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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
V2021.11

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Summary of Contents for DT SWISS F 535 ONE

  • Page 1 FORKS F 535 ONE TECHNICAL MANUAL V2021.11...

  • Page 2: Table Of Contents

    1. GENERAL ..................... 3 2. SERVICE AND CARE ..................5 3. TROUBLE SHOOTING ................... 6 4. SMALL SERVICE ..................7 5. CONVERTING THE CONTROL ELEMENTS FROM MANUAL TO REMOTE . 17 6. CONVERT THE CONTROL ELEMENTS FROM REMOTE TO MANUAL ..23 7.

  • 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. The DT Swiss contact details can be found on the back. 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 condition of the tools are perfect. Always keep the tools in their original packaging or adequate devices to prevent damage.

  • Page 5: Service And Care

    Incorrect maintenance or assembly of the fork can lead to incorrect function! • Maintenance and assembly may only be done by a skilled professional. • In case of any doubt, contact a DT Swiss service center. • Only use original spare parts.

  • Page 6: Trouble Shooting

    DT Swiss service center to solve this problem. Remote Lockout: The lockout Check the proper fixation and the tension cable is not tensioned correctly. of the lockout cable. If the problem cannot be solved, contact a DT Swiss service center!

  • Page 7: Small Service

    4064XXXXXXXX000024 Wiper seal mounting tool FWTXXXXXX10015661S Reworked 8 mm hex bit FXTXXXXXXXX018482S Mounting tool for spring unit FWTXXXXXXXX014126S Syringe (minimum volume 20 ml) Tire lever Degreaser Torque wrench 25 Nm Plastic hammer Shock pump F 535 ONE Technical Manual V2021.11...
  • Page 8 4.1 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 GRADUALLY release the air. 5.
  • Page 9 → After the screws have been screwed in, about 20 ml of oil runs out of both dropouts. Collect the leaking oil using a suitable container. 4. Carefully remove lower unit. 5. Collect the leaking oil using a suitable container. F 535 ONE Technical Manual V2021.11...
  • Page 10 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.
  • Page 11 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 12 4.4 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 13 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 14 4.6 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 15 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 16 4.7 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 17: Converting The Control Elements From Manual To Remote

    FXTXXXXXXXX018645S Torque wrench with Torx T10 and 2.5 mm hexagon socket insert 5.2 OVERVIEW CONTROLS KIT cover compression spring clamping screw for remote cable O-ring washer remote wheel spring dust seal cover limitation pin F 535 ONE Technical Manual V2021.11...
  • Page 18 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 19 8 mm / 16 mm wrench. → The raster wheel must not turn while unscrewing the nut. 7. Remove the raster wheel. 8. Remove the O-ring. 9. Remove the raster caps. 10. Remove the springs. F 535 ONE Technical Manual V2021.11...
  • Page 20 5.4 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 21 9. Hold in this position and tighten the nut with a torque of 5 Nm using the tool FXTXXXXXXXX018645S. FXTXXXXXXXX018645S 19 mm 10. Put the O-ring into the remote wheel. 11. Put on the compression cover. F 535 ONE Technical Manual V2021.11...
  • Page 22 5.5 ATTACHING THE REMOTE CABLE 1. 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 23: Convert The Control Elements From Remote To Manual

    Torque wrench with a 2 mm hexagon and T10 Torx bit Loctite 241 or Loctite 243 Degreaser 6.2 OVERVIEW CONTROLS KIT fixing screw for the mode lever O-ring mode lever index pin compression adjuster spring compression nut cover index wheel F 535 ONE Technical Manual V2021.11...
  • Page 24 6.3 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. 4.
  • Page 25 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 ONE Technical Manual V2021.11...
  • Page 26 6.4 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 27 9. Turn the lockout shaft counterclockwise until stop (= OPEN position). 10. Put on the cover and tighten the fixing screw handtight (max. 0,2 Nm). 0.2 Nm F 535 ONE Technical Manual V2021.11...
  • Page 28 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 torque of 1.2 Nm.

  • Page 29: Add / Removing Apt Volume Spacers

    + 1 SETTING: VERY PROGRESSIVE When three APT spacers are used, the fork gets progressive and offers a direct ride feel. That makes this setting suitable for strong riders with an aggressive riding style. F 535 ONE Technical Manual V2021.11...
  • Page 30 7.2 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 7.3 RELEASING THE AIR 1. Unscrew the fixing screw of the cover on the spring side.
  • Page 31 3. Unscrew the air chamber cap with a 15 mm hexagon socket and a ratchet. 4. Pull the air chamber cap out of the air chamber. F 535 ONE Technical Manual V2021.11...
  • Page 32 7.5 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 33 If the valve cap corresponding to the number of volume spacers mounted is screwed on, it is possible later to see how many volume spacers have been mounted without opening the air chamber. F 535 ONE Technical Manual V2021.11...
  • Page 34 3. Put on the cover and tighten the fixing screw handtight (max. 0.2 Nm). T10 Torx max. 0.2 Nm...
  • Page 35 USA - Grand Junction, CO 81505 59302 Oelde techusa@dtswiss.com Germany service.de@dtswiss.com DT SWISS (FRANCE) S.A.S. DT SWISS POLSKA Sp. z o.o. Parc d‘Activites de la Sarrée ul. Towarowa 36 Route de Gourdon PL-64-600 Oborniki F - 06620 Le Bar sur Loup Poland service.fr@dtswiss.com...