WP 4860 - E Workshop Manual

Workshop manual
4860 MXMA
Product
Exploded View
Disassembly & Assembling
12_234
Frontfork
4860 MX Multi Adjuster 2003

05/2002
Introduction 2
Exploded view 3
Disassembly forkleg 4
Disassembly cartridge 17
Frontfork 4860 MXMA 2003
Disassembly compression holder 21

Assembling compression holder 24
Disassembly tap rebound 27
Assembling tap rebound 31
Assembling cartridge 34
Assembling forkleg 37
1
Workshop manual
4860 MXMA
Product
Exploded View
Introduction
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.
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!!
05/2002
2
Workshop manual
4860 MXMA
Product
Exploded View
Disassembly & assembling
Exploded view
05/2002
3
Workshop manual
4860 MXMA
Product
Exploded View
Disassembly forkleg
Note the rebound position by turning the

knob to the right.
12_062
After removing the rubber cap.

Note the compression position by
turning the screw to the right.
12_063
05/2002
Clamp the outer-tube in T1403S and

unscrew the screw-cap PA with T103.
4
Workshop manual
4860 MXMA
Product
Exploded View
Clamp the forkleg (axle-clamp) in the

vice and let the outer-tube down.
Pull the spring downwards...
12_067
...and place open-end spanner (size 22)

on the hydraulic stop.
12_068
05/2002
Unscrew the screw-cap.

5
Workshop manual
4860 MXMA
Product
Exploded View
Remove the screw-cap from the

piston- rod.
12_070
Remove the preload spacers.
12_074
05/2002
Pull the spring downwards and remove

the spanner.
12_075
6
Workshop manual
4860 MXMA
Product
Exploded View
Remove the spring.
12_076
Remove the adjustment tube with the

O-ring.
12_089
05/2002
7
Workshop manual
4860 MXMA
Product
Exploded View
Drain the oil out the forkleg.
12_094
Clamp the axle-clamp in the vice so that

the forkleg is at an angle of ±45 degrees.
12_095
05/2002
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)
12_096
8
Workshop manual
4860 MXMA
Product
Exploded View
Remove holder compression.

Caution: oil iscoming out the cartridge.
12_097
Disassemble the cartridge out the

forkleg.
12_098
05/2002
Disassemble the dust-wiper.

12_099
9
Workshop manual
4860 MXMA
Product
Exploded View
Disassemble the circlip.
12_100
Heat the outer-tube near the oilseal.

(not too hot)
05/2002
Heat the outer-tube at this level..

10
Workshop manual
4860 MXMA
Product
Exploded View
Pull with both hands the outer-tube from

the inner-tube.
Remove DU-bush inner-tube.

05/2002
1. Remove DU-bush.
11
Workshop manual
4860 MXMA
Product
Exploded View
Remove DU-bush inner-tube.
Remove DU-bush outer-tube.

05/2002
12
Workshop manual
4860 MXMA
Product
Exploded View
Remove support ring.
12_105
Disassemble the oilseal.

Pay attention to the assembling
direction!!!
12_106
05/2002
13
Workshop manual
4860 MXMA
Product
Exploded View
Remove the circlip.
12_107
Remove the dust wiper.
12_108
05/2002
14
Workshop manual
4860 MXMA
Product
Exploded View
Heat the axle-clamp.
12_111
Use T1404S...
12_112
05/2002
15
Workshop manual
4860 MXMA
Product
Exploded View
...and unscrew the inner-tube from the

axle-clamp.
12_113
Remove the inner-tube.
12-114
05/2002
Remove the O-ring out the groove of the

axle-clamp.
12_115
16
Workshop manual
4860 MXMA
Product
Exploded View
Disassembly cartridge
1. Clamp the tube with plug in the

clamping-block (Tool T508S + T509).
12_116
2.
12_117
05/2002
3.
12_118
17
Workshop manual
4860 MXMA
Product
Exploded View
Unscrew the screw sleeve (size 22).
12_119
Turn the screw sleeve out of the tube.
12_120
05/2002
Disassemble the piston-rod “complete”.

Pay attention to the piston ring!!!
12_121
18
Workshop manual
4860 MXMA
Product
Exploded View
Clamp the piston rod in T508S “not too

tight” and unscrew the hydraulic stop
from the piston-rod.
12_164
Remove the hydraulic stop.
12_165
05/2002
19
Workshop manual
4860 MXMA
Product
Exploded View
Remove the screw sleeve with spring

retainer.
12_167
Disassemble the DU-bush with

T507 and press it out the screw sleeve
with support of the vice.
12_168
05/2002
- Spring retainer
- screw sleeve
- DU-bush
12_169
20
Workshop manual
4860 MXMA
Product
Exploded View
Disassembly holder
compression
Clamp the compression holder in the
vice and unscrew the check-valve nut.
(size 17)
Version with a locking: remove the
12_124 locking with a file.
Remove the check-valve nut.
12_125
05/2002
Remove the check-valve spring.

direction!!!
12_126
21
Workshop manual
4860 MXMA
Product
Exploded View
Remove the check-valve shim.
12_127
Disassemble the compression

piston with O-ring.
direction!!!
12_128
05/2002
Place a screwdriver on top of the holder

and remove the entire shim packet.
12_129
22
Workshop manual
4860 MXMA
Product
Exploded View
Disassemble the O-ring.
12_130
Remove the copper washer.
12_131
05/2002
- Holder compression
- copper washer
- O-ring
- shims compression
12_132 - piston compression with O-
ring
- shim check-valve
- spring check-valve
- nut check-valve
23
Workshop manual
4860 MXMA
Product
Exploded View
Assembling holder
compression
Replace copper washer.
12_133
Assemble the O-ring.
12_134
05/2002
Replace the entire shim packet.

12_135
24
Workshop manual
4860 MXMA
Product
Exploded View
Replace piston.
direction!!!
12_136
Replace shim check-valve.
12_137
05/2002
Replace spring check-valve.

direction!!!
12_138
25
Workshop manual
4860 MXMA
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Exploded View
Wetting the thread of the nut with T132

and tighten it...
12_140
...to a torque of 5Nm.
12_141
05/2002
Check if the spring is correctly placed

in the chamber of the nut.
12_142
26
Workshop manual
4860 MXMA
Product
Exploded View
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_143
Remove the rebound tap “complete”.
12_144/
145/146 -
posterize
05/2002
Remove the rebound spring.

12_147
27
Workshop manual
4860 MXMA
Product
Exploded View
Pull the rebound needle with spring out

of the tap rebound.
12_148
Check the O-ring.
12_149
05/2002
Pay attention to the position of the

triangular shims on the piston!!!
Clamp the tap in the vice and unscrew

the nut. (Size 10)
12_150 Version with locking: Remove the
locking with a file.
28
Workshop manual
4860 MXMA
Product
Exploded View
Remove the nut.

direction!!!
12_151
Place a screwdriver on top of the tap

and remove the entire shim packet.
12_152
05/2002
Remove piston rebound.

direction!!!
12_153
29
Workshop manual
4860 MXMA
Product
Exploded View
Remove check-valve shims.
12_154
Remove spring check-valve.
12_155
05/2002
- Rebound adjustment needle with

O-ring
- spring
- tap rebound
12_156 - spring check-valve
- shims check-valve
- piston rebound
- shims
- nut M6x0.5
30
Workshop manual
4860 MXMA
Product
Exploded View
Assembling tap rebound
Assemble the spring and shims check-

valve.
12_157
Assemble the piston rebound.

direction!!!
12_158
05/2002
Replace the shims.

Pay attention to the position of the
triangular shims on the piston!!!
12_159
31
Workshop manual
4860 MXMA
Product
Exploded View
Wetting the thread of the nut with T132.

Screw the nut on the tap...
12_160
...tighten the nut to a torque of 5 Nm.
12_161
05/2002
Grease the O-ring of the adjustment

needle with T158.
12_162
32
Workshop manual
4860 MXMA
Product
Exploded View
Mount the needle with spring into the tap

rebound.
12_163
05/2002
33
Workshop manual
4860 MXMA
Product
Exploded View
Assembling cartridge
Press with T507 the DU-bush into the

screw sleeve.
12_171
Clamp the piston-rod in T508S.

At the level where the hydraulic stop is
mounted.
12_172
05/2002
Wetting the thread with T131.

And screw the tap in the piston-rod.
12_173
34
Workshop manual
4860 MXMA
Product
Exploded View
Tighten the tap rebound.
12_174
Clamp the piston-rod “not too tight” in

at the other side and replace the screw
sleeve with spring retainer.
12_175
05/2002
Screw the hydraulic stop “hand tight” to

the end of the thread of the piston-rod.
12_176
35
Workshop manual
4860 MXMA
Product
Exploded View
Clamp the tube with plug in the

clamping block (T508S and T509) and
assemble the piston-rod “cpl.” into the
tube.
12_177 Guide the piston ring!!!
Before assembling wet the thread of

the screw sleeve with T131.
Screw the screw sleeve into the tube.

12_178
05/2002
Tighten the screw sleeve.

12_179
36
Workshop manual
4860 MXMA
Product
Exploded View
Assembling forkleg
Replace a new O-ring in the groove of

the axle-clamp.
12_180
Wetting the thread of the axle-clamp

with T132.
12_181
05/2002
Wetting the thread of the inner-tube with

T132.
12_182
37
Workshop manual
4860 MXMA
Product
Exploded View
Assemble the inner-tube in the axle-

clamp.
12_183
Screw very tight the inner-tube with

T503S / T1404S.
12_184
05/2002
Apply the dust wiper with T511.

14_0007
38
Workshop manual
4860 MXMA
Product
Exploded View
Place T1401 over the inner-tube and

assemble the dust wiper.
14_0008
Replace the circlip.
14_0011
05/2002
Apply the innerside of the oilseal with

T511 and the outerside with frontfork oil.
14_0010
39
Workshop manual
4860 MXMA
Product
Exploded View
Assemble the oilseal.

direction!!!
14_0012
Remove the tool and replace the

support ring.
12_190
05/2002
40
Workshop manual
4860 MXMA
Product
Exploded View
Replace the DU-bush.
Replace the tube.

05/2002
Replace the DU-bush.

41
Workshop manual
4860 MXMA
Product
Exploded View
Replace the DU-bush on the inner-tube.
Slide carefully the outer-tube over the

inner-tube.
05/2002
42
Workshop manual
4860 MXMA
Product
Exploded View
Assemble with T1402S the DU-bush -

with the flat side- and...
12_194
...tap or push it into the outer-tube.
12_195
05/2002
43
Workshop manual
4860 MXMA
Product
Exploded View
Use the other side of T1402S...
12_196
...and tap the oilseal into the outer-tube.
12_197
05/2002
Assemble the circlip into the groove of

the outer-tube.
Important: Check this very

carefully!!!
12_198
44
Workshop manual
4860 MXMA
Product
Exploded View
Assemble the dust wiper with T1402S.
12_199
Place the cartridge into the forkleg.

05/2002
Apply the O-ring of the compression

piston with frontfork oil.
12_202
45
Workshop manual
4860 MXMA
Product
Exploded View
Assemble the cartridge in the center of

the axle-clamp and tighten the holder
compression to a torque of 25Nm.
12_203
Assemble the adjustment tube with the

O-ring into the piston-rod.
12_204
05/2002
46
Workshop manual
4860 MXMA
Product
Exploded View
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
12_206 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.
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
12_208 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 outer-
tube fully down, and fill the forkleg with
oil till about 25mm under the 4 holes of
the inner-tube. Move the piston-rod and
05/2002
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.
12_209
47
Workshop manual
4860 MXMA
Product
Exploded View
Pull the piston-rod out and assemble the

spring.
12_211
Pull the spring downwards and place

open-end spanner 22 on the hydraulic
stop.
12_212
05/2002
Replace first the steel washer on the

spring, then the preload spacer(s).
12_213
48
Workshop manual
4860 MXMA
Product
Exploded View
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.
05/2002
49
Workshop manual
4860 MXMA
Product
Exploded View
Pull the spring downwards and remove

the spanner.
Tighten the screw-cap with T103.

05/2002
Position rebound!
50
Workshop manual
4860 MXMA
Product
Exploded View
Position compression!
And replace the rubber cap.
12_226
05/2002
51

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Workshop manual

4860 MX Multi Adjuster 2003

Disassembly compression holder 21

Pay attention to the following notes, when you are

Always use clean and professional tools.

Always use aluminium protector-plates, when clamping

Always replace damaged or worn parts.

Clean all parts before assembling.

Note the rebound position by turning the

After removing the rubber cap.

Clamp the outer-tube in T1403S and

Clamp the forkleg (axle-clamp) in the

...and place open-end spanner (size 22)

Unscrew the screw-cap.

Remove the screw-cap from the

Remove the preload spacers.

Pull the spring downwards and remove

Remove the spring.

Remove the adjustment tube with the

Drain the oil out the forkleg.

Clamp the axle-clamp in the vice so that

Unscrew the compression holder out of

(when the cartridge is rotating with the

Remove holder compression.

Disassemble the cartridge out the

Disassemble the dust-wiper.

Disassemble the circlip.

Heat the outer-tube near the oilseal.

Heat the outer-tube at this level..

Pull with both hands the outer-tube from

Remove DU-bush inner-tube.

Remove DU-bush inner-tube.

Remove DU-bush outer-tube.

Remove support ring.

Disassemble the oilseal.

Remove the circlip.

Remove the dust wiper.

Heat the axle-clamp.

...and unscrew the inner-tube from the

Remove the inner-tube.

Remove the O-ring out the groove of the

1. Clamp the tube with plug in the

Unscrew the screw sleeve (size 22).

Turn the screw sleeve out of the tube.

Disassemble the piston-rod “complete”.

Clamp the piston rod in T508S “not too

Remove the hydraulic stop.

Remove the screw sleeve with spring

Disassemble the DU-bush with

Remove the check-valve nut.

Remove the check-valve spring.

Remove the check-valve shim.

Disassemble the compression

Place a screwdriver on top of the holder

Disassemble the O-ring.