OWNERS HANDBOOK CONTENTS Introduction 1. Before Taking to the Road Page 4 Controls Standard instrumentation Explanation of dashboard Stack display with windscreen CSR Integral dash R500 Stack display operation 4 4 5 6 7 8 9 Before you drive away Pedal adjustment Seats and seat belts Harness Weather equipment Security Starting the engine Running-in Catalytic convertor Gearbox Fuel Braking system 10 10 10 10 11 12 14 14 14 15 15 16 2.
INTRODUCTION Congratulations on ownership of your new Caterham Seven sports car. Designed for racing and built for living, your Caterham Seven is competition-developed and capable of performance well in excess of your average super car. Please take the time to read this manual, get well acquainted with the controls and understand the maintenance requirements of your car. This will help you appreciate its capabilities to the full and allow you to derive maximum pleasure from ownership.
1. BEFORE TAKING TO THE ROAD Figure 1: Dashboard layout for models with standard instruments Figure 1a: Five or six speed gear shift patterns Controls 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 4 Brake fail indicator Hazard warning light switch Rear fog light switch Heated windscreen switch Heater fan switch Immobilizer warning light Windscreen washers switch Windscreen wipers switch Side lights/head lights switch Indicators switch Main beam switch 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.
EXPLANATION OF DASHBOARD Brake fail indicator Hazard warning light Rear fog light Heated windscreen Heater fan Windscreen washers Windscreen wipers Indicator switch Side/Head lights Main beam Headlamp flasher Heater valve control Starter push button Horn push button Single position spring loaded switch, illuminates to indicate low fluid level. Press to test bulb. Single position switch activates all indicators. Single position switch activates rear fog lights when dipped headlights are illuminated.
Figure 2: Dashboard layout for models with Stack Instruments and full windscreen Controls 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 6 Heated windscreen switch Brake fail indicator Hazard warning light switch Rear fog light switch Side/Head lights switch Heater fan switch Windscreen washers switch Windscreen wipers switch Stack button 1 Stack button 2 Stack button 4 Stack button 3 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.
Figure 3: Dashboard layout for CSR with Integral dash Controls 1. 2. 3. 4. 5. 6. 7. 8. 9. Air vent Oil pressure gauge Temperature gauge Heater fan control switch Fuel gauge Oil temperature gauge Indicators Side/Head lights Main beam Headlamp flasher Tachometer Speedometer 10. Immobilizer warning light 11. Windscreen wipers Wiper speed control 12. Windscreen washer switch 13. Gear lever 14. Heated screen switch 15. Horn Push button 16. Starter push button 17. Handbrake 18. Rear fog light switch 19.
Figure 4: Dashboard layout for R500 Controls 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Aero screen Heated screen switch Hazard warning light switch Windscreen washer switch Windscreen wipers switch Launch control push button Gear shift lights Stack display Stack button 3 Main beam switch 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Headlight main beam – BLUE Illuminates when the headlights are switched to main beam. Immobiliser Warning light - Red See section on Immobilisation. Stack Display System The Stack display system combines an analogue tachometer with a digital display for the following performance parameters: 1. 2. 3. 4. 5. 6. 7. 8. Vehicle speed Engine speed Oil pressure Oil temperature Water temperature Fuel level Battery Voltage Lap times (optional) available from aftersales.
Lap Times The lap time for each lap is recorded either by the infrared time sensor when passing an optional lap time beacon or when the driver presses button 4. The most recent lap time is held in screen 5. • • The stack display has an internal battery that needs to be changed every 4-5 years. When the power from this battery drops below a safe level, an alarm is triggered and the warning “Internal Battery Low" is displayed. Contact Caterham Aftersales when this occurs.
adjuster strap. A harness should feel tight when warn and not allow any movement of the torso. Although this feels restrictive at first, a driver will quickly get used to and ultimately prefer this feeling in a Seven. To exit from the harness, the spring loaded buckle is rotated 90deg Figure 5: 4-Point Harness Harness Adjustment Slide the tail strap web through the metal three bar slide to set up the perfect strap length.
Figure 7: Tensioning the hood Figure 8: Hood folding procedure vii) The tops of the sidescreens tuck under the flaps on the hood sides in order to make the hood watertight. At the rear, however, the sidescreens overlap the hood. Removal and storage To remove the hood slacken the buckles and remove in reverse to the above. (Vii to i) It is important that the hood is folded correctly when removed in order to avoid unsightly creases and to prevent the clear plastic windows being scratched.
WARNING! Your system will automatically re-arm within twenty seconds of disarming if you do not turn the ignition on. Programming new transponder tags If you require a new transponder tag for an additional user, or as a replacement through loss or damage, please contact Caterham Aftersales Department. Once you have received your new transponder tag, you will need to programme it. To do this you must have an existing transponder tag that already operates the system.
Starting the engine Running-In WARNING! Before starting the engine ENSURE you are familiar with the procedures below. Catalytic converters are easily damaged through improper use, particularly if the wrong fuel is used or if an engine misfire occurs – before starting the engine you should be aware of the precautions detailed in the ‘Catalytic converter’ section.
Switching off: DO NOT switch off the engine whilst the car is in motion, with a forward or reverse drive gear selected. Vehicle maintenance: Any engine misfire, loss of engine performance or engine run-on, could seriously damage the catalytic converter. For this reason, it is vital that unqualified persons do not tamper with the engine and that regular maintenance is carried out by Caterham Cars, in accordance with the service interval plan included in this book.
WARNING! DO NOT fully fill the tank if the car is to be parked on a slope in direct sunlight or high ambient temperature – expansion of the fuel could cause spillage. Filling difficulties The fuel delivery rate of filling station pumps can vary significantly from one garage forecourt to another.
10.8:1 9.7:1 Solid 16v DOHC 94.0mm 87.5mm 2261cc 4 cyl-in-line Duratec 200 12.0:1 Solid 16v DOHC 94.0mm 87.5mm 2261cc 4 cyl-in-line Duratec 260 11.75:1 Solid 16v DOHC 83.1mm 87.
Technical data Kerb Weights Vehicle Type 2 Seater, convertible sports car. Classic 540 Roadsport 550 850 SV 575 875 R400 515 815 R500 506 806 CSR 575 875 CSR Superlight 550 850 Min Weight Construction Tubular steel space frame. Aluminium panels with aluminium honeycomb cockpit side impact protection. GRP (Glass-reinforced plastic) or Carbon fibre nosecone and wings.
Wheels – Tyres -- Pressure TYRE PRESSURE TYRE WHEELS FRONT REAR 18 -- Front Avon 175/55 R13 CR500 Front 6J x 13” alloy -- 18 Rear Avon 205/55 R13 CR500 Rear 8J x 13” alloy 20 20 Avon 185/60 R 14 Avon ZV3 18 18 Avon 195/45 R 15 Avon CR500 6.5J x 15" alloy 24 -- Front Avon 195/45 R15 CR500 Front 6.
TRACK USE ENJOYING TRACK DAYS & COMPETING IN YOUR CATERHAM SEVEN Due to the difficulty - and illegality - of using the Caterham Seven’s full performance on the public roads, many owners choose to use their cars in competition events, such as circuit racing, sprints and hill climbs, as well as non-competitive track days. MOTORSPORT As an introduction to Motorsport, Caterham Cars introduced the Academy series in 1995; a race series exclusively for novice drivers in identical Caterham machinery.
Honeycomb fuel tank or bag tank Honeycomb floor impact protection panels Rear wheel protection bar Bespoke seat All these parts, along with advice, are available from the Caterham Parts Department and Caterham online store. Whilst a Caterham is perfect for track use, there are a number of essential checks that should be made to ensure that your day passes smoothly Wheel nuts - must be torqued to the correct setting (see Technical Data). Check after every session.
Figure 10a: Underbonnet location – EU4 Sigma 120 1. Brake Fluid Reservoir 2. Clutch Fluid Reservoir 3. Battery 4. ECU 5. Air Box 22 6. Windscreen Washer Fluid 7. Dip stick 8. Engine Oil Filler Cap 9.
Figure 10b: Under bonnet location - Sigma 125 1. Brake Fluid Reservoir 2. Clutch Fluid Reservoir 3. Battery 4. MAP 5. ECU 6. Air Filter 7. Windscreen Washer Fluid 8. Dip Stick 9. Engine Oil Filler Cap 10.
Figure 10c: Underbonnet location - Sigma 150 1. Brake Fluid Reservoir 2. Clutch Fluid Reservoir 3. Battery 4. MAP 5. ECU 24 6. Air Filter 7. Windscreen Washer Fluid 8. Dip Stick 9. Engine Oil Filler Cap 10.
Figure 10d: Underbonnet location – Duratec 210 (R400) 1. Brake Fluid Reservoir 2. Clutch Fluid Reservoir 3. Battery 4. MFU 5. Air filter 6. Windscreen Washer Fluid 7. ECU 8. Dip Stick 9. Engine Oil Filler Cap 10. Coolant Filler Cap NOTE: Under bonnet location for R400 with dry sump is similar as standard R400 apart from oil tank located near coolant tank and oil cooler in front of the radiator.
Figure 10e: Underbonnet location – EU4 Duratec 200 (CSR) 1. Brake Fluid Reservoir 2. Clutch Fluid Reservoir 3. Battery 4. Air box 5. Dip stick 6. Windscreen Washer Fluid 7. Brake fluid Reservoir 8. Coolant Filler Cap 9.
Figure 10f: Underbonnet location - Duratec 260 (CSR) 1. Brake Fluid Reservoir 2. Clutch Fluid Reservoir 3. Battery 4. ECU 5. MFU 6. Dip Stick 7. Coolant Filler Cap 8. Breather Bottle 9. Windscreen Washer Fluid 10. Air Filter 11.
Figure 10g: Underbonnet location – Duratec 263 (R500) 1. Brake Fluid Reservoir 2. Clutch Fluid Reservoir 3. Coolant Filler Cap 4. ECU 5. Battery 6. Air Filter 7. Dry Sump Tank 8. Engine Oil Filler Cap 9.
Regular checks: Operation of lights, horn, direction indicators, wipers, washers and warning lights. Operation of seat belts and brakes. Look for fluid deposits on the floor beneath the car, which may indicate a fluid leak. Weekly checks: Engine oil level. Cooling system level. Condition and pressure of tyres. Brake fluid levels. Clutch fluid levels. Screen washer reservoir level.
Poisonous liquids Most liquids used in motor vehicles are poisonous and should not be consumed or brought into contact with open wounds (these substances include; battery acid, anti-freeze, brake fluid, petrol, oil and windscreen washer additives). Obey all instructions printed on labels and containers! Used engine oil Prolonged contact with engine oil may cause serious skin disorders, including dermatitis and cancer of the skin. Wash thoroughly after contact.
The oil should be at the maximum level at all times. (As a guide the difference between min and max is approximately 1/2 litre). If oil is required it should be added via the oil filler cap on the top of the engine and must be of the correct specification for your engine type. (See technical data). It is advisable to add a small amount at a time and recheck by repeating above procedures until the correct level is achieved. Care should be taken not to overfill the engine with oil.
Figure 16: Brake Fluid reservoir Brake/Clutch fluid must be completely replaced every after two years regardless of mileage. Brake/Clutch fluid is inflammable; do not allow fluid to come into contact with hot components or naked flames. Wipers & Washers Windscreen washers Check the reservoir level at least every week and topup with a mixture of water and Comma screenwash. WARNING! Screenwash is flammable, particularly if high or undiluted concentrations are exposed to sparks.
On clothing or the skin – remove any contaminated clothing immediately, flush the skin with large amounts of water, and seek medical attention urgently. In the eyes – flush with clean water immediately for at least 15 minutes. Seek medical attention urgently. Swallowing battery acid can be fatal unless IMMEDIATE action is taken – seek medical attention urgently.
Wheels & Tyres WARNING! DEFECTIVE TYRES ARE DANGEROUS! DO NOT drive your car if any tyre is excessively worn or damaged, or is inflated to an incorrect pressure. Incorrect tyres can affect the stability and handling characteristics of your car – only fit replacement tyres that are identical to the original specification. Caring for your tyres Always drive with consideration for the condition of the tyres, and frequently inspect the tread and side walls for any sign of distortion (bulges), cuts or wear.
Figure 19: Front jacking point Figure 20: Rear jacking point Whenever refitting the wheel nuts it is imperative that they are tightened to the correct torque. Check wheel nut torque as soon as possible. WARNING! Always observe the following precautions! Choose a safe place to stop, away from the main thoroughfare, and ensure your passenger gets out of the car and waits in a safe area, away from other traffic. Switch on the hazard warning lights to alert other road users.
WARNING! Some high pressure cleaning systems available on garage forecourts are sufficiently powerful to damage fragile components. Never aim the water jet directly at components that might easily be damaged. Removing tar spots Use a tar removal product such as Auto Glym intensive tar remover to remove tar spots and stubborn grease stains from paintwork. Then wash immediately with soapy water, to remove all traces of the spirit. Body protection After washing, inspect the paintwork for damage.
Travelling abroad In certain countries, it is illegal to fit parts which have not been made to the vehicle manufacturer’s specification. Owners should ensure that any parts or accessories fitted to the car while travelling abroad will also conform to the legal requirements of their home country. NOTE: There are certain items you are required to carry with you whilst travelling abroad. Please consult your motoring organisation for the latest requirements. 4.
Emergency towing Fuses - Sigma Both the front and rear towing eyes are intended for use ONLY by the emergency services, or qualified vehicle recovery specialists, to assist in the recovery of your car should a breakdown or accident occur. DO NOT use the lashing eyes to tow your car behind another vehicle. DO NOT using the lashing eyes for towing another vehicle.
Figure 22: Fuse box and relay location WARNING! It is extremely hazardous to fit parts or accessories where installation requires the dismantling of, or addition to, either the electrical or fuel systems. Fitting parts or accessories that have not been approved by Caterham, or the carrying out of non-approved alterations or conversions, may be dangerous and could affect the safety of the car and occupants, and also invalidate the terms and conditions of the car’s warranty.
7. Number plate lamp The number plate lamp contains two bulbs which can be removed and refitted by pushing and turning through 45°. To gain access to the bulbs the black cover must be removed, this is held in place by a single screw in the centre of the cover.
SERVICE SCHEDULES Service Interval Annually or every 6,000 miles if sooner Roadsport & Superlight All Ford Sigma & Duratec Engine Variants New Car First Second First Service Annual Annual 3 Months 12 Months 24 Months (or 1000) (or 6000) Engine oil Check and top up (# check level before changing oil) # Engine oil Drain and replace Engine oil filter Replace Differential oil level Check and top up Gearbox oil level Check and top up Screen washer fluid level Check and top up
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SERVICE RECORD continued 44
CAMBELT REPLACEMENT FACTORY UPGRADE RECORD 45
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