Air IL Complete 100 Hour Service Instructions (Part 3 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 Reassembly
Step 1 – Prepping Low Speed Needles
Lightly grease and install o-ring (.DB11102) on Low Speed needles. Apply a small amount of grease on the needle hole and reinstall spring and detent balls (ball-spring-ball).
Installing O-Ring on Low Speed Needle
O-Ring on Low Speed Needle
Low Speed Needle Ready for Install
Step 2 – Low Speed Needles Install
Press, then thread needle into Low Speed control on valve body. Take care to not catch o-ring on circlip removal grove. Thread past circlip shelf. Confirm presence of detent clicks at this point. Install new circlip (AAD0920) into groove. Back needle out gently to ensure proper seatment of circlip.
Low Speed Needle Started into Valve Body
Working O-Ring Past Circlip Grove
Low Speed Circlips
Low Speed Circlips Installed
Step 3 – Prepping High Speed Adjusters
Install lightly greased o-rings (AAD0478) onto adjusters.
High Speed Adjustor Parts
Installing O-Ring on High Speed Adjustor
Installed O-Ring on High Speed Adjustor
Spring Installed on High Speed Adjustor (Rebound)
Step 4 – High Speed Rebound Adjuster Install
Thread High Speed adjuster with 30wt (black) spring into Rebound valve. Be sure to thread past circlip shelf. Install circlip (AAD0947). Back adjuster out gently to ensure proper seatment of circlip.
Trunnion High Speed Rebound Install 1
Trunnion High Speed Rebound Install 2
Trunnion High Speed Rebound Circlip Install
Trunnion High Speed Rebound Circlip Seating
Step 5 – High Speed Compression Adjuster Install
Thread High Speed adjuster with 20wt (silver) spring into Compression valve. Be sure to thread past circlip shelf. Install circlip (AAD0947). Back adjuster out gently to ensure proper seatment of circlip.
Trunnion High Speed Compression Install 1
Trunnion High Speed Compression Install 2
Trunnion High Speed Compression Circlip Install
Trunnion High Speed Compression Circlip Seating
Step 6 – Spool Valve Install
Lightly grease and install o-ring (AAD2579) on spool valve using CS Bullet tool (AAD1454). Install spool valve into valve body using the CS Lever. Bottom out spool valve, then back out approximately one full rotation to have spool valve to a 3:30 position.
Spool Valve O-Ring Install
Spool Valve O-Ring Installed
Spool Valve Install
Spool Valve Installed & Clocked
Step 7 – Climb Switch Set Screws Install
Apply blue Loctite (243) to the three CS set screws. Reinstall 2 CS set screws into bottom of valve body. Note approach angle. Torque to 0.2 Nm using 1.5mm Allen. Install lightly greased detent and spring into threaded detent capture hole on top of valve body. Reinstall remaining CS set screw to capture detent and spring. Torque to 0.2 Nm using 1.5mm Allen. Test CS function. If binding, back off set screw half turn.
CS Set Screw Loctite
CS Set Screw Install 1
CS Set Screw Install 2
CS Detent Ball Install
CS Detent Spring
CS Detent Spring Install
CS Detent Spring Installed
CS Set Screw Install 3
Step 8 – Valve Body O-ring & Bladder Install
Lightly grease and install o-ring (AAD0955) on valve body. Ensure o-ring is fully seated in groove. Gently work dry bladder (AAD2468 for Trunnion, AAD1333 for Standard) onto valve body groove. Ensure it is seated all the way around.
Valve Body O-Ring Installation
Trunnion Valve Body Bladder Installation
Trunnion Valve Body Bladder Installation
Valve Body Bladder Installed
Step 9 – Gland Cover/End Eye Install
Apply grease to entire bladder surface, focusing on edges where gland cover/end eye will contact. Place gland cover/end eye on bladder. Install gland nut using an inch feed of blue Loctite (243). Set correct gland cover/end eye orientation and allow gland nut to self seat cover. Clamp valve body in vise (Trunnion) or cradle (Standard). Hand thread gland nut tight. Using Gland Nut Wrench torque gland nut to 52 Nm.
Greasing Bladder
End Eye & Gland Nut Set
End Eye & Gland Nut Set w/ Loctite
Gland Cover & Gland Nut Set w/ Loctite
Step 10 – Inner Damper Tube Install
Ensure all old Loctite is removed from inner damper tube. Apply fresh red Loctite (263) to threads. Flip valve body in vise. Thread inner damper tube into valve body. Using inner damper tube wrench, torque to 17 Nm.
Inner Damper Tube Loctite Removal
Inner Damper Tube Loctite Removed
Inner Damper Tube Loctite Application
Standard Inner Damper Tube Install
Trunnion Inner Damper Tube Install
Attaching Inner Damper Tube Wrench
Torquing Inner Damper Tube
Step 11 – Outer Damper Tube Install
Apply thin layer of shock oil to outer damper tube on the end without an internal chamfer. Press and rotate outer damper tube into valve body until seated on o-ring.
Outer Damper Tube w/ Internal Chamfer
Outer Damper Tube w/o Internal Chamfer
Coating Outer Damper Tube w/ Shock Oil
Outer Damper Tube Install
Seating Outer Damper Tube
Step 12 – Shaft Assembly Install
Apply thin layer of shock oil to piston band on shaft assembly. Use piston to apply layer of shock oil to inner surface of outer damper tube. Insert shaft assembly into inner damper tube, threading oil seal head into outer damper tube. Using Oil Seal Head Wrench, tighten oil seal head to 15 Nm.
Use non-threaded holes and ensure all three pins are properly seated and even pressure is applied to tool to prevent damaging tool pins.
Applying Oil to Air Piston
Shaft Assembly Install
Oil Seal Head Pin Holes
Aligning Seal Tool Pins w/ Seal Head Pin Holes
Seating Outer Damper Tube
Step 13 – Climb Switch Install
Place Climb Switch on spool valve. Apply blue Loctite (243) to Climb Switch screw. Install Climb Switch screw. Torque to 1.2 Nm with T10.
Climb Switch Lever Install
Climb Switch Screw Loctite
Climb Switch Screw Install
Continue to Part 4
Next