DT SWISS SPLINE WHEEL User manual

SPLINE WHEELS
TECHNICAL MANUAL
V2022.03

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 General Maintenance Information.............................................................................. 4
1.7 Environmental protection............................................................................................ 4
1.8 Exclusion of liability..................................................................................................... 4
1.9 Warranty....................................................................................................................... 4
2. CONVERTING THE END CAPS.................................................................................5
2.1 Converting the end caps on the front wheel [plugged-in end caps] ......................... 5
2.2 Changing the end caps on the front wheel [pressed-on end caps]........................... 7
2.3 Converting the end caps on the rear wheel ............................................................... 11
3. HUB MAINTENANCE ...............................................................................................13
3.1 Service intervals .......................................................................................................... 13
3.2 Safety ........................................................................................................................... 13
3.3 Rear hub maintenance with Ratchet and Ratchet LN system................................... 14
3.4 Maintenance of the rear wheel hub with Ratchet EXP®System ............................... 20
4. MAINTENANCE OF THE WHEEL.............................................................................26
4.1 Service intervals .......................................................................................................... 26
4.2 Safety ........................................................................................................................... 26
4.3 Changing a spoke: Basics ........................................................................................... 27
4.4 PHR System: Basics.................................................................................................... 29
4.5 Replacing a spoke with crossed lacing....................................................................... 30
4.6 Replacing a spoke with radial lacing .......................................................................... 33
5. TROUBLE SHOOTING...............................................................................................36
5.1 Trouble Shooting Hubs................................................................................................ 36
5.2 Trouble Shooting Wheels ............................................................................................ 37
6. TECHNICAL DATA ....................................................................................................38
6.1 Spoke tension .............................................................................................................. 38
6.2 Tolerances.................................................................................................................... 38

SPLINE Wheels - Technical Manual 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 21.03.22. 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.
NOTE
… indicates a potentially hazardous situation that may result in damage to property.
1.3 TARGET GROUP
This manual is intended for the user of the component and dealers. This manual offers the experienced user
the possibility to carry out minor service work himself. If you have any doubts about your own abilities, you
should denitely contact an expert 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.

4
1.6 GENERAL MAINTENANCE INFORMATION
Unless otherwise specied, moving parts, threads, O-rings and sealings 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 and degreasers 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 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.
1.7 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.
1.8 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 an expert or your region's DT Swiss pro level service center.
1.9 WARRANTY
Warranty conditions, see www.dtswiss.com

SPLINE Wheels - Technical Manual 5
2. CONVERTING THE END CAPS
2.1 CONVERTING THE END CAPS ON THE FRONT WHEEL [PLUGGED-IN END CAPS]
OVERVIEW
1
2
1 end cap non drive side 2 end cap drive side
You can nd the possible conversion options for your wheel at dtswiss.com/en/support/product-support.
REQUIRED WEARING PARTS AND MATERIALS
Wearing parts / Materials Specication Quantity Article number
DT Swiss universal grease 20 g HXTXXX00NMG20S

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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. Clean both end caps and ball bearings with a dry
cloth.
3. Grease the bearings and the inner surface 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.
5. Push in end caps by hand.

SPLINE Wheels - Technical Manual 7
2.2 CHANGING THE END CAPS ON THE FRONT WHEEL [PRESSED-ON END CAPS]
OVERVIEW
1
1
2
3
1cover 2 end cap non drive side 3 end cap drive side
You can nd the possible conversion options for your wheel at dtswiss.com/en/support/product-support.
REQUIRED TOOLS
Tools Specication Quantity Article number
Tool set 350 Ø15 mm, includes 1 HWTXXX00N5290S
• installation cylinder Ø28 mm 1
• mounting pin Ø15 mm 1
MATERIALS NEEDED
Material Specication Quantity Article number
DT Swiss universal grease 20 g HXTXXX00NMG20S

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REMOVING THE END CAPS
NOTE
RISK OF DAMAGE TO THE END CAPS AND THE BALL BEARINGS!
The mounting pin must not touch the ball bearing while the end caps are being levered out.
1. Insert the mounting pin into one of the end caps.
→Risk of damage: see note!
2. Push the mounting pin downwards (see picture).
3. Remove end cap and cover.
4. Repeat previous steps at the second end cap.
5. Clean both end caps and ball bearings with a dry
cloth.

SPLINE Wheels - Technical Manual 9
MOUNTING END CAPS Ø 15 MM
1. Grease the bearings and the inner surface of both
end caps.
2. Fit one of the two end caps and the cover onto the
installation cylinder.
→end cap non drive side: Push the end cap
with cover onto the small diameter of the
installation cylinder.
→end cap drive side: Fit the end cap with cover
onto the large diameter of the installation
cylinder.
3. Insert the mounting pin into the installation
cylinder.
4. Tap the cover onto the hub shell.
→The longer end cap must be placed on the
non drive side.
5. Repeat the procedure for the second end cap.

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MOUNTING END CAPS Ø 12 MM AND Ø 5 MM
When converting to end caps for Ø 12 mm and Ø 5 mm axes, plug-in end caps are tted instead of the
pressed-on end caps.
1. Grease the bearings and the inner surface of both
end caps.
2. Put on the left and the right end cap.
→The shorter end cap must be placed on the
drive side.
3. Push in end caps by hand.

SPLINE Wheels - Technical Manual 11
2.3 CONVERTING THE END CAPS ON THE REAR WHEEL
OVERVIEW
1
2
1 end cap non drive side 2 end cap drive side
You can nd the possible conversion options for your wheel at dtswiss.com/en/support/product-support.
REQUIRED WEARING PARTS AND MATERIALS
Wearing parts / Materials Specication Quantity Article number
DT Swiss universal grease 20 g HXTXXX00NMG20S

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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. Clean both end caps and ball bearings with a dry
cloth.
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.
5. Push in end caps by hand.

SPLINE Wheels - Technical Manual 13
3. HUB MAINTENANCE
This chapter describes a small hub service. This includes:
• End caps: Disassembling, cleaning, greasing and assembling
• Freewheel body: Disassembling, cleaning, greasing and assembling
• Freewheel system: Cleaning and degreasing.
The description of a full hub service can be found in the technical manual of the respective hubs at
dtswiss.com.
3.1 SERVICE INTERVALS
The following regular maintenance and care work is recommended by DT Swiss:
Task Interval
Small Service
• Under normal operating conditions 6 months
• in extreme operating conditions (frequent riding in rain, mud, snow) as required
Full hub service (see Technical Manual at dtswiss.com)
• Under normal operating conditions 12 months
• in extreme operating conditions (frequent riding in rain, mud, snow) as required
Check the hub for damage before and after each ride
Clean with soft cloth and a suitable cleaner (see “Cleaning“ on page 4).
Do not use high pressure cleaners or aggressive cleaning agents!
after each ride
3.2 SAFETY
DANGER
DANGER TO LIFE DUE TO INCORRECT MAINTENANCE AND INCORRECT SPARE PARTS!
Unpredictable malfunctions can occur due to incorrect maintenance, incorrect installation or incorrect
spare parts.
• Maintenance may only be carried out by experienced specialists.
• Use only original DT Swiss spare parts or spare parts approved by DT Swiss.
• In cases of doubt, please contact a DT Swiss Service Center.

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3.3 REAR HUB MAINTENANCE WITH RATCHET AND RATCHET LN SYSTEM
OVERVIEW
2
34
3
5
6
1
1 end cap non drive side 4 ratchet
2 spacer 5 freewheel body
3 spring 6 end cap drive side
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

SPLINE Wheels - Technical Manual 15
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.
3. Remove springs, ratchets and spacer from the
hub.

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CLEANING AND CHECKING ALL PARTS
1. Thoroughly clean all parts of the hub. The existing grease must be completely removed from the hub
body and from the ratchets.
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.
3. Check the freewheel body for damages.
→Grooves from the cassette are no damages. These are normal signs of usage.
4. Remove bad notches on the freewheel body using a le.
5. Clean the freewheel body. Metal chips and metal particles must be removed completely.

SPLINE Wheels - Technical Manual 17
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. 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.
2. Grease the teeth of the freewheel body and the
ring nut with DT Swiss special grease.
3. Attach the spacer and the rst spring.
→The spring must rest on the hub with its large
diameter.

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4. Attach both ratchets and the second spring.
5. The spring must rest with its small diameter on
the ratchet.
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 the bearings and the inner surface of both
end caps.

SPLINE Wheels - Technical Manual 19
4. Put on the left and the right end cap.
→The shorter end cap must be placed on the
drive side.
5. Push in end caps by hand.
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.

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3.4 MAINTENANCE OF THE REAR WHEEL HUB WITH RATCHET EXP®SYSTEM
OVERVIEW
2
3
4
5
6
7
8
1
1 end cap non drive side 4 loose ratchet 7 freewheel body
2 threaded ratchet 5 spring 8 end cap drive side
3 spacer 6 washer
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