5060 Extreme

8/3/2019 5060 Extreme

1/52

Workshop manual

Product

Exploded View

Disassembly & assembling

1

5060 Extreme

Frontfork5060Extreme

0

3/2002

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
http://sub%20menu%20englisch.pdf/

8/3/2019 5060 Extreme

2/52

Product

Exploded View

Disassembly & Assembling

Workshop manual

5060 Extreme

2


0

3/2002

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!!

8/3/2019 5060 Extreme

3/52

Workshop manual

Product

Exploded View

Disassembly & assembling

3


0

3/2002

5060 Extreme

Exploded view

8/3/2019 5060 Extreme

4/52

Product

Exploded View


Workshop manual

5060 Extreme

4


0

3/2002

Note the position of

rebound / compression.

Clamp the inner-tube in the vice with

T903S.

821

822

Disassembly forkleg

8/3/2019 5060 Extreme

5/52

Product

Exploded View


Workshop manual

5060 Extreme

5


0

3/2002

Disassemble the screw-cap.

Remove the screw-cap.

Check the rubber sealing ring inside.

824

826

827

8/3/2019 5060 Extreme

6/52

Product

Exploded View


Workshop manual

5060 Extreme

6


0

3/2002

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

8/3/2019 5060 Extreme

7/52

Product

Exploded View


Workshop manual

5060 Extreme

7


0

3/2002

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

8/3/2019 5060 Extreme

8/52

Product

Exploded View


Workshop manual

5060 Extreme

8


0

3/2002

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

8/3/2019 5060 Extreme

9/52

Product

Exploded View


Workshop manual

5060 Extreme

9


0

3/2002

1. Pull out the cartridge.

2.

3.

839

840

841

8/3/2019 5060 Extreme

10/52

Product

Exploded View


Workshop manual

5060 Extreme

10


0

3/2002

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

8/3/2019 5060 Extreme

11/52

Product

Exploded View


Workshop manual

5060 Extreme

11


0

3/2002

Remove the dust wiper.

Disassemble the lock washer.

Remove the lock washer.

843

844

845

8/3/2019 5060 Extreme

12/52

Product

Exploded View


Workshop manual

5060 Extreme

12


0

3/2002

Heat the outer-tube near the oilseal.

Pull with both hands the inner- out the

outer-tube.

Remove the oilseal.

8

8

8

8/3/2019 5060 Extreme

13/52

Product

Exploded View


Workshop manual

5060 Extreme

13


0

3/2002

Remove the support ring.

Remove the DU-bush outer-tube.

Disassemble the DU-bush of the inner-tube.

8

8

8

8/3/2019 5060 Extreme

14/52

Product

Exploded View


Workshop manual

5060 Extreme

14


0

3/2002

- 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

8/3/2019 5060 Extreme

15/52

Product

Exploded View


Workshop manual

5060 Extreme

15


0

3/2002

Place a fitting axle-rod in the axle-clamp

and tighten both bolts.

Unscrew the axle-clamp.

Remove the axle-clamp.

8

8

8

8/3/2019 5060 Extreme

16/52

Product

Exploded View


Workshop manual

5060 Extreme

16


0

3/2002

Lift the O-ring out the groove of the axle-

clamp.

8

8/3/2019 5060 Extreme

17/52

Product

Exploded View


Workshop manual

5060 Extreme

17


0

3/2002

Clamp the tube of the cartridge in

T639S.

Assemble T907S on the screw-cap.

8

8

Unscrew the screw-cap.

8

Disassembly cartridge

8/3/2019 5060 Extreme

18/52

Product

Exploded View


Workshop manual

5060 Extreme

18


0

3/2002

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

8/3/2019 5060 Extreme

19/52

Product

Exploded View


Workshop manual

5060 Extreme

19


0

3/2002

Unscrew the rod tap from the piston-rod.

Remove the rod tap.

871

872

Remove the rebound spring.

873

8/3/2019 5060 Extreme

20/52

Product

Exploded View


Workshop manual

5060 Extreme

20


0

3/2002

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

8/3/2019 5060 Extreme

21/52

Product

Exploded View


Workshop manual

5060 Extreme

21


0

3/2002

The piston-rod adaptor compression.

879

Unscrew the piston-rod adaptor.

987

The piston-rod adaptor rebound.

989

8/3/2019 5060 Extreme

22/52

Product

Exploded View


Workshop manual

5060 Extreme

22


0

3/2002

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

8/3/2019 5060 Extreme

23/52

Product

Exploded View


Workshop manual

5060 Extreme

23


0

3/2002

Place a screwdriver on top of the rod tap

and remove the entire shim packet.

883

Remove the piston.


direction!!!

885

Disassemble the shim for check-valve.

886

8/3/2019 5060 Extreme

24/52

Product

Exploded View


Workshop manual

5060 Extreme

24


0

3/2002

Remove the spring for check-valve.


direction!!!

887

- rod tap rebound / compression

- spring for check-valve

- shim for check-valve

- piston- piston ring

- rebound shims

- nut M6x0.5 rebound.

888

8/3/2019 5060 Extreme

25/52

Product

Exploded View


Workshop manual

5060 Extreme

25


0

3/2002

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

8/3/2019 5060 Extreme

26/52

Product

Exploded View


Workshop manual

5060 Extreme

26


0

3/2002

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

8/3/2019 5060 Extreme

27/52

Product

Exploded View


Workshop manual

5060 Extreme

27


0

3/2002

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

8/3/2019 5060 Extreme

28/52

Product

Exploded View


Workshop manual

5060 Extreme

28


0

3/2002

Remove the shim for check-valve.

898

Remove the piston and check the O-

ring.


direction!!!899

Place a screwdriver on top and removethe entire shim packet.

901

8/3/2019 5060 Extreme

29/52

Product

Exploded View


Workshop manual

5060 Extreme

29


0

3/2002

- tap compression

- compression shims

- piston with O-ring

- shim for check-valve

- spring for check-valve

- check-valve nut902

8/3/2019 5060 Extreme

30/52

Product

Exploded View


Workshop manual

5060 Extreme

30


0

3/2002

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

8/3/2019 5060 Extreme

31/52

Product

Exploded View


Workshop manual

5060 Extreme

31


0

3/2002

Use T619 to press the DU-bush out the

screw-cap with support ...

907

...of the vice.

908

909

Disassembly screw-cap

8/3/2019 5060 Extreme

32/52

Product

Exploded View


Workshop manual

5060 Extreme

32


0

3/2002

Assembling the DU-bush with support

of...

910

...the vice.

911

Assembling screw-cap

8/3/2019 5060 Extreme

33/52

Product

Exploded View


Workshop manual

5060 Extreme

33


0

3/2002

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

8/3/2019 5060 Extreme

34/52

Product

Exploded View


Workshop manual

5060 Extreme

34


0

3/2002

Clamp the piston-rod with the bevelled

edge on top in the clamping block.

915

Assemble the screw-cap with steel

washer.


direction!!!916

Replace the rebound spring.

917

8/3/2019 5060 Extreme

35/52

Product

Exploded View


Workshop manual

5060 Extreme

35


0

3/2002

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

8/3/2019 5060 Extreme

36/52

Product

Exploded View


Workshop manual

5060 Extreme

36


0

3/2002

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

8/3/2019 5060 Extreme

37/52

Product

Exploded View


Workshop manual

5060 Extreme

37


0

3/2002

Assembling screw-cap.

924

Tighten the screw-cap.

925

8/3/2019 5060 Extreme

38/52

Product

Exploded View


Workshop manual

5060 Extreme

38


0

3/2002

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

8/3/2019 5060 Extreme

39/52

Product

Exploded View


Workshop manual

5060 Extreme

39


0

3/2002

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

8/3/2019 5060 Extreme

40/52

Product

Exploded View


Workshop manual

5060 Extreme

40


0

3/2002

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

8/3/2019 5060 Extreme

41/52

Product

Exploded View


Workshop manual

5060 Extreme

41


0

3/2002

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

8/3/2019 5060 Extreme

42/52

Product

Exploded View


Workshop manual

5060 Extreme

42


0

3/2002

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

8/3/2019 5060 Extreme

43/52

Product

Exploded View


Workshop manual

5060 Extreme

43


0

3/2002

Assemble the oilseal with the other side

of T902 into the outer-tube.

956

1. Assemble the circlip into the groove.

957

2.

959

8/3/2019 5060 Extreme

44/52

Product

Exploded View


Workshop manual

5060 Extreme

44


0

3/2002

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

8/3/2019 5060 Extreme

45/52

Product

Exploded View


Workshop manual

5060 Extreme

45


0

3/2002

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

8/3/2019 5060 Extreme

46/52

Product

Exploded View


Workshop manual

5060 Extreme

46


0

3/2002

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

8/3/2019 5060 Extreme

47/52

Product

Exploded View


Workshop manual

5060 Extreme

47


0

3/2002

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

8/3/2019 5060 Extreme

48/52

Product

Exploded View


Workshop manual

5060 Extreme

48


0

3/2002

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

8/3/2019 5060 Extreme

49/52

Product

Exploded View


Workshop manual

5060 Extreme

49


0

3/2002

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

8/3/2019 5060 Extreme

50/52

Product

Exploded View


Workshop manual

5060 Extreme

50


0

3/2002

Assemble the spring.

978

Replace the steel washer and the

preload spacers.

979

Assemble the spring retainer

980

8/3/2019 5060 Extreme

51/52

Product

Exploded View


Workshop manual

5060 Extreme

51


0

3/2002

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

8/3/2019 5060 Extreme

52/52

Product

Exploded View


Workshop manual

5060 Extreme

5060Extreme

0

3/2002

Position REB / COM!

984

Documents

5060 Extreme