Caterham SEVEN Owner's Handbook Manual
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Summary of Contents for Caterham SEVEN
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Page 3: Table Of Contents
Contents Contents ..................................1 Table of figures ................................4 Table of tables ................................5 Using this Handbook .............................. 6 1. Before taking to the road ............................7 Explanation of Dashboard............................8 Speedometer ..............................8 Digital display within speedometer ......................... 8 Trip recorder reset button .......................... - Page 4 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 5 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 ............................
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Page 6: Table Of Figures
Figure 1: Dashboard layout for models with standard instruments Figure 2: Dashboard layout for CSR with Integral dash Figure 3: Dashboard layout for Seven 485/ Superlight R400 (Reverse for RHD) Figure 4: Dashboard Layout for Seven 620 R Figure 5: 4-point and 6-point harness... -
Page 7: Table Of Tables
Table 3: Kerb weights Table 4: Wheels - Tyres – Pressures Table 5: Gearbox ratios Table 6: Final Drive Ratio: Table 7: Fluid capacities Table 8: Bulb replacement part numbers from Caterham Table 9: Torque Figures Table 10: Torque Figures continued... -
Page 8: Using This Handbook
This handbook has been divided into sections, each dealing with the different aspects of owning and caring for your Caterham. You will find lots of useful and worthwhile advice and tips to help you get to know and look after your new car. -
Page 9: Before Taking To The Road
Before taking to the road Figure 1: 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. -
Page 10: Explanation Of Dashboard
Single position switch activates rear fog lights when dipped headlights are illuminated. (spring loaded switch for Seven 160/165, 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 11: 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 12: Figure 2: Dashboard Layout For Csr With Integral Dash
Figure 2: Dashboard layout for CSR with Integral dash Controls Air vent 10. Immobilizer warning light Oil pressure gauge 11. Windscreen wipers Temperature gauge Wiper speed control Heater fan control switch 12. Windscreen washer switch Fuel gauge 13. Gear lever Oil temperature gauge (CSR 260 14. -
Page 13: Figure 3: Dashboard Layout For Seven 485/ Superlight R400 (Reverse For Rhd)
Figure 3: Dashboard layout for Seven 485/ Superlight R400 (Reverse for RHD) 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... -
Page 14: Figure 4: Dashboard Layout For Seven 620 R
Figure 4: Dashboard Layout for Seven 620 R Note: 620 R 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... -
Page 15: 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 16: 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 17: Security
WARNING! 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. Immobilisation Most Caterhams are fitted with an immobiliser as standard. -
Page 18: Vehicle Battery Disconnection
However, the consumption in the armed state is additional user, or as a replacement through loss or such that it should not adversely affect your car damage, please contact Caterham. battery. Once you have received your new transponder tag, WARNING! you will need to programme it. -
Page 19: Starting The Engine
Warming up the car lacks power while driving, it may be driven In the interest of fuel economy, it is advisable to SLOWLY (at risk of catalyst damage) to Caterham drive the car soon after starting, remembering that for assistance. -
Page 20: Vehicle Maintenance
For this reason, it is vital that unqualified Figure 8: 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 21: Fuel
Brake pads Brake pads and linings require a period of bedding in. For the first 500 miles, avoid situations where All Caterham Seven models run on unleaded heavy braking is required. petrol. 95 RON (minimum). Higher performance Remember that regular servicing is vital to ensure... -
Page 22: Useful Information
2. Useful information Table 1: Specifications... -
Page 23: 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. Table 2: Dimensions Wheelbase 2225 2225 2225 2225 2225 2305 2315... -
Page 24: Braking System (All Models Excluding 160 / 165)
Table 3: Kerb weights Min Weight Max Weight Seven 160/165 Roadsport Supersport/R Superlight R400 Seven 485 Seven 620 Braking system (All models excluding 160 / 165) Twin circuit, equal split front/rear, with system warning of low fluid level. Discs front and rear. -
Page 25: Table 4: Wheels - Tyres - Pressures
Table 4: Wheels - Tyres – Pressures TYRE SPEED PRESSURE* TYRE RATING WHEELS (MPH) FRONT REAR 4.5J x 14” steel Avon ZT5 155/65R14 T (118) 6J x 13” alloy Avon 175/55 R13 CR500 V (149) Front 8J x 13” alloy Avon 205/55 R13 CR500 V (149) Rear... -
Page 26: Recommended Fluid Specification
Table 7: Fluid capacities Gearbox 5/6 speed Std/Seq – Fuel Tank STD S3 36 L 1.9 L Sigma/Duratec Fuel Tank STD SV/CSR 41 L Gearbox 5 speed - K6A 1.2 L Cooling System without heater – K6A EU4 175 Fuel Tank S3 30 L 4.0 L Cooling System without heater –... -
Page 27: Track Use
If you would like to partake in a track or experience modifications to the same Academy vehicle. The day in a Caterham other than you own then we Championships have been designed to promote have just the solution. We offer a factory Caterham close and cost-effective racing by virtue of the strict Experience which operates from Silverstone. - Page 28 Therefore, if your car isn’t fitted with an oil temperature gauge, we would recommend Whilst a Caterham is perfect for track use, there are building up the maximum revs used cautiously for a number of essential checks that should be made the first few laps of use.
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Page 29: 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. Figure 9: Under bonnet location – EU5 K6A Brake fluid reservoir 5. -
Page 30: Figure 10: Under Bonnet Location - Eu4 Sigma 120
Figure 10: Under bonnet location – EU4 Sigma 120 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 5. Air box... -
Page 31: Figure 11: Under Bonnet Location - Sigma 125 / 140
Figure 11: Under bonnet location - Sigma 125 / 140 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. -
Page 32: Figure 12: Under Bonnet Location - Duratec 175
Figure 12: Under bonnet location – Duratec 175 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 33: Figure 13: Under Bonnet Location - Duratec 180 / 210
Figure 13: Under bonnet location – Duratec 180 / 210 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 34: Figure 14: Under Bonnet Location - Duratec 237
Figure 14: Under bonnet location - Duratec 237 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 35: Figure 15: Under Bonnet Location - Duratec 310
Figure 15: Under bonnet location – Duratec 310 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. -
Page 36: Regular Checks
NOTE: Any significant or sudden drop in fluid DO NOT touch exhaust or cooling system levels, or uneven tyre wear, should be reported to components until they are cool. Caterham without delay. touch electrical leads components with the ignition switch turned... -
Page 37: 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 38: Engines With Dry Sump Tank - Except Csr 200 / 260
Caterham once a year. The back into the engine and a false reading will be coolant should be completely renewed every four obtained. -
Page 39: Brake/Clutch Fluid Check & Top-Up
Fluid level in the brake/clutch reservoir may fall slightly during normal use, but should not drop below the lower level mark. If there is any appreciable drop in level over a short period, consult Caterham. Topping-up WARNING! Wipe the filler cap clean before removing to prevent ... -
Page 40: Washer Jets
Swallowing battery acid can be fatal unless which could cause a fire hazard when connected to IMMEDIATE action is taken – seek medical the car’s electrical system. Replacement batteries attention urgently. can be purchased directly from Caterham or your During normal operation... -
Page 41: Battery Disposal
– you should seek advice pressure. 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 42: Valve Caps
NOTE: Due to the minimal weight of the Caterham Turning the jack screw by hand, raise the jack until it is more prone to aquaplaning in wet conditions. It the centre of the jack platform fits snugly up to the is for this reason that we recommend tyres are jacking point. - Page 43 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. WARNING! Always check the tyre pressures before driving off or as soon afterwards as possible. ...
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Page 44: Cleaning And Car Care
Regularly clean the windscreen, inside and out, various areas of your Caterham to help keep it in using Autoglym ‘Fast Glass’ or an approved glass excellent condition. These videos are available to view on the ‘Owners’... -
Page 45: 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 46: 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 minutes. Now start the engine of the car with the Emergency starting discharged battery –... -
Page 47: Fuses And Relays
12 = EMS Ignition Supplies (critical) 13 = Flasher Unit Fuses and relays 14 = Diagnostic Connector 15 = Side Lamps & Rear Fog Light 7.5A 16 = Immobiliser 7.5A The fuse box is located under the dashboard on the 17 = EMS ECU Power vertical face of the engine bulkhead (see illustration 18 = Spare... -
Page 48: Fuses And Relays - Duratec
R = Keyless Immobilizer almost immediately, this indicates a serious Note: * 620R uses 30A electrical problem and the circuit MUST be checked Fuses and relays - Duratec EU4 175 / 237 by Caterham. Duratec EU4 175 / 237 Fuse colours Relays Starter... -
Page 49: Parts & Accessories
A comprehensive parts resource is available from and pull free to enable bulb changing. The side Caterham Aftersales or via our online store at lamp bulb is a capless bulb and can be removed by www.caterhamcars.com pulling it straight out of its holder. -
Page 50: Table 9: Torque Figures
Table 9: Torque Figures Torque Location Washers Front lower wishbone front Spring and plain Front lower wishbone rear Plain spacers Front upper wishbone front Front upper wishbone rear Front spring damper top Spring and plain Front spring damper bottom Loctite Upright top ball joint Upright bottom fixing Spacer (widetrack only) -
Page 51: Table 10: Torque Figures Continued
Table 10: 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 Starter motor Spring under bolt head LH engine mounting bracket Spring under bolt head RH engine mounting bracket Spring under bolt head... -
Page 52: Servicing
Caterham parts which can be easily obtained through any Caterham approved service centre. All Caterham genuine parts are identical to those first fitted to your vehicle and therefore specifically designed to work with your Seven guaranteeing a continuation of performance, fuel efficacy and therefore delivering optimum driving pleasure. Additionally, having the servicing schedule carried out by a qualified Caterham technician will ensure these parts are replaced using the best techniques and to the highest standards. -
Page 53: Service Schedules - K6A Suzuki Engine Variants
Service schedules - K6A Suzuki Engine Variants Service Interval Caterham Seven 160 New Car First Six Month Annual Annually or every Suzuki K6A Suzuki engine variants Service Service Service 6,000 miles if sooner (Oil 3 Months 6 Months 12 Months... -
Page 54: Service Schedules - Ford Sigma 125/140 & Duratec 175/180/210 Engine Variants
Service schedules - Ford Sigma 125/140 & Duratec 175/180/210 Engine Variants Service Interval Roadsport, Supersport, Supersport (R) and R400 New Car First Second First Annual Annually or every 6,000 Service Annual miles if sooner For listed Sigma Engines and Duratec variants 3 Months 12 Months 24 Months... -
Page 55: Service Schedules - Duratec 237 Only
Service schedules – Duratec 237 only Service Interval Duratec 237 ( Seven 485) New Car First Second First Annual Annually or every 6,000 Service Annual miles if sooner For Duratec 237 Engine Variant 3 Months 12 Months 24 Months (or 1000) -
Page 56: Service Schedules - Duratec 310 Only
Service schedules – Duratec 310 only New Car Interim First Second Service Interval First Service Service Annual Annual Duratec 310 (Seven 620R) Annually or every 6,000 miles if 3 Months 12 Months 24 Months For Duratec Supercharged 310 sooner months (or 1000) (or 6000) 3000) 12,000) ... -
Page 57: Service Record
Service record... - Page 58 Service record continued...
- Page 59 Service record continued...
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Page 60: Cambelt Replacement
Cambelt replacement FACTORY UPGRADE RECORD... -
Page 61: Factory Upgrade Record
Factory upgrade record...
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