Birkin S3 User manual

O W N E R S M A N U A L
Copyright Birkin Cars (Pty) Ltd

C O N T E N T S
Registration Form ............................................................. 3
Introduction ............................................................. 4
Know Your Vehicle .............................................................
5
Regular Maintenance 16
.............................................................
Service Data 20
.............................................................
Service Record 22
.............................................................
Copyright Birkin Cars (Pty) Ltd

O W N E R S R E G I S T R A T I O N
Questions marked with (*) are optional and are general
information for our records.
Either fax [phone]) or email ([e-mail])us your details
Name: - Vehicle Model:-
*Age: - V.I.N. / Chassis Number:-
Postal Address:- Engine Number:-
Supplying Dealer:-
Country: -
Date of Delivery: -
Contact Telephone Number:-
Registration Number:-
Email Address:-
*Profession:-
I wish to be kept
updated on new
developments,
promotions, new
accessories:-Yes No
03
Copyright Birkin Cars (Pty) Ltd

INTR ODUC TION
In producing this manual, the object has been to confine the contents to information
essential to the proper running and operation of the vehicle.
Nevertheless, the operator will find all the guidance necessary to maintain the vehicle in
first-class condition and to ensure trouble free service. Every vehicle leaving the
factory is capable of giving absolute satisfaction if the maintenance instructions
detailed in the following pages are carefully carried out.
Remember that an approved Distributor/Dealer is better equipped to provide routine
repair and service than most, he is at your service and should be consulted if you
encounter trouble. When emergency work has been undertaken by someone other
than a competent workshop, the vehicle should be submitted to an approved
Distributor/Dealer for inspection.
All warranty work must be carried out by an approved Distributor/Dealer.
Official Dealer must perform scheduled services to preserve warranty.
04
Copyright Birkin Cars (Pty) Ltd

KNOW YOUR VEHICLE
It is important to become familiar with your vehicles instruments, controls and switches before
driving, so that using them becomes automatic and instinctive.
Identification - Factory Built Vehicles
V I N n u m be r : 17 digit identification number on a plate which is welded to the top left
hand diagonal brace in the engine bay.
E n g i n e n u mb e r : stamped onto the left side of the engine block at the rear next to
the bellhousing. 05
Copyright Birkin Cars (Pty) Ltd

FUSE BOX
06
Situated in the Engine Bay
F u s e B o x # 1 F u s e B o x # 4
DIP RELAY
MAIN 40 AMP
HORN
10 AMP
SEAT BELT
7.5 AMP
HANDBRAKE
7.5 AMP
SPARE 25 AMP
SPARE 40 AMP
F u s e B o x # 3
INDICATOR 10 AMP
WASHER 25
AMP
W/SCREEN
15 AMP
HEATER 15
AMP
GAUGES
10 AMP
WIPER 15
AMP
D
HAZARD
RELAY
IGNITION
RELAY
LIGHTS
RELAY
HEATED
W/SCREEN
RELAY
INDICATOR
RELAY
Fuse Bo x # 2
RESERVOIR
10 AMP
FUEL PUMP
15 AMP
LOW BEAM
15 AMP
REAR FOG
15 AMP
REVERSE
10 AMP
RAD FAN
25 AMP
HI BEAM
25 AMP
HAZARD
10 AMP
HEAD
25 AMP
BRAKE
10 AMP
PARK
10 AMP
E.C.U.
15 AMP
Copyright Birkin Cars (Pty) Ltd

DASHBOARD LAYOUT for Right Hand Vehicle
KEY
1Speedometer 9Dip switch 16 Windscreen washer switch
2Rev counter/Tachometer 10 Indicator light 17 Handbrake warning light
3Oil pressure gauge 11 Brake fluid warning light 18 Demister switch
4Ammeter 12 Indicator switch 19 Emergency lights switch
5High beam warning light 13 Hooter switch 20 Windscreen wipers switch
6Water temperature gauge 14 Test switch - Brake Fluid 21 Lights switch
7Ignition light warning circuit (Optional) 22 Rear fog light switch (Optional)
07
8Fuel gauge 15 Heater fan switch 23 Seat belt warning light
Copyright Birkin Cars (Pty) Ltd

DASHBOARD LAYOUT for Left Hand Vehicle
1Speedometer 9Dip switch 16 Windscreen washer switch
2Rev counter/Tachometer 10 Indicator light 17 Handbrake warning light
3Oil pressure gauge 11 Brake fluid warning light 18 Demister switch
4Ammeter 12 Indicator switch 19 Emergency lights switch
5High beam warning light 13 Hooter switch 20 Windscreen wipers switch
6Water temperature gauge 14 Test switch - Brake Fluid 21 Lights switch
7Ignition light warning circuit (Optional) 22 Rear fog light switch (Optional)
8
Fuel gauge
15
Heater fan switch
23
Seat belt warning light
08
Copyright Birkin Cars (Pty) Ltd

PEDAL BOX ADJUSTMENT
The pedal box can be moved forward or backwards by positioning the pedal box
locating bolts in one of the four positions indicated below.
09
Pedal box adjustment fasteners
Copyright Birkin Cars (Pty) Ltd

CLUTCH, BRAKE AND ACCELERATOR PEDAL ADJUSTMENT
The pedal pads may be adjusted vertically and laterally by using alternative
mounting positions on the clutch, brake and acceleratory pedals as shown below.
1. Default (factory set) 2. View showing clutch
position of the pedals pedal (right) raised on
the pedal box as vertically upwards.
shown from back of
pedals.
3. View showing lateral
adjustment of clutch
pedal (right pedal)
positioned on left side of
lever arm.
10
Copyright Birkin Cars (Pty) Ltd

BRAKE BIAS ADJUSTMENT
It is possible to adjust the braking bias between the front and rear by adjusting the
Bias Bar on the pedal box. Instructions follow on next page.
Front Bias Rear Bias
11
Master cylinder
push rod lock
Nuts. _________
Copyright Birkin Cars (Pty) Ltd

Instructions for setting adjustment on Bias Bar:
1. Loosen the master cylinder push rod lock nuts (point #1) and adjust the push
rod lengths until they are equal, with approximately 0,5mm free-play.
2. Loosen the bias lock nut (point #2) with a 13 mm spanner.
3. Using a screwdriver (point #3), rotate the bias bar (point #4) in a clockwise direction to
increase braking to rear or anticlockwise to increase to the front.
4. Once set, nip up lock nut before replacing cover.
12
Copyright Birkin Cars (Pty) Ltd

H A N D B R A K E A D J U S T M E N T
The handbrake tension must be set correctly as described below.
By adjusting the nuts on the
handbrake (as indicated), the
tension to the handbrake can
be adjusted accordingly. It is
recommended that the tension
be set so that the handbrake
begins to take after 2 ‘clicks’
and that it is fully engaged
after 4 to 5 ‘clicks’.
For previous models that used Honda calipers, the handbrake tension on each
Caliper (ie the balance) may be set independently by adjusting the nuts.
! Firstly, adjust the tension on one Caliper until the brake disk does not rotate
at all.
! Now, reduce the tension gradually until the disk rotates freely while keeping
count of the number of turns of the nut.
! Repeat for the opposite Caliper. The number of turns for both should be the
same. 13
The calipers are self adjusting in the newer models.
Copyright Birkin Cars (Pty) Ltd

ADJUSTING THE RIDE HEIGHT
The factory ride height settings are as such:
! At the rear, the ring retainer nut is set 20mm (15 threads) up.
To adjust the ride height of either the rear or the front suspension:
1. Loosen the grub screw on the ring retainer nut using the appropriate allen key.
2. Adjust the ring retainer nut up or down as required.
3. Lock the grub screw that was loosened in step 1.
Relative diagrams appear on the next page.
14
Copyright Birkin Cars (Pty) Ltd

15
Copyright Birkin Cars (Pty) Ltd

REGULAR MAINTENANCE
Before performing any maintenance on your vehicle, ensure the engine is not
running and the handbrake is engaged, unless otherwise instructed in the text
that follows. Be sure to keep tools, hands and any parts away from any moving parts.
Oil Level:
Water Level:
Important! First park the car on level ground and then wait a few minutes
before checking the dipstick with a clean rag. The two marks on the dipstick
indicate minimum and maximum oil levels, the difference between the marks
being 500ml. If your vehicle is fitted with a dry sump system, the nose cone
must be removed to allow the level indicator to be visible. Perform a visually
check on the oil pump drive belt to confirm it has not become worn and then
start the engine. Through the filler cap you will notice a baffle plate, the oil
level must be just below this while the engine is running. Should the oil need
topping up, switch off the engine first before refilling. It is then important to
warm up the engine before driving as the viscosity of cold oil will put strain on
the oil pump drive belt causing unnecessary ware.
Every 20,000km the coolant system should be flushed and replaced with a
recommended anti-corrosion inhibitor.
DO NOT REMOVE THE FILLER NECK CAP WHILST THE ENGINE IS HOT.
The pressure and temperature of water and/or engine coolant from a hot
engine is extremely high and capable of causing severe injury or burns
should these instructions be ignored. Should an emergency occur where the
filler neck cap has to be removed while the engine is hot, protect yourself by
muffling the cap with a thick rag and rotate it in the opening direction very
slowly. This allows a gradual release of any harmful pressure and potentially
scolding steam before the removal of the cap.
16
Copyright Birkin Cars (Pty) Ltd

Brake Fluid: BRAKE FLUID IS A HIGHLY CORROSIVE AND POTENTIALLY
DANGEROUS SUBSTANCE.
It should therefore, be used with the utmost care and stored safely away
from other substances and out of harms reach.
The minimum and maximum marks can be found on the side of the
reservoir. Should it be necessary to top up any levels, take care not to
overfill the container and only use recommended brake fluid which has not
been exposed to the atmosphere. Should any brake fluid spill over or come
in contact with anything other than the inside of the reservoir, wash down
the affected area immediately with cold water.
It is advisable to protect your skin and eyes when working with Brake Fluid.
In the event of it coming in contact with any part of the human body, follow
the medical instructions provided by the brake fluid manufacturer or contact a
medical practitioner immediately.
Battery: The supplied battery is a sealed and maintenance free.
Fan Belt: Check movement of the belt between the water pump pulley and the
alternator pulley. The belt should have a free play of 10mm with normal
wrist movement.
Air Cleaner: The factory air cleaners should never require replacement. A filter
fitted
cleaning solution is available through after-market engine accessory shops.
17
Copyright Birkin Cars (Pty) Ltd

Tyres: Tyre pressures should be checked when the tyres are cold. The
recommended pressures are 180Kpa all round, and be sure to check the
spare. Regular tyre maintenance and wheel alignment will ensure a longer
tyre life and an economic fuel consumption.
Bodywork: The aluminium bodywork is best kept clean by using a metal polish such as
‘Brasso’. Fine scratches can be removed by using a rubbing compound. The
paintwork should be washed frequently using lukewarm water, and dried off
using a chamois cloth. A good wax on the paint is recommended once a
month. The use of high pressure water hoses or steam cleaners is not
recommended. Use of such can cause damage to the bodywork and or
autoelectrical failure..
Upholstery: Keep the upholstery clean by using a suitable after-market product such as
‘Armourall’. This is recommended not only for upholstery, but for rubber
components aswell.
Weather 1. Wet trim must be left on the car to dry with all the press studs fastened.
Trim: Do not pack trim away when wet.
2. The hood must be fitted starting from the windscreen first. The reverse
applies when taking the hood off. (start from the rear)
3. To fit the tonneau cover, start by connecting the zip to the boot cover
first. Next, fasten the front press studs and working your way down the
sides towards the rear.
4. When using weather trim, always ensure all press studs are securely fastened. 18
Copyright Birkin Cars (Pty) Ltd

Jacking Points Jacks must be placed under the steel members of the chassis in
the positions as indicated by red crosses below.
19
Copyright Birkin Cars (Pty) Ltd

SERVICE DATA
Service Intervals
The service intervals are applicable to the vehicles fitted with Ford Zetec engines.
PRE-DELI VERY
SERVICE
2500km
MINOR
SERVICE
15 000km
MIDWAY
SERVICE
30 000km
MAJOR
SERVICE
An optional 500 0 km service is recommende d for
ve hicles which trave l le ss than 1000 km eve ry year. 20
Copyright Birkin Cars (Pty) Ltd