"My son did say that he was having to turn the wheel more than he did on the old chassis which would suggest understeer to me but at the time, "
If he meant that it took a lot more force to turn the wheel and hold it, rather than needing to turn the wheel further, then it is probable that he has too much grip all round.
you can set the kart up so that it feels very solid in the corners, runs around on rails except for the tendency for the front to flick out as you accelerate out. In which case you need to widen the rear track and then adjust the balance until he can drive with minimal cornering loads.
The clue is given by the fact that you go so much faster on old tyres, with less grip.
If his forearms ache with the load after a few laps, the setup is wrong.
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