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
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.
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.
|Rider Weight||Air Pressure (PSI) 60-100|
|120-139lbs | 54-63kg||60-65psi|
|140-159lbs | 64-72kg||65-70psi|
|160-179lbs | 73-81kg||70-75psi|
|180-199lbs | 82-90kg||75-80psi|
|200-219lbs | 91-100kg||85-90psi|
|220+lbs | 100+kg||95-100psi|
SAG is the amount your fork compresses under your body weight (don’t forget to include your riding gear), also referred to as Rider Weight. Since this is a Downhill specific fork, measure SAG by mounting your bike with your riding gear on, standing up and in the ready position.
The ready position is basically, knees and elbows slightly bent, bars weighted but body weight on your feet. Every rider has a different riding weight and ready position based on rider height and style.
1. During initial SAG set-up ensure that the SAG ADJUST / PRELOAD knob is turned all the way counterclockwise. This is a secondary setting and should not be used when setting your initial SAG.
2. Refer to the recommended SAG settings chart below. To ensure the proper function of your fork and to deliver optimum performance of it, setting proper SAG is the only way to find the right air pressure for your fork.
The Off-The-Top (OTT) feature is an exclusive DVO Suspension design that allows the rider to adjust the initial feeling of the suspension. Typically, a stiffer feeling fork (high air pressure) will have poor or no small bump compliance. With OTT, a stiff set-up (high air pressure) can also have amazing small bump sensitivity. This is accomplished by externally increasing or decreasing the preload on the negative springs. Increasing the OTT will make the fork more sensitive (softer) at the beginning stroke. Decreasing the OTT will make the fork less sensitive (firmer).The OTT feature will not change the end stroke of your fork.
Clockwise = Softer | Counterclockwise = Stiffer
LOW SPEED COMPRESSION
Low speed compression controls the influence of the rider’s weight and the bikes attitude under slower suspension movement regardless of riders speed. This is accomplished by turning a needle in or out of a port located in the base valve
HIGH SPEED COMPRESSION
High Speed Compression controls the damping force under higher suspension movements regardless of the riders speed. This is accomplished by turning a knob to increase or decrease preload on a pressure spring on a shim stack located in the base valve.
Setting up your fork is one of the most important things you can do to get the most out of your suspension. Follow these base tunes and get your suspension dialed. Remember, these are starting-points. Rider ability, preference and track conditions will vary.
When setting up your suspension, start from Wide-Open. Wide-Open is characterized by taking the adjuster and turning it counter-clockwise until it stops. Turn each adjuster to the Wide-Open setting before starting your base tune. Each adjustment below refers to making adjustments clockwise from the Wide-Open setting
Air Pressure Range: 60-100psi
OTT Range: 6 clicks = 1 full rotation. 15 full rotations total.
Rebound Range: 40 clicks total
High Speed Compression (HSC) Range: 33 clicks total
Low Speed Compression (LSC) Range: 27 clicks total
|Rider Weight||Air Pressure||OTT||Rebound||HSC||LSC|
|120-139lbs | 54-63kg||60-65psi||0-2 rotations||3-7 clicks||0-1 clicks||0-1 clicks|
|140-159lbs | 64-72kg||65-70psi||3-4 rotations||5-8 clicks||0-2 clicks||0-2 clicks|
|160-179lbs | 73-81kg||70-75psi||5-6 rotations||6-10 clicks||2-3 clicks||2-3 clicks|
|180-199lbs | 82-90kg||75-80psi||6-7 rotations||7-11 clicks||2-4 clicks||2-4 clicks|
|200-219lbs | 91-100kg||85-90psi||8-10 rotations||8-12 clicks||3-5 clicks||3-5 clicks|
|220+lbs | 100+kg||95-100psi||11-14 rotations||10-14 clicks||5-7 clicks||5-7 clicks|