DVO DIAMOND Service manual

SEAL SERVICE &
CASTING CLEANING

WEAR SAFETY GEAR!
This manual will guide you step by step performing a
seal service and casting cleaning on a DVO
Diamond. Please follow each instruction carefully to
achieve the best and safest results.
*Always wear your safety gear while working on
suspension products.We care about you, make sure
you wear your safety glasses and protective gloves
while servicing DVO Suspension Products.
Tools needed:
Allen key- 2.5mm
32mm thin wall socket
18mm thin wall socket
Rubber Mallet
Oil Measuring Container
35mm Seal Press
Suspension Clean
7.5 wt Oil
18mm Open end Wrench
IMPORTANT!
USE A THIN WALL SOCKET
OR DAMAGE MAY OCCUR
// Intro // Intro

Remove 2.5mm bolt from low speed
adjuster. Use the 32mm socket to loosen
damper side top cap. Do not
completley unthread.
Lift the high and low speed
compression adjusters up to reveal the
detent insert.
Tip: Remove the adjusters slowly to
keep the detents from falling.
Use the 32mm socket to loosen
air side top cap. Do not
completley unthread.
Remove the two detents from the
detent insert.
Use the 18mm socket to loosen the
rebound side footnut.
1. 4.
2. 5.
3.
// pg. 1 // pg. 2
6.

Use the 18mm socket to loosen the air
side footnut.
Use the rubber mallet and tap on the
footnuts until they are ush with the
casting.
Do not completely remove the foot-
nuts from the casting. Make sure there
is a gap as shown.
The footnuts are now ush with the
casting. The cartridges are now free
from the casting.
Do not completely remove the foot-
nuts from the casting. Make sure there
is a gap as shown.
Remove both adjusters from the
casting.
// pg. 3 // pg. 4
7. 10.
11.
12.
8.
9.
OTT Adjuster/Air Side
Rebound Adjuster/ Damper

Drain the oil from both sides of the
casting.
Completely remove upper assembly
from the casting.
Once the oil has been drained, re-
move both cartridges completely. Use an 18mm open end wrench to
remove the seal from the casting.
With one hand grab the arch, and with
the other hand, pull the upper assem-
bly upward.
Make sure the seal is completely
removed.
16.13.
17.14.
18.15.
// pg. 5 // pg. 6

.
// pg. 7 // pg. 8
After both dust seals have been
removed, remvoe the foam rings from
the casting.
Make sure the seal area and
upper bushing is thoroughly clean and
free of any debris.
Use suspension clean to remove any
contaminents from inside the casting. Grab the new foam rings and soak
them in 7.5 wt oil.
Wipe clean with a paper towel. Lightly grease the inside of the casting
where the new seal will sit.
22.19.
23.20.
24.21.

.
// pg. 9 // pg. 10
Use the 35mm seal press to install the
new seal.
Grab the foam rings from the oil con-
tainer to insert them under the seal.
Use the rubber mallet to press in the
new seal. The foam ring will sit under the seal
and right above the upper bushing.
The new dust seals should sit ush in
the casting. Make sure the edges of
the seal are evenly pressed into
casting.
Repeat steps 24-27 for the second
seal.
Apply a thin layer of grease on inside
of the seal.
28.25.
29.26.
30.27.

.
// pg. 12// pg. 11
Reinsert upper assembly into
casting. Start with the stanchion tubes
at a slight angle as shown.
Raise the upper assembly until the
crown touches the top caps of the
cartridges.
Hand tighten top caps into crown.
Once the stanchion tube has passed
the dust seal, insert straight down. Flip the fork upside down and it should
look like this.
Now insert both cartridges. Insert 35cc’s of 7.5 wt. oil into the
damper side.
Tip: Pull up on the casting to make
room for the oil to pour in.
34.31.
35.32.
36.33.

.
// pg. 14
Pour 25cc’s of 7.5 wt. oil into the air
side.
Tip: Pull up on the casting to make
room for the oil to pour in.
Use the 18mm socket to tighten both
footnuts to 10nm.
Pull the casting down until the bottom
of the cartridges are touching the oor
of the casting.
Use the 32mm socket to tighten both
top caps to 20nm.
Insert both adjusters. Reinstall the two detents into the
detent insert.
Tip: You can apply some grease to the
detents to keep them from falling out.
40.37.
41.38.
42.39.
// pg. 13

Thank you for choosing DVO Suspension!
If you have any further questions please email
[email protected]
For all other technical information please visit
www.tech.dvosuspension.com
www.DVOSUSPENSION.COM
// pg. 16 // pg. 15
Line up the at edges of the
compression adjusters with the at
edges of the detent insert.
Use the 2.5mm allen key to tighten the
compression adjusters.
43.
44.