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HELM MKII Air Spring Complete 100 Hour Service Instructions

Mar 2022 orig.

Table of Contents

Recommendations and Warnings

Ā 
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.
Ā 
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.
Ā 
Please dispose of all waste products and materials through proper channels to avoid contamination of theĀ 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 centerĀ or contactĀ us at ourĀ 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.Ā 

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 – 30mm chamfer-less
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 Specs

Torque & Loctite Chart

Oil Chart

Related Technical Service Bulletins

Review all related TSBs before performing any service.

  • TSB037 – HELM MKII Air Piston Update

Lower Assembly Removal

Prior to beginning damper service, remove the lower assembly per the 50 hour service instructions.

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.

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 useĀ 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.

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

Step 2 – Air Seal Head Removal

Remove any travel reduction, spacer, and top out bumper. Remove and discard air seal head andĀ foot nut o-ring.

Compression Rod Reassembly

Step 1 – Air Spring Assembly Install

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.Ā 

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 crowsfoot, torque top nut on seal head to 6.0 Nm.

Step 3 – Shaft Components Install

Grease and install foot nut o-ring (.AD0111) on air spring shaft foot nut. Install top out bumper, spacer and travel reduction spacer as needed.

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

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.

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.

Lower Assembly Install

Upon completion of the spring side install and any damper service, install lower assembly per the 50 hour service instructions.

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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: Ā 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 youā€™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 corporateĀ 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.