DBair CS Complete 100 Hour Service (Part 1 of 3)
DBair CS Complete 100 Hour Service Instructions
June 2022 orig., June 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 DBair CS and Coil CS share many service steps. Additionally, the Standard and Trunnion variants of both models have identical service procedures other than where to clamp the cylinder head. Some images in these instructions may not be identical to the the valve body or outer damper tube on the Air CS, but process is the same for the shock in the image and the shock on your bench.
Additionally, running changes happened throughout the lifespan of the Air CS. Many of those are addressed in the Technical Service Bulletins below, but always take note of the way the shock is originally built and replicate that during reassembly to maintain the original performance, tune, set up, etc.
Service Kits
BAD0241 – DBair/DBair CS Air Spring Rebuild Kit
BAD2375 – DBair CS Damper Rebuild Kit
Required Cane Creek Tools
DBT018 – DB Seal Head Pin Spanner Wrench
AAD1361-01 – DBCoil/ DBAir – Oil Fill Needle Adapter
DBT016 – DB Gas Fill Needle
AAD0555 – 8mm & 9.5mm Shaft Clamp
AAD0756 – DB Valve Seat Tool
AAD1002 – DBair Air Seal Head Bullet
BCD0344 – Kitsuma/DBair/DBair IL Air Seal Head Tool
DBT012 – DB IFP Setting Tool
Additional Tools & Supplies
Allen wrenches – 1.5 & 3mm
Torx wrenches – T20
Sockets – 6mm
Crowfoot wrenches – 1/2″
Torque wrenches
Pick
Pin Spanner
Needle Nose Pliers
Strap wrench
Suspension Grease
PolyLube Grease
Motorex 4wt Racing Fork Oil
Royal Purple 10w-30
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) |
| Climb Switch Plate Cover | 0.16 Nm | 243 (Blue) |
| Outer Damper Tube | Tight | 263 (Red) |
| Valve Seat | 4.8 Nm | None |
| Climb Switch Screw | 1.2 Nm | 243 (Blue) |
| Oil Seal Head | 15 Nm | None |
| Air Piston Screws | 4 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 | 8 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
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.
TSB018 – DBair CS & DBcoil CS Eyelet Change
Shock Ready for Service
Hardware & Bushing Removed
Air Bleed
Air Spring Disassembly
Step 1 – Outer Air Can Removal
Remove air can retaining o-ring. Clamp shock in soft jaw vise. Using strap wrench, turn air can and pull down away from air seal head. Unclamp shock. Remove air can. Note and remove any air volume reduction.
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.
Air Can Retaining O-Ring Removal
Air Can Retaining O-Ring Removed
Shock Clamped in Vise
Strap Wrench on Outer Air Can
Outer Air Can Freed
Volume Reduction Present
Step 2 – Freeing Inner Air Can & Air Seal Head
Reclamp shock. Align teeth on Air Seal Head Tool (BCD0344) with grooves on air seal head. Unthread air seal head from inner air can. Use strap wrench on inner air can to prevent rotation in end eye if necessary. Thoroughly clean inner air can with alcohol or other cleaner. Using strap wrench, remove inner air can from end eye.
Aligning Air Seal Head Tool on Seal Head
Air Seal Head Tool on Seal Head
Air Seal Head Freed from Inner Air Can
Cleaning Inner Air Can
Freeing Inner Air Can from End Eye
Inner Air Can Freed from End Eye
Step 3 – End Eye & Inner Air Can Removal
Clamp shaft in vise between end eye and inner air can.
Using 1/2″ crowsfoot, unthread end eye from shaft. Remove stroke reduction and/or spacer (if present) and bottom out bumper. Remove inner air can. Pinch & remove and discard outer air can o-rings from inner air can and end eye.
TSB005 – DBair/DBair CS Stop Shim
Clamped for End Eye Removal
Freeing End Eye
End Eye Removed, Stroke Reduction, Spacer & Bottom Out Bumper Shown
Stroke Reduction Removed
Spacer and Bottom Out Bumper Removed
Inner Air Can Removal
Outer Air Can O-Rings Removal
Step 4 - Air Piston Removal
Clamp shock at valve body. Using T20, remove 3 air piston screws. Remove air piston. Remove and discard air piston o-ring, back up L-rings and quad ring.
TSB022 – DBair CS Air Piston Change
If gold piston is present, replace with a new, blue piston (AAD1796).
Air Piston Set Screw Removal
Air Piston Removal
Air Piston O-Ring Removal
First Air Piston Back Up L-Ring Removal
Air Piston Quad Ring Removal
Second Air Piston Back Up L-Ring Removal
Step 5 – Air Seal Head Removal
Remove air seal head from outer damper tube. Remove and discard wiper, air seal head o-ring, back up ring, quad ring and glide ring. Remove and discard sag o-ring from out damper tube.
TSB014 – DBair/DBair CS Air Seal Head Quad Ring Change
Air Seal Head Removal
Air Seal Head Wiper Removal
Air Seal Head O-Ring Removal
Air Seal Head Back Up Ring Removal
Air Seal Head Glide Ring Removal
Air Seal Head Stripped
Sag O-Ring Removal
Damper Disassembly
Step 1 – Nitrogen Bleed & Oil Removal
***Use caution as nitrogen is pressurized.***
Using T20, remove gas fill screw and bleed any gas with fill needle. Using T20, remove oil fill screw. Cycle shaft to remove all damper fluid. Temporarily reinstall end eye if necessary to help cycle shaft.
Gas Fill Screw Removal
Gas Fill Needle Inserted
Bleeding Gas
Oil Fill Screw Removal (Standard)
Oil Fill Screw Removal (Trunnion)
Oil Fill Screw Removed
Cycling Oil From Damper
Step 2 – Reservoir End Removal
Depress reservoir end cap to expose circlip. IFP setting tool may be used. Remove reservoir tube circlip. Remove end cap with IFP setting tool (DBT012). Pinch & remove and discard res end o-ring.
Threading IFP Tool into Res End
Depressing Res End
Res End Circlip Removal
Res End Removal
Res End O-Ring Removal 1
Res End O-Ring Removal 2
Step 3 – Oil Seal Head/Shaft Assembly Removal
Using Oil Seal Head tool, unthread oil seal head from outer damper tube. Take care not to use threaded holes on seal head. Remove complete shaft assembly. Using spanner, remove inner damper tube by pulling straight up.
Oil Seal Head, Noting Threaded Holes
Oil Seal Head Removal
Oil Seal Head Unthreaded
Shaft Assembly Removed
Hooking Inner Damper Tube
Inner Damper Tube Removal
Step 4 – IFP Removal
Using IFP tool, remove the IFP. Pinch & remove and discard IFP quad ring. Remove any remaining oil and thoroughly clean outer damper tube, reservoir tube and cylinder head.
IFP Removal
IFP Removed
IFP Quad Ring Removed
Oil Disposal
Shock Body Cleaning
Step 5 – Outer Damper & Res Tube Inspection (Removal if necessary)
Thoroughly inspect damper tube and res tube. Replace if necessary. Test tightness of outer damper tube and reservoir tube. If either comes loose without much force, remove completely. Otherwise, only remove if replacing.
With outer damper tube and/or res tube removed, remove and discard o-rings. Thoroughly clean all Loctite residue from cylinder head threads.
Testing (and Removing if Necessary) Outer Damper Tube
Threads Before Cleaning
Cylinder Head O-Ring Removal 1
Cylinder Head O-Ring Removal 2
Testing (and Removing if Necessary) Res Tube
Cleaning Threads
Step 6 – Climb Switch & CS Cover Removal
Using T10, remove Climb Switch screw and Climb Switch. Using 1.5mm Allen, remove Climb Switch cover plate screws and cover plate.
Climb Switch Screw Removal
Climb Switch Removal
Climb Switch Cover Plate Screw Removal 1
Climb Switch Cover Plate Screw Removal 2
Climb Switch Cover Plate Removal
Step 7 – High Speed Adjusters Removal
Using 3mm Allen, remove High Speed adjusters. Take note of the Rebound adjuster (0.8 with port) and spring (red, 30wt weight) and Compression adjuster (will vary from 0.0 without port, to 0.8, 1.0 or 1.2 with port) and spring (yellow, 10wt or standard 20wt). Spring color may have worn off. Pinch & remove and discard High Speed adjuster o-rings.
HSR Adjuster Removal
HSR Adjuster Removed
HSC Adjuster Removed
High Speed Adjusters Removed, Rebound on Right
High Speed Adjuster w/ Port (0.8), Front
High Speed Adjuster w/ Port (0.8), Rear
High Speed Adjuster w/o Port (0.0), Front
High Speed Adjuster w/o Port (0.0), Rear
High Speed Adjuster External O-Ring Removal
High Speed Adjuster Poppet O-Ring Removal
Step 8 – High Speed Valve Seat Check
Using CS Valve Seat tool (AAD0756), check for proper torque (4.8 Nm) on valve seats. No need to remove valve seats as part of a standard service.
Valve Seat Tool
Valve Seat Torque Check
Step 9 – Climb Switch Spool Valve Removal
Using 6mm socket, thread spool valve closed (clockwise) and note location of the indicator dot. Then open (counterclockwise) the valve at least half a turn and then onto indicator dot at the 6:00 position. This is the default setting for reassembly. Make note of this position from fully closed. Unthread and remove spool valve assembly. Pliers may be necessary to remove assembly once completely unthreaded. Remove and discard spool valve o-ring. Remove and clean detent balls and spring.
Spool Valve Properly Clocked Ahead of Removal
CS Spool Valve Removal
CS Spool Valve Removal Past O-Ring w/ Pliers
CS Spool Valve Removed
CS Spool Valve O-Ring Removed
CS Spool Valve Detent Balls & Spring Removed
Step 10 – Low Speed Needle Removal
Using 3mm Allen, remove Low Speed needles. Pliers may be necessary to remove assembly once completely unthreaded. Take note of labeling on needles for reinstallation back into same circuit. Remove and clean detent balls and spring. Pinch & remove Low Speed needle o-rings.
Low Speed Rebound Needle Removal 1
Low Speed Rebound Needle Removal 2
Low Speed Compression Needle Removal 1
Low Speed Compression Needle Removal Noting Labeling
Low Speed Compression Needle Removal 2
Low Speed Rebound Needle Detent Balls & Spring Removal
Low Speed Rebound Needle O-Ring Removal
Continue to Part 2
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