Frontfork 4860 MX Multi Adjuster 2003

1 Workshop manualProductExploded ViewDisassembly & Assembling14860 MXMAF rontfork 4860 MXMA 200305/2002 Frontfork4860 MX Multi Adjuster 200312_234 Introduction2 Exploded view3 Disassembly forkleg4 Disassembly cartridge17 Disassembly compression holder21 Assembling compression holder24 Disassembly tap rebound27 Assembling tap rebound31 Assembling cartridge34 Assembling forkleg37 ProductExploded ViewDisassembly & AssemblingWorkshop manual4860 MXMA2 Frontfork 4860 MXMA 200305/2002 IntroductionGeneral notice:Pay attention to the following notes, when you areworking with WP Suspension products as described inthis workshop use clean and professional you need next to the general equipment, thespecial tools of WP tools with a unique T number (available atWP Suspension) protect you from damaging the use aluminium protector-plates, when clampingour products or parts in the replace damaged or worn all parts before :Many times it is necesarry to assemble parts withT131, T132 and parts must dry for at least four hours!

2 !Workshop manualProductExploded ViewDisassembly & assembling34860 MXMAF rontfork 4860 MXMA 200305/2002 Exploded viewProductExploded ViewDisassembly & AssemblingWorkshop manual4860 MXMA4 Frontfork 4860 MXMA 200305/2002 Note the rebound position by turning theknob to the removing the rubber the compression position byturning the screw to the the outer-tube in T1403S andunscrew the screw-cap PA with forkleg12_062 ProductExploded ViewDisassembly & AssemblingWorkshop manual4860 MXMA5 Frontfork 4860 MXMA 200305/2002 Clamp the forkleg (axle-clamp) in thevice and let the outer-tube the spring place open-end spanner (size 22)on the hydraulic the ViewDisassembly & AssemblingWorkshop manual4860 MXMA6 Frontfork 4860 MXMA 200305/2002 Remove the screw-cap from thepiston- the preload the spring downwards and removethe ViewDisassembly & AssemblingWorkshop manual4860 MXMA7 Frontfork 4860 MXMA 200305/2002 Remove the the adjustment tube with ViewDisassembly & AssemblingWorkshop manual4860 MXMA8 Frontfork 4860 MXMA 200305/2002 Clamp the axle-clamp in the vice so thatthe forkleg is at an angle of 45 the compression holder out ofthe axle-clamp.

3 (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 ViewDisassembly & AssemblingWorkshop manual4860 MXMA9 Frontfork 4860 MXMA 200305/2002 Remove holder : oil iscoming out the the cartridge out the ViewDisassembly & AssemblingWorkshop manual4860 MXMA10 Frontfork 4860 MXMA 200305/2002 Disassemble the the outer-tube near the oilseal.(not too hot)Heat the outer-tube at this ViewDisassembly & AssemblingWorkshop manual4860 MXMA11 Frontfork 4860 MXMA 200305/2002 Pull with both hands the outer-tube fromthe DU-bush Remove ViewDisassembly & AssemblingWorkshop manual4860 MXMA12 Frontfork 4860 MXMA 200305/2002 Remove DU-bush DU-bush ViewDisassembly & AssemblingWorkshop manual4860 MXMA13 Frontfork 4860 MXMA 200305/2002 Remove support the attention to the assemblingdirection!!!12_106 ProductExploded ViewDisassembly & AssemblingWorkshop manual4860 MXMA14 Frontfork 4860 MXMA 200305/2002 Remove the the dust ViewDisassembly & AssemblingWorkshop manual4860 MXMA15 Frontfork 4860 MXMA 200305/2002 Heat the ViewDisassembly & AssemblingWorkshop manual4860 MXMA16 Frontfork 4860 MXMA 200305 unscrew the inner-tube from the O-ring out the groove of the ViewDisassembly & AssemblingWorkshop manual4860 MXMA17 Frontfork 4860 MXMA 200305/20021.

4 Clamp the tube with plug in theclamping-block (Tool T508S + T509). ViewDisassembly & AssemblingWorkshop manual4860 MXMA18 Frontfork 4860 MXMA 200305/2002 Unscrew the screw sleeve (size 22).Turn the screw sleeve out of the the piston-rod complete .Pay attention to the piston ring!!!12_121 ProductExploded ViewDisassembly & AssemblingWorkshop manual4860 MXMA19 Frontfork 4860 MXMA 200305/2002 Clamp the piston rod in T508S not tootight and unscrew the hydraulic stopfrom the the hydraulic ViewDisassembly & AssemblingWorkshop manual4860 MXMA20 Frontfork 4860 MXMA 200305/2002 Remove the screw sleeve with the DU-bush withT507 and press it out the screw sleevewith support of the Spring retainer- screw sleeve- DU-bush12_169 ProductExploded ViewDisassembly & AssemblingWorkshop manual4860 MXMA21 Frontfork 4860 MXMA 200305/2002 Clamp the compression holder in thevice and unscrew the check-valve nut.(size 17)Version with a locking: remove thelocking with a the check-valve the check-valve attention to the assemblingdirection!

5 !!12_126 Disassembly holdercompressionProductExploded ViewDisassembly & AssemblingWorkshop manual4860 MXMA22 Frontfork 4860 MXMA 200305/2002 Remove the check-valve the compressionpiston with attention to the assemblingdirection!!!12_128 Place a screwdriver on top of the holderand remove the entire shim ViewDisassembly & AssemblingWorkshop manual4860 MXMA23 Frontfork 4860 MXMA 200305/2002 Disassemble the the copper Holder compression- copper washer- O-ring- shims compression- piston compression with O- ring- shim check-valve- spring check-valve- nut check-valve12_132 ProductExploded ViewDisassembly & AssemblingWorkshop manual4860 MXMA24 Frontfork 4860 MXMA 200305/2002 Replace copper the the entire shim holdercompressionProductExploded ViewDisassembly & AssemblingWorkshop manual4860 MXMA25 Frontfork 4860 MXMA 200305/2002 Replace attention to the assemblingdirection!!!12_136 Replace shim spring attention to the assemblingdirection!!!12_138 ProductExploded ViewDisassembly & AssemblingWorkshop manual4860 MXMA26 Frontfork 4860 MXMA 200305/2002 Wetting the thread of the nut with T132and tighten a torque of if the spring is correctly placedin the chamber of the ViewDisassembly & AssemblingWorkshop manual4860 MXMA27 Frontfork 4860 MXMA 200305/2002 Clamp the piston-rod (at the level wherethe hydraulic stop is mounted) in T508 Sand unscrew the rebound tap.

6 (Size 17)12_143 Remove the rebound tap complete .12_144/145/146 -posterizeRemove the rebound tap reboundProductExploded ViewDisassembly & AssemblingWorkshop manual4860 MXMA28 Frontfork 4860 MXMA 200305/2002 Pull the rebound needle with spring outof the tap the 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 ViewDisassembly & AssemblingWorkshop manual4860 MXMA29 Frontfork 4860 MXMA 200305/2002 Remove the attention to the assemblingdirection!!!12_151 Place a screwdriver on top of the tapand remove the entire shim piston attention to the assemblingdirection!!!12_153 ProductExploded ViewDisassembly & AssemblingWorkshop manual4860 MXMA30 Frontfork 4860 MXMA 200305/2002 Remove check-valve spring Rebound adjustment needle with O-ring- spring- tap rebound- spring check-valve- shims check-valve- piston rebound- shims- nut ViewDisassembly & AssemblingWorkshop manual4860 MXMA31 Frontfork 4860 MXMA 200305/2002 Assemble the spring and shims the piston attention to the assemblingdirection!

7 !!12_158 Replace the attention to the position of thetriangular shims on the piston!!!12_159 Assembling tap reboundProductExploded ViewDisassembly & AssemblingWorkshop manual4860 MXMA32 Frontfork 4860 MXMA 200305/2002 Wetting the thread of the nut with the nut on the the nut to a torque of 5 the O-ring of the adjustmentneedle with ViewDisassembly & AssemblingWorkshop manual4860 MXMA33 Frontfork 4860 MXMA 200305/2002 Mount the needle with spring into the ViewDisassembly & AssemblingWorkshop manual4860 MXMA34 Frontfork 4860 MXMA 200305/2002 Press with T507 the DU-bush into thescrew the piston-rod in the level where the hydraulic stop the thread with screw the tap in the cartridgeProductExploded ViewDisassembly & AssemblingWorkshop manual4860 MXMA35 Frontfork 4860 MXMA 200305/2002 Tighten the tap the piston-rod not too tight inat the other side and replace the screwsleeve with spring the hydraulic stop hand tight tothe end of the thread of the ViewDisassembly & AssemblingWorkshop manual4860 MXMA36 Frontfork 4860 MXMA

8 200305/2002 Clamp the tube with plug in theclamping block (T508S and T509) andassemble the piston-rod cpl. into the piston ring!!!12_177 Before assembling wet the thread ofthe screw sleeve with the screw sleeve into the the screw ViewDisassembly & AssemblingWorkshop manual4860 MXMA37 Frontfork 4860 MXMA 200305/2002 Replace a new O-ring in the groove ofthe the thread of the axle-clampwith the thread of the inner-tube forklegProductExploded ViewDisassembly & AssemblingWorkshop manual4860 MXMA38 Frontfork 4860 MXMA 200305/2002 Assemble the inner-tube in the very tight the inner-tube withT503S / the dust wiper with ViewDisassembly & AssemblingWorkshop manual4860 MXMA39 Frontfork 4860 MXMA 200305/2002 Place T1401 over the inner-tube andassemble the dust the the innerside of the oilseal withT511 and the outerside with Frontfork ViewDisassembly & AssemblingWorkshop manual4860 MXMA40 Frontfork 4860 MXMA 200305/2002 Assemble the attention to the assemblingdirection!

9 !!14_0012 Remove the tool and replace thesupport ViewDisassembly & AssemblingWorkshop manual4860 MXMA41 Frontfork 4860 MXMA 200305/2002 Replace the the the ViewDisassembly & AssemblingWorkshop manual4860 MXMA42 Frontfork 4860 MXMA 200305/2002 Slide carefully the outer-tube over the DU-bush on the ViewDisassembly & AssemblingWorkshop manual4860 MXMA43 Frontfork 4860 MXMA 200305/2002 Assemble with T1402S the DU-bush -with the flat side- or push it into the ViewDisassembly & AssemblingWorkshop manual4860 MXMA44 Frontfork 4860 MXMA 200305/2002 Use the other side of tap the oilseal into the the circlip into the groove ofthe : Check this verycarefully!!!12_198 ProductExploded ViewDisassembly & AssemblingWorkshop manual4860 MXMA45 Frontfork 4860 MXMA 200305/2002 Assemble the dust wiper with the O-ring of the compressionpiston with Frontfork the cartridge into the ViewDisassembly & AssemblingWorkshop manual4860 MXMA46 Frontfork 4860 MXMA 200305/2002 Assemble the cartridge in the center ofthe axle-clamp and tighten the holdercompression to a torque of the adjustment tube with theO-ring into the ViewDisassembly & AssemblingWorkshop manual4860 MXMA47 Frontfork 4860 MXMA 200305/2002 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 oil must stay above the 4 holes ofthe inner-tube, if necesarry fill someextra oil in the the piston-rod (keep theadjustment tube on his place)

10 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 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 the piston-rod and outer-tube fullydown and adjust the oil level(airchamber) with ViewDisassembly & AssemblingWorkshop manual4860 MXMA48 Frontfork 4860 MXMA 200305/2002 Pull the piston-rod out and assemble the spring downwards and placeopen-end spanner 22 on the first the steel washer on thespring, then the preload spacer(s).12_213 ProductExploded ViewDisassembly & AssemblingWorkshop manual4860 MXMA49 Frontfork 4860 MXMA 200305/2002 Screw handtight the screw-cap on down the screw-cap, till the is against the screw-cap andtighten it to a torque of ViewDisassembly & AssemblingWorkshop manual4860 MXMA50 Frontfork 4860 MXMA 200305/2002 Pull the spring downwards and removethe the screw-cap with rebound!