Installation

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Emerald Fork Installation Tire Clearance

Emerald Fork Installation & Tire Clearance

Tools and Parts Needed for installation

  • 3mm, 4mm, 5mm, and 6mm allen wrenches
  • 1 1/8 star nut and star nut setter
  • Hacksaw or pipe cutter for steerer tube
  • Crown race setter

 

 

Warning!
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.

Note! All fixing bolts have to be tightened with the proper fastening torque stated by the manufacturers.

1. Remove front brake from fork and existing fork from your bicycle. Afterwards remove the headset crown race from the fork.

2. Using a headset race installer, install the headset crown race on new steer tube making sure it’s firmly against the fork crown. For fitment information see dvosuspension.com/tech

3. Remove top and bottom clamps from fork assembly to ensure proper mounting. Install the lower fork clamp on to the bike with all the headset parts included and a minimum 3mm spacer on the top of the headset.

Now install upper crown ensuring headset operates smoothly and is just snug. Mark steer tube just above the top of the upper crown (only if using a direct mount stem otherwise you must also install the stem before marking the steer tube). Remove clamps from bike and cut steer tube. You can also use the following formula for steer tube length:

Frame head tube + headset stack height+ 3mm + top clamp(12mm)

Warning!
Minimum total stack height = 120mm and a maximum total stack height = 165mm

4. Install the lower fork clamp on to the bike with all head set parts and a minimum 3mm spacer on top of the headset, then the upper fork clamp.

5. Install remainder of fork assembly ensuring that the upper legs are tightened to the lower clamp at or within 8mm of the step in the upper tube. The upper legs must be the same on both sides. Tighten lower clamp bolts to the appropriate torque value of 7 N.m / 62 in.lbf

Do not tighten any of the upper clamp bolts until Step # 8

6. Install front wheel back on your bike. Insert the axle into the right drop-out / non-disc brake side then tighten axle bolt to the appropriate torque value of 7 N.m / 62 in.lbf.

Leave drop-out pinch bolts loose until step #9.

7. Install the front brake according to the manufacturer’s instructions and fasten brake line to guard. Make sure you adjust the brake pads properly. Ensure that brake line length is the appropriate length to not effect steering or compression and extension of fork.

8. Remove bike from stand. With the front brake on, lightly rock the fork back and forth to ensure the headset preload is at the appropriate torque value. Now tighten the upper fork clamp bolts to the appropriate torque value of 7 N.m / 62 in.lbf.

9. Holding the front brake, using your body weight compress your fork. Do this a few times to allow the fork legs to self-align on the axle. Now tighten the drop-out / axle bolts down to the appropriate torque value of 7 N.m / 62 in.lbf.

TIRE CLEARANCE

DVO Suspension forks are designed around both 26” and 27.5” tires; make sure you have the correct wheel size for your fork model. Each tire and manufacturer has a different outer diameter (tire width and height). Therefore the clearance between your tire and fork needs to be checked to make sure it does not come in contact with any part of the fork.

Warning!
Inadequate tire clearance will result in an accident, personal injury or death.

Tire Clearance Test:

1. Release all air from your fork.

2. Compress your fork completely

3. Measure the distance between the top of the tire and the bottom of the crown. Make sure this gap is NO LESS than 6mm! Exceeding maximum tire size will cause the tire to jam against the bottom of the crown when the fork is fully compressed.

4. Inflate the fork again.

Keep in mind that if you are using a mudguard the clearance can be even more limited. Repeat the “Tire Clearance Test” again to make sure the gap is big enough. Every time you are going to change your tires you have to repeat the test.