DT SWISS RATCHET EXP Guide

RATCHET EXP HUBS
FREEWHEEL MAINTENANCE
V2021.04

2
1. GENERAL .................................................................................................................3
1.1 Validity.......................................................................................................................... 3
1.2 Safety ........................................................................................................................... 3
1.3 Target group................................................................................................................. 3
1.4 Layout........................................................................................................................... 3
1.5 DT Swiss manual concept ........................................................................................... 3
1.6 How to use the manual ............................................................................................... 4
1.7 General Maintenance Information.............................................................................. 4
1.8 Environmental protection............................................................................................ 4
1.9 Exclusion of liability..................................................................................................... 4
1.10 Warranty....................................................................................................................... 4
2. MAINTENANCE OF THE FREEWHEEL SYSTEM [RATCHET EXP®].........................5
2.1 Overview....................................................................................................................... 5
2.2 Required wearing parts and materials....................................................................... 6
2.3 Removing end caps, freewheel body and freewheel system ..................................... 6
2.4 Cleaning and checking all parts ................................................................................. 8
2.5 Mounting the freewheel system.................................................................................. 9
2.6 Putting on the freewheel body and the end caps....................................................... 11
2.7 Check the functionality................................................................................................ 11
3. TROUBLE SHOOTING...............................................................................................12

Ratchet EXP - Maintenance of the freewheel system 3
1. GENERAL
1.1 VALIDITY
This manual describes the component specied on the front page and the footer. This manual is
valid for the design of the product as of 23.04.21. Deviations are possible and all items are subject
to technical changes.
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.
NOTICE
… 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 denitely contact a specialist or a DT Swiss Service Center.
Any warranty claims will lapse if work is not carried out properly.
1.4 LAYOUT
The cover page and the footing provide information about the type of product and manual as well
as the version of the manual. The DT Swiss contact details can be found on the back. A list of all
DT Swiss service centers can be found at www.dtswiss.com.
This manual is intended for being printed as an A5 booklet. Only print this manual if electronic
usage is not possible.
1.5 DT SWISS MANUAL CONCEPT
The DT Swiss manuals are split into the following types of manuals:
• User Manual: Information for the end user on how to install and use the component.
• Technical Manual: Detailed information for the end user and the dealer on how to maintain
the component, spare parts and technical data.

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1.6 HOW TO USE THE 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.
1.7 GENERAL MAINTENANCE INFORMATION
Unless otherwise specied, moving parts, threads, 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 "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 condition of the tools
are perfect. Always keep the tools in their original packaging or adequate devices to prevent
damage.
1.8 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.
1.9 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 wrongly
maintained or installed components. If you have doubts, please contact your region's DT Swiss
pro level service center.
1.10 WARRANTY
Warranty conditions, see www.dtswiss.com

Ratchet EXP - Maintenance of the freewheel system 5
2. MAINTENANCE OF THE FREEWHEEL SYSTEM [RATCHET EXP®]
Preparatory Steps: Cross reference / Note
Dismount the brake rotor see manufacturer's instructions
Dismount cassette see manufacturer's instructions
Clean the hub
NOTICE
This manual describes a maintenance of the freewheel system. If problems such as a slipping
freewheel and thus a failure of the drive system occur, a DT Swiss Service Center or your
dealer must be involved!
2.1 OVERVIEW
1
23
4567
8
1 end cap non drive side 5 spring
2 threaded ratchet 6 washer
3 loose ratchet 7 freewheel body
4 spacer 8 end cap drive side

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2.2 REQUIRED WEARING PARTS AND MATERIALS
Wearing parts / Materials Specication Quantity Article number
DT Swiss universal grease 20 g HXTXXX00NMG20S
DT Swiss special grease 20 g HXT10032508S
loose ratchet 36 teeth 1 HCDXXX00N2426S
loose ratchet 54 teeth 1 HCDXXX00N3936S
2.3 REMOVING END CAPS, FREEWHEEL BODY AND FREEWHEEL SYSTEM
1. Pull off both end caps by hand.
If the end caps cannot be pulled off by hand,
clamp the end caps carefully into a vise with
ground clamping jaws and pull the hub / wheel
upwards.
2. Pull the freewheel body off the hub.

Ratchet EXP - Maintenance of the freewheel system 7
3. Pull the spacer off the axle.
4. Remove the spring, the ratchet and the
washer from the freewheel body.

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2.4 CLEANING AND CHECKING ALL PARTS
1. Clean all parts of the hub, threaded ratchet, sleeve, spring and end caps. The existing grease
must be completely removed from the hub body and from the threaded ratchet.
2. Check the ratchets for wear.
The wear of the ratchets usually starts at
the outer circumference and shows itself by
strongly attened edges with uneven wear.
In case of heavy wear, the ratchets must be
changed immediately. For more information,
please refer to the Ratchet EXP Hub Technical
Manual at www.dtswiss.com. Alternatively, you
can contact a DT Swiss Service Center for the
exchange of the threaded ratchet.
3. Check the internal teeth of the freewheel
body for wear.
If the black surface of the gearing is heavily
worn (no longer black but silver), if there are
burrs or if material has been removed, the
freewheel body must be replaced.

Ratchet EXP - Maintenance of the freewheel system 9
2.5 MOUNTING THE FREEWHEEL SYSTEM
DANGER
RISK OF INJURY DUE TO LIMITED FREEWHEEL FUNCTION DUE TO INCORRECT
LUBRICATION!
If too much grease is applied on the ratchets, the actuation of the ratchets may not work. The
ratchets may slip during pedaling.
• Only apply a thin, even layer of grease.
• Only use the red DT Swiss special grease.
1. Lightly grease the teeth of the freewheel
body with DT Swiss special grease.
2. Apply DT Swiss special grease evenly to the
outer and the inner toothing of the ratchets
using a ne brush.
→For an optimal functionality of the
freewheel system, a thin layer of grease
is sufcient.

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3. Put the spacer onto the axle.
4. Put the spring onto the washer and put the
ratchet o to the spring.
5. Put the washer, spring, and ratchet into the
freewheel body.

Ratchet EXP - Maintenance of the freewheel system 11
2.6 PUTTING ON THE FREEWHEEL BODY AND THE END CAPS
1. Put the freewheel body onto the hub.
2. Check if the freewheel body can be turned
and if the ratchets are engaging.
3. Grease both bearings and the inner side of
both end caps.
4. Put on the left and the right end cap.
→The shorter end cap must be placed on
the drive side.
2.7 CHECK THE FUNCTIONALITY
1. Turn the freewheel body in both directions.
→The freewheel body can be turned
counterclockwise easily.
The ratchets engage audibly and
perceptibly.
→The freewheel body cannot be turned
clockwise.
2. Check the tightness of the end caps.
→ The end caps are rmly seated on the
axle and are fully pushed on.
Closing Steps: Cross reference / Note
Mount the brake rotor see manufacturer's instructions
Assembling the cassette see manufacturer's instructions
Clean the hub

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3. TROUBLE SHOOTING
Issue Reason Solution
Freewheel is blocked Spacer was forgotten during
assembly.
Check correct assembly, see “2.1
Overview”, page 5.
Spacer was compressed by
overtightening the thru axle.
Measure the length of the spacer.
If the spacer is shorter than 10.7
mm, it must be replaced.
Freewheel does not engage
/ slips
Loose ratchet is mounted
upside down.
Check correct assembly, see “2.1
Overview”, page 5.
Too much or wrong grease on
the ratchets.
Clean and grease the ratchets.
Ratchets are worn. Replace ratchets.
Spring was forgotten during
assembly.
Check correct assembly, see “2.1
Overview”, page 5.
Wear of the internal teeth of
the freewheel body
Replace loose ratchet, replace
freewheel body. Thoroughly clean
the freewheel system.
Hub has axial play Ball bearings were not
mounted correctly.
Check correct assembly, see “2.1
Overview”, page 5.
Ball bearings are worn out. Replace ball bearings.
Hub rotates stify Ball bearings are worn out. Replace ball bearings.
Ball bearing non drive side
too tight.
Check correct assembly, see “2.1
Overview”, page 5.
Mounting sequence of the ball
bearings not observed.
Ball bearing pressed too far
into the threaded ratchet
before assembly.
Hub makes noise Ball bearings are worn out. Replace ball bearings.
Notches from the cassette
on the freewheel body.
The steel cassette works
itself into the alloy web of the
freewheel body.
Remove bad notches from the
rotor using a le.
Freewheel body rotates with
difculty.
Ball bearings in the freewheel
body are worn out.
Replace freewheel body.
Freewheel is too noisy / too
quiet.
The perception of the freewheel sound is very subjective. While
some riders prefer a loud freewheel sound, other riders want
a quiet freewheel. In principle, the freewheeling sound can be
inuenced by the amount of grease between the ratchets. Less
grease increases the freewheeling sound, but at the same time
leads to higher wear. Too much grease, on the other hand, can
impair the freewheeling function.

DT SWISS ASIA LTD.
No.5, Jingke 5th Rd., Nantun District
Taichung City 408
Taiwan (R.O.C.)
[email protected]
DT SWISS DEUTSCHLAND GmbH
Pixeler Strasse 56
D-33378 Rheda–Wiedenbrück
Germany
[email protected]
DT SWISS POLSKA Sp. z o.o.
ul. Towarowa 36
PL-64-600 Oborniki
Poland
[email protected]
DT SWISS AG
Längfeldweg 101
CH - 2504 Biel/Bienne
[email protected]
DT SWISS, INC.
2493 Industrial Blvd.
USA - Grand Junction, CO 81505
[email protected]
DT SWISS (FRANCE) S.A.S.
Parc d‘Activites de la Sarrée
Route de Gourdon
F - 06620 Le Bar sur Loup
[email protected]
Subject to technical alterations, errors and misprints excepted.
All rights reserved.
© by DT SWISS AG
www.dtswiss.com