Kart Maintenance: Safety and Performance
Kart maintenance is not just mechanics: it is safety. An unchecked brake, a tyre at the wrong pressure or a loose nut can turn a session into a problem. You do not need to be an expert mechanic to maintain a kart properly: you need method and regularity.
TKS RaceLab has condensed years of trackside work into a series of practical guides covering the essential checks every karter should know.
In short Before every session, check tyre pressures (cold, with a kart gauge), brake pads, brake fluid level, wheel nut tightness, chain and axle grub screws. Replace the pads when 2-3 mm of material is left, and always bleed the brakes afterwards.
Kart brakes: checking and replacing pads
A kart's braking system is simple but needs constant attention. Pads wear quickly, especially in intense sessions or with driving styles that load the rear brake heavily. A visual check before every session takes less than a minute.
When the pads are down to 2-3 mm of friction material, it is time to replace them. The procedure is within anyone's reach, but it includes a mandatory step that many people skip: bleeding the brake circuit after every pad change. Without bleeding, air in the circuit makes the pedal spongy and braking unpredictable.
Mojo D5 tyres: pressures, warm-up and wear management
Mojo D5 tyres are the official tyre of the Rotax MAX Challenge for Senior MAX and DD2. They are not a generic tyre: they have specific characteristics that need careful management. The correct pressure is 0.60 bar (±0.05), measured cold with a kart-specific gauge such as the Alfano TJR2. A car tyre gauge is not precise enough.
Mojo D5 tyres still perform well beyond 80 laps; after that grip drops, but they can be used up to about 150 laps. Driving style has a big effect: harsh braking and wheelspin wear the compound faster.
Kart maintenance checklist: pre-session checks you must not skip
Before every track session, in 5 minutes:
1. Tyre pressure: check with a dedicated gauge, cold, before going on track
2. Brake pads: visual check from the side of the caliper
3. Brake fluid level: the reservoir must be above the minimum
4. Wheel nuts: check all 4 nuts by hand
5. Chain: correct tension, not too tight and not too slack
6. Axle grub screws: none must be loose
7. Steering wheel: the locking ring must be fully tightened
Articles in the Maintenance series
Frequently asked questions
How often should kart brake pads be checked?
Before every track session: it is one of the essential safety checks. The visual check takes less than a minute: look at the caliper from the side and check the thickness of the friction material. It is part of the pre-session checklist in TKS RaceLab Arrive & Drive Pro.
What is the correct pressure for Mojo D5 tyres?
0.60 bar (±0.05), measured cold before going on track. It must be measured with a kart-specific gauge with 0.01 bar resolution, such as the Alfano TJR2. For the D2XX on the Junior MAX the cold reference is 0.65 bar (±0.05). Car gauges are not precise enough to detect differences of 0.02-0.03 bar that you can clearly feel on track.
What happens if you do not bleed the brakes after changing the pads?
Pushing back the pistons to make room for new pads can let air into the hydraulic circuit. Compressible air makes the pedal spongy: the first braking can catch the driver out. Bleeding is mandatory after every pad change: it is not optional.
How many laps do Mojo D5 tyres last?
It depends a lot on the driver: they usually still perform well beyond 80 laps, then the surface compound wears and grip drops, but they can be used up to about 150 laps. Driving style has a big effect: harsh braking and wheelspin on exit shorten tyre life.
Want to learn maintenance and setup directly at the track? With our Arrive & Drive programme you get the kart, the track and technical support from the TKS RaceLab team at Lonato, Franciacorta, Cremona and Ala. → Discover Arrive & Drive →
Conclusion
Maintenance is the foundation everything else is built on. Setup, driving and preparation are of little use if the kart is not in good condition. With method and regularity, the essential checks take only a few minutes and make the difference between a trouble-free session and one that ends in the pits because of avoidable problems.
Questions about this topic?
Message us on WhatsApp: we reply personally, with the experience of people who live at the track. And if you want to drive a real racing kart, with Arrive & Drive you jump into one of ours, ready to go on track. Need the right spare part? You will find it in the shop.
TKS RaceLab | Performance Engineering Karting | tksracelab.com
Read also: Kart axles: complete guide → · REVOLUTION electric kart trolley and paddock equipment → · Rotax MAX EVO: classes and how to choose →
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Author: Sergio, TKS RaceLab | Published: 12 June 2026 | Updated: 4 October 2026
TKS RaceLab is the Italian online store dedicated to karting: spare parts, accessories and everything you need to get on track. With Arrive & Drive you arrive at South Garda Karting (Lonato), Franciacorta, Cremona or Ala and find your kart ready to go. No hassle, just driving.
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