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Tigon Complete 100 & 200 Hour Service Instructions

Feb 2024 orig., Mar 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 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. 200 hour service

The only difference between the 100 hour service and the 200 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 200 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 Kit

 

BDD0341– Tigon Complete 100 Hour Rebuilt Kit
OR
BDD0343– 
Tigon Complete 200 Hour Rebuilt Kit

Required Cane Creek Tools

 

ADD0320 – Tigon Oil Seal Head Pin Spanner
ADD0327 – Tigon Shaft Seal Head Bullet
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

No TSBs exist for Tigon.

General Prep

Clean shock. Record tune if desired. Remove hardware. Remove bushings if replacing. Remove preload collar circlip. Remove preload collar and spring.

RAMP Tube Removal

Step 1 –  Nitrogen Bleed & Air Removal 

***Use caution as nitrogen is pressurized.***

Back off gas fill screw using 4mm Allen. Use fill needle to release nitrogen charge. Remove valve cap and release any air from RAMP tube. Remove spring spacer.

Step 2 – RAMP Tube Removal

Clamp valve body in soft jaw vise. Loosen RAMP tube using 34mm crowsfoot. Use caution as contents of shock can still have pressurized gas. Hold outer damper tube and remove RAMP tube.

Damper Disassembly

Step 1 – Damper Tube Removal

Flip shock in vise. Using Tigon Oil Seal Head Pin Spanner (ADD0320), loosen oil seal head. Unthread oil seal head from damper tube and remove complete assembly. Pour off damper oil into proper disposal container. Inspect interior of outer damper tube for any damage.

Step 2 – Shaft Assembly Removal

Clamp valve body in soft jaw vise. Using 12mm crowsfoot or socket, loosen shaft assembly via shaft nut. Heat may be used to help free shaft assembly. Remove shaft assembly and any stroke reduction if present. If shaft nut threads off rather than assembly, clamp shaft with 12.7mm shaft clamp and turn valve body to unthread. Using pick, remove both valve body o-rings and discard.

Always use extreme caution when using a pick in this step or others to avoid scratching metal parts. Failure to do this can create scratches in the o-ring glands which cause leak paths for oil or gas. When possible, pinch and remove o-rings rather than using a pick.

Step 3 – Piston and Shim Stack Removal

Remove shaft o-ring and discard. Clean shaft threads of any Loctite and thoroughly clean shaft assembly. Using 12.7mm shaft clamp, secure shaft assembly in vise with piston up. With 12mm crowsfoot or socket, loosen shaft nut and remove. Remove piston and shim stack, noting shim sequence. Remove and discard piston band and o-ring.

Step 4 – Shaft Disassembly

Using 19mm open end wrench, loosen shaft coupler and remove. Heat my be used to help free shaft components. Remove coupler o-ring. May be on coupler or on shaft. Remove oil seal head assembly from shaft. Remove spring and sleeve from oil seal head assembly and retain.

Step 5 – Oil Seal Head Disassembly

Inspect Oil Seal Head for bearing wear. If worn, discard and replace entire assembly (200 hour service). If bearings are in good condition, proceed with disassembly.

Using pick, remove internal quad ring, external quad ring & o-ring and discard. Thoroughly clean seal head assembly (100 hour service).

Inspect shaft for wear.

Step 6 – Outer Reservoir Tube Removal

Thoroughly clean outside of outer resevoir tube and clamp valve body in vise. Unthread outer reservoir tube. Strap wrench may be necessary. Remove tube. Remove gas fill screw from res tube with 4mm Allen. Remove and discard fill plug.

Step 7 – IFP Removal

Thread M8x1.25mm bolt into IFP and pull IFP out of inner reservoir tube. Using pick, remove IPF quad ring and discard.

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 depth to around 10mm for fill. (Final IFP depth is 20mm.)

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).

200 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.

Step 3 – Oil Seal Head Assembly Install

Insert Shaft Seal Head Bullet tool 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. 

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.

Step 5 – Complete Shaft Assembly

Insert inner shaft into outer shaft. Apply red (263) Loctite to inner shaft threads. Thread shafts together. Grease and install shaft o-ring (ADD0183) on shaft. Apply red (263) Loctite outer shaft 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.

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.

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 (ADD0320), torque seal head to 30 Nm.

Damper Fill

Step 1 – Prepping Shock for Fill

Remove fill screw using T20 wrench. Discard o-ring. Secure shock with IFP secured and set at 20mm (or less if setting depth after fill) from rim of res tube to top of IFP. 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.

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.

Step 3 – Valve Body Closure

If IFP depth still needs to be set, do so now at 20mm from rim of res tube to top of IFP. Holding horizontal, disconnect fill machine. Drip some oil on to top of fill. Install oil fill screw with T20, ensuring o-ring is present.

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.

 

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.

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.

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

Install spring spacers and then spring. Install coil preloader with correct orientation for shock size. Install preloader clip.

Install any bushings and hardware.

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