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DBcoil CS Complete 100 Hour Service Instructions

May 2022 orig., July 2022 rev.

Table of Contents

Recommendations and Warnings

 
Cane Creek recommends only trained suspension technicians perform service on all suspension, using all required tools and following all proper procedures. Anyone without access to the proper equipment or with any concerns on the procedures should defer to an authorized Cane Creek service center for service. Improper service can result in loss of performance or suspension failure.
 
All Cane Creek shocks have pressurized nitrogen and oil, even coil shocks. Follow the service procedures exactly as written to avoid possible injury or harm to the suspension. Always wear eye protection while performing suspension service.

Please dispose of all waste products and materials through proper channels to avoid contamination of the environment.

Any damage or issues resulting from improper service will not be covered by warranty. If you have a shock still in its original warranty period and do not wish to void your warranty, please contact an authorized Cane Creek service center.

These service instructions cover the basic service procedures using standard service kits. If your suspension requires parts beyond standard replacement parts – shaft, damper tubes, end eyes – please consult your authorized Cane Creek service center or contact us at our Cane Creek Support Center.

Service Notes

The DBair CS and Coil CS share many service steps. Additionally, the Standard and Trunnion variants of both models have identical service procedures other than where to clamp the cylinder head. Some images in these instructions may not be identical to the the valve body or outer damper tube on the Coil CS, but process is the same for the shock in the image and the shock on your bench.

Additionally, running changes happened throughout the lifespan of the Coil CS. Many of those are addressed in the Technical Service Bulletins below, but always take note of the way the shock is originally built and replicate that during reassembly to maintain the original performance, tune, set up, etc. 

8mm Shafts
In 2018, all Coil CS shocks transitioned from 8mm to 9.5mm shafts to be more compatible with modern higher leverage ratio bikes. Factory service support is no longer available for 8mm shafts outside of 9.5mm shaft upgrade kits. If you are interested in maintaining an 8mm shaft on a shock, please consult your authorized Cane Creek service center.

Service Kit

BAD2376 – DBcoil CS Complete Rebuild Kit

If 8mm shaft present, ONE of the following 9.5mm shaft upgrade kits is required (plus any stroke reduction clips needed from full stroke):
BAD1599 – 9.5mm Shaft Assembly – 200x57mm
BAD1600 – 9.5mm Shaft Assembly – 216x63mm 
BAD1601 – 9.5mm Shaft Assembly – 222x70mm 
BAD2322 – 9.5mm Shaft Assembly – 230x70mm
BAD0356 – 9.5mm Shaft Assembly – 240x76mm
BAD1603 – 9.5mm Shaft Assembly – 267x90mm

Required Cane Creek Tools

DBT018 – DB Seal Head Pin Spanner Wrench
AAD1361 – DBCoil/ DBAir – Oil Fill Needle Adapter
DBT016 – DB Gas Fill Needle
AAD0555 – 8mm & 9.5mm Shaft Clamp
AAD0756 – DB Valve Seat Tool
BAD1298 – DBcoil Seal Head Bullet
DBT012 – DB IFP Setting Tool

Additional Tools & Supplies

Allen wrenches – 1.5 & 3mm
Torx wrenches – T20
Sockets – 13mm
Crowfoot wrenches – 1/2″
9.5mm Shaft Bullet 
Torque wrenches
Pick
Pin Spanner
Needle Nose Pliers
Strap wrench
Suspension Grease
PolyLube Grease
Motorex 4wt Racing Fork Oil
Vacuum Oil Fill Machine
Nitrogen Fill System

Torque, Loctite, Oil & Nitrogen Specs

Torque & Loctite Chart

Oil Chart

Nitrogen Chart

Related Technical Service Bulletins

Review all related TSBs before performing any service.

  • TSB018 – DBair CS & DBcoil CS Eyelet Change
  • TSB025 – DBair CS & DBcoil CS High & Low Speed Valve Standardization
  • TSB034 – DBcoil CS Oil Piston Change

General Prep

Clean shock. Record tune if desired. Remove hardware. Remove bushings if replacing. Unthread spring preload. Remove spring clip. Remove spring. Note and remove any stroke reduction clips. 

TSB018 – DBair CS & DBcoil CS Eyelet Change

Damper Disassembly

Step 1 –  Nitrogen Bleed & Oil Removal 

***Use caution as nitrogen is pressurized.***

Using T20, remove gas fill screw and bleed any gas with fill needle. Using T20, remove oil fill screw. Cycle shaft to remove all damper fluid.

Step 2 – Reservoir End Removal

Depress reservoir end cap to expose circlip. IFP setting tool may be used. Remove reservoir tube circlip. Remove end cap with IFP setting tool (DBT012). Pinch & remove and discard res end o-ring.

Always use extreme caution when using a pick in this step or others to avoid scratching metal parts. Failure to do this can create scratches in the o-ring glands which cause leak paths for oil or gas. When possible, pinch and remove o-rings rather than using a pick.

Step 3 – Oil Seal Head/Shaft Assembly Removal

Clamp shock using soft jawed vise. Using Oil Seal Head tool, unthread oil seal head from outer damper tube. Take care not to use threaded holes on seal head. Remove complete shaft assembly. Using spanner, remove inner damper tube by pulling straight up.

Step 4 – IFP Removal

Using IFP tool, remove the IFP. Pinch & remove and discard IFP quad ring. Remove any remaining oil and thoroughly clean outer damper tube, reservoir tube and cylinder head.

Step 5 – Outer Damper & Res Tube Inspection (Removal if necessary)

Thoroughly inspect damper tube and res tube. Replace if necessary. Test tightness of outer damper tube and reservoir tube. If either comes loose without much force, remove completely. Otherwise, only remove if replacing.
With outer damper tube and/or res tube removed, remove and discard o-rings. Thoroughly clean all Loctite residue from cylinder head threads.

Step 6 – Climb Switch & CS Cover Removal

Using T10, remove Climb Switch screw and Climb Switch. Using 1.5mm Allen, remove Climb Switch cover plate screws and cover plate.

Step 7 – High Speed Adjusters Removal

Using 3mm Allen, remove High Speed adjusters. Take note of the Rebound adjuster (0.8 with port) and spring (red, 30wt weight) and Compression adjuster (0.0 without port) and spring (20wt). Spring color may have worn off. Pinch & remove and discard High Speed adjuster o-rings.

Step 8 – High Speed Valve Seat Check

Using CS Valve Seat tool (AAD0756), check for proper torque (4.8 Nm) on valve seats. No need to remove valve seats as part of a standard service.

Step 9 – Climb Switch Spool Valve Removal

Using 6mm socket, thread spool valve closed (clockwise) and note location of the indicator dot. Then open (counterclockwise) the valve at least half a turn and then onto indicator dot at the 6:00 position. This is the default setting for reassembly. Make note of this postion from fully closed. Unthread and remove spool valve assembly. Pliers may be necessary to remove assembly once completely unthreaded. Remove and discard spool valve o-ring. Remove and clean detent balls and spring.

Step 10 – Low Speed Needle Removal

Using 3mm Allen, remove Low Speed needles. Pliers may be necessary to remove assembly once completely unthreaded. Take note of labeling on needles for reinstallation back into same circuit. Remove and clean detent balls and spring. Pinch & remove Low Speed needle o-rings.

Shaft Disassembly

If replacing an 8mm shaft with a complete 9.5mm shaft assembly, this step section can be skipped and the complete 8mm shaft assembly can be discarded.

Step 1 – Piston Assembly Removal

Using shaft clamp, secure shaft between end eye and bottom out bumper. Using 13mm socket, remove shaft locknut. Remove piston, shims and stop washer, noting orientation. Some Coil CS shocks use a single sided Air CS shim stack.

TSB034 – DBcoil CS Oil Piston Change

Step 2 – Shim & Piston Inspection

Check face shim for port wear and flip on reinstall if necessary. Check ports on piston for excessive wear. If present, resurfacing or replacement of piston may be necessary.

Step 3 – Final Disassembly

Remove and discard top out bumper and oil seal head. Remove bottom out bumper.

Shaft Reassembly

If replacing an 8mm shaft with a complete 9.5mm shaft assembly, this step section can be skipped. The replacement 9.5 shaft assembly comes ready for installation.

Step 1 – Oil Seal Head Install

Using 9.5mm shaft bullet, install bottom out bump, new oil seal (AAD0355), and new top out bumper (AAD1090).

Step 2 – Shim Stack & Piston Install

Remove bullet and install stop washer, shims and piston. Note shim stack orientation. Flip face shim if needed. Apply blue (243) Loctite to threads of locknut. Install and torque shaft locknut to 14.5 Nm using 13mm socket.

TSB034 – DBcoil CS Oil Piston Change

Damper Reassembly

Step 1 – High Speed Adjuster Prep

Lightly grease the walls of the spool valve and adjuster housing on valve body. Lightly grease and install high speed adjuster outside o-ring (AAD0032). Install high speed adjuster poppet o-ring (.DB11101). Install spring and poppet on high speed adjuster.

Replicate the original set up from disassembly. Take note of the Rebound adjuster (0.8 with port) and spring (red, 30wt weight) and Compression adjuster (0.0 without port) and spring (20wt). Spring color may have worn off.

Step 2 – High Adjuster Install

Using 3mm Allen, install High Speed Rebound adjuster into Rebound housing. Thread below cover plate surface.

Using 3mm Allen, install High Speed Compression adjuster into Compression housing. Thread below cover plate surface.

Step 3 – Low Speed Needle Install

Lightly grease and install low speed needle o-rings (.DB11102). Using grease, install detent ball, spring and second detent ball. Using 3mm Allen, install low speed needles into valve body. Be sure to match needle to original circuit. Thread needles below cover plate surface. Test for detent clicks at this time.

Step 4 – Cover Plate Install

Apply blue (243) Loctite to cover plate screw holes on valve body. Install Climb Switch cover plate. Torque plate screws to 0.16 Nm with 1.5mm Allen. Be sure to tighten screws in an even pattern.

Step 5 – Climb Switch Spool Valve Install

Lightly grease and install spool valve o-ring (.DB11102). Lightly grease spool valve opening on cover plate. Using grease, install detent ball, spring and second detent ball.
Install spool valve. Repeat removal process of threading spool valve all the way closed (clockwise) then opening (counterclockwise) 1/2 turn and onto indicator dot at 6:00. 

Step 6 – Climb Switch Lever Install

Apply blue (243) Loctite to internal threads on spool valve. Install Climb Switch with lever pointing towards the Rebound adjusters (in the climb switch “on” position). Install Climb Switch screw and torque to 1.2 Nm using a T10 wrench. Back out both low and high speed adjusters until gently touching the cover plate.

Step 7 – Outer Damper Install (if necessary)

Lightly grease and install damper tube o-rings (.DB11110 & .DB11109) in cylinder head. Apply small amount of red (263) Loctite to outer damper tube threads. Thread outer damper tube into cylinder head. Tighten in place with strap wrench.

Step 8 – IFP Install

Lightly grease and install IPF quad ring (.DB11120). Lightly grease wall of reservoir tube and install IFP by pushing tube onto piston.

Step 9 – Inner Damper Tube & Oil Seal Head Install

Coat piston with shock oil and insert shaft assembly into inner damper tube. Note location of holes on seal head end. Install inner damper tube/shaft assembly into outer damper tube. Thread oil seal head into outer damper tube and torque to 15 Nm using Oil Seal Head wrench.

Damper Fill

Step 1 – Setting IFP Depth

Thread IFP tool into IFP until bottomed. Push into reservoir tube until bottomed. Slide plunger into res tube. Install res end circlip. With IFP bottomed, slide the plunger out until contacting circlip. Lock plunger in place. Lock spacer in place onto top of plunger. Loosen plunger and pull IFP out 5mm. Relock plunger in position to set IFP depth.

Step 2 – Prepping Shock for Fill

Install fill port o-ring (.DB11102). Attach oil fill needle to fill port. Attached to fill machine per manufacturer instructions.

Step 3 – Vacuum and Oil Fill Process

Vacuum system to (4) mbar. Pressure with Oil to (3) bar. Slowly cycle shaft finishing with shaft fully out. Cut fill and equalize pressure. Vacuum system to (4) mbar, leaving shaft out. Pressure again with Oil to (3) bar. Slowly cycle shaft finishing with shaft fully out. Cut fill.

Step 4 – Valve Body Closure

Holding horizontal, disconnect fill machine. Drip some oil on to top of fill. Install oil fill screw with T20.

Step 5 – Reservoir End Cap Install

Lightly grease and install reservoir end o-ring (.DB11119). Apply Royal Purple to wall of res tube. Install res end by pushing tube onto cap. Press res end cap in as necessary and install circlip.

Step 6 – Nitrogen Fill

Insert gas fill needle in gas fill port on reservoir end cap. Pressurize to 11-12 bars of nitrogen. Compress shaft and ensure proper gas by observing shaft return to full extension. Submerge valve body in water to check for gas leaks. Install fill screw.

If mechanic dyno equipment is available, run shock on dyno at this point.

Final Testing and Set Up

Step 1 – Dyno Test

Set adjusters to factory neutral. Using hand dyno, test shock for function. Ensure Climb Switch engages and operates properly. Turn individual adjusters to test each one. Set back to original tune if desired.

Step 2 – Spring Reinstall

Reinstall any stroke reducer clips as needed below bottom out bumper. Reinstall spring and spring clip. Install all necessary bushings and hardware.

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Reed Mann

Design Engineer
Name: Reed Mann
Position: Design Engineer
Year started: 2022
Best part of being a part of the Cane Creek family:  It’s very refreshing to work for a small, tight-knit company where we all share the same passions and to develop new products that make cycling better for everyone.
What you’ll find me doing on the weekends: Obviously riding bikes, but also wrenching on bikes or cars, exploring the mountains, and watching F1 races.
How I got here (at Cane Creek): Feeling pretty unfulfilled with a corporate engineering job, I happened to see that Cane Creek was hiring. I jumped at the opportunity to get my hands dirty working on the latest bike tech and was fortunate enough to be offered the position.