HELM MKII Damper Complete 100 Hour Service Instructions (Part 2 of 2)
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 damper leg of a complete 100 hour service. Combine these instructions with the appropriate spring side – air or coil; original or MKII – and 50 hour lower service to get a complete 100 hour fork service.
Additionally, follow these instructions for damper removal and reinstall if sending the damper off for a service with an authorized Cane Creek service center.
Service Kit
BAG0713 – HELM MKII Damper Rebuilt Kit
Required Cane Creek Tools
BAG0405 – Compression Retaining Nut Socket – Thin Walled 11mm socket
AAG0086 – HELM Cartridge Fill Tool
AAG0367 – HELM Oil Seal Head Bullet
AAG0406 – HELM Compression Outer Sleeve Spanner
Additional Tools & Supplies
Allen wrenches – 4mm
Torx wrenches – T10
Sockets – 10, 13 & chamfer-less 30mm
Crowfoot wrenches – 10, 18, 20 & 22mm
Open Ended Box wrenches – 10, 18, 20 & 22mm
10mm Shaft Clamp
Torque wrenches
Knipex pliers
Pick
Suspension Grease
PolyLube Grease
Motorex 2.5wt Racing Fork Oil
Vacuum Oil Fill Machine
Torque, Loctite, Oil & Nitrogen Specs
Torque & Loctite Chart
| Part | Torque Spec | Loctite Spec |
|---|---|---|
| Rebound Adjuster | 5 Nm | 243 (Blue) |
| Damper Top Cap to Gold Coupling | 9 Nm | None |
| Oil Seal Head to Damper Tube | 13 Nm | None |
| Damper Install | 36 Nm | 243 (Blue) |
| Compression Nut | Hand Tight | 243 (Blue) |
| LSC Knob Screw | 1.6 Nm | 243 (Blue) |
Oil Chart
| Oil Location | Oil Type | Oil Amount |
|---|---|---|
| Damper Fill | Motorex 2.5wt Racing Fork Oil | Fill to 2 Bars |
Related Technical Service Bulletins
Review all related TSBs before performing any service.
No specific HELM MKII damper TSBs at this time.
Damper Reassembly
Step 1 – Prepping Damper for Fill
Grease bushing on new oil seal head (AAG0636). Using Oil Seal Head bullet (AAG0367), install oil seal head onto damper shaft .Note orientation with threaded side towards piston end of shaft.
Greasing Oil Seal Head 1
Greasing Oil Seal Head 2
Oil Seal Head Bullet on Shaft
Oil Seal Head Install
Oil Seal Head Installed 1
Oil Seal Head Installed 2
Step 2 – Rebound Adjuster Install
Clamp damper shaft with 10mm shaft clamp. Grease and install rebound adjuster o-ring (AAD1060). Apply blue Loctite (243) to rebound adjuster threads. Install rebound adjuster into damper shaft. Torque to 5.0 Nm with 10mm crowfoot.
Rebound Adjuster O-Ring Install
Rebound Adjuster O-Ring Installed
Loctite on Rebound Adjuster
Rebound Adjuster Install
Threading on Rebound Adjuster
Rebound Adjuster Torque
Step 3 – Piston Band Install
Install new piston band (AAG0212) on rebound piston.
Piston Band Install
Piston Band Installed
Step 4 – Bladder, Claw & Helix Install
Install new bladder (AAG0216HNBR) on compression outer sleeve. Ensure bladder and outer compression sleeve threads are exposed. Insert claw into compression outer sleeve, lining up claw pegs with channels on the outer compression sleeve. Holding claw in place, rotate helix onto claw.
Bladder Install
Bladder Installed
Claw Install
Claw Installed
Helix Installed
Complete Compression Assembly
Step 5 – Damper Top Cap Install
Apply damper oil to inside of damper top cap. Holding claw in place, fully thread damper top cap onto compression outer sleeve. Using 10mm socket, check for free rotation of helix and claw. Leave fully open (counterclockwise).
Lubing Damper Top Cap
Supporting Claw Inside Compression Sleeve
Compression Sleeve Threads Fully Exposed
Damper Top Cap Install
Threading Damper Top Cap
Damper Top Cap Installed
Testing Claw & Helix 1
Testing Claw & Helix 2
Step 6 – Check Spring & Piston Assembly Install
Install compression check spring onto claw. Install compression piston assembly with poppet contacting spring.
Check Spring Install
Check Spring Installed
Piston Assembly Install
Piston Assembly Installed
Step 7 – Compression Circuit Reassembly
Apply damper oil to damper coupling. Thread damper coupling onto compression outer sleeve. Clamp damper coupling and torque damper top cap to 9 Nm using 30mm socket. Recheck that the helix still turns freely.
Lubing Damper Coupling
Damper Coupling Install
Damper Coupling Torque
Checking for Helix Rotation
Step 8 – Rebound Circuit Install
Coat rebound piston in damper oil. Insert rebound assembly into damper tube. Thread oil seal head into damper tube. Secure damper coupling using vise or Knipex and torque oil seal head to 13 Nm using 22mm crowfoot.
Coating Rebound Piston
Coating Rebound Install 1
Coating Rebound Install 2
Oil Seal Head Threaded in Damper Tube
Clamping Damper Coupler (Knipex)
Seal Head Torque 1 (Knipex)
Seal Head Torque 2 (Knipex)
Seal Head Torque 1 (Vise)
Seal Head Torque 2 (Vise)
Damper Fill
Step 1 – Prepping Damper for Fill
Attach Cartridge fill tool (AAG0086) to helix through top cap. Ensure rebound is open (counterclockwise). Fully compress damper. Attach fill tool to fill machine per your manufacturer’s instructions.
Fill Tool Attached
Opening Rebound Completely
Connected to Fill Machine
Step 2 – Vacuum and Oil Fill Process
Fill vacuum to (3) mbar. Equalize pressure. Pressurize damper to (2) bars while extending damper shaft.
***Do not overfill. Can cause bladder to rupture.***
Fill vacuum to (3) mbar allowing damper shaft to return to compressed. Equalize pressure. Pressurize damper to (2) bars while extending damper shaft.
Switching to Equalize
Equalizing Pressure
Pressurizing to 2 bars
Extending Damper Shaft
Vacuuming Damper
Allowing Damper Shaft to Compress
Step 3 – Damper Closure
Disconnect damper from fill machine with fill tool attached. Hold finger over fill adapter to keep oil from leaking. Slowly compress shaft 5cm allowing oil overflow. Insert low speed needle. Thread needle into until flush with helix using 4mm Allen.
Disconnect from Fill Machine
Damper Before Pre-Compression
Damper Compressed 5cm
Fill Tool Removal
Oil Overflow
Low Speed Needle Install
Low Speed Needle Closure Until Flush
Low Speed Needle Flush
Step 4 – Damper Test
Clear top cap of any excess oil. Close (clockwise) high speed with 10mm socket. Close (clockwise)low speed with 4mm Allen. Close (clockwise) rebound. Cycle damper to check for proper function.
If mechanic dyno equipment is available, run damper on dyno at this point.
Dumping Excess Oil
Cleaning Damper
Closing High Speed Compression
Closing Low Speed Compression 1
Closing Low Speed Compression 2
Closing Rebound
Damper Install
Step 1 – Damper Install
Lightly grease o-ring on damper top cap. Apply blue Loctite (243) to damper top cap threads. Insert damper. Torque to 36 Nm using 30mm socket.
Applying Grease to Damper Top Cap O-Ring
Applying Loctite to Damper Top Cap
Damper Top Cap Torque
Step 2 – High Speed Compression Knob Install
Apply PolyLube to detents on the damper top cap. Fully open (counterclockwise) the High Speed compression (helix). Install High Speed knob. Note orientation with tab towards the front.
Greasing Top Cap Detents 1
Greasing Top Cap Detents 2
Cleaning HSC Knob
Fully Opening HSC Adjuster
HSC Knob Install
HSC Knob Installed
Step 3 – Compression Retaining Nut Install
Install red take up adapter. Apply blue Loctite (243) to inner threads on compression retaining nut. Install retaining nut. Tighten with 11mm compression nut socket until hand tight. Note knob will rotate to closed position.
LSC Take Up Adjuster Insall
LSC Take Up Adjuster Insalled
Applying Loctite to Retaining Nut
LSC Retaining Nut Install
LSC Retaining Nut Tighten
Step 4 – Low Speed Compression Knob Install
Install Low Speed knob. Apply blue Loctite (243) to threads on Low Speed compression screw. Install screw and torque to 1.6 Nm with T10.
Low Speed Knob Install
Applying Loctite to LSC Knob Screw
LSC Knob Screw Install
LSC Knob Screw Torque
Lower Assembly Install
Upon completion of the damper install and any spring side service, install lower assembly per the 50 hour service instructions.
Lowers Install 1