DBair CS Complete 100 Hour Service Instructions (Part 3 of 3)
June 2022 orig., June 2024 rev.
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 shocks have pressurized nitrogen and oil, even coil shocks. 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 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.
Service Notes
The DBair CS and Coil CS 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 Air CS, but process is the same for the shock in the image and the shock on your bench.
Additionally, running changes happened throughout the lifespan of the Air CS. Many of those are addressed in the Technical Service Bulletins below, but always take note of the way the shock is originally built and replicate that during reassembly to maintain the original performance, tune, set up, etc.
Service Kits
BAD0241 – DBair/DBair CS Air Spring Rebuild Kit
BAD2375 – DBair CS Damper Rebuild Kit
Required Cane Creek Tools
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
AAD0756 – DB Valve Seat Tool
AAD1002 – DBair Air Seal Head Bullet
BCD0344 – Kitsuma/DBair/DBair IL Air Seal Head Tool
DBT012 – DB IFP Setting Tool
Additional Tools & Supplies
Allen wrenches – 1.5 & 3mm
Torx wrenches – T20
Sockets – 6mm
Crowfoot wrenches – 1/2″
Torque wrenches
Pick
Pin Spanner
Needle Nose Pliers
Strap wrench
Suspension Grease
PolyLube Grease
Motorex 4wt Racing Fork Oil
Royal Purple 10w-30
Vacuum Oil Fill Machine
Nitrogen Fill System
Torque, Loctite, Oil & Nitrogen Specs
Torque & Loctite Chart
| Part | Torque Spec | Loctite Spec |
|---|---|---|
| Shaft Bolt | 5 Nm | 243 (Blue) |
| Climb Switch Plate Cover | 0.16 Nm | 243 (Blue) |
| Outer Damper Tube | Tight | 263 (Red) |
| Valve Seat | 4.8 Nm | None |
| Climb Switch Screw | 1.2 Nm | 243 (Blue) |
| Oil Seal Head | 15 Nm | None |
| Air Piston Screws | 4 Nm | 243 (Blue) |
| End Eye | 4.8 Nm | 243 (Blue) |
| Inner Air Can/Air Seal Head | 22.6 Nm | None (PolyLube) |
Oil Chart
| Oil Location | Oil Type | Oil Amount |
|---|---|---|
| Air Can | Royal Purple 10w-30 | 8 mL |
| Damper Fill | Motorex 4wt Racing Fork Oil | Fill to 3 Bars |
Nitrogen Chart
| Nitrogen Location | Nitrogen Pressure |
|---|---|
| Valve Body | 11 - 12 Bars |
Related Technical Service Bulletins
Damper Fill
Step 1 – Setting IFP Depth
Thread IFP tool into IFP until bottomed. Push into reservoir tube until bottomed. Slide plunger into res tube. Install res end circlip. With IFP bottomed, slide the plunger out until contacting circlip. Lock plunger in place. Lock spacer in place onto top of plunger. Loosen plunger and pull IFP out 5mm. Relock plunger in position to set IFP depth.
IFP Setting Tool Threaded into IFP
Bottoming IFP in Reservoir Tube
Plunger Inserted into Reservoir Tube
Reservoir Tube Circlip Install
Reservoir Tube Circlip Installed
Ensuring IFP Stays Bottomed Out in Res Tube
Sliding Plunger Up to Res Tube Circlip
Plunger Seated on Res Tube Circlip
Plunger Locked in Place, Spacer Seated & Locked On Plunger
Loosening Plunger from IFP Tool Shaft
Setting Plunger w/ IFP Now Set at 5mm
Confirming IFP Set at 5mm
Step 2 – Prepping Shock for Fill
Temporally install end eye. Install fill port o-ring (.DB11102). Attach oil fill needle to fill port. Attached to fill machine per manufacturer instructions.
Oil Fill Port O-Ring Installed
Attaching Fill Needle to Fill Port
Attached to Fill Machine
Step 3 – Vacuum and Oil Fill Process
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.
Vacuum System to (4) mbar
Shaft Extended (On Factory IFP Setting Tool)
Shaft Compressed (On Factory IFP Setting Tool)
Oil Pre-Fill
Oil Fill to (3) bar
Step 4 – Valve Body Closure
Holding horizontal, disconnect fill machine. Drip some oil on to top of fill. Install oil fill screw with T20.
Dripping Fill Oil onto Fill Port
Installing Oil Fill Screw 1
Installing Oil Fill Screw 2
Oil Fill Screw Installed
Step 5 – Reservoir End Cap Install
Lightly grease and install reservoir end o-ring (.DB11119). Apply Royal Purple to wall of res tube. Install res end by pushing tube onto cap. Press res end cap in as necessary and install circlip.
Res End O-Ring Greased
Res End O-Ring Installed
Lubricating Res Tube Wall
Res End Install 1
Res End Install 2
Res End Circlip Install
Res End Circlip Installed
Step 6 – Nitrogen 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 fill screw.
If mechanic dyno equipment is available, run shock on dyno at this point.
Insert Nitrogen Fill Needle
Nitrogen Fill Needle Inserted
Connect to Nitrogen Hose
Nitrogen Filled to Pressure
Compression Test 1
Compression Test 1
Gas Leak Test
Gas Fill Screw Install
Dyno Testing
Air Spring Reassembly
Step 1 – Air Seal Reassembly
Lightly grease air seal head quad ring channel. Install new air seal head glide ring (AAD0017) into first groove on air seal head. Install new back up ring (AAD0131) below glide ring. Thoroughly grease and install new quad ring (AAD1847) behind back up ring. Lightly grease and install new external seal head o-ring (AAD1162). Install new wiper (AAD0129).
Greasing Quad Ring Channel
Air Seal Head Glide Ring Install
Air Seal Head Glide Ring Installed
Air Seal Head Back Up Ring
Air Seal Head Back Up Ring Install
Air Seal Head Back Up Ring Installed
Greasing Quad Ring
Air Seal Head Quad Ring Installation
Air Seal Head Quad Ring Installed
Air Seal Head External O-Ring Greased
Air Seal Head External O-Ring Install
Air Seal Head External O-Ring Installed
Air Seal Head Wiper Install
Air Seal Head Wiper Installed
Air Seal Head Exploded
Step 2 – Air Seal Head Install
Thoroughly grease interior of air seal head assembly. Using air seal head bullet tool (AAD1002), install air seal head. Note correct orientation with wiper towards cylinder head.
Greasing Air Seal Head
Air Seal Head Bullet on Shaft/Damper Tube
Air Seal Head Install
Air Seal Head Installed
Step 3 – Air Piston Reassembly
Lightly grease channel on air piston. Thoroughly grease new air piston quad ring (ADD0010). Precompress new back up L-rings (AAD0900). Install back up rings on opposite side of quad ring with openings opposite of each other on piston. Lightly grease new internal piston o-ring (AAD0138) and install on piston.
Greasing Air Piston Channel
Greasing Air Piston Quad Ring
Air Piston Quad Ring Install
Precompressing Air Piston Back Up Rings
First Air Piston Back Up Ring Install
Second Air Piston Back Up Ring Install
Greasing Internal Air Piston O-Ring
Internal Air Piston O-Ring Install
Internal Air Piston O-Ring Installed
Step 4 – Air Piston Install
Install piston on oil seal head. Note orientation for proper installation of air piston screws. Add blue (243) Loctite to piston threads on oil seal head. Install air piston screws and torque to 4 Nm using a T20. Lightly grease quad ring on piston. Install bottom out bumper and any required stroke and/or volume reduction. Note correct orientation of large reduction spacer.
Air Piston Install
Air Piston Installed
Applying Loctite to Oil Seal Head Threads
Air Piston Screws Install
Greasing Air Piston Quad Ring
Bottom Out Bumper Installed
Stroke Reduction and Spacer Install
Stroke Reduction and Spacer Installed
Stroke/Volume Reduction Installed
Step 5 – Inner Air Can Install
Lightly grease inner air can below the interior threads. Apply Poly Lube to external threads on same end. Lightly grease and install new outer air can o-ring (AAD0136B) in groove on inner air can. Work inner air can past air piston pressing against air seal head.
Inner Air Can
Greasing Inner Air Can Wall
Greasing Inner Air Can Threads
Greasing Outer Air Can Sealing O-Ring
Outer Air Can Sealing O-Ring Install
Outer Air Can Sealing O-Ring Installed
Inner Air Can Install
Inner Air Can Installed
Inner Air Can and Air Seal Head Pressed Down on Outer Damper Tube
Step 6 – End Eye Install
Install new end eye shim (AAD1543). Lightly grease and install new outer air can o-ring (AAD0136B) in groove on end eye. Apply blue (243) Loctite to shaft threads. Bring shaft to end eye to avoid losing end eye shim and thread end eye onto shaft. Remove any excess Loctite. Clamp shaft in vise leaving room to tighten end eye. Torque end eye to 4.8 Nm using 1/2″ crowsfoot.
End Eye Shim Install
End Eye Shim Installed
End Eye Outer Air Can O-Ring Greased
End Eye Outer Air Can O-Ring Install
End Eye Outer Air Can O-Ring Installed
Threading End Eye to Shaft 1
Threading End Eye to Shaft 2
End Eye Installed
Clamping Shaft w/ Ample Space
Torquing End Eye
Step 7 – Air Seal Head/Inner Air Can/End Eye Install
Apply Poly Lube to end eye threads on inner air can. Clamp end eye in vise. Add 8mL of Royal Purple 10w-30 to end eye. Thread inner air can onto end eye. Continue threading air seal head onto inner air can. Torque air seal head to 22.6 Nm using air seal head tool. Clean off any excess Poly Lube.
Grease on Inner Air Can Threads
Adding Oil to End Eye
Oil Added to End Eye
Threading Inner Air Can onto End Eye
Threading Air Seal Head, Inner Air Can and End Eye Together
Air Seal Head Threaded onto Inner Air Can
Torquing Air Seal Head/Inner Air Can/End Eye 1
Torquing Air Seal Head/Inner Air Can/End Eye 2
Step 8 – Outer Air Can Install
Lightly grease interior of air can on both ends. Flip shock in vise. Install outer air can onto shock working past end eye o-ring. Note air valve orientation towards cylinder head. Install any volume reduction if necessary. Install outer air can the rest of the way onto inner air can. Strap wrench can be used as needed. Install new outer air can retainer o-ring (AAD1102) on air can.
Greasing Outer Air Can Wall
Outer Air Can Installed Past End Eye O-Ring
Outer Air Can onto Inner Air Can O-Ring
Volume Reduction Added (if necessary) 1
Volume Reduction Added (if necessary) 2
Outer Air Can Install w/ Strap Wrench 1
Outer Air Can Install w/ Strap Wrench 2
Outer Air Can Retaining O-Ring Install
Outer Air Can Retaining O-Ring Installed
Final Testing and Set Up
Step 1 – Leak Check
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.
Attaching Pump
Airing Up Shock
Dunk Test
Soap Test 1
Soap Test 2
Cleaning Shock 1
Cleaning Shock 2
Valve Cap Installed
Step 2 – Dyno Test
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.
Install any bushings and hardware.
Bushings & Hardware to be Installed