5060 extreme
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Workshop manual
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Disassembly & assembling
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5060 Extreme
Frontfork5060Extreme
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Frontfork
5060 Extreme
820
Introduction 2Exploded view 3Disassembly forkleg 4
Disassembly cartridge 17Disassembly rod tap rebound / compression 22Assembling rod tap rebound / compression 25
Disassembly tap compression 26Assembling tap compression 30Disassembly screw-cap 31
Assembling screw-cap 32Assembling cartridge 33Assembling forkleg 38
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Introduction
General notice
Pay attention to the folowing notes, when you areworking with WP Suspension products asdescribed in this 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 byWP Suspension) protect you from damaging theparts.
Use always aluminium protector-plates.
Replace always 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 to dry for at least four hours!!
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Note the position of
rebound / compression.
Clamp the inner-tube in the vice with
T903S.
821
822
Disassembly forkleg
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Disassemble the screw-cap.
Remove the screw-cap.
Check the rubber sealing ring inside.
824
826
827
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Let the inner-tube down into the outer-
tube.
Remove the spring retainer, preload
spacers and steel washer.
- steel washer- preload spacers
- springretainer
829
830
831
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Remove the spring.
Check the oil level with T137S.
Slide the O-ring on level with the edge of
the compressed inner-tube.
Drain the oil out the forkleg.
832
833
835
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836
Clamp the axle-clamp in the vice so that
the forkleg is about a 45 degrees angle.
Unscrew the bolt out of the axle-clamp.
Copper washer and bolt.
837
838
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1. Pull out the cartridge.
2.
3.
839
840
841
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Remove the steel washer.
Pay attention to the assembling
direction!!!
Hold forkleg up side down and remove
the house hydraulic stop.
Disassemble the dust wiper.
864
848
842
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Remove the dust wiper.
Disassemble the lock washer.
Remove the lock washer.
843
844
845
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Heat the outer-tube near the oilseal.
Pull with both hands the inner- out the
outer-tube.
Remove the oilseal.
8
8
8
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Remove the support ring.
Remove the DU-bush outer-tube.
Disassemble the DU-bush of the inner-tube.
8
8
8
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- dust wiper
- circlip
- oilseal
- support ring
- DU-bush outer-tube
- DU-bush inner-tube
Assemble T904S into the outer-tube.
Clamp the outer-tube in the vice andheat the axle-clamp.
8
8
9
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Place a fitting axle-rod in the axle-clamp
and tighten both bolts.
Unscrew the axle-clamp.
Remove the axle-clamp.
8
8
8
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Lift the O-ring out the groove of the axle-
clamp.
8
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Clamp the tube of the cartridge in
T639S.
Assemble T907S on the screw-cap.
8
8
Unscrew the screw-cap.
8
Disassembly cartridge
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Pull the piston-rod out of the tube.
By removing, pay attention to the piston
ring.
8
869
Clamp the piston-rod in T639S.Keep sufficient distance with the vice.
870
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Unscrew the rod tap from the piston-rod.
Remove the rod tap.
871
872
Remove the rebound spring.
873
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Remove the screw-cap.
874
Clamp the piston-rod in, on the other
side in the vice.
875
Unscrew the piston-rod adaptor.(size 22)
876
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The piston-rod adaptor compression.
879
Unscrew the piston-rod adaptor.
987
The piston-rod adaptor rebound.
989
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Clamp the rod tap in the vice.
880
Unscrew the nut. (size 10)
Pay attention to the position of the
triangular shims and the assembling
direction of the nut!!!881
Remove the nut.
882
Disassembly rod tap
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Place a screwdriver on top of the rod tap
and remove the entire shim packet.
883
Remove the piston.
Pay attention to the assembling
direction!!!
885
Disassemble the shim for check-valve.
886
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Remove the spring for check-valve.
Pay attention to the assembling
direction!!!
887
- rod tap rebound / compression
- spring for check-valve
- shim for check-valve
- piston- piston ring
- rebound shims
- nut M6x0.5 rebound.
888
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Assemble the spring for check-valve in
the chamber of the rod tap.
889
Assemble the shim for checke-valve,
piston and rebound shims.
890
Tighten the nut to a torque of 5Nm.
891
Assembling rod tap
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Push the tap compression out the tube
with support of the piston-rod.
892
Tap compression.
893
Clamp the tap compression in theclamping block.
894
Disassembly tapcompression
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Unscrew the check-valve nut (size 17).
895
Remove the check-valve nut.
896
Remove the spring for check-valve.Pay attention to the assembling
direction!!!
897
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Remove the shim for check-valve.
898
Remove the piston and check the O-
ring.
Pay attention to the assembling
direction!!!899
Place a screwdriver on top and removethe entire shim packet.
901
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- tap compression
- compression shims
- piston with O-ring
- shim for check-valve
- spring for check-valve
- check-valve nut902
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Replace the piston with O-ring and the
shims on the tap.
904
Assemble the shim and spring for
check-valve.
905
Tighten the check-valve nut to a torqueof 5Nm.
Check if the spring is assembled in the
chamber of the nut.
906
Assembling tapcompression
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Use T619 to press the DU-bush out the
screw-cap with support ...
907
...of the vice.
908
909
Disassembly screw-cap
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Assembling the DU-bush with support
of...
910
...the vice.
911
Assembling screw-cap
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Grease the O-ring of the piston with
frontfork oil.
912
Assemble the tap compression into the
tube.
913
Push with support of the piston-rod thetap compression till the springring.
914
Assembling cartridge
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Clamp the piston-rod with the bevelled
edge on top in the clamping block.
915
Assemble the screw-cap with steel
washer.
Pay attention to the assembling
direction!!!916
Replace the rebound spring.
917
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Assemble the rod tap.
918
Tighten the rod tap.
919
Clamp the piston-rod in on the otherside and screw in the piston-rod
adaptor.
920
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Tighten the piston-rod adaptor.
921
Clamp the tube in the clamping block.
922
Assemble the piston-rod complete withpiston ring into the tube.
923
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Assembling screw-cap.
924
Tighten the screw-cap.
925
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Replace a new O-ring in the groove of
the axle-clamp.
926
Wetting the thread of the inner-tube with
T132.
927
Wetting the thread in the axle-clampwith T132.
928
Assembling forkleg
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Clamp the outer-tube with T904S inside
in the clamping block and assemble the
axle-clamp.
929
Assemble the axle rod and...
930
...tight firmly the axle-clamp.
931
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Assemble the DU-bush on the inner-
tube and clamp the (axle-clamp) outer-
tube in the vice.
935
Slide the inner-tube slowly in the outer-
tube.
936
Assemble the DU-bush outer-tube.
952
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Use T902 -flat side- to tap or push the
DU-bush in the outer-tube
938
Tapping the DU-bush into the outer-tube.
953
Replace the support ring.
954
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Place T901 on top into the inner-tube.
942
Dip in oil or grease the entire oilseal with
frontfork oil.
943
Slide the oilseal over the inner-tube.
955
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Assemble the oilseal with the other side
of T902 into the outer-tube.
956
1. Assemble the circlip into the groove.
957
2.
959
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Grease the innerside of the dust wiper
with frontfork oil.
960
Slide the dust wiper on the inner-tube.
961
Tapping the dust wiper into theouter-tube.
962
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Release carefully the air between the
assembled dust wiper and outer-tube
with a small screwdriver.
963
Let inner-tube completely down in the
outer-tube and assemble the hydraulic
house.
964
Replace the steel washer.Pay attention to the assembling
direction!!!
965
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Assemble the cartridge into the forkleg.
966
In case of a older type of screw-cap,
use T905 for assembling.
967
Assemble the bolt with a new copperwasher.
968
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Tighten the bolt to a torque of 22Nm.
969
Assemble the forkleg in the vice.
970
Fill the forkleg with oil just under theedge of the fully compressed inner-tube.
971
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Move the piston-rod several times up
and down, until you feel that all air is
bled out.
(The damping is smooth over the entirestroke)972
Rebound side: Oil is coming
through this hole.973
Moving the inner-tube not too high, up
and down.
974
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Adjust T137S on level.
975
Hold the hexagonal upper side of the
piston-rod exactly level with the edge of
the fully compressed inner-tube.
Also the O-ring of the bottle.Remove the oil till the correct level.976
Replace the spring with the conical sideunder.
977
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Assemble the spring.
978
Replace the steel washer and the
preload spacers.
979
Assemble the spring retainer
980
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Pull the inner-tube up.
981
Screw the screw-cap into the inner-
tube.
982
And tighten the screw-cap to a torque of25Nm.
983
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Position REB / COM!
984