mxma front fork assembly
DESCRIPTION
ghjk7TRANSCRIPT
Workshop manual
ProductExploded View
Disassembly & Assembling
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Frontfork
4357 / 4860 MX Multi Adjuster
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Introduction 2Exploded view 3Disassembly forkleg 4Disassembly screw-cap 15Assembling screw-cap 17Disassembly cartridge 18Disassembly compression holder 22Assembling compression holder 25Disassembly tap rebound 28Assembling tap rebound 32Assembling cartridge 35Assembling forkleg 38
Product
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Disassembly & Assembling
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Introduction
General notice:
Pay attention to the following notes, when you areworking with WP Suspension products as described inthis workshop manual.
Always use clean and professional tools.Regular you need next to the general equipment, thespecial tools of WP Suspension.These tools with a unique “T” number (available atWP Suspension) protect you from damaging the parts.
Always use aluminium protector-plates, when clampingour 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 withT131, T132 and T163.These parts must dry for at least four hours!!
Workshop manual
ProductExploded View
Disassembly & assembling
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Note the rebound position by turning theknob to the right.
After removing the rubber cap.Note the compression position byturning the screw to the right.
Clamp the outer-tube in (4357) T501S /(4860) T1403S and unscrew thescrew-cap. (size 24)Cap PA with T103.
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12_064
Disassembly forkleg
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Clamp the forkleg (axle-clamp) in thevice and let the outer-tube down.Pull the spring downwards...
...and place open-end spanner (size 22)on the hydraulic stop.
Unscrew the screw-cap.
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Remove the screw-cap from thepiston- rod.
12_070
Remove the preload spacers.
12_074
Pull the spring downwards and removethe spanner.
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Remove the spring.
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Remove the adjustment tube with theO-ring.
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Clamp the axle-clamp in the vice so thatthe forkleg is at an angle of ±45 degrees.
12_095
Unscrew the compression holder out ofthe axle-clamp. (size 19)(when the cartridge is rotating with theholder, bend the piston- rod a little bit tothe side)
12_096
Drain the oil out the forkleg.
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Remove holder compression.Caution: oil iscoming out the cartridge.
Disassemble the cartridge out theforkleg.
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12_099
Disassemble the dust-wiper.
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Disassemble the circlip.
Heat the outer-tube near the oilseal.(not too hot)
Pull with both hands the outer-tube fromthe inner-tube.
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Remove DU-bush inner-tube.
Remove DU-bush outer-tube.
Remove support ring.
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Disassemble the oilseal.Pay attention to the assemblingdirection!!!
Remove the circlip.
Remove the dust wiper.
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- Dust wiper- circlip- oilseal- support ring- DU-bush outer-tube- DU-bush inner-tube
Heat the axle-clamp.
Use (4357) T503S / (4860) T1404S...
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...and unscrew the inner-tube from theaxle-clamp.
Remove the O-ring out the groove of theaxle-clamp.
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1 2 - 1 1 4
Remove the inner-tube.
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Disassemble the adjustment knob.Pay attention to the steel balls andspring!!!
For PA version: Manual PA Front Fork2000
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Unscrew plastic holder adjustment tubeout of the screw-cap.
12_228
Remove air release screw with O-ring.
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Disassembly screw-cap
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- Rebound adjusting knob with steel balls and spring- holder adjustment tube- airrelease screw with O-ring- screw-cap with O-ring
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Assemble the air release screw
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Screw the holder adjustment tube in thescrew-cap.
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Grease the O-ring, steel balls and springwith T158.Assemble the knob with steel balls andspring.
12_233
Assembling screw-cap
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1. Clamp the tube with plug in theclamping-block (Tool T508S + T509).
2.
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Disassembly cartridge
3.
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Unscrew the screw sleeve (size 22).
Turn the screw sleeve out of the tube.
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Disassemble the piston-rod “complete”.Pay attention to the piston ring!!!
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Clamp the piston rod in T508S “not tootight” and unscrew the hydraulic stopfrom the piston-rod.
12_164
Remove the hydraulic stop.
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Remove the screw sleeve with springretainer.
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Disassemble the DU-bush withT507 and press it out the screw sleevewith support of the vice.
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- Spring retainer- screw sleeve- DU-bush
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Clamp the compression holder in thevice and unscrew the check-valve nut.(size 17)Version with a locking: remove thelocking with a file.12_124
Remove the check-valve nut.
12_125
Remove the check-valve spring.Pay attention to the assemblingdirection!!!
12_126
Disassembly holdercompression
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Remove the check-valve shim.
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Disassemble the compressionpiston with O-ring.Pay attention to the assemblingdirection!!!
12_128
Place a screwdriver on top of the holderand remove the entire shim packet.
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Disassemble the O-ring.
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Remove the copper washer.
12_131
- Holder compression- copper washer- O-ring- shims compression- piston compression with O- ring- shim check-valve- spring check-valve- nut check-valve
12_132
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Replace copper washer.
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Assemble the O-ring.
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Replace the entire shim packet.
12_135
Assembling holdercompression
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Replace piston.Pay attention to the assemblingdirection!!!
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Replace shim check-valve.
12_137
Replace spring check-valve.Pay attention to the assemblingdirection!!!
12_138
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Wetting the thread of the nut with T132and tighten it...
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...to a torque of 5Nm.
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Check if the spring is correctly placedin the chamber of the nut.
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Clamp the piston-rod (at the level wherethe hydraulic stop is mounted) in T508Sand unscrew the rebound tap.(Size 17)
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Remove the rebound tap “complete”.
12_144/145/146 -posterize
Remove the rebound spring.
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Disassembly tap rebound
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Pull the rebound needle with spring outof the tap rebound.
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Check the O-ring.
12_149
Pay attention to the position of thetriangular shims on the piston!!!Clamp the tap in the vice and unscrewthe nut. (Size 10)Version with locking: Remove thelocking with a file.
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Remove the nut.Pay attention to the assemblingdirection!!!
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Place a screwdriver on top of the tapand remove the entire shim packet.
12_152
Remove piston rebound.Pay attention to the assemblingdirection!!!
12_153
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Remove check-valve shims.
12_154
Remove spring check-valve.
12_155
- Rebound adjustment needle with O-ring- spring- tap rebound- spring check-valve- shims check-valve- piston rebound- shims- nut M6x0.5
12_156
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Assemble the spring and shims check-valve.
12_157
Assemble the piston rebound.Pay attention to the assemblingdirection!!!
12_158
Replace the shims.Pay attention to the position of thetriangular shims on the piston!!!
12_159
Assembling tap rebound
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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
Grease the O-ring of the adjustmentneedle with T158.
12_162
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Mount the needle with spring into the taprebound.
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Press with T507 the DU-bush into thescrew sleeve.
12_171
Clamp the piston-rod in T508S.At the level where the hydraulic stop ismounted.
12_172
Wetting the thread with T131.And screw the tap in the piston-rod.
12_173
Assembling cartridge
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Tighten the tap rebound.
12_174
Clamp the piston-rod “not too tight” inat the other side and replace the screwsleeve with spring retainer.
12_175
Screw the hydraulic stop “hand tight” tothe end of the thread of the piston-rod.
12_176
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Clamp the tube with plug in theclamping block (T508S and T509) andassemble the piston-rod “cpl.” into thetube.Guide the piston ring!!!12_177
Before assembling wet the thread ofthe screw sleeve with T131.
Screw the screw sleeve into the tube.
12_178
Tighten the screw sleeve.
12_179
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Replace a new O-ring in the groove ofthe axle-clamp.
12_180
Wetting the thread of the axle-clampwith T132.
12_181
Wetting the thread of the inner-tube withT132.
12_182
Assembling forkleg
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Assemble the inner-tube in the axle-clamp.
12_183
Screw very tight the inner-tube withT503S / T1404S.
12_184
Apply the dust wiper with T511.
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Place (4357) T512 / (4860) T1401 overthe inner-tube and assemble the dustwiper.
14_0008
Replace the circlip.
14_0011
Apply the innerside of the oilseal withT511 and the outerside with frontfork oil.
14_0010
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Assemble the oilseal.Pay attention to the assemblingdirection!!!
14_0012
Remove the tool and replace thesupport ring.
12_190
Assemble both DU-bushes.
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Slide carefully the outer-tube over theinner-tube.
12_193
Assemble with (4357) T502S / (4860)T1402S the DU-bush -with the flat side-and...
12_194
...tap or push it into the outer-tube.
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Use the other side of T502S / T1402S...
12_196
...and tap the oilseal into the outer-tube.
12_197
Assemble the circlip into the groove ofthe outer-tube.Important: Check this verycarefully!!!
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Assemble the dust wiper with T502S /T1402S.
12_199
Apply the O-ring of the compressionpiston with frontfork oil.
12_202
Place the cartridge into the forkleg.
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Assemble the cartridge in the center ofthe axle-clamp and tighten the holdercompression to a torque of 25Nm.
12_203
Assemble the adjustment tube with theO-ring into the piston-rod.
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Keep the outer-tube down and thepiston- rod a little bit extended (likepicture), fill the forkleg with oil till theedge of the outer-tube, wait a fewmoments, you will see air bubbles risingup.The oil must stay above the 4 holes ofthe inner-tube, if necesarry fill someextra oil in the forkleg.
12_206
Move the piston-rod (keep theadjustment tube on his place) severaltimes up and down till you feel that thecartridge is full with oil, (the damping issmooth over the entire stroke) mostly itis 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 withoil till about 25mm under the 4 holes ofthe inner-tube. Move the piston-rod andthe outer-tube at the same time severaltimes up and down over the entirestroke.
Push the piston-rod and outer-tube fullydown and adjust the oil level(airchamber) with T137S.
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Pull the piston-rod out and assemble thespring.
12_211
Pull the spring downwards and placeopen-end spanner 22 on the hydraulicstop.
12_212
Replace first the steel washer on thespring, then the preload spacer(s).
12_213
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Turn the adjusting knob completely tothe left.
12_220
Screw handtight the screw-cap on thepiston-rod.
12_221
Screw down the screw-cap, till the hydr.stop is against the screw-cap andtighten it to a torque of 20Nm.
12_222
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Pull the spring downwards and removethe spanner.
12_223
Tighten the screw-cap to a torque of25Nm.Use T103 with the PA version.
12_224
Position rebound!
12_225
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12_218
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Position compression!And replace the rubber cap.
12_226