DT Swiss DICUT Service Manual
WHEELS
DICUT
Technical Manual
V2017.07
1 General 2
1.1 Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Information on Using this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Target Group 3
Layout 3
DT Swiss Manual Concept 3
How to Use this Manual 3
Cross References 3
1.3 Warranty (Europe) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4 Limited Equipment Warranty USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.5 General Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cleaning 5
Tools 5
Environmental Protection 5
Disclaimer 5
2Safety 6
3Maintenance 7
3.1 Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Truing the Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3 Changing a Single Spoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.3.1 DICUT nondisc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Loosen the Nipple 11
Changing the Spoke on the Drive Side of the Rear Wheel 12
Replacing a Spoke on the Front Wheel / on the Non Drive Side of the Rear Wheel 13
Putting Nipples on DICUT Wheels with Aluminum Rims 14
Putting Nipples on DICUT Wheels with Carbon Rims 14
3.3.2 DICUT Aero . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.3.3 DICUT Disc Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.4 Rebuilding the Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.4.1 Lacing the Wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.4.2 Stress Relieving the Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.5 Servicing the Freewheel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Removing the End Cap and the Rotor 22
Cleaning and Checking the Parts 23
Putting on the Ratchet System® 23
4 Technical Data 26
4.1 Spoke Tension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.2 Tolerance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
V2017.07
DICUT® Technical Manual
1
1General
DANGER
CAUTION
NOTICE
This manual describes the component specified on the front page and the footer. Deviations are possible
Ge n er a lV2017.07
and all items are subject to technical changes.
1.1 Safety
The safety instructions are classified as follows:
...indicates a hazardous situation that, if not avoided, will result in death or serious injury.
...indicates a hazardous situation that, if not avoided, could result in a minor or moderate injury.
...indicates information considered important, but not hazard-related.
...characterizes further information, or information which supplement the respective steps.
DICUT® Technical Manual
2
1.2 Information on Using this Manual
Target Group
This manual is intended for end users and dealers.
It offers the possibility for experienced users to carry out small maintenance works on their own. If there are
any doubts concerning the own skills, a DT Swiss service center should be contacted.
Warranty will expire if works are not done properly.
Layout
The cover page and the footing provide information about the type of product and manual as well as the
version of the manual.
Information on Using this ManualV2017.07
The backside provides a list of the DT Swiss service centers. 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.
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.
How to Use 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.
Moving parts, threads, O-rings and sealings must be greased before assembling.
Cross References
To simplify the use of this manual, some text is edited as hypertext. Whenever the text is formatted blue and
underlined, it is a reference to a chapter. If the text is formatted black and underlined, it is a reference to a
figure. After clicking you will be automatically redirected to the target of the reference.
Example: Click here:
chap. 1, page 2 to jump to the beginning of this chapter.
DICUT® Technical Manual
3
1.3 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
Warranty (Europe)V2017.07
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
• Modification of components
• Incorrect use or misuse
• Carelessness
• Leasing, commercial use or use in competitions
• Damage caused by accidents
• Delivery and transport damage
• Modification, defacing or removal of the serial number
1.4 Limited Equipment Warranty USA
DT Swiss LTD makes every effort to assure that its product meets high quality and durability standards and
warrants to the original retail consumer/purchaser of our product that each product is free from defects in
materials and workmanship as follows:
2 YEAR LIMITED WARRANTY ON THIS DT SWISS PRODUCT. This warranty does not apply to defects due
directly or indirectly to misuse, abuse, negligence or accidents, repairs or alterations outside our facilities
or to a lack of maintenance.
DT SWISS LTD LIMITS ALL IMPLIED WARRANTIES TO THE PERIOD OF TWO YEARS FROM THE DATE OF
INITIAL PURCHASE AT RETAIL. EXCEPT AS STATED HEREIN, ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS ARE EXCLUDED. SOME STATES MAY NOT ALLOW LIMITATIONS ON HOW LONG THE
IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU. DT SWISS LTD SHALL IN
NO EVENT BE LIABLE FOR DEATH, INJURIES TO PEOPLE OR PROPERTY OR FOR INCIDENTAL,
CONTINGENT, SPECIAL OR CONSEQUENTIAL DAMAGES ARISING FROM THE USE OF OUR PRODUCTS.
SOME STATES MAY NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL
DAMAGES, SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU.
To take advantage of this warranty, the product or part must be returned for examination, postage prepaid,
to the dealer where you bought the product or to a DT Swiss service center. Proof of purchase date and an
explanation of the complaint must accompany the product. If our inspection discloses a defect, DT Swiss will
either repair or replace the product or refund the purchase price, if we cannot readily and quickly provide a
repair or replacement. DT Swiss will return repaired product or replacement at DT Swiss expense, but if it
is determined there is no defect, or that the defect resulted from causes not within the scope of this
warranty, then the user must bear the cost of shipping. This warranty gives you specific legal rights, and you
may also have other rights which vary from state to state. Legal venue and place of performance is Biel
(Switzerland). Swiss law shall apply. Subject to technical changes. Please keep the user manual and
warranty for future use.
DICUT® Technical Manual
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1.5 General Maintenance Information
Cleaning
For an optimal result of the maintenance works, every component that will be disassembled must be
cleaned. Only cleaners which do not damage the components may be used. Especially the cleaning of Orings and sealings requires mild cleaners. Always consider the instructions of the respective cleaner.
DT Swiss recommends the following cleaners:
• Motorex Rex
• Motorex Swissclean
• Motorex OPAL 2400, OPAL 3000, OPAL 5000
General Maintenance InformationV2017.07
Use soap water or similar mild cleaners for external cleaning.
Tools
If special materials like grease or oil are needed, they will be specified in the table «Required Material» at
the beginning of a chapter.
Environmental Protection
Whenever possible, waste should be avoided. Waste, especially carbon, lubricants, cleaners and any other
fluids must be disposed in an environmentally compatible manner.
Only print this manual if electronic usage is not possible.
Disclaimer
The operations described in this manual should only be performed by experts. The user is liable for any
damage or consequential damage caused by wrong maintained or wrong installed components. If you have
doubts, please contact a DT Swiss service center.
DICUT® Technical Manual
5
2Safety
DANGER
DANGER
DANGER
NOTICE
SafetyV2017.07
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 functioning.
• Assembly and maintenance of the component requires a basic knowledge of handling bicycle components. If in any doubt, consult your retailer.
• Components should only be used in accordance with their intended use,otherwise the user shall
assume full responsibility.
• The component must be compatible with all parts of the bicycle.
• Only use original spare parts.
• The components must not be changed or modified.
• The component must not be used if it is damaged or there are any signs of damage. If in any doubt,
consult your retailer.
Risk of death caused by incorrectly assembled or faulty wheels!
• Check that the wheel is connected correctly before each ride.
• Check the wheel for damage before and after each ride.
• Regularly check the spoke tension, rotation and wear of the wheel.
Risk of death caused by failure or reduction of the brake performance when using wheels for rim
brakes!
• Brake with both brakes!
• When riding down hill only brake briefly with pauses in between.
• Avoid sliding and permanent braking, as the wheel will overheat thus causing the failure of the rim,
tyre or inner tube.
• If using new wheels or brake pads, the braking power is also reduced in wet conditions. Adjust the
manner of cycling accordingly.
• Do not expose the wheel to temperatures above 90°C during transport or storage.
Risk of damaging the wheel by selecting incorrect components or tools!
• Do not use metal tire levers. These can damage the surface of the rim, tyre or inner tube.
• Only use valves with a diameter of 6.5 mm and of an adequate length.
• The maximum tyre pressure of the wheel and of the tyre used must not be exceeded.
• Only use rim tapes, inner tubes and tyres which fit the dimensions of the wheel.
• Carbon rims must not be used with tubeless kits and tubeless tyres.
• Carbon rims must not be used with latex tubes.
DICUT® Technical Manual
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3Maintenance
DANGER
CAUTION
This chapter describes activities which are concerning the whole wheel:
MaintenanceV2017.07
• Truing the wheel, see
• Changing a single spoke, see chap. 3.3, page 12
• Rebuilding the wheel, chap. 3.4, page 18
Maintenance works of the hub can be found in the technical manual at www.dtswiss.com.
DT Swiss recommends the following service works:
Action Interval
Maintenance of the hub (see Technical Manual at www.dtswiss.com). annually
Check spoke tension, run-out and wear of the wheel. 10 hours of use
Check the wheel for damages.
Clean the wheel with a soft cloth and an appropriate cleaner.
Do not use high pressure cleaners and aggressive cleaners!
Check the proper fixation of the wheel. before each ride
Check the braking surface and the brake pads:
chap. 3.2, page 9
or as required
before and after each
ride
after each ride
before each ride
• Remove any contaminations (especially oil and grease) from the brake sur-
faces.
• Check the degree of wear of the brake pads.
• Remove any entrenched impurities (grit, swarf, etc.).
• Check the degree of wear of the rim brake surfaces. In case of any doubts or
viewable wear, contact a skilled professional.
3.1 Safety
Danger to life due to wrong maintenance!
Incorrect maintenance or assembly 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.
Risk of injury due to wrong spare parts!
Incorrect spare parts can lead to unpredictable errors!
• Only use original spare parts.
DICUT® Technical Manual
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3.2 Truing the Wheel
NOTICE
Preparatory Steps
Remove the wheel from the bike.
Truing the WheelV2017.07
Remove the rim strip, the inner tube and the tire.
Clean the wheel and check for damages.
Required Material Specification Amount
spoke holder 1.0 - 1.3 mm TTSXXXXS05644S 1
spoke holder 0.8 - 1.0 mm TTSXXXXR05641S 1
nipple wrench TORX TTSXXXXS05630S 1
nipple wrench square TTSXXXXR05631S 1
spokey square TTSXXXXR05664S 1
Risk of damaging the bladed spokes and the nipples!
• Bladed spokes must be hold with the spoke holder while turning the nipple.
• There are used different spokes types. Ensure that the correct tool is being used.
• When holding the spoke, push the spoke holder as far as possible in direction of the rim.
DICUT® Technical Manual
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