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DT SWISS O.L Technical Manual

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FORKS
O.L / Single Shot 2
Technical Manual
V2015.09_EN

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Summary of Contents for DT SWISS O.L

  • Page 1 FORKS O.L / Single Shot 2 Technical Manual V2015.09_EN...

  • Page 2: Table Of Contents

    Damping: Single Shot 2 / O.L ........
  • Page 3 Small Service ............39 Releasing the Air Dismounting the Lower Unit Dismounting the Wiper Seals Dismounting the NCS Unit Mounting the NCS Unit O.L / Single Shot 2 Forks - Technical Manual...
  • Page 4 Changing the O-Rings of the Connecting Pieces Mounting the Wiper Seals Mounting the Lower Unit Trouble Shooting Bedding-In Time After a Crash Bushing Clearance Trouble Shooting O.L / Single Shot 2 Forks - Technical Manual...

  • Page 5: General

    The cover page and the footing provide information about the type of product and manual as well as the version of the manual. The backside provides a list of the DT Swiss service centers. A list of all DT Swiss service centers can be found at www.dtswiss.com.

  • Page 6: Dt Swiss Manual Concept

    Biel/Switzerland. Swiss law shall apply. Submit any warranty claims to your retailer or a DT Swiss service center. Any defects recognized by DT Swiss AG as a warranty claim will be repaired or replaced by a DT Swiss service center.

  • Page 7: Limited Equipment Warranty Usa

    To take advantage of this warranty, the product or part must be returned for examination, postage prepaid, to the dealer where you bought the product or to a DT Swiss service center. Proof of purchase date and an expla- nation of the complaint must accompany the product. If our inspection discloses a defect, DT Swiss will either repair or replace the product or refund the purchase price, if we cannot readily and quickly provide a repair or replacement.

  • Page 8: General Maintenance Information

    The usage of differing tools is up to the user. If components are being damaged by the usage of differing tools, the user is liable. 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.

  • Page 9: Description

    Spring: NCS (Negative Coil Spring) DT Swiss forks with NCS (Negative Coil Spring) technology use an air spring consisting of a positive air chamber and a negative steel spring. The negative spring counteracts to the pressure inside the positive air chamber. This way the negative spring improves the response characteristics drastically.

  • Page 10: Function Of The Compression Damping In Detail

    The blow-off itself does not represent a damping function, it protects rider and material from big hits. O.L / Single Shot 2 Forks - Technical Manual...

  • Page 11: Low Speed Rebound

    LSR (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 HSR. This ensures separate damping characteris- tics on small and medium or on fast rebound speeds. O.L / Single Shot 2 Forks - Technical Manual...

  • Page 12: Remote Control Elements

    Remote Control Elements 2.3.1 Two In One Remote Lever The Two In One remote lever is available as a single stage and a double stage version. For forks with O.L dam- ping, a single stage or double stage lever can be used.

  • Page 13: Function Single Stage

    2.3.2 Lightweight Remote Lever The remote lever is available as a single stage and a double stage version. For forks with O.L damping, a single stage lever must be used. One single lever can operate a fork or a shock.

  • Page 14: Installation

    5 mm spacer on top of the stem. 5. Cut the steerer to the desired length. DT Swiss re- commends to use a pipe cutter. 6. Deburr the steerer on the inside and on the out- side using a file.

  • Page 15: Installing The Fork

    • Only use crown race reducers of the respective headset manufacturer. • DT Swiss forks are built for a stem clamp without thread. Do not add any holes or threading, nor make any kind of technical alterations to the fork.

  • Page 16: Installing The Crown Race

    2 to 3 mm. Installing the Crown Race 1. Aluminum steerer: Apply a thin layer of grease onto the contact area of steerer and crown race. DT Swiss recommends Motorex Langzeitfett 2000. Install the crown race in accordance with the instructions of the manufacturer.

  • Page 17: Adjusting The Bearing Play Of The Headset

    Align the stem and tighten the fixing screws in accordance with the instructions of the manufacturer. Closing Steps Link Install the brake. chap. 3.3, page 17 Inflate the fork. chap. 4.1, page 20 O.L / Single Shot 2 Forks - Technical Manual...

  • Page 18: Installing The Brake

    Link not required DT Swiss O.L. and Single Shot 2 forks are compatible with brake discs with a maximum diameter of 210 mm. All DT Swiss Forks from 2009 on are equipped with Post Mount (PM) brake mounting standard for 160 mm.

  • Page 19: Installing The Front Wheel

    • Check hubs, thru axles or quick releases for sharp edges. • Do not use hubs, thru axles or quick releases if there are sharp edges. • DT Swiss recommends the usage of DT Swiss hubs and quick releases. Using a RWS Thru Axle 1.

  • Page 20: Collision Test

    4. If necessary, reduce the tire pressure to the desired operating pressure. Closing Steps Link Check the correct installation of the fork and function of the brake. Install a remote lever if required. see following O.L / Single Shot 2 Forks - Technical Manual...

  • Page 21: Operation And Setting

    245 / 110 122 / 8.4 120 / 8.3 117 / 8.1 113 / 7.8 max. air pressure 174 / 12 174 / 12 174 / 12 174 / 12 [psi / bar] O.L / Single Shot 2 Forks - Technical Manual...

  • Page 22: Setting The Sag (Negative-Travel)

    3. Sit on the bike with full equipment (backpack, hel- met, shoes...). 4. Sit on the bike as you would sit during the ride. The fork goes down because of your own weight. Avoid impact loads. O.L / Single Shot 2 Forks - Technical Manual...
  • Page 23 6. Set the air pressure if necessary (see following). Repeat steps above until the correct SAG is set. O.L / Single Shot 2 Forks - Technical Manual...

  • Page 24: Setting The Air Pressure

    Setting the Air Pressure In all DT Swiss fork models, the air spring is located in the left stanchion. By adjusting the air pressure, the spring rate will be affected. The higher the air pressure, the harder the spring. Adjusting the air pressure is possible by changing the air pressure. Adjusting the air pressure to the weight of the rider can slightly change the total length of the fork.

  • Page 25: Setting The Damping

    The aim of setting the rebound damping is to achieve the best setting possible, which meets the requirements of the terrain best. Rough, fast downhills requires a low rebound damping, while flowy downhills without big hits requires a higher damping. O.L / Single Shot 2 Forks - Technical Manual...

  • Page 26: Remote Lockout

    To activate the lockout turn the lever to position «LOCK». Remote Lockout There are two different DT Swiss remote levers available: The lightweight lever and the Two In One lever. The lightweight lever may only control one fork, while the Two In One lever may control a fork and a shock at the same time (see also chap.

  • Page 27: Converting The Control Elements

    5 Converting the Control Elements DT Swiss forks are available with manual or remote control elements. The following chapters describe the conversion between these versions and the installation of the remote levers. • Converting from remote to manual operation: chap. 5.1, page 26 •...
  • Page 28 5. Lift the remote wheel and remove it while perfor- ming a rotary motion. 6. Remove the spring. 7. Unscrew the stop screw of the remote wheel using a 2 mm Allen key. O.L / Single Shot 2 Forks - Technical Manual...

  • Page 29: Mounting The Manual Control Elements

    5. Put on the index plate The index points have different distances. The po- sitioning must be like the accompanying picture. This position must not be changed during the fol- lowing steps. O.L / Single Shot 2 Forks - Technical Manual...
  • Page 30 0.25 Nm using a T8 Torx key. 14. Fully close the rebound and then turn back the wheel 6 clicks. Closing Steps Link Check all functions of the fork. O.L / Single Shot 2 Forks - Technical Manual...

  • Page 31: Converting From Manual To Remote Operation

    2. Take off the rebound wheel and the fixing screw. 3. Unscrew the fixing nut of the lever using an 8 mm socket wrench. 4. Remove the nut and the lever. 5. Remove the index plate. O.L / Single Shot 2 Forks - Technical Manual...

  • Page 32: Mounting The Remote Control Elements

    4. Put thread lock onto the thread of the stop screw.  Required thread lock, see table on page 26. 5. Screw the stop screw into the thread next to the rebound pin. O.L / Single Shot 2 Forks - Technical Manual...
  • Page 33 17. Hold the rebound wheel and tighten the fixing screw with a torque of 0.25 Nm using a T8 Torx key. 18. Fully close the rebound and then turn back the wheel 6 clicks. O.L / Single Shot 2 Forks - Technical Manual...
  • Page 34 Closing Steps Link Install the remote lever. chap. 5.3, page 34 Check all functions of the fork. O.L / Single Shot 2 Forks - Technical Manual...

  • Page 35: Installing The Remote Lever

    The lightweight lever can only operate a single DT Swiss fork, while the Two In One lever can operate a DT Swiss fork and a DT Swiss Shock at the same time. Both levers are available as single stage and double stage versions.
  • Page 36 5.3.2 Installing the Remote Lever [Two In One] General Information: Two In One Lever • The remote lever can be used for DT Swiss forks and/or DT Swiss shocks. • The remote lever must be installed on the left top side of the handlebar.

  • Page 37: Installing The Pipe, Cable And Cable Housing

    10. Press the remote lever a few times. 11. Set the tension of the cable with the knurled screw at the pipe. In pos.2 the lever must lock com- pletely and the lockout must be active. O.L / Single Shot 2 Forks - Technical Manual...
  • Page 38 12. Cut the cable to the desired length and attach a cable end cap. Closing Steps Link The fork is installed completely. After setting the fork (see chap. 4, page 20), you should go for a ride! O.L / Single Shot 2 Forks - Technical Manual...

  • Page 39: Service And Care

    Clean with a soft cloth and a suitable cleaner, especially in the area of the after each ride main seals Do not use high pressure cleaners and aggressive cleaners! *If you use your bike in extreme conditions, you will have to service your components sooner. O.L / Single Shot 2 Forks - Technical Manual...

  • Page 40: Small Service

    Small Service This manual only describes a small service. Further service works will be executed by a DT Swiss service center. A small service should be carried out in the following cases: • bad performance • after rides in extreme conditions •...

  • Page 41: Releasing The Air

    Dismounting the Lower Unit 1. Screw both hexagonal socket screws into the dropouts clockwise using a 4 mm Allen key. 2. Collect the leaking oil using a suitable container. O.L / Single Shot 2 Forks - Technical Manual...
  • Page 42 3. Remove the lowers carefully. 4. Collect the leaking oil using a suitable container. O.L / Single Shot 2 Forks - Technical Manual...

  • Page 43: Dismounting The Wiper Seals

    The foam rings should be replaced on every ser- vice. 3. Lever out the wiper seal using a metal tire lever. Caution: The lowers must not be damaged. Remove the spring rings before dismounting the wiper seals. O.L / Single Shot 2 Forks - Technical Manual...
  • Page 44 4. Remove the wiper seals. 5. Remove the second wiper seal the same way. O.L / Single Shot 2 Forks - Technical Manual...

  • Page 45: Dismounting The Ncs Unit

    If the valve insert faces down- wards, the oil can escape through the valve. 4. Clean the NCS unit using a dry textile cloth. Do not use paper towels. Small fibers can lead to air leakages. O.L / Single Shot 2 Forks - Technical Manual...

  • Page 46: Mounting The Ncs Unit

    Required grease, see table on page 39. 3. Position the upper unit so that the open end faces slightly upwards. 4. Fill 2 ml DT Swiss Factory Lube Fluid into the left stanchion.  Required oil, see table on page 39.
  • Page 47 Wind the ring by pressing down around the cir- cumference until the entire ring is inserted into the groove. [C]. d) Check, if the ring is installed properly [D]. 8. Check if the NCS unit is fixed properly. O.L / Single Shot 2 Forks - Technical Manual...

  • Page 48: Changing The O-Rings Of The Connecting Pieces

    Required tool, see table on page 39 7. Slide the new O-ring onto its seat on the connec- ting piece.  Required material, see table on page 39 8. Remove the tool. O.L / Single Shot 2 Forks - Technical Manual...

  • Page 49: Mounting The Wiper Seals

    5. Remove the tool from the wiper seal. 6. Mount the second wiper seal the same way. 7. Leave the lowers for minimum 15 minutes and allow the wiper seals to seat. O.L / Single Shot 2 Forks - Technical Manual...

  • Page 50: Mounting The Lower Unit

    3. Slide the SAG O-ring onto the upper unit 4. Slide the lower unit about 2 cm onto the upper unit. 5. Fill 7 ml DT Swiss Fork Oil into the air side of the lower unit.  Required oil, see table on page 39.
  • Page 51 Dispose the oil in an environmentally compatible manner. Inflate the fork. chap. 4.1, page 20 Clean the fork. Check all functions of the fork. The maintenance of the fork is complete. Enjoy the Ride! O.L / Single Shot 2 Forks - Technical Manual...

  • Page 52: Trouble Shooting

    Functional check: Check if all functions are working correctly. • Acoustic check: Listen for unusual noises during slow riding or braking in a secure area. Do not use a defective fork! Contact your local dealer or the responsible DT Swiss service center to repair the damage! Bushing Clearance DT Swiss forks use bushings in combination with oil lubrication.

  • Page 53: Trouble Shooting

    If the problem can‘t be solved, contact a DT Swiss service center! O.L / Single Shot 2 Forks - Technical Manual...
  • Page 54 F - 06620 Le Bar sur Loup E-Mail: service.fr@dtswiss.com DT Swiss (Asia) Ltd. No. 26, 21st Road Industrial Park Taichung City E-mail: info@dtswiss-asia.com www.dtswiss.com Subject to technical alterations, errors and misprints excepted. All rights reserved. © by DT Swiss AG...

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Single shot 2

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