DBKitsuma Coil Complete 100 Hour Service Instructions (Part 4 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 Bolt | 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
Damper Fill
Step 1 – Prepping Shock for Fill
Lightly grease and install new fill port o-ring (AAD0012). Temporarily reinstall end eye. Thread fill nozzle onto valve body. Back all adjusters to fully open and open Climb Switch. Fully compress damper. Attach bladder fill tool with spacer. Attach oil fill machine to fill port per your manufacturer’s instructions.
Fill Port O-Ring installed
Attaching End Eye
Attaching Fill Adapter
Attaching Bladder Fill Tool
Attaching Bladder Fill Tool Spacer
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
Oil Fill Cycle 1
Oil Fill Cycle 2
Oil Fill Cycle 3
Oil Pre-Fill
Oil Fill to (3) bar
Step 3 – Valve Body Closure
Holding horizontal, disconnect fill machine. Drip some oil on to top of fill. Install oil fill screw with T20. Remove bladder fill tool.
Removing Oil Fill Adapter
Installing Oil Fill Screw
Oil Fill Screw Installed
Removing Bladder Fill Tool Spacer
Removing Bladder Fill Tool
Step 4 – 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 new res end cap o-ring (.DB11102) and fill screw.
If mechanical dyno equipment is available, run shock on dyno at this point.
Insert Nitrogen Fill Needle
Connect to Nitrogen Hose
Nitrogen Filled to Pressure
Compression Test
Leak Test
Fill Screw O-Ring Installed
Fill Screw Install
Final Testing and Set Up
Step 1 – 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. Set back to original tune if desired.
Step 2 – Spring Reinstall
Reinstall any stroke reducer clips as needed below bottom out bumper. Reinstall spring and spring clip. Install all necessary bushings and hardware.
Stroke Reduction Install
Stroke Reduction Installed
Spring Install
Spring Clip Install
Spring Clip Installed
Engaging Preload Collar 1
Engaging Preload Collar 1