Air IL Complete 100 Hour Service Instructions (Part 2 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 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.
TSN Disassembly (if desired)
TSN service is not required as part of a standard IL service. However, if the shock exhibits any audible sounds, usually a “chirp”, during use, this could be related to a bent TSN spring. No additional parts are required to do the TSN service. Images from Previous Gen DB IL valve body, but the process is identical to the Next Gen IL.
Step 1 – TSN Removal
Remove TSN stem from valve body using T15 from both High Speed valves. Clean valve body TSN threads with tap if green Loctite has built up on threads
TSN Removal from High Speed Valves
TSN Removed from High Speed Valves
Step 2 – TSN Disassembly
Disassemble TSN assembly by unthreading spring from the TSN stem. Remove TSN shim, piston and poppet.
TSN Disassembly 1
TSN Disassembly 2
TSN Disassembly 3
TSN Disassembly 4
TSN Disassembled
Step 3 – TSN Inspection
Inspect spring for possible bent end of spring tail which can cause valve chirp. (Correcting bent spring covered in TSN Reassembly.)
TSN Spring - Good vs. Bad 1
TSN Spring - Good vs. Bad 2
TSN Stem
Shaft Disassembly
Step 1 – Piston Assembly Removal
Clamp shaft in vise with oil seal head end up. Remove shaft bolt with T25. Remove piston, shims and stop washer, noting orientation.
Shaft Clamped for Disassembly
Freeing Shaft Bolt
Piston, Shim & Stop Washer Removal
Piston and Shim Stack Orientation
Step 2 – Shim & Piston Inspection
Check face shim for port wear and flip on reinstall if necessary. Check ports on piston for excessive wear. If present, resurfacing or replacement of piston may be necessary. Carefully cut piston band off piston. Pinch & remove piston o-ring.
Sealing Shim with Port Wear
Piston with Port Wear
Piston Band Removal
Piston O-Ring Removal
Step 3 – Final Disassembly
Remove oil seal head and top out bumper. Discard oil seal head only.
Oil Seal Head Removal
Top Out Bumper Removal
Shaft Reassembly
Step 1 – Piston Reassembly
Install new piston o-ring (AAD0800) and piston band (AAD0469) on piston.
Piston, O-Ring & Band
O-Ring Install on Piston
Band Install on Piston
Step 2 – Piston and Shim Stack Install
Reassemble shim stack, flipping face shim if necessary, and reinstall stop washer, shim stack and piston on shaft. Add one drop of blue Loctite (243) on the shaft threads. Install shaft bolt with T25. Torque to 5 Nm.
When installing the piston bolt, keep downward pressure on the piston with your other hand to prevent any Loctite from getting between the piston and face shim.
Piston and Shim Stack Orientation
Piston & Shim Stack Installed
Apply Loctite to Shaft
Install Shaft Bolt
Torque Shaft Bolt
Step 3 – Top Out Bumper & Oil Seal Head Install
Grease the bushing and quad ring of oil seal head. If available, slide shaft cover (.DBT010 – discontinued) on shaft to cover threads only. Trim shaft cover to length if necessary. If cover not available, you can use tape to cover threads or simply take care installing seal head. Install new top out bumper (AAD1090) and new oil seal head (AAD2643). Remove shaft cover if used.
Shaft Cover Install (if available)
Shaft Cover Installed & Trimmed (if available)
Top Out Bumper Installed
Oil Seal Head Installed
TSN Reassembly (if required)
Step 1 – Prepping TSN Springs, Pistons & Poppets
If TSN spring tail is bent, trim the spring to remove damaged end. Surface piston and poppet if necessary using a surfacing block or high grit sandpaper.
TSN Spring - Good vs. Bad
Trimming Bent TSN Spring
TSN Piston & Poppet
Resurfacing TSN Piston & Poppet
Step 2 – Rebound TSN Reassembly
Rebound TSN stem has a small bleed port. Reinstall poppet, piston, and shim, noting the correct orientation for rebound: On piston, small ports face poppet; large ports face shim. Thread spring onto stem.
TSN Rebound Side Disassembled
TSN Rebound Stem w/ Port
TSN Rebound Stem w/ Poppet Installed
TSN Rebound Stem w/ Piston Installed
TSN Rebound Stem w/ Shim Installed
TSN Rebound Stem w/ Spring Installed
Step 3 – Compression TSN Reassembly
Compression TSN stem has no bleed port. Reinstall poppet, piston, and shim, noting the correct orientation for compression: On piston, large ports face poppet; small ports face shim. Thread spring onto stem.
TSN Compression Stem w/o Port
TSN Compression Stem w/ Poppet Installed
TSN Compression Stem w/ Piston Installed
TSN Compression Stem w/ Shim Installed
TSN Compression Stem w/ Spring Installed
Step 4 – TSNs into Valve Body Install
With a straight pick apply a small amount of green Loctite (668) to TSN threads in valve body. Install TSNs ensuring the correct TSN is installed on the correct side of valve body. Torque to 0.6 Nm with T15.
TSN Seat in Valve Body
TSN Seat in Valve Body - Close-Up
Loctite on Pick
Applying Loctite to Rebound TSN Threads
Applying Loctite to Compression TSN Threads
Installing Rebound TSN
Installing Compression TSN
Continue to Part 3