brakes LOTUS ELISE 2005 Owners Manual

• Powerful anti-lock four wheel disc brakes.
• High geared responsive steering requiring only small steering
wheel movements to alter course
• Exceptional road holding with optimised handling character
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istics
You and your passenger cannot take full advantage of these
safety features unless you remain sitting in a proper position
and always wear your seat belt properly. In fact, some safety
features can contribute to injuries if they are not used properly. Drivers should be aware of their own limitations as well as
those of the car, and ensure that all road driving is conducted
well within both sets of capabilities, particularly on wet roads, or under adverse weather conditions.
Remember:
Driving a car requires:
• Care;
• Attention; and
• Sensible judgement.
Be aware that any motor car has the potential to cause death
or injury both to its occupants and/or other persons, and must
be used only in a responsible and cautious manner. This entire
handbook is filled with important safety information.
Please
read it carefully.
Remember:
• ALWAYS WEAR YOUR SEAT BELT.
• Never drive while under the influence of alcohol or drugs.
• Never drive when excessively tired.
• Never use mobile phones, map read or attempt other distract
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ing activities whilst driving.
• Always obey all speed and traffic laws and regulations and never drive faster than the posted speed limit or than condi
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tions allow.
• Be particularly careful driving on slippery or wet surfaces.
• Familiarise yourself with the car and always drive prudently, being aware of your own limitations and the limitations of the
car. Failure to operate the car properly can result in an ac
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cident and serious injury.
Safety Information
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Seat Belt Tell Tale
The red seat belt tell tale is provided as a reminder that both
driver and passenger should always wear the seat belts, no
matter how short the journey. The lamp will flash until the driv
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er’s seat belt is fastened, accompanied for the first 8 seconds by a buzzer.
Brake Tell Tale
This tell tale will glow red with the ignition switched on
whenever the parking brake is applied. Driving the car with the brake not fully released will cause overheat damage to the rear
brakes. Each time the parking brake is released, check that the
tell tale is extinguished. With the parking brake released, if the tell tale should light
at any time after the six second check period, stop the car im
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mediately, as the circuit has detected a dangerously low level of brake fluid in the master cylinder reservoir, possibly caused
by a hydraulic leak in one of the separate front or rear brake
circuits. In the event of a leak there is a danger that air may enter the hydraulic system and cause spongy operation and
extended pedal travel. The divided brake circuit should ensure
that emergency braking remains, but the car should not be driven until the fault has been identified and rectified.
WARNING: If the tell tale remains lit when the parking brake has been
released, the footbrake may not be working properly. Stop
the car immediately it is safe to do so, and do not continue until the fault has been rectified. Continuing to drive could cause a crash and result in death or serious injury.
Oil Pressure Tell Tale
This red tell tale warns of low engine oil pressure. The lamp
will be lit whenever the ignition is on and the engine is stopped, but should go out as soon as the engine is started. If the lamp
fails to go out after engine start up, or comes on when the engine is running, stop the engine immediately and do not restart until
the cause has been investigated and rectified.
Instruments & Switches
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FootbrakeVentilated disc brakes are fitted to all four wheels of the
Elise. These are operated by separate front and rear hydraulic
circuits, supplied from a tandem master cylinder with vacuum
servo. Anti-lock control is provided by a microprocessor based

electro-hydraulic unit, integrated into the base braking system. The braking system is designed to provide good pedal feed
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back, with efficient disc cooling to inhibit brake fade. With a
new car, or new brake system components, maximum braking
efficiency will be achieved if, for the first few hundred miles, needless heavy braking is avoided. Allow the brake pads and discs to ‘bed in’ fully before using the brakes to their full potential.
Pedal effort will reduce as the brakes are bedded in, and as they
are warmed from cold to normal working temperature. Note that
the hard grade pad material may give rise to a certain amount of brake noise under some conditions; such noise is not harmful
and does not affect the life or efficiency of the brakes.
WARNING:
• After driving through a ford, or a flooded road, some loss of braking response may be experienced until the brakes
have dried out. As soon as it is safe to do so after such an encounter, apply the brakes until normal operation
is restored. Failure to do so may result in an accident in
which you or others may be killed or seriously injured.
• The brake assistance servo uses vacuum supplied from the engine intake plenum, such that assistance is avail
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able only when the engine is running. Never coast down
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hill with the engine stopped. If this situation accidently arises, avoid repeated application of the brakes, or the
stored vacuum supply will be rapidly used up. Greater
pedal pressures will be required. This may adversely affect performance of the brakes which may result in an
accident in which you or others may be killed or seriously
injured.
Anti-lock Brake System The Anti-lock Brake System (ABS) is used to optimise brake
performance in extreme conditions and reduce the potential
for any wheel to lock up. Under most conditions, the maximum braking force is provided by a wheel which is rotating at about
90% of road speed. Apart from the likelihood of increasing the
Driving Controls
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stopping distance, a locked wheel provides little or no steering
force, such that with both front wheels locked, movement of the steering wheel has no effect on car direction. With the anti-lock
system, even panic braking results in controlled deceleration and the retention of steering response. ABS is especially ad
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vantageous when braking on slippery road surfaces and in bad driving conditions, but it is important to realise that the ABS
cannot increase the friction level at the road surface, but can only make optimum use of the grip available.
WARNING: When driving in adverse weather, or on poor road sur
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faces, always be alert to the possibility of slippery condi
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tions and make the necessary allowance for increased stop
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ping distances. Failure to do so may result in an accident in which you or others may be killed or seriously injured.
Normal braking, controlled by the pressure applied to the
brake pedal, occurs when the road conditions allow for decel
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eration to be achieved without danger of wheel lock. The relative
speeds of the four wheels are continuously monitored by the
ABS when the brakes are applied, and if one or more wheels begin to lock, the brake pressure to that wheel(s) is modulated
by the ABS to help keep the wheel rotating and provide the
maximum controlled braking force. The wheels may appear
to lock momentarily as the wheel speed rapidly changes, and some tire noise (intermittent screeching) may be heard which is normal and will vary with road and tire conditions. Note that the
ABS does not function at speeds below 5 mph (7 km/h). When the ABS is activated, the driver is will feel a ‘pulsing’
sensation at the brake pedal as the fluid pressure is modulated, and also by audible clicking sounds. These signals indicate to
the driver that maximum braking is occuring, and that driving style should be modified to suit the conditions.
The minimum stopping distance is achieved by applying the
brakes firmly and steadily, and allowing the ABS to modulate
hydraulic pressure. The driver should not attempt to emulate
this process by ‘pumping’ the brake pedal, as modulation at the pedal will treat all four wheels similarly, rather than the individual
wheel control allowed by the electronics. An ABS tell tale lamp in the instrument panel is provided
to warn of any problems in the system and to indicate that the
Driving Controls
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Parking BrakeThe parking brake, which operates on only the rear wheels
is applied by a hand lever mounted between the seats. A red
tell tale icon in the instrument cluster warns of parking brake application (see ‘Tell Tale Lamps’). The brake should be applied by pulling up the lever with high
effort, and engaging the highest ratchet setting attainable. When
parking the car on a slope take the additional precaution of leav
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ing the transmission in first (facing downhill) or reverse (facing uphill) gear and steering the wheels towards the kerb.
WARNING: If the parking brake is applied when the brakes are hot
(e.g. after prolonged or frequent hard use), special care
should be taken to ensure that the parking brake is securely engaged in order to allow for any potential brake force
reduction as the discs cool. Failure to do so may result in
the car rolling away and causing an accident in which you
or others may be killed or seriously injured.
To release the brake, pull up the lever, press and hold the
release button in the end of the handgrip, and lower the lever fully.
Before driving off, always check that the parking brake has been
fully released, as confirmed by the tell tale icon being turned off,
or damage to the brake system may be caused. Note that the parking brake uses a cable mechanism to
apply the rear brake calipers, and is totally independent of the
footbrake hydraulic circuit.
Driving Controls
70
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PARKING BRAKE LEVER

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NOTICE: The use of wide throttle openings and/or high rpm before the engine has reached normal running temperature will
result in premature wear, and should be avoided.
Idle Speed Engine idle speed is controlled electronically by the engine
management computer, and is normally about 850 rpm. A
raised idle speed is required under certain operating conditions
including the engine warm up phase, when the increased speed helps the catalytic converter to reach operating temperature, as
well as inhibiting engine stall. Idle speed will return to normal automatically when the engine has warmed sufficiently.
Engine Break-In Although the Elise powertrain is built to close tolerances
using modern technology, the progressive and sympathetic
breaking-in (or bedding-in) of a new engine and transmission
remains a major factor in attaining ef ficient operation with
smooth, durable and economic performance to last throughout
the life of the car.
NOTICE: Failure to comply with the following break-in provi
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sions could invalidate the terms of the car warranty:
It is important during the car’s early life to limit the workload on
the engine and thus control the heat generated within it, which is primarily a function of throttle opening and rpm. However, being
too sympathetic on the car will not allow the piston rings to bed in
satisfactorily, so a balance of spirited and gentle use is required.
For the first 600 miles (1,000 km), use no more than moderate
throttle openings (about half of the available accelerator pedal
travel) and do not run the engine continuously at engine speeds over 4,500 rpm. Occasional short bursts at wider throttle and
higher rpm will be beneficial, as will a constantly changing cruis
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ing speed and making full use of the gearbox. Do not allow the
engine to labour in too high a gear ratio, but change down and
let the engine operate in its natural power band. When changing gear, use only a light touch on the gear lever.
Forcing the change will cause unnecessary wear on the system components and result in higher shift efforts being required. Al
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low the brakes to bed-in by avoiding needless heavy braking for
the first 100 miles (160 km). Both gearchange and brake pedal
Starting & Engine Break-In
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Brake Fluid ReservoirUnder normal circumstances, there is no requirement for
routine 'topping up' of the brake master cylinder reservoir. A
visual safety check is all that is required. Every week, check the level of fluid in the brake fluid reservoir
located in the driver’s side of the front services compartment, beneath the access panel: Without disturbing the filler cap,
check that the level lies between the 'MA X' and 'MIN' marks moulded on the translucent reservoir body. As the brake pads
wear, the level will drop gradually from the 'MA X' mark towards the 'MIN', but if the level drops rapidly over a short period, have
your Lotus dealer investigate without delay. If the level is found
to be below the 'MIN’ mark, it is likely there has been some fluid loss, and that air will have entered the hydraulic system. The car
should not be driven until the fault has been investigated and rectified. Note that a single reservoir is used to supply both of
the independent hydraulic circuits for the front and rear brakes, and also serves the hydraulic clutch release circuit. If any fluid is to be added, first clean the surrounding area
to guard against dirt ingress before unscrewing the reservoir cap.
NOTICE: Spilled brake fluid can seriously damage the car’s paintwork and some plastic compoments, for example, the side
marker lamps. Take suitable precautions to protect the paintwork
from contamination, and in case of spillage, rinse the affected area with water immediately: DO NOT WIPE.
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BRAKE FLUID RESERVOIR CAP
Servicing & Maintenance
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Use only a non-mineral type DOT 4 brake fluid from a sealed
container marked with a yellow and black (non-mineral) symbol.
Do not use DOT 5 silicone fluid, or any fluid which has been
exposed to the atmosphere for more than a brief period, or
any fluid suspected of being wet, dirty or contaminated. Do not over fill, and replace the cap securely. Brake fluid, being hygroscopic, absorbs water from the atmos
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phere over a period of time, resulting in a lowering of the boiling
point of the fluid, and corrosion of the hydraulic system. For
optimum safety and brake performance, the brake fluid should be renewed every twelve months by your Lotus Dealer.
WARNING:
• Brake fluid is hazardous to health and may be fatal if swallowed. Keep out of children’s reach.
• Using the wrong type of brake fluid can damage brake system components and result in brake failure causing a
crash in which you and others could be killed or seriously
injured. See ‘Recommended Lubricants’.
Brake Pads The thickness of the brake pad lining material should be
checked at every service, and under no circumstances be al
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lowed to fall below 0.1 inch (2.5 mm). If the brakes are in very frequent or arduous use, as when driving in mountainous terrain,
or on race circuits, it is recommended that they be examined
more frequently. The pads should be renewed if of insufficient
thickness to ensure safe braking until the next scheduled service.
Note that in order to ensure that brake pads with the correct
material specification are used, only genuine Lotus replacement parts should be fitted, and in the interests of safety, pad renewal
should be entrusted to your Lotus dealer.
WARNING: Using incorrect brake pads, or pads below 0.1 inch
(2.5mm) thickness, may cause a crash in which you or
others could be killed or seriously injured. With a new car, or new brake system components, maxi
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mum braking efficiency will be achieved if, for the first few
hundred miles, needless heavy braking is avoided, and the
brake pads and discs are allowed to ‘bed in’ fully before
being used to their full potential (see also ‘Footbrake’).
Servicing & Maintenance
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Important Safety Information About ModificationsDo not remove any original equipment or modify your car
in any way that would alter its design or operation. This could
make your car unsafe or illegal to drive. For example, do not install wheels and tires with a differ
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ent overall diameter. Such modifications can adversely affect handling, and interfere with the operation of the car’s anti-lock
brakes and other systems. In addition, any modifications that decrease ground clearance
beyond Lotus approval, increase the chance of undercarriage
parts striking a kerb, speed bump, or other raised object, which
could cause your airbags to deploy as well as damaging the
chassis and body underside. Do not modify your steering wheel or any other part of your air
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bag system. Modifications could make the system ineffective.
WARNING: Do not attach or place objects on the airbag covers.
Any object attached to or placed on the covers marked
‘AIRBAG’, in the centre of the steering wheel and on top of the dashboard, could interfere with the proper operation of the airbags. Or, if the airbags inflate, the objects could be propelled inside the car and hurt someone.
Accessories
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Spark plugs NGK IFR6A11
DensoSK20R11
Spark plug gap 1.1 mm
Max. continuous engine speed 8000 rpm (8500 transient)
Fuel requirement Unleaded
Minimum octane 91 (RON+MON)/2
Fuel system Multi-point fully sequential
fuel injection with Lotus T4
controller.
Peak power (SAE DIN 70020) 190 bhp (141.7 kW) @
7,800 rpm
Peak torque (SAE DIN 70020) 138 lbf.ft (187 Nm) @
6,800 rpm
Transmission
Type 6 speed manual transaxle.
Bevel gear differential.
Gear Ratio Final Drive mph/1000 rpm First 3.17:1 ) 5.1
Second 2.05:1 ) 7.7
Third 1.48:1 ) 4.53:1 10.7
Fourth 1.17:1 ) 13.6
Fifth 0.92:1 ) 17.3
Sixth 0.81:1 ) 19.4
Reverse 3.25:1 )
Brakes
Type Front and rear discs with
curved vane ventilation
and cross drilling.
AP Racing aluminium op
posed piston front calipers.
Single piston sliding rear
calipers.
Disc Size - front and rear 288mm
Operation Tandem master cylinder
with vacuum servo and
ABS
Parking Brake Cable operation of rear
calipers, self adjusting for
pad wear.
Technical Data
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