Suffolk SS100 Manuals

Suffolk SS100 Manuals

Manuals and User Guides for Suffolk SS100. We have 1 Suffolk SS100 manual available for free PDF download: Build Manual

Suffolk SS100 Build Manual

Suffolk SS100 Build Manual (114 pages)

Brand: Suffolk | Category: Automobile | Size: 3.03 MB

Table of Contents

Table of Contents
3
Index
3
Tools, Equipment & Ordering of Parts
6
Tools Required
6
Fasteners
6
Introduction
6
Ordering of Parts
7
Parts Delivery Disclaimer
7
Build Sequence & Parts List
8
3.2 Parts List
12
Chassis, Suspension, Steering & Final Drive
18
Rear Suspension and Final Drive
18
- Fitting Bushes
  19
- Differential Mounting Plate
  19
- Rear Axle Set up
  19
- Installing Axle
  19
- Handbrake Return Springs
  20
Front Suspension
20
- Rear Tie Bars
  20
- Coil over Damper Mounting with Spacer
  20
- Upper Wishbone Pivot Shaft
  21
- Upper Wishbone Bushes
  21
- Upper Ball Joint
  21
- Lower Wishbone Pivot Shaft
  21
- Lower Wishbone Bushes
  22
- Hub and Brake Disc
  22
- Fitting the Hub
  22
- Coil over Dampers
  22
Steering
23
- Fitting Brake Caliper, Steering Arm and Disc Protector
  23
- Pre-Drill Brake Line Hose Clips
  23
- Steering Rack
  23
- Clutch Master Cylinder
  24
- Pedals
  24
- Brake Master Cylinder and Servo
  24
Braking System & Clutch Hydraulics
24
- Rear Brake Line
  25
- Rear Brake Link Pipes
  25
- Front Brake Lines
  25
- Brake Lamp Switch
  25
Fuel Tank, Fuel Pump and Fuel Line
26
- Setting Tank Fuel Sender
  26
- Fitting Tank Fuel Sender
  26
- Fuel Tank and Straps
  26
Engine, Gearbox, Exhaust System, Cooling System & Initial Wiring
27
Engine, Gearbox & Prop-Shaft
27
- Engine Brackets and Timing Pointer
  27
- Gearbox Mount Plate, Rubber Mount and Adaptor
  27
Exhaust System
28
- Servo Vacuum Hose
  28
- Connect and Bleed Clutch
  28
- Clutch Slave Cylinder
  28
- Fitting Engine
  28
Cooling System
29
- Down Pipes or Stainless Manifold Extension Pipes
  29
- Silencers
  29
- Rear Tie Bracket
  29
Initial Wiring
30
- Radiator Lower Mounts
  30
- Bottom Hose
  30
- Radiator Top Mounts
  30
- Front End Wiring Loom
  31
- Rear and Gearbox Loom
  31
- Coil
  31
- Electric Oil Gauge Sender
  31
- Overdrive Inhibit Switch
  32
- Fuel Pump
  32
- Overdrive Solenoid
  32
- Cooling Fan and Switch
  32
- Fog Lamp
  33
- Reverse Lamp
  33
- Brake Fluid Reservoir Wires
  33
- Starter Moto
  33
Wheels & Tyres
34
Splined Hubs
34
Fitting Wheels
34
Body, Doors and Bonnet Fitting
34
7.1 Body
34
Preparing Wheels
34
- Lifting on the Body
  35
- Bolting on the Bod
  35
- Body Tightening Sequence
  35
- Dashboard Stays
  36
Bonnet
36
- Final Body Mount Bolts and Spacers
  36
- Windscreen Wiper/Scuttle Bracket
  36
- Door Fitting
  36
- Bonnet Details
  37
- Bonnet Fitting/Cutting Advice
  37
- Preparing Centre Hinge
  37
- Preparing Outer Hinges
  38
- Positioning Top Hinge
  38
- Radiator Hoop and Long Stays
  38
- Radiator Shell
  38
- Securing Top Bonnet Panel
  39
- Marking the Bonnet Panels
  39
- Cutting the Top Bonnet Panels
  39
- Fitting Side Hinges
  39
7.3 Painting
40
- Fitting Bonnet Studs
  40
- Cutting Bottom Panels
  40
- Bottom Bonnet Beaded Edge
  40
- Refitting Body
  41
- Refitting Doors
  41
- Refitting Painted Bonnet
  41
Body Fittings
42
Safe Storage
42
Floorboards, Handbrake and Seat Runners
42
- Handbrake Cable
  42
- Rear Floorboard Upright Mount
  43
- Rear Floorboard
  43
- Rear Brake Access Panel and Tool Tray
  43
- Handbrake Lever
  43
Windscreen and Wipers
44
- Gearbox Cover
  44
- Sealing Floorboards
  44
- Wiper Spindle Holes
  45
- Mirror and Aero Screen Brackets
  45
- Fixing Windscreen
  45
- Windscreen Positioning
  45
Remaining Body Fittings
46
- Tenax and Lift the Dot Studs
  46
- Aero Screens
  46
- Wiper Arms and Blades
  46
- Front Valance and Dummy Starting Handle Eye
  47
- Fitting the Lamp Bar
  47
- Lamp Bar Stays
  47
- Wing Stays
  47
- Upper Steering Column
  48
- Lower Steering Column and Escutcheon
  48
- Throttle Pedal
  48
- Choke Cable
  48
- Fuel Cap, Adaptor and Link Pipe
  49
- Rear Reflectors
  49
- Spare Wheel Bracket
  49
- Rear Lamp Brackets
  49
- Running Board Strakes
  50
Dashboard Fittings
51
- Grab Handle
  51
- Fuel Switch (Dummy)
  51
Wiring and Electrical Fittings
51
- Main Earth
  52
- Main Power Feed
  52
- Stalk Switch
  52
- Relay Earths
  52
- Steering Column Ignition Key
  53
- Hazard Warning Lamps
  53
- Heater
  53
- Electrical Instruments and Automatic Gearbox Illumination
  54
- Low Charge Warning
  54
- Main Wiring Earth
  54
- Wiper Motor
  54
- Instrument Illumination
  55
- Ammeter
  55
- Headlamp Switch
  55
- Fuel Gauge
  56
- Windscreen Wiper Switch
  56
- Starter Push Button
  56
- Dashboard Ignition Key
  56
- Overdrive Switch
  57
- Tachometer
  57
- Spot Lamp Feed
  57
- Oil Pressure Gauge
  57
Front Lamps, Horns and Alternator
58
- Speedometer
  58
- Headlamps Type 40 and Horns
  58
- Headlamps QK596 and Horns
  59
- Flasher Lamps
  60
- Spot Lamps
  60
- Rear Lamps
  61
- Side Lamps Combined with Flasher Lamps
  61
- Alternator
  61
- Right Hand Lamp
  62
- Left Hand Rear Lamp
  62
- Fuel Gauge Sender
  62
- Earth Feed
  62
- Testing
  63
- Wiper Blade Fitting
  63
Interior Trimming
64
Trimming
65
Final Body Fittings
66
Steering Wheel and Boss
66
Front Number Plate
66
Rear Number Plate and GB Plate
66
Luggage Rack
66
- Ignition Settings
  67
- Ignition Setting, Carburetion, Testing Running and Tuning
  67
- Chassis Plate
  67
- Seat Belts
  67
- Carburetion
  68
- Carburettor Base Settings
  68
- Warm up
  68
- Dwell Angle
  68
- Setting Mixtures
  69
- Engine Checks
  69
- Test Running and Tuning
  69
- Driving and Service
  69
- Road Preparation
  70
- Wheel Alignment
  70
- Suspension Setting
  70
- Headlamp Alignment
  70
- Servicing
  71
- Tyre Pressures & Greasing Points
  71
- Speedometer Calibration
  71
- Electrical Systems
  72
- Wiring Loom Positions Key
  72
- Fuses
  74
- Line Fuses
  74
- Relay Fuses
  74
- Relays
  74
- Wiring Diagram
  75
- Key to Circuit Diagram
  75
- Wire Colour Coding
  75
- Optional Items
  75
- Figures
  77
- Puller for Differential Mounting Bushes
  78
- Setting Rear Wheel Camber
  78
- Exhaust System Assembly
  79
- Early XJ6 Upper Wishbones
  80
- Early XJ6 Lower Wishbones
  80
- Late XJ6 Lower Wishbones
  80
- Front Wishbone Identification
  80
- Peering of the Bonnet Panel Edges
  81
- Carburettor Pipe Location
  81
- Seat Runner Positions
  82
- Jig Tool for Marking out Lower Body Fixing Holes
  83
- Location of Throttle Pedal
  83
- Location of Door Latches
  84
- Location of Rear Reflectors
  84
- Strake Fitting
  85
- Cutting and Gluing Rubber Insert
  85
- Dashboard Layout and Grab Handle Location
  86
- Windscreen Fitting
  86
- Floorboard Fitting Kit
  87
- Picture to Left
  87
- Body to Chassis Fixing Locations
  88
- Heater Fitting Instructions
  89
- Heater Kit Contents
  89
- Loom Placement Diagram
  90
- Drilling Hole of Bonnet Hinges for Rivets
  91
- Headlamp Bar Fixings Positions
  91
- Steering Column Locating Jig
  91
- Cut out Holes in Gearbox Cover for Maintenance
  92
- Shock Absorber Height Adjustment
  92
- Wiring of Rear Lamps
  93
- Photographs
  94
- Rear Axle Components
  94
- Assembled Engine, Gearbox and Rear Axle
  94
- Rear Axle Fitted
  95
- Early Build Stages
  96
- Rolling Chassis
  96
- Stainless Steel Manifolds Fitted
  97
- Lucas Qk596 Headlamps
  98
- Different Headlamp Options
  98
- Type 40 Headlamps
  98
- Fluids, Lubricants and Maintenance Data
  99
- Tyre Pressures
  99
- Wire Wheels
  99
- Adjustable Shock Absorbers
  99
- Running in and Service Instructions
  100
- 500 Miles
  100
- 500 - 1000 Miles
  100
- 1500 Miles
  100
- Suffolk Sportscars ANNUAL SERVICE
  101
- Speedo Calibration
  103
- RHD Brake Pipe Locations
  104
- Suffolk SS100 Dimensions
  105
- Suffolk SS100 Chassis Details
  106

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