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

- 1 -
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

- 2 -
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,

- 3 -
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.

- 4 -
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

- 5 -
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.

- 6 -
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 ….

- 7 -
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

- 8 -
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

- 9 -
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