Tigon Complete 100 & 200 Hour Service Instructions (Part 2 of 2)

Tigon Complete 100 & 400 Hour Service Instructions (Part 2 of 2)

Feb 2024 orig., Jan 2025 rev.

Recommendations and Warnings Service Notes Service Kits Required Cane Creek Tools Additional Tools & Supplies Torque, Loctite, Oil & Nitrogen Specs Related Technical Service Bulletins General Prep RAMP Tube Removal Damper Disassembly Damper Reassembly Damper Fill RAMP Tube Reassembly 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 Standard and Trunnion variants of the Tigon 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, but process is the same for the shock in the image and the shock on your bench.

100 vs. 400 hour service

The only difference between the 100 hour service and the 400 hour service is whether to service or replace the Oil Seal Head. At 100 hours, the Seal Head should be cleaned, serviced and reinstalled. At 400 hours, it should be replaced. If uncertain on hours, check for wear on the dual bushings inside the Seal Head. When in doubt, replace.

Service Kits

BDD0341– Tigon Complete 100 Hour Rebuilt Kit
OR
BDD0343– Tigon Complete 400 Hour Rebuilt Kit

Required Cane Creek Tools

BDD0320 – Tigon Oil Seal Head Pin Spanner
ADD0327 – Tigon Shaft Seal Head Bullet
ADD0328 – Tigon IFP Service Plug
AAD1361-01 – DBCoil/ DBAir – Oil Fill Needle Adapter
DBT016 – DB Gas Fill Needle

Additional Tools & Supplies

Shaft Clamp – 12.7mm (1/2″)
Allen wrench – 4mm
Torx wrench – T20
Crowfoot wrenches – 12 & 34mm
Open end wrench – 19mm
Torque wrenches
Knipex pliers
Pick – metal & plastic
Strap wrench
M8 x 1.25 bolt, min. 45mm length
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
Inner Shaft to Outer Shaft	None	263 (Red)
Shaft Assembly to Valve Body	10 Nm	263 (Red)
Oil Seal Head	30 Nm	None
RAMP Tube	14.5 Nm	None

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.

TSB052 - Tigon Top Out Bumper Update

Damper Reassembly

Step 1 – IFP Install

Thoroughly grease and install IFP quad ring (.DB11120). Reinstall IFP into IFP tube. Use plastic pick to help work past tube rim. Remove bolt from IFP. Set IFP just below flush with the edge of the IFP tube. No deeper than 10mm.

IFP Quad Ring Greased

IFP Quad Ring Install

IFP Quad Ring Installed

IFP Install 1

IFP Install 2

IFP Installed

Step 2 – Oil Seal Head Assembly

100 hour service – Thoroughly grease and install inner (ADD0129) & outer (ADD0138) quad rings and o-ring (AAD0771) on oil seal head. Inner quad ring will require Shaft Seal Head Bullet (ADD0327).

400 hour service – Thoroughly grease outer inner quad ring on new oil seal head (ADD0342).

Both – Install spring and sleeve into oil seal head. Press on spring to seat properly.

Oil Seal Head O-Ring Install

Oil Seal Head Outer Quad Ring Install

Oil Seal Head Outer Quad & O-Rings Installed

Oil Seal Head Inner Quad Ring Install

Oil Seal Head Inner Quad Ring Install w/ Plastic Pick

Oil Seal Head Inner Quad Ring Install w/ Bullet Tool

Greasing Oil Seal Head Inner Quad Ring

Oil Seal Head Spring & Sleeve Install

Oil Seal Head Spring & Sleeve Installed

Oil Seal Head Spring & Sleeve Compressed to Seat

Step 3 – Oil Seal Head Assembly Install

Insert Shaft Seal Head Bullet tool (ADD0327) into non-threaded end of shaft. Slide oil seal head onto shaft followed by coupler o-ring. Sleeve may slide out of assembly. Slide it back into spring.

Oil Seal Head Bullet Tool Install

Oil Seal Head Bullet Tool Installed

Oil Seal Head Install 1

Oil Seal Head Install 2

Oil Seal Head Installed

Coupler O-Ring Install

Step 4 – Main Piston Install

Lightly grease piston o-ring (AAD0800) and install. Install piston ring (ADD0182). Install shim stack and piston on inner shaft. Ensure rounded edge of stop washer goes towards coupler shelf. Concave side of piston faces out. Install shaft nut and finger tighten.

Stop Washer Orientation on Coupler

Main Piston Orientation on Coupler

Main Piston Installed

Main Piston & Shims Installed

Shaft Nut Install

Complete Shim Stack Orientation

Step 5 – Complete Shaft Assembly

Grease and install new top out bumper (ADD0188) on outer shaft. Insert inner shaft into outer shaft. Apply red (263) Loctite to inner shaft threads. Thread shafts together. Slide top out bumper against coupler. Grease and install shaft o-ring (ADD0183) on shaft. Apply red (263) Loctite outer shaft threads.

TSB052 - Tigon Top Out Bumper Update

Inner Shaft Install

Loctite on Inner Shaft Threads

Shaft O-Ring Install

Loctite on Shaft Assembly Threads

Step 6 – Valve Body Prep

Grease and install inner (AAG0445) and outer (ACD0317) valve body o-rings into valve body. Clamp valve body in soft jaw vise.

Inner Valve Body O-Ring Greased

Inner Valve Body O-Ring Install 1

Inner Valve Body O-Ring Install 2

Outer Valve Body O-Ring Greased

Outer Valve Body O-Ring Install 1

Outer Valve Body O-Ring Install 2

Outer Valve Body O-Ring Install 3

Outer Valve Body O-Ring Install 4

Step 7 – Shaft Assembly Install

Thread shaft into valve body. Using 12mm crowsfoot or socket, tighten entire shaft assembly onto valve body to 10 Nm.

Shaft Assembly Install

Threading Shaft Assembly into Valve Body

Tightening Shaft Assembly into Valve Body

Torquing Shaft Assembly into Valve Body

Step 8 – Damper Tube Install

Apply suspension oil to piston band. Install outer damper tube onto oil seal head and thread it on. Clamp end eye in vise. Using Tigon Oil Seal Head Pin Spanner (BDD0320), torque seal head to 30 Nm.

Lubing Main Piston Band

Damper Tube Install

Threading Damper Tube onto Oil Seal Head

Torquing Oil Seal Head onto Damper Tube

Damper Fill

Step 1 – Prepping Shock for Fill

Remove fill screw using T20 wrench. Discard o-ring. Insert Tigon IFP Service Plug (ADD0328) into IFP tube, pushing the IFP to the correct depth. Install the reservoir tube onto the IFP tube to secure the IFP Plug in place. Hand tighten. Thread fill nozzle onto valve body with new fill screw o-ring (.DB11102) either on tool or in shock. Back all adjusters to fully open and open Climb Switch. Fully compress damper. Attach oil fill machine to fill port per your manufacturer’s instructions.

Fill Screw Removed

IFP Service Plugs

IFP Service Plug Install

Securing IFP Service Plug

Hand Tightening Res Tube on IFP Tube

Attaching Fill Needle

Fill Needle Attached, Shock Compressed

Fill Machine Connected, Shock Compressed

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.

Oil Pre-Fill

Damper Fill, Shaft Extended

Vacuum System to (-4) mbar

Damper Fill, Shaft Compressed

Oil Fill to 3 bar

Damper Fill, Final Shaft Extension

Step 3 – Valve Body Closure

Holding horizontal, disconnect fill machine. Drip some oil on to top of fill. Install oil fill screw with T20, ensuring o-ring is present. Remove res tube and IFP Plug.

Fill Screw Install

Res Tube and IFP Plug Removal

RAMP Tube Reassembly

Step 1 – Reservoir Tube Install

Install new gas fill plug (.DB11115) in reservoir tube. Chamfer goes towards res tube. Using 4mm Allen, reinstall set screw, but do not tighten. Thread res tube onto valve body. Tighten with strap wrench.

Gas Fill Plug Chamfer

Gas Fill Plug Install

Gas Fill Set Screw Install

Res Tube Install

Threading Res Tube onto Valve Body

Tightening Res Tube onto Valve Body

Step 2 – Nitrogen Fill

Insert gas fill needle in gas fill port on reservoir tube. Pressurize to 11-12 bars of nitrogen. Tighten fill plug set screw with 4mm. 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.

Inserting Fill Needle

Fill Needle Attached

Connect Nitrogen Hose

Nitrogen Filled to Pressure

Gas Plug Set Screw Tightened

Gas Leak Dunk Test

Step 3 – RAMP Tube Install

Lightly grease inner rim of RAMP tube and outer edge of oil seal head. Install RAMP tube on damper tube, using a pick to work RAMP tube past oil seal head. Install stroke reduction if needed. Be sure to seat fin on reduction in valve body properly. Clamp valve body in soft jaw vise. Using 34mm crowsfoot, tighten RAMP tube onto valve body to 14.5 Nm.

Greasing RAMP Tube

Greasing Oil Seal Head

RAMP Tube Install

Working Oil Seal Head Past RAMP Tube Lip 1

Working Oil Seal Head Past RAMP Tube Lip 2

RAMP Tube Past Oil Seal Head

Stroke Reduction Install

Stroke Reduction Installed on Shaft

Stroke Reduction Installed in Valve Body

Seating RAMP Tube on Valve Body

RAMP Tube Seated on Valve Body

Valve Body Clamped for RAMP Tube Install

Threading RAMP Tube on Valve Body

Torquing RAMP Tube on Valve Body

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.