DT SWISS F 535 ONE Trail Bike Forks Instruction Manual

DT SWISS F 535 ONE Trail Bike Forks

Product Information

• Product Name: F 535 / F 535 ONE 44 MM
• User Manual Version: V2023.05
• Fits: (suspension fork)
• Includes: Assembly, adjustment, maintenance, and care of the suspension fork, as well as warranty terms.

Safety Information
General Safety:

• E-Bike (Bike Type E-Bike)
•  (Max. System Weight)*: 150 kg
• (Category of Use):
  • (Category 3) – non-E-Bike: 130 kg
  •  (Category 4) . DT Swiss

Product Usage Instructions

Montage (Assembly) (Installing the Suspension Fork into the Frame)

1. Clean the stem, parts of the headset, and suspension fork.
2. The stem should not have any sharp edges. If there are sharp edges, do not use the cone.
3. The gap between the stem and the top of the fork steerer tube should be at least 7 mm.
4. The stem should not have any sharp edges.
5. Insert the fork steerer tube through the head tube.
6. Attach the manufacturer’s specified components to the fork steerer tube.
7. Attach the spacers (2) with a minimum of 5 mm and a maximum of 30 mm.
8. Attach the stem (1) to the fork steerer tube.
9. Tighten the stem attachment screws to the manufacturer’s specified torque.

(Installing the Wheel)

1. Position the wheel in the dropout.
2. Insert the RWS through the dropout and the hub.
3. To remove the RWS lever if necessary, pull it off.
4. Insert the RWS lever, lift it up, and release it.

(Brake Assembly)
Follow the manufacturer’s instructions for brake assembly.

(Mounting the Brake Line Holder)

1. Click the brake line holder onto the brake line.
2. Screw in the mounting screws and tighten them to a torque of 1.5 Nm.

(Mounting the Mudguard)
Follow the manufacturer’s instructions for mudguard assembly.

Setup(Adjusting Air Pressure)
Refer to the provided table to adjust the air pressure based on the system weight and desired travel range.

GENERAL INFORMATION

• This user manual is intended for the user of the fork. It includes information on the assembly, setup, maintenance and care of the fork along with the provisions of the warranty.
• For further information and activities refer to www.dtswiss.com.
• Users must have read and understood the manual before use. Third-party users must also be informed about the following provisions. Keep this user manual handy / for reference in case you need to refer to it later.

SAFETY

GENERAL SAFETY INFORMATION

DANGER: Incorrect handling, installation, maintenance or servicing can lead to accidents causing severe injuries or death!

• Compliance with the following provisions is a prerequisite for accident-free use and faultless performance.
• Assembly and maintenance of the fork requires a basic knowledge of handling bicycle components. If in doubt, contact your dealer.
• The fork should only be used in accordance with its intended use. Otherwise the user shall assume responsibility.
• The fork must be compatible with all parts of the bicycle.
• Before riding for the first time, the fork must be checked for ease of action.
  • The fork crown must not touch the down tube when the handlebar is fully turned!
  • The fender must not touch the down tube when the fork is fully compressed!
  • The tire must not touch the fender or fork when the fork is fully compressed!
• Contact between a cable and the steerer tube can cause indentations, which can weaken the steerer tube and lead to failure. In the case of cables routed in the frame, cables or brake hoses must not touch the steerer tube.
• Contact between a cable and the fork crown can cause scuff marks. Cover possible contact points with a protective film.
• Maintenance and repair of the fork must only be carried out by a trained specialist.
• None of the add-on parts must have any sharp edges.
• Only use original DT Swiss accessories and spare parts.
• The fork must not be changed or modified.
• The fork must not be used if it is damaged or there are any signs of damage. If in doubt, contact your dealer.

COMPATIBILITY

• Do not use front wheels with a hub motor.
• Do not use the fork on bicycles with bicycle trailers.

INTENDED USE AND MAXIMUM SYSTEM WEIGHT

• The intended use for DT Swiss products is classified in five categories from riding on paved roads to downhill and freeride riding.
• Only use DT Swiss products within their intended category (or lower). Otherwise the user shall assume full responsibility.

type of bicycle| max. system weight*| intended use (description of the category, see below)
---|---|---
E-Bike| 150 kg| category 3
non-E-Bike| 130 kg| category 4

maximum system weight = rider, bicycle, equipment and luggage.

1. Category 1 represents the use of DT Swiss components on mainly paved surfaces. The ground contact of the tires can be lost unintentionally for a short time.
2. Category 2 represents the use of DT Swiss components under the conditions of category 1 as well as on mostly paved and partly unpaved surfaces with a slight gradient. The tires may briefly lose contact with the ground when riding over steps up to 15 cm in height.
3. Category 3 represents the use of DT Swiss components under the conditions of categories 1 and 2 as well as on paved and rough, unpaved surfaces by riders with advanced riding skills. The tires may not always be in contact with the ground. Occasional steps / jumps of approx. 60 cm height are permitted. Due to the weight-optimized design of the components, despite complying with these conditions, this use can also cause damage to the material in the event of riding errors, which can also lead to injuries to the rider.
4. Category 4 represents the use of DT Swiss components under the conditions of categories 1, 2 and 3 as well as in very rough, blocked terrain with jumps / steps up to approx. 120 cm height and speeds up to 40 km/h by riders with very good riding skills. DT Swiss components in this category must be checked for possible damage after each ride due to the high loads. Impairments of the product service life cannot be ruled out.
5. Category 5 represents the use of DT Swiss components under the conditions of categories 1, 2, 3 and 4 as well as in extremely steep and rough terrain with very large jumps / steps and speeds above 40 km/h by riders with exceptionally good riding skills. DT Swiss components in this category may also be used in bike parks and on downhill tracks. DT Swiss components in this category must be checked for possible damage after each ride due to the very high loads, since existing damage can lead to failure of the component even at significantly lower loads during subsequent usage. The product service life can be impacted by this extreme use.

ASSEMBLY

DANGER: Risk of accident caused by damage resulting from add-on parts with sharp edges! Installing parts with sharp edges can damage the fork.

• Ensure that none of the add-on parts such as the hub or thru axle etc. has sharp edges.

SHORTENING THE STEERER

1. Clamp the steerer tube into a saw guide and shorten it with a hand saw.
2. Carefully smooth the inside and outside of the cut edges of the steerer tube with abrasive paper.

INSTALLING THE FORK IN THE FRAME

1. Clean the stem, parts of the headset and fork.

2. Check the stem:

3. The height of the flange of the discontinuous clamp area of the stem (A) must be at least

4. The clamp height of the stem must be a maximum of 45 mm.

5. The stem must not exhibit any sharp edges.

6. Check the bearing cone for damage and sharp edges. If damage or sharp edges are present, the cone must not be used.

7. Fit the star fangled nut and headset and their components (3) as per the manufacturer’s instructions.

8. Push the steerer tube through the head tube.

9. Place the headset parts (3) on the steerer tube in accordance with the manufacturer’s specifications.

10. Place the spacer (2) on the steerer tube (4) with a min. installation height of 5 mm and max. of 30 mm.

11. Place the stem (1) on the steerer tube.

12. Attach the spacer (2) on the stem (1) with a min. installation height of 5 mm.

13. Ensure that the spacer projects 2 to 3 mm above the handlebar stem.

14. Set the play of the headset according to the manufacturer’s specifications.

15. Tighten the fixing screws for the stem to the torque specified by the manufacturer.

16. Check to ensure the fork is installed correctly.

INSTALLING THE WHEEL

1. Clean and lightly grease the thru axle (RWS). The thread of the RWS and the thread of the fork`s dropout must be free of grease.
2. Clean the contact surfaces between the hub and the fork and check for sharp edges. If sharp edges are present, the hub must not be used.
3. Position the wheel between the fork dropouts.
4. Push the RWS through the dropouts and hub.

FITTING THE RWS:
The RWS lever can be removed if necessary (D).
ATTENTION: Always ensure that the plug in lever is properly installed so that it does not rattle loose and get lost.

1. Turn the RWS clockwise and secure as tightly as possible by hand (min. 15 Nm / max. 20 Nm).
2. To check that the torque is correct, pull off the lever (D) and tighten the RWS to min. 15 Nm / max. 20 Nm with a torque wrench.
3. Insert the RWS lever, raise it (A), turn it to the required position (B) and let go (C).
4. Check to ensure the wheel is secured in the fork.

OPENING THE RWS

1. Insert the RWS lever and turn anticlockwise until the RWS can be pulled out of the fork dropouts.

CHECKS BEFORE EVERY RIDE
Before every trip, ensure that the wheel is securely mounted in the fork. Ensure that the RWS is tightened to at least 15 Nm.

ASSEMBLING THE BRAKE
The fork has a PM 7″ brake calliper mount. If the brake calliper is mounted on the fork without an adapter, a Ø180 mm brake disc can be used. A brake rotor up to Ø203 mm can be used with a suitable adapter. Do not use brake rotors bigger than 203 mm!

1. Ensure that the thread lengths of the fastening screws on the brake calliper or brake adapter are at least 8 mm and no more than 15 mm (see figure opposite).
2. Fit and adjust the brake according to the manufacturer’s specifications.
3. Check that all components are moving freely.

FITTING THE BRAKE HOSE HOLDER

1. Click the brake hose holder onto the brake hose.
2. Insert the brake hose holder with the brake hose clicked in into the mounting hole on the fork bridge.
3. Insert the screw through the fork bridge from behind, screw it into the brake hose holder and tighten with a torque of 1 Nm.
4. Make sure that the brake hose does not touch the fork crown during operation and does not impair the function of other components.

FITTING THE FENDER

1. Attach the fender to the rear of the fork bridge.
2. Insert both fixing screws and tighten them to 1,5 Nm.

ATTENTION: Do not exceed the specified tightening torque of the fixing screw under any circumstances! This can damage the fork threads beyond repair.

CHECKING THE FORK

1. Check that there is no play on the fork or wheel.
2. Check the freedom of movement of the tire in use.
   • Inflate the tires up to their maximum approved pressure. The lower pressure specified for the tire or rim applies.
   • Let all the air out of the fork.
   • Fully compress the fork.
   • When the fork is fully compressed there must be a gap of at least 6 mm between the tire and the fork and/or mudguard.
3. Adjust the air pressure on the fork and tire to the required operating pressure.
4. Turn the fork in both directions and make sure that it turns freely. The fork and the fender must not interfere with other parts or vice versa!
5. Check the functionality of the fork.
6. If there are any problems or malfunctions, contact the dealer or the DT Swiss Service Center.

SETUP

• In addition to the information shown here, you will find useful tips and videos on adjusting the fork at www.setupguide.dtswiss.com.
• Scan the adjoining QR code with your mobile phone to be forwarded directly to the DT Swiss website.

ADJUSTING THE AIR PRESSURE
The values given here are the recommendations of DT Swiss. The air pressure should be adjusted in accordance with the rider‘s personal preferences.

F 535 ONE

system weight [kg]

| Travel
---|---
120 mm [bar/psi]| 130 mm [bar/psi]| 140 mm [bar/psi]| 150 mm [bar/psi]| 160 mm [bar/psi]
50| 3.2| 46| 2.9| 42| 2.6| 38| 2.4| 35| 2.3| 33
55| 3.7| 54| 3.3| 48| 3| 44| 2.8| 41| 2.6| 38
60| 4.1| 59| 3.7| 54| 3.4| 49| 3.2| 46| 3| 44
65| 4.6| 67| 4.2| 61| 3.8| 55| 3.6| 52| 3.3| 48
70| 5| 73| 4.6| 67| 4.2| 61| 3.9| 57| 3.7| 54
75| 5.5| 80| 5| 73| 4.6| 67| 4.3| 62| 4| 58
80| 5.9| 86| 5.4| 78| 5| 73| 4.7| 68| 4.4| 64
85| 6.4| 93| 5.8| 84| 5.4| 78| 5| 73| 4.7| 68
90| 6.8| 99| 6.3| 91| 5.8| 84| 5.4| 78| 5.1| 74
95| 7.3| 106| 6.7| 97| 6.2| 90| 5.8| 84| 5.4| 78
100| 7.7| 112| 7.1| 103| 6.6| 96| 6.2| 90| 5.8| 84
105| 8.2| 119| 7.5| 109| 7| 102| 6.5| 94| 6.1| 88
110| 8.6| 125| 7.9| 115| 7.4| 107| 6.9| 100| 6.5| 94
115| 9.1| 132| 8.4| 122| 7.8| 113| 7.3| 106| 6.8| 99
120| 9.5| 138| 8.8| 128| 8.1| 117| 7.6| 110| 7.2| 104
125| 10| 145| 9.2| 133| 8.5| 123| 8| 116| 7.5| 109
130| 10.4| 151| 9.6| 139| 8.9| 129| 8.4| 122| 7.9| 115
135| 10,9| 158| 10| 145| 9,3| 135| 8,8| 128| 8,2| 119
140| 11,3| 164| 10,5| 152| 9,7| 141| 9,1| 132| 8,6| 125
145| 11,8| 171| 10,9| 158| 10,1| 146| 9,5| 138| 8,9| 129
150| 12,2| 177| 11,3| 164| 10,5| 152| 9,9| 144| 9,3| 135
max. air pressure:| 13.6| 197| 12.8| 186| 12.1| 175| 11.3| 164| 10.6| 154
F 535

system weight [kg]

| Travel
---|---
120 mm [bar/psi]| 130 mm [bar/psi]| 140 mm [bar/psi]| 150 mm [bar/psi]| 160 mm [bar/psi]
50| 2.8| 41| 2.5| 36| 2.2| 32| 2| 29| 1.9| 28
55| 3.3| 48| 2.9| 42| 2.6| 38| 2.4| 35| 2.2| 32
60| 3.7| 54| 3.3| 48| 3| 44| 2.8| 41| 2.6| 38
65| 4.2| 61| 3.8| 55| 3.4| 49| 3.2| 46| 2.9| 42
70| 4.6| 67| 4.2| 61| 3.8| 55| 3.5| 51| 3.3| 48
75| 5.1| 74| 4.6| 67| 4.2| 61| 3.9| 57| 3.6| 52
80| 5.5| 80| 5| 73| 4.6| 67| 4.3| 62| 4| 58
85| 6| 87| 5.4| 78| 5| 73| 4.6| 67| 4.3| 62
90| 6.4| 93| 5.9| 86| 5.4| 78| 5| 73| 4.7| 68
95| 6.9| 100| 6.3| 91| 5.8| 84| 5.4| 78| 5| 73
100| 7.3| 106| 6.7| 97| 6.2| 90| 5.8| 84| 5.4| 78
105| 7.8| 113| 7.1| 103| 6.6| 96| 6.1| 88| 5.7| 83
110| 8.2| 119| 7.5| 109| 7| 102| 6.5| 94| 6.1| 88
115| 8.7| 126| 8| 116| 7.4| 107| 6.9| 100| 6.4| 93
120| 9.1| 132| 8.4| 122| 7.7| 112| 7.2| 104| 6.8| 99
125| 9.6| 139| 8.8| 128| 8.1| 117| 7.6| 110| 7.1| 103
130| 10| 145| 9.2| 133| 8.5| 123| 8| 116| 7.5| 109
135| 10,5| 152| 9,6| 139| 8,9| 129| 8,4| 122| 7,8| 113
140| 10,9| 158| 10,1| 146| 9,3| 135| 8,7| 126| 8,2| 119
145| 11,4| 165| 10,5| 152| 9,7| 141| 9,1| 132| 8,5| 123
150| 11,8| 171| 10,9| 158| 10,1| 146| 9,5| 138| 8,9| 129
max. air pressure:| 13.2| 191| 12.4| 180| 11.7| 170| 10.9| 158| 10.2| 148

INCREASING THE AIR PRESSURE

1. Set the fork to “OPEN” mode (see Sec. 4.2 on page 25/ Sec. 4.3 on page 25).

2. Unscrew the valve cap.

3. Screw on the shock pump and inflate the fork up to the required pressure.
   Follow the instructions issued by the pump manufacturer!

   • With the shock pump attached, slowly compress the fork twice by about 10 mm and then decompress fully
   • This equalizes the positive and negative air chambers.

4. Once the pressure displayed on the shock pump stops changing after compression, the two air chambers have equalized.

5. Repeat steps 3 and 4 until the desired pressure is displayed on the shock pump after compression.

6. Unscrew the shock pump and screw the valve cap onto the valve.

REDUCING THE AIR PRESSURE

1. Set the fork to “OPEN” mode (see Sec. 4.2 on page 25/Sec. 4.3 on page 25).
2. Unscrew the valve cap.
3. GRADUALLY press the valve insert with a suitable object. or Screw on the shock pump and GRADUALLY reduce the air pressure by pressing the release valve on the shock pump.
4. With the shock pump attached, slowly compress the fork twice by about 10 mm and then decompress fully.
   • This equalizes the positive and negative air chambers.
   • Once the pressure displayed on the shock pump stops changing after compression, the two air chambers have equalized.
5. Repeat steps 3 and 4 until the desired pressure is displayed on the shock pump after compression.
6. Unscrew the shock pump and screw the valve cap onto the valve.

SETTING THE RIDING MODE [F 535 ONE]
The riding mode setting determines the compression speed of the fork. There are three settings. To adjust the setting, use the lever on the fork:

OPEN:
“OPEN” mode is the most sensitive, factory-set setting. The fork responds sensitively to small unevennesses in the terrain.

DRIVE: If the lever on the fork is moved to the middle position, the compression damping is partially closed. This makes the fork much more firm and encourages effective pedalling in situations where full performance is not required (uphill climbing on roads or easy trails, rides on level ground).

LOCK:
If the lever on the fork is moved to the “LOCK” position, the flow of oil is blocked. A blow-off valve opens the flow of oil in the event of heavy impacts and therefore prevents damage to the shock.

SETTING THE RIDING MODE [F 535] The riding mode setting determines the compression speed of the fork. There are two settings. To adjust the setting, use the lever on the fork:

OPEN:
“OPEN” mode is the most sensitive, factory-set setting. The fork responds sensitively to small unevennesses in the terrain.

LOCK:
If the lever on the fork is moved to the “LOCK” position, the flow of oil is blocked. A blow-off valve opens the flow of oil in the event of heavy impacts and therefore prevents damage to the shock.

The operation of the fork via a remote lever and the conversion of the control elements can be found in the Technical Manual of this fork at www.dtswiss.com.

ADJUSTING THE COMPRESSION

• In order to meet the requirements of all riders, the low-speed compression can be set.
• The fork is very sensitive and comfortable when the compression damping is fully open (counterclockwise to the stop).
• To use the full potential of the fork, we recommend using it with the compression damping fully open regardless of the rider’s weight and the bicycle. The compression damping can be incrementally increased for a less sensitive response.

ADJUSTING THE REBOUND

• The traction level regulates the rebound speed of the fork and can be set by turning the traction level adjuster.
  • To increase the rebound damping, turn the adjuster clockwise (lower rebound speed).
  • To decrease the rebound damping, turn the adjuster counterclockwise (= higher rebound speed).
• If the rebound damping is too low, the front wheel will rebound too quickly. A rebound damping that is set too low will be felt through the frame bouncing up when riding.
• If the rebound damping is too high, the front wheel can no longer follow rapid-succession impacts and the suspension hardens.
• The aim of the rebound setting is to absorb the rebound movement as effectively as possible based on the demands of the terrain. On fast, rough descents, for example, a lower
• rebound damping (= faster rebound speed) should be selected than on smooth descents without any major obstacles.
• We recommend a rebound setting according to the pressure inside the air chamber (see “4.1 Adjusting the air pressure“):

The adjoining values are our recommendation for an ambient temperature of approx. 25° C. Since the viscosity of the oil changes with the ambient temperature, the rebound setting should be adjusted accordingly. The rebound damping should be opened at cold temperatures and closed at hot temperatures. For example at 0° C it is recommended to open the rebound by 6 clicks compared to the above value.

TUNING

APT (ADAPTABLE PROGRESSION TUNE)

• The APT (Adaptable Progression Tune) system allows the rider to adjust the progression of the air spring curve by adding or removing volume spacers in the fork‘s air chamber.
• The suspension fork is supplied with one mounted volume spacer. Two additional volume spacers are included for personal customization.
• Information on fitting/removing the volume spacer can be found at www.dtswiss.com.

• The “-1 setting” provides a linear and comfortable suspension curve for light or comfort-seeking riders.
• The “stock setting” offers a slightly less comfortable and less linear suspension curve, recommended for the average rider looking for a comfortable and well-behaved ride.
• The “+1 setting” offers a more progressive suspension curve for sporty riders looking for direct handling.
• The “+2 setting” provides a progressive suspension curve for aggressive riders looking for very direct handling.

 HANDLING

TRANSPORT
Careful transport avoids damage to the fork. The stanchions in particular must be protected from damage.

STORAGE ( > 1 MONTH)
Careful storage prolongs the life of the fork. Note the following points:

• Reduce the air pressure.
• Clean the fork and control elements.

RECOMMISSIONING AFTER STORAGE

1. Invert the fork.
2. The lubricating oil runs from the lower section of the fork over the bushings, therefore lubricating them.
3. Gently compress the fork a few times.
4. The lubricating oil is distributed.
5. Check the air pressure in the spring element and adjust it as necessary (see “4.1 Adjusting the air pressure“ on page 23).
6. Actuate the control elements several times.
7. The oil is distributed over the seals.
8. Check all functions of the control elements
9. If there are any malfunctions, contact the DT Swiss Service Center.

MAINTENANCE AND CARE

operating hours
Small service (to be completed by a DT Swiss Service Center if necessary): refer to the Technical Manual available at www. dtswiss.com| 50 operating hours

more frequently in case of extreme operating conditions.

Check fork for damage and cracks.

If there is any damage, contact the DT Swiss Service Centre.

| Before and after every ride and after a crash
Check the fastening is correct / check tightening torques| Before each ride
Check that the brake cable is securely seated| 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 seals.
• Do not use high pressure cleaners or aggressive cleaning agents!

| After each ride

Aluminium is subject to a slow but steady fatigue of the material. Even statically uncritical loads can lead to deformation or fracture of a component after fatigue of the material. In order to counteract this fatigue, we recommend that the upper unit of the suspension fork be replaced by a DT Swiss Service Center after 3 years in case of very heavy use, such as above-average frequent use of the fork under high load.

DISPOSAL AND 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.

WARRANTY
Warranty conditions can be found at www.dtswiss.com.

DT SWISS AG

• Längfeldweg 101
• CH – 2504 Biel/Bienne
• info.ch@dtswiss.com

DT SWISS, INC.

• 2493 Industrial Blvd.
• USA – Grand Junction, CO 81505 info.us@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 ASIA LTD.

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

DT SWISS DEUTSCHLAND GmbH Albert-Einstein-Strasse 3

• 59302 Oelde
• Germany
• info.de@dtswiss.com

DT SWISS POLSKA Sp. z o.o.

• ul. Towarowa 36
• PL-64-600 Oborniki
• Poland
• info.pl@dtswiss.com

References

• DT Swiss: manufacturer of bicycle components | DT Swiss
• DT Swiss – Setup Guide | Create configuration
• DT Swiss: manufacturer of bicycle components | DT Swiss
• DT Swiss: producent części rowerowych | DT Swiss
• DT Swiss – Setup Guide | Create configuration
• DT Swiss – Setup Guide | Create configuration
• DT Swiss – Setup Guide | Create configuration

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