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Summary of Contents for DVO DIAMOND 36
- Page 1 DIAMOND 36 FULL SERVICE GUIDE Version 1.0...
- Page 2 Forks and rear shocks contain fluids 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 4. Make sure your wheel is attached and centered properly in order to avoid any contact with the authorized technician.
- Page 3 Service Overview Contents This manual will guide you step by step performing a full service to your Diamond 36. Please follow each instruction carefully to achieve the best and safest results. Chassis Disassembly ......Page 4-9 *Always wear your safety gear while working on suspension products.
- Page 4 Set cap aside. Remove the rebound knob by pulling Using a catch pain or basin, drain the oil straight down and set aside. from the lowers. Set the lowers safely aside.v Diamond 36 Full Service Guide...
- Page 5 Using snap-ring pliers, gently remove the snap-ring located at the bottom of the air spring leg. Grasping the airshaft, carefully remove the SL or OTT assembly and set aside. Diamond 36 Full Service Guide...
- Page 6 Invert the damper cartridge and gently clamp in vice using 26mm shaft clamps, again using just enough force to keep it from rotating. Diamond 36 Full Service Guide...
- Page 7 Gently grasping the bladder assembly with one hand, use needle-nose pliers to grasp the compression shaft nut and pull the assembly from the bladder. Next, carefully remove the two washers and set aside. Diamond 36 Full Service Guide...
- Page 8 Using an 8mm allen wrench to hold the Install the piston in the direction as bolt, use a 13mm crows-foot wrench or shown. socket and torque to 5Nm. Diamond 36 Full Service Guide...
- Page 9 Apply a small amount of grease to your finger and use it to “grab” the bearing, and gently place it on top of the spring. The grease will hold it in position. Diamond 36 Full Service Guide...
- Page 10 Remove the bladder from the shaft, Reinstall the bladder coupler, and then press the seal unit back onto the base then remove the green bladder ring and bladder coupler. and reinstall the retaining clip as shown. Diamond 36 Full Service Guide...
- Page 11 Slide the coupler onto the shaft, and Apply a light coat of Loctite 243 Blue then install a new o-ring in the shaft to the shaft threads, then thread the groove. topcap assembly back on. Diamond 36 Full Service Guide...
- Page 12 Reinstall the two washers. Turn the shaft over in the clamps and remove the nut using a 10mm wrench. Diamond 36 Full Service Guide...
- Page 13 Apply a light coat of grease to the inside followed by the shim. of the end cap and reinstall on the shaft. Note: The shim ID is 7mm. Do not mix with the 6mm ID shims. Diamond 36 Full Service Guide...
- Page 14 Torque the cassette tool. (IMPORTANT: ensure the to 11Nm using an 18mm crows-foot inner tube o-ring doesn’t get pinched in wrench. the process). Thread a bleed syringe into the topcap bleed port. Diamond 36 Full Service Guide...
- Page 15 Insert cartridge back in upper tube. Using a cassette tool, torque the topcap Lay the nut, spring, shims, piston, and to 20Nm. washer out for cleaning and inspection. Diamond 36 Full Service Guide...
- Page 16 Remove the clip at the opposite side, Reinstall the shaft in the shaft clamps, and press the bladder ring off of the loosen the assembly using a 11mm coupler. open end wrench, and remove the inner shaft. Diamond 36 Full Service Guide...
- Page 17 Install a new o-ring on the shaft. Install Be sure that the set screw is completely Locktite Blue 243 on the shaft threads inserted and flush with the surface. and allow to cure. Using cleaner, remove any excess grease from the assembly. Diamond 36 Full Service Guide...
- Page 18 Firmly press coupler, and then apply a light coat of to ensure that it is fully seated on the grease on the outside edge. coupler. Take care not to distort the bladder during this process. Diamond 36 Full Service Guide...
- Page 19 The D2 damper service is complete. Proceed to step 62 to continue. Begin reassembling the shims and piston in the order they were removed. Ensure that the clamp shim is installed with the chamfer edge facing the spool, and the flat side facing the first shim. Diamond 36 Full Service Guide...
- Page 20 Remove and then reinstall the SL top After the Loctite has cured, reinstall the out bumper. foot buffer on the shaft and torque to 7N.m. Next, clean the inside of the air stanchion thoroughly and wipe dry. Diamond 36 Full Service Guide...
- Page 21 Fully seat the support ring so that the buffers make contact with the bottom groove in the stanchion is exposed. of the casting. Insert 20cc’s of 7.5wt oil into each leg, and then completely seat the lowers to the buffers. Diamond 36 Full Service Guide...
- Page 22 Double check that the bumper is flat at the bottom of the leg before proceeding. Gently use a long rod to seat flat if required. 140. Soak the new foam rings in 7.5Wt oil. Diamond 36 Full Service Guide...
- Page 23 Remove the foam rings from the oil bath, and gently place into the legs. 144. Ensure that the foam rings are seated correctly above the bushings and below the seal, then wipe down the excess oil. Diamond 36 Full Service Guide...
- Page 24 149. Apply a light coat of grease to the new large o-ring, and place in assembly groove. Apply a light coat of grease to the back of the assembly. Diamond 36 Full Service Guide...
- Page 25 Reinstall the rebound footnut using an 18mm socket and torque to 10Nm. 156. 160. Reinstall rebound knob by pressing Install a shock pump and inflate to firmly into place. 75Psi, then reinstall the air cap. Diamond 36 Full Service Guide...
- Page 26 19.50IDx1.5W O-RING 9.80IDx1.9W O-RING POLY BAG-120X220 BLADDER - ONYX SC HEADER CARD BLADDER CLIP 1 LABEL 12.42IDx1.78W O-RING BLADDER RING SPRING TOP CAP BLADDER DAMPER KNOB & TOP CAP DUST SEAL COMPRESSION REBOUND AIR SPRING Diamond 36 Full Service Guide...
- Page 27 Tuning Notes...
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