Sodi EVO5 Operating instructions

CONFIGURE THE KART ACCORDING TO THE GUIDE INSTRUCTIONS
USE SPARE PARTS OF SODIKART ORIGIN
USER MAINTENANCE GUIDE
EVO5
MAN021.002
JANUARY 2008
This document can not be reproduced or released without the sodikart authorization.

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EVO5 MANUAL
SUMMARY EVO5
SAFETY INSTRUCTIONS 3
PREPARING THE ASSEMBLY
1- GETTING EVO 5 OUT OF THE PACKING 4
2- TOOLS FOR ASSEMBLY 5
3-MAINTENANCEPRODUCTS 5
SEQUENCE OF ASSEMBLY 6
4- ASSEMBLY OF THE STEERING COLUMN AND OF THE STEERING WHEEL 7-8
5- ASSEMBLY OF THE FUEL TANK AND OF THE OVERFLOW BOTTLE 9
6- ASSEMBLY OF THE SEAT AND OF THE SEAT STIFFENERS 10-12
7-ASSEMBLYOFTHEKGBODYWORK 13-15
8-STARTINGYOUREVO5 16
STANDARD ADJUSTMENTS
9-TABLEOFTHESTANDARDADJUSTMENTS 17
10- ADJUSTMENT OF THE FRONT END 18-23
11- ADJUSTMENT OF THE REAR END 24-25
12-ADJUSTMENTOFTHESEAT 26
MAINTENANCE
13-TYRES 27-28
14-BRAKES 29-30
15-CLEANINGTHECHASSIS 31
16-MAINTENANCEPLAN 32
17-TROUBLESHOOTING 33
T
his document can not be reproduced or released without the SODIKART authorization.
VERSION : JANUARY 2008 MAN021.002

EVO5 MANUAL
You have decided to acquire a SODI chassis. We would like to thank you for choosing the SODI
EVO5.
Your kart has been developed for performance and safety.
It is the outcome of SODIKART’s experience and of the latest research at the highest level of
competition.
This manual contains instructions for the assembly and the maintenance of your kart, according
to the rules of the art.
Safety on a track is a personal and collective matter at the same time: taking care of your EVO5
is the first guarantee of your safety and of the safety of other pilots.
This manual also contains advice about adjustments.
Their purpose is to help you exploiting all the potential of your EVO5.
Enjoy driving your EVO5,
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VERSION : JANUARY 2008 MAN021.002

EVO5 MANUAL
SAFETY INSTRUCTIONS
The EVO 5 has been designed for leisure and high level competition.
Its design, which complies with the pending rules of the CIK, ensures an optimum safety in
normal working conditions.
Its high speed and performances imply a proper maintenance.
•For your safety and the one of other pilots, please thoroughly respect :
-The assembly instructions.
-The adjustment recommendations.
-The maintenance plan.
•Please pay especial attention to the instructions or comments to the following symbols
below :
NOTE:Gives useful information.
: indicates a high risk of severe injury if the instructions are not
followed.
¾Should you not find an answer to your questions in this manual or face any problem, please
get advice from the SODIKART distribution network.
¾The SODI EVO5 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.
¾The SODI chassis can only be used on an approved track and by a driver who is in
possession of a valid membership card of the go-kart’s federation of his own country.
¾Prior to going on the track, please check all points related to safety.
¾In order to avoid fire, put the kart at least one meter away from the buildings. Never
leave inflammable objects close to the kart.
¾If fuel has been poured, wipe and wait for vapors to dissipate, before starting the
kart.
¾Kids and domestic animals have to be kept away from the kart and the track.
¾Never drive the kart without adequate pilot equipment.
¾Use spare parts of SODIKART origin.
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EVO5 MANUAL
1- GETTING EVO5 OUT OF THE PACKING
SPOILER
EVO5 FRAME
SEAT
LEFT SIDE POD
NASSEAU PANEL
LEFT SIDE POD
SUPPORT
STEERING COLUMN
ASSEMBLY
STEERING WHEEL
EXHAUST
SUPPORT
RIMS
OVERFLOW
BOTTLE
RIGHT SIDE POD
SUPPORT
RIGHT SIDE POD
FUEL TANK
SLOTTED WRENCH
STUB AXLE
SPACER ADJUSTER
STUB AXLE SCREW
ADJUSTER
NOTE: -Prior to assembling your kart, check the above described elements and
familiarize yourself with them.
-The part numbers of the various items can be found in the “spare parts
catalogue “.
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EVO5 MANUAL
2-TOOLING FOR ASSEMBLY AND ADJUSTMENT
DESIGNATION DIAMETER PART NUMBER
-T handle wrench allen key 4mm OU 911.002
-T handle wrench allen key 5 mm OU 911.003
-T handle wrench allen key 6 mm OU 911.004
-T handle wrench allen key 8 mm OU 911.005
-T handle socket spanner 8 mm OU 912.004
-T handle socket spanner 10 mm OU 912.001
-T handle socket spanner 11 mm OU 912.002
-T handle socket spanner 13 mm OU 912.003
-Key for slotted round nut M20 supplied OU 914.003
- Stub axle spacer adjuster Hub supplied OU 931.007
- Stub axle screw adjuster Stub axle supplied OU 931.006
3- MAINTENANCE PRODUCTS
-Cleaner : (paint - plastics) : LU 832.007
-WD40 LU 833.003
-Greaseforchain LU 822.002
NOTE:
FOR OTHER TOOLS, ACCESSORIES AND EQUIPMENTS PLEASE REFER TO THE ITAKA
CATALOGUE.
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EVO5 MANUAL
SEQUENCE OF ASSEMBLY AND INSTRUCTIONS
STEERING COLUMN AND STEERING WHEEL (chapter 4).
FUEL TANK AND OVERFLOW BOTTLE (chapter 5).
SEAT AND STIFFENNERS (chapter 6).
KG BODYWORK (chapter 7).
NOTE: Recommended tightening torques:
Ø6 = 10 to 12 m.N
Ø8 = 12 to 24 m.N
Ø10 = 24 to 48 m.N
Do not overtighten screws and bolts
Screws without bolts are to be blocked with 1 drop of special glue (LU 861.001)
Lubricate rotating parts, ball joints, gas cable ….

EVO5 MANUAL
4- ASSEMBLY OF THE STEERING COLUMN AND STEERING WHEEL.
THE SET CONSISTS IN:
6
4
2
5
3
1
PIC 1
¾One plastic steering column support (1).
¾One steering wheel support (2).
¾Two nassau panel supports (3).
¾One steering column (4).
¾One steering column support (5).
¾Two steering tie rods + ball joints (6).
¾Raise the set as in picture 1.
2
1
3
PIC 2
4.1 ASSEMBLY OF THE STEERING COLUMN
SUPPORT (PIC 2)
¾Place the steering column support on the two pins
canons (1) and (2).
¾Put the CHC M6x30 (3) screws + nylstop M6 bolts
as indicated in picture 2.
¾Tighten.
4
5
PIC 3 4.2 ASSEMBLY OF THE STEERING COLUMN (PIC 3)
¾Insert the threaded end of the steering column in
the ball joint (4).
¾Place the bolt (5).
¾Tighten.
4.3 ASSEMBLY OF THE TIE-RODS (PIC 4)
6 7
PIC 4
Inner hole
After cutting the tie-wrap maintaining the stub axles:
¾Place the ball joints (6) above the stub axle arm
(7).
¾Insert the BHC M8x30 screw in the outer hole of
the stub axle arm.
¾Place the washer on top of the ball joint and insert
the screw.
¾Place the M8 bolt and tighten.
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EVO5 MANUAL
4.4 TIGHTENING THE PLASTIC STEERING COLUMN SUPPORT.
¾Tighten the CHC M8x65 screw (8).
4.5 ASSEMBLY OF THE STEERING WHEEL.
¾Tighten the steering wheel (1) with the 3 FHC M6x30 screws, on the steering wheel support
(2).
¾Tighten the steering wheel support on the steering column.
Check: once the steering system is assembled, please check that the steering wheel is free to
make a quarter of a turn right and left.
9A bad assembly or a bad adjustment of the steering system can lead to accidents.
9Systematically check the tightening of the system and its adjustment.
2
STRAIGHT PART
FORWARD
1
8
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EVO5 MANUAL
5- ASSEMBLY OF THE FUEL TANK AND OF THE OVERFLOW BOTTLE.
1
3
2
¾Insert the fuel tank between the steering column support (1) and the steering column (2)
(see pictures )
¾Tighten with the fly nut (3)
5
4
9
6
7
8
¾Insert the overflow bottle (4) between the nassau panel supports (5).
¾Connect the overflow bottle hose (6) to the return (7).
¾Connect the petrol tank hose (8) to the red plug (9).
NOTE:
-CHECK THE PRESENCE OF THE DIVER UNDER THE RED PLUG (9).
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EVO5 MANUAL
6-ASSEMBLY OF THE SEAT AND SEAT STIFFENERS.
4 FIXING
POINTS
¾The washers of the seat fixing kit comply with CIK/FIA and with your local national
rules.
6-1 GROUND CLEARANCE
Measurements given below correspond to
the standard adjustment of the seat,
recommended by SODIKART, for the EVO5.
Get the seat supports (1) closer, or wider,
depending on the seat size.
Use the shims of the seat fixing kit to get a
good fit.
1
SEAT
1Bar
24mm or 6 rear sprockets
GROUND
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EVO5 MANUAL
6-2 DISTANCE BETWEEN THE REAR AXLE AND THE MIDDLE OF THE ROUND REAR
EDGE OF THE SEAT.
260mm
Measure from the
middle of the
rounded edge
6-3 DISTANCE BETWEEN THE AXIS OF THE LEFT SIDE STUB AXLE FORK AND THE
MIDDLE OF THE REAR ROUNDED EDGE OF THE SEAT.
1020mm
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EVO5 MANUAL
6-4 ASSEMBLY OF THE SEAT STIFFENERS.
ASSEMBLY OF THE LOWER END (PIC 1)
1. Place the CHC M8 screw (1) in the hole of the
bearing support (2).
2. Place the stay bolt PC 0332.004 (3) as indicated.
3. Put the seat stiffener lower end (4) in place.
4. Put the bolt in place and pre-tighten.
1
2
3
4
PIC 1
For screws and bolts references, refer to the
spare parts catalogue.
ASSEMBLY OF THE UPPER END (PIC 2)
5. Place the upper end of the stiffener (5).
6. Make sure there is no contact with the exhaust
system and with any part of the engine.
If necessary, slightly bend the stiffener.
7. Drill a 8.5 mm diameter hole (5) in the seat.
8. Place one FHC M8 screw + conical washer.
5
PIC 2 9. Tighten both upper and lower end.
For screws and bolts references, refer to the
spare parts catalogue.
FOR OTHER TYPES OF STIFFENERS, PLEASE REFER TO THE EVO 5 SPARE
PARTS CATALOGUE OR TO THE ITAKA CATALOGUE
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EVO5 MANUAL
7-ASSEMBLY OF THE KG BODYWORK.
7-1 PREPARING THE KG SIDE POD SUPPORTS.
In order to comply with the CIK/FIA rules, carefully prepare the supports as indicated below.
Do not respect the dimensions may lead to relegation during a race.
1. Cut 50mm the end of the side pod support. (see
below the picture)
2. Insert the side pod support into the bushings until
the ring (1) of the side pod support touch the
bushing. (see the right picture) 2
2
1
3. Use the holes (2) on the frame to drill the side pod
support and bushings with Ø6.5mm drill.
50mm
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EVO5 MANUAL
1
2
3
4
7-2 ASSEMBLY OF THE SIDE POD ON ITS
SUPPORTS
¾Place the side pod (1) on the side pod support (2).
¾Place the screws (3) through the side pod (1) and
the side pod support (2).
¾Tighten the assembly with the nuts (4).
Refer to the EVO5 spare parts catalogue for the
bolting
2
1
1
7-3 ASSEMBLY ON THE FRAME
¾Check that the bushings are pushed in the frame.
¾Insert the side pod assembly into the bushings.
¾Tighten with the screws (1) and the nuts (2)
Refer to the EVO5 spare parts catalogue for the
bolting
2 4
3
1
3
7-4 ASSEMBLY OF THE SPOILER UPPER SUPPORT
ON THE FRAME
¾Place the spoiler upper support (1) on the outer
face of the lug (2).
¾Tighten with the screws (3) and the nuts (4).
Refer to the EVO5 spare parts catalogue for the
bolting
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EVO5 MANUAL
7-5 ASSEMBLY OF THE SPOILER
¾Assemble the spoiler fixation kit (1) between the spoiler upper support (2) and the frame
(3) with two screws and two nuts.
¾Place the flanges (4) between the spoiler support (2) and the frame (3), then lock.
Refer to the EVO5 spare parts catalogue for the bolting
4
3
2
3
1
2
7-6 ASSEMBLY OF THE NASSEAU PANEL
¾Place the nasseau panel (1) on the nasseau panel upper support (2) and the nasseau panel
lower support (3).
¾Draw the 3 drill points on the nasseau panel (1).
¾Drill the Ø6.5mm holes.
¾Place the nasseau panel (1) on its supports (2) and (3)
¾Tighten the nasseau panel (1) on its supports (2) and (3) with screws, nuts, and washers.
Refer to the EVO5 spare parts catalogue for the bolting
3
1
2
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EVO5 MANUAL
8- STARTING YOUR EVO5
SAFETY INSTRUCTIONS TO THE PILOTS
WARNING
YOUR KART CAN ONLY BE DRIVEN ON A TRACK APPROVED BY CIK/FIA, OR YOUR
LOCAL FEDERATION AND BY A DRIVER WHO IS IN POSSESSION OF A VALID
MEMBERSHIP CARD OF THE GO-KART’S FEDERATION OF HIS OWN COUNTRY.
PILOT PROTECTION
Before going on the track, the pilot must wear the following protections:
•Integral helmet: CIK/FIA approved, fitting the pilot head size, with tightened strap and
closed visor. Refer to CIK/FIA regulations (compulsory).
•Suit: CIK / FIA level 1 or level 2 approved. (compulsory)
•Gloves. (compulsory)
•Neck protection : CIK/FIA approved (compulsory)
•Rib protection: fitting pilot’s size and seat (recommended).
•Rain suit: with water tight fasteners (recommended when necessary).
CHOOSE THOSE EQUIPMENTS WITHIN THE CIK / FIA APPROVED ONES OF THE
ITAKA CATALOGUE
DRIVING IS FORBIDDEN TO ANY PILOT:
¾Wearing a scarf because of risk with rotating parts.
¾With long hair coming out of the helmet.
¾With wide floating clothes.
¾With health problems, not compatible with high speed driving.
¾Under the influence of drugs and (or) alcohol.
9For your safety and the safety of other pilots, strictly follow the above instructions:
not doing so may lead to severe, even fatal injuries.
9Be aware that some medicines reduce your ability to drive
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EVO5 MANUAL
9-STANDARD ADJUSTMENTS OF THE EVO 5
DRY WET
STUB AXLE HEIGHT
FRONT TRACKING WIDTH
REAR TRACKING WIDTH
REAR AXLE POSITION /
TIGHTENING OF THE
CENTRAL BEARING
POSITION OF MASSES
POSITION OF EXCENTRICS
POSITION OF STEERING
TIE RODS ENDS
4mm 4mm+4mm
4mm +2mm 2mm
2 rings inside All rings inside
Short hub 60mm Long hub 80mm
1
2
1340mm
FOR TYRE PRESSURES, REFER TO TABLE PAGE 28
A-2
OR
B
-
3
B-3
3
3
1320mm
Mark – Inward
Eccentrics 4°
TOP
BOTTOM
FWD
ard
Mark - Forward
Mark - Backw
Eccentrics
TOP
TOP
Tightened central bearing Tightened central bearing
FWD
TOP
BOTTOM
Mark - Forward
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EVO5 MANUAL
10- ADJUSTMENT OF FRONT WHEELS
10.1 ADJUSTMENT OF FRONT TRACKING WIDTH
DRY TRACK
¾On dry track, place 2 rings inside with SHORT HUBS L60mm.
WET TRACK
¾On wet track, place all the rings inside with LONG HUBS L80mm.
¾For more grip forward, place one or
two 5 mm rings on the chassis side.
Steering becomes harder.
¾For less grip forward, place one
or two 5 mm rings outside.
Steering becomes lighter.
3x5mm
2x5mm
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EVO5 MANUAL
10.2 ADJUSTMENT OF FRONT WHEEL HEIGHT
DRY TRACK
¾Place one 4mm spacer on top and one 4 mm + one 2 mm spacer at the bottom (1).
4mm
(1) DRY TRACK
4+2mm
WET TRACK
¾Place one 4 mm + one 4 mm spacers on top, and one 2 mm spacer at the bottom (2).
¾The adjustment of dry track (1) can be suitable for wet track.
4+4mm
(2) WET TRACK
2mm
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