WP SUSPENSION 53000272en APEX PRO 6500 Cartridge Owner’s Manual

WP SUSPENSION 53000272en APEX PRO 6500 Cartridge

MEANS OF REPRESENTATION

Symbols used

The meaning of specific symbols is described below.

• Indicates an expected reaction (e.g. of a work step or a function).
• Indicates an unexpected reaction (e.g. of a work step or a function).
• All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs performed by a WP Authorized Center! There your WP chassis will be treated with the optimum care and attention by specially
• trained experts using the necessary special tools.
• Indicates a page reference (more information is provided on the specified page).
• Indicates information with more details or tips.
• Indicates the result of a testing step.
• Indicates the end of an activity, including potential rework.

Formats used

The typographical formats used in this document are explained below.

• Proprietary name Indicates a proprietary name.
• Name® Indicates a protected name.
• Brand™ Indicates a brand available on the open market.
• Underlined terms Refer to technical details or indicate technical terms, which are explained in the glossary.

SAFETY ADVICE

Use definition – intended use

This chassis component is designed and built to withstand the normal stresses and strains of road use and racing.

Info
Only use this chassis component in the vehicle for which the chassis component is approved and/or recommended.

Misuse

The chassis component must only be used as intended.
Dangers can arise for people, property and the environment through use not as intended.
Any use of the chassis component beyond the intended and defined use constitutes misuse.
Misuse also includes the use of operating and auxiliary fluids which do not meet the required specification for the respective use

Safety advice

A number of safety instructions need to be followed to operate the product described safely. Therefore read this instruction and all further instructions included carefully. The safety instructions are highlighted in the text and are referred to at the relevant passages.

Info
Various information and warning labels are attached in prominent locations on the product described.
Do not remove any information or warning labels. If they are missing, you or others may not recognize dangers and may therefore be injured.

Degrees of risk and symbols

Danger
Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken.

Warning
Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.

Note
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.

Safe operation

Danger
Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others.

• Do not operate the vehicle and use chassis components if you are not fit to ride due to alcohol, drugs or medication.
• Do not operate the vehicle and use chassis components if you are physically or mentally impaired.

Only use the chassis component when it is in perfect technical condition, in accordance with its intended use, and in a safe and environmentally compatible manner.

SAFETY ADVICE

If there are faults, which impair safety, have them immediately remedied in a WP Authorized Center. Adhere to the information and warning labels on the chassis component.

Work rules

Special tools are necessary for certain tasks. The tools are not a component of the chassis component, but can be ordered using the number in parentheses.
During assembly, use new parts to replace parts which cannot be reused (e.g., seals, seal rings, O-rings).
In the case of certain screws, a thread locker (e.g. Loctite®) is required. Observe the manufacturer’s instructions.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn parts.
After completing a repair or service work, check the operating safety of the chassis component.

Environment

If you use your chassis component responsibly, you can ensure that problems and conflicts do not occur.
When disposing of used oil, other operating and auxiliary fluids, and used components, comply with the laws and regulations of the respective country.

Owner’s Manual

It is important that you read this Owner’s Manual carefully and completely before making your first trip. The Owner’s Manual contains useful information and many tips on how to operate, handle, and service your motorcycle. This is the only way for you to find out how to set up the chassis component ideally and how to protect yourself from injury.
Keep the Owner’s Manual in an accessible place to enable you to refer to it as needed.
If you would like to know more about the chassis component or have questions on the material you read, please contact a WP Authorized Center.
The Owner’s Manual is an important part of the chassis component and must be handed over to the new owner if the vehicle is sold.

Correct installation

Correct installation in the same way as for the original components and in accordance with the repair manual of the vehicle is essential for ensuring maximum safety and functionality.
It is therefore strongly recommended that you have the chassis component installed at a WP Authorized Center.

Chassis tightening torques

Unless otherwise stated, the tightening torques specified in the operating and repair manual apply for the vehicle.

IMPORTANT NOTES

Manufacturer warranty, implied warranty

The work prescribed in the service schedule must be carried out in a WP Authorized Center only, since otherwise no warranty claims will be recognized. Damage or secondary damage caused by tampering with and/or conversions on the chassis component are not covered by the manufacturer warranty.

Fuel, auxiliary substances

Use operating and auxiliary substances (such as fuel and lubricants) as specified in the Owner’s Manual.

Spare parts, accessories

For your safety, only use spare parts and accessory products that are approved and/or recommended by WP and have them installed in a WP Authorized Center. WP accepts no liability for other products and any resulting damage or loss.
Certain spare parts and accessory products are specified in parentheses in the descriptions. Your WP Authorized Center will be pleased to advise you.

Service

A prerequisite for perfect operation and prevention of premature wear is that the service, care, and tuning work is properly carried out as described in the Owner’s Manual. Incorrect suspension setting can lead to damage and breakage of chassis components.
Use of the chassis component under difficult conditions, such on wet surfaces, can lead to considerably more rapid wear. For this reason, it may be necessary to inspect or replace parts before the next scheduled service.
It is imperative that you adhere to the stipulated service intervals. If you observe these exactly, you will ensure a much longer service life for your chassis component.

Figures

The figures contained in the manual may depict special equipment.
In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not always necessary to disassemble the component to perform the activity in question. Please follow the instructions in the text.

Customer service

If you have any questions about your chassis component or WP, your WP Authorized Center will be pleased to advise you.
A list of WP Authorized Centers can be found on the WP website.
International WP Suspension website: http://www.wp-suspension.com

SERIAL NUMBERS

Cartridge article number

Cartridge article number 1 is located on the side of the screw cap.

PREPARING FOR USE

Advice on preparing for first use

Warning
Danger of accident Modifications to the suspension setting may seriously alter the handling characteristic.
Extreme modifications to the suspension setting may cause a serious deterioration in the handling characteristic and overload components.

• Only make adjustments within the recommended range.
• Ride slowly to start with after making adjustments to get the feel of the new handling characteristic.
  • Adjust the compression damping of the fork.
  • Adjust the rebound damping of the fork.
  • Adjust the spring preload of the fork.

Checks and maintenance measures when preparing for use

Info
Before every use, check the condition of the chassis component and ensure that it is safe to operate.
The chassis must be in perfect technical condition when it is being operated.

• Check chassis component for damage.
• Clean the dust boots of the fork legs.
• Bleed the fork legs.
• Check all screw connections to ensure that they are tight.

SERVICE SCHEDULE

Additional information

Any further work that results from the compulsory work or from the recommended work must be ordered separately and invoiced separately.
Different service intervals may apply in your country, depending on the local operating conditions.

Required work

• Periodic interval

Recommended work

• One-time interval

SERVICE WORK ON THE CHASSIS

Raising the motorcycle with work stand

Note
Danger of damage The parked vehicle can roll away or fall over.

• Park the vehicle on a firm and level surface.

• Lift up the motorcycle according to the repair manual.
  Neither wheel is in contact with the ground.

• Secure the motorcycle against falling over.

Removing the standard fork legs

• Remove the standard fork legs according to the repair manual.
• Remove the standard cartridge according to the repair manual.

Installing the WP PRO COMPONENTS fork legs

Info
This product is suitable for several vehicles.
Contact a WP Authorized Center for any necessary conversions.

SERVICE WORK ON THE CHASSIS

• Install the WP PRO COMPONENTS cartridge in accordance with WP Suspension fitting instructions.
• Install the fork legs according to the repair manual.
  • Bleeder screws 1 on the left fork leg point to the left, the bleeder screws on the right fork leg point to the right.
  • Adjusting screw COMP is located at the upper end of the left fork leg.
  • Adjusting screw REB is located at the upper end of the right fork leg.
• Attach the stickers (included).

Bleeding the fork legs

Preparatory work

• Raise motorcycle with work stand.

Main work

• Release bleeder screws 1.
  • Any excess pressure escapes from the interior of the fork.
• Tighten the bleeder screws.

Finishing work

• Remove the motorcycle from the work stand.

Cleaning the dust boots of the fork legs

Preparatory work

• Raise motorcycle with work stand.
• Remove the fender.

Main work

• Push dust boots 1 of both fork legs downward.

Info
The dust boots remove dust and coarse dirt particles from the inside fork tubes. Over time, dirt can accumulate behind the dust boots. If this dirt is not
removed, the oil seals behind can start to leak.

SERVICE WORK ON THE CHASSIS

Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.

• Always keep the brake discs free of oil and grease.
• Clean the brake discs with brake cleaner when necessary.
• Clean and oil the dust boots and inner fork tubes of both fork legs.

Universal oil spray

• Press the dust boots back into the installation position.
• Remove the excess oil.

Finishing work

• Install the fender.
• Remove the motorcycle from the work stand.

Removing the motorcycle from the work stand

Note
Danger of damage The parked vehicle can roll away or fall over.

• Park the vehicle on a firm and level surface.
• Remove the motorcycle from the work stand according to the repair manual.
• Remove the work stand.

TUNING THE CHASSIS

Checking the basic chassis setting with the rider’s weight

• For optimal motorcycle riding characteristics and to avoid damage to forks, shock absorbers, link fork and frame, the basic settings of the suspension components must match the rider’s weight.
• This chassis component is factory set to a standard rider’s weight.

Guideline

• * Standard rider weight 75 … 85 kg (165 … 187 lb.)

• If the rider’s weight is above or below this range, the basic setting of the suspension components must be adjusted accordingly.
• Minor differences in the rider’s weight can be compensated for by modifying the spring preload.
• In case of larger differences, appropriate springs must be fitted.

Info
This product is suitable for several vehicles. Contact a WP Authorized Center for any necessary conversions.

Checking the basic setting of the fork

Info
For various reasons, no exact riding sag can be determined for the fork.

• As with the shock absorber, smaller differences in the rider’s weight can be compensated by the spring preload.
• However, if the fork frequently bottoms out (hard end stop on compression), harder springs must be fitted to avoid damage to the fork and frame.
• If the fork feels unusually hard after extended periods of operation, the fork legs need to be bled.

Adjusting the compression damping of the fork

Info
The hydraulic compression damping determines the fork suspension behavior.

TUNING THE CHASSIS

• Turn adjusting screw 1 clockwise up to the last perceptible click.

I n fo
Adjusting screw COMP 1 is located at the upper end of the left fork leg.

• Turn counterclockwise by the number of clicks corresponding to the fork type.

Guideline  

Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping during compression.
This product is suitable for several vehicles.
Contact a WP Authorized Center for any necessary conversions.

Adjusting the rebound damping of the fork

Info
The hydraulic rebound damping determines the fork suspension behavior.

• Turn adjusting screw 1 clockwise up to the last perceptible click.

Info
Adjusting screw REB 1 is located at the upper end of the right fork leg.

• Turn counterclockwise by the number of clicks corresponding to the fork type.

Guideline

TUNING THE CHASSIS

Info
Turn clockwise to increase the damping; turn counterclockwise to reduce damping when the shock absorber rebounds.
This product is suitable for several vehicles.
Contact a WP Authorized Center for any necessary conversions.

Adjusting the spring preload of the fork

Preparatory work

• Raise motorcycle with work stand. ( p. 10)

Main work

• Turn the preload adjusters to the desired marking.

Guideline

The preload adjusters snap into place noticeably

Info
Turn clockwise to increase the spring preload; turn counterclockwise to reduce the spring preload.
Adjusting the spring preload has no influence on the absorption setting of the rebound.
Basically, however, you should set the rebound damping higher with a higher spring preload.
This product is suitable for several vehicles.
Contact a WP Authorized Center for any necessary conversions .

Finishing work

• Remove the motorcycle from the work stand.

TECHNICAL DATA

Fork

SUBSTANCES

Fork oil (SAE 4) (48601166S1)

Standard/classification

• SAE ( p. 19) (SAE 4)

Guideline

• Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties.

AUXILIARY SUBSTANCES

Universal oil spray

Recommended supplier

MOTOREX®

• Joker 440 Synthetic

STANDARDS

SAE

The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their viscosity. The viscosity describes only one property of oil and says nothing about quality

INDEX OF SPECIAL TERMS

LIST OF ABBREVIATIONS

References

• PRO COMPONENTS - WP Suspension %

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