DT SWISS Forks EX, XMM120, XM Series, XRC100, XM140, Ex SERIES, XMM100 Instruction manual

FORKS
Forks
www.dtswiss.com
ENGLISH
INSTRUCTION MANUAL AND WARRANTY RULES
4 – 22
Thank you for choosing a DT Swiss fork. You’ve purchased a product of best Swiss quality and innovative technology.
This instruction manual explains the installation, operation and handling of DT Swiss
forks. For further questions, which are not covered in this instruction manual, please
contact your local dealer or the responsible DT Swiss Service Center (contact information at the end of this manual).
More technical information see www.dtswiss.com
Plus d'informations techniques sur www.dtswiss.com.
Mehr technische Informationen unter www.dtswiss.com.
42 – 60
1 G E N E R A L I N F O R M AT I O N
1.1 GENERAL INFORMATION
•
•
•
•
•
The installation of the fork should only be carried out by qualified bicycle mechanics.
During bike riding always wear a helmet, sufficient protection gear and eye protection.
Don’t mount the bike on a roof rack using the fork’s dropouts. The fork might get damaged.
Please read the instruction manual and warranty rules attentively before installing or using the fork!
The information contained in the instruction manual and warranty rules respectively, must be accessible to the end user of
the product!
• Please take note that it is in the riders responsibility to have the product regularly checked to determine if it needs to be
serviced. DT Swiss recommends regular maintenance and inspection by a DT Swiss Service Center. Please read the instruction manual and warranty rules of your DT Swiss fork.
• If the fork shows any scratches or grooves, contact your local dealer or the responsible DT Swiss Service Center to evaluate
the damage. Do not continue to ride the fork until an assessment has been made by the Service Center.
1.2 TERMS
The terms suspension fork and fork as well as carbon steerer and steerer are to be understood equally in this document.
1.3 USE OF WARNING SYMBOLS
CAUTION
Shows a danger, which can cause damage to the material or to a third person, as well as serious injuries or even death.
INFORMATION
Shows practice-oriented information and tips which allow an optimal use.
DT Swiss forks are designed to be used by a single rider, on mountain trails and similar off-road conditions. A non adapted use
can cause damage to the material or a third person, as well as serious injuries or even death.
Model
Max. rider weight
210 lbs / 95 kg
245 lbs / 110 kg
245 lbs / 110 kg
245 lbs / 110 kg
1.5 OPERATING PURPOSE
• DT Swiss Forks are recommended only for the use in bicycles.
• DT Swiss Forks must only be used in electrically power assisted bicycles according to DIN EN 15194 standards and only if the
power transmission does not go over the front wheel (Front hub).
• DT Swiss Forks cannot be used for other applications than shown in the chart below or as a tool or toy or for anything else
than described in the user's manual.
XR Cross Race
XRC
XRM
XMC
XMM
EXC
EXM
4
XM Cross Mountain
EX Enduro Cross
FR Freeride
2 TECHNOLOGIES
Spring technology
ABS
• Single Shot with optional Remote
Control
• Twin Shot with optional Remote
Control
Launch Control
DT Swiss forks with ABS spring technology use positive and 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
chambers is always in an optimal way to the weight of the rider.
DT Swiss forks with Single Shot damping technology have an extern adjustable low speed rebound damping. The high speed
compression and rebound damping, as well as the low speed compression damping are factory setting and not adjustable.
The compression lock out can be activated on the top of the fork or by Remote Control on the handlebar.
2.4 TWIN SHOT
DT Swiss forks with Twin Shot damping technology do have an externally adjustable low speed rebound and compression
damping. The high speed rebound and compression damping are factory setting and not adjustable. The sequential rebound
and compression Lockout is externally adjustable with an adjuster lever or by Remote Control on the handlebar.
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 full travel.
The compression lock out will be mostly used in sprints or on the road. The compression damping is closed, so that the fork
cannot move anymore.
DT Swiss forks with Launch Control damping technology do have an externally adjustable low speed rebound and compression
damping. The high speed compression damping is factory setting and not adjustable.
The Launch Control function is an assistance for climbing where the rebound damping circuit will be closed to a pre-defined
level. The fork cannot rebound completely and stays in lowered position until the Launch Control function gets deactivated.
5
Damping technology
Model
ENGLISH
3 I N S TA L L AT I O N
3.1 GENERAL INFORMATION
CAUTION
Please take note of the following safety advice for the assembly.
• To fasten bolted connections, always use a torque wrench in the appropriate torque range specified by DT Swiss, by the
headset-manufacturer or the stem-manufacturer.
• Please note the maximum and minimum torque while fastening the parts. The lowest value is authoritative, but the torque
should not go below the lowest value given by DT Swiss.
• Your DT Swiss fork can have a straight steerer with a diameter of 28.6mm (1 1/8“) or a tapered steerer with a diameter of
39.82mm (1.5") at the bottom and 28.6mm (1 1/8“) at the top. Please only use a headset which is compatible with your
steerer diameter.
• Do not use any steerer adapters or reducer bushings.
• Your DT Swiss fork is built for a stem clamp without thread. Do not add any holes or threading, or make any kind of technical alternations to the fork.
• Be careful not to damage the steerer or the crown when assembling or using your DT Swiss fork. Pay special attention when
fitting the headset crown race to the base of the steerer tube. The parts mounted on your 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.
CAUTION
The spacers used between the headset and the stem when assembling, must not under-run the minimal height of 5mm or
exceed the maximal height of 30mm.
The steerer clamp of the stem must not be larger than 45mm.
A 5mm spacer must be applied above the stem, to guarantee that the whole clamping length of the stem rests on the steerer.
Make sure, that there is a big enough gap between the top edge of the spacer and the steerer, so you can adjust the play of
your steerer correctly (DT Swiss recommends 2-3mm)
6
Because shortening the steerer essentially depends on the headset and the stem as well as the stem model, it is mandatory to
consult the instruction manual of the headset and that of the stem.
• Disassemble your old fork from the frame.
• Remove the headset crown race from the old fork.
• Measure the steerer length of the old fork and transfer the result onto the steerer of your new DT Swiss fork. Make sure
that the length is measured from the supporting area of the headset crown race on the crown to the top edge of the
steerer.
• Make sure, that the residual clamping area complies with the overall installation height of the stem including a 5mm spacer
above the stem.
ca. 2mm
Auflagefläche Steuersatzkonus unten
Supporting area headset base plate
Base du jeu de direction
3.2.1 SPECIAL PROCEDURE FOR CARBON STEERER
CAUTION
Take special precautions for the safety of your health, especially the skin, eyes and respiratory passages before shortening a
carbon steerer.
For assembling your headset and stem do not use a conventional A-Head-Set Star-Nut. Only use the steerer expander provided
by DT Swiss. For safety reasons the steerer expander must be permanently mounted.
INFORMATION
Take note, that the steerer expander provided by DT Swiss elongates the installation height of the steerer of about 2mm.
3.2.1.1 REQUIRED MATERIAL
•
•
•
•
•
•
ENGLISH
Please take note, that when exchanging the headset and/or the stem, the new installation height can have an effect on the
length of the steerer.
safety goggles
breathing protection
protective gloves
masking tape
handsaw (new saw blade for metal with at least 24 teeth per Inch)
sandpaper (min. grit 400)
7
3.2.1.2 PROCEDURE
• Only use a handsaw to shorten your carbon steerer.
• Wrap masking tape tightly around the steerer at height of the measured length in order to prevent the carbon fiber from
fraying when it is cut. Saw to achieve the desired length. Carefully file a smooth radius or chamfer on the inside and outside
at the top edge of the steerer with sandpaper. The carbon fiber of the steerer must not be allowed to fray.
• Carefully remove all of the masking tape from the steerer. Do no use any aggressive dissolvers to remove any left over
masking tape (DT Swiss recommends the use of Motorex Swissclean 2300).
• Check inside the steerer for any grit or dirt, clean if necessary.
• Insert the steerer expander into the steerer until the arrester securely rests on the ring surface of the steerer. Make sure the
slotted bushing is orientated backwards.
• Hold the expander whilst tightening the screw with an Allen wrench size 6mm until the expander stops turning, without
exceeding the maximal torque of 7Nm.
• The expander should always stay mounted in your fork.
3.2.2 SPECIAL PROCEDURE FOR ALUMINIUM STEERER
3.2.2.1 REQUIRED MATERIAL
• pipe cutter
• file
•
3.2.2.2 PROCEDURE
• Cut the steerer to the desired length. DT Swiss recommends to use a pipe cutter.
• Deburr the steerer with the file, inside and outside
• Put a star-nut inside the steerer using an appropriate tool
3.3 ASSEMBLING THE FORK IN THE FRAME
INFORMATION
Assemble the headset as described in the instruction manual by the headset-manufacturer. Pay attention to the following
restrictions by DT Swiss.
The adjusting screw is used to set up the bearing play of the headset. This screw should not be used for tightening!
CAUTION
The headset crown race and headset top cone must not have any sharp edges as they can scratch or groove the steerer and
shorten the life-span or even lead to failure of your DT Swiss fork.
By mounting the crown race and the stem take care not to damage the fork and especially the shaft. Damages on the fork
could shorten the life-span or even lead to failure of your DT Swiss fork.
• By aluminum steerer, please put some grease on the steerer and on the crown race of the headset. By carbon steerer, please
use carbon mounting paste (Art. No. FXXXXX0XXX040717S).
• Press the crown race on the steerer following the instruction of the headset manufacturer
• Assemble the fork with the pressed on headset crown race onto your frame. Make sure, that the headset crown race and
the compliant headset are fitted together properly.
• Assemble the headset top bearing according to the instruction of the headset-manufacturer. Use the spacer at the bottom
of the stem to adjust the stem to the desired height.
• Without tightening the fastening screw, mount the stem including the spacer above the stem on the steerer. Take note
of the restrictions concerning minimal and maximal height of the spacer between the headset and the stem. In case of a
carbon steerer, apply a fine film of carbon adhesive paste onto the clamping area of the stem.
• Adjust the bearing play of the headset using the cap and the adjusting screw provided by the headset-manufacturer.
• Tighten the screw, with open stem clamping screws, to the point when there is no more bearing play noticeable when pulling the front brake and moving the bicycle forwards and backwards. The fork must turn freely in the steerer tube.
• Check the bearing play of the upper and lower bearing shell with your thumb and index finger whilst the front brake is
pulled and the bicycle is moved forwards and backwards.
INFORMATION
If the steerer is installed properly, there is no bearing play noticeable and the handle bar resp. the front wheel tilts over on its
own when the bicycle is placed at an angle.
• Adjust the stem and tighten the fastening screw of the stem as described in the instruction manual of the stem-manufacturer. Take note of the maximal fastening torque of the fastening screws for carbon steerers.
INFORMATION
If the stem-manufacturer does not supply any torque information for carbon steerers, continue as follows:
• Tighten the fastening screw to 4Nm using a torque wrench.
• Check if the stem is fitting securely on the steerer by jamming the front wheel between your legs and trying to twist the handlebar.
• If this is not the case, enhance the torque in steps of 0.5Nm and alternately tighten the fastening screw until the stem cannot be twisted anymore.
8
CAUTION
In this procedure, do not exceed the maximal torque mentioned by the stem-manufacturer. The steerer expander delivered
with the fork has to be mounted during these operations.
• The remote lever is only available with forks with Single Shot and Twin Shot damping technologies
• The remote lever can be mounted on the right side as well as on the left side of the handlebar.
• There has to be enough space between the grip and all the handling elements (brakes, switchers, etc.) on the bar. Please
mount the remote lever so that its function won't be hindered from any other component. The function and handling of all
the other components (especially the brakes) should not be hindered either.
• Please use a special mounting paste to mount the remote lever on the handlebar. DT Swiss recommend the delivered Carbon mounting paste (Art. Nr. FXXXXX0XXX040717S)
• The pipe has to be mounted on the crown side, it is not allowed to mount it on the remote lever side.
ENGLISH
3.4 REMOTE LOCKOUT
3.4.1 GENERAL INFORMATION
INFORMATION
The remote lever is made for handlebars with a diameter of Ø22,2mm. If the handlebar has a too small diameter, the remote
lever cannot be tightened enough and can turn on the handlebar.
CAUTION
The screw M3x8 should be tightened with a maximum torque of 1.5Nm. A higher torque could lead to damage the handlebar.
Choose the length of the outer casing of the remote lockout long enough to prevent the arrester on the crown to break in
case of exaggerated twisting of the handlebar (for ex. crash)
3.4.2 INSTALLATION OF THE REMOTE LOCKOUT
3.4.2.1 REQUIRED MATERIAL
•
•
•
•
Cable
4mm outer casing
2,5mm Allen key
2mm Allen key
• In case of a carbon handlebar, apply some carbon mounting paste on the handlebar (Art. Nr. FXXXXX0XXX040717S).
• Mount the remote lever on the handlebar and tighten with the M3x8 bolt.
• Cut the outer casing to the correct length. The handlebar has to turn freely once the cable with outer casing and pipe has
been assembled.
• Use non-coated inner cables only!
• Make sure the set screw on the pipe is fully screwed in
• Set the lever to pos. 1
• Feed the cable through the hole in the lever, the outer casing, the pipe and the crown. Make sure the outer casing and the
pipe are correctly placed.
9
Put the cable around the silver wheel and through the hole.
Pull on the cable with the hand so that everything gets into its place.
Tighten the cable with the hand and tighten the M4x4 screw with 1Nm to clamp the cable
Switch the lever several times through the different positions
Set the tension of the cable with the setting screw on the pipe so that the lockout is activated when the lever is in position 3.
Cut the cable to the wished length and apply a cable ferrule at its end.
Put the cable behind the M2 screw.
Loose the M3x4 screw on the hex wheel
Put the cable around the hex wheel and under the M3x4 screw
Pull on the cable with the hand so that everything gets into its place.
Tighten the cable with the hand and tighten the M3x4 screw with 1Nm to clamp the cable
Switch the lever several times through the different positions
Set the tension of the cable with the setting screw on the pipe so that the lockout is activated when the lever is in position 3.
Cut the cable to the wished length and apply a cable ferrule at its end.
Pos 1
10
Lockout open
Pos 2
Rebound Lockout activated
(only Twin Shot)
Pos 3
Compression Lockout
activated
3.5 BRAKES
3.5.1 GENERAL INFORMATION
Maximum allowed disc brake diameters:
Model
Max. diameter
185 mm
210 mm
ENGLISH
CAUTION
Do not use screws that are too long for the mounting of the brake caliper. Screws that are too long may damage the post
mount socket. Make sure that the screw does not touch the end of the thread without clamping the brake caliper. The thread
depth of the screw in the fork should be between 8 and 10mm.
Tighten the bolts alternately with min 6Nm and max. 10Nm. The highest value required by the brake manufacturer should not
be exceeded.
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.
Do not affix the brake pipe to the crown. Scratch areas must be protected by a suitable sticker.
th
d dep
Threa /max. 10
8
min.
When using a DT Swiss fork the following installation of the brake pipe is recommended.
11
3.5.2 INSTALLATION OF THE BRAKE
INFORMATION
All DT Swiss forks, models 2009 onwards, are made for the post mount brake standard for a disc brake diameter of 160mm. For
disc brake diameters larger than 160mm, a special adapter from the brake manufacturer must be used
3.6 FRONT WHEEL
3.6.1 TYRE SIZES
CAUTION
After tyre installation, a collision test must be made!
• Inflate tyre up to maximum allowed pressure. The maximum pressure will be defined either by the tyre or by the rim. Authoritative is the lower pressure of the two parts.
• Deflate fork and compress completely .
• Check if the tyre touches either the fork crown or the fork stanchions. If this is the case, the tyre must not be used.
•
Model
Max. diameter of the wheel
Max. tire width
686 mm
59 mm
690 mm
65 mm
756 mm
62 mm
3.6.2 INSTALLING THE FRONT WHEEL WITH QUICK RELEASE (QR)
CAUTION
Grinding the security tabs of the fork dropouts away could lead to lose the front wheel during the ride and is strongly prohibited. Any modification leads to the loss of any warranty claim.
Install the wheel according to the instructions of the manufacturer.
3.6.3 INSTALLING THE FRONT WHEEL WITH FORKS WITH THRU AXLE RWS
(Option XRM, XMM and EXM Models)
•
•
•
•
•
•
Remove thru axle from the fork.
Lightly grease the thru axle, especially the thread of the thru axle.
Position the front wheel between the dropouts, so that the hole of the hub and the dropouts are aligned.
Push the thru axle into the right dropout, through the hub until the thru axle touches the thread of the left dropout.
Screw the thru axle into the thread and tighten the RWS lever hand-tight (min. 15 Nm).
For the end position of the RWS lever, follow the steps in the picture.
1
2
1. Lift lever
2. Rotate the lever in the desired position
3. Release lever
INFORMATION
Do not use the red bolt for opening or closing the RWS.
12
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 correctly adjusted, the front wheel can better follow the ground during the ride.
Use
15% of full travel
Cross Country/Race
20% of full travel
Marathon/Tour
25% of full travel
4.1.2 ADJUSTMENT OF THE AIR PRESSURE
CAUTION
Do not use the fork while the shock pump is mounted. This may cause the shock pump to touch the frame and the valvethread will break off.
INFORMATION
Only use a suitable shock pump to adjust the air pressure. We suggest to use the DT Swiss shock pump
(Art. Nr. FXTXXX0S000040223S)
In all DT Swiss fork models, the air spring is located in the left stanchion. By adjusting the air pressure, the spring 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 can slightly change
the total length of the fork.
•
•
•
•
•
SAG Guide value
• To measure the SAG you have to deactivate the function of your fork:
• EX-Models: deactivate the Launch control
• XM-Models: put the Single Shot or Twin Shot on position 1
• Push the o-ring on the right stanchion to the bottom, until it touches the wiper seal
• Sit with full equipment (backpack, helmet, shoes...) on the bike as you would sit during the ride. The fork goes down
because of your own weight.
• Step down of your bike and measure the distance between o-ring and wiper seal. This measurement is called SAG. The SAG
should be between 15% and 25% of the full travel and can be adjusted depending on the riding style and use.
ENGLISH
To set up the SAG, you will have to adjust the air pressure in your fork. You may eventually need the help of another person.
Position the fork resp. the bicycle that the valve on the left upper stanchion is upward.
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.
Screw the valve cap on to the valve-housing.
13
4.1.3 MAXIMUM AIR PRESSURE
Model
Max. diameter
ABS
203 psi/14 bar
174 psi/12 bar
4.1.4 RECOMMENDED AIR PRESSURE
XRC100
Rider weight (lbs/kg)
XRM100
XMM100 29"
XM120
XMM120 29"
XM140
XM150
EX150
88 / 40
80/5.5
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
220 / 100
116/8.0
110/7.6
109/7.5
104/7.2
122/8.4
116/8.0
113/7.8
109/7.5
232 / 105
128/8.4
122/8.4
119/8.2
113/7.8
245 / 110
133/9.2
126/8.7
123/8.5
117/8.1
DT Swiss forks use oil damping. We differentiate between:
• Rebound damping: Damping when the fork extends
• Compression damping: Damping when the fork compresses
Model
Adjustable Rebound damping
x
x (Twin Shot)
x
x (Twin Shot)
x
x
14
4.2.1 SINGLE SHOT
4.2.1.1 ADJUSTMENT OF THE REBOUND DAMPING
The lockout closes the compression damping circuit. The fork cannot be compressed anymore. A pressure control valve, called
«Blow off», protects the system against damages caused by impacts on the fork while the lockout is activated. A whistling
sound can be heard when the blow off opens, this sound is normal and cannot be seen as a failure.
To activate the lockout turn the lever from position 1 to position 2
Pos 1
Single Shot
Lockout open
Pos 2
Single Shot
Lockout closed
4.2.1.3 REMOTE LOCKOUT
MANIPULATION
To activate the remote lockout push the remote lever to position 2. To deactivate it pull it back to position 1.
ADJUSTMENT
• Deactivate the lockout function by pulling the remote lever to position 1. The cable of the remote lockout is loose.
• Screw the adjustment screw of the pipe until block
• Unscrew the adjustment screw step by step to adjust the tension of the cable
• Control the lockout function by pushing the remote lever from position 1 into position 2. The adjustment is correct once the
fork cannot be compressed anymore.
Pos 1
Single Shot
Lockout open
Pos 2
Single Shot
Lockout closed
15
ENGLISH
You can turn the red wheel on top of the right stanchion to adjust the rebound damping. Clockwise to get it slower, counterclockwise to get it faster.
4.2.2 TWIN SHOT
4.2.2.1 ADJUSTMENT OF THE REBOUND DAMPING
You can turn the red wheel on top of the right stanchion to adjust the rebound damping. Clockwise to get it slower, counterclockwise to get it faster.
4.2.2.2 ADJUSTMENT OF THE COMPRESSION DAMPING
You can turn the blue wheel on top of the right stanchion to adjust the compression damping. Clockwise to get it harder,
counterclockwise to get it softer.
You can activate the rebound lockout by turning the lever from position 1 to position 2. The fork cannot extend to full travel
anymore.
If a big force applies on the front wheel, the fork will be lowered by about a third of its full travel, during the ride it always
comes back to this position
INFORMATION
Once the fork is lowered, it can be that it slowly extends of about 6 to 8mm during a few seconds, before getting stable.
You can activate the compression damping by turning the lever to position 3. The fork cannot move anymore
INFORMATION
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 the lever to position 1 and close the lockouts again by moving the lever to position 3.
Pos 1
16
Lockout open
Pos 2
Rebound lockout
activated
Pos 3
Compression lockout
activated
4.2.2.4 REMOTE LOCKOUT
MANIPULATION
Push the remote lever to position 2 to activate the rebound lockout. Pull the remote lever back to position 1 to deactivate it.
Lockout open
Pos 2
Rebound Lockout activated
(only Twin Shot)
Pos 3
Compression Lockout
activated
Through horizontal or upside-down storage of the fork, air gets into the damping oil chamber. The damping as well as the
Launch Control function does not work correctly. By compressing the fork repeatedly in upright position, the oil chamber gets
bled and the damping as well as the Launch Control function will work correctly.
4.2.3.1 ADJUSTMENT OF THE REBOUND DAMPING
You can turn the red wheel on top of the right stanchion to adjust the rebound damping. Clockwise to get it slower, counterclockwise to get it faster.
4.2.3.2 ADJUSTMENT OF THE COMPRESSION DAMPING
To adjust the low speed compression, turn the blue adjuster knob at the bottom end of the right stanchion. The turning-direction is shown on the dropout by +/– symbols.
+ Increase of the low speed compression, the fork gets harder
– Decrease of the low speed compression, the fork gets softer
17
Pos 1
ADJUSTMENT
• Deactivate the lockout function by pulling the remote lever to position 1. The cable of the remote lockout is loose.
• Screw the adjustment screw of the pipe until block
• Unscrew the adjustment screw step by step to adjust the tension of the cable
• Control the lockout function by pushing the remote lever from position 1 into position 2. The adjustment is correct once the
fork cannot be compressed anymore.
ENGLISH
Push the lever to position 3 to activate the compression lockout. Pull the remote lever back to position 1 to deactivate it. When
you deactivate the compression lockout, the remote lever springs automatically back to position 1.
4.2.3.3 ADJUSTEMENT OF LAUNCH CONTROL AND THRESHOLD
INFORMATION
If low speed compression is turned to maximum then it may have an influence on the Launch Control function if the Threshold
Adjuster is in position 1. In such a case decrease the low speed compression by turning the blue adjuster knob at the bottom
end of the right stanchion or increase the release force of the Launch Control function by turning the nickel-plated adjuster
lever clockwise.
• ACTIVATING:
Press the red adjuster knob on the right stanchion down completely and compress the fork. After strongly compressing the
fork, the fork will rebound to a pre-defined level.
• DEACTIVATING:
CAUTION
The fork can rebound very fast, when deactivating the Launch Control function manually. Therefore the head of the rider
must not be over the stem or the handlebar.
Adjustment of the release force may not be made when the bicycle is in motion!
The Launch Control function can be deactivated manually or automatically.
The force needed to deactivate the Launch Control can be adjusted by turning the grey lever on the top of the right stanchion.
Clockwise to get the force higher, counterclockwise to get it lower.
• Manually: Pull the red adjuster knob on the top of the right stanchion out. The fork expands completely.
• Automatically: Through a shock from the ground (e.g. riding over obstacles) the Launch Control function will be automatically deactivated. The release force to deactivate the Launch Control function can be adjusted using the nickel-plated
adjuster lever (Threshold Adjuster).
5 TROUBLE SHOOTING
5.1 BEDDING-IN TIME
Some parts of the new fork may need some bedding-in or sagging-in time. Especially the bushings of the new fork 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.
Check the fork for externally visible damage such as cracks or deep scratches. Listen for unusual noises during slow riding or
braking in a secure area. Do not use a defective fork!
If one of the mentioned incidences above apply, contact your local dealer or the responsible DT Swiss Service Center.
5.3 AFTER A CRASH
After a crash the danger of damage is very high. Check your fork thoroughly after each crash.
Visual check: Look for damage such as cracks, breaks, oil leakages and scratches etc.
Functional check: Try out whether all functions such as damping, suspension and Lockout or Launch Control work correctly.
Acoustic check: Listen for unusual noises during slow riding or braking in a secure area.
CAUTION
Do not use a defective fork! Contact your local dealer or the responsible DT Swiss Service Center to repair the damage.
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 function of the fork and may be noticeable. A possible
noticeable bushing clearance does not automatically mean an excessive wear out.
18
5.5 SET UP ADVICE
Please follow the following advice to set up your fork
Cause
Solution
The fork is not responding properly.
The bedding-in time is not over
Continue riding
The air pressure is too high.
Decrease the air pressure controlled
using a suitable shock pump.
To much low speed compression.
Decrease low speed compression.
The fork needs a service for lubrication
Contact your local dealer or the
responsible DT Swiss Service Center to
change the lubricating oil
The air pressure is too low.
Increase the air pressure controlled
using a suitable shock pump.
Not enough low speed compression.
Increase low speed compression.
The fork does not rebound completely
and hardens on fast repetitive bumps.
Too much rebound damping.
Decrease rebound damping.
The fork rebounds too fast, the front
wheel loses contact to the ground
after bumps or it slides in curves.
Not enough rebound damping.
Increase rebound damping.
Too fast decreasing of the air pressure.
Increase the air pressure controlled
using a suitable shock pump until
achieving the initial air pressure or pull
the fork manually apart and hold it a
short time pressed against the top out.
Then decrease the air pressure controlled using a suitable shock pump.
The fork loses its damping characteristics and does loud noises
The air chamber on the damping unit
side loss its pressure
Contact your local dealer or the
responsible DT Swiss Service Center to
solve this problem
The lockout does not work well
Leaks inside the cartridge
Contact your local dealer or the
responsible DT Swiss Service Center to
solve this problem
6-8mm rebound until the bypass channel is completely closed.
Normal effect due to the construction.
The performance of the fork is not
affected
Backflow of oil thru micro gaps in the
upper damping unit.
This is acceptable if the fork gets to its
full travel in more than one hour.
Leaks inside the cartridge
Contact your local dealer or the
responsible DT Swiss Service Center to
solve this problem
There is air in the oil chamber.
By compressing the fork repeatedly
in upright position, the oil chamber
gets bled and the damping as well
the Launch Control function will work
correctly
The fork bottoms out on moderate
bumps.
ENGLISH
Problem
AIR SPRING
The fork becomes compressed while
decreasing the air pressure.
TWIN SHOT
The fork slowly extends while the lever
is in position 2 (rebound lockout)
The fork quickly extends while the
lever is in position 2 (rebound lockout)
Lockouts do not work well
LAUNCH CONTROL
The damping as well as the Launch
Control function do not work properly
19
LAUNCH CONTROL
Even with activated Launch Control
function the fork expands slowly.
There is air in the oil chamber.
By compressing the fork repeatedly
in upright position, the oil chamber
gets bled and the damping as well
the Launch Control function will work
correctly
The seal is defective.
The defective seal must be replaced
by the responsible DT Swiss Service
Center.
Normal flow through micro holes in
the seal.
This is acceptable if the fork gets to its
full travel in more than one hour.
The Launch Control adjusting knob
releases immediately after activating.
The release force is to low.
The release force must be increased by
turning the nickel-plated adjuster lever
clockwise.
Through small shocks from the ground,
the fork leaps back to ground position.
The compression damping is completely closed
Slightly open the compression damping
Even with a big impact on the front
wheel, the Launch Control does not
release.
The release force is too high
The release force must be decreased by
turning the nickel-plated adjuster lever
counterclockwise
The Remote Lockout lever does not
work properly
The sliding surface of the lever is dirty
or not properly lubricated
Wash the Remote Lockout lever on the
handlebar with water and properly
lubricate it with oil
The Remote Lockout function works
correctly, but the lever does not stay in
the desired position.
The tension of the Remote Lockout
cable is too high.
Turn the knurled cable adjusting screw
clockwise, so that the cable tension
is reduced. At the same time, check
whether
the lever now stays in the desired
position.
The lever-index is worn out.
Contact your local dealer or the
responsible DT Swiss Service Center,
to have the Remote Lockout lever
replaced.
This can have several causes for example: crashes, dirt,
wear, etc.
Contact your local dealer or the
DT Swiss Service Center, to have the
Remote Lockout cable replaced.
REMOTE LOCKOUT
The Remote Lockout cable
is defective.
20
6 MAINTENANCE
To ensure a long product life, follow the instructions below:
Clean the fork with a damp cloth. Remove dirt between stanchion/lower unit.
Never use aggressive cleaners that attack rubber materials (main seals)!
Never use high pressure cleaners (e.g. steam jet). Water and dirt can get into the system and damage it!
Remove all visible, dried dirt form the area of the main seal. This will prevent dirt from getting into the fork.
It is not necessary to additionally grease the main seal. To get a good lubrication of the main seal you can regularly turn
your bike/fork upside down
• After the cleaning, lubricate regularly the sliding surface of the remote lever on the handlebar.
ENGLISH
•
•
•
•
•
INFORMATION
If service intervals are not respected any warranty claims can be denied.
x
Check the whole fork for damages, scratches or grooves
x
Check the air pressure
x
Check and lubricate the remote lever on the handlebar
x
Check the torque of all the
parts screwed on the fork
x
After 50 hours
Remove the lower unit,
check the bushings and
change the lubricating oil
x
Check and lubricate the ABS
spring system
x
Big service in a DT Swiss
Service Center
Once a year
After each ride
Wash the whole fork, only
with smooth soap and water
To get the most fun and security out of your DT Swiss fork, you have to get it to service regularly. If you use your bike in extreme conditions, you will have to service your components sooner.
x
7 DT S W I S S S E R V I C E C E N T E R S
Please find the list of our Service Centers on www.dtswiss.com.
8 WA R R A N T Y
8.1 WARRANTY TERMS EUROPE
The first owner has the right to claims under the guarantee as covered by -general law against the sales contract partner
(retailer). In addition to the general -guarantee required by law, DT Swiss LTD with head office in Biel/Switzerland, guarantees
the DT Swiss fork for two years (24 months) from the date of purchase. A valid purchasing receipt has to be delivered with any
warranty claim.
There shall be no claim under the guarantee for:
normal wear of parts, subject to wear (bushings, seals, sliding surfaces, -shifters etc.)
incorrect assembly or in combination with products that do not fit
incorrect maintenance, incorrect repair or alteration
incorrect use, bad treatment, misuse, negligence, carelessness -during -installation, maintenance or use, commercial use or use
in cycling -competitions
delivery and transport damage
DT Swiss LTD shall reject any liability for both indirect damage caused by -accidents and consequential damage. In case of warranty repair/replacement please -contact the dealer where you bought the product. DT Swiss forks which have to be -checked,
can be sent postage paid to a DT Swiss Service Center.
Legal venue and place of performance is Biel (Switzerland). Swiss law shall apply. Subject to technical changes. Please keep the
user‘s manual and warranty for future use.
21
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 lack of 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 WARRANTY LASTS, 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.
To take advantage of this warranty, the product or part must be returned for examination, postage prepaid, to the dealer
where you bought the product or to a DT Swiss Service Centre. 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.
22
1 I N F O R M AT I O N S G E N E R A L E S
1.1 INFORMATIONS DE SECURITE
ENGLISH
•
•
•
•
•
•
1.2 NOTIONS
Modèles DT Swiss XRC
210 lbs / 95 kg
Modèles DT Swiss XRM
245 lbs / 110 kg
Modèles DT Swiss XM
245 lbs / 110 kg
Modèles DT Swiss EX
245 lbs / 110 kg
1.5 UTILISATION
XR Cross Race
XM Cross Mountain
EX Enduro Cross
FR Freeride
XRC
XRM
XMC
XMM
EXC
EXM
23
Modèles DT Swiss XR
ABS
Modèles DT Swiss XM
• S ingle Shot avec option
Remote Control
• Twin Shot avec option
Remote Control
Modèles DT Swiss EX
Launch Control
2.4 TWIN SHOT
24
3 M O N TAG E
3.1 INFORMATIONS GENERALES
ENGLISH
25
3.2 RACCOURCIR ET PREPARER LE PIVOT AU MONTAGE
Auflagefläche Steuersatzkonus unten
Supporting area headset base plate
Base du jeu de direction
3.2.1.1 MATERIEL REQUIS
•
•
•
•
•
•
26
3.2.1.2 PROCEDURE
ENGLISH
3.2.2 SPECIAL POUR PIVOT EN ALUMINUM
3.2.2.1 MATERIEL REQUIS
3.2.2.2 PROCEDURE
27
28
Pos 1
Pos 2
Pos 3
•
•
•
•
•
•
ENGLISH
•
•
•
•
•
29
Diamètre maximal
Modèles DT Swiss XRC
185 mm
Modèles DT Swiss XRM
210 mm
Modèles DT Swiss XM
Modèles DT Swiss EX
INFORMATION
3.5.2 MONTAGE DU FREIN
ATTENTION
30
Modèles DT Swiss XRC
686 mm
59 mm
Modèles DT Swiss XRM 26"
690 mm
65 mm
756 mm
62 mm
Modèles DT Swiss XM 26"
Modèles DT Swiss EX 26"
Modèles DT Swiss XMM 29"
3.6.2 MONTAGE DE LA ROUE AVANT AVEC SERRAGE RAPIDE (QR)
ATTENTION
1
2
INFORMATION
31
Modèle
ENGLISH
4 M A N I P U L AT I O N
4.1 RESSORT
4.1.1 REGLAGE DU SAG
Utilisation
Cross Country/Race
Marathon/Tour
INFORMATION
32
4.1.3 PRESSIONS MAXIMALES
Modèle
Modèles DT Swiss XRC
203 psi/14 bar
Modèles DT Swiss XRM 26"
174 psi/12 bar
Modèles DT Swiss XM 26"
ENGLISH
Modèles DT Swiss EX 26"
Modèles DT Swiss XMM 29"
4.1.4 PRESSIONS RECOMMANDEES
XM120
XMM120 29"
XM140
XM150
EX150
88 / 40
80/5.5
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
220 / 100
116/8.0
110/7.6
109/7.5
104/7.2
122/8.4
116/8.0
113/7.8
109/7.5
232 / 105
128/8.4
122/8.4
119/8.2
113/7.8
245 / 110
133/9.2
126/8.7
123/8.5
117/8.1
XRM100
XMM100 29"
XRC100
4.2 AMORTISSEMENT
Modèles DT Swiss XR
x
x (seulement Twin Shot)
Modèles DT Swiss XM
x
x
x
33
4.2.1 SINGLE SHOT
4.2.1.1 REGLAGE DE L'AMORTISSEMENT EN DETENTE
Pos 1
Single Shot
Lockout ouvert
Pos 2
Single Shot
Lockout fermé
4.2.1.3 REMOTE LOCKOUT
Pos 1
34
Single Shot
Lockout ouvert
Pos 2
Single Shot
Lockout fermé
4.2.2 TWIN SHOT
4.2.2.1 REGLAGE DE L'AMORTISSEMENT EN DETENTE
ENGLISH
4.2.2.2 REGLAGE DE L'AMORTISSEMENT EN COMPRESSION
INFORMATION
INFORMATION
Pos 1
Pos 2
Pos 3
35
4.2.2.4 REMOTE LOCKOUT
Pos 1
Pos 2
Pos 3
4.2.3.2 REGLAGE DE L'AMORTISSEMENT EN COMPRESSION
36
4.2.3.3 LAUNCH CONTROL ET REGLAGE DU THRESHOLD
INFORMATION
• Activer le Launch Control
5 TROUBLE SHOOTING
5.1 RODAGE
5.2 AVANT CHAQUE UTILISATION
5.3 APRES CHAQUE CHUTE
ATTENTION
37
ATTENTION
ENGLISH
5.5 CONSEILS DE REGLAGE
Cause
38
ENGLISH
39
x
x
x
x
x
x
x
Grand service dans un DT
Swiss Service Center
40
x
7 DT S W I S S S E R V I C E C E N T E R
Vous trouvez les adresses de tous les DT Swiss Services Centers sous www.dtswiss.com
41
ENGLISH
1 A L LG E M E I N E I N F O R M AT I O N E N
1.1 SICHERHEITSINFORMATIONEN
1.4 MAXIMALE FAHRERGEWICHTE
210 lbs / 95 kg
245 lbs / 110 kg
245 lbs / 110 kg
245 lbs / 110 kg
1.5 EINSATZBEREICHE
XR Cross Race
XRC
XRM
XMC
XMM
EXC
EXM
42
XM Cross Mountain
EX Enduro Cross
FR Freeride
• Single Shot mit optionalem
Remote Control
• Twin Shot mit optionalem
Remote Control
Launch Control
2.4 TWIN SHOT
43
Modell
ENGLISH
2.1 ÜBERSICHT GABELMODELLE
44
ENGLISH
ca. 2mm
Auflagefläche Steuersatzkonus unten
Supporting area headset base plate
Base du jeu de direction
45
46
3.4.2 MONTAGE REMOTE LOCKOUT
3.4.2.1 BENÖTIGTES MATERIAL
•
•
•
•
47
3.4 REMOTE LOCKOUT
3.4.1 ALLGEMEINE INFORMATIONEN
ENGLISH
3.4.2.3 WEITERE SCHRITTE SINGLE SHOT
3.4.2.4 WEITERE SCHRITTE TWIN SHOT
•
•
•
•
Pos 1
48
Lockout offen
Pos 2
Pos 3
3.5 BREMSEN
3.5.1 ALLGEMEINE INFORMATIONEN
185 mm
210 mm
INFORMATION
49
ENGLISH
686 mm
59 mm
690 mm
65 mm
756 mm
62 mm
1
2
INFORMATION
50
Cross Country/Race
Marathon/Tour
ENGLISH
51
4.1.3 MAXIMALE LUFTDRÜCKE
Modell
Max. Luftdruck
ABS
203 psi/14 bar
174 psi/12 bar
XRM100
XMM100 29"
XM120
XMM120 29"
XM140
XM150
EX150
88 / 40
80/5.5
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
220 / 100
116/8.0
110/7.6
109/7.5
104/7.2
122/8.4
116/8.0
113/7.8
109/7.5
232 / 105
128/8.4
122/8.4
119/8.2
113/7.8
245 / 110
133/9.2
126/8.7
123/8.5
117/8.1
x
x (Nur Twin Shot)
x
x (Nur Twin Shot)
x
x
52
ENGLISH
4.2.1.2 LOCK OUT
Pos 1
Single Shot
Lockout offen
Pos 2
4.2.1.3REMOTE LOCK OUT
Pos 1
Single Shot
Lockout offen
Pos 2
53
4.2.2.3 LOCK OUT
INFORMATION
INFORMATION
Pos 1
54
Lockout offen
Pos 2
Pos 3
4.2.2.4 REMOTE LOCK OUT
Pos 1
Lockout offen
Pos 2
Pos 3
ENGLISH
55
4.2.3.3 LAUNCH CONTROL UND THRESHOLD VERSTELLUNG
INFORMATION
• AKTIVIEREN:
5.3 NACH JEDEM STURZ
56
5.5 EINSTELLUNGSTIPPS
Tipp
Problem
ENGLISH
57
REMOTE LOCKOUT
58
x
x
x
x
x
x
x
Grösser Service im DT Swiss
Service Center
ENGLISH
x
59
7 DT S W I S S S E R V I C E C E N T E R
Sie finden alle DT Swiss Service Center unter www.dtswiss.com.
60
61
ENGLISH
62
63
ENGLISH
DT Swiss, Inc.
2493 Industrial Blvd.
USA - Grand Junction, CO 81505
Phone +1 (970) 242 92 32
Fax +1 (970) 244 89 18
Mail: [email protected]
DT Swiss (Asia) Ltd.
No. 26, 21st Road Industrial Park
Taichung City
Taiwan R.O.C
Phone +886 (423) 585256
Fax +886 (423) 598290
Mail: [email protected]
www.dtswiss.com
printed on 100% recycling paper
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