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4860 MXMA
Workshop Manual
51 pgs1.6 Mb7

WP 4860 MXMA Workshop Manual

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Page 1
Workshop manual
4860 MXMA
Product
Exploded View Disassembly & Assembling
12_234
Frontfork 4860 MXMA 2003 05/2002
Frontfork
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!!
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Workshop manual
4860 MXMA
Product
Exploded View
Disassembly & assembling
Exploded view
Frontfork 4860 MXMA 2003 05/2002
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Workshop manual
4860 MXMA
Product Exploded View
Disassembly & Assembling
12_062
Disassembly forkleg
Note the rebound position by turning the knob to the right.
12_063
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.
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Workshop manual
4860 MXMA
Product Exploded View
Disassembly & Assembling
12_067
Clamp the forkleg (axle-clamp) in the vice and let the outer-tube down. Pull the spring downwards...
12_068
...and place open-end spanner (size 22) on the hydraulic stop.
Unscrew the screw-cap.
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Workshop manual
4860 MXMA
Product Exploded View
Disassembly & Assembling
12_070
Remove the screw-cap from the piston- rod.
12_074
12_075
Remove the preload spacers.
Pull the spring downwards and remove the spanner.
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Workshop manual
4860 MXMA
Product Exploded View
Disassembly & Assembling
12_076
Remove the spring.
12_089
Remove the adjustment tube with the O-ring.
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Workshop manual
4860 MXMA
Product Exploded View
Disassembly & Assembling
12_094
Drain the oil out the forkleg.
12_095
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)
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12_096
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Workshop manual
4860 MXMA
Product Exploded View
Disassembly & Assembling
12_097
Remove holder compression. Caution: oil iscoming out the cartridge.
12_098
Disassemble the cartridge out the forkleg.
Disassemble the dust-wiper.
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12_099
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Workshop manual
4860 MXMA
Product Exploded View
Disassembly & Assembling
12_100
Disassemble the circlip.
Heat the outer-tube near the oilseal. (not too hot)
Heat the outer-tube at this level..
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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.
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Workshop manual
4860 MXMA
Product Exploded View
Disassembly & Assembling
Remove DU-bush inner-tube.
Remove DU-bush outer-tube.
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Workshop manual
4860 MXMA
Product Exploded View
Disassembly & Assembling
12_105
Remove support ring.
12_106
Disassemble the oilseal. Pay attention to the assembling direction!!!
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Workshop manual
4860 MXMA
Product Exploded View
Disassembly & Assembling
12_107
Remove the circlip.
12_108
Remove the dust wiper.
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4860 MXMA
Product Exploded View
Disassembly & Assembling
12_111
Heat the axle-clamp.
12_112
Use T1404S...
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Workshop manual
4860 MXMA
Product Exploded View
Disassembly & Assembling
12_113
...and unscrew the inner-tube from the axle-clamp.
12-114
12_115
Remove the inner-tube.
Remove the O-ring out the groove of the axle-clamp.
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Workshop manual
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Product Exploded View
Disassembly & Assembling
12_116
Disassembly cartridge
1. Clamp the tube with plug in the clamping-block (Tool T508S + T509).
12_117
12_118
2.
3.
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Product Exploded View
Disassembly & Assembling
12_119
Unscrew the screw sleeve (size 22).
12_120
12_121
Turn the screw sleeve out of the tube.
Disassemble the piston-rod “complete”. Pay attention to the piston ring!!!
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Product Exploded View
Disassembly & Assembling
12_164
Clamp the piston rod in T508S “not too tight” and unscrew the hydraulic stop from the piston-rod.
12_165
Remove the hydraulic stop.
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Workshop manual
4860 MXMA
Product Exploded View
Disassembly & Assembling
12_167
Remove the screw sleeve with spring retainer.
12_168
12_169
Disassemble the DU-bush with T507 and press it out the screw sleeve with support of the vice.
- Spring retainer
- screw sleeve
- DU-bush
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Workshop manual
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Product Exploded View
Disassembly & Assembling
12_124
Disassembly holder compression
Clamp the compression holder in the vice and unscrew the check-valve nut. (size 17) Version with a locking: remove the locking with a file.
12_125
12_126
Remove the check-valve nut.
Remove the check-valve spring. Pay attention to the assembling direction!!!
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4860 MXMA
Product Exploded View
Disassembly & Assembling
12_127
Remove the check-valve shim.
12_128
12_129
Disassemble the compression piston with O-ring. Pay attention to the assembling direction!!!
Place a screwdriver on top of the holder and remove the entire shim packet.
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Product Exploded View
Disassembly & Assembling
12_130
Disassemble the O-ring.
12_131
12_132
Remove the copper washer.
- Holder compression
- copper washer
- O-ring
- shims compression
- piston compression with O­ ring
- shim check-valve
- spring check-valve
- nut check-valve
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Product Exploded View
Disassembly & Assembling
12_133
Assembling holder compression
Replace copper washer.
12_134
12_135
Assemble the O-ring.
Replace the entire shim packet.
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Product Exploded View
Disassembly & Assembling
12_136
Replace piston. Pay attention to the assembling direction!!!
12_137
12_138
Replace shim check-valve.
Replace spring check-valve. Pay attention to the assembling direction!!!
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Product Exploded View
Disassembly & Assembling
12_140
Wetting the thread of the nut with T132 and tighten it...
12_141
12_142
...to a torque of 5Nm.
Check if the spring is correctly placed in the chamber of the nut.
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Product Exploded View
Disassembly & Assembling
12_143
Disassembly tap rebound
Clamp the piston-rod (at the level where the hydraulic stop is mounted) in T508S and unscrew the rebound tap. (Size 17)
12_144/ 145/146 - posterize
12_147
Remove the rebound tap “complete”.
Remove the rebound spring.
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Product Exploded View
Disassembly & Assembling
12_148
Pull the rebound needle with spring out of the tap rebound.
12_149
12_150
Check the O-ring.
Pay attention to the position of the triangular shims on the piston!!! Clamp the tap in the vice and unscrew the nut. (Size 10) Version with locking: Remove the locking with a file.
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Workshop manual
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Product Exploded View
Disassembly & Assembling
12_151
Remove the nut. Pay attention to the assembling direction!!!
12_152
12_153
Place a screwdriver on top of the tap and remove the entire shim packet.
Remove piston rebound. Pay attention to the assembling direction!!!
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Workshop manual
4860 MXMA
Product Exploded View
Disassembly & Assembling
12_154
Remove check-valve shims.
12_155
12_156
Remove spring check-valve.
- Rebound adjustment needle with O-ring
- spring
- tap rebound
- spring check-valve
- shims check-valve
- piston rebound
- shims
- nut M6x0.5
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Product Exploded View
Disassembly & Assembling
12_157
Assembling tap rebound
Assemble the spring and shims check­valve.
12_158
12_159
Assemble the piston rebound. Pay attention to the assembling direction!!!
Replace the shims.
Pay attention to the position of the triangular shims on the piston!!!
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Workshop manual
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Product Exploded View
Disassembly & Assembling
12_160
Wetting the thread of the nut with T132. Screw the nut on the tap...
12_161
12_162
...tighten the nut to a torque of 5 Nm.
Grease the O-ring of the adjustment needle with T158.
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Product Exploded View
Disassembly & Assembling
12_163
Mount the needle with spring into the tap rebound.
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Product Exploded View
Disassembly & Assembling
12_171
Assembling cartridge
Press with T507 the DU-bush into the screw sleeve.
12_172
12_173
Clamp the piston-rod in T508S. At the level where the hydraulic stop is mounted.
Wetting the thread with T131. And screw the tap in the piston-rod.
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Product Exploded View
Disassembly & Assembling
12_174
Tighten the tap rebound.
12_175
12_176
Clamp the piston-rod “not too tight” in at the other side and replace the screw sleeve with spring retainer.
Screw the hydraulic stop “hand tight” to the end of the thread of the piston-rod.
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Workshop manual
4860 MXMA
Product Exploded View
Disassembly & Assembling
12_177
Clamp the tube with plug in the clamping block (T508S and T509) and assemble the piston-rod “cpl.” into the tube. Guide the piston ring!!!
12_178
12_179
Before assembling wet the thread of the screw sleeve with T131.
Screw the screw sleeve into the tube.
Tighten the screw sleeve.
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Product Exploded View
Disassembly & Assembling
12_180
Assembling forkleg
Replace a new O-ring in the groove of the axle-clamp.
12_181
12_182
Wetting the thread of the axle-clamp with T132.
Wetting the thread of the inner-tube with T132.
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Workshop manual
4860 MXMA
Product Exploded View
Disassembly & Assembling
12_183
Assemble the inner-tube in the axle­clamp.
12_184
14_0007
Screw very tight the inner-tube with T503S / T1404S.
Apply the dust wiper with T51 1.
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Workshop manual
4860 MXMA
Product Exploded View
Disassembly & Assembling
14_0008
Place T1401 over the inner-tube and assemble the dust wiper.
14_0011
14_0010
Replace the circlip.
Apply the innerside of the oilseal with T51 1 and the outerside with frontfork oil.
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Product Exploded View
Disassembly & Assembling
14_0012
Assemble the oilseal. Pay attention to the assembling direction!!!
12_190
Remove the tool and replace the support ring.
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Workshop manual
4860 MXMA
Product Exploded View
Disassembly & Assembling
Replace the DU-bush.
Replace the tube.
Replace the DU-bush.
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Workshop manual
4860 MXMA
Product Exploded View
Disassembly & Assembling
Replace the DU-bush on the inner-tube.
Slide carefully the outer-tube over the inner-tube.
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4860 MXMA
Product Exploded View
Disassembly & Assembling
12_194
Assemble with T1402S the DU-bush ­with the flat side- and...
12_195
...tap or push it into the outer-tube.
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4860 MXMA
Product Exploded View
Disassembly & Assembling
12_196
Use the other side of T1402S...
12_197
12_198
...and tap the oilseal into the outer-tube.
Assemble the circlip into the groove of the outer-tube.
Important: Check this very carefully!!!
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Product Exploded View
Disassembly & Assembling
12_199
Assemble the dust wiper with T1402S.
12_202
Place the cartridge into the forkleg.
Apply the O-ring of the compression piston with frontfork oil.
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4860 MXMA
Product Exploded View
Disassembly & Assembling
12_203
Assemble the cartridge in the center of the axle-clamp and tighten the holder compression to a torque of 25Nm.
12_204
Assemble the adjustment tube with the O-ring into the piston-rod.
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Product Exploded View
Disassembly & Assembling
12_206
Keep the outer-tube down and the piston- rod a little bit extended (like picture), fill the forkleg with oil till the edge of the outer-tube, wait a few moments, you will see air bubbles rising up. The oil must stay
above the 4 holes of the inner-tube, if necesarry fill some extra oil in the forkleg.
12_208
12_209
Move the piston-rod (keep the adjustment tube on his place) several times up and down till you feel that the cartridge is full with oil, (the damping is smooth over the entire stroke) mostly it is necesarry to fill some (not too much) extra oil in the forkleg. Now compress the piston-rod and outer­tube fully down, and fill the forkleg with oil till about 25mm
under the 4 holes of the inner-tube. Move the piston-rod and the outer-tube at the same time several times up and down over the entire stroke.
Push the piston-rod and outer-tube fully down and adjust the oil level (airchamber) with T137S.
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4860 MXMA
Product Exploded View
Disassembly & Assembling
12_211
Pull the piston-rod out and assemble the spring.
12_212
12_213
Pull the spring downwards and place open-end spanner 22 on the hydraulic stop.
Replace first the steel washer on the spring, then the preload spacer(s).
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Workshop manual
4860 MXMA
Product Exploded View
Disassembly & Assembling
Screw handtight the screw-cap on the piston-rod.
Screw down the screw-cap, till the hydr. stop is against the screw-cap and tighten it to a torque of 25Nm.
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Workshop manual
4860 MXMA
Product Exploded View
Disassembly & Assembling
Pull the spring downwards and remove the spanner.
Tighten the screw-cap with T103.
Position rebound!
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4860 MXMA
Product Exploded View
Disassembly & Assembling
12_226
Position compression! And replace the rubber cap.
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