Workshop manual CONE VALVE Edit1 - Freecontiman.free.fr/revues techniques/suspension/CONE... ·...
Transcript of Workshop manual CONE VALVE Edit1 - Freecontiman.free.fr/revues techniques/suspension/CONE... ·...
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Workshop Manual
MXMA 4800 Cone Valve
2014
WP Performance Systems GmbH Gewerbegebiet Nord 8 5222 Munderfing Austria
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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
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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.
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Worksho
3.1.1
Conditi
The fork
- Rem- Note- Com
The st
op Manual 0
DISASS
ion
k legs are d
move protece down the
mpletely ope
Info
teps are ide
1‐2013; Rev
SEMBL
disassemble
ctive cover opresent sta
en the adjus
entical for bo
.0
LING TH
ed.
on the bottoate of rebouster of the r
- Cla
Cla
- Loo
- Ta
- Pu
Rin
oth fork leg
9
HE FORK
om of the found and comrebound dam
amp the fork
amping stan
osen cartrid
ake out the f
ush the oute
ng wrench (
s
K LEGS
ork legs mpression dmping and c
k leg in the
nd (T1403S)
dge.
fork leg.
er tube dow
(T14017)
S
damping compressio
area of low
)
nward. Drai
on damping
wer triple cla
in the fork o
.
amp.
oil.
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Worksho
op Manual 01‐2013; Rev
.0
- Lo
- Pspe
Su
- Ho
- Re
- Prespec
U
Dbr
10
oosen rebou
Press the caecial tool.
upport hold
old nut and
move adjus
ess the cartcial tool.
se soft jaws
Info
Do not use beneath it, arebound adj
und adjustm
rtridge aga
er (T14020
remove the
sting tube.
ridge again
s
impact wreas asually sjustment ca
ment nut.
in the spring
)
e rebound a
st the sprin
nch. Place asome oil willannot remov
g and remo
adjuster.
ng and remo
a fluid collel drain out. ved jet
ove
ove
ector The
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Worksho
op Manual 0
1‐2013; Rev
.0
- Re
- Re
- Re
- Re
- Pul
S
Hed
11
move the c
move dust
move the tw
move the s
ll out the ou
Strap spann
Info
Heat up the end of the odismounting
cartridge and
boot with a
wo rings.
eal holder.
uter tube.
ner ( T14058
outer tube outer tube. Cg.
d spring.
screw drive
8)
( 50⁰C/ 122Check the g
er carefully.
2⁰F) at the lguiding bush
.
lower hes after
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Worksho
op Manual 01‐2013; Rev
.0
- Re
- Re
- Kno
Tuhit
12
move the s
move the lo
ock out the
Info
urn the seal ts in each p
eal holder a
ock ring by
seal carefu
holder seveosition to pr
and the dus
using a sma
ully.
eral times arevent cant
st boot.
all screw dr
and give jus.
river.
st small
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Worksho
3.1.2
Beforemain s- If thespace- If thespace
op Manual 0
ASSEM
Info
e mountingspring and e measureders. e measureders.
1‐2013; Rev
MBLING
, check evecompare th
d valve is gr
d valve is le
.0
G THE FO
- Gre
- For
- Mo
Gr
Ass
ery part for dhe measure reater than t
ss than the
The
Do
13
ORK LE
easy the se
rce in the n
ount lock rin
rease (T140
sembly tool
damages. C with the dathe specifie
specified v
Info
e lock ring m
Info
not close th
EGS
eal holder in
ew seal on
ng.
034)
(T14040S)
Clean everyates on the ed value: Re
value: Increa
must audibly
he special too
side on bot
the lower s
y part. Checsetting list. educe the th
ase the thic
lock into pla
ol completely
th sides.
side of the r
ck the length
hickness of
ckness of th
ce
y.
ing.
h of the
the
he
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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)
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Worksho
op Manual 0
1‐2013; Rev
.0
Ha
- Slid
- Mo
- Greoute
Gre
- Slid
- Hoof th
- Pre
As
- Scr
Str
GeSla
Heendi
15
Info
and-tight.
de on the lo
ount upper s
easy the fitter tube.
ease (T1403
de on the o
ld the lowere special to
ess the oute
ssembly too
rew on the
rap spanne
Info
ently pull theather the tub
Info
eat up the ond of the ousmounting.
ower sliding
sliding bush
ting of the lo
34)
uter tube.
r sliding busool.
er tube all th
ol (T14040S
complete se
r (T14058)
em apart witbe with fork
outer tube (uter tube. C
bushing.
hing.
ower sliding
shing with th
he way in.
S)
eal holder a
thout using aoil
50⁰C/ 122⁰heck the gu
g bushing in
he longer s
and mount r
a tool.
⁰F) at the louiding bushe
n the
houlder
rings.
ower es after
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Worksho
op Manual 01‐2013; Rev.0
- Mo
- Co
(T- M
- M
- Tig
- Fil
Thco
25
MEn
16
ount the spr
ompress th
T14020) ount the da
ount the hy
ghten the s
lling the out
Info
he mother scompletely fir
Info
5 Nm
Info
Motocross: 38nduro: 375 m
ring with the
e fork and p
amping adju
ydro stop
crewing.
ter tube with
crew has to bst.
85 ml ml
e spacer on
place specia
ustment tube
h SAE 4 for
be turned on
n the bottom
al tool.
e
rk oil
n the thread
m.
-
Worksho
op Manual 01‐2013; Rev
.0
- T
(T
30
17
ighten the f
T14017)
Info
0 Nm
fork cap with special toool.
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Worksho
3.2.1
op Manual 0
Disass
1‐2013; Rev
sembling
.0
g the Ca- Cla
Cla
- Loo
Pin
- Re
- Em
- loo
Heend
18
artridgeamp the car
amping stan
osen and re
n wrench (T
move screw
mpty the car
osen the scr
Info
eat up the cad next to the
e rtridge into a
nd (T 14015
emove screw
103)
w cap.
rtridge.
rew sleeve a
artridge ( 10e mother sc
a vise. )
w cap.
and remove
00⁰C/ 212⁰Fcrew.
e the piston
F) at the low
rod.
wer
-
Worksho
3.2.2
3.2.3
op Manual 0
Disass
Assem
1‐2013; Rev
sembling
mbling th
.0
g the pi- Cla
Cla
- Re
- Re
- Re
he pisto- Mo
- Mo
Ma
T
Gp
19
iston roamp the pist
amping stan
move the n
move rebou
move pisto
on rod ount the pist
ount the new
Info
ake sure tha
Info
The convexiti
Info
Grind the rebplate with 12
od ton rod into
nd ( T14016
nut on the to
und shim st
n.
ton and the
w piston ring
t the parts c
ies has to be
bound piston200 grid pape
a vise.
)
op.
tack.
delta rebo
g.
annot be mix
e in one line.
n on the top er.
ound shim s
xed up.
side on a su
tack.
rface
-
Worksho
3.2.4
op Manual 0
Disass
1‐2013; Rev
sembling
.0
- Modown
g the sc- Cla
(T1
- Op
(T1
Aligreb
Clea
5 N
20
ount and tighnward Guid
crew caamp the car
4015)
pen the sprin
4017)
Info
gn triangularbound piston
Info
an all the pa
Info
m and Loctit
hten new nudeline.
ap rtridge in a v
ng preload
plates exact.
rts tidy befo
te 243
ut with the c
vise using s
adjuster co
tly with the o
re mounting
collar facing
special tool.
mpletely.
openings of t
g.
g
.
the
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Worksho
3.2.5
op Manual 0
Assem
1‐2013; Rev
mbling th
.0
- Cla
Too
- Op
Rin
- Ch
he screw
Heasite
Gre
Loc
21
amp special
ol ( T 1285S
pen the sprin
ng wrench (T
ange the o-
w cap
Info
at up the cae.
Info
ease every o
Info
ctite 243
l tool in a vi
S)
ng preload
T 14028)
- ring seal.
artridge ( 50
o‐ ring seal be
se
adjuster.
0⁰C/ 122⁰F)
efore mount
) at the uppe
ting.
er
-
Worksho
op Manual 0
1‐2013; Rev
.0
- Gre
(T1
- Cla
(T1
- Gre
(T1
- Mo
Rin
80
22
ease the ba
59)
amp cartridg
14015)
ease the thr
59)
ount spring p
ng wrench (
Info
Nm and Loc
alls.
ge in a vise
read of the
preload adj
(T15028)
tite 243
using spec
preload adj
ustment nu
cial tool.
justment nu
t
ut.
-
Worksho
3.2.6
3.2.7
op Manual 0
Disass
Assem
1‐2013; Rev
sembling
mbling th
.0
g the co- fix
Sup
- Re
- Re
he comp- ch
Cle
23
ompresthe part in a
pport tool (T
move nut.
emove pisto
pressioange the o-
Info
ean all the pa
ssion daa vise.
T1286S)
n and shim
on damp-ring seal an
arts tidy befo
amping
stack.
ping nd the pisto
ore mounting
on ring if ne
g.
cessary.
-
Worksho
3.2.8
op Manual 0
SERVIC
1‐2013; Rev
CE SCR
.0
- Mo
- Mo
REW SL- Re
- Ch
(T1
- Scr
- Ch
- Prespec
(T1
(T1
5,5
Thepro
Gre
24
ount piston,
ount and tigh
LEEVE move ring a
ange O-ring
59)
rew the spe
ange the se
ess the pilotcial tool. 4022)
14023)
Info
5 Nm
Info
e special toootect the tre
Info
ease the new
the shim an
hten the nu
and check v
g
ecial tool on
eal.
t bushing ou
ol must have ad.
w O‐ring befo
nd the sprin
t.
valve stop.
to the screw
ut of screw
an overhang
ore mounting
ng.
w sleeve.
sleeve usin
g of 1mm to
g.
ng
-
Worksho
op Manual 0
1‐2013; Rev
.0
- Slid
(T6
- Posspec
- Prenum
(T1
- Musleev
- Morod
- Mo
Enth
Lu
25
de the new
620)
sition the picial tool and
ess the specber of times
4021)
unt the checve.
ount the was
ount the nut
Info
nsure that spere is an ove
Info
ubricate spec
pilot bushin
ilot bushingd press it all
cial tool thros to calibrat
ck valve sto
sher and the
.
pecial tool (T1erhang to pro
cial tool with
ng onto the
in the scre the way.
ough the nete the bushi
p and the ri
e srew slee
14023) is mootect the thr
oil SAE 4.
special too
ew sleeve w
ew pilot busing.
ing on the s
eve on the p
ounted and tread.
l.
with the
shing a
screw
piston
that
-
Worksho
3.2.9
op Manual 0
Assem
1‐2013; Rev
mbling th
.0
he cartr- Cla
Sup
- Re
- Mo
- Cla
Cla
- Lub
- Mo
18
Gre
25
26
ridge amp the pist
pport tool (
place the n
ount and tigh
amp the out
amping stan
bricate the p
ount the pist
Info
Nm and Loc
Info
ease the O‐r
Info
Nm and Loc
ton rod in a
T 14016)
eedle.
hten the pis
ter tube in a
nd (T14015)
piston ring w
ton rod and
ctite 243
ing seal with
tite 243
vise.
ston.
a vise
)
with oil SAE
tight the nu
h (T159)
E 4
ut.
-
Worksho
op Manual 0
1‐2013; Rev
.0
- Fill
- Mo
.
- Gre
(T
160
Oilco
27
ing with for
ove up and d
ease the thr
T159)
Info
0‐180 ml SAE
Info
l level 1,5 cmmpletely dri
k oil.
down the pi
read.
E 4
m underneatven into.
iston severa
h the hole w
al times.
when piston i
s
-
Worksho
See
op Manual 0
Chapter 3.1
1‐2013; Rev
1.2
.0
- Mo
(T1
- tigh
Pin
- com
ha
WP click
The
To
28
ount the com
286S)
hten the uni
n wrench (T
mpress the
Info
nd tight.
Info
delivers all fk.
Info
ere can be a s
Info
o put on a hig
mpression d
it.
103)
cartridge co
forks with a
small oil flow
gher pressure
damping uni
ompletely s
standard spr
w throughout
e you can us
it.
several time
ring preload
t the holes.
se special too
es.
of 1
ol
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Workshop Manual 01‐2013; Rev.0 29
NOTES: