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Mar 2022 orig., Jul 2023 rev.
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.
The Kistuma Air and Coil 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 Kitsuma Coil, but process is the same for the shock in the image and the shock on your bench.
BCD0338-01 – Kitsuma Coil Complete Rebuild Kit (w/ Bladder)
BCD0169 – Bladder Res End Cap (if replacing older IFP system)
ACD0354 – Bladder Res End Fill Tool
DBT018 – DB Seal Head Pin Spanner Wrench
AAD1361-01 – DBCoil/ DBAir – Oil Fill Needle Adapter
DBT016 – DB Gas Fill Needle
AAD0555 – 8mm & 9.5mm Shaft Clamp
AAD2465 – Kitsuma Valve Seat Tool
ACD0322 – Kitsuma Low Speed Detent Funnel
BAD1298 – DB 9.5mm Shaft Bullet
DBT012 – DB IFP Setting Tool
Torx wrenches – T10 & T20
Sockets – 4, 8 & 13mm
9.5mm Shaft Bullet
Torque wrenches
Knipex pliers
Pick
Strap wrench
Suspension Grease
PolyLube Grease
Motorex 4wt Racing Fork Oil
Vacuum Oil Fill Machine
Nitrogen Fill System
Torque & Loctite Chart
| Part | Torque Spec | Loctite Spec |
| Shaft Nut | 14.5 Nm | 243 (Blue) |
| Outer Damper Tube | Tight | 263 (Red) |
| Valve Seat | 4.8 Nm | None |
| High Speed Adjuster | 7 Nm | None |
| Climb Switch Screw | 1.2 Nm | 243 (Blue) |
| Oil Seal Head | 22 Nm | None |
| End Eye | 14.5 Nm | 263 (Red) |
Oil Chart
| Oil Location | Oil Type | Oil Amount |
| Damper Fill | Motorex 4wt Racing Fork Oil | Fill to 3 Bars |
Nitrogen Chart
| Nitrogen Location | Nitrogen Pressure |
| Valve Body | 11-12 Bars |
Review all related TSBs before performing any service.
Clean shock. Record tune if desired. Remove hardware. Remove bushings if replacing. Unthread spring preload. Use rag if needed for better grip. Remove clip. Remove spring. Note and remove any stroke reduction clips.
TSB040 – Kitsuma Coil Endeye Material Change
***Use caution as nitrogen is pressurized.***
Remove reservoir end cap screw using T20. Remove and discard o-ring. Use gas fill needle to bleed nitrogen from reservoir tube. Remove oil fill screw with T20. Cycle the shaft to remove as much oil as possible from the damper. Dispose of oil properly.
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.
Using IFP tool (DBT012), press cap into the reservoir tube exposing circlip. Press on circlip to remove from channel. Pick should not be required but could be used if needed. Thread IFP tool back into end cap, remove and discard. Thread IFP tool into metal IFP and remove from reservoir tube. Use adaptor for plastic IFP. Discard IFP.
TSB045 – Kitsuma IFP Changed to Bladder
Using bladder setting tool (ACD0354), press res end cap into reservoir, exposing circlip. Press on circlip to remove from channel. Pick should not be required but could be used if needed. Use IFP setting tool (DBT012) to pull end cap out of reservoir tube. If bladder does not come out with end cap, remove with pick.
TSB045 – Kitsuma IFP Changed to Bladder
Using T10, remove Climb Switch mounting screw.
Remove Climb Switch. Remove and discard Climb Switch o-ring. Remove CS detent. Turn CS valve so that the tab on the spool valve is no longer engaged with the valve body and remove assembly. Pinch & remove and discard spool valve o-ring.
Using 8mm socket, remove high speed adjuster housing. Apply heat to aid removal.
***Note high speed adjuster housing may also be silver.***
TSB039 – Kitsuma High Speed Cap (ACD0275) Loctite Removal from Installation
Press out detent spring and balls. Unthread shuttle, remove gold shim and remove both o-rings. Discard o-rings. Note the differences between the poppets and springs from the compression and rebound sides.
TSB038 – Kitsuma HSR Revalve
To address knocking coming from high speed valve seats.
Using Valve Seat tool (AAD2465), remove the high speed valve seats. Take care to seat the tool properly and use even pressure to avoid damaging seats and tool. Clean valve seats. Valve seats can be disassembled by removing circlip. If valve seat housing, washers or shims are damaged, the entire assembly (BCD0238) can be replaced.
***Do not attempt to remove the low speed needle seats. If damaged, then complete shock must be replaced.***
Clean shaft clamp and shaft with alcohol. Clamp shaft between bottom out bumper and oil seal. Using 13mm socket, remove shaft nut. Remove piston, shims, stop washer, top out bumper & spacer. Remove and discard oil seal head. Note orientation of the shims. Flip face shim on reinstall if showing signs of wear. Inspect shaft for any wear or damage.
TSB043 – Kitsuma Coil Shaft Lengthened & Washer Added
TSB049 – Kitsuma Top Out Bumper
Clamp shaft in vise. Thoroughly grease bushing and quad ring on oil seal head. Using 9.5mm shaft bullet, install new oil seal head (ACD0327). Reinstall spacer, top out bumper, stop washer, shim stack and new piston. When installing piston, gently rotate with threads to avoid damaging o-ring. Apply blue Loctite (243) to threads on shaft nut. Install shaft nut. Torque to 14.5 Nm using 13mm socket.
TSB043 – Kitsuma Coil Shaft Lengthened & Washer Added
Lightly grease and install valve body o-rings (.DB11109 & .DB11110) into valve body. Clamp valve body in vise. Apply 3-5 cms of red Loctite (263) to threads of outer damper tube. Hand thread damper tube into valve body. Thoroughly clean any grease or oil from damper tube. Use strap wrench to tighten damper tube.
Install new back up ring (ACD0272) and lightly greased o-ring (ACD0252) on low speed needles. Using grease, reinstall spring and detent balls into low speed needles. Install low speed needles into valve body. Needle detent funnel (ACD0322) maybe used to ease install. Thread until bottomed then back out to ensure detents engagement. Then lightly bottom out the needle again.
Thoroughly clean high speed adjustor threads and shuttle. Install shuttle onto adjustor. Note the orientation of the shuttle. Lightly grease and install high speed adjustor o-ring (ACD0265) and poppet o-ring (ACD0219).
TSB038 – Kitsuma HSR Revalve
Insert gold shim into bottom of high speed adjustor housing. Using grease, reinstall spring and detent balls into high speed adjuster. Insert assembled high speed adjustors into high speed adjutor housing. Install circlip. Lightly grease and install high speed adjustor housing o-ring (ACD0212).
Install poppet assembly with shims towards valve body followed by poppet spring. Note rebound gets the stronger (40w) poppet spring and has 3 shims on poppet; compression has lighter (20w) spring and 1 shim. Using an 8mm socket, torque to 7 Nm.
TSB039 – Kitsuma High Speed Cap (ACD0275) Loctite Removal from Installation
Light grease and install Climb Switch valve o-ring (ACD0266). IL CS bullet (AAD1454) can be used here. Apply grease to Climb Switch valve on valve body and to Climb Switch valve. Insert valve into valve body with tab at 3:00. Once engaged, rotate CS valve tab underneath valve body tab.
Light grease and install Climb Switch o-ring (AAD0800) on back side of lever. Place lever onto Climb Switch valve with lever at 9:00. Note that proper orientation of lever and valve required for proper interface. Apply blue Loctite (243) to Climb Switch mounting bolt. Secure CS lever with bolt. Torque to 1.2 Nm with T10.
Lightly grease and install low speed adjustor dial o-rings (ACD0254) on back of dial. Apply thin layer of grease to the valve/dial interface on the valve body. Check that low speed controls are fully closed (clockwise). Line up dial at 6:00. Rotate dial and valve counterclockwise while applying gentle pressure until the dial seats onto the valve.
If updating from older IFP system, a new reservoir end cap (BCD0169) is required.
Grease all three sides of the quad ring portion of bladder.
Work bladder onto reservoir cap. Insert end cap/bladder assembly into reservoir. Apply pressure to fully seat and expose circlip channel. Install circlip. Back end cap out against circlip using bladder fill tool or IFP setting tool.
TSB045 – Kitsuma IFP Changed to Bladder
Coat piston band with shock oil. Work piston into inner damper tube. Insert inner damper tube/oil seal head assembly into outer damper tube. Thread oil seal head onto outer damper tube. Torque to 22 Nm with Oil Seal Head tool.
Lightly grease and install new fill port o-ring (AAD0012).
Temporarily reinstall end eye. Thread fill nozzle onto valve body. Back all adjusters to fully open and open Climb Switch. Fully compress damper. Attach bladder fill tool with spacer. Attach oil fill machine to fill port 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.
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 new res end cap o-ring (.DB11102) and fill screw.
If mechanical dyno equipment is available, run shock on dyno at this point.
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.
