USER MAINTENANCE GUIDE
MAN020.006
NORDIC
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
T
NORDIC MANUAL
SUMMARY
SAFETY INSTRUCTIONS 3
PREPARING THE ASSEMBLY
1- GETTING NORDIC OUT OF THE PACKING 4
2- TOOLS FOR ASSEMBLY 5
3- MAINTENANCE PRODUCTS 5
SEQUENCE OF ASSEMBLY 6
4- ASSEMBLY OF THE STEERING COLUMN AND OF THE STEERING WHEEL 7
5- ASSEMBLY OF THE FUEL TANK AND OF THE OVERFLOW BOTTLE 9
6- ASSEMBLY OF THE SEAT AND OF THE SEAT STIFFENERS 10
7- ASSEMBLY OF THE KG BODY WORK 13
8- STARTING YOUR NORDIC 16
STANDARD ADJUSTMENTS
9- TABLE OF THE STANDARD ADJUSTMENTS 17
10- ADJUSTMENT OF THE FRONT END 18
11- ADJUSTMENT OF THE REAR END 24
12- ADJUSTMENT OF THE SEAT 26
MAINTENANCE
13- TYRES 27
14- CHANGING BRAKE PADS 28
15- BLEEDING THE BRAKE SYSTEM 29
16- CLEANING THE CHASSIS 30
17- MAINTENANCE PLAN 31
18- TROUBLE SHOOTING 32
his document can not be reproduced or released without the SODIKART authorization.
VERSION : JANUARY 2008
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MAN020.006
NORDIC MANUAL
You have decided to acquire a SODI chassis. We would like to thank you for choosing the SODI
NORDIC.
Your kart has been developed for performance and safety.
It is the outcome of SODIKART’s experience and of the latest research at the highest level of
competition.
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
NORDIC is the first guarantee of your safety and of the safety of other pilots.
This manual also contains advice about adjustments.
Their purpose is to help you exploiting all the potential of your NORDIC.
Enjoy driving your NORDIC,
VERSION : JANUARY 2008
2/32
MAN020.006
NORDIC MANUAL
SAFETY INSTRUCTIONS
The NORDIC has been designed for leisure and high level competition.
Its design, which complies with the pending rules of the CIK, ensures an optimum safety in
normal working conditions.
Its high speed and performances imply a proper maintenance.
•
For your safety and the one of other pilots, please thoroughly respect :
- The assembly instructions.
- The adjustment recommendations.
- The maintenance plan.
•
Please pay especial attention to the instructions or comments to the following symbols
below :
NOTE: Gives useful information.
: indicates a high risk of severe injury if the instructions are not
followed.
¾ Should you not find an answer to your questions in this manual or face any problem, please
get advice from the SODIKART distribution network.
¾ The SODI NORDIC 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.
¾ 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.
¾ Prior to going on the track, please check all points related to safety.
¾ In order to avoid fire, put the kart at least one meter away from the buildings. Never
leave inflammable objects close to the kart.
¾ If fuel has been poured, wipe and wait for vapors to dissipate, before starting the
kart.
¾ Kids and domestic animals have to be kept away from the kart and the track.
¾ Never drive the kart without adequate pilot equipment.
¾ Use spare parts of SODIKART origin.
3/32
NORDIC MANUAL
1- GETTING NORDIC OUT OF THE PACKING
NORDIC FRAME
STEERING COLUMN
ASSEMBLY
STEERING WHEEL
LEFT SIDE POD
SEAT
LEFT SIDE POD
SUPPORT
RIMS
SPACER ADJUSTER
STUB AXLE
SPOILER
NASSEAU PANEL
OVERFLOW
BOTTLE
RIGHT SIDE POD
SUPPORT
RIGHT SIDE POD
FUEL TANK
EXHAUST
SLOTTED WRENCH
NOTE:
STUB AXLE SCREW
ADJUSTER
- Prior to assembling your kart, check the above described elements and
familiarize yourself with them.
- The part numbers of the various items can be found in the “spare parts
catalogue “.
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NORDIC MANUAL
2-TOOLING FOR ASSEMBLY AND ADJUSTMENT
DESIGNATION DIAMETER PART NUMBER
- T handle wrench allen key 4mm 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
- T handle socket spanner 8 mm OU 912.004
- T handle socket spanner 10 mm OU 912.001
- T handle socket spanner 11 mm OU 912.002
- T handle socket spanner 13 mm OU 912.003
- Key for slotted round nut M20 supplied OU 914.003
- Stub axle spacer adjuster Hub supplied OU 931.007
- Stub axle screw adjuster Stub axle supplied OU 931.006
3- MAINTENANCE PRODUCTS
- Cleaner : (paint - plastics) : LU 832.007
- WD 40 LU 833.003
- Grease for chain LU 822.002
NOTE:
FOR OTHER TOOLS, ACCESSORIES AND EQUIPMENTS PLEASE REFER TO THE ITAKA
CATALOGUE.
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NORDIC 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 BODYWORK (chapter 7).
NOTE:
Recommended tightening torques:
Ø6 = 10 to 12 m.N
Ø8 = 12 to 24 m.N
Ø10 = 24 to 48 m.N
Do not overtighten screws and bolts
Screws without bolts are to be blocked with 1 drop of special glue (LU 861.001)
Lubricate rotating parts, ball joints, gas cable ….
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NORDIC MANUAL
4- ASSEMBLY OF THE STEERING COLUMN AND STEERING WHEEL.
THE SET CONSISTS IN:
2
3
4
5
6
PIC 2
3
PIC 3
5
PIC 4
6
1
PIC 1
1
2
4
7
Inner hole
¾ One plastic steering column support (1).
¾ One steering wheel support (2).
¾ Two nassau panel supports
¾ One steering column (4).
¾ One steering column support (5).
¾ Two steering tie rods + ball joints (6).
¾ Raise the set as in picture 1.
4.1 ASSEMBLY OF THE STEERING COLUMN
SUPPORT (PIC 2)
¾ Place the steering column support on the two pins
canons (1) and (2).
¾ Put the CHC M6x30 (3) screws + nylstop M6 bolts
as indicated in picture 2.
¾ Tighten.
4.2 ASSEMBLY OF THE STEERING COLUMN (PIC 3)
¾ Insert the threaded end of the steering column in
the ball joint (4).
¾ Place the bolt (5).
¾ Tighten.
4.3 ASSEMBLY OF THE TIE-RODS (PIC 4)
After cutting the tie-wrap maintaining the stub axles:
¾ Place the ball joints (6) above the stub axle arm
(7).
¾ Insert the BHC M8x30 screw in the outer hole of
the stub axle arm.
¾ Place the washer on top of the ball joint and insert
the screw.
¾ Place the M8 bolt and tighten.
(3).
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NORDIC MANUAL
4.4 TIGHTENING THE PLASTIC STEERING COLUMN SUPPORT.
¾ Tighten the CHC M8x65 screw (8).
8
4.5 ASSEMBLY OF THE STEERING WHEEL.
1
¾ Tighten the steering wheel (1) with the 3 FHC M6x30 screws, on the steering wheel support
(2).
¾ Tighten the steering wheel support on the steering column.
Check: once the steering system is assembled, please check that the steering wheel is free to
make a quarter of a turn right and left.
9 A bad assembly or a bad adjustment of the steering system can lead to accidents.
9 Systematically check the tightening of the system and its adjustment.
STRAIGHT PART
FORWARD
2
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NORDIC MANUAL
5- ASSEMBLY OF THE FUEL TANK AND OF THE OVERFLOW BOTTLE.
3
1
2
¾ Insert the fuel tank between the steering column support (1) and the steering column (2)
(see pictures )
¾ Tighten with the fly nut (3)
4
9
5
8
¾ Insert the overflow bottle (4) between the nassau panel supports (5).
¾ Connect the overflow bottle hose (6) to the return (7).
¾ Connect the petrol tank hose (8) to the red plug (9).
NOTE:
- CHECK THE PRESENCE OF THE DIVER UNDER THE RED PLUG (9).
6
7
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NORDIC MANUAL
6-ASSEMBLY OF THE SEAT AND SEAT STIFFENERS.
4 FIXING
POINTS
1
Measurements given below correspond to
the standard adjustment of the seat,
recommended by SODIKART, for the
NORDIC.
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.
¾ The washers of the seat fixing kit comply with CIK/FIA and with your local national
rules.
6-1 GROUND CLEARANCE
SEAT
1Bar
24mm or 6 rear sprockets
GROUND
10/32
NORDIC MANUAL
6-2 DISTANCE BETWEEN THE REAR AXLE AND THE MIDDLE OF THE ROUND REAR
EDGE OF THE SEAT.
250mm
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.
990mm
11/32
NORDIC MANUAL
6-4 ASSEMBLY OF THE SEAT STIFFENERS
ASSEMBLY OF THE LOWER END (PIC 1)
1. Place the CHC M8 screw (1) in the hole of the
bearing support (2).
2. Place the stay bolt PC 0332.004 (3) as indicated.
3. Put the seat stiffener lower end (4) in place.
4. Put the bolt in place and pre-tighten.
For screws and bolts references, refer to the
spare parts catalogue.
ASSEMBLY OF THE UPPER END (PIC 2)
5. Place the upper end of the stiffener (5).
6. Make sure there is no contact with the exhaust
system and with any part of the engine.
If necessary, slightly bend the stiffener.
7. Drill a 8.5 mm diameter hole (5) in the seat.
8. Place one FHC M8 screw + conical washer.
9. Tighten both upper and lower end.
For screws and bolts references, refer to the
spare parts catalogue.
4
2
1
3
PIC 1
5
PIC 2
FOR OTHER TYPES OF STIFFENERS, PLEASE REFER TO THE NORDIC
SPARE PARTS CATALOGUE OR TO THE ITAKA CATALOGUE
.
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NORDIC MANUAL
7-ASSEMBLY OF THE KG BODYWORK.
7-1 PREPARING THE KG SIDE POD 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.
1. Cut the end of the side pod support according to
your local federation rules. (see below the
picture)
2. Insert the side pod support into the bushings
until the distance (1) between the extremities of
the side pods is in accordance with your local
federation rules. (see the right picture)
3. Use the holes (1) on the frame to drill the side
pod support and bushings with Ø6.5mm drill.
2
X mm
1
2
13/32
2
1
3 1 3
NORDIC MANUAL
7-2 ASSEMBLY OF THE SIDE POD ON ITS
SUPPORTS
¾ Place the side pod (1) on the side pod support (2).
¾ Place the screws (3) through the side pod (1) and
the side pod support (2).
¾ Tighten the assembly with the nuts (4).
Refer to the NORDIC spare parts catalogue for the
bolting
7-3 ASSEMBLY ON THE FRAME
¾ Check that the bushings are pushed in the frame.
¾ Insert the side pod assembly into the bushings.
¾ Tighten with the screws (1) and the nuts (2)
Refer to the NORDIC spare parts catalogue for the
bolting
7-4 ASSEMBLY OF THE SPOILER UPPER SUPPORT ON THE FRAME
¾ Place the spoiler upper support (1) on the outer
face of the lug (2).
¾ Tighten with the screws (3) and the nuts (4).
Refer to the NORDIC spare parts catalogue for the
bolting
3
1
4
2
1
2
4
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3 2
NORDIC MANUAL
7-5 ASSEMBLY OF THE SPOILER
¾ Assemble the spoiler fixation kit (1) between the spoiler upper support (2) and the frame
(3) with two screws and two nuts.
¾ Place the flanges (4) between the spoiler support (2) and the frame (3), then lock.
Refer to the NORDIC spare parts catalogue for the bolting
7-6 ASSEMBLY OF THE NASSEAU PANEL
2
3
1
¾ Place the nasseau panel (1) on the nasseau panel u pper support (2) and the nasseau panel
lower support (3).
¾ Draw the 3 drill points on the nasseau panel (1).
¾ Drill the Ø6.5mm holes.
¾ Place the nasseau panel (1) on its supports (2) and (3)
¾ Tighten the nasseau panel (1) on its supports (2) and (3) with screws, nuts, and washers.
Refer to the NORDIC spare parts catalogue for the bolting
1
2
4
3
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NORDIC MANUAL
8- STARTING YOUR NORDIC
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.
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
closed visor. Refer to CIK/FIA regulations (compulsory).
• Suit: CIK / FIA level 1 or level 2 approved. (compulsory)
• Gloves. (compulsory)
• Neck protection : CIK/FIA approved (compulsory)
• Rib protection: fitting pilot’s size and seat (recommended).
• Rain suit: with water tight fasteners (recommended when necessary).
CHOOSE THOSE EQUIPMENTS WITHIN THE CIK / FIA APPROVED ONES OF THE
ITAKA CATALOGUE
DRIVING IS FORBIDDEN TO ANY PILOT:
¾ Wearing a scarf because of risk with rotating parts.
¾ With long hair coming out of the helmet.
¾ With wide floating clothes.
¾ With health problems, not compatible with high speed driving.
¾ Under the influence of drugs and (or) alcohol.
9 For your safety and the safety of other pilots, strictly follow the above instructions:
not doing so may lead to severe, even fatal injuries.
9 Be aware that some medicines reduce your ability to drive
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NORDIC MANUAL
9-STANDARD ADJUSTMENTS OF THE NORDIC
STUB AXLE HEIGHT
DRY WET
4mm 4mm+4mm
FRONT TRACKING WIDTH
REAR TRACKING WIDTH
REAR AXLE POSITION /
TIGHTENING OF THE
CENTRAL BEARING
POSITION OF MASSES
4mm +2mm
1 ring inside
1200mm
TOP
Tightened central bearing
1
2mm
All rings inside
1150mm
TOP
Tightened central bearing
2
POSITION OF EXCENTRICS
POSITION OF STEERING
TIE RODS ENDS
TOP
Mark - Forward
BOTTOM
Mark – Inward
Eccentrics
A-2
OR
-
FWD
TOP
Mark - Forward
BOTTOM
Mark - Backw
Eccentrics 4°
B-3
FWD
ard
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NORDIC MANUAL
10- ADJUSTMENT OF FRONT WHEELS
10.1 ADJUSTMENT OF FRONT TRACKING WIDTH
DRY TRACK
¾ On dry track, place 1 ring inside.
WET TRACK
¾ On wet track, place all the rings inside.
1x5mm
¾ For more grip forward,
place one or two 5 mm rings
on the chassis side.
Steering becomes harder.
1X15mm
3x5mm
18/32
¾ For less grip forward, place
one or two 5 mm rings
outside.
Steering becomes lighter.
10.2 ADJUSTMENT OF FRONT WHEEL HEIGHT
DRY TRACK
¾ Place one 4mm spacer on top and one 4 mm + one 2 mm spacer at the bottom (1).
WET TRACK
¾ Place one 4 mm + one 4 mm spacers on top, and one 2 mm spacer at the bottom (2).
¾ The adjustment of dry track (1) can be suitable for wet track.
4mm
(1) DRY TRACK
4+2mm
4+4mm
(2) WET TRACK
2mm
- 19 -
T
T T
T
10.3-ADJUSTMENT OF THE CAMBER AND OF THE CASTER
DESCRIPTION OF THE ECCENTRIC.
ADJUSTMENT OF THE CASTER
FIG 1
LEF
Marked slot
1 for 1°
HIGH CASTER
FRONT
TOP
BOTTOM
REAR
FIG 2
RIGH
LEF
diam. 4 mm pin on the fork
Eccentric
LOW CASTER
FRONT
TOP
RIGH
BOTTOM
REAR
Eccentrics on top:
The mark is positioned in front of the Ø4 mm
pin.
(Towards the front of the chassis)
STANDARD ADJUSTMENT
¾ 1° eccentrics place in high caster position (fig 1).
(4° eccentric in the same position are often used to obtain a good grip of front wheels)
INCREASE THE CASTER
¾ 2° eccentric in high caster (fig 1) position.
In extreme conditions, use 3°, 4° or more eccentrics.
REDUCE THE CASTER
¾ 2°ou 3° eccentric (even more in extreme conditions) in low caster position.
(fig 1)
(fig 1)
(fig 2)
Eccentrics on top:
The mark is positioned on the opposite side of
the Ø4 mm pin.
(Towards the rear of the chassis) .
- 20 -
ADJUSTMENT OF THE CAMBER
T
T
T
USE THE ECCENTRICS AT THE BOTTOM:
FIG 3
LEFT
Eccentrics at the bottom:
¾ The mark is positioned towards the
outside of the chassis.
STANDARD ADJUSTMENT
INCREASE THE CAMBER
¾ Use the same position fig 4 and change the eccentric of 1° by the eccentric of 2°.
REDUCE THE CAMBER
¾ Use position fig 3.
MORE POSITIVE MORE NEGATIVE
(fig 4)
(fig 3)
FOR HIGH DEGREES ECCENTRICS TO BE USED IN EXTREME CONDITIONS,
FIG 4
RIGH
(Corresponds to fig4)
REFER TO THE ITAKA CATALOGUE
LEF
Eccentrics at the bottom :
¾ The mark is positioned towards
the inside of the chassis.
NOTE:
- Some negative camber generally improves the performances of the NORDIC.
RIGH
- 21 -
10.4 ADJUSTMENT OF PARALLELISM
1. 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).
¾ Attention: on the stub axle side, lock nuts are
right hand; on the steering column side, lock nuts
are left hand.
4. Position the steering wheel in the axis of the kart.
5. Measure A and B with a tape. Adjust the tie rods
until you get A=B with a tie rod length on the right
side 1.5mm bigger than the tie rod length on the
left side.
6. When A=B the parallelism is perfect.
Tighten the 2 lock nuts on each tie rod (2).
7. Remove the adjustment tool (1). Mount the wheels;
mind the direction of rotation indicated on the side of
the tires.
PERFECT
ADJUSTMENT
A=B
A
2
B
1
NOTE:
- On wet track, recommended adjustment: B+20mm than A
- Do not forget to tighten the 2 lock nuts on the tie rods; otherwise the
parallelism will be lost in a few minutes.
- Any time you work on the front wheels, check the parallelism. Do the same
after shocks.
9 Never drive with badly tightened wheels: it may lead to severe, even fatal injuries.
9 Make sure that each ball joint penetrates at least 5 threads in the tie rods.
- 22 -
10.5- ADJUSTMENT OF TIE RODS.
3
ADJUSTMENT B-3
ADJUSTMENT A-3
¾ Lighter steering
NOT RECOMMENDED IN WET
CONDITIONS
3
- 23 -
11- ADJUSTMENT OF REAR WHEELS
11-1 ADJUSTMENT OF HUBS
1. Lay the kart on a trolley.
2. Loosen the three bolts of each tyre. Then
remove the two wheels.
3. Measure the distance
the hub (2) to the axle edge (3).
4. Loosen the CHC (4) screws to allow the sliding
of the hub on the axle and cotter pin (5).
5. Slide the hub up to the position you wish.
6. Tighten and block the CHC (4) screws.
7. Mount the wheels; mind the direction of
rotation indicated on the side of the tires.
Tighten the bolts and block.
A, from the basis of
AXLE
4
HUB
5
HUB
3
A
1
NOTE:
- A rear tracking width is measured from the outside of the rims (left and right).
- A wider rear tracking width tends to increase sliding. Too narrow a rear tracking
width may lead to a bumpy chassis.
9 Badly tightened wheels may lead to severe, even fatal injuries.
9 Check the cotter pin is correctly positioned.
9 Never position the hubs beyond the maximum allowed width: it may lead to severe or
even fatal injuries.
2
- 24 -
11-2 POSITION OF REAR AXLE
¾ A large ground clearance means more grip.
¾ A low groun d clearance means more sliding.
In most conditions, the correct axle position is the low ground clearance one.
This corresponds to a high position of the axle , relative to the frame.
- 25 -
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.
You will find the best position of the seat, adapted to your size and weight, by trial-and error.
We recommend you to bear in mind the following:
SEAT MOVED FORWARD:
Gives more grip on the front wheels; more sliding of the rear wheels.
SEAT MOVED BACKWARDS:
Less grip on the front wheels; more grip on the rear wheels.
SEAT LOWER:
Less grip (front and rear wheels); to try on very high grip conditions.
SEAT HIGHER:
Increases the grip; 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.
- 26 -
13- TYRES
13-1 CHANGING THE TYRES
1. 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).
4. Put grease (3) (LU823.003) on the edges of
the new tire.
5. Install the tire on the rim; mind the
direction of rotation.
6. Inflate to let the tire get its position on the
rim.
7. Adjust the pressure according to table next
page, with the manometer (OU943.002).
9 Check the direction of rotation on the sides of the tire.
9 Never inflate above 4 bars: there is a risk of severe injury due to potential failure of
the rim.
:
Sens de roulage
3
2
- 27 -
14- CHANGING BRAKE PADS.
2
1
3
4
ADJUSMENTS
9 The brake system is a key safety item of the kart. Regularly check all its components.
In case of doubt, do not drive before fixing the problem.
9 Bad maintenance of the brakes can lead to severe, even fatal injuries.
9 Never repair a break system on your own; return it to SODIKART through your local
dealer.
: the adjustment of the gap between the disk and the pads is done
with the screw (1).The standard gap is 1 mm.
¾ Unscrew the piston adjustment screw
to its back stop (1).
¾ Remove the 4 screws with springs (2).
¾ Remove the safety pin (3).
¾ Remove the pads; insert the new ones
(4).
¾ Insert the safety pin (3).
¾ Place the 4 screws with springs with
drop of glue.
¾ Tighten the screw (1) until the pads
touch the disk; unscrew (1) by one and
one quarter of a turn to get the gap
between the pads and the disk.
- 28 -
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.
4- Close the bleed screw (3).
5- Release the brake pedal.
6- Fill the brake liquid tank with DOT 4 only (Ref. LU842.013).
7- Make sure the maximum level is (2).
Repeat operations 3 to 8, until the brake pedal becomes hard.
1
2
3
NOTE:
- The brake system must be regularly checked: level of brake fluid, cover of the
fluid reservoir, state of screws and bolts.
- If the brake fluid becomes black, bleed and change it.
- Bleed and change the brake fluid after each brake pads replacement.
- The gap between the brake disk and the brake pads is 1mm.
9 Use brake liquid DOT 4 only.
9 Don’t use DOT 5, it can damage the seal and cause a lost of braking power.
- 29 -
NORDIC 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.
Avoid products which are not recommended in the ITAKA catalogue. They may be too
aggressive and damage painted and coated areas, plastic parts as well as gaskets.
1. Protect the break calipers and the brake disk with a dry piece of cloth.
2. Spray the whole kart with the cleaning product, and let it act for 30 seconds.
3. Wipe the frame and the components with a dry cloth.
NOTE:
- Clean your kart on a regular basis: it is a good way to check it and detect
damages, if any.
9 Spray cleaning product on brake pads or brake caliper may reduce the braking ability
partially or totally, and can lead to a serious accident.
9 If any doubt, drive carefully the first laps, and test the brakes until the braking
ability becomes normal.
- 30 -
17- MAINTENANCE RECAP:
Screws and bolts (general):
¾ 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.
• Steering tie rods ball joint screws.
• Front and rear wheels bolts.
• Rear wheel hub screws.
• Engine support screws.
• Seat screws.
¾ Damaged screws and bolts have to be changed.
Steering:
¾ Check the tightening torque of the steering column support.
¾ Check the tightening torque of the stub axle screw.
¾ Check the parallelism.
Body work:
¾ Check the various body work components: make sure they are free of damages such as
cracks, likely to propagate when driving.
¾ Check the fixings of the body work components: make sure they are not loose or damaged.
¾ When replacing a body work component, make sure the screws and bolts are put in the right
direction (as original).
Tires:
¾ Pay a special attention to the assembly of the tires.
¾ Make sure the direction of rotation is correct, as indicated on the sides of the tires.
¾ Check the wear of the tires. The wear indicator should always be visible
¾ Damaged tires must be changed.
¾ Check the pressures before driving, according to recommendations (table page 28).
Brake system
¾ Check the brake system before going on the track.
¾ Ensure the system is tight by pressing the brake pedal: once the pads are in touch with the
disk, the pedal should not move any further.
.
- 31 -
18- TROUBLE SHOOTING.
Brakes do not work:
1. Is the pedal working correctly (not blocked)?
2. Are the break pads worn out?
3. Is the caliper correctly tightened on its support?
The brake pads permanently touch the disk:
1. Is the brake fluid old or black?
2. Is the brake disk correctly aligned?
3. Is the caliper well tightened on its support?
4. Is the brake pedal free to rotate around its axis?
5. Is the brake pads gap correct?
The steering is hard.
1. Are the screws of the stub axles tightened with the right torque?
2. Is the caster too high?
The steering of the kart is not precise.
1. Are the steering tie rods bent?
2. Is the plastic steering column support well tightened?
3. Is the steering column support well tightened on the frame?
The kart tends to go to the right or to the left.
1. Is the parallelism OK?
2. Are the pressures of the tires OK (left vs. right)?
3. Are the tires diameter equal (middle and sides)?
4. Are the two block nuts of the steering tie rods well tightened?
5. Are the tie rods bent?
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TRACK: DATE: TRIAL TIMES
P
S
Heigh
Di
M
Axl
Stiff
ENGINE
Adj
Exh
Length
PILOT: TRIAL: TIME:
TRACK:
State of the track: °C
CHASSIS:
Stub axle height :
Caster and camber :
Tyre type: Diameter:
PRESSURE
START
arallelism :
eat position :
t : Dist- axle :
asses :
e type :
eners :
:
carburator type :
usments :
aust type :
:
Gear ratio : Chain length :
NOTES:
st- fork :
1
2
3
4
5
6
7
8
9
10
Partial 1 Partial 2 Partial 3LAP
Partial 4
PRESSURE
ARRIVAL
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