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DT SWISS R 535 ONE, Technical Manual

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Summary of Contents for R 535 ONE

Page 1: ...R 535 ONE TECHNICAL MANUAL V2021 10...

Page 2: ...2 1 GENERAL 3 2 TROUBLE SHOOTING 5 3 CARE AND MAINTENANCE 7 4 REPLACING DU BUSHINGS 17 5 REPLACING SPHERICAL BEARINGS 22 6 ATTACHING THE REMOTE CABLE 24...

Page 3: ...ation that may result in damage to property 1 3 TARGET GROUP This manual is intended for the user of the component and dealers This manual offers the experienced user the possibility to carry out mino...

Page 4: ...ser If components are 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 i...

Page 5: ...loth after each ride Tiny amounts of oil on the rebound wheel or on the end cap None normal residue from assembly Clean the area and check again after a while If this area is oily again a full service...

Page 6: ...joints DU bushings see 5 Changing the spherical bearings on page 22 or 4 Replacing DU bushings on page 17 Loss of oil at the oil chamber noticeable when the air chamber is removed Sealings are at the...

Page 7: ...Remove all visible dried dirt from the area of the wiper seal This will prevent dirt from getting into the shock It is not necessary to grease the shock in the area of the wiper seal After cleaning lu...

Page 8: ...service All of these parts can be changed without using special tools 1a 2 2 3 3 4 4 5 5 6 6 7 7 1b Standard Mount Trunnion Mount 1a O ring air chamber standard mount 4 support ring 1b O ring air cha...

Page 9: ...PARATORY STEPS Link Dismount the shock from the bike Dismount the shock hardware Clean the surface of the shock see 1 5 General Maintenance Information on page 4 REQUIRED MATERIAL Specification Quanti...

Page 10: ...place a cloth over the valve while the air is being released The valve must face down away from your body while releasing the air Immediately call a doctor if shock oil was swallowed or entered airway...

Page 11: ...IR CHAMBER 1 Remove the SAG O ring from the oil chamber 2 Clamp the shock into a vice vertically 3 Unscrew the air chamber by hand 4 If the air chamber can not be loosened by hand unscrew the air cham...

Page 12: ...the O ring from the air chamber cap 2 Clean the seat of the O ring on the air chamber cap 3 Check the air chamber cap for damages in the area of the O ring 4 Slightly grease the O ring and put it bac...

Page 13: ...13 R 535 ONE Technical Manual V2021 10 9 Put both support rings on both sides of the quad ring onto the oil chamber tap 10 Slightly grease the oil chamber GREASE...

Page 14: ...support ring 3 Remove the quad ring from the air chamber housing by hand Do not re use the quad ring NOTE RISK OF DAMAGE DUE TO WRONG CLEANERS Aggressive cleaners can cause damages to the wiper seal A...

Page 15: ...he air chamber see figure Ensure that the quad ring is not twisted 6 Put a new support ring onto the web between both grooves of the air chamber see figure 7 Slightly grease the new wiper seal and put...

Page 16: ...see table Required Material on page 9 GREASE 9 Clamp the shock into the vice 10 Slide on the air chamber and tighten it by hand Ensure that the O ring and the support ring does not get jammed 11 Take...

Page 17: ...he shock from the bike Clean the surface of the shock see Cleaning on page 4 Required tools and materials Specification Quantity cleaner degreaser see Cleaning on page 4 as required grease Buzzy s Sli...

Page 18: ...pin to check the DU bushing If the shock can be rotated without resistance the DU Bushings must be changed See following If the shock can be rotated with resistance the DU bushing must not be changed...

Page 19: ...receiver TOOL KIT DU PIN UNMOUNTING ASSEMBLY CWTXX10031935S 3 Push out the DU pin using a press or a bench vise REMOVING THE DU BUSHING 1 Slide the pusher into the DU bushing 2 Align the receiver like...

Page 20: ...g GREASE 2 Put the bushing onto the pusher 3 Position the bushing to the shock eyelet that the gap is oriented 90 to the axis of movement of the shock 4 Align the receiver like shown in the picture TO...

Page 21: ...while turning the shock pushing it to the center 4 Wait a few minutes and check the DU bushing again see Testing the DU bushings on page 18 If this test fails a second time contact a DT Swiss service...

Page 22: ...e with each other Preparatory Steps Link Dismount the shock from the bike Clean the surface of the shock see Cleaning on page 4 Required tools and materials Specification Quantity cleaner degreaser se...

Page 23: ...ye of the shock with a degreaser and put a small amount of high strength thread locker onto the inner surface of the shock s eye threadlocker 5 Position the spherical bearing in the shock eye so that...

Page 24: ...oute the cable 4 through the cable housing 1 3 Place the cable 4 around the remote wheel on the shock and clamp it using the clamping screw 3 When tightening the clamping screw do not exceed a tighten...

Page 25: ...SWISS DEUTSCHLAND GmbH Albert Einstein Strasse 3 59302 Oelde Germany info de dtswiss com DT SWISS POLSKA Sp z o o ul Towarowa 36 PL 64 600 Oborniki Poland info pl dtswiss com DT SWISS AG L ngfeldweg 1...

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