1. Introduction
This manual provides detailed instructions for the installation, usage, and maintenance of your Cusco 965 540 A Type OS Front Strut Bar. This product is engineered from high-quality tubular aluminum oval shaft material to enhance vehicle performance and longevity. It is designed to fit and function to exacting standards for Scion FR-S, Subaru BRZ, and Toyota 86 models.
Please read this manual thoroughly before installation and operation to ensure proper use and to maximize the benefits of your strut bar.
2. Safety Information
- Always ensure the vehicle is parked on a level surface and the parking brake is engaged before beginning any work.
- Use appropriate safety gear, including gloves and eye protection.
- If you are unsure about any step of the installation process, consult a qualified automotive technician.
- Do not modify the strut bar or its components. Unauthorized modifications can compromise safety and performance.
- Ensure all fasteners are tightened to the manufacturer's recommended torque specifications.
3. Package Contents
Verify that all components are present before beginning installation:
- Cusco 965 540 A Type OS Front Strut Bar assembly
- Necessary mounting hardware (bolts, nuts, washers)
- Instruction sheet (this document)
Note: The primary component is the Automotive Suspension Product itself.
4. Setup and Installation
The Cusco 965 540 A Front Strut Bar is designed for straightforward installation. Follow these steps carefully:
- Prepare the Vehicle: Open the vehicle's hood and locate the top mounting points of the front suspension struts. These are typically visible in the engine bay.
- Clear Obstructions: Identify any components or covers that may obstruct the installation of the strut bar. Temporarily remove these if necessary.
- Position the Strut Bar: Carefully place the Cusco strut bar into position, aligning the mounting plates with the strut tower bolts. It may be necessary to slightly adjust the angle of the bar to achieve proper alignment.
- Secure Mounting Plates: Once aligned, secure the mounting plates to the strut towers using the provided hardware. Hand-tighten all bolts initially.
- Final Tightening: Using appropriate tools, progressively tighten all bolts to the vehicle manufacturer's recommended torque specifications for strut tower fasteners. Ensure even tightening on both sides.
- Reinstall Obstructions: Reinstall any components or covers that were removed during step 2.
- Inspect: Double-check all connections to ensure they are secure before closing the hood and operating the vehicle.
5. Operating and Usage
The Cusco Front Strut Bar is designed to improve chassis rigidity by connecting the top of the vehicle's front suspension strut towers. This reduces chassis flex during cornering and aggressive driving, leading to several benefits:
- Enhanced Handling: Expect a more responsive and predictable steering feel, especially during turns and high-speed maneuvers.
- Improved Stability: The vehicle's front end may feel more stable and controlled, reducing body roll.
- Increased Chassis Life: By distributing stress more evenly, the strut bar can help reduce fatigue on the chassis over time.
While the effects may be subtle for everyday driving, the benefits become more apparent during spirited driving or track use.
6. Maintenance
The Cusco Strut Bar requires minimal maintenance to ensure its longevity and performance:
- Regular Inspection: Periodically check all mounting bolts for tightness. Vibrations from driving can sometimes loosen fasteners over time.
- Cleaning: Clean the strut bar with a mild automotive cleaner and a soft cloth to remove dirt and grime. Avoid abrasive cleaners or harsh chemicals that could damage the finish.
- Corrosion Check: Inspect the bar and mounting points for any signs of corrosion or damage, especially if driving in harsh weather conditions.
7. Troubleshooting
If you encounter any issues after installing your Cusco Strut Bar, consider the following:
- Improper Fitment: If the bar does not seem to fit correctly, re-check the alignment of the mounting plates with the strut towers. Ensure no other engine bay components are interfering.
- Unusual Noises: If you hear rattling or squeaking, re-check all mounting bolts for proper tightness. Loose hardware is a common cause of such noises.
- No Perceived Improvement: The effects of a strut bar can be subtle. Ensure you are testing the vehicle in conditions where chassis rigidity improvements are most noticeable (e.g., spirited cornering).
If problems persist, contact Cusco customer support or a professional mechanic.
8. Specifications
| Feature | Detail |
|---|---|
| Brand | Cusco |
| Model Number | 965 540 A |
| Auto Part Position | Front |
| Material | Tubular Aluminum Oval Shaft |
| Exterior Finish | Black |
| Item Weight | 3 pounds |
| Vehicle Service Type | Car (Scion FR-S, Subaru BRZ, Toyota 86) |
9. Warranty Information
Cusco products are manufactured to high standards. For specific warranty terms and conditions, please refer to the official Cusco website or contact their customer service directly. Keep your proof of purchase for any warranty claims.
10. Support
For technical assistance, installation questions, or product inquiries, please visit the official Cusco website or contact their customer support department. Contact information can typically be found on their website or product packaging.
