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DT SWISS F 535 ONE Technical Manual
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DT SWISS F 535 ONE Technical Manual

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FORKS
F 535 ONE
TECHNICAL MANUAL
V2018.09

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Summary of Contents for DT SWISS F 535 ONE

  • Page 1 FORKS F 535 ONE TECHNICAL MANUAL V2018.09...

  • Page 2: Table Of Contents

    1. GENERAL ..................... 3 2. DESCRIPTION ....................6 3. SMALL SERVICE ..................11 4. CONVERTING THE CONTROL ELEMENTS FROM MANUAL TO REMOTE . 21 5. CONVERT THE CONTROL ELEMENTS FROM REMOTE TO MANUAL ..27 6. ADDING / REMOVING APT VOLUME SPACERS........... 33...

  • Page 3: General

    The cover page and the footing provide information about the type of product and manual as well as the version of the manual. On the back you will find the DT Swiss contact details. A list of all DT Swiss service centers can be found at www.dtswiss.com.
  • Page 4 DT Swiss special tools are precision tools. Damage-free mounting and dismounting of the components can only be ensured if the tools are working properly and if the conditions of the tools are perfect. Always keep the...
  • Page 5 In addition to the general guarantee required by law, DT Swiss AG based in Biel/Switzerland, provides a guarantee for 24 months from the date of purchase. DT Swiss AG shall reject any liability for both indirect damage caused by accidents and consequential damage.

  • Page 6: Description

    2. DESCRIPTION The damping unit controls the compression and rebound speed of the fork. During compression and rebound movements of the suspension fork, oil is pressed through holes with adjustable cross section and through small spring plates (shims) which allow more oil to pass through as the oil pressure increases (the faster the movement of the suspension fork, the higher the oil pressure).
  • Page 7 COMPRESSION - FUNCTION IN DETAIL OPEN 2 OPEN 1 DRIVE LOCK figure 1: Compression - function in detail When the fork compresses, the piston inside the oil chamber is pushed upwards. Some of the oil passes through a one way valve past the piston (see figure 1) into the lower part of the oil chamber.
  • Page 8 High speed compression (HSC) Additionally, the oil flows through the oil channel of the high-speed compression (HSC). Shims are placed at the end of the oil channel. These shims only open when a defined oil pressure is attained. Oil which cannot flow through the oil channels of the LSC (because of fast deflection of the fork, and thus big displacement of the oil generated by the piston), flows through the oil channels of the HSC.
  • Page 9 2.3 SPRING The Line Air system consists of a bypass located in the air chamber. The bypass ensures that the pressure inside the negative air chamber is higher than in the positive air chamber when the fork is fully extended. This reduces the force of the beginning stroke.
  • Page 10 2.4 SPRING CONNECTOR The spring unit is connected to the lower unit of the fork via a spring connector. The spring connector basically consists of a coil spring and a guide bushing. The steel spring of the spring connector absorbs minor impacts before they can be transferred to the spring unit.

  • Page 11: Small Service

    Specification Quantity Article number Wiper seal kit Ø35 • 2 x wiper FWKXXXXXXXXX20369S • 2 x foam ring • 2x O-ring DT Swiss Lube Fluid 100 ml 4064XXXXXXXX000026 DT Swiss Fork Oil 100 ml 4064XXXXXXXX000024 Wiper seal mounting tool FWTXXXXXX10015661S...
  • Page 12 3.2 RELEASING THE AIR 1. Unscrew the fixing screw of the cover on the spring side. 2. Remove the cover. T10 Torx 3. Unscrew the valve cap. 4. Carefully press the back of the valve cap onto the valve insert and slowly release the air.
  • Page 13 3.3 REMOVING THE LOWER UNIT 1. Make sure the valve cap is removed and the air is completely released (see „3.2 Releasing The Air“ on page 12). FXTXXXXXXXX018482S 27,5“ 29“ 2. Screw in the screw on the spring side clockwise into the lower unit using the tool FXTXXXXXXXXXX018482S.
  • Page 14 6. Remove the O-rings of the connectors. If there is no O-ring on one of the connectors, it may be inside the lower unit and must be removed from there. 7. Slightly grease the new O-rings and put it on the connectors. 3.4 CHANGING THE WIPER SEALS 1.
  • Page 15 9. Leave the lower unit for about 15 minutes and allow the wiper seals to seat. 10. Put two new, in DT Swiss Lube Fluid soaked foam rings between the bushings and the wiper seals. → Make sure that the foam rings are not twisted and completely evenly between seal and bushing.
  • Page 16 3.5 REMOVING THE SPRING UNIT As part of the small service we recommend to remove the spring unit in order to remove introduced lubricating oil from the spring unit and from the left stanchion. DANGER RISK OF INJURY FROM PRESSURIZED COMPONENTS! If the spring unit or the air chamber cap is removed without first releasing the air, the spring unit or the air chamber cap is ejected from the stanchion after loosening the screw connection.
  • Page 17 3.6 ASSEMBLING THE SPRING UNIT 1. Make sure that there is still residual oil on the seals of the spring unit. Grease the seals with a small amount of DT Swiss Fork Oil if necessary. 2. Push the screw connection of the spring unit as far as possible in the direction of the piston.
  • Page 18 3.7 ASSEMBLING THE LOWER UNIT 1. Before mounting the lower unit, the damping unit should be fully compressed once. This ensures that the correct amount of damping oil is in the damping unit. A small amount of oil may drip from the stanchion. 2.
  • Page 19 6. Fix the fork 45° - 70° upright. 7. Fill 20 ml DT Swiss Fork Oil into the spring side of the lower unit. 8. Fill 20 ml DT Swiss Fork Oil into the damping side of the lower unit.
  • Page 20 3.8 INFLATING THE FORK 1. Inflate the fork (see user manual for detailed information). 2. Screw on the valve cap. 3. Put on the cover and tighten the fixing screw handtight (max. 0.2 Nm). T10 Torx max. 0.2 Nm...

  • Page 21: Converting The Control Elements From Manual To Remote

    4. CONVERTING THE CONTROL ELEMENTS FROM MANUAL TO REMOTE 4.1 REQUIRED TOOLS AND MATERIALS Required tools and materials Quantity Article number Controls kit ICP remote FWKXXXXXXXXX20621S 2 mm Allen key T10 Torx key or T10 Setup tool from the RWS-axle 8 mm, 16 mm, 19 mm open end wrench 8 mm socket FXTXXXXXXXX018645S...
  • Page 22 4.3 REMOVING THE MANUAL CONTROL ELEMENTS 1. Unscrew the fixing screw of the mode lever a few turns. 2. Remove the lever. 2 mm 3. Unscrew the fixing screw of the cover and remove the cover. 4. Pull out the compression adjuster.
  • Page 23 5. Hold the raster wheel with a 16 mm wrench. 6. Unscrew the compression nut using an 8 mm / 16 mm 8 mm wrench. → The raster wheel must not turn while unscrewing the nut. 7. Remove the raster wheel. 8.
  • Page 24 4.4 ASSEMBLING THE REMOTE CONTROL ELEMENTS 1. Turn the lockout shaft clockwise until stop (LOCK mode). 2. Put on the dust seal. 3. Put on the spring and the limiter cap. → Both the spring and the limiter cap must be placed in the bore next to the mark on the damping unit.
  • Page 25 7. Turn the remote wheel clockwise for about 270° until the limiter cap snaps into the 19 mm hole of the remote wheel with an audible „klick“ using a 19 mm wrench. 8. Continue turning the remote wheel about 70° until stop. →...
  • Page 26 12. Put on the cable housing (2) and the cable adjuster (1). • Only cable housings with an outer diameter of 4 mm must be used. • Slide the cable housing through the cable holder on the backside of the fork crown (A). •...

  • Page 27: Convert The Control Elements From Remote To Manual

    5. CONVERT THE CONTROL ELEMENTS FROM REMOTE TO MANUAL 5.1 REQUIRED TOOLS AND MATERIALS Required tools and materials Quantity Article number Controls kit ICP FWKXXXXXXXXX20620S T10 Torx key or T10 Setup tool from the RWS-axle 8 mm bit FXTXXXXXXXX018645S 16 mm, 19 mm open end wrench Torque wrench with a 2 mm hexagon and T10 Torx bit Loctite 241 or Loctite 243 Degreaser...
  • Page 28 5.3 REMOVING THE REMOTE CONTROL ELEMENTS 1. Unscrew the fastening screw of the cover on the damping side and remove the cover. 2. Pull off the compression cover and the O-ring. 3. Hold the remote wheel with a 19 mm wrench.
  • Page 29 5. Pull off the remote wheel. 6. Remove the spring. 7. Pull off the limiter cap and the spring. 8. Remove the dust seal. F 535 - technical manual...
  • Page 30 5.4 ASSEMBLING THE MANUAL CONTROL ELEMENTS 1. Insert springs and index pins into the bores of the damping unit. → The holes must be selected so that the index pins are offset by 120°. 2. Turn the lockout shaft clockwise to its stop (= LOCK position).
  • Page 31 7. Put the O-Ring into the groove between cap and raster. 8. Slightly grease the toothing of the compression adapter and put it into the lockout shaft. 9. Turn the lockout shaft counterclockwise until stop (= OPEN position). 10. Put on the cover and tighten the fixing screw handtight (max.
  • Page 32 11. Place the lockout lever in riding direction of the fork. 12. Degrease the fixing screw of the lockout lever and put Loctite 241 onto the thread of the screw. 13. Screw in the fixing screw and tighten it to a 2 mm 1.2 Nm torque of 1.2 Nm.

  • Page 33: Adding / Removing Apt Volume Spacers

    6. ADDING / REMOVING APT VOLUME SPACERS 6.1 OVERVIEW / FUNCTION The APT (Adaptable Progression Tune) system allows the rider to adjust the progression of the air spring curve by adding or removing volume spacers in the fork‘s air chamber. The fork is delivered with two mounted volume spacers.
  • Page 34 6.2 REQUIRED TOOLS AND MATERIALS Required tools and materials Specification Quantity Article number APT ADJUSTMENT KIT F535 FWXXXXXXXXXX18795S 15 mm hexagon socket 28 mm open end wrench Torque wrench 25 Nm 6.3 RELEASING THE AIR 1. Unscrew the fixing screw of the cover on the spring side.
  • Page 35 5. Carefully press the back of the valve cap onto the valve insert and slowly release the air. 6. Slowly compress the fork two times about 10 mm with the valve insert pressed and pull it apart again. → This balances the positive and negative air chambers.
  • Page 36 6.5 CHANGING THE O-RING OF THE AIR CHAMBER CAP 1. Remove the O-ring from the air chamber cap. 2. Clean the seat of the O-ring and the thread of the air chamber cap and grease it slightly. 3. Slightly grease the new O-ring and fit it onto the air chamber cap.
  • Page 37 6.7 CLOSING THE AIR CHAMBER 1. Clean the thread of the air chamber and the thread of the air chamber cap. 2. Slightly grease the thread and O-ring. 3. Screw in the air chamber cap as far as possible by hand. 4.
  • Page 38 3. Put on the cover and tighten the fixing screw handtight (max. 0.2 Nm). T10 Torx max. 0.2 Nm...
  • Page 39 F - 06620 Le Bar sur Loup info.fr@dtswiss.com DT SWISS (ASIA) LTD. No.5, Jingke 5th Rd., Nantun District Taichung City 408 Taiwan (R.O.C.) info.tw@dtswiss.com Subject to technical alterations, errors and misprints excepted. All rights reserved. © by DT SWISS AG www.dtswiss.com FXD10000002583S...