Overview
This is the Level 1 post-event maintenance checklist for EK1 karts. It must be completed after every event.All tasks marked Standard must be completed before a kart is returned to service. Non-standard tasks should be reported and scheduled for resolution.
Demobilise
| Task | Duration (mins) | Standard |
|---|---|---|
| Remove transponders and return to charging case | 1 | ✓ |
| Remove ballast and return to storage box | 4 | ✓ |
| Remove all driver aids — seat foam and pedal extenders (where fitted, replace with standard pedals) | 2 | ✓ |
| Remove all circuit race numbers and return to allocated storage | 1 | ✓ |
| Fit factory magnetic identification numbers | 1 | ✓ |
| Remove all wheels, refit nuts and spacers to spindles hand tight | 8 | ✓ |
| Remove chain guard, check for damage and missing hardware | 1 | ✓ |
| Remove SevCon cover | 10 | ✓ |
Cleaning
| Task | Duration (mins) | Standard |
|---|---|---|
| Clean main chassis and crash bars utilising supplied materials | 2.5 | ✓ |
| Clean front spindles using abrasive pad, removing all surface rust | 2.5 | ✓ |
| Clean rear axle using abrasive pad, removing all surface rust and debris | 2.5 | ✓ |
| Clean steering components | 2.5 | ✓ |
| Clean all bodywork, removing tyre and abrasion marks | 5 | ✓ |
Bodywork
| Task | Duration (mins) | Standard |
|---|---|---|
| Check all bodywork for damage — holed items must be renewed, manipulate crushed items using blow-off gun to inflate back to form | 2 | ✓ |
| Time to resolve damage | 12 | |
| Check serviceability of company livery — burnt-through livery to be replaced with new, record usage | 2 | ✓ |
Livery Replacement Times
| Component | Duration (mins) |
|---|---|
| Nose cone | 8 |
| Left side pod | 5 |
| Right side pod | 5 |
| Nassau | 12 |
| SevCon cover | 5 |
| Motor cover | 3 |
Controls
| Task | Duration (mins) | Standard |
|---|---|---|
| Check both pedals for lateral and axial play | 2 | ✓ |
| Adjust both pedals for lateral and axial play, adjust as necessary using spacers | 15 | |
| Check linear return springs for presence, damage and integrity | 1 | ✓ |
Throttle System
| Task | Duration (mins) | Standard |
|---|---|---|
| Check throttle pedal components present and securing hardware tight | 1 | ✓ |
| Check correct routing of throttle position sensor loom, ensuring security against chassis at correct locations | 1 | ✓ |
| Check throttle actuation is smooth without resistance in movement | 2 | ✓ |
| Check throttle position sensor for damage and integrity, ensuring actuation mechanism hardware is present and tight | 2 | ✓ |
Rear Axle
| Task | Duration (mins) | Standard |
|---|---|---|
| Slacken 2x motor mount clamps from underside of chassis and remove drive chain | 6 | ✓ |
| Rotate axle by hand — check for axle trueness and condition of bearings following acceptable run-out guidelines | 5 | ✓ |
| Check brake disc for condition and wear, also disc centred within caliper — ensure clamping bolt is tight and key present | 1 | ✓ |
| Brake disc adjustment | 5 | |
| Check drive sprocket for wear | 2 | ✓ |
| Check drive sprocket — replace as necessary according to SOP | 5 | |
| Check condition of sprocket protector, ensuring all securing hardware present and tight | 1 | |
| Check pinion sprocket for wear | 2 | ✓ |
| Pinion sprocket wear — report and replace as necessary | 5 | |
| Check drive chain for wear, measure length against tool for excessive stretching | 2 | ✓ |
| Drive chain — report and replace as necessary | 2 | |
| Clean and lubricate drive chain | 1 | ✓ |
| Refit drive chain onto sprockets, align and tension using tool. Tighten motor and sprocket carrier to specified torque | 6 | ✓ |
| Check rear hubs for damage to main body and wheel studs, ensure both axle keys are present and correctly located | 2 | ✓ |
| Check and ensure rear hub spacing is correct, ensure hub clamping bolts tight | 3 | ✓ |
| Clean and refit chain guard | 3 | ✓ |
Braking System
| Task | Duration (mins) | Standard |
|---|---|---|
| Check brake pad thickness using tool | 1 | ✓ |
| Brake pad wear limit — report and replace if necessary | 12 | |
| Check brake pad air gap | 1 | ✓ |
| Brake pad air gap — adjust as necessary using caliper adjustment screws | 7 | |
| Check for damage, abrasion and correct routing of outer brake cables, ensuring they are secured against chassis at specified points | 2 | ✓ |
| Check inner cables are secured via clamps and sufficiently tightened, adjust cables obeying necessary free play | 2 | ✓ |
| Check brake actuation — ensure no sticking and freedom of movement | 1 | ✓ |
Front Axle
| Task | Duration (mins) | Standard |
|---|---|---|
| Check steering components for trueness including track rods, rod ends, steering column and front spindles | 6 | ✓ |
| Check rod ends for excessive play | 1 | ✓ |
| Check front spindle alignment using gauges for toe, camber and caster — adjust as necessary | 5 | ✓ |
| Ensure correct number of spacers present on front spindles | 1 | ✓ |
Chassis
| Task | Duration (mins) | Standard |
|---|---|---|
| Check underside of chassis for abrasion and flattening of tubing | 2 | ✓ |
| Check all welded outriggers, seat stays, yokes etc. for premature cracking and metal fatigue | 5 | ✓ |
| Check all underside battery and motor mounting clamps are tight and to specified torque | 2 | ✓ |
| Check front ballast post is tight, ensuring locking nut is present on underside of plate and ballast securing clip is fitted | 1 | ✓ |
| Check condition of seat for cracking and damage, ensuring seat bolts are tight | 2 | ✓ |
| Chassis stripped for internal jigging | 6 | ✓ |
| Chassis stripped for external jigging | 240 | |
| Chassis straightening in house | 60 |
Electrical
| Task | Duration (mins) | Standard |
|---|---|---|
| Check location, security and serviceability of charging plug and associated loom on seat, ensuring correct location and securement to chassis | 2 | ✓ |
| Check for correct routing of HC and LC looms, ensuring securing ties are present in specified locations | 3 | ✓ |
| Check for damage and abrasion to HC and LC looms | 1 | ✓ |
| Check contactor is secure, check contactor nuts and spade terminals are located correctly and tight | 1 | ✓ |
| Clean SevCon of all dirt, debris and oil | 3 | ✓ |
| Check all terminal screws are tight and HC loom configured correctly | 2 | ✓ |
| Refit SevCon cover | 10 | ✓ |
Wheels
| Task | Duration (mins) | Standard |
|---|---|---|
| Check all tyres for serviceability and wear | 3 | ✓ |
| Report and replace front tyres | 8 | |
| Report and replace rear tyres | 8 | |
| Check all rims for damage, chipping and cracking — report and replace | 2 | ✓ |
| Check condition of front wheel bearings — replace and report as necessary | 1 | ✓ |
| Inflate tyres, checking for leaks using soap and water via applicator gun where necessary | 3 | ✓ |
| Remount all 4 wheels in correct orientation to specified torque, ensuring front spindle spacer end float is maintained | 7 | ✓ |
Charge
| Task | Duration (mins) | Standard |
|---|---|---|
| Charge kart | 3 | ✓ |
Configuration
| Task | Duration (mins) | Standard |
|---|---|---|
| Return kart to power mode 3 | 5 | ✓ |
| Check throttle calibration — adjust where necessary | 5 | ✓ |
| Check and record charge of batteries | 1 | ✓ |