Manuel d'entretien et d'utilisation

user maintenance guide

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 Manuel d'entretien et d'utilisation
user maintenance guide

Avant-propos
Ce document a été préparé sur la base des spécifications les plus récentes à la date de publication. Sodikart se
réserve toutefois le droit d’apporter des changements afin de maintenir sa politique d’amélioration continue de ses
produits. Si des modifications ont été effectuées depuis, certaines différences peuvent exister entre le contenu du
manuel et le kart que vous possédez.

Le document s’applique à tous les modèles Sodikart et comprend des descriptions sur l’équipement tant de série
qu’optionnel. Aussi, vous pourrez trouver dans ce manuel des sections qui ne s’appliquent pas à votre modèle de
kart. Les illustrations sont utilisées pour décrire les principes d’assemblage. Elles ne sont pas censées représenter
exactement le kart dans le détail.

En cas de problème ou pour toute question concernant votre kart, veuillez vous adresser à votre distributeur ou
représentant local, ou bien à la société Sodikart.

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

The document applies to all Sodikart models and includes descriptions and explanations concerning both the standard
and optional equipment. This means that this manual might contain some sections that do not apply to your go-kart
model. The illustrations are used to describe the principles of assembly. They are not intended to be an exact, detailed
representation of the go-kart.

If you have problems or questions about your go-kart, please contact your local distributor or representative of
Sodikart.

© Sodikart 2019.

Parc d’activités des Hauts de Couëron

B.P.60 - 44220 COUËRON - France
Tel. : (33) 02 40 38 26 20
Fax : (33) 02 40 38 26 21
www.sodikart.com - [email protected]

CE DOCUMENT NE PEUT ÊTRE REPRODUIT OU COMMUNIQUÉ SANS LA PERMISSION DE SODIKART.

THIS DOCUMENT CAN NOT BE REPRODUCED OR RELEASED WITHOUT THE SODIKART AUTHORIZATION.

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Table des matières

Table of contents
1 - General........................................................ 4 6 - Maintenance............................................. 25
1.1 - Warning................................................................... 4 6.1 - Brakes - Usual maintenance................................. 25
1.2 - General precautions................................................ 4 6.1.1 - Fluids and lubricants.......................................... 25
1.3 - Safety instructions................................................... 4 6.1.2 - Frequency of cleaning and maintenance........... 26
1.3.1 - Meaning of the flags............................................. 5 6.1.3 - Replacing brake pads on the D18 4-piston
calipers (front).................................................... 27
1.3.2 - Safety stickers...................................................... 5
6.1.4 - Replacing brake pads on the D20 4-piston
calipers (rear)..................................................... 27
2 - Reception.................................................... 6 6.1.5 - Adjusting the gap between the pads and
2.1 - Main components.................................................... 6 the disc............................................................... 28
2.2 - Tooling for assembly and adjustment ..................... 7 6.1.6 - Replacing the brake hose.................................. 28
2.3 - Maintenance products............................................. 7 6.1.7 - Tightness of the brake hose screew.................. 28
6.1.8 - Bleeding the front brake circuit.......................... 29
3 - Assembly.................................................... 8 6.1.9 - Bleeding the rear brake circuit........................... 30
3.1 - Precautions and recommendations......................... 8 6.1.10 - Cleaning........................................................... 30
3.2 - Frame stabilizers..................................................... 8 6.2 - Brakes - Workshop maintenance.......................... 31
6.2.1 - Replacing calliper seals / 4 piston caliper
3.3 - Positioning of the safety brake cable...................... 8 pistons D18 (front)............................................. 31
3.4 - Assembly of the fuel tank and of the overflow 6.2.2 - Replacing calliper seals / 4 piston caliper
bottle...................................................................... 8 pistons D20 (rear).............................................. 32
3.5 - Assembly of the steering column and steering 6.2.3 - Replacing master cylinder seals and pistons 34
wheel...................................................................... 9 6.3 - Tyres...................................................................... 36
3.6 - Assembly of the seat............................................. 10 6.3.1 - Tyres change...................................................... 36
3.7 - Assembly of the seat stiffeners.............................. 11 6.3.2 - Table of the recommended tyre pressures......... 37
3.9 - Assembly of the bodywork.................................... 11 6.4 - Cleaning the chassis............................................. 37
3.10 - Mounting the rear protections............................. 14 6.5 - Maintenance summary.......................................... 38
6.5.1 - Bolting................................................................ 38
3.11 - Mounting the rear protections DD2...................... 14
6.5.2 - Steering.............................................................. 38
4 - Commissioning........................................ 15 6.5.3 - Bodywork parts.................................................. 38
6.5.4 - Tyres.................................................................. 38
4.1 - Safety instructions to the pilots............................. 15
6.5.5 - Braking............................................................... 38
4.2 - Pilot protection...................................................... 15
7 - Trouble shooting...................................... 38
5 - Adjustments.............................................. 16
7.1 - The kart will not brake........................................... 38
5.1 - Standard adjustments........................................... 16
7.2 - The kart brakes continually................................... 38
5.2 - Adjustment of front wheels.................................... 18
7.3 - The kart is hard to turn.......................................... 38
5.2.1 - Adjustment of front tracking width...................... 18
5.2.2 - Adjustment of front wheel height........................ 18 7.4 - The steering of the kart is not precise................... 38
5.2.3 - Adjustment of the caster..................................... 19 7.5 - The kart tends to go to the side............................. 38
5.2.4 - Adjustment of the camber.................................. 20 7.6 - The kart skids very much on bends....................... 38
5.2.5 - Quick adjustment of caster/camber pill.............. 20
5.2.6 - Front wheel alignment........................................ 22 8 - Index.......................................................... 39
5.2.7 - Adjustment of tie rods......................................... 22
5.3 - Adjustment of rear wheels..................................... 23 9 - Homologation........................................... 40
5.3.1 - Adjustment of hubs............................................. 23
5.3.2 - Position of rear axle........................................... 23
5.3.3 - Type of axle........................................................ 23
5.3.4 - Tightening torque for rear axle bearing.............. 24
5.4 - Adjustment of seat................................................. 24
5.5 - Adjustment of the brake distributor........................ 24
5.5.1 - Standard adjustment.......................................... 24
5.5.2 - More braking power on the front brakes............ 24
5.5.3 - More braking power on the rear brakes............. 24

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1 - General ●● Check the correct tightening of all parts and their
functionality after reassembly.
1.1 - Warning ●● To protect the environment, comply with all legal
requirements for the disposal of used fluids, batteries, and
A go-kart can be dangerous if is not correctly maintained or
tyres.
used. Read carefully this manual and pay a particular attention
to safety warnings and notes. ●● To protect nature and the environment, dispose of used
parts in accordance with regulations.
●● Not following the safety instructions of this manual, may
involve your liability if an accident occurs.
1.3 - Safety instructions
●● Read carefully hints, instructions or warnings following a
The kart has been designed in accordance with the pending
“notes” or a “warning”:
rules of the CIK / FIA in force, which ensures an optimum
►►Indicates a strong possibility of serious safety in normal conditions of use.
personal injury or death if instructions are not Its high speed and performances imply a proper maintenance.
followed.
For your safety and the one of other pilots, please
thoroughly respect:
●● Indicates a risk of property damage if
instructions are not followed. ●● The assembly instructions.
●● The adjustment recommendations.
●● The maintenance plan.
●● Provides useful information.
►►The SODI chassis is designed for safety
●● The warnings and precautions contained in this and reliability in normal conditions of use.
manual cannot cover every possible risk related to the Before using it, please read this manual and
maintenance, or lack of maintenance, of a go-kart. carefully follow the instructions. By not doing
so, you might be exposed to a risk of severe,
●● In addition to the messages given, it is important to
even fatal injury, and your kart might suffer
apply good judgement and apply the basic principles of
damages.
mechanical safety.
►►The SODI chassis can only be used on an
●● In case of any doubt on the way a particular operation of
approved track and by a driver who is in
maintenance must be made, ask for advice from a more
possession of a valid membership card of the
experienced mechanic.
kart’s federation of his own country.
1.2 - General precautions ► ►Prior to going on the track, please check all
points related to safety.
●● Keep the go-kart in it’s original state.
►►In order to avoid fire, put the kart at least one
●● Do not modify the go-kart. meter away from the buildings. Never leave
●● Use original Sodikart parts only. inflammable objects close to the kart.
●● For the safety and reliability of the go-kart, it is important to ►►If fuel has been poured, wipe and wait for
carry out the appropriate maintenance and repairs. vapours to dissipate, before starting the kart.
●● If toxic or flammable products are used, make sure that the ►►Kids and domestic animals have to be kept
places are ventilated well and that all the instructions of the away from the kart and the track.
manufacturer of these products are respected. ►►Never let anybody use the kart without making
●● Never use petrol as a substitute for cleaning solvent. sure before that the driver has knowledge of
●● Check all hoses and mountings in the brake system to all the safety instructions and that he wears
ensure that there are no leaks. the adequate protections.
●● Ensure that the safety stickers are present and in good ► ►Driving prohibited for a pilot with health
condition. problems (for example: heart problems).
●● Put in order the parts that must be reused, to be able to ►►Driving prohibited for a pilot who having a
reassemble them in the correct manner. strange behaviour or under drugs or alcohol.
●● Use adapted or special tools for every operation if
specified.
●● Check parts cleanliness before reassembly. Apply grease if
needed.
●● Use only lubricants, glues or specified waterproof products.
●● Replace by new parts : O’ rings, self locking nuts,
split pins, circlips, and other specific parts after every
disassembly.
●● Clean the contact areas from any trace of material, before
reassembling the parts.
●● Tighten up all fixations bolts to the specified tightening
torque using a torque wrench.
●● Remove any trace of oil or grease from all threads.

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1.3.1 - Meaning of the flags 1.3.2 - Safety stickers
Green flag Location
Do not apply the throttle before this flag is out
Black flag
Driver is to proceed to Pit Lane immediately,
wait for staff instructions.
Blue flag
A faster driver is behind you.
Move off the ideal driving line.
Yellow flag
There is a dangerous situation ahead of you.
Ease off the throttle and do not pass.
This flag will be used in combination with the
warning lights along the track.
Red flag
Trouble on the track - Drive slowly.
Drive to Pit Lane immediately,
Checkered flag 1 2
The driving session is finished.
Enter the pit-lane slowly.

1 AC701.121 “Safety instructions GB” sticker

2 AC701.122 “Safety instructions FR” sticker
3 AC701.124 Sticker “DOT4”
Meaning
Summary of the main safety
instructions for the driver.
Summary of the main safety
instructions for the driver.
LIQUIDE DE FREIN Use brake fluid DOT4 only.
!
DOT 4 UNIQUEMENT
BRAKE FLUID
DOT 4 ONLY

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2 - Reception
2.1 - Main components
8 10 13

7
1

8
9

2 11
12

Legend
1 Frame pre-equipped
2 Spoiler
3 Spoiler brackets
4 Nassau panel
5 Fuel tank
6 Steering wheel
7 Rims
8 Side pod
9 Left side pod bracket
10 Right side pod bracket
11 Seat
12 Seat stiffeners
13 Rear bumper

●● At reception of your frame check the presence of

all elements above.
●● For part numbers, refer to the exploded view.

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2.2 - Tooling for assembly and adjustment 2.3 - Maintenance products
1 2 3
2

4 5
1

6 5
7
4
8 3

9
10 11

7
8
12

6
Designation Ø Part No
1 Ring centering device(Hub) (*) - OU931.010
2 Stub axle screw centering device (*) - OU931.006
3 Wrench 6
4 T-shaped Allen key 3 OU911.001
4 T-shaped Allen key 4 OU911.002
4 T-shaped Allen key 5 OU911.003 Designation Part No
4 T-shaped Allen key 6 OU911.004 1 MEKAONE cleaner degreaser LU839.001
4 T-shaped Allen key 8 OU911.005
2 MEKAONE multilube LU839.002
5 T-shaped socket wrench 8 OU912.004
5 T-shaped socket wrench 10 OU912.001 3 MEKAONE brake cleaner LU839.003
5 T-shaped socket wrench 11 OU912.002 4 MEKAONE chain grease LU821.001
5 T-shaped socket wrench 13 OU912.003
5 “TYP200” DOT4 brake fluid LU842.010
6 Piston stop centring device - OU951.004
7 Brake bleeding system - OU951.002 6 243 Frenetanch Loctite LU861.001
8 Socket set 1/2' 22 pcs - OU914.017 7 PFG110 grease tube LU823.004
9 Socket set 1/4' 46 pcs - OU914.016
8 Tyre grease LU823.003
10 Tyre iron - OU942.002
11 Manometer - OU943.002
●● For other tools, accessories and equipment, visit
12 Torque wrench - OU914.012 ITAKA web site..

●● (*) Supplied with the chassis..

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3 - Assembly 3.3 - Positioning of the safety brake cable

3.1 - Precautions and recommendations

●● Tightening torque Ø 6 = 10 to 12 mN. 2 1
●● Tightening torque Ø 8 = 12 to 23 mN.
●● Tightening torque Ø 10 = 23 to 47 mN.
●● Tightening torque for Tekneex rear axle bearing 80/50
C4 : 8 Nm.
●● 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 ...
Legend
●● Do not overtighten screws and bolts. 1 Safety cable
2 Brake rod

►►Always fit the safety cable clips (1) under the

3.2 - Frame stabilizers staples of the brake rod (2).

1 2

1
2

Legend
1 Spring clip
2 Plastic collar “Rilsan”

►►Securing clips (1) of the brake control with a

plastic tie “Rilsan” (2).

3.4 - Assembly of the fuel tank and of the

overflow bottle

3
2 1

1
2

Legend
1 Frame stabilizer
2 Stabilizer sleeve
Legend
1 Fuel tank
●● Always attach the stabilisers to the frame with 2 Steering column support
a sleeve at each side. 3 Fly nut

●● Insert the fuel tank (1) between the steering column

support (2).
●● Tighten the fuel tank (1) with the fly nut (4).

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Step 2
6

4 5
1
9 2

10
7

3
Legend
4 Overflow bottle
5 Nassau panel support Legend
6 Overflow bottle support 1 Ball joint
7 Overflow bottle hose 2 Nut
8 Return 3 Fastener clip
9 Petrol tank hose
10 Red plug ●● Insert the threaded end of the steering column in the ball
joint (1).
●● Put the overflow bottle (4) on the nassau panel support (5) ●● Tighten the nut (2).
with the overflow bottle support (6).
●● Tighten the assembly.
●● Connect the overflow bottle hose (7) to the return (8).
●● Put the fastener clip (3).
●● Connect the petrol tank hose (9) to the red plug (10).
Step 3
●● Check the presence of the diver under the red
plug.

3.5 - Assembly of the steering column and 2 1

steering wheel
●● See chapter “standard settings” for the
assemblies’ dimensions which correspond to the
standard setting recommended for your frame.
Step 1

Legend
1 Ball joint
2 Stub axle arm

●● 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).
●● Tighten the nut.
Legend ●● Tighten the assembly.
1 Screw + nut

●● Tighten the nut (1).

●● Tighten the assembly.

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Step 4 Ground clearance

2
3

4 A 4

Legend
1 Seat
Legend 2 Frame tubes
1 Support
2 Screw ●● Adjust the bottom of the seat (1) with the lower face of the
3 Top of the wheel frame tubes (2).
4 Steering column
Seat Position
●● 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, B
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.

3.6 - Assembly of the seat

●● See chapter “standard settings” for the ●● Position the seat following dimension B.
assemblies’ dimensions which correspond to the
standard setting recommended for your frame. ●● Drill a 8.5 mm diameter hole in the seat.
●● Tighten up screws and washers on assembly points (1).
1

1
2

Legend
1 Fixing points
2 Seat supports

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

the seat size.
●● Use the shims of the seat fixing kit to get a good fit.

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3.7 - Assembly of the seat stiffeners 3.9 - Assembly of the bodywork
●● See chapter “standard settings” for the ●● For screws and nuts references, refer to the spare
assemblies’ dimensions which correspond to the parts.
standard setting recommended for your frame.
Lower end Step 1

1
1

2
3

Legend
1 Seat stiffener
2 Screw

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

●● Pre-tighten the assembly with the screw (2). Legend
1 Side pod
●● For screws and nuts references, refer to the spare 2 Side pod support
parts. 3 Screw
4 Washer
Upper end ●● Place the side pod (1) on the side pod support (2).
●● Tighten the side pod (1) with the screws (3). Remember to
include the washers (4).
1 Step 2
2

1
3

Legend 1
1 Seat stiffener
2 Screw + conical washer + nut
2
●● Place the upper end of the stiffener.
●● Make sure there is no contact with the exhaust system and 3
with any part of the engine.
If necessary, slightly bend the stiffener.
●● Drill a 8.5 mm diameter hole in the seat. Legend
1 Bushing
●● Place one screw + conical washer (2).
2 Screw
●● Tighten both upper and lower end. 3 Nut
●● Apply the same procedure to mount the stiffener on the left
●● Insert the bushings (1) in the nozzles on the frame.
side of the seat.
●● For screws and nuts references, refer to the spare ●● Insert the assembly into the bushings (1).
parts. ●● Drill the bushings (1) using the holes as a guide and
●● For other types of stiffeners, refer to the spare tighten the assembly with the screws (2) and nuts (3).
parts and the web site ITAKA.
●● It is possible to install several seat stiffener
(left and right).

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Step 3 Step 5

1 3
2
3 4

Legend Legend
1 Lower support for Nassau panel 1 Spoiler lower support
2 Screw 2 Front cross member
3 Nut 3 Screw
4 Nut
●● Tighten the lower support on the frame with the screws (2)
and the nuts (3). ●● Insert the spoiler lower support (1) into the front cross
member of the frame (2).
Step 4
●● Tighten with the screws (3) and the nuts (4).
Step 6

4
3

1 4

3
2 1

3 2 3
2
Legend
1 Spoiler
2 Fixing plate Legend
3 Screw 1 Spoiler upper support
●● Assemble the fixing plates (2) on the spoiler (1) using 2 Lug
3 Screw
screws (3). 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).

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Step 7 Step 9

2 5
5
1

4 3

1 1
3
Legend
Legend 1 Nassau panel
1 Mounting flange spoiler 2 Lower support
2 Upper support 3 Upper support
3 Lower support
4 Screw ●● Tighten the nassau panel (1) on its supports (2) and (3)
5 Nut with screws, nuts, and washers.
●● Assemble the mounting flange spoiler (1) between the
spoiler upper support (2) and the spoiler lower support (3)
with two screws and two nuts.
Step 8

3
6

Legend
2 Upper support
3 Lower support
6 Clamp

●● Place the spoiler (1) between the spoiler supports (2) and
(3).
●● Tighten the spoiler (1) and the spoiler supports (2) & (3)
with the 2 clamps (6).

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3.10 - Mounting the rear protections 3.11 - Mounting the rear protections DD2

2
5

4
1

3 3 3
2 4

Legend Legend
1 Mounting kit 1 Tire protection
2 Bumper support 2 Rear protection
3 Tube chassis 3 Screw + nut
4 Screw + nut
●● Assemble the mounting kit (1) with the element of the 5 Tube protection
bumper support (2).
●● Mount the assembly in the tube chassis (3), tighten with ●● Assemble the tire protection (1) on the rear protection (2),
the screw of the fixing kit (1). tighten using the screws and nuts (3).
●● Apply the same procedure for the other side. ●● Assemble the rear protections (2) per pair and tighten
using the screws and nuts (4).
●● Assemble the rear protections (2) with the 2 protection
6 tubes (5).

7 5

7 7
4

9
7
4 6
7
6
6

Legend
4 Bumper support
5 Bumper
6 Screw + nut
7 Screw + nut
6
●● Assemble bumper support (4) on the bumper (5) using 6
screws and nuts (6).
●● Assemble the bumper (5) on the chassis with screws and Legend
nuts (7). 6 Screw + nut
7 Rear protection support

●● Assemble rear protection support (7) on the frame. Tighten

with screws and nuts (6).
●● Apply the same procedure for the other side.

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4 - Commissioning
10
7 10 4.1 - Safety instructions to the pilots
9 ►►Your kart can only be driven on a track
9 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
8 own country.

4.2 - Pilot protection

Before going on the track, the pilot must wear the following
protections:
8
●● Integral helmet: CIK/FIA approved, fitting the pilot head
Legend size, with tightened strap and closed visor. Refer to CIK/
7 Rear protection FIA regulations (Compulsory).
8 Rear protection support ●● Suit: CIK / FIA level 1 or level 2 approved (Compulsory).
9 Washer
10 Screw
●● Gloves (Compulsory).
●● Neck protection : CIK/FIA approved (Compulsory).
●● Place the rear protection (7) on the rear protection support ●● Rib protection: fitting pilot’s size and seat (Recommended).
(8).
●● Rain suit: with water tight fasteners (Recommended when
●● Place the washers (9) and tighten using the screws (10). necessary).

●● Choose those equipments within the CIK / FIA

approved ones of the ITAKA web site.

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 floating clothes.
●● With health problems.
●● Under the influence of drugs and (or) alcohol.
►►For your safety and the safety of other
pilots, strictly follow the above instructions:
not doing so may lead to severe, even fatal
injuries.

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5 - Adjustments
5.1 - Standard adjustments
Dry track Wet track
Stub axle height

A
Sigma RS - KZ - DD2 Sigma RS - KZ - DD2
A = 6 mm A = 10 mm
B = 8 mm B = 4 mm
B

Front tracking width

A B
Sigma RS Sigma RS
A = 3 rings inside (15 mm) A = 5 rings inside (25 mm)
B = 90 mm B = 100 mm

Front tracking width (with front brake)

A B Sigma RS
A = 2 rings inside (10 mm)
Sigma RS - KZ - DD2
B = 90 mm
A = 4 rings inside (20 mm).
Sigma KZ - DD2
B = 90 mm
A = 3 rings inside (15 mm).
B = 90 mm

Rear tracking width

A
Sigma RS Sigma RS
A = 1390 mm to 1400 mm A = 1360 mm to 1380 mm
Sigma KZ - DD2 Sigma KZ - DD2
A = 1400 mm A = 1370 mm to 1380 mm

Rear axle position

Sigma RS
A B Sigma RS - KZ - DD2 B : Medium
B : Medium Sigma KZ - DD2
B : High
C

Position of eccentrics
Front

B C Sigma RS - KZ - DD2 Sigma RS - KZ - DD2

1
A : eccentrics 1° A : eccentrics 3° and 4°
B : TOP Mark forward B : TOP 4° Mark forward
1

C : BOTTOM Mark inside C : BOTTOM 3° Mark Backward

A
Front

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Dry track Wet track
Position of steering tie rods ends
2
A 1
B
C 4 3 Sigma RS Short tie rod Sigma RS Short tie rod
A2 A2
Sigma KZ - DD2 Long tie rod Sigma KZ - DD2 Short tie rod
B1 A2

Front stabilizer

Sigma RS - KZ - DD2 Sigma RS - KZ - DD2

Remove or place the stabilizer following Remove or place the stabilizer following
track conditions. track conditions.

Position of seat

Sigma RS Sigma RS
A = Lower face of the tubes (0 mm) A = Lower face of the tubes (0 mm)
B = 1040 mm ± 10 mm B = 1040 mm ± 10 mm
A
Sigma KZ - DD2 Sigma KZ - DD2
A = Lower face of the tubes (0 mm) A = Lower face of the tubes (0 mm)
B B = 1045 mm ± 10 mm B = 1060 mm ± 10 mm

Seat stiffeners Sigma RS Sigma RS

Left side (A) : 2 Left side (A) : 2
2 B Right side (B) : 1 Right side (B) : 1
A Sigma KZ Sigma KZ
1
2 Left side (A) : 2 Left side (A) : 2
Right side (B) : 2 Right side (B) : 2
Sigma DD2 Sigma DD2
Left side (A) : 1 Left side (A) : 1
Right side (B) : 0 Right side (B) : 0

●● These adjustments are given for information. It is advisable to refine 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.

2
2
1
2

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5.2 - Adjustment of front wheels Wet track (with front brake)

5.2.1 - Adjustment of front tracking width A B

The adjustment of the front width is realized with several
spacers (spacer of 15 mm, and spacers of 5 mm for each stub
axle), and 2 hubs type (short hub: 90 mm or long hub: 100
mm).
●● The wider the front is widened, the harder the
steering is hard.
●● The narrower the front is narrows, the easier
the steering is easy.
●● If you wish increase the grip of front, it suffice
to increase the width of the front with spacers.

Dry track It is advisable to adjust the front with a spacer of 20 mm (A)

maximum (1 spacer of 15 mm and 1 spacer of 5 mm inside),
A B and use the long hubs: 100 mm (B).
●● With the front brake on your chassis, the
adjustment of the front is limited.
●● No more than 20mm of spacers (A) (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 (B) on wet track.

5.2.2 - Adjustment of front wheel height

It is advisable to adjust the front with a spacer of 15 mm (A) (1 A

spacer of 15 mm inside), and use the short hubs: 90 mm (B).
●● With the front brake on your chassis, the
adjustment of the front is limited.
●● No more than 20mm of spacers (A) (1 spacer
of 15mm and 1 spacer of 5mm), yoke side on
each stub axle if the kart is equipped with front
brake. B
Wet track (without front brake))

A B ●● Place one 6mm spacer on top and one 8mm spacer at the
bottom.
Adjustment (A + B = 14mm)
A B
4 10
Standard adjustment 6 8
7 7
8 6
10 4

It is advisable to adjust the front with a spacer of 25 mm (A) (1

spacer of 15 mm and 2 spacers of 5 mm inside), and use the
long hubs: 100 mm (B).

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5.2.3 - Adjustment of the caster Adjustment of the caster - Low
Description of the eccentric. Front

Front

3
1 1

1 1

4 1
1

Rear
Rear
Eccentrics on top:
●● The mark is positioned on the opposite side of the screw.
Legend
(Towards the rear of the chassis).
1 Eccentric
2 Screw on the fork Eccentrics on bottom:
3 Marked slot ●● The mark is positioned in front of the screw.
4 Mark
(Towards the front of the chassis).
(1=0.5°, 2 eccentric marked “1” gives 1°)

Adjustment of the caster - High

Standard adjustment
Front
●● 1° upper eccentrics place in high caster position .
1
1

Increase the caster

●● 2° eccentric in high caster position.
1
●● In extreme conditions, use 3°, 4° or more
eccentrics.

1 1

Reduce the caster

●● 2°or 3° eccentric in low caster position.
Rear ●● In extreme conditions use eccentrics higher
Eccentrics on top: degrees..
●● The mark is positioned in front of the screw.
(Towards the front of the chassis).
Eccentrics on bottom:
●● The mark is positioned on the opposite side of the screw.
(Towards the rear of the chassis).

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5.2.4 - Adjustment of the camber Camber - More negative
Front
●● Use the eccentrics at the bottom.

Description of the eccentric.

1
1
Front

3
2

4
1 Rear

Eccentrics at the bottom:

●● The mark is positioned towards the inside of the chassis.
Standard adjustment
Rear
●● 1° Lower eccentrics place in negative camber position .
Legend
1 Eccentric
2 Screw on the fork Increase the camber
3 Marked slot ●● Same position as the “More negative” adjustment by
4 Mark replacing the lower 1° eccentric by the 2° eccentric.
(1=0.5°, 2 eccentric marked “1” gives 1°)

Camber - More positive Reduce the camber

Front ●● 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 web site
1
1

●● Some negative camber generally improves the

performances of the kart.
5.2.5 - Quick adjustment of caster/camber pill
1

Rear

Eccentrics at the bottom:

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

●● Remove the 2 screws.

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2

●● Unlock axle of the front stub.

●● Rotate the 2 caster/camber pills tu adjust the caster or

camber angle.
Adjustment
Caster angle : Top caster/camber pill
Camber angle : Low caster/camber pill

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5.2.6 - Front wheel alignment

1
A=B
C
A

2 2

1 1
●● 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
B dimension C for the second wheel.
●● The two dimensions C must be equal.
Recommended setting on a dry track
●● 2 mm opening : B = A +2mm.

●● Make sure the dimensions C are equal on each

side.

3 Recommended setting on a wet track

●● 7 mm opening : B = A +7mm.

●● Make sure the dimensions C are equal on each

side.
5

●● Remove the front wheel alignment disk (1).

4
●● Do not forget to tighten the 2 lock nuts on the
tie rods; otherwise the parallelism will be lost
Legend in a few minutes.
1 Wheel alignment disk ●● Any time you work on the front wheels, check
2 Tie rod nut and lock nut the parallelism. Do the same after shocks
3 Steering wheel in straight position
4 Maximum steering angle position
5 Steering wheel fully turned position ►►Never drive with badly tightened wheels: it
may lead to severe, even fatal injuries.
●● Place the kart on a trolley. ►►Make sure that each ball joint penetrates at
●● Place the front wheel alignment disk (1) least 5 threads in the tie rods.
(available on ITAKA web site).
●● Unscrew the lock nuts (2) of the 2 tie rods. 5.2.7 - Adjustment of tie rods
Warning: lock nut of tie rod side is a right hand thread;
lock nut of steering column side is left-hand thread.
●● Position the upper branch of the steering wheel in the kart
axle. 2
A 1
●● Measure A and B with a roll meter. Adjust the tie rods until B
you get A=B with a tie rod length on the right side 1.5mm C 4 3
bigger than the tie rod length on the left side.

●● Standard adjustment short tie rod : A 2.

●● Standard adjustment long tie rod : B 1.

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5.3 - Adjustment of rear wheels 5.3.2 - Position of rear axle

5.3.1 - Adjustment of hubs

5
7

A 2
6 4 3
1
On most tracks, the correct axle position is middle position.
This corresponds to a low position of the chassis relative to
Legend the ground.
1 Ruler
2 Hub base ●● A large ground clearance means more grip.
3 Top of the axle
4 CHC screw ●● A low ground clearance means more sliding.
5 Cotter pin
6 Axle 5.3.3 - Type of axle
7 Hub
The stiffness of the axle plays an important part in the
●● Place the kart on a trolley. behaviour of the kart.
●● Unscrew the 3 nylstop nuts from the rear wheels with the
proper size wrench, and then remove wheels. ●● Visit ITAKA web site for different axle types.
●● Using a rule (1) or any depth gauge, measure between the
hub base (2) and the top of the axle (3).
●● A flexible axle suits high grip conditions (Heat and (or) gum
●● Undo the CHC screws (4) of the rear hub with an on the track).
appropriate wrench until the hub can slide along the axle
●● A stiff axle suits low grip conditions (rain, humid track, cold
shaft (6) and cotter pin (5).
with little gum track).
●● Move the hub (7) to the desired position with the rule (1) in In order to get the best out of your kart, do not hesitate to test
place against the hub base (2). different stiffness of axle :
●● Retighten and block the CHC (4) screws.
●● Repeat the operation on the other hub. SOFT MEDIUM HARD
●● Replace both wheels following the rotation direction Q20 Adapt C25 Q30 Q32
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).
TM20
●● A wider rear tracking width tends to increase
sliding. Too narrow a rear tracking width may TS20
TMS20 TH20 TS25 TH25 TH30 THH20
lead to a bumpy chassis. THM20 SOFT MEDIUM HARD
SOFT MEDIUM HARD
SOFT MEDIUM HARD
►►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 ●● TS20, TMS20, TM20, THM20 and TH20 axles
allowed width: it may lead to severe or even without inner sleeve are not recommended in
fatal injuries. KZ category.

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

5.5 - Adjustment of the brake distributor

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

Legend 4
1 screw
2
●● Tighten the screws (1) to 8 Nm. 5

5.4 - Adjustment of seat

The position of the centre of gravity has also a key influence
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. 1
It directly affects the understeering or oversteered chassis 3
behaviour.
Legend
Depending on your weight, your height, your riding style, the
1 Handle
ideal position may change a little. 2 Brake distributor
Compared to the standard position (Cf. chap. 3.5), moving the 3 Axle
seat has the following effects: 4 Front brake pump
5 Rear brake pump
4
5.5.1 - Standard adjustment
2
●● Turn the handle on the bottom (max on the front) and then
back to the rear of 15 “clicks”

5.5.2 - More braking power on the front brakes

●● Turn the handle (1) toward anti-clockwise direction.
●● The brake distributor (2) move toward the front brake
pump.
●● The kart will brake more with the front brakes.
1
5.5.3 - More braking power on the rear brakes
3
●● Turn the handle (1) toward clockwise direction.
●● The brake distributor (2) move toward the rear brake pump.
1) Seat moved forward ●● The kart will brake more with the rear brake.
●● Gives more grip on the front wheels (more sliding of the
rear wheels). ►►The brake system is a key safety item of the
kart. Regularly check all its components.
●● Allow to correct the front wheel axle unit imprecise, but
delays the time it is possible to accelerate into the turn, ►►In case of doubt, do not drive before fixing the
(Rear more slippery). problem.
►►Bad maintenance of the brakes can lead to
severe, even fatal injuries.
2) Seat moved backwards
►►Never repair a break system on your own;
●● Less grip on the front wheels. return it to your local dealer.
●● More grip on the rear wheels.

3) Seat lower
●● Less grip (front and rear wheels).
●● To try on very high grip conditions.

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6 - Maintenance
6.1 - Brakes - Usual maintenance
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 fluid (refer to the ITAKA web site for product references) and recommends
that the disc and pads should be cleaned using brake cleaner only (refer to the ITAKA web site for product references).
Use PFG110 grease to install the seals (visit the ITAKA site for product catalogue numbers).
Brake fluid.....................“TYP200”.................Ref : LU842.010

►►The “TYP200” brake fluid has been designed for racing use and is used exclusively for
this purpose (forbidden on open road).

Brake cleaner................MEKAONE............................... Ref : LU839.003

Grease...........................Graisse PFG110....................... Ref : LU823.004

►►Use brake fluid DOT4 only. Using another brake fluid could cause leaks and failure of
the brake system.

●● The brake system is not compatible with DOT 5.

●● Place the fluids in watertight cans and recycle them according to the regulations in force.

●● Never spray brake cleaner on the master cylinder and brake caliper seals.

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6.1.2 - Frequency of cleaning and maintenance

Before After 1 After 3 After 5 As

any meeting or meeting or meeting or soon as
session 100 km 300 km 500 km required
Checking the brake fluid level X
Replacing the brake fluid 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 brake hose screew 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

PLAQUETTES DE FREIN - BRAKE PADS

- braking power +

A c B
NEW
D

Braking power -
●● Brake pads : Hard (slow wear)
●● Braking Distance : Lengthy

Braking power +
●● Brake pads : Soft (rapid wear)
●● Braking Distance : Short

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6.1.3 - Replacing brake pads on the D18 4-piston 6.1.4 - Replacing brake pads on the D20 4-piston
calipers (front) calipers (rear)
5
2 4
2 4 Nm

1
4
3

1
3

Loctite 648
Legend Legend
1 Pin 1 Adjustment screw
2 Brake pad 2 Return screw
3 Piston 3 Spring (not on KZ and DD2)
4 Calliper body 4 Pin
5 Brake pad
●● Straighten the ends of the pin (1) and then remove it.
●● Remove the used brake pads (2). ●● Adjust the brake pads until they reach the stop using the
adjustment screws (1).
●● Push the four pistons (3) back into the calliper body (4).
●● Remove the four return screws (2) and the four springs (3).
●● Place the new pads (2) in position.
●● Straighten the ends of the pin (4) and then remove it.
●● Place the new pin (1) in position, and then twist its ends.
●● Remove the used brake pads (5).
●● Apply the same procedure for the second calliper.
●● Place the new pads (5) in position.
●● Do not operate the brake lever or pedal unless
pads are installed. This would make the ●● Place the new pin (4) in position, and then twist its ends.
pistons difficult to return to their position, and ●● Reinstall the four return screws (2) and the new springs
brake fluid leaks might then occur. (3). Tightening torque 4 mN. Applying a drop of high thread
●● Always replace the pads of the two front locking compound on the threads of the screw.
calipers at the same time. ●● Tighten the screws (1) to put the pads in position. The gap
between the pad and the disc must be 1 mm.
►►Check the pads for wear before every start-up.
●● Do not mount the return spring if the go-kart is
►►Never drive with excessively worn pads equipped with front and rear brake distributor.
(minimum thickness for the D18 4-piston ●● Do not operate the brake pedal unless pads
calipers (front): 4mm). are installed. This would make the pistons
►►The brake is an essential safety element. If the difficult to return to their position, and brake
braking system is defective or you have the fluid leaks might then occur.
slightest doubt, do not put the kart in service.
►►Check the pads for wear before every start-up.
►►Never drive with excessively worn pads
(minimum thickness of pads for D20 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.

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6.1.5 - Adjusting the gap between the pads and the 6.1.7 - Tightness of the brake hose screew
disc

1 mm
1 mm
2 20 Nm
3

Legend
1 Adjustment screw
2 Disc
3 Pad

●● 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 fluid 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 fixation 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 fluid DOT 4 only.

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6.1.8 - Bleeding the front brake circuit Niveau Max.
2 Max. Level

●● Top up the brake fluid in the master cylinder to its

1 maximum level, and retighten the cap (2) and the
diaphragm (4).

●● We recommend that you drain and refill the

brake circuit after every brake pad change.
Legend This will allow you to maintain optimum
1 Bleeder screw braking performance.
2 Cap ●● To bleed your brake system more rapidly,
3 Brake pedal especially for a big fleet, we recommend the
4 Diaphragm priming system SODIKART (Ref. OU951.002).
●● Store the used brake fluid in labelled
●● Use a pipe and a container to collect the used fluid. containers until it is collected by a specialist
●● Remove the protective caps from the bleed screws (1) on waste disposal company.
each front calliper, and then place a hose on the bleed ●● The brake liquid doesn’t contain petrol, so
screw. The other end of the hose should be placed in an never pour the liquid into a using oil tank.
empty container. ●● Brake fluid absorbs water Make sure the
●● Gently unscrew the bleeder (1) screw and the cap (2). replacement brake fluid comes from a
●● Repeatedly press the brake pedal (3) until all the fluid has container that has been stored in good
conditions and is recent.
drained out.
●● Check that the pedal is firm after each bleed.
●● When all the fluid has been drained, remove the cap (2),
the diaphragm (4) and top up to the maximum level with
brake fluid. Tighten the bleed screw (1), and then press the ►►An air bubble in the brake system can lead to
brake pedal (3) three or four times. a partial or total lost of brakes and may lead to
●● Loosen the bleeder screw (1) of the front right calliper. a serious or even fatal injury.
Brake fluid should flow out. Retighten the bleed screw, and ►►Leaks in the brake system may lead to a
repeat this step several times to feed the circuit properly. serious or even fatal injury.
Remember to add brake fluid to the master cylinder as ►►Moisture in the brake fluid may cause vapour
required. Bleed the circuit so that the brake fluid flowing lock and a sudden loss of braking power, may
out of the hose contains no air bubbles. lead to a serious or even fatal injury.
●● Retighten the calliper bleed screw (1), remove the pipe and ►►Use brake fluid DOT 4 only
reapply the protective cap.
►►Test the brake after each bleed.
●● Repeat the operation for the front left calliper.

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6.1.9 - Bleeding the rear brake circuit ●● We recommend that you drain and refill the
brake circuit after every brake pad change.
2 This will allow you to maintain optimum
braking performance.
3
●● To bleed your brake system more rapidly,
especially for a big fleet, we recommend the
priming system SODIKART (Ref. OU951.002).
●● Store the used brake fluid in labelled
1 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 fluid absorbs water Make sure the
replacement brake fluid comes from a
container that has been stored in good
conditions and is recent.
●● Check that the pedal is firm after each bleed.
Legend
1 Bleeder screw 6.1.10 - Cleaning
2 Cap
3 Diaphragm Brakes should be cleaned using a dry cloth and brake cleaner
only.
●● Use a pipe and a container to collect the used fluid. Do not use WD40 or other greasy products to clean the
●● Remove the bleeder screw (1) protective cover and callipers and brake discs.
connect the hose to the bleed nipple with the free end in ►►If WD-40 or a similar cleaning product is
the receptacle. splashed on the brake disc or calliper, braking
●● Gently unscrew the bleeder screw (1) and the filler cap (2). will be less efficient or possibly totally
●● Repeatedly press the brake pedal until all the fluid has ineffective for a few revolutions. This could
drained out. cause a serious or fatal accident.
●● When all the fluid has been drained, remove the cap (2), ►►Do not apply WD-40 or other cleaning
the diaphragm (3) and top up to the maximum level with products to the brake pump.
brake fluid. Tighten the bleed screw (1), and then press the
brake pedal three or four times.
●● Loosen the bleeder screw (1) of the calliper. Brake fluid
should flow out. Retighten the bleed screw, and repeat this
step several times to feed the circuit properly. Remember
to add brake fluid to the master cylinder as required. Bleed
the circuit so that the brake fluid flowing 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 fluid in the master cylinder to its maximum level,
and retighten the cap (2) and the diaphragm (3).
►►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 fluid may cause vapour
lock and a sudden loss of braking power, may
lead to a serious or even fatal injury. ●● Never spray brake cleaner on the master
cylinder and brake caliper seals.
►►Use brake fluid DOT 4 only
►►Test the brake after each bleed.

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6.2 - Brakes - Workshop maintenance Reassembly

6.2.1 - Replacing calliper seals / 4 piston caliper

pistons D18 (front) PFG110 8

This operation must be performed by a Sodikart

dealer.

Removing
5

7
1

6 PFG110
4 2
Legend
5 O-ring
6 Piston
7 Gasket
8 Groove

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

3
●● Check that the bases of the grooves (8) are clean.
Legend ●● Place the O-rings (7) in position in the grooves (8).
1 Pin ●● Place the pistons (6) in position.
2 Brake pad
3 Bleeder screw ●● Apply the same procedure for the second half-calliper.
4 Mounting screw ●● Apply PFG110 grease to the O-rings (5).
●● Untwist the ends of the pin (1) and then remove it. ●● Place the O-rings (5) in position, and then connect the two
half-callipers.
●● Remove the brake pads (2).
●● Remove the bleed screw (3) and its cap. Loctite 221
●● Disconnect the yoke by removing the two mounting screws
(4).

8 Nm

7 3
15 Nm

Legend
6 3 Bleeder screw
4 Mounting screw

Legend ●● Tighten the two screws (4). Torque 15 Nm, applying a drop
5 O-ring of weak thread locking compound to each screw.
6 Piston ●● Tighten the bleed screw and its cap (3).
7 Gasket
Torque 8 Nm.
●● Remove the two O-rings (5), the two pistons (6), and the ●● Reinstall brake pads (refer to the section on Cleaning/
two seals (7) from each half-calliper. Replacement of front brake pads).
●● Clean the half calliper bodies. Do not use WD40 or other
●● Always use new seals and clips.
greasy products to clean the callipers.
●● Replace any defective parts, using only
►►Do not use any cleaning product that could original SODIKART parts.
damage the seals. A brake fluid leak could ●● Install a new set of pads after any servicing of
appear, causing a serious or fatal accident. the callipers.

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6.2.2 - Replacing calliper seals / 4 piston caliper
pistons D20 (rear)
This operation must be performed by a Sodikart 14
dealer.

Removing
5 7
4
2

12
13

1
Legend
12 Clip
13 Piston stop
3 14 O-ring

●● Remove the piston stop clip (12) using fine pliers or a

6 scriber.
●● Loosen the piston stop (13) and remove the O-ring (14).
Legend
●● Apply the same procedure for the second half-calliper.
1 Adjustment screw
2 Return screw ●● Clean the half calliper bodies. Do not use WD40 or other
3 Spring (not on KZ and DD2) greasy products to clean the callipers.
4 Pin
5 Brake pad ►►Do not use any cleaning product that could
6 Bleeder screw damage the seals. A brake fluid leak could
7 Mounting screw appear, causing a serious or fatal accident..
●● Adjust the brake pads until they reach the stop using the Reassembly
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.
●● Disconnect the yoke by removing the two mounting screws
(7).

12

10

Legend
12 Clip

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

11

Legend
9 O-ring
10 Piston
11 Gasket

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

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PFG110

14
13 12
13
13
Legend Legend
13 Piston stop 12 Clip
14 O-ring 13 Piston stop

●● Apply PFG110 grease to a new O-ring (14). ●● Place the piston stop clip (12) in the groove of the piston
●● Place the O-ring (14) in the piston stop groove (13). stop (13).
●● Apply PFG110 grease to the O-ring (14) and the piston ●● Check that the piston stop clip (12) is correctly clipped in
stop (13). 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
13 body.
15 PFG110
9

10

Legend
13 Piston stop 11 16
15 Sodikart tools
Legend
●● Push the piston stop (13) into the tool (15), taking care not 9 O-ring
to damage the O-ring (14). 10 Piston
●● Place the piston stop (13) and the tool (15) on the half 11 Gasket
calliper. 16 Groove
●● Fully tighten the piston stop (13) on the half-calliper using a ●● Apply PFG110 grease to the O-rings (11).
screwdriver, and then remove the tool (15). ●● 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 half-calliper.
●● Apply PFG110 grease to the O-rings (9).
●● Place the O-rings (9) in position, and then connect the two
half-callipers.

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5
7

15 Nm

Loctite 221

6
8 Nm
Legend
5 Piston
6 Gasket
Legend 7 Seal
6 Bleeder screw
7 Mounting screw ●● Remove the gasket (6) and the seal (7).
●● Clean the body of the master cylinder. Do not use WD40 or
●● Tighten the 2 screws (7). Torque 15 Nm, applying a drop of other greasy products to clean the master
weak thread locking compound to each screw.
●● Tighten the bleed screw and its cap (6). ►►Do not use any cleaning product that could
Torque 8 Nm. damage the seals. A brake fluid leak could
appear, causing a serious or fatal accident
●● Reinstall brake pads (refer to the section on Cleaning/
Replacement of rear brake pads). Reassembly
●● Always use new seals and clips.
PFG110
●● Replace any defective parts, using only
original SODIKART parts.
●● Install a new set of pads after any servicing of
the callipers.

6.2.3 - Replacing master cylinder seals and pistons

7

This operation must be performed by a Sodikart 6

dealer.

Removing
5
4

3
Legend
4
5 Piston
4 6 Gasket
7 Seal

●● Apply PFG110 grease to the gasket (6) and the seal (7).
●● Place the gasket (6) in the piston groove (5).
●● Install the seal (7) on the piston (5).
1 ●● Apply PFG110 grease to the gasket (6), the seal (7), and
the piston (6).
2

Legend
1 Pressure pin
2 Dust cover
3 Pin
4 Lever & piston

●● 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.

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1
3

2
4

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

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

cylinder.
●● 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.

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6.3 - Tyres ●● Always change the whole set whenever a tyre
is changed (fronts, rears, or all the set).
6.3.1 - Tyres change ●● Always place the tyres so that they rotate in
the direction indicated on the tyre wall.
●● Never inflate 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

6 according to local environmental regulation.
3
1 ►►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.
5 ►►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.
4 ►►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
2 under impact, and lead to a tendency to go on
two wheels. It also increases the risk of riding
over.
Legend ►►Store tyres in an appropriate area to prevent
1 Rim
fire hazard.
2 Tyre
3 Direction of rotation ►►Never inflate above 4 bars: there is a risk of
4 Inflation system severe injury due to potential failure of the rim.
5 Grease
6 Tyre iron

●● Place the kart on a trolley.

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

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6.3.2 - Table of the recommended tyre pressures
Pressure (bar)
Slick tyres Cold (20°) Warm
Categories Brand Type Front Rear Front Rear
OK JUNIOR CIK VEGA XH2 0,6 0,6 0,8 0,8
KZ CIK LECONT LP 0,6 0,6 0,8 0,8
KZ2 (France) LECONT LOZ 0,65 0,7 0,85 0,85
X30 KOMET K1H 0,65 0,7 0,85 0,9
ROTAX MAX BRIDGESTONE YLM 0,65 0,7 0,85 0,9
ROTAX MAX MASTER BRIDGESTONE YLM 0,65 0,7 0,85 0,9
ROTAX DD2 BRIDGESTONE YLM 0,65 0,7 0,85 0,9
ROTAX DD2 MASTER BRIDGESTONE YLM 0,65 0,7 0,85 0,9
NATIONALE BRIDGESTONE YNC 0,65 0,7 0,85 0,9
Wet tyres Cold (20°) Warm
Categories Brand Type Front Rear Front Rear
OK JUNIOR CIK VEGA W5 1 1 1,1 1,1
KZ2 (France) LECONT LW 1 1 1,1 1,1
X30 KOMET K1W 1 1 1,1 1,1
ROTAX MAX BRIDGESTONE YNP 1,2 1,2 1,3 1,3
ROTAX MAX MASTER BRIDGESTONE YNP 1,2 1,2 1,3 1,3
ROTAX DD2 BRIDGESTONE YNP 1,2 1,2 1,3 1,3
ROTAX DD2 MASTER BRIDGESTONE YNP 1,2 1,2 1,3 1,3
NATIONALE BRIDGESTONE YNP 1,2 1,2 1,3 1,3

Wet conditions:
●● Little water: slightly drop the pressure from the
recommended value.
●● Much water: increase the pressure from the recommended
value.

6.4 - Cleaning the chassis

The cleaning of the chassis and its components is to be done
with a special cleaning product (refer to the ITAKA web site).
Do not use the product on brake pads and brake calipers.
This fluid 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 let it
act for 30 seconds.
●● Wipe the frame and the components with a dry cloth.

●● 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.

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6.5 - Maintenance summary 7 - Trouble shooting
6.5.1 - Bolting 7.1 - The kart will not brake
Before each use, check the state of the screws and bolts. Pay 1. Is the brake pedal free?
a special attention to the ones directly linked to the safety of
the kart: 2. Is the hydraulic brake pump container cap fully tightened?
●● Stub axle screw. 3. Is there enough brake fluid?
●● Steering tie rods ball joint screws. 4. Are the hoses correctly connected?
●● Front and rear wheels bolts. 5. Are the brake pads worn?
●● Rear wheel hub screws. 6. Is the calliper fully tightened on its support?
●● Engine support screws.
●● Seat screws. 7.2 - The kart brakes continually
Damaged screws and bolts have to be changed. 1. Is the brake fluid old?
2. Is the brake disk correctly centred in relation to brake
6.5.2 - Steering pads?
●● Check daily the upper and lower column plastic support 3. Is the calliper fully tightened on its support?
torque as well as stub axle screws. 4. Is the brake pedal too tight?
●● Make sure that front wheel axle unit is not out of line (stub
5. Are the brake pads correctly assembled?
axles bent or broken).
●● Check that the tie rods are not damaged.
7.3 - The kart is hard to turn
6.5.3 - Bodywork parts 1. Are the stub axles tightened to torque specification?
●● Parts of the bodywork must not be broken or have sharp 2. Is the front axle unit checked?
edges.
●● Check the body part fastenings. 7.4 - The steering of the kart is not precise
●● Whenever bodywork parts are changed, make sure that 1. Are the front wheels tightened?
nuts and bolts are assembled with nuts on the inside and 2. Are the stub axles to torque tightening specification?
bolt heads on the outside, in order not to cause any injury.
3. Are the column plastic supports tightened to torque
6.5.4 - Tyres specification?
●● Take particular care when fitting tyres that they rotate in 4. Are the tie rods correctly assembled and to torque
the right direction. Follow the directional arrows on the tyre specification?
wall. 5. Is the front wheel axle unit adjustment checked?
●● Check for tyre wear with the indicators in the tread. One
must always be able to see them. Tears or tread separation 7.5 - The kart tends to go to the side
must not be found. 1. Is the front wheel axle unit adjustment checked?
●● Before each session check tyre pressures. 2. Are the tie rods correctly assembled?
6.5.5 - Braking 3. Are the tie rods locking nuts securely tightened?
●● Make sure before all sessions that the braking system is 4. Is there a tie rod bent or broken?
working properly. 5. Do the rear wheels have exactly the same circumference?
●● Brake fluid should not be black.
●● Drain and change black fluid. Check levels. 7.6 - The kart skids very much on bends
●● Ensure that brake pads are correctly fitted and do not fall 1. Are the tyres worn?
below the minimum thickness of 6 mm (Lining + Steel 2. Are the tyres inflated to the recommended pressures?
support).
3. Is the rear axle adjustment suited to the track conditions?
●● Brake hoses must not show any leaks at connection points.
Replace if damaged. 4. Is the front wheel axle unit adjustment correctly checked?

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8 - Index R
A Rear bumper............................................................................ 6
Axle........................................................................................ 23 Rim......................................................................................... 36
Rims......................................................................................... 6
B
Ball joint.................................................................................... 9 S
Brake bleeding system............................................................. 7 seat......................................................................................... 24
Brake cleaner......................................................................... 25 Seat.................................................................................... 6, 10
brake distributor...................................................................... 24 Side pod............................................................................. 6, 11
Brake fluid.............................................................................. 25 Spoiler................................................................................ 6, 12
Brake pad................................................................... 27, 31, 32 stabilizers................................................................................. 8
Brake pedal............................................................................ 29 Steering column................................................................. 8, 10
Bumper................................................................................... 14 Steering wheel.......................................................................... 6
Bushing.................................................................................. 11 stiffener................................................................................... 11
stiffeners................................................................................... 6
C Stub axle.................................................................................. 9
Clip......................................................................................... 32
T
D Tie rod.................................................................................... 22
Diaphragm........................................................................ 29, 30
Tyre........................................................................................ 36
Disc......................................................................................... 28
Tyre iron............................................................................. 7, 36
E W
Eccentric........................................................................... 19, 20
Wrench..................................................................................... 7
F
Fastener clip............................................................................. 9
Frame....................................................................................... 6
Fuel tank............................................................................... 6, 8

G
Gasket.................................................................. 31, 32, 33, 34
Grease.................................................................................... 25

H
Hub......................................................................................... 23

M
Manometer............................................................................... 7

N
Nassau..................................................................... 6, 9, 12, 13

O
O-ring......................................................................... 31, 32, 33

P
Pad......................................................................................... 28
Piston............................................................. 27, 31, 32, 33, 34

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9 - Homologation

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Track: Trial:

Pilot: Date: Time:

TRACK CHASSIS
State of the track: Stub axle height:

Temperature: Caster / Camber:

Parallelism:
ENGINE Seat position:
Carburator type: ●● Height:

Adjustments: ●● Distance axle:

Exhaust type: ●● Distance fork:

Gear ratio: Masses:

Length: Axle type:

Chain length : Stiffeners:

Notes

TRIAL TIMES
Tyre type:

Diameter:

Lap Partial 1 Partial 2 Partial 3 Partial 4 Pressure start / Wheel unit width
1 1 1
2 2 2
3 3
3
4 4
4
5 1 1
2 2
6 3 3
7 4 4

8
9 Pressure arrival

10 1 1
2 2
3 3
4 4

1 1
2 2
3 3
4 4

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