FORKS

Twin Shot
Technical Manual
V2013.08_EN

1

1.1

4

Validity

4

Safety4

Target Group4

Layout4

DT Swiss Manual Concept

4

How to Use this Manual

5

Cross References

5

Warranty (Europe)

5

Limited Equipment Warranty USA

6

General Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cleaning

7

Tools

7

Environmental Protection

7

Disclaimer

72

Description

8

2.1

Spring: ABS (Auto Balancing Spring System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.2

Damping: Twin Shot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3Installation

3.1

Shortening the Steerer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.2

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General9

Shortening a Carbon Steerer

10

Shortening a Aluminium Steerer

12

Installation of the Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Install the Crown Race

14

Install the Fork and the Stem

14

Install the Stem and the Spacers

14

Adjust the Bearing Play of the Headset

14

Install the Stem

15

3.3

Installation of the Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.4

Installation of the front Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.5

Usage of a RWS thru Axle

17

Usage of a quick release17

Collision Test

17

Installation of the Remote-Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Installation of the Remote Lever [Lightweight]

18

Installation of the Remote Lever [Two In One]

19

Twin Shot Technical Manual2Installation of the Pipe, Cable and Cable Housing

19

4

Operation and Setting

22

4.1

Setting the Air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

4.2

4.3

Recommended Air pressure

22

Setting the SAG (Negative-Travel)

23

Set the Air pressure

23

Set the Damping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Rebound-Lockout

25

Compression-Lockout

25

Remote Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Operating the remote-unit

26

Adjustment of the Remote Unit

26

5

Service and Care

27

5.1

Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

5.2

Service Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

5.3

Small Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Release the Air

29
29
29

Dismount the Main Sealing

31

Dismount the ABS Unit

32

Check and clean the Parts

32

Mount the ABS Unit

33

Mount the Main Sealings

34

Mount the lower Unit

36

Trouble Shooting

38

Bedding-In Time38

After a Crash

38

Bushing Clearance

38

Trouble Shooting

38

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6

Dismount the lower Unit

Twin Shot Technical Manual3General

1 General
ValidityThis manual describes the component shown on the front page and the footer. It is valid for the constructionlevel of the component on the 2013-08-14. Deviations are possible and all items are subject to technical changes.

SafetyThe safety instructions are classified as follows:

NOTE...characterizes danger for goods.

CAUTION...characterizes danger with a high risk, which causes mayhem if it is not being avoided.

DANGER...characterizes immediate danger with a high risk, which causes death or mayhem if it is not being
avoided.

Target Group
This manual is intended for the end user and dealers.
For experienced users, it offers the possibility to carry out small maintenance works on their own. If there areany doubts concerning the 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 product and manual as well as theversion 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 atwww.dtswiss.com.
This manual is intended for printing as a A5 booklet. Only print this manual if electronical usage is not possible.

DT Swiss Manual Concept

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The DT Swiss manuals are splitted into the following types of manuals:• User Manual
Information for the end user of how to install and use the component.
• Technical Manual
Detailed information for the end user and the dealer of how to maintain the component, spare parts
and technical data.
• Service Sheet
Short instructions strictly for the service centers to solve current issues.
• Service Center Manual
Information strictly for the service centers about all service works, disassembling, checking and reassembling of the component.

Twin Shot Technical Manual4General

How to Use this Manual
The steps described in this manual must be carried out in the order they are shown. If steps are ignored or executed in a wrong order, the function of the component cannot be guaranteed.
Instructions are beginning with the table «Preparatory Steps» and ending with the table «Closing Steps». The
instructions in these tables must be carried out.
Moving parts, threads, o-rings and sealings must be greased before assembling.

Cross References
In order to simplify the use of this manual, some text is edited as hypertext. Whenever the text is formatted
blue and underlined, you can click on the text. After clicking you will be automatically redirected to the targetof the link.
Example: Click here: chap. 1, page 4 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 guarantee for 24 months from the date of purchase in accordance with European Directive 99/44/EC. DT Swiss AG
shall reject any liability for both indirect damage caused by accidents and consequential damage.
Any contradictory or extended national rights of the purchaser are not affected by this warranty. Place of performance and jurisdiction is Biel/Switzerland. Swiss law shall apply.
Submit any warranty claims to your retailer or a DT Swiss service center. Any defects recognised by DT Swiss AG
as a warranty claim will be repaired or replaced by a DT Swiss service center.
Warranty and guarantee claims can only be made by the original purchaser with a valid sales receipt.
There shall be no claim under the guarantee for:Normal wear and tear caused by use of the components
Incorrect assembly
Incorrect or non-existent maintenance
Incorrectly completed repairs
Use of unsuitable products
Modification of components
Incorrect use or misuse
Carelessness
Leasing, commercial use or use in competitions
Damage caused by accidents
Delivery and transport damage
Modification, defacing or removal of the serial number

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•
•
•
•
•
•
•
•
•
•
•
•

Twin Shot Technical Manual5General

Limited Equipment Warranty USA
DT Swiss LTD makes every effort to assure that its product meets high quality and durability standards and warrants to the original retail consumer/purchaser of our product that each product is free from defects in materials and workmanship as follows:
2 YEAR LIMITED WARRANTY ON THIS DT SWISS PRODUCT. This warranty does not apply to defects due directly
or indirectly to misuse, abuse, negligence or accidents, repairs or alterations outside our facilities or to a lackof maintenance.
DT SWISS LTD LIMITS ALL IMPLIED WARRANTIES TO THE PERIOD OF TWO YEARS FROM THE DATE OF INITIAL
PURCHASE AT RETAIL. EXCEPT AS STATED HEREIN, ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS ARE EXCLUDED. SOME STATES MAY NOT ALLOW LIMITATIONS ON HOW LONG THE IMPLIED WARRANTYLASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU. DT SWISS LTD SHALL IN NO EVENT BE LIABLE FOR
DEATH, INJURIES TO PEOPLE OR PROPERTY OR FOR INCIDENTAL, CONTINGENT, 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 EXCLUSION MAY
NOT APPLY TO YOU.

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To take advantage of this warranty, the product or part must be returned for examination, postage prepaid, tothe dealer where you bought the product or to a DT Swiss service center. Proof of purchase date and an explanation of the complaint must accompany the product. If our inspection discloses a defect, DT Swiss will either
repair or replace the product or refund the purchase price, if we cannot readily and quickly provide a repair or
replacement. DT Swiss will return repaired product or replacement at DT Swiss expense, but if it is determined
there is no defect, or that the defect resulted from causes not within the scope of this warranty, then the user
must bear the cost of shipping. This warranty gives you specific legal rights, and you may also have other rights
which vary from state to state. Legal venue and place of performance is Biel (Switzerland). Swiss law shall apply.
Subject to technical changes. Please keep the user manual and warranty for future use.

Twin Shot Technical Manual6General

1.1

General Maintenance Information

Cleaning
For a optimal result of the maintenance works, every component that will be disassembled must be cleaned.
There may only be used cleaners which do not damage the components. Especially the cleaning of o-rings andsealings 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

For external cleaning may be used soap water or similar mild cleaners.

Tools
To ensure a damage-free mounting and dismounting of the components, only the tools which are mentioned
in this manual must be used. The usage of differing tools is up to the user. If components are being damagedby the usage of differing tools, the user is liable.

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 electronical usage is not possible.

Disclaimer

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The operations described in this manual should only be done by professionals. The user is liable for any damage
or consequential damage which is caused by wrong maintained or wrong installed components. If you havedoubts, please contact a DT Swiss service center.

Twin Shot Technical Manual7Description

2 Description
2.1

Spring: ABS (Auto Balancing Spring System)

DT Swiss forks with ABS spring technology are using a positive and a negative air spring. While adjusting the
air pressure in the positive air chamber, the air pressure in the negative air chamber adjusts automatically. The
air pressure in the positive and negative air chamber is always in an optimal ratio to the weight of the rider.

2.2

Damping: Twin ShotDT Swiss forks with Twin Shot damping technology are equipped with an externally adjustable low speed
rebound and compression damping. The high speed rebound and compression damping are preset and not
adjustable. The sequential rebound and compression lockout can be adjusted externally with an adjuster leveror by remote control on the handlebar.

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The rebound lock out is an assistance for climbing, the rebound circuit is closed after a defined height. The fork
cannot extend completely anymore and stays down, at about a third of its normal travel.
The compression lock out will be used mostly in sprints or on the road. The compression damping is closed, sothat the fork cannot move anymore.

Twin Shot Technical Manual

8Installation

3 Installation

DANGER
Danger due to exceeding or falling below the given torque!
Especially for carbon parts, the exceeding or the falling below the given torques may lead to faulty mechanical connections.
• Use torque wrenches with a appropriate adjustment range.
• Consider the torque values of each component. The lowest values are decisive, but it may not be fallen
below the minimum values given by DT Swiss.

3.1

Shortening the Steerer

The length of the steerer essentially depends on the headset and the stem. It is mandatory to consult the instruction manual of the headset and the stem.

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NOTE: When the headset and/or the stem will be exchanged, the new installation height can have an effect on
the length of the steerer.

figure 3-1:

SteererTwin Shot Technical Manual9Installation

Preparatory Steps

Link

1. Dismount the fork from the bike.
2. Dismount the crown race off the old fork.
3. Measure the length of the old fork‘s steerer.
Ensure to measure the length from the support of the crown race to the end of
the steerer.
4. Transfer the measured value to the new steerer.
5. Ensure, that the remaining clamping surface on the steerer complies the totalheight of the stem including a 5 mm spacer on top of the stem.

-

Shortening a Carbon Steerer

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 starting shortening the carbon steerer.
• Wear protective goggles.
• Wear protective gloves.
• Wear a respirator mask.

DANGER
Risk of injury when using a star nut in combination with a carbon steerer!
There must be no star nut used in combination with a carbon steerer.
• Only use the original DT Swiss steerer expander.
• The DT Swiss steerer expander must be mounted at every time.
The original DT Swiss steerer expander extends the lengths of the steerer about 2 mm.
Required Material

Specification

steerer expander

Amount1-

1

protective gloves-

1 pairrespiration mask-1adhesive tape-as required

handsaw

new saw blade for metal with min.
24 teeth per inch

1

sandpaper

grain min. 400

as required

cleaner

Motorex Swissclean 2300

as required

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protective goggles

Twin Shot Technical Manual

10Installation

1. Put adhesive tape around the steerer in the place
the steerer needs to be cut. This prevents the carbon fibers to fringe.

2. Cut the steerer to the desired length.
Use a saw guide for cutting a carbon steerer!

3. Carefully remove the adhesive tape from the steerer completely. Do nut use aggressive cleaners tomove remaining adhesive.
4. Grind the cutting edges on the inside and the outside of the steerer using sand paper. The carbon
fibres on the cutting edge must not fringe.
5. Check the inner surface of the steerer for dirt andclean it if necessary.

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6. 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.

Twin Shot Technical Manual11Installation

7. Hold the expander and tighten the screw that fast,that the expander does not turn itself using a
6 mm Allen key. The maximum torque of 7 Nmmust not be exceeded.

Shortening a Aluminium Steerer
Required Material

Specification

Amountstar nutfor 1 1/8“ steerers

1pipe cutter

-

1

file

-

1

1. Cut the steerer to the desired length. DT Swiss recommends to use a pipe cutter.
2. Deburr the steerer on the inside and on the outside using a file.
3. Drive the start nut into the steerer using a suitable tool.
Link

Install the fork.

see following

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Closing StepsTwin Shot Technical Manual

12Installation

3.2

Installation of the Fork

Preparatory Steps

Link

Read the instructions of the manufacturer of the stem.

DANGER
Danger due to incorrect installation of the fork!
• Only use compatible headsets.
DT Swiss forks either have a straight steerer with a diameter of 28.6 mm (1 1/8“) or a tapered steerer
with a diameter of 39.82 mm (1.5") at the bottom and 28.6 mm (1 1/8“) at the top. Only use a headset
which is compatible with your steerer diameter.
• Only use crown race reducers of the respective headset manufacturer.
• DT Swiss forks are built for a stem clamp without thread. Do not add any holes or threading, or makeany kind of technical alternations to the fork.
• The steerer or the crown must not be damaged when assembling or using the DT Swiss fork. Special attention must be paid when fitting the headset crown race to the base of the steerer tube. The parts
mounted on the fork should have no sharp edges.
• Do not use cotter style stems.
• The flange of the discontinuous clamp area of the stem must be at least 7mm high (see following
figure).

DANGER

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Danger due to incorrect installation of the headset!
• The max. torque given by the manufacturer of the headset must not be exceeded.
• The DT Swiss steerer expander must be installed when a carbon steerer is used.
• Stem and headset must be installed in accordance with the instructions of the respective manufacturer.
• The adjusting screw of the headset is intended for adjusting the play of the headset. The screw is notintended for fixing!
• The crown race must not have sharp edges. These edges causes scratches to the steerer and shortens the
lifetime of the fork or induces a breakage of the steerer.
• The fork must not be damaged while installing. Damages shortens the lifetime of the fork and cancause a breakage.
• If you are using a carbon steerer, only use stems which are released for usage in combination with carbon steerers.

Twin Shot Technical Manual

13Installation

DANGER
Danger due to incorrect installation of the headset!
For a faultless function, the following instructions must be followed:• The spacers between headset and stem must be within the following limits:• minimum height: 5 mm
• maximum height: 30 mm• There must be a spacer on top of the stem with a height of 5 mm. This ensures that the stem is contacting the steerer with its entire surface.
• Ensure that the distance between the upper edge of the spacer and the steerer is big enough. Otherwise the play of the headset cannot be adjusted correctly. DT Swiss recommends a distance of 2 - 3 mm.

Install the Crown Race
1. Aluminium steerer: Apply a thin layer of grease onto the contact area of steerer and crown race. DT Swiss
recommends Motorex Langzeitfett 2000.
Carbon steerer: Apply a thin layer of DT Swiss Carbon fitting lubricant.
2. Install the crown race in accordance with the instructions of the manufacturer.

Install the Fork and the Stem
1. Install the fork to the frame.
2. Ensure that the headset crown race and the compliant headset are fitted together properly.
3. Install the upper part of the headset in accordance with the instructions of the manufacturer.

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Install the Stem and the Spacers
1. Add the spacers onto the steerer to set the desired height of the stem.
2. Carbon steerer: Apply a thin layer of DT Swiss Carbon fitting lubricant onto the contact area of the stemand the steerer.
3. Slide the stem onto the steerer. Do not tighten the fixing screws.
4. Add the spacer to the top of the stem.
Note the restrictions regarding the height of the spacers between stem and headset (see above).

Adjust the Bearing Play of the Headset
Adjust the bearing play in accordance with the instructions of the manufacturer.

Twin Shot Technical Manual141. Align the stem and tighten the fixing screws in accordance with the instructions of the manufacturer.
Consider the max. torque for carbon steerers!
2. In case the manufacturer of the stem does not specify specific torques for carbon steerers, 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 andtrying to twist the handlebar.
c) If this is not the case, enhance the torque in steps of 0.5 Nm and alternately tighten the fastening screw
until the stem cannot be twisted anymore.
• Do not exceed the maximum torque mentioned by the stem-manufacturer.
• The steerer expander delivered with the fork has to be mounted during these operations.
Closing Steps

Link

Install the brake.

chap.3.3, p.16

Inflate the fork.

chap.4.1, p.22

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Installation

Install the StemTwin Shot Technical Manual

15Installation

3.3

Installation of the Brake

Preparatory StepsLink

not required
Fork-Model

Max. brake disc diameter

DT Swiss XRC

185 mmDT Swiss XRM

210 mmDT Swiss XMM
DT Swiss XM
DT Swiss EX

210 mm

All DT Swiss Forks from 2009 on are equipped with Post Mount (PM) brake mounting standard for
160 mm. For usage of a brake discs with a bigger diameter than 160 mm, a appropriate adapter isneeded.
1. Install the brake lever in accordance to the instructions of the manufacturer.
2. Install the brake pipe like 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 atorque of min. 6 Nm and max. of 10 Nm.
• The max. torque must not exceed the specifications of the manufacturer.
• The length of the thread must be min. 8 mm
and max. 10 mm.

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5. When using disc brakes without Center Lock adapter or disc brakes with a spider arm construction, a collision test must be made between the front wheel with mounted disc brake and the fork.
6. Install the brake in according to the instructions of the manufacturer.

Closing Steps

Link

Install the front wheel and perform a braking test.

see following

Twin Shot Technical Manual

16Installation

3.4

Installation of the front Wheel

Preparatory StepsLink

not required

see following

DANGER
Risk of injury due to collision of the tire with parts of the fork!
A collision test must be performed after the front wheel was installed!

Usage of a RWS thru Axle
1.
2.
3.
4.

Remove the RWS from the fork.
Grease the RWS and its thread.
Put the front wheel into the dropout of the fork.
Slide the RWS through the right dropout of the fork, until the axle hits the thread in the left dropout.

5. Screw the RWS into the thread clockwise.
6. The lever of the RWS touches the fork lower during the last turns. When the lever touches the lower, lift the lever (1), turn the lever anti clockwise
while lifted (2), release it (3) and continue fastening.
7. Repeat steps until the RWS is tightened.
8. Tighten the RWS with a min. torque of 15 Nm.

Usage of a quick release
Install the front wheel in accordance with the instructions of the manufacturer of the quick release.

Collision Test

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1. Inflate the used tire to the max. pressure.
The max. pressure is given by either the tire or the rim. Decisive is the lower pressure of both components.
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 tire or thewheel must not be used!
4. If necessary, reduce the tire pressure to the desired operating pressure.
Closing Steps

Link

Check the correct installation of the fork and function of the brake.

Twin Shot Technical Manual

17Installation

3.5

Installation of the Remote-Lever
There are different DT Swiss remote levers available: The lightweight lever and the two-in-one lever.
The lightweight lever can only operate a single DT Swiss fork, while the two-in-one lever can operatea DT Swiss fork and a DT Swiss Shock at the same time. Both levers are available as single stage anddouble stage versions. For a Twin Shot fork the double stage lever must be used.

Preparatory StepsLink

not required
Required Material

Specification

Amountcable

uncoatedca. 70 cm

cable housing

Ø 4,2 mm

ca. 55 cm

carbon fitting lubricant

as required

Installation of the Remote Lever [Lightweight]

NOTE
General Information: Lightweight-Lever• The remote 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. If the diameter of the handlebar issmaller, the clamp of the remote lever can not be fixed strong enough.

1. Carbon handlebars: Apply a thin layer carbon fitting lubricant on the contact area of remote leverand handlebar.
2. Put the remote lever onto the handlebar and tighten the fixing screw with a torque of 1.5 Nm.
3. Check the proper function of the remote lever andthe control elements next to it.
Whether the remote lever nor any other control
element may be affected in its proper function.
4. Push the remote lever in the position «open» (seefigure).

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5. Cut the cable housing to the desired length. Checkif the handlebar with the installed cable housing
can be turned without being affected.
6. Put the cable into the remote lever.
Only use uncoated cables!

Twin Shot Technical Manual

18Installation

Installation of the Remote Lever [Two In One]NOTE
General Information: Two In One-Lever• The remote lever can be used for DT Swiss forks and/or DT Swiss shocks.
• The remote lever must be installed on the left top side of the handlebar.
• The remote lever is designed for a handlebar diameter of 22.2 mm. If the diameter of the handlebar issmaller, the clamp of the remote lever can not be fixed strong enough.

1. Carbon handlebars: Apply a thin layer carbon fitting lubricant on the contact area of remote leverand handlebar.
2. Put the remote lever onto the handlebar and tighten the fixing screw with a torque of 1.5 Nm.
3. Check the proper function of the remote lever andthe control elements next to it.
Whether the remote lever nor any other control
element may be affected in its proper function.
4. Push the remote lever in the position «open» (seefigure).

5. Cut the cable housing to the desired length. Checkif the handlebar with the installed cable housing
can be turned without being affected.
6. Put the cable into the remote lever.
Only use uncoated cables!

Installation of the Pipe, Cable and Cable Housing

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1. Put the pipe into the cable guide on the fork
crown.
2. Screw in the adjusting screw of the pipe completely.

Twin Shot Technical Manual

19Installation

3. Slide the cable housing onto the cable.
4. Slide the cable housing into the remote lever andthe pipe on the fork crown.

5. Put the cable through the pipe at the fork crown.
6. Ensure that the cable housing is fully pushed inside the pipe and the remote lever.

In order not to damage the fixing screw, only use a
Allen key without spherical head.
7. Loosen the fixing screw on the remote wheel.
8. Attach the fixing screw in 3 o‘clock position in driving direction.
9. Put the cable around the remote wheel and behind the fixing screw.
10. Pull the cable and tighten the fixing screw with amax. torque of 1 Nm.
11. Apply the remote lever a few times.

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12. Set the tension of the cable with the knurled screw at the pipe. In pos.3 the lever must lock completely
and the lockout must be active.

Twin Shot Technical Manual

20Installation

13. Cut the cable to the desired length and put on acable end cap.

Closing Steps

Link

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The fork is installed completely. You should go for a ride!

Twin Shot Technical Manual21

Operation and Setting

4 Operation and Setting
4.1

Setting the Air pressure

Recommended Air pressure
The following air pressures are only reference values. The air pressure should be set to your personal preferences and to the correct SAG.
XRC 100
Rider‘s Weight [lbs / kg]

XRM 100

XMM 120

XMM 100 29

XMM 120 29

XMM 140

XMM 150

Recommended Air Pressure [psi / bar]
88 / 4080 / 5.5

52 / 3.6

52 / 3.6

52 / 3.6

54 / 3.7

99 / 45

90 / 6.2

58 / 4.0

58 / 4.0

58 / 4.0

58 / 4.0

110 / 50

99 / 6.8

64 / 4.4

62 / 4.3

62 / 4.3

62 / 4.3

121 / 55

110 / 7.5

70 / 4.8

68 / 4.7

68 / 4.7

68 / 4.7

132 / 60

119 / 8.2

75 / 5.2

74 / 5.1

73 / 5.0

73 / 5.0

143 / 65

128 / 8.8

81 / 5.6

78 / 5.4

78 / 5.4

77 / 5.3

154 / 70

138 / 9.5

87 / 6.0

84 / 5.8

83 / 5.7

81 / 5.6

165 / 75

148 / 10.2

93 / 6.4

90 / 6.2

88 / 6.1

86 / 5.9

176 / 80

157 / 10.8

99 / 6.8

94 / 6.5

93 / 6.4

90 / 6.2

187 / 85

167 / 11.5

104 / 7.2

100 / 6.9

99 / 6.8

96 / 6.6

198 / 90

177 / 12.2

110 / 7.6

106 / 7.3

103 / 7.1

100 / 6.9

210 / 95

186 / 12.8

116 / 8.0

110 / 7.6

109 / 7.5

104 / 7.2

220 / 100

122 / 8.4

116 / 8.0

113 / 7.8

109 / 7.5

232 / 105

128 / 8.8

122 / 8.4

119 / 8.2

113 / 7.8

245 / 110133 / 9.2

126 / 8.7

123 / 8.5

117 / 8.1

174 / 12174 / 12174 / 12174 / 12203 / 14

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max. air pressure[lbs / kg]

Twin Shot Technical Manual22

Operation and Setting

Setting the SAG (Negative-Travel)
The SAG is the amount of travel of which the fork will be compressed by the weight of the rider with full equipment. If the SAG is adjusted correctly, the front wheel can follow the ground during the ride better.
Riding Style

SAG-Value

Cross Country / Race

15% of the travel

Marathon / Tour

20% of the travel

All Mountain / Enduro

25% of the travel

To set the SAG, you should use the help of a second person.
1. Deactivate the lockout.
a) Push the lever (see fig.4-1, p.24) in pos. 1 orb) push the remote lever (see fig.4-2, p.25 / fig.4-3, p.26) in pos. 1
2. Push the o-ring on the right stanchion to the bottom, until it touches the main sealing.
3. Sit on the bike with full equipment (backpack, helmet, shoes...).
4. Sit on the bike as you would sit during the ride.
The fork goes down because of your own weight.
Avoid impact loads.
5. Get off your bike and measure the distance between o-ring and main sealing.
This measurement is called SAG.
The SAG should be between 15% and 25% of the full travel and can be adjusted depending on theriding style and use.
6. Set the air pressure if necessary (see following). Repeat steps above until the correct SAG is set.

Set the Air pressure
In all DT Swiss fork models, the air spring is located in the left stanchion. By adjusting the air pressure, thespring rate will be affected. The higher the air pressure, the harder the spring.
The air chamber is filled with a small amount of lubricating oil. Make sure that the valve is upwards during
inflation or deflation.
Adjustment is possible by changing the air pressure. Adjusting the air pressure to the weight of the rider canslightly change the total length of the fork.

NOTE
Do not use the fork while the shock pump is mounted. This may cause the shock pump to touch theframe and the thread of the valve will break off.
Only use a suitable shock pump to adjust the air pressure. We suggest to use the DT Swiss shock pump.
Position the fork resp. the bicycle that the valve on the left upper stanchion is pointing upwards.
Remove the valve cap from the valve housing.
Mount a suitable shock pump on to the valve housing.
Adjust the air pressure by in- or deflating.
Check, if the correct SAG is set (see above).
5. Screw the valve cap on to the valve housing.

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1.
2.
3.
4.

Twin Shot Technical Manual23

Operation and Setting

4.2

Set the Damping

The correct setting of the damping requires some patience, but the full potential of the fork can only be attained, if the setting is perfect.

figure 4-1:

4.2.1

Twin Shot Damping

Rebound

The rebound controls the speed of the decompression movement.
To adjust the rebound damping, turn the red wheel (see fig.4-1, p.24) on top of the right stanchion.
• Turn clockwise to increase the rebound damping.
• Turn anti-clockwise to decrease the rebound damping.

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If the rebound damping is too low, the front wheel decompresses too fast and looses the contact to the ground.
If the rebound damping is too high, the front wheel can‘t follow fast impacts and the suspension hardens.
The aim of setting the rebound damping is to achieve the best setting possible, which meets the requirementsof the terrain best. Rough, fast downhills requires a low rebound damping, while flowy downhills without big
hits requires a higher damping.

Twin Shot Technical Manual24

Operation and Setting

4.2.2 Compression
The compression controls the sensibility of the fork. Turn the blue wheel (see fig.4-1, p.24) on top of the rightstanchion.
• Turning clockwise increases the compression damping.
• Turning anti-clockwise decreases the compression damping.
The compression controls the sensibility of the fork. If the compression damping is fully opened, the sensibilityof the fork is at it‘s maximum. At the same time, a fully opened compression damping has the effect of negative
influences from pedaling and more compression while riding steps in descents. Increasing the compression
damping reduces these effects.
As well as the rebound, the setting of the compression damping depends on the terrain and the personal riding
style. Fast, rough downhills requires a low compression damping. Slow, technical downhills requires a higher
compression damping.

4.2.3 Lock Out
Rebound-Lockout
The rebound-lockout is activated by pushing the lever (see fig.4-1, p.24) from pos 1 to pos 2. The fork cannot
extend to it‘s full travel anymore. If a big force applies on the front wheel, the fork will be lowered by about athird of its full travel, during the ride it always comes back to this position.
Once the fork is lowered, it might extend slowly about 6 to 8 mm within a few seconds, before getting stable.

Compression-Lockout
The compression lockout is activated by pushing the lever (see fig.4-1, p.24 / fig.4-3, p.26) from pos 2 in pos 3.
The fork will be blocked in it‘s actual position.
As you cannot activate the compression lockout without having the rebound lockout activated, the fork will
stay lowered if the blow off opens on an impact.
To get the fork back to its normal position, both lockouts have to be opened, this means you have to move thelever to pos 1 and close the lockouts again by moving the lever to pos 3.

4.3

Remote Lockout
There are two different DT Swiss remote levers available: The lightweight lever and the two-in-one
lever. The lightweight lever may only control one fork, while the two-in-one lever may control a fork
and a shock at the same time.

Lightweight Remote Lever

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figure 4-2:

Twin Shot Technical Manual25

Operation and Setting
figure 4-3:

Two In One Remote Lever

Operating the remote-unit
1. Activation of the rebound-lockout: Push the remote lever in pos 2 (see fig.4-2, p.25 / fig.4-3, p.26).
2. Deactivation of the rebound lockout: Push the remote lever in pos.1 (lightweight lever) or push the release
lever (two-in-one lever).
3. Activation of the compression lockout: Push the remote lever in pos 3.
4. Deactivation of the compression lockout: Push the remote lever in pos.1 (lightweight lever) or push the release-lever (two-in-one lever).
The lever skips pos 2 and switches to pos 1 directly.

Adjustment of the Remote Unit

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1. Deactivate the lockout function by pulling the remote lever to pos 1.
The cable of the remote lockout is loose.
2. Screw the adjustment screw of the pipe until block.
3. Unscrew the adjustment screw step by step to adjust the tension of the cable.
4. Control the lockout function by pushing the remote lever from pos 1 into pos 2. The adjustment is correct
once the fork cannot be compressed anymore.

Twin Shot Technical Manual

26

Service and Care

5 Service and Care
5.1

Care

To ensure a long product life, follow the instructions below:
•
•
•
•
•
•

5.2

Clean the fork with a damp cloth. Remove dirt between stanchion/lower unit.
Never use aggressive cleaners that damage rubber materials (main seals)!
Never use high pressure cleaners. Water and dirt can get into the system and damage it!
Remove all visible, dried dirt from the area of the main seals. This will prevent dirt from getting into thefork.
It is not necessary to grease the main seals. To get a good lubrication of the main seals, regularly turn yourbike or fork upside down.
After cleaning, lubricate the sliding surface of the remote lever on the handlebar.

Service Intervals

If service intervals are not respected, any warranty claims can be denied.
ActionInterval

Big service by a DT Swiss service center

annual or after 200 operating
hours*

Small service (see following)

50 operating hours*

Check the fork for damages and faultless function

before and after each ride

Check proper fixation

before and after each ride

Check the air pressure

before each ride

Check and grease the remote lever on the handlebar

after each ride

Clean with a soft cloth and a suitable cleaner, especially in the area of the after each ridemain seals
Do not use high pressure cleaners and aggressive cleaners!

V2013.08_EN*If you use your bike in extreme conditions, you will have to service your components sooner.

Twin Shot Technical Manual27

Service and Care

5.3

Small Service

This manual only describes a small service. Further service works will be executed by a DT Swiss service center.
A small service should be carried out in the following cases:
•
•
•
•
•

bad performancethe fork is loosing air
after rides in extreme conditions
after 50 operating hours
after a crash to check the parts

DANGER
Danger to life due to wrong maintenance!
Incorrect maintenance or assembly 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.

DANGER
Risk of injury due to high air pressure!
Air with high pressure can escape suddenly while dismounting the fork!
• Always release the air before starting any works.

Preparatory Steps

Link

Clean the fork.
Check all functions of the fork.
Required Material

Specification

Amountfork oilDT Swiss Lube Fluid

1 Bottle à 100 ml

fork oilDT Swiss Fork Oil

1 Bottle à 100 ml

Degreaser

Motorex Swissclean

as required

main seal kit Ø28,6 mmormain seal kit Ø32 mm

contains 2 wipers, 2 foam rings, 2 springrings

as required

1

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special tool for wiper Ø28.6 mm
orspecial tool for wiper Ø32 mm

Twin Shot Technical Manual28Service and Care

Release the Air
1. Unscrew the valve cap.
2. Release the air completely.

Dismount the lower Unit
1. Screw both hexagonal socket screws into thedropouts clockwise using a 4 mm Allen key.
2. Collect the leaking oil using a suitable container.

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3. Remove the lowers carefully.
4. Collect the leaking oil using a suitable container.

Twin Shot Technical Manual29Service and Care

5. Remove both spring rings from the main sealings.

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6. Remove both foam rings below the main sealings.
7. Check the foam rings.
Change the foam rings, if they are worn or badly
soiled.
If the main sealings are going to be changed,
the foam rings can be changed additionally. The
main seal kit includes main sealings and foamrings.

Twin Shot Technical Manual

30

Service and Care

Dismount the Main Sealing
The main sealings don‘t have to be changed obligatory. If there are signs of wear, or if the stanchions
are oily constantly, a change is recommended.
There‘s a special tool needed for assembly!
1. Lever out the main sealing using a metal tire lever.
Caution: The lowers must not be damaged. Remove the spring rings before dismounting themain sealings.

2. Remove the main sealings.

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3. Remove the second main sealing in a similar manner.

Twin Shot Technical Manual31Service and Care

Dismount the ABS Unit
1. Check, if the air is released (see Release the Air,p.29).
2. Remove the circlip using circlip pliers.
Caution: Do not scratch the piston rod!

3. Push the valve insert and remove the ABS unit.

Check and clean the Parts

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1. Clean the inside and the outside of the lower unit
carefully.
2. Clean the inside and the outside of the upper unit
carefully.
3. Clean the ABS unit.
4. Check all parts for wear, deformation, damagesetc.
5. If parts are damaged, contact a DT Swiss service
center.

Twin Shot Technical Manual32Service and Care

Mount the ABS Unit
1. Lubricate the elastomers and the sealings of the
ABS unit with 3 ml DT Swiss Lube Fluid.

2. Press the valve insert and slide the ABS unit into
the upper unit for about 7 cm.

3. Fill 2 ml DT Swiss Lube Fluid into the negative airchamber.

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4. Slide the ABS unit into the upper unit completely.
5. Install the circlip using circlip pliers.
6. Check if the circlip is installed correctly.

Twin Shot Technical Manual33

Service and Care

Mount the Main Sealings
If the main sealings were not dismounted, the following chapter can be skipped. Next step: Mountthe lower Unit, p.36
1. Degrease the seats of both main sealings.

2. Remove the spring rings from the main sealings.
3. Put on the main sealings.

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4. Slide the tool into the first main sealing.

Twin Shot Technical Manual

34

Service and Care

5. Carefully drive in the main sealing.
The main sealings must be flush with the upperedge of the lower unit.
6. Remove the tool from the main sealing.

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7. Mount the second main sealing in a similar manner.

Twin Shot Technical Manual

35

Service and Care

Mount the lower Unit
1. Soak the foam rings with DT Swiss Lube Fluid.
2. Put the foam rings between the bushings and themain sealings.

3. Slide both spring rings and the SAG o-ring onto
the upper unit.

4. Slide the lower unit about 2 cm onto the upper
unit.

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5. Fill 7 ml DT Swiss Fork Oil into the air side of thelower unit (A).
6. Fill 7 ml DT Swiss Fork Oil into the damping side ofthe lower unit (B).
7. Fix the fork vertically for about 2 minutes to allow
the bushings to be lubed.

Twin Shot Technical Manual36Service and Care

8. Fully slide the lower unit onto the stanchions.

9. Screw both hexagonal socket screws into the lower unit anti clockwise using a 4 mm Allen key.
10. Tighten both hexagonal socket screws with atorque of 4 Nm.

11. Slide the spring rings onto the main sealings.

Closing Steps

Link

Dispose the oil in an environmentally compatible manner.
Inflate the fork.

chap.4.1, p.22

Check all functions of the fork.

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The maintenance of the fork is complete. Enjoy the Ride!

Twin Shot Technical Manual

37Trouble Shooting

6 Trouble Shooting

DANGER
Risk of injury due to a damaged fork!
If there are noticed damages or malfunctions, the fork must not be used!
• Contact a DT Swiss service center or your dealer to solve the problem.

Bedding-In Time
Some parts of the new fork may need some bedding-in or sagging-in time. Especially the bushings of a newfork may have a higher breakaway force. Therefore the fork may be uncomfortable. After about 20 hours of
riding, the fork should be run in, and the effect will disappear.

After a Crash
After a crash the danger of damages is very high. Check your fork after each crash.
•••

Visual check: Check for damages such as cracks, breaks, oil leakages and scratches etc.
Functional check: Check if all functions are working correctly.
Acoustic check: Listen for 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 thedamage!

Bushing Clearance
DT Swiss forks use bushings in combination with oil lubrication. The function of the bushings is laid out for driving operation regarding an optimum of lubrication, thermal expansion of parts based on warming, manufacturing tolerances and the occurring loads. The bushing clearance is therefore necessary for the correct functionof the fork and may be noticeable. A noticeable bushing clearance does not automatically mean an excessive
wear out.

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Trouble Shooting
Problem

Cause

ActionThe fork is not responding properly.

The bedding-in time is not over.

Continue riding (beding-in time isabout 20 operating hours).

The air pressure is too high.

Decrease the air pressure controlled using a suitable shockpump.

The fork needs a small service.

Carry out a small service (seechap.5.3, p.28) yourself or by yourdealer or a DT Swiss service center.

The fork bottoms out on moderatebumps.

The air pressure is too low.

Increase the air pressure controlledusing a suitable shock pump.

The fork does not rebound completely and hardens on fast repetitive bumps.

Too much rebound damping.

Decrease rebound damping.

The fork rebounds too fast, thefront wheel loses contact to theground after bumps or it slides inturns.

Not enough rebound damping.

Increase rebound damping.

Twin Shot Technical Manual38Trouble Shooting

Problem

Cause

ActionAir Spring
The fork becomes compressed
while decreasing the air pressure.

Too fast decreasing of the air pres- Increase the air pressure controlledsure.
using a suitable shock pump untilachieving the initial air pressure orpull the fork manually apart andhold it a short time pressed against
the top out. Then decrease the airpressure controlled using a suitableshock pump.

Damping
Leaks inside the cartridge.

Contact your local dealer or the responsible DT Swiss service center tosolve this problem.

Remote Lockout: The lockout cable
is not tensioned correctly.

Check the proper fixation and thetension of the lockout cable.

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The lockout does not work well.

Twin Shot Technical Manual39

DT Swiss AG
Längfeldweg 101
CH - 2504 Biel/Bienne
E-mail: mail@dtswiss.com
DT Swiss, Inc.
2493 Industrial Blvd.
USA - Grand Junction, CO 81505
E-mail: info@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 City
E-mail: info@dtswiss-asia.com

www.dtswiss.com

Subject to technical alterations, errors andmisprints excepted. All rights reserved.
© by DT Swiss AG