5060 Extreme: Workshop Manual

Workshop manual
Frontfork 5060 Extreme
Product
Exploded View
Disassembly & Assembling
820
Frontfork
5060 Extreme
Introduction 2
Exploded view 3
Disassembly forkleg 4
Diassembly cartridge 17
Disassembly rod tap 22
Assembling rod tap 25
Diassembly tap compression 26
Assembling tap compression 30
Disassembly screwcap 31
Assembling screwcap 32
Assembling cartridge 33
Assembling forkleg 38
1 Frontfork 5060 Extreme

Workshop manual
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.
Use always aluminium protector-plates.
Always replace damaged or worn parts.
Clean all parts before assembling.
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
Product
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Exploded view

Workshop manual
Product
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Disassembly forkleg
Note the position of rebound/compression
821
Clamp the inner-tube in the vice with T903.
822
Bleed the air from the fork by releasing the

screw on top of the cover.
823
4 Frontfork 5060 Extreme Disassembly forkleg

Workshop manual
Product
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Disassemble the screwcover. (size 24)
824
Remove the screwcover
826
Check the rubber sealing ring inside.
827

Workshop manual
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Move the inner-tube down into the outer-tube.
829
Remove the springretainer, preload spacers

and steel washer.
830
- steel washer
- preload spacers
- springretainer
831

Workshop manual
Product
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Take out the spring.
832
Check the oil level with T137S.

Slide the O-ring on level with the edge of the
compressed inner-tube.
833
Drain the oil out the forkleg.
835

Workshop manual
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Clamp the axle-clamp in the vice so that the

forkleg is at an angle of 45 degrees.
836
Untighten the bolt out of the axle-clamp.
837
Copper washer and bolt.
838

Workshop manual
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Pull out the cartridge.
839
Remove the cartridge.
840
The cartridge
841

Workshop manual
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Remove the ring.
864
Hold forkleg up side down and remove the

house hydraulic stop.
848
Disassemble the dust stripper
842

Workshop manual
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Remove the dust stripper.
843
Disassemble the lockwasher.
844
Remove the lockwasher.
845

Workshop manual
Product
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Heat the outer-tube near the oilseal.
Pull with both hands the inner-tube out of

the outer-tube.
Remove the oilseal.

Workshop manual
Product
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Remove the support ring.
Remove the DU-bush of the outer-tube.
Disassemble the DU-bush of the inner-tube.

Workshop manual
Product
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- dust stripper
- circlip
- oilseal
- support ring
- DU-bush outer-tube
- DU-bush inner-tube
Assemble T904 in the outer-tube.
Clamp outer-tube in the vice and heat the

axle-clamp.

Workshop manual
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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.

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

clamp.

Workshop manual
Product
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Diassembly cartridge
Clamp the tube of the cartridge in T639S.
Assemble T907S on the screwcap.
Unscrew the screwcap.
17 Frontfork 5060 Extreme Disassembly cartridge

Workshop manual
Product
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Pull the piston rod out of the tube.
While removing, pay attention to the piston

ring.
869
Clamp the piston rod in T639S.

Keep sufficient distance to the vice.
870

Workshop manual
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Unscrew the rod tap from the piston rod.
871
Remove the rod tap.
872
Remove the reboundspring.
873

Workshop manual
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Remove the screwcap including steel ring.
874
Clamp the piston rod, on the other side in

the vice.
875
Unscrew the piston rod adaptor. (size 22)
876

Workshop manual
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The piston rod compression adaptor.
879
Unscrew the piston rod adaptor..
987
The piston rod rebound adaptor.
989

Workshop manual
Product
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Disassembly rod tap
Clamp the rod tap in the vice.
880
Unscrew the nut. (size 10)

Pay attention on the position of the
triangular shims and the assembling
direction of the nut!!
881
Remove the nut.
882
22 Frontfork 5060 Extreme Disassembly rod tap

Workshop manual
Product
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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

Workshop manual
Product
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Remove the spring for check-valve.

887
- rod tap rebound/compression

- spring for check-valve
- shim for check-valve
- piston
888 - piston ring
- rebound shims
- nut M6x0.5 reb.

Workshop manual
Product
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Assembling rod tap
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
25 Frontfork 5060 Extreme Assembling rod tap

Workshop manual
Product
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Diassembly tap compression
Push the tap compression out the tube with

support of the piston rod.
892
Tap compression.
893
Clamp the tap compression in the clamping

block.
894
26 Frontfork 5060 Extreme Disassembly tap compression

Workshop manual
Product
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Unscrew the check-valve nut. (size 17)
895
Remove the check-valve nut.
896
Remove the spring for check-valve.

897

Workshop manual
Product
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Remove the shim for check-valve.
898
Remove the piston and check the O-ring.

899
Place a screwdriver on top and remove the

entire shim packet.
901

Workshop manual
Product
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- tap compression
- compression shims
- piston with O-ring
- shim for check-valve
902 - spring for check-valve
- check-valve nut

Workshop manual
Product
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Assembling tap compression
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 torque of

5Nm.
Check if the spring is positioned correctly in
the chamber of the nut.
906
30 Frontfork 5060 Extreme Assembling tap compression

Workshop manual
Product
Exploded View
Disassembly screwcap
Use T619 to press the DU-bush out of the

screwcap with support ....
907
....of the vice.
908
The DU-bush.
909
31 Frontfork 5060 Extreme Disassembly screwcap

Workshop manual
Product
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Assembling screwcap
Assembling the DU-bush with support of....
910
....the vice.
911
32 Frontfork 5060 Extreme Assembling screwcap

Workshop manual
Product
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Assembling cartridge
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 the tap

comp. until the springring.
914
33 Frontfork 5060 Extreme Assembling cartridge

Workshop manual
Product
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Clamp the piston rod with the bevelled edge

on top in the clamping block.
915
Assemble the screwcap with steel ring.
916
Replace the reboundspring..
917

Workshop manual
Product
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Assemble the rod tap.
918
Tighten the rod tap..
919
Clamp the piston rod in on the other side and

screw in the piston rod adaptor.
920

Workshop manual
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Tighten the piston rod adaptor.
921
Clamp the tube in the clamping block.
922
Assemble the piston rod complete with

piston ring into the tube.
923

Workshop manual
Product
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Assambling screwcap.
924
Screw down the screwcap.
925

Workshop manual
Product
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Assembling forkleg
Place 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-clamp with

T132.
928
38 Frontfork 5060 Extreme Assembling forkleg

Workshop manual
Product
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Clamp the outer-tube with T904 inside in the

clamping block and assemble the axle-clamp.
929
Assemble the axle rod and....
930
....screw down the axle-clamp.
931

Workshop manual
Product
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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

Workshop manual
Product
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Use T902 -flat side- to tap or push the DU-

bush in the outer-tube
938
Tapping the DU-bush in the outer-tube.
953
Replace the support ring.
954

Workshop manual
Product
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Place T901 on top in the inner-tube.
942
Dip the entire oilseal in frontfork oil / Apply

frontfork oil to the entire seal.
943
Slide the oilseal over the inner-tube.
955

Workshop manual
Product
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Assemble the oilseal with the other side of

T902 in the outer-tube.
956
1. Assemble the circlip.
957
2.
959

Workshop manual
Product
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Grease the innerside of the dust stripper with

frontfork oil.
960
Slide the dust stripper over the inner-tube.
961
Tapping the dust stripper in the outer-tube.
962

Workshop manual
Product
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Carefully release the air between the

assembled dust stripper and outer-tube with
a small screwdriver.
963
Slide inner-tube completely down in the

outer-tube and assemble the hydraulic house.
964
Caution:
Replace the ring with the spherical side on
top of the screwcap.
965
45 Frontfork 5060 Extreme Assembling forkleg.

Workshop manual
Product
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Assemble the cartridge in the forkleg.
966
In case of an older type screwcap use T905

for assembling.
967
Assemble the bolt with a new copper washer.
968

Workshop manual
Product
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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 the edge

of the fully compressed inner-tube.
971

Workshop manual
Product
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Move the inner-tube up and down a couple of

times. (not too high)
974
Move the piston rod several times up and

down, until you feel that all air is bled out.
(The damping is smooth over the entire
stroke)
972
Rebound side: Oil is coming through this

hole.
973

Workshop manual
Product
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Adjust T137S to the correct level.
975
Hold the upper side of the piston rod exactly

level with the edge of the fully compressed
inner-tube.
Hold squeezed bottle so that the O-ring
976 touches the edge of the inner-tube.
Releasing the pressure to the bottle will suck
up the oil till the correct level.
Replace the spring with the conical side

under.
977

Workshop manual
Product
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Assemble the spring.
978
Replace the steel washer first and then the

preload spacers.
979
Assemble the springretainer
980

Workshop manual
Product
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Pull the inner-tube up.
981
Screw in the screwcover.
982
And tighten the screwcover to a torque of

30Nm.
983

Workshop manual
Product
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Position REB/COM!
984
52 Frontfork 5060 Extreme Adjusting

5060 Extreme: Workshop Manual

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Workshop manual

Frontfork 5060 Extreme

1 Frontfork 5060 Extreme

Frontfork 5060 Extreme

Pay attention to the following notes, when you are

Always use clean and professional tools.

Use always aluminium protector-plates.

Always replace damaged or worn parts.

Clean all parts before assembling.

2 Frontfork 5060 Extreme

Frontfork 5060 Extreme

3 Frontfork 5060 Extreme

Frontfork 5060 Extreme

Note the position of rebound/compression

Clamp the inner-tube in the vice with T903.

Bleed the air from the fork by releasing the

4 Frontfork 5060 Extreme Disassembly forkleg

Frontfork 5060 Extreme

Disassemble the screwcover. (size 24)

Remove the screwcover

Check the rubber sealing ring inside.

5 Frontfork 5060 Extreme Disassembly forkleg

Frontfork 5060 Extreme

Move the inner-tube down into the outer-tube.

Remove the springretainer, preload spacers

6 Frontfork 5060 Extreme Disassembly forkleg

Frontfork 5060 Extreme

Take out the spring.

Check the oil level with T137S.

Drain the oil out the forkleg.

7 Frontfork 5060 Extreme Disassembly forkleg

Frontfork 5060 Extreme

Clamp the axle-clamp in the vice so that the

Untighten the bolt out of the axle-clamp.

Copper washer and bolt.

8 Frontfork 5060 Extreme Disassembly forkleg

Frontfork 5060 Extreme

Pull out the cartridge.

Remove the cartridge.

9 Frontfork 5060 Extreme Disassembly forkleg

Frontfork 5060 Extreme

Remove the ring.

Hold forkleg up side down and remove the

Disassemble the dust stripper

10 Frontfork 5060 Extreme Disassembly forkleg

Frontfork 5060 Extreme

Remove the dust stripper.

Disassemble the lockwasher.

Remove the lockwasher.

11 Frontfork 5060 Extreme Disassembly forkleg

Frontfork 5060 Extreme

Heat the outer-tube near the oilseal.

Pull with both hands the inner-tube out of

Remove the oilseal.

12 Frontfork 5060 Extreme Disassembly forkleg

Frontfork 5060 Extreme

Remove the support ring.

Remove the DU-bush of the outer-tube.