R 535 ONE
TECHNICAL MANUAL
V2021.10

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
2

1. GENERAL
1.1 VALIDITY
This manual describes the component specified on the front page and the footer. It is valid for the technicalcondition of the component at the Okt. 15, 2021. Design changes are reserved.

1.2 SAFETY
The safety instructions are classified as follows:

DANGER...indicates a hazardous situation that, if not avoided, will result in death or serious injury.

CAUTION… indicates a hazard with a medium level of risk which, if not avoided, may result in minor or moderate
injury.

NOTE… indicates a potentially hazardous situation 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 minor service work himself. If you have any doubts about your own abilities, you
should definitely contact a specialist or a DT Swiss Service Center.
Any warranty claims will lapse if work is not carried out properly.

1.4 HOW TO USE THE MANUALThe 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 begin with the table «Preparatory Steps» and end with the table «Closing Steps». The instructionsin these tables must be carried out.

R 535 ONE Technical Manual V2021.10

3

1.5 GENERAL MAINTENANCE INFORMATION
Unless otherwise specified, O-rings and seals must be greased before assembly.

CLEANING
For an optimal result of the maintenance works, every component that will be disassembled must be cleaned.
Only use cleaners which do not damage the components. Especially the cleaning of O-rings and seals
requires mild cleaners. Observe the instructions for use of the respective cleaner.
DT Swiss recommends the following cleaners:•

Motorex Rex•

Motorex Swissclean•

Motorex OPAL 2400, 3000 OPAL, OPAL 5000

Use soap water or similar mild cleaners for external cleaning.

TOOLS
To ensure a damage-free mounting and dismounting of the components, only use the tools which are
mentioned in this manual. Special tools are indicated at the beginning of a chapter in the table "Requiredmaterial".
The use of different tools is at the discretion of the user. 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 canonly be ensured if the tools are working properly and if the condition of the tools are perfect. Always keep thetools in their original packaging or adequate devices to prevent damage.

1.6 ENVIRONMENTAL PROTECTION
The statutory regulations shall apply. Whenever possible, avoid creating waste. 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.

1.7 EXCLUSION OF LIABILITY
The activities listed in this manual may only be carried out by persons with sufficient specialist knowledge.
The user is liable for any damage or consequential damage caused by wrongly maintained or installed
components. If you have doubts, please contact your region's DT Swiss pro level service center.

1.8 WARRANTY (EUROPE)
Warranty conditions can be found at www.dtswiss.com.

42. TROUBLE SHOOTING
Issue

ReasonSolution

Air loss after long term storage
or riding.

Normal effect. The shock can lose
about 1-2 bar per month.

Inflate the air chamber andperform standard set up.

Air loss after short time.

Quadring, wiper or guide band of
the air chamber is worn.

Change the sealings of the airchamber seal kit. See “3.5 Small
Service“ on page 9.

Wrong grease used.

Disassemble and clean the innersurface of the air chamber and theoil chamber tab.
Grease the inner surface of the airchamber, the oil chamber tab andthe wiper using Slick Honey Bike
Grease.
See“3.5 Small Service“ on page9.

Air chamber is damaged.

Change the air chamber.

The outer surface of the oilchamber is damaged / scratched.

Full service necessary.
Contact a DT Swiss service center.

Tiny amounts of oil or grease on
the outside.

Normal residue from installation
or operation.

Clean the shock with a damp cloth
after each ride.

Tiny amounts of oil on therebound wheel or on the end cap.

None - normal residue fromassembly.

Clean the area and check again
after a while. If this area is oily
again, a full service is necessary.
Contact a DT Swiss service center.

Shock loses oil in the area of therebound wheel.

O-ring of the lockout pin isdamaged.

Full service necessary.
Contact a DT Swiss service center.

Shock makes slight flowing sound(effect changes depending on therebound adjustment).

Normal effect (damping effect of oil and bores).

Shock makes “smacking”
sound.

Air inside the oil chamber.

Full service necessary.
Contact a DT Swiss service center.

The rebound does not work.

The rebound pin is stuck.

Full service necessary.
Contact a DT Swiss service center.

The lockout does not work.

The remote cable is not adjusted
correctly.

Adjust the remote cable via theknurled wheel.

The sealing of the damping piston
is worn or damaged.

Full service necessary.
Contact a DT Swiss service center.

The lockout cap does not closecompletely.
Only trunnion mount shocks:
Dirt between lockout shaft andrebound wheel or between
rebound wheel and end cap.

R 535 ONE Technical Manual V2021.10

5IssueReasonSolution

The shock cannot be inflated (airescapes immediately when thepump is unscrewed).

Valve or valve insert of the shockis damaged.

Change or retighten the valve
inserts (max. 0.4 Nm).

Leakage.

Check in a water bath where theshock is leaking. Contact yourdealer or a DT Swiss Service
Center to solve the problem.

The pressure indicated on thepressure gauge rises rapidly while
pumping.

Valve does not open.

Check the positioning of the pumpon the shock or change the pump.

Shock has noticeable play at thespherical bearings / DU bushings.

Wrong mounting hardware,incorrect tightened screws or
wear.

Check whether the correct
mounting hardware was used or
the screws are tightened correctly.
If necessary, replace ball joints /DU bushings (see “5. Changing thespherical bearings“ on page 22
or “4. Replacing DU bushings“ onpage 17).

Loss of oil at the oil chamber(noticeable when the air chamberis removed).

Sealings are at their wear limits.

Full service necessary.
Contact a DT Swiss service center.

Oil sprays out of the valve while
deflating the air chamber.
Noise while compressing theshock after about 10 mm of thestroke.

Normal sound of the air balance between the positive and the negative
air chamber.

Clacking noise whencompressing.

Defective lockout cap.

Full service necessary.
Contact a DT Swiss service center.

IFP not in correct position.

Full service necessary.
Contact a DT Swiss service center.

Shock squeaks while riding, when
the shock gets hot.

Wiper seal is dry.

Small service necessary.
See “3.5 Small Service“ on page
9.

Shock gets hot while riding.

The shock can get very hot on long downhills. This does not affect theperformance of the shock.

6

3. CARE AND MAINTENANCE
3.1 SAFETYDANGERDANGER TO LIFE DUE TO WRONG MAINTENANCE OF THE SHOCK!
Incorrect maintenance or assembly of the shock can lead to incorrect function!
• 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.

3.2 CARE
The following care and cleaning instructions must be observed:•

Clean the shock with a damp cloth after each ride. Remove dirt accumulations in the area of the wiper
seal.

•

Never use aggressive cleaners that damage the wiper seal.

•

Never use high pressure cleaners. Water and dirt can get into the shock and damage it!

•

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, lubricate the sliding surface of the remote lever on the handlebar.

3.3 SERVICE INTERVALS
If service intervals are not respected, any warranty claims can be denied.
Task

Interval

Small Service• intensive use: 40 operating hours• normal use: 100 operating hours• or as required

Full service carried out by a DT Swiss service center

Annually or after 200 operating hours

Check the shock for damage

Before and after each ride

Check the fastening is correct

Before each ride

Check the functionality

Before each ride

Clean with a soft sponge and a suitable cleaning
agent, especially in the area around the wiper seal.

After each ride

Do not use high pressure cleaners or aggressive
cleaning agents!

R 535 ONE Technical Manual V2021.10

7

3.4 OVERVIEW SEAL KIT AIR CHAMBER
The seal kit includes all parts needed for a small service. All of these parts can be changed without using
special tools.

Standard Mount

1a
2

3

Trunnion Mount

4

5

2

3

6

7

4

1b
5

8

1a

O-ring air chamber standard mount4

support ring

1b

O-ring air chamber trunnion mount5

quad-ring2

support ring6

support ring3

quad-ring7

wiper seal

67

3.5 SMALL SERVICEThis 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).

•

Leakage that becomes apparent through repeated air loss. The shock must be inflated regularly.

•

Unusual sounds (squeaking).

•

Other defects or malfunctions.

PREPARATORY 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

Quantity

service kit air chamber

Gen1 (grooves on air chamber):

1•

standard mount: CWXXXXXX10095S•

trunnion mount: CWKXXXXX23788S

Gen2 (no grooves on air chamber):grease•standard mount: CWKXXXXX37898S•

trunnion mount: CWKXXXXX37893S
Buzzy‘s Slick Honeyas required

4.7 dl: 40341000AD02000001
or
20 ml: TZXXXXXNSLICKSNOTERISK OF DAMAGING THE SHOCK!
To avoid damages, always clamp the shock or parts of the shock into ground clamping jaws, aluminum
clamping jaws or plastic clamping jaws.

R 535 ONE Technical Manual V2021.10

9

RELEASING THE AIRDANGER
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.

DANGERSHOCK OIL MAY BE FATAL IF SWALLOWED AND ENTERS AIRWAYS!
Oil mist might escape through the valve while releasing the air from the air chamber.
•If the air is released without using a shock pump, 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 airways.

1. Set the shock to “OPEN” mode.
2. Unscrew the valve cap on the shock.
3. If the air is released without using a shock pump,place a cloth over the valve.
4. GRADUALLY press the valve insert with the backof the valve cap.
or
Screw on the shock pump and GRADUALLY
reduce the air pressure by pressing the releasevalve on the shock pump.
The shock can compress up to the point at which the equalization of the positive and negative air chambers
occurs.

10

REMOVING THE AIR 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 chamber using a strap wrench.

5. Slide off the air chamber.

R 535 ONE Technical Manual V2021.10

11

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.

Only shock with standard mount:
1. Remove 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 thearea of the O-ring.
4. Slightly grease the O-ring and put it back onto the
air chamber cap.
5. Remove both support rings from the oil chamber
tap.
6. Remove the quad-ring from the oil chamber tap.
7. Clean the seat of the quad-ring and the support
ring,

8. Slightly grease the new quad-ring and fit it onto
the oil chamber tap.
→ Ensure that the quad-ring is not twisted.

12

9. Put both support rings on both sides of the quadring onto the oil chamber tap.

10. Slightly grease the oil chamber.

GREASER 535 ONE Technical Manual V2021.10

13

REPLACING THE WIPER SEAL
1. Carefully remove the wiper seal from the airchamber 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 chamberhousing by hand.
→ Do not re-use the support ring!

3. Remove the quad-ring from the air chamberhousing 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 damaged wiper seal is the reason for air
leakages of the shock.
•

Only use cleaners mentioned in section “Cleaning“ on page 4.

4. Clean the air chamber housing with a clean, lint-free and dry cloth.
There must be no lint and no residuals of grease after cleaning!

145. Slightly grease the new quad-ring and put it into
the inner groove of the 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 it into
the outer groove of the air chamber (see figure).
→ Ensure, the wiper seal lays evenly all aroundthe groove.

R 535 ONE Technical Manual V2021.10

15

8. Slightly grease the inner surface of the airchamber housing and the thread. Grease thewiper seal generously.
→ Required grease, 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 the shock out of the vice.

12. Put the SAG O-ring onto the oil chamber.

Closing steps.
Mount the shock hardware.
Mount the shock.
16

Link

4. REPLACING DU BUSHINGSDT Swiss shocks use DU bushings or spherical bearings. These two types, as well as their hardware andtools, are not compatible 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

Quantitycleaner / degreaser

see “Cleaning“ on page 4

as required

greaseBuzzy‘s Slick Honeyas required

Tool kit for dismounting the DU pin

CWTXX10031935S

1Tool kit for dismounting the DU bushingCWTXX10031927S

1Tool kit for mounting the DU bushingCXTXX10031928S

1OVERVIEW

sleeveDU-bushings

shock eye

DU-pinsleeveR 535 ONE Technical Manual V2021.10

17

REMOVING THE SLEEVES
1. Remove the sleeves by hand.

TESTING THE DU BUSHINGS
1. Clamp the DU pin into a vice.
2. Rotate the shock on the pin to check the DU
bushing.
→ If the shock can be rotated without
resistance, the DU Bushings must bechanged. See following.
→ If the shock can be rotated with resistance,
the DU bushing must not be changed.
Check the DU bushing again within the next
small service.
Mount the sleeves and the O-rings again (see“Mounting the sleeve“ on page 21).

18

REMOVING THE DU-PIN
1. Slide the pusher into the DU pin.
2. Align the receiver like shown in the picture.

receiverpusher

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 shown in the picture.

receiverpusher

TOOL KIT DU BUSHING UNMOUNTING ASSEMBLY CWTXX10031927S

3. Push out the DU bushing using a press or a bench
vise.

R 535 ONE Technical Manual V2021.10

19

MOUNTING THE DU BUSHINGS
1. Slightly grease the inner surface of the shockeyelet and the outer surface of the bushing.

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 theshock.
4. Align the receiver like shown in the picture.

receiverpusher

TOOL KIT DU BUSHING MOUNTING ASSEMBLY CXTXX10031928S

5. Push in the bushing using a press or a bench vise.

20

MOUNTING THE DU-PIN
1. Slightly grease the inner surface of the DU
bushing and the outer surface of the DU pin.

GREASE
2. Push in the DU pin by hand.
3. Position the pin centrally by clamping the pin in
the vice and while turning the shock, pushing it to
the center.
4. Wait a few minutes and check the DU bushingagain (see “Testing the DU bushings“ on page18).
If this test fails a second time, contact a DT Swiss
service center.

MOUNTING THE SLEEVE
1. Slightly grease the DU pin.
2. Slide the O-rings onto the sleeves.

GREASE

Closing Steps

Link

Dispose all waste in an environmentally compatible
manner.

“1.6 Environmental protection“ on page 4

Assemble the shock to your bicycle.

R 535 ONE Technical Manual V2021.10

215. REPLACING SPHERICAL BEARINGSDT Swiss shocks use DU bushings or spherical bearings. These two types, as well as their hardware andtools, are not compatible 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

Quantitycleaner / degreaser

see “Cleaning“ on page 4

as required

thread locker

high-strength

as required

tool kit spherical bearingsCWTXX10028914S

1

OVERVIEW

ball

22

plastic ringshock eyelet

CHECKING THE SPHERICAL BEARINGS
1. Check the play of the spherical bearing by hand.
→ If the spherical bearing can be moved without resistance, the spherical bearing should be replaced.

CHANGING THE SPHERICAL BEARINGS
1. Put the pin of the disassembly tool from one side
into the spherical bearing.
2. Push the counter sleeve of the disassembly toolon the other side of the spherical bearing onto thepin of the disassembly tool.
3. Press out the spherical bearing by compressing
the disassembly tool.
A vice, a hand press or the like can be used forpressing.

4. Clean the eye of the shock with a degreaser andput 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 sothat the gap in the plastic ring is offset by 90° to
the axis of motion of the shock.
6. Press in the new spherical bearing using theassembly tool.
A vice, a hand press or the like can be used forpressing in.
7. Take the tools and the shock out of the vice.
8. Remove excess threadlocker with a degreaser.

9. Check whether the spherical bearing is in the middle of the shock eye.
10. Check the spherical bearing again (see “Checking the spherical bearings“ on page 23).
Closing Steps

Link

Dispose all waste in an environmentally compatible
manner.

“1.6 Environmental protection“ on page 4

Assemble the shock to your bicycle.
R 535 ONE Technical Manual V2021.10

23

6.

ATTACHING THE REMOTE CABLE
3

1
2

4
5

6
7
8

1. Insert the cable housing (1) into the remote lever on the handlebars and into the cable adjuster (2)on the shock.
→ Only use cable housings with an outer diameter of 4 mm.
→ The cable housing must be long enough to allow the handlebars to turn fully in both directions.
The shock and other components must function properly at all times.
2. Switch the remote lever to the “OPEN” position and route 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 tightening torque of 1.3 Nm.
4. Shorten the cable housing (4) and press on the cable end crimp (5).
5. Switch to “DRIVE” mode using the remote lever and adjust the cable tension.
→ Shock with standard mount: The “DRIVE” marking (7) on the remote wheel must face the stop
screw (6).
→ Shock with trunnion mount: The “DRIVE” marking (8) on the remote wheel must face the valve.
6. If necessary, adjust the cable via the cable adjuster (2) until both markings are correct.

24

DT SWISS AG
Längfeldweg 101
CH - 2504 Biel/Bienne
info.ch@dtswiss.com

DT SWISS ASIA LTD.
No.5, Jingke 5th Rd., Nantun District
Taichung City 408
Taiwan (R.O.C.)
info.tw@dtswiss.com

DT SWISS, INC.
2493 Industrial Blvd.
USA - Grand Junction, CO 81505
info.us@dtswiss.com

DT SWISS DEUTSCHLAND GmbH
Albert-Einstein-Strasse 359302 Oelde
Germany
info.de@dtswiss.com

DT SWISS (FRANCE) S.A.S.
Parc d‘Activites de la Sarrée
Route de Gourdon
F - 06620 Le Bar sur Loup
info.fr@dtswiss.com

DT SWISS POLSKA Sp. z o.o.
ul. Towarowa 36
PL-64-600 Oborniki
Polandinfo.pl@dtswiss.com

Subject to technical alterations, errors and misprints excepted.
All rights reserved.
© by DT SWISS AG
www.dtswiss.com
WXD10000000905S