Caterham Seven Datasheet

Brand: Caterham

Model: Seven

Category: Motor vehicle accessories & components

Type: Datasheet

OWNERS HANDBOOK

CONTENTS

Introduction Page

1. Before Taking to the Road 4

Controls 4

Standard instrumentation 4

Explanation of dashboard 5

Stack display with windscreen 6

CSR Integral dash 7

R500 8

Stack display operation 9

Before you drive away 10

Pedal adjustment 10

Seats and seat belts 10

Harness 10

Weather equipment 11

Security 12

Starting the engine 14

Running-in 14

Catalytic convertor 14

Gearbox 15

Fuel 15

Braking system 16

2. Useful Information 17

Engine specification 17

Technical data 18

Track use 20

3. Maintenance 21

Owner maintenance 21

Under bonnet location 21

EU4 Sigma 120 22

Sigma 125 23

Sigma 150 24

Duratec 210 (R400) 25

EU4 Duratec 200 (CSR) 26

Duratec 260 (CSR) 27

Duratec 263 (R500) 28

Safety in the garage 29

Axle stand positioning 29

Checking fluid levels 30

Oil 30

Coolant 31

Brake Fluid 32

Clutch Fluid 32

Windscreen washers 32

Battery 32

Wheels & Tyres 34

Changing a wheel 34

Cleaning and car care 35

Laying your vehicle up for

long periods 36

Travelling abroad 37

4. In an Emergency 37

Emergency starting 37

Emergency towing 38

Fuses & relays 38

Parts & accessories 39

Bulb replacement 39

5. Servicing 41

Service schedules 41

Service & modification record 42

Warranty

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.

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. Brake fail indicator

2. Hazard warning light switch

3. Rear fog light switch

4. Heated windscreen switch

5. Heater fan switch

6. Immobilizer warning light

7. Windscreen washers switch

8. Windscreen wipers switch

9. Side lights/head lights switch

10. Indicators switch

11. Main beam switch

12. Headlamp flasher switch

13. Horn

14. Fuel gauge

15. Temperature gauge

16. Oil Pressure gauge

17. Tachometer

18. Speedometer

19. main beam warning light

20. Indicator warning light

21. Ignition warning light

22. Push starter button

23. Trip reset button

24. Heater valve control

EXPLANATION OF DASHBOARD

Brake fail indicator Single position spring loaded switch, illuminates to indicate low fluid level. Press to test

bulb.

Hazard warning light Single position switch activates all indicators.

Rear fog light Single position switch activates rear fog lights when dipped headlights are illuminated.

Heated windscreen Single position switch activates heating elements to demist front windscreen.

Heater fan Two position switch provides low and high speed fan control.

Windscreen washers Single position spring loaded switch activates washer jets when depressed.

Windscreen wipers 2 position switch to provide low and high speed continuous wipe.

Indicator switch 3 position switch Left-Off-Right (non-self cancelling)

Side/Head lights 2 position switch, first position side lights, second position dipped beam headlight.

Main beam 2 position switch for dip or main beam.

Headlamp flasher Single position spring loaded switch to flash headlights.

Heater valve control This is located on the inside of engine compartment bulkhead, above the driver’s knee.

Pull towards driver to increase heat.

Starter push button Single position spring loaded push switch, press to start engine

Horn push button Single position spring loaded push switch

Speedometer

Indicates road speed in miles per hour and/or

kilometres per hour.

Digital display within speedometer

The display shows the following:

 Odometer reading (shows the total distance

travelled by the car).

 Trip recorder (for recording individual journey

distances). The word trip is also displayed.

Trip recorder reset button

Whenever the ignition switch is turned on, the display

shows the odometer reading. By pressing the trip

recorder reset button briefly, the display will change to

show the trip recorder reading (a further press of the

button returns the display to the odometer reading).

Press and hold the reset button to reset the display to

zero.

Tachometer

Indicates engine speed in revolutions per minute.

NOTE: An electronic limiter will prevent engine speed

rising above a pre-determined factory set level.

Oil Pressure Gauge

The needle indicates the oil pressure measured in bar.

The needle will quickly rise when the engine is started.

If the needle falls into the Red mark during normal

running the oil pressure is at a critical level and severe

engine damage could result; switch off the engine

immediately (safety permitting) and seek qualified

assistance. (Engine pressure will fluctuate as engine

revs change)

WARNING!

Never restart the engine or drive the car with the oil

pressure gauge indicating red.

Temperature Gauge

Indicates the temperature of the engine coolant. During

normal operation, the needle will rise from the lower

(cold) mark to the middle part of the gauge, where it

will remain while the engine is operating at its normal

temperature.

In severe driving conditions, such as very hot weather

or extended hill climbing, the needle may rise. If the

needle rises to the RED mark, the coolant is too hot

and severe engine damage could result; stop the car

as soon as safety permits and seek qualified

assistance.

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

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.

Figure 2: Dashboard layout for models with Stack Instruments and full windscreen

Controls

1. Heated windscreen switch

2. Brake fail indicator

3. Hazard warning light switch

4. Rear fog light switch

5. Side/Head lights switch

6. Heater fan switch

7. Windscreen washers switch

8. Windscreen wipers switch

9. Stack button 1

10. Stack button 2

11. Stack button 4

12. Stack button 3

13. Shift light button

14. Indicator warning light

15. Indicator switch

16. Main beam warning light

17. Starter push button

18. Stack display

19. Horn push button

20. Main beam switch

21. Headlamp flasher switch

22. Gear shift lights

23. Immobiliser warning light

24. Heater valve control

Figure 3: Dashboard layout for CSR with Integral dash

Controls

1. Air vent

2. Oil pressure gauge

3. Temperature gauge

4. Heater fan control switch

5. Fuel gauge

6. Oil temperature gauge

7. Indicators

Side/Head lights

Main beam

Headlamp flasher

8. Tachometer

9. 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

Figure 4: Dashboard layout for R500

NOTE: For full windscreen option the wiring connection to dashboard buttons for heated screen, wipers etc are

already connected.

Controls

1. Aero screen

2. Heated screen switch

3. Hazard warning light switch

4. Windscreen washer switch

5. Windscreen wipers switch

6. Launch control push button

7. Gear shift lights

8. Stack display

9. Stack button 3

10. Main beam switch

11. Side/Head light switch

12. Stack button 4

13. Heater valve control

14. Stack button 2

15. Stack button 1

16. Horn push button

17. Starter push button

18. Rear fog light switch

19. Heater fan switch

20. Brake fail indicator

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. Vehicle speed

2. Engine speed

3. Oil pressure

4. Oil temperature

5. Water temperature

6. Fuel level

7. Battery Voltage

8. 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.

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.

• 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

Figure 6: 6-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

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)

Figure 7: Tensioning the hood

Figure 8: Hood folding procedure

vi) The Velcro lined strips inside the hood should now

capture the front hoodstick, which prevents the

hood from ballooning at speed.

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

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 re-

programme 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.

Starting the engine

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.

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.

Running-In

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.

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.

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!

Figure 9: Five and six speed

gear shift patterns

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.

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.

Duratec 263

4 cyl-in-line

1999cc

87.5mm

83.1mm

16v DOHC

Solid

11.75:1

263bhp@8500 rpm

176lbft@7165 rpm

8500rpm

MBE

Four port roller

barrel

Multi point injection

Unleaded 95 RON

Duratec 260

4 cyl-in-line

2261cc

87.5mm

94.0mm

16v DOHC

Solid

12.0:1

260bhp@7500rpm

200lbft@6000rpm

7800rpm

MBE

Four port roller

barrel

Multi point injection

Unleaded 95 RON

Duratec 200

4 cyl-in-line

2261cc

87.5mm

94.0mm

16v DOHC

Solid

9.7:1

200bhp@7000rpm

165lbft@5750rpm

7500rpm

MBE

CSR 200

Ford EU4

Single butterfly

Multi point injection

Unleaded 95 RON

Duratec 210

4 cyl-in-line

1999cc

87.5mm

83.1mm

16v DOHC

Solid

10.8:1

210bhp@7600 rpm

150lbft@6300 rpm

7600rpm

MBE

Single butterfly

Multi point injection

Unleaded 95 RON

Sigma 150

4 cyl-in-line

1596cc

79.0mm

81.4mm

16v DOHC

Solid

11.0:1

150bhp@6900 rpm

120lbft@5600 rpm

7500rpm

MBE

Four port throttle

bodies

Multi point injection

Unleaded 95 RON

Sigma 125

4 cyl-in-line

1596cc

79.0mm

81.4mm

16v DOHC

Solid

11.0:1

125bhp@6100 rpm

120lbft@5350 rpm

6800rpm

MBE

Single butterfly

Multi point injection

Unleaded 95 RON

Sigma 120

4 cyl-in-line

1596cc

79.0mm

81.4mm

16v DOHC

Solid

11.0:1

120bhp@6000 rpm

113lbft@4000 rpm

6450rpm

Ford

Single butterfly

Multi point injection

Unleaded 95 RON

2. USEFUL INFORMATION - Engine Specifications

Engine Type

Capacity

Bore

Stroke

Cylinder Head

Valve Actuation

Compression Ratio

Maximum Powe

Maximum Torque

Maximum RPM

Ignition System

Induction System

Fuel System

Fuel Type

Technical data

Vehicle Type

2 Seater, convertible sports car.

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

Kerb Weights

Min Weight Max Weight

Classic 540 840

Roadsport 550 850

SV 575 875

R400 515 815

R500 506 806

CSR 575 875

CSR Superlight 550 850

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.

Suspension

Front Adjustable double wishbone with

(Except CSR) Anti-roll bar

Coil Springs over dampers

Rear De Dion axle located by lower 'A'

(Except CSR) frame and radius arms or 'A' Frame

and Watts linkage

Progressive Coil springs

Dampers

Optional - Adjustable anti-roll bar

Front CSR only Pushrod actuated double wishbones

with Anti-roll bar. Coil springs over

dampers

Rear CSR only Independent double wishbone.

Coil over spring

Damper units.

Steering

Mechanism Rack and Pinion

Turns lock to lock Standard 2.46

Race 1.75

Road wheel nut torque

All 55lbft 75 n-m

Electrical

12 Volt, Negative earth

Alternator output: 45 amperes

Battery Capacity 30 amps/hrs

47 amps/hrs

Manual Transmission

Hydraulic Clutch Actuation all models

Classic/Roadsport

Superlight

CSR

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

Wheels – Tyres -- Pressure

Fluid Capacities

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

CSR radiator 5.5 L

Differential 1.2 L

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 Ford Engine oil

Formula E-5W-30

CSR/R400 Caterham Motorsport Oil 5W-50

Track driving Caterham Motorsport Oil 5W-50

Gearbox Oil*

5/6 SPEED Caterham Gearbox Oil EP80 grade

Sequential

Differential

All cars Caterham Differential Oil EP90

LSD's Lubeguard Limited Slip Diff additive

Engine Coolant

CSR/R400 Comma X-stream Red OAT

Ford Sigma Ford Super Plus Anti-frezz

Brake Fluid Comma DOT4

Gearbox ratios

5 SPEED 6 SPEED 6 SPEED SEQ

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

6 1.00 1.00

R 3.37 2.96 2.4

TYRE PRESSURE

FRONT REAR

TYRE WHEELS

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 6J x 14" alloy

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 9J x 15" alloy

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.

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

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Caterham Seven Datasheet

Brand: Caterham

Model: Seven

Category: Motor vehicle accessories & components

Type: Datasheet

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Caterham Seven Datasheet

Caterham Seven Datasheet

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