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DT SWISS F 232 ONE Service Manual

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FORKS
F 232 ONE
SERVICE CENTER MANUAL
V2021.10

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Summary of Contents for DT SWISS F 232 ONE

  • Page 1 FORKS F 232 ONE SERVICE CENTER MANUAL V2021.10...

  • Page 2: Table Of Contents

    1. USER INFORMATION ................3 GENERAL ........................3 GENERAL MAINTENANCE INFORMATION ..............4 WARRANTY ........................4 2. OVERVIEW .................... 5 FORK OVERVIEW ......................5 SERVICE KITS .........................6 TOOLS ..........................9 3. SAFETY ....................10 4. SERVICE INFORMATION ................ 11 GENERAL ........................11 SERVICE INTERVALS ......................11 SERVICE WORKS ......................11 5.

  • Page 3: User Information

    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 4: General Maintenance Information

    DT SWISS MANUAL CONCEPT The DT Swiss user and service information is split into the following types of manuals: • User Manual Information for the end user on how to install and use the component. • Technical Manual Detailed information for the end user and the dealer on how to maintain the component, spare parts and technical data.

  • Page 5: Overview

    2.1 FORK OVERVIEW Description Description RWS axle fender rebound adjuster upper unit damping unit spring unit manual control elements volume reduction spacer remote control elements air chamber cap with volume spacers lower unit valve cap F 232 ONE Service Center Manual...

  • Page 6: Service Kits

    2.2 SERVICE KITS SEAL KIT DAMPING UNIT Art.No. FWKXXXXXXXXX28871S 1 O-ring Ø15 x 2 mm 2 O-ring Ø16 x 1.5 mm 3 O-ring Ø20 x 2 mm 4 O-ring Ø22 x 3 mm 5 O-ring Ø26 x 1.5 mm 6 compression pin 7 2x O-ring Ø2 x 1 mm (already mounted on the compression pin) 8 clip...
  • Page 7 1 2x wiper seal Ø32 2 2x foam ring 3 2x O-ring Ø15 x 2 mm CLIPS KIT ICP Art.No. FWKXXXXXXXXX20370S 20x clip SPRING AND BALL KIT Art.No. FWKXXXXXXXXX20416S 1 20x spring 2 20x ball F 232 ONE Service Center Manual...
  • Page 8 DUST SEAL KIT REMOTE ICP Art.No. FWKXXXXXXXXX21572S 5x dust seal...

  • Page 9: Tools

    8 mm FWTXXXXXX10024414S FXTXXXXXX10028188S spring unit mounting tool volume reduction spacer mounting tool FWTXXXXXXXX018638S FXTXXXXXX10028191S stanchion grease tool volume reduction spacer positioning tool FXTXXXXXXXX018645S reworked hex socket 8 mm F 232 ONE Service Center Manual...

  • Page 10: Safety

    • Maintenance and assembly must only be done by a skilled professional. • In case of any doubt, contact a DT Swiss service center. DANGER RISK OF INJURY DUE TO HIGH AIR PRESSURE! Air with high pressure can escape suddenly while dismounting the fork! •...

  • Page 11: Service Information

    Action Interval Full service annually or after 200 operating hours* A full service must be executed by a DT Swiss service center. Small service 50 operating hours* A small service can be executed by a DT Swiss service center, a skilled dealer or user.

  • Page 12: Disassembling

    5. DISASSEMBLING Preparatory Steps Link Clean the fork „CLEANING“ on page 4 Required Tools and Material Quantity Article number reworked 8 mm hex nut FXTXXXXXXXX018645S special 8 mm internal hex bit FXTXXXXXXXX018482S mounting tool for damping unit FXTXXX0XXXX011744S clip extraction tool FXTXXXXXXXX018412S tool for ball and spring FXTXXXXXXXX018400S...

  • Page 13: Releasing The Air

    2. Release the air SLOWLY by pressing the valve insert. 3. With the valve insert pressed, slowly compress the fork twice by about 10 mm and then decompress fully. → This equalises the positive and negative air chambers. F 232 ONE Service Center Manual...

  • Page 14: Disassembling The Control Elements

    5.2 DISASSEMBLING THE CONTROL ELEMENTS 5.2.1 REMOVING THE REMOTE CONTROL ELEMENTS 1. Pull off the compression cover. 2. Unscrew the nut of the remote wheel using the tool FXTXXXXXXXX018645S. FXTXXXXXXXX018645S 3. Pull off the remote wheel.
  • Page 15 1. Pull off the compression cover. 2. Hold the lever with one hand. → The lever must not turn while unscrewing the nut! 3. Unscrew the nut of the remote wheel using the FXTXXXXXXXX018645S tool FXTXXXXXXXX018645S. F 232 ONE Service Center Manual...
  • Page 16 4. Remove the lever and the O-ring underneath. 5. Remove the raster wheel, the raster caps and the springs.

  • Page 17: Disassembling The Lower Unit

    4. Screw the screw on the damping side into the dropout clockwise using an 8 mm hex nut. → After the screws are screwed in, about 14 ml oil will leak out of each dropout. Collect the leaking oil using a suitable container. F 232 ONE Service Center Manual...
  • Page 18 5. Remove the lower unit carefully. → The O-rings on the connectors may fall off after removing the lower unit. Ensure that the O-rings do not stay inside the lower unit. 6. Collect the leaking oil using a suitable container.

  • Page 19: Disassembling The Damping Unit

    5.4 DISASSEMBLING THE DAMPING UNIT 1. Unscrew the damping unit using the special installation tool FXTXXX0XXXX011744S. 2. Pull out the damping unit. → Collect the leaking oil using a suitable container. FXTXXX0XXXX011744S 17 mm 3/8 inch F 232 ONE Service Center Manual...
  • Page 20 5.4.1 REMOVING THE COMPRESSION PIN 1. Make sure the compression pin is not screwed in or out to the maximum. → If the compression pin is screwed in or out to FXTXXXXXXXX018412S the maximum, removing it will be difficult. 2. Push the clip out of the compression pin using the tool FXTXXXXXXXX018412S and forceps.
  • Page 21 → One of both screw joints loosens. No Loctite must get into the oil chamber of the damping unit! The oil chamber must not be clamped! 3. Release the entire oil by pushing in the damping rod. F 232 ONE Service Center Manual...

  • Page 22: Disassembling The Spring Unit

    5.5 DISASSEMBLING THE SPRING UNIT 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 23: Disassembling The Volume Reduction Spacer

    5.6 DISASSEMBLING THE VOLUME REDUCTION SPACER 1. Push out the volume reduction spacer from the top using a suitable plastic tool. Closing Steps Link Servicing the fork „6. Servicing“ on page 24 F 232 ONE Service Center Manual...

  • Page 24: Servicing

    (can be used if only a small service will be done) presstool wiper seal Ø32 SKF FWTXXXXXXXX013089S Solid tire lever 100 ml 4064XXXXXXXX000026 DT Swiss Lube Fluid 1000 ml 4064XXXXXXXX000028 6.1.1 REMOVING THE WIPER SEALS 1. Remove both foam rings below the wiper seals.
  • Page 25 5. Repeat steps to mount the second wiper seal. 6. If small rubber slices were cut off from the wiper when pressing in, remove them. 7. Put two new, in DT Swiss Lube Fluid soaked foam rings between the bushings and the wiper seals. Closing Steps Link If no further service works are necessary, mount the lower unit „7.6 assembling the lower unit“...

  • Page 26: Changing The O-Rings Of The Damping Unit

    Disassembling the damping unit „5.4 Disassembling the damping unit“ on page 19 Required Tools and Material Quantity Article number SEAL KIT INC FWKXXXXXXXXX28871S DT Swiss Fork Oil 100 ml 4064XXXXXXXX000024 1000 ml 4064XXXXXXXX000025 6.2.1 SEAL KIT OVERVIEW O-ring top unit...
  • Page 27 CHANGING THE O-RING OF THE OIL CHAMBER 1. Remove the O-ring from the open end of the oil chamber using plastic forceps. 2. Put DT Swiss fork oil onto the new O-ring. 3. Put the O-ring onto the open end of the oil chamber.
  • Page 28 CHANGING THE OUTER O-RINGS OF THE DAMPING UNIT 1. Remove the three outer O-rings. 2. Put DT Swiss Fork Oil onto the three new O-rings. 3. Put one new O-ring onto the top unit. 4. Put one new O-ring onto the IFP tube.

  • Page 29: Changing The O-Rings Of The Spring Unit

    1. Remove the quadring from the air piston. 2. Check the seat of the quadring for damages. 3. Slightly grease the new quadring with Slick Honey and put it onto the air piston. 4. Check, if the quadring is not twisted. F 232 ONE Service Center Manual...
  • Page 30 7. Remove the O-ring from the lower air chamber cap. 8. Slightly lubricate the new O-ring with DT Swiss Fork Oil and put it onto the seal head. 6.3.3 CHANGING THE O-RINGS OF THE VOLUME REDUCTION SPACER 1.

  • Page 31: Assembling

    FXTXXXXXX10028553S clip assembly tool FXTXXXXXX10018855S stanchion grease tool FWTXXXXXXXX018638S volume reduction spacer mounting tool FXTXXXXXX10028188S volume reduction spacer positioning tool FXTXXXXXX10028191S spring unit mounting tool FWTXXXXXX10024414S special 8 mm internal hex bit FXTXXXXXXXX018482S F 232 ONE Service Center Manual...
  • Page 32 Required Tools and Material Quantity Article number reworked 8 mm hex nut FXTXXXXXXXX018645S DT Swiss Fork Oil 100 ml 4064XXXXXXXX000024 4064XXXXXXXX000025 4064XXXXXXXX000027 torque wrench (min. 0.2 Nm / max. 25 Nm) Buzzy‘s Slick Honey 4.7 dl 40341000AD02000001 dust seal kit remote ICP...

  • Page 33: Assembling The Damping Unit

    → Take care not to damage the O-rings. 4. Tighten the damping unit using the tool FXTXXX0XXXX011744S and a torque wrench with a torque of 15 Nm. FXTXXX0XXXX011744S 17 mm 3/8 inch 15 Nm F 232 ONE Service Center Manual...
  • Page 34 3. When the bleeding tool is screwed on fully, turn back the bleeding tool about 70° (= OPEN position). 4. Fill DT Swiss Fork Oil into the syringe. 5. Bleed the damping unit by pulling and pushing the piston rod several times.
  • Page 35 INFO: The clip is part of the seal kit ICP (art. no. FWKXXXXXXXXX28871S). The clip is also available as a service part (art. no. FWKXXXXXXXXX20370S). 8. Push in the clip using the tool FXTXXXXXX10018855S. F 232 ONE Service Center Manual...

  • Page 36: Greasing The Stanchion Tube

    GREASING THE STANCHION TUBE 1. Put Slick Honey onto the foam part of the tool FWTXXXXXXXX018638S. 2. Slide the tool into the stanchion tube. 3. Remove the tool and check if the inner surface of the stanchion tube is greased evenly.

  • Page 37: Setting The Volume Reduction Spacer

    → The tool FXTXXXXXX10028191S pushes the volume reduction spacer into the correct position. → The distance from the top end of the stanchion to the spacer must be set to 61.5 - 65.5 mm. F 232 ONE Service Center Manual...
  • Page 38 4. Grease the inner surface of the stanchion below the volume reduction spacer again (see „7.2 Greasing the Stanchion Tube“ on page 36). Ensure, that the position of the volume reduction spacer will not be changed.

  • Page 39: Assembling The Spring Unit

    4. Screw in the spring unit from the bottom using the tool FWTXXXXXX10024414S. Make sure the sealhead is pushed as far as possible in the direction of the piston. FWTXXXXXX10024414S 20 Nm 27 mm F 232 ONE Service Center Manual...

  • Page 40: Assembling The Air Chamber Cap

    ASSEMBLING THE AIR CHAMBER CAP 1. Ensure that the required amount of volume spacers are mounted on the air chamber cap. The maximum amount of volume 15 Nm spacers is three! Do not exceed! 2. Check the O-ring of the air chamber cap for damages.
  • Page 41 4. Fill 14 ml DT Swiss Fork Oil into the air side of the lower unit. 5. Fill 14 ml DT Swiss Fork Oil into the damping side of the lower unit. 6. Fix the fork 45° - 70° upright for about 60 seconds to allow the bushings to be lubed.

  • Page 42: Assembling The Control Elements

    10. Put the rebound adjuster onto the hex of the damping unit. 11. Put Loctite onto the thread of the fixing screw. 12. Hold the rebound adjuster using a 12 mm wrench and screw on the fixing screw of the rebound adjuster using a long 2.5 mm hex key.
  • Page 43 (see picture). 14. Screw on the fixing nut clockwise using FXTXXXXXXXX018645S the special tool FXTXXXXXXXX018645S and tighten the fixing nut with a torque of 5 Nm 5 Nm. F 232 ONE Service Center Manual...
  • Page 44 15. Check the correct assembly of the remote wheel: Turn the remote wheel using the short end of an angled 2 mm Allen key. → The remote wheel must turn from the left stop to the cable stop. → If the remote wheel cannot be turned in this angle, the lockout pin is not positioned correctly.
  • Page 45 «OPEN», «DRIVE» and «LOCK» by compressing the fork. 10. Put on the O-ring into the groove of the remote wheel and pop on the compression cover. Closing Steps Link Check all functions of the fork F 232 ONE Service Center Manual...
  • Page 46 USA - Grand Junction, CO 81505 59302 Oelde info.us@dtswiss.com Germany info.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 info.fr@dtswiss.com...