HELM MKII Air Spring Complete 100 Hour Service Instructions
Mar 2022 orig.
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 forks have pressurized oil. 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 fork 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 – CSU, compression rods, etc. – please consult your authorized Cane Creek service center or contact us at our Cane Creek Support Center.
Service Notes
These instructions cover just the air spring leg of a complete 100 hour service. Combine these instructions with the appropriate damper side and 50 hour lower service to get a complete 100 hour fork service.
Additionally, you can send the damper for a service with an authorized Cane Creek service center.
Service Kit
BAG0642 – HELM MKII Air Spring Rebuilt Kit
Required Cane Creek Tools
AAD0555 – 8mm & 9.5mm Shaft Clamp
Additional Tools & Supplies
Sockets – chamfer-less 30mm
Crowfoot wrenches – 20mm
Open Ended Box wrenches – 20mm
Thin Open Ended Box wrenches – 29mm
Torque wrenches
Pick
Suspension Grease
Royal Purple 10w-30
Torque, Loctite, Oil & Nitrogen Specs
Torque & Loctite Chart
| Part | Torque Spec | Loctite Spec |
|---|---|---|
| Seal Head | 6 Nm | 243 (Blue) |
| Air Piston to Shaft | 6 Nm | 263 (Red) |
| Doublair Top Cap | 36 Nm | 243 (Blue) |
Oil Chart
| Oil Location | Oil Type | Oil Amount |
|---|---|---|
| Top of Air Spring | Royal Purple 10w-30 | 2.5 mL |
Related Technical Service Bulletins
Review all related TSBs before performing any service.
TSB037 – HELM MKII Air Piston Update
Lower Assembly Removal
Prior to beginning spring service, remove the lower assembly per the 50 hour service instructions.
Removing CSU from Lowers 1
Removing CSU from Lowers 2
Spring Assembly Removal
Step 1 – Doublair Top Cap Removal
Secure CSU. Double check all air has been removed from air spring of BOTH the positive AND negative chambers by pressing the main air fill valve AND the negative charge button simultaneously. Failure to do so can result in injury. Using 30mm chamferless socket, remove Doublair volume piston. Breaker bar may be necessary. Note position of volume reduction, if present.
Releasing Positive Air Pressure
Releasing Negative Air Pressure
Socket on Doublair Top Cap
Freeing Doublair Top Cap
Doublair Top Cap Removal (w/o Piston)
Doublair Top Cap Removal (w/ Piston)
Doublair Top Cap Removed
Step 2 – Compression Rod Assembly Removal
Remove air spring seal head circlip. Remove air spring by pulling straight up. Clean all oil from air spring using diluted alcohol.
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 air. When possible, pinch and remove o-rings rather than using a pick.
Air Spring Circlip Removal
Air Spring Circlip Removed
Air Spring Assembly Removal 1
Air Spring Assembly Removal 2
Cleaning Air Spring Assembly w/ Solvant
Cleaning Air Spring Assembly w/ Air
Compression Rod Disassembly
Step 1 – Air Piston Removal
Using 8mm shaft clamp, clamp air spring assembly between the air seal head and air piston. Using 20mm open ended wrench, remove air piston from air shaft. Pinch & remove and discard air piston quad ring. If piston is blue, discard and replace with new red piston.
TSB037 – HELM MKII Air Piston Update
Air Comp Rod Assembly Clamped
Freeing Air Piston
Air Piston Removed
Air Piston Quad Ring Removal
Air Piston Quad Ring Removed
Step 2 – Air Seal Head Removal
Remove any travel reduction, spacer, and top out bumper. Remove and discard air seal head and footnut o-ring.
Travel Reduction Removal
Bottom Out Bumper Removal
Air Seal Head Removal
Air Seal Head Removed
Footnut O-Ring Removal
Compression Rod Reassembly
Step 1 – Air Seal Head Assembly
Grease bushing on new air seal head (AAG0635). Grease air seal head quad ring (AAD1809). Slide air seal head top nut (AAG1021) onto air shaft, noting correct orientation. Install first back up ring (AAD1807), quad ring and second back up ring. Noting the concave side of back up rings towards quad ring. Install new air seal head.
Greasing Air Seal Head
Greasing Air Seal Head Quad Ring
Air Seal Head Top Nut Install
Air Seal Head Top Nut Installed
First Back Up Ring Installed
Quad Ring Installed
Second Back Up Ring Installed
Complete Air Seal Head Parts Installed
Step 2 – Air Seal Head Assembly
Apply blue Loctite (243) to air seal threads. Push quad and back up rings into the air seal head until fully seated. Thread air seal head top nut onto the air seal head. Using thin 29mm wrench and 20mm crowfoot, torque top nut on seal head to 6.0 Nm.
Applying Loctite to Air Seal Head
Quad & Back Up Rings Pressed into Air Seal Head
Threading Top Nut onto Air Seal Head
Top Nut Threaded onto Air Seal Head
Air Seal Head Torque 1
Air Seal Head Torque 2
Step 3 – Shaft Components Install
Grease and install footnut o-ring (.AD0111) on air spring shaft foot nut. Install top out bumper, spacer and travel reduction spacer as needed.
Footnut O-Ring Install
Footnut O-Ring Installed
Top Out Bumper Installed
Top Out Bumper Spacer Installed
Travel Reduction Installed
Step 4 – Air Piston Install
Grease quad ring groove on air piston. Grease and install air piston quad ring (AAG0115) on the air piston. Ensure the quad ring is flush and not twisted. Clamp air shaft. Add red Loctite (263) to air shaft threads. Install air piston. Thread on with 20mm open ended wrench. Torque to 6.0 Nm using 13mm socket.
TSB037 – HELM MKII Air Piston Update
Greasing Air Piston Quad Ring
Greasing Air Piston Quad Ring Channel
Air Piston Quad Ring Installed
Comp Rod Shaft Clamped
Applying Loctite to Shaft
Threading Piston onto Shaft
Tightening Piston onto Shaft
Air Piston Torque
Complete Air Spring Comp Rod Assembly
Spring Assembly Install
Step 1 – Air Spring Assembly Install
Install sag o-ring (AAG0408) on spring side stanchion. Lightly grease inside of air spring stanchion. Lightly grease air piston quad ring and air seal head o-ring. Install air spring assembly into stanchion. Ensure seal head is fully seated and circlip channel is exposed. Reinstall seal head circlip. Pull up on air spring to ensure circlip is properly seated.
Sag O-Ring Install
Greasing Air Spring Stanchion
Greasing Air Spring Quad Ring
Greasing Air Seal Head O-Ring
Air Spring Assembly Install
Seating Air Seal Head
Air Seal Head Circlip Install
Air Seal Head Circlip Seating
Confirming Proper Circlip Install
Step 2 – Doublair Top Cap Install
Add 2.5 ml of Royal Purple 10w-30 to the top side of the air spring. Lightly grease stanchion below the threads. Lightly grease o-ring on Doublair top cap o-ring and volume reduction if present. Apply blue Loctite (243) to threads on Doublair top cap. Install assembly. Torque to 36 Nm using 30mm socket.
Air Spring Oil
Adding Oil to Top of Air Spring
Greasing Stanchion Below Threads
Greasing Doublair Top Cap O-Ring
Greasing Volume Reduction O-Ring
Applying Loctite to Doublair Top Cap
Doublair Top Cap & Volume Piston Install
Doublair Top Cap Torque
Lower Assembly Install
Step 1 – Air Spring Assembly Install
Upon completion of the spring side install and any damper service, install lower assembly per the 50 hour service instructions.
Lowers Install 1