Sodi ST32 BV Operating instructions

CONFIGURE THE KART ACCORDING TO THE GUIDE INSTRUCTIONS
USE SPARE PARTS OF SODIKART ORIGIN
USER MAINTENANCE GUIDE
ST32 BV
MAN038.011
JANUARY 2010
This document can not be reproduced or released without the sodikart authorization.

USER GUIDE ST32BV
SUMMARY ST32BV
SAFETY INSTRUCTIONS 3
PREPARING THE ASSEMBLY
1- GETTING ST32BV 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 7-8
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-ASSEMBLYOFTHEKGBODYWORK 13-14
8-STARTINGYOURST32BV 15
STANDARD ADJUSTMENTS
9-TABLEOFTHESTANDARDADJUSTMENTS 16
10- ADJUSTMENT OF THE FRONT END 17-22
11-ADJUSTMENTOFTHEREAREND 23-25
12-ADJUSTMENTOFTHESEAT 26
13- ADJUSTMENT OF THE BRAKE DISTRIBUTOR 27
MAINTENANCE
14-TYRES 28-29
15-BRAKEPADSREPLACEMENT 30
16- BLEEDING OF THE BRAKE SYSTEM 31-32
17-CLEANINGTHECHASSIS 33
18-MAINTENANCEPLAN 34
19-TROUBLESHOOTING 35
T
his document can not be reproduced or released without the SODIKART authorization.
- 1 –
EDITION : JANUARY 2010 MAN038.011

USER GUIDE ST32BV
You have decided to acquire a SODI chassis. We would like to thank you for choosing the SODI
ST32BV.
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
ST32BV 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 ST32BV.
Enjoy driving your ST32BV,
- 2 –
EDITION : JANUARY 2010 MAN038.011

USER GUIDE ST32BV
SAFETY INSTRUCTIONS
The ST32BV 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.
Should you not find an answer to your questions in this manual or face any problem, please
get advice from the SODIKART distribution network.
The SODI ST32BV 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 and by a driver who is in
possession of a valid membership card of the go-kart’s federation of his own country.
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 vapors 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.
- 3 –
EDITION : JANUARY 2010 MAN038.011

USER GUIDE ST32BV
1- GETTING ST32BV OUT OF THE PACKING
RIGHT SIDE POD
SUPPORT
RIGHT SIDE POD
SPOILER
ST32BV FRAME
FUEL TANK
SEAT
LEFT SIDE POD
NASSEAU PANEL
LEFT SIDE POD
SUPPORT
STEERING COLUMN
ASSEMBLY
STEERING WHEEL
OVERFLOW
BOTTLE
GEAR LEVER
ASSEMBLY
RIMS
REAR BUMPER
STUB AXLE SCREW
A
DJUSTER
STUB AXLE
SPACER ADJUSTER SLOTTED WRENCH
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“.
- 4 –
EDITION : JANUARY 2010 MAN038.011

USER GUIDE ST32BV
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.
- 5 –
EDITION : JANUARY 2010 MAN038.011

USER GUIDE ST32BV
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 SODI BODYWORK (chapter 7).
NOTE:
RECOMMENDED TIGHTENING TORQUES:
Do not overtighten screws and bolts
Ø6 = 10 to 12 m.N
Ø8 = 12 to 24 m.N
Ø10 = 24 to 48 m.N
Screws without bolts are to be blocked with 1 drop of special glue (LU 861.001)
Lubricate rotating parts, ball joints, gas cable ….
- 6 –
EDITION : JANUARY 2010 MAN038.011

USER GUIDE ST32BV
4- ASSEMBLY OF THE STEERING COLUMN AND STEERING WHEEL.
- 7 –
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).
3 2
4 1
5
Pict. 1
6 Two steering tie rods + ball joints (6).
Raise the set as in picture 1.
Pict.2
3
1
2
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 screws (3) + nylstop bolts as indicated in
picture 2.
Tighten.
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.
Pict 3
5
4.3 ASSEMBLY OF THE TIE-RODS (PIC 4)
Pict. 4
Inner holes
7
6
After cutting the tie-wrap maintaining the stub axles:
Place the ball joints (6) above the stub axle arm
(7).
Insert the 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 bolt and tighten.
EDITION : JANUARY 2010 MAN038.011

USER GUIDE ST32BV
4.4 TIGHTENING THE PLASTIC STEERING COLUMN SUPPORT.
- 8 –
After completing the above steps :
Tighten the screw (8).
8
4.5 ASSEMBLY OF THE STEERING WHEEL.
Tighten the steering wheel (1) with the 3 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.
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.
STRAIGHT PART
FORWARD
2
1
EDITION : JANUARY 2010 MAN038.011

USER GUIDE ST32BV
5- ASSEMBLY OF THE FUEL TANK AND OF THE OVERFLOW BOTTLE.
3
1
2
Insert the fuel tank between the steering column support (1) and the steering column (2)
(see pictures )
Tighten with the fly nut (3)
4
10 8
7
9
6
5
Put the overflow bottle (4) on the nassau panel support (5) with the overflow bottle stand
(6).
Connect the overflow bottle hose (7) to the return (8).
Connect the petrol tank hose (9) to the red plug (10).
NOTE:
-CHECK THE PRESENCE OF THE DIVER UNDER THE RED PLUG.
- 9 –
EDITION : JANUARY 2010 MAN038.011

USER GUIDE ST32BV
6-ASSEMBLY OF THE SEAT AND SEAT STIFFENERS.
- 10 –
1
4 fixin
g
points
The washers of the seat fixing kit comply with CIK/FIA and with your local national
rules.
Measurements given below correspond
to the standard adjustment of the
seat, recommended by SODIKART,
for the ST32BV.
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.
6-1 GROUND CLEARANCE
GROUND
SEAT
24mm ou 6 rear s
p
rockets
1Bar
EDITION : JANUARY 2010 MAN038.011

USER GUIDE ST32BV
6-2 DISTANCE BETWEEN THE REAR AXLE AND THE MIDDLE OF THE ROUND REAR
EDGE OF THE SEAT.
Measure from the
middle of the
rounded edge
200 mm
(7.87inch)
6-3 DISTANCE BETWEEN THE AXIS OF THE LEFT SIDE STUB AXLE FORK AND THE
MIDDLE OF THE REAR ROUNDED EDGE OF THE SEAT.
1040mm
- 11 –
EDITION : JANUARY 2010 MAN038.011

USER GUIDE ST32BV
6-4 ASSEMBLY OF THE SEAT STIFFENERS.
- 12 –
ASSEMBLY OF THE LOWER END (PIC 1)
1- Put the seat stiffener lower end (1) in place.
2- Put the bolt (2) in place and pre-tighten.
For screws and bolts references, refer to the
ST32BV spare parts catalogue
Pict. 1
2
1
ASSEMBLY OF THE UPPER END (PIC 2)
5. Place the upper end of the stiffener.
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 in the seat.
8. Place one screw + conical washer.
9. Tighten both upper and lower end.
For screws and bolts references, refer to the ST30
/ ST32 spare parts catalogue
FOR OTHER TYPES OF STIFFENERS, PLEASE REFER TO THE ST32BV
SPARE PARTS CATALOGUE OR TO THE ITAKA CATALOGUE
EDITION : JANUARY 2010 MAN038.011

USER GUIDE ST32BV
7- ASSEMBLY OF THE KG BODYWORK.
3
4
2
1
7-1 ASSEMBLY OF THE SIDE POD ON ITS
SUPPORTS
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).
Refer to the ST32BV spare parts catalogue for the
bolting.
7-2 ASSEMBLY ON THE FRAME
2
1
Check that the bushings are pushed in the frame.
Insert the side pod assembly into the bushings.
Tighten with the screws (1) and the nuts (2).
Refer to the ST32BV spare parts catalogue for the
bolting
7-3 ASSEMBLY OF THE SPOILER LOWER
SUPPORT ON THE FRAME
- 13 –
Insert the spoiler lower support (1) into the front
cross member of the frame (2).
1
3
4
2
Tighten with the screws (3) and the nuts (4).
Refer to the ST32BV spare parts catalogue for the
bolting
7-4 ASSEMBLY OF THE SPOILER UPPER
SUPPORT ON THE FRAME 2
4
Place the spoiler upper support (1) on the outer
face of the lug (2).
Tighten with the screws (3) and the nuts (4).
Refer to the ST32BV spare parts catalogue for the
bolting 13
EDITION : JANUARY 2010 MAN038.011

USER GUIDE ST32BV
7-5 ASSEMBLY OF THE SPOILER
2
Assemble the spoiler fixation kit (1) between the
spoiler upper support (2) and the spoiler lower
support (3) with two screws and two nuts.
- 14 –
4
3
3
2
1
Place the flanges (4) between the spoiler support
(2) and (3), then lock.
Refer to the ST32BV spare parts catalogue for the
bolting
7-6 ASSEMBLY OF THE NASSEAU PANEL 1
Tighten the nasseau panel (1) on its supports (2)
and (3) with screws, nuts, and washers.
3
Refer to the ST32BV spare parts catalogue for the
bolting
2
EDITION : JANUARY 2010 MAN038.011

USER GUIDE ST32BV
8- STARTING YOUR ST32BV
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:
Wearing a scarf because of risk with rotating parts.
With long hair coming out of the helmet.
With wide floating clothes.
With health problems, not compatible with high speed driving.
Under the influence of drugs and (or) alcohol.
For your safety and the safety of other pilots, strictly follow the above instructions:
not doing so may lead to severe, even fatal injuries.
Be aware that some medicines reduce your ability to drive
- 15 –
EDITION : JANUARY 2010 MAN038.011

USER GUIDE ST32BV
9- STANDARD ADJUSTMENTS OF THE ST32BV
DRY WET
STUB AXLE HEIGHT
FRONT TRACKING WIDTH
REAR TRACKING WIDTH
REAR AXLE POSITION
POSITION OF MASSES
4mm +2mm
4mm
2mm
4mm+4mm
2 rings inside (10mm) 2 rings inside (20mm)
1400 1360 à 1370
TOP TOP
1
1
2
POSITION OF EXCENTRICS
Eccentrics 4°
TOP
BOTTOM
FWD
TOP
BOTTOM
Eccentrics 1°
Mark - Forward
Mark – Inward
Mark - Forward FWD
Mark - Backward
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.
B-3
21
A
B
21
A
B
FOR TYRE PRESSURES, REFER TO TABLE CHAP 14-2
- 16 –
EDITION : JANUARY 2010 MAN038.011

- 17 –
EDITION : JANUARY 2010 MAN038.011
USER GUIDE ST32BV
10- ADJUSTMENT OF FRONT WHEELS
10.1 ADJUSTMENT OF FRONT TRACKING WIDTH
The adjustment of the front width is realized with several spacers (1 spacer of 15mm, and 3
spacers of 5mm for each stub axle.), and 3 hubs type (short hub: 60mm, long hub: 80mm or
extra-long hub: 100mm).
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.
DRY TRACK
D
We advise you to adjust the front with two
spacers of 5mm inside (D=10mm), and
use the long hubs: 80mm.
If you wish increase the grip of front, it
suffice to increase the width of the front
with spacers.
With the front brake on your chassis,
the adjustment of the front is limited.
Place a maximum of 20mm of spacers
inside. (D max=20mm). Use extra-
longs hubs: 100mm on wet track.
WET TRACK
D
max
We advise you to adjust the front with one
spacer of 15mm and one spacer of 5mm
inside (D=20mm), and use the long hubs:
80mm.
If you wish increase the grip of front, it
suffice to increase the width of the front
with spacers
With the front brake on your chassis,
the adjustment of the front is limited.
Place a maximum of 20mm of spacers
inside. (D max=20mm). Use extra-
longs hubs: 100mm on wet track.

USER GUIDE ST32BV
10.2 ADJUSTMENT OF FRONT WHEEL HEIGHT
DRY TRACK
Place 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
Place one 4 mm + one 4 mm spacers on top, and one 2 mm spacer at the bottom (2).
The adjustment of dry track (1) can be suitable for wet track.
4+4mm
2mm
(2) WET TRACK
EDITION : JANUARY 2010 MAN038.011
- 18 –

USER GUIDE ST32BV
10.3-ADJUSTMENT OF THE CAMBER AND OF THE CASTER
DESCRIPTION OF THE ECCENTRIC.
- 19 –
ADJUSTMENT OF THE CASTER
STANDARD ADJUSTMENT (fig 1)
1° eccentrics place in high caster position (fig 1).
INCREASE THE CASTER (fig 1)
2° eccentric in high caster (fig 1) position.
In extreme conditions, use 3°, 4° or more eccentrics.
REDUCE THE CASTER (fig 2)
2°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
FRON
T
FRON
T
TOP
BOTTOM
FIG 2
REAR
LEF
T
RIGH
T
FIG 1
TOP
RIGH
T
LEF
T
BOTTOM
REAR
Eccentrics on top: Eccentrics on top:
The mark is positioned in front of the Ø4 mm
pin.
The mark is positioned on the opposite side of
the Ø4 mm pin.
(Towards the front of the chassis) (Towards the rear of the chassis) .
EDITION : JANUARY 2010 MAN038.011