DVO ONYX DC User manual

ONYX DC Service Guide
Full Service

2ONYX DC FULL SERVICE
SERVICE OVERVIEW
This manual will guide you step by step performing a full service on an
ONYX DC suspension fork. 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.
WARNING: We recommend that you have your DVO suspension serviced by a qualied bicycle mechanic. Servicing DVO
suspension requires knowledge of suspension components, as well as the use of specialized tools and lubricants/fluids.
Failure to follow the procedures outlined in this service manual may cause damage to your component and void the
warranty.
WARNING: Always use genuine DVO parts and proper service methods when maintaining your DVO Suspension product.
Improper service, or use of after-market replacement parts with DVO Suspension may cause the product to malfunction,
resulting in SERIOUS INJURY OR DEATH.
WARNING: Modication, improper service, or use of after-market replacement parts with DVO Suspension may cause the
product to malfunction, resulting in SERIOUS INJURY OR DEATH. DO NOT modify any part of a fork or shock, including the
fork brace (lower leg cross brace), crown, steerer, upper and lower leg tubes, or internal parts, except as instructed herein.
Any unauthorized modication may void the warranty, and may cause failure or the fork or shock, resulting in SERIOUS
INJURY OR DEATH.
WEAR SAFETY GEAR!

3ONYX DC FULL SERVICE
Tools Needed For Service:
• Oil Drain Pan
• 11mm, 18mm Wrench
• 32mm, 22mm, 14mm Socket
• Flathead Screwdriver
• Vice
• 25mm, 30mm shaft clamps
• Shock Pump
• 2mm, 4mm Allen Key
• Rubber Mallet
• 3mm Punch
• Pick
•Needle Nose Pliers
Contents:
pg. 4-6 .....................................
pg. 7-8 .....................................
pg. 9-14 ..................................
pg. 15-21 .................................
Disassembly
Seal Service
Air Side Rebuild
Damper Side Rebuild
Fluids & Cleaner Needed For Service:
• Safety Glasses
• Clean, Lint Free Rag
• Suspension Cleaner or Alcohol
• Blue Loctite
• 2.5 & 7.5 wt oil. No Maxima
• Slickoleum Grease
• Graduated Cylinder
Recommended Service Interval:
• Full Service .......................100 Hours of Ride Time

4ONYX DC FULL SERVICEONYX DC FULL SERVICE
CAUTION - EYE HAZARD
Use a 2.5mm allen key to remove the low speed
knob. Then lift off the high speed compression ring.
Use needle nose pliers to remove the detent xture.
Be cautious of the detent balls falling out. Then use
a 32mm socket wrench to loosen the air side top
cap. You do not need to completely un-thread the
top caps.
Remove the air cap. Depress the valve to release the
air pressure.
A Disassembly
3.
2.
1.

ONYX DC FULL SERVICEONYX DC FULL SERVICE
With a 14mm socket wrench, loosen and remove
the OTT foot-nut.
With a 14mm socket wrench, loosen and remove
the rebound foot-nut.
5
Loosen the damper side top cap. You do not need
to completely un-thread it.
4.
5.
6.

6ONYX DC FULL SERVICEONYX DC FULL SERVICE
9.
8.
7.
Stand the fork up vertically and remove the damper
cartridge and air volume unit.
Drain the oil in an oil catch pan.
Place a plastic punch in the in the casting and
rmly tap with a rubber mallet to un-seat the
cartridges from the casting.

ONYX DC FULL SERVICEONYX DC FULL SERVICE7
10.
11.
12.
Now you can separate the upper assembly from
the casting.
Remove the foam ring from under the seal with a
small pick. Then remove the pressure spring on
the upper seal lips.
Place a flathead screwdriver under the seal lip
and pry the seal out of the casting.
NOTE: To prevent any damage to the casting, you
can place a rag or towel under the screwdriver.
Seal Service B

8ONYX DC FULL SERVICEONYX DC FULL SERVICE
15.
14.
13.
Make sure the seal is pressed in evenly all around with
no gaps. Re-install the foam rings under the seal.
Place the new seal in the casting and press into place
using the rubber mallet.
Soak the new foam rings in 7.5 wt suspension oil.
Place the new seals on a 36mm seal press.

ONYX DC FULL SERVICE9ONYX DC FULL SERVICE
The flat edge is for
the wrench.
16.
17.
18.
The foam rings should sit flush in the casting.
Make sure there are no gaps. Apply a thin layer of
grease to the inner lips of the seal.
Clamp the steer tube in the vice with 30mm shaft
clamps. Pull the air shaft upward.
To loosen the lock ring, use an 18mm wrench and
a set of pin spanners. The wrench goes on the flat
surface of the lock ring shown in the left image.
Hold the lock ring with the wrench, then un-thread
the plug with the pin spanners with
counter-clockwise rotations.
C Air Service

10 ONYX DC FULL SERVICEONYX DC FULL SERVICE
19.
20.
21.
Once the lock ring is removed, you can pull up and
remove the entire OTT assembly.
Use a long shaft or stick to push the air piston out of
the stanchion tube.
Pull up the lock ring and shaft. Use a small flat-head
screwdriver to remove the retainer clip in the
stanchion.