DT SWISS MTB 2013 SPLINE EX 1501 Technical Manual Download Page 65

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SPLINE

Technical Manual

Cha

ing a

Sin

e [

OAD]

5.5.4 Changing a Single Spoke on the Rear Wheel

Removing the Spoke

Attaching a New Spoke

Preparatory Steps

Link

Dismount the wheel.

Dismount the tire and if necessary the tube and the rim tape.

Clean the wheel and check for damages.

Loosen the spoke.

chap.5.5.1, p.58

Slide the spoke with the nipple out of the rim.

Only for spokes on the inner side of the hub:
Pull the spoke over the spoke of the second cros-
sing.

Slide the spoke through the hub and remove it.

Slide a new spoke through the spoke hole of the
hub.

Summary of Contents for MTB 2013 SPLINE EX 1501

Page 1: ...WHEELS SPLINE Technical Manual english V2013 11_EN...

Page 2: ...ystem 26 4 6 Maintenance of the Rear Wheel Hub Two Pawl System 32 4 7 Maintenance of the Rear Wheel Hub Three Pawl System 42 5 Maintenance of the Wheel 48 5 1 Safety 48 5 2 Special Tools 49 5 3 Truing...

Page 3: ...SPLINE Technical Manual 2 V2013 11_EN 6 Technical Data 74 6 1 Spoke Tension 74 6 2 Tolerances 74...

Page 4: ...own skills there should be contacted a DT Swiss service center Warranty will expire if works are not done properly Layout The cover page and the footing are providing information about the type of pr...

Page 5: ...3 to jump to the beginning of this chapter Warranty Europe In addition to the general guarantee required by law DT Swiss AG based in Biel Switzerland provides a gua rantee for 24 months from the date...

Page 6: ...TINGENT SPECIAL OR CONSEQUENTIAL DAMAGES ARISING FROM THE USE OF OUR PRODUCTS SOME STATES MAY NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE LIMITATION OR EX...

Page 7: ...aning Tools To ensure a damage free mounting and dismounting of the components only use the tools which are menti oned in this manual The usage of differing tools is up to the user If components are b...

Page 8: ...ity The component must be compatible with all parts of the bicycle Only use original spare parts The components must not be changed or modified The component must not be used if it is damaged or there...

Page 9: ...olt 15 100 mm Thru Axle Link 5 mm QR 10 135 mm Thru Bolt 12 135 mm Thru Axle 12 142 Thru Axle Link ROAD 2013 RC 38 R 28 R 23 MTB 2013 X 1600 chap 3 2 p 13 chap 3 1 p 10 X 1900 chap 3 2 p 13 XR 1450 ch...

Page 10: ...RC 28 RC 38 RC 46 RC 55 R 23 R 28 MTB 2014 XRC 1250 chap 3 1 p 10 chap 3 1 p 10 XR 1450 chap 3 1 p 10 chap 3 1 p 10 XR 1501 chap 3 1 p 10 chap 3 1 p 10 XM 1501 chap 3 1 p 10 chap 3 1 p 10 X 1900 chap...

Page 11: ...E Risk of damage of the adapters To avoid damages only use grind clamping jaws aluminium clamping jaws or special tools to clamp the adapters NOTE Deviation of the figures For simplification the conve...

Page 12: ...r Putting on the Adapters 1 Clean both adapters and the accessible parts of the hub with a dry cloth 2 Grease the bearing and the contact surface of the adapter 1 Put the left and the right adapter on...

Page 13: ...INE Technical Manual 12 Converting the Hub Inserted Adapters V2013 11_EN 2 Push in the adapters by hand Closing Steps Link Rear wheel Put on the cassette if necessary see instructions of the manufactu...

Page 14: ...Amount multi purpose grease as required adapter adapter 15 mm to QR 1 NOTE Limited conversion options Hubs with pressed on adapters can t be converted to a different axle diameter by changing the ada...

Page 15: ...wards you to the required chapter Front Wheel Rear Wheel front wheel with inserted adapters version 1 front wheel with inserted adapters version 2 front wheel with pressed on adapters rear wheel with...

Page 16: ...anual at www dtswiss com normal operating conditions 12 months extreme operating conditions frequent rides in rain mud snow as required Check the hub for damages before and after each ride Cleaning wi...

Page 17: ...ect maintenance or wrong spare parts Wrong maintenance wrong assembly or wrong spare parts can lead to unpredictable errors Maintenance must only be done by professionals Only use original spare parts...

Page 18: ...le 5 adapter right 2 ball bearing 4 hub shell Preparatory Steps Link not required Required Material Specification Amount multi purpose grease as required NOTE Risk of damage of the adapters To avoid d...

Page 19: ...g p 6 2 Check the bearings If the hub doesn t turn smoothly change the bea rings see Technical Manual at www dtswiss com 3 Grease the bearings fig 4 1 2 and the contact sur face of both adapters fig 4...

Page 20: ...l Hub Inserted Adapters Version 2 figure 4 2 Overview front wheel with inserted adapters version 2 Removing the Adapters 1 adapter 3 axle 5 sticker 2 ball bearing 4 hub shell Preparatory Steps Link no...

Page 21: ...Clean the hub the bearings and the adapters see Cleaning p 6 2 Check the bearings If the hub doesn t turn smoothly change the bea rings see Technical Manual at www dtswiss com 3 Grease the bearings a...

Page 22: ...rs Required Tools 1 cover 4 axle 7 sticker 2 adapter left 5 o ring 8 adapter right 3 ball bearing 6 hub shell Preparatory Steps Link not required Required Material Specification Amount multi purpose g...

Page 23: ...to the adapters and the ball bearings The mounting pin must not touch the ball bearing while disassembling the adapters 1 Plug the mounting pin of the tool set into one of the adapters fig 4 3 2 8 2 P...

Page 24: ..._EN Cleaning and Greasing the Parts 1 Clean the adapters fig 4 3 2 8 the covers fig 4 3 1 and the accessible parts of the hub see Cleaning p 6 2 Grease the bearings fig 4 3 3 3 Check the bearings If t...

Page 25: ...EN Putting on the Left Adapter 1 Put the cover fig 4 3 1 and the left adapter fig 4 3 2 onto the hub 2 Put the small diameter of the mounting bushing of the tool set onto the left adapter fig 4 3 2 3...

Page 26: ...ting on the Right Adapter 1 Put the right adapter fig 4 3 8 and the cover fig 4 3 1 onto the hub 2 Put the big diameter of the mounting bushing of the tool set onto the right adapter 3 Slide the mount...

Page 27: ...4 hub shell 9 spacer 5 sticker 10 spring Preparatory Steps Link Remove the cassette see instructions of the manufacturer Required Material Specification Amount grease for star ratchet DT Swiss special...

Page 28: ...left adapter fig 4 4 1 into a vice 2 Pull off the wheel respectively the hub 3 Clamp the left adapter Abb 4 4 13 into a vice 4 Pull off the wheel respectively the hub Take care that the rotor does no...

Page 29: ...ages and wear 3 Check the bearings If the hub doesn t turn smoothly change the bea rings see Technical Manual at www dtswiss com 4 Clean the toothing of the rotor and the ring nut 5 Check the rotor fo...

Page 30: ...rease For an optimal functionality a thin layer of grease is sufficient 2 Grease the toothing of the rotor using DT Swiss special grease 3 Grease the bearing on the drive side using multi purpose grea...

Page 31: ...ing fig 4 4 10 The small diameter of the spring must be placed on the star ratchet 1 Grease the rotor and put it onto the hub 2 Check if the rotor can be turned easily and if the star ratchets are loc...

Page 32: ...SPLINE Technical Manual 31 Maintenance of the Rear Wheel Hub Ratchet System V2013 11_EN 5 Push the adapters in by hand Closing Steps Link Mount the cassette see instructions of the manufacturer...

Page 33: ...9 pawl 14 rotor 5 screw fitting for pawl carrier 10 spring 15 adapter left Preparatory Steps Link Remove the cassette see instructions of the manufacturer Required Material Specification Amount multi...

Page 34: ...to a vice using the axle holder 2 Loosen the knurled disc fig 4 5 1 on the drive side using a 17 mm wrench 3 Clamp the axle at the drive side into a vice using the axle holder 4 Loosen the knurled dis...

Page 35: ...SPLINE Technical Manual 34 Maintenance of the Rear Wheel Hub Two Pawl System V2013 11_EN 7 Remove the adapter fig 4 5 2 8 Remove the rotor sealing...

Page 36: ...edle Cage 1 Lever the spring fig 4 5 10 out of the groove Caution If the spring is bent or damaged it must be exchanged 2 Slide the spring fig 4 5 10 upwards over the bea ring shell fig 4 5 12 and rem...

Page 37: ...dtswiss com 3 Check the needle cage the pawls and the spring for damages and replace them if required 4 Clean the rotor fig 4 5 14 using a mild cleaner 5 Check the rotor for damages Grooves from the...

Page 38: ...grease 2 Grease the bearing shell fig 4 5 12 the inner sur face of the hub shell the axle and the thread using multi purpose grease 3 Slide the needle cage fig 4 5 11 onto the hub and attach the need...

Page 39: ...aring shell fig 4 5 12 The spring must not be damaged while mounting 7 Slide the spring fig 4 5 10 onto the pawls fig 4 5 9 8 Check if the spring sits inside the groove over the complete circumference...

Page 40: ...Grease the rotor sealing using multi purpose gre ase 2 Mount the rotor sealing The sealing lip must face to the rotor see picture 3 Fill the seat of the needle cage with multi purpose grease 4 Slide...

Page 41: ...5 onto the drive side 3 Put the left adapter fig 4 5 2 on the non drive side of the hub 4 Attach both knurled discs fig 4 5 1 and tighten them by hand 5 Put the knurled disc at the non drive side into...

Page 42: ...SPLINE Technical Manual 41 Maintenance of the Rear Wheel Hub Two Pawl System V2013 11_EN Closing Steps Link Mount the cassette see instructions of the manufacturer...

Page 43: ...Remove cassette see instructions of the manufacturer Required Material Specification Amount multi purpose grease as required service kit 3 pawl system as required NOTE Risk of damage of the adapters T...

Page 44: ...em V2013 11_EN Removing Pawls Spring and Rotor Sealing 5 Pull the rotor fig 4 6 7 off the hub 6 Pull the spacer fig 4 6 6 off the axle 1 Remove the spring using a small flat screwdriver 2 Remove the p...

Page 45: ...e Cleaning p 6 2 Check all parts for wear and damages 3 Check the bearings If the hub doesn t turn smoothly change the bea rings see Technical Manual at www dtswiss com 4 Check the rotor for damages G...

Page 46: ...EN 2 Slightly grease the rotor fig 4 6 7 and the rotor sealing 3 Mount the pawls Grease the pawls generously This way the pawls stuck in the correct position 4 Mount the spring The open end of the spr...

Page 47: ...e Rotor and the Adapters 1 Grease the bearing and the axle 2 Slide the spacer fig 4 6 6 onto the axle 3 Slide the rotor fig 4 6 7 onto the hub while per forming a rotary motion 4 Check if the rotor ca...

Page 48: ...e Rear Wheel Hub Three Pawl System V2013 11_EN 6 Put on both adapters fig 4 6 1 8 and push them in by hand Caution The shorter adapter must be attached on the drive side Closing Steps Link Mount the c...

Page 49: ...cleaners after each ride Check the proper fixation of the wheel before each ride Wheels for rim brakes Remove any contaminations especially oil and traces of grease from the brake surfaces Check the...

Page 50: ...wheels In the figures of the following work instructions only the old versions are used 1 2 3 4 5 6 7 8 9 Pos Description 1 spokey square 2 spoke holder 1 1 3 mm spoke holder NEW AERO 3 spoke holder...

Page 51: ...he nipples Bladed spokes must be hold with the spoke holder while turning the nipple Whenever possible there should be used the universal spoke holder see chap 5 2 p 49 to avoid dama ges to the spokes...

Page 52: ...ng the building process First time at approxi mately 50 of the maximum spoke tension see chap 6 1 p 74 After finishing truing the wheel should be distressed once again There should be no more changes...

Page 53: ...d with the spoke holder while turning the nipple Whenever possible there should be used the universal spoke holder see chap 5 2 p 49 to avoid dama ges to the spokes The spoke holder made out of metal...

Page 54: ...e spoke using a screw clamp b Cut the spoke c Take off the screw clamp 3 Check if there is a washer PHR washer on the nipple 4 Take the spoke with the nipple out of the rim If there is a PHR washer Ta...

Page 55: ...f the spoke red that needs to be replaced into the middle of the spoke tree NOTE Risk of damages to the spoke and the hub Take care not to damage the paint of the spoke and the hub while removing the...

Page 56: ...a new spoke on a SPLINE ONE wheel see Attaching a New Spoke SPLINE ONE 1 Slide the new spoke through the spoke hole Push the opposite spoke beside slightly 2 Screw on a new nipple Caution The figure s...

Page 57: ...NE Wheels NOTE Caution SPLINE ONE wheels must only be build with DT Swiss Squorx nipples and special washers PHR washers 1 Grease the contact surface of the PHR washer and the Squorx nipple 2 Slide th...

Page 58: ...ingle Spoke MTB V2013 11_EN 6 Screw the Squorx nipple onto the spoke until the thread disappears Closing Steps Link True the wheel chap 5 3 p 50 Mount tire and if necessary rim tape and tube or tubele...

Page 59: ...es types see chap 6 1 p 74 Ensure that the correct tool is being used To avoid damages to the spoke slide the spoke holder as far as possible in direction of the rim To avoid damages to the nipples sl...

Page 60: ...OAD V2013 11_EN 2 If necessary loosen the spoke by hand a Slide the spoke holder onto the spoke b Unscrew the nipple using the nipple wrench Take care that the nipple does not fall into the rim profil...

Page 61: ...ub Preparatory Steps Link Dismount the wheel Dismount the tire and if necessary the tube and the rim tape Clean the wheel and check for damages Loosen the spoke chap 5 5 1 p 58 1 Take off the adapter...

Page 62: ...1_EN 5 Screw on a new nipple 6 Tighten the spoke 7 Check the bearing Clean and grease the bearing if it is badly soiled 8 Put on the adapter Closing Steps Link True the wheel chap 5 3 p 50 Mount tire...

Page 63: ...e Clean the wheel and check for damages Loosen the spoke chap 5 5 1 p 58 1 Remove the adapter a Put the axle holder see chap 5 2 p 49 into a vice b Clamp the adapter on the side of the spoke which nee...

Page 64: ...1_EN 5 Screw on a new nipple 6 Tighten the spoke 7 Check the bearing Clean and grease the bearing if it is badly soiled 8 Put on the adapter Closing Steps Link True the wheel chap 5 3 p 50 Mount tire...

Page 65: ...e wheel Dismount the tire and if necessary the tube and the rim tape Clean the wheel and check for damages Loosen the spoke chap 5 5 1 p 58 1 Slide the spoke with the nipple out of the rim 2 Only for...

Page 66: ...Manual 65 Changing a Single Spoke ROAD V2013 11_EN 2 Screw on a new nipple 3 Tighten the spoke Closing Steps Link True the wheel chap 5 3 p 50 Mount tire and if necessary rim tape and tube Mount the w...

Page 67: ...ing on the Spokes on the Front Wheel Preparatory Steps All spokes are available in the correct lengths 1 Slide all spokes through the spoke holes on the first side of the hub 2 Slide all spokes throug...

Page 68: ...shown in the picture 1 Slide all spokes through the spoke holes on the first side of the hub For easier handling first put the spokes into the inner side of the hub 2 Slide all spokes through the spok...

Page 69: ...ded spokes must be hold with the spoke holder while turning the nipple Whenever possible there should be used the universal spoke holder see chap 5 2 p 49 to avoid dama ges to the spokes The spoke hol...

Page 70: ...heel ROAD V2013 11_EN Increasing the Spoke Tension 1 Increase the spoke tension see chap 6 1 p 74 by using appropriate tools see chap 5 2 p 49 Caution The figure shows a wheel with bladed spo kes Clos...

Page 71: ...lengths General The crossing of the spokes must always be like shown in the picture 1 Slide all spokes through the spoke holes on the first side of the hub For easier handling first put the spokes int...

Page 72: ...Whenever possible there should be used the universal spoke holder see chap 5 2 p 49 to avoid dama ges to the spokes The spoke holder made out of metal see chap 5 2 p 49 should only be used if the uni...

Page 73: ...NE Wheels NOTE Caution SPLINE ONE wheels must only be build with DT Swiss Squorx nipples and special washers PHR washers 1 Grease the contact surface of the PHR washer and the Squorx nipple 2 Slide th...

Page 74: ...e Spoke Tension 6 Screw the Squorx nipple onto the spoke until the thread disappears 1 Increase the spoke tension see chap 6 1 p 74 by using appropriate tools see chap 5 2 p 49 Caution The figure show...

Page 75: ...of the Higher Tightened Wheel Side Min Tolerated Spoke Tension of the Higher Tightened Wheel Side Average Spoke Tension of the Higher Tightened Wheel Side N N N Disc Brake FW 1 200 950 1150 1000 RW 1...

Page 76: ...dtswiss us com DT Swiss France S A S Parc d Activites de la SARREE Route de Gourdon F 06620 Le Bar sur Loup E Mail service fr dtswiss com DT Swiss Asia Ltd No 26 21st Road Industrial Park Taichung Ci...

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