Sodi SIGMA User Maintenance Manual
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Sodi SIGMA User Maintenance Manual

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Manuel d'entretien et d'utilisation
user maintenance guide
MAN_Sigma_16_GB_00

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Summary of Contents for Sodi SIGMA

  • Page 1 Manuel d'entretien et d'utilisation user maintenance guide MAN_Sigma_16_GB_00...
  • Page 2 Manuel d'entretien et d'utilisation user maintenance guide Avant-propos Ce document a été préparé sur la base des spécifications les plus récentes à la date de publication. Sodikart se réserve toutefois le droit d’apporter des changements afin de maintenir sa politique d’amélioration continue de ses produits.

  • Page 3: Table Of Contents

    Manuel d'entretien et d'utilisation user maintenance guide Table des matières Table of contents 1 - General ............4 6 - Maintenance..........24 1.1 - Warning ..............4 6.1 - Brakes - Usual maintenance ........ 24 6.1.1 - Fluids and lubricants ......... 24 1.2 - General precautions ..........

  • Page 4: General

    ► The SODI chassis can only be used on an ● In case of any doubt on the way a particular operation of approved track and by a driver who is in maintenance must be made, ask for advice from a more possession of a valid membership card of the experienced mechanic.

  • Page 5: Meaning Of The Flags

    Manuel d'entretien et d'utilisation user maintenance guide 1.3.1 - Meaning of the flags meaning Summary of the main safety Green flag instructions for the driver. Do not apply the throttle before this flag is out Summary of the main safety Black flag instructions for the driver.

  • Page 6: Reception

    Manuel d'entretien et d'utilisation user maintenance guide 2 - Reception 2.1 - Main components Legend Frame pre-equipped Spoiler Spoiler brackets Nassau panel Fuel tank Steering wheel Rims Side pod Left side pod bracket 10 Right side pod bracket 11 Seat 12 Seat stiffeners 13 Rear bumper ●...

  • Page 7: Tooling For Assembly And Adjustment

    Manuel d'entretien et d'utilisation user maintenance guide 2.2 - Tooling for assembly and adjustment 2.3 - Maintenance products Designation Ø Part No Designation Part No OU931.010 1 Ring centering device(Hub) (*) LU834.003 1 Motul Motowash OU931.006 2 Stub axle screw centering device (*) LU833.00M 2 WD40 3 Wrench...

  • Page 8: Assembly

    Manuel d'entretien et d'utilisation user maintenance guide 3 - Assembly 3.3 - Positioning of the safety brake cable 3.1 - Precautions and recommendations ● tightening torque Ø 6 = 10 to 12 mn. ● tightening torque Ø 8 = 12 to 23 mn. ●...

  • Page 9: Assembly Of The Steering Column And Steering Wheel

    Manuel d'entretien et d'utilisation user maintenance guide step 2 Legend Overflow bottle Legend Nassau panel support Overflow bottle support Ball joint Overflow bottle hose Fastener clip Return Petrol tank hose ● Insert the threaded end of the steering column in the ball 10 Red plug joint (1).

  • Page 10: Assembly Of The Seat

    Manuel d'entretien et d'utilisation user maintenance guide step 4 Ground clearance Legend Seat Legend Frame tubes Support ● Adjust the bottom of the seat (1) with the lower face of the Screw frame tubes (2). Top of the wheel Steering column seat position ●...

  • Page 11: Assembly Of The Seat Stiffeners

    Manuel d'entretien et d'utilisation user maintenance guide 3.7 - Assembly of the seat stiffeners 3.9 - Assembly of the bodywork ● See chapter “standard settings” for the ● For screws and nuts references, refer to the spare assemblies’ dimensions which correspond to the parts.
  • Page 12 Manuel d'entretien et d'utilisation user maintenance guide step 3 step 5 Legend Legend Spoiler Spoiler upper support Fixing plate Screw Screw ● Assemble the fixing plates (2) on the spoiler (1) using ● Place the spoiler upper support (1) on the outer face of the screws (3).

  • Page 13: Mounting The Rear Protections

    Manuel d'entretien et d'utilisation user maintenance guide step 7 3.10 - Mounting the rear protections Legend Legend Upper support Mounting kit Lower support Bumper support Clamp Tube chassis ● Place the spoiler (1) between the spoiler supports (2) and ● Assemble the mounting kit (1) with the element of the (3).

  • Page 14: Mounting The Rear Protections Dd2

    Manuel d'entretien et d'utilisation user maintenance guide 3.11 - Mounting the rear protections DD2 Legend Rear protection Legend Rear protection support Tire protection Washer Rear protection 10 Screw Screw + nut ● Place the rear protection (7) on the rear protection support Screw + nut (8).

  • Page 15: Commissioning

    Manuel d'entretien et d'utilisation user maintenance guide 4 - Commissioning 4.1 - Safety instructions to the pilots ► Your kart can only be driven on a track approved by CIK/FIA, or your local federation and by a driver who is in possession of a valid membership card of the kart’s federation of his own country.

  • Page 16: Adjustments

    5.1 - Standard adjustments dry track wet track Stub axle height sigma rs - kz - dd2 sigma rs - kz - dd2 A = 2 + 4 + 4 mm A = 4 mm B = 2 + 4 mm...
  • Page 17 Position of steering tie rods ends sigma rs short tie rod sigma rs short tie rod sigma kz - dd2 long tie rod sigma kz - dd2 short tie rod Front stabilizer sigma rs - kz - dd2...

  • Page 18: Adjustment Of Front Wheels

    Manuel d'entretien et d'utilisation user maintenance guide 5.2 - Adjustment of front wheels wet track (with front brake) 5.2.1 - Adjustment of front tracking width The adjustment of the front width is realized with several spacers (spacer of 15 mm, and spacers of 5 mm for each stub axle), and 2 hubs type (short hub: 90 mm or long hub: 100 mm).

  • Page 19: Adjustment Of The Caster

    Manuel d'entretien et d'utilisation user maintenance guide 5.2.3 - Adjustment of the caster adjustment of the caster - low Front description of the eccentric. Front Rear Rear Eccentrics on top: ● The mark is positioned on the opposite side of the screw. Legend (Towards the rear of the chassis).

  • Page 20: Adjustment Of The Camber

    Manuel d'entretien et d'utilisation user maintenance guide 5.2.4 - Adjustment of the camber camber - more negative Front ● Use the eccentrics at the bottom. description of the eccentric. Front Rear Eccentrics at the bottom: ● The mark is positioned towards the inside of the chassis. standard adjustment Rear ●...

  • Page 21: Front Wheel Alignment

    Manuel d'entretien et d'utilisation user maintenance guide 5.2.5 - Front wheel alignment A = B ● Turn the steering wheel to put stub axle in position (4), measure the dimension C. ● Turn the wheels in the opposite direction and measure the dimension C for the second wheel.

  • Page 22: Adjustment Of Rear Wheels

    Manuel d'entretien et d'utilisation user maintenance guide 5.3 - Adjustment of rear wheels 5.3.2 - Position of rear axle 5.3.1 - Adjustment of hubs On most tracks, the correct axle position is middle position. This corresponds to a low position of the chassis relative to the ground.

  • Page 23: Adjustment Of Seat

    Manuel d'entretien et d'utilisation user maintenance guide 5.4 - Adjustment of seat 5.5 - Adjustment of the brake distributor The position of the centre of gravity has also a key influence The brake distributor allow to monitor the bracking power on the behaviour of the kart.

  • Page 24: Maintenance

    Manuel d'entretien et d'utilisation user maintenance guide 6 - Maintenance 6.1 - Brakes - Usual maintenance 6.1.1 - Fluids and lubricants Do not use any oil-based lubricant, which would cause swelling of the rubber parts. SODIKART recommends the use of DOT 4 brake fluid (refer to the ITAKA web site for product references) and recommends that the disc and pads should be cleaned using brake cleaner only (refer to the ITAKA web site for product references).

  • Page 25: Replacing Brake Pads On The D18 4-Piston Calipers (Front)

    Manuel d'entretien et d'utilisation user maintenance guide 6.1.3 - Replacing brake pads on the D18 4-piston 6.1.4 - Replacing brake pads on the D20 4-piston calipers (front) calipers (rear) 4 Nm Loctite 648 Legend Legend Adjustment screw Brake pad Return screw Piston Spring (not on KZ and DD2) Calliper body...

  • Page 26: Adjusting The Gap Between The Pads And The Disc

    Manuel d'entretien et d'utilisation user maintenance guide 6.1.5 - Adjusting the gap between the pads and the 6.1.7 - Bleeding the front brake circuit disc 1 mm 1 mm Legend Bleeder screw Legend Adjustment screw Brake pedal Disc Diaphragm ● Use a pipe and a container to collect the used fluid. ●...

  • Page 27: Bleeding The Rear Brake Circuit

    Manuel d'entretien et d'utilisation user maintenance guide ● Loosen the bleeder screw (1) of the calliper. Brake fluid ● We recommend that you drain and refill the should flow out. Retighten the bleed screw, and repeat this brake circuit after every brake pad change. step several times to feed the circuit properly.

  • Page 28: Bleeding The Steering Wheel Controlled Front Brake Circuit

    Manuel d'entretien et d'utilisation user maintenance guide 6.1.9 - Bleeding the steering wheel controlled front ● We recommend that you drain and refill the brake circuit brake circuit after every brake pad change. This will allow you to maintain optimum braking performance.

  • Page 29: Brakes - Workshop Maintenance

    Manuel d'entretien et d'utilisation user maintenance guide 6.2 - Brakes - Workshop maintenance reassembly 6.2.1 - Replacing calliper seals / 4 piston caliper pistons D18 (front) PFG110 This operation must be performed by a Sodikart dealer. removing PFG110 Legend O-ring Piston Gasket Groove...

  • Page 30: Replacing Calliper Seals / 4 Piston Caliper Pistons D20 (Rear)

    Manuel d'entretien et d'utilisation user maintenance guide 6.2.2 - Replacing calliper seals / 4 piston caliper pistons D20 (rear) This operation must be performed by a Sodikart dealer. removing Legend 12 Clip 13 Piston stop 14 O-ring ● Remove the piston stop clip (12) using fine pliers or a scriber.
  • Page 31 Manuel d'entretien et d'utilisation user maintenance guide PFG110 Legend Legend 12 Clip 13 Piston stop 13 Piston stop 14 O-ring ● Place the piston stop clip (12) in the groove of the piston ● Apply PFG110 grease to a new O-ring (14). stop (13).

  • Page 32: Replacing Master Cylinder Seals And Pistons

    Manuel d'entretien et d'utilisation user maintenance guide 15 Nm Loctite 221 8 Nm Legend Piston Gasket Seal Legend Bleeder screw ● Remove the gasket (6) and the seal (7). Mounting screw ● Clean the body of the master cylinder. Do not use WD40 or ●...

  • Page 33: Replacing The Front Master Cylinder Pistons

    Manuel d'entretien et d'utilisation user maintenance guide 6.2.4 - Replacing the front master cylinder pistons This operation must be performed by a Sodikart dealer. PFG110 Legend Screw Legend Handle Pressure pin Push rod Dust cover Piston Piston lever removing ● Remove the screw (1) and the nut (2). ●...

  • Page 34: Tyres

    Manuel d'entretien et d'utilisation user maintenance guide 6.3 - Tyres ● Always change the whole set whenever a tyre is changed (fronts, rears, or all the set). ● 6.3.1 - Tyres change Always place the tyres so that they rotate in the direction indicated on the tyre wall.

  • Page 35: Table Of The Recommended Tyre Pressures

    Manuel d'entretien et d'utilisation user maintenance guide 6.3.2 - Table of the recommended tyre pressures Pressure (bar) Slick tyres Cold (20°) Warm Categories Brand Type Front Rear Front Rear KF2 –SLICK VEGA KF3 –SLICK VEGA VEGA 0,65 0,85 0,85 VEGA 0,45 0,75 0,75...

  • Page 36: Maintenance Summary

    Manuel d'entretien et d'utilisation user maintenance guide 6.5 - Maintenance summary 7 - Trouble shooting 6.5.1 - Bolting 7.1 - The kart will not brake Before each use, check the state of the screws and bolts. Pay 1. Is the brake pedal free? a special attention to the ones directly linked to the safety of 2.

  • Page 37: Index

    Manuel d'entretien et d'utilisation user maintenance guide 8 - Index Axle..................22 Rear bumper................6 Reservoir ................28 Rim ..................34 Ball joint ................... 9 Rims ..................6 Brake bleeding system ............7 Brake cleaner ................ 24 brake distributor ..............23 seat ..................

  • Page 38: Homologation

    COMMISSION INTERNATIONALE DE KARTING - FIA CADRE DU CHÂSSIS / CHASSIS FRAME Constructeur Manufacturer SODIKART Marque Make SODI Modèle Model ST30 KF4 – KF3 – KF2 – KZ2 – KZ1 – ICE Catégorie Category Durée de l’homologation Validity of the homologation...
  • Page 39 Manuel d'entretien et d'utilisation user maintenance guide BRP-ROTAX CHASSIS APPROVAL FORM Manufacturer SODIKART Chassis model SODI DD2 CIK FIA 41/CH/14 ROTAX MAX Challenge, 125 MAX DD2 class Category without limitation Validity of approval 2013 10 17 Date of approval by BRP-ROTAX...
  • Page 40 Manuel d'entretien et d'utilisation user maintenance guide Track: Trial: Pilot: Date: Time: TRACK CHASSIS State of the track: Stub axle height: Temperature: Caster / Camber: Parallelism: Seat position: ENGINE Carburator type: ● Height: ● Distance axle: Adjustments: ● Distance fork: Exhaust type: Masses: Gear ratio:...

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