Caterham Seven manuals

Owner’s manuals and user’s guides for Cars Caterham Seven.
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Caterham Seven User Manual (227 pages)


Brand: Caterham | Category: Cars | Size: 11.48 MB |

 

Table of contents

ASSEMBLY GUIDE

1

ALL CATERHAM SEVEN MODELS

1

Version 02.2014

1

Contents

2

List of Tables

11

List of Figures

12

Page

13

Page

14

Page

15

Page

16

1.0) Introduction

20

2.0) Kit contents

28

Exhaust silencer

29

Exhaust primary pipes

29

Cat/ collector

29

Cat guard

29

Polythene bag

29

1. RH driveshaft

33

4. Nyloc nut (white insert)

33

2. Speed sensor ring

33

5. LH driveshaft assembly

33

3. Nyloc nut (green insert)

33

1. LH headlight bracket

38

2. RH headlight bracket

38

1. Upright assembly (RH)

39

2. Upright assembly (LH)

39

4.0) Steering

59

1. Steering wheel

63

4. Fixing screw

63

2. Steering column

63

5. Wheel centre

63

3. Mounting boss

63

5.0) Front suspension

65

1. Copper washer

71

3. Braided brake hose

71

2. Female union

71

4. Adaptor

71

1. Clutch release bearing

74

2. Hydraulic connection

74

1. Gearbox

74

2. Plug

74

3. Gearbox mounting

74

SWL of 150 Kg

77

2. ‘U’ hose

78

3. Water rail

78

1. Fuel rail connection

83

2. Fuel pipe (from pump)

83

4. Bobbin

85

2. Spring washer

85

3. Setscrew

85

1. Primary pipe

86

1. Hose to ‘T’ piece

88

1. Cam cover

94

2. Breather pipe

94

3. Throttle body

94

1. Air intake

95

2. Trunking

95

1. Brake master cylinder

97

4. Heater control cable

97

2. Clutch master cylinder

97

5. Battery

97

3. Heater

97

1. Banjo bolt

104

3. Hose union

104

2. Copper washers

104

4. Clutch master

104

1. Angle bracket

105

2. Bobbin

105

1.Primary pipe

106

2.Collector/catalyst

106

1. Silencer bracket

107

3. Lambda probe

107

2. Band clamp

107

2. Bottom radiator hose

108

1. Cruciform

109

1. Scuttle panel

113

2. Heater control cable

113

3. Locknut

113

1. Heater valve

113

1. Throttle cable

114

2. Throttle cable adjuster

114

3. Throttle body linkage

114

4. Throttle cable nipple

114

Description

117

Engine hoist and sling

117

SWL if 150 Kg (min)

117

1. Engine connection

118

2. Long ‘L’ hose

118

1. ‘T’ piece

131

3. Small straight hose

131

2. Hose to

131

4. Hose to heater outlet

131

1. Oil breather hose

135

2. ‘P’ clip

135

3. Breather bottle

135

4. Breather elbow

135

5. Cam cover

135

1. Cable bracket

137

9.0) Rear suspension

140

1. Brake pipe (RH)

141

4. Brake pipe (LH)

141

5. Di Dion ear (RH)

141

3. Three way union

141

1. P-clip

142

2. Brake pipe LH

142

3. Three way connector

142

1. Bell crank

143

2. Rod end

143

4. Link arm (forward)

143

5. Link arm (rearward)

143

1. De Dion tube RH end

144

2. Link arm (forward)

144

3. Bellcrank

144

4. Link arm (rearward)

144

5. Bellcrank spacer

144

1. Metalistic brush

145

4. Nylon washers

145

2. Bolt

145

5. Nyloc nut

145

3. ‘A’ frame

145

4. Drive shaft

148

5. Speed sensor

148

1. De Dion ear

148

2. ARB bracket

148

3. Anti-roll bar

148

1. Bolt

149

4. Drop link

149

2. Plain washer

149

5. Anti-roll bar

149

3. Extension piece

149

1. Pulley

151

10.0) Interior and trim

154

1. Knee trim panel

157

2. Roll cage (optional)

157

3. Piping

157

4. Self-tapping screws

157

1. Spacers

161

2. Adjusting handle

161

1. Composite seat

162

2. Six-point harness

162

3. Seat adjuster

162

1. Large recess

162

2. Spacer

162

1. Rear bulkhead carpet

164

2. Footwell carpet

164

3. Tunnel carpet

164

4. Tunnel top

164

11.0) Fibreglass

165

1. Rear wing fixings

168

2. Rear wings

168

1. Wing piping

169

2. ‘V’ Shaped notches

169

3. Rectangular notches

169

12.0) Lighting

170

13.0) Weather equipment

175

1. Screw

176

2. Washer (or popper base)

176

3. Hoodstrap

176

4. Rear body skin

176

5. Chassis tube

176

1. Hoodstick

177

2. Popper base

177

3. Rear wing

177

1. Windscreen stanchions

177

2. Sidescreen hinges

177

1. Sidescreen

179

2. Vinyl strap

179

1. Popper base

182

2. Boot cover

182

3. Fastener socket

182

1. Tonneau cover

183

1. Windscreen support

183

1. Punch

184

2. Dished base

184

14.0) Wheel fitment

185

1. Mounting wishbone

186

2. Wheel nuts

186

3. Fibre washer

186

4. Spare wheel bolt

186

5. Spacer

186

1. Pipe to master cylinder

189

2. Push-fit connector

189

3. Bleed key

189

1. Grommets

203

Page

205

17.0) Options

206

1. Front hoop saddle bracket

209

3. Chassis top tube - sill

209

1. Bucket bush location

210

2. Roll cage rear hoop

210

3. Seat back harness rail

210

1. Speed sensor bracket

219

2. Lock nut

219

3. Speed sensor

219

18.0) Wiring diagrams

223

Page

227


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