Sodi SR5 Operating instructions

CONFIGURE THE KART ACCORDING TO THE GUIDE INSTRUCTIONS
USE SPARE PARTS OF SODIKART ORIGIN
USER MAINTENANCE GUIDE
SR5
MAN027.002
JANUARY 2008
This document can not be reproduced or released without the sodikart authorization.

- 1 -
SR5 MANUAL
SUMMARY SR5
SAFETY INSTRUCTIONS 3
PREPARING THE ASSEMBLY
1- GETTING SR5 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-STARTINGYOURSR5 16
STANDARD ADJUSTMENTS
9-TABLEOFTHESTANDARDADJUSTMENTS 17
10- ADJUSTMENT OF THE FRONT END 18-23
11- ADJUSTMENT OF THE REAR END 24-26
12-ADJUSTMENTOFTHESEAT 27
MAINTENANCE
13-TYRES 28-29
14-BRAKEPADSREPLACEMENT 30
15- BLEEDING OF THE BRAKE SYSTEM 31
16-CLEANINGTHECHASSIS 32
17-MAINTENANCEPLAN 33
18-TROUBLESHOOTING 34
EDITION : JANUARY 2008 MAN027.002
T
his document can not be reproduced or released without the SODIKART authorization.

SR5 MANUAL
You have decided to acquire a SODI chassis. We would like to thank you for choosing the SODI
SR5.
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 SR5
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 SR5.
Enjoy driving your SR5,
- 2 -
EDITION : JANUARY 2008 MAN027.002

SR5 MANUAL
SAFETY INSTRUCTIONS
The SR5 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 SR5 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.
- 3 -

SR5 MANUAL
1- GETTING SR5 OUT OF THE PACKING
SPOILER
SR5 FRAME
FUEL TANK
SEAT
KG LEFT SIDE POD
NASSEAU PANEL
LEFT SIDE POD
SUPPORT
STEERING COLUMN
A
SSEMBLY
STEERING WHEEL
OVERFLOW
BOTTLE
EXHAUST PIPE
SUPPORT
KG RIGHT SIDE POD
RIMS
REAR BUMPER
RIGHT SIDE POD
SUPPORT
SLOTTED WRENCH
STUB AXLE
SPACER ADJUSTER
STUB AXLE SCREW
A
DJUSTER
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 “.
- 4 -

SR5 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.
- 5 -

- 6 -
SR5 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 UNICO BODYWORK (chapter 7).
SODI BODYWORK (chapter 8).
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 ….

SR5 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.
- 7 -

SR5 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
- 8 -

SR5 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).
- 9 -