Sodi mini 950 Operating instructions

CONFIGURE THE KART ACCORDING TO THE GUIDE INSTRUCTIONS
USE SPARE PARTS OF SODIKART ORIGIN
USER MAINTENANCE GUIDE
MINI 900/950
MAN023.012
JANUARY 2009
This document can not be reproduced or released without the sodikart authorization.

VERSION : JANUARY 2009 1/26 MAN023.012
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SUMMARY
SAFETY INSTRUCTIONS 3
PREPARING THE ASSEMBLY
1- GETTING MINIKART OUT OF THE PACKING 4
2- TOOLS FOR ASSEMBLY 5
3-MAINTENANCEPRODUCTS 5
SEQUENCE OF ASSEMBLY 6
4- ASSEMBLY OF THE STEERING WHEEL 7
5- ASSEMBLY OF THE FUEL TANK AND THE OVERFLOW BOTTLE 8
6- ASSEMBLY OF THE SEAT 9
7-ASSEMBLYOFTHEBODYWORK 11
8-STARTINGYOURMINIKART 13
STANDARD ADJUSTMENTS
9-ADJUSTMENTOFTHEFRONT 14
10-ADJUSTMENTOFTHEREAR 17
11-ADJUSTMENTOFTHESEAT 19
MAINTENANCE
12-TYRES 20
13-HYDRAULICBRAKE 21
14-MECHANICALBRAKE 22
15-CLEANINGTHECHASSIS 24
16-MAINTENANCEPLAN 25
17-TROUBLESHOOTING 26
T
his document can not be reproduced or released without the SODIKART authorization.

VERSION : JANUARY 2009 2/26 MAN023.012
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You have decided to acquire a SODI chassis. We would like to thank you for choosing the SODI
MINIKART.
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
MINIKART 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 MINIKART.
Enjoy driving your MINIKART,

VERSION : JANUARY 2009 3/26 MAN023.012
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SAFETY INSTRUCTIONS
The MINIKART 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 MINIKART 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.

VERSION : JANUARY 2009 4/26 MAN023.012
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1- GETTING MINIKART OUT OF THE PACKING
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 “.
RIGHT SIDE POD
SUPPORT
FUEL TANK
OVERFLOW
BOTTLE
RIGHT SIDE POD
MINIKART 900/950
2
TFRAM
E
RIMS
SEAT
LEFT SIDE POD
LEFT SIDE POD
SUPPORT
STEERING WHEEL
SPOILER NASSEAU PANEL
STEERING COLUMN
ASSEMBLY

VERSION : JANUARY 2009 5/26 MAN023.012
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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
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.

VERSION : JANUARY 2009 6/26 MAN023.012
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SEQUENCE OF ASSEMBLY AND INSTRUCTIONS
STEERING WHEEL (chapter 4).
FUEL TANK AND OVERFLOW BOTTLE (chapter 5).
SEAT (chapter 6).
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 ….

VERSION : JANUARY 2009 7/26 MAN023.012
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4- ASSEMBLY OF STEERING WHEEL.
¾Tighten the steering wheel (1) with the 3 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.
1
2
STRAIGHT PART
FORWARD

VERSION : JANUARY 2009 8/26 MAN023.012
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5- ASSEMBLY OF THE FUEL TANK AND THE OVERFLOW BOTTLE.
¾Insert the fuel tank between the steering column support (1) and the steering column (2)
(see pictures )
¾Tighten with the fly nut (3)
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).
2
1
3
4
5
8
9
7
6

VERSION : JANUARY 2009 9/26 MAN023.012
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6-ASSEMBLY OF THE SEAT
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
MINIKART.
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.
SEAT
1Bar
24mm or 6 rear sprockets
GROUND
4 FIXING
POINTS
1

VERSION : JANUARY 2009 10/26 MAN023.012
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6-2 DISTANCE BETWEEN THE REAR AXLE AND THE MIDDLE OF THE ROUND REAR
EDGE OF THE SEAT.
6-3 DISTANCE BETWEEN THE AXIS OF THE LEFT SIDE STUB AXLE FORK AND THE
MIDDLE OF THE REAR ROUNDED EDGE OF THE SEAT.
Measure from the
middle of the
rounded edge
250mm
865mm

VERSION : JANUARY 2009 11/26 MAN023.012
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7 – ASSEMBLY OF THE BODYWORK
7.1 – ASSEMBLY OF THE SIDE POD ON ITS SUPPORT
¾Position the side pod (1) on its support
(2).
¾Place the screws (3) through the fixing
holes of the side pod support (2), the
side pod (1), and the washers.
¾Tighten the parts together with the
screws (3) and the nuts (4).
For the bolting, refer to the spare parts
catalogue
7.2 – ASSEMBLY OF THE SIDE POD SUPPORT ON THE FRAME
¾Place the side pod support (1) on the
frame (2).
¾Place the screw (3) through the fixing
hole of the side pod support (1).
¾Tighten the parts together with the screw
(3) and the nut (4).
For the bolting, refer to the spare parts
catalogue
7.3 – ASSEMBLY OF THE FRONT BUMPER
¾Position the front bumper (1) on the outer
face of the lug (2).
¾Place the plastic washers (3) between
the front bumper (1) and the lug (2).
¾Tighten the front bumper (1) with the
screws (4) and the nuts (5).
For the bolting, refer to the spare parts
catalogue
4
3
2 1
3
4
3
2
1
1
4
3
1
5
2

VERSION : JANUARY 2009 12/26 MAN023.012
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7.4 – ASSEMBLY OF THE LOWER FLAP ON THE SPOILER
¾Place the two screws (1) through the
lower flap (2) and the spoiler (3).
¾Tighten the parts together with the
screws (1) and the nuts (4).
For the bolting, refer to the spare parts
catalogue
7.5 – ASSEMBLY OF THE SPOILER ON THE FRAME
¾Mount the spoiler fixing kit (1) on the front
bumper (2) and the frame (3) with the
bolting (4).
¾Tighten the spoiler fixing kit (1).
¾Place the spoiler (5) between the front
bumper (2) and the frame (3).
¾Pull down the front bumper (2) on the
spoiler (5)
¾Put the bridle (6) on the front bumper (2)
and the frame (3), then lock.
For the bolting, refer to the spare parts
catalogue
7.6 – ASSEMBLY OF THE NASSEAU PANEL
¾Position the nasseau panel (1) on the
lower flap (2) and the upper flaps (3).
¾Draw the 3 drill points on the nasseau
panel (1).
¾Drill with the Ø6.5mm drill.
¾Place the nassau panel on its fixations.
Then tighten the parts together with 3
screws and 3 nuts.
For the bolting, refer to the spare parts
catalogue
5
1
2
6
3
4
4
2
3
2
1
3
1
2
4

VERSION : JANUARY 2009 13/26 MAN023.012
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8- STARTING YOUR MINIKART
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

VERSION : JANUARY 2009 14/26 MAN023.012
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9- ADJUSTMENT OF THE FRONT
9.1 ADJUSTMENT OF THE FRONT WIDTH
The adjustment of the front width (X) is done with several spacers (one spacer of 17mm, 10mm,
and 5mm for each stub axle.).
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.
17mm
10mm
5mm
984mm < X < 1048mm

VERSION : JANUARY 2009 15/26 MAN023.012
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9.2 ADJUSTMENT OF PARALLELISM
1. Lay the kart on a trolley.
2. Place the adjustment tool (1) (refer to the ITAKA
catalogue).
3. Loosen the lock nuts on each tie rod (2).
¾Attention: on the stub axle side, lock nuts are
right hand; on the steering column side, lock nuts
are left hand.
4. Position the steering wheel in the axis of the kart.
5. Measure A and B with a tape. 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.
6. When A=B the parallelism is perfect.
Tighten the 2 lock nuts on each tie rod (2).
7. Remove the adjustment tool (1). Mount the wheels;
mind the direction of rotation indicated on the side of
the tires.
NOTE:
-Do not forget to tighten the 2 lock nuts on the 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.
9Never drive with badly tightened wheels: it may lead to severe, even fatal injuries.
9Make sure that each ball joint penetrates at least 5 threads in the tie rods.
A
B
2
PERFECT
ADJUSTMENT
A=B
1

VERSION : JANUARY 2009 16/26 MAN023.012
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9.3- ADJUSTMENT OF TIE RODS.

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10- ADJUSTMENT OF THE REAR
10-1 ADJUSTMENT OF HUBS
1. Lay the kart on a trolley.
2. Loosen the three bolts of each tyre. Then
remove the two wheels.
3. Measure the distance A, from the basis of
the hub (3) to the axle edge (2).
4. Loosen the CHC (4) screws to allow the sliding
of the hub on the axle and cotter pin (5).
5. Slide the hub up to the position you wish.
6. Tighten and block the CHC (4) screws.
7. Mount the wheels; mind the direction of
rotation indicated on the side of the tires.
Tighten the bolts and block.
NOTE:
- 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.
9Badly tightened wheels may lead to severe, even fatal injuries.
9Check the cotter pin is correctly positioned.
9Never position the hubs beyond the maximum allowed width: it may lead to severe or
even fatal injuries.
HUB
4
AXLE
1
2
3
5
A
HUB

VERSION : JANUARY 2009 18/26 MAN023.012
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10-2 POSITION OF REAR AXLE
¾A large ground clearance means more grip.
¾A low ground clearance means more sliding.
In most conditions, the correct axle position is the low ground clearance one.
This corresponds to a high position of the axle, relative to the frame.

VERSION : JANUARY 2009 19/26 MAN023.012
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11- ADJUSTMENT OF SEAT
POSITION OF THE SEAT
The position of the center of gravity has also a key influence on the behavior of the kart.
One can monitor this center of gravity by changing the position of the seat.
You will find the best position of the seat, adapted to your size and weight, by trial-and error.
We recommend you to bear in mind the following:
SEAT MOVED FORWARD:
Gives more grip on the front wheels; more sliding of the rear wheels.
SEAT MOVED BACKWARDS:
Less grip on the front wheels; more grip on the rear wheels.
SEAT LOWER:
Less grip (front and rear wheels); to try on very high grip conditions.
SEAT HIGHER:
Increases the grip; to be tried in wet conditions.