Caterham Seven - Regular checks; Weekly checks

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Figure 14: Under bonnet location - Duratec 237

1. Brake fluid reservoir

2. Clutch fluid reservoir

6. Air filter

7. Oil tank filter

3. Battery

7. Oil tank filler cap

4. Coolant filler cap

8. Oil filler cap

5. ECU

9. Washer bottle (located in boot as illustrated)

Main Page

Table of Contents3
Contents3
Table of Figures6
Table of Tables7
Using this Handbook8
Before Taking to the Road9
Figure 1: Dashboard Layout for Models with Standard Instruments9
Explanation of Dashboard10
Speedometer10
Digital Display Within Speedometer10
Trip Recorder Reset Button10
Tachometer10
Oil Pressure Gauge10
Temperature Gauge10
Fuel Gauge11
Warning Lights11
Figure 2: Dashboard Layout for CSR with Integral Dash12
Figure 3: Dashboard Layout for Seven 485/ Superlight R400 (Reverse for RHD)13
Figure 4: Dashboard Layout for Seven 620 R14
Before You Drive Away15
Pedal Adjustment Facility15
Seats/Seat Belts/Harness15
Weather Equipment Assembly16
Figure 5: 4-Point and 6-Point Harness16
Figure 6: Tensioning the Hood16
Security17
Keys/Key Numbers17
Immobilisation17
Figure 7: Hood Folding Procedure17
Vehicle Battery Disconnection18
Ignition Switch and Steering Lock18
Steering Lock18
Starting the Engine19
Starting in Cold Climates19
Warming up19
Running-In19
Catalytic Converter19
Filling up with Fuel19
Driving the Car19
Switching off19
Vehicle Maintenance20
Gearbox20
Selecting Reverse Gear20
Precautions While Driving20
Sequential Gearbox Operation20
Figure 8: 5/6 Speed and Sequential Gearbox20
Fuel21
Fuel Filling21
Filling Difficulties21
Braking System21
Brake Pads21
Handbrake21
Useful Information22
Table 1: Specifications22
Technical Data23
Vehicle Type23
Construction23
Table 2: Dimensions23
Braking System (All Models Excluding 160 / 165)24
Braking System (160 / 165 Only)24
Parking Brake24
Suspension - Standard / SV Chassis24
Suspension - CSR Chassis24
Steering Mechanism24
Road Wheel Nut Torque24
Electrical24
Manual Transmission24
Table 3: Kerb Weights24
Table 4: Wheels - Tyres - Pressures25
Table 5: Gearbox Ratios25
Table 6: Final Drive Ratio25
Recommended Fluid Specification26
Table 7: Fluid Capacities26
Track Use27
Enjoying Track Days and Competing in Your Caterham Seven27
Motorsport27
Track Days27
Maintenance29
Figure 9: under Bonnet Location - EU5 K6A29
Figure 10: under Bonnet Location - EU4 Sigma 12030
Figure 11: under Bonnet Location - Sigma 125 / 14031
Figure 12: under Bonnet Location - Duratec 17532
Figure 13: under Bonnet Location - Duratec 180 / 21033
Figure 14: under Bonnet Location - Duratec 23734
Figure 15: under Bonnet Location - Duratec 31035
Regular Checks36
Weekly Checks36
Emission Control36
Safety in the Garage36
Figure 16: Front Axle Stand Positioning36
Figure 17: Rear Axle Stand Position36
Poisonous Liquids37
Used Engine Oil37
Checking Fluid Levels37
Engine Oil Levels37
Engines with Standard Wet Sump Arrangement37
Figure 18: Wet Sump Dipstick Level Indicator37
Figure 19: Dry Sump Tank Cap and Level Indicator for CSR 200 / 260 Only37
Engines with Dry Sump Tank - Except CSR 200 / 26038
Engines with Dry Sump Bell Tank and Swirl Tower - CSR 200 / 260 Models Only38
Supercharger Oil Level Checking and Maintenance (for 620 R Only)38
Coolant Check & Top-Up38
Anti-Freeze38
Figure 20: Coolant Expansion Bottle38
Brake/Clutch Fluid Check & Top-Up39
Wipers & Washers39
Windscreen Washers39
Figure 21: Clutch Fluid Reservoir39
Figure 22: Brake Fluid Reservoir39
Washer Jets40
Wiper Blades40
Battery40
Battery Maintenance40
Battery Removal and Replacement40
Replacement Battery40
Figure 23: Battery and Clamp40
Battery Disposal41
Battery Charging41
Wheels & Tyres41
Caring for Your Tyres41
Tyre Pressures41
Tyre Wear Indicators41
Valve Caps42
Punctured Tyres42
Replacement Tyres42
Changing a Wheel and Tyre Assembly42
Tools Required42
Positioning the Jack42
Removing and Refitting the Wheel and Tyre Assembly42
Figure 24: Front and Rear Jack Points42
Cleaning and Car Care44
Washing Your Car44
Removing Tar Spots44
Body Protection44
Windscreen44
Hood/Sidescreen44
Mirrors44
Wiper Blades44
Looking after the Interior44
Laying Your Vehicle up for Long Periods45
Travelling Abroad45
In an Emergency46
Emergency Starting46
Emergency Towing46
Towing for Recovery46
Before Being Towed46
Figure 25: Jump Lead Connection46
Fuses and Relays47
Fuses and Relays - K6A Suzuki47
Fuses and Relays - Sigma47
Figure 26: Fuse Box and Relay Location47
Figure 27: K6A Fuse Box and Relay Layout47
Fuses and Relays - Duratec48
Fuses and Relays - Duratec EU4 175 / 23748
Renewing a Fuse48
Fuse Colours48
Figure 28: Duratec Fuse Box and Relay Layout48
Parts & Accessories49
Service Parts & Accessories49
Bulb Replacement49
Headlamps49
Side Lamp (Front)49
Indicators (Front)49
Indicator Repeaters (Front)49
Stop/Tail and Indicators (Rear)49
Rear Fog Light, Reversing Light49
Number Plate Lamp49
Table 9: Torque Figures50
Table 10: Torque Figures Continued51
Servicing52
Service Schedules - K6A Suzuki Engine Variants53
Service Schedules - Ford Sigma 125/140 & Duratec 175/180/210 Engine Variants54
Service Schedules - Duratec 237 Only55
Service Schedules - Duratec 310 Only56
Service Record57
Cambelt Replacement60
Factory Upgrade Record61

Caterham Seven - Regular checks; Weekly checks

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