DBKitsuma Air Complete 100 & 200 Hour Service (Part 1 of 4)
DBKitsuma Air Complete 100 & 200 Hour Service Instructions
Mar 2022 orig., Jul 2023 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 Kitsuma Air and Coil 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 valve body or outer damper tube on the Kitsuma Air, but process is the same for the shock in the image and the shock on your bench.
100 vs. 200 hour service
The only difference between the 100 hour service and the 200 hour service is whether to service or replace the Air Oil Seal Head and the Main Oil Piston. At 100 hours, those can be cleaned, serviced and reinstalled. At 200 hours, they should be replaced. If uncertain on hours, check for wear on the dual bushings inside the Air Oil Seal Head and on the piston band on the Main Oil Piston. When in doubt, replace both.
Service Kits
BCD0337 – Kitsuma Air Complete 100 Hour Rebuilt Kit (w/ Bladder)
OR
BCD0339-01 – Kitsuma Air Complete 200 Hour Rebuild Kit (w/ Bladder) – includes new Air Oil Seal Head & Main Oil Piston
BCD0169 – Bladder Res End Cap (if replacing older IFP system)
Required Cane Creek Tools
ACD0354 – Bladder Res End Fill Tool
AAD1361-01 – DBCoil/ DBAir – Oil Fill Needle Adapter
DBT016 – DB Gas Fill Needle
AAD0555 – 8mm & 9.5mm Shaft Clamp
AAD2465 – Kitsuma Valve Seat Tool
ACD0322 – Kitsuma Low Speed Detent Funnel
BAD1298 – DB 9.5mm Shaft Bullet
ACD0334 – Kitsuma Air Oil Seal Head Tool
BCD0344 – Kitsuma/DBair/DBair IL Air Seal Head Tool
DBT012 – DB IFP Setting Tool
Additional Tools & Supplies
Allen wrenches – 3 & 4mm
Torx wrenches – T10 & T20
Sockets – 4, 8 & 13mm
Crowfoot wrenches – 1/2″ & 32mm
9.5mm Shaft Bullet
Torque wrenches
Knipex pliers
Pick
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) |
| Outer Damper Tube | Tight | 263 (Red) |
| Valve Seat | 4.8 Nm | None |
| High Speed Adjuster | 7 Nm | None |
| Climb Switch Screw | 1.2 Nm | 243 (Blue) |
| Oil Seal Head | 22 Nm | None |
| 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 |
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.
Hardware & Bushing Removed
Clamped for Disassembly
Pump Attach
Air Bleed
Air Can Disassembly
Step 1 – Outer Air Can Removal
Pinch & 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.
Air Can Retaining O-Ring Removal
Air Can Retaining O-Ring Removed
Strap Wrench on Air Can
Air Can Removal
Volume Reduction Removal
Outer Air Can Removed
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 and inner air can from end eye. Splash oil may be present. Gently clamp inner air can and use air seal head tool to loosen air seal head from inner air can. Take care to not crush inner air can.
Air Seal Head Tool on Air Seal Head
Loosening Air Seal Head & Inner Air Can
Inner Air Can Freed from End Eye
Gently Clamping Inner Air Can
Loosening Air Seal Head from Inner Air Can
Air Seal Head Removed from Inner Air Can
Step 3 - End Eye Removal
Option 1 (pictured):
Clamping valve body, use 4mm Allen insert into end eye and 1/2″ crowsfoot, loosen end eye from shaft.
Option 2 (not pictured):
Using shaft vise, clamp shaft between end eye and air can. Use 1/2″ crowsfoot to loosen end eye from shaft.
Remove and discard air can and shaft o-rings from end eye. Remove any stroke/volume reduction 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.
Loosening Shaft from End Eye 1
Loosening Shaft from End Eye 2
Unthreading Shaft from End Eye
Removing Air Can O-Ring from End Eye
Removing Shaft O-Ring from End Eye
Volume/Stroke Reduction & Bottom Out Bumper
Step 4 – Inner Air Can Removal
Slide off inner air can. Remove inner air can o-rings and discard. Inspect inner air can for wear. Replace if necessary. Note that anodization rack marks are normal and do not impact shock performance.
Inner Air Can Removal
Inner Air Can Removed
Inner Air Can O-Ring Removal
Air Spring Disassembled
Damper Disassembly
Step 1 – Nitrogen Bleed & Oil Removal
***Use caution as nitrogen is pressurized.***
Remove reservoir end cap screw using T20. Remove and discard o-ring. Use gas fill needle to bleed nitrogen from reservoir tube. Temporarily reinstall end eye on shaft. Remove oil fill screw with T20. Cycle the shaft to remove as much oil as possible from the damper. Dispose of oil properly. Remove end eye.
Res End Cap Fill Screw Removal
Res End Cap Fill Screw Removed
Res End Cap Fill Screw O-Ring Removed
Bleeding Nitrogen
End Eye Reinstall
Oil Fill Screw Removal
Oil Drain 1
Oil Drain 2
Oil Drain 3
Step 2 – Oil Seal Head & Air Piston Removal
Clamp valve body into vise. Using Air Oil Seal Head tool (ACD0334) with 32mm crowsfoot, loosen and remove oil seal head/air piston.
Clamped for Oil Seal Head/Air Piston Removal
Oil Seal Head/Air Piston Tool
Crowsfoot on Oil Seal Head/Air Piston Tool
Loosening Oil Seal Head/Air Piston
Oil Seal Head/Air Piston Freed
Oil Seal Head/Air Piston Removed
Step 3 – Inner Damper Tube Removal
Inner damper tube should come out with air piston. If not, reinstall piston and use rotational movement to free damper tube. Inspect inner damper tube for piston wear. Replace if necessary.
Inserting Air Piston
Removing Inner Damper Tube w/ Air Piston
Inspecting Inner Damper Tube
Step 4 – Air Seal Head Disassembly
Remove negative volume reducers if present (225 Trunnion and 250 standard do not have these). Remove air seal head. Remove and discard sag o-ring. Pour out any remaining damper oil. From air seal head, remove wiper seal, L-rings, quad ring and outer o-ring.
Neg Volume Reducer Removal 1
Neg Volume Reducer Removal 2
Air Seal Head Removal
Sag O-Ring Removal
Discarding Remaining Oil
Air Seal Head Outer O-Ring Removal
Air Seal Head Wiper Removal
Air Seal Head First L-Ring Removal
Air Seal Head Quad Ring Removal
Air Seal Head Second L-Ring Removal
Step 5 – Air Oil Seal Head Removal
Remove air oil seal head and inspect. For 100 hour service, remove external o-ring & internal quad-ring and discard. For 200 hour service or if wear is present on dual bushings, discard the complete air oil seal head. Remove shaft spacer and top out bumper.
Air Oil Seal Head Removal
Shaft Spacer Removal
Top Out Bumper Removal
Step 6a – IFP Removal
Using IFP tool (DBT012), press cap into the reservoir tube exposing circlip. Press on circlip to remove from channel. Pick should not be required but could be used if needed. Thread IFP tool back into end cap, remove and discard. Thread IFP tool into metal IFP and remove from reservoir tube. Use adaptor for plastic IFP. Discard IFP.
TSB045 – Kitsuma IFP Changed to Bladder
Threading IFP Tool onto Res End Cap
Depressing Res End Cap
Freeing Res End Cap Circlip
Res End Cap Circlip Removed
Res End Cap Removed
Old IFPs, Metal vs. Plastic
Metal IFP Removal
Adapter for Removing Plastic IFP
Plastic IFP Removal
OR
Step 6b – Bladder Removal
Using bladder setting tool (ACD0354), press res end cap into reservoir, exposing circlip. Press on circlip to remove from channel. Pick should not be required but could be used if needed. Use IFP setting tool (DBT012) to pull end cap out of reservoir tube. If bladder does not come out with end cap, remove with pick.
TSB045 – Kitsuma IFP Changed to Bladder
Bladder Setting Tool
Bladder Setting Tool Attached to End Cap
Depressing End Cap
Freeing End Cap Circlip
End Cap Circlip Removed
Res End Cap Removed
Bladder Removal
Bladder Removed
Step 7 – Climb Switch & Spool Valve Removal
Using T10, remove Climb Switch mounting screw. Remove Climb Switch. Remove and discard Climb Switch o-ring. Remove CS detent. Turn CS valve so that the tab on the spool valve is no longer engaged with the valve body and remove assembly. Pinch & remove and discard spool valve o-ring.
Climb Switch Mounting Screw Removal
Climb Switch Removal
Climb Switch O-Ring Removal
Climb Switch O-Ring Removed
Climb Switch Detent Removal
Aligning Spool Valve for Removal
Spool Valve Removal
Spool Valve Removed
Spool Valve O-Ring Removal
Step 8 – Adjuster Dials Removal
Using Kinipex, gently grab outside edges of High and Low Speed adjuster tabs and remove. Place rag over adjusters to protect them (not shown in photo). Pinch & remove and discard adjuster o-rings.
HSC Dial Removal
HSR Dial Removal
LSC Dial Removal
LSR Dial Removal
Dial O-Ring Removal 1
Dial O-Ring Removal 2
Step 9 – High Speed Adjuster Housing Removal
Using 8mm socket, remove high speed adjuster housing. Apply heat to aid removal.
***Note high speed adjuster housing may also be silver.***
TSB039 – Kitsuma High Speed Cap (ACD0275) Loctite Removal from Installation
8mm Socket for Adjuster Housing
Applying Heat to Adjuster Housing
Adjuster Housing Removal
HSR Adjuster Housing Removed
HSC Adjuster Housing Removed
Step 10 – High Speed Adjuster Housing Disassembly
Disassemble high speed adjustors by removing poppet and spring. Remove circlip from housing and press adjustor out of housing. Pinch & remove and discard housing o-ring.
HS Housing Spring Removal
HS Housing Circlip Removal
HS Housing Circlip Removed
Removing Adjuster from Housing 1
Removing Adjuster from Housing 2
Removing O-Ring from Housing
Step 11 – Shuttle Disassembly
Press out detent spring and balls. Unthread shuttle, remove gold shim and remove both o-rings. Discard o-rings. Note the differences between the poppets and springs from the compression and rebound sides.
TSB038 – Kitsuma HSR Revalve
Detent Ball & Spring Removal
Unthreading Shuttle
Shuttle Shim Removal
Shuttle O-Ring Removal 1
Shuttle O-Ring Removal 2
Fully Disassembled Adjuster
Adjuster Poppet, Compression (L), Rebound (R)
Adjuster Spring, Compression (L), Rebound (R)
Continue to Part 2
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