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Part Number: ALS3T0022FVersion: 1

USA Exige Cup Car MY’07Supplementary Manual

Lotus Sport USA Exige Cup Race CarSupplementary Manual

(TRACK USE ONLY, THIS CAR IS NOT ROAD LEGAL)VINs: SCCVA11177H81449 Onwards

All data and instructions in this Supplementary Manualtake precedence over material in the Owner's Handbook.

Technical DataSupplementary to Workshop Manual A120T0327J

Supplementary to Parts Manual A120T0325J

Issue number: 005Issue date: 12 March 2007

Lotus Sport contact details: [email protected]

Lotus SportLotus Cars LtdPotash Lane

HethelNorwich

Norfolk, UKNR14 8EZ

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Contents

1.0 LEGAL DISCLAIMER AND WARRANTY ISSUES .............................................................................................................. 3

2.0 ADDITIONAL PARTS (INCLUDING OPTION PACKS) ...................................................................................................... 4

3.0 DELETED ITEMS ....................................................................................................................................................................... 15

4.0 PARTS LIST – USA CUP CAR ADDITIONAL PARTS – STANDARD FIT..................................................................... 16

5.0 SUSPENSION SETTINGS.......................................................................................................................................................... 21

6.0 BRAKE PAD BEDDING IN PROCEDURE ............................................................................................................................ 22

7.0 SERVICE LIFE ............................................................................................................................................................................ 23

8.0 ACCUSUMP INFORMATION .................................................................................................................................................. 25

9.0 ODYSSEY BATTERY................................................................................................................................................................. 29

10.0 ÖHLINS DAMPERS - GENERAL INSTRUCTIONS.......................................................................................................... 37

11.0 ÖHLINS DAMPERS - TRACK INSTRUCTIONS ............................................................................................................... 45

12.0 AIRJACKS - SERVICING INSTRUCTIONS ....................................................................................................................... 53

NOTE: This manual is written for the experienced track enthusiast; proper experience is necessaryto both understand this manual and operate the Exige Cup race car.

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1.0 Legal, Safety and Warranty Issues

The purpose of this supplementary document is to inform the owner/driver of some of the technical specifications andother differences from the standard Lotus Exige. Any alteration or misuse of the car or deviation from the instructionsin this document or other documents supplied with the car could result in accident or injury and/or damage to the caror third party property.

There is no written warranty or guarantee of any type associated on this product. To the extent permitted bylaw, Lotus disclaims any implied warranties, including any implied warranties of merchantability or fitness fora particular purpose. Some states do not allow the disclaimer of implied warranties so this disclaimer may notapply to you.

This car is strictly for track use only, and neither suitable nor legal for any road use what so ever. This is arace vehicle and is not certified under US Department of Transport or Environmental Protection Agencyrequirements for street use.

Warning – This is a performance car with characteristics that differ from normal production vehicles. Propertrack training is required prior to usage.

No adjustments or servicing explained in this manual should be undertaken by inexperienced or untrainedindividuals. Adjustments or servicing by inexperienced or untrained individuals can result in injury or deathand may invalidate any warranty.

Lotus accepts no liability for any direct, incidental or consequential damage or loss arising from use of the vehicle orthe application of these instructions by any person. Some states do not allow the exclusion of incidental orconsequential damages so that part of this disclaimer may not apply to you.

The vehicle owner or driver is responsible for ensuring the vehicle complies with their respective race and / or trackregulations.

For vehicle maintenance schedule, please see ‘Section 7’ of this manual.

It is essential that vehicle safety checks are carried out on the vehicle before each track session. Please refer to‘Section 7’ service life data in this manual for further information.

Never drive this vehicle without safety harnesses fitted, and without wearing an appropriate safety helmet correctly.

Lotus Sport strongly recommends that full safety clothing, boots and gloves are also worn whilst driving this vehicle ontrack.

Only use an approved fuel container for refuelling in the pits. Always ensure the engine is switched off, andappropriate safety clothing is worn during refuelling. Ensure fuel cap is in place and secured tightly before startingengine.

Please note that some of the technical data included in this document refers to options that may not be fitted to yourspecific vehicle.

Whilst every effort is made to ensure the accuracy of the particulars contained in this manual, neither the manufacturernor the distributor or dealer, by whom this manual is supplied, shall in any circumstances be held liable for anyinaccuracy or the consequences thereof.

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2.0 Additional Parts (including option packs)

The Lotus Sport Exige Cup (USA) is fitted with the following equipment that differs from the standard Exige.

Supercharger

The Lotus Sport Exige Cup is fitted with an Eaton M62 Supercharger that is belt driven from the crankshaft. This isthen intercooled using an Air to Air Intercooler, which is fed, from the roof scoop. The components used for theconversion are listed in ‘Section 4’ of this manual. The Supercharger is self-lubricating and no special maintenanceprocedures are required.

Clutch Plate and Cover

Please note that this vehicle is fitted with an Uprated Clutch Plate and Cover - no maintenance is required, refer to‘Section 4’ of this manual for replacement part numbers.

Öhlins Dampers

The Öhlins Dampers as fitted to the Lotus Sport Exige Cup Cars are two way adjustable in Compression (Bump) andin Rebound, thus offering a greater tuning potential than a standard damper.

These dampers are specifically tuned to this car whilst operating on LTS branded Yokohama slick tyres. This tuningincludes both the valve code and spring rate.

These dampers have a separate reservoir, where the Compression adjustment clicker can be found. Rebound controlis adjusted by using the clicker at the foot of the damper unit. On both the front and rear, the compression reservoir ispositioned on the lower wishbone.

Ride Height adjustment is made by using 2x 'C' Spanners and slackening off the top retaining ring, then eitherscrewing the spring platform in or out. Compressing the spring will raise the ride height; releasing compression fromthe spring will lower the ride height. Please refer to Section 5 of this manual for slick setting and adjustment details.

Rebound Adjustment – Clockwise Full Hard Bump Adjustment – Clockwise Full Hard

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Front Anti Roll Bar (Anti Sway Bar)

The Lotus Sport Exige Cup Cars are also fitted with a front adjustable anti roll bar. This is adjustable for five positions.Moving the mounting position forward to P1 makes the Roll Bar Stiffer and rearward to P5 makes it softer. P3 is set asstandard.

Track Control Arm

The car comes as standard with up-rated rear Lotus Cars track control arms. Please adhere strictly to serviceinstructions in Lotus service manual, particularly because of track use.

Accusump

To provide protection against the possibility of oil starvation caused by the extreme g-forces possible with track use onslick tyres, the Cup cars are fitted with an Accusump oil storage system. For further details of the system and serviceinformation, please see ‘Section 8’ of this manual.

Fluids

The fluids used on the Lotus Sport Exige Cup remain the same as shown in the service manual, with the exception ofFuel, which should be Unleaded 98 Ron, and Brake Fluid, which is Castrol SRF. Do not use/mix any other brakefluids.

Wheels and Tyres

The wheels used are different to the standard wheels in that they are taken from the Lotus Sport Exige 240R. They area forged five spoke wheel that are 16” x 7.0J at the front and 17” x 8.0J at the rear. These wheels are available ineither black or silver depending on your car colour scheme.

These are available from Lotus Sport with part numbers listed in ’Section 4’ of this supplement.

The centre wheel caps are removable on these wheels for service reasons. It is recommended that these be removedwhilst on track, to avoid being lost.

The tyres that are supplied with this car are the Lotus Sport tuned Yokohama A005 slick racing tyre. These arebespoke Lotus tyres that have been developed and approved by both Lotus Sport and Lotus Ride and Handling.

The Lotus Sport tuned Yokohama wet tyres are available through the Lotus Cars dealer network.

P5 P3 P1

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Tyre Pressures and Tyre Life

Slick and wet tyre operating pressures should be varied to each individual circuit in order to obtain the optimumperformance. These tyres are a sprint spec tyre and shall degrade at different rates according to track surface /operating conditions etc.

Initial recommendations for tyre pressures are:

Front Tyre 21 PSI COLDRear Tyre 18 PSI COLD

Front and Rear Tyres 25 PSI (ALL ROUND) HOT

Note: This is dependent upon camber/toe and ambient and track temperature conditions, and should be adjusted tosuit particular conditions.

When using the A005 slicks, please note that the front tyres may appear to be mounted backwards. This is the correctmounting: The rear directional rotation arrow should match the forward driven rotation, however the front tyres shouldbe mounted with the arrow pointing in the opposite direction to actual forward rotation. This is due to the loads that thetyre experiences, and is to resist delamination of the rears under acceleration, and the fronts under braking.

Race Battery

The battery installed on the Lotus Sport Exige Cup vehicle uses absorbed glass mat (AGM) technology to offer thecharacteristics of two separate batteries. It can deep cycle as well as provide large cranking power.

This battery is capable of providing engine cranking pulses in excess of 2250A for 5 seconds as well as 400charge/discharge cycles to 80% depth of discharge (DOD). This battery should provide short duration high amperagepulse or low rate long duration drains.

The battery is very different from standard liquid-acid batteries that are openly vented. This battery is and operates asa sealed battery, recycling all gases internally. There is no corrosion of the positive terminal or corrosion to thesurrounding area.

The battery was installed fully charged from Lotus Sport, but prior to use please check the battery’s voltage to see if itis 12.65 volts or greater. If not, recharge it using the battery manufacturer’s procedure below. Never attempt toremove the top decal cover, as it will cause the battery to fail!

The state of charge in the battery can be determined from the following chart:

VOLTMETER READING STATE OF CHARGE12.84 Volts 100%12.50 Volts 75 %12.18 Volts 50 %11.88 Volts 25 %

The battery does not lose its charged energy during cold storage temperatures, so there should be no need to trickleor float charge during winter months. To store off season, measure the battery voltage to make sure it is fully charged,12.84 volts or greater; recharge if necessary. Disconnect the negative battery cable to prevent any applied electricalload during storage. Your Lotus Sport Exige Cup battery should not freeze in temperatures down to -40°C or -40°F soit can be left in the vehicle. It can be stored for 2 years or more below 77°F.

A 12V, 3 amp trickle charger can also be left connected to the battery if it is kept in storage for extended periods or ifthe battery is subject to parasitic loads during storage. Please read carefully and fully understand batterymanufacturers manual supplied with vehicle before use, and if trickle charged use battery manufacturer’srecommended make of charger.

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Brakes

The front brake discs, front calipers, front and rear pads, front and rear hoses and fluid are uprated to sportsspecification for increased track performance.

Please be aware that discs used on racing circuits will be subject to higher temperatures and wear rates than achievedwith normal road use. This can have an effect on the life of the disc, especially when high friction competition pads areused. Discs along with pads are consumable items, and service life will vary, depending on driving style and vehicleuse.

Discs must be regularly and frequently inspected for excessive heat crazing and cracking. Discs with cracksemanating from mounting holes / slots, inside diameter, scallops, or outside diameter should be changed immediately.After heavy and prolonged use some surface crazing will often be evident. If this turns into distinct surface cracksradiating towards the inside or outside diameter, the disc should be changed. IF IN DOUBT, REPLACE. All cast ironbrake discs need to be bedded-in to ensure heat stabilization and improve resistance to cracking. Cracks or even discfailure can occur during the first few heavy stops if careful bedding is not carried out.

If pads do not get bedded properly and / or used to hard right out of the box, it is likely to lead to pad glazing. Padglazing is a condition where the resins in the pad crystallize on both the pad friction surface and the brake discsurface, resulting in poor stopping performance, brake judder and vibrations. Also rapidly escaping volatile elementsand moisture from the resin would seek an immediate escape route out of the friction compound, creating smallfissures that would lead shortly to cracking and chunking.

Brake Calipers are a safety critical item and it is recommended that calipers are reconditioned and piston sealsinspected regularly to maintain optimum performance. Where calipers have been subjected to high temperatures orhave been used in adverse conditions, the calipers should be reconditioned and the seals replaced more frequently toensure that safety and performance levels are maintained. It is recommended that Brake Calipers, if cleaned, shouldbe washed with soapy water. Do not use petrol or gasoline, as this will damage the seals. Parts must be absolutely drybefore re-assembly.

To obtain the best performance from racing brake systems, bleed the system thoroughly, immediately prior to eachevent using brake fluid from a new sealed bottle. This is particularly important in wet or humid conditions or when thebrakes are excessively hot. Always use fresh fluid and replace bottle cap when not in use. Never re-use brake fluid.Circuits and drivers vary enormously in the amount of work they demand from the brakes and therefore the brakesystem may need to be tuned for each circuit by adjustment of the cooling airflow. The temptation to over cool the discshould be resisted. The aim is to keep the temperature as stable as possible within the working temperature range.High maximum to low minimum temperature cycles are the enemy of disc life.

Please read carefully and fully understand AP Racing ‘Formula Big Brake Kit Owner’s Manual’ supplied with vehiclebefore use of the vehicle.

Electronic Control Module

The Lotus ECM is used to control normal engine parameters however a USA Cup specific program is used and this isnot compatible with the standard Exige program, previous USA Cup MY’06 programs or with any other Lotus program.Only the USA SC/Cup MY07 program (ALS3M0240J) should be used on this vehicle.

Spark Plugs / Catalytic Converter

Spark plug type A128E6006F. The Spark Plugs used differ from the standard components and should be changedwith each service. If the vehicle is fitted with a Catalytic Converter then there is a modified version specific to LotusSport. Some Cup models will have a de-cat pipe/cat replacement pipe fitted in place of the catalytic converter, this isspecific to Lotus Sport.

Fuel Injectors

The fuel injectors are bespoke to this variant and can not be replaced by the standard injectors.

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Limited Slip Differential – Standard

The car as standard comes with the Lotus Cars limited slip differential. This is a torsen type differential with a 2:1 biasratio.

Exhaust Silencer

The car as standard comes with the Stage One sports exhaust. The Stage Two sports exhaust is available as a nocost option on this variant.

Drivers Seat

The car is supplied with an FIA approved racing seat. This seat is supplied with mounting brackets that allow for setpositive adjustments to be made. Limited space in the cabin restricts the degree of adjustment possible.

Passenger Seat

The car is supplied with an Exige sports seat for passenger rides. This seat is not intended in any way as a substitutefor a race seat. This seat or its installation is not FIA approved.

Drivers Seat Belt Harness

An FIA approved 6-point seat belt is installed into this car. The installation of this belt has been optimised for the Lotuschassis and does not suggest that this is suitable for other vehicles. Please check the label on the harness for renewaldate, do not use beyond this point or after an accident. Replace with suitably appropriate harnesses.

Passenger Seat Belt Harness

An FIA approved 4-point seat belt is installed into this car. The installation of this belt has beenoptimised for the Lotus chassis and does not suggest that this is suitable for other vehicles.Please note that this belt does not include the crotch straps that give further added protectionover a standard four point harness. Please check the label on the harness for renewal date, donot use beyond this point or after an accident. Replace with suitably appropriate harnesses.

Passengers 4-Point Harness Drivers 6-Point Harness

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To help reduce the risk of serious injury in an accident:• Never strap more than one person in place with each

harness belt.• Never use the harness belt system for persons which

weigh less than 40 kg (88 lbs) or those who are lessthan 150 cm (4‘11“) tall, regardless of age.

• Never use the lap belt portion of the harness beltwithout the shoulder belts.

• All straps must permanently run through the slots ofthe bucket seat – as shown in the figure below.

• Always make sure that no strap is twisted when worn.• Always wear the lap belt portion of the harness system

low and tight across the pelvis.• Pressure of shoulder belts on your shoulder and chest

must be equal.• Never wear the belts over heavy clothing as it can

interfere with proper positioning and adjustment of thebelts, reducing the overall effectiveness of the system.

• Never wear the belts over rigid or breakable objects inor on your clothing, such as eye glasses, pens,jewelry, keys etc as these may cause injury.

• Never allow straps to rub against sharp objects.• Never allow the belts to be damaged by becoming

caught in door or seat hardware.

CARE AND MAINTENANCE

INSPECTION

• Inspect the harness belt thoroughly for damage before each use.• Make sure that the inspection of the belt is included with regular checkups of the race car and its equipment.• Regularly check correct torque of bolts.• Check for expiration date of the racing harness as it applies to the regulation of your sanctioning body and/or

the FIA, SFI or NASCAR tag, prior to each use.

CLEANING

• To clean the harness belt, use only mild soap and warm water.• Never use solvents or other cleaning solutions, they can weaken the webbing or stitch pattern.• Never use chemical solvents or cleaning solutions to clean the rotary buckle. The high impact resistant

polycarbonate [PC] material is sensitive to any kind of hydrocarbons, also to spray cleaners containinghydrocarbons.

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• Do not dry the belt in the sun or near a radiator, in a clothes dryer or with a hair dryer or with any othermechanical or electrical heating device. Heating webbing may make the material shrink and the preciselydesigned elongation rate will be changed.

• Always allows a cleaned belt to air dry naturally.• Always have damaged sub-assemblies of the harness belt replaced before using the harness belt again.• Never modify, disassemble or repair the belt by yourself.

Accident

• Any harness belt which was used during an accident is unfit for further use and must be replaced.• Never continue to use a harness belt, which was in use during an accident. Replace it immediately.• In SCHROTH Profi asm ® models, a partly or fully ripped open SCHROTH asm ® system indicates the need

of immediate replacement of the racing harness.FIA and other sanctioning bodies require that inspectors cut the racing harness, or cut the labels off the racingharness, after an accident. Always inspect all anchorages for damages such as deformations or cracks, after anaccident. Strictly follow the recommendations of the vehicle or roll cage manufacturer if a repair should be necessary.

Removable Steering Wheel

The standard steering wheel has been replaced with a removable steering wheel. This is to assist both ingress andegress from the vehicle. It is paramount to ensure that the steering wheel is 100% engaged and secure prior to driving.This steering wheel does not have an airbag fitted. Note there is also no passenger air bag fitted.

Fire Extinguisher

The Fire Extinguisher fitted is an electrically operated FIA approved system. The bottle will require servicing, pleasecheck with the date shown on your extinguisher bottle label for servicing requirements. As an additional safetymeasure, please check that the needle on the gauge is located within the green section before driving the car.

Bottle Pressure Gauge Extinguisher Control Box Service Date

There are four nozzles installed as part of the fire extinguisher system. Two nozzles are located in the cockpit, bothunderneath the dash and aimed at the driving position. The other two nozzles are located in the engine bay and aimedat the fuel rail and catalytic converter. To operate the fire extinguisher, there are two red push buttons. One is locatedinside the cockpit next to the battery master switch, the other is located on the rear clamshell on the opposite side tothe fuel filler cap and labelled with the letter E. The extinguisher control box has a toggle switch that auto-returns away

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from the driver and latches towards the driver. With the toggle in the centre position, the red E buttons in the cockpitand on the clam can be tested; pressing the buttons will light the green system test LED on the extinguisher controlbox. With the toggle pushed to the auto-return side, the amber battery check LED will illuminate. If either of these testsfail, there is an issue with the fire extinguisher system and it will not function. This must be resolved before any drivingcommences. If the two system tests pass, and the bottle gauge shows sufficient pressure, then the system can bearmed ready for racing. This is done by switching the toggle towards the driver. This is accompanied by the redsystem armed LED illuminating. Ensure the fire extinguisher is armed before starting any track session. It isrecommended that the system is disabled when the car is not being driven, to avoid accidental triggering of thesystem.

Battery Master switch

Always turn the engine off using the main vehicle ignition key, NOT the battery master switch. When leaving thevehicle for any period of time turn the battery master switch to the OFF position. The battery master switch is intendedand designed for EMERGENCY use only on the race track and not day to day use. Please note that the battery masterswitch can be operated by either turning the switch inside the cockpit anti-clockwise or from outside the vehicle by thepull cable. Activating the battery master switch whilst the engine is running will lose the ‘learning’ that the ECM hasaccrued during that single trip (since the ignition was switched on) and some period of time will be required to allowthe ECM to ‘re learn’ the information.

Internal Switches External Switches

Fuel Filler Cap

The fuel filler cap fitted to this car is of a locking type. This is to suit the non road fuel system that is fitted to this car.

SCCA Roll Cage

The roll cage fitted to this vehicle is the SCCA compliant roll cage and not the FIA approved cage. The SCCA cage isnot removable.

Lotus Sport Build Plate

Each Cup car is fitted with a bespoke factory Lotus Sport build plate. The plate shows that the car is an official LotusSport model and has been created at the Lotus Sport headquarters at the Lotus Cars factory, Hethel in the UK. Eachbuild plate is numbered to distinguish the car from other Cup cars produced. The build plate is mounted on thepassenger’s side inner sill.

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Decals

The exterior of the car has specific Lotus Sport markings. These markings show that this is a Lotus Sport variant andnot a standard Lotus Cars vehicle. Each car has a Union Jack badge fitted on the rear clam to show its origins.

Chassis VIN Plate

The Exige Cup cars are stamped with a non road legal VIN. The VIN assigned is off-road specific and prevents the carfrom being road registered.

Racing Fuel Cell – Cost Option

This fuel cell sits in the same location as the standard tank, uses the carry over fittings and an uprated fuel pump. It holds 74liters nominally. Internally it has three baffles running to 80% of the height of the tank, each with two fuel apertures at thebottom between chambers. The ‘fuel pump’ chamber additionally has 2 x TF331 trapdoors, to hold fuel close to the pump.The fuel pump operates as normal with the level/float giving correct indication (you will find that the fuel level gauge will notmove for a period on a full tank of fuel – this is normal, as a proportion of the fuel will be above the pump). The fuel cell ismade from ATL 810-C material in accordance with FT3 1999 specification, and includes reticulated foam in all chambersexcept in fuel pump chamber, 4x6 top plate with filler neck and vent. As manufactured it is FIA Approved.

THIS FUEL CELL IS FOR TRACK USE ONLY.

MAJOR SANCTIONING BODIES SUCH THE FIA HAVE RECOGNISED THAT FUEL CELLS ARE AFFECTED BYOZONE, ULTRAVIOLET, AGEING, AND THE CHEMICAL ACTION OF GASOLINE AND RACING FUELS. HENCE,A FIVE YEAR LEGAL LIFE SPAN HAS BEEN SET ON ALL FUEL CELLS. THE RUBBER BLADDER PORTION OFYOUR FUEL CELL SYSTEM MUST BE REPLACED WITHIN 5 YEARS OF ITS MANUFACTURE DATE. ACERTIFICATE WITH THE REPLACEMENT DATE IS ISSUED WITH THE VEHICLE AND A STICKER WITH THESAME DATE IS ATTACHED TO THE PASSENGER SIDE INSIDE SILL (NEXT TO THE LOTUS SPORT BUILDPLATE).

Gasoline, as well as other flammable materials and liquids (adhesives, solvents, etc.) and the vapors they produce areextremely dangerous. Be sure to read and follow the instructions. Failure to do so can result in property damage, bodilyinjury, or death. Take all reasonable precautions to guard against safety.

This fuel cell is designed for the use of hydrocarbon gasoline only! The fuel cell may experience minor swelling whensubjected to fuel. Due to the elastomeric nature of fuel bladders, a certain amount of vapor permeation or “diffusion” willoccur. Always allow generous ventilation around the cell/vehicle so as to preclude the accumulation of fuel vapors.

Water vapor and direct sunlight (UV) exposure can adversely affect fuel bladders. Keep the system externally and internallyfree of water and water vapor. When storing a fuel cell, drain the bladder completely, allow to dry out, close off all ports, andkeep it in a dark, dry, cool environment. Fuel cell ‘capacities’ are expressed herein as nominal values. Please be sure tostudy ATL’s Product Safety Bulletin #DS-381 before installing or using any ATL product. Remember, improper selection,installation or use can cause personal injury, property damage or death. Don’t take unnecessary risks.

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Your fuel cell should be serviced at least once a year. Most importantly, the bladder should be inspected for any fuel leaks orblistering. Any damage or broken components should be repaired or replaced before use.

All fuel cells should be static ground during refueling and during use on a track. Never use a PVC tube for refueling. It cancreate enough static build up, to cause a spark. Check specific series regulations to confirm that installation of fuel cell meetsrequirements (although the fuel cell is FIA approved the installation may have to vary between regulations).

Do not over-fill or top-off your vehicle tank, which can cause gasoline spillage. Avoid prolonged breathing of fuel vapors. Usefuel only in open areas that get plenty of fresh air. Keep your face away from the nozzle or container opening. Never siphonfuel by mouth nor put fuel in your mouth for any reason. Fuel can be harmful or fatal if swallowed. If someone swallowsgasoline, do not induce vomiting. Contact a doctor or and emergency medical service provider immediately. Keep fuel awayfrom your eyes and skin; it may cause irritation.

Please read carefully, fully understand and follow stringently all ATL documentation supplied with vehicle before use ofthe vehicle. Please particularly note the lifespan of the fuel cell.

Please read carefully and fully understand ATL ‘Product Safety Bulletin’ supplied with vehicle before use of thevehicle. A certificate of compliance is also supplied with the vehicle,

WARNING: Unless the racing fuel cell cost option has been selected, the Cup car will be fitted with a standardLotus fuel tank. In certain conditions, enthusiastic driving combined with slick tyres will generate high lateral‘g’ forces, which when coupled with low fuel loads in the standard tank may induce an element of fuel surge.

Limited Slip Differential – Cost Option

An option of the Lotus Sport limited slip differential is available. This is a 1.5 way adjustable plate type differential thatcan have the preload varied to determine slip %. Due to its type, this differential needs servicing every 15,000 miles.

If you need to adjust the initial torque, you have to add/remove clutch plates shown as (2) in the picture. Note:Additional parts are required to fully adjust the limited slip differential:

ALS3F0153F SHIM (T=0.1)

ALS3F0154F SHIM (T=0.2)

ALS3F0155F REPAIR KIT CLUTCH

Switchable Traction Control – Cost Option

Switchable traction control is available on the Cup car as a cost option. For further details, please refer to the owner’shandbook, pages 195 – 197.

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Air Jacks – Cost Option

These Cup cars are fitted with three air jacks (lift system), one in a central front position and two at the rear in front ofthe rear wheels.

AP Racing air jacks are designed to operate at a maximum pressure of 20 Bar. Never work under a vehicle supportedonly by air jacks unless safety props are in place.

Do not use 'U' bolt type clamps, as distortion of the body will cause the air jack to stick. Do not loosen or removeadapter. Jacks must be vertical during operation. Mounting brackets or clamps to be fitted to threaded section of bodyonly. Do not use petrol or paraffin for cleaning the air jacks as this will damage the rubber seals. Use an alcohol basedcleaning fluid e.g. methylated spirit. Use only silicone spray or silicone grease when internal lubrication is necessary.

Ensure the end cap reinforcing ring is tightened before use. Inlet connections are designed for dash 6 hose fittingssuch as Aeroquip or Goodridge.

To raise the car with the air jacks, a lance (Lotus Sport part number ALS4T2079F) is required. Ensure that the car isparked on a flat, clear surface before using the air jacks. The valve on the front right wing of the car must be presseddown (shown in picture above). The lance should then be pushed onto the valve, and provided the lance has sufficientpressure, the air jacks will lift the car. As soon as the jacks have reached full height, a safety prop (Lotus Sport partnumber ALS4T2078F) must be positioned on each jack (three jacks on each cup car). This is to protect against the airjacks failing to hold the car up. Finally, the lance should be carefully removed, to not pull the valve up with it (theconsequence of which would be loss of pressure in the air jack system).

To lower the car back to the ground, re-attach the lance and raise the jacks. Carefully remove the safety props andonce everybody and all parts and tools are clear of the car, the valve can be pulled up to release the pressure from thesystem.

Air Conditioning – Cost Option

Air conditioning is available on the Cup car as a cost option. For further details, please refer to the owner’s handbook,pages 61 – 65.

Starshield – Cost Option

A protective Starshield body coat is available on the Cup car as a cost option.

Press down toclose the valve

Pull up toopen the

valve (dropthe car)

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3.0 Deleted Items

The Lotus Sport Exige Cup (USA) has the following equipment deleted in comparison to the standard road vehicle.

Security FeaturesThis vehicle is not fitted with either remote or central locking. In order to lock each door, the ignition key must be usedto manually lock each door lock.

Neither the alarm nor immobiliser is fitted to this vehicle. The vehicle is immobilised through using the electrical batterymaster switch.

Soft TrimThere are no footwell carpets, interior trim, hardtop trim or boot carpets fitted to this vehicle. The door trim inserts havebeen replaced with an ABS door trim panel.

Hard TrimThis vehicle is not fitted with a battery cover (replaced with positive terminal cover), NVH Pads, passenger footrest orbulkhead trim.

WARNING! DO NOT PLACE ANY OBJECT ACROSS THE BATTERY TERMINALS.

RadioThis vehicle is not fitted with a radio or speakers.

Road Safety FeaturesAs this Exige Cup Car is not road legal, the following have been deleted: standard seats, inertia reel seatbelts,headlights, driver and passenger airbags.

FOR ALL RUNNING IN DETAILS PLEASE REFER TO THE OWNERS HANDBOOK OR TECHNICAL SERVICEMANUAL. BE AWARE THAT SOME OF THE TECHNICAL INFORMATION MAY VARY FROM THAT SHOWN INTHE HANDBOOK.

PLEASE BE AWARE THAT THE SPARK PLUGS AND V-BELT USED ON THIS ENGINE DIFFER TO THAT OF THESTANDARD ENGINE. UNDER NO CIRCUMSTANCES SHOULD THE PARTS FROM THE STANDARD ENGINE BEUSED ON THIS CAR.

Front Mud FlapsRemoved.

Foot RestRemoved.

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4.0 PARTS LIST – USA Cup Car Additional Parts – Standard Fit

PART NUMBER DESCRIPTION QTY PER CAR

DAMPERS

ALS3C0067J 240 SLICK ÖHLINS 2-WAY DAMPER - FRONT LEFT LOF 1G50_1 1

ALS3C0068J 240 SLICK ÖHLINS 2-WAY DAMPER - FRONT RIGHT 2G50_1 1

ALS3D0080J 240 SLICK ÖHLINS 2-WAY DAMPER - REAR LEFT 3G50_1 1

ALS3D0078J 240 SLICK ÖHLINS 2-WAY DAMPER - REAR RIGHT 4G50_1 1

CLUTCH

ALS3Q6000F CLUTCH COVER 1

ALS3Q6001F CLUTCH PLATE 1

BRAKES

A111J0151S BRAKE PADS, REAR 1

ALS3J0046F BRAKE HOSE KIT, BRAIDED 1

A340J6001S BRAKE FLUID 1

ALS3J0048F FRONT PAD SET, PAGID RS14 1

ALS3J0049F BOLT KIT (BELLS TO DISC, INC BOLTS, WASHERS, NUTS) 1

ALS3J0050F BANJO FEMALE ADAPTER 2

ALS3J0051F SINGLE BANJO BOLT TO SUIT CALIPER 2

ALS3J0052F BANJO WASHERS 4

ALS3J0095F FRONT CALIPER, RH 1

ALS3J0096F FRONT CALIPER, LH 1

ALS3J0097F BELLS, BRAKE DISC 2

ALS3J0098F BRACKETS, CALIPERS 2

ALS3J0099F BRACKET BOLTS 4

ALS3J0111F BOLTS, BRACKET TO UPRIGHT 4

ALS3J0100F FRONT DISC, RH, CROSS DRILLED 1

ALS3J0101F FRONT DISC, LH, CROSS DRILLED 1

FUEL SYSTEM

ALS3L0041F FUEL PUMP, UPRATED 1

BLS3L0040F RETAINER CAP, UPRATED FUEL PUMP 1

RACE BATTERY

ALS3M0241J RACE BATTERY AND BATTERY CASE AND TERMINALS 1

ALS3M0260F ODYSSEY 680 BATTERY HOLD DOWN BRACKET 1

6-POINT HARNESS

ALS1V0018F BRACKET, CRUTCH STRAP 1

ALS1V0019F SPREADER PLATE 1

ALS1V6017F EYE BOLTS 2

CLS1V0052K STRAP PLATE AND SPREADER PLATE 2

ALS1V0015F HARNESS 1

A111W3154F M8 K-NUTS 4

A111W7175F M8 BUTTON HEAD SCREWS 4

4-POINT HARNESS

A122V0050F FOUR POINT HARNESS 1

DRIVERS SEAT

BLS3V6043F RECARO SEAT - FIA APPROVED 1

CLS3V0047F BRKT, DRIVERS, SEAT RUNNER, LH 1

CLS3V0048F BRKT, DRIVERS, SEAT RUNNER, RH 1

A079W4019F SPACERS 4

16 of 54



A075W1039Z M8 BOLTS 4

A075W3010Z M8 NYLOC NUTS 4

A075W4020Z WASHER, M8 X 17 X 1.6, ZINC, SEAT BRKT TO SEAT RUNNER 8

A082B6057F GROMMET 1

PASSENGERS SEAT

A122V0044S SPORTS PASSENGER - BLACK ALCANTARA 1

A122U0067F SEAT MOUNTING FRAME, PASSENGER, LHD 1

ROLL CAGE

ALS3V0058F SCCA COMPLIANT ROLL CAGE & PETTY BAR - FITTED 1

HEADLIGHTS

ALS3M0236F PAINTED HEADLAMP COVER - GLOSS BLACK, INC SEAL, RH 1

ALS3M0237F PAINTED HEADLAMP COVER - GLOSS BLACK, INC SEAL, LH 1

ACCUSUMP

ALS3E6001F ACCUSUMP, 2 QT 1

ALS3E6002F CLAMP, ACCUSUMP MOUNTING 1

ALS3E6003J VALVE, EPC, ACCUSUMP 1

ALS3E6005F CONNECTOR, ACCUSUMP, -10 JIC, FOR 5/8 HOSE 2

ALS3E6006F CONNECTOR, ACCUSUMP, T PIECE 1

ALS3E6007F CONNECTOR, ACCUSUMP, ONE WAY VALVE 1

ALS3E6008F CONNECTOR, ACCUSUMP, -10 JIC, FOR 1/2 HOSE 1

ALS3E6009F CONNECTOR, ACCUSUMP, 1/2 NPT FOR 1/2 HOSE 1

ALS3E6012F HOSE, ACCUSUMP, 1/2 ID, LOW PRESSURE, BLACK 2.5

ALS3M0006K ACCUSUMP WIRING KIT 1

ALS3M0131F DIODE KIT 1

ALS3E6016F FILTER, OIL, IN LINE, 120 MICRON 1

ALS3E6017F CONNECTION, OIL FILTER, -8 TO 1/2" HOSE 2

A111W6624F P CLIP 1

A075W1030Z MOUNTING BOLTS, M6 1

A075W3009Z MOUNTING NUTS, M6 1

A075W4015Z MOUNTING WASHERS, M6 5

A111W1163F MOUNTING BOLTS, M5 2

A100W3113F MOUNTING NUTS, M5 2

A111W4168F MOUNTING WASHERS, M5 2

X036B6010Z GROMMET 1


A100B6163F BLANKING GROMMET 1

A075W3031Z JACKNUT, 6MM 4

A918W5217F BOLT, FLANGE HEAD, M6 X 40 4

ALS3U0002F LABEL, WARNING, ACCUSUMP FITMENT, ENGLISH 1

A111U0368F NYLON SPACER 4

A075W6038Z CABLE TIE 10

A121W6768F OETKA CLIP, 21.0MM 4

A117W6706F OETKA CLIP, 25.6MM 2

A117W6729F CABLE TIE BLOCK 1

ALS3M0153F DIODE 2

ADDITIONAL PARTS

ALS3U0014F LOTUS SPORT DECAL, SIDE, BLACK, RH 1

ALS3U0015F LOTUS SPORT DECAL, SIDE, BLACK, LH 1

ALS3U0019F EXIGE CUP DECAL, REAR, BLACK 1

17 of 54



MOTSP00030 LOTUS SPORT DECAL, SIDE, YELLOW/SILVER, RH 1

ALS3U0016F LOTUS SPORT DECAL, SIDE, YELLOW/SILVER, LH 1

ALS3U0018F EXIGE CUP DECAL, REAR, YELLOW/SILVER 1

ALS3U0021F LOTUS SPORT WINDSCREEN DECAL 1

MOTSP00157 KEY FOB 1

ALS3M0240JASSY, ECM, SUPERCHARGER, USA SC/CUP MY07 ELECTRONICTHROTTLE

0

A129E6000F CUP FUEL INJECTORS 4

A082W6528F POP RIVET 10

A075W6090Z FIXING 4

ALS3U0011F LUGGAGE LABEL, 48KG 1

LSPAC00037 UNION JACK BADGE 1

ALS3H0017J SPARCO STEERING WHEEL KIT 1

ALS3B0133K REAR ACRYLIC WINDOW 1

A117V0530F SPEAKER GRILLE BLANKS 2

ELECTRICAL BATTERYMASTER SWITCH

A340M6007F MTA BOX 1

ALS1M6018F BATTERY MASTER SWITCH 1

ALS3M6005F PULL CABLE 1

ALS1V0049K MOUNTING BRKT, PULL CABLE 1

A082W6512F RIVET 2

ALS3V0005F DECAL, BATTERY MASTER SWITCH 1

ALS1B0094K CUP, ABS, IGN PULL CABLE 1

ALS3M0002F MOUNTING RING, IGN PULL CABLE 1

ALS3M6004F SCREW, M5 X 20, COUNTERSUNK, S/S 8

A100W3113F NUT, NYLOC, M5 8

A111W4168F WASHER, M5 8

ALS3M0007K WIRE AND CONNECTORS, BATTERY MASTER SWITCH 1

ALS3M0007K BATTERY LEADS 1

ALS3M0010K IMMOBILIZER BRIDGING LINK 1

A075W3021Z NUT, M8, MTA BOX TERMINAL 2

A075W4048Z WASHER, M8 SPRING, MTA BOX TERMINAL 2

A117F6000F PLASTIC CLIP, YELLOW 4

A117F6001F TORQ HEAD SCREWS 4

A075W1030Z BOLT, M6, MTA BOX MTG 1

A075W4015Z WASHER, M6, MTA BOX MTG 1

A075W3031Z JACKNUT FOR MTA BOX 1

A082W7040F CAP HEAD SCREW, M6 X 40, BATTERY MASTER SWITCH MTG 2

A075W4015Z WASHER, M6, BATTERY MASTER SWITCH MTG 2

X036B6010Z GROMMET, PULL CABLE/BULKHEAD 1

A082H6046F GROMMET FOR CABLE THRO BOOT 1

A075W1028Z BOLT, M6, DUMP RESISTER MTG 1

A079W6156F RIVNUT, M6, DUMP RESISTOR MTG 1

A075W4015Z WASHER, M6, DUMP RESISTOR MTG 1

A075Q6013Z P CLIP FOR D R MTG 1

A117W6713F GROMMET, HEATER VENT PANEL MTG 2

A075W6038Z CABLE TIES 10

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FIRE EXTINGUISHER SYSTEM

ALS3V0038J FIRE EXTINGUISHER, ELECTRIC 1

ALS3M0001F COVER PLATE 1

ALS3V0006F DECAL, FIRE EXTINGUISHER 1

ALS1B0095K CUP, ABS, FIRE EXT BUTTON 1

ALS3M0003F MOUNTING RING, FIRE EXT BUTTON 1

ALS3M6004F SCREW, M5 X 20, COUNTERSUNK, S/S 6

A111W6566F RIVNUT 6

ALS3M0008K FIRE EXTINGUISHER WIRING KIT 1

BLS3V0027F BRKT, FIRE EXT NOZZLE MTG 4

X036B6010F GROMMET 4

A075W6038Z CABLE TIES 15

A117W6729F STICKY PADS 2

A100W6376F STICKY PADS 20

A082W6512F RIVET 6

A111W6660F RIVNUT, M6 4

A075W1028Z BOLT, M6 X 20 4

A075W4015Z WASHER, M6 4

A116K6020F CLIP 1

A117W6729F TIE WRAP BASE 1

WHEELS & TYRES

ALS3G6026J HPS WHEEL 7X16 & SLICK TYRE - LHF 1

ALS3G6027J HPS WHEEL 7X16 & SLICK TYRE - RHF 1

ALS3G6044J HPS WHEEL 8X17 & SLICK TYRE - LHR 1

ALS3G6045J HPS WHEEL 8X17 & SLICK TYRE - RHR 1

BLS3G6014F 240R WHEELS - FRONT WHEEL - SILVER 2

BLS3G6019F 240R WHEELS - REAR WHEEL - SILVER 2

BLS1H6001F YOKOHAMA SLICK FRONT TYRE 2

BLS1H6002F YOKOHAMA SLICK REAR TYRE 2

INTERCOOLER

ALS3E0169F INTERCOOLER CUP255/GT3 STYLE 1

ALS3E0170F BRACKET, INTERCOOLER LHS 1

ALS3E0171F BRACKET, INTERCOOLER RHS 1

ALS3E0175K DUCT, BELLOWS TO INTERCOOLER, CUP255 LARGER INTERCOOLER 1

ROOF

ALS3B0126F UP-RATED ROOF - PAINTED ASSEMBLY 1

AIRBOX

ALS3E0157F AIRBOX, LOWER HALF, NA UPGRADE KIT 1

ALS3E0158F AIR FILTER, NA UPGRADE KIT 1

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OPTIONS

SPORTS EXHAUST - LEVEL 2

ALS3S0014S DE-CAT PIPE 1

LOTAC05335 SPORTS EXHAUST - LEVEL 2 1

LOTUS SPORT LSD

ALS3F6000J LIMITED SLIP DIFFERENTIAL PLATE TYPE (LSD) 1

FIA APPROVED FUEL CELL

BLS3L6009F FIA APPROVED 70 LITRE BAG TANK 1

ALS3L0042F RING SPACING FUEL PUMP MTG 1

ALS3L0043F O-RING, RING SPACER FUEL PUMP MTG 1

A117W6729F TIE WRAP BASE 6

A075W6038Z TIE WRAPS 6

A079W6156F M6 RIVNUT 1

A075W1028Z M6 BOLT 1

A075W4015Z M6 WASHER 1


A111V0206K BLANKING DOTS 10

A116V6008F SILVER TANK TAPE 1

A121L0031H RING-FUEL PUMP MTG SPACING 1

AIR JACKS

ALS4O3045F AIRJACK 3

ALS4O3046F AIR JACK VALVE 1

A111W6614F RIVET 28

A117B0209V PLEXUS 1

A075W6065Z POP RIVET 12

ALS3A0047F REAR AIRJACK MTG 2

ALS4O3048F FRONT LOWER AIRJACK MTG 1

ALS4O3049F FRONT UPPER AIRJACK MTG 1

ALS4O3041F HOSE - AIRJACK FRONT TO REAR 1

ALS4O3042F HOSE - AIRJACK TEE TO LANCE 1

ALS4O3043F HOSE - AIRJACK REAR - TEE 2

END OF ADDITIONAL PARTS LIST

The Lotus Sport USA Cup cars are based around a left-hand drive European Exige. There are therefore somecomponents that may not be available immediately through the standard Lotus Cars dealer network. These parts canbe obtained through the Lotus Cars dealer network but may have a longer lead-time due to shipping times. Theseparts are present within Parts Manual A120T0325J.

20 of 54



5.0 Suspension Settings

Suspension Settings – Slick Cup Öhlins Dampers

Recommended Settings – Easy TrackFront Damper Full Hard Full Soft

Bump P11 P1 (Clockwise) P22 (Anti-Clockwise)Rebound P8 P1 (Clockwise) P60 (Anti-Clockwise)

Rear DamperBump P15 P1 (Clockwise) P22 (Anti-Clockwise)

Rebound P15 P1 (Clockwise) P60 (Anti-Clockwise)

Recommended Settings Race

Bump P1 (Clockwise) P22 (Anti-Clockwise)Rebound P1 (Clockwise) P60 (Anti-Clockwise)

Bump P1 (Clockwise) P22 (Anti-Clockwise)Rebound P1 (Clockwise) P60 (Anti-Clockwise)

Front AntiRoll Bar

P3 P1 P5

Suspension GeometryFront

Parameter Specification Tolerance Difference side to sideRide Height 120 mm -2.0 / + 1.0 mm +/- 2.0 mm

Camber REFER TO SERVICE MANUAL

Castor REFER TO SERVICE MANUALToe REFER TO SERVICE MANUAL

Bump Steer REFER TO SERVICE MANUALSpring Rate 457 lbs/in

RearParameter Specification Tolerance Difference side to side

Ride Height 120 mm +2.0 / - 1.0 mm +/- 2.0 mmCamber REFER TO SERVICE MANUAL

Toe REFER TO SERVICE MANUALBump Steer REFER TO SERVICE MANUALSpring Rate 571 lbs/in

Notes: Ride heights taken with _ a tank of fuel and 1 x 75kg driver.Ensure front ride height is never higher than rear ride height.

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6.0 Brake Pad Bedding in Procedure

PLEASE NOTE: IT IS IMPERATIVE THAT THE BEDDING IN PROCEDURES ARE PERFORMED ONLY ON A RACETRACK. THESE CARS ARE NOT LEGAL FOR STREET USE.

Why bedding?• To transfer a layer of friction material onto the brake disc faces to achieve maximum performance.• To stabilise compressible materials to avoid a spongy pedal.• To boil off volatile elements in the friction compound in order to have the initial ‘green’ fading during bedding

and not during the race.• To align the pad surface with the brake disc surface to have full contact.

If pads are not bedded in properly and / or are used hard right out of the box, this is likely to lead to pad glazing. Padglazing is a condition where the resins in the pad crystallise on both the pad friction surface and the brake discsurface, resulting in poor stopping performance, brake judder and vibrations.

Also rapidly escaping volatile elements and moisture from the resin would seek an immediate escape route out of thefriction compound, creating small fissures that would lead shortly to cracking and chunking.

BASIC BEDDING IN

To initiate some heat in the brake discs and pads:• 4 to 6 stops with medium brake pressure from approximately 150 km/h (90 mph) to approximately 80 km/h (50

mph).• Distance between each brake stop approximately 300 - 400 meters (327 to 436 yards).• The pads should not reach temperatures above 400° Centigrade (550° Fahrenheit).• No dragging!• Blocking of the air ducts might be helpful to reach appropriate temperatures quicker.

IMMEDIATELY AFTER BASIC BEDDING IN AT HIGH SPEED

Simulating race conditions:• One stop with medium to heavy brake pressure, without allowing brakes to lock from approximately 180 km/h

(110 MPH) to approximately 80 km/h (50 MPH).• No dragging!• Recovery stops with light brake pressure 3 to 4 times (cleaning procedure).• Repeat the high-speed stops including recovery stops 2 to 3 times.• Allow a cool-off distance of approximately 500 m (550 yards) between high-speed stops.

If possible, pads should be bedded on used but NOT worn out brake discs.

MOUNTING NEW PADS ON USED DISCS

Edges of pad surface should be filed roughly to 45 degrees, to ensure that the pad carries fully and evenly, and is nottouching the edge of the disc.

PROLONGED USE OF THE BRAKES

Please note that after track use of a vehicle, the handbrake should not be used in order to prevent heat transfer fromthe discs through to the pads and brake fluid. It should be noted however that the vehicle should be otherwiserestricted to roll forward or backwards when the handbrake is not applied.

It is also advised that the brakes are given at least one lap of the circuit to cool at reduced track pace; the brakesshould not be ridden during any point in order to avoid reducing braking of any type. Aggressive braking technique willresult in accelerated disc and pad wear and more frequent service intervals will be required.

22 of 54



7.0 Service Life

Before EveryTrackSessionOtherIntervalsLubrication1Gearbox oil - check levelX2Gearbox oil - renew3Engine oil - check leve reservoirs, check adjuster settings,lubricate adjusters and spring platforms38Lubricate anti roll bar chassis mountings and

Before EveryTrack

SessionOther

Intervals

1 Gearbox oil - check level X2 Gearbox oil - renew3 Engine oil - check level X4 Engine oil - renew5 Oil Filter - renew6 Accusump system - check operation, replace as necessary X7 Accusump system - replace in-line filter8 Inspect engine & transmission for oil leaks X

9 Inspect condition of drive shaft gaiters X10 Engine mounts - check tight & crack check 2,000 miles11 Inspect auxiliary drive belt condition X12 Air Filter - check condition X13 Air Filter - renew air cleaner element X

14 Remove bellows and inspect chargecooler for damage. renewdouble sided tape. Check c/cooler duct hose clips

15 Inspect integrity of fuel system X16 Renew spark plugs 1,000 miles17 Timing Chain - check, replace as necessary 10,000 miles18 Exhaust System - check security of all joints X19 Gear Cables - check condition, replace as necessary X

20 Cooling system - Check Pressure

21 Inspect water radiator & oil cooler hoses & pipework for damage orleaks. Clean radiator & oil cooler finning X

22 Check coolant level X23 Renew coolant 1,000 miles

24 Brake Pads - check friction thickness, replace at 4mm depth X25 Brake Discs - check condition, replace as necessary X26 Inspect parking brake adjustment27 Inspect brake hoses, pipes & hydraulic units X28 Check brake fluid level X29 Renew brake/clutch fluid 1,000 miles

30 Wishbone bushes and rod ends - check for play X31 Front and rear wheel bearings - check for play X32 Suspension geometry - check and adjust as necessary33 Hub nuts - check torque and adjust as necessary X

34 Check security and condition of front & rear suspension inc. freearticulation of rear toe link ball joints

35 Check torque of rear toe link inboard fixing (50 Nm) X36 Inspect dampers for leaks and performance

37 Check security of damper reservoirs, check adjuster settings,lubricate adjusters and spring platforms

38 Lubricate anti roll bar chassis mountings and adjuster threads39 Inspect steering ball joints and gaiters40 Inspect free play at steering wheel

X

XXX

X

X

X

XX

X

X

Op.No. Operation Description

Service TypeEvery 500Miles or 4Hours*

X

X

X

X

X

X

XXX

X

X

X

X

X

XX

X

X

XX

X

X

X

Lubricati no

Powertrain

Cooling system

Braking system

Steering & Suspension

23 of 54



Please note that the above timings are suggested service intervals. In no way does this list guarantee the service lifeof any part on this vehicle. The intervals will be dependent on driving style and vehicle use; the table above istherefore to be treated as a guideline.

EverySessionOtherIntervalsWheels & Tyres41Inspect tyre condition & set pressuresX42Wheels - check for damage, replace

EverySession

OtherIntervals

41 Inspect tyre condition & set pressures X42 Wheels - check for damage, replace as necessary X

43 Fire extinguisher check operation and service annually X44 Fire extinguisher - arm prior to each track session X45 Wheel bolts - check torque X46 Safety harnesses - check stitching, replace after any accident

47 Check battery & terminals for security & condition X48 Inspect operation of all lights X49 Temperature sensors - check operation X50 Electrical systems - check system X

51 Clean and dry floor X52 Check hardtop air intake for obstructions X53 Inspect adjustment of hinges and latches54 Windscreen - check for cracks, clean before each session X55 Door locks - ensure unlocked prior to driving X56 Bodywork - ensure all fitted correctly and is secure57 Inspect wiper operation & top up windscreen washer reservoir X

* Whichever comes sooner

XX

X

Op.No. Operation Description

Service Type

X

X

X

XX

X

X

XX

X

X

X

Wheels & Tyres

Safety

Electrical

Body

Every 500Miles or 4Hours*

24 of 54



8.0 Accusump Information

The Accusump System on Exige Cup Cars is already fitted and charged, but the following procedure applies forservicing/repairs and general use.

Operation

Initial charging and oil changes

NOTE: ALL LSPC ACCUSUMP SYSTEMS COME WITH AN ELECTRONIC CONTROL VALVE WHICH ISOPERATED BY THE IGNITION SYSTEM

1. Before adding oil to the engine, pressurise the air end of the Accusump (cylinder located in the luggagecompartment using a tyre inflator) to about 50 psi as read on the air pressure gauge, then bleed the pressure to 7psi, using the bleed valve indicated by arrow 'A'. A minimum pre-charge of 7 psi is required in the air chamber ofthe Accusump, so that the unit cannot become fully discharged. If in doubt as to whether the Accusump is fullydischarged, please refer to point 4 of IMPORTANT PROCEDURES covered later in this manual.

2. The Accusump is now ready to operate. Fill the system with oil as described in the owners handbook then start theengine, DO NOT rev the engine or drive the vehicle, leave running at idle.

3. The Accusump will take approximately 2 litres of oil from the oil pan and store this within its chamber. From cold,run the engine at idle (pressure will be approximately 80 psi initially) and wait until the pressure in the Accusumpdrops to between 30 - 40 psi on the Accusump pressure gauge.

4. While the engine is still running, disconnect the purple wire with the blue collar that leads to the AccusumpSolenoid (indicated by Arrow 'B') then turn off the engine. Ensure that all electrical safety requirements arefollowed so as to avoid any risk of injury. Recheck the Oil level and top up to the maximum mark on thedipstick. Once this is complete reconnect the purple wire. The procedure is then complete.

A

B

25 of 54



WARNING - DO NOT DRIVE THE VEHICLE UNTIL THE OIL LEVEL IS AT THE MAXIMUM LEVEL ON THE ENGINEDIPSTICK. DO NOT ALLOW THE OIL LEVEL TO EXCEED THE MAXIMUM LEVEL INDICATED ON THE DIPSTICK.

Maintenance

The Accusump is protected by an inline oil filter which does not have a bypass. The filter should be replaced andinspected at frequent intervals, Lotus recommend that this is undertaken during service periods. The life of theAccusump, like the life of your engine, will be affected by how clean your oil remains.

The Accusump has close tolerances of roundness; care must be taken that the cylinder is not damaged or distorted.The unit should be mounted so that it is not twisted or bent, however slightly. Do not use the Accusump as a step orallow anything to be dropped on it.

Keep the dust cap on the air valve to prevent the ingress of dirt into the air end of the unit.

Oil Contamination

In the unlikely event that the oil should become contaminated, the Accusump and all its related components should bereplaced.

Important Precautions

The following precautions must be taken for the Accusump to operate correctly. Failure to do so can result in damageto the unit.

1. Never allow the Accusump to become hydraulically locked, that is, having the unit totally filled with oil with thevalve closed.

2. There should be 7 - 15 psi pre-charge of air when the unit is totally empty of oil.

3. When in operation, the reading on the gauge of the unit should increase and decrease with engine oil pressurefluctuations.

4. Routinely check the pre-charge pressure with the unit totally empty of the oil to make sure air has not leaked out ofthe unit. Recommend at least once a week. This is achieved by turning the ignition key to position 2 and readingthe value from the charge gauge after the Accusump has finished discharging its oil.

5. Never bleed air from the unit whilst in operation or when full of oil as this will defeat the purpose of the pre-chargeand make the unit ineffective.

6. These units should not be mounted in a place where they can become excessively hot, especially not in a placewhere they will absorb heat after the engine has been switched off and the Accusump control valve is closed.

7. Improper disassembly can cause damage to the Accusump and can be dangerous.

26 of 54



Accusump Parts Information

Qty

1

1

1

1

1

2

1

1

1

1M

3M

1

2

1

1

1

2

2

2

1

1

1

4

4

2

1

Part Number

ALS3E6001F Accusump, 2 Qt

Description

ALS3E6003J

ALS3E6002F

EPC Valve

Mounting Clamps, Accusump

ALS3E6009F

ALS3E6008F

Connection, Male, 1/2 NPT to 1/2 hose

Connection, Female, -10 JIC to 1/2 hose

ALS3E6005F

ALS3E6004F Connection, Female, 90, 5/8 BSP to 5/8 hose

Connection, Female, -10 JIC to 5/8 hose

ALS3E6006F

ALS3E6007F

Connection, T Piece, M/M/F, -10 JIC

Check Valve, -10 JIC, M/M

ALS3E6011F

ALS3E6012F

Hose, AQP, 5/8 ID, Low Pressure

Hose, AQP, 1/2 ID, Low Pressure

ALS1E0072K

A111W6624F

Mounting Brkt

P Clip

A075W1030Z

A075W3009Z

Mounting Bolts, M6

Mounting Nuts, M6

A075W4015Z

A111W1163F

Mounting Washers, M6

Mounting Bolts, M5

A100W3113F

A111W4168F

Mounting Nuts, M5

Mounting Washers, M5

X036B6010Z

X036B6167Z

GROMMET

GROMMET

A082H6046F

A075W3031Z

GROMMET

JACKNUT, 6MM

ALS3E6016F FILTER, OIL, IN LINE, 120 MICRON

A918W5217F

ALS3E6017F CONNECTION, OIL FILTER, -8 TO 1/2" HOSE

BOLT, FLANGE HEAD, M6 X 40

27 of 54



28 of 54

O W N E R ’ S M A N U A L

™

INTRODUCTIONThe ODYSSEY™ battery ingeniously uses absorbed glass mat (AGM) technology to offer, inone box, the characteristics of two separate batteries. It can deep cycle as well as provideenormous cranking power - it is almost as if a champion long distance runner and a worldclass sprinter are one and the same person.

These batteries are capable of providing engine cranking pulses in excess of 2250A for 5seconds as well as 400 charge/discharge cycles to 80% depth of discharge (DOD). A typicalstarting, lighting and ignition (SLI) battery can do one or the other, but not both. It is either asprinter or a long distance runner; ODYSSEY batteries will do both — provide short durationhigh amperage pulse or low rate long duration drains.

WHY USE ODYSSEY BATTERIES?GUARANTEED LONGER SERVICE LIFEWith an eight to twelve year design life (float) and a three to ten year service life, ODYSSEYsaves you time and money because you do not have to replace the battery as often.ODYSSEY is warranted against factory defects for two full years in powersports or three fullyears in automotive, commercial and heavy-duty marine applications.

SUPERIOR CRANKING AND FAST CHARGE CAPABILITY The 5 second cranking power of ODYSSEY batteries is double to triple that of equally sizedconventional batteries, even when the temperature is as low as - 40°C (-40°F). Also, withsimple constant voltage charging (alternator or independent charger), there is no limitationon the inrush current, so the user is assured of fast charge recovery.

MOUNTING FLEXIBILITY The ODYSSEY battery may be installed in any orientation (except inverted) withoutsacrificing any performance attributes. There is no fear of any acid spillage as ODYSSEYrecycles the internal gas during operation or charging. The sealed design of the ODYSSEYbattery eliminates the need for an acid vent tube; eliminating the fear of acid burns ordamage to expensive chrome or paint.

SUPERIOR VIBRATION RESISTANCE ODYSSEY batteries are of military grade and have endured rigorous tests that demonstratetheir overall ruggedness and exceptional tolerance of mechanical abuse.

READY OUT OF THE BOX ODYSSEY batteries are shipped fully charged. If ODYSSEY’S voltage is 12.65V or greatersimply install the battery in your vehicle and you are ready to go! If below 12.65V, boostcharge following the instructions in the ODYSSEY Owner’s Manual and/or Technical Manual.Putting a boost on the battery will not hurt it, even if its voltage reads higher than 12.65V.

WORRY-FREE SHIPPING Owing to the drycell design, the US Department of Transportation (USDOT) has classified theODYSSEY battery as a nonspillable, so it may be shipped worry-free by Express Service orby air.

LONGER STORAGE LIFE Unlike conventional batteries that need to be recharged every six to twelve weeks theODYSSEY battery, when fully charged, can be stored for up to 2 years at 25°C (77°F). Simplyrecharge and ODYSSEY is returned to full power. At lower temperatures, storage times willbe even longer.

DEEP DISCHARGE RECOVERYShould ODYSSEY become deeply discharged, simply recharge following instructions in theODYSSEY Owners Manual.

2 Publication No. 2602-0232, Rev. 2 - September 2005www.odysseyfactory.com

1. Using proper procedures as recommended by the vehicle manufacturer, carefullydisconnect the cables from your old battery and remove it from the vehicle. Return the spentbattery to the battery dealer for proper recycling.

2. Inspect existing battery cables for corrosion, acid damage or insulation deterioration.Replace if deterioration is present.

3. Position your ODYSSEY in the battery holder and fasten firmly to the vehicle.

4. Connect the positive cable from your ignition to the Positive (+) terminal.

5. Connect the negative cable from your engine or chassis to the Negative (-) terminal.

6. Torque the bolt, screw or nut per the specification noted in table. If you’re using theAccessory Bolt (C), hold the Brass Post (A) with vise grips and counter torque. Do the samewith General Motors automotive battery cable installation.

NOTE: This is a valve regulated sealed battery and never needs to have water or electrolyte(acid) added. Warranty will be void if opened!

B

A. BoltB. WasherC. Battery

A. Brass PostB. Helicoil InsertC. Accessory Bolt3/8“ Course Thread (not included)D. Battery

A

C

A

B

C

D

A

DINTERMINAL

3/8”-16 UNCTHREAD

B

A. 0.72”/18.2mm MAXB. 0.96”/24.5mm MAX

M6 x 1THREAD

3/8-16 UNCTHREAD

0.61”(15.5mm)

0.74”(18.8mm)

NTS

PC625 PC2150

SAETerminals

PC2250

AllOtherModels

NOTE: PC535 Bolt installationis in horizontal orientation.

Publication No. 2602-0232, Rev. 2 - September 2005www.odysseyfactory.com 3

INSTALLATION Your ODYSSEY is normally ready to install right out of the box! Measure the battery voltage;if it is 12.65 volts or greater, install; if less, then refer to the charging section.

ANY OF THE FOLLOWING WILL VOID YOUR WARRANTY:• EXPOSING BATTERY TO GASOLINE OR DIESEL FUEL • REMOVING THE LABELED COVER • REMOVING OR DESTROYING THE BATTERY’S DATE CODE

DO NOT SHORT CIRCUIT YOUR ODYSSEY’S TERMINALS! Remove any metallic items such as watches, bracelets and other personal jewelry to ensuresafe installation.

Mod

el

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eH

otCr

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th(m

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10-H

our

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6.67

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1800

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1616

1514

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592

538

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05(1

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04(1

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(A) How do I know the state of charge(SOC) of the battery?

Figure 2: ODYSSEY OCV vs. state ofcharge

As long as the battery has not beencharged or discharged for 6 or morehours, Figure 2 can be used todetermine the SOC of the ODYSSEYbattery. Use a high quality digitalvoltmeter to measure its open circuitvoltage (OCV). The graph shows that ahealthy, fully charged ODYSSEY batterywill have an OCV of 12.84V or higher at25ºC.

(B) How long can the battery be stored?

Refer to Figure 3 below. At 25°C (77ºF),these batteries can be stored for up to2 years. The lower the temperature, thelonger the storage time. The batterymust be charged before storage.

Roughly every 10°C (18°F) increase intemperature cuts storage time in half.If the temperature rises to 35°C (95°F)the battery may be stored for only1 year before a recharge becomesnecessary. Figure 3 will apply only if thebattery is charged before storage.

Figure 3: ODYSSEY storage time attemperatures

State of Charge (SOC), %

Op

enci

rcu

itvo

ltag

e(O

CV

),V

13.0

12.8

12.6

12.4

12.2

12.0

11.8

11.610 20 30 40 50 60 70 80 90 100

12.84V or higher indicates100% SOC

Per

cen

to

f0.

05C

cap

acit

y

100

90

80

70

60

50

40

30

Open circuit storage time in weeks

10 20 30 40 50 60 700

25°C 45°C 65°C

PULSE DISCHARGE CAPABILITIES Table 1 shows the 5, 10, 20 and 30-second pulse discharge numbers for these batteriesto 7.2V at 25ºC (77ºF). Sufficient time must be given between successive discharges toallow the terminals to cool down. Also, fully charged batteries will meet these.

Battery Pulse discharge in amps to 7.2V5 sec. 10 sec. 20 sec. 30 sec.

PC310 310 250 225 200PC535 535 465 410 380PC545 545 495 420 380PC680 680 595 525 400PC625 625 545 480 450PC925 925 870 765 675PC1200 1,200 1,090 900 825PC1700 1,700 1,540 1,355 1,195PC2150 2,150 1,985 1,750 1,600PC2250 2,250 2,075 1,775 1,675

Table 1: Pulse discharge of ODYSSEY batteries

ODYSSEY STORAGE AND DEEP DISCHARGE RECOVERY Figure 2 shows the relationship between open circuit voltage (OCV) and state ofcharge (SOC) for the ODYSSEY battery.


MAINTENANCE ODYSSEY is very different from standard liquid-acid batteries that are openly vented.ODYSSEY is and operates as a sealed battery, recycling all gases internally. There is nocorrosion of the positive terminal or corrosion to the surrounding area. ODYSSEY is shippedfully charged from the factory, but prior to installation, check the battery’s voltage to see if itis 12.65 volts or greater. If not, recharge it using the procedure below.

Never attempt to remove the top decal cover, as it will cause the battery to fail.

CHARGING The state of charge in an ODYSSEYbattery can be determined from the following chart:

Powersport Vehicles - have limited charging systems. To get long life from the ODYSSEYbattery, it is important that the battery is kept near full charge, approximately 12.8 volts. Ifthere are electrical loads during storage, then the negative battery cable should bedisconnected or an independent float charger used. Low power 2.0 amp chargers for storagecharge will keep a fully charged battery fully charged but cannot recharge if ODYSSEYbecomes discharged.

Racing Vehicles using total loss (no alternator) - standard automotive type chargers are notdesigned to return 105-108% of the energy removed. They normally boost charge to 80-95%and expect the alternator to complete the charge. Special chargers as listed onwww.odysseyfactory.com under “Approved Chargers” specifically designed for ODYSSEYare required for routine deep discharge applications. They provide the 105-108% rechargeand then switch to storage charge.

To fully charge a PC2150, 20 amps minimum constant voltage is required with chargervoltage within the range of 14.1 V to 14.7V. It is imperative not to exceed15.0V as this willcause the pressure valves to open and out-gas hydrogen, oxygen and water from inside thebattery. This will shorten the life of the battery and cause premature failure. Some portablechargers exceed 15.0V, especially two-wheel garage chargers, so charging voltages shouldbe verified by measuring the charging voltage during the time when the charging amperageis reducing from full output. The deep cycle charging voltage must be within 14.1V minimumto 14.7V maximum.

If a standard automotive charger is used to boost charge a discharged battery because of anaccessory left on, it is important to make sure the charging voltage does not exceed 15 voltsduring charge. A hand held voltmeter can be used to monitor this periodically. The followingchart provides recharge times under this type of boost charging to an 80-95% recharge andthen allows the vehicle charging system to complete the charge.

Voltmeter Reading State of Charge

12.84 Volts 100%

12.50 Volts 75%

12.18 Volts 50%

11.88 Volts 25%


WINTER STORAGE ODYSSEY does not lose its charged energy during cold storage temperatures, so there is noneed to trickle or float charge during winter months. To store off•season, measure the batteryvoltage to make sure it is fully charged, 12.84 volts or greater; recharge if necessary.Disconnect the negative battery cable to prevent any applied electrical load during storage.ODYSSEY cannot freeze down to -40°C or -40°F so it can be left in the vehicle. It can bestored for 2 years or more below 77°F.

A 12V, 3 amp trickle charger can also be left connected to the battery if it is kept in storagefor extended periods or if the battery is subject to parasitic loads during storage. Informationon two such chargers we recommend, including where to buy them, can be found on ourwebsite at www.odysseyfactory.com/odycharg_c.htm.

ODYSSEY Charge time for 100% discharged battery (11.5 volts)

Model 10-amp charger 20-amp charger

PC310 48 minutes 24 minutes

PC535 11/2 hours 45 minutes

PC545 2 hours 45 minutes

PC625 2 hours 1 hour

PC680 2 hours 1 hour

PC925 21/2 hours 11/4 hours

PC1200 4 hours 2 hours

PC1700 7 hours 31/2 hours




WARRANTY: LIMITED 2-YEAR AND 3-YEAR FULL REPLACEMENTEnerSys Energy Products Inc. (seller), warrants its ODYSSEY batteries to be free of defects in material and workmanship. This warranty iseffective for 2 years in powersports applications and 3 years in automotive/commercial/industrial applications from the date of purchasewith original receipt; 2 and 3 years respectively from manufacturer’s shipping date if no original receipt is available; or within 400 cycles to80% depth of discharge, whichever occurs first. Within the warranty period, the battery will be replaced free of charge if adjustment isnecessary due to defect in material or workmanship (not merely discharged). Simply return the battery to any authorized ODYSSEY dealerwith the original receipt for a replacement. This warranty may vary from country to country; contact your appropriate sales region forconfirmation.

GENERAL PROVISIONSA. Seller has no obligation under the limited warranty set forth above in the event the battery is damaged or destroyed as a result of:

Willful abuse or neglect or if the top decorative cover has been removed.Natural forces such as wind, lightning, hail; damage due to fire, collision, explosion, vandalism, theft, penetration or opening of thebattery case in any manner.Overcharging, undercharging, charging or installing in reverse polarity, improper maintenance, allowing the battery to be deeplydischarged via a parasitic load or mishandling of the battery such as but not limited to using the terminals for lifting or carrying thebattery.Failure to properly install the battery or lack of metal jacket for high temperature or vibration applications.Normal deterioration in the electrical qualities or the acceleration of such deterioration due to conditions that accelerate suchdeterioration.If the battery is used for any application that requires higher cranking power or a greater reserve rating than the battery is designed todeliver or the battery capacity is less than the battery capacity specified by the vehicle manufacturer or the battery is otherwise used inapplications for which it was not designed.

B. To obtain warranty service:1. Return battery to any authorized ODYSSEY wholesaler or dealer.2. If the battery is determined to be defective for material or workmanship under terms of the warranty, it will be replaced.

THIS LIMITED WARRANTY IS IN LIEU OF, AND SELLER DISCLAIMS AND EXCLUDES, ALL OTHER WARRANTIES, STATUTORY, EXPRESS ORIMPLIED, INCLUDING, WITHOUT LIMITATION, ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE THATWOULD OTHERWISE BE IN EFFECT FOR LONGER THAN THE EFFECTIVE WARRANTY PERIOD. SELLER’S EXCLUSIVE LIABILITY FOR BREACHOF WARRANTY SHALL BE TO REPLACE THE BATTERY WITHIN THE EFFECTIVE WARRANTY PERIOD. IN NO EVENT SHALL SELLER BELIABLE FOR ANY LOSS OR DAMAGES OF ANY OTHER KIND, WHETHER DIRECT, INCIDENTAL, CONSEQUENTIAL, EXEMPLARY, SPECIAL OROTHERWISE NOR SHALL SELLER BE LIABLE FOR ANY REMOVAL OR INSTALLATION EXPENSE, OR THE LOSS OF TIME OR PROFITS.

Some countries and/or states do not allow limitations on how long an implied warranty lasts or the exclusion or the limitation of incidental orconsequential damages, so the above limitations may not apply to you. This warranty gives you specific legal rights which may vary fromcountry to country and/or state to state.

W e b s i t e : w w w . o d y s s e y f a c t o r y . c o m

For your convenience, this space is provided forattaching your original receipt.

EnerSys Energy Products Inc. 617 North Ridgeview Drive,Warrensburg, MO 64093-9301, USA Tel: +1-660-429-2165Fax: +1-660-429-1758

EnerSysP.O. Box 14145 Reading, PA 19612-4145, USA Tel: +1-610-208-1991

+1-800-538-3627Fax: +1-610-372-8613

Regional SalesEnerSys LimitedRake Lane,Clifton Junction,Manchester M27 8LR UKEmail: [email protected]: +44 (0)161 727 3951Fax: +44 (0)161 727 3949

EnerSys Australia Pty Ltd12 Jellico Drive,Scoresby, Melbourne,Victoria, Australia 3179Tel: + 61 (0)39 763 7083Fax: + 61 (0)39 763 9751Toll-free: 1-800-550-153

Always properly recycle your lead acidbattery by returning to an authorizedrecycling center or automotive dealer.

NEVER PLACE USED BATTERIES INYOUR REGULAR TRASH!

Keep your receipt. Receipt is required for longest Warranty Protection.

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© 2005 EnerSys. All rights reserved. Printed in USATrademarks are the property of EnerSys and its affiliates unless otherwise noted.

1

Owners ManualÖhlins shock absorber basic information

Including:

Safety

Tuning thesuspension

Design

Function

Settings

Setting yourvehicle

Inspection andmaintenance

2

Safety signalsImportant information concerning safety isdistinguished in this manual by thefollowing notations:

The Safety alert symbol means:Caution! Your safety is involved.

WARNING!Failure to follow warning instructionscould result in severe or fatal injuryto anyone working with, inspecting orusing the suspension, or to bystanders.

CAUTION!Caution indicates that special pre-cautions must be taken to avoid dam-age to the suspension.

NOTE!This indicates information that is ofimportance with regard to procedures.

IntroductionAll of Öhlins advanced suspension products areadepted to the brand and model. This means thatlength, travel springaction and damping character-istics, are tested individually just for the vehicle thatyou have decided to fit with Öhlins suspension.

Before installationÖhlins Racing AB can not be held responsible forany damage whatsoever to suspension or vehicle,or injury to persons, if the instructions for fittingand maintenance are not followed exactly.

Similarly, the warranty will become null and voidif the instructions are not adhered to.

© Öhlins Racing AB.All rights reserved.

Any reprinting or unauthorized usewithout the written permission ofÖhlins Racing AB is prohibited.

Printed in Sweden.

WARNING!1. Installing a suspension, that is notapproved by the vehicle manufacturer, mayaffect the stability of your vehicle. ÖhlinsRacing AB cannot be held responsible forany personal injury or damage whatsoeverthat may occur after fitting the suspension.Contact an Öhlins dealer or other qualifiedperson for advice.

2. Please study and make certain that youfully understand all the mounting instructionsand the owners manuals before handling thissuspension kit. If you have any questionsregarding proper installation procedures,contact an Öhlins dealer or other qualifiedperson.

3. The vehicle service manual must be referredto when installing the Öhlins suspension.

NOTEÖhlins products are subject to continual improve-ment and development. Consequently, althoughthese instructions include the most up-to-dateinformation available at the time of printing, theremay be minor differences between your suspen-sion and this manual. Please consult your Öhlinsdealer if you have any questions with regard tothe contents of the manual.

ContentsSafety ............................................................. 2Tuning the suspension .................................... 3Design ............................................................ 3Function ......................................................... 4Settings .......................................................... 4Setting your vehicle ........................................ 6Inspection and maintenance .......................... 7

3

Dividingpiston

Fluid

Gas

Mainpiston

Fluid

Fluid

4. External gasreservoir piggyback

Fluid

Mainpiston

Fluid

Dividingpiston

Dividingpiston

Gas

Fluid

Mainpiston

FluidGas

Tuning the suspensionRoad holding qualitiesAll vehicles are designed with a suspensiongeometry that includes wheel movemnets andangles. The changing of components can affectthis and it is therefore essential that both the rearand the front ends match each other. Changingto Öhlins suspension gives optimum performanceonly when both the front and the rear suspen-sion interact properly.

Everything must harmonizeIncorrect spring action can affect the road holdingabilities in a negative way. This in turn can give atendency for oversteering or understeering, whichcould seriously affect the road holding charac-teristics of the vehicle. It´s important that thesprings are checked for correct lenght andstiffness when Öhlins shock absorbers aremounted.

DesignMost of Öhlins suspensions are of the De Carbontype.

The fluid is put under gas pressure and the gasand the fluid are kept apart by a separating pis-ton. The gas and the separating piston are oftenfitted in separate fluid reservoir, connected byhose or fixed direct on top of the shock absorber(piggyback), there are also cases where every-thing is fitted inside the main shock absorber (in-ternal gas reservoir), some shock absorbers havea large diameter internal fluid reservoir and a baseplate, with damping qualities. There is even asmall number of emulsion shock absorbers thatdo not have a separating piston.

Pressurization of the fluid is made with nitrogen.The pressurization prevents cavitation of the fluidand the shock absorbing action is therefore moreeven. The external fluid chambers also contribute

to better cooling of the fluid, giving longer servicelife for both the fluid and components.Öhlins shock absorbers have integratedtemperature compensation. As the temperatureincreases and the fluid flows more easily the flowis controlled accordingly. The shock absorbingeffect is therefore independent of the temperature.

Öhlins shock absorbers provide the possibilityfor adjustment, making them adaptable to mostvehicles, drivers and ranges of use. All of theshock absorbers, equipped with springs, haveadjustable preloading of the spring action; eithermechanically or hydraulically. The more advancedmodels permit individual adjustment ofcompression damping and rebound damping,and also certain adjustment of the length of theshock absorber. The most advancedmodels canbe equipped with high- and low speed compres-sion damping.

Design principles

1. Emulsionshock absorber

2. Internaldividing piston

3. External gas reservoirhose connected

1. Emulsionshock absorber

2. Internal gas reservoir3. External reservoir

with hose connection4. External piggyback

reservoir5. Internal gas reservoir

with base plate

Dividingpiston

Gas

Fluid

Base plate

5. Internal gas reservoirwith base plate

Mainpiston

4

FunctionThe function, in principle, is that fluid is forcedthrough needle valves at a low rate of flow (Fig.1)and through a number of apertures in the pistonat a high rate of flow (Fig.2). The flow throughthese apertures is regulated by shims (thin steelwashers) that at high pressure are deflected toopen for the fluid. On some models the needlevalves can be set individually.

By altering the size of the shims-stack (ie,number, thickness, diameter) (Fig. 3) the charac-teristics of the damping action can be varied (thisshall only be done by Öhlins authorized serviceworkshops).

Compression dampingWhen movement of the vehicle causes compres-sion in the shock absorber, the fluid flows throughthe needle valve (combined compression andreturn valve) in the piston rod. If velocity of thepiston is high, ie, in the case of rapid compres-sion, this will not be sufficient and consequently

the shims underneath the piston will open to allowa greater rate of flow. The fluid that is displacedby the volume of the piston rod is forced into theexternal fluid chamber via a separate compres-sion valve. Even this valve is fitted with shims thatopen at high piston velocity. The separating pis-ton is displaced, thus increasing the gas pressure.

Rebound dampingWhen the spring presses the shock absorber outagain, the fluid flows back through the needlevalve in the piston rod. The fluid flowing into thechamber is forced by the pressure of the gas backinto the shock absorber via a separate nonreturnvalve (illustration). If velocity of the piston is high,the shims on top of the piston will also open toallow the fluid to flow though.

SettingsBasic settingsAlways ensure that the basic setting made bythe Öhlins dealer is correct. It is adapted to thespecific make and model the shock absorber (s)is/are designed for.

Setting the spring preloadPreload on the spring/springs is very important,because it affects the height of the vehicle andthe wheel angles. Consequently, road holdingcharacteristics can be changed, even negatively.

Adjusters are mechanical or hydraulical. Me-chanical adjustment is made with the rings onthe shock absorber (Fig.4). Hold the upper ringand adjust the lower one to the desired position,then lock with the upper ring.

Hydraulic preload adjuster is turned in desireddirection (Fig.5)

Stop washer

Shims stack

Piston

Fig 2. Flow regulatedby shims

Piston with aperture Fig 3. Shim stack

Rebound flowCompression flowReboundshims stack

Compressionshims stack

Fig 1. Flow throughneedle valve

5

NOTE!On shock absorbers that have mechanical typeadjustment the position of the adjusting/preloadrings can be adjusted.

Setting the dampingThe adjusting possibilities of Öhlins shockabsorbers facilitate fine setting. You can optimizeadjustments to suit your own vehicles weight andequipment, your individual way of driving and thecondition of the road. To be able to improve theroad holding qualities it is of the utmost impor-tance that you fully understand the functioningof the shock absorbers. Then you can learn bytrial and error how they affect the vehicle.

NOTE!Ensure that the springs are properly preloadedbefore attempting to make any adjustments. Asimple rule is that increased preload of the springshould be followed by an increase of rebounddamping by two steps.

Depending on the model there are adjustmentsfor rebound damping and compression damp-ing. Damping is set with the knobs , they havea normal right-hand thread. By turning clock-wise they increase the damping action and an-ticlockwise they reduce it. The knobs have defi-nite positions with a noticeable “click”, so it iseasy to count to the right setting.

Rebound damping action affects the char-acteristics of the vehicle most. The setting knobis at the bottom on the piston rod (Fig.6). It canbe adjusted in about 40 steps. The compres-sion damping knob is on the top of the cylinder(Fig.7). This can be adjusted in about 25 steps.

NOTE!When making new adjustments it is easiest togo back to zero, and then count forward to thenew setting. The adjusting knobs should not beturned in too hard. Avoid tools when attempt-ing to adjust the shock absorber. The adjust-ment should be made when the shock absorberis cold.

Setting the shock absorber lengthSensitivity of the steering can be adjusted byaltering the length of the shock absorber, with-out affecting other characteristics. The length isadjusted using two nuts down and the treadedclevis at the end of the piston rod (Fig. 1). Theshock absorber can be adjusted up to 12 mm.The length may never be altered more than towhere the groove that is cut in the thread be-comes just visible.

Adjusting the shock absorber lengthEach complete turn of the shock absorber givesone millimetre. The length may never be alteredmore than to where the groove that is cut in thethread becomes just visible under the lower nut ofthe level brachet. Make small steps and test run.

Hose connectedadjuster

7. Compressionadjustment

6. Reboundadjustment

C-spanner

4. Mechanicaladjustment

8. Adjustment of shockabsorbers lenght

Integratedadjuster

5.Hydraulicpreload adjuster

Groove

6

Setting your vehicleBy utilizing the adjustment possibilities you cantest by trial and error, and learn how they affectyour vehicle.

Always begin by test driving with all adjust-ments at their basic setting. Choose a short runof varying character, ie, long and sharp bends,hard and soft bumps. Keep to the same run andadjust only one setting at a time.

NOTE!Always begin with the basic settings recommendedby the Öhlin dealer. Always make notes, adjust insmall steps and make only one adjustment at a time.Adjustments should be made with two steps (clicks)at a time. Adjustments should not be more thanfour steps from the basic setting.

Start with the rebound dampingIf the vehicle feels unstable, loose and ratherbouncy then the rebound damping should be in-creased (Fig.9). Begin by turning the adjustingknob 4 steps (clicks) clockwise. Test run againand adjust two steps back if it felt too hard andbumpy.

If the vehicle is hard and bumpy, especially overa series of bumps, then the rebound dampingshould be reduced. Turn counterclockwise 4steps, test run and make any necessary correc-tion to 2 steps.

Compression dampingIf the vehicle feels soft, has low riding position anda tendency to bottom easily in long dips then thecompression damping should be increased(Fig.10). Screw clockwise 4 steps and test runagain. If this was too much then turn back twosteps (anticlockwise).

If the vehicle feels harsh and has hard resilience,eg, over changes in the road paving, then thecompression damping must be reduced. Screwanticlockwise 4 steps. Test run and make anynecessary correction to two steps.

When you have sufficient feel of the vehiclethen you can make further fine adjustments. It isfeeling and experience that counts.

NOTE!If no “click“ is felt, the shock absorber must beinspected by an authorized service workshop. Itcould be due to incorrect or lack of gas pressure.

When you feel that you have achieved animprovement, go back to where you started andcheck once more. Be observant of other relevantfactors such as tyres, temperature, etc. Test runto make sure whether further fine adjustmentshould be made.

-+

Addeddamping force

Reduceddamping force

-

+

-+

9. Rebound adjustment

+

-

10. Adjustment of compression damping

+

-

High speed

Low speed

7

Preventive maintenance and regular inspectionreduces the risk of functional disturbance. If thereis any need for additional service, please get intouch with an authorized Öhlins service work-shop. There they have the necessary tools andknow-how for whatever you need.

WARNING!Never alter the gas pressure. Special-purposecharging equipment and access to nitrogen isrequired. The gas pressure should normally neverbe altered.

NOTE!Make certain that your shock absorbers are al-ways filled with Öhlins High Performance ShockAbsorber Oil.

Remember!Regular maintenance and inspection contributeto the prevention of functional disturbances.Recommended service intervals:

Road: Every 20 000 – 30 000 km

Inspection and maintenanceKeep the shock absorbers clean and alwaysspray them with oil (QS 14, WR40 or CRC 5-56)after washing the vehicle.Inspection points:

1. Check ball joints for possible excessive play.

2. Check the piston shaft for leakage and damage.

3. Check the shock absorber body and forexternal damages.

4. Check the external reservoir for damages thatcan restrict the floating piston from moving freely.

5. Excessive wear of rubber components

6. Fastening to the vehicle

• Check the hose equipped models for leaks inhose and inlet plugs.

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Lift the bump rubber andclean the area below.

Inspection points:

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The ultimate suspension site.Find out everything about your suspension.

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Öhlins Racing AB, Box 722, S-194 27 Upplands Väsby, Sweden Phone +46 8 590 025 00, Fax +46 8 590 025 80

Your Öhlins dealer:

More infowww.ohlins.com

1

Owners ManualÖhlins shock absorber, Car Road & Track

Including:

Safety

Tuning thesuspension

Design

Function

Settings

Setting yourvehicle

Inspection andmaintenance

2

Safety signalsImportant information concerning safety isdistinguished in this manual by thefollowing notations:

The Safety alert symbol means:Caution! Your safety is involved.

WARNING!Failure to follow warning instructionscould result in severe or fatal injuryto anyone working with, inspecting orusing the suspension, or to bystanders.

CAUTION!Caution indicates that special pre-cautions must be taken to avoid dam-age to the suspension.

NOTE!This indicates information that is ofimportance with regard to procedures.

IntroductionAll of Öhlins advanced suspension products areadepted to the brand and model. This means thatlength, travel springaction and damping character-istics, are tested individually just for the vehicle thatyou have decided to fit with Öhlins suspension.

Before installationÖhlins Racing AB can not be held responsible forany damage whatsoever to suspension or vehicle,or injury to persons, if the instructions for fittingand maintenance are not followed exactly.

Similarly, the warranty will become null and voidif the instructions are not adhered to.

© Öhlins Racing AB.All rights reserved.

Any reprinting or unauthorized usewithout the written permission ofÖhlins Racing AB is prohibited.

WARNING!1. Installing a suspension, that is notapproved by the vehicle manufacturer, mayaffect the stability of your vehicle. ÖhlinsRacing AB cannot be held responsible forany personal injury or damage whatsoeverthat may occur after fitting the suspension.Contact an Öhlins dealer or other qualifiedperson for advice.

2. Please study and make certain that youfully understand all the mounting instructionsand the owners manuals before handling thissuspension kit. If you have any questionsregarding proper installation procedures,contact an Öhlins dealer or other qualifiedperson.

3. The vehicle service manual must be referredto when installing the Öhlins suspension.

NOTEÖhlins products are subject to continual improve-ment and development. Consequently, althoughthese instructions include the most up-to-dateinformation available at the time of printing, theremay be minor differences between your suspen-sion and this manual. Please consult your Öhlinsdealer if you have any questions regarding thecontents of the manual.

ContentsSafety ............................................................. 2Tuning the suspension .................................... 3Design ............................................................ 3Function ......................................................... 4Settings .......................................................... 4Setting your vehicle ........................................ 6Inspection and maintenance .......................... 7

3

Dividingpiston

Fluid

Gas

Mainpiston

Fluid

3. External gas reservoirpiggyback

Fluid

Mainpiston

Fluid

Dividingpiston

Dividingpiston

Gas

Fluid

Mainpiston

FluidGas

Design principles

1. Internal gasreservoir

2. External gas reservoirhose connected

Tuning the suspensionRoad holding qualitiesAll vehicles are designed with a suspension ge-ometry that includes wheel movements and an-gles. The changing of components can affect thisand it is therefore essential that both the rear andthe front ends match each other. Changing toÖhlins suspension gives optimum performanceonly when both the front and the rear suspen-sion interact properly.

Everything must harmonizeIncorrect spring action can affect the road holdingabilities in a negative way, can give a tendency foroversteering or understeering. It is important thatthe springs are checked for correct length andstiffness when Öhlins suspension is mounted.

DesignMost of Öhlins suspensions are of the De Car-bon type.

The fluid is put under gas pressure. The gasand the fluid are kept apart by a separating pis-ton. The separating piston is fitted inside the mainshock absorber (internal gas reservoir) (1) or in aseparate fluid reservoir, connected by hose (2) orfixed direct on top of the shock absorber (piggy-back) (3). A few shock absorbers have a largerdiameter separating piston combined with a baseplate (4) Pressurization of the fluid is made with nitro-gen. The pressurization prevents cavitation of thefluid and the shock absorbing action is thereforemore even. The external fluid chambers also con-tribute to better cooling of the fluid, giving longerservice life for both the fluid and the components.

Öhlins shock absorbers have integrated tempera-ture compensation. As the temperature increasesand the fluid flows more easily, the flow is con-trolled accordingly. The shock absorbing effectis therefore independent of the temperature.

Öhlins shock absorbers provide the possibilityfor adjustment, making them adaptable to mostvehicles, drivers and ranges of use. Some of theshock absorbers, equipped with springs, haveadjustable preloading of the spring action. Themore advanced models permit individual adjust-ment of compression damping and rebounddamping.

4. Internal gas reservoirwith base plate

Dividingpiston

Gas

Fluid

Base plate

4

FunctionThe function, in principle, is that fluid is forcedthrough a needle valve at a low rate of flow andthrough a number of apertures in the piston at ahigh rate of flow. The flow through these aper-tures is regulated by shims (thin steel washers)that at high pressure are deflected to open forthe fluid. On some models the needle valves canbe set individually.

By altering the size of the shims-stack (ie,number, thickness, diameter) the characteristicsof the damping action can be varied (this shallonly be done by Öhlins authorized service work-shops).

CAUTION!Do not try to open the shock absorber yourself.The warranty will be null and void if the shockabsorber is not handled by an Öhlins authorizedworkshop.

Compression dampingWhen movement of the vehicle causes compres-sion in the shock absorber, the fluid flows throughthe needle valve (combined compression andreturn valve) in the piston rod. If velocity of thepiston is high, ie, in the case of rapid compres-sion, this will not be sufficient and consequentlythe shims underneath the piston will open to al-low a greater rate of flow. The fluid that is dis-placed by the volume of the piston rod is forcedinto the internal or external fluid reservoir. Theseparating piston is displaced, thus increasingthe gas pressure. In a damper equipped with anexternal reservoir the fluid flows via a separatecompression valve. Even this valve is fitted withshims that open at high piston velocity. Shockabsorbers equipped with a base plate have asimilar flow.

Rebound dampingWhen the spring presses the shock absorber outagain, the fluid flows back through the needlevalve in the piston rod. The fluid flowing into thechamber is forced by the pressure of the gas backinto the shock absorber via a separate non re-turn valve. If velocity of the piston is high, theshims on top of the piston will also open to allowthe fluid to flow though.

2. Piston with apertures1. Flow throughneedle valve

3. Shims stack

Stop washer

Shims stack

Piston

Compression flow Rebound flow

4. Flow through piston

5

Mounted downwards

C-spanner

5. Mechanical adjustment 7. Individual compression adjuster

SettingsBasic settingsAlways ensure that the basic setting made byÖhlins is correct. It is adapted to the specific makeand model (in its original state).

Setting the spring preload, measuring(adjustable models only):Preload on the spring/springs is very important,because it affects the height of the vehicle andthe wheel angles. Consequently, road holdingcharacteristics can be changed, even negatively.

Setting the spring preload, adjusting(adjustable models only):Adjust the preload with the rings on the shockabsorber, hold the upper ring and adjust the lowerone to the desired position. Then lock with theupper ring.

Setting the dampingThe adjusting possibilities of Öhlins shock ab-sorbers facilitate fine setting. You can optimizeadjustments to suit your own vehicles weight andequipment, your individual way of driving and thecondition of the road. To be able to improve theroad holding qualities it is of the utmost impor-tance that you fully understand the functioningof the shock absorbers. Then you can learn bytrial and error how they affect the vehicle.

Depending on the model there are adjustmentsfor damping forces; rebound damping and com-pression damping. Damping is set with a knobwith a normal right-hand thread (Fig 6). By turn-ing clockwise they increase the damping actionand counter clockwise they reduce it. The knobhas definite positions with a noticeable “click”,so it is easy to count to the right setting. On somemodels compression and rebound damping areset individually (Fig 7).

NOTE!When making new adjustments it is easiest to goback to zero, and then count forward to the newsetting. The adjusting knob should not bescrewed in too hard. Never use tools when at-tempting to adjust the shock absorber. The ad-justment should be made when the shock ab-sorber is cold.

CAUTION!If no “click” is felt, the shock absorber must beinspected by an authorized service workshop. Itcould be due to incorrect or lack of gas pressure.

6. Damping force adjusters:When adjusting, simply useyour fingers, avoid tools.

Mounted upwards

9. Damping force

Setting your vehicleBy utilizing the adjustment possibilities you cantest by trial and error, and learn how they affectyour vehicle.

Always begin by test driving with all adjust-ments at their basic setting. Choose a short runof varying character, ie, long and sharp bends,hard and soft bumps. Keep to the same run andadjust only one setting at a time.

Setting the dampingIf the vehicle feels unstable, loose and ratherbouncy then the damping should be increased.If the vehicle is hard and bumpy, especially overa series of bumps, then the damping should bereduced.

If the vehicle feels soft, has low riding positionand a tendency to bottom easily in long dips thenthe damping should be increased. If the vehiclefeels harsh and has hard resilience, eg, overchanges in the road paving, then the dampingmust be reduced.

Begin by turning the adjusting knob two (2) steps(clicks). Test run again and adjust one (1) stepback if it affects the vehicle too much.

When you have sufficient feel of the vehiclethen you can make further fine adjustments. It isfeeling and experience that counts.

NOTE!Ensure that the springs are in good conditionsand properly preloaded before attempting tomake any adjustments.

NOTE!Always begin with the basic settings recom-mended by Öhlins. Always make notes, adjust insmall steps and make only one adjustment at atime. Adjustments should be made with max. twosteps (clicks) at a time. Do not shut adjuster morethan one click from fully closed.

When you feel that you have achieved an im-provement, go back to where you started andcheck once more. Be observant of other relevantfactors such as tyres, temperature, etc. Test runto make sure whether further fine adjustmentshould be made.

CAUTION!When suspension components are exchanged itis of greatest importance that the wheelalignments are checked.

Addeddamping force

Reduceddamping force

-

+

-+

is any need for additional service, please get intouch with an authorised Öhlins service work-shop. There they have the necessary tools andknow-how for whatever you need.

Recommended inspectionand maintenance intervals:For normal use, clean and inspect the shockabsorbers once a year.

Never use detergents that can damage the sur-faces of the shock absorber. E.g. thinner andbrake cleaner will dry the surfaces too much.

Inspection points:1 Check brackets or bushings for

possible excessive play.

2 Check the piston shaft for leakageand damage.

3 Check the shock absorber bodyfor external damages.

4 Check the dust cover for damagees.

5 Spring condition

6 Excessive wear of rubber componentsand dust covers

7 Fastening to the vehicle

Preventive maintenance and regular inspectionreduces the risk of functional disturbance. If there

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Inspection points:

Inspection and maintenanceClean the shock absorbers externally with a softdetergent. Lift the dust cover and use com-pressed air. Be c`‰eful that all dirt and debris isremoved. Lift the bump rubber and clean the areabelow.

Keep the shock absorbers clean and alwaysspray them with oil (QS 14, WD40 or CRC 5-56or similar)

CAUTION!

Once a year, general:Change shock absorber oil. Use Öhlins shockabsorber oil only.

WARNING!

Never alter the gas pressure. Special-purposecharging equipment and access to nitrogen isrequired. The gas pressure should normally neverbe altered.

NOTE!

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The ultimate suspension site.Find out everything about your suspension.

Download mounting instructions, manuals and brochures.And a lot more.

Öhlins Racing AB, Box 722, S-194 27 Upplands Väsby, Sweden Phone +46 8 590 025 00, Fax +46 8 590 025 80

Your Öhlins dealer:

More infowww.ohlins.com

Dis-Assembly Instructions1. Hold the Air Jack in a vice using the pair of threaded Body Clamps (Tool 1). Do not over tighten. (See Fig 1.)

2. Using 2 standard ‘C’ spanners (Not supplied), lock together a pair of the Air Jacks Mounting Rings supplied with theAirjack. (See Fig 1.)

3. Remove from the vice and fit the Cap Clamp (Tool 2) to the knurled Airjack Cap. Locate the Air Jack and Cap Clampvertically, clamping the Cap Clamp in the vice. (See Fig 2.)

4. Using a ‘C’ spanner, rotate the lower Mounting Ring anti-clockwise to unscrew the Body from the Cap. Note:- Approxi-mately every ½ turn of the Body, use Pin Tool (Tool 3), located in the Airjack Foot to rotate the Foot clockwise ½ turn. Thisis to prevent the internal Tension Spring being wound up and damaged.Continue for approximately 6 full turns until the Cap thread is fully out of the Body. The internal Tension Spring will keep the 2parts pulled together. (See Fig 2.)

Fig 1. Fig 2.

AP Racing, Wheler Road, Coventry, CV3 4LB, UKTel: +44 (0)24 7663 9595 Fax: +44 (0)24 7663 9559 E-Mail:[email protected] Web: www.apracing.com

Publication Ref: P14.083 - Issue 2

Continued Overleaf........

CP2985 Air JackServicing Instructions(Kit Part Number CP4985-10)

5. Remove unit from the vice, take off the Cap Tool and re-locate the unit horizontally in the vice again using the BodyClamps (Tool 1). (See Fig 3.)

6. Screw the ‘T’ Bar (Tool 4) onto the Air Jack Inlet Adaptor thread. Pull on the ‘T’ Bar to expose approximately 8 coils of theinternal Tension Spring and slide the Spring Trap Plate (Tool 5) over 1 spring coil and against the open end of the Body.(See Fig 3.)

7. Remove the ‘T’ Bar and unhook the Cap from the Tension Spring. Locate Spring Hook Tool (Tool 6) onto the Tension Springhook, pull gently to take the spring load and remove the Spring Trap Plate. Carefully release the load to allow the spring fullyback inside the Air Jack and remove the Hook Tool. (See Fig 4.)

8. Remove the unit from the vice and pull on the Foot to expose the Air Jack Ram. Fit the pair of Ram Clamps (Tool 7) to theRam and tighten securely in the vice but do not over tighten. Then clean the Ram first if it is dirty. Fit Pin Tool (Tool 3) ontothe Foot and unscrew the Foot anti-clockwise out of the Ram using either a Torque spanner and a 21mm Socket or using a15mm diameter Tommy Bar (Not supplied) through the hole in the Pin Tool. Pull the Foot and spring out of the Ram.(See Fig 5.)

9. Remove the Inlet Adaptor from the Cap and discard the copper washers.

10. The Bearing Housing is still located in the Body, but no tool is supplied, as it is not necessary to remove it. The smallBearing in the Bearing housing can be replaced in situ.

11. The Air Jack is now sufficiently dis-assembled to clean, lubricate and fit replacement parts.

Airjack Servicing Instructions and Re-Assembly

These notes assume that all metal components are in a re-usable condition. If any component is damaged beyond use, thenthe Air Jack should either be returned to AP Racing for full re-conditioning, including replacement of the damaged components,or additonal replacement parts will need to be ordered.

1. Remove all 3 O-rings from the Cap, the Piston and the Foot and both plastic Bearings and discard them. Thoroughlyclean all other metal components. Use an alcohol based cleaning fluid. i.e. Methylated Spirit or warm soapy water. DO NOTUSE ANY PETROLEUM BASED CLEANERS AS THESE WILL DAMAGE THE RUBBER SEALS.

2. Use the 3 O-rings, the 2 Bearings and the 2 Copper washers contained in Repair Kit CP2985-1RK to replace those partsdiscarded. In order to install both Bearings, they will need to be split as shown in the illustration included in the repair kit.

3. Apply Silicon Spray lubricant to the main Bore of the Body and pack the Main O-Ring groove of the Piston with SiliconGrease as shown in the illustration below. Take care not to allow lubricant onto any of the threads that are to be bonded withLoctite. (See fig 6.)

4. Re-Assembly is the exact reverse of the operationslisted above. Assembly Bullet (Tool 8) is to be engagedin the end of the Ram to aid its re-insertion through theBody and Bearing Housing assembly.

5. The Foot is to be bonded to the Ram and the Cap isto be bonded into the Body using Loctite 270. Ensurethreads are clean, apply Loctite Activator 7649 and then apply 1 complete circumferential ring of Loctite to the first turn onlyof the Male thread. Do not apply excess Loctite. With the Activator applied, the Loctite will set quickly, so follow the procedureabove, only just prior to threading any pair of parts together. Quickly screw parts together until fully seated, ensuring that anyO-rings are correctly positioned and are not cut. Using the same tools used for dis-assembly, tighten all parts securely. Usea compressed air supply of 5 Bar maximum to check for leaks.

(Fig 3.) (Fig 4.) (Fig 5.)

Position O-Ring in this groove, against the face shown.Pack the remainder of the seal groove with silicon grease.

(fig 6.)

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