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Sodi DD2 User Maintenance Manual

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USER MAINTENANCE GUIDE
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  • Page 1 USER MAINTENANCE GUIDE...

  • Page 2: Table Of Contents

    DD2 MANUAL SUMMARY DD2 SAFETY INSTRUCTIONS PREPARING THE ASSEMBLY 1- GETTING DD2 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 This manual contains instructions for the assembly and the maintenance of your kart, according to the rules of the art. Safety on a track is a personal and collective matter at the same time: taking care of your DD2 is the first guarantee of your safety and of the safety of other pilots.

  • Page 4: Safety Instructions

    The SODI chassis can only be used on an approved track and by a driver who is in possession of a valid membership card of the go-kart’s federation of his own country.

  • Page 5: 1- Getting Dd2 Out Of The Packing

    DD2 MANUAL 1- GETTING DD2 OUT OF THE PACKING FIXING KIT SPOILER UPPER SPOILER SUPPORT LOWER SPOILER UPPER NASSAU SUPPORT PANNEL STEERING COLUMN LOWER NASSAU ASSY PANNEL STEERING WHEEL OVERFLOW BOTTLE KG UNICO SIDE RIGHT SIDE POD SUPPORT SEAT FUEL TANK...

  • Page 6: 2- Tools For Assembly

    DD2 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

    STEERING COLUMN AND STEERING WHEEL (chapter 4). FUEL TANK AND OVERFLOW BOTTLE (chapter 5). SEAT (chapter 6). KG UNICO BODYWORK (chapter 7). SODI BODYWORK (chapter 8). NOTE: Recommended tightening torques: Ø6 = 10 to 12 m.N Ø8 = 12 to 24 m.N Ø10 = 24 to 48 m.N...

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

    DD2 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 DD2 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

    DD2 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 panel supports (5).

  • Page 11: 6- Assembly Of The Seat

    DD2 MANUAL 6- ASSEMBLY OF THE SEAT. FIXING POINTS Measurements given below correspond to the standard adjustment of the seat, recommended by SODIKART, for the DD2. Get the seat supports (1) closer, or wider, depending on the seat size. Use the shims of the seat fixing kit to get a good fit.
  • Page 12 DD2 MANUAL 2 DISTANCE BETWEEN THE REAR AXLE AND THE MIDDLE OF THE ROUND REAR EDGE OF THE SEAT. 210mm Measure from the middle 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: 7-Assembly Of The Kg Unico Body Work

    DD2 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 SIDE POD SUPPORT End to cut DRILL 6.5 MM DIAM HOLE,...
  • Page 14 DD2 MANUAL 7-2 ASSEMBLY OF THE SIDE POD ON its SUPPORT (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. Drill a hole, diameter 6.5 mm.
  • Page 15 Mark the points to be drilled (10). Drill to diameter 6.5. Insert the screws. Place the bolts and tighten. PIC 7 NOTE: For details and references of screws, bolts and washers, please refer to the DD2 spare parts catalogue. - 14 -...

  • Page 16: 8- Starting Your Dd2

    DD2 MANUAL 8- STARTING YOUR DD2 SAFETY INSTRUCTIONS TO THE PILOTS WARNING 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 GO-KART’S FEDERATION OF HIS OWN COUNTRY.

  • Page 17: 9- Table Of The Standard Adjustments

    DD2 MANUAL 9-STANDARD ADJUSTMENTS OF THE DD2 4mm+4mm STUB AXLE HEIGHT 4mm +2mm 3 rings inside All rings inside Short hub 60mm Long hub 80mm FRONT TRACKING WIDTH REAR TRACKING WIDTH 1360 to 1370mm 1400mm POSITION OF MASSES Eccentrics 1°...

  • Page 18: 10- Adjustment Of The Front End

    DD2 MANUAL 10- ADJUSTMENT OF FRONT WHEELS 10.1 ADJUSTMENT OF FRONT TRACKING WIDTH DRY TRACK SHORT HUBS On dry track, place 3 rings inside with L60mm. 3x5mm 1X15m For more grip forward, add one or two 5 mm rings on the chassis side.
  • Page 19 DD2 MANUAL 10.2 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 20: Standard Adjustments

    DD2 MANUAL 10.3-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 FRONT FRONT FIG 2 FIG 1...
  • Page 21 Use the same position fig 4 and change the eccentric of 1° by the eccentric of 2°. 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 DD2. - 20 -...
  • Page 22 DD2 MANUAL 10.4 ADJUSTMENT OF PARALLELISM Lay the kart on a trolley. Place the adjustment tool (1) (refer to the ITAKA catalogue). Loosen the lock nuts on each tie rod (2). Attention: on the stub axle side, lock nuts are right hand;...
  • Page 23 DD2 MANUAL 10.5- ADJUSTMENT OF TIE RODS. ADJUSTMENT B-3 ADJUSTMENT A-3 Lighter steering. NOT RECOMMENDED IN WET CONDITIONS - 22 -...

  • Page 24: 11- Adjustment Of The Rear End

    DD2 MANUAL 11- ADJUSTMENT OF REAR WHEELS 11-1 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 25 DD2 MANUAL 11-2 TYPE OF AXLE The stiffness of the axle plays an important part in the behavior of the kart. AXLE DIAMETER 50, STANDARD MD 25 Available in the ITAKA catalogue. AXLE DIAMETER 50, FLEXIBLE MD 20 Available in the ITAKA catalogue.

  • Page 26: 12- Adjustment Of The Seat

    DD2 MANUAL 12- ADJUSTMENT OF SEAT POSITION OF THE SEAT The position of the center of gravity has also a key influence on the behavior of the kart. One can monitor this center of gravity by changing the position of the seat.

  • Page 27: 13- Tyres

    DD2 MANUAL 13- TYRES 13-1 CHANGING THE TYRES Lay the kart on a trolley. 2. Lay the wheel on the tire removal tool (Available on the ITAKA catalogue) 3. Once the edges of the tire are separated from the rim on both sides, remove the tire with the tool (2).
  • Page 28 DD2 MANUAL 13-2 TABLE OF THE RECOMMENDED TYRE PRESSURES (in bar). PRESSURES SLICK TYRES COLD 20° WARM CATEGORIES BRAND TYPE FRONT REAR FRONT REAR BRIDGE 0,65 0,85 MOJO 0,65 0,85 WET TYRES COLD 20° WARM BRIDGE MOJO WET CONDITIONS: Little water: slightly drop the pressure from the recommended value.

  • Page 29: 14- Brake Pads Replacement

    DD2 MANUAL 14- 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). Insert the safety pin (3).

  • Page 30: 15- Bleeding Of The Brake System

    DD2 MANUAL 15- 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 31: 16- Cleaning The Chassis

    DD2 MANUAL 16- 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 the product on brake pads and brake calipers.

  • Page 32: 17- Maintenance Plan

    DD2 MANUAL 17- 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 33: 18- Trouble Shooting

    DD2 MANUAL 18- 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. Are the hoses correctly connected? 5.
  • Page 34 TRACK: DATE: TRIAL TIMES Tyre type: Diameter: PILOT: TRIAL: TIME: TRACK: PRESSURE START State of the track: °C CHASSIS: Stub axle height : Caster and camber : Partial 1 Partial 2 Partial 3 Partial 4 Parallelism : Seat position : Height : Dist- axle : Dist- fork :...

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