Sodikart GT2 Istruzioni operative

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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

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

USER MAINTENANCE GUIDE

TABLE OF CONTENTS

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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

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.

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.

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

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.

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

• 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. : (33) 02 40 38 26 20 - Fax : (33) 02 40 38 26 21

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)

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)

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)

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

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.

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