Sodi Sigma KZ,Sigma S3,Sigma DD2 User Manual

Download

MAN.SIG.EN.02

This document can not be reproduced or released without the Sodikart authorization.

Congure the kart according to the guide instructions.

Use spare parts of Sodi origin.

User maintenance guide

You have decided to acquire a SODI chassis. We would like to thank you for your trust (in us).

Your kart has been developed for performance and safety.

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 kart is the rst 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 kart.

Enjoy driving your kart,

It is the outcome of SODIKART’s experience and of the latest research at the

This document can not be reproduced or released without the Sodikart authorization.

CONFIGURE THE KART ACCORDING TO THE GUIDE INSTRUCTIONS

MAN.SIG.EN.02

04/2014

Table of contents

1 - Safety instructions ............................4

1.1 - Recap of all warnings included in this manual

........................................................ 5

6 - Maintenance.....................................26

6.1 - Brakes ........................................................ 26

2 - Reception ...........................................6

2.1 - Tooling for assembly and adjustment .......... 7

2.2 - Maintenance products

.................................. 7

3 - Assembly ...........................................8

3.1 - Precautions and recommendations .............. 8

3.2 - Assembly of the steering column and steering wheel

............................................. 8

3.3 - Positioning of the safety brake cable.......... 10

3.4 - Frame stabilizers

........................................ 10

3.5 - Assembly of the fuel tank and of the overow bottle

3.6 - Assembly of the seat

3.7 - Assembly of the seat stiffeners

........................................... 10

.................................. 11

................... 12

3.8 - Assembly of the bodywork.......................... 13

3.9 - Mounting the rear protections..................... 15

3.10 - Mounting the rear protections DD2

3.11 - Mounting the front brake hose (optional)

.......... 15

.. 16

6.2 - Tyres ........................................................... 38

4 - Commissioning ...............................17

4.1 - Safety instructions to the pilots................... 17

4.2 - Pilot protection............................................ 17

6.3 - Cleaning the chassis .................................. 40

6.4 - Maintenance summary

5 - Adjustments .....................................18

5.1 - Standard adjustments ................................ 18

5.2 - Adjustment of front wheels

5.2.1 - Adjustment of front tracking width .......... 20

5.2.2 - Adjustment of front wheel height

5.2.3 - Adjustment of the caster

5.2.4 - Adjustment of the camber

This document can not be reproduced or released without the Sodikart authorization.

5.2.5 - Front wheel alignment

5.2.6 - Adjustment of tie rods

5.3 - Adjustment of rear wheels .......................... 24

5.3.1 - Adjustment of hubs ................................. 24

5.3.2 - Position of rear axle

5.3.3 - Type of axle

............................................ 24

5.4 - Adjustment of seat ...................................... 25

5.5 - Adjustment of the brake distributor

5.5.1 - Standard adjustment .............................. 25

5.5.2 - More braking power on the front brakes

5.5.3 - More braking power on the rear brakes

......................... 20

............ 20

......................... 21

...................... 22

............................ 23

............................. 23

............................... 24

............. 25

. 25

7 - Trouble shooting .............................41

7.1 - The kart will not brake ................................ 41

7.2 - The kart brakes continually

7.3 - The kart is hard to turn

7.4 - The steering of the kart is not precise

7.5 - The kart tends to go to the side

7.6 - The kart skids very much on bends

8 - Index .................................................42

9 - Homologation

9.1 - SIGMA S3................................................... 45

9.2 - SIGMA KZ

9.3 - SIGMA DD2

6.1.1 - Fluids and lubricants .............................. 26

6.1.2 - Frequency of cleaning and maintenance

6.1.3 - Replacing brake pads on the D18

6.1.4 - Replacing brake pads on the D24

6.1.5 - Adjusting the gap between the pads

6.1.6 - Replacing the brake hose

6.1.7 - Bleeding the front brake circuit............... 28

6.1.8 - Bleeding the rear brake circuit

6.1.9 - Bleeding the steering wheel

6.1.10 - Replacing rear calliper seals / 4

6.1.11 - Replacing rear calliper seals / 4

6.1.12 - Replacing master cylinder seals

6.1.13 - Replacing the front master cylinder

6.1.14 - Cleaning

6.2.1 - Tyres change .......................................... 38

6.2.2 - Table of the recommended tyre

4-piston calipers (front)

4-piston calipers (rear)

and the disc

controlled front brake circuit

piston caliper pistons D18 (front)

piston caliper pistons D24 (rear)

and pistons

pistons

pressures

............................................ 28

............................................. 35

.................................................... 37

............................................... 37

............................................... 39

.......................... 27

........................... 27

...................... 28

............... 30

................... 31

........... 32

............ 33

............................... 40

6.4.1 - Bolting .................................................... 40

6.4.2 - Steering

6.4.3 - Bodywork parts

6.4.4 - Tyres

6.4.5 - Braking

.................................................. 40

...................................... 40

...................................................... 40

................................................... 40

........................ 41

............................... 41

........ 41

.................. 41

............ 41

..................................45

.................................................. 46

................................................ 47

User maintenance guide

MAN.SIG.EN.02 04/2014

USE SPARE PARTS OF SODI ORIGIN

User maintenance guide

This user guide is updated by SODIKART to allow, without delay, to know the last safety and maintenance improvements.

Refer to our website regularly, to download the last version of user guide.

This document is a translation of the French manual, Document MAN.SIG.CEL.FR.01 (original version), which will prevail in the event of a dispute.

The illustrations are non-contractual. © Sodikart 2014 .

1 - Safety instructions

The kart has been designed in accordance with the pending rules of the CIK / FIA in force, which ensures an optimum safety in normal conditions of use.

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:

► The SODI chassis 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.

► 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 kart’s federation of his own country.

► Prior to going on the track, please check

all points related to safety.

► In order to avoid re, put the kart at

least one meter away from the buildings. Never leave inammable objects close to the kart.

► If fuel has been poured, wipe and wait

for vapours to dissipate, before starting the kart.

► Kids and domestic animals have to be

kept away from the kart and the track.

► Never drive the kart without adequate

pilot equipment.

● Gives useful information.

●● Indicates●a●risk●of●property●damage●if●

instructions●are●not●followed.

► Indicates a strong possibility of serious

personnal injury or death if instructions are not followed.

If you have problems or questions

about your kart, please contact our local

distributor or representative of SODIKART.

Parc d’activités des Hauts de Couëron

This document can not be reproduced or released without the Sodikart authorization.

B.P.60 - 44220 COUËRON - France

Tel. : (33) 02 40 38 26 20 Fax : (33) 02 40 38 26 21

www.sodikart.com - sodikart@sodikart.com

CONFIGURE THE KART ACCORDING TO THE GUIDE INSTRUCTIONS

MAN.SIG.EN.02

04/2014

1.1 - Recap of all warnings included in this manual

Chapter: Assembly

► A bad assembly or a bad adjustment of the steering

system can lead to accidents. Systematically check the tightening of the system and its adjustment./ Page 9

► Always t the safety cable clips (1) under the staples

of the brake rod (2)./ Page 10

► Always attach the stabilisers to the frame with a

sleeve at each side./ Page 10

Chapter: Commissioning

► 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 17

► For your safety and the safety of other pilots, strictly

follow the above instructions: not doing so may lead to severe, even fatal injuries./ Page 17

Chapter: Adjustments

► Never drive with badly tightened wheels: it may lead

to severe, even fatal injuries./ Page 23

► Make sure that each ball joint penetrates at least 5

threads in the tie rods./ Page 23

► Badly tightened wheels may lead to severe, even

fatal injuries./ Page 24

► Check the hub key (5) is correctly

positioned./ Page 24

► Never position the hubs beyond the maximum

allowed width: it may lead to severe or even fatal injuries./ Page 24

► The brake system is a key safety item of the kart.

Regularly check all its components./ Page 25

► In case of doubt, do not drive before xing the

problem./ Page 25

► Bad maintenance of the brakes can lead to severe,

even fatal injuries./ Page 25

► Never repair a break system on your own; return it

to your local dealer./ Page 25

Chapter: Maintenance

This document can not be reproduced or released without the Sodikart authorization.

► The Super Blue brake uid has been designed for

racing use and is used exclusively for this purpose (forbidden on open road)./ Page 26

► Use brake uid DOT4 only. Using another brake

uid could cause leaks and failure of the brake system./ Page 26

► Check the pads for wear before every start-

up./ Page 27

► Never drive with excessively worn pads (minimum

thickness for the D18 4-piston calipers (front): 4mm)./ Page 27

► The brake is an essential safety element. If the

braking system is defective or you have the slightest doubt, do not put the kart in service./ Page 27

► Never drive with excessively worn pads (minimum

thickness of pads for D24 4-piston calipers (rear): 6 mm)./ Page 27

► The brake is an essential safety element. Do not put

the kart in operation if the break system is faulty or if you have a doubt./ Page 28

► Faulty braking system may lead to a serious or even

fatal injury./ Page 28 ► Check connexions of hoses, no leak./ Page 28 ► Use brake uid DOT 4 only./ Page 28 ► An air bubble in the brake system can lead to a

partial or total lost of brakes and may lead to a

serious or even fatal injury./ Page 29 ► Leaks in the brake system may lead to a serious or

even fatal injury./ Page 29 ► Moisture in the brake uid may cause vapour lock

and a sudden loss of braking power, may lead to a

serious or even fatal injury./ Page 29 ► Use brake uid DOT 4 only/ Page 29 ► Test the brake after each bleed./ Page 29 ► Do not use any cleaning product that could damage

the seals. A brake uid leak could appear, causing a

serious or fatal accident. ► If WD-40 or a similar cleaning product is splashed

on the brake disc or calliper, braking will be less

efcient or possibly totally ineffective for a few

revolutions. This could cause a serious or fatal

accident./ Page 37 ► Do not apply WD-40 or other cleaning products to

the brake pump./ Page 37 ► Change all damaged rims. A damaged rim may lead

to a loss of tyre or loss of pressure and may lead to

a serious or even fatal injury./ Page 38 ► Check the tyre wear daily. Worn or damaged tyres

may lead to a serious or even fatal injury./ Page 38 ► Never run with worn or damaged tyres: a burst

of tyre may lead to a serious or even fatal

injury./ Page 38 ► Always blow up tyre with the pressure

recommended by the manufacturer./ Page 38 ► Cold tyres have a reduced adherence, and increase

the loss of control of the kart. This may lead to a

serious or even fatal injury./ Page 38 ► Too much grip reduces the stability of the kart under

impact, and lead to a tendency to go on two wheels.

It also increases the risk of riding over./ Page 38 ► Store tyres in an appropriate area to prevent re

hazard./ Page 38 ► Never inate above 4 bars: there is a risk of severe

injury due to potential failure of the rim. / Page 38 ► Spray cleaning product on brake pads or brake

caliper may reduce the braking ability partially or

totally, and can lead to a serious accident./ Page 40

/ Page 33

User maintenance guide

MAN.SIG.EN.02 04/2014

USE SPARE PARTS OF SODI ORIGIN

User maintenance guide

2 - Reception

Legend 1 Spoiler 2 Nassau panel 3 Steering column assembly 4 Steering wheel 5 Frame 6 Overow bottle 7 Left side pod 8 Left side pod support 9 Right side pod 10 Right side pod support 11 Gear lever assembly (KZ only) 12 Rear bumper 13 Fuel tank 14 Seat 15 Rim

This document can not be reproduced or released without the Sodikart authorization.

●● Prior●to●assembling●your●kart,●check●the●

above●described●elements●and●familiarize● yourself●with●them.

● For part numbers, refer to the exploded

view.

CONFIGURE THE KART ACCORDING TO THE GUIDE INSTRUCTIONS

MAN.SIG.EN.02

04/2014

2.1 - Tooling for assembly and adjustment

2.2 - Maintenance products

6 9

Cleaner : (paint - plastics) LU834.003

WD 40 LU833.003

Grease (for chain) LU825.005

Designation Part No.

● For other tools, accessories and

equipment, visit ITAKA website.

User maintenance guide

Designation Ø Part No.

1 Stub axle spacer adjuster

- OU931.007

(Hub) (*)

2 Stub axle screw adjuster

- OU931.006

(Stub axle) (*)

3 Key for slotted round nut (*) M20 OU914.003 4 T handle wrench Allen key 3 OU911.001 4 T handle wrench Allen key 4 OU911.002 4 T handle wrench Allen key 5 OU911.003 4 T handle wrench Allen key 6 OU911.004

This document can not be reproduced or released without the Sodikart authorization.

4 T handle wrench Allen key 8 OU911.005 5 T handle socket spanner 8 OU912.004 5 T handle socket spanner 10 OU912.001 5 T handle socket spanner 11 OU912.002 5 T handle socket spanner 13 OU912.003 6 Piston stop centring device - OU951.004 7 Master cylinder tool kit - OU951.003 8 Brake bleeder - OU951.002 9 Special glue - LU861.001

● (*) Supplied with the chassis.

MAN.SIG.EN.02 04/2014

USE SPARE PARTS OF SODI ORIGIN

User maintenance guide

3 - Assembly

3.1 - Precautions and recommendations

●● Do●not●overtighten●screws●and●bolts.

Step 1

● Tightening torque Ø 6 = 10 to 12 mN.

● Tightening torque Ø 8 = 12 to 23 mN.

● Tightening torque Ø 10 = 23 to 47 mN.

● Tightening torques for rims on hub : 25 mN.

● Screws without bolts: 1 drop of special glue (LU861.001).

● Lubricate rotating parts, ball joints, gas cable ...

3.2 - Assembly of the steering column and steering wheel

Legend 1 Pin canon 2 Screw + nut

● Place the steering column support on the two pins canons (1).

● Put the screws + nuts (2) as indicated in picture.

● Tighten the assembly.

Step 2

Legend 1 Plastic steering column support 2 Steering wheel support 3 Nassau panel support 4 Steering column 5 Steering column support 6 Steering tie rods + Ball joints 7 Clutch handle (KZ only) 8 Gearbox control lever (KZ only)

● Raise the set as in picture.

Legend 1 Ball joint 2 Nut 3 Split pin

● Insert the threaded end of the steering column in the ball joint (1).

● Tighten the nut (2).

● Tighten the assembly.

● Put the split pin (3) into the hole of steering column.

This document can not be reproduced or released without the Sodikart authorization.

CONFIGURE THE KART ACCORDING TO THE GUIDE INSTRUCTIONS

MAN.SIG.EN.02

04/2014

Step 3

Step 5

Legend 1 Screw + nut

● Tighten the nut (1).

● Tighten the assembly.

Step 4

Legend 1 Ball joint 2 Stub axle arm

User maintenance guide

Legend 1 Support 2 Screw 3 Top of the wheel 4 Steering column

● Tighten the steering wheel (straight side up (3)) with the 3 screws (2) on the steering wheel support (1).

● Tighten the steering wheel support (1) on the steering column (4).

●● Once●the●steering●system●is●assembled,●

please●check●that●the●steering●wheel●is●free● to●make●a●quarter●of●a●turn●right●and●left.

► A bad assembly or a bad adjustment

of the steering system can lead to

accidents. Systematically check the tightening of the system and its adjustment.

● Cut the tie-wrap maintaining the stub axles.

● Place the ball joints (1) above the stub axle arm (2).

● Insert the screw into the stub axle arm.

● Place the washer between the ball joint (1) and the stub axle arm (2).

This document can not be reproduced or released without the Sodikart authorization.

● Tighten the nut.

● Tighten the assembly.

MAN.SIG.EN.02 04/2014

USE SPARE PARTS OF SODI ORIGIN

User maintenance guide

3.3 - Positioning of the safety brake cable

Legend 1 Safety cable 2 Brake rod

3.5 - Assembly of the fuel tank and of the overow bottle

2 4

► Always t the safety cable clips (1)

under the staples of the brake rod (2).

3.4 - Frame stabilizers

Legend 1 Frame stabilizer 2 Stabilizer sleeve

► Always attach the stabilisers to the

frame with a sleeve at each side.

Legend 1 Fuel tank 2 Steering column support 3 Steering column 4 Fly nut

● Insert the fuel tank (1) between the steering column support (2) and the steering column (3).

● Tighten the fuel tank (1) with the y nut (4).

Legend 5 Overow bottle 6 Nassau panel support 7 Overow bottle support 8 Overow bottle hose 9 Return 10 Petrol tank hose 11 Red plug

This document can not be reproduced or released without the Sodikart authorization.

● Put the overow bottle (5) on the nassau panel support (6) with the overow bottle support (7).

● Connect the overow bottle hose (8) ) to the return (9).

● Connect the petrol tank hose (10) to the red plug (11).

CONFIGURE THE KART ACCORDING TO THE GUIDE INSTRUCTIONS

MAN.SIG.EN.02

04/2014

●● Check●the●presence●of●the●diver●under●the●

red●plug.

3.6 - Assembly of the seat

Ground clearance

Legend 1 Fixing points 2 Seat supports

● Measurements given below correspond

to the standard adjustment of the seat, recommended by SODIKART, for your chassis.

● Get the seat supports (2) closer, or wider, depending on the seat size.

● Use the shims of the seat xing kit to get a good t.

●● The●washers●of●the●seat●xing●kit●comply●

with●CIK/FIA●and●with●your●local●national● rules.●

Legend 1 Seat 2 Frame tubes

● Adjust the bottom of the seat (1) with the lower face of the frame tubes (2).

Seat Position

User maintenance guide

SIGMA S3

SIGMA KZ

This document can not be reproduced or released without the Sodikart authorization.

SIGMA DD2

● B = 220 mm ± 5 mm (mid-point of the rounded, middle of the seat).

● C = 1020 mm ± 10 mm.

● B = 210 mm ± 5 mm (mid-point of the rounded, middle of the seat).

● C = 1050 mm ± 10 mm.

● B = 210 mm ± 5 mm (mid-point of the rounded, middle of the seat).

● C = 1040 mm ± 10 mm.

MAN.SIG.EN.02 04/2014

USE SPARE PARTS OF SODI ORIGIN

User maintenance guide

3.7 - Assembly of the seat stiffeners

Lower end

Upper end

Legend 1 Seat stiffener 2 Screw

● Put the seat stiffener lower end (1) in place.

● Pre-tighten the assembly with the screw (2).

● For screws and nuts references, refer to

the spare parts.

Legend 1 Seat stiffener 2 Screw + conical washer + nut

● Place the upper end of the stiffener.

● Make sure there is no contact with the exhaust system and with any part of the engine. If necessary, slightly bend the stiffener.

● Drill a 8.5 mm diameter hole in the seat.

● Place one screw + conical washer (2).

● Tighten both upper and lower end.

● Apply the same procedure to mount the stiffener on the left side of the seat.

Note: It is possible to install several seat stiffener (left

and right):

- SIGMA S3-SIGMA KZ-SIGMA DD2 : 2 stiffeners left side and 1 right side stiffener.

● For screws and nuts references, refer to

the spare parts.

● For other types of stiffeners, refer to the

spare parts and the website ITAKA.

This document can not be reproduced or released without the Sodikart authorization.

CONFIGURE THE KART ACCORDING TO THE GUIDE INSTRUCTIONS

MAN.SIG.EN.02

04/2014

3.8 - Assembly of the bodywork

Step 1

Legend 1 Side pod 2 Side pod support 3 Screw 4 Washer 5 Nut

● Place the side pod (1) on the side pod support (2).

● Place the screws (3) through the side pod (1) and the side pod support (2).

● Tighten the assembly using the nuts (5). Remember to include the washers (4).

Legend 1 Spoiler lower support 2 Front cross member 3 Screw 4 Nut

● Insert the spoiler lower support (1) into the front cross member of the frame (2).

● Tighten with the screws (3) and the nuts (4).

● For screws and nuts references, refer to

the spare parts.

Step 4

User maintenance guide

● For screws and nuts references, refer to

the spare parts.

Step 2

This document can not be reproduced or released without the Sodikart authorization.

Legend 1 Bushing 2 Screw 3 Nut

● Insert the bushings (1) in the nozzles on the frame.

● Insert the assembly into the bushings (1).

● Drill the bushings (1) using the holes as a guide and tighten the assembly with the screws (2) and nuts (3).

Legend 1 Spoiler upper support 2 Lug 3 Screw 4 Nut

● Place the spoiler upper support (1) on the outer face of the lug (2).

● Tighten with the screws (3) and the nuts (4).

● For screws and nuts references, refer to

the spare parts.

Step 3

MAN.SIG.EN.02 04/2014

● For screws and nuts references, refer to

the spare parts.

USE SPARE PARTS OF SODI ORIGIN

User maintenance guide

Step 5

Step 7

Legend 1 Spoiler 2 Fixing plate 3 Screw

● Assemble the fixing plates (2) on the spoiler (1) using screws (3).

Step 6

Legend 1 Nasseau panel 2 Lower support 3 Upper support

● Tighten the nasseau panel (1) on its supports (2) and (3) with screws, nuts, and washers.

● For screws and nuts references, refer to

the spare parts.

Legend 1 Mounting ange spoiler 2 Upper support 3 Lower support 4 Screw

5 Nut

● Assemble the mounting flange spoiler (1) between the spoiler upper support (2) and the spoiler lower support (3) with two screws and two nuts.

Legend 2 Upper support 3 Lower support 6 Staple

This document can not be reproduced or released without the Sodikart authorization.

● Place the staples (6) between the spoiler fixations (2) and (3).

● Tighten the assembly.

● For screws and nuts references, refer to

the spare parts.

CONFIGURE THE KART ACCORDING TO THE GUIDE INSTRUCTIONS

MAN.SIG.EN.02

04/2014

3.9 - Mounting the rear protections

3.10 - Mounting the rear protections DD2

Legend 1 Mounting kit 2 Bumper support 3 Tube chassis 4 Safety lug 5 Chassis lug

● Assemble the mounting kit (1) with the element of the bumper support (2).

● Mount the assembly in the tube chassis (3), tighten with the screw of the fixing kit (1).

● Fix the safety lug (4) on the chassis lug (5).

● Apply the same procedure for the other side.

User maintenance guide

Legend 1 Tire protection 2 Rear protection 3 Screw + nut 4 Screw + nut 5 Tube protection

● Assemble the tire protection (1) on the rear cover (2), tighten using the screws and nuts (3).

● Assemble the rear protections (2) per pair and tighten using the screws and nuts (4).

● Assemble the rear protections (2) with the 2 protection tubes (5).

Legend 6 Bumper support 7 Bumper

This document can not be reproduced or released without the Sodikart authorization.

8 Screw + nut 9 Screw + nut

● Assemble bumper support (6) on the bumper (7) using screws and nuts (8).

● Assemble the bumper (7) on the chassis with screws and nuts (9).

MAN.SIG.EN.02 04/2014

USE SPARE PARTS OF SODI ORIGIN

Legend 7 Rear protection 8 Tubes chassis 9 Washer 10 Screw

● Place the rear protection (7) on the chassis tubes (8).

● Place the washers (9) and tighten using the screws (10).

3.11 - Mounting the front brake hose (optional)

User maintenance guide

Legend 1 Brake hose 2 Landmark drilling 3 Screw + nut 4 Screw + nut

● Drill the alu board to 6 mm on the landmark (2).

● Place the clamps on the brake hose (1) and tighten the screws and nuts (3).

● Tighten the connection of the brake hose (1) with the screw and the nut (4).

● To adjust the front tracking width see

Standard adjustments / Front tracking width (Kart with front brake).

CONFIGURE THE KART ACCORDING TO THE GUIDE INSTRUCTIONS

This document can not be reproduced or released without the Sodikart authorization.

MAN.SIG.EN.02

04/2014

4 - Commissioning

4.1 - 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 kart’s federation of his own country.

4.2 - Pilot protection

Before going on the track, the pilot must wear the following protections:

● Integral helmet: CIK/FIA approved, tting 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: tting pilot’s size and seat (Recommended).

● Rain suit: with water tight fasteners (Recommended when necessary).

User maintenance guide

●● Choose●those●equipments●within●the●CIK●/●

FIA●approved●ones●of●the●ITAKA●website.

Driving is forbidden to any pilot:

● Wearing a scarf because of risk with rotating parts.

● With long hair coming out of the helmet.

● With wide oating clothes.

● With health problems, not compatible with high speed driving.

● Under the inuence of drugs and (or) alcohol.

This document can not be reproduced or released without the Sodikart authorization.

► For your safety and the safety of

other pilots, strictly follow the above instructions: not doing so may lead to severe, even fatal injuries.

MAN.SIG.EN.02 04/2014

USE SPARE PARTS OF SODI ORIGIN

User maintenance guide

5 - Adjustments

5.1 - Standard adjustments

Dry track Wet track

Stub axle height

SIGMA S3 SIGMA DD2

Stub axle height

SIGMA KZ

Front tracking width

4mm

4mm + 2mm

4mm

4mm + 2mm

B A

4mm + 4mm

2mm

4mm + 4mm + 2mm

0mm

B A

A = 1 rings inside (5mm) B = 100mm

A = 6 rings inside (30mm) B = 100mm

Front tracking width (Kart with front brake)

A = 1 rings inside (5mm). B = 100mm

A = 4 rings inside (20mm). B = 100mm

Rear tracking width

1390

1400

Rear axle position MEDIUM MEDIUM

1360

1380

This document can not be reproduced or released without the Sodikart authorization.

CONFIGURE THE KART ACCORDING TO THE GUIDE INSTRUCTIONS

MAN.SIG.EN.02

04/2014

Dry track Wet track

Position of eccentrics

Position of steering tie rods ends

Lateral stabilizer

SIGMA S3 SIGMA DD2

Lateral stabilizer

SIGMA KZ

Eccentric 1°

TOP

Mark - Forward

BOTTOM

Mark – Backward

B-1 or A-1

2 1

REMOVE the stabilizer.

FWD

B A

Eccentric 1°

TOP

Mark - Forward

FWD

BOTTOM

Mark – Backward

A-1

B A

2 1

REMOVE or PLACE the stabilizer following track conditions.

User maintenance guide

Front stabilizer REMOVE or PLACE the stabilizer

following track conditions.

Tyres

(Cf. chap. 6.2.2) (Cf. chap. 6.2.2)

Seat stiffeners SIGMA S3 - SIGMA DD2 :

- 2 on the left and 1 on the right.

SIGMA KZ :

- 2 on the left and 1 on the right.

This document can not be reproduced or released without the Sodikart authorization.

● These adjustments are given for

information. It is advisable to rene these adjustments according to track conditions (weather - grip), driving, engine and tires.

●● Always●attach●the●stabilisers●to●the●frame●

with●a●sleeve●at●each●side.

REMOVE or PLACE the stabilizer following track conditions.

SIGMA S3 - SIGMA DD2 :

- 2 on the left and 1 on the right.

SIGMA KZ :

- 2 on the left and 2 on the right.

MAN.SIG.EN.02 04/2014

USE SPARE PARTS OF SODI ORIGIN

User maintenance guide

5.2 - Adjustment of front wheels

5.2.1 - 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 2 hubs type (short hub: 80mm or long hub: 100mm).

● The wider the front is widened, the harder

the steering is hard.

● The narrower the front is narrows, the

easier the steering is easy.

Dry track

● If you wish increase the grip of front, it

sufce to increase the width of the front with spacers.

Wet track (with front brake)

It is advisable to adjust the front with a spacer of 20mm maximum (1 spacer of 15mm and 1 spacer of 5mm inside), and use the long hubs: 100mm.

●● With●the●front●brake●on●your●chassis,●the●

adjustment●of●the●front●is●limited.●

●● No●more●than●20mm●of●spacers●(1●spacer●

of●15mm●and●1●spacer●of●5mm),●yoke●side● on●each●stub●axle●if●the●kart●is●equipped● with●front●brake.

●● Use●longs●hubs:●100mm●on●wet●track.

It is advisable to adjust the front with a spacer of 5mm (1 spacer of 5mm inside), and use the long hubs: 100mm.

●● With●the●front●brake●on●your●chassis,●the●

adjustment●of●the●front●is●limited.●

●● No●more●than●20mm●of●spacers●(1●spacer●

of●15mm●and●1●spacer●of●5mm),●yoke●side● on●each●stub●axle●if●the●kart●is●equipped● with●front●brake.

Wet track (without front brake)

We advise you to adjust the front to the maximum (1 spacer of 15 mm and 3 spacers of 5mm inside), and use the long hubs: 100mm.

5.2.2 - Adjustment of front wheel height

4mm

4mm + 2mm

● Place one 4mm spacer on top and one 4 mm + one 2 mm spacer at the bottom.

This document can not be reproduced or released without the Sodikart authorization.

CONFIGURE THE KART ACCORDING TO THE GUIDE INSTRUCTIONS

MAN.SIG.EN.02

04/2014

5.2.3 - Adjustment of the caster

Adjustment of the caster - Low

Description of the eccentric

Front

Rear

Legend 1 Eccentric 2 Screw on the fork 3 Marked slot 4 Mark

(1=0.5°, 2 eccentric marked "1" gives 1°)

Adjustment of the caster - High

Left

Front

Top

Right

Front

Left

Front

Top

Rear

Front

Right

Front

Rear

Front

User maintenance guide

Bottom

Rear

Eccentrics on top:

● The mark is positioned on the opposite side of the screw. (Towards the rear of the chassis).

Eccentrics on bottom:

● The mark is positioned in front of the screw. (Towards the front of the chassis).

Standard adjustment

● 1° eccentrics place in high caster position .

Rear

Front

Rear

Front

Bottom

Reduce the caster

Increase the caster

Rear

Eccentrics on top:

● The mark is positioned in front of the screw. (Towards the front of the chassis).

Eccentrics on bottom:

This document can not be reproduced or released without the Sodikart authorization.

● The mark is positioned on the opposite side of the screw. (Towards the rear of the chassis).

● 2° eccentric in high caster position.

● In extreme conditions, use 3°, 4° or more

eccentrics.

● 2°or 3° eccentric in low caster position.

● In extreme conditions use eccentrics higher

degrees.

MAN.SIG.EN.02 04/2014

USE SPARE PARTS OF SODI ORIGIN

User maintenance guide

5.2.4 - Adjustment of the camber

●● Use●the●eccentrics●at●the●bottom.

Description of the eccentric

Front

Rear

Legend 1 Eccentric 2 Screw on the fork 3 Marked slot 4 Mark

(1=0.5°, 2 eccentric marked "1" gives 1°)

Camber - More positive

Standard adjustment

● See "Camber - More positive".

Increase the camber

● Same position as the “More negative” adjustment by replacing the lower 1° eccentric by the 2° eccentric.

Reduce the camber

● Same position as the "More positive" adjustment. See "Camber - More positive".

● For high degrees eccentrics to be used

in extreme conditions, refer to the ITAKA website

● Some negative camber generally improves

the performances of the kart.

Note: To facilitate adjustment of camber and caster, it

is possible to loose the screw (2). In this case be careful to not lose the screw.

Left

Front

Right

Front

Bottom

Rear

Eccentrics at the bottom:

● The mark is positioned towards the outside of the chassis.

Camber - More negative

Left

Front

Right

Front

Bottom

Rear

Eccentrics at the bottom:

● The mark is positioned towards the inside of the chassis.

This document can not be reproduced or released without the Sodikart authorization.

CONFIGURE THE KART ACCORDING TO THE GUIDE INSTRUCTIONS

MAN.SIG.EN.02

04/2014

5.2.5 - Front wheel alignment

A = B

2 2

Recommended setting on a dry track

Recommended setting on a wet track

Legend 1 Wheel alignment disk 2 Tie rod nut and lock nut 3 Steering wheel in straight position 4 Maximum steering angle position 5 Steering wheel fully turned position

● Place the kart on a trolley.

● Place the front wheel alignment disk (1) (available on ITAKA website).

● Unscrew the lock nuts (2) of the 2 tie rods. Warning: lock nut of tie rod side is a right hand

This document can not be reproduced or released without the Sodikart authorization.

thread; lock nut of steering column side is left-hand thread.

5.2.6 - Adjustment of tie rods

● Position the upper branch of the steering wheel in the kart axle.

● Measure A and B with a roll meter. 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.

● 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.

● The two dimensions C must be equal.

● 2 mm opening : B = A +2mm.

●● Make●sure●the●dimensions●C●are●equal●on●

each●side.

● 7 mm opening : B = A +7mm.

●● Make●sure●the●dimensions●C●are●equal●on●

each●side.

● Remove the front wheel alignment disk (1).

●● 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.

► Never drive with badly tightened wheels:

it may lead to severe, even fatal injuries.

► Make sure that each ball joint penetrates

at least 5 threads in the tie rods.

B-1

2 1

A-1

B A

2 1

User maintenance guide

MAN.SIG.EN.02 04/2014

● Standard adjustment: B-1

● Recommended in wet conditions: A-1.

USE SPARE PARTS OF SODI ORIGIN

User maintenance guide

5.3 - Adjustment of rear wheels

5.3.1 - Adjustment of hubs

5.3.2 - Position of rear axle

5 3 2

Legend 1 Ruler 2 Hub base 3 Top of the axle 4 CHC screw 5 Cotter pin 6 Axle 7 Hub

● Place the kart on a trolley.

● Unscrew the 3 nylstop nuts from the rear wheels with the proper size wrench, and then remove wheels.

● Using a rule (1) or any depth gauge, measure between the hub base (2) and the top of the axle (3).

● Undo the CHC screws (4) of the rear hub with an appropriate wrench until the hub can slide along the axle shaft (6) and cotter pin (5).

● Move the hub (7) to the desired position with the rule (1) in place against the hub base (2).

● Retighten and block the CHC (4) screws.

● Repeat the operation on the other hub.

● Replace both wheels following the rotation direction indicated on tyre wall.

● Replace locknuts (nylstop) and tighten securely.

●● 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.

On most tracks, the correct axle position is middle position.

This corresponds to a low position of the chassis relative to the ground.

● A large ground clearance means more grip.

● A low ground clearance means more

sliding.

5.3.3 - Type of axle

The stiffness of the axle plays an important part in the behaviour of the kart.

● Visit ITAKA website for different axle types.

● A exible axle suits high grip conditions (Heat and (or) gum on the track).

● A stiff axle suits low grip conditions (rain, humid track, cold with little gum track).

In order to get the best out of your kart, do not hesitate to test different stiffness of axle :

Arbres TEKNEEX Ø 50

Q32

THH20

Q30

TH30

TH25

EXTRA DUR

This document can not be reproduced or released without the Sodikart authorization.

DUR

MEDIUM

TS25

► Badly tightened wheels may lead to

severe, even fatal injuries.

► Check the hub key (5) is correctly

positioned.

► Never position the hubs beyond the

maximum allowed width: it may lead to severe or even fatal injuries.

CONFIGURE THE KART ACCORDING TO THE GUIDE INSTRUCTIONS

TH20

TM20

TS20

●● TH20,●TM20●and●TS20●axles●are●not●

recommended●in●KZ●category.

MEDIUM/SOUPLE

SOUPLE

EXTRA SOUPLE

MAN.SIG.EN.02

04/2014

5.4 - Adjustment of seat

The position of the centre of gravity has also a key inuence on the behaviour of the kart.

One can monitor this centre of gravity by changing the position of the seat.

This position affects the masses distribution between front and rear axle.

It directly affects the understeering or oversteered chassis behaviour.

Depending on your weight, your height, your riding style, the ideal position may change a little.

Compared to the standard position (Cf. chap. 3.5), moving the seat has the following effects:

1) Seat moved forward

● Gives more grip on the front wheels (more sliding of the rear wheels).

● Allow to correct the front wheel axle unit imprecise, but delays the time it is possible to accelerate into the turn, (Rear more slippery).

5.5 - Adjustment of the brake distributor

The brake distributor allow to monitor the bracking power between the front and rear brakes.

Legend 1 Handle 2 Brake distributor 3 Axle 4 Front brake pump 5 Rear brake pump

5.5.1 - Standard adjustment

● Turn the handle on the bottom (max on the front) and then back to the rear of 15 “clicks”

User maintenance guide

2) Seat moved backwards

5.5.2 - More braking power on the front brakes

● Less grip on the front wheels.

● More grip on the rear wheels.

3) Seat lower

● Less grip (front and rear wheels).

● To try on very high grip conditions.

This document can not be reproduced or released without the Sodikart authorization.

4) Seat higher

5.5.3 - More braking power on the rear brakes

● 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.

● Turn the handle (1) toward anti-clockwise direction.

● The brake distributor (2) move toward the front brake pump.

● The art will brake more with the front brakes.

● Turn the handle (1) toward clockwise direction.

● The brake distributor (2) move toward the rear brake pump.

● The kart will brake more with the rear brake.

► The brake system is a key safety item

of the kart. Regularly check all its components.

► In case of doubt, do not drive before

xing the problem.

► Bad maintenance of the brakes can lead

to severe, even fatal injuries.

► Never repair a break system on your

own; return it to your local dealer.

MAN.SIG.EN.02 04/2014

USE SPARE PARTS OF SODI ORIGIN

User maintenance guide

6 - Maintenance

6.1 - Brakes

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 uid (refer to the ITAKA website for product references) and recommends that the disc and pads should be cleaned using brake cleaner only (refer to the ITAKA website for product references).

Use PFG110 grease to install the seals (visit the ITAKA site for product catalogue numbers).

6.1.2 - Frequency of cleaning and maintenance

Brake uid.....................SUPER BLUE DOT4

Ref : LU842.010

► The Super Blue brake uid has been

designed for racing use and is used exclusively for this purpose (forbidden on open road).

Brake cleaner Ref : LU835.001

Grease ..........................Grease PFG110

Ref : LU823.004

...............................WYNN'S

► Use brake uid DOT4 only. Using

another brake uid could cause leaks and failure of the brake system.

●● The●brake●system●is●not●compatible●with●

DOT●5.

●● Place●the●uids●in●watertight●cans●and●

recycle●them●according●to●the●regulations● in●force.

Before

any

session

Checking the brake uid level X Replacing the brake uid X Checking the brake pads for wear X Replacing the brake pads X Checking for leaks in the hose X Checking the condition of the brake hose X Checking the tightness of the kart brake system X Checking the condition of the brake disc X Checking the brake disc for wear X Replacing the brake disc X

After 1

meeting or

100 km

After 3

meeting or

300 km

After 5

meeting or

500 km

soon as

required

This document can not be reproduced or released without the Sodikart authorization.

CONFIGURE THE KART ACCORDING TO THE GUIDE INSTRUCTIONS

MAN.SIG.EN.02

04/2014

6.1.3 - Replacing brake pads on the D18 4-piston calipers (front)

6.1.4 - Replacing brake pads on the D24 4-piston calipers (rear)

Legend 1 Adjustment screw 2 Return screw

Legend 1 Pin 2 Brake pad 3 Piston 4 Calliper body

3 Spring (not on KZ and DD2) 4 Pin 5 Brake pad

● Straighten the ends of the pin (1) and then remove it.

● Remove the used brake pads (2).

● Push the four pistons (3) back into the calliper body (4).

● Place the new pads (2) in position.

● Place the new pin (1) in position, and then twist its ends.

● Apply the same procedure for the second calliper.

●● Do●not●operate●the●brake●lever●or●pedal●

unless●pads●are●installed.●This●would● make●the●pistons●difcult●to●return●to●their● position,●and●brake●uid●leaks●might●then● occur.

This document can not be reproduced or released without the Sodikart authorization.

●●

Always●replace●the●pads●of●the●two●front● calipers●at●the●same●time.

► Check the pads for wear before every

start-up.

► Never drive with excessively worn pads

(minimum thickness for the D18 4-piston calipers (front): 4mm).

► The brake is an essential safety element.

If the braking system is defective or you have the slightest doubt, do not put the kart in service.

● Adjust the brake pads until they reach the stop using the adjustment screws (1).

● Remove the four return screws (2) and the four springs (3).

● Straighten the ends of the pin (4) and then remove it.

● Remove the used brake pads (5).

● Place the new pads (5) in position.

● Place the new pin (4) in position, and then twist its ends.

● Reinstall the four return screws (2) and the new springs (3), applying a drop of weak thread locking compound on the threads of the screw.

● Tighten the screws (1) to put the pads in position. The gap between the pad and the disc must be 1 mm.

●● Do●not●mount●the●return●spring●if●the●go-

kart●is●equipped●with●front●and●rear●brake● distributor.

●●

Do●not●operate●the●brake●pedal●unless● pads●are●installed.●This●would●make●the● pistons●difcult●to●return●to●their●position,● and●brake●uid●leaks●might●then●occur.

► Check the pads for wear before every

start-up.

► Never drive with excessively worn pads

(minimum thickness of pads for D24 4-piston calipers (rear): 6 mm).

► The brake is an essential safety element.

If the braking system is defective or you have the slightest doubt, do not put the kart in service.

User maintenance guide

MAN.SIG.EN.02 04/2014

USE SPARE PARTS OF SODI ORIGIN

User maintenance guide

6.1.5 - Adjusting the gap between the pads and the disc

Legend 1 Adjustment screw 2 Disc 3 Pad

6.1.7 - Bleeding the front brake circuit

● Tighten or loosen the screw (1) to obtain a 1 mm gap between the disc (2) and the pad (3).

6.1.6 - Replacing the brake hose

● The brake uid hoses are a critical safety element. It is very important to check their state regularly.

● Check the state of the hoses especially at connecting points and xation points.

● Replace any damaged hose.

● Use a spanner to loosen the screw at each end of the hose and the mounting points on the kart.

● Install a new hose with new seals and banjo screws.

● Ensure that the mounts securing the hoses to the kart are properly tightened.

► The brake is an essential safety element.

Do not put the kart in operation if the break system is faulty or if you have a doubt.

► Faulty braking system may lead to a

serious or even fatal injury.

► Check connexions of hoses, no leak. ► Use brake uid DOT 4 only.

Legend 1 Bleeder screw 2 Cap 3 Brake pedal 4 Reservoir

● Use a pipe and a container to collect the used uid.

● Remove the protective caps from the bleed screws (1) on each front calliper, and then place a hose on the bleed screw. The other end of the hose should be placed in an empty container.

● Gently unscrew the bleeder (1) screw and the ller cap (2).

● Repeatedly press the brake pedal (3) until all the uid has drained out.

● When all the uid has been drained, remove the ller cap (2) and top up to the maximum level with brake uid. Tighten the bleed screw (1), and then press the brake pedal (3) three or four times.

● Loosen the bleeder screw (1) of the front right calliper. Brake uid should ow out. Retighten the bleed screw, and repeat this step several times to feed the circuit properly. Remember to add brake uid to the reservoir (4) as required. Bleed the circuit so that the brake uid owing out of the hose contains no air bubbles.

● Retighten the calliper bleed screw (1), remove the pipe and reapply the protective cap.

● Repeat the operation for the front left calliper.

● Top up the brake uid in the reservoir (4) to its maximum level, and retighten the cap (2).

This document can not be reproduced or released without the Sodikart authorization.

CONFIGURE THE KART ACCORDING TO THE GUIDE INSTRUCTIONS

MAN.SIG.EN.02

04/2014

●● We●recommend●that●you●drain●and●rell●the●

brake●circuit●after●every●brake●pad●change.● This●will●allow●you●to●maintain●optimum● braking●performance.

●● To●bleed●your●brake●system●more●

rapidly,●especially●for●a●big●eet,●we● recommend●the●priming●system●SODIKART● (Ref.●OU951.002).

●● Store●the●used●brake●uid●in●labelled●

containers●until●it●is●collected●by●a●specialist● waste●disposal●company.

●● The●brake●liquid●doesn’t●contain●petrol,●so●

never●pour●the●liquid●into●a●using●oil●tank.

●● Brake●uid●absorbs●water●Make●sure●the●

replacement●brake●uid●comes●from●a● container●that●has●been●stored●in●good● conditions●and●is●recent.

●● Check●that●the●pedal●is●rm●after●each●

bleed.

► An air bubble in the brake system can

lead to a partial or total lost of brakes and may lead to a serious or even fatal injury.

► Leaks in the brake system may lead to a

serious or even fatal injury.

► Moisture in the brake uid may cause

vapour lock and a sudden loss of braking power, may lead to a serious or

even fatal injury.

► Use brake uid DOT 4 only ► Test the brake after each bleed.

User maintenance guide

This document can not be reproduced or released without the Sodikart authorization.

MAN.SIG.EN.02 04/2014

USE SPARE PARTS OF SODI ORIGIN

User maintenance guide

6.1.8 - Bleeding the rear brake circuit

Legend 1 Bleeder screw 2 Cap 3 Reservoir

● Use a pipe and a container to collect the used uid.

● Remove the bleeder screw (1) protective cover and connect the hose to the bleed nipple with the free end in the receptacle.

● Gently unscrew the bleeder screw (1) and the ller cap (2).

● Repeatedly press the brake pedal until all the uid has drained out.

● When all the uid has been drained, remove the ller cap (2) and top up to the maximum level with brake uid. Tighten the bleed screw (1), and then press the brake pedal three or four times.

● Loosen the bleeder screw (1) of the calliper. Brake uid should ow out. Retighten the bleed screw, and repeat this step several times to feed the circuit properly. Remember to add brake uid to the reservoir (3) as required. Bleed the circuit so that the brake uid owing out of the hose contains no air bubbles.

● Retighten the calliper bleed screw (1), remove the pipe and reapply the protective cap.

● Top up the uid in the reservoir (3) to its maximum level, and retighten the cap (2).

●● We●recommend●that●you●drain●and●rell●the●

brake●circuit●after●every●brake●pad●change.● This●will●allow●you●to●maintain●optimum● braking●performance.

●● To●bleed●your●brake●system●more●rapidly,●

especially●for●a●big●eet,●we●recommend● the●priming●system●SODIKART●(Ref.● OU951.002).

●●

Store●the●used●brake●uid●in●labelled● containers●until●it●is●collected●by●a●specialist● waste●disposal●company.

●● The●brake●liquid●doesn’t●contain●petrol,●so●

never●pour●the●liquid●into●a●using●oil●tank.

●● Brake●uid●absorbs●water●Make●sure●the●

replacement●brake●uid●comes●from●a● container●that●has●been●stored●in●good● conditions●and●is●recent.

●● Check●that●the●pedal●is●rm●after●each●

bleed.

► An air bubble in the brake system can

lead to a partial or total lost of brakes and may lead to a serious or even fatal injury.

► Leaks in the brake system may lead to a

serious or even fatal injury.

► Moisture in the brake uid may cause

vapour lock and a sudden loss of braking power, may lead to a serious or

even fatal injury.

► Use brake uid DOT 4 only ► Test the brake after each bleed.

This document can not be reproduced or released without the Sodikart authorization.

CONFIGURE THE KART ACCORDING TO THE GUIDE INSTRUCTIONS

MAN.SIG.EN.02

04/2014

6.1.9 - Bleeding the steering wheel controlled front brake circuit

Legend 1 Bleeder screw 2 Cap 3 Brake lever 4 Reservoir

● Use a pipe and a container to collect the used uid.

● Remove the protective caps from the bleed screws (1) on each front calliper, and then place a hose on the bleed screw. The other end of the hose should be placed in an empty container.

● Gently unscrew the bleeder (1) screw and the ller cap (2).

● Apply the brake lever (3) repeatedly until all the brake uid has drained out.

● When all the uid has been drained, remove the ller cap (2) and top up to the maximum level with brake uid. Tighten the bleed screw (1), and then press the brake lever (3) three or four times.

This document can not be reproduced or released without the Sodikart authorization.

● Retighten the calliper bleed screw (1), remove the pipe and reapply the protective cap.

● Repeat the operation for the front left calliper.

● Top up the brake uid in the reservoir (4) to its maximum level, and retighten the cap (2).

●● We●recommend●that●you●drain●and●rell●the●

brake●circuit●after●every●brake●pad●change.● This●will●allow●you●to●maintain●optimum● braking●performance.

●● To●bleed●your●brake●system●more●

rapidly,●especially●for●a●big●eet,●we● recommend●the●priming●system●SODIKART● (Ref.●OU951.002).

●● Store●the●used●brake●uid●in●labelled●

containers●until●it●is●collected●by●a●specialist● waste●disposal●company.

●● The●brake●liquid●doesn’t●contain●petrol,●so●

never●pour●the●liquid●into●a●using●oil●tank.

●● Brake●uid●absorbs●water●Make●sure●the●

replacement●brake●uid●comes●from●a● container●that●has●been●stored●in●good● conditions●and●is●recent.

●● Check●that●the●pedal●is●rm●after●each●

bleed.

► An air bubble in the brake system can

lead to a partial or total lost of brakes and may lead to a serious or even fatal injury.

► Leaks in the brake system may lead to a

serious or even fatal injury.

► Moisture in the brake uid may cause

vapour lock and a sudden loss of braking power, may lead to a serious or

even fatal injury.

► Use brake uid DOT 4 only. ► Test the brake after each bleed.

User maintenance guide

MAN.SIG.EN.02 04/2014

USE SPARE PARTS OF SODI ORIGIN

User maintenance guide

6.1.10 - Replacing calliper seals / 4 piston caliper pistons D18 (front)

This operation must be performed by a Sodikart dealer.

Removing

Reassembly

Legend 1 Pin 2 Brake pad 3 Bleeder screw 4 Mounting screw

● Untwist the ends of the pin (1) and then remove it.

● Remove the brake pads (2).

● Remove the bleed screw (3) and its cap.

● Disconnect the yoke by removing the two mounting screws (4).

Legend 5 O-ring 6 Piston 7 Gasket 8 Groove

● Apply PFG110 grease to the O-rings (7).

● Check that the bases of the grooves (8) are clean.

● Place the O-rings (7) in position in the grooves (8).

● Place the pistons (6) in position.

● Apply the same procedure for the second halfcalliper.

● Apply PFG110 grease to the O-rings (5).

● Place the O-rings (5) in position, and then connect the two half-callipers.

Legend 5 O-ring 6 Piston 7 Gasket

● Remove the two O-rings (5), the two pistons (6), and the two seals (7) from each half-calliper.

● Clean the half calliper bodies. Do not use WD40 or other greasy products to clean the callipers.

► Do not use any cleaning product that

could damage the seals. A brake uid leak could appear, causing a serious or fatal accident.

This document can not be reproduced or released without the Sodikart authorization.

Legend 3 Bleeder screw 4 Mounting screw

● Tighten the two screws (4). Torque 12 Nm, applying a drop of weak thread locking compound to each screw.

● Tighten the bleed screw and its cap (3). Torque 8 Nm.

● Reinstall brake pads (refer to the section on Cleaning/Replacement of front brake pads).

●● 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.

CONFIGURE THE KART ACCORDING TO THE GUIDE INSTRUCTIONS

MAN.SIG.EN.02

04/2014

6.1.11 - Replacing calliper seals / 4 piston caliper pistons D24 (rear)

This operation must be performed by a Sodikart dealer.

Removing

1 8

Legend 1 Adjustment screw 2 Return screw 3 Spring (not on KZ and DD2) 4 Pin 5 Brake pad 6 Bleeder screw 7 Ball 8 Mounting screw

Legend 9 O-ring 10 Piston 11 Gasket

Legend 12 Clip 13 Piston stop

● Adjust the brake pads until they reach the stop using the adjustment screws (1). Remove the four return screws (2) and the four springs (3).

● Untwist the ends of the pin (4) and then remove it.

● Remove the brake pads (5).

● Remove the bleed screw (6) and its cap.

● Remove the ball (7), taking care not to lose it (if equipped).

● Disconnect the yoke by removing the two mounting screws (8).

This document can not be reproduced or released without the Sodikart authorization.

● Remove the two O-rings (9), the two pistons (10), and the two seals (11) from each half-calliper.

12 13

● Remove the piston stop clip (12) using ne pliers or a scriber.

● Loosen the piston stop (13) and remove the O-ring.

● Apply the same procedure for the second halfcalliper.

● Clean the half calliper bodies. Do not use WD40 or other greasy products to clean the callipers.

► Do not use any cleaning product that

could damage the seals. A brake uid leak could appear, causing a serious or fatal accident.

User maintenance guide

● A - Bleeder screw with ball

● B - Bleeder screw without ball

MAN.SIG.EN.02 04/2014

USE SPARE PARTS OF SODI ORIGIN

User maintenance guide

Reassembly

Legend 12 Clip

● Place a new piston stop clip (12) in position.

12 1313

Legend 12 Clip 13 Piston stop

● Place the piston stop clip (12) in the groove of the piston stop (13).

● Check that the piston stop clip (12) is correctly clipped in the groove of the piston stop (13).

● IMPORTANT: To ensure that the clip is positioned on the piston stop, loosen the stop; it should not leave the calliper body.

13 14

Legend 13 Piston stop 14 O-ring

● Apply PFG110 grease to a new O-ring (14).

● Place the O-ring (14) in the piston stop groove (13).

● Apply PFG110 grease to the O-ring (14) and the piston stop (13).

Legend 13 Piston stop 15 Sodikart tools

● Push the piston stop (13) into the tool (15), taking care not to damage the O-ring.

● Place the piston stop (13) and the tool (15) on the half calliper.

● Fully tighten the piston stop (13) on the half-calliper using a screwdriver, and then remove the tool (15).

Legend 9 O-ring 10 Piston 11 Gasket 16 Groove

● Apply PFG110 grease to the O-rings (11).

● Check that the bases of the grooves (16) are clean.

● Place the O-rings (11) in position in the grooves (16).

● Place the pistons (10) in position.

● Apply the same procedure for the second halfcalliper.

● Apply PFG110 grease to the O-rings (9).

● Place the O-rings (9) in position, and then connect the two half-callipers.

This document can not be reproduced or released without the Sodikart authorization.

CONFIGURE THE KART ACCORDING TO THE GUIDE INSTRUCTIONS

MAN.SIG.EN.02

04/2014

6.1.12 - Replacing master cylinder seals and pistons

This operation must be performed by a Sodikart dealer.

Removing

Legend 6 Bleeder screw 7 Ball 8 Mounting screw

● Tighten the 2 screws (8). Torque 18Nm, applying a drop of weak thread locking compound to each screw.

● Reinsert the ball (7) in its housing (if necessary).

● Tighten the bleed screw and its cap (6). Torque 10 Nm.

● Reinstall brake pads (refer to the section on Cleaning/Replacement of rear brake pads).

Legend 1 Pressure pin 2 Dust cover 3 Pin 4 Piston lever

● Remove the two pressure pins (1) and the dust cover (2).

● Withdraw the pin (3) and remove the piston lever assembly (4) from the master cylinder.

User maintenance guide

● A - Bleeder screw with ball

● B - Bleeder screw without ball

●● Always●use●new●seals●and●clips.

●● Replace●any●defective●parts,●using●only●

This document can not be reproduced or released without the Sodikart authorization.

original●SODIKART●parts.

●● Install●a●new●set●of●pads●after●any●servicing●

of●the●callipers.

Legend 5 Yoke 6 Piston 7 O-ring 8 Gasket

● Disconnect the yoke (5) from the piston (6).

● Remove the O-ring (7) and the seal (8).

● Clean the body of the master cylinder. Do not use WD40 or other greasy products to clean the master cylinder.

► Do not use any cleaning product that

could damage the seals. A brake uid leak could appear, causing a serious or fatal accident.

MAN.SIG.EN.02 04/2014

USE SPARE PARTS OF SODI ORIGIN

User maintenance guide

Reassembly

Legend 5 Yoke 6 Piston 7 O-ring 8 Gasket

● Apply PFG110 grease to the O-ring (7) and the gasket (8).

● Place the O-ring (7) in the piston groove (6).

● Install the gasket (8) on the piston (6).

● Apply PFG110 grease to the O-ring (7) the gasket (8), and the piston (6).

● Fit the yoke (5) to the piston (6).

Legend 1 Pressure pin 2 Dust cover 3 Pin 4 Piston lever 9 Sodikart tools

● Reinstall the piston lever assembly (4) in the master cylinder.

● Place the master cylinder on the tool (9) and reinstall the pin (3).

● Reinstall the dust cover (2) and pressure pins (1) on the master cylinder.

●● Always●use●new●seals.

●● Replace●any●defective●parts,●using●only●

original●SODIKART●parts.

This document can not be reproduced or released without the Sodikart authorization.

CONFIGURE THE KART ACCORDING TO THE GUIDE INSTRUCTIONS

MAN.SIG.EN.02

04/2014

6.1.13 - Replacing the front master cylinder pistons

This operation must be performed by a Sodikart dealer.

6.1.14 - Cleaning

Brakes should be cleaned using a dry cloth and brake cleaner only.

Do not use WD40 or other greasy products to clean the callipers and brake discs.

Legend 1 Screw 2 Nut 3 Handle 4 Push rod 5 Piston

Removing

● Remove the screw (1) and the nut (2).

● Remove the handle (3) and the push rod (4).

● Remove the piston (5) from the master cylinder.

● Clean the body of the master cylinder. Do not use WD40 or other greasy products to clean the master cylinder.

► If WD-40 or a similar cleaning product is

splashed on the brake disc or calliper, braking will be less efcient or possibly totally ineffective for a few revolutions. This could cause a serious or fatal accident.

► Do not apply WD-40 or other cleaning

products to the brake pump.

User maintenance guide

► Do not use any cleaning product that

could damage the seals. A brake uid leak could appear, causing a serious or fatal accident.

Reassembly

● Apply PFG110 grease to the piston (5).

● Reinsert the piston (5) in the master cylinder.

● Reinstall the handle (3) and push rod (4) using the

This document can not be reproduced or released without the Sodikart authorization.

screw (1) and nut (2).

●● Replace●any●defective●parts,●using●only●

original●SODIKART●parts.

MAN.SIG.EN.02 04/2014

USE SPARE PARTS OF SODI ORIGIN

User maintenance guide

6.2 - Tyres

6.2.1 - Tyres change

Legend 1 Rim 2 Tyre 3 Direction of rotation 4 Ination system 5 Grease 6 Tyre iron

● Place the kart on a trolley.

● Place the wheel on a tyre remover (OU942.002).

● When the tyre (2) is detached on both sides, remove it completely using tyre irons (6).

● Take the new tyre and grease the tyre (grease LU823.003 (5)) in order to make assembly and removal easier.

● Replace the tyre (2) on the valve side of the wheel rim (1) ensuring the correct rotation direction.

● Once in place, strap your tyre with a belt when you inate more than 3 bars.

● Put the wheel back on the kart and tighten the nuts back again securely.

● Adjust the pressure with a manometer (4) (OU943.002).

●● Always●change●the●whole●set●whenever●a●

tyre●is●changed●(fronts,●rears,●or●all●the●set).

●● Always●place●the●tyres●so●that●they●rotate●in●

the●direction●indicated●on●the●tyre●wall.

●● Never●inate●the●tyres●more●than●4●bars.

●● Excessive●wear●of●tyres●can●be●result●from●

bad●front●wheel●axle●unit●alignment.

●● Use●tyres●with●a●grip●adapted●to●your●track.

●● Give●worn●tyres●at●a●specialist●of●tyre●

treatment●according●to●local●environmental● regulation.

► Change all damaged rims. A damaged

rim may lead to a loss of tyre or loss of pressure and may lead to a serious or even fatal injury.

► Check the tyre wear daily. Worn or

damaged tyres may lead to a serious or

even fatal injury.

► Never run with worn or damaged tyres:

a burst of tyre may lead to a serious or even fatal injury.

► Always blow up tyre with the pressure

recommended by the manufacturer.

► Cold tyres have a reduced adherence,

and increase the loss of control of the kart. This may lead to a serious or even fatal injury.

► Too much grip reduces the stability of

the kart under impact, and lead to a tendency to go on two wheels. It also increases the risk of riding over.

► Store tyres in an appropriate area to

prevent re hazard.

► Never inate above 4 bars: there is a

risk of severe injury due to potential failure of the rim.

This document can not be reproduced or released without the Sodikart authorization.

CONFIGURE THE KART ACCORDING TO THE GUIDE INSTRUCTIONS

MAN.SIG.EN.02

04/2014

6.2.2 - Table of the recommended tyre pressures

Pressure (bar) Slick tyres Cold (20°) Warm Categories Brand Type Front Rear Front Rear

KF2 –SLICK (MEDIUM) VEGA XM 0,5 0,5 0,7 0,7 KF3 –SLICK DUR VEGA XH 0,6 0,6 0,8 0,8 KZ2 – SLICK MEDIUM VEGA XM 0,5 0,45 0,75 0,75 KZ125 VEGA SL4 0,7 0,65 0,85 0,85 X30 KOMET K1H 0,65 0,7 0,85 0,9 ROTAX MAX MOJO F2 0,7 0,65 0,9 0,9 ROTAX MAX Euro challenge MOJO D2 0,7 0,65 0,9 0,9 ROTAX Junior MOJO D1 0,9 0,85 1,05 1,05 ROTAX DD2 MOJO D3 0,65 0,55 0,85 0,85 NATIONALE MOJO F1 0,9 0,85 1,05 1,05

Wet tyres Cold (20°) Warm Categories Brand Type Front Rear Front Rear

KF2/KF3 VEGA W5 1 1 1,1 1,1 KZ2 VEGA W5 1 1 1,1 1,1 KZ125 VEGA W5 1 1 1,1 1,1 X30 KOMET K1W 1 1 1,1 1,1 ROTAX MAX MOJO W2 1,2 1,2 1,3 1,3 ROTAX DD2 MOJO W2 1,2 1,2 1,3 1,3 NATIONALE

MOJO (slick) F1 2,5 2,5 2,5 2,5

User maintenance guide

Wet conditions:

● Little water: slightly drop the pressure from the recommended value.

● Much water: increase the pressure from the recommended value.

This document can not be reproduced or released without the Sodikart authorization.

MAN.SIG.EN.02 04/2014

USE SPARE PARTS OF SODI ORIGIN

6.3 - Cleaning the chassis

The cleaning of the chassis and its components is to be done with a special cleaning product (refer to the ITAKA website). Do not use the product on brake pads and brake calipers.

This uid cleans, removes grease, protects, lubricates and protects the rotating parts from damp (stub axle, tie rods, etc).

● Protect the break calipers and the brake disk with a dry piece of cloth.

● Spray the whole kart with the cleaning product, and

User maintenance guide

let it act for 30 seconds.

● Wipe the frame and the components with a dry cloth.

6.4 - Maintenance summary

6.4.1 - Bolting

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.

Damaged screws and bolts have to be changed.

●● Clean●your●kart●on●a●regular●basis:●it●is●a●

good●way●to●check●it●and●detect●damages,● if●any.

●● The●complete●kart●cleaning●must●be●done●

after●each●run.

► Spray cleaning product on brake pads

or brake caliper may reduce the braking ability partially or totally, and can lead to a serious accident.

6.4.2 - Steering

● Check daily the upper and lower column plastic support torque as well as stub axle screws.

● Make sure that front wheel axle unit is not out of line (stub axles bent or broken).

● Check that the tie rods are not damaged.

6.4.3 - Bodywork parts

● Parts of the bodywork must not be broken or have sharp edges.

● Check the body part fastenings.

● Whenever bodywork parts are changed, make sure that nuts and bolts are assembled with nuts on the inside and bolt heads on the outside, in order not to cause any injury.

6.4.4 - Tyres

● Take particular care when tting tyres that they rotate in the right direction. Follow the directional arrows on the tyre wall.

● Check for tyre wear with the indicators in the tread. One must always be able to see them. Tears or tread separation must not be found.

● Before each session check tyre pressures.

6.4.5 - Braking

● Make sure before all sessions that the braking system is working properly.

● Brake uid should not be black.

● Drain and change black uid. Check levels.

● Ensure that brake pads are correctly tted and do not fall below the minimum thickness of 6 mm (Lining + Steel support).

● Brake hoses must not show any leaks at connection points. Replace if damaged.

CONFIGURE THE KART ACCORDING TO THE GUIDE INSTRUCTIONS

This document can not be reproduced or released without the Sodikart authorization.

MAN.SIG.EN.02

04/2014

7 - Trouble shooting

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 uid?

4. Are the hoses correctly connected?

5. Are the brake pads worn?

6. Is the calliper fully tightened on its support?

7.2 - The kart brakes continually

1. Is the brake uid old?

2. Is the brake disk correctly centred in relation to brake pads?

3. Is the calliper fully tightened on its support?

4. Is the brake pedal too tight?

5. Are the brake pads correctly assembled?

7.3 - The kart is hard to turn

1. Are the stub axles tightened to torque specication?

2. Is the front axle unit checked?

User maintenance guide

7.4 - The steering of the kart is not precise

1. Are the front wheels tightened?

2. Are the stub axles to torque tightening specication?

3. Are the column plastic supports tightened to torque specication?

4. Are the tie rods correctly assembled and to torque specication?

5. Is the front wheel axle unit adjustment checked?

7.5 - The kart tends to go to the side

1. Is the front wheel axle unit adjustment checked?

2. Are the tie rods correctly assembled?

3. Are the tie rods locking nuts securely tightened?

This document can not be reproduced or released without the Sodikart authorization.

4. Is there a tie rod bent or broken?

5. Do the rear wheels have exactly the same circumference?

7.6 - The kart skids very much on bends

1. Are the tyres worn?

2. Are the tyres inated to the recommended pressures?

3. Is the rear axle adjustment suited to the track conditions?

4. Is the front wheel axle unit adjustment correctly checked?

MAN.SIG.EN.02 04/2014

USE SPARE PARTS OF SODI ORIGIN

User maintenance guide

8 - Index

Adjustment screw ........................................... 27, 28, 33

Axle............................................................................. 24

Ball joint .................................................................... 8, 9

Bleeder screw Brake bleeder Brake distributor Brake lever Brake pad Brake pedal Brake rod Bumper Bumper support

Bushing....................................................................... 13

..................................... 28, 30, 31, 32, 33

............................................................... 7

......................................................... 25

................................................................. 31

....................................................... 27, 32, 33

................................................................ 28

.................................................................... 10

....................................................................... 15

.......................................................... 15

Calliper body............................................................... 27

Cap

................................................................. 28, 30, 31

Chassis lug Cleaner

Clutch handle................................................................ 8

................................................................. 15

......................................................................... 7

Direction of rotation .................................................... 38

Disc

............................................................................. 28

Dust cover

.................................................................. 35

Eccentric ............................................................... 21, 22

Fixing points ................................................................11

Fly nut

......................................................................... 10

Frame

........................................................................... 6

Front brake pump Fuel tank

................................................................. 6, 10

....................................................... 25

Ination system........................................................... 38

Key for slotted round nut .............................................. 7

Left side pod ................................................................. 6

Left side pod support

................................................... 6

Marked slot ........................................................... 21, 22

Master cylinder tool kit Mounting kit

................................................................ 15

.................................................. 7

Nassau panel................................................................ 6

Nassau panel support............................................. 8, 10

Overow bottle........................................................ 6, 10

Overow bottle hose

Overow bottle support............................................... 10

................................................... 10

Pad ............................................................................. 28

Petrol tank hose.......................................................... 10

Pin canon...................................................................... 8

Piston........................................................ 27, 32, 35, 37

Piston lever

Piston stop

Piston stop centring device........................................... 7

Plastic steering column support.................................... 8

........................................................... 35, 36

............................................................ 33, 34

This document can not be reproduced or released without the Sodikart authorization.

Gearbox control lever ................................................... 8

Gear lever assembly..................................................... 6

Grease

.......................................................................... 7

Hub ......................................................................... 7, 24

Hub base

.................................................................... 24

CONFIGURE THE KART ACCORDING TO THE GUIDE INSTRUCTIONS

MAN.SIG.EN.02

04/2014

Rear brake pump ........................................................ 25

Rear bumper................................................................. 6

Rear protection Red plug Reservoir Return screw

Right side pod............................................................... 6

Right side pod support.................................................. 6

Rim

......................................................................... 6, 38

........................................................... 15

..................................................................... 10

........................................................ 28, 30, 31

........................................................ 27, 33

Safety cable ................................................................ 10

Safety lug.................................................................... 15

Seat

.........................................................................6, 11

Seat stiffener Seat supports Side pod Side pod support Sodikart tools Spoiler Spoiler lower support Spoiler upper support Spring stabilizer

Steering column.................................................. 8, 9, 10

Steering column assembly

Steering column support......................................... 8, 10

Steering tie rods Steering wheel Steering wheel support

Stub axle....................................................................... 7

Stub axle arm

This document can not be reproduced or released without the Sodikart authorization.

Stub axle screw adjuster Stub axle spacer adjuster

.............................................................. 12

..............................................................11

..................................................................... 13

........................................................ 13

........................................................ 34, 36

.................................................................... 6, 14

.................................................. 13

................................................. 13

......................................................................... 27

..................................................................... 10

........................................... 6

........................................................... 8

.............................................................. 6

................................................. 8

............................................................... 9

.............................................. 7

............................................. 7

User maintenance guide

T handle socket spanner .............................................. 7

T handle wrench allen key Tire protection Tube protection

Tyre............................................................................. 38

Tyre iron...................................................................... 38

MAN.SIG.EN.02 04/2014

............................................ 7

............................................................. 15

........................................................... 15

USE SPARE PARTS OF SODI ORIGIN

Track:

Trial:

Pilot:

TRACK

State of the track:

Temperature:

User maintenance guide

ENGINE

Carburator type:

Adjustments:

Exhaust type:

Gear ratio:

Length:

Chain length :

Notes

Date: Time:

CHASSIS

Stub axle height:

Caster / Camber:

Parallelism:

Seat popsition:

● Height:

● Distance axle:

● Distance fork:

Masses:

Axle type:

Stiffeners:

TRIAL TIMES

Tyre type:

Diameter:

Lap Partial 1 Partial 2 Partial 3 Partial 4

Pressure start / Wheel unit width

1 2

3 4

1 2

3 4

Pressure arrival

1 2

3 4

1 2

3 4

1 2

3 4

1 2

3 4

This document can not be reproduced or released without the Sodikart authorization.

1 2

3 4

CONFIGURE THE KART ACCORDING TO THE GUIDE INSTRUCTIONS

1 2

3 4

MAN.SIG.EN.02

04/2014

9 - Homologation

9.1 - SIGMA S3

Homologation N°

Constructeur Marque Modèle Catégorie Durée de l’homologation Nombre de pages

La présente Fiche d’Homologation reproduit descriptions, illustrations et dimensions du cadre du châssis au moment de l’homologation CIK-FIA. Le Constructeur a la possibilité de les modifier par extension, mais seulement dans les limites fixées par le Règlement CIK-FIA en vigueur.

PHOTO VUE DE DESSUS DU CHÂSSIS COMPLET IDENTIQUE À L’UN DES MODÈLES PRÉSENTÉS À

PHOTO FROM ABOVE OF COMPLETE CHASSIS IDENTICAL TO ONE OF THE MODELS SUBMITTED

CADRE DU CHÂSSIS / CHASSIS FRAME

L’HOMOLOGATION SANS PARE-CHOCS, CARROSSERIE, SIEGE, NI PNEUMATIQUES

FOR HOMOLOGATION WITHOUT BUMPERS, BODYWORK, SEAT OR TYRES

Signature et tampon de l’ASN Signature et tampon de la CIK-FIA

Signature and stamp of the ASN Signature and stamp of the CIK-FIA

FICHE D’HOMOLOGATION

HOMOLOGATION FORM

COMMISSION INTERNATIONALE

DE KARTING - FIA

Manufacturer Make Model Category Validity of the homologation Number of pages

This Homologation Form reproduces descriptions, illustrations and dimensions of the chassis frame at the moment of the CIK-FIA homologation. The Manufacturer may modify them by Extension, but only within the limits set by the CIK-FIA Regulations in force.

SODIKART SODI ST30

KF4 – KF3 – KF2 – KZ2 – KZ1 – ICE

6 ans / years 4

41/CH/14

Homologation N°

DESSIN TECHNIQUE DU CADRE -

Le dessin technique sert pour identifier la structure et la géométrie principale du cadre. (dimensions et numérotation des tubes selon tableau section B)

The technical drawing is used for the identification of the structure and the main geometry of the frame. (dimensions and tubes numbering according

Représenter seulement les tubes principaux de la structure et les attaches supportant les fusées et les barres de

Only show tubes from the structure and fixations sustaining the stub axles and the stiffening bars that require details and

Échelle 1:10

A TECHNICAL DRAWING OF FRAME –

table in section B)

VUE DE DESSUS / VIEW FROM ABOVE

rigidification nécessitant informations et dimensions à la section B

dimensions as featured in section B

VUE DE CÔTÉ / SIDE VIEW

41/CH/14

Scale 1:10

User maintenance guide

Homologation N°

1. Cadre

A= Empattement mesures fixes

B= Tubes principaux de la structure,

C = Nombre de courbes dans les tubes

This document can not be reproduced or released without the Sodikart authorization.

D = Nombre de tubes ayant un Ø

E = Largeur avant extérieure

F = Largeur arrière extérieure

G1 = Porte-à-faux arriére des tubes

G2 = Porte-à-faux avant du tube

Remarque / Remark: Dans les points B, C et D, seuls les tubes principaux d’une longueur supérieure à 150 mm sont à prendre en considération à

l’exclusion tous les supports pour accessoires. In points B, C and D, only the main tubes of a length of more than 150 mm are to be taken into

consideration, excluding all supports for accessories.

COTES

diamètre minimum 21mm, d'une longueur supérieure à 150mm, à l'exception des tubes d'un diamètre inférieur à 21mm et tous les supports pour les accessoires.

de Ø supérieur à 21mm

supérieur à 21mm

principaux (obligatoire)

principal

PHOTO DU MARQUAGE DU NUMERO

D’HOMOLOGATION

1. Frame

Data

A= Wheel base fix ed measurements

B= Main tubes of the structure,

minimum diameter of 21mm, length over 150mm, except tubes with a diameter of less than 21mm and all the supports for the accessories.

C = Number of bends on the tubes

with a diameter greater than 21mm.

D = Number of tubes with a diameter

greater than 21mm

E = Outer front width

F = Outer rear width

G1 = Rear overhang for the main

tubes (mandatory)

G2 = Front overhang for the main

tube

C PHOTO OF THE HOMOLOGATION NUMBER MARKING

Données

1) 30

2) 30

3) 30

4) 30

5) 30

6) 30

7) 28

DIMENSIONS

1048

725 640

210

252

41/CH/14

Tolérances

Tolerances

+/- 10mm

+/- 0.5mm

+/- 0.5mm +/- 0.5mm +/- 0.5mm +/- 0.5mm +/- 0.5mm +/- 0.5mm +/- 0.5mm +/- 0.5mm +/- 0.5mm

____

+/- 10mm

+/- 15mm

+/- 10mm

41/CH/14

Homologation N°

PHOTO DE LA COMMANDE DE FREINAGE

La commande de freinage doit être isolée du châssis et montrer la double commande

The brake control must be separated from chassis and show the double linkage

d PHOTO OF BRAKE CONTROL CABLE

MAN.SIG.EN.02 04/2014

Le marquage indiqué sur le tube transversal arriére doit rester clairement visible en permanence

The marking located on the rear strut must be clearly visible at all times

USE SPARE PARTS OF SODI ORIGIN

User maintenance guide

Homologation N°

52/CH/17

COTES

DIMENSIONS

1. Cadre

1.●Frame●

Données

Tolérances

● Data●

Tolerances●

A= Empattement mesures fixes

A=● Wheel●base●fixed●measurements●

1040

+/- 10mm

B= Tubes principaux de la structure,

diamètre minimum 21mm, d'une longueur supérieure à 150mm, à l'exception des tubes d'un diamètre inférieur à 21mm et tous les supports pour les accessoires.

B=●●Main●tubes●of●the●structure,●

minimum●diameter●of●21mm,● length●over●150mm,●except●tubes● with●a●diameter●of●less●than● 21mm●and●all●the●supports●for●the● accessories.●

1)28

2)28

3)30

4)30

5)30

6)28

+/- 0.5mm

+/- 0.5mm +/- 0.5mm +/- 0.5mm +/- 0.5mm +/- 0.5mm +/- 0.5mm +/- 0.5mm +/- 0.5mm +/- 0.5mm

C = Nombre de courbes dans les tubes

de Ø supérieur à 21mm�

C●=●Number●of●bends●on●the●tubes●

with●a●diameter●greater●than● 21mm.●

____

D = Nombre de tubes ayant un Ø

supérieur à 21mm

D●=●Number●of●tubes●with●a●diameter●

greater●than●21mm●●

____

E = Largeur avant extérieure

E●=● Outer●front●width●

725

+/- 10mm

F = Largeur arrière extérieure

F●=● Outer●rear●width●

638

+/- 10mm

G1 = Porte-à-faux arriére des tubes

principaux (obligatoire)

G1 = Rear overhang for the main

tubes (mandatory)

210

+/- 15mm

G2 = Porte-à-faux avant du tube

principal

G2 = Front overhang for the main

tube

249

+/- 10mm

Remarque / Remark: Dans les points B, C et D, seuls les tubes principaux d’une longueur supérieure à 150 mm sont à prendre en considération à

l’exclusion tous les supports pour accessoires.●In●points●B,●C●and●D,●only●the●main●tubes●of●a●length●of●more●than●150●mm●are●to●be●taken●into●

consideration,●excluding●all●supports●for●accessories.

PHOTO DU MARQUAGE DU NUMERO

D’HOMOLOGATION

C PHOTO●OF●THE●HOMOLOGATION●NUMBER●MARKING

Le marquage indiqué sur le tube transversal arriére doit rester clairement visible en permanence

The marking located on the rear strut must be clearly visible at all times

Homologation N°

52/CH/17

PHOTO DE LA COMMANDE DE FREINAGE

d PHOTO●OF●BRAKE●CONTROL●CABLE●

La commande de freinage doit être isolée du châssis et montrer la double commande

The brake control must be separated from chassis and show the double linkage

9.2 - SIGMA KZ

Homologation N°

FICHE D’HOMOLOGATION

HOMOLOGATION FORM

COMMISSION INTERNATIONALE

Constructeur Marque Modèle Catégorie Durée de l’homologation Nombre de pages

PHOTO VUE DE DESSUS DU CHÂSSIS COMPLET IDENTIQUE À L’UN DES MODÈLES PRÉSENTÉS À

PHOTO FROM ABOVE OF COMPLETE CHASSIS IDENTICAL TO ONE OF THE MODELS SUBMITTED

CADRE DU CHÂSSIS / CHASSIS FRAME

L’HOMOLOGATION SANS PARE-CHOCS, CARROSSERIE, SIEGE, NI PNEUMATIQUES

FOR HOMOLOGATION WITHOUT BUMPERS, BODYWORK, SEAT OR TYRES

Signature et tampon de l’ASN Signature et tampon de la CIK-FIA

Signature and stamp of the ASN Signature and stamp of the CIK-FIA

DE KARTING - FIA

Manufacturer Make Model Category Validity of the homologation Number of pages

SODIKART SODI ST32

KF4 – KF3 – KF2 – KZ2 – KZ1 – ICE

6 ans / years

43/CH/14

Homologation N°

DESSIN TECHNIQUE DU CADRE -

Le dessin technique sert pour identifier la structure et la géométrie principale du cadre. (dimensions et numérotation des tubes selon tableau section B)

The technical drawing is used for the identification of the structure and the main geometry of the frame. (dimensions and tubes numbering according

Représenter seulement les tubes principaux de la structure et les attaches supportant les fusées et les barres de

Only show tubes from the structure and fixations sustaining the stub axles and the stiffening bars that require details and

Échelle 1:10

A TECHNICAL DRAWING OF FRAME –

table in section B)

VUE DE DESSUS / VIEW FROM ABOVE

rigidification nécessitant informations et dimensions à la section B

dimensions as featured in section B

VUE DE CÔTÉ / SIDE VIEW

43/CH/14

Scale 1:10

Homologation N°

1. Cadre

A= Empattement mesures fixes

B= Tubes principaux de la structure,

diamètre minimum 21mm, d'une longueur supérieure à 150mm, à l'exception des tubes d'un diamètre inférieur à 21mm et tous les supports pour les accessoires.

C = Nombre de courbes dans les tubes

de Ø supérieur à 21mm

D = Nombre de tubes ayant un Ø

supérieur à 21mm

E = Largeur avant extérieure

F = Larg eur arrière extérieure

G1 = Porte-à-faux arriére des tubes

principaux (obligatoire)

G2 = Porte-à-faux avant du tube

principal

Remarque / Remark: Dans les points B, C et D, seuls les tubes principaux d’une longueur supérieure à 150 mm sont à prendre en considération à

l’exclusion tous les supports pour accessoires. In points B, C and D, only the main tubes of a length of more than 150 mm are to be taken into

consideration, excluding all supports for accessories.

COTES

1. Frame

Data

A= Wheel base fixed measurements

B= Main tubes of the structure,

minimum diameter of 21mm, length over 150mm, except tubes with a diameter of less than 21mm and all the supports for the

PHOTO DU MARQUAGE DU NUMERO

D’HOMOLOGATION

accessories.

C = Number of bends on the tubes

with a diameter greater than 21mm.

D = Number of tubes with a diameter

greater than 21mm

E = Outer front width

F = Outer rear width

G1 = Rear overhang for the main

tubes (mandatory)

G2 = Front overhang for the main

tube

Le marquage indiqué sur le tube transversal arriére doit rester clairement visible en permanence

The marking located on the rear strut must be clearly visible at all times

CONFIGURE THE KART ACCORDING TO THE GUIDE INSTRUCTIONS

C PHOTO OF THE HOMOLOGATION NUMBER MARKING

Données

1048

1) 32

2) 32

3) 32

4) 32

5) 32

6) 32

7) 28

725 642

210

253

DIMENSIONS

+/- 0.5mm

43/CH/14

Tolérances

Tolerances

+/- 10mm

+/- 0.5mm +/- 0.5mm +/- 0.5mm +/- 0.5mm +/- 0.5mm +/- 0.5mm +/- 0.5mm +/- 0.5mm +/- 0.5mm

____

+/- 10mm

+/- 15mm

+/- 10mm

Homologation N°

PHOTO DE LA COMMANDE DE FREINAGE

d PHOTO OF BRAKE CONTROL CABLE

43/CH/14

This document can not be reproduced or released without the Sodikart authorization.

La commande de freinage doit être isolée du châssis et montrer la double commande

The brake control must be separated from chassis and show the double linkage

MAN.SIG.EN.02

04/2014

9.3 - SIGMA DD2

Manufacturer

Chassis model

Sodi Sigma KZ,Sigma S3,Sigma DD2 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1 - Safety instructions

1.1 - Recap of all warnings included in this manual

2 - Reception

2.1 - Tooling for assembly and adjustment

2.2 - Maintenance products

3 - Assembly

3.1 - Precautions and recommendations

3.2 - Assembly of the steering column and steering wheel

3.3 - Positioning of the safety brake cable

3.4 - Frame stabilizers

3.6 - Assembly of the seat

3.7 - Assembly of the seat stiffeners

3.8 - Assembly of the bodywork

3.9 - Mounting the rear protections

3.10 - Mounting the rear protections DD2

3.11 - Mounting the front brake hose (optional)

4 - Commissioning

4.1 - Safety instructions to the pilots

4.2 - Pilot protection

5 - Adjustments

5.1 - Standard adjustments

5.2 - Adjustment of front wheels

5.2.1 - Adjustment of front tracking width

5.2.2 - Adjustment of front wheel height

5.2.3 - Adjustment of the caster

5.2.4 - Adjustment of the camber

5.2.5 - Front wheel alignment

5.2.6 - Adjustment of tie rods

5.3 - Adjustment of rear wheels

5.3.1 - Adjustment of hubs

5.3.2 - Position of rear axle

5.3.3 - Type of axle

5.4 - Adjustment of seat

5.5 - Adjustment of the brake distributor

5.5.1 - Standard adjustment

5.5.2 - More braking power on the front brakes

5.5.3 - More braking power on the rear brakes

6 - Maintenance

6.1 - Brakes

6.1.1 - Fluids and lubricants

6.1.2 - Frequency of cleaning and maintenance

6.1.3 - Replacing brake pads on the D18 4-piston calipers (front)

6.1.4 - Replacing brake pads on the D24 4-piston calipers (rear)

6.1.5 - Adjusting the gap between the pads and the disc

6.1.7 - Bleeding the front brake circuit

6.1.6 - Replacing the brake hose

► Check connexions of hoses, no leak. ► Use brake uid DOT 4 only.

► Use brake uid DOT 4 only ► Test the brake after each bleed.

6.1.8 - Bleeding the rear brake circuit

6.1.9 - Bleeding the steering wheel controlled front brake circuit

6.1.12 - Replacing master cylinder seals and pistons

6.1.13 - Replacing the front master cylinder pistons

6.1.14 - Cleaning

6.2 - Tyres

6.2.1 - Tyres change

6.2.2 - Table of the recommended tyre pressures

6.3 - Cleaning the chassis

6.4 - Maintenance summary

6.4.1 - Bolting

6.4.2 - Steering

6.4.3 - Bodywork parts

6.4.4 - Tyres

6.4.5 - Braking

7 - Trouble shooting

7.1 - The kart will not brake

7.2 - The kart brakes continually

7.3 - The kart is hard to turn

7.4 - The steering of the kart is not precise

7.5 - The kart tends to go to the side

7.6 - The kart skids very much on bends

8 - Index

9 - Homologation

9.1 - SIGMA S3

9.2 - SIGMA KZ

9.3 - SIGMA DD2