Sodi SR5 User Maintenance Manual
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Sodi SR5 User Maintenance Manual

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USER MAINTENANCE GUIDE
JANUARY 2008
This document can not be reproduced or released without the sodikart authorization.
CONFIGURE THE KART ACCORDING TO THE GUIDE INSTRUCTIONS
USE SPARE PARTS OF SODIKART ORIGIN

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  • Page 1 USER MAINTENANCE GUIDE JANUARY 2008 This document can not be reproduced or released without the sodikart authorization. CONFIGURE THE KART ACCORDING TO THE GUIDE INSTRUCTIONS USE SPARE PARTS OF SODIKART ORIGIN...

  • Page 2: Table Of Contents

    SR5 MANUAL SUMMARY SR5 SAFETY INSTRUCTIONS PREPARING THE ASSEMBLY 1- GETTING SR5 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 SR5 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 Sr5 Out Of The Packing

    SR5 MANUAL 1- GETTING SR5 OUT OF THE PACKING SPOILER NASSEAU PANEL SR5 FRAME STEERING COLUMN ASSEMBLY STEERING WHEEL OVERFLOW BOTTLE KG LEFT SIDE POD RIGHT SIDE POD SUPPORT SEAT KG RIGHT SIDE POD LEFT SIDE POD SUPPORT FUEL TANK...

  • Page 6: 2- Tools For Assembly

    SR5 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 AND STIFFENNERS (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

    SR5 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 SR5 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

    SR5 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 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 SR5. Get the seat supports (1) closer, or wider, 4 FIXING POINTS depending on the seat size.
  • Page 12 SR5 MANUAL 2 DISTANCE BETWEEN THE REAR AXLE AND THE MIDDLE OF THE ROUND REAR EDGE OF THE SEAT. 210mm (8.27inch) 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 PIC 2 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 SR5 SPARE PARTS CATALOGUE OR TO THE ITAKA CATALOGUE - 12 -...

  • Page 14: 7-Assembly Of The Kg Bodywork

    SR5 MANUAL 7-ASSEMBLY OF THE KG BODYWORK. 7-1 PREPARING THE KG SUPPORTS. In order to comply with the CIK/FIA rules, carefully prepare the supports as indicated below. Do not respect the dimensions may lead to relegation during a race. 7-1-1 KG SIDE POD SUPPORT Cut 50mm the end of the side pod support.
  • Page 15 Place the screws (3) through the side pod (1) and the side pod support (2). Tighten the assembly with the nuts (4). Refer to the SR5 spare parts catalogue for the bolting 7-3 ASSEMBLY ON THE FRAME Check that the bushings are pushed in the frame.
  • Page 16 (3) with two screws and two nuts. Place the flanges (4) between the spoiler support (2) and (3), then lock. Refer to the SR5 spare parts catalogue for the bolting 7-7 ASSEMBLY OF THE NASSEAU PANEL Place the nasseau panel (1) on the nasseau panel upper support (2) and the nasseau panel lower support (3).

  • Page 17: 8- Starting Your Sr5

    SR5 MANUAL 8- STARTING YOUR SR5 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 18: 9- Table Of The Standard Adjustments

    SR5 MANUAL 9-STANDARD ADJUSTMENTS OF THE SR5 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 REAR AXLE POSITION / TIGHTENING OF THE...

  • Page 19: 10- Adjustment Of The Front End

    SR5 MANUAL 10- ADJUSTMENT OF FRONT WHEELS 10.1 ADJUSTMENT OF FRONT TRACKING WIDTH The adjustment of the front width is realized with several spacers (1 spacer of 15mm, and 3 spacers of 5mm for each stub axle.), and two hubs type (short hub: 60mm or long hub: 80mm).
  • Page 20 SR5 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 21 SR5 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 22 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 SR5. - 21 -...
  • Page 23 SR5 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 24 SR5 MANUAL 10.5- ADJUSTMENT OF TIE RODS. ADJUSTMENT B-3 ADJUSTMENT A-3 Lighter steering NOT RECOMMENDED IN WET CONDITIONS - 23 -...

  • Page 25: 11- Adjustment Of The Rear End

    SR5 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 26 A stiff axle suits low grip conditions (rain, humid track, cold with little gum track). In order to get the best out of the SR5, do not hesitate to test different stiffness of axle. To guide your trials, see table next page. - 25 -...
  • Page 27 AXLES DIAMETER 50 SR5 MANUA BLACK RANGE CHROMIUM RANGE EXTRA FLEXIBLE FLEXIBLE MEDIUM STIFF EXTRA STIFF - 26 - - 26 -...

  • Page 28: 12- Adjustment Of The Seat

    SR5 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 29: 13- Tyres

    SR5 MANUAL 13- TYRES 13-1 CHANGING THE TYRES Lay the kart on a trolley. 2. Lay the wheel on the tire removal tool (OU942.002) 3. Once the edges of the tire are separated from the rim on both sides, remove the tire with the tool (2).
  • Page 30 SR5 MANUAL 13-2 TABLE OF THE RECOMMENDED TYRE PRESSURES (in bar). PRESSURES SLICK TYRES COLD 20° WARM CATEGORIES BRAND TYPE FRONT REAR FRONT REAR ICA / JUNIOR / ICC BRIDGE 0,55 0,55 0,80 0,80 FA ELITE BRIDGE 0,55 0,55 0,75...

  • Page 31: 14- Brake Pads Replacement

    SR5 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 32: 15- Bleeding Of The Brake System

    SR5 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 33: 16- Cleaning The Chassis

    SR5 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 34: 17- Maintenance Plan

    SR5 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 35: 18- Trouble Shooting

    SR5 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 36 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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