HKS HIPERMAX MAX IV GT Installation Guide

Introduction

Thank you for purchasing the HKS HIPERMAX SUSPENSION SERIES. This manual assumes you have the necessary knowledge and tools to safely perform the installation. Please read this manual carefully before proceeding. HKS is not responsible for any damage caused by incorrect installation, misuse, or modification of the product. Product specifications are subject to change without notice.

Safety Precautions

WARNING: Indicates risk of serious injury or possible death.

CAUTION: Indicates risk of injury or possible property damage.

• Never use the vehicle's on-board jack for lifting. Use a proper vehicle lift or garage jack with jack-stands.
• This product contains nitrogen gas; do not disassemble or incinerate it. Avoid dropping or subjecting the product to excessive impact, as it may explode.
• Installation may affect vehicle safety systems like collision avoidance.
• Oil or grease may exude from seals; this is normal.
• Clean parts with a suitable cleaner.

Before Use

• Ensure the vehicle is properly supported before starting any work.
• Handle the product with care to avoid damage.

Installation Precautions

• Installation must be performed by a professional.
• Do not modify or remodel the product.
• Do not release or fill the nitrogen gas.
• Replace suspensions in pairs (left and right sides simultaneously).
• Use a spring compressor for spring removal and installation. Ensure it is securely fitted.
• Avoid using an impact wrench on the upper mount. If necessary, ensure the suspension is compressed to avoid damage.
• Refer to the vehicle's service manual for factory suspension removal.
• Tighten all bolts and nuts to the specified torque values.
• Do not hold the product shaft with tools to prevent oil leakage.
• Do not loosen the hexagon socket countersunk head screw.
• Ensure springs are properly seated and do not have excessive play.
• If abnormal noises, smells, or vibrations occur, consult the installer immediately.

Vehicle Height Adjustment

• Adjust vehicle height only when the vehicle has cooled down (approx. 40°C).
• Adjustment can be made via the ride height adjuster screw or bracket position (for adjustable case length).
• Use the provided spanner wrench for adjustments.
• When adjusting spring seats, ensure no load is on the spring.
• After adjustment, check for any contact between suspension components and the vehicle chassis (e.g., driveshaft, suspension arm).
• Ensure there is no spring play when the suspension is fully extended.
• Verify the upper part of the spring is securely seated in the upper mount guide.
• CAUTION: Adjust within the specified range to prevent suspension damage.

Damping Force Adjustment

• The damping force dial has 30 steps. Turn clockwise to the end, then counterclockwise to the first click for the 0 setting.
• Do not overtighten or turn more than 30 steps counterclockwise.
• Ensure the dial positions are the same on both the left and right sides for optimal handling.

Maintenance

• Regular maintenance is crucial for safety and performance.
• Perform a break-in period of approximately 50km (31 miles) after installation.
• Regularly check bolts, nuts, vehicle height, and cleanliness.
• Periodic overhaul is recommended to maintain suspension performance due to wear on components like pillow balls and shafts.

Troubleshooting

• If the vehicle or product is damaged, seek professional repair.
• If abnormal noise, smell, or vibration occurs while driving, stop using the product immediately and consult a professional.

After-sales Service

• For inquiries, optional parts, or overhaul requests, contact the dealer where the product was purchased.
• Keep the removed factory suspension as a temporary replacement during repair or overhaul.

Product Disposal

• Consult the dealer or a disposal agent for proper disposal.
• Wear safety glasses when handling the product for disposal, as oil may scatter.

Parts List

The following parts are included in the kit:

• Front Suspension Assy (2)
• Rear Shock Absorber Assy (2)
• Rear Spring (2)
• Rear Ride Height Adjuster Assy (2)
• Flange Nut (Thin) (2)
• Spanner Wrench (Large) (1)
• Dial (2)
• Tie Wrap (Large) (8)
• Cable (2)
• Adjustment Cable (2)
• Tie Wrap (Small) (2)
• Screw (4)
• Warranty Certificate (1)
• Allen Wrench (1)
• Installation Guide (1)
• Spanner Wrench (Slotted) (1)

Suspension Components Diagram

Diagrams illustrating the front and rear suspension components and their assembly are provided.

Front Components: Strut Rod Cap, Upper Nut, Strut Rebound Stopper, Lower Nut, Strut Support, Plate, Upper Mount Assy, Dust Boot, Spring, Ride Height Adjuster, Locking Spring, Locking Bracket, Bracket.

Rear Components: Flange Nut (Thick), Plate, Body, Factory Spherical Collar, Dust Boot, Bump Stop Plate, Bump Rubber, Locking Bracket, Spherical Nut, Rear Ride Height Adjuster Assy, Locking Spring, Ride Height Adjuster, Rear Spring, Spring Lower Seat.

Installation Procedure

Removing the Factory Front Suspensions

1. Remove the cowl top garnish (left side) and right side cover.
2. Jack up the vehicle and remove wheels.
3. Disconnect the speed sensor harness, brake line bolt, and stabilizer joint nut.
4. Remove the bolts from the lower front suspension assembly.
5. Remove the nut from the upper front suspension assembly.
6. Remove the factory front suspension assembly from the vehicle.
7. Adjust the position of the speed sensor grommet using tie wraps as instructed for ZC21S and ZC31S models.
8. Remove the rear side harness of the speed sensor harness.
9. Bend the front side bracket backward.
10. NOTICE: Be careful not to pull on the brake line and ABS sensor when removing the front suspension assembly.

Installing the Front Suspensions

1. Install factory parts to the provided front suspension assembly.
2. Install the provided front suspension assembly to the vehicle using the upper front suspension assembly installation nut.
3. Install the lower front suspension assembly bolts, stabilizer joint nut, brake line installation bolt, and speed sensor harness.
4. Secure the speed sensor harness with tie wraps if it contacts other parts.
5. Mount the wheels and lower the vehicle.
6. Reinstall the right side cover and cowl top garnish.
7. CAUTION: Ensure the product does not contact wheels/tires after re-mounting. Wheel alignment is required after installation.

Removing the Factory Rear Suspensions

1. Remove the trunk side trim.
2. Jack up the vehicle and remove wheels.
3. Remove the nut from the lower rear shock absorber assembly.
4. Remove the factory spring.
5. Remove the nut from the upper rear shock absorber assembly.
6. Remove the factory rear shock absorber assembly from the vehicle.
7. NOTICE: Be careful not to pull on the brake line and ABS sensor when removing the rear suspension assembly.

Installing the Rear Suspensions

1. Install factory parts to the provided rear shock absorber assembly.
2. Install the provided rear shock absorber assembly to the vehicle, temporarily tightening the thin flange nut.
3. Install the factory spring upper seat, rear ride height adjuster assembly, rear spring, and factory spring lower seat.
4. Install the thick flange nut.
5. Fully tighten the thin flange nut.
6. Mount the wheels and lower the vehicle.
7. Make a 10mm hole in the trunk side trim for the adjustment cable.
8. Remove the dial from the adjustment cable and install the cable to the adjustment shaft of the rear shock absorber assembly.
9. Adjust the screw position and tighten with the Allen wrench.
10. Install the trunk side trim and route the cable through the hole.
11. Attach the dial to the cable using the Allen wrench.
12. CAUTION: Ensure the product does not contact wheels/tires after re-mounting. Wheel alignment is required after installation.

Development Vehicle Data

Data from the test vehicle (Suzuki Swift Sport ZC31S, M16A 5MT) used during development is provided below. Note that minor variations may occur between individual vehicles.