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Sodi SR4 User Maintenance Manual

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USER MAINTENANCE GUIDE
MANUEL D'UTILISATION
ET D'ENTRETIEN
4
SR
SODIKART - Parc d'Activités des Hauts de Couëron
44220 COUËRON - FRANCE
Tél. (33) 02 40 38 26 20 - Fax. (33) 02 40 38 26 21
E-mail : sodikart@sodikart.com - www.sodikart.com

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  • Page 1 USER MAINTENANCE GUIDE MANUEL D’UTILISATION ET D’ENTRETIEN SODIKART - Parc d’Activités des Hauts de Couëron 44220 COUËRON - FRANCE Tél. (33) 02 40 38 26 20 - Fax. (33) 02 40 38 26 21 E-mail : sodikart@sodikart.com - www.sodikart.com...

  • Page 2: Table Of Contents

    SR4 MANUAL SUMMARY SR4 SAFETY INSTRUCTIONS PREPARING THE ASSEMBLY 1- GETTING SR4 OUT OF THE PACKING 2- TOOLS FOR ASSEMBLY 3- MAINTENANCE PRODUCTS SEQUENCE OF ASSEMBLY 4- ASSEMBLY OF THE STEERING COLUMN AND OF THE STEERING WHEEL 5- ASSEMBLY OF THE FUEL TANK AND OF THE OVERFLOW BOTTLE...
  • Page 3 Safety on a track is a personal and collective matter at the same time : taking care of your SR4 is the first guarantee of your safety and of the safety of other pilots . This manual also contains advice about adjustments.

  • Page 4: Safety Instructions

    SODIKART distribution network. ATTENTION  The SODI SR4 is designed for safety and reliability in normal conditions of use. Before using it, please read this manual and carefully follow the instructions . By not doing so, you might be exposed to a risk of severe , even fatal injury, and your kart might suffer damages.

  • Page 5: 1- Getting Sr4 Out Of The Packing

    SR4 MANUAL 1- GETTING SR4 OUT OF THE PACKING STEERING COLUMN EXHAUST PIPE ASSY SUPPORT MAX / FA FRAME SR4 SEAT STEERING RIGHT SIDE POD WHEEL SUPPORT LEFT SIDE POD KG UNICO SUPPORT SIDE POD SLOTTED NUT KEY FUEL TANK...

  • Page 6: 2- Tools For Assembly

    SR4 MANUAL 2-TOOLING FOR ASSEMBLY AND ADJUSTMENT DESIGNATION DIAMETER PART NUMBER T handle wrench allen key OU 911.002 T handle wrench allen key 5 mm OU 911.003 T handle wrench allen key 6 mm OU 911.004 T handle wrench allen key 8 mm OU 911.005...

  • Page 7: Sequence Of Assembly

    SR4 MANUAL SEQUENCE OF ASSEMBLY AND INSTRUCTIONS STEERING COLUMN AND STEERING WHEEL (chapter 4). FUEL TANK AND OVERFLOW BOTTLE (chapter 5). SEAT AND STIFFENNERS (chapter 6). KG UNICO BODYWORK (chapter 7). SODI BODYWORK (chapter 8). NOTE : Recommended tightening torques : diam. 6 = 10 to 12 m.N diam.

  • Page 8: 4- Assembly Of The Steering Column And Of The Steering Wheel

    SR4 MANUAL 4- ASSEMBLY OF THE STEERING COLUMN AND STEERING WHEEL. THE SET CONSISTS IN :   one plastic steering column support (1).  One steering wheel support (2).  Two nassau panel supports (3).  One steering column (4).  One steering column support (5).
  • Page 9 SR4 MANUAL 4.4 TIGHTENING THE PLASTIC STEERING COLUMN SUPPORT.  Tighten the Chc M8x65 screw (8). 4.5 ASSEMBLY OF THE STEERING WHEEL . STRAIGHT PART FORWARD  Tighten the steering wheel (1) with the 3 FHc M6x30 screws, on the steering wheel support (2).

  • Page 10: 5- Assembly Of The Fuel Tank And Of The Overflow Bottle

    SR4 MANUAL 5- ASSEMBLY OF THE FUEL TANK AND OF THE OVERFLOW BOTTLE.  Insert the fuel tank between the steering column support (1) and the steering column (2) (see pictures )  Tighten with the fly nut (3)  Insert the overflow bottle (4) between the nassau pannel supports (5).

  • Page 11: 6- Assembly Of The Seat And Of The Seat Stiffeners

    6-ASSEMBLY OF THE SEAT AND SEAT STIFFENERS. Measurements given below correspond to the standard adjustment of the seat, recommended by SODIKART, for the SR4. Get the seat supports (1) closer , or wider, 4 FIXING POINTS depending on the seat size.
  • Page 12 SR4 MANUAL 2 DISTANCE BETWEEN THE REAR AXLE AND THE MIDDLE OF THE ROUND REAR EDGE OF THE SEAT. 220 mm Measure from the middle of the rounded edge. 6-3 DISTANCE BETWEEN THE AXIS OF THE LEFT SIDE STUB AXLE FORK AND THE MIDDLE OF THE REAR ROUNDED EDGE OF THE SEAT.
  • Page 13 9- Tighten both upper and lower end. For screws and bolts references, refer to the spare parts catalogue . FOR OTHER TYPES OF STIFFENERS , PLEASE REFER TO THE SR4 SPARE PARTS CATALOGUE OR TO THE ITAKA CATALOGUE - 12 -...

  • Page 14: 7-Assembly Of The Kg Unico Body Work

    SR4 MANUAL 7-ASSEMBLY OF THE KG UNICO BODY WORK. 7-1 PREPARING THE KG UNICO SUPPORTS. In order to comply with the CIK/FIA rules , carefully prepare the supports as indicated below. ( Measurements in mm ) SPOILER LOWER SUPPORT SPOILER UPPER SUPPORT End to cut DRILL 6.5 MM DIAM HOLE,...
  • Page 15 SR4 MANUAL 7-2 ASSEMBLY OF THE SIDE POD ON IT’S SUPPORT PIC 1 (PIC 1)  Place the side pod on its support.  Adjust the distance of 10 mm (1) as shown in the picture.  Mark the first point to be drilled.
  • Page 16  Mark the points to be drilled (10).  Drill to diameter 6.5.  Insert the screws.  Place the bolts and tighten. NOTE : For details and references of screws , bolts and washers, please refer to the SR4 spare parts catalogue . - 15 -...

  • Page 17: 8- Assembly Of The Sodi Body Work

     Place the shock absorber on the side pod support. ATTENTION : the rounded edges must face the upper part of the support . Assemble the absorber with 4 BHC M6x16 panhead screws and d6 D18 th 1.2 zinc flat washers under the screw heads . ( detail in SR4 spare parts catalogue ).
  • Page 18 SR4 MANUAL  Drill two 6.5 mm diameter holes in the absorber , through the holes in the side pod. Remove the set “ side pod + side pod support “ from the frame. Assemble the side pod on the absorber ; screws and conical washers facing outside , bolts and d6 D18 th 1.2 washers facing inside.
  • Page 19 SR4 MANUAL 8.2 ASSEMBLY OF THE SPOILER AND THE NASSAU PANEL  Place the two shock absorbers on the lower spoiler support. Assemble the two absorbers with BHC M6x16 panhead screw + d6 D18 th 1.2 washer under the screw head.
  • Page 20 SR4 MANUAL  Lift the kart and tighten the spoiler on the support with BHC M6x16 screw. nylstop bolt BHC M6x16  Assemble the lower nassau support to the frame as shown , with a BHC M6x16 screw. Link the spoiler and the nassau together on the upper end of the lower nassau support with a BHC M6x16 screw.

  • Page 21: 9- Starting Your Sr4

    SR4 MANUAL 9- STARTING YOUR SR4 SAFETY INSTRUCTIONS TO THE PILOTS WARNING YOUR KART CAN ONLY BE DRIVEN ON A TRACK APPROVED EITHER BY CIK/FIA , OR YOUR LOCAL FEDERATION. PILOT PROTECTION Before going on the track , the pilot must wear the following protections : Integral helmet : CIK/FIA approved , fitting the pilot head size , with tightened strap and...

  • Page 22: 10- Table Of The Standard Adjustments

    SR4 MANUAL 10-STANDARD ADJUSTMENTS OF THE SR4 4mm+4mm STUB AXLE HEIGHT 4mm +2mm FRONT TRACKING WIDTH REAR TRACKING WIDTH 1400 1354 HIGH HIGH REAR AXLE POSITION POSITION OF MASSES TOPT POSITION OF EXCENTRICS 1° BOTTOM BOTTOM POSITION OF STEERING TIE...

  • Page 23: 11- Adjustment Of The Front End

    SR4 MANUAL 11- ADJUSTMENT OF FRONT WHEELS 11.1 ADJUSTMENT OF FRONT TRACKING WIDTH DRY TRACK  Place the rings on the slotted round nut side (1). 1X15 mm 3x5mm (1) DRY TRACK  For more grip forward , place one or two 5 mm rings on the chassis side.
  • Page 24 SR4 MANUAL 11.2 ADJUSTMENT OF FRONT WHEEL HEIGHT DRY TRACK  Place one 4mm spacer on top and one 4 mm + one 2 mm spacer at the bottom (1). (1) DRY TRACK 4+2mm WET TRACK  Place one 4 mm + one 4 mm spacers on top , and one 2 mm spacer at the bottom (2).
  • Page 25 SR4 MANUAL 11.3-ADJUSTMENT OF THE CAMBER AND OF THE CASTER DESCRIPTION OF THE ECCENTRIC. diam. 4 mm pin on the fork Marked slot 1 for 1° Eccentric ADJUSTMENT OF THE CASTER HIGH CASTER LOW CASTER CASTERSTER CHASSE FRONT FIG 2...

  • Page 26: Standard Adjustments

     Use the position fig 4. REDUCE THE CAMBER (fig 3)  Use position fig 3. FOR HIGH DEGREES ECCENTRICS TO BE USED IN EXTREME CONDITIONS, REFER TO THE ITAKA CATALOGUE NOTE : Some negative camber generally improves the performances of the SR4. - 25 -...
  • Page 27 SR4 MANUAL 11.4 ADJUSTMENT OF PARALLELISM Lay the kart on a trolley. 2. Place the adjustment tool (1) ( refer to the ITAKA catalogue ). 3. Loosen the lock nuts on each tie rod (2) . Attention ; on the stub axle side , lock nuts are ...
  • Page 28 SR4 MANUAL 11.5- ADJUSTMENT OF TIE RODS. ADJUSTMENT B-2 STANDARD ADJUSTMENT B-3  Adjustment B-3 is also commonly used . ADJUSTMENT A-2  Lighter steering NOT RECOMMENDED IN WET CONDITIONS - 27 -...

  • Page 29: 12- Adjustment Of The Rear End

    SR4 MANUAL 12- ADJUSTMENT OF REAR WHEELS 12-1 ADJUSTMENT OF HUBS Lay the kart on a trolley. AXLE 2. Remove the two wheels . 3. Measure the distance , from the basis of the hub to the axle edge. 4. Loosen the CHC (4) screws to allow the sliding of the hub on the axle.
  • Page 30 ( rain , humid track , cold with little gum track ). In order to get the best out of the SR4 , do not hesitate to test different stiffnesses of axle.  To guide your trials, see table next page.
  • Page 31 SR4 MANUAL AXLES DIAMETER 50 BLACK RANGE CHROMIUM RANGE ROTAX + 100 CC 125 CC BV ROTAX + 100 CC EXTRA FLEXIBLE FLEXIBLE MEDIUM T25BV STIFF EXTRA STIFF - 30 - -30-...

  • Page 32: 13- Adjustment Of The Seat

    SR4 MANUAL 13- ADJUSTMENT OF SEAT POSITION OF THE SEAT The position of the center of gravity has also a key influence on the behaviour of the kart. One can monitor this center of gravity by changing the position of the seat.

  • Page 33: 14- Tyres

    SR4 MANUAL 14- TYRES 14-1 CHANGING THE TYRES  (Fig.8) Fig8 Lay the kart on a trolley. 2. Lay the wheel on the tyre removal tool (OU942.002) 3. Once the edges of the tyre are separated from the rim on Direction of rotation both sides, remove the tyre with the tool (2) .
  • Page 34 SR4 MANUAL 14-2 TABLE OF THE RECOMMENDED TYRE PRESSURES ( in bar ). WET CONDITIONS : Little water : slightly drop the pressure from the recommended value. Much water : increase the pressure from the recommended value. ATTENTION  Systematically check the rims. If one of them shows damages, change it . Not doing so could lead to severe, or even fatal injuries.

  • Page 35: 15- Brake Pads Replacement

    SR4 MANUAL 15- CHANGING BRAKE PADS.  Unscrew the piston adjustment screw to its back stop (1).  Remove the 4 screws with springs (2).  Remove the safety pin (3).  Remove the pads ; insert the new ones(4) .

  • Page 36: 16- Bleeding Of The Brake System

    SR4 MANUAL 16- BLEEDING THE BRAKE SYSTEM 1- Take a petrol hose and put it on the bleed screw (3) . 2- Press the brake pedal (1 ) and maintain the pressure. 3- Open the bleed screw (3); liquid and air bubbles come out.

  • Page 37: 17- Cleaning The Chassis

    SR4 MANUAL 17- CLEANING THE CHASSIS The cleaning of the chassis and its components is to be done with a special cleaning product • ( refer to the ITAKA catalogue ) . Do not use other products on brake pads and brake callipers.

  • Page 38: 18- Maintenance Plan

    SR4 MANUAL 18- MAINTENANCE RECAP : Screws and bolts ( general )  :  Before each use, check the state of the screws and bolts . Pay a special attention to the ones directly linked to the safety of the kart : Stub axle screw.

  • Page 39: 19- Trouble Shooting

    SR4 MANUAL 19- TROUBLE SHOOTING . Brakes do not work : Is the pedal working correctly ( not blocked ) ? 2. Is the cap of the fluid reservoir tight  ? 3. is the level of the brake fluid correct ? 4.

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