Caterham Seven User guide

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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...............................................................................................................................8
Tachometer.....................................................................................................................................................8
Oil pressure gauge .........................................................................................................................................8
Temperature gauge........................................................................................................................................8
Fuel gauge......................................................................................................................................................9
Warning lights.................................................................................................................................................9
Before you drive away .........................................................................................................................................13
Pedal adjustment facility...............................................................................................................................13
Seats/seat belts/harness..............................................................................................................................13
Weather equipment assembly.............................................................................................................................14
Security ................................................................................................................................................................15
Keys/key numbers........................................................................................................................................15
Immobilisation...............................................................................................................................................15
Vehicle battery disconnection.......................................................................................................................16
Ignition switch and steering lock...................................................................................................................16
Steering lock.................................................................................................................................................16
Starting the engine...............................................................................................................................................17
Starting in cold climates................................................................................................................................17
Warming up ..................................................................................................................................................17
Running-In............................................................................................................................................................17
Catalytic converter........................................................................................................................................17
Filling up with fuel:........................................................................................................................................17
Starting the engine: ......................................................................................................................................17
Driving the car:..............................................................................................................................................17
Switching off: ................................................................................................................................................17
Vehicle maintenance: ...................................................................................................................................18
Gearbox ...............................................................................................................................................................18
Selecting reverse gear..................................................................................................................................18
Precautions while driving..............................................................................................................................18
Sequential Gearbox Operation.....................................................................................................................18
Fuel ......................................................................................................................................................................19
Fuel Filling ....................................................................................................................................................19
Filling difficulties............................................................................................................................................19
Braking System....................................................................................................................................................19
Brake pads....................................................................................................................................................19
Handbrake ....................................................................................................................................................19
2. Useful information ...................................................................................................................................................20
Technical data......................................................................................................................................................21
Vehicle type ..................................................................................................................................................21
Construction..................................................................................................................................................21
Braking system (All models excluding 160 / 165) ........................................................................................22
Braking system (160 / 165 only)...................................................................................................................22
Parking brake................................................................................................................................................22
Suspension –Standard / SV Chassis ..........................................................................................................22

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Suspension –CSR Chassis.........................................................................................................................22
Steering mechanism.....................................................................................................................................22
Road wheel nut torque .................................................................................................................................22
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:.............................................................................................................................................34
Emission control ...........................................................................................................................................34
Safety in the garage.............................................................................................................................................34
Poisonous liquids..........................................................................................................................................35
Used engine oil.............................................................................................................................................35
Checking fluid levels............................................................................................................................................35
Engine oil levels............................................................................................................................................35
Engines with standard wet sump arrangement............................................................................................35
Engines with dry sump tank - except CSR 200 / 260 ..................................................................................36
Engines with dry sump bell tank and swirl tower - CSR 200 / 260 Models only..........................................36
Supercharger oil level checking and maintenance (For 620 R only)...........................................................36
Coolant check & top-up................................................................................................................................36
Anti-freeze ....................................................................................................................................................36
Brake/clutch fluid check & top-up.................................................................................................................37
Wipers & Washers...............................................................................................................................................37
Windscreen washers....................................................................................................................................37
Washer jets...................................................................................................................................................38
Wiper blades.................................................................................................................................................38
Battery..................................................................................................................................................................38
Battery maintenance.....................................................................................................................................38
Battery removal and replacement ................................................................................................................38
Replacement battery ....................................................................................................................................38
Battery disposal............................................................................................................................................39
Battery charging ...........................................................................................................................................39
Wheels & Tyres....................................................................................................................................................39
Caring for your tyres.....................................................................................................................................39
Tyre pressures..............................................................................................................................................39
Tyre wear indicators.....................................................................................................................................39
Valve caps....................................................................................................................................................40
Punctured tyres ............................................................................................................................................40
Replacement tyres........................................................................................................................................40
Changing a wheel and tyre assembly..................................................................................................................40
Tools required...............................................................................................................................................40
Positioning the jack.......................................................................................................................................40
Removing and refitting the wheel and tyre assembly ..................................................................................40
Cleaning and car care..........................................................................................................................................42
Washing your car..........................................................................................................................................42
Removing tar spots.......................................................................................................................................42
Body protection.............................................................................................................................................42
Windscreen...................................................................................................................................................42
Hood/Sidescreen..........................................................................................................................................42

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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......................................................................................................................................44
Before being towed:......................................................................................................................................44
Fuses and relays..................................................................................................................................................45
Fuses and relays - K6A Suzuki ....................................................................................................................45
Fuses and relays - Sigma.............................................................................................................................45
Fuses and relays - Duratec ..........................................................................................................................46
Fuses and relays - Duratec EU4 175 / 237..................................................................................................46
Renewing a fuse...........................................................................................................................................46
Fuse colours .................................................................................................................................................46
Parts & Accessories.............................................................................................................................................47
Service parts & accessories.........................................................................................................................47
Bulb Replacement................................................................................................................................................47
Headlamps....................................................................................................................................................47
Side lamp (front)...........................................................................................................................................47
Indicators (front)............................................................................................................................................47
Indicator repeaters (front).............................................................................................................................47
Stop/tail and indicators (rear) .......................................................................................................................47
Rear fog light, reversing light........................................................................................................................47
Number plate lamp .......................................................................................................................................47
5. Servicing..................................................................................................................................................................50
Service schedules - K6A Suzuki Engine Variants...............................................................................................51
Service schedules - Ford Sigma 125/140 & Duratec 175/180/210 Engine Variants ..........................................52
Service schedules –Duratec 237 only ................................................................................................................53
Service schedules –Duratec 310 only ................................................................................................................54
Service record .............................................................................................................................................................55
Cambelt replacement ..................................................................................................................................................58
Factory upgrade record...............................................................................................................................................59

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Table of figures
Figure 1: Dashboard layout for models with standard instruments 7
Figure 2: Dashboard layout for CSR with Integral dash 10
Figure 3: Dashboard layout for Seven 485/ Superlight R400 (Reverse for RHD) 11
Figure 4: Dashboard Layout for Seven 620 R 12
Figure 5: 4-point and 6-point harness 14
Figure 6: Tensioning the hood 14
Figure 7: Hood folding procedure 15
Figure 8: 5/6 speed and sequential gearbox 18
Figure 9: Under bonnet location –EU5 K6A 27
Figure 10: Under bonnet location –EU4 Sigma 120 28
Figure 11: Under bonnet location - Sigma 125 / 140 29
Figure 12: Under bonnet location –Duratec 175 30
Figure 13: Under bonnet location –Duratec 180 / 210 31
Figure 14: Under bonnet location - Duratec 237 32
Figure 15: Under bonnet location –Duratec 310 33
Figure 16: Front axle stand positioning 34
Figure 17: Rear axle stand position 34
Figure 18: Wet sump dipstick level indicator 35
Figure 19: Dry sump tank cap and level indicator for CSR 200 / 260 only 35
Figure 20: Coolant expansion bottle 36
Figure 21: Clutch fluid reservoir 37
Figure 22: Brake fluid reservoir 37
Figure 23: Battery and clamp 38
Figure 24: Front and rear jack points 40
Figure 25: Jump lead connection 44
Figure 26: Fuse box and relay location 45
Figure 27: K6A Fuse box and relay layout 45
Figure 28: Duratec Fuse Box and Relay layout 46

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Table of tables
Table 1: Specifications 20
Table 2: Dimensions 21
Table 3: Kerb weights 22
Table 4: Wheels - Tyres –Pressures 23
Table 5: Gearbox ratios 23
Table 6: Final Drive Ratio:23
Table 7: Fluid capacities 24
Table 8: Bulb replacement part numbers from Caterham 47
Table 9: Torque Figures 48
Table 10: Torque Figures continued 49

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INTRODUCTION
Congratulations on the ownership of your new Caterham Seven sports car.
Designed for racing and built for living, your Caterham Seven is competition-developed and capable of
performance well in excess of your average supercar. Please take the time to read this manual, get well acquainted
with the controls and understand the maintenance requirements of your car. This will help you appreciate its
capabilities to the full whilst ensuring the appropriate upkeep of your Seven enabling you to derive maximum
pleasure from ownership.
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 within this manual is adhered to. This will ensure that the vehicle is kept in the best
possible condition and performing at its optimum. For all servicing, MOT’s and other vehicle maintenance we
recommend that you return your car to us here at Caterham where the work will be carried out by factory trained
technicians. Alternatively servicing and maintenance can be carried out by one of the Caterham approved service
agents. Please refer to the Caterham website for up to date contact information www.caterhamcars.com.
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.
‘Before taking to the road’ –Includes controls, pedal adjustment, seat adjustment, weather equipment
fitting and storage, security and other information that you should know before you drive your new car.
‘Useful information’–This section is where you will find all the technical data on your Caterham Seven.
‘Maintenance’ –Detailed here are all the regular checks you will need to carry out to ensure you continue to
get the best from your Caterham.
‘In an emergency’–Should an emergency arise then here you will find advice on what you can do, including
jump starting, checking the fuses and changing a bulb.
‘Servicing’ –This section provides vehicle service information including service schedules. In addition you
will find pages that can be used to keep a record of when and where a service took place plus an additional
section for any future modifications or upgrades to your vehicle.
Engine Codes –The manual referrers to engine packages by codes, depending on what model of Seven
you have. A breakdown of this can be seen in the table below:
Model
160/165
Roadsport 125/140
Roadsport 175
Supersport
Supersport R
Engine
Suzuki K6A
Sigma 125/140
Duratec 175
Sigma 140
Duratec 180
Model
Superlight R400
485 R
620 R
CSR 200
CSR 260
Engine
Duratec 210
Duratec 237
Duratec 310
Duratec 175
Duratec 260
WARNING!
Safety warnings are included in this handbook. These indicate either a procedure which must be followed precisely,
or information that should be considered with great care in order to avoid the possibility of personal injury or serious
damage to the vehicle.

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1. Before taking to the road
Controls
1. Brake fail indicator (excl. K6A)
2. Hazard warning light switch
3. Rear fog light switch
4. Heated windscreen switch
5. Heater fan switch
6. Immobilizer warning light
7. Windscreen washers switch
8. Windscreen wipers switch
9. Side lights/head lights switch
10. Indicators switch
11. Main beam switch
12. Headlamp flasher switch
13. Horn
14. Fuel gauge
15. Temperature gauge
16. Oil Pressure gauge
17. Tachometer
18. Speedometer
19. main beam warning light
20. Indicator warning light
21. Ignition warning light, MIL & brake
system warning light
22. Push starter button
23. Trip reset button
24. Heater valve control
Standard 5 Speed.
Standard 6 Speed.
Sequential 6 Speed.
Note for 6 speed
sequential: Arrows are
for illustration only:
Upwards arrow = Down
shift 1 gear
Downwards arrow = Up
shift 1 gear
See Figure 8 for further
details.
Figure 1: Dashboard layout for models with standard instruments

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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.
(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.)
Heated windscreen Single position switch activates heating elements to demist front windscreen.
Heater fan Two position switch provides low and high speed fan control.
Windscreen washers Single position spring loaded switch activates washer jets when depressed.
Windscreen wipers Two position switch to provide low and high speed continuous wipe.
Indicator switch Three position switch Left-Off-Right (non self-cancelling)
Side/Head lights Two position switch, first position side lights, second position dipped beam headlight.
Main beam Two position switch for dip or main beam.
Headlamp flasher Single position spring loaded switch to flash headlights.
Heater valve control This is located on the inside of engine compartment bulkhead, above the driver’s knee.
Pull towards driver to increase heat.
Starter push button Single position spring loaded push switch, press and hold to start engine
Horn push button Single position spring loaded push switch
Speedometer
Indicates road speed in miles per hour and/or kilometres per hour.
Digital display within speedometer
The display shows the following:
Odometer reading (shows the total distance travelled by the car).
Trip recorder (for recording individual journey distances). The word trip is also displayed.
Trip recorder reset button
Whenever the ignition switch is turned on, the display shows the odometer reading. By pressing the trip recorder
reset button briefly, the display will change to show the trip recorder reading (a further press of the button returns
the display to the odometer reading). Press and hold the reset button to reset the display to zero.
Tachometer
Indicates engine speed in revolutions per minute.
NOTE: An electronic limiter will prevent engine speed rising above a pre-determined factory set level.
Oil pressure gauge
The needle indicates the oil pressure measured in bar. The needle will quickly rise when the engine is started. If the
needle falls into the red mark during normal running the oil pressure is at a critical level and severe engine damage
could result; switch off the engine immediately (safety permitting) and seek qualified assistance. (Engine pressure
will fluctuate as engine revs change).
WARNING!
Never restart the engine or drive the car with the oil pressure gauge indicating red.
Temperature gauge
Indicates the temperature of the engine coolant. During normal operation, the needle will rise from the lower (cold)
mark to the middle part of the gauge, where it will remain while the engine is operating at its normal temperature.
In severe driving conditions, such as very hot weather or extended hill climbing, the needle may rise. If the needle
rises to the red mark, the coolant is too hot and severe engine damage could result; stop the car as soon as safety
permits and seek qualified assistance.