OVO Jade X User manual

Jade X Full Service Guide
Rebuild, Service, and Bleed

2 3JADE X FULL SERVICE
SERVICE OVERVIEW
This manual will guide you step by step performing a full service to your
Jade X. 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 aftermarket 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 aftermarket 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.
Tools Needed For Service:
• Allen Key Set
• Shaft Clamps
• Vice
• Adjustable Wrench
• 24mm socket
• Torque Wrench
• Kniplex or Pliers
• Pick
• Valve Core Remover
Fluids & Cleaner Needed For Service:
• Safety Glasses
• Clean, Lint Free Rag
• 2.5 wt suspension oil. (no maxima)
• Suspension Cleaner or Alcohol
• Shock Pump
• Loctite 242 BLUE
Recommended Service Interval:
• Full Service .......................100 Hours of Ride Time
WEAR SAFETY GEAR!

4 5JADE X FULL SERVICE
A Disassembly
CAUTION - EYE HAZARD
4.
5.
6.3.
2.
1.
Thread on a valve puller tool and push
the bladder cap downward.
This allows access to the retainer clip.
Use a small pick to remove the clip.
Thread the valve core puller tool back
onto the bladder cap and pull back to
remove the bladder.
Remove the air valve and set aside.
Release air pressure from the bladder.
Use a valve core removal tool to un-
thread the air valve.
Prepare your shock for service. Remove
the spring and clean thoroughly.
Remove the air cap from the bladder
reservoir.

6 7JADE X FULL SERVICE
10.
11.
12.9.
8.
7.
Fully remove the shaft assembly and set
aside in a clean area.
Drain the oil from the shock body and
housing.
Use a 4mm allen key to loosen the
compression unit end cap from the
reservoir.
Fully un-thread the seal head and remove
the shaft assembly.
Fix the head of the shock into a vice.
Using a 24mm open end wrench to
loosen the seal head.
Completely remove the bladder and
bladder cap from the reservoir.

8 9JADE X FULL SERVICE
18.
17.
16.13.
14.
15.
Remove the o-ring from the upper eyelet
as shown.
Remove the alignment pin from the
housing as shown.
Fix the shaft in 14mm shaft clamps with
the rebound adjuster facing outward.
This will give clearance to prevent
damage.
Use a 16mm socket or adjustable wrench
to loosen the piston bolt.
Fully un-thread the cap and set aside.
Use a knipex or similar tool and clamp
the 10mm nut on the compression
assembly. Use this to pull the assembly
out of the housing.
Use a 3mm allen key to loosen the
housing bolts and remove from the upper
eyelet.

10 11JADE X FULL SERVICE
24.21.
23.20.
22.19.
Clean the damper body thoroughly with
suspension clean.
Remove the piston assembly from the
shaft.
Clean the piston group thoroughly with
suspension clean. Set aside.
Remove the seal head and bottom out
bumper from the shaft.
Get your Jade X rebuild kit ready.
Part Number: 191-9010
Use a 2mm allen key to remove the bleed
screw from the upper housing.

12 13JADE X FULL SERVICE
30.
29.
28.25.
26.
27.
Time to disassemble the piston bolt
group. Start by removing the backing
plate.
Remove the compression shims and the
piston.
Install the seal head onto the shaft in the
direction shown.
Install the bottom out bumper back onto
the shaft in the direction shown.
Apply a thin layer of slikoleum grease to
inner lip of the dust seal.
Apply a thin layer of slikoleum grease to
top part of the shaft. Apply over the
rebound port as well.
B Rebuild and Clean

14 15JADE X FULL SERVICE
36.
35.
34.31.
32.
33.
Take note of the piston direction.
From left to right,
this is the order of
the shims. Rebound
shims are in red,
compression in blue.
Install the 11mm clamp shim rst, then
the 13mm shim.
Install the new glide-ring onto the piston.
Use a small pick to remove the glide-ring
from the piston.
Remove the rebound side shims and set
aside.
16
mm
11
mm 13 mm
15
mm 14 mm 13 mm 11 mm 22 mm 20 mm 18 mm 18 mm 11 mm
Bolt Piston Back
Plate
Rebound
Side
Compression
Side

16 17JADE X FULL SERVICE
37. 40.
38. 41.
39. 42.
The rst compression shim is a 22mm
then 20mm.
Add the two 18mm shims to the stack.
Finish the compression side with the
11mm clamp shim.
At this point, the assembly should look
like this. Note, the piston orientation
should look like this.
The last shim on the rebound side is
16mm. Then place the piston in the
direction shown.
Install the 14mm and 15mm shim.
14
mm 15 mm
16
mm
22
mm
18
mm
20
mm
18
mm
11
mm

18 19JADE X FULL SERVICE
43. 46.
44. 47.
45. 48.
If you look in the rebound port, you can
see the needle through the window. The
needle should be in the open position.
Apply a thin layer of blue Loctite to the
threads of the piston bolt.
Use a torque wrench to tighten the piston
bolt group to the shaft.
Tighten to 15Nm
Open the rebound fully.
Counter-clockwise rotations will open the
rebound.
The flat side of the plate should be facing
upward as shown.
Note the orientation of the plate. There is
an inner lip of the plate that should face
the clamp shim.
Open PositionClosed Position

20 21JADE X FULL SERVICE
49. 52.
50. 53.
51. 54.
Re-install the housing onto the eyelet and
tighten the 3mm bolts to 3Nm.
Use a small allen key to push the pin out
of the compression unit as shown.
Use a pick to remove the main o-ring.Below the o-ring, place the alignment pin
into the groove as shown. Apply a thin
layer of Slikoleum grease to hold the pin
in place.
Place the new o-ring in the groove as
shown.
Apply a thin layer of Slikoleum grease to
the eyelet o-ring.

22 23JADE X FULL SERVICE
55. 58.
56. 59.
57. 60.
Replace the pin o-ring.
Clean the compression unit with
suspension clean. Make sure it is free of
any debris.
Apply a thin layer of slikoleum grease
to the new o-ring and place it into the
grooves of the compression piston.
Clean the compression pin with suspen-
sion cleaner. Make sure it is free of any
debris.
Make sure it ts together securely with
no gaps present.
Remove the lower o-ring with a pick as
shown.

24 25JADE X FULL SERVICE
61. 64.
62. 65.
63. 66.
Place the compression unit into the
housing in the direction shown.
Push the compression unit all the way
down to the bottom of the housing.
At this point, the assembly should look
like this.
Apply a thin layer of slikoleum grease to
inner side of the compression unit
housing.
Apply a thin layer of slikoleum grease
inside the port of the compression
assembly. Re-install the pin in the
direction shown.
Apply a thin layer of slikoleum grease
to the new o-ring and place it into the
grooves of the compression spool.

26 27JADE X FULL SERVICE
67. 70.
68. 71.
69. 72.
Clean thoroughly with suspension clean.
Apply a thin layer of Slikoleum grease to
the new o-ring and install it onto the cap.
Begin to thread the cap back into the
housing.
Torque to 4Nm.Remove the o-ring on the compression
unit cap.
Use a small allen key to push the inner
pin of the compression unit as shown.
Move the compression switch to the
open position.
Open PositionClosed Position

28 29JADE X FULL SERVICE
73. 76.
74. 77.
75. 78.
Use a 3mm allen key to tighten the bleed
screw into the upper eyelet.
Fill the reservoir to the top with 2.5wt
suspension oil as shown.
Apply a layer of Slikoleum grease to the
outside of the bladder as shown.
Apply a layer of Slikoleum grease to the
top of the inner lip on the bladder.
Install the bladder on to the cap.
Install the new valve core into the bladder
cap.
Install the bladder into the reservoir. Oil
will overflow.

30 31JADE X FULL SERVICE
79. 82.
80. 83.
81. 84.
Install the shaft assembly into the
damper body as shown. Oil will overflow
and that is OK.
Tighten the seal head to 27Nm with
24mm torque wrench.
Fix the shock in a vice as shown. Fill the
damper body with 2.5wt suspension oil
to the top.
Using a valve puller tool, pull the bladder
upward and lock into place.
Push the bladder deep into the reservoir
and install the retainer clip into the upper
grooves of the reservoir.
C Assembly and Bleed
Fix the shock in the vice in an upright
position. Remove the 3mm bleed screw.

32 33JADE X FULL SERVICE
85. 88.
86.
87.
After the bleed process is completed,
re-install the 3mm bleed screw.
Tighten to 3Nm
Inflate the bladder to the desired
pressure and you are good to go!
Pressure range: 170-200PSI
Cycle the shock up and down to remove
any air bubbles trapped in the system.
Thread the bleed syringe into the bleed
port. Fill the cylinder half way with 2.5wt
suspension oil.

34 35JADE X FULL SERVICE34 35
Notes: