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Jul 2022 orig.
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.
As the predecessor of the Air (and Coil) IL, the two shocks share many service steps. Some images in these instructions may not be identical to the the valve body or outer damper tube on the Inline or Air IL, but that is only when the process is the same for the shock in the image and the shock on your bench.
BAD1214 – DBInline/DBair IL Damper Rebuild Kit (Standard)
BAD2279 – DBair IL Air Spring Rebuild Kit
AAD1801 – DBInline Purple Fat Quad Piston (if needed)
One of the following DBInline to DBair IL Upgrade Kits:
BAD2135 – DBInline to DBair IL Upgrade Kit – 184mm
BAD2136 – DBInline to DBair IL Upgrade Kit – 190mm
BAD2137 – DBInline to DBair IL Upgrade Kit – 200 & 210mm
BAD2138 – DBInline to DBair IL Upgrade Kit – 216mm
AAD1101-01 – Keith Cradle
BCD0344 – Kitsuma/DBair/DBair IL Air Seal Head Tool
AAD1193 – Air Seal Head Bullet – Red (or original AAD1182 – Air Seal Head Bullet – Green)
BAD1459 – Air Piston Funnel
BAD1032 – Gland Nut Wrench
BAD1174 – Oil Seal Head Pin Spanner Wrench
.DBT010 – DB 8mm Shaft Thread Cover (included in Rebuild Kit)
BAD1268 – Inline – Oil Fill Needle Adaptor
DBT016 – DB Gas Fill Needle
AAD0555 – 8mm & 9.5mm Shaft Clamp
BAD1273 – Inner Damper Tube Install Tool (if replacing inner damper tube)
Torque & Loctite Chart
Clamp shock in soft jaw vise. Remove air can circlip using a pick. Flip the shock and clamp end eye. Using strap wrench, twist and apply downward force to free outer air can. Work outer air can past end eye to remove completely. Note any air volume reduction. Use valve core removal tool to remove valve core form valve housing. Use 3mm Allen to remove valve housing from air can.
Slide inner air can up shock body to expose shaft. Clamp shaft in 8mm shaft clamp with end eye up. Remove end eye using 1/2″ crows foot. Pinch & remove then discard inner can o-ring and stop shim from end eye. Remove any stroke reduction spacer, shim and bottom out bumper.
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.
TSB004 – DBInline Stop Shim
Using T10 loosen and slowly remove all 3 air piston screws. Use caution as this will release any air trapped in negative chamber. Pull up on inner air can to remove inner air can and piston. Press piston out of inner air can. If piston is red, discard. If purple, remove 2 L-back up rings, quad ring and interior o-ring from piston and discard.
TSB008 – DBInline Fat Quad Air Piston
***Use caution as nitrogen is pressurized.***
Loosen gas fill cover half a turn with 4mm Allen. Bleed gas with gas fill needle. Remove gas fill cover completely. Use pick to pry out gas fill plug.
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.
Clamp shock valve body in vise. Use Oil Seal Head Pin Spanner (BAD1174) to free oil seal head. Note oil seal head may be red (old) or purple (current). Remove shaft assembly from damper body. Pour out any remaining oil from damper body. Remove and discard outer damper tube.
TSB007 – DBInline Fat Quad Oil Seal Head
Unthread spool valve capture screw with 1.5mm Allen. Using 3mm Allen, dial High Speed adjusters in to gain access to High Speed circlips. Remove circlips. Back High Speed adjusters all the way out. Remove and discard o-rings on adjusters.
Note that the Compression spring is 20wt (silver), rebound is 30wt (black). Rebound spring may be silver on older models.
Unthread Low Speed Compression needle on spool valve with 3mm Allen and remove. Remove and discard o-rings on needle. Depress spool valve detent with razor blade to free spool valve. Remove detent and unthread spool valve. Remove and discard spool valve o-ring.
Gently bottom out Low Speed Rebound needle with 3mm Allen. Using pick, work circlip below retaining shelf all the way to needle. Back needle out 5-7 clicks and then rebottom needle to gain access to circlip. Using pick centered on circlip, pry up diagonally to pull circlip past shelf and remove. Unthread and remove needle. Remove and discard o-ring.
Converting Inline to Air IL involves flipping the rebound side TSN piston, covered here. Additionally, if the shock exhibits any audible sounds, usually a “chirp”, during use, this could be related to a bent TSN spring on rebound and/or compression. Compete compression side as needed. No additional parts are required to do the TSN service.
Reassemble shim stack, flipping face shim if necessary, and reinstall stop washer, shim stack and piston on shaft. Add one drop of blue Loctite (243) on the shaft threads. Install shaft bolt with T25. Torque to 5 Nm.
When installing the piston bolt, keep downward pressure on the piston with your other hand to prevent any Loctite from getting between the piston and face shim.
Grease the bushing and quad ring of oil seal head. Slide shaft cover (.DBT010) on shaft to cover threads only. Trim shaft cover to length if necessary. Install new (AAD1090) top out bumper and new oil seal head (AAD1804). Remove shaft cover.
TSB007 – DBInline Fat Quad Oil Seal Head
Rebound TSN stem has a small bleed port. Reinstall poppet, piston, and shim, noting the correct orientation for rebound: On piston, small ports face poppet; large ports face shim. Thread spring onto stem.
Apply a small amount of grease on the Compression (laser etched dot) needle hole and reinstall spring and detent balls (ball-spring-ball). Press then thread Compression needle into spool valve until flush. Confirm presence of detent clicks at this point.
Thread spool valve into Low Speed Compression on valve body. Thread until full bottom out. Install detent plunger and spring. Depress detent plunger and back out spool valve half to one and a half turns to capture detent in track. Ensure spool valve can fully reach both open and closed positions. Reinstall capture screw on spool valve with blue Loctite (243). Torque to .16 Nm with 1.5mm Allen.
Apply a small amount of grease on the Rebound (no laser etching) needle hole and reinstall spring and detent balls (ball-spring-ball). Press then thread Rebound needle into Low Speed Rebound on valve body. Thread past circlip shelf. Confirm presence of detent clicks at this point. Install circlip into groove. Back needle out gently to ensure proper seatment of circlip.
Lightly grease and install o-ring (AAD0955) on valve body. Ensure o-ring is fully seated in groove. Clamp valve body end eye in vise. Ensure all old Loctite is removed from inner damper tube. Apply fresh red Loctite (263) to threads. Thread inner damper tube into valve body. Using inner damper tube wrench, torque to 17 Nm.
If not already installed, lightly grease and install o-ring (AAD0955) on valve body. Ensure o-ring is fully seated in groove. Set valve body in Keith Cradle or clamp end eye. Apply thin layer of shock oil to outer damper tube on the external chamfer end. Press and rotate outer damper tube into valve body until seated on o-ring.
Apply thin layer of shock oil to piston band on shaft assembly. Use piston to apply layer of shock oil to inner surface of outer damper tube. Insert shaft assembly into inner damper tube, threading oil seal head into outer damper tube. Using Oil Seal Head Wrench, tighten oil seal head to 15 Nm.
Use non-threaded holes and ensure all three pins are properly seated and even pressure is applied to tool to prevent damaging tool pins.
Place upper end eye on bladder. Do not push end eye onto valve body as it can unseat the bladder. Install gland nut using an inch feed of blue Loctite (243). Set correct end eye orientation and allow gland nut to self seat the end eye. Using Gland Nut Wrench and Keith Cradle torque gland nut to 52 Nm.
Install new o-ring (AAD0532) on fill plug screw. Temporarily install end eye on shaft. Secure shock in horizontal position with fill port facing up. Back all adjusters to fully open and open Climb Switch. Thread Inline oil fill adaptor (BAD1268) into fill port. Fully compress damper. Attach oil fill machine per your manufacturer’s instructions.
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.
Leaving horizontal, disconnect fill machine. Unthread fill needle. Drip some oil on to top of fill. Install oil fill screw with T15. Insert new gas fill plug (.DB11115) leading with beveled edge. Thread gas fill plug screw in, leaving 2 threads exposed outside of the end eye.
Submerge valve body in water to check for gas leaks. Rotate spool valve to down position. Reinstall oil fill cover. Apply a drop of blue Loctite (243) to Climb Switch set screw. Install new Climb Switch (AAD0850K) on spool valve and install set screw. Torque to .16 Nm with 1.5mm Allen.
If mechanical dyno equipment is available, run shock on dyno at this point.
Ensure inner and outer air cans, end eye, and piston are thoroughly cleaned. Grease piston quad ring channel. Thoroughly grease all sides of quad ring (AAD1928). Install quad ring on piston channel. Pre-compress back up L-rings (AAD1098) to improve fit on piston. Install back up L-rings on either side of quad ring, ensuring that flat side contacts quad ring. Lightly grease and install piston o-ring (AAD0955) on bottom side of piston.
Grease lower channel on interior of inner air can.
Install first L-ring (AAD1134) on lower shelf with flat side toward interior of channel. Thoroughly grease all sides of quad ring (AAD1846). Install quad ring into channel. Install second L-ring (AAD1134) on top of quad ring with flat side against quad ring.
Install dry wiper seal (AAD0415) into top groove of inner air can. Thoroughly grease upper inner assembly of air can. Grease and install inner air can outer o-rings (AAD2142) on exterior of air can in the two grooves. Lightly grease the lower interior inner air can. Excess grease can clog charge port.
Clamp valve body end eye in vise or use Keith Cradle. Place Oil Seal Head Bullet (AAD1193 or AAD1182) onto shaft. Install sag indicator o-ring (.DB11108). Install inner air can. Gently work the can past the bullet tool onto the body with a slight rotation and even pressure.
Thoroughly grease the exterior of air piston. Apply blue Loctite (243) to three air piston set screws. Place Air Piston Funnel (BAD1459) on inner air can. Set inner air can halfway on outer damper tube to allow for space to install air piston. Install piston with set screw holes facing out. Gently work piston past funnel into inner air can. Bottom piston onto seal head. Once flush with seal head, rotate inner can and piston to align screw holes with seal head threads.
Install piston set screws. Torque to 3.2 Nm with T10.
Reinstall bottom out bumper, shim and stroke reduction (if present) with chamfered edge towards end eye. Apply blue Loctite (243) to shaft threads and end eye threads. Thread end eye onto the shaft. Clamp shaft into vise with shaft clamp. Using 1/2″ crowsfoot, torque end eye to 4.8 Nm. Clean any extra Loctite from shaft and end eye.
Apply blue Loctite (243) to valve housing threads. Install valve housing into air can using 3mm Allen. Torque to 2.0 Nm. Install valve core. Torque to .42 Nm. Clamp valve body end into vise. Work outer air can gently past o-rings. Note correct orientation of air can. Final o-ring will be tight. Strap wrench may be necessary. Engage Climb Switch to aid installation. Ensure valve is oriented away from Climb Switch. Install outer air can retention clip.
Due to differences in the air cans of the Inline and Air IL, progression is increased in the Air IL. As a result, it is recommended to remove up to one full (5 rows) volume reduction band when converting from Inline to Air IL to maintain original progression.
Set adjusters to factory neutral: HSC & HSR 2.5 turns from full bottom (or 2 turns from full open); LSC 11 clicks from full bottom; LSR 13 from full bottom. 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.
Install any bushings and hardware.