Clean shock. Record tune if desired. Remove hardware. Remove bushings if replacing. Remove valve cap. Bleed air from shock using shock pump. Be sure to depressurize shock slowly to avoid trapping air in the negative chamber.

Clamp shock in vise using soft jaws. Remove air can circlip using a pick. Flip the shock in the vise. 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.

Reclamp shock. Align teeth on Air Seal Head Tool (BCD0344) with grooves on air seal head. Unthread air seal head/inner air can from end eye. Splash oil may be present. Slide inner air cap up shock body to expose shaft.

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.

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. Remove 2 L-back up rings, quad ring and interior o-ring from piston and discard.

Remove both o-rings and blue wiper seal from inner air can. Remove 2 L-back up rings and quad ring from interior of inner air can. Remove sag o-ring. Discard all rings, seals and wiper. Inspect inner air can for wear. Replace as necessary.

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

Standard Valve Body Degassing:
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.

Trunnion Valve Body Degassing:
Bleed gas with gas fill needle.

Oil Removal for Both:
Remove oil fill screw with T15. Remove slowly as there may be aerated oil behind fill screw. Empty oil through fill screw by cycling the damper.

Clamp shock valve body in vise. Use Oil Seal Head Pin Spanner (BAD1174) to free oil seal head. Remove shaft assembly from damper body. Outer damper tube will likely come off as well. Pour out any remaining oil from damper body. Remove outer damper tube if still installed.

Using Inner Damper Tool Wrench (BAD1273), remove inner damper from valve body. Inspect interior of inner damper tube for piston band wear. Inspect damper tube threads and remove any remaining Loctite with pick. Clean thoroughly. Replace inner damper tube if necessary. Remove valve body o-ring and discard.

Using T10, remove Climb Switch lever screw. Remove CS lever. Reclamp valve body in vise. Use Service Cradle (AAD2650) for Standard valve body. Using Gland Nut Wrench, remove gland nut. Breaker bar may be required. Pry off gland cover or end eye. Remove bladder with pick and discard.

Using a 1.5mm Allen, remove 2 set screws located inside of valve body next to inner damper tube purchase. Remove remaining set screw in valve body exposing spring and detent ball. Remove spring and detent ball. Using CS lever, unthread spool valve and remove. Pinch & remove and discard spool valve o-ring.

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. Pinch & remove and discard o-rings on adjusters.

Note that the Compression spring is 20wt (silver), rebound is 30wt (black).

Gently bottom out Low Speed adjuster needles with 3mm Allen. Rotate circlip until the end lines up with removal groove. Using pick, get behind circlip, remove and discard. Unthread and remove needles. Remove and discard o-rings.

Remove TSN stem from valve body using T15 from both High Speed valves. Clean valve body TSN threads with tap if green Loctite has built up on threads

Disassemble TSN assembly by unthreading spring from the TSN stem. Remove TSN shim, piston and poppet.

Inspect spring for possible bent end of spring tail which can cause valve chirp. (Correcting bent spring covered in TSN Reassembly.)

Clamp shaft in vise with oil seal head end up. Remove shaft bolt with T25. Remove piston, shims and stop washer, noting orientation.

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. Carefully cut piston band off piston. Pinch & remove piston o-ring.

Remove oil seal head and top out bumper. Discard oil seal head only.

Install new piston o-ring (AAD0800) and piston band (AAD0469) on piston. 

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. If available, slide shaft cover (.DBT010 – discontinued) on shaft to cover threads only. Trim shaft cover to length if necessary. If cover not available, you can use tape to cover threads or simply take care installing seal head. Install new top out bumper (AAD1090) and new oil seal head (AAD2643). Remove shaft cover if used.

If TSN spring tail is bent, trim the spring to remove damaged end. Surface piston and poppet if necessary using a surfacing block or high grit sandpaper.

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.

Compression TSN stem has no bleed port. Reinstall poppet, piston, and shim, noting the correct orientation for compression: On piston, large ports face poppet; small ports face shim. Thread spring onto stem.

With a straight pick apply a small amount of green Loctite (668) to TSN threads in valve body. Install TSNs ensuring the correct TSN is installed on the correct side of valve body. Torque to 0.6 Nm with T15.

Lightly grease and install o-ring (.DB11102) on Low Speed needles. Apply a small amount of grease on the needle hole and reinstall spring and detent balls (ball-spring-ball).

Press, then thread needle into Low Speed control on valve body. Take care to not catch o-ring on circlip removal grove. Thread past circlip shelf. Confirm presence of detent clicks at this point. Install new circlip (AAD0920) into groove. Back needle out gently to ensure proper seatment of circlip.

Install lightly greased o-rings (AAD0478) onto adjusters.

Thread High Speed adjuster with 30wt (black) spring into Rebound valve. Be sure to thread past circlip shelf. Install circlip (AAD0947). Back adjuster out gently to ensure proper seatment of circlip.

Thread High Speed adjuster with 20wt (silver) spring into Compression valve. Be sure to thread past circlip shelf. Install circlip (AAD0947). Back adjuster out gently to ensure proper seatment of circlip.

Lightly grease and install o-ring (AAD2579) on spool valve using CS Bullet tool (AAD1454). Install spool valve into valve body using the CS Lever. Bottom out spool valve, then back out approximately one full rotation to have spool valve to a 3:30 position.

Apply blue Loctite (243) to the three CS set screws. Reinstall 2 CS set screws into bottom of valve body. Note approach angle. Torque to 0.2 Nm using 1.5mm Allen. Install lightly greased detent and spring into threaded detent capture hole on top of valve body. Reinstall remaining CS set screw to capture detent and spring. Torque to 0.2 Nm using 1.5mm Allen. Test CS function. If binding, back off set screw half turn.

Lightly grease and install o-ring (AAD0955) on valve body. Ensure o-ring is fully seated in groove. Gently work dry bladder (AAD2468 for Trunnion, AAD1333 for Standard) onto valve body groove. Ensure it is seated all the way around.

Apply grease to entire bladder surface, focusing on edges where gland cover/end eye will contact. Place gland cover/end eye on bladder. Install gland nut using an inch feed of blue Loctite (243). Set correct gland cover/end eye orientation and allow gland nut to self seat cover. Clamp valve body in vise (Trunnion) or cradle (Standard). Hand thread gland nut tight. Using Gland Nut Wrench torque gland nut to 52 Nm.

Ensure all old Loctite is removed from inner damper tube. Apply fresh red Loctite (263) to threads. Flip valve body in vise. Thread inner damper tube into valve body. Using inner damper tube wrench, torque to 17 Nm.

Apply thin layer of shock oil to outer damper tube on the end without an internal chamfer. 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 Climb Switch on spool valve. Apply blue Loctite (243) to Climb Switch screw. Install Climb Switch screw. Torque to 1.2 Nm with T10.

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 IL G2 oil fill adaptor (BAD2651) 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. 

For Standard mount, Install gas fill plug (.DB11115) chamfer first. Thread fill screw in halfway. Trunnion, begin here. Insert gas fill needle (DBT016) and pressurize to 11-12 bars of nitrogen. Thread fill screw flush. Compress shaft and ensure proper gas by observing shaft return to full extension. Submerge valve body in water to check for gas leaks.

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 (ADD0125). Install quad ring on piston channel. Pre-compress back up L-rings (AAD2572) to improve fit on piston. Install back up L-rings on either side of quad ring, ensuring that flat side contacts quad ring.

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.

Grease and install o-ring (AAD2142) into top groove on lower end eye. Insert stop shim (AAD1542) into end eye. Press into place below threads. Grease inner ridges of both ends on outer air can.

Clamp valve body in vise. Place Oil Seal Head Bullet (AAD1193) 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 air piston o-ring (AAD2573) and place on oil seal head grove. Thoroughly grease the exterior of air piston. Apply blue Loctite (243) to three air piston set screws. Place IL G2 Air Piston Funnel (ADD0313) 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). Apply blue Loctite (243) to shaft threads and end eye threads. Thread end eye onto the shaft. Clamp shaft into vise with shaft clamp allowing space for end eye to clear vise when tightened. Using 1/2″ crowsfoot, torque end eye to 4.8 Nm. Clean any extra Loctite from shaft and end eye.

Clamp end eye in vise. Add 5 ml of Royal Purple to end eye. Add PolyLube grease to threads on inner air can. Thread inner air can onto end eye. Torque to 22.6 Nm using Air Seal Head tool.

Clamp valve body end into vise. Work outer air can gently past o-rings. Note correct orientation of air can and reinstall any volume reduction. 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.

Air up shock to at least 100 psi. On hand dyno or bike frame, slowly cycle shock and listen for negative volume chamber to pressurize. Using soapy water and dunk tank, test for any possible air leaks. Install valve cap.

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.