Westfield XTR2 Instructions for use

Westfield Sports Cars Limited, Unit One Gibbons Industrial Park, Dudley Road, Kingswinford, West Midlands,
DY6 8XF
+ 44 (0) 1384 400077

Westfield Sports Cars Limited, Unit One Gibbons Industrial Park, Dudley Road, Kingswinford, West Midlands,
DY6 8XF
+ 44 (0) 1384 400077
Published by WESTFIELD SPORTS CARS LTD.
First Published 2002
Copyright ©2003
Westfield Sports Cars Ltd.
A
ll rights reserved. Apart from any fair dealing for the purposes o
f
private study, research, criticism or review, as permitted under the
Copyright, Design and Patents Act 1988, no part of this publication
may be reproduced, stored in a retrieval system, or transmitted in any
form or by means electronic, electrical, chemical, optical,
photocopying, recording or otherwise without prior written permission.
All enquiries should be addressed to the publisher.

1.1
Section 1

1.2

1.3
WELCOME
Because you are reading this CONSTRUCTION MANUAL you are
either contemplating the purchase of a WESTFIELD Sports Car or
have already done so. In either case we would like to thank you
for your interest in our product which we firmly believe is the best
available. To that end we are prepared to back up our claims with
a full warranty on every part bought through us.
WESTFIELD SPORTS CARS were established in 1982. Since then
WESTFIELD has produced many thousands of cars. We lay claim
to the title of 'Europe's biggest component car manufacturer'.
Though an enviable title, WESTFIELD does not intend to rest on
its laurels. We are constantly improving our cars, developing
many options and additions with which to further the desirability
of our product.
At WESTFIELD SPORTS CARS we believe that much of the
enjoyment of the car should be in its actual construction, this is
why this CONSTRUCTION MANUAL has been produced.
The whole point of building a WESTFIELD is to realise a vehicle
that will suit the purpose for which it is intended. With many
thousands of satisfied owners, both here and abroad, we believe
that at WESTFIELD we have accomplished that objective.
It is in our best interests to deliver to you the means of building a
car, simply and quickly, with a minimum of complication and a
maximum amount of fun.
We sincerely hope you enjoy that experience.
Chris Smith
Managing Director
WESTFIELD SPORTS CARS

1.4
CONTENTS Page
Section
1 INTRODUCTION
Contents 1.2
Safety 1.3
Getting Started 1.4
Tools you will Need 1.5
Suzuki MegaBusa Donor List 1.6
Torque Chart 1.7
Bolt Finder Chart 1.9
2 Brake Pipes
3 Clutch Line
4 Chassis Wiring Loom
5 Pedals & Brackets
6 Steering
7 Fuel Tank
8 Gear Change Lever Bracket
9 Hand Brake Lever & Cable
10 Gear Lever & Linkage
11 Front Suspension
12 Track Rods & Front Brake Hoses
13 Rear Differential & Sprocket
14 Anti-Roll Bar Assembly
15 Rear Suspension
16 Fuel System
17 Dry Sump Tank & Catch Tank
18 Dry Sump Kit
19 Engine Fitting & Installation
20 Reverse Mechanism & Linkage
21 Bodywork
22 Exhaust Installation
23 Interior

1.5
SAFETY
You will Not need to use Welding or Grinding equipment in the
Building of a WESTFIELD Sports Car, however, it is VERY IMPORTANT
that you take ALL necessary SAFETY Precautions.
1. ALWAYS WEAR:
- Goggles or Protective Glasses when Drilling.
- Protective Gloves when Handling Fibreglass.
2. DO NOT Guess at the Torque Settings.
- Always refer to the Torque Settings Table.
- If you do not own a Torque Wrench, then hire one from a Good
Quality Hire Shop.
3. IT IS ESSENTIAL that the Supports placed Under the Chassis during
the Build Process are Suitable and SAFE for use.
- WESTFIELD SPORTS CARS manufacture Chassis Support Frames that
are Designed Specifically for the Purpose and are available from the
Factory.
4. DO NOT use Bricks, Building Blocks or Wooden Packing Cases.
- Bricks and building blocks are NOT suitable as they are liable to
topple.
- Wooden Packing Cases are NOT suitable, as they are liable to Crush
as the Weight of the Car increases during the Build Process.
5. DO NOT Connect the Battery +TVE Lead until the Wiring Loom has
been Fully Installed and ALL Earth Cables have been Connected.
- The Battery MUST NOT be connected until ALL TESTS have been
completed.
6. DO NOT Fill the Fuel Tank until the car is complete.
- The Fuel Tank MUST NOT be filled until all of the 'SET-UP' Tests
have been completed.
7. PLEASE take Care with Brake Fluid and Brake Fluid Spillage.
8. ALWAYS have a Suitable Fire Extinguisher at Hand.
Have FUN but please, be SAFE!

1.6
GETTING STARTED
1. If you HAVE purchased the Optional WESTFIELD Chassis Support
Stands then, with the help of an assistant, Lift and Position the Chassis
onto these Supports.
- If you HAVE NOT purchased these stands, then ensure that the
chassis is positioned onto suitable supports, which allow the various
parts to be fitted.
IMPORTANT
DO NOT ATTEMPT to MODIFY ANY of he items supplied without
specific reference to the TECHNICAL HELPLINE at the FACTORY
STORAGE OF BODYWORK
- The Bodywork MUST NOT be Stored in Plastic Sheet, in Damp or
Humid Conditions.
- DO NOT Store Bodywork in Direct Sunlight, in Greenhouses or
Conservatories.
- WESTFIELD SPORTS CARS WILL NOT accept any WARRANTY
CLAIM for Damage to Bodywork where the Damage has been
caused by any of the above conditions

1.7
TOOLS you will NEED
1. Combination Spanner Set : 5/16" To 3/4" A/F Imperial
2. Combination Spanner Set : 8mm To 19mm A/F Metric
3. Socket Set : Imperial And Metric
4. Torque Wrench : 1/2" Square Drive : Range O-100 lb ft
5. Drill Set To Include : 5/32", 3/16", 1/4" & 5/16" Drill Bits
6. Metric `Allen’ Keys : 1 Set
7. Socket Drive `Allen' Key : 6mm
8. Socket Drive `Allen' Key : 8mm
9. Circlip Pliers : Internal And External
10. Tap : 1/2" UNF
11. Tap : M18 X 1.5mm
- (Note The M18 X 1.5mm Tap Is Only Required To Clean Out The
Residual Powder Coating That May Have Been Left- In The Top
Wishbone Threads)
12. Hole Cutter : 1 ¼" Diameter - Steering Column
13. Hole Cutter : 1 ¾" Diameter - (45mm) Loom
14. Hole Cutter : 2" Diameter - Gear Stick
15. Pop Rivet Gun
16. Brake Pipe Bending Tool
17. Rivnut Fixing Kit
18. Electric Drill
19. 12" Hacksaw
20. Engineering Hammer
21. Centre Punch
22. Hide Hammer
23. Two 'G' Clamps
24. Bench Vice : Machine Type
25. Flat Blade Screwdrivers : 1 Set
26. Phillips Screwdrivers : 1 Set
27. Round File : 5/16” Diameter
28. File : 12” Long Flat Blade File
29. Tape Measure
30. Metal Cutters
IN ADDITION, for the WESTFIELD `SEi’ & XTR2 ONLY:
1. 41mm A/F METRIC Socket
2. Torque Wrench, ½” Square Drive with a Range of 250 lb ft.
(If necessary, HIRE both the Socket and Torque Wrench when required)

1.8
SUZUKI MEGABUSA DONOR LIST
PARTS REQUIRED:-
- Engine & Gearbox Complete (With Number.)
- Throttle Linkages & Injection Assembly
- Full Engine Wiring Harness* (Requires Modification – See Note Below)
- E.C.U.
SENSORS:-
- Intake Air Pressure Sensor
- Atmospheric Pressure Sensor
- Intake Air Temperature Sensor
- Starter Motor Assembly
- Starter Motor Relay
- Chain Sprocket Nut & Washer
- Ignition Coils x 4 (These are part of the Spark Plug Caps)
- Regulator / Rectifier Unit
- Fuel Pump Relay
- Dash Complete (For Fault Finding)
- Photo Copy Of Donor Log Book If Available
IMPORTANT NOTES:
- Never purchase engines with any damage to casings or without
IDENTITY NUMBERS.
- Establish if the safety recall has been completed on Timing Chain
Tension Adjuster (Suzuki Warranty). If this has been done there will be a
‘RECALL COMPLETION’ LABEL attached under the pillion seat on the left
hand side of The ‘U’ LOCK storage area.
Example:-
*Note*
The Wiring Loom will require modification before installation.
WESTFIELD SPORTS CARS can carry out this modification for a fee.

1.9
TORQUE CHART
Settings in Pounds Feet and Newton Metres: ft-lbs. Nm
Three Way Brake Pipe Unions 5 7
Rear Brake Caliper Mounting Bolts (Steel) 40 54 *
Steering Rack Mounting Bolts to Chassis 20 27
Track Rod End Nuts to Steering Arm 28 38
Wishbone Securing Bolts to Chassis 35 40
Lower Ball Joint Securing Bolts to Wishbone 22 34
Lower Ball Joint Nut to Upright Block 28 38
Top Ball Joint Nut to Upright Block 25 34
Steering Column Upper Mounting Bolts 20 27 **
Steering Column Shaft Couplings 20 27 **
Steering Column Securing Clamp 28 38 **
Front Brake Caliper Mounting Bolts (Steel) 40 54 *
Shock Absorber to Chassis Mounting Bolts 30 40
Handbrake Mounting Bolts 22 30
Seat Belt Mounting Bolts 26 35
Steering Wheel Nut 35 47
Wheel Nuts (Rimstock) 65 90
Differential Unit Bolts to Chassis (SEi) 30 40
Rear Brake Caliper Mounting Bolts (SEi) 35 47 *
Drive Shaft Hub Nut (SEi) 250 340
Oil Pressure Switch 9 12
Neutral Switch 9 12
Sprocket Retaining Bolt (Modified Cap Head) 104 54 *
6mm Bolts 9 12
8mm Bolts 18 24
9mm Bolts 20 27
10mm Bolts 28 39
Sump Pan Retaining Bolts 9 12
(In sequence as instructed)

1.10
TORQUE CHART Continued…
General Notes:
i) Use the Bolt Finder Chart to identify the CORRECT bolt sizes
ii) Use Extra Care when Torque Tightening into Alloy Engine Block &
Components.
* Denotes: APPLY a Thread Locking Adhesive to threads when fitting
** Denotes: MAXIMUM Torque Setting
Suspension Bolt Tightening Notes:
i) It is IMPORTANT to REMEMBER that ALL suspension bolts and Nyloc
Nuts will be Torque tightened during the Set-Up stage.
WESTFIELD SPORTS CARS STRONGLY RECOMMEND that during the
assembly of the suspension that ALL suspension bolts and Nyloc Nuts
are `NIPPED’ ONLY and NOT Torque tightened.

1.11
BOLT FINDER PAGE
METRIC BOLT FINDER DIAMETER
(Actual Length) (Actual Size)
M5 (5mm Diameter)
M6 (6mm Diameter)
M8 (8mm Diameter)
M10 (10mm Diameter)
M12 (12mm Diameter)
20m
16m
25m
NOTES:
i) The DIFFERENCE between a BOLT and a SETSCREW is:
- A Bolt is only partially threaded and has a plain upper section whereas
a Setscrew is threaded along its whole length.
ii) The Length of a BOLT or a SETSCREW is measured from the underside
of the head, refer to Diagrams above.
iii) The Diameter of a BOLT is measured across the plain (non-threaded)
section.
iv) The Diameter of a SETSCREW is measured across the top of the
threads.
30m
35m
40m
45m
50m
55m
60m
60mm
Measure length from below head as shown
Plain Section
(Shank) Threaded Section
Di
(Diameter)

1.12

2.1
Section 2

2.2

2.3
SECTION 02 - BRAKE PIPES
- ALWAYS USE NEW BRAKE PIPES.
- TAKE CARE when FORMING the brake pipes to make sure that you achieve a smooth uniform
bend using a pipe bending tool if possible.
- Westfield recommends that you PRACTICE bending on a scrap or spare brake pipe before
attempting to bend any of the brake pipes supplied.
- DO NOT USE metal clips to support the brake pipes or allow the brake pipes to make contact
with other metal parts or foul any nuts, bolts or moving parts.
- To comply with SVA Regulations, all pipes MUST be secured with clips spaced at a Maximum
Distance of 300mm apart.
Tools Required:-
- Electric Drill / 3.5 (or 9/64) Dia Drill Bit / Pop Rivet Gun / Pipe Bending Tool / 2 x 10mm
Spanners / 11mm Spanner / 13mm Spanner / 17mm Spanner
Parts Required:-
- 1 x Brake Pipe Kit (See Page 5 For List Of Pipes Supplied)
- 2 x Brake Master Cylinders
- “P” Clips + Pop Rivets to Suit
- 3 x Three Way Brake Pipe Connector ( “T” Piece )
- 1 x Brake Light Switch and Copper Washer
Step 1: Fit Brake Master Cylinders & Brake Light Switch
View From Drivers Side
Rear Brake Cylinder
Front Brake Cylinder
Brake Light Switch
Rear Brake Line

2.4
Step 1: Cont’d,
View From Front
Step 2: Fit Rear Brake Line
View From Drivers Side
(Front Section Of Chassis)
Brake Light Switch
Rear Brake Line
Brake Light Switch
Front Brake Cylinder
Rear Brake Cylinder
Copper Washer
This Brake Line MUST Run Along the Side
Edge of the Chassis Rail (As Shown)
& NOT Along the Top of the Chassis Rail.
3 Way Brake Pipe Connector
Drill Out Mounting Hole To
Fit Onto M8 Bolt x 50 Long
Prior To Installation
3 x M8 Bolts x 25 Long
(Plus 1x50 Long Bolt For
Switch Mounting).
Insert Bolts From Inside
Pedal Box & Secure With
N
y
loc Nuts

2.5
Step 2: Cont’d,
End
Of Fuel
Tank
Oil
Catch
Tank
View From Drivers Side
(Mid Section Of Chassis)
View From Drivers Side
(Engine Bay Area Of Chassis)
View From Rear Of Car
(Rear Section Of Chassis)
Oil
Catch
Tank
Rear Brake Pipe Coupler
Rear Brake Line
Rear Brake Line
3 Way Brake Pipe Connector
Rear Brake Line

2.6
Step 3: Fit Front Brake Line 3 Way Connector
3 Way Brake Pipe Connector
View From Front
Step 4: Fit Front Drivers Side Brake Line
View From Front
Front Brake Line
(Drivers Side)
Step 5: Fit Front Passenger Side Brake Line
View From Front
Front Brake Line
(Passenger Side)