Sodi Sigma DD2 User Manual

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MAN.SIG.EN.02
04/2014
3
USE SPARE PARTS OF SODI ORIGIN
User maintenance guide
Table of contents
1 - Safety instructions ............................4
1.1 - Recap of all warnings included in this
manual
........................................................ 5
2 - Reception ...........................................6
2.1 - Tooling for assembly and adjustment .......... 7
2.2 - Maintenance products
.................................. 7
3 - Assembly ...........................................8
3.1 - Precautions and recommendations .............. 8
3.2 - Assembly of the steering column and
steering wheel
............................................. 8
3.3 - Positioning of the safety brake cable.......... 10
3.4 - Frame stabilizers
........................................ 10
3.5 - Assembly of the fuel tank and of the
overow bottle
........................................... 10
3.6 - Assembly of the seat
.................................. 11
3.7 - Assembly of the seat stiffeners
................... 12
3.8 - Assembly of the bodywork.......................... 13
3.9 - Mounting the rear protections..................... 15
3.10 - Mounting the rear protections DD2
.......... 15
3.11 - Mounting the front brake hose (optional)
.. 16
4 - Commissioning ...............................17
4.1 - Safety instructions to the pilots................... 17
4.2 - Pilot protection............................................ 17
5 - Adjustments .....................................18
5.1 - Standard adjustments ................................ 18
5.2 - Adjustment of front wheels
......................... 20
5.2.1 - Adjustment of front tracking width .......... 20
5.2.2 - Adjustment of front wheel height
............ 20
5.2.3 - Adjustment of the caster
......................... 21
5.2.4 - Adjustment of the camber
...................... 22
5.2.5 - Front wheel alignment
............................ 23
5.2.6 - Adjustment of tie rods
............................. 23
5.3 - Adjustment of rear wheels .......................... 24
5.3.1 - Adjustment of hubs ................................. 24
5.3.2 - Position of rear axle
............................... 24
5.3.3 - Type of axle
............................................ 24
5.4 - Adjustment of seat ...................................... 25
5.5 - Adjustment of the brake distributor
............. 25
5.5.1 - Standard adjustment .............................. 25
5.5.2 - More braking power on the front brakes
25
5.5.3 - More braking power on the rear brakes
. 25
6 - Maintenance.....................................26
6.1 - Brakes ........................................................ 26
6.1.1 - Fluids and lubricants .............................. 26
6.1.2 - Frequency of cleaning and maintenance
26
6.1.3 - Replacing brake pads on the D18
4-piston calipers (front)
.......................... 27
6.1.4 - Replacing brake pads on the D24
4-piston calipers (rear)
........................... 27
6.1.5 - Adjusting the gap between the pads
and the disc
............................................ 28
6.1.6 - Replacing the brake hose
...................... 28
6.1.7 - Bleeding the front brake circuit............... 28
6.1.8 - Bleeding the rear brake circuit
............... 30
6.1.9 - Bleeding the steering wheel
controlled front brake circuit
................... 31
6.1.10 - Replacing rear calliper seals / 4
piston caliper pistons D18 (front)
........... 32
6.1.11 - Replacing rear calliper seals / 4
piston caliper pistons D24 (rear)
............ 33
6.1.12 - Replacing master cylinder seals
and pistons
............................................. 35
6.1.13 - Replacing the front master cylinder
pistons
.................................................... 37
6.1.14 - Cleaning
............................................... 37
6.2 - Tyres ........................................................... 38
6.2.1 - Tyres change .......................................... 38
6.2.2 - Table of the recommended tyre
pressures
............................................... 39
6.3 - Cleaning the chassis .................................. 40
6.4 - Maintenance summary
............................... 40
6.4.1 - Bolting .................................................... 40
6.4.2 - Steering
.................................................. 40
6.4.3 - Bodywork parts
...................................... 40
6.4.4 - Tyres
...................................................... 40
6.4.5 - Braking
................................................... 40
7 - Trouble shooting .............................41
7.1 - The kart will not brake ................................ 41
7.2 - The kart brakes continually
........................ 41
7.3 - The kart is hard to turn
............................... 41
7.4 - The steering of the kart is not precise
........ 41
7.5 - The kart tends to go to the side
.................. 41
7.6 - The kart skids very much on bends
............ 41
8 - Index .................................................42
9 - Homologation
..................................45
9.1 - SIGMA S3................................................... 45
9.2 - SIGMA KZ
.................................................. 46
9.3 - SIGMA DD2
................................................ 47

Sodi Sigma DD2 Specifications

General

Brand	Sodi
Model	Sigma DD2
Category	Utility Vehicle
Language	English