owner`s manual

RENTAL
owner’s manual
RENTAL
owner’s manual
Foreword
The purpose of the Owner’s Manual is to familiarise you with the operation, maintenance, and safety features of
of publication. Sodikart nevertheless reserves the right to apply changes in order to uphold its policy of continuous
ferences
between the content of the manuals and the go-kart you own.
The manual applies to all Sodikart models and includes descriptions and explanations concerning both the standard
and optional equipment. This means that this manual might contain some sections that do not apply to your go-kart
model. The illustrations in the manuals are used to describe the basic principles of operation and the work procedures.
They are not intended to be an exact, detailed representation of the go-kart.
This document is a translation of the French manual, document LR5_Owner_FR_00 (original version), which will
prevail in the event of a dispute.
© Sodikart 2014.
2
This document can not be reproduced or released without the Sodikart authorization.
If you have problems or questions about your go-kart, please contact your local distributor or representative of
Sodikart.
04/2014
owner’s manual
RENTAL
Table of contents
1 - General�������������������������������������������� 4 6.5 - Spark plug............................................... 12
1.1 - Warning..................................................... 4 6.6 - Rocker arm.............................................. 12
1.2 - Safety instructions..................................... 4 6.7 - Idle.......................................................... 12
1.2.1 - Track.............................................................4 6.8 - Fill with fuel............................................. 12
1.2.2 - Buildings........................................................4 6.9 - Brake pads.............................................. 13
1.2.3 - Restricted access areas................................4
6.10 - Brake fluid............................................. 13
1.2.4 - Staff...............................................................4
6.11 - Belt tension............................................ 14
1.2.5 - Go-karts........................................................4
1.2.6 - Drivers...........................................................4 6.12 - Tyres...................................................... 15
1.2.7 - Prohibitions...................................................5 6.13 - Safety harness...................................... 15
1.2.8 - Briefing-communication.................................5 6.14 - Chassis cleaning................................... 16
This document can not be reproduced or released without the Sodikart authorization.
1.2.9 - During a session...........................................5
1.3 - Safety stickers........................................... 6
7 - Troubleshooting��������������������������� 16
2 - Presentation of the go-kart������������ 6 8 - Declaration of conformity������������ 17
2.1 - Delivery..................................................... 6
2.2 - Standards.................................................. 6
2.3 - Dimensions and weight............................. 6
2.4 - Chassis..................................................... 7
2.5 - Engine....................................................... 7
2.6 - Lubricant................................................... 7
3 - Start up of the go-kart�������������������� 7
3.1 - First start up.............................................. 7
3.2 - Run-in........................................................ 7
3.3 - Start up with a driver on the go-kart.......... 8
3.4 - Start up with no driver on the go-kart........ 8
4 - Driving the go-kart������������������������� 8
4.1 - Pedals....................................................... 8
4.2 - Steering wheel.......................................... 8
4.3 - Seat........................................................... 9
5 - Frequency of maintenance���������� 10
5.1 - Go-kart maintenance table...................... 10
5.2 - Engine maintenance table....................... 10
6 - Routine maintenance
programme������������������������������������ 11
6.1 - Engine oil................................................ 11
6.2 - Reducer oil.............................................. 11
6.3 - Air filter.................................................... 11
6.3.1 - Paper filter unit............................................11
6.3.2 - Foam filter element.....................................11
6.4 - Sediment cup.......................................... 11
LR5_Owner_EN_00
3
1 - General
1.1 - Warning
A go-kart can be dangerous 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”:
ff Indicates a strong possibility of serious
personal injury or death if instructions
are not followed.
●● Indicates a risk of property damage if
instructions are not followed.
●● Provides useful information.
1.2.3 - Restricted access areas
●● 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).
1.2.4 - Staff
●● Staff must be informed about safety, trained, and
made aware of the importance of the matter.
1.2.5 - Go-karts
●●
●●
●●
●●
The warnings and precautions contained in this
manual cannot cover every possible risk related to the
maintenance, or lack of maintenance, of a go-kart.
●●
●●
●● In addition to the messages given, it is important to
apply good judgement and apply the basic principles
of mechanical safety.
●●
1.2 - Safety instructions
1.2.1 - 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.
1.2.2 - 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.
4
owner’s manual
●●
●●
●●
●●
Keep the go-kart in it’s original state.
Do not modify the go-kart.
Use original Sodikart parts only.
For the safety and reliability of the go-kart, it is
important to carry out the appropriate maintenance
and repairs.
Never use petrol as a substitute for cleaning solvent.
Check all hoses and mountings in the brake system to
ensure that there are no leaks.
Ensure that the safety stickers are present and in
good condition.
To protect the environment, comply with all legal
requirements for the disposal of used fluids, batteries,
and tyres.
To protect nature and the environment, dispose of
used parts in accordance with regulations.
Use tyres with a grip adapted to the surface of the
track. In case of difficulty, contact SODIKART
Check and maintain the safety components with care:
-- The brakes
-- The steering system
-- The tyres
-- The bodywork parts
-- The nuts and bolts
This document can not be reproduced or released without the Sodikart authorization.
RENTAL
ff Keep the go-kart in it’s original state.
ff Use ONLY spare parts of SODIKART
origin.
ff Use of damaged equipment may lead to a
serious or even a fatal injury.
ff Not using a go-kart in it’s original
configuration may lead to a serious or
even fatal injury.
1.2.6 - 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 7 years old and measure
130cm minimum).
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●● For small driver (between 130cm and 150cm), use a
spacer (removable foam).
ff Not 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.
This document can not be reproduced or released without the Sodikart authorization.
1.2.7 - Prohibitions
●● Driving prohibited for a pilot:
-- Wearing a scarf since it may wind around rotating
parts of the go-kart.
-- With long hair sticking out of the helmet.
-- With hair which could reach a rotating parts when
the driver is seated in the go-kart.
-- Wearing loose or short clothing (skirts, shorts,
hoods).
-- Wearing sandals, heeled shoes, or shoes with long
laces presenting a risk of entanglement in rotating
parts of the go-kart.
-- With health problems (for example: heart
problems).
-- Having a strange behaviour or under drugs or
alcohol.
●● Access prohibited to restricted areas (example:
technical zone).
●● Prohibit the driver:
-- Touch the engine and warm parts.
-- Step on the throttle cable.
-- Place the feet on the fuel and brake hoses.
-- 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).
-- 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).
LR5_Owner_EN_00
owner’s manual
-- Suit for wet conditions with waterproof fastening
(recommended when necessary).
ff The mobcap is design for the hygiene. It
is not a device to secure long hair.
ff Long 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 gokart.
ff Make sure safety instructions are well
understood by the pilots.
1.2.8 - 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.
1.2.9 - 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.
●● Stop immediately all drivers who despite the safety
instructions, have had long hair sticking out of the
helmet, or loose clothes.
ff Not following safety rules may lead to
serious or even fatal injuries.
ff A driver with dangerous behaviour
exposes himself and other pilots to a risk
of serious or even fatal injury.
ff Driving 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.
ff Not following the instructions of this
manual may lead to serious or even fatal
injuries, and involve the track liability.
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2 - Presentation of the go-kart
1.3 - Safety stickers
Location
2.1 - Delivery
4
During the delivery, check the go-kart is not damaged,
and all documents are supplied (user maintenance guide,
declaration of conformity). Otherwise contact SODIKART.
3
● Make sure the go-kart and the engine correspond to
your order.
5
2.2 - Standards
This go-kart complies with the French standard
NF S52-002 of February 2001.
!
2
!
1
AC701.124
Sticker «DOT4»
2
AC701.123
‘Safety instructions’ sticker
3
AC701.128
‘Prohibitions’ sticker
4
AC701.127
‘Prohibitions’ sticker
5
AC701.115
‘Prohibitions’ sticker
LIQUIDE DE FREIN
DOT 4 UNIQUEMENT
1
SODIKART : Parc d’Activités des Hauts
de Couëron-BP60
44220 COUËRON-FRANCE
BRAKE FLUID
DOT 4 ONLY
Année : 2014
2.3 - Dimensions and weight
Meaning
!
LIQUIDE DE FREIN
DOT 4 UNIQUEMENT
H1
BRAKE FLUID
DOT 4 ONLY
!
INSTRUCTIONS DE SECURITE
● Maintenir le kart en bon état de fonctionnement
(se référer au manuel d'entretien)
● Faire respecter les règles et consignes de sécurité
(briefing obligatoire)
● Ne pas laisser un pilote conduire :
► Sans les protections adéquates
► Avec les cheveux long à l'extérieur du casque
► Avec une écharpe ou des vêtements flottants
► Sous l'emprise de drogue ou d'alcool
Summary of the main safety
instructions for the driver.
H
!
L
SAFETY INSTRUCTIONS
● Keep the kart in good condition
(refer to maintenance manual)
● Instruct the pilot about safety
(compulsory briefing)
● Do not let a pilot drive:
► Without adequate protections
► With long hair out of the helmet
► With a scarf or floating clothes
► Under the influence of drugs or alcohol
l
No long hair sticking out from
the helmet.
No scarves.
No loose clothing.
6
Length (L) ............................................................2092 mm
Width (l) ...............................................................1450 mm
Height (H) ............................................................ 680 mm
Height with roll-over bar (H1)...............................1070 mm
Weight (Engine GX120)...........................................122 kg
Weight (Engine GX160)..........................................124 kg
This document can not be reproduced or released without the Sodikart authorization.
This go-kart complies with the european standard
2006/42 (Look on the right front of chassis the C.E.
sticker.).
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owner’s manual
RENTAL
2.4 - Chassis
2.5 - Engine
●● Check that the maintenance and operating manual
for the engine has been supplied. If not, contact
SODIKART at the above address.
●● Use only unleaded fuel 98 or 95.
4
3
2.6 - Lubricant
Fuel...............................Unleaded fuel 98 or 95
Engine oil.......................Oil 4T KARTLUB 10W40
Reducer oil....................Oil 4T KARTLUB 10W40
Brake fluid.....................LUCAS brake fluid DOT4
(75ml±5)
1
This document can not be reproduced or released without the Sodikart authorization.
2
●● The brake system is not compatible with
DOT 5.
ff Use brake fluid DOT4 only. f
Using another brake fluid could cause
leaks and failure of the brake system.
Legend
1 Right
2 Front
3 Left
4 Rear
3 - Start up of the go-kart
Check that the go-kart you plan to start is operational
(all instructions on the maintenance sheet have been
checked and all necessary repairs carried out).
J
The person who start up the go-kart must be outside of
this one.
G
If the driver is in position, he must be seated, and on
driving position.
H
F
3.1 - First start up
I
C
D
E
B
A�����Front protection
B�����Spoiler
C�����Nassau panel
D�����Side protection
E�����Pedals
F�����Steering wheel
G�����Seat
H�����Rear protection
I������Engine
J������Roll-over bar
LR5_Owner_EN_00
A
●● Put oil in the engine and the reducer (if any).
●● Fill the fuel tank.
●● To start the engine, apply the procedure described in
the engine manual.
3.2 - Run-in
●● Break in 10 min, go-kart must be stopped.
●● Run the engine for two 10-minute sessions at a
moderate speed (the speed can be increased
gradually from one session to the next) to run in the
components of the go-kart (brake pads, tyres) and
check that the main systems of the go-kart (braking,
steering, etc.) are functioning properly. Refer to the
maintenance tables for the checks to be performed
after run-in.
7
RENTAL
3.3 - Start up with a driver on the go-kart
●●
●●
●●
●●
Place the driver on the go-kart.
Set the start button to ON.
Pull the starter lever.
To feed petrol to the engine, push the petrol valve to
the right.
●● Ask to push the throttle pedal lightly.
●● Yank the starter pull cord.
owner’s manual
4 - Driving the go-kart
4.1 - Pedals
Adjusting the position of the pedals
3.4 - Start up with no driver on the go-kart
●● Use the throttle lever to check that there is a
little play in the throttle cable.
●● If the engine does not start, repeat the
handling.
●● Repeat the handling often can drown the
engine.
ff Push the throttle pedal at maximum
when you start the engine ,may lead to a
serious or even fatal injury.
ff The engine is source of heat which
presents a risk of burn for the driver.
ff The engine is a rotation part which
presents a risk of serious or even fatal
injury, by winding of long hairs or loosing
clothes.
ff A throttle cable too tight, may accelerate
the go-kart without driver, and may lead
to a serious or even fatal injury.
ff Pressing the throttle pedal with your foot
whilst yanking the starter pull cord can
cause a serious—or even fatal—accident.
This document can not be reproduced or released without the Sodikart authorization.
●● Set the start button to ON.
●● Pull the starter lever.
●● To feed petrol to the engine, push the petrol valve to
the right.
●● Push the throttle lever lightly.
●● Yank the starter pull cord.
1
Legend
1 Indexing button
●● Use the button (1) to adjust the front/rear position of
the pedals according to the driver’s height.
●● Check that the pedals are properly indexed in a
position.
4.2 - Steering wheel
Steering wheel height adjustment
1
Legend
1 Lever
●● Loosen the lever half a turn (1) to adjust the steering
wheel height according to the driver's height.
●● Check that the lever is tight before the go-kart departs.
8
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4.3 - Seat
Adjusting the position of the seat
This document can not be reproduced or released without the Sodikart authorization.
1
Legend
1 Belt
●● Pull the strap (1) to adjust the front/rear position of the
seat according to the driver’s height.
●● Check that the seat is properly indexed in a position.
LR5_Owner_EN_00
9
owner’s manual
RENTAL
5 - Frequency of maintenance
●● The following tables list the recommended frequency
of all the periodic maintenance operations required to
ensure optimum go-kart operation.
●● When go-karts are used under harsh
conditions, carry out maintenance more
often.
●● I = Inspect and then clean, adjust, replace, or grease if
necessary
●● N = Clean
●● C = Replace
●● R = Retighten
Parts
After
or
once per
0.5 h
(end of
run-in)
3h
20 h
100 h
1000 h
Day
Week
Month
Year
Floor and fasteners
I
Steering tie rod
I
R
Front axle unit and fasteners
R
R
Alignment
I
I
Steering wheel and fasteners
I
R
Steering column and fasteners
I
R
Operation of the adjustable column
I
Rear shaft pins
I
Rear wheel hub
I
R
Bearings and bearing supports
I
R
Rear axle
I
Tyre pressures
I
Condition of rims
I
Rim tightness
R
R
Seat and fasteners
I
R
Protections
I
R
Pedals
I
R
Operation of the adjustable pedal unit
I
Brake fluid
I
C
Brake pads
I
C
Brake disc
I
C
Throttle cable
I
C
Brake hoses
I
Belt
I
Belt tension
This document can not be reproduced or released without the Sodikart authorization.
5.1 - Go-kart maintenance table
C
I
Safety stickers
I
5.2 - Engine maintenance table
After
or
once per
3h
20 h
50 h
100 h
500 h
Day
Week
2 week
Month
6 month
Engine oil
I
Reducer oil
I
Air filter
I
C
C
N
C
Sediment cup
N
Spark plug
I
Valve clearance inspection
Idling
10
C
I
I
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6 - Routine maintenance programme
6.1 - Engine oil
6.3 - Air filter
1
1
1
5
6
3
4
2
2
Legend
1 Paper filter unit
2 Foam filter element
3 Soapy water or solvent
4 Engine oil
This document can not be reproduced or released without the Sodikart authorization.
3
Legend
1 Filler cap / Oil gauge
2 Drain plug
3 Washer
4 Lower edge of the oil fill hole
5 Oil maximum level
6 Oil minimun level
6.3.1 - Paper filter unit
Gently tap the filter unit on a hard surface several times
to detach the dirt, or use an air gun (201 kPa (maximum
2.1 kgf/cm)) to blow through the filter element from the
inside.
●● Never try to remove the dirt using a brush.
This only embeds the dirt in the fibres.
10W40
0
20
-20 -10
40
0
60
10
20
4
3
2
80
30
T°
100 °F
40 °C
6.3.2 - Foam filter element
Clean the filter element in hot soapy water, rinse, and
allow to dry thoroughly.
Legend
T° Ambient temperature
It could also be cleaned in a non-flammable solvent, and
then allow it to dry.
●● Oil reference: Oil 4T KARTLUB 10W40 LU814.007.
●● Capacity:
-- GX120 : 0.60 litre.
-- GX160 : 0.60 litre.
Soak the filter element in clean motor oil, and then wring
out the excess oil.
6.2 - Reducer oil
●● If too much oil remains in the foam, the
engine will smoke when started up.
6.4 - Sediment cup
1
2
1
2
3
4
4
Legend
1 Filler cap / Oil gauge
2 Drain pluge
3 Oil maximum level
4 Oil minimun level
●● Oil reference: Oil 4T KARTLUB 10W40 LU814.007.
●● Capacity:
-- GX120 : 0.50 litre.
-- GX160 : 0.50 litre.
LR5_Owner_EN_00
3
5
4
Legend
1 Closed
2 Petrol valve lever
3 O-ring
4 Sediment cup
5 Solvent
11
owner’s manual
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6.8 - Fill with fuel
6.5 - Spark plug
2
ff Petrol is highly flammable and explosive,
and serious injuries can occur when
filling up.
ff Switch off the engine and ban any heat
sources, sparks, or flames in the vicinity.
3
0.7 / 0.8mm
Legend
1 Spark plug
2 Sealing washer
3 Electrodes
●● Spark plug recommended: BPR6ES (NGK),
ref.: PM366.056.
6.6 - Rocker arm
1
2
●● Never use spoiled or contaminated petrol
or an oil/petrol mixture. Prevent dirt and
water from entering the fuel tank.
●● Fuel can damage paint and certain types
of plastic.
●● Take care not to spill any petrol when filling
the tank.
Fill up again in a well ventilated area with the engine off.
If the engine has just been running, allow it to cool down
first. Never fill up inside a building where petrol fumes
could come into contact with flames or sparks.
Immediately wipe up any spilt fuel.
●● Place the go-kart on a horizontal surface, and then
shut off the engine.
●● Remove the fuel filler cap and check the fuel level. If
the fuel level is low, fill the tank.
●● Fill up to the fuel tank’s maximum level.
●● Wipe up any spilt fuel before starting the engine.
●● Fill the tank carefully, to avoid spilling fuel. Do not
fill the fuel tank completely. Under certain operating
conditions, it might be necessary to lower the fuel
level.
●● After filling up, fully tighten the filler cap.
3
Legend
1 Rocker arm
2 Rocker arm pivot locknut
3 Rocker arm pivot
●● Standard valve play:
-- 0.15 mm ± 0.02 mm (adm)
-- 0.20 mm ± 0.02 mm (ech)
6.7 - Idle
1
ff Keep petrol away from the pilot lights of
devices, barbeques, electrical devices,
power tools, etc.
●● Spilt fuel does not only create a fire risk; it is
also harmful to the environment.●
Immediately wipe up any spilt fuel.
Legend
1 Idle stop screw
This document can not be reproduced or released without the Sodikart authorization.
1
●● Standard idling speed:
-- 1400 ±150 (rpm)
12
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6.9 - Brake pads
●● Double-check that the clips (4) are properly
engaged.
●● Ensure that the pads are in the correct
position.
●● It is strongly advised to bleed and renew the
braking circuit after each change of brake
pads. The go-kart will have optimum braking
performance.
The brake pads must be changed, when their have worn
down to minimum thickness.
-- Minimum brake pad thickness: 8 mm (4 mm lining
and 4 mm steel support).
-- Minimum brake disc thickness: 17 mm.
ff Never operate the go-kart if the brake
pads have worn beyond their permitted
limits.
ff Use only genuine SODIKART brake pads.
ff Make sure the pads are assembled
correctly and that the braking system is
working efficiently before operating the
go-kart.
ff Check brake pad wear daily.
1
3
5
This document can not be reproduced or released without the Sodikart authorization.
6
6.10 - Brake fluid
4
3
7
4
2
6
2
3
1
4
Legend
1 Brake fluid reservoir cap
2 Right pad
3 Left pad
4 Retaining clip
5 Upper guide stem
6 Lower guide stem
●● Unscrew and remove the brake fluid filler cap (1).
Wrap a dry rag around the neck of the filler to prevent
spillage.
●● Using your hand push back the left-hand pad (3) to
return the piston in their initial positions. The brake
fluid will rise several millimetres in the tank.
●● Remove the retention pins (4) from the brake pad
guide stems (5) and (6).
●● Remove the 2 stalk of guide (5) and (6) and remove
both worn plaques of brake.
●● Insert the new pads taking care to position them
correctly.
●● Hold the two pads in position and slide the two guide
stems (5) and (6).
●● Check that the clips (4) are in good condition, and
then engage them.
●● Check that the clips (4) are properly engaged.
●● If the brake fluid is above maximum level, partially
bleed the system, top up and replace the filler cap with
its sealing ring.
●● Test the brake before to rent the go-kart.
LR5_Owner_EN_00
1
2
1
5
Legend
1 Hose and container
2 Bleeder screw
3 Filler cap
4 Brake pedal
5 Calliper
6 Brake fluid reservoir
7 Retaining ring
●● Use a pipe and a container (1) to collect the used
fluid.
●● Remove the bleeder screw (2) protective cover and
connect the hose to the bleed nipple with the free end
in the receptacle.
●● Gently unscrew the bleeder screw and the filler cap
(3).
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●● Repeatedly press the brake pedal (4) until all the fluid
has drained out.
●● When all the fluid has been drained, remove the filler
cap (3) and top up to the maximum level with brake
fluid.
●● Tighten the bleed screw (2), and then press the brake
pedal (4) three or four times.
●● Loosen the bleeder screw (2). Brake fluid should flow
out.
●● Retighten the bleed screw, and repeat this step
several times to feed the circuit properly.
●● Remember to add brake fluid to the reservoir (6) as
required.
●● Bleed the circuit so that the brake fluid flowing out of
the hose (1) contains no air bubbles.
●● Retighten the calliper bleed screw (2), remove the
pipe (1) and reapply the protective cap.
●● Refill the master cylinder tank (6) with fluid up to the
maximum level and tighten down the filler cap (3) and
seal (8).
●● We recommend that you drain and refill the
brake circuit after every brake pad change.
This will allow you to maintain optimum
braking performance.
●● To bleed your brake system more
rapidly, especially for a big fleet, we
recommend the priming system SODIKART
(Ref. OU951.002).
●● Store the used brake fluid in labelled
containers until it is collected by a specialist
waste disposal company.
●● The brake liquid doesn’t contain petrol, so
never pour the liquid into a using oil tank.
●● Brake fluid absorbs water Make sure the
replacement brake fluid comes from a
container that has been stored in good
conditions and is recent.
ff An 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.
ff Leaks in the brake system may lead to a
serious or even fatal injury.
ff Moisture in the brake fluid may cause
vapour lock and a sudden loss of braking
power, may lead to a serious or even fatal
injury.
ff Use brake fluid DOT 4 only.
14
owner’s manual
6.11 - Belt tension
Tension check
5 à 10 mm
2
1
Legend
1 Belt
2 Roller
●● Check that the drive belt is tightened, and in a good
state. It prevents mechanical damages
●● Tighten the belt (1) with the roller adjuster (2). It must
have 5 to 10mm allowance.
●● Check the tension daily. Incorrect tension
leads to premature wear.
●● Replace any damaged belt to eliminate the
risk of engine overspeed.
Belt tension adjustment
5 à 10 mm
3
5
4
1
2
Legend
1 Screw
2 Adjuster
3 Roller
4 Screw
5 Locknut
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RENTAL
●● Loosen but do not remove the screw (1) of the
tensioner using a spanner of the appropriate size.
●● Manually pull the tensioner (2) towards the rear of the
go-kart so that the tensioning roller (3) retightens the
belt.
●● Adjust the adjustment screw (4) to obtain 5 to 10mm
belt clearance.
●● Retighten the screw (1) of the adjuster (middle screw:
40 Nm). Check the belt clearance.
●● Control that the rubber stop of screw (4) is in contact
with the frame.
●● Retighten the locknut (5).
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owner’s manual
RENTAL
●● A poorly tightened belt is subject to
premature wear. Check its tension regularly.
●● An excessively tight belt causes engine and
chassis fatigue.
ff Change 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.
ff Check the tyre wear daily Worn or
damaged tyres may lead to a serious or
even fatal injury.
ff Never run with worn or damaged tyres:
a burst of tyre may lead to a serious or
even fatal injury.
ff Always blow up tyre with the pressure
recommended by the manufacturer.
ff Driving with cold tyres can lead to
skidding and may cause a serious or fatal
accident.
ff Too 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.
ff Store tyres in an appropriate area to
prevent fire hazard.
ff The transmission (including the rear
shaft) is a moving part that creates a
risk of serious or fatal accident if long
hair or clothing should become caught
in it. Make sure that the protections are
correctly secured and in a good state.
6.12 - Tyres
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1
6.13 - Safety harness
The harness option provides additional safety in the gokart in the event of an accident.
2
It is very important that safety systems is checked and
maintained regularly.
Legend
1 Wear indicator
2 Arrow (direction of rotation)
5
1
●● Check the tyre pressures:
Duro tyre
Front
1.5 to 1.7 bar
Rear
1.7 to 1.9 bar
●● 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 best performance inflate tyres according
to above mentioned pressures.
●● Excessive wear of a tyre may be caused by a
bad front wheel alignment.
●● Use tyres with a grip adapted to your track.
LR5_Owner_EN_00
4
2
1
2
3
2
Legend
1 Belt
2 Mounting points
3 Harness tongue
4 Buckle
5 Retractor
●● Check the straps (1) for frayed edges, broken fibres,
unravelled stitching, notches, and chemical damage,
as well as both surfaces of both straps to detect any
faults in them.
●● Check that the four mounting points (2) of the harness
are tight.
●● Check that the tongue of the harness (3) fits properly
into the buckle (4) and that it is held securely.
●● Push the buckle button to check that it unbinds the
tongue.
15
●● Check that the retractors (5) are operating properly:
-- Pull the strap and then release it to find out
whether it rolls up fully.
-- Yank the strap to check that it locks in the event
of a collision (take care not to cut yourself with the
edge of the belt when performing this test).
●● After an accident, check the condition of
the harness straps and the fasteners before
returning the go-kart to operation.
●● Before allowing the go-kart to depart,
always check that the driver and passenger
have secured their harnesses and that the
harnesses hold them onto their seats.
ff Modifying the harness system can cause
a serious, or even fatal, accident.
ff Cleaning the harness straps with
chemicals can affect their effectiveness
and cause a serious, or even fatal,
accident.
ff An unlocked harness can cause a
serious, or even fatal, accident.
6.14 - Chassis cleaning
●● Clean your chassis at least once a week.
●● Use only go-kart cleaner WD40 (ref. LU833.004).
●● Cleaning the go-kart with a pressure
washer can lead to fast deterioration of
certain go-kart components (e.g. stickers,
bearings, etc.).
●● After each cleaning, check that the go-kart
components are in good condition. Follow
the recommendations for use of your
device when washing your go-kart.
owner’s manual
7 - Troubleshooting
The go-kart will not brake
●● Is the brake pedal free?
●● Is the hydraulic brake pump container cap fully
tightened?
●● Is there enough brake fluid?
●● Are the hoses correctly connected?
●● Are the brake pads worn?
●● Is the calliper fully tightened on its support?
●● The displacement of the brake pedal is enough ?
The go-kart brakes continually
●● Is the brake fluid old?
●● Is the brake disk correctly centred in relation to brake
pads?
●● Is the calliper fully tightened on its support?
●● Is the brake pedal too tight?
●● Are the brake pads correctly assembled?
The go-kart is hard to turn
●● Are the stub axles tightened to torque specification?
●● Is the front axle unit checked?
The steering of the go-kart is not precise
●● Are the front wheels tightened?
●● Are the stub axles tightened to torque specification?
●● Are the column plastic supports tightened to torque
specification?
●● Are the tie rods correctly assembled and to torque
specification?
●● Is the front wheel axle unit adjustment checked?
The go-kart tends to go to the side
●●
●●
●●
●●
●●
Is the front wheel axle unit adjustment checked?
Are the tie rods correctly assembled?
Are the tie rods locking nuts securely tightened?
Is there a tie rod bent or broken?
Do the rear wheels have exactly the same
circumference?
●● Is the chassis twisted?
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RENTAL
The go-kart skids very much on bends
●● Are the tyres worn?
●● Are the tyres inflated to the recommended pressures?
●● Is the rear axle adjustment suited to the track
conditions?
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owner’s manual
RENTAL
8 - Declaration of conformity
This document can not be reproduced or released without the Sodikart authorization.
EC DECLARATION OF CONFORMITY
I, the undersigned,
Sodikart
declare that go-kart model:
SODI LR5
complies with the regulatory provisions of European directive 2006/42/CE.
The product was designed to satisfy the requirements of the following reference documents:
- The NFS52-002.
- The FFSA technical and safety rules for karting.
- The CIK-FIA recommendations for leisure karting.
Made at Couëron,
on 28-02-2014
on behalf of Sodikart,
Mister : Gilles BAGNARIOL
Job title : Technical director
Signature :
LR5_Owner_EN_00
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