DT SWISS RATCHET EXP User manual

RATCHET EXP HUBS
TECHNICAL MANUAL
V2022.01

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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 REAR WHEEL HUB WITH RATCHET EXP®SYSTEM.......5
2.1 Overview....................................................................................................................... 5
2.2 Required tools.............................................................................................................. 6
2.3 Required wearing parts and materials....................................................................... 6
2.4 Removing end caps, freewheel body and freewheel system ..................................... 8
2.5 Dismounting the ball bearing on the non drive side.................................................. 9
2.6 Dismounting the threaded ratchet ............................................................................. 10
2.7 Dismounting the bearing from the threaded ratchet................................................. 11
2.8 Checking the sealing................................................................................................... 12
2.9 Cleaning and checking all parts ................................................................................. 12
2.10 Pressing the ball bearing into the threaded ratchet.................................................. 13
2.11 Screwing the threaded ratchet with the bearing into the hub shell.......................... 14
2.12 Mounting the ball bearing at the non drive side ........................................................ 16
2.13 Mounting the hub seal................................................................................................. 17
2.14 Mounting the freewheel system.................................................................................. 18
2.15 Putting on the freewheel body and the end caps....................................................... 20
2.16 Check the functionality................................................................................................ 20
3. TROUBLE SHOOTING...............................................................................................22

Ratchet EXP - 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 11.01.22. 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.

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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 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.
1.8 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 an expert or your region's
DT Swiss pro level service center.
1.10 WARRANTY
Warranty conditions, see www.dtswiss.com

Ratchet EXP - Technical Manual 5
2. MAINTENANCE OF THE REAR WHEEL HUB WITH RATCHET EXP®SYSTEM
2.1 OVERVIEW
12
3
45678910 11
12 13
1 end cap non drive side 8 spacer
2 ball bearing non drive side 9 loose ratchet
3axle 10 spring
4 hub shell 11 washer
5 ball bearing drive side 12 freewheel body
6 threaded ratchet 13 end cap drive side
7 hub seal

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2.2 REQUIRED TOOLS
Tools Specication Quantity Article number
tool kit*, consisting of: 1 HWTXXX00N2544S
installation cylinder Ø15 x 24 x 60
mm
(only required for ball bearings on
the non drive side with 180 hubs)
1 HXTXXX00N5025S
installation cylinder Ø15 x 26 x 40
mm 1 HXTXXX00N5314S
mounting / dismounting tool for the
threaded ratchet 1 HXTXXX00N8387S
mounting / dismounting tool ball
bearing drive side 1 HXTXXX00N6106S
installation tool for hub seal 1 HXTXXX00N1000S
* The tool kit can be purchased as a complete set or the included tools can be purchased
separately.
2.3 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

Ratchet EXP - Technical Manual 7
Wearing parts / Materials Specication Quantity Article number
ball bearing for 180 hubs:
• Drive side
1526 Ø15 x 26 x 7 mm
1 HSBXXX00N3741S
• Non-drive side
6802 Ø15 x 24 x 5 mm 1 HSBXXX00N2464S
ball bearing for 240 hubs:
Drive side / non-drive side
1526 Ø15 x 26 x 7 mm
2 HSBXXX00N3741S
hub seal 1 HSOXXX00N1031S
spacer HRDXXX00N8242S
Service Kit 36 teeth consisting of
• loose ratchet 36T
• threaded ratchet 36T
• spring
• washer
• DT Swiss special grease
1 HWYXXX00N0042S
Service kit 54 teeth consisting of:
• loose ratchet 54T
• threaded ratchet 54T
• spring
• washer
• DT Swiss special grease
1 HWYXXX00N9376S

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2.4 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. Pull the spacer off the axle.

Ratchet EXP - Technical Manual 9
4. Remove the spring, the ratchet and the
washer from the freewheel body.
2.5 DISMOUNTING THE BALL BEARING ON THE NON DRIVE SIDE
1. Tap out the ball bearing on the non drive
side with a plastic hammer with slight
hammer strokes onto the axle.
2. Remove the ball bearing from the axle.

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2.6 DISMOUNTING THE THREADED RATCHET
Due to the torque which acts on the threaded ratchet during pedaling, the threaded ratchet
tightens during riding. We recommend loosening the ratchet only when the wheel is complete as
the lever is much larger.
1. Clamp the mounting / dismounting tool for
the threaded ratchet into the vice.
2. Fit the hub or wheel onto the tool in such a
way that the teeth of the tool engage in the
teeth of the threaded ratchet.
3. Insert the axle with the long side rst into
the hub and through the threaded ratchet.
→If the axle is inserted through the ratchet
with the short side rst, the tool is not
sufciently guided. The axle, the ratchet
or the tool can be damaged.
HXTXXX00N8387S
4. Push the installation cylinder onto the non
drive side of the hub.
5. Loosen and screw off the ratchet by turning
the hub counterclockwise.
→While unscrewing the threaded ratchet,
some pressure should be applied to the
hub from above so that the tool engages
securely in the ratchet at all times.
6. Remove the hub from the tool.
HXTXXX00N5314S/
HXTXXX00N5025S
7. Remove the ratchet with the bearing.

Ratchet EXP - Technical Manual 11
2.7 DISMOUNTING THE BEARING FROM THE THREADED RATCHET
1. Put the threaded ratchet with the bearing
into the mounting / dismounting tool.
→The toothing of the threaded ratchet
must face upwards.
→Put the ratchet on the side of the tool
with the tting diameter. The ratchet
may only move minimally in tool.
HXTXXX00N6106S
2. Slide the axle with its short end through the
bearing.
3. Use a plastic hammer to knock the ball
bearing out of the ratchet with light hammer
strokes.
4. Remove the ratchet and the bearing from
the tool.

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2.8 CHECKING THE SEALING
The sealing must only be dismounted and changed when it is damaged.
1. Check the sealing for damages.
2. If there is clearly visible damage, replace the sealing:
To replace the sealing, there is a notch in the
hub shell.
3. Using a slotted screwdriver with a blade
width of 2.5 mm, slide under the seal into
the notch in the hub shell.
4. Turn the screwdriver 90° around its
longitudinal axis and push the seal out of its
seat.
2.9 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.

Ratchet EXP - Technical Manual 13
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.
2.10 PRESSING THE BALL BEARING INTO THE THREADED RATCHET
1. Slightly grease the contact surface of the
bearing and the threaded ratchet.
2. Put the threaded ratchet with the toothing
facing downwards onto the mounting /
dismounting tool.
→Put the ratchet on the side of the tool
with the tting diameter. The ratchet
may only move minimally in the tool.
3. Put a new ball bearing with the colored side
facing downwards onto the ratchet.
1-2 mm
HXTXXX00N6106S
4. Carefully press the bearing into the ratchet with light hammer strokes on the outer ring of the
ball bearing until the bearing protrudes 1 to 2 mm beyond the ratchet.
→The ball bearing must not be pressed further into the ratchet.

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2.11 SCREWING THE THREADED RATCHET WITH THE BEARING INTO THE HUB SHELL
1. Slightly grease the threaded ratchet and
the thread of the hub shell with universal
grease.
2. Put the installation cylinder into the vise.
3. Insert the axle into the installation cylinder
with the short side rst.
4. Push the hub shell onto the installation
cylinder with the drive side facing upwards.
5. Slide the threaded ratchet with the ball
bearing onto the axle.
→The toothing of the threaded ratchet
must face upwards.

Ratchet EXP - Technical Manual 15
6. Push the mounting tool into the toothing of
the ratchet and screw the ratchet into the
hub shell by a few turns with light pressure.
→Before the ratchet engages in the thread
of the hub shell, it must be pushed over
the sealing (if the sealing is installed)
with a little pressure.
→While screwing in, make sure that the
ratchet is screwed in straight and does
not cant!
→It must be possible to screw in the ratchet without effort until a high resistance is created.
Now the ball bearing is in contact with the hub shell and the ratchet must be brought into
the end position with greater force. Continue with next step.
7. Remove the mounting tool, remove the hub from the installation cylinder and unclamp the
installation cylinder from the vice.
8. Clamp the mounting / dismounting tool for
the threaded ratchet into the vice.
9. Slide the axle with its long end through the
ball bearing.
→If the axle is inserted through the ratchet
with the short side rst, the tool is not
sufciently guided. The axle, the ratchet
or the tool can be damaged.
10. Put the hub / the wheel with the mounted ratchet onto the mounting tool.
11. Push the installation cylinder onto the non
drive side of the hub.
→By using the axle and the installation
cylinder, the hub shell is guided when
the ratchet is screwed on. The ratchet
cannot cant.
12. Tighten the threaded ratchet as tight as
possible by turning the hub clockwise by
hand.
→During tightening of the threaded
ratchet, some pressure should be
applied to the hub from above so that the
tool engages securely in the ratchet at
all times.
HXTXXX00N5314S /
HXTXXX00N5025S

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13. Remove the hub from the mounting / dismounting tool and put the tool out of the vice.
2.12 MOUNTING THE BALL BEARING AT THE NON DRIVE SIDE
1. Make sure that the axle is in the hub with
the long side rst.
2. Grease the bearing seat and the axle with
universal grease.
3. Push a new bearing on the axle with the
colored side facing outwards.
4. Clamp the mounting / dismounting tool for
the threaded ratchet into the vice.
5. Put the hub on the tool in the vice.
6. Put the installation cylinder onto the
bearing.
7. Tap in the ball bearing carefully with slight
hammer strokes. HXTXXX00N5314S /
HXTXXX00N5025S
HXTXXX00N8387S

Ratchet EXP - Technical Manual 17
8. Check the ball bearings.
→It must be possible to turn the hub with
slight resistance.
→The hub must not have axial play.
9. Tap the ball bearing on the non drive side
in or out and repeat previous steps until the
hub is turning smoothly.
2.13 MOUNTING THE HUB SEAL
1. Put the sealing onto the mounting tool.
HXTXXX00N1000S
2. Make sure that the axle is in the hub with
the short side rst.
3. Put the mounting tool with the sealing onto
the axle.
4. Push on the installation cylinder and drive
in the sealing with slight hammer strokes.
HXTXXX00N5314S /
HXTXXX00N5025S

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2.14 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. Put the spacer onto the axle.

Ratchet EXP - Technical Manual 19
3. Put the spring onto the washer and put the
ratchet o to the spring.
4. Put the washer, spring, and ratchet into the
freewheel body.

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2.15 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.
2.16 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.