WP 4860 MXMA Workshop Manual
Workshop manual
4860 MXMA
Product
Exploded View
Disassembly & Assembling
12_234
Frontfork 4860 MXMA 2003 05/2002
Frontfork
4860 MX Multi Adjuster 2003
Introduction 2
Exploded view 3
Disassembly forkleg 4
Disassembly cartridge 17
Disassembly compression holder 21
Assembling compression holder 24
Disassembly tap rebound 27
Assembling tap rebound 31
Assembling cartridge 34
Assembling forkleg 37
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Workshop manual
4860 MXMA
Product
Exploded View
Disassembly & Assembling
General notice:
Pay attention to the following notes, when you are
working with WP Suspension products as described in
this workshop manual.
Always use clean and professional tools.
Regular you need next to the general equipment, the
special tools of WP Suspension.
These tools with a unique “T” number (available at
WP Suspension) protect you from damaging the parts.
Introduction
Always use aluminium protector-plates, when clamping
our products or parts in the vice.
Always replace damaged or worn parts.
Clean all parts before assembling.
Caution:
Many times it is necesarry to assemble parts with
T131, T132 and T163.
These parts must dry for at least four hours!!
Frontfork 4860 MXMA 2003 05/2002
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Workshop manual
4860 MXMA
Product
Exploded View
Disassembly & assembling
Exploded view
Frontfork 4860 MXMA 2003 05/2002
3
Workshop manual
4860 MXMA
Product
Exploded View
Disassembly & Assembling
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Disassembly forkleg
Note the rebound position by turning the
knob to the right.
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After removing the rubber cap.
Note the compression position by
turning the screw to the right.
Clamp the outer-tube in T1403S and
unscrew the screw-cap PA with T103.
Frontfork 4860 MXMA 2003 05/2002
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Workshop manual
4860 MXMA
Product
Exploded View
Disassembly & Assembling
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Clamp the forkleg (axle-clamp) in the
vice and let the outer-tube down.
Pull the spring downwards...
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...and place open-end spanner (size 22)
on the hydraulic stop.
Unscrew the screw-cap.
Frontfork 4860 MXMA 2003 05/2002
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Workshop manual
4860 MXMA
Product
Exploded View
Disassembly & Assembling
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Remove the screw-cap from the
piston- rod.
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Remove the preload spacers.
Pull the spring downwards and remove
the spanner.
Frontfork 4860 MXMA 2003 05/2002
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Workshop manual
4860 MXMA
Product
Exploded View
Disassembly & Assembling
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Remove the spring.
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Remove the adjustment tube with the
O-ring.
Frontfork 4860 MXMA 2003 05/2002
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Workshop manual
4860 MXMA
Product
Exploded View
Disassembly & Assembling
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Drain the oil out the forkleg.
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Clamp the axle-clamp in the vice so that
the forkleg is at an angle of ±45 degrees.
Unscrew the compression holder out of
the axle-clamp. (size 19)
(when the cartridge is rotating with the
holder, bend the piston- rod a little bit to
the side)
Frontfork 4860 MXMA 2003 05/2002
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Workshop manual
4860 MXMA
Product
Exploded View
Disassembly & Assembling
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Remove holder compression.
Caution: oil iscoming out the cartridge.
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Disassemble the cartridge out the
forkleg.
Disassemble the dust-wiper.
Frontfork 4860 MXMA 2003 05/2002
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Workshop manual
4860 MXMA
Product
Exploded View
Disassembly & Assembling
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Disassemble the circlip.
Heat the outer-tube near the oilseal.
(not too hot)
Heat the outer-tube at this level..
Frontfork 4860 MXMA 2003 05/2002
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Workshop manual
4860 MXMA
Product
Exploded View
Disassembly & Assembling
Pull with both hands the outer-tube from
the inner-tube.
Remove DU-bush inner-tube.
1. Remove DU-bush.
Frontfork 4860 MXMA 2003 05/2002
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Workshop manual
4860 MXMA
Product
Exploded View
Disassembly & Assembling
Remove DU-bush inner-tube.
Remove DU-bush outer-tube.
Frontfork 4860 MXMA 2003 05/2002
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Workshop manual
4860 MXMA
Product
Exploded View
Disassembly & Assembling
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Remove support ring.
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Disassemble the oilseal.
Pay attention to the assembling
direction!!!
Frontfork 4860 MXMA 2003 05/2002
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Workshop manual
4860 MXMA
Product
Exploded View
Disassembly & Assembling
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Remove the circlip.
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Remove the dust wiper.
Frontfork 4860 MXMA 2003 05/2002
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Workshop manual
4860 MXMA
Product
Exploded View
Disassembly & Assembling
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Heat the axle-clamp.
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Use T1404S...
Frontfork 4860 MXMA 2003 05/2002
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Workshop manual
4860 MXMA
Product
Exploded View
Disassembly & Assembling
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...and unscrew the inner-tube from the
axle-clamp.
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Remove the inner-tube.
Remove the O-ring out the groove of the
axle-clamp.
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