DT SWISS R 535 ONE User manual

R 535 ONE
TECHNICAL MANUAL
V2019.08

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

3
1. GENERAL
1.1 VALIDITY
This manual describes the component specied on the front page and the footer. It is valid for the technical
condition of the component at the Sep. 02, 2019. Design changes remain reserved.
1.2 SAFETY
The safety instructions are classied 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 only intended for DT Swiss service centers. The works described in this manual may only be
done by skilled professionals trained by DT Swiss. If you have any doubts about your own abilities, you should
denitely contact a specialist or a DT Swiss Service Center.
If the work is not carried out properly, any warranty claims expire.
1.4 USING 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 begin with the table «Preparatory Steps» and end with the table «Closing Steps». The instructions
in these tables must be carried out.

R 535 ONE Technical Manual - GENERAL4
1.5 GENERAL MAINTENANCE INFORMATION
Unless otherwise specied, 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 sealings
requires mild cleaners. Observe the instructions for use of the respective cleaning agent.
DT Swiss recommends the following cleaning products:
• 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 "Required
material".
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 can
only be ensured if the tools are working properly and if the conditions of the tools are perfect Always keep the
tools in their original packaging or adequate devices to save them from damages.

5
1.6 ENVIRONMENTAL PROTECTION
The statutory regulations shall apply. Whenever possible, avoid creating waste. Waste, especially carbon,
lubricants, cleaners and any other uids 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 sufcient specialist knowledge.
The user is liable for any damage or consequential damage caused by wrong maintained or wrong installed
components. If you have doubts, please contact your allocated DT Swiss pro level service center.
1.8 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. 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 recognized 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 nonexistent maintenance
• Incorrectly completed repairs
• Use of unsuitable products
• Modication of components
• Incorrect use or misuse
• Carelessness
• Leasing, commercial use or use in competitions
• Damage caused by accidents
• Delivery and transport damage
• Modication, defacing or removal of the serial number

R 535 ONE Technical Manual - DESCRIPTION6
2. DESCRIPTION
2.1 SPRING
2.1.1 SAB (SMOOTH AUTO BALANCING)
NEGATIVE
POSITIVE
The SAB (Smooth Auto Balancing) system only consists of a bypass located in the air chamber. The bypass
ensures that the pressure inside the negative air chamber is higher than in the positive air chamber when the
shock is fully extended. This reduces the force of the beginning stroke. The shock responds very smooth and
offers more comfort and traction.
Function in detail, see following.

7
FUNCTION IN DETAIL
After inating or changing the air pressure:
When the shock compresses, the piston moves over
the bypass of the air chamber. When the piston is
located on the bypass, the bypass ensures a pressure
equalization of the positive and negative air chamber
(see red arrow).
NEGATIVE
POSITIVE
Function during operation:
Due to the pressure equalization, the pressure in the
negative air chamber is higher than in the positive air
chamber when the shock is fully extended.
This increased pressure inside the negative air
chamber counteracts to the breakaway torque and
improves the response characteristics drastically.
NEGATIVE
POSITIVE
When the shock is compressed further, only the air
inside the positive air chamber is compressed.
When the shock extends again, a pressure builds up in
the negative air chamber and the cycles starts again.
NEGATIVE
POSITIVE

R 535 ONE Technical Manual - DESCRIPTION8
2.2 DAMPING
The shock is a closed system. The damping oil is kept under pressure by a prestressed internal oating
piston (IFP) even in the rest position. This prevents the oil from foaming and ensures a constant damping
performance even on long, rough downhills.
The oil touches the inside of the oil chamber over the entire area, enabling optimum heat dissipation.
2.2.1 COMPRESSION
The compression damping regulates the compression speed of the shock and can be adjusted in three stages
via the lever on the shock or using the remote lever on the handlebars.
OPEN
In “OPEN” mode, the compression of the shock is in the most sensitive, factory-set setting. The shock
responds sensitively to small unevennesses in the terrain.
The ne tuning of the low and high speed compression is factory set and cannot be changed.
Detailed description, see chap. „Function in detail: OPEN Mode“ on page 9.
DRIVE
If the lever on the shock or remote lever on the handlebars is moved to the middle position, the compression
damping is partially closed. This makes the bike much more rm and encourages effective pedalling in
situations where the full performance of the shock is not required (uphill climbing on roads or easy trails,
rides on level ground).
Detailed description, see chap. „Function in detail: DRIVE Mode“ on page 10.
LOCK
The «LOCK» mode blocks the shock in fully extended position. This is mostly suitable for situations where no
suspension is needed (for example riding on the road or connecting trails).
A blow-off valve protects rider and material from unexpected hits.
Detailed description, see chap. „Function in detail: LOCK Mode / Blow Off“ on page 11.
OPEN
DRIVE
LOCK
OPEN
DRIVE
LOCK

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FUNCTION IN DETAIL: OPEN MODE
HSC
LSC
When the shock compresses, the damping piston moves through the oil chamber. The oil ows through the
damping piston. During slow compression movements, the oil ows through the low speed compression (LSC)
channel. The oil ow is regulated by shims. Depending on the "factory setting", these shims are differently
hard and thus inuence the damping curve.
In the case of rapid compression movements, the oil also ows through the oil channel of the high speed
compression (HSC). Before the oil can ow into the rebound chamber, it must rst overcome the force exerted
by the shims. Depending on the "factory setting", these shims are differently hard and thus inuence the
damping curve.
Due to the piston rod, the volume of the oil chamber is different on both sides of the damping piston. More
oil is displaced than can be absorbed behind the piston. This excess oil compresses a chamber lled with
nitrogen, which is separated from the damping oil by an internal oating piston (IFP).

R 535 ONE Technical Manual - DESCRIPTION10
FUNCTION IN DETAIL: DRIVE MODE
DRIVE (HSC)
If the DRIVE mode is activated, a slider blocks the oil channel of the low speed compression (LSC). The
displaced oil can only ow through the oil channel of the high speed compression (HSC).

11
FUNCTION IN DETAIL: LOCK MODE / BLOW OFF
The Blow Off function is a safety mechanism to protect against excessive forces acting on the components of
the shock while it is in "LOCK" mode.
Blow Off
If the shock is blocked in the "LOCK" mode, a slider blocks the oil channels of the low speed and high speed
compression. There are two channels in the damping piston which directly connect the compression chamber
and the rebound chamber. These channels are closed by shims. There is no oil ow from the compression
chamber to the rebound chamber until the force of the shims is overcome. Since the two channels have a
small pressure surface (2x Ø1.5 mm), there must be a high pressure so that the blow off enables the oil ow.

R 535 ONE Technical Manual - DESCRIPTION12
2.2.2 REBOUND
The rebound controls the speed of the decompression movement of the shock. Depending on the
decompression speed, the decompression movement is controlled by the low speed rebound or the high
speed rebound.
The low speed rebound damping can be adjusted from the outside using the red rebound wheel. The rotation
of the rebound wheel is passed on to the rebound pin. The rebound pin is moved forwards and backwards via
a thread.
FUNCTION IN DETAIL
HSR
LSR
When the shock is relieved, the damping piston is pushed through the oil chamber. The oil ows from the
rebound chamber into the compression chamber. All the oil must ow through the damping piston where the
rebound damping takes place.
During slow decompression movements, the oil ows through the low speed rebound (LSR) channel. The
position of the rebound pin controls the ow resistance of the oil and thus the intensity of damping. The higher
the ow resistance, the higher the damping.
Oil which cannot ow through the oil channels of the LSR (because of fast rebound speed of the shock and
thus big displacement of the oil generated by the piston) ows through the oil channels of the high speed
rebound (HSR). At the end of the oil channel there is a pre-tensioned shim which only opens at a certain oil
pressure, thus enabling oil ow. This separation of the low speed and high speed rebound ensures separate
damping characteristics at low to medium and high extension speeds.
Like the high speed compression, the high speed rebound is controlled by pre-tensioned shims. Depending on
the "factory setting", these shims are differently hard and thus inuence the damping curve.

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3. OPERATION AND SETTING
3.1 SETTING THE SAG (NEGATIVE TRAVEL)
The SAG (negative spring deection) is the degree by which the shock compresses under the weight of the
rider. If the SAG is set correctly, the rear wheel can follow the unevenness of the terrain better during the ride.
The setting of the SAG depends on the riding style. If you prefer a rm suspension for cross country or
marathon use, you should choose a low SAG value. If you ride all mountain or enduro, a higher SAG value
should be chosen. The stroke of the shock will be used more efcient and the rear wheel will follow the
bumps much better.
The following values can be used for setting the SAG:
shock length / stroke [mm]
876 910 11 12 13 14 15 16 17 18 19 20 21 22 23
SAG [mm]
20 %
35 %
SAG 20 - 35 %
170*30
170*35
165*40 / 190*40
165*45 / 190*45
185*50 / 210*50
185*55 / 210*55
205*60 / 230*60
205*65 / 230*65
To set the SAG, you should use the help of a second person.
1. Inate the air chamber of the shock to approx. 15 bar (see chap. „3.2 Adjusting the air pressure“ on page
14). Based on this pressure, the SAG can be set.
2. Deactivate the lockout: Turn the remote lever on the shock or on the handlebar in position «OPEN».
3. Push the SAG O-ring onto the wiper seal.

R 535 ONE Technical Manual - OPERATION AND SETTING14
4. With full cycling equipment (helmet, backpack,
shoes, etc.), sit on the bicycle.
5. Assume the normal position.
→ Only strain the shock with the weight of the
rider.
→ Avoid sudden load impacts.
6. Get off the bicycle and measure the distance
between the SAG O-ring and the wiper seal.
→ This dimension is referred to as SAG.
→ The SAG should be between 20% and 35% of
the shock stroke and varies depending on use
and riding style (see image, top).
SAG
7. Adjust the air pressure if necessary (see following).
8. Repeat the steps above until you reach the required SAG.
3.2 ADJUSTING THE AIR PRESSURE
USING THE DT SWISS SHOCK PUMP
1
23 4
The DT Swiss shock pump has a pressure gauge (1) which can be used to precisely adjust the shock's
pressure. A release valve (2) allows the pressure in the shock to be reduced. A valve lever (3) on the pump
head (4) allows the shock pump to be unscrewed without any loss of pressure.
Operating the shock pump
A Screw the pump head (4) fully onto the valve on the
shock.
B Close the valve lever (3) (push the lever towards the
valve) and inate the shock.
→ Closing the valve lever (3) opens the valve on
the shock.
→ Pressing the release valve (2) allows the
pressure in the shock to be reduced.
C Open the valve lever (3) (push the lever towards the
pump tube).
A B C D
→ Opening the valve lever closes the valve on the shock. When unscrewing, no air can escape from the
shock.
D Unscrew the pump head (4) from the valve on the shock.

15
INCREASING THE AIR PRESSURE
By adjusting the air pressure of the air chamber, the spring rate will be affected. The higher the air pressure,
the harder the spring.
Adjusting the air pressure to the weight of the rider can slightly change the total length of the shock.
1. Set the shock to “OPEN” mode.
2. Unscrew the valve cap on the shock.
3. Screw the shock pump onto the valve of the shock and inate the shock up to the required pressure.
→ Note the instructions issued by the shock
pump's manufacturer!
→ When using the DT Swiss shock pump, see
chap. „Using the DT Swiss shock pump“ on
page 14.
4. Slowly compress the shock with the shock pump
screwed on ten times by around 25% of its stroke.
→ This equalizes the positive and negative air
chambers (also see chap. „2.1.1 SAB (Smooth Auto
Balancing)“ on page 6).
→ Once the pressure displayed on the shock pump
stops changing after compression, the two air
chambers have equalized.
5. Repeat the process 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 shock to “OPEN” mode.
2. Unscrew the valve cap on the shock.
3. GRADUALLY press the valve insert with the back
of the valve cap.
or
Screw on the shock pump and GRADUALLY
reduce the air pressure by pressing the release
valve on the shock pump.
The shock can compress up to the point at which
the equalization of the positive and negative air
chambers occurs.

R 535 ONE Technical Manual - OPERATION AND SETTING16
3.3 SETTING THE DAMPING
3.3.1 ADJUSTING THE REBOUND
The rebound damping regulates the rebound speed of the shock and can
be set by rotating the red rebound wheel by around 40 clicks (shock with
standard mount) or 22 clicks (shock with trunnion mount).
→ The rebound damping is increased in a clockwise
direction.
→ The rebound damping is decreased in an
counterclockwise direction.
If the rebound damping is too low, the rear 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 rear 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.
+
–
+
–

17
3.3.2 ADJUSTING THE COMPRESSION
The compression controls the speed of the compression movement of the shock.
OPEN:
In “OPEN” mode, the compression of the shock is in the most
sensitive, factory-set setting. The shock responds sensitively to
small bumps in the terrain.
DRIVE:
If the lever on the shock or remote lever on the handlebars is moved
to the middle position “DRIVE”, the compression damping is partially
closed. This makes the bike much more rm and encourages
effective pedalling in situations where the full performance of the
shock is not required (uphill climbing on roads or easy trails, rides
on level ground).
OPEN
DRIVE
LOCK
LOCK:
If the lever on the shock or remote lever on the handlebars
is moved to the “LOCK” position, the ow of oil at the shock
piston is blocked. A blow off valve opens the ow of oil in the
event of heavy impacts and therefore prevents damage to
the shock.
OPEN
DRIVE
LOCK

R 535 ONE Technical Manual - SERVICE AND CARE18
4. SERVICE AND CARE
4.1 SAFETY
DANGER
DANGER TO LIFE DUE TO WRONG MAINTENANCE OF THE SHOCK!
Incorrect maintenance or assembly of the shock can lead to unpredictable errors!
• Maintenance and assembly may only be done by a skilled professional.
• In case of any doubt, contact a DT Swiss service center.
• Only use original spare parts.
4.2 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.
4.3 SERVICE INTERVALS
If service intervals are not respected, any warranty claims can be denied.
Task Interval
Small service (see 4.5 auf Seite 20)• 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.
Do not use high pressure cleaners or aggressive
cleaning agents!
After each ride

19
4.4 SEAL KIT
The seal kit includes all parts needed for a small service. All of these parts can be changed without using
special tools.
1a
2
2
3
3
4
4
5
5
6
6
7
7
1b
Standard Mount
Trunnion Mount
1a O-ring air chamber standard mount 4support ring
1b O-ring air chamber trunnion mount 5quad-ring
2support ring 6support ring
3quad-ring 7wiper seal

R 535 ONE Technical Manual - SERVICE AND CARE20
4.5 SMALL SERVICE
This chapter describes a small service. Further service works will be carried out by a DT Swiss service center.
A small service should be carried out in the following cases:
• The interval for a small service is expired (see table at the beginning of this chapter).
• Leakage that becomes apparent through repeated air loss. The shock must be inated 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 Specication Quantity
service kit air chamber standard mount: CWXXXXXX10095S
trunnion mount: CWKXXXXX23788S
1
grease Buzzy‘s Slick Honey
4.7 dl: 40341000AD02000001
or
20 ml: TZXXXXXNSLICKS
as required
NOTE
RISK 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.