Dual Compression Control Manual

Workshop Manual

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Disassembly & Assembling

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Dual Compression Control

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Introduction 2Exploded view 3Disassembly DCC 4Assembling DCC 16


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Introduction

This workshop Manual of the DCC is for the“ROAD” shockabsorbers, the DCC for the”OFF ROAD” shockabsorbers is the same onlywithout the adjustment knobs.

General notice

Pay attention to the following notes, when you are workingwith WP suspension products as described in thisworkshop 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 atWP Suspension) protect you from damaging the parts.Always use aluminium protector-plates, when clampingour products or parts in the vice.

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

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DCC for the “OFF ROAD” shockabsorbers.Hexagonal size 17 for the High-Speedcompression adjustment.Adjusting screw for the Low-Speedcompression adjustment.

Disassembly DCC

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1. Remove the screw-cap with thehexagonal high-speed adjustment.

2.

Turn clockwise the hexagonaladjustment part out of the screw-cap.(size 17)

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The hexagonal adjustment part out ofthe screw-cap.

Remove the plate (backplate) from thespring.

Remove the high-speed spring.

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Clamp the mechanism in T1208S.

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Unscrew the nut.(size 10)

Turn the nut of the dampings adaptor.

Remove the piston with check-valvemechanism.

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Check-valve side.

DCC piston side.

Disassemble the O-ring.

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Remove the disk.Pay attention to the assemblingdirection!!!

Disassemble the entire dampings(shims) package.Pay attention to the assemblingdirection!!!

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Remove the locking ring of the dampingsadaptor.

Clamp the mechanism not too tight inthe clamping block in this position.

Turn with the knob or screwdriver the Low-Speed compression fullyinwards.

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Remove the springring out of thedampings adaptor.

Turn with the adjusting knob orscrewdriver the Low-speed needlecompletely out.

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Disassemble or pull the Low-Speedadjustment needle out.Pay attention to the spring and steel ball.

Remove the steel ball and spring.

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Remove the O-ring out of the groove ofthe screw-cap.

Remove the O-ring out of the groove ofthe High-Speed hexagonal.

Remove the O-ring inside.

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All parts of the DCC mechanism.

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Assemble the spring into the Low-Speedadjustment needle.

Grease some T159 on top of the springand also on the O-ring.

Place the steel ball on the spring.

Assembly DCC

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1. Assemble the Low-Speed adjustmentneedle dampings adaptor.

2.

Turn completely the needle inwards.

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Assemble the springring into the grooveof the dampings adaptor.

Assemble the locking ring.

Assemble the disk.Pay attention to the assemblingdirection!!!

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Replace the entire DCC setting.Pay attention to the assemblingdirection!!!

1. Replace the piston with check-valvemechanism.

2.

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Wet the thread of the nut with T132.

Tighten the nut to a torque of 4Nm.

Assemble the spring of the High-Speedadjustment.

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Replace the plate (backplate).

High-Speed adjustment part with theassembled O-ring.

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Assemble the O-ring inside the groove ofthe hexagonal High-speed adjustmentpart.

Grease the O-ring with T159.

Grease with T159 the O-ring inside.

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Assemble the O-ring into the groove ofthe screw-cap.

Assemble the hexagonal into thescrew-cap.

Turn the hexagonal High-Speedadjustment part anti clock wise throughthe screw-cap of the DCC.

Documents

Dual Compression Control Manual