Westfield XTR2 Construction Manual
  1. Manuals
  2. Brands
  3. Westfield Manuals
  4. Automobile
  5. XTR2
  6. Construction manual

Westfield XTR2 Construction Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Westfield Sports Cars Limited, Unit One Gibbons Industrial Park, Dudley Road, Kingswinford, West Midlands,
DY6 8XF
+ 44 (0) 1384 400077

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the XTR2 and is the answer not in the manual?

Questions and answers

Related Manuals for Westfield XTR2

Summary of Contents for Westfield XTR2

  • Page 1 Westfield Sports Cars Limited, Unit One Gibbons Industrial Park, Dudley Road, Kingswinford, West Midlands, DY6 8XF + 44 (0) 1384 400077...
  • Page 2 Westfield Sports Cars Limited, Unit One Gibbons Industrial Park, Dudley Road, Kingswinford, West Midlands, DY6 8XF + 44 (0) 1384 400077 Published by WESTFIELD SPORTS CARS LTD. First Published 2002 Copyright © 2003 Westfield Sports Cars Ltd. All rights reserved. Apart from any fair dealing for the purposes of...
  • Page 3 Section 1...
  • Page 5 CONSTRUCTION MANUAL has been produced. The whole point of building a WESTFIELD is to realise a vehicle that will suit the purpose for which it is intended. With many thousands of satisfied owners, both here and abroad, we believe that at WESTFIELD we have accomplished that objective.

  • Page 6: Table Of Contents

    CONTENTS Page Section INTRODUCTION Contents Safety Getting Started Tools you will Need Suzuki MegaBusa Donor List Torque Chart Bolt Finder Chart Brake Pipes Clutch Line Chassis Wiring Loom Pedals & Brackets Steering Fuel Tank Gear Change Lever Bracket Hand Brake Lever & Cable Gear Lever &...

  • Page 7: Safety

    SAFETY You will Not need to use Welding or Grinding equipment in the Building of a WESTFIELD Sports Car, however, it is VERY IMPORTANT that you take ALL necessary SAFETY Precautions. ALWAYS WEAR: - Goggles or Protective Glasses when Drilling.

  • Page 8: Getting Started

    GETTING STARTED If you HAVE purchased the Optional WESTFIELD Chassis Support Stands then, with the help of an assistant, Lift and Position the Chassis onto these Supports. - If you HAVE NOT purchased these stands, then ensure that the chassis is positioned onto suitable supports, which allow the various parts to be fitted.

  • Page 9: Tools You Will Need

    12” Long Flat Blade File 29. Tape Measure 30. Metal Cutters IN ADDITION, for the WESTFIELD `SEi’ & XTR2 ONLY: 1. 41mm A/F METRIC Socket 2. Torque Wrench, ½” Square Drive with a Range of 250 lb ft. (If necessary, HIRE both the Socket and Torque Wrench when required)

  • Page 10: Suzuki Megabusa Donor List

    ‘RECALL COMPLETION’ LABEL attached under the pillion seat on the left hand side of The ‘U’ LOCK storage area. Example:- *Note* The Wiring Loom will require modification before installation. WESTFIELD SPORTS CARS can carry out this modification for a fee.

  • Page 11: Torque Chart

    TORQUE CHART Settings in Pounds Feet and Newton Metres: ft-lbs. Three Way Brake Pipe Unions Rear Brake Caliper Mounting Bolts (Steel) Steering Rack Mounting Bolts to Chassis Track Rod End Nuts to Steering Arm Wishbone Securing Bolts to Chassis Lower Ball Joint Securing Bolts to Wishbone Lower Ball Joint Nut to Upright Block Top Ball Joint Nut to Upright Block Steering Column Upper Mounting Bolts...
  • Page 12 It is IMPORTANT to REMEMBER that ALL suspension bolts and Nyloc Nuts will be Torque tightened during the Set-Up stage. WESTFIELD SPORTS CARS STRONGLY RECOMMEND that during the assembly of the suspension that ALL suspension bolts and Nyloc Nuts are `NIPPED’ ONLY and NOT Torque tightened.
  • Page 13 BOLT FINDER PAGE METRIC BOLT FINDER DIAMETER (Actual Length) (Actual Size) M5 (5mm Diameter) M6 (6mm Diameter) M8 (8mm Diameter) M10 (10mm Diameter) M12 (12mm Diameter) Plain Section Threaded (Shank) Section 60mm Measure length from below head as shown (Diameter) NOTES: The DIFFERENCE between a BOLT and a SETSCREW is: - A Bolt is only partially threaded and has a plain upper section whereas...
  • Page 14 1.12...
  • Page 15 Section 2...

  • Page 17: Brake Pipes

    - TAKE CARE when FORMING the brake pipes to make sure that you achieve a smooth uniform bend using a pipe bending tool if possible. - Westfield recommends that you PRACTICE bending on a scrap or spare brake pipe before attempting to bend any of the brake pipes supplied.
  • Page 18 Step 1: Cont’d, 3 x M8 Bolts x 25 Long (Plus 1x50 Long Bolt For Switch Mounting). Insert Bolts From Inside Pedal Box & Secure With Nyloc Nuts Front Brake Cylinder Rear Brake Cylinder 3 Way Brake Pipe Connector Drill Out Mounting Hole To Fit Onto M8 Bolt x 50 Long Prior To Installation Copper Washer...
  • Page 19 Step 2: Cont’d, Rear Brake Line View From Drivers Side (Mid Section Of Chassis) Of Fuel Catch Tank Tank Rear Brake Pipe Coupler Rear Brake Line View From Drivers Side (Engine Bay Area Of Chassis) Catch Tank Rear Brake Line 3 Way Brake Pipe Connector View From Rear Of Car (Rear Section Of Chassis)
  • Page 20 Step 3: Fit Front Brake Line 3 Way Connector 3 Way Brake Pipe Connector View From Front Step 4: Fit Front Drivers Side Brake Line Front Brake Line (Drivers Side) View From Front Step 5: Fit Front Passenger Side Brake Line Front Brake Line (Passenger Side) View From Front...
  • Page 21 Brake Pipe List:- Item Quantity Description Pipe Length Location On Car Supplied (Westfield Code) (Millimetres) Brake Pipe Front Brake Cylinder To Front T-Piece (2312041) Clutch Pipe 2250 From Clutch Cylinder To Rear Of Car (2312049) (See Section 3 Of This Manual)
  • Page 22 Section 3...

  • Page 24: Clutch Line

    - TAKE CARE when FORMING the clutch pipe to make sure that you achieve a smooth uniform bend using a pipe bending tool if possible. - Westfield recommends that you PRACTICE bending on a scrap or spare pipe before attempting to bend the clutch pipe supplied.
  • Page 25 Step 1: Cont’d, Do NOT Fit Clutch Push Rod At This Stage Lubricate Bush With Copper Slip BEFORE Installation M8 x 45mm Bolt and Nyloc Nut. DO NOT OVERTIGHTEN NUT Ensure Quadrant Moves Freely Do NOT Fit Pedal Push Rod At This Stage Quadrant Installation Clutch Cylinder Fit Spacers Either Side Of Cylinder...
  • Page 26 Step 1: Cont’d, Pedal Push Rod 5/16” Rod End M6 Bolt x 30 Long M6 Nyloc Nut Pedal Push Rod End Assembly Step 2: Fit Clutch Line Clutch Line Clutch Line View From Front Of Car Clutch Line Clutch Line Must Be Fitted To The Edge Of The Tube as Shown And Not Along The Top Face...
  • Page 27 Step 2: Cont’d, Clutch Line End Connector Clutch Line This Clutch Line MUST Run Along the Side Edge of the Chassis Rail (As Shown) & NOT Along the Top of the Chassis Rail. View From Passenger Side (Mid Section Of Chassis) Step 3: Fit Clutch Reservoir M6 Button Head Screw x 16 Long + Nyloc Nut...
  • Page 28 Section 4...

  • Page 30: Chassis Wiring Loom

    Parts Required:- - Westfield Chassis Loom / Loom Saddles / 4.1mm Dia x 10mm Long Closed Pop Rivets / Cable Ties / 4 x M5 x 25mm Button Head Screws / 4 x M5 Nyloc Nuts / 4 x M5 Plain Washers / 4 x Aluminum Spacers / 1”...
  • Page 31 Step 3: ECU Mounting Plate Loom Saddles (3 Places) (Rivet Through Saddles & Panel Into Chassis Rail) ECU Mounting Plate View From Passenger Side (Engine Bay Area Of Chassis) Step 4: Installation Of Main Chassis Loom Saddles Fit Loom Saddles In Approximate Positions Shown By Arrows 4 On Underside Of Top Rail 1 On Rear Main Earth Lead...
  • Page 32 Step 5: Main Loom Identifier & Installation Near Side Nose Loom Handbrake Warning Light Indicator Horn Clutch Switch Front Brake Light Switch Of Car Brake Level warning Light Fuse Box Main Loom Battery +ve supply (Connects To Master Switch) Fuel Tank Sender Dash Loom Connectors Auxiliary...
  • Page 33 Step 5: Cont’d, Main Battery Power Cables Fuse Box On Underside Of Brackets Place Loom Onto The Passenger Side Loom Mounting Panel. Arrange Loom So The Fuse Boxes Line Up With The Fuse Box Mounting Plate View From Front Of Car Under Scuttle Panel (Top Frame Section Of Chassis) Run The 2 Red Main...
  • Page 34 Step 5: Cont’d, Rear Of ECU Mounting Plate View From Rear Of Car (Rear Section Of Chassis) Rear Of ECU Mounting Plate View From Underside & Drivers Side Of Car (Rear Section Of Chassis) View From Rear Of Car (Rear Section Of Chassis)
  • Page 35 Step 6: Master Switch Installation & Connection Large Hole Already In Chassis Top Frame Drill 2 More Holes For Fixing Screws Fix Master Switch In As Shown Front Front Of Car Of Car Views From Front Of Car (Top Frame Section Of Chassis) To Resistor Brown Wire From Earth From Main Loom...
  • Page 36 Step 7: Battery Tray & Battery Installation Battery Strap M6 Stud welded on Chassis Battery –VE Cable Battery Battery Tray Fixing Details - Drill 4 Holes Through Battery Tray & Floor Panel - Run A Bead Of Silicone All Around The Bottom Of The Tray View From Drivers Side - Fix Tray To Floor Panel Using Rivets...
  • Page 37 Step 9; Main Power Cables In Engine Bay Starter Relay Reverse Solonoid Reverse Motor 4.10...
  • Page 38 MAIN WIRING LOOM DETAILS CONNECTION LOOM CONNECTOR TYPE LOOM WIRE COLOURS NOTES LOOM FRONT SECTION BRAKE LEVEL WARNING LIGHT 4 FEMALE SPADE CONNECTORS BLACK ; BLACK / WHITE 2 PAIRS TOTAL. 1 PAIR TO EACH CYLINDER TOP. ORIENTATION OF EACH PAIR UNIMPORTANT BRAKE LIGHT SWITCH 2 FEMALE SPADE CONNECTORS GREEN ;...
  • Page 39 LOOM MID SECTION FUEL TANK SENDER 2 FEMALE SPADE CONNECTORS BLACK ; GREEN / BLACK ORIENTATION UNIMPORTANT PRIMARY FUEL PUMP 1 FEMALE SPADE CONNECTOR GREEN PRE-WIRED TO PUMP MOUNTED ON CHASSIS SIDE EARTH TO HIGH PRESSURE 1 FEMALE SPADE CONNECTOR BLACK PRE-WIRED TO PUMP MOUNTED ON CHASSIS FLOOR FUEL PUMP...
  • Page 40 SECTION 04 - DASHBOARD WIRING LOOM Step 9: Dashboard Loom Identifier & Installation Ignition Feed Main Warning Lamp Tachometer Auxiliary Horn Off Side (Connect To Loom Connections Indicator Master Switch) (Black Wires) Reverse Fuel Gauge Switch Driver Passenger (Off) Side (Near) Side Of Car Of Car...
  • Page 41 Dashboard Wiring Loom Fitted to Chassis Dashboard Loom Runs along Top of Chassis Rail Relays Mounted Under Dashboard Chassis Rail 4.14...
  • Page 42 DASHBOARD WIRING LOOM DETAILS CONNECTION LOOM CONNECTOR TYPE LOOM WIRE COLOURS NOTES MAIN LOOM 13 WAY BLACK CONNECTOR 8 WIRES PRE-WIRED BLOCK – MALE 13 WAY BLACK CONNECTOR 11 WIRES PRE-WIRED BLOCK – FEMALE IGNITION RELAY EARTH FEED BARE WIRES 2 BLACK CUSTOMER TO FIT TO MASTER SWITCH WARNING LAMP CONNECTIONS...
  • Page 44 Main Loom Engine Loom (See Note Below) Starter Motor Relay Front OF ECU Mounting Plate View From Passenger Side ECU Unit (Engine Bay Area Of Chassis) NOTE The Engine Loom Supplied MUST Be returned to Westfield Sports Cars For Modification.
  • Page 45 Front Light Wiring Loom Main Front Bodywork Plug R/H Main Headlights R/H Sidelights & Indicator L/H Main Headlights L/H Sidelights & Indicator LEFT HAND CLUSTER Blue/Pink Dipped Beam (OUTER LIGHT) Blue/Slate Main Beam (INNER LIGHT) Black Common Earth Red/Orange Sidelight Black Earth Green/Red...
  • Page 46 Section 5...

  • Page 48: Pedals & Brackets

    SECTION 05 - PEDALS & BRACKETS Tools Required:- - 2 x 13mm Combination Spanners / 2x 10mm Combination Spanners / Long Nosed Pliers / Electric Drill / 6.5mm Drill Bit / 5mm Drill Bit Parts Required:- - Throttle Pedal / Brake Pedal / Clutch Pedal (all Pedals are fitted with `DU’ bearing bushes as standard) / 3 x Pedal Pivot Bush / 5 x Mounting Brackets / 1 x Clevis / 1 x Clevis Pin / 1 x Split Pin / 2 x Extension Rods (Brake Pedal) / 1 x Extension Rod (Clutch Pedal) / 2 x Pedal Rubbers / 1 x Throttle Cable / 1 x Throttle Cable Bracket / 1 x Non-Adjustable Brake Bias...
  • Page 49 Step 2: Fit Pedals Brake Pedal Brake Pedal NOTE NOTE Clutch Pedal The Brake Pedal Is Shown The Brake Pedal Is Shown With An Adjustable Bias-Bar With An Adjustable Bias-Bar Fitted. The Non-Adjustable Fitted. The Non-Adjustable Bias-Bar Bias-Bar MUST MUST Fitted Fitted Initially To Pass The SVA...
  • Page 50 Step 4: Fit Accelerator Cable & Bracket M5 Button Head Screws Front Of Car Accelerator M5 Button Bracket Throttle Pedal Head Screws Cable M5 Button Head Screw. Apply ‘Loctite’ To Thread Before Fitting. Do Not Tighten Down Completely. Ensure The Cable Clevis Rotates Freely.
  • Page 51 Section 6...

  • Page 53: Steering

    SECTION 06 - STEERING COMPONENT INSTALLATION Tools Required:- - Electric Drill / 8mm Dia Drill Bit / 2 x 13mm Spanners / 1 x 6mm Allen Key - NOTE: Instructions to convert from R/H to L/H see page 6.6 Parts Required:- - 1 x Steering Rack / 1 Set Rack Clamp Blocks / 1 x Upper steering Column / 1 x Centre Steering Column / 1 x Steering Column Mounting Bracket - 6 x M8 Bolts x 80mm Long + Washers + Nyloc Nuts...
  • Page 54 Step 1: Cont’d, Front Of Car Steering Rack Install Rack With Pinion Shaft Facing Up Towards The Passenger Seat Approximately As Shown. NOTE Do NOT Fully Tighten The Clamp Bolts At This Stage. Step 2: Install Upper Steering Column & Mounting Bracket Column Mounting Bracket M8 Bolts x 80mm Long (At Front &...
  • Page 55 Step 3: Install Main Steering Column Steering Rack Lower Connection Main Steering Pinch Bolt Column Upper Steering Column Main Steering Column Upper Connection Pinch Bolt NOTE Ensure That The Steering Column Rotates Freely BEFORE Tightening Up The Pinch Bolts And The Steering Column Mounting Block Bolts.
  • Page 56 Instructions To Convert Steering Rack From R/H To L/H Remove four cap screws from Aluminium Cover Housing. Remove Locknut and Grubscrew from Aluminium Rack Casting. Carefully remove Spring and Tensioner below Grubscrew. Remove Split pin from Steering Arm Housing nearest the Pinion. Remove Steering Arm Housing Carefully taking care not to loose any components.
  • Page 57 Section 7...

  • Page 59: Fuel Tank

    SECTION 07 - FUEL TANK INSTALLATION Tools Required:- - Electric Drill / 5.5mm Dia Drill Bit / 2 x 8mm Spanners Parts Required:- - 1 x Fuel Tank / 1 Pair Tank Clamp Straps / Adhesive Backed Foam Strip - 4 x M5 Button Head Screws x 15mm Long + Large Diameter Washers + Nyloc Nuts Step 1: Install Fuel Tank Seat Back Chassis Rails Inlet Spigot...
  • Page 60 Section 8...
  • Page 62 - 1 Electric Drill, 3.2mm Drill Bit and Pop Rivet Tool Parts Required:- - 1 Westfield Gear lever Bracket, 3.2mm Pop Rivets. Step 1: Bracket Installation Place the Gear Lever Bracket onto the Top of the Tunnel as shown so that the Angle matches the Tunnel Top.
  • Page 63 Section 9...

  • Page 65: Hand Brake Lever & Cable

    SECTION 09 - HANDBRAKE LEVER & CABLE Tools Required:- - Electric Drill / 5.5mm Dia Drill Bit / 25mm Dia. Drill / 1 x 13mm Spanner / 2 x 8mm Spanners / Long Nose Pliers Parts Required:- - 1 x Handbrake Lever / 1 x Handbrake Rod / 2 x Spacers / 1 x Handbrake Cable & Compensator 2 x Handbrake Cable Mounting Plates - 2 x M8 Clevis Pins + Split Pins - 5 x M8 Washers...
  • Page 66 Step 3: Install The Handbrake Lever & Rod Front Spacer Of Car Drivers Seat Area Handbrake Lever Centre Tunnel / Mounting Bracket Handbrake Lever Mounting Plate M8 Nyloc Nuts Fitted To Handbrake Lever Mounting Studs Spacer View From Rear Of Assembly Handbrake Lever Mounting Plate Handbrake Lever...
  • Page 67 Step 4: Layout The Handbrake Cable Compensator & Install Mounting Plates Fuel Tank Gearchange Rod Handbrake Rod Handbrake Compensator Handbrake Mounting Plates Handbrake Cable NOTE Rear i) Once Cable & Brackets Are In Of Car The Correct Position, Mark The Mounting Plate Hole Positions Onto The Chassis Floor &...
  • Page 68 Section 10 10.1...
  • Page 69 10.2...

  • Page 70: Gear Lever & Linkage

    SECTION 10 - GEAR LEVER AND LINKAGE Tools Required: - 2 x 13mm Spanners / 2 x 10mm Spanners Parts Required:- - 1 x Gear Lever / 1 x Linkage Rod (long) 2 x M6 Male Rod Ends 2 x M6 plain nuts - 1 x M8 x 50 Long Bolt 2 x M8 Flat Washers 1 x M8 Nyloc Nut 1 x M6 x 25 Hex Bolt - 1 x M6 Nyloc 1 x 42mm Long Inner Bush Step 1: Assemble Gear Change Rod &...
  • Page 71 M8 Washer & Nyloc Nut M8 Bolt x 50 Long Ensure Bolt Head Is This Side To Clear Handbrake Lever View From Rear Of Car NOTE: The rest of the Linkage Cannot be fitted until the Engine is Installed. Adjustment of the Rod Ends will be made after final installation. 10.4...
  • Page 72 Section 11 11.1...
  • Page 73 11.2...

  • Page 74: Front Suspension

    SECTION 11 - FRONT SUSPENSION / WISHBONES AND UPRIGHTS Tools Required:- - 1 x 5/8” AF Spanner / 1 x 11/16” AF Spanner / 2 x 17mm Spanner / 1 x 13mm Spanner / 1 x 27mm Spanner / 1 x 6mm Allen Key Parts Required:- - 2 x Lower Front Wishbones / 2 x Top Front Wishbones / 2 x Lower Front Ball Joints - 2 x Upper Front Ball Joints / 6 x 7/16”...
  • Page 75 Step 3: Lower Ball Joints M10 Setscrews x 25 Long M10 x Nyloc Nuts View From Drivers Side Step 4: Upper Ball Joints 1 x M18 Thin Locknut Note: For a start point set the ball joint with about 15mm of thread exposed.
  • Page 76 Step 6: Fitting Front Upright Once the Ball Joint Blocks are Bolted up tight you are ready to Install the Front Upright. Hold the Upright with the Steering Arm towards the Front of the Car and the Brake Caliper towards the Rear. Place the Upright onto the Lower Block and Assemble using Two Cap Screws.
  • Page 77 Section 12 12.1...
  • Page 78 12.2...

  • Page 79: Track Rods & Front Brake Hoses

    SECTION 12 - TRACK RODS & FRONT BRAKE HOSES Tools Required:- - 1 x 12mm Spanner / 2 x 13mm Spanners / 1 x 14mm Spanner Parts Required:- - 2 x Track Rods / 2 x Rod Ends (3/8” UNF x 5/16” Hole) / 2 x 3/8” UNF Lock Nuts - 2 x M8 Setscrews x 45mm Long / 2 x M8 Nyloc Nuts / 4 x M8 Washers / 4 x 6mm Long Spacers - 2 x Front Brake Hoses Step 1: Install Track Rod...
  • Page 80 Steering Rack End Stud & 3/8” Lock Nut Track Rod View From Front Passenger Side Of Car Repeat Procedure For Other Side Of Car. Step 2: Install Front Brake Hoses Brake Hose View From Rear Of Passenger Side Of Car NOTE Ensure The Brake Hose Is Finally Adjusted...
  • Page 81 Section 13 13.1...
  • Page 82 13.2...

  • Page 83: Rear Differential & Sprocket

    SECTION 13 - REAR DIFFERENTIAL & SPROCKET Tools Required:- - 2 x 17mm Spanners / 2 x 5/8” Spanners / 1 x 8mm Allen Key / 1 x 3mm Allen Key Parts Required:- - 1 x Differential Unit / 1 x Sprocket / 2 x Differential Unit Adjusters /2 x Bearing Carriers / Loctite - 2 x 7/16”...
  • Page 84 Step 2: Install Differential Unit & Chain Tensioners Fit Chain Tensioners To Differential And Chassis Quadrant Plate M10 Bolt x 55mm Long With Washers Under Head Fit Washer & Nyloc Nut On Other Side Of Quadrant Plate To Secure Bolt M10 Socket Cap Screw x 100mm Long With Washers &...
  • Page 85 Step 3: Install Sprocket Use M10 x 30 Bolts and Nyloc Nuts Provided. NOTE: On the Internal Diameter of The Sprocket on One Side Only There Is A Chamfer. This Must Go up To The Flange Face On The Diff. View From Rear Of Car Note;...
  • Page 86 Section 14 14.1...
  • Page 87 14.2...
  • Page 88 SECTION 14 - ANTI-ROLL BAR ASSEMBLIES Tools Required: - 2 x 10mm Spanners / 2 x 5/8” Spanners Parts Required:- - Front Anti Roll Bar / Rear Anti-Roll Bar / 4 x Anti Roll Bar Mounting Blocks / 4 x Upper Clevis Blocks / 2 x Lower Front Clevis Blocks / 2 x Rear Mounting Brackets / 2 x Front Drop Link Rods / 2 x Rear Drop Link Rods / 8 x Rod Ends (5/16”...

  • Page 89: Anti-Roll Bar Assembly

    M6 Bolt x 40mm Long Step 3: Assemble Lower Front Clevis Block Ensure Bolt Passes Through The Clevis Block, The Shouldered Rod End Bushes & The Rod End Before Being Secured with A Washer and Nyloc Nut 7/16” UNF Bolt X 2¾” Long Lower Front Clevis Block Assemble 1 Pair For Front Step 4: Install Front Drop Links...
  • Page 90 Step 6: Install Rear Drop Links Assemble the Rear Drop Links in the same manner as the Front Drop Links. The rear Drop Link tubes are 178mm Long. Note that the Lower Rod End fits into the Mounting Bracket on the Lower Wishbone.
  • Page 91 Section 15 15.1...
  • Page 92 15.2...

  • Page 93: Rear Suspension

    SECTION 15 - REAR SUSPENSION / WISHBONES, UPRIGHTS & DRIVESHAFTS Tools Required:- - 1 x 5/8” AF Spanner / 1 x 11/16” AF Spanner / 2 x 17mm Spanner / 1 x 13mm Spanner / 1 x 27mm Spanner / 1 x 6mm Allen Key Parts Required:- - 2 x Lower Rear Wishbones / 2 x Top Rear Wishbones / 2 x Assembled Rear Upright Corners - 2 x Driveshafts / 2 Rear Brake Hoses...
  • Page 94 Step 2: Top Rear Wishbones Cont’d Anti-Roll Bar Mounting Clevis & Block Assembly Anti-Roll Bar Top Wishbone View From Rear Step 3: Fit Rod Ends ½” UNF Lock Nut NOTE: For a start point set the Rod Ends with about 5mm of thread exposed.
  • Page 95 Step 4: Fit Upright Lower Fixings Hold the Upright Assembly with the Brake Caliper towards the Rear of the Car. Each Upright has a letter `L’ or `R’ on it to identify which side of the car it should go on. (`R’...
  • Page 96 Step 6: Fit Rear Bake Hoses Rear Brake Hose NOTE Ensure The Brake Hose Is Finally Adjusted To Clear Any Moving Parts (Must Clear To Pass SVA) Hose + Copper Washer Bleed Valve Rear Brake Caliper View From Rear Of Car Step 7: Connect Handbrake Cable Hole In ECU Mounting Plate Cable Tie To Wishbone Arm...
  • Page 97 Section 16 16.1...
  • Page 98 16.2...

  • Page 99: Fuel System

    SECTION 16 - FUEL SYSTEM Tools Required:- - Electric Drill / 3.2mm Drill Bit / Pop Rivet Tool / 6.5mm Drill Bit / 4mm Allen Key / 7mm Socket / Flat Blade Screwdriver / 2 x 12mm Spanner Parts Required:- - 1 x Swirl Pot / 1 x `Facet’...
  • Page 100 Step 3: Fuel Filter Installation Position Bracket As Shown, Mark Hole Centres, Drill Through Floor Plate Using 3.2mm Drill Bit & Rivet Bracket To Floor. Secure Filter With Jubilee Clip. Fuel Tank Front Of Car Jubilee Clip Fuel Filter Fuel Filter Bracket View From Inside Engine Bay Step 4: Secondary Fuel Pump Installation -`Facet’...
  • Page 101 Step 5: Fuel Regulator Fitting Fit the Fuel Pressure Regulator to the Top Engine Mounting Frame as shown. NOTE The Regulator Should Only Be Fitted After The Frame Has Been Bolted To The Engine and Installed In The Car. Fuel Pressure Regulator M6 Bolts x 40mm Long with Nyloc Nuts Top Engine Frame View From Rear Of Car...
  • Page 102 Remaining Fuel Pipe Connection Details Fit remaining pipes using a Jubilee Clip at each end. See sketch below for further details. PIPE SIZE FROM Pipe No. On sketch Before Engine Fitting: 1/2” Swirl Pot Main Fuel Pump 8mm (5/16”) Swirl Pot `Facet’...
  • Page 103 Section 17 17.1...
  • Page 104 17.2...
  • Page 105 SECTION 17 - DRY SUMP TANK & OIL CATCH TANK Tools Required:- - 1 Electric Drill / 9mm Drill Bit / Rivsert Tool / 2 x 10mm Spanner Parts Required:- - 1 x Dry Sump Tank / 1 x Oil Catch Tank / 2 x 20mm Long Spacers / 2 x M6 Bolts x 35 Long x M6 Setscrews x 20mm Long / 6 x M6 Nyloc Nuts / 10 x M6 Washers / 2 x M6 Rivserts - 1 x Dry Sump Tank Bracket Step 1: Catch Tank &...
  • Page 106 Dry Sump Tank Drill Through Brackets And Secure Tank With 2 x M6 Bolts 20mm Long Washers & Nyloc Nuts To Locate The Tank On The Bottom Of The Tank There Is A Drain Plug With A Protection Tube Around It. The Tank Must Be Positioned So The Drain Point Tube Protrudes Through The Floor Panel Until The...
  • Page 107 Section 18 18.1...
  • Page 108 18.2...

  • Page 109: Dry Sump Kit

    SECTION 18 - DRY SUMP KIT FITTING Parts Required:- - 1 x Engine / 1 x Dry Sump Kit / 1 Set Of Dry Sump Installation Instructions THE PHOTOS SHOWN IN THIS SECTION ARE TO BE READ IN CONJUNCTION WITH THE INSTALLATION INSTRUCTION PACK PROVIDED WITH THE DRY SUMP KIT Starter Motor Drive Cover Starter Clutch Cover...
  • Page 110 Lever Bar Re-Fit Crank Case Bolt To Secure Tail End Of Bracket Use Cap Head Bolt (Item 13) To Secure Top Of Bracket. Position Lever Bar As Shown To Hold The Nut At The Rear Of The Bracket. This Will Assist With The Tightening Of The Bolt.
  • Page 111 Oil Pressure Relief Valve DO NOT Remove Oil Pick-Up Pipe REMOVE & DISCARD `O’-Ring MUST BE Re-Fitted Oil Return Pipe Remove & Shorten To Suit Drawing Scavenge Pipe (Item 56) Scavenge Pipe (Item 31) Dry Sump Pan Scavenge Pipe (Item 55) Sump Plug (Tighten) Scavenge Pipe (Item 57) Oil Feed Pipe (Item 53)
  • Page 112 Section 19 19.1...
  • Page 113 19.2...
  • Page 114 SECTION 19 - ENGINE PREPARATION & INSTALLATION Tools Required:- - 1 x Spanner Parts Required:- - 1 x Engine Fitted With Dry Sump System / Drive Sprocket / Reverse Gear Drive Flange / Clutch Slave Cylinder + Mounting Brackets / Oil Pressure Adapter / Gear Linkage Support Plate, Bracket, Levers &...
  • Page 115 Remove the Existing Bike Manifold and Cap Head Screws from the Engine if they have not been removed already. Carefully clean the mounting surface on the Engine and fit the 8 Exhaust Manifold Mounting Studs supplied by Westfield Step 4: Oil Pressure Adaptor Dry Sump Pump Drive Pulley Oil Pressure Adaptor Connection Point Step 5: Gear Linkage Plates &...
  • Page 116 Step 5: Gear Linkage Plates & Mechanism Gear Change Support Bracket Top Fixings M8 x 45mm Long + Washer Under Head Rear Gear Change Rod Fitted With Rod Ends + Lock Nuts At Each End View From Nearside Of Engine (As Installed In Car) M6 Bolt x 20mm Long + Spring Washer Gear Change Lever –...
  • Page 117 Metalastic Bushes Nearside Mounting Point Offside Mounting Point Step 8: Fit Sensors Throttle Position Sensor (Already Located) Fuel Rail Return (Modified by Westfield Upon Request) Manifold Pressure Sensor (MAP) Locate On End Of Fuel Rail As Shown Atmospheric Air Pressure...
  • Page 118 Step 10: Fit & Pipe Up Elbow Elbow Supplied By Westfield Connected to Engine Pulse Air Tube Step 11: Fit Engine to Earth Strap Engine end Fitted with M10 x 1 Bolt Chassis end Fitted To M6 Bolt Provided on Chassis With M6 Nyloc And Washer 19.7...
  • Page 119 Section 20 20.1...
  • Page 120 20.2...

  • Page 121: Bodywork

    SECTION 20 - REVERSE GEAR ASSEMBLY Tools Required:- - 4mm Allen Key / 3mm Allen Key / 2 x mm Spanner / 1 x mm Spanner / 1 x mm Spanner Parts Required:- - 1 x Reverse Gear Lever, Inner Bush & Knob / 1 x Reverse Gear Cable & Rose Joints / 1 x Reverse Gear Motor Assembly - 3 x M8 Bolts x 25mm Long + 3 x Washers + 3 x Nyloc Nut - All Fixings For Mounting This Assembly Should Be Supplied with The Assembly...
  • Page 122 Step 2: Engine End Of Cable Rod End ECU Mounting Plate Bulkhead Mounting (Welded To Chassis) Step 3: Mounting Reverse Assembly This Step of the Assembly needs quite a lot of care taken to make sure the mechanism is aligned with the engine correctly. Before you start it is advisable that you remove the Motor from the mechanism to make it easier to handle.
  • Page 123 NOTE: With The Drive Flanges Still In The Clamped Position Top Mounting Point, When Positioned Correctly Drill Two Holes Through Angle To Take M8 x 25mm Bolts. If Required Place Washers As Spacers Between Mounting Plates To Keep The Plates And Flanges Parallel Bottom Mounting Point, When Positioned Correctly Drill One Hole...
  • Page 124 Step 4 : Refit Electric Motor Replace Motor Using 2 off M8X 25 Set screws and Washers Provided. Solenoid For Reverse Mechanism SEE WIRING DIAGRAM ON NEXT PAGE 20.6...
  • Page 125 Installation For Left Hand Drive The Cockpit Lever end of the cable is mounted in the same way as shown in Step 1 of this section of the manual except the handle and knob should face in towards the driver. The Engine End Of The Cable Small operating lever on reverse mechanism.
  • Page 126 20.8...
  • Page 127 WIRING DIAGRAM – XTR2 REVERSE MECHANISM CABLE LENGTH TERMINALS 100” M6 - M10 84” M8 - M10 16” M6 - M8 11” M6 - M8 20.9 50” M6 - M6...
  • Page 128 Section 21...
  • Page 130 SECTION 21 – BODYWORK TRIMMING AND FITTING Parts Required: - - Full Set of Bodywork / Water Radiator / Oil Cooler / Cooling Fan / Oil Cooler Brackets / Splitter Frame and Board / Brake Ducting / Light Fittings Front And Rear / Rear Bodywork Stays / Nose Fitting Catches And Pins / Windscreen / Side Repeaters Step 1: Bodywork Trimming Most of the trimming of your bodywork should have been done for you before you receive it.
  • Page 131 1.c. Fog light holes Centre Hole For Cable Two Smaller holes for M5 Retaining Studs. 1.d. Fuel Filler Hole The main hole will already be in place on your bodywork but you need to drill the six fixing holes as shown. Insert filler cap into pre- cut hole and drill the six 5mm holes through.
  • Page 132 1.f. Windscreen Mounting Holes Carefully position the windscreen onto the pre-formed recess, and drill through the five holes in the screen with a 4mm drill. Then remove the screen and drill through the underside surface only with a 9mm drill. This is to allow the M4 nut to clamp up on the correct face of the bodywork.
  • Page 133 1.h. Radiator and Cooling Fan Thermostat Switch and Washer Fan Mounting Kit Cooling fan needs to be positioned close to the thermostat switch socket and retained by the fan mounting kit. Care is needed when pushing the fan mounting pins through the radiator, so as not to pierce the tubes.
  • Page 134 The radiator sits level with the bottom of the intake with the inlet and outlet towards the back of the car, and is bolted through the return flanges at either end using the M6 tapped holes. View From Inside Engine Bay Towards The Left Side Air Intake 1.i.

  • Page 135: Interior

    1.j. Dashboard And Surround Place the already trimmed dashboard into position in the interior panel. Check in the areas shown that there is clearance behind the dashboard for the clocks and switches to pass through. Mark them with a marker pen. Remove the marked areas Drill through the dashboard mounting holes then remove...
  • Page 136 1.k. Pedal Box Cover Place the cover into the recess on the main body section and drill two 5mm pilot holes through both surfaces. Then remove the cover and drill and rivnut the underneath flange. 1.l. Reverse Lever and Button Holes Measure as accurately as possible the position of your reverse lever in the cockpit and...
  • Page 137 1.n. Side Repeaters Drill a pilot hole in each side of the bodywork at 380mm from the bottom of the body and 90mm from the nose location step. Then file out the shape 90mm shown until it locates the side repeater correctly.
  • Page 138 Step2; Fit Splitter Frame Mount the splitter frame from the four “U” brackets welded to the chassis. The two top fixings on the frame are adjustable so that when fitting the nose and splitter board the correct fit can be obtained.
  • Page 139 Now re-check that all of the pre-trimmed areas mentioned above, to be sure you have the correct fit now that the bodywork is in position. When you are happy with all these points then you can drill the fixings underneath the car. These holes are drilled through the 25mm overhanging section of the Aluminium floor pan about 12mm in from the outside edge of the sheet.
  • Page 140 Bodywork to be level with this cross member on the wing mounting plates. Step 3 b. Splitter Board Mounting The splitter board is mounted on top of the three tags welded to the bottom rail of the chassis and then through the five tapped bushes along the front rail of the frame.
  • Page 141 Step 3 c; Nose Fitting The nose should now sit onto the splitter board and slide back onto the locating blocks on the main body section. The five slots in the lower front return should locate around the M6 bosses in the front cross member of the splitter frame to both hold the nose sideways and down onto the splitter board.
  • Page 142 Step 3 d. Headlight Covers Place the Headlight covers in position and drill three holes down each side with a 5mm drill through both the lens and the fibreglass. Then remove the lens and open up the holes in the bodywork and fit rinuts.
  • Page 143 2.16...
  • Page 144 2.17...
  • Page 145 2.18...
  • Page 146 Section 22...
  • Page 148 If you are putting your XTR2 through an SVA test then you cannot submit it with the wing or post fitted, so just fit the exhaust as now described.
  • Page 149 Main Catalyst Silencer Band Clamp Round End of Silencer with Catalyst Fitted Oval End Rear Mounting Bracket for Long Silencer will fit level to outside of chassis tubes (Later Chassis do not have the flat plates with swaged holes) Step 3 ; Rear Pipe and Small Silencer The later exhaust systems have a loose section of pipe that goes between the two silencers to make fitting slightly easier.
  • Page 150 View Looking Towards The Back of the Car Inside the Engine Bay Small Rear Silencer Box and Link Pipe going through the Wing Mounting Post. Silencer Mounting Strap bolted to the top of the Anti Roll Bar Blocks...
  • Page 153 SECTION 23 – INTERIOR AND DASHBOARD Parts Required:- - Dashboard, Speedo/Tacho, Water Temp Gauge, Oil Press/Temp Gauge, All Switches, Fuel Level Indicator, Ignition Switch, LED Warning Lights Step 1:Assemble Dashboard First mount the three clocks in positions with the Speedo/Tacho in the centre, water temperature on the left and oil pressure/temperature on the right.
  • Page 154 Switch Layout Hazard Warning Light Switch Fog Light Main Beam Dip Beam Side Lights Switch & Headlight & Headlight LED (Red) LED (Blue) Secondary Ignition Switch/Immobiliser Handbrake Fuel Level Ignition Switch & Warning Light Indicator Starter Button...
  • Page 155 Step 2 ; Seat Frame Mountings Assemble the two seat mounting frames using the 18 M6 x 20 button head screws and then bolt to the adjustable seat runners using the M8 x 20 cap screws and nuts. Then locate in the front two mounting holes in the chassis and mark the position of the two rear holes.
  • Page 156 Tunnel Covers And Gaiters Gear Lever Gaiter Handbrake Lever Gaiter Rear Tunnel Front Tunnel Cover Cover Under Scuttle Panels These panels will fit under the scuttle behind the dashboard and cover the triangular section of the chassis from the inside where the fuse boxes are located and the same on the opposite of the car.
  • Page 157 Step 4 ; Seat Belt Mountings The seat belts are to be fixed as shown below Outer Lower Seatbelt Mounting The two outer lower seatbelt straps are fixed using two special 7/16 UNF thin headed bolts and a 7/16 washer. Centre Tunnel Mounting This centre tunnel monuting is one 7/16 unf x 4 inch long bolt staight through,with nyloc and washers.
  • Page 159 Tachometer Controls...

Table of Contents