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Old 11-04-2007, 01:36 AM   #1
The Misinformant OP
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640 ADV Forks

Has anyone changed the springs themselves on the 4860WP forks? Is there any special tools required and is it a reasonable easy job?

Have found a set of .46 WP springs out of a 06 640 to replace my .44 WP springs in my 03 640 ADV - which we think are a direct swap.
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Old 11-04-2007, 01:17 AM   #2
Laromonster
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Arent the 03 forks 43mm and the 06 48 mm ?
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Old 11-04-2007, 02:05 AM   #3
The Misinformant OP
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My owners manual says 4860, so I assume they are 48's. Let me look in the shed.
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Old 11-04-2007, 02:17 AM   #4
GodSilla
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Big forks on '03

The '03 model got the hi-flow head and the rally 48mm forks, from memory.
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Old 11-04-2007, 02:26 AM   #5
The Misinformant OP
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Yep books say 48mm. Can't measure them tonight as it not here. Bloody squids!
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Old 11-04-2007, 03:43 AM   #6
Para504
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My '02 has 48mm (measured them to be sure) as well. The literature is notoriously wrong!
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Old 11-04-2007, 01:47 PM   #7
Luke
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Quote:
Originally Posted by The Misinformant
Has anyone changed the springs themselves on the 4860WP forks? Is there any special tools required and is it a reasonable easy job?

Have found a set of .46 WP springs out of a 06 640 to replace my .44 WP springs in my 03 640 ADV - which we think are a direct swap.


It's pretty easy, there was one special tool that I needed. In order to separate the top cap from the bottoming bumper, I needed to grind down a wrench so that it was thin enought to slip onto the flats on the bumper's nut. I think it was a 15mm wrench.
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Old 11-05-2007, 09:52 AM   #8
Zerodog
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Yes the 03 has 48mm forks. They are pretty much the same fork as the MX bikes. They just have a slightly shorter stroke on the cartridge. That is why they take the shorter springs. The 510mm springs will also work if you remove all the preload spacers except the thinest one. They are also the same interally as the 07 640. The .46 will most likely still be too light. But it will still be an improvement.
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