Tigon Complete 100 & 200 Hour Service Instructions (Part 1 of 2)
Tigon Complete 100 & 200 Hour Service Instructions
Feb 2024 orig., Jun 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 Standard and Trunnion variants of the Tigon 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, 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 Oil Seal Head. At 100 hours, the Seal Head should be cleaned, serviced and reinstalled. At 200 hours, it should be replaced. If uncertain on hours, check for wear on the dual bushings inside the Seal Head. When in doubt, replace.
Service Kits
BDD0341– Tigon Complete 100 Hour Rebuilt Kit
OR
BDD0343– Tigon Complete 200 Hour Rebuilt Kit
Required Cane Creek Tools
BDD0320 – Tigon Oil Seal Head Pin Spanner
ADD0327 – Tigon Shaft Seal Head Bullet
ADD0328 – Tigon IFP Service Plug
AAD1361-01 – DBCoil/ DBAir – Oil Fill Needle Adapter
DBT016 – DB Gas Fill Needle
Additional Tools & Supplies
Shaft Clamp – 12.7mm (1/2″)
Allen wrench – 4mm
Torx wrench – T20
Crowfoot wrenches – 12 & 34mm
Open end wrench – 19mm
Torque wrenches
Knipex pliers
Pick – metal & plastic
Strap wrench
M8 x 1.25 bolt, min. 45mm length
Suspension Grease
Motorex 4wt Racing Fork Oil
Vacuum Oil Fill Machine
Nitrogen Fill System
Torque, Loctite, Oil & Nitrogen Specs
Torque & Loctite Chart
| Part | Torque Spec | Loctite Spec |
|---|---|---|
| Inner Shaft to Outer Shaft | None | 263 (Red) |
| Shaft Assembly to Valve Body | 10 Nm | 263 (Red) |
| Oil Seal Head | 30 Nm | None |
| RAMP Tube | 14.5 Nm | None |
Oil Chart
| Oil Location | Oil Type | Oil Amount |
|---|---|---|
| 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
Review all related TSBs before performing any service.
No Tigon specific TSBs at this time.
General Prep
Clean shock. Record tune if desired. Remove hardware. Remove bushings if replacing. Remove preload collar circlip. Remove preload collar and spring.
Shock to be Serviced
Preload Collar Circlip Removal
Preload Collar Circlip Removed
Preload Collar Removal
Spring Removal
Shock Ready for Service
RAMP Tube Removal
Step 1 – Nitrogen Bleed & Air Removal
***Use caution as nitrogen is pressurized.***
Back off gas fill screw using 4mm Allen. Use fill needle to release nitrogen charge. Remove valve cap and release any air from RAMP tube. Remove spring spacer.
Backing Off Gas Fill Screw
Gas Fill Screw Backed Off
Degassing Shock
Valve Cap Removal
Air Removal from RAMP Tube
Spring Spacer Removal
Step 2 – RAMP Tube Removal
Clamp valve body in soft jaw vise. Loosen RAMP tube using 34mm crowsfoot. Use caution as contents of shock can still have pressurized gas. Hold outer damper tube and remove RAMP tube.
Shock Clamped for RAMP Tube Removal
Freeing RAMP Tube
Unthreading RAMP Tube
RAMP Tube Removal
RAMP Tube Removed
Damper Disassembly
Step 1 – Damper Tube Removal
Flip shock in vise. Using Tigon Oil Seal Head Pin Spanner (BDD0320), loosen oil seal head. Unthread oil seal head from damper tube and remove complete assembly. Pour off damper oil into proper disposal container. Inspect interior of outer damper tube for any damage.
Clamped for Damper Tube Removal
Freeing Damper Tube
Unthreading Damper Tube
Valve Body Assembly Removal from Damper Tube
Damper Tube Removed
Valve Body Assembly Removed
Remaining Damper Oil Disposal
Inspecting Damper Tube
Step 2 – Shaft Assembly Removal
Clamp valve body in soft jaw vise. Using 12mm crowsfoot or socket, loosen shaft assembly via shaft nut. Heat may be used to help free shaft assembly. Remove shaft assembly and any stroke reduction if present. If shaft nut threads off rather than assembly, clamp shaft with 12.7mm shaft clamp and turn valve body to unthread. Using pick, remove both valve body o-rings and discard.
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.
Valve Body Clamped for Shaft Removal
Freeing Shaft Assembly from Valve Body
Shaft Assembly Removal
Detail of Outer Valve Body O-Ring
Detail of Inner Valve Body O-Ring
Outer Valve Body O-Ring Removal
Inner Valve Body O-Ring Removal
Step 3 – Piston and Shim Stack Removal
Remove shaft o-ring and discard. Clean shaft threads of any Loctite and thoroughly clean shaft assembly. Using 12.7mm shaft clamp, secure shaft assembly in vise with piston up. With 12mm crowsfoot or socket, loosen shaft nut and remove. Remove piston and shim stack, noting shim sequence. Remove and discard piston band and o-ring.
Shaft Assembly
Shaft Assembly O-Ring Removal
Loctite Removal from Shaft Assembly
Cleaning Shaft Assembly
Shaft Assembly Clamped for Shaft Nut Removal
Shaft Nut Removal
Shaft Nut Removed
Main Piston & Shim Stack Removal
Main Piston & Shim Stack Removed
Main Piston & Shim Stack Laid Out
Main Piston Band Removal
Main Piston O-Ring Removal
Step 4 – Shaft Disassembly
Using 19mm open end wrench, loosen shaft coupler and remove. Heat my be used to help free shaft components. Remove coupler o-ring. May be on coupler or on shaft. Remove oil seal head assembly from shaft. Remove spring and sleeve from oil seal head assembly and retain.
Freeing Shaft Coupler
Shaft Coupler Removal
Shaft Coupler Removed
Oil Seal Head Removal
Oil Seal Head Removed
Oil Seal Head Spring & Sleeve Removal
Oil Seal Head Spring & Sleeve Removed
Step 5 – Oil Seal Head Disassembly
Inspect Oil Seal Head for bearing wear. If worn, discard and replace entire assembly (200 hour service). If bearings are in good condition, proceed with disassembly.
Using pick, remove internal quad ring, external quad ring & o-ring and discard. Thoroughly clean seal head assembly (100 hour service).
Inspect shaft for wear.
Inspect Oil Seal Head Bearings
Oil Seal Head Outer Quad Ring Removal
Oil Seal Head Outer Quad Ring Removed
Oil Seal Head Outer O-Ring Removal
Oil Seal Head Outer O-Ring Removed
Oil Seal Head Inner Quad Ring Removal
Inspect Outer Shaft
Step 6 – Outer Reservoir Tube Removal
Thoroughly clean outside of outer reservoir tube and clamp valve body in vise. Unthread outer reservoir tube. Strap wrench may be necessary. Remove tube. Remove gas fill screw from res tube with 4mm Allen. Remove and discard fill plug.
Cleaning Outer Res Tube
Freeing Outer Res Tube
Unthreading Outer Res Tube
Outer Res Tube Removed
Gas Fill Screw Removed
Fill Plug Removal
Fill Plug Removed
Step 7 – IFP Removal
Thread M8x1.25mm bolt into IFP and pull IFP out of inner reservoir tube. Using pick, remove IPF quad ring and discard.
M8x1.25 Bolt Threaded into IFP
IFP Removal
IFP Removed
IFP Quad Ring Removal
Continue to Part 2
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