Video Reference:
At 3:00 in this video, you can see the procedure used to strike the damper and air shafts into the lowers. 

Included in this Kit:

• 30mm Shaft Clamp: for holding the air spring cartridge safely near the top cap

Read: How to Clamp Big Diameter Shafts Properly (IMPORTANT)

• Optional 10mm Shaft Punches: for tapping damper and air shafts loose
• Dust Wiper Press Tool (the one you selected)

Need help choosing your dust wiper tool size? Use our tool finder:

Open Dust Wiper Tool Finder 
 Full press tool usage instructions: View guide

 

What You’ll Need:

• 18mm socket (for foot nuts)
• Rubber/plastic mallet (for gently tapping adjusters or shafts)
• Pin spanner or circlip pliers (for unscrewing air cartridge sealhead)
• Heat gun (to soften red Loctite on air sealhead)
• Long wood/plastic dowel (to push air piston out)
• Marine grease (for OTT spring)
• 25cc per side of 7.5wt fork oil (any lower leg oil is fine)
• Allen key (to test OTT adjuster function after reassembly)
• Blue Loctite
• Air pump

 Reference manuals:
- Diamond Air Spring Manual
- Beryl OTT Travel Guide

Recommended Tools & Supplies:

• Pin Spanner Wrench (for sealhead removal): Amazon Link
• Marine Grease for OTT Spring (resists mixing with oil): Lucas Marine Grease (Amazon)
• Top Cap Tool (for DVO forks): ALEOED 6-in-1 Top Cap Socket

If a link stops working or you find a better version, feel free to message us. We love learning better methods.

Special Notes:

• The DVO air spring is a sealed cartridge: clamp only at the top (see manual page 4, step 10).
• The air piston is not attached to the shaft; it must be pushed out gently with a dowel and reinstalled carefully.
  • It looks like an IFP, or it actually is an IFP, whatever, it's actually easier to service it becasue the whole piston comes with the seal kit from DVO, just a bit different from other brands.
• Always apply marine grease generously to the OTT coil spring to isolate it from the air shaft cartridge.
• For tricky sealhead removal, heat up the stanchion externally to weaken Loctite before using a spanner or pliers.
• Once the air spring is reassembled, verify the OTT adjuster rotates properly with an Allen key.
• Then perform a standard 50h lower leg service, including dust wiper replacement.
• Don't forget to put 5-7ml (or cc) of oil in the positive air chamber before closing the fork! Don't put too much, it will act as volumes spacers!

Emerald Owners:
This kit does not apply to the inverted DVO Emerald. However, that fork requires no special tools from us but the 36mm dust wiper seal press. You can follow the service video here: Watch Emerald Service.

⚠️ Warnings:

• Never clamp the cartridge in the middle, only clamp near the top cap where the manual indicates
• Do not overtighten the sealhead or use red Loctite; use blue only
• Be cautious with the pin spanner to avoid rounding out the sealhead holes and to not touch the air shaft.
• Recheck air pressure and OTT adjuster after reassembly

Disclaimer:
Some tools mentioned (pin spanners, grease, dowels) are not included. This rebuild procedure is based on DVO’s official manuals and our own testing where possible. Always verify compatibility before disassembly. See our Terms of Service.