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Table of Contents
Related Manuals for DVO ONYX DC
Summary of Contents for DVO ONYX DC
- Page 1 ONYX DC Service Guide Full Service...
- Page 2 DVO Suspension Products. WEAR SAFETY GEAR! WARNING: We recommend that you have your DVO suspension serviced by a qualified bicycle mechanic. Servicing DVO suspension requires knowledge of suspension components, as well as the use of specialized tools and lubricants/fluids.
- Page 3 • Slickoleum Grease • Shock Pump • Graduated Cylinder • 2mm, 4mm Allen Key • Rubber Mallet • 3mm Punch • Pick •Needle Nose Pliers Recommended Service Interval: • Full Service .......100 Hours of Ride Time ONYX DC FULL SERVICE...
- Page 4 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. ONYX DC FULL SERVICE ONYX DC FULL SERVICE...
- Page 5 Loosen the damper side top cap. You do not need to completely un-thread it. With a 14mm socket wrench, loosen and remove the rebound foot-nut. With a 14mm socket wrench, loosen and remove the OTT foot-nut. ONYX DC FULL SERVICE ONYX DC FULL SERVICE...
- Page 6 Drain the oil in an oil catch pan. Stand the fork up vertically and remove the damper cartridge and air volume unit. ONYX DC FULL SERVICE ONYX DC FULL SERVICE...
- Page 7 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. ONYX DC FULL SERVICE ONYX DC FULL SERVICE...
- Page 8 Place the new seal in the casting and press into place using the rubber mallet. Make sure the seal is pressed in evenly all around with no gaps. Re-install the foam rings under the seal. ONYX DC FULL SERVICE ONYX DC FULL SERVICE...
- Page 9 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. ONYX DC FULL SERVICE ONYX DC FULL SERVICE...
- Page 10 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. ONYX DC FULL SERVICE ONYX DC FULL SERVICE...
- Page 11 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. ONYX DC FULL SERVICE ONYX DC FULL SERVICE...
- Page 12 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. ONYX DC FULL SERVICE ONYX DC FULL SERVICE...
- Page 13 Apply a thin layer of Loctite to the threads of the end plug. Tighten with the pin spanner wrench. Pour 5cc’s of 7.5wt suspension fluid into the stanchion tube above the air piston. ONYX DC FULL SERVICE ONYX DC FULL SERVICE...
- Page 14 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. ONYX DC FULL SERVICE ONYX DC FULL SERVICE...
- Page 15 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. ONYX DC FULL SERVICE ONYX DC FULL SERVICE...
- Page 16 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. ONYX DC FULL SERVICE ONYX DC FULL SERVICE...
- Page 17 Remove the shaft and mid-valve/rebound p from the cartridge body. Clean the mid-valve thoroughly with suspension cleaner. Use a 4mm allen wrench to close the rebound. Pour 160cc’s of 2.5wt suspension oil into a graduated cylinder. ONYX DC FULL SERVICE ONYX DC FULL SERVICE...
- Page 18 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. ONYX DC FULL SERVICE ONYX DC FULL SERVICE...
- Page 19 Then you can push the bladder unit all the way into the cartridge body. Note: Oil will pour over the edge as you lower the bladder unit into the cartridge. ONYX DC FULL SERVICE ONYX DC FULL SERVICE...
- Page 20 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. ONYX DC FULL SERVICE ONYX DC FULL SERVICE...
- Page 21 Then place the low speed knob over top. Make sure to clock the adjuster so the numbers line up with the rotation of the needle. You’re good to go! ONYX DC FULL SERVICE ONYX DC FULL SERVICE...
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