Remo Racing Kosmic Kart User manual

SET-UP GUIDE
AUSTRALIAN IMPORTER
REMO RACING PTY LTD
E
-
mail:
[email protected]m.a
u
121 Firebrace Street, Horsham Victoria Australia 3400 Telephone [phone] Fax [phone]
OFFICIAL WEBSITES
www.remoracing.com.au www.kosmickartaustralia.com www.leopardengine.com

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KOSMIC KART SET-UP GUIDE
INDEX
Chapter Description
1 Seat Installation (100 and 125cc)
1A Ballast (Weight Mounting)
1B Rear Seat Struts
2 Front Track Adjustment
3 Rear Track Adjustment
4 Caster / Camber adjustments
5 Front-End Ride Height Adjustments
6 Ackerman and Steering Adjustments
7 Rear Ride Height Adjustments
8 Tyre Pressures
9 Axle Chart and the effectiveness
10 Tuning Bars (Front Torsion Bars)
10A Tuning Bars (Rear Torsion Bar)
11 Rear Hubs
12 Braking Systems (Rear)
12B Braking Systems (Front)
12C Brake Pad Identification
12D Brake Bleeding
13 Basic Wet Weather Tips

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1. Seat Installation (100 and 125cc)
A (mm) Dimension………………………………..610mm
B (mm) Dimension………………………………..605mm
C (mm) Dimension………………………………..220mm
G (mm) Dimension………………………………..10cm
-If the driver is taller, measurements A and B can be increased by up to 10mm each, while reducing
dimension C by 5mm.
-If the track is very ‘Green’ lacking rubber all dimensions can be changed as well. Often time
dimensions A and B can be increased by 20-25mm in order to increase the effective weight
percentage on the rear of the chassis, thus increasing the chassis grip. This will increases the chassis
effectiveness when the driver is applying the power. In low grip conditions the seat can also be raised
higher by increasing dimension G from 10cm to 11-11.5 cm. This change will effectively increase
the chassis ‘Side Bite’ allowing the chassis to work the tyres more.
Part Number Product Description
0037.FP Flat Bottom Seat – Fibreglass
0037.00 Standard Seat – Fibreglass
1A. Ballast (Weight Mounting)
Remo Racing recommends using OTK weights, either 1 Kg (2.2 lbs) or 3 Kg (6.6 lbs). Part Numbers
for both items are: (PN 0275.03) and (PN 0275.01) When fastening the weights to the seat use both
provided holes on the weights with the proper hardware purchased through Remo Racing. Check
with the organization(s) you are competing with to insure all rules are met. For general balance of the
chassis depending upon how much if any weight you need to mount, it should be placed opposite of
the engine and below the seat on the front edge that contours the driver’s legs. This will provide for a
good starting point.

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1B. Rear Seat Struts
Each Kosmic Kart is supplied with two (2) supplemental seat struts, one (1) for each side.
The extra seat struts are designed to be fixed atop the rear axle cassette and then fastened to the seat
with the provided hardware. A good place to start is using one (1) on each side.
Many drivers prefer to use two (2) on each side, which will effectively force more direct-pressure
from the driver’s weight transfer on the rear tyres. This will consequently improve grip to the rear of
the chassis.
By removing seat struts you allow for the rear of the chassis to release and spring off the track easier.
This can be an added benefit when attempting to improve the chassis performance during corning.
Be careful though, by removing seat struts, the initial cornering may improve, but the potential to
create an over-steer on exist will become more prevalent as well as the overall balance of the chassis.
Remo Racing has several lengths of seat struts, so don’t rush it, get the right size!
Part Number Product Description
0006.280 Supplementary Seat’s Support 280mm
0006.300 Supplementary Seat’s Support 300mm
0006.320 Supplementary Seat’s Support 320mm
0006.340 Supplementary Seat’s Support 340mm
0006.380 Supplementary Seat’s Support 380mm
0006.400 Supplementary Seat’s Support 400mm
0007.340 Supplementary Bent Seat’s Support 340mm

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2. Front Track Adjustment
Nearly all Post-2005 Kosmic Racing Karts are sold with HST front stub axle, which has a 25mm
stub in order increase the chassis front-end grip or effectiveness. The recommended front width is to
use 3-5mm spacers on the inside of the hub (Standard 90mm HST Hub).
If the track has less grip a narrow front track will improve the chassis initial reaction, however, this
may cause the chassis to lose performance on longer corners. A track with medium to high grip often
times requires a wider front track width in order to increase the chassis weight transfer. This also
helps the chassis to be more effective on longer corners when more driver input is often times
required to keep the speed up.
3. Rear Track Adjustment
We recommend always starting with the standard OTK 92mm rear hubs. Typically we will start the
rear track at the maximum.
- For the senior divisions this will be 55” and for the junior divisions this will be 53 ½”.
(Measured from outside rear wheel to outside rear wheel) From this point the only real movement is
to narrow the rear track.
- By narrowing the rear track of the chassis while leaving the front track untouched the chassis will
become more effective at releasing the inside rear tyres during cornering. This can initially improve
the chassis performance as well as through the entire corner. However, as grip levels change a
narrow rear track can also create too much ‘Side Bite’ thus, giving the chassis too much grip in the
middle of the corner and decreasing its effectiveness.
It is also recommended when the grip levels are low to test the rear track width narrower due the
potential increase in ‘Side Bite’ from the tyre.
Rear width can sometimes be complicated in regards to the effects it has on the chassis performance,
therefore, make minuet changes when adjusting.
One of the major factors with rear width is chassis balance ‘Feel’. Some drivers do not like to drive
on a chassis with a narrower rear track width, so know your driver.

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4. Caster / Camber adjustments
Caster and Camber can be adjusted at the front-end of the chassis. Depending on which model
Kosmic Racing Kart you have, there will be either 4-position ball bearing adjustment, 4-position
non-bearing eccentric either in D.8mm or D.10mm, or Post-2007 20-position ball bearing
adjustment.
Remo Racing recommends starting with full caster, which can be attained with the top eccentric
arrow facing forward and the bottom eccentric arrow facing backwards. This will give the front-end
maximum grip from a caster perspective and can possibly make the chassis more difficult to turn as
well. This is the most often setup regarding the caster position.
The eccentrics can be rotated to reduce the amount of caster, which will make the chassis easier to
steer and it will remove front-end grip as well. The Front-end geometry can affect the chassis in
many different ways as well depending upon the track conditions.
We recommend keeping it basic until you are familiar and comfortable making these changes to your
chassis.
2008 Kosmic Eccentric! Notice the Added Adjustment Holes!
Part Number Product Description
0211.D0KIT Complete HST Excentric Bush D.22-10 New - 2008
0211.C0 Integral Excentric Bush HST
0212.C0 Integral Concentric Bush HST
0212.A0KIT Complete Concentric Bush D.22
0211.A0KIT Complete Excentric Bush d.22

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5. Front-End Ride Height Adjustments
The Kosmic Racing Kart has three (3) washers that are placed between the stub axles and the ‘C’ on
the Front-end of the chassis. Two (2) of the washers are special 4mm thick washers (PN 0215.00)
and one (1) standard 1.5mm thick washer (PN RP 10x16x1.5).
By altering these washers you will be effectively changing the front ride height. The chassis comes
standard with one 4mm washer on top of the stub axle and the remaining washers below the stub
axle. This is a recommended starting position at all venues.
RAISING THE FRONT RIDE HEIGHT
This is accomplished by placing washers from the bottom of the stub axle and placing them on top of
the stub axle. This has a positive effect on the entire chassis when the grip levels increase and the
chassis begins to understeer.
Essentially, the front ride height has been increased so, when the steering wheel is turned the inside
tyre is pushed/forced further into the track thus giving the driver a more positive feel (Front-Grip)
and it will result in a better handling chassis.
LOWERING THE FRONT RIDE HEIGHT
The process for lowering the front ride height is the exact opposite as raising the front ride height.
The advantages here are that the front-end will feel ‘lighter’ while losing some of its efficiencies.
This can also sometimes be good on high grip tracks where the driver has troubles driving on the
higher grip.
*Front-End ride height adjustments can make a big difference if applied correctly; however, this
adjustment is best saved after other adjustments have been made to your Kosmic.

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6. Ackerman and Steering Adjustments
Kosmic Racing Kart’s have two (2) different types of steering columns both are 47cm. The standard
steering columns part number is (PN 0005.BA). The pitman arm or mounting plate on the column
has two (2) locations for fixing the tie rod tubes. The standard and most often used fixing points are
the lower set of holes, this gives maximum Ackerman setting.
When the tie rod tubes are located in the upper holes, Ackerman has essentially reduced. Reducing
the Ackerman will effectively make the steering lighter and easier for driver physically; however,
this will also reduce the radius at which the front wheels turn making the front end less effective and
responsive to input from the driver throughout the turning process.
The second steering column available in 47cm is (PN 0005.F0). The pitman arm on this column is
longer, thus moving both sets of holed further away from the column, which increases the grip and
responsiveness of the chassis front-end.
! Notice the two sets of holes!
! Notice the ‘Slot’!
This indicates the 47cm column with added Ackerman

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7. Rear Ride Height Adjustments
Kosmic Karts that have been produced from 2006 and beyond are equipped with a three (3) position
rear carriage adjustment. This is a nice feature with gives the owner ample room to adjust the rear
axle of their chassis. Each chassis comes standard with the axle placed in the centre position of holes.
We highly recommend starting with the rear ride height in the centre and adjusting as needed once at
the track. Typically the adjustments here are not very frequent, however, when adjustments are made
and in the right direction positive gains will be found on the stopwatch.
LOWERING THE REAR RIDE HEIGHT
This essentially means raising the axle to the top set of holes, which will conversely lower the
chassis position to the track surface. The typical reasoning behind this move is to ‘free’ the back of
the chassis, therefore, reducing the grip level. How does this work? Essentially by doing so you have
reduced the chassis effort to release or lift the inside rear tyre during cornering, which can be crucial
in optimizing a racing Karts performance.
Note: Lifting the inside rear tyre too much, will cause more negative problems than being a benefit.
The benefit of this move will be noticed under braking also, with the chassis closer to the track
surface, general braking will result in a less nervous chassis.
RAISING THE REAR RIDE HEIGHT
This option can yield effective results, but rarely. This change will increase chassis rear grip level.
! Notice the chassis is in the centre position!
! Notice the additional holes for
adjustment!

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8. Tyre Pressures
Due to the many specifications and compounds of kart tyres in Australia today, we suggest you seek
information from your kart dealer or particular tyre distributor.
General rule:
The higher the tyre pressure is started out at, the quicker the tyre will reach its optimum pressure.
This will also cause the tyre to have a decreased window of effectiveness. Therefore, in longer races
it is better to start off at a lower pressure giving the tyre a longer window of optimum operating time.
9. Axle Chart and the effectiveness
Axles are very much talked about regarding tuning a Kart and rightfully so. OTK produces six (6)
axles for the 100cc category and five (5) for the 125cc gearbox category. OTK Type ‘N’ is the
standard axle and medium stiffness for the entire range. This axle is also what each chassis comes
standard with from the factory.
Which is the best axle to use when? Generally the consensus is that a softer axle (Type U) will free
the chassis letting it operate more freely around the track. This may be true in some instances but
typically not with the OTK material. Typically it is recommended to use a harder axle (Type H or
HH) when the grip levels increase.
Softer axles are recommended more for use when the grip levels are low. Why is this true? This
holds true mainly due to the fact the chassis are made of soft 30mm tubular steel. With a soft chassis
and a softer axle you will essential create the tyre to work more creating “Side Bite” or the sidewall
of the tyre to rollover. This will cause the chassis to ‘Hop’ and therefore lose its effectiveness
throughout the race. Keep with the ‘N’ axle; we use this axle 80% of the time and as the grip level
increase the ‘H’ will work for your needs.
Remember that the axle doesn’t simply work outside the chassis, it also creates balance between the
frame rails, and therefore, increased stiffness on your axle selection will give the chassis more
balance as well.
*SEE AXLE CHARTS PROVIDED ON NEXT PAGE

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AXLE HARDNESS SCALE D.50
Type
Size
Model
Soft
Hardness
Hard
Code
E50x1030 DD 0054.G0E
U50x1030 DD 0054.G0U
Q50x1030 DD 0054.G0Q
N50x1030 DD 0054.G0N
H50x1030 DD 0054.G0H
HH 50x1030 DD 0054.G0HH
U50x1030 GB 0054.H0U
Q50x1030 GB 0054.H0Q
N50x1030 GB 0054.H0N
H50x1030 GB 0054.H0H
HH 50x1030 GB 0054.H0HH
Model DD : direct drive kart Model GB : gear box kart
AXLE HARDNESS SCALE D.40

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10. Tuning Bars (Front Torsion Bars)
Each chassis is supplied with a ‘Flat’ steel front torsion bar. This bar can be replaced with three (3)
additional round 30mm bars made of different wall thicknesses.
The added torsion bars come with a 1.0mm, 1.5mm, 2.0mm wall thickness. Each bar improves the
front-end effectiveness during changing track conditions.
The 2.0mm is the stiffest, which effectively allows the front-end to work better during high-grip
levels; however, it will require increased input and strength from the driver as well.
Many REMO RACING Team Drivers prefer the
1.0mm bar Part Number 0235.FAK – 1,0mm (see picture)
10A. Tuning Bars (Rear Torsion Bar)
Kosmic Racing Karts are provided with only one (1) style rear torsion bar. The bar is made of steel
and measures 470mm (PN 0235.GA). The bar is round on each end at 30mm with the centre being
flattened to resemble a ‘Blade’. Since the rear torsion bar is manufactured in a ‘Blade’ configuration
we also suggest using it in the horizontal position, thus the blade laying flat.
In typical dry conditions we recommend to NOT use the rear bar. The rear bar will make the chassis
more stable; however, it can cause the chassis to work the tyres too much, which will result in poor
tyre wear and a large possibility of an understeer. *Note: This is a good option if you are looking for
added grip.
When should you use the rear torsion bar? The rear torsion bar has its main advantages in longer
sweeping corners. If the track layout is made of sweeping corners try the rear bar, but only do this on
applications where the Hp is greater than 100cc application.

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11. Rear Hubs
The possible options for rear hubs on the Kosmic Kart are very large. They range from different
lengths to different material stiffness.
All Kosmic (Racing Edition) Karts come outfitted with magnesium rear hubs where Kosmic
(Competition Edition) Karts come outfitted with aluminium rear hubs.
We recommend the magnesium hubs since they are stiffer than the optional soft aluminium hubs.
This creates added consistency as well as improved handling and driver feel as well.
Below is a breakdown of the different options:
Part Number Product Description Material Type
0046.KE Wheel’s Boss AL D.50x56 Aluminium
0053.KE Wheel’s Boss AL D.50x92 Aluminium
0046.E0 Wheel’s Boss MG D.50x56 Magnesium
0053.E0 Wheel’s Boss MG D.50x92 Magnesium
0053.F0 Wheel’s Boss MG D.50x148 Magnesium
Each Kosmic Kart comes standard with either 50 x 92 rear hub. This hub is recommended for
primary use. Using either the 56mm or 148mm rear hubs are great options as well. The 56mm rear
hub will allow the wheel and tyre to flex more creating the potential for a better outcome on lower
Hp applications.
The largest hub, 148mm, is only used and recommended for use in gearbox applications. This hub
adds more rear grip and stability, which are often times required by larger Hp applications.
(0053.KE) “This Hub is the best option nearly all the time” – Remo Racing

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12. Braking Systems (REAR)
Depending on the year of production, your Kosmic Racing Kart may have several different baking
systems. All braking systems are equipped with highest of quality standards as well as CIK/FIA
Homologated.
Typically any chassis purchased later than 2006 will come fully equipped with the BS6 rear calliper
and for gearbox applications the BS6 with its counterpart the BS5 system. In order to simplify the
situation we have provided an estimated time line detail the braking system you may have:
*Brake Fluid requirements are as follows:
Fluid System
Dot 4 BS 1-2
Dot 4 BS 4
Dot 5 BS 5/6
Production Year Part # Product Description System Type
2000-2003 0082.KA Complete hydraulic Rear Brake Calliper BS 1-2
2003-2005 0082.DA Complete Hydraulic Self-Adjusting
Rear Brake Calliper BS 4
2005-2008 0082.EA Complete Hydraulic Self-Adjusting
Rear Brake Calliper BS 6

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12b. Braking Systems (FRONT)
Depending on the year of production, your Kosmic Racing Kart may have several different baking
systems. All braking systems are equipped with highest of quality standards as well has CIK/FIA
Homologated. Typically any chassis purchased later than 2006 will come fully equipped with the
BS6 rear calliper and for gearbox applications the BS6 with its counterpart the BS5 system.
In order to simplify the situation we have provided an estimated time line detail the braking system
you may have:
Production Year Part # Product Description System Type
2000-2003 0100.BA Complete hydraulic Front Brake Calliper BS 1-2
2003-2005 0100.DA Complete Hydraulic Self-Adjusting
Front Brake Calliper BS 3
2005-2008 0100.EA Complete Hydraulic Self-Adjusting
Front Brake Calliper BS 5

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12c. Brake Pad Identification
With the several different braking system options, there are corresponding brake pads for each
system.
The unique advantages to the OTK braking systems are that the BS3/4 and BS 5/6 all require the
same brake pad for the front and rear.
The BS 1-2 system is the only system that calls for separate rear and front brake pads.
Part # Product Description System Type
0082.B4 Rear Brake pad BS 1-2
0100.B4 Front Brake Pad BS 1-2
0082.D4 Rear / Front Brake Pad BS 3/4/5/6
0082.D4A Rear / Front Brake pad Sintered BS 3/4/5/6

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12d. Brake Bleeding
When bleeding your make sure have the proper OTK brake bleed kit (PN 0156.00).
This tool enables for and effective and efficient job. Here are the steps required.
1. Take a 5mm Allen wrench and remove the braking pumps discharge plug
2. Insert your OTK Bleeding Kit; carefully begin screwing it into the fitting.
3. Once secure, remove the top cap on the Bleeding Kit and turn the valve to the ‘On’ Position’
4. Now, move to the rear calliper and underneath the bleeding screws place a rag (in order to absorb
any residue and spillage).
5. Once complete remove bleeding screw and let the bleeding kit force all the air out of the brake line
6. Once the air appears to be gone, insert the bleeding screw.
7. Repeat this step for each brake pump on the chassis
8. When finished make sure that you have securely tightened the discharge plugs.
(Pic #1) 3mm Allen (Pic #2) 8mm Wrench (Pic #3) 8mm Wrench
(Above) Pump’s Discharge Plug (5mm Allen)

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13. Basic Wet Weather Tips
Most of the time, the dreaded rain comes and the change over from dry to wet setup is rushed with
only a 15-25 minute window to make the changes. What can be done is such a short window of
time? Actually alot almost everything you’ll need to do.
WET CONDITIONS
Wide the front hubs as far as possible
Narrow the rear track width so the centre line of the rear tyre matches the centre line of
the front tyre
Loosen the extra seat struts, you can keep them on, but make sure they are loose with the
nut barely attached (so it will not fall off)
Remove the front torsion bar (and rear if you were running it in the wet)
Loosen the floor tray bolts
Adjust the front-end geometry to 4mm open toe-in *This will be a very good starting point
VERY WET CONDITIONS
Wide the front hubs as far as possible (Install Longer Front Hubs if Possible)
Narrow the rear track width so the centre line of the rear tyre matches the centre line of
the front tyre (Use shorter rear hubs 56mm)
Loosen the extra seat struts, you can keep them on, but make sure they are loose with the
nut barely attached (so it will not fall off)
Remove the front torsion bar (and rear if you were running it in the wet)
Loosen the floor tray bolts
Adjust the front-end geometry to 4mm open toe-in
Raise the front ride height
Install a softer axle or try raising the rear axle
Remember if the track has sweeping corners, try the rear bar. It will lose efficiency in
the slower corners, but the gains in the long sweeping corners may offset the difference?
Try to also raise the seat in an attempt to bring the driver’s centre of gravity higher
*This will be a very good starting point
! Notice the Longer Front Hub for added Grip!
14. Conclusion
COMMITMENT

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CONCLUSION
REMO RACING is committed to making all Kosmic Racing Kart owner’s champions and race
winners. We hope this informative ‘Knowledge Packet’ will further help our customer’s to
understand the basic workings of their chassis.
SUPPORT
REMO RACING director Remo Luciani is always available for any clarification(s) or added
understandings regarding the material found in this packet or additional information required.
KNOWLEDGE PACKET CONTENTS
The information supplied in this packet by Kosmic Kart Technical Department is ‘general
knowledge’ and may not apply to all owners or track conditions encountered. Keep in mind that trial
and error is still a great means of understanding the Kosmic material.
PRODUCT UPDATES
Kosmic Kart Technical Department release regular updates on certain products both new and current
to keep the entire customer base worldwide up to Speed!
So, CHECK OUT the KOSMIC KART AUSTRALIA WEBSITE for any updates relating to the
Australian market.
Drivers, please feel free to contact me directly on 0418 340640 or email [e-mail]
for any queries or concerns you may have.
BEST OF LUCK!
REMO RACING PTY LTD
Remo Luciani
Director
www.kosmickartaustralia.com
Your Local Kosmic Kart Dealer is