Sodi Delta 900 Operating instructions
This document can not be reproduced or released without the Sodikart authorization.
This document can not be reproduced or released without the Sodikart authorization.
MAN.DEL.EN.02
05/2014
You have decided to acquire a SODI chassis. We would like to thank you for
your trust (in us).
Your kart has been developed for performance and safety.
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 kart is the rst guarantee of your safety and of the safety of other
pilots.
This manual also contains advice about adjustments.
Their purpose is to help you exploiting all the potential of your kart.
Enjoy driving your kart,
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MAN.DEL.EN.02
05/2014 3
4
1.1 - Recap of all warnings included in this
manual ........................................................4
6
2.1 - Tooling for assembly and adjustment ..........7
2.2 - Maintenance products..................................7
8
3.1 - Precautions and recommendations..............8
3.2 - Assembly of the steering column and
steering wheel.............................................8
3.3 - Assembly of the fuel tank and of the
overow bottle .............................................9
3.4 - Assembly of the seat..................................10
3.5 - Assembly of the bodywork..........................10
3.6 - Mounting the rear protections.....................12
13
4.1 - Safety instructions to the pilots...................13
4.2 - Pilot protection............................................13
14
5.1 - Adjustment of the front ...............................14
5.1.1 - Adjustment of the front width.................. 14
5.1.2 - Front wheel alignment............................14
5.1.3 - Adjustment of tie rods............................. 15
5.2 - Adjustment of the rear................................15
5.2.1 - Adjustment of hubs................................. 15
5.2.2 - Position of rear axle ............................... 15
5.3 - Adjustment of seat......................................16
17
6.1 - Hydraulic brake ..........................................17
6.1.1 - Fluids and lubricants.............................. 17
6.1.2 - Frequency of cleaning and maintenance17
6.1.3 - Replacing brake pads ............................ 18
6.1.4 - Replacing the brake hose ...................... 18
6.1.5 - Bleeding the rear brake circuit ............... 18
6.1.6 - Replacing rear calliper seals / 4
piston caliper pistons D18 (front) ........... 19
6.1.7 - Replacing master cylinder seals and
pistons....................................................20
6.1.8 - Cleaning................................................ 22
6.2 - Mechanical brake.......................................22
6.2.1 - Points to check.......................................22
6.2.2 - Brake pads replacement........................ 22
6.3 - Tyres..........................................................22
6.3.1 - Tyres change.......................................... 23
6.3.2 - Table of the recommended tyre
pressures ............................................... 24
6.4 - Cleaning the chassis..................................25
6.5 - Maintenance summary...............................25
6.5.1 - Bolting.................................................... 25
6.5.2 - Steering..................................................25
6.5.3 - Bodywork parts ...................................... 25
6.5.4 - Tyres ...................................................... 25
6.5.5 - Braking................................................... 25
6.6 - Brake hoses must not show any leaks
at connection points. Replace if
damaged. .................................................25
7.1 - The kart will not brake................................26
7.2 - The kart brakes continually ........................26
7.3 - The kart is hard to turn...............................26
7.4 - The steering of the kart is not precise........26
7.5 - The kart tends to go to the side..................26
7.6 - The kart skids very much on bends............26
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MAN.DEL.EN.02
05/2014
4
This user guide is updated by SODIKART to
allow, without delay, to know the last safety
and maintenance improvements.
Refer to our website regularly, to download
the last version of user guide.
The illustrations are non-contractual.
© Sodikart 2014.
The kart has been designed in accordance with the
pending rules of the CIK / FIA in force, which ensures
an optimum safety in normal conditions of use.
Its high speed and performances imply a proper
maintenance.
For your safety and the one of other pilots, please
thoroughly respect:
●The assembly instructions.
●The adjustment recommendations.
●The maintenance plan.
Please pay especial attention to the instructions or
comments to the following symbols below:
●Gives useful information
●Indicates a risk of property damage if
instructions are not followed.
If fuel has been poured, wipe and wait for vapors to
dissipate, before starting the kart. / Page 4
In order to avoid re, put the kart at least one meter
away from the buildings. Never leave inammable
objects close to the kart. / Page 4
Kids and domestic animals have to be kept away
from the kart and the track. / Page 4
Never drive the kart without adequate pilot
equipment. / Page 4
Prior to going on the track, please check all points
related to safety. / Page 4
The SODI chassis can only be used on an approved
track and by a driver who is in possession of a valid
membership card of the go-kart’s federation of his
own country. / Page 4
The SODI chassis is designed for safety and
reliability in normal conditions of use. Before using
it, please read this manual and carefully follow the
instructions. By not doing so, you might be exposed
to a risk of severe, even fatal injury, and your kart
might suffer damages. / Page 4
A bad assembly or a bad adjustment of the steering
system can lead to accidents. Systematically
check the tightening of the system and its
adjustment./ Page 9
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MAN.DEL.EN.02
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Your kart can only be driven on a track approved by
cik/a, 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./ Page 13
For your safety and the safety of other pilots, strictly
follow the above instructions: not doing so may lead
to severe, even fatal injuries./ Page 13
Be aware that some medicines reduce your ability to
drive/ Page 13
Never drive with badly tightened wheels: it may lead
to severe, even fatal injuries./ Page 14
Make sure that each ball joint penetrates at least 5
threads in the tie rods./ Page 14
Badly tightened wheels may lead to severe, even
fatal injuries./ Page 15
Check the hub key (5) is correctly
positioned./ Page 15
Never position the hubs beyond the maximum
allowed width: it may lead to severe or even fatal
injuries./ Page 15
The Super Blue brake uid has been designed for
racing use and is used exclusively for this purpose
(forbidden on open road)./ Page 17
Use brake uid DOT4 only. Using another brake
uid could cause leaks and failure of the brake
system./ Page 17
Check the pads for wear before every start-
up./ Page 18
Never drive with excessively worn pads (minimum
thickness for the D18 4-piston calipers (front):
4mm)./ Page 18
The brake is an essential safety element. If the
braking system is defective or you have the slightest
doubt, do not put the kart in service./ Page 18
The brake is an essential safety element. Do not put
the kart in operation if the break system is faulty or if
you have a doubt./ Page 18
Faulty braking system may lead to a serious or even
fatal injury./ Page 18
Check connexions of hoses, no leak./ Page 18
Use brake uid DOT 4 only./ Page 18
If WD-40 or a similar cleaning product is splashed
on the brake disc or calliper, braking will be less
efcient or possibly totally ineffective for a few
revolutions. This could cause a serious or fatal
accident./ Page 22
Do not apply WD-40 or other cleaning products to
the brake pump./ Page 22
The brake system is a key safety item of the
kart. Regularly check all its components. In
case of doubt, do not drive before xing the
problem./ Page 22
Bad maintenance of the brakes can lead to severe,
even fatal injuries./ Page 22
Use spare parts of SODIKART origin./ Page 22
Change all damaged rims. A damaged rim may lead
to a loss of tyre or loss of pressure and may lead to
a serious or even fatal injury./ Page 23
Check the tyre wear daily. Worn or damaged tyres
may lead to a serious or even fatal injury./ Page 23
Never run with worn or damaged tyres: a burst
of tyre may lead to a serious or even fatal
injury./ Page 23
Always blow up tyre with the pressure
recommended by the manufacturer./ Page 23
Cold tyres have a reduced adherence, and increase
the loss of control of the kart. This may lead to a
serious or even fatal injury./ Page 23
Too much grip reduces the stability of the kart under
impact, and lead to a tendency to go on two wheels.
It also increases the risk of riding over./ Page 23
Store tyres in an appropriate area to prevent re
hazard. / Page 23
Spray cleaning product on brake pads or brake
caliper may reduce the braking ability partially or
totally, and can lead to a serious accident./ Page 25
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MAN.DEL.EN.02
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6
1
2
8
7
10
9
6
5
43
11
14
13
12
●Prior to assembling your kart, check the
above described elements and familiarize
yourself with them.
●For part numbers, refer to the exploded
view.
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MAN.DEL.EN.02
05/2014 7
13
5
5
5
2
4
6
Ø
1
- OU931.006
3 OU911.001
4 OU911.002
5 OU911.003
6 OU911.004
8 OU911.005
3 8 OU912.004
3 10 OU912.001
3 11 OU912.002
3 13 OU912.003
4 - LU861.001
5 - OU951.003
6 - OU951.002
LU834.003
LU833.003
LU825.005
●For other tools, accessories and
equipment, visit ITAKA website.
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MAN.DEL.EN.02
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8
●Do not overtighten screws and bolts.
●Tightening torque Ø 6 = 10 to 12 mN.
●Tightening torque Ø 8 = 12 to 23 mN.
●Tightening torque Ø 10 = 23 to 47 mN.
●Tightening torques for rims on hub : 25 mN.
●Screws without bolts: 1 drop of special glue
(LU861.001).
●Lubricate rotating parts, ball joints, gas cable ...
Step 1
2
1
3
●Insert the threaded end of the steering column in the
ball joint (1).
●Tighten the nut (2).
●Tighten the assembly.
●Put the split pin (3) into the hole of steering column.
Step 2
1
2
4
3
4
3
●Assembling the Steering column (1) with the Plastic
steering column support (2).
●Put the plastic steering column support (2) on the
steering wheel supports (3).
●Tighten the 2 screws (4).
1
2
4
3
●Put the plastic steering column support (2) between
the steering wheel supports.
●Put the screw (3) tighten the plastic steering column
support (2) with nut (4).
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Step 3
1
2
4
3
●Tighten the steering wheel (straight side up (3)) with
the 3 screws (2) on the steering wheel support (1).
●Tighten the steering wheel support (1) on the
steering column (4).
●Once the steering system is assembled,
please check that the steering wheel is free
to make a quarter of a turn right and left.
Step 1
2
1
3
4
5
●Insert the fuel tank (1) between the steering column
support (2) and the steering column (3).
● Tighten the fuel tank (1) with the y nut (5).
●Use the adapter (4) for mount the 3 liters
fuel tank.
Step 2
1
7
8
10
9
6
● Put the overow bottle (6) between the nassau
panel supports (7).
● Connect the overow bottle hose (9) to the return of
fuel tank (1).
●Connect the petrol tank hose (10) to the plug (8).
●Check the presence of the diver under the
plug.
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MAN.DEL.EN.02
05/2014
2
2
1
1
●Measurements given below correspond
to the standard adjustment of the seat,
recommended by Sodikart for the chassis.
●Get the seat supports (2) closer, or wider, depending
on the seat size.
● Use the shims of the seat xing kit to get a good t.
●The washers of the seat xing kit comply
with CIK/FIA and with your local national
rules.
Ground clearance
1
2
1 bar
A
●A = Outer edge of tube + 2 sprockets.
Seat Position
C
B
DELTA 900
●B = 240 mm ± 5 mm (mid-point of the rounded,
middle of the seat).
●C = 900 mm ± 10 mm.
DELTA 950
●B = 230 mm ± 5 mm (mid-point of the rounded,
middle of the seat).
●C = 855 mm ± 10 mm.
Step 1
2
1
4
4
3
3
●Place the side pod (1) on the side pod support (2).
●Place the screws (3) through the side pod (1) and
the side pod support (2).
●Tighten the assembly with the nuts (4).
●For screws and nuts references, refer to
the spare parts.
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Step 2
1
2
4
3
4
3
●Place the side pod support (2) on the frame (1).
●Tighten with the screws (3) and the nuts (4).
●For screws and nuts references, refer to
the spare parts.
Step 3
1
2
4
3
4
●Place the spoiler (1) between the spoiler upper
support (2) and the spoiler lower support (3)
● Place the staples (4) between the spoiler xations
(2) and (3).
●Tighten the assembly.
●For screws and nuts references, refer to
the spare parts.
Step 4
1
2
3
●Tighten the nasseau panel (1) on its supports (2)
and (3) with screws, nuts, and washers.
●For screws and nuts references, refer to
the spare parts.
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MAN.DEL.EN.02
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Step 1
1
2
3
●Assemble the mounting kit (1) with the element of
the bumper support (2).
●Mount the assembly in the tube chassis (3), tighten
with the screw of the xing kit (1).
●Apply the same procedure for the other side.
Step 2
5
4
46
6
7
●Assemble bumper support (4) on the bumper (5)
using screws and nuts (6).
●Assemble the bumper (5) on the chassis with
screws and nuts (7).
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Before going on the track, the pilot must wear the
following protections:
● Integral helmet: CIK/FIA approved, tting the pilot
head size, with tightened strap and closed visor.
Refer to CIK/FIA regulations (compulsory).
●Suit: CIK / FIA level 1 or level 2 approved.
(compulsory)
●Gloves. (compulsory)
●Neck protection : CIK/FIA approved (compulsory)
● Rib protection: tting pilot’s size and seat
(recommended).
●Rain suit: with water tight fasteners (recommended
when necessary).
●Choose those equipments within the CIK /
FIA approved ones of the ITAKA website.
Driving is forbidden to any pilot:
●Wearing a scarf because of risk with rotating parts.
●With long hair coming out of the helmet.
● With wide oating clothes.
●With health problems, not compatible with high
speed driving.
● Under the inuence of drugs and (or) alcohol.
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MAN.DEL.EN.02
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14
1
2
3
A
The adjustment of the front width is done with several
spacers (one spacer of 17mm (1), 10mm (2), and 5mm
(3) for each stub axle.).
●front width :
A = 984 mm to 1048 mm
●The wider the front is widened, the harder
the steering is hard, and the narrower the
front is narrows, the easier the steering is
easy
A
B
22
1
●Place the kart on a trolley.
●Place the front wheel alignment disk (1)
(available on ITAKA website).
●Unscrew the lock nuts (2) of the 2 tie rods.
: 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.
●Measure A and B with a roll meter. Adjust the tie
rods until you get A=B with a tie rod length on the
right side 1.5mm bigger than the tie rod length on
the left side.
●When A=B the parallelism is perfect.
●Tighten the 2 lock nuts on each tie rod (2).
●Remove the adjustment tool (1). Mount the wheels;
mind the direction of rotation indicated on the side of
the tires.
●he tie rods; otherwise the parallelism will be
lost in a few minutes.
●Any time you work on the front wheels,
check the parallelism. Do the same after
shocks.
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MAN.DEL.EN.02
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A
B
1
B-1
●Standard adjustment: B-1.
A
12
7
6
5
4
3
●Place the kart on a trolley.
●Unscrew the 3 nylstop nuts from the rear wheels
with the proper size wrench, and then remove
wheels.
●Using a rule (1) or any depth gauge, measure
between the hub base (2) and the top of the axle
(3).
●Undo the CHC screw (4) of the rear hub with an
appropriate wrench until the hub can slide along the
axle shaft (6) and cotter pin (5).
●Move the hub (7) to the desired position with the
rule (1) in place against the hub base (2).
●Retighten and block the CHC (4) screw. Repeat the
operation on the other hub.
●Replace both wheels following the rotation direction
indicated on tyre wall. Replace locknuts (nylstop)
and tighten securely.
●A rear tracking width is measured from the
outside of the rims (left and right).
●A wider rear tracking width tends to
increase sliding. Too narrow a rear tracking
width may lead to a bumpy chassis.
1
On most tracks, the correct axle position is high
position (1).
This corresponds to a low position of the chassis
relative to the ground.
●A large ground clearance means more grip.
●A low ground clearance means more
sliding.
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MAN.DEL.EN.02
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16
The position of the centre of gravity has also a key
inuence on the behaviour of the kart.
One can monitor this centre of gravity by changing the
position of the seat.
This position affects the masses distribution between
front and rear axle.
It directly affects the understeering or oversteered
chassis behaviour.
Depending on your weight, your height, your riding
style, the ideal position may change a little.
Compared to the standard position (Cf. chap. 3.4),
moving the seat has the following effects:
1
2
3
4
1) Seat moved forward
●Gives more grip on the front wheels (more sliding of
the rear wheels).
●Allow to correct the front wheel axle unit imprecise,
but delays the time it is possible to accelerate into
the turn, (Rear more slippery).
2) Seat moved backwards
●Less grip on the front wheels.
●More grip on the rear wheels.
3) Seat lower
●Less grip (front and rear wheels).
●To try on very high grip conditions.
4) Seat higher
●Increases the grip.
●To be tried in wet conditions.
●Always use a seat tightener. One on the left
hand side and one on the right hand side
give an optimal performance on almost all
types of tracks.
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MAN.DEL.EN.02
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Do not use any oil-based lubricant, which would cause
swelling of the rubber parts.
SODIKART recommends the use of DOT 4 brake uid
(refer to the ITAKA website for product references) and
recommends that the disc and pads should be cleaned
using brake cleaner only (refer to the ITAKA website for
product references).
Use PFG110 grease to install the seals (visit the ITAKA
site for product catalogue numbers).
Brake uid.....................SUPER BLUE DOT4
Ref : LU842.010
Brake cleaner ...............................WYNN’S
Ref : LU835.001
Grease..........................Grease PFG110
Ref : LU823.004
●The brake system is not compatible with
DOT 5.
●Place the uids in watertight cans and
recycle them according to the regulations
in force.
Checking the brake uid level X
Replacing the brake uid X
Checking the brake pads for wear X
Replacing the brake pads X
Checking for leaks in the hose X
Checking the condition of the brake hose X
Checking the tightness of the kart brake system X
Checking the condition of the brake disc X
Checking the brake disc for wear X
Replacing the brake disc X
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MAN.DEL.EN.02
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18
2
4
1
3
●Straighten the ends of the pin (1) and then remove
it.
●Remove the used brake pads (2).
●Push the four pistons (3) back into the calliper body
(4).
●Place the new pads (2) in position.
●Place the new pin (1) in position, and then twist its
ends.
●Apply the same procedure for the second calliper.
●Do not operate the brake lever or pedal
unless pads are installed. This would
make the pistons difcult to return to their
position, and brake uid leaks might then
occur.
●Always replace the pads of the two front
calipers at the same time.
● The brake uid hoses are a critical safety element. It
is very important to check their state regularly.
●Check the state of the hoses especially at
connecting points and xation points.
●Replace any damaged hose.
●Use a spanner to loosen the screw at each end of
the hose and the mounting points on the kart.
●Install a new hose with new seals and banjo screws.
●Ensure that the mounts securing the hoses to the
kart are properly tightened.
2
3
1
● Use a pipe and a container to collect the used uid.
●Remove the bleeder screw (1) protective cover and
connect the hose to the bleed nipple with the free
end in the receptacle.
● Gently unscrew the bleeder screw (1) and the ller
cap (2).
● Repeatedly press the brake pedal until all the uid
has drained out.
● When all the uid has been drained, remove the
ller cap (2) and top up to the maximum level with
brake uid. Tighten the bleed screw (1), and then
press the brake pedal three or four times.
●Loosen the bleeder screw (1) of the calliper. Brake
uid should ow out. Retighten the bleed screw,
and repeat this step several times to feed the
circuit properly. Remember to add brake uid to the
reservoir (3) as required. Bleed the circuit so that
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MAN.DEL.EN.02
05/2014 19
the brake uid owing out of the hose contains no
air bubbles.
●Retighten the calliper bleed screw (1), remove the
pipe and reapply the protective cap.
● Top up the uid in the reservoir (3) to its maximum
level, and retighten the cap (2).
●We recommend that you drain and rell the
brake circuit after every brake pad change.
This will allow you to maintain optimum
braking performance.
●To bleed your brake system more rapidly,
especially for a big eet, we recommend
the priming system SODIKART (Ref.
OU951.002).
●Store the used brake uid in labelled
containers until it is collected by a specialist
waste disposal company.
●The brake liquid doesn’t contain petrol, so
never pour the liquid into a using oil tank.
●Brake uid absorbs water Make sure the
replacement brake uid comes from a
container that has been stored in good
conditions and is recent.
●Check that the pedal is rm after each
bleed.
Removing
2
3
4
1
●Untwist the ends of the pin (1) and then remove it.
●Remove the brake pads (2).
●Remove the bleed screw (3) and its cap.
●Disconnect the yoke by removing the two mounting
screws (4).
6
5
7
●Remove the two O-rings (5), the two pistons (6), and
the two seals (7) from each half-calliper.
●Clean the half calliper bodies. Do not use WD40 or
other greasy products to clean the callipers.
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MAN.DEL.EN.02
05/2014
Reassembly
6
5
7
8
●Apply PFG110 grease to the O-rings (7).
●Check that the bases of the grooves (8) are clean.
●Place the O-rings (7) in position in the grooves (8).
●Place the pistons (6) in position.
●Apply the same procedure for the second half-
calliper.
●Apply PFG110 grease to the O-rings (5).
●Place the O-rings (5) in position, and then connect
the two half-callipers.
3
4
●Tighten the two screws (4). Torque 12 Nm, applying
a drop of weak thread locking compound to each
screw.
●Tighten the bleed screw and its cap (3).
Torque 8 Nm.
●Reinstall brake pads (refer to the section on
Cleaning/Replacement of front brake pads).
●Always use new seals and clips.
●Replace any defective parts, using only
original SODIKART parts.
●Install a new set of pads after any servicing
of the callipers.
Removing
3
4
1
2
●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.
This manual suits for next models
1
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