4860 MX Multi Adjuster 2003: Workshop Manual

Workshop manual
4860 MXMA
Product
Exploded View
Disassembly & Assembling
12_234
Frontfork
Frontfork 4860 MXMA 2003
05/2002
4860 MX Multi Adjuster 2003

Introduction
Exploded view
Disassembly forkleg
Disassembly cartridge
Disassembly compression holder
Assembling compression holder
Disassembly tap rebound
Assembling tap rebound
Assembling cartridge
Assembling forkleg
2
3
4
17
21
24
27
31
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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.
05/2002
Caution:
Many times it is necesarry to assemble parts with
T131, T132 and T163.
These parts must dry for at least four hours!!
Workshop manual
4860 MXMA
Product
Exploded View
Disassembly & assembling
05/2002
Exploded view
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.
05/2002
12_063
Clamp the outer-tube in T1403S and

unscrew the screw-cap PA with T103.
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.
05/2002
12_068
Unscrew the screw-cap.
Workshop manual
4860 MXMA
Product
Exploded View
Remove the screw-cap from the

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

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

O-ring.
05/2002
12_089
Workshop manual
4860 MXMA
Product
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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.
05/2002
12_095
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
Workshop manual
4860 MXMA
Product
Exploded View
Remove holder compression.

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

forkleg.
05/2002
12_098
Disassemble the dust-wiper.
12_099
Workshop manual
4860 MXMA
Product
Exploded View
Disassemble the circlip.
12_100
05/2002
Heat the outer-tube near the oilseal.

(not too hot)
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.
05/2002
Remove DU-bush inner-tube.
1. Remove DU-bush.
11
Workshop manual
4860 MXMA
Product
Exploded View
Remove DU-bush inner-tube.
05/2002
Remove DU-bush outer-tube.
12
Workshop manual
4860 MXMA
Product
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Remove support ring.
12_105
Disassemble the oilseal.

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

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

axle-clamp.
12_115
16
Workshop manual
4860 MXMA
Product
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Disassembly cartridge
1. Clamp the tube with plug in the
clamping-block (Tool T508S + T509).
12_116
2.
05/2002
12_117
3.
12_118
17
Workshop manual
4860 MXMA
Product
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Unscrew the screw sleeve (size 22).
12_119
Turn the screw sleeve out of the tube.
05/2002
12_120
Disassemble the piston-rod complete.

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

tight and unscrew the hydraulic stop
from the piston-rod.
12_164
Remove the hydraulic stop.
05/2002
12_165
19
Workshop manual
4860 MXMA
Product
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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.
05/2002
12_168
- Spring retainer
- screw sleeve
- DU-bush
12_169
20
Workshop manual
4860 MXMA
Product
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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_124
Remove the check-valve nut.
05/2002
12_125
Remove the check-valve spring.

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

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

and remove the entire shim packet.
12_129
22
Workshop manual
4860 MXMA
Product
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Disassemble the O-ring.
12_130
Remove the copper washer.
05/2002
12_131
- Holder compression
- copper washer
- O-ring
- shims compression
- piston compression with Oring
- shim check-valve
- spring check-valve
- nut check-valve
12_132
23
Workshop manual
4860 MXMA
Product
Exploded View
Assembling holder
compression
Replace copper washer.
12_133
Assemble the O-ring.
05/2002
12_134
Replace the entire shim packet.
12_135
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Workshop manual
4860 MXMA
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Replace piston.
direction!!!
12_136
Replace shim check-valve.
05/2002
12_137
Replace spring check-valve.

direction!!!
12_138
25
Workshop manual
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Wetting the thread of the nut with T132

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

in the chamber of the nut.
12_142
26
Workshop manual
4860 MXMA
Product
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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.
05/2002
12_144/
145/146 posterize
Remove the rebound spring.
12_147
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Workshop manual
4860 MXMA
Product
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Pull the rebound needle with spring out

of the tap rebound.
12_148
Check the O-ring.
05/2002
12_149
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.
12_150
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.
05/2002
12_152
Remove piston rebound.

direction!!!
12_153
29
Workshop manual
4860 MXMA
Product
Exploded View
Remove check-valve shims.
12_154
Remove spring check-valve.
05/2002
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
30
Workshop manual
4860 MXMA
Product
Exploded View
Assembling tap rebound

Assemble the spring and shims checkvalve.
12_157
Assemble the piston rebound.

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

Pay attention to the position of the
triangular shims on the piston!!!
12_159
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Workshop manual
4860 MXMA
Product
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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.
05/2002
12_161
Grease the O-ring of the adjustment

needle with T158.
12_162
32
Workshop manual
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Product
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Mount the needle with spring into the tap

rebound.
05/2002
12_163
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.
05/2002
12_172
Wetting the thread with T131.

And screw the tap in the piston-rod.
12_173
34
Workshop manual
4860 MXMA
Product
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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.
05/2002
12_175
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.
Guide the piston ring!!!
12_177
Before assembling wet the thread of

the screw sleeve with T131.
Screw the screw sleeve into the tube.
05/2002
12_178
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.
05/2002
12_181
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 axleclamp.
12_183
Screw very tight the inner-tube with

T503S / T1404S.
05/2002
12_184
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.
05/2002
14_0011
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.
05/2002
12_190
40
Workshop manual
4860 MXMA
Product
Exploded View
Replace the DU-bush.
05/2002
Replace the tube.
Replace the DU-bush.
41
Workshop manual
4860 MXMA
Product
Exploded View
Replace the DU-bush on the inner-tube.
05/2002
Slide carefully the outer-tube over the

inner-tube.
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.
05/2002
12_195
43
Workshop manual
4860 MXMA
Product
Exploded View
Use the other side of T1402S...
12_196
...and tap the oilseal into the outer-tube.
05/2002
12_197
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
05/2002
Place the cartridge into the forkleg.
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.
05/2002
12_204
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
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_206
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.
05/2002
12_208
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.
05/2002
12_212
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.
05/2002
Screw down the screw-cap, till the hydr.

stop is against the screw-cap and
tighten it to a torque of 25Nm.
49
Workshop manual
4860 MXMA
Product
Exploded View
Pull the spring downwards and remove

the spanner.
05/2002
Tighten the screw-cap with T103.
Position rebound!
50
Workshop manual
4860 MXMA
Product
Exploded View
Position compression!
And replace the rubber cap.
05/2002
12_226
51

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