HELM Damper Side (Air & Coil) 100 Hour Service (Part 1 of 3)
HELM Damper 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 damper leg of a complete 100 hour service. Combine these instructions with the appropriate spring side – air or coil; original or MKII – and 50 hour lower service to get a complete 100 hour fork service.
Additionally, follow these instructions for damper removal and reinstall if sending the damper off for a service with an authorized Cane Creek service center.
Service Kit
BAG0714 – HELM Damper Rebuilt Kit
Required Cane Creek Tools
BAG0405 – Compression Retaining Nut Socket – Thin Walled 11mm socket
AAG0086 – HELM Cartridge Fill Tool
AAG0367 – HELM Oil Seal Head Bullet
AAG0406 – HELM Compression Outer Sleeve Spanner
Additional Tools & Supplies
Allen wrenches – 4mm
Torx wrenches – T10
Sockets – 10mm & chamfer-less 30mm
Crowfoot wrenches – 10 & 18mm
Open Ended Box wrenches – 10 & 18mm
10mm Shaft Clamp
Torque wrenches
Knipex pliers
Pick
Suspension Grease
PolyLube Grease
Motorex 2.5wt Racing Fork Oil
Vacuum Oil Fill Machine
Torque, Loctite, Oil & Nitrogen Specs
Torque & Loctite Chart
| Part | Torque Spec | Loctite Spec |
|---|---|---|
| Rebound Piston Assembly | 3 Nm | 263 (Red) |
| Rebound Piston Install | 5 Nm | 243 (Blue) |
| Rebound Adjuster | 5 Nm | 243 (Blue) |
| Damper Top Cap to Gold Coupling | 9 Nm | None |
| Oil Seal Head to Damper Tube | 13 Nm | None |
| Damper Install | 36 Nm | 243 (Blue) |
| Compression Nut | Hand Tight | 243 (Blue) |
| LSC Knob Screw | 1.6 Nm | 243 (Blue) |
Oil Chart
| Oil Location | Oil Type | Oil Amount |
|---|---|---|
| Damper Fill | Motorex 2.5wt Racing Fork Oil | Fill to 2 Bars |
Lower Assembly Removal
Prior to beginning damper service, remove the lower assembly per the 50 hour service instructions.
Removing CSU from Lowers 1
Removing CSU from Lowers 2
Damper Removal
Step 1 – Low Speed Compression Nut Removal
Secure CSU. Using T10 Torx, remove Low Speed Compression knob screw. Remove LSC knob. Using thin walled 11mm socket (BAG0405), remove Low Speed Compression retaining nut. Remove High Speed Compression adjustor. Remove Low Speed Compression take up adaptor.
LSC Knob Screw Removal
LSC Knob Screw Removed
LSC Knob Removal
LSC Retaining Nut Socket
LSC Retaining Nut
Putting Socket on LSC Retaining Nut
LSC Retaining Nut Backed Off
HSC Knob Removed
LSC Take Up Adaptor Removal
LSC Take Up Adaptor Removed
Step 2 – Damper Removal
Using 30mm chamferless socket, remove damper assembly. Breaker bar may be necessary.
Socket on Damper
Freeing Damper 1
Freeing Damper 2
Freeing Damper 3
Damper Removal
Damper Removed
Step 3 – Damper & CSU Inspection
Clean excess oil from damper assembly and inspect. Clean and inspect CSU. Remove and discard sag o-ring. Clean all small parts in solvent.
Cleaning Damper
Cleaning CSU
Sag O-Ring Removal
Cleaning Small Parts
Damper Disassembly
Step 1 – Oil Seal Head Removal
***Do not clamp damper tube. It will collapse.***
Using 4mm Allen, thread in (clockwise) Low Speed Compression needle to expose retaining circlip. If necessary, use pick to remove circlip and discard. (Circlip may not be present and will not be replaced.) Using Knipex or vise, secure damper on gold damper coupling. Use 18mm open end wrench (or crowsfoot) to loosen oil seal head. Remove oil seal head and rebound circuit using a circular motion. Discard damper oil in appropriate container.
Thread in LSC Needle
LSC Circlip Removal
Clamping Damper Coupler (Knipex)
Clamping Damper Coupler (Vise)
Tool on Oil Seal Head (Open End)
Tool on Oil Seal Head (Crowfoot)
Freeing Oil Seal Head
Oil Seal Head & Rebound Circuit Removal
Oil Seal Head & Rebound Circuit Removed
Oil Seal Head & Rebound Circuit Cleaning
Disposing Damper Oil
Step 2 – Compression Circuit Disassembly
***Use caution when removing Low Speed needle. Ensure damper shaft is not compressed and top of damper is pointing away from harm in case oil and/or needle have pressure.***
Remove Low Speed needle from top of damper using 4mm Allen. Clamp damper coupling in vise. Using 30mm socket on top cap while simultaneously holding bladder with hand, loosen entire assembly above damper coupling. Remove bladder assembly, compression check spring and compression piston assembly.
TBS029 – Check Spring Change
LSC Needle Removal 1
LSC Needle Removal 2
LSC Needle Removed
Damper Clamped for Disassembly
Tool on Top Cap
Turning Complete Damper Assembly
Complete Damper Assembly Removal
Compression Check Spring Removal
Compression Piston Removal
Compression Piston Removed
Step 3 – Compression Outer Sleeve Disassembly
Using Compression Outer Sleeve Spanner (AAG0406) and 30mm socket, unthread top cap from compression outer sleeve. Remove top cap, helix and claw from outer sleeve. Take care as detent balls will fall out upon disassembly. Remove and discard bladder from outer sleeve.
TSB017 – Change to Rebound Range
Compression Sleeve Spanner
Tool on Damper Top Cap
Unthreading Top Cap from Compression Sleeve 1
Unthreading Top Cap from Compression Sleeve 2
Separating Top Cap from Compression Sleeve
Helix Removed (w/ Loose Detents)
Claw Removed
Compression Assembly Disassembled
Bladder Removal
Step 4 – Rebound Shaft Disassembly
Thoroughly clean rebound assembly. Using 10mm shaft clamp, clamp damper shaft between seal head and rebound adjuster. Using 10mm open ended wrench, remove adjuster. Pinch & remove and discard o-ring from rebound adjuster. Remove rebound shuttle rod. Remove and discard oil seal head.
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.
TSB017 – Change to Rebound Range
Rebound Shaft Clamped for Disassembly
Rebound Adjuster Removal 1
Rebound Adjuster Removal 2
Rebound Adjuster Removed
Rebound Adjuster O-Ring Removal
Rebound Rod Removal
Oil Seal Head Removed
Step 5 – Rebound Piston Removal (if necessary)
Reclamp damper shaft with piston facing up. Using 10mm open ended wrench, remove piston assembly from damper shaft. Remove low speed return spring Take care to not remove low speed rebound needle and return spring. Remove and discard piston band from rebound piston.
TSB015 – Rebound Piston Flip
TBS029 – Check Spring Change
Rebound Piston Removal
Rebound Piston Removed
Rebound Needle w/ Spring
Rebound Piston Band Removal
Step 6 – Rebound Piston Disassembly (if necessary)
Using two 10mm open ended wrenches, remove jam nut. Take care as it is spring loaded. Remove spacer, shim stack (noting order), piston, bottom shim and check spring or wave washer. (Check spring and waver washer we re both used in production and are interchangeable.)
Tool for Rebound Piston Assembly Disassembly
Rebound Piston Assembly Jam Nut Removal
Rebound Spacer Removal
Rebound Spacer Removed
Rebound Piston Shim Stack
Rebound Shim Stack Removed
Rebound Piston Removed
Rebound Bottom Shim Removed
Rebound Check Spring Removed
Complete Rebound Piston Assembly Disassembled
Continue to Part 2
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