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DT SWISS O.D.L., Техническое руководство

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O.D.L - Technical Manual

6

General Maintenance Information

V2016.10

1.1

General Maintenance Information

Cleaning

For an optimal result of the maintenance works, every component that will be disassembled must be cleaned.
Only cleaners which do not damage the components may be used. Especially the cleaning of O-rings and
sealings requires mild cleaners. Always consider the instructions of the respective cleaner.

DT Swiss recommends the following cleaners:

•

Motorex Rex

•

Motorex Swissclean

•

Motorex OPAL 2400, OPAL 3000, OPAL 5000

Use soap water or similar mild cleaners for external cleaning.

Tools

If special materials like grease or oil are needed, they will be specified in the table «Required Material» at the
beginning of a chapter. The symbol «

» refers to the table «Required Material» in the respective steps.

Environmental Protection

Whenever possible, waste has to be avoided. Waste, especially carbon, lubricants, cleaners and any other fluids
must be disposed in an environmentally compatible manner.

Only print this manual if electronic usage is not possible.

Disclaimer

The operations described in this manual should only be performed by experts. The user is liable for any damage
or consequential damage caused by wrong maintained or wrong installed components. If you have doubts, ple-
ase contact a DT Swiss service center.

Содержание O.D.L.

Страница 1: ...FORKS O D L Technical Manual V2016 10...

Страница 2: ...3 Installation 10 3 1 Shortening the Steerer 10 3 1 1 Shortening a Carbon Steerer 11 3 1 2 Shortening an Aluminum Steerer 13 3 2 Mounting the Steerer Expander 14 3 2 1 Installation of the Steerer Expa...

Страница 3: ...verting from Manual to Remote Operation 38 6 3 Installing the Remote Lever 42 6 3 1 Installing the Remote Lever Lightweight 42 6 3 2 Installing the Remote Lever Two In One 43 6 4 Installing the Pipe C...

Страница 4: ...t done properly Layout The cover page and the footing provide information about the type of product and manual as well as the ver sion of the manual The backside provides a list of the DT Swiss servic...

Страница 5: ...the target of the reference Example Click here chap 1 page 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 Swi...

Страница 6: ...NGENT 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 EXCL...

Страница 7: ...aners for external cleaning Tools If special materials like grease or oil are needed they will be specified in the table Required Material at the beginning of a chapter The symbol refers to the table...

Страница 8: ...the mode OPEN with the blue compression adjusting wheel When the compression is completely opened compression adjusting wheel is turned anti clockwise until stop the fork is very sensible and comforta...

Страница 9: ...and thus the intensity of damping The higher the flow resistance the higher the damping Additionally the oil flows through the oil channel of the high speed compression HSC Shims are placed at the end...

Страница 10: ...of the damping unit into the oil chamber see A The rebound damping happens in the damping piston see B When the fork rebounds slowly the oil flows through the oil channel of the low speed rebound LSR...

Страница 11: ...m is exchanged the new installation height can have an effect on the length of the steerer Figure 3 1 Steerer DANGER Danger due to exceeding or falling below the given torque Especially for carbon par...

Страница 12: ...ng a 5 mm spacer on top of the stem DANGER Risk of injuries when carrying out works with carbon Take measures to protect yourself especially your eyes your skin and your respiratory tract before star...

Страница 13: ...eerer 3 Remove the adhesive tape from the steerer completely Do not use aggressive cleaners to remove remaining adhesive 4 Grind the cutting edges on the inside and the outside of the steerer using sa...

Страница 14: ...red length DT Swiss recommends using a pipe cutter 2 Deburr the steerer on the inside and on the outside using a file 3 Drive the star nut into the steerer using a suitable tool Required Material Spec...

Страница 15: ...steerer and with all forks with aluminum steerer Must be used in combination with O D L Race and O D L Limited forks Installation see chap 3 2 1 page 15 Installation see chap 3 2 2 page 16 The DT Swi...

Страница 16: ...WXXXX0XXXX046011S 1 1 Slide the steerer expander into the steerer until the upper part of the expander contacts the upper part of the steerer Align the slotted bushing backwards opposite drive directi...

Страница 17: ...eerer using a dry cloth 2 Apply carbon installation paste in the area of the contact surface between the steerer expander and the steerer 3 Insert the expander into the steerer up to the stop The expa...

Страница 18: ...to the base of the steerer tube The parts mounted on the fork must not have sharp edges Do not use cotter style stems The flange of the discontinuous clamp area of the stem must be at least 7 mm high...

Страница 19: ...ght of the stem 2 Carbon steerer Apply a thin layer of DT Swiss carbon fitting lubricant onto the contact area of the stem and the steerer 3 Slide the stem onto the steerer Do not tighten the fixing s...

Страница 20: ...rs proceed as follows a Tighten the fixing screws with a torque of 4 Nm using a torque wrench b Check if the stem is fitting securely on the steerer by jamming the front wheel between your legs and tr...

Страница 21: ...e shown in the picture Do not affix the brake pipe to the crown Scratch areas must be protected by a suitable sticker 3 Install the brake caliper 4 Screw in the fixing screws and tighten them with a t...

Страница 22: ...f the fork Check hubs thru axles or quick releases for sharp edges Do not use hubs thru axles or quick releases if there are sharp edges Preparatory Steps Link not required 1 Remove the axle from the...

Страница 23: ...pressure of both compo nents 2 Release the air from the fork completely Compress the fork completely 3 Check if the tire touches any part of the fork while it is fully compressed Is this the case the...

Страница 24: ...e pump head 4 allows the shock pump to be unscrewed without any loss of pressure Operating the shock pump A Screw the pump head 4 fully onto the valve on the fork B Close the valve lever 3 push the le...

Страница 25: ...3 5 50 3 2 46 50 110 4 1 60 4 0 58 3 9 56 3 8 55 3 5 51 55 121 4 5 65 4 4 63 4 3 62 4 2 61 3 9 56 60 132 4 8 70 4 7 69 4 6 67 4 5 66 4 2 61 65 143 5 2 75 5 1 74 5 0 73 4 9 71 4 6 67 70 154 5 5 80 5 4...

Страница 26: ...al lever in position OPEN or push the lever into position OPEN or push the remote lever into position OPEN Riding Style SAG of Travel SAG mm of Travel 100 mm 120 mm 130 mm 140 mm 150 mm Cross Country...

Страница 27: ...is facing upwards 2 Remove the valve cap 3 Mount a suitable shock pump onto the valve 4 Adjust the air pressure by in or deflating Check if the correct SAG is set see above 5 Screw on the valve cap 5...

Страница 28: ...fast and loses the contact to the ground If the rebound damping is too high the front wheel cannot follow fast impacts and the suspension hardens The aim of setting the rebound damping is to achieve...

Страница 29: ...mostly suitable for rough downhills DRIVE The DRIVE mode meets the compression setting of the mode OPEN with fully closed compression In this mode the adjustment of the blue wheel has no effect see O...

Страница 30: ...near and comfortable suspension curve for lighter riders or riders who prefer more comfort The 1 setting offers a slightly less comfortable and less linear suspension curve recommended for the ave rag...

Страница 31: ...NOTICE The APT system only fits with forks with a hexagonal air chamber cap non hexagonal air chamber cap hexagonal air chamber cap Preparatory Steps Link Clean the area of the air chamber cap DANGER...

Страница 32: ...carefully using the backside of the valve cap and slowly release the air The valve must face from your body while releasing the air 1 Ensure the valve cap is removed and the air is released 2 Unscrew...

Страница 33: ...l get damaged Never install more than three volume spacers 1 Add or remove volume spacer s using a 25 mm wrench The maximum amount of volume spacers is three 2 Tighten the volume spacer s with a torqu...

Страница 34: ...he air chamber cap with a torque of 10 Nm using a torque wrench with a 15 mm socket 1 Inflate the fork The air pressure should be set to your personal preferences and to the correct SAG see chap 4 2 p...

Страница 35: ...nual operation chap 6 1 page 34 Conversion from manual to remote operation chap 6 2 page 38 Installation of the lightweight remote lever chap 6 3 1 page 42 Installation of the Two In One remote lever...

Страница 36: ...unit 6 Remove the O ring from the top of the damping unit 1 Ensure that the lockout pin is turned until stop in clockwise direction Turn the lockout pin if needed 2 Put the springs into the index caps...

Страница 37: ...blue 5 Put on the mode lever 6 Put the O ring between the angled end of the lever and the fork crown 7 Screw on the fixing nut by hand 8 Hold the lever in position LOCK and tighten the fixing nut wit...

Страница 38: ...g around the lever 12 Put thread lock onto the thread of the fixing screw of the compression wheel Required thread lock see table on page 34 13 Put on the compression wheel and tighten the fixing nut...

Страница 39: ...s Preparatory Steps Link Clean the fork Check all functions of the fork 1 Hold the compression wheel and unscrew the fixing screw anti clockwise using a T8 Torx key 2 Remove the compression wheel and...

Страница 40: ...s th similar 1 Ensure that the lockout pin is turned until stop in clockwise direction Turn the lockout pin if needed 2 Slightly grease the O ring and put it into the groove on the top of the damping...

Страница 41: ...ble guide must face in drive direction to the middle of the fork without touching the fork crown 6 Put the end of the spring facing upwards into the bore of the remote wheel 7 Put the remote wheel ont...

Страница 42: ...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 cor rectly Dismount the remote wheel and posi tion...

Страница 43: ...ote lever can only be used for DT Swiss forks The remote lever can be installed on the right side or on the left side of the handlebar The remote lever is designed for a handlebar diameter of 22 2 mm...

Страница 44: ...n layer carbon fitting lubricant on the contact area of remote lever and handlebar 2 Put the remote lever onto the handlebar and tighten the fixing screw with a torque of 1 3 Nm 3 Check the proper fun...

Страница 45: ...of 1 3 Nm 8 Press the remote lever a few times 9 Set the tension of the cable with the adjusting screw at the pipe In Position LOCK see Function and Compat ibility the lever must lock completely and t...

Страница 46: ...pside down After cleaning lubricate the sliding surface of the remote lever on the handlebar 7 2 Service Intervals If you use your bike in extreme conditions you will have to service your components s...

Страница 47: ...ngs in DT Swiss Lube Fluid Required Material Specification Amount fork oil DT Swiss Lube Fluid 100 ml 4064XXXXXXXX000026 1 bottle 100 ml fork oil DT Swiss Fork Oil 100 ml 4064XXXXXXXX000024 1 bottle 1...

Страница 48: ...efore starting any works 1 Unscrew the valve cap 2 Release the air completely by pressing the valve insert using the upper side of the valve cap Left dropout 1 Screw the hexagonal socket screw into th...

Страница 49: ...Manual 48 Small Service V2016 10 Right dropout 5 Screw the hexagonal screw into the dropout clockwise using an 8 mm hexagon spanner 6 Remove the lowers carefully 7 Collect the leaking oil using a sui...

Страница 50: ...orn out they should be changed earlier 1 If present remove both spring rings from the wiper seals 2 Remove both foam rings below the wiper seals The foam rings should be replaced on every service 3 Le...

Страница 51: ...O D L Technical Manual 50 Small Service V2016 10 4 Remove the wiper seals 5 Remove the second wiper seal the same way...

Страница 52: ...the removal notch b Pry out the first end of the ring c Manually spiral the ring around until it is free from the groove 3 Push the valve insert and remove the NCS unit There is a small amount of lub...

Страница 53: ...he NCS unit There must be no grease on the inner surface of the air chamber cap 3 Required grease see table on page 46 3 Position the upper unit so that the open end faces slightly upwards 4 Fill 2 ml...

Страница 54: ...ower end of the stanchion A b Separate the ring coils and insert one end of the ring into the groove B c Wind the ring by pressing down around the cir cumference until the entire ring is inserted into...

Страница 55: ...l onto the thread of the connecting piece Required tool see table on page 46 3 Slide the new O ring onto its seat on the connec ting piece Required material see table on page 46 4 Remove the tool 5 Re...

Страница 56: ...f the wiper seals must not be enlarged or damaged 2 Clean the lower unit with an appropriate cleaner see section Cleaning page 6 If you are using soap water flush the lower unit with clear water after...

Страница 57: ...er seals Ensure that the foam rings are not twisted 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...

Страница 58: ...ey 10 Tighten the hexagonal socket screw with a torque of 6 Nm Right dropout 11 Screw the hexagonal screw into the lower unit anti clockwise using an 8 mm hexagon spanner 12 Tighten the hexagonal scre...

Страница 59: ...10 Closing Steps Link Dispose the oil in an environmentally compatible manner Inflate the fork chap 4 2 page 24 Clean the fork Set the damping chap 4 3 page 27 Check all functions of the fork The main...

Страница 60: ...r 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...

Страница 61: ...r pressure is too high Reduce the air pressure Wrong measurement of the travel Some forks do not use the full stroke of the stanchions Always measure the distance between wiper seal and SAG O ring The...

Страница 62: ...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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