HELM Air Spring Side Complete 100 Hour Service
HELM Air Spring Complete 100 Hour Service Instructions
June 2022 orig.
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 forks have pressurized oil. 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 fork 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 – CSU, compression rods, etc. – please consult your authorized Cane Creek service center or contact us at our Cane Creek Support Center.
Service Notes
These instructions cover just the air spring leg of a complete 100 hour service. Combine these instructions with the appropriate damper side and 50 hour lower service to get a complete 100 hour fork service.
Additionally, you can send the damper for a service with an authorized Cane Creek service center.
Service Kit
BAG0451 – HELM Air Spring Rebuilt Kit
Required Cane Creek Tools
AAD0555 – 8mm & 9.5mm Shaft Clamp
Additional Tools & Supplies
Sockets – 8mm, deep well 22mm & chamfer-less 30mm
Crowfoot wrenches – 20mm
Open Ended Box wrenches – 10, 20 & 22mm
Torque wrenches
Pick
Suspension Grease
Royal Purple 10w-30
Torque, Loctite, Oil & Nitrogen Specs
Torque & Loctite Chart
| Part | Torque Spec | Loctite Spec |
|---|---|---|
| Seal Head Assembly | 5 Nm | 243 (Blue) |
| Air Piston to Shaft | 6 Nm | 263 (Red) |
| Seal Head Install | 16 Nm | None |
| Doublair Top Cap | 36 Nm | 243 (Blue) |
Oil Chart
| Oil Location | Oil Type | Oil Amount |
|---|---|---|
| Top of Air Spring | Royal Purple 10w-30 | 2.5 mL |
Related Technical Service Bulletins
Review all related TSBs before performing any service.
No specific HELM Air spring TSBs at this time.
Lower Assembly Removal
Prior to beginning spring service, remove the lower assembly per the 50 hour service instructions.
Removing CSU from Lowers 1
Removing CSU from Lowers 2
Spring Assembly Removal
Step 1 – Doublair Top Cap Removal
Secure CSU. Double check all air has been removed from air spring of BOTH the positive AND negative chambers by pressing the main air fill valve AND the negative charge button simultaneously. Failure to do so can result in injury. Using 30mm chamferless socket, remove Doublair volume piston. Breaker bar may be necessary. Note position of volume reduction, if present.
Releasing Positive Air Pressure
Releasing Negative Air Pressure
Socket on Doublair Top Cap
Freeing Doublair Top Cap
Doublair Top Cap Removal
Doublair Top Cap Removed
Step 2 – Compression Rod Assembly Removal
Press negative charge button and compress shaft all the way down. Remove and discard sag o-ring. Using 22mm wrench, remove air spring seal head. Dispose of splash oil. Remove air spring assembly by walking piston out past stanchion threads. Note orientation of travel spacer, plastic spacer, top out bumper and any metal shims on either side of top out bumper that may be present.
Compressing Shaft
Sag O-Ring Removal
Freeing Air Spring Seal Head
Air Spring Oil Disposal
Air Spring Removal
Air Spring Removed
Complete Air Spring Removed
Step 3 – Air Spring and Stanchion Cleaning
Thoroughly clean air spring assembly and stanchion. Use a very clean rag or shop towel to clean interior of stanchion.
Cleaning Air Spring
Cleaning Stanchion 1
Cleaning Stanchion 2
Compression Rod Disassembly
Step 1 – Air Piston Removal
Remove and discard back up and quad rings from main air piston. Using 8mm shaft clamp, clamp air spring assembly between the air seal head and air piston. Using 8mm socket, crack free air piston and remove.
Air Spring First Back Up Ring Removal
Air Spring Quad Ring Removal
Air Spring Second Back Up Ring Removal
Freeing Air Piston
Air Piston Removed
Step 2 – Air Seal Head Removal
Remove any travel reduction, spacer, and top out bumper. Remove and discard air seal head/top out spacer and footnut o-ring. Inspect shaft for any wear. Remove any Loctite residue.
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 air. When possible, pinch and remove o-rings rather than using a pick.
Footnut O-Ring Removal
Travel Reduction, Spacer & Top Out Bumper Removal
Air Seal Head/Top Out Spacer Removal
Inspecting Shaft
Loctite Removal
Compression Rod Reassembly
Step 1 – Air Seal Head Assembly
Grease and install footnut o-ring (.AD0111) on air spring shaft foot nut. Grease bushing on new air seal head (AAG0179). Slide air seal head onto air shaft, noting correct orientation. Thoroughly grease air seal head quad ring (AAD1809). Walk it past the threads onto shaft. Press quad ring into air seal head. Install back up ring (AAG0383) on shaft. Press back up ring against quad ring into seal head.
Footnut O-Ring Install
Air Seal Head Bushing Greased
Air Seal Head Install
Air Seal Head Quad Ring Install
Air Seal Head Quad Ring on Shaft
Air Seal Head Quad Ring into Air Seal Head Install
Air Seal Head Quad Ring into Air Seal Head Installed
Air Seal Head Back Up Ring Install
Air Seal Head Back Up Ring into Air Seal Head Install
Step 2 – Top Out Spacer & Air Seal Head Assembly
Apply blue Loctite (243) to seal head threads. Install new top out spacer (AAG0312) and thread onto seal head. Hold top out spacer with 10mm open ended wrench, avoiding putting wrench flats on port hole. Torque seal head to 5 Nm using 22mm deep well socket.
Applying Loctite to Air Seal Head
Top Out Spacer Install 1
Top Out Spacer Install 2
Threading Top Out Spacer onto Seal Head
Wrench on Top Out Spacer
Avoiding Port Holes w/ Wrench Flats
Air Seal Head Torque
Step 3 – Air Piston Install
Install top out bumper (and any metal shims if present), plastic spacer, and any travel adjustment. Apply red Loctite (263) to rod threads. Thread air piston onto rod. Clamp rod in vise directly under air piston with enough space to torque. Torque air piston to 6 Nm using 8mm socket.
Top Out Bumper, Spacer & Travel Reduction Installed
Applying Loctite
Air Piston Install
Air Piston Installed
Shaft Clamped for Air Piston Torque
Air Piston Torque
Step 4 – Air Piston Assembly
Grease air piston gland. Thoroughly grease all sides of air piston quad ring (AAG0115). Install first back up ring (AAG0116-01), quad ring, and second back up ring with flat sides of back up rings facing the quad ring.
Greasing Air Piston
First Air Piston Back Up Ring Install
Air Piston Quad Ring Install
Second Air Piston Back Up Ring Install
Air Piston Assembled
Spring Assembly Install
Step 1 – Air Spring Assembly Install
Install sag o-ring (AAG0408) on stanchion. Thoroughly grease inner stanchion and air piston. Install air spring assembly by carefully walking the air piston past threads on stanchion. If needed, use damper side stanchion to better seat rings on air piston to aid install. Keep hand above seal head to avoid pinching hand. Press negative charge button and compress shaft all the way down. Torque air seal to 16 Nm using 22mm deep well socket.
Sag O-Ring Install
Greasing Air Spring Stanchion
Greasing Air Spring
Using Damper Stanchion to Size Piston Rings
Air Spring Assembly Install
Air Spring Assembly Installed
Air Spring Assembly Torque
Step 2 – Doublair Top Cap Install
Add 2.5 ml of Royal Purple 10w-30 to the top side of the air spring. Lightly grease stanchion below the threads. Lightly grease o-ring on Doublair top cap o-ring and volume reduction if present. Apply blue Loctite (243) to threads on Doublair top cap. Install assembly. Torque to 36 Nm using 30mm socket.
Air Spring Oil
Adding Oil to Top of Air Spring
Greasing Stanchion Below Threads
Greasing Doublair Top Cap O-Ring
Greasing Volume Reduction O-Ring
Applying Loctite to Doublair Top Cap
Doublair Top Cap Install
Doublair Top Cap Torque
Lower Assembly Install
Step 1 – Air Spring Assembly Install
Upon completion of the spring side install and any damper service, install lower assembly per the 50 hour service instructions.
Lowers Install 1