Caterham Seven Technical data

OWNERS HANDBOOK
CONTENTS
Introduction
1. Before Taking to the Road
Page
4
Controls
Standard instrumentation
Explanation of dashboard
Stack display with windscreen
CSR Integral dash
R500
Stack display operation
4
4
5
6
7
8
9
Before you drive away
Pedal adjustment
Seats and seat belts
Harness
Weather equipment
Security
Starting the engine
Running-in
Catalytic convertor
Gearbox
Fuel
Braking system
10
10
10
10
11
12
14
14
14
15
15
16
2. Useful Information
17
Engine specification
Technical data
Track use
17
18
20
3. Maintenance
Owner maintenance
Under bonnet location
EU4 Sigma 120
Sigma 125
Sigma 150
Duratec 210 (R400)
EU4 Duratec 200 (CSR)
Duratec 260 (CSR)
Duratec 263 (R500)
Safety in the garage
Axle stand positioning
Checking fluid levels
Oil
Coolant
Brake Fluid
Clutch Fluid
Windscreen washers
Battery
Wheels & Tyres
Changing a wheel
Cleaning and car care
Laying your vehicle up for
long periods
Travelling abroad
4. In an Emergency
Emergency starting
Emergency towing
Fuses & relays
Parts & accessories
Bulb replacement
5. Servicing
Service schedules
Service & modification record
Warranty
21
21
21
22
23
24
25
26
27
28
29
29
30
30
31
32
32
32
32
34
34
35
36
37
37
37
38
38
39
39
41
41
42
1
2
INTRODUCTION
Congratulations on 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 super car. 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 and allow 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 in this manual is
adhered to. This will ensure that the vehicle is always in the best possible condition and
performing at its optimum. For all servicing we recommend that you return your car to the
Aftersales Department at Caterham Dartford or Caterham Midlands. Alternatively you
may find it more convenient to use one of the Caterham approved service agents located
around the UK.
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, 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.
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.
3
1.
BEFORE TAKING TO THE ROAD
Figure 1: Dashboard layout for models with standard instruments
Figure 1a: Five or six
speed gear shift patterns
Controls
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
4
Brake fail indicator
Hazard warning light switch
Rear fog light switch
Heated windscreen switch
Heater fan switch
Immobilizer warning light
Windscreen washers switch
Windscreen wipers switch
Side lights/head lights switch
Indicators switch
Main beam switch
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
Headlamp flasher switch
Horn
Fuel gauge
Temperature gauge
Oil Pressure gauge
Tachometer
Speedometer
main beam warning light
Indicator warning light
Ignition warning light
Push starter button
Trip reset button
Heater valve control
EXPLANATION OF DASHBOARD
Brake fail indicator
Hazard warning light
Rear fog light
Heated windscreen
Heater fan
Windscreen washers
Windscreen wipers
Indicator switch
Side/Head lights
Main beam
Headlamp flasher
Heater valve control
Starter push button
Horn push button
Single position spring loaded switch, illuminates to indicate low fluid level. Press to test
bulb.
Single position switch activates all indicators.
Single position switch activates rear fog lights when dipped headlights are illuminated.
Single position switch activates heating elements to demist front windscreen.
Two position switch provides low and high speed fan control.
Single position spring loaded switch activates washer jets when depressed.
2 position switch to provide low and high speed continuous wipe.
3 position switch Left-Off-Right (non-self cancelling)
2 position switch, first position side lights, second position dipped beam headlight.
2 position switch for dip or main beam.
Single position spring loaded switch to flash headlights.
This is located on the inside of engine compartment bulkhead, above the driver’s knee.
Pull towards driver to increase heat.
Single position spring loaded push switch, press to start engine
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.
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.
Fuel gauge
The needle indicates the fuel level. After refuelling, the
gauge slowly rises to the new level once the ignition
switch is turned on.
WARNING! NEVER allow the car to run out of fuel (the
resultant misfire could destroy the catalytic converter).
WARNING LIGHTS
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.
Battery charging – RED
The light illuminates as a bulb check when the ignition
switch is turned to position ‘II’ and extinguishes as
soon as the engine is running. If it remains on, or
illuminates whilst driving, a fault with the battery
charging system is indicated. Seek qualified
assistance.
Direction indicators – GREEN
The indicator warning light flashes in time with the left
or right direction indicator lights, whenever they are
operated. If the warning light fails to illuminate or
flashes very rapidly, this means that one of the
indicator lights is not operating.
5
Figure 2: Dashboard layout for models with Stack Instruments and full windscreen
Controls
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
6
Heated windscreen switch
Brake fail indicator
Hazard warning light switch
Rear fog light switch
Side/Head lights switch
Heater fan switch
Windscreen washers switch
Windscreen wipers switch
Stack button 1
Stack button 2
Stack button 4
Stack button 3
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
Shift light button
Indicator warning light
Indicator switch
Main beam warning light
Starter push button
Stack display
Horn push button
Main beam switch
Headlamp flasher switch
Gear shift lights
Immobiliser warning light
Heater valve control
Figure 3: Dashboard layout for CSR with Integral dash
Controls
1.
2.
3.
4.
5.
6.
7.
8.
9.
Air vent
Oil pressure gauge
Temperature gauge
Heater fan control switch
Fuel gauge
Oil temperature gauge
Indicators
Side/Head lights
Main beam
Headlamp flasher
Tachometer
Speedometer
10. Immobilizer warning light
11. Windscreen wipers
Wiper speed control
12. Windscreen washer switch
13. Gear lever
14. Heated screen switch
15. Horn Push button
16. Starter push button
17. Handbrake
18. Rear fog light switch
19. Hazard warning light switch
20. Heater valve control
7
Figure 4: Dashboard layout for R500
Controls
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Aero screen
Heated screen switch
Hazard warning light switch
Windscreen washer switch
Windscreen wipers switch
Launch control push button
Gear shift lights
Stack display
Stack button 3
Main beam switch
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Side/Head light switch
Stack button 4
Heater valve control
Stack button 2
Stack button 1
Horn push button
Starter push button
Rear fog light switch
Heater fan switch
Brake fail indicator
NOTE: For full windscreen option the wiring connection to dashboard buttons for heated screen, wipers etc are
already connected.
8
Headlight main beam – BLUE
Illuminates when the headlights are switched to main
beam.
Immobiliser Warning light - Red
See section on Immobilisation.
Stack Display System
The Stack display system combines an analogue
tachometer with a digital display for the following
performance parameters:
1.
2.
3.
4.
5.
6.
7.
8.
Vehicle speed
Engine speed
Oil pressure
Oil temperature
Water temperature
Fuel level
Battery Voltage
Lap times (optional) available from aftersales.
An alarm light alerts the driver that a warning condition
has been detected. The warning conditions are based
on pre-set alarm values for the above listed
performance parameters 3-7. When the alarm light is
on, a warning message is shown on the digital display
to identify the condition. It is possible to enable or
disable the warning system for each parameter
individually. The warning message can be cancelled by
pressing any switch. Doing this does not turn off the
warning condition alarm light, which stays on until the
condition no longer applies.
The digital display has five screen display options each
showing certain parameters and their values. The
different screen can be changed by pressing button 3.
Screen 1

Fuel level

Current speed

Trip indicator

Odometer
Press button 3 to change to screen 2
Screen 2

Oil temperature

Current speed

Oil pressure
Press button 3 to change to screen 3
Screen 3

Water temperature

Current speed

Oil pressure
Press button 3 to change to screen 4.
Screen 4

Current speed

Battery Voltage

Ambient air temperature is shown but not utilised
in the set-up. This will default to a reading of -999
Press button 3 to change the display to screen 5
Screen 5

Number of current lap

Current speed (mph or km/h)

Last lap time

Previous best lap time
Press button 3 to change the display back to screen 1.
NOTE: The minimum oil and water temperature for
which the display gives a true reading is 12°C or 53°F.
The unit displays temperatures that are less than this
as 0°C or 32°F.
Peak values (Tell Tales)
The system records Max (or Min where appropriate)
values for each parameter, when the engine is running
at more than 1200 rpm.
This is to prevent abnormal peak values from being
recorded when, for example, the engine is either not
running, is idling, or is being warmed up.
Displaying the Peak Values
Press and hold button 1 to show the peak values for
the parameters currently being displayed. Release the
switch to return to the normal display.
Resetting Peak Values
The peak values remain stored until reset. To reset,
press and hold button 1 and then press button 4 as
well. This clears all the peak values & lap times.
Alarms
The display system has built-in warnings to alert the
driver when certain parameters either exceed or fall
below their alarm values.
Displaying an Alarm
When an alarm condition occurs, the built in red
warning light turns on, and the digital display gives a
warning message to show the type of alarm.
NOTE: The amber light indicates low fuel warning.
Clearing an Alarm
Press button 2.
Showing the Last Alarm
Press and hold button 2.
9
Lap Times
The lap time for each lap is recorded either by the
infrared time sensor when passing an optional lap time
beacon or when the driver presses button 4.
The most recent lap time is held in screen 5.
•
•
The stack display has an internal battery that needs to
be changed every 4-5 years. When the power from this
battery drops below a safe level, an alarm is triggered
and the warning “Internal Battery Low" is displayed.
Contact Caterham Aftersales when this occurs.
•
•
BEFORE YOU DRIVE AWAY
•
Pedal Adjustment Facility
•
On some models the pedals may be adjusted to suit
the driver. Please contact your caterham agent for
details. (CSR/EU4 cars does not have this facility)
Seats/Seat belts/Harness
Forward/backward adjustment
Push the seat adjustment lever to one side to release
the catch enabling the seat to slide back or forward.
Ensure the seat is locked in position before driving off.
WARNING!
DO NOT adjust the seat while the car is in motion.
Head Restraints
Head restraints are designed to restrain rearward
movement of the head in the event of an accident or
sudden stop. On non-race type seats the head
restraints can be removed completely to allow for
fitment of the tonneau cover.
WARNING!
Never drive the car with the head restraints removed.
Seat belt safety
The seat belts supplied with your car are intended for
use by adult sized occupants and must be used by one
occupant ONLY. Seat belts are life saving equipment.
In a collision, unrestrained passengers can be thrown
around inside, or possibly thrown out of the car,
resulting in injury to themselves and to other
occupants.
ENSURE that the passenger is securely strapped in
at all times.
•
10
ALWAYS adjust seat belts to eliminate any slack
in the webbing. DO NOT slacken the webbing by
pulling the belt away from the body – to be fully
effective, the seat belt must remain in full contact
with the body at all times.
ALWAYS fit the lap strap across the pelvis (never
across the abdomen), and ensure that the
diagonal strap passes across the chest, without
slipping off the shoulder, or pressing against the
neck.
DO NOT fit more than one person into a belt, or
use a seat belt that is twisted or obstructed in any
way that could impede its smooth operation.
DO NOT wear seat belts over hard or fragile items
in clothing, such as pens, keys, spectacles etc.
DO NOT allow a baby or infant to be carried on
the lap. The force of a crash can increase effective
body weight by as much as 30 times, making it
impossible to hold on to the child.
DO NOT allow foreign matter to enter the seat belt
buckles as this can render the buckles inoperative.
Pregnant women should ask their doctor for
advice about the safest way to wear seat belts.
Caring for seat belts
Regularly inspect the belt webbing for signs of fraying,
cuts and wear, also paying particular attention to the
condition of the fixing points and adjusters.
Care should be taken to avoid contamination of the
webbing from the effects of polish, oil and chemicals
(see ‘Cleaning & car care’).
Three tests for checking seat belts
1) With the seat belt fastened, give the webbing near
the buckle a quick upward pull – the buckle should
remain securely locked!
2) With the seat belt unfastened, unreel the webbing to
the limit of its travel. Check that unreeling is free from
snatches and snags.
3) With the webbing half unreeled, hold the tongue
plate and give it a quick forward pull – the mechanism
must lock automatically and prevent any further
unreeling!
WARNING!
Always replace a seat belt assembly that has withstood
the strain of a severe vehicle impact, or one where the
webbing shows signs of fraying.
Harness
A multi-point harness holds the driver firmly in the seat
at all times (unlike a seatbelt which ‘locks’ on impact
only). Aside from the increased safety benefit and
being held more securely in extreme circumstances
such as a trackday driving, a harness will remove the
tendency for the driver to brace themselves in corners
using the steering wheel, with better control of the car
as a result.
The lap strap is engaged first, ensuring that it is
adjusted so that it sits across the lap at the lowest
point. It should tight enough that it requires effort to
engage. Shoulder straps are then engaged into the
appropriate slot and tightened by pulling on the
adjuster strap. A harness should feel tight when warn
and not allow any movement of the torso. Although
this feels restrictive at first, a driver will quickly get
used to and ultimately prefer this feeling in a Seven.
To exit from the harness, the spring loaded buckle is
rotated 90deg
Figure 5:
4-Point Harness
Harness Adjustment
Slide the tail strap web through the metal three bar
slide to set up the perfect strap length. The shoulder
strap adjusters should sit on the breast bone, by doing
this first you will ensure that the comfort pads are
located in the correct position tighten the lap straps first
making sure the release buckle is in a central position,
final adjustment is taken up by pulling down on the
shoulder straps.
WARNINGS!
Always check your harness regularly for chaffing, stitch
damage or hardware corrosion. Pay particular attention
to areas that may be visible such as under seat or
cowlings, petrol, battery acid, bleach or similar solvent
must not spill onto web.
Always wear your harness as tight as comfort will allow
but no tight that loss of circulation occurs.
Always replaces a harness that has been involved in
an accident or damage has taken place
Never make any changes to your system either by
cutting and re-sewing web or by modifying the
hardware
Weather equipment
Figure 6:
6-Point Harness
Erecting the hood is relatively straightforward if the
correct procedure is followed. Therefore we
recommend the following sequence is adopted:i) Erect the hoodsticks slacken the buckles to allow
the front hoodsticks to collapse forwards.
ii) Unfold the hood and clip it onto the windscreen
first.
iii) Stretch the rear of the hood over the back of the
car and clip it over the poppers situated on the
back panel starting at the outside and working into
the centre.
iv) Attach to the remaining poppers on the sides of
the vehicle.
v) From the inside of the car, tension the hood by
pulling on the loose end of the straps retensioning
the buckle (the buckle will automatically lock in
position when released). The straps should be
adjusted until the front hoodstick is in line with the
hood seam. (See Fig 6)
11
Figure 7: Tensioning the hood
Figure 8: Hood folding procedure
vii) The tops of the sidescreens tuck under the flaps
on the hood sides in order to make the hood
watertight. At the rear, however, the sidescreens
overlap the hood.
Removal and storage
To remove the hood slacken the buckles and remove
in reverse to the above. (Vii to i)
It is important that the hood is folded correctly when
removed in order to avoid unsightly creases and to
prevent the clear plastic windows being scratched. We
suggest that it is always folded and then rolled as
shown in Fig 7.
To help prevent damage, and free up storage space, a
protective hood bag is available from Caterham Cars
Parts Counter.
NOTE: Never store the hood when wet.
Security
Keys/key numbers
You have been supplied with 4 keys: 2 for the ignition
and 2 for the fuel cap. The numbers for these can be
found on a small tag attached to the key ring.
You will also have been supplied with 2 coded
transponder tags.
WARNING!
Keep the key tag and spare key in a safe place – NOT
IN THE CAR!
If the key or tag is lost please contact Caterham Cars
to make arrangements for a additional keys and tags.
Immobilisation
Most Caterhams are fitted with an immobiliser as
standard, this will be Sterling Excel vehicle immobiliser
system.
Disarming the system
Insert your ignition key with the transponder unit
attached to the same key ring and the reader unit will
automatically recognise the transponder and disarm
your immobiliser. The LED will stop flashing and turn a
constant red indicating the vehicle can be started
vi) The Velcro lined strips inside the hood should now
capture the front hoodstick, which prevents the
hood from ballooning at speed.
12
Arming the system
When the vehicle’s ignition is switched off and the keys
are removed from the ignition, the immobiliser will
prepare to arm and the red LED will illuminate. During
this period, the ignition can be switched back on,
cancelling the arming and permitting the vehicle to be
started as normal.
If after twenty seconds the ignition has not been turned
on, then the immobiliser will automatically ‘arm’ and the
red LED will flash. This ‘auto-arming’ sequence means
that it is impossible to leave your vehicle unprotected.
WARNING!
Your system will automatically re-arm within twenty
seconds of disarming if you do not turn the ignition on.
Programming new transponder tags
If you require a new transponder tag for an additional
user, or as a replacement through loss or damage,
please contact Caterham Aftersales Department.
Once you have received your new transponder tag,
you will need to programme it. To do this you must
have an existing transponder tag that already operates
the system.
1) Disarm the system using an existing transponder tag
attached to the ignition key.
2) Switch the ignition on and off twice and then turn the
ignition back on, all within 7 seconds (the LED will flash
rapidly).
3) The system will then recognise the transponder tag
on the key ring and re-programme it.
4) The LED will flash once to indicate it recognises the
transponder tag.
5) Remove the ignition key with the transponder tag
attached.
6) Pass a new transponder tag close to the ignition
barrel.
7) The LED will flash twice to indicate that the new
transponder tag is in the memory.
8) Pass any additional transponder tag close to the
ignition barrel.
9) For each transponder tag programmed into the
system the LED will flash a number of times to indicate
how many transponder tags are programmed into the
system.
10) When you have finished, switch the ignition off and
the Sterling Excel will exit the programming mode.
Each time you programme a new transponder tags into
the system it will automatically erase all other
transponder tags in the memory therefore all
transponder tags required to operate the system must
be programmed back in.
NOTE: For EU4 cars the transponder is in the key, if
you require a new transponder as a replacement
through loss or damage please contact your local ford
dealer.
Deleting lost transponder tags from the system
memory
If you lose one of your transponder tags, your vehicle
is no longer totally secure, as anyone who finds your
lost transponder tag could disarm your immobiliser. To
prevent this from happening you are able to delete
transponder tags from the system.
Because your Sterling Excel system will recognise up
to five different transponder tags, you will have to reprogramme all of your existing transponder tags every
time you enter programming mode.
NOTE: Sterling Excel is an electronic immobiliser and
derives its main power from your car battery. However,
the consumption in the armed state is such that it
should not adversely affect your car battery.
WARNING!
The tags contain delicate electronic circuits and must
be protected from impact and water damage, high
temperatures and humidity, direct sunlight, effects of
solvents, waxes and abrasive cleaners.
Vehicle battery disconnection
If the car battery is disconnected for any reason the
status of the security system prior to disconnection will
be memorised and automatically reset when the
battery is reconnected.
Ignition Switch and Steering Lock
The ignition switch uses the following sequence of key
positions to operate the steering lock, electrical circuits
and starter motor:
‘O’ – Steering locked
With the key removed, the steering column will be
locked and most electrical circuits are non-operational.
‘I’ – Steering unlocked
Turn the switch to position ‘I’ to unlock the steering.
‘II’ – Electrical circuits on
With the switch in position ‘II’ all electrical circuits are
operational.
‘III’ – Starter motor operates
Turn the switch to position ‘III’ to operate the starter
motor; release the key as soon as the engine starts
(the key will automatically return to position ‘II’).
Steering Lock
To unlock the steering:
Insert the key FULLY and turn the ignition switch to
position ‘I’ – a small movement of the steering wheel
may be necessary to disengage the lock.
To lock the steering:
With the ignition switch turned to position ‘O’, remove
the key and turn the steering wheel until the lock
engages.
NOTE: Cars fitted with a quick release steering wheel
do not have a steering lock mechanism.
WARNING!
Once the steering lock is engaged it is impossible to
steer the car.
DO NOT remove the key, or turn the ignition switch to
position ‘O’ while the car is in motion.
13
Starting the engine
Running-In
WARNING!
Before starting the engine ENSURE you are familiar
with the procedures below. Catalytic converters are
easily damaged through improper use, particularly if
the wrong fuel is used or if an engine misfire occurs –
before starting the engine you should be aware of the
precautions detailed in the ‘Catalytic converter’ section.
Never start or leave the engine running in an
unventilated building – exhaust gases are poisonous
and contain carbon monoxide which can cause
unconsciousness and may even be fatal.
The engine, gearbox, brakes and tyres need time to
‘bed-in’ and adjust to the demands of everyday
motoring. During the first 500 miles (1,000 km) it is
essential that you drive with consideration for the
running-in process and heed the following advice:

DO NOT allow the engine to exceed 4,000
rev/min in any gear.

DO NOT operate at full throttle in any gear.

DO NOT allow the engine to labour in any gear.

AVOID heavy braking.
After the running-in distance has been completed,
engine speeds may be gradually increased.
Starting the engine:
1) Check that the handbrake is on and that the gear
lever is in neutral.
2) Switch off all unnecessary electrical equipment.
3) Turn the ignition switch to position ‘II’ and release
the key as soon as the engine has started.
NOTE: For cars fitted with a push button start, turn the
ignition switch to position ‘II’ and press the red push
button and release the button as soon as the engine
starts.
WARNING!
DO NOT press the accelerator pedal while starting and
DO NOT operate the starter for more than 15 seconds
at a time. If the engine fails to start switch off and wait
for at least 10 seconds before trying again.
NOTE: When the battery is in a low state of charge,
depress the clutch before starting and hold it down until
the engine is running.
Starting in cold climates
In freezing conditions, fully depress the clutch pedal
while starting and hold it down until the engine is
running. Note that engine cranking times will increase
and that the battery charging light may take several
seconds to extinguish.
Warming up
In the interest of fuel economy, it is advisable to drive
the car soon after starting, remembering that harsh
acceleration or labouring the engine before the normal
operating temperature has been reached can damage
the engine.
14
Catalytic Converter
The exhaust system on your car incorporates a
catalytic converter, which converts poisonous exhaust
emissions from the engine into environmentally less
harmful gases, thereby reducing atmospheric pollution.
WARNING!
The catalytic converter can be easily damaged through
improper use, particularly if the wrong fuel is used. For
this reason, it is VERY IMPORTANT that you heed the
following precautions:
Filling up with fuel:
Use ONLY fuel recommended for your car (see
Technical Data).
Starting the engine:
WARNING!
DO NOT continue operating the starter if the engine
fails to start after a few attempts (unburnt fuel may be
drawn into the exhaust system, thereby damaging a
catalyst) – seek qualified assistance.
If a misfire is suspected when starting, DO NOT drive
the car or attempt to clear the misfire by pressing the
accelerator pedal. DO NOT attempt to push or tow
start the car. Instead, turn the ignition switch off
immediately and seek qualified assistance.
Driving the car:
Provided the engine has reached its normal operating
temperature, if a misfire is suspected or the car lacks
power while driving, it may be driven SLOWLY (at risk
of catalyst damage) to Caterham Cars for assistance.
Never
Allow the car to run out of fuel (the resultant misfire
could destroy a catalyst).
An engine burning excessive oil (blue smoke from the
exhaust), will progressively reduce catalyst efficiency.
Do not overload the engine.
Switching off:
DO NOT switch off the engine whilst the car is in
motion, with a forward or reverse drive gear selected.
Vehicle maintenance:
Any engine misfire, loss of engine performance or
engine run-on, could seriously damage the catalytic
converter. For this reason, it is vital that unqualified
persons do not tamper with the engine and that regular
maintenance is carried out by Caterham Cars, in
accordance with the service interval plan included in
this book.
Figure 9: Five and six speed
gear shift patterns
WARNING!
DO NOT run the engine with a spark plug or lead
removed, or use any device that requires an insert into
a spark plug.
Exhaust temperatures can be extremely high; DO NOT
park on ground where combustible materials, such as
dry grass or leaves, could come in contact with the
exhaust system – in dry weather a fire could result.
Cooling fans may operate after the engine is switched
off. Keep clear of all fans while working in the engine
compartment.
Before carrying out maintenance checks or working in
the engine compartment, ALWAYS observe the safety
precautions listed under ‘Safety in the garage’.
Gearbox
The gear positions are indicated on the gear lever
knob. Synchromesh engagement is provided on all
forward gears and in the neutral position the gear lever
is spring loaded to rest naturally between 3rd and 4th
gears.
Selecting reverse gear
Before selecting reverse gear, ENSURE THE CAR IS
STATIONARY; then, fully depress the clutch pedal and
pause briefly before moving the gear lever into position
by pushing the knob downwards prior to moving the
lever fully to the left and forwards.
Precautions while driving
WARNING!
DO NOT rest your hand on the gear lever while driving;
pressure transmitted from your hand, may cause
premature wear to the gear selector mechanism.
DO NOT rest your foot on the clutch pedal while
driving; excessive wear to the clutch will result!
Fuel
USE ONLY UNLEADED PETROL
95 RON (minimum)
WARNING!
USE ONLY UNLEADED PETROL. Serious damage to
the catalytic converter will occur if incorrect fuel is
used.
Fuel Filling
Always fill the tank SLOWLY until the filler nozzle
automatically cuts-off the fuel supply. DO NOT attempt
to fill the tank beyond this point or spillage could result
due to expansion of the fuel.
The filler tube is designed to accept a narrow filler
nozzle of the type found on pumps that deliver ONLY
unleaded fuel. A flap lies across the filler neck; insert
the filler nozzle sufficiently to fully open the flap before
filling.
15
WARNING!
DO NOT fully fill the tank if the car is to be parked on a
slope in direct sunlight or high ambient temperature –
expansion of the fuel could cause spillage.
Filling difficulties
The fuel delivery rate of filling station pumps can vary
significantly from one garage forecourt to another. This
coupled with the fact that modern pumps are equipped
with a sensor which automatically cuts off the supply
as soon as turbulence is detected in the upper part of
the car’s filler neck could result in isolated fuel filling
problems.
If individual owners experience difficulty, the following
advice may be useful:

Hold the filler gun with the trigger directly below
the nozzle (at right angles to the ground).
Twisting the gun to either side, is unlikely to ease
the filling process.

Fill the tank slowly – DO NOT fully squeeze the
trigger.
Braking System
The hydraulic braking system operates through dual
circuits; if one circuit should fail, the other will continue
to function. However, in the event of a brake failure
where only one circuit is operational, the car should
ONLY be driven with EXTREME CAUTION to pull off
the road.
Brake pads
Brake pads and linings require a period of bedding in.
For the first 500 miles, avoid situations where heavy
braking is required.
Remember that regular servicing is vital to ensure that
the brake components are examined for wear at the
correct intervals and changed whenever necessary to
ensure optimum safety and performance.
WARNING!
DO NOT rest your foot on the brake pedal while
driving; this may overheat the brakes, reducing their
efficiency and causing excessive wear.
Handbrake
The handbrake operates on the rear wheels only and
should not require adjustment. To apply the
handbrake, pull the lever up. Always apply the
handbrake FULLY whenever you park the car. To
release, pull the lever up slightly, depress the button
and fully lower the lever.
WARNING!
DO NOT drive with the handbrake applied; this could
damage the rear brakes.
16
17
10.8:1
9.7:1
Solid
16v DOHC
94.0mm
87.5mm
2261cc
4 cyl-in-line
Duratec 200
12.0:1
Solid
16v DOHC
94.0mm
87.5mm
2261cc
4 cyl-in-line
Duratec 260
11.75:1
Solid
16v DOHC
83.1mm
87.5mm
1999cc
4 cyl-in-line
Duratec 263
Single butterfly
Four port throttle
bodies
Four port roller
barrel
MBE
MBE CSR 200
Ford EU4
Single butterfly
7800rpm
7500rpm
Four port roller
barrel
MBE
8500rpm
Unleaded 95 RON
Unleaded 95 RON
Unleaded 95 RON
Unleaded 95 RON
Unleaded 95 RON
Unleaded 95 RON
Unleaded 95 RON
Single butterfly
MBE
MBE
7600rpm
176lbft@7165 rpm
Fuel Type
Single butterfly
Induction System
MBE
7500rpm
200lbft@6000rpm
Multi point injection Multi point injection Multi point injection Multi point injection Multi point injection Multi point injection Multi point injection
Ford
Ignition System
6800rpm
165lbft@5750rpm
Fuel System
6450rpm
Maximum RPM
120lbft@5600 rpm 150lbft@6300 rpm
113lbft@4000 rpm 120lbft@5350 rpm
11.0:1
Solid
16v DOHC
83.1mm
87.5mm
1999cc
4 cyl-in-line
Duratec 210
Maximum Torque
11.0:1
Solid
16v DOHC
81.4mm
79.0mm
1596cc
4 cyl-in-line
Sigma 150
120bhp@6000 rpm 125bhp@6100 rpm 150bhp@6900 rpm 210bhp@7600 rpm 200bhp@7000rpm 260bhp@7500rpm 263bhp@8500 rpm
11.0:1
Compression Ratio
Solid
16v DOHC
81.4mm
79.0mm
1596cc
4 cyl-in-line
Sigma 125
Maximum Power
Solid
Valve Actuation
81.4mm
Stroke
16v DOHC
79.0mm
Bore
Cylinder Head
1596cc
4 cyl-in-line
Capacity
Engine Type
Sigma 120
2. USEFUL INFORMATION - Engine Specifications
Technical data
Kerb Weights
Vehicle Type
2 Seater, convertible sports car.
Classic
540
Roadsport
550
850
SV
575
875
R400
515
815
R500
506
806
CSR
575
875
CSR Superlight
550
850
Min Weight
Construction
Tubular steel space frame.
Aluminium panels with aluminium honeycomb cockpit
side impact protection.
GRP (Glass-reinforced plastic) or Carbon fibre
nosecone and wings.
Dimensions
840
Classic/Roadsport
Superlight
SV
CSR
Braking System
Twin circuit, equal split front/rear, with system warning
of low fluid level. Discs front and rear
Parking brake operating on rear wheels actuated by
hand lever.
Wheelbase
(mm)
2225
2225
2305
2315
Front Track
(mm)
1270
1336
1446
1505
Rear Track
(mm)
1336
1336
1446
1465
Length
(mm)
3380
3100
3530
3300
Width
(mm)
1575
1575
1685
1685
Height (Hood
up) (mm)
1115
1115
1140
1140
Height (Hood
down) (mm)
990
990
1015
1015
Turning Circle
(meter)
10
10
11
11
Internal width
(mm)
930
930
1110
1110
Seat to roof
height (mm)
838
838
865
865
Luggage
capacity (ltr)
120
120
130
130
Suspension
Front
(Except CSR)
Rear
(Except CSR)
Front CSR only
Rear CSR only
Steering
Mechanism
Turns lock to lock
Adjustable double wishbone with
Anti-roll bar
Coil Springs over dampers
De Dion axle located by lower 'A'
frame and radius arms or 'A' Frame
and Watts linkage
Progressive Coil springs
Dampers
Optional - Adjustable anti-roll bar
Pushrod actuated double wishbones
with Anti-roll bar. Coil springs over
dampers
Independent double wishbone.
Coil over spring
Damper units.
Rack and Pinion
Standard
Race
Road wheel nut torque
All
55lbft
75 n-m
Electrical
12 Volt, Negative earth
Alternator output:
Battery Capacity
45 amperes
30 amps/hrs
47 amps/hrs
Manual Transmission
Hydraulic Clutch Actuation all models
18
Max Weight
2.46
1.75
Wheels – Tyres -- Pressure
TYRE PRESSURE
TYRE
WHEELS
FRONT
REAR
18
--
Front Avon 175/55 R13 CR500
Front
6J x 13” alloy
--
18
Rear Avon 205/55 R13 CR500
Rear
8J x 13” alloy
20
20
Avon 185/60 R 14 Avon ZV3
18
18
Avon 195/45 R 15 Avon CR500
6.5J x 15" alloy
24
--
Front Avon 195/45 R15 CR500
Front 6.5J x 15" alloy
--
23
Rear Avon 255/40 R15 CR500
Rear
Fluid Capacities
6J x 14" alloy
9J x 15" alloy
Gearbox ratios
Fuel Tank STD
36 L
Fuel Tank SV/CSR
41 L
Oil (incl Filter) wet sump
4.5 L
Dry sump
6.0 L
Gearbox 5/6 speed Std/Sequential
1.9 L
Cooling System without heater (expect CSR)
4.5 L
Cooling System with heater (expect CSR)
5.1 L
5 SPEED
6 SPEED
1
3.36
2.69
2.4
2
1.81
2.01
1.84
3
1.26
1.59
1.48
4
1.00
1.32
1.26
5
0.82
1.13
1.10
1.00
1.00
2.96
2.4
CSR radiator
5.5 L
6
Differential
1.2 L
R
3.37
6 SPEED SEQ
NOTE: Gearbox and differential fluid capacities are
approximate and the correct level should be obtained
via the level plug
Recommended Fluid Specification
Engine Oil
Ford Sigma
CSR/R400
Track driving
Gearbox Oil*
5/6 SPEED
Sequential
Differential
All cars
LSD's
Engine Coolant
CSR/R400
Ford Sigma
Brake Fluid
Ford Engine oil
Formula E-5W-30
Caterham Motorsport Oil 5W-50
Caterham Motorsport Oil 5W-50
Caterham Gearbox Oil EP80 grade
Caterham Differential Oil EP90
Lubeguard Limited Slip Diff additive
Comma X-stream Red OAT
Ford Super Plus Anti-frezz
Comma DOT4
19
TRACK USE
ENJOYING TRACK DAYS & COMPETING IN YOUR
CATERHAM SEVEN
Due to the difficulty - and illegality - of using the
Caterham Seven’s full performance on the public
roads, many owners choose to use their cars in
competition events, such as circuit racing, sprints and
hill climbs, as well as non-competitive track days.
MOTORSPORT
As an introduction to Motorsport, Caterham Cars
introduced the Academy series in 1995; a race series
exclusively for novice drivers in identical Caterham
machinery. The Academy package comprises of the
car and a complete multi-discipline season taking the
driver from total novice, through the licence process
and training, on to becoming a bona fide race driver. It
has become the most successful programme of its type
in Europe, turning out more than 50 new racers each
year.
The success of the Academy has led to a complete
‘ladder’ of Caterham Motorsport forming to
accommodate all.
Ex-Academy drivers typically
continue into Roadsport-B, a full race series tailored for
the newly experienced drivers, in the same car with
minor modifications. Roadsport-A follows with yet
further modifications, producing Caterham’s most
popular series.
The Roadsports series have been
designed to promote close and cost-effective racing by
virtue of the strict regulations and the use of sealed
engines.
Beyond Roadsports, using Academy based cars, are
the two Superlight championships, using dedicated
cars. The Superlight R400 is Caterham’s premier UK
race series and uses a fearsome 210 Bhp engine with
sequential gear box, coupled to a limited slip
differential. It also has bespoke race suspension and
Evon CR500 developed specifically for the car to
deliver phenomenal performance. The Superlight R300
is a 175 Bhp version of the same car, provides a cost
effective step for drivers progression up the ladder.
In addition to the factory series, the well supported
Caterham Graduates Racing Club, formed in 1998,
provides an independent home for many ex-Academy
drivers in its three classes; two for Roadsport based
cars and one for the old live axle cars of the 1990’s.
Caterham Sevens are also highly popular for hillclimb
and sprint events, from club to national level. These
events are run solely against the clock, with one car on
the course at a time divided into a range of classes.
20
The owners club has its own sprint championship
which is the largest single make series of its kind in the
UK.
The Motor Sports Association (MSA) is responsible for
all forms of motor sport in the UK including all the
above, and in order to compete, a competition licence
must be held. To hold a 'speed' licence for hillclimb
and sprint events you only need to pay the relevant
fee. For a race licence however a one-day ARDS
driving course must be completed and you will need to
pass a medical examination with a doctor. Full details
can be obtained from the MSA or Caterham Cars.
TRACK DAYS
Track driving days give owners the opportunity to
experience all the performance and handling that their
car can deliver, in a safe and legal environment. Days
are generally operated by Track Day Organisers
(TDO’s), companies that specialise in hiring a circuit for
a day, then selling spaces to the general public. TDO’s
can be found by contacting the circuits, or an internet
search. As the quality of service and time varies, word
of mouth recommendation is a valuable medium.
A day will either be sessioned to typically 20 minutes in
the hour (for novice, intermediate and experienced), or
‘open-pitlane’ which allows the owner to take as much
track time as they want. In the latter case, we would
recommend no more than 20 minutes at a time as
personal fatigue can set in and concentration wander.
Remember to drink plenty of fluids.
The Caterham Seven is ideally suited to trackdays and
it can be almost guaranteed that there will be a
Caterham at every single day! The light weight and
race bred design means that the car can be driven to
the circuit, used all day and driven home with complete
confidence.
These same qualities mean that
Caterhams are typically quicker than most cars on
circuit, including much more powerful exotica.
As trackdays cater for the general public in their
regular road cars, only personal safety equipment
(such as a crash helmet) is a requirement. However,
many owners choose to make use of race-developed
safety enhancements for peace of mind. Caterham
Cars would recommend the following options if you
intend using your car on circuit:

Race harness safety belts (4 point or 6 point)

Track day roll over bar

Arm restraints

Ignition cut out switch
Further safety enhancements include:


Plumbed in fire extinguisher
Full race roll cage




Honeycomb fuel tank or bag tank
Honeycomb floor impact protection panels
Rear wheel protection bar
Bespoke seat
All these parts, along with advice, are available from
the Caterham Parts Department and Caterham online
store.
Whilst a Caterham is perfect for track use, there are a
number of essential checks that should be made to
ensure that your day passes smoothly






Wheel nuts - must be torqued to the correct
setting (see Technical Data). Check after every
session.
Tyre pressures – check the hot temperature
immediately after a session. The tyre pressure
will increase beyond that of normal road use and
may need releasing a little. Avon CR500’s
should be approx 22-24psi hot. For more road
orientated tyres, 28psi hot typically gives the best
control.
Oil and coolant. These should be filled to
maximum marks and checked regularly.
Remove all loose objects from boot area
Check brake pad wear and fluid level
Before taking to the track it is wise to give the car
a general ‘spanner check’ to ensure everything is
tight.
Oil Temperature
Once again high rpm or full throttle should not be
used until the engine oil temperature is at least
50C. Oil temperature rises with engine rpm and
loading, so it won’t come up to temperature at
idle like the water. Therefore, if your car isn’t
fitted with an oil temperature gauge, we would
recommend building up the maximum revs used
cautiously for the first few laps of use. The oil will
come up to temperature quickly. A maximum oil
temperature of 120C is recommended. If track
usage causes this figure to be exceeded then
fitment of oil cooler is recommended.
Oil changes
The engine oil should be changed more
frequently with cars used on the track. We
recommend every 1000 track miles as a
minimum. More frequent changes can only be
beneficial.
For Enhanced Track Performance, you may wish to
upgrade your car to include some of the following as
this will improve both your enjoyment and safety whilst
on the track.

Track usage is among the toughest environments for
any vehicle and even though your Caterham has been
designed around this environment it is vital that careful
monitoring of the gauges is carried out whilst driving
under these harsh conditions. The following
recommendations are designed to reduce the risk of
engine damage:
Water Temperature
Always allow the engine to warm up to at least
65C before using high rpm or full throttle. The
optimum operating water temperature for your
engine is 110C.





13" wheels fitted with Avon CR500 road tyres
(This may require adjustable spring
platforms to be fitted.
For further
information contact Caterham Technical
Department).
Uprated anti roll bars (front and rear)
Uprated front or rear springs
Clutch and throttle pedal stops
Uprated brake master cylinder
Race dampers
NOTE: For track use, cars fitted with uprated brake
master cylinder must use race cap to avoid any leaks.
3.
Maintenance
Owner Maintenance
In addition to the routine services and inspections
described in this book, the following simple checks
must be carried out more frequently. You can do these
yourself and advice is given on the pages that follow.
21
Figure 10a: Underbonnet location – EU4 Sigma 120
1. Brake Fluid Reservoir
2. Clutch Fluid Reservoir
3. Battery
4. ECU
5. Air Box
22
6. Windscreen Washer Fluid
7. Dip stick
8. Engine Oil Filler Cap
9. Coolant Filler Cap
Figure 10b: Under bonnet location - Sigma 125
1. Brake Fluid Reservoir
2. Clutch Fluid Reservoir
3. Battery
4. MAP
5. ECU
6. Air Filter
7. Windscreen Washer Fluid
8. Dip Stick
9. Engine Oil Filler Cap
10. Coolant Filler Cap
23
Figure 10c: Underbonnet location - Sigma 150
1. Brake Fluid Reservoir
2. Clutch Fluid Reservoir
3. Battery
4. MAP
5. ECU
24
6. Air Filter
7. Windscreen Washer Fluid
8. Dip Stick
9. Engine Oil Filler Cap
10. Coolant Filler Cap
Figure 10d: Underbonnet location – Duratec 210 (R400)
1. Brake Fluid Reservoir
2. Clutch Fluid Reservoir
3. Battery
4. MFU
5. Air filter
6. Windscreen Washer Fluid
7. ECU
8. Dip Stick
9. Engine Oil Filler Cap
10. Coolant Filler Cap
NOTE: Under bonnet location for R400 with dry sump is similar as standard R400 apart from oil tank located near
coolant tank and oil cooler in front of the radiator.
25
Figure 10e: Underbonnet location – EU4 Duratec 200 (CSR)
1. Brake Fluid Reservoir
2. Clutch Fluid Reservoir
3. Battery
4. Air box
5. Dip stick
6. Windscreen Washer Fluid
7. Brake fluid Reservoir
8. Coolant Filler Cap
9. Engine Oil Filler Cap
NOTE: SVR Under bonnet location is similar to EU4 CSR apart from the Battery location
26
Figure 10f: Underbonnet location - Duratec 260 (CSR)
1. Brake Fluid Reservoir
2. Clutch Fluid Reservoir
3. Battery
4. ECU
5. MFU
6. Dip Stick
7. Coolant Filler Cap
8. Breather Bottle
9. Windscreen Washer Fluid
10. Air Filter
11. Engine Oil Filler Cap
NOTE: CSR 200 under bonnet location is similar to 260 apart from air filter which is similar to R400 location
27
Figure 10g: Underbonnet location – Duratec 263 (R500)
1. Brake Fluid Reservoir
2. Clutch Fluid Reservoir
3. Coolant Filler Cap
4. ECU
5. Battery
6. Air Filter
7. Dry Sump Tank
8. Engine Oil Filler Cap
9. Oil Cooler
NOTE: The windscreen Screen washer bottle is located above the battery for the cars fitted with full windscreen
28
Regular checks:

Operation of lights, horn, direction indicators,
wipers, washers and warning lights.

Operation of seat belts and brakes.

Look for fluid deposits on the floor beneath the
car, which may indicate a fluid leak.
Weekly checks:

Engine oil level.

Cooling system level.

Condition and pressure of tyres.

Brake fluid levels.

Clutch fluid levels.

Screen washer reservoir level.
NOTE: Any significant or sudden drop in fluid levels, or
uneven tyre wear, should be reported to Caterham
Cars without delay.
Emission control
Your car is fitted with emission control equipment
designed to meet specific legal requirements. You
should be aware that unauthorised replacement,
modification or tampering with this equipment by an
owner or motor vehicle repairer, could be unlawful and
subject to legal penalties.
In addition, engine settings must not be tampered with.
These have been established to ensure that your car
complies with stringent exhaust emission regulations.
Incorrect engine settings may adversely affect exhaust
emissions, engine performance and fuel consumption,
as well as causing high temperatures, which could
result in damage to the catalytic converter and the car.
Safety in the garage
If you need to carry out maintenance on your vehicle,
observe the following safety precautions at all times:
WARNINGS!

ALWAYS keep hands, tools and items of
clothing, clear of all drive belts and pulleys

DO NOT touch exhaust or cooling system
components until they are cool.

DO NOT touch electrical leads or components
with the ignition switch turned on.

NEVER leave the engine running in an
unventilated area – exhaust gases are poisonous
and extremely dangerous.

DO NOT work beneath the car with a vehicle
lifting jack as the only means of support. (See
axle stand positioning).

Ensure sparks and naked lights are kept away
from the engine compartment.

Remove all metal wrist bands and jewellery,
before working in the engine compartment and
NEVER allow the battery terminals, or leads, to
make contact with tools or other metal parts of
the car.
Figure 11:
Front Axle Stand
Positioning
Figure 12:
Rear Axle Stand
Positioning
29
Poisonous liquids
Most liquids used in motor vehicles are poisonous and
should not be consumed or brought into contact with
open wounds (these substances include; battery acid,
anti-freeze, brake fluid, petrol, oil and windscreen
washer additives).
Obey all instructions printed on labels and containers!
Used engine oil
Prolonged contact with engine oil may cause serious
skin disorders, including dermatitis and cancer of the
skin. Wash thoroughly after contact.
Checking fluid levels
Due to the nature of the Caterham Seven with its high
revving engines and extreme cornering speeds it is
vitally important that the correct engine oil level is
maintained at all times.
Engine oil level cannot be checked too often
We recommend that it be checked at least every 500
miles and before any long journey or before every
session at a track day.
There are several different oil systems fitted to the
Seven, each of which requires a different means for
checking the level. It is important that you are clear on
the correct procedure for the system fitted to your car.

Standard wet sump arrangements & engines
fitted with oil/air separator tank

Engines with dry sump Bell tank and swirl tower
Figure 13
Engines with dry sump bell tank and swirl tower
Engines with Standard Wet Sump Arrangement







30
Start the engine and run until the normal
operating temperature is achieved (90-100°C).
Stop the engine and remove the dipstick from its
tube and wipe clean before re-dipping, please
leave the dipstick in place for 30sec this will
ensure that the correct indication is achieved.
The oil should be at the maximum level at all
times. (As a guide the difference between min
and max is approximately 1/2 litre).
If required, oil should be added via the oil filler
cap on the top of the engine and must be of the
correct specification of oil for your engine type.
(See technical data).
It is advisable to add a small amount at a time
and recheck by repeating the above procedures
until the correct level is achieved.
Care should be taken not to overfill the engine
with oil.
Always make sure the oil filler cap and dipstick
are fitted back in place before restarting the
engine.
Figure 14



Start the engine and run it until the normal
operating temperature is achieved (90-100°C).
Switch off the engine.
Unscrew the tank cap from the top of the swirl
tower. Wipe clean the dipstick provided before
dipping, this will ensure that the correct indication
is achieved. Be sure the dipstick fully home when
dipping.






The oil should be at the maximum level at all
times. (As a guide the difference between min
and max is approximately 1/2 litre).
If oil is required it should be added via the oil filler
cap on the top of the engine and must be of the
correct specification for your engine type. (See
technical data).
It is advisable to add a small amount at a time
and recheck by repeating above procedures until
the correct level is achieved.
Care should be taken not to overfill the engine
with oil.
Overfilling this system will result in oil being
blown out into the oil catch tank the next time the
vehicle is driven.
Always take off the dipstick from the swirl tank
and make sure the oil filler cap and swirl tank cap
are fitted back in place before restarting the
engine.
NOTE: With this system the oil level must be
checked within one minute of the engine being
switched off otherwise the oil will start to drain
back into the engine and a false reading will be
obtained. Should this be the case restart the
engine again and let it run for approximately one
minute before repeating the checking procedure.
Engines with Dry Sump Tank (R400/R500)
Start the engine and run it until the normal operating
temperature achieved (90-100°C). Keep the engine
running, open the dry sump tank cap and look inside,
you will find two baffle levels with centre holes. In
normal condition the oil should run approximately 5mm
below the middle baffle level. Top up the oil if required
Coolant check & top-up
The coolant level should be checked weekly when the
system is cold and topped up with appropriate coolant
(see technical date). Top up to the ‘MAX’ mark shown
on the exterior of the reservoir. If the level falls
appreciably during a short period; suspect leakage or
overheating and arrange for Caterham Aftersales to
examine the vehicle.
Anti-freeze
The anti-freeze content of the coolant must be
maintained all the year round. Caterham use Comma
X-stream Red and Ford Superplus premium (ready
mixed), however, if a water/antifreeze mix is
substituted for any reason a minimum of 50%
antifreeze is required. To ensure that its anti-corrosion
properties are retained, the anti-freeze content should
be checked by Caterham Aftersales once a year. The
coolant should be completely renewed every four
years.
Figure 15: Coolant, Expansion bottle
WARNING!

DO NOT use anti-freeze to any specification
other than that recommended (see technical
data).

DO NOT add rust inhibitors or other additives to
the coolant – these may not be compatible with
the coolant or engine components.

DO NOT remove the reservoir cap when the
cooling system is hot – escaping steam or water
could cause serious injury.

Anti-freeze is poisonous and can be fatal if
swallowed. If accidental consumption of antifreeze is suspected, seek appropriate medical
attention immediately.

Take precautions to prevent anti-freeze coming
in contact with the skin or eyes. If this should
happen, rinse immediately with plenty of water.

Anti-freeze is inflammable. Take care not to spill
anti-freeze onto a hot engine – a fire may result.

When topping up, avoid spillage onto painted
body panels – anti-freeze may damage painted
surfaces.
Brake/Clutch fluid check & top-up
Fluid level in the Brake/Clutch reservoir may fall slightly
during normal use, but should not drop below the lower
level mark. If there is any appreciable drop in level over
a short period, consult Caterham Aftersales.
Topping-up
Wipe the filler cap clean before removing to prevent
dirt from entering the reservoir and then top-up the
reservoir to the ‘MAX’ mark using a recommended
fluid: (See technical data)
For the clutch reservoir, ‘Max’ and ‘Min’ levels are
highlighted on the outer surface of the reservoir.
31
Figure 16: Brake Fluid reservoir


Brake/Clutch fluid must be completely replaced
every after two years regardless of mileage.
Brake/Clutch fluid is inflammable; do not allow
fluid to come into contact with hot components or
naked flames.
Wipers & Washers
Windscreen washers
Check the reservoir level at least every week and topup with a mixture of water and Comma screenwash.
WARNING!
Screenwash is flammable, particularly if high or
undiluted concentrations are exposed to sparks. Do not
allow screenwash to come into contact with naked
flames or sources of ignition.
1. Reservoir filler cap
2. ‘MAX’ – maximum level
3. 'DANGER' – minimum level
Use only new fluid from a sealed container (old fluid
from uncapped containers or fluid previously bled from
the system will absorb moisture, and adversely affect
performance).
To refit the cap, replace slowly to prevent leakage and
screw up by hand only.
Figure 17: Clutch fluid reservoir
Body panels may suffer discolouration as a result of
screenwash spillage. Take care to avoid spillage,
particularly if an undiluted or high concentration of
screenwash is being used. If spillage occurs, wash the
affected area immediately with water.
WARNING!
Do not use an anti-freeze or vinegar/water solution in
the screen washer reservoir – anti-freeze will damage
painted surfaces, while vinegar can damage the
windscreen washer pump.
Washer jets
Once set the water jets should not require further
adjustment. If a jet becomes blocked, use a thin wire or
pin as a probe to clear the obstruction.
Wiper blades
Wash the wiper blades in warm soapy water and
periodically check their condition. If signs of hardness
or cracking in the rubber are found, or if the wipers
leave streaks or unwiped areas on the windscreen
during use, then the wiper blades should be replaced.
Clean the windscreen regularly with glass cleaner and
ensure the screen is thoroughly cleaned before fitting
replacement wiper blades.
Battery
WARNING!

DO NOT drive the car if the fluid level is below
the ‘DANGER’ mark.

Brake/Clutch fluid may damage painted surfaces:
Soak up any spillage with an absorbent cloth
immediately and wash the area with a mixture of
car shampoo and water.

If Brake/Clutch fluid should come into contact
with the skin or eyes, rinse immediately with
plenty of water.
32
Battery maintenance
The battery is designed to be maintenance free, so
topping-up is unnecessary. The battery will lose charge
if your vehicle is laid up unused. See “Laying your
vehicle up for long periods” later in this section.
WARNING!
Batteries contain acid, which is both corrosive and
poisonous. If spillage occurs:





On clothing or the skin – remove any
contaminated clothing immediately, flush the skin
with large amounts of water, and seek medical
attention urgently.
In the eyes – flush with clean water immediately
for at least 15 minutes. Seek medical attention
urgently.
Swallowing battery acid can be fatal unless
IMMEDIATE action is taken – seek medical
attention urgently.
During normal operation batteries emit explosive
hydrogen gas – ensure sparks and naked lights
are kept away from the engine compartment.
For your safety remove all metal wrist bands and
jewellery before working in the engine
compartment and NEVER allow the battery
terminals or vehicle leads to make contact with
tools or metal parts of the vehicle.
WARNING!

DO NOT reverse the polarity of the battery – the
electrical system will sustain extensive damage if
the battery leads are connected to the wrong
terminals.
Battery removal and replacement
Before disconnecting the battery, switch off all
electrical equipment and remove the ignition key.
To remove: disconnect the negative (‘–’) cable first and
then the positive (‘+’) cable. When reconnecting,
connect the positive cable first and then the negative
cable. Do not allow the battery terminals to make
contact with metal parts of the vehicle.
To release the battery from the car, undo the two bolts
securing the battery clamp and remove the clamp.
When replacing, ensure the battery is fitted the right
way round and that the clamp is secure. Tighten the
clamp bolts until the clamp is free from movement, but
do not overtighten.
Figure 18: Battery and battery clamp
Replacement battery
Only fit a replacement battery of the same type and
specification as the original – other batteries may vary
in size or have different terminal positions which could
cause a fire hazard when connected to the car’s
electrical system.
Battery disposal
Used batteries should be recycled. However, batteries
are hazardous – you should seek advice about
disposal from a Caterham dealer or your local
authority.
WARNING!

Keep the battery upright at all times – damage
will be caused if the battery is tilted more than 45
degrees.

DO NOT run the engine with the battery
disconnected, or disconnect the battery while the
engine is running.
Battery charging
Batteries generate explosive gases, contain corrosive
acid and produce levels of electric current sufficient to
cause serious injury. While charging always heed the
following precautions:

Before charging, disconnect and remove the
battery from the vehicle – charging the battery
with the cables connected may damage the
vehicle’s electrical system.

Make sure the battery charger leads are securely
clamped to the battery terminals BEFORE
switching on the battery charger. Do not move
the leads once the charger is switched on.

While charging, shield your eyes or avoid leaning
over the battery and keep the area around the
top of the battery well ventilated.

Do not allow naked lights near the battery
(batteries generate flammable hydrogen during
and after charging).

When charging is finished, switch off the battery
charger BEFORE disconnecting the leads from
the battery terminals.

After charging, leave the battery for an hour
BEFORE reconnection to the vehicle – this will
allow time for explosives gases to disperse,
thereby minimising the risk of fire or explosion.
NOTE: Be aware that a battery will take longer to
charge in a cold environment.
WARNING!

DO NOT charge the battery if it is connected to
the car – this may seriously damage the electrical
system.

DO NOT charge the battery if it is suspected of
being frozen.
33
Wheels & Tyres
WARNING!
DEFECTIVE TYRES ARE DANGEROUS!
DO NOT drive your car if any tyre is excessively worn
or damaged, or is inflated to an incorrect pressure.
Incorrect tyres can affect the stability and handling
characteristics of your car – only fit replacement tyres
that are identical to the original specification.
Caring for your tyres
Always drive with consideration for the condition of the
tyres, and frequently inspect the tread and side walls
for any sign of distortion (bulges), cuts or wear.
The most common causes of tyre failure are:

Bumping against kerbs

Driving over deep pot holes

Driving with under or over-inflated tyres.
Tyre pressures
Correctly inflated tyres will ensure that you enjoy the
best combination of tread life, ride comfort, fuel
economy and road holding.
Check the pressures at least every week (including the
spare wheel), preferably when the tyres are cold (be
aware that the car can be driven up to one mile (1.6
km), before the tyres start to warm up).
Air pressure naturally increases in warm tyres; if it is
necessary to check the tyres when they are warm
(after the car has been driven for a while, even in cold
weather), you should expect the pressures to have
increased by between 4 and 6 Psi. In this
circumstance, DO NOT let air out of the tyres in order
to match the recommended pressures.
The recommended pressures are shown in ‘Technical
Data’ section of this book.
Remember; incorrectly inflated tyres may wear rapidly
or unevenly, are more easily damaged, and can
seriously affect the car’s handling characteristics.
Tyre wear indicators
The tyres on your car have wear indicators moulded
into the tread pattern at several points around the
circumference. When the tread has worn down to 1.6
mm, the indicators will come to the surface of the tread
pattern, producing the effect of a continuous band of
rubber across the width of the tyre.
The indicators provide warning that there is insufficient
tread remaining to provide good traction, particularly on
wet roads.
NOTE: Due to the minimal weight of the Caterham it is
more prone to aquaplaning in wet conditions. It is for
this reason that we recommend tyres are changed at
2.5mm even though the legal minimum is 1.6mm.
34
If tyre wear is uneven (on one side of the tyre only), or
becomes abnormally excessive, the suspension
geometry should be checked.
Valve caps
Keep the valve caps screwed down firmly. They
prevent dirt from entering the valve.
Punctured tyres
Your car is fitted with tubeless tyres, which will
normally lose pressure very slowly if penetrated by a
sharp object, provided it remains in the tyre. If you are
aware of this occurring, reduce speed immediately and
drive with caution until the spare wheel or replacement
tyre can be fitted. Remember, punctured or damaged
tyres must be permanently repaired or replaced, AS
SOON AS POSSIBLE!
NOTE: All cars are supplied with tyre fix repair spray to
repair a small puncture on the tyre surface temporarily.
Please follow the instruction on the repair spray can.
Caterham Cars recommend to replace the tyre rather
than repair. A tyre repair may not withstand the
performance demands you place upon it
Replacement tyres
Wheel rims and tyres are matched to suit the handling
characteristics of the car. Changing the specification of
a wheel or a tyre, can adversely affect the car’s
handling and ultimately, your own safety in emergency
road situations.
To be safe, ONLY fit replacement tyres that are
identical to the original specification shown in
‘Technical Data’ section of this book.
Changing a Wheel and Tyre assembly
Tools required

Jack & handle

Wheel nut spanner
Before you start, ensure that the vehicle is on firm level
ground. Always apply the handbrake and put into 1st
gear.
Positioning the jack
Position the jack under the jacking point (see
illustration).
Turning the jack screw by hand, raise the jack until the
centre of the jack platform fits snugly up to the jacking
point. Do not raise the car.
Figure 19: Front jacking point
Figure 20: Rear jacking point

Whenever refitting the wheel nuts it is imperative
that they are tightened to the correct torque.
Check wheel nut torque as soon as possible.
WARNING!
Always observe the following precautions!

Choose a safe place to stop, away from the main
thoroughfare, and ensure your passenger gets
out of the car and waits in a safe area, away from
other traffic.

Switch on the hazard warning lights to alert other
road users. Apply the handbrake and engage 1st
gear.

Ensure the jack is positioned on firm, level
ground. Do not position the jack on metal
gratings or manhole covers, or use additional
material between the base of the jack and the
ground.

If jacking on a slope, place chocks at the front
and rear of the wheel diagonally opposite the one
to be removed.

Care must be taken to avoid accidental contact
with any underbody parts, especially the hot
exhaust system components, likely to cause
personal injury during the raising or lowering of
the car.
WARNING!
NEVER jack the car with passengers inside!
NEVER work beneath the car with the jack as the only
means of support. The jack is designed for wheel
changing only!
Removing and refitting the Wheel and Tyre
assembly
Before raising the vehicle, use the wheel brace to
slacken the wheel nuts ½ a turn anti-clockwise.
Ensure the jack is placed as far inboard as possible
when jacking the front of vehicle on lower wishbone.
Attach the jack handle to the jack and turn clockwise
until the tyre is just clear of the ground. (Do not allow
the jack to tilt on its base).
Remove all the wheel nuts and the wheel. (Do not
place the wheel face down on the ground as this may
cause scratching to the surface of the wheel).
Replace the wheel and wheel nuts (tapered end
towards the wheel) and tighten the nuts until the wheel
is seated firmly against the hub.
Lower the car by turning the jack handle anti-clockwise
then remove the jack from under the car. Finally fully
tighten the wheel nuts in a diagonal sequence.
WARNING!

Always check the tyre pressures before driving
off or as soon afterwards as possible.
Cleaning and car care
Washing your car
WARNING!
Take care to avoid contact with a hot exhaust system
when washing the car.
Road dirt, oil, and deposits from birds and trees, can
permanently spoil the paint finish. Wash your car
frequently, using a clean, grit free sponge and
generous quantities of cold or lukewarm water,
containing a car shampoo. Rinse and dry off with a
chamois leather.

In hot weather, DO NOT wash the car in direct
sunlight – move the car into the shade!

DO NOT use detergent soap products or
washing up liquid.
During winter months when salt has been used on the
roads, use a hose to wash the underside. Pay
particular attention to wheel arches, panel seams and
to removing accumulations of mud.
When using a hose, do not direct the jet into the heater
air intake ducts, or through the wheels onto the brake
components.
35
WARNING!
Some high pressure cleaning systems available on
garage forecourts are sufficiently powerful to damage
fragile components. Never aim the water jet directly at
components that might easily be damaged.
Removing tar spots
Use a tar removal product such as Auto Glym intensive
tar remover to remove tar spots and stubborn grease
stains from paintwork. Then wash immediately with
soapy water, to remove all traces of the spirit.
Body protection
After washing, inspect the paintwork for damage. Treat
paint chips and scratches with touch-up paint. If the
damage has revealed bare metal, use a coloured
primer first, then apply the base coat and finish off with
a lacquer pencil, if appropriate. Carry out this treatment
after washing, but before polishing or waxing.
However, take care to ensure that car polish and body
cleaning compounds are not applied to the window
glass or seals.
Windscreen
Regularly clean the windscreen, inside and out, using
an approved glass cleaner.
Hood/Sidescreen
The windows in the hood and sidescreen are made of
plastic and should be cleaned with soapy water. Never
use an abrasive cleaner on these windows.
Mirrors
Mirror glass is particularly susceptible to damage; DO
NOT use abrasive cleaning compounds or metal
scrapers.
Wiper blades
Always clean the windscreen before fitting replacement
wiper blades. Regularly wash the wiper blades with
warm soapy water (NEVER use a spirit or petrol based
solvent).
Looking after the interior
Vinyl/plastic/cloth-faced materials: Clean with diluted
upholstery cleaner.
Leather: Seats, steering wheel and any trim features
should be cleaned with warm water and a nondetergent soap. Dry and polish the leather with a clean,
dry, lint-free cloth.
DO NOT use petrol, detergents, furniture creams or
polishes!
Carpets: Sweep regularly with a brush or vacuum
cleaner and clean with diluted upholstery cleaner.
36
Seat belts
Extend the belts, then use warm water and a nondetergent soap to clean. On no account use bleaches,
dyes or cleaning solvents – these can weaken the belt
webbing. Finally, allow the belts to air-dry naturally and
do not retract them, or use the car, until they are
completely dry.
Laying your vehicle up for long periods
Should your Caterham be laid up unused for more than
12 weeks at a time then we recommend the following
precautionary measures be taken to avoid
unnecessary deterioration:
1. Ensure the bodywork and trim are properly
cleaned and protected to prevent corrosion.
2. Erect and correctly tension weather equipment to
prevent storage damage.
3. Raise car off the ground and place on axle stands
taking the weight of the car off of the tyres.
4. Check Antifreeze content as this will not only
protect your engine from the cold but most
antifreeze also includes additives to prevent
corrosion inside the cooling system.
5. It is importance that the battery charge level is
maintained during storage. Recharging of the
battery may not be successful if the battery is
allowed to discharge below a certain level.
We recommend that a battery conditioner is fitted
to the vehicle whilst in storage as this unit will
maintain a minimum charge at all times. Suitable
device is available from Caterham Parts
department. Should this option not be available to
you then the battery should be disconnected and
charged periodically. See section on battery
removal and replacement.
6. Ensure that the handbrake is off and that all the
wheels turn freely as this will help to prevent the
brake pads from sticking to the discs in cold and
damp conditions.
After long periods of storage
Before reusing your vehicle after storage, the following
checks should be carried out:
1. Tyre pressures and condition
2. Check all fluid levels
NOTE: Should your vehicle have been laid up in
excess of 6 months then we strongly recommend that
the engine oil and oil filter are changed and the braking
system is checked. A full safety check is available from
the Caterham Aftersales Department.
Travelling abroad
In certain countries, it is illegal to fit parts which have
not been made to the vehicle manufacturer’s
specification.
Owners should ensure that any parts or accessories
fitted to the car while travelling abroad will also
conform to the legal requirements of their home
country.
NOTE: There are certain items you are required to
carry with you whilst travelling abroad. Please consult
your motoring organisation for the latest requirements.
4.
1)
2)
3)
4)
5)
IN AN EMERGENCY
Emergency Starting
WARNING!

During normal use, batteries emit hydrogen gas,
sufficient to cause severe explosions capable of
causing serious personal injury – ensure sparks
and naked lights are kept well away from the
engine compartment.

DO NOT disconnect the discharged battery.

Make sure BOTH batteries are of the same
voltage (12 volts) and that the jump leads are
approved for use with 12 volt car batteries.

To avoid injury, always adopt the following
procedure when using jump leads.
If a donor vehicle is to be used, the vehicles
should be parked with their battery locations
adjacent to one another. Ensure that the two
vehicles do not touch.
Apply the handbrakes and ensure that the gear
levers on both vehicles are in neutral.
Turn off the ignition switch and ALL electrical
equipment of BOTH vehicles.
Connect the RED jump lead between the positive
(+) terminals of BOTH batteries.
Connect the BLACK jump lead from the negative
(–) terminal of the donor battery, to a good earth
point (eg. engine mounting, engine block or other
unpainted surface), remote from the battery and
well away from fuel and brake lines (see
illustrations).
DO NOT connect a jump lead to the negative (–)
terminal of the discharged battery!
6) Check that the cables are clear of the moving
parts of both engines, then start the engine of the
donor vehicle and allow it to idle for a few minutes.
7) Now start the engine of the car with the
discharged battery – DO NOT crank the engine for
more than 15 seconds at a time.
8) Once both engines are running normally, allow
them to idle for two minutes, before switching off
the engine of the donor vehicle and disconnecting
the jump leads. DO NOT switch on any electrical
circuits on the previously disabled vehicle, until
AFTER the jump leads have been removed.
Figure 21: Jump lead connection
9)
Using jump leads from a donor battery, or a battery
fitted to a donor vehicle, is the only approved method
of starting a car with a flat battery. Push or tow starting
is NOT recommended!
Disconnecting the jump leads must be an EXACT
reversal of the procedure used to connect them,
ie: disconnect the BLACK cable from the earth
point on the disabled vehicle FIRST.
37
Emergency towing
Fuses - Sigma
Both the front and rear towing eyes are intended for
use ONLY by the emergency services, or qualified
vehicle recovery specialists, to assist in the recovery of
your car should a breakdown or accident occur.

DO NOT use the lashing eyes to tow your car
behind another vehicle.

DO NOT using the lashing eyes for towing
another vehicle.
Towing for recovery
If your car is to be towed, most qualified recovery
specialists will use wheel lift equipment to suspend the
front wheels while the rear wheels remain on the
ground. However, if it is necessary for the car to be
towed with all four wheels on the ground, follow this
procedure.
Before being towed:
1) Turn the ignition key to position ‘I’ to unlock the
steering, and then to position ‘II’ to enable the brake
lights, wipers and direction indicators to be operated if
necessary.
2) Place the gear lever in neutral.
3) Release the handbrake.
WARNING!

DO NOT attempt to tow the car unless the
ignition switch is turned to position ‘I’, in order to
unlock the steering (if, due to an accident or
electrical fault, this is considered unsafe,
disconnect the battery before turning the switch).

DO NOT remove the ignition key, or turn the
switch to position ‘O’, while the car is in motion.
Fuses and Relays
The fuse box is located under the dashboard on the
vertical face of the engine bulkhead (see figure 21).
Although the fuses and relays are not numbered the
tables below are in the order that they will be found in
the fuse box working from the top down.
Relays
Sigma
Ignition
Lights
Indicator
Hazard
Starter
Fuel Pump
Cooling Fan
38
Duratec
1
2
3
4
5
6
7
Horn
Lights
Hazard
Flasher
Stack dash
1
2
3
4
5
A= Brake Lights
B = Reverse Light
C = Instruments
D = Heater
E = Heated Screen
F = Rear Fog Light
G = R/H Side/Tail Light
H = L/H Side/Tail Light
I = Main Beam
J = Dip Beam
K = Wipe/Wash
L = Horn
M = Flasher Unit
N = Fuel Pump
O = Power Socket
P = Ignition Supply Engine
Q = Ignition Supply Engine
R = Ignition Supply Engine
S = Ignition Supply Engine
T = Main Feed Engine
U = Acc Cluster engine
7.5A
5A
7.5A
7.5A
10A
5A
7.5A
5A
15A
15A
15A
7.5A
10A
15A
10A
15A
15A
15A
15A
15A
7.5A
Fuses – Duratec
A = Brake/Reverse Light
B = Instruments/Heater
C = Ignition Supply (Engine)
D = Heated Screen
E = Rear Fog Light
F = R/H Side Tail Light
G = L/H Side Tail Light
H = Main Beam
I = Dip Beam
J = Wipe/Wash
K = Horn
L = Flasher Unit
M = Fuel Pump
N = Battery Supply (Engine)
O = Power Socket
15A
10A
15A
10A
5A
7.5A
5A
15A
15A
15A
20A
10A
15A
30A
10A
Fuses are simple circuit breakers, which protect
electrical equipment by preventing the electrical circuits
from being overloaded. A ‘blown’ fuse is indicated
when the electrical equipment it protects becomes
inoperative. Check a suspect fuse by removing it from
the fuse box and looking for a break in the wire inside
the fuse.
Renewing a fuse
Always turn off the ignition switch and the appropriate
electrical circuit before removing a fuse. Always
replace a fuse with another of the same (or lower)
rating. If a replacement fuse blows almost immediately,
this indicates a serious electrical problem and the
circuit MUST be checked by Caterham Cars.
Figure 22: Fuse box and relay location
WARNING!

It is extremely hazardous to fit parts or
accessories where installation requires the
dismantling of, or addition to, either the electrical
or fuel systems.

Fitting parts or accessories that have not been
approved by Caterham, or the carrying out of
non-approved alterations or conversions, may be
dangerous and could affect the safety of the car
and occupants, and also invalidate the terms and
conditions of the car’s warranty.
Bulb Replacement
Fuse colours
The fuses are colour coded to identify their amperage
ratings as follows:
ORANGE
BROWN
RED
BLUE
YELLOW
CLEAR
GREEN
5 amp
7.5 amp
10 amp
15 amp
20 amp
25 amp
30 amp
Parts & Accessories
Service parts & accessories
Only Caterham Cars and their dealers are able to
provide the full range of recommended parts and
accessories which meet our rigorous standards of
safety, durability and performance.
To ensure your future driving pleasure and safety, we
strongly recommend that only Caterham approved
parts are fitted to your car.
All genuine Caterham parts and accessories are
guaranteed for twelve months or 6000 miles
(whichever is sooner) with unlimited mileage.
A comprehensive parts resource is available from
Caterham Parts Department or via our online part store
at www.caterhamparts.co.uk
Fitment of non-Caterham approved parts could affect
the resale value of your car.
1. Headlamps
Loosen the screw on top of the headlamp bowl until the
rim with the light attached can be unclipped and pulled
free. The wiring is released from the back of the lamp
unit by pulling off the plastic connection. The bulbs can
be changed by removing the rubber dust cover then
squeezing the retaining clip to release the bulb itself.
Care should be taken not to touch the Halogen bulb
glass as this may cause it to blow on first use.
2. Side lamp (front)
First release headlamps as above. Sidelamps are
connected separately into the back of the headlamp
and pull free to enable bulb changing. The side lamp
bulb is a capless bulb and can be removed by pulling it
straight out of its holder.
3. Indicators (front)
Remove the two screws holding the lens in place. The
bulb can then be removed and the new one refitted by
Pushing and turning through 45°.
4. Indicator repeaters (front)
Remove the single screw holding the lens and unclip.
The bulb can then be removed and the new one
refitted by pushing and turning through 45°.
5. Stop/tail and indicators (rear)
The lenses are held in place by two screws which allow
the complete lens to be removed for access. The bulbs
can then be removed and the new ones refitted by
pushing and turning through 45°.
6. Rear fog light, reversing light
The lenses are held in place by two screws which allow
the lens to be removed for access. The bulbs can then
be removed and the new ones refitted by pushing and
turning through 45°. When refitting the lens ensure that
the rubber seal is fitted correctly to prevent water
ingress.
39
7. Number plate lamp
The number plate lamp contains two bulbs which can
be removed and refitted by pushing and turning
through 45°. To gain access to the bulbs the black
cover must be removed, this is held in place by a
single screw in the centre of the cover.
Bulb Replacement Part Numbers from Caterham
Light Unit
Headlamp (halogen)
Sidelamp
Front/Rear Indicator
Tail/Stop
Rear Fog
Side Repeater Indicator
Reversing
Rear Number Plate (x2)
40
Wattage
60/55
5
21
21/5
21
4
21
4
Caterham Part
Number
BB472
LLB501
LLB382
LLB380
LLB382
LLB233
LLB382
LLB233
SERVICE SCHEDULES
Service Interval
Annually or every 6,000
miles if sooner
Roadsport & Superlight
All Ford Sigma & Duratec Engine Variants
New Car
First
Second
First Service
Annual
Annual
3 Months
12 Months 24 Months
(or 1000)
(or 6000)
Engine oil
Check and top up (# check level before changing oil)

#
Engine oil
Drain and replace


Engine oil filter
Replace


Differential oil level
Check and top up


Gearbox oil level
Check and top up


Screen washer fluid level Check and top up


Screen washers
Check operation and alignment


Brake fluid
Check level and top up


Coolant
Check level and top up


Coolant hoses
Check for condition, leaks and security


Alternator drive belt
Check tension and condition, replace if necessary


Roller Barrels
Check and set balance, idle and throttle pot settings


Lights and bulbs
Check all lights and replace bulbs as necessary


Switchgear
Check operation


Wheel nut torques
Check for tightness


Clutch
Check operation, adjustment & fluid level


Handbrake operation
Check and adjust


Brake pads
Check for wear, replace if necessary


CV gaitors
Check condition


Tyres
Check condition and pressure


Seatbelts and harnesses Check for condition and operation


Horn
Check


Wipers
Check condition and operation, replace if necessary


Steering joints and gaitors Check


Wheel bearing end float
Check and adjust


Brake hoses
Check condition and for leaks


Brake discs
Check for condition and wear


ECU diagnostics
Check if possible


Battery
Check security, condition and connections, top up


Headlight alignment
Check and adjust


Exhaust system
Check mountings and exhaust condition


Spark plugs
Replace


Suspension security
Check and retorque bolts


Suspension bushes
Check and replace if necessary


Front wheel alignment
Check and adjust if necessary


Brake pipes and unions
Check for security and leaks


Brake fluid
Replace


Clutch Fluid
Replace


Engine mountings
Check


Air filter
Clean, (change at 4 years)


Wheel bearings
Repack at 4 years


Brake hoses
Replace at 4 years


Coolant
Drain and replace at 4 years


Fuel lines
Check for security and leaks


Cam belts
Replace at 6 years or sooner if prefered
Road test
To check dampers, brakes, steering, instruments etc.


4 - Items are required to be replaced every 4 years
6 - Items are required to be replaced every 6 years
For prices Please contact aftersales
(or 12,000)
#
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

























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








4
4
4
4
6
6

41
42
SERVICE RECORD continued
43
SERVICE RECORD continued
44
CAMBELT REPLACEMENT
FACTORY UPGRADE RECORD
45
FACTORY UPGRADE RECORD
46