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DT SWISS R 535 ONE Technical Manual
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DT SWISS R 535 ONE Technical Manual

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R 535 ONE
TECHNICAL MANUAL
V2019.08

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Summary of Contents for DT SWISS R 535 ONE

  • Page 1 R 535 ONE TECHNICAL MANUAL V2019.08...

  • Page 2: Table Of Contents

    1. GENERAL ...................3 2. DESCRIPTION ..................6 3. OPERATION AND SETTING ...............13 4. SERVICE AND CARE ................18 5. REPLACING THE SPHERICAL BEARING ..........28 6. TROUBLE SHOOTING ................30...

  • Page 3: General

    1.3 TARGET GROUP This manual is only intended for DT Swiss service centers. The works described in this manual may only be done by skilled professionals trained by DT Swiss. If you have any doubts about your own abilities, you should definitely contact a specialist or a DT Swiss Service Center.
  • 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 conditions of the tools are perfect Always keep the tools in their original packaging or adequate devices to save them from damages.
  • Page 5 In addition to the general guarantee required by law, DT Swiss AG based in Biel/Switzerland, provides a guarantee for 24 months from the date of purchase. DT Swiss AG shall reject any liability for both indirect damage caused by accidents and consequential damage.

  • Page 6: Description

    This reduces the force of the beginning stroke. The shock responds very smooth and offers more comfort and traction. Function in detail, see following. R 535 ONE Technical Manual - DESCRIPTION...
  • Page 7 FUNCTION IN DETAIL After inflating or changing the air pressure: When the shock compresses, the piston moves over the bypass of the air chamber. When the piston is located on the bypass, the bypass ensures a pressure equalization of the positive and negative air chamber (see red arrow).
  • Page 8 (for example riding on the road or connecting trails). A blow-off valve protects rider and material from unexpected hits. Detailed description, see chap. „Function in detail: LOCK Mode / Blow Off“ on page 11. R 535 ONE Technical Manual - DESCRIPTION...
  • Page 9 FUNCTION IN DETAIL: OPEN MODE When the shock compresses, the damping piston moves through the oil chamber. The oil flows through the damping piston. During slow compression movements, the oil flows through the low speed compression (LSC) channel. The oil flow is regulated by shims. Depending on the "factory setting", these shims are differently hard and thus influence the damping curve.
  • Page 10 If the DRIVE mode is activated, a slider blocks the oil channel of the low speed compression (LSC). The displaced oil can only flow through the oil channel of the high speed compression (HSC). R 535 ONE Technical Manual - DESCRIPTION...
  • Page 11 FUNCTION IN DETAIL: LOCK MODE / BLOW OFF The Blow Off function is a safety mechanism to protect against excessive forces acting on the components of the shock while it is in "LOCK" mode. Blow Off If the shock is blocked in the "LOCK" mode, a slider blocks the oil channels of the low speed and high speed compression.
  • Page 12 Like the high speed compression, the high speed rebound is controlled by pre-tensioned shims. Depending on the "factory setting", these shims are differently hard and thus influence the damping curve. R 535 ONE Technical Manual - DESCRIPTION...

  • Page 13: Operation And Setting

    3. OPERATION AND SETTING 3.1 SETTING THE SAG (NEGATIVE TRAVEL) The SAG (negative spring deflection) is the degree by which the shock compresses under the weight of the rider. If the SAG is set correctly, the rear wheel can follow the unevenness of the terrain better during the ride. The setting of the SAG depends on the riding style.
  • Page 14 USING THE DT SWISS SHOCK PUMP The DT Swiss shock pump has a pressure gauge (1) which can be used to precisely adjust the shock's pressure. A release valve (2) allows the pressure in the shock to be reduced. A valve lever (3) on the pump head (4) allows the shock pump to be unscrewed without any loss of pressure.
  • Page 15 3. Screw the shock pump onto the valve of the shock and inflate the shock up to the required pressure. → Note the instructions issued by the shock pump's manufacturer! → When using the DT Swiss shock pump, see chap. „Using the DT Swiss shock pump“ on page 14.
  • Page 16 On fast, rough descents, for example, a lower rebound damping (= faster rebound speed) should be selected than on smooth descents without any major obstacles. – R 535 ONE Technical Manual - OPERATION AND SETTING...
  • Page 17 3.3.2 ADJUSTING THE COMPRESSION The compression controls the speed of the compression movement of the shock. OPEN: In “OPEN” mode, the compression of the shock is in the most sensitive, factory-set setting. The shock responds sensitively to small bumps in the terrain. DRIVE: If the lever on the shock or remote lever on the handlebars is moved OPEN...

  • Page 18: Service And Care

    Incorrect maintenance or assembly of the shock can lead to unpredictable errors! • 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 19 4.4 SEAL KIT The seal kit includes all parts needed for a small service. All of these parts can be changed without using special tools. Standard Mount Trunnion Mount 1a O-ring air chamber standard mount support ring 1b O-ring air chamber trunnion mount quad-ring support ring support ring...
  • Page 20 4.5 SMALL SERVICE This chapter describes a small service. Further service works will be carried out by a DT Swiss service center. A small service should be carried out in the following cases: • The interval for a small service is expired (see table at the beginning of this chapter).
  • Page 21 RELEASING THE AIR DANGER RISK OF INJURY FROM PRESSURIZED COMPONENTS! During the disassembly of the shock, compressed air can escape uncontrolled or pressurized components can be ejected. • Release the air before carrying out any work on the shock. DANGER SHOCK OIL MAY BE FATAL IF SWALLOWED AND ENTERS AIRWAYS! Oil mist might escape through the valve while releasing the air from the air chamber.
  • Page 22 3. Unscrew the air chamber by hand. 4. If the air chamber can not be loosened by hand, unscrew the air chamber using a strap wrench. 5. Slide off the air chamber. R 535 ONE Technical Manual - SERVICE AND CARE...
  • Page 23 REPLACING THE O-RING OF THE AIR CHAMBER, QUAD-RING AND SUPPORT RING Only shock with trunnion mount: 1. Remove the O-ring from the air chamber. 2. Clean the seat of the O-ring on the air chamber. 3. Slightly grease the new O-ring and fit it onto the air chamber.
  • Page 24 9. Put both support rings on both sides of the quad ring onto the oil chamber tap. 10. Slightly grease the oil chamber. GREASE R 535 ONE Technical Manual - SERVICE AND CARE...
  • Page 25 REPLACING THE WIPER SEAL 1. Carefully remove the wiper seal from the air chamber using plastic forceps. → Do not damages the air chamber housing! → Do not re-use the wiper seal! 2. Remove the support ring from the air chamber housing by hand.
  • Page 26 7. Slightly grease the new wiper seal and put it into the outer groove of the air chamber (see figure). → Ensure, the wiper seal lays evenly all around the groove. R 535 ONE Technical Manual - SERVICE AND CARE...
  • Page 27 8. Slightly grease the inner surface of the air chamber housing and the thread. Grease the wiper seal generously. → Required grease, see table on page 28. GREASE 9. Clamp the shock into the vice. 10. Slide on the air chamber and tighten it by hand. →...

  • Page 28: Replacing The Spherical Bearing

    → A vice, a hand press or the like can be used for pressing. 4. Degrease the shock eye and apply high-strength threadlocker to the inner surface of the shock eye. threadlocker R 535 ONE Technical Manual - REPLACING THE SPHERICAL BEARING...
  • Page 29 5. Push the new spherical bearing onto the pin of the assembly tool. 6. Position the spherical bearing in the shock eye so that the gap in the plastic ring is offset by 90° to the axis of motion of the shock. →...

  • Page 30: Trouble Shooting

    Adjust the remote cable via the correctly. knurled wheel. The sealing of the damping piston Contact your dealer or a DT Swiss is worn. Service Center to solve the problem. The lockout cap does not close completely. R 535 ONE Technical Manual - TROUBLE SHOOTING...
  • Page 31 Shock gets hot while riding. The shock can get very hot on long downhills. This does not affect the performance of the shock. In case of further issues or questions, please contact your dealer or a DT Swiss service center.
  • Page 32 USA - Grand Junction, CO 81505 D-33378 Rheda–Wiedenbrück 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...