Excerpts from the 2005 Official Copen Catalog (Pages 16–20,From roof mechanism to suspension tuning) More pages to come — the full catalog will be featured in upcoming posts.

 Active Top

A single switch takes you to another world.
That door—
The first electric retractable roof in a kei car:
Active Top.

Open-air cruising, closer than ever.
To place yourself in a space with nothing to block you—
No barriers, just the sky.
To feel every sensation of driving and nature, united as one.
We wanted to turn that overwhelming joy into an everyday reality for everyone.
And so, we developed the first electric retractable hardtop ever in a kei car.

Just unlock the roof, press the switch,
and in only about 20 seconds,
the drama begins—
a drive painted in light and wind,
all while you remain in your cockpit.

Made from lightweight aluminum,
the roof offers excellent durability against sunlight and sound,
and also enhances theft protection.
It operates with a hydraulic pump and is supported by four motors
that move the side and quarter windows.
A total of 12 sensors constantly monitor system status,
ensuring reliable movement and safety.

Even when closed, the Active Top completes a graceful coupe silhouette.
It also enhances cabin spaciousness and light.
In every way, it harmonizes design and practicality.

With the roof closed, the trunk offers enough capacity to store one golf bag,* providing generous space.
Even with the roof open, there’s still room to fit a handbag or other small items.
For Active Top models, the trunk lid features a power gate closer system, which automatically secures the lid when lightly pressed.

*Note: Capacity may vary depending on the size of the golf bag.

We entrusted this design with two dreams:
the dream of exhilarating driving,
and the dream of owning a car that brings joy across generations.

Built on a cabin-forward layout made possible by the FF drivetrain,
the design features a teardrop-shaped silhouette that evokes low center of gravity and powerful motion.
Its voluminous and fluid surface composition, paired with symmetrical front and rear lighting elements,
creates a form that is both solid and serene — yet instantly approachable and unmistakably unique.

"Harnessing sharp power for a performance-driven ride."

The transmission is engineered to extract the full potential of the engine’s responsive power.

The 5-speed manual prioritizes acceleration with a specially tuned close-ratio gear setup.
The shift stroke is shortened by 20% compared to previous models, and the synchronizer rings are molybdenum-coated, delivering precise and comfortable gear engagement.
MT models are also equipped with a front Super-LSD*, which distributes optimal driving force to the left and right front wheels depending on the conditions—ensuring sharp cornering and enhancing the joy of total driving control.

The electronically controlled 4-speed automatic, equipped with Super Active Shift (ESAT)**, offers the thrill of sporty driving even in AT.
By precisely controlling torque converter slippage, it delivers a direct and exhilarating acceleration feel.
Super Active Shift allows for minimal shift lag and responds instantly even in quick successions of gear changes like 4-3-2-1.
It provides a shifting feel that rivals that of a manual transmission.

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*LSD: Limited Slip Differential
**ESAT: Economy & Smooth Automatic Transmission

"A power feel that connects straight to your heart."

Step on the accelerator, and it responds instantly, revving up smoothly.
From low revs, you feel solid torque enveloping you, and as the RPM climbs, acceleration thrills your chest.
To deliver such an exhilarating drive, we further tuned the already trusted and refined twin-cam 4-cylinder 16-valve EFI turbo engine.

The exhaust manifold adopts a dual-flow layout to avoid interference between exhaust pulses, improving turbo efficiency from low RPMs.
A compact turbo unit minimizes inertia and improves throttle response.
Additionally, a specially developed abradable seal is used on the compressor side to boost responsiveness — delivering 90% of maximum torque at just 2,000 rpm.
This provides both high responsiveness and class-leading torque for a direct, emotionally engaging drive.

We also refined the exhaust system to reduce back pressure, enhancing both power and response, while producing a satisfying, linear exhaust note that deepens the joy of acceleration.

The front-end module integrates an intercooler and compact oil filter, optimizing space efficiency.
And of course, the engine complies with Japan’s 2005 emissions regulations (Heisei 17), offering excellent fuel economy and thorough environmental consideration.

“Rigidity and lightness, rooted in sports car heritage.”

How can a car respond linearly to accelerator and steering input?
At the heart of that challenge lies structural rigidity and weight reduction.

Copen begins with the underbody, reinforcing it through highly efficient methods that prioritize lightness.
The floor panel adopts a three-piece layout, thickened only around the center tunnel where rigidity is crucial.
Furthermore, brace structures are employed to strengthen joint rigidity between core sections.
Five types of braces, including double cross beams, are strategically positioned to provide rigidity beyond that of a closed-body vehicle.
Combined with reinforced suspension mounting points, this delivers both precise handling response and a composed, vibration-free ride—an unshakable sense of rigidity.

As for the upper body, aluminum components are used for the hood, the Active Top roof, and the trunk lid.
In addition, weight reduction was achieved by straightening the placement of braces in the front and center pillars, reducing brace mass itself.

These efforts resulted in a weight reduction of approximately 25 kg.
A newly developed resin front-end module integrates multiple components around the radiator, further reducing the front-end weight and contributing significantly to overall lightness.

By achieving both high rigidity and weight reduction—two typically opposing goals—Copen’s body is engineered to unleash its full performance potential.

“Stopping power with precision control — just as you intend.”

Braking is not just about coming to a stop — it’s about how naturally your intention is translated into motion.
Responsiveness must be sharp, with minimal change in the vehicle's posture.

To achieve this, play and looseness from the brake pedal to the tires has been minimized, enhancing pedal rigidity.
A large-diameter master cylinder shortens pedal stroke, while an 8-inch booster assists braking power, providing quick, responsive brake feel.
In addition, 14-inch ventilated disc brakes in the front, combined with high-friction brake pads, ensure powerful and fade-resistant stopping performance even for a high-output car.

These enhancements deliver consistent brake feel and confident deceleration across both dry and wet road conditions.
To prevent wheel lock during sudden stops, EBD-equipped ABS is standard.
A four-wheel independent brake control system has also been added, with rear left-right independent modulation.
This allows stable braking even during cornering or when road conditions differ between the left and right sides.

Paired with high-grip tires, Copen achieves one of the shortest braking distances among Japanese passenger cars — all with braking that responds linearly to your command.

"Agile handling that makes your feet long for the next corner."

Feel your heart race with the sensation of gripping the road — handling so intuitive and precise, it feels as if the car is part of your own body.
Copen delivers pure handling pleasure through a suspension system specially tuned for this goal.

Based on its inherently low center of gravity, the car adopts a MacPherson strut front suspension and a torsion beam rear suspension, with arm geometry optimized for maximum stability.
Roll axis, geometry, and steering characteristics are all finely tuned.
With high roll rigidity achieved by large-diameter stabilizers front and rear, the car offers precise line tracing and a highly natural roll feel.

Both the front and rear dampers are gas-filled for excellent responsiveness, and the cylinder design ensures high structural rigidity.
To further improve stability and steering feel, front suspension bush compliance has been minimized, and the rear features a Toe Correct Bush, a first for kei cars.
This setup enables superb straight-line stability and crisp steering feedback.

The tires are newly developed 15-inch models with 50% aspect ratio and directional tread design.
A well-balanced combination of tread and sidewall rigidity offers high responsiveness and strong grip, in both dry and wet conditions.

Together with the lightweight, high-rigidity body and short wheelbase, these features deliver agile turning performance and sharp steering response, while still maintaining a supple ride quality — true to the spirit of a lightweight sports car.

A special Sports Pack is also available, featuring stiffer springs and dampers.
In the rear, it includes a high-response, separate-type pressurized damper with external reservoir, enhancing high-speed cornering stability and maintaining a flat, composed ride.

"Steering feel refined — for performance and sensory delight."

To fully realize the Copen’s high dynamic potential, and to enhance the sheer pleasure of driving, a functional and intuitive interface was essential.

Copen adopts a hydraulic power steering system equipped with an engine speed-sensitive non-recirculating pump valve. This setup delivers light, agile steering response at low speeds, while providing solid, reassuring feedback at high speeds.

Furthermore, by increasing the mounting rigidity of the steering gear, the system achieves enhanced stability and precise control, offering a steering feel that is both responsive and confidence-inspiring.