Caterham Seven Owner's Handbook Manual
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Caterham Seven Owner's Handbook Manual

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OWNERS HANDBOOK

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Summary of Contents for Caterham Seven

  • Page 1 OWNERS HANDBOOK...

  • Page 2: Table Of Contents

    Contents Using this Handbook .............................. 7 1. Before taking to the road............................8 Explanation of Dashboard............................9 Speedometer ..............................9 Digital display within speedometer ......................... 9 Trip recorder reset button ..........................9 Tachometer ..............................9 Oil pressure gauge ............................9 Temperature gauge ............................
  • Page 3 Electrical ............................... 22 Manual transmission............................. 22 Recommended fluid specification ........................ 24 Track use ................................25 Enjoying track days and competing in your Caterham Seven..............25 Motorsport..............................25 Track days ..............................25 3. Maintenance ................................27 Regular checks: ............................34 Weekly checks: .............................
  • Page 4 Mirrors ................................42 Wiper blades ..............................42 Looking after the interior ..........................42 Laying your vehicle up for long periods ....................... 43 Travelling abroad ..............................43 4. In an emergency ..............................44 Emergency starting .............................. 44 Emergency towing ............................... 44 Towing for recovery ............................

  • Page 6: Using This Handbook

    This handbook has been divided into sections, each dealing with the different aspects of owning and caring for your Caterham Seven. You will find lots of useful and worthwhile advice and tips to help you get to know and look after your new car.

  • Page 7: Before Taking To The Road

    Before taking to the road Dashboard layout for models with standard instruments Note for 6 speed sequential: Arrows are for illustration only: Upwards arrow = Down shift 1 gear Downwards arrow = Up shift 1 gear Standard 5 Speed. Standard 6 Speed. Sequential 6 Speed.

  • Page 8: Explanation Of Dashboard

    Rear fog light Single position switch activates rear fog lights when dipped headlights are illuminated. (spring-loaded switch for Seven 170 & 270/275/280/310, operates when ignition is on and main or dip beam headlamps are illuminated. The rear fog light will automatically switch off if the ignition or headlamps are switched off.)

  • Page 9: Fuel Gauge

    ‘II’ and extinguishes soon after. The light will continue to illuminate for as long as the hand brake is applied. If it remains on when the hand brake is released, a fault with the brake fluid level is indicated. Seek qualified assistance from Caterham. Headlight main beam – Blue Illuminates when the headlights are switched to main beam.
  • Page 10 Dashboard layout for Seven 480/485 Controls Dipped / Side Lights Horn switch Main Beam switch Start switch Left indicator switch Fog light switch Speedometer Fan control switch Rev Counter Heated screen switch Sport Mode switch Handbrake indicator Wiper switch Oil pressure gauge...
  • Page 11 Dashboard Layout for Seven 620 Note: 620 Dashboard with steering wheel removed. Controls Fuel gauge Wiper Switch Temperature gauge Dipped beam / sidelights Oil pressure gauge Start Switch Fog light switch Indicator Switch Heated Screen switch Rev Counter Display Screen washer switch...

  • Page 12: Before You Drive Away

    On some models the pedals may be adjusted to • DO NOT allow a baby or infant to be carried on suit the driver. Please contact your Caterham the lap. The force of a crash can increase dealer or local agent for details, (Note: not all cars effective body weight by as much as 30 times, have this facility).

  • Page 13: Weather Equipment Assembly

    Seven. Erect the hoodsticks slacken the buckles to allow the front hoodsticks to collapse forwards To exit from the harness, the spring loaded buckle over the roll bar.

  • Page 14: Security

    Hood folding procedure Keep the key tag and spare key in a safe place – NOT IN THE CAR! If the key or tag is lost please contact Caterham to make arrangements for an additional set of keys and tags.

  • Page 15: Vehicle Battery Disconnection

    1) Disarm the system using an existing transponder tag attached to the ignition key. WARNING! 2) Switch the ignition on and off twice and then turn The tags contain delicate electronic circuits and the ignition back on, all within 7 seconds (the LED must be protected from impact and water damage, will flash rapidly).

  • Page 16: Starting The Engine

    Warming up SLOWLY (at risk of catalyst damage) to Caterham In the interest of fuel economy, it is advisable to for assistance.

  • Page 17: Vehicle Maintenance

    For this reason, it is vital that unqualified 5/6 speed and sequential gearbox persons do not tamper with the engine and that regular maintenance is carried out by Caterham, in accordance with the service interval plan included in this book.

  • Page 18: Fuel

    Fuel Compatibility Identification Before refuelling, check the symbol (where provided) adjacent to the filler cap, also shown All Caterham Seven models run on unleaded below, and compare them with the symbol shown on petrol, 95 RON (minimum). Higher performance the petrol pump (where provided) to ensure Caterham Sevens in our range require high octane compatibility.

  • Page 19: Useful Information

    2. Useful information Specifications...

  • Page 20: Technical Data

    Technical data Vehicle type 2 Seater, convertible sports car. Construction Tubular steel space frame. Aluminium panels with aluminium honeycomb cockpit side impact protection. GRP (Glass-reinforced plastic) or Carbon fibre nosecone and wings. Dimensions Wheelbase 2225 2225 2225 2305 2315 (mm) Front Track 1220 1270...

  • Page 21: Braking System (All Models Excluding 170)

    Braking system (All models excluding 170) Twin circuit, equal split front/rear, with system warning of low fluid level. Discs front and rear. Braking system (170 only) Twin circuit, equal split front/rear, with system warning of low fluid level. Front discs and rear drums. Parking brake This operates on the rear wheels and is actuated by hand lever on all models Front Suspension (Excluding CSR)
  • Page 22 245/40R15 Avon ZZS *All tyre pressures quoted are for cold condition Gearbox ratios 5 SPEED 6 SPEED 5 SPEED 6 SPEED All models SEQUENTIAL Seven 170 only All models (expect 170) Seven 620R 5.11 3.14 2.69 2.07 3.02 1.89 2.01 1.60...

  • Page 23: Recommended Fluid Specification

    Table 5: Fluid Capacities Fuel Tank S3 Chassis 36 L Gearbox 5 speed – 160/165 1.2 L Cooling System without heater – Fuel Tank SV & CSR Chassis 4.1 L 4.0 L 160/165 only Cooling System without heater – exc Oil (incl Filter) –...

  • Page 24: Track Use

    Avon ZZR tyres developed specifically for the will be a Caterham at every single day! The light car to deliver phenomenal performance. weight and race bred design means that the car...
  • Page 25 The oil will Whilst a Caterham is perfect for track use, there come up to temperature quickly. A maximum oil are a number of essential checks that should be temperature of 120C is recommended.

  • Page 26: Maintenance

    3. Maintenance In addition to the routine services and inspections described in this book, the following simple checks must be carried out more frequently. You can do this yourself and advice is given on the pages that follow. Under bonnet location –170 1. B rake fluid reservoir 4. W indscreen washer fluid (left hand drive)
  • Page 27 Figure 9: Under bonnet location – 275/280 1. Brake fluid reservoir 6. Windscreen washer fluid 2. Clutch fluid reservoir 7. Dip stick 3. Battery 8. Engine oil filler cap 4. ECU 9. Coolant filler cap (under nosecone) 5. Air box...
  • Page 28 Figure 10: Under bonnet location – 270/310 1. Brake fluid reservoir 6. Windscreen washer fluid 2. Clutch fluid reservoir 7. Dip stick 3. Battery 8. Engine oil filler cap 4. ECU (Located under battery) 9. Coolant filler cap 5. Air filter...
  • Page 29 Figure 11: Under bonnet location – 355 Brake fluid reservoir 6. Dip stick Clutch fluid reservoir 7. Windscreen washer fluid Battery 8. Coolant filler cap Air box 9. Engine oil filler cap...
  • Page 30 Figure 12: Under bonnet location – 360/420 1. Brake fluid reservoir 6. Air filter 2. Clutch fluid reservoir 7. Engine oil filler cap 3. Battery 8. Oil tank filler cap 4. Coolant filler cap 9. Oil catch tank cap (for dry sump systems) 5.
  • Page 31 Figure 13: Under bonnet location - 485 Brake fluid reservoir 6. Air filter Clutch fluid reservoir 7. Oil tank filter Battery 7. Oil tank filler cap Coolant filler cap 8. Oil filler cap 9. Washer bottle (located in boot as illustrated)
  • Page 32 Figure 14: Under bonnet location – 620 1. Brake fluid reservoir 6. Oil tank filler cap 2. Clutch fluid reservoir 7. Oil catch tank 3. Air filter 8. Oil filler cap 4. Coolant filler cap 9. Supercharger reservoir cap 5. ECU (under header tank) 10.

  • Page 33: Regular Checks

    NOTE: Any significant or sudden drop in fluid clothing, clear of all drive belts and pulleys • levels, or uneven tyre wear, should be reported to DO NOT touch exhaust or cooling system Caterham without delay. components until they are cool. • touch electrical...

  • Page 34: Poisonous Liquids

    Wash thoroughly after contact. Checking fluid levels Due to the nature of the Caterham Seven with its high revving engines and extreme cornering speeds it is vitally important that the correct engine oil level is maintained at all times.

  • Page 35: Engines With Dry Sump Tank - Except Csr 200 / 260

    To ensure that its anti-corrosion oil canister and too little may cause damage to the properties are retained, the anti-freeze content supercharger. should be checked by Caterham once a year. The coolant should be completely renewed every four years. WARNING! •...

  • Page 36: Brake/Clutch Fluid Check & Top-Up

    If there is any appreciable drop in level over a short period, consult Caterham. Topping-up Wipe the filler cap clean before removing to prevent dirt from entering the reservoir and then top-up the reservoir to the ‘MAX’...

  • Page 37: Washer Jets

    • the car’s electrical system. Replacement batteries During normal operation batteries emit can be purchased directly from Caterham or your explosive hydrogen gas – ensure sparks and local representative. naked lights are kept away from the engine compartment.

  • Page 38: Battery Disposal

    – you should seek advice Incorrect tyres can affect the stability and handling about disposal from a Caterham representative or characteristics of your car – only fit replacement your local authority. tyres that are identical to the original specification.

  • Page 39: Valve Caps

    Positioning the jack NOTE: Due to the minimal weight of the Caterham Position the jack under the jacking point (see Seven it is more prone to aquaplaning in wet illustrations). conditions. It is for this reason that we recommend Turning the jack screw by hand, raise the jack until tyres are changed at 2.5mm even though the legal...
  • Page 40 Replace the wheel and wheel nuts (tapered end towards the wheel) and tighten the nuts until the wheel is seated firmly against the hub. Lower the car by turning the jack handle anti- clockwise then remove the jack from under the car. Finally fully tighten the wheel nuts in a diagonal sequence.

  • Page 41: Cleaning And Car Care

    Cleaning and car care Body protection After washing, inspect the paintwork for damage. Treat paint chips and scratches with touch-up paint. If the damage has revealed bare metal, use a Washing your car coloured primer first, then apply the base coat and finish off with a lacquer pencil, if appropriate.

  • Page 42: Laying Your Vehicle Up For Long Periods

    More information on this can be found online by visiting https://www.gov.uk/driving-abroad Should your Caterham be laid up unused for more than 12 weeks at a time then we recommend the NOTE: There are certain items you are required to following precautionary measures be taken to avoid carry with you whilst travelling abroad.

  • Page 43: In An Emergency

    4. In an emergency Check that the cables are clear of the moving parts of both engines, then start the engine of the donor vehicle and allow it to idle for a few Emergency starting minutes. Now start the engine of the car with the discharged battery –...

  • Page 44: Fuses And Relays

    (or lower) rating. If a replacement fuse blows Relays almost immediately, this indicates a serious Ignition electrical problem and the circuit MUST be checked Lights by Caterham. Indicator Hazard Fuse colours Starter The fuses are colour coded to identify their...

  • Page 45: Fuses And Relays - 360/420/620

    G = R/H Side/Tail Light 7.5A I = Wash / Wipe H = L/H Side/Tail Light J = Power Socket I = Main Beam K = Horn 7.5A J = Dip Beam L = Flasher Unit – Fog / Dipped Beam K = Wipe/Wash M = Switch LED’s L = Horn...

  • Page 46: Parts & Accessories

    A comprehensive parts resource is available from pulling it straight out of its holder. Caterham Aftersales or via our online store at www.caterhamcars.com Indicators (front) Fitment of non-Caterham approved parts may Remove the two screws holding the lens in place.
  • Page 47 Torque Figures Torque Location Washers Front lower wishbone front Spring and plain Front lower wishbone rear Plain spacers Front upper wishbone front None Front upper wishbone rear None Front spring damper top Spring and plain Front spring damper bottom Loctite Upright top ball joint None Upright bottom fixing...
  • Page 48 Torque Figures continued Torque Location Washers Gearbox to bell-housing Spring under bolt head Gearbox mount Spring under bolt head Engine to bell-housing Spring under bolt head Bell-housing to sump None Starter motor Spring under bolt head LH engine mounting bracket Spring under bolt head RH engine mounting bracket Spring under bolt head...

  • Page 49: Servicing

    Caterham Cars Limited, 2–3 Kennet Road, Dartford, Kent, DA1 4QN /CaterhamCars @caterhamcars caterhamcarsltd © Caterham 2021 Content is subject to change without notice. Images are for illustrative purposes only. Printed in the UK. Service Book Edition 1.0 10/21...

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