Page 1: Table Of Contents
OWNERS HANDBOOK CONTENTS Introduction Page 1. Before Taking to the Road 3. Maintenance Controls Owner maintenance Standard instrumentation Under bonnet location Explanation of dashboard EU4 Sigma 120 Stack display with windscreen Sigma 125 CSR Integral dash Sigma 150 R500 Duratec 210 (R400) Stack display operation EU4 Duratec 200 (CSR) Duratec 260 (CSR)
Page 3 As a high performance car, it is likely that your Caterham will be subjected to the stresses and strains of enthusiastic driving, particularly on the track. Therefore it is essential that the maintenance programme of regular servicing and checks contained in this manual is adhered to.
Page 4: Before Taking To The Road
BEFORE TAKING TO THE ROAD Figure 1: Dashboard layout for models with standard instruments Figure 1a: Five or six speed gear shift patterns Controls 12. Headlamp flasher switch Brake fail indicator 13. Horn Hazard warning light switch 14. Fuel gauge Rear fog light switch 15.
Page 5: Explanation Of Dashboard
EXPLANATION OF DASHBOARD Brake fail indicator Single position spring loaded switch, illuminates to indicate low fluid level. Press to test bulb. Hazard warning light Single position switch activates all indicators. Rear fog light Single position switch activates rear fog lights when dipped headlights are illuminated. Heated windscreen Single position switch activates heating elements to demist front windscreen.
Page 6: Stack Display With Windscreen
Figure 2: Dashboard layout for models with Stack Instruments and full windscreen Controls Heated windscreen switch Shift light button Brake fail indicator Indicator warning light Hazard warning light switch Indicator switch Rear fog light switch Main beam warning light Side/Head lights switch Starter push button Heater fan switch Stack display...
Page 7: Csr Integral Dash
Figure 3: 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 14.
Page 8: R500
Figure 4: Dashboard layout for R500 Controls Aero screen Side/Head light switch Heated screen switch Stack button 4 Hazard warning light switch Heater valve control Windscreen washer switch Stack button 2 Windscreen wipers switch Stack button 1 Launch control push button Horn push button Gear shift lights Starter push button...
Page 9: Stack Display Operation
Headlight main beam – BLUE Screen 4  Illuminates when the headlights are switched to main Current speed  beam. Battery Voltage  Ambient air temperature is shown but not utilised in the set-up. This will default to a reading of -999 Immobiliser Warning light - Red Press button 3 to change the display to screen 5 See section on Immobilisation.
Page 10: Before You Drive Away
Pregnant women should ask their doctor for advice about the safest way to wear seat belts. On some models the pedals may be adjusted to suit the driver. Please contact your caterham agent for Caring for seat belts details. (CSR/EU4 cars does not have this facility)
Page 11: Weather Equipment
Seven. this first you will ensure that the comfort pads are...
Page 12: 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 Cars to make arrangements for a additional keys and tags. Immobilisation Most Caterhams are fitted with an immobiliser as standard, this will be Sterling Excel vehicle immobiliser system.
Page 13 The tags contain delicate electronic circuits and must user, or as a replacement through loss or damage, be protected from impact and water damage, high please contact Caterham Aftersales Department. temperatures and humidity, direct sunlight, effects of Once you have received your new transponder tag, solvents, waxes and abrasive cleaners.
Page 14: Starting The Engine
SLOWLY (at risk the engine. of catalyst damage) to Caterham Cars for assistance. Never Allow the car to run out of fuel (the resultant misfire could destroy a catalyst).
Page 15: Gearbox
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.
Page 16: Braking System
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.
Page 18: Technical Data
Technical data Kerb Weights Vehicle Type Min Weight Max Weight 2 Seater, convertible sports car. Classic Roadsport Construction Tubular steel space frame. R400 Aluminium panels with aluminium honeycomb cockpit side impact protection. R500 (Glass-reinforced plastic) Carbon fibre nosecone and wings. CSR Superlight Dimensions Braking System...
Page 19 Ford Engine oil Formula E-5W-30 CSR/R400 Caterham Motorsport Oil 5W-50 Track driving Caterham Motorsport Oil 5W-50 Gearbox Oil* 5/6 SPEED Caterham Gearbox Oil EP80 grade Sequential Differential All cars Caterham Differential Oil EP90 LSD's Lubeguard Limited Slip Diff additive Engine Coolant...
Page 20: Track Use
Remember to drink plenty of fluids. designed to promote close and cost-effective racing by virtue of the strict regulations and the use of sealed The Caterham Seven is ideally suited to trackdays and engines. it can be almost guaranteed that there will be a...
Page 21: Maintenance
The oil will Whilst a Caterham is perfect for track use, there are a come up to temperature quickly. A maximum oil temperature of 120C is recommended. If track...
Page 22: Eu4 Sigma 120
Figure 10a: Underbonnet 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 23: Sigma 125
Figure 10b: Under bonnet location - Sigma 125 1. Brake Fluid Reservoir 6. Air Filter 2. Clutch Fluid Reservoir 7. Windscreen Washer Fluid 3. Battery 8. Dip Stick 4. MAP 9. Engine Oil Filler Cap 5. ECU 10. Coolant Filler Cap...
Page 24: Sigma 150
Figure 10c: Underbonnet location - Sigma 150 1. Brake Fluid Reservoir 6. Air Filter 2. Clutch Fluid Reservoir 7. Windscreen Washer Fluid 3. Battery 8. Dip Stick 4. MAP 9. Engine Oil Filler Cap 5. ECU 10. Coolant Filler Cap...
Page 25: Duratec 210 (R400)
Figure 10d: Underbonnet location – Duratec 210 (R400) 1. Brake Fluid Reservoir 6. Windscreen Washer Fluid 2. Clutch Fluid Reservoir 7. ECU 3. Battery 8. Dip Stick 4. MFU 9. Engine Oil Filler Cap 5. Air filter 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.
Page 26: Eu4 Duratec 200 (Csr)
Figure 10e: Underbonnet location – EU4 Duratec 200 (CSR) 1. Brake Fluid Reservoir 6. Windscreen Washer Fluid 2. Clutch Fluid Reservoir 7. Brake fluid Reservoir 3. Battery 8. Coolant Filler Cap 4. Air box 9. Engine Oil Filler Cap 5. Dip stick NOTE: SVR Under bonnet location is similar to EU4 CSR apart from the Battery location...
Page 27: Duratec 260 (Csr)
Figure 10f: Underbonnet location - Duratec 260 (CSR) 1. Brake Fluid Reservoir 7. Coolant Filler Cap 2. Clutch Fluid Reservoir 8. Breather Bottle 3. Battery 9. Windscreen Washer Fluid 4. ECU 10. Air Filter 5. MFU 11. Engine Oil Filler Cap 6.
Page 28: Duratec 263 (R500)
Figure 10g: Underbonnet location – Duratec 263 (R500) 1. Brake Fluid Reservoir 6. Air Filter 2. Clutch Fluid Reservoir 7. Dry Sump Tank 3. Coolant Filler Cap 8. Engine Oil Filler Cap 4. ECU 9. Oil Cooler 5. Battery NOTE: The windscreen Screen washer bottle is located above the battery for the cars fitted with full windscreen...
Page 29: Safety In The Garage
 DO NOT touch electrical leads or components NOTE: Any significant or sudden drop in fluid levels, or with the ignition switch turned on. uneven tyre wear, should be reported to Caterham  NEVER leave engine running Cars without delay.
Page 30: Checking Fluid Levels
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 31: Coolant
To ensure that its anti-corrosion properties are retained, the anti-freeze content should be checked by Caterham Aftersales once a year. The coolant should be completely renewed every four years.
Page 32: Brake Fluid
 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 top- up with a mixture of water and Comma screenwash.
Page 33 – you should seek advice about  During normal operation batteries emit explosive disposal from a Caterham dealer or your local hydrogen gas – ensure sparks and naked lights authority. are kept away from the engine compartment.
Page 34: Wheels & Tyres
Do not raise the car. NOTE: Due to the minimal weight of the Caterham it is more prone to aquaplaning in wet conditions. It is for this reason that we recommend tyres are changed at...
Page 35: Cleaning And Car Care
 Figure 19: Front 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.
Page 36: Laying Your Vehicle Up For Long Periods
Then wash immediately with soapy water, to remove all traces of the spirit. Should your Caterham be laid up unused for more than 12 weeks at a time then we recommend the following Body protection...
Page 37: Travelling Abroad
Travelling abroad If a donor vehicle is to be used, the vehicles should be parked with their battery locations adjacent to one another. Ensure that the two In certain countries, it is illegal to fit parts which have vehicles do not touch. been made vehicle...
Page 38: Emergency Towing
Starter Stack dash replace a fuse with another of the same (or lower) Fuel Pump rating. If a replacement fuse blows almost immediately, Cooling Fan this indicates a serious electrical problem and the circuit MUST be checked by Caterham Cars.
Page 39: Parts & Accessories
Service parts & accessories Indicators (front) Only Caterham Cars and their dealers are able to Remove the two screws holding the lens in place. The provide the full range of recommended parts and bulb can then be removed and the new one refitted by accessories which meet our rigorous standards of Pushing and turning through 45°.
Page 40 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. Bulb Replacement Part Numbers from Caterham Caterham Part Light Unit Wattage...
Page 41: Servicing
SERVICE SCHEDULES Service Interval New Car First Second Annually or every 6,000 Roadsport & Superlight First Service Annual Annual miles if sooner All Ford Sigma & Duratec Engine Variants 3 Months 12 Months 24 Months (or 1000) (or 6000) (or 12,000) ...
Page 43 SERVICE RECORD continued...
Page 44 SERVICE RECORD continued...
Page 45 CAMBELT REPLACEMENT FACTORY UPGRADE RECORD...
Page 46 FACTORY UPGRADE RECORD...

Caterham Seven Owner's Handbook Manual

1 Before Taking to the Road

2 Useful Information

3 Maintenance

4 In an Emergency

5 Servicing

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