Emerald

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The DVO Emerald uses a Tapered 1 1/8″ to 1.5″ steer tube. Your frame must have a straight 1.5″ head tube or a tapered 1 1/8″ to 1.5″ head tube. Depending on your frame manufacturer you will either have a external cup press-fit or integrated style headset. Please contact your bike manufacturer to make sure you have the correct headset configuration that can accept a tapered steer tube for your frame.

Common Headset Sizes and Styles
EC49 – External headset lower 1.5″. This is a pressed in headset where the bearing sits in a cup on the outside the frame
ZS56 – Internal headset lower 1.5″.  Internal cups press almost completely into the frame. These are often preferred for their low stack height and clean look.
IS52 – Integrated headset lower 1.5″.  A bearing (usually a sealed cartridge unit) sits directly into the frame eliminating the need for cups.  Found on many carbon fiber bikes today.

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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

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)

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.

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.

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To access the air valve you must remove the air spring cap that is found above the OTT adjuster. Attach your shock pump securely and inflate the air spring to the recommended air pressure. After you have added the proper amount of air pressure remember to securely replace the air spring cap so that no dirt or moisture can get inside.

To access the air valve you must remove the air spring cap by rotating the cap counter clockwise.

Keep in mind that when attaching the shock pump some pressure will be lost. The amount being displayed will be less than what was previously set at.

Air Pressure Range: 60-100psi
OTT Range: 6 clicks = 1 full rotation. 15 full rotations total. (OTT settings start from completely open counter clockwise)

*If you are out of the range of our recommended base tunes then custom tuning might be for you. Check out our Custom Tuning Page for more details.

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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. Do not sit on the saddle while measuring SAG. Every rider has a different riding weight and ready position based on rider height and style.

1. Before adding air to the fork make sure that both high speed and low seed compression is turned all the way counter clockwise and release all the air out of the fork.

2. Set the correct amount of rotations to the OTT knob based on your weight. Refer to the OTT Guide or basetune to find the recommended setting for OTT.

3. Add the recommended air pressure to the fork based on your weight. Refer to the basetune to find the recommended air pressure setting.

For detailed instructions on measuring and setting up sage check out this video and step by step instructions.

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OTT gives you the “Best of Both Worlds” for softer initial feel while being firm in the mid-stroke…run higher air pressures without the harshness

OTT exclusive performance features:

• Externally adjust how the initial 70mm’s feel no matter what your air pressure is
• Improves small bump traction and sensitivity
• Increases comfort & reduces hand and arm fatigue
• Improved vision

Higher air pressures allows fast moving riders to skip over bumps and holes but the downside is the harshness. With the OTT feature, the initial 70mm’s of travel can be independently tuned regardless of air pressure. Heavier or fast riders can run higher air pressures while still having amazing small bump sensitivity & traction by simply increasing OTT.  Lighter riders who run lower air pressures will use less OTT allowing use of all the travel without having the fork sack or hammock in the middle of the stroke. The Best of Both Worlds!

Clockwise = Softer | Counterclockwise = Stiffer

Air Pressure Range: 60-100psi
OTT Range: 6 clicks = 1 full rotation. 15 full rotations total.

*If you are out of the range of our recommended base tunes then custom tuning might be for you. Check out our Custom Tuning Page for more details.

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Rebound controls the speed at which the fork extends after compression. Turn the knob clock-wise for SLOWER rebound and counter clock-wise for FASTER rebound. Rebound damping control is relative to the amount of air pressure used. Higher air pressure requires more (slower) rebound damping and a lower air pressure will require less (faster) rebound damping so please adjust accordingly.

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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

*If you are out of the range of our recommended base tunes then custom tuning might be for you. Check out our Custom Tuning Page for more details.

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