Sodi RS3 KZ DD2 User And Maintenance Manual
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Sodi RS3 KZ DD2 User And Maintenance Manual

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USER
AND MAINTENANCE MANUAL
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Summary of Contents for Sodi RS3 KZ DD2

  • Page 1 USER AND MAINTENANCE MANUAL MAN_Sigma_EN_02...
  • Page 2 USER AND MAINTENANCE MANUAL Foreword This document is based on the most recent specifications at the time of publication. Sodikart nevertheless reserves the right to apply changes in order to uphold its policy of continuous improvement of its products. If modifications have been made in the meantime, there may be certain differences between the content of the user guide and the go-kart you own.

  • Page 3: Table Of Contents

    USER AND MAINTENANCE MANUAL Table of contents General ..........4 Maintenance ........25 1.1 - Warning ..............4 6.1 - Brakes - Usual maintenance......... 25 6.1.1 - Fluids and lubricants .........25 1.2 - General precautions ..........4 6.1.2 - Frequency of cleaning and maintenance ..25 1.3 - Safety instructions ..........

  • Page 4: General

    ► The SODI chassis can only be used on an experienced mechanic. approved track and by a driver who is in possession of a valid membership card of 1.2 - General precautions...

  • Page 5: Meaning Of The Flags

    USER AND MAINTENANCE MANUAL 1.3.1 - Meaning of the flags 1.3.2 - Safety stickers Location Green flag Do not apply the throttle before this flag is out. Black flag Driver is to proceed to the pit lane immediately, wait for staff instructions. Blue flag A faster driver is behind you.

  • Page 6: Reception

    USER AND MAINTENANCE MANUAL 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

    USER AND MAINTENANCE MANUAL 2.2 - Tooling for assembly and adjustment 2.3 - Maintenance products Designations Ø Parts N° 1 Ring centring device (Hub) (*) OU931.010 2 Stub axle screw centring device (*) OU931.012 3 Wrench 4 T-shaped Allen key 3 OU911.001 4 T-shaped Allen key 4 OU911.002...

  • Page 8: Assembly

    USER AND MAINTENANCE MANUAL Assembly ● Always attach the stabilisers to the frame with a sleeve at each side. 3.1 - Precautions and recommendations 3.3 - Positioning of the safety brake cable ● Tightening torque Ø 6 = 10 to 12 Nm. ●...

  • Page 9: Assembly Of The Fuel Tank And Of The Overflow Bottle

    USER AND MAINTENANCE MANUAL ► Securing clips (1) of the brake control with a ● Check the presence of the diver under the red plastic tie Rilsan (2). plug. 3.5 - Assembly of the steering column and 3.4 - Assembly of the fuel tank and of the overflow steering wheel bottle ●...

  • Page 10: Assembly Of The Seat

    USER AND MAINTENANCE MANUAL ● Tighten the assembly. ► A bad assembly or a bad adjustment of ● Put the fastener clip (3). the steering system can lead to accidents. Systematically check the tightening of the Étape 3 system and its adjustment. 3.6 - Assembly of the seat ●...

  • Page 11: Assembly Of The Seat Stiffeners

    USER AND MAINTENANCE MANUAL Seat Position Upper end Legend Seat stiffener ● Position the seat following dimension B. Screw + conical washer + nut ● Drill a 8.5 mm diameter hole in the seat. ● Place the upper end of the stiffener. ●...

  • Page 12: Assembly Of The Bodywork

    USER AND MAINTENANCE MANUAL 3.8 - Assembly of the bodywork Étape 3 ● For screws and nuts references, refer to the spare parts catalogue. Étape 1 Legend Lower support for Nassau panel Screw ● Tighten the lower support on the frame with the screws Legend (2) and the nuts (3).
  • Page 13 USER AND MAINTENANCE MANUAL Étape 5 Étape 7 Legend Legend Spoiler lower support Mounting flange spoiler Front cross member Upper support Screw Lower support Screw ● Insert the spoiler lower support (1) into the front cross member of the frame (2). ●...

  • Page 14: Mounting The Rear Protections

    USER AND MAINTENANCE MANUAL Étape 9 3.9 - Mounting the rear protections Legend Mounting kit Bumper support Tube chassis ● Assemble the mounting kit (1) with the element of the bumper support (2). ● Mount the assembly in the tube chassis (3), tighten with Legend the screw of the fixing kit (1).

  • Page 15: Commissioning

    USER AND MAINTENANCE MANUAL 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

    USER AND MAINTENANCE MANUAL Adjustments 5.1 - Standard adjustments Dry track Wet track Stub axle height Sigma RS - KZ - DD2 Sigma RS - KZ - DD2 A = 6 mm A = 10 mm B = 8 mm B = 4 mm Front tracking width Sigma RS...
  • Page 17 USER AND MAINTENANCE MANUAL Dry track Wet track 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 Sigma RS - KZ - DD2 Remove or place the stabilizer following...

  • Page 18: Adjustment Of Front Wheels

    USER AND MAINTENANCE MANUAL Wet track (with front brake) 5.2 - Adjustment of front wheels 5.2.1 - Adjustment of front tracking width The adjustment of the front width is realised 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

    USER AND MAINTENANCE MANUAL 5.2.3 - Adjustment of the caster Adjustment of the caster - Low Description of the eccentric FRONT Front Rear REAR Eccentrics on top: Legend ● The mark is positioned on the opposite side of the screw Eccentric (towards the rear of the chassis).

  • Page 20: Adjustment Of The Camber

    USER AND MAINTENANCE MANUAL 5.2.4 - Adjustment of the camber Camber - More negative Front ● Ideally adjust 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: Quick Adjustment Of Caster/Camber Pill

    USER AND MAINTENANCE MANUAL 5.2.5 - Quick adjustment of caster/camber pill ● Remove both screws. ● Unlock axle of the front stub. ● Rotate the 2 caster/camber pills to adjust the caster or camber angle. Adjustments Caster angle: Top caster/camber pill Camber angle: Low caster/camber pill MAN_Sigma_EN_02...

  • Page 22: Front Wheel Alignment

    USER AND MAINTENANCE MANUAL 5.2.6 - Front wheel alignment ● Turn the steering wheel to put the 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 23: Adjustment Of Rear Wheels

    USER AND MAINTENANCE MANUAL 5.3 - Adjustment of rear wheels 5.3.2 - Position of rear axle 5.3.1 - Adjustment of hub On most tracks, the correct axle position is the middle one. This corresponds to a low position of the chassis relative to the ground.

  • Page 24: Tightening Torque For Rear Axle Bearing

    USER AND MAINTENANCE MANUAL 5.3.4 - Tightening torque for rear axle bearing 4) Seat higher ● Increases the grip. 8 Nm ● To be tried in wet conditions. ● Always use a seat tightener. One on the left hand side and one on the right hand side give an optimal performance on almost all types of tracks.

  • Page 25: Maintenance

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

  • Page 26: Replacing Brake Pads On The D18 4-Pistons Callipers (Front)

    USER AND MAINTENANCE MANUAL 6.1.3 - Replacing brake pads on the D18 4-pistons 6.1.4 - Replacing brake pads on the D20 4-pistons callipers (front) callipers (rear) 4 Nm Loctite 648 Legend Legend Adjustment screw Brake pad Return screw Piston Spring Calliper body Brake pad ●...

  • Page 27: Replacing Brake Pads On The D28 2-Pistons Callipers (Rear)

    USER AND MAINTENANCE MANUAL 6.1.5 - Replacing brake pads on the D28 2-pistons 6.1.6 - Adjusting the gap between the pads and the callipers (rear) disc 1 mm 1 mm Legend Adjustment screw Disc ● Tighten or loosen the screw (1) to obtain a 1 mm gap Legend between the disc (2) and the pad (3).

  • Page 28: Tightness Of The Brake Hose Screew

    USER AND MAINTENANCE MANUAL Niveau Max. 6.1.8 - Tightness of the brake hose screew Max. Level ● Top up the brake fluid in the master cylinder to its 20 Nm maximum level, and retighten the cap (2) and the diaphragm (4). ►...

  • Page 29: Bleeding The Rear Brake Circuit

    USER AND MAINTENANCE MANUAL ► An air bubble in the brake system can lead to 6.1.10 - Bleeding the rear brake circuit a partial or total loss of brake and may lead to a serious or even fatal injury. ► Leaks in the brake system may lead to a serious or even fatal injury.

  • Page 30: Cleaning

    USER AND MAINTENANCE MANUAL 6.1.11 - Cleaning 6.2 - Brakes - Workshop maintenance Brake should be cleaned using a dry cloth and brake cleaner 6.2.1 - Replacing calliper seals / 4 pistons calliper D18 only. (front) Do not use WD40 or other greasy products to clean the callipers and brake discs.
  • Page 31 USER AND MAINTENANCE MANUAL Reassembly ● Always use new seals and clips. ● Replace any defective parts, using only original SODIKART parts. ● Install a new set of pads after any servicing PFG110 of the callipers. PFG110 Legend O-ring Piston Gasket Groove ●...

  • Page 32: Replacing Calliper Seals / 4 Pistons Calliper Pistons D20 (Rear)

    USER AND MAINTENANCE MANUAL 6.2.2 - Replacing calliper seals / 4 pistons calliper pistons D20 (rear) This operation must be performed by a SODIKART dealer. Removing Legend 11 Clip 12 Piston stop 13 O-ring ● Remove the piston stop clip (11) using fine pliers or a scriber.
  • Page 33 USER AND MAINTENANCE MANUAL PFG110 Legend Legend Clip Piston stop Piston stop O-ring ● Place the piston stop clip (1) in the groove of the piston ● Apply PFG110 grease to a new O-ring (2). stop (2). ● Place the O-ring (2) in the piston stop groove (1). ●...

  • Page 34: Replacing Calliper Seals / 2 Pistons Calliper D28 (Rear)

    USER AND MAINTENANCE MANUAL 6.2.3 - Replacing calliper seals / 2 pistons calliper D28 (rear) This operation must be performed by a 25 Nm SODIKART dealer. Removing Loctite 268 16 Nm Legend Mounting screw Bleeder screw ● Apply three drops 120° apart of loctite alongside the screw thread (2).

  • Page 35: Replacing Master Cylinder Seals And Pistons

    USER AND MAINTENANCE MANUAL Reassembly ● Always use new seals and clips. ● Replace any defective parts, using only original SODIKART parts. ● Install a new set of pads after any servicing of the callipers. 6.2.4 - Replacing master cylinder seals and pistons This operation must be performed by a SODIKART dealer.
  • Page 36 USER AND MAINTENANCE MANUAL ► Do not use any cleaning product that could damage the seals. A brake fluid leak could appear, causing a serious or fatal accident Reassembly PFG110 Legend Legend Piston Gasket Pressure pin Seal Dust cover ● Apply PFG110 grease to the gasket (2) and the seal (3). Piston lever ●...

  • Page 37: Tyres

    USER AND MAINTENANCE MANUAL 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 38: Cleaning The Chassis

    USER AND MAINTENANCE MANUAL 6.4 - Cleaning the chassis 6.5 - Maintenance summary The cleaning of the chassis and its components is to be 6.5.1 - Bolting done with a special cleaning product (refer to the ITAKA web site). Do not use the product on brake pads and brake Before each use, check the state of the screws and bolts.

  • Page 39: Troubleshooting

    USER AND MAINTENANCE MANUAL Troubleshooting 7.1 - The kart will not brake 1. Is the brake pedal free? 2. Is the hydraulic brake pump container cap fully tightened? 3. Is there enough brake fluid? 4. Are the hoses correctly connected? 5.

  • Page 40: Index

    USER AND MAINTENANCE MANUAL Index Axle..................23 Maintenance products ............7 Manometer ................7 Master cylinder ..............35 Bleeder screw ..............28 Bleeding................28 Bodywork ................4 Nassau ..............6, 9, 12, 14 Bolting.................38 Brake ..................24 O-ring..............31, 32, 33, 35 Brake bleeding system ............7 Overflow bottle..............9 Brake cleaner ..............25 Brake distributor ..............24 Brake fluid................25 Pad ..................27...

  • Page 41: Homologation

    USER AND MAINTENANCE MANUAL Homologation MAN_Sigma_EN_02...
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  • Page 50 USER AND MAINTENANCE MANUAL Track: Trial: Pilot: Date: Time: TRACK CHASSIS State of the track: Stub axle height: Temperature: Caster / Camber: Parallelism: ENGINE Seat position: Carburator type: ● Height: ● Distance axle: Adjustments: ● Distance fork: Exhaust type: Masses: Gear ratio: Axle type: Length:...

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