Sodikart GT2 Operating instructions

This document can not be reproduced or released without the Sodikart authorization.MAN.GT2.EN.01
Keep go-kart in original configuration
Use spare parts of Sodikart origin
January, 2009
MAN.GT2.EN.01

USER MAINTENANCE GUIDE
JANUARY, 2009
This document can not be reproduced or released without the Sodikart authorization.MAN.GT2.EN.01
Keep go-kart in original configuration
Use spare parts of Sodikart origin
SODI RENTAL LINE

3
USER MAINTENANCE GUIDE
TABLE OF CONTENTS
This document can not be reproduced or released without the Sodikart authorization.MAN.GT2.EN.01
Keep go-kart in original configuration
Use spare parts of Sodikart origin
1 - Safety instructions....................................................................................... 5
1.1 - General instructions............................................................................. 5
Track...................................................................................................................................5
Buildings.............................................................................................................................5
Areas with restricted access...............................................................................................5
Staff .................................................................................................................................... 5
Go-karts..............................................................................................................................5
Drivers ................................................................................................................................ 6
Briefing-communication...................................................................................................... 6
During a session.................................................................................................................6
1.2 - Recap of all warnings included in this manual.................................. 7
1.3 - Safety stickers .................................................................................... 10
2 - Go-kart reception....................................................................................... 11
2.1 - Standards ............................................................................................ 11
2.2 - Engine.................................................................................................. 11
2.3 - Delivery................................................................................................ 11
2.4 - Start up of the go-kart ........................................................................ 12
First start up:.....................................................................................................................12
Start up with a driver on the go-kart .................................................................................12
Start up with no driver on the go-kart ...............................................................................12
3 - Checking before cessions......................................................................... 13
3.1 - Braking ................................................................................................ 13
3.2 - Steering ............................................................................................... 14
3.3 - Pedals .................................................................................................. 15
3.4 - Engine, transmission, and feeding ................................................... 15
Engine ..............................................................................................................................15
Reducer............................................................................................................................15
Feeding.............................................................................................................................16
Drive belt ..........................................................................................................................16
3.5 - Tyre pressures.................................................................................... 16
3.6 - Bodywork parts................................................................................... 17
3.7 - Bolting ................................................................................................. 18
3.8 - Adjustable seat ................................................................................... 19
Adjustment of the seat......................................................................................................19
4 - Adjustment and maintenance of the chassis.......................................... 20
4.1 - Braking ................................................................................................ 21
Brake fluid.........................................................................................................................21
Brake pads .......................................................................................................................22
Brake fluid hoses..............................................................................................................23
4.2 - Pedals .................................................................................................. 23
4.3 - Throttle cable change......................................................................... 24
4.4 - Front wheel alignment........................................................................ 25

4
USER MAINTENANCE GUIDE
TABLE OF CONTENTS
Keep go-kart in original configuration
Use spare parts of Sodikart origin
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4.5 - Rear wheel axle unit adjustment........................................................25
4.6 - Easy-to-remove wheel sprocket ........................................................26
Removing the engine spocket ..........................................................................................26
Removing the belt sprocket ..............................................................................................27
4.7 - Drive belt adjustment..........................................................................27
4.8 - Chain adjustment................................................................................27
4.9 - Tyres change.......................................................................................28
4.10 - Assembly of the bodyworks and protections.................................29
Protections........................................................................................................................29
Bodyworks ........................................................................................................................30
4.11 - Bolting................................................................................................33
Check points.....................................................................................................................33
4.12 - Seat belt and harness.......................................................................34
Seat belt............................................................................................................................34
Harness ............................................................................................................................34
4.13 - Studded tyres change.......................................................................35
4.14 - Chassis cleaning...............................................................................36
4.15 - Maintenance summary......................................................................36
Bolting...............................................................................................................................36
Notched belt......................................................................................................................36
Steering ............................................................................................................................36
Bodywork parts.................................................................................................................36
Tyres.................................................................................................................................37
Braking..............................................................................................................................37
Chassis cleaning...............................................................................................................37
5 - Trouble shooting ........................................................................................38
The go-kart will not brake .................................................................................................38
The go-kart brakes continually..........................................................................................38
The go-kart is hard to turn ................................................................................................38
The steering of the go-kart is not precise .........................................................................38
The go-kart tends to go to the side...................................................................................38
The go-kart skids very much on bends.............................................................................38
6 - Index............................................................................................................39
7 - Maintenance schedules.............................................................................41
7.1 - Daily maintenance...............................................................................43
7.2 - Monthly maintenance..........................................................................45
7.3 - Annual maintenance ...........................................................................47

5
USER MAINTENANCE GUIDE
SAFETY INSTRUCTIONS
This document can not be reproduced or released without the Sodikart authorization.MAN.GT2.EN.01
Keep go-kart in original configuration
Use spare parts of Sodikart origin
This user guide is updated by SODIKART to
allow, without delay, to know the last safety and
maintenance improvements.
Refer to our website regularly, to dowload the last version
of user guide.
The illustrations are non-contractual.
© Sodikart 2009.
1 - Safety instructions
A go-kart can be dangerous if if is not correctly
maintained or used. Read carefully this manual and pay
a particular attention to safety warnings and notes.
• Not following the safety instructions of this manual,
may involve your liability if an accident occurs.
• Read carefully hints, instructions or warnings
following a “notes” or a “warning”:
1.1 - General instructions
Track
• Use the go-kart only on a go-kart track.
• Get the track approved.
• Make sure the track complies with the rules and
regulations of your country or state.
• Use adequate track protections that comply with the
regulations of your country (example: protection of
poles).
• Make sure the track surface is uniform (no holes).
• Maintain the track properly.
• Eliminate all fuel spills and fuel traces.
This list is not comprehensive. Refer to the rules and
regulations applicable in your country and (or) state.
NOTES
• indicates a risk of property damage if instructions
are not followed.
WARNING
!
• indicates a strong possibility of serious personnal
injury or death if instructions are not followed.
WARNING
!
DNot following size and age restrictions exposes the
driverandotherpilotstoserious or even fatal injuries,
and may involve the liability of the track.
DKeep the go-kart in it’s original state.
DUse ONLY spare parts of SODIKART origin.
DUse of damaged equipment may lead to a serious or
even a fatal injury.
Buildings
• Make sure that buildings comply with the current rules
and regulations applicable in your country and (or)
state.
• Pay a particular attention to the fire hazard issue (new
and used tyres stock, fuel station, fire security system,
and emergency exit).
• If fuel has been spilled, clean, and wait for all fuel
vapours to be dissipated prior to starting a cession.
• For indoor track, make sure that the ventilation is
adequate, and measurement systems of carbon
monoxide (CO) work correctly and are controlled at
regular intervals.
Areas with restricted access
• Clearly indicate the areas, the access of which is
forbidden to non authorized persons (example:
technical zone).
• Keep the children away from the track. They are not
aware of the danger for themselves and the drivers.
• Request animals to be attached or kept on a leash.
Animals must never go on the track.
Staff
• Staff must be informed about safety, trained, and
made aware of the importance of the matter.
Go-karts
•Keep the go-karts in their original state.
(Cf. chap. 4).
•Use tyres with a grip adapted to the surface of the
track (In case of difficulty, contact SODIKART).
(Cf. chap. 3.5), (Cf. chap. 4.9) and (Cf. chap. 4.13).
•Maintain the go-karts properly.
• Use only spare parts of SODIKART origin.
• Check and maintain the safety components with care:
- the brakes (Cf. chap. 3.1), (Cf. chap. 3.3),
(Cf. chap. 4.1), (Cf. chap. 4.2) ;
- the steering system (Cf. chap. 3.2),
(Cf. chap. 4.4) ;
- the tyres (Cf. chap. 3.5), (Cf. chap. 4.9) and
(Cf. chap. 4.13) ;
- the bodywork parts (Cf. chap. 3.6),
(Cf. chap. 4.10) ;
- the nuts and bolt (Cf. chap. 3.7),
(Cf. chap. 4.11).
.
WARNING
!
DNot using a go-kart in it’s original configuration may
lead to a serious or even fatal injury.

6
USER MAINTENANCE GUIDE
SAFETY INSTRUCTIONS
Keep go-kart in original configuration
Use spare parts of Sodikart origin
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Drivers
Follow the mandatory safety instructions carefully.
Age and size restrictions
• Make sure the age and size restrictions are respected,
according to the current laws and regulation in your
country or state.
• Forbid a pilot to drive with a size and (or) age are
below the minimum imposed by the regulation (In
France, the driver must be 14 years old and measure
140cm minimum).
• For small driver (between 140cm and 150cm), use a
spacer (removable foam).
Things prohibited to the driver
• Driving prohibited for a pilot:
- wearing a scarf since it may wind around rotating
parts of the go-kart (Cf. chap. 3.4),
(Cf. chap. 3.6), (Cf. chap. 4.10) ;
- with long hair sticking out of the helmet
(Cf. chap. 3.4), (Cf. chap. 3.6),
(Cf. chap. 4.10) ;
- with hair which could reach a rotating parts when
the driver is seated in the go-kart;
- wearing loose clothes. (Cf. chap. 3.4),
(Cf. chap. 3.6), (Cf. chap. 4.10) ;
- wearing sandals, heeled shoes, or shoes with
long laces presenting a risk of entanglement in
rotating parts of the go-kart;
- having health problems especially with a history
of heart conditions, head neck or back ailment,
nervous disorder, seizure;
- having a strange behaviour;
- under drugs or alcohol.
• Access prohibited to restricted areas (example:
technical zone).
• Prohibited to:
- touch the engine and warm parts.
(Cf. chap. 3.4) ;
- step on the throttle cable;
- step on fuel and brake hoses connections;
- step on side pods when going in, or leaving the
go-kart.
• Make sure that, prior to being dressed for driving,
pilots have been informed about restrictions and
prohibited things.
Clothes-protections
• Make sure the drivers wear the following protections,
prior to reaching the go-karts:
- mean of securing long hair under the helmet
(mandatory for pilots with long hair);
- disposable mobcap (hygiene) (mandatory);
- had sock for pilots having hair likely to come out
of the helmet (highly recommended);
- helmet of correct size for the pilot’s head,
approved according to national regulation, with
strap to secure under the chin, and visor
(mandatory);
- long, non floating, clothes giving a good
protection of arms and legs (mandatory);
- closed shoes (mandatory) – short lace tied;
- suit with a ribbed border cuff and ankle
(recommended);
- driving gloves (dry) (recommended);
- neck brace for the drivers with neck and head
problems, or on driver’s request (highly
recommended);
- rib protection of correct size (recommended);
- suit for wet conditions with waterproof fastening
(recommended when necessary).
Briefing-communication
• Display all safety instructions clearly (Panels, boards ,
videos, etc.).
• Before starting the go-karts, have a briefing with the
pilots about:
- the way to use the throttle and brake pedals and
the position of the hands on the steering wheel
(10h10);
- the driving without simultaneous use of throttle
and brake;
- the way to lock the adjustable seat, the steering
column (if adjustable), and the pedals;
- the rules of overtaking;
- the meaning of the flags and the obligation to
follow track personnel instructions;
- the applicable sanctions if rules are not followed,
especially in case of dangerous driving.
• Prior to starting the session, make sure all pilots
comply with the safety rules and have understood the
safety instructions.
During a session
• Ensure safety rules are followed (importance of track
personnel, flags, etc.).
• Warn, penalize, or exclude immediately all drivers
having a dangerous, too aggressive or queer
behaviour.
WARNING
!
DThe mobcap is design for the hygiene. It is not a
device to secure long hair.
DLong hair sticking out of the helmet and (or) loose
clothes expose the driver to a risk of serious or even
fatal injuries, by winding around rotating parts of the
go-kart.
DMake sure safety instructions are well understood by
the pilots.

7
USER MAINTENANCE GUIDE
SAFETY INSTRUCTIONS
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Keep go-kart in original configuration
Use spare parts of Sodikart origin
• Stop immediately all drivers who despite the safety
instructions, have had long hair sticking out of the
helmet, or loose clothes.
If you have problems or questions
about your go-kart, please contact our
local distributor or representative of
Sodikart.
.
Parc d’activités des Hauts de Couëron
B.P.60 - 44220 COUËRON - France
Tél. : [phone] - Fax : [phone]
www.sodikart.com - [email protected]
WARNING
!
DNotfollowingsafetyrulesmaylead to serious or even
fatal injuries.
DA driver with dangerous behaviour exposes himself
and other pilots to a risk of serious or even fatal injury.
DDriving with long hair sticking out of the helmet and
(or) loosing clothes exposes to a risk of serious, or
even fatal injury by winding around rotating parts of
the go-kart.
WARNING
!
DNot following the instructions of this manual may lead
to serious or even fatal injuries, and involve the track
liability.
1.2 - Recap of all warnings included in this
manual
Chapter: Safety instructions
DNot following size and age restrictions exposes the
driver and other pilots to serious or even fatal
injuries, and may involve the liability of the track.
(Page 5)
DKeep the go-kart in it’s original state. (Page 5)
DUse ONLY spare parts of SODIKART origin. (Page 5)
DUseofdamagedequipmentmayleadtoaseriousor
even a fatal injury. (Page 5)
DNot using a go-kart in it’s original configuration may
lead to a serious or even fatal injury. (Page 5)
DThe mobcap is design for the hygiene. It is not a
device to secure long hair. (Page 6)
DLong hair sticking out of the helmet and (or) loose
clothes expose the driver to a risk of serious or even
fatal injuries, by winding around rotating parts of the
go-kart. (Page 6)
DMake sure safety instructions are well understood
by the pilots. (Page 6)
DNot following safety rules may lead to serious or
even fatal injuries. (Page 7)
DA driver with dangerous behaviour exposes himself
and other pilots to a risk of serious or even fatal
injury. (Page 7)
DDriving with long hair sticking out of the helmet and
(or) loosing clothes exposes to a risk of serious, or
even fatal injury by winding around rotating parts of
the go-kart. (Page 7)
DNot following the instructions of this manual may
lead to serious or even fatal injuries, and involve the
track liability. (Page 7)
DControl presence and good state of the safety
stickers, and follow the instructions mentioned on
them. (Page 10)
DReplace a damaged sticker. (Page 10)
Chapter: Go-kart reception
DPush the throttle pedal at maximum when you start
the engine ,may lead to a serious or even fatal
injury. (Page 12)
DThe engine is source of heat which presents a risk
of burn for the driver, Make sure that protections are
correctly secured and in a good state. (Page 12)
DThe engineis a rotation part which presents a risk of
serious or even fatal injury, by winding of long hairs
or loosing clothes. (Page 12)
DA throttle cable too tight, may accelerate the go-kart
without driver, and may lead to a serious or even
fatal injury. (Page 12)
DPush the throttle pedal with the foot and yank on the
recoil together, may lead to a serious or even fatal
injury. (Page 12)

8
USER MAINTENANCE GUIDE
SAFETY INSTRUCTIONS
Keep go-kart in original configuration
Use spare parts of Sodikart origin
This document can not be reproduced or released without the Sodikart authorization.MAN.GT2.EN.01
Chapter: Checking before cessions
DThe brake is an essential safety element. Do not put
the go-kart in operation if the break system is faulty
or if you have a doubt. (Page 13)
DFaulty braking systemmaylead toa serious or even
fatal injury. (Page 13)
DA leak in the brake system may lead to a loss of
breaking power and may lead to a serious or even
fatal injury. (Page 13)
DDonotputagreasyliquidonthe brake diskoronthe
brake calliper; it may cause a significant loss of
braking power, and may lead to a serious or even
fatal injury. (Page 13)
DUsingbrakefluidotherthanDOT4maydamagethe
seals in the break system, and cause a loss of
braking power. (Page 13)
DUse brake fluid DOT 4 only. (Page 13)
DFaulty steering may lead to a serious or even fatal
injury. Check steering prior to cessions. (Page 14)
DA faulty pedal system may expose the driver to a
riskofthedriver and otherdriverstoa risk of serious
or even fatal injury. (Page 15)
DDamaged of braking hoses may lead toa serious or
even fatal injury. (Page 15)
DIf fuel has been spilled, clean and wait for fuel
vapours to be dissipated before starting the go-kart.
(Page 16)
DThe engine and the exhaust are sources of heat
which present a risk of burns for the driver. Make
sure that the protections are correctly secured and
in a good state. (Page 16)
DThe engine and transmission (rear axle included)
are rotation parts which present a risk of serious,
even fatal injury, by winding of long hairs or loosing
clothes.Makesurethatthe protections are correctly
secured and in a good state. (Page 16)
DThe engine generates toxic gas emissions. Make
sure that the buildings are ventilated correctly.
(Page 16)
DA fuel spill can cause accidents or fire hazard.
(Page 16)
DChangealldamagedrims.A damaged rim maylead
to a loss of tyre or loss of pressure and may lead to
a serious or even fatal injury. (Page 17)
DCheck the tyre wear daily. Worn or damaged tyres
may lead to a serious or even fatal injury. (Page 17)
DNever run with worn or damaged tyres: a burst of
tyre may lead to a serious or even fatal injury.
(Page 17)
DAlways blow up tyre with the pressure
recommended by the manufacturer. (Page 17)
DColdtyres have areducedadherence,andincrease
the loss of control of the go-kart. This may lead to a
serious or even fatal injury. (Page 17)
DToo much grip reduces the stability of the go-kart
under impact, and lead to a tendency to go on two
wheels. It also increases the risk of riding over.
(Page 17)
DStore tyres in an appropriate area to prevent fire
hazard. (Page 17)
DA rear axle cover which is badly secured or in a bad
state may lead to a serious or even fatal injury, by
winding of long hair or loose clothes around the rear
axle. (Page 18)
DMake sure that the rear axle cover is the good
version. (Page 18)
DA bodywork part with dangerous sharp edges may
lead to a serious or even fatal injury. (Page 18)
DNever allow a go-kart to run with broken or missing
bodywork parts, it may lead to a serious or even
fatal injury. (Page 18)
DA loosened adjustable seat can result in serious
bodily injury or death. (Page 19)
DAn adjustable seat system that is faulty or in bad
state can result in serious or bodily injury or death.
(Page 19)
Chapter: Adjustment and maintenance of
the chassis
DAn air bubble in the brake system can lead to a
partial or total lost of brakes and may lead to a
serious or even fatal injury. (Page 21)
DLeaks in the brake system may lead to a serious or
even fatal injury. (Page 21)
DMoisture in the brake fluid may cause vapour lock
and a sudden loss of braking power, may lead to a
serious or even fatal injury. (Page 21)
DUse brake fluid DOT 4 only. (Page 21)
DNever operate the go-kart if the brake pads have
worn beyond their permitted limits. (Page 22)
DIt is essential to use only genuine SODIKART brake
pads. (Page 22)
DMake sure the pads are assembled correctly and
that the braking system is working efficiently before
operating the go-kart. (Page 22)
DCheck brake pad wear daily. (Page 22)
DThe brake is an essential safety element. Do not put
the go-kart in operation if the break system is faulty
or if you have a doubt. (Page 23)
DFaultybrakingsystemmay lead toa serious or even
fatal injury. (Page 23)
DCheck connexions of hoses, no leak. (Page 23)
DUse brake fluid DOT 4 only. (Page 23)
DA faulty pedal system may lead to a serious or even
fatal injury. (Page 23)
DAdjust the throttle plate on open position when the
throttle pedal is released, may lead to a serious or
even fatal injury. (Page 24)
DNever drive the go-kart with the wheels not
tightened, as this may leadto a seriousor even fatal
injury. (Page 25)
DDo not drive with bent or broken tie rods, it exposes
the pilot to a risk of a serious, or even fatal injury.
(Page 25)
DDriving with badly tightenedwheel screws may lead
to a serious or even fatal injury. (Page 26)

9
USER MAINTENANCE GUIDE
SAFETY INSTRUCTIONS
This document can not be reproduced or released without the Sodikart authorization.MAN.GT2.EN.01
Keep go-kart in original configuration
Use spare parts of Sodikart origin
DExceeding themaximum rear wheelunitadjustment
may cause the breaking of the hub, and may lead to
a serious or even fatal injury. (Page 26)
DChangealldamagedrims.A damaged rim may lead
to a loss of tyre or loss of pressure and may lead to
a serious or even fatal injury. (Page 28)
DCheck the tyre wear daily. Worn or damaged tyres
may lead to a serious or even fatal injury. (Page 28)
DNever run with worn or damaged tyres: a burst of
tyre may lead to a serious or even fatal injury.
(Page 28)
DAlways blow up tyre with the pressure
recommended by the manufacturer. (Page 28)
DCold tyres have a reduced adherence, and increase
the loss of control of the go-kart. This may lead to a
serious or even fatal injury. (Page 28)
DToo much grip reduces the stability of the go-kart
under impact, and lead to a tendency to go on two
wheels. It also increases the risk of riding over.
(Page 28)
DStore tyres in an appropriate area to prevent fire
hazard. (Page 28)
DA bodywork part with dangerous sharp edges may
lead to a serious or even fatal injury. (Page 29)
DNever allow a go-kart to run with broken or missing
bodywork parts, it may lead to a serious or even
fatal injury. (Page 29)
DDo not modify bodywork parts, you might unwillingly
significantly reduce it’s efficiency as a safety item.
(Page 29)
DAlthough the safety points listed here must be
checked daily, it is obvious that other fastenings
must not be ignored.Indeed it is advised to check all
fastenings almost daily to minimise all risks. (Page 33)
DModify the seat belt or harness system may lead to
a serious or even fatal injury. (Page 34)
DCleanthebeltwithchemicalproductmaymodifythe
efficiency of the belt, and lead to a serious or even
fatal injury. (Page 34)
DA seat belt or harness not locked may lead to a
serious or even fatal injury. (Page 34)
DChangealldamagedrims.A damaged rim may lead
to a loss of tyre or loss of pressure and may lead to
a serious or even fatal injury. (Page 35)
DCheck the tyre wear daily. Worn or damaged tyres
may lead to a serious or even fatal injury. (Page 35)
DNever run with worn or damaged tyres : a burst of
tyre may lead to a serious or even fatal injury.
(Page 35)
DAlways blow up tyre with the pressure
recommended by the manufacturer. (Page 35)
DCold tyres have a reduced adherence, and increase
the loss of control of the go-kart. This may lead to a
serious or even fatal injury. (Page 35)
DToo much grip reduces the stability of the go-kart
under impact, and lead to a tendency to go on two
wheels. It also increases the risk of riding over.
(Page 35)
DThestuddedtyremustbe used only onthe ice track.
(Page 35)
DStore tyres in an appropriate area to prevent fire
hazard. (Page 35)
DIf WD40 is sprayed on the brake disk or brake
calliper, brake efficiency will be partially or
completely reduced, and this may lead to a serious
or even fatal injury. (Page 36)
DDo not put WD40 into brake pump. (Page 36)

10
USER MAINTENANCE GUIDE
SAFETY INSTRUCTIONS
Keep go-kart in original configuration
Use spare parts of Sodikart origin
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1.3 - Safety stickers
Kit of 3 small safety stikers
Ref.: AC701.127
Kit of 3 big safety stickers
Ref.: AC701.128
Ref. AC701.123
Ref. AC701.124
WARNING
!
DControl presence and good state of the safety
stickers, and follow the instructions mentioned on
them.
DReplace a damaged sticker.

11
USER MAINTENANCE GUIDE
GO-KART RECEPTION
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Keep go-kart in original configuration
Use spare parts of Sodikart origin
2 - Go-kart reception
2.1 - Standards
This go-kart complies with the French standard
NF S52-002 of February 2001.
This go-kart complies with the european standard 98/37.
(Look on the right front of chassis the C.E. sticker.).
2.2 - Engine
The Honda manual is always included with the delivery of
Hondaengine.Checkthatengineusermaintenanceguide
is supplied, otherwise contact SODIKART.
Use only: Unleaded fuel 98.
2.3 - Delivery
Duringthedelivery,check thego-kartisnotdamaged, and
all documents are supplied (user maintenance guide,
engine user’s guide, spare parts catalogue, otherwise
contact SODIKART).
Make sure the go-kart and the engine correspond to your
order.
Overall dimensions
Proline
Proline
Length (L) 1 780 mm
Width (l) 1 275 mm
Height (H) 630 mm
Height with roll-over bar 1 040 mm
l
L
H
Overall dimensions
Sport
Sport
Length (L) 1 890 mm
Width (l) 1 245 mm
Height (H) 630 mm
Height with roll-over bar 1 040 mm
l
H
L

12
USER MAINTENANCE GUIDE
GO-KART RECEPTION
Keep go-kart in original configuration
Use spare parts of Sodikart origin
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2.4 - Start up of the go-kart
Thepersonwho startupthego-kartmustbeoutsideofthis
one.
If the driver is in position, he must be seated, and on
driving position.
First start up:
• Fill the oil tank (Cf. chap. 3.4).
• Fill the fuel tank.
• Break in 10 min, go-kart must be stoped.
• Check that main parts (brake, steering, etc.) run
correctly during 10 min.
• Check the tightening of bolting.
Start up with a driver on the go-kart
• Check that maintenance of the go-kart is done. Each
maintenance instructions were checked and modified
if it is required.
• Place the driver on the go-kart.
Legend
1 Throttle pedal
• Ask to push the throttle pedal (1) lightly.
1
.
Legend
2 Starter pull cord
3 Throttle lever
• Yank the starter pull cord (2).
Start up with no driver on the go-kart
• Check that maintenance of the go-kart is done. Each
maintenance instructions were checked and modified
if it is required.
• Push the throttle lever (3) lightly
• Yank the starter pull cord (2).
NOTES
Check with the throttle lever that the throttle cable have
a play (3).
If the engine does not start, repeat the handling.
Repeat the handling often can drown the engine.
WARNING
!
DPush the throttle pedal at maximum when you start
the engine ,may lead to a serious or even fatal injury.
DThe engine is source of heat which presents a risk
of burn for the driver, Make sure that protections
are correctly secured and in a good state.
DThe engine is a rotation part which presents a risk of
seriousorevenfatalinjury, bywindingoflong hairs or
loosing clothes.
DA throttle cable too tight, may accelerate the go-kart
without driver, and may lead toa serious or even fatal
injury.
DPush the throttle pedal with the foot and yank on the
recoil together, may lead to a serious or even fatal
injury.
23

13
USER MAINTENANCE GUIDE
CHECKING BEFORE CESSIONS
This document can not be reproduced or released without the Sodikart authorization.MAN.GT2.EN.01
Keep go-kart in original configuration
Use spare parts of Sodikart origin
3 - Checking before cessions
3.1 - Braking
Legend
1 Reservoir
2 Master cylinder
3Brakehose
4 Brake calliper
5 Support
6 Frame
7Brakepad
8Brakedisc
9Pin
10 Rear axle
11 Wear indicator
• Check that the brake fluid in the reservoir (1) of the
master cylinder (2) is at the maximum level. If the level
is low, fill to the upper level mark.
7
3
1
4
2
9
510
6
8
7
11
• Check the hoses (3) to hydraulic brake; it is essential
there should be no leak. Carefully check hose
connexions and replace if damaged. (Cf. chap. 4.13)
• Check the hoses are not damaged near the clamp.
• Tighten the hydraulic calliper (4) on its support (5)
which must be tightened on the chassis (6).
• Position correctly the brake pads (7) on the calliper (4)
and fasten them with 2 guide axles and the retaining
clips.
• Make sure that brake disk (8) is wedged with an axle
pin (9) and tightened onto rear axle shaft (10). The
brake disk must be centred in relation to calliper brake
pads.
FOR REPLACEMENT OF BRAKE PARTS, PLEASE
REFER TO CHAPTER ADJUSTMENT AND
MAINTENANCE OF THE CHASSIS, SECTION BRAKE.
(Cf. chap. 4.1)
NOTES
It is imperative to check the braking system everyday:
fluid, secure closure of the hydraulic brake pump
container cap, fluid level, calliper tightening, brake pad
fastening, break pad brake disk tightening and centring,
mechanical contact between the pedal and master
cylinder.
If the brake fluid becomes black, drain the brake fluid
and refill the braking system (Cf. chap. 4.1).
WARNING
!
DThe brake is an essential safety element. Do not put
thego-kartinoperationifthebreaksystem is faulty or
if you have a doubt.
DFaulty braking system may lead to a serious or even
fatal injury.
DA leak in the brake system may lead to a loss of
breaking power and may lead to a serious or even
fatal injury.
DDo not put a greasy liquid on the brake disk or on the
brake calliper; it may cause a significant loss of
braking power, and may lead to a serious or even
fatal injury.
DUsing brake fluid other than DOT 4 may damage the
seals in the break system, and cause a loss of
braking power.
DUse brake fluid DOT 4 only.

14
USER MAINTENANCE GUIDE
CHECKING BEFORE CESSIONS
Keep go-kart in original configuration
Use spare parts of Sodikart origin
This document can not be reproduced or released without the Sodikart authorization.MAN.GT2.EN.01
3.2 - Steering
Legend
1Steeringwheel
2 Steering wheel sloping hub
3Steeringcolumn
4 Plastic column support
5 Lower plastic column support
6 Tie rod
7 Ball joint
8 Stub axle
9Bolt
• Tighten the steering wheel (1) with 3 screws into the
steering wheel sloping hub (2). The sloping hub must
be tightened to the steering column (3). The steering
wheel must be free to turn ¼ turn to the right and to
the left.
• Check for proper tightening (25 Nm) of the upper
plastic column support screw (4) and the bolt holding
the lower plastic column support (5), as well as the
bolt (9) holding the lower column mount to the floor.
• Mount the 2 tie rods (6) correctly on the stub axle (7)
and the steering column (3) knuckle joints.
• Stubs axles (8) must be tightened to the chassis
(60Nm) with axle screws and locking nut and the
washer.
• The front wheel axle unit alignment must be perfect.
There should be no pinching or unlocking of the front
wheel axle unit.
124
7
3
8
6
5
98
6
7
• For front wheel axle unit alignment procedure refer to
chapter: adjustment and maintenance of the chassis,
section front wheel axle unit alignment.
NOTES
Damaged tie rods affect wheel alignment, and may
cause a rapid tyre wear and increased driver’s tiredness.
The locking nuts and stub axle bolts must be jammed.
The stub axle must be tightened to the correct torque
specification to obtain correct allowance for free rotation
around the axle. Accurate adjustment leads to steering
precision and reduces driver’s tiredness.
WARNING
!
DFaulty steering may lead to a serious or even fatal
injury. Check steering prior to cessions.

15
USER MAINTENANCE GUIDE
CHECKING BEFORE CESSIONS
This document can not be reproduced or released without the Sodikart authorization.MAN.GT2.EN.01
Keep go-kart in original configuration
Use spare parts of Sodikart origin
3.3 - Pedals
Driving in an ergonomic position is safer.
Legend
1Brakepedal
2 Throttle pedal
3Flap
4 Brake safety cable
• Press the brake pedal (1) and throttle (2) to check that
they return to their original position.
• Check that the brake safety cable (4) is in position and
tight.
• Check that the pedal flap (3) rotates freely.
• Check the brake fluid level.
• Check the hose connections and ensure that there is
no leakage.
WARNING
!
DA faulty pedal system may expose the driver to a risk
of the driver and other drivers to a risk of serious or
even fatal injury.
DDamaged of braking hoses may lead to a serious or
even fatal injury.
4
3.4 - Engine, transmission, and feeding
Engine
Legend
1 Oil filler cap
2 Required oil level
• Remove the oil filling cap (1).
• Fill the oil pan of engine with engine oil for go-kart:
- For the engine 200 cc : 0.60 liter.
- For the engine 270 cc : 1.10 liter.
• Check oil level.
• Loosen the oil filling cap, and check there is no leak
near the oil change nuts.
Reducer
Legend
1 Oil filler cap
2 Oil change nut
3 Minimum level
• Remove the oil filling cap (1).
• Fill with engine oil for go-kart:
- For the engine 200 cc : 0.35 liter.
- For the engine 270 cc : 0.45 liter.
• Check oil level.
• Loosen the oil filling cap, and check there is no oil leak
near the oil change nuts (2).
1
21
1
32

16
USER MAINTENANCE GUIDE
CHECKING BEFORE CESSIONS
Keep go-kart in original configuration
Use spare parts of Sodikart origin
This document can not be reproduced or released without the Sodikart authorization.MAN.GT2.EN.01
Feeding
Checkthatthefuel hoses andthetankdo not leakandthat
hoses are well connected to the tank, carburettor, fuel
container, fuel filter and fuel pump.
Drive belt
Legend
1 Notched belt
2Roller
• Check that the drive belt is tightened, and in a good
state. It prevents mechanical damages.
• Tighten the notched belt (1) with the roller adjuster (2).
The notched belt must have 5mm allowance.
For tension of the notched belt, (Cf. chap. 4.7).
WARNING
!
DIf fuel has been spilled, clean and wait for fuel
vapours to be dissipated before starting the go-kart.
NOTES
Tighten the notched belt daily. Good tension increases
the lifetime of the belt.
Replaceany damagedbelttoeliminatetheriskofengine
overspeed.
WARNING
!
DThe engine and the exhaust are sources of heat
whichpresentariskofburns for the driver.Makesure
that the protections are correctly secured and in a
good state.
DThe engine and transmission (rear axle included) are
rotation parts which present a risk of serious, even
fatal injury, by winding of long hairs or loosing
clothes. Make sure that the protections are correctly
secured and in a good state.
DThe engine generates toxic gas emissions. Make
sure that the buildings are ventilated correctly.
DA fuel spill can cause accidents or fire hazard.
5 mm
2
1
3.5 - Tyre pressures
Legend
1 Wear indicator
2 Arrow (direction of rotation)
• Check the pressure of the front and rear tyres:
- Duro tyre:
- Itaka tyre:
• Check the tyres wear indicators (1). If any of indicators
are not visible, replace the tyre.
• Carefully check the state of tyres if there are
scrubbing or tears, replace them.
• Check the tyre rotation direction with the arrow (2)
visible on the tyre wall.
For tyre replacement procedure, (Cf. chap. 4.9).
Front 1.5 to 1.7 bar
Rear 1.7 to 1.9 bar
Front 1.5 to 1.7 bar
Rear 1.7 to 1.9 bar
NOTES
For best performance inflate tyres according to above
mentioned pressures. Bad pressure leads to excessive
wear of the tyres and degrades the go-kart’s
performance.
Warning: Excessive wear of a tyre may be caused by a
bad front wheel alignment.
Use tyres with a grip adapted to your track.
1
2

17
USER MAINTENANCE GUIDE
CHECKING BEFORE CESSIONS
This document can not be reproduced or released without the Sodikart authorization.MAN.GT2.EN.01
Keep go-kart in original configuration
Use spare parts of Sodikart origin
WARNING
!
DChange all damaged rims. A damaged rim may lead
to a loss of tyre or loss of pressure and may lead to a
serious or even fatal injury.
DCheck the tyre wear daily. Worn or damaged tyres
may lead to a serious or even fatal injury.
DNever run with worn or damaged tyres: a burst of tyre
may lead to a serious or even fatal injury.
DAlways blow up tyre with the pressure recommended
by the manufacturer.
DCold tyres have a reduced adherence, and increase
the loss of control of the go-kart. This may lead to a
serious or even fatal injury.
DToo much grip reduces the stability of the go-kart
under impact, and lead to a tendency to go on two
wheels. It also increases the risk of riding over.
DStore tyres in an appropriate area to prevent fire
hazard.
3.6 - Bodywork parts
The bodywork parts are essential safety components.
They protect the driver against:
- The rotating parts – risk of entanglement of long
hair and loose clothes.
- The stability under impact - risk of lifting, etc.
- The hot areas - risk of burns.
• Check that the bodyworks parts are not damaged.
• Check the bodywork fixations (1).
• Check the state of protections (2).
GT2 PROLINE
Legend
1 Bodywork fixation
2 Protection
1 1
1
2
1
1
1
1
1
1
2
1

18
USER MAINTENANCE GUIDE
CHECKING BEFORE CESSIONS
Keep go-kart in original configuration
Use spare parts of Sodikart origin
This document can not be reproduced or released without the Sodikart authorization.MAN.GT2.EN.01
GT2 SPORT
Legend
1 Bodywork fixation
2 Protection
.
NOTES
A screw head that protrudes outside the protections will
rapidly degrade the other bodywork parts. Change the
corresponding protection immediately.
WARNING
!
DA rear axle cover which is badly secured or in a bad
state may lead to a serious or even fatal injury, by
winding of long hair or loose clothes around the rear
axle.
DMake sure that the rear axle cover is the good
version.
DA bodywork part with dangerous sharp edges may
lead to a serious or even fatal injury.
DNever allow a go-kart to run with broken or missing
bodywork parts, it may lead to a serious or even fatal
injury.
1
1
1
1
1
1
1
2
1
2
2
1
1
3.7 - Bolting
• Check all nuts and screws on the go-kart:
- rear hub, wheel, rear hollow axle screws, seat
screws, engine platen screws, body, braking, gas
and brake pedal screws, steering screws,
notched belt tension screws.
For adjustment and maintenance of the chassis,
(Cf. chap. 4.11).
NOTES
Check the engine platen screws regularly (because of
engine vibration).
Check the stub axle nuts and bolts with particular care.

19
USER MAINTENANCE GUIDE
CHECKING BEFORE CESSIONS
This document can not be reproduced or released without the Sodikart authorization.MAN.GT2.EN.01
Keep go-kart in original configuration
Use spare parts of Sodikart origin
3.8 - Adjustable seat
This option allows driving in an ergonomic position, and
improves safety. The tall and small people can sit
comfortably.
Adjustment of the seat
Legend
1 Seat
2 Lever
• Turn the locking lever (2) forward to unlock the seat
(1).
• Move the seat (1) to adapt its position to the length of
the legs.
• Turn the locking lever (2) backward to lock the seat
(1).
NOTES
Checkthetighteningofscrews and nutsofthe adjustable
seat daily.
Check the seat is locked before the go-kart operates.
1
2
1
2
WARNING
!
DAloosened adjustableseatcanresultinseriousbodily
injury or death.
DAn adjustable seat system that is faulty or in bad state
can result in serious or bodily injury or death.

20
USER MAINTENANCE GUIDE
ADJUSTMENT AND MAINTENANCE OF THE CHASSIS
Keep go-kart in original configuration
Use spare parts of Sodikart origin
This document can not be reproduced or released without the Sodikart authorization.MAN.GT2.EN.01
4 - Adjustment and maintenance of
the chassis
Use the sheets included at the end of user maintenance
guide, to control and follow the maintenance of the
go-kart.