Air IL Complete 100 Hour Service Instructions (Part 4 of 4)
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.
Damper Fill
Step 1 – Prepping Shock for Fill
Install new o-ring (AAD0532) on fill plug screw. Temporarily install end eye on shaft. Secure shock in horizontal position with fill port facing up. Back all adjusters to fully open and open Climb Switch. Thread IL G2 oil fill adaptor (BAD2651) into fill port. Fully compress damper. Attach oil fill machine per your manufacturer’s instructions.
New O-Ring on Fill Screw
Trunnion Shock Set Horizontally
Standard Shock Set Horizontally
Fill Needle Attached
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
Cycling Shock
Oil Pre-Fill
Oil Fill to (3) bar
Step 3 – Valve Body Closure
Leaving horizontal, disconnect fill machine. Unthread fill needle. Drip some oil on to top of fill. Install oil fill screw with T15.
Disconnecting Fill Machine
Installing Oil Fill Screw (Standard)
Installing Oil Fill Screw (Trunnion)
Oil Fill Screw Installed (Trunnion)
Step 4 – Nitrogen Fill
For Standard mount, Install gas fill plug (.DB11115) chamfer first. Thread fill screw in halfway. Trunnion, begin here. Insert gas fill needle (DBT016) and pressurize to 11-12 bars of nitrogen. Thread fill screw flush. 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.
Install Gas Fill Plug (Standard only)
Install Gas Fill Plug Screw (Standard only)
Insert Nitrogen Fill Needle (Standard)
Insert Nitrogen Fill Needle (Trunnion)
Connect to Nitrogen Hose
Nitrogen Filled to Pressure
Threading Fill Screw Flush (Standard only)
Compression Test
Leak Test
Air Spring Reassembly
Step 1 – Air Piston Reassembly
Ensure inner and outer air cans, end eye, and piston are thoroughly cleaned. Grease piston quad ring channel. Thoroughly grease all sides of quad ring (ADD0125). Install quad ring on piston channel. Pre-compress back up L-rings (AAD2572) to improve fit on piston. Install back up L-rings on either side of quad ring, ensuring that flat side contacts quad ring.
Quad Ring Install on Air Piston
Air Piston L-Ring
Air Piston L-Ring Install
Air Piston Assembled
Step 2 – Inner Air Can Quad Ring Install
Grease lower channel on interior of inner air can. Install first L-ring (AAD1134) on lower shelf with flat side toward interior of channel. Thoroughly grease all sides of quad ring (AAD1846). Install quad ring into channel. Install second L-ring (AAD1134) on top of quad ring with flat side against quad ring.
Greasing Quad Ring Channel
First Air Can L-Ring Install
First Air Can L-Ring Installed
Greasing Quad Ring
Air Can Quad Ring Installed
Second Air Can L-Ring Install
Second Air Can L-Ring Installed
Step 3 – Inner Air Can Wiper & O-Ring Install
Install dry wiper seal (AAD0415) into top groove of inner air can. Thoroughly grease upper inner assembly of air can. Grease and install inner air can outer o-rings (AAD2142) on exterior of air can in the two grooves. Lightly grease the lower interior inner air can. Excess grease can clog charge port.
Air Can Wiper Install
Air Can Wiper Installed
Air Can O-Ring Install
Air Can O-Ring Installed
Inner Air Can Grease
Step 4 – End Eye & Outer Air Can Prep
Grease and install o-ring (AAD2142) into top groove on lower end eye. Insert stop shim (AAD1542) into end eye. Press into place below threads. Grease inner ridges of both ends on outer air can.
Air Can End Eye O-Ring Install
Air Can Stop Shim Install
Air Can Stop Shim Installed
Outer Air Can Grease 1
Outer Air Can Grease 2
Step 5 – Inner Air Can Install
Clamp valve body in vise. Place Oil Seal Head Bullet (AAD1193) onto shaft. Install sag indicator o-ring (.DB11108). Install inner air can. Gently work the can past the bullet tool onto the body with a slight rotation and even pressure.
Sag O-Ring Install
Oil Seal Head Bullet on Shock
Inner Air Can Install
Inner Air Can Installed
Step 6 – Air Piston Install
Thoroughly grease air piston o-ring (AAD2573) and place on oil seal head grove. Thoroughly grease the exterior of air piston. Apply blue Loctite (243) to three air piston set screws. Place IL G2 Air Piston Funnel (ADD0313) on inner air can. Set inner air can halfway on outer damper tube to allow for space to install air piston. Install piston with set screw holes facing out. Gently work piston past funnel into inner air can. Bottom piston onto seal head. Once flush with seal head, rotate inner can and piston to align screw holes with seal head threads. Install piston set screws. Torque to 3.2 Nm with T10.
Air Piston O-Ring Install
Air Piston O-Ring Installed
Greasing Air Piston
Prepping Piston Set Screws
Air Piston Funnel on Inner Air Can
Air Piston Installed Through Funnel
Aligning Air Piston w/ Seal Head
Piston Set Screws Install
Step 7 – End Eye Install
Reinstall bottom out bumper, shim and stroke reduction (if present). Apply blue Loctite (243) to shaft threads and end eye threads. Thread end eye onto the shaft. Clamp shaft into vise with shaft clamp allowing space for end eye to clear vise when tightened. Using 1/2″ crowsfoot, torque end eye to 4.8 Nm. Clean any extra Loctite from shaft and end eye.
Bottom Out Bumper Installed
Shim Installed
Stroke Reduction Installed
Applying Loctite to Shaft
Applying Loctite to End Eye
Threading Shaft to End Eye
Clamping Shaft w/ Ample Space
Torquing End Eye
Cleaning Shaft & End Eye of Loctite
Step 8 – Inner Air Can to End Eye Install
Clamp end eye in vise. Add 5 ml of Royal Purple to end eye. Add PolyLube grease to threads on inner air can. Thread inner air can onto end eye. Torque to 22.6 Nm using Air Seal Head tool.
Clamped for Inner Air Can to End Eye Install
Adding Oil to End Eye
Adding PolyLube to Inner Air Can
Lowering Inner Air Can onto End Eye
Threading Inner Air Can onto End Eye
Air Seal Head Tool
Air Seal Head Tool on Inner Air Can
Step 9 – Outer Air Can Install
Clamp valve body end into vise. Work outer air can gently past o-rings. Note correct orientation of air can and reinstall any volume reduction. Final o-ring will be tight. Strap wrench may be necessary. Engage Climb Switch to aid installation. Ensure valve is oriented away from Climb Switch. Install outer air can retention clip.
Shock Clamped (Trunnion)
Outer Air Can Installation 1
Outer Air Can Installation 2
Outer Air Can Installed
Outer Air Can Retention Ring Install
Outer Air Can Retention Ring Installed
Final Testing and Set Up
Step 1 – Leak Check
Air up shock to at least 100 psi. On hand dyno or bike frame, slowly cycle shock and listen for negative volume chamber to pressurize. Using soapy water and dunk tank, test for any possible air leaks. Install valve cap.
Airing Up Shock
Shock on Hand Dyno
Soap Test 1
Soap Test 2
Soap Test 3
Soap Test 4
Dunk Test
High Speed Adjust
Step 2 – Dyno Test
Set adjusters to factory neutral: HSC & HSR 2.5 turns from full bottom (or 2 turns from full open); LSC 11 clicks from full bottom; LSR 13 from full bottom. 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.
Install any bushings and hardware.
High Speed Adjust
Low Speed Adjust