DBair CS Complete 100 Hour Service Instructions (Part 2 of 3)
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
Shaft Disassembly
Step 1 – Piston Assembly Removal
Remove and discard oil seal head and top out bumper. Inspect shaft for any damage. Replace if necessary. Clamp shaft in vise with piston up. Using 3mm Allen, remove shaft bolt. Remove piston, shim stack and stop washer. Note order of shim stack. Inspect piston port holes and check shim for wear. Flip face shim on reinstall if necessary.
Top Out Bumper Removal
Inspecting Shaft
Shaft Clamped for Disassembly
Freeing Shaft Bolt
Shaft Bolt Removal
Piston, Shim Stack & Stop Washer Removed
Inspecting Piston Band
Inspecting Port Holes
Inspecting Shim Face
Shaft Reassembly
Step 1 – Oil Seal Head Install
Thoroughly grease bushing and quad ring on new oil seal head (AAD0163). Lightly grease and install exterior oil seal head o-ring (.DB11108). If available, slide shaft cover 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 oil seal head and new top out bumper (AAD1090), noting correct orientation.
Greasing Oil Seal Head
Shaft Cover Install (if available)
Oil Seal Head Install
Oil Seal Head Installed
Top Out Bumper Installed
Step 2 – Piston and Shim Stack Install
Clamp shaft with threads down. Install stop washer, shim stack and piston. Note correct shim stack order. Apply blue (243) Loctite to interior shaft threads. Install and torque shaft bolt to 5.0 Nm with 3mm Allen.
Shaft Clamped for Shim & Piston Install
Stop Washer Installed
Shim Stack Installed
Piston Installed
Apply Loctite to Shaft Threads
Install Shaft Bolt
Shaft Bolt Installed
Damper Reassembly
Step 1 – High Speed Adjuster Prep
Lightly grease the walls of the spool valve and adjuster housing on valve body. Lightly grease and install high speed adjuster outside o-ring (AAD0032). Install high speed adjuster poppet o-ring (.DB11101). Install spring and poppet on high speed adjuster.
Replicate the original set up from disassembly. 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.
Greasing Climb Switch Spool Valve Housing
Greasing High Speed Valve Housings
Greasing Low Speed Valve Housings
High Speed Adjuster Poppet O-Ring Installed
High Speed Adjuster Outside O-Ring Installed
High Speed Adjuster O-Rings Installed
High Speed Adjuster Spring & Poppet Install
High Speed Adjuster Spring & Poppet Installed
Step 2 – High Adjuster Install
Using 3mm Allen, install High Speed Rebound adjuster into Rebound housing. Thread below cover plate surface.
Using 3mm Allen, install High Speed Compression adjuster into Compression housing. Thread below cover plate surface.
High Speed Rebound Install 1
High Speed Rebound Install 2
High Speed Rebound Installed
High Speed Compression Install
Step 3 – Low Speed Needle Install
Lightly grease and install low speed needle o-rings (.DB11102). Using grease, install detent ball, spring and second detent ball. Using 3mm Allen, install low speed needles into valve body. Be sure to match needle to original circuit. Thread needles below cover plate surface. Test for detent clicks at this time.
Low Speed Needle O-Ring Installed
Low Speed Needles O-Ring Installed
Low Speed Detent Balls & Spring Install
Low Speed Detent Balls & Spring Installed
Low Speed Compression Needle Install 1
Low Speed Compression Needle Install 2
Low Speed Rebound Needle Install 1
Low Speed Rebound Needle Install 1
Low Speed Needles Below Cover Plate Surface
Step 4 – Cover Plate Install
Apply blue (243) Loctite to cover plate screw holes on valve body. Install Climb Switch cover plate. Torque plate screws to 0.16 Nm with 1.5mm Allen. Be sure to tighten screws in an even pattern.
Applying Loctite to Cover Plate Screws 1
Applying Loctite to Cover Plate Screws 2
Cover Plate Install
Cover Plate Screws Install
Torquing Cover Plate Screws
Cover Plate Screws Installed
Step 5 – Climb Switch Spool Valve Install
Lightly grease and install spool valve o-ring (.DB11102). Lightly grease spool valve opening on cover plate. Using grease, install detent ball, spring and second detent ball. Install spool valve. Repeat removal process of threading spool valve all the way closed (clockwise) then opening (counterclockwise) 1/2 turn and onto indicator dot at 6:00.
Spool Valve O-Ring Installed
Greasing Cover Plate Interior
Spool Valve Detent Balls & Spring Installed
Spool Valve Install
Threading Spool Valve
Clocking Spool Valve
Spool Valve Installed & Clocked
Step 6 – Climb Switch Lever Install
Apply blue (243) Loctite to internal threads on spool valve. Install Climb Switch with lever pointing towards the Rebound adjusters (in the climb switch “on” position). Install Climb Switch screw and torque to 1.2 Nm using a T10 wrench. Back out both low and high speed adjusters until gently touching the cover plate.
Spool Valve O-Ring Installed
CS Lever Clocked & Installed
CS Lever Screw Install
CS Lever Screw Installed
Backing Out HSR to Cover Plate
Backing Out HSC to Cover Plate
Backing Out LS Needles to Cover Plate
LSC Needle Backed Out to Cover Plate
Step 7 – Outer Damper Install (if necessary)
Lightly grease and install damper tube o-rings (.DB11110 & .DB11109) in cylinder head. Apply small amount of red (263) Loctite to outer damper tube threads. Thread outer damper tube into cylinder head. Tighten in place with strap wrench.
Greased Damper Tube O-Rings
Damper Tube O-Ring Channels
Damper Tube O-Ring Install
Valve Body O-Rings for Outer Damper Tube & Res Tube
Damper Tube O-Rings Installed
Applying Loctite to Outer Damper Tube
Loctite Applied to Outer Damper Tube
Threading Outer Damper Tube into Cylinder Head
Outer Damper Tube Threaded into Cylinder Head
Tightening Outer Damper Tube
Step 8 – IFP Install
Lightly grease and install IPF quad ring (.DB11120). Lightly grease wall of reservoir tube and install IFP by pushing tube onto piston.
IFP & Quad Ring
Greasing IFP Quad Ring
IFP Quad Ring Install
Greasing Reservoir Tube Wall
IFP Install 1
IFP Install 2
IFP Installed
Step 9 – Inner Damper Tube & Oil Seal Head Install
Install sag o-ring (AAD0837). Coat air piston with shock oil and insert shaft assembly into inner damper tube. Note location of holes on seal head end. Install inner damper tube/shaft assembly into outer damper tube. Thread oil seal head into outer damper tube and torque to 15 Nm using Oil Seal Head wrench.
Do not use tool in holes with threads to avoid damaging threads.
Sag O-Ring Install
Sag O-Ring Installed
Coating Air Piston
Inserting Air Piston into Inner Damper Tube
Air Piston/Shaft Assembly Installed into Inner Damper Tube
Inner Damper Tube/Shaft Assembly Inserted into Outer Damper Tube
Torquing Oil Seal Head to Outer Damper Tube
Oil Seal Head Torqued to Outer Damper Tube
Continue to Part 3
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