Why are my stub axles pointing at the sky?
It is likely that you have the stub axles fitted to the incorrect side, so they are effectively upside down and therefore at the incorrect angle. Taking them off and re-fitting them to the opposite side should correct this issue.
Top tip for getting the stub axle spacers into the gap
Often it is helpful to fit the kingpin bolt through the top frame hole so it very slightly protrudes through, line up the top set of spacers and the stub axle, and push the kingpin bolt halfway through to help hold the top section in place. Using the other hand, push the bottom set of spacers into place, then push the kingpin bolt the remainder of the way through.
If it is proving difficult to line up, you can use a tool such as an Allen key, inserted through the frame hole from below, to help line everything up. Once everything is lined up, you may need to gently tap the bolt through from above with a hammer or rubber mallet.
How can I better get to the nut at the bottom of the steering column?
You could use a 13mm ratchet and socket, or a spanner often referred to as a ring spanner that has offset ends, to help make tricky areas more accessible.
What if we are struggling to set the tracking?
Ensure both track rods and the four connecting nuts are loose. Use a piece of chalk to mark each front tyre with a line, ideally in the same place on both tyres — a piece of tape works for this too. Then, standing behind the kart, centre the steering wheel so it is pointing straight (regardless of the tyres' position at this point).
By hand, turn the track rods to adjust the position of each tyre so they look as though they are pointing forwards, checking the steering wheel position as you go in case it moves during track rod adjustment (you may need to reset it).
Once they are pointing straight, use a tape measure to measure across the front of the tyres to the marks you have made, and note the measurement. Then spin the tyres so the mark faces backwards, and measure again.
If the measurement is identical, your tracking is neutral, meaning the tyres are pointing perfectly straight, which is perfectly acceptable. Racing karts will usually have a small amount of toe out to help the kart turn into corners. To achieve this, adjust the track rods so the measurement on the front of the tyre is between 5–10mm larger than the measurement on the back of the tyre — this means the front tyres are pointing very slightly outwards, which creates toe out.
Which way up should the steering wheel be?
The steering wheel should be fitted so that one of the three spokes is pointing to the top of the steering wheel in a central position, with the other two pointing towards the bottom and to the sides of the kart. Adjusting the mounting position to the steering boss via the three bolts can help rotate the steering wheel into the desired position.
The pedals wiggle left to right — why? Is it ok?
The pedals need to be slightly loose, as tightening them completely up would prevent them from operating correctly. This will create some sideways movement, which is nothing to worry about. If it feels excessive, try tightening the bolts up slightly, while ensuring the pedal can still move freely.