CUSCO Strut Bar Oval Shaft Type OS (Front) Instruction Manual

1. Introduction

Thank you for purchasing the CUSCO Strut Bar Oval Shaft Type OS (Front). This product is designed to enhance your vehicle's handling and ride comfort by increasing front suspension rigidity. By connecting the left and right upper mounting points of the front suspension, it ensures precise suspension operation and reduces unnecessary chassis distortion.

This manual provides essential information for the proper installation, operation, and maintenance of your CUSCO Strut Bar. Please read it thoroughly before installation and keep it for future reference.

2. Safety Information

• Always ensure the vehicle is securely supported on jack stands or a lift before working underneath it.
• Wear appropriate personal protective equipment (PPE), including safety glasses and gloves.
• Ensure all tools are in good condition and used correctly.
• Do not modify the product. Any modifications may compromise its integrity and performance.
• If you are unsure about any step of the installation process, consult a qualified mechanic.
• Keep children and pets away from the work area.

3. Package Contents

Please verify that all components are present before beginning installation:

• CUSCO Strut Bar Oval Shaft (Front) x 1
• Mounting Hardware (bolts, nuts, washers) x 1 set
• Instruction Manual (this document) x 1

Figure 3.1: The CUSCO Strut Bar Oval Shaft, showing its polished main bar and blue end plates with mounting holes.

4. Installation Guide

4.1. Vehicle Compatibility

This product is designed for the following vehicle models:

• Honda Fit GR1 FF 1.3 (from February 2020)
• Honda Fit GR2 4WD 1.3 (from February 2020)
• Honda Fit GR5 FF 1.3 (from February 2020)
• Honda Fit GR7 4WD 1.3 (from February 2020)

Note: Compatibility with 1.5L Hybrid models is unconfirmed. Before purchasing and installing, please verify your vehicle's model, engine type, drive system, year, and grade using your vehicle inspection certificate or caution plate. Always cross-reference with the manufacturer's official website to ensure correct vehicle fitment.

4.2. Tools Required

• Socket wrench set
• Torque wrench
• Pry tool (if needed for plastic covers)
• Shop rags

4.3. Installation Steps (Bolt-On)

The CUSCO Strut Bar is designed for straightforward bolt-on installation. Follow these general steps:

1. Preparation: Park the vehicle on a level surface and engage the parking brake. Open the hood and locate the front suspension's upper mounting points on both the left and right sides of the engine bay.
2. Access: Depending on your vehicle model, you may need to remove any plastic covers or components obstructing access to the strut tower mounting bolts.
3. Loosen Bolts: Carefully loosen the existing bolts on the strut tower mounting points. Do not remove them completely yet.
4. Position Strut Bar: Place the CUSCO Strut Bar over the strut tower mounting points, aligning the holes on the bar's end plates with the existing bolt holes.
5. Install Bolts: Reinsert the original bolts (or use provided hardware if specified by CUSCO) through the strut bar's end plates and into the strut tower. Hand-tighten all bolts first to ensure proper alignment.
6. Tighten Bolts: Using a torque wrench, tighten all bolts to the vehicle manufacturer's specified torque settings. Ensure even tightening on both sides. Refer to your vehicle's service manual for exact torque specifications.
7. Reassemble: Reinstall any covers or components that were removed during step 2.
8. Final Check: Double-check all bolts to ensure they are securely tightened. Close the hood.

Figure 4.1: The CUSCO Strut Bar installed in the engine bay of a Honda Fit, demonstrating its position across the front strut towers.

5. Product Functionality and Benefits

The CUSCO Strut Bar Oval Shaft provides several performance benefits:

• Improved Handling: By rigidly connecting the front suspension towers, the strut bar minimizes chassis flex during cornering, leading to more precise and sharp steering response.
• Enhanced Ride Comfort: The reduction in chassis distortion allows the suspension components to work more effectively and accurately, which can lead to a smoother and more controlled ride, especially over uneven surfaces.
• Increased Stability: The added structural rigidity contributes to overall vehicle stability, particularly during high-speed maneuvers or aggressive driving.
• Aesthetic Appeal: The product features a beautiful finish, offering an excellent dress-up effect for your engine bay.

6. Maintenance

The CUSCO Strut Bar requires minimal maintenance. Periodically inspect the following:

• Bolt Tightness: Check all mounting bolts periodically (e.g., every 5,000 km or during routine service) to ensure they remain securely tightened. Re-torque if necessary.
• Visual Inspection: Inspect the bar for any signs of damage, corrosion, or wear. Clean the bar with a soft cloth and mild cleaner if it becomes dirty.
• Clearance: Ensure the strut bar does not interfere with any other engine bay components or moving parts.

7. Troubleshooting

If you encounter any issues after installation, consider the following:

• Unusual Noises: If you hear rattling or clunking noises, re-check all mounting bolts for proper tightness. Ensure no components are loose or making contact with the strut bar.
• Improper Fitment: If the bar does not fit correctly, double-check the vehicle compatibility information (Section 4.1) against your specific vehicle model. Do not force the installation.
• Reduced Performance: If you do not experience the expected performance benefits, ensure the installation was completed correctly and all bolts are torqued to specification.

For persistent issues, please contact CUSCO customer support or a professional mechanic.

8. Specifications

9. Warranty and Support

CUSCO products are manufactured to high standards. For information regarding product warranty, please refer to the warranty card included with your purchase or visit the official CUSCO website. For technical support or inquiries, please contact CUSCO customer service through their official channels.

Always purchase genuine CUSCO products from authorized dealers to ensure authenticity and warranty coverage.