CUSCO SPORT S Coilover Kit Instruction Manual

1. Introduksjon

Takk for kjøpetasing the CUSCO SPORT S Coilover Kit. This product is designed to provide superior handling and ride comfort for both street and circuit driving. It features a large-capacity mono-tube shock absorber with 24-step damping force adjustment and full-length ride height adjustment. Please read this manual thoroughly before installation and use to ensure proper operation and safety.

2. Sikkerhetsregler

• Installation should only be performed by qualified professionals with appropriate tools and knowledge. Improper installation can lead to serious accidents or product damage.
• Always wear appropriate personal protective equipment (PPE) during installation and adjustment.
• Ensure the vehicle is securely supported on a lift or jack stands before beginning any work. Never work under a vehicle supported only by a jack.
• Do not modify the product in any way. Unauthorized modifications can compromise safety and void the warranty.
• After installation, perform a thorough inspection of all fasteners and connections. Re-check torque specifications after the first 100 km of driving.
• Regularly inspect the coilovers for any signs of damage, leaks, or wear.

3. Komponentliste

The CUSCO SPORT S Coilover Kit includes the following main components:

• Front Coilover Assemblies (2)
• Rear Shock Absorbers (2)
• Rear Springs (2)
• Upper Mounts (Pillow ball or Reinforced Rubber, depending on application)
• Adjustment Wrenches
• Bruksanvisning

4. Kompatibilitet med kjøretøy

This CUSCO SPORT S Coilover Kit (Model: 6C1-64S-CN) is compatible with the following vehicles:

• Toyota GR86 (Model: ZN8), manufactured from October 2021 onwards.
• Subaru BRZ (Model: ZD8), manufactured from August 2021 onwards.

Note: Always verify compatibility with your vehicle's specific model, engine type, drive system, and year using the manufacturer's official website or product catalog before installation.

5. Oppsett og installasjon

5.1 Kontroller før installasjon

• Confirm all components are present and undamaged.
• Ensure the vehicle is on a level surface and properly secured.
• Refer to your vehicle's service manual for specific torque specifications and removal procedures for original suspension components.

5.2 Front Coilover Installation (Strut Type)

1. Fjern forhjulene.
2. Disconnect brake lines, ABS sensors, and any other components attached to the original strut assembly.
3. Unbolt the lower strut mount from the knuckle.
4. Remove the upper strut nuts from the engine bay. Carefully remove the original strut assembly.
5. Install the CUSCO SPORT S front coilover. Ensure the upper mount is correctly oriented.
6. Secure the upper mount nuts to the specified torque.
7. Attach the lower strut mount to the knuckle. The front coilovers feature an inverted (ram type) shock absorber design for enhanced rigidity.
8. Reconnect all brake lines, ABS sensors, and other components.

5.3 Rear Shock Absorber and Spring Installation

1. Fjern bakhjulene.
2. Remove the original rear shock absorbers and springs.
3. Install the CUSCO SPORT S rear springs into their designated seats.
4. Install the CUSCO SPORT S rear shock absorbers, securing both upper and lower mounting points to the specified torque.

5.4 Etter installasjon

• Reinstall all wheels and torque lug nuts to vehicle manufacturer specifications.
• Lower the vehicle and perform an initial ride height adjustment (see Section 6.1).
• Perform a wheel alignment immediately after installation and ride height adjustment.
• Test drive the vehicle carefully to ensure proper function and no abnormal noises.

6. Operating & Adjustment

6.1 Ride Height Adjustment (Full-Length Type)

The CUSCO SPORT S coilovers feature a full-length adjustment mechanism, allowing ride height changes without altering the spring preload or shock stroke. This ensures optimal suspension performance regardless of ride height.

1. Loosen the lower lock collar and the main body lock collar using the provided adjustment wrenches.
2. Rotate the main body of the shock absorber to raise or lower the vehicle. Turning clockwise lowers the vehicle, and counter-clockwise raises it.
3. Once the desired ride height is achieved, tighten both lock collars securely to prevent movement.
4. Ensure both left and right sides are adjusted equally to maintain balance.

6.2 Damping Force Adjustment (24-Step)

The shock absorbers feature 24 levels of damping force adjustment, allowing fine-tuning for various driving conditions, from comfortable street use to aggressive circuit driving. The adjustment knob is typically located at the top of the shock absorber shaft (front) or bottom (rear, depending on design).

1. Finn damping adjustment knob.
2. Turn the knob clockwise for firmer damping (harder ride) and counter-clockwise for softer damping (mykere kjøring).
3. Each click represents one step of adjustment. Start from the softest setting and gradually increase until the desired feel is achieved.
4. Ensure all four corners are adjusted consistently for balanced handling.

6.3 Front Camber Adjustment

For strut-type front suspensions, camber adjustment is possible via the pillow ball upper mount and/or an eccentric collar on the knuckle bracket. This allows for a camber range of approximately -1.5° to -4.5°.

• Upper Mount Adjustment: Loosen the bolts on the pillow ball upper mount and slide the mount to adjust camber.
• Knuckle Bracket Adjustment: Some models may utilize an eccentric collar on the knuckle bracket for additional camber adjustment.
• Always perform a wheel alignment after any camber adjustments.

7. Vedlikehold

• Regelmessig inspeksjon: Periodically inspect the coilovers for any signs of oil leaks, rust, damage to the dust boots, or loose fasteners.
• Rengjøring: Keep the coilover bodies and threads clean from dirt and debris. Use a mild soap and water solution. Avoid harsh chemicals that may damage coatings.
• Gjengesmøring: Apply a thin layer of anti-seize grease to the threaded sections of the shock body to prevent corrosion and ensure smooth ride height adjustments.
• Remoment: After initial installation and after any adjustments, re-torque all mounting bolts to the specified values.
• Overhaul Service: CUSCO offers an overhaul service for the SPORT S coilovers, which can include damping force and stroke changes. Contact CUSCO support for details.

8. Feilsøking

9. Spesifikasjoner

• Modell: CUSCO SPORT S (6C1-64S-CN)
• Støtdempertype: Mono-rør
• Damping Force Adjustment: 24-trinns
• Justering av kjørehøyde: Full-length adjustable (Full-tap type)
• Front Shock Design: Inverted (Ram type) strut
• Øvre fjell: Pillow ball type or Reinforced rubber type (application dependent)
• Front Camber Adjustment Range: Approx. -1.5° to -4.5° (via upper mount and/or knuckle bracket eccentric collar)
• Springs: CUSCO SPORT "Blue spring"
• Korrosjonsbeskyttelse: Anti-rust coating, 500-hour salt spray test cleared for threaded parts.
• Produksjon: Domestic production (Japan), ISO9001 certified, ASEA standard compliant.
• Vekt: Omtrent 30 kg (pakket)
• Pakkedimensjoner: 70 x 50 x 40 cm

10. Garanti og støtte

CUSCO SPORT S Coilover Kits come with a manufacturer's warranty of 1 year or 10,000 km, whichever comes first. User registration is required to activate the warranty.

For warranty claims, technical support, or inquiries regarding overhaul services, please contact CUSCO customer service or an authorized CUSCO dealer. Please have your product model number (6C1-64S-CN) and proof of purchase ready.

Produsent: Cusco (株式会社キャロッセ)

Offisiell Webnettsted: www.cusco.co.jp (Please check for the latest contact information and product details.)