk of engine overspeed e An excessively tight belt can cause premature engine wear presents a risk of burn for the driver 1 gt The engine is source of heat which Make sure that the protections are correctly secured and in a good state gt The engine and transmission rear axle included are rotation parts which present a risk of serious even fatal injury by winding of long hairs or loosing clothes Make sure that the protections are correctly secured and in a good state 3 5 Tyre pressures Legend 1 Wear indicator 2 Arrow direction of rotation e Check the pressure of the front and rear tyres Duro tyre Itaka tyre Check the tyres wear indicators 1 If any of indicators are not visible replace the tyre Carefully check the state of tyres if there are scrubbing or tears replace them Check the tyre rotation direction with the arrow 2 visible on the tyre wall For tyre replacement procedure Cf chap 4 8 KEEP GO KART IN ORIGINAL CONFIGURATION e For best performance inflate tyres according to above mentioned pressures Bad pressure leads to excessive wear of the tyres and degrades the go kart s performance e Warning Excessive wear of a tyre may be caused by a bad front wheel alignment e Use tyres
26. Install the battery cover 2 and secure it using the 2 9 screws 1 e Remove the used battery 6 e Repeat this operation for the other battery e Install the new battery 6 e Install the mounting hook 5 and the battery mount A 4 e Tighten the 2 screws 3 e Connecting the battery to the circuit e Install the battery cover 2 and secure it using the screws 1 A e Always replace all four go kart batteries at the same time e Always replace all four go kart batteries at the same time USE SPARE PARTS SODIKART ORIGIN e ADJUSTMENT AND MAINTENANCE OF THE CHASSIS gt The batteries are the only electrical e Check that the retractor 3 run correctly 5 A components that you can replace Yank the belt then release it to check that it roll gt Use electrically insulated tools up completly o gt Remove your jewellery rings etc to Yank the belt to check that it arrest the body in avoid an electrical discharge that could case of shock be careful the side of the belt is lead to a serious or fatal accident edged gt Do not incinerate the battery because it Check that the tongue 5 gets in the buckle could explode causing a serious or fatal correctly and there are well maintained Iz accident e Push the red buckle button to check that it unbinds 5 gt Do not damage the battery and do not the tongue 5 attempt to open it This could lead to a
27. NG 5 Trouble shooting 5 2 Mechanical fault 2 5 1 Electrical fault 5 2 1 The go kart will not brake o 1 Is the brake pedal free o 5 1 1 The go kart does not start 2 15 the hydraulic brake pump container cap fully 1 Is the ON OFF button in the ON position tightened a 2 Is the mode switch set to forward or reverse 3 Is there enough brake fluid t 3 Are the batteries charged 4 Are the hoses correctly connected 4 Is the brake contactor locked 5 Are the brake pads worn 5 Is the accelerator pedal in rest position when power 6 Is the calliper fully tightened on its support p is applied to the go kart 7 The displacement of the brake pedal is enough 5 6 Is the clearance of the accelerator potentiometer adequate 5 2 2 The go kart brakes continually 1 Is the brake fluid old The gokan goes LL 2 Is the brake disk correctly centred in relation to 1 Is the speed selector in the correct position brake pads 2 Are the batteries adequately charged 3 Is the calliper fully tightened on its support 4 Is the brake pedal too tight 1 3 Th ries no longer hold their 91 2 longer MOINE 5 Are the brake pads correctly assembled charge 1 Is the battery voltage adequate 5 2 3 The go kart is hard to turn 2 Is the charger properly connected to the electrical 1 Are the stub axles tightened to torque specification power supply 3 Is the charger operatin
28. One letter per set of batteries with the date of entry into service A01 01 2010 A 4 11 2 Working life of the batteries Battery life depends on their conditions of use The more the batteries are used the more their performance characteristics deteriorate The first sign of battery weakness is that a go kart covers less distance between two charging cycles e All batteries on a go kart must have the same markings e Never break up battery sets that have been created e Check that there is no problem in the electrical circuit of the go kart e Testthe batteries using a battery tester e f you have no battery tester drive the go kart until it slows down A gt To limit the risk of deep discharge and destruction of batteries never allow a go kart to become fully discharged gt To limit the risks of engine overheating never use one go kart to push another and never accelerate when the go kart is blocked wall track guard etc gt To limit the risks of discharge check after each session that the go kart s on off button is set to OFF gt Between sessions and at night never store go karts in an area exposed to rain or at a temperature below 5 C KEEP GO KART IN ORIGINAL CONFIGURATION ADJUSTMENT AND MAINTENANCE OF THE CHASSIS EXIDE MAXXIMA 900DC batteries e As soon as the go kart slows down switch off the gokart and return it to the stand After 3 minutes use a voltmeter to measure the volta
29. Page 21 To perform this operation use insulated spanners only Page 21 No not use tools whose insulating coating is cracked nicked or otherwise damaged Page 21 An air bubble in the brake system can lead to a partial or total lost of brakes and may lead to a Serious or even fatal injury Page 22 Moisture in the brake fluid may cause vapour lock and a sudden loss of braking power may lead to a serious or even fatal injury Page 22 Altering the adjustment of the brake system levers may cause a loss of braking Page 22 Never operate the go kart if the brake pads have worn beyond their permitted limits Page 23 Use only genuine SODIKART brake pads Page 23 Make sure the pads are assembled correctly and that the braking system is working efficiently before operating the go kart Page 23 Check brake pad wear daily Page 23 The brake is an essential safety element Do not put the go kart in operation if the break system is faulty or if you have a doubt Page 23 Faulty braking system may lead to a serious or even fatal injury Page 23 Check connexions of hoses no leak Page 23 Use brake fluid DOT 4 only Page 23 A faulty pedal system may lead to a serious or even fatal injury Page 24 The functioning of pedalboard in a forward position may be held up by an absorption system in a bad state Page 24 Adjusting the potentiometer to maximum speed position when the accelerator pedal is released can lead to
30. This document can not be reproduced or released without the Sodikart authorization MAN VOLT EN 02 December 2010 Keep go kart in original configuration Use spare parts of Sodikart origin m 5 5 6 6 17 RISK OF STRANGULATION WEARING A SCARF WEARING LONG HAIR STICKING OUT FROM UNDER THE HELMET WEARING LOOSE CLOTHING ot be reproduced or released without the Sodikart authorization This document can n MAN VOLT EN 02 12 2010 Table of contents 1 Safety instructions 4 4 4 Front wheel 26 1 1 General instructions 4 4 5 Rear wheel axle unit adjustment 27 AT AS TRACK m 4 4 5 1 Position of hub on 27 1 152 Buildings ei ca cree ctae 4 4 6 Easy to remove wheel sprocket 28 i j pe with restricted 4 6 1 Removing the engine 28 1 1 5 Go karts ttc 1 1 6 Batteries no an 5 4 7 Drive belt 29 1 1 7 Drivers iei 5 4 8 Tvr han 1 1 8 Briefing communication eeeee 6 2 1 1 9 D firig a 8688lOh iet cite esee re
31. Under drugs or alcohol e Access prohibited to restricted areas example technical zone e Prohibited to Touch the engine and warm parts Cf chap 3 4 Step on the throttle cable Step on fuel and brake hoses connections Step on side pods when going in or leaving the go kart e Make sure that prior to being dressed for driving pilots have been informed about restrictions and prohibited things This document can not be reproduced or released without the Sodikart authorization USE SPARE PARTS SODIKART ORIGIN SAFETY INSTRUCTIONS Clothes protections e Make sure the drivers wear the following protections prior to reaching the go karts Mean of securing long hair under the helmet mandatory for pilots with long hair Disposable mobcap hygiene mandatory Had sock for pilots having hair likely to come out of the helmet highly recommended Helmet of correct size for the pilot s head approved according to national regulation with strap to secure under the chin and visor mandatory Long non floating clothes giving a good protection of arms and legs mandatory Closed shoes mandatory short lace tied Suit with a ribbed border cuff and ankle recommended Driving gloves dry recommended Neck brace for the drivers with neck and head problems or on driver s request highly recommended Rib protection of correct size recommended Sui
32. User maintenance guide Things prohibited to the driver e Itis essential that you apply the following safety e Driving prohibited for a pilot instructions and recommendations Wearing a scarf since it may wind around Never open the batteries rotating parts of the go kart Observe the conditions for storage use Cf chap 3 4 Cf chap 3 6 Cf chap 4 9 installation and maintenance With long hair sticking out of the helmet Store batteries in an enclosed dry room at Cf chap 3 4 Cf chap 3 6 Cf chap 4 9 moderate temperature With hair which could reach a rotating parts when recharge the batteries use the approved the driver is seated in the go kart charger only Wearing loose clothes Cf chap 3 4 Cf chap 3 6 Cf chap 4 9 Wearing sandals heeled shoes or shoes with long laces presenting a risk of entanglement in rotating parts of the go kart Having health problems especially with a history of heart conditions head neck or back ailment nervous disorder seizure Never short circuit the batteries Replace the batteries immediately in the event of leakage or unusual odours Avoid all contact with the battery s electrolyte In the event of contact with the skin immediately wash the affected areas using soap and water In the event of contact with eyes rinse with plenty of water for 15 minutes and immediately seek Having a strange behaviour medical advice
33. a rotation part which s presents a risk of serious or even fatal injury by winding of long hairs or 8 loosing clothes 5 gt A throttle cable too tight may accelerate 3 the go kart without driver and may lead 5 to a serious or even fatal injury gt The button 2 must always be returned to the OFF position when the go kart is at the stand without a driver MAN VOLT EN 02 USE SPARE PARTS OF SODIKART ORIGIN 12 2010 CHECKING BEFORE CESSIONS So 3 Checking before cessions For replacement of brake parts please refer A to chapter adjustment and maintenance of the 3 1 Braking chassis section brake Cf chap 4 1 e It is imperative to check the braking A system everyday fluid secure closure of the hydraulic brake pump container cap fluid level calliper tightening brake pad fastening break pad brake disk tightening and centring mechanical contact between the pedal and master cylinder e f the brake fluid becomes black drain the brake fluid and refill the braking system Cf chap 4 1 User maintenance guide gt The brake is an essential safety element A Do not put the go kart in operation if the break system is faulty or if you have a doubt gt Faulty braking system may lead to serious or even fatal injury gt A leak in the brake system may lead to loss of breaking power and may lead to a serious or even fatal injury gt Do not put a greasy liquid on the brake disk or on the br
34. a serious or even fatal accident Page 25 Remove power from the go kart before performing any servicing To do this place the ON OFF button in the OFF position and disconnect the go kart from the charger Page 25 Never drive the go kart with the wheels not tightened as this may lead to a serious or even fatal injury Page 26 KEEP GO KART IN ORIGINAL CONFIGURATION vv Do not drive with bent or broken tie rods it exposes the pilot to a risk of a serious or even fatal injury Page 26 Driving with badly tightened wheel screws may lead to a serious or even fatal injury Page 27 Exceeding the maximum rear wheel unit adjustment may cause the breaking of the hub and may lead to a serious or even fatal injury Page 27 An excessively tight belt can damage the engine bearings Page 29 The use of an unsuitable gear ratio for the track or running the engine at too low a speed can cause engine overheating and damage Page 29 Change all damaged rims A damaged rim may lead to a loss of tyre or loss of pressure and may lead to a serious or even fatal injury Page 30 Check the tyre wear daily Worn or damaged tyres may lead to a serious or even fatal injury Page 30 Never run with worn or damaged tyres a burst of tyre may lead to a serious or even fatal injury Page 30 Always blow up tyre with the pressure recommended by the manufacturer Page 30 Cold tyres have a reduced adherence and increase the loss of contro
35. ake calliper it may cause a significant loss of braking power and may lead to a serious or even fatal injury gt Using brake fluid other than DOT 4 may damage the seals in the break system Legend and cause a loss of braking power Reservoir Master cylinder gt Use brake fluid DOT 4 only Brake hose Brake calliper Support Frame Brake pad Brake disc Pin Rear axle Wear indicator Check that the brake fluid in the reservoir 1 of the master cylinder 2 is at the maximum level If the level is low fill to the upper level mark e Check the hoses 3 to hydraulic brake it is essential there should be no leak Carefully check hose connexions and replace if damaged Cf chap 4 1 e Check the hoses are not damaged near the clamp e Check that the hydraulic brake calliper 4 is securely mounted on its support 5 e Check that the brake pads 7 are in position in the calliper 4 e Check the presence of the wear indicator 11 on the brake pads 7 If not found replace the brake pads Cf chap 4 1 e Make sure that brake disk 8 is wedged with an axle pin 9 and tightened onto rear axle shaft 10 gt M O O1 BR N o This document can not be reproduced or released without the Sodikart authorization 14 KEEP GO KART IN ORIGINAL CONFIGURATION iili ahs CHECKING BEFORE CESSIONS amp NV ah 9 KS User maintenance guide This document can no
36. art on a trolley e Loosen but do not remove the screws 1 of the engine mount 2 using a spanner of the appropriate size e Pull the engine mount 2 by hand to place tension on the belt 3 e Loosen the nut 5 e Adjust the adjustment screw 4 to obtain 5 mm belt clearance e Tighten the screws 1 on the engine mount 2 Check the belt clearance 5 mm e Check that the adjustment screw 4 is in contact with the engine mount 2 e Tighten the nut 5 User maintenance guide ADJUSTMENT AND MAINTENANCE OF THE CHASSIS 4 8 Tyres change Legend OO O1 B ND Rim Tyre Direction of rotation Inflation system Grease Tyre iron Place the go kart on a trolley Remove the front wheel or rear wheel with the proper size wrench Place the wheel on a tyre remover Available on the ITAKA catalogue When the tyre 2 is detached on both sides remove it completely using tyre irons 6 available in the ITAKA catalogue Take the new tyre and grease the tyre in order to make assembly and removal easier Replace the tyre 2 on the valve side of the wheel rim 1 ensuring the correct rotation direction Once the tyre is correctly positioned inflate with a compressed air line to a pressure of 3 5 bar so that the walls make a good seal with the wheel rim Then deflate to recommended pressures Reinstall the wheel on the go kart Check the tightening torque of the mounting nut KEEP GO KART IN
37. being mechanic technician must sign the maintenance sheet after that inspects all go karts e g Write a V in the engine mount box the motorization amp transmission is on the recto of the the tightness of the engine sheet and the chassis on the verso Write A in the engine mount tightening box if the tightness of the engine mount has been changed Maintenance schedule Surname Signature X sm Jm VE 458 Motorization amp transmission BETAH x T LI Emwessms 1 A E 2 X X 1 8 8 x x x x e 1 Check the current of the engine running off load MAINTENANCE SCHEDULES So e Write the letter representing the check A carried out in the box for the go kart being inspected e g Write a V in the engine mount box after checking the tightness of the engine mount Write A in the engine mount tightening box if the tightness of the engine mount has been changed Maintenance schedule Surname Signature Safety stickers xx IL ROTE Beepdwer TXT Pedals displacement X x ll stopligntstatey XXI Front train alignment X X tt Steering rods state XIXI Tt mgMenngofwhees amp stubaxes X X
38. brake pads must be changed when their have A engaged 5 worn down to minimum thickness e Ensure that the pads are in the correct D position Minimum brake pad thickness 8 mm 4 mm It is strongly advised to bleed and renew e lining 4 mm steel support the braking circuit after each change of Minimum brake disc thickness 17 mm brake pads The go kart will have optimum a braking performance gt Never operate the go kart if the brake pads have worn beyond their permitted limits 2 gt Use only genuine SODIKART brake pads gt Make sure the pads are assembled correctly and that the braking system is working efficiently before operating the go kart gt Check brake pad wear daily 4 1 3 Brake fluid hoses Legend Brake fluid reservoir cap Right pad Left pad Retaining clip Upper guide stem Lower guide stem e Unscrew and remove the brake fluid filler cap 1 The brake fluid hoses are a critical safety element it is Wrap a dry rag around the neck of the filler to very important to check their state regularly prevent spillage e Check the state of the hoses especially at e Using your hand push back the left hand pad 3 to connecting points and fixation points return the piston in their initial positions The brake e Change damaged hoses fluid will rise several millimetres in the tank gt The brake is an essential safety element e Remove the retention pins 4
39. chap 3 2 Cf chap 4 4 thetyres Cf chap 3 5 Cf chap 4 8 Cf chap 4 13 the bodywork parts Cf chap 3 6 Cf chap 4 9 the nuts and bolt Cf chap 3 7 Cf chap 4 10 gt Not using a go kart in it s original A configuration may lead to a serious or even fatal injury This document can not be reproduced or released without the Sodikart authorization MAN VOLT EN 02 12 2010 SAFETY INSTRUCTIONS 1 1 6 Batteries 1 1 7 Drivers e The batteries must be used under optimum Follow the mandatory safety instructions carefully conditions otherwise battery life will be reduced e Failure to apply the instructions can lead to leakage fire explosion or permanent damage to the battery and its environment e The batteries are intended for use with the FunnyVolt go kart e Any other used is deemed inappropriate and prohibited e Sodikart shall not under any circumstances be held responsible for loss or damage resulting from inappropriate use e Any risk is borne entirely by the user Age and size restrictions e Make sure the age and size restrictions are respected according to the current laws and regulation in your country or state e Forbid a pilot to drive with a size and or age are below the minimum imposed by the regulation In France the driver must be 14 years old and measure 140cm minimum e For small driver between 140cm and 150cm use a spacer removable foam
40. cover which is badly secured or in a bad state may lead to a serious or even fatal injury by winding of long hair or loose clothes around the rear axle Page 19 Make sure that the rear axle cover is the good version Page 19 A bodywork part with dangerous sharp edges may lead to a serious or even fatal injury Page 19 Never allow a go kart to run with broken or missing bodywork parts it may lead to a serious or even fatal injury Page 19 USE SPARE PARTS OF SODIKART ORIGIN SAFETY INSTRUCTIONS User maintenance guide User maintenance guide gt SAFETY INSTRUCTIONS Operation of the pedals in forward position can be obstructed by a front shock absorber system in poor condition Page 19 Never modify an engine cowl or axle cover because there is a risk of entanglement of the driver s loose clothing Page 19 A loosened adjustable seat can result in serious bodily injury or death Page 20 An adjustable seat system that is faulty or in bad state can result in serious or bodily injury or death Page 20 Never adjust the seat whilst driving Page 20 Adjustments must be made by track personnel before you start out Page 20 Chapter Adjustment and maintenance of vv vv v Vv v VVV v the chassis Wear insulating gloves and goggles for all operations on the electrical circuit Page 21 Never short circuit the batteries This could cause an explosion fire or a serious or even fatal accident
41. der tank 6 with fluid up to the maximum level and tighten down the filler cap 3 and seal 8 To change the brake hose connexions unscrew the 2 banjobols 9 and screw the new brake hose connexions brake parts closer to their original state and improves braking e To bleed your brake system more rapidly especially for a big fleet we recommend the priming system SODIKART Ref OU951 002 e Store old brake liquid in a dedicated tank e The brake liquid doesn t contain petrol so never pour the liquid into a using oil tank e Brake fluid absorbs water Make sure the replacement brake fluid comes from a container that has been stored in good conditions and is recent e Correct replacement of brake fluid keeps gt An air bubble in the brake system can lead to a partial or total lost of brakes and may lead to a serious or even fatal injury gt Leaks in the brake system may lead to a serious or even fatal injury gt Moisture in the brake fluid may cause vapour lock and a sudden loss of braking power may lead to a serious or even fatal injury gt Use brake fluid DOT 4 only gt Altering the adjustment of the brake system levers may cause a loss of braking e This document can not be reproduced or released without the Sodikart authorization MAN VOLT EN 02 12 2010 ADJUSTMENT AND MAINTENANCE OF THE CHASSIS 4 1 2 Brake pads e Double check that the clips 4 are properly 3 The
42. des 6 4 9 Assembly of the bodyworks and in thi PrOTECIIONS estos cust eda eun su Da ki Do Lau 31 1de Recap all wamings 7 4 9 1 Protections dst eee 31 MANUA sens MS UR 4 9 2 BODWOFKS 32 522 quee dx B ee APUD 33 1 3 2 Batteries MEM d 8 4 11 Batteries 4 34 N 4 11 1 Battery 34 2 Go kart reception 11 4 11 2 Working life of the batteries 34 8 2 1 Standards 11 4 11 3 Storage 34 x 8 2 2 Eee 11 4 11 4 Replacement nene 35 BB r 23 1 Type EXIDE MAXXIMA 900DC ERES 11 5 2 3 2 Type 4 000 2 10 1 100 11 4 13 Studded tyres change 37 2 4 Charger cierra e Yn 11 4 14 Electric 38 g 2 5 Delivery 12 4 14 1 Brush inspection 38 CEBIT 2 5 1 Connecting LiFePo4 12 TOT PON a UST reap COMI sexe 39 S _ gt 2 6 Charger 43 4 15 Chassis cleaning 39 4 16 Maintenance
43. e Check the body part fastenings e Whenever bodywork parts are changed make sure that nuts and bolts are assembled with nuts on the inside and bolt heads on the outside in order not to cause any injury This document can not be reproduced or released without the Sodikart authorization USE SPARE PARTS SODIKART ORIGIN ADJUSTMENT AND MAINTENANCE OF THE CHASSIS 9 4 16 5 Tyres e Take particular care when fitting tyres that they rotate in the right direction Follow the directional arrows on the tyre wall e Check for tyre wear with the indicators in the tread One must always be able to see them Tears or tread separation must not be found e Before each session check tyre pressures Duro tyre Itaka tyre User maintenance guide 4 16 6 Braking e Make sure before all sessions that the braking system is working properly e Brake fluid should not be black Drain and change black fluid Check levels e Ensure that brake pads are correctly fitted and do not fall below the minimum thickness of 8 mm 4 mm lining 4 mm steel support e Brake hoses must not show any leaks at connection points Replace if damaged 4 16 7 Chassis cleaning e Clean your chassis at least once a week e Use only go kart cleaner WD40 ref LU833 004 This document can not be reproduced or released without the Sodikart authorization KEEP GO KART IN ORIGINAL CONFIGURATION iili ce TROUBLE SHOOTI
44. e throttle pedal at maximum when you start the engine may lead to a serious or even fatal injury Page 13 The engine is a rotation part which presents a risk of serious or even fatal injury by winding of long hairs or loosing clothes Page 13 A throttle cable too tight may accelerate the go kart without driver and may lead to a serious or even fatal injury Page 13 The button 2 must always be returned to the OFF position when the go kart is at the stand without a driver Page 13 Chapter Checking before cessions The brake is an essential safety element Do not put the go kart in operation if the break system is faulty or if you have a doubt Page 14 Faulty braking system may lead to a serious or even fatal injury Page 14 A leak in the brake system may lead to a loss of breaking power and may lead to a serious or even fatal injury Page 14 Do not put a greasy liquid on the brake disk or on the brake calliper it may cause a significant loss of braking power and may lead to a serious or even fatal injury Page 14 Using brake fluid other than DOT 4 may damage the seals in the break system and cause a loss of braking power Page 14 Use brake fluid DOT 4 only Page 14 Faulty steering may lead to a serious or even fatal injury Check steering prior to cessions Page 15 A faulty pedal system may expose the driver to a risk of the driver and other drivers to a risk of serious or even
45. endit tabe tete pneri 36 Power harness 12 sucede tenian t tete eee tetas 30 Power INGICALON iiss cria Cose eere eo eue pe Ea rte Pe acs 13 Idm 30 37 iere 19 U R Upper engine 16 REAM axle hier 14 Upper guide 23 Bumper E 31 5 EE 14 14 18 5 Rest position 24 i 3 Retaining Clip suite rire date eed ees 23 ed 25 5 22 12 E Retractor 36 Returti spring niente 24 8 Right pad RINT RR 23 Ll e P 30 37 2A n 17 29 27 E S 3 Safety Blasio eoo RT ce en be 16 o co 15 8 TRU RM 20 o m 24 8 Shock MOUN 31 32 2 31 32 g Side pod mounting flange 32 2 Side 31 32 M 24 Speed selector 13 SDpOIlGr une indiens 31 32 Sprocket t 28 Steering co
46. ersion hot areas risk of burns gt A bodywork part with dangerous sharp S e Check that the bodyworks parts are not damaged edges may lead to a serious or even e Check the bodywork fixations 1 fatal injury e Check the state of protections 2 gt Never allow a go kart to run with broken 5 or missing bodywork parts it may lead to a serious or even fatal injury gt Operation of the pedals in forward position can be obstructed by a front shock absorber system in poor condition gt Never modify an engine cowl or axle cover because there is a risk of entanglement of the driver s loose clothing 3 7 Bolting Check all nuts and screws on the go kart Rearhub wheel rear hollow axle screws seat Screws engine platen screws body braking gas and brake pedal screws steering screws notched belt tension screws For adjustment and maintenance of the chassis Cf chap 4 10 because of engine vibration e Check the stub axle nuts and bolts with particular care e Check the engine platen screws regularly This document can not be reproduced or released without the Sodikart authorization Legend 1 Bodywork fixation 2 Protection e A screw head that protrudes outside the A protections will rapidly degrade the other bodywork parts Change the corresponding protection immediately jr USE SPARE PARTS OF SODIKART ORIGIN CHECKING BEFORE CESSIONS 9 3
47. fatal injury Page 16 Damaged of braking hoses may lead to a serious or even fatal injury Page 16 To limit the risk of electrocution check that the go kart is switched off and disconnected from the charger Page 16 The engine is source of heat which presents a risk of burn for the driver Make sure that the protections are correctly secured and in a good state Page 18 The engine and transmission rear axle included are rotation parts which present a risk of serious even fatal injury by winding of long hairs or loosing clothes Make sure that the protections are correctly secured and in a good state Page 18 Change all damaged rims A damaged rim may lead to a loss of tyre or loss of pressure and may lead to a serious or even fatal injury Page 18 Check the tyre wear daily Worn or damaged tyres may lead to a serious or even fatal injury Page 18 Never run with worn or damaged tyres a burst of tyre may lead to a serious or even fatal injury Page 18 Always blow up tyre with the pressure recommended by the manufacturer Page 18 Cold tyres have a reduced adherence and increase the loss of control of the go kart This may lead to a serious or even fatal injury Page 18 Too much grip reduces the stability of the go kart under impact and lead to a tendency to go on two wheels It also increases the risk of riding over Page 18 Store tyres in an appropriate area to prevent fire hazard Page 18 A rear axle
48. g properly 2 Is the front axle unit checked 5 2 4 The steering of the go kart is not precise 1 Are the front wheels tightened 2 Are the stub axles to torque tightening specification 3 Are the column plastic supports tightened to torque specification 4 Are the tie rods correctly assembled and to torque specification 5 Is the front wheel axle unit adjustment checked 5 2 5 The go kart tends to go to the side 1 Is the front wheel axle unit adjustment checked Are the tie rods correctly assembled Are the tie rods locking nuts securely tightened Is there a tie rod bent or broken Do the rear wheels have exactly the same circumference 6 Is the chassis twisted This document can not be reproduced or released without the Sodikart authorization oR 5 2 6 The go kart skids very much on bends 1 Are the tyres worn 2 Are the tyres inflated to the recommended pressures 3 Is the rear axle adjustment suited to the track conditions USE SPARE PARTS SODIKART ORIGIN User maintenance guide 6 Index Adjustment SCIeW econtra eee 29 Arrow direction of 18 27 AXIS E Taia 32 a Ball io tret ome ires 15 242 12 10 22 derniere 12 17 21 35 Battery Connector 12 Battery cover
49. ge at the terminals of each battery and write it down Ifthe potential difference between the four batteries is less than 0 5 V you may continue to use the go kart Ifthe potential difference between the four batteries is greater than 0 5 V replace the set of batteries e You can create new sets of batteries by combining batteries of the same age put in service on the same date and similar voltage below 0 5 V e Identify the new assemblies created A e Do not mix new batteries with batteries already in use e To maintain the battery charge level at 10096 charge the batteries all night long on alternate nights e f one or more batteries of a go kart are completely discharged or their voltage is below 10 V or if the voltage of the whole set of batteries is below 40 V recharge the batteries using a conventional charger up to a voltage of 12 V before using the ZIVAN charger LifePo4 batteries e LifePo4 battery charging periodicity 10 minutes driving 10 minutes charging e Below 0 C the battery must be activated A by driving for a few minutes before charging gt For safety reasons and to avoid any risk of fire never leave the batteries unattended during charging 4 11 3 Storage EXIDE MAXXIMA 900DC batteries e Battery storage temperature 10 C to 40 C in a dry location e Store the charged batteries LifePo4 batteries e Battery storage temperature 5 C to 40 C in a dry location
50. ged tyres may lead to a serious or even fatal injury Page 37 gt Never run with worn or damaged tyres a burst of tyre may lead to a serious or even fatal injury Page 37 gt Always blow up tyre with the pressure recommended by the manufacturer Page 37 gt Cold tyres have a reduced adherence and increase the loss of control of the go kart This may lead to a serious or even fatal injury Page 37 Too much grip reduces the stability of the go kart under impact and lead to a tendency to go on two wheels It also increases the risk of riding over Page 37 The studded tyre must be used only on the ice track Page 37 Store tyres in an appropriate area to prevent fire hazard Page 37 An excessively tight belt can damage the engine bearings Page 38 The use of an unsuitable gear ratio for the track or running the engine at too low a speed can cause engine overheating and damage Page 38 gt If WDAO is sprayed on the brake disk or brake calliper brake efficiency will be partially or completely reduced and this may lead to a serious or even fatal injury Page 39 gt Do not put WD40 into brake pump Page 39 gt Do not use a pressure washer Cleaning the go kart with a pressure washer can lead to fast deterioration of certain go kart components e g electrical components of the go kart stickers bearings etc Page 39 User maintenance guide v v vy y Kit of 3 small safety stikers Ref AC701 12
51. ggressive or queer behaviour e Stop immediately all drivers who despite the safety instructions have had long hair sticking out of the helmet or loose clothes gt Not following safety rules may lead to A serious or even fatal injuries gt A driver with dangerous behaviour exposes himself and other pilots to a risk of serious or even fatal injury gt Driving with long hair sticking out of the helmet and or loosing clothes exposes to a risk of serious or even fatal injury by winding around rotating parts of the go kart If you have problems or questions about your go kart please contact our local distributor or representative of Sodikart Parc d activit s des Hauts de Cou ron B P 60 44220 COUERON France Tel 33 02 40 38 26 20 Fax 33 02 40 38 26 21 www sodikart com sodikart sodikart com gt Not following the instructions of this manual may lead to serious or even fatal injuries and involve the track liability This document can not be reproduced or released without the Sodikart authorization MAN VOLT EN 02 12 2010 This document can not be reproduced or released without the Sodikart authorization MAN VOLT EN 02 12 2010 1 2 Recap of all warnings included in this manual Chapter Safety instructions Vw wv V v Not following size and age restrictions exposes the driver and other pilots to serious or even fatal injuries and may involve the liabil
52. his document can not be reproduced or released without the Sodikart authorization gt Control presence and good state of A the safety stickers and follow the instructions mentioned on them gt Replace a damaged sticker GO KART IN ORIGINAL CONFIGURATION iil 7 This document can not be reproduced or released without the Sodikart authorization MAN VOLT EN 02 12 2010 2 Go kart reception 2 1 Standards This go kart complies with the French standard NF 552 002 of February 2001 This go kart complies with the european standard 98 37 Look on the right front of chassis the C E sticker SODIKART Parc d Activit s des Hauts de Cou ron BP60 44220 COU RON FRANCE CC Mod le Funny Volt Ann e 2010 2 2 Engine Continuous output 8 5 kW Speed of rotation 4 000 rpm 2 3 Battery A gt Use EXXIDE MAXIMA 900 DC or LifePo4 batteries only 2 3 1 Type EXIDE MAXXIMA 900DC Watertight battery No risk of explosion No acid vapour e Go karts are delivered with their LiFePo4 batteries disconnected See battery connection Cf chap 2 5 1 Type Working life Capacity Voltage Quantity per go kart Safety characteristics GO KART RECEPTION 2 3 2 Type LifePo4 Type e The batteries are paired Always replace them in pairs A 2 4 Charger Check that the battery charger operation and installation manual has been supplied If not contact SODIKART
53. incorrect connection e Do not apply force to the connectors whilst connecting them This document can not be reproduced or released without the Sodikart authorization MAN VOLT EN 02 12 2010 GO KART RECEPTION 2 7 Start up of the go kart 3 O 6 6 Legend 5 1 Speed selector 2 ON OFF button Legend 3 Mode switch forward stop reverse 1 Charger socket 4 Power indicator recharge the go kart batteries connect the The person who starts up the go kart must be sitting in 5 charger to the socket 1 driving position 5 e Always observe the battery charging time e Setthe mode switch 3 to STOP A e After each session the go karts must e Set the speed selector 1 to the desired speed z always be stored with their batteries 9 e Press the brake pedal 8 e During winter storage the batteries must Place the ON OFF button 2 in the ON position p be stored charged The indicator light 4 lights up e To maintain the battery charge level at e Set the mode switch 3 to RUN 8 100 charge the batteries all night long alternate nights e The go karts are equipped with an anti gas E A brake system This function shuts off power to the engine as soon as the driver presses 3 the brake pedal gt Push the throttle pedal at maximum E A when you start the engine may lead to a 8 serious or even fatal injury gt The engine is
54. ity of the track Page 4 Keep the go kart in it s original state Page 4 Use ONLY spare parts of SODIKART origin Page 4 Use of damaged equipment may lead to a serious or even a fatal injury Page 4 Not using a go kart in it s original configuration may lead to a serious or even fatal injury Page 4 The mobcap is design for the hygiene It is not a device to secure long hair Page 6 Long hair sticking out of the helmet and or loose clothes expose the driver to a risk of serious or even fatal injuries by winding around rotating parts of the go kart Page 6 Make sure safety instructions are well understood by the pilots Page 6 Not following safety rules may lead to serious or even fatal injuries Page 6 A driver with dangerous behaviour exposes himself and other pilots to a risk of serious or even fatal injury Page 6 Driving with long hair sticking out of the helmet and or loosing clothes exposes to a risk of serious or even fatal injury by winding around rotating parts of the go kart Page 6 Not following the instructions of this manual may lead to serious or even fatal injuries and involve the track liability Page 6 Control presence and good state of the safety stickers and follow the instructions mentioned on them Page 10 Replace a damaged sticker Page 10 Chapter Go kart reception Use EXXIDE MAXIMA 900 DC or LifePo4 batteries only Page 11 Push th
55. jury gt Check the tyre wear daily Worn or damaged tyres may lead to a serious or even fatal injury gt Never run with worn or damaged tyres a burst of tyre may lead to a serious or even fatal injury gt Always blow up tyre with the pressure recommended by the manufacturer gt Cold tyres have a reduced adherence and increase the loss of control of the go kart This may lead to a serious or even fatal injury gt Too much grip reduces the stability of the go kart under impact and lead to a tendency to go on two wheels It also increases the risk of riding over gt The studded tyre must be used only on the ice track gt Store tyres in an appropriate area to prevent fire hazard USE SPARE PARTS OF SODIKART ORIGIN E 6 m c 6 n ADJUSTMENT AND MAINTENANCE OF THE CHASSIS e Tighten the four screws 3 e Reinstall the cover 1 4 14 Electric motor 4 14 2 Contact brush replacement e Use compressed air to clean the engine e Remove the cover 1 E A after each use e Remove the contact brush kit by removing the 4 The engine air intake must never be screws 3 obstructed by foreign body e Install the new contact brush kit e Never use the engine in extremely wet T conditions or in the presence of fine e Align the engine index mark with the index mark on powdery snow the contact brush kit and the
56. l of the go kart This may lead to a serious or even fatal injury Page 30 Too much grip reduces the stability of the go kart under impact and lead to a tendency to go on two wheels It also increases the risk of riding over Page 30 Store tyres in an appropriate area to prevent fire hazard Page 30 A bodywork part with dangerous sharp edges may lead to a serious or even fatal injury Page 31 Never allow a go kart to run with broken or missing bodywork parts it may lead to a serious or even fatal injury Page 31 Do not modify bodywork parts you might unwillingly significantly reduce it s efficiency as a safety item Page 31 Although the safety points listed here must be checked daily it is obvious that other fastenings must not be ignored Indeed it is advised to check all fastenings almost daily to minimise all risks Page 33 To limit the risk of deep discharge and destruction of batteries never allow a go kart to become fully discharged Page 34 To limit the risks of engine overheating never use one go kart to push another and never accelerate when the go kart is blocked wall track guard etc Page 34 To limit the risks of discharge check after each session that the go kart s on off button is set to OFF Page 34 Between sessions and at night never store go karts in an area exposed to rain or at a temperature below 5 C Page 34 For safety reasons and to avoid any risk of fire never leave the ba
57. ley e Unscrew and remove the locking nuts of the wheels with the proper size wrench e Once the wheels are removed place the front wheel alignment disk 1 e Unscrew the lock nuts 2 of the 2 tie rods with the proper size wrench Warning lock nut of tie rod side is a righthand thread lock nut of steering column side is left hand thread e Position the upper branch of the steering wheel in the gokart axle e Measure A and B with a roll meter Then if necessary make the modifications so that A B by turning at the same time the right and left tie rods in the wished direction e When A B the front wheel axle unit alignment is perfect Screw back again the lock nuts 2 of the 2 tie rods e Remove the front wheel adjustment disk 1 and replace right and left wheels Make sure you follow the rotation direction showing on the tyre wall e Screw back again the 2 nuts for wheels tighten securely then unscrew the nuts 1 4 turn in order not to compress the wheel ball bearing e Check that each knuckle joint is screwed at least rotations in the tie rod This document can not be reproduced or released without the Sodikart authorization The front wheel must be always parallel A B 0 KEEP GO KART ORIGINAL CONFIGURATION iili ce This document can not be reproduced or released without the Sodikart authorization MAN VOLT EN 02 12 2010 Legend O1 B ND Ruler Hub Axle Screw Pin Place
58. lumn 15 Steering Wheel iEn 15 Steering wheel sloping hub 15 SUb 15 otudded tyre cet c 37 SUDDOLt orit eti vede ss 14 31 32 MAN VOLT EN 02 USE SPARE PARTS OF SODIKART ORIGIN 12 2010 User maintenance guide MAINTENANCE SCHEDULES 9 7 Maintenance schedules User maintenance guide This document can not be reproduced or released without the Sodikart authorization p KEEP GO KART IN ORIGINAL CONFIGURATION iili ce MAINTENANCE SCHEDULES 7 1 Daily maintenance e Write the letter representing the check Inspect each go kart which will be used all day The A carried out in the box being mechanic technician must sign the maintenance sheet inspected after that he inspects all go karts e g Write a V in the engine mount box the motorization amp transmission is on the recto of the the tightness of the engine sheet and the chassis on the verso Write A in the engine mount tightening box if the tightness of the engine mount has been changed Maintenance schedule Surname Signature Controls Motorization amp transmission 10 11 12 13 14 15 CLS L5 7 SSSR 2 i Mn AL EIE Replacement ARE Adjustment e 1 Check that the engine does not run when the brake pedal is depressed A This document can
59. n rotate the contact i e Check the contact brushes for wear after brush kit 1 mm in the direction indicated by the 100 sessions arrows D a E gt An excessively tight belt can damage A the engine bearings gt The use of an unsuitable gear ratio for the track or running the engine at too low a speed can cause engine overheating and damage 4 14 1 Brush inspection This document can not be reproduced or released without the Sodikart authorization e Remove the cover 1 e Check that the 8 cables 2 can move freely e Check that there are no traces of a burn on the contact brush kit e Remove the contact brush kit by removing the 4 screws 3 Clean the contact brush kit by blowing with compressed air e Check that the contact brushes measure more than 5 mm KEEP GO KART IN ORIGINAL CONFIGURATION ide 0 ADJUSTMENT AND MAINTENANCE OF THE CHASSIS 4 15 Chassis cleaning 4 16 Maintenance summary The chassis and its parts with the exception of the brake calliper and brake disk should be cleaned with 4 16 1 Bolting the special gokart cleaning fluid WD40 available from e Check daily all nuts and bolts and more especially the ITAKA catalogue the check points This fluid cleans removes grease protects lubricates Stub axle screws and protects the rotating parts from damp stub axle tie Steering rod ball joint screws User maintenance guide rods etc Rear wheel nyl
60. nferior screw 4 is tangent of cable hole e Tighten the throttle cable with the superior screw 3 B ND This document can not be reproduced or released without the Sodikart authorization MAN VOLT EN 02 12 2010 This document can not be reproduced or released without the Sodikart authorization MAN VOLT EN 02 12 2010 Legend 8 Potentiometer 9 Pushrod e The clearance J between the potentiometer and the push rod must be between 0 5 and 1 mm e Check the tightness and orientation of the sheath end 5 Refer to the sketch e Actuate the accelerator pedal to control the position of the potentiometer in fast and stopped position A 4 3 1 Clearance adjustment e f the potentiometer does not return to the rest position when the brake pedal is released the go kart will go into fault condition e Loosen the upper screw 3 e Slightly loosen or tighten the accelerator cable 1 to obtain the correct clearance and then retighten e Move the pedals through several positions to check that the potentiometer remains in the rest position 6 m c 6 n Legend 10 Locknut 11 A A USE SPARE PARTS OF SODIKART ORIGIN Screw Disconnect the potentiometer 8 from the go kart Connect a multimeter to the ohmmeter position on the potentiometer plugs Press the accelerator pedal fully home The multimeter should indicate 4
61. nslation of the French manual Document MAN VOLT FR 02 original version which will prevail in the event of a dispute The illustrations are non contractual Sodikart 2010 1 Safety instructions A go kart can be dangerous if if is not correctly maintained or used Read carefully this manual and pay a particular attention to safety warnings and notes e Not following the safety instructions of this manual may involve your liability if an accident occurs e Read carefully hints instructions or warnings following a notes or a warning A A A e Indicates a risk of property damage if instructions are not followed gt Indicates a strong possibility of serious personnal injury or death if instructions are not followed gt Not following size and age restrictions exposes the driver and other pilots to serious or even fatal injuries and may involve the liability of the track gt Keep the go kart in it s original state gt Use ONLY spare parts of SODIKART origin gt Use of damaged equipment may lead to a serious or even a fatal injury 1 1 General instructions 1 1 1 Track e Use the go kart only on a go kart track e Getthe track approved e Make sure the track complies with the rules and regulations of your country or state e Use adequate track protections that comply with the regulations of your country example protection of poles e Make sure the track surface is uniform no h
62. ntenance of the chassis section front wheel axle unit alignment Cf chap 4 4 e Mount the 2 tie rods 6 correctly on the stub axle 7 gt Faulty steering may lead to a serious or 2 USE SPARE PARTS SODIKART ORIGIN CHECKING BEFORE CESSIONS So 3 3 Pedals 3 4 Engine transmission and batteries Driving in an ergonomic position is safer gt To limit the risk of electrocution check that the go kart is switched off and disconnected from the charger 3 4 1 Engine User maintenance guide Legend 1 Brake security 2 Safety elastic e Move pedals on several positions to check its functioning e Press and release the brake and throttle pedals to check that they go back to their original position e Check that brake security 1 is well placed and the safety elastic 2 is on the brake security e Check the brake hoses no leak in the system gt A faulty pedal system may expose the asm driver toa risk of the driver and other 2 Engine mount drivers to a risk of serious or even fatal 3 Screw injury 4 Chassis gt Damaged of braking hoses may lead to 5 Screw a serious or even fatal injury 6 Upper engine flange 7 Lower engine flange 8 Screw Check that the screws 3 are holding the engine 1 securely on the engine mount 2 e Check that the screws 8 are holding the upper engine flanges 6 securely on the engine mount 2 e Check that the screws 5 are holding the engine
63. o e Write the letter representing the check A carried out in the box for the go kart being inspected e g Write a V in the engine mount box after checking the tightness of the engine mount Write A in the engine mount tightening box if the tightness of the engine mount has been changed Maintenance schedule Surname Signature xx NN MX Chassis Replacement Adjustment This document can not be reproduced or released without the Sodikart authorization ms 1 NS Fixedseatstate X dT TT Adjustable seat state tt Optional equipment ES KEEP GO KART IN ORIGINAL CONFIGURATION illie ro SSS S SSA EC DECLARATION OF CONFORMITY the undersigned Sodikart Parc d activit des hauts de Cou ron BP60 44220 Cou ron declare that go kart model SODI FUNNY VOLT complies with the regulatory provisions of European directive 98 37 The product was designed to satisfy the requirements of the following reference documents The NFS52 002 The FFSA technical and safety rules for karting The CIK FIA recommendations for leisure karting Made at Cou ron on 01 12 2010 on behalf of Sodikart Mister Gilles BAGNARIOL Job title Technical director Signature Parc d Activit s des haut de Cou ron B P 60 44220 COUERON FRANCE T l 33 02 40 38 26 20 Fax 33 0
64. oles e Maintain the track properly e Eliminate all fuel spills and fuel traces This list is not comprehensive Refer to the rules and regulations applicable in your country and or state KEEP GO KART IN ORIGINAL CONFIGURATION 1 1 2 Buildings e Make sure that buildings comply with the current rules and regulations applicable in your country and or state e Pay a particular attention to the fire hazard issue new and used tyres stock fuel station fire security System and emergency exit 1 1 3 Areas with restricted access e Clearly indicate the areas the access of which is forbidden to non authorized persons example technical zone e Keep the children away from the track They are not aware of the danger for themselves and the drivers e Request animals to be attached or kept on a leash Animals must never go on the track 1 1 4 Staff e Staff must be informed about safety trained and made aware of the importance of the matter 1 1 5 Go karts e Keep the go karts in their original state Cf chap 4 e Usetyres with a grip adapted to the surface of the track In case of difficulty contact SODIKART Cf chap 3 5 Cf chap 4 8 Cf chap 4 13 e Maintain the go karts properly e Use only spare parts of SODIKART origin e Check and maintain the safety components with care the brakes Cf chap 3 1 Cf chap 3 3 Cf chap 4 1 Cf chap 4 2 the steering system Cf
65. rocket 3 e Clean the cotter pin 5 and the axle e Place a drop of green Loctite with activator in the groove of the engine pin e Position the pin 5 on the edge of the shaft and wipe off any excess Loctite e Tighten the two screws 2 on the sprocket to 10 Nm e Tighten the cotter pin 5 with a Rilsan tape This document can not be reproduced or released without the Sodikart authorization 2 GO KART IN ORIGINAL CONFIGURATION iili ce This document can not be reproduced or released without the Sodikart authorization MAN VOLT EN 02 USE SPARE PARTS OF SODIKART ORIGIN 12 2010 User maintenance guide 7 settings on the engine mount 2 according to the gear ratio and the belt tension e Check belt tension daily to ensure long service Too tight a belt fatigues the engine and the frame e Too tight a belt fatigues the engine and the frame e e The roller 6 can have 3 different positions gt An excessively tight belt can damage A the engine bearings Legend 1 Screw gt The use of an unsuitable gear ratio 2 Engine mount for the track or running the engine 3 Belt at too low a speed can cause engine E oo screw overheating and damage u Place the go k
66. stop nuts e Protect the calliper and brake disk with a dry rag Rearhub screws e Spray the whole of the go kart with WD40 cleaner S for beari as Allow the cleaner to take effect for a few seconds DEI gs e With a dry cloth rub thoroughly the chassis tubes Ses and nuts for engine platen and all fixed parts Belt adjuster bolt e It is vital to clean the go kart regularly as m eaEDals A this provides the opportunity to notice more Carefully check worn nuts and screws and replace if easily worn parts and missing nuts bolts damaged and screws Clean your Go Kart weekly 4 16 2 Notched belt gt If WD40 is sprayed on the brake disk e Check daily the notched belt adjustment the A or brake calliper brake efficiency will notched belt must have 5 mm play be partially or completely reduced and this may lead to a serious or even fatal 4 16 3 Steering injury e Check daily the upper and lower column plastic gt Do not put WD40 into brake pump support torque as well as stub axle screws gt Do not use a pressure washer Cleaning e Make sure that front wheel axle unit is not out of line the go kart with a pressure washer stub axles bent or broken can lead to fast deterioration of certain e Check that the tie rods are not damaged go kart components e g electrical components of the go kart stickers 4 16 4 Bodywork parts peanings Gie e Parts of the bodywork must not be broken or have sharp edges
67. t be reproduced or released without the Sodikart authorization Legend 1 Steering wheel 2 Steering wheel sloping hub 3 Steering column 4 Plastic colomn support 5 Lower plastic column support 6 Tie rod 7 joint 8 Stub axle 9 Screw e Tighten the steering wheel 1 with 3 screws into e Damaged tie rods affect wheel alignment the steering wheel sloping hub 2 The sloping hub A and may cause a rapid tyre wear and must be tightened to the steering column 3 The increased driver s tiredness steering wheel must be free to turn turn to the e The locking nuts and stub axle bolts right and to the left must be jammed The stub axle must be tightened to the correct torque specification Make sure that the screws of the column plastic to obtain correct allowance for free rotation support 4 the 3 screws of the flanged guides around the axle Accurate adjustment leads steering shaft 5 and the screw under the steering to steering precision and reduces driver s column 9 are securely tightened 25Nm tiredness and the steering column 3 knuckle joints even fatal injury Check steering prior to e Stubs axles 8 must be tightened to the chassis cessions 60Nm with axle screws and locking nut and the washer e The front wheel axle unit alignment must be perfect There should be no pinching or unlocking of the front wheel axle unit e Forfront wheel axle unit alignment procedure refer to chapter adjustment and mai
68. t for wet conditions with waterproof fastening recommended when necessary User maintenance guide gt The mobcap is design for the hygiene It A is not a device to secure long hair gt Long hair sticking out of the helmet and or loose clothes expose the driver to a risk of serious or even fatal injuries by winding around rotating parts of the go kart gt Make sure safety instructions well understood by the pilots 1 1 8 Briefing communication e Display all safety instructions clearly Panels boards videos etc e Before starting the go karts have a briefing with the pilots about The way to use the throttle and brake pedals and the position of the hands on the steering wheel 10h10 The driving without simultaneous use of throttle and brake The way to lock the adjustable seat the steering column if adjustable and the pedals The rules of overtaking The meaning of the flags and the obligation to follow track personnel instructions The applicable sanctions if rules are not followed especially in case of dangerous driving e Prior to starting the session make sure all pilots comply with the safety rules and have understood the safety instructions KEEP GO KART IN ORIGINAL CONFIGURATION 1 1 9 During a session e Ensure safety rules are followed importance of track personnel flags etc e Warn penalize or exclude immediately all drivers having a dangerous too a
69. the go kart on a trolley Unscrew the nylstop nuts from the rear wheels with the proper size wrench and then remove wheels Using a rule 1 or any depth gauge measure between the hub base 2 and the top of the axle 3 Undo the CHC screws 4 of the rear hub with an appropriate wrench until the hub can slide along the axle shaft and cotter pin 5 Move the hub 2 to the desired position with the rule 1 in place against the hub base 2 Retighten screws securely repeat the operation on the other hub Replace both wheels following the rotation direction indicated on tyre wall Replace locknuts nylstop and tighten securely User maintenance guide KL A USE SPARE PARTS OF SODIKART ORIGIN JN DP e Accurate adjustment of the rear axle assembly will greatly improve the go kart performance e Too wide an adjustment of rear wheels causes a tendency to slide and too narrow an adjustment will cause a tendency to jump e Check the cotter pin of hub and rear axle are in their slotted home gt Driving with badly tightened wheel screws may lead to a serious or even fatal injury gt Exceeding the maximum rear wheel unit adjustment may cause the breaking of the hub and may lead to a serious or even fatal injury ADJUSTMENT AND MAINTENANCE OF THE CHASSIS 4 6 Easy to remove wheel sprocket 4 6 2 Removing the belt sprocket Unscrew the
70. to 4 5 ohms To adjust the pedal travel loosen the locknut 10 Adjust the pedal travel using screw 11 until the correct value is obtained on the multimeter Tighten the locknut 10 remove the multimeter and reconnect the go kart harness e Check the tension of the throttle cable daily e Check that the throttle cable adjuster is well directed to avoid a premature wear of the throttle cable gt Adjusting the potentiometer to maximum speed position when the accelerator pedal is released can lead to a serious or even fatal accident gt Remove power from the go kart before performing any servicing To do this place the ON OFF button in the OFF position and disconnect the go kart from the charger e Retighten both locknuts on each tie rod until locked After any wheel adjustment or violent impact always carry out wheel alignment procedures e Bad alignment may cause excessive wear of the front tyres Bad alignment reduces cornering ability of the go kart ADJUSTMENT AND MAINTENANCE OF THE CHASSIS 4 4 Front wheel alignment gt Never drive the go kart with the wheels not tightened as this may lead to a serious or even fatal injury gt Do not drive with bent or broken tie rods it exposes the pilot to a risk of a serious or even fatal injury User maintenance guide Legend 1 Wheel alignment disc 2 Tie rod nut and lock nut e Place the go kart on a trol
71. tteries unattended during charging Page 34 The batteries are the only electrical components that you can replace Page 36 Use electrically insulated tools Page 36 Remove your jewellery rings etc to avoid an electrical discharge that could lead to a serious or fatal accident Page 36 This document can not be reproduced or released without the Sodikart authorization MAN VOLT EN 02 12 2010 SAFETY INSTRUCTIONS gt Do not incinerate the battery because it 1 3 Safety stickers could explode causing a serious or fatal accident Page 36 gt Do not damage the battery and do not attempt Tod Gokart to open it This could lead to a serious or fatal accident Page 36 Explanation of pictograms gt Use EXXIDE MAXIMA 900 DC or LifePo4 batteries only Page 36 gt LiFePo4 batteries are paired up at the time of mounting and must never be separated If servicing is required send the complete set of batteries Page 36 gt Modify the seat belt system may lead to a serious or even fatal injury Page 36 gt Clean the belt with chemical product may modify the efficiency of the belt and lead to a serious or even fatal injury Page 36 gt A seat belt not locked may lead to a serious or even fatal injury Page 36 gt Change all damaged rims A damaged rim may lead to a loss of tyre or loss of pressure and may lead to a serious or even fatal injury Page 37 Check the tyre wear daily Worn or dama

ADJUSTMENT AND MAiNTENANcE Of THE cHASSiS

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