Caterham Seven User Manual download pdf (Page 166)

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mm drill. Ensure that the drill cannot

contact the tyre.

Drill an additional hole in the underside of

the front wingstay near the open end

using a 5/32” drill. Remove all sharp

edges on the inside and outside of the

wingstay tube.

Loosely fit the cycle wing to check the

alignment of the cycle wing and wingstays

relative to the tyre. The cycle wing should

be checked to ensure that it is centrally

located over the tyre. Remove the cycle

wing. Place a strip of masking tape

across the tyre underneath the drilled

wingstay. Using a ruler held at 90 to the

surface of the tyre, mark the lateral

positions of the two holes. Rotate the

wheel so that the masking tape is under

the rear tube of the wingstay and transfer

the bolt hole position to the wingstay tube.

Centre punch and drill using a 6 mm drill

as for the front holes.

Refit the cycle wing, loosely bolting it at

the front and aligning it over the tyre and

then carefully remove the wheel without

disturbing the wing. Masking tape can be

used to hold the wing in place. Carefully

mark the underneath of the wing with the

bolt hole positions and then remove the

wing. Drill a small pilot hole from

underneath the cycle wing, taking care not

to damage the gel coat/painted surface.

Check alignment of the holes with the

wingstays, adjusting if required, then drill

through from the top of the cycle wing with

a 5 mm drill.

Place a strip of self-adhesive foam

(fastener pack ZFG12 Item 7) on the top

of each cycle wingstay tube. Cut two

rubber grommets in half to provide four

rubber washers. Pass screw (5) through

the manufactured washers and down

through the cycle wing and wingstay.

Secure using washers (4) and nyloc nuts

(2). Tighten until the rubber washer is

slightly larger than the screw head. The

black wire from the indicator repeater is

the earth lead and should be attached to

the front wingstay using a pop-rivet in the

5/32” hole drilled at Para 10. Remove

paint to ensure a good contact.

Route the green wire from the indicator

repeater inside the wingstay until it

emerges from the pre-drilled hole near the

wingstay brace. From the wingstay the

wire must be routed along the rear of the

upper wishbone ball joint, and the upper

wishbone. Secure using small cable ties

at 50 mm intervals, refer to Fig 152.

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