3612 / 4681 BAVP: Workshop Manual

Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Disassembly & Assembling
455
Shock absorber
3612 / 4681 BAVP

02/2002
Introduction 2
Exploded view 3
Adjustment 4
Disassembly shock absorber 5
Shock absorber 3612/4681 BAVP
Disassembly piston-rod 7
Disassembly adaptor DU-bush 15
Disassembly tube side 18
Disassembly heim-joint KGW 24
Assembling heim-joint KGW 26
Assembling piston-rod 28
Assembling adaptor DU-bush 35
Assembling tube side 40
Bleeding 53
Under pressure with nitrogen 58
Assembling the spring 59
Adjusting 61
1
Workshop manual
3612 / 4681 BAVP
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 an unique “T”number (available by
WP Suspension) protect you from damaging the parts.
Always use aluminium protector-plates, when clamping

our products or parts in the vice.
Replace always damaged or worn parts.
Clean all parts before assembling.
Caution:
Many times it is necesarry to assemble parts with
02/2002
T131, T132 and T163.

These parts must to dry for at least four hours!!
Shock absorber 3612/4681BAVP
2
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Disassembly & assembling
Exploded view
02/2002
3
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Adjustment
Measure the length (preload) of the

spring.
458
Take note of position compression.
456
02/2002
Take note of position rebound.
457
4
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Disassembly shock
absorber
Disassemble the spring with T101S and

remove the open spring retainer.
459
Remove the spring.
460
02/2002
Adjust the rebound to position 1.
462
5
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Remove the rubber cap.
464
Unscrew slowly the nitrogen plug and

release the pressure.
465
02/2002
Unscrew the screw-cap with T125S.
467
6
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Lift the O-ring out of the tube.
469
Pull piston-rod “complete” out of the

tube.
470
02/2002
Disassembly piston-rod
Unscrew piston-rod nut.
(size 22)
471
7
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Place a screwdriver on top of the piston-

rod and remove the entire assembly.
568
The piston-rod nut BA. (Bleed Adjuster)
474
02/2002
Disassemble the piston-rod nut.
475
8
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
- piston-rod nut
- shims
- bush
- bleed bolt (Allen screw)
476
- rebound bush plane

- compression shims
- piston
- rebound shims
- washer
473
02/2002
Remove (should this be the case) the

spacers.
Pay attention to the assembling
direction!!!
600
9
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Remove adaptor DU-bush.
479
Remove the circlip and O-ring.
480
02/2002
Remove the dirt scraper and screw-cap.
481
10
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Remove the bump rubber.
482
Remove the steel washer and

springring.
02/2002
11
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Take off the adjusting knob.
485
Remove the pin. (D4)
486
02/2002
Remove the position ring.
487
12
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Remove the seal.
488
Clamp the piston-rod in the vice with

T104S.
489
02/2002
Heat the mounting fork / eye.
490
13
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Unscrew the mounting fork / eye.
491
Remove mounting fork / eye.
492
02/2002
Unscrew the seat with an Allenkey.

(size 3)
493
14
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Remove the seat.
494
Remove the adjusting needle BA.
495
02/2002
Disassembly adaptor
DU-bush
Prise the rebound rubber out the adaptor
496 DU-bush.
15
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Remove the washer.
497
Remove the quad ring and back-up ring.
498
02/2002
Disassemble with T105S the DU-bush.
500
16
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Press the DU-bush out of ithe adaptor.
501
- rebound rubber
- washer
- quad ring
- back-up ring
- DU-bush
- adaptor
502
02/2002
17
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Disassembly tube side
Unscrew the compression adjusting knob

with Allenkey 2.5.
503
Remove the adjusting knob.
504
02/2002
Remove the ball-steel.
506
18
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Remove the lock washer.
507
Lift out the compression control

mechanism.
508
02/2002
Screw the screw-cap hand tight into the

tube.
511
19
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Heat the bottom.
510
Unscrew the tube with T146 and T148.
3612 BAVP with T146 and T315.
584
02/2002
Clamp the tube with T146 and T148 and

heat the threaded bush.

513
20
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Unscrew the threaded bush with T106.
3612 BAVP with T304.
514
Threaded bush with the spring retainers.
515
02/2002
Disassemble the spring retainers with

T106.

516
21
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Heat reservoir near bottom.
517
Unscrew reservoir with T146 and T147.
518
02/2002
Push the separation piston out of the

reservoir with T107S.
519
22
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
The separation piston.
520
Clamp reservoir into T146 and T147.
Unscrew the screw-cap with T125S and

T145S.
521
02/2002
23
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Disassembly heim-
joint KGW
Remove the seals on both sides.
429
Tap the adaptor bushes out of the heim-

joint with T120.
431
02/2002
Tapping the adaptor bushes out.
432 / 433
24
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Disassemble the heim-joint KGW with

T130S...
279
...with support of the vice.
280
02/2002
- seal
- adaptorbush
- heim-joint KGW
- bottom
434 - adaptor bush
- seal
25
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Assembling heim-joint
KGW
Drip on the innerside of bottom-eye T163

and mount heim-joint KGW with T129.
(With the bevelled edge direction bottom-
eye)
311
Press the heim-joint into the bottom with

the vice.
290
02/2002
Assemble with T129 adaptor bush on

one side...
435
26
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
...and without tool the other side.
436
Assemble the seals in the groove of the

bottom- eye.
437
02/2002
27
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Assembling piston-rod
Grease O-ring adjusting needle rebound

with T158.
522
Assemble the adjusting needle in

piston-rod.
524
02/2002
Drip T132 on thread of the mounting

fork / eye.
525
28
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Drip on thread piston-rod T132.
526
Screw mounting fork / eye on the

piston-rod.
527
02/2002
Tighten the mounting fork / eye.
491
29
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Replace the seal and the position ring.
528
02/2002
30
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Place T107S through mounting fork / eye

under the needle and adjust position ring
in the highest position.
529 / 531
Assemble a new seat greased with

T152 on the thread.
533
02/2002
Tight seat light till T107S and turn two

rotations backwards.
535
31
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Grease the ring and pin with T159 and

assemble the pin.
536
Grease innerside adjusting knob with

T159 and replace the seal.
538
02/2002
Assemble the adjusting knob and turn

the knob to position 1.
539
32
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Assemble the steel washer and

springring.
541
Push needle downwards on pin with

Allenkey size 2.
543
02/2002
33
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Place T108 on top of the piston-rod.
544
Assemble the bump rubber.
545
02/2002
Assemble the screw-cap.
546
34
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Grease the innerside dirt scraper with

T625 and assemble.
547
Replace the O-ring.
548
02/2002
Assembling adaptor
DU-bush
Press DU-bush in adaptor with T150S.
549
35
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Pressing DU-bush into adaptor with

support of the vice.
550
Calibrate DU-bush with T149 and part of

T150S.
554
02/2002
Wet the mandrel with oil.

Drive the calibration mandrel through the
DU-bush.
555
36
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Assemble the back-up ring.
558
Assemble the quad ring.
559
02/2002
Assemble the washer.
561
37
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
After assembly the rebound rubber, check

if the rubber can be rotate in the holder.
562
Assemble the DU-bush adaptor.
563
02/2002
Should it be the case to assemble

spacers, then place them with the flat
side direction rebound rubber.
564
38
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Replace the entire damping packet.
565
Screw the piston-rod nut on piston-

rod....
566
02/2002
....and tighten the nut to a torque of

40Nm.
3612 BAVP with 30Nm.
567
39
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Assembling tube side
Grease the O-ring of the separation

piston with T158.
569
4681 BAVP:
Assembly direction separation piston:
With the flat side of the piston into
direction flat side bottom.
570
02/2002
3612 BAVP:
Assembly direction separation piston:
With the hollow side of the piston into
direction spherical surface bottom.
2060
40
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Assemble separation piston (with

piston-ring) always into direction of the
screw-cap.
573
Drip T132 on thread reservoir.
574
02/2002
Drip T132 on the thread of the

screw-cap.
575
41
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Drip T132 on thread of the bottom.
577
Tighten the screw-cap and reservoir

with T125S and T145S.
578
02/2002
Assemble both spring retainers on

threaded bush.
579
42
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Drip T132 on thread of the tube...
580
...and on the thread of the bottom.
581
02/2002
Assemble the threaded bush until the

end of thread of the tube.
582
43
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Assemble the tube in the bottom.
583
Screw down with T146 and T148.
585
02/2002
Screw threaded bush against the

bottom.
586
44
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Tighten threaded bush with T106.
587
Grease the O-rings with T158.

Assembly compression control
mechanism.
588
02/2002
Assemble mechanism, so that the hole

of this is facing the hole in the direction
of the tube.
589
45
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Push the mechanism with T160 past the

lock washer groove.
590
Assemble the lock washer with flat side

above.
591
02/2002
Grease the upper side compression

mechanism with T159 and place
ball-steel next to the pin.
592
46
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Push adjusting knob with the spring

directly on the steel ball and tighten Allen
screw.
Adjust compression control mechanism
to position 1.
593
Push the separation piston with T107S

to the bottom and slide O-ring as far as
the screw-cap.
596
02/2002
Fill the tube with oil about 15mm under

the springring groove.
597
47
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Place T110S in the tube and push the

plunger downwards.
3612 BAVP with T306S.
598
Push the separation piston downwards,

and hold the tube side in a angle. (about
45 degrees)
Repeat those procedures several times.
604
02/2002
Adjust separation piston about 10mm

from the bottom, O-ring on the shaft will
be 10mm above the screw-cap.
599
48
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Adjust oil level about 45mm under the

edge of the tube and set compression
adjusting knob on position 1.
602
Slide piston-rod “complete” into the tube

and assemble the springring above the
piston in the groove with support of...
605
02/2002
...T155.
Pull light the piston against the
springring and hold this till assembly
screw-cap.

606/607
49
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
(Assemble the spacers)
609
Assemble adaptor DU-bush.
610
02/2002
Remove (if necesarry) the oil above the

adaptor with T137S.
612
50
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Slide O-ring against the adaptor.
614
Slide dirts craper against the adaptor.
615
02/2002
Screw the screw-cap into the tube.
616
51
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Tighten the screw-cap with T125S.
617
02/2002
52
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Bleeding
Disassemble compression control

mechanism.
508
Connect the adaptor ot T144S into the

housing.
618
02/2002
Ensure that there is sufficient oil in the

bottle and that the hose is also full with oil.
You will see air bubbles rising up
through the hose.
619 / 620
53
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Push the piston-rod slowly in and out.
621
Cant to a view times the shock absorber

and repeat the procedures several times
until all air is bled out.
623
02/2002
Check the position of the separation

piston with T107S.
624
54
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Assemble mechanism without adjusting

needle. (left handed thread)
370
Note: hole of mechanism facing hole

direction tube.
371
02/2002
372
55
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Screw the adjusting needle hand tight

into mechanism.
373
Push compression control mechanism

past lock washer groove.
328
02/2002
Assemble lock washer with flat side

above.
329
56
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Replace the steel ball on the left position

next to the pin.
Place the steel ball:

By CC no. 11: the third position on the
right side of the pin.
By CC no. 16: next on the right side of the
331 pin.
1. Assemble adjusting knob with spring

on the steel ball.
332
02/2002
2.
333
57
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
On pressure with
nitrogen
Replace the nitrogen plug with O-ring

several turns into the screw-cap.
625
Place the shock absorber (reservoir) in

T170S and fill it with nitrogen (±20 sec.)
and tighten the plug under pressure.
626
02/2002
Assemble the rubber cap “do not open”
627
58
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Assembling spring
Turn mounting fork / eye parallel with

bottom-eye.
629
Assemble the spring.
630
02/2002
Assemble the open spring retainer with

T101S.
Closed side of the retainer on the end of the
coil.
631
59
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Adjust the spring preload.
632
Tighten the spring retainers with T106.
634
02/2002
60
Workshop manual
3612 / 4681 BAVP
Product
Exploded View
Adjusting
Position rebound!
633
Position compression!
635
02/2002
61

3612 / 4681 BAVP: Workshop Manual

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Workshop manual

3612 / 4681 BAVP

3612 / 4681 BAVP

3612 / 4681 BAVP

Pay attention to the following notes, when you are

Always use clean and professional tools.

Always use aluminium protector-plates, when clamping

Replace always damaged or worn parts.

Clean all parts before assembling.

T131, T132 and T163.

3612 / 4681 BAVP

3612 / 4681 BAVP

Measure the length (preload) of the

Take note of position compression.

Take note of position rebound.

3612 / 4681 BAVP

Disassemble the spring with T101S and

Remove the spring.

Adjust the rebound to position 1.

3612 / 4681 BAVP

Remove the rubber cap.

Unscrew slowly the nitrogen plug and

Unscrew the screw-cap with T125S.

3612 / 4681 BAVP

Lift the O-ring out of the tube.

Pull piston-rod “complete” out of the

3612 / 4681 BAVP

Place a screwdriver on top of the piston-

The piston-rod nut BA. (Bleed Adjuster)

Disassemble the piston-rod nut.

3612 / 4681 BAVP

- rebound bush plane

Remove (should this be the case) the

3612 / 4681 BAVP

Remove adaptor DU-bush.

Remove the circlip and O-ring.

Remove the dirt scraper and screw-cap.

3612 / 4681 BAVP

Remove the bump rubber.

Remove the steel washer and

3612 / 4681 BAVP

Take off the adjusting knob.

Remove the pin. (D4)

Remove the position ring.

3612 / 4681 BAVP

Remove the seal.

Clamp the piston-rod in the vice with

Heat the mounting fork / eye.

3612 / 4681 BAVP

Unscrew the mounting fork / eye.

Remove mounting fork / eye.

Unscrew the seat with an Allenkey.

3612 / 4681 BAVP

Remove the seat.

Remove the adjusting needle BA.

3612 / 4681 BAVP

Remove the washer.

Remove the quad ring and back-up ring.

Disassemble with T105S the DU-bush.

3612 / 4681 BAVP

Press the DU-bush out of ithe adaptor.

3612 / 4681 BAVP