Sodi Sigma DD2 Operating instructions

USER MAINTENANCE GUIDE
D
D

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DD2 MANUAL
SUMMARY DD2
SAFETY INSTRUCTIONS 3
PREPARING THE ASSEMBLY
1- GETTING DD2 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
5- ASSEMBLY OF THE FUEL TANK AND OF THE OVERFLOW BOTTLE 9
6- ASSEMBLY OF THE SEAT 10
7- ASSEMBLY OF THE KG UNICO BODY WORK 12
8-STARTINGYOURDD2 15
STANDARD ADJUSTMENTS
9-TABLEOFTHESTANDARDADJUSTMENTS 16
10-ADJUSTMENTOFTHEFRONTEND 17
11-ADJUSTMENTOFTHEREAREND 23
12-ADJUSTMENTOFTHESEAT 25
MAINTENANCE
13-TYRES 27
14-BRAKEPADSREPLACEMENT 28
15- BLEEDING OF THE BRAKE SYSTEM 29
16-CLEANINGTHECHASSIS 30
17-MAINTENANCEPLAN 31
18-TROUBLESHOOTING 32
T
his document can not be reproduced or released without the SODIKART authorization.
EDITION : JULY 2006 MAN036.002

DD2 MANUAL
You have decided to acquire a SODI chassis. We would like to thank you for choosing the SODI
DD2.
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 DD2
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 DD2.
Enjoy driving your DD2,
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EDITION : JULY 2006 MAN036.002

DD2 MANUAL
SAFETY INSTRUCTIONS
The DD2 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 DD2 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.
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DD2 MANUAL
1- GETTING DD2 OUT OF THE PACKING
RIGHT SIDE POD
SUPPORT
FUEL TANK
UPPER NASSAU
PANNEL
LOWER NASSAU
PANNEL
OVERFLOW
BOTTLE
EXHAUST PIPE
SUPPORT
SPOILER UPPER SPOILER
SUPPORT
FIXING KIT
LOWER SPOILER
SUPPORT
FRAME DD2
SEAT
KG UNICO SIDE
POD
LEFT SIDE POD
SUPPORT
STEERING COLUMN
ASSY
STEERING WHEEL
SLOTTED NUT KEY
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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DD2 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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DD2 MANUAL
SEQUENCE OF ASSEMBLY AND INSTRUCTIONS
STEERING COLUMN AND STEERING WHEEL (chapter 4).
FUEL TANK AND OVERFLOW BOTTLE (chapter 5).
SEAT (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 ….

DD2 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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DD2 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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DD2 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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DD2 MANUAL
6- ASSEMBLY OF THE SEAT.
FIXING
POINTS Measurements given below correspond
to the standard adjustment of the
seat, recommended by SODIKART, for
the DD2.
Get the seat supports (1) closer, or
wider, depending on the seat size.
¾The washers of the seat fixing kit comply with CIK/FIA and with your local national
rules.
6-1 GROUND CLEARANCE
Use the shims of the seat fixing kit to
get a good fit.
1
SEAT
1Bar
20mm
GROUND
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DD2 MANUAL
6-2 DISTANCE BETWEEN THE REAR AXLE AND THE MIDDLE OF THE ROUND REAR
EDGE OF THE SEAT.
210mm
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.
1015mm
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DD2 MANUAL
7-ASSEMBLY OF THE KG UNICO BODY WORK.
7-1 PREPARING THE KG UNICO SUPPORTS.
In order to comply with the CIK/FIA rules, carefully prepare the supports as indicated below.
(Measurements in mm)
SPOILER LOWER SUPPOR
T
SIDE POD SUPPOR
T
DRILL 6.5MM DIAM HOLE,
VERTICAL
DRILL 6.5 MM DIAM HOLE,
HORIZONTAL
End to cut
End to cut
NOTE:
-NOT COMPLYING WITH THE CIK/FIA RULES MAY LEAD TO
DISQUALIFICATION DURING A COMPETITION.
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DD2 MANUAL
1
PIC 1
10 mm
7-2 ASSEMBLY OF THE SIDE POD ON its
SUPPORT (PIC 1)
¾Place the side pod on its support.
¾Adjust the distance of 10 mm (1) as shown in the
picture.
¾Mark the first point to be drilled.
¾Drill a hole, diameter 6.5 mm.
¾Place screw, washers and bolt; tighten.
¾Drill 6.5 mm holes at the 5 other fixing points.
¾Place screw, washers and bolt; tighten.
¾Repeat the operations for the other support.
7-3 ASSEMBLY ON THE CHASSIS (PIC 2)
PIC 2
2
¾Insert the flexible plastic sleeves in the frame.
¾Insert the ends of the support in the sleeves.
¾Tighten with screws and bolts through holes (2).
7-4 ASSEMBLY OF THE LOWER SPOILER
SUPPORT (PIC 3)
¾Insert the support (3) in the frame (4).
¾Insert the two CHC screws in the holes (5).
¾Place the bolts and tighten.
PIC 3
3
4
5
7-5 ASSEMBLY OF THE UPPER SPOILER SUPPORT
(PIC 4).
¾Place the ends of the support (6) as on the picture
(inside the frame (7).
¾Insert the FHC screws and washers (7).
¾Place the bolts and tighten.
PIC 4
6
7
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DD2 MANUAL
ASSEMBLY OF THE KG UNICO BODYWORK
7-6 ASSEMBLY OF THE SPOILER (PIC 5)
¾Place the fixing kit between the upper and lower
spoiler support.
¾Insert the spoiler between the two supports, and
tighten.
7-7 ASSEMBLY OF THE LOWER NASSAU PANNEL
(PIC 6)
¾Assemble the upper and lower nassau panel with
the supplied bolts and screws.
¾Position the nassau panel on the connection part (8)
¾Insert the screws
¾Place the bolts and tighten.
7-8 ASSEMBLY OF THE UPPER NASSAU PANEL
(PIC 7)
¾Tilt the upper nassau panel supports (9) to the
adequate position.
¾Mark the points to be drilled (10).
¾Drill to diameter 6.5.
¾Insert the screws.
¾Place the bolts and tighten.
PIC 5
Kit fixation
PIC 6
8
PIC 7
9
10
NOTE: -For details and references of screws, bolts and washers, please refer to the
DD2 spare parts catalogue.
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DD2 MANUAL
8- STARTING YOUR DD2
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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DD2 MANUAL
9-STANDARD ADJUSTMENTS OF THE DD2
DRY WET
STUB AXLE HEIGHT
FRONT TRACKING WIDTH
REAR TRACKING WIDTH
POSITION OF MASSES
POSITION OF EXCENTRICS
POSITION OF STEERING
TIE RODS ENDS
DOUBLE LATERAL CRADDLE /
REAR TORSION BAR
REMOVE the double lateral
craddle.
REMOVE the torsion bar.
PLACE the double lateral
craddle.
PLACE the torsion bar
horizontally.
4mm 4mm+4mm
4mm +2mm 2mm
3 rings inside
Short hub 60mm All rings inside
Long hub 80mm
1360 to 1370mm
1400mm
2
1
FOR TYRE PRESSURES, REFER TO TABLE PAGE 2
7
A-2
OR
B
-
3
B-3
3
3
FWD
TOP
rd
Mark - Forward
BOTTOM
Mark – Inwa
Eccentrics 4°
TOP
BOTTOM
Eccentrics 1°
FWD
Mark - Backward
Mark - Forward
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DD2 MANUAL
10- ADJUSTMENT OF FRONT WHEELS
10.1 ADJUSTMENT OF FRONT TRACKING WIDTH
DRY TRACK
¾On dry track, place 3 rings inside with SHORT HUBS L60mm.
WET TRACK
¾On wet track, place all the rings inside with LONG HUBS L80mm.
¾For more grip forward, add one or
two 5 mm rings on the chassis side.
Steering becomes harder.
¾For less grip forward, add one or
two 5 mm rings outside.
Steering becomes lighter.
3x5mm
1X15m
1
X
15m 3x5mm
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DD2 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
2mm
(2) WET TRACK
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DD2 MANUAL
10.3-ADJUSTMENT OF THE CAMBER AND OF THE CASTER
DESCRIPTION OF THE ECCENTRIC.
ADJUSTMENT OF THE CASTER
STANDARD ADJUSTMENT (fig 1)
¾1° eccentrics place in high caster position (fig 1).
INCREASE THE CASTER (fig 1)
¾2° eccentric in high caster (fig 1) position.
In extreme conditions, use 3°, 4° or more eccentrics.
REDUCE THE CASTER (fig 2)
¾2°ou 3° eccentric (even more in extreme conditions) in low caster position.
diam. 4 mm pin on the fork
Marked slot
1 for 1°
Eccentric
HIGH CASTER LOW CASTER
Eccentrics on top:
The mark is positioned on the opposite side of
the Ø4 mm pin.
(Towards the rear of the chassis) .
Eccentrics on top:
The mark is positioned in front of the Ø4 mm
pin.
(Towards the front of the chassis)
TOP
BOTTOM
FIG 1 FRON
T
REAR
LEF
FRON
T
TOP
BOTTOM
FIG 2
REAR
LEF
T
RIGH
T
T
RIGH
T
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