Included in this Kit:

• 10mm Shaft Clamp: for holding the air shaft safely during rebuild
• 38mm dust wiper seal tool
• 10mm Bullet Tool: for inserting the negative sealhead on the sharp-edged air shaft
  • We haven’t had the chance to test a full rebuild on the Onyx 38 ourselves yet.
  • DVO makes their own bullet tools, and they’re cheap but unfortunately, they don’t specify which one fits this fork. It’s probably the 10.0 × 8.0mm SHAFT (Not BORE) bullet, but we can’t confirm.
  • If you want, we also offer a Fox NA2 Bullet Tool for 10mm shafts. It’s just +$8 in that kit and might work fine too.
  • Recommendation: Try to get the DVO bullet tool if possible but our Fox NA2 tool may be enough.

What You’ll also Need (not included in the kit):

• Cassette Tool: to remove the top cap (unlike other DVO forks that use a socket)
• Metal picks: to remove and reinstall the air piston clip
• Blue Loctite: for air shaft threads
• Air pump: to repressurize after reassembly

Official Manual: View Onyx 38 Full Service Guide (PDF)

Special Notes:

• No OTT spring: The Onyx 38 uses a standard air spring, unlike older DVO forks but I think you can still get some with an OTT, make sure you know which one you have.
• Top cap is splined: Requires a cassette tool for removal like this one on Amazon.
• Air piston is secured with a circlip: no threaded sealhead or cartridge to clamp
• Always add 5–7cc of oil to the positive chamber during reassembly

Helpful Links:

• Dust Wiper Tool Finder
• How to Clamp 10mm Shafts Properly

⚠️ Warnings:

• Do not overfill the air chamber or it will act as a volume spacer
• Use blue Loctite only, never red, on reassembly threads

Disclaimer: This kit does not include a cassette tool or circlip pliers or any normal tools. The procedure is based on the official DVO Onyx 38 guide and real-world workshop logic. Always verify compatibility before disassembly. See our Terms of Service.