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Summary of Contents for GAS GAS TOPAZ WP1
- Page 2 Failure to comply with these warnings and instructions may cause SERIOUS INJURY, DEATH, or DAMAGE TO YOUR PRODUCT. PRE-RIDE SAFETY CHECK 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, 1.
- Page 3 Service Overview Contents 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. Damper Service ......Page 6-16 *Always wear your safety gear while working on suspension products.
- Page 4 Damper Service Remove the air cap. Depress the valve Remove the o-ring located above the to release the air pressure. threads of the housing and thoroughly clean the housing with suspension cleaner. EYE HAZARD Remove the bladder cap and release Apply a thin layer of grease to the new o-ring and install it in the housing.
- Page 5 Damper Service Remove the bladder from the reservoir Remove the metal washer and o-ring. and drain the oil into a catch pan. Using a 2mm allen wrench, remove the Remove the sealhead. This may be compression knob bolt and LSC knob. difficult, but remove the white washer Next, remove the bent shim and HSC from the inside of the shaft.
- Page 6 Damper Service (continued) Remove the rebound adjuster unit. Get your new o-rings for your rebound adjuster and apply a thin layer of grease to them. Install the upper o-ring. Remove the metal washer and lower Install the middle o-ring and then the o-ring.
- Page 7 Damper Service (continued) Double check to make sure the holes Slide the sealhead back onto the shaft line up and are pointing straight up in the direction shown. Then remove the inside the housing. seal bullet. Apply a small amount of blue loctite to Apply a small amount of grease to the the threads of the rebound adjuster set tip of the rebound needle.
- Page 8 Damper Service (continued) Apply a thin layer of red loctite to the Invert the shock so the bleed screw is threads of the damper shaft. Thread the at the highest point. Use the small pick shaft into the housing. to remove the filling on the bleed screw. Then use a 2mm allen key to remove the screw.
- Page 9 Damper Service (continued) Damper Bleed Slightly stretch the new white bushing Thread on bleed syringe and fill syringe as shown and install it on the sealhead. with oil. Ensure the oil level never drops below 10cc’s. This will ensure no air gets re-introduced into the system.
- Page 10 Air Can Service Remove the o-ring below the outer air Remove the blue glide ring as shown. sleeve. Then remove the air sleeve. Remove the lower and middle o-ring Get your rebuild kit, part #223-9008-WP. from the body. Clean the inside of the shock body with suspension clean.
- Page 11 Air Can Service (continued) Make sure the main seal is sitting flush Apply a thin layer of grease to the new with no gaps. Get the second white dust seal. Install the new dust seal bushing and slightly stretch it as shown. above the second bushing.
- Page 12 Air Can Service (continued) Rebuild Kit Contents Reinstall shock on bike, or affix to a hand-dyno and begin to add air to the main chamber. Be sure to cycle the shock several times as you gradually increase air pressure. Fill bladder to desired starting pressure. Be sure that the bladder always has between 140-180psi.
- Page 13 Spare Parts List Notes ITEM NO. PART NUMBER DESCRIPTION QTY. 223-9008-WP Seal/ Repair Kit Topaz 2-WP 257-WP01 Compression Lever Kit Jade X-WP / Topaz 2-WP 257-9001-WP Compression Assembly Jade X-WP / Topaz 2-WP 223-1002T-WP HOUSING TRUNNION TOPAZ 2 WP 223-9006-5 5mm Travel Spacer Topaz 2 223-1005-65 Damper Shaft 65/60 Topaz 2...
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