CUSCO Suspension Kit Instruction Manual
Contents
1. and Warning Symbols manual for complete instructions Z Do not Do not install this kit in flammable environment Avoid flammable environment San l Do not dispose in fire We do not accept liability for any damage or accident arising from improper modification installation G Do not disassemble or modify assembly or misuse Check 6 When you sell or pass it on this product make sure you supply this installation manual and the attached manual with the product C Cautions Removal amp Installation Failure to follow the instructions could result in serous injury and or death N Warnin g caused by an accident Use of any part other than component parts or genuine parts can lead to insufficient strength or loose which can result in an accident or damage to your car s Make sure this product fits your vehicle by checking your vehicle information model and year against the product s part number listed in the attached manual oH a O i ar a a Do not attempt to disassemble modify or add to any part of this akesi aiae ied T kit or do not replace any part contained in this kit with he manuia contained non qualified parts Some kit requires preparation of Assemble this kit with parts contained in this kit only OSC Ral el separare y S JO Check the conditions of existing suspensions and check every part for damage before installation If you find any deformation or damage re2. LN 1 No tool or removed part is left in the engine room 2 The vehicle s transmission is put in neutral or parking and the parking brake is securely engaged 3 Jacks lifts or rigid racks must be securely placed apart from the vehicle body and all four tires touch the ground The measuring point of ride height varies by the model or installed accessory AN Perform daily inspection or maintenance for safe and comfortable If damping force adjustment is pee erie available make sure the both sides 1 Periodically retighten fasteners selatihe sanelevel 2 Shock absorbers deteriorate gradually When oil leakage deterioration at mounting points at washers or at rubber damage abnormal pitch or roll vibration or noise is realized while driving stop the vehicle as soon as possible Contact your purchasing dealer or service shop and replace with designated repair shock absorbers if necessary Failure to follow the instructions could result in injury and or damage to AN Warning ee j your car Before start driving make sure ground clearance required by the Changes in ride height can alter applicable law is maintained and the spring has no play alignment Sr When ride height is changed adjustment of wheel alignment is needed Wheel alignment should be adjusted within the manufacturer s specification stated in your service manual E Some vehicle model contains adjustable pillow ball upper mounts or camber adjustment bolts
3. failure Altering to the maximum hard damping force level reduces noise Installation of pillow ball upper mounts with this kit improves response However be aware that in some model noise from the suspension kit or other parts gutter on arm ball joints or hub bearing rings etc may increase When larger wheels are chosen inch up it alters tire rigidity and also changes ride feeling of or noise from the suspension kit When Those ride height datashown in this manual is actual recommended measured values and designed values obtained from our test setting doesnt vehicles Ride height varies by the model grade their fit your car accessories aging conditions or mounting conditions of bushes on arms etc Ride height also changes if a vehicle Set to the maximum hard damping force level They are not broken if noise is reduced or erased Theses measurements shown in this manual are reference only equipped with non standard springs Make sure you measure your vehicle s ride height on a flat level surface To the Customers Weare not liable for any deformation or product malfunction arising from deterioration over age Be aware that we take no responsibility for any property damage accident or personal injury arising from improper regular inspections or maintenance We make effort to improve our products to achieve superior performance thus be aware that we may change our product specifications without notifica
4. Keep this manual for future reference PROGRESSIVE EQUIPMENT cUScCoO Flexible Wagon Gear CUSCO aGdhZa_ Suspension Kit Instruction Manual This instruction manual provides you with important Definitions of Symbols instructions on proper and safe installation and use of this This manual contains safety and warning product Please read instructions carefully before symbols as follows Understand each starting any work on this suspension kit Keep this meaning before reading this manual manual in a safe place for future reference Warning Caution For Your Safety Indicates a potentially hazardous situation which if instructions are not followed exactly Please read this instruction manual and the attached or the product is handled improperly may manual carefully before beginning result in a serious accident which could lead to serious injury or death Jo Installation of this product must be performed by a qualified mechanic at a fully equipped service shop Caution C Installation workers have responsibility for removal and Indicates a potentially hazardous situation installation of this kit Read this manual carefully and which if instructions are not followed exactly understand all required work or the product is handled improperly may result in personal injury or property damage amp The attached manual only covers main points of procedures Please refer to your vehicle s service Other Safety
5. Refer to the attached manual for proper adjustment p For damping force adjustable shock absorbers set the right and left dials or selectors in an identical position Refer to the attached manual for details AN When scrapping shock absorbers drill a 2 mm 0 079 to 3 mm 0 118 hole at a position shown below to release gas Gas cartridge Mono tube inverted type Mono twin tube Twin tube strut type Twin tube full length ride gas type height adjustment type Cautions After Installation Failure to observe the following instructions could result in injury and or damage to A Warning your car Before installation remove sand or dust from the spring AN seat lock nut case lock nut and adjusting case with lubricant Fasten to the specified torque shown below using the wrench included with shipment Specified torque N anera 7 Spring seat lock nut 29 4N m 3 0kgf m Lock nut o Case lock nut strut 78 2N m 8 0kgf m E 4 Case lock nut Case lock nut Wishbone 39 2N m 4 0kgf m Jiini ii N Adjusting case J There is a tolerance on every part comprising this suspension kit The spring may have some play even if it is set at conditions recommended in this instruction manual Adjust it in a way that the spring has no play if necessary A Clean the adjustment portion before modifying ride height A Tighten each fastener to the specified torque A N Due to the vehicle design or individual differen
6. ce sometimes the right and left fender height may not correspond even though the spring seat positions are set at the same level Reposition the spring seat at proper height if necessary Breaking in or warming up can lead to long term performance of the ride height adjustable suspension kit ih After installation of the kit we recommend to have your vehicle driven for 500 km 310 7 mi to 1000 km 621 4 mi Break in your vehicle for 500km 310 7 mi to breaking it in to 1000 km 621 4 mi after the installation The break in process allows sliding surfaces to be polished of the height adjustable suspension kit and life span of your vehicle can be maximized In the case of twin tube type shock absorbers oil and air may be mixed during shipment This problem can be also solved by breaking in ih Full throttle operation should be avoided right after the installation Like engines transmissions or differentials warming up will lead to improved long term performance Warm up your vehicle after the installation Avoid heavy loads Troubleshooting Information D There are a few troubleshooting items that you can perform Please check instructions listed below before you have your suspensions repaired or replaced Noise lf your shock absorbers set at a soft damping force level they make swish swish noise This shock absorber structurally produces these noise when oil passes a damping force bypass and it is not
7. cle with rigid racks to ensure your safety Never modify any part of this product or your vehicle unless specified in this manual 4 Installation right after diving is not safe ts Make sure the jack or rigid rack comes in contact with the LOPS r Ak proper lift point of your vehicle a O Pe gt e gt vehicle Caution Make sure this product fits your vehicle by checking your vehicle information model and year against the product s part number listed in the attached manual Make sure you have every part listed in this instruction manual and assembly drawings When additional genuine parts are required make sure you prepare requested genuine parts Retighten every part to the specified torque recommended in this instruction manual or assembly drawings Vehicle weight accessories or tire sizes alters ground clearance Make sure your vehicle meets the statutory ground clearance 9 cm with this kit before installation by checking against product specification sheet specified in the attached manual When camber adjustable upper mounts are used the strut may interfere with the vehicle body and it damages parts and the vehicles Ensure that the strut doesn t touch the vehicle body to prevent damage to your vehicle and the struts Vehicle owners are required to follow the statutory ground clearance 9 cm If you fail to comply with the law you may be liable for legal penalties Cover the surface with fender cove
8. place before installation if necessary Never modify or assemble with non qualified parts j js yy Make sure all fasteners are torqued to the proper Ghcetreusina pans o specifications specified in the attached manual or your tor their conditions ies vehicle s service manual before fitting them Gy Contact Information CARROSSER Co Ltd Address 1664 1 Shinbo cho Takasaki shi Gunma ken Japan Manufacturer TEL 027 352 3578 FAX J027 352 1919 e mail cusco cusco co jp CUSCO U S A INC Address 16631 Gemini Lane Huntington Beach CA 92647 U S A Branch Office TEL 714 907 0033 FAX 714 369 81 42 e mail cuscousa cusco co jp Cautions Removal amp Installation Failure to follow the instructions could result in serous injury or death caused by an accident Failure to take adequate safety measures may cause the car to fall or parts to be damaged which can result in an accident and or injury Wear heat resistance groves work outfit hard hat safety glasses N Wear outfit when performing the procedures covered in this manual which covers Warning Make sure every part is fully cooled to normal temperature before your body and starting installation Do not start installation right after the engine is is easy to move turned off to prevent Installation should be performed with the engine being turned off injury Park your vehicle on a stable and flat ground during installation Lift up your vehi
9. r to avoid any damage to your car C When installation of this kit requires to temporally remove genuine parts keep them in a safe place to avoid any damage for later use Be careful not to break or short circuit when temporally removing wiring couplers or connectors Handling of Shock Absorbers A N Caution gt PE 9 Warning Is the engine turned off Is work area flat and level Pa A s the car cooled p Failure to follow the instructions could result in injury or failure of your Fasten every comprising part and designated genuine part to the torque specified in the attached manual or your vehicle s service manual The statutory ground clearance must be maintained The measuring point of ground clearance varies by the model or accessories N Measure a distance between a projecting portion such a muffler or differential box and the ground Cover the surface with Fender cover to avoid any damage while installation ET C A Be careful not to cut or damage electric cables or couplers AN Never grip the shock absorber piston rod Never modify any part of the shock absorber The shock with a tool Never drop the body absorber contains high pressure gas in its cylinder Use extra caution when disposing them AN Never use a tool to handle the piston rod 660 gt Be welding flame Always wear safety glasses out when releasing gas Disposing shock absorbers is dange
10. rous contact your service shop or dismanitler Do not dispose in fire Never place the shock absorber close to fire or Oil or dust may blow Please Cautions After Installation caused by an accident If component parts or other genuine parts are improperly installed or if removed parts or used tools are handled improperly it can result in an accident or injury D After installation check the following carefully 1 The kit is properly installed as specified in the attached manual and your vehicle s service manual 2 The spring and spring seat fit securely Failure to follow the instructions could result in serous injury and or death Warning Is every shock installed properly 3 No fastener is damaged and every fastener is tightened in S position to their proper torque ae fe 4 The installed suspension doesn t come into contact with the tire or Z wheel even during driving N RS Check the following when a wheel spacer is used to maintain proper Is ground clearance clearance between the vehicle body tires and wheels A maintained 1 Wheel nuts can be tightened to the manufacturer s specified Don t tires or wheels protrude torque and at least first twelve 12 threads of wheel hub bolt are beyond the body covered by a nut 2 No tire and wheel protrudes beyond the exterior body A a Check the following before starting the engine after the completion of Is ground clearance maintained work
11. tion
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