GAS GAS JADE X WP1 User manual

Jade X Full Service Guide
2 3
Be sure to read this manual carefully before using your DVO suspension. Throughout this manual,
reference is made that “an accident” could occur. Any accident may cause damage to the product,
SERIOUS INJURY, OR DEATH.
These instructions contain important information about the correct installation, guidelines for set-
up, service and maintenance of your suspension. Nevertheless, please be informed that special
knowledge and tools are essential to install, service and to maintain DVO Suspension. Common
mechanical knowledge may not be sufcient to repair, service or maintain your suspension. There-
fore we strongly recommend getting your suspension installed, serviced and/or maintained by a
trained and qualied bicycle mechanic. Improper installation, service or maintenance can result in
an accident.
Forks and rear shocks contain uids and air under extreme pressure. DO NOT attempt to disas-
semble any portion of a DVO Suspension product unless instructed to do so by a DVO Suspension
authorized technician.
Only use genuine DVO Suspension replacement parts. Modication, improper service, or the use of
aftermarket replacement or spare parts may result in an accident and VOIDS the warranty of your
product.
DVO Suspension forks and rear shocks are designed for the usage by a single rider only.
DO NOT use DVO Suspension products on any powered vehicle that is not a pedal-assist Class-1
or Class-3 e Bike.
Always be equipped with proper safety gear. This includes a properly tted and fastened helmet.
According to your riding style you should use additional safety protection. Make sure your equip-
ment is in awless condition.
Make sure you select the correct fork and rear shock according to your frame manufacturer spec-
ication. Installing suspension that does not match the geometry of your frame could result in a
failure of the suspension itself and void the suspension warranty. Installing a fork or rear shock not
designed for your frame will change the geometry and handling of your bike. Learn how to ride and
train your skills. Know your limits and never ride beyond those.
Study all other manuals provided with your bicycle and make yourself familiar with all components
mounted to your bike.
Failure to comply with these warnings and instructions may cause SERIOUS
INJURY, DEATH, or DAMAGE TO YOUR PRODUCT.
1. DO NOT ride your bicycle if any one of the following test criteria is not passed! Riding your bike
without eliminating any defect or carrying out the necessary adjustments can result in an accident,
SERIOUS INJURY OR DEATH.
2. Do you notice any cracks, dents, bent, or tarnished parts of your suspension fork or shock, or any
other part of your bicycle? If so, please contact a trained and qualied bicycle mechanic to check
your fork, shock, seat post, saddle, and complete bike.
3. Do you notice any oil leaking from your fork and/or shock? If so, please consult a trained and
qualied bicycle mechanic to check your suspension and bike before riding.
4. Make sure your wheel is attached and centered properly in order to avoid any contact with the
suspension fork or brake system.
5. Make sure your axle system is secure. There should be no play between the hub and fork lower.
6. Make sure your brakes are properly installed, adjusted, and work properly. This also applies to
every other part of your bike like handlebars, pedals, cranks arms, seat post, saddle, etc.
7. Check the cable length and routing of your braking components. Make sure they do not interfere
with your steering actions or full compression and extension of your suspension.
8. Check your shock hardware and ensure there is no play between the shock and mounting surfaces.
Ensure your shock hardware is tightened to the bike manufacturer’s recommend torque before riding.
PRE-RIDE SAFETY CHECK

Jade X Full Service Guide
4 5
Lubricant
Brand
Wt.
Notes
Shock oil
DVO, Motul, Motorex, Silkoline, R.S.P.
2.5
Do NOT use Rock Shox or Maxima powersports
suspension fluids under any circumstances. Permanent
seal damage will occur.
Grease
Slickoleum, Slick Honey
-
The data contained in this document supersedes any and all previous lubrication, torque, and thread coat specifications. Failure to
follow these specifications will void the product warranty and may lead to serious injury or death.
Product
Part
Torque
Notes
DVO-WP Jade X
Bleed screw
2 N.m
N/A
Damper body end cap
20 N.m
N/A
Housing to damper body
20 N.m
LocUte 2701 Green
Reservoir housing bolts (x2)
3 N.m
N/A
Damper sha[ to eyelet
15 N.m
LocUte 263 Red
Piston group bolt
15 N.m
LocUte 243 Blue
Piston nut
5 N.m
LocUte 243 Blue
CV Compression unit
5 N.m
N/A
HSC/LSC knob set screw
.6 N.m
LocUte 243 Blue
Valve core
.6 N.m
N/A
Product
Oil / Grease
Volume
Type (Wt.)
DVO-WP Jade X
Damper
70-80 cc
2.5
Slickoleum, Slick Honey
N/A
2.5
1
Service Overview
This manual will guide you step by step performing a full service to your Topaz shock. 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.
ALWAYS WEAR SAFTY GEAR!
Tools Needed For Service
Supplies Needed For Service
Recommended Service Interval
1. Valve Core Remover
2. Valve Puller
3. Oil Drain Pan
4. Bleed Syringe
5. 24mm Crows-foot Wrench
6. 16mm Socket or Crows-foot Wrench
7. Flathead Screwdriver
8. Vice
9. 14mm Shaft Clamps
10. Pick
11. Shock Pump
12. 2mm, 3mm, 4mm Allen Key
13. Torque Wrench
14. 14mm Seal Bullet (#140-M080-S)
1. Rebuild Kit part #223-9008
2. Gloves
3. Safety Glasses
4. Clean, Lint Free Rag
5. Suspension Cleaner or Alcohol
6. Loctite 263 RED
7. Loctite 243 BLUE
8. 2.5 wt oil. No Maxima
9. Slickoleum Grease
• Full Service .......................100 Hours of Ride Time
Damper Service ............................. Page 6-14
Damper Bleed ............................. Page 15-16
Rebuild Kit Contents...........................Page 17
Spare Parts List ...............................Page 18
Lube & Torque Specs
Contents

Jade X Full Service Guide
6 7
Damper Service
1.
Rotate the spring preload collar counter-
clockwise to decrease tension on the
spring, and remove the lower spring
clip. Remove the spring and spring
spacer and set aside.
3.
Thread on the valve puller, and press
the bladder cap inward, exposing the
bladder air plug clip. Remove the valve
puller. Use a small pick or athead and
gently remove the clip and set aside.
EYE HAZARD
2.
Remove the bladder cap and release
the air from the bladder.
4.
Thread the valve puller back on, and
pull up to remove the bladder. Remove
the bladder cap and bladder from the
valve puller and set aside, and pour the
reservoir oil into a catch basin.
6.
Unthread and remove the shaft
assembly and set aside. Drain the
oil from the damper body into a catch
basin.
5.
Gently clamp the shock housing in a
vice with the shaft/eyelet facing up/
vertical. Use a 24mm wrench to loosen
the damper and cap.
7.
Using a 2mm allen wrench, remove the
compression knob bolt and LSC knob.
Next, remove the bent shim and HSC
knob and set aside.
8.
Using a 24mm wrench, loosen and
remove the CV compression assembly
and set aside.

Jade X Full Service Guide
8 9
9.
Use a 3mm allen wrench to remove
the reservoir to housing bolts, and then
remove the reservoir from the upper
housing and set aside.
10.
Using a small pick, remove the o-ring
from the upper housing. Remove the
alignment pin from the reservoir as
shown. Take care not to misplace!
13.
Remove the damper end cap and
bottom out bumper and discard. A new
damper endcap and bottom out bumper
are included in the rebuild kit.
12.
Remove the piston bolt group, spray
clean with suspension cleaner and set
aside.
14.
If you are servicing a new shock for
the first time, you will need to remove
the wax pellet from the bleed screw
before it can be removed. Use a pick
to remove the wax and expose the hex
opening. Use a 2mm allen wrench to
then remove the bleed screw.
15.
Using suspension cleaner, spray and
clean the inside of the damper body and
housing and set aside.
11.
Clamp the damper shaft in a vice
using 14mm shaft clamps. Be sure the
rebound adjuster is facing outward to
provide adequate clearance and prevent
damage. Use a 16mm socket to loosen
the piston bolt.
16.
Disassemble, clean and inspect the
piston bolt group.
Damper Service (continued)

Jade X Full Service Guide
10 11
Damper Service (continued)
17.
Carefully use a razor blade to cut and
remove the glide ring from the piston.
20.
Using small needle-nose pliers, gently
grasp and remove the rebound needle.
Remove and reinstall the o-ring and set
aside.
18.
Reinstall the new glide ring by pressing
it on as shown.
21.
Install the shaft bullet tool
(#140-M080-S) on the shaft and apply
a light coat of grease. Slide the bottom
out bumper back on the shaft.
19.
Begin reassembling the piston bolt
group. Ensure the washers, shims, and
piston are installed in the correct order.
After reassembly set aside.
22.
Apply a light coat of grease to both end
of the seals on the damper end cap,
slide back onto shaft, and then remove
the shaft bullet.
23.
Rotate the rebound knob counter-
clockwise, so that it is in the full-open
position. (Do not back the knob all the
way out of the eyelet). Place rebound
needle back in shaft. Holding the shaft
assembly vertically, push the needle
into the shaft.
24.
Visibly check that the needle is in the
open position.
Open Position Closed Position

Jade X Full Service Guide
12 13
Damper Service (continued)
26.
Using a 16mm socket, torque the piston
bolt to 15Nm.
27.
Reinstall and apply a light coat of
grease to the housing o-ring and
centering pin, then reinstall the reservoir
housing bolts. Using a 3mm allen
wrench, torque to 3Nm.
29.
Place the CV compression assembly
into the housing, taking care not to
damage the o-rings. Thread the
assembly by hand, and then torque to
5Nm using a 24mm wrench.
28.
Using a pick, remove and replace
the o-rings on the CV compression
assembly, then apply a light coat of
grease. If you are replacing the entire
CV compression assembly, Apply
grease, and move to the next step.
30.
Press the black LSC knob on the hex
and open the LSC circuit by turning the
knob counter-clockwise until it stops.
Remove knob and set aside.
31.
Reinstall the bleed screw into the
housing. Next, apply a light coating of
grease to the bladder and bladder cap,
coating the edges all the way around.
32.
Over your catch basin, fill the bladder
reservoir with oil. Slowly press the
bladder back into the reservoir (oil will
overow).
25.
Apply a light coat of Loctite 243 Blue
to the piston bolt threads and allow to
cure. Clamp the damper shaft into the
14mm shaft clamps, and reinstall the
piston bolt group.

Jade X Full Service Guide
14 15
Damper Service (continued) Damper Bleed
35.
Fix the housing in a vice with the
damper body upward and ll to the top
with 2.5wt suspension oil. Slowly insert
the shaft assembly into the damper
body. Oil will overflow and that is
acceptable.
34.
Reinstall the valve puller and pull the
bladder plug up until it locks into place.
36.
Thread the damper end cap in and then
torque to 20Nm. using a 24mm crows-
foot wrench.
37.
Fix the shock in the vice in an upright,
aged position as shown, and remove
the bleed screw.
38.
Thread the bleed syringe into the bleed
port, and ll half of the the cylinder with
2.5wt suspension oil. Cycle the shock
up and down to remove any air bubbles
trapped in the system.
39.
After the bleed process is completed,
remove and replace the o-ring on the
old bleed screw, or install a new bleed
screw and torque to 2Nm. using a 3mm
allen wrench.
40.
Using a shock pump, inate the bladder
to your desired pressure. Suggested
range is 140-180PSI. Do not exceed
180psi. Reinstall the bladder air cap.
33.
Install the valve puller and slowly press
the bladder cap into the reservoir
enough to expose the clip groove.
(Ensure that the bladder remains straight
during this process). Remove the valve
puller and reinstall the retaining clip.

Jade X Full Service Guide
16 17
Damper Bleed (continued)
42.
Reinstall the spring preload collar and
spring spacer, followed by the spring.
43.
Guide the spring clip into place, and
then slightly compress the spring while
pressing down on the clip so that it fully
seats on the eyelet base.
41.
Reinstall the red HSC knob and bent
washer. Reinstall the black LSC knob
and torque bolt to 0.6N.m using a 2mm
allen wrench.
44.
Wipe down the shock and reinstall
on the bike according to the bike
manufacturer specications.
Rebuild Kit Contents
1
10
12
11
17
20
21
16
18
14
9
3
13
15
19
2
5
6
7
8
4
ITEM NO. PART NUMBER DESCRIPTION QTY.
1 RSB024 RESERVIOR SHCS 2
2
FAA175 RES TO HOUSING O-RING 1
3
REE253 RES TO HOUSING DOWEL PIN 1
4
RAA150-150 LS ADJ O-RING 1
5
D257-1001 SHIM BENT 1
6
D257-1012 DETENT WASHER 1
7
RAA141 COMP HEAD O-RING 1
8
RAA118 PISTON O-RING 1
9
DVO1421019-A GLIDE RING 1
10
DVO1561049 BLADDER AIR PLUG CLIP 1
11
DVO1421014 BUMPER 1
13 D191-1005 BLADDER 1
14
RAA 095 DUST SEAL 1
15
RAA 096 SHAFT SEAL 1
16
DVO1421015-10 END CAP - RED 1
17
FAA256 ENDCAP O-RING 1
18
FAA149 ENDCAP O-RING 1
19
REE112 14MM BUSHING 1
20
RAA062 ENDCAP TOP-OUT O-RING 1
21
FAA135 REB NEEDLE O-RING 1
ITEM NO. PART NUMBER DESCRIPTION QTY.
12 FAA170-10 VALVE CORE 1
Contents of the rebuild kit subject to change without notice based on product changes or improvements.

Jade X Full Service Guide
18 19
15
ITEM NO. PART NUMBER DESCRIPTION QTY.
1 257-WP03 Air Cap Jade X-WP / Topaz 2-WP 1
2
209-1002-WP Reservior Body Jade X-WP 1
3 1569012
Bladder Kit Jade X/ Topaz 2 1
4 1429020
DU Bushing Kit 1
5
1429011-WP Shaft Eyelet Jade X-WP Long 1
6
191-1001T-SP Upper Housing Trunnion Jade X 1
7
1421011-WP Preload Collar Jade X-WP 1
8
1421009-65 Main Body 65 Jade/ Jade X 1
9
191-1017-65 14mm Metric Jade X Shock Shaft 65mm 1
10
1429004-30 Piston Bolt Group Jade X 1
11
257-WP01 Compression Lever Kit Jade X-WP / Topaz 2-WP 1
12
257-9001-WP Compression Assembly Jade X-WP / Topaz 2-WP 1
13
191-1024-65 Jade X-WP HD Rebound Needle 65mm 1
14
1421013-10-WP Spring Clip 0mm Jade X-WP 1
15
191-9010-10-WP Seal/ Repair Kit Jade X-WP 1
1
3
7
14
10
4
6
2
9
12
11
5
13
8
Spare Parts List Notes