Rev9 Hyper-Street II Coilover Kit (R9-HS2-104) for Toyota Yaris (2006-2014)

1. Introduction

This manual provides comprehensive instructions for the installation, adjustment, and maintenance of the Rev9 Hyper-Street II Coilover Kit, model R9-HS2-104, designed for Toyota Yaris models (XCP90/XCP130) manufactured between 2006 and 2014. This kit is engineered to enhance vehicle handling and aesthetics through adjustable ride height and damping force.

The Hyper-Street II Coilover Kit features mono-tube shocks with 32 clicks of rebound adjustment and full-length adjustability. The mono-tube design offers a larger capacity for gas and oil, contributing to improved comfort in lowered vehicles. Independent spring tension and full-length adjustment allow for ride height modification without compromising spring preload.

2. Safety Information

WARNING: Professional installation is highly recommended. Improper installation or adjustment can lead to serious injury or vehicle damage. Always wear appropriate personal protective equipment (PPE) during installation.

• Ensure the vehicle is securely supported on jack stands on a level surface before beginning any work.
• Never work under a vehicle supported only by a jack.
• Disconnect the battery's negative terminal before working on any electrical components.
• Refer to your vehicle's service manual for specific torque specifications and removal procedures.
• Do not modify any components of the coilover kit.
• After installation, perform a wheel alignment to ensure proper vehicle handling and tire wear.

3. Kit Components

The Rev9 Hyper-Street II Coilover Kit includes the following components:

• Front Coilover Assemblies (2)
• Rear Coilover Assemblies (2)
• Adjusting Wrenches (2)
• Hex Key (1)
• End Links (2) - Specific to certain applications, verify included parts.

Image 3.1: Overview of the Rev9 Hyper-Street II Coilover Kit, showing front and rear coilover assemblies, springs, and end links.

Image 3.2: Included tools: two green adjusting wrenches for ride height and spring preload, and a hex key for securing spring seats.

4. Setup and Installation

The following steps outline the general installation process. Specific vehicle disassembly and reassembly procedures should be referenced from a Toyota Yaris service manual.

4.1 Front Coilover Installation

1. Safely lift the vehicle and secure it on jack stands. Remove the front wheels.
2. Locate and disconnect the brake line and ABS sensor wire from the factory strut assembly.
3. Remove the lower strut mounting bolts and the upper strut tower nuts. Carefully remove the factory strut assembly from the vehicle.
4. Transfer necessary components from the factory strut to the new coilover. This typically includes the OEM top mount, strut bearing, and spring top plate. Refer to Image 4.1 for a visual guide.


Image 4.1: OE Top Mount Installation Guide. This diagram illustrates the components to be transferred from the factory strut and the sequence for assembling them onto the new coilover rod.

5. Install the new Rev9 front coilover assembly into the vehicle. Secure the upper strut tower nuts first, then the lower mounting bolts. Do not fully tighten until the vehicle is at ride height.
6. Reconnect the brake line and ABS sensor wire.

4.2 Rear Coilover Installation

1. Safely lift the vehicle and secure it on jack stands. Remove the rear wheels.
2. Locate and remove the lower shock mounting bolt and the upper shock mounting nuts. Carefully remove the factory shock and spring assembly.
3. Install the new Rev9 rear coilover assembly. Secure the upper mounting nuts first, then the lower mounting bolt. Do not fully tighten until the vehicle is at ride height.

4.3 Final Steps

1. Reinstall all wheels and lower the vehicle to the ground.
2. With the vehicle at ride height, fully tighten all upper and lower mounting bolts and nuts to factory specifications.
3. Perform a test drive in a safe area to ensure proper function.
4. It is mandatory to get a professional wheel alignment after coilover installation to prevent premature tire wear and ensure safe handling.

5. Operating and Adjustment

The Rev9 Hyper-Street II Coilovers offer adjustable ride height and damping force.

5.1 Ride Height Adjustment

Ride height is adjusted by rotating the lower mounting bracket on the threaded shock body. Use the provided adjusting wrenches for this procedure.

1. Loosen the lower locking collar using the adjusting wrench.
2. Rotate the lower mounting bracket to raise or lower the vehicle. Turning clockwise will lower the vehicle, counter-clockwise will raise it.
3. Once the desired ride height is achieved, tighten the lower locking collar securely against the mounting bracket.
4. Ensure the spring preload is set correctly. The spring should be snug between the upper and lower spring seats, with minimal to no compression at full extension. Adjust the spring seat collars if necessary, then secure them with the hex bolt.


Image 5.1: Close-up of the improved revision spring seat, which locks with a hex bolt for secure spring preload adjustment.

5.2 Damping Force Adjustment

The coilovers feature 32 clicks of rebound damping adjustment. This allows fine-tuning of the suspension's stiffness.

1. Locate the damping adjustment knob at the top of the front coilovers and at the bottom of the rear shocks.
2. Turn the knob clockwise for firmer damping (harder ride) and counter-clockwise for softer damping (softer ride).
3. Start with a neutral setting (e.g., 16 clicks from full soft) and adjust incrementally to find your preferred ride quality.
4. Ensure all four coilovers are set to the same damping level for balanced handling.

6. Maintenance

Regular maintenance helps ensure the longevity and performance of your Rev9 coilovers.

• Regular Inspection: Periodically inspect the coilovers for any signs of damage, leaks, or loose components. Check for corrosion on threaded sections.
• Cleaning: Keep the coilover bodies and threads clean, especially after driving in harsh conditions (e.g., snow, salt, dirt). Use a mild soap and water solution.
• Lubrication: Apply a thin layer of anti-seize lubricant to the threaded sections of the coilover body during initial installation and periodically thereafter to prevent seizing and facilitate future adjustments.
• Torque Check: Re-check all mounting bolts and nuts to ensure they are torqued to factory specifications after the first 500 miles and then periodically.

7. Troubleshooting

This section addresses common issues that may arise with coilover suspension.

• Noise (Clunking/Squeaking):
  • Check for loose mounting bolts or nuts.
  • Ensure spring preload is adequate; springs should not be loose when the suspension is at full droop.
  • Inspect end links for wear or looseness.
  • Verify that no components are rubbing against each other.
• Uneven Ride Height:
  • Measure ride height from a consistent point (e.g., fender to wheel center) on all four corners.
  • Adjust the lower mounting brackets to achieve desired and even ride height.
• Poor Handling/Unstable Ride:
  • Ensure damping settings are appropriate and consistent across all coilovers.
  • Verify that a wheel alignment has been performed after installation.
  • Check tire pressure.

8. Specifications

9. Warranty and Support

For warranty information and technical support, please refer to the official Rev9 website or contact your authorized Rev9 dealer. Keep your purchase receipt as proof of purchase for any warranty claims.

For further assistance, please visit the Rev9 Brand Store on Amazon or contact the seller directly.