Air IL Complete 100 Hour Service Instructions (Part 1 of 3)
Air IL Complete 100 Hour Service Instructions
May 2023 orig., May 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 Air IL and Coil IL as well as the Standard and Trunnion and Previous Gen and Current Gen variants of both share many service steps. Some images in these instructions may not be identical to the he valve body or outer damper tube to the shock being serviced, but that is only when the process is the same for the shock in the image and the shock on your bench. When steps vary, that will be noted and images included.
Service Kits
BAD1214-G2 or BAD1214T-G2 – Air IL G2 Damper Rebuild Kit (Standard or Trunnion)
BAD2279-G2 – Air IL G2 Air Spring Rebuild Kit
Required Cane Creek Tools
BCD0344 – Kitsuma/DBair/DBair IL Air Seal Head Tool
AAD1193 – Air Seal Head Bullet – Red
BAD1459 – Air Piston Funnel
BAD1032 – Gland Nut Wrench
BAD1174 – Oil Seal Head Pin Spanner Wrench
.DBT010 – DB 8mm Shaft Thread Cover (included in Rebuild Kit)
BAD2651 – IL G2 Fill Needle assembly
DBT016 – DB Gas Fill Needle
AAD0555 – 8mm & 9.5mm Shaft Clamp
AAD1454 – Kitsuma/IL Trunnion CS Bullet
BAD1273 – Inner Damper Tube Install Tool
AAD2650 – IL G2 Service Cradle (Standard Mount only)
Additional Tools & Supplies
Allen wrenches – 1.5, 3 & 4mm
Torx wrenches – T10, T15 & T25
1/2″ crowfoot wrench
Torque wrenches
Pick
Suspension Grease
Royal Purple 10w-30 Oil
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) |
| Air Piston Screws | 3.2 Nm | 243 (Blue) |
| End Eye | 4.8 Nm | 243 (Blue) |
| Inner Air Can/Air Seal Head | 22.6 Nm | None (PolyLube) |
Oil Chart
| Oil Location | Oil Type | Oil Amount |
|---|---|---|
| Air Can | Royal Purple 10w-30 | 5 mL |
| 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 Air IL specific TSBs at this time.
General Prep
Clean shock. Record tune if desired. Remove hardware. Remove bushings if replacing. Remove valve cap. Bleed air from shock using shock pump. Be sure to depressurize shock slowly to avoid trapping air in the negative chamber.
Hardware & Bushing Removed
Valve Cap Removed
Pump Attach
Air Bleed
Air Spring Disassembly
Step 1 – Outer Air Can Removal
Clamp shock in vise using soft jaws. Remove air can circlip using a pick. Flip the shock in the vise. Using strap wrench, twist and apply downward force to free outer air can. Work outer air can past end eye to remove completely. Note any air volume reduction.
Clamped for Air Can Circlip Removal
Air Can Circlip Removal
Air Can Circlip Removed
Strap Wrench on Air Can
Air Can Freed Past First O-Ring
Air Can Removed
Step 2 - Freeing Inner Air Can
Reclamp shock. Align teeth on Air Seal Head Tool (BAD1273) with grooves on air seal head. Unthread air seal head/inner air can from end eye. Splash oil may be present. Slide inner air cap up shock body to expose shaft.
Air Seal Head Wrench IL End
Air Seal Head Wrench on Air Seal Head
Freeing Inner Air Can from End Eye
Inner Air Can Freed from End Eye 1
Inner Air Can Freed from End Eye 2
Step 3 - End Eye Removal
Slide inner air can up shock body to expose shaft. Clamp shaft in 8mm shaft clamp with end eye up. Remove end eye using 1/2″ crows foot. Pinch & remove then discard inner can o-ring and stop shim from end eye. Remove any stroke reduction spacer, shim and bottom out bumper.
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.
Clamped for End Eye Removal
Freeing End Eye
End Eye Removed
End Eye O-Ring Removal
Stop Shim Removal
Stop Shim Removed
Stroke Reduction, Shim & Bottom Out Bumper Removal
Stroke Reduction, Shim & Bottom Out Bumper Removed
Step 4 - Air Piston Removal
Using T10 loosen and slowly remove all 3 air piston screws. Use caution as this will release any air trapped in negative chamber. Pull up on inner air can to remove inner air can and piston. Press piston out of inner air can. Remove 2 L-back up rings, quad ring and interior o-ring from piston and discard.
Air Piston Set Screw Removal
Inner Air Can Removal
Air Piston Removal 1
Air Piston Removal 2
Back Up Ring Removal
Back Up Rings, Quad Ring & O-Ring Removed
Step 5 – Inner Air Can Disassembly
Remove both o-rings and blue wiper seal from inner air can. Remove 2 L-back up rings and quad ring from interior of inner air can. Remove sag o-ring. Discard all rings, seals and wiper. Inspect inner air can for wear. Replace as necessary.
Sag O-Ring Removal
Inner Air Can O-Ring Removal
Inner Air Can Wiper Seal Removal
Inner Air Can Back Up Ring Removal
Inner Air Can Quad Ring Removal
Inner Air Can Inspection
Damper Disassembly
Step 1 – Gas & Oil Removal
***Use caution as nitrogen is pressurized.***
Standard Valve Body Degassing:
Loosen gas fill cover half a turn with 4mm Allen. Bleed gas with gas fill needle. Remove gas fill cover completely. Use pick to pry out gas fill plug.
Trunnion Valve Body Degassing:
Bleed gas with gas fill needle.
Oil Removal for Both:
Remove oil fill screw with T15. Remove slowly as there may be aerated oil behind fill screw. Empty oil through fill screw by cycling the damper.
Backing Off Standard Valve Body Gas Fill Cover
Degassing Standard Valve Body
Removing Standard Valve Body Gas Fill Cover
Removing Standard Valve Body Gas Fill Fill Plug
Degassing Trunnion Valve Body 1
Degassing Trunnion Valve Body 2
Standard Valve Body Oil Fill Screw Removal
Cycling Oil From Standard Valve Body
Trunnion Valve Body Oil Fill Screw Removal
Cycling Oil From Trunnion Valve Body
Step 2 – Oil Seal Head & Shaft Assembly Removal
Clamp shock valve body in vise. Use Oil Seal Head Pin Spanner (BAD1174) to free oil seal head. Remove shaft assembly from damper body. Outer damper tube will likely come off as well. Pour out any remaining oil from damper body. Remove outer damper tube if still installed.
Air IL Trunnion Valve Body Clamped
Freeing Oil Seal Head
Oil Seal Head (w/ Damper Tube) Removal
Oil Disposal
Oil Seal Head Removal from Outer Damper Tube
Step 3 – Inner Damper Tube Removal
Using Inner Damper Tool Wrench (BAD1273), remove inner damper from valve body. Inspect interior of inner damper tube for piston band wear. Inspect damper tube threads and remove any remaining Loctite with pick. Clean thoroughly. Replace inner damper tube if necessary. Remove valve body o-ring and discard.
Attaching Inner Damper Tube Tool Wrench
Inner Damper Tube Tool Wrench Attached
Freeing Inner Damper Tube
Removing Inner Damper Tube
Inspecting Interior of Inner Damper Tube
Removing Valve Body O-Ring
Step 4 – Gland Nut & Bladder Removal
Using T10, remove Climb Switch lever screw. Remove CS lever. Reclamp valve body in vise. Use Service Cradle (AAD2650) for Standard valve body. Using Gland Nut Wrench, remove gland nut. Breaker bar may be required. Pry off gland cover or end eye. Remove bladder with pick and discard.
Climb Switch Lever Screw Removal (Standard)
Climb Switch Lever Screw Removal (Trunnion)
Climb Switch Lever Removal
Standard Body Clamped in Service Cradle
Standard Body Freeing Gland Nut
Standard Body Gland Nut Removed
End Eye Removed
Trunnion Body Freeing Gland Nut
Trunnion Body Gland Nut Removal
Trunnion Body Gland Nut Removed
Trunnion Body Prying Gland Cover
Trunnion Body Gland Cover Removal
Standard Body Bladder Removal
Trunnion Body Bladder Removal
Step 5 – CS Spool Valve Removal
Using a 1.5mm Allen, remove 2 set screws located inside of valve body next to inner damper tube purchase. Remove remaining set screw in valve body exposing spring and detent ball. Remove spring and detent ball. Using CS lever, unthread spool valve and remove. Pinch & remove and discard spool valve o-ring.
Set Screw Removal
Detent Screw Removed
Detent Spring Removal
Detent Spring Removed
CS Set Screw, Spring & Detent
Using CS Lever to Back out Spool Valve
Spool Valve Backed Out
Spool Valve O-Ring Removal
Step 6 – High Speed Adjusters Removal
Using 3mm Allen, dial High Speed adjusters in to gain access to High Speed circlips. Remove circlips. Back High Speed adjusters all the way out. Pinch & remove and discard o-rings on adjusters.
Note that the Compression spring is 20wt (silver), rebound is 30wt (black).
Dialing in HS Adjustor
HS Adjustor Circlip Removal
HS Adjustor Removed
HS Spring Removed
HS Springs in Adjustors (Comp, Rebound)
HS O-Ring Removal
Step 7 – Low Speed Adjusters Removal
Gently bottom out Low Speed adjuster needles with 3mm Allen. Rotate circlip until the end lines up with removal groove. Using pick, get behind circlip, remove and discard. Unthread and remove needles. Remove and discard o-rings.
Aligning Low Speed Rebound Circlip
Low Speed Rebound Circlip Removal
Low Speed Rebound Needle Removal
Low Speed Rebound Needle w/ Detent Balls & Spring Removed
Low Speed Rebound Needle O-Ring Removal
Continue to Part 2
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