Fork Installation

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Fork Installation

Warning
DVO Suspension strongly recommends that your fork be installed by a trained and qualified bicycle mechanic. Special knowledge and tools are essential to properly install DVO Suspension forks. Common mechanical knowledge may not be sufficient to install a DVO Suspension fork. If you intend on installing the fork by yourself, the whole job needs to be inspected by a trained and qualified bicycle mechanic. Please note, that improperly installed forks are extremely dangerous and cause damage to the product, serious injury or even death. All DVO Suspension forks come with a threadless steer tube. Do not add a thread to it! DVO Suspension fork steer tubes are for one-time press fit only which cannot be removed. Do not try to replace the steer tube with a threaded steer tube. This will void the warranty of your fork and result in a failure of the product or cause serious injuries or even death to the rider.
  1. If changing a fork on an existing bicycle, remove the front wheel and brake from your fork. After, remove the headset crown race from the fork.
  2. Using a headset race installer, install the headset crown race on new steer tube. Make sure it is firmly against the fork crown leaving no space between the crown race and the fork crown. (Refer to your headset manufacturer’s instructions to make sure the crown race is properly installed)Measure the steer tube length of existing fork and transfer this measurement to your new DVO Diamond steer tube. If you do not have an existing fork to measure you must install the fork into the bicycles head tube with the complete headset, stem and spacers. (Refer to your stem manufacturer’s instructions to be sure there will be enough clamping surface for the stem.) In this case you may need to cut your steer tube slightly shorter (3mm) to allow enough clamping surface so that the stem cap bolt can pull up on the steer tube, ensuring a snug and proper fit.
  3. If it is necessary to cut the steer tube, MEASURE TWICE CUT ONCE. It is recommended that a cutting guide be used when cutting the steer tube.
  4. Install the star nut into the steer tube using a star nut installation tool to the proper depth.
  5. Install the DVO Diamond fork into the frame head tube. Tighten the star nut bolt so that there is no play or drag in the headset when turning the steer tube.
  6. Properly align the stem and handlebars then torque the stem clamping bolts to the stem manufacturer’s specifications.
  7. Install the front brake according to the manufacturer’s instructions and make sure you adjust the brake pads properly. Ensure that brake line length is the correct length to not effect steering or compression and extension of the fork. NOTE: Rotor size must be between 160mm-203mm
  8. Install the front brake hose through the cable guide. Make sure the hose is routed on the inside of the leg. Use a 2mm allen key and torque to 3nm to secure hose and cable guide.