DBKitsuma Coil Complete 100 Hour Service Instructions (Part 2 of 4)
Mar 2022 orig., Jul 2023 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 Kitsuma Air and Coil 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 valve body or outer damper tube on the Kitsuma Air, but process is the same for the shock in the image and the shock on your bench.
Service Kits
BCD0338-01 – Kitsuma Coil Complete Rebuild Kit (w/ Bladder)
BCD0169 – Bladder Res End Cap (if replacing older IFP system)
Required Cane Creek Tools
ACD0354 – Bladder Res End Fill Tool
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
AAD2465 – Kitsuma Valve Seat Tool
ACD0322 – Kitsuma Low Speed Detent Funnel
BAD1298 – DB 9.5mm Shaft Bullet
DBT012 – DB IFP Setting Tool
Additional Tools & Supplies
Torx wrenches – T10 & T20
Sockets – 4, 8 & 13mm
9.5mm Shaft Bullet
Torque wrenchesKnipex pliers
Pick
Strap wrench
Suspension Grease
PolyLube 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 Nut | 14.5 Nm | 243 (Blue) |
| Outer Damper Tube | Tight | 263 (Red) |
| Valve Seat | 4.8 Nm | None |
| High Speed Adjuster | 7 Nm | None |
| Climb Switch Screw | 1.2 Nm | 243 (Blue) |
| Oil Seal Head | 22 Nm | None |
| End Eye | 14.5 Nm | 243 (Blue) |
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.
TSB038 – Kitsuma HSR Revalve
TSB039 – Kitsuma High Speed Cap (ACD0275) Loctite Removal from Installation
TSB040 – Kitsuma Coil Endeye Material Change
TSB043 – Kitsuma Coil Shaft Lengthened & Washer Added
TSB045 – Kitsuma IFP Changed to Bladder
TSB048 – Kitsuma Oil Seal Head Torque Valve
Optional Damper Disassembly
Step 1 – High Speed Valve Seat Removal
To address knocking coming from high speed valve seats.
Using Valve Seat tool (AAD2465), remove the high speed valve seats. Take care to seat the tool properly and use even pressure to avoid damaging seats and tool. Clean valve seats. Valve seats can be disassembled by removing circlip. If valve seat housing, washers or shims are damaged, the entire assembly (BCD0238) can be replaced.
***Do not attempt to remove the low speed needle seats. If damaged, then complete shock must be replaced.***
Valve Seat Tool & Valve Seat
Valve Seat Removal 1
Valve Seat Removal 2
Valve Seat Removal 3
Valve Seat Removal 4
Valve Seat Removal 5
Valve Seat Circlip Removal
Valve Seat Disassembled
Step 2 – Outer Damper Tube Removal
If outer damper tube is damaged or leaking at valve body.
Apply heat to outer damper tube and remove with strap wrench. Remove and discard two o-rings from valve body.
Applying Heat to Outer Damper Tube
Loosening Outer Damper Tube
Unthreading Outer Damper Tube
Outer Damper Tube Removed
Valve Body O-Ring Removal 1
Valve Body O-Ring Removal 2
Shaft Disassembly
Step 1 – Piston Assembly Removal
Clean shaft clamp and shaft with alcohol. Clamp shaft between bottom out bumper and oil seal. Using 13mm socket, remove shaft nut. Remove piston, shims, stop washer, top out bumper & spacer. Remove and discard oil seal head. Note orientation of the shims. Flip face shim on reinstall if showing signs of wear. Inspect shaft for any wear or damage.
TSB043 – Kitsuma Coil Shaft Lengthened & Washer Added
Shaft Clamped Between Oil Seal Head & Bumper
Freeing Shaft Nut
Shaft Nut Loose
Shaft Nut Removed
Piston & Shim Stack Removal
Wear on Face Shim
Piston and Shim Stack Orientation
Shaft Reassembly
Step 1 – Oil Seal Head and Piston Install
Clamp shaft in vise. Thoroughly grease bushing and quad ring on oil seal head. Using 9.5mm shaft bullet, install new oil seal head (ACD0327). Reinstall spacer, top out bumper, stop washer, shim stack and new piston. When installing piston, gently rotate with threads to avoid damaging o-ring. Apply blue Loctite (243) to threads on shaft nut. Install shaft nut. Torque to 14.5 Nm using 13mm socket.
TSB043 – Kitsuma Coil Shaft Lengthened & Washer Added
Shaft Clamped, Bullet Placed
Greasing Oil Seal Head
Oil Seal Head Install
Spacer & Top Out Bumper Installed
Shim Installed
Piston Install
Applying Loctite to Shaft Nut
Piston Installed
Shaft Nut on Shaft
Torquing Shaft Nut on Shaft
Exploded Shim Stack
Complete Shaft Assembly
Optional Damper Reassembly
Step 1 – Outer Damper Tube Install
Lightly grease and install valve body o-rings (.DB11109 & .DB11110) into valve body. Clamp valve body in vise. Apply 3-5 cms of red Loctite (263) to threads of outer damper tube. Hand thread damper tube into valve body. Thoroughly clean any grease or oil from damper tube. Use strap wrench to tighten damper tube.
Valve Body O-Ring Install 1
Valve Body O-Ring Install 2
Valve Body O-Rings Installed
Loctite on Outer Damper Tube
Threading Outer Damper Tube
Cleaning Outer Damper Tube Prior to Tightening
Tightening Outer Damper Tube
Step 2 – Valve Seat Install
Reassemble valve seat with shim, wave washer and shim. Note the orientation of the wave washer. Using valve seat tool, reinstall valve seats into valve body. Torque to 4.8 Nm.
Valve Seat First Shim Install
Valve Seat Wave Washer Install
Valve Seat Second Shim Install
Valve Seat Circlip Install
Valve Seat Assembled
Exploded HS Valve Seat
Valve Seat and Valve Seat Tool
HSC Valve Seat Install 1
HSC Valve Seat Install 2
HSR Valve Seat Install
Continue to Part 3