Step-by-Step: Rebuilding Your Jade Fork Concept Suspension Fork

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The DVO Jade Fork Concept [paid link] suspension fork is known for its high performance and durability in both cross-country and aggressive trail riding. Over time, however, like all suspension forks, it may need a rebuild to maintain its performance and smooth action. Rebuilding your Jade Fork Concept [paid link] will ensure that it continues to provide you with optimal handling, plushness, and control. This guide will take you through the necessary steps to perform a full rebuild on your DVO Jade Fork Concept.

Tools Required

  • 5mm, 6mm, and 8mm Allen wrenches [paid link]
  • Suspension oil (specific to DVO’s recommendations)
  • Torque wrench [paid link]
  • 10mm socket wrench
  • Flathead screwdriver
  • Phillips head screwdriver
  • Syringe for oil transfer
  • Clean rags or towels
  • Small parts container for organization
  • Soft brush for cleaning
  • DVO suspension service kit (if available)
  • Replacement seals and bushings (if necessary)

Disassembling the Jade Fork Concept

Before beginning the rebuild process, make sure you have a clean, well-lit workspace. A workbench is ideal for disassembling and servicing your suspension fork.

1. Remove the Fork from the Bike

  • Begin by loosening the quick-release or through-axle that holds the front wheel.
  • Use a 5mm Allen wrench [paid link] to loosen and remove the fork from the bike’s head tube. Make sure to also disconnect the brake hose if your fork is equipped with hydraulic disc brakes.

2. Remove the Damper Assembly

  • Place the fork in a stand or secure it in a vice with soft jaws to avoid damage.
  • Use a 6mm Allen wrench [paid link] to remove the damper bolts from the crown. These bolts are typically located near the top of the fork.
  • Gently pull the damper assembly out of the stanchion. Be careful not to lose any small parts, such as washers or spacers.

3. Disassemble the Air Spring

  • Next, use an 8mm Allen wrench to unscrew the top cap from the air spring side of the fork.
  • Once the top cap is removed, slowly release the air from the air chamber by using a shock pump or appropriate tool.
  • Carefully remove the air spring assembly from the stanchion. You may need to use a soft brush to clean the assembly while it is removed.

4. Separate the Stanchions from the Lowers

  • After the air spring and damper are removed, it’s time to separate the fork’s lowers from the stanchions.
  • Use your 10mm socket wrench to remove the bolts that hold the lowers to the stanchions. Once the bolts are removed, gently pull the lowers off the stanchions.

5. Remove the Dust Wipers and Seals

  • The dust wipers and seals on the stanchions must be replaced during the rebuild. Use a flathead screwdriver or seal driver to carefully pry off the dust wipers and seals from the lowers.
  • Pay attention to any debris that might have accumulated in the seals. Clean the surface of the lowers to prepare them for reassembly.

Cleaning and Inspecting Components

Once all parts have been disassembled, you must clean and inspect the individual components to ensure everything is functioning correctly and free from damage.

1. Clean the Fork Components

  • Use a clean rag to wipe down the lowers, stanchions, and other components. Pay close attention to removing any old oil, dirt, or debris.
  • Use a soft brush to clean out any hard-to-reach areas, particularly around the seals and the bushings.

2. Inspect the Fork for Damage

  • Check the stanchions for any visible wear or scratches. If you notice any deep gouges, you may need to replace the stanchions, as they could lead to poor seal performance.
  • Inspect the bushings for any signs of play or excessive wear. If the bushings are damaged, replace them with new ones.
  • Examine the damper and air spring components for any signs of oil leakage or damaged parts.

Rebuilding the Jade Fork Concept

Once all components are clean and inspected, it’s time to begin the reassembly process.

1. Install New Seals and Dust Wipers

  • Begin by installing the new dust wipers and seals onto the lowers. Carefully press them into place using a seal driver to avoid damaging the new parts.
  • Make sure the seals are seated properly before moving on to the next step.

2. Reassemble the Air Spring

  • Take the air spring assembly and insert it back into the stanchion. Make sure that the air spring is properly aligned and seated into the fork’s lowers.
  • Reinstall the top cap on the air spring side, ensuring it is threaded securely but not overtightened. Be sure to lubricate the threads with a small amount of suspension oil to avoid binding.
  • Use a shock pump to reintroduce air into the air spring at the manufacturer-recommended pressure. Double-check the air pressure to ensure proper suspension performance.

3. Reinstall the Damper Assembly

  • Reinstall the damper assembly into the stanchion, making sure it slides smoothly and is properly aligned.
  • Tighten the damper bolts with a 6mm Allen wrench to the manufacturer’s recommended torque setting.

4. Reassemble the Fork Lowers and Stanchions

  • Slide the lowers back onto the stanchions, making sure that the seals and dust wipers fit snugly against the stanchions.
  • Reinstall the lower mounting bolts, tightening them to the specified torque settings.

5. Reattach the Fork to the Bike

  • Once the fork is fully reassembled, it’s time to reattach it to your bike. Slide the fork back into the head tube and secure it with the quick-release or through-axle.
  • Reattach the brake hose and any other components that were disconnected during disassembly.

Troubleshooting Common Issues

Even with a proper rebuild, you may encounter some common issues with the suspension fork. Here are a few troubleshooting tips:

Fork Sticking or Not Compressing Smoothly

  • If the fork feels sticky or doesn’t compress smoothly, check for dirt or debris trapped inside the seals or dust wipers. Clean them thoroughly and reapply fresh suspension oil.
  • Ensure that the damper and air spring are properly adjusted to your weight and riding style.

Leaking Oil or Air

  • If you notice oil or air leakage, inspect the seals and O-rings for wear. Replace any damaged seals, and make sure the air spring and damper components are properly sealed and tightened.

Fork Bottoming Out

  • If your fork is bottoming out too easily, you may need to increase the air pressure in the air spring. Adjust the compression settings or consider upgrading to stiffer springs if necessary.

Customizing and Optimizing Your Jade Fork Concept

To get the most out of your DVO Jade Fork Concept, consider the following customization tips:

Fine-Tuning Compression and Rebound Settings

  • Use the compression and rebound adjustments to dial in your fork’s performance based on the terrain you ride most frequently. For aggressive downhill riding, increase compression to prevent bottoming out, and adjust rebound to maintain control.

Upgrading the Damper

  • For riders looking for maximum performance, consider upgrading to a higher-end damper for improved damping characteristics and finer adjustments.

Experimenting with Air Pressure

  • Experiment with the air pressure in your air spring to find the perfect balance between comfort and support for your riding style and terrain. Adjusting the air pressure can help optimize small bump sensitivity and overall fork performance.

Conclusion

Rebuilding your DVO Jade Fork Concept suspension fork ensures that it continues to perform at its best. By following this step-by-step guide, you’ll be able to disassemble, clean, and reassemble your fork with confidence. Regular maintenance and attention to detail will keep your fork operating smoothly, allowing you to enjoy the full potential of your bike’s suspension system. Whether you’re replacing seals, adjusting the air spring, or fine-tuning the damping, your Jade Fork Concept will continue to provide you with the performance you need for all types of riding.