DBcoil IL Trunnion Mount Complete 100 Hour Service (Part 4 of 4)

DBcoil IL (Trunnion Mount) Complete 100 Hour Service Instructions (Part 4 of 4)

Mar 2022 orig., Jun 2024 rev.

Recommendations and Warnings Service Notes Service Kits Required Cane Creek Tools Torque, Loctite, Oil & Nitrogen Specs Related Technical Service Bulletins General Prep Damper Disassembly TSN Disassembly (if desired) Shaft Disassembly Shaft Reassembly TSN Reassembly (if required) Damper Reassembly Damper Fill Final Testing and Set Up

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 Air IL and Coil IL as well as the Standard and Trunnion variants of both share many service steps. Some images in these instructions may not be identical to the valve body or outer damper tube on the Air IL Standard, but that is only when the process is the same for the shock in the image and the shock on your bench.

Service Kits

BAD2370T – DBcoil IL Rebuild Kit (Trunnion)

Required Cane Creek Tools

BAD1032 – Gland Nut Wrench
BAD1174 – Oil Seal Head Pin Spanner Wrench
BAD1268 – Inline – Oil Fill Needle Adaptor
DBT016 – DB Gas Fill Needle
AAD0555 – 8mm & 9.5mm Shaft Clamp
AAD1454 – Kitsuma/IL Trunnion CS Bullet
BAD1273 – Inner Damper Tube Install Tool

Additional Tools & Supplies

Allen wrenches – 1.5, 3 & 4mm
Torx wrenches – T10, T15 & T25
1/2″ crowfoot wrench
Torque wrenches
Pick
Suspension Grease
Motorex 4wt Racing Fork Oil
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)
TSN	0.6 Nm	668 (Green)
Climb Switch Set Screws	0.2 Nm	243 (Blue)
Inner Damper Tube	17 Nm	263 (Red)
Oil Seal Head	15 Nm	None
Gland Nut	52 Nm	243 (Blue)
Climb Switch Screw	0.16 Nm	243 (Blue)
End Eye	8 Nm	263 (Red)

Oil Chart

Oil Location	Oil Type	Oil Amount
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

Review all related TSBs before performing any service.

No Coil IL Trunnion specific TSBs at this time.

Damper Fill

Step 1 – Prepping Shock for Fill

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 Inline oil fill adaptor (BAD1268) into fill port. Fully compress damper. Attach oil fill machine per your manufacturer’s instructions.

New O-Ring on Fill Screw

Valve Body Secured

Fill Adapter Attached

Attached to Fill Machine

Step 2 – 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

Cycling Shock

Oil Pre-Fill

Oil Fill to (3) bar

Step 3 – Valve Body Closure

Leaving horizontal, disconnect fill machine. Unthread fill needle. Drip some oil on to top of fill. Install oil fill screw with T15.

Disconnecting Fill Machine

Oil Overflow from Port

Installing Oil Fill Screw (Trunnion)

Oil Fill Screw Installed (Trunnion)

Step 4 – Nitrogen Fill

Insert gas fill needle (DBT016) and 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.

If mechanical dyno equipment is available, run shock on dyno at this point.

Insert Nitrogen Fill Needle (Trunnion)

Connect to Nitrogen Hose

Nitrogen Filled to Pressure

Compression Test

Leak Test

Final Testing and Set Up

Step 1 – Dyno Test

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.

If mechanical dyno equipment is available, run shock on dyno at this point.