WP 5018 Pds 1998

Workshop manual
5018 PDS 1998
Product
Exploded View
Disassembly & assembling
Shock absorber
5018 PDS 1998

02/2002
Introduction 2
Exploded view 3
Disassembly shock absorber 4
Shock absorber 5018 PDS 1998
Disassembly piston-rod 10
Disassembly adaptor DU-bush 14
Assembling adaptor DU-bush 16
Assembling piston-rod 20
Disassembly tube-side 25
Assembling tube-side 32
Bleeding 46
On pressure with nitrogen 53
Assembling spring 54
Adjusting 56
1
Workshop manual
5018 PDS 1998
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 general equipment, the
special tools of WP Suspension.
These tools with a unique “T” number (available by
WP Suspension) protect you from damaging the parts.
Always use aluminium protector-plates, when clamping

our products in the vice.
Replace always damaged or worn parts.
Clean all parts before assembling.
Caution:
Many times it is necesarry to assemble parts with
T131, T132 and T163.
02/2002
These parts must to dry for at least four hours!!

2
Workshop manual
5018 PDS ‘98
Product
Exploded View
Disassembly & Assembling
Exploded view
02/2002
3
Workshop manual
5018 PDS 1998
Product
Exploded View
Disassembly
shockabsorber
Measure the length (preload) of the

spring.
175
Take notice of position rebound.

(1 is closed, “+” mark)
176
02/2002
Take notice of position compression,

and turn knob to position 1.
(1 is open “–” mark)
177
4
Workshop manual
5018 PDS 1998
Product
Exploded View
Unscrew with T106 the spring retainers.
395 / 396
Turn both spring retainers to the

bottom.
397
02/2002
5
Workshop manual
5018 PDS 1998
Product
Exploded View
Remove the spring retainer open.
181
Remove the spring.
183
02/2002
6
Workshop manual
5018 PDS 1998
Product
Exploded View
Remove the spring washer.
184
Remove rubber cap of the nitrogen

reservior.
185
02/2002
Release slowly the nitrogen pressure.

Allenkey size 4.
186
7
Workshop manual
5018 PDS 1998
Product
Exploded View
Tap off the cover on one side...
398
...and on the other side.
399
02/2002
Tap the adaptor DU-bush loose with

T1216.
400
8
Workshop manual
5018 PDS 1998
Product
Exploded View
Push the adaptor downwards.
401
Remove the circlip.
194
02/2002
Pull firmly but carefully the piston-rod

“complete” out of the tube.
402
9
Workshop manual
5018 PDS 1998
Product
Exploded View
Disassembly piston-rod
Remove the piston-rod bolt. (size 22)
403
Place a screwdriver on top of the piston-

rod and lift the entire assembly,
consisting of rings, pistons and shims.
404
02/2002
- rebound bush
- compression shims piston 1
- piston 1
- piston ring
405 - rebound shims piston 1
- washer
- compression shims piston 2
- piston 2
- rebound shims piston 2
- piston-rod bolt.
10
Workshop manual
5018 PDS 1998
Product
Exploded View
Remove the adaptor DU-bush.
407
Remove the cap.
408
02/2002
Remove bump rubber.
409
11
Workshop manual
5018 PDS 1998
Product
Exploded View
Disassemble the screw-cap rebound with

T1218.
204
Disassemble rebound adjusting holder

out of the mounting fork with a
screwdriver.
207
02/2002
Rebound adjusting holder.
410
12
Workshop manual
5018 PDS 1998
Product
Exploded View
Remove the rebound valve seat and

bush.
411
The rebound adjusting mechanism in

parts.
412
02/2002
13
Workshop manual
5018 PDS 1998
Product
Exploded View
Disassembly adaptor
DU-bush
Pull the rebound rubber out of the

adaptor.
209
Prise the dirt scraper out of the holder.
211
02/2002
Disassemble the DU-bush with T1208

and T1209.
215
14
Workshop manual
5018 PDS 1998
Product
Exploded View
Press the DU-bush out of the adaptor.
216
- rebound rubber
- disc steel
- quad ring
- back-up ring
- DU-bush
- adaptor
217 - O-ring
- dirt scraper
02/2002
15
Workshop manual
5018 PDS 1998
Product
Exploded View
Assembling adaptor
DU-bush
Assemble a new DU-bush with T1208

and T1209.
220
Press the DU-bush into the adaptor.
221
02/2002
Calibrate the DU-bush with T1205 and

T1209.
222
16
Workshop manual
5018 PDS 1998
Product
Exploded View
Drive the calibration mandrel through the

DU-bush.
224
Press with T1204 a new dirt scraper into

the adaptor.
227
02/2002
Replace the O-ring.
228
17
Workshop manual
5018 PDS 1998
Product
Exploded View
Assemble the back-up ring.
229
Assemble the quad ring.
230
02/2002
Assemble the steel disc.
231
18
Workshop manual
5018 PDS 1998
Product
Exploded View
After assembly the rebound rubber check if

the rubber can be rotate in the adaptor.
232
02/2002
19
Workshop manual
5018 PDS 1998
Product
Exploded View
Assembling piston-rod
Grease both O-rings of rebound

mechanism with T158.
414
Place the entire assembly inside the

housing.
415
02/2002
Tighten the screw-cap with T1218.
237 dit
klopt!
20
Workshop manual
5018 PDS 1998
Product
Exploded View
Place T1215 on top of the piston-rod.
238
Assemble bump rubber.
416
02/2002
Place the cap.
417
21
Workshop manual
5018 PDS 1998
Product
Exploded View
Grease dirt scraper with T625 and...
241
...assemble the DU-bush adaptor.
418
02/2002
Replace the entire damping packet.
419
22
Workshop manual
5018 PDS 1998
Product
Exploded View
Grease the O-ring of the adaptor with

T158.
244
Drip T163 on the thread of the piston-rod

bolt.
421
02/2002
Slide T1214 over both pistons and the

adaptor and assemble the bolt.
422
23
Workshop manual
5018 PDS 1998
Product
Exploded View
Place T107S through T1214, washer and

piston-rod.
247
Tighten the bolt to a torque of 40Nm.
248
02/2002
24
Workshop manual
5018 PDS 1998
Product
Exploded View
Disassembly tube-side
Heat the nitrogen reservoir on the bottom

side.
250
Unscrew reservoir with T146 and T147.
251
02/2002
Clamp nitrogen reservoir into T146 and

T147 and unscrew the screw-cap with
T125S and T145S.
252
25
Workshop manual
5018 PDS 1998
Product
Exploded View
Push the separation piston out of the

reservoir with T107S.
253
Remove springring from the tube.
423
02/2002
Remove spring guide.
425
26
Workshop manual
5018 PDS 1998
Product
Exploded View
Remove the second springring.
427
02/2002
27
Workshop manual
5018 PDS 1998
Product
Exploded View
Screw both screw retainers from the

tube.
428
Unscrew (size 2.5) the compression

adjusting knob and remove it.
261
02/2002
Remove the ball-steel.
262
28
Workshop manual
5018 PDS 1998
Product
Exploded View
Disassemble the lockwasher.

Pay attention to the assembling
direction!!!
264
Pull out the compression control

mechanism.
265
02/2002
The compression control mechanism

complete.
275
29
Workshop manual
5018 PDS 1998
Product
Exploded View
Remove both seals with a screwdriver.
429
Disassemble the adaptor bushes with

T120.
431
02/2002
Tap adaptor bushes out the heim- joint

KGW.
432 / 433
30
Workshop manual
5018 PDS 1998
Product
Exploded View
Disassemble heim-joint KGW with

T1207S.
279
Press with the vice the heim-joint KGW

out of the bottom.
280
02/2002
- seal
- adaptor bush
- heim- joint KGW
- bottom
434 - adaptor bush
- seal
31
Workshop manual
5018 PDS 1998
Product
Exploded View
Assembling tube-side
Drip on the innerside of the bottom-eye

T163, and mount heim- joint KGW with
T1206.
(With the bevelled edge direction bottom)
311
Press heim joint into the bottom-eye

with support of the vice.
290
02/2002
Press one adaptor bush in the heim-

joint with T1206.
435
32
Workshop manual
5018 PDS 1998
Product
Exploded View
And the second without tool.
436
Assemble the seals.
437
02/2002
Building up the nitrogen reservoir.

Grease the O-ring of the separation
piston with T158.
294
33
Workshop manual
5018 PDS 1998
Product
Exploded View
Assemble the separation piston with the

spherical surface in the direction of the
bottom.
295
Wetting the thread of the reservoir on

both inner sides wih T132.
298
02/2002
34
Workshop manual
5018 PDS 1998
Product
Exploded View
Drip T132 on thread screw-cap reservoir.
299
And T132 on the thread of the bottom.
301
02/2002
Assemble the screw-cap with the

reservior.
302
35
Workshop manual
5018 PDS 1998
Product
Exploded View
Tighten screw-cap and reservior on

bottom with T125S and T145S.
303
Assemble both springretainers.
438
02/2002
Screw the screw retainers against the

bottom.
440
36
Workshop manual
5018 PDS 1998
Product
Exploded View
Assemble the springring in the groove.
441
Slide spring guide over the tube.
443
02/2002
Place upper springring in the groove.
444
37
Workshop manual
5018 PDS 1998
Product
Exploded View
Assembling the compression control

mechanism.
Grease the O-rings with T158.
326
02/2002
38
Workshop manual
5018 PDS 1998
Product
Exploded View
Assemble the mechanism so that the

hole of this, is facing the hole to the
direction of the tube.
327
Push mechanism with T160 past the

lock washer groove.
328
02/2002
Assemble the lock washer with the flat

side above.
329
39
Workshop manual
5018 PDS 1998
Product
Exploded View
Grease the upper side of compression

mechanism with T159 and the place steel
ball next to the pin.
331
Mount the adjusting knob with the spring

directly on the steel ball.
332
02/2002
Push on the knob and tighten it.

Adjust knob to position 1.
333
40
Workshop manual
5018 PDS 1998
Product
Exploded View
Fill the tube with oil about 10mm under

the springring groove.
330
Place T1210S into the tube and T107S

into the nitrogen resevoir, slide the
O-ring as far as the screw-cap.
336
02/2002
Push the plunger downwards.
337
41
Workshop manual
5018 PDS 1998
Product
Exploded View
Push T107S (separation piston) and

plunger alternate downwards.
337 / 338
Adjust the separation piston about

10mm from bottom, also the O-ring on
the shaft of T107S will be 10mm above
the screw-cap.
339
02/2002
Adjust compression mechanism to “+”

mark. (closed)
340
42
Workshop manual
5018 PDS 1998
Product
Exploded View
Fill up oil 35mm beneath the edge of the

tube.
346
Assemble piston-rod “complete”.

Grease the O-ring of the DU-bush
adaptor with T158.
445
02/2002
Slide piston-rod “complete” into the tube.
446 + 447
(tweede
kader
maken)
43
Workshop manual
5018 PDS 1998
Product
Exploded View
Push the adaptor DU-bush into the tube.
352
Push adaptor past the springring

groove.
353
02/2002
Assemble the springring into the groove.
354
44
Workshop manual
5018 PDS 1998
Product
Exploded View
Pull up the piston-rod, and the springring

will spring in the groove.
355
Tap the cap back into position.
448
02/2002
45
Workshop manual
5018 PDS 1998
Product
Exploded View
Bleeding
Remove the compression adjusting

knob.
261
Remove the steel ball.
262
02/2002
Remove the lock washer.
264
46
Workshop manual
5018 PDS 1998
Product
Exploded View
1. Remove the compression control

mechanism.
265
2.
275
02/2002
Clamp the shock absorber (not too tight)

on the spring guide into the vice at an
angle of
± 45 degrees with the housing of the
compression mechanism at the highest
level. Connect the adaptor of T144S into
the housing.
362
363
47
Workshop manual
5018 PDS 1998
Product
Exploded View
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.
364
Push the piston-rod slowly in.
365
02/2002
Pull the piston-rod out.
366
48
Workshop manual
5018 PDS 1998
Product
Exploded View
Remove the shock absorber out the vice

and turn it 45 degrees to the right and left
several times.
Repeate the procedures until all air is
bled out.
367
Pull the piston-rod entirely out.

Check position of the separate piston
with T107S. (O-ring on shaft tool)
368
02/2002
Unscrew adjusting needle clockwise out

of the compression control mechanism.
370
49
Workshop manual
5018 PDS 1998
Product
Exploded View
Assemble the compression mechanism

without needle.
Note: hole of mechanism facing hole
direction tube.
371
Assembled compression control

mechanism.
372
02/2002
Screw the adjusting needle hand tight

into the mechanism.
373
50
Workshop manual
5018 PDS 1998
Product
Exploded View
Push mechanism with T160 past the

lock washer groove.
02/2002
51
Workshop manual
5018 PDS 1998
Product
Exploded View
Assemble lock washer with the flat side

above.
329
Place the steel ball next to pin.
331
02/2002
Assemble the adjusting knob with spring

on steel ball, push on the knob and
tighten it.
332
333
52
Workshop manual
5018 PDS 1998
Product
Exploded View
On pressure with
nitrogen
Screw the nitrogen plug with O-ring

several turns into the screw-cap.
374
Place the shock absorber in T170S

and fill the reservior with nitrogen
(±20 sec.) and tighten the bolt under
pressure.
379
02/2002
Replace rubber dop “do not open”
380
53
Workshop manual
5018 PDS 1998
Product
Exploded View
Assembling the spring
Turn the mounting-fork parallel with

bottom eye.
Rebound and compression mechanism
in the same direction.
381
Replace the spring washer.
382
02/2002
Replace the spring with the progressive

coiles into the direction of the bottom.
451
54
Workshop manual
5018 PDS 1998
Product
Exploded View
Assemble open spring retainer with the

closed side on the end of the coil.
385
Turn the spring and retainer in this

position.
387
02/2002
Adjust the preload and tighten the spring

retainers with T106.
452
55
Workshop manual
5018 PDS 1998
Product
Exploded View
Adjusting
Adjust the rebound position. (from closed

position)
391
Adjust the compression position.
392
02/2002
56

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Workshop manual

5018 PDS 1998

5018 PDS 1998

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.

These parts must to dry for at least four hours!!

Measure the length (preload) of the

Take notice of position rebound.

Take notice of position compression,

Unscrew with T106 the spring retainers.

Turn both spring retainers to the

Remove the spring retainer open.

Remove the spring.

Remove the spring washer.

Remove rubber cap of the nitrogen

Release slowly the nitrogen pressure.

Tap off the cover on one side...

...and on the other side.

Tap the adaptor DU-bush loose with

Push the adaptor downwards.

Remove the circlip.

Pull firmly but carefully the piston-rod

Remove the piston-rod bolt. (size 22)

Place a screwdriver on top of the piston-

Remove the adaptor DU-bush.

Remove the cap.

Remove bump rubber.

Disassemble the screw-cap rebound with

Disassemble rebound adjusting holder

Rebound adjusting holder.

Remove the rebound valve seat and

The rebound adjusting mechanism in

Pull the rebound rubber out of the

Prise the dirt scraper out of the holder.

Disassemble the DU-bush with T1208

Press the DU-bush out of the adaptor.

Assemble a new DU-bush with T1208

Press the DU-bush into the adaptor.

Calibrate the DU-bush with T1205 and

Drive the calibration mandrel through the

Press with T1204 a new dirt scraper into

Replace the O-ring.

Assemble the back-up ring.

Assemble the quad ring.

Assemble the steel disc.

After assembly the rebound rubber check if

Grease both O-rings of rebound

Place the entire assembly inside the

Tighten the screw-cap with T1218.

Place T1215 on top of the piston-rod.

Assemble bump rubber.

Place the cap.

Grease dirt scraper with T625 and...

...assemble the DU-bush adaptor.