Workshop Manual

MXMA 4800 Cone Valve

2014

WP Performance Systems GmbH Gewerbegebiet Nord 8 5222 Munderfing Austria

  

Workshop Manual 01‐2013; Rev.0  1     

TABLE OF CONTENTS

1 INTRODUCTION 1

2 EXPLODED VIEWS 2

3 WORK ON FORK

3.1 STANDARD SERVICE

3.1.1 DISASSEMBLING THE FORK LEGS 8

3.1.2 ASSEMBLING THE FORK LEGS 12

3.2 CARTRIDGE SERVICE

3.2.1 DISASSEMBLING THE CARTRIDGE 16

3.2.2 DISASSEMBLING THE PISTON ROD 17

3.2.3 ASSEMBLING THE PISTON ROD 17

3.2.4 DISASSEMBLING THE SCREW CAP 18

3.2.5 ASSEMBLING THE SCREW CAP 19

3.2.6 DISASSEMBLING THE COMPRESSION DAMPING 21

3.2.7 ASSEMBLING THE COMPRESSION DAMPING 21

3.2.8 SERVICE THE SCREW SLEEVE 22

3.2.9 ASSEMBLING THE CARTRIDGE 24

  

Workshop Manual 01‐2013; Rev.0  2     

1 INTRODUCTION

Read this Repair Manual carefully and thoroughly before beginning work. It contains useful information and tips that will help you repair and maintain your suspension. This manual assumes that the necessary special WP tools and WP workplace and workshop equipment are available. We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here. It is assumed that repair work will be performed by a fully trained mechanic. Special tools are necessary for certain tasks. The tools are not contained in the delivery contents but can be ordered under the number in parentheses. E.g.: (T1290 INNER T. DISASSEMBLY TOOL D35/D40 ) During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be replaced by new parts. In some instances, a thread locker (e.g. Loctite®) is required. The manufacturer instructions for use must be followed. After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn parts. After you complete the repair or service work, check the operating safety of the vehicle. The work prescribed in the service schedule must be carried out by an authorized WP workshop only otherwise, all warranty claims will be void. No warranty claims can be considered for damage resulting from manipulations and/or alterations to the vehicle.

  

Worksho 

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1‐2013; Rev

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Worksho 

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Worksho 

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Worksho 

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Worksho 

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1‐2013; Rev

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Worksho 

3.1.1

Conditi

The fork

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DISASS

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Worksho 

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3.1.2

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Workshop Manual 01‐2013; Rev.0  14     

- Install dust boot. Assembly tool (T14040S)

- Greasy the seal and dust boot on the inside.

Grease (T14034)

- Slip on the mounted seal holder.

Protecting sleeve (T1401)

  

Worksho 

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5 Nm 

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Worksho 

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T14017)

Info

0 Nm 

fork cap with special toool.

 

  

Worksho 

3.2.1

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Disass

1‐2013; Rev

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Worksho 

3.2.2

3.2.3

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The convexiti

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Grind the rebplate with 12

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Worksho 

3.2.4

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Disass

1‐2013; Rev

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Worksho 

3.2.5

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1‐2013; Rev

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Worksho 

op Manual 0

1‐2013; Rev

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Nm and Loc

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Worksho 

3.2.6

3.2.7

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1‐2013; Rev

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Worksho 

3.2.8

op Manual 0

SERVIC

1‐2013; Rev

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5 Nm 

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Worksho 

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1‐2013; Rev

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4021)

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Info

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ubricate spec

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Worksho 

3.2.9

op Manual 0

Assem

1‐2013; Rev

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26

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Info

Nm and Loc

Info

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Info

Nm and Loc

ton rod in a

T 14016)

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piston ring w

ton rod and

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vise.

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a vise

)

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E 4

ut.

 

  

Worksho 

op Manual 0

1‐2013; Rev

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- Fill

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27

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Info

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when piston i

 

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Worksho 

See

op Manual 0

Chapter 3.1

1‐2013; Rev

1.2

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(T1

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Pin

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WP click

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28

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ere can be a s

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forks with a 

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ol  

  

Workshop Manual 01‐2013; Rev.0  29     

NOTES: