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ONYX DC Service Guide

Full Service

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Summary of Contents for ONYX DC

Page 1: ...ONYX DC Service Guide Full Service ...

Page 2: ...cedures 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 Modification improper service or u...

Page 3: ...er 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 ...

Page 4: ...f the high speed compression ring Use needle nose pliers to remove the detent fixture 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 ...

Page 5: ...X 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 ...

Page 6: ... 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 firmly tap with a rubber mallet to un seat the cartridges from the casting ...

Page 7: ...ng 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 ...

Page 8: ... 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 ...

Page 9: ...se 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 ...

Page 10: ...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 ...

Page 11: ...ide of the stanchion tube with suspension clean Wipe thoroughly with a clean rag Apply a thin layer of grease to the inside of the stanchion tube Insert the new air piston in the direction shown with the recessed side facing away from the tube Apply a generous amount of grease to the inside of the plastic spring guide ...

Page 12: ... Apply a generous amount of grease to the entire negative spring and spring guide Re install the OTT unit into the stanchion tube until the green plug is inserted Re install the retainer clip into the tube then pull the shaft downward to lock it in place ...

Page 13: ...ERVICE 13 29 28 30 Pour 5cc s of 7 5wt suspension fluid into the stanchion tube above the air piston Place the lock ring back onto the plug Apply a thin layer of Loctite to the threads of the end plug Tighten with the pin spanner wrench ...

Page 14: ...14 ONYX DC FULL SERVICE ONYX DC FULL SERVICE 31 32 Re install the volume adjuster and top cap unit into the stanchion Tighten with a 32mm socket Inflate to the desired PSI and re install the air cap ...

Page 15: ... the damper cartridge in the 25mm shaft clamps Use the 22mm socket to loosen the top of the cartridge Un thread completely and remove the bladder Remove the entire bladder and set aside Note Oil will drip from the bladder so it s best to do this over a drain pan Damper Rebuild D ...

Page 16: ... Pour the oil out of the cartridge and into the drain pan Place a clean rag into the cartridge to catch any re sidual oil from pouring out Then clamp the cartridge as shown with 25mm shaft clamps Use an 18mm wrench to loosen the end plug of the cartridge ...

Page 17: ...RVICE 40 39 41 Use a 4mm allen wrench to close the rebound Pour 160cc s of 2 5wt suspension oil into a graduated cylinder Remove the shaft and mid valve rebound p from the cartridge body Clean the mid valve thoroughly with suspension cleaner ...

Page 18: ...VICE 44 42 43 Make sure the cartridge is at full extension Pour the oil into through the top Now you can cycle the shaft up and down to pull the oil through the system Use a 2mm allen key to remove the bleed screw from the top of the bladder ...

Page 19: ... way into the cartridge body Note Oil will pour over the edge as you lower the bladder unit into the cartridge Use the needle nose pliers to turn the low speed needle all the way counter clockwise Then place the bladder unit back into the cartridge body Push the bladder unit downward until you see the oil level get to the top Once you get to this point stop pushing down STOP WHEN OIL REACHES THE T...

Page 20: ...e unit back into the cartridge with the 22mm socket Re install the bleed screw with the 2mm allen key Once the screw is tightened you can drain the ex cess oil from the top cap Clean thoroughly with the suspension cleaner Re install the cartridge into the damper side of the fork Tighten with 32mm socket ...

Page 21: ...sure to clock the adjuster so the numbers line up with the rotation of the needle You re good to go Pour 25cc s of 7 5wt suspension oil into both sides of the casting Re install the rebound adjuster foot nut Tighten the foot nut with an 18mm socket Use needle nose pliers to re install the detent fixture back into the top cap Be cautious of the ball bear ings ...

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