Lotus Exige S/C Service Notes

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Lotus Service Notes Exige S/C

SUPPLEMENT

EXIGE SUPERCHARGED (S/C)

Sub-Section Page

Concept & Overview Exige S/C.# 2

Technical Data

Exige S/C.TD 3

Body

Exige S/C.B 4

Front Suspension

Exige S/C.C 5

Rear Suspension

Exige S/C.D 5

Engine

Exige S/C.E 5

Wheels & Tyres

Exige S/C.G 11

Brakes

Exige S/C.J 11

Cooling

Exige S/C.K 11

Maintenance & Lubrication

Exige S/C.O 12

Clutch

Exige S/C.Q 12

Miscellaneous Exige S/C.Z 12

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Lotus Service Notes Exige S/C

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Lotus Sport Exige 240R

EXIGE S/C.# - CONCEPT & OVERVIEW

In February 2005, Lotus announced the Lotus Sport Exige 240R (243 bhp) to provide discerning customers
with an exclusive very high performance derivative of the Exige, to be built in a global limited edition of 50 units.
The cars to be produced to customer order as post registration official factory conversions of the '05 Exige by
the Lotus Sport workshops at Hethel, and available for the U.K. and certain overseas territories where regula

­tions allow. In November 2005, Lotus Sport commenced build of a limited number of Exige Cup 240 cars in
road or race specification for selected markets, and differing in detail to the 240R. Then in January 2006, an
official production version of the supercharged car, Exige S, was introduced with a simplified specification.

The performance of the standard Exige is uprated by the fitment of a Magnuson supercharger belt driven
from the crankshaft, feeding through an air/air chargecooler into a new plenum/intake manifold, and featuring a
supercharger integral by-pass valve. The 240R engine uses a mechanical throttle and a 5th injector mounted
in the intake manifold plenum, whereas the '06 M.Y. Cup cars use an electronic throttle, larger port injectors
and no 5th injector, and the Exige S utilises standard injectors.

Chassis dynamics on 240R and Cup cars are uprated by the fitment of Ohlins 2-way adjustable dampers,
with adjustable spring platforms for the uprated springs, and new lightweight forged 5-spoke roadwheels of
slightly wider section to accommodate optional track use only slick tyres.

This supplement describes the features of the supercharged variants which differ from the standard '05
Exige model. For information on any subject matter not included here, refer to the main manual.

240Rint

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Lotus Service Notes Exige S/C

EXIGE S/C.TD - TECHNICAL DATA

Where different to standard Exige:

Engine

Forced induction Magnuson MP62 supercharger with
integral by-pass valve.
Air/air chargecooler.
Maximum boost pressure 0.5 bar (7 psi)
Max. power - 240R & Cup 181 kW (243 bhp; 247 PS) @ 8000rpm

- Exige S 162.5 kW (218 bhp; 221 PS) @ 7800rpm
Max. torque - 240R & Cup 236 Nm (174 lbf.ft; 24 kgf.m) @ 7000rpm

- Exige S 215 Nm (158.6 lbf.ft; 22 kgf.m) @
5500rpm
Power to weight ratio - 240R & Cup 195 kW/t (261 hp/t; 266 PS/t)
Specific power output - 240R & Cup 100.78 kW/l (136.97 hp/l; 137.4 PS/l)
Lubrication system supplement - 240R & Cup Accusump oil storage reservoir
Oil cooling Twin front mounted oil coolers

Wheels & Tyres

Wheels - type - 240R Lightweight forged alloy 5-spoke, satin
black or high power silver

- size - front - 240R 7J x 16

- rear - 240R 8J x 17

Suspension

Ride height, mid laden, front/rear - 240R & Cup 120/120 (2 x 75 kg pass., ½ tank fuel)
Spring rate - front - 240R & Cup 325 lb/in

- rear - 240R & Cup 425 lb/in
Front anti-roll bar - 240R & Cup 5-position adjustable
Dampers - 240R & Cup Ohlins gas pressurised with remote
reservoirs, 2-way damper adjustment,
adjustable spring top platforms.

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Lotus Service Notes Exige S/C

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EXIGE S/C.B - BODY

Exterior

All 50 of the 240R cars are finished in high metallic content paint in either Sport Yellow or Sport Black,
reflecting the brand colour scheme of Lotus Sport. Yellow cars are complemented by black roadwheels, and
black cars with high power silver wheels.

A Lotus Sport 240R decal is applied to the RH side of the rear transom.

Paint Codes:
Sport Yellow: Lotus code B112 Du Pont code X3454
Sport Black: Lotus code B111 Du Pont code X3453

240 Cup and Exige S models were offered in the complete range of colours with the front splitter, side
intake scoops and the rear aerofoil (excluding support struts) finished in body colour rather than satin black.
Exige S cars feature an 'Exige S' decal on the rear trabnsom, and an 'S' decal on each fron quarter panel. Both
decals available in grey or silver dependent on body colour.

The chargecooler air intake scoop on the roof of Exige S models is fitted with an enlargement funnel mouth
(without grille) for increased airflow and enhanced chargecooler efficiency.

Interior

Each Lotus Sport Exige 240R is individually numbered from 001 to 050, and identified by a Lotus Sport
build plate styled after those used by Team Lotus for the Formula One cars. The plate is riveted to the chassis
main side rail on the passenger side, and is engraved with the unique Limited Edition number.

The 240R features black leather sports seats embroidered on the head restraints with Exige branding in
yellow, with further Lotus Sport yellow highlights on the seat sides, door trim inserts, gear lever gaiter and park­ing brake lever gaiter. Cup cars use black leather/suede/carbon effect trim with '06 M.Y. Probax sports seats.

240R and Cup cars are fitted with four point seat belt harnesses, with the shoulder straps anchored to a
seat belt mounting frame (roll hoop) cross bar. The roll hoop and back stays on these cars are manufactured
in T45 steel to allow easy conversion to U.K. motorsport MSA approval by the addition of an 'A' frame and
diagonal brace.

All 240Rs are equipped with air conditioning, but is optional on other models.

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Lotus Service Notes Exige S/C

EXIGE S/C.C - FRONT SUSPENSION - 240R & CUP

Stiffened road springs front and rear are fitted on new Ohlins dampers featuring remote gas reservoirs,
adjustable spring platforms and separate adjustments for compression and rebound damping. The spring plat

­forms allow for lowering of the car to 120/120mm mid-laden ride height for track use, and the 22 compression
and 60 rebound damper settings allow the characteristics to be fine tuned to individual requirements. The gas
reservoir is mounted on the inboard crossbrace of the lower wishbone, and is connected to the damper body
by a steel braided hose.

Compression (bump) damping is adjusted by turning the knob on the end of the gas reservoir canister: Turn
clockwise to increase damping, and couterclockwise to decrease. Recommended settings are as follows:
Road use: 11 clicks from full hard
Track use: 11 clicks from full hard

Rebound damping is adjusted via a ribbed collar below the bottom spring seat: Turn clockwise (as viewed
from below) to increase damping, and counterclockwise to decrease. Recommended settings are as follows:
Road use: 8 clicks from full hard
Track use: 8 clicks from full hard

The motorsport stiffened and 5-position adjustable front anti-roll bar provides further opportunity for fine
tuning. To stiffen the bar, use a more forward hole, and to soften, use a more rearward hole. Recommeded
setting:
Road use: Central hole
Track use: Central hole

Suspension geometry is unchanged - refer to Section TDQ.

EXIGE S/C.D - REAR SUSPENSION - 240R & CUP

Stiffened road springs front and rear are fitted on new Ohlins dampers featuring remote gas reservoirs,
adjustable spring platforms and separate adjustments for compression and rebound damping. The spring
platforms allow for lowering of the car to 120/120mm mid-laden ride height for track use, and the 22 compres

­sion and 60 rebound damper settings allow the characteristics to be fine tuned to individual requirements. On
240R models the gas reservoirs are mounted on the roll over bar backstays, and on Cup cars, on the toe-links.
Each reservoir is connected to its damper body by a steel braided hose.

Compression (bump) damping is adjusted by turning the knob on the end of the gas reservoir canister: Turn
clockwise to increase damping, and couterclockwise to decrease. Recommended settings are as follows:
Road use: 15 clicks from full hard
Track use: 10 clicks from full hard

Rebound damping is adjusted via a ribbed collar below the bottom spring seat: Turn clockwise (as viewed
from below) to increase damping, and counterclockwise to decrease. Recommended settings are as follows:
Road use: 15 clicks from full hard
Track use: 12 clicks from full hard

Suspension geometry is unchanged - refer to Section TDQ. The Track Use Chassis Rear Brace Kit is
fitted as detailed in sub-section DH.5.

EXIGE S/C.E - ENGINE

The 1.8 litre 2ZZ-GE engine with VVTL-i (Variable Valve Timing and Lift - intelligent) of the standard Exige
is fitted with a low pressure Roots type Magnuson MP62 supercharger to provide up to 0.5 bar (7 psi) of boost
pressure. The supercharger is mounted on the left hand side of the block and driven by a lengthened version
of the multirib auxiliary belt. The unit is self contained and features helix twisted rotors to minimise output
pressure variations, and maintenance free gearing and bearings, requiring no externally sourced lubrication.
An integral by pass valve under ECU control, operates to recirculate air from the compressor outlet back to the
inlet under conditions of idle and part throttle to the benefit of economy and quiet operation.

The supercharger is hung off the new intake manifold by two bolts in conjunction with eccentric sleeves in
order to ensure stress free alignment. An alloy bracket supports the nose of the unit to the RH engine mounting
plinth, and a tubular strut braces the intake end of the unit to the clutch slave cylinder mounting point.

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