DBair IL Trunnion Mount Complete 100 Hour Service (Part 1 of 4)

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.

Clamp shock in soft jaw vise. Remove air can circlip using a pick. Flip the shock and clamp end eye. Using strap wrench, twist and apply downward force to free outer air can. Work outer air can past end eye to remove completely. Note any air volume reduction.

Reclamp shock. Align teeth on Air Seal Head Tool (BAD1273) with grooves on air seal head. Unthread air seal head/inner air can from end eye. Splash oil may be present. Slide inner air cap up shock body to expose shaft.

Slide inner air can up shock body to expose shaft. Clamp shaft in 8mm shaft clamp with end eye up. Remove end eye using 1/2″ crows foot. Pinch & remove then discard inner can o-ring and stop shim from end eye. Remove any stroke reduction spacer, shim and bottom out bumper.

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.

Using T10 loosen and slowly remove all 3 air piston screws. Use caution as this will release any air trapped in negative chamber. Pull up on inner air can to remove inner air can and piston. Press piston out of inner air can. Remove 2 L-back up rings, quad ring and interior o-ring from piston and discard.

Remove both o-rings and blue wiper seal from inner air can. Remove 2 L-back up rings and quad ring from interior of inner air can. Remove sag o-ring. Discard all rings, seals and wiper. Inspect inner air can for wear. Replace as necessary.

***Use caution as nitrogen is pressurized.***

Bleed gas with gas fill needle. Remove oil fill screw with T15. Remove slowly as there may be aerated oil behind fill screw. Empty oil through fill screw by cycling the damper.

Clamp shock valve body in vise. Use Oil Seal Head Pin Spanner (BAD1174) to free oil seal head. Remove shaft assembly from damper body. Pour out any remaining oil from damper body. Remove outer damper tube.

Using Inner Damper Tool Wrench (BAD1273), remove inner damper from valve body. Inspect interior of inner damper tube for piston band wear. Inspect damper tube threads and remove any remaining Loctite with pick. Clean thoroughly. Replace inner damper tube if necessary. Remove valve body o-ring and discard.

Using Inner Damper Tool Wrench (BAD1273), remove inner damper from valve body. Inspect interior of inner damper tube for piston band wear. Inspect damper tube threads and remove any remaining Loctite with pick. Clean thoroughly. Replace inner damper tube if necessary. Remove valve body o-ring and discard.

Using a 1.5mm Allen, remove 2 set screws located inside of valve body next to inner damper tube purchase. Remove remaining set screw in valve body exposing spring and detent ball. Remove spring and detent ball. Using CS lever, unthread spool valve and remove. Pinch & remove and discard spool valve o-ring.

Using 3mm Allen, dial High Speed adjusters in to gain access to High Speed circlips. Remove circlips. Back High Speed adjusters all the way out. Pinch & remove and discard o-rings on adjusters.

Note that the Compression spring is 20wt (silver), rebound is 30wt (black).

Gently bottom out Low Speed adjuster needles with 3mm Allen. Using a sharp blade, work circlips below retaining shelf all the way to needles. Back needles out 5-7 clicks and then rebottom needles to gain access to circlips. Using pick centered on circlips, pry up diagonally to pull circlips past shelf and remove. Unthread and remove needles. Remove and discard o-rings.