Sodi SR4 Operating instructions

USER MAINTENANCE GUIDE
MANUEL D’UTILISATION
ET D’ENTRETIEN
SODIKART - Parc d’Activités des Hauts de Couëron
44220 COUËRON - FRANCE
Tél. [phone] - Fax. [phone]
E-mail : [email protected] - www.sodikart.com
SR4

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SR4 MANUAL
SUMMARY SR4
SAFETY INSTRUCTIONS 3
PREPARING THE ASSEMBLY
1- GETTING SR4 OUT OF THE PACKING 4
2- TOOLS FOR ASSEMBLY 5
3- MAINTENANCE PRODUCTS 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- ASSEMBLY OF THE KG UNICO BODY WORK 13-15
8- ASSEMBLY OF THE SODI BODY WORK 16-19
9- STARTING YOUR SR4 20
STANDARD ADJUSTMENTS
10- TABLE OF THE STANDARD ADJUSTMENTS 21
11- ADJUSTMENT OF THE FRONT END 22-27
12- ADJUSTMENT OF THE REAR END 28-30
13- ADJUSTMENT OF THE SEAT 31
MAINTENANCE
14- TYRES 32-33
15- BRAKE PADS REPLACEMENT 34
16- BLEEDING OF THE BRAKE SYSTEM 35
17- CLEANING THE CHASSIS 36
18- MAINTENANCE PLAN 37
19- TROUBLE SHOOTING 38

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SR4 MANUAL
You have decided to acquire a SODI chassis!. We would like to thank you for choosing the SODI
SR4.
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 SR4 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 SR4.
Enjoy driving your SR4,

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SR4 MANUAL
SAFETY INSTRUCTIONS.
The SR4 has been designed for leisure and high level competition.
Its design , wich 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 aspecial attention to the instructions or comments wich follow the symbol
below :
NOTE!: Gives a useful information.
ATTENTION!: indicates a high risk of severe injury if the instructions are not followed.
Should you not find an answer to your questions in this manual or face any problem, please
get advice from the SODIKART distribution network.
ATTENTION
The SODI SR4 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.
The SODI chassis can only be used on an approved track.
Prior to going on the track, please check all points related to safety.
In order to avoid fire, put the kart at least one meter away from the buildings.
Never leave inflammable objects close to the kart.
If fuel has been poured, wipe and wait for vapours to dissipate, before starting the
kart.
Kids and domestic animals have to be kept away from the kart and the track.
Never drive the kart without adequate pilot equipment.

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SR4 MANUAL
1- GETTING SR4 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 “.
FRAME SR4
KG UNICO
SIDE POD
LEFT SIDE POD
SUPPORT
RIGHT SIDE POD
SUPPORT
UPPER NASSAU
PANNEL
LOWER NASSAU
PANNEL
SPOILER
FIXING KIT
FUEL TANK
OVERFLOW
BOTTLE
STEERING
WHEEL
SEAT
UPPER SPOILER
SUPPORT
LOWER SPOILER
SUPPORT
STUB AXLE SPACER
AJUSTER
STUB AXLE SCREW
ADJUSTER
SLOTTED NUT KEY
STEERING COLUMN
ASSY
EXHAUST PIPE
SUPPORT
MAX / FA

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SR4 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 ( supplied ) OU 931.007
- Stub axle screw adjuster ( supplied ) OU 931.006
3- MAINTENANCE PRODUCTS
-Cleaner!: (paint - plastics)!:LU 832.007
-WD 40 LU 833.003
-Grease for chain LU 822.002
NOTE!:
FOR OTHER TOOLS , ACCESSORIES AND EQUIPMENTS, PLEASE REFER TO THE
ITAKA CATALOGUE.

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SR4 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 :
diam. 6 = 10 to 12 m.N
diam. 8 = 12 to 24 m.N
diam. 10 = 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 ….

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SR4 MANUAL
4.1 ASSEMBLY OF THE STEERING COLUMN
SUPPORT (PIC 2)
Place the steering column support on the two pins
canons (1) and (2).
Put the Chc M6x30 (3) screws + nylstop M6
bolts as indicated in picture 2 .
Tighten .
4- ASSEMBLY OF THE STEERING COLUMN AND STEERING WHEEL.
THE SET CONSISTS IN!:!
one plastic steering column support (1).
One steering wheel support (2).
Two nassau panel supports (3).
One steering column (4).
One steering column support (5).
Two steering tie rods + ball joints (6).
Raise the set as in picture 1 .
4-
6
4
2
5
3
Photo 1
2
1
3
4
5
7
6
Outer
hole
4
4.2 ASSEMBLY OF THE STEERING COLUMN
(PIC 3)
Insert the threaded end of the steering
column in the ball joint (4).
Place the bolt (5).
Tighten.
4.3 ASSEMBLY OF THE TIE-RODS (PIC 4)
after cutting the tie-wrap maintaining the stub axles :
Place the ball joints (6) under the stub axle arm
(7).
Insert the Bhc M8x30 screw in the outer hole of
the stub axle arm .
Place the washer on top of the ball joint and
insert the screw.
Place the M8 bolt and tighten.
PIC 2
Photo3
PIC 4
7
PIC 3
1
PIC 1

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SR4 MANUAL
4.4 TIGHTENING THE PLASTIC STEERING COLUMN SUPPORT.
Tighten the Chc M8x65 screw (8).
4.5 ASSEMBLY OF THE STEERING WHEEL .
Tighten the steering wheel (1) with the 3 FHc M6x30 screws, on the steering wheel support
(2).
Tighten 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.
STRAIGHT PART
FORWARD
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.
8
1
2
ATTENTION

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SR4 MANUAL
5- ASSEMBLY OF THE FUEL TANK AND OF THE OVERFLOW BOTTLE.
Insert the fuel tank between the steering column support (1) and the steering column (2)
(see pictures )
Tighten with the fly nut (3)
Insert the overflow bottle (4) between the nassau pannel supports (5).
Connect the overflow bottle hose (6) to the return (7).
Connect 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

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SR4 MANUAL
6-ASSEMBLY OF THE SEAT AND SEAT STIFFENERS.
The washers of the seat fixing kit comply with CIK/FIA and FFSA rules .
6-1 GROUND CLEARANCE
1
4 FIXING POINTS
20 mm
Measurements given below correspond to
the standard adjustment of the seat,
recommended by SODIKART, for the SR4.
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.
1bar
KG
SEAT
GROUND

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SR4 MANUAL
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.
220 mm

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SR4 MANUAL
6-5 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.
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.
9- Tighten both upper and lower end.
For screws and bolts references, refer to the spare
parts catalogue .
1
2
3
4
5
FOR OTHER TYPES OF STIFFENERS!, PLEASE REFER TO THE SR4 SPARE
PARTS CATALOGUE OR TO THE ITAKA CATALOGUE
PIC 2
PIC 1

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SR4 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 SUPPORT
SPOILER UPPER SUPPORT
End to cut
End to cut
NOT COMPLYING WITH THE CIK/FIA RULES MAY LEAD TO DISQUALIFICATION DURING
A COMPETITION .
NOTE!:
DRILL 6.5 MM DIAM HOLE,
HORIZONTAL
DRILL 6.5MM DIAM HOLE,
VERTICAL

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SR4 MANUAL
Photo 1
10 mm
7-2 ASSEMBLY OF THE SIDE POD ON IT’S SUPPORT
(PIC 1)
Place the side pod on its support.
Adjust the distance of 10 mm (1) as shown in the
picture.
Mark the first point to be drilled.
Drill a hole , diameter 6.5 mm.
Place screw , washers and bolt!; tighten.
Drill 6.5 mm holes at the 5 other fixing points.
Place screw , washers and bolt!; tighten.
Repeat the operations for the other support.
7-3 ASSEMBLY ON THE CHASSIS (PIC 2)
Insert the flexible plastic sleeves in the frame.
Insert the ends of the support in the sleeves.
Tighten with screws and bolts through holes (2).
1
7-4 ASSEMBLY OF THE LOWER SPOILER SUPPORT (PIC 3)
Insert the support (3) in the frame (4).
Insert the two Chc screws in the holes (5).
Place the bolts and tighten.
PIC 3
PIC 2
PIC 1
3
4
2
5
7-5 ASSEMBLY OF THE UPPER SPOILER SUPPORT (PIC 4).
Place the ends of the support (6) as on the picture ( inside
the frame (7).
Insert the Fhc screws and washers (7).
Place the bolts and tighten.
PIC 4
7
6

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SR4 MANUAL
ASSEMBLY OF THE KG UNICO BODYWORK
7-6 ASSEMBLY OF THE SPOILER (PIC 5)
Place the fixing kit between the upper and lower
spoiler support.
Insert the spoiler between the two supports, and
tighten.
7-7 ASSEMBLY OF THE LOWER NASSAU PANNEL (PIC 6)
Assemble the upper and lower nassau panel with the
supplied bolts and screws.
Position the nassau panel on the connection part (8)
Insert the screws
Place the bolts and tighten.
7-8 ASSEMBLY OF THE UPPER NASSAU PANEL (PIC 7)
Tilt the upper nassau panel supports (9) to the adequate
position.
Mark the points to be drilled (10).
Drill to diameter 6.5.
Insert the screws.
Place the bolts and tighten.
For details and references of screws , bolts and washers, please refer to
the SR4 spare parts catalogue .
NOTE!:
PIC 5
PIC 6
PIC 7
Fixation Kit
KI
8
9
10

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SR4 MANUAL
8- ASSEMBLY OF THE SODI BODY WORK
8.1 ASSEMBLY OF THE SODI SIDE PODS
Take the left side pod and the left lateral shock absorber.
Place the shock absorber on the side pod support. ATTENTION!: the rounded edges must
face the upper part of the support . Assemble the absorber with 4 BHC M6x16 panhead
screws and d6 D18 th 1.2 zinc flat washers under the screw heads . ( detail in SR4 spare
parts catalogue ).
Assemble the set “ side pod support + absorber”on the frame. Mount the tyres , pressure 1.2
bars. Lay the side pod on its support. Adjust with 2 X 40mm wedges in the front, and 1
43mm wedge at the rear.
Side pod
support , left
Position
of the
rounded
edge
M6 Bolts
Boltsnylstop
40mm Wedge
43mm Wedge
Position of
the rounded
edge
2 connection points
inside the side pod
support.
Bhc M6x16 screw + washer d6 D18

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SR4 MANUAL
Drill two 6.5 mm diameter holes in the absorber , through the holes in the side pod. Remove
the set “ side pod + side pod support!“ from the frame. Assemble the side pod on the
absorber ; screws and conical washers facing outside , bolts and d6 D18 th 1.2 washers
facing inside.
Adjust the rear side of the side pod on the support!; check the distance of 5 to 6 mm as
shown. Assemble with a BHC M6x16 screw and bolt.
Adjust the front end of the side pod on the support. Check the distance of 5 to 6 mm as
shown. Assemble with a BHC screw and bolt .
2 holes in the absorber through
the holes of the side pod
2 conical washers + FHC 6x25 screws
and bolts + washers d6 D18 inside the
absorber
5 – 6 mm
mmmm
BHC M6x16
screw
5 – 6 mm
BHC M6x16

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SR4 MANUAL
8.2 ASSEMBLY OF THE SPOILER AND THE NASSAU PANEL
Place the two shock absorbers on the lower spoiler support. Assemble the two absorbers
with BHC M6x16 panhead screw + d6 D18 th 1.2 washer under the screw head.
Place the spoiler on the set!«!lower spoiler support + absorber!»!and assemble with 2 BHC
M6x16 screws.
Insert the support in the frame. Put the wheels on . Set the pressure at 1.2 bars . Adjust
the 43 mm ground clearance with a wedge in the middle.
Drill 5 mm diameter holes in the absorbers , through the holes in the spoiler. Assemble the
spoiler with 4 d5 blind rivets.
dow
nun
dol
up
dow
n
up
BHC M6x16 screw + d6 washer
washerwasherRondelle d6 D18
BHC M6x16 screw + d6 washer
plus Rondelle d6 D18
BHC
M6x16
screws
Metal piece inside the
spoiler
43mm
wedge
ee
Holes to drill
through
absorbeurs

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SR4 MANUAL
Lift the kart and tighten the spoiler on the support with BHC M6x16 screw.
Assemble the lower nassau support to the frame as shown , with a BHC M6x16 screw. Link
the spoiler and the nassau together on the upper end of the lower nassau support with a BHC
M6x16 screw.
M6
nylstop
bolt
BHC M6x16
BHC M6x16
BHC M6x16